1997 XJ Service Book

LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1
JUMP STARTING, TOWING AND HOISTING . . . . 9
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
CLASSIFICATION OF LUBRICANTS . . . . . . . . . . . 2
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 3
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Servi ce and mai ntenance procedures for compo-
nents and systems l i sted i n Schedul e A or B can
be found by usi ng the Group Tab Locator i ndex at
the front of thi s manual . I f i t i s not cl ear whi ch
group contai ns the i nformati on needed, refer to the
i ndex at the back of thi s manual .
There are two mai ntenance schedul es that show
proper servi ce based on the condi ti ons that the vehi -
cl e i s subjected to.
Schedul e A , l i sts schedul ed mai ntenance to be
performed when the vehi cl e i s used for general trans-
portati on.
Schedul e B, l i sts mai ntenance i nterval s for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of the Mai ntenance Schedul e secti on.
Use the schedul e that best descri bes your dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
PARTS AND LUBRICANT RECOMMENDATIONS
When servi ce i s requi red, Chrysl er Corporati on
recommends that onl y Mopar brand parts, l ubri -
cants and chemi cal s be used. Mopar provi des the
best engi neered products for servi ci ng Chrysl er Cor-
porati on vehi cl es.
INTERNATIONAL SYMBOLS
Chrysl er Corporati on uses i nternati onal symbol s to
i denti fy engi ne compartment l ubri cant and fl ui d
i nspecti on and fi l l l ocati ons (Fi g. 1).
Fig. 1 International Symbols
XJ LUBRICATION AND MAINTENANCE 0 - 1
CLASSIFICATION OF LUBRICANTS
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used to servi ce a
Chrysl er Corporati on vehi cl e.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range.
SAE 30 = si ngl e grade engi ne oi l .
SAE 10W-30 = mul ti pl e grade engi ne oi l .
Chrysl er Corporati on onl y recommends mul ti pl e
grade engi ne oi l s.
API QUALITY CLASSIFICATION
Thi s symbol (Fi g. 2) on the front of an oi l contai ner
means that the oi l has been certi fi ed by the Ameri -
can Petrol eum I nsti tute (API ) to meet al l the l ubri -
cati on requi rements speci fi ed by Chrysl er
Corporati on.
Refer to Group 9, Engi ne for gasol i ne engi ne oi l
speci fi cati on.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti pl e grade gear
l ubri cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
G. Chassi s l ubri cant i s i denti fi ed by the l atter L.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
0 - 2 LUBRICATION AND MAINTENANCE XJ
GENERAL INFORMATION (Continued)
FLUID CAPACITIES
FUEL TANK
Al l . . . . . . . . . . . . . . . . . . . . . . . . . 76.4 L (20.2 gal .)
ENGINE OIL
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (4.0 qts.)
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)
COOLING SYSTEM
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qts.)*
4.0L . . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (12 qts.)**
*I ncl udes 2.2 L (2.3 qts) for cool ant recovery reser-
voi r.
**I ncl udes 0.9 L (1.0 qt) for cool ant recovery reser-
voi r.
AUTOMATIC TRANSMISSION
Dry fi l l capaci ty*
AW4 . . . . . . . . . . . . . . . . . . . . . . . . 7.8 L (16.5 pts.)
30RH . . . . . . . . . . . . . . . . . . . . . . . 4.67 L (9.86pts.)
*Dependi ng on type and si ze of i nternal cool er,
l ength and i nsi de di ameter of cool er l i nes, or use of
an auxi l i ary cool er, these fi gures may vary. Refer to
Group 21, Transmi ssi on for proper fl ui d fi l l proce-
dure.
MANUAL TRANSMISSION
AX5 (4X2) . . . . . . . . . . . . . . . . . . . . . 3.5 L (3.7 qts.)
AX5 (4X4) . . . . . . . . . . . . . . . . . . . . . 3.3 L (3.5 qts.)
AX15 (4X2) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qts.)
AX15 (4X4) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qts.)
TRANSFER CASE
SELEC-TRAC 242 . . . . . . . . . . . . . . 1.3 L (2.85 pts.)
COMMAND-TRAC 231 . . . . . . . . . . . 1.0 L (2.2 pts.)
FRONT AXLE
181FBI . . . . . . . . . . . . . . . . . . . . 1.48 L (3.13 pts.)
REAR AXLE
194RBI . . . . . . . . . . . . . . . . . . . . 1.66 L (3.5 pts.*)
8-1/4 . . . . . . . . . . . . . . . . . . . . . . . 2.08 L (4.4 pts.**)
* When equi pped wi th TRAC-LOK, i ncl ude 3.5
ounces of Fri cti on Modi fi er Addi ti ve.
** When equi pped wi th TRAC-LOK, i ncl ude 4
POWER STEERING
Power steeri ng fl ui d capaci ti es are dependent on
engi ne/chassi s opti ons as wel l as steeri ng gear/cool er
opti ons. Dependi ng on type and si ze of i nternal
cool er, l ength and i nsi de di ameter of cool er l i nes, or
use of an auxi l i ary cool er, these capaci ti es may vary.
Refer to Secti on 19 of the servi ce manual for proper
fi l l and bl eed procedures.
MAINTENANCE SCHEDULES
INDEX
page
GENERAL INFORMATION
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
MAINTENANCE SCHEDULES
There are two mai ntenance schedul es that show
proper servi ce for the Cherokee.
Fi rst i s Schedul e A . I t l i sts al l the schedul ed
mai ntenance to be performed under normal operat-
i ng condi ti ons.
Second i s Schedul e B . I t i s a schedul e for vehi -
cl es that are operated under these condi ti ons:
Frequent short tri ps dri vi ng l ess than 5 mi l es (8
km)
Frequent dri vi ng i n dusty condi ti ons
Frequent trai l er towi ng
Extensi ve i dl i ng
More than 50% of dri vi ng i s at sustai ned hi gh
speeds duri ng hot weather, above 90F (32C)
Off-road dri vi ng
Desert operati on
Use the schedul e that best descri bes the dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
At Each Stop For Fuel
Check engi ne oi l l evel , add as requi red.
Check wi ndshi el d washer sol vent and add i f
requi red.
Once A Month
Check ti re pressure and l ook for unusual wear
or damage.
I nspect battery and cl ean and ti ghten termi nal s
as requi red. Check el ectrol yte l evel and add water as
needed.
Check fl ui d l evel s of cool ant reservoi r, power
steeri ng, brake master cyl i nder, and transmi ssi on
and add as needed.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
I nspect exhaust system.
I nspect brake hoses.
Rotate the ti res at each oi l change i nterval
shown on Schedul e A (7,500 mi l es) or every other
i nterval shown on Schedul e B (6,000 mi l es).
Check cool ant l evel , hoses, and cl amps.
After compl eti on of off-road operati on, the
undersi de of the vehi cl e shoul d be thoroughl y
i nspected. Exami ne threaded fasteners for l ooseness.
EMISSION CONTROL SYSTEM MAINTENANCE
The schedul ed emi ssi on mai ntenance l i sted i n bold
type on the Mai ntenance Schedul es, must be done at
the mi l eage speci fi ed to assure the conti nued proper
functi oni ng of the emi ssi on control system. These,
and al l other mai ntenance servi ces i ncl uded i n thi s
manual , shoul d be done to provi de the best vehi cl e
performance and rel i abi l i ty. More frequent mai nte-
nance may be needed for vehi cl es i n severe operati ng
condi ti ons such as dusty areas and very short tri p
dri vi ng.
FLUID FILL LOCATIONS AND LUBRICATION
POINTS
The fl ui d fi l l /check l ocati ons and l ubri cati on poi nts
are l ocated i n each appl i cabl e group.
SCHEDULE A
7,500 Miles (12 000 km) or at 6 months
Change engi ne oi l .
Repl ace engi ne oi l fi l ter.
Lubri cate steeri ng l i nkage (4x4 onl y).
Lubri cate steeri ng l i nkage.
Lubri cate steeri ng and suspensi on bal l joi nts.
I nspect brake l i ni ngs.
Replace air cleaner element.
Replace spark plugs.
I nspect dri ve bel t, adjust tensi on as necessary.
Drai n and refi l l automati c transmi ssi on fl ui d.
Drai n and refi l l transfer case fl ui d.
Drai n and refi l l manual transmi ssi on fl ui d.
Fl ush and repl ace engi ne cool ant at 36 months,
regardl ess of mi l eage.
Fl ush and repl ace engi ne cool ant i f not done at
36 months.
Replace engine air cleaner element.
Replace ignition cables.
Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
change.
change.
change.
Important: I nspecti on and servi ce shoul d al so be
performed any ti me a mal functi on i s observed or sus-
pected.
SCHEDULE B
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
12,000 Miles (19 000 km)
Drai n and refi l l front and rear axl es.
15,000 Miles (24 000 km)
Inspect engine air cleaner element, replace
as necessary.
18,000 Miles (29 000 km)
21,000 Miles (34 000 km)
24,000 Miles (38 000 km)
27,000 Miles (43 000 km)
30,000 Miles (48 000 km)
33,000 Miles (53 000 km)
36,000 Miles (58 000 km)
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
as necessary.
48,000 Miles (77 000 km)
51,000 Miles (82 000 km)
Fl ush and repl ace engi ne cool ant.
54,000 Miles (86 000 km)
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
63,000 Miles (101 000 km)
66,000 Miles (106 000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
75,000 Miles (120 000 km)
as necessary.
78,000 Miles (125 000 km)
81,000 Miles (134 000 km)
30,000 mi l es (48 000 km) si nce l ast change.
84,000 Miles (134 000 km)
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
99,000 Miles (158 000 km)
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
as necessary.
108,000 Miles (173 000 km)
111,000 Miles (178 000 km)
30,000 mi l es (48 000 km) si nce l ast change.
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
Off-hi ghway operati on, trai l er towi ng, taxi , l i mou-
si ne, bus, snow pl owi ng, or other types of commerci al
servi ce or prol onged operati on wi th heavy l oadi ng,
especi al l y i n hot weather, requi re front and rear axl e
servi ce i ndi cated wi th a i n Schedul e B. Perform
these servi ces i f the vehi cl e i s usual l y operated under
these condi ti ons.
Important: I nspecti on and servi ce shoul d al so be
performed any ti me a mal functi on i s observed or sus-
pected.
J UMP STARTING, TOWING AND HOISTING
INDEX
page page
SERVICE PROCEDURES
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . . . 11
FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . . . 11
HOISTING RECOMMENDATIONS . . . . . . . . . . . . 11
JUMP STARTING PROCEDURE . . . . . . . . . . . . . . 9
TOWING RECOMMENDATIONS . . . . . . . . . . . . . 10
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . 10
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, turn off al l accessori es, pl ace gear sel ector i n
park or neutral , set park brake and operate engi ne at
1200 rpm.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake. Turn off al l accesso-
ri es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t.
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK
jumper cabl e cl amp to engi ne ground as cl ose to the
ground cabl e attachi ng poi nt as possi bl e (Fi g. 1).
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
Fig. 1 Jumper Cable ConnectionsTypical
(6) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TOWING RECOMMENDATIONS
A vehi cl e equi pped wi th an SAE approved Wheel -
l i ft towi ng devi ce can be used to tow al l Cherokee
vehi cl es (Fi g. 2). When towi ng a 4WD vehi cl e, use
tow dol l i es under the opposi te end of the vehi cl e. A
vehi cl e wi th a fl at-bed devi ce can al so be used to
transport a di sabl ed vehi cl e.
NOTE: A vehicle equipped with a SAE approved
sling type towing device can be used to tow a Cher-
okee with the rear end lifted, provided the Cherokee
is not equipped with a factory installed trailer tow
package. Damage to the harness connector bracket
may result from sling contact.
SAFETY PRECAUTIONS
Secure l oose and protrudi ng parts.
Al ways use a safety chai n system that i s i nde-
pendent of the l i fti ng and towi ng equi pment.
Do not al l ow towi ng equi pment to contact the
di sabl ed vehi cl es fuel tank.
Do not al l ow anyone under the di sabl ed vehi cl e
whi l e i t i s l i fted by the towi ng devi ce.
Do not al l ow passengers to ri de i n a vehi cl e
bei ng towed.
Al ways observe state and l ocal l aws regardi ng
towi ng regul ati ons.
Do not tow a vehi cl e i n a manner that coul d
jeopardi ze the safety of the operator, pedestri ans or
other motori sts.
Do not attach tow chai ns, T-hooks, J-hooks, or a
tow sl i ng to a bumper, steeri ng l i nkage, dri ve shafts
or a non-rei nforced frame hol e.
GROUND CLEARANCE
CAUTION: If vehicle is towed with wheels removed,
install lug nuts to retain brake drums.
A towed vehi cl e shoul d be rai sed unti l l i fted wheel s
are a mi ni mum 100 mm (4 i n) from the ground. Be
sure there i s adequate ground cl earance at the oppo-
si te end of the vehi cl e, especi al l y when towi ng over
rough terrai n or steep ri ses i n the road. I f necessary,
remove the wheel s from the l i fted end of the vehi cl e
and l ower the vehi cl e cl oser to the ground, to
i ncrease the ground cl earance at the opposi te end of
the vehi cl e. I nstal l l ug nuts on wheel attachi ng studs
to retai n brake drums.
FLAT-BED TOWING RAMP ANGLE
I f a vehi cl e wi th fl at-bed towi ng equi pment i s used,
the approach ramp angl e shoul d not exceed 15
degrees.
TWO-WHEEL-DRIVE VEHICLE TOWING
TOWING-REAR END LIFTED (SLING-TYPE)
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD XJ vehi cl es can be towed wi th the front
wheel s on the surface for extended di stances at
speeds not exceedi ng 48 km/h (30 mph). I f the vehi cl e
i s equi pped wi th a factory i nstal l ed trai l er tow pack-
age, use a SAE approved wheel l i ft devi ce.
(1) Attach J-hooks around the axl e shaft tube out-
board of the shock absorber.
(2) Pl ace the sl i ng crossbar under and forward of
the bumper.
(3) Attach safety chai ns around the frame rai l s.
Fig. 2 Tow Vehicles With Approved Equipment
SERVICE PROCEDURES (Continued)
(4) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(5) Secure steeri ng wheel i n the strai ght ahead
posi ti on wi th a cl amp devi ce desi gned for towi ng.
(6) Veri fy that steeri ng components are i n good
condi ti on.
(7) Shi ft the transmi ssi on to NEUTRAL.
TOWING-REAR END LIFTED (WHEEL LIFT)
(1) Rai se front of vehi cl e off ground and i nstal l tow
dol l i es under front wheel s.
(2) Attach wheel l i ft to rear wheel s.
(3) Pl ace transmi ssi on i n neutral .
(4) Rai se vehi cl e to towi ng hei ght.
(5) Pl ace transmi ssi on i n park (automati c trans-
mi ssi on) or fi st gear (manual transmi ssi on).
TOWING-FRONT END LIFTED
To prevent damage to front fasci a components, use
onl y a Wheel -Li ft type towi ng devi ce or Fl at-Bed
haul i ng equi pment.
I f usi ng the wheel -l i ft towi ng method:
(1) Rai se rear of vehi cl e off ground and i nstal l tow
dol l i es under rear wheel s.
(2) Attach wheel l i ft to front wheel s.
mi ssi on) or fi st gear (manual transmi ssi on).
FOUR-WHEEL-DRIVE VEHICLE TOWING
Chrysl er Corporati on recommends that a 4WD
vehi cl e be transported on a fl at bed devi ce. A wheel
l i ft or sl i ng type devi ce can be used provi ded al l
wheel s are l i fted off the ground usi ng tow dol l i es.
I f the vehi cl e i s equi pped wi th a factory i nstal l ed
trai l er tow package, use a SAE approved wheel l i ft
devi ce.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
TOWING-REAR END LIFTED (SLING TYPE)
(2) Attach J-hooks around rear axl e shaft tube out-
board of shock absorber.
(3) Pl ace sl i ng crossbar under and forward of
bumper.
(4) Attach safety chai ns around frame rai l s.
(5) Turn i gni ti on swi tch to OFF posi ti on to unl ock
steeri ng wheel .
(6) Secure steeri ng wheel i n the strai ght ahead
posi ti on wi th a cl amp devi ce desi gned for towi ng.
(7) Shi ft transfer case to neutral .
TOWING-REAR END LIFTED (WHEEL LIFT)
(2) Attach wheel l i ft to rear wheel s.
mi ssi on) or fi rst gear (manual transmi ssi on).
TOWING-FRONT END LIFTED
To prevent damage to front fasci a components, use
onl y a Wheel -Li ft type towi ng devi ce or Fl at-Bed
haul i ng equi pment.
(1) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(2) Attach wheel l i ft to front wheel s.
mi ssi on) or fi rst gear (manual transmi ssi on).
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehi cl es are equi pped wi th front and
rear emergency tow hooks. The tow hooks shoul d be
used for EMERGENCY purposes onl y.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
HOISTING RECOMMENDATIONS
Refer to the Owners Manual for emergency vehi cl e
l i fti ng procedures.
FLOOR JACK
When properl y posi ti oned, a fl oor jack can be used
to l i ft a Jeep vehi cl e (Fi g. 3) and (Fi g. 4). Support the
vehi cl e i n the rai sed posi ti on wi th jack stands at the
front and rear ends of the frame rai l s.
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
An axl e tube.
A body si de si l l .
A steeri ng l i nkage component.
A dri ve shaft.
The engi ne or transmi ssi on oi l pan.
The fuel tank.
A front suspensi on arm.
NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
HOIST
A vehi cl e can be l i fted wi th:
A si ngl e-post, frame-contact hoi st.
A twi n-post, chassi s hoi st.
A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 3 Vehicle Lifting Locations
Fig. 4 Correct Vehicle Lifting Locations
LUBRICATION AND MAINTENANCE
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INDEX
page page
SPECIFICATIONS
ENGINE OILDIESEL ENGINES . . . . . . . . . . . . . 1
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS
ENGINE OILDIESEL ENGINES
Use onl y Di esel Engi ne Oi l meeti ng standard MIL-
2104C or API Cl assi fi cati on SG/CD or CCMC PD2.
SAE VISCOSITY GRADE
CAUTION: Low viscosity oils must have the proper
API quality or the CCMC G5 designation.
To assure of properl y formul ated engi ne oi l s, i t i s
recommended that SAE Grade 15W-40 engi ne oi l s
that meet Chrysl er materi al standard MS-6395, be
used. European Grade 10W-40 oi l s are al so accept-
abl e.
Oi l s of the SAE 5W-30 or 10W-30 grade number
are preferred when mi ni mum temperatures consi s-
tentl y fal l bel ow -12C.
FLUID CAPACITIES
FUEL TANK
Di esel Engi ne Equi pped Vehi cl es . . . . . . . . . . 76.4 L
ENGINE OIL
2.5L Di esel Engi ne (i ncl udes fi l ter) . . . . . . . . . 6.5 L
COOLING SYSTEM
2.5L Di esel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 L
MANUAL TRANSMISSION
Recommended l ubri cant for AX15 transmi ssi ons i s
Mopar 75W90, API Grade GL3 gear l ubri cant, or
equi val ent.
Correct l ubri cant l evel i s from the bottom edge, to
no more than 6 mm (1/4 i n.) bel ow the bottom edge of
the fi l l pl ug hol e.
Approximate dry fill lubricant capacity is:
3.10 l i ters (3.27 qts.) for 4wheel dri ve appl i ca-
ti ons.
ti ons.
TRANSFER CASE
COMMAND-TRAC 231 . . . . . . . . . . . . . . . . . . 1.3 L
FRONT AXLE
Model 181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 L
REAR AXLE
Model 194 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 L*
8-1/4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 L**
* When equi pped wi th TRAC-LOK, i ncl ude 4
** When equi pped wi th TRAC-LOK, i ncl ude 5
MAINTENANCE SCHEDULE
INDEX
page page
GENERAL INFORMATION
MAINTENANCE SCHEDULEDIESEL ENGINE . . 2
SCHEDULEA . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SCHEDULEB . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
MAINTENANCE SCHEDULEDIESEL ENGINE
The fol l owi ng are engi ne rel ated Mai ntenance
i tems whi ch are uni que to Di esel engi ne-equi pped
vehi cl es. Refer to the 1997 XJ Servi ce Manual for
gasol i ne engi ne and non-engi ne rel ated Mai ntenance
Schedul es.
The servi ce i nterval s are based on odometer read-
i ngs i n ki l ometers. There are two mai ntenance sched-
ul es that show proper servi ce i nterval s. Use the
schedul e that best descri bes the condi ti ons the vehi -
cl e i s operated under. Schedule-A l i sts al l the sched-
ul ed mai ntenance to be performed under normal
operati ng condi ti ons. Schedule-B i s the schedul e for
vehi cl es that are operated under one or more of the
fol l owi ng condi ti ons:
Day and ni ght temperatures are bel ow freezi ng.
Stop and go dri vi ng.
Long peri ods of engi ne i dl i ng.
Dri vi ng i n dusty condi ti ons.
Short tri ps of l ess than 8 ki l ometers (5 mi l es).
Operati on at sustai ned hi gh speeds duri ng hot
weather above 32C (90F).
Taxi , pol i ce or del i very servi ce.
Trai l er towi ng.
AT EACH STOP FOR FUEL OR SCHEDULED
SERVICE STOP
Check engi ne oi l l evel .
Check engi ne cool ant l evel .
I nspect dri ve bel t.
Vi sual l y i nspect i ntercool er for obstructi on.
Cl ean as necessary.
Vi sual l y i nspect radi ator for obstructi on. Cl ean
as necessary.
I nspect for fuel , oi l or cool ant l eaks.
I nspect battery cabl e connecti on and excessi ve
corrosi on.
I nspect for presence of water i n fuel fi l ter/water
separator, drai n i f necessary.
SCHEDULEA
1 000 KM
Change engi ne oi l fi l ter.
Check al l fl ui d l evel s.
Check correct torque, i ntake mani fol d mounti ng
nuts.
Check correct torque, exhaust mani fol d mount-
i ng nuts.
Check correct torque, turbocharger mounti ng
nuts.
Check correct torque, water mani fol d bol ts.
10 000 KM
20 000 KM
Repl ace ai r fi l ter el ement.
Check dri ve bel t tensi on.
Check gl ow pl ug operati on.
Retorque cylinder head bolts.*
* Engi nes equi pped wi th a steel head gasket do not
need thi s servi ce procedure performed. Refer to
Group 9, Engi nes for head gasket i denti fi cati on.
30 000 KM
40 000 KM
Repl ace fuel fi l ter/water separator el ement.**
50 000 KM
60 000 KM
Repl ace dri ve bel t.
Check engi ne smoke.
Repl ace engi ne cool ant.
70 000 KM
80 000 KM
90 000 KM
100 000 KM
EVERY 40 000 KM AFTER 80 000 KM
**The fuel fi l ter/water separator el ement shoul d be
repl aced once a year i f the vehi cl e i s dri ven l ess than
40 000 km annual l y or i f power l oss from fuel star-
vati on i s detected.
SCHEDULEB
500 KM
Check correct torque, i ntake mani fol d mounti ng
nuts.
Check correct torque, exhaust mani fol d mount-
i ng nuts.
Check correct torque, turbocharger mounti ng
nuts.
Check correct torque, water mani fol d bol ts.
1 000 KM
Check al l fl ui d l evel s.
5 000 KM
10 000 KM
15 000 KM
20 000 KM
Retorque cylinder head bolts.*
* Engi nes equi pped wi th a steel head gasket do not
need thi s servi ce procedure performed. Refer to
Group 9, Engi nes for head gasket i denti fi cati on.
25 000 KM
30 000 KM
35 000 KM
40 000 KM
Repl ace fuel fi l ter/water separator el ement.
45 000 KM
50 000 KM
55 000 KM
60 000 KM
65 000 KM
70 000 KM
75 000 KM
80 000 KM
85 000 KM
90 000 KM
95 000 KM
100 000 KM
EXHAUST SYSTEM
CONTENTS
page page
GENERAL INFORMATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 1
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 2
REMOVAL AND INSTALLATION
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . . . . 3
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 4
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION
EXHAUST SYSTEM
The basi c exhaust system consi sts of an engi ne
exhaust mani fol d, exhaust pi pe wi th oxygen sensor,
catal yti c converter wi th oxygen sensor, muffl er and
exhaust tai l pi pe (Fi g. 1).
The exhaust system uses a si ngl e muffl er wi th a cat-
al yti c converter consi sti ng of dual cerami c monol i ths.
The 4.0L engi nes use a seal between the engi ne
exhaust mani fol d and exhaust pi pe to assure a ti ght
seal and strai n free connecti ons.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. I f the sys-
tem contacts any body panel , i t may ampl i fy objec-
ti onabl e noi ses ori gi nati ng from the engi ne or body.
When i nspecti ng an exhaust system, cri ti cal l y
i nspect for cracked or l oose joi nts, stri pped screw or
bol t threads, corrosi on damage and worn, cracked or
broken hangers. Repl ace al l components that are
badl y corroded or damaged. DO NOT attempt to
repai r.
When repl acement i s requi red, use ori gi nal equi p-
ment parts (or thei r equi val ent). Thi s wi l l assure
proper al i gnment and provi de acceptabl e exhaust
noi se l evel s.
CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera-
tures and objectionable fumes.
CATALYTIC CONVERTER
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unl eaded gasol i ne must be used to avoi d contami -
nati ng the catal yst core.
Fig. 1 Exhaust System2.5L/4.0L
XJ EXHAUST SYSTEM 11 - 1
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
EXHAUST PIPE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Saturate the bol ts and nuts wi th heat val ve
l ubri cant (Fi g. 2). Al l ow 5 mi nutes for penetrati on.
(3) Di sconnect the oxygen sensor connector (Fi g.
3).
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. Di scard the seal (4.0L engi ne,
onl y).
(5) Support the transmi ssi on and remove the rear
crossmember.
(6) Remove the cl amp nuts and cl amp (Fi g. 2). To
remove the exhaust pi pe from the catal yti c converter,
appl y heat unti l the metal becomes cherry red. Di s-
connect the exhaust pi pe from the catal yti c converter
(Fi g. 2). Remove the exhaust pi pe.
INSTALLATION
(1) Assembl e exhaust pi pe to mani fol d and cata-
l yti c converter l oosel y to permi t proper al i gnment of
al l parts.
(2) Use a new cl amp and ti ghten the nuts to 61
Nm (45 ft. l bs.) torque.
(3) Connect the exhaust pi pe to the engi ne exhaust
mani fol d. I nstal l a new seal between the exhaust
mani fol d and the exhaust pi pe (4.0L engi ne onl y).
Ti ghten the nuts to 31 Nm (23 ft. l bs.) torque (Fi g.
2).
(4) I nstal l the rear crossmember. I nstal l and
ti ghten the four (4) crossmember to rear mount nuts
to 22 Nm (16 ft. l bs.) I nstal l and ti ghten the cross-
member to si l l bol ts to 42 Nm (31 ft. l bs.) torque.
Remove the support from the transmi ssi on.
(5) Coat the oxygen sensor wi th anti -sei ze com-
pound. I nstal l the sensor and ti ghten the nut to 27
(6) Lower the vehi cl e.
11 - 2 EXHAUST SYSTEM XJ
(7) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
CATALYTIC CONVERTER
sensor harness will damage the wiring and/or sen-
sor.
REMOVAL
(2) Remove the cl amps from the catal yti c converter
and muffl er connecti on (Fi g. 4).
(3) Di sconnect and remove the oxygen sensor from
the catal yti c converter.
(4) Heat the catal yti c converter and muffl er con-
necti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(5) Whi l e the metal i s sti l l cherry red, twi st the
muffl er assembl y back and forth to separate i t from
the catal yti c converter.
(6) Di sconnect the exhaust pi pe from the catal yti c
converter (Fi g. 4). I f needed, heat up the pi pes to sep-
arate.
INSTALLATION
(1) Connect the catal yti c converter to the exhaust
pi pe and the muffl er/tai l pi pe assy. (Fi g. 4). Use a new
cl amp and ti ghten the nuts to 61 Nm (45 ft. l bs.)
torque.
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
Fig. 2 Exhaust Pipe Removal2.5L/4.0L
Fig. 3 Oxygen Sensor Location2.5L/4.0L
REMOVAL AND INSTALLATION (Continued)
(3) I nstal l a new cl amp at the muffl er and cata-
l yti c converter connecti on (Fi g. 4). Ti ghten the cl amp
nut to 61 Nm (45 ft. l bs.) torque.
(4) Coat the oxygen sensor wi th anti -sei ze com-
pound. I nstal l the sensor and ti ghten the nut to 27
MUFFLER AND EXHAUST TAILPIPE
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
THE FLAME NEAR THE FUEL LINE.
sensor harness will damage the wiring and/or sensor.
REMOVAL
(2) Di sconnect front tai l pi pe hanger from the i nsu-
l ator (Fi g. 5).
(3) Remove the front exhaust cl amp from the cat-
al yti c converter and muffl er connecti on (Fi g. 6).
(4) Heat the catal yti c converter-to-muffl er connec-
ti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(5) Whi l e the metal i s sti l l cherry red, remove the
exhaust muffl er/tai l pi pe assembl y from the catal yti c
converter.
(6) Sl i de the muffl er/tai l pi pe assy. rearward and
out of the rear exhaust tai l pi pe mounti ng bracket
(Fi g. 7).
(7) Remove the muffl er from the exhaust tai l pi pe:
To remove an ori gi nal equi pment exhaust muf-
fl er/tai l pi pe combi nati on, cut the exhaust tai l pi pe
Fig. 4 Catalytic Converter to Muffler and Exhaust
Pipe Connection
Fig. 5 Front Exhaust Tailpipe Hanger
Fig. 6 Catalytic Converter to Muffler Connection
11 - 4 EXHAUST SYSTEM XJ
cl ose to the muffl er. Col l apse the part remai ni ng i n
the muffl er and remove.
To remove a servi ce exhaust tai l pi pe/muffl er
combi nati on, appl y heat unti l the metal becomes
cherry red. Remove the exhaust tai l pi pe/muffl er
cl amp and twi st the exhaust tai l pi pe out of the muf-
fl er.
INSTALLATION
(1) I nstal l the muffl er onto the catal yti c converter.
I nstal l the cl amp and ti ghten the nut fi nger ti ght.
(2) I nstal l the exhaust tai l pi pe i nto the rear of the
muffl er.
(3) I nstal l the exhaust tai l pi pe/muffl er assembl y
on the rear exhaust tai l pi pe mounti ng bracket. Make
sure that the exhaust tai l pi pe has suffi ci ent cl ear-
ance from the fl oor pan.
(4) I nstal l front tai l pi pe hanger i nto the i nsul ator
(Fi g. 5).
(5) Al i gn the muffl er and ti ghten the nuts on the
muffl er-to-catal yti c converter cl amp to 61 Nm (45 ft.
l bs.) torque (Fi g. 6).
(6) Al i gn the tai l pi pe and i nstal l a new cl amp at
the muffl er to tai l pi pe connecti on.
(7) Ti ghten the muffl er to tai l pi pe cl amp to 61 Nm
(45 ft. l bs.)
SPECIFICATIONS
TORQUE SPECIFICATIONS
Description Torque
Catalytic Converter/Exhaust Pipe
Exhaust Cl amp Nut . . . . . . . . . . 61 Nm (45 ft. l bs.)
Crossmember to Sill
Bol ts . . . . . . . . . . . . . . . . . . . . . . 42 Nm (31 ft. l bs.)
Crossmember to Transmission Mount
Nuts . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 ft. l bs.)
Exhaust Pipe to Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Exhaust Manifold2.5L Engine
Bol t #1 . . . . . . . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Nuts #6&7 . . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Nuts #6&7 . . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Bol t #3 . . . . . . . . . . . . . . . . . . . . 33 Nm (24 ft. l bs.)
Intake Manifold2.5L Engine
Bol t #25 . . . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Intake & Exhaust Manifold2.5L Engine
Bol ts #25 . . . . . . . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Intake & Exhaust Manifold4.0L Engine
Nuts/Bol ts #1,2,4,5,811 . . . . . . . 33 Nm (24 ft. l bs.)
Muffler to Catalytic Converter
Exhaust Cl amp Nut . . . . . . . . . . 61 Nm (45 ft. l bs.)
Oxygen Sensors
Nut . . . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Rear Tail Pipe Hanger
Nuts . . . . . . . . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Fig. 7 Rear Exhaust Tailpipe Mounting Bracket
EXHAUST SYSTEM AND TURBOCHARGER
CONTENTS
page page
GENERAL INFORMATION
EXHAUST HEAT SHIELDS . . . . . . . . . . . . . . . . . 1
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
EXHAUST MANIFOLD AND TURBOCHARGER
(LHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(RHD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 10
MUFFLER AND EXHAUST TAILPIPE . . . . . . . . . . 2
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
EXHAUST SYSTEM
The basi c exhaust system consi sts of an engi ne
exhaust mani fol d, exhaust pi pe, exhaust heat
shi el d(s), muffl er and exhaust tai l pi pe.
The exhaust system uses a si ngl e muffl er.
The exhaust system must be properl y al i gned to
prevent stress, l eakage and body contact. I f the sys-
tem contacts any body panel , i t may ampl i fy objec-
ti onabl e noi ses ori gi nati ng from the engi ne or body.
When i nspecti ng an exhaust system, cri ti cal l y
i nspect for cracked or l oose joi nts, stri pped screw or
bol t threads, corrosi on damage and worn, cracked or
broken hangers. Repl ace al l components that are
badl y corroded or damaged. DO NOT attempt to
repai r.
When repl acement i s requi red, use ori gi nal equi p-
ment parts (or equi val ent). Thi s wi l l assure proper
al i gnment and provi de acceptabl e exhaust noi se l ev-
el s.
CAUTION: Avoid application of rust prevention
compounds or undercoating materials to exhaust
system floor pan exhaust heat shields. Light over-
spray near the edges is permitted. Application of
coating will result in excessive floor pan tempera-
tures and objectionable fumes.
EXHAUST HEAT SHIELDS
Exhaust heat shi el ds are needed to protect both
the vehi cl e and the envi ronment from the hi gh tem-
peratures (Fi g. 1).
DO NOT al l ow the engi ne to operate at fast i dl e for
extended peri ods (over 5 mi nutes). Thi s condi ti on
may resul t i n excessi ve temperatures i n the exhaust
system and on the fl oor pan.
Fig. 1 Heat Shields
XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 1
EXHAUST PIPE
REMOVAL
(2) Saturate the bol ts and nuts at turbo down pi pe
to exhaust pi pe wi th heat val ve l ubri cant. Al l ow 5
mi nutes for penetrati on.
(3) Di sconnect bol ts from exhaust pi pe to turbo
down pi pe (Fi g. 2).
(4) Remove the cl amp nuts at muffl er (Fi g. 3). To
remove the exhaust pi pe from the muffl er, appl y heat
unti l the metal becomes cherry red. Di sconnect the
exhaust pi pe from the muffl er. Remove the exhaust
pi pe.
INSTALLATION
(1) Assembl e exhaust pi pe to muffl er, l oosel y to
permi t proper al i gnment of al l parts.
(2) Connect the exhaust pi pe to the turbo down
pi pe mani fol d. Ti ghten the bol ts to 22.5 Nm torque.
(3) Use a new cl amp and ti ghten the nuts to 43
Nm torque.
MUFFLER AND EXHAUST TAILPIPE
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
REMOVAL
(2) Remove the front muffl er cl amp from the
exhaust pi pe and muffl er connecti on.
(3) Remove the rear exhaust tai l pi pe hanger cl amp
and remove the exhaust tai l pi pe from the front
exhaust tai l pi pe hanger.
(4) Remove the exhaust tai l pi pe assembl y from the
muffl er.
INSTALLATION
(1) I nstal l the muffl er onto the exhaust pi pe.
I nstal l the cl amp and ti ghten the nuts fi nger ti ght.
(2) I nstal l the exhaust tai l pi pe i nto the rear of the
muffl er.
(3) I nstal l the exhaust tai l pi pe/muffl er assembl y
on the rear exhaust tai l pi pe hanger. Make sure that
the exhaust tai l pi pe has suffi ci ent cl earance from the
fl oor pan.
(4) I nstal l the remai ni ng cl amps and the front
exhaust tai l pi pe hanger.
(5) Ti ghten the nuts on the muffl er-to-exhaust pi pe
cl amp to 43 Nm torque.
(6) Ti ghten the nuts on the muffl er-to-exhaust pi pe
cl amp to 43 Nm torque.
Fig. 2 Exhaust Down Pipe to Front Exhaust Pipe
Fig. 3 Front Pipe to Muffler
11 - 2 EXHAUST SYSTEM AND TURBOCHARGER XJ
(LHD)
REMOVAL
(1) Di sconnect the negati ve battery cabl e.
(2) Di sconnect the breather hose from ai r cl eaner
outl et hose (Fi g. 4).
(3) Remove the ai r fi l ter cover and hose from tur-
bocharger, remove the assembl y (Fi g. 4).
(4) Remove the EGR vacuum suppl y hose from the
EGR val ve.
(5) Remove the i nnercool er i nl et and outl et hoses
from the engi ne (Fi g. 4).
(6) Remove the (2) bol ts hol di ng the EGR tube to
the EGR val ve.
(7) Remove the i ntake mani fol d el bow and EGR
val ve as an assembl y.
(8) Rai se the vehi cl e on a hoi st.
(9) Drai n the cool i ng system. Refer to Group 7,
Cool i ng System for procedure.
(10) Remove the exhaust system support cl amp
(Fi g. 5).
(11) Di sconnect the exhaust system at the (3) bol t
fl ange (Fi g. 5).
CAUTION: Heatshield is very sharp. Wear gloves to
prevent injury.
(12) Unstrap the exhaust downpi pe heatshi el d
(Fi g. 6).
(13) Di sconnect the turbocharger oi l return hose
from the engi ne bl ock (Fi g. 7).
(14) Lower the vehi cl e from the hoi st.
(15) Remove the EGR tube from exhaust mani fol d.
(16) Remove the (2) exhaust mani fol d heatshi el d
retai ni ng bol ts and remove the heatshi el d.
(17) Remove the heater core suppl y hoses from the
vehi cl e.
(18) Remove the oi l pressure suppl y l i ne bango
bol t from the turbocharger.
Fig. 5 Exhaust System Inlet Pipe Connection
Fig. 6 Exhaust Downpipe Heatshield
Fig. 4 Engine Compartment
prevent injury.
(19) Remove the exhaust downpi pe heatshi el d by
pul l i ng strai ght up.
(20) Remove the (5) bol ts from exhaust mani fol d
downpi pe and remove pi pe.
(21) Remove the (8) exhaust mani fol d retai ni ng
bol ts, i t i s necessary to access the bol t behi nd the
mani fol d outl et from the underneath of the vehi cl e.
(22) Remove the exhaust mani fol d and turbo-
charger assembl y from the vehi cl e.
(23) Pl ace assembl y i n a vi ce to remove the (3)
exhaust mani fol d to turbocharger retai ni ng nuts (Fi g.
8).
Cleaning
Al l ol d gaskets shoul d be i nspected for any tears or
si gns of pri or l eakage. I f any gaskets show such i ndi -
cati ons, they shoul d be repl aced wi th new gaskets.
Al l gasket mati ng surfaces must be cl eaned of ol d
gasket materi al to produce a smooth and di rt free
seal i ng surface for the new gasket.
INSTALLATION
(1) Transfer the oi l return hose to the new turbo-
charger (Fi g. 9).
(2) I nstal l the turbo on the exhaust mani fol d (Fi g.
9). Torque the nuts to 32 Nm (23 ft. l bs.).
(3) I nstal l the exhaust mani fol d and turbocharger
assembl y i n the vehi cl e.
(4) I nstal l the (8) exhaust mani fol d retai ni ng nuts.
Torque nuts to 32 Nm (23 ft. l bs.).
(5) I nstal l the exhaust mani fol d downpi pe. Torque
bol ts to 32 Nm (23 ft. l bs.).
prevent injury.
(6) Sl i de the exhaust downpi pe heatshi el d down
over pi pe. Do not attempt to strap heatshi el d i n posi -
ti on at thi s ti me, wai t unti l vehi cl e i s rai sed on hoi st.
Fig. 8 Turbocharger / Exhaust Manifold Assembly
Fig. 7 Turbocharger Oil Return Hose
(7) I nstal l the oi l pressure suppl y l i ne on turbo-
charger. Torque bango bol t fi tti ng to 27 Nm (20 ft.
l bs.).
(8) I nstal l the heater core suppl y hoses.
(9) Posi ti on and i nstal l the exhaust mani fol d heat-
shi el d. Torque bol ts to 11 Nm (97 i n. l bs.).
(11) I nstal l the turbocharger oi l return hose on the
engi ne bl ock (Fi g. 10).
(12) Strap the exhaust downpi pe heatshi el d i n i ts
ori gi nal posi ti on.
(13) Connect the exhaust system at the (3) bol t
fl ange (Fi g. 11). Torque the bol ts to 23 Nm (17 ft.
l bs.).
(14) I nstal l the exhaust system support cl amp
(Fi g. 11). Torque nuts to 23 Nm (17 ft. l bs.).
(16) I nstal l the i ntake mani fol d el bow and EGR
val ve as an assembl y. Torque bol ts to 27 Nm (20 ft.
l bs.).
(17) I nstal l the (2) bol ts hol di ng the EGR tube to
the EGR val ve. Torque bol ts to 27 Nm (20 ft. l bs.).
(18) I nstal l the i nnercool er i nl et and outl et hoses
on the engi ne (Fi g. 12).
(19) I nstal l the EGR vacuum suppl y hose on the
EGR val ve.
(20) I nstal l the ai r fi l ter cover and outl et hose on
turbocharger (Fi g. 12).
(21) Connect the breather hose on the ai r cl eaner
outl et hose (Fi g. 12).
(22) Fi l l the cool i ng system. Refer to Group 7,
(23) Connect the negati ve battery cabl e
(24) Start the engi ne and check for l eaks.
(RHD)
REMOVAL
(2) Di sconnect the breather hose from the ai r
cl eaner outl et hose.
Fig. 12 Engine Compartment
(3) Remove the ai r fi l ter cover and the hose from
the turbocharger, remove the assembl y.
(5) Drai n the cool i ng system. Refer to Group 7,
Cool i ng System for the procedure.
(6) Remove the exhaust system support cl amp
(Fi g. 13).
(7) Di sconnect the exhaust system at the (3) bol t
fl ange (Fi g. 13).
prevent injury.
(8) Unstrap the exhaust downpi pe heatshi el d (Fi g.
14).
prevent injury.
(9) Remove the exhaust downpi pe heatshi el d by
pul l i ng strai ght down.
(10) Di sconnect the turbocharger oi l return hose
from the engi ne bl ock (Fi g. 15).
(12) Di sconnect the heater core cool ant suppl y and
the brake vacuum suppl y hoses from the ri ght si de of
the engi ne. Remove the steel l i ne support bracket
from the top of the rocker cover and posi ti on the
assembl y out of the way.
(13) Remove the EGR vacuum suppl y hose from
the EGR val ve.
(14) Remove the i nnercool er i nl et and outl et hoses
from the engi ne.
(15) Remove the (2) bol ts hol di ng the EGR tube to
the EGR val ve.
(16) Remove the i ntake mani fol d el bow and the
EGR val ve as an assembl y.
(17) Remove the EGR tube from the exhaust man-
i fol d.
(18) Remove the (2) exhaust mani fol d heatshi el d
retai ni ng bol ts and remove the heatshi el d (Fi g. 16).
(19) Remove the oi l pressure suppl y l i ne from the
turbocharger (Fi g. 16).
(20) Remove the cl utch master cyl i nder heatshi el d
(Fi g. 16).
(21) Remove the wastegate actuator vacuum sup-
pl y hose from the actuator (Fi g. 17).
(22) Remove the turbocharger oi l pressure suppl y
l i ne from the engi ne bl ock (Fi g. 17).
(23) Worki ng i nsi de of the vehi cl e, remove the
Knee Bl ocker. Refer to Group 8E, I nstrument Panel
Systems for the procedure.
(24) Di sconnect the neutral safety swi tch el ectri cal
connector at the cl utch pedal .
(25) Remove the (2) cl utch master cyl i nder retai n-
i ng nuts from the bul khead.
(26) Worki ng from the i nsi de of the engi ne com-
partment, remove the cl utch master cyl i nder from
the bul khead and posi ti on the cyl i nder and l i ne
assembl y out of the way.
(27) Remove the (5) bol ts from the exhaust mani -
fol d downpi pe and remove the pi pe.
(28) Remove the (8) exhaust mani fol d retai ni ng
bol ts, i t i s necessary to access the bol t behi nd the
mani fol d outl et from the underneath of the vehi cl e.
(29) Remove the steeri ng shaft pi nchbol t and sl i de
the shaft strai ght off of the gearbox i nput shaft. Posi -
ti on asi de.
(30) Remove the exhaust mani fol d and the turbo-
charger assembl y from the vehi cl e.
(31) Pl ace the turbo assembl y i n a vi ce to remove
the (3) exhaust mani fol d to turbocharger retai ni ng
nuts (Fi g. 18).
Cleaning
Al l ol d gaskets shoul d be i nspected for any tears or
si gns of pri or l eakage. I f any gasket shows such i ndi -
cati ons, i t must be repl aced wi th a new gasket. Al l
gasket mati ng surfaces must be cl eaned of al l ol d
gasket materi al to produce a smooth and di rt free
seal i ng surface for the new gasket.
INSTALLATION
(1) I nstal l the turbocharger on the exhaust mani -
fol d (Fi g. 19). Torque nuts to 32 Nm (23 ft. l bs.).
Fig. 16 2.5L Turbo Diesel Heatshields
Fig. 17 R.H.D. Turbo Position & Orientation
(2) I nstal l the exhaust mani fol d and turbocharger
assembl y i n the vehi cl e.
(3) I nstal l the (8) exhaust mani fol d retai ni ng nuts,
i t i s necessary to access the bol t behi nd the mani fol d
outl et from the underneath of the vehi cl e. Torque
nuts to 32 Nm (23 ft. l bs.).
(4) I nstal l the exhaust mani fol d downpi pe. Torque
the bol ts to 32 Nm (23 ft. l bs.).
(5) Posi ti on the turbocharger oi l pressure suppl y
l i ne i n i ts ori gi nal posi ti on (Fi g. 20). Torque the turbo
fi tti ng to 27 Nm (20 ft. l bs.).
(6) I nstal l the wastegate actuator vacuum suppl y
hose on the actuator (Fi g. 20).
(7) I nstal l the exhaust mani fol d heatshi el d (Fi g.
21). Torque bol ts to 11 Nm (97 i n. l bs.).
(8) I nstal l the EGR tube on the exhaust mani fol d.
Leave l oose at thi s ti me.
prevent injury.
(10) Sl i de the exhaust downpi pe heatshi el d up
over the pi pe and strap i t i n i ts ori gi nal posi ti on (Fi g.
22).
(11) I nstal l the steeri ng shaft. Torque the pi nch
bol t to 49 Nm (36 ft. l bs.).
(12) I nstal l the turbocharger oi l return hose on the
(13) Connect the exhaust system at the (3) bol t
fl ange (Fi g. 24). Torque the bol ts to 23 Nm (17 ft.
l bs.).
(14) I nstal l the exhaust system support cl amp
(Fi g. 24). Torque nuts to 23 Nm (17 ft. l bs.).
(15) Lower the vehi cl e on hoi st.
(16) I nstal l the cl utch master cyl i nder through the
bul khead.
(17) Worki ng from the i nsi de of the vehi cl e, I nstal l
the (2) cl utch master cyl i nder retai ni ng nuts.
(18) Connect the neutral safety swi tch at the
cl utch pedal .
Fig. 20 R.H.D. Turbo Position & Orientation
Fig. 21 2.5L Turbo Diesel Heatshields
(19) I nstal l the Knee Bl ocker. Refer to Group 8E,
I nstrument Panel Systems for procedure.
(20) I nstal l the cl utch master cyl i nder heatshi el d.
(21) I nstal l the i ntake mani fol d el bow and the
EGR val ve as an assembl y. Torque the i ntake el bow
bol ts to 27 Nm (20 ft. l bs.).
(22) I nstal l the (2) bol ts hol di ng the EGR tube to
the EGR val ve. Torque to bol ts 27 Nm (20 ft. l bs.).
(23) Torque the EGR tube on the exhaust mani fol d
to 28 Nm (21 ft. l bs.).
(24) I nstal l the i nnercool er i nl et and outl et hoses
on the engi ne.
(25) I nstal l the EGR vacuum suppl y hose on the
EGR val ve.
(26) I nstal l the ai r fi l ter cover and outl et hose on
the turbocharger.
(27) Connect the breather hose on the ai r cl eaner
outl et hose.
(28) I nstal l the heater core cool ant suppl y and the
brake vacuum suppl y l i nes i n there ori gi nal posi ti on.
(29) Connect the negati ve battery cabl e.
(30) Fi l l the cool i ng system. Refer to Group 7,
Cool i ng System for the procedure.
(31) Start the engi ne and check for l eaks.
INTAKE MANIFOLD
REMOVAL
(1) Remove exhaust mani fol d and turbocharger
assembl y.
(2) Remove water mani fol d.
(3) Remove i ntake mani fol d.
CLEANING
Cl ean the i ntake mani fol d and cyl i nder head mat-
i ng surfaces. DO NOT allow foreign material to
enter either the intake manifold or the ports in
the cylinder head.
INSTALLATION
(1) I nstal l the new i ntake mani fol d gasket.
(2) Posi ti on the i ntake mani fol d i n pl ace and fi n-
ger ti ghten the mounti ng nuts.
(3) Ti ghten the fasteners i n sequence and to the
speci fi ed torque 30 Nm.
(4) Posi ti on the water mani fol d i n pl ace and fi nger
ti ghten the mounti ng nuts.
(5) Ti ghten the fasteners to the speci fi ed torque 12
Nm.
(6) I nstal l exhaust mani fol d and turbocharger
assembl y.
(7) I nstal l charge ai r cool er hose to i ntake mani -
fol d.
(8) Connect the battery negati ve cabl e.
(9) Start engi ne and check for l eaks.
SPECIFICATIONS
Description Torque
EGR
Attachi ng Nuts . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
EGR
Tube Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm
EGR
Tube Fl ange Bol ts . . . . . . . . . . . . . . . . . . . . 26 Nm
Exhaust Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Exhaust Manifold
Heat Shi el d Nuts . . . . . . . . . . . . . . . . . . . . . 11 Nm
Exhaust Pipe
Support Cl amp Bol ts . . . . . . . . . . . . . . . . . 22.5 Nm
Exhaust Pipe
Support Cl amp Screw . . . . . . . . . . . . . . . . 22.5 Nm
Intake Manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Nm
Muffler-to-Exhaust Pipe
Cl amp Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 43 Nm
Tail Pipe Clamp
Hanger bol t . . . . . . . . . . . . . . . . . . . . . . . . 22.5 Nm
Turbocharger-to-Exhaust manifold
Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
Turbocharger
Oi l Feed Li ne . . . . . . . . . . . . . . . . . . . . . . . 27.4 Nm
Turbocharger Down Pipe-to-Exhaust Pipe
Bol ts/Nuts . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 Nm
Turbocharger Down Pipe-to-Turbocharger
Bol ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Nm
FRAME AND BUMPERS
CONTENTS
page page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BUMPERS
INDEX
page page
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT BUMPER END CAP . . . . . . . . . . . . . . . . . 1
FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . 2
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR BUMPER END CAP . . . . . . . . . . . . . . . . . . 2
REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT BUMPER END CAP
REMOVAL
(1) Remove the ri vet attachi ng the end cap to the
ai r defl ector.
(2) Remove the bol ts and nuts attachi ng the end
cap to the bumper (Fi g. 1).
(3) Pul l back the wheel house l i ner and remove the
screws attachi ng the end cap to the front fender.
(4) Li fti ng the end cap from the bottom, ti l t
sl i ghtl y upward and sl i de i t outward to di sengage the
retai ner tab from the bumper (Fi g. 2).
(5) Separate the end cap from the bumper.
INSTALLATION
(1) Posi ti on the end cap on the bumper and engage
the retai ni ng tab.
(2) I nstal l the screws attachi ng the end cap to the
front fender.
(3) I nstal l the bol ts attachi ng the end cap to the
bumper. Ti ghten the nut to 9 Nm (7 ft. l bs.) torque.
(4) I nstal l the ri vet attachi ng the end cap to ai r
defl ector.
FRONT BUMPER
REMOVAL
(1) Remove bumper end caps.
(2) I f equi pped, di sengage fog l amp wi re harness
connectors.
(3) Di sconnect vacuum l i ne from reservoi r (Fi g. 3).
(4) Remove Torx-head bol ts that attach bumper to
mounti ng brackets (Fi g. 1).
(5) Remove bumper from vehi cl e.
(6) I f necessary, remove bol ts attachi ng bumper
mounti ng brackets to frame.
INSTALLATION
(1) I f removed, i nstal l bol ts attachi ng bumper
mounti ng brackets to frame. Ti ghten bol ts to 55 Nm
(41 ft. l bs.) torque.
(2) Posi ti on bumper on front of vehi cl e.
(3) I nstal l Torx-head bol ts that attach bumper to
mounti ng brackets. Ti ghten bol ts to 55 Nm (41 ft.
l bs.) torque.
(4) Connect vacuum l i ne to reservoi r.
(5) I f equi pped, engage fog l amp wi re harness con-
nectors.
(6) I nstal l bumper end caps.
XJ FRAME AND BUMPERS 13 - 1
FRONT TOW HOOK
REMOVAL
(1) Remove bol ts attachi ng tow hook to tow hook
rei nforcement (Fi g. 4).
(2) Separate tow hook from rei nforcement.
(3) I f necessary, remove bol t attachi ng tow hook
rei nforcement to frame.
INSTALLATION
(1) I f removed, i nstal l bol t attachi ng tow hook
rei nforcement to frame. Ti ghten bol t to 30 Nm (22 ft.
l bs.) torque.
(2) Posi ti on tow hook on rei nforcement.
(3) I nstal l bol ts attachi ng tow hook to tow hook
rei nforcement. Ti ghten bol ts to 100 Nm (74 ft. l bs.)
torque.
REAR BUMPER END CAP
REMOVAL
(1) Remove the bol ts and nuts attachi ng the
undersi de of the end cap to the bumper (Fi g. 5).
(2) Remove the screw attachi ng the front of the
end cap to the undersi de of the quarter panel .
Fig. 1 Front Bumper
Fig. 2 Bumper End Cap
Fig. 3 Vacuum Reservoir
13 - 2 FRAME AND BUMPERS XJ
(3) Li ft the end cap sl i ghtl y upward and sl i de i t
rearward to rel ease i t from the retai ner.
(4) Separate the end cap from the vehi cl e.
INSTALLATION
(1) Posi ti on the end cap on the rear of the retai ner
and the outer edge of the bumper.
(2) Sl i de the end cap forward onto the retai ner.
Ensure the end cap overl aps the l i p of the rear
wheel house l i ner.
(3) I nstal l the screw attachi ng the front of the end
cap to the undersi de of the quarter panel .
(4) I nstal l the bol ts and nuts attachi ng the under-
si de of the end cap to the bumper.
REAR BUMPER
REMOVAL
(1) For vehi cl es equi pped wi th a trai l er hi tch,
remove hi tch before removi ng bumper. I f necessary,
refer to removal procedure wi thi n Group 13, Frame
and Bumpers.
(2) Remove bumper end caps.
(3) Remove upper nuts that attach bumper to
bumper support brackets (Fi g. 5).
(4) Remove l ower bol ts that attach bumper to
bumper support brackets.
(5) Remove bumper from vehi cl e.
(6) I f necessary, remove bumper support brackets
from the rear si l l .
INSTALLATION
(1) I f removed, i nstal l bumper support brackets on
the rear si l l . Ti ghten bol ts to 55 Nm (41 ft. l bs.)
torque.
(2) Posi ti on bumper on support brackets.
(3) I nstal l bol ts that attach bumper to bumper
support brackets. Ti ghten nuts to 55 Nm (41 ft. l bs.)
torque.
(4) I nstal l bumper end caps.
(5) I f removed, i nstal l trai l er hi tch.
Fig. 4 Front Tow Hook
Fig. 5 Rear Bumper
REAR TOW HOOK
REMOVAL
(1) Remove bol ts that attach tow hook bracket and
tow hook to frame rai l (Fi g. 6).
(2) Remove bracket and tow hook from frame rai l .
INSTALLATION
(1) Posi ti on bracket and tow hook on frame rai l .
(2) I nstal l bol ts that attach tow hook bracket and
tow hook to frame rai l . Ti ghten bol ts to 94 Nm (70
ft. l bs.) torque.
Fig. 6 Rear Tow Hook
FRAME
INDEX
page page
FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . . . 5
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . 5
TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . 5
SPECIFICATIONS
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . 6
FRAME TORQUE SPECIFICATIONS . . . . . . . . . . 8
FRONT SKID PLATE
REMOVAL
(1) Remove the screws that attach ski d pl ate to
si de si l l s.
(2) Remove the nuts that attach the ski d pl ate to
the crossmember (Fi g. 1).
(3) Remove the ski d pl ate from the vehi cl e.
INSTALLATION
(1) Posi ti on the ski d pl ate at front crossmember
and si de si l l s.
(2) I nstal l the nuts to attach the ski d pl ate to
crossmember.
(3) I nstal l the screws to attach ski d pl ate to si de
si l l s.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support ski d pl ate.
(2) Remove bol ts that attach ski d pl ate to trans-
mi ssi on support crossmember and frame si l l (Fi g. 2).
(3) Remove support and ski d pl ate from vehi cl e.
INSTALLATION
(1) Posi ti on and support ski d pl ate at frame si l l
and transmi ssi on support crossmember.
(2) Attach ski d pl ate to frame si l l and crossmem-
ber wi th bol ts. Ti ghten bol ts to 22 Nm (16 ft. l bs.)
torque.
FUEL TANK SKID PLATE
REMOVAL
(1) Posi ti on a support under ski d pl ate.
(2) Remove bol ts that attach ski d pl ate to under-
body si de rai l s (Fi g. 3).
(3) Remove support and ski d pl ate from vehi cl e.
INSTALLATION
(1) Posi ti on and support ski d pl ate under fuel
tank.
Fig. 1 Front Skid Plate
Fig. 2 Transfer Case Skid Plate
(2) I nstal l bol ts to attach ski d pl ate to underbody
rai l s. Ti ghten bol ts to 74 Nm (55 ft. l bs.) torque.
(3) Remove support from under ski d pl ate.
TRAILER HITCH
REMOVAL
(1) I f necessary, remove the trai l er tow wi re har-
ness connector from the hi tch (Fi g. 4).
(2) Support the hi tch.
(3) Remove the bol ts that attach the trai l er hi tch
to the frame si l l s and rei nforcement brackets (Fi g. 5).
(4) I f equi pped, remove the fuel tank ski d pl ate.
NOTE: The reinforcement brackets are held on the
frame sills with two blind rivets.
INSTALLATION
(1) I nstal l frame rei nforcement brackets, i f
removed. Sl i de the brackets through the vehi cl e rear
si l l openi ngs and attach to the frame si l l s wi th bl i nd
ri vets.
(2) Usi ng an adequate l i fti ng devi ce, posi ti on hi tch
at the proper l ocati on for i nstal l ati on on vehi cl e and
support i t.
(3) I f equi pped, posi ti on fuel tank ski d pl ate on
vehi cl e frame si l l s.
(4) Loosel y i nstal l the bol ts to attach the trai l er
hi tch (and the ski d pl ate) to frame si l l s and rei nforce-
ment brackets.
(5) Ti ghten al l bol ts/nuts to 74 Nm (55 ft. l bs.)
torque.
(6) Remove the l i ft/support.
(7) I f removed, attach the trai l er wi re harness con-
nector to the hi tch.
SPECIFICATIONS
FRAME DIMENSIONS
Frame di mensi ons are l i sted i n mi l l i meter scal e.
Al l di mensi ons are from center to center of Pri nci pal
Locati ng Poi nt (PLP), or from center to center of PLP
and fastener l ocati on (Fi g. 6).
Fig. 3 Fuel Tank Skid Plate
Fig. 4 Trailer Hitch Harness Connector
Fig. 5 Trailer Hitch
Fig. 6 Frame Dimensions
SPECIFICATIONS (Continued)
FRAME TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Front Ski d Pl ate Screw . . . . . . . . . . . . . . . . 42 Nm
(31 ft. l bs.)
Front Ski d Pl ate Nut . . . . . . . . . . . . . . . . . . 17 Nm
(125 i n. l bs.)
Transfer Case Ski d Pl ate Bol t . . . . . . . . . . . 22 Nm
(16 ft. l bs.)
Fuel Tank Ski d Pl ate Bol t . . . . . . . . . . . . . . 74 Nm
(55 ft. l bs.)
Front Bumper End Cap to
Mounti ng Bracket Nut . . . . . . . . . . . . . . . . 9 Nm
(7 ft. l bs.)
Front Bumper Mounti ng
Bracket to Frame Bol t . . . . . . . . . . . . . . . 55 Nm
(41 ft. l bs.)
Front Bumper to
Mounti ng Bracket Bol t . . . . . . . . . . . . . . . 55 Nm
(41 ft. l bs.)
Front Tow Hook Bol t . . . . . . . . . . . . . . . . . 100 Nm
(74 ft. l bs.)
Front Tow Hook
Rei nforcement Bol t . . . . . . . . . . . . . . . . . . 30 Nm
(22 ft. l bs.)
Rear Bumper to
Mtg. Bracket Nut . . . . . . . . . . . . . . . . . . 55 Nm
(41 ft. l bs.)
Rear Bumper Mtg. Bracket to
Rear Si l l Bol t . . . . . . . . . . . . . . . . . . . . . . 55 Nm
(41 ft. l bs.)
Rear Tow Hook Bol t . . . . . . . . . . . . . . . . . . . 94 Nm
(70 ft. l bs.)
Trai l er Tow
Rei nforcement Brkt Bol t . . . . . . . . . . . . . 74 Nm
(55 ft. l bs.)
FRAME AND BUMPERS
CONTENTS
page page
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SWING AWAY SPARE TIRE CARRIER . . . . . . . . . 1
SWING AWAY SPARE TIRE CARRIER
INDEX
page
DISASSEMBLY AND ASSEMBLY
SWING AWAY SPARE TIRE CARRIER
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SWING AWAY SPARE TIRE CARRIER MOUNTING
Fig. 1 Spare Tire Carrier Mounting
FRAME
INDEX
page
GENERAL INFORMATION
EMERGENCY TOW EYES . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
EMERGENCY TOW EYES
I f your vehi cl e i s equi pped wi th emergency tow
eyes, one i s mounted i n the front and one i n the rear.
The front tow eye has two hol es, the front hol e i s
for towi ng use onl y and the rear angl ed hol e i s for
shi ppi ng use onl y.
CAUTION: Do not use the angled hole for towing.
You could damage your vehicle.
WARNING: Stand clear of vehicles when pulling
with tow eyes. Tow straps and chains may break,
causing serious injury.
CAUTION: Tow eyes are for emergency use only, to
rescue a vehicle stranded off road. Do not use tow
eyes for tow truck hookup or highway towing. You
could damage your vehicle.
Fig. 1 Emergency Tow Eyes
FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . 23
FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 3
FUEL FILTER/FUEL PRESSURE REGULATOR . . . 4
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 4
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 3
FUEL RAIL/FUEL DAMPER2.5L ENGINE . . . . . . 5
FUEL RAIL4.0L ENGINE . . . . . . . . . . . . . . . . . . 5
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . 6
PCM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 1
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 6
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . . . 5
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 10
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . 10
FUEL PRESSURE LEAK DOWN TEST . . . . . . . . . 7
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . . 8
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . . 7
FUEL PUMP PRESSURE TESTALL ENGINES
WITH PRESSURE TEST PORT . . . . . . . . . . . . . 6
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL TUBES/LINES/HOSES AND CLAMPS . . . . 10
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 11
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 20
FUEL FILTER/FUEL PRESSURE REGULATOR . . 13
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 15
FUEL INJECTOR RAIL2.5L ENGINE . . . . . . . . 16
FUEL INJECTOR RAIL4.0L ENGINE . . . . . . . . 17
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . . 15
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 14
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . 20
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . 21
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . 22
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . 22
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 22
PCM REPLACEMENT
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
FUEL REQUIREMENTS
Your engi ne i s desi gned to meet al l emi ssi ons reg-
ul ati ons and provi de excel l ent fuel economy and per-
formance when usi ng hi gh qual i ty unl eaded gasol i ne
havi ng an octane rati ng of 87. The use of premi um
gasol i ne i s not recommended. The use of premi um
gasol i ne wi l l provi de no benefi t over hi gh qual i ty reg-
ul ar gasol i ne, and i n some ci rcumstances may resul t
i n poorer performance.
Li ght spark knock at l ow engi ne speeds i s not
harmful to your engi ne. However, conti nued heavy
spark knock at hi gh speeds can cause damage and
i mmedi ate servi ce i s requi red. Engi ne damage resul t-
XJ FUEL SYSTEM 14 - 1
i ng from operati on wi th a heavy spark knock may
not be covered by the new vehi cl e warranty.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng and hesi tati ons. I f you experi -
ence these symptoms, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
The Ameri can Automobi l e Manufacturers Associ a-
ti on, AAMA, has i ssued gasol i ne speci fi cati ons to
defi ne the mi ni mum fuel properti es necessary to
del i ver enhanced performance and durabi l i ty for your
vehi cl e. Chrysl er recommends the use of gasol i ne
that meet the AAMA speci fi cati ons i f they are avai l -
abl e.
REFORMULATED GASOLINE
Many areas of the country requi re the use of
cl eaner burni ng gasol i ne referred to as reformul at-
ed gasol i ne. Reformul ated gasol i ne contai n oxygen-
ates, and are speci fi cal l y bl ended to reduce vehi cl e
emi ssi ons and i mprove ai r qual i ty.
Chrysl er strongl y supports the use of reformul ated
gasol i ne. Properl y bl ended reformul ated gasol i ne wi l l
provi de excel l ent performance and durabi l i ty for the
engi ne and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
oxygenates such as 10% ethanol , MTBE, and ETBE.
Oxygenates are requi red i n some areas of the country
duri ng the wi nter months to reduce carbon monoxi de
emi ssi ons. Fuel s bl ended wi th these oxygenates may
be used i n your vehi cl e.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT
MMT i s a manganese-contai ni ng metal l i c addi ti ve
that i s bl ended i nto some gasol i ne to i ncrease octane.
Gasol i ne bl ended wi th MMT provi de no performance
advantage beyond gasol i ne of the same octane num-
ber wi thout MMT. Gasol i ne bl ended wi th MMT
reduce spark pl ug l i fe and reduce emi ssi on system
performance i n some vehi cl es. Chrysl er recommends
that gasol i ne wi thout MMT be used i n your vehi cl e.
The MMT content of gasol i ne may not be i ndi cated
on the gasol i ne pump; therefore, you shoul d ask your
gasol i ne retai l er whether or not hi s/her gasol i ne con-
tai ns MMT.
I t i s even more i mportant to l ook for gasol i ne wi th-
out MMT i n Canada because MMT can be used at
l evel s hi gher than al l owed i n the Uni ted States.
MMT i s prohi bi ted i n Federal and Cal i forni a refor-
mul ated gasol i ne.
SULFUR IN GASOLINE
I f you l i ve i n the northeast Uni ted States, your
vehi cl e may have been desi gned to meet Cal i forni a
l ow emi ssi on standards wi th cl ean-burni ng, l ow-sul -
fur, Cal i forni a gasol i ne. Gasol i ne sol d outsi de of Cal -
i forni a i s permi tted to have hi gher sul fur l evel s
whi ch may affect the performance of the vehi cl es cat-
al yti c converter. Thi s may cause the Check Engi ne or
Servi ce Engi ne Soon l i ght to i l l umi nate.
I l l umi nati on of ei ther l i ght whi l e operati ng on hi gh
sul fur gasol i ne does not necessari l y mean your emi s-
si on control system i s mal functi oni ng. Chrysl er rec-
ommends that you try a di fferent brand of unl eaded
gasol i ne havi ng l ower sul fur to determi ne i f the prob-
l em i s fuel rel ated pri or to returni ng your vehi cl e to
an authori zed deal er for servi ce.
CAUTION: If the Check Engine or Service Engine
Soon light is flashing, immediate service is
required; see on-board diagnostics system section.
MATERIALS ADDED TO FUEL
Al l gasol i ne sol d i n the Uni ted States and Canada
are requi red to contai n effecti ve detergent addi ti ves.
Use of addi ti onal detergents or other addi ti ves i s not
needed under normal condi ti ons.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicles performance:
The use of l eaded gas i s prohi bi ted by Federal
l aw. Usi ng l eaded gasol i ne can i mpai r engi ne perfor-
mance, damage the emi ssi on control system, and
coul d resul t i n l oss of warranty coverage.
An out-of-tune engi ne, or certai n fuel or i gni ti on
mal functi ons, can cause the catal yti c converter to
overheat. I f you noti ce a pungent burni ng odor or
some l i ght smoke, your engi ne may be out of tune or
mal functi oni ng and may requi re i mmedi ate servi ce.
Contact your deal er for servi ce assi stance.
When pul l i ng a heavy l oad or dri vi ng a ful l y
l oaded vehi cl e when the humi di ty i s l ow and the tem-
perature i s hi gh, use a premi um unl eaded fuel to
hel p prevent spark knock. I f spark knock persi sts,
l i ghten the l oad, or engi ne pi ston damage may resul t.
The use of fuel addi ti ves whi ch are now bei ng
sol d as octane enhancers i s not recommended. Most
of these products contai n hi gh concentrati ons of
methanol . Fuel system damage or vehi cl e perfor-
mance probl ems resul ti ng from the use of such fuel s
or addi ti ves i s not the responsi bi l i ty of Chrysl er Cor-
porati on and may not be covered under the new vehi -
cl e warranty.
14 - 2 FUEL SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
The fuel del i very system consi sts of:
the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel fi l ter/fuel pressure regul ator, fuel
gauge sendi ng uni t (fuel l evel sensor) and a separate
fuel fi l ter l ocated at bottom of pump modul e
fuel tubes/l i nes/hoses
qui ck-connect fi tti ngs
fuel i njector rai l
fuel i njectors
fuel tank
fuel tank fi l l er/vent tube assembl y
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and rol l over val ve (refer to Group 25,
Emi ssi on Control System for rol l over val ve i nforma-
ti on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum fuel fi l l er cap i s used. The fuel fi l l er tube
contai ns a spri ng-l oaded fl ap (door) l ocated bel ow the
fuel fi l l cap. The fl ap i s used as a secondary way of
seal i ng the fuel tank i f the fuel fi l l cap has not been
properl y ti ghtened. The fl ap i s used as part of the
EVAP moni tor system when the vehi cl e i s equi pped
wi th a Leak Detecti on Pump (LDP). The fl ap wi l l be
i nstal l ed to al l fuel fi l l er tubes (equi pped/not
equi pped wi th LDP and EVAP moni tor system).
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s found i n Group 25, Emi ssi on
Control Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
FUEL PUMP MODULE
The fuel pump modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 1) or (Fi g. 2). The fuel pump modul e
contai ns the fol l owi ng components:
A combi nati on fuel fi l ter/fuel pressure regul ator
A separate fuel pi ck-up fi l ter (strai ner)
An el ectri c fuel pump
A threaded l ocknut to retai n modul e to tank
A gasket between tank fl ange and modul e
Fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel suppl y tube (l i ne) connecti on
The fuel gauge sendi ng uni t, pi ck-up fi l ter and fuel
fi l ter/fuel pressure regul ator may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump requi res servi ce,
the enti re fuel pump modul e must be repl aced.
FUEL PUMP
DESCRIPTION
The el ectri c fuel pump i s l ocated i nsi de of the fuel
pump modul e.
Fig. 1 Fuel Tank/Fuel Pump Module (Top View)
Fig. 2 Fuel Pump Module Components
OPERATION
The fuel pump used i n thi s system has a permanent
magnet el ectri c motor. Fuel i s drawn i n through a fi l ter
at the bottom of the modul e and pushed through the
el ectri c motor gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test for more i nformati on.
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
FUEL GAUGE SENDING UNIT
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor (track).
OPERATION
The resi stor track i s used to send el ectri cal si gnal s to
the Powertrai n Control Modul e (PCM) for fuel gauge
operati on and for OBD I I emi ssi on requi rements.
For fuel gauge operation: As fuel l evel
i ncreases, the fl oat and arm move up. Thi s decreases
the sendi ng uni t resi stance, causi ng the fuel gauge to
read ful l . As fuel l evel decreases, the fl oat and arm
move down. Thi s i ncreases the sendi ng uni t resi s-
tance causi ng the fuel gauge to read empty.
After thi s fuel l evel si gnal i s sent to the PCM, the
PCM wi l l transmi t the data across the CCD bus ci r-
cui ts to the i nstrument panel . Here i t i s transl ated
i nto the appropri ate fuel gauge l evel readi ng.
For OBD II emission monitor requirements: A
vol tage si gnal i s sent from the resi stor track on the
sendi ng uni t to the PCM to i ndi cate fuel l evel . The pur-
pose of thi s feature i s to prevent the OBD I I system
from recordi ng/setti ng fal se mi sfi re and fuel system
moni tor troubl e codes. The feature i s acti vated i f the
fuel l evel i n the tank i s l ess than approxi matel y 15 per-
cent of i ts rated capaci ty. I f equi pped wi th a Leak
Detecti on Pump (EVAP system moni tor), thi s feature
wi l l al so be acti vated i f the fuel l evel i n the tank i s
more than approxi matel y 85 percent of i ts rated capac-
i ty.
FUEL FILTER/FUEL PRESSURE REGULATOR
A combi nati on fuel fi l ter and fuel pressure regul a-
tor i s used on al l engi nes. I t i s l ocated on the top of
fuel pump modul e (Fi g. 1). A separate frame mounted
fuel fi l ter i s not used wi th any engi ne.
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 kPa 34
kPa (49.2 psi 5 psi ) at the fuel i njectors. I t con-
tai ns a di aphragm, cal i brated spri ngs and a fuel
return val ve. The i nternal fuel fi l ter i s al so part of
the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 3).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump. Refer to Fuel PumpDescription and
Operation for more information. Also refer to
the Fuel Pressure Leak Down Test and the Fuel
Pump Pressure Tests.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49 psi , an i nternal di aphragm cl oses
and excess fuel i s routed back i nto the tank through
the pressure regul ator. A separate fuel return l i ne i s
not used.
Fig. 3 Fuel Filter/Fuel Pressure Regulator
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e.
OPERATION
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
A rol l over val ve(s) i s mounted i nto the top of the
fuel tank (or pump modul e). Refer to Emi ssi on Con-
trol System for rol l over val ve i nformati on.
An evaporati on control system i s connected to the
rol l over val ve(s) to reduce emi ssi ons of fuel vapors
i nto the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP). Refer to Emi ssi on Control
System for addi ti onal i nformati on.
ROLLOVER VALVE(S)
Refer to Group 25, Emi ssi on Control System for
i nformati on.
FUEL INJECTORS
The fuel i njectors (Fi g. 4) are el ectri cal sol enoi ds.
The i njector contai ns a pi ntl e that cl oses off an ori -
fi ce at the nozzl e end. When el ectri c current i s sup-
pl i ed to the i njector, the armature and needl e move a
short di stance agai nst a spri ng, al l owi ng fuel to fl ow
out the ori fi ce. Because the fuel i s under hi gh pres-
sure, a fi ne spray i s devel oped i n the shape of a pen-
ci l stream. The sprayi ng acti on atomi zes the fuel ,
addi ng i t to the ai r enteri ng the combusti on chamber.
An i ndi vi dual fuel i njector i s used for each i ndi vi d-
ual cyl i nder. The top (fuel entry) end of the i njector i s
attached i nto an openi ng on the fuel rai l .
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Duri ng start up, battery vol tage i s suppl i ed to the
i njectors through the ASD rel ay. When the engi ne i s
operati ng, vol tage i s suppl i ed by the chargi ng sys-
tem. The PCM determi nes i njector pul se wi dth based
on vari ous i nputs.
FUEL RAIL/FUEL DAMPER 2. 5L ENGINE
The fuel rai l suppl i es the necessary fuel to each
i ndi vi dual fuel i njector and i s mounted to the i ntake
mani fol d (Fi g. 5). On the 2.5L engi ne, a fuel
damper i s l ocated at the front of the fuel rai l (Fi g.
5). The damper i s used onl y to hel p control fuel pres-
sure pul sati ons. These pul sati ons are the resul t of
the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
Dependi ng on vehi cl e model /engi ne, the fuel rai l
may/may not be equi pped wi th a fuel pressure test
port. Refer to the Fuel Pump Pressure Test for addi -
ti onal i nformati on.
The fuel rai l i s not repai rabl e.
FUEL RAIL 4. 0L ENGINE
The fuel rai l suppl i es the necessary fuel to each
i ndi vi dual fuel i njector and i s mounted to the i ntake
mani fol d (Fi g. 6). The fuel pressure regul ator i s not
mounted to the fuel rai l on any 4.0L engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
Dependi ng on vehi cl e model /engi ne, the fuel rai l
may/may not be equi pped wi th a fuel pressure test
port. Refer to the Fuel Pump Pressure Test for addi -
Fig. 4 Fuel InjectorTypical
The fuel rai l i s not repai rabl e.
FUEL TANK FILLER TUBE CAP
The l oss of any fuel or vapor out of fi l l er neck i s
prevented by the use of a pressure-vacuum fuel tank
fi l l er tube cap. Rel i ef val ves i nsi de the cap wi l l
rel ease fuel tank pressure at predetermi ned pres-
sures. Fuel tank vacuum wi l l al so be rel eased at pre-
determi ned val ues. Thi s cap must be repl aced by a
si mi l ar uni t i f repl acement i s necessary. Thi s i s i n
order for the system to remai n effecti ve.
CAUTION: Remove fuel tank filler tube cap before
servicing any fuel system component. This is done
to help relieve tank pressure. If equipped with a
California emissions package and a Leak Detection
Pump (LDP), the secondary seal below the fill cap
must be pressed (opened) to relieve fuel tank pres-
sure.
QUICK-CONNECT FITTINGS
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type. Some are equi pped wi th safety l atch cl i ps.
Refer to the Removal /I nstal l ati on secti on for more
i nformati on.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
FUEL PUMP PRESSURE TEST ALL ENGINES
WITH PRESSURE TEST PORT
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found el sewhere i n thi s
group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove protecti ve cap at fuel rai l test port.
Connect the 0414 kPa (0-60 psi ) fuel pressure gauge
Fig. 5 Fuel Rail/Fuel Damper2.5L Engine
Fig. 6 Fuel Rail4.0L Engine
(from gauge set 5069) to test port pressure fi tti ng on
fuel rai l (Fi g. 7).
(2) Start and warm engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs, but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, but speci fi cati ons for ei ther the Fuel Pump
Capaci ty, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, repl ace fuel pump
modul e assembl y. Refer to Fuel Pump Modul e
Removal /I nstal l ati on.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for more i nformati on.
(5) I nstal l protecti ve cap to fuel rai l test port.
FUEL PUMP CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Rel ease fuel system pressure. Refer to Fuel
Pressure Rel ease Procedure.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs. Some engi nes may requi re
ai r cl eaner housi ng removal before l i ne di sconnecti on.
(3) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(4) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose i nto di sconnected fuel suppl y l i ne.
I nsert other end of Adaptor Tool Hose i nto a gradu-
ated contai ner.
(5) Remove fuel fi l l cap.
(6) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump wi l l del i ver at l east 1/4 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter/
fuel pressure regul ator. The fi l ter/regul ator may be
servi ced separatel y on certai n appl i cati ons. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for addi ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace fuel pump modul e assembl y. Refer to Fuel
Pump Modul e Removal /I nstal l ati on.
FUEL PRESSURE LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
Fuel pressure bl eedi ng past a fuel i njector(s).
Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
(1) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Fuel Tubes/Li nes/Hoses and Cl amps i n thi s secti on
of the group for procedures. On some engi nes, ai r
cl eaner housi ng removal may be necessary before
fuel l i ne di sconnecti on.
(2) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(3) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose between di sconnected fuel l i ne
and fuel rai l (Fi g. 8).
Fig. 7 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)
DIAGNOSIS AND TESTING (Continued)
(4) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . The fittings on both
tools must be in good condition and free from
any small leaks before performing the proceed-
ing test.
(5) Start engi ne and bri ng to normal operati ng
temperature.
(6) Observe test gauge. Normal operati ng pressure
shoul d be 339 kPa 34 kPa (49.2 psi 5 psi ).
(7) Shut engi ne off.
(8) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
(9) I f pressure fal l s bel ow 30 psi , i t must be deter-
mi ned i f a fuel i njector, the check val ve wi thi n the
fuel pump modul e, or a fuel tube/l i ne i s l eaki ng.
(10) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(12) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of Adaptor
Tool between the fuel rai l and the test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a fuel i njector or the fuel rai l i s l eaki ng.
(13) Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Cl amp off the rubber hose porti on of Adaptor Tool
between the vehi cl e fuel l i ne and test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a l eak may be found at a fuel tube/l i ne. I f no
l eaks are found at fuel tubes or l i nes, one of the
check val ves i n ei ther the el ectri c fuel pump or fi l ter/
regul ator may be l eaki ng.
Note: A qui ck l oss of pressure usual l y i ndi cates a
defecti ve check val ve i n the fi l ter/regul ator. A sl ow
l oss of pressure usual l y i ndi cates a defecti ve check
val ve i n the el ectri c fuel pump.
The el ectri c fuel pump i s not servi ced separatel y.
Repl ace the fuel pump modul e assembl y. The fi l ter/
regul ator may be repl aced separatel y on certai n
appl i cati ons. Refer to Fuel Fi l ter/Fuel Pressure Reg-
ul ator Removal /I nstal l ati on for addi ti onal i nforma-
ti on.
FUEL PUMP AMPERAGE TEST
Thi s amperage (current draw) test i s to be done i n
conjuncti on wi th the Fuel Pump Pressure Test, Fuel
Pump Capaci ty Test and Fuel Pressure Leak Down
Test. Before performi ng the amperage test, be sure
the temperature of the fuel tank i s above 50 F (10
C).
The DRB Scan Tool al ong wi th the DRB Low Cur-
rent Shunt (LCS) adapter (Fi g. 9) and i ts test l eads
wi l l be used to check fuel pump amperage speci fi ca-
ti ons.
(1) Be sure fuel tank contai ns fuel before starti ng
test. I f tank i s empty or near empty, amperage read-
i ngs wi l l be i ncorrect.
(2) Obtai n LCS adapter.
(3) Pl ug cabl e from LCS adapter i nto DRB scan
tool at SET 1 receptacl e.
(4) Pl ug DRB i nto vehi cl e 16way connector (data
l i nk connector).
(5) Connect (-) and (+) test cabl e l eads i nto LCS
adapter receptacl es. Use 10 amp (10A +) receptacl e
and common (-) receptacl es.
Fig. 8 Connecting Adapter ToolTypical
Fig. 9 Low Current Shunt Adapter
(6) Gai n access to MAI N MENU on DRB screen.
(7) Press DVOM button on DRB.
(8) Usi ng l eft/ri ght arrow keys, hi ghl i ght CHAN-
NEL 1 functi on on DRB screen.
(9) Press ENTER three ti mes.
(10) Usi ng up/down arrow keys, hi ghl i ght RANGE
on DRB screen (screen wi l l defaul t to 2 amp scal e).
(11) Press ENTER to change 2 amp scal e to 10
amp scal e. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Di stri buti on Center
(PDC).
(13) Remove fuel pump rel ay from PDC. Refer to
l abel on PDC cover for rel ay l ocati on.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND FUEL
SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: TO PREVENT POSSIBLE DAMAGE TO
THE VEHICLE ELECTRICAL SYSTEM AND LCS
ADAPTER, THE TEST LEADS MUST BE CON-
NECTED INTO RELAY CAVITIES EXACTLY AS
SHOWN IN FOLLOWING STEPS.
Dependi ng upon vehi cl e model , year or engi ne con-
fi gurati on, three di fferent types of rel ays may be
used: Type-1, type-2 and type3.
(14) I f equi pped wi th type1 relay (Fi g. 10),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 10).
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 11).
cavi ti es number 3 and 5. For l ocati on of these cavi -
ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 12).
(17) When LCS adapter test l eads are attached i nto
rel ay cavi ti es, fuel pump will be activated. Determi ne
fuel pump amperage on DRB screen. Amperage
shoul d be bel ow 10.0 amps. I f amperage i s bel ow 10.0
amps, and speci fi cati ons for the Fuel Pump Pressure,
Fuel Pump Capaci ty and Fuel Pressure Leak Down
tests were met, the fuel pump modul e i s OK.
Fig. 10 Type1 Relay
Fig. 11 Type2 Relay
Fig. 12 Type3 Relay
(18) I f amperage i s more than 10.0 amps, repl ace
fuel pump modul e assembl y. The el ectri c fuel pump
i s not servi ced separatel y.
(19) Di sconnect test l eads from rel ay cavi ti es
i mmedi atel y after testi ng.
The fuel gauge sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to I nstrument
Panel and Gauges for Fuel Gauge testi ng. To test the
gauge sendi ng uni t onl y, i t must be removed from
vehi cl e. The uni t i s part of the fuel pump modul e.
Refer to Fuel Pump Modul e Removal /I nstal l ati on for
procedures. Measure the resi stance across the send-
i ng uni t termi nal s. Wi th fl oat i n up posi ti on, resi s-
tance shoul d be 20 ohms (+/- 5%). Wi th fl oat i n down
posi ti on, resi stance shoul d be 270 ohms (+/- 5%).
FUEL INJECTOR TEST
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, use the DRB scan tool and refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. The i njector i s equi pped wi th 2
el ectri cal termi nal s (pi ns). Pl ace an ohmmeter across
the termi nal s. Resi stance readi ng shoul d be approxi -
matel y 12 ohms 1.2 ohms at 20C (68F).
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE
Use following procedure if fuel rail is or is
not equipped with fuel pressure test port.
(1) Remove fuel fi l l cap.
(2) The fuel fi l l er tube contai ns a spri ng-l oaded
fl ap (door) l ocated bel ow fuel fi l l cap. The fl ap i s used
as a secondary way of seal i ng fuel tank i f fuel fi l l cap
has not been properl y ti ghtened. I t i s part of EVAP
moni tor system when vehi cl e i s equi pped wi th a
Leak Detecti on Pump (LDP). The vehicle may be
equipped with flap installed into fuel filler tube
even though vehicle is not equipped with LDP
and EVAP monitor system. Pl ace a nonmetal l i c
object i nto fuel fi l l tube and press on fl ap to rel i eve
any tank pressure.
(3) Remove Fuel Pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(4) Start and run engi ne unti l i t stal l s.
(5) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(6) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(7) Unpl ug connector from any fuel i njector.
(8) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(9) Connect other end of jumper wi re to posi ti ve
si de of battery.
(10) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(11) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
(12) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(13) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(14) Return fuel pump rel ay to PDC.
(15) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB scan tool must be
used to erase a DTC.
FUEL TUBES/LINES/HOSES AND CLAMPS
OPERATION
Al so refer to Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
I nspect al l hose connecti ons such as cl amps, cou-
pl i ngs and fi tti ngs to make sure they are secure and
l eaks are not present. The component shoul d be
repl aced i mmedi atel y i f there i s any evi dence of deg-
radati on that coul d resul t i n fai l ure.
Never attempt to repai r a pl asti c fuel l i ne/tube.
Repl ace as necessary.
Avoi d contact of any fuel tubes/hoses wi th other
vehi cl e components that coul d cause abrasi ons or
scuffi ng. Be sure that the pl asti c fuel l i nes/tubes are
properl y routed to prevent pi nchi ng and to avoi d heat
sources.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
Ti ghten hose cl amps to 3 Nm (25 i n. l bs.) torque.
QUICK-CONNECT FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure i n thi s group.
(2) Di sconnect negati ve battery cabl e from battery.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 13). The tab
i s removabl e. After tab i s removed, qui ck-connect fi t-
ti ng can be separated from fuel system component.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 14). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 14).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 15).
(5) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 16). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 16) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
(6) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 17) usual l y bl ack i n
col or.
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
Fig. 13 Single-Tab Type Fitting
Fig. 14 Disconnecting Single-Tab Type Fitting
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 17). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(7) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 18) or (Fi g. 19). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 18).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 19) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 20). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
Fig. 15 Removing Pull Tab
Fig. 16 Typical Two-Tab Type Quick-Connect Fitting
Fig. 17 Plastic Retainer Ring Type Fitting
Fig. 18 Latch ClipType 1
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(8) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(8) Connect negati ve cabl e to battery.
(9) Start engi ne and check for l eaks.
FUEL FILTER/FUEL PRESSURE REGULATOR
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s l ocated on the fuel pump modul e. The fuel
pump modul e i s l ocated on top of fuel tank.
The fi l ter/regul ator may be removed wi thout
removi ng fuel pump modul e al though fuel tank must
be removed.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Cl ean area around fi l ter/regul ator.
(3) Di sconnect fuel l i ne at fi l ter/regul ator. Refer to
Qui ck-Connect Fi tti ngs i n thi s group for procedures.
(4) Remove retai ner cl amp from top of fi l ter/regu-
l ator (Fi g. 21). Cl amp snaps to tabs on pump modul e.
Di scard ol d cl amp.
(5) Pry fi l ter/regul ator from top of pump modul e
wi th 2 screwdri vers. Uni t i s snapped i nto modul e.
(6) Di scard gasket bel ow fi l ter/regul ator (Fi g. 22).
(7) Before di scardi ng fi l ter/regul ator assembl y,
i nspect assembl y to veri fy that o-ri ngs (Fi g. 23) are
i ntact. I f the smal l est of the two o-ri ngs can not be
found on bottom of fi l ter/regul ator, i t may be neces-
sary to remove i t from the fuel i nl et passage i n fuel
pump modul e.
INSTALLATION
(1) Cl ean recessed area i n pump modul e where fi l -
ter/regul ator i s to be i nstal l ed.
(2) Obtai n new fi l ter/regul ator (two new o-ri ngs
shoul d al ready be i nstal l ed) .
(3) Appl y a smal l amount of cl ean engi ne oi l to
o-ri ngs. Do not install o-rings separately into
fuel pump module. They will be damaged when
installing filter/regulator.
(4) I nstal l new gasket to top of fuel pump modul e.
(5) Press new fi l ter/regul ator i nto top of pump
modul e unti l i t snaps i nto posi ti on (a posi ti ve cl i ck
must be heard or fel t).
Fig. 19 Latch ClipType 2
Fig. 20 Fuel Line Disconnection Using Special Tool
(6) The arrow (Fi g. 21) mol ded i nto top of fuel
pump modul e shoul d be poi nted towards front of
vehi cl e (12 ocl ock posi ti on).
(7) Rotate fi l ter/regul ator unti l fuel suppl y tube
(fi tti ng) i s poi nted towards front of vehi cl e (12 ocl ock
posi ti on).
(8) I nstal l new retai ner cl amp (cl amp snaps over
top of fi l ter/regul ator and l ocks to fl anges on pump
modul e).
(9) Connect fuel l i ne at fi l ter/regul ator. Refer to
(10) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL PUMP MODULE
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
REMOVAL
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL PUMP MODULE,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
(1) Drai n fuel tank and remove tank. Refer to the
Fuel Tank Removal /I nstal l ati on secti on of thi s group.
(2) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(3) Di sconnect fuel l i ne at fi l ter/regul ator. Refer to
(4) The pl asti c fuel pump modul e l ocknut i s
threaded onto fuel tank (Fi g. 24). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 25). The fuel pump modul e wi l l spri ng up
when l ocknut i s removed.
(5) Remove modul e from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
module gasket must be replaced.
(1) Thoroughl y cl ean l ocknut threads and mati ng
fuel tank threads. Use a soap/water sol uti on. Do not
use carburetor cl eaner to cl ean threads.
(2) Usi ng a new gasket, posi ti on gasket and fuel
pump modul e i nto openi ng i n fuel tank.
(3) Appl y cl ean water to gasket and l ocknut
threads.
Fig. 21 Fuel Filter/Fuel Pressure Regulator
Fig. 22 Fuel Filter/Fuel Pressure Regulator Gasket
Fig. 23 Fuel Filter/Fuel Pressure Regulator O-Rings
(4) Posi ti on l ocknut over top of fuel pump modul e.
(5) Rotate modul e unti l mol ded arrow (Fi g. 24) i s
poi nted toward front of vehi cl e (12 ocl ock posi ti on).
Thi s step must be done to prevent fl oat/fl oat rod
assembl y from contacti ng si des of fuel tank.
(6) I nstal l Speci al Tool 6856 to l ocknut.
(7) Ti ghten l ocknut to 74 Nm (55 ft. l bs.) torque.
(8) Rotate fuel fi l ter/fuel pressure regul ator unti l
i ts fi tti ng i s poi nted toward front of vehi cl e (12
ocl ock posi ti on).
(9) Connect fuel l i ne at fi l ter/regul ator. Refer to
(10) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on i n thi s secti on.
FUEL PUMP INLET FILTER
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 26). The fuel
pump modul e i s l ocated on top of fuel tank.
REMOVAL
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove fi l ter by pryi ng from bottom of modul e
wi th 2 screwdri vers. Fi l ter i s snapped to modul e.
(4) Cl ean bottom of pump modul e.
INSTALLATION
(1) Snap new fi l ter to bottom of modul e.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
I nstal l ati on.
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 27). The fuel pump modul e i s l ocated
wi thi n the fuel tank.
REMOVAL
I nstal l ati on.
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 28) to remove send-
i ng uni t from pump modul e.
Fig. 24 Top View of Fuel Tank and Fuel Pump
Module
Fig. 25 Locknut Removal/InstallationTypical
Fig. 26 Fuel Pump Inlet Filter
INSTALLATION
(1) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(2) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
I nstal l ati on.
FUEL INJECTOR RAIL 2. 5L ENGINE
REMOVAL
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure as descri bed i n thi s Group.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Remove i njector harness el ectri cal connectors
at each i njector. Each i njector connector shoul d have
a numeri cal tag attached i denti fyi ng i ts correspond-
i ng cyl i nder (Fi g. 29). I f not, i denti fy each connector
before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs i n
thi s group for procedures.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on i n thi s group
for procedures.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System for procedures.
(9) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(10) Remove cabl e routi ng bracket (Fi g. 29) at
i ntake mani fol d.
(11) Remove nut securi ng crankshaft posi ti on sen-
sor pi gtai l harness to fuel rai l mounti ng stud.
Remove cl amp and harness from fuel rai l mounti ng
stud.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
29).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
Fig. 27 Fuel Gauge Sending Unit Location
Fig. 28 Fuel Gauge Sending Unit Release Tab
Fig. 29 Fuel Rail Mounting2.5L Engine
INSTALLATION
(1) Cl ean each i njector bore at i ntake mani fol d.
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 3 Nm (100 25 i n. l bs.) torque.
(5) Posi ti on crankshaft posi ti on sensor pi gtai l wi re
harness cl amp and wi re harness to fuel rai l mount-
i ng stud. I nstal l nut securi ng harness to fuel rai l
mounti ng stud.
(6) Connect tagged i njector harness connectors to
appropri ate i njector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs i n thi s group for
procedures.
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
(15) Connect negati ve battery cabl e to battery.
(16) Start engi ne and check for fuel l eaks.
FUEL INJECTOR RAIL 4. 0L ENGINE
REMOVAL
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure as descri bed i n thi s Group.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Remove i njector harness el ectri cal connectors
at each i njector. Each i njector connector shoul d have
a numeri cal tag attached i denti fyi ng i ts correspond-
i ng cyl i nder (Fi g. 30). I f not, i denti fy each connector
before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs i n
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on i n thi s group
for procedures.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System for procedures.
(9) Di sconnect automati c transmi ssi on cabl e at
(10) Remove cabl e routi ng bracket (Fi g. 30) at
i ntake mani fol d.
(11) Remove nut securi ng crankshaft posi ti on sen-
sor pi gtai l harness to fuel rai l mounti ng stud.
Remove cl amp and harness from fuel rai l mounti ng
stud.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
30).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
INSTALLATION
(1) Cl ean each i njector bore at i ntake mani fol d.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 3 Nm (100 25 i n. l bs.) torque.
(5) Posi ti on crankshaft posi ti on sensor pi gtai l wi re
harness cl amp and wi re harness to fuel rai l mount-
Fig. 30 Fuel Rail Mounting4.0L Engine
i ng stud. I nstal l nut securi ng harness to fuel rai l
mounti ng stud.
(6) Connect tagged i njector harness connectors to
appropri ate i njector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs i n thi s group for
procedures.
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
FUEL INJECTORS
REMOVAL
(1) Remove fuel rai l . Refer to Fuel I njector Rai l
Removal i n thi s secti on.
(2) Remove cl i p(s) that retai n fuel i njector(s) to
fuel rai l (Fi g. 31) or (Fi g. 32).
INSTALLATION
(1) I nstal l fuel i njector(s) i nto fuel rai l assembl y
and i nstal l retai ni ng cl i p(s).
(2) I f same i njector(s) i s bei ng rei nstal l ed, i nstal l
new o-ri ng(s).
(4) I nstal l fuel rai l . Refer to Fuel Rai l I nstal l ati on
i n thi s secti on.
FUEL TANK
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING FUEL TANK.
Two di fferent procedures may be used to drai n fuel
tank (l oweri ng tank or usi ng DRB scan tool ).
The qui ckest drai ni ng procedure i nvol ves l oweri ng
the fuel tank.
As an al ternati ve procedure, the el ectri c fuel pump
may be acti vated al l owi ng tank to be drai ned at fuel
rai l connecti on. Refer to DRB scan tool for fuel pump
acti vati on procedures. Before di sconnecti ng fuel l i ne
at fuel rai l , rel ease fuel pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group for
procedures. Attach end of speci al test hose tool num-
ber 6541, 6539, 6631 or 6923 at fuel rai l di sconnec-
ti on (tool number wi l l depend on model and/or engi ne
appl i cati on). Posi ti on opposi te end of thi s hose tool to
an approved gasol i ne drai ni ng stati on. Acti vate fuel
pump and drai n tank unti l empty.
I f el ectri c fuel pump i s not operati ng, tank must be
l owered for fuel drai ni ng. Refer to fol l owi ng proce-
dures.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Rel ease fuel system pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group.
(3) Rai se and support vehi cl e.
Fig. 31 Injector Mounting
Fig. 32 Injector Retaining ClipsTypical Injector
(4) I f Equi pped: Remove fuel tank ski d pl ate. Refer
to Group 23, Body for procedures.
(5) Remove 4 fuel hose shi el d mounti ng bol ts and
remove fuel hose shi el d (Fi g. 33) from body.
(6) Remove fuel tank fi l l hose and vent hose
cl amps at fuel tank fi l l er tube (Fi g. 34). Remove both
hoses at fuel fi l l er tube (Fi g. 34).
(7) Remove exhaust tai l pi pe heat shi el d mounti ng
bol ts and remove shi el d.
CAUTION: To protect fuel tank from exhaust heat,
this shield must reinstalled after tank installation.
(8) Pl ace a hydraul i c jack to bottom of fuel tank.
WARNING: PLACE A SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
(9) Di sconnect fuel suppl y l i ne from fuel extensi on
l i ne near front of fuel tank (Fi g. 35). Refer to Fuel
Tubes/Li nes/Hoses and Cl amps i n thi s group. Al so
refer to Qui ck-Connect Fi tti ngs for procedures.
(10) Di sconnect EVAP cani ster vent l i ne near front
of tank (Fi g. 35).
(11) Di sconnect fuel pump modul e el ectri cal con-
nector (pi gtai l harness) near front of tank (Fi g. 35).
Harness connector i s cl i pped to body.
(12) Remove two fuel tank strap nuts (Fi g. 36).
Posi ti on both tank support straps away from tank.
(13) Careful l y l ower ri ght si de of tank whi l e feed-
i ng both fuel hoses through access hol e i n body. Fuel
Fig. 33 Fuel Hose Shield
Fig. 34 Fuel Fill and Vent Hoses
Fig. 35 Fuel Tank Connections at Front of Fuel Tank
Fig. 36 Fuel Tank Mounting Straps/Nuts
Tank Full And Not Drained Using DRB Scan
Tool: To prevent fuel l oss through hoses, keep l eft
si de of tank hi gher than ri ght si de whi l e l oweri ng.
Do not al l ow hose openi ngs to drop l ower than top of
tank.
(14) Conti nue l oweri ng tank unti l cl ear of vehi cl e.
Pl ace tank on fl oor wi th l eft si de (hose si de) hi gher
than ri ght si de.
(15) Drai n tank by removi ng fuel fi l l hose at tank.
Fuel fi l l hose i s l argest of 2 hoses (Fi g. 37). I nsert the
drai n hose (from an approved gasol i ne drai ni ng sta-
ti on) i nto hose openi ng. Drai n tank unti l empty.
(16) I f fuel pump modul e removal i s necessary,
refer to Fuel Pump Modul e Removal /I nstal l ati on i n
INSTALLATION
(1) I f fuel pump modul e i s bei ng i nstal l ed, refer to
Fuel Pump Modul e Removal /I nstal l ati on i n thi s
group for procedures.
(2) I nstal l fuel fi l l /vent hoses to tank fi tti ngs. To
prevent hose from ki nki ng, rotate each hose unti l
i ndex mark on hose i s al i gned to i ndex tang on fuel
tank (Fi g. 37).
(3) I nstal l hose cl amps to hoses. Posi ti on cl amps
between i ndex marks on each hose (Fi g. 37).
(4) Posi ti on fuel tank to hydraul i c jack.
(5) Rai se tank i nto posi ti on whi l e gui di ng fuel fi l l
and vent hoses i nto and through access hol e i n body.
(6) Conti nue rai si ng tank unti l posi ti oned to body.
(7) Attach two fuel tank mounti ng straps and
mounti ng nuts. Ti ghten nuts to 10 Nm (90 i n. l bs.)
torque. Do not over ti ghten nuts.
(8) I nstal l both fuel hoses to fuel fi l l tube. Ti ghten
both retai ni ng cl amps.
(9) Posi ti on fuel hose shi el d to body. I nstal l and
ti ghten 4 mounti ng bol ts.
(10) Connect fuel pump modul e pi gtai l harness
el ectri cal connector near front of tank.
(11) Connect fuel pump modul e suppl y l i ne near
front of tank. Refer to Qui ck-Connect Fi tti ngs for
procedures.
(12) Connect EVAP hose near front of tank.
(13) I nstal l exhaust tai l pi pe heat shi el d.
(14) I nstal l fuel tank ski d pl ate (i f equi pped).
(15) Lower vehi cl e and connect battery cabl e to
battery.
FUEL TANK FILLER TUBE CAP
I f repl acement of the fuel tank fi l l er tube cap i s
necessary, i t must be repl aced wi th an i denti cal cap
to be sure of correct system operati on.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
ACCELERATOR PEDAL
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the upper part of the accel erator pedal arm by a
pl asti c retai ner (cl i p) (Fi g. 38). Thi s retai ner (cl i p)
snaps i nto the top of the accel erator pedal arm.
Retai ner tabs (bui l t i nto the cabl e sheathi ng) (Fi g.
38) fasten the cabl e to the dash panel .
Dual throttl e return spri ngs (attached to the throt-
tl e shaft) are used to cl ose the throttl e.
CAUTION: Never attempt to remove or alter these
springs.
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
REMOVAL
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of accel erator
pedal arm (Fi g. 38). Pl asti c cabl e retai ner (cl i p) snaps
i nto pedal arm.
(2) Remove accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
Fig. 37 Fuel Fill/Vent Hose Index Marks
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
5 Nm (36 i n. l bs.) torque.
(2) Sl i de throttl e cabl e i nto openi ng i n top of pedal
arm. Push pl asti c cabl e retai ner (cl i p) i nto accel era-
tor pedal arm openi ng unti l i t snaps i nto pl ace.
(3) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
THROTTLE CABLE
REMOVAL
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of accel erator pedal arm
(Fi g. 38). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal
arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, pi nch both si des of cabl e
housi ng retai ner tabs (Fi g. 38) at dash panel .
Remove cabl e housi ng from dash panel and pul l i nto
engi ne compartment.
(4) Remove cabl e from cabl e gui de on engi ne cyl i n-
der head (val ve) cover (Fi g. 39).
(5) Remove throttl e cabl e bal l end socket at throt-
tl e body l i nkage (snaps off) (Fi g. 40).
(6) Remove throttl e cabl e from throttl e body
mounti ng bracket by compressi ng squeeze tabs (Fi g.
39) and pushi ng cabl e through hol e i n bracket.
(7) Remove throttl e cabl e from vehi cl e.
INSTALLATION
(1) Sl i de throttl e cabl e through hol e i n throttl e
body bracket unti l retai ner tabs l ock i nto bracket.
(2) Connect cabl e bal l end to throttl e body l i nkage
bal l (snaps on).
(3) Snap cabl e i nto cabl e gui de on engi ne cyl i nder
head (val ve) cover.
(4) Push other end of cabl e through openi ng i n
dash panel unti l retai ni ng tabs l ock i nto panel .
(5) From i nsi de dri vers compartment, sl i de throttl e
cabl e core wi re i nto openi ng i n top of accel erator
pedal arm. Push cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i n pl ace.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
Fig. 38 Accelerator Pedal MountingTypical
Fig. 39 Cable Guide and Squeeze TabsTypical
Fig. 40 Throttle (Accelerator) Cable at Throttle
BodyTypical
SPECIFICATIONS
FUEL TANK CAPACITY
FUEL SYSTEM PRESSURE
339 kPa 34 kPa (49.2 psi 5 psi ).
TORQUE CHART
DESCRIPTION TORQUE
Accel erator Pedal Bracket Mounti ng Nuts . . . 5 Nm
(36 i n. l bs.)
Fuel Hose Cl amps . . . . . . . . . . . . 3 Nm (25 i n. l bs.)
Fuel Rai l Mounti ng Bol ts . . . . . 11 Nm (100 i n. l bs.)
Fuel Tank Mounti ng Strap Nuts . . . . . . . . . 10 Nm
(90 i n. l bs.)
Fuel Pump Modul e Locknut . . . . 74 Nm (55 ft. l bs.)
Models Liters U.S. Gallons
All 76 20
Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
FUEL INJ ECTION SYSTEM
INDEX
page page
AIR CONDITIONING (A/C) CLUTCH RELAY
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 33
AIR CONDITIONING (A/C) CONTROLSPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
AUTO SHUTDOWN (ASD) RELAYPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSEPCM INPUT . . . . . . . . . . . . . . . . . . . 28
BATTERY TEMPERATURE SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . . 28
BRAKE SWITCHPCM INPUT . . . . . . . . . . . . . . 28
CAMSHAFT POSITION SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . . . . 34
CRANKSHAFT POSITION SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DATA LINK CONNECTORPCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
DUTY CYCLE EVAP PURGE SOLENOID
VALVE-PCM OUTPUT . . . . . . . . . . . . . . . . . . . 34
ENGINE COOLANT TEMPERATURE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
EXTENDED IDLE SWITCHPCM INPUT . . . . . . 30
FIVE VOLT SENSOR SUPPLYPRIMARY . . . . . 28
FIVE VOLT SENSOR SUPPLYSECONDARY . . 28
FUEL INJECTORSPCM OUTPUT . . . . . . . . . . 34
FUEL LEVEL SENSORPCM INPUT . . . . . . . . . 28
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . . . . 35
GENERATOR FIELD DRIVER (-)PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GENERATOR FIELD SOURCE (+)PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GENERATOR LAMPPCM OUTPUT . . . . . . . . . 35
GENERATOR OUTPUTPCM INPUT . . . . . . . . . 30
IDLE AIR CONTROL (IAC) MOTORPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
IGNITION CIRCUIT SENSEPCM INPUT . . . . . 30
IGNITION COILPCM OUTPUT . . . . . . . . . . . . . 35
INTAKE MANIFOLD AIR TEMPERATURE
SENSORPCM INPUT . . . . . . . . . . . . . . . . . . 30
LEAK DETECTION PUMP (SWITCH) SENSE
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
LEAK DETECTION PUMPPCM OUTPUT . . . . . 35
MALFUNCTION INDICATOR LAMPECM/PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORPCM INPUT . . . . . . . . . . . . . . . . . . 31
MODES OF OPERATION . . . . . . . . . . . . . . . . . . 25
OIL PRESSURE SENSORPCM INPUT . . . . . . 31
OXYGEN SENSOR (HO2S)PCM INPUT . . . . . 30
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . . 31
POWER STEERING PRESSURE SWITCH
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
POWERTRAIN CONTROL MODULE (PCM) . . . . 24
RADIATOR FAN RELAYPCM OUTPUT . . . . . . 35
SENSOR RETURNPCM INPUT . . . . . . . . . . . . 32
SPEED CONTROL SOLENOIDSPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPEED CONTROL SWITCHESPCM INPUT . . . 32
TACHOMETERPCM OUTPUT . . . . . . . . . . . . . 35
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . 35
THROTTLE POSITION SENSOR (TPS)PCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
TRANSMISSION PARK/NEUTRAL SWITCH
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
VEHICLE SPEED AND DISTANCE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . . 39
ENGINE COOLANT TEMPERATURE
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
EXTENDED IDLE SWITCH TEST . . . . . . . . . . . . 43
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . . 42
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 40
OXYGEN (O2S) SENSORS . . . . . . . . . . . . . . . . 41
POWER STEERING PRESSURE SWITCH . . . . . 42
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE . . . . . . . . . . . . . . . . . . . 44
THROTTLE POSITION SENSOR (TPS) . . . . . . . 44
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 43
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . 36
AIR CLEANER ELEMENT (FILTER) . . . . . . . . . . 49
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 45
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
ENGINE COOLANT TEMPERATURE SENSOR . . 50
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . 45
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OXYGEN SENSOR . . . . . . . . . . . . . . . . . . . . . . . 48
POWER STEERING PRESSURE SWITCH2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . 45
THROTTLE POSITION SENSOR (TPS) . . . . . . . 46
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 51
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 52
POWERTRAIN CONTROL MODULE (PCM)
The Powertrai n Control Modul e (PCM) (Fi g. 1)
operates the fuel system. The PCM was formerl y
referred to as the SBEC or engi ne control l er. The
PCM i s a pre-programmed, tri pl e mi croprocessor di g-
i tal computer. I t regul ates i gni ti on ti mi ng, ai r-fuel
rati o, emi ssi on control devi ces, chargi ng system, cer-
tai n transmi ssi on features, speed control , ai r condi -
ti oni ng compressor cl utch engagement and i dl e
speed. The PCM can adapt i ts programmi ng to meet
changi ng operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed, power
steeri ng pump pressure (2.5L engi ne onl y), and the
brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
A/C request (i f equi pped wi th factory A/C)
A/C sel ect (i f equi pped wi th factory A/C)
Auto shutdown (ASD) sense
Battery temperature
Battery vol tage
Brake swi tch
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Camshaft posi ti on sensor si gnal
Crankshaft posi ti on sensor
Data l i nk connecti on for DRB scan tool
Engi ne cool ant temperature sensor
Extended i dl e swi tch (4.0L engi ne wi th pol i ce
package)
Fuel l evel
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
I ntake mani fol d ai r temperature sensor
Leak detecti on pump (swi tch) sense (i f equi pped)
Mani fol d absol ute pressure (MAP) sensor
Oi l pressure
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Power steeri ng pressure swi tch (2.5L engi ne
onl y)
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Vehi cl e speed sensor
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
CCD bus (+/-) ci rcui ts for: speedometer, vol tme-
ter, fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
Data l i nk connecti on for DRB scan tool
Fig. 1 PCM Location
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fi ve vol t sensor suppl y (pri mary)
Fi ve vol t sensor suppl y (secondary)
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
I dl e ai r control (I AC) motor
I gni ti on coi l
Leak detecti on pump (i f equi pped)
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through CCD ci rcui ts.
Radi ator cool i ng fan rel ay
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through CCD
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t
MODES OF OPERATION
As i nput si gnal s to the powertrai n control modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the powertrai n control
modul e (PCM) recei ves i nput si gnal s and responds
onl y accordi ng to preset PCM programmi ng. I nput
from the oxygen (O2S) sensors i s not moni tored dur-
i ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
The powertrai n control modul e (PCM) pre-posi -
ti ons the i dl e ai r control (I AC) motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the ASD rel ay. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The powertrai n control modul e (PCM) recei ves
i nputs from:
Battery vol tage
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the powertrai n control modul e (PCM) recei ves
i nputs from:
Battery vol tage
Camshaft posi ti on sensor si gnal (i n the di stri butor)
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the powertrai n
control modul e (PCM) recei ves i nputs from:
Battery vol tage
Extended i dl e swi tch (4.0L engi ne wi th pol i ce
package onl y)
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Battery vol tage
trans. onl y)
Oxygen sensors
Power steeri ng pressure swi tch (2.5L engi ne
onl y)
Based on these i nputs, the fol l owi ng occurs:
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
The opti onal Extended I dl e Swi tch i s used to rai se
and hol d the engi ne i dl e speed to approxi matel y 1000
rpm. Thi s i s when the shi fter i s i n ei ther the Park or
Neutral posi ti on and throttl e pedal i s not used. A
rocker-type swi tch (extended i dl e swi tch) i s mounted
to the i nstrument panel . Thi s swi tch wi l l suppl y a
ground ci rcui t (i nput) to the powertrai n control mod-
ul e (PCM). The switch is available only with 4.0L
engine when supplied with optional police
package.
On 2.5L 4cyl i nder engi nes, a power steeri ng pres-
sure swi tch i s used to suppl y an i nput to the PCM
when steeri ng pump pressure i s hi gh. Thi s wi l l rai se
engi ne speed. Refer to Power Steeri ng Pressure
Swi tch i n thi s group for addi ti onal i nformati on. The
4.0L 6cylinder engine does not use this switch.
CRUISE MODE
i s a Cl osed Loop mode. At crui si ng speed, the power-
trai n control modul e (PCM) recei ves i nputs from:
Battery vol tage
tor)
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The powertrai n control
modul e (PCM) recogni zes an abrupt i ncrease i n
throttl e posi ti on or MAP pressure as a demand for
i ncreased engi ne output and vehi cl e accel erati on. The
PCM i ncreases i njector pul se wi dth i n response to
i ncreased throttl e openi ng.
DECELERATION MODE
i s an Open Loop mode. Duri ng hard decel erati on, the
powertrai n control modul e (PCM) recei ves the fol l ow-
i ng i nputs.
Battery vol tage
tor)
trans. onl y)
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the powertrai n control modul e
(PCM) recei ves the fol l owi ng i nputs.
Battery vol tage
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
AIR CONDITIONING (A/C) CONTROLS PCM
INPUT
OPERATION
The A/C control system i nformati on appl i es to fac-
tory i nstal l ed ai r condi ti oni ng uni ts.
A/C SELECT SIGNAL: When the A/C swi tch i s i n
the ON posi ti on, an i nput si gnal i s sent to the Pow-
ertrai n Control Modul e (PCM). The si gnal i nforms
the PCM that the A/C has been sel ected. The PCM
adjusts i dl e speed to a pre-programmed rpm through
the i dl e ai r control (I AC) motor to compensate for
i ncreased engi ne l oad.
A/C REQUEST SIGNAL: Once A/C has been
sel ected, the PCM recei ves the A/C request si gnal
from the cl utch cycl i ng pressure swi tch. The i nput
i ndi cates that the evaporator pressure i s i n the
proper range for A/C appl i cati on. The PCM uses thi s
i nput to cycl e the A/C compressor cl utch (through the
A/C rel ay). I t wi l l al so determi ne the correct engi ne
i dl e speed through the i dl e ai r control (I AC) motor
posi ti on.
I f the A/C l ow-pressure swi tch or hi gh-pressure
swi tch opens (i ndi cati ng a l ow or hi gh refri gerant
pressure), the PCM wi l l not recei ve an A/C request
si gnal . The PCM wi l l then remove the ground from
the A/C rel ay. Thi s wi l l deacti vate the A/C compres-
sor cl utch.
I f the swi tch opens, (i ndi cati ng that evaporator i s
not i n proper pressure range), the PCM wi l l not
recei ve the A/C request si gnal . The PCM wi l l then
remove the ground from the A/C rel ay, deacti vati ng
the A/C compressor cl utch.
SENSE PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC). The
PDC i s l ocated i n the engi ne compartment (Fi g. 2).
Refer to l abel on PDC cover for rel ay l ocati on. The
rel ay i s used to connect the oxygen sensor heater el e-
ments, i gni ti on coi l and fuel i njectors to 12 vol t +
power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the powertrai n control modul e (PCM)
does not see 12 vol ts at thi s i nput when the ASD
shoul d be acti vated, i t wi l l set a di agnosti c troubl e
code (DTC).
BATTERY TEMPERATURE SENSOR PCM
INPUT
OPERATION
Provi des a si gnal to the PCM correspondi ng to the
battery temperature.
BATTERY VOLTAGE PCM INPUT
OPERATION
The battery vol tage i nput provi des power to the
Powertrai n Control Modul e (PCM). I t al so i nforms
the PCM what vol tage l evel i s suppl i ed to the i gni -
ti on coi l and fuel i njectors.
I f battery vol tage i s l ow, the PCM wi l l i ncrease
i njector pul se wi dth (peri od of ti me that the i njector
i s energi zed). Thi s i s done to compensate for the
reduced fl ow through i njector caused by the l owered
vol tage.
BRAKE SWITCH PCM INPUT
OPERATION
When the brake l i ght swi tch i s acti vated, the Pow-
ertrai n Control Modul e (PCM) recei ves an i nput i ndi -
cati ng that the brakes are bei ng appl i ed. After
recei vi ng thi s i nput, the PCM mai ntai ns i dl e speed to
a schedul ed rpm through control of the I dl e Ai r Con-
trol (I AC) motor. The brake swi tch i nput i s al so used
to di sabl e vent and vacuum sol enoi d output si gnal s
to the speed control servo.
FIVE VOLT SENSOR SUPPLY PRIMARY
OPERATION
Suppl i es the requi red 5 vol t power source to the
crankshaft posi ti on sensor, camshaft posi ti on sensor,
MAP sensor and throttl e posi ti on sensor.
FIVE VOLT SENSOR SUPPLY SECONDARY
OPERATION
Suppl i es the requi red 5 vol t source to certai n sen-
sors.
FUEL LEVEL SENSOR PCM INPUT
OPERATION
The Powertrai n Control Modul e (PCM) suppl i es
power to the fuel l evel sensor (fuel gauge sendi ng
uni t). The fuel l evel sensor wi l l then return a si gnal
to the PCM to i ndi cate fuel l evel . The purpose of thi s
feature i s to prevent a fal se setti ng of mi sfi re and
fuel system moni tor troubl e codes. Thi s i s i f the fuel
l evel i s l ess than approxi matel y 15 percent, or, i f
equi pped wi th a Leak Detecti on Pump (LDP), more
than approxi matel y 85 percent of i ts rated capaci ty.
Thi s i nput i s al so used to send a si gnal to the PCM
for fuel gauge operati on vi a the CCD or J1850 bus
ci rcui ts.
Fig. 2 Power Distribution Center (PDC)
CAMSHAFT POSITION SENSOR PCM INPUT
A sync si gnal i s provi de by the camshaft posi ti on
sensor l ocated i n the di stri butor (Fi g. 3). The sync
si gnal from thi s sensor works i n conjuncti on wi th the
crankshaft posi ti on sensor to provi de the Powertrai n
Control Modul e (PCM) wi th i nputs. Thi s i s done to
establ i sh and mai ntai n correct i njector fi ri ng order.
Refer to Camshaft Posi ti on Sensor i n Group 8D,
I gni ti on System for more i nformati on.
CRANKSHAFT POSITION SENSOR PCM
INPUT
Thi s sensor i s a hal l effect devi ce that detects
notches i n the fl ywheel (manual transmi ssi on) or
fl expl ate (automati c transmi ssi on).
Thi s sensor i s used to i ndi cate to the powertrai n
control modul e (PCM) that a spark and or fuel i njec-
ti on event i s to be requi red. The output from thi s
sensor, i n conjuncti on wi th the camshaft posi ti on sen-
sor si gnal , i s used to di fferenti ate between fuel i njec-
ti on and spark events.
The sensor i s bol ted to the transmi ssi on bel l hous-
i ng (Fi g. 4).
Refer to Group 8D, I gni ti on System for more
crankshaft posi ti on sensor i nformati on.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
PCM INPUT
The engi ne cool ant temperature sensor i s i nstal l ed
i n the thermostat housi ng (Fi g. 5) and protrudes i nto
the water jacket. The sensor provi des an i nput vol t-
age to the Powertrai n Control Modul e (PCM) rel ati ng
cool ant temperature. The PCM uses thi s i nput al ong
wi th i nputs from other sensors to determi ne i njector
pul se wi dth and i gni ti on ti mi ng. As cool ant tempera-
ture vari es, the cool ant temperature sensors resi s-
tance changes. The change i n resi stance resul ts i n a
di fferent i nput vol tage to the PCM.
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
Refer to Open Loop/Cl osed Loop Modes of Opera-
ti on i n thi s secti on of the group for more i nformati on.
Fig. 3 Camshaft Position SensorTypical
Fig. 4 Crankshaft Position SensorTypical
Fig. 5 Engine Coolant Temperature SensorTypical
EXTENDED IDLE SWITCH PCM INPUT
OPTIONAL POLICE PACKAGE WITH 4. 0L ENGINE
ONLY
The extended i dl e swi tch i s used to rai se the
engi ne i dl e speed to approxi matel y 1000 rpm. Thi s i s
when the shi fter i s i n ei ther the Park or Neutral
posi ti on. A rocker-type swi tch (extended i dl e swi tch)
i s mounted to the i nstrument panel . Thi s swi tch wi l l
suppl y a ground ci rcui t to the powertrai n control
modul e (PCM). The switch is available only with
4.0L engine when supplied with the optional
police package.
For testi ng and di agnosi s of thi s swi tch and i ts ci r-
cui t, refer to the Di agnosi s and Testi ng secti on of thi s
group.
GENERATOR OUTPUT PCM INPUT
OPERATION
Provi des a chargi ng system vol tage i nput to the
Powertrai n Control Modul e (PCM). I t i s sensed at the
battery i nput to the PCM.
OXYGEN SENSOR (HO2S) PCM INPUT
Two heated O2S sensors are used. The sensors pro-
duce vol tages from 0 to 1 vol t, dependi ng upon the
oxygen content of the exhaust gas i n the exhaust
mani fol d. When a l arge amount of oxygen i s present
(caused by a l ean ai r/fuel mi xture), the sensors pro-
duces a l ow vol tage. When there i s a l esser amount
present (ri ch ai r/fuel mi xture) i t produces a hi gher
vol tage. By moni tori ng the oxygen content and con-
verti ng i t to el ectri cal vol tage, the sensors act as a
ri ch-l ean swi tch.
The oxygen sensors are equi pped wi th a heati ng
el ement that keeps the sensors at proper operati ng
temperature duri ng al l operati ng modes. Mai ntai ni ng
correct sensor temperature at al l ti mes al l ows the
system to enter i nto cl osed l oop operati on sooner.
Al so, i t al l ows the system to remai n i n cl osed l oop
operati on duri ng peri ods of extended i dl e.
I n Cl osed Loop operati on, the PCM moni tors the
O2S sensor i nput (al ong wi th other i nputs) and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2S sen-
sor i nput. The PCM adjusts i njector pul se wi dth
based on preprogrammed (fi xed) val ues and i nputs
from other sensors.
The Automati c Shutdown (ASD) rel ay suppl i es bat-
tery vol tage to both the upstream and downstream
heated oxygen sensors. The oxygen sensors are
equi pped wi th a heati ng el ement. The heati ng el e-
ments reduce the ti me requi red for the sensors to
reach operati ng temperature.
UPSTREAM HEATED OXYGEN SENSOR
The upstream O2S sensor i s l ocated i n the exhaust
downpi pe (Fi g. 6). I t provi des an i nput vol tage to the
PCM. The i nput tel l s the PCM the oxygen content of
the exhaust gas. The PCM uses thi s i nformati on to
fi ne tune the ai r/fuel rati o by adjusti ng i njector pul se
wi dth.
DOWNSTREAM HEATED OXYGEN SENSOR
The downstream heated oxygen sensor i s l ocated
near the outl et end of the catal yti c convertor (Fi g. 6).
The downstream heated oxygen sensor i nput i s used
to detect catal yti c convertor deteri orati on. As the con-
vertor deteri orates, the i nput from the downstream
sensor begi ns to match the upstream sensor i nput
except for a sl i ght ti me del ay. By compari ng the
downstream heated oxygen sensor i nput to the i nput
from the upstream sensor, the PCM cal cul ates cata-
l yti c convertor effi ci ency.
When the catal yti c converter effi ci ency drops bel ow
emi ssi on standards, the PCM stores a di agnosti c
troubl e code and i l l umi nates the Mal functi on I ndi ca-
tor Lamp (MI L). For more i nformati on, refer to
Group 25, Emi ssi on Control Systems.
IGNITION CIRCUIT SENSE PCM INPUT
OPERATION
The i gni ti on ci rcui t sense i nput tel l s the Power-
trai n Control Modul e (PCM) the i gni ti on swi tch has
energi zed the i gni ti on ci rcui t.
SENSOR PCM INPUT
The i ntake mani fol d ai r temperature sensor i s
i nstal l ed i n the i ntake mani fol d wi th the sensor el e-
ment extendi ng i nto the ai r stream (Fi g. 7) or (Fi g.
8). The sensor provi des an i nput vol tage to the Pow-
ertrai n Control Modul e (PCM) i ndi cati ng i ntake man-
Fig. 6 Heated Oxygen Sensors
i fol d ai r temperature. The i nput i s used al ong wi th
i nputs from other sensors to determi ne i njector pul se
wi dth. As the temperature of the ai r-fuel stream i n
the mani fol d vari es, the sensor resi stance changes.
Thi s resul ts i n a di fferent i nput vol tage to the PCM.
LEAK DETECTION PUMP (SWITCH) SENSE
PCM INPUT
Provi des an i nput to the PCM that the l eak detec-
ti on pump (LDP) has been acti vated. Refer to Group
25, Emi ssi on Control System for LDP i nformati on.
SENSOR PCM INPUT
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d. I t provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM). As engi ne l oad
changes, mani fol d pressure vari es. The change i n
mani fol d pressure causes MAP sensor vol tage to
change. The change i n MAP sensor vol tage resul ts i n
a di fferent i nput vol tage to the PCM. The i nput vol t-
age l evel suppl i es the PCM wi th i nformati on about
ambi ent barometri c pressure duri ng engi ne l oad
whi l e the engi ne i s runni ng. The PCM uses thi s
i nput al ong wi th i nputs from other sensors to adjust
ai r-fuel mi xture.
The MAP sensor i s mounted on the si de of the
engi ne throttl e body (Fi g. 7). The sensor i s connected
to the throttl e body wi th a rubber L-shaped fi tti ng.
OIL PRESSURE SENSOR PCM INPUT
DESCRIPTION
The engi ne oi l pressure sensor (sendi ng uni t) i s
l ocated i n an engi ne oi l pressure gal l ery.
OPERATION
A si gnal i s sent from the oi l pressure sensor to the
Powertrai n Control Modul e (PCM) rel ati ng to engi ne
oi l pressure.
POWER GROUND
OPERATION
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng Powertrai n Control Modul e
(PCM) l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l (s)
Certai n rel ays/sol enoi ds
POWER STEERING PRESSURE SWITCH PCM
INPUT
A pressure sensi ng swi tch i s i ncl uded i n the power
steeri ng system (mounted on the hi gh-pressure l i ne).
Thi s swi tch wi l l be used onl y on vehi cl es equi pped
wi th a 2.5L engi ne and power steeri ng. The swi tch
(Fi g. 9) provi des an i nput to the Powertrai n Control
Modul e (PCM). Thi s i nput i s provi ded duri ng peri ods
of hi gh pump l oad and l ow engi ne rpm; such as dur-
i ng parki ng maneuvers. The PCM wi l l then i ncrease
the i dl e speed through the I dl e Ai r Control (I AC)
motor. Thi s i s done to prevent the engi ne from stal l -
i ng under the i ncreased l oad.
When steeri ng pump pressure exceeds 3275 kPa
690 kPa (475 psi 100 psi ), the normal l y cl osed
Fig. 7 Intake Man. Air Temp. Sensor Location4.0L
Engine
Fig. 8 Intake Man. Air Temp. Sensor Location2.5L
Engine
swi tch wi l l open and the PCM wi l l i ncrease the
engi ne i dl e speed. Thi s wi l l prevent the engi ne from
stal l i ng.
When pump pressure drops to approxi matel y 1379
kPa (200 psi ), the swi tch ci rcui t wi l l re-cl ose and
engi ne i dl e speed wi l l return to i ts previ ous setti ng.
SENSOR RETURN PCM INPUT
OPERATION
Sensor Return provi des a l ow noi se ground refer-
ence for al l engi ne control system sensors.
SPEED CONTROL SWITCHES PCM INPUT
Two separate speed control swi tch modul es are
mounted on the steeri ng wheel to the l eft and ri ght
si de of the dri vers ai rbag modul e. Wi thi n the two
swi tch modul es, fi ve momentary contact swi tches,
supporti ng seven di fferent speed control functi ons
are used. The outputs from these swi tches are fi l -
tered i nto one i nput. The Powertrai n Control Modul e
(PCM) determi nes whi ch output has been appl i ed
through resistive multiplexing. The i nput ci rcui t
vol tage i s measured by the PCM to determi ne whi ch
swi tch functi on has been sel ected.
A speed control i ndi cator l amp, l ocated on the
i nstrument panel cl uster i s energi zed by the PCM vi a
the CCD Bus. Thi s occurs when speed control system
power has been turned ON, and the engi ne i s run-
ni ng.
The two swi tch modul es are l abel ed: ON/OFF, SET,
RESUME/ACCEL, CANCEL and COAST. Refer to
Group 8H, Speed Control System for more i nforma-
ti on.
TRANSMISSION PARK/NEUTRAL SWITCH
PCM INPUT
The park/neutral swi tch i s l ocated on the transmi s-
si on housi ng and provi des an i nput to the Powertrai n
Control Modul e (PCM). Thi s wi l l i ndi cate that the
automati c transmi ssi on i s i n Park, Neutral or a dri ve
gear sel ecti on. Thi s i nput i s used to determi ne i dl e
speed (varyi ng wi th gear sel ecti on), fuel i njector
pul se wi dth and i gni ti on ti mi ng advance. Refer to
Group 21, Transmi ssi ons, for testi ng, repl acement
and adjustment i nformati on. I t i s al so used as a con-
di ti on for speed control operati on.
THROTTLE POSITION SENSOR (TPS) PCM
INPUT
The TPS i s mounted on the throttl e body (Fi g. 7).
The TPS i s a vari abl e resi stor that provi des the Pow-
ertrai n Control Modul e (PCM) wi th an i nput si gnal
(vol tage) that represents throttl e bl ade posi ti on. The
sensor i s connected to the throttl e bl ade shaft. As the
posi ti on of the throttl e bl ade changes, the resi stance
of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
VEHICLE SPEED AND DISTANCE SENSOR
PCM INPUT
The vehi cl e speed sensor i s l ocated on the speed-
ometer pi ni on gear adapter (Fi g. 10) or (Fi g. 11). The
pi ni on gear adapter i s l ocated on the extensi on hous-
i ng of the transmi ssi on (dri vers si de2WD), or on
the transfer case (4WD). The sensor i nput i s used by
the powertrai n control modul e (PCM) to determi ne
vehi cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Under decel erati on condi ti ons, the PCM adjusts
the i dl e ai r control (I AC) motor to mai ntai n a desi red
MAP val ue. Under i dl e condi ti ons, the PCM adjusts
the I AC motor to mai ntai n a desi red engi ne speed.
Fig. 9 Power Steering Pump Pressure Switch2.5L
Engine
AIR CONDITIONING (A/C) CLUTCH RELAY
PCM OUTPUT
The A/C rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated i n the engi ne com-
partment (Fi g. 12). Refer to l abel on PDC cover for
rel ay l ocati on.
The powertrai n control modul e (PCM) acti vates the
A/C compressor through the A/C cl utch rel ay. The
PCM regul ates A/C compressor operati on by swi tch-
i ng the ground ci rcui t for the A/C cl utch rel ay on and
off.
When the PCM recei ves a request for A/C from A/C
evaporator swi tch, i t wi l l adjust i dl e ai r control (I AC)
motor posi ti on. Thi s i s done to i ncrease i dl e speed.
The PCM wi l l then acti vate the A/C cl utch through
the A/C cl utch rel ay. The PCM adjusts i dl e ai r control
(I AC) stepper motor posi ti on to compensate for
i ncreased engi ne l oad from the A/C compressor.
By swi tchi ng the ground path for the rel ay on and
off, the PCM i s abl e to cycl e the A/C compressor
cl utch. Thi s i s based on changes i n engi ne operati ng
condi ti ons. The PCM wi l l al so de-energi ze the rel ay i f
cool ant temperature exceeds 125C (257F).
AUTO SHUTDOWN (ASD) RELAY PCM
OUTPUT
DESCRIPTION
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC).
OPERATION
The ASD suppl i es battery vol tage to the fuel i njec-
tors and i gni ti on coi l (s). Wi th certai n emi ssi ons pack-
ages i t al so suppl ys vol tage to the oxygen sensor
heati ng el ements. The ground ci rcui t for the coi l i n
the ASD rel ay i s control l ed by the Powertrai n Con-
trol Modul e (PCM). The PCM operates the rel ay by
swi tchi ng the ground ci rcui t on and off.
Fig. 10 Vehicle Speed Sensor Location2WD
Typical
Typical
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS
The Powertrai n Control Modul e (PCM) sends cer-
tai n output si gnal s through the CCD bus ci rcui ts.
These si gnal s are used to control certai n i nstrument
panel l ocated i tems and to determi ne certai n i denti -
fi cati on numbers.
Refer to Group 8E, I nstrument Panel and Gauges
for addi ti onal i nformati on.
DATA LINK CONNECTOR PCM INPUT AND
OUTPUT
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the powertrai n control modul e (PCM).
The data l i nk connector i s l ocated under the i nstru-
ment panel to the l eft of the steeri ng col umn (Fi g.
13). For operati on of the DRB scan tool , refer to the
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce manual .
DUTY CYCLE EVAP PURGE SOLENOID
VALVE-PCM OUTPUT
i nformati on.
FUEL INJECTORS PCM OUTPUT
Si x i ndi vi dual fuel i njectors are used wi th the 4.0L
6-cyl i nder engi ne (Fi g. 14). Four i ndi vi dual fuel i njec-
tors are used wi th the 2.5L 4-cyl i nder engi ne (Fi g.
15). The fuel i njectors are attached to the fuel rai l .
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Duri ng start up, battery vol tage i s suppl i ed to the
i njectors through the ASD rel ay. When the engi ne i s
operati ng, vol tage i s suppl i ed by the chargi ng sys-
tem. The PCM determi nes i njector pul se wi dth based
on vari ous i nputs.
Fig. 13 Data Link Connector Location
Fig. 14 Fuel Rail and Injectors4.0L 6Cyl. Engine
Fig. 15 Fuel Rail and Injectors2.5L 4Cyl. Engine
FUEL PUMP RELAY-PCM OUTPUT
DESCRIPTION
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC).
OPERATION
The PCM energi zes the el ectri c fuel pump through
the fuel pump rel ay. Battery vol tage i s appl i ed to the
fuel pump rel ay when the i gni ti on key i s ON. The
rel ay i s energi zed when a ground si gnal i s provi ded
by the PCM.
The fuel pump wi l l operate for approxi matel y three
seconds unl ess the engi ne i s operati ng or the starter
motor i s engaged.
GENERATOR FIELD SOURCE (+) PCM
OUTPUT
OPERATION
Thi s output from the Powertrai n Control Modul e
(PCM) regul ates chargi ng system vol tage to the gen-
erator fi el d source (+) ci rcui t. The vol tage range i s
12.9 to 15.0 vol ts. Model s of previ ous years had used
the ASD rel ay (di rectl y) to appl y the 12 vol t + power
suppl y to the generator fi el d source (+) ci rcui t.
GENERATOR FIELD DRIVER (-) PCM OUTPUT
OPRATION
Thi s output from the Powertrai n Control Modul e
(PCM) regul ates chargi ng system ground control to
the generator fi el d dri ver (-) ci rcui t.
GENERATOR LAMP PCM OUTPUT
I f the powertrai n control modul e (PCM) senses a
l ow chargi ng condi ti on i n the chargi ng system, i t wi l l
i l l umi nate the generator l amp (i f equi pped) on the
i nstrument panel . For exampl e, duri ng l ow i dl e wi th
al l accessori es turned on, the l amp may momentari l y
go on. Refer to Groups 8A and 8C for chargi ng sys-
tem i nformati on.
IDLE AIR CONTROL (IAC) MOTOR PCM
OUTPUT
The I AC motor i s mounted on the throttl e body
(Fi g. 7) and i s control l ed by the Powertrai n Control
Modul e (PCM).
The throttl e body has an ai r control passage that
provi des ai r for the engi ne at i dl e (the throttl e pl ate
i s cl osed). The I AC motor pi ntl e protrudes i nto the
ai r control passage and regul ates ai r fl ow through i t.
Based on vari ous sensor i nputs, the PCM adjusts
engi ne i dl e speed by movi ng the I AC motor pi ntl e i n
and out of the ai r control passage. The I AC motor i s
posi ti oned when the i gni ti on key i s turned to the On
posi ti on.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
IGNITION COIL PCM OUTPUT
System vol tage from the Automati c Shutdown
(ASD) rel ay i s suppl i ed to the i gni ti on coi l posi ti ve
termi nal . The Powertrai n Control Modul e (PCM)
operates the i gni ti on coi l . Ignition timing is not
adjustable. The PCM adjusts i gni ti on ti mi ng to
meet changi ng engi ne operati ng condi ti ons.
Refer to Group 8D, I gni ti on System for addi ti onal
i nformati on.
LEAK DETECTION PUMP PCM OUTPUT
Certai n engi nes wi th certai n emi ssi ons packages
are equi pped wi th a l eak detecti on pump (LDP). The
LDP i s acti vated through thi s PCM output. Refer to
Group 25, Emi ssi on Control System for addi ti onal
i nformati on.
RADIATOR FAN RELAY PCM OUTPUT
An el ectri c radi ator cool i ng fan i s used wi th certai n
model s/engi nes. I t i s control l ed by the powertrai n
control modul e (PCM) through the radi ator fan rel ay.
The rel ay i s energi zed when cool ant temperature i s
above 103C (217F). I t wi l l then de-energi ze when
cool ant temperature drops to 98C (208F). Refer to
Group 7, Cool i ng Systems for more i nformati on.
The rel ay i s l ocated i n the power di stri buti on cen-
ter (PDC) (Fi g. 12).
MALFUNCTION INDICATOR LAMP ECM/PCM
OUTPUT
i nformati on.
SPEED CONTROL SOLENOIDS PCM OUTPUT
Speed control operati on i s regul ated by the power-
trai n control modul e (PCM). The PCM control s the
vacuum to the throttl e actuator through the speed
control vacuum and vent sol enoi ds. Refer to Group
8H for Speed Control I nformati on.
TACHOMETER PCM OUTPUT
The powertrai n control modul e (PCM) suppl i es
engi ne rpm val ues to the i nstrument cl uster tachom-
eter. Refer to Group 8E for tachometer i nformati on.
THROTTLE BODY
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body (Fi g. 16). Fuel
does not enter the i ntake mani fol d through the throt-
tl e body. Fuel i s sprayed i nto the mani fol d by the fuel
i njectors. The throttl e body i s mounted on the i ntake
mani fol d. I t contai ns an ai r control passage (Fi g. 16)
control l ed by an I dl e Ai r Control (I AC) motor. The ai r
control passage i s used to suppl y ai r for i dl e condi -
ti ons. A throttl e val ve (pl ate) i s used to suppl y ai r for
above i dl e condi ti ons.
The Throttl e Posi ti on Sensor (TPS), I AC motor and
Mani fol d Absol ute Pressure sensor (MAP) are
attached to the throttl e body. The accel erator pedal
cabl e, speed control cabl e (when equi pped) and auto-
mati c transmi ssi on control cabl e (when equi pped) are
connected to the throttl e arm.
control l ed by the PCM.
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy the three 32way el ectri cal connectors
are ful l y i nserted i nto the connector of the power-
trai n control modul e (PCM) (Fi g. 17).
(2) I nspect battery cabl e connecti ons. Be sure they
are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect ASD
rel ay connecti ons. I nspect starter motor rel ay connec-
ti ons. I nspect rel ays for si gns of physi cal damage and
corrosi on. The rel ays are l ocated i n Power Di stri bu-
ti on Center (PDC) (Fi g. 18). Refer to l abel on PDC
cover for rel ay l ocati on.
(4) I nspect i gni ti on coi l connecti ons. Veri fy coi l sec-
ondary cabl e i s fi rml y connected to coi l (Fi g. 19) or
(Fi g. 20).
(5) Veri fy di stri butor cap i s correctl y attached to
di stri butor. Be sure spark pl ug cabl es are fi rml y con-
nected to di stri butor cap and spark pl ugs are i n thei r
correct fi ri ng order. Be sure coi l cabl e i s fi rml y con-
nected to di stri butor cap and coi l . Be sure camshaft
Fig. 16 Throttle Body (4.0L Engine Shown)
Fig. 17 Powertrain Control Module (PCM)
posi ti on sensor wi re connector (at di stri butor) i s
fi rml y connected to harness connector. I nspect spark
pl ug condi ti on. Connect vehi cl e to an osci l l oscope and
i nspect spark events for foul ed or damaged spark
pl ugs or cabl es. Refer to Group 8D, I gni ti on System
(6) Veri fy generator output wi re, generator connec-
tor and ground wi re are fi rml y connected to genera-
tor.
(7) I nspect system body grounds for l oose or di rty
connecti ons. Refer to Group 8, Wi ri ng for ground
l ocati ons.
(8) Veri fy crankcase venti l ati on (CCV) operati on.
Refer to Group 25, Emi ssi on Control System for addi -
(9) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(10) Veri fy hose connecti ons to al l ports of vacuum
fi tti ngs on i ntake mani fol d are ti ght and not l eaki ng.
(11) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and crui se control cabl e con-
necti ons (i f equi pped). Check thei r connecti ons to
throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(12) I f equi pped wi th vacuum brake booster, veri fy
vacuum booster hose i s fi rml y connected to fi tti ng on
i ntake mani fol d. Al so check connecti on to brake vac-
uum booster.
(13) I nspect ai r cl eaner i nl et and ai r cl eaner el e-
ment for di rt or restri cti ons.
(14) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(15) Veri fy i ntake mani fol d ai r temperature sensor
wi re connector i s fi rml y connected to harness connec-
tor (Fi g. 21) or (Fi g. 22).
(16) Veri fy MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 22). Al so veri fy
rubber L-shaped fi tti ng from MAP sensor to throttl e
body i s fi rml y connected (Fi g. 23).
(17) Veri fy fuel i njector wi re harness connectors
are fi rml y connected to i njectors i n correct order.
Each harness connector i s numeri cal l y tagged wi th
i njector number (I NJ 1, I NJ 2 etc.) of i ts correspond-
i ng fuel i njector and cyl i nder number.
(18) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor and throttl e
posi ti on sensor (TPS) (Fi g. 22).
(19) Veri fy wi re harness connector i s fi rml y con-
nected to engi ne cool ant temperature sensor (Fi g.
24).
Fig. 19 Ignition Coil2.5L Engine
Fig. 20 Ignition Coil4.0L Engine Fig. 21 Intake Manifold Air Temp. Sensor Location
2.5L Engine
(21) Veri fy both oxygen sensor wi re connectors are
fi rml y connected to sensors. I nspect sensors and con-
nectors for damage (Fi g. 25).
(22) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(23) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(24) I f equi pped wi th automati c transmi ssi on, ver-
i fy el ectri cal harness i s fi rml y connected to park/neu-
tral swi tch. Refer to Automati c Transmi ssi on secti on
of Group 21.
(25) Veri fy el ectri cal harness connector i s fi rml y
connected to vehi cl e speed sensor (Fi g. 26) or (Fi g.
27).
(26) 2.5L 4Cyl i nder Engi ne Onl y: Veri fy good
el ectri cal connecti on at power steeri ng pressure
swi tch (Fi g. 28). Thi s swi tch i s not used wi th 4.0L
engi nes.
(27) Veri fy good el ectri cal connecti ons at fuel pump
modul e connector at front of fuel tank (Fi g. 29).
(28) Veri fy good EVAP cani ster vent l i ne connec-
ti on at front of fuel tank (Fi g. 29).
(29) Veri fy good fuel suppl y l i ne connecti on at
front of fuel tank (Fi g. 29).
(30) I nspect al l fuel l i nes/hoses for cracks or l eaks.
(31) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
(32) Veri fy battery cabl e and sol enoi d feed wi re
connecti ons to starter sol enoi d are ti ght and cl ean.
I nspect for chaffed wi res or wi res rubbi ng up agai nst
other components.
Fig. 22 Sensor Locations4.0L Engine
Fig. 23 Rubber L-Shaped FittingMAP Sensor-to-
Throttle Body
Fig. 24 Engine Coolant Temperature Sensor
Typical
Fig. 25 Location of Oxygen Sensors
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered (Fi g. 30) or (Fi g.
31).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
Fig. 28 Power Steering Pressure Switch2.5L
Engine
Fig. 29 Fuel Tank Connections at Front of Fuel Tank
Fig. 26 Vehicle Speed Sensor2WD
Fig. 27 Vehicle Speed Sensor4WD
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to the Wi ri ng
Di agrams.
SENSOR TEST
To perform a compl ete test of MAP sensor (Fi g. 32)
and i ts ci rcui try, refer to DRB scan tool and appro-
pri ate Powertrai n Di agnosti cs Procedures manual . To
test the MAP sensor onl y, refer to the fol l owi ng:
(1) I nspect rubber L-shaped fi tti ng from MAP sen-
sor to throttl e body (Fi g. 33). Repai r as necessary.
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(2) Test MAP sensor output vol tage at MAP sensor
connector between termi nal s A and B (Fi g. 34). Wi th
Fig. 30 ASD and Fuel Pump Relay Terminals
Fig. 31 ASD and Fuel Pump Relay Terminals
Fig. 32 Sensor Location (4.0L Engine Shown)
i gni ti on swi tch ON and engi ne OFF, output vol tage
shoul d be 4-to-5 vol ts. The vol tage shoul d drop to 1.5-
to-2.1 vol ts wi th a hot, neutral i dl e speed condi ti on.
(3) Test Powertrai n Control Modul e (PCM) cavi ty
A-27 for same vol tage descri bed above to veri fy wi re
harness condi ti on. Repai r as necessary.
(4) Test MAP sensor suppl y vol tage at sensor con-
nector between termi nal s A and C (Fi g. 34) wi th i gni -
ti on ON. The vol tage shoul d be approxi matel y 5 vol ts
(0.5V). Fi ve vol ts (0.5V) shoul d al so be at cavi ty
A-17 of the PCM wi re harness connector. Repai r or
repl ace wi re harness as necessary.
(5) Test the MAP sensor ground ci rcui t at sensor
connector termi nal A (Fi g. 34) and PCM connector
A-4. Repai r wi re harness i f necessary.
Refer to Group 8W, Wi ri ng Di agrams for cavi ty
l ocati ons.
OXYGEN (O2S) SENSORS
To perform a compl ete test of the O2S sensors and
thei r ci rcui try, refer to the DRB scan tool and appro-
pri ate Powertrai n Di agnosti cs Procedures manual . To
test the O2S sensors onl y, refer to the fol l owi ng:
The upstream O2S sensor i s l ocated on the exhaust
downpi pe (Fi g. 35).
The downstream O2S sensor i s l ocated near the
outl et end of the catal yti c converter (Fi g. 35).
Each O2S heati ng el ement can be tested wi th an
ohmmeter as fol l ows:
Di sconnect the O2S sensor connector. Connect the
ohmmeter test l eads across the whi te wi re termi nal s
of the sensor connector. Resi stance shoul d be
between 4.5 .5 ohms and 7 ohms. Repl ace the sen-
sor i f the ohmmeter di spl ays an i nfi ni ty (open) read-
i ng.
To perform a compl ete test of the engi ne cool ant
temperature sensor and i ts ci rcui try, refer to DRB
scan tool and appropri ate Powertrai n Di agnosti cs
Procedures manual . To test the sensor onl y, refer to
the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor (Fi g. 36).
(2) Test the resi stance of sensor wi th a hi gh i nput
i mpedance (di gi tal ) vol t-ohmmeter. Refer to SENSOR
RESI STANCE (OHMS)COOLANT TEMPERA-
TURE SENSOR/I NTAKE AI R TEMPERATURE
SENSOR chart. The resi stance (as measured across
sensor termi nal s) shoul d be wi thi n range shown i n
chart. I f not, repl ace sensor.
(3) Test conti nui ty of the wi re harness between the
PCM wi re harness connector and the cool ant sensor
connector termi nal s. Refer to Group 8, Wi ri ng for ter-
mi nal /cavi ty l ocati ons. Repai r the wi re harness i f an
open ci rcui t i s i ndi cated.
Fig. 33 Rubber L-Shaped FittingMAP Sensor-to-
Throttle Body
Fig. 34 MAP Sensor Connector TerminalsTypical
Fig. 35 Oxygen Sensor Location
IDLE AIR CONTROL (IAC) MOTOR
To perform a compl ete test of the I AC motor and
i ts ci rcui try, refer to DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual .
SENSOR
To perform a compl ete test of the i ntake mani fol d
ai r temperature sensor and i ts ci rcui try, refer to DRB
tester and appropri ate Powertrai n Di agnosti cs Proce-
dures manual . To test the sensor onl y, refer to the
fol l owi ng:
(1) Di sconnect wi re harness connector from i ntake
mani fol d ai r temperature sensor (Fi g. 37) or (Fi g.
38).
(2) Test the resi stance of sensor wi th a hi gh i nput
i mpedance (di gi tal ) vol t-ohmmeter. Refer to SENSOR
RESI STANCE (OHMS)COOLANT TEMPERA-
TURE SENSOR/I NTAKE AI R TEMPERATURE
SENSOR chart. The resi stance (as measured across
sensor termi nal s) shoul d be wi thi n range shown i n
chart. I f not, repl ace sensor.
(3) Test resi stance of wi re harness. Do thi s
between PCM wi re harness connector A-15 and sen-
sor connector termi nal . Al so check between PCM con-
nector A-4 to sensor connector termi nal . Repai r wi re
harness as necessary i f resi stance i s greater than 1
ohm.
2. 5L 4Cylinder Engine Only
Thi s swi tch (Fi g. 39) provi des an i nput to the Pow-
ertrai n Control Modul e (PCM). The i nput i s provi ded
Typical
SENSOR RESISTANCE (OHMS)COOLANT
TEMPERATURE SENSOR/INTAKE AIR
TEMPERATURE SENSOR
TEMPERATURE RESISTANCE (OHMS)
CEL. FAHR. MIN. MAX.
-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
110 230 480 540
120 248 370 410
Fig. 37 Intake Manifold Air Temperature Sensor
4.0L Engine
duri ng peri ods of hi gh pump l oad and l ow engi ne
rpm; such as duri ng parki ng maneuvers. The PCM
wi l l then i ncrease i dl e speed through the I dl e Ai r
Control (I AC) motor. Thi s i s done to prevent the
engi ne from stal l i ng under the i ncreased l oad.
When steeri ng pump pressure exceeds 3275 kPa
690 kPa (475 psi 100 psi ), the normal l y cl osed
swi tch ci rcui t wi l l open and the PCM wi l l i ncrease
the engi ne i dl e speed.
When power steeri ng pump pressure drops to
approxi matel y 1379 kPa (200 psi ), the swi tch ci rcui t
wi l l re-cl ose and i dl e speed wi l l return to normal .
To test switch:
(1) Di sconnect el ectri cal connector at swi tch.
(2) Connect a pai r of jumper wi res to swi tch termi -
nal s. Route and secure jumper wi res away from fan
bl ades and fan bel t.
(3) Connect an ohmmeter to jumper wi res and
observe conti nui ty. Ci rcui t shoul d be cl osed wi th
engi ne not runni ng. I f conti nui ty i s observed, swi tch
i s OK. I f swi tch ci rcui t i s open, repl ace swi tch.
(4) Start engi ne and observe ohmmeter. Wi th
engi ne at i dl e speed, conti nui ty shoul d be observed
unti l steeri ng wheel has been turned to l eft or ri ght
posi ti on. Do not hold steering wheel in full left
or right position for more than a few seconds.
Damage to power steering pump may occur.
(5) I f conti nui ty i s sti l l observed after turni ng
wheel (ci rcui t di d not open) , repl ace swi tch.
VEHICLE SPEED SENSOR
To perform a compl ete test of the sensor and i ts
ci rcui try, refer to DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual .
EXTENDED IDLE SWITCH TEST
OPTIONAL POLICE PACKAGE ONLY
The extended i dl e swi tch i s used to rai se engi ne
i dl e speed to approxi matel y 1000 rpm when the
shi fter i s i n ei ther Park or Neutral posi ti on. A rocker-
type swi tch (extended i dl e swi tch) i s mounted to
i nstrument panel . This switch is available only
with 4.0L engine when supplied with optional
police package.
The extended i dl e swi tch wi l l control a ground ci r-
cui t goi ng to the powertrai n control modul e (PCM).
When a ground si gnal (through the swi tch) has been
recei ved at pi n/cavi ty A-12 (ci rcui t K78) of the PCM,
engi ne i dl e speed wi l l i ncrease.
(1) Bri ng engi ne to normal operati ng temperature
and turn extended i dl e swi tch to ON posi ti on. Engi ne
i dl e speed shoul d now i ncrease to approxi matel y
1000 rpm when shi fter i s i n ei ther Park or Neutral
posi ti on.
(2) I f i dl e speed does not i ncrease, unpl ug 4way
el ectri cal connector from swi tch.
(3) Check ci rcui t Z1L for ground. Ground shoul d
be present at al l ti mes. I f not, repai r open ci rcui t to
ground. Refer to Group 8W, Wi ri ng Di agrams for ci r-
cui t and wi ri ng i nformati on.
(4) I f ground i s present at Z1L, check conti nui ty of
swi tch between ci rcui ts Z1L and K78. I f conti nui ty i s
not present, repl ace swi tch. I f swi tch i s OK proceed
to next step.
(5) Wi th 4way el ectri cal connector sti l l unpl ugged
from swi tch, appl y a good ground to ci rcui t K78.
Engi ne i dl e speed shoul d i ncrease. I f not, proceed to
next step.
Fig. 38 Intake Manifold Air Temperature Sensor
2.5L Engine
Fig. 39 Power Steering Pump Pressure Switch2.5L
Engine
(6) Ground pi n/cavi ty A-12 di rectl y at PCM usi ng a
smal l paper cl i p. Be careful not to damage wi ri ng
wi th paper cl i p. I f engi ne i dl e speed i ncreases, i t can
be assumed that PCM i s functi oni ng correctl y. Repai r
open ci rcui t i n ci rcui t K78. I f engi ne i dl e speed wi l l
not i ncrease after appl yi ng a ground to pi n/cavi ty
A-12 (ci rcui t K78) di rectl y at PCM, repl ace PCM.
THROTTLE POSITION SENSOR (TPS)
To perform a compl ete test of the TPS (Fi g. 37) and
i ts ci rcui try, refer to the DRB scan tool and appropri -
ate Powertrai n Di agnosti cs Procedures manual . To
test the TPS onl y, refer to the fol l owi ng:
The TPS can be tested wi th a di gi tal vol tmeter.
The center termi nal of the TPS i s the output termi -
nal .
Wi th the i gni ti on key i n the ON posi ti on, check the
TPS output vol tage at the center termi nal wi re of the
connector. Check thi s at i dl e (throttl e pl ate cl osed)
and at Wi de Open Throttl e (WOT). At i dl e, TPS out-
put vol tage shoul d be greater than .26 vol ts but l ess
than .95 vol ts. At wi de open throttl e, TPS output
vol tage must be l ess than 4.49 vol ts. The output vol t-
age shoul d i ncrease gradual l y as the throttl e pl ate i s
sl owl y opened from i dl e to WOT.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
The fol l owi ng test procedure has been devel oped to
check throttl e body cal i brati ons for correct i dl e condi -
ti ons. The procedure shoul d be used to di agnose the
throttl e body for condi ti ons that may cause i dl e prob-
l ems. This procedure should be used only after
normal diagnostic procedures have failed to
produce results that indicate a throttle body
related problem. Be sure to check for proper
operation of the idle air control motor before
performing this test.
A speci al fi xed ori fi ce tool (number 6714) (Fi g. 40)
must be used for the fol l owi ng test. Thi s tool has a
fi xed i nternal di ameter of 0.185.
(1) Start the engi ne and bri ng to operati ng tem-
perature. Be sure al l accessori es are off before per-
formi ng thi s test.
(2) Shut off engi ne and remove ai r duct at throttl e
body.
(3) 2.5L 4Cylinder Engine: Near front/top of
val ve cover, di sconnect CCV tube at fi xed ori fi ce fi t-
ti ng (Fi g. 41). I nsert Speci al Tool 6714 i nto end of
di sconnected CCV tube (i nsert ei ther end of tool i nto
tube). Let tool and tube hang di sconnected at si de of
engi ne.
(4) 4.0L 6Cylinder Engine: Di sconnect CCV
tube (Fi g. 42) at i ntake mani fol d fi tti ng. Attach a
short pi ece of rubber hose to speci al tool 6714 (i nsert
rubber hose to ei ther end of tool ). I nstal l rubber hose/
tool to i ntake mani fol d fi tti ng. Let CCV tube hang
di sconnected at si de of engi ne.
(5) Connect DRB scan tool to 16way data l i nk
connector. Thi s connector i s l ocated at l ower edge of
i nstrument panel near steeri ng col umn. Refer to
vi ce manual for DRB operati on.
(6) Start engi ne and al l ow to warm up.
(7) Usi ng the DRB scan tool , scrol l through menus
as fol l ows: sel ectStand Al one DRB I I I , sel ect 1999
Di agnosti cs, sel ectEngi ne, sel ectSystem Test,
sel ectMi ni mum Ai r Fl ow.
(8) The DRB scan tool wi l l count down to stabi l i ze
i dl e rpm and di spl ay mi ni mum ai r fl ow i dl e rpm. The
i dl e rpm shoul d be between 500 and 900 rpm. I f i dl e
speed i s outsi de these speci fi cati ons, repl ace throttl e
body. Refer to Throttl e Body Removal /I nstal l ati on.
(9) Di sconnect DRB scan tool from vehi cl e.
Fig. 40 6714 Fixed Orifice Tool
Fig. 41 Install Orifice Tool 2.5L 4Cylinder Engine
(10) Remove ori fi ce tool and connect CCV tube to
engi ne.
(11) I nstal l ai r duct to throttl e body.
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 43). Refer to l abel on PDC cover
for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
FUEL PUMP RELAY
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 43). Refer to l abel on PDC
cover for rel ay l ocati on.
REMOVAL
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
THROTTLE BODY
control l ed by the Powertrai n Control Modul e (PCM).
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 44) or (Fi g.
45).
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(4) Remove four throttl e body mounti ng bol ts.
(5) Remove throttl e body from i ntake mani fol d.
Fig. 42 Install Orifice Tool 4.0L 6Cylinder Engine
(6) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
(1) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
Nm (100 i n. l bs.) torque.
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
(7) I nstal l ai r cl eaner at throttl e body.
THROTTLE POSITION SENSOR (TPS)
The TPS i s mounted to the throttl e body (Fi g. 44)
or (Fi g. 45).
REMOVAL
(1) Di sconnect TPS el ectri cal connector.
(2) Remove TPS mounti ng screws (Fi g. 46).
(3) Remove TPS.
INSTALLATION
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 47). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs).
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
Fig. 44 Throttle Body and Sensor Locations4.0L
Engine
Fig. 45 Throttle Body and Sensor Locations2.5L
Engine
Fig. 46 TPS Mounting Screws
Fig. 47 Throttle Position SensorInstallation
The I AC motor i s l ocated on the si de of the throttl e
body (Fi g. 44) or (Fi g. 45).
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 48).
(4) Remove I AC motor from throttl e body.
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r cl eaner tube to throttl e body.
SENSOR
The MAP sensor i s mounted to the si de of the
throttl e body (Fi g. 44) or (Fi g. 45). An L-shaped rub-
ber fi tti ng i s used to connect the MAP sensor to
throttl e body (Fi g. 49).
REMOVAL
(1) Remove ai r cl eaner i ntake tube at throttl e
body.
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 49).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 49) from throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
(4) I nstal l ai r cl eaner i ntake tube.
SOLENOID
removal /i nstal l ati on procedures.
The PCM i s l ocated i n the engi ne compartment
next to the ai r cl eaner assembl y (Fi g. 50).
REMOVAL
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
Fig. 48 Mounting Bolts (Screws)IAC Motor
Fig. 49 MAP Sensor Mounting
Fig. 50 PCM Location
(2) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(3) Careful l y unpl ug the three 32way connectors
(Fi g. 51) from PCM.
(4) Remove three PCM mounti ng bol ts and remove
PCM from vehi cl e.
INSTALLATION
(1) I nstal l PCM and mounti ng bol ts to vehi cl e.
(2) Ti ghten bol ts to 4 Nm (35 i n. l bs.).
(3) Check pi n connectors i n the PCM and the three
32way connectors for corrosi on or damage. Al so, the
pi n hei ghts i n connectors shoul d al l be same. Repai r
as necessary before i nstal l i ng connectors.
(4) I nstal l three 32way connectors.
(5) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(6) I nstal l battery cabl e.
(7) Use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal I denti fi cati on Number (VI N)
and ori gi nal vehi cl e mi l eage.
POWER STEERING PRESSURE SWITCH 2. 5L
ENGINE
Thi s swi tch i s not used wi th 4.0L si x-cyl i nder
engi nes.
The power steeri ng pressure swi tch i s i nstal l ed i n
the power steeri ng hi gh-pressure hose (Fi g. 52).
REMOVAL
(1) Di sconnect el ectri cal connector from power
steeri ng pressure swi tch.
(2) Pl ace a smal l contai ner or shop towel beneath
swi tch to col l ect any excess fl ui d.
(3) Remove swi tch. Use back-up wrench on power
steeri ng l i ne to prevent l i ne bendi ng.
INSTALLATION
(1) I nstal l power steeri ng swi tch i nto power steer-
i ng l i ne.
(2) Ti ghten to 1422 Nm (124195 i n. l bs.) torque.
(3) Connect el ectri cal connector to swi tch.
(4) Check power steeri ng fl ui d and add as neces-
sary.
(5) Start engi ne and agai n check power steeri ng
fl ui d. Add fl ui d i f necessary.
OXYGEN SENSOR
The upstream O2S sensor i s l ocated i n exhaust
downpi pe. The downstream sensor i s l ocated near
outl et end of catal yti c converter. Refer to (Fi g. 53).
Fig. 51 PCM Mounting
Fig. 52 Power Steering Pressure Switch
Fig. 53 Oxygen Sensor Locations
REMOVAL
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(2) Di sconnect wi re connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor. Snap-On oxygen sensor
wrench (number YA 8875) may be used for removal
and i nstal l ati on.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 Nm (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector.
(3) Lower vehi cl e.
AIR CLEANER ELEMENT (FILTER)
REMOVAL
(1) Unl ock ai r tube cl amp (Fi g. 54) at ai r cl eaner
cover. To unl ock cl amp, attach adjustabl e pl i ers to
cl amp and rotate pl i ers as shown i n (Fi g. 55).
(2) Remove ai r tube at cover.
(3) Pry back three cl i ps retai ni ng ai r cl eaner cover
to ai r cl eaner housi ng.
(4) Remove housi ng cover and remove ai r cl eaner
el ement.
(5) Cl ean i nsi de of housi ng before repl aci ng el e-
ment.
INSTALLATION
(1) I nstal l ai r cl eaner el ement i nto housi ng.
(2) I nstal l ai r cl eaner cover to housi ng (three
cl i ps). Be sure cover i s properl y seated to ai r cl eaner
housi ng.
(3) I nstal l ai r tube and cl amp to cover. Compress
cl amp snugl y wi th adjustabl e pl i ers as shown i n (Fi g.
56).
Fig. 54 Air Cleaner Housing and Element (Filter)
Fig. 55 Clamp Removal
Fig. 56 Clamp Installation
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
The cool ant temperature sensor i s i nstal l ed i n the
thermostat housi ng (Fi g. 57).
REMOVAL
(1) Parti al l y drai n cool i ng system unti l cool ant
l evel i s bel ow cyl i nder head. Observe the WARN-
INGS i n Group 7, Cool i ng.
(2) Di sconnect cool ant temperature sensor wi re
connector.
(3) Remove sensor from thermostat housi ng.
INSTALLATION
(1) Appl y seal ant to sensor threads (new repl ace-
ment sensors wi l l have seal ant al ready appl i ed).
(2) I nstal l cool ant temperature sensor i nto thermo-
stat housi ng. Ti ghten to 11 Nm (8 ft. l bs.) torque.
(3) Connect wi re connector.
(4) Fi l l cool i ng system. Refer to Group 7, Cool i ng
System.
SENSOR
The i ntake mani fol d ai r temperature (I AT) sensor
i s i nstal l ed i nto i ntake mani fol d pl enum near throttl e
body (Fi g. 58) or (Fi g. 59).
REMOVAL
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
(2) Remove sensor from i ntake mani fol d.
INSTALLATION
(1) I nstal l I AT sensor i nto i ntake mani fol d.
Ti ghten sensor to 28 Nm (20 ft. l bs.) torque.
(2) Connect el ectri cal connector to sensor.
The vehi cl e speed sensor i s l ocated on the speed-
ometer pi ni on gear adapter (Fi g. 60) or (Fi g. 61). The
pi ni on gear adapter i s l ocated on the extensi on hous-
i ng of transmi ssi on (dri vers si de).
Typical
Fig. 58 IAT Sensor Location4.0L Engine
Fig. 59 IAT Sensor Location2.5L Engine
REMOVAL
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor mounti ng bol t (Fi g. 62).
(4) Remove sensor (pul l strai ght out) from speed-
ometer pi ni on gear adapter (Fi g. 62). Do not remove
gear adapter from transmi ssi on.
INSTALLATION
(1) Cl ean i nsi de of speedometer pi ni on gear
adapter before i nstal l i ng speed sensor.
(2) I nstal l sensor i nto speedometer gear adapter
and i nstal l mounti ng bol t. Before tightening bolt,
verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
(3) Ti ghten sensor mounti ng bol t to 2.2 Nm (20 i n.
l bs.) torque.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Ai r Cl eaner Housi ng Mount. Bol ts . . . . . . . . . 8 Nm
(71 i n. l bs.)
Engi ne Cool ant Temperature Sensor . . . . . . 11 Nm
(96 i n. l bs.)
I AC Motor-To-Throttl e Body Bol ts . . . . . . . . . 7 Nm
(60 i n. l bs.)
I ntake Mani fol d Ai r Temp. Sensor . . . . . . . . 28 Nm
(20 ft. l bs.)
MAP Sensor Mounti ng Screws . . 3 Nm (25 i n. l bs.)
Oxygen Sensor . . . . . . . . . . . . . . 30 Nm (22 ft. l bs.)
PCM Mounti ng Screws . . . . . . . . 4 Nm (35 i n. l bs.)
Power Steeri ng Pressure Swi tch . . . . . . . 1422 Nm
(124195 i n. l bs.)
Throttl e Body Mounti ng Bol ts . 11 Nm (100 i n. l bs.)
Throttl e Posi ti on Sensor Mounti ng Screws . . 7 Nm
(60 i n. l bs.)
Typical
Typical
Fig. 62 Sensor Removal/Installation
DESCRIPTION TORQUE
Vehi cl e Speed Sensor Mounti ng Bol t . . . . . . 2.2 Nm
(20 i n. l bs.)
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench, Fuel Pump Module Locknut6856
Adapters, Fuel Pressure Test6539 and/or 6631
Fitting, Air Metering6714
O2S (Oxygen Sensor) Remover/InstallerC-4907
Test Kit, Fuel Pressure5069
Test Kit, Fuel PressureC-4799-B
Fuel Line Removal Tool6782
FUEL SYSTEM2.5L DIESEL ENGINE
CONTENTS
page page
2. 5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . 2
FUEL INJECTION SYSTEM
2. 5L DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . 23
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
FUEL REQUIREMENTS2.5L DIESEL . . . . . . . . . 1
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . . 1
GENERAL INFORMATION
FUEL SHUTDOWN SOLENOID
The fuel shutdown solenoid is controlled and
operated by the MSA.
The fuel shutdown (shut-off) sol enoi d i s used to
el ectri cal l y shut off the di esel fuel suppl y to the hi gh-
pressure fuel i njecti on pump. The sol enoi d i s
mounted to the rear of the i njecti on pump.
The sol enoi d control s starti ng and stoppi ng of the
engi ne regardl ess of the posi ti on of the accel erator
pedal . When the i gni ti on (key) swi tch i s OFF, the
sol enoi d i s shut off and fuel fl ow i s not al l owed to the
fuel i njecti on pump. When the key i s pl aced i n the
ON or START posi ti ons, fuel suppl y i s al l owed at the
i njecti on pump.
FUEL REQUIREMENTS 2. 5L DIESEL
Premi um qual i ty di esel fuel wi th a mi ni mum Cet-
ane rati ng of 50 or hi gher i s requi red.
XJ FUEL SYSTEM 2. 5L DIESEL ENGINE 14 - 1
FUEL DELIVERY SYSTEM2.5L DIESEL ENGINE
INDEX
page page
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . . 6
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . . 3
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 3
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . . 7
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . 4
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL SHUTDOWN SOLENOID . . . . . . . . . . . . . . 3
FUEL SYSTEM PRESSURE WARNING . . . . . . . . 2
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FUEL TANK MODULE . . . . . . . . . . . . . . . . . . . . . 3
LOW-PRESSURE TYPE . . . . . . . . . . . . . . . . . . 5
HIGH-PRESSURE FUEL LINES . . . . . . . . . . . . . . 6
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 2
QUICK-CONNECT FITTINGSLOW PRESSURE
TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR IN FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . 10
FUEL HEATER RELAY TEST . . . . . . . . . . . . . . . 10
FUEL INJECTION PUMP TEST . . . . . . . . . . . . . . 11
FUEL INJECTOR / NEEDLE MOVEMENT
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 11
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . 10
FUEL SHUTDOWN SOLENOID TEST . . . . . . . . . 12
FUEL SUPPLY RESTRICTIONS . . . . . . . . . . . . . 11
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 7
HIGH-PRESSURE FUEL LINE LEAK TEST . . . . . 12
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
AIR BLEED PROCEDURES . . . . . . . . . . . . . . . . 12
FUEL INJECTION PUMP TIMING . . . . . . . . . . . . 13
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 13
AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . 13
FUEL DRAIN TUBES . . . . . . . . . . . . . . . . . . . . . 14
FUEL FILTER/WATER SEPARATOR . . . . . . . . . . 14
FUEL HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL HEATER RELAY . . . . . . . . . . . . . . . . . . . . 15
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . 15
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . 15
FUEL RESERVOIR MODULE . . . . . . . . . . . . . . . 21
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HIGH-PRESSURE LINES . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
FUEL INJECTOR FIRING SEQUENCE . . . . . . . . 22
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . 22
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . 22
IDLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
INTRODUCTION
Thi s Fuel Del i very secti on wi l l cover components
not control l ed by the PCM. For components con-
trol l ed by the PCM, refer to the Fuel I njecti on Sys-
tem2.5L Di esel Engi ne secti on of thi s group.
The fuel heater rel ay, fuel heater and fuel gauge
are not operated by the PCM. These components are
control l ed by the i gni ti on (key) swi tch. Al l other fuel
system el ectri cal components necessary to operate
the engi ne are control l ed or regul ated by the PCM.
FUEL SYSTEM PRESSURE WARNING
WARNING: HIGHPRESSURE FUEL LINES DELIVER
DIESEL FUEL UNDER EXTREME PRESSURE FROM
THE INJECTION PUMP TO THE FUEL INJECTORS.
THIS MAY BE AS HIGH AS 45,000 KPA (6526 PSI).
USE EXTREME CAUTION WHEN INSPECTING FOR
HIGHPRESSURE FUEL LEAKS. INSPECT FOR
HIGHPRESSURE FUEL LEAKS WITH A SHEET OF
CARDBOARD (Fig. 1). HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL TANK
The fuel tank and tank mounti ng used wi th the
di esel powered engi ne i s the same as used wi th gas-
ol i ne powered model s, al though the fuel tank modul e
i s di fferent.
The fuel tank contai ns the fuel tank modul e and
two rol l over val ves. Two fuel l i nes are routed to the
fuel tank modul e. One l i ne i s used for fuel suppl y to
the fuel fi l ter/water separator. The other i s used to
return excess fuel back to the fuel tank.
The fuel tank modul e contai ns the fuel gauge el ec-
tri cal sendi ng uni t. An electrical fuel pump is not
used with the diesel engine.
14 - 2 FUEL SYSTEM 2. 5L DIESEL ENGINE XJ
FUEL TANK MODULE
An el ectri c fuel pump i s not attached to the fuel
tank modul e for di esel powered engi nes. Fuel i s
si phoned by the fuel i njecti on pump.
The fuel tank modul e i s i nstal l ed i n the top of the
fuel tank. The fuel tank modul e contai ns the fol l ow-
i ng components:
Fuel reservoi r
A separate i n-tank fuel fi l ter
El ectri c fuel gauge sendi ng uni t
Fuel suppl y l i ne connecti on
Fuel return l i ne connecti on
The fuel gauge sendi ng uni t i s attached to the si de
of the fuel pump modul e. The sendi ng uni t consi sts of
a fl oat, an arm, and a vari abl e resi stor (track). The
track i s used to send an el ectri cal si gnal used for fuel
gauge operati on.
As the fuel l evel i ncreases, the fl oat and arm move
up. Thi s decreases the sendi ng uni t resi stance, caus-
i ng the PCM to send a si gnal to the fuel gauge on the
i nstrument panel to read ful l . As the fuel l evel
decreases, the fl oat and arm move down. Thi s
i ncreases the sendi ng uni t resi stance, causi ng the
PCM to send a si gnal to the fuel gauge on the i nstru-
ment panel to read empty.
FUEL FILTER/WATER SEPARATOR
The fuel fi l ter/water separator assembl y i s l ocated
i n the engi ne compartment near the strut tower (Fi g.
2).
The combi nati on fuel fi l ter/water separator pro-
tects the fuel i njecti on pump by hel pi ng to remove
water and contami nants from the fuel . Moi sture col -
l ects at the bottom of the fi l ter/separator i n a pl asti c
bowl .
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and fuel drai n
val ve.
For i nformati on on the fuel heater, refer to Fuel
Heater i n thi s group.
Refer to the mai ntenance schedul es i n Group 0 i n
thi s manual for the recommended fuel fi l ter repl ace-
ment i nterval s.
For peri odi c drai ni ng of water from the bowl , refer
to Fuel Fi l ter/Water Separator Removal /I nstal l ati on
i n thi s group.
The fuel shutdown solenoid is controlled and
operated by the MSA.
The fuel shutdown (shut-off) sol enoi d i s used to
el ectri cal l y shut off the di esel fuel suppl y to the hi gh-
pressure fuel i njecti on pump. The sol enoi d i s
mounted to the rear of the i njecti on pump.
The sol enoi d control s starti ng and stoppi ng of the
engi ne regardl ess of the posi ti on of the accel erator
pedal . When the i gni ti on (key) swi tch i s OFF, the
sol enoi d i s shut off and fuel fl ow i s not al l owed to the
fuel i njecti on pump. When the key i s pl aced i n the
ON or START posi ti ons, fuel suppl y i s al l owed at the
i njecti on pump.
Fig. 1 Typical Fuel Pressure Test at Injector Fig. 2 Fuel Filter/Water Separator Location
FUEL INJECTION PUMP
The fuel i njecti on pump i s a mechani cal di stri bu-
tortype, Bosch VP36 seri es (Fi g. 3). A gear on the
end of the i njecti on pump shaft meshes wi th the
dri ve gear at the front of engi ne. The pump i s
mechani cal l y ti med to the engi ne. The MSA can
make adjustments to the ti mi ng of the i njecti on
pump.
The i njecti on pump contai ns the fuel shutdown
sol enoi d, fuel temperature sensor, control sl eeve sen-
sor, fuel quanti ty actuator and the fuel ti mi ng sol e-
noi d (Fi g. 3).
I n the el ectroni cal l y control l ed i njecti on pump, the
pump pl unger works the same as the pump pl unger
i n a mechani cal l y control l ed i njecti on pump, but the
amount of fuel and the ti me the fuel i s i njected i s
control l ed by the vehi cl es MSA, i nstead of by a
mechani cal governor assembl y. A sol enoi d control l ed
by the MSA i s used i n pl ace of the mechani cal gover-
nor assembl y, and i t moves a control sl eeve i nsi de the
pump that regul ates the amount of fuel bei ng
i njected. There i s no mechani cal connecti on between
the accel erator pedal and the el ectroni cal l y control l ed
i njecti on pump. I nstead, a sensor connected to the
accel erator pedal sends a si gnal to the MSA that rep-
resents the actual posi ti on of the accel erator pedal .
The MSA uses thi s i nput, al ong wi th i nput from
other sensors to move the control sl eeve to del i ver
the appropri ate amount of fuel . Thi s system i s known
as Dri ve-By-Wi re.
The actual ti me that the fuel i s del i vered i s very
i mportant to the di esel combusti on process. The MSA
moni tors outputs from the engi ne speed sensor (fl y-
wheel posi ti on i n degrees), and the fuel i njector sen-
sor (mechani cal movement wi thi n the #1 cyl i nder
fuel i njector). Outputs from the Accel erator Pedal
Posi ti on sensor, engi ne speed sensor (engi ne rpm)
and engi ne cool ant temperature sensor are al so used.
The MSA wi l l then compare i ts set val ues to these
outputs to el ectri cal l y adjust the amount of fuel ti m-
i ng (amount of advance) wi thi n the i njecti on pump.
Thi s i s referred to as Cl osed Loop operati on. The
MSA moni tors fuel ti mi ng by compari ng i ts set val ue
to when the i njector #1 opens. I f the val ue i s greater
than a preset val ue a faul t wi l l be set.
Actual el ectri c fuel ti mi ng (amount of advance) i s
accompl i shed by the fuel ti mi ng sol enoi d mounted to
the bottom of the i njecti on pump (Fi g. 3). Fuel ti mi ng
wi l l be adjusted by the MSA, whi ch control s the fuel
ti mi ng sol enoi d.
An overfl ow val ve i s attached i nto the fuel return
l i ne at the rear of the fuel i njecti on pump (Fi g. 3).
Thi s val ve serves two purposes. One i s to ensure that
a certai n amount of resi dual pressure i s mai ntai ned
wi thi n the pump when the engi ne i s swi tched off.
Thi s wi l l prevent the fuel ti mi ng mechani sm wi thi n
the i njecti on pump from returni ng to i ts zero posi -
ti on. The other purpose i s to al l ow excess fuel to be
returned to the fuel tank through the fuel return
l i ne. The pressure val ues wi thi n thi s val ve are preset
and can not be adjusted.
The fuel i njecti on pump suppl i es hi ghpressure
fuel of approxi matel y 45,000 kPa (6526 psi ) to each
i njector i n preci se metered amounts at the correct
ti me.
For mechani cal i njecti on pump ti mi ng, refer to
Fuel I njecti on Pump Ti mi ng i n the Servi ce Proce-
dures secti on of thi s group.
FUEL INJECTORS
Fuel drai n tubes (Fi g. 4) are used to route excess
fuel back to the overfl ow val ve at the rear of the
i njecti on pump. Thi s excess fuel i s then returned to
the fuel tank through the fuel return l i ne.
The i njectors are connected to the fuel i njecti on
pump by the hi ghpressure fuel l i nes. A separate
i njector i s used for each of the four cyl i nders. An
i njector contai ni ng a sensor (Fi g. 5) i s used on the
cyl i nder number one i njector. Thi s i njector i s cal l ed
i nstrumented i njector #1 or needl e movement sensor.
I t i s used to tel l the MSA when the #1 i njectors
i nternal spri ng-l oaded val ve seat has been forced
open by pressuri zed fuel bei ng del i vered to the cyl i n-
der, whi ch i s at the end of i ts compressi on stroke.
When the i nstrumented i njectors val ve seat i s force
open, i t sends a smal l vol tage spi ke pul se to the
MSA. Thi s tel l s the MSA that cyl i nder #1 i s fi ri ng. I t
i s not used wi th the other three i njectors.
Fuel enters the i njector at the fuel i nl et (top of
i njector) and i s routed to the needl e val ve bore. When
fuel pressure ri ses to approxi matel y 15,00015,800
Fig. 3 Fuel Injection Pump
kPa (21752291 psi ), the needl e val ve spri ng tensi on
i s overcome. The needl e val ve ri ses and fuel fl ows
through the spray hol es i n the nozzl e ti p i nto the
combusti on chamber. The pressure requi red to l i ft
the needl e val ve i s the i njector openi ng pressure set-
ti ng. Thi s i s referred to as the pop-off pressure set-
ti ng.
Fuel pressure i n the i njector ci rcui t decreases after
i njecti on. The i njector needl e val ve i s i mmedi atel y
cl osed by the needl e val ve spri ng and fuel fl ow i nto
the combusti on chamber i s stopped. Exhaust gases
are prevented from enteri ng the i njector nozzl e by
the needl e val ve.
A copper washer (gasket) i s used at the base of
each i njector (Fi g. 5) to prevent combusti on gases
from escapi ng.
Fuel i njector fi ri ng sequence i s 1342.
LOW-PRESSURE TYPE
Al so refer to the proceedi ng secti on on Qui ckCon-
nect Fi tti ngs.
I nspect al l hose connecti ons such as cl amps, cou-
pl i ngs and fi tti ngs to make sure they are secure and
l eaks are not present. The component shoul d be
repl aced i mmedi atel y i f there i s any evi dence of deg-
radati on that coul d resul t i n fai l ure.
Never attempt to repai r a pl asti c fuel l i ne/tube or a
qui ckconnect fi tti ng. Repl ace compl ete l i ne/tube as
necessary.
Avoi d contact of any fuel tubes/hoses wi th other
vehi cl e components that coul d cause abrasi ons or
scuffi ng. Be sure that the fuel l i nes/tubes are prop-
erl y routed to prevent pi nchi ng and to avoi d heat
sources.
The l i nes/tubes/hoses are of a speci al constructi on.
I f i t i s necessary to repl ace these l i nes/tubes/hoses,
use onl y ori gi nal equi pment type.
The hose cl amps used to secure the rubber hoses
are of a speci al rol l ed edge constructi on. Thi s con-
structi on i s used to prevent the edge of the cl amp
from cutti ng i nto the hose. Onl y these rol l ed edge
type cl amps may be used i n thi s system. Al l other
types of cl amps may cut i nto the hoses and cause
fuel l eaks.
Where a rubber hose i s joi ned to a metal tube
(staked), do not attempt to repai r. Repl ace enti re
l i ne/tube assembl y.
Use new ori gi nal equi pment type hose cl amps.
Ti ghten hose cl amps to 2 Nm (20 i n. l bs.) torque.
QUICK-CONNECT FITTINGS LOW PRESSURE
TYPE
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type (Fi g. 6). Refer to Qui ck-Connect Fi tti ngs i n
the Removal /I nstal l ati on secti on for more i nforma-
ti on.
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fig. 4 Fuel Injectors and Drain Tubes
Fig. 5 Fuel Injector Sensor
HIGH-PRESSURE FUEL LINES
CAUTION: The highpressure fuel lines must be
held securely in place in their holders. The lines
cannot contact each other or other components. Do
not attempt to weld highpressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of highpressure
fuel line is necessary.
Hi ghpressure fuel l i nes del i ver fuel under pres-
sure of up to approxi matel y 45,000 kPa (6526 psi )
from the i njecti on pump to the fuel i njectors. The
l i nes expand and contract from the hi ghpressure
fuel pul ses generated duri ng the i njecti on process. Al l
hi ghpressure fuel l i nes are of the same l ength and
i nsi de di ameter. Correct hi ghpressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
WARNING: USE EXTREME CAUTION WHEN
INSPECTING FOR HIGHPRESSURE FUEL LEAKS.
INSPECT FOR HIGHPRESSURE FUEL LEAKS WITH
A SHEET OF CARDBOARD. HIGH FUEL INJECTION
PRESSURE CAN CAUSE PERSONAL INJURY IF
CONTACT IS MADE WITH THE SKIN.
FUEL DRAIN TUBES
These rubber tubes are l owpressure type.
Some excess fuel i s conti nual l y vented from the
fuel i njecti on pump. Duri ng i njecti on, a smal l amount
of fuel fl ows past the i njector nozzl e and i s not
i njected i nto the combusti on chamber. Thi s fuel
drai ns i nto the fuel drai n tubes (Fi g. 7) and back to
the tee banjo fi tti ng, whi ch i s connected to the same
l i ne as the overfl ow val ve, whi ch al l ows a vari abl e
quanti ty to return to the fuel tank. The overfl ow
val ve i s cal i brated to open at a preset pressure.
Excess fuel not requi red by the pump to mai ntai n the
mi ni mum pump cavi ty pressure i s then returned
through the overfl ow val ve and on to the fuel tank
through the fuel return l i ne.
FUEL HEATER
The fuel heater i s used to prevent di esel fuel from
waxi ng duri ng col d weather operati on. The fuel
heater i s l ocated i n the bottom pl asti c bowl of the
fuel fi l ter/water separator (Fi g. 8).
The el ement i nsi de the heater assembl y i s made of
a Posi ti ve Temperature Coeffi ci ent (PTC) materi al ,
and has power appl i ed to i t by the fuel heater rel ay
anyti me the i gni ti on key i s i n the on posi ti on. PTC
materi al has a hi gh resi stance to current fl ow when
i ts temperature i s hi gh, whi ch means that i t wi l l not
generate heat when the temperature i s above a cer-
tai n val ue. When the temperature i s bel ow 7C (45
F), the resi stance of the PTC el ement i s l owered, and
al l ows current to fl ow through the fuel heater el e-
ment warmi ng the fuel . When the temperature i s
above 29C (85 F), the PTC el ements resi stance
ri ses, and current fl ow through the heater el ement
stops.
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch and through the fuel heater
rel ay. Refer to the fol l owi ng Fuel Heater Rel ay for
Fig. 6 Plastic Retainer Ring-Type Fitting
Fig. 7 Fuel Drain Tubes
addi ti onal i nformati on. The fuel heater and fuel
heater relay are not controlled by the Power-
train Control Module (ECM).
Current draw for the heater el ement i s 150 watts
at 14 vol ts (DC).
FUEL HEATER RELAY
Vol tage to operate the fuel heater i s suppl i ed from
the i gni ti on (key) swi tch through the fuel heater
rel ay. The PCM or MSA is not used to control
this relay.
The fuel heater rel ay i s l ocated i n the PDC. The
PDC i s l ocated next to the battery i n the engi ne com-
partment. For the l ocati on of the rel ay wi thi n the
PDC, refer to l abel on PDC cover.
GENERAL INFORMATION
Thi s secti on of the group wi l l cover a general di ag-
nosi s of di esel engi ne fuel system components.
Diagnostic Trouble Codes: Refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System
for a l i st of Di agnosti c Troubl e Codes (DTCs) for cer-
tai n fuel system components.
The PCM and MSA must be tested wi th the
DRBI I I scan tool . The DRBI I I shoul d be the fi rst
step i n any di agnosi s of engi ne performance com-
pl ai nts. Refer to the 1997 ZJ/ZG 2.5L Di esel Power-
trai n Di agnosti c Procedures manual for di agnosi s
and testi ng of the di esel engi ne control system.
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected, or i ncor-
rectl y routed wi res and hoses shoul d be made before
attempti ng to di agnose or servi ce the di esel fuel
i njecti on system. A vi sual check wi l l hel p fi nd these
condi ti ons. I t al so saves unnecessary test and di ag-
nosti c ti me. A thorough vi sual i nspecti on of the fuel
i njecti on system i ncl udes the fol l owi ng checks:
(1) Be sure that the battery connecti ons are ti ght
and not corroded.
(2) Be sure that the 60 way connector i s ful l y
engaged wi th the PCM (Fi g. 9).
(3) Be sure that the 68 way connector i s ful l y
engaged wi th the MSA (Fi g. 10).
(4) Veri fy that the el ectri cal connecti ons for the
ASD rel ay are cl ean and free of corrosi on. Thi s rel ay
i s l ocated i n the PDC. For the l ocati on of the rel ay
wi thi n the PDC, refer to l abel on PDC cover.
(5) Veri fy that the el ectri cal connecti ons for the
fuel heater rel ay are cl ean and free of corrosi on. Thi s
rel ay i s l ocated i n the PDC. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
(6) Be sure the el ectri cal connectors at the ends of
the gl ow pl ugs (Fi g. 11) are ti ght and free of corro-
si on.
(7) Be sure that the el ectri cal connecti ons at the
gl ow pl ug rel ay are ti ght and not corroded. The gl ow
pl ug rel ay i s l ocated i n the engi ne compartment on
the l efti nner fender (Fi g. 12).
(8) I nspect the starter motor and starter sol enoi d
connecti ons for ti ghtness and corrosi on.
Fig. 8 Fuel Heater Temperature Sensor and Element
Location
Fig. 9 PCM LocationTypical
(9) Veri fy that the Fuel I njecti on Pump el ectri cal
connector i s fi rml y connected. I nspect the connector
for corrosi on or damaged wi res. The sol enoi d i s
mounted to the rear of the i njecti on pump (Fi g. 13).
(10) Veri fy that the fuel heater el ectri cal connector
i s fi rml y attached to the fi l ter bowl at the bottom of
the fuel fi l ter/water separator. I nspect the connector
for corrosi on or damaged wi res.
(11) Veri fy that the el ectri cal pi gtai l connector
(sensor connector) (Fi g. 14) for the fuel i njector sen-
sor i s fi rml y connected to the engi ne wi ri ng harness.
I nspect the connector for corrosi on or damaged wi res.
Thi s sensor i s used on the #1 cyl i nder i njector onl y.
(12) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes or a col l apsed or pl ugged
muffl er.
(13) Veri fy that the harness connector i s fi rml y
connected to the vehi cl e speed sensor (Fi g. 15) or
(Fi g. 16).
(14) Veri fy turbocharger wastegate operati on.
Refer to Group 11, Exhaust System and I ntake Man-
i fol d Group for i nformati on.
(15) Veri fy that the harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor.
The sensor i s l ocated on the si de of cyl i nder head
near the rear of fuel i njecti on pump (Fi g. 17).
(16) Check for ai r i n the fuel system. Refer to the
Ai r Bl eed Procedure.
(17) I nspect al l fuel suppl y and return l i nes for
si gns of l eakage.
Fig. 10 MSA LocationTypical
Fig. 11 Glow Plug Connector
Fig. 12 Glow Plug Relay Location
Fig. 13 Fuel Shutdown Solenoid Location
(18) Be sure that the ground connecti ons are ti ght
and free of corrosi on. Refer to Group 8, Wi ri ng for
l ocati ons of ground connecti ons.
(19) I nspect the ai r cl eaner el ement (fi l ter) for
restri cti ons.
(20) Be sure that the turbocharger output hose i s
properl y connected to the charge ai r cool er (i nter-
cool er) i nl et tube. Veri fy that the charge ai r cool er
output hose i s properl y connected to the cool er and
the i ntake mani fol d. Refer to Group 11, Exhaust Sys-
tem and I ntake Mani fol d for i nformati on.
(21) Be sure that the vacuum hoses to the vacuum
pump are connected and not l eaki ng. The vacuum
pump i s l ocated i n the front of engi ne (i nternal ) and
i s dri ven from the crankshaft gear (Fi g. 18). Di scon-
nect the hose and check for mi ni mum vacuum from
the pump. Refer to Group 5, Brake System for spec-
i fi cati ons and procedures.
(22) Be sure that the accessory dri ve bel t i s not
damaged or sl i ppi ng.
(23) Veri fy there i s a good connecti on at the engi ne
speed sensor. Refer to the Fuel I njecti on System i n
thi s secti on for l ocati on of the engi ne speed sensor
l ocati on.
Fig. 15 Vehicle Speed Sensor2 Wheel Drive
Location
(24) Veri fy there i s a good connecti on at the Boost
Pressure Sensor, whi ch i s a part of the ai r i ntake
assembl y.
AIR IN FUEL SYSTEM
Ai r wi l l enter the fuel system whenever the fuel
suppl y l i nes, fuel fi l ter/water separator, fuel fi l ter
bowl , i njecti on pump, hi ghpressure l i nes or i njectors
are removed or di sconnected. Ai r wi l l al so enter the
fuel system whenever the fuel tank has been run
empty.
Ai r trapped i n the fuel system can resul t i n hard
starti ng, a rough runni ng engi ne, engi ne mi sfi re, l ow
power, excessi ve smoke and fuel knock. After servi ce
i s performed, ai r must be bl ed from the system
before starti ng the engi ne.
I nspect the fuel system from the fuel tank to the
i njectors for l oose connecti ons. Leaki ng fuel i s an
i ndi cator of l oose connecti ons or defecti ve seal s. Ai r
can al so enter the fuel system between the fuel tank
and the i njecti on pump. I nspect the fuel tank and
fuel l i nes for damage that mi ght al l ow ai r i nto the
system.
For ai r bl eedi ng, refer to Ai r Bl eed Procedure i n
the Servi ce Procedures secti on of thi s group.
FUEL HEATER RELAY TEST
The fuel heater rel ay i s l ocated i n the Power Di s-
tri buti on Center (PDC). Refer to Rel aysOperati on/
Testi ng i n Fuel I njecti on System secti on of thi s group
for test procedures.
FUEL INJECTOR TEST
The fuel i njecti on nozzl es, l ocated on the engi ne
cyl i nder head, spray fuel under hi gh pressure i nto
the i ndi vi dual combusti on chambers. Pressuri zed
fuel , del i vered by the fuel i njecti on pump, unseats a
spri ng-l oaded needl e val ve i nsi de the i njector, and
the fuel i s atomi zed as i t escapes through the i njector
openi ng i nto the engi nes combusti on chamber. I f the
fuel i njector does not operate properl y, the engi ne
may mi sfi re, or cause other dri veabi l i ty probl ems.
A l eak i n the i njecti on pumptoi njector hi ghpres-
sure fuel l i ne can cause many of the same symptoms
as a mal functi oni ng i njector. I nspect for a l eak i n the
hi ghpressure l i nes before checki ng for a mal func-
ti oni ng fuel i njector.
WARNING: THE INJECTION PUMP SUPPLIES
HIGHPRESSURE FUEL OF UP TO APPROXI-
MATELY 45,000 KPA (6526 PSI) TO EACH INDIVID-
UAL INJECTOR THROUGH THE HIGHPRESSURE
LINES. FUEL UNDER THIS AMOUNT OF PRESSURE
CAN PENETRATE THE SKIN AND CAUSE PER-
SONAL INJURY. WEAR SAFETY GOGGLES AND
ADEQUATE PROTECTIVE CLOTHING. AVOID CON-
TACT WITH FUEL SPRAY WHEN BLEEDING HIGH
PRESSURE FUEL LINES.
WARNING: DO NOT BLEED AIR FROM THE FUEL
SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
BLEEDING AIR FROM THE FUEL SYSTEM.
To determi ne whi ch fuel i njector i s mal functi oni ng,
run the engi ne and l oosen the hi ghpressure fuel l i ne
nut at the i njector (Fi g. 19). Li sten for a change i n
engi ne speed. I f engi ne speed drops, the i njector was
operati ng normal l y. I f engi ne speed remai ns the
same, the i njector may be mal functi oni ng. After test-
i ng, ti ghten the l i ne nut to 30 Nm (22 ft. l bs.)
torque. Test al l i njectors i n the same manner one at
a ti me.
Once an i njector has been found to be mal functi on-
i ng, remove i t from the engi ne and test i t. Refer to
the Removal /I nstal l ati on secti on of thi s group for pro-
cedures.
After the i njector has been removed, i nstal l i t to a
benchmount i njector tester. Refer to operati ng
i nstructi ons suppl i ed wi th tester for procedures.
The openi ng pressure or pop pressure shoul d be
15,00015,800 kPa (21752291 psi ). I f the fuel i njec-
tor needl e val ve i s openi ng (poppi ng) to earl y or to
l ate, repl ace the i njector.
Fig. 18 Vaccum Pump at Front of Engine
FUEL INJECTOR / NEEDLE MOVEMENT
SENSOR TEST
The needl e movement sensor i s used onl y on the
number1 cyl i nder fuel i njector (Fi g. 20). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
Testi ng the needl e movement sensor requi res the
use of a DRB Scan tool . Refer to the Powertrai n
Di agnosti c Procedures manual for addi ti onal i nfor-
mati on.
FUEL INJECTION PUMP TEST
The injection pump is not to be serviced or
the warranty may be voided. If the injection
pump requires service, the complete assembly
must be replaced.
I ncorrect i njecti on pump ti mi ng (mechani cal or
el ectri cal ) can cause poor performance, excessi ve
smoke and emi ssi ons and poor fuel economy.
A defecti ve fuel i njecti on pump, defecti ve fuel ti m-
i ng sol enoi d or mi sadjusted mechani cal pump ti mi ng
can cause starti ng probl ems or prevent the engi ne
from revvi ng up. I t can al so cause:
Engi ne surge at i dl e
Rough i dl e (warm engi ne)
Low power
Excessi ve fuel consumpti on
Poor performance
Low power
Bl ack smoke from the exhaust
Bl ue or whi te fog l i ke exhaust
I ncorrect i dl e or maxi mum speed
The el ectroni cal l y control l ed fuel pump has no
mechani cal governor l i ke ol der mechani cal l y con-
trol l ed fuel pumps. Do not remove the top cover of
the fuel pump, or the screws fasteni ng the wi ri ng
pi gtai l to the si de of the pump. The warranty of
the injection pump and the engine may be void
if those seals have been removed or tampered
with.
FUEL SUPPLY RESTRICTIONS
LOWPRESSURE LINES
Restri cted or Pl ugged suppl y l i nes or fuel fi l ter can
cause a ti mi ng faul t that wi l l cause the ECM to oper-
ate the engi ne i n a Li mp Home mode. See the
i ntroducti on of the Fuel I njecti on System i n thi s
group for more i nformati on on the Li mp Home mode.
Fuel suppl y l i ne restri cti ons can cause starti ng prob-
l ems and prevent the engi ne from revvi ng up. The
starti ng probl ems i ncl ude; l ow power and bl ue or
whi te fog l i ke exhaust. Test al l fuel suppl y l i nes for
restri cti ons or bl ockage. Fl ush or repl ace as neces-
sary. Bl eed the fuel system of ai r once a fuel suppl y
l i ne has been repl aced. Refer to the Ai r Bl eed Proce-
dure secti on of thi s group for procedures.
HIGHPRESSURE LINES
Restri cted (ki nked or bent) hi ghpressure l i nes can
cause starti ng probl ems, poor engi ne performance
and bl ack smoke from exhaust.
Exami ne al l hi ghpressure l i nes for any damage.
Each radi us on each hi ghpressure l i ne must be
smooth and free of any bends or ki nks.
Repl ace damaged, restri cted or l eaki ng hi ghpres-
sure fuel l i nes wi th the correct repl acement l i ne.
clamped securely in place in the holders. The lines
Fig. 19 Typical Inspection of Fuel Injector
Fig. 20 Needle Movement Sensor Location
FUEL SHUTDOWN SOLENOID TEST
Refer to 1997 ZJ/ZG 2.5L Di esel Powertrai n Di ag-
nosti c Manual for the Fuel Shutdown Sol enoi d test.
HIGH-PRESSURE FUEL LINE LEAK TEST
Hi ghpressure fuel l i ne l eaks can cause starti ng
probl ems and poor engi ne performance.
WARNING: DUE TO EXTREME FUEL PRESSURES OF
UP TO 45,000 KPA (6526 PSI), USE EXTREME CAU-
TION WHEN INSPECTING FOR HIGHPRESSURE FUEL
LEAKS. DO NOT GET YOUR HAND, OR ANY PART OF
YOUR BODY NEAR A SUSPECTED LEAK. INSPECT
FOR HIGHPRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD. HIGH FUEL INJECTION PRESSURE
CAN CAUSE PERSONAL INJURY IF CONTACT IS
MADE WITH THE SKIN.
Start the engi ne. Move the cardboard over the
hi ghpressure fuel l i nes and check for fuel spray onto
the cardboard (Fi g. 21). I f a hi ghpressure l i ne con-
necti on i s l eaki ng, bl eed the system and ti ghten the
connecti on. Refer to the Ai r Bl eed Procedure i n thi s
group for procedures. Repl ace damaged, restri cted or
l eaki ng hi ghpressure fuel l i nes wi th the correct
repl acement l i ne.
SERVICE PROCEDURES
AIR BLEED PROCEDURES
AIR BLEEDING AT FUEL FILTER
A certai n amount of ai r may become trapped i n the
fuel system when fuel system components are ser-
vi ced or repl aced. Bl eed the system as needed after
fuel system servi ce accordi ng to the fol l owi ng proce-
dures.
Some ai r enters the fuel system when the fuel fi l -
ter or i njecti on pump suppl y l i ne i s changed. Thi s
smal l amount of ai r i s vented automati cal l y from the
i njecti on pump through the fuel drai n mani fol d tubes
i f the fi l ter was changed accordi ng to i nstructi ons.
Ensure the bowl of the fuel fi l ter/water separator i s
ful l of fuel .
I t may be necessary to manual l y bl eed the system
i f:
The bowl of the fuel fi l ter/water separator i s not
parti al l y fi l l ed before i nstal l ati on of a new fi l ter
The i njecti on pump i s repl aced
Hi ghpressure fuel l i ne connecti ons are l oosened
or l i nes repl aced
I ni ti al engi ne startup or startup after an
extended peri od of no engi ne operati on
Runni ng fuel tank empty
FUEL INJECTION PUMP BLEEDING
(1) I f the fuel i njecti on pump has been repl aced,
ai r shoul d be bl ed at the overfl ow val ve before
attempti ng to start engi ne.
(a) Loosen the overfl ow val ve (Fi g. 22) at the
rear of the i njecti on pump.
(b) Pl ace a towel bel ow the val ve.
WARNING: WHEN CRANKING THE ENGINE TO
BLEED AIR FROM THE INJECTION PUMP, THE
ENGINE MAY START. PLACE THE TRANSMISSION
IN NEUTRAL OR PARK AND SET PARKING BRAKE
BEFORE ENGAGING THE STARTER MOTOR.
CAUTION: Do not engage the starter motor for
more than 30 seconds at a time. Allow 2 minutes
between cranking intervals.
Fig. 21 Typical Fuel Pressure Test at Injector
(2) Crank the engi ne for 30 seconds at a ti me to
al l ow ai r trapped i n the i njecti on pump to vent out
the fuel i njector drai n tubes. Conti nue thi s procedure
unti l the engi ne starts. Observe the previ ous WARN-
I NG and CAUTI ON.
(3) Ti ghten overfl ow val ve.
HIGHPRESSURE FUEL LINE BLEEDING
WARNING: THE INJECTION PUMP SUPPLIES HIGH-
PRESSURE FUEL OF APPROXIMATELY 59,000 KPA
(8,557 PSI) TO EACH INDIVIDUAL INJECTOR
THROUGH THE HIGHPRESSURE LINES. FUEL
UNDER THIS AMOUNT OF PRESSURE CAN PENE-
TRATE THE SKIN AND CAUSE PERSONAL INJURY.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING AND AVOID CONTACT WITH
FUEL SPRAY WHEN BLEEDING HIGHPRESSURE
FUEL LINES.
Bl eed ai r from one i njector at ti me.
(1) Loosen the hi ghpressure fuel l i ne fi tti ng at
the i njector (Fi g. 23).
(2) Crank the engi ne unti l al l ai r has been bl ed
from the l i ne. Do not operate the starter motor
for longer than 30 seconds. Wait 2 minutes
between cranking intervals.
(3) Start the engi ne and bl eed one i njector at a
ti me unti l the engi ne runs smoothl y.
FUEL INJECTION PUMP TIMING
Refer to Removal /I nstal l ati on and Adjusti ng Fuel
Pump Ti mi ng i n thi s Group.
ACCELERATOR PEDAL
REMOVAL
(1) Di sconnect el ectri cal connector.
(2) Remove accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
(2) Connect el ectri cal connector.
(3) Before starti ng the engi ne, operate the accel er-
ator pedal to check for any bi ndi ng.
AIR CLEANER ELEMENT
REMOVAL
(1) Remove hose cl amp at Mass Ai r Fl ow Sensor.
(2) Remove hose from Mass Ai r Fl ow Sensor.
(3) Loosen 2 cl amps hol di ng ai r cl eaner housi ng
hal ves together.
(4) Remove l eft si de of ai r cl eaner housi ng.
(5) Remove el ement from ai r cl eaner housi ng.
INSTALLATION
(1) I nstal l a new el ement i n housi ng.
(2) Posi ti on l eft si de of housi ng.
(3) Snap cl amps i nto pl ace.
(4) I nstal l hoses and cl amps.
Fig. 22 Overflow Valve
Fig. 23 Bleeding HighPressure Fuel LineTypical
FUEL DRAIN TUBES
The fuel drai n tubes (Fi g. 25) are l owpressure
type.
Pul l each tube from the i njector for removal . Push
on for i nstal l ati on. Cl amps are not requi red for these
tubes.
FUEL FILTER/WATER SEPARATOR
The fuel fi l ter/water separator i s l ocated i n the
engi ne compartment on the l eft si de near the shock
tower. (Fi g. 26).
The fuel fi l ter/water separator assembl y contai ns
the fuel fi l ter, fuel heater el ement, and fuel drai n
val ve (Fi g. 26).
DRAINING WATER FROM FILTER BOWL
Moi sture (water) col l ects at the bottom of the fi l ter/
separator i n a pl asti c bowl . Water enteri ng the fuel
i njecti on pump can cause seri ous damage to the
pump. Note that the bulb will be illuminated for
approximately 2 seconds each time the key is
initially placed in the ON position. This is done
for a bulb check.
WARNING: DO NOT ATTEMPT TO DRAIN WATER
FROM THE FILTER/SEPARATOR WITH THE ENGINE
HOT.
(1) The bottom of the fi l ter/separator bowl i s
equi pped wi th a drai n val ve (Fi g. 26). The drai n
val ve i s equi pped wi th a fi tti ng. Attach a pi ece of
rubber hose to thi s fi tti ng. Thi s hose i s to be used as
a drai n hose.
(2) Pl ace a drai n pan under the drai n hose.
(3) Wi th the engi ne not runni ng, open the drai n
val ve (unscrewdrai n val ve has ri ght hand threads)
from the fi l ter/separator bowl . To gai n access to thi s
fi tti ng, the two fi l tertomounti ng bracket nuts (Fi g.
26) may have to be l oosened a few turns.
(4) Hol d the drai n open unti l cl ean fuel exi ts the
drai n.
(5) After drai ni ng, cl ose drai n val ve.
(6) Remove rubber drai n hose.
(7) Di spose of mi xture i n drai n pan accordi ng to
appl i cabl e l ocal or federal regul ati ons.
Fig. 24 Accelerator Pedal Mounting-Typical
Fig. 25 Fuel Injectors and Drain Tubes
Fig. 26 Fuel Filter/Water Separator Location
FUEL FILTER REMOVAL
(1) Drai n al l fuel and/or water from fuel fi l ter/wa-
ter separator assembl y. Refer to the previ ous Drai n-
i ng Water From Fi l ter Bowl .
(2) Unpl ug the el ectri cal connectors at bottom of
pl asti c bowl .
(3) Remove pl asti c bowl from bottom of fuel fi l ter
(unscrews).
(4) Remove fuel fi l ter from bottom of fi l ter base
(unscrews).
FUEL FILTER INSTALLATION
(1) Cl ean bottom of fuel fi l ter base.
(2) Appl y cl ean di esel fuel to new fuel fi l ter gasket.
(3) I nstal l and ti ghten fi l ter to fi l ter base. The bev-
el ed part of the rubber gasket shoul d be faci ng up
towards the fi l ter base.
(4) Cl ean the i nsi de of bowl wi th a soap and water
mi xture before i nstal l ati on. Careful l y cl ean any resi -
due between the two metal probes at the top of the
wateri nfuel sensor. Do not use chemi cal cl eaners
as damage to the pl asti c bowl may resul t.
(5) Pour di esel fuel i nto the pl asti c bowl before
i nstal l i ng bowl to bottom of fuel fi l ter. Do thi s to hel p
prevent ai r from enteri ng fuel i njecti on pump whi l e
attempti ng to starti ng engi ne.
(6) I nstal l fi l ter bowl to bottom of fi l ter.
(7) I nstal l the el ectri cal connectors at bottom of
bowl .
(8) Ti ghten the fi l tertomounti ng bracket nuts
(Fi g. 26) to 28 Nm (250 i n. l bs.) torque.
FUEL HEATER
I f the fuel heater el ement needs repl acement, the
pl asti c fi l ter bowl assembl y must be repl aced. Refer
to Fuel Fi l ter/Water Separator for i nformati on.
FUEL HEATER RELAY
The fuel heater rel ay i s l ocated i n the PDC. For
the l ocati on of the rel ay wi thi n the PDC (Fi g. 27),
refer to l abel on PDC cover.
FUEL LEVEL SENSOR
The fuel l evel sensor i s l ocated on the si de of the
fuel pump modul e (Fi g. 28).
REMOVAL
I nstal l ati on.
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 29) to remove send-
i ng uni t from pump modul e.
FUEL INJECTION PUMP
REMOVAL
(2) Thoroughl y cl ean the area around the i njecti on
pump and fuel l i nes of al l di rt, grease and other con-
tami nants. Due to the close internal tolerances
of the injection pump, this step must be per-
formed before removing pump.
Fig. 27 Power Distribution Center (PDC) Location
Fig. 28 Fuel Level Sensor
(3) Remove the engi ne accessory dri ve bel t. Refer
to Group 7, Cool i ng System for procedures.
(4) Remove the generator assembl y.
(5) Remove the rubber fuel return and suppl y
hoses from the metal l i nes at the pump (Fi g. 30).
(6) Remove the el ectri cal connector at engi ne cool -
ant temperature sensor.
(7) Di sconnect the Fuel I njecti on Pump el ectri cal
connector at fuel pump (Fi g. 30).
(8) Di sconnect the mai n engi ne wi ri ng harness
from the gl ow pl ugs.
(9) Di sconnect the four hi ghpressure fuel l i nes
from the fuel i njecti on pump. Al so di sconnect fuel
l i nes at the fuel i njectors. For procedures, refer to
Hi ghPressure Fuel Li nes i n thi s group. Pl ace a rag
beneath the fi tti ngs to catch excess fuel .
(10) Remove the pl ug from ti mi ng gear cover.
(11) The Top Dead Center (TDC) compressi on fi r-
i ng stroke for the #1 cyl i nder can be determi ned as
fol l ows:
(a) Usi ng a socket attached to the front of the
crankshaft, rotate the engi ne cl ockwi se unti l spe-
ci al al i gnment tool VM# 1035 can be i nserted
through the hol e i n the bottom of the cl utch hous-
i ng, stoppi ng the fl ywheel rotati on. Thi s posi ti on i s
TDC or 180 away from TDC. Engine must be at
TDC #1 compression firing stroke.
(b) To veri fy that you are at TDC. Remove the
oi l fi l l cap from the cyl i nder head cover and the
al i gnment tool from the cl utch housi ng.
(c) Rotate the crankshaft one-quarter turn cl ock-
wi se and counter-cl ockwi se whi l e observi ng the
rocker arm through the oi l fi l l cap hol e. I f the
rocker arm moves you are not at TDC.
(d) I f TDC was found conti nue, i f not rotate the
crankshaft one revol uti on unti l the al i gnment tool
can be re-i nstal l ed i n the fl ywheel . You are now at
TDC for the #1 cyl i nder compressi on fi ri ng stroke.
Mark the damper and ti mi ng cover for reference to
TDC. Remove the al i gnment tool from the cl utch
housi ng.
(12) Remove access pl ug and pl ug washer at rear
of pump (Fi g. 31). Thread speci al di al i ndi cator and
adapter tool VM.1011 (Fi g. 32) i nto thi s openi ng.
Hand ti ghten onl y.
(13) Sl i ghtl y rotate the engi ne i n a counter-cl ock-
wi se di recti on unti l the di al gauge i ndi cator stops
movi ng (20-25 before TDC).
(14) Remove i njecti on pump dri ve gear nut (Fi g.
33).
(15) A speci al 3pi ece gear removal tool set
VM.1003 (Fi g. 34) must be used to remove the i njec-
ti on pump dri ve gear from the pump shaft.
(a) Thread the adapter (Fi g. 35) i nto the ti mi ng
cover.
(b) Thread the gear pul l er i nto the i njecti on
pump dri ve gear (Fi g. 35). Thi s tool i s al so used to
hol d the gear i n synchroni zati on duri ng pump
removal .
(c) Remove the three i njecti on pumptogear
cover mounti ng nuts (Fi g. 36). CAUTION: This
step must be done to prevent injection pump
damage.
(d) I nstal l the dri ve bol t i nto the gear pul l er
(Fi g. 35). Ti ghten the dri ve bol t to press (remove)
the dri ve gear from i njecti on pump shaft whi l e
Fig. 29 Fuel Level Sensor Release Tab
Fig. 30 Fuel Injection Pump
dri vi ng i njecti on pump rearward from ti mi ng gear
cover mounti ng studs.
(16) Remove pump from engi ne. Do not rotate
engine while gear puller is installed. Engine
damage will occur.
INSTALLATION/ADJUSTING PUMP TIMING
(1) Cl ean the mati ng surfaces of i njecti on pump
and ti mi ng gear cover.
(2) I nstal l a new i njecti on pumptoti mi ng gear
cover gasket.
(3) Remove the gear removi ng bol t (dri ve bol t)
from gear pul l er. CAUTION: Do not remove the
special gear puller or timing cover adapter
tools from timing cover at this time. Gear mis-
alignment will result.
(4) Pl ace the key way on the pump shaft to the 11
ocl ock posi ti on as vi ewed from the front of pump.
I nstal l the pump i nto the rear of ti mi ng gear cover
whi l e al i gni ng key way on pump shaft i nto pump
gear.
(5) I nstal l and snug the 3 i njecti on pump mount-
i ng nuts. Thi s i s not the fi nal ti ghteni ng sequence.
(6) Remove the speci al gear pul l er and adapter
tool s from ti mi ng gear cover.
Fig. 31 Access Plug at Rear of Pump
Fig. 32 Installing Dial Indicator and Special Adapter
Tools
Fig. 33 Removing Pump Drive Gear Nut
Fig. 34 Pump Gear Tools
(7) I nstal l the i njecti on pump dri ve gear nut.
Ti ghten nut to 88 Nm (65 ft. l bs.) torque.
(8) Remove the access pl ug and pl ug washer at
rear of pump (Fi g. 37). Thread speci al di al i ndi cator
adapter tool VM.1011 (Fi g. 38) i nto thi s openi ng.
Hand ti ghten onl y.
(9) Attach speci al di al i ndi cator tool VM.1013 i nto
the adapter tool (Fi g. 38).
(10) Usi ng a socket attached to the front of the
crankshaft, rotate the engi ne i n a counter-cl ockwi se
di recti on unti l the di al gage i ndi cator stops movi ng
(2025 before TDC).
(11) Set the di al i ndi cator to 0mm. Be sure the ti p
of the di al i ndi cator i s touchi ng the ti p i nsi de the
adapter tool .
(12) The Top Dead Center (TDC) compressi on fi r-
i ng stroke can be determi ned as fol l ows:
(a) Rotate the engi ne cl ockwi se unti l speci al
al i gnment tool VM#1035 can be i nserted through
the hol e i n the bottom of the cl utch housi ng, stop-
pi ng the fl ywheel rotati on. Thi s posi ti on i s TDC or
180 away from TDC. Engine must be at TDC #1
compression firing stroke.
Fig. 35 Installing Pump Drive Gear Removal Tools
Fig. 36 Injection Pump Mounting Nuts
Fig. 37 Access Plug at Rear of Pump
Fig. 38 Installing Dial Indicator and Special Adapter
Tools
(b) To veri fy that you are at TDC. Remove the
oi l fi l l cap from the rocker cover and the al i gnment
tool from the cl utch housi ng.
(c) Rotate the crankshaft one-quarter turn cl ock-
wi se and counter-cl ockwi se whi l e observi ng the
rocker arm through the oi l fi l l cap hol e. I f the
rocker arm moves you are not at TDC.
(d) I f TDC was found conti nue, i f not rotate the
crankshaft one revol uti on unti l the al i gnment tool
can be re-i nstal l ed i n the fl ywheel . You are now at
TDC.
(13) The gauge readi ng shoul d be at 0.60 mm. I f
not, the pump must be rotated for adjustment:
(a) Loosen the three i njecti on pump mounti ng
nuts at the mounti ng fl anges. These fl anges are
equi pped wi th sl otted hol es. The sl otted hol es are
used to rotate and posi ti on the i njecti on pump for
fuel ti mi ng. Loosen the three nuts just enough to
rotate the pump.
(b) Rotate the pump unti l 0.60 mm i s i ndi cated
on the di al i ndi cator gauge. I f whi l e rotati ng the
pump the 0.60mm speci fi cati on i s passed do not
attempt to rotate the pump i n the opposi te di rec-
ti on. You must rotate the pump back bel ow the
0.60mm speci fi cati on and start the procedure over
from the start of the TDC procedure. Thi s wi l l pre-
vent a fal se readi ng due to gear backl ash.
(c) Ti ghten the three pump mounti ng nuts to 30
(d) Recheck the di al i ndi cator after ti ghteni ng
the pump mounti ng nuts. Gauge shoul d sti l l be
readi ng 0.60 mm.
(14) Remove di al i ndi cator and adapter tool s.
(15) I nstal l access pl ug and washer to rear of
i njecti on pump.
(16) I nstal l pl ug at ti mi ng gear cover.
(17) I nstal l and connect the four hi ghpressure
fuel l i nes to the fuel i njecti on pump. Al so connect
fuel l i nes at the fuel i njectors. For procedures, refer
to Hi ghPressure Fuel Li nes i n thi s group.
(18) I nstal l el ectri cal connector at engi ne cool ant
temperature sensor.
(19) Connect el ectri cal connector at fuel shutdown
sol enoi d.
(20) Connect the mai n engi ne wi ri ng harness to
the gl ow pl ugs.
(21) Connect the fuel ti mi ng sol enoi d pi gtai l har-
ness to the engi ne wi ri ng harness.
(22) Connect the overfl ow val ve/banjo fi tti ng (fuel
return l i ne assembl y). Repl ace copper gaskets before
i nstal l i ng.
(23) Connect the rubber fuel return and suppl y
hoses to metal l i nes at pump. Ti ghten hose cl amps to
(24) I nstal l generator assembl y.
(25) I nstal l engi ne accessory dri ve bel t. Refer to
Group 7, Cool i ng System for procedures.
(26) I nstal l negati ve battery cabl e to battery.
(27) Start the engi ne and bri ng to normal operat-
i ng temperature.
(28) Check for fuel l eaks.
FUEL INJECTORS
Four fuel i njectors are used on each engi ne. Of
these four, two di fferent types are used. The fuel
i njector used on cyl i nder number one i s equi pped
wi th a fuel i njector sensor (Fi g. 39). The other three
fuel i njectors are i denti cal . Do not place the fuel
injector equipped with the fuel injector sensor
into any other location except the cylinder
number one position.
REMOVAL
(2) Thoroughl y cl ean the area around the i njector
wi th compressed ai r.
(3) Remove the fuel drai n hoses (tubes) at each
i njector (Fi g. 40) bei ng servi ced. Each of these hoses
i s sl i pfi t to the fi tti ng on i njector.
(4) Remove the hi ghpressure fuel l i ne at i njector
bei ng removed. Refer to Hi ghPressure Fuel Li nes i n
(5) Remove the i njector usi ng speci al socket tool
number VM.1012A. When removi ng cyl i nder number
one i njector, thread the wi ri ng harness through the
access hol e on the speci al socket (Fi g. 41).
(6) Remove and di scard the copper washer (seal ) at
bottom of i njector (Fi g. 39).
Fig. 39 Fuel Injector Sensor #1 Cylinder
INSTALLATION
(1) Cl ean the i njector threads i n cyl i nder head.
(2) I nstal l new copper washer (seal ) to i njector.
(3) I nstal l i njector to engi ne. Ti ghten to 70 Nm
(4) I nstal l hi ghpressure fuel l i nes. Refer to Hi gh
Pressure Fuel Li nes i n thi s group for procedures.
(5) I nstal l fuel drai n hoses (tubes) to each i njector.
Do not use cl amps at fuel drai n hoses.
(7) Bl eed the ai r from the hi ghpressure l i nes.
Refer to the Ai r Bl eed Procedure secti on of thi s
group.
FUEL TANK
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(2) I nsert fuel si phon hose i nto fuel fi l l er neck and
push i t i nto the tank.
(3) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed diesel safety contai ner.
(4) Rai se vehi cl e on hoi st.
(5) Di sconnect both the fuel fi l l and fuel vent rub-
ber hoses at the fuel tank.
(6) Di sconnect fuel suppl y and return l i nes from
the steel suppl y l i ne (Fi g. 42).
The fuel reservoir module electrical connec-
tor has a retainer that locks it in place.
(7) Sl i de el ectri cal connector l ock to unl ock.
(8) Push down on connector retai ner (Fi g. 44) and
pul l connector off modul e.
(9) Use a transmi ssi on jack to support fuel tank.
Remove bol ts from fuel tank straps.
Fig. 40 Fuel InjectorTypical
Fig. 41 Wiring Harness Through Socket
Fig. 42 Fuel Tank Connections at Front of Tank
Fig. 43 Fuel Fill/Vent Hose Index Marks
(10) Lower tank sl i ghtl y. Careful l y remove fi l l er
hose from tank.
(11) Lower the fuel tank. Remove cl amp and
remove fuel fi l l er tube vent hose. Remove fuel tank
from vehi cl e.
INSTALLATION
(1) Posi ti on fuel tank on transmi ssi on jack. Con-
nect fuel fi l l er tube vent hose and repl ace cl amp.
(2) Rai se tank i nto posi ti on and careful l y work
fi l l er tube i nto tank. A l i ght coati ng of cl ean engi ne
oi l on the tube end may be used to ai d assembl y.
(3) Feed fi l l er vent l i ne thorough frame rai l . Care-
ful not to cross l i nes.
(4) Ti ghten strap bol ts to 9 Nm (80 i n. l bs.).
Remove transmi ssi on jack.
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(5) Connect modul e el ectri cal connector. Pl ace
retai ner i n l ocked posi ti on.
(6) Lubri cate the fuel suppl y and return l i nes wi th
cl ean 30 wei ght engi ne oi l , i nstal l the qui ck connect
fuel fi tti ng. Refer to Tube/Fi tti ng Assembl y i n the
Fuel Del i very secti on of thi s Group.
(7) Attach fi l l er l i ne to fi l l er tube. Pul l on connec-
tor to make sure of connecti on.
(8) Fi l l fuel tank, repl ace cap, and connect battery
negati ve cabl e.
FUEL RESERVOIR MODULE
REMOVAL
WARNING: THE FUEL RESERVOIR OF THE FUEL
MODULE DOES NOT EMPTY OUT WHEN THE TANK
IS DRAINED. THE FUEL IN THE RESERVOIR WILL
SPILL OUT WHEN THE MODULE IS REMOVED.
(2) Drai n fuel tank dry i nto hol di ng tank or a
properl y l abel ed diesel safety contai ner.
(4) Use a transmi ssi on jack to support the fuel
tank. Remove bol ts from fuel tank straps. Lower
tank sl i ghtl y.
(5) Cl ean area around fuel reservoi r modul e and
tank to keep di rt and forei gn materi al out of tank.
(6) Di sconnect fuel l i nes from fuel modul e by
depressi ng qui ck connect retai ners wi th thumb and
fore fi nger.
(7) Sl i de modul e el ectri cal connector l ock to
unl ock.
(8) Push down on connector retai ner and pul l con-
nector off modul e.
(9) Usi ng Speci al Tool 6856, remove pl asti c l ocknut
countercl ockwi se to rel ease pump modul e (Fi g. 45).
(10) Careful l y remove modul e and o-ri ng from
tank.
(11) Di scard ol d o-ri ng.
INSTALLATION
(1) Thoroughl y cl ean l ocknut threads and mati ng
ful e tank threads. Use a soap/water sol uti on. Do not
use carburetor cleaner to clean threads.
(2) Appl y cl ean water to the o-ri ng seal and pl ace
on the mati ng fuel tank threads.
(3) Wi pe seal area of tank cl ean and pl ace a new
o-ri ng seal i n posi ti on on pump.
(4) Posi ti on fuel reservoi r modul e i n tank wi th
l ocknut.
(5) Ti ghten l ocknut to 75 Nm (55 ft. l bs.).
(6) Connect fuel l i nes.
(7) Pl ug i n el ectri cal connector. Sl i de connector
l ock i nto posi ti on.
(8) Rai se fuel tank, i nstal l bol ts i nto fuel tank
straps and ti ghten.
(9) Lower vehi cl e on hoi st.
Fig. 44 Module Connector Retainer and Lock
Fig. 45 Fuel Reservoir Module Lock Nut Removal
(10) Connect negati ve cabl e from battery.
(11) Fi l l fuel tank. Check for l eaks.
(12) I nstal l fuel fi l l er cap.
HIGH-PRESSURE LINES
Al l hi ghpressure fuel l i nes are of the same l ength
and i nsi de di ameter. Correct hi ghpressure fuel l i ne
usage and i nstal l ati on i s cri ti cal to smooth engi ne
operati on.
REMOVAL
(2) Remove the necessary cl amps hol di ng the l i nes
to the engi ne.
(3) Cl ean the area around each fuel l i ne connec-
ti on. Di sconnect each l i ne at the top of each fuel
i njector (Fi g. 46).
(4) Di sconnect each hi ghpressure l i ne fi tti ng at
each fuel i njecti on pump del i very val ve.
(5) Very careful l y remove each l i ne from the
engi ne. Note the posi ti on (fi ri ng order) of each l i ne
whi l e removi ng. Do not bend the line while
removing.
CAUTION: Be sure that the highpressure fuel lines
are installed in the same order that they were
removed. Prevent the injection pump delivery valve
holders from turning when removing or installing
highpressure lines from injection pump.
INSTALLATION
(1) Careful l y posi ti on each hi ghpressure fuel l i ne
to the fuel i njector and fuel i njecti on pump del i very
val ve hol der i n the correct fi ri ng order. Al so posi ti on
each l i ne i n the correct l i ne hol der.
(2) Loosel y i nstal l the l i ne cl amp/hol der bol ts.
(3) Ti ghten each l i ne at the del i very val ve to 30
(4) Ti ghten each l i ne at the fuel i njector to 30 Nm
Be sure the lines are not contacting each
other or any other component.
(5) Ti ghten the cl amp bracket bol ts to 24 Nm (18
ft. l bs.) torque.
(6) Bl eed ai r from the fuel system. Refer to the Ai r
Bl eed Procedure secti on of thi s group.
SPECIFICATIONS
FUEL TANK CAPACITY
75 Liters (20.0 Gals.)
Nomi nal refi l l capaci ti es are shown. A vari ati on
may be observed from vehi cl e to vehi cl e due to man-
ufacturi ng tol erances, ambi ent temperatures and
refi l l procedures.
IDLE SPEED
900 rpm 25 rpm wi th engi ne at normal operat-
i ng temperature.
FUEL INJECTOR FIRING SEQUENCE
1342
FUEL SYSTEM PRESSURE
Peak Injection Pressure/Fuel Injection Pump
Operating Pressure: 40,00045,000 kPa (5801
6526 psi ).
Opening Pressure of Fuel Injector:
15,00015,800 kPa (21752291 psi ).
Fig. 46 Fuel Lines at Fuel Injectors
FUEL INJ ECTION SYSTEM2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 23
AIR CONDITIONING (A/C) CONTROLS
ECM INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . 27
AIR CONDITIONING RELAYECM OUTPUT . . . 28
ASD RELAYECM INPUT . . . . . . . . . . . . . . . . . 28
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . . 25
BOOST / PRESSURE SENSOR . . . . . . . . . . . . . 25
BRAKE SWITCHECM INPUT . . . . . . . . . . . . . . 27
DATA LINK CONNECTORPCM AND ECM
INPUT AND OUTPUT . . . . . . . . . . . . . . . . . . . 27
ELECTRIC VACUUM MODULATOR (EVM)
ECM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE COOLANT GAUGEPCM OUTPUT . . . 28
ECM/PCM INPUT . . . . . . . . . . . . . . . . . . . . . . 26
ENGINE OIL PRESSURE GAUGE
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 28
ENGINE SPEED/CRANK POSITION SENSOR
ECM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FIVE VOLT POWERECM/PCM OUTPUT . . . . . 28
FUEL INJECTOR SENSORGROUND . . . . . . . . 26
GLOW PLUG LAMPPCM OUTPUT . . . . . . . . . 28
GLOW PLUG RELAYECM OUTPUT . . . . . . . . 29
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 30
IGNITION CIRCUIT SENSEMSA/PCM INPUT . 25
IGNITION CIRCUIT SENSEPCM INPUT . . . . . 26
NEEDLE MOVEMENT OR INSTRUMENTED
FIRST INJECTORECM INPUT . . . . . . . . . . . 26
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . . 26
SENSOR RETURNECM/PCM INPUT
(ANALOG GROUND) . . . . . . . . . . . . . . . . . . . . 25
SPEED CONTROLECM INPUT . . . . . . . . . . . . 28
SPEED CONTROLPCM OUTPUTS . . . . . . . . . 28
TACHOMETERPCM OUTPUT . . . . . . . . . . . . . 29
TIMING SOLENOIDECM OUTPUT . . . . . . . . . . 29
VEHICLE SPEED SENSORECM INPUT . . . . . 27
VEHICLE THEFT ALARM . . . . . . . . . . . . . . . . . . 25
ASD RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . 30
BOOST / PRESSURE SENSOR . . . . . . . . . . . . . 33
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 34
DIESEL DIAGNOSTICS . . . . . . . . . . . . . . . . . . . 30
SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . 30
ENGINE SPEED SENSOR TEST . . . . . . . . . . . . 30
GLOW PLUG RELAY TEST . . . . . . . . . . . . . . . . 32
GLOW PLUG TEST . . . . . . . . . . . . . . . . . . . . . . 31
RELAYSOPERATION/TESTING . . . . . . . . . . . . 32
VEHICLE SPEED SENSOR TEST . . . . . . . . . . . . 34
A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . 34
ASD RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . 34
GLOW PLUG RELAY . . . . . . . . . . . . . . . . . . . . . 35
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SPECIFICATIONS
GLOW PLUG CURRENT DRAW . . . . . . . . . . . . . 37
TORQUE CHART2.5L DIESEL . . . . . . . . . . . . 37
GENERAL INFORMATION
INTRODUCTION
Thi s secti on wi l l cover components ei ther regul ated
or control l ed by the ECM control l er and the Power-
trai n Control Modul e (PCM). The fuel heater rel ay
and fuel heater are not operated by the ECM control -
l er or the PCM. These components are control l ed by
the i gni ti on (key) swi tch. Al l other fuel system el ec-
tri cal components necessary to operate the engi ne
are control l ed or regul ated by the ECM control l er,
whi ch i nterfaces wi th the PCM. Refer to the fol l ow-
i ng descri pti on for more i nformati on.
Certai n fuel system component fai l ures may cause
a no start, or prevent the engi ne from runni ng. I t i s
i mportant to know that the ECM has a feature
where, i f possi bl e, i t wi l l i gnore the fai l ed sensor, set
a code rel ated to the sensor, and operate the engi ne
i n a Li mp Home mode. When the ECM i s operati ng
i n a Li mp Home mode, the Check Engi ne Lamp on
the i nstrument panel may be constantl y i l l umi nated,
and the engi ne wi l l most l i kel y have a noti ceabl e l oss
of performance. An exampl e of thi s woul d be an
Accel erator Pedal Posi ti on Sensor fai l ure, and i n that
si tuati on, the engi ne woul d run at a constant 1100
RPM, regardl ess of the actual posi ti on of the pedal .
Thi s i s the most extreme of the three Li mp Home
modes.
When the Check Engi ne Lamp i s i l l umi nated con-
stantl y wi th the key on and the engi ne runni ng, i t
usual l y i ndi cates a probl em has been detected some-
where wi thi n the fuel system. The DRBI I I scan tool
i s the best method for communi cati ng wi th the ECM
and PCM to di agnose faul ts wi thi n the system.
On LHD vehi cl es, the ECM i s mounted behi nd the
l ower I nstrument Panel to the ri ght of the accel era-
tor pedal (Fi g. 1). On RHD vehi cl es, the ECM i s
mounted behi nd the l ower I nstrument Panel to the
l eft of the cl utch pedal . The Powertrai n Control Mod-
ul e (PCM) i s mounted i n the engi ne compartment.
(Fi g. 2).
The ECM Control l er i s a preprogrammed, di gi tal
computer. I t wi l l ei ther di rectl y operate or parti al l y
regul ate the:
Speed Control
Speed Control l amp
Fuel Ti mi ng Sol enoi d
Check Engi ne Li ght
Gl ow Pl ug Rel ay
Gl ow Pl ugs
Gl ow Pl ug Lamp
ASD Rel ay
Ai r Condi ti oni ng
Tachometer
El ectri c Vacuum Modul ator (EVM)
The ECM can adapt i ts programmi ng to meet
changi ng operati ng condi ti ons.
The ECM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
ECM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as ECM Outputs. The sensors
and swi tches that provi de i nputs to the ECM are
consi dered ECM Inputs.
ECM Inputs are:
Ai r Condi ti oni ng Sel ecti on
Theft Al arm
ASD Rel ay
Control Sl eeve Posi ti on Sensor
Fuel Temperature Sensor
Mass Ai r Fl ow Sensor
Accel erator Pedal Posi ti on Sensor
Engi ne Cool ant Temperature Sensor
Low I dl e Posi ti on Swi tch
5 Vol t Suppl y
Vehi cl e Speed Sensor
Engi ne Speed/Crank Posi ti on Sensor (rpm)
Needl e Movement Sensor
Starter Si gnal
Brake Swi tch
Speed Control Swi tch
Power Ground
I gni ti on (key) Swi tch Sense
ECM Outputs:
After i nputs are recei ved by the ECM and PCM,
certai n sensors, swi tches and components are con-
trol l ed or regul ated by the ECM and PCM. These are
consi dered ECM Outputs. These outputs are for:
A/C Cl utch Rel ay (for A/C cl utch operati on)
Speed Control Lamp
ASD Rel ay
5 Vol ts Suppl y
Fuel Quanti ty Actuator
Fuel Ti mi ng Sol enoi d
Fuel Shutdown Sol enoi d
Fig. 1 ECM Controller Location
Fig. 2 PCM Location
Gl ow Pl ug Lamp
Check Engi ne Lamp (On/Off si gnal )
El ectri c Vacuum Modul ator (EVM)
Gl ow Pl ug Rel ay
Tachometer
The PCM sends and reci eves si gnal s to and from
the ECM control l er. PCM inputs are:
Power Gound
5 Vol ts Suppl y
Vehi cl e Speed Sensor
Water-I n-Fuel Sensor
Cool ant Temperature Sensor
Low Cool ant Sensor
Sensor Return
Fuel Level Sensor
Oi l Pressure Sensor
Tachometer Si gnal
Gl ow Pl ug Lamp
Check Engi ne Lamp (On/Off si gnal )
Brake On/Off Swi tch
Battery Vol tage
ASD Rel ay
PCM Outputs:
A/C On Si gnal
Vehi cl e Theft Al arm Ok to Run si gnal
Body Control Modul e CCD Bus (+)
Body Control Modul e CCD Bus ()
Scan Tool Data Li nk Reci eve
Scan Tool Data Li nk Transmi t
Low Cool ant Lamp
Generator Control
BOOST / PRESSURE SENSOR
The Boost Pressure Sensor i s mounted to the top of
the i ntake mani fol d (Fi g. 3). I t i s a sensor that mea-
sures both mani fol d vacuum and turbo boost, and i t
al so contai ns an i ntegrated i ntake ai r temperature
sensor. The Boost Pressure Sensor takes the pl ace of
the Mass Ai r Fl ow (MAF). I n the I ntake Ai r Temper-
ature Sensor component, there i s a cerami c el ement
that changes i ts resi stance based on temperature.
The cerami c el ement i s part of an el ectroni c ci rcui t
connected to the PCM, and has a vol tage appl i ed to
i t. The cerami c el ement i s exposed to the ai r i nsi de
the i ntake. Thi s ai r has a cool i ng effect on the
cerami c el ement, and i ts resi stance changes. Thi s
causes the vol tage fl owi ng through the i ntake ai r
temperature ci rcui t to vary. The vol tage si gnal pro-
duced by the I ntake Ai r Temperature Sensor changes
i nversel y to the temperature, and i s measured by the
PCM. As a general rul e, when the temperature of the
ai r i n the i ntake i s hi gh, the vol tage si gnal produced
by the I ntake Ai r Temperature Sensor i s l ow. The
component of the Boost Pressure Sensor that mea-
sures mani fol d vacuum and turbo boost produces a
vol tage si gnal that i s proporti onal to the pressure i n
the i ntake mani fol d. When the i ntake mani fol d pres-
sure i s l ow, the vol tage i s l ow, and when the pressure
i s hi gh, the vol tage i s hi gh. The PCM uses the vol t-
age si gnal s from the Boost Pressure Sensor, and the
I ntake Ai r Temperature Sensor to determi ne the
amount of ai r fl owi ng through the i ntake mani fol d.
VEHICLE THEFT ALARM
The PCM can l earn i f the vehi cl e has a Vehi cl e
Theft Al arm (VTA) system. Once i t detects the vehi -
cl e havi ng VTA, the controller can ONLY BE
USED ON VEHICLES WITH VTA.
I f the PCM i s put i t on a vehi cl e wi thout VTA the
Gl ow Pl ug Lamp wi l l start to bl i nk and the vehi cl e
wi l l not start.
The PCM cannot be fl ashed to remove the VTA.
BATTERY VOLTAGE PCM INPUT
The battery vol tage i nput provi des power to the
PCM. I t al so i nforms the PCM what vol tage l evel i s
bei ng suppl i ed by the generator once the vehi cl e i s
runni ng.
The battery i nput al so provi des the vol tage that i s
needed to keep the PCM memory al i ve. The memory
stores Di agnosti c Troubl e Code (DTC) messages.
Troubl e codes wi l l sti l l be stored even i f the battary
vol tage i s l ost.
SENSOR RETURN ECM/PCM INPUT (ANALOG
GROUND)
Sensor Return provi des a l ow noi se Anal og ground
reference for al l system sensors.
IGNITION CIRCUIT SENSE MSA/PCM INPUT
The i gni ti on ci rcui t sense i nput si gnal s the MSA
and PCM that the i gni ti on (key) swi tch has been
Fig. 3 Boost Pressure Sensor Location
turned to the ON posi ti on. Thi s si gnal i ni ti ates the
gl ow pl ug control routi ne to begi n the preheat
cycl e.
IGNITION CIRCUIT SENSE PCM INPUT
The i gni ti on ci rcui t sense i nput si gnal s the PCM
that the i gni ti on (key) swi tch has been turned to the
ON posi ti on. Thi s si gnal i ni ti ates the gl ow pl ug con-
trol routi ne to begi n the preheat cycl e.
POWER GROUND
Provi des a common ground for power devi ces (sol e-
noi d and rel ay devi ces).
NEEDLE MOVEMENT OR INSTRUMENTED
FIRST INJECTOR ECM INPUT
Thi s i nput from the ECM suppl i es a constant 30
mA el ectri cal current source for the fi rst i njector sen-
sor. I t wi l l vary the vol tage to thi s sensor when i t
senses a mechani cal movement wi thi n the i njector
needl e (pi ntl e) of the number1 cyl i nder fuel i njector.
When thi s vol tage has been determi ned by the ECM,
i t wi l l then control an output to the fuel ti mi ng sol e-
noi d (the fuel ti mi ng sol enoi d i s l ocated on the fuel
i njecti on pump). Al so refer to Fuel I njecti on Pump for
addi ti onal i nformati on.
The fi rst i njector sensor i s a magneti c (i nducti ve)
type.
The fi rst i njector sensor i s used onl y on the fuel
i njector for the number1 cyl i nder (Fi g. 4). I t i s not
used on the i njectors for cyl i nders number 2, 3, or 4.
FUEL INJECTOR SENSOR GROUND
Provi des a l ow noi se ground for the fuel i njector
sensor onl y.
ECM/PCM INPUT
The 05 vol t i nput from thi s sensor tel l s the ECM
and PCM the temperature of the engi ne cool ant.
Based on the vol tage recei ved at the ECM, i t wi l l
then determi ne operati on of the fuel ti mi ng sol enoi d,
gl ow pl ug rel ay, el ectri cal vacuum modul ator (emi s-
si on component) and generator (chargi ng system).
The sensor i s l ocated on the si de of the #3 cyl i nder
head near the rear of fuel i njecti on pump (Fi g. 5).
ENGINE SPEED/CRANK POSITION SENSOR
ECM INPUT
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the l eft/rear si de of the engi ne
bl ock (Fi g. 6).
Fig. 5 Engine Coolant Temperature Sensor Location
Fig. 6 Engine Speed Sensor Location
The engi ne speed sensor produces i ts own output
si gnal . I f thi s si gnal i s not recei ved, the ECM wi l l not
al l ow the engi ne to start.
The engi ne speed sensor i nput i s used i n conjunc-
ti on wi th the fi rst i njector sensor to establ i sh fuel
i njecti on pump ti mi ng.
The fl ywheel has four notches at i ts outer edge
(Fi g. 7). Each notch i s spaced equal l y every 90. The
notches cause a pul se to be generated when they
pass under the speed sensor (Fi g. 7). These pul ses
are the i nput to the ECM. The i nput from thi s sensor
determi nes crankshaft posi ti on (i n degrees) by moni -
tori ng the notches.
The sensor al so generates an rpm si gnal to the
ECM. Thi s si gnal i s used as an i nput for the control
of the generator fi el d, vehi cl e speed control , and
i nstrument panel mounted tachometer.
I f the engi ne speed sensor shoul d fai l , the system
i s unabl e to compensate for the probl em and the car
wi l l stop.
AIR CONDITIONING (A/C) CONTROLS ECM
INPUTS
The A/C control system i nformati on appl i es to fac-
tory i nstal l ed ai r condi ti oni ng uni ts.
A/C REQUEST SIGNAL: When ei ther the A/C or
Defrost mode has been sel ected and the A/C l ow and
hi ghpressure swi tches are cl osed, an i nput si gnal i s
sent to the ECM. The ECM uses thi s i nput to cycl e
the A/C compressor through the A/C rel ay.
I f the A/C l ow or hi ghpressure swi tch opens, the
ECM wi l l not recei ve an A/C request si gnal . The
PCM wi l l then remove the ground from the A/C rel ay.
Thi s wi l l deacti vate the A/C compressor cl utch. Al so,
i f the engi ne cool ant reaches a temperature outsi de
normal of i ts normal range, or i t overheats, the ECM
wi l l deacti vate the A/C cl utch.
BRAKE SWITCH ECM INPUT
When the brake l i ght swi tch i s acti vated, the ECM
recei ves an i nput i ndi cati ng that the brakes are
bei ng appl i ed. After recei vi ng thi s i nput, the ECM i s
used to control the speed control system. There i s a
Pri mary and a Secondary brake swi tch. The Second-
ary brake swi tch i s cl osed unti l the brake pedal i s
pressed.
DATA LINK CONNECTOR PCM AND ECM
INPUT AND OUTPUT
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool wi th the PCM and ECM. The data
l i nk connector i s l ocated under the i nstrument panel
near the bottom of steeri ng col umn (Fi g. 8).
VEHICLE SPEED SENSOR ECM INPUT
The vehi cl e speed sensor i s l ocated i n the extensi on
housi ng of the transmi ssi on (2WD) (Fi g. 9) or on the
transfer case extensi on housi ng (Fi g. 10). The sensor
i nput i s used by the ECM to determi ne vehi cl e speed
and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the accel erator pedal posi -
ti on sensor, i ndi cate an i dl e decel erati on to the ECM.
When the vehi cl e i s stopped at i dl e, a rel eased pedal
si gnal i s recei ved by the ECM (but a speed sensor
si gnal i s not recei ved).
Fig. 7 Speed Sensor Operation
Fig. 8 Data Link Connector Location
I n addi ti on to determi ni ng di stance and vehi cl e
speed, the output from the sensor i s used to control
speed control operati on.
SPEED CONTROL ECM INPUT
The speed control system provi des fi ve separate
i nputs to the ECM: On/Off, Set, Resume/Accel , Can-
cel , and Decel . The On/Off i nput i nforms the ECM
that the speed control system has been acti vated.
The Set i nput i nforms the ECM that a fi xed vehi cl e
speed has been sel ected. The Resume i nput i ndi cates
to the ECM that the previ ous fi xed speed i s
requested.
Speed control operati on wi l l start at 50 km/h142
km/h (3585 mph). The upper range of operati on i s
not restri cted by vehi cl e speed. I nputs that effect
speed control operati on are vehi cl e speed sensor and
accel erator pedal posi ti on sensor.
Refer to Group 8H for further speed control i nfor-
mati on.
ASD RELAY ECM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the ECM
that the ASD rel ay has been acti vated. The ASD
rel ay i s l ocated i n the PDC. The PDC i s l ocated next
to the battery i n the engi ne compartment. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the ECM does not see 12 vol ts (+) at
thi s i nput when the ASD rel ay shoul d be acti vated, i t
wi l l set a Di agnosti c Troubl e Code (DTC).
FIVE VOLT POWER ECM/PCM OUTPUT
Thi s ci rcui t suppl i es approxi matel y 5 vol ts to
power the Accel erator Pedal Posi ti on Sensor, and the
Boost / Pressure Sensor.
ENGINE COOLANT GAUGE PCM OUTPUT
Refer to the I nstrument Panel and Gauges group
ENGINE OIL PRESSURE GAUGE PCM
OUTPUT
Refer to the I nstrument Panel and Gauges group
GLOW PLUG LAMP PCM OUTPUT
The Gl ow Pl ug l amp (mal functi on i ndi cator l amp)
i l l umi nates on the message center each ti me the i gni -
ti on (key) swi tch i s turned on. I t wi l l stay on for
about two seconds as a bul b test.
SPEED CONTROL PCM OUTPUTS
These two ci rcui ts control the fuel quanti ty actua-
tor to regul ate vehi cl e speed. Refer to Group 8H for
Speed Control i nformati on.
AIR CONDITIONING RELAY ECM OUTPUT
Thi s ci rcui t control s a ground si gnal for operati on
of the A/C cl utch rel ay. Al so refer to Ai r Condi ti oni ng
Fig. 9 Vehicle Speed SensorTypical
Fig. 11 Glow Plug Lamp Symbol
(A/C) Control sECM I nput for addi ti onal i nforma-
ti on.
The A/C rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated next to the battery
i n the engi ne compartment. For the l ocati on of the
rel ay wi thi n the PDC, refer to l abel on PDC cover.
TIMING SOLENOID ECM OUTPUT
The ti mi ng sol enoi d i s l ocated on the bottom of the
fuel i njecti on pump (Fi g. 12).
Thi s 12(+) vol t, pul se wi dth modul ated (dutycycl e)
output control s the amount of fuel ti mi ng (advance)
i n the fuel i njecti on pump. The hi gher the dutycy-
cl e, the l ower the advance. The l ower the dutycycl e,
the more advanced the fuel ti mi ng.
The dutycycl e i s determi ned by the ECM from
i nputs i t recei ves from the fuel i njector sensor and
engi ne speed sensor.
TACHOMETER PCM OUTPUT
The PCM reci eves engi ne rpm val ues from the
ECM control l er, and then suppl i es engi ne rpm val ues
to the Body Control l er that then suppl i es the i nstru-
ment cl uster mounted tachometer (i f equi pped). Refer
to Group 8E for tachometer i nformati on.
GLOW PLUG RELAY ECM OUTPUT
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the ECM rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the ECM wi l l determi ne
i f, when and for how l ong a peri od the gl ow pl ug
rel ay shoul d be acti vated. Thi s i s done before, duri ng
and after the engi ne i s started. Whenever the gl ow
pl ug rel ay i s acti vated, i t wi l l control the 12V+ 100
amp ci rcui t for the operati on of the four gl ow pl ugs.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the fol l owi ng Gl ow Pl ug Control
chart for a temperature/ti me compari son of gl ow pl ug
rel ay operati on.
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
Fig. 12 Timing Solenoid
GLOW PLUG CONTROL
GLOW PLUGS
Gl ow pl ugs are used to hel p start a col d or cool
engi ne. The pl ug wi l l heat up and gl ow to heat the
combusti on chamber of each cyl i nder. An i ndi vi dual
pl ug i s used for each cyl i nder. Each pl ug i s threaded
i nto the cyl i nder head above the fuel i njector (Fi g.
14).
Each pl ug wi l l momentari l y draw approxi matel y 25
amps of el ectri cal current duri ng the i ni ti al keyon
cycl e. Thi s i s on a col d or cool engi ne. After heati ng,
the current draw wi l l drop to approxi matel y 912
amps per pl ug.
Total momentary current draw for al l four pl ugs i s
approxi matel y 100 amps on a col d engi ne droppi ng to
a total of approxi matel y 40 amps after the pl ugs are
heated.
El ectri cal operati on of the gl ow pl ugs are con-
trol l ed by the gl ow pl ug rel ay. Refer to the previ ous
Gl ow Pl ug Rel ayECM Output for addi ti onal i nfor-
mati on.
ELECTRIC VACUUM MODULATOR (EVM) ECM
OUTPUT
Thi s ci rcui t control s operati on of the El ectri c Vac-
uum Modul ator (EVM). The EVM control s operati on
of the EGR val ve.
i nformati on. See El ectri c Vacuum Modul ator.
DIESEL DIAGNOSTICS
The ECM control l ers perform engi ne off di agnosti c
tests, whi ch may be heard for about 60 seconds after
turni ng the key off.
ASD RELAY TEST
To perform a test of the rel ay and i ts rel ated ci r-
cui try, refer to the DRB scan tool . To test the rel ay
onl y, refer to Rel aysOperati on/Testi ng i n thi s sec-
ti on of the group.
ENGINE SPEED SENSOR TEST
To perform a test of the engi ne speed sensor and
i ts rel ated ci rcui try, refer to the DRB scan tool .
TEST
near the rear of fuel i njecti on pump (Fi g. 15).
For a l i st of Di agnosti c Troubl e Codes (DTCs) for
certai n fuel system components, refer to On-Board
Di agnosti cs i n Group 25, Emi ssi on Control System.
To test the sensor onl y, refer to the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor.
(2) Test the resi stance of the sensor wi th a hi gh
i nput i mpedance (di gi tal ) vol tohmmeter. The resi s-
tance (as measured across the sensor termi nal s)
shoul d be l ess than 1340 ohms wi th the engi ne
warm. Refer to the fol l owi ng Sensor Resi stance
Fig. 14 Glow Plug
Location
(OHMS) chart. Repl ace the sensor i f i t i s not wi thi n
the range of resi stance speci fi ed i n the chart.
(3) Test conti nui ty of the wi re harness. Do thi s
between the ECM wi re harness connector and the
sensor connector termi nal . Al so test conti nui ty of
wi re harness to the sensor connector termi nal . Refer
to Group 8W for wi ri ng connector and ci rcui try i nfor-
mati on. Repai r the wi re harness i f an open ci rcui t i s
i ndi cated.
(4) After tests are compl eted, connect el ectri cal
connector to sensor.
GLOW PLUG TEST
Hard starti ng or a rough i dl e after starti ng may be
caused by one or more defecti ve gl ow pl ugs. Before
testi ng the gl ow pl ugs, a test of the gl ow pl ug rel ays
shoul d be performed. Thi s wi l l ensure that 12V+ i s
avai l abl e at the pl ugs when starti ng the engi ne.
Refer to the Gl ow Pl ug Rel ay Test for i nformati on.
For accurate test resul ts, the gl ow pl ugs shoul d be
removed from the engi ne. The pl ugs must be checked
when col d. Do not check the plugs if the engine
has recently been operated. If plugs are
checked when warm, incorrect amp gauge
readings will result.
Use Churchi l l Gl ow Pl ug Tester DX.900 or an
equi val ent (Fi g. 16) for the fol l owi ng tests. Thi s
tester i s equi pped wi th 4 ti mer l amps.
(1) Remove the gl ow pl ugs from the engi ne. Refer
to Gl ow Pl ug Removal /I nstal l ati on.
(2) Attach the red l ead of the tester to the 12V+
(posi ti ve) si de of the battery.
(3) Attach the bl ack l ead of the tester to the 12V
(negati ve) si de of the battery.
(4) Fi t the gl ow pl ug i nto the top of the tester and
secure i t wi th the spri ng l oaded bar (Fi g. 16).
(5) Attach the thi rd l ead wi re of the tester to the
el ectri cal termi nal at the end of the gl ow pl ug.
(6) When performi ng the test, the tester button
(Fi g. 16) shoul d be hel d conti nuousl y wi thout rel ease
for 20 seconds as i ndi cated by the 4 ti mer l amps.
Each i l l umi nated l amp represents a 5 second ti me
l apse.
(a) Press and hol d the tester button (Fi g. 16)
and note the amp gauge readi ng. The gauge read-
i ng shoul d i ndi cate a momentary, i ni ti al current
draw (surge) of approxi matel y 25 amps. After the
i ni ti al surge, the amp gauge readi ng shoul d begi n
to fal l off. The gl ow pl ug ti p shoul d start to gl ow
an orange col or after 5 seconds. I f the ti p di d not
gl ow after 5 seconds, repl ace the gl ow pl ug. Before
di scardi ng the gl ow pl ug, check the posi ti on of the
ci rcui t breaker on the bottom of the pl ug tester. I t
may have to be reset. Reset i f necessary.
(b) Conti nue to hol d the tester button whi l e
observi ng the amp gauge and the 4 ti mer l amps.
When al l 4 l amps are i l l umi nated, i ndi cati ng a 20
second ti me l apse, the amp gauge readi ng shoul d
i ndi cate a 912 amp current draw. I f not, repl ace
the gl ow pl ug. Refer to Gl ow Pl ug Removal /I nstal -
l ati on.
(7) Check each gl ow pl ug i n thi s manner usi ng one
20 second cycl e. I f the gl ow pl ug i s to be retested, i t
must fi rst be al l owed to cool to room temperature.
SENSOR RESISTANCE (OHMS)
Fig. 16 Typical Glow Plug Tester
WARNING: THE GLOW PLUG WILL BECOME
EXTREMELY HOT (GLOWING) DURING THESE
TESTS. BURNS COULD RESULT IF IMPROPERLY
HANDLED. ALLOW THE GLOW PLUG TO COOL
BEFORE REMOVING FROM TESTER.
(8) Remove the gl ow pl ug from the tester.
GLOW PLUG RELAY TEST
The gl ow pl ug rel ay i s l ocated i n the engi ne com-
partment on the l efti nner fender (Fi g. 17).
When the i gni ti on (key) swi tch i s pl aced i n the ON
posi ti on, a si gnal i s sent to the ECM rel ati ng current
engi ne cool ant temperature. Thi s si gnal i s sent from
the engi ne cool ant temperature sensor.
After recei vi ng thi s si gnal , the ECM wi l l determi ne
i f, when and for how l ong a peri od the gl ow pl ug
rel ay shoul d be acti vated. Thi s i s done before, duri ng
and after the engi ne i s started. Whenever the gl ow
pl ug rel ay i s acti vated, i t wi l l control the 12V+ 100
amp ci rcui t for the operati on of the four gl ow pl ugs.
The Gl ow Pl ug l amp i s ti ed to thi s ci rcui t. Lamp
operati on i s al so control l ed by the ECM.
Wi th a col d engi ne, the gl ow pl ug rel ay and gl ow
pl ugs may be acti vated for a maxi mum ti me of 200
seconds. Refer to the Gl ow Pl ug Control chart for a
temperature/ti me compari son of gl ow pl ug rel ay oper-
ati on.
I n thi s chart, PreHeat and PostHeat ti mes are
menti oned. Preheat i s the amount of ti me the gl ow
pl ug rel ay ci rcui t i s acti vated when the i gni ti on (key)
swi tch i s ON, but the engi ne has yet to be started.
Postheat i s the amount of ti me the gl ow pl ug rel ay
ci rcui t i s acti vated after the engi ne i s operati ng. The
Gl ow Pl ug l amp wi l l not be i l l umi nated duri ng the
postheat cycl e.
TESTING:
Di sconnect and i sol ate the el ectri cal connectors
(Fi g. 18) at al l four gl ow pl ugs. Wi th the engi ne cool
or col d, and the key i n the ON posi ti on, check for
1012 vol ts + at each el ectri cal connector. 1012 vol ts
+ shoul d be at each connector whenever the ECM i s
operati ng i n the preheat or postheat cycl es (refer
to the fol l owi ng Gl ow Pl ug Control chart). Be very
careful not to allow any of the four discon-
nected glow plug electrical connectors to con-
tact a metal surface. When the key is turned to
the ON position, approximately 100 amps at 12
volts is supplied to these connectors. I f 1012
vol ts + i s not avai l abl e at each connector, check con-
ti nui ty of wi ri ng harness di rectl y to the rel ay. I f con-
ti nui ty i s good di rectl y to the rel ay, the faul t i s ei ther
wi th the rel ay or the rel ay i nput from the ECM. To
test the rel ay onl y, refer to Rel aysOperati on/Test-
i ng i n thi s secti on of the group. I f the rel ay test i s
good, refer to the DRB scan tool .
RELAYS OPERATION/TESTING
The following description of operation and
tests apply only to the ASD and other relays.
The termi nal s on the bottom of each rel ay are num-
bered (Fi g. 19).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and other rel ays, termi nal 30
i s connected to battery vol tage at al l ti mes.
The ECM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
Fig. 18 Wiring Connection at Glow Plug
When the PCM de-energi zes the ASD and other
rel ays, termi nal number 87A connects to termi nal 30.
Thi s i s the Off posi ti on. I n the off posi ti on, vol tage i s
not suppl i ed to the rest of the ci rcui t. Termi nal 87A
i s the center termi nal on the rel ay.
When the ECM energi zes the ASD and other
rel ays, termi nal 87 connects to termi nal 30. Thi s i s
the On posi ti on. Termi nal 87 suppl i es vol tage to the
rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
other rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and other rel ay ci rcui ts. Refer to group 8W, Wi ri ng
Di agrams.
BOOST / PRESSURE SENSOR
I f the boost pressure sensor fai l s, the PCM records
a DTC i nto memory and conti nues to operate the
GLOW PLUG CONTROL
Fig. 20 Boost Pressure Sensor Location
engi ne i n one of the three l i mp-i n modes. When the
PCM i s operati ng i n thi s mode, a l oss of power wi l l
be present, as i f the turbocharger was not operati ng.
The best method for di agnosi ng faul ts wi th the boost
pressure sensor i s wi th the DRB I I I scan tool . Diag-
nostic Trouble Codes: Refer to On-Board Di agnos-
ti cs i n Group 25, Emi ssi on Control System for a l i st
of Di agnosti c Troubl e Codes (DTCs) for certai n fuel
system components.
VEHICLE SPEED SENSOR TEST
To perform a test of the sensor and i ts rel ated ci r-
cui try, refer to DRB scan tool .
DIAGNOSTIC TROUBLE CODES
For a l i st of Di agnosti c Troubl e Codes (DTCs),
refer to Group 25, Emi ssi on Control System for i nfor-
mati on. See On-Board Di agnosti cs.
ASD RELAY
The ASD rel ay i s l ocated i n the PDC. For the l oca-
ti on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
A/C CLUTCH RELAY
The A/C cl utch rel ay i s l ocated i n the PDC. For the
l ocati on of the rel ay wi thi n the PDC, refer to l abel on
PDC cover.
ENGINE SPEED SENSOR
The engi ne speed sensor i s mounted to the trans-
mi ssi on bel l housi ng at the rear of the engi ne bl ock
(Fi g. 21).
REMOVAL
(1) Di sconnect the harness (on the sensor) from
the mai n el ectri cal harness.
(2) Remove the sensor mounti ng bol ts.
(3) Remove the sensor.
INSTALLATION
(1) I nstal l the sensor fl ush agai nst the openi ng i n
the transmi ssi on housi ng.
(2) I nstal l and ti ghten the sensor mounti ng bol t to
19 Nm (14 ft. l bs.) torque.
(3) Connect the el ectri cal connector to the sensor.
near the rear of fuel i njecti on pump.
REMOVAL
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Parti al l y drai n cool i ng system. Refer to Group
7, Cool i ng.
(2) Di sconnect el ectri cal connector from sensor.
(3) Remove sensor from cyl i nder head.
INSTALLATION
(1) I nstal l a new copper gasket to sensor.
(2) I nstal l sensor to cyl i nder head.
(3) Ti ghten sensor to 18 Nm (13 ft. l bs.) torque.
(5) Repl ace any l ost engi ne cool ant. Refer to Group
7, Cool i ng System.
GLOW PLUGS
The gl ow pl ugs are l ocated above each fuel i njector
(Fi g. 22). Four i ndi vi dual pl ugs are used.
REMOVAL
(1) Di sconnect the negati ve battery cabl e at the
battery.
(2) Cl ean the area around the gl ow pl ug wi th com-
pressed ai r before removal .
(3) Di sconnect el ectri cal connector (Fi g. 23) at gl ow
pl ug.
(4) Remove the gl ow pl ug (Fi g. 22) from cyl i nder
head.
Fig. 21 Engine Speed Sensor
INSTALLATION
(1) Appl y hi ghtemperature anti sei ze compound
to gl ow pl ug threads before i nstal l ati on.
(2) I nstal l the gl ow pl ug i nto the cyl i nder head.
Ti ghten to 23 Nm (203 i n. l bs.) torque.
(3) Connect battery cabl e to battery.
GLOW PLUG RELAY
The gl ow pl ug rel ay i s l ocated i n the engi ne com-
partment on the l efti nner fender (Fi g. 24).
REMOVAL
battery.
(2) Remove rel ay mounti ng bol t.
(3) Di sconnect el ectri cal connector at rel ay and
remove rel ay.
INSTALLATION
(1) Check condi ti on of el ectri cal connector for dam-
age or corrosi on. Repai r as necessary.
(2) I nstal l el ectri cal connector to rel ay.
(3) I nstal l rel ay to i nner fender.
The PCM i s mounted to a bracket mounted to the
i nner si de of the ri ght fender wel l behi nd the ai r
cl eaner assembl y (Fi g. 25).
REMOVAL
battery.
Fig. 22 Glow Plug
Fig. 23 Glow Plug Electrical Connector
Fig. 25 PCM Location
(2) Loosen the 60Way connector (Fi g. 25). The
el ectri cal connector has a sl i di ng bar whi ch moves
i nward to l ock or outward to unl ock.
(3) Remove the el ectri cal connector by pul l i ng
strai ght out.
(4) Remove PCM.
INSTALLATION
(1) After the PCM el ectri cal connector has been
separated from the PCM, i nspect the pi ns for corro-
si on, bei ng spread apart, bent or mi sal i gned. Al so
i nspect the pi n hei ghts i n the connector. I f the pi n
hei ghts are di fferent, thi s woul d i ndi cate a pi n has
separated from the connector. Repai r as necessary.
(2) Engage 60way connector i nto PCM. Move
sl i de bar to l ock connector.
The vehi cl e speed sensor (Fi g. 26) i s l ocated on the
extensi on housi ng of the transmi ssi on for 2 wheel
dri ve vehi cl e, or on the transfer case housi ng for 4
wheel dri ve vehi cl es (Fi g. 27).
REMOVAL
(2) Cl ean the area around the sensor before
removal .
(3) Di sconnect the el ectri cal connector from the
sensor (Fi g. 28).
(4) Remove the sensor mounti ng bol t (Fi g. 28).
(5) Pul l the sensor from the speedometer pi ni on
gear adapter for removal .
INSTALLATION
(1) I nstal l new sensor i nto speedometer gear
adapter.
(2) Ti ghten sensor mounti ng bol t. To prevent dam-
age to sensor or speedometer adapter, be sure the
sensor i s mounted fl ush to the adapter before ti ght-
eni ng.
Fig. 26 Vehicle Speed Sensor Location2 Wheel
Drive
Fig. 28 Sensor Removal/InstallationTypical
SPECIFICATIONS
GLOW PLUG CURRENT DRAW
Initial Current Draw: Approxi matel y 2225
amps per pl ug.
After 20 seconds of operation: Approxi matel y
912 amps per pl ug.
TORQUE CHART 2. 5L DIESEL
STEERING
CONTENTS
page page
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 5
POWER STEERING GEAR . . . . . . . . . . . . . . . . . . 11
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 23
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 27
POWER STEERING
INDEX
page page
GENERAL INFORMATION
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
POWER STEERING SYSTEM
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
STEERING SYSTEM
The power steeri ng system has a hydraul i c pump.
The pump i s a constant fl ow rate and di spl acement ,
vane-type pump. The pump on the 4.0L engi ne has a
reservoi r mounted to i t (Fi g. 1). The 2.5L engi ne has
a remote mounted reservoi r.
The steeri ng gear used i s a reci rcul ati ng bal l type
gear. The gear acts as a rol l i ng thread between the
worm shaft and the rack pi ston. When the steeri ng
wheel i s turned the worm shaft turns whi ch moves
the rack pi ston. The rack pi ston movement turns the
pi tman shaft whi ch i s connected to the steeri ng l i nk-
age by the pi tman arm. Thi s gear i s used on al l mod-
el s.
The power steeri ng system consi sts of:
Hydraul i c pump
Reci rcul ati ng bal l steeri ng gear
Steeri ng col umn
Steeri ng l i nkage
NOTE: Right hand drive (RHD) and left hand drive
(LHD) service procedures and torque specifications
for steering linkage, gear and column are the same.
The power steering pump procedures are different.
Refer to appropriate service procedures regarding
each component in the system.
Fig. 1 Power Steering Gear & Pump - 4.0L
XJ STEERING 19 - 1
POWER STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
CONDITION POSSIBLE CAUSES CORRECTION
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash panel
seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components.
2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other
components.
5. Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
19 - 2 STEERING XJ
BINDING AND STICKING
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
2. Tire pressure. 2. Adjust tire pressure.
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of
adjustment.
7. Repair or replace gear.
INSUFFICIENT ASST. OR POOR RETURN TO CENTER
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as
necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair
as necessary.
STEERING WHEEL
DOES NOT WANT TO RETURN TO
CENTER POSITION
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.
XJ STEERING 19 - 3
LOOSE STEERING AND VEHICLE LEAD
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
1. Repair as necessary.
2. Worn or loose wheel bearings. 2. Repair as necessary.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.
VEHICLE PULLS OR LEADS TO
ONE SIDE
1. Tire Pressure. 1. Adjust tire pressure.
2. Radial tire lead. 2. Cross front tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering or
suspension components.
6. Repair as necessary.
19 - 4 STEERING XJ
POWER STEERING PUMP
INDEX
page page
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 5
POWER FLOW AND PRESSURE . . . . . . . . . . . . . 5
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . . . 6
SERVICE PROCEDURES
POWER STEERING PUMP INITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PUMP RESERVOIR-2.5L . . . . . . . . . . . . . . . . . . . 8
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . 9
FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
POWER STEERING PUMP
Hydraul i c pressure i s provi ded for operati on of the
power steeri ng gear by a bel t dri ven power steeri ng
pump. The power steeri ng pump i s a constant fl ow
rate and di spl acement, vane-type pump. The i nternal
parts i n the housi ng operate submerged i n fl ui d. The
fl ow control ori fi ce i s part of the hi gh pressure l i ne
fi tti ng. The pressure rel i ef val ve i nsi de the fl ow con-
trol val ve l i mi ts the pump pressure. The reservoi r i s
attached to the pump body wi th spri ng cl i ps on the
4.0L engi ne. On the 2.5L engi ne the reservoi r i s sep-
arate from the pump.
The power steeri ng pump i s connected to the steer-
i ng gear by the pressure and return hoses. The pump
shaft has a pressed-on dri ve pul l ey that i s bel t dri ven
by the crankshaft pul l ey (Fi g. 1).
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
POWER FLOW AND PRESSURE
The fol l owi ng procedure i s used to test the operati on
of the power steeri ng system on the vehi cl e. Thi s test
wi l l provi de the gal l ons per mi nute (GPM) or fl ow rate
of the power steeri ng pump al ong wi th the maxi mum
rel i ef pressure. Perform test any ti me a power steeri ng
system probl em i s present. Thi s test wi l l determi ne i f
the power steeri ng pump or power steeri ng gear i s not
functi oni ng properl y. The fol l owi ng pressure and fl ow
test i s performed usi ng Power Steeri ng Anal yzer Tool
Ki t 6815 (Fi g. 2) and Adapter Ki t 6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6865.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect hi gh pressure hose at gear or pump.
Use a contai ner for dri ppi ng fl ui d.
(5) Connect Tube 6865 to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to Adapter 6826.
Fig. 1 Pump With Integral Reservoir
XJ STEERING 19 - 5
(7) Open the test val ve compl etel y.
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge and to get ai r out of the fl ui d. Then shut off
engi ne.
(9) Check fl ui d l evel , add fl ui d as necessary. Start
engi ne agai n and l et i dl e.
(10) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. The readi ng shoul d be 2.4 - 2.8
GPM, i f the readi ng i s bel ow thi s speci fi cati on the
pump shoul d be repl aced.
CAUTION: The next step involves testing maximum
pump pressure output and flow control valve oper-
ation. Do not leave valve closed for more than three
seconds as the pump could be damaged.
(12) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(13) Open the test val ve, turn steeri ng wheel
extreme l eft and ri ght posi ti ons agai nst the stops.
Record the hi ghest i ndi cated pressure at each posi -
ti on. Compare readi ngs to speci fi cati ons. I f hi ghest
output pressures are not the same agai nst ei ther
stop, the gear i s l eaki ng i nternal l y and must be
repai red.
CAUTION: Do not force the pump to operate
against the stops for more than 2 to 3 seconds at a
time because, pump damage will result.
PUMP SPECIFICATIONS
ENGINE
RELIEF
PRESSURE
50
FLOW RATE (GPM)
2.5L
9653 kPa
(1400 psi)
1500 RPM
2.4 - 2.8 GPM
4.0L
9653 kPa
(1400 psi)
PUMP LEAKAGE DIAGNOSIS
SERVICE PROCEDURES
OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Fig. 2 Power Steering Analyzer
19 - 6 STEERING XJ
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
POWER STEERING PUMP
NOTE: The power steering pump is mounted in the
same position on LHD and RHD vehicles. On 4.0L
RHD vehicles the front bracket is different. The ser-
vice procedures are the same.
REMOVAL
(1) Remove serpenti ne dri ve bel t, refer to Group 7
Cool i ng.
(2) Remove pressure and return hoses from pump,
and drai n pump.
(3) Remove 3 pump mounti ng bol ts through pul l ey
access hol es .
(4) Loosen the 3 pump bracket bol ts (Fi g. 3) and
(Fi g. 4).
(5) Ti l t pump downward and remove from engi ne.
(6) Remove pul l ey from pump.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) I nstal l pump on engi ne.
(3) Ti ghten pump bracket bol ts to 47 Nm (35 ft.
l bs.).
Fig. 3 Pump Mounting
XJ STEERING 19 - 7
(4) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 Nm (20 ft. l bs.).
(5) I nstal l the pressure and return hoses to pump.
(6) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(7) Add power steeri ng fl ui d and perform Power
Steeri ng Pump I ni ti al Operati on.
PUMP RESERVOIR-2. 5L
REMOVAL
(1) Remove the hoses from the bottom of the res-
ervoi r and drai n the reservoi r.
(2) Remove the push-i n fastener from the top of
the fan shroud.
(3) Sl i de reservoi r up off the fan shroud.
INSTALLATION
(1) Sl i de reservoi r down onto fan shroud.
(2) I nstal l the push-i n fastener i n the top of fan
shroud.
(3) I nstal l the pump hoses.
(4) Fi l l reservoi r to proper l evel . Refer to Power
Steeri ng Pump I ni ti al Operati on.
PUMP PULLEY
DISASSEMBLY
(1) Remove pump assembl y.
(2) Remove pul l ey from pump wi th Pul l er C-4333
(Fi g. 5).
ASSEMBLY
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
(Fi g. 6) fl ush wi th the end of the shaft. Ensure the
tool and pul l ey remai n al i gned wi th the pump shaft.
(3) I nstal l pump assembl y.
(4) Wi th Serpenti ne Bel t, run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
Fig. 4 Pump Mounting 4.0L RHD
Fig. 5 Pulley Removal
19 - 8 STEERING XJ
PUMP RESERVOIR
DISASSEMBLY
(1) Remove power steeri ng pump.
(2) Cl ean exteri or of pump.
(3) Cl amp the pump body i n a soft jaw vi ce.
(4) Pry up tab and sl i de the retai ni ng cl i ps off (Fi g.
7).
NOTE: Use new retaining clips for installtion.
(5) Remove fl ui d reservoi r from pump body.
Remove and di scard O-ri ng seal .
ASSEMBLY
(1) Lubri cate new O-ri ng Seal wi th Mopar Power
Steeri ng Fl ui d or equi val ent.
(2) I nstal l O-ri ng seal i n housi ng.
(3) I nstal l reservoi r onto housi ng.
(4) Sl i de and tap i n new reservoi r retai ner cl i ps
unti l tab l ocks to housi ng.
(5) I nstal l power steeri ng pump.
(6) Add power steeri ng fl ui d, refer to Pump I ni ti al
Operati on.
FLOW CONTROL VALVE
DISASSEMBLY
(1) Cl ean area around fi tti ng to prevent di rt from
enteri ng pump. Remove pressure hose from pump fi t-
ti ng.
(2) Remove fi tti ng from pump housi ng (Fi g. 8).
Prevent flow control valve and spring from
sliding out of housing bore.
(3) Remove and di scard O-ri ng seal .
ASSEMBLY
(1) I nstal l spri ng and fl ow control val ve i nto pump
housi ng bore. Be sure the hex nut end of the
valve is facing in toward pump.
(2) I nstal l O-ri ng seal onto fi tti ng.
(3) I nstal l fl ow control val ve i n pump housi ng and
ti ghten to 75 Nm (55 ft. l bs.).
(4) I nstal l pressure hose to val ve.
Fig. 6 Pulley Installation
Fig. 7 Pump Reservoir Clips
Fig. 8 Flow Control Valve
XJ STEERING 19 - 9
DISASSEMBLY AND ASSEMBLY (Continued)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Pump
Bracket to Pump . . . . . . . . . . . . . . . . . . . . 28 Nm
(21 ft. l bs.)
Bracket to Engi ne . . . . . . . . . . . . . . . . . . . 47 Nm
(35 ft. l bs.)
Fl ow Control Val ve . . . . . . . . . . . . . . . . . . 75 Nm
(55 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . . . . . . . . . . 28 Nm
(21 ft. l bs.)
SPECIAL TOOLS
POWER STEERING PUMP
Analyzer Set, Power Steering Flow/Pressure 6815
Installer, Power Steering Pulley C-4063B
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
19 - 10 STEERING XJ
POWER STEERING GEAR
INDEX
page page
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 11
POWER STEERING GEAR LEAKAGE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 13
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . . 13
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . . 14
SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 15
RACK PISTON AND WORM SHAFT . . . . . . . . . . 17
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS
POWER STEERING GEAR
The power steeri ng gear i s a reci rcul ati ng bal l type
gear (Fi g. 1). The gear acts as a rol l i ng thread
between the worm shaft and rack pi ston. The worm
shaft i s supported by a thrust beari ng at the l ower
end and a beari ng assembl y at the upper end. When
the worm shaft i s turned the rack pi ston moves. The
rack pi ston teeth mesh wi th the pi tman shaft. Turn-
i ng the worm shaft turns the pi tman shaft, whi ch
turns the steeri ng l i nkage.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
XJ STEERING 19 - 11
Fig. 1 Recirculating Ball Type Gear
19 - 12 STEERING XJ
POWER STEERING GEAR LEAKAGE DIAGNOSIS
STEERING GEAR
REMOVAL
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on wi th the steeri ng wheel centered.
(2) Di sconnect and cap the fl ui d hoses from steer-
i ng gear.
(3) Remove the col umn coupl er shaft from the
gear.
(4) Remove pi tman arm from gear.
(5) Remove the steeri ng gear retai ni ng bol ts and
remove the gear (Fi g. 2) .
INSTALLATION
(1) Al i gn the col umn coupl er shaft to steeri ng gear.
(2) I nstal l steeri ng gear (and bracket) on the frame
rai l and ti ghten bol ts to 95 Nm (70 ft. l bs.)
(3) Al i gn and i nstal l the pi tman arm and ti ghten
nut to 251 Nm (185 ft. l bs.).
(4) Connect fl ui d hoses to steeri ng gear and
(5) Fi l l power steeri ng system to proper l evel .
HOUSING END PLUG
DISASSEMBLY
(1) Unseat and remove retai ni ng ri ng from groove
wi th a punch through the hol e i n the end of the
housi ng (Fi g. 3).
(2) Sl owl y rotate stub shaft wi th 12 poi nt socket
COUNTER-CLOCKWI SE to force the end pl ug out
from housi ng.
Fig. 2 Steering Gear Mounting (LHD)
Fig. 3 End Plug Retaining Ring
XJ STEERING 19 - 13
CAUTION: Do not turn stub shaft any further than
necessary. The rack piston balls will drop out of the
rack piston circuit if the stub shaft is turned too far.
(3) Remove O-ri ng from the housi ng (Fi g. 4).
ASSEMBLY
(1) Lubri cate O-ri ng wi th power steeri ng fl ui d and
i nstal l i nto the housi ng.
(2) I nstal l end pl ug by tappi ng the pl ug l i ghtl y
wi th a pl asti c mal l et i nto the housi ng.
(3) I nstal l retai ni ng ri ng so one end of the ri ng
covers the housi ng access hol e (Fi g. 5).
PITMAN SHAFT/SEALS/BEARING
DISASSEMBLY
(1) Cl ean exposed end of pi tman shaft and housi ng
wi th a wi re brush.
(2) Remove prel oad adjuster nut (Fi g. 6).
(3) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotati ng i t from the
stop 1/2 of the total amount of turns.
(5) Remove si de cover bol ts and remove si de cover,
gasket and pi tman shaft as an assembl y (Fi g. 6).
NOTE: The pitman shaft will not clear the housing
if it is not centered.
(6) Remove pi tman shaft from the si de cover.
(7) Remove dust seal from the housi ng wi th a seal
pi ck (Fi g. 7).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retai ni ng ri ng wi th snap ri ng pl i ers.
(9) Remove washer from the housi ng.
(10) Remove oi l seal from the housi ng wi th a seal
pi ck.
(11) Remove pi tman shaft beari ng from housi ng
wi th a beari ng dri ver and handl e (Fi g. 8).
Fig. 4 End Plug Components
Fig. 5 Installing The Retaining Ring
Fig. 6 Side Cover and Pitman Shaft
19 - 14 STEERING XJ
ASSEMBLY
(1) I nstal l pi tman shaft beari ng i nto housi ng wi th
a beari ng dri ver and handl e.
(2) Coat the oi l seal and washer wi th special
grease suppl i ed wi th the new seal .
(3) I nstal l the oi l seal wi th a dri ver and handl e.
(4) I nstal l backup washer.
(5) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(6) Coat the dust seal wi th special grease sup-
pl i ed wi th the new seal .
(7) I nstal l dust seal wi th a dri ver and handl e.
(8) I nstal l pi tman shaft to si de cover by screwi ng
shaft i n unti l i t ful l y seats to si de cover.
(9) I nstal l prel oad adjuster nut. Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(10) I nstal l gasket to si de cover and bend tabs
around edges of si de cover (Fi g. 6).
(11) I nstal l pi tman shaft assembl y and si de cover
to housi ng.
(12) I nstal l si de cover bol ts and ti ghten to 60 Nm
(44 ft. l bs.).
(13) Perform over-center rotati on torque adjustment.
SPOOL VALVE
DISASSEMBLY
(1) Remove l ock nut (Fi g. 9).
(2) Remove adjuster nut wi th Spanner Wrench
C-4381.
(3) Remove thrust support assembl y out of the
housi ng (Fi g. 10).
(4) Pul l stub shaft and val ve assembl y from the
Fig. 7 Pitman Shaft Seals & Bearing
Fig. 8 Needle Bearing Removal
Fig. 9 Lock Nut and Adjuster Nut
Fig. 10 Thrust Support Assembly
XJ STEERING 19 - 15
(5) Remove stub shaft from val ve assembl y by
l i ghtl y tappi ng shaft on a bl ock of wood to l oosen
shaft. Then di sengage stub shaft pi n from hol e i n
spool val ve and separate the val ve assembl y from
stub shaft (Fi g. 12).
(6) Remove spool val ve from val ve body by pul l i ng
and rotati ng the spool val ve from the val ve body (Fi g.
13).
(7) Remove spool val ve O-ri ng and val ve body
tefl on ri ngs and O-ri ngs underneath the tefl on ri ngs
(Fi g. 14).
(8) Remove the O-ri ng between the worm shaft
and the stub shaft.
ASSEMBLY
NOTE: Clean and dry all components, then lubri-
cate with power steering fluid.
(1) I nstal l spool val ve spool O-ri ng.
(2) I nstal l spool val ve i n val ve body by pushi ng
and rotati ng. Hol e i n spool val ve for stub shaft pi n
must be accessi bl e from opposi te end of val ve body.
(3) I nstal l stub shaft i n val ve spool and engage
l ocati ng pi n on stub shaft i nto spool val ve hol e (Fi g.
15).
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
Fig. 11 Valve Assembly With Stub Shaft
Fig. 12 Stub Shaft
Fig. 13 Spool Valve
Fig. 14 Valve Seals
19 - 16 STEERING XJ
(4) I nstal l O-ri ngs and tefl on ri ngs over the
O-ri ngs on val ve body.
(5) I nstal l O-ri ng i nto the back of the stub shaft
cap (Fi g. 16).
(6) I nstal l stub shaft and val ve assembl y i n the
housi ng. Li ne up worm shaft to sl ots i n the val ve
assembl y.
(7) I nstal l thrust support assembl y.
NOTE: The thrust support is serviced as an assem-
bly. If any component of the thrust support is dam-
aged the assembly must be replaced.
(8) I nstal l adjuster nut and l ock nut.
(9) Adjust Thrust Beari ng Prel oad and Over-Cen-
ter Rotati ng Torque.
RACK PISTON AND WORM SHAFT
DISASSEMBLY
(1) Remove housi ng end pl ug.
(2) Remove rack pi ston pl ug (Fi g. 17).
(3) Remove si de cover and pi tman shaft.
(4) Turn stub shaft COUNTERCLOCKWI SE unti l
the rack pi ston begi ns to come out of the housi ng.
(5) I nsert Arbor C-4175 i nto bore of rack pi ston
(Fi g. 18) and hol d tool ti ghtl y agai nst worm shaft.
(6) Turn the stub shaft wi th a 12 poi nt socket
COUNTERCLOCKWI SE, thi s wi l l force the rack pi s-
ton onto the tool and hol d the rack pi ston bal l s i n
pl ace.
Fig. 15 Stub Shaft Installation
Fig. 16 Stub Shaft Cap O-Ring
Fig. 17 Rack Piston End Plug
Fig. 18 Rack Piston with Arbor
XJ STEERING 19 - 17
(7) Remove the rack pi ston and tool together from
housi ng.
(8) Remove tool from rack pi ston.
(9) Remove rack pi ston bal l s.
(10) Remove cl amp bol ts, cl amp and bal l gui de
(Fi g. 19).
(11) Remove tefl on ri ng and O-ri ng from the rack
pi ston (Fi g. 20).
(12) Remove the adjuster l ock nut and adjuster
nut from the stub shaft.
(13) Pul l the stub shaft wi th the spool val ve and
thrust support assembl y out of the housi ng.
(14) Remove the worm shaft from the housi ng
(Fi g. 21).
ASSEMBLY
NOTE: Clean and dry all components and lubricate
with power steering fluid.
(1) Check for scores, ni cks or burrs on the rack
pi ston fi ni shed surface. Sl i ght wear i s normal on the
worm gear surfaces.
(2) I nstal l O-ri ng and tefl on ri ng on the rack pi s-
ton.
(3) I nstal l worm shaft i n the rack pi ston and al i gn
worm shaft spi ral groove wi th rack pi ston bal l gui de
hol e (Fi g. 22).
CAUTION: The rack piston balls must be installed
alternately into the rack piston and ball guide. This
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.
Fig. 19 Rack Piston
Fig. 20 Rack Piston Teflon Ring and O-Ring
Fig. 21 Worm Shaft
Fig. 22 Installing Balls in Rack Piston
19 - 18 STEERING XJ
(4) Lubri cate and i nstal l rack pi ston bal l s through
return gui de hol e whi l e turni ng worm shaft COUN-
TERCLOCKWI SE (Fi g. 22).
(5) I nstal l remai ni ng bal l s i n gui de usi ng grease to
hol d the bal l s i n pl ace (Fi g. 23).
(6) I nstal l the gui de onto rack pi ston and i nstal l
cl amp and cl amp bol ts. Ti ghten bol ts to 58 Nm (43
ft. l bs.).
(7) I nsert Arbor C-4175 i nto bore of rack pi ston
and hol d tool ti ghtl y agai nst worm shaft.
(8) Turn the worm shaft COUNTERCLOCKWI SE
whi l e pushi ng on the arbor. Thi s wi l l force the rack
pi ston onto the arbor and hol d the rack pi ston bal l s
i n pl ace.
(9) I nstal l the races and thrust beari ng on the
worm shaft and i nstal l shaft i n the housi ng (Fi g. 21).
(10) I nstal l the stub shaft wi th spool val ve, thrust
support assembl y and adjuster nut i n the housi ng.
(11) I nstal l the rack pi ston and arbor tool i nto the
housi ng.
(12) Hol d arbor ti ghtl y agai nst worm shaft and
turn stub shaft CLOCKWI SE unti l rack pi ston i s
seated on worm shaft.
(13) I nstal l pi tman shaft and si de cover i n the
housi ng.
(14) I nstal l rack pi ston pl ug and ti ghten to 150
Nm (111 ft. l bs.).
(15) I nstal l housi ng end pl ug.
(16) Adjust worm shaft thrust beari ng prel oad and
over-center rotati ng torque.
ADJ USTMENTS
STEERING GEAR
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
WORM THRUST BEARING PRELOAD
(1) Mount the gear careful l y i nto a vi se.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Remove adjuster pl ug l ocknut (Fi g. 24).
(3) Rotate the stub shaft back and forth wi th a 12
poi nt socket to drai n the remai ni ng fl ui d.
(4) Turn the adjuster i n wi th Spanner Wrench
C-4381. Ti ghten the pl ug and thrust beari ng i n the
housi ng unti l fi rml y bottomed i n the housi ng about
34 Nm (25 ft. l bs.).
(5) Pl ace an i ndex mark on the housi ng even wi th
one of the hol es i n adjuster pl ug (Fi g. 25).
(6) Measure back (countercl ockwi se) 5.08 mm (0.20
i n) and mark housi ng (Fi g. 26).
(7) Rotate adjustment cap back (countercl ockwi se)
wi th spanner wrench unti l hol e i s al i gned wi th the
second mark (Fi g. 27).
Fig. 23 Balls in the Return Guide
Fig. 24 Adjuster Lock Nut
XJ STEERING 19 - 19
(8) I nstal l and ti ghten l ocknut to 108 Nm (80 ft.
l bs.). Be sure adjustment cap does not turn whi l e
ti ghteni ng the l ocknut.
OVER-CENTER
NOTE: Before performing this procedure, the worm
bearing preload adjustment must be performed.
(1) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(2) Starti ng at ei ther stop, turn the stub shaft
back 1/2 the total number of turns. Thi s i s the center
of the gear travel (Fi g. 28).
(3) Pl ace the torque wrench i n the verti cal posi ti on
on the stub shaft. Rotate the wrench 45 degrees each
si de of the center and record the hi ghest rotati onal
torque i n thi s range (Fi g. 29). Thi s i s the Over-Cen-
ter Rotati ng Torque.
Fig. 25 Alignment Marking On Housing
Fig. 26 Second Marking On Housing
Fig. 27 Aligning To The Second Mark
Fig. 28 Steering Gear Centered
19 - 20 STEERING XJ
ADJ USTMENTS (Continued)
NOTE: The stub shaft must rotate smoothly without
sticking or binding.
(4) Rotate the stud shaft between 90 and 180 to
the l eft of center and record the l eft off-center pre-
l oad. Repeat thi s to the ri ght of center and record the
ri ght off-center prel oad. The average of these two
recorded readi ngs i s the Prel oad Rotati ng Torque.
(5) The Over-Center Rotati ng Torque shoul d be
0.45-0.9 Nm (4-8 i n. l bs.) higher than the Prel oad
Rotati ng Torque.
(6) I f an adjustment to the Over-Center Rotati ng
Torque i s necessary, fi rst l oosen the adjuster l ock
nut. Then turn the pi tman shaft adjuster screw back
(COUNTERCLOCKWI SE) unti l ful l y extended, then
turn back i n (CLOCKWI SE) one ful l turn.
(7) Remeasure Over-Center Rotati ng Torque. I f
necessary turn the adjuster screw and repeat mea-
surement unti l correct Over-Center Rotati ng Torque
i s reached.
NOTE: To increase the Over-Center Rotating Torque
turn the screw CLOCKWISE.
(8) Prevent the adjuster screw from turni ng whi l e
ti ghteni ng adjuster l ock nut. Ti ghten the adjuster
l ock nut to 49 Nm (36 ft. l bs.).
SPECIFICATIONS
POWER STEERING GEAR
Steering Gear
Type . . . . . . . . . . . . . . . . . . . . . Reci rcul ati ng Bal l
Gear Ratio
RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:1
LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:1
WormShaft Bearing
Prel oad . . . . . . . . . . . . . . . . . . . . . 0.451.13 Nm
(410 i n. l bs.)
Pitman Shaft Overcenter Drag
New Gear (under 400 mi l es) . . . . . 0.450.90 Nm
(48 i n. l bs.)
+ Worm Shaft Prel oad
Used Gear (over 400 mi l es) . . . . . . . . 0.50.6 Nm
(45 i n. l bs.)
+ Worm Shaft Prel oad
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Gear
Adjustment Cap Locknut . . . . . . . . . . . . 108 Nm
(80 ft. l bs.)
Adjustment Screw Locknut . . . . . . . . . . . . 49 Nm
(36 ft. l bs.)
Gear to Frame Bol ts . . . . . . . . . . . . . . . . . 95 Nm
(70 ft. l bs.)
Pi tman Shaft Nut . . . . . . . . . . . . . . . . . . 251 Nm
(185 ft. l bs.)
Rack Pi ston Pl ug . . . . . . . . . . . . . . . . . . . 102 Nm
(75 ft. l bs.)
Si de Cover Bol ts . . . . . . . . . . . . . . . . . . . . 60 Nm
(44 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . . . . . . . . . . 28 Nm
(21 ft. l bs.)
Return Li ne . . . . . . . . . . . . . . . . . . . . . . . 28 Nm
(21 ft. l bs.)
Return Gui de Cl amp Bol t . . . . . . . . . . . . . 58 Nm
(43 ft. l bs.)
Fig. 29 Checking Over-center Rotation Torque
XJ STEERING 19 - 21
SPECIAL TOOLS
POWER STEERING GEAR
Remover/Installer, Steering Plug C-4381
Remover, Pitman Arm C-4150A
Remover/Installer Steering Rack Piston C-4175
19 - 22 STEERING XJ
STEERING LINKAGE
INDEX
page page
GENERAL INFORMATION
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . 23
SERVICE PROCEDURES
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STEERING DAMPER . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIAL TOOLS
GENERAL INFORMATION
STEERING LINKAGE
The steeri ng l i nkage consi st of a pi tman arm, drag
l i nk, ti e rod, ti e rod ends and a steeri ng damper (Fi g.
1) and (Fi g. 2). The servi ce procedures and torque
speci fi cati ons are the same for LHD and RHD vehi -
cl es.
SERVICE PROCEDURES
STEERING LINKAGE
The ti e rod end and bal l stud seal s shoul d be
i nspected duri ng al l oi l changes. I f a seal i s damaged,
i t shoul d be repl aced. Before i nstal l i ng a new seal ,
i nspect bal l stud at the throat openi ng. Check for
l ubri cant l oss, contami nati on, bal l stud wear or cor-
rosi on. I f these condi ti ons exi st, repl ace the ti e rod. A
repl acement seal can be i nstal l ed i f l ubri cant i s i n
good condi ti on. Otherwi se, a compl ete repl acement
bal l stud end shoul d be i nstal l ed.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
Fig. 1 Steering LinkageLHD
XJ STEERING 19 - 23
TIE ROD
CAUTION: Use a Puller tool C-3894-A for tie rod
removal. Failure to use this tool could damage the
ball stud and seal (Fig. 3).
REMOVAL
(1) Remove the cotter pi ns and nuts at the ti e rod
bal l studs and drag l i nk.
(2) Loosen the bal l studs wi th a pul l er tool to
remove the ti e rod.
(3) Loosen cl amp bol ts and unthread the ti e rod
end from the tube.
INSTALLATION
(1) Thread the ti e rod end i nto the tube and posi -
ti on the cl amp to i ts ori gi nal posi ti on (Fi g. 4).
Ti ghten the cl amp bol ts to 27 Nm (20 ft. l bs.).
(2) I nstal l the ti e rod on the drag l i nk and steeri ng
knuckl e. I nstal l the retai ni ng nuts.
Fig. 2 Steering LinkageRHD
Fig. 3 Ball Stud Puller
Fig. 4 Tie Rod/Drag Link Clamps
19 - 24 STEERING XJ
(3) Ti ghten the bal l stud nut on the steeri ng
knuckl e to 47 Nm (35 ft. l bs.). Ti ghten the bal l stud
nut to drag l i nk to 88 Nm (65 ft. l bs.). I nstal l new
cotter pi ns.
PITMAN ARM
REMOVAL
(1) Remove the cotter pi n and nut from the drag
l i nk at the pi tman arm.
(2) Remove the drag l i nk bal l stud from the pi t-
man arm wi th a pul l er.
(3) Remove the nut and washer from the steeri ng
gear shaft. Mark the pi tman shaft and pi tman arm
for i nstal l ati on reference. Remove the pi tman arm
from steeri ng gear wi th Pul l er C-4150-A (Fi g. 5).
INSTALLATION
(1) Al i gn and i nstal l the pi tman arm on steeri ng
gear shaft.
(2) I nstal l the washer and nut on the shaft and
ti ghten nut to 251 Nm (185 ft. l bs.).
(3) I nstal l drag l i nk bal l stud to pi tman arm
i nstal l nut and ti ghten to 74 Nm (55 ft. l bs.). I nstal l
a new cotter pi n.
DRAG LINK
REMOVAL
(1) Remove cotter pi ns and nuts from drag l i nk
(2) Remove the steeri ng damper bal l stud from the
drag l i nk.
(3) Remove ti e rod from drag l i nk
(4) Remove drag l i nk from the steeri ng knuckl e
and pi tman arm.
INSTALLATION
(1) I nstal l the drag l i nk onto steeri ng knuckl e and
pi tman arm.
(2) I nstal l nut at steeri ng knuckl e and ti ghten to
47 Nm (35 ft. l bs.). I nstal l new cotter pi ns.
(3) I nstal l nut at pi tman arm and ti ghten to 75
Nm (55 ft. l bs.). I nstal l new cotter pi ns.
(4) I nstal l ti e rod onto drag l i nk and i nstal l nut.
Ti ghten nut to 75 Nm (55 ft. l bs.) and i nstal l new
cotter pi ns.
(5) I nstal l steeri ng damper onto drag l i nk and
i nstal l nut. Ti ghten nut to 75 Nm (55 ft. l bs.) and
i nstal l a new cotter pi n.
STEERING DAMPER
REMOVAL
(1) Remove the steeri ng damper retai ni ng bol t
from the axl e bracket.
(2) Remove the cotter pi n and nut from the bal l
stud at the drag l i nk.
(3) Remove the steeri ng damper bal l stud from the
drag l i nk wi th Pul l er C-3894-A.
INSTALLATION
(1) I nstal l steeri ng damper onto the axl e bracket
and drag l i nk.
(2) I nstal l steeri ng damper bol t i n axl e bracket
and ti ghten nut to 75 Nm (55 ft. l bs.).
(3) I nstal l bal l stud nut at the drag l i nk and
ti ghten nut to 75 Nm (55 ft. l bs.). I nstal l a new cot-
ter pi n.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Pitman Arm
Shaft . . . . . . . . . . . . . . . . . . 251 Nm (185 ft. l bs.)
Drag Link
Bal l Studs . . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Cl amp . . . . . . . . . . . . . . . . . . . 49 Nm (36 ft. l bs.)
Tie Rod Ends
Bal l Studs . . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Cl amp . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Tie Rod
Bal l Stud . . . . . . . . . . . . . . . . . 88 Nm (65 ft. l bs.)
Steering Damper
Frame . . . . . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Drag Li nk . . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Fig. 5 Pitman Arm Puller
XJ STEERING 19 - 25
SPECIAL TOOLS
STEERING LINKAGE
Puller C-3894A
Remover Pitman C-4150A
19 - 26 STEERING XJ
STEERING COLUMN
INDEX
page page
GENERAL INFORMATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 27
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 27
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 29
GENERAL INFORMATION
STEERING COLUMN
The standard non-ti l t and ti l t steeri ng col umn has
been desi gned to be servi ced as an assembl y. The key
cyl i nder, swi tches, cl ock spri ng, tri m shrouds and
steeri ng wheel are servi ced separatel y. On the non-
ti l t col umn the upper mounti ng bracket i s al so ser-
vi ced separatel y.
The col umn i s mounted to the col umn support
bracket studs and secured by four nuts. The col umn
i s connected to the steeri ng gear by a one pi ece col -
l apsi bl e shaft wi th a coupl er at each end. The cou-
pl ers secure the shaft to the steeri ng col umn and
steeri ng gear.
SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Group 8M and fol l ow al l WARNI NGS and
CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
STEERING COLUMN
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO GROUP 8M RESTRAINT SYS-
TEMS FOR SERVICE PROCEDURES. FAILURE TO
DO SO MAY RESULT IN ACCIDENTAL DEPLOY-
MENT OF THE AIRBAG AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Posi ti on front wheel s straight ahead.
(2) Remove and i sol ate the negati ve battery
ground cabl e.
(3) Remove the ai rbag, refer to Group 8M
Restrai nt Systems for servi ce procedures.
NOTE: If equipped with cruise control, disconnect
clock spring harness from cruise switch harness on
the steering wheel.
(4) Remove the steeri ng wheel wi th an appropri ate
pul l er (Fi g. 1).
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel.
(5) Turn i gni ti on cyl i nder to the on posi ti on and
remove cyl i nder by pressi ng rel ease through l ower
shroud access hol e (Fi g. 2).
(6) Remove knee bl ocker cover and knee bl ocker,
Refer to Group 8E I nstrument Panel Systems.
(7) Remove screws from the l ower col umn shroud
(Fi g. 3) and remove l ower shroud.
(8) Remove the steeri ng coupl er bol t and col umn
mounti ng nuts (Fi g. 4) then l ower col umn off the
mounti ng stud.
(9) Remove upper col umn shroud (Fi g. 3).
XJ STEERING 19 - 27
(10) Di sconnect and remove the wi ri ng harness
from the col umn (Fi g. 5).
NOTE: If vehicle is equipped with automatic trans-
mission, remove shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for pro-
cedure.
(11) Remove col umn.
(12) Remove nut and bol t from the upper col umn
mounti ng bracket on non-ti l t col umn (Fi g. 6). Remove
the bracket from the col umn and note the mount-
ing location and orientation of the bracket. .
(13) Remove cl ock spri ng, swi tches, (SKI M i f
equi pped) and i gni ti on key cyl i nder, refer to Group 8
El ectri cal for servi ce procedures.
INSTALLATION
(1) I nstal l upper col umn mounti ng bracket on non-
ti l t col umn. I nstal l the mounti ng bol t and ti ghten the
nut to 17 Nm (150 i n. l bs.).
(2) I nstal l swi tches, refer to Group 8 El ectri cal for
servi ce procedures.
(3) Al i gn and i nstal l col umn i nto the steeri ng cou-
pl er.
(4) I nstal l col umn harness and connect harness to
swi tches.
Fig. 1 Steering Wheel
Fig. 2 Key Cylinder Release Access Hole
Fig. 3 Column Shrouds
Fig. 4 Tilt Steering Column Mounting
Fig. 5 Steering Column Harness
19 - 28 STEERING XJ
NOTE: If vehicle is equipped with automatic trans-
mission install shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for pro-
cedure.
(5) I nstal l upper col umn shrouds.
(6) I nstal l col umn onto the mounti ng studs.
(7) I nstal l mounti ng nuts and ti ghten to 23 Nm
(17 ft. l bs.).
(8) I nstal l steeri ng col umn coupl er bol t and ti ghten
to 49 Nm (36 ft. l bs.).
(9) Center the cl ock spri ng and i nstal l i t on the
col umn, refer to Group 8 El ectri cal for servi ce proce-
dures.
(10) I nstal l l ower col umn shroud and i nstal l
mounti ng screws.
(11) I nstal l i gni ti on cyl i nder.
(12) I nstal l knee bl ocker and knee bl ocker cover,
Refer to Group 8E I nstrument Panel Systems.
(13) I nstal l steeri ng wheel and ti ghten nut to 54
Nm (40 ft. l bs.).
NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.
(14) I nstal l ai rbag, refer to Group 8M Restrai nt
Systems for servi ce procedures.
(15) I nstal l negati ve battery termi nal .
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Tilt Steering Column
Steeri ng Wheel Nut . . . . . . . . 54 Nm (40 ft. l bs.)
Mounti ng Nuts . . . . . . . . . . . . 23 Nm (17 ft. l bs.)
Coupl er Bol t . . . . . . . . . . . . . . 49 Nm (36 ft. l bs.)
Non-Tilt Steering Column
Upper Bracket Nut . . . . . . . . 17 Nm (150 i n. l bs.)
Fig. 6 Non-Tilt Column
XJ STEERING 19 - 29
STEERING
CONTENTS
page page
POWER STEERING PUMP 2. 5L VM DIESEL . . . 2
POWER STEERING 2. 5L VM DIESEL . . . . . . . . 1
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . 8
POWER STEERING2.5L VM DIESEL
INDEX
page
GENERAL INFORMATION
GENERAL INFORMATION
POWER STEERING PUMP
The power steeri ng pump used wi th the 2.5L VM
Di esel engi ne operates the same way as the power
steeri ng pump used wi th the 2.5/4.0L gasol i ne
engi nes. Refer to the Descri pti on and Operati on sec-
ti on for the 2.5/4.0L gasol i ne engi ne power steeri ng
pump for more i nformati on.
XJ STEERING 19 - 1
POWER STEERING PUMP2.5L VM DIESEL
INDEX
page page
SERVICE PROCEDURES
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER STEERING PUMP LHD . . . . . . . . . . . 2
POWER STEERING PUMP RHD . . . . . . . . . . . 5
SERVICE PROCEDURES
OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal ambi ent temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
POWER STEERING PUMP LHD
Removal
(2) Remove the A/C l i ne support bracket from the
rear of the rocker cover.
(3) Di sconnect the A/C compressor el ectri cal con-
nector.
(4) Remove the (2) engi ne mount upper si l l pl ate
nuts (Fi g. 1).
(5) Make sure the steeri ng wheel i s i n the
unl ocked posi ti on.
Fig. 1 Engine Mount Sill Plate Nuts
19 - 2 STEERING XJ
(7) Remove the steeri ng shaft pi nch bol t and sl i de
the steeri ng shaft strai ght off the gearbox i nput
shaft, posi ti on the shaft asi de.
CAUTION: Avoid turning the steering shaft while
disconnected from the steering gearbox. Damage to
steering column clockspring could occur.
(8) Remove the power steeri ng fl ui d suppl y hose
from the pump and l et the fl ui d drai n.
(9) Loosen the (4) H-Bl ock retai ni ng bol ts. Do not
remove the bol ts at thi s ti me.
(10) Remove the accessory dri ve bel t from the
power steeri ng pump pul l ey. Refer to Group 7, Cool -
i ng System for procedure.
(11) Remove the power steeri ng pump pul l ey. Use
a hex socket to secure the pump shaft whi l e remov-
i ng the pul l ey nut wi th a box wrench (Fi g. 2).
NOTE: Mark the position of the H-Block in relation
to the A/C Compressor so it may be reinstalled in
the same position.
(12) Remove the (2) bol ts retai ni ng the H-Bl ock to
the power steeri ng pump shaft coupl er.
(13) Loosen the coupl er pi nch bol t and sl i de the
coupl er towards the pump.
(14) Remove the power steeri ng pump pressure
l i ne from the steeri ng gear. Thi s i s more accessi bl e,
but wi l l requi re you to i nstal l the pressure l i ne on
the new pump pri or to i nstal l ati on.
(15) Remove the remai ni ng 2 bol ts from the
H-Bl ock and remove the H-Bl ock from the compres-
sor.
(16) Support the A/C compressor wi th mechani cs
wi re before procedi ng to the next step.
(17) Remove the (4) A/C compressor retai ni ng
bol ts.
(18) Remove the l eft engi ne mount throughbol t nut
onl y. Do not remove the bol t at thi s ti me.
(19) Posi ti on a jack stand and rai se wei ght off l eft
engi ne mount.
(20) Remove the track bar support bracket retai n-
i ng bol ts and remove bracket (Fi g. 3).
(21) Remove the l ower engi ne mount bol t from the
si l l pl ate (Fi g. 3).
(22) Remove the (4) engi ne mount bracket bol ts
from the engi ne bl ock.
(23) Remove the engi ne mount throughbol t.
(24) Remove the engi ne mount and engi ne mount
bracket from the vehi cl e.
(25) Remove the (2) power steeri ng pump retai ni ng
nuts (Fi g. 4).
(26) Remove the power steeri ng pump from the
vehi cl e.
Installation
WARNING: Power steering system fluid may be
contaminated with metal shavings, overheated or
improper fluid. All fluid should be drained from the
system. After component replacement, system
should be flushed and filled with Mopar Power
Steering Fluid, or equivalent.
Fig. 2 Removing the Power Steering Pump Pulley
Fig. 3 Engine Mount Retaining Bolts
XJ STEERING 19 - 3
(1) Transfer the pressure l i ne to the new pump ,
maki ng sure l i ne i s i n ori gi nal posi ti on.
(2) Transfer the coupl er to the new pump l eavi ng
pi nch bol t l ose at thi s ti me (Fi g. 5).
(3) I nstal l the power steeri ng pump (Fi g. 5).
(4) I nstal l the engi ne mount and the engi ne mount
bracket i n the vehi cl e.
(5) I nstal l the engi ne mount throughbol t and l eave
l oose at thi s ti me.
(6) I nstal l , but do not torque the engi ne mount
and track bar support bracket bol ts (Fi g. 6).
(7) I nstal l the (4) engi ne mount bracket to engi ne
bl ock retai ni ng bol ts. Torque bol ts to 47 Nm (35 ft.
l bs.).
(8) Torque the engi ne mount si l l pl ate bol ts to 41
Nm (30 ft. l bs.).
(9) Torque the l arger trackbar support bracket
bol ts to 125 Nm (92ft. l bs.).
(10) Remove the jack stand.
(11) I nstal l the H-Bl ock on the A/C compressor i n
i ts ori gi nal posi ti on and l eave the bol ts l oose at thi s
ti me.
(12) Posi ti on and i nstal l the A/C compressor.
(13) Sl i de the dri ve coupl er i n i ts ori gi nal posi ti on
and i nstal l the remai ni ng (2) H-Bl ock bol ts.
(14) I nstal l the power steeri ng pump pul l ey (Fi g.
7). Torque nut to 166 Nm (120 ft. l bs.).
(15) I nstal l the accessory dri ve bel t. See Group 7,
(16) Torque al l the H-Bl ock bol ts.
(17) I nstal l the steeri ng shaft. Torque the steeri ng
shaft pi nch bol t to 49 Nm (36 ft. l bs.).
(18) I nstal l the pressure l i ne on steeri ng gear.
Torque nut to 28 Nm (21 ft. l bs.).
(19) I nstal l the power steeri ng fl ui d suppl y hose on
the pump.
(21) I nstal l and torque the engi ne mount upper si l l
pl ate nuts to 41 Nm (30 ft. l bs.) (Fi g. 8).
(22) Connect the A/C compressor el ectri cal connec-
tor.
Fig. 4 Power Steering Pump
Fig. 6 Engine Mount Retaining Bolts
19 - 4 STEERING XJ
(23) I nstal l the A/C l i ne support bracket bol t at the
rear of the val ve cover.
(24) Fi l l the power steeri ng fl ui d. See Group 19,
Steeri ng for Power Steeri ng Pump-I ni ti al operati on
procedure.
POWER STEERING PUMP RHD
Removal
(2) Remove the refri gerent l i ne support bracket
bol t from the top of the radi ator.
(3) Remove the A/C fi l ter-dri er assembl y support
bracket nuts from l eft fender wel l .
(4) Di sconnect the A/C compressor el ectri cal con-
nector.
(6) Remove the power steeri ng fl ui d suppl y hose
from pump and drai n fl ui d.
(7) Remove power steeri ng l i ne support bracket
bol t from bel ow radi ator.
(8) Remove the engi ne mount upper si l l pl ate nuts.
(9) Loosen the (4) H-Bl ock retai ni ng bol ts. Do not
remove at thi s ti me.
(10) Remove the accessory dri ve bel t from the
power steeri ng pump pul l ey. See Group 7, Cool i ng
System for procedure.
(11) Remove the power steeri ng pump pul l ey. Use
a hex socket to secure the pump shaft whi l e remov-
i ng the pul l ey nut wi th a box wrench (Fi g. 9).
NOTE: Mark position of the H-Block in relation to
the A/C Compressor so it can be installed in the
same position.
(12) Remove the (2) bol ts retai ni ng the H-Bl ock to
the power steeri ng pump shaft coupl er.
(13) Loosen the coupl er pi nch bol t and sl i de cou-
pl er towards pump.
Fig. 7 Installing Pump Pulley
Fig. 8 Engine Mount Sill Plate Nuts
Fig. 9 Removing Pump Pulley
XJ STEERING 19 - 5
(14) Remove the l eft engi ne mount throughbol t nut
onl y. Do not remove the bol t at thi s ti me.
(15) Remove the remai ni ng 2 bol ts from the
H-Bl ock and remove the H-Bl ock from the compres-
sor.
(16) Posi ti on a jack stand and rai se wei ght off l eft
engi ne mount.
(17) Remove the (2) engi ne mount si l l pl ate bol ts.
(18) Remove the (4) engi ne mount bracket bol ts
from the engi ne bl ock.
(19) Remove the engi ne mount throughbol t.
(20) Remove the engi ne mount and engi ne mount
bracket from vehi cl e.
(21) Remove the (2) power steeri ng pump retai ni ng
nuts (Fi g. 10).
(22) Sl i de pump off mounti ng studs and posi ti on so
pressure l i ne can be removed. Thi s wi l l requi re you
to i nstal l pressure l i ne on the new pump pri or to
i nstal l i ng i t i n the engi ne bl ock.
(23) Remove the power steeri ng pump from the
vehi cl e.
Installation
WARNING: Power steering system fluid may be
contaminated with metal shavings, overheated or
improper fluid. All fluid should be drained from the
system. After component replacement, system
should be flushed and filled with Mopar Power
Steering Fluid, or equivalent.
(1) I nstal l the pressure l i ne on pump i n ori gi nal
posi ti on.
(2) Transfer the dri ve coupl er to new pump l eavi ng
pi nch bol t l ose at thi s ti me (Fi g. 11).
(3) I nstal l the power steeri ng pump i n the engi ne
bl ock. Torque retai ni ng nuts to 24 Nm (18 ft. l bs.)
(Fi g. 11).
(4) I nstal l the engi ne mount and engi ne mount
bracket i n vehi cl e.
(5) I nstal l the engi ne mount throughbol t and l eave
l oose at thi s ti me.
(6) I nstal l , do not torque engi ne mount si l l pl ate
nuts and bol ts.
(7) I nstal l (4) engi ne mount bracket to engi ne
bl ock retai ni ng bol ts and Torque to 61 Nm (45 ft.
l bs.).
(8) Torque the engi ne mount si l l pl ate nuts to 41
Nm (30 ft. l bs.).
(9) Torque the engi ne mount si l l pl ate bol ts to 41
Nm (30 ft. l bs.).
(10) Remove jack stand.
(11) I nstal l the H-Bl ock on the A/C compressor i n
the ori gi nal posi ti on and l eave bol ts l oose at thi s
ti me.
(12) Posi ti on and i nstal l A/C compressor.
(13) Sl i de the dri ve coupl er i nto i ts ori gi nal posi -
ti on and start remai ni ng (2) H-Bl ock bol ts.
(14) I nstal l the power steeri ng pump pul l ey (Fi g.
12). Torque nut to 166 Nm (120 ft. l bs.).
19 - 6 STEERING XJ
(15) I nstal l the accessory dri ve bel t. See Group 7,
Cool i ng for procedure.
(16) Torque al l the H-Bl ock bol ts.
(17) Torque the engi ne mount throughbol t nut to
65 Nm (48 ft. l bs.).
(18) I nstal l the power steeri ng fl ui d suppl y hose on
pump.
(19) I nstal l the power steeri ng l i ne support
bracket bol t.
(20) Lower the vehi cl e from hoi st.
(21) I nstal l the refri gerent l i ne support bracket
and bol t on the top of the radi ator.
(22) I nstal l the A/C fi l ter-dri er assembl y support
bracket nuts on the l eft fender wel l .
(23) Reconnect the A/C compressor el ectri cal con-
nector.
(24) Re-fi l l the power steeri ng fl ui d. Refer to
Group 19, Steeri ng for Power Steeri ng Pump-I ni ti al
Operati on for procedure.
Fig. 12 Installing Pump Pulley
XJ STEERING 19 - 7
STEERING COLUMN
INDEX
page page
GENERAL INFORMATION
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 8
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 9
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERAL INFORMATION
STEERING COLUMN
The ti l t and standard col umn (Fi g. 1) has been
desi gned to be servi ced as an assembl y; l ess wi ri ng,
swi tches, shrouds, steeri ng wheel , etc. Most steeri ng
col umn components can be servi ced wi thout remov-
i ng the steeri ng col umn from the vehi cl e.
SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Group 8 M and fol l ow al l WARNI NGS and
CAUTI ONS.
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISARM THE AIRBAG FIRING MECHANISM.
FAILURE TO DO SO COULD RESULT IN ACCIDEN-
TAL DEPLOYMENT OF THE AIRBAG AND POSSI-
BLE PERSONAL INJURY.
WARNING: THE FASTENERS, SCREWS, AND
BOLTS, ORIGINALLY USED FOR THE AIRBAG COM-
PONENTS, HAVE SPECIAL COATINGS AND ARE
SPECIFICALLY DESIGNED FOR THE AIRBAG SYS-
TEM. THEY MUST NEVER BE REPLACED WITH ANY
SUBSTITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
Fig. 1 Steering Column
19 - 8 STEERING XJ
CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Do not
remove ignition locking link, shaft lock plate or
plate retainer. This will damage the column (Fig. 2)
and (Fig. 3).
IGNITION SWITCH
TEST AND REPAIR
I f the i gni ti on swi tch effort i s excessi ve, remove the
i gni ti on swi tch from the steeri ng col umn. Refer to
Group 8D I gni ti on System. Usi ng a key cyl i nder,
check the turni ng effort of the swi tch. I f the i gni ti on
swi tch bi nds l ook for the fol l owi ng condi ti ons.
(1) Look for rough areas or fl ash i n the casti ng
and i f found remove wi th a fi l e (Fi g. 4).
(2) Wi th the i gni ti on swi tch removed, sl i de the
sl i der i n i ts sl ot i n the sl eeve and veri fy a l oose fi t
over the l ength of the sl ot. I f the sl i der bi nds i n the
sl ot at any poi nt l i ghtl y fi l e the sl i der or sl ot unti l
cl earance i s achi eved.
(3) I f no bi ndi ng i s found, l i ghtl y fi l e the ramp on
the i gni ti on swi tch, (The ramp fi ts i nto the casti ng)
unti l bi ndi ng no l onger occurs.
STEERING COLUMN
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED, REFER TO GROUP 8M RESTRAINT SYS-
TEMS FOR SERVICE PROCEDURES. FAILURE TO
DO SO MAY RESULT IN ACCIDENTAL DEPLOY-
MENT OF THE AIRBAG AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Posi ti on the front wheel s straight ahead .
(2) Remove the negati ve (ground) cabl e from the
battery.
(3) Di sarm and remove ai rbag, steeri ng wheel and
cl ockspri ng, refer to group 8M Restrai nt Systems for
(4) Remove l ower i nstrument panel /knee bl ocker.
(5) Remove col umn coupl er upper pi nch bol t (Fi g.
5).
(6) Remove rel ay box.
(7) Remove ti l t l ever (i f equi pped) from col umn.
(8) Remove upper and l ower steeri ng col umn
shrouds.
(9) Remove l ower fi xed col umn shroud.
(10) Remove col umn braces (Fi g. 6).
(11) Remove col umn bracket mounti ng nuts and
l ower col umn.
Fig. 2 Observe Cautions
Fig. 3 Observe Cautions
Fig. 4 Steering Column Flash Removal And
Non-Serviceable Components
XJ STEERING 19 - 9
(12) Remove upper fi xed col umn shroud.
(13) Remove mul ti -functi on swi tch tamper proof
mounti ng screws and connector screw. Connector
screw wi l l stay i n the connector.
(14) Unpl ug wi ri ng harness from the col umn
swi tches (Fi g. 7).
(15) Remove the wi ri ng harness from steeri ng col -
umn.
(16) Remove i gni ti on swi tch.
(17) Remove i nterl ock cabl e from the steeri ng col -
umn, refer to Group 21 Automati c Transmi ssi on
Shi fter/I gni ti on I nterl ock.
(18) Remove the col umn.
INSTALLATION
(1) Al i gn and i nstal l the col umn to the coupl er. Do
not apply force at the top of the steering col-
umn shaft.
(2) Ensure the ground cl i p i s posi ti on (Fi g. 8).
(3) I nstal l i nterl ock cabl e from the steeri ng col -
umn, refer to Group 21 Automati c Transmi ssi on
Shi fter/I gni ti on I nterl ock.
(4) I nstal l wi ri ng harness connecti ons to steeri ng
col umn.Ensure the wiring is not pinched and all
connections are correctly locked in place.
(5) I nstal l wi ri ng harness connector onto mul ti
functi on swi tch. Ti ghten functi on swi tch wi ri ng har-
ness connector retai ni ng bol t to 2 Nm (17 i n. l bs.).
(6) Pl ug i n wi ri ng harness connector to remai ni ng
swi tches.
(7) I nstal l i gni ti on swi tch.
(8) I nstal l upper fi xed col umn shroud cover.
(9) I nstal l shaft coupl er pi nch bol t l oose, l oad col -
umn up to panel bracket.
Fig. 5 Steering Column
Fig. 6 Steering Column Braces
19 - 10 STEERING XJ
(10) Be sure both spacers are ful l y seated i n the
col umn support bracket. Ti ghten the col umn panel
bracket support nuts to 12 Nm (105 i n. l bs.).
(11) Ti ghten the coupl er pi nch bol t to 47 Nm (35
ft. l bs.).
(12) I nstal l l ower fi xed shroud.
(13) I nstal l upper and l ower shrouds. I nstal l the
ti l t l ever (i f equi pped).
(14) I nstal l rel ay box.
(15) I nstal l l ower i nstrument panel /knee bl ocker.
(16) I nstal l cl ockspri ng, steeri ng wheel and ai rbag.
Refer to Group 8M Restrai nt Systems for servi ce pro-
cedures.
(17) Remove the col umn shaft shi ppi ng l ock pi n
(i nstal l ed i n servi ce col umn).
(18) Connect the battery ground (negati ve) cabl e.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Tilt Steering Column
Non-Tilt Steering Column
Upper Bracket Nut . . . . . . . . 17 Nm (150 i n. l bs.)
Fig. 7 Steering Column Wiring Harness
Fig. 8 Ground Clip & Spacer
XJ STEERING 19 - 11
SUSPENSION
CONTENTS
page page
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 7
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 14
ALIGNMENT
INDEX
page page
GENERAL INFORMATION
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 1
SUSPENSION AND STEERING SYSTEM . . . . . . . 3
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL INFORMATION
WHEEL ALIGNMENT
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe posi ti on (Fi g. 1).
CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e rearward provi des posi ti ve caster. Ti l ti ng the
top of the knuckl e forward provi des negati ve caster.
Caster i s a di recti onal stabi l i ty angl e. Thi s angl e
enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns.
CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re. The angl e i s not
adjustabl e, damaged component(s) must be repl aced
to correct the camber angl e.
WHEEL TOE POSITION i s the di fference
between the l eadi ng i nsi de edges and trai l i ng i nsi de
edges of the front ti res. I ncorrect wheel toe posi ti on
i s the most common cause of unstabl e steeri ng and
uneven ti re wear. The wheel toe posi ti on i s the final
front wheel al i gnment adjustment.
STEERING AXIS INCLINATION ANGLE i s
measured i n degrees and i s the angl e that the steer-
i ng knuckl es are ti l ted. The i ncl i nati on angl e has a
fi xed rel ati onshi p wi th the camber angl e. I t wi l l not
change except when a spi ndl e or bal l stud i s dam-
aged or bent. The angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the steeri ng
axi s i ncl i nati on angl e.
THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the thrust
angl e.
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
XJ SUSPENSION 2 - 1
Fig. 1 Wheel Alignment Measurements
2 - 2 SUSPENSION XJ
SUSPENSION AND STEERING SYSTEM
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
VEHICLE PULLS TO ONE
SIDE
necessary.
4. Radial tire lead. 4. Rotate or replace tire as necessary.
5. Brake pull. 5. Repair brake as necessary.
6. Weak or broken spring. 6. Replace spring.
XJ SUSPENSION 2 - 3
SERVICE PROCEDURES
PRE-ALIGNMENT
Before starti ng wheel al i gnment, the fol l owi ng
i nspecti on and necessary correcti ons must be com-
pl eted. Refer to Suspensi on and Steeri ng System
Di agnosi s Chart for addi ti onal i nformati on.
(1) I nspect ti res for si ze and tread wear.
(2) Set ti re ai r pressure.
(3) I nspect front wheel beari ngs for wear.
(4) I nspect front wheel s for excessi ve radi al or l at-
eral runout and bal ance.
(5) I nspect bal l studs, l i nkage pi vot poi nts and
steeri ng gear for l ooseness, roughness or bi ndi ng.
(6) I nspect suspensi on components for wear and
noi se.
WHEEL ALIGNMENT
Before each al i gnment readi ng, the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down several ti mes. Al ways rel ease the bumper i n
the down posi ti on. Set the front end al i gnment to
speci fi cati ons wi th the vehi cl e at i ts NORMAL RI DE
HEI GHT.
CAMBER
The wheel camber angl e i s preset. Thi s angl e i s not
adjustabl e and cannot be al tered.
CASTER
Before checki ng the caster of the front axl e for cor-
rect angl e, be sure the axl e i s not bent or twi sted.
Road test the vehi cl e, make l eft and ri ght turns. I f
the steeri ng wheel returns to the center posi ti on
unassi sted, the caster angl e i s correct. I f steeri ng
wheel does not return toward the center posi ti on
unassi sted, an i ncorrect caster angl e i s probabl e.
Caster can be adjusted by i nstal l i ng the appropri -
ate si ze shi ms (Fi g. 2).
NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3 Dif-
ferential & Driveline for additional information.
TOE POSITION (LHD)
NOTE: The wheel toe position adjustment is the
final adjustment. The engine must remain running
during the entire toe position adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the wheel s. Secure the steeri ng
wheel wi th the front wheel s i n the strai ght-ahead
posi ti on.
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
3).
(3) Adjust the ri ght wheel toe posi ti on wi th the
drag l i nk. Turn the sl eeve unti l the ri ght wheel i s at
correct TOE-I N speci fi cati ons. Posi ti on the cl amp
bol ts as shown (Fi g. 4) and ti ghten to 49 Nm (36 ft.
l bs.).
NOTE: Make sure the toe setting does not change
during clamp tightening.
(4) Adjust the l eft wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the l eft wheel i s at speci fi -
cati ons. Posi ti on the cl amp bol ts as shown (Fi g. 4)
and ti ghten to 27 Nm (20 ft. l bs.).
(5) Veri fy the ri ght toe setti ng and turn off engi ne.
(6) Road test the vehi cl e on a fl at l evel road to ver-
i fy the steeri ng wheel i s centered.
NOTE: Once the toe setting is correct, the steering
wheel can be re-centered by adjusting only the drag
link.
Fig. 2 Caster Adjustment
2 - 4 SUSPENSION XJ
TOE POSITION (RHD)
NOTE: The wheel toe position adjustment is the
final adjustment. The engine must remain running
during the entire toe position adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the wheel s. Secure the steeri ng
wheel wi th the front wheel s i n the strai ght-ahead
posi ti on.
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
5).
(3) Adjust the l eft wheel toe posi ti on wi th the drag
l i nk. Turn the sl eeve unti l the l eft wheel i s at the
correct TOE-I N speci fi cati ons. Posi ti on the cl amp
bol ts to thei r ori gi nal posi ti on and ti ghten to 49 Nm
(36 ft. l bs.).
(4) Adjust the ri ght wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the ri ght wheel i s at cor-
rect TOE-I N speci fi cati ons. Posi ti on the cl amp bol ts
to thei r ori gi nal posi ti on and ti ghten to 27 Nm (20
ft. l bs.).
(5) Veri fy the ri ght toe setti ng and turn off engi ne.
(6) Road test the vehi cl e on a fl at l evel road to ver-
i fy the steeri ng wheel i s centered.
NOTE: Once the toe setting is correct, the steering
wheel can be re-centered by adjusting only the drag
link.
Fig. 3 Steering Linkage (LHD)
Fig. 4 Drag Link and Tie Rod Clamp (LHD)
XJ SUSPENSION 2 - 5
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
ADJUSTMENT PREFERRED RANGE
MAX RT/LT
DIFFERENCE
CASTER + 7.0
+ 5.25to +
8.5
1.25
ADJUSTMENT PREFERRED RANGE
MAX RT/LT
DIFFERENCE
CAMBER
(fixed angle)
0.25
0.75to +
0.5
1.0
TOTAL
TOE-IN
+ 0.25
0to +
0.45
.05
THRUST ANGLE 0 0.15
Fig. 5 Steering Linkage (RHD)
2 - 6 SUSPENSION XJ
FRONT SUSPENSION
INDEX
page page
SUSPENSION COMPONENTS . . . . . . . . . . . . . . . 7
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 8
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . 9
COIL SPRING/JOUNCE BUMPER . . . . . . . . . . . . 9
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 9
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 10
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . 10
FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . . . 10
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 11
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FRONT HUB BEARING . . . . . . . . . . . . . . . . . . . 12
WHEEL MOUNTING STUDS-FRONT . . . . . . . . . 12
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . 13
SUSPENSION COMPONENTS
The front suspensi on i s a l i nk/coi l desi gn (Fi g. 1).
Thi s suspensi on i s use on Left Hand Dri ve (LHD)
and Ri ght Hand Dri ve (RHD) vehi cl es. The suspen-
si on i s compri sed of:
Dri ve axl e (4WD), tube axl e (2WD)
Dual -acti on shock absorbers
Coi l spri ngs
Upper and l ower suspensi on arms
Stabi l i zer bar
Track bar
Jounce bumpers
Link/Coil Suspension: Thi s suspensi on al l ows
each wheel to adapt to di fferent road surfaces wi th-
Fig. 1 Suspension Components (LHD)
XJ SUSPENSION 2 - 7
out greatl y affecti ng the opposi te wheel . Wheel s are
attached to a hub/beari ngs whi ch bol ts to the knuck-
l es. The hub/beari ng i s not servi ceabl e and i s
repl aced as a uni t. Steeri ng knuckl es pi vot on
repl aceabl e bal l studs attached to the axl e tube
yokes.
Shock Absorbers: The shocks dampen jounce and
rebound of the vehi cl e over vari ous road condi ti ons.
The top of the shock absorbers are bol ted to the body.
The bottom of the shocks are bol ted to the axl e
spri ng bracket.
Coil Springs: The spri ngs control ri de qual i ty and
mai ntai n proper ri de hei ght. The coi l spri ngs mount
up i n the fender shi el d to a bracket whi ch i s part of
the uni ti zed body. A rubber i sol ator i s l ocated
between the top of the spri ng and the body. The bot-
tom of the spri ng seats on a axl e pad and i s retai ned
wi th a cl i p.
Upper & Lower Suspension Arms: The suspen-
si on arms are di fferent l engths, wi th bushi ngs at
both ends. They bol t the axl e assembl y to the body.
The l ower arms use shi ms at the body mount to
al l ow for adjustment of caster and dri ve shaft pi ni on
angl e. The suspensi on arm travel i s l i mi ted through
the use of jounce bumpers i n compressi on and shocks
absorbers i n rebound.
Stabilizer Bar: The stabi l i zer bar i s used to mi n-
i mi ze vehi cl e body rol l duri ng turns. The spri ng steel
bar hel ps to control the vehi cl e body i n rel ati onshi p
to the suspensi on. The bar extends across the front
undersi de of the chassi s and connects to the body
rai l s. Li nks are connected from the bar to the axl e
brackets. Stabi l i zer bar mounts are i sol ated by rub-
ber bushi ngs.
Track Bar: The track bar i s used to l ocate the
axl e l ateral l y. The bar i s attached to a body rai l
bracket wi th a bal l stud and i sol ated wi th a bushi ng
at the axl e bracket.
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
SHOCK DIAGNOSIS
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
2 - 8 SUSPENSION XJ
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retai ner and grommet from
the upper stud i n the engi ne compartment (Fi g. 2).
(2) Remove the l ower nuts and bol ts from the axl e
bracket.
(3) Remove the shock absorber.
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
shock stud. I nsert the shock absorber through the
shock tower hol e.
(2) I nstal l the l ower bol ts and nuts. Ti ghten nuts
to 23 Nm (17 ft. l bs.).
(3) I nstal l the upper grommet and retai ner on the
stud. I nstal l the nut and ti ghten to 10 Nm (8 ft.
l bs.).
COIL SPRING/JOUNCE BUMPER
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support i t.
(2) Remove the wheel and ti re assembl i es.
(3) Mark and di sconnect the front propel l er shaft
from the axl e.
(4) Remove l ower suspensi on arms mounti ng nuts
and bol ts from the axl e (Fi g. 2).
(5) Remove the stabi l i zer bar l i nk and shock
absorber from the axl e.
(6) Remove the track bar from the body rai l
bracket.
(7) Remove the drag l i nk from the pi tman arm.
(8) Lower the axl e unti l the spri ng i s free from the
upper mount. Remove the coi l spri ng cl i p and remove
the spri ng.
(9) Pul l jounce bumper out of mount.
INSTALLATION
(1) I nstal l jounce bumper i nto mount.
(2) Posi ti on the coi l spri ng on the axl e pad. I nstal l
the spri ng cl i p and bol t. Ti ghten bol t to 21 Nm (16
ft. l bs.).
(3) Rai se the axl e i nto posi ti on unti l the spri ng
seats i n the upper mount.
(4) I nstal l the stabi l i zer bar l i nks and shock
absorbers to the axl e bracket.
(5) I nstal l the track bar to the body rai l bracket.
(6) I nstal l the l ower suspensi on arms to the axl e.
I nstal l mounti ng bol ts and nuts fi nger ti ght.
(7) I nstal l the front propel l er shaft to the axl e.
(8) I nstal l the wheel and ti re assembl i es.
(9) Remove the supports and l ower the vehi cl e.
(10) Ti ghten l ower suspensi on arms nuts to 115
Nm (85 ft. l bs.).
STEERING KNUCKLE
For servi ce procedures on the steeri ng knuckl e and
bal l joi nts refer to Group 3 Di fferenti al s And Dri v-
el i ne.
Fig. 2 Coil Spring & Shock Absorber
XJ SUSPENSION 2 - 9
LOWER SUSPENSION ARM
REMOVAL
(2) Remove the l ower suspensi on arm nut and bol t
from the axl e bracket.
(3) Remove the nut and bol t from the rear bracket
and remove the l ower suspensi on arm (Fi g. 3).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm at the axl e
bracket and rear bracket.
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(3) Remove support and l ower the vehi cl e.
(4) Ti ghten the front and rear nuts to 115 Nm (85
ft. l bs.).
UPPER SUSPENSION ARM
REMOVAL
(2) Remove the upper suspensi on arm nut and bol t
at the axl e bracket.
(3) Remove the nut and bol t at the frame rai l and
remove the upper suspensi on arm (Fi g. 3).
INSTALLATION
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(4) Ti ghten the nut at the axl e to 75 Nm (55 ft.
l bs.). Ti ghten the nut at the frame bracket to 90 Nm
(66 ft. l bs.).
FRONT AXLE BUSHING
REMOVAL
(1) Remove the upper suspensi on arm from axl e.
(2) Posi ti on Spacer 7932-3 over the axl e bushi ng
on a 4x2 vehi cl e and ri ght si de on a 4x4 vehi cl e.
(3) Pl ace Recei ver 7932-1 over fl anged end of the
bushi ng. (Fi g. 4).
(4) Pl ace smal l end of Remover/I nstal l 7932-2
agai nst other si de of the bushi ng.
(5) I nstal l bol t 7604 through remover, bushi ng and
recei ver.
(6) I nstal l Long Nut 7603 and ti ghten nut too pul l
bushi ng out of the axl e bracket.
(7) Remove nut, bol t, recei ver, remover and bush-
i ng.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 7932-3 in position for bushing instal-
lation.
INSTALLATION
(1) Pl ace Recei ver 7932-1on the other si de of the
axl e bracket.
(2) Posi ti on new bushi ng up to the axl e bracket,
and l arge end of Remover/I nstal l 7932-2 agai nst the
bushi ng (Fi g. 5).
(3) I nstal l bol t 7604 through recei ver, bushi ng and
i nstal l er.
(4) I nstal l Long Nut 7603 and ti ghten nut to draw
the bushi ng i nto the axl e bracket.
(5) Remove tool s and i nstal l the upper suspensi on
arm.
Fig. 3 Upper and Lower Suspension Arms
Fig. 4 Bushing Removal
2 - 10 SUSPENSION XJ
STABILIZER BAR
REMOVAL
(2) Remove nuts, retai ners and grommets from the
l i nks at the stabi l i zer bar (Fi g. 6).
(3) Remove the l i nks mounti ng nuts and bol ts
from the axl e brackets.
(4) Remove the stabi l i zer bar cl amps from the
body rai l s. Remove the stabi l i zer bar.
INSTALLATION
(1) I nspect stabi l i zer bar bushi ngs. Repl ace bush-
i ngs i f cracked, cut, di storted, or worn.
(2) Posi ti on the stabi l i zer bar on the body rai l and
i nstal l the bushi ngs and cl amps. Ensure the bar i s
centered wi th equal spaci ng on both si des. Ti ghten
the bol ts to 75 Nm (40 ft. l bs.).
(3) I nstal l the l i nks and grommets onto the stabi -
l i zer bar and axl e brackets.
(4) Ti ghten the l i nk nuts at the axl e bracket to 95
Nm (70 ft. l bs.).
(5) Ti ghten the l i nk nuts at the stabi l i zer bar to 36
Nm (27 ft. l bs.).
TRACK BAR
REMOVAL
(2) Remove the cotter pi n and nut from the bal l
stud end at the body rai l bracket.
(3) Use a uni versal pul l er tool to separate the bal l
stud from the frame rai l bracket.
(4) Remove the bol t and fl ag nut from the axl e
shaft tube bracket (Fi g. 7).
(5) Remove the track bar.
INSTALLATION
(1) I nstal l the track bar at axl e tube bracket.
Loosel y i nstal l the retai ni ng bol t and fl ag nut.
(2) I t may be necessary to pry the axl e assembl y
over to i nstal l the track bar at the body rai l . I nstal l
track bar at the body rai l bracket. I nstal l the retai n-
i ng nut on the stud.
(4) Ti ghten the retai ni ng bol t at the axl e shaft
tube bracket to 100 Nm (74 ft. l bs.).
Fig. 5 Bushing Installation
Fig. 6 Stabilizer Bar (LHD)
Fig. 7 Track Bar (LHD)
XJ SUSPENSION 2 - 11
(5) Ti ghten the bal l stud nut to 81 Nm (60 ft.
l bs.). I nstal l a new cotter pi n.
FRONT HUB BEARING
REMOVAL
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per, rotor and ABS wheel
speed sensor, refer to Group 5 Brakes.
(4) Remove the cotter pi n, nut retai ner and axl e
hub nut (Fi g. 8).
(5) Remove the hub beari ng mounti ng bol ts from
the back of the steeri ng knuckl e. Remove hub bear-
i ng from the steeri ng knuckl e and off the axl e shaft.
INSTALLATION
(1) I nstal l the hub beari ng and brake dust shi el d
to the knuckl e.
(2) I nstal l the hub beari ng to knuckl e bol ts and
(3) I nstal l the hub washer and nut. Ti ghten the
hub nut to 237 Nm (175 ft. l bs.). I nstal l the nut
retai ner and a new cotter pi n.
(4) I nstal l the brake rotor, cal i per and ABS wheel
speed sensor, refer to Group 5 Brakes.
(5) I nstal l the wheel and ti re assembl y.
WHEEL MOUNTING STUDS-FRONT
REMOVAL
(2) Remove wheel and ti re assembl y.
(3) Remove brake cal i per and rotor, refer to Group
5 Brakes for procedure.
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 9).
INSTALLATION
(1) I nstal l new stud i nto hub fl ange.
(2) I nstal l three washers onto stud, then i nstal l
l ug nut wi th the fl at si de of the nut agai nst the
washers.
Fig. 8 Hub Bearing & Knuckle
Fig. 9 Wheel Stud Removal
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor and cal i per, refer to
Group 5 Brakes for procedure.
(6) I nstal l wheel and ti re assembl y, use new l ug
nut on stud or studs that were repl aced.
(7) Remove support and l ower vehi cl e.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . . . 11 Nm (8 ft. l bs.)
Lower Nut . . . . . . . . . . . . . . . . 23 Nm (17 ft. l bs.)
Suspension ArmUpper
Front Nut . . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Rear Nut . . . . . . . . . . . . . . . . . 89 Nm (66 ft. l bs.)
Suspension ArmLower
Front Nut . . . . . . . . . . . . . . . 115 Nm (85 ft. l bs.)
Rear Nut . . . . . . . . . . . . . . . . 115 Nm (85 ft. l bs.)
Stabilizer Bar
Cl amp Bol t . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Li nk Upper Nut . . . . . . . . . . . 36 Nm (27 ft. l bs.)
Li nk Lower Nut . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Track Bar
Bal l Stud Nut . . . . . . . . . . . . . 81 Nm (60 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . 100 Nm (74 ft. l bs.)
Track Bar Bracket
Bol ts . . . . . . . . . . . . . . . . . . . 125 Nm (92 ft. l bs.)
Nut . . . . . . . . . . . . . . . . . . . . 100 Nm (74 ft. l bs.)
Support Bol ts . . . . . . . . . . . . . 42 Nm (31 ft. l bs.)
Hub/Bearing
Bol ts . . . . . . . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Axl e Nut . . . . . . . . . . . . . . . 237 Nm (175 ft. l bs.)
SPECIAL TOOLS
FRONT SUSPENSION
Nut, Long 7603
Bolt, Special 7604
Remover C-4150A
Remover Tie Rod End MB-990635
Remover/Installer Suspension Bushing 7932
REAR SUSPENSION
INDEX
page page
SUSPENSION COMPONENT . . . . . . . . . . . . . . . 14
SPRING AND SHOCK DIAGNOSIS . . . . . . . . . . . 14
SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . 15
STABILIZER BAR . . . . . . . . . . . . . . . . . . . . . . . . 15
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LEAF SPRING AND SHACKLE BUSHING . . . . . . 16
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 17
SUSPENSION COMPONENT
The rear suspensi on i s compri sed of:
Dri ve Axl e
Leaf Spri ngs
Dual -Acti on Shock Absorbers
Stabi l i zer Bar (opti onal )
Jounce Bumpers
Leaf Springs: The rear suspensi on system uses a
mul ti -l eaf spri ngs and a sol i d dri ve axl e. The forward
end of the spri ngs are mounted to the body rai l hang-
ers through rubber bushi ngs. The rearward end of
the spri ngs are attached to the body by the use of
shackl es. The spri ng and shackl es use rubber bush-
i ngs. The bushi ng hel p to i sol ate road noi se. The
shackl es al l ow the spri ngs to change thei r l ength as
the vehi cl e moves over vari ous road condi ti ons.
Shock Absorbers: Ri de control i s accompl i shed
through the use of dual -acti on shock absorbers. The
shocks dampen the jounce and rebound as the vehi cl e
travel s over vari ous road condi ti ons. The top of the
shock absorbers are bol ted to the body crossmember.
The bottom of the shocks are bol ted to the axl e
bracket.
Stabilizer Bar: The stabi l i zer bar i s used to mi n-
i mi ze vehi cl e body rol l . The spri ng steel bar hel ps to
control the vehi cl e body i n rel ati onshi p to the sus-
pensi on. The bar extends across the undersi de of the
vehi cl e and i s bol ted to the axl e. Li nks at the end of
the bar are bol ted to the frame.
J ounce Bumpers: The jounce bumpers are used
to l i mi t the spri ng and axl e travel . They are bol ted to
the frame rai l above the axl e.
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
SPRING AND SHOCK DIAGNOSIS
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The spri ng eye and shock absorber bushi ngs do not
requi re any type of l ubri cati on. Do not attempt to
stop spri ng bushi ng noi se by l ubri cati ng them.
Grease and mi neral oi l -base l ubri cants wi l l deteri o-
rate the bushi ng rubber.
I f the vehi cl e i s used for severe, off-road operati on,
the spri ngs shoul d be exami ned peri odi cal l y. Check
for broken and shi fted l eafs, l oose and mi ssi ng cl i ps,
and broken center bol ts. Refer to Spri ng and Shock
Absorber Di agnosi s chart for addi ti onal i nformati on.
SPRING AND SHOCK ABSORBER DIAGNOSIS
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SHOCK ABSORBER
REMOVAL
(1) Remove the shock absorber upper bol ts from
the body bracket (Fi g. 1).
(2) Remove l ower attachi ng nut and washer from
the bracket stud. Remove the shock absorber.
INSTALLATION
(1) I nstal l the shock absorber l ower eye on the
spri ng bracket stud. I nstal l the shock absorber and
upper bol ts on the body bracket.
(2) Ti ghten the l ower nut to 62 Nm (46 ft. l bs.).
(3) Ti ghten the upper bol ts to 23 Nm (17 ft. l bs.).
STABILIZER BAR
REMOVAL
Fig. 1 Rear Suspension Components
(2) Di sconnect stabi l i zer bar l i nks from spri ng
brackets (Fi g. 2).
(3) Di sconnect the stabi l i zer bar brackets from the
body rai l s. Remove the stabi l i zer bar and l i nks.
INSTALLATION
(1) Posi ti on the stabi l i zer bar l i nks at the spri ng
brackets. I nstal l the attachi ng bol ts and nuts and
(2) Attach the stabi l i zer bar to the body rai l brack-
ets wi th the bol ts. Ti ghten to 54 Nm (40 ft. l bs.).
LEAF SPRING
REMOVAL
(1) Rai se vehi cl e at body rai l s.
(3) Support axl e wi th hydraul i c jack to rel i eve axl e
wei ght.
(4) Di sconnect the stabi l i zer bar l i nk from the
spri ng bracket stud.
(5) Remove nuts, U-bol ts and spri ng bracket from
axl e.
(6) Remove nut and bol t attachi ng spri ng front eye
to shackl e.
(7) Remove nut and bol t from spri ng rear eye.
(8) Remove spri ng from vehi cl e.
INSTALLATION
(1) Posi ti on the spri ng front eye i n the bracket.
Loosel y i nstal l the attachi ng bol t and nut. Do not
ti ghten at thi s ti me.
(2) Posi ti on the rear eye i n the shackl e bracket.
Loosel y i nstal l the attachi ng bol t and nut. Do not
ti ghten at thi s ti me.
(3) Posi ti on the axl e. I nstal l the spri ng bracket,
U-bol ts and nuts. Ti ghten the nuts to 70 Nm (52 ft.
l bs.).
(4) Connect the stabi l i zer bar l i nk to the spri ng
bracket.
(5) Remove the hydraul i c jack.
(7) Ti ghten the spri ng front eye attachi ng bol ts to
156 Nm (115 ft. l bs.).
(8) Ti ghten the spri ng rear eye attachi ng bol ts to
108 Nm (80 ft. l bs.).
(9) Ti ghten the stabi l i zer bar l i nk to 74 Nm (55 ft.
l bs.).
LEAF SPRING AND SHACKLE BUSHING
For front bushi ngs bend tabs DOWN before
removal . Use an appropri ate dri ver tool and force the
ori gi nal bushi ng out of the spri ng eye.
(1) Assembl e tool s shown (Fi g. 3). Ti ghten nut at
the socket wrench end of the threaded rod unti l the
bushi ng i s forced out.
(2) Assembl e and al i gn the bushi ng i nstal l ati on
tool s.
(3) Al i gn the bushi ng wi th the spri ng eye or
shackl e eye and ti ghten the nut at the socket wrench
end of the threaded rod. Ti ghten unti l the bushi ng i s
forced i nto the spri ng eye.
Fig. 2 Stabilizer Bar
Fig. 3 Spring Eye Bushing Removal
NOTE: The bushing must be centered in the spring
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the
spring eye.
(4) For front bushi ngs bend tabs up after i nstal l a-
ti on.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Bol t . . . . . . . . . . . . . . . 23 Nm (17 ft. l bs.)
Lower Nut . . . . . . . . . . . . . . . . 62 Nm (46 ft. l bs.)
Stabilizer Bar
Cl amp Bol t . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Li nk Upper Bol t . . . . . . . . . . . . 12 Nm (9 ft. l bs.)
Li nk Lower Nut . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Spring
U-Bol t Nut . . . . . . . . . . . . . . . 70 Nm (52 ft. l bs.)
Front Pi vot Bol t . . . . . . . . . 156 Nm (115 ft. l bs.)
Upper Shackl e Bol t . . . . . . . 156 Nm (115 ft. l bs.)
Lower Shackl e Bol t . . . . . . . . 108 Nm (80 ft. l bs.)
TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
AUTOMATIC TRANSMISSION 30RH . . . . . . . . 73
AW4 AUTOMATIC TRANSMISSION . . . . . . . . 163
AX15 MANUAL TRANSMISSION . . . . . . . . . . . . 37
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . 1
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 280
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 306
AX5 MANUAL TRANSMISSION
INDEX
page page
GENERAL INFORMATION
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . 1
GEAR RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RECOMMENDED LUBRICANT . . . . . . . . . . . . . . . 1
TRANSMISSION ASSEMBLY INFORMATION . . . . 2
TRANSMISSION IDENTIFICATION . . . . . . . . . . . . 1
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION NOISE . . . . . . . . . . . . . . . . . . . . 4
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . . 7
EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . 7
FRONT BEARING RETAINER SEAL . . . . . . . . . . . 6
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADAPTER/EXTENSION HOUSING AND FRONT
BEARING RETAINER . . . . . . . . . . . . . . . . . . . . 8
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 26
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 27
SEMI-SYNCHRONIZED REVERSE
IDLER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 15
CLEANING AND INSPECTION
AX5 MANUAL TRANSMISSION COMPONENTS . . . 32
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPECIAL TOOLS
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
GENERAL INFORMATION
The AX5 i s a fi ve speed manual transmi ssi on wi th
fi fth gear bei ng the overdri ve range. An adapter
housi ng i s used to attach the transmi ssi on to the
transfer case on 4-wheel dri ve appl i cati ons. A stan-
dard styl e extensi on housi ng i s used for the 2-wheel
dri ve appl i cati ons. The shi ft mechani sm i s i ntegral to
the transmi ssi on assembl y and mounted i n the shi ft
tower porti on of the adapter/extensi on housi ng (Fi g.
1).
TRANSMISSION IDENTIFICATION
The AX5 i denti fi cati on code i s on the bottom sur-
face of the transmi ssi on case near the fi l l pl ug (Fi g.
2). The fi rst number i s year of manufacture. The sec-
ond and thi rd numbers i ndi cate month of manufac-
ture. The next seri es of numbers i s the transmi ssi on
seri al number.
GEAR RATIOS
Gear rati os for the AX5 manual transmi ssi on are
as fol l ows:
Fi rst gear: 3.93:1
Second gear: 2.33:1
Thi rd gear: 1.45:1
Fourth gear: 1.00:1
Fi fth gear: 0.85:1
Reverse gear: 4.74:1
RECOMMENDED LUBRICANT
equi val ent.
XJ TRANSMISSION AND TRANSFER CASE 21 - 1
The fi l l pl ug i s on the passenger si de of the
adapter housi ng (Fi g. 3). The drai n pl ug i s on the
bottom of the case.
Approxi mate dry fi l l l ubri cant capaci ty i s:
3.3 l i ters (3.49 quarts) for 4wheel dri ve appl i ca-
ti ons.
3.5 l i ters (3.70 quarts) for 2wheel dri ve appl i ca-
ti ons.
TRANSMISSION ASSEMBLY INFORMATION
Lubri cate the transmi ssi on components wi th
Mopar 75W90, GL 3 gear l ubri cant duri ng assem-
bl y. Use petrol eum jel l y to l ubri cate seal l i ps and/or
hol d parts i n pl ace duri ng i nstal l ati on.
Refer to (Fi g. 4) duri ng assembl y for AX5 gear
assembl y i denti fi cati on.
Fig. 1 AX5 Manual Transmission
Fig. 2 Transmission Identification
Fig. 3 Fill Plug Location
21 - 2 TRANSMISSION AND TRANSFER CASE XJ
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adaptor or extensi on
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a nonrecommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab, and/or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng nonrecommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Component damage, i ncorrect cl utch adjustment,
or a damaged cl utch pressure pl ate or di sc are addi -
ti onal probabl e causes of i ncreased shi ft effort. I ncor-
rect adjustment or a worn/damaged pressure pl ate or
di sc can cause i ncorrect rel ease. I f the cl utch probl em
i s advanced, gear cl ash duri ng shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear cl ash
when shi fti ng i nto any forward gear. I n some new or
rebui l t transmi ssi ons, new synchro ri ngs may tend to
sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n most
cases, thi s condi ti on wi l l decl i ne as the ri ngs wear
i n.
Fig. 4 Geartrain Components
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear breakage.
TRANSMISSION
REMOVAL
(1) Shi ft transmi ssi on i nto fi rst or thi rd gear.
(2) Rai se and support vehi cl e on sui tabl e safety
stands.
(3) Di sconnect necessary exhaust system compo-
nents.
(4) Remove ski d pl ate, i f equi pped.
(5) Remove sl ave cyl i nder from cl utch housi ng.
(6) Mark rear propel l er shaft and rear axl e yokes
for i nstal l ati on al i gnment (Fi g. 5).
(7) Mark front propel l er shaft, axl e, and transfer
case yokes for i nstal l ati on al i gnment, i f equi pped.
(8) Remove propel l er shaft(s).
(9) Uncl i p wi re harnesses from transmi ssi on and
transfer case, i f equi pped.
(10) Di sconnect transfer case vent hose, i f
equi pped.
(11) Di sengage any wi re connectors attached to
transmi ssi on or transfer case, i f equi pped, compo-
nents.
(12) Support transfer case, i f equi pped, wi th trans-
mi ssi on jack.
(13) Secure transfer case, i f equi pped, to jack wi th
safety chai ns.
(14) Di sconnect transfer case shi ft l i nkage at
(15) Remove nuts attachi ng transfer case to trans-
mi ssi on, i f equi pped.
(16) Remove transfer case, i f equi pped.
(17) Remove crankshaft posi ti on sensor (Fi g. 6),
(Fi g. 7).
Fig. 5 Marking Propeller Shaft And Axle Yokes
Fig. 6 Crankshaft Position Sensor2.5L Engine
Fig. 7 Crankshaft Position Sensor 4.0L Engine
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.
(18) Support engi ne wi th adjustabl e jack stand.
Posi ti on wood bl ock between jack and oi l pan to
avoi d damagi ng pan.
(19) Support transmi ssi on wi th transmi ssi on jack.
(20) Secure transmi ssi on to jack wi th safety
chai ns.
(21) Di sconnect rear cushi on and bracket from
transmi ssi on.
(22) Remove rear crossmember.
(23) Di sconnect transmi ssi on shi ft l ever as fol l ows:
(a) Lower transmi ssi ontransfer case assembl y
approxi matel y 78 cm (3 i n.) for access to shi ft
l ever.
(b) Reach up and around transmi ssi on case and
unseat shi ft l ever dust boot from transmi ssi on shi ft
tower (Fi g. 8). Move boot upward on shi ft l ever for
access to retai ner that secures l ever i n shi ft tower.
(c) Reach up and around transmi ssi on case and
press shi ft l ever retai ner downward wi th fi nger
pressure. Turn retai ner countercl ockwi se to rel ease
i t.
(d) Li ft l ever and retai ner out of shi ft tower (Fi g.
8). Do not remove the shi ft l ever from the fl oor con-
sol e shi fter boots. Leave the l ever i n pl ace for
transmi ssi on i nstal l ati on.
(24) Remove cl utch housi ng brace rod.
(25) Remove cl utch housi ng-to-engi ne bol ts.
(26) Pul l transmi ssi on jack rearward unti l i nput
shaft cl ears cl utch. Then sl i de transmi ssi on out from
under vehi cl e.
(27) Remove cl utch rel ease beari ng, rel ease fork,
and retai ner cl i p.
(28) Remove cl utch housi ng from transmi ssi on
(Fi g. 9).
INSTALLATION
(1) I nstal l cl utch housi ng on transmi ssi on. Ti ghten
housi ng bol ts to 37 Nm (27 ft. l bs.) torque.
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork, and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l and ti ghten cl utch housi ng-to-engi ne
bol ts to 38 Nm (28 ft. l bs.) torque (Fi g. 9). Be sure
the housing is properly seated on engine block
before tightening bolts.
(8) I nstal l cl utch housi ng brace rod.
(9) Lower transmi ssi on approxi matel y 78 cm (3
i n.) for access to shi ft tower. Be sure transmi ssi on i s
i n fi rst or thi rd gear.
(10) Reach up and around transmi ssi on and i nsert
shi ft l ever i n shi ft tower. Press l ever retai ner down-
ward and turn i t cl ockwi se to l ock i t i n pl ace. Then
i nstal l l ever dust boot on shi ft tower.
Fig. 8 Removing/Installing Shift Lever
Fig. 9 Clutch Housing
(11) I nstal l rear crossmember. Ti ghten crossmem-
ber-to-frame bol ts to 41 Nm (31 ft. l bs.) torque.
(12) I nstal l fasteners to hol d rear cushi on and
bracket to transmi ssi on. Then ti ghten transmi ssi on-
to-rear support bol ts/nuts to 45 Nm (33 ft. l bs.)
torque.
(13) Remove support stands from engi ne and
transmi ssi on.
(14) I nstal l and connect crankshaft posi ti on sensor.
(15) Posi ti on transfer case on transmi ssi on jack, i f
equi pped.
(16) Secure transfer case to jack wi th safety
chai ns, i f equi pped.
(17) Rai se transfer case, i f equi pped, and al i gn
transfer case i nput shaft to the transmi ssi on output
shaft.
(18) Sl i de transfer case forward unti l case i s
seated on transmi ssi on, i f necessary.
(19) I nstal l nuts to attach transfer case to trans-
mi ssi on, i f equi pped. Ti ghten transfer case-to-trans-
mi ssi on nuts to 35 Nm (26 ft. l bs.) torque.
(20) Connect transfer case shi ft l i nkage at transfer
case, i f equi pped.
(21) Connect transfer case vent hose, i f equi pped.
(22) Secure wi re harnesses i n cl i ps/ti e straps on
transmi ssi on and transfer case, i f equi pped.
(23) Engage wi re connectors attached to al l neces-
sary transmi ssi on or transfer case, i f equi pped, com-
ponents.
(24) I nstal l rear propel l er shaft sl i p yoke to trans-
mi ssi on or transfer case, i f equi pped, output shaft.
(25) Al i gn marks on rear propel l er shaft and rear
axl e yokes (Fi g. 10).
(26) I nstal l and ti ghten propel l er shaft Ujoi nt
cl amp bol ts to 19 Nm (170 i n. l bs.) torque.
(27) Al i gn marks on front propel l er shaft, axl e,
and transfer case yokes, i f equi pped.
(29) I nstal l sl ave cyl i nder i n cl utch housi ng.
(30) I nstal l ski d pl ate, i f equi pped. Ti ghten bol ts to
42 Nm (31 ft. l bs.) torque. Ti ghten stud nuts to 17
(31) Fi l l transmi ssi on and transfer case, i f
equi pped, wi th recommended l ubri cants. Refer to the
Lubri cant Recommendati on secti ons of the appropri -
ate component for correct fl ui d.
FRONT BEARING RETAINER SEAL
REMOVAL
(1) Remove rel ease beari ng and l ever from the
transmi ssi on.
(2) Remove the bol ts hol di ng the front beari ng
retai ner to the transmi ssi on case.
(3) Remove the front beari ng retai ner from the
transmi ssi on case.
(4) Usi ng a sui tabl e pry tool , remove the front
beari ng retai ner seal .
INSTALLATION
(1) Usi ng Tool Handl e C-4171 and Seal I nstal l er
8211, i nstal l new seal i n to the front beari ng retai ner
(Fi g. 11).
(2) Remove any resi dual gasket materi al from the
seal i ng surfaces of the beari ng retai ner and the
(3) I nstal l new front beari ng retai ner gasket to the
front beari ng retai ner.
Fig. 10 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks
Fig. 11 Install Front Bearing Retainer Seal
(4) I nstal l the front beari ng retai ner onto the
(5) I nstal l the bol ts to hol d the beari ng retai ner
onto the transmi ssi on case.
(6) Ti ghten the bol ts to 17 Nm (12 ft. l bs.).
(7) I nstal l rel ease beari ng and l ever onto the
transmi ssi on.
EXTENSION HOUSING SEAL
REMOVAL
(2) Remove propel l er shaft. Refer to Group 3, Di f-
ferenti al and Dri vel i ne, for proper procedures.
(3) Usi ng a sui tabl e seal pul l er or screw wi th a
sl i de hammer, remove the extensi on housi ng seal
(Fi g. 12).
INSTALLATION
(1) Cl ean seal bore of extensi on housi ng of any
resi dual seal er materi al from ori gi nal seal .
8212, i nstal l new extensi on housi ng seal so that the
seal i s l ocated 0 0.5 mm (0 0.02 i n.) to the face
of the extensi on housi ng (Fi g. 13).
(3) I nstal l propel l er shaft. Refer to Group 3, Di ffer-
enti al and Dri vel i ne, for proper procedures.
(4) Check and add fl ui d to transmi ssi on as neces-
sary. Refer to the Recommended Lubri cant secti on for
proper fl ui d requi rements.
ADAPTER HOUSING SEAL
REMOVAL
(1) Hoi st and support vehi cl e.
(2) Remove transfer case.
(3) Usi ng a sui tabl e pry tool , or a sl i de hammer
mounted screw, remove the adapter housi ng seal
(Fi g. 14).
INSTALLATION
(1) Cl ean seal bore of adapter housi ng of any
8208, i nstal l new seal so that the seal i s l ocated 0
0.2 mm (0 0.008 i n.) to the seal bore face of
adapter housi ng (Fi g. 15).
(3) I nstal l transfer case.
Fig. 12 Remove Extension Housing Seal
Fig. 13 Install Extension Housing Seal
Fig. 14 Remove Adapter Housing Seal
BEARING RETAINER
DISASSEMBLY
(1) Drai n transmi ssi on l ubri cant, i f necessary.
(2) Remove rel ease beari ng and l ever.
(3) Remove cl utch housi ng bol ts and remove hous-
i ng (Fi g. 18).
(4) Remove vehi cl e speed sensor and speedometer
adapter, i f necessary.
(5) Remove bol ts hol di ng shi ft tower to transmi ssi on case.
(6) Remove shi ft tower from transmi ssi on case (Fi g. 16).
(7) Remove shi ft tower gasket from shi ft tower or
transmi ssi on case (Fi g. 17).
(8) Remove detent bal l pl ug (Fi g. 19).
(9) Remove detent spri ng and bal l wi th penci l
magnet (Fi g. 20), (Fi g. 21).
Fig. 15 Install Adapter Housing Seal
Fig. 16 Remove Shift Tower
Fig. 17 Remove Shift Tower Gasket
(10) Remove shi ft arm retai ner bol t (Fi g. 22).
(11) Remove shi ft arm restri ctor pi ns (Fi g. 23).
(12) Remove shi ft l ever shaft pl ug (Fi g. 24).
(13) Remove shi fter shaft wi th l arge magnet
(Fi g. 25).
(14) Remove the shi ft arm from the adapter hous-
i ng.
(15) Remove adapter/extensi on housi ng bol ts.
Fig. 19 Remove Detent Ball Plug
Fig. 20 Remove Detent Spring
Fig. 21 Remove Detent Ball
Fig. 22 Shift Arm Retainer Bolt Removal
Fig. 23 Shift Arm Rstrictor Pins
(16) Loosen adapter/extensi on housi ng by tappi ng
i t l oose wi th pl asti c mal l et (Fi g. 26).
(17) Remove adapter/extensi on housi ng (Fi g. 27).
(18) On 4x2 transmi ssi ons;
(a) Remove speedometer gear retai ni ng snap-
ri ng from output shaft.
(b) Remove speedometer gear from output shaft
and remove speedometer gear l ock bal l from output
shaft.
(c) Remove speedometer dri ve gear l ocati ng
snap-ri ng (Fi g. 28).
(20) Remove the beari ng retai ner from transmi s-
si on case (Fi g. 29).
(21) Remove i nput shaft beari ng snap-ri ng (Fi g.
30).
(22) Remove countershaft front beari ng snap-ri ng.
Fig. 24 Removing Shift Lever Shaft Plug
Fig. 25 Remove Shifter Shaft
Fig. 26 Loosen Adapter/Extension Housing
Fig. 27 Remove Adapter/Extension HousingTypical
Fig. 28 Speedometer Drive Gear Assembly
(23) Separate i ntermedi ate pl ate and transmi ssi on
case by tappi ng them l oose wi th pl asti c mal l et (Fi g.
31).
(24) Separate the i ntermedi ate pl ate from the
ASSEMBLY
(1) Remove any resi dual seal er from transmi ssi on
case, i ntermedi ate pl ate, and adapter/extensi on hous-
i ng.
(2) Appl y a 1/8 to 3/16 i nch wi de bead of Threeb-
ond Li qui d Gasket TB1281, P/N 83504038, as
shown, maki ng sure to keep seal er bead to i nsi de of
bol t hol es (Fi g. 33).
(3) Al i gn geartrai n and shi ft rai l s wi th mati ng
hol es i n transmi ssi on case and i nstal l transmi ssi on
case to the i ntermedi ate pl ate (Fi g. 34). Veri fy that
the transmi ssi on case i s seated on the i ntermedi ate
pl ate l ocati ng pi ns.
Fig. 29 Remove Front Bearing Retainer
Fig. 30 Remove Input Shaft Bearing Snap-ring
Fig. 31 Separate Intermediate Plate and
Transmission Case
Fig. 32 Remove Intermediate Plate from
Transmission Case
Fig. 33 Apply Sealer to Transmission Gear Case
(4) I nstal l new front beari ng snap ri ngs (Fi g. 35).
(5) I nstal l front beari ng retai ner gasket to front
beari ng retai ner.
(6) I nstal l the front beari ng retai ner (Fi g. 36) and
ti ghten bol ts to 17 Nm (12 ft. l bs.).
(a) I nstal l speedometer dri ve gear l ocati ng snap-
ri ng (Fi g. 37).
(b) I nstal l speedometer gear l ock bal l i n output
shaft and i nstal l speedometer gear onto output
shaft.
(c) I nstal l speedometer gear retai ni ng snap-ri ng
onto output shaft.
ond Li qui d Gasket TB1281, P/N 83504038, to seal -
i ng surface of adapter/extensi on housi ng, maki ng
sure to keep seal er bead to i nsi de of bol t hol es.
(9) I nstal l adapter or extensi on housi ng on i nter-
medi ate pl ate (Fi g. 38). Ti ghten housi ng bol ts to 34
(10) Posi ti on shi ft arm i n shi fter tower openi ng of
adapter or extensi on housi ng (Fi g. 39). Be sure that
the shi fter arm i s engaged i nto the shi ft rai l s.
(11) Start shi fter arm shaft i n hol e i n back of
adapter or extensi on housi ng. Al i gn shi ft arm and
shi fter arm shaft and i nsert shi fter arm shaft
through the shi fter arm and i nto the forward porti on
of the adapter or extensi on housi ng (Fi g. 40).
(12) Rotate the shi fter arm shaft unti l the hol e i n
the shi ft arm i s al i gned wi th the hol e i n the shaft.
(13) I nstal l the shi ft arm retai ner bol t and ti ghten
to 38 Nm (28 ft. l bs.) (Fi g. 41).
(14) I nstal l and ti ghten shi fter arm shaft pl ug to
18 Nm (13 ft. l bs.) torque (Fi g. 42).
(15) I nstal l shi ft restri ctor pi ns i n shi ft tower and
ti ghten to 27 Nm (20 ft. l bs.) (Fi g. 43).
Fig. 34 Install Transmission Gear Case to the
Intermediate Plate
Fig. 35 Install Front Bearing Snap-rings
Fig. 36 Install Front Bearing Retainer
Fig. 38 Install Adapter/Extension HousingTypical
Fig. 39 Position Shift Arm in Adapter or Extension
Housing
Fig. 40 Install Shifter Arm Shaft
Fig. 41 Install Shift Arm Retainer Bolt
Fig. 42 Shifter Arm Shaft Plug Installation
Fig. 43 Install Shifter Restrictor Pins
(16) I nstal l shi ft detent bal l i n detent openi ng of
case (Fi g. 44).
(17) I nstal l detent spri ng i n case (Fi g. 45).
(18) I nstal l detent pl ug and ti ghten to 19 Nm (14
ft. l bs.) (Fi g. 46).
(19) I nstal l shi ft tower gasket onto shi ft tower.
(20) I nstal l the shi ft tower oi l defl ector and gasket
onto the adapter or extensi on housi ng.
(21) I nstal l shi ft tower onto transmi ssi on case
(Fi g. 47).
(22) I nstal l bol ts to hol d shi ft tower to transmi s-
si on case. Ti ghten tower bol ts to 18 Nm (13 ft. l bs.)
torque.
(23) I nstal l new metal o-ri ng onto the backup l amp
swi tch.
(24) I nstal l backup l amp swi tch (Fi g. 48). Ti ghten
swi tch to 44 Nm (32.5 ft. l bs.) torque.
(25) I nstal l new seal i n adapter/extensi on housi ng.
(26) I nstal l vehi cl e speed sensor, i f necessary.
Fig. 44 Install Detent Ball
Fig. 45 Install Detent Spring
Fig. 46 Install Detent Ball Plug
Fig. 47 Install Shift Tower
Fig. 48 Install Backup Lamp Switch
(27) I nstal l cl utch housi ng, rel ease beari ng, rel ease
fork and retai ner cl i p.
SHIFT MECHANISM AND GEARTRAIN
DISASSEMBLY
(1) I nstal l sui tabl e bol ts and washers i n i ntermedi -
ate pl ate (Fi g. 49). Then cl amp pl ate and gear assem-
bl y i n vi se. Use enough washers to prevent bol ts
from touchi ng. Al so be sure vi se jaws are cl amped on
bol t heads.
(2) Remove countershaft fi fth gear retai ni ng snap-
ri ng (Fi g. 50).
(3) Remove bol t hol di ng fi fth gear shi ft fork to
shi ft rai l (Fi g. 51).
(4) Remove fi fth gear bl ocker ri ng from counter-
shaft assembl y wi th Pul l er L-4407 (Fi g. 52).
(5) Remove fi fth gear synchro ri ng (Fi g. 53).
(6) Remove the countershaft fi fth gear assembl y
from countershaft (Fi g. 54).
(7) Remove fi fth gear thrust ri ng from counter-
shaft (Fi g. 55).
(8) Remove fi fth gear thrust ri ng l ock bal l from
countershaft (Fi g. 56).
NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.
(9) Remove bol t hol di ng reverse i dl er gear shaft
l ock pl ate to the i ntermedi ate pl ate.
(10) Remove reverse i dl er gear shaft and reverse
i dl er gear assembl y (Fi g. 57).
NOTE: Be sure to retrieve the pin and compression
spring from the reverse idler shaft.
Fig. 49 Positioning Intermediate Plate In Vise
Fig. 50 Remove Fifth Gear Snap-ring
Fig. 51 Remove Shift Fork Retainer Bolt
(11) Remove bol ts hol di ng output shaft rear bear-
i ng retai ner to the i ntermedi ate pl ate and remove
retai ner (Fi g. 58).
(12) Remove bol ts hol di ng 12 and 34 shi ft forks
to the shi ft rai l s (Fi g. 59) and di scard bol ts.
Fig. 52 Remove Fifth Gear Blocker Ring
Fig. 53 Remove Fifth Gear Synchro Ring
Fig. 54 Remove Fifth Gear and Synchro Assembly
Fig. 55 Remove Fifth Gear Thrust Ring
Fig. 56 Remove Fifth Gear Thrust Ring Lock Ball
Fig. 57 Remove Reverse Idler Shaft
(13) Remove bol ts hol di ng reverse shi ft arm
bracket to i ntermedi ate pl ate (Fi g. 60).
(14) Remove snap-ri ng hol di ng output shaft rear
beari ng i nto the i ntermedi ate pl ate (Fi g. 61).
(15) Remove countershaft rear beari ng snap-ri ng.
(16) Wi th ai d of an assi stant, support the mai n-
shaft and countershaft. Tap on the rear of the mai n-
shaft and countershaft wi th a sui tabl e pl asti c mal l et.
Thi s wi l l rel ease the countershaft from the counter-
shaft rear beari ng and the mai nshaft rear beari ng
from the i ntermedi ate pl ate. The countershaft wi l l
rel ease from the countershaft beari ng fi rst and can
be removed by movi ng the countershaft rearward and
downward (Fi g. 62).
(17) Remove the mai nshaft by movi ng the mai n-
shaft forward unti l the mai nshaft rear beari ng i s
cl ear of the i ntermedi ate pl ate and then rotati ng the
mai nshaft downward out of the shi ft forks (Fi g. 63).
(18) Remove the 34 shi ft fork from the 34 shi ft
rai l (Fi g. 64).
Fig. 58 Remove Output Shaft Rear Bearing Retainer
Fig. 59 Remove Shift Fork To Shift Rail Bolts
Fig. 60 Remove Reverse Shift Arm Bracket Bolts
Fig. 61 Remove Output Shaft Rear Bearing
Snap-ring
(19) Remove the snap-ri ng from near the end of
the 12 shi ft rai l to al l ow the removal of the 12
shi ft fork.
(20) Remove the 12 shi ft fork from the 12 and
the 34 shi ft rai l s (Fi g. 65).
(21) Remove threaded pl ugs from i ntermedi ate
pl ate. Then remove l ock bal l and spri ng from pl ug
hol es wi th penci l magnet (Fi g. 66). Note that the bot-
tom spri ng i s shorter i n l ength than the other two
spri ngs.
(22) Remove the i ntermedi ate pl ate from the vi se,
rotate the pl ate 180, and rei nstal l the pl ate i n the
vi se usi ng the same bol t and washer mounti ng set-
up.
CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.
(23) Remove fi fth gear shi ft rai l (Fi g. 67).
(24) Remove fi fth gear check bal l (Fi g. 68) and
i nterl ock pi n.
(25) Remove reverse shi ft head and rai l assembl y
(Fi g. 69).
(26) Remove snap-ri ng hol di ng reverse shi ft rai l
i nto i ntermedi ate pl ate.
(27) Remove reverse shi ft rai l and reverse shi ft
fork and arm assembl y from i ntermedi ate pl ate (Fi g.
70).
Fig. 62 Remove Countershaft and Countershaft
Rear Bearing
Fig. 63 Remove Mainshaft
Fig. 64 Remove 34 Shift Fork
Fig. 65 Remove 12 Shift Fork
(28) Remove i nterl ock pi n from reverse shi ft rai l
(Fi g. 71).
(29) Remove reverse el ongated check bal l (Fi g. 72).
(30) Remove snap-ri ng on 34 shi ft rai l .
(31) Remove 12 shi ft rai l from i ntermedi ate pl ate.
(32) Remove i nterl ock pi n from 12 shi ft rai l (Fi g.
73).
(33) Remove 12 shi ft rai l el ongated check bal l
from i ntermedi ate pl ate (Fi g. 74).
(34) Remove 34 shi ft rai l from i ntermedi ate pl ate.
Fig. 66 Remove Lock Ball And Spring
Fig. 67 Remove Fifth Gear Shift Rail
Fig. 68 Remove Fifth Gear Check Ball
Fig. 69 Remove Reverse Shift Head And Rail
Assembly
Fig. 70 Remove Reverse Shift Rail
ASSEMBLY
Refer to (Fi g. 75) whi l e assembl i ng and i nstal l i ng
the shi ft rai l components. Al so, veri fy that al l shi ft
rai l components are i n thei r neutral posi ti on when
i nstal l i ng the check bal l s and i nterl ock pi ns.
(1) I nstal l the 34 shi ft rai l i nto the i ntermedi ate
pl ate.
(2) I nstal l the 12 el ongated check bal l i nto the
i ntermedi ate pl ate (Fi g. 76).
(3) I nstal l the i nterl ock pi n i nto the 12 shi ft rai l
(Fi g. 77).
(4) I nstal l the 12 shi ft rai l i nto the i ntermedi ate
pl ate.
Fig. 71 Remove Interlock Pin From Reverse Shift
Rail
Fig. 72 Remove Reverse Check Ball
Fig. 73 Remove 12 Shift Rail Interlock Pin
Fig. 74 Remove 12 Check Ball
(5) I nstal l snap-ri ng onto 34 shi ft rai l .
(6) I nstal l the reverse check bal l i nto the i nterme-
di ate pl ate (Fi g. 78).
(7) I nstal l the i nterl ock pi n i nto the reverse shi ft
rai l (Fi g. 79).
(8) Assembl e the reverse arm bracket to the
reverse fork (Fi g. 80).
Fig. 75 Shift Rail Components
Fig. 76 Install 12 Check Ball Fig. 77 Install 12 Shift Rail Interlock Pin
(9) I nstal l reverse shi ft rai l i nto i ntermedi ate pl ate
and posi ti on reverse arm bracket to i ntermedi ate
pl ate (Fi g. 81).
(10) I nstal l snap-ri ng onto reverse shi ft rai l (Fi g.
82).
(11) I nstal l reverse shi ft head and rai l assembl y
i nto the i ntermedi ate pl ate.
(12) I nstal l the fi fth gear i nterl ock bal l and check
bal l (Fi g. 83).
(13) I nstal l fi fth gear shi ft rai l (Fi g. 84).
(14) Remove the i ntermedi ate pl ate from the vi se,
rotate the pl ate 180, and rei nstal l the pl ate i n the
vi se usi ng the same bol t and washer mounti ng set-
up.
(15) I nstal l the shi ft rai l detent bal l s i n the i nter-
medi ate pl ate.
Fig. 78 Install Reverse Check Ball
Fig. 79 Install Reverse Interlock Pin
Fig. 80 Install Reverse Arm Bracket to Fork
Fig. 81 Install Reverse Shift Rail
Fig. 82 Install Reverse Snap-ring
(16) I nstal l the shi ft rai l detent spri ngs i n the
i ntermedi ate pl ate. Note that the bottom detent
spri ng i s shorter than the others.
(17) I nstal l the shi ft rai l detent pl ugs i n the i nter-
medi ate pl ate.
(18) I nstal l the 12 shi ft fork onto the 12 and 34
shi ft rai l s (Fi g. 85).
(19) I nstal l the snap-ri ng onto the 12 shi ft rai l .
(20) I nstal l the 34 shi ft fork onto the 34 shi ft
rai l (Fi g. 86).
(21) I nstal l mai nshaft i nto the i ntermedi ate pl ate
by gui di ng the output shaft through openi ng i n i nter-
medi ate pl ate unti l the shi ft forks are al i gned wi th
the appropri ate synchroni zer sl eeves. The mai nshaft
rear beari ng wi l l be started i n the i ntermedi ate pl ate
but not ful l y dri ven i n at thi s poi nt.
(22) Whi l e an assi stant supports the mai nshaft,
al i gn rear of countershaft wi th i nner race of counter-
shaft rear beari ng.
(23) Rai se countershaft upward unti l gears mesh
wi th the mati ng gears on the mai nshaft.
(24) Usi ng a sui tabl e rubber mal l et, tap on the
i nput shaft and the front of the countershaft equal l y
to i nstal l the mai nshaft rear beari ng i nto the i nter-
medi ate pl ate and the rear of the countershaft i nto
the rear countershaft beari ng. I t may be necessary to
occasi onal l y hol d the countershaft i nto the i ntermedi -
ate pl ate and tap the countershaft rear beari ng onto
the countershaft and i nto the i ntermedi ate pl ate.
(25) I nstal l snap-ri ngs onto the rear mai nshaft and
countershaft beari ngs.
(26) I nstal l the bol ts to hol d the reverse shi ft arm
bracket to the i ntermedi ate pl ate.
(27) I nstal l new bol ts to hol d the shi ft forks to the
(28) Posi ti on the mai nshaft rear beari ng retai ner
over the output shaft and onto the i ntermedi ate
pl ate.
(29) I nstal l new bol ts to hol d the beari ng retai ner
to the i ntermedi ate pl ate.
Fig. 83 Install Fifth Gear Check Ball
Fig. 84 Install Fifth Gear Shift Rail
Fig. 85 Install 12 Shift Fork
Fig. 86 Install 34 Shift Fork
(30) Move the reverse shi ft arm i nto the reverse
gear posi ti on. The reverse gear posi ti on i s wi th the
arm moved away from the i ntermedi ate pl ate (Fi g.
88).
(31) I nstal l the reverse i dl er gear assembl y i nto
posi ti on on the mai nshaft and reverse shi ft arm.
(32) I nstal l the compressi on spri ng and pi n i nto
the reverse i dl er gear shaft (Fi g. 89).
(33) I nstal l the reverse i dl er shaft through the
i ntermedi ate pl ate and reverse i dl er gear assembl y
(Fi g. 90) unti l the i dl er shaft pi n contacts the gear
assembl y. Make sure that the notched cut-out i n the
i dl er shaft i s to the rear of the transmi ssi on.
(34) Al i gn the pi n wi th the al i gnment notch i n the
reverse i dl er gear assembl y (Fi g. 91). The al i gnment
notch i n the reverse i dl er gear race/hub i s a smal l
rel i ef cut above one of the mai n l ongi tudi nal sl ots. Be
sure that the pi n i s al i gned wi th the proper sl ot, the
opposi te sl ot has an oi l drai n hol e whi ch the pi n wi l l
drop i nto. The assembl y wi l l then be l ocked onto the
shaft and wi l l need to be di sassembl ed i n order to be
removed.
(35) Depress compressi on spri ng and pi n i n
reverse i dl er gear shaft (Fi g. 92).
Fig. 87 Install Shift Fork Bolts
Fig. 88 Reverse Shift Arm Position
Fig. 89 Install Compression Spring And Pin
Fig. 90 Install Reverse Idler Shaft
Fig. 91 Align Idler Shaft Pin
(36) I nstal l the reverse i dl er gear shaft the
remai nder of the way through the reverse i dl er gear
assembl y.
(37) Posi ti on the reverse i dl er gear shaft l ock pl ate
onto the i ntermedi ate pl ate.
(38) I nstal l a new bol t to hol d the i dl er gear shaft
l ock pl ate to the i ntermedi ate pl ate.
(39) I nstal l the fi fth gear thrust ri ng l ock bal l to
the countershaft (Fi g. 93).
(40) I nstal l the fi fth gear thrust ri ng onto the
countershaft and over the l ock bal l (Fi g. 94).
(41) I nstal l fi fth gear shi ft fork to the countershaft
fi fth gear assembl y.
(42) I nstal l the countershaft fi fth gear beari ngs
i nto the countershaft fi fth gear assembl y.
(43) Posi ti on the countershaft fi fth gear assembl y
on the countershaft. Ensure that the fi fth gear fork i s
i nstal l ed onto the fi fth gear shi ft rai l .
(44) I nstal l the fi fth gear synchro ri ng.
(45) Posi ti on the fi fth gear bl ocker ri ng onto the
countershaft.
(46) Usi ng a sui tabl e mal l et and spacer, tap the
fi fth gear bl ocker ri ng onto the countershaft.
(47) I nstal l new bol t to hol d fi fth gear shi ft fork to
the fi fth gear shi ft rai l (Fi g. 95).
(48) Measure countershaft fi fth gear thrust cl ear-
ance.
(49) Sel ect a snap-ri ng so that the thrust cl earance
i s 0.100.30 mm (0.0040.010 i n.).
(50) I nstal l snap-ri ng to hol d fi fth gear bl ocker
ri ng onto countershaft.
(51) Remove i ntermedi ate pl ate from vi se and
remove bol ts and washers from i ntermedi ate.
Fig. 92 Depress Pin In Reverse Idler Gear Shaft
Fig. 93 Install Fifth Gear Thrust Ring Lock Ball
Fig. 94 Install Fifth Gear Thrust Ring
Fig. 95 Install Fifth Gear Retainer Bolt
COUNTERSHAFT
DISASSEMBLY
(1) Remove sel ect fi t snap-ri ng hol di ng the coun-
tershaft front beari ng onto the countershaft (Fi g. 96).
(2) Usi ng Beari ng Spl i tter P-334, a sui tabl e spacer
on center of countershaft, and a shop press, remove
the countershaft front beari ng from the countershaft.
ASSEMBLY
(1) Remove any ni cks or burrs on countershaft hub
wi th fi ne emery or crocus cl oth.
(2) Posi ti on countershaft front beari ng on end of
countershaft.
(3) Usi ng Speci al Tool 8109 and a shop press,
press beari ng onto countershaft.
(4) Sel ect the thi ckest snap-ri ng that wi l l fi t i nto
the snap-ri ng groove of the countershaft (Fi g. 96).
(5) I nstal l snap-ri ng to hol d countershaft front
beari ng onto countershaft.
INPUT SHAFT
DISASSEMBLY
(1) Veri fy that the 34 synchroni zer i s i n the neu-
tral posi ti on.
(2) Separate i nput shaft from output shaft (Fi g.
97). Note that the output shaft pi l ot beari ng i s an
uncaged rol l er type beari ng.
(3) Remove the output shaft pi l ot beari ng rol l ers
from the i nput shaft and the output shaft.
(4) Remove the fourth gear synchroni zer ri ng from
the i nput shaft (Fi g. 98).
(5) Remove the sel ect fi t snap-ri ng hol di ng the
i nput shaft beari ng onto the i nput shaft.
(6) Usi ng Beari ng Spl i tter P-334 and a shop press,
remove the beari ng from the i nput shaft.
ASSEMBLY
(1) Posi ti on i nput shaft beari ng onto i nput shaft.
(2) Usi ng Dri ver L-4507, dri ve beari ng onto i nput
shaft.
the snap-ri ng groove of the i nput shaft (Fi g. 99).
(4) Lubri cate output shaft pi l ot beari ng bore of
i nput shaft wi th petrol eum jel l y.
(5) I nstal l output shaft pi l ot beari ng rol l ers i n
i nput shaft bore (Fi g. 100). Ensure to use suffi ci ent
petrol eum jel l y to hol d rol l ers i n posi ti on.
(6) I nstal l the fourth gear synchroni zer ri ng onto
the i nput shaft.
(7) I nstal l i nput shaft to output shaft. Use care
when mati ng the two shafts not to di spl ace any out-
put shaft pi l ot beari ng rol l ers.
Fig. 96 Countershaft Front Bearing Snap-ring
Fig. 97 Separate Input and Output Shafts
Fig. 98 Input Shaft Components
OUTPUT SHAFT
DISASSEMBLY
(1) Remove i nput shaft and output shaft pi l ot
beari ng rol l ers from output shaft.
(2) Measure and note thrust cl earance of output
shaft gears (Fi g. 101). Cl earance shoul d be 0.10
0.25 mm (0.004 0.010 i n.).
(3) Remove output shaft fi fth gear snap ri ng wi th
two screwdri vers (Fi g. 102).
(4) Usi ng Beari ng Spl i tter P-334 or sui tabl e press
pl ates posi ti oned under fi rst gear, press fi fth gear,
rear beari ng, fi rst gear, and fi rst gear beari ng i nner
race off output shaft (Fi g. 103).
Fig. 99 Select Input Shaft Bearing Snap-ring
Fig. 100 Install Output Shaft Pilot Bearing Rollers
Fig. 101 Check Output Shaft Gear Thrust Clearance
(5) Remove fi rst gear needl e rol l er beari ng from
output shaft.
(6) Remove fi rst gear beari ng i nner race l ock bal l
wi th penci l magnet (Fi g. 104).
(7) Remove fi rst gear synchroni zer ri ng.
pl ates posi ti oned under second gear, press 12 syn-
chroni zer, reverse gear, and second gear from output
shaft (Fi g. 105).
(9) Remove second gear needl e rol l er beari ng from
the output shaft or second gear.
(10) Remove sel ect fi t snap-ri ng hol di ng the 34
synchroni zer onto the output shaft (Fi g. 106).
pl ates posi ti oned under thi rd gear, press the 34 syn-
chroni zer and thi rd gear from output shaft (Fi g. 107).
Fig. 103 Remove Fifth Gear, First Gear Bearing, And
Race
Fig. 104 Remove First Gear Bearing Inner Race
Lock Ball
Fig. 105 Remove Second Gear, Reverse Gear, And
12 Synchronizer
(12) Remove thi rd gear needl e rol l er beari ng from
output shaft or gear.
ASSEMBLY
(1) Lubri cate transmi ssi on components wi th speci -
fi ed gear l ubri cant.
(2) I f necessary, assembl e 12 and 34 synchro-
ni zer hubs, sl eeves, spri ngs and key i nserts (Fi g.
108).
(3) I nstal l thi rd gear needl e beari ng onto the out-
put shaft.
(4) I nstal l thi rd gear over beari ng and onto output
shaft fl ange.
(5) I nstal l thi rd gear synchroni zer ri ng to thi rd
gear.
(6) Posi ti on the 34 synchroni zer onto the output
shaft.
(7) Usi ng Adapter 6747-1A and a shop press, press
the 34 synchroni zer onto the output shaft.
the snap-ri ng groove of the output shaft (Fi g. 109).
Fig. 106 Remove 34 Synchronizer Snap Ring
Fig. 107 Remove 34 Synchronizer And Third Gear
Fig. 108 Synchronizer Identification
Fig. 109 Select 34 Synchronizer Snap-ring
(9) I nstal l snap-ri ng to hol d 34 synchroni zer onto
output shaft.
(10) Veri fy thi rd gear thrust cl earance wi th feel er
gauge (Fi g. 110). Cl earance shoul d be 0.10 0.25 mm
(0.004 0.010 i n.). I f cl earance i s out of speci fi cati on,
refer to Cl eani ng and I nspecti on secti on wi thi n thi s
group.
(11) I nstal l second gear needl e beari ng onto output
shaft.
(12) I nstal l second gear over beari ng and onto out-
put shaft fl ange.
(13) I nstal l second gear synchroni zer ri ng onto sec-
ond gear.
(14) Posi ti on 12 synchroni zer assembl y onto
spl i nes of output shaft.
(15) Usi ng Dri ver MD-998805, Adapter 6747-1A,
and a shop press, press the 12 synchroni zer onto
the output shaft.
(16) I nstal l fi rst gear synchroni zer ri ng i nto 12
synchroni zer.
(17) I nstal l fi rst gear beari ng i nner race l ock bal l
i n output shaft (Fi g. 111).
(18) I nstal l fi rst gear needl e beari ng onto output
shaft (Fi g. 112).
(19) I nstal l fi rst gear onto output shaft and over
beari ng.
(20) I nstal l fi rst gear beari ng i nner race onto out-
put shaft and i nsi de fi rst gear beari ng. Rotate bear-
i ng race unti l race i nstal l s over l ock bal l .
(21) Posi ti on output shaft rear beari ng onto output
shaft. Ensure that the snap ri ng groove i n beari ng
outer race i s toward rear of output shaft.
(22) Usi ng Dri ver L-4507 and sui tabl e mal l et,
dri ve beari ng onto output shaft.
(23) I nstal l snap-ri ng onto output shaft rear bear-
i ng outer race.
Fig. 110 Check Third Gear Clearance
Fig. 111 Install First Gear Bearing Inner Race Lock
Ball
Fig. 112 First Gear Components
(24) Check fi rstsecond gear thrust cl earance (Fi g.
113). Standard cl earance i s 0.10 0.25 mm (0.004
0.010 i n.). I f cl earance i s out of speci fi cati on, refer to
Cl eani ng and I nspecti on secti on wi thi n thi s group.
(25) Posi ti on fi fth gear onto output shaft wi th the
gears short shoul der toward the rear of shaft.
Ensure that the gear and output shaft spl i nes are
al i gned.
(26) Usi ng Adapter 6747-1A, Dri ver L-4507, and a
shop press, press fi fth gear onto output shaft.
(28) I nstal l snap-ri ng to hol d fi fth gear onto output
shaft.
Fig. 113 Check FirstSecond Gear Thrust Clearance
Fig. 114 Select/Install Fifth Gear Snap Ring
SEMI-SYNCHRONIZED REVERSE IDLER GEAR
DISASSEMBLY
(1) Remove snap-ri ng hol di ng the reverse i dl er
gear onto the reverse i dl er gear hub/race (Fi g. 115).
(2) Remove the pl ate washer from the reverse i dl er
gear hub/race (Fi g. 116).
(3) Remove the reverse i dl er gear from the reverse
i dl er gear hub/race (Fi g. 117).
(4) Remove the reverse i dl er gear synchroni zer
ri ng from the reverse i dl er gear hub/race (Fi g. 118).
ASSEMBLY
(1) I nstal l the reverse i dl er gear synchroni zer ri ng
onto the reverse i dl er gear hub/race. Appl y a fi l m of
75W-90 GL-3 transmi ssi on oi l to the contact surface
of the synchroni zer ri ng pri or to assembl y.
(2) I nstal l the reverse i dl er gear onto the reverse
i dl er gear hub/race. Appl y a fi l m of 75W-90 GL-3
transmi ssi on oi l to the reverse i dl er gear bushi ng
pri or to assembl y.Veri fy that the teeth on the syn-
chroni zer ri ng are properl y engaged i nto the recesses
of the reverse i dl er gear.
(3) I nstal l the pl ate washer over the reverse i dl er
gear hub/race and onto the reverse i dl er gear.
(4) I nstal l the snap-ri ng to hol d the reerse i dl er
gear onto the reverse i dl er hub/race.
AX5 MANUAL TRANSMISSION COMPONENTS
GENERAL INFORMATION
Cl ean the transmi ssi on components i n sol vent. Dry
the cases, gears, shi ft mechani sm and shafts wi th
compressed ai r. Dry the beari ngs wi th cl ean, dry
shop towel s onl y. Never use compressed ai r on the
beari ngs. Thi s coul d cause severe damage to the
beari ng rol l er and race surfaces.
I f output shaft or i nner race fl ange thi ckness i s
wi thi n speci fi cati on but any gear thrust cl earance i s
Fig. 115 Remove Reverse Idler Gear Snap-ring
Fig. 116 Remove Reverse Idler Gear Plate Washer
Fig. 117 Remove Reverse Idler Gear
Fig. 118 Remove Reverse Idler Gear Synchronizer
Ring
out of speci fi cati on, repl ace the necessary gear and
gear needl e beari ng as an assembl y.
GEAR CASE, ADAPTER/EXTENSION HOUSING,
INTERMEDIATE PLATE
Cl ean the case, housi ng, and i ntermedi ate pl ate
wi th sol vent and dry wi th compressed ai r. Repl ace
the case i f cracked, porous, or i f any of the beari ng
and gear bores are damaged.
I nspect the threads i n the case, housi ng, and pl ate.
Mi nor thread damage can be repai red wi th steel
thread i nserts, i f necessary. Do not attempt to repai r
any threads whi ch show evi dence of cracks around
the threaded hol e.
OUTPUT SHAFT
Check thi ckness of the output shaft and i nner
beari ng race fl anges wi th a mi crometer or verni er
cal i pers (Fi g. 119).
Mi ni mum thi ckness for shaft fl ange i s 4.80 mm
(0.189 i n.)
Mi ni mum thi ckness for fi rst gear beari ng i nner
race fl ange i s 3.99 mm (0.157 i n.)
Measure di ameter of the output shaft journal sur-
faces wi th a mi crometer. Repl ace the shaft i f ei ther of
these surfaces are worn beyond speci fi ed l i mi ts.
Second gear surface mi ni mum di ameter i s
37.964 mm (1.495 i n.)
Thi rd gear surface mi ni mum di ameter i s 34.984
mm (1.377 i n.)
Measure di ameter of the fi rst gear beari ng i nner
race. Mi ni mum di ameter i s 38.985 mm (1.535 i n.).
Measure output shaft runout wi th a di al i ndi cator
(Fi g. 120). Runout shoul d not exceed 0.05 mm (0.002
i n.).
Repl ace output shaft or fi rst gear i nner beari ng
race i f measurement of any surface i s out of speci fi -
cati on. Do not attempt to repai r out of speci fi cati on
components.
COUNTERSHAFT
I nspect the countershaft gear teeth. Repl ace the
countershaft i f any teeth are worn or damaged.
I nspect the beari ng surfaces and repl ace shaft i f any
surface shows damage or wear.
Check condi ti on of the countershaft front beari ng.
Repl ace the beari ng i f worn, noi sy, or damaged.
GEAR AND SYNCHRONIZER
I nstal l the needl e beari ng and i nner race i n the
fi rst gear. Then check oi l cl earance between the gear
and i nner race (Fi g. 121). Cl earance shoul d be 0.009
0.032 mm (0.0004 0.0013 i n.).
I nstal l the needl e beari ngs and the second, thi rd
and counter fi fth gears on the output shaft. Then
check oi l cl earance between the gears and shaft wi th
a di al i ndi cator (Fi g. 122). Oi l cl earance for al l three
gears i s 0.009 0.0013 mm (0.0004 0.0013 i n.).
Check synchroni zer ri ng wear (Fi g. 123). I nsert
each ri ng i n matchi ng gear. Measure cl earance
between each ri ng and gear wi th feel er gauge.
Repl ace ri ng i f cl earance exceeds 2.0 mm (0.078 i n.).
Fig. 119 Check Shaft And Bearing Race Flange
Thickness
Fig. 120 Check Output Shaft Runout
CLEANING AND INSPECTION (Continued)
Check shi ft forktosynchroni zer hub cl earance
wi th a feel er gauge (Fi g. 124). Repl ace the fork i f
cl earance exceeds 1.0 mm (0.039 i n.).
(1) I nspect al l mai nshaft gear teeth. Repl ace any
gear whi ch shows any worn or damaged teeth.
Fig. 121 Check GearToRace Clearance
Fig. 122 Check GearToShaft Oil Clearance
Fig. 123 Check Synchronizer Ring Wear
Fig. 124 Check ForkToHub Clearance
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ugs, Access . . . . . . . . . . . . . . . . 19 Nm (14 ft.l bs.)
Bol ts, Adapter Housi ng . . . . . . . . 34 Nm (25 ft.l bs.)
Swi tch, Back-up Li ght . . . . . . . 44 Nm (32.5 ft.l bs.)
Pl ugs, Drai n and Fi l l . . . . . . . . 44 Nm (32.5 ft.l bs.)
Bol ts, Front Beari ng Retai ner . . . 17 Nm (12 ft.l bs.)
Pl ugs, I nterl ock and Detent . . . . . 19 Nm (14 ft.l bs.)
Screws, Propel l er Shaft Cl amp . . . . . . . . 1623 Nm
(140200 i n.l bs.)
Bol ts, Rear Mount to Transmi ssi on . . . . 3360 Nm
(2444 ft.l bs.)
Nut, Rear Mount Cl evi s . . 5475 Nm (4055 ft.l bs.)
Nuts, Rear Mount to Crossmember . . . . 3349 Nm
(2436 ft.l bs.)
Pi ns, Restri ctor . . . . . . . . . . . . . 27.4 Nm (20 ft.l bs.)
Bol ts, Reverse Shi ft Arm Bracket . . . . . . . . . 18 Nm
(13 ft.l bs.)
Screw, Shi ft Arm Set . . . . . . . . . . 38 Nm (28 ft.l bs.)
Screws, Shi ft Fork Set . . . . . . . . . 20 Nm (15 ft.l bs.)
Nut, Shi ft Knob . . . . . . . . 2034 Nm (1525 ft.l bs.)
Screws, Shi fter Fl oor Cover . . . . . . . . . . . . 23 Nm
(1730 i n.l bs.)
Bol ts, Shi ft Tower . . . . . . . . . . . . 18 Nm (13 ft.l bs.)
Nuts, Transfer Case Mounti ng . . . . . . . . 3041 Nm
(2230 ft.l bs.)
SPECIAL TOOLS
AX5
C-3339 Dial Indicator Set
C-3995-A Installer, Extension Housing Seal
C-4171 Handle, Universal Tool
8211 Installer, Seal
P-334 Splitter, Bearing
8109 Cup, Installer
L-4507 Tube, Driver
67471A Adapter, Fixture
MD-998805 Installer, Seal
SPECIAL TOOLS (Continued)
INDEX
page page
GENERAL INFORMATION
AX15 MANUAL TRANSMISSION . . . . . . . . . . . . . 37
RECOMMENDED LUBRICANT . . . . . . . . . . . . . . 37
TRANSMISSION ASSEMBLY INFORMATION . . . 38
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . 37
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 37
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . 39
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . 38
TRANSMISSION NOISE . . . . . . . . . . . . . . . . . . . 40
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . 43
EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . 43
FRONT BEARING RETAINER SEAL . . . . . . . . . . 42
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 40
BEARING RETAINER . . . . . . . . . . . . . . . . . . . 44
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 63
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 64
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . 64
SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 51
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . 69
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
SPECIAL TOOLS
AX15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
GENERAL INFORMATION
The AX15 i s a 5speed, synchromesh, manual
transmi ssi on. Fi fth gear i s an overdri ve range wi th a
rati o of 0.79:1. An adapter housi ng i s used to attach
the transmi ssi on to the transfer case on 4wheel
dri ve model s. A standard extensi on housi ng i s used
on 2wheel dri ve model s. The shi ft mechani sm i s
i ntegral and mounted i n the shi ft tower porti on of
the adapter housi ng (Fi g. 1).
The AX15 i denti fi cati on code numbers are on the
bottom surface of the i ntermedi ate pl ate (Fi g. 2).
The fi rst number i s year of manufacture. The sec-
seri al number.
TRANSMISSION GEAR RATIOS
Gear rati os for the AX15 manual transmi ssi on are
as fol l ows:
Fi rst gear: 3.83:1
Second gear: 2.33:1
Thi rd gear: 1.44:1
Fourth gear: 1.00:1
Fi fth gear: 0.79:1
Reverse: 4.22:1
RECOMMENDED LUBRICANT
equi val ent.
The fi l l pl ug i s l ocated on the dri vers si de of the
transmi ssi on case (Fi g. 3). The drai n pl ug i s l ocated
on the passenger si de of the transmi ssi on case near
the bottom (Fi g. 4).
ti ons.
ti ons.
Lubri cate the transmi ssi on components wi th
Mopar 75W90, GL 3 gear l ubri cant duri ng assem-
bl y. Use petrol eum jel l y to l ubri cate seal l i ps and/or
hol d parts i n pl ace duri ng i nstal l ati on.
Refer to (Fi g. 5) duri ng assembl y for AX15 gear
assembl y i denti fi cati on.
LOW LUBRICANT LEVEL
case, i ntermedi ate pl ate and adaptor or extensi on
ponent mati ng surfaces wi l l probabl y be the resul t of
Fig. 1 AX15 Manual Transmission
Fig. 2 Identification Code Number Location
i ng the di sc to sl i p, grab, and/or chatter.
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng nonrecommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Component damage, i ncorrect cl utch adjustment,
or a damaged cl utch pressure pl ate or di sc are addi -
ti onal probabl e causes of i ncreased shi ft effort. I ncor-
rect adjustment or a worn/damaged pressure pl ate or
di sc can cause i ncorrect rel ease. I f the cl utch probl em
i s advanced, gear cl ash duri ng shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear cl ash
when shi fti ng i nto any forward gear. I n some new or
rebui l t transmi ssi ons, new synchro ri ngs may tend to
sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n most
cases, thi s condi ti on wi l l decl i ne as the ri ngs wear
i n.
Fig. 5 Output Shaft and Gears
Fig. 4 Drain Plug Location
TRANSMISSION NOISE
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear breakage.
TRANSMISSION
REMOVAL
(1) Shi ft transmi ssi on i nto fi rst or thi rd gear.
(2) Rai se and support vehi cl e on sui tabl e safety
stands.
(3) Di sconnect necessary exhaust system compo-
nents.
(4) Remove ski d pl ate, i f equi pped.
(5) Remove sl ave cyl i nder from cl utch housi ng.
(6) Mark rear propel l er shaft and rear axl e yokes
for i nstal l ati on al i gnment (Fi g. 6).
(7) Mark front propel l er shaft, axl e, and transfer
case yokes for i nstal l ati on al i gnment, i f equi pped.
(8) Remove propel l er shaft(s).
(9) Uncl i p wi re harnesses from transmi ssi on and
(10) Di sconnect transfer case vent hose, i f
equi pped.
(11) Di sengage any wi re connectors attached to
transmi ssi on or transfer case, i f equi pped, compo-
nents.
(12) Support transfer case, i f equi pped, wi th trans-
mi ssi on jack.
(13) Secure transfer case, i f equi pped, to jack wi th
safety chai ns.
(14) Di sconnect transfer case shi ft l i nkage at
mi ssi on, i f equi pped.
(16) Remove transfer case, i f equi pped.
(17) Remove crankshaft posi ti on sensor (Fi g. 7),
(Fi g. 8).
Fig. 6 Marking Propeller Shaft And Axle Yokes
Fig. 8 Crankshaft Position Sensor 4.0L Engine
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.
(18) Support engi ne wi th adjustabl e jack stand.
Posi ti on wood bl ock between jack and oi l pan to
avoi d damagi ng pan.
(19) Support transmi ssi on wi th transmi ssi on jack.
chai ns.
(21) Di sconnect rear cushi on and bracket from
transmi ssi on.
(23) Di sconnect transmi ssi on shi ft l ever as fol l ows:
(a) Lower transmi ssi ontransfer case assembl y
approxi matel y 78 cm (3 i n.) for access to shi ft
l ever.
(b) Reach up and around transmi ssi on case and
unseat shi ft l ever dust boot from transmi ssi on shi ft
tower (Fi g. 9). Move boot upward on shi ft l ever for
access to retai ner that secures l ever i n shi ft tower.
(c) Reach up and around transmi ssi on case and
press shi ft l ever retai ner downward wi th fi nger
pressure. Turn retai ner countercl ockwi se to rel ease
i t.
(d) Li ft l ever and retai ner out of shi ft tower (Fi g.
9). Do not remove the shi ft l ever from the fl oor con-
sol e shi fter boots. Leave the l ever i n pl ace for
transmi ssi on i nstal l ati on.
(24) Remove cl utch housi ng brace rod.
(25) Remove cl utch housi ng-to-engi ne bol ts.
(26) Pul l transmi ssi on jack rearward unti l i nput
shaft cl ears cl utch. Then sl i de transmi ssi on out from
under vehi cl e.
(27) Remove cl utch rel ease beari ng, rel ease fork,
and retai ner cl i p.
(28) Remove cl utch housi ng from transmi ssi on
(Fi g. 10).
INSTALLATION
(1) I nstal l cl utch housi ng on transmi ssi on. Ti ghten
housi ng bol ts to 37 Nm (27 ft. l bs.) torque.
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork, and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l and ti ghten cl utch housi ng-to-engi ne
bol ts to 38 Nm (28 ft. l bs.) torque (Fi g. 10). Be sure
the housing is properly seated on engine block
before tightening bolts.
(8) I nstal l cl utch housi ng brace rod.
(9) Lower transmi ssi on approxi matel y 78 cm (3
i n.) for access to shi ft tower. Be sure transmi ssi on i s
i n fi rst or thi rd gear.
(10) Reach up and around transmi ssi on and i nsert
shi ft l ever i n shi ft tower. Press l ever retai ner down-
ward and turn i t cl ockwi se to l ock i t i n pl ace. Then
i nstal l l ever dust boot on shi ft tower.
Fig. 9 Removing/Installing Shift Lever
(11) I nstal l rear crossmember. Ti ghten crossmem-
ber-to-frame bol ts to 41 Nm (31 ft. l bs.) torque.
(12) I nstal l fasteners to hol d rear cushi on and
bracket to transmi ssi on. Then ti ghten transmi ssi on-
to-rear support bol ts/nuts to 45 Nm (33 ft. l bs.)
torque.
(13) Remove support stands from engi ne and
transmi ssi on.
(15) Posi ti on transfer case on transmi ssi on jack, i f
equi pped.
(16) Secure transfer case to jack wi th safety
chai ns, i f equi pped.
(17) Rai se transfer case, i f equi pped, and al i gn
transfer case i nput shaft to the transmi ssi on output
shaft.
(18) Sl i de transfer case forward unti l case i s
seated on transmi ssi on, i f necessary.
(19) I nstal l nuts to attach transfer case to trans-
mi ssi on, i f equi pped. Ti ghten transfer case-to-trans-
mi ssi on nuts to 35 Nm (26 ft. l bs.) torque.
(20) Connect transfer case shi ft l i nkage at transfer
case, i f equi pped.
(21) Connect transfer case vent hose, i f equi pped.
(22) Secure wi re harnesses i n cl i ps/ti e straps on
transmi ssi on and transfer case, i f equi pped.
(23) Engage wi re connectors attached to al l neces-
sary transmi ssi on or transfer case, i f equi pped, com-
ponents.
(24) I nstal l rear propel l er shaft sl i p yoke to trans-
mi ssi on or transfer case, i f equi pped, output shaft.
(25) Al i gn marks on rear propel l er shaft and rear
axl e yokes (Fi g. 11).
(27) Al i gn marks on front propel l er shaft, axl e,
and transfer case yokes, i f equi pped.
(29) I nstal l sl ave cyl i nder i n cl utch housi ng.
(30) I nstal l ski d pl ate, i f equi pped. Ti ghten bol ts to
42 Nm (31 ft. l bs.) torque. Ti ghten stud nuts to 17
(31) Fi l l transmi ssi on and transfer case, i f
equi pped, wi th recommended l ubri cants. Refer to the
Lubri cant Recommendati on secti ons of the appropri -
ate component for correct fl ui d.
FRONT BEARING RETAINER SEAL
REMOVAL
(1) Remove rel ease beari ng and l ever from the
transmi ssi on.
(3) Remove the front beari ng retai ner from the
(4) Usi ng a sui tabl e pry tool , remove the front
beari ng retai ner seal .
INSTALLATION
8209, i nstal l new seal i n to the front beari ng retai ner
(Fi g. 12).
(2) Remove any resi dual gasket materi al from the
seal i ng surfaces of the beari ng retai ner and the
(3) I nstal l new front beari ng retai ner gasket to the
(4) I nstal l the front beari ng retai ner onto the
Fig. 11 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks
(5) I nstal l the bol ts to hol d the beari ng retai ner
onto the transmi ssi on case.
(6) Ti ghten the bol ts to 17 Nm (12 ft. l bs.).
(7) I nstal l rel ease beari ng and l ever onto the
transmi ssi on.
EXTENSION HOUSING SEAL
REMOVAL
(2) Remove propel l er shaft. Refer to Group 3, Di f-
ferenti al and Dri vel i ne, for proper procedures.
(3) Usi ng a sui tabl e seal pul l er or screw wi th a
sl i de hammer, remove the extensi on housi ng seal
(Fi g. 13).
INSTALLATION
(1) Cl ean seal bore of extensi on housi ng of any
8212, i nstal l new extensi on housi ng seal so that the
seal i s l ocated 0 0.5 mm (0 0.02 i n.) to the face
of the extensi on housi ng (Fi g. 14).
(3) I nstal l propel l er shaft. Refer to Group 3, Di ffer-
enti al and Dri vel i ne, for proper procedures.
REMOVAL
(1) Hoi st and support vehi cl e.
(3) Usi ng a sui tabl e pry tool , or a sl i de hammer
mounted screw, remove the adapter housi ng seal
(Fi g. 15).
INSTALLATION
(1) Cl ean seal bore of adapter housi ng of any
8208, i nstal l new seal so that the seal i s l ocated 0
0.2 mm (0 0.008 i n.) to the seal bore face of
adapter housi ng (Fi g. 16).
Fig. 13 Remove Extension Housing Seal
Fig. 14 Install Extension Housing Seal
Fig. 15 Remove Adapter Housing Seal
BEARING RETAINER
DISASSEMBLY
(1) Drai n transmi ssi on l ubri cant, i f necessary.
(2) Remove rel ease beari ng and l ever.
(3) Remove cl utch housi ng bol ts and remove hous-
i ng (Fi g. 19).
(4) Remove vehi cl e speed sensor and speedometer
adapter, i f necessary.
(5) Remove bol ts hol di ng shi ft tower to transmi s-
si on case.
(6) Remove shi ft tower from transmi ssi on case
(Fi g. 17).
(7) Remove shi ft tower gasket from shi ft tower or
(8) Remove reverse shi ft head detent bal l pl ug
(Fi g. 20).
(9) Remove detent bal l spri ng and bal l wi th penci l
magnet (Fi g. 21), (Fi g. 22).
Fig. 16 Install Adapter Housing Seal
Fig. 17 Remove Shift Tower
Fig. 18 Remove Shift Tower Gasket
(10) Remove shi ft arm retai ner bol t (Fi g. 23).
(11) Remove shi ft arm restri ctor pi ns (Fi g. 24).
(12) Remove shi ft l ever shaft pl ug (Fi g. 25).
(13) Remove shi fter shaft wi th l arge magnet (Fi g.
26).
(14) Remove the shi ft arm from the adapter hous-
i ng.
Fig. 20 Remove Detent Ball Plug
Fig. 21 Remove Detent Spring
Fig. 22 Remove Detent Ball
Fig. 23 Shift Arm Retainer Bolt Removal
Fig. 24 Shift Arm Rstrictor Pins
Fig. 25 Removing Shift Lever Shaft Plug
(15) Remove adapter/extensi on housi ng bol ts (Fi g.
27).
(16) Loosen adapter/extensi on housi ng by tappi ng
i t l oose wi th pl asti c mal l et (Fi g. 28).
(17) Remove adapter/extensi on housi ng (Fi g. 29).
(a) Remove speedometer gear retai ni ng snap-
ri ng from output shaft.
(b) Remove speedometer gear from output shaft
and remove speedometer gear l ock bal l from output
shaft.
(c) Remove speedometer dri ve gear l ocati ng
snap-ri ng (Fi g. 30).
(20) Remove the beari ng retai ner from transmi s-
si on case (Fi g. 31).
(21) Remove i nput shaft beari ng snap-ri ng (Fi g.
32).
(22) Remove cl uster gear beari ng snap-ri ng (Fi g.
33).
(23) Separate i ntermedi ate pl ate and transfer case
by tappi ng them l oose wi th pl asti c mal l et (Fi g. 34).
(24) Separate the i ntermedi ate pl ate from the
Fig. 26 Remove Shifter Shaft
Fig. 27 Adapter/Extension Housing Bolts
ASSEMBLY
(1) Remove any resi dual seal er from transmi ssi on
case, i ntermedi ate pl ate, adapter/extensi on housi ng,
and front beari ng retai ner.
ond Li qui d Gasket TB1281, P/N 83504038, as
shown, maki ng sure to keep seal er bead to i nsi de of
bol t hol es (Fi g. 36).
Fig. 28 Loosen Adapter/Extension Housing
Fig. 29 Remove Adapter/Extension Housing
Fig. 31 Remove Front Bearing Retainer
Fig. 32 Remove Input Shaft Bearing Snap-ring
Fig. 33 Remove Cluster Gear Snap-ring
(3) Al i gn geartrai n and shi ft rai l s wi th mati ng
hol es i n transmi ssi on case and i nstal l transmi ssi on
case to the i ntermedi ate pl ate (Fi g. 37). Veri fy that
the transmi ssi on case i s seated on the i ntermedi ate
pl ate.
(4) I nstal l new front beari ng snap ri ngs (Fi g. 38).
(5) Appl y 1/8 i nch wi de bead of Threebond Li qui d
Gasket TB1281, P/N 83504038, to the front beari ng
retai ner seal i ng surface.
(6) I nstal l the front beari ng retai ner (Fi g. 39) and
ti ghten bol ts to 17 Nm (12 ft. l bs.).
(a) I nstal l speedometer dri ve gear l ocati ng snap-
ri ng (Fi g. 40).
(b) I nstal l speedometer gear l ock bal l i n output
shaft and i nstal l speedometer gear onto output
shaft.
(c) I nstal l speedometer gear retai ni ng snap-ri ng
onto output shaft.
Fig. 34 Separate Intermediate Plate and
Transmission Case
Fig. 35 Remove Intermediate Plate from
Transmission Case
Fig. 36 Apply Sealer to Transmission Gear Case
Fig. 37 Install Transmission Gear Case to the
Intermediate Plate
Fig. 38 Install Front Bearing Snap-rings
ond Li qui d Gasket TB1281, P/N 83504038, to seal -
i ng surface of adapter/extensi on housi ng, maki ng
sure to keep seal er bead to i nsi de of bol t hol es.
(9) I nstal l adapter or extensi on housi ng on i nter-
medi ate pl ate (Fi g. 41). Ti ghten housi ng bol ts to 37
(10) Posi ti on shi ft arm i n shi fter tower openi ng of
adapter[e]xtensi on housi ng (Fi g. 42). Be sure that
the shi fter arm i s engaged i nto the shi ft rai l s.
(11) Start shi fter arm shaft i n hol e i n back of
adapter[e]xtensi on housi ng. Al i gn shi ft arm and
shi fter arm shaft and i nsert shi fter arm shaft
through the shi fter arm and i nto the forward porti on
of the adapter[e]xtensi on housi ng (Fi g. 43).
(12) Rotate the shi fter arm shaft unti l the hol e i n
the shi ft arm i s al i gned wi th the hol e i n the shaft.
(13) I nstal l the shi ft arm retai ner bol t and ti ghten
to 38 Nm (28 ft. l bs.) (Fi g. 44).
(14) I nstal l and ti ghten shi fter arm shaft pl ug to
Fig. 41 Install Adapter/Extension Housing
Fig. 42 Position Shift Arm in Transmission Case
Fig. 43 Install Shifter Arm Shaft
(15) I nstal l shi fter restri ctor pi ns i n shi ft tower
and ti ghten to 27 Nm (20 ft. l bs.) (Fi g. 46).
(16) I nstal l shi ft detent bal l i n detent openi ng (Fi g.
47).
(17) I nstal l detent spri ng (Fi g. 48).
(18) I nstal l detent pl ug and ti ghten to 19 Nm (14
ft. l bs.) (Fi g. 49).
Fig. 44 Install Shift Arm Retainer Bolt
Fig. 45 Shifter Arm Shaft Plug Installation
Fig. 46 Install Shifter Restrictor Pins
Fig. 47 Install Detent Ball
Fig. 48 Install Detent Spring
(19) I nstal l shi ft tower and new gasket on housi ng
(Fi g. 50). Ti ghten tower bol ts to 18 Nm (13 ft. l bs.)
torque.
(20) I nstal l new metal o-ri ng to the backup l amp
swi tch.
(21) I nstal l backup l amp swi tch (Fi g. 50). Ti ghten
swi tch to 37 Nm (27 ft. l bs.) torque.
(22) I nstal l new seal i n adapter/extensi on housi ng.
(23) I nstal l vehi cl e speed sensor, i f necessary.
(24) I nstal l cl utch housi ng, rel ease beari ng, rel ease
fork and retai ner cl i p.
SHIFT MECHANISM AND GEARTRAIN
DISASSEMBLY
(1) I nstal l sui tabl e bol ts and washers i n i ntermedi -
ate pl ate (Fi g. 51). Then cl amp pl ate and gear assem-
bl y i n vi se. Use enough washers to prevent bol ts
from touchi ng. Al so be sure vi se jaws are cl amped on
bol t heads.
Fig. 50 Installing Shift Tower And Backup Lamp
Switch
Fig. 51 Positioning Intermediate Plate In Vise
Fig. 49 Install Detent Ball Plug
(2) Measure thrust cl earance between countershaft
fi fth gear and thrust ri ng wi th feel er gauge. Cl ear-
ance shoul d be 0.10 to 0.40 mm (0.003 to 0.019 i n.).
I f cl earance exceeds l i mi ts, gear and/or ri ng wi l l have
to be repl aced.
(3) Remove countershaft fi fth gear retai ni ng snap-
ri ng (Fi g. 52).
(4) Remove bol t hol di ng fi fth gear shi ft fork to
(5) Move fi fth gear shi ft rai l forward unti l the rai l
i s cl ear of the shi ft fork.
(6) Remove the fi fth gear shi ft fork from the syn-
chroni zer sl eeve (Fi g. 54).
(7) Remove the reverse shi ft head and rai l assem-
bl y from the i ntermedi ate pl ate (Fi g. 55).
(8) Remove fi fth gear bl ocker ri ng from counter-
shaft assembl y wi th Pul l er L-4407 (Fi g. 56).
(9) Remove fi fth gear synchro ri ng (Fi g. 57).
(10) Remove the countershaft fi fth gear assembl y
from countershaft (Fi g. 58).
Fig. 53 Remove Fifth Gear Shift Fork Retainer Bolt
Fig. 54 Remove Fifth Gear Shift Fork
Fig. 55 Remove Reverse Shift Head Assembly
(11) Remove fi fth gear thrust ri ng from counter-
shaft (Fi g. 59).
(12) Remove fi fth gear thrust ri ng l ock bal l from
NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.
Fig. 56 Remove Fifth Gear Blocker Ring
Fig. 57 Remove Fifth Gear Synchro Ring
Fig. 58 Remove Fifth Gear And Synchro Assembly
Fig. 59 Remove Fifth Gear Thrust Ring
Fig. 60 Remove Fifth Gear Thrust Ring Lock Ball
(13) Remove bol ts hol di ng output shaft rear bear-
i ng retai ner to i ntermedi ate pl ate (Fi g. 61).
(14) Remove rear beari ng retai ner (Fi g. 62).
(15) Remove reverse i dl er gear shaft and gear (Fi g.
63).
(16) Remove bol ts hol di ng reverse shi ft arm
bracket to i ntermedi ate pl ate (Fi g. 64).
(17) Remove threaded l ock bal l pl ugs from i nter-
medi ate pl ate (Fi g. 65).
(18) Then remove l ock bal l and spri ng from pl ug
hol es wi th penci l magnet (Fi g. 66).
Bolts
Fig. 63 Remove Reverse Idler Shaft And Gear
Fig. 64 Reverse Shift Arm Components
Fig. 65 Lock Ball Plug Locations
(19) Remove the fi fth gear shi ft rai l (Fi g. 67).
(20) Retri eve the fi fth gear shi ft rai l l ock bal l from
the i ntermedi ate pl ate usi ng a magnet (Fi g. 68).
Fig. 66 Remove Lock Ball And Spring
Fig. 67 Shift Rail Identification
Fig. 68 Remove Fifth Gear Shift Rail Lock Ball
(21) Remove the 12 and 34 shi ft rai l c-ri ngs
usi ng two equal l y si zed screwdri vers (Fi g. 69).
(22) Remove bol ts hol di ng 12 and 34 shi ft forks
to the shi ft rai l s (Fi g. 70) and di scard bol ts.
(23) Remove the 34 shi ft rai l from the 12 and
34 shi ft forks and the i ntermedi ate pl ate (Fi g. 71).
(24) Remove the 34 shi ft rai l i nterl ock pl ug from
the i ntermedi ate pl ate wi th a smal l magnet (Fi g. 72).
(25) Remove the 34 shi ft fork (Fi g. 73).
Fig. 69 Remove Shift Rail C-rings
Fig. 70 Remove Shift Fork To Shift Rail Bolts
Fig. 71 Remove 34 Shift Rail
Fig. 72 Remove 34 Shift Rail Interlock Plug
(26) Remove the 12 shi ft rai l from the 12 shi ft
fork and the i ntermedi ate pl ate (Fi g. 74).
(27) Remove the 12 shi ft rai l i nterl ock pi n from
the 12 shi ft rai l (Fi g. 75).
(28) Remove the 12 shi ft rai l i nterl ock pl ug from
the i ntermedi ate pl ate (Fi g. 76).
(29) Remove the 12 shi ft fork (Fi g. 73).
(30) Remove the c-ri ng hol di ng the reverse shi ft
rai l i nto the i ntermedi ate pl ate usi ng two equal l y
si zed screwdri vers (Fi g. 77).
(31) Remove the reverse shi ft rai l and fork from
the i ntermedi ate pl ate (Fi g. 78).
(32) Remove the i nterl ock pi n from the reverse
(33) Remove snap-ri ng hol di ng output shaft rear
(34) Remove countershaft rear beari ng snap-ri ng.
(35) Wi th ai d of an assi stant, support the mai n-
shaft and countershaft. Tap on the rear of the mai n-
shaft and countershaft wi th a sui tabl e rubber mal l et.
Thi s wi l l rel ease the countershaft from the counter-
shaft rear beari ng and the mai nshaft rear beari ng
from the i ntermedi ate pl ate. The mai nshaft wi l l
rel ease from the i ntermedi ate pl ate fi rst and can be
removed by movi ng the mai nshaft rearward and
upward (Fi g. 81).
Fig. 73 Remove Shift Forks
Fig. 74 Remove 12 Shift Rail
Fig. 75 Remove 12 Shift Rail Interlock Pin
Fig. 76 Remove 12 Shift Rail Interlock Plug
(36) Remove the countershaft by movi ng the coun-
tershaft rearward unti l the countershaft i s cl ear of
the i ntermedi ate pl ate.
(37) Remove the countershaft rear beari ng from
ASSEMBLY
(1) Lubri cate countershaft journal and rear bear-
i ng wi th petrol eum jel l y or gear l ubri cant.
(2) Posi ti on the mai nshaft i nto the i ntermedi ate
pl ate.
Fig. 77 Remove Reverse Shift Rail C-ring
Fig. 78 Remove Reverse Shift Rail
Fig. 79 Remove Reverse Shift Rail Interlock Pin
Fig. 80 Remove Output Shaft Rear Bearing
Snap-ring
Fig. 81 Remove Mainshaft
(3) Tap the mai nshaft assembl y rear beari ng i nto
the i ntermedi ate pl ate wi th a sui tabl e rubber mal l et.
(4) I nstal l the countershaft thru the countershaft
rear beari ng journal of the i ntermedi ate pl ate.
(5) Al i gn and mesh the mai nshaft and counter-
shaft gears as much as possi bl e.
(6) I nstal l the countershaft beari ng over the coun-
tershaft beari ng boss and i nto the i ntermedi ate pl ate.
Be sure to l eave the snap-ri ng groove i n the beari ng
faci ng the rear of the uni t. I t may be necessary to tap
on the beari ng wi th a pl asti c mal l et to ful l y seat the
beari ng i nto i ntermedi ate pl ate.
(7) Veri fy that the mai nshaft and countershaft
gears are correctl y meshed and rotate properl y.
(8) I nstal l snap-ri ng to hol d output shaft rear
(9) I nstal l countershaft rear beari ng snap-ri ng.
NOTE: Coat all shift components with petroleum
jelly during assembly. Petroleum jelly will hold com-
ponents in position during installation.
(10) I nstal l i nterl ock pi n i n reverse shi ft rai l (Fi g.
82).
(11) I nstal l the reverse shi ft rai l i n the i ntermedi -
ate pl ate (Fi g. 83).
(12) I nstal l c-ri ng to hol d the reverse shi ft rai l i nto
(13) I nstal l the 12 and 34 shi ft forks i nto the
synchroni zer sl eeves (Fi g. 84).
(14) I nstal l 12 shi ft rai l i nterl ock pl ug i n the
(15) I nstal l i nterl ock pi n i n 12 shi ft rai l (Fi g. 86).
(16) I nstal l 12 shi ft rai l through i ntermedi ate
pl ate and 12 shi ft fork (Fi g. 87).
(17) I nstal l 34 shi ft rai l i nterl ock pl ug i nto the
(18) I nstal l the 34 shi ft rai l through the i nterme-
di ate pl ate, 12 and 34 shi ft forks (Fi g. 89).
Fig. 82 Install Reverse Shift Rail Interlock Pin
Fig. 83 Install Reverse Shift Rail
Fig. 84 Install Shift Forks
(19) I nstal l new bol ts to hol d the shi ft forks to the
(20) I nstal l c-ri ngs to 12 and 34 shi ft rai l s (Fi g.
91).
(21) I nstal l the fi fth gear shi ft rai l l ock bal l i n the
(22) I nstal l the fi fth gear shi ft rai l i nto the i nter-
medi ate pl ate.
Fig. 85 Install 12 Shift Rail Interlock Plug
Fig. 86 Install 12 Shift Rail Interlock Pin
Fig. 87 Install 12 Shift Rail
Fig. 88 Install 34 Shift Rail Interlock Plug
Fig. 89 Install 34 Shift Rail
Fig. 90 Install Shift Fork To Shift Rail Bolts
(23) I nstal l reverse i dl er gear and i dl er gear shaft
(Fi g. 92). Veri fy that the notch i n the i dl er shaft i s to
the rear of the transmi ssi on.
(24) Posi ti on output shaft rear beari ng retai ner on
i ntermedi ate pl ate and i nto reverse i dl er shaft notch.
(25) I nstal l new bol ts to hol d retai ner to i nterme-
di ate pl ate (Fi g. 93).
(26) I nstal l the fi fth gear thrust ri ng l ock bal l i nto
the countershaft (Fi g. 95).
(27) I nstal l fi fth gear thrust ri ng onto countershaft
and over l ock bal l (Fi g. 96).
(28) I nstal l countershaft fi fth gear beari ng hal ves
i nto countershaft fi fth gear assembl y (Fi g. 97).
(29) I nstal l countershaft fi fth gear assembl y onto
(30) I nstal l fi fth gear synchroni zer ri ng (Fi g. 99).
(31) Posi ti on fi fth gear bl ocker ri ng onto counter-
shaft. Veri fy that bl ocker ri ng and countershaft
spl i nes are al i gned.
(32) Usi ng a sui tabl e dri ver and mal l et, seat the
bl ocker ri ng onto the countershaft.
(33) Sel ect the thi ckest snap-ri ng the wi l l fi t i nto
the snapri ng groove of the countershaft.
(34) I nstal l snap-ri ng to hol d the countershaft fi fth
gear assembl y onto the countershaft (Fi g. 100).
Fig. 91 Install Shift Rail C-rings
Fig. 92 Install Reverse Idler Gear And Shaft
Fig. 93 Install Output Shaft Rear Bearing Retainer
Fig. 94 Install Fifth Gear Shift Rail Lock Ball
Fig. 95 Install Fifth Gear Thrust Ring Lock Ball
(35) I nstal l the reverse shi ft head and rai l assem-
bl y (Fi g. 101).
(36) Move reverse shi ft rai l forward as far as pos-
si bl e and i nstal l fi fth gear shi ft fork onto synchro-
ni zer sl eeve (Fi g. 102).
(37) I nstal l new bol t to hol d fi fth gear shi ft fork to
(38) I nstal l detent bal l s and spri ngs i nto openi ngs
i n the i ntermedi ate pl ate (Fi g. 104).
(39) I nstal l new l ock bal l pl ugs i nto the i ntermedi -
ate pl ate. Ti ghten pl ugs to 19 Nm (14 ft. l bs.).
Fig. 96 Install Fifth Gear Thrust Ring
Fig. 97 Install Countershaft Fifth Gear Bearings
Fig. 98 Install Countershaft Fifth Gear Assembly
Fig. 99 Install Fifth Gear Synchronizer Ring
Fig. 100 Install Fifth Gear Snap-ring
(40) I nstal l bol ts to hol d reverse shi ft arm to the
i ntermedi ate pl ate. Ti ghten bol ts to 18 Nm (13 ft.
l bs.).
COUNTERSHAFT
DISASSEMBLY
(1) Remove sel ect fi t snap-ri ng hol di ng the coun-
tershaft front beari ng onto the countershaft (Fi g.
105).
(2) Usi ng Beari ng Spl i tter P-334, a sui tabl e spacer
on center of countershaft, and a shop press, remove
the countershaft front beari ng from the countershaft.
ASSEMBLY
(1) Remove any ni cks or burrs on countershaft hub
wi th fi ne emery or crocus cl oth.
(2) Posi ti on countershaft front beari ng on end of
countershaft. Be sure the snap-ri ng groove i n beari ng
i s faci ng forward.
(3) Usi ng Speci al Tool 8109 and a shop press,
press beari ng onto countershaft.
the snap-ri ng groove of the countershaft (Fi g. 105).
(5) I nstal l snap-ri ng to hol d countershaft front
beari ng onto countershaft.
Fig. 101 Install Reverse Shift Head And Rail
Assembly
Fig. 102 Install Fifth Gear Shift Fork
Fig. 103 Install Fifth Gear Shift Fork Retainer Bolt
Fig. 104 Install Detent Balls And Springs
INPUT SHAFT
DISASSEMBLY
(1) Veri fy that the 34 synchroni zer i s i n the neu-
tral posi ti on.
(2) Separate i nput shaft from output shaft (Fi g.
106).
(3) Remove the output shaft pi l ot beari ng from the
i nput shaft or output shaft (Fi g. 107).
(4) Remove the fourth gear synchroni zer ri ng from
the i nput shaft (Fi g. 108).
(5) Remove the sel ect fi t snap-ri ng hol di ng the
i nput shaft beari ng onto the i nput shaft.
(6) Usi ng Beari ng Spl i tter P-334 and a shop press,
remove the beari ng from the i nput shaft.
ASSEMBLY
(1) Posi ti on i nput shaft beari ng onto i nput shaft.
Be sure that the snap-ri ng groove i n the beari ng i s
faci ng forward.
(2) Usi ng Dri ver 6052, dri ve beari ng onto i nput
shaft.
the snap-ri ng groove of the i nput shaft (Fi g. 109).
(4) Lubri cate output shaft pi l ot beari ng bore of
i nput shaft wi th petrol eum jel l y.
(5) I nstal l output shaft pi l ot beari ng i n i nput shaft
bore (Fi g. 107).
(6) I nstal l the fourth gear synchroni zer ri ng onto
the i nput shaft.
(7) I nstal l i nput shaft to output shaft.
OUTPUT SHAFT
Refer to (Fi g. 110) for parts i denti fi cati on duri ng
di sassembl y and assembl y of the output shaft.
Fig. 105 Countershaft Front Bearing Snap-ring
Fig. 106 Separate Input and Output Shafts
Fig. 107 Remove Output Shaft Pilot Bearing
Fig. 108 Input Shaft Components
DISASSEMBLY
(1) Remove i nput shaft and output shaft pi l ot
beari ng from output shaft (Fi g. 111), i f necessary.
(2) Measure and note thrust cl earance of output
shaft gears (Fi g. 112). Fi rst gear cl earance shoul d be
0.10 0.40 mm (0.004 0.0197 i n.). Second and thi rd
gear cl earance shoul d be 0.10 0.30 mm (0.003
0.0118 i n.).
(3) Remove output shaft fi fth gear snap ri ng wi th
two screwdri vers (Fi g. 113).
pl ates posi ti oned under fi rst gear, press fi fth gear,
Fig. 110 Output Shaft And Gears
Fig. 109 Select Input Shaft Bearing Snap-ring
Fig. 111 Remove Output Shaft Pilot Bearing
rear beari ng, fi rst gear, and fi rst gear thrust washer
off output shaft (Fi g. 114).
(5) Remove fi rst gear thrust washer l ocati ng pi n
from output shaft.
(6) Remove fi rst gear needl e rol l er beari ng from
output shaft.
(7) Remove fi rst gear spacer from output shaft.
(8) Remove fi rst gear synchroni zer ri ng.
synchroni zer/reverse gear onto the output shaft.
pl ates posi ti oned under second gear, press 12 syn-
chroni zer/reverse gear and second gear from output
shaft (Fi g. 115).
(11) Remove second gear needl e rol l er beari ng
from the output shaft or second gear.
Fig. 112 Check Output Shaft Gear Thrust Clearance
Fig. 114 Remove Fifth Gear, First Gear Bearing, And
Thrust Washer
Fig. 115 Remove Second Gear And 12
Synchronizer/Reverse Gear
synchroni zer onto the output shaft (Fi g. 116).
pl ates posi ti oned under thi rd gear, press the 34 syn-
chroni zer and thi rd gear from output shaft (Fi g. 117).
(14) Remove thi rd gear needl e rol l er beari ng from
output shaft or gear.
ASSEMBLY
(1) Lubri cate transmi ssi on components wi th speci -
fi ed gear l ubri cant duri ng assembl y.
(2) I f necessary, assembl e 12 and 34 synchro-
ni zer hubs, sl eeves, spri ngs and key i nserts (Fi g.
118).
(3) I nstal l thi rd gear needl e beari ng onto the out-
put shaft.
(4) I nstal l thi rd gear over beari ng and onto output
shaft fl ange.
(5) I nstal l thi rd gear synchroni zer ri ng to thi rd
gear.
(6) Posi ti on the 34 synchroni zer onto the output
shaft.
(7) Usi ng Adapter 6761 and a shop press, press
the 34 synchroni zer onto the output shaft.
(9) I nstal l snap-ri ng to hol d 34 synchroni zer onto
output shaft.
(10) Veri fy thi rd gear thrust cl earance wi th feel er
gauge (Fi g. 120). Cl earance shoul d be 0.10 0.30 mm
(0.003 0.0118 i n.). I f cl earance i s out of speci fi ca-
ti on, refer to Cl eani ng and I nspecti on secti on wi thi n
thi s group.
(11) I nstal l second gear needl e beari ng onto output
shaft.
(12) I nstal l second gear over beari ng and onto out-
put shaft fl ange.
(13) I nstal l second gear synchroni zer ri ng onto sec-
ond gear.
(14) Posi ti on 12 synchroni zer/reverse gear assem-
bl y onto spl i nes of output shaft.
(15) Usi ng Dri ver MD-998805, Adapter 6761, and
a shop press, press the 12 synchroni zer/reverse gear
onto the output shaft.
Fig. 116 Remove 34 Synchronizer Snap Ring
Fig. 117 Remove 34 Synchronizer And Third Gear
Fig. 118 Synchronizer Identification
(17) I nstal l snap-ri ng to hol d 12 synchroni zer/re-
verse gear onto output shaft.
(18) I nstal l fi rst gear synchroni zer ri ng i nto 12
synchroni zer/reverse gear.
(19) I nstal l the fi rst gear spacer onto the i nput
shaft and agai nst the 12 synchroni zer/reverse gear
snap-ri ng.
(20) I nstal l fi rst gear needl e beari ng onto output
shaft (Fi g. 122).
(21) I nstal l fi rst gear onto output shaft and over
beari ng.
(22) I nstal l the fi rst gear thrust washer l ocati ng
pi n i nto the output shaft.
(23) I nstal l the fi rst gear thrust washer onto the
output shaft. Rotate the thrust washer unti l the
washer l ocati ng pi n al i gns wi th the notch i n the
washer.
(24) Posi ti on output shaft rear beari ng onto output
shaft. Ensure that the snap ri ng groove i n beari ng
outer race i s toward rear of output shaft.
(25) Usi ng Dri ver L-4507 and sui tabl e mal l et,
dri ve beari ng onto output shaft.
(26) I nstal l snap-ri ng onto output shaft rear bear-
i ng outer race.
(27) Check fi rst and second gear thrust cl earance
(Fi g. 123). Fi rst gear cl earance shoul d be 0.10 0.40
mm (0.003 0.0197 i n.). Second gear cl earance
shoul d be 0.10 0.30 mm (0.003 0.0118 i n.). I f
Fig. 119 Select 34 Synchronizer Snap-ring
Fig. 120 Check Third Gear Clearance
Fig. 121 Second Gear And Synchronizer Assembly
Fig. 122 First And Fifth Gear Components
cl earance i s out of speci fi cati on, refer to Cl eani ng and
I nspecti on secti on wi thi n thi s group.
(28) Posi ti on fi fth gear onto output shaft wi th the
gears l ong shoul der toward the rear of shaft. Ensure
that the gear and output shaft spl i nes are al i gned.
(29) Usi ng Adapter 6761, Dri ver L-4507, and a
shop press, press fi fth gear onto output shaft.
(31) I nstal l snap-ri ng to hol d fi fth gear onto output
shaft.
(32) I nstal l output shaft pi l ot beari ng i nto the
i nput shaft.
(33) I nstal l the i nput shaft to the output shafts.
AX15 MANUAL TRANSMISSION COMPONENTS
GENERAL INFORMATION
Cl ean the transmi ssi on components i n sol vent. Dry
the cases, gears, shi ft mechani sm and shafts wi th
compressed ai r. Dry the beari ngs wi th cl ean, dry
shop towel s onl y. Never use compressed ai r on the
beari ngs. Thi s coul d cause severe damage to the
beari ng rol l er and race surfaces.
I f output shaft fl ange thi ckness i s wi thi n speci fi ca-
ti on but any gear thrust cl earance i s out of speci fi ca-
ti on, repl ace the necessary gear and gear needl e
beari ng as an assembl y.
GEAR CASE, ADAPTER/EXTENSION HOUSING,
INTERMEDIATE PLATE
Cl ean the case, housi ng, and i ntermedi ate pl ate
wi th sol vent and dry wi th compressed ai r. Repl ace
the case i f cracked, porous, or i f any of the beari ng
and gear bores are damaged.
I nspect the threads i n the case, housi ng, and pl ate.
Mi nor thread damage can be repai red wi th steel
thread i nserts, i f necessary. Do not attempt to repai r
any threads whi ch show evi dence of cracks around
the threaded hol e.
OUTPUT SHAFT
Check thi ckness of the output shaft fl ange wi th a
mi crometer or verni er cal i pers (Fi g. 125). Mi ni mum
al l owabl e fl ange thi ckness i s 4.70 mm (0.185 i n.).
Check di ameter of the fi rst, second, and thi rd gear
beari ng surfaces on the output shaft. Mi ni mum
di ameters are as fol l ows:
Fi rst gear beari ng surface i s 38.86 mm (1.529
i n.).
Second gear beari ng surface i s 46.86 mm (1.844
i n.).
Thi rd gear beari ng surface i s 37.86 mm (1.490
i n.).
Fig. 123 Check FirstSecond Gear Thrust Clearance
Fig. 124 Select/Install Fifth Gear Snap Ring
Measure output shaft runout wi th a di al i ndi cator
and V-bl ocks (Fi g. 125). Runout shoul d not exceed
0.06 mm (0.0024 i n.).
Repl ace output shaft i f measurement of any sur-
face i s out of speci fi cati on. Do not attempt to repai r
out of speci fi cati on components.
COUNTERSHAFT
I nspect the countershaft gear teeth. Repl ace the
countershaft i f any teeth are worn or damaged.
I nspect the beari ng surfaces and repl ace shaft i f any
surface shows damage or wear.
Check condi ti on of the countershaft front beari ng.
Repl ace the beari ng i f worn, noi sy, or damaged.
GEAR AND SYNCHRONIZER
I nstal l the needl e beari ngs i n the fi rst, second,
thi rd and counter fi fth gears. I nstal l the gears on the
output shaft. Then check oi l cl earance between the
gears and shaft wi th a di al i ndi cator (Fi g. 126). Oi l
cl earance for al l three gears i s 0.16 mm (0.0063 i n.)
maxi mum.
Check synchroni zer ri ng wear (Fi g. 127). I nsert
each ri ng i n matchi ng gear. Measure cl earance
between each ri ng and gear wi th feel er gauge. Cl ear-
ance shoul d be 0.06 1.6 mm (0.024 0.063 i n.).
Check shi ft forktosynchroni zer hub cl earance
wi th a feel er gauge (Fi g. 128). Repl ace the fork i f
cl earance exceeds 1.0 mm (0.039 i n.).
Check the condi ti on of the reverse i dl er gear bush-
i ng (Fi g. 129). Repl ace the gear i f the bushi ng i s
damaged or worn.
Fig. 125 Check Output Shaft Tolerances
Fig. 126 Check GearToShaft Oil Clearance
Fig. 127 Check Synchronizer Ring Wear
Fig. 128 Check ForkToHub Clearance
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ugs, Access . . . . . . . . . . . . . . . . 19 Nm (14 ft.l bs.)
Bol ts, Adapter Housi ng . . . . . . . . 34 Nm (25 ft.l bs.)
Swi tch, Back-up Li ght . . . . . . . 44 Nm (32.5 ft.l bs.)
Pl ugs, Drai n and Fi l l . . . . . . . . 44 Nm (32.5 ft.l bs.)
Bol ts, Front Beari ng Retai ner . . . 17 Nm (12 ft.l bs.)
Pl ugs, I nterl ock and Detent . . . . . 19 Nm (14 ft.l bs.)
Screws, Propel l er Shaft Cl amp . . . . . . . . 1623 Nm
(140200 i n.l bs.)
Bol ts, Rear Mount to Transmi ssi on . . . . 3360 Nm
(2444 ft.l bs.)
Nut, Rear Mount Cl evi s . . 5475 Nm (4055 ft.l bs.)
Nuts, Rear Mount to Crossmember . . . . 3349 Nm
(2436 ft.l bs.)
Pi ns, Restri ctor . . . . . . . . . . . . . 27.4 Nm (20 ft.l bs.)
Bol ts, Reverse Shi ft Arm Bracket . . . . . . . . . 18 Nm
(13 ft.l bs.)
Screw, Shi ft Arm Set . . . . . . . . . . 38 Nm (28 ft.l bs.)
Screws, Shi ft Fork Set . . . . . . . . . 20 Nm (15 ft.l bs.)
Nut, Shi ft Knob . . . . . . . . 2034 Nm (1525 ft.l bs.)
Screws, Shi fter Fl oor Cover . . . . . . . . . . . . 23 Nm
(1730 i n.l bs.)
Bol ts, Shi ft Tower . . . . . . . . . . . . 18 Nm (13 ft.l bs.)
Nuts, Transfer Case Mounti ng . . . . . . . . 3041 Nm
(2230 ft.l bs.)
SPECIAL TOOLS
AX15
Fig. 129 Reverse Idler Gear Bushing
C-4171 Handle, Universal Tool
L-4407A Puller, Gear
P-334 Splitter, Bearing
8109 Cup, Installer
6052 Tube, Driver
6761 Adapter, Installer
MD-998805 Tube, Driver
L-4507 Tube, Driver
AUTOMATIC TRANSMISSION30RH
INDEX
page page
GENERAL INFORMATION
30RH AUTOMATIC TRANSMISSION . . . . . . . . . . 74
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 74
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 74
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 74
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 76
RECOMMENDED FLUID . . . . . . . . . . . . . . . . . . . 74
TORQUE CONVERTERELECTRONIC
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . 76
TRANSMISSION IDENTIFICATION . . . . . . . . . . . 74
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CONVERTER CLUTCH ENGAGEMENT . . . . . . . 77
CONVERTER DRAINBACK VALVE . . . . . . . . . . . 77
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . . 76
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION . . . . . . . . . . . . . . . . . . . . . 82
ANALYZING ROAD TEST . . . . . . . . . . . . . . . . . . 79
AUTOMATIC TRANSMISSION DIAGNOSIS . . . . . 77
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
CONVERTER STALL TEST . . . . . . . . . . . . . . . . . 81
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . . . . . 83
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . 79
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 80
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 78
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . 77
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 79
STALL TEST ANALYSIS . . . . . . . . . . . . . . . . . . . 82
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . . 79
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 93
CONVERTER DRAINBACK CHECK VALVE
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
FLUID AND FILTER REPLACEMENT . . . . . . . . . 91
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . 91
FLUSHING COOLERS AND TUBES . . . . . . . . . . 93
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 92
TRANSMISSION FILL PROCEDURE . . . . . . . . . . 92
BRAKE TRANSMISSION SHIFT INTERLOCK . . 100
EXTENSION HOUSING . . . . . . . . . . . . . . . . . . . 98
EXTENSION HOUSING BUSHING . . . . . . . . . . . 97
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 100
GOVERNOR AND PARK GEAR . . . . . . . . . . . . 102
OUTPUT SHAFT REAR BEARING . . . . . . . . . . 102
PARK LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . . 98
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 96
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 94
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 100
YOKE SEAL REPLACEMENT . . . . . . . . . . . . . . . 97
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 126
FRONT SERVO PISTON . . . . . . . . . . . . . . . . . . 121
OIL PUMP AND REACTION SHAFT SUPPORT . . 123
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 130
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 127
REAR SERVO PISTON . . . . . . . . . . . . . . . . . . . 122
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 112
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 105
EXTENSION HOUSING AND PARK LOCK . . . . 136
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 139
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . . . 138
OIL PUMP AND REACTION SHAFT
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
DRUM/OVERDRIVE PISTON RETAINER . . . . 138
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . 140
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 139
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . . . 138
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 137
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ADJUSTMENTS
CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . 141
FRONT BAND ADJUSTMENT . . . . . . . . . . . . . . 142
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 140
REAR BAND ADJUSTMENT . . . . . . . . . . . . . . . 143
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 141
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . 143
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . 144
SPECIFICATIONS
30RH AUTOMATIC TRANSMISSION . . . . . . . . . 157
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
SPECIAL TOOLS
30RH TRANSMISSIONS . . . . . . . . . . . . . . . . . . 158
GENERAL INFORMATION
30RH AUTOMATIC TRANSMISSION
The 30RH automati c transmi ssi on i s used wi th the
2.5L engi ne (Fi g. 1). The 30RH i s a three speed
transmi ssi ons wi th a l ock-up cl utch i n the torque
converter. The torque converter cl utch i s control l ed
by the Powertrai n Control Modul e (PCM). The torque
converter cl utch i s hydraul i cal l y appl i ed and i s
rel eased when fl ui d i s vented from the hydraul i c ci r-
cui t by the torque converter control (TCC) sol enoi d
on the val ve body. The torque converter cl utch
engages i n thi rd gear when the vehi cl e i s crui si ng on
a l evel pl ane after the vehi cl e has warmed up. The
torque converter cl utch wi l l di sengage when the vehi -
cl e begi ns to go uphi l l or the accel erator i s appl i ed.
The torque converter cl utch feature i ncreases fuel
economy and reduces the transmi ssi on fl ui d temper-
ature. The 30RH transmi ssi on i s cool ed by an i nte-
gral fl ui d cool er i nsi de the radi ator.
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
orderi ng repl acement parts.
RECOMMENDED FLUID
Mopar ATF Pl us 3, Type 7176 automati c trans-
mi ssi on fl ui d i s the recommended fl ui d for Chrysl er
automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
EFFECTS OF INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve, cl utch and servo operati on. Foami ng al so
causes fl ui d expansi on whi ch can resul t i n fl ui d over-
fl ow from the transmi ssi on vent or fi l l tube. Fl ui d
overfl ow can easi l y be mi staken for a l eak i f i nspec-
ti on i s not careful .
CAUSES OF BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
FLUID CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to reverse fl ush cool er and l i nes after
repai r
fai l ure to repl ace contami nated converter after
repai r.
The use of non recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on for some ti me, an overhaul
may al so be necessary; especi al l y i f shi ft probl ems
had devel oped.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool -
ers as wel l . The torque converter shoul d al so be
repl aced whenever a fai l ure generates sl udge and
debri s. Thi s i s necessary because normal converter
fl ushi ng procedures wi l l not remove al l contami -
nants.
Fig. 1 30RH Automatic Transmission
TORQUE CONVERTER ELECTRONIC CLUTCH
The torque converter i s a hydraul i c devi ce that
coupl es the engi ne crankshaft to the transmi ssi on.
The torque converter consi sts of an outer shel l wi th
an i nternal turbi ne, a stator, an overrunni ng cl utch,
an i mpel l er and an el ectroni cal l y appl i ed converter
cl utch. Torque mul ti pl i cati on i s created when the sta-
tor di rects the hydraul i c fl ow from the turbi ne to
rotate the i mpel l er i n the di recti on the engi ne crank-
shaft i s turni ng. The turbi ne transfers power to the
pl anetary gear sets i n the transmi ssi on. The transfer
of power i nto the i mpel l er assi sts torque mul ti pl i ca-
ti on. At l ow vehi cl e speed, the overrunni ng cl utch
hol ds the stator (duri ng torque mul ti pl i cati on) and
al l ows the stator to free wheel at hi gh vehi cl e speed.
The converter cl utch provi des reduced engi ne speed
and greater fuel economy when engaged. Cl utch
engagement al so provi des reduced transmi ssi on fl ui d
temperatures. The converter cl utch engages i n thi rd
gear. The torque converter hub dri ves the transmi s-
si on oi l (fl ui d) pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
Forward gear rati os are:
2.74:1 (fi rst gear)
1.54:1 (second gear)
1.00:1 (thi rd gear)
GEARSHIFT MECHANISM
The shi ft mechani sm i s cabl e operated and pro-
vi des si x shi ft posi ti ons. The shi ft i ndi cator i s l ocated
on the consol e next to the gear shi ft. The shi ft posi -
ti ons are:
Park (P)
Reverse (R)
Neutral (N)
Dri ve (D)
Manual Second (2)
Manual Low (1)
Manual l ow (1) range provi des fi rst gear onl y. Over
run braki ng i s al so provi ded i n thi s range. Manual
second (2) range provi des fi rst and second gear onl y.
Dri ve range provi des fi rst, second, and thi rd gear
ranges.
HYDRAULIC CONTROL SYSTEM
The transmi ssi on hydraul i c control system per-
forms four basi c functi ons.
pressure suppl y
pressure regul ati on
fl ow control and l ubri cati on
cl utch/band appl i cati on
PRESSURE SUPPLY
The oi l pump devel ops fl ui d pressure for cl utch/
band appl i cati on and for l ubri cati on. The pump i s
dri ven by the torque converter. The converter i s
dri ven by a dri vepl ate attached to the engi ne crank-
shaft.
Pressure Regulation
The pressure regul ator val ve mai ntai ns l i ne (oper-
ati ng) pressure. The amount of pressure devel oped i s
control l ed by throttl e pressure whi ch i s dependent on
the degree of throttl e openi ng. The regul ator val ve i s
l ocated i n the val ve body.
The throttl e val ve determi nes throttl e pressure
and shi ft speed. Governor pressure i ncreases i n pro-
porti on to vehi cl e speed. The throttl e val ve control s
upshi ft and downshi ft speeds by regul ati ng pressure
accordi ng to throttl e posi ti on.
Flow Control And Lubrication
The manual val ve i s operated by the gearshi ft l i nk-
age and provi des the operati ng range sel ected by the
dri ver.
The swi tch val ve control s l i ne pressure to the con-
verter cl utch. The val ve al so di rects oi l to the cool i ng
and l ubri cati on ci rcui ts. The swi tch val ve regul ates
oi l pressure to the torque converter by l i mi ti ng max-
i mum oi l pressure to 130 psi .
Fig. 2 Transmission Part And Serial Number
Location
The 1-2 shi ft val ve provi de 1-2 and 2-1 shi fts and
the 2-3 shi ft val ve provi de 2-3 and 3-2 shi fts.
The 1-2 shi ft control val ve transmi ts 1-2 shi ft pres-
sure to the accumul ator pi ston. Thi s control s ki ck-
down band capaci ty on 1-2 upshi fts and 3-2
downshi fts.
The 2-3 val ve throttl e pressure pl ug provi des 3-2
downshi fts at varyi ng throttl e openi ngs dependi ng on
vehi cl e speed.
The ki ckdown val ve provi des forced downshi fts
dependi ng on vehi cl e speed. Downshi fts occur when
the throttl e i s opened beyond downshi ft detent posi -
ti on. Detent i s reached just before wi de open throttl e
posi ti on.
The l i mi t val ve determi nes maxi mum speed at
whi ch a 3-2 part throttl e ki ckdown can be made.
Some transmi ssi ons do not have the l i mi t val ve and
maxi mum speed for a 3-2 ki ckdown i s at the detent
posi ti on.
The shuttl e val ve has two functi ons. Fi rst i s fast
front band rel ease and smooth engagement duri ng
l i ft foot 2-3 upshi fts. Second i s to regul ate front
cl utch rel ease and band appl i cati on duri ng 3-2 down-
shi fts.
The fai l safe val ve restri cts feed to the converter
cl utch i f front cl utch pressure drops. I t permi ts
cl utch engagement onl y i n di rect (thi rd) gear and
provi des fast cl utch rel ease duri ng ki ckdown.
Clutch/Band Application
The front/rear cl utch pi stons and servo pi stons are
actuated by l i ne pressure. When l i ne pressure i s
removed, the pi stons are rel eased by spri ng tensi on.
On 2-3 upshi fts, the front servo pi ston i s rel eased
by spri ng tensi on and hydraul i c pressure. The accu-
mul ator control s hydraul i c pressure on the appl y si de
of the front servo duri ng 1-2 upshi fts and at al l
throttl e openi ngs.
CONVERTER CLUTCH ENGAGEMENT
Converter cl utch engagement i n thi rd gear i s con-
trol l ed by sensor i nputs to the powertrai n control
modul e. I nputs that determi ne cl utch engagement
are: cool ant temperature, vehi cl e speed and throttl e
posi ti on. The torque converter cl utch i s engaged by
the cl utch sol enoi d on the val ve body. The cl utch wi l l
engage at approxi matel y 56 km/h (35 mph) wi th l i ght
throttl e, after the shi ft to thi rd gear.
CONVERTER DRAINBACK VALVE
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne. The val ve prevents fl ui d
from drai ni ng from the converter i nto the cool er and
l i nes when the vehi cl e i s shut down for l engthy peri -
ods. Producti on val ves have a hose ni ppl e at one end,
whi l e the opposi te end i s threaded for a fl are fi tti ng.
Al l val ves have an arrow (or si mi l ar mark) to i ndi -
cate di recti on of fl ow through the val ve.
MECHANISM
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 3). The system l ocks the shi fter i nto the
PARK posi ti on. The I nterl ock system i s engaged
whenever the i gni ti on swi tch i s i n the LOCK or
ACCESSORY posi ti on. An addi ti onal el ectri cal l y acti -
vated feature wi l l prevent shi fti ng out of the PARK
posi ti on unl ess the brake pedal i s depressed at l east
one-hal f an i nch. A magneti c hol di ng devi ce i n l i ne
wi th the park/brake i nterl ock cabl e i s energi zed
when the i gni ti on i s i n the RUN posi ti on. When the
key i s i n the RUN posi ti on and the brake pedal i s
depressed, the shi fter i s unl ocked and wi l l move i nto
any posi ti on. The i nterl ock system al so prevents the
i gni ti on swi tch from bei ng turned to the LOCK or
ACCESSORY posi ti on (Fi g. 4) unl ess the shi fter i s
ful l y l ocked i nto the PARK posi ti on.
AUTOMATIC TRANSMISSION DIAGNOSIS
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
PRELIMINARY DIAGNOSIS
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(2) Check fl ui d l evel and condi ti on.
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform stal l test i f compl ai nt i s based on sl ug-
gi sh accel erati on. Or, i f abnormal throttl e openi ng i s
needed to mai ntai n normal speeds wi th a properl y
tuned engi ne.
(6) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(7) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(1) Check fl ui d l evel and condi ti on.
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri ve pl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
PARK/NEUTRAL POSITION SWITCH
The center termi nal of the park/neutral posi ti on
swi tch i s the starter-ci rcui t termi nal . I t provi des the
ground for the starter sol enoi d ci rcui t through the
sel ector l ever i n PARK and NEUTRAL posi ti ons onl y.
The outer termi nal s on the swi tch are for the backup
l amp ci rcui t.
SWITCH TEST
To test the swi tch, remove the wi ri ng connector.
Test for conti nui ty between the center termi nal and
the transmi ssi on case. Conti nui ty shoul d exi st onl y
when the transmi ssi on i s i n PARK or NEUTRAL.
Fig. 3 Ignition Interlock Cable Routing
Fig. 4 Ignition Key Cylinder Actuation
Shi ft the transmi ssi on i nto REVERSE and test
conti nui ty at the swi tch outer termi nal s. Conti nui ty
shoul d exi st onl y when the transmi ssi on i s i n
REVERSE. Conti nui ty shoul d not exi st between the
outer termi nal s and the case.
Check gearshi ft l i nkage adjustment before repl ac-
i ng a swi tch that tests faul ty.
GEARSHIFT CABLE
(1) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti onAppl y forward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(b) PARK posi ti onAppl y rearward force on cen-
must be possi bl e.
(c) NEUTRAL posi ti onNormal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti onEngi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from neutral to reverse.
THROTTLE VALVE CABLE
Transmi ssi on throttl e val ve cabl e adjustment i s
extremel y i mportant to proper operati on. Thi s adjust-
ment posi ti ons the throttl e val ve, whi ch control s shi ft
speed, qual i ty, and part-throttl e downshi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve. Refer to the Adjust-
ments secti on for the proper adjustment procedure.
ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned
by compari ng whi ch i nternal uni ts are appl i ed i n the
vari ous gear ranges. The Cl utch and Band Appl i ca-
ti on chart provi des a basi s for anal yzi ng road test
resul ts.
ANALYZING ROAD TEST
Refer to the Cl utch and Band Appl i cati on chart
and note whi ch el ements are i n use i n the vari ous
gear ranges.
Veri fy that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Veri fy that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear. For exampl e: I f sl i ppage occurs i n fi rst gear i n
D and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, veri fy that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd gear. I f the transmi s-
si on sl i ps i n thi rd gear, ei ther the front cl utch or the
rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the thi rd gear and the
di rect cl utch were to fai l , the transmi ssi on woul d l ose
both reverse gear and overrun braki ng i n 2 posi ti on
(manual second gear). I f the transmi ssi on sl i ps i n
any other forward gears, the transmi ssi on rear cl utch
i s probabl y sl i ppi ng.
Fig. 5 Clutch And Band Application
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
HYDRAULIC PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
An accurate tachometer and two test gauges are
requi red for the pressure test. Test Gauge C-3292
has a 100 psi range and i s used at the accumul ator,
governor, and front servo pressure ports. Test Gauge
C-3293-SP has a 300 psi range and i s used at the
rear servo port and overdri ve test ports where pres-
sures are hi gher. I n cases where two test gauges are
requi red, the 300 psi gauge can be used at any of the
other test ports.
Pressure Test Port Locations
Pressure test ports l ocati ons are provi ded at the
accumul ator, front servo, and rear servo, governor
passage, and overdri ve cl utch pressure passage (Fi g.
6), (Fi g. 7) and (Fi g. 8).
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
Connect a tachometer to the engi ne. Posi ti on the
tachometer so i t can be observed from under the
vehi cl e. Rai se the vehi cl e on a hoi st that wi l l al l ow
the wheel s to rotate freel y.
PRESSURE TEST PROCEDURE
Test One - Transmission In 1 Range
Thi s test checks pump output, pressure regul ati on,
and condi ti on of the rear cl utch and servo ci rcui t.
Test Gauges C-3292 and C-3293-SP are requi red for
thi s test. Gauge C-3292 has a 100 psi range. Gauge
C-3293-SP has a 300 psi range.
(1) Connect 100 psi Gauge C-3292 to accumul ator
port.
(2) Connect 300 psi Gauge C-3293-SP to rear servo
port (Fi g. 6) and (Fi g. 7).
(3) Di sconnect throttl e and gearshi ft rods from
manual and throttl e l evers.
(4) Start and run engi ne at 1000 rpm.
(5) Move shi ft l ever (on manual l ever shaft) al l the
way forward i nto 1 range.
(6) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and note pressures on
both gauges.
(7) Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
l ever i s moved rearward.
(8) Rear servo pressure shoul d be same as l i ne
pressure wi thi n 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
Thi s test checks pump output and pressure regul a-
ti on. Use 100 psi Test Gauge C-3292 for thi s test.
(1) Connect test gauge to accumul ator pressure
port (Fi g. 6) and (Fi g. 7).
Fig. 6 Pressure Test Ports At Side Of Case
Fig. 7 Pressure Test Ports At Rear Of Case2WD
Fig. 8 Pressure Test Ports At Rear Of Case4WD
(2) Start and run engi ne at 1000 rpm.
(3) Move shi ft l ever on val ve body manual l ever
shaft, one detent rearward from ful l forward posi ti on.
Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure at
both gauges.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three - Transmission In D Range
Thi s test checks pressure regul ati on and condi ti on
of the cl utch ci rcui ts. Use both pressure Test Gauges
C-3292 and C-3293-SP for thi s test.
(1) Connect test gauges to accumul ator and front
servo ports (Fi g. 6) and (Fi g. 7). Use ei ther test
gauge at the two ports.
(2) Start and run engi ne at 1600 rpm for thi s test.
(3) Move sel ector l ever to D range. Thi s i s two
detents rearward from ful l forward posi ti on.
(4) Read pressures on both gauges as transmi ssi on
throttl e l ever i s moved from ful l forward to ful l rear-
ward posi ti on.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease as l ever i s moved rearward.
(6) Front servo i s pressuri zed onl y i n D range and
shoul d be same as l i ne pressure wi thi n 3 psi (21 kPa)
up to downshi ft poi nt.
Test Four - Transmission In Reverse
Thi s test checks pump output, pressure regul ati on
and the front cl utch and rear servo ci rcui ts. Use 300
psi Test Gauge C-3293-SP for thi s test.
(1) Connect 300 psi gauge to rear servo port (Fi g.
6) and (Fi g. 7).
(2) Start and run engi ne at 1600 rpm for test.
(3) Move val ve body sel ector l ever four detents
rearward from the ful l forward posi ti on. Thi s i s
Reverse range.
(4) Move throttl e l ever al l way forward then al l
way rearward and note gauge readi ngs.
(5) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th l ever forward and i ncrease to 230 - 280 psi
(1586-1931 kPa) as l ever i s moved rearward.
Test Five - Governor Pressure
Thi s test checks governor operati on by measuri ng
governor pressure response to changes i n engi ne
speed. I t i s usual l y not necessary to check governor
operati on unl ess shi ft speeds are i ncorrect or i f the
transmi ssi on wi l l not downshi ft.
(1) Connect 100 psi Test Gauge C-3292 to governor
pressure port (Fi g. 6) and (Fi g. 7).
(2) Move shi ft l ever to D range.
(3) Start and run engi ne at curb i dl e speed and
note pressure. At i dl e and wi th vehi cl e stopped, pres-
sure shoul d be zero to 1.5 psi maxi mum. I f pressure
exceeds thi s fi gure, governor val ve or wei ghts are
sti cki ng open.
(4) Sl owl y i ncrease engi ne speed and observe
speedometer and pressure test gauge. Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
(5) Pressure ri se shoul d be smooth and drop back
to 0 to 1.5 psi when wheel s stop rotati ng.
(6) Compare resul ts of pressure tests wi th anal ysi s
charts (Fi g. 9).
CONVERTER STALL TEST
Stal l testi ng i nvol ves determi ni ng maxi mum
engi ne speed obtai nabl e at ful l throttl e wi th the rear
wheel s l ocked and the transmi ssi on i n D range. Thi s
test checks the hol di ng abi l i ty of the converter over-
runni ng and transmi ssi on cl utches.
WARNING: NEVER ALLOW ANYONE TO STAND
DIRECTLY IN LINE WITH THE VEHICLE FRONT OR
REAR DURING A STALL TEST. ALWAYS BLOCK
THE WHEELS AND FULLY APPLY THE SERVICE
AND PARKING BRAKES DURING THE TEST.
Fig. 9 Pressure Test Analysis
STALL TEST PROCEDURE
(1) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be vi ewed from dri vers seat.
(2) Dri ve vehi cl e to bri ng transmi ssi on fl ui d up to
normal operati ng temperature. Vehi cl e can be dri ven
on road or on chassi s dynamometer, i f avai l abl e.
(3) Check transmi ssi on fl ui d l evel . Add fl ui d i f nec-
essary.
(4) Bl ock front wheel s.
(5) Ful l y appl y servi ce and parki ng brakes.
(6) Open throttl e compl etel y and record maxi mum
engi ne speed regi stered on tachometer. I t takes 4-10
seconds to reach max rpm. Once max rpm has
been achieved, do not hold wide open throttle
for more than 4-5 seconds.
CAUTION: Stalling the converter causes a rapid
increase in fluid temperature. To avoid fluid over-
heating, hold the engine at maximum rpm for no
more than 5 seconds. If engine exceeds 2500 rpm
during the test, release the accelerator pedal imme-
diately; transmission clutch slippage is occurring.
(7) I f a second stal l test i s requi red, cool down
fl ui d before proceedi ng. Shi ft i nto NEUTRAL and run
engi ne at 1000 rpm for 20-30 seconds to cool fl ui d.
STALL TEST ANALYSIS
Stall Speed Too High
I f the stal l speed exceeds 2500 rpm, transmi ssi on
cl utch sl i ppage i s i ndi cated.
Stall Speed Low
Low stal l speed wi th a properl y tuned engi ne i ndi -
cate a torque converter overrunni ng cl utch probl em.
The condi ti on shoul d be confi rmed by road testi ng. A
stal l speed 250-350 rpm bel ow normal i ndi cates the
converter overrunni ng cl utch i s sl i ppi ng. The vehi cl e
al so exhi bi ts poor accel erati on but operates normal l y
once hi ghway crui se speeds are reached. Torque con-
verter repl acement wi l l be necessary.
Stall Speed Normal But Acceleration Poor
I f stal l speeds are normal (1800-2300 rpm) but
abnormal throttl e openi ng i s requi red for accel era-
ti on, or to mai ntai n crui se speed, the converter over-
runni ng cl utch i s sei zed. The torque converter wi l l
have to be repl aced.
Converter Noise During Test
A whi ni ng noi se caused by fl ui d fl ow i s normal dur-
i ng a stal l test. However, l oud metal l i c noi ses i ndi -
cate a damaged converter. To confi rm that the noi se
i s ori gi nati ng from the converter, operate the vehi cl e
at l i ght throttl e i n DRI VE and NEUTRAL on a hoi st
and l i sten for noi se comi ng from the converter hous-
i ng.
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
servo and cl utch appl y passages are shown (Fi g. 10).
Front Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Apply Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Fig. 10 Air Pressure Test Passages
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
O-ri ng or pump body l eaks fol l ow the same path as a
seal l eak (Fi g. 11). Pump vent or pump attachi ng bol t
l eaks are general l y deposi ted on the i nsi de of the
converter housi ng and not on the converter i tsel f
(Fi g. 11). Pump seal or gasket l eaks usual l y travel
down the i nsi de of the converter housi ng. Front band
l ever pi n pl ug l eaks are general l y deposi ted on the
housi ng and not on the converter.
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 12).
(2) Leaks at the converter hub wel d (Fi g. 12).
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Ti ghten front band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way. Be sure to l oosen the front band before
i nstal l i ng the oi l pump, damage to the oi l pump seal
may occur i f the band i s sti l l ti ghtened to the front
cl utch retai ner.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or Permatex No. 2 to pl ug
threads and ti ghten pl ug to 17 Nm (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
DIAGNOSIS CHARTS
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts, i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
neutral , thi rd, fourth and reverse gear ranges. Nor-
mal worki ng pressures are al so suppl i ed for each of
the gear ranges.
Fig. 11 Converter Housing Leak Paths
Fig. 12 Converter Leak PointsTypical
DIAGNOSIS CHART
HARSH ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE
1. Fluid Level Low. 1. Add Fluid.
2. Throttle Linkage Misadjusted. 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose. 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken. 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect. 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect. 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Misadjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component Damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch (if equipped)
Faulty.
11. Replace converter and flush cooler and
line before installing new converter.
DELAYED ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Misadjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Rear Band Misadjusted. 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/Damaged. 6. Remove transmission and replace oil
pump.
7. Hydraulic Pressure Incorrect. 7. Perform pressure test, remove
transmission and repair as needed.
8. Reaction Shaft Seal Rings
Worn/Broken.
8. Remove transmission, remove oil pump
and replace seal rings.
9. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
9. Remove and disassemble transmission
and repair as necessary.
10. Governor Valve Stuck. 10. Remove and inspect governor
components. Replace worn or damaged
parts.
11. Regulator Valve Stuck. 11. Clean.
12. Cooler Plugged. 12. Flush transmission cooler and inspect
convertor drainback valve.
NO DRIVE RANGE
(REVERSE OK)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check press and inspect valve body.
Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in good
condition.
7. Transmission Internal Component
Damaged.
Repair or replace failed components as
needed. Remove and disassemble
transmission. Repair or replace failed
components as needed.
8. Park Sprag not Releasing. 8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Check Stall Speed, Worn/Damaged/
Stuck. Inspect and replace as required.
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Throttle Linkage Misadjusted. 2. Adjust linkage as described in service
section.
3. Throttle Linkage Binding. 3. Check cable for binding. Check for return
to closed throttle at transmission.
Misadjusted.
4. Adjust linkage/cable as described in
service section.
5. Fluid Filter Clogged. 5. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
6. Governor Valve Sticking. 6. Inspect, clean or repair.
7. Governor Seal Rings Worn/
Damaged.
7. Inspect/replace.
8. Clutch or Servo Failure. 8. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
9. Front Band Misadjusted. 9. Adjust band.
10. Pump Suction Passage Leak. 10. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES
OK)
Misadjusted/Damaged.
1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Inspect and replace as necessary.
3. Rear Band Misadjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Front Clutch Burnt. 6. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
1. Governor Valve, Shaft, Weights or
Body Damaged/Stuck.
1. Remove governor assembly and clean or
repair as necessary.
2. Valve Body Malfunction. 2. Stuck 1-2 shift valve or governor plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
2. Governor Valve Sticking. 2. Remove, clean and inspect. Replace
faulty parts.
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)
1. Governor Valve Sticking. 1. Remove governor, clean, inspect and
repair as required.
2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift 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.
NO KICKDOWN OR
NORMAL DOWNSHIFT
1. Throttle Linkage Misadjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.
2. Floor mat under pedal, accelerator cable
worn or brackets bent.
3. Governor/Valve Body Hydraulic
Pressures Too High or Too Low Due
to Sticking Governor, Valve Body
Malfunction or Incorrect Hydraulic
Control Pressure Adjustments.
3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
4. Valve Body Malfunction. 4. Perform hydraulic pressure tests to
Correct valve body pressure adjustments as
required.
5. Valve Body Malfunction. 5. Sticking 1-2, 2-3 shift valves, or governor
plugs.
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)
1. Throttle Linkage Misadjusted/
Stuck.
1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage and repair linkage if worn
or damaged.
3. Governor/Valve Body, Governor
Valve Stuck Closed; Loose Output
Shaft Support or Governor Housing
Bolts, Leaking Seal Rings or Valve
Body Problem (i.e., Stuck 1- 2 Shift
Valve/Gov. Plug).
3. Check line and governor pressures to
determine cause. Correct as required.
4. Front Band Out of Adjustment . 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Misadjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped
Welded.
2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
BUZZING NOISE 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Misassembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Misassembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking. 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6.Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage.
4. Rear Band Worn. 4. Replace as required.
5. Hydraulic Pressure Too Low. 5. Perform hydraulic pressure tests to
determine cause.
6. Rear Servo Leaking. 6. Air pressure check clutch-servo operation
and repair as required.
7. Band Linkage Binding. 7. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
3. Throttle Linkage Misadjusted. 3. Adjust linkage.
4. Gearshift Linkage Misadjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking
Governor, Leaking Seal Rings,
Clutch Seals Leaking, Servo Leaks,
Clogged Filter or Cooler Lines.
6. Perform hydraulic and air pressure tests
to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.
7. Air pressure check clutch-servo operation
and repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR D
ONLY, BUT NOT IN 1
POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
GROWLING, GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.
5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.
6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Misadjusted.
8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed. 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Misadjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
WHINE/NOISE RELATED
TO ENGINE SPEED
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2 OR 2-3
SHIFTS
Lockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK OR
NEUTRAL
Misadjusted.
1. Adjust linkage/cable.
2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Neutral Switch Faulty. 3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
NO REVERSE (OR SLIPS
IN REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
3. Front Clutch Malfunctioned/Burnt. 3. Air pressure test clutch operation.
Remove and rebuild if necessary.
OIL LEAKS (ITEMS
LISTED REPRESENT
POSSIBLE LEAK POINTS
AND SHOULD ALL BE
CHECKED.
1. Speedometer Adapter Leaks. 1. Replace both adapter seals.
2. Fluid Lines and Fittings Loose/
Leaks/Damaged.
2. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
3. Filler Tube (where tube enters
case) Leaks/Damaged.
3. Replace O-ring seal. Inspect tube for
cracks in tube.
4. Pressure Port Plug Loose
Loose/Damaged.
4. Tighten to correct torque. Replace plug
or reseal if leak persists.
5. Pan Gasket Leaks. 5. Tighten pan screws to 150 inch pounds.
If leaks persist, replace gasket. Do no over
tighten screws.
6. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
6. Replace shaft seal.
7. Rear Bearing Access Plate Leaks. 7. Replace gasket. Tighten screws.
8. Gasket Damaged or Bolts are
Loose.
8. Replace bolts or gasket or tighten both.
9. Adapter/Extension Gasket
Damaged Leaks/Damaged.
9. Replace gasket.
10. Neutral Switch Leaks/Damaged. 10. Replace switch and gasket.
11. Converter Housing Area Leaks. 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. Pump Seal Leaks/Worn/
Damaged.
12. Replace seal.
13. Torque Converter Weld
Leak/Cracked Hub.
13. Replace converter.
14. Case Porosity Leaks. 14. Replace case.
SERVICE PROCEDURES
FLUID LEVEL CHECK
Transmi ssi on fl ui d l evel shoul d be checked monthl y
under normal operati on. I f the vehi cl e i s used for
trai l er towi ng or si mi l ar heavy l oad haul i ng, check
fl ui d l evel and condi ti on weekl y. Fl ui d l evel i s
checked wi th the engi ne runni ng at curb i dl e speed,
the transmi ssi on i n NEUTRAL and the transmi ssi on
fl ui d at normal operati ng temperature.
FLUID LEVEL CHECK PROCEDURE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82C (180F).
(2) Posi ti on vehi cl e on l evel surface.
(3) Start and run engi ne at curb i dl e speed.
(4) Appl y parki ng brakes.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to Neutral .
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 13) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough Mopar ATF
Pl us 3 to restore correct l evel . Do not overfi l l .
CAUTION: Do not overfill the transmission. Overfill-
ing may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the
excess fluid is picked up and churned by the gear
train. This will significantly reduce fluid life.
FLUID AND FILTER REPLACEMENT
Refer to the Mai ntenance Schedul es i n Group 0,
Lubri cati on and Mai ntenance, for proper servi ce
i nterval s. The servi ce fl ui d fi l l after a fi l ter change i s
approxi matel y 3.8 l i ters (4.0 quarts).
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(3) Remove bol ts hol di ng front and si des of pan to
transmi ssi on (Fi g. 14).
(4) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(5) Sl owl y separate front of pan away from trans-
mi ssi on al l owi ng the fl ui d to drai n i nto drai n pan.
(6) Hol d up pan and remove remai ni ng bol ts hol d-
i ng pan to transmi ssi on.
(7) Whi l e hol di ng pan l evel , l ower pan away from
transmi ssi on.
(8) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(9) Remove screws hol di ng fi l ter to val ve body
(Fi g. 15).
(10) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(11) Di spose used trans fl ui d and fi l ter properl y.
Fig. 13 Dipstick Fluid Level MarksTypical
Fig. 14 Transmission Pan
Fig. 15 Transmission Filter
INSPECTION
I nspect bottom of pan and magnet for excessi ve
amounts of metal or fi ber contami nati on. A l i ght
coati ng of cl utch or band materi al on the bottom of
the pan does not i ndi cate a probl em unl ess accompa-
ni ed by sl i ppi ng condi ti on or shi ft l ag. I f fl ui d and
pan are contami nated wi th excessi ve amounts or
debri s, refer to the di agnosi s secti on of thi s group.
Check the adjustment of the front and rear bands,
adjust i f necessary. Refer to Adjustment secti on of
thi s group for proper procedure.
CLEANING
(1) Usi ng a sui tabl e sol vent, cl ean pan and mag-
net.
(2) Usi ng a sui tabl e gasket scraper, cl ean gasket
materi al from gasket surface of transmi ssi on case
and the gasket fl ange around the pan.
INSTALLATION
(1) Pl ace repl acement fi l ter i n posi ti on on val ve
body.
(2) I nstal l screws to hol d fi l ter to val ve body (Fi g.
15). Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
(3) Pl ace new gasket i n posi ti on on pan. and
i nstal l pan on transmi ssi on.
(4) Pl ace pan i n posi ti on on transmi ssi on.
(5) I nstal l screws to hol d pan to transmi ssi on (Fi g.
14). Ti ghten bol ts to 17 Nm (150 i n. l bs.) torque.
(6) Lower vehi cl e and fi l l transmi ssi on wi th
Mopar ATF Pl us 3, type 7176 fl ui d.
TRANSMISSION FILL PROCEDURE
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
Pl us 3 to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 3
pints (1-1/2 quarts) of ATF Pl us 3 to transmi s-
si on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 12 pints (6 quarts) of ATF
Pl us 3 to transmi ssi on.
(4) Start and run engi ne at normal curb i dl e
speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on
through al l gear ranges then back to NEUTRAL, set
parki ng brake, and l eave engi ne runni ng at curb i dl e
speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow
mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
CONVERTER DRAINBACK CHECK VALVE
SERVICE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
tank. The val ve prevents fl ui d drai nback when the
vehi cl e i s parked for l engthy peri ods. The val ve check
bal l i s spri ng l oaded and has an openi ng pressure of
approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not
repai rabl e. Do not cl ean the val ve i f restri cted, or
contami nated by sl udge, or debri s. I f the val ve fai l s,
or i f a transmi ssi on mal functi on occurs that gener-
ates si gni fi cant amounts of sl udge and/or cl utch par-
ti cl es and metal shavi ngs, the val ve must be
repl aced.
The val ve must be removed whenever the cool er
and l i nes are reverse fl ushed. The val ve can be fl ow
tested when necessary. The procedure i s exactl y the
same as for fl ow testi ng a cool er.
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
OIL PUMP VOLUME CHECK
After the new or repai red transmi ssi on has been
i nstal l ed, fi l l to the proper l evel wi th Mopar ATF
PLUS 3 (Type 7176) automati c transmi ssi on fl ui d.
The vol ume shoul d be checked usi ng the fol l owi ng
procedure:
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed , wi th the
shi ft sel ector i n neutral .
(3) I f fl ui d fl ow i s i ntermi ttent or i t takes more
than 20 seconds to col l ect one quart of ATF PLUS 3,
di sconnect the To Cooler l i ne at the transaxl e.
(4) Refi l l the transaxl e to proper l evel and recheck
pump vol ume.
(5) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
repl ace the cool er. Then fi l l transmi ssi on to the
proper l evel , usi ng Mopar ATF PLUS 3 (Type 7176)
automati c transmi ssi on fl ui d.
(6) I f fl ui d fl ow i s sti l l found to be i nadequate,
check the l i ne pressure usi ng the Transaxl e Hydrau-
l i c Pressure Test procedure.
FLUSHING COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The torque
converter must al so be repl aced. Thi s wi l l i nsure that
metal parti cl es or sl udged oi l are not l ater trans-
ferred back i nto the recondi ti oned (or repl aced) trans-
mi ssi on.
The onl y recommended procedure for fl ushi ng cool -
ers and l i nes i s to use Tool 6906 Cool er Fl usher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906
(1) Remove cover pl ate fi l l er pl ug on Tool 6906.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will preventreverse
flushing the system.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne.
(7) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes. Moni tor pressure readi ngs
and cl ear return l i nes. Pressure readi ngs shoul d sta-
bi l i ze bel ow 20 psi . for vehi cl es equi pped wi th a si n-
gl e cool er and 30 psi . for vehi cl es equi pped wi th dual
cool ers. I f fl ow i s i ntermi ttent or exceeds these pres-
sures, repl ace cool er.
(8) Turn pump OFF.
(9) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(10) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(11) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF Pl us 3, type 7176 automati c
transmi ssi on fl ui d.
(12) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(13) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts
of dri l l i ng out the worn-out damaged threads. Then
tap the hol e wi th a speci al Hel i -Coi l tap, or equi va-
l ent, and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent,
i nto the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
TRANSMISSION
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal.
REMOVAL
(1) Di sconnect battery negati ve cabl e.
(2) Di sconnect and l ower or remove necessary
exhaust components.
(3) Remove engi ne-to-transmi ssi on bendi ng braces.
(4) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(5) Remove starter motor.
(6) Di sconnect and remove crankshaft posi ti on sen-
sor. Retai n sensor attachi ng bol ts.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov-
ing the transmission.
(7) Remove torque converter access cover.
(8) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(9) Remove ski d pl ate for access, i f necessary.
(10) Remove fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . On 4 x 4
model s, i t wi l l al so be necessary to remove bol t
attachi ng transfer case vent tube to converter hous-
i ng.
(11) Mark torque converter and dri ve pl ate for
assembl y al i gnment. Note that bol t hol es i n crank-
shaft fl ange, dri ve pl ate and torque converter al l
have one offset hol e.
(12) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(13) Mark propel l er shaft and axl e yokes for
assembl y al i gnment. Then di sconnect and remove
propel l er shaft. On 4 x 4 model s, remove both propel -
l er shafts.
(14) Di sconnect wi res from park/neutral posi ti on
swi tch and vehi cl e speed sensor.
(15) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever.
(16) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever.
(17) On 4 x 4 model s, di sconnect shi ft rod from
transfer case shi ft l ever or remove shi ft l ever from
transfer case.
(18) Support rear of engi ne wi th safety stand or
jack.
(19) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(20) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember. Rai se trans-
mi ssi on sl i ghtl y, sl i de exhaust hanger arm from
bracket and remove rear support.
(21) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(22) Di sconnect transfer case vent hose. Then di s-
connect vacuum swi tch harness.
(23) On 4 x 4 model s, remove transfer case.
(24) Remove al l converter housi ng bol ts.
(25) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(26) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(27) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
(28) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal at i nstal l ati on.
(2) Lubri cate converter dri ve hub and oi l pump
seal l i p wi th transmi ssi on fl ui d.
(3) Lubri cate converter pi l ot hub wi th transmi s-
si on fl ui d.
(4) Al i gn converter and oi l pump.
(5) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(6) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 18). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(7) Temporari l y secure converter wi th C-cl amp.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th safety chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
(12) Rotate converter so al i gnment marks scri bed
on converter are al i gned wi th mark on dri vepl ate.
(13) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft.
(14) I nstal l and ti ghten bol ts that attach transmi s-
si on converter housi ng to engi ne bl ock (Fi g. 19).
CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten-
ing any bolts.
(15) I nstal l torque converter attachi ng bol ts.
Ti ghten bol ts to fol l owi ng torque.
54 Nm (40 ft. l bs.) wi th 9.5 i n. 3-l ug converter
31 Nm (270 i n. l bs.) wi th 10.75 i n. 4-l ug con-
verter
(16) I nstal l crankshaft posi ti on sensor.
(17) I nstal l transmi ssi on fi l l tube and seal . I nstal l
new fi l l tube seal i n transmi ssi on before i nstal l ati on.
(18) Connect transmi ssi on cool er l i nes to transmi s-
si on.
(19) I nstal l transfer case onto transmi ssi on.
(20) I nstal l rear crossmember and attach trans-
mi ssi on rear support to crossmember.
(21) Remove engi ne support fi xture.
(22) Remove transmi ssi on jack.
(23) Connect vehi cl e speed sensor wi res.
(24) Connect wi res to park/neutral posi ti on swi tch.
(25) I nstal l crankshaft posi ti on sensor.
(26) I nstal l converter housi ng access cover.
(27) I nstal l exhaust pi pes and support brackets, i f
removed.
(28) I nstal l starter motor and cool er l i ne bracket.
(29) I nstal l new pl asti c retai ner grommet on any
shi ft l i nkage rod or l ever that was di sconnected.
Grommets shoul d not be reused. Use pry tool to
remove rod from grommet and cut away ol d grom-
met. Use pl i ers to snap new grommet i nto l ever and
to snap rod i nto grommet at assembl y.
(30) Connect gearshi ft and l i nkage and throttl e
cabl e.
(31) Connect transfer case shi ft l i nkage.
Fig. 18 Typical Method Of Checking Converter
Seating
(32) Adjust gearshi ft l i nkage and throttl e val ve
cabl e i f necessary.
(33) Al i gn and connect propel l er shaft(s).
(34) I nstal l ski d pl ate, rear cushi on and bracket, i f
removed.
(35) Fi l l transfer case to bottom edge of fi l l pl ug
hol e.
(36) Lower vehi cl e and fi l l transmi ssi on to correct
l evel wi th Mopar ATF Pl us 3, type 7176 fl ui d.
TORQUE CONVERTER
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate converter hub and oi l pump seal l i p
wi th transmi ssi on fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
Fig. 19 Transmission Attachment
(6) Check converter seati ng wi th a scal e and
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
YOKE SEAL REPLACEMENT
REMOVAL
(1) Rai se vehi cl e.
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(3) Di sconnect and remove propel l er shaft.
(4) Remove ol d seal wi th Seal Remover C-3985-B
(Fi g. 21) from extensi on housi ng.
INSTALLATION
(1) Pl ace seal i n posi ti on on extensi on housi ng.
(2) Dri ve seal i nto extensi on housi ng wi th Seal
I nstal l er C-3995-A or C-3972 (Fi g. 22).
(3) Careful l y gui de propel l er shaft sl i p yoke i nto
housi ng and onto output shaft spl i nes. Al i gn marks
made at removal and connect propel l er shaft to rear
axl e pi ni on yoke.
EXTENSION HOUSING BUSHING
REMOVAL
(1) Remove housi ng yoke seal .
(2) I nsert Remover 6957 i nto extensi on housi ng.
Ti ghten tool to bushi ng and remove bushi ng (Fi g.
23).
INSTALLATION
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n extensi on
housi ng.
(2) Tap bushi ng i nto pl ace wi th I nstal l er 6951 and
Handl e C-4171.
(3) I nstal l new oi l seal i n housi ng usi ng Seal
I nstal l er C-3995A (Fi g. 24).
Fig. 20 Checking Torque Converter Seating
Fig. 21 Removing Extension Housing Yoke Seal
Fig. 22 Installing Extension Housing Yoke Seal
Fig. 23 Bushing RemovalTypical
EXTENSION HOUSING
REMOVAL
(2) Support transmi ssi on wi th a sui tabl e l i fti ng
devi ce.
(3) Remove transmi ssi on ski d pl ate. Refer to
Group 13, Frame and Bumpers, for proper procedure.
(4) Remove propel l er shafts. Refer to Group 3, Di f-
ferenti al and Dri vel i ne, for proper procedure.
(6) Remove bol ts hol di ng extensi on housi ng to
(7) Separate extensi on housi ng from transmi ssi on.
(8) Sl i de extensi on housi ng rearward and off out-
put shaft (Fi g. 25).
INSTALLATION
Cl ear gasket materi al from seal i ng surfaces on
extensi on housi ng and rear of transmi ssi on. Repl ace
output shaft beari ng, i f necessary.
(1) I nstal l new rear seal i n extensi on housi ng. Use
Tool Handl e C-4171 and Seal I nstal l er C-3860-A to
i nstal l seal .
(2) Pl ace extensi on housi ng gasket i n posi ti on on
rear of transmi ssi on.
(3) Sl i de extensi on housi ng forward and over out-
(4) Gui de park shaft i nto park sprag and push
extensi on housi ng forward unti l rod passes through
openi ng behi nd sprag. I t may be necessary to use a
wi re to hol d sprag to the si de for rod to pass through.
(5) I nstal l bol ts to hol d extensi on housi ng to rear
of transmi ssi on.
(7) I nstal l propel l er shafts.
(8) I nstal l rear transmi ssi on mount and ski d pl ate.
(9) Lower vehi cl e and veri fy transmi ssi on fl ui d
l evel . Add fl ui d as necessary.
SPEEDOMETER ADAPTER
Rear axl e gear rati o and ti re si ze determi ne speed-
ometer pi ni on requi rements.
REMOVAL
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 26).
(4) Remove speed sensor and speedometer adapter
as assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 26).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter i f necessary (Fi g. 26).
(3) Lubri cate sensor and adapter O-ri ngs wi th
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 Nm
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
Fig. 24 Extension Housing Seal Installation
Fig. 25 Extension Housing
(7) Note i ndex numbers on adapter body (Fi g. 27).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 ocl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 Nm (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel , i f necessary.
REMOVAL
(1) Rai se vehi cl e and posi ti on drai n pan under
swi tch.
(2) Di sconnect swi tch wi res.
(3) Remove swi tch from case.
INSTALLATION
(1) Move shi ft l ever to Park and Neutral posi ti ons.
Veri fy that swi tch operati ng l ever fi ngers are cen-
tered i n swi tch openi ng i n case (Fi g. 28).
(2) I nstal l new seal on swi tch and i nstal l swi tch i n
case. Ti ghten swi tch to 34 Nm (25 ft. l bs.) torque.
Fig. 26 Speedometer Pinion Adapter Components
Fig. 27 Index Numbers On Speedometer Pinion
Adapter
Fig. 28 Park/Neutral Position Switch
(3) Test conti nui ty of new swi tch wi th 12V test
l amp.
(4) Connect swi tch wi res and l ower vehi cl e.
(5) Top off transmi ssi on fl ui d l evel .
GEARSHIFT CABLE
REMOVAL
(1) Shi ft transmi ssi on i nto Park.
(2) Remove shi ft l ever bezel and necessary consol e
parts for access to shi ft l ever assembl y.
(3) Di sconnect cabl e at shi ft l ever and feed cabl e
through dash panel openi ng to undersi de of vehi cl e.
(5) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng
bracket. Then remove ol d cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n dash panel . Ful l y
seat cabl e grommet i nto dash panel .
(2) Pl ace the auto transmi ssi on manual shi ft con-
trol l ever i n Park detent (rearmost) posi ti on and
rotate prop shaft to ensure transmi ssi on i s i n park.
(3) Connect shi ft cabl e to shi fter mechani sm by
snappi ng cabl e retai ni ng ears i nto shi fter bracket
and press cabl e end fi tti ng onto l ever bal l stud.
(4) Pl ace the fl oor shi fter l ever i n park posi ti on.
Ensure that the pawl i s seated wi thi n the confi nes of
the adjustment gauge cl i p.
(5) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
(6) Lock shi ft cabl e i nto posi ti on by pushi ng
upward on the adjusti ng l ock button.
(7) Remove and di scard the shi ft cabl e adjustment
gauge cl i p from the park gate of the shi fter.
REMOVAL
(1) Remove l ower steeri ng col umn cover. Refer to
Group 8E, I nstrument Panel and Gauges, for proper
procedure.
(2) Remove l ower steeri ng col umn shroud. Refer to
Group 19, Steeri ng, for proper procedure.
(3) Remove ti e strap near the sol enoi d retai ni ng
the brake transmi ssi on i nterl ock cabl e to the steeri ng
col umn.
(4) Di sengage wi re connector from sol enoi d.
(5) Wi th the i gni ti on removed or i n the unl ocked
posi ti on, di sengage l ock tab hol di ng cabl e end to
steeri ng col umn (Fi g. 29).
(6) Pul l cabl e end from steeri ng col umn.
(7) Remove the fl oor consol e and rel ated tri m.
Refer to Group 23, Body, for proper procedure.
(8) Di sconnect the cabl e eyel et from the bel l crank
(Fi g. 30).
(9) Di sconnect and remove the cabl e from the shi ft
bracket.
INSTALLATION
(1) Route repl acement cabl e behi nd i nstrument
panel and under fl oor consol e area to shi ft mecha-
ni sm (Fi g. 30).
(2) I nsert cabl e end i nto openi ng i n steeri ng col -
umn hub under i gni ti on l ock. Push cabl e i nward
unti l l ock tab engages.
(3) Connect the cabl e end eyel et onto shi fter
bel l crank pi n.
(4) Pl ace gear sel ector i n PARK.
(5) Push the spri ng-l oaded cabl e adjuster forward
and snap cabl e i nto bracket.
(6) Adjust the brake transmi ssi on shi fter i nterl ock
cabl e. Refer to the Adjustment porti on of thi s secti on
for proper procedures.
(7) Veri fy that the cabl e adjuster l ock cl amp i s
pushed downward to the l ocked posi ti on.
(8) Test the park-l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
(10) I nstal l ti e strap to hol d cabl e to base of steer-
i ng col umn.
(11) I nstal l l ower steeri ng col umn shroud and i gni -
ti on l ock.
(12) I nstal l l ower steeri ng col umn cover.
VALVE BODY
REMOVAL
(2) Remove oi l pan and drai n fl ui d.
(3) Loosen cl amp bol ts and remove throttl e and
manual val ve l evers from manual l ever shaft.
(4) Remove park/neutral posi ti on swi tch.
(5) Remove fi l ter from val ve body.
Fig. 29 Brake/Park Interlock Cable
(6) Depress retai ni ng cl i p and pul l sol enoi d wi re
from case connector (Fi g. 31).
(7) Remove val ve body attachi ng screws.
(8) Lower val ve body enough to remove accumul a-
tor pi ston and pi ston spri ng (Fi g. 32).
(9) Pul l val ve body forward to di sengage park rod.
(10) Push manual l ever shaft and sol enoi d case
connector out of transmi ssi on case.
(11) Lower val ve body, rotate i t away from case,
pul l park l ock rod out of sprag, and remove val ve
body (Fi g. 33).
INSTALLATION
(1) Veri fy that park/neutral posi ti on swi tch i s NOT
i nstal l ed. Val ve body cannot be i nstal l ed wi th swi tch
i n pl ace. Remove swi tch i f necessary.
(2) I nstal l new seal s on accumul ator pi ston i f nec-
essary, and i nstal l pi ston i n case. Use smal l amount
of petrol eum jel l y to hol d pi ston i n pl ace.
(3) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) to ease i nserti ng park rod i nto sprag.
Fig. 30 Cable and Shifter
Fig. 31 Solenoid Wire Connector
Fig. 32 Accumulator Piston And Springs
(4) Use screwdri ver to push park sprag i nto
engagement wi th park gear. Thi s makes cl earance for
knob on l ock rod to move past sprag when val ve body
i s i nstal l ed. Rotate output shaft to veri fy sprag
engagement.
(5) Posi ti on accumul ator spri ng between accumul a-
tor pi ston and val ve body.
(6) Posi ti on val ve body on transmi ssi on and work
knob on park l ock rod past sprag. Be sure accumul a-
tor pi ston and spri ng remai n i n posi ti on.
(7) Hol d val ve body i n posi ti on and i nstal l val ve
body screws fi nger ti ght.
(8) I nstal l park/neutral posi ti on swi tch.
(9) Ti ghten val ve body screws al ternatel y and
evenl y to 11 Nm (100 i n. l bs.) torque.
(10) I nstal l new fl ui d fi l ter on val ve body. I nstal l
and ti ghten fi l ter screws to 4 Nm (35 i n. l bs.) torque.
(11) Connect sol enoi d wi re to case connector.
(12) I nstal l manual and throttl e l evers on throttl e
l ever shaft. Ti ghten l ever cl amp screws and check for
free operati on. Shaft and l evers must operate freel y
wi thout any bi nd.
(13) I nstal l oi l pan and new gasket. Ti ghten pan
bol ts to 17 Nm (150 i n. l bs.) torque. I nstal l gasket
dry; do not use seal er.
(14) Connect park/neutral posi ti on swi tch and con-
verter cl utch sol enoi d wi res.
(15) I nstal l speedometer pi ni on gear, adapter and
speed sensor.
(17) Fi l l transmi ssi on wi th Mopar ATF Pl us 3,
Type 7176 fl ui d.
(18) Adjust gearshi ft and throttl e cabl e i f neces-
sary.
OUTPUT SHAFT REAR BEARING
REMOVAL
(1) Remove extensi on housi ng.
(2) Remove snap ri ng that retai ns rear beari ng on
output shaft (Fi g. 34).
(3) Remove beari ng from output shaft.
INSTALLATION
(1) I nstal l beari ng on output shaft. Be sure retai n-
i ng ri ng groove i n outer ci rcumference of beari ng i s
toward the governor.
(2) I nstal l rear beari ng retai ni ng snap ri ng (Fi g.
34).
(3) I nstal l extensi on housi ng.
GOVERNOR AND PARK GEAR
REMOVAL
(2) Mark propel l er shaft and axl e yoke for assem-
bl y reference. Then di sconnect and remove shaft.
(3) Di sconnect parki ng brake cabl e at equal i zer
and di sconnect exhaust components as necessary.
(4) Support transmi ssi on on a sui tabl e l i fti ng
devi ce.
(5) Remove ski d pl ate and rear transmi ssi on
mount.
(7) Loosen but do not remove bol ts that hol d gov-
ernor body to park gear.
(8) Rotate transmi ssi on output shaft unti l gover-
nor wei ght assembl y i s accessi bl e.
(9) Remove E-cl i p at end of governor val ve shaft
(Fi g. 35).
(10) Remove governor val ve and shaft from gover-
nor body (Fi g. 35).
(11) Remove snap ri ngs and spacer that retai n
governor body and park gear assembl y on output
shaft (Fi g. 36).
(12) Remove bol ts hol di ng governor body to park
gear (Fi g. 37).
(13) Separate governor from park gear.
(14) Pul l park gear from rear support.
INSTALLATION
(1) I nstal l park gear i nto rear support so crown on
curved boss i s i n l i ne wi th hol e through output shaft.
(2) I nstal l governor fi l ter i n park gear.
Fig. 33 Valve Body
Fig. 34 Output Shaft Rear BearingTypical
(3) Sl i p governor body over output shaft and al i gn
port to fi l ter.
(4) I nstal l bol ts to hol d governor body to park gear.
Ti ghten bol ts to 11 Nm (95 i n. l bs.) torque (Fi g. 37).
(5) I nstal l governor body-park gear snap ri ngs and
washer on output shaft as fol l ows:
(a) I nstal l thi n snap ri ng fi rst. Then i nstal l
thrust washer second, and thi ck snap ri ng l ast
(Fi g. 36).
(b) Veri fy correct posi ti on of snap ri ngs. Be sure
flat side of each snap ring is toward governor
body.
(6) I nsert governor val ve and shaft through gover-
nor and i nstal l E-cl i p (Fi g. 35).
(7) I nstal l extensi on housi ng and gasket on trans-
mi ssi on. Ti ghten housi ng bol ts to 32 Nm (24 ft. l bs.).
(8) I nstal l rear transmi ssi on mount and ski d pl ate.
(9) I nstal l speed sensor and speedometer compo-
nents and connect speed sensor wi res.
(10) Connect exhaust components and brake cabl e,
i f removed.
(11) I nstal l propel l er shaft.
(12) Remove supports and l ower vehi cl e.
(13) Check transmi ssi on fl ui d l evel . Add fl ui d i f
necessary.
PARK LOCK
REMOVAL
(1) Rai se vehi cl e and remove propel l er shaft.
(3) Sl i de sprag shaft out of extensi on housi ng and
remove sprag and spri ng (Fi g. 38).
(4) Remove snap ri ng and sl i de reacti on pl ug and
pi n assembl y out of housi ng.
(5) I f park rod requi res servi ce, i t wi l l be necessary
to remove val ve body.
INSTALLATION
(1) I nspect sprag shaft for scores and free move-
ment i n housi ng and sprag. I nspect sprag and control
rod spri ngs for di storti on and l oss of tensi on. repl ace
worn, damaged parts as necessary.
(2) I nspect square l ug on sprag for broken edges.
Check l ugs on park gear for damage. I nspect knob on
end of control rod for wear grooves, or bei ng sei zed
on rod. Repl ace rod i f bent, i f knob i s worn/grooved,
or i t has sei zed on rod. Repl ace park gear i f l ugs are
damaged. Repl ace the park l ock rod i f i t i s suspected
that the rod i s not the correct l ength.
(3) I nstal l reacti on pl ug and pi n assembl y i n hous-
i ng and secure wi th new snap ri ng (Fi g. 38).
(4) Posi ti on sprag and spri ng i n housi ng and i nsert
sprag shaft. Be sure square l ug on sprag i s toward
park gear. Al so be sure spri ng i s posi ti oned so i t
moves sprag away from gear.
(5) I nstal l extensi on housi ng.
(6) I nstal l propel l er shaft and l ower vehi cl e.
(7) Check transmi ssi on fl ui d l evel . Add fl ui d i f nec-
essary.
Fig. 35 Governor Valve
Fig. 36 Snap Rings And Spacer
Fig. 37 Governor Body
DISASSEMBLY
(1) Remove governor body from transmi ssi on.
(2) Cl ean and i nspect governor fi l ter (Fi g. 39).
(3) Remove snap ri ng and washer that secure gov-
ernor wei ght assembl y i n body (Fi g. 40).
(4) Remove governor wei ght assembl y from gover-
nor body bore.
(5) Sl i de i ntermedi ate and i nner wei ght from outer
wei ght.
(6) Posi ti on i ntermedi ate wei ght on sui tabl e si ze
socket (Fi g. 41).
(7) Push i nner wei ght downward wi th nut dri ver.
Then remove i nner wei ght snap ri ng wi th Mi l l er
Pl i er Tool 6823 (Fi g. 41).
(8) Remove i nner wei ght and spri ng from i nterme-
di ate wei ght.
ASSEMBLY
CAUTION: Exercise care when installing the rings.
They are easily broken if overspread or twisted dur-
ing installation.
I f i t was necessary to remove the park gear,
i nspect the seal ri ngs and bore i n rear support.
I nstal l new seal ri ngs on park gear hub onl y i f ori g-
i nal ri ngs are damaged, or worn. I nstal l ri ng wi th
i nterl ock ends fi rst and ri ng wi th pl ai n ends l ast.
Sl i p each ri ng on hub and seat them i n grooves. Ver-
i fy that rear ri ng ends are securel y i nterl ocked before
proceedi ng. I f the bore i n rear support i s damaged,
repl ace the rear support.
Fig. 38 Park Lock
Fig. 39 Governor Filter
Fig. 40 Snap Ring, Washer, and Outer Weight
Fig. 41 Inner Weight Snap Ring
(1) Lubri cate governor components wi th Mopar
ATF Pl us 3, Type 7176 transmi ssi on fl ui d before
assembl y.
(2) Cl ean and i nspect governor wei ghts and bores
for scori ng or wear. Repl ace the governor body and
wei ghts i f damaged. Refer to Cl eani ng and I nspecti on
secti on of thi s group for proper procedure.
(3) I nsert spri ng i nto i ntermedi ate wei ght.
(4) I nsert i nner wei ght i nto i ntermedi ate wei ght
and i nstal l snap-ri ng (Fi g. 42). Veri fy snap-ri ng i s
ful l y seated i n groove i n i ntermedi ate wei ght (Fi g.
41).
(5) Assembl e governor wei ghts i nto governor body
(Fi g. 40).
(6) I nstal l washer and snap ri ng to hol d wei ghts i n
governor body.
(7) I nstal l governor body i n transmi ssi on.
VALVE BODY
DISASSEMBLY
Posi ti on the val ve body on a cl ean work surface to
avoi d contami nati on.
CAUTION: Do not clamp any part of the valve body
assembly (Fig. 43) in a vise. This 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. The valves and valve
body will be damaged if force is used. Also tag or
mark the valve body springs for reference as they
are removed. Do not allow them to become inter-
mixed.
(1) Remove screws attachi ng adjusti ng screw
bracket to val ve body and transfer pl ate. Hol d
bracket fi rml y agai nst spri ng force whi l e removi ng
l ast screw.
(2) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw (Fi g. 44).
(3) Remove swi tch val ve and spri ng, pressure reg-
ul ator val ve and spri ng, ki ckdown val ve and spri ng,
and throttl e val ve from val ve body (Fi g. 44).
(4) Secure detent bal l and spri ng i n housi ng wi th
Retai ner Tool 6583 (Fi g. 45).
(5) Remove manual shaft E-cl i p, washer, and seal
(Fi g. 46).
(6) Pul l manual shaft and park rod assembl y
upward out of val ve body and off throttl e l ever
(Fi g. 46).
(7) Remove manual val ve from val ve body
(Fi g. 47).
(8) Remove Retai ner Tool 6583. Then remove and
retai n detent bal l and spri ng (Fi g. 46).
(9) Remove throttl e l ever (Fi g. 46).
(10) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 48).
Fig. 42 Intermediate and Inner Governor Weights
Fig. 43 Valve Body Assembly
Fig. 44 Adjusting Screw Bracket, Springs, Valve
Removal
(11) Remove converter cl utch sol enoi d from separa-
tor pl ate (Fi g. 49). A T25 torx bi t i s requi red to
remove sol enoi d attachi ng screw.
(12) Remove screws attachi ng converter cl utch
modul e to val ve body and remove modul e and con-
necti ng tube (Fi g. 50).
(13) Remove screws attachi ng end cover pl ate to
torque converter modul e (Fi g. 51).
(14) Remove converter cl utch val ve, fai l safe val ve,
and spri ngs (Fi g. 51).
(15) Turn val ve body over so transfer pl ate i s fac-
i ng upward (Fi g. 52). Wi th val ve body i n thi s posi -
ti on, val ve body check bal l s wi l l remai n i n pl ace and
not fal l out when transfer pl ate i s removed.
(16) Remove screws attachi ng transfer pl ate to
val ve body (Fi g. 52).
(17) Remove transfer pl ate and separator pl ate
from val ve body (Fi g. 52). Note posi ti on of fi l ter and
cl utch sol enoi d for reference. Remove val ve body
check bal l s.
(18) Posi ti on transfer pl ate on bench so separator
pl ate, and fi l ter are faci ng up. Thi s wi l l avoi d havi ng
rear cl utch and rear servo check bal l s fal l out when
pl ates are separated.
(19) Remove screws attachi ng separator pl ate to
transfer pl ate (Fi g. 53).
(20) Note posi ti on of fi l ter, rear cl utch servo and
rear servo check bal l s for assembl y reference
(Fi g. 53) and (Fi g. 54).
Fig. 45 Securing Detent Ball And Spring With
Retainer Tool
Fig. 46 Manual And Throttle Levers
Fig. 47 Manual Valve
Fig. 48 Park Rod
Fig. 49 Converter Clutch Solenoid
(21) Remove shuttl e val ve end pl ate (Fi g. 55).
(22) Remove shuttl e val ve E-cl i p and remove sec-
ondary spri ng and spri ng gui des from end of val ve
(Fi g. 56).
(23) Remove governor pl ug end pl ate (Fi g. 57).
Fig. 50 Clutch Module And Connecting Tube
Fig. 51 Converter Clutch and Fail Safe Valves
Fig. 52 Valve Body Transfer Plate Screws
Fig. 53 Transfer And Separator Plates
Fig. 54 Rear Servo and Rear Clutch Check Balls
Fig. 55 Shuttle Valve End Plate
(24) Remove 1-2 and 2-3 shi ft val ve governor pl ugs
from val ve body (Fi g. 57).
(25) Remove shuttl e val ve throttl e pl ug, pri mary
spri ng and shuttl e val ve from val ve body (Fi g. 57).
(26) Remove screws attachi ng ki ckdown l i mi t
val ve body to val ve body (Fi g. 57).
(27) Remove 1-2 shi ft control val ve and spri ng
from val ve body (Fi g. 57).
(28) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 57).
(29) Remove 1-2 shi ft val ve and spri ng from val ve
body (Fi g. 57).
(30) Remove throttl e pressure pl ug from ki ckdown
l i mi t val ve body (Fi g. 57).
(31) Remove retai ner from end of ki ckdown l i mi t
(32) Remove ki ckdown l i mi t val ve and spri ng from
ki ckdown l i mi t val ve body (Fi g. 57).
(33) Remove regul ator val ve end pl ate from val ve
body (Fi g. 57).
(34) Remove regul ator val ve l i ne pressure pl ug,
pressure pl ug sl eeve, regul ator val ve throttl e pres-
sure pl ug and spri ng (Fi g. 57).
ASSEMBLY
Cl ean and i nspect al l val ve body components for
damage or wear. Refer to the Cl eani ng and I nspec-
ti on secti on of thi s group for proper procedure.
Fig. 57 Control Valves, Shift Valves, And Governor Plugs
Fig. 56 Shuttle Valve E-Clip And Secondary Spring
CAUTION: Do not force valves 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
operation. Tighten valve body screws to recom-
mended torque only.
(1) Lubri cate val ve body bores, val ves and pl ugs
wi th Mopar ATF Pl us 3, Type 7176, transmi ssi on
fl ui d.
(2) I nstal l regul ator val ve l i ne pressure pl ug, pres-
sure pl ug sl eeve, regul ator val ve throttl e pressure
pl ug, and spri ng i nto val ve body (Fi g. 57). Veri fy
val ve components sl i de freel y.
(3) I nstal l regul ator val ve end pl ate on val ve body
(Fi g. 57).
(4) I nstal l ki ckdown l i mi t val ve and spri ng i n ki ck-
down l i mi t val ve body (Fi g. 57). Veri fy val ve compo-
nents sl i de freel y.
(5) Compress spri ng i nto ki ckdown l i mi t val ve
body.
(6) I nstal l retai ner i n grooves at end of ki ckdown
l i mi t val ve body (Fi g. 57).
(7) I nstal l throttl e pressure pl ug i n ki ckdown l i mi t
(8) I nstal l 1-2 shi ft val ve and spri ng i nto val ve
body (Fi g. 57).
(9) I nstal l 2-3 shi ft val ve and spri ng i nto val ve
body (Fi g. 57).
(10) I nstal l 1-2 shi ft control val ve and spri ng i nto
(11) Veri fy val ve components sl i de freel y.
(12) Pl ace ki ckdown l i mi t val ve body and end pl ate
i n posi ti on on val ve body and compress spri ngs (Fi g.
57).
(13) I nstal l screws to attach ki ckdown l i mi t val ve
body to val ve body (Fi g. 57).
(14) I nstal l shuttl e val ve throttl e pl ug, pri mary
spri ng and shuttl e val ve i nto val ve body (Fi g. 57).
Veri fy val ve components sl i de freel y.
(15) I nstal l 1-2 and 2-3 shi ft val ve governor pl ugs
i nto val ve body (Fi g. 57). Veri fy val ve components
sl i de freel y.
(16) Pl ace governor pl ug end pl ate i n posi ti on on
val ve body and compress spri ng.
(17) I nstal l screws to attach governor pl ug end
pl ate to val ve body (Fi g. 57).
(18) Assembl e shuttl e val ve spri ng and gui des
(Fi g. 57). Pl ace spri ng and gui des i n posi ti on on shut-
tl e val ve stem.
(19) Compress spri ng and i nstal l E-cl i p i n groove
on shuttl e val ve stem (Fi g. 58).
(20) Pl ace shuttl e val ve end pl ate i n posi ti on on
(21) I nstal l screws to attach shuttl e val ve end
pl ate to val ve body (Fi g. 59).
(22) I nstal l rear cl utch servo and rear servo check
bal l s i n proper cavi ti es i n transfer pl ate (Fi g. 60).
(23) I nsert fi l ter i nto openi ng i n separator pl ate
(Fi g. 61).
(24) Pl ace separator pl ate i n posi ti on on transfer
pl ate and i nstal l screws to attach separator pl ate to
transfer pl ate (Fi g. 61).
(25) Pl ace one 11/32 i n. check bal l and si x 1/4 i n.
check bal l s i n the proper cavi ti es i n the val ve body
(Fi g. 62).
(26) Pl ace transfer pl ate i n posi ti on on val ve body
(Fi g. 63).
(27) I nstal l screws to attach transfer pl ate to val ve
body (Fi g. 63).
(28) Turn val ve body over to expose the separator
pl ate.
Fig. 58 Shuttle Valve E-Clip And Secondary Spring
Fig. 59 Shuttle Valve End Plate
(29) I nsert converter cl utch val ve and spri ng i nto
converter cl utch val ve modul e (Fi g. 64). Veri fy val ve
components sl i de freel y.
(30) I nsert spri ng and fai l -safe val ve i nto converter
cl utch val ve modul e (Fi g. 64). Veri fy val ve compo-
nents sl i de freel y.
(31) Pl ace cover pl ate i n posi ti on on converter
cl utch val ve modul e (Fi g. 64).
(32) I nstal l screws to attach cover to converter
cl utch val ve modul e (Fi g. 64).
(33) I nsert connecti ng tube i nto converter cl utch
val ve modul e (Fi g. 64).
(34) I nsert connecti ng tube i nto val ve body open-
i ng (Fi g. 65).
(35) Pl ace converter cl utch val ve modul e i n posi -
ti on on separator pl ate. I nstal l screws to attach con-
verter cl utch modul e to val ve body (Fi g. 65).
(36) I f necessary, i nstal l a new O-ri ng on converter
cl utch sol enoi d (Fi g. 66).
(37) I nsert converter cl utch sol enoi d i nto transfer
pl ate (Fi g. 66).
(38) I nstal l screw to attach sol enoi d to transfer
pl ate (Fi g. 66).
(39) I f necessary, i nsert park rod end i nto manual
l ever and i nstal l E-cl i p (Fi g. 67).
(40) I nsert detent spri ng and bal l i nto openi ng i n
val ve body and i nstal l Retai ner Tool 6583 (Fi g. 68).
(41) I nstal l manual val ve i nto val ve body (Fi g. 69).
(42) I nsert throttl e l ever through transfer pl ate
si de of val ve body and upward (Fi g. 70).
Fig. 60 Rear Servo and Rear Clutch Check Balls
Fig. 61 Transfer And Separator Plates
Fig. 62 Correct Position Of Valve Body Check Balls
Fig. 63 Valve Body Transfer Plate Screws
(43) I nsert throttl e l ever i nto groove i n manual
val ve (Fi g. 71).
(44) I nstal l seal , washer, and E-cl i p to retai n man-
ual shaft to val ve body (Fi g. 70).
(45) I nstal l swi tch val ve and spri ng, pressure reg-
ul ator val ve and spri ng, ki ckdown val ve and spri ng,
and throttl e val ve i nto val ve body (Fi g. 72).
(46) Pl ace adjusti ng screw bracket and l i ne pres-
sure adjusti ng screw i n posi ti on on val ve body and
compress spri ngs (Fi g. 44).
(47) I nstal l screws to attach adjuster bracket to
val ve body.
Fig. 64 Converter Clutch Valve Module
Fig. 65 Clutch Module And Connecting Tube
Fig. 66 Converter Clutch Solenoid
Fig. 67 Park Rod
Fig. 68 Securing Detent Ball And Spring With
Retainer Tool
TRANSMISSION
DISASSEMBLY
(1) Remove transmi ssi on from vehi cl e.
(2) I nstal l a sui tabl e tai l shaft housi ng pl ug to
avoi d contami nati ng i nternal components wi th cl ean-
i ng sol vents.
(3) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(4) Remove torque converter from transmi ssi on.
(5) Remove throttl e and shi ft l evers from val ve
body manual shaft and throttl e l ever shaft.
(6) Mount transmi ssi on i n repai r stand C-3750-B
or si mi l ar type stand (Fi g. 73).
(8) Remove fl ui d pan.
(9) Remove park/neutral posi ti on swi tch and seal
(Fi g. 74).
(10) Remove val ve body.
(11) Remove accumul ator spri ng and pi ston (Fi g.
75).
Fig. 70 Manual And Throttle Levers
Fig. 71 Manual Valve And Throttle Lever Alignment
Fig. 72 Adjusting Screw Bracket, Springs, and
Valves
Fig. 73 Repair Stand
Fig. 74 Park/Neutral Position Switch
(12) Loosen front band adjusti ng screw l ock nut
(Fi g. 76) 4-5 turns. Then ti ghten band adjusti ng
screw unti l band i s ti ght around front cl utch. Thi s
prevents front/rear cl utches from comi ng out wi th
pump and possi bl y damagi ng cl utch or pump compo-
nents.
(13) Remove oi l pump bol ts.
(14) Thread bol ts of Sl i de Hammer Tool s C-3752
i nto threaded hol es i n pump body fl ange (Fi g. 77).
(15) Bump sl i de hammer wei ghts outward to
remove pump and reacti on shaft support assembl y
from case (Fi g. 77).
(16) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose (Fi g. 76).
(17) Squeeze front band together and remove band
strut (Fi g. 78).
(18) Remove front and rear cl utch uni ts as an
assembl y. Grasp i nput shaft, hol d cl utch uni ts
together and remove them from case (Fi g. 79).
(19) Li ft front cl utch off rear cl utch (Fi g. 80). Set
cl utch uni ts asi de for overhaul .
(20) Remove output shaft thrust washer from out-
put shaft (or from rear cl utch hub) (Fi g. 81).
(21) Remove output shaft thrust pl ate and washer
from output shaft hub (Fi g. 81).
(22) Remove front band from case (Fi g. 82).
(23) Remove extensi on housi ng from transmi ssi on
case.
(24) Remove governor body and park gear from
output shaft.
(25) Remove output shaft and pl anetary geartrai n
as assembl y (Fi g. 83). Support geartrai n wi th both
hands duri ng removal . Do not al l ow machi ned sur-
faces on output shaft to become ni cked or scratched.
(26) Loosen rear band adjusti ng screw 4-5 turns
(Fi g. 84).
(27) Remove snap ri ng that secures l ow-reverse
drum to rear support hub, however do not remove
drum (Fi g. 85).
(28) Remove bol ts attachi ng rear support to trans-
mi ssi on case and pul l support from l ow-reverse drum
(Fi g. 86).
(29) Remove bol ts attachi ng overrunni ng cl utch
cam and l ow-reverse drum to transmi ssi on case (Fi g.
87).
Fig. 75 Accumulator Piston And Spring
Fig. 76 Front Band Adjusting Screw Lock Nut
Fig. 77 Oil Pump/Reaction Shaft Support
Fig. 78 Front Band Strut
(30) Usi ng snap-ri ng pl i er, pul l rear band anchor
pi n (l ocated on the servo si de of the rear support)
from transmi ssi on case.
(31) Remove rear band and l i nk from transmi ssi on
(Fi g. 88).
(32) Separate l i nk from rear band (Fi g. 89).
(33) I f necessary remove front and rear band servo
l evers. Al l transmi ssi on components can be servi ced
wi thout removi ng the l evers.
(a) Usi ng a 1/4 i nch dri ve extensi on remove
front band reacti on pi n access pl ug (Fi g. 90).
(b) Remove front band reacti on pi n wi th penci l
magnet. Pi n i s accessi bl e from converter housi ng
si de of case (Fi g. 91).
(c) Remove front band l ever (Fi g. 92).
(d) Usi ng snap-ri ng pl i er, pul l rear band l ever
pi vot from transmi ssi on case (Fi g. 93).
(e) Separate rear band servo l ever from trans-
mi ssi on.
Fig. 79 Front/Rear Clutch Assemblies
Fig. 80 Separating Front Clutch From Rear Clutch
Fig. 81 Output Shaft Thrust Plate and Washer
Fig. 82 Front Band
Fig. 83 Planetary Geartrain
(34) Compress front servo rod gui de about 1/8 i n.
wi th l arge C-cl amp and Tool C-4470, or Spri ng Com-
pressor Tool C-3422-B (Fi g. 94).
(35) Remove front servo rod gui de snap ri ng (Fi g.
94). Exercise caution when removing snap ring.
Servo bore can be scratched or nicked if care is
not exercised.
(36) Remove compressor tool s and remove front
servo rod gui de, spri ng and servo pi ston.
(37) Compress rear servo spri ng retai ner about
1/16 i n. wi th C-cl amp and Tool C-4470 or SP-5560
(Fi g. 95). Val ve Spri ng Compressor C-3422-B can al so
be used to compress spri ng retai ner.
Fig. 84 Rear Band Adjuster Location
Fig. 85 Low-Reverse Drum Snap Ring
Fig. 86 Rear Support
Fig. 87 Overrunning Clutch Cam Bolt Locations
Fig. 88 Rear Band and Link
Fig. 89 Rear Band and Link
(38) Remove rear servo spri ng retai ner snap ri ng.
Then remove compressor tool s and remove rear servo
spri ng and pi ston.
ASSEMBLY
(1) I nstal l rear servo pi ston, spri ng and spri ng
retai ner. Compress rear servo spri ng and retai ner
wi th Compressor Tool C-3422-B (Fi g. 95) or a l arge
C-cl amp.
(2) I nstal l front servo pi ston, spri ng, and rod
gui de. Compress front servo rod gui de wi th Val ve
Spri ng Compressor C-3422-B and i nstal l servo snap
ri ng (Fi g. 94).
(3) Assembl e l i nk bar to band. Notched si de of l i nk
toward band (Fi g. 93).
(4) I nsert rear band through pan openi ng i n trans-
mi ssi on case.
(5) I nsert hook on band onto adjuster l ever.
(6) Al i gn hol es i n l i nk bar wi th hol e i n transmi s-
si on case outboard of rear support openi ng (Fi g. 92).
(7) I nsert anchor pi n i nto case through l i nk bar.
(8) Exami ne bol t hol es i n overrunni ng cl utch cam.
Note that one hol e i s not threaded (Fi g. 96). Thi s
hol e must al i gn wi th bl ank area i n cl utch cam bol t
ci rcl e.
NOTE: The bolt holes in cam are slightly counter-
sunk on one side. This side of cam faces rearward
(toward rear support).
Fig. 90 Front Band Reaction Pin Access Plug
Fig. 91 Front Band Reaction Pin
Fig. 92 Front Band Lever
Fig. 93 Rear Band Servo Lever Pin
Fig. 94 Compressing Front Servo
(9) Lubri cate overrunni ng cl utch rol l ers, spri ngs
and cam wi th Mopar ATF Pl us 3, type 7176, trans-
mi ssi on fl ui d.
(10) Posi ti on overrunni ng cl utch on a cl ean, fl at
work surface wi th countersunk hol es downward.
(11) Pl ace rear of l ow-reverse drum over overrun-
ni ng cl utch and al i gn cl utch rol l ers to hub of drum.
(12) Whi l e sl i ghtl y pi voti ng l ow-reverse drum,
push hub of drum i nto overrunni ng cl utch. Veri fy
that countersunk hol es are faci ng outward. Cam
should be able to rotate in the drum clockwise
only.
(13) I nsert a sui tabl e awl through the rear support
mounti ng hol e cl osest to the pan seal i ng face. The
awl shoul d be next to the wi de space area at the
back of transmi ssi on case.
(14) I nsert l ow-reverse drum and overrunni ng
cl utch i nto front of transmi ssi on case and i nto rear
band.
(15) I nsert awl ti p i nto the threaded hol e next to
the non-threaded hol e i n the overrunni ng cl utch cam.
Veri fy that non-threaded hol e i s al i gned wi th wi de
space area on transmi ssi on case.
(16) Push l ow-reverse drum rearward to cl ose gap
between cam and case.
(17) I nstal l overrunni ng cl utch cam bol ts. Clutch
cam bolts are shorter than rear support bolts.
Ti ghten cam bol ts to 17 Nm (150 i n. l bs. or 13 ft.
l bs.) torque.
(18) Hol d l ow-reverse drum i n posi ti on so rear sup-
port wi l l not push i t out of overrunni ng cl utch.
(19) I nsert rear support i nto openi ng at rear of
(20) Al i gn support wi th the embossed arrow i n the
di recti on of the pan face.
(21) I nstal l and ti ghten rear support bol ts to 17
(22) I nstal l snap ri ng to retai n l ow-reverse drum
to hub of rear support (Fi g. 98).
Fig. 95 Compressing Rear Servo Spring
Fig. 96 Clutch Cam Alignment
Fig. 97 Rear Support
Fig. 98 Low-Reverse Drum Snap Ring
(23) Lubri cate output shaft, rear support bore and
l ow-reverse drum hub wi th transmi ssi on fl ui d.
(24) I nstal l assembl ed output shaft and pl anetary
geartrai n i n case (Fi g. 99).
(25) Al i gn dri ve l ugs on rear pl anetary gear wi th
sl ots i n l ow-reverse drum (Fi g. 99). Then seat pl ane-
tary assembl y i n drum.
(26) I nstal l governor on output shaft.
(27) Turn and secure transmi ssi on so that front
openi ng i s upward.
(28) Assembl e front and rear cl utches together.
(a) Check i nput shaft seal ri ngs (Fi g. 100). Veri fy
that di agonal -cut ends of Tefl on seal ri ng are
properl y joi ned and ends of metal ri ng are correctl y
hooked together. Al so be sure ri ngs are i nstal l ed i n
sequence shown.
(b) Al i gn teeth on cl utch di scs i n l i ne.
(c) I nsert i nput shaft on rear cl utch i nto center
of front cl utch (Fi g. 101).
(d) Engage teeth on rear cl utch hub i nto teeth
on cl utch (Fi g. 103). Rotate front cl utch retai ner
back and forth unti l compl etel y seated on rear
cl utch.
(29) I nstal l output shaft thrust pl ate on shaft hub
i n pl anetary geartrai n dri vi ng shel l (Fi g. 102). Use
petrol eum jel l y to hol d thrust pl ate i n pl ace.
(30) Check rear cl utch thrust washer. Use addi -
ti onal petrol eum jel l y to hol d washer i n pl ace i f nec-
essary.
(31) Coat output shaft thrust washer wi th petro-
l eum jel l y. I nstal l washer i n rear cl utch hub (Fi g.
104). Use enough petrol eum jel l y to hol d washer i n
pl ace. Be sure grooved side of washer faces
rearward (toward output shaft) as shown. Also
note that washer only fits one way in clutch
hub.
(32) Al i gn dri ve teeth on rear cl utch di scs wi th
smal l screwdri ver (Fi g. 105). Thi s wi l l make i nstal l a-
ti on i nto front of pl anetary geartrai n easi er.
(33) I nsert front band i nto openi ng at front of
(34) I nstal l front and rear cl utch uni ts as assembl y
(Fi g. 107). Al i gn rear cl utch wi th front annul us gear
Fig. 99 Output Shaft And Planetary Geartrain
Fig. 100 Input Shaft Seal Ring Location
Fig. 101 Front and Rear Clutches
Fig. 102 Output Shaft Thrust Plate
and i nstal l assembl y i n dri vi ng shel l . Be sure out-
put shaft thrust washer and thrust plate are
not displaced during installation.
(35) Careful l y work assembl ed cl utches back and
forth to engage and seat rear cl utch di scs on front
annul us gear. Veri fy that front cl utch dri ve l ugs are
ful l y engaged i n sl ots of dri vi ng shel l after i nstal l a-
ti on.
(36) Engage front band on adjusti ng screw and
hol d band i n pl ace.
(37) I nstal l strut between band l ever and front
band (Fi g. 108).
(38) Ti ghten front band adjusti ng screw unti l band
just gri ps cl utch retai ner. Veri fy that front/rear
cl utches are sti l l seated before conti nui ng.
(39) Veri fy that reacti on shaft support hub seal
ri ngs are hooked together (Fi g. 109).
(40) Coat front cl utch thrust washer wi th petro-
l eum jel l y to hol d i t i n pl ace. Then i nstal l washer
over reacti on shaft hub and seat i t on pump (Fi g.
110).
Fig. 103 Assembling Front And Rear Clutch Units
Fig. 104 Output Shaft Thrust Washer
Fig. 105 Aligning Rear Clutch Disc Lugs
Fig. 106 Front Band
Fig. 107 Installing Front/Rear Clutch
CAUTION: The thrust washer bore (I.D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
(41) Thread two Pi l ot Stud Tool s C-3288-B i nto
bol t hol es i n oi l pump fl ange (Fi g. 111).
(42) Al i gn and i nstal l oi l pump gasket (Fi g. 111).
(43) Lubri cate oi l pump seal s wi th Mopar Door-
Ease, or Ru-Gl yde, Door Eze, or ATF Pl us 3.
(44) I nstal l oi l pump (Fi g. 112). Al i gn and posi ti on
pump on pi l ot studs. Sl i de pump down studs and
work i t i nto front cl utch hub and case by hand. Then
i nstal l two or three pump bol ts to hol d pump i n
pl ace.
(45) Remove pi l ot stud tool s and i nstal l remai ni ng
oi l pump bol ts. Ti ghten bol ts al ternatel y i n di agonal
pattern to 20 Nm (15 ft. l bs.).
(46) Measure i nput shaft end pl ay (Fi g. 113).
Fig. 108 Front Band Linkage Installation
Fig. 109 Reaction Shaft Support Seal Rings
Fig. 110 Front Clutch Thrust Washer Installation
Fig. 111 Installing Pilot Studs And Oil Pump Gasket
Fig. 112 Installing Oil Pump And Reaction Shaft
Support
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or output shaft thrust
washer and/or thrust plate are worn and need to be
changed.
(a) Attach di al i ndi cator (C-3339) to converter
housi ng. Posi ti on i ndi cator pl unger agai nst i nput
shaft and zero i ndi cator.
(b) Move i nput shaft i n and out and record read-
i ng. End pl ay shoul d be 0.56 - 2.31 mm (0.022 -
0.091 i n.).
(47) Posi ti on transmi ssi on on work surface wi th
pan face upward.
(48) I nstal l val ve body.
(49) Adjust front and rear bands.
(50) I nstal l fl ui d fi l ter and pan.
(51) I nstal l rear extensi on housi ng.
(52) I nstal l torque converter.
OVERRUNNING CLUTCH/LOW-REVERSE DRUM
DISASSEMBLY
(1) I f the cl utch assembl y came out wi th the l ow-
reverse drum, thread two cl utch cam bol ts i nto the
cam. Then l i ft the cam out of the drum wi th the bol ts
(Fi g. 114). Rotate the cam back and forth to ease
removal i f necessary.
(2) Remove the cl utch rol l er and spri ng assembl y
from the overrunni ng cl utch race.
ASSEMBLY
(1) Assembl e cl utch rol l ers and spri ngs i n retai ner
i f necessary (Fi g. 115).
(2) I nstal l overrunni ng cl utch rol l er, spri ng and
retai ner assembl y i n cl utch cam (Fi g. 116).
(3) Temporari l y assembl e and check overrunni ng
cl utch operati on as fol l ows:
(a) Assembl e cam and cl utch.
(b) I nstal l cl utch assembl y on l ow-reverse drum
wi th twi sti ng moti on (Fi g. 117).
(c) I nstal l drum-cl utch assembl y i n case and
i nstal l cl utch cam bol ts.
(d) I nstal l rear support and support attachi ng
bol ts.
(e) Check l ow-reverse drum rotati on. Drum
should rotate freely in clockwise direction
and lock when turned in counterclockwise
direction (as viewed from front of case).
FRONT SERVO PISTON
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 119).
(2) Remove smal l snap ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
Fig. 113 Checking Input Shaft End Play
Fig. 114 Removing Overrunning Clutch From
Low-Reverse Drum
Fig. 115 Overrunning Clutch Rollers, Springs,
Retainer
(3) Remove and di scard servo component O-ri ng
and seal ri ngs.
ASSEMBLY
(1) Lubri cate new O-ri ng and seal ri ngs wi th
petrol eum jel l y and i nstal l them on pi ston, gui de and
rod.
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap ri ng (Fi g.
119).
(3) Set servo components asi de for i nstal l ati on dur-
i ng transmi ssi on reassembl y.
REAR SERVO PISTON
DISASSEMBLY
(1) Remove smal l snap ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 120).
(2) Remove and di scard servo pi ston seal ri ng.
ASSEMBLY
(1) Lubri cate pi ston and gui de seal s wi th petro-
l eum jel l y. Lubri cate other servo parts wi th Mopar
ATF Pl us 3, Type 7176, transmi ssi on fl ui d.
(2) I nstal l new seal ri ng on servo pi ston.
(3) Assembl e pi ston, pl ug, spri ng and new snap
ri ng.
(4) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
Fig. 116 Assembling Overrunning Clutch And Cam
Fig. 117 Temporary Assembly Of Clutch And Drum
To Check Operation
Fig. 118 Assembled Overrunning Clutch
Fig. 119 Front Servo
OIL PUMP AND REACTION SHAFT SUPPORT
DISASSEMBLY
(1) Remove seal ri ng from housi ng and reacti on
shaft support (Fi g. 121).
(2) Mark pump housi ng and support assembl y for
al i gnment reference.
(3) Remove bol ts attachi ng pump body to support
(Fi g. 122).
(4) Separate support from pump housi ng (Fi g.
123).
(5) Remove i nner and outer gears from reacti on
shaft support (Fi g. 124).
(6) I f pump seal was not removed duri ng transmi s-
si on di sassembl y, remove seal wi th punch and ham-
mer.
(7) Remove front cl utch thrust washer from sup-
port hub (Fi g. 125).
OIL PUMP BUSHING REPLACEMENT
(1) Remove pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng Remover SP-3551 from Tool Set
C-3887-J (Fi g. 126).
(2) I nstal l new pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng I nstal l er SP-5117 (Fi g. 126).
Bushi ng shoul d be fl ush wi th pump housi ng bore.
Fig. 120 Rear Servo Components
Fig. 121 Removing Pump Seal Ring
Fig. 122 Pump Support Bolts
Fig. 123 Separating Pump Housing From Reaction
Shaft Support
Fig. 124 Pump Gear Removal
Fig. 125 Support Hub Thrust Washer
(3) Stake new pump bushi ng i n two pl aces wi th
bl unt punch (Fi g. 127). Remove burrs from stake
poi nts wi th kni fe bl ade afterward.
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assembl e Bushi ng Remover Tool s SP-1191,
3633 and 5324 (Fi g. 128). Do not clamp any part
of reaction shaft or support in vise.
(2) Hol d Cup Tool SP-3633 fi rml y agai nst reacti on
shaft and thread remover SP-5324 i nto bushi ng as
far as possi bl e by hand. Then thread remover tool 3-4
addi ti onal turns i nto bushi ng wi th a wrench.
(3) Turn remover tool hex nut down agai nst
remover cup to pul l bushi ng from shaft. Cl ean al l
chi ps from shaft after bushi ng removal .
(4) Li ghtl y gri p ol d bushi ng i n vi se or wi th pl i ers
and back remover tool out of bushi ng.
(5) Assembl e Bushi ng I nstal l er Tool s C-4171 and
SP-5325 (Fi g. 128).
(6) Sl i de new bushi ng onto I nstal l er Tool SP-5325.
(7) Posi ti on reacti on shaft support upri ght on a
cl ean smooth surface.
(8) Al i gn bushi ng i n bore. Then tap bushi ng i nto
pl ace unti l Bushi ng I nstal l er SP-5325 bottoms.
(9) Cl ean reacti on shaft support thoroughl y after
i nstal l i ng bushi ng.
ASSEMBLY
(1) Lubri cate gear bore i n pump housi ng wi th
(2) Lubri cate pump gears wi th transmi ssi on fl ui d.
(3) Support pump housi ng on wood bl ocks (Fi g.
129).
(4) I nstal l outer gear i n pump housi ng (Fi g. 129).
Gear can be i nstal l ed ei ther way (i t i s not a one-way
fi t).
(5) I nstal l pump i nner gear (Fi g. 130).
CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter
(I.D.) is chamfered. Be sure the chamfered side
faces forward (to front of pump).
(6) I nstal l new thrust washer on hub of reacti on
shaft support. Lubri cate washer wi th transmi ssi on
fl ui d or petrol eum jel l y.
(7) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub (Fi g. 131).
Lubri cate seal ri ngs wi th transmi ssi on fl ui d or petro-
l eum jel l y after i nstal l ati on. Squeeze each ri ng unti l
ri ng ends are securel y hooked together.
Fig. 126 Removing Oil Pump Bushing
Fig. 127 Staking Oil Pump Bushing
Fig. 128 Replacing Reaction Shaft Support Bushing
CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
during installation.
(8) I nstal l reacti on shaft support on pump housi ng
(Fi g. 132).
(9) Al i gn reacti on support on pump housi ng. Use
al i gnment marks made at di sassembl y. Or, rotate
support unti l bol t hol es i n support and pump housi ng
are al l al i gned (hol es are offset for one-way fi t).
(10) I nstal l al l bol ts that attach support to pump
housi ng. Then ti ghten bol ts fi nger ti ght.
(11) Ti ghten support-to-pump bol ts to requi red
torque as fol l ows:
(a) Reverse pump assembl y and i nstal l i t i n
transmi ssi on case. Posi ti on pump so bol ts are fac-
i ng out and are accessi bl e.
(b) Secure pump assembl y i n case wi th 2 or 3
bol ts, or wi th pi l ot studs.
(c) Ti ghten support-to-pump bol ts to 20 Nm (15
ft. l bs.).
(d) Remove pump assembl y from transmi ssi on
case.
(12) I nstal l new oi l seal i n pump wi th Speci al Tool
C-4193 and Tool Handl e C-4171 (Fi g. 133). Be sure
seal l i p faces i nward.
(13) I nstal l new seal ri ng around pump housi ng.
Be sure seal i s properl y seated i n groove.
(14) Lubri cate l i p of pump oi l seal and O-ri ng seal
Fig. 129 Supporting Pump And Installing Outer Gear
Fig. 130 Pump Inner Gear Installation
Fig. 131 Hub Seal Ring Position
Fig. 132 Assembling Reaction Shaft Support And
Pump Housing
Fig. 133 Pump Oil Seal Installation
FRONT CLUTCH
DISASSEMBLY
(1) Remove waved snap ri ng and remove pressure
pl ate, cl utch pl ates and cl utch di scs (Fi g. 134).
(2) Compress cl utch pi ston spri ng wi th Compressor
Tool C-3575-A (Fi g. 135). Be sure l egs of tool are
seated squarel y on spri ng retai ner before compress-
i ng spri ng.
(3) Remove retai ner snap ri ng and remove com-
pressor tool .
(4) Remove spri ng retai ner and cl utch spri ng. Note
posi ti on of retai ner on spri ng for assembl y reference.
(5) Remove cl utch pi ston from cl utch retai ner.
Remove pi ston by rotati ng i t up and out of retai ner.
(6) Remove seal s from cl utch pi ston and cl utch
retai ner hub. Di scard both seal s as they are not reus-
abl e.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal s on pi ston and i n hub of
retai ner. Be sure l i p of each seal faces i nteri or of
cl utch retai ner.
(3) Lubri cate l i ps of pi ston and retai ner seal s wi th
l i beral quanti ty of Mopar Door Ease, or Ru-Gl yde.
Then l ubri cate retai ner hub, bore and pi ston wi th
l i ght coat of transmi ssi on fl ui d.
(4) I nstal l cl utch pi ston i n retai ner (Fi g. 136). Use
twi sti ng moti on to seat pi ston i n bottom of retai ner. A
thi n stri p of pl asti c (about 0.020 thi ck), can be used
to gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(5) Posi ti on spri ng i n cl utch pi ston (Fi g. 137).
(6) Posi ti on spri ng retai ner on top of pi ston spri ng
(Fi g. 138). Make sure retainer is properly
installed. Small raised tabs should be facing
upward. Semicircular lugs on underside of
retainer are for positioning retainer in spring.
(7) Compress pi ston spri ng and retai ner wi th Com-
pressor Tool C-3575-A (Fi g. 135). Then i nstal l new
snap ri ng to secure spri ng retai ner and spri ng.
(8) I nstal l cl utch pl ates and di scs (Fi g. 134).
I nstal l steel pl ate then di sc unti l al l pl ates and di scs
are i nstal l ed. The front cl utch uses 4 cl utch di scs.
Fig. 134 Front Clutch Components
(9) I nstal l pressure pl ate and waved snap ri ng
(Fi g. 134).
(10) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pl ate cl earance (Fi g. 139).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 139).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and compress the waved snap-ri ng. Thi s
wi l l assure that the snap-ri ng i s at the top of the
groove.
(c) Rel ease the pressure pl ate and zero the di al
i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
waved snap-ri ng and record the di al i ndi cator read-
i ng.
Cl earance shoul d be 1.70 to 3.40 mm (0.067 to
0.134 i n.). I f cl earance i s i ncorrect, cl utch di scs,
pl ates pressure pl ates and snap ri ng may have to be
changed.
REAR CLUTCH
DISASSEMBLY
(1) Remove thrust washer from forward si de of
cl utch retai ner.
(2) Remove i nput shaft front/rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap ri ng (Fi g.
140).
Fig. 135 Compressing Front Clutch Piston Spring
Fig. 136 Front Clutch Piston Installation
Fig. 137 Clutch Piston Spring Installation
Fig. 138 Correct Spring Retainer Installed Position
Fig. 139 Measuring Front Clutch Pack Clearance
(4) Remove top pressure pl ate, cl utch di scs, steel
pl ates, bottom pressure pl ate and wave snap ri ng
and wave spri ng (Fi g. 140).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft snap-ri ng (Fi g. 141). I t
may be necessary to press the i nput shaft i n sl i ghtl y
to rel i eve tensi on on the snap-ri ng.
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft i f necessary (Fi g. 142).
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then press i nput
shaft i nto retai ner. Use a sui tabl y si zed press tool to
support retai ner as cl ose to i nput shaft as possi bl e.
(4) I nstal l i nput shaft snap-ri ng (Fi g. 141).
(5) I nvert retai ner and press i nput shaft i n oppo-
si te di recti on unti l snap-ri ng i s seated.
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
(8) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
Fig. 140 Rear Clutch Components
Fig. 141 Removing/Installing Input Shaft Snap-Ring
stri p of pl asti c (about 0.020 thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston (Fi g. 145). Concave si de of spri ng faces down-
ward (toward pi ston).
(10) I nstal l wave spri ng i n retai ner (Fi g. 145). Be
sure spri ng i s compl etel y seated i n retai ner groove.
(11) I nstal l bottom pressure pl ate (Fi g. 140).
Ri dged si de of pl ate faces downward (toward pi ston)
and fl at si de toward cl utch pack.
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
bottom pressure pl ate. Then i nstal l a cl utch pl ate fol -
l owed by a cl utch di sc unti l enti re cl utch pack i s
i nstal l ed (4 di scs and 3 pl ates are requi red) (Fi g.
140).
(13) I nstal l top pressure pl ate.
(14) I nstal l sel ecti ve snap ri ng. Be sure snap ri ng
i s ful l y seated i n retai ner groove.
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 146).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 146).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
(c) Zero the di al i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.64 - 1.14 mm (0.025 - 0.045
i n.). I f cl earance i s i ncorrect, steel pl ates, di scs, sel ec-
ti ve snap ri ng and pressure pl ates may have to be
changed.
The sel ecti ve snap ri ng thi cknesses are:
.107.109 i n.
Fig. 142 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
Fig. 143 Input Shaft Seal Ring Identification
Fig. 144 Pressing Input Shaft Into Rear Clutch
Retainer
.098.100 i n.
.095.097 i n.
.083.085 i n.
.076.078 i n.
.071.073 i n.
.060.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 147). Use enough petrol eum
jel l y to hol d washer i n pl ace.
PLANETARY GEARTRAIN/OUTPUT SHAFT
DISASSEMBLY
(1) Remove pl anetary snap ri ng (Fi g. 148).
(2) Remove front annul us and pl anetary assembl y
from dri vi ng shel l (Fi g. 148).
(3) Remove snap ri ng that retai ns front pl anetary
gear i n annul us gear (Fi g. 149).
(4) Remove tabbed thrust washer and tabbed
thrust pl ate from hub of front annul us (Fi g. 150).
(5) Separate front annul us and pl anetary gears
(Fi g. 150).
(6) Remove front pl anetary gear front thrust
washer from annul us gear hub.
(7) Separate and remove dri vi ng shel l , rear pl ane-
tary and rear annul us from output shaft (Fi g. 151).
(8) Remove front pl anetary rear thrust washer
from dri vi ng shel l .
(9) Remove tabbed thrust washers from rear pl an-
etary gear.
(10) Remove l ock ri ng that retai ns sun gear i n
dri vi ng shel l . Then remove sun gear, spacer and
thrust pl ates.
ASSEMBLY
(1) Lubri cate output shaft and pl anetary compo-
nents wi th transmi ssi on fl ui d. Use petrol eum jel l y to
l ubri cate and hol d thrust washers and pl ates i n posi -
ti on.
(2) Assembl e rear annul us gear and support i f di s-
assembl ed. Be sure support snap ri ng i s seated and
Fig. 145 Piston Spring/Wave Spring Position
Fig. 146 Checking Rear Clutch Pack Clearance
Fig. 147 Installing Rear Clutch Thrust Washer
Fig. 148 Front Annulus And Planetary Assembly
Removal
that shoul der-si de of support faces rearward (Fi g.
152).
(3) I nstal l rear thrust washer on rear pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace. Al so be sure al l four washer tabs are properl y
engaged i n gear sl ots.
(4) I nstal l rear annul us over and onto rear pl ane-
tary gear (Fi g. 152).
(5) I nstal l assembl ed rear pl anetary and annul us
gear on output shaft (Fi g. 153). Veri fy that assembl y
i s ful l y seated on shaft.
(6) I nstal l front thrust washer on rear pl anetary
gear (Fi g. 154). Use enough petrol eum jel l y to hol d
washer on gear. Be sure al l four washer tabs are
seated i n sl ots.
(7) I nstal l spacer on sun gear (Fi g. 155).
(8) I nstal l thrust pl ate on sun gear (Fi g. 156). Note
that dri vi ng shel l thrust pl ates are i nterchangeabl e.
Use ei ther pl ate on sun gear and at front/rear of
shel l .
(9) Hol d sun gear i n pl ace and i nstal l thrust pl ate
over sun gear at rear of dri vi ng shel l (Fi g. 157).
(10) Posi ti on wood bl ock on bench and support sun
gear on bl ock (Fi g. 158). Thi s makes i t easi er to al i gn
and i nstal l sun gear l ock ri ng. Keep wood bl ock
Fig. 149 Front Planetary Snap Ring Removal
Fig. 150 Front Planetary And Annulus Gear
Disassembly
Fig. 151 Removing Driving Shell, Rear Planetary
And Rear Annulus
Fig. 152 Assembling Rear Annulus And Planetary
Gear
Fig. 153 Installing Rear Annulus And Planetary On
Output Shaft
handy as i t wi l l al so be used for geartrai n end pl ay
check.
(11) Al i gn rear thrust pl ate on dri vi ng shel l and
i nstal l sun gear l ock ri ng. Be sure ri ng i s ful l y seated
i n sun gear ri ng groove (Fi g. 159).
(12) I nstal l assembl ed dri vi ng shel l and sun gear
on output shaft (Fi g. 160).
(13) I nstal l rear thrust washer on front pl anetary
gear (Fi g. 161). Use enough petrol eum jel l y to hol d
washer i n pl ace and be sure al l four washer tabs are
seated.
(14) I nstal l front pl anetary gear on output shaft
and i n dri vi ng shel l (Fi g. 162).
(15) I nstal l front thrust washer on front pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace and be sure al l four washer tabs are seated.
(16) Assembl e front annul us gear and support, i f
necessary. Be sure support snap ri ng i s seated.
(17) I nstal l front annul us on front pl anetary (Fi g.
162).
(18) Posi ti on thrust pl ate on front annul us gear
support (Fi g. 163). Note that plate has two tabs
on it. These tabs fit in notches of annulus hub.
Fig. 154 Installing Rear Planetary Front Thrust
Washer
Fig. 155 Installing Spacer On Sun Gear
Fig. 156 Installing Driving Shell Front Thrust Plate
On Sun Gear
Fig. 157 Installing Driving Shell Rear Thrust Plate
Fig. 158 Supporting Sun Gear On Wood Block
(19) I nstal l thrust washer i n front annul us (Fi g.
164). Align flat on washer with flat on planetary
hub. Also be sure washer tab is facing up.
(20) I nstal l front annul us snap ri ng (Fi g. 165). Use
snap ri ng pl i ers to avoi d di storti ng ri ng duri ng
i nstal l ati on. Al so be sure ri ng i s ful l y seated.
(21) I nstal l pl anetary sel ecti ve snap ri ng wi th
snap ri ng pl i ers (Fi g. 166). Be sure ri ng i s ful l y
seated.
(22) Turn pl anetary geartrai n assembl y over so
dri vi ng shel l i s faci ng workbench. Then support
geartrai n on wood bl ock posi ti oned under forward
end of output shaft. Thi s al l ows geartrai n compo-
nents to move forward for accurate end pl ay check.
(23) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 167). Gauge goes between shoul der
on output shaft and end of rear annul us support.
(24) Geartrai n end pl ay shoul d be 0.12 to 1.22 mm
(0.005 to 0.048 i n.). I f end pl ay i s i ncorrect, snap ri ng
(or thrust washers) may have to be repl aced. Snap
ri ng i s avai l abl e i n three di fferent thi cknesses for
adjustment purposes.
Fig. 159 Installing Sun Gear Lock Ring
Fig. 160 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
Fig. 161 Installing Rear Thrust Washer On Front
Planetary Gear
Fig. 162 Installing Front Planetary And Annulus
Gears
Fig. 163 Positioning Thrust Plate On Front Annulus
Support
Thoroughl y cl ean al l the governor parts i n a sui t-
abl e cl eani ng sol uti on but do not use any type of
causti c cl eani ng agents.
The governor wei ght components (Fi g. 168) and the
governor val ve (Fi g. 169), must sl i de freel y i n thei r
bores when cl ean and dry. Mi nor surface scratches
and burrs can be smoothed wi th crocus cl oth.
The al umi num governor val ve and outer wei ght
have a hard coati ng on them. Check condi ti on of thi s
coati ng careful l y. Do not reuse ei ther part i f the coat-
i ng i s damaged.
I nspect the governor wei ght spri ng for di storti on.
Repl ace the spri ng, i f di storted, col l apsed, or broken.
Cl ean the fi l ter i n sol vent and dry i t wi th compressed
ai r. Repl ace the fi l ter, i f damaged. I nspect the park
gear for chi pped or worn gear teeth or damaged ri ng
grooves. Repl ace the gear, i f damaged.
Check the teeth on the park gear for wear or dam-
age. Repl ace the gear i f necessary. I nspect the metal
seal ri ngs on the park gear hub. Repl ace the ri ngs
onl y i f severel y worn, or broken.
Fig. 164 Installing Front Annulus Thrust Washer
Fig. 165 Installing Front Annulus Snap Ring
Fig. 166 Installing Planetary Selective Snap Ring
Fig. 167 Checking Planetary Geartrain End Play
Fig. 168 Governor Weights
Fig. 169 Governor Components
EXTENSION HOUSING AND PARK LOCK
Cl ean the housi ng and park l ock components i n
sol vent and dry them wi th compressed ai r.
Exami ne the park l ock components i n the housi ng.
I f repl acement i s necessary, remove the shaft wi th
paral l el jaw snap ri ng pl i ers (Fi g. 170) and remove
the sprag and spri ng. Then remove the spri ng cl i p
and reacti on pl ug (Fi g. 171). Compress the reac-
tion plug spring clip only enough to remove
and install it. Do not distort the clip during
removal or installation.
Be sure a repl acement sprag i s i nstal l ed so the
sprag l ocki ng l ug wi l l face the park gear (Fi g. 172).
Al so be sure the spri ng i s correctl y posi ti oned as
shown (Fi g. 172). The sprag may not retract i f the
spri ng i s i mproperl y i nstal l ed.
VALVE BODY
Servi ceabl e val ve body components are:
park l ock rod and E-cl i p
swi tch val ve and spri ng
pressure adjusti ng screw bracket
throttl e val ve l ever
manual l ever
manual l ever shaft seal , washer, E-cl i p and
detent bal l
fl ui d fi l ter
converter cl utch sol enoi d
The remai ni ng val ve body components are servi ced
onl y as part of a compl ete val ve body assembl y.
Cl ean the val ve body components i n a parts cl ean-
i ng sol uti on onl y. Do not use gasol i ne, kerosene, or
any type of causti c sol uti on. Dry the parts wi th com-
pressed ai r. Make sure al l passages are cl ean and
free from obstructi ons.
NOTE: Do not use rags or shop towels to wipe off
valve body components. Lint from these materials
will adhere to the valve body components. Lint will
interfere with valve operation and may clog filters
and fluid passages.
Fig. 170 Park Sprag, Shaft And Spring
Fig. 171 Park Sprag Reaction Plug And Spring
Location
Fig. 172 Correct Position Of Sprag And Spring
I nspect the throttl e and manual val ve l evers and
shafts. Do not attempt to strai ghten a bent shaft or
correct a l oose l ever. Repl ace these components i f
worn, bent, l oose or damaged i n any way.
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th cro-
cus cl oth. The cl oth shoul d be i n sheet form and be
posi ti oned on a surface pl ate, sheet of pl ate gl ass, or
equal l y fl at surface. However, i f di storti on i s severe
or any surfaces are heavi l y scored, the val ve body
wi l l have to be repl aced.
CAUTION: Many of the valve body valves and plugs
are made of coated aluminum. Aluminum compo-
nents can be identified by the dark color of the spe-
cial coating applied to the surface (or by testing
with a magnet). DO NOT polish or sand aluminum
valves or plugs with any type of material, or under
any circumstances. This practice might damage the
special coating and cause the valves and plugs to
stick and bind.
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Al so i nspect the coati ng on the al u-
mi num val ves and pl ugs (Fi g. 173). I f the coati ng i s
damaged or worn through, the val ve (or val ve body)
shoul d be repl aced.
Al umi num val ves and pl ugs shoul d not be sanded
or pol i shed under any ci rcumstances. However, mi nor
burrs or scratches on steel val ves and pl ugs can be
removed wi th crocus cl oth but do not round off the
val ve or pl ug edges. Squareness of these edges i s
vi tal l y i mportant. These edges prevent forei gn matter
from l odgi ng between the val ves, pl ugs and bore.
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
spri ngs must be free of di storti on, warpage or broken
coi l s.
Tri al fi t each val ve and pl ug i n i ts bore to check
freedom of operati on. When cl ean and dry, the val ves
and pl ugs shoul d drop freel y i nto the bores. Val ve
body bores do not change di mensi onal l y wi th use. I f
the val ve body functi oned correctl y when new, i t wi l l
conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
TRANSMISSION
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will
readily adhere to case surfaces and transmission
components and will circulate throughout the trans-
mission after assembly. A sufficient quantity of lint
can block fluid passages and interfere with valve
body operation.
I nspect the case for cracks, porous spots, worn
servo bores, or damaged threads. However, the case
wi l l have to be repl aced i f i t exhi bi ts damage or wear.
Lubri cate the front band adjusti ng screw and l ock-
nut wi th petrol eum jel l y and thread i t part way i nto
the case. Be sure the screw turns freel y and does not
bi nd. I nstal l the l ocknut on the screw after checki ng
screw thread operati on.
I nspect al l the transmi ssi on bushi ngs duri ng over-
haul . Bushi ng condi ti on i s i mportant as worn, scored
bushi ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. Repl ace worn,
or scored bushi ngs, or i f doubt exi sts about bushi ng
condi ti on.
Use recommended tool s to repl ace bushi ngs. The
tool s are si zed and desi gned to remove, i nstal l and
seat bushi ngs correctl y. The bushi ng repl acement
tool s are i ncl uded i n Bushi ng Tool Sets C-3887-B, or
C-3887-J.
Pre-si zed servi ce bushi ngs are avai l abl e for
repl acement purposes. Onl y the sun gear bushi ngs
are not servi ced. Repl ace the gear as an assembl y i f
the bushi ngs are severel y scored, or worn.
Hel i -Coi l i nserts are recommended for repai ri ng
damaged, stri pped or worn threads i n al umi num
parts. Stai nl ess steel i nserts are preferred.
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
val ves, use extreme care to avoi d roundi ng off sharp
edges. Sharp edges are vi tal as they prevent forei gn
matter from getti ng between the val ve and val ve
bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
Lubri cate transmi ssi on parts wi th Mopar ATF
Pl us 3, Type 7176 transmi ssi on fl ui d duri ng assem-
bl y. Use Mopar Door Ease, or Ru-Gl yde to l ubri cate
pi ston seal s and O-ri ngs. Use petrol eum jel l y on
thrust washers and to hol d parts i n pl ace duri ng
reassembl y.
DRUM/OVERDRIVE PISTON RETAINER
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
FRONT SERVO
Cl ean the servo pi ston components wi th sol vent
and dry them wi th compressed ai r. Wi pe the band
cl ean wi th l i nt free shop towel s.
Repl ace the front band i f di storted, l i ni ng i s
burned, fl aki ng off, or worn to the poi nt where the
grooves i n the l i ni ng materi al are no l onger vi si bl e.
I nspect the servo components (Fi g. 174). Repl ace
the spri ngs i f col l apsed, di storted or broken. Repl ace
the gui de, rod and pi ston i f cracked, bent, or worn.
Di scard the servo snap ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
REAR SERVO
Remove and di scard the servo pi ston seal ri ng (Fi g.
175). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap ri ngs and use a new ones at assembl y.
Fig. 173 Valve Body Components
OIL PUMP AND REACTION SHAFT SUPPORT
(1) Cl ean pump and support components wi th sol -
vent and dry them wi th compressed ai r.
(2) Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
(3) I nspect the pump and support components.
Repl ace the pump or support i f the seal ri ng grooves
or machi ned surfaces are worn, scored, pi tted, or
damaged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
(4) I nspect the pump bushi ng. Then check the
reacti on shaft support bushi ng. Repl ace ei ther bush-
i ng onl y i f heavi l y worn, scored or damaged. I t i s not
necessary to repl ace the bushi ngs unl ess they are
actual l y damaged.
(5) I nstal l the gears i n the pump body and mea-
sure pump component cl earances as fol l ows:
(a) Cl earance between outer gear and reacti on
shaft housi ng shoul d be 0.010 to 0.063 mm (0.0004
to 0.0025 i n.). Cl earance between i nner gear and
reacti on shaft housi ng shoul d be 0.010 to 0.063
mm (0.0004 to 0.0025 i n.). Both cl earances can be
measured at the same ti me by:
(I ) I nstal l i ng the pump gears i n the pump
housi ng.
(I I ) Posi ti on an appropri ate pi ece of Pl asti -
gage across both gears.
(I I I ) Al i gn the pl asti gage to a fl at area on the
reacti on shaft housi ng.
(I V) I nstal l the reacti on shaft to the pump
housi ng.
(V) Separate the reacti on shaft housi ng from
the pump housi ng and measure the Pl asti gage
fol l owi ng the i nstructi ons suppl i ed wi th i t.
(b) Cl earance between i nner gear tooth and
outer gear shoul d be 0.08 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
(c) Cl earance between outer gear and pump
housi ng shoul d al so be 0.010 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
FRONT CLUTCH
Cl ean and i nspect the front cl utch components.
Repl ace the cl utch di scs i f warped, worn, scored,
burned or charred, or i f the faci ng i s fl aki ng off.
Repl ace the steel pl ates i f heavi l y scored, warped, or
broken. Be sure the dri vi ng l ugs on the pl ates are i n
good condi ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the cl utch spri ng and spri ng retai ner i f
ei ther i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged.
Check acti on of the check bal l i n the retai ner (Fi g.
176). The bal l must move freel y and not sti ck.
NOTE: Inspect the clutch retainer bushings care-
fully (Fig. 177). The retainer bushings are NOT ser-
viceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
REAR CLUTCH
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r.
Check condi ti on of the i nput shaft seal ri ngs. I t i s
not necessary to remove or repl ace ri ngs unl ess they
are broken, cracked, or no l onger securel y hooked
together.
I nspect the i nput shaft spl i nes and machi ned sur-
faces. Very mi nor ni cks or scratches can be smoothed
off wi th crocus cl oth. repl ace the shaft i f the spl i nes
are damaged, or any of the machi ned surfaces are
severel y scored.
Fig. 174
Fig. 175 Rear Servo Components
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off.
Repl ace the steel pl ates and the pressure pl ate i f
heavi l y scored, warped, or broken. Be sure the dri v-
i ng l ugs on the di scs and pl ates are al so i n good con-
di ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged. Al so
check acti on of the retai ner check bal l . The bal l must
move freel y and not sti ck.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y damaged.
Check thrust washer condi ti on. Washer thi ckness
shoul d be 1.55 to 1.60 mm (0.061 to 0.063 i n.).
Repl ace the washer i f worn or damaged.
Check condi ti on of the two seal ri ngs on the i nput
shaft and the si ngl e seal ri ng on the pi ston retai ner
hub. Repl ace the seal ri ngs onl y i f severel y worn,
cracked, or cannot be hooked together.
PLANETARY GEARTRAIN/OUTPUT SHAFT
Cl ean the i ntermedi ate shaft and pl anetary compo-
nents i n sol vent and dry them wi th compressed ai r.
Do not spi n the pl anetary pi ni on gears wi th com-
pressed ai r.
I nspect the pl anetary gear sets and annul us gears.
The pl anetary pi ni ons, shafts, washers, and retai ni ng
pi ns are servi ceabl e. However, i f a pi ni on carri er i s
damaged, the enti re pl anetary gear set must be
repl aced as an assembl y.
Repl ace the annul us gears i f the teeth are chi pped,
broken, or worn, or the gear i s cracked. Repl ace the
pl anetary thrust pl ates and the tabbed thrust wash-
ers i f cracked, scored or worn.
I nspect the machi ned surfaces of the output shaft.
Be sure the oi l passages are open and cl ear. Repl ace
the shaft i f scored, pi tted, or damaged.
I nspect the sun gear and dri vi ng shel l . I f ei ther
component i s worn or damaged, remove the sun gear
rear retai ni ng ri ng and separate the sun gear and
thrust pl ate from the dri vi ng shel l . Then repl ace the
necessary component.
Repl ace the sun gear as an assembl y i f the gear
teeth are chi pped or worn. Al so repl ace the gear as
an assembl y i f the bushi ngs are scored or worn. The
sun gear bushi ngs are not servi ceabl e. Repl ace the
thrust pl ate i f worn, or severel y scored. Repl ace the
dri vi ng shel l i f di storted, cracked, or damaged i n any
way.
Repl ace al l snap ri ngs duri ng geartrai n assembl y.
Reusi ng snap ri ngs i s not recommended.
ADJ USTMENTS
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n Park
and Neutral . Adjustment i s OK i f the engi ne starts
onl y i n these posi ti ons. Adjustment i s i ncorrect i f the
engi ne starts i n one but not both posi ti ons. I f the
engi ne starts i n any posi ti on other than Park or Neu-
tral , or i f the engi ne wi l l not start at al l , the park/
neutral posi ti on swi tch may be faul ty.
Gearshift Adjustment Procedure
Fig. 176 Front Clutch Piston Retainer Check Ball
Location
Fig. 177 Retainer Bushing Location/Inspection
(3) Rel ease cabl e adjuster cl amp (at transmi ssi on
end of cabl e) to unl ock cabl e.
(4) Unsnap cabl e from cabl e mounti ng bracket on
(5) Sl i de cabl e eyel et off transmi ssi on shi ft l ever.
(6) Veri fy transmi ssi on shi ft l ever i s i n Park
detent by movi ng l ever ful l y rearward. Last rearward
detent i s Park posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Sl i de cabl e eyel t onto transmi ssi on shi ft l ever.
(9) Snap shi ft cabl e adjuster i nto mounti ng
bracket on transmi ssi on.
(10) Lock shi ft cabl e by pressi ng cabl e adjuster
cl amp down unti l i t snaps i nto pl ace.
(11) Lower vehi cl e and check engi ne starti ng.
Engi ne shoul d start onl y i n Park and Neutral .
CABLE ADJUSTMENT
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove shi ft l ever bezel and consol e screws.
Rai se bezel and consol e for access to cabl e.
(3) Pul l cabl e l ock button up to rel ease cabl e (Fi g.
179).
(4) Turn i gni ti on swi tch to LOCK posi ti on.
(5) Use a spacer to create a one mi l l i meter gap
between the shi fter pawl and top of the shi ft gate.
(6) Pul l cabl e forward. Then rel ease cabl e and
press cabl e l ock button down unti l i t snaps i n pl ace.
(7) Check adjustment as fol l ows:
(a) Check movement of rel ease shi ft handl e but-
ton (fl oor shi ft) or rel ease l ever (col umn shi ft). You
shoul d not be abl e to press button i nward or move
col umn l ever.
(b) Turn i gni ti on swi tch to RUN posi ti on.
(c) Shi fti ng out of park shoul d not be possi bl e.
(d) Appl y the brake and attempt to shi ft out of
PARK. Shi fti ng shoul d be possi bl e.
(e) Whi l e the transmi ssi on i s shi fted out of
PARK, rel ease the brake and attempt to shi ft
through al l gears. Rel ease the shi ft button at l east
once duri ng thi s procedure. The i gni ti on key shoul d
not go to the LOCK posi ti on.
(f) Return transmi ssi on to the PARK posi ti on
wi thout appl yi ng the brake.
(8) Move shi ft l ever back to PARK and check i gni -
ti on swi tch operati on. You shoul d be abl e to turn
swi tch to LOCK posi ti on and shi ft l ever rel ease but-
ton/l ever shoul d not move.
ADJUSTMENT
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 180). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
Fig. 178 Shift Cable Attachment At
TransmissionTypical
Fig. 179 Park Lock Cable Attachment
Checking Throttle Valve Cable Adjustment
(2) Remove ai r cl eaner.
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on. Then veri fy that transmi ssi on throttl e l ever
(Fi g. 181) i s al so at i dl e (ful l y forward) posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on.
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
Throttle Valve Cable Adjustment Procedure
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) I nsert a smal l screwdri ver under edge of
retai ni ng cl i p and remove retai ni ng cl i p.
(6) Center cabl e end on attachment stud to wi thi n
1 mm (0.039 i n.).
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(7) I nstal l retai ni ng cl i p onto cabl e housi ng.
(8) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
FRONT BAND ADJUSTMENT
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 182).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 Nm (72 i n.
l bs.) torque wi th I nch Pound Torque Wrench
C-3380-A, a 3-i n. extensi on and 5/16 socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw (Fig. 183), tighten the screw to only
5 Nm (47-50 in. lbs.) torque.
(4) Back off front band adjusti ng screw 2-1/2
turns.
(5) Hol d adjuster screw i n posi ti on and ti ghten
l ocknut to 41 Nm (30 ft. l bs.) torque.
Fig. 180 Throttle Cable Attachment At Engine
Fig. 181 Throttle Cable Attachment At Transmission
REAR BAND ADJUSTMENT
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
(3) Loosen band adjusti ng screw l ocknut 5-6 turns.
Be sure adjusti ng screw turns freel y i n l ever.
(4) Ti ghten adjusti ng screw to 5 Nm (41 i n. l bs.)
(Fi g. 184).
(5) Back off adjusti ng screw 7 turns.
(6) Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
(7) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.) torque.
(8) Lower vehi cl e and refi l l transmi ssi on wi th
Mopar ATF Pl us 3, Type 7176, fl ui d.
VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
val ve body;
Li ne Pressure
Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 185).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
Fig. 182 Front Band Adjustment Screw Location
Fig. 183 Band Adjustment Adapter Tool
Fig. 184 Rear Band Adjustment Screw Location
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 186).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
Fig. 185 Line Pressure Adjustment
Fig. 186 Throttle Pressure Adjustment
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SCHEMATICS AND DIAGRAMS (Continued)
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SPECIFICATIONS
30RH AUTOMATIC TRANSMISSION
GENERAL
COMPONENT METRIC INCH
Oil pump gear tip clearance 0.089-0.190 mm 0.0035-0.0075 in.
Planetary end play 0.125-1.19 mm 0.001-0.047 in.
Input shaft end play 0.56-2.31 mm 0.022-0.091 in.
Clutch pack clearance/Front 4-disc. 1.70-3.40 mm 0.067-0.134 in.
Clutch pack clearance/Rear 4-disc. 0.559-0.940 mm 0.022-0.037 in.
Front clutch spring usage 1 spring
30RH-Front Band adjustment from 72 in. lbs. Back off 2.5 turns
30RH-Rear Band adjustment from 41 in. lbs. Back off 7 turns
Recommended fluid Mopar, ATF Plus 3, Type 7176
THRUST WASHER/SPACER/SNAP RING DIMENSIONS
COMPONENT METRIC INCH
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Output shaft thrust plate (output shaft pilot hub) 1.5-1.6mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.7-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.086 in.
Rear clutch pack snap ring 1.5-1.6 mm 0.06-0.062 in.
1.7-1.8 mm 0.068-0.070 in.
1.9-2.0 mm 0.076-0.078 in.
Planetary geartrain snap ring
(at front of output shaft)
1.0-1.1 mm 0.040-0.044 in.
1.6-1.7 mm 0.062-0.066 in.
2.1-2.2 mm 0.082-0.086 in.
PRESSURE TEST ALL
ITEM RANGE PRESSURE
Line pressure (at
accumulator)
Closed throttle 372-414 kPa (54-60 psi).
Front servo Third gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi) at 1600
rpm.
Governor D range closed
throttle
Pressure should respond smoothly to changes in mph and return
to 0-7 kPa (0-1.5 psi) when stopped with transmission in D, 1, 2.
Pressure above 7 kPa (1.5 psi) at stand still will prevent
transmission from downshifting.
TORQUE
DESCRIPTION TORQUE
Bol t, torque convertor . . . . . . . . . 31 Nm (23 ft. l bs.)
Bol t/nut, crossmember . . . . . . . . 68 Nm (50 ft. l bs.)
Bol t, dri vepl ate to crankshaft . . . 75 Nm (55 ft. l bs.)
Pl ug, front band reacti on . . . . . . 17 Nm (13 ft. l bs.)
Locknut, front band adj. . . . . . . . 34 Nm (25 ft. l bs.)
Swi tch, park/neutral . . . . . . . . . . 34 Nm (25 ft. l bs.)
Bol t, fl ui d pan . . . . . . . . . . . . . . 17 Nm (13 ft. l bs.)
Bol t, oi l pump . . . . . . . . . . . . . . . 20 Nm (15 ft. l bs.)
Bol t, overrunni ng cl utch cam . . . 17 Nm (13 ft. l bs.)
Pl ug, pressure test port . . . . . . . 14 Nm (10 ft. l bs.)
Bol t, reacti on shaft support . . . . 20 Nm (15 ft. l bs.)
Locknut, rear band . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bol t. speedometer adapter . . . . . . 11 Nm (8 ft. l bs.)
Screw, fl ui d fi l ter . . . . . . . . . . . . . 4 Nm (35 i n. l bs.)
Bol t, val ve body to case . . . . . . 12 Nm (100 i n. l bs.)
SPECIAL TOOLS
30RH TRANSMISSIONS
Remover6957
Installer6951
Retainer, Detent Ball and Spring6583
Snap-ring Plier6823
Pilot StudC-3288-B
Pressure GaugeC-3292
Pressure GaugeC-3293SP
Dial IndicatorC-3339
Spring CompressorC-3422-B
Fixture, Engine SupportC-3487-A
Spring CompressorC-3575-A
Spring CompressorC-3863-A
Adapter, Band AdjusterC-3705
Transmission Repair StandC-3750-B
Puller, Slide HammerC-3752
Gauge, Throttle SettingC-3763
Seal InstallerC-3860-A
Bushing Remover/InstallerC-3887-J
Cup, RemoverSP-3633
Remover, BushingSP-5301
Installer, BushingSP-5118
Snap-ring PlierC-3915
Seal RemoverC-3985-B
Bushing, Remover6957
Flusher, Oil Cooler6906
InstallerC-3995-A
Universal HandleC-4171
Remover/InstallerC-4470
Nut, Bushing RemoverSP-1191
AW4 AUTOMATIC TRANSMISSION
INDEX
page page
GENERAL INFORMATION
AW4 AUTOMATIC TRANSMISSION . . . . . . . . . 164
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . 165
EFFECTS OF INCORRECT FLUID LEVEL . . . . 164
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . 165
RECOMMENDED FLUID CAPACITY . . . . . . . . . 164
TRANSMISSION IDENTIFICATION . . . . . . . . . . 164
TRANSMISSION RANGES AND SHIFT LEVER
POSITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 165
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . 176
ELECTRONIC CONTROLS . . . . . . . . . . . . . . . . 166
FIRST/SECOND/THIRD/REVERSE GEAR
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 167
FOURTH GEAR OVERDRIVE
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 166
GEARTRAIN OPERATION AND APPLICATION
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . 169
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . 166
TRANSMISSION CONTROL MODULE (TCM) . . 166
TRANSMISSION COOLER . . . . . . . . . . . . . . . . 176
TRANSMISSION VALVE BODY
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 169
TRANSMISSION VALVE BODY SOLENOIDS . . 166
FLOW TESTING TRANSMISSION MAIN
COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 183
GENERAL DIAGNOSIS INFORMATION . . . . . . . 177
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . 179
MANUAL SHIFTING TEST . . . . . . . . . . . . . . . . 178
PARK/NEUTRAL POSITION SWITCH . . . . . . . . 183
PRELIMINARY INSPECTION AND
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 177
PRESSURE TEST ANALYSIS . . . . . . . . . . . . . . 179
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . 180
SPEED SENSOR TESTING . . . . . . . . . . . . . . . 183
STALL SPEED TEST ANALYSIS . . . . . . . . . . . . 180
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . 180
THROTTLE VALVE CABLE . . . . . . . . . . . . . . . . 183
TIME LAG TEST . . . . . . . . . . . . . . . . . . . . . . . . 180
TIME LAG TEST ANALYSIS . . . . . . . . . . . . . . . 180
TORQUE CONVERTER STALL TEST . . . . . . . . 179
TORQUE CONVERTER STATOR CLUTCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 184
TRANSMISSION SOLENOID TESTING . . . . . . 180
SERVICE PROCEDURES
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . 186
CHECKING FLUID CONDITION . . . . . . . . . . . . 185
CHECKING FLUID LEVEL . . . . . . . . . . . . . . . . 185
FLUSHING COOLERS AND TUBES . . . . . . . . . 186
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . 185
REFILLING AFTER OVERHAUL OR FLUID/
FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . 185
TRANSMISSION CONTROL MODULE (TCM)
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
ACCUMULATOR PISTONS AND SPRINGS . . . . 199
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . 189
BRAKE TRANSMISSION SHIFT INTERLOCK . . 193
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 192
MANUAL VALVE SHAFT SEAL . . . . . . . . . . . . . 198
OIL PUMP SEAL . . . . . . . . . . . . . . . . . . . . . . . . 203
PARK ROD AND PAWL . . . . . . . . . . . . . . . . . . . 201
PARK/NEUTRAL POSITION SWITCH . . . . . . . . 191
SECOND COAST BRAKE SERVO . . . . . . . . . . 200
SOLENOID HARNESS ADAPTER SEAL . . . . . . 196
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . 189
SPEED SENSOR ROTOR-SPEEDOMETER
DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 190
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . 189
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . 188
TRANSMISSION AND TORQUE
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . 187
TRANSMISSION CONTROL MODULE . . . . . . . 196
TRANSMISSION THROTTLE CABLE . . . . . . . . 202
TRANSMISSION VALVE BODY . . . . . . . . . . . . . 194
TRANSMISSION VALVE BODY SOLENOIDS . . 193
DIRECT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 243
FORWARD CLUTCH . . . . . . . . . . . . . . . . . . . . . 247
FRONT PLANETARY GEAR . . . . . . . . . . . . . . . 252
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
OVERDRIVE PLANETARY GEAR AND
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
OVERDRIVE SUPPORT . . . . . . . . . . . . . . . . . . 240
PLANETARY/BRAKE PACK/OUTPUT SHAFT . . 260
SECOND BRAKE . . . . . . . . . . . . . . . . . . . . . . . 256
SUN GEAR AND NO. 1 ONEWAY CLUTCH . . . 254
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 204
TRANSMISSION VALVE BODY . . . . . . . . . . . . . 264
TRANSMISSION PARTS CLEANING AND
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 267
ADJUSTMENTS
CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . 267
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 267
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 268
SPECIFICATIONS
AW-4 AUTOMATIC TRANSMISSION . . . . . . . . . 269
SPECIAL TOOLS
AW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
GENERAL INFORMATION
AW4 AUTOMATIC TRANSMISSION
The AW4 i s a 4speed, el ectroni cal l y control l ed
automati c transmi ssi on (Fi g. 1).
The runni ng gear consi sts of an oi l pump, pl ane-
tary gear sets, cl utch and brake uni ts, hydraul i c
accumul ators, a val ve body wi th el ectri cal sol enoi ds,
and a transmi ssi on control modul e (TCM). Cabl es are
used to provi de shi ft and throttl e pressure control
i nformati on. A park/neutral posi ti on swi tch permi ts
engi ne starti ng i n the Park and Neutral ranges onl y.
The val ve body sol enoi ds are control l ed by si gnal s
from the transmi ssi on control modul e (TCM). Si gnal
sequence i s determi ned by i nputs from vari ous sen-
sors to the TCM.
Fourth gear i s an 0.75:1 rati o overdri ve range.
Fi rst, second, thi rd and reverse gear are conventi onal
ranges. Thi rd gear rati o i s 1:1. A separate pl anetary
gear set provi des overdri ve operati on i n fourth gear.
The transmi ssi on I .D. pl ate i s attached to the case
(Fi g. 2). The pl ate contai ns the transmi ssi on seri al
and model numbers. Refer to the i nformati on on thi s
pl ate when orderi ng servi ce parts.
RECOMMENDED FLUID CAPACITY
Recommended and preferred fl ui d for the AW4
transmi ssi on i s Mopar Dexron I I E/Mercon.
Mopar Dexron I I can be used but onl y i n emer-
gency si tuati ons where Mercon fl ui d i s not avai l abl e.
Approxi mate refi l l capaci ty for the AW4 i s 8.0
l i ters (16.9 pi nts).
EFFECTS OF INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
Fig. 1 AW4 Automatic Transmission
Fig. 2 Transmission Identification
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve, cl utch and servo operati on. Foami ng al so
causes fl ui d expansi on whi ch can resul t i n fl ui d over-
fl ow from the transmi ssi on vent or fi l l tube. Fl ui d
overfl ow can easi l y be mi staken for a l eak i f i nspec-
ti on i s not careful .
CAUSES OF BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
FLUID CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to reverse fl ush cool er and l i nes after
repai r
fai l ure to repl ace contami nated converter after
repai r
The use of non recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on for some ti me, an overhaul
may al so be necessary; especi al l y i f shi ft probl ems
had devel oped.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool -
ers as wel l . The torque converter shoul d al so be
repl aced whenever a fai l ure generates sl udge and
debri s. Thi s i s necessary because normal converter
fl ushi ng procedures wi l l not remove al l contami -
nants.
TRANSMISSION RANGES AND SHIFT LEVER
POSITIONS
The AW4 transmi ssi on has si x ranges and shi ft
l ever posi ti ons. Park, Reverse and Neutral are con-
venti onal and mechani cal l y operated. The 12, 3 and
D ranges provi de el ectroni cal l y control l ed shi fti ng.
The 12 posi ti on provi des fi rst and second gear
onl y. The 3 posi ti on provi des fi rst, second and thi rd
gear.
The D range provi des fi rst through fourth gear.
Overdri ve fourth gear range i s avai l abl e onl y when
the shi ft l ever i s i n D posi ti on (Fi g. 3).
Fig. 3 AW4 Shift Lever Positions And Transmission
Ranges
ELECTRONIC CONTROLS
The AW4 i s el ectroni cal l y control l ed i n 1, 2, 3 and
D ranges. Control s consi st of the transmi ssi on control
modul e (TCM), val ve body sol enoi ds and vari ous sen-
sors. The sensors moni tor vehi cl e speed, throttl e
openi ng, shi ft l ever posi ti on and brake pedal appl i ca-
ti on.
The modul e determi nes shi ft and converter cl utch
engagement ti mi ng based on si gnal s from sensors.
The val ve body sol enoi ds are acti vated, or deacti -
vated accordi ngl y.
The TCM has a sel f di agnosti c program. Compo-
nent and ci rcui try mal functi ons can be di agnosed
wi th the DRB scan tool . Once a mal functi on i s noted
and stored i n control modul e memory, i t i s retai ned
even after the probl em has been corrected. To cancel
a stored mal functi on, di sconnect and reconnect the
Trans. fuse i n the modul e harness.
TRANSMISSION VALVE BODY SOLENOIDS
The sol enoi ds are mounted on the val ve body and
operated by the TCM. The sol enoi ds control operati on
of the converter cl utch and shi ft val ves i n response to
i nput si gnal s from the modul e.
SENSORS
Sensors i ncl ude:
throttl e posi ti on sensor (TPS)
transmi ssi on speed sensor
vehi cl e speed sensor
park/neutral posi ti on swi tch
brake swi tch
The throttl e posi ti on sensor i s mounted on the
throttl e body. I t el ectroni cal l y determi nes throttl e
posi ti on and rel ays thi s i nformati on to the transmi s-
si on control modul e to determi ne shi ft poi nts and
converter cl utch engagement.
The transmi ssi on speed sensor consi sts of a rotor
and magnet on the transmi ssi on output shaft and a
swi tch i n the extensi on housi ng or adapter. The sen-
sor swi tch i s acti vated each ti me the rotor and mag-
net compl ete one revol uti on. Sensor si gnal s are sent
to the transmi ssi on control modul e.
The park/neutral posi ti on swi tch i s mounted on the
val ve body manual shaft. The swi tch si gnal s shi ft
l i nkage and manual val ve posi ti on to the transmi s-
si on control modul e through an i nterconnecti ng har-
ness. The swi tch prevents engi ne starti ng i n al l gears
other than Park or Neutral .
The brake swi tch i s i n ci rcui t wi th the torque con-
verter cl utch sol enoi d. The swi tch di sengages the
converter cl utch whenever the brakes are appl i ed.
The swi tch i s mounted on the brake pedal bracket
and si gnal s the transmi ssi on control modul e when
the pedal i s pressed or rel eased.
TORQUE CONVERTER
A three el ement torque converter i s used for al l
appl i cati ons. The converter contai ns an i mpel l er, sta-
tor, and turbi ne.
The AW4 converters are al l equi pped wi th a con-
verter cl utch mechani sm. The cl utch consi sts of a
sl i di ng cl utch pi ston, cl utch spri ngs and the cl utch
di sc materi al (Fi g. 4). The cl utch provi des opti mum
torque transfer and economy when engaged.
The cl utch di sc i s attached to the converter front
cover. The cl utch pi ston and cl utch spri ngs are
attached to the turbi ne hub. The spri ngs dampen
engi ne fi ri ng i mpul ses and l oads duri ng the i ni ti al
phase of converter cl utch engagement.
Cl utch engagement i s control l ed by transmi ssi on
val ve body sol enoi d number three and by the con-
verter cl utch rel ay val ve. The sol enoi d channel s l i ne
pressure to the cl utch through the rel ay val ve at
cl utch engagement speeds.
Torque converter cl utch engagement occurs i n sec-
ond gear i n 12 posi ti on; thi rd gear i n 3 posi ti on and
thi rd and fourth gear i n D posi ti on.
FOURTH GEAR OVERDRIVE COMPONENTS
The overdri ve system consi sts of the i nput shaft,
oneway cl utch, pl anetary sun gear, ri ng gear, pl an-
etary carri er, overdri ve cl utch and overdri ve brake
(Fi g. 5). The overdri ve el ements are control l ed and
Fig. 4 Torque Converter (With Clutch)
appl i ed through transmi ssi on val ve body sol enoi d
number two.
I n fourth gear, the overdri ve brake prevents the
overdri ve sun gear from turni ng. The overdri ve i nput
shaft and pl anetary carri er rotate as a uni t. The sun
gear and overdri ve di rect cl utch drum are i n mesh
and operate as a si ngl e uni t. The di rect cl utch
spl i nes functi on as the hub for the overdri ve brake.
The oneway cl utch outer race i s i n mesh wi th the
pl anetary carri er. The i nner race i s fi xed to the sun
gear shaft.
FIRST/SECOND/THIRD/REVERSE GEAR
COMPONENTS
Fi rst through thi rd and reverse gear components
are outl i ned i n (Fi g. 6).
The i nput shaft i s meshed wi th the di rect cl utch
hub and the forward cl utch drum. These el ements
rotate as a uni t. The forward cl utch hub rotates as a
uni t wi th the front pl anetary ri ng gear. The di rect
cl utch drum i s meshed wi th the forward end of the
pl anetary sun gear.
The second brake hub serves as the outer race of
oneway cl utch No. 1. The cl utch i nner race i s l ocked
wi th the front/rear sun gear. The i nner race of one
way cl utch No. 2 i s spl i ned to the transmi ssi on case
Fig. 5 Fourth Gear Overdrive Components
Fig. 6 First/Second/Third/Reverse Gear Components
and i s l ocked. The outer race rotates as a uni t wi th
the rear pl anetary carri er.
The rear pl anetary ri ng gear i s spl i ned to the out-
put shaft. The front pl anetary carri er and rear car-
ri er ri ng gear are meshed and rotate as a uni t wi th
the output shaft.
GEARTRAIN OPERATION AND APPLICATION
CHARTS
Operati on and appl i cati on of the fi rst through
fourth and reverse gear el ements are outl i ned i n the
functi on and appl i cati on charts.
The Component Functi on Chart descri bes basi c
functi on of vari ous geartrai n el ements. The Compo-
nent Appl i cati on Chart i ndi cates whi ch el ements
(i ncl udi ng val ve body sol enoi ds), are appl i ed i n the
vari ous gear ranges.
COMPONENT FUNCTION CHART
COMPONENT NAME COMPONENT FUNCTION
Overdrive Direct Clutch Connects overdrive sun gear and overdrive carrier.
Overdrive Brake Prevents overdrive sun gear from turning either clockwise or
counter-clockwise.
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 to the front and rear ring gears.
Second Coast Brake Prevents front and rear sun gear from turning either clockwise or
counter-clockwise.
Second Brake Prevents outer race of number 1 one-way clutch from turning either
clockwise or counter-clockwise, thus preventing the front and rear sun
gears from turning counter-clockwise.
First/Reverse Brake Prevents the rear planetary carrier from turning either clockwise or
counter-clockwise.
Number 1 One-way Clutch When second brake is operating, prevents the front and rear sun
gears from turning counter-clockwise.
Number 2 One-Way Clutch Prevents the rear planetary carrier from turning counter-clockwise.
HYDRAULIC SYSTEM
The hydraul i c system consi sts of the pump, val ve
body and sol enoi ds, and four hydraul i c accumul ators.
The oi l pump provi des l ubri cati on and operati ng
pressure.
The val ve body control s appl i cati on of the cl utches,
brakes, second coast band, and the converter cl utch.
The val ve body sol enoi ds control sequenci ng of the
12, 23 and 34 shi ft val ves. The sol enoi ds are acti -
vated by si gnal s from the transmi ssi on control mod-
ul e.
The accumul ators are used i n the cl utch and brake
feed ci rcui ts to control i ni ti al appl y pressure. Spri ng
l oaded accumul ator pi stons modul ate the i ni ti al
surge of appl y pressure for smooth engagement.
OIL PUMP
A geartype oi l pump i s used. The pump gears are
mounted i n the pump body. The pump dri ve gear i s
operated by the torque converter hub. Dri ve tangs on
the hub engage i n dri ve sl ots i n the dri ve gear.
TRANSMISSION VALVE BODY COMPONENTS
Transmi ssi on operati ng pressure i s suppl i ed to the
cl utch and brake appl y ci rcui ts through the transmi s-
si on val ve body. The val ve body consi sts of an upper
body, l ower body, separator pl ate and upper and
l ower gaskets (Fi g. 7). The vari ous spool val ves,
sl eeves, pl ugs and spri ngs are l ocated wi thi n the two
body secti ons.
The manual val ve, 12 shi ft val ve, pri mary regul a-
tor val ve, accumul ator control val ve, check bal l s,
sol enoi ds and oi l strai ners are l ocated i n the l ower
body secti on (Fi g. 8). The remai ni ng control and shi ft
val ves pl us check bal l s and one addi ti onal oi l
strai ner are l ocated i n the upper body secti on
(Fi g. 9).
COMPONENT APPLICATION CHART
Fig. 7 TwoSection Transmission Valve Body
MANUAL VALVE
The manual val ve i s operated by the gearshi ft l i nk-
age. The val ve di verts fl ui d to the appl y ci rcui ts
accordi ng to shi ft l ever posi ti on (Fi g. 10).
PRIMARY REGULATOR VALVE
The pri mary regul ator val ve (Fi g. 11) modul ates
l i ne pressure to the cl utches and brakes accordi ng to
engi ne l oad. The val ve i s actuated by throttl e val ve
pressure.
Duri ng hi gh l oad operati on, the val ve i ncreases
l i ne pressure to mai ntai n posi ti ve cl utch and brake
engagement. At l i ght l oad, the val ve decreases l i ne
pressure just enough to mai ntai n smooth engage-
ment.
Fig. 8 Upper Body Components
Fig. 9 Lower Body Components
THROTTLE VALVE AND DOWNSHIFT PLUG
The throttl e val ve and downshi ft pl ug (Fi g. 12)
control throttl e pressure to the pri mary regul ator
val ve.
The downshi ft pl ug and throttl e val ve are operated
by the throttl e val ve cam and throttl e cabl e i n
response to engi ne throttl e posi ti on. Throttl e val ve
pressure i s al so modul ated by the cutback val ve i n
second, thi rd and fourth gear ranges.
CUTBACK VALVE
The cutback val ve (Fi g. 13) hel ps prevent exces-
si ve pump pressure bui l dup i n second, thi rd and
fourth gear. The val ve i s actuated by throttl e pres-
sure and by l i ne pressure from the second brake. The
val ve al so hel ps regul ate l i ne pressure by control l i ng
the amount of cutback pressure to the throttl e
val ve.
SECONDARY REGULATOR VALVE
The secondary regul ator val ve (Fi g. 14) regul ates
converter cl utch and transmi ssi on l ubri cati on pres-
sure. When pri mary regul ator val ve pressure exceeds
requi rements for cl utch engagement or transmi ssi on
l ubri cati on, the secondary regul ator val ve i s moved
upward exposi ng the drai n port. Excess pressure
Fig. 11 Primary Regulator Valve
Fig. 12 Throttle Valve And Downshift Plug
then bl eeds off as needed. As pressure drops, spri ng
tensi on moves the val ve downward cl osi ng the drai n
port.
CONVERTER CLUTCH RELAY VALVE
The converter cl utch rel ay val ve (Fi g. 15) control s
fl ui d fl ow to the converter cl utch. The val ve i s oper-
ated by l i ne pressure from the 12 shi ft val ve and i s
control l ed by sol enoi d val ve number three.
12 SHIFT VALVE
The 12 shi ft val ve (Fi g. 16) control s the 12
upshi fts and downshi fts. The val ve i s operated by the
No. 2 val ve body sol enoi d and l i ne pressure from the
manual val ve, second coast modul ator val ve and the
23 shi ft val ve.
When the transmi ssi on control modul e deacti vates
the sol enoi d, l i ne pressure at the top of the val ve
moves the val ve down cl osi ng the second brake accu-
mul ator feed port. As the sol enoi d i s acti vated and
the drai n port opens, spri ng force moves the val ve up
exposi ng the second brake feed port for the shi ft to
second gear.
23 SHIFT VALVE
The 23 shi ft val ve (Fi g. 17) control s the 23
upshi fts and downshi fts. The val ve i s actuated by the
No. 1 val ve body sol enoi d and by l i ne pressure from
the manual val ve and pri mary regul ator val ve.
When the TCM acti vates sol enoi d No. 1, l i ne pres-
sure at the top of the 23 val ve i s rel eased through
the sol enoi d drai n port. Spri ng tensi on moves the
val ve up to hol d the val ve i n second gear posi ti on. As
the sol enoi d i s deacti vated, l i ne pressure then moves
the val ve down exposi ng the di rect cl utch feed port
for the shi ft to thi rd gear.
Fig. 13 CutBack Valve
Fig. 14 Secondary Regulator Valve
Fig. 15 Converter Clutch Relay Valve
34 SHIFT VALVE
The 34 shi ft val ve (Fi g. 18) i s operated by the No.
2 sol enoi d and by l i ne pressure from the manual
val ve, 23 val ve and pri mary regul ator val ve.
Energi zi ng the No. 2 sol enoi d causes l i ne pressure
at the top of the 34 val ve to be rel eased through the
sol enoi d val ve drai n port. Spri ng tensi on moves the
val ve up exposi ng the overdri ve cl utch accumul ator
feed port to appl y the cl utch.
Deenergi zi ng the sol enoi d causes the drai n port to
cl ose. Li ne pressure then moves the val ve down
exposi ng the overdri ve brake accumul ator feed port
for the shi ft to fourth gear.
I n the 12 or 3 gearshi ft l ever posi ti ons, l i ne pres-
sure from the 23 shi ft val ve i s appl i ed to the l ower
end of the 34 val ve. Thi s hol ds the val ve upward,
cl osi ng off the overdri ve brake feed port preventi ng a
shi ft i nto fourth gear.
Fig. 16 12 Shift Valve
SECOND COAST MODULATOR VALVE
The second coast modul ator val ve (Fi g. 19) momen-
tari l y reduces l i ne pressure from the 12 shi ft val ve.
Thi s cushi ons appl i cati on of the second coast brake.
The val ve i s operati ve when the shi ft l ever and man-
ual val ve are i n the 3 posi ti on.
LOW COAST MODULATOR VALVE
The l ow coast modul ator val ve (Fi g. 20) momen-
tari l y reduces l i ne pressure from the 23 shi ft val ve;
thi s acti on cushi ons appl i cati on of the fi rst/reverse
brake. The modul ator val ve operates when the shi ft
l ever and manual val ve are i n the 12 posi ti on.
Fig. 19 Second Coast Modulator Valve
Fig. 20 Low Coast Modulator Valve
ACCUMULATOR CONTROL VALVE
The accumul ator control val ve (Fi g. 21) cushi ons
the transmi ssi on cl utch and brake appl i cati ons. Thi s
i s achi eved by reduci ng back pressure to the accumu-
l ators when throttl e openi ng i s smal l . The val ve i s
operated by l i ne and throttl e pressure.
ACCUMULATORS
Four accumul ators are used to cushi on cl utch and
brake appl i cati on. The accumul ators (Fi g. 22), consi st
of spri ng l oaded pi stons. The pi stons dampen the i ni -
ti al surge of appl y pressure to provi de smooth
engagement duri ng shi fts.
Control pressure from the accumul ator control
val ve i s conti nuousl y appl i ed to the back pressure
si de of the accumul ator pi stons. Thi s pressure pl us
spri ng tensi on hol ds the pi stons down. As l i ne pres-
sure from the shi ft val ves enters the opposi te end of
the pi ston bore, control pressure and spri ng tensi on
momentari l y del ay appl i cati on of ful l l i ne pressure to
cushi on engagement. The accumul ators are al l
l ocated i n the transmi ssi on case (Fi g. 22).
Three sol enoi ds are used (Fi g. 23). The No. 1 and 2
sol enoi ds control shi ft val ve operati on by appl yi ng or
rel easi ng l i ne pressure. The si gnal to appl y or rel ease
pressure i s provi ded by the transmi ssi on control
modul e.
The No. 3 sol enoi d control s operati on of the torque
converter cl utch. The sol enoi d operates i n response to
si gnal s from the transmi ssi on control modul e.
When the No. 1 and 2 sol enoi ds are acti vated, the
sol enoi d pl unger i s moved off i ts seat openi ng the
drai n port to rel ease l i ne pressure. When ei ther sol e-
noi d i s deacti vated, the pl unger cl oses the drai n port.
Fig. 21 Accumulator Control Valve
Fig. 22 Accumulators
Fig. 23 Transmission Valve Body Solenoids
The No. 3 sol enoi d operates i n reverse. When the
sol enoi d i s deacti vated, the sol enoi d pl unger i s moved
off i ts seat openi ng the drai n port to rel ease l i ne
pressure. When the sol enoi d i s acti vated, the pl unger
cl oses the drai n port.
TRANSMISSION COOLER
MAIN COOLER
The transmi ssi on mai n cool er i s l ocated i n the
radi ator. The mai n cool er can be fl ushed when neces-
sary, however, the cool er i s not a repai rabl e compo-
nent. I f the cool er i s damaged, pl ugged, or l eaki ng,
the radi ator wi l l have to be repl aced.
AUXILIARY COOLER
The auxi l i ary cool er i s mounted i n front of the
radi ator at the dri ver si de of the vehi cl e (Fi g. 24).
The cool er can be fl ushed when necessary, whi l e
mounted i n the vehi cl e. The cool er can al so be
removed for access, repai r, or repl acement as needed.
The mai n and auxi l i ary cool ers shoul d both be
fl ushed whenever a transmi ssi on or converter cl utch
mal functi on generates sl udge, debri s, or parti cl es of
cl utch fri cti on materi al .
COOLER SERVICE
The mai n cool er (and radi ator) and the auxi l i ary
cool er can be removed for servi ce or access to other
components. Auxi l i ary cool er removal requi res that
the front bumper and radi ator support be removed
for access to the cool er l i nes and attachi ng bracket.
MECHANISM
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 25). The system l ocks the shi fter i nto the
PARK posi ti on. The I nterl ock system i s engaged
whenever the i gni ti on swi tch i s i n the LOCK or
ACCESSORY posi ti on. An addi ti onal el ectri cal l y acti -
vated feature wi l l prevent shi fti ng out of the PARK
posi ti on unl ess the brake pedal i s depressed at l east
one-hal f an i nch. A magneti c hol di ng devi ce i n l i ne
wi th the park/brake i nterl ock cabl e i s energi zed
when the i gni ti on i s i n the RUN posi ti on. When the
key i s i n the RUN posi ti on and the brake pedal i s
depressed, the shi fter i s unl ocked and wi l l move i nto
any posi ti on. The i nterl ock system al so prevents the
i gni ti on swi tch from bei ng turned to the LOCK or
Fig. 24 Auxiliary Cooler Mounting (Left Hand Drive)
ACCESSORY posi ti on (Fi g. 26) unl ess the shi fter i s
ful l y l ocked i nto the PARK posi ti on.
GENERAL DIAGNOSIS INFORMATION
Shi ft poi nts are control l ed by the transmi ssi on con-
trol modul e (TCM). Before attempti ng repai r, deter-
mi ne i f a mal functi on i s el ectri cal or mechani cal .
The TCM used wi th the AW4 transmi ssi on has a
sel fdi agnosti c program compati bl e wi th the DRBI I I
scan tool . The tester wi l l i denti fy faul ts i n the el ec-
tri cal control system.
Di agnosi s shoul d begi n wi th the Prel i mi nary
I nspecti on And Adjustment procedure. I t i s wi l l hel p
determi ne i f a probl em i s mechani cal or el ectri cal .
The fi rst procedure step i s I ni ti al I nspecti on and
Adjustment.
PRELIMINARY INSPECTION AND ADJUSTMENT
(1) Check and adjust transmi ssi on shi ft cabl e i f
necessary.
(2) Veri fy transmi ssi on throttl e cabl e operati on.
Repai r or repl ace cabl e i f necessary.
(3) Check engi ne throttl e operati on. Operate accel -
erator pedal and observe i njector throttl e pl ate move-
ment. Adjust l i nkage i f throttl e pl ate does not reach
wi de open posi ti on.
(4) Check transmi ssi on fl ui d l evel when fl ui d i s at
normal operati ng temperature. Start engi ne. Shi ft
transmi ssi on through al l gear ranges then back to
Neutral . Correct l evel i s to Ful l or Add mark on di p-
sti ck wi th engi ne at curb i dl e speed.
(5) Check and adjust park/neutral posi ti on swi tch
i f necessary.
(6) Check throttl e posi ti on sensor adjustment and
operati on. Adjust the sensor i f necessary.
Fig. 25 Ignition Interlock Cable Routing
Fig. 26 Ignition Key Cylinder Actuation
MANUAL SHIFTING TEST
(1) Thi s test determi nes i f probl em i s rel ated to
mechani cal or el ectri cal component.
(2) Stop engi ne and di sconnect transmi ssi on con-
trol modul e or modul e fuse.
(3) Road test vehi cl e. Shi ft transmi ssi on i nto each
gear range. Transmi ssi on shoul d operate as fol l ows:
l ock i n Park
back up i n Reverse
not move i n Neutral
provi de fi rst gear onl y wi th shi ft l ever i n 12
posi ti on
operate i n thi rd gear onl y wi th shi ft l ever i n 3
posi ti on
operate i n overdri ve fourth gear i n D posi ti on.
(4) I f transmi ssi on operates as descri bed, proceed
to next step. However, i f forward gear ranges were
di ffi cul t to di sti ngui sh (al l feel the same), or vehi cl e
woul d not back up, refer to di agnosi s charts. Do not
perform stal l or ti me l ag tests.
CAUTION: Do not over speed the engine during the
next test step. Ease off the throttle and allow the
vehicle to slow before downshifting.
(5) Conti nue road test. Manual l y downshi ft trans-
mi ssi on from D to 3, and from 3 to 12 posi ti on.
Then manual l y upshi ft transmi ssi on through forward
ranges agai n.
(6) I f transmi ssi on operati on i s OK, perform stal l ,
ti me l ag and pressure tests. I f transmi ssi on shi fti ng
probl em i s encountered, refer to di agnosi s charts.
(7) I f a probl em sti l l exi sts, conti nue testi ng wi th
DRB scan tool .
Preliminary Diagnosis Check Procedure
HYDRAULIC PRESSURE TEST
Pressure Test Procedure
(1) Connect pressure test gauge to test port on
passenger si de of transmi ssi on (Fi g. 27). Use Adapter
7554 to connect gauge. Be sure test gauge has mi ni -
mum capaci ty of 300 psi (2100 kPa).
(2) Be sure transmi ssi on fl ui d i s at normal operat-
i ng temperature.
(3) Appl y parki ng brakes and bl ock wheel s.
WARNING: DO NOT ALLOW ANYONE TO STAND AT
THE FRONT OR REAR OF THE VEHICLE WHILE
PERFORMING THE FOLLOWING STEPS IN THE
PRESSURE TEST.
(4) Check and adjust engi ne curb i dl e speed.
(5) Appl y (and hol d) servi ce brakes.
(6) Shi ft transmi ssi on i nto D range and note l i ne
pressure wi th engi ne at curb i dl e speed. Pressure
shoul d be 61to70 psi (421to481 kPa).
(7) Press accel erator pedal to wi de open throttl e
posi ti on and note l i ne pressure. Pressure shoul d be
173to209 psi (1196to1442 kPa).
CAUTION: Do not hold wide open throttle for more
than 34 seconds at a time.
(8) Shi ft transmi ssi on i nto Reverse and note l i ne
pressure wi th engi ne at curb i dl e speed. Pressure
shoul d be 75to90 psi (519to618 kPa).
(9) Press accel erator to wi de open throttl e posi ti on
and note l i ne pressure i n Reverse. Pressure shoul d
be 213to263 psi (1471to1814 kPa).
CAUTION: Do not hold wide open throttle for more
than 4 seconds.
(10) I f l i ne pressure i s not wi thi n speci fi cati ons,
adjust transmi ssi on throttl e cabl e and repeat pres-
sure test.
PRESSURE TEST ANALYSIS
I f pressures i n D and Reverse are hi gher than
speci fi ed i n test, check for the fol l owi ng:
throttl e cabl e l oose, worn, bi ndi ng or out of
adjustment
throttl e val ve, downshi ft pl ug, throttl e cam, or
pri mary regul ator val ve are sti cki ng, worn or dam-
aged
I f pressures i n D and Reverse are l ower than spec-
i fi ed i n test, check for fol l owi ng:
throttl e cabl e l oose, worn, bi ndi ng or out of
adjustment
throttl e val ve, downshi ft pl ug, or throttl e cam
sti cki ng, worn or damaged
pri mary regul ator val ve sti cki ng, worn, or dam-
aged
oi l pump gears or housi ng worn, or damaged
overdri ve cl utch worn, or damaged
I f pressures are l ow i n D range onl y, check for fol -
l owi ng:
forward cl utch worn or damaged
fl ui d l eakage i n D range ci rcui t (component seal
and Ori ngs)
I f pressures are l ow i n Reverse onl y, check for fol -
l owi ng:
shi ft cabl e and manual val ve out of adjustment
fl ui d l eakage i n reverse ci rcui t (component seal
and Ori ngs)
di rect cl utch worn or damaged
fi rst/reverse brake worn or damaged.
TORQUE CONVERTER STALL TEST
Stal l testi ng checks the hol di ng abi l i ty of the trans-
mi ssi on cl utches and brakes and of the torque con-
verter stator overrunni ng cl utch. Stall speeds are
checked in both Drive and Reverse ranges with
the AW4 transmission.
(1) Before starti ng test, be sure fl ui d l evel i s cor-
rect and fl ui d i s at normal operati ng temperature.
(2) Connect tachometer to engi ne. Posi ti on tachom-
eter so i t can be vi ewed from dri vers seat.
(3) Appl y parki ng brakes and bl ock wheel s.
(4) Appl y and hol d servi ce brakes.
(5) Shi ft transfer case i nto 2H posi ti on.
(6) Start engi ne.
WARNING: DO NOT ALLOW ANYONE TO STAND AT
THE FRONT OR REAR OF THE VEHICLE DURING
THE TEST.
Fig. 27 Pressure Test Gauge Connection
(7) Shi ft transmi ssi on i nto D range.
(8) Open throttl e compl etel y and record maxi mum
engi ne rpm regi stered on tachometer. I t takes any-
where from 4 to 10 seconds to reach maxi mum rpm.
However, once maxi mum rpm has been achi eved, do
not hold wide open throttle for more than 34
seconds.
CAUTION: Stalling the converter causes a rapid
increase in fluid temperature. To avoid fluid over-
heating, hold wide open throttle for no more than 4
seconds after reaching peak rpm. In addition, if
more than one stall test is required, run the engine
at 1000 rpm with the transmission in Neutral for at
least 20 seconds to cool the fluid.
(9) Stal l speed shoul d be i n 21002400 rpm range
i n Dri ve.
(10) Rel ease throttl e, shi ft transmi ssi on i nto Neu-
tral , and run engi ne for 2030 seconds to cool fl ui d.
(11) Shi ft transmi ssi on i nto Reverse.
(12) Repeat stal l test.
(13) Stal l speed i n Reverse shoul d al so be i n 2100
2400 rpm range.
(14) Rel ease accel erator pedal , shi ft transmi ssi on
i nto Neutral , and run engi ne for 2030 seconds to
cool fl ui d.
STALL SPEED TEST ANALYSIS
I f engi ne rpm i s l ower than speci fi ed i n D and
Reverse, check for the fol l owi ng:
engi ne output/performance i nsuffi ci ent
stator overrunni ng cl utch i n torque converter
not hol di ng i f engi ne speed was 1500 rpm or l ess.
I f stal l speed i n D range i s hi gher than speci fi ed,
check for the fol l owi ng:
l i ne pressure l ow
forward cl utch sl i ppi ng
No. 2 oneway cl utch not hol di ng
overdri ve oneway cl utch not hol di ng
I f stal l speed i n Reverse was hi gher than speci fi ed,
check for the fol l owi ng:
di rect cl utch sl i ppi ng
fi rst/ reverse brake sl i ppi ng
overdri ve oneway cl utch not hol di ng
I f stal l speeds were hi gher than speci fi ed i n both D
and Reverse, check for the fol l owi ng:
l ow fl ui d l evel
overdri ve oneway cl utch not hol di ng.
TIME LAG TEST
Thi s test checks general condi ti on of the overdri ve
cl utch, forward cl utch, rear cl utch and fi rst/reverse
brake. Condi ti on i s i ndi cated by the amount of ti me
requi red for cl utch/brake engagement wi th the
engi ne at curb i dl e speed. Engagement ti me i s mea-
sured for D and Reverse posi ti ons. A stop watch i s
recommended for test accuracy.
TEST PROCEDURE
(1) Check and adjust transmi ssi on fl ui d l evel i f
necessary.
(2) Bri ng transmi ssi on to normal operati ng tem-
perature.
(3) Appl y parki ng brakes and turn off ai r condi -
ti oni ng uni t.
(4) Shi ft transfer case i nto 2H range.
(5) Start engi ne and check curb i dl e speed. Adjust
speed i f necessary. Curb i dl e must be correct to
ensure accurate test resul ts.
(6) Shi ft transmi ssi on i nto Neutral and set stop
watch.
(7) Duri ng fol l owi ng test steps, start stop watch as
soon as shi ft l ever reaches D and Reverse ranges.
(8) Shi ft transmi ssi on i nto D range and record
ti me i t takes for engagement. Repeat test two more
ti mes.
(9) Reset stop watch and shi ft transmi ssi on back
to Neutral .
(10) Shi ft transmi ssi on i nto Reverse and record
ti me i t takes for engagement. Repeat test two more
ti mes.
(11) Engagement ti me i n D range shoul d be a
maxi mum of 1.2 seconds. Engagement ti me for
Reverse shoul d be a maxi mum of 1.5 seconds.
TIME LAG TEST ANALYSIS
I f engagement ti me i s l onger than speci fi ed for D
range, check for the fol l owi ng:
shi ft cabl e mi sadjusted
forward cl utch worn
overdri ve cl utch worn or damaged.
I f engagement ti me i s l onger than speci fi ed for
Reverse, check for the fol l owi ng:
shi ft cabl e mi sadjusted
di rect cl utch worn
fi rst/reverse brake worn
overdri ve cl utch worn or damaged.
SERVICE DIAGNOSIS
TRANSMISSION SOLENOID TESTING
Test sol enoi d resi stance wi th an ohmmeter. Con-
nect the ohmmeter l eads to the sol enoi d mounti ng
bracket and to the sol enoi d wi re termi nal (Fi g. 28).
Sol enoi d resi stance shoul d be 1115 ohms. Repl ace
the sol enoi d i f resi stance i s above or bel ow the spec-
i fi ed range.
DIAGNOSIS TABLE
DIAGNOSIS TABLE CONTINUED
SWITCH TESTING
Test swi tch conti nui ty wi th an ohmmeter. Di scon-
nect the swi tch and check conti nui ty at the connector
termi nal posi ti ons and i n the gear ranges i ndi cated
i n Fi gure 3. Swi tch conti nui ty shoul d be as fol l ows:
Conti nui ty shoul d exi st between termi nal s
B and C wi th the transmi ssi on i n Park and Neutral
onl y (Fi g. 29).
Conti nui ty shoul d exi st between termi nal s A and
E wi th the transmi ssi on i n Reverse (Fi g. 29).
G wi th the transmi ssi on i n thi rd gear (Fi g. 29).
H wi th the transmi ssi on i n fi rst and/or second gear
(Fi g. 29).
Conti nui ty shoul d not exi st i n D posi ti on.
GEARSHIFT CABLE
(1) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti onAppl y forward force on cen-
must be possi bl e.
(b) PARK posi ti onAppl y rearward force on cen-
must be possi bl e.
(c) NEUTRAL posi ti onNormal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti onEngi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from neutral to reverse.
THROTTLE VALVE CABLE
Transmi ssi on throttl e val ve cabl e adjustment i s
extremel y i mportant to proper operati on. Thi s adjust-
ment posi ti ons the throttl e val ve, whi ch control s shi ft
speed, qual i ty, and part-throttl e downshi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve. Refer to the Adjust-
ments secti on for the proper adjustment procedure.
SPEED SENSOR TESTING
Test the speed sensor wi th an ohmmeter. Pl ace the
ohmmeter l eads on the termi nal s i n the sensor con-
nector (Fi g. 30).
Rotate the transmi ssi on output shaft and observe
the ohmmeter needl e. The needl e shoul d defl ect i ndi -
cati ng the swi tch i s openi ng/cl osi ng as the rotor
moves past the sensor (Fi g. 30). Repl ace the sensor i f
the ohmmeter does not di spl ay any ki nd of readi ng.
I f a di gi tal ohmmeter i s bei ng used, the sensor
shoul d generate an ohmmeter readout each ti me the
swi tch opens and cl oses.
Fig. 28 Testing Transmission Valve Body Solenoid
Fig. 29 Park/Neutral Position Switch Terminals And
Testing
FLOW TESTING TRANSMISSION MAIN
COOLER
Cool er fl ow i s checked by measuri ng the amount of
fl ui d fl ow through the cool er i n a 20 second ti me
peri od. The test i s performed wi th the engi ne run-
ni ng and transmi ssi on i n neutral . Fl ui d i s then
pumped through the cool er by the transmi ssi on oi l
pump.
(1) Di sconnect cool er i nl et l i ne at transmi ssi on fi t-
ti ng.
(2) Securel y attach hose to end of i nl et l i ne and
posi ti on l i ne i n a one quart test contai ner.
(3) Add extra quart of fl ui d to transmi ssi on.
(4) Use stopwatch to check fl ow test ti me.
(5) Shi ft transmi ssi on i nto neutral and set parki ng
brake.
(6) Start and run engi ne at curb i dl e speed and
i mmedi atel y note cool er fl ow. Approxi matel y one
quart of fl ui d shoul d fl ow i nto test contai ner i n 20
second peri od.
(7) I f cool er fl ow i s i ntermi ttent, fl ows l ess than
one quart i n 20 seconds, or does not fl ow at al l ,
cool er i s faul ty and must be repl aced.
TORQUE CONVERTER STATOR CLUTCH
INSPECTION
(1) I nsert Rotati ng Tool 7547 i nto converter hub
and seat tool i n oneway cl utch (Fi g. 31).
(2) I nsert Stopper Tool 7548 i n one converter hub
notch and i nto outer race of rotati ng tool .
(3) Turn rotati ng tool cl ockwi se. Converter cl utch
shoul d rotate freel y and smoothl y. Less than 2.5 Nm
Fig. 30 Speed Sensor Testing
Fig. 31 Checking Operation Of Torque Converter
Stator OneWay Clutch
(22 i n. l bs.) of torque shoul d be requi red to rotate
cl utch i n cl ockwi se di recti on.
(4) Turn rotati ng tool i n countercl ockwi se di rec-
ti on. Converter cl utch shoul d l ock.
(5) Repl ace converter i f cl utch bi nds or wi l l not
l ock.
SERVICE PROCEDURES
CHECKING FLUID LEVEL
(1) Be sure transmi ssi on fl ui d i s at normal operat-
i ng temperature. Normal operati ng temperature i s
reached after approxi matel y 15 mi l es (25 km) of
operati on.
(2) Posi ti on vehi cl e on l evel surface. Thi s i s i mpor-
tant for an accurate fl ui d l evel check.
(3) Shi ft transmi ssi on through al l gear ranges and
back to Park.
(5) Veri fy that transmi ssi on i s i n Park.
(6) Wi pe off di psti ck handl e to prevent di rt from
enteri ng fi l l tube. Then remove di psti ck and check
fl ui d l evel and condi ti on.
(7) Correct fl ui d l evel i s to FULL mark on dip-
stick when fluid is at normal operating temper-
ature (Fi g. 32).
(8) I f fl ui d l evel i s l ow, top off l evel wi th Mopar
Dexron I I E/Mercon. Mopar Dexron I I can be used but
onl y i f Mercon i s not avai l abl e. Do not overfill
transmission. Add only enough fluid to bring
level to Full mark.
(9) I f too much fl ui d was added, excess amount can
be removed wi th sucti on gun and appropri ate di ame-
ter pl asti c tubi ng. Tubi ng onl y has to be l ong enough
to extend i nto oi l pan.
CHECKING FLUID CONDITION
I nspect the appearance of the fl ui d duri ng the fl ui d
l evel check. Fl ui d col or shoul d range from dark red to
pi nk and be free of forei gn materi al , or parti cl es. I f
the fl ui d i s dark brown or bl ack i n col or and smel l s
burnt, the fl ui d has been overheated and must be
changed.
Transmi ssi on operati on shoul d al so be checked i f
the fl ui d i s severel y di scol ored and contai ns quanti -
ti es of forei gn materi al , metal parti cl es, or cl utch di sc
fri cti on materi al .
A small quantity of friction material or metal
particles in the oil pan is normal. The particles
are usually generated during the breakin
period and indicate normal seating of the vari-
ous transmission components.
REFILLING AFTER OVERHAUL OR FLUID/
FILTER CHANGE
The best way to refi l l the transmi ssi on after a fl ui d
change or overhaul i s as fol l ows:
(1) I f transmi ssi on has been overhaul ed, i nstal l
transmi ssi on i n vehi cl e.
(2) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(3) Add fol l owi ng i ni ti al quanti ty of Mopar Dexron
I I E/Mercon to transmi ssi on:
(4) I f fl ui d/fi l ter change was performed, add 4
pints (2 quarts) of fl ui d to transmi ssi on.
(a) I f transmi ssi on was compl etel y overhaul ed
and torque converter was repl aced or drai ned, add
10 pints (5 quarts) of fl ui d to transmi ssi on.
(b) Remove funnel and i nstal l di psti ck.
(5) Operate vehi cl e unti l fl ui d reaches normal
operati ng temperature.
(7) Let engi ne run at normal curb i dl e speed, appl y
servi ce brakes. Then shi ft transmi ssi on through al l
gear ranges and back to PARK (l eave engi ne run-
ni ng).
(8) Remove di psti ck and check fl ui d l evel . Add onl y
enough fl ui d to bri ng l evel to Ful l mark on di psti ck.
Do not overfi l l . If too much fluid is added, excess
amount can be removed with suction gun and
plastic tubing. Tubing only has to be long
enough to extend into oil pan.
(9) When fl ui d l evel i s correct, shut engi ne off,
rel ease park brake, remove funnel , and reseat di p-
sti ck i n fi l l tube.
SERVICE
Use the DRB scan tool to di agnose transmi ssi on
control modul e functi on whenever a faul t i s sus-
pected. Repl ace the modul e onl y when the scan tool
i ndi cates the modul e i s actual l y faul ty.
OIL PUMP VOLUME CHECK
After the new or repai red transmi ssi on has been
i nstal l ed, fi l l to the proper l evel wi th Mopar ATF
PLUS 3 (Type 7176) automati c transmi ssi on fl ui d.
The vol ume shoul d be checked usi ng the fol l owi ng
procedure:
Fig. 32 Transmission Fluid Level
(1) Di sconnect the From cooler l i ne at the trans-
mi ssi on and pl ace a col l ecti ng contai ner under the
di sconnected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed , wi th the
shi ft sel ector i n neutral .
(3) I f fl ui d fl ow i s i ntermi ttent or i t takes more
than 20 seconds to col l ect one quart of ATF PLUS 3,
di sconnect the To Cooler l i ne at the transaxl e.
(4) Refi l l the transaxl e to proper l evel and recheck
pump vol ume.
(5) I f fl ow i s found to be wi thi n acceptabl e l i mi ts,
repl ace the cool er. Then fi l l transmi ssi on to the
proper l evel , usi ng Mopar ATF PLUS 3 (Type 7176)
(6) I f fl ui d fl ow i s sti l l found to be i nadequate,
check the l i ne pressure usi ng the Transaxl e Hydrau-
l i c Pressure Test procedure.
FLUSHING COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The torque
converter must al so be repl aced. Thi s wi l l i nsure that
metal parti cl es or sl udged oi l are not l ater trans-
ferred back i nto the recondi ti oned (or repl aced) trans-
mi ssi on.
The onl y recommended procedure for fl ushi ng cool -
ers and l i nes i s to use Tool 6906 Cool er Fl usher.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906
(1) Remove cover pl ate fi l l er pl ug on Tool 6906.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will preventreverse
flushing the system.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes. Moni tor pressure readi ngs
and cl ear return l i nes. Pressure readi ngs shoul d sta-
bi l i ze bel ow 20 psi . for vehi cl es equi pped wi th a si n-
gl e cool er and 30 psi . for vehi cl es equi pped wi th dual
cool ers. I f fl ow i s i ntermi ttent or exceeds these pres-
sures, repl ace cool er.
(8) Turn pump OFF.
(9) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(10) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(11) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF Pl us 3, type 7176 automati c
(12) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(13) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts
of dri l l i ng out the worn-out damaged threads. Then
tap the hol e wi th a speci al Hel i -Coi l tap, or equi va-
l ent, and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent,
i nto the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
TRANSMISSION AND TORQUE CONVERTER
REMOVAL
(2) Drai n transmi ssi on fl ui d and rei nstal l oi l pan
drai n pl ug.
(3) On model s wi th 2pi ece fi l l tube, remove upper
hal f of tube (Fi g. 33).
(4) Di sconnect cool er l i nes at transmi ssi on.
(5) Support engi ne wi th safety stand and support
transmi ssi on wi th jack.
(6) Di sconnect transmi ssi on and transfer case shi ft
l i nkage.
(7) Remove necessary exhaust components.
(8) Di sconnect vehi cl e speed sensor wi res
(9) Mark posi ti on of front and rear propel l er shafts
for al i gnment reference. Then remove shafts from
vehi cl e.
(11) Di sconnect transmi ssi on shi ft cabl e at trans-
mi ssi on. Then di sconnect transmi ssi on throttl e val ve
cabl e at engi ne.
(12) Di sconnect necessary vacuum and fl ui d hoses.
(13) Remove transfer case from transmi ssi on.
(14) Di sconnect and remove crankshaft posi ti on
sensor (Fi g. 34).
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov-
ing the transmission.
(15) Remove starter motor.
(16) Remove bol ts attachi ng converter to dri ve
pl ate.
(17) Remove bol ts attachi ng converter housi ng to
engi ne.
chai ns.
(19) Pul l transmi ssi on rearward for access to con-
verter. Then secure converter i n pump wi th Ccl amp
or strap bol ted to converter housi ng.
(20) Remove transmi ssi on from under vehi cl e.
(21) Remove torque converter i f converter or oi l
pump seal are to be servi ced.
INSTALLATION
(1) Mount transmi ssi on on transmi ssi on jack. Then
secure transmi ssi on to jack wi th safety chai ns.
(2) Lubri cate converter dri ve hub and oi l pump
seal l i p wi th transmi ssi on fl ui d. Then i nstal l con-
verter. Be sure converter i s ful l y seated i n oi l pump
gears before proceedi ng. Hol d converter i n pl ace wi th
Ccl amp or strap attached to converter housi ng.
(3) Al i gn and posi ti on transmi ssi on and converter
on engi ne.
(4) Remove cl amp or strap used to hol d torque con-
verter i n pl ace.
(5) Move transmi ssi on forward seat and i t on
engi ne. Be sure torque converter hub i s ful l y seated.
(6) I nstal l converter housi ngtoengi ne bol ts (Fi g.
35).
(7) I nstal l converter-to-dri ve pl ate bol ts.
(8) I nstal l and connect starter motor.
Fig. 33 Transmission Fill Tube (TwoPiece)
Fig. 34 Crankshaft Position Sensor
(10) I nstal l transfer case on transmi ssi on.
(11) Connect transfer case shi ft l i nkage and vac-
uum hoses.
(12) Connect exhaust components.
(13) I nstal l rear crossmember and remove jack
used to support transmi ssi on assembl y.
(14) Connect speed sensor wi re harness to sensor.
(15) Connect wi re harness to park/neutral posi ti on
swi tch.
(16) Al i gn and connect front and rear propel l er
shafts.
(17) Connect transmi ssi on wi re harnesses and
transfer case vacuum and wi re harnesses.
(18) Connect transmi ssi on cool er l i nes.
(19) Connect transmi ssi on throttl e cabl e at engi ne.
(20) I nstal l new Ori ng seal on upper hal f of
transmi ssi on fi l l tube. Then connect upper and l ower
tube hal ves.
(22) Fi l l transmi ssi on wi th Mopar Dexron I I E/Mer-
con automati c transmi ssi on fl ui d.
TORQUE CONVERTER
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate converter hub and oi l pump seal l i p
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
Fig. 35 Transmission Mounting
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
REMOVAL
(2) Di sconnect or remove components necessary to
gai n access to seal (e.g. propel l er shaft, crossmember,
shi ft l i nkage, transfer case, exhaust components,
hoses, wi res).
(3) On 4X2 vehi cl es, remove dust shi el d from the
adapter housi ng by tappi ng gentl y wi th a brass dri ft
and hammer (Fi g. 37).
(4) On 4X2 vehi cl es, remove the adapter housi ng
seal wi th Seal Pul l er 7550.
(5) On 4X4 vehi cl es, remove the adapter housi ng
seal usi ng a sl i de hammer mounted screw.
INSTALLATION
(1) I nstal l new adapter housi ng seal wi th Seal
I nstal l er 7888.
(2) On 4X2 vehi cl es, i nstal l dust shi el d usi ng Spe-
ci al Tool D-187-B.
(3) Rei nstal l components removed to gai n access to
seal .
(4) Top off transmi ssi on fl ui d i f necessary.
SPEED SENSOR
REMOVAL
(1) Di sconnect sensor wi re harness connector.
(2) Remove sensor retai ner bol t and remove sensor
(Fi g. 38).
(3) Remove and di scard speed sensor Ori ng.
INSTALLATION
(1) I nstal l new Ori ng on speed sensor and i nstal l
sensor i n transmi ssi on case.
(2) I nstal l sensor bracket and retai ner bol t.
Ti ghten bol t to 7.4 Nm (65 i n. l bs.) torque.
(3) Connect sensor wi re harness connector.
SPEEDOMETER ADAPTER
Rear axl e gear rati o and ti re si ze determi ne speed-
ometer pi ni on requi rements.
REMOVAL
Fig. 36 Checking Torque Converter Seating
Fig. 37 Adapter Housing Seals
as assembl y.
oxi di zed. Repl ace sensor i f faul ty, or pi ns are l oose,
INSTALLATION
ati on.
ometer adapter i f necessary (Fi g. 39).
pi ni on.
are at 6 ocl ock posi ti on. Be sure range i ndex num-
i n. l bs.) torque.
l evel , i f necessary.
SPEED SENSOR ROTOR-SPEEDOMETER DRIVE
GEAR
REMOVAL
(2) Remove components necessary to gai n access to
rotor and dri ve gear such as propel l er shaft, transfer
case, crossmember, and shi ft l i nkage.
(3) Di sengage wi re connector from the output
speed sensor.
(4) Remove the bol t hol di ng the output speed sen-
sor to the adapter housi ng.
(5) Remove the output speed sensor from the
adapter housi ng.
(6) Remove the bol ts hol di ng the adapter housi ng
to the transmi ssi on case.
(7) Tap the adapter housi ng at the joi nt l i ne gentl y
wi th a rubber mal l et to separate the adapter housi ng
from the transmi ssi on case.
(8) Remove the adapter housi ng from the trans-
mi ssi on case.
(9) Remove speedometer dri ve gear snap ri ng (Fi g.
41).
(10) Remove the speedometer dri ve gear and
spacer, i f equi pped.
(11) Remove rotor from the output shaft. I t may be
necessary to use a wood dowel or hammer handl e
(Fi g. 42) to gentl y pry the rotor from the output
shaft. Be sure to retri eve the rotor l ocati ng key from
the output shaft or rotor.
INSTALLATION
(1) Cl ean seal i ng surfaces of transmi ssi on case and
extensi on/adaptor housi ng.
(2) I nstal l rotor, spacer (i f equi pped) and dri ve
gear on output shaft. Then i nstal l dri ve gear snap
ri ng (Fi g. 41).
(3) Appl y 1/8 3/16 i nch wi de bead of Threebond
Li qui d Gasket TB1281, P/N 83504038, to transmi s-
si on case seal i ng surface and i nstal l extensi on/
adapter housi ng on case.
(4) Ti ghten adaptor housi ng bol ts to 34 Nm (25 ft.
l bs.) torque.
(5) I nstal l components removed to gai n access to
rotor and dri ve gear.
Fig. 38 Transmission Speed Sensor Removal/
Installation
REMOVAL
(2) Di sconnect swi tch wi re harness connector.
(3) Pry washer l ock tabs upward and remove
swi tch attachi ng nut and tabbed washer (Fi g. 43).
(4) Remove swi tch adjusti ng bol t (Fi g. 43).
(5) Sl i de swi tch off manual val ve shaft.
INSTALLATION
(1) Di sconnect shi ft l i nkage rod from shi ft l ever on
l eft si de of transmi ssi on.
(2) Rotate manual shi ft l ever al l the way rear-
ward. Then rotate l ever forward two detent posi ti ons
to Neutral .
(3) I nstal l swi tch on manual val ve shaft and
i nstal l swi tch adjusti ng bol t fi nger ti ght. Do not
ti ghten bol t at thi s ti me.
(4) I nstal l tabbed washer on manual val ve shaft
and i nstal l swi tch attachi ng nut. Ti ghten nut to 6.9
Nm (61 i n. l bs.) torque but do not bend washer l ock
tabs over nut at thi s ti me.
Fig. 39 Speedometer Pinion Adapter Components
Fig. 40 Index Numbers On Speedometer Pinion
Adapter
Fig. 41 Removing/Installation Speedometer Drive
Gear
(5) Veri fy that transmi ssi on i s i n Neutral .
(6) Rotate swi tch to al i gn neutral standard l i ne
wi th verti cal groove on manual val ve shaft (Fi g. 44).
(7) Al i gn swi tch standard l i ne wi th groove or fl at
on manual val ve shaft.
(8) Ti ghten swi tch adjusti ng bol t to 13 Nm (9 ft.
l bs.) torque.
(9) Bend at l east two washer l ock tabs over swi tch
attachi ng nut to secure i t.
(10) Connect shi ft l i nkage rod to shi ft l ever on l eft
si de of case.
(11) Connect swi tch wi res to harness and l ower
vehi cl e.
(12) Check swi tch operati on. Engi ne shoul d start
i n Park and Neutral onl y.
GEARSHIFT CABLE
REMOVAL
(2) Remove shi ft l ever bezel and necessary consol e
parts for access to shi ft l ever assembl y.
(3) Di sconnect cabl e at shi ft l ever and feed cabl e
through dash panel openi ng to undersi de of vehi cl e.
(5) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng
bracket. Then remove ol d cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n dash panel . Ful l y
seat cabl e grommet i nto dash panel .
(2) Pl ace the auto transmi ssi on manual shi ft con-
trol l ever i n Park detent (rearmost) posi ti on and
rotate prop shaft to ensure transmi ssi on i s i n park.
(3) Connect shi ft cabl e to shi fter mechani sm by
snappi ng cabl e retai ni ng ears i nto shi fter bracket
and press cabl e end fi tti ng onto l ever bal l stud.
(4) Pl ace the fl oor shi fter l ever i n park posi ti on.
Ensure that the pawl i s seated wi thi n the confi nes of
the adjustment gauge cl i p.
(5) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
Fig. 42 Removing Speed Sensor Rotor
Fig. 43 Park/Neutral Position Switch Removal/
Installation
Fig. 44 Park/Neutral Position Switch Adjustment
(6) Lock shi ft cabl e i nto posi ti on by pushi ng
upward on the adjusti ng l ock button.
(7) Remove and di scard the shi ft cabl e adjustment
gauge cl i p from the park gate of the shi fter.
REMOVAL
(1) Remove l ower steeri ng col umn cover. Refer to
Group 8E, I nstrument Panel and Gauges, for proper
procedure.
(2) Remove l ower steeri ng col umn shroud. Refer to
Group 19, Steeri ng, for proper procedure.
(3) Remove ti e strap near the sol enoi d retai ni ng
the brake transmi ssi on i nterl ock cabl e to the steeri ng
col umn.
(4) Di sengage wi re connector from sol enoi d.
(5) Wi th the i gni ti on removed or i n the unl ocked
posi ti on, di sengage l ock tab hol di ng cabl e end to
steeri ng col umn (Fi g. 45).
(6) Pul l cabl e end from steeri ng col umn.
(7) Remove the fl oor consol e and rel ated tri m.
Refer to Group 23, Body, for proper procedure.
(8) Di sconnect the cabl e eyel et from the bel l crank
(Fi g. 46).
(9) Di sconnect and remove the cabl e from the shi ft
bracket.
INSTALLATION
(1) Route repl acement cabl e behi nd i nstrument
panel and under fl oor consol e area to shi ft mecha-
ni sm (Fi g. 46).
(2) I nsert cabl e end i nto openi ng i n steeri ng col -
umn hub under i gni ti on l ock. Push cabl e i nward
unti l l ock tab engages.
(3) Connect the cabl e end eyel et onto shi fter
bel l crank pi n.
(4) Pl ace gear sel ector i n PARK.
(5) Push the spri ng-l oaded cabl e adjuster forward
and snap cabl e i nto bracket.
(6) Adjust the brake transmi ssi on shi fter i nterl ock
cabl e. Refer to the Adjustment porti on of thi s secti on
(7) Veri fy that the cabl e adjuster l ock cl amp i s
pushed downward to the l ocked posi ti on.
(8) Test the park-l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
(10) I nstal l ti e strap to hol d cabl e to base of steer-
i ng col umn.
(11) I nstal l l ower steeri ng col umn shroud and i gni -
ti on l ock.
(12) I nstal l l ower steeri ng col umn cover.
REMOVAL
(1) Remove transmi ssi on oi l pan drai n pl ug and
drai n fl ui d.
(2) Remove pan bol ts and remove oi l pan.
(3) Remove oi l screen bol ts and remove screen
(Fi g. 47) and gasket. Di scard the gasket.
(4) Di sconnect sol enoi d wi re connector (Fi g. 48).
(5) I f al l sol enoi ds are bei ng removed, mark or tag
wi res for assembl y reference before di sconnecti ng
them.
(6) Remove bol t attachi ng sol enoi ds to val ve body
and remove sol enoi ds (Fi g. 49). Do not al l ow any
val ve body components to fal l out when sol enoi ds are
removed.
(7) Cl ean oi l fi l ter and pan wi th sol vent and dry
wi th compressed ai r.
(8) Remove ol d seal er materi al from oi l pan and
INSTALLATION
(1) Posi ti on sol enoi ds on val ve body and i nstal l
sol enoi d bol ts. Ti ghten bol ts to 10 Nm (7 ft. l bs.)
torque.
(2) Connect feed wi res to sol enoi ds.
(3) I nstal l new gaskets on oi l screen and i nstal l
screen. Ti ghten screen bol ts to 10 Nm (7 ft. l bs.)
torque.
(4) Appl y bead of Threebond Li qui d Gasket
TB1281, P/N 83504038, seal er to oi l pan seal i ng sur-
face. Seal er bead shoul d be at l east 3.0 mm (1/8 i n.)
wi de.
(5) I nstal l oi l pan on transmi ssi on. Ti ghten pan
bol ts to 7 Nm (65 i n. l bs.) torque.
(6) I nstal l and ti ghten oi l pan drai n pl ug to 20
con.
Fig. 45 Brake/Park Interlock Cable
REMOVAL
(1) Remove oi l pan pl ug and drai n transmi ssi on
fl ui d.
(2) Remove oi l pan and oi l screen. Cl ean pan and
screen i n sol vent and dry them wi th compressed ai r.
(3) Di sconnect sol enoi d wi re connectors (Fi g. 50).
Mark wi res for assembl y reference.
(4) Remove val ve body oi l tubes (Fi g. 51). Careful l y
pry tubes out of val ve body wi th screwdri ver.
(5) Di sconnect throttl e cabl e from throttl e cam
(Fi g. 52).
Fig. 46 Cable and Shifter
Fig. 47 Oil Screen Removal/Installation
Fig. 48 Solenoid Wire Connectors
(6) Remove val ve body bol ts. Bol t l ocati ons are
outl i ned i n (Fi g. 53).
(7) Lower val ve body and remove overdri ve cl utch
accumul ator spri ngs, di rect cl utch accumul ator
spri ngs and second brake accumul ator spri ng (Fi g.
54).
(8) Remove val ve body and check bal l and spri ng
(Fi g. 55).
INSTALLATION
(1) Connect cabl e to throttl e cam (Fi g. 52).
(2) I nstal l check bal l and spri ng (Fi g. 55).
(3) Posi ti on accumul ator spri ngs and spacers on
val ve body.
(4) Al i gn val ve body manual val ve wi th shi ft sector
(Fi g. 56) and careful l y posi ti on val ve body on case.
(5) I nstal l val ve body bol ts (Fi g. 53). Ti ghten bol ts
evenl y to 10 Nm (7 ft. l bs.) torque.
(6) I nstal l val ve body oi l tubes. Be sure tube ends
(L) and (M) are i nstal l ed as shown i n (Fi g. 57).
(7) Remove ol d seal er materi al from oi l pan and
(8) Cl ean oi l screen and oi l pan wi th sol vent (i f not
done previ ousl y). Dry both components wi th com-
pressed ai r onl y. Do not use shop towel s.
screen on case. Ti ghten screen attachi ng bol ts to 10
TB1281, P/N 83504038 to seal i ng surface of oi l pan.
Seal er bead shoul d be at l east 3 mm (1/8 i n.) wi de.
Fig. 49 Transmission Valve Body Solenoids
Fig. 51 Removing Transmission Valve Body Oil
Tubes
Fig. 52 Removing/Installing Throttle Cable
Then i nstal l oi l pan and ti ghten pan bol ts to 7.4 Nm
(65 i n. l bs.) torque.
(11) I nstal l new gasket on oi l pan drai n pl ug and
i nstal l pl ug i n pan. Ti ghten pl ug to 20 Nm (15 ft.
l bs.) torque.
(12) Fi l l transmi ssi on wi th Mopar Dexron I I E/
Mercon.
TRANSMISSION CONTROL MODULE
The transmi ssi on control modul e i s mounted under
the i nstrument panel . On l eft hand dri ve model s, i t i s
at the dri ver si de of the l ower fi ni sh panel (Fi g. 58).
On ri ght hand dri ve model s, i t i s at the passenger
si de of the l ower fi ni sh panel (Fi g. 59).
To remove the modul e, di sconnect the wi re har-
ness, remove the mounti ng screws and remove the
modul e from the fi ni sh panel . Ti ghten the modul e
mounti ng screws securel y after i nstal l ati on. Al so be
sure the wi re harness i s not twi sted, ki nked or touch-
i ng any body panel s.
SOLENOID HARNESS ADAPTER SEAL
REMOVAL
(1) Remove oi l pan and oi l screen.
(2) Di sconnect sol enoi d wi re connectors (Fi g. 60).
Fig. 53 Transmission Valve Body Bolt Locations
Fig. 54 Accumulator Springs
Fig. 55 Removing/Installing Check Ball And Spring
Fig. 56 Shift Sector And Manual Valve Alignment
(3) Remove bracket securi ng sol enoi d harness
adaptor (Fi g. 61) to case.
(4) Pul l harness adapter and wi res out of case.
(5) Remove and di scard adapter Ori ng.
INSTALLATION
(1) Lubri cate new Ori ng and i nstal l i t on adapter.
(2) I nstal l sol enoi d wi re harness and adapter i n
case.
(3) I nstal l adapter bracket and bracket bol t.
(4) Connect wi res to sol enoi ds.
(5) I nstal l oi l screen.
TB1281, P/N 83504038, to oi l pan seal surface.
Seal er bead shoul d be at l east 3 mm (1/8 i n.) wi de.
(7) I nstal l oi l pan on transmi ssi on. Ti ghten pan
(8) I nstal l and ti ghten oi l pan drai n pl ug to 20
con.
Fig. 57 Installing Transmission Valve Body Oil
Tubes
Fig. 58 TCM Location (Left Hand Drive)
Fig. 59 TCM Location (Right Hand Drive)
Fig. 61 Harness Adapter Removal/Installation
MANUAL VALVE SHAFT SEAL
REMOVAL
(1) Remove park/neutral posi ti on swi tch and di s-
connect transmi ssi on shi ft l ever (Fi g. 62).
(2) Remove oi l pan and val ve body.
(3) Remove bol ts attachi ng park rod bracket to
case (Fi g. 63).
(4) Remove park rod from shi ft sector (Fi g. 64).
(5) Cut spacer sl eeve wi th chi sel and remove i t
from manual val ve shaft (Fi g. 65).
(6) Remove pi n from shaft and sector wi th pi n
punch.
(7) Remove shaft and sector from case.
(8) Pry shaft seal s out of case (Fi g. 66).
INSTALLATION
(1) I nspect the manual val ve shaft and sector.
Repl ace ei ther component i f worn or damaged.
(2) Coat repl acement shaft seal s wi th petrol eum
jel l y and seat them i n the case usi ng an appropri -
atel y si zed dri ver/socket (Fi g. 67).
Fig. 62 Manual Valve Shaft And Seals
Fig. 63 Removing/Installing Park Rod Bracket
Fig. 64 Removing/Installing Park Rod
Fig. 65 Cutting Spacer Sleeve
(3) I nstal l new spacer sl eeve on sector (Fi g. 68).
(4) Lubri cate manual val ve shaft wi th petrol eum
jel l y and i nstal l i t through the l eft si de of the trans-
mi ssi on case.
(5) Lubri cate sector and sl eeve wi th petrol eum
jel l y and i nstal l them on shaft.
(6) I nstal l the manual val ve shaft through the
remai nder of the transmi ssi on case.
(7) Al i gn hol e i n spacer sl eeve wi th notch i n sector.
Then i nstal l shi ft sector rol l pi n. Tap pi n i nto sector
and shaft and securel y stake sl eeve to sector and
shaft.
(8) Connect park rod to sector (Fi g. 64).
(9) I nstal l park rod bracket (Fi g. 69). Ti ghten
bracket bol ts to 10 Nm (7 ft. l bs.) torque.
(10) I nstal l val ve body, oi l screen and oi l pan.
(11) I nstal l park/neutral posi ti on swi tch.
ACCUMULATOR PISTONS AND SPRINGS
REMOVAL
(2) Remove accumul ator pi stons wi th compressed
ai r (Fi g. 70). Appl y ai r through smal l feed hol e next
Fig. 66 Removing Manual Valve Shaft Seals
Fig. 67 Installing Manual Valve Shaft Seals
Fig. 68 Installing Spacer Sleeve On Sector
Fig. 69 Installing Park Rod Bracket
to each pi ston bore. Catch each pi ston i n a shop
towel as i t exi ts bore.
CAUTION: Use only enough air pressure to ease
each piston out of the bore. In addition, remove the
pistons one at a time and tag the pistons and
springs for assembly reference. Do not intermix
them.
(3) Remove and di scard pi ston Ori ng seal s. Then
cl ean pi stons and spri ngs wi th sol vent.
INSTALLATION
(1) I nspect pi stons, spri ngs and pi ston bores.
Repl ace worn damaged pi stons. Repl ace broken, col -
l apsed or di storted spri ngs. Repl ace case i f pi ston
bores are damaged.
(2) I f smal l cushi on spri ng i n any pi ston must be
repl aced, remove spri ng retai ner cl i p and remove
spri ng from pi ston (Fi g. 71). A smal l hooked tool or
smal l thi n bl ade screwdri ver can be used to remove
cl i p. A thi n wal l , deep socket, or pi n punch can be
used to seat cl i p after spri ng repl acement.
(3) I nstal l new Ori ng seal s on pi stons. Lubri cate
seal s and pi stons and pi ston bores wi th transmi ssi on
fl ui d.
(4) I nstal l pi stons and spri ngs (Fi g. 72).
SECOND COAST BRAKE SERVO
REMOVAL
(2) Remove servo pi ston cover snap ri ng wi th snap
ri ng pl i ers (Fi g. 73).
(3) Remove servo pi ston and cover wi th com-
pressed ai r. Appl y compressed ai r through oi l hol e i n
servo boss to ease pi ston out of bore (Fi g. 74).
(4) Remove and di scard seal and Ori ngs from
cover and pi ston (Fi g. 75). I nspect Eri ng, pi ston,
spri ng and retai ner, pi ston rod and pi ston spri ng.
Repl ace worn or damaged parts.
Fig. 70 Accumulator Piston Removal
Fig. 71 Small Cushion Spring Retention
Fig. 72 Accumulator Pistons, Springs And Spacers
INSTALLATION
(1) I nstal l new seal s on cover and pi ston.
(2) Lubri cate servo components wi th transmi ssi on
fl ui d.
(3) Assembl e and i nstal l servo components i n case.
Be sure servo pi ston rod i s properl y engaged i n the
second coast brake band.
(4) Compress cover and pi ston and i nstal l cover
snap ri ng.
PARK ROD AND PAWL
REMOVAL
(1) Remove val ve body as outl i ned i n thi s secti on.
case (Fi g. 76).
Fig. 73 Removing/Installing Servo Piston Cover
Snap Ring
Fig. 74 Removing Servo Cover And Piston
Fig. 75 Second Coast Brake Servo Components
Fig. 76 Removing/Installing Park Rod Bracket
(3) Remove park rod from manual val ve shaft sec-
tor (Fi g. 77).
(4) Remove park rod.
(5) Remove park pawl , pi n and spri ng (Fi g. 78).
INSTALLATION
(1) Exami ne park rod, pawl , pi n and spri ng.
Repl ace any component that i s worn or damaged.
(2) I nstal l pawl i n case. I nsert pi n and i nstal l
spri ng. Be sure spri ng i s posi ti oned as shown i n Fi g-
ure 35.
(3) I nstal l park rod and bracket (Fi g. 76). Ti ghten
TRANSMISSION THROTTLE CABLE
REMOVAL
(1) I n engi ne compartment, di sconnect cabl e from
throttl e l i nkage. Then compress cabl e mounti ng ears
and remove cabl e from engi ne bracket (Fi g. 79).
Fig. 78 Removing/Installing Park Pawl, Pin And
Spring
Fig. 77 Removing/Installing Park Rod
Fig. 79 Transmission Throttle Cable Attachment
(3) Remove transmi ssi on oi l pan.
(4) Di sengage cabl e from throttl e val ve cam (Fi g.
80).
(5) Remove cabl e bracket bol t and remove cabl e
and bracket from case (Fi g. 81).
(6) Remove and di scard cabl e seal .
INSTALLATION
(1) Lubri cate and i nstal l new seal on cabl e.
(2) I nsert cabl e i n transmi ssi on case.
(3) Attach cabl e to throttl e cam (Fi g. 80).
(4) I nstal l cabl e bracket on case and ti ghten
attachi ng bol t to 10 Nm (7 ft. l bs.) torque (Fi g. 81).
(5) I nstal l pan and ti ghten pan bol ts to 7 Nm (65
i n. l bs.) torque.
(6) I nstal l new gasket on oi l pan drai n pl ug.
I nstal l and ti ghten pl ug to 20 Nm (15 ft. l bs.) torque.
(7) Connect cabl e to engi ne bracket and throttl e
l i nkage.
(8) Fi l l transmi ssi on wi th Mopar Dexron/Mercon
I I E.
(9) Adjust the cabl e as descri bed i n cabl e adjust-
ment procedure.
OIL PUMP SEAL
REMOVAL
(1) Remove converter.
(2) Remove ol d seal . Use bl unt punch to col l apse
seal and pry seal out of pump housi ng. Do not
scratch or damage seal bore.
INSTALLATION
(1) Lubri cate l i p of new seal wi th transmi ssi on
fl ui d and i nstal l seal i n pump wi th tool 7549 (Fi g.
82).
(2) Lubri cate converter dri ve hub wi th transmi s-
si on fl ui d.
(3) Al i gn and i nstal l converter n oi l pump.
Fig. 80 Removing/Installing Transmission Throttle
Cable
Fig. 81 Removing/Installing Transmission Throttle
Cable And Bracket
Fig. 82 Installing Oil Pump Seal
TRANSMISSION
DISASSEMBLY
(1) Remove torque converter.
(2) Remove cl amps attachi ng wi re harness and
throttl e cabl e (Fi g. 83) to transmi ssi on.
(3) Remove shi ft l ever from manual val ve shaft at
l eft si de of transmi ssi on.
(4) Remove park/neutral posi ti on swi tch.
(5) Remove speed sensor.
(6) Remove converter housi ng bol ts and remove
housi ng (Fi g. 84) from case.
(7) Remove adapter housi ng, speedometer dri ve
gear, and speed sensor rotor.
(8) Remove transmi ssi on oi l pan, oi l screen and
screen gaskets (Fi g. 85).
(9) Remove val ve body oi l feed tubes (Fi g. 86).
(10) Di sconnect val ve body sol enoi d wi res (Fi g. 87).
(11) Remove harness bracket bol t and remove har-
ness and bracket (Fi g. 88).
Fig. 83 Typical Harness And Cable Clamp
Attachment
Fig. 84 Converter Housing Removal
Fig. 85 Removing Oil Screen
Fig. 86 Valve Body Oil Tube Removal
(12) Remove val ve body bol ts (Fi g. 89).
(13) Di sconnect throttl e cabl e from throttl e cam
(Fi g. 90).
Fig. 87 Solenoid Wire Location
Fig. 88 Removing Bracket And Harness
Fig. 89 Valve Body Bolt Locations
Fig. 90 Disconnecting Throttle Cable
(14) Remove val ve body from case. Then remove
accumul ator spri ngs, check bal l , and spri ng (Fi g. 91).
(15) Remove second brake and cl utch accumul ator
pi stons wi th compressed ai r (Fi g. 92). Appl y ai r pres-
sure through feed port and ease the pi stons and
spri ngs out of the bore. Note and i denti fy the ori gi nal
l ocati on of al l spri ngs.
(16) Remove overdri ve brake accumul ator pi ston
wi th compressed ai r (Fi g. 92). Note and i denti fy the
ori gi nal l ocati on of al l spri ngs.
(17) Remove overdri ve cl utch accumul ator pi ston
wi th compressed ai r (Fi g. 92).
(18) Remove throttl e cabl e.
(19) Remove oi l pump bol ts and remove pump wi th
bri dgetype Pul l er 7536 (Fi g. 93).
(20) Remove race from oi l pump (Fi g. 94).
(21) Remove overdri ve pl anetary gear and cl utch
assembl y (Fi g. 95).
(22) Remove race from overdri ve pl anetary (Fi g.
96).
Fig. 91 Removing Accumulator Springs, Spacers
And Check Ball
Fig. 92 Accumulator Piston Removal
Fig. 93 Oil Pump Removal
Fig. 94 Oil Pump Race Removal
Fig. 95 Removing Overdrive Planetary And Clutch
Assembly
Fig. 96 Fourth Gear Planetary Race Removal
(23) Remove thrust beari ng, race and overdri ve
pl anetary ri ng gear (Fi g. 97).
(24) Measure stroke l ength of overdri ve brake pi s-
ton as fol l ows:
(a) Mount di al i ndi cator on case usi ng Mi l l er
Tool C-3339 and a sui tabl e bol t threaded i nto the
(b) Veri fy that the di al i ndi cator i s mounted sol -
i dl y and square to the di recti on of the pi ston
travel .
(c) Appl y 57114 psi ai r pressure through pi ston
appl y port and note pi ston stroke on di al i ndi cator.
Stroke l ength shoul d be: 1.40 1.70 mm (0.055
0.0699 i n.).
(d) Record the readi ng for use duri ng re-assem-
bl y.
(e) Remove the di al i ndi cator set-up from the
transmi ssi on.
(25) Measure stroke l ength of second coast brake
pi ston rod as fol l ows:
(a) I nstal l a smal l wi re ti e strap around the sec-
ond coast brake pi ston rod ti ght agai nst the trans-
mi ssi on case.
(b) Appl y 57114 psi ai r pressure through pi ston
feed hol e and check stroke l ength wi th Gauge Tool
7552.
(c) Stroke l ength shoul d be 1.5 3.0 mm (0.059
0.118 i n.).
(d) Record the readi ng for use duri ng re-assem-
bl y.
(26) Remove the bol t hol di ng the i nput speed sen-
sor to the transmi ssi on case.
(27) Remove the i nput speed sensor from the
(28) Remove overdri ve brake pack snap ri ng (Fi g.
98).
(29) Remove overdri ve brake pack di scs and
pl ates. I nspect and repl ace as necessary.
(30) Remove overdri ve support l ower race and
upper beari ng and race assembl y (Fi g. 99).
Fig. 97 Removing Bearing, Race And Planetary Ring
Gear
Fig. 98 Removing Overdrive Brake Pack Snap Ring
Fig. 99 Overdrive Support Bearing/Race Removal
(31) Remove overdri ve support snap ri ng wi th
Snap Ri ng Pl i er Tool 7540 (Fi g. 100).
(32) Remove overdri ve support bol ts (Fi g. 101).
(33) Remove overdri ve support (Fi g. 102) wi th
bri dgetype Pul l er 7536.
(34) Remove race from hub of overdri ve support
(Fi g. 103).
(35) Remove second coast brake pi ston snap ri ng
wi th Snap Ri ng Pl i er Tool 7540. Then remove pi ston
cover and pi ston assembl y.
(36) Di sassembl e second coast brake pi ston (Fi g.
104), i f necessary.
Fig. 100 Overdrive Support Snap Ring Removal/
Installation
Fig. 101 Overdrive Support Bolt Removal
Fig. 102 Removing Overdrive Support
Fig. 103 Remove Overdrive Support Race
(37) Remove di rect and forward cl utch assembl y
(Fi g. 105).
(38) Remove thrust beari ng and race from cl utch
hub (Fi g. 106).
(39) Remove second coast brake band Eri ng from
band pi n and remove pi n and brake band (Fi g. 107).
(40) Remove front pl anetary beari ng race and
remove front pl anetary ri ng gear (Fi g. 108).
Fig. 104 Second Coast Brake Piston Components
Fig. 105 Removing Direct And Forward Clutch
Assembly
Fig. 106 Bearing And Race Removal From Clutch
Hub
Fig. 107 Second Coast Brake Band Removal
(41) Remove thrust beari ng and rear race from
ri ng gear (Fi g. 109).
(42) Remove pl anetary thrust race.
(43) Push forward on output shaft to rel i eve the
l oad on the pl anetary snap ri ng.
(44) Remove pl anetary snap ri ng and remove pl an-
etary gear (Fi g. 110).
(45) Remove sun gear, i nput drum, oneway
cl utch, and thrust washer as assembl y (Fi g. 111).
Fig. 108 Front Planetary Ring Gear Removal
Fig. 109 Removing Ring Gear Bearing And Rear
Race
Fig. 110 Removing Planetary Snap Ring And Gear
Fig. 111 Removing Sun Gear, Input Drum And
OneWay Clutch
(46) Measure second brake cl utch pack cl earance
(Fi g. 112). Cl earance shoul d be 0.62 1.98 mm
(0.0244 0.0780 i n.). Record measurement for use
duri ng re-assembl y.
(47) Remove second brake cl utch pack snap ri ng
(Fi g. 113).
(48) Remove second brake cl utch pack (Fi g. 114).
I nspect and repl ace as necessary.
case. Then di sconnect park rod from manual shaft
l ever and remove rod and bracket (Fi g. 115).
(50) Remove park pawl spri ng, pi n and pawl (Fi g.
116).
(51) Measure cl earance of fi rstreverse brake
cl utch pack (Fi g. 117). Cl earance shoul d be: 0.70
1.2 mm (0.028 0.047 i n.). record measurement for
use duri ng re-assembl y.
(52) Remove second brake pi ston sl eeve (Fi g. 118).
(53) Remove second brake snap-ri ng.
(54) Remove rear pl anetary gear, second brake
drum and output shaft as an assembl y (Fi g. 119).
(55) Remove pl anetary and brake drum thrust
beari ng and race assembl y (Fi g. 120).
Fig. 112 Checking Second Brake Clutch Pack
Clearance
Fig. 113 Removing Second Brake Clutch Pack Snap
Ring
Fig. 114 Removing/Measuring Second Brake Clutch
Disc Thickness
(56) Remove second brake drum gasket from case
wi th screwdri ver.
(57) Measure i nsi de di ameter of transmi ssi on case
rear bushi ng wi th bore gauge or i nsi de mi crometer
(Fi g. 121). Maxi mum al l owabl e di ameter i s 38.18 mm
(1.5031 i n.). Replace transmission case if bush-
ing I.D. is greater than specified. Bushing is not
serviceable.
Fig. 115 Removing Park Rod And Bracket
Fig. 116 Removing Park Pawl, Pin And Spring
Fig. 117 Checking FirstReverse Brake Clutch Pack
Clearance
Fig. 118 Removing Second Brake Piston Sleeve
(58) Check fi rst/reverse brake pi ston operati on
wi th compressed ai r (Fi g. 122). Pi ston shoul d move
smoothl y and not bi nd or sti ck. I f pi ston operati on i s
i ncorrect, case or pi ston may requi re repl acement.
Fig. 119 Removing Rear Planetary, Second Brake
Drum And Output Shaft
Fig. 120 Removing/Installing Bearing And Race
Assembly
Fig. 121 Checking Rear Bushing Inside Diameter
Fig. 122 Checking FirstReverse Brake Piston
Operation
(59) Compress pi ston return spri ngs wi th Tool
7539 and remove pi ston snap ri ng (Fi g. 123).
(60) Remove Tool 7539 and remove pi ston return
spri ngs.
(61) Remove No. 2 fi rstreverse brake pi ston wi th
compressed ai r. Appl y ai r through same transmi ssi on
feed hol e used for checki ng pi ston operati on.
(62) Remove reacti on sl eeve wi th Sl eeve Remover
Tool 7542 (Fi g. 124). I nsert tool fl anges under sl eeve
and l i ft tool and sl eeve out of case.
(63) Remove No. 1 fi rst/reverse brake pi ston wi th
Pi ston Pul l er 7543 (Fi g. 125). Sl i p tool under pi ston
and l i ft tool and pi ston out of case.
ASSEMBLY
(1) Duri ng assembl y, l ubri cate components wi th
transmi ssi on fl ui d or petrol eum jel l y as i ndi cated.
(2) Veri fy thrust beari ng and race i nstal l ati on dur-
i ng assembl y. Refer to the Thrust Beari ng Chart (Fi g.
126) for beari ng and race l ocati on and correct posi -
ti oni ng.
(3) I nstal l new seal s onto the No.1 fi rst-reverse
brake pi ston. Lubri cate seal s wi th transmi ssi on fl ui d.
(4) I nstal l the No.1 fi rst-reverse brake pi ston i nto
the transmi ssi on case.
(5) I nstal l new seal onto the fi rst-reverse brake
pi ston reacti on sl eeve. Lubri cate seal s wi th transmi s-
si on fl ui d.
Fig. 123 Removing/Installing Piston Snap Ring
Fig. 124 Removing/Installing Reaction Sleeve
Fig. 125 Removing/Installing FirstReverse Brake
No.1 Piston
(6) I nstal l the fi rst-reverse brake pi ston reacti on
sl eeve i nto the transmi ssi on case.
(7) I nstal l new seal onto the No. 2 fi rst-reverse
brake pi ston. Lubri cate seal s wi th transmi ssi on fl ui d.
(8) I nstal l the No. 2 fi rst-reverse brake pi ston i nto
the transmi ssi on case.
(9) I nstal l the spri ng pl ate i nto the No. 2 fi rst-re-
verse brake pi ston.
(10) I nstal l Spri ng Compressor 7539 onto the fi rst-
reverse brake pi ston.
(11) Compress the fi rst-reverse brake pi ston spri ng
and i nstal l the fi rst-reverse brake pi ston snap-ri ng.
(12) Remove Spri ng Compressor 7539.
(13) I nstal l rear pl anetary gear, second brake
drum and output shaft as outl i ned i n fol l owi ng steps:
(14) Veri fy No. 10 thrust beari ng and race (Fi g.
126). Beari ng and race outer di ameter i s 57.7 mm
(2.272 i n.) and i nsi de di ameter i s 39.2 mm (1.543 i n.).
(15) Coat thrust beari ng and race assembl y wi th
petrol eum jel l y and i nstal l i n case (Fi g. 127). Race
faces down. Beari ng rol l ers face up.
(16) Al i gn teeth of second brake drum and cl utch
pack (Fi g. 128).
(17) Al i gn rear pl anetary-output shaft assembl y
teeth wi th case sl ots and i nstal l assembl y i n case
(Fi g. 129).
(18) I nstal l rear pl anetary snap ri ng wi th snap
ri ng pl i ers. Chamfered si de of snap ri ng faces up and
toward case front (Fi g. 130).
Fig. 126 Thrust Bearing Chart
(19) Check fi rstreverse brake pack cl earance wi th
feel er gauge (Fi g. 131). Cl earance shoul d be 0.70
1.20 mm (0.028 0.047 i n.). I f cl earance i s i ncorrect,
pl anetary assembl y, thrust beari ng or snap ri ng i s
not properl y seated i n case. Remove and rei nstal l
components i f necessary.
(20) I nstal l second brake pi ston sl eeve (Fi g. 132).
Sl eeve l i p faces up and toward case front as shown.
(21) I nstal l second brake drum gasket.
(22) I nstal l park l ock pawl , spri ng and pi n
(Fi g. 133).
(23) I nstal l the manual val ve shi ft assembl y.
(24) Connect park l ock rod to manual val ve shi ft
sector (Fi g. 134).
Fig. 127 Installing Thrust Bearing And No. 10 Race
Fig. 128 Aligning Second Brake Drum And Clutch
Pack Teeth
Fig. 129 Output Shaft/Rear Planetary Assembly
Installation
Fig. 130 Planetary Snap Ring Installation
(25) Posi ti on park l ock rod bracket on case and
ti ghten bracket attachi ng bol ts to 10 Nm (7 ft. l bs.)
torque (Fi g. 135).
(26) Veri fy park l ock operati on. Move shi ft sector
to Park posi ti on. Park pawl shoul d be fi rml y engaged
(l ocked) i n pl anetary ri ng gear (Fi g. 136).
(27) I nstal l No. 1 oneway cl utch (Fi g. 137). Short
fl anged si de of cl utch faces up and toward case front.
(28) I nstal l second brake pack (Fi g. 138). I nstal l
di sc then pl ate. Conti nue i nstal l ati on sequence unti l
fi ve di scs and fi ve pl ates are i nstal l ed.
Fig. 131 Checking FirstReverse Brake Pack
Clearance
Fig. 132 Second Brake Piston Sleeve Installation
Fig. 133 Park Lock Pin, Spring And Pawl Installation
Fig. 134 Park Lock Rod Installation
(29) I nstal l second brake pack retai ner wi th
rounded edge of retai ner faci ng di sc.
(30) I nstal l second brake pack snap ri ng.
(31) Check brake pack cl earance wi th feel er gauge
(Fi g. 139). Cl earance shoul d be 0.062 1.98 mm
(0.024 0.078 i n.). I f brake pack cl earance i s not cor-
rect, brake pack components are not seated. Reas-
sembl e brake pack i f necessary.
(32) I nstal l pl anetary sun gear and i nput drum
(Fi g. 140). Be sure drum thrust washer tabs are
seated i n drum. Use petrol eum jel l y to hol d thrust
washer i n posi ti on i f necessary.
(33) I nstal l front pl anetary gear on sun gear
(Fi g. 141).
(34) Support output shaft wi th wood bl ocks
(Fi g. 142).
Fig. 135 Park Rod Bracket Installation
Fig. 136 Checking Park Pawl Engagement
Fig. 137 Installing No. 1 OneWay Clutch
Fig. 138 Second Brake Pack Installation
Fig. 139 Checking Second Brake Pack Clearance
(35) I nstal l pl anetary snap ri ng on sun gear wi th
snap ri ng pl i er tool 7541 (Fi g. 143).
(36) I nstal l tabbed thrust race on front pl anetary
gear. Washer tabs face down and toward gear. Race
outer di ameter i s 47.8 mm (1.882 i n.). I nsi de di ame-
ter i s 34.3 mm (1.350 i n.).
Fig. 140 Installing Sun Gear And Input Drum
Fig. 141 Installing Front Planetary Gear
Fig. 142 Supporting Output Shaft
Fig. 143 Installing Front Planetary Snap Ring
(37) I nstal l second coast brake band (Fi g. 144).
(38) I nstal l pi n i n second coast brake band. Then
i nstal l retai ni ng ri ng on pi n (Fi g. 145).
(39) I nstal l thrust beari ng and race i n forwarddi -
rect cl utch (Fi g. 146). Coat beari ng/race wi th petro-
l eum jel l y to hol d them i n pl ace.
(40) Veri fy forwarddi rect cl utch thrust beari ng
si ze.
Race outer di ameter i s 48.9 mm (1.925 i n.) and
i nsi de di ameter i s 26.0 mm (1.024 i n.).
Beari ng outer di ameter i s 46.7 mm (1.839 i n.)
and i nsi de di ameter i s 26.0 mm (1.024 i n.).
(41) Coat front pl anetary ri ng gear race wi th
petrol eum jel l y and i nstal l i t i n ri ng gear (Fi g. 147).
(42) Veri fy ri ng gear race si ze. Outer di ameter i s
47.0 mm (1.850 i n.) and i nsi de di ameter i s 26.5 mm
(1.045 i n.).
(43) Al i gn forwarddi rect cl utch di sc spl i nes wi th
screwdri ver (Fi g. 148).
(44) Al i gn and i nstal l front pl anetary ri ng gear i n
forwarddi rect cl utch (Fi g. 149).
(45) Coat beari ng and race wi th petrol eum jel l y
and i nstal l them i n ri ng gear (Fi g. 150). Veri fy bear-
i ng/race si ze.
Fig. 144 Installing Second Coast Brake Band
Fig. 145 Installing Second Coast Brake Band
Retaining Pin
Race outer di ameter i s 53.6 mm (2.110 i n.) and
i nsi de di ameter i s 30.6 mm (1.205 i n.).
(46) I nstal l assembl ed pl anetary gear/forwarddi -
rect cl utch (Fi g. 151).
(47) Check cl earance between sun gear i nput drum
and di rect cl utch drum (Fi g. 152). Cl earance shoul d
be 9.8 11.8 mm (0.386 0.465 i n.). I f cl earance i s
i ncorrect, pl anetary gear/forwarddi rect cl utch
assembl y i s not seated or i s i mproperl y assembl ed.
Remove, and correct i f necessary.
Fig. 146 Installing ForwardDirect Clutch Thrust
Bearing And Race
Fig. 147 Installing Planetary Ring Gear Race
Fig. 148 Aligning ForwardDirect Clutch Splines
Fig. 149 Installing Front Planetary Ring Gear
Fig. 150 Installing Ring Gear Bearing And Race
petrol eum jel l y and i nstal l i t on cl utch shaft. Beari ng
faces up and toward case front as shown. Veri fy bear-
i ng/race si ze. Beari ng and race outer di ameter i s 47.8
mm (1.882 i n.) and i nsi de di ameter i s 33.6 mm (1.301
i n.).
(49) Assembl e second coast brake pi ston compo-
nents (Fi g. 153).
(50) I nstal l assembl ed second coast brake pi ston i n
case. Veri fy that the pi ston rod contacts the second
coast brake band.
(51) I nstal l repl acement seal s on second coast
brake pi ston cover and i nstal l cover i n case.
(52) I nstal l second coast brake pi ston snap ri ng
wi th snap ri ng pl i er tool (Fi g. 154).
(53) Check second coast brake pi ston stroke as fol -
l ows:
(a) I nstal l a smal l wi re ti e strap around the sec-
ond coast brake pi ston rod ti ght agai nst the trans-
mi ssi on case.
(b) Appl y 57114 psi ai r pressure through pi ston
feed hol e and check stroke l ength wi th Gauge Tool
7552.
(c) Stroke l ength shoul d be 1.5 3.0 mm (0.059
0.118 i n.).
(d) I f stroke l ength i s i ncorrect, pi ston, cover or
snap ri ng i s not seated. Reassembl e and check
stroke agai n i f necessary.
(54) Coat thrust race and tabbed washer wi th
petrol eum jel l y and i nstal l them on overdri ve support
(Fi g. 157). Veri fy race si ze. Race outer di ameter i s
50.9 mm (2.004 i n.) and i nsi de di ameter i s 36.2 mm
(1.426 i n.).
Fig. 151 Installing Front Planetary And
ForwardDirect Clutch Assembly
Fig. 152 Checking Input DrumToDirect Clutch
Drum Clearance
Fig. 153 Assembling Second Coast Brake Piston
Fig. 154 Installing Second Coast Brake Piston Snap
Ring
(55) I nstal l overdri ve support i n case. Use two l ong
bol ts to hel p al i gn and gui de support i nto posi ti on
(Fi g. 158).
(56) I nstal l overdri ve support snap ri ng wi th Snap
Ri ng Pl i er Tool 7540 (Fi g. 159). Chamfered si de of
snap ri ng faces up and toward case front. Snap ring
ends must be aligned with case opening with
ring ends approximately 24 mm (0.94 in.) from
center line of case opening.
(57) I nstal l and ti ghten overdri ve support bol ts to
(58) Check output shaft end pl ay wi th di al i ndi ca-
tor (Fi g. 161). End pl ay shoul d be 0.27 0.86 mm
(0.0106 0.0339 i n.).
(59) I f output shaft end pl ay i s i ncorrect, one or
more of i nstal l ed components i s not seated. Reassem-
bl e as necessary and check end pl ay agai n.
(60) I nstal l overdri ve brake cl utch pack (Fi g. 162).
I nstal l thi ckest cl utch pl ate fi rst. Rounded edge of
pl ate faces up. I nstal l fi rst di sc fol l owed by another
pl ate unti l four di scs and three pl ates are i nstal l ed.
Fig. 155 Marking Brake Piston Rod
Fig. 156 Checking Second Coast Brake Piston
Stroke
Fig. 157 Installing Overdrive Support Thrust Race
And Washer
Fig. 158 Installing Overdrive Support
(61) I nstal l stepped ri ng retai ner pl ate wi th fl at
si de faci ng di sc. Then i nstal l brake pack snap ri ng
(Fi g. 163).
(62) Check overdri ve brake pi ston stroke as fol -
l ows:
(a) Mount di al i ndi cator on case usi ng Mi l l er
Tool C-3339 and a sui tabl e bol t threaded i nto the
(b) Veri fy that the di al i ndi cator i s mounted sol -
i dl y and square to the di recti on of the pi ston
travel .
Fig. 159 Installing Overdrive Support Snap Ring
Fig. 160 Installing Overdrive Support Bolts
Fig. 161 Checking Output Shaft End Play
Fig. 162 Installing Overdrive Brake Clutch Pack
Fig. 163 Installing Overdrive Brake Snap Ring
(c) Appl y 57114 psi ai r pressure through pi ston
appl y port and note pi ston stroke on di al i ndi cator.
Stroke l ength shoul d be: 1.40 1.70 mm (0.055
0.0699 i n.).
(d) I f stroke i s i ncorrect, brake pack or pi ston i s
i nstal l ed i ncorrectl y. Check and correct as neces-
sary and measure pi ston stroke agai n.
(e) Remove the di al i ndi cator set-up from the
transmi ssi on.
(63) Coat overdri ve l ower race, thrust beari ng and
upper race wi th petrol eum jel l y and i nstal l them i n
overdri ve support (Fi g. 164). Be sure races and bear-
i ng are assembl ed and i nstal l ed as shown.
(64) Veri fy beari ng/race si zes before proceedi ng.
Beari ng race si zes are:
Outer di ameter of l ower race i s 47.8 mm (1.882
i n.) and i nsi de di ameter i s 34.3 mm (1.350 i n.).
Outer di ameter of beari ng i s 47.7 mm (1.878 i n.)
Outer di ameter of upper race i s 47.8 mm (1.882
i n.) and i nsi de di ameter i s 30.7 mm (1.209 i n.).
(65) I nstal l overdri ve pl anetary ri ng gear i n sup-
port (Fi g. 165).
(66) Coat ri ng gear thrust race and thrust beari ng
assembl y wi th petrol eum jel l y and i nstal l them i n
gear (Fi g. 166).
(67) Veri fy beari ng/race si ze before proceedi ng.
Outer di ameter of ri ng gear racebeari ng i s 47.8
i n.).
(68) Coat tabbed thrust race wi th petrol eum jel l y
and i nstal l i t on pl anetary gear (Fi g. 167). Race outer
di ameter i s 41.8 mm (1.646 i n.) and i nsi de di ameter
i s 27.1 mm (1.067 i n.).
(69) I nstal l assembl ed overdri ve pl anetary gear
and cl utch (Fi g. 168).
petrol eum jel l y and i nstal l i t on cl utch i nput shaft
(Fi g. 169). Beari ng and race outer di ameter i s 50.2
i n.).
(71) Coat thrust beari ng race wi th petrol eum jel l y
and i nstal l i t i n oi l pump (Fi g. 170). Beari ng race
Fig. 164 Installing Overdrive Support Thrust Bearing
And Races
Fig. 165 Installing Overdrive Planetary Ring Gear
Fig. 166 Installing Ring Gear Thrust Bearing And
Race
outer di ameter i s 47.2 mm (1.858 i n.) and i nsi de
di ameter i s 28.1 mm (1.106 i n.).
(72) Lubri cate and i nstal l repl acement Ori ng on
oi l pump body.
(73) I nstal l oi l pump i n case. Al i gn pump and case
bol t hol es and careful l y ease pump i nto pl ace.
CAUTION: Do not use force to seat the pump. The
seal rings on the stator shaft could be damaged if
they bind or stick to the direct clutch drum.
(74) Ti ghten oi l pump bol ts to 22 Nm (16 ft. l bs.)
torque.
(75) Veri fy i nput shaft rotati on. Shaft shoul d
rotate smoothl y and not bi nd.
(76) Lubri cate and i nstal l new Ori ng on trans-
mi ssi on throttl e cabl e adapter and i nstal l cabl e i n
case (Fi g. 171).
(77) Check cl utch and brake operati on. Operate
cl utches and brakes wi th compressed ai r appl i ed
through feed hol es i n case (Fi g. 172). Li sten for
cl utch and brake appl i cati on. I f you do not hear a
cl utch or brake appl y, di sassembl e transmi ssi on and
repai r faul t before proceedi ng. It is necessary to
block the overdrive clutch accumulator feed
hole No. 8 (Fig. 172) in order to check direct
clutch operation.
Fig. 167 Installing Planetary thrust Race
Fig. 168 Installing Overdrive Planetary And Clutch
Assembly
Fig. 169 Installing Input Shaft Thrust Bearing And
Race Assembly
Fig. 170 Installing Oil Pump Thrust Race
(78) Lubri cate and i nstal l new Ori ngs on accumu-
l ator pi stons (Fi g. 173).
(79) Assembl e and i nstal l accumul ator pi stons and
spri ngs (Fi g. 173).
(80) I nstal l new check bal l body and spri ng (Fi g.
174).
(81) Posi ti on val ve body on case (Fi g. 175).
(82) I nstal l detent spri ng (Fi g. 175).
(83) Al i gn manual val ve, detent spri ng and shi ft
sector (Fi g. 175).
(84) Connect transmi ssi on throttl e cabl e to throttl e
val ve cam (Fi g. 176).
Fig. 171 Installing Transmission Throttle Cable
Fig. 172 Clutch And Brake Feed Hole Locations
Fig. 173 Accumulator Piston And Spring Installation
Fig. 174 Installing Check Ball Body And Spring
(85) I nstal l and ti ghten val ve bodytocase bol ts to
(86) Connect val ve body sol enoi d wi res to sol enoi ds
(Fi g. 177).
(87) I nstal l new Ori ng on sol enoi d harness
adapter and secure adapter to case.
(88) I nstal l val ve body oi l tubes (Fi g. 178). Tap
tubes i nto pl ace wi th a pl asti c mal l et. Be sure the
fl anged tube ends and strai ght tube ends are
i nstal l ed as shown.
screen on val ve body. Ti ghten screen bol ts to 10 Nm
(90) I nstal l magnet i n oi l pan. Be sure magnet
does not i nterfere wi th val ve body oi l tubes.
(91) Appl y Threebond Li qui d Gasket TB1281,
P/N 83504038, to seal i ng surface of oi l pan. Seal er
bead shoul d be at l east 3 mm (1/8 i n.) wi de. I nstal l
pan on case and ti ghten pan bol ts to 7 Nm (65 i n.
l bs.) torque.
(92) I nstal l transmi ssi on speed sensor rotor and
key on output shaft (Fi g. 179).
(93) I nstal l spacer and speedometer dri ve gear on
output shaft. Then i nstal l retai ni ng snap ri ng (Fi g.
180).
TB1281, P/N 83504038, to seal i ng surface at rear of
case (Fi g. 181).
Fig. 175 Aligning Manual Valve, Shift Sector And
Detent Spring
Fig. 176 Connecting Transmission Throttle Cable
Fig. 177 Connecting Valve Body Solenoid Wires
Fig. 178 Installing Valve Body Oil Tubes
(95) I nstal l adapter housi ng on transmi ssi on.
Ti ghten adapter bol ts to 34 Nm (25 ft. l bs.) torque.
(96) I nstal l transmi ssi on speed sensor (Fi g. 182).
Ti ghten sensor bol t to 7.4 Nm (65 i n. l bs.) torque
and connect sensor wi re harness connector.
(97) I nstal l converter housi ng (Fi g. 183). Ti ghten
12 mm di ameter housi ng bol ts to 57 Nm (42 ft. l bs.)
torque. Ti ghten 10 mm di ameter housi ng bol ts to 34
(98) I nstal l transmi ssi on shi ft l ever on manual
val ve shaft. Do not i nstal l l ever attachi ng nut at thi s
ti me.
(99) Move transmi ssi on shi ft l ever ful l y rearward.
Then move l ever two detent posi ti ons forward.
(100) Mount park/neutral posi ti on swi tch on man-
ual val ve shaft and ti ghten swi tch adjusti ng bol t just
enough to keep swi tch from movi ng (Fi g. 184).
(101) I nstal l park/neutral posi ti on swi tch tabbed
washer and retai ni ng nut (Fi g. 184). Ti ghten nut to
6.9 Nm (61 i n. l bs.) torque, but do not bend any of
the washer tabs agai nst the nut at thi s ti me.
(102) Al i gn park/neutral posi ti on swi tch standard
l i ne wi th groove or fl at on manual shaft (Fi g. 184).
(103) Ti ghten park/neutral posi ti on swi tch adjust-
i ng bol t to 13 Nm (9 ft. l bs.) torque.
(104) I nstal l transmi ssi on shi ft l ever on manual
val ve shaft. Ti ghten l ever attachi ng nut to 16 Nm
(105) I nstal l retai ni ng cl amp for wi re harness and
throttl e cabl e (Fi g. 185).
Fig. 179 Installing Transmission Speed Sensor
Rotor And Key
Fig. 180 Installing Spacer And Speedometer Drive
Gear
Fig. 181 Applying Sealer To Case Rear Flange
Fig. 182 Installing Transmission Speed Sensor
(106) I nstal l torque converter.
(107) Veri fy that converter i s seated by measuri ng
di stance between converter housi ng fl ange and one of
the converter mounti ng pads (Fi g. 186). Use strai ght-
edge and verni er cal i pers to measure di stance. On
6cyl . transmi ssi ons, di stance shoul d be 16.5 mm
(0.650 i n.).
(108) Secure converter i n transmi ssi on wi th
Ccl amp or metal strappi ng. Do thi s before mounti ng
transmi ssi on on jack or movi ng transmi ssi on under
vehi cl e.
(109) I nstal l l ower hal f of transmi ssi on fi l l tube
(i nstal l upper hal f after transmi ssi on i s i n vehi cl e).
CAUTION: The transmission cooler and lines must
be reverse flushed if overhaul corrected a malfunc-
tion that generated sludge, metal particles, or
clutch friction material. The torque converter should
also be replaced if contaminated by the same mal-
function. Debris and residue not flushed from the
cooler and lines will flow back into the transmission
and converter. The result will be a repeat failure and
shop comeback.
Fig. 183 Installing Converter Housing
Fig. 184 Park/Neutral Position Switch Installation/
Adjustment
Fig. 185 Installing Cable/Harness Clamps
Fig. 186 Checking Converter Installation
OIL PUMP
DISASSEMBLY
(1) Remove pump body Ori ng (Fi g. 187).
(2) Remove pump seal .
(3) Remove pump seal ri ngs (Fi g. 187).
(4) Remove bol ts attachi ng stator shaft to pump
body and separate components.
(5) Remove dri ve gear and dri ven gear from pump
body (Fi g. 187).
ASSEMBLY
(1) Measure i nsi de di ameter of pump body bushi ng
wi th bore gauge or i nsi de mi crometer (Fi g. 188).
Di ameter shoul d be maxi mum of 38.19 mm (1.5035
i n.). Repl ace pump body i f bushi ng I .D. i s greater
than speci fi ed.
(2) Measure i nsi de di ameter of stator shaft bush-
i ng (Fi g. 188). Take measurements at front and rear
of bushi ng. Di ameter shoul d be maxi mum of 21.58
mm (0.08496 i n.) at front and 27.08 mm (1.0661 i n.)
at rear. Repl ace stator shaft i f bushi ng di ameter i s
greater than speci fi ed.
(3) Measure oi l pump cl earances (Fi g. 189).
Cl earance between pump dri ven gear and pump
body shoul d be maxi mum of 0.3 mm (0.012 i n).
Cl earance between ti ps of pump gear teeth
shoul d be maxi mum of 0.3 mm (0.012 i n).
Cl earance between rear surface of pump housi ng
and pump gears shoul d be maxi mum of 0.1 mm
(0.004 i n.).
(4) Repl ace pump body and gears i f any cl earance
i s greater than speci fi ed.
(5) I nstal l new seal wi th Seal I nstal l er 7549 (Fi g.
190).
(6) Lubri cate and i nstal l gears i n pump body.
(7) Assembl e stator shaft and pump body. Ti ghten
shafttobody bol ts to 10 Nm (7 ft. l bs.) torque.
Fig. 187 Oil Pump Components
Fig. 188 Checking Pump/Stator Shaft Bushings
(8) I nstal l new Ori ng on pump body and new seal
ri ngs on stator shaft.
(9) I nstal l pump i n torque converter and check
pump gear rotati on (Fi g. 191). Gears must rotate
smoothl y when turned cl ockwi se and countercl ock-
wi se.
(10) Lubri cate pump Ori ng and seal ri ngs wi th
petrol eum jel l y.
Fig. 189 Checking Pump Gear Clearances
Fig. 190 Installing Pump Seal
Fig. 191 Checking Pump Gear Rotation
OVERDRIVE PLANETARY GEAR AND CLUTCH
DISASSEMBLY
(1) Check operati on of oneway cl utch i n cl utch
drum (Fi g. 192). Hol d drum and turn pl anetary shaft
cl ockwi se and countercl ockwi se. Shaft shoul d turn
cl ockwi se freel y but l ock when turned countercl ock-
wi se. Repl ace oneway cl utch i f necessary.
(2) Remove overdri ve cl utch from pl anetary gear
(Fi g. 193).
(3) Measure stroke l ength of overdri ve cl utch pi s-
ton as fol l ows:
(a) Mount oi l pump on torque converter. Then
mount cl utch on oi l pump (Fi g. 194).
(b) I nstal l a sui tabl e threaded bol t/rod i nto oi l
pump for use i n mounti ng Mi l l er Tool C-3339 di al
i ndi cator components securel y.
(c) Mount di al i ndi cator on the bol t/rod and posi -
ti on the di al i ndi cator squarel y on the cl utch pi s-
ton.
(d) Appl y compressed ai r through cl utch feed
hol e i n oi l pump and note pi ston stroke l ength.
Stroke l ength shoul d be 1.85 2.15 mm (0.0728
0.0846 i n.).
Overdrive Planetary Gear And Clutch Components
(4) Remove thrust beari ng and race assembl y from
cl utch drum (Fi g. 195).
(5) Remove cl utch pack snap ri ng and remove the
cl utch pack (Fi g. 196).
(6) Measure overdri ve cl utch di sc thi ckness. Mi ni -
mum al l owabl e thi ckness i s 1.84 mm (0.0724 i n.).
(7) I f the cl utch pack stroke l ength i s out of speci -
fi cati on or any cl utch di sc fai l s to meet the mi ni mum
thi ckness, new di scs wi l l need to be i nstal l ed duri ng
assembl y.
Fig. 192 Checking OneWay Clutch
Fig. 193 Removing Overdrive Clutch From Gear
Fig. 194 Assembling Converter, Pump And Clutch
For Test
Fig. 195 Removing Clutch Drum Bearing And Race
(8) Compress pi ston return spri ng wi th Tool 7538
(Fi g. 197). Remove snap ri ng and remove compressor
tool .
(9) Remove the pi ston return spri ngs.
(10) Mount oi l pump on converter. Then mount
cl utch on oi l pump (Fi g. 198).
(11) Hol d cl utch pi ston by hand and appl y com-
pressed ai r through oi l pump feed hol e to ease pi ston
out (Fi g. 198). Appl y onl y enough ai r pressure to
remove pi ston.
(12) Measure free l ength of pi ston return spri ngs
wi th spri ngs i n retai ner (Fi g. 199). Length shoul d be
16.8 mm (0.661 i n.). Repl ace spri ng and retai ner
assembl y i f necessary.
(13) Check cl utch pi ston check bal l (Fi g. 200).
Shake pi ston to see i f bal l moves freel y. Then check
bal l seal i ng by appl yi ng l ow pressure compressed ai r
to bal l i nl et as shown. Ai r shoul d not l eak past check
bal l .
Fig. 196 Removing Clutch Pack Snap Ring
Fig. 197 Removing Clutch Piston Snap Ring
Fig. 198 Removing Overdrive Clutch Piston
Fig. 199 Checking Piston Return Spring Length
(14) Check i nsi de di ameter of cl utch drum bush-
i ngs wi th bore gauge or i nsi de mi crometer (Fi g. 201).
Maxi mum i nsi de di ameter i s 27.11 mm (1.0673 i n.).
Repl ace drum i f bushi ng i nsi de di ameter i s greater
than speci fi ed.
(15) Remove beari ng and race from ri ng gear (Fi g.
202).
(16) Remove snap ri ng from ri ng gear and remove
ri ng gear hub (Fi g. 203).
Fig. 200 Testing Clutch Piston Check Ball
Fig. 201 Checking Clutch Drum Bushings
Fig. 202 Removing Ring Gear Bearing And Race
Fig. 203 Removing Ring Gear Hub
(17) Remove race from pl anetary gear (Fi g. 204).
(18) Remove snap ri ng and remove retai ni ng pl ate
(Fi g. 205).
(19) Remove oneway cl utch and outer race as
assembl y. Then separate race from cl utch (Fi g. 206).
(20) Remove thrust washer (Fi g. 207).
(21) Check i nsi de di ameter of pl anetary gear bush-
i ng (Fi g. 208). Maxi mum i nsi de di ameter i s 11.27
mm (0.4437 i n.). Repl ace pl anetary gear i f bushi ng
i nsi de di ameter i s greater then speci fi ed.
ASSEMBLY
(1) I nstal l thrust washer i n pl anetary gear (Fi g.
209). Grooved side of washer faces up and
toward front.
(2) I nstal l cl utch race i nto pl anetary gear.
(3) I nstal l oneway cl utch i nto the outer race (Fi g.
210). Be sure fl anged si de of cl utch i s faci ng upward.
(4) I nstal l cl utch retai ni ng pl ate and snap ri ng i n
pl anetary gear.
(5) Coat pl anetary race wi th petrol eum jel l y and
i nstal l i t on pl anetary gear. Outsi de di ameter of race
Fig. 204 Remove Planetary Gear Race
Fig. 205 Removing Snap Ring And Retaining Plate
Fig. 206 Removing OneWay Clutch
Fig. 207 Removing Planetary Thrust Washer
shoul d be 41.8 mm (1.646 i n.); i nsi de di ameter i s 27.1
mm (1.067 i n.).
(6) I nstal l hub i n pl anetary ri ng gear and i nstal l
snap ri ng.
(7) Coat race and beari ng wi th petrol eum jel l y and
i nstal l i n pl anetary ri ng gear (Fi g. 211).
(8) Veri fy beari ng/race si ze. Outsi de di ameter of
race i s 47.8 mm (1.882 i n.) and i nsi de di ameter i s
24.2 mm (0.953 i n.). Outsi de di ameter of beari ng i s
46.8 mm (1.843 i n.) and i nsi de di ameter i s 26 mm
(1.024 i n.).
(9) Lubri cate new cl utch pi ston Ori ngs wi th
Mopar Door Ease, or RuGl yde. Then i nstal l ri ngs
on cl utch pi ston and i nstal l pi ston i n cl utch drum.
(10) I nstal l pi ston return spri ngs i n cl utch pi ston
(Fi g. 212).
(11) I nstal l pi ston snap ri ng. Compress pi ston
return spri ngs wi th Tool 7538 and shop press (Fi g.
213).
(12) I nstal l overdri ve cl utch pack i n drum. I nstal l
steel pl ate fi rst, then a di sc (Fi g. 214). Conti nue
i nstal l ati on sequence unti l requi red number of di scs
and pl ates have been i nstal l ed.
Fig. 208 Checking Planetary Bushing
Fig. 209 Install Planetary Thrust Washer
Fig. 210 Assembling OneWay Clutch And Race
Fig. 211 Install Ring Gear Bearing And Race
(13) I nstal l cl utch pack retai ner wi th fl at si de fac-
i ng downward. Then i nstal l retai ner snap ri ng (Fi g.
215). Compress spri ngs wi th sui tabl e tool .
(14) I nstal l cl utch drum beari ng and race assembl y
(Fi g. 216). Be sure beari ng rol l ers face upward as
shown. Outsi de di ameter of assembl ed beari ng and
race i s 50.2 mm (1.976 i n.). I nsi de di ameter i s 28.9
mm (1.138 i n.).
(15) I nstal l cl utch on pl anetary gear.
(16) Veri fy oneway cl utch operati on. Hol d drum
and turn pl anetary shaft cl ockwi se and countercl ock-
wi se. Shaft shoul d turn cl ockwi se freel y but l ock
when turned countercl ockwi se.
OVERDRIVE SUPPORT
DISASSEMBLY
(1) Check brake pi ston operati on. Mount support
on cl utch (Fi g. 217).
Fig. 212 Installing Piston Return Springs
Fig. 213 Installing Clutch Piston Snap Ring
Fig. 214 Installing Overdrive Clutch Discs And
Plates
Fig. 215 Installing Retainer And Snap Ring
(2) Appl y compressed ai r through support feed
hol e and observe brake pi ston movement (Fi g. 217).
Pi ston shoul d move smoothl y and not bi nd or sti ck. I f
operati on i s i ncorrect, repl ace pi ston and support.
(3) Remove thrust beari ng front race, thrust bear-
i ng and rear race (Fi g. 218).
(4) Turn overdri ve support over and remove bear-
i ng race and cl utch drum thrust washer (Fi g. 219).
(5) Compress pi ston return spri ng wi th Spri ng
Compressor 7537 and remove pi ston snap ri ng (Fi g.
220).
Fig. 216 Installing Clutch Drum Bearing And Race
Assembly
Fig. 217 Checking Brake Piston Movement
Fig. 218 Removing Support Thrust Bearing And
Races
Fig. 219 Removing Clutch Drum Thrust Washer And
Race
(6) Mount support i n di rect cl utch and remove
brake pi ston wi th compressed ai r. Appl y ai r to same
feed hol e used when checki ng pi ston operati on.
(7) Remove and di scard support Ori ngs (Fi g. 221).
(8) Remove support seal ri ngs (Fi g. 222).
wi th spri ngs mounted i n retai ner (Fi g. 223). Length
shoul d be 17.23 mm (0.678 i n.).
(10) Cl ean support components and dry them wi th
compressed ai r.
(11) I nspect overdri ve support and brake pi ston.
Repl ace support and pi ston i f ei ther part i s worn or
damaged.
ASSEMBLY
(1) Lubri cate new support seal ri ngs. Then com-
press ri ngs and i nstal l them on support (Fi g. 224).
(2) Lubri cate and i nstal l new Ori ngs on brake
pi ston. Then careful l y seat pi ston i n support.
(3) I nstal l return spri ngs on brake pi ston.
(4) Compress return spri ngs wi th Spri ng Compres-
sor 7537 (Fi g. 220) and i nstal l pi ston snap ri ng.
(5) I nstal l support beari ng race and cl utch drum
thrust washer (Fi g. 219).
Fig. 220 Removing/Installing Piston Snap Ring
Fig. 221 Overdrive Support Components
Fig. 222 Removing Support Seal Rings
(6) I nstal l thrust beari ng and front and rear bear-
i ng races. Thrust beari ng rol l ers shoul d face upward
as shown (Fi g. 224).
(7) Veri fy thrust beari ng/race si zes (Fi g. 225).
Front race outer di ameter i s 47.8 mm (1.882 i n.)
Rear race outer di ameter i s 47.8 mm (1.882 i n.)
(8) Veri fy brake pi ston operati on. Use same proce-
dure descri bed at begi nni ng of di sassembl y. Pi ston
shoul d operate smoothl y and not bi nd or sti ck.
DIRECT CLUTCH
DISASSEMBLY
(1) Remove di rect cl utch from forward cl utch (Fi g.
226).
(2) Remove cl utch drum thrust washer (Fi g. 227).
Fig. 224 Installing Support Seal Rings
Fig. 225 Installing Support Thrust Bearing And
Races
Fig. 226 Separate Direct Clutch From Forward
Clutch
(3) Check cl utch pi ston stroke l ength as outl i ned
i n fol l owi ng steps.
(4) Mount di rect cl utch on overdri ve support
assembl y (Fi g. 228).
(5) Mount di al i ndi cator on cl utch and posi ti on
i ndi cator pl unger on cl utch pi ston (Fi g. 229).
(6) Appl y 57114 psi ai r pressure through feed
hol e i n overdri ve support and note pi ston stroke
l ength (Fi g. 229). Check stroke at l east twi ce.
(7) Pi ston stroke l ength shoul d be 1.37 mm 1.67
mm (0.054 0.065 i n.). I f stroke l ength i s i ncorrect,
ei ther the cl utch pack retai ner or cl utch di scs wi l l
have to be repl aced.
(8) Remove cl utch pack snap ri ng and remove
retai ner and cl utch pack from drum (Fi g. 230).
(9) Compress cl utch pi ston return spri ngs wi th tool
7538 and remove cl utch pi ston snap ri ng (Fi g. 231).
(10) Remove compressor tool and return spri ng.
(11) Remove cl utch pi ston. Remount cl utch on
overdri ve support (Fi g. 232). Appl y compressed ai r
Fig. 227 Removing Clutch Drum Thrust Washer
Fig. 228 Mount Direct Clutch On Overdrive Support
Fig. 229 Checking Direct Clutch Piston Stroke
Length
Fig. 230 Removing Clutch Pack Snap Ring
through pi ston feed hol e i n support to remove pi ston.
Use onl y enough ai r to ease pi ston out.
(12) Remove and di scard cl utch pi ston Ori ngs.
(13) Measure cl utch di sc thi ckness. Mi ni mum
al l owabl e thi ckness i s 1.84 mm (0.0724 i n). Repl ace
cl utch pack i f any di sc i s bel ow mi ni mum thi ckness.
wi th spri ngs i n retai ner (Fi g. 233). Length shoul d be
21.32 mm (0.839 i n.). Repl ace return spri ngs i f not
wi thi n speci fi cati on.
(15) Check cl utch pi ston check bal l (Fi g. 234).
Shake pi ston to see i f bal l moves freel y. Then check
bal l seati ng by appl yi ng l ow pressure compressed ai r
to bal l i nl et as shown. Ai r shoul d not l eak past check
bal l .
(16) Measure i nsi de di ameter of cl utch drum bush-
i ng. I nsi de di ameter shoul d be no more than 53.97
mm (2.1248 i n.). Repl ace drum i f bushi ng i nsi de
di ameter i s greater than speci fi ed.
ASSEMBLY
(1) Lubri cate and i nstal l repl acement Ori ngs on
cl utch pi ston (Fi g. 235).
Fig. 231 Removing Piston Return Spring
Fig. 232 Removing Direct Clutch Piston
Fig. 234 Testing Piston Check Ball Seating
(2) I nstal l cl utch pi ston i n drum and i nstal l return
spri ngs on pi ston.
(3) Compress pi ston return spri ngs wi th Tool 7538
and i nstal l snap ri ng (Fi g. 231). Be sure snap ri ng
end gap i s not al i gned wi th spri ng retai ner tab.
(4) I nstal l cl utch di scs and pl ates (Fi g. 236).
I nstal l pl ate then di sc unti l al l pl ates and di scs are
i nstal l ed. Four pl ates and di scs are requi red.
Fig. 235 Direct Clutch Components
Fig. 236 Installing Direct Clutch Discs And Plates
(5) I nstal l cl utch pack retai ner i n drum (Fi g. 237).
(6) I nstal l cl utch pack snap ri ng (Fi g. 237).
(7) Check snap ri ng posi ti on. I f necessary, shi ft
snap ri ng unti l end gap i s not al i gned wi th any
notches i n cl utch drum (Fi g. 238).
(8) Lubri cate cl utch drum thrust washer wi th
petrol eum jel l y and i nstal l i t i n drum (Fi g. 228).
(9) Mount di rect cl utch assembl y on forward cl utch
assembl y and check assembl ed hei ght (Fi g. 239).
Hei ght shoul d be 70.3 to 71.5 mm (2.767 to 2.815
i n.).
(10) I f assembl ed hei ght i s i ncorrect, cl utches are
not seated.
FORWARD CLUTCH
DISASSEMBLY
(1) Check cl utch pi ston stroke as outl i ned i n fol -
l owi ng steps.
(2) Posi ti on overdri ve support on wood bl ocks and
mount forward cl utch drum on support (Fi g. 241).
(3) Remove beari ng and race from forward cl utch
drum (Fi g. 241).
(4) I nstal l a sui tabl e threaded bol t/rod i nto the
si de of the overdri ve support.
(5) Mount Mi l l er Tool C-3339 di al i ndi cator compo-
nents onto the threaded rod as necessary.
(6) Posi ti on di al i ndi cator pl unger squarel y agai nst
cl utch pi ston.
(7) Appl y compressed ai r through ri ght si de feed
hol e i n support and note pi ston stroke l ength on di al
i ndi cator.
(8) Stroke l ength shoul d be 3.55 3.73 mm (0.1348
0.1469 i n.).
(9) Repl ace cl utch di scs i f stroke l ength i s i ncor-
rect.
(10) Remove cl utch pack snap ri ng and remove
retai ner and cl utch pack (Fi g. 242).
(11) Remove cl utch pack cushi on pl ate (Fi g. 243).
(12) Compress cl utch spri ngs wi th Tool 7538 and
remove pi ston snap ri ng.
(13) Remove spri ng compressor tool and pi ston
return spri ngs.
(14) Remount forward cl utch drum on overdri ve
support (Fi g. 244).
Fig. 237 Install Clutch Pack Retainer
Fig. 238 Adjusting Clutch Pack Snap Ring Position
Fig. 239 Checking Direct Clutch Assembled Height
(15) Appl y compressed ai r through feed hol e i n
support to remove pi ston (Fi g. 244). Use onl y enough
ai r pressure to ease pi ston out of drum.
(16) Remove and di scard cl utch pi ston Ori ngs
(Fi g. 245).
(17) Remove cl utch drum Ori ng from rear hub of
drum.
(18) Remove three seal ri ngs from cl utch drum
shaft (Fi g. 246).
(19) Remove thrust beari ng and race assembl y
from cl utch drum (Fi g. 247).
(20) Measure cl utch di sc thi ckness (Fi g. 248). Mi n-
i mum al l owabl e thi ckness i s 1.51 mm (0.0595 i n.).
Repl ace cl utch pack i f any di sc fal l s bel ow speci fi ed
mi ni mum thi ckness.
shoul d be 19.47 mm (0.767 i n.). Repl ace spri ngs and
retai ner i f l ength i s i ncorrect.
(22) I nspect cl utch pi ston check bal l (Fi g. 250).
Bal l shoul d move freel y wi thi n pi ston. Check bal l
seati ng by appl yi ng l ow pressure compressed ai r to
Fig. 240 Forward Clutch Components
bal l feed hol e. Bal l shoul d seat fi rml y and not l eak
ai r.
(23) Measure i nsi de di ameter of bushi ng i n cl utch
drum hub. Maxi mum al l owabl e di ameter i s 24.08
mm (0.9480 i n.). Repl ace cl utch drum i f bushi ng
i nsi de di ameter i s greater than speci fi ed.
ASSEMBLY
(1) Lubri cate beari ng and race assembl y wi th
petrol eum jel l y and i nstal l i t i n cl utch drum (Fi g.
251). Race si de of assembl y faces downward and
toward drum. Beari ng rol l ers face up (Fi g. 251)
(2) Coat new cl utch drum shaft seal ri ngs wi th
petrol eum jel l y. Before i nstal l i ng drum shaft seal
ri ngs, squeeze each ri ng so ri ng ends overl ap (Fi g.
252). Thi s ti ghtens ri ng maki ng cl utch i nstal l ati on
easi er.
(3) I nstal l seal ri ngs on shaft. Keep ri ngs cl osed as
ti ghtl y as possi bl e duri ng i nstal l ati on. Avoi d over-
spreadi ng them.
(4) Mount cl utch drum on overdri ve support.
(5) Lubri cate and i nstal l new Ori ng on cl utch
drum hub (Fi g. 245).
Fig. 241 Positioning Drum And Support On Wood
Blocks
Fig. 242 Removing Retainer And Clutch Pack
Fig. 243 Removing Cushion Plate
Fig. 244 Removing Forward Clutch Piston
(6) Lubri cate new cl utch pi ston Ori ngs wi th
Mopar Door Ease, or RuGl yde. I nstal l ri ngs on
cl utch pi ston and i nstal l pi ston i n drum.
(7) I nstal l pi ston return spri ngs.
(8) Compress pi ston return spri ngs wi th Tool 7538
and shop press and i nstal l pi ston snap ri ng. Be sure
snap ri ng end gap i s not al i gned wi th any notches i n
drum.
(9) I nstal l cushi on pl ate i n drum. Concave si de of
pl ate faces downward (Fi g. 243).
(10) I nstal l cl utch di scs, pl ates and retai ner (Fi g.
253). I nstal l tabbed pl ate fol l owed by di sc unti l
requi red number of pl ates and di scs are i nstal l ed.
Use si x pl ates and di scs.
(11) I nstal l cl utch pack snap ri ng.
(12) Recheck cl utch pi ston stroke l ength usi ng
same method outl i ned at begi nni ng of di sassembl y
procedure. I f stroke l ength i s not wi thi n speci fi ed
l i mi ts, repl ace cl utch di scs.
(13) Lubri cate race and beari ng wi th petrol eum
jel l y and i nstal l them i n cl utch drum (Fi g. 254). Be
Fig. 245 Removing/Installing Clutch Drum ORing
Fig. 246 Removing Clutch Drum Seal Rings
Fig. 247 Removing Clutch Drum Thrust Bearing
Assembly
Fig. 248 Measuring Clutch Disc Thickness
sure beari ng rol l ers face up and race l i p seats i n
drum as shown.
(14) Veri fy beari ng and race si ze.
Outer di ameter of beari ng i s 46.7 mm (1.839 i n).
Outer di ameter of race i s 48.9 mm (1.925 i n.).
I nner di ameter of beari ng and race i s 26.0 mm
(1.024 i n.).
(15) Mount forward cl utch on di rect cl utch and
check assembl ed hei ght (Fi g. 255). Hei ght shoul d be
70.3 71.5 mm (2.767 2.815 i n.).
Fig. 249 Checking Return Spring Length
Fig. 250 Testing Piston Check Ball
Fig. 251 Installing Thrust Bearing And Race
Fig. 252 Installing Clutch Drum Shaft Seal Rings
FRONT PLANETARY GEAR
DISASSEMBLY
(1) Remove ri ng gear from pl anetary gear (Fi g.
256).
(2) Remove front beari ng and the two races from
(3) Remove tabbed thrust race from pl anetary gear
(Fi g. 256).
(4) Remove snap ri ng attachi ng pl anetary gear to
shaft and remove gear.
(5) Remove rear beari ng and race from pl anetary
gear.
(6) Measure i nsi de di ameter of ri ng gear bushi ng.
Maxi mum al l owabl e di ameter i s 24.08 mm (0.9480
i n.). Repl ace ri ng gear i f bushi ng i nsi de di ameter i s
(7) Check condi ti on of pl anetary gear. Repl ace gear
i f teeth are worn, pi ns are l oose, or carri er i s cracked,
di storted, or worn.
Fig. 253 Installing Forward Clutch Discs And Plates
Fig. 254 Installing Thrust Bearing And Race
Fig. 255 Checking Forward Clutch Assembled
Height
ASSEMBLY
(1) Lubri cate pl anetary and ri ng gear beari ngs and
races wi th petrol eum jel l y.
(2) I denti fy pl anetary beari ngs and races before
i nstal l ati on. (Fi g. 256). Beari ngs and races can be
i denti fi ed by fol l owi ng di mensi ons:
Outer di ameter of rear beari ng i s 47.7 mm
(1.878 i n.). I nner di ameter i s 35.5 mm (1.398 i n.).
Outer di ameter of rear race 47.6 mm (1.874 i n.).
I nner di ameter i s 33.7 mm (1.327 i n.).
Outer di ameter of front race i s 53.6 mm (2.110
i n.). I nner di ameter i s 30.5 mm (1.201 i n.).
Outer di ameter of front beari ng i s 47.7 mm
(1.878 i n.). I nner di ameter i s 32.6 (1.283 i n.).
Outer di ameter of forward race i s 47.0 mm
(1.850 i n.). I nner di ameter i s 26.5 mm 1.043 i n.).
(3) I nstal l rear race and beari ng i n gear (Fi g. 257).
(4) Turn pl anetary over and i nstal l thrust race
(Fi g. 258).
(5) I nstal l front race and beari ng and forward race
i n ri ng gear (Fi g. 259).
Fig. 256 Front Planetary Gear Components
Fig. 257 Front Planetary Rear Bearing and Race
Installation
SUN GEAR AND NO. 1 ONEWAY CLUTCH
Fig. 259 Front Planetary Front Bearing And Races
Installation
Fig. 258 Front Planetary Thrust Race Installation
Sun Gear And OneWay Clutch Components
DISASSEMBLY
(1) Hol d sun gear and turn second brake hub
cl ockwi se and countercl ockwi se (Fi g. 260). Hub
shoul d rotate freel y cl ockwi se but l ock when turned
countercl ockwi se. Repl ace oneway cl utch and hub i f
they do not operate properl y.
(2) Remove oneway cl utch/second brake hub
assembl y from drum (Fi g. 261).
(3) Remove thrust washer from drum (Fi g. 262).
(4) Remove two seal ri ngs from sun gear (Fi g.
263).
(5) Support sun gear on wood bl ock (Fi g. 264).
Then remove fi rst sun gear snap ri ng and separate
drum from gear.
(6) Remove remai ni ng snap ri ng from sun gear
(Fi g. 265).
(7) Measure i nsi de di ameter of sun gear bushi ngs
wi th bore gauge or i nsi de mi crometer (Fi g. 266).
Maxi mum al l owabl e di ameter i s 27.08 mm (1.0661
i n.). Repl ace sun gear i f bushi ng i nsi de di ameter i s
Fig. 260 Checking OneWay Clutch Operation
Fig. 261 Removing/Installing Brake Hub And Clutch
Assembly
Fig. 262 Removing/Installing Thrust Washer
Fig. 263 Removing/Installing Sun Gear Seal Rings
ASSEMBLY
(1) I nstal l fi rst snap ri ng on sun gear.
(2) I nstal l sun gear i n drum and i nstal l remai ni ng
snap ri ng.
(3) Coat repl acement seal ri ngs wi th petrol eum
jel l y and i nstal l them on sun gear. Be sure seal
ring ends are interlocked.
(4) I nstal l thrust washer. Be sure washer tabs are
seated i n drum sl ots.
(5) I nstal l oneway cl utch/second brake hub
assembl y on sun gear. Deep si de of hub fl ange faces
upward (Fi g. 267).
(6) Check oneway cl utch operati on agai n (Fi g.
260). Hol d sun gear and turn second brake hub cl ock-
wi se and countercl ockwi se. Hub shoul d turn cl ock-
wi se freel y, but l ock when turned countercl ockwi se.
SECOND BRAKE
DISASSEMBLY
(1) Remove second brake drum from output shaft
(Fi g. 268).
(2) Remove thrust washer from second brake drum
(Fi g. 269).
(3) Compress pi ston return spri ngs wi th shop
press and tool 7538. Then remove pi ston snap ri ng
(Fi g. 270).
(4) Remove compressor tool and remove spri ng
retai ner and return spri ngs.
Fig. 264 Removing/Installing Sun Gear
Fig. 265 Removing/Installing Second Snap Ring
Fig. 266 Checking Sun Gear Bushings
Fig. 267 Installing Clutch And Hub Assembly On
Sun Gear
(5) Remove second brake pi ston and sl eeve from
drum wi th compressed ai r (Fi g. 271). Use onl y
enough ai r pressure to ease pi ston out of drum.
(6) Remove and di scard brake pi ston Ori ngs.
shoul d be approxi matel y 16.05 mm (0.632 i n.).
Repl ace return spri ngs i f l ength i s l ess than speci -
fi ed.
Second Brake Components
Fig. 268 Removing/Installing Second Brake
Assembly
Fig. 269 Removing/Installing Second Brake Drum
Thrust Washer
ASSEMBLY
(1) Lubri cate and i nstal l new Ori ngs on brake
pi ston. Then i nstal l brake pi ston i n drum.
(2) I nstal l return spri ngs and retai ner on brake
pi ston.
(3) Compress return spri ngs wi th shop press and
Compressor Tool 7538. I nstal l pi ston snap ri ng and
remove brake assembl y from press.
(4) Check brake pi ston operati on wi th l ow pres-
sure compressed ai r (Fi g. 273). Appl y ai r pressure
through feed hol e i n drum. Pi ston shoul d move
smoothl y when appl yi ngrel easi ng ai r pressure.
Fig. 270 Removing/Installing Second Brake Piston
Snap Ring
Fig. 271 Removing/Installing Piston And Sleeve
Fig. 272 Measuring Second Brake Piston Return
Springs
Fig. 273 Checking Second Brake Piston Operation
(5) Coat thrust washer wi th petrol eum jel l y and
i nstal l i t i n drum. Be sure washer notches are
al i gned wi th tabs on spri ng retai ner (Fi g. 274).
Fig. 274 Installing Second Brake Thrust Washer
PLANETARY/BRAKE PACK/OUTPUT SHAFT
DISASSEMBLY
(1) Remove output shaft from gear assembl y
(Fi g. 275).
(2) Remove and di scard shaft seal ri ng (Fi g. 276).
(3) Remove brake pack from pl anetary gear
(Fi g. 277).
(4) Remove pl anetary gear from ri ng gear
(Fi g. 278).
Rear Planetary, Brake Pack, Output Shaft Components
Fig. 275 Removing/Installing Output Shaft
(5) Check No. 2 oneway cl utch (Fi g. 279). Hol d
pl anetary gear and turn cl utch i nner race i n both
di recti ons. Race shoul d turn freel y countercl ockwi se,
but l ock when turned cl ockwi se. Repl ace oneway
cl utch i f necessary.
(6) Remove cl utch i nner race from pl anetary gear
(Fi g. 280).
(7) Remove cl utch snap ri ng and remove No. 2
oneway cl utch top end cap from pl anetary.
(8) Remove No. 2 oneway cl utch from pl anetary
(Fi g. 281).
Fig. 276 Removing/Installing Shaft Seal Ring
Fig. 277 Removing/Installing FirstReverse Brake
Pack
Fig. 278 Removing/Installing Rear Planetary
Fig. 279 Checking No. 2 OneWay Clutch Operation
(9) Remove No. 2 oneway cl utch bottom end cap
from pl anetary.
(10) Remove front and rear thrust washers from
pl anetary gear (Fi g. 282).
(11) Remove thrust beari ng and washers from ri ng
gear (Fi g. 283).
(12) Remove ri ng gear snap ri ng and remove ri ng
gear hub (Fi g. 284).
(13) I nspect and repl ace any worn or damaged
pl anetary gearcomponents.
Fig. 280 Removing/Installing Clutch Inner Race
Fig. 281 Removing/Installing OneWay Clutch
ASSEMBLY
(1) Measure thi ckness of each brake pack di sc.
Mi ni mum thi ckness i s 1.51 mm (0.0594 i n.). Repl ace
al l di scs i f any di sc i s thi nner than speci fi ed.
(2) I nstal l hub and snap ri ng i n ri ng gear (Fi g.
284)
(3) I denti fy ri ng gear thrust beari ng and races by
fol l owi ng di mensi ons (Fi g. 283):
Outer di ameter of bottom race i s 44.8 mm (1.764
i n.) and i nner di ameter i s 27.6 mm (1.087 i n.).
and i nner di ameter i s 30.1 mm (1.185 i n.).
Outer di ameter of upper race i s 44.8 mm (1.764
i n.) and i nner di ameter i s 28.8 mm (1.134 i n.).
(4) Lubri cate ri ng gear thrust beari ng and races
wi th petrol eum jel l y and i nstal l them i n ri ng gear
(Fi g. 283).
(5) Coat pl anetary thrust washers wi th petrol eum
jel l y and i nstal l them i n gear (Fi g. 282).
(6) I nstal l No. 2 oneway cl utch bottom end cap
i nto the pl anetary gear.
(7) I nstal l No. 2 oneway cl utch i n pl anetary gear.
Be sure fl anged si de of cl utch faces upward (Fi g.
285).
(8) I nstal l No. 2 oneway cl utch top end cap i nto
the pl anetary gear.
(9) I nstal l cl utch retai ni ng snap ri ng and i nstal l
cl utch i nner race (Fi g. 280). Turn race countercl ock-
wi se to ease i nstal l ati on.
(10) Veri fy oneway cl utch operati on. Hol d gear
and turn i nner race i n both di recti ons. Race shoul d
turn freel y countercl ockwi se, but l ock when turned
cl ockwi se.
(11) I nstal l pl anetary gear i n ri ng gear.
Fig. 282 Removing/Installing Rear Planetary Thrust
Washers
Fig. 283 Removing/Installing Ring Gear Thrust
Bearing And Races
Fig. 284 Removing/Installing Ring Gear Hub
(12) I nstal l thrust beari ng and washers onto the
(13) Assembl e cl utch di scs and cl utch pl ates (Fi g.
277). Sequence i s di sc fi rst, then a pl ate. Use seven
di scs and pl ates.
(14) I nstal l brake pack on pl anetary gear (Fi g.
277).
(15) I nstal l new seal ri ng on output shaft (Fi g.
276). Be sure ri ng ends are i nterl ocked as shown.
The val ve body assembl y consi sts of two secti ons
whi ch are the upper body and l ower body (Fi g. 286)
and (Fi g. 287). Di sassembl y, i nspecti on and overhaul
procedures for each secti on are outl i ned separatel y.
Refer to the appropri ate procedure as needed.
Fig. 285 Installing No. 2 OneWay Clutch
Fig. 286 Lower Body Components
Fig. 287 Upper Body Components
TRANSMISSION PARTS CLEANING AND
INSPECTION
Cl ean the transmi ssi on components wi th sol vent
and dry them wi th compressed ai r onl y. Do not use
shop towel s or rags.
Bl ow compressed ai r through al l oi l feed passages
and channel s to be sure they are cl ear. I nspect the
transmi ssi on components for wear and damage.
Repl ace components that are damaged or worn
beyond the l i mi ts speci fi ed i n the i ndi vi dual overhaul
procedures.
Repl ace al l Ori ngs, gaskets and seal s. These com-
ponents are not reusabl e. Al so repl ace any snap ri ng
that i s di storted or damaged.
Duri ng overhaul assembl y operati ons, l ubri cate the
transmi ssi on components wi th Mopar Mercon auto-
mati c transmi ssi on fl ui d or petrol eum jel l y as i ndi -
cated. Petrol eum jel l y shoul d be used to prel ubri cate
thrust beari ngs, washers and races. I t can al so be
used to hol d parts i n posi ti on duri ng assembl y.
Soak replacement clutch and brake pack
components in transmission fluid for at least 30
minutes before installation.
ADJ USTMENTS
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n Park
and Neutral . Adjustment i s OK i f the engi ne starts
onl y i n these posi ti ons. Adjustment i s i ncorrect i f the
engi ne starts i n one but not both posi ti ons. I f the
engi ne starts i n any posi ti on other than Park or Neu-
tral , or i f the engi ne wi l l not start at al l , the park/
neutral posi ti on swi tch may be faul ty.
Gearshift Adjustment Procedure
(3) Rel ease cabl e adjuster cl amp (at transmi ssi on
end of cabl e) to unl ock cabl e.
(4) Unsnap cabl e from cabl e mounti ng bracket on
(5) Sl i de cabl e eyel et off transmi ssi on shi ft l ever.
(6) Veri fy transmi ssi on shi ft l ever i s i n Park
detent by movi ng l ever ful l y rearward. Last rearward
detent i s Park posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Sl i de cabl e eyel t onto transmi ssi on shi ft l ever.
(9) Snap shi ft cabl e adjuster i nto mounti ng
bracket on transmi ssi on.
(10) Lock shi ft cabl e by pressi ng cabl e adjuster
cl amp down unti l i t snaps i nto pl ace.
(11) Lower vehi cl e and check engi ne starti ng.
Engi ne shoul d start onl y i n Park and Neutral .
CABLE ADJUSTMENT
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove shi ft l ever bezel and consol e screws.
Rai se bezel and consol e for access to cabl e.
(3) Pul l cabl e l ock button up to rel ease cabl e (Fi g.
289).
(4) Turn i gni ti on swi tch to LOCK posi ti on.
Fig. 288 Shift Cable Attachment At
TransmissionTypical
Fig. 289 Park Lock Cable Attachment
(5) Use a spacer to create a one mi l l i meter gap
between the shi fter pawl and top of the shi ft gate.
(6) Pul l cabl e forward. Then rel ease cabl e and
press cabl e l ock button down unti l i t snaps i n pl ace.
(7) Check adjustment as fol l ows:
(a) Check movement of rel ease shi ft handl e but-
ton (fl oor shi ft) or rel ease l ever (col umn shi ft). You
shoul d not be abl e to press button i nward or move
col umn l ever.
(b) Turn i gni ti on swi tch to RUN posi ti on.
(c) Shi fti ng out of park shoul d not be possi bl e.
(d) Appl y the brake and attempt to shi ft out of
PARK. Shi fti ng shoul d be possi bl e.
(e) Whi l e the transmi ssi on i s shi fted out of
PARK, rel ease the brake and attempt to shi ft
through al l gears. Rel ease the shi ft button at l east
once duri ng thi s procedure. The i gni ti on key shoul d
not go to the LOCK posi ti on.
(f) Return transmi ssi on to the PARK posi ti on
wi thout appl yi ng the brake.
(8) Move shi ft l ever back to PARK and check i gni -
ti on swi tch operati on. You shoul d be abl e to turn
swi tch to LOCK posi ti on and shi ft l ever rel ease but-
ton/l ever shoul d not move.
ADJUSTMENT
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 290). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
Checking Throttle Valve Cable Adjustment
(2) Remove ai r cl eaner.
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on. Then veri fy that transmi ssi on throttl e l ever
(Fi g. 291) i s al so at i dl e (ful l y forward) posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on.
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
Throttle Valve Cable Adjustment Procedure
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
Fig. 290 Throttle Cable Attachment At Engine
Fig. 291 Throttle Cable Attachment At Transmission
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) I nsert a smal l screwdri ver under edge of
retai ni ng cl i p and remove retai ni ng cl i p.
(6) Center cabl e end on attachment stud to wi thi n
1 mm (0.039 i n.).
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(7) I nstal l retai ni ng cl i p onto cabl e housi ng.
(8) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
SPECIFICATIONS
AW-4 AUTOMATIC TRANSMISSION
AW-4 GENERAL SPECIFICATIONS
AW-4 OIL PUMP WEAR LIMITS
AW-4 CLUTCH DISC AND PLATE THICKNESS
AW-4 BUSHING AND PISTON CLEARANCE
AW-4 RETAINER AND PISTON SPECIFICATIONS
AW-4 VALVE BODY BALL DIMENSIONS
AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS
AW-4 VALVE AND SPRING IDENTIFICATION
AW-4 ACCUMULATOR COMPONENT
IDENTIFICATION
AW-4 TORQUE SPECIFICATIONS
SPECIAL TOOLS
AW-4
C-484 Snap Ring Plier
C-3293-SP Gauge
C-4959 Caliper, Metric Vernier
C-4960 Micrometer
7536 Puller, Oil Pump
7538 Compressor, Piston #2 Spring
7539 Compressor, Piston #3 Spring
7540 Pliers, Large Snap Ring
7542 Puller, Reaction Sleeve
7543 Puller, Piston #1
7544 Installer, Brake Drum Seal
7552 Gauge, 3.0 mm Wire
7554 Adapter, Pressure Port
NV231 TRANSFER CASE
INDEX
page page
GENERAL INFORMATION
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 280
RECOMMENDED LUBRICANT AND FILL
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
TRANSFER CASE IDENTIFICATION . . . . . . . . . 280
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 281
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . 283
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 282
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 282
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 282
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 285
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . 299
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . 303
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
SPECIAL TOOLS
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
GENERAL INFORMATION
NV231 TRANSFER CASE
The NV231 i s a part-ti me transfer case wi th a l ow
range reducti on gear system. The NV231 has three
operati ng ranges pl us a Neutral posi ti on. A l ow range
system provi des a reducti on rati o for i ncreased l ow
speed torque capabi l i ty.
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range hub. The
front output shaft i s operated by a dri ve chai n that
connects the shaft to a dri ve sprocket on the mai n-
shaft. The dri ve sprocket i s engaged/di sengaged by
the mode fork, whi ch operates the mode sl eeve and
hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
Transfer case operati ng ranges are:
2WD (2-wheel dri ve)
4x4 (4-wheel dri ve)
4 Lo (4-wheel dri ve l ow range
The 2WD range i s for use on any road surface at
any ti me.
The 4x4 and 4 Lo ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4 Lo range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate.
TRANSFER CASE IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations
RECOMMENDED LUBRICANT AND FILL LEVEL
Recommended l ubri cant for the NV231 transfer
case i s Mopar Dexron I I , or ATF Pl us 3, type 7176.
Approxi mate l ubri cant fi l l capaci ty i s 1.2 l i ters (2.5
pi nts).
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 1). Correct fi l l l evel i s to the bottom edge of the
fi l l pl ug hol e. Be sure the vehi cl e i s l evel to ensure
an accurate fl ui d l evel check.
NV231 DIAGNOSIS
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.
1) Vehicle speed to great to permit
shifting.
1) Slow vehicle and shift into
desired range.
2) If vehicle was operated for an
extended period in 4H mode on dry
surface, driveline torque load may
cause difficulty.
2) Stop vehicle and shift transfer
case to Neutral position. Transfer
case can then be shifted to the
desired mode.
3) Transfer case shift linkage
binding.
3) Repair or replace linkage as
necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case
components binding, worn, or
damaged.
5) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
lubricant.
Transfer case noisy while in, or
jumps out of, 4L mode.
1) Transfer case not completely
engaged in 4L position.
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of
adjustment.
2) Adjust linkage as necessary.
3) Transfer case shift linkage loose
or binding.
3) Repair, replace, or tighten linkage
components as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
necessary.
5) Low range gear worn or
damaged.
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4H mode
on dry surfaces,
1) Operate vehicle in 2H mode on
dry surfaces.
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember, or ski d pl ate.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 2)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (26 ft. l bs.) torque (Fi g. 2).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
(8) Al i gn and connect propel l er shafts. Refer to
Group 3, Di fferenti al and Dri vel i ne, for proper proce-
dures and speci fi cati ons.
(9) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 Nm (30 ft. l bs.)
torque.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 3). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
torque shaft.
(5) Remove consol e. Refer to Group 23, Body, for
proper procedures.
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. Refer to Group 23, Body, for
proper procedures.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
(6) Lower vehi cl e and check transfer case shi ft
operati on.
SPEEDOMETER
REMOVAL
Fig. 2 Transfer Case Mounting
as an assembl y.
Repl ace pi ni on i f chi pped, cracked, or worn.
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
INSTALLATION AND INDEXING
ati on.
ometer adapter (Fi g. 4), i f necessary.
pi ni on.
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
i n. l bs.) torque.
l evel i f necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
6).
Fig. 3 Shift Linkage
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143 as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 7). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
Fig. 4 Speedometer Components
Fig. 5 Location Of Index Numbers On Speedometer
Adapter
Fig. 6 Remove Front Output Shaft Seal
NV231 TRANSFER CASE
DISASSEMBLY
Posi ti on transfer case on shal l ow drai n pan.
Remove drai n pl ug and drai n l ubri cant remai ni ng i n
case.
REAR RETAINER AND OIL PUMP REMOVAL
(1) Remove the speedometer adapter.
(2) Spread band cl amp whi ch hol ds output shaft
boot to sl i nger wi th a sui tabl e awl , or equi val ent.
(3) Remove output shaft boot from sl i nger and out-
put shaft.
(4) Usi ng Pul l er MD-998056-A, remove rear
sl i nger (Fi g. 8).
(5) Remove sl i nger stop spacer and snap-ri ng from
(6) Use a sui tabl e pry tool , or a sl i de hammer
mounted screw, to remove the seal from the rear
(7) Remove the rear output beari ng I .D. retai ni ng
ri ng (Fi g. 11).
(8) Remove the bol ts hol di ng the rear retai ner to
the rear case hal f.
(9) Tap rear retai ner wi th rawhi de or rubber mal -
l et to l oosen seal er bead.
(10) Remove rear retai ner from rear case hal f (Fi g.
12).
(11) Remove snap-ri ng hol di ng oi l pump i n posi ti on
on output shaft.
(12) Di sengage oi l pi ckup tube from oi l pump and
remove oi l pump assembl y. Remove oi l pump by ti l t-
i ng the edge of the oi l pump from under the edge of
the rear case hal f and sl i di ng the pump (Fi g. 13).
(13) Remove pi ck-up tube o-ri ng from oi l pump
(Fi g. 14), i f necessary. Do not di sassembl e the oi l
pump, i t i s not servi ceabl e.
Fig. 7 Front Output Seal Installation
Fig. 8 Rear Slinger Removal
Fig. 9 Slinger Stop Spacer and Snap-ring
Fig. 10 Rear Retainer Seal
YOKE AND RANGE LEVER REMOVAL
(1) Remove transfer case i ndi cator swi tch.
(2) Remove front yoke nut as fol l ows:
(a) Move range l ever to 4L posi ti on.
(b) Then remove nut wi th socket and i mpact
wrench (Fi g. 15).
(3) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 16). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
Fig. 11 Output Shaft Rear Bearing Retaining Ring
Fig. 12 Rear Retainer Removal
Fig. 14 Pick-up Tube O-ring Location
Fig. 15 Yoke Nut Removal
Fig. 16 Yoke Removal
(4) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(5) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 17).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Support transfer case so rear case i s faci ng
upward.
(2) Remove bol ts hol di ng front case to rear case.
The case al i gnment bol ts requi re fl at washers (Fi g.
18).
(3) Loosen rear case wi th fl at bl ade screwdri ver to
break seal er bead. I nsert pry tool bl ade onl y i nto
notches provi ded at each end of case (Fi g. 19).
(4) Remove rear case from front case.
(5) Remove oi l pi ckup tube from rear case (Fi g.
20).
(6) Remove mode fork spri ng (Fi g. 21).
(7) Pul l front output shaft upward and out of front
output shaft beari ng (Fi g. 22).
(8) Remove front output shaft and chai n.
SHIFT FORKS AND MAINSHAFT REMOVAL
(1) Remove detent pl ug, O-ri ng, detent spri ng and
detent pl unger (Fi g. 23).
(2) Remove mai nshaft from mode sl eeve and i nput
gear pi l ot beari ng.
Fig. 17 Range Lever Removal
Fig. 18 Rear Case Alignment Bolt Locations
Fig. 19 Loosening Rear Case
Fig. 20 Oil Pickup Tube Removal
Fig. 21 Mode Fork Spring Removal
(3) Remove mode fork and sl eeve as an assembl y
(Fi g. 24). Note posi ti on of sl eeve for assembl y refer-
ence. The short si de of the sl eeve faces upward.
(4) Remove range fork and hub as an assembl y
(Fi g. 25). Note fork posi ti on for i nstal l ati on reference.
(5) Remove shi ft sector from front case (Fi g. 26).
(6) Remove shi ft sector bushi ng and O-ri ng (Fi g.
27).
MAINSHAFT DISASSEMBLY
(1) Remove mode hub retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 28).
(2) Sl i de mode hub off mai nshaft (Fi g. 29).
(3) Sl i de dri ve sprocket off mai nshaft (Fi g. 30).
INPUT GEAR AND LOW RANGE GEAR REMOVAL
(1) Remove front beari ng retai ner attachi ng bol ts
(Fi g. 31).
Fig. 22 Remove Front Output Shaft And Chain
Fig. 23 Detent Plug, Spring And Plunger Removal
Fig. 24 Mode Fork And Sleeve Removal
Fig. 25 Range Fork And Hub Removal
Fig. 26 Shift Sector Removal
(2) Remove front beari ng retai ner. Pry retai ner
l oose wi th pry tool posi ti oned i n sl ots at each end of
Fig. 27 Sector Bushing And O-Ring Removal
Fig. 28 Mode Hub Retaining Ring Removal
Fig. 29 Mode Hub Removal
Fig. 30 Drive Sprocket Removal
Fig. 31 Front Bearing Retainer Bolts
Fig. 32 Front Bearing Retainer Removal
(3) Remove front beari ng retai ner seal . Tap seal
out wi th dri ft and hammer.
(4) Remove i nput gear retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 33)
(5) Pl ace front case i n hori zontal posi ti on. Then
remove i nput gear and l ow range gear as an assem-
bl y (Fi g. 34). Tap gear out of beari ng wi th pl asti c
mal l et i f necessary.
INPUT AND LOW RANGE GEAR DISASSEMBLY
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 35).
(2) Remove retai ner (Fi g. 36).
(3) Remove front tabbed thrust washer (Fi g. 37).
(4) Remove i nput gear (Fi g. 38).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 39).
ASSEMBLY
Lubri cate transfer case components wi th Mopar
Dexron I I automati c transmi ssi on fl ui d or petrol eum
jel l y (where i ndi cated) duri ng assembl y.
Fig. 33 Removing Input Gear Retaining Ring
Fig. 34 Input Gear And Planetary Carrier Removal
Fig. 35 Input Gear Snap-Ring Removal
Fig. 36 Input Gear Retainer Removal
Fig. 37 Front Tabbed Thrust Washer Removal
BEARING AND SEAL INSTALLATION
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
(1) Remove the front output shaft seal from case
wi th pry tool (Fi g. 40).
(2) Remove the front output shaft beari ng retai n-
i ng ri ng wi th screwdri ver (Fi g. 41).
(3) Remove beari ng wi th Tool Handl e C-4171 and
Tool 5065 (Fi g. 42).
(4) I nstal l front output shaft front beari ng i n case
wi th Tool Handl e C-4171 and I nstal l er 5064 (Fi g. 43).
(5) I nstal l output shaft front beari ng retai ni ng
ri ng (Fi g. 44). Start ri ng i nto pl ace by hand. Then
use smal l screwdri ver to work ri ng i nto case groove.
Be sure ri ng i s ful l y seated before proceedi ng.
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
mer (Fi g. 45). Once seal i s started, conti nue tap-
Fig. 38 Input Gear Removal
Fig. 39 Rear Tabbed Thrust Washer Removal
Fig. 40 Front Output Seal Removal
Fig. 41 Front Output Shaft Bearing Retaining Ring
Removal
Fig. 42 Front Output Shaft Bearing Removal
pi ng seal i nto bore unti l i nstal l er tool bottoms
agai nst case.
(7) Remove the output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 46).
(8) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 47). The beari ng bore i s
chamfered at the top. I nstal l the beari ng so i t i s
fl ush wi th the l ower edge of thi s chamfer (Fi g. 48).
(9) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng from i nsi de the annul us
gear openi ng i n the case. (Fi g. 49).
(10) I nstal l l ocati ng ri ng on new beari ng.
(11) Posi ti on case so forward end i s faci ng upward.
(12) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng i nto case. The beari ng
Fig. 43 Front Output Shaft Bearing Installation
Fig. 44 Installing Output Shaft Front Bearing
Retaining Ring
Fig. 46 Output Shaft Rear Bearing Removal
Fig. 47 Output Shaft Rear Bearing Installation
l ocati ng ri ng must be ful l y seated agai nst case sur-
face (Fi g. 50).
(13) Remove i nput gear pi l ot beari ng by i nserti ng
a sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 51).
(14) I nstal l new pi l ot beari ng wi th I nstal l er 5065
and Handl e C-4171 (Fi g. 52).
(15) Remove front beari ng retai ner seal wi th sui t-
abl e pry tool .
Fig. 48 Output Shaft Rear Bearing Installation Depth
Fig. 49 Input Shaft Bearing Removal
Fig. 50 Seating Input Shaft Bearing
Fig. 51 Remove Input Gear Pilot Bearing
Fig. 52 Install Input Gear Pilot Bearing
(16) I nstal l new front beari ng retai ner seal wi th
I nstal l er 7884 (Fi g. 53).
(17) Remove seal from oi l pump housi ng wi th a
sui tabl e pry tool .
(18) I nstal l new seal i n oi l pump housi ng wi th
(19) Remove rear retai ner beari ng wi th I nstal l er
8128 and Handl e C-4171.
(20) I nstal l rear beari ng i n retai ner wi th Handl e
C-4171 and I nstal l er 5064 (Fi g. 55).
INPUT AND LOW RANGE GEAR ASSEMBLY
(1) Lubri cate gears and thrust washers (Fi g. 56)
wi th recommended transmi ssi on fl ui d.
(2) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 56). Be sure washer tabs are properl y al i gned i n
gear notches.
(3) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
(4) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(5) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
INPUT GEAR AND LOW RANGE GEAR INSTALLATION
(1) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 57). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
Fig. 54 Oil Pump Seal Installation
Fig. 55 Installing Rear Bearing In Retainer
Fig. 56 Input/Low Range Gear Components
(2) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 58).
(3) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(4) Appl y a 3 mm (1/8 i n.) bead of Mopar gasket
maker or si l i cone adhesi ve to seal i ng surface of
retai ner.
(5) Al i gn cavi ty i n seal retai ner wi th fl ui d return
hol e i n front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Mopar gas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(6) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 59). Ti ghten to 21 Nm (16 ft. l bs.) of torque.
MAINSHAFT ASSEMBLY
(1) Lubri cate mai nshaft spl i nes wi th recommended
(2) Sl i de dri ve sprocket onto mai nshaft.
(3) Sl i de mode hub onto mai nshaft.
(4) I nstal l mode hub retai ni ng ri ng. Veri fy that the
retai ni ng ri ng i s ful l y seated i n mai nshaft groove.
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 60).
(2) I nstal l shi ft sector i n case (Fi g. 61). Lubri cate
sector shaft wi th transmi ssi on fl ui d before i nstal l a-
ti on.
(3) I nstal l range l ever, washer, and nut on sector
shaft (Fi g. 62). Ti ghten range l ever nut to 2734 N.m
(4) Assembl e and i nstal l range fork and hub (Fi g.
63). Be sure hub i s properl y seated i n l ow range gear
and engaged to the i nput gear.
Fig. 57 Input/Low Range Gear Installation
Fig. 58 Install Snap-Ring
Fig. 60 Sector O-Ring And Bushing Installation
(5) Al i gn and i nsert range fork pi n i n shi ft sector
sl ot.
(6) I nstal l assembl ed mai nshaft (Fi g. 64). Be sure
shaft i s seated i n pi l ot beari ng and i nput gear.
(7) I nstal l new pads on mode fork i f necessary.
(8) I nsert mode sl eeve i n mode fork mode fork. Be
sure l ong si de of sl eeve i s toward l ong end of shi ft
rai l (Fi g. 65).
(9) I nstal l assembl ed mode fork and sl eeve (Fi g.
66). Be sure fork rai l goes through range fork and
i nto case bore. Al so be sure sl eeve i s al i gned and
seated on mai nshaft hub.
(10) Rotate sector to Neutral posi ti on.
(11) I nstal l new O-ri ng on detent pl ug (Fi g. 67).
(12) Lubri cate detent pl unger wi th transmi ssi on
fl ui d or l i ght coat of petrol eum jel l y.
Fig. 61 Shift Sector Installation
Fig. 62 Range Lever Installation
Fig. 63 Install Range Fork And Hub Assembly
Fig. 64 Mainshaft Assembly Installation
Fig. 65 Assembling Mode Fork And Sleeve
Fig. 66 Mode Fork And Sleeve Installation
(13) I nstal l detent pl unger, spri ng and pl ug (Fi g.
67).
(14) Veri fy that pl unger i s properl y engaged i n sec-
tor.
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) Lubri cate front output shaft-sprocket assembl y,
dri ve chai n, and dri ve sprocket wi th transmi ssi on
fl ui d.
(2) Assembl e dri ve chai n and front output shaft
(Fi g. 68).
(3) Start chai n on mai nshaft dri ve sprocket.
(4) Gui de front shaft i nto beari ng and dri ve
sprocket onto mai nshaft dri ve gear (Fi g. 68).
(5) I nstal l mode spri ng on upper end of mode fork
OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION
(1) I nstal l magnet i n front case pocket (Fi g. 70).
(2) Assembl e oi l pi ckup screen, connecti ng hose,
and tube.
(3) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 71).
(4) I nsert oi l pi ckup tube i n oi l pump i nl et.
(5) Posi ti on assembl ed oi l pump and pi ckup tube
i n rear case. Be sure pi ckup screen i s securel y seated
i n case sl ot. Al so be sure oi l pump l ocati ng tabs are
outsi de rear case (Fi g. 72).
(6) Appl y 3 mm (1/8 i n.) wi de bead of Mopar gas-
ket maker or si l i cone adhesi ve seal er to mounti ng
fl ange of front case. Work seal er bead around bol t
hol es.
(7) Li ft rear case and oi l pump and careful l y posi -
ti on assembl y on front case. Be sure case dowel s are
al i gned and that mode fork rai l extends through rear
case before seati ng rear case on front case.
(8) I nstal l case attachi ng bol ts. Al i gnment bol ts at
each end of case are onl y ones requi ri ng washers
(Fi g. 73).
(9) Ti ghten case bol ts to 27-34 Nm (20-25 ft. l bs.)
torque.
YOKE AND RANGE LEVER INSTALLATION
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
(2) I nstal l range l ever, washer and l ocknut on sec-
tor shaft (Fi g. 74). Ti ghten l ocknut to 27-34 Nm
(20-25 ft. l bs.) torque.
(3) I nstal l new seal washer on front output shaft
(Fi g. 76).
(4) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(5) I nstal l new seal washer on front shaft.
Fig. 67 Shift Detent Components
Fig. 68 Installing Drive Chain And Front Output
Shaft
Fig. 69 Install Mode Fork Spring
(6) I nstal l yoke and new yoke nut on front output
shaft (Fi g. 75).
(7) Ti ghten yoke nut to 122-176 Nm (90-130 ft.
l bs.) torque. Use Tool C-3281, or si mi l ar tool to hol d
yoke whi l e ti ghteni ng yoke nut.
REAR RETAINER INSTALLATION
(1) Appl y bead of Mopar Seal er P/N 82300234, or
Locti te Ul tra Gray, to mati ng surface of rear
retai ner. Seal er bead shoul d be a maxi mum of 3/16
i nch.
(2) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 2027 Nm (1520 ft. l bs.) torque.
Fig. 70 Installing Case Magnet
Fig. 71 Pickup Tube O-Ring Position
Fig. 72 Oil Pump And Pickup Tube Installation
Fig. 73 Alignment Bolt Location
Fig. 74 Range Lever Installation
Fig. 75 Output Shaft Yoke Installation
(3) I nstal l rear beari ng I .D. retai ni ng ri ng and
spacer on output shaft.
(4) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(5) Sl i de seal onto Seal Protector 6992 (Fi g. 77).
Sl i de seal protector and seal onto output shaft.
(6) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th i nstal l er
C-4076-B and handl e MD-998323 (Fi g. 78).
(7) I nstal l rear sl i nger wi th i nstal l er C-4076-A and
handl e MD-998323 (Fi g. 78).
(8) I nstal l boot on output shaft sl i nger and cri mp
retai ni ng cl amp wi th tool C-4975-A (Fi g. 79).
NV231 TRANSFER CASE
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and 3M
al l purpose cl eaner. Use compressed ai r to remove
sol vent resi due from oi l feed passages i n the case
hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket (Fi g. 80). Mi nor ni cks and
scratches can be smoothed wi th an oi l stone. However,
repl ace any part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320400 gri t emery cl oth but do
not try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 81). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
Fig. 76 Yoke Seal Washer Installation
Fig. 77 Output Shaft Seal and Protector
Fig. 78 Rear Seal Installation
Fig. 79 Slinger Boot Installation
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 82). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320400 gri t emery cl oth.
I nspect the shi ft fork wear pads (Fi g. 83). The
mode fork pads are servi ceabl e and can be repl aced i f
necessary. The range fork pads are not servi ceabl e.
Fig. 80 Mainshaft, Mode Hub, And Drive Sprocket
Fig. 81 Input Gear And Carrier Components
The fork must be repl aced as an assembl y i f the pads
are worn or damaged.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/SEAL/SLINGER/BOOT
I nspect the retai ner components (Fi g. 84). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and 3M al l
purpose cl eaner. Thi s wi l l ensure proper adhesi on of
the seal er duri ng reassembl y.
Repl ace the sl i nger and seal outri ght; do not reuse
ei ther part.
I nspect the retai ni ng ri ngs and washers. Repl ace
any part i f di storted, bent, or broken. Reuse i s not
recommended. Al so repl ace the boot i f cut or torn.
Repl ace the boot band cl amps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 85). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke
nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320400 gri t emery
to smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 86).
FRONT-REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and
3M al l purpose cl eaner. Thi s wi l l ensure proper
seal er adhesi on at assembl y. Repl ace the i nput
retai ner seal ; do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai nl ess
steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
Fig. 82 Shift forks
Fig. 83 Shift Fork And Wear Pad Locations
Fig. 84 Rear Retainer Components
Fig. 85 Seal Contact Surface Of Yoke Slinger Fig. 86 Low Range Annulus Gear
ADJ USTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shi ft transfer case i nto 4L posi ti on.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
87).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Detent . . . . . . . . . . 1624 Nm (1218 ft. l bs.)
Pl ug, Drai n/Fi l l . . . . . . . . 2034 Nm (1525 ft. l bs.)
Bol t, Front Brg. Retai ner . . . . . . 21 Nm (16 ft. l bs.)
Bol t, Front Brg. Retai ner . . . . . . 21 Nm (16 ft. l bs.)
Bol t, Case Hal f . . . . . . . . 2734 Nm (2025 ft. l bs.)
Nut, Front Yoke . . . . . 122176 Nm (90130 ft. l bs.)
Nut, Range Lever . . . . . . 2734 Nm (2025 ft. l bs.)
Bol t, Rear Retai ner . . . . . 3546 Nm (2634 ft. l bs.)
Nuts, Mounti ng . . . . . . . . 3547 Nm (2635 ft. l bs.)
Swi tch, I ndi cator . . . . . . . 2034 Nm (1525 ft. l bs.)
SPECIAL TOOLS
NV231
InstallerC-4076-B
Puller, SlingerMD-998056A
InstallerMD-998323
Seal Protector6992
Installer, Boot ClampC-4975-A
Installer, Seal8143
Handle, UniversalC-4171
Installer, SealC-4210
Installer, Bearing5064
Installer, Bushing5066
RemoverL-4454
Cup8148
Installer, Seal7884
Installer, Pump Housing Seal7888
NV242 TRANSFER CASE
INDEX
page page
GENERAL INFORMATION
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 306
RECOMMENDED LUBRICANT AND FILL
LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
TRANSFER CASE IDENTIFICATION . . . . . . . . . 306
NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 307
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . 309
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 308
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 308
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 308
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 311
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . 330
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . 333
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
SPECIAL TOOLS
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
GENERAL INFORMATION
NV242 TRANSFER CASE
The NV242 i s a ful l and part-ti me transfer case
(Fi g. 1). I t provi des ful l ti me 2-wheel , or 4-wheel
dri ve operati on.
A di fferenti al i n the transfer case i s used to control
torque transfer to the front and rear axl es. A l ow
range gear provi des i ncreased l ow speed torque capa-
bi l i ty for off road operati on. The l ow range provi des a
2.72:1 reducti on rati o.
put shaft. I t dri ves the mai nshaft through the pl an-
etary gear and range hub. The front output shaft i s
operated by a dri ve chai n that connects the shaft to a
dri ve sprocket on the mai nshaft. The dri ve sprocket
i s engaged/di sengaged by the mode fork, whi ch oper-
ates the mode sl eeve and hub. The sl eeve and hub
are not equi pped wi th a synchro mechani sm for shi ft-
i ng.
OPERATING RANGES
NV242 operati ng ranges are 2WD (2-wheel dri ve),
4x4 part-ti me, 4x4 ful l ti me, and 4 Lo.
The 2WD and 4x4 ful l ti me ranges can be used at
any ti me and on any road surface.
The 4x4 part-ti me and 4 Lo ranges are for off road
use onl y. The onl y ti me these ranges can be used on
hard surface roads, i s when the surface i s covered
wi th snow and i ce.
SHIFT MECHANISM
are marked on the shi fter bezel cover pl ate, or on the
shi ft knob.
Fig. 1 NV242 Transfer Case
Recommended l ubri cant for the NV242 transfer
case i s Mopar Dexron I I , or ATF Pl us, type 7176.
Approxi mate l ubri cant fi l l capaci ty i s 1.35 l i ters (2.85
pi nts).
NV242 DIAGNOSIS
DIAGNOSIS CHART
binding.
necessary.
lubricant.
damaged.
necessary.
modes.
lubricant.
seals or vent.
level.
restricted.
necessary.
Transfer case will not shift through
4X4 part time range (light remains
on)
1) Incomplete shift due to drivetrain
torque load.
1) Momentarily release the
accelerator pedal to complete the
shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive Tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
TRANSFER CASE
REMOVAL
(6) Remove rear crossmember, or ski d pl ate.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
range l ever.
mi ssi on.
gage transfer case.
INSTALLATION
to 35 Nm (26 ft. l bs.) torque (Fi g. 3).
hose.
on transfer case.
(8) Al i gn and connect propel l er shafts. Refer to
Group 3, Di fferenti al and Dri vel i ne, for proper proce-
dures and speci fi cati ons.
(9) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 Nm (30 ft. l bs.)
torque.
operati on.
SHIFT LEVER
REMOVAL
(3) Loosen adjusti ng trunni on l ocknut and sl i de
torque shaft.
(5) Remove consol e. Refer to Group 23, Body, for
proper procedures.
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. Refer to Group 23, Body, for
proper procedures.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
(6) Lower vehi cl e and check transfer case shi ft
operati on.
SPEEDOMETER
REMOVAL
as an assembl y.
ati on.
pi ni on.
i n. l bs.) torque.
REMOVAL
(4) Remove seal from front case wi th pry tool
(Fi g. 7).
INSTALLATION
I nstal l er Tool 6952-A as fol l ows:
Adapter
NV242 TRANSFER CASE
DISASSEMBLY
REAR RETAINER REMOVAL
(1) Remove output shaft boot. Spread band cl amp
that secures boot on sl i nger wi th a sui tabl e awl .
Then sl i de boot off shaft (Fi g. 9).
(2) Usi ng pul l er MD-998056-A, remove rear sl i nger
(Fi g. 10).
(3) Remove sl i nger stop spacer and snap-ri ng from
(4) Remove rear seal from retai ner (Fi g. 12). Use
pry tool , or col l apse seal wi th punch to remove i t.
(5) Remove rear output beari ng I .D. retai ni ng ri ng
(Fi g. 13).
(6) Remove speedometer adapter.
(7) Remove rear retai ner bol ts.
(8) Remove rear retai ner. Tap retai ner wi th mal l et
and pry upward to break seal er bead. Then sl i de
retai ner off case and output shaft (Fi g. 14).
Fig. 9 Output BootTypical
Fig. 10 Rear Slinger Removal
Fig. 11 Slinger Stop Spacer and Snap-ring
Fig. 12 Rear Seal Removal
(9) Remove rear beari ng O.D. retai ni ng ri ng wi th
snap ri ng pl i ers. Then ti l t pump and sl i de i t off out-
(10) Remove pi ckup tube O-ri ng from pump (Fi g.
16) but do not di sassembl e pump; i t i s not a repai r-
abl e part.
(11) Remove seal from oi l pump wi th pry tool .
(12) Remove bol ts attachi ng rear case to front case
(Fi g. 17). Note posi ti on of the two bl ack fi ni sh bol ts
at each end of the case. These bol ts go through the
case dowel s and requi re a washer under the bol t
head.
(13) Remove rear case from front case (Fi g. 18).
I nsert screwdri vers i nto sl ots cast i nto each end of
case. Then pry upward to break seal er bead and
remove rear case.
CAUTION: Do not pry on the sealing surface of
either case half as the surfaces will become dam-
aged.
(14) Remove oi l pi ckup tube and screen from rear
case (Fi g. 19).
YOKE AND RANGE LEVER REMOVAL
(1) Remove front yoke nut:
(a) Move range l ever to 4L posi ti on.
(b) Remove nut wi th socket and i mpact wrench
(Fi g. 20).
Fig. 13 Rear Bearing I.D. Retaining Ring Removal
Fig. 14 Rear Retainer Removal
Fig. 16 Pickup Tube O-Ring Location
Fig. 17 Spline And Dowel Bolt Locations
(2) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 21). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
(3) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(4) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 22).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Remove dri ve sprocket snap-ri ng (Fi g. 23).
(2) Remove dri ve sprocket and chai n (Fi g. 24).
(3) Remove front output shaft (Fi g. 25).
SHIFT FORKS AND MAINSHAFT REMOVAL AND
DISASSEMBLY
(1) Remove shi ft detent pl ug, spri ng and pi n (Fi g.
26).
(2) Remove seal pl ug from l ow range fork l ockpi n
access hol e. Then move shi ft sector to al i gn l ow range
fork l ockpi n wi th access hol e.
(3) Remove range fork l ockpi n wi th si ze number
one easy-out tool as fol l ows:
(a) I nsert easy-out tool through access hol e i n
si de of transfer case and i nto l ock-pi n.
(b) Tap easy-out tool i nto l ock-pi n wi th hammer
unti l tool i s securel y engaged i nto the l ock-pi n.
Fig. 18 Loosening/Removing Rear case
Fig. 19 Oil Pickup Screen, Hose And Tube Removal
Fig. 20 Yoke Nut Removal
Fig. 22 Range Lever Removal
(c) I nstal l a t-handl e, such as from a tap and di e
set, onto the easy-out tool .
(d) Securel y ti ghten the t-handl e onto the tool .
(e) I n one moti on, pul l upward and turn the
t-handl e counter-cl ockwi se to remove the l ock-pi n.
(4) Remove shi ft rai l by pul l i ng i t strai ght up and
out of fork (Fi g. 27).
(5) Remove mode fork and mai nshaft as assembl y
(Fi g. 28).
(6) Remove mode shi ft sl eeve and mode fork
assembl y from mai nshaft (Fi g. 29). Note posi ti on of
mode sl eeve i n fork and remove sl eeve.
Fig. 23 Drive Sprocket Snap-Ring Removal
Fig. 24 Drive Sprocket And Chain Removal
Fig. 25 Removing Front Output Shaft
Fig. 26 Detent Component Removal
(7) Remove i ntermedi ate cl utch shaft snap-ri ng
(Fi g. 30).
(8) Remove cl utch shaft thrust ri ng (Fi g. 31).
(9) Remove i ntermedi ate cl utch shaft (Fi g. 32).
(10) Remove di fferenti al snap-ri ng (Fi g. 33).
Fig. 27 Shift Rail Removal
Fig. 28 Mode Fork And Mainshaft Removal
Fig. 29 Mode Fork And Sleeve Removal
Fig. 30 Intermediate Clutch Shaft Snap-Ring
Removal
(11) Remove di fferenti al (Fi g. 34).
(12) Remove di fferenti al needl e beari ngs and both
needl e beari ng thrust washers from mai nshaft.
(13) Sl i de l ow range fork pi n out of shi ft sector sl ot
(Fi g. 35).
(14) Remove l ow range fork and hub (Fi g. 36).
(15) Remove shi ft sector (Fi g. 37).
(16) Remove shi ft sector bushi ng and O-ri ng
(Fi g. 38).
Fig. 31 Clutch Shaft Thrust Ring Removal
Fig. 32 Intermediate Clutch Shaft Removal
Fig. 33 Differential Snap-Ring Removal
Fig. 34 Differential Removal
INPUT GEAR/LOW RANGE ASSEMBLY REMOVAL AND
DISASSEMBLY
(1) Remove front beari ng retai ner bol ts.
(2) Remove front beari ng retai ner. Careful l y pry
retai ner l oose wi th screwdri ver (Fi g. 39). Posi ti on
screwdri ver i n sl ots cast i nto retai ner.
(3) Remove i nput gear snap-ri ng (Fi g. 40).
(4) Remove i nput/l ow range gear assembl y from
beari ng wi th Tool Handl e C-4171 and Tool 7829A
(Fi g. 41).
(5) Remove l ow range gear snap-ri ng (Fi g. 42).
(6) Remove i nput gear retai ner, thrust washers
and i nput gear from l ow range gear (Fi g. 43).
(7) I nspect l ow range annul us gear (Fi g. 44). Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oi l seal s from fol l owi ng components:
rear retai ner.
oi l pump.
case hal ves.
Fig. 35 Disengaging Low Range Fork
Fig. 36 Low Range Fork And Hub Removal
Fig. 37 Shift Sector Position
Fig. 38 Sector Bushing And O-Ring Removal
DIFFERENTIAL DISASSEMBLY
(1) Mark di fferenti al case hal ves for reference.
(2) Remove di fferenti al case bol ts.
(3) I nvert di fferenti al on workbench.
(4) Separate top case from bottom case. Use sl ots
i n case hal ves to pry them apart (Fi g. 45).
(5) Remove thrust washers and pl anet gears from
case pi ns (Fi g. 46).
(6) Remove mai nshaft and sprocket gears from
bottom case (Fi g. 47). Note gear posi ti on for reference
before separati ng them.
Fig. 39 Front Bearing Retainer Removal
Fig. 40 Input Gear Snap-Ring Removal
Fig. 41 Input And Low Range Gear Assembly
Removal
Fig. 42 Low Range Gear Snap-Ring Removal/
Installation
ASSEMBLY
Lubri cate transfer case components wi th automati c
transmi ssi on fl ui d or petrol eum jel l y (where i ndi -
cated) duri ng assembl y.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
BEARING AND SEAL INSTALLATION
(1) Remove snap-ri ng that retai ns front output
shaft front beari ng i n case (Fi g. 48). Then remove
beari ng. Use hammer handl e, or hammer and brass
punch to tap beari ng out of case.
(2) I nstal l new front output shaft front beari ng
wi th Tool Handl e C-4171 and I nstal l er 8033A wi th
the tapered cone upward (Fi g. 49).
(3) I nstal l front beari ng snap-ri ng (Fi g. 48).
(4) Remove front output shaft seal usi ng an appro-
pri ate pry tool (Fi g. 50) or sl i de-hammer mounted
screw.
(5) I nstal l new front output shaft oi l seal wi th
I nstal l er 6952-A (Fi g. 51).
Fig. 43 Low Range Gear Disassembly
Fig. 44 Inspecting Low Range Annulus Gear
Fig. 45 Separating Differential Case Halves
Fig. 46 Planet Gears And Thrust Washer Removal
(6) Remove i nput gear beari ng wi th Tool Handl e
C-4171 and Remover C-4210 (Fi g. 52).
(7) I nstal l snap-ri ng on new i nput gear beari ng.
(8) I nstal l new i nput gear beari ng wi th Tool Han-
dl e C-4171 and Remover C-4210. I nstal l beari ng far
enough to seat snap-ri ng agai nst case (Fi g. 53).
(9) Remove the i nput gear pi l ot beari ng by i nsert-
i ng a sui tabl y si zed dri ft i nto the spl i ned end of the
i nput gear and dri vi ng the beari ng out wi th the dri ft
and a hammer (Fi g. 54).
(10) I nstal l new pi l ot beari ng wi th I nstal l er 8128
Fig. 47 Mainshaft And Sprocket Gear Removal
Fig. 48 Front Output Shaft Front Bearing Snap-Ring
Removal
Fig. 49 Front Output Shaft Front Bearing Installation
Fig. 51 Install Front Output Shaft Seal
(11) I nstal l new seal i n front beari ng retai ner wi th
(12) Remove output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 57).
(13) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 58). Lubri cate beari ng after
i nstal l ati on.
(14) I nstal l new seal i n oi l pump feed housi ng wi th
Speci al Tool 7888 (Fi g. 59).
(15) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 60).
Fig. 52 Input Gear Bearing Removal
Fig. 53 Seating Input Gear Bearing
Fig. 54 Remove Input Gear Pilot Bearing
Fig. 55 Install Input Gear Pilot Bearing
DIFFERENTIAL ASSEMBLY
(1) Lubri cate di fferenti al components wi th auto-
mati c transmi ssi on fl ui d.
(2) I nstal l sprocket gear i n di fferenti al bottom case
(Fi g. 61).
(3) I nstal l di fferenti al pl anet gears and new thrust
washers (Fi g. 62). Be sure thrust washers are
installed at top and bottom of each planet gear.
(4) I nstal l di fferenti al mai nshaft gear (Fi g. 62).
(5) Al i gn and posi ti on di fferenti al top case on bot-
tom case (Fi g. 63). Al i gn usi ng scri be marks made at
di sassembl y.
(6) Whi l e hol di ng di fferenti al case hal ves together,
i nvert the di fferenti al and start the di fferenti al case
bol ts.
(7) Ti ghten di fferenti al case bol ts to speci fi ed
torque.
Fig. 56 Front Bearing Retainer Seal Installation
Fig. 57 Remove Front Output Shaft Rear Bearing
Fig. 58 Install Front Output Shaft Rear Bearing
Fig. 59 Oil Pump Seal Installation
Fig. 60 Pickup Tube O-Ring Installation
Fig. 61 Installing Differential Sprocket Gear
Fig. 62 Installing Mainshaft And Planet Gears
Fig. 63 Differential Case Assembly
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assembl e l ow range gear, i nput gear thrust
washers, i nput gear and i nput gear retai ner (Fi g. 64).
(2) I nstal l l ow range gear snap ri ng (Fi g. 65).
(3) Lubri cate i nput gear and l ow range gears wi th
(4) Start i nput gear shaft i nto front case beari ng.
(5) Press i nput gear shaft i nto front beari ng.
(6) I nstal l new i nput gear snap ri ng (Fi g. 66).
ket maker or si l i cone adhesi ve seal er to seal surface
of front beari ng retai ner.
(8) I nstal l front beari ng retai ner (Fi g. 67). Ti ghten
retai ner bol ts to 16 ft. l bs. (21 Nm) torque.
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 68).
(2) I nstal l shi ft sector.
(3) I nstal l new pads on l ow range fork, i f neces-
sary, (Fi g. 69).
(4) Assembl e l ow range fork and hub (Fi g. 69).
(5) Posi ti on l ow range fork and hub i n case. Be
sure l ow range fork pi n i s engaged i n shi ft sector sl ot
(Fi g. 70).
Fig. 64 Low Range And Input Gear Assembly
Fig. 65 Install Low Range Gear Snap Ring
Fig. 66 Input Gear Snap Ring Installation
Fig. 67 Installing Front Bearing Retainer
(6) I nstal l fi rst mai nshaft beari ng spacer on mai n-
shaft (Fi g. 71).
(7) I nstal l beari ng rol l ers on mai nshaft (Fi g. 71).
Coat bearing rollers with generous quantity of
petroleum jelly to hold them in place.
(8) I nstal l remai ni ng beari ng spacer on mai nshaft
(Fi g. 71). Do not di spl ace any beari ngs whi l e i nstal l -
i ng spacer.
Fig. 68 Sector O-Ring And Bushing Installation
Fig. 69 Assembling Low Range Fork And Hub
Fig. 70 Positioning Low Range Fork
Fig. 71 Installing Mainshaft Bearing Rollers and
Spacers
(9) I nstal l di fferenti al (Fi g. 72). Do not displace
mainshaft bearings when installing differential.
(10) I nstal l di fferenti al snap-ri ng (Fi g. 73).
(11) I nstal l i ntermedi ate cl utch shaft (Fi g. 74).
(12) I nstal l cl utch shaft thrust washer (Fi g. 75).
(13) I nstal l cl utch shaft snap-ri ng (Fi g. 76).
(14) I nspect mode fork assembl y (Fi g. 77). Repl ace
pads and bushi ng i f necessary. Repl ace fork tube i f
bushi ngs i nsi de tube are worn or damaged. Al so
check spri ngs and sl i der bracket (Fi g. 77). Repl ace
worn, damaged components.
(15) I nstal l mode sl eeve i n mode fork (Fi g. 78).
Then i nstal l assembl ed sl eeve and fork on mai nshaft.
Be sure mode sl eeve spl i nes are engaged i n di fferen-
ti al spl i nes.
(16) I nstal l mode fork and mai nshaft assembl y i n
case (Fi g. 79). Rotate mai nshaft sl i ghtl y to engage
shaft wi th l ow range gears.
Fig. 72 Differential Installation
Fig. 73 Installing Differential Snap-Ring
Fig. 74 Installing Intermediate Clutch Shaft
Fig. 75 Installing Clutch Shaft Thrust Washer
(17) Rotate mode fork pi n i nto shi ft sector sl ot.
(18) I nstal l shi ft rai l (Fi g. 80). Be sure rail is
seated in both shift forks.
(19) Rotate shi ft sector to al i gn l ockpi n hol e i n l ow
range fork wi th access hol e i n case.
(20) I nsert an easy-out i n range fork l ockpi n to
hol d i t securel y for i nstal l ati on (Fi g. 81). Lockpin is
slightly tapered on one end. Insert tapered end
into fork and rail.
(21) I nsert l ockpi n through access hol e and i nto
shi ft fork (Fi g. 81). Then remove easy-out and seat
the pi n wi th pi n punch.
(22) I nstal l pl ug i n l ockpi n access hol e.
(23) I nstal l detent pl unger, detent spri ng and
detent pl ug i n case (Fi g. 82).
Fig. 76 Installing Clutch Shaft Snap-Ring
Fig. 77 Mode Fork Assembly Inspection
Fig. 78 Installing Mode Fork And Sleeve
Fig. 79 Assembled Mainshaft And Mode Fork
Installation
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) I nstal l front output shaft (Fi g. 83).
(2) I nstal l dri ve chai n (Fi g. 83). Engage chai n wi th
front output shaft sprocket teeth.
(3) I nstal l dri ve sprocket (Fi g. 83). Engage dri ve
sprocket teeth wi th chai n. Then engage sprocket
spl i nes wi th mai nshaft spl i nes.
(4) I nstal l dri ve sprocket snap-ri ng (Fi g. 84).
OIL PUMP AND REAR CASE INSTALLATION
(1) I nsert oi l pi ckup tube i n oi l pump and attach
oi l screen and connector hose to pi ckup tube. Then
i nstal l assembl ed pump, tube and screen i n rear case
(Fi g. 85). Be sure screen i s seated i n case sl ot as
shown.
(2) I nstal l magnet i n front case pocket (Fi g. 86).
ket maker or si l i cone adhesi ve seal er to seal surface
of front case.
(4) Al i gn and i nstal l rear case on front case. Be
sure case l ocati ng dowel s are i n pl ace and that mai n-
shaft spl i nes are engaged i n oi l pump i nner gear.
(5) I nstal l and ti ghten front case-to-rear case bol ts
to 41 Nm (30 ft. l bs.) torque. Be sure to install a
Fig. 80 Shift Rail Installation
Fig. 81 Installing Low Range Fork Lockpin
Fig. 82 Detent Pin, Spring And Plug Installation
Fig. 83 Drive Chain And Sprocket Installation
washer under each bolt used at case dowel
locations.
REAR RETAINER INSTALLATION
(1) Remove rear beari ng i n retai ner usi ng I nstal l er
8128 and Handl e C-4171.
(2) I nstal l rear beari ng i n retai ner wi th Tool s
C-4171 and 5064 (Fi g. 87).
(3) I nstal l rear beari ng O.D. retai ni ng ri ng wi th
snap-ri ng pl i ers (Fi g. 88). Be sure retai ni ng ri ng i s
ful l y seated i n retai ner groove.
(4) Appl y bead of Mopar Seal er P/N 82300234, or
Locti te Ul tra Gray, to mati ng surface of rear
Fig. 84 Drive Sprocket Snap-Ring Installation
Fig. 85 Oil Screen And Pickup Tube Installation
Fig. 86 Installing Case Magnet
Fig. 87 Installing Rear Bearing In Retainer
Fig. 88 Rear Bearing Retaining Ring Installation
retai ner. Seal er bead shoul d be a maxi mum of 3/16
i n.
(5) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 2027 Nm (1520 ft. l bs.) torque.
(6) I nstal l rear beari ng I .D. retai ni ng ri ng and
spacer on output shaft.
(7) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(8) Sl i de seal onto Seal Protector 6992 (Fi g. 89).
Sl i de seal protector and seal onto output shaft.
(9) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th i nstal l er
C-4076-B and handl e MD-998323 (Fi g. 90).
(10) I nstal l rear sl i nger wi th i nstal l er C-4076-A
and handl e MD-998323 (Fi g. 90).
(11) I nstal l boot on output shaft sl i nger and cri mp
retai ni ng cl amp wi th tool C-4975-A (Fi g. 91).
FRONT YOKE AND SWITCH INSTALLATION
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
(2) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(3) I nstal l new seal washer on front shaft.
(4) I nstal l yoke on front shaft. Secure yoke wi th
new nut.
NV242 TRANSFER CASE
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and al l
purpose cl eaner. Use compressed ai r to remove sol -
vent resi due from oi l feed passages i n the case
hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket. Mi nor ni cks and scratches can
be smoothed wi th an oi l stone. However, repl ace any
part i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320400 gri t emery cl oth but do
not try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 92). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300400 gri t emery cl oth i f necessary.
Fig. 89 Output Shaft Seal and Protector
Fig. 90 Rear Seal Installation
Fig. 91 Slinger Boot Installation
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 93). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320400 gri t emery cl oth.
I nspect the shi ft fork wear pads. The mode fork
pads are servi ceabl e and can be repl aced i f necessary.
The range fork pads are al so servi ceabl e.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
I nspect the retai ner components (Fi g. 94). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and al l pur-
pose cl eaner. Thi s wi l l ensure proper adhesi on of the
seal er duri ng reassembl y.
Repl ace the sl i nger and seal outri ght; do not reuse
ei ther part.
I nspect the retai ni ng ri ngs and washers. Repl ace
any part i f di storted, bent, or broken. Reuse i s not
recommended. Al so repl ace the boot i f cut or torn.
Repl ace the boot band cl amps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 95). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke
nut and seal washer as nei ther part shoul d be
reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320400 gri t emery
to smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
Fig. 92 Input Gear And Carrier Components
Fig. 93 Shift forks
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 96).
FRONT-REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and al l
purpose cl eaner. Thi s wi l l ensure proper seal er adhe-
si on at assembl y. Repl ace the i nput retai ner seal ; do
not reuse i t.
Fig. 94 Rear Retainer Components
Fig. 95 Seal Contact Surface Of Yoke Slinger
Fig. 96 Low Range Annulus Gear
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai nl ess
steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ADJ USTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shi ft transfer case i nto 4L posi ti on.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
97).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Detent . . . . . . . . . . 1624 Nm (1218 ft. l bs.)
Bol t, Di ff. Case . . . . . . . . 1727 Nm (1524 ft. l bs.)
Pl ug, Drai n/Fi l l . . . . . . . . 2025 Nm (1525 ft. l bs.)
Bol t, Front Brg. Retai ner . . . . 1627 Nm (1220 ft.
l bs.)
Bol t, Case Hal f . . . . . . . . 3546 Nm (2634 ft. l bs.)
Nut, Front Yoke . . . . . 122176 Nm (90130 ft. l bs.)
Screw, Oi l Pump . . . . . . 1.21.8 Nm (1215 i n. l bs.)
Nut, Range Lever . . . . . . 2734 Nm (2025 ft. l bs.)
Bol t, Rear Retai ner . . . . . 3546 Nm (2634 ft. l bs.)
Nuts, Mounti ng . . . . . . . . . . . . . 35 Nm (26 ft. l bs.)
Bol ts, U-Joi nt . . . . . . . . . . . . . . . 19 Nm (17 ft. l bs.)
SPECIAL TOOLS
NV242
InstallerC-4076-B
Handle, UniversalC-4171
RemoverC-4210
Puller, SlingerMD-998056A
InstallerMD-998323
Installer8128
Installer5066
Installer6952-A
RemoverL-4454
Cup8148
Seal Protector6992
Installer, Input Gear Bearing7829-A
Installer, Seal7884
Installer, Pump Housing Seal7888
Installer, Bearing8033-A
Installer, Boot ClampC-4975-A
TRANSMISSION AND TRANSFER CASE
CONTENTS
page page
AX15 MANUAL TRANSMISSION . . . . . . . . . . . . . 1 NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . . 7
INDEX
page page
GENERAL INFORMATION
AX 15 MANUAL TRANSMISSION . . . . . . . . . . . . . 1
TRANSMISSION ASSEMBLY INFORMATION . . . . 3
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . . 3
TRANSMISSION IDENTIFICATION . . . . . . . . . . . . 2
TRANSMISSION LUBRICANT . . . . . . . . . . . . . . . . 2
TRANSMISSION SHIFT PATTERN . . . . . . . . . . . . 2
TRANSMISSION SWITCH AND PLUG
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 3
LOW LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION NOISE . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL INFORMATION
AX 15 MANUAL TRANSMISSION
The AX 15 i s a 5speed, synchromesh, manual
transmi ssi on. Fi fth gear i s an overdri ve range wi th a
rati o of 0.79:1. The shi ft mechani sm i s i ntegral and
mounted i n the shi ft tower porti on of the adapter
housi ng (Fi g. 1).
Fig. 1 AX 15 Manual Transmission
The AX 15 i denti fi cati on code numbers are on the
bottom surface of the transmi ssi on gear case (Fi g. 2).
The fi rst number i s year of manufacture. The sec-
seri al number.
TRANSMISSION SHIFT PATTERN
The AX 15 shi ft pattern i s shown i n (Fi g. 3). Fi rst
and second and thi rd and fourth gear ranges are i n
l i ne for i mproved shi fti ng. Fi fth and reverse gear
ranges are al so i n l i ne at the extreme ri ght of the
pattern (Fi g. 3).
The AX 15 i s equi pped wi th a reverse l ockout
mechani sm. The shi ft l ever must be moved through
the Neutral detent before maki ng a shi ft to reverse.
TRANSMISSION LUBRICANT
Recommended l ubri cant for AX 15 transmi ssi ons i s
equi val ent.
3.10 l i ters (3.27 qts.) i n 4wheel dri ve model s
TRANSMISSION SWITCH AND PLUG
LOCATIONS
The fi l l pl ug i s at the dri ver si de of the gear case
(Fi g. 4).
The drai n pl ug and backup l i ght swi tch are on the
passenger si de of the gear case (Fi g. 5).
Fig. 2 Identification Code Number Location
Fig. 3 AX 15 Shift Pattern
Fig. 5 Drain Plug/Backup Light Switch Location
AX 15 gear rati os are:
Fi rst gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83:1
Second gear . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33:1
Thi rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44:1
Fourth gear . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
Fi fth gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.79:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22:1
Lubri cate the transmi ssi on components wi th gear
l ubri cant duri ng assembl y. Use petrol eum jel l y to
l ubri cate seal l i ps and/or hol d parts i n pl ace duri ng
i nstal l ati on.
LOW LUBRICANT LEVEL
case, i ntermedi ate pl ate and adapter or extensi on
ponent mati ng surfaces wi l l usual l y be the resul t of
i ng sl i p, grab and chatter.
Transmi ssi ons fi l l ed from ai r or el ectri cal l y pow-
ered l ubri cant contai ners can be under fi l l ed. Thi s
general l y happens when the contai ner del i very mech-
ani sm i s i mproperl y cal i brated. Al ways check the
l ubri cant l evel after fi l l i ng to avoi d an under fi l l con-
di ti on.
when the vehi cl e i s l evel ; use a dri veon hoi st to
ensure thi s. Al so al l ow the l ubri cant to settl e for a
mi nute or so before checki ng. These recommenda-
ti ons wi l l ensure an accurate check and avoi d an
underorover fi l l condi ti on.
HARD SHIFTING
l evel , i mproper or contami nated l ubri cants, compo-
nent damage, i ncorrect cl utch adjustment, or by a
damaged cl utch pressure pl ate or di sc.
Substanti al l ubri cant l eaks can resul t i n gear, shi ft
rai l , synchro and beari ng damage. I f a l eak goes
undetected for an extended peri od, the fi rst i ndi ca-
ti ons of a probl em are usual l y hard shi fti ng and
noi se.
I ncorrect or contami nated l ubri cants can al so con-
tri bute to hard shi fti ng. The consequence of usi ng
nonrecommended l ubri cants i s noi se, excessi ve
wear, i nternal bi nd and hard shi fti ng.
I mproper cl utch rel ease i s a frequent cause of hard
shi fti ng. I ncorrect adjustment or a worn, damaged
pressure pl ate or di sc can cause i ncorrect rel ease. I f
the cl utch probl em i s advanced, gear cl ash duri ng
shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear
cl ash when shi fti ng i nto any forward gear. I n some
new or rebui l t transmi ssi ons, new synchro ri ngs may
tend to sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n
most cases, thi s condi ti on wi l l decl i ne as the ri ngs
weari n.
TRANSMISSION NOISE
i ng normal operati on. Rotati ng gears can generate a
mi l d whi ne that may onl y be audi bl e at extreme
speeds.
Severe, obvi ousl y audi bl e transmi ssi on noi se i s
general l y the resul t of a l ubri cant probl em. I nsuffi -
ci ent, i mproper, or contami nated l ubri cant can pro-
mote rapi d wear of gears, synchros, shi ft rai l s, forks
and beari ngs. The overheati ng caused by a l ubri cant
probl em, can al so l ead to gear breakage.
TRANSMISSION
REMOVAL
1. Di sconnect the battery negati ve cabl e.
2. Remove the shi fter boot and shi fter.
3. Rai se the vehi cl e on a hoi st.
4. Drai n the transmi ssi on fl ui d (Fi g. 6).
5. Support the engi ne and transmi ssi on wi th an
adjustabl e jack stand.
6. Remove exhaust pi pe and heat shi el d.
7. Mark the front and rear propel l er shafts for
i nstal l ati on al i gnment (Fi g. 7).
8. Remove the front propel l er shaft.
9. Remove the rear propel l er shaft.
10. Remove the transmi ssi on ski d pl ate.
11. Di sconnect the transfer case l i nkage and vehi -
cl e speed sensor el ectri cal connector and vent tube
hose (Fi g. 8).
12. Reposi ti on the adjustabl e jackstand under the
engi ne.
13. Pl ace a transmi ssi on jack under the transmi s-
si on and secure the transmi ssi on wi th safety chai ns.
14. Remove the rear transmi ssi on mount.
15. Remove the rear crossmember.
16. Remove the transfer case assembl y. Refer to
Transfer Case removal l ater i n thi s Group.
17. Lower the engi ne and transmi ssi on no more
than 7.6 cm.
18. Remove the two (2) upper and two (2) mi d
cl utch housi ng to engi ne bol ts.
19. Remove the engi ne speed sensor (crankshaft
posi ti on sensor) (Fi g. 9).
20. Remove the cl utch sl ave cyl i nder from the
cl utch housi ng.
21. Remove the l ower transmi ssi on bol ts.
22. Remove the transmi ssi on assembl y from the
vehi cl e.
INSTALLATION
1. Mount the transmi ssi on on a transmi ssi on jack
and secure the transmi ssi on wi th safety chai ns.
2. I nstal l the transmi ssi on to the vehi cl e (Fi g. 10).
3. I nstal l the two (2) l ower transmi ssi on bol ts.
Ti ghten the bol ts to 74.6 Nm.
4. I nstal l the cl utch sl ave cyl i nder to the cl utch
housi ng.
5. I nstal l the engi ne speed sensor (crankshaft posi -
ti on sensor) to the vehi cl e (Fi g. 9).
6. I nstal l the two (2) upper cl utch housi ng to
engi ne bol ts. Ti ghten the bol ts to 36.6 Nm.
7. I nstal l the two (2) mi d cl utch housi ng to engi ne
bol ts. Ti ghten the bol ts to 58.3 Nm.
8. Rai se the engi ne and transmi ssi on wi th the
adjustabl e jackstand.
9. I nstal l the transfer case assembl y. Refer to
Transfer Case i nstal l ati on l ater i n thi s Group.
10. I nstal l the rear crossmember.
Fig. 6 Drain Plug and Backup Light Switch Location
Fig. 7 Marking Propeller Shaft and Axle Yoke
Fig. 8 Vehicle Speed Sensor
Fig. 9 Engine Speed Sensor
11. I nstal l the rear transmi ssi on mount.
12. Connect the transfer case l i nkage and vehi cl e
speed sensor el ectri cal connector and vent tube (Fi g.
8).
13. I nstal l the transmi ssi on ski d pl ate.
14. Al i gn and i nstal l the front and rear propel l er
shafts.
15. I nstal l the exhaust pi pe and heat shi el d.
16. Remove the transmi ssi on jack.
17. Fi l l the transmi ssi on wi th the proper fl ui d
(Fi g. 12).
18. Remove the adjustabl e jackstand from under
the engi ne.
Fig. 10 Transmission to Engine Mounting
Fig. 11 Clutch Housing to Transmission
19. Lower the vehi cl e from the hoi st.
20. I nstal l the shi fter boot and shi fter.
21. Reconnect the battery negati ve cabl e.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Cl utch Housi ng to Engi ne Top (2) Bol ts . . . 36.6 Nm
(27 ft. l bs.)
Cl utch Housi ng to Engi ne Mi d-Poi nt (2) Bol ts . 58.3
Nm (43 ft. l bs.)
Cl utch Housi ng to Engi ne Bottom (2) Bol ts . . . 74.6
Nm (55 ft. l bs.)
Cl utch Housi ng to Transmi ssi on bol ts . 38.0 Nm (28
ft. l bs.)
Transfer Case to Transmi ssi on Attachi ng Nuts . . 35
Nm (26 ft. l bs.)
Propel l er Shaft Bol ts . . . . . . 26.5 Nm (19.5 ft. l bs.)
NV231 TRANSFER CASE
INDEX
page page
GENERAL INFORMATION
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . . 7
RECOMMENDED LUBRICANT AND FILL LEVEL . 7
TRANSFER CASE IDENTIFICATION . . . . . . . . . . 7
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . . 11
REAR RETAINER BUSHING AND SEAL . . . . . . . 11
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 9
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
SPECIAL TOOLSNV231 . . . . . . . . . . . . . . . . . 12
GENERAL INFORMATION
NV231 TRANSFER CASE
The NV231 i s a part-ti me transfer case wi th a l ow
range reducti on gear system. The NV231 has three
operati ng ranges pl us a Neutral posi ti on. A l ow range
system provi des a reducti on rati o for i ncreased l ow
speed torque capabi l i ty.
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range hub. The
front output shaft i s operated by a dri ve chai n that
connects the shaft to a dri ve sprocket on the mai n-
shaft. The dri ve sprocket i s engaged/di sengaged by
the mode fork, whi ch operates the mode sl eeve and
hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
OPERATING RANGES
Transfer case operati ng ranges are:
2WD (2-wheel dri ve)
4x4 (4-wheel dri ve)
4 Lo (4-wheel dri ve l ow range
The 2WD range i s for use on any road surface at
any ti me.
The 4x4 and 4 Lo ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4 Lo range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
are marked on the shi fter bezel cover pl ate.
Recommended l ubri cant for the NV231 transfer case
i s Mopar Dexron I I , or ATF Pl us 3, type 7176. Approx-
i mate l ubri cant fi l l capaci ty i s 1.2 l i ters (2.5 pi nts).
NV231 DIAGNOSIS
DIAGNOSIS CHART
1) Vehicle speed to great to permit
shifting.
1) Slow vehicle and shift into
desired range.
2) If vehicle was operated for an
extended period in 4H mode on dry
surface, driveline torque load may
cause difficulty.
2) Stop vehicle and shift transfer
case to Neutral position. Transfer
case can then be shifted to the
desired mode.
binding.
necessary.
lubricant.
damaged.
necessary.
modes.
lubricant.
Transfer case noisy while in, or
jumps out of, 4L mode.
1) Transfer case not completely
engaged in 4L position.
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of
adjustment.
2) Adjust linkage as necessary.
3) Transfer case shift linkage loose
or binding.
3) Repair, replace, or tighten linkage
components as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
necessary.
5) Low range gear worn or
damaged.
necessary.
seals or vent.
level.
restricted.
necessary.
Abnormal tire wear. 1) Extended operation in 4H mode
on dry surfaces.
1) Operate vehicle in 2H mode on
dry surfaces.
TRANSFER CASE
REMOVAL
(6) Remove rear crossmember and ski d pl ate, i f
equi pped.
(7) Di sconnect and support front/rear propel l er
shafts at transfer case.
range l ever.
mi ssi on.
gage transfer case.
INSTALLATION
to 35 Nm (Fi g. 2).
hose.
on transfer case.
NOTE: Do no reuse bearing straps or bolts. Discard
and replace with new.
(8) Al i gn and connect propel l er shafts. Ti ghten
shaft attachi ng bol ts to 26.5 Nm torque.
(9) Fi l l transfer case wi th correct fl ui d. Refer to
Recommended Lubri cant And Fi l l Level secti on for
proper fl ui d and capaci ty.
(10) I nstal l rear crossmember and ski d pl ate, i f
equi pped. Ti ghten crossmember bol ts.
operati on.
SHIFT LEVER
REMOVAL
(2) Remove transfer case shi fter knob cap.
(3) Remove nut hol di ng shi fter knob to shi ft l ever.
(4) Remove shi fter knob.
(6) Loosen adjusti ng trunni on l ock bol t and sl i de
shi ft l ever.
(7) Remove bol ts hol di ng shi ft l ever to transmi s-
si on.
(8) Separate shi ft l ever from vehi cl e.
INSTALLATION
(1) Posi ti on shi ft l ever on transmi ssi on. Use care
when passi ng the shi ft l ever through the shi fter boot
to prevent damage to the shi fter boot.
(2) I nstal l bol ts to hol d shi ft l ever to transmi ssi on.
(3) I nstal l trunni on to shi ft l ever, i f necessary.
(4) I nstal l shi ft rod to trunni on, i f necessary.
(5) Move shi ft l ever and transfer case to 4L posi -
ti on.
(6) Ti ghten trunni on l ock bol t.
(8) I nstal l shi ft knob on shi ft l ever.
(9) I nstal l nut to hol d shi fter knob to shi ft l ever.
(10) I nstal l shi fter knob cap.
(11) Veri fy transfer case operati on.
SPEEDOMETER
REMOVAL
as an assembl y.
ati on.
pi ni on.
Fig. 3 Shift Lever
i n. l bs.) torque.
REMOVAL
(4) Remove seal from front case wi th pry tool (Fi g.
6).
INSTALLATION
REAR RETAINER BUSHING AND SEAL
REMOVAL
(2) Remove rear propel l er shaft. Refer to Group 3,
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 6957, remove bushi ng from
rear retai ner (Fi g. 8).
Adapter
Fig. 8 Rear Retainer Bushing Removal
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n retai ner.
(3) Usi ng I nstal l er 8160, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 9).
(4) Usi ng I nstal l er C-3995-A, i nstal l seal i n rear
(6) Veri fy proper fl ui d l evel .
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Drai n/Fi l l . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Nuts, Mounti ng . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Swi tch, I ndi cator . . . . . . . . . . . . . . . . . . . . . 26 Nm
SPECIAL TOOLS
SPECIAL TOOLSNV231
Installer, Seal8143
Remover, Bushing6957
Installer, Bushing8160
Installer, SealC-3995-A
Fig. 9 Rear Retainer Bushing Install
Fig. 10 Install Rear Retainer Seal
TIRES AND WHEELS
CONTENTS
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRES
INDEX
page page
RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . . . 2
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . . 3
SPARE TIRETEMPORARY . . . . . . . . . . . . . . . . . 2
TIRE INFLATION PRESSURES . . . . . . . . . . . . . . 2
TIRE INFORMATION . . . . . . . . . . . . . . . . . . . . . . 1
TIRE PRESSURE FOR HIGH SPEED
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . . 3
TIRE NOISE OR VIBRATION . . . . . . . . . . . . . . . . 4
TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . . . . 3
TREAD WEAR INDICATORS . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
MATCH MOUNTING . . . . . . . . . . . . . . . . . . . . . . . 4
REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . . . . 5
ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANING TIRES . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
TIRE SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TIRE INFORMATION
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe brake appl i cati ons
Hi gh speed dri vi ng
Excessi ve speeds on turns
Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val shown i n the secti on on Ti re Rotati on. Thi s wi l l
hel p to achi eve a greater tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 1).
Performance ti res have a speed rati ng l etter after
the aspect rati o number.
LETTER SPEED RATING
S 180 km/h (112 mph)
T 190 km/h (118 mph)
U 200 km/h (124 mph)
H 210 km/h (130 mph)
V 240 km/h (149 mph)
W 270 km/h (168 mph)
Y 300 km/h (186 mph)
The speed rati ng i s not al ways pri nted on the ti re
si dewal l .
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owners Manual for more i nformati on.
XJ TIRES AND WHEELS 22 - 1
RADIAL-PLY TIRES
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
SPARE TIRETEMPORARY
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty and rei nstal l . Do
not exceed speeds of 50 MPH. Refer to Owners Man-
ual for compl ete detai l s.
TIRE INFLATION PRESSURES
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 2).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti res abi l i ty to cushi on shocks (Fi g. 3).
I mproper i nfl ati on can cause:
Uneven wear patterns
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl e.
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once a month. The
spare ti re pressure shoul d be check at l east twi ce
annual l y. Ti re pressure decreases as the ambi ent
temperature drops. Check ti re pressure frequentl y
when ambi ent temperature vari es wi del y.
Fig. 1 Tire Identification
Fig. 2 Under Inflation Wear
Fig. 3 Over Inflation Wear
22 - 2 TIRES AND WHEELS XJ
I nfl ati on pressures speci fi ed on the pl acards are
col d i nfl ati on pressure. The vehi cl e must si t for at
l east 3 hours to obtai n the correct col d i nfl ati on pres-
sure readi ng. Or dri ven l ess than one mi l e after si t-
ti ng for 3 hours. Ti re i nfl ati on pressures may
i ncrease from 2 to 6 pounds per square i nch (psi )
duri ng operati on, due to i ncreased ti re temperature.
WARNING: OVER OR UNDER INFLATED TIRES
CAN AFFECT VEHICLE HANDLING AND TREAD
WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUD-
DENLY, RESULTING IN LOSS OF VEHICLE CON-
TROL.
TIRE PRESSURE FOR HIGH SPEED
OPERATION
Chrysl er Corporati on advocates dri vi ng at safe
speeds wi thi n posted speed l i mi ts. Where speed l i m-
i ts al l ow the vehi cl e to be dri ven at hi gh speeds, cor-
rect ti re i nfl ati on pressure i s very i mportant. For
speeds up to and i ncl udi ng 120 km/h (75 mph), ti res
must be i nfl ated to the pressures shown on the ti re
pl acard.
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at conti nuous speeds above 75 mph
(120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
REPLACEMENT TIRES
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommend that ti res equi val ent to the ori gi -
nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res not l i sted i n the speci fi ca-
ti on charts may cause i nterference wi th vehi cl e com-
ponents. Under extremes of suspensi on and steeri ng
travel , i nterference wi th vehi cl e components may
cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
PRESSURE GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
TREAD WEAR INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 4).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
TIRE WEAR PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 5).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 5).
Fig. 4 Tread Wear Indicators
TIRE NOISE OR VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on,
decel erati on and sl i ght l eft and ri ght steeri ng i nputs.
SERVICE PROCEDURES
ROTATION
Ti res on the front and rear operate at di fferent
l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons they wear at
unequal rates and tend to devel op i rregul ar wear
patterns. These effects can be reduced by rotati ng
the ti res at regul ar i nterval s. The benefi ts of ti re
rotati on are:
I ncrease tread l i fe
Mai ntai n tracti on l evel s
A smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 6).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
MATCH MOUNTING
Ti res and wheel s are currentl y match mounted at
the factory. Match mounti ng i s a techni que used to
reduce runout i n the wheel /ti re assembl y. Thi s means
that the hi gh spot of the ti re i s al i gned wi th the l ow
spot on the wheel ri m. The hi gh spot on the ti re i s
marked wi th a pai nt mark or a bri ght col ored adhe-
si ve l abel on the outboard si dewal l . The l ow spot on
the ri m i s i denti fi ed wi th a l abel on the outsi de of the
ri m and a dot on the i nsi de of the ri m. I f the outsi de
l abel has been removed the ti re wi l l have to be
removed to l ocate the dot on the i nsi de of the ri m.
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Use a di al i ndi cator to l ocate the hi gh spot of
the ti re on the center tread ri b (Fi g. 7). Record the
i ndi cator readi ng and mark the hi gh spot on the ti re.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 8).
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 9).
(3) Measure the total runout agai n and mark the
ti re to i ndi cate the hi gh spot.
(4) I f runout i s sti l l excessi ve use the fol l owi ng
procedures.
(a) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot and i s sti l l excessi ve, repl ace the
ti re.
Fig. 5 Tire Wear Patterns
Fig. 6 Tire Rotation Pattern
(b) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot on the wheel , the wheel may be out
of speci fi cati ons. Refer to Wheel and Ti re Runout.
(c) I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 10). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount.
REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 11). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on.
Fig. 7 Dial Indicator
Fig. 8 First Measurement On Tire
Fig. 9 Remount Tire 180 Degrees
Fig. 10 Remount Tire 90 Degrees In Direction of
Arrow
CLEANING TIRES
Remove protecti ve coati ng on ti res before del i very
of vehi cl e. Thi s coati ng may cause deteri orati on of
ti res.
To remove the protecti ve coati ng appl yi ng warm
water and l et i t soak for a few mi nutes. Then scrub
the coati ng away wi th a soft bri stl e brush. Steam
cl eani ng may al so be used to remove the coati ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or wire brush for cleaning.
SPECIFICATIONS
TIRE SIZE
TIRE SIZE SUPPLIER
P215/75R15 Goodyear
P225/75R15 Goodyear
P225/70R15 Goodyear
Fig. 11 Tire Repair Area
WHEELS
INDEX
page page
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . . 7
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
TIRE AND WHEEL BALANCE . . . . . . . . . . . . . . . . 9
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 10
WHEEL
The ri m si ze i s on the vehi cl e safety certi fi cati on
l abel l ocated on the dri vers door shut face. The si ze
of the ri m i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s/ri ms are desi gned for
operati on up to the speci fi ed maxi mum vehi cl e capac-
i ty.
Al l model s use stamped steel , cast al umi num or
forged al umi num wheel s. Every wheel has rai sed sec-
ti ons between the ri m fl anges and ri m drop wel l
cal l ed safety humps (Fi g. 1).
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. Al l al umi num and some steel wheel s
have wheel stud nuts wi th an enl arged nose. Thi s
enl arged nose i s necessary to ensure proper retenti on
of the wheel s. Do not use repl acement studs or nuts
wi th a di fferent desi gn or l esser qual i ty.
WHEEL INSPECTION
I nspect wheel s for:
Excessi ve run out
Dents or cracks
Damaged wheel l ug nut hol es
Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by ham-
mering, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY AFFECT
THE SAFETY AND HANDLING OF THE VEHICLE.
USED WHEELS ARE NOT RECOMMENDED. THE
SERVICE HISTORY OF THE WHEEL MAY HAVE
INCLUDED SEVERE TREATMENT OR VERY HIGH
MILEAGE. THE RIM COULD FAIL WITHOUT WARN-
ING.
TIRE AND WHEEL RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 2).
Lateral runout i s the wobble of the ti re or wheel .
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Fig. 1 Safety Rim
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 3) and l ateral
runout (Fi g. 4).
STEEL WHEELS: Radi al runout 0.040 i n., Lat-
eral runout 0.045 i n. (maxi mum)
ALUMI NUM WHEELS: Radi al runout 0.030 i n.,
Lateral runout 0.035 i n. (maxi mum)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout, Refer to match mounti ng procedure.
SERVICE PROCEDURES
WHEEL INSTALLATION
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
Fig. 2 Checking Tire/Wheel/Hub Runout
Fig. 3 Radial Runout
Fig. 4 Lateral Runout
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
sequence to the proper torque speci fi cati on (Fi g. 5).
Never use oil or grease on studs or nuts.
WHEEL REPLACEMENT
Wheel s must be repl aced i f they have:
Excessi ve runout
Bent or dented
Leak ai r through wel ds
Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
Load carryi ng capaci ty
Di ameter
Wi dth
Offset
Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
TIRE AND WHEEL BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two
plane balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd l ocati on of heavy spot
causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 6).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 7).
Fig. 5 Lug Nut Tightening Pattern
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Lug Nut
1/2 X 20 wi th 60 Cone . . . . . . . . . . . 115-150 Nm
(85-115 ft. l bs.)
Fig. 6 Static Unbalance & Balance
Fig. 7 Dynamic Unbalance & Balance
BODY
CONTENTS
page page
BODY COMPONENT SERVICE . . . . . . . . . . . . . . 17
GENERAL SERVICE INFORMATION . . . . . . . . . . . 1
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL SERVICE INFORMATION
GENERAL INFORMATION
SAFETY PRECAUTIONS AND WARNINGS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
USE A OSHA APPROVED BREATHING FILTER
WHEN SPRAYING PAINT OR SOLVENTS IN A CON-
FINED AREA. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
Chrysl er Corporati on uses many di fferent types of
push-i n fasteners to secure the i nteri or and exteri or
tri m to the body. Most of these fasteners can be
reused to assembl e the tri m duri ng vari ous repai r
procedures. At ti mes, a push-i n fastener cannot be
removed wi thout damagi ng the fastener or the com-
ponent i t i s hol di ng. I f i t i s not possi bl e to remove a
fastener wi thout damagi ng a component or body, cut
or break the fastener and use a new one when
i nstal l i ng the component. Never pry or pound on a
pl asti c or pressed-board tri m component. Usi ng a
sui tabl e fork-type pryi ng devi ce, pry the fastener
from the retai ni ng hol e behi nd the component bei ng
removed. When i nstal l i ng, veri fy fastener al i gnment
wi th the retai ni ng hol e by hand. Push di rectl y on or
over the fastener unti l i t seats. Appl y a l ow-force pul l
to the panel to veri fy that i t i s secure.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges hol di ng the component i n
pl ace.
XJ BODY 23 - 1
PAINT
INDEX
page page
GENERAL INFORMATION
BASE COAT/CLEAR COAT FINISH . . . . . . . . . . . . 2
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . 2
WET SANDING, BUFFING, AND POLISHING . . . . 2
SPECIFICATIONS
AFTERMARKET PAINT REPAIR PRODUCTS . . . . 3
GENERAL INFORMATION
PAINT CODE
Exteri or vehi cl e body col ors are i denti fi ed on the
Body Code pl ate. The pl ate i s l ocated on the l eft si de
of the dash panel i n the engi ne compartment. Refer
to the I ntroducti on secti on at the front of thi s man-
ual for body code pl ate descri pti on. The pai nt code i s
al so i denti fi ed on the Vehi cl e Safety Certi fi cati on
Label whi ch i s l ocated on the dri vers door shut face.
The col or names provi ded i n the Pai nt and Tri m
Code Descri pti on chart are the col or names used on
most repai r product contai ners.
BASE COAT/CLEAR COAT FINISH
On most vehi cl es a two-part pai nt appl i cati on (base
coat/cl ear coat) i s used. Col or pai nt that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
WET SANDING, BUFFING, AND POLISHING
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl ear coat or si ngl e-stage fi ni shes can be reduced
wi th l i ght wet sandi ng, hand buffi ng, and pol i shi ng.
If the finish has been wet sanded in the past, it
cannot be repeated. Wet sanding operation
should be performed by a trained automotive
paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
PAINTED SURFACE TOUCH-UP
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
TOUCH-UP PROCEDURE
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y wet sanded (1500 gri t) and pol -
i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
23 - 2 BODY XJ
SPECIFICATIONS
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLOR
EXTERIOR
COLOR
CHRY
CODE
*
PPG DuPONT
S-W**
M-S**
AKZO
NOBEL
SIKKENS
ICI**
Flame Red Clear
Coat
PR4 4679 B9326 46916 CHA93:PR4
2NN6B
Chili Pepper Red VEA 5361 B9823 54470 CHA98:VEA HMT3B
Medium Fern
Pearl Coat
RJP 4969 B9524 50270 CHA99:RJP 7CD6B
Forest Green
Pearl Coat
SG8 5065 B9609 51062 CHA95:SG8 7MR8B
Intense Blue Pearl
Coat
VB3 5357 B9822 54468 CHA98:VB3 HMR9B
Desert Sand WTD 5474 B9884 56153 CHA99:WTD KGC7B
Deep Amethyst
Pearl Coat
TCN 5246 B9736 52026 CHA97:TCN
FNE4B
Black Clear Coat DX8 9700 99 34858 CHA85:DX8 TC60B
Gunmetal Pearl
Coat
TQ7 5248 B9735 52952 CHA97:TQ7
ERA9B
Stone White Clear
Coat
SW1 83542 B9622 51539 CHA96:SW1
8KY5B
INTERIOR COLOR
INTERIOR
COLOR
CHRY
CODE*
PPG DuPONT
S-W**
M-S**
AKZO
NOBEL
SIKKENS
ICI**
Agate AZ
9856 /
2-1461
C9208 45994
CHALAZI 7WC8
Camel / Dark
Green
KG N/A N/A N/A
N/A K5/G8
NOTE: *Herberts Standox, Spies Hecker, and BASF
use the Chrysler paint code as listed on the Body
Code Plate and the Vehicle Safety Certification
label. ** S-W = Sherwin-Williams, M-S = Martin
Senour, ICI = ICI Autocolor.
XJ BODY 23 - 3
STATIONARY GLASS
INDEX
page page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . 4
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . . 9
REAR DOOR STATIONARY WINDOW GLASS . . . 7
REAR QUARTER WINDOW GLASS . . . . . . . . . . . 8
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY PRECAUTIONS
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
ADHESIVE BY BRAND. TECHNICIANS SHOULD
REVIEW PRODUCT LABELS AND TECHNICAL DATA
SHEETS, AND USE ONLY ADHESIVES THAT THEIR
MANUFACTURES WARRANT WILL RESTORE A
VEHICLE TO THE REQUIREMENTS OF FMVSS 212.
TECHNICIANS SHOULD ALSO INSURE THAT PRIM-
ERS AND CLEANERS ARE COMPATIBLE WITH THE
PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURERS DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
I t i s di ffi cul t to sal vage a wi ndshi el d duri ng the
removal operati on. The wi ndshi el d i s part of the
structural support for the roof. The urethane bondi ng
used to secure the wi ndshi el d to the fence i s di ffi cul t
to cut or cl ean from any surface. I f the mol di ngs are
set i n urethane, i t woul d al so be unl i kel y they coul d
be sal vaged. Before removi ng the wi ndshi el d, check
the avai l abi l i ty of the wi ndshi el d and mol di ngs from
the parts suppl i er.
WINDSHIELD
The wi ndshi el d i s posi ti oned i n the reveal mol di ng
and i s bonded to the wi ndshi el d frame wi th urethane
adhesi ve.
Dependi ng on the ci rcumstances, ei ther one of two
wi ndshi el d gl ass i nstal l ati on methods can be used:
The short method.
The extended method.
The short method i s used when the wi ndshi el d
gl ass i s removed i ntact, and the body openi ng and
the pi nchwel d fl anges do not requi re repai r.
The extended method must be used when the body
openi ng or a fl ange i s damaged. The extended
method must al so be used when urethane no l onger
adheres to ei ther the wi ndshi el d gl ass or the pi nch-
wel d fl anges.
REMOVAL
(1) Cover the i nteri or and exteri or body surface
areas wi th a protecti ve coveri ng.
(2) Remove the wi ndshi el d wi per arms and the
rearvi ew mi rror.
(3) Usi ng a razor kni fe, sl i de the bl ade between
the wi ndshi el d gl ass and the i nboard edge of the
reveal mol di ng.
(4) Cut around the i nteri or peri meter of the reveal
mol di ng and sever the cap of the reveal mol di ng.
23 - 4 BODY XJ
(5) Usi ng a col d kni fe, cut the urethane around the
peri meter of the wi ndshi el d (Fi g. 1).
(6) Remove the wi ndshi el d gl ass from the frame.
INSTALLATION SHORT METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
(1) Tri m the urethane from the pi nchwel d fl anges.
Leave a 3 mm (0.1 i n.) l evel base of urethane on the
pi nchwel d fl anges.
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(2) Cl ean i nsi de of wi ndshi el d wi th ammoni a based
gl ass cl eaner and l i nt-free cl oth.
(3) Pri me outer peri meter of i nteri or si de of gl ass
16 mm (5/8 i nch) from edge. Use a wi pe-off type ure-
thane pri mer and wi pe gl ass dry after pri mer appl i -
cati on.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Appl y the mol di ng to the wi ndshi el d:
Wi th the mol di ng at room temperature, press
the mol di ng onto the wi ndshi el d corners.
From corner to corner, work the mol di ng to the
center of each si de. (Some stretchi ng of the mol di ng
may be requi red duri ng thi s procedure.)
(5) Pl ace the gl ass on the pi nchwel d fl anges and
i nspect for gaps i n the urethane. Gaps i n excess of 3
mm (1/8 i nch) must be fi l l ed wi th urethane.
(6) Adjust wi ndshi el d gl ass posi ti on unti l i t i s
al i gned wi th the fl anges and adhesi ve.
(7) Usi ng a grease penci l or equi val ent, make
al i gnment marks on the gl ass and body.
(8) Remove repl acement wi ndshi el d from wi nd-
shi el d openi ng.
(9) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 2).
CAUTION: Avoid spilling or dripping primer on
painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.
(10) I f the repl acement wi ndshi el d gl ass does not
have bl ackout pri mer:
Attach a 25 mm (1 i n) wi de maski ng tape band
around the i nteri or si de of the gl ass 16 mm (5/8 i n)
from the edge of the gl ass (Fi g. 3).
Do not attach tape al ong the bottom of the gl ass
and attach it only to the inside of the glass.
Cl ean the 16-mm (5/8-i n) wi de surface area
around the gl ass wi th i sopropyl al cohol .
Thoroughl y mi x and appl y gl ass bl ackout pri mer
to the 16 mm (5/8 i n) surface area around the i nte-
ri or si de of the gl ass (Fi g. 4).
Al l ow the pri mer to dry for at l east 10-12 mi n-
utes.
(11) Appl y a smal l amount of adhesi ve to the bot-
tom support spacers and attach the support spacers
to the bottom of the wi ndshi el d, 170 mm i nboard
from the outer wi ndshi el d edge (Fi g. 5).
(12) Cut the urethane adhesi ve appl i cator nozzl e
(Fi g. 6).
CAUTION: Be prepared to install the glass immedi-
ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
(13) Appl y a conti nuous, 6-mm (1/4-i n) di ameter
bead of urethane adhesi ve to the surface area.
(14) Al i gn the gl ass wi th the reference marks and
posi ti on the gl ass on the pi nchwel d fl anges. Ensure
that the wi ndshi el d gl ass i s correctl y seated on the
support spacers.
(15) Force the wi ndshi el d gl ass i nward just enough
to wet-out and set the urethane. Use care to avoi d
excessi ve squeeze-out of adhesi ve.
(16) Water test the wi ndshi el d wi th a water spray
after i nstal l ati on. Do not di rect hi gh pressure
streams of water di rectl y at urethane. I f any l eaks
are detected, appl y urethane as necessary.
(17) I f used, remove the maski ng tape from the
i nner surface of the gl ass.
(18) I nstal l al l components and cl ean the vehi cl e.
Fig. 1 Cutting Urethane Around WindshieldTypical
XJ BODY 23 - 5
(19) Open the vehi cl e wi ndows to prevent i nteri or
pressure whi l e the urethane i s curi ng. If not
vented, pressure in the interior of the vehicle
may interfere with proper glass bonding.
(20) I nstal l the rearvi ew mi rror.
INSTALLATION EXTENDED METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
(1) Remove the al l of urethane from al l pi nchwel d
fl anges.
(2) I nspect and repai r the wi ndshi el d openi ng and
pi nchwel d fl anges.
(3) Pri me the pi nchwel d fl anges wi th a urethane
base pri mer. However, i f the fl ange i s col or-coated
wi th pai nt, pri me the fl anges wi th a pai nt fi ni sh
pri mer. This is important because urethane
adhesive will not adhere to all color-coat
paints. Al l ow pri mer suffi ci ent ti me to dry.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Appl y the reveal mol di ng to the wi ndshi el d:
Wi th the mol di ng at room temperature, press
the mol di ng onto the wi ndshi el d corners.
From corner to corner, work the mol di ng to the
center of each si de. (Some stretchi ng of the mol di ng
may be requi red duri ng thi s procedure).
(5) I nstal l and i nspect the fi t of the wi ndshi el d on
the pi nchwel d fl anges as fol l ows:
Posi ti on wi ndshi el d unti l i t i s al i gned wi thi n
wi ndshi el d openi ng.
Fig. 2 Work Surface Set up
Fig. 3 Masking Tape Location For Blackout Primer
Fig. 4 Blackout Primer Application
Fig. 5 Windshield Bottom Support Spacers
23 - 6 BODY XJ
Measure the gap between the pi nchwel d fl anges
and gl ass around peri meter of the gl ass and fl ange.
The reveal mol di ng shoul d equal l y cover the
A-Pi l l ars on both si des.
The fl anges shoul d al so extend above the gl ass
edge equal l y around the peri meter of the openi ng.
(6) I f the pi nchwel d fl anges requi re repai r, remove
the wi ndshi el d gl ass and strai ghten, al i gn, or repai r
the fl ange(s) as necessary.
(7) Posi ti on the wi ndshi el d i n the openi ng and
i nspect the wi ndshi el d fi t agai n. Mark the wi ndshi el d
fi nal posi ti on on the gl ass and body wi th a wax pen-
ci l (or use maski ng tape). The marks (or maski ng
tape) wi l l be used for i nstal l ati on al i gnment refer-
ence.
(8) I f the repl acement wi ndshi el d does not have
bl ackout pri mer:
Attach a 25-mm (1-i n) wi de maski ng tape band
around the i nteri or si de of gl ass 16 mm (5/8 i n) from
edge of gl ass (Fi g. 3).
Do not attach tape al ong the bottom of the gl ass
and attach only to the inside of glass.
Thoroughl y mi x and appl y bl ackout pri mer to
the 16 mm (5/8 i n) surface area around the i nteri or
si de of the gl ass (Fi g. 4).
Al l ow the pri mer to dry for at l east 10-12 mi n-
utes.
(9) Appl y a smal l amount of adhesi ve to the bot-
tom support spacers and attach the support spacers
to the bottom of the wi ndshi el d, 170 mm i nboard
from the outer wi ndshi el d edge (Fi g. 5).
(10) Cut the urethane appl i cator nozzl e (Fi g. 6).
(11) Appl y a conti nuous bead of urethane to the
surface area wi th bl ackout pri mer on the i nteri or
si de of gl ass. The bead shoul d be 9-mm (3/8-i n) wi de
by 12.7-mm (1/2-i n) deep for best resul ts.
CAUTION: Be prepared to install the glass immedi-
ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
(12) Al i gn the wi ndshi el d wi th the wax penci l
i nstal l ati on al i gnment reference marks (or the tape
stri ps). Posi ti on the wi ndshi el d on pi nchwel d fl anges
and spacers.
(13) Force the wi ndshi el d i nward just enough to
wet-out and set the urethane. Use care to avoi d
excessi ve squeeze-out of adhesi ve.
(14) Water test the wi ndshi el d wi th a water spray
after i nstal l ati on. Do not di rect hi gh pressure
streams of water di rectl y at the urethane. I f any
l eaks are detected, appl y urethane as necessary.
(15) I f used, remove the maski ng tape from the
i nner surface of gl ass.
(16) I nstal l al l components and cl ean the vehi cl e.
I f necessary, refer to the i nstal l ati on procedures.
(17) Open the vehi cl e wi ndows to prevent i nteri or
pressure whi l e the urethane adhesi ve i s curi ng. If
not vented, pressure in the interior of vehicle
will interfere with glass bonding.
(18) I nstal l the rearvi ew mi rror on the bracket.
REAR DOOR STATIONARY WINDOW GLASS
REMOVAL
The rear door stati onary wi ndow gl ass i s bonded to
the di vi si on bar and i s servi ced as an assembl y.
(1) Lower the wi ndow gl ass.
(2) Remove the i nner and outer bel tl i ne weather-
stri p.
(3) Remove the tri m panel and waterdam from
door i nner panel .
(4) Remove the screws attachi ng the di vi si on bar/
gl ass to the door (Fi g. 7).
(5) Ti l t the di vi si on bar/gl ass forward and remove
i t from the door.
Fig. 6 Applicator Nozzle Preparation
Fig. 7 Division Bar/Stationary Glass
XJ BODY 23 - 7
INSTALLATION
(1) Posi ti on the di vi si on bar/gl ass i n the door.
(2) I nstal l the screws attachi ng the di vi si on bar/
gl ass to the door. Fi nger ti ghten the screws.
(3) Ti ghten the upper screw to 6 Nm (5 ft-l bs)
torque.
(4) Ti ghten the l ower screw to 6 Nm (5 ft-l bs)
torque.
(5) I nstal l the bel tl i ne weatherstri p.
(6) I nstal l the door waterdam and tri m panel .
REAR QUARTER WINDOW GLASS
REMOVAL
(1) I f equi pped, remove the quarter wi ndow reveal
mol di ng (Fi g. 8).
(2) Remove the quarter wi ndow i nteri or tri m cov-
ers.
(3) Separate the weatherstri p seal l i p from the
wi ndow openi ng fl anges. Use a pry tool and careful l y
push the wi ndow gl ass and seal outward.
(4) Remove the weatherstri p seal and wi ndow
gl ass from wi ndow openi ng.
(5) Remove the weatherstri p seal from the wi ndow
gl ass.
INSTALLATION
(1) Cl ean the ori gi nal seal ant from the weather-
stri p channel s and wi ndow openi ng fl anges.
(2) Appl y a 4-mm (1/6-i n) di ameter bead of seal ant
to the wi ndow channel i n the weatherstri p seal .
(3) I nstal l the weatherstri p on the wi ndow gl ass.
I nstal l the seal i nstal l ati on cord i n the wi ndow open-
i ng fl ange channel (Fi g. 9) as fol l ows:
Moi sten a l ength of 6-mm (1/4-i n) di ameter cord
wi th a soap and water sol uti on.
Ensure that the cord i s l ong enough to go al l the
way around the peri meter of the weatherstri p.
I nsert the cord i nto the wi ndow openi ng fl ange
channel i n the weatherstri p seal .
(4) Appl y a 6-mm (1/4-i n) di ameter bead of seal ant
to the wi ndow openi ng fl anges.
(5) For two-door vehi cl es, appl y a 3-mm (1/8-i n)
di ameter bead of seal ant at the quarter panel appl i -
que and l i ftgate pi l l ar seam.
(6) Posi ti on the quarter wi ndow gl ass and the
weatherstri p seal i n the wi ndow openi ng (Fi g. 10)
wi th the free ends of the cord i nsi de the vehi cl e (Fi g.
11).
(7) Pul l on each end of the cord to pul l the weath-
erstri p seal channel l i p over the wi ndow openi ng
fl anges.
(8) Test the vent wi ndow for water l eaks.
(9) I nstal l the i nteri or tri m cover.
(10) I f equi pped, i nstal l the quarter wi ndow reveal
mol di ng.
Fig. 8 Quarter Window Reveal Molding, Glass and
Seal
Fig. 9 Weatherstrip Seal and Cord Installation
Fig. 10 Quarter Window With Vent
23 - 8 BODY XJ
LIFTGATE GLASS
REMOVAL
(1) Open l i ftgate.
(2) Remove l i ftgate tri m panel .
(3) Di sconnect heated backl i te (HBL) connector.
(4) Remove wi per arm.
(5) Remove CHMSL l ens.
(6) Usi ng a razor kni fe, sl i de the bl ade between
the l i ftgate gl ass and the i nboard edge of the reveal
mol di ng.
(7) Cut around the i nteri or peri meter of the reveal
mol di ng and severe the cap of the reveal mol di ng.
(8) Usi ng a col d kni fe, cut urethane bondi ng from
around l i ftgate gl ass. A pneumati c cutti ng devi ce can
be used i f avai l abl e.
(9) Separate gl ass from Li ftgate.
INSTALLATION
CAUTION: Open a window before installing glass.
This will avoid pressurizing the passenger compart-
ment. If a door or liftgate is slammed before ure-
thane is cured, water leaks can result.
(1) Tri m the urethane from the l i ftgate gl ass open-
i ng fl anges. Leave a 3 mm (0.1 i n.) l evel base of ure-
thane on the fl anges.
(2) Starti ng i n the corners, press reveal mol di ng
onto gl ass.
(3) Pl ace repl acement gl ass i nto l i ftgate openi ng
and posi ti on gl ass i n the center of the openi ng
agai nst fl ange.
(4) Veri fy the gl ass l ays evenl y agai nst the fence at
the si des, top and bottom. I f not, the fl ange must be
formed to the shape of the new gl ass.
(5) Usi ng a grease penci l or equi val ent, make ref-
erences marks on the gl ass and body.
(6) Remove repl acement gl ass from l i ftgate open-
i ng.
(7) Posi ti on the gl ass i nsi de up on a sui tabl e work
surface.
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(8) Cl ean i nsi de of gl ass wi th Mopar Gl ass Cl eaner
and l i nt-free cl oth.
(9) Appl y PVC (vi nyl ) pri mer 25 mm (1 i n.) wi de
around edge of gl ass. Wi pe wi th cl ean/dry l i nt-free
cl oth.
(10) I f necessary, appl y fence pri mer around edge
of fence. Al l ow at l east ei ghteen mi nutes dryi ng ti me.
(11) Appl y a 10 mm (0.4 i n.) bead of urethane
around gl ass border.
(12) Posi ti on gl ass i nto l i ftgate openi ng and refer-
ence marks.
(13) Push the gl ass i nward unti l the reveal mol d-
i ng i s seated onto the l i ftgate frame. Use care to
avoi d excessi ve squeeze-out of adhesi ve.
(14) Open wi ndows to prevent pressure bui l d-up
whi l e the urethane i s curi ng.
(15) Appl y 150 mm (6 i n.) l engths of 50 mm (2 i n.)
maski ng tape spaced 250 mm (10 i n.) apart to hol d
gl ass i n pl ace unti l urethane cures.
(16) I nstal l the wi per arm.
(17) I nstal l CHMSL l ens.
(18) Connect heated backl i te (HBL) connector.
(19) After urethane has cured, remove tape stri ps
and water test to veri fy repai r.
(20) I nstal l l i ftgate tri m panel .
Fig. 11 Quarter Window Glass and Seal Installation
XJ BODY 23 - 9
SEATS
INDEX
page page
BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BUCKET SEAT CUSHION COVER . . . . . . . . . . . 13
BUCKET SEAT PLATFORM . . . . . . . . . . . . . . . . 12
BUCKET SEAT RECLINER . . . . . . . . . . . . . . . . . 14
BUCKET SEAT TRACK . . . . . . . . . . . . . . . . . . . . 12
BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . . . 13
BUCKET SEATBACK COVER . . . . . . . . . . . . . . . 12
HEAD RESTRAINT COVER . . . . . . . . . . . . . . . . 11
HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . . . . 10
REAR SEAT CUSHION . . . . . . . . . . . . . . . . . . . . 14
REAR SEAT CUSHION COVER . . . . . . . . . . . . . 15
REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . 15
REAR SEATBACK COVER . . . . . . . . . . . . . . . . . 16
REAR SEATBACK LATCH STRIKER AND
BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SPECIAL TOOLS
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HEAD RESTRAINT SLEEVE
REMOVAL
NOTE: When replacing a head restraint sleeve, the
retaining tabs on the sleeve will be damaged during
the removal process. Check the availability of
replacement parts before servicing.
(1) Rai se head restrai nt to the ful l up posi ti on.
(2) Turn head restrai nt l ock thumbwheel to rel ease
head restrai nt and pul l head restrai nt upward to
remove from seat back.
(3) I nsert head restrai nt sl eeve extractor (speci al
tool 6773) (Fi g. 1) and (Fi g. 2) i nto the seat back.
(4) The retai ni ng tabs are posi ti oned on each si de
of the sl eeve, when i nserti ng the extractor, ensure
that the fl at of the col l ar i s faci ng the si de of the
seatback (Fi g. 3).
(5) Usi ng a smal l hammer, tap extractor down-
ward to rel ease sl eeve retai ni ng tab.
(6) Remove extractor tool from sl eeve, rotate tool
180 degrees (Fi g. 4) and repeat steps 3 and 4.
(7) Remove extractor tool from sl eeve and remove
sl eeve from seat back.
INSTALLATION
(1) Posi ti on the sl eeve i n the seat back.
(2) Fi rml y, push sl eeve down to snap i nto pl ace.
(3) I nstal l head restrai nt.
Fig. 1 Head Restraint Sleeve Extractor
Fig. 2 Head Restraint Sleeve Extractor Installation
23 - 10 BODY XJ
HEAD RESTRAINT COVER
REMOVAL
(1) Remove head restrai nt from the bucket seat.
(2) Remove the screws attachi ng the bezel and
adjuster bar to the head restrai nt (Fi g. 5).
(3) Pul l the adjuster bar from the head restrai nt.
(4) Rol l the cover upward and separate from the
head restrai nt cushi on (Fi g. 6).
INSTALLATION
(1) Posi ti on the cover on the head restrai nt cush-
i on and rol l the cover downward.
(2) Posi ti on the adjuster bar i n the head restrai nt.
(3) I nstal l the screws attachi ng the bezel and
adjuster bar to the head restrai nt.
(4) I nstal l head restrai nt i n the bucket seat.
BUCKET SEAT
REMOVAL
(1) Remove bol ts attachi ng seat to fl oor pan (Fi g.
7).
(2) Remove nut attachi ng seat to fl oor pan.
(3) For power seat, di sconnect wi re harness con-
nector. I f equi pped, di sconnect wi re harness for
heated seat.
(4) Di sconnect seat bel t buckl e warni ng wi re har-
ness connector.
(5) Separate seat from fl oor panel .
INSTALLATION
(1) Posi ti on seat on fl oor pan.
Fig. 3 Head Restraint Sleeve Extractor Positioning
Fig. 4 Head Restraint Sleeve Extractor Positioning
Fig. 5 Head Restraint
Fig. 6 Head Restraint Cover
XJ BODY 23 - 11
(2) Connect seat bel t buckl e warni ng wi re harness
connector.
(3) For power seats, connect wi re harness connec-
tor. I f equi pped, connect harness for heated seat.
(4) I nstal l front fasteners attachi ng seat to fl oor
pan. Ti ghten to 27 Nm (20 ft. l bs.) torque.
(5) I nstal l rear fasteners attachi ng seat to fl oor
pan. Ti ghten to 27 Nm (20 ft. l bs.) torque.
(6) I nstal l nut attachi ng seat to fl oor pan. Ti ghten
to 40 Nm (30 ft. l bs.) torque.
BUCKET SEAT TRACK
REMOVAL
NOTE: If the vehicle is equipped with manually
adjusted bucket seats, the inboard or outboard seat
track may be serviced separately.
(1) Remove bucket seat from vehi cl e.
(2) Remove screws attachi ng the si de shi el d tri m
cover from the seat.
(3) I f equi pped, di sengage the power seat connec-
tor from the power seat swi tch.
(4) Remove the nuts attachi ng the seat track to
the bucket seat pl atform.
(5) When separati ng the seat track from the pl at-
form, route the power seat swi tch connector through
the access hol e i n the seat cushi on frame, i f
equi pped.
INSTALLATION
(1) Whi l e posi ti oni ng the seat track on the bucket
seat pl atform, route the power seat swi tch connector
through the access hol e i n the seat cushi on frame, i f
equi pped.
(2) I nstal l the nuts attachi ng the seat track to the
bucket seat pl atform.
(3) I f equi pped, engage the power seat connector to
the power seat swi tch.
(4) I nstal l screws attachi ng the si de shi el d tri m
cover to the seat.
(5) I nstal l bucket seat.
BUCKET SEAT PLATFORM
Bucket seat pl atforms are not repai rabl e. I f the
seat pl atform i s damaged, repl ace pl atform as a uni t.
BUCKET SEATBACK COVER
REMOVAL
(1) Remove head restrai nt, i f equi pped.
(2) Remove screws attachi ng si de shi el d tri m cover
to bucket seat.
(3) I f equi pped, di sengage power seat wi re connec-
tor from power seat swi tch.
(4) Remove the i nboard seatback pi vot bol t.
(5) Posi ti on the seatback i n the ful l forward or ful l
recl i ne posi ti on.
(6) Remove the seatback cover zi pper from the
base of the seatback.
(7) Di sengage the cover zi pper and route the zi p-
per end between the i nboard seatback and seat cush-
i on frame.
(8) Rol l the seatback cover upward (Fi g. 8).
(9) Di sengage the hogri ngs attachi ng the seatback
cover to the seatback cushi on support wi res (Fi g. 9).
(10) Rol l the seatback cover upward and di sengage
the hook and l oop fastener (Fi g. 10).
(11) Rol l seatback cover up and over the head
restrai nt sl eeves, i f equi pped and separate from the
seatback.
INSTALLATION
(1) Posi ti on the seatback cover on the seatback
cushi on and rol l seatback cover down over the head
restrai nt sl eeves. Route the sl eeves through the
access hol es i n the cover, i f equi pped.
(2) Rol l the seatback cover downward and engage
the hook and l oop fastener.
(3) Conti nue rol l i ng the cover downward and
engage the hogri ngs attachi ng the seatback cover to
the seatback cushi on support wi res.
(4) Route the zi pper end between the i nboard seatback
and seat cushi on frame and engage the cover zi pper.
(5) I nstal l the i nboard seatback pi vot bol t.
(6) I nstal l the si de shi el d tri m cover.
(7) I nstal l head restrai nt, i f equi pped.
Fig. 7 Bucket SeatPower Seat
23 - 12 BODY XJ
BUCKET SEATBACK
REMOVAL
(1) Remove si de shi el d tri m cover.
(2) Remove i nboard seatback pi vot bol t.
(3) Remove bol ts attachi ng recl i ner to seat cushi on
frame (Fi g. 11).
(4) Separate seatback from vehi cl e.
INSTALLATION
(1) Posi ti on seatback on seat cushi on frame.
(2) I nstal l i nboard seatback pi vot bol t.
(3) I nstal l bol ts attachi ng recl i ner to seat cushi on
frame.
(4) I nstal l si de shi el d tri m cover.
BUCKET SEAT CUSHION COVER
REMOVAL
(1) Remove seat from vehi cl e.
(3) Remove seatback.
(4) Wi th the cushi on si de down, di sengage the for-
ward, rearward and i nboard J-straps.
(5) Di sengage the cl i ps attachi ng the outboard si de
of the cover to the cushi on frame.
(6) Turn the cushi on over and rol l the cover off the
cushi on.
(7) Remove the hog ri ngs attachi ng the cover to
the cushi on support wi res (Fi g. 12).
(8) Separate the cover from the cushi on.
INSTALLATION
(1) Posi ti on the cover on the cushi on.
(2) I nstal l the hog ri ngs attachi ng the cover to the
cushi on support wi res.
(3) Wi th the cushi on si de down, engage the for-
ward, rearward and i nboard J-straps.
(4) Engage the cl i ps attachi ng the outboard si de of
the cover to the cushi on frame.
Fig. 8 Seatback Cover
Fig. 9 Hog Ring
Fig. 10 Hook And Loop Fastener
Fig. 11 Bucket Seatback
XJ BODY 23 - 13
(5) I nstal l seatback.
(7) I nstal l seat.
BUCKET SEAT RECLINER
REMOVAL
(2) Di sengage seatback cover zi pper.
(3) Rol l outer seatback cover upward.
(4) Remove bol ts attachi ng recl i ner to seatback
and seat cushi on frames (Fi g. 13).
(5) Separate recl i ner from seat.
INSTALLATION
(1) Posi ti on recl i ner on seat.
(2) I nstal l bol ts attachi ng recl i ner to seatback and
seat cushi on frames (Fi g. 13).
(3) Rol l seatback cover downward.
(4) Engage seatback cover zi pper.
REAR SEAT CUSHION
REMOVAL
(1) Di sengage seat cushi on at rear by pul l i ng
upward on rel ease strap (Fi g. 14).
(2) Ti l t seat cushi on forward.
(3) Di sengage seat cushi on l atch wi th ri ght si de
rel ease l ever. Separate ri ght si de l atch and l eft si de
seat bracket from fl oor anchor bol ts, and remove
cushi on from vehi cl e (Fi g. 15).
Fig. 12 Seat Cushion Cover Hog Rings
Fig. 13 Bucket Seat Recliner
Fig. 14 Seat Cushion Release Strap
Fig. 15 Rear Seat Cushion/Seat Back
23 - 14 BODY XJ
INSTALLATION
(1) Posi ti on seat cushi on i n vehi cl e.
(2) I nsert l eft pi vot i n anchor grommet.
(3) Force ri ght si de l atch onto anchor bol t and
pi vot seat cushi on to hori zontal posi ti on.
(4) Lock seat cushi on i n-pl ace by pressi ng fi rml y
on center of cushi on unti l l atch engages.
REAR SEATBACK
REMOVAL
(1) Di sengage the seat cushi on at the rear by pul l -
i ng upward on the rel ease strap.
(2) Ti l t the seat cushi on forward.
(3) Remove the shoul der/l ap bel t buckl es from the
el asti c straps.
(4) Rel ease the seatback l atch from the stri ker.
(5) Remove the pi vot bol ts and the washers from
the wheel house panel anchors (Fi g. 15).
(6) Ti l t the seatback forward, l i ft i t upward and
remove i t from the vehi cl e.
INSTALLATION
(1) Posi ti on the seatback i n the vehi cl e.
(2) I nstal l the pi vot bol ts and the washer. Ti ghten
the bol ts wi th 33 Nm (25 ft. l bs.) torque.
(3) Engage the seatback l atch wi th the stri ker.
(4) I nsert the shoul der/l ap bel t buckl es i n the el as-
ti c straps.
(5) Pi vot the seat cushi on to the hori zontal posi -
ti on and l ock i t i n-pl ace by pressi ng fi rml y on the
center of the cushi on unti l the l atch engages.
REAR SEAT CUSHION COVER
REMOVAL
(1) Remove the seat cushi on from the vehi cl e.
(2) Remove the cover si de, front and rear retai ni ng
cl i ps from the wi re retai ners wi th an appropri ate
removal tool (Fi g. 16).
(3) Remove the serrated retai ners from the front
ends of the cover wi th a tri m panel removal tool (Fi g.
17).
(4) Remove the seat cover from the cushi on.
INSTALLATION
(1) Posi ti on the repl acement cover on the cushi on.
(2) Compress the cover and attach the retai ni ng
cl i ps to the front and rear wi re retai ners.
(3) I nstal l the serrated retai ners at the ends of the
cover.
(4) I nstal l the seat cushi on i n the vehi cl e. I f neces-
sary, refer to the i nstal l ati on procedure.
REAR SEATBACK LATCH STRIKER AND
BUMPER
REMOVAL
(1) Di sengage seat cushi on at the rear by pul l i ng
upward on the rel ease strap.
(2) Ti l t seat cushi on forward.
(3) Rel ease seatback l atch from stri ker.
(4) Ti l t seatback forward for access to stri ker
bracket.
(5) Remove screws (Fi g. 18) attachi ng l atch stri ker
bracket and shi ms to tri m panel .
INSTALLATION
(1) Posi ti on shi ms and l atch stri ker bracket on
tri m panel .
Fig. 16 Seat Cushion Cover Retaining Clip Removal
Fig. 17 Seat Cushion Cover Retaining Clip Removal
XJ BODY 23 - 15
(2) I nstal l screws attachi ng l atch stri ker bracket
and shi ms to tri m panel . Ti ghten screws to 6 Nm (50
i n. l bs.) torque.
(3) Engage seatback l atch wi th stri ker.
(4) Pi vot seat cushi on to hori zontal posi ti on and
l ock i t i n-pl ace by pressi ng fi rml y on center of the
cushi on unti l l atch engages.
REAR SEATBACK COVER
REMOVAL
(1) Remove the seatback from the vehi cl e.
(2) Remove the seatback l atch rel ease handl e and
bezel from the seatback.
(3) Di sengage the cover zi ppers.
(4) Di sengage the J-strap attachi ng the cover to
the seat back frame (Fi g. 19).
(5) Remove the cover from the seatback pad.
INSTALLATION
(1) I nstal l the cover on the seatback.
(2) Attach the cover J-strap to the seatback frame.
(3) Engage the cover zi ppers.
(4) I nstal l the seat l atch rel ease bezel and handl e.
(5) I nstal l the seatback i n the vehi cl e.
SPECIAL TOOLS
SEATS
Fig. 18 Seatback Latch Striker Bracket
Fig. 19 Seatback Cover Removal
Extractor Head Restraint Sleeve 6773
23 - 16 BODY XJ
BODY COMPONENT SERVICE
INDEX
page page
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SERVICE PROCEDURES
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . . 19
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 44
AIR EXHAUST GRILLE . . . . . . . . . . . . . . . . . . . . 43
ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . . . . 45
B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 45
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . 24
BODY SIDE MOLDING . . . . . . . . . . . . . . . . . . . . 42
C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 45
COWL GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COWL WEATHERSTRIP . . . . . . . . . . . . . . . . . . . 24
DOOR SILL SCUFF PLATE . . . . . . . . . . . . . . . . . 45
DRIP RAIL MOLDING . . . . . . . . . . . . . . . . . . . . . 42
EXTERIOR NAMEPLATES . . . . . . . . . . . . . . . . . 25
FRONT CARPET/MAT . . . . . . . . . . . . . . . . . . . . 50
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . . 35
FRONT DOOR GLASS EXTERIOR MOLDING . . . 34
FRONT DOOR GLASS RUN CHANNEL
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 33
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . . 30
FRONT DOOR INNER BELT WEATHERSTRIP . . 32
FRONT DOOR INSIDE HANDLE ACTUATOR . . . 32
FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . . 31
FRONT DOOR LATCH STRIKER . . . . . . . . . . . . 32
FRONT DOOR LOCK CYLINDER . . . . . . . . . . . . 31
FRONT DOOR OPENING SECONDARY
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 33
FRONT DOOR OPENING WEATHERSTRIP . . . . 33
FRONT DOOR OUTER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 32
FRONT DOOR OUTSIDE HANDLE . . . . . . . . . . . 31
FRONT DOOR RESTRAINT . . . . . . . . . . . . . . . . 30
FRONT DOOR SPACER BLOCKSTWO-DOOR
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . . . 28
FRONT DOOR WATERDAM . . . . . . . . . . . . . . . . 29
FRONT DOOR WINDOW REGULATOR . . . . . . . 34
FRONT FENDER FLARE . . . . . . . . . . . . . . . . . . 26
FRONT INNER SCUFF PLATE . . . . . . . . . . . . . . 45
FRONT SHOULDER BELT/BUCKLE . . . . . . . . . . 48
FRONT WHEELHOUSE LINER . . . . . . . . . . . . . . 27
FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . . . 50
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GRILLE OPENING PANEL (GOP) . . . . . . . . . . . . 20
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . 20
HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HOOD LATCH STRIKER . . . . . . . . . . . . . . . . . . . 22
HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . . 22
HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . . . 23
HOOD SILENCER PAD . . . . . . . . . . . . . . . . . . . . 23
LEFT FRONT FENDER . . . . . . . . . . . . . . . . . . . . 27
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . . . . 54
LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . . . 55
LIFTGATE LATCH STRIKER . . . . . . . . . . . . . . . . 56
LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . . 55
LIFTGATE OPENING UPPER TRIM . . . . . . . . . . 47
LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . . 55
LIFTGATE PILLAR TRIM . . . . . . . . . . . . . . . . . . 47
LIFTGATE SCUFF PLATE . . . . . . . . . . . . . . . . . . 48
LIFTGATE SUPPORT ROD BALL STUD . . . . . . 55
LIFTGATE SUPPORT ROD CYLINDER . . . . . . . . 54
LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . . 53
LIFTGATE WEATHERSTRIP . . . . . . . . . . . . . . . . 56
LOWER A-PILLAR COWL TRIM . . . . . . . . . . . . . 44
LUGGAGE RACK . . . . . . . . . . . . . . . . . . . . . . . . 43
QUARTER PANEL TRIM AND WHEELHOUSE
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
QUARTER PANEL TRIM EXTENSION . . . . . . . . . 46
QUARTER WINDOW APPLIQUE . . . . . . . . . . . . . 42
REAR CARPET/MAT . . . . . . . . . . . . . . . . . . . . . 50
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
REAR DOOR GLASS EXTERIOR MOLDING . . . . 40
REAR DOOR GLASS RUN CHANNEL
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 39
REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . . . 38
REAR DOOR INNER BELT WEATHERSTRIP . . . 39
REAR DOOR INSIDE HANDLE ACTUATOR . . . . 39
REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . . . 38
REAR DOOR LATCH STRIKER . . . . . . . . . . . . . 39
REAR DOOR OUTER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . . . 39
REAR DOOR OUTSIDE HANDLE . . . . . . . . . . . . 38
REAR DOOR RESTRAINT . . . . . . . . . . . . . . . . . 37
REAR DOOR TRIM PANEL . . . . . . . . . . . . . . . . . 36
REAR DOOR WATERDAM . . . . . . . . . . . . . . . . . 37
REAR DOOR WEATHERSTRIP . . . . . . . . . . . . . 40
REAR DOOR WINDOW GLASS . . . . . . . . . . . . . 41
REAR DOOR WINDOW REGULATOR . . . . . . . . 40
REAR FENDER FLARE . . . . . . . . . . . . . . . . . . . 42
REAR SHOULDER/LAP BELT/BUCKLE . . . . . . . . 49
XJ BODY 23 - 17
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . 51
REARVIEW MIRROR SUPPORT BRACKET . . . . 51
RIGHT FRONT FENDER . . . . . . . . . . . . . . . . . . 27
SAFETY LATCH STRIKER . . . . . . . . . . . . . . . . . 23
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . 26
SUNVISORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
ADJUSTMENTS
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DOOR LATCH ADJUSTMENT . . . . . . . . . . . . . . . 57
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . 58
SPECIFICATIONS
BODY GAP AND FLUSH MEASUREMENTS . . . 117
BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . . . 58
BODY OPENING DIMENSIONS . . . . . . . . . . . . 118
BODY SEALING LOCATIONS . . . . . . . . . . . . . . 102
STRUCTURAL ADHESIVE LOCATIONS . . . . . . 114
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 125
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 59
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water-test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons refer to Group 0,
Lubri cati on and Mai ntenance, General I nformati on
secti on.
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
23 - 18 BODY XJ
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
cross wi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose
mol di ngs can fl utter, creati ng a buzzi ng or chatteri ng
noi se. An open cavi ty or protrudi ng edge can create a
whi stl i ng or howl i ng noi se. I nspect the exteri or of the
vehi cl e to veri fy that these condi ti ons do not exi st.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f compo-
nent al i gnment or seal i ng i s necessary, refer to the
appropri ate secti on of thi s group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
SERVICE PROCEDURES
BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
sengers cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng):
Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
XJ BODY 23 - 19
GRILLE
REMOVAL
(1) Remove the headl amp/park l amp bezel s.
(2) Remove the screws attachi ng the gri l l e to the
gri l l e openi ng panel (GOP) (Fi g. 1).
(3) Separate the gri l l e from the GOP.
INSTALLATION
(1) Posi ti on the gri l l e i n the GOP.
(2) I nstal l the screws.
(3) I nstal l the headl amp/park l amp bezel s.
GRILLE OPENING PANEL (GOP)
REMOVAL
(1) Remove headl amp bezel s.
(2) Remove gri l l e.
(3) Remove si de marker l amps.
(4) Remove headl amps and park/turn si gnal
l amps.
(5) Open hood.
(6) Remove nuts that attach GOP to front fenders
(Fi g. 2).
(7) Remove nuts attachi ng GOP to support
bracket.
(8) Pul l GOP forward and di sconnect harness cl i ps
and front l amp harness connectors.
(9) Remove GOP from vehi cl e.
INSTALLATION
(1) Pl ace GOP on bumper and secure al l harness
cl i ps.
(2) Connect al l l amp wi re harness connectors.
(3) Posi ti on GOP on vehi cl e.
(4) I nstal l nuts attachi ng GOP to front fenders.
Ti ghten nuts to 4 Nm (38 i n-l bs) torque.
(5) I nstal l nuts attachi ng GOP to support bracket.
Ti ghten nuts to 4 Nm (38 i n-l bs) torque.
(6) I nstal l headl amps and park/turn si gnal l amps.
(7) I nstal l gri l l e.
(8) I nstal l si de marker l amps.
(9) I nstal l headl amp bezel s.
(10) Adjust headl amp ai m, i f necessary.
HOOD
REMOVAL
(1) Rai se hood.
(2) Di sconnect underhood l amp wi re harness con-
nector, i f equi pped.
(3) Di sconnect rel ease cabl e from l atch rel ease
bel l crank.
(4) Remove l atch rel ease cabl e cl i ps and remove
cabl e from hood (Fi g. 3).
(5) Mark l ocati on of hood, hi nges and hi nge shi ms
for i nstal l ati on.
(6) Remove bol ts that attach hi nges to hood.
(7) Remove hood from vehi cl e wi th ai d of a hel per.
INSTALLATION
(1) Posi ti on hood on shi ms and hi nges; fi nger-
ti ghten hi nge bol ts.
(2) Al i gn hi nges and shi ms wi th reference marks
and ti ghten hi nge bol ts.
(3) Connect l atch rel ease cabl e and l atch connect-
i ng rod to bel l crank.
(4) Attach l atch rel ease cabl e to cl i ps.
(5) Connect underhood l amp wi re harness connec-
tor.
HOOD HINGE
REMOVAL
(1) Rai se and support hood.
Fig. 1 Grille
Fig. 2 Grille Opening Panel
23 - 20 BODY XJ
Fig. 3 Hood Components
XJ BODY 23 - 21
(2) Usi ng a grease penci l or equi val ent, mark posi -
ti on of hood.
(3) Remove seal from hi nge base (Fi g. 4).
(4) Remove hi nge retai ni ng nuts from studs.
INSTALLATION
(1) Posi ti on hi nge over studs and al i gn wi th refer-
ence marks.
(2) I nstal l nuts.
NOTE: If a replacement hinge seal is being
installed, position it around hinge arm, force it
against hinge base.
(3) Posi ti on hi nge seal around hi nge arm and on
hi nge base.
(4) Adjust hood as necessary.
HOOD LATCH
REMOVAL
(1) Remove the screw that attaches the l atch to
the hood i nner panel (Fi g. 5).
(2) Di sconnect the l atch connecti ng rod.
(3) Remove the l atch from the hood.
INSTALLATION
(1) Connect the l atch to the l atch connecti ng rod
and
(2) Posi ti on the l atch on the hood i nner panel .
(3) I nstal l the screw that attaches the l atch to the
hood i nner panel .
HOOD LATCH STRIKER
REMOVAL
(1) Remove headl amp bezel .
(2) Remove parkl amp.
(3) Rel ease the spri ng attachi ng the headl amp
mounti ng bucket to the gri l l e openi ng panel (GOP).
(4) Remove the headl amp wi th mounti ng bucket
attached from the adjusti ng screws.
(5) Remove the upper bol t attachi ng the stri ker to
the top of the (GOP).
(6) Remove the l ower bol t attachi ng the stri ker to
the (GOP).
(7) Remove the stri ker and shi ms.
INSTALLATION
(1) Posi ti on the shi ms and stri ker on the (GOP)
and i nstal l the bol ts.
(2) I nstal l the headl amp and mounti ng bucket.
(3) I nstal l parkl amp.
(4) I nstal l the headl amp bezel .
(5) Test the stri ker/hood al i gnment by openi ng and
cl osi ng the hood several ti mes. Adjust the stri ker, i f
necessary.
HOOD RELEASE CABLE
REMOVAL
(1) Dri l l out bel l crank to hood ri vet heads and
remove ri vets (Fi g. 6).
(2) Di sconnect bel l crank from l atch rod and hood
rel ease cabl e. Remove bel l crank from hood.
(3) Di sconnect hood rel ease cabl e from cl i ps on
hood.
(4) Remove l eft cowl si de tri m panel .
(5) Remove cabl e bracket screws from cowl si de
panel .
(6) Route cabl e through dash panel and remove i t
from under i nstrument panel .
INSTALLATION
(1) I nsert repl acement cabl e end through hol e i n
dash panel i nto engi ne compartment.
(2) Route cabl e forward and seat grommet i n dash
panel .
Fig. 4 Hood Hinge and Seal
Fig. 5 Hood Latch
23 - 22 BODY XJ
(3) Posi ti on cabl e bracket on cowl si de panel and
i nstal l screws.
(4) I nstal l l eft cowl si de tri m panel .
(5) Connect cabl e and l atch rod to bel l crank.
(6) Posi ti on bel l crank on hood and i nstal l ri vets.
(7) Attach cabl e to cl i ps.
(8) Test rel ease cabl e for proper operati on.
HOOD SAFETY LATCH
REMOVAL
(1) Open and support hood.
(2) Remove the nuts attachi ng the safety l atch to
the i nner hood panel (Fi g. 7).
(3) Separate the safety l atch from the hood.
INSTALLATION
(1) Posi ti on the safety l atch on the hood.
(2) I nstal l the nuts attachi ng the safety l atch to
the i nner hood panel .
(3) Cl ose hood.
SAFETY LATCH STRIKER
REMOVAL
(1) Remove stri ker screws from radi ator support
crossmember (Fi g. 8).
(2) Remove stri ker from crossmember.
INSTALLATION
(1) Posi ti on stri ker on radi ator support crossmem-
ber and i nstal l screws.
(2) Test safety l atch operati on.
HOOD SILENCER PAD
REMOVAL
(1) Open and support hood.
(2) Remove the hood l atch rel ease bel l crank.
(3) Remove the cl i ps attachi ng the l atch connect-
i ng rod to the hood i nner panel .
(4) Remove the retai ners attachi ng the hood
si l encer pad to the i nner hood panel (Fi g. 9).
(5) Separate the hood si l encer pad from the hood.
Fig. 6 Hood Release Cable Bellcrank
Fig. 7 Hood Safety Latch
Fig. 8 Hood Safety Latch Striker
Fig. 9 Hood Silencer Pad
XJ BODY 23 - 23
INSTALLATION
(1) Posi ti on the hood si l encer pad on the hood
i nner panel .
(2) I nstal l the retai ners attachi ng the hood
si l encer pad to the i nner hood panel .
(3) I nstal l the cl i ps attachi ng the l atch connecti ng
rod to the hood i nner panel .
(4) I nstal l the hood l atch rel ease bel l crank.
(5) Cl ose hood.
COWL WEATHERSTRIP
REMOVAL
The cowl weatherstri p i s attached to the cowl wi th
adhesi ve tape.
(1) Peel weatherstri p from cowl (Fi g. 10).
INSTALLATION
(1) Cl ean contact surface wi th Mopar Super Kl een
or equi val ent.
(2) Posi ti on weatherstri p on cowl .
(3) Press weatherstri p i nto pl ace.
COWL GRILLE
REMOVAL
(1) Remove the wi ndshi el d wi per arms from the
pi vots.
(2) Remove the screws that attach the gri l l e to the
cowl .
(3) Remove the wi ndshi el d washer tubes from the
nozzl es.
(4) Remove the cowl gri l l e and screen from the
cowl (Fi g. 11).
INSTALLATION
CAUTION: The washer fluid tubes must be routed
and installed so that they are not pinched.
(1) Posi ti on the cowl gri l l e and screen on the cowl .
(2) I nstal l the wi ndshi el d washer tubes on the noz-
zl es.
(3) I nstal l the cowl screen and gri l l e screws wi th
new seal er. Ti ghten i n sequence (Fi g. 12).
NOTE: Force the cowl grille rearward while tighten-
ing the screws.
(4) I nstal l the wi ndshi el d wi per arms on the pi v-
ots.
BODY DECALS
Smal l ni cks, scratches and other surface marks i n
a decal can be touched-up wi th pai nt.
To el i mi nate bl i sters and ai r bubbl es i n a decal ,
pi erce them wi th a needl e or pi n.
A heat gun can al so be used to remove smal l wri n-
kl es i n a decal .
Decal repl acement requi res that the metal repai r
and pai nt refi ni sh be compl eted fi rst.
Fig. 10 Cowl Weatherstrip
Fig. 11 Cowl Grille, Screen & Washer Nozzles
Fig. 12 Cowl Grille Screw Tightening Sequence
23 - 24 BODY XJ
The work area temperature shoul d be between
21C (70F) and 32C (90F). A decal should not be
replaced if the work area temperature is less
than 21C (70F).
The fol l owi ng equi pment and materi al are neces-
sary for removal and i nstal l ati on:
Li qui d di sh detergent (for the wetti ng sol uti on).
Mi xture of wetti ng sol uti on.
Commerci al wax and si l i cone removal sol uti on.
I sopropyl (rubbi ng) al cohol .
Smal l squeegee (pl asti c or hard rubber).
Water bucket and sponge.
Cl ean wi pi ng rags or paper towel s.
Heat gun (or i nfra-red heat bul b).
Wax penci l .
Sharp kni fe, si ngl e edge razor bl ade or X-acto
kni fe.
Pai r of sci ssors.
Needl e or pi n.
WARNING: USE DECAL REMOVAL SOLUTION IN A
WELL-VENTILATED AREA ONLY.
A decal removal sol uti on can be used for removal
at areas where a heat gun i s i neffecti ve. Fol l ow the
manufacturers i nstructi ons whenever thi s type of
product i s used.
REMOVAL
(1) Cl ean the repai red surface as necessary.
(2) Start at one end of the decal and appl y heat
wi th a heat gun. Sl owl y peel the decal from the panel
by pul l i ng i t back. Do not pull the decal outward
from panel.
INSTALLATION
(1) The area that wi l l be covered by the decal must
be cl eaned wi th cl eani ng sol uti on.
(2) Freshl y pai nted surfaces must be thoroughl y
dry.
(3) Cl ean the pai nted surface wi th a commerci al
wax and si l i cone removal sol uti on. Wi pe the surface
wi th a cl ean cl oth and al l ow i t to dry.
(4) Prepare a wetti ng sol uti on by mi xi ng two or
three teaspoons of di sh detergent wi th 1 gal l on of
water. Do not use soap.
NOTE: Too much detergent will reduce the effec-
tiveness of the mixture.
(5) Use a cl ean sponge and appl y the wetti ng sol u-
ti on to the adhesi ve si de of the decal and to the
pai nted panel surface. The wetti ng sol uti on wi l l per-
mi t ease of decal movement when posi ti oni ng i t.
(6) Al i gn a strai ght edge wi th the exi sti ng decal
ends (Fi g. 13).
NOTE: If applicable, the body panel character line
can be used as the decal alignment reference.
(7) Posi ti on the decal and carri er on the body
panel (Fi g. 14) and the mark l ength wi th a wax pen-
ci l .
(8) Posi ti on the decal and carri er on the body
panel and hol d i t i n-pl ace wi th maski ng tape.
(9) Li ft the bottom edge of decal and carri er. Use
the tape secti ons as hi nges, and reverse the posi ti on
of decal and carri er.
CAUTION: Always remove the carrier from the
decal, never remove the decal from carrier
(10) Bend a corner of carri er outward and then,
wi th a fl i ck of the fi nger, separate the corner of car-
ri er from the decal .
(11) Return the decal back to i ts ori gi nal posi ti on.
I f a sol uti on i s bei ng used, posi ti on adhesi ve si de of
the decal on panel . Appl y the sol uti on to the outsi de
of the decal .
(12) Hol d the decal agai nst the panel surface whi l e
separati ng the carri er from the decal .
(13) I f appl i cabl e, remove the cover from face of
decal .
(14) Usi ng a squeegee smooth out the decal to
remove wri nkl es and/or ai r bubbl es.
(15) I nspect the decal wi th refl ected l i ght to fi nd
any damage. Remove al l the ai r and/or moi sture bub-
bl es.
EXTERIOR NAMEPLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
Fig. 13 Decal Alignment Reference Mark
XJ BODY 23 - 25
(1) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge of the namepl ate to use as a
gui de, i f necessary.
(2) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun. Do not exceed 52C
(120F) when heati ng embl em.
(3) I nsert a pl asti c tri m sti ck or a hard wood
wedge behi nd the embl em to separate the adhesi ve
backi ng from the body.
(4) Cl ean adhesi ve resi due from body wi th MOPAR
Super Cl ean sol vent or equi val ent.
INSTALLATION
(1) Remove protecti ve cover from adhesi ve tape on
back of embl em.
(2) Posi ti on embl em properl y on body (Fi g. 15).
(3) Press embl em fi rml y to body wi th pal m of
hand.
(4) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun to assure adhesi on.
Do not exceed 52C (120F) when heati ng embl em.
SIDE VIEW MIRROR
REMOVAL
(1) Remove the door tri m panel .
(2) Remove the screw attachi ng the mi rror tri m
cover/speaker gri l l e to the door i nner panel .
(3) remove push-i n fastener attachi ng tri m cover
to door i nner panel (use speci al tool C-4829).
(4) Di sconnect the power mi rror wi re connector, i f
equi pped.
(5) Remove the screws attachi ng the mi rror to the
door (Fi g. 16).
(6) Separate the mi rror from the door.
INSTALLATION
(1) Posi ti on the mi rror on the door.
(2) I nstal l the screws attachi ng the mi rror to the
door.
(3) Connect the power mi rror wi re connector, i f
equi pped.
(4) I nstal l new push-i n fastener.
(5) I nstal l the mi rror tri m cover/speaker gri l l e.
(6) I nstal l the door tri m panel .
FRONT FENDER FLARE
REMOVAL
(1) Remove the screw attachi ng the l ower part of
fl are to the bottom of the fender.
(2) Remove the nuts attachi ng the fender fl are
retai ner to the wheel house spl ash shi el d (Fi g. 17).
(3) Remove the l i ner from the fender.
(4) Remove the fasteners attachi ng the fender fl are
and retai ner to the fender.
(5) Separate the fender fl are and retai ner from the
fender.
Fig. 14 Body Decals
Fig. 15 Exterior Nameplates
Fig. 16 Side View Mirror
23 - 26 BODY XJ
INSTALLATION
(1) Posi ti on the fender fl are and retai ner on the
fender.
(2) I nstal l the nuts attachi ng the fender fl are and
retai ner to the wheel house fender.
(3) I nstal l the screw attachi ng the l ower part of
FRONT WHEELHOUSE LINER
REMOVAL
(1) Hoi st vehi cl e.
(2) Remove ti re.
(3) Remove the push-i n fasteners attachi ng the
wheel house l i ner to the i nner fender.
(4) Separate the wheel house l i ner from the fender
(Fi g. 18).
INSTALLATION
(1) Posi ti on the wheel house l i ner i n the fender.
(2) I nstal l new push-i n fasteners attachi ng the
wheel house l i ner to the i nner fender.
(3) I nstal l ti re.
RIGHT FRONT FENDER
REMOVAL
(1) Rai se and support the hood.
(2) Remove the gri l l e openi ng panel (GOP).
(3) I f equi pped, remove the radi o antenna mast,
and components from the fender.
(4) Remove the cool ant recovery bottl e.
(6) Remove the ri ght front wheel .
(7) Remove the front bumper end cap.
(8) Remove the wheel house l i ner.
(9) Remove the fender fl are and retai ners.
(10) Di sconnect al l wi re harness connectors.
(11) Remove the ai r defl ector.
(12) Remove the fender l ower screws (Fi g. 19).
(13) Remove the fender top, front and the rear
screws.
(14) Remove the screws attachi ng the fender to the
i nner support bracket (Fi g. 20).
(15) Separate the fender from the i nner fender
panel .
INSTALLATION
(1) Posi ti on the fender on the i nner fender panel .
(2) I nstal l al l fender screws fi nger-ti ght.
(3) Al i gn the fender wi th the body panel s and
ti ghten the screws attachi ng the fender to the body
panel s.
(4) I nstal l the ai r defl ector.
(5) I nstal l the fender fl are and retai ners.
(6) I nstal l the wheel house l i ner.
(7) I nstal l the front bumper end cap.
(8) I nstal l the wheel , remove the support and
l ower the vehi cl e.
(9) I nstal l the gri l l e openi ng panel (GOP).
(10) I nstal l the radi o antenna.
LEFT FRONT FENDER
REMOVAL
(1) Rai se and support the hood.
(2) Remove the gri l l e openi ng panel (GOP).
(4) Remove the l eft front wheel .
(5) Remove the front bumper end cap.
(6) Remove the fender fl are and retai ners.
(7) Remove the wheel house l i ner.
(8) Remove the ai r defl ector.
(9) Remove the fender l ower screws.
(10) Remove the fender top, front and the rear
screws.
Fig. 17 Fender Flare
Fig. 18 Front Wheelhouse Liner
XJ BODY 23 - 27
(11) Remove the screws attachi ng the fender to the
i nner support bracket.
(12) Separate the fender from the i nner fender
panel .
INSTALLATION
(1) Posi ti on the fender on the i nner fender panel .
(2) I nstal l al l fender screws fi nger-ti ght.
(3) Al i gn the fender wi th the body panel s and
ti ghten the screws attachi ng the fender to the body
panel s.
(4) I nstal l the ai r defl ector.
(5) I nstal l the wheel house l i ner.
(6) I nstal l the fender fl are and retai ners.
(7) I nstal l the front bumper.
(8) I nstal l the wheel , remove the support and
(9) I nstal l the gri l l e openi ng panel (GOP).
FRONT DOOR TRIM PANEL
REMOVAL
(1) Rol l wi ndow down.
(2) Remove wi ndow crank, i f equi pped (Fi g. 21).
(3) Remove the screws attachi ng the tri m panel to
the door i nner panel (Fi g. 22) and (Fi g. 23).
(4) Separate the tri m panel fasteners from door
i nner panel wi th a pry tool (use speci al tool C-4829)
(Fi g. 24).
(5) Li ft the tri m panel up and outward to separate
from the i nner bel t seal .
(6) Move the door tri m panel outward and di scon-
nect the handl e-to-l atch rods.
(7) Di sconnect the power door l ocks/wi ndows/mi r-
rors wi re harness connectors, i f equi pped.
(8) Remove the tri m panel from door.
INSTALLATION
(1) Repl ace any broken or damaged push-i n fasten-
ers.
(2) Connect the power door l ocks/wi ndows/mi rrors
wi re harness connectors, i f equi pped.
(3) Move the door tri m panel outward and connect
the handl e-to-l atch rods.
(4) Posi ti on the tri m panel on the i nner bel t seal
and push down to seat.
(5) Al i gn the l ocati ng pi ns and push- (Fi g. 25) i n
fasteners. Press i nward to secure.
Fig. 19 Right Front Fender
Fig. 20 Inner Support Bracket
23 - 28 BODY XJ
(6) I nstal l the screws attachi ng the tri m panel to
the door i nner panel .
(7) I nstal l the wi ndow crank, i f equi pped.
FRONT DOOR WATERDAM
REMOVAL
The waterdam i s attached to the door i nner panel
wi th a butl y adhesi ve. I f cohesi ve separati on of the
butl y between the waterdam and door i nner panel
occurs duri ng the removal process, cut the strands of
butl y wi th a razor kni fe or equi val ent.
(1) Remove door tri m panel .
(2) Di sengage cl i ps attachi ng wi re harnesses to the
door i nner panel .
(3) Push the harnesses/connectors through the
waterdam and i nto the door.
(4) Grasp the upper and l ower rearward corners of
the waterdam and rapi dl y peel back the waterdam
from the door i nner panel .
(5) Separate the waterdam from the door i nner
panel .
Fig. 21 Window CrankTypical
Fig. 22 Front Door Trim Panel-Manual Window
Fig. 23 Front Door Trim Panel-Power Window
Fig. 24 Detaching Trim Panel Push-In Fasteners
Fig. 25 Push-In Fasteners
XJ BODY 23 - 29
INSTALLATION
(1) Route the l atch rods through the waterdam.
(2) Posi ti on the waterdam on the door, appl y adhe-
si ve as necessary and press i nto pl ace.
(3) Route the harnesses/connectors through the
waterdam.
(4) Engage cl i ps attachi ng wi re harnesses to the
door i nner panel .
(5) I nstal l door tri m panel .
FRONT DOOR
REMOVAL
(1) Remove door restrai nt (check) retai ni ng pi n.
(2) For vehi cl es equi pped wi th power wi ndows,
power mi rrors and power door l ocks, remove tri m
panel and waterdam. Di sconnect al l components and
route wi re harness out of door.
(3) Remove bol ts that attach hi nge to door. (Fi g.
26).
(4) Remove door from vehi cl e.
INSTALLATION
(1) Posi ti on door i n body openi ng.
(2) Al i gn door hi nges, pl ates and shi ms and i nstal l
bol ts. Ti ghten bol ts to 3 Nm (2 ft. l bs.) torque.
(3) I nstal l door restrai nt (check) pi n.
(4) I f appl i cabl e, route and connect wi re harness
connectors.
(5) I nstal l door waterdam and tri m panel .
FRONT DOOR HINGE
REMOVAL
(2) Remove door hi nge bol ts and shi ms (Fi g. 27).
(3) Retai n door hi nge shi ms for correct i nstal l a-
ti on.
INSTALLATION
(1) Posi ti on hi nge pl ates and shi ms on door face.
(2) Al i gn door hi nges and shi ms wi th bol t hol es
and i nstal l hi nge bol ts. Ti ghten bol ts to 3 Nm (2 ft.
l bs.) torque.
(3) Adjust/al i gn l atch stri ker and l atch as neces-
sary.
(4) I nstal l door restrai nt (check) retai ni ng pi n.
FRONT DOOR RESTRAINT
REMOVAL
(2) Remove door radi o speaker from door i nner
panel .
(3) Remove door restrai nt (check) retai ni ng pi n
from bracket wi th a punch.
(4) Remove nuts and remove restrai nt vi a speaker
openi ng. (Fi g. 28).
Fig. 26 Front Door Hinge
Fig. 27 Front Door Hinge
Fig. 28 Door Restraint (Check)
23 - 30 BODY XJ
INSTALLATION
(1) Posi ti on door restrai nt i n door by way of open-
i ng and i nstal l nuts.
NOTE: Ensure the spring on the door restraint is
facing outward.
(2) Posi ti on door restrai nt i n bracket wi th hol es
al i gned and i nsert retai ni ng pi n.
(3) I nstal l radi o speaker and door tri m panel .
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove the door tri m panel and waterdam.
(2) Remove the access hol e cover and remove the
rearward nut attachi ng the door handl e to the door.
(Fi g. 29).
(3) Di sconnect the handl e-to-l atch rod from the
handl e l atch rel ease l ever arm.
(4) Remove the forward nut attachi ng the handl e
to the door.
(5) Separate the handl e from the door.
INSTALLATION
(1) Posi ti on the handl e i n the door.
(2) I nstal l the forward nut attachi ng the handl e to
the door.
(3) Connect the l atch to handl e rod, to the handl e
l atch rel ease l ever arm.
(4) I nstal l the rearward nut attachi ng the door
handl e to the door.
(5) I nstal l the access hol e cover.
(6) I nstal l the door waterdam and tri m panel .
FRONT DOOR LOCK CYLINDER
REMOVAL
(2) Peel back waterdam to access l ock cyl i nder.
(3) Di sconnect the door l atch-to-l ock cyl i nder rod
at the door l atch (Fi g. 30).
(4) Remove the l ock cyl i nder retai ner cl i p.
(5) Remove the l ock cyl i nder.
(6) I f appl i cabl e, remove the door l atch-to-l ock cyl -
i nder rod from the ori gi nal l ock cyl i nder. Connect i t
to the repl acement l ock cyl i nder.
INSTALLATION
(1) Posi ti on the l ock cyl i nder and i n the door open-
i ng.
(2) I nstal l the retai ner cl i p.
(3) Connect the door l atch-to-l ock cyl i nder rod to
the door l atch.
(4) Press the waterdam i nto posi ti on.
FRONT DOOR LATCH
REMOVAL
(1) Remove door tri m panel and waterdam.
(2) Remove screws attachi ng l atch to door.
(3) Di sconnect al l rods from l atch (Fi g. 31).
(4) Di sconnect power l ock motor wi re connector, i f
equi pped.
(5) Remove l atch from door face.
INSTALLATION
(1) Posi ti on l atch on door face.
(2) Connect power l ock motor wi re connector, i f
equi pped.
(3) Connect al l rods to l atch.
(4) I nstal l screws attachi ng l atch to door. Ti ghten
screws to 11 Nm (8 ft. l bs.) torque.
Fig. 29 Front Door Outside Handle
Fig. 30 Door Lock Cylinder
XJ BODY 23 - 31
(5) I nstal l waterdam and door tri m panel .
FRONT DOOR LATCH STRIKER
REMOVAL
ti on of stri ker.
(2) Remove screws attachi ng stri ker to B-pi l l ar
(Fi g. 32).
(3) Separate stri ker from B-pi l l ar.
INSTALLATION
(1) Posi ti on and al i gn stri ker on B-pi l l ar.
(2) I nstal l screws attachi ng stri ker to B-pi l l ar.
Ti ghten screws to 28 Nm (20 ft. l bs.) torque.
FRONT DOOR INSIDE HANDLE ACTUATOR
REMOVAL
The front door i nsi de handl e actuator i s heat
staked to the front door tri m panel duri ng the man-
ufacturi ng process.
(2) Usi ng an X-ACTO kni fe or equi val ent, cut the
mel ted tabs securi ng the i nsi de handl e to the door
tri m panel .
(3) Separate the i nsi de handl e from the tri m
panel .
INSTALLATION
(1) Posi ti on the i nsi de handl e i n the tri m panel .
(2) Heat stake the i nsi de handl e to the tri m panel .
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL
(3) Pul l up on the rear corner of the weatherstri p
and l i ft from the door (Fi g. 33).
INSTALLATION
(1) Posi ti on the weatherstri p on the door.
(2) Push weatherstri p down to seat onto door.
FRONT DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(2) Usi ng a tri m sti ck, pry up the rear outer corner
of the weatherstri p.
(3) Li ft the weatherstri p up to separate from the
door (Fi g. 33).
INSTALLATION
Fig. 31 Door Latch
Fig. 32 Front Door Latch Striker
Fig. 33 Front Door Inner/Outer Belt Weatherstrip
23 - 32 BODY XJ
FRONT DOOR GLASS RUN CHANNEL
WEATHERSTRIP
REMOVAL
(2) Remove waterdam.
(3) Starti ng at rear corner, peel weatherstri p from
around door frame.
INSTALLATION
(1) I nstal l the weatherstri p i n the fol l owi ng
sequence:
Press weatherstri p i nto upper rear corner.
Press weatherstri p i nto l ower front corner.
Work/press the weatherstri p upward and to the
upper front corner, seat the weatherstri p i nto the
channel .
Conti nue worki ng/pressi ng the weatherstri p i nto
the channel al ong the upper wi ndow frame.
Press weatherstri p i nto l ower rear corner.
Work/press the weatherstri p upward and to the
upper rear corner, seat the weatherstri p i nto the
channel .
Press the weatherstri p to seat i nto the front
l ower gl ass run channel .
(2) As appl i cabl e, move upward and forward
evenl y unti l the weatherstri p seal i s ful l y seated i n
the channel .
(3) I nstal l waterdam.
FRONT DOOR OPENING WEATHERSTRIP
REMOVAL
(1) Remove A-pi l l ar tri m panel .
(2) Remove B-pi l l ar upper tri m panel .
(3) Remove cowl si de tri m panel .
(4) Remove i nner scuff pl ate.
(5) Remove B-pi l l ar l ower tri m panel .
(6) Grasp seal and separate from door openi ng.
INSTALLATION
(1) Posi ti on weatherstri p at corners.
(2) Move upward and around edge of door openi ng.
Seat seal on fl ange.
(3) When i nstal l i ng a door openi ng weatherstri p
seal , start at the door si l l center l i ne.
(4) Move upward and around the peri meter of the
door openi ng and seat the weatherstri p on the fl ange
(Fi g. 35).
(5) I nstal l cowl si de tri m panel .
(6) I nstal l i nner scuff pl ate.
(7) I nstal l B-pi l l ar l ower tri m panel .
(8) I nstal l B-pi l l ar upper tri m panel .
(9) I nstal l A-pi l l ar tri m panel .
FRONT DOOR OPENING SECONDARY
WEATHERSTRIP
REMOVAL
The front door openi ng secondary weatherstri p i s
attached to the A-pi l l ar wi th adhesi ve tape (Fi g. 34).
(1) Usi ng a heat gun, heat the weatherstri p and
sl owl y peel the weatherstri p from the A-pi l l ar
Fig. 34 Door Opening Weatherstrip
XJ BODY 23 - 33
INSTALLATION
(1) Cl ean the contact surface on the A-pi l l ar.
(2) Remove the carri er backi ng and posi ti on the
weatherstri p on the A-pi l l ar. Press i nto pl ace.
FRONT DOOR GLASS EXTERIOR MOLDING
REMOVAL
(1) Open the wi ndow compl etel y.
(2) Remove the outer bel t weatherstri p.
(3) Pry and pul l the mol di ng secti ons from the
door panel fl ange (Fi g. 36).
INSTALLATION
(1) Start at the forward end of the upper mol di ng,
force the mol di ng onto the door panel and conti nue
rearward unti l i t i s compl etel y seated on the fl ange.
(2) Mate the rear mol di ng wi th the upper mol di ng
and force the mol di ng edge i nward.
(3) Conti nue pressi ng and movi ng downward to
compl ete the i nstal l ati on.
(4) I nstal l the outer bel t weatherstri p.
FRONT DOOR WINDOW REGULATOR
REMOVAL
(2) Remove the waterdam.
(3) Remove the wi ndow gl ass.
(4) Loosen the bol ts attachi ng the regul ator to the
i nner door panel (Fi g. 37) and (Fi g. 38) as appl i cabl e.
(5) Li ft the regul ator upward to rel ease i t from the
key hol e sl ots and remove i t through the access hol e
i n the door i nner panel .
INSTALLATION
(1) Posi ti on the regul ator i n the door and al i gn
wi th key hol e sl ots.
(2) Attach the regul ator to door i nner panel wi th
bol ts (Fi g. 39).
(3) I nstal l the wi ndow gl ass
(4) I nstal l the waterdam.
(5) I nstal l the tri m panel .
FRONT DOOR SPACER BLOCKS TWO-DOOR
VEHICLES
REMOVAL
(1) Upper spacer bl ock: dri l l -out the ri vet heads
and remove them from the rei nforcement pl ate (Fi g.
40).
(2) Lower spacer bl ock: remove the screws from
the door face (Fi g. 41).
(3) As appl i cabl e, remove the spacer bl ock from the
door wi ndow frame or door face.
INSTALLATION
(1) As appl i cabl e, posi ti on the spacer bl ock on the
door wi ndow frame or door face.
Fig. 36 Front Door Glass Exterior Molding
Fig. 37 Power Window Regulator
Fig. 38 Manual Window Regulator
23 - 34 BODY XJ
(2) Upper spacer bl ock: I nstal l the repl acement
ri vets i n the spacer bl ock and rei nforcement pl ate.
(3) Lower spacer bl ock: i nstal l the screws i n the
door face. Ti ghten the screws to 1 Nm (11 i n-l bs)
torque.
FRONT DOOR GLASS
REMOVAL
(3) Remove i nner and outer bel t weatherstri p.
(4) Rol l gl ass up to expose the bol ts attachi ng the
gl ass to the regul ator.
(5) Remove the bol ts attachi ng the gl ass to the
regul ator (Fi g. 42).
(6) Li ft the gl ass upward and out of the door.
INSTALLATION
(1) Posi ti on the gl ass i n the door.
(2) I nstal l the bol ts attachi ng the gl ass to the reg-
ul ator Ti ghten the bol ts to 4 Nm (36 i n-l bs) torque.
(3) I nstal l i nner and outer bel t weatherstri p.
(4) Attach the door waterdam to the door i nner
panel wi th adhesi ve/seal ant.
Fig. 39 Front Door Regulator
Fig. 40 Front Door Upper Spacer BlockTwo-Door
Fig. 41 Front Door Lower Spacer BlockTwo-Door
XJ BODY 23 - 35
REAR DOOR TRIM PANEL
REMOVAL
(2) Remove wi ndow crank, i f equi pped (Fi g. 43).
(3) Remove the screws attachi ng the tri m panel to
the door i nner panel (Fi g. 44) and (Fi g. 45).
(4) Separate the tri m panel fasteners from door
i nner panel wi th a pry tool (use speci al tool C-4829)
(Fi g. 46).
(5) Li ft the tri m panel up and outward to separate
from the i nner bel t seal .
(6) Move the door tri m panel outward and di scon-
nect the handl e-to-l atch rods (Fi g. 47).
(7) Di sconnect the power wi ndows wi re harness
connectors, i f equi pped.
(8) Remove the tri m panel from door.
Fig. 42 Front Door Glass
Fig. 43 Window CrankTypical
Fig. 44 Rear Door Trim PanelManual Window
Fig. 45 Rear Door Trim PanelPower Window
Fig. 46 Detaching Trim Panel Push-In Fasteners
23 - 36 BODY XJ
INSTALLATION
(1) Repl ace any broken or damaged push-i n fasten-
ers.
(2) Connect the power wi ndow wi re harness con-
nectors, i f equi pped.
(3) Move the door tri m panel outward and connect
the handl e-to-l atch rods.
(4) Posi ti on the tri m panel on the i nner bel t seal
and push down to seat.
(5) Al i gn the l ocati ng pi ns and push-i n fasteners
(Fi g. 48). Press i nward to secure.
(6) I nstal l the screws attachi ng the tri m panel to
(7) I nstal l the wi ndow crank, i f equi pped.
REAR DOOR WATERDAM
REMOVAL
(2) Peel the waterdam from the door.
(3) Route the l atch rods and wi re harnesses
through the waterdam.
(4) Separate the waterdam from the door i nner
panel .
INSTALLATION
(1) Route the l atch rods and wi re harnesses
through the waterdam.
(2) Posi ti on the waterdam on the door, appl y adhe-
si ve as necessary and press i nto pl ace.
REAR DOOR
REMOVAL
(2) For vehi cl es equi pped wi th power wi ndows and
power door l ocks, remove tri m panel and waterdam.
Di sconnect al l components and route wi re harness
out of door.
(3) Remove bol ts attachi ng hi nge to door face.
(4) Separate door from vehi cl e.
INSTALLATION
(1) Posi ti on door i n body openi ng.
(2) Al i gn door hi nges, pl ates and shi ms and i nstal l
bol ts. Ti ghten bol ts to 3 Nm (2 ft. l bs.) torque.
(3) I nstal l door restrai nt (check).
(4) I f appl i cabl e, route and connect wi re harness
connectors.
(5) I f necessary, i nstal l door waterdam and tri m
panel .
REAR DOOR RESTRAINT
REMOVAL
(2) Remove the door restrai nt (check) retai ni ng pi n
from the bracket wi th a punch.
(3) Remove the nuts and remove the restrai nt vi a
the access openi ng i n the door i nner panel (Fi g. 49).
Fig. 47 Latch Rods
Fig. 48 Push-In Fasteners
Fig. 49 Door Restraint (Check)
XJ BODY 23 - 37
INSTALLATION
(1) Posi ti on the door restrai nt i n the door by way
of the openi ng and i nstal l the nuts. Ti ghten the nuts
to 10 Nm (7 ft-l bs) torque.
(2) Posi ti on the door restrai nt i n bracket wi th the
hol es al i gned and i nsert the retai ni ng pi n.
REAR DOOR HINGE
REMOVAL
(1) Remove door restrai n (check) pi n.
(2) Remove door hi nge bol ts and shi ms.
(3) Retai n bol ts and shi ms for correct i nstal l ati on.
INSTALLATION
(1) Posi ti on hi nge pl ates and shi ms on door face.
(2) Al i gn door hi nges and shi ms wi th bol t hol es
and i nstal l hi nges. Ti ghten bol ts to 3 Nm (2 ft. l bs.).
(3) Adjust/al i gn l atch stri ker and l atch as neces-
sary.
(4) I nstal l door restrai n (check) retai ni ng pi n.
REAR DOOR OUTSIDE HANDLE
REMOVAL
(2) Rol l the wi ndow to the ful l up posi ti on.
(3) Peel back the waterdam to access the fasteners
for the outsi de handl e.
(4) Remove the l atch.
(5) Remove the access hol e cover.
(6) Remove the nuts attachi ng the door handl e to
the door (Fi g. 50).
(7) Di sconnect the handl e-to-l atch rod from the
handl e l atch rel ease l ever arm (Fi g. 51).
INSTALLATION
(1) Posi ti on the handl e at the door panel .
(2) Connect the l atch-to-handl e rod to the handl e
l atch rel ease l ever arm.
(3) I nstal l nuts attachi ng the door handl e to the
door.
(4) I nstal l the l atch.
REAR DOOR LATCH
REMOVAL
(1) Remove access pl ug.
(4) Remove screws attachi ng door l atch to door
(Fi g. 52).
(5) Di sconnect al l rods from door l atch.
(6) Remove door l atch from door.
Fig. 50 Rear Door Outside Handle
Fig. 51 Latch Rod
Fig. 52 Rear Door Latch
23 - 38 BODY XJ
INSTALLATION
(1) Posi ti on door l atch i n door.
(2) Connect al l rods to door l atch.
(3) I nstal l screws attachi ng door l atch to door.
(6) I nstal l access pl ug.
REAR DOOR LATCH STRIKER
REMOVAL
ti on of stri ker.
(2) Remove screws attachi ng stri ker to C-pi l l ar
(Fi g. 53).
(3) Separate stri ker from C-pi l l ar.
INSTALLATION
(1) Posi ti on and al i gn stri ker on C-pi l l ar.
(2) I nstal l screws attachi ng stri ker to C-pi l l ar.
REAR DOOR INSIDE HANDLE ACTUATOR
REMOVAL
The rear door i nsi de handl e actuator i s heat staked
to the rear door tri m panel duri ng the manufacturi ng
process.
(2) Usi ng an XACTO kni fe or equi val ent, cut the
mel ted tabs securi ng the i nsi de handl e to the door
tri m panel .
(3) Separate the i nsi de handl e from the tri m
panel .
INSTALLATION
(1) Posi ti on the i nsi de handl e i n the tri m panel .
(2) Heat stake the i nsi de handl e to the tri m panel .
REAR DOOR INNER BELT WEATHERSTRIP
REMOVAL
(3) Pul l up on the rear corner of the weatherstri p
and l i ft from the door (Fi g. 54).
INSTALLATION
REAR DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(2) Usi ng a tri m sti ck, pry up the rear outer corner
of the weatherstri p.
(3) Sl owl y and careful l y, l i ft the weatherstri p up to
separate from the door (Fi g. 54).
INSTALLATION
REAR DOOR GLASS RUN CHANNEL
WEATHERSTRIP
REMOVAL
(3) Remove wi ndow gl ass.
Fig. 53 Rear Door Latch Striker
Fig. 54 Rear Door Inner/Outer Belt Weatherstrip
XJ BODY 23 - 39
(4) Starti ng at rear corner, peel weatherstri p from
around door frame (Fi g. 54).
INSTALLATION
(1) Starti ng at the top corner, press seal i nto pl ace.
A smal l amount of adhesi ve can be used to hol d the
weatherstri p i n-pl ace, i f necessary.
(2) As appl i cabl e, move downward evenl y unti l the
weatherstri p seal i s ful l y seated i n the channel .
(3) I nstal l wi ndow gl ass.
REAR DOOR GLASS EXTERIOR MOLDING
REMOVAL
(1) Open the wi ndow.
(2) Remove the outer bel t mol di ng.
(3) Pry and pul l the mol di ng secti ons from the
door panel fl ange (Fi g. 55).
INSTALLATION
(1) Starti ng at the forward end of the upper mol d-
i ng, force the mol di ng onto the door panel fl ange and
conti nue rearward unti l i t i s compl etel y seated on
the fl ange.
(2) Mate the rear mol di ng wi th the upper mol di ng
and force the mol di ng edge i nward.
(3) Conti nue pressi ng and movi ng downward to
(4) I nstal l the outer bel t mol di ng.
REAR DOOR WEATHERSTRIP
REMOVAL
(1) Remove B-pi l l ar upper tri m.
(2) Remove i nner scuff pl ate.
(3) Remove B-pi l l ar l ower tri m.
(4) Remove upper door openi ng tri m.
(5) Grasp seal and separate from door openi ng
(Fi g. 56).
INSTALLATION
(1) When i nstal l i ng a door openi ng weatherstri p
seal , start at the door si l l center l i ne.
(2) Move upward and around edge of door openi ng.
Seat seal on fl ange.
(3) Move upward and around the peri meter of the
door openi ng and seat the weatherstri p on the fl ange
(Fi g. 57).
(4) I nstal l upper door openi ng tri m.
(5) I nstal l i nner scuff pl ate.
(6) I nstal l B-pi l l ar l ower tri m panel .
(7) I nstal l B-pi l l ar upper tri m panel .
REAR DOOR WINDOW REGULATOR
REMOVAL
(3) Remove the bol t attachi ng the wi ndow gl ass to
the regul ator and support the gl ass (Fi g. 58).
(4) Remove the l ower bol ts attachi ng the regul ator
to the i nner door panel (Fi g. 59).
(5) Remove the nuts attachi ng the regul ator motor
to the i nner door panel , i f equi pped.
(6) Loosen the upper bol t that attaches the regul a-
tor to the i nner door panel .
(7) Di sconnect the wi re harness connector from the
regul ator dri ve motor, i f equi pped.
(8) Remove the regul ator and dri ve motor, i f
equi pped.
Fig. 55 Rear Glass Exterior Molding
23 - 40 BODY XJ
INSTALLATION
(1) Posi ti on wi ndow regul ator and, i f equi pped,
dri ve motor wi thi n the door panel s.
(2) I nstal l the fasteners attachi ng the regul ator to
(3) Connect the regul ator wi re harness connector.
(4) Posi ti on the wi ndow gl ass at the regul ator and
i nstal l the retai ner, bushi ng and bol t.
REAR DOOR WINDOW GLASS
REMOVAL
(1) Lower the wi ndow gl ass.
(2) Remove the tri m panel .
(4) Remove i nner and outer bel tl i ne weatherstri p.
(5) Remove the wi ndow weatherstri p from the
door.
(6) Remove the di vi si on bar/stati onary gl ass (Fi g.
60).
(7) Remove the wi ndow gl ass screw, bushi ng and
retai ner from the regul ator.
(8) Remove the wi ndow gl ass from door.
INSTALLATION
(1) I nstal l the gl ass i n the door, and i nstal l the
retai ner, bushi ng and screw.
(2) Ti ghten the gl ass attachi ng screw 6 Nm (53 i n-
l bs) torque.
(3) I nstal l the di vi si on bar/stati onary gl ass i n the
door.
Fig. 58 Regulator To Glass Screw Removal/
Installation
Fig. 59 Rear Door Window
Fig. 60 Division Bar/Stationary Glass
XJ BODY 23 - 41
(4) I nstal l the gl ass run channel weatherstri p.
(5) I nstal l the i nner and outer bel tl i ne weather-
stri p.
BODY SIDE MOLDING
REMOVAL
(1) Loosen the body si de mol di ng (Fi g. 61) wi th a
heat gun.
(2) Li ft edge of mol di ng wi th a putty kni fe and
peel mol di ng from body panel . Appl y heat to any
l ocati on where the mol di ng remai ns adhered to a
panel .
(3) Remove the adhesi ve from the body panel wi th
Mopar Super Cl ean sol vent or equi val ent.
(4) I f the ori gi nal mol di ng wi l l be i nstal l ed, al so
remove al l adhesi ve from i t.
INSTALLATION
(1) I f the ori gi nal mol di ng wi l l be i nstal l ed, appl y
3M 5344 doubl e-si ded tape on the mol di ng.
(2) For verti cal al i gnment, use maski ng tape or a
stri ng as reference.
(3) Remove the backi ng from the tape, al i gn the
mol di ng and posi ti on i t on the body panel .
(4) Press the mol di ng onto the body panel wi th a
rol l er or hand pressure.
REAR FENDER FLARE
REMOVAL
(1) Remove the screw attachi ng the l ower part of
(2) Remove the nuts attachi ng the fender fl are
retai ner to the wheel house l i ner (Fi g. 62).
(3) Separate the fender fl are and retai ner from the
fender.
INSTALLATION
(1) Posi ti on the fender fl are and retai ner on the
fender.
(2) I nstal l the nuts attachi ng the fender fl are and
retai ner to the wheel house l i ner.
(3) I nstal l the screw attachi ng the l ower part of
QUARTER WINDOW APPLIQUE
REMOVAL
(1) Remove the l i ftgate pi l l ar tri m.
(2) Remove nuts from i nsi de vehi cl e (Fi g. 63).
(3) Usi ng a tri m si ck or equi val ent, careful l y pry
the appl i que the from panel .
INSTALLATION
(1) Posi ti on the repl acement appl i que the on panel
and i nstal l the nuts.
(2) I nstal l the l i ftgate pi l l ar tri m.
DRIP RAIL MOLDING
REMOVAL
(1) Pry the cl i ps from the roof fl ange.
(2) Remove the cl i ps and mol di ng from the roof
fl ange (Fi g. 63).
(3) Remove the remai ni ng seal ant and cl ean the
roof fl ange.
(1) Pry the cl i ps from the roof fl ange.
(2) Remove the cl i ps and mol di ng from the roof
fl ange (Fi g. 63).
(3) Remove the remai ni ng seal ant and cl ean the
roof fl ange.
INSTALLATION
(1) Posi ti on the dri p rai l mol di ng wi th cl i ps at the
roof fl ange and force the cl i ps onto the roof fl ange.
Fig. 61 Body Side Molding4-Door
Fig. 62 Fender Flare
23 - 42 BODY XJ
(2) Appl y seal ant to the i nner si de of the mol di ng
to seal the roof fl ange.
LUGGAGE RACK
REMOVAL
(1) Remove sl i de rai l screws (Fi g. 64).
(2) Remove l uggage rack from roof.
NOTE: Skid strips are attached to roof panel with
adhesive.
(3) Loosen each ski d stri p wi th a heat gun.
(4) Li ft one edge of each ski d stri p wi th a putty
kni fe and peel i t from roof panel .
(5) Remove ori gi nal adhesi ve from roof wi th an
adhesi ve removal sol uti on.
(6) I f ori gi nal ski d stri ps are i nstal l ed, remove al l
ori gi nal adhesi ve from m.
INSTALLATION
(1) I nstal l 3M 06379 doubl e-si ded tape, or an
equi val ent on ski d stri ps.
(2) Remove backi ng from doubl e-si ded tape, al i gn
each ski d stri p on roof, and posi ti on i t on roof panel .
(3) Veri fy that each ski d stri p i s properl y al i gned.
(4) Press each ski d stri p onto roof panel wi th a
rol l er (or use hand pressure).
NOTE: To prevent water leaks, apply 3M Drip-Chek
Sealant, or equivalent.
(5) Posi ti on l uggage rack on roof wi th screw hol es
al i gned.
(6) I nstal l and ti ghten sl i de rai l screws.
AIR EXHAUST GRILLE
REMOVAL
(1) Remove the screw that attaches the gri l l e to
door the openi ng panel (Fi g. 65).
(2) Pry the bottom edge of the gri l l e from the door
openi ng panel .
(3) Pul l downward and remove the gri l l e from
exhaust port i n the door openi ng panel .
INSTALLATION
(1) Posi ti on the sl ot l ocated i n the upper end of
repl acement gri l l e at the exhaust port and i nsert
edge i n the sl ot.
(2) Push i nward and seat the gri l l e i n the exhaust
port.
(3) I nstal l the screw to attach the gri l l e to the door
openi ng panel .
Fig. 63 Quarter Window Applique and Drip Molding
Fig. 64 Luggage Rack
Fig. 65 Door Opening Air Exhaust Grille
XJ BODY 23 - 43
A-PILLAR TRIM
REMOVAL
(1) Remove front and rear assi st handl es, i f
equi pped.
(2) Remove the i nner scuff pl ate.
(3) Remove the l ower A-pi l l ar cowl tri m.
(4) Usi ng a smal l fl at bl ade, pry the tri m pl ugs
from the A-pi l l ar tri m.
(5) Remove the screws attachi ng the A-pi l l ar tri m
to the A-pi l l ar (Fi g. 66).
(6) Separate the A-pi l l ar tri m from the A-pi l l ar.
INSTALLATION
(1) Posi ti on the A-pi l l ar tri m on the A-pi l l ar.
(2) I nstal l the screws attachi ng the A-pi l l ar tri m to
the A-pi l l ar.
(3) I nstal l the tri m pl ugs.
(4) I nstal l the l ower A-pi l l ar cowl tri m.
(5) I nstal l the i nner scuff pl ate.
(6) I nstal l the assi st handl es.
LOWER A-PILLAR COWL TRIM
REMOVAL
(2) Remove the nut behi nd the fuse panel access
door (Ri ght si de onl y) (Fi g. 67).
(3) Remove the fasteners attachi ng the l ower A-pi l -
l ar cowl tri m to the A-pi l l ar l ower cowl .
(4) Separate the l ower A-pi l l ar cowl tri m from the
A-pi l l ar l ower cowl .
INSTALLATION
(1) Posi ti on the l ower A-pi l l ar cowl tri m on the
A-pi l l ar l ower cowl .
Fig. 66 Trim Panels2-Door Vehicles
Fig. 67 Lower A-Pillar Cowl Trim
23 - 44 BODY XJ
(2) I nstal l the screws attachi ng the l ower A-pi l l ar
cowl tri m to the A-pi l l ar l ower cowl .
(3) I nstal l the nut behi nd the fuse panel access
door (Ri ght si de onl y).
FRONT INNER SCUFF PLATE
REMOVAL
(1) I f necessary, remove the bucket seat si de shi el d
tri m cover.
(2) Remove the screws attachi ng the i nner scuff
pl ate to the front door si l l (Fi g. 66).
(3) Separate the i nner scuff pl ate from the door
si l l .
INSTALLATION
(1) Posi ti on the i nner scuff pl ate on the front door
si l l .
(2) I nstal l the screws attachi ng the i nner scuff
pl ate to the front door si l l .
(3) I f removed, i nstal l the bucket seat si de shi el d
tri m cover.
DOOR SILL SCUFF PLATE
REMOVAL
(1) Remove the screws attachi ng the door si l l scuff
pl ate to the door si l l (Fi g. 68).
(2) Separate the scuff pl ate from the door si l l .
INSTALLATION
(1) Posi ti on the scuff pl ate on the door si l l .
(2) I nstal l the screws attachi ng the door si l l scuff
pl ate to the door si l l .
ASSIST HANDLE
REMOVAL
(1) Usi ng a tri m sti ck or equi val ent, open the end
covers to access the screws.
(2) Remove the screws (Fi g. 66).
(3) Separate the assi st handl e from the tri m.
INSTALLATION
(1) Posi ti on the handl e on the tri m.
(2) I nstal l the screws.
(3) I nstal l the covers.
B-PILLAR TRIM
REMOVAL
(2) Remove the upper door openi ng tri m (4-door
vehi cl es) (Fi g. 69).
(3) Remove the upper quarter panel tri m (2-door
(4) Remove the rear A-pi l l ar tri m screw.
(5) Remove the shoul der bel t turni ng l oop.
(6) Remove the seat/shoul der bel t anchor bol t.
(7) Remove the screws attachi ng the B-pi l l ar tri m
to the B-pi l l ar (2-door vehi cl es).
(8) Route the shoul der bel t through the l ower
B-pi l l ar tri m (2-door vehi cl es).
(9) Separate the B-pi l l ar tri m from the B-pi l l ar.
INSTALLATION
(1) Route the shoul der bel t through the l ower
B-pi l l ar tri m (2-door vehi cl es).
(2) Posi ti on the B-pi l l ar tri m on the B-pi l l ar and
al i gn push-i n fasteners.
(3) Press the B-pi l l ar tri m on the B-pi l l ar to
secure.
(4) I nstal l the screws attachi ng the B-pi l l ar tri m to
the B-pi l l ar (2-door vehi cl es).
(5) I nstal l the seat/shoul der bel t anchor bol t.
(6) I nstal l the shoul der bel t turni ng l oop.
(7) I nstal l the A-pi l l ar tri m.
(8) I nstal l the upper quarter panel tri m (2-door
(9) I nstal l the upper door openi ng tri m (4-door
C-PILLAR TRIM
REMOVAL
(2) Remove the upper door openi ng tri m.
(3) Remove the upper quarter panel tri m.
(4) Remove the quarter panel tri m extensi on.
Fig. 68 Door Sill Scuff Plate
XJ BODY 23 - 45
(5) Remove the screws attachi ng the C-pi l l ar tri m
to the C-pi l l ar (Fi g. 69).
(6) Separate the C-pi l l ar tri m from the C-pi l l ar.
INSTALLATION
(1) Posi ti on the C-pi l l ar tri m on the C-pi l l ar.
(2) I nstal l the screws attachi ng the C-pi l l ar tri m to
the C-pi l l ar.
(3) I nstal l the quarter panel tri m extensi on.
(4) I nstal l the upper quarter panel tri m.
(5) I nstal l the upper door openi ng tri m.
QUARTER PANEL TRIM EXTENSION
REMOVAL
(2) Separate quarter panel tri m extensi on from the
wheel house and quarter tri m panel s (Fi g. 69).
INSTALLATION
(1) Posi ti on the quarter panel tri m extensi on on
the wheel house and quarter tri m panel s.
QUARTER PANEL TRIM AND WHEELHOUSE
COVER
REMOVAL
(2) Remove quarter panel tri m extensi on.
(3) Remove l i ftgate scuff pl ate.
(4) Remove the screws attachi ng the quarter panel
tri m from the quarter panel and wheel house tri m
cover (Fi g. 69) and (Fi g. 66).
(5) I f necessary, remove the ti re and mounti ng
brackets from the l eft quarter panel tri m (Fi g. 70).
(6) Remove the screws attachi ng the wheel house
cover to the wheel house.
(7) Separate the wheel house cover from the wheel -
house.
INSTALLATION
(1) Posi ti on the wheel house cover on the wheel -
house.
(2) I nstal l the screws attachi ng the wheel house
cover to the wheel house.
(3) I f removed, i nstal l the ti re and mounti ng
bracket on the l eft quarter panel tri m.
(4) Posi ti on the quarter panel tri m on the quarter
panel and wheel house cover.
Fig. 69 B-Pillar Trim4-Door Vehicles
23 - 46 BODY XJ
(5) I nstal l the screws attachi ng quarter panel tri m
on the quarter panel and wheel house cover.
(6) I nstal l l i ftgate scuff pl ate.
(7) I nstal l quarter panel tri m extensi on.
LIFTGATE PILLAR TRIM
REMOVAL
(1) Remove the l i ftgate openi ng upper tri m.
(2) Remove the l i ftgate pi l l ar tri m screws (Fi g. 71).
(3) Remove the screws attachi ng the l ower quarter
panel tri m to the l i ftgate pi l l ar.
(4) Pul l the tri m panel outward to detach the
spri ng steel cl i ps attachi ng the tri m panel to the pi l -
l ar (2-dr vehi cl es).
(5) Remove l i ftgate pi l l ar tri m.
INSTALLATION
(1) Posi ti on the l i ftgate pi l l ar tri m on the l i ftgate
pi l l ar.
(2) Press the tri m panel i nto pl ace to engage the
spri ng steel cl i ps attachi ng the tri m panel to the pi l -
l ar (2-dr vehi cl es).
(3) I nstal l the screws attachi ng the l ower quarter
panel tri m to the l i ftgate pi l l ar.
(4) I nstal l the l i ftgate pi l l ar tri m screws.
(5) I nstal l the l i ftgate openi ng upper tri m.
LIFTGATE OPENING UPPER TRIM
REMOVAL
(1) Remove the screws attachi ng the l i ftgate open-
i ng upper tri m to the roof panel (Fi g. 72).
(2) Pul l downward to di sengage steel cl i ps attach-
i ng the l i ftgate openi ng upper tri m to the roof panel .
(3) Separate tri m from vehi cl e.
INSTALLATION
Steel cl i ps are used for manufacturi ng purposes
and are not requi red for servi ce.
Fig. 70 Spare Tire
Fig. 71 Liftgate Pillar Trim
XJ BODY 23 - 47
(1) Posi ti on tri m on roof panel .
(2) I nstal l the screws attachi ng the l i ftgate open-
i ng upper tri m to the roof panel .
LIFTGATE SCUFF PLATE
REMOVAL
(1) Remove the screws attachi ng the l i ftgate scuff
pl ate to the fl oor pan (Fi g. 73).
(2) Separate the scuff pl ate from the vehi cl e.
INSTALLATION
(1) Posi ti on the scuff pl ate on the vehi cl e.
(2) Center stri ker i n openi ng.
(3) I nstal l the screws attachi ng the l i ftgate scuff
pl ate to the fl oor pan.
FRONT SHOULDER BELT/BUCKLE
CAUTION: Inspect the front shoulder belts and
buckles. Replace any belt that is either cut, frayed,
torn or damaged in any way. Replace the shoulder
belt if the retractor is damaged or inoperative.
REMOVAL
(1) Sl i de the front seats al l the way forward for
access to the bel t anchor bol t.
(2) Di sconnect the bel t wi re harness connector.
(3) Remove the anchor bol t cover.
(4) Remove the anchor bol t attachi ng the buckl e to
the seat.
(5) Remove the turni ng l oop cover conceal i ng the
shoul der bel t upper anchor bol t.
(6) Use a Torx bi t to remove the upper anchor bol t
(Fi g. 74). Remove the support/gui de washer.
(7) Remove the i nner scuff pl ate/tri m panel from
the door si l l and remove the shoul der bel t l ower
anchor bol t(s) wi th a Torx bi t (Fi g. 75) and (Fi g. 76).
(8) Remove the shoul der bel t and the retractor.
INSTALLATION
(1) Posi ti on the shoul der bel t retractor i n the
shi el d and i nstal l the l ower anchor bol t wi th a Torx
bi t. Ti ghten bol t to 43 Nm (32 ft. l bs.) torque.
(2) Posi ti on the support/gui de washer and shoul der
bel t upper anchor pl ate on the tri m panel . I nstal l the
upper anchor bol t wi th a Torx bi t.
(3) Route bel t through tri m panel .
(4) Ti ghten the upper and l ower anchor bol ts to 43
Fig. 72 Liftgate Opening Upper Trim
Fig. 73 Liftgate Scuff Plate
Fig. 74 Anchor Bolt
23 - 48 BODY XJ
(5) I nstal l the door si l l i nner scuff pl ate/tri m panel
and i nstal l the cap over the upper anchor bol t.
(6) I nstal l the shoul der bel t buckl e and anchor
bol t. Connect the wi re harness connectors. Ti ghten
the buckl e anchor bol t to 43 Nm (32 ft. l bs.) torque.
REAR SHOULDER/LAP BELT/BUCKLE
WARNING: Inspect rear shoulder/lap belts and
buckles. Replace any belt that is either cut, frayed,
torn or damaged in any way. Replace shoulder belt
if retractor is damaged or inoperative.
REMOVAL
(1) Pul l rear seat rel ease strap and ti l t seat cush-
i on forward.
(2) Remove shoul der bel t buckl e and l ap bel t/
buckl e anchor pl ate bol ts from fl oor pan (Fi g. 77).
(3) Remove shoul der bel t l ower outer anchor bol t.
(4) Remove quarter tri m panel . I f necessary, refer
to removal procedure.
(5) Remove shoul der bel t upper anchor bol t.
(6) Remove bol t attachi ng retractor to rear quarter
rai l .
(7) Separate retractor and shoul der bel t from tri m
panel .
INSTALLATION
(1) Posi ti on shoul der bel t buckl e and l ap bel t/
buckl e anchor pl ates on fl oor panel .
(2) I nstal l anchor bol ts. Ti ghten bol ts to 43 Nm
(3) I nstal l retractor support on rear quarter rai l .
Ti ghten screw.
(4) Route shoul der bel t through quarter tri m panel
sl ot.
Fig. 75 Front Shoulder Belt2-Door Vehicles
Fig. 76 Front Shoulder Belt4-Door Vehicles
Fig. 77 Rear Seat Shoulder/Lap Belts and Buckles
XJ BODY 23 - 49
(5) Posi ti on shoul der bel t at roof rai l and i nstal l
upper anchor bol t. Ti ghten bol t to 43 Nm (32 ft. l bs.)
torque.
(6) I nstal l quarter tri m panel .
(7) I nstal l shoul der bel t l ower anchor bol t. Ti ghten
bol t to 43 Nm (32 ft. l bs.) torque.
(8) Return rear seat cushi on to normal posi ti on
and engage l atch.
FULL FLOOR CONSOLE
REMOVAL
(1) Remove the transmi ssi on shi ft l ever handl e/
knob:
Automati c transmi ssi ons, pul l the handl e
strai ght upward to remove i t.
I nsert a thi n-bl ade tool under the edge of the
transmi ssi on shi ft i ndi cator bezel and pry up to
remove.
Manual transmi ssi ons, l oosen the l ocknut and
un-thread the shi ft knob from the shaft.
Pul l the shi ft boot up to remove.
(2) I nsert a thi n-bl ade tool under the edge of the
transfer case shi ft i ndi cator bezel or cover pl ate and
pry up to remove.
(3) Open the consol e l i d.
(4) Remove the screws attachi ng the consol e to the
fl oor and mounti ng bracket (Fi g. 78).
(5) Di sconnect the wi re harness connector.
(6) Separate the consol e from the fl oor.
INSTALLATION
(1) Posi ti on the consol e on the fl oor.
(2) Attach the ai r duct to the ai r outl et duct.
(3) Connect the wi re harness connectors.
(4) I nstal l the screws attachi ng the consol e to the
mounti ng bracket.
(5) I nstal l the shi ft i ndi cator bezel s (or cover
pl ate).
(6) I nstal l the shi ft l ever handl e/knob.
FRONT CARPET/MAT
REMOVAL
(1) Remove the door si l l i nner scuff pl ates.
(2) Remove the front and rear seats (as appl i ca-
bl e).
(3) Remove fl oor consol e.
(4) As necessary, remove the tri m panel s and
mol di ngs.
(5) Remove al l other i nterferi ng components.
(6) Remove the carpet and mat from the fl oor
panel (Fi g. 79).
INSTALLATION
(1) Posi ti on the carpet and mat on the fl oor panel .
(2) I nstal l al l the components that were removed
to faci l i tate carpet/mat removal .
(3) I nstal l the tri m panel s and mol di ngs.
(4) I nstal l the door si l l i nner scuff pl ates.
(5) I nstal l fl oor consol e.
(6) I nstal l the front and rear seats (as appl i cabl e).
REAR CARPET/MAT
REMOVAL
(1) Remove the l i ftgate l atch stri ker and scuff
pl ate.
(2) Dri l l -out the retai ni ng ri vet heads and remove
the cargo ti e-down footman l oops from the carpet.
(3) As necessary, remove the tri m panel s and
mol di ngs.
(4) Remove the al l other i nterferi ng components.
(5) Remove the carpet and mat from the fl oor
panel .
(6) I f necessary, remove the i nsul ati on from the
wheel house (Fi g. 80).
INSTALLATION
(1) I f removed, i nstal l the i nsul ati on on the wheel -
houses.
Fig. 78 Floor Console
Fig. 79 Front Carpet and Mat
23 - 50 BODY XJ
(2) Posi ti on the mat on the fl oor panel .
(3) Posi ti on the carpet on the mat.
(4) I nstal l al l the components that were removed
to faci l i tate carpet and mat removal .
(5) I nstal l the tri m panel s and mol di ngs.
(6) I nstal l the cargo ti e-down footman l oops on the
carpet wi th repl acement ri vets.
(7) I nstal l the l i ftgate scuff pl ate and l atch stri ker.
REARVIEW MIRROR
REMOVAL
(1) Loosen the mi rror base setscrew (Fi g. 81).
(2) Sl i de the mi rror base upward and off the
bracket.
INSTALLATION
(1) Posi ti on the mi rror base at the bracket and
sl i de i t downward onto the support bracket.
(2) Ti ghten setscrew to1 Nm (9 i n. l bs.) torque.
REARVIEW MIRROR SUPPORT BRACKET
INSTALLATION
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
Crush the vi al to saturate the fel t appl i cator.
Remove the paper sl eeve.
Appl y accel erator to the contact surface on the
bracket.
Al l ow the accel erator to dry for fi ve mi nutes.
Do not touch the bracket contact surface after
the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
Appl y one drop of adhesi ve at the center of the
bracket contact-surface on the wi ndshi el d gl ass.
Appl y an even coat of adhesi ve to the contact
surface on the bracket.
Al i gn the bracket wi th the marked posi ti on on
the wi ndshi el d gl ass.
Press and hol d the bracket i n pl ace for at l east
one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
Fig. 80 Wheelhouse Insulation
Fig. 81 Rearview Mirror
XJ BODY 23 - 51
SUNVISORS
REMOVAL
(1) Remove the screws that attach the sunvi sor
arm support bracket to the headl i ner and the roof
panel (Fi g. 82) and (Fi g. 83).
(2) Di sconnect vani ty l amp connector, i f equi pped.
(3) Detach the sunvi sor from the support cl i p.
(4) Remove the sunvi sor from the vehi cl e.
(5) Remove the retai ni ng screw and support cl i p.
On vehi cl es equi pped wi th an overhead consol e, the
support cl i p i s i ntegral wi th the overhead consol e.
INSTALLATION
(1) I nstal l the support bracket and the retai ni ng
screw.
(2) Connect vani ty l amp connector, i f equi pped.
(3) Posi ti on the sunvi sor i n the support cl i p and
al i gn the arm support bracket hol es wi th the head-
l i ner hol es.
(4) I nstal l the screws that attach the sunvi sor arm
support bracket to the headl i ner and the roof panel .
HEADLINER
The upper tri m mol di ngs and the headl i ner are
attached to the roof rai l wi th a combi nati on of
screws, cl i p retai ners and rai l retai ners (Fi g. 84).
To remove a headl i ner, al l of the upper tri m mol d-
i ngs must be removed from the peri meter of the
headl i ner al ong wi th (as appl i cabl e):
Assi st handl es.
Sunvi sors.
Dome/cargo l amps.
Overhead consol e.
Al l other attached/overl appi ng components.
Refer to the appropri ate removal and i nstal l ati on
procedure l ocate i n thi s secti on or i n Group 8, El ec-
tri cal .
REMOVAL
CAUTION: The headliner is a one-piece, molded
component (Fig. 85). It has limited flexibility and
must not be bent during removal/installation.
(1) Remove the upper tri m mol di ngs from the
peri meter of the headl i ner (Fi g. 86).
(2) Ensure that al l the retai ner cl i ps and screws
are di sengaged before removi ng the headl i ner.
(3) Di sengage tabs attachi ng headl i ner/speaker
structure to roof rai l , i f equi pped (Fi g. 85).
(4) Di sengage rear speaker harness connector, i f
equi pped.
INSTALLATION
(1) Engage tabs attachi ng headl i ner/speaker struc-
ture to roof rai l , i f equi pped. (Fi g. 85)
(2) On vehi cl es wi thout headl i ner speakers, ensure
that the retai ner cl i ps on upper l i ftgate openi ng tri m
and rai l s are i nstal l ed. (Fi g. 87)
(3) Engage rear speaker harness connector.
Fig. 82 Sunvisor
Fig. 83 Sunvisor w/Vanity Lamp
Fig. 84 Headliner Trim Moldings
23 - 52 BODY XJ
(4) I nstal l the upper tri m mol di ngs around the
peri meter of the headl i ner. Ti ghten the retai ni ng
screws to 1 Nm (11 i n. l bs.) torque.
(5) As appl i cabl e, i nstal l :
Assi st handl es.
Sunvi sors.
Dome/cargo l amps.
Overhead consol e.
Al l other attached/overl appi ng components.
LIFTGATE TRIM PANEL
REMOVAL
(1) Usi ng a smal l fl at bl ade, pry out the tri m pl ugs
from the l i ftgate assi st handl e.
(2) Remove the screws attachi ng the assi st handl e
to the l i ftgate (Fi g. 88).
(3) Remove the screws that attach the l i ftgate tri m
panel to the l i ftgate.
(4) Usi ng a tri m panel removal tool , detach the
push-i n fasteners from the l i ftgate.
(5) Remove the tri m panel from the l i ftgate.
INSTALLATION
(1) Posi ti on the tri m panel on l i ftgate.
(2) Usi ng new push-i n fasteners, al i gn the push-i n
fasteners wi th the hol es i n the l i ftgate i nner panel
and press the tri m panel i nto pl ace.
(3) I nstal l the screws to attach the l i ftgate tri m
panel to the l i ftgate.
(4) I nstal l the screws attachi ng the assi st handl e
to the l i ftgate.
(5) Press the tri m pl ugs i nto the l i ftgate assi st
handl e.
Fig. 85 Headliner
Fig. 86 Upper Trim Molding4-Door
Fig. 87 Headliner Retainer Clip and Retainer Rail
Fig. 88 Liftgate Trim Panel
XJ BODY 23 - 53
LIFTGATE
REMOVAL
WARNING: DO NOT DISCONNECT SUPPORT ROD
CYLINDERS WITH LIFTGATE CLOSED. SUPPORT
ROD PISTONS ARE OPERATED BY HIGH PRES-
SURE GAS. THIS COULD CAUSE DAMAGE AND/OR
PERSONAL INJURY IF THEY ARE REMOVED WHILE
PISTONS ARE COMPRESSED.
(1) Remove center hi gh mounted stop l amp
(CHMSL).
(2) Open and support l i ftgate.
(4) Di sconnect and pl ug backl i te washer fl ui d sup-
pl y l i ne.
(5) Remove screws that attach rear wi per and l i ft-
gate power l ock wi re harness connectors to l i ftgate
and di sconnect connectors.
(6) Usi ng access hol e created by removal of
CHMSL, route backl i te washer fl ui d suppl y l i ne and
rear wi per and l i ftgate power l ock wi re harness/
grommets through access hol e and separate from l i ft-
gate.
(7) Remove retai ner cl i ps that secure support rods
to bal l studs.
(8) Remove support rods from bal l studs.
(9) Remove bol ts attachi ng hi nges to l i ftgate.
(10) Remove l i ftgate from vehi cl e.
INSTALLATION
(1) Posi ti on and support l i ftgate at openi ng i n body
and i nstal l bol ts attachi ng hi nges to l i ftgate. Ti ghten
bol ts to 26 Nm (19 ft. l bs.) torque.
(2) Connect l i ftgate support rods to bal l studs and
i nstal l retai ner cl i ps.
(3) Route backl i te washer fl ui d suppl y l i ne and
rear wi per and l i ftgate power l ock wi re harnesses/
grommets through access hol e.
(4) Connect connectors and i nstal l screws that
attach rear wi per and l i ftgate power l ock wi re har-
ness connectors to l i ftgate.
(5) Unpl ug and connect backl i te washer fl ui d sup-
pl y l i ne.
(7) Remove supports and cl ose l i ftgate.
(8) I nstal l (CHMSL).
LIFTGATE HINGE
REMOVAL
I t i s not necessary to remove the l i ftgate to repl ace
one or both hi nges.
(1) Open and support the l i ftgate.
(2) Remove the l i ftgate openi ng upper tri m.
(3) Remove the bol ts attachi ng the hi nge to the
header panel (Fi g. 89).
(4) Remove the bol ts attachi ng the hi nge to the
l i ftgate.
INSTALLATION
(1) Posi ti on the hi nge on the l i ftgate.
(2) I nstal l the bol ts attachi ng the hi nge to the l i ft-
gate. Ti ghten to 26 Nm (19 ft. l bs.) torque.
(3) I nstal l the bol ts attachi ng the hi nge to the
header panel . Ti ghten to 26 Nm (19 ft. l bs.) torque.
(4) I nstal l the l i ftgate openi ng upper tri m.
(5) Remove the support and cl ose the l i ftgate.
LIFTGATE SUPPORT ROD CYLINDER
REMOVAL
WARNING: DO NOT REMOVE A SUPPORT ROD
CYLINDER WITH THE LIFTGATE CLOSED. EACH
SUPPORT ROD PISTON IS OPERATED BY HIGH
PRESSURE GAS. IT CAN CAUSE DAMAGE AND/OR
PERSONAL INJURY IF IT IS REMOVED WITH THE
PISTON COMPRESSED. DO NOT ATTEMPT TO DIS-
ASSEMBLE OR REPAIR A SUPPORT ROD CYLIN-
DER.
(1) Open the l i ftgate.
(2) Support the l i ftgate i n the open posi ti on.
(3) Remove the cl i p attachi ng the support rod to
the bal l stud.
(4) Di sconnect the support rod from the bal l stud.
(5) Remove the bol ts attachi ng the support rod to
the l i ftgate (Fi g. 90).
(6) Separate the support rod from the l i ftgate.
INSTALLATION
(1) Posi ti on the support rod on the l i ftgate.
(2) I nstal l the bol ts attachi ng the support rod to
the l i ftgate.
Fig. 89 Liftgate Hinge
23 - 54 BODY XJ
(3) Connect the support rod to the bal l stud.
(4) Secure the support rod to the bal l stud wi th
the retai ner cl i p.
(5) Remove the support from the l i ftgate.
LIFTGATE SUPPORT ROD BALL STUD
REMOVAL
(2) Support the l i ftgate i n the open posi ti on.
(3) Remove the retai ner cl i p attachi ng the support
rod to the bal l stud.
(4) Di sconnect the support rod from the bal l stud.
(5) Remove the bal l stud.
INSTALLATION
(1) I nstal l the repl acement bal l stud.
(2) Connect the support rod to the bal l stud.
(3) Secure the support rod to the bal l stud wi th
the cl i p.
(4) Remove the support from the l i ftgate.
LIFTGATE OUTSIDE HANDLE
REMOVAL
(2) Di sconnect l i ftgate actuator l i nkages.
(3) Di sconnect l i ftgate outsi de handl e to l atch rod.
(4) Remove nut attachi ng outsi de handl e to l i ftgate
(Fi g. 91).
(5) Separate outsi de handl e from l i ftgate.
(6) I f necessary, remove l ock cyl i nder (Fi g. 92).
INSTALLATION
(1) I f necessary, i nstal l l ock cyl i nder.
(2) Posi ti on outsi de handl e on l i ftgate.
(3) I nstal l nut attachi ng outsi de handl e to l i ftgate.
(4) Connect l i ftgate outsi de handl e to l atch rod.
(5) Connect l i ftgate actuator l i nkages.
LIFTGATE LOCK CYLINDER
For servi ce procedures, refer to the Li ftgate Out-
si de Handl e Removal /I nstal l ati on procedures.
LIFTGATE LATCH
REMOVAL
(1) Rai se l i ftgate.
(3) Remove screws attachi ng l atch to l i ftgate (Fi g.
93).
(4) Di sconnect rod from l atch.
(5) Di sconnect power l ock connector from handl e, i f
equi pped.
(6) Remove l atch from l i ftgate.
INSTALLATION
(1) Posi ti on l atch i n l i ftgate.
Fig. 90 Liftgate Support Rod Fig. 91 Liftgate Outside Handle
Fig. 92 Liftgate Lock Cylinder
XJ BODY 23 - 55
(2) Connect power l ock connector to handl e, i f
equi pped.
(3) Connect l atch rod.
(4) I nstal l screws attachi ng l atch to l i ftgate.
LIFTGATE LATCH STRIKER
REMOVAL
(1) From undersi de of vehi cl e, remove nuts attach-
i ng stri ker to fl oor pan (Fi g. 94).
(2) Separate stri ker from vehi cl e.
INSTALLATION
(1) Posi ti on stri ker on vehi cl e.
(2) I nstal l nuts. Ti ghten nuts to 54 Nm (40 ft.
l bs.) torque.
LIFTGATE WEATHERSTRIP
REMOVAL
(1) Pul l the seal away from the fl ange around the
peri meter of l i ftgate openi ng and remove i t.
(2) Cl ean the fl ange as necessary.
INSTALLATION
(1) Posi ti on weatherstri p seal i n the openi ng wi th
the l eft end of the seal at the openi ng centerl i ne.
I nstal l the seal i n a cl ockwi se di recti on.
(2) Move to the l eft and mate the seal wi th the
bottom-l eft fl ange (Fi g. 95).
(3) Move upward and mate the seal wi th the l eft-
si de fl ange.
(4) Move to the ri ght and mate the seal wi th the
top-l eft roof fl ange.
(5) Seat the i nstal l ed part of the seal wi th a rol l er.
Move the rol l er from the l eft-bottom end of seal to
the top-l eft hal f of the seal .
(6) Move to the ri ght and mate the seal wi th the
top-ri ght roof fl ange.
(7) Move downward and mate the seal wi th the
ri ght-si de fl ange.
(8) Move to the l eft and mate the seal wi th the
bottom-ri ght fl ange.
(9) Center and butt seal the ends together at the
centerl i ne.
(10) Seat the remai ni ng part of the seal wi th a
rol l er. Move the rol l er the from top-l eft hal f of the
seal to the ri ght-bottom end of the seal .
Fig. 93 Liftgate Latch
Fig. 94 Liftgagte Striker
Fig. 95 Liftgate Weatherstrip Installation
23 - 56 BODY XJ
ADJ USTMENTS
HOOD
The hood bol t hol es are el ongated for fore and aft
and si de-to-si de adjustment.
(1) I f hood i s l ow to the cowl panel , i nsert shi ms
between the hi nge and hood at the rear hi nge bol ts.
(2) Adjust the hood bumper (Fi g. 96) i n or out to
provi de proper hood-to-fender hei ght al i gnment.
(3) Adjust the hood stri kers (Fi g. 97) wi th shi ms
as necessary. Ti ghten the screws to 22 Nm (16 ft-l bs)
torque after adjustment.
(4) Al i gn each l atch and stri ker so that the stri ker
enters l atch squarel y.
DOOR
IN AND OUT MINOR ADJUSTMENT
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker i nward i f the door charac-
ter l i ne i s outboard of the body character l i ne or tap
the l atch stri ker outward i f the door character l i ne i s
i nboard of the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker
wi th 28 Nm (20 ft. l bs.) torque.
UP AND DOWN MINOR ADJUSTMENT
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker downward i f the door
character l i ne i s hi gher than the body character l i ne
or tap the l atch stri ker upward i f the door character
l i ne i s l ower than the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker
wi th 28 Nm (20 ft. l bs.) torque.
ALIGNMENT MAJOR ADJUSTMENT
Adjustment for al i gnment of the door i s made by
i nstal l i ng shi ms between hi nge and door face (Fi g.
98).
(1) I f not l oosened, l oosen the door hi nge bol ts.
(2) Add or remove shi ms as necessary to obtai n
the best door fi t.
(3) Ti ghten door hi nge bol ts to 3 Nm (2 ft-l bs)
torque after adjustment i s compl eted.
(4) Appl y general purpose seal ant around the door
hi nges/door face mati ng area.
DOOR LATCH ADJUSTMENT
(1) Locate access hol e (Fi g. 99).
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e button several ti mes to
rel ease any restri cti on because of mi s-al i gnment.
Fig. 96 Hood Bumper
Fig. 97 Hood Latch Striker
Fig. 98 Door Adjustment Shims
XJ BODY 23 - 57
(4) Ti ghten adjustment screw to 3 Nm (30 i n-l bs)
torque.
(5) Test handl e button and l ock cyl i nder for proper
operati on.
LIFTGATE
The posi ti on of l i ftgate can be adjusted upward or
downward by use of sl ots i n the hi nge. An i nward or
outward adjustment i s achi eved by use of sl ots i n the
body. I f an i nward or outward adjustment i s needed,
use 3M Fast and Fi rm or equi val ent on the hi nge
to body mati ng surface as a seal ant.
REAR SEATBACK
(1) Unl atch and posi ti on seatback i n cargo posi -
ti on.
(2) Loosen the screws attachi ng the stri kers to the
rear wheel house.
(3) Posi ti on the seat back i n the ful l upri ght posi -
ti on and secure the l atch i nto the stri kers.
(4) From the cargo area of the vehi cl e, push the
rear of the seatback forward.
(5) Unl atch and posi ti on seatback i n cargo posi ti on.
(6) Ti ghten the screws attachi ng the stri kers to
the rear wheel house.
(7) Posi ti on the seat back i n the ful l upri ght posi -
ti on and secure the l atch i nto the stri kers.
(8) Veri fy l atch operati on.
SPECIFICATIONS
BODY LUBRICANTS
COMPONENT SERVICE INTERVAL LUBRICANT
Door Latches As Required Multi-Purpose Grease NLGI
GC-LB (Water Resistant) (1)
Hood Latch, Release Mechanism & Safety
Latch
As Required
(When Performing Other
Underhood Service)
Multi-Purpose Grease NLGI
GC-LB 2 EP (2)
Hood Hinges As Required Engine Oil
Seat Track & Release Mechanism As Required Multi-Purpose Grease NLGI
GC-LB 2 EP (2)
Liftgate Hinge As Required Multi-Purpose Grease NLGI
GC-LB 2 EP (2)
Liftgate Support Arms As Required Engine Oil
Liftgate Latches As Required White Spray Lubricant (3)
Liftgate Release Handle (Pivot & Slide Contact
Surfaces)
As Required Multi-Purpose Grease NLGI
GC-LB 2 EP (2)
Window System Components As Required White Spray Lubricant (3)
Lock Cylinders Twice A Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI
GC-LB 2 EP (1)
1 = Mopar Wheel Bering Grease (High Temp)
2 = Mopar Multi-Mileage Lubricant
3 = Mopar Spray White Lube
4 = Mopar Lock Cylinder Lubricant
Fig. 99 Door Latch Adjustment
23 - 58 BODY XJ
WELD LOCATIONS
UPPER COWL
XJ BODY 23 - 59
UPPER COWL
23 - 60 BODY XJ
COWL
XJ BODY 23 - 61
A PILLAR
23 - 62 BODY XJ
A PILLAR
XJ BODY 23 - 63
A PILLAR
23 - 64 BODY XJ
A PILLAR
XJ BODY 23 - 65
B PILLAR
23 - 66 BODY XJ
D PILLAR
XJ BODY 23 - 67
FUEL FILLER OPENING
23 - 68 BODY XJ
CARGO AREA FLOOR PAN
XJ BODY 23 - 69
ROOF AND D PILLAR
23 - 70 BODY XJ
LIFTGATE OPENING
XJ BODY 23 - 71
ROOF
23 - 72 BODY XJ
ROOF
XJ BODY 23 - 73
FRAME RAIL
23 - 74 BODY XJ
FRAME RAIL
XJ BODY 23 - 75
FRAME RAIL
23 - 76 BODY XJ
FRAME RAIL
XJ BODY 23 - 77
REINFORCEMENT
23 - 78 BODY XJ
FRONT INNER FENDER
XJ BODY 23 - 79
FRONT INNER FENDER AND RADIATOR CLOSURE PANEL
23 - 80 BODY XJ
REINFORCEMENT
FRONT FENDER
XJ BODY 23 - 81
BODY SIDE
23 - 82 BODY XJ
REAR WHEELHOUSE
XJ BODY 23 - 83
REAR INNER WHEELHOUSE
23 - 84 BODY XJ
BODY SIDE
XJ BODY 23 - 85
BODY SIDE
23 - 86 BODY XJ
BODY SIDE
XJ BODY 23 - 87
BODY SIDE
23 - 88 BODY XJ
BODY SIDE
XJ BODY 23 - 89
BODY SIDE
23 - 90 BODY XJ
UNDERBODY
XJ BODY 23 - 91
UNDERBODY
23 - 92 BODY XJ
UNDERBODY
XJ BODY 23 - 93
UNDERBODY
23 - 94 BODY XJ
UNDERBODY
XJ BODY 23 - 95
UNDERBODY
23 - 96 BODY XJ
UNDERBODY
XJ BODY 23 - 97
UNDERBODY
23 - 98 BODY XJ
UNDERBODY
XJ BODY 23 - 99
UNDERBODY
23 - 100 BODY XJ
UNDERBODY
XJ BODY 23 - 101
BODY SEALING LOCATIONS
APPLICATION METHODS
23 - 102 BODY XJ
COWL AND DASH PANEL
XJ BODY 23 - 103
DASH PANEL AND FLOOR PAN
23 - 104 BODY XJ
FLOOR PAN
XJ BODY 23 - 105
REAR INNER WHEELHOUSE
23 - 106 BODY XJ
FRONT INNER WHEELHOUSE
XJ BODY 23 - 107
BODY SIDE
23 - 108 BODY XJ
BODY SIDE
XJ BODY 23 - 109
BODY SIDE
23 - 110 BODY XJ
ROOF PANEL
XJ BODY 23 - 111
FUEL FILLER HOUSING
23 - 112 BODY XJ
LIFTGATE OPENING
XJ BODY 23 - 113
STRUCTURAL ADHESIVE LOCATIONS
LEFT QUARTER PANEL
23 - 114 BODY XJ
REAR WHEELHOUSE
XJ BODY 23 - 115
ROOF BOWS
23 - 116 BODY XJ
BODY GAP AND FLUSH MEASUREMENTS
XJ BODY 23 - 117
BODY OPENING DIMENSIONS
WINDSHIELD OPENING
A. & B. Center of radi us at bottom to center of
radi us at top
23 - 118 BODY XJ
FRONT DOOR OPENING 2DOOR
A. Center of front door l ower rear radi us to cen-
ter of A-pi l l ar radi us
B. Center of radi us at bottom rear to center of
radi us at l ower A-pi l l ar
C. Center of radi us at bottom front to center of
radi us at top rear
XJ BODY 23 - 119
FRONT DOOR OPENING 4DOOR
C. Center of front door l ower rear radi us to cen-
ter of A-pi l l ar radi us
E. Center of radi us at bottom rear to center of
radi us at l ower A-pi l l ar
F. Center of radi us at bottom front to center of
radi us at top rear
23 - 120 BODY XJ
REAR DOOR OPENING
A. Quarter panel to front outer body si de upper
and l ower seam
B. Center of front upper door radi us to center of
rear l ower door radi us
C. Center of front l ower door radi us to center of
rear upper door radi us
D. Fl ange to rear door stri ker mount
XJ BODY 23 - 121
QUARTER WINDOW OPENING 2DOOR
A. Center of upper and l ower rear quarter wi n-
dow openi ng
B. Center of radi us front l ower corner to center
of radi us rear upper corner
C. Center of radi us front upper corner to center
of radi us rear l ower corner
23 - 122 BODY XJ
QUARTER WINDOW OPENING 4DOOR
A. Center of upper and l ower rear quarter wi n-
dow openi ng
B. Center of radi us front l ower corner to center
of radi us rear upper corner
C. Center of radi us front upper corner to center
of radi us rear l ower corner
XJ BODY 23 - 123
ENGINE COMPARTMENT
23 - 124 BODY XJ
LIFTGATE OPENING
A. Center of upper l i ftgate openi ng to l i ftgate
stri ker mount
B. & C. Center of radi us upper corner to center
of radi us l ower corner
D. Di stance between outer quarter panel to tai l
l amp mounti ng panel to i nner quarter panel seams
DESCRIPTION TORQUE
Bucket Seat to Fl oor Pan Bol t . . 27 Nm (20 ft. l bs.)
Bucket Seat to Fl oor Pan Nut . . 40 Nm (30 ft. l bs.)
Front Door Hi nge Bol ts . . . . . . . . . 3 Nm (2 ft. l bs.)
Front Door Latch Screw . . . . . . . . 11 Nm (8 ft. l bs.)
Front Door Latch Stri ker Screw . . . . . . . . . . 28 Nm
(20 ft. l bs.)
Front Seat Bel t Anchor Bol t . . . . 43 Nm (32 ft. l bs.)
Front Retractor Anchor Bol t . . . . 43 Nm (32 ft. l bs.)
Front Seat Bel t Buckl e Anchor Bol t . . . . . . . 43 Nm
(32 ft. l bs.)
GOP to Support Bracket Nut . . . . 4 Nm (38 i n. l bs.)
GOP to Fender Nut . . . . . . . . . . . 4 Nm (38 i n. l bs.)
Li ftgate Hi nge to Body and/or Li ftgate
Bol t . . . . . . . . . . . . . . . . . . . . 26 Nm (19 ft. l bs.)
Li ftgate Latch Screw . . . . . . . . . . 13 Nm (9 ft. l bs.)
Li ftgate Latch Stri ker Nut . . . . . 54 Nm (40 ft. l bs.)
DESCRIPTION TORQUE
Rear Door Hi nge Bol t . . . . . . . . . . . 3 Nm (2 ft. l bs.)
Rear Door Latch Screw . . . . . . . . 11 Nm (8 ft. l bs.)
Rear Door Latch Stri ker Screw . . . . . . . . . . 28 Nm
(20 ft. l bs.)
Rear Shoul der Bel t Lower Anchor Bol t . . . . 43 Nm
(32 ft. l bs.)
Rear Seatback Pi vot Bol t . . . . . . 33 Nm (25 ft. l bs.)
Rear Seat Bel t/Buckl e Anchor Bol t . . . . . . . . 43 Nm
(32 ft. l bs.)
Rear Shoul der Bel t Upper Anchor Bol t . . . . 43 Nm
(32 ft. l bs.)
XJ BODY 23 - 125
SPECIAL TOOLS
BODY
Remover, Moldings C-4829
23 - 126 BODY XJ
HEATING AND AIR CONDITIONING
CONTENTS
page page
GENERAL INFORMATION
HEATER AND AIR CONDITIONER CONTROL . . 2
HEATER AND AIR CONDITIONER . . . . . . . . . . . 2
SERVICE WARNINGS AND PRECAUTIONS . . . . 3
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . 4
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . 5
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . . 5
BLOWER MOTOR SWITCH . . . . . . . . . . . . . . . . 5
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 4
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . . 6
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . . . . 6
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . 5
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . 6
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . . 6
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . 6
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . . 7
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . . 7
LOW PRESSURE CYCLING CLUTCH SWITCH . 7
REFRIGERANT LINE COUPLER . . . . . . . . . . . . 8
REFRIGERANT LINE . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . . . 8
REFRIGERANT SYSTEM SERVICE
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REFRIGERANT SYSTEM SERVICE PORT . . . . . 8
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . 7
VACUUM CHECK VALVE . . . . . . . . . . . . . . . . . . 9
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 9
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . . . 9
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . 15
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . 18
BLOWER MOTOR SWITCH . . . . . . . . . . . . . . . 18
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . 15
COMPRESSOR CLUTCH COIL . . . . . . . . . . . . 19
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . 19
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 19
HEATER PERFORMANCE . . . . . . . . . . . . . . . . 13
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 20
LOW PRESSURE CYCLING
CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . 20
REFRIGERANT SYSTEM LEAKS . . . . . . . . . . . 20
VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14
SERVICE PROCEDURES
REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . . 21
REFRIGERANT RECOVERY . . . . . . . . . . . . . . 21
REFRIGERANT SYSTEM CHARGE . . . . . . . . . 21
REFRIGERANT SYSTEM EVACUATE . . . . . . . . 21
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . 32
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . 37
BLOWER MOTOR RESISTOR . . . . . . . . . . . . . 38
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . 35
COMPRESSOR CLUTCH RELAY . . . . . . . . . . . 29
COMPRESSOR CLUTCH . . . . . . . . . . . . . . . . . 26
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 25
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DUCTS AND OUTLETS . . . . . . . . . . . . . . . . . . 44
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . 43
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . 31
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . 44
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . . . 35
HEATER-A/C HOUSING DOOR . . . . . . . . . . . . 42
HEATER-A/C HOUSING . . . . . . . . . . . . . . . . . . 39
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 23
KICK COVER . . . . . . . . . . . . . . . . . . . . . . . . . . 37
LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LOW PRESSURE CYCLING
CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . 31
MODE DOOR VACUUM ACTUATOR . . . . . . . . . 38
REFRIGERANT LINE COUPLER . . . . . . . . . . . 22
SUCTION AND DISCHARGE LINE . . . . . . . . . . 23
TEMPERATURE CONTROL CABLE . . . . . . . . . 36
VACUUM CHECK VALVE . . . . . . . . . . . . . . . . . 34
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . 34
XJ HEATING AND AIR CONDITIONING 24 - 1
GENERAL INFORMATION
HEATER AND AIR CONDITIONER
Al l vehi cl es are equi pped wi th a common heater-
A/C housi ng assembl y (Fi g. 1). The system combi nes
ai r condi ti oni ng, heati ng, and venti l ati ng capabi l i ti es
i n a si ngl e uni t housi ng mounted under the i nstru-
ment panel . On heater-onl y systems, the evaporator
coi l and reci rcul ati ng ai r door are omi tted from the
housi ng.
Outsi de fresh ai r enters the vehi cl e through the
cowl top openi ng at the base of the wi ndshi el d, and
passes through a pl enum chamber to the heater-A/C
system bl ower housi ng. Ai r fl ow vel oci ty can then be
adjusted wi th the bl ower motor speed sel ector swi tch
on the heater-A/C control panel . The ai r i ntake open-
i ngs must be kept free of snow, i ce, l eaves, and other
obstructi ons for the heater-A/C system to recei ve a
suffi ci ent vol ume of outsi de ai r.
The heater and opti onal ai r condi ti oner are bl end-
ai r type systems. I n a bl end-ai r system, a bl end-ai r
door control s the amount of uncondi ti oned ai r (or
cool ed ai r from the evaporator on model s wi th ai r
condi ti oni ng) i s al l owed to fl ow through, or around,
the heater core. A temperature control l ever on the
heater-A/C control panel determi nes the di scharge
ai r temperature by movi ng a cabl e, whi ch operates
the bl end-ai r door. Thi s al l ows an al most i mmedi ate
manual control of the output ai r temperature of the
system.
The mode control knob on the heater-A/C control
panel i s used to di rect the condi ti oned ai r to the
sel ected system outl ets. Both mode control swi tches
use engi ne vacuum to control the mode doors through
vacuum actuator motors.
On ai r condi ti oned vehi cl es, the outsi de ai r i ntake
can be shut off by sel ecti ng the Reci rcul ati on Mode
wi th the mode control knob. Thi s wi l l open a vacuum
actuated reci rcul ati ng ai r door and reci rcul ate the ai r
that i s al ready i nsi de the vehi cl e.
The opti onal ai r condi ti oner for al l model s i s
desi gned for the use of non-CFC, R-134a refri gerant.
The ai r condi ti oni ng system has an evaporator to cool
and dehumi di fy the i ncomi ng ai r pri or to bl endi ng i t
wi th the heated ai r. Thi s system uses a fi xed ori fi ce
tube i n the l i qui d l i ne near the condenser outl et tube
to meter refri gerant fl ow to the evaporator coi l . To
mai ntai n mi ni mum evaporator temperature, a fi xed
pressure setti ng swi tch on the accumul ator cycl es the
compressor cl utch.
NOTE: This group covers both Left-Hand Drive
(LHD) and Right-Hand Drive (RHD) versions of this
model. Whenever required and feasible, the RHD
versions of affected vehicle components have been
constructed as mirror-image of the LHD versions.
While most of the illustrations used in this group
represent only the LHD version, the diagnostic and
service procedures outlined can generally be
applied to either version. Exceptions to this rule
have been clearly identified as LHD or RHD, if a
special illustration or procedure is required.
HEATER AND AIR CONDITIONER CONTROL
Both the heater-onl y and heater-A/C systems use a
combi nati on of mechani cal , el ectri cal , and vacuum
control s. These control s provi de the vehi cl e operator
wi th a number of setti ng opti ons to hel p control the
cl i mate and comfort wi thi n the vehi cl e. Refer to the
owners manual for more i nformati on on the sug-
gested operati on and use of these control s.
The heater-onl y or heater-A/C control panel i s
l ocated to the ri ght of the i nstrument cl uster on the
i nstrument panel . The control panel contai ns a rotat-
i ng-type temperature control knob, a rotati ng-type
mode control swi tch knob, and a rotati ng-type bl ower
motor swi tch knob.
The heater-onl y or heater-A/C control panel cannot
be repai red. I f faul ty or damaged, the enti re uni t
must be repl aced.
Fig. 1 Common Blend-Air Heater-Air Conditioner
System - Typical
HEATER CORE BLEND-AIR DOOR
EVAPORATOR A/C
ONLY
RECIRCULATING AIR DOOR A/C ONLY FLOOR/PANEL DOOR
FLOOR/DE-
FROST
DOOR
24 - 2 HEATING AND AIR CONDITIONING XJ
SERVICE WARNINGS AND PRECAUTIONS
WARNING:
THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER
SERVICE PROCEDURES. REPAIRS SHOULD ONLY
BE PERFORMED BY QUALIFIED SERVICE PERSON-
NEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC LEAK DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIG-
ERANT AT AVERAGE TEMPERATURE AND ALTI-
TUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE
VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
CAUTION:
Liquid refrigerant is corrosive to metal sur-
faces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
R-12 refrigerant oil must not be mixed with
R-134a refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the
R-134a system. Damage to the system will result.
Do not overcharge the refrigerant system. This
will cause excessive compressor head pressure
and can cause noise and system failure.
I n addi ti on to the warni ngs and cauti ons l i sted above,
the fol l owi ng precauti ons must al so be observed when-
ever servi ci ng the ai r condi ti oni ng system:
Recover the refri gerant before openi ng any fi t-
ti ng or connecti on. Open the fi tti ngs wi th cauti on,
even after the system has been di scharged. Never
open or l oosen a connecti on before recoveri ng the
refri gerant.
The refri gerant system must al ways be evacu-
ated before chargi ng.
Do not open the refri gerant system or uncap a
repl acement component unti l you are ready to servi ce
the system. Thi s wi l l prevent contami nati on i n the sys-
tem.
Before di sconnecti ng a component, cl ean the out-
si de of the fi tti ngs thoroughl y to prevent contami na-
ti on from enteri ng the refri gerant system.
I mmedi atel y after di sconnecti ng a component
from the refri gerant system, seal the open fi tti ngs
wi th a cap or pl ug.
Before connecti ng an open refri gerant fi tti ng,
al ways i nstal l a new seal or gasket. Coat the fi tti ng
and seal wi th cl ean refri gerant oi l before connecti ng.
Do not remove the seal i ng caps from a repl ace-
ment component unti l i t i s to be i nstal l ed.
When i nstal l i ng a refri gerant l i ne, avoi d sharp
bends that may restri ct refri gerant fl ow. Posi ti on the
refri gerant l i nes away from exhaust system components
or any sharp edges, whi ch may damage the l i ne.
Ti ghten refri gerant fi tti ngs onl y to the speci fi ed
torque. The al umi num fi tti ngs used i n the refri gerant
system wi l l not tol erate overti ghteni ng.
When di sconnecti ng a refri gerant fi tti ng, use a
wrench on both hal ves of the fi tti ng. Thi s wi l l pre-
vent twi sti ng of the refri gerant l i nes or tubes.
Refri gerant oi l wi l l absorb moi sture from the
atmosphere i f l eft uncapped. Do not open a contai ner
of refri gerant oi l unti l you are ready to use i t.
Repl ace the cap on the oi l contai ner i mmedi atel y
after usi ng. Store refri gerant oi l onl y i n a cl ean, ai r-
ti ght, and moi sture-free contai ner.
Keep servi ce tool s and the work area cl ean. Con-
tami nati on of the refri gerant system through carel ess
work habi ts must be avoi ded.
COOLING SYSTEM REQUIREMENTS
To mai ntai n the performance l evel of the heati ng-
ai r condi ti oni ng system, the engi ne cool i ng system
must be properl y mai ntai ned.
The use of a bug screen i s not recommended. Any
obstructi ons i n front of the radi ator or condenser wi l l
reduce the performance of the ai r condi ti oni ng and
engi ne cool i ng systems.
COOLANT PRECAUTIONS
WARNING:
ANTIFREEZE IS AN ETHYLENE GLYCOL
BASED COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT-
ING. IF INHALED, MOVE TO A FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY.
WASH THE SKIN AND CLOTHING THOR-
OUGHLY AFTER COMING IN CONTACT WITH ETH-
YLENE GLYCOL.
KEEP OUT OF THE REACH OF CHILDREN
AND PETS.
DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE.
PERSONAL INJURY MAY RESULT.
DO NOT STORE ENGINE COOLANT IN OPEN
OR UNMARKED CONTAINERS.
HOT ENGINE COOLANT CAN CAUSE SEVERE
BURNS. DO NOT OPEN THE RADIATOR DRAIN
COCK WHEN THE COOLING SYSTEM IS HOT AND
PRESSURIZED. ALLOW THE COOLANT TO REACH
TO ROOM TEMPERATURE BEFORE STARTING
REPAIR OPERATIONS.
The engi ne cool i ng system i s desi gned to devel op
i nternal pressures of 97 to 124 kPa (14 to 18 psi ).
Al l ow the vehi cl e 15 mi nutes to cool down, or wai t
unti l a safe temperature and pressure are attai ned,
before openi ng the cool i ng system. Refer to Group 7 -
Cool i ng System for more i nformati on.
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS
Ki nks or sharp bends i n the refri gerant pl umbi ng
wi l l reduce the capaci ty of the enti re system. Hi gh
pressures are produced i n the system when i t i s oper-
ati ng. Extreme care must be exerci sed to make sure
that al l refri gerant system connecti ons are pressure
ti ght.
A good rul e for the fl exi bl e hose refri gerant l i nes i s
to keep the radi us of al l bends at l east ten ti mes the
di ameter of the hose. Sharp bends wi l l reduce the
fl ow of refri gerant. The fl exi bl e hose l i nes shoul d be
routed so they are at l east 80 mm (3 i nches) from the
exhaust mani fol d. I t i s a good practi ce to i nspect al l
fl exi bl e refri gerant system hose l i nes at l east once a
year to make sure they are i n good condi ti on and
properl y routed.
There are two types of refri gerant fi tti ngs:
Al l fi tti ngs wi th O-ri ngs need to be coated wi th
refri gerant oi l before i nstal l ati on. Use onl y O-ri ngs
approved for use wi th R-134a refri gerant. Fai l ure to
do so may resul t i n a l eak.
Uni fi ed pl umbi ng connecti ons wi th al umi num
gaskets cannot be servi ced wi th O-ri ngs. The gaskets
are not reusabl e and new gaskets do not requi re
l ubri cati on before i nstal l i ng.
Usi ng the proper tool s when maki ng a refri gerant
pl umbi ng connecti on i s very i mportant. I mproper
tool s or i mproper use of the tool s can damage the
refri gerant fi tti ngs. Al ways use two wrenches when
l ooseni ng or ti ghteni ng tube fi tti ngs. Use one wrench
to hol d one si de of the connecti on stati onary, whi l e
l ooseni ng or ti ghteni ng the other si de of the connec-
ti on wi th a second wrench.
The refri gerant must be recovered compl etel y from
the system before openi ng any fi tti ng or connecti on.
Open the fi tti ngs wi th cauti on, even after the refri g-
erant has been recovered. I f any pressure i s noti ced
as a fi tti ng i s l oosened, ti ghten the fi tti ng and
recover the refri gerant from the system agai n.
Do not di scharge refri gerant i nto the atmosphere.
Use an R-134a refri gerant recovery/recycl i ng devi ce
that meets SAE Standard J2210.
The refri gerant system wi l l remai n chemi cal l y sta-
bl e as l ong as pure, moi sture-free R-134a refri gerant
and refri gerant oi l i s used. Di rt, moi sture, or ai r can
upset thi s chemi cal stabi l i ty. Operati onal troubl es or
seri ous damage can occur i f forei gn materi al i s
present i n the refri gerant system.
When i t i s necessary to open the refri gerant sys-
tem, have everythi ng needed to servi ce the system
ready. The refri gerant system shoul d not be l eft open
to the atmosphere any l onger than necessary. Cap or
pl ug al l l i nes and fi tti ngs as soon as they are opened
to prevent the entrance of di rt and moi sture. Al l l i nes
and components i n parts stock shoul d be capped or
seal ed unti l they are to be i nstal l ed.
Al l tool s, i ncl udi ng the refri gerant recycl i ng equi p-
ment, the mani fol d gauge set, and test hoses shoul d
be kept cl ean and dry. Al l tool s and equi pment must
be desi gned for R-134a refri gerant.
ACCUMULATOR
The accumul ator i s mounted i n the engi ne com-
partment between the evaporator coi l outl et tube and
the compressor i nl et. Refri gerant enters the accumu-
l ator cani ster as a l ow pressure vapor through the
i nl et tube.
Any l i qui d, oi l -l aden refri gerant fal l s to the bottom
of the cani ster, whi ch acts as a separator. A desi ccant
bag i s mounted i nsi de the accumul ator cani ster to
absorb any moi sture whi ch may have entered and
become trapped i n the refri gerant system (Fi g. 2).
BLOWER MOTOR
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the heater-A/C housi ng,
bel ow the gl ove box. The bl ower motor control s the
vel oci ty of ai r fl owi ng through the heater-A/C hous-
i ng by spi nni ng a squi rrel cage-type bl ower wheel
wi thi n the housi ng at the sel ected speed. The bl ower
motor and wheel can be removed from the engi ne
compartment si de of the housi ng wi thout heater-A/C
housi ng removal .
The bl ower motor wi l l onl y operate when the i gni -
ti on swi tch i s i n the On posi ti on, and the heater-A/C
mode control swi tch knob i s i n any posi ti on, except
Off. The bl ower motor recei ves a fused battery feed
through the bl ower motor rel ay whenever the i gni -
ti on swi tch i s i n the On posi ti on. The bl ower motor
battery feed ci rcui t i s protected by a fuse i n the
Power Di stri buti on Center (PDC). Bl ower motor
speed i s control l ed by regul ati ng the ground path
through the heater-A/C control bl ower motor swi tch
and the bl ower motor resi stor.
The bl ower motor and bl ower motor wheel cannot
be repai red and, i f faul ty, they must be repl aced. The
bl ower motor and bl ower wheel are servi ced onl y as a
uni t.
BLOWER MOTOR RELAY
The bl ower motor rel ay i s a I nternati onal Stan-
dards Organi zati on (I SO)-type rel ay. The rel ay i s a
el ectromechani cal devi ce that swi tches battery cur-
rent from a fuse i n the Power Di stri buti on Center
(PDC) di rectl y to the bl ower motor. The rel ay i s ener-
gi zed when the rel ay coi l i s provi ded a vol tage si gnal
by the i gni ti on swi tch. See the Di agnosi s and Testi ng
secti on of thi s group for more i nformati on on the
operati on of the bl ower motor rel ay.
The bl ower motor rel ay i s l ocated i n a wi re harness
connector that i s secured to the heater-A/C housi ng
behi nd the gl ove box on the passenger si de of the
vehi cl e, next to the heater-A/C wi re harness connec-
tor i n the passenger compartment.
The bl ower motor rel ay cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
BLOWER MOTOR RESISTOR
The bl ower motor resi stor i s mounted to the bot-
tom of the heater-A/C housi ng on the passenger si de
of the vehi cl e under the i nstrument panel . I t can be
accessed for servi ce by removi ng the heater-A/C
housi ng ki ck cover.
The resi stor has mul ti pl e resi stor wi res, each of
whi ch reduce the current fl ow to the bl ower motor by
changi ng the resi stance i n the bl ower motor ground
path. The bl ower motor swi tch di rects the ground
path through the correct resi stor wi re to obtai n the
sel ected speed. When the hi ghest bl ower speed i s
sel ected, the bl ower motor swi tch connects the bl ower
motor di rectl y to ground, bypassi ng the bl ower motor
resi stor.
The bl ower motor resi stor cannot be repai red and,
i f faul ty, i t must be repl aced.
BLOWER MOTOR SWITCH
The heater or heater-A/C bl ower motor i s con-
trol l ed by a four posi ti on rotary-type bl ower motor
swi tch, mounted i n the heater-A/C control panel . The
swi tch al l ows the sel ecti on of one of four bl ower
motor speeds, but can onl y be turned off by sel ecti ng
the Off posi ti on wi th the heater-A/C mode control
swi tch knob.
The bl ower motor swi tch di rects the bl ower motor
ground path through the mode control swi tch to the
bl ower motor resi stor, or di rectl y to ground, as
requi red to achi eve the sel ected bl ower motor speed.
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, the enti re heater-A/C control
panel must be repl aced.
COMPRESSOR
The ai r condi ti oni ng system uses a Sanden
SD7H15 fi xed di spl acement compressor on al l mod-
el s. A l abel i denti fyi ng the use of R-134a refri gerant
i s l ocated on the compressor. The purpose of the com-
pressor i s to compress the l ow-pressure refri gerant
vapor from the evaporator i nto a hi gh-pressure, hi gh-
temperature vapor. The compressor i s servi ced onl y
as an assembl y.
Fig. 2 Accumulator - Typical
INLET FROM EVAPORATOR CLUTCH CYCLING PRES- SURE SWITCH PRESSURE SWITCH FITTING OUTLET TO COM- PRESSOR ANTI-SIPHON HOLE DESICCANT BAG OIL RETURN ORIFICE FIL- TER VAPOR RETURN TUBE ACCUMULATOR DOME O-RING SEAL
COMPRESSOR CLUTCH
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a hub beari ng and pul -
l ey assembl y, and a cl utch pl ate (Fi g. 3). The
el ectromagneti c coi l and pul l ey are retai ned on the
compressor wi th snap ri ngs. The cl utch pl ate i s
mounted on the compressor shaft and secured wi th a
nut.
These components provi de the means to engage
and di sengage the compressor from the engi ne ser-
penti ne accessory dri ve bel t. When the cl utch coi l i s
energi zed, i t magneti cal l y draws the cl utch i nto con-
tact wi th the pul l ey and dri ves the compressor shaft.
When the coi l i s not energi zed, the pul l ey freewheel s
on the cl utch hub beari ng, whi ch i s part of the pul l ey.
The compressor cl utch and coi l are the onl y servi ced
parts on the compressor.
The compressor cl utch i s control l ed by several com-
ponents: the heater-A/C mode control swi tch, the l ow
pressure cycl i ng cl utch swi tch, the hi gh pressure cut-
off swi tch, the compressor cl utch rel ay, and the Pow-
ertrai n Control Modul e (PCM). The PCM may del ay
compressor cl utch engagement for up to 30 seconds.
Refer to Group 14 - Fuel System for more i nforma-
ti on on the PCM control s.
COMPRESSOR CLUTCH RELAY
The compressor cl utch rel ay i s a I nternati onal
Standards Organi zati on (I SO) mi cro-rel ay. The termi -
nal desi gnati ons and functi ons are the same as a con-
venti onal I SO rel ay. However, the mi cro-rel ay
termi nal ori entati on (footpri nt) i s di fferent, current
capaci ty i s l ower, and the rel ay case di mensi ons are
smal l er than those of the conventi onal I SO rel ay.
The compressor cl utch rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the compres-
sor cl utch coi l when the Powertrai n Control Modul e
(PCM) grounds the coi l si de of the rel ay. The PCM
responds to i nputs from the heater-A/C mode control
swi tch, the l ow pressure cycl i ng cl utch swi tch, and
the hi gh pressure cut-off swi tch. See the Di agnosi s
and Testi ng secti on of thi s group for more i nforma-
ti on on the operati on of the compressor cl utch rel ay.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
The compressor cl utch rel ay cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
CONDENSER
The condenser i s l ocated i n front of the engi ne cool -
i ng radi ator. I t i s a heat exchanger that al l ows the
hi gh-pressure refri gerant gas to gi ve up i ts heat to
the ai r passi ng over the condenser fi ns. Thi s causes
the refri gerant gas to condense i nto a hi gh-pressure
l i qui d refri gerant.
The condenser cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
EVAPORATOR COIL
The evaporator coi l i s l ocated i n the heater-A/C
housi ng, under the i nstrument panel . Refri gerant
enters the evaporator as a l ow-temperature, l ow-
pressure l i qui d. As ai r passes over the fi ns of the
evaporator, the humi di ty i n the ai r condenses on the
fi ns, and the heat from the ai r i s absorbed by the
refri gerant. Heat absorpti on causes the refri gerant to
become a l ow-pressure gas before i t l eaves the evap-
orator.
The evaporator coi l cannot be repai red and, i f
FIXED ORIFICE TUBE
The fi xed ori fi ce tube i s i nstal l ed i n the l i qui d l i ne
between the outl et tube of the condenser and the
i nl et tube of the evaporator. The fi xed ori fi ce tube i s
l ocated i n the end of the l i qui d l i ne or l i qui d l i ne
jumper that connects to the condenser outl et tube.
The i nl et and outl et ends of the tube have a screen
to fi l ter the refri gerant. O-ri ngs on the tube body pre-
vent the refri gerant from bypassi ng the fi xed ori fi ce.
The fi xed ori fi ce tube i s used to meter the fl ow of l i q-
ui d refri gerant i nto the evaporator coi l .
The fi xed ori fi ce tube cannot be repai red and, i f
faul ty or pl ugged, the l i qui d l i ne or l i qui d l i ne
jumper contai ni ng the fi xed ori fi ce tube must be
repl aced.
HEATER CORE
The heater core i s l ocated i n the heater-A/C hous-
i ng, under the i nstrument panel . I t i s a heat
exchanger made of rows of tubes and fi ns. Engi ne
cool ant i s ci rcul ated through heater hoses to the
heater core at al l ti mes. As the cool ant fl ows through
Fig. 3 Compressor Clutch
CLUTCH PLATE SHAFT KEY PULLEY COIL CLUTCH SHIMS SNAP RING SNAP RING
the heater core, heat removed from the engi ne i s
transferred to the heater core fi ns and tubes.
Ai r di rected through the heater core pi cks up the
heat from the heater core fi ns. The bl end ai r door
al l ows control of the heater output ai r temperature
by control l i ng how much of the ai r fl owi ng through
the heater-A/C housi ng i s di rected through the
heater core. The bl ower motor speed control s the
amount of ai r fl owi ng through the heater-A/C hous-
i ng.
The heater core cannot be repai red and, i f faul ty or
HIGH PRESSURE CUT-OFF SWITCH
The hi gh pressure cut-off swi tch i s l ocated on the
di scharge l i ne between the compressor and the con-
denser i nl et. Thi s swi tch i s connected i n seri es wi th
the l ow pressure cycl i ng cl utch swi tch between
ground and the Powertrai n Control Modul e (PCM).
The swi tch contacts open and cl ose causi ng the PCM
to turn the compressor cl utch on and off. Thi s pre-
vents compressor operati on when the di scharge l i ne
pressure approaches hi gh l evel s.
The hi gh pressure cut-off swi tch contacts are open
when the di scharge l i ne pressure ri ses above 3100 to
3375 kPa (450 to 490 psi ). The swi tch contacts wi l l
cl ose when the di scharge l i ne pressure drops to 1860
to 2275 kPa (270 to 330 psi ).
The hi gh pressure cut-off swi tch i s a factory-cal i -
brated uni t. The swi tch cannot be adjusted or
repai red and, i f faul ty or damaged, i t must be
repl aced.
HIGH PRESSURE RELIEF VALVE
The hi gh pressure rel i ef val ve i s l ocated on the
compressor. The val ve i s used to prevent excessi ve
refri gerant system pressure. The val ve vents the sys-
tem when a pressure of 3445 to 4135 kPa (500 to 600
psi ), and above, i s reached. Thi s prevents damage to
the compressor and other system components due to
condenser ai r fl ow bei ng restri cted or an overcharge
of refri gerant. The val ve cl oses wi th a mi ni mum
pressure of 2756 kPa (400 psi ).
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce system pressure, and then
re-seats i tsel f. The majori ty of the refri gerant i s con-
served i n the system. I f the val ve vents refri gerant, i t
does not mean the val ve i s faul ty. The val ve i s part of
the compressor assembl y and must not be removed or
otherwi se di sturbed.
LOW PRESSURE CYCLING CLUTCH SWITCH
The l ow pressure cycl i ng cl utch swi tch i s mounted
on top of the accumul ator. The swi tch i s connected i n
seri es wi th the hi gh pressure cut-off swi tch, between
ground and the Powertrai n Control Modul e (PCM).
The swi tch contacts open and cl ose causi ng the PCM
to turn the compressor cl utch on and off. Thi s regu-
l ates the system pressure and control s evaporator
temperature. Control l i ng evaporator temperature
prevents condensate water on the evaporator fi ns
from freezi ng and obstructi ng ai r condi ti oni ng system
ai r fl ow.
The l ow pressure cycl i ng cl utch swi tch contacts are
open when the sucti on pressure i s approxi matel y 141
kPa (20.5 psi ) or l ower. The swi tch contacts wi l l cl ose
when the sucti on pressure ri ses to approxi matel y 234
to 262 kPa (34 to 38 psi ) or above. Lower ambi ent
temperatures, bel ow approxi matel y -1C (30F) dur-
i ng col d weather wi l l al so open the swi tch contacts.
Thi s i s due to the pressure/temperature rel ati onshi p
of the refri gerant i n the system.
The l ow pressure cycl i ng cl utch swi tch i s a factory-
cal i brated uni t. I t cannot be adjusted or repai red
REFRIGERANT
The R-134a refri gerant used i n thi s ai r condi ti on-
i ng system i s a non-toxi c, non-fl ammabl e, cl ear, and
col orl ess l i quefi ed gas. R-134a refri gerant i s not com-
pati bl e wi th R-12 refri gerant i n an ai r condi ti oni ng
system.
Even a smal l amount of R-12 added to a R-134a
refri gerant system, wi l l cause compressor fai l ure,
refri gerant oi l sl udge, or poor ai r condi ti oni ng system
performance. The refri gerant system servi ce ports
have been desi gned to ensure that the system i s not
acci dental l y fi l l ed wi th the wrong refri gerant (R-12).
REFRIGERANT LINE
The refri gerant l i nes are used to carry the refri g-
erant between the vari ous ai r condi ti oni ng system
components. A barri er hose desi gn i s used for the ai r
condi ti oni ng system on thi s vehi cl e. The ends of the
refri gerant hoses are made from l i ghtwei ght al umi -
num, and use braze-l ess fi tti ngs.
ti ght.
properl y routed.
The refri gerant l i nes and hoses cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
REFRIGERANT LINE COUPLER
Spri ng-l ocki ng refri gerant l i ne coupl ers are used to
connect refri gerant l i nes and other components to the
refri gerant system. The coupl i ng i s hel d together by
a garter spri ng i nsi de a ci rcul ar cage.
When the coupl i ng hal ves are connected, the fl ared
end of the femal e fi tti ng sl i ps behi nd the garter
spri ng i nsi de the cage of the mal e fi tti ng. The garter
spri ng and cage prevent the fl ared end of the femal e
fi tti ng from pul l i ng out of the cage. Secondary cl i ps
are i nstal l ed over the coupl i ng at the factory for
added bl owoff protecti on.
O-ri ngs are used to seal the coupl i ng. These
O-ri ngs are compati bl e wi th R-134a refri gerant and
must be repl aced wi th O-ri ngs made of the same
materi al .
REFRIGERANT OIL
The oi l used i n the SD7H15 compressor i s a pol y-
al kyl ene gl ycol , syntheti c (SP-20 PAG), wax-free
refri gerant oi l . Use onl y refri gerant oi l of the same
type to servi ce the system.
Refri gerant oi l wi l l absorb any moi sture i t comes i n
contact wi th, even moi sture i n the ai r. The oi l con-
tai ner shoul d be kept ti ghtl y capped unti l i t i s ready
to be used. Then, cap the oi l i mmedi atel y after usi ng,
to prevent contami nati on.
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED,
BEFORE CONNECTING TO OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
When servi ci ng the ai r condi ti oni ng system, a
refri gerant chargi ng stati on and a recovery/recycl i ng
devi ce for R-134a must be used. Thi s devi ce must
meet SAE Standard J2210. Contact an automoti ve
servi ce equi pment suppl i er for refri gerant chargi ng
and recycl i ng/recoveri ng equi pment. Refer to the
operati ng i nstructi ons provi ded wi th the equi pment
for proper operati on.
A mani fol d gauge set may be needed wi th some
chargi ng and/or recovery/recycl i ng devi ces (Fi g. 4).
The servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE
The l ow pressure hose (Bl ue wi th Bl ack stri pe)
attaches to the sucti on servi ce port. Thi s port i s
l ocated on the sucti on l i ne between the accumul ator
outl et and the compressor.
HIGH PRESSURE GAUGE HOSE
The hi gh pressure hose (Red wi th Bl ack stri pe)
attaches to the di scharge servi ce port. Thi s port i s
l ocated on the di scharge l i ne between the compressor
and the condenser i nl et.
RECOVERY/RECYCLING/EVACUATION/CHARGING
HOSE
The center mani fol d hose (Yel l ow, or Whi te, wi th Bl ack
stri pe) i s used to recover, evacuate, and charge the refri g-
erant system. When the l ow or hi gh pressure val ves on
the mani fol d gauge set are opened, the refri gerant i n the
system wi l l escape through thi s hose.
REFRIGERANT SYSTEM SERVICE PORT
The two refri gerant system servi ce ports are used
to charge, recover/recycl e, evacuate, and test the ai r
condi ti oni ng refri gerant system. Uni que servi ce port
coupl er si zes are used on the R-134a system, to
ensure that the refri gerant system i s not acci dental l y
contami nated by the use of the wrong refri gerant
(R-12), or refri gerant system servi ce equi pment.
Fig. 4 Manifold Gauge Set
LOW PRESSURE GAUGE HIGH PRESSURE GAUGE VALVE VACUUM/REFRIG- ERANT HOSE (YEL- LOW W/BLACK STRIP) HIGH PRESSURE HOSE (RED W/BLACK STRIP) LOW PRESSURE HOSE (BLUE W/BLACK STRIP) VALVE
The hi gh pressure servi ce port i s l ocated on the
di scharge l i ne, between the compressor and the con-
denser i nl et. The l ow pressure servi ce port i s l ocated
on the sucti on l i ne, between the accumul ator outl et
and the compressor. After servi ci ng the refri gerant
system, al ways rei nstal l the servi ce port caps.
VACUUM CHECK VALVE
A one-way vacuum check val ve i s i nstal l ed i n the
accessory vacuum suppl y l i ne near the vacuum tap
on the engi ne i ntake mani fol d i n the engi ne compart-
ment. Thi s check val ve hel ps to mai ntai n the system
vacuum needed to retai n the sel ected heater-A/C
mode setti ngs by preventi ng the engi ne from bl eed-
i ng down system vacuum through the i ntake mani -
fol d duri ng extended heavy engi ne l oad (l ow engi ne
vacuum) operati on.
The vacuum check val ve cannot be repai red and, i f
VACUUM RESERVOIR
The vacuum reservoi r i s mounted to the front
bumper bar behi nd the passenger si de bumper end
cap. Vacuum stored i n the reservoi r i s used to oper-
ate the vacuum-control l ed vehi cl e accessori es duri ng
peri ods of l ow engi ne vacuum, such as when the
vehi cl e i s cl i mbi ng a steep grade or under other hi gh
engi ne l oad operati ng condi ti ons.
The vacuum reservoi r cannot be repai red and, i f
A/C PERFORMANCE
The ai r condi ti oni ng system i s desi gned to provi de
the passenger compartment wi th l ow temperature
and l ow humi di ty ai r. The evaporator, l ocated i n the
heater-A/C housi ng on the dash panel bel ow the
i nstrument panel , i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes over the
fi ns i n the evaporator, the ai r i s cool ed and the moi s-
ture i s removed as i t condenses on the fi ns. Duri ng
peri ods of hi gh heat and humi di ty, an ai r condi ti on-
i ng system wi l l be more effecti ve i n the Reci rcul ati on
Mode. Wi th the system i n the Reci rcul ati on Mode,
onl y ai r from the passenger compartment passes
through the evaporator. As the passenger compart-
ment ai r dehumi di fi es, the ai r condi ti oni ng system
performance l evel s i mprove.
Humi di ty has an i mportant beari ng on the temper-
ature of the ai r del i vered to the i nteri or of the vehi -
cl e. I t i s i mportant to understand the effect that
humi di ty has on the performance of the ai r condi ti on-
i ng system. When humi di ty i s hi gh, the evaporator
has to perform a doubl e duty. I t must l ower the ai r
temperature, and i t must l ower the temperature of
the moi sture i n the ai r that condenses on the evapo-
rator fi ns. Condensi ng the moi sture i n the ai r trans-
fers heat energy i nto the evaporator fi ns and tubi ng.
Thi s reduces the amount of heat the evaporator can
absorb from the ai r. Hi gh humi di ty greatl y reduces
the abi l i ty of the evaporator to l ower the temperature
of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
Revi ew the Servi ce Warni ngs and Precauti ons i n
the front of thi s group before performi ng thi s proce-
dure. The ai r temperature i n the test room and i n
the vehi cl e must be a mi ni mum of 21C (70F) for
thi s test.
(1) Connect a tachometer and a mani fol d gauge set.
(2) Set the heater-A/C mode control swi tch knob i n
the Reci rcul ati on Mode posi ti on, the temperature
control knob i n the ful l cool posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
(3) Start the engi ne and hol d the i dl e at 1,000 rpm
wi th the compressor cl utch engaged.
(4) The engi ne shoul d be at operati ng temperature.
The doors and wi ndows must be open.
(5) I nsert a thermometer i n the dri ver si de center
A/C (panel ) outl et. Operate the engi ne for fi ve mi nutes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty. I f the
cl utch cycl es, unpl ug the l ow pressure cycl i ng cl utch
swi tch wi re harness connector from the swi tch
l ocated on the accumul ator (Fi g. 5). Pl ace a jumper
wi re across the termi nal s of the l ow pressure cycl i ng
cl utch swi tch wi re harness connector.
Fig. 5 Low Pressure Cycling Clutch Switch
CLUTCH CYCLING PRESSURE SWITCH ACCUMULATOR
(7) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature and the compressor di s-
charge pressure.
(8) Compare the di scharge ai r temperature to the
Performance Temperature and Pressure chart (Fi g.
6). I f the di scharge ai r temperature i s hi gh, see
Refri gerant System Leaks and Refri gerant System
Charge i n thi s group.
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart
Ambient 21C 27C 32C 38C 43C
Temperature (70F) (80F) (90F) (100F) (110F)
Air Temperature -3 to 3C 1 to 7C 3 to 9C 6 to 13C 10 to 18C
at Center Panel
Outlet (27-38F) (33-44F) (37-48F) (43-55F) (50-64F)
Evaporator 179-241 kPa 221-283 kPa 262-324 kPa 303-365 kPa 345-414 kPa
Inlet Pressure
at Charge Port (26-35 psi) (32-41 psi) (38-47 psi) (44-53 psi) (50-60 psi)
Compressor 1240-1655 kPa 1380-1790 kPa 1720-2070 kPa 1860-2345 kPa 2070-2690 kPa
Discharge
Pressure (180-240 psi) (200-260 psi) (250-300 psi) (270-340 psi) (300-390 psi)
Fig. 6 Performance Temperature and Pressure
Pressure Diagnosis
Condition Possible Causes Correction
Rapid compressor clutch cycling
(ten or more cycles per minute).
1. Low refrigerant system charge. 1. See Refrigerant System Leaks in
this group. Test the refrigerant
system for leaks. Repair, evacuate
and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the refrigerant
system.
2. Faulty fuse.
3. Faulty compressor clutch coil.
4. Faulty compressor clutch relay.
5. Improperly installed or faulty low
pressure cycling clutch switch.
6. Faulty high pressure cut-off
switch.
7. Faulty Powertrain Control Module
(PCM).
1. See Refrigerant System Leaks in
required.
2. Check the fuses in the Power
Distribution Center and the junction
block. Repair the shorted circuit or
component and replace the fuses, if
required.
3. See Compressor Clutch Coil in
this group. Test the compressor
clutch coil and replace, if required.
4. See Compressor Clutch Relay in
this group. Test the compressor
clutch relay and relay circuits. Repair
the circuits or replace the relay, if
required.
5. See Low Pressure Cycling Clutch
Switch in this group. Test the low
pressure cycling clutch switch and
tighten or replace, if required.
6. See High Pressure Cut-Off Switch
in this group. Test the high pressure
cut-off switch and replace, if
required.
7. Refer to the proper Diagnostic
Procedures manual for testing of the
PCM. Test the PCM and replace, if
required.
Normal pressures, but A/C
Performance Test air temperatures
at center panel outlet are too high.
1. Excessive refrigerant oil in
system.
2. Temperature control cable
improperly installed or faulty.
3. Blend-air door inoperative or
sealing improperly.
1. See Refrigerant Oil Level in this
group. Recover the refrigerant from
the refrigerant system and inspect
the refrigerant oil content. Restore
the refrigerant oil to the proper level,
if required.
2. See Temperature Control Cable in
this group. Inspect the temperature
control cable for proper routing and
operation and correct, if required.
3. See Blend-Air Door under
Heater-A/C Housing Door in this
group. Inspect the blend-air door for
proper operation and sealing and
correct, if required.
Pressure Diagnosis
The low side pressure is normal or
slightly low, and the high side
pressure is too low.
1. Low refrigerant system charge.
2. Refrigerant flow through the
accumulator is restricted.
3. Refrigerant flow through the
evaporator coil is restricted.
4. Faulty compressor.
required.
2. See Accumulator in this group.
Replace the restricted accumulator, if
required.
3. See Evaporator Coil in this group.
Replace the restricted evaporator
coil, if required.
4. See Compressor in this group.
Replace the compressor, if required.
The low side pressure is normal or
slightly high, and the high side
pressure is too high.
1. Condenser air flow restricted.
2. Inoperative cooling fan.
3. Refrigerant system overcharged.
4. Air in the refrigerant system.
5. Engine overheating.
1. Check the condenser for
damaged fins, foreign objects
obstructing air flow through the
condenser fins, and missing or
improperly installed air seals. Refer
to Group 7 - Cooling System for
more information on air seals. Clean,
repair, or replace components as
required.
2. Refer to Group 7 - Cooling
System for more information. Test
the cooling fan and replace, if
required.
3. See Refrigerant System Charge in
this group. Recover the refrigerant
from the refrigerant system. Charge
the refrigerant system to the proper
level, if required.
required.
System for more information. Test
the cooling system and repair, if
required.
The low side pressure is too high,
and the high side pressure is too
low.
1. Accessory drive belt slipping.
2. Fixed orifice tube not installed.
3. Faulty compressor.
System for more information. Inspect
the accessory drive belt condition
and tension. Tighten or replace the
accessory drive belt, if required.
2. See Fixed Orifice Tube in this
group. Install the missing fixed orifice
tube, if required.
3. See Compressor in this group.
Replace the compressor, if required.
Pressure Diagnosis
The low side pressure is too low,
and the high side pressure is too
high.
1. Restricted refrigerant flow through
the refrigerant lines.
the fixed orifice tube.
the condenser.
1. See Liquid Line and Suction and
Discharge Line in this group. Inspect
the refrigerant lines for kinks, tight
bends or improper routing. Correct
the routing or replace the refrigerant
line, if required.
2. See Fixed Orifice Tube in this
group. Replace the restricted fixed
orifice tube, if required.
3. See Condenser in this group.
Replace the restricted condenser, if
required.
.
HEATER PERFORMANCE
PREPARATIONS
Revi ew the Servi ce Warni ngs and Precauti ons i n
the front of thi s group before performi ng the fol l ow-
i ng procedures.
Check the radi ator cool ant l evel , serpenti ne dri ve
bel t tensi on, and engi ne vacuum l i ne connecti ons.
Al so check the radi ator ai r fl ow and the radi ator fan
operati on. Start the engi ne and al l ow i t to warm up
to normal operati ng temperature.
WARNING: DO NOT REMOVE THE RADIATOR
PRESSURE CAP WHEN THE ENGINE IS AT OPER-
ATING TEMPERATURE, PERSONAL INJURY MAY
RESULT.
I f the vehi cl e has been operated recentl y, wai t fi f-
teen mi nutes or l onger before removi ng the radi ator
pressure cap. Pl ace a rag over the cap and turn i t to
the fi rst safety stop. Al l ow any pressure to escape
through the overfl ow tube. When the system stabi -
l i zes, remove the cap compl etel y.
MAXIMUM HEATER OUTPUT
Engi ne cool ant i s del i vered to the heater core
through two heater hoses. Wi th the engi ne i dl i ng at
normal operati ng temperature, set the temperature
control knob i n the ful l hot posi ti on, the mode control
swi tch knob i n the Fl oor posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the ai r temperature
comi ng from the fl oor outl ets, refer to the Tempera-
ture Reference chart (Fi g. 7).
I f the fl oor outl et ai r temperature i s l ow, refer to
Group 7 - Cool i ng System for the cool ant tempera-
ture speci fi cati ons. Both of the heater hoses shoul d
be hot to the touch. The cool ant return hose shoul d
be sl i ghtl y cool er than the suppl y hose. I f the cool ant
return hose i s much cool er than the suppl y hose,
l ocate and repai r the engi ne cool ant fl ow obstructi on
i n the heater system.
OBSTRUCTED COOLANT FLOW
Possi bl e l ocati ons or causes of obstructed cool ant
fl ow:
Pi nched or ki nked heater hoses.
I mproper heater hose routi ng.
Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons (refer to Group 7 -
Cool i ng System).
A pl ugged heater core.
I f proper cool ant fl ow through the heater system i s
veri fi ed, and outl et ai r temperature i s sti l l l ow, a
mechani cal probl em may exi st.
MECHANICAL PROBLEMS
Possi bl e l ocati ons or causes of i nsuffi ci ent heat:
An obstructed cowl ai r i ntake.
Obstructed heater system outl ets.
A bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater di scharge ai r temperature cannot be
adjusted wi th the temperature control knob on the
Minimum Heater
System
Ambient Temperature Floor Outlet
Temperature
Celsius Fahrenheit Celsius Fahrenheit
15.5 60 62.2 144
21.1 70 63.8 147
26.6 80 65.5 150
32.2 90 67.2 153
Fig. 7 Temperature Reference
heater-A/C control panel , the fol l owi ng coul d requi re
servi ce:
The heater-A/C control .
The temperature control cabl e.
The bl end-ai r door.
I mproper engi ne cool ant temperature.
VACUUM SYSTEM
Vacuum control i s used to operate the mode doors
i n the heater-A/C housi ng. Testi ng of the heater-A/C
mode control swi tch operati on wi l l determi ne i f the
vacuum, and mechani cal control s are functi oni ng.
However, i t i s possi bl e that a vacuum control system
that operates perfectl y at engi ne i dl e (hi gh engi ne
vacuum) may not functi on properl y at hi gh engi ne
speeds or l oads (l ow engi ne vacuum). Thi s can be
caused by l eaks i n the vacuum system, or a faul ty
vacuum check val ve.
A vacuum system test wi l l hel p to i denti fy the
source of poor vacuum system performance, or l ocate
vacuum system l eaks. Before starti ng thi s test, stop
the engi ne and make certai n that the probl em i snt a
di sconnected vacuum suppl y tube at the engi ne
i ntake mani fol d vacuum tap or the vacuum reservoi r.
Use an adjustabl e vacuum test set (Speci al Tool
C-3707) and a sui tabl e vacuum pump to test the
heater-A/C vacuum control system. Wi th a fi nger
pl aced over the end of the vacuum test hose probe
(Fi g. 8), adjust the bl eed val ve on the test set gauge
to obtai n a vacuum of exactl y 27 kPa (8 i n. Hg.).
Rel ease and bl ock the end of the probe several ti mes
to veri fy that the vacuum readi ng returns to the
exact 27 kPa (8 i n. Hg.) setti ng. Otherwi se, a fal se
readi ng wi l l be obtai ned duri ng testi ng.
VACUUM CHECK VALVE
(1) Remove the vacuum check val ve. The val ve i s
l ocated i n the (bl ack) vacuum suppl y tube at the
heat-A/C system vacuum tap.
(2) Connect the test set vacuum suppl y hose to the
heat-A/C system si de of the val ve. When connected to
thi s si de of the check val ve, no vacuum shoul d pass
and the test set gauge shoul d return to the 27 kPa (8
i n. Hg.) setti ng. I f OK, go to Step 3. I f not OK,
repl ace the faul ty val ve.
(3) Connect the test set vacuum suppl y hose to the
engi ne vacuum si de of the val ve. When connected to
thi s si de of the check val ve, vacuum shoul d fl ow
through the val ve wi thout restri cti on. I f not OK,
repl ace the faul ty val ve.
HEATER-A/C CONTROLS
(1) Connect the test set vacuum probe to the heat-
A/C system vacuum suppl y (bl ack) tube at the tee i n
the engi ne compartment. Posi ti on the test set gauge
so that i t can be vi ewed from the passenger compart-
ment.
(2) Pl ace the heater-A/C mode control swi tch knob
i n each mode posi ti on, one at a ti me, and pause after
each sel ecti on. The test set gauge shoul d return to
the 27 kPa (8 i n. Hg.) setti ng shortl y after each sel ec-
ti on i s made. I f not OK, a component or vacuum l i ne
i n the vacuum ci rcui t of the sel ected mode has a
l eak. See the procedure i n Locati ng Vacuum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
LOCATING VACUUM LEAKS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Di sconnect the vacuum harness connector
behi nd the gl ove box and i nboard of the gl ove box
openi ng on the heater-A/C housi ng.
(2) Connect the test set vacuum hose probe to each
port i n the heater-A/C housi ng hal f of the vacuum
harness connector, one at a ti me, and pause after
each connecti on (Fi g. 9). The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
heater-A/C control . I f not OK, go to Step 3.
(3) Determi ne the vacuum l i ne col or of the vacuum
ci rcui t that i s l eaki ng. To determi ne the vacuum l i ne
Fig. 8 Adjust Vacuum Test Bleed Valve
VACUUM PUMP TOOL C-4289 VACUUM TEST SET C-3707 BLEED VALVE PROBE
col ors, refer to the Vacuum Ci rcui ts chart (Fi g. 10) or
(Fi g. 11).
(4) Di sconnect and pl ug the vacuum l i ne from the
component (fi tti ng, actuator, val ve, swi tch, or reser-
voi r) on the other end of the l eaki ng ci rcui t. I nstru-
ment panel di sassembl y or removal may be necessary
to gai n access to some components. See the servi ce
procedures i n thi s group.
(5) Connect the test set hose or probe to the open
end of the l eaki ng ci rcui t. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
di sconnected component. I f not OK, go to Step 6.
(6) To l ocate a l eak i n a vacuum l i ne, l eave one
end of the l i ne pl ugged and connect the test set hose
or probe to the other end. Run your fi ngers sl owl y
al ong the l i ne whi l e watchi ng the test set gauge. The
vacuum readi ng wi l l fl uctuate when your fi ngers con-
tact the source of the l eak. To repai r the vacuum
l i ne, cut out the l eaki ng secti on of the l i ne. Then,
i nsert the l oose ends of the l i ne i nto a sui tabl e l ength
of 3 mm (1/8-i nch) i nsi de di ameter rubber hose.
BLOWER MOTOR
INJURY.
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. Possi bl e causes of an i noperati ve
bl ower motor i ncl ude:
Faul ty fuse
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors
Faul ty bl ower motor resi stor
Faul ty bl ower motor rel ay
Faul ty bl ower motor swi tch
Faul ty heater-A/C mode control swi tch
Faul ty bl ower motor.
Possi bl e causes of the bl ower motor not operati ng
i n al l speeds i ncl ude:
Faul ty fuse
Faul ty bl ower motor swi tch
Faul ty bl ower motor resi stor
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors.
VIBRATION
Possi bl e causes of bl ower motor vi brati on i ncl ude:
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower wheel out of bal ance or bent
Bl ower motor faul ty.
NOISE
To veri fy that the bl ower i s the source of the noi se,
unpl ug the bl ower motor wi re harness connector and
operate the heater-A/C system. I f the noi se goes
away, possi bl e causes i ncl ude:
Forei gn materi al i n the heater-A/C housi ng
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower motor faul ty.
BLOWER MOTOR RELAY
INJURY.
RELAY TEST
The bl ower motor rel ay i s l ocated i n a wi re harness
connector that i s secured to the heater-A/C housi ng
behi nd the gl ove box on the passenger si de of the
vehi cl e, next to the heater-A/C wi re harness connec-
tor i n the passenger compartment. Remove the rel ay
from i ts connector to perform the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
Fig. 9 Vacuum Circuit Test
VACUUM CIRCUIT LEGEND
I.D. Function Color
A Not Used N/A
B Defrost Actuator (Full Position) Yellow
C Floor Actuator Brown
D Defrost Actuator (Mid-Position) Blue
E Vacuum Supply (Reservoir) Black
F Panel Actuator Red
G Not Used N/A
Fig. 10 Vacuum Circuits - Heater Only
VACUUM VENTED OFF Yellow Brown Blue Black Red BI-LEVEL Yellow Brown Blue Black Red PANEL Yellow Brown Blue Black Red FLOOR Yellow Brown Blue Black Red MIX Yellow Brown Blue Black Red DEFROST Yellow Brown Blue Black Red
VACUUM CIRCUIT LEGEND
I.D. Function Color
A Not Used N/A
B Defrost Actuator (Full Position) Yellow
C Floor Actuator Brown
D Defrost Actuator (Mid-Position) Blue
E Vacuum Supply (Reservoir) Black
F Panel Actuator Red
G Recirculation Actuator Green
Fig. 11 Vacuum Circuits - Heater-A/C
VACUUM VENTED OFF Yellow Brown Blue Green Black Red A/C-BI LEVEL Yellow Brown Blue Green Black Red A/C-OUTSIDE OR PANEL Yellow Brown Blue Green Black Red A/C-RECIRCULATION Yellow Brown Blue Green Black Red MIX Yellow Brown Blue Green Black Red FLOOR Yellow Brown Blue Green Black Red DEFROST Yellow Brown Blue Green Black Red
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Ci rcui t Test i n thi s group. I f
not OK, repl ace the faul ty rel ay.
CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to fused battery feed di rectl y from a fuse
i n the Power Di stri buti on Center (PDC), and shoul d
be hot at al l ti mes. Check for battery vol tage at the
connector cavi ty for rel ay termi nal 30. I f OK, go to
Step 2. I f not OK, repai r the open ci rcui t to the PDC
as requi red.
(2) The rel ay normal l y cl osed termi nal cavi ty (87A)
i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the bl ower motor. When the rel ay i s
energi zed, termi nal 87 i s connected to termi nal 30
and provi des ful l battery current to the bl ower motor
feed ci rcui t. There shoul d be conti nui ty between the
connector cavi ty for termi nal 87 and the bl ower
motor rel ay output ci rcui t cavi ty of the bl ower motor
wi re harness connector at al l ti mes. I f OK, go to Step
4. I f not OK, repai r the open ci rcui t to the bl ower
motor as requi red.
(4) The coi l battery termi nal cavi ty (86) i s con-
nected to the i gni ti on swi tch. When the i gni ti on
swi tch i s pl aced i n the On posi ti on, fused i gni ti on
swi tch output i s di rected from a fuse i n the juncti on
bl ock to the rel ay el ectromagneti c coi l to energi ze the
rel ay. There shoul d be battery vol tage at the connec-
tor cavi ty for rel ay termi nal 86 wi th the i gni ti on
swi tch i n the On posi ti on. I f OK, go to Step 5. I f not
OK, repai r the open ci rcui t to the juncti on bl ock fuse
as requi red.
(5) The coi l ground termi nal cavi ty (85) i s con-
nected to ground. Thi s termi nal suppl i es the ground
for the rel ay el ectromagnet coi l . There shoul d be con-
ti nui ty between the cavi ty for rel ay termi nal 85 and
a good ground at al l ti mes. I f not OK, repai r the open
ci rcui t as requi red.
i ng Di agrams.
INJURY.
To test the bl ower motor resi stor, unpl ug the resi s-
tor wi re harness connector. Each bl ower motor swi tch
i nput termi nal on the resi stor must have conti nui ty
to the resi stor output termi nal , whi ch i s connected to
the ci rcui t goi ng to the bl ower motor. I f the bl ower
motor resi stor conti nui ty does not check OK, repl ace
the faul ty resi stor.
BLOWER MOTOR SWITCH
i ng Di agrams. The bl ower motor swi tch i s onl y ser-
vi ced as a part of the heater-onl y or heater-A/C
control assembl y.
(1) Turn the i gni ti on swi tch to the Off posi ti on.
Remove the heater-A/C control from the i nstrument
panel . Check for conti nui ty between the ground ci r-
cui t cavi ty of the control wi re harness connector and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 2. I f not OK, repai r the open ci rcui t to ground
as requi red.
(2) Wi th the heater-A/C control wi re harness con-
nector unpl ugged, pl ace the mode control swi tch knob
i n any posi ti on except the Off posi ti on. Check for con-
ti nui ty between the ground ci rcui t termi nal and each
of the bl ower motor dri ver ci rcui t termi nal s of the
control as you move the bl ower swi tch to each of the
four speed posi ti ons. There shoul d be conti nui ty at
each dri ver ci rcui t termi nal i n onl y one bl ower motor
swi tch speed posi ti on. I f OK, test and repai r the
bl ower dri ver ci rcui ts between the control connector
and the bl ower motor resi stor as requi red. I f not OK,
repl ace the faul ty heater-A/C control uni t.
Blower Motor Relay
RELAY TERMINALS RELAY CAVITIES
COMPRESSOR
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne temperature, and any other speci al con-
di ti ons.
Noi ses that devel op duri ng ai r condi ti oni ng opera-
ti on can often be mi sl eadi ng. For exampl e: What
sounds l i ke a fai l ed front beari ng or connecti ng rod,
may be caused by l oose bol ts, nuts, mounti ng brack-
ets, or a l oose cl utch assembl y. Veri fy serpenti ne
dri ve bel t tensi on. I mproper bel t tensi on can cause a
mi sl eadi ng noi se when the compressor i s engaged.
The noi se may not occur when the compressor i s di s-
engaged.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se.
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
cl utch whi l e engaged and di sengaged.
(2) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to make sure that the di scharge pressure does not
exceed 2070 kPa (300 psi ).
(3) Ti ghten al l compressor mounti ng bol ts, the
cl utch mounti ng nut, the cl utch coi l mounti ng screw
or nut, and the serpenti ne dri ve bel t to the correct
speci fi cati ons.
(4) Check the refri gerant system pl umbi ng for rub-
bi ng or i nterference, whi ch can cause unusual noi ses.
(5) Check the refri gerant system charge. See the
Chargi ng Refri gerant System procedure i n thi s
group.
(6) Check the compressor noi se as i n Step 1.
(7) I f the noi se sti l l exi sts, l oosen the compressor
mounti ng bol ts and ti ghten agai n. Repeat Step 1.
(8) I f the noi se conti nues, repl ace the compressor
and repeat Step 1.
COMPRESSOR CLUTCH COIL
i ng Di agrams. The battery must be ful l y-charged
before performi ng the fol l owi ng tests. Refer to Group
8A - Battery for more i nformati on.
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the heater-A/C mode control swi tch i n any
A/C mode, and the bl ower motor swi tch i n the l owest
speed posi ti on, start the engi ne and run i t at normal
i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n two vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n two vol ts of the battery vol tage, test the
cl utch coi l feed ci rcui t for excessi ve vol tage drop and
repai r as requi red. I f there i s no vol tage readi ng at
the cl utch coi l , use a DRB scan tool and the proper
Di agnosti c Procedures manual for testi ng of the com-
pressor cl utch ci rcui t. The fol l owi ng components
must be checked and repai red as requi red before you
can compl ete testi ng of the cl utch coi l :
Fuses i n the juncti on bl ock and the Power Di s-
tri buti on Center (PDC)
Heater-A/C mode control swi tch
Compressor cl utch rel ay
Hi gh pressure cut-off swi tch
Low pressure cycl i ng cl utch swi tch
Powertrai n Control Modul e (PCM).
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s 2.0 to 3.9
amperes wi th el ectri cal system vol tage at 11.5 to 12.5
vol ts. Thi s shoul d onl y be checked wi th the work
area temperature at 21 C (70 F). I f system vol tage
i s more than 12.5 vol ts, add el ectri cal l oads by turn-
i ng on el ectri cal accessori es unti l the system vol tage
drops bel ow 12.5 vol ts.
(a) I f the cl utch coi l current readi ng i s 4
amperes or more, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
RELAY TEST
i ng Di agrams.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC). Refer to the PDC l abel for
rel ay i denti fi cati on and l ocati on. Remove the rel ay
from the PDC to perform the fol l owi ng tests:
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
i ng Di agrams.
connected to fused battery feed. There shoul d be bat-
tery vol tage at the cavi ty for rel ay termi nal 30 at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s not
used i n thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the compressor cl utch coi l . There shoul d
be conti nui ty between thi s cavi ty and the A/C com-
pressor cl utch rel ay output ci rcui t cavi ty of the com-
pressor cl utch coi l wi re harness connector. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t as
requi red.
(4) The rel ay coi l battery termi nal (86) i s con-
nected to the fused i gni ti on swi tch output (run/start)
ci rcui t. There shoul d be battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
On posi ti on. I f OK, go to Step 5. I f not OK, repai r the
open ci rcui t to the fuse i n the juncti on bl ock as
requi red.
(5) The coi l ground termi nal cavi ty (85) i s swi tched
to ground through the Powertrai n Control Modul e
(PCM). There shoul d be conti nui ty between thi s cav-
i ty and the A/C compressor cl utch rel ay control ci r-
cui t cavi ty of the PCM wi re harness connector C
(gray) at al l ti mes. I f not OK, repai r the open ci rcui t
as requi red.
i ng Di agrams.
(1) Veri fy that the refri gerant system i s properl y
charged.
(2) Unpl ug the hi gh pressure swi tch wi re harness
connector and test for conti nui ty between the swi tch
termi nal s. There shoul d be conti nui ty. I f OK, refer to
the wi ri ng di agrams and repai r the A/C request si g-
nal ci rcui t as requi red. I f not OK, repl ace the faul ty
swi tch.
Before performi ng di agnosi s of the l ow pressure
cycl i ng cl utch swi tch, be certai n that the swi tch i s
properl y i nstal l ed on the accumul ator fi tti ng. The l ow
pressure cycl i ng cl utch swi tch shoul d be hand-ti ght-
ened onto the fi tti ng. I f the swi tch i s too l oose i t may
not open the Schrader-type val ve i n the accumul ator
fi tti ng, whi ch wi l l prevent the swi tch from correctl y
moni tori ng the refri gerant system pressure.
Al so veri fy that the refri gerant system has the cor-
rect refri gerant charge. See Refri gerant System
Charge i n thi s group for more i nformati on.
i ng Di agrams.
(1) Unpl ug the l ow pressure cycl i ng cl utch swi tch
wi re harness connector from the swi tch on the accu-
mul ator, and i nstal l a jumper wi re between the two
connector cavi ti es.
(2) Connect a mani fol d gauge set to the refri gerant
system servi ce ports.
(3) Pl ace the heater-A/C mode control swi tch knob
i n any A/C posi ti on and start the engi ne.
(4) Check the conti nui ty between the two termi -
nal s of the l ow pressure swi tch. There shoul d be con-
ti nui ty wi th a sucti on pressure readi ng of 296 kPa
(43 psi ) or above, and no conti nui ty wi th a sucti on
pressure readi ng of 172 kPa (25 psi ) or bel ow. I f OK,
test and repai r the A/C request si gnal ci rcui t as
requi red. I f not OK, repl ace the faul ty swi tch.
REFRIGERANT SYSTEM LEAKS
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
LEAK TESTING THE SYSTEM.
I f the ai r condi ti oni ng system i s not cool i ng prop-
erl y, determi ne i f the refri gerant system i s ful l y-
charged. See A/C Performance i n thi s group. I f the
refri gerant system i s l ow or empty, a l eak at a l i ne,
fi tti ng, or component seal i s l i kel y. Fi tti ngs, l i nes, or
components that appear to be oi l y i ndi cate a possi bl e
refri gerant l eak. To detect a l eak i n the refri gerant
system, perform one of the fol l owi ng procedures:
Compressor Clutch Relay
SYSTEM EMPTY
(1) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group.
(2) Connect and di spense 0.283 kPa (0.6 l bs. or 10
oz.) of R-134a refri gerant i nto the evacuated refri ger-
ant system. See Refri gerant System Charge i n thi s
group.
(3) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(4) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Move the
l eak detector probe sl owl y al ong the bottom si de of
al l l i nes and fi tti ngs, because R-134a i s heavi er than
ai r.
(5) To i nspect the evaporator coi l for l eaks, i nsert
the l eak detector probe i nto the center panel outl et.
Set the bl ower motor swi tch to the l owest speed posi -
ti on, and the mode control swi tch i n the Reci rcul a-
ti on Mode.
SYSTEM LOW
(1) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(2) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run wi th the ai r condi ti oni ng system on
for fi ve mi nutes.
(3) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Move the
l eak detector probe sl owl y al ong the bottom si de of
al l l i nes and fi tti ngs, because R-134a i s heavi er than
ai r.
(4) To i nspect the evaporator coi l for l eaks, i nsert
the l eak detector probe i nto the center panel outl et.
Set the bl ower motor swi tch to the l owest speed posi -
ti on, and the mode control swi tch i n the Reci rcul a-
ti on Mode.
SERVICE PROCEDURES
REFRIGERANT RECOVERY
RECOVERING REFRIGERANT.
R-134a refri gerant i s a hydrofl uorocarbon (HFC)
that does not contai n chl ori ne. A R-134a refri gerant
recovery/recycl i ng stati on that meets SAE Standard
J2210 must be used to recover the refri gerant. Refer
to the operati ng i nstructi ons provi ded wi th the equi p-
ment for proper operati on.
REFRIGERANT SYSTEM EVACUATE
EVACUATING THE SYSTEM.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be charged. Moi sture and ai r mi xed wi th the
refri gerant wi l l rai se the compressor head pressure
above acceptabl e operati ng l evel s. Thi s wi l l reduce
the performance of the ai r condi ti oner and damage
the compressor. Evacuati ng wi l l boi l the moi sture out
of the refri gerant system at near room temperature.
To evacuate the refri gerant system, use the fol l owi ng
procedure:
(1) Connect a sui tabl e chargi ng stati on and mani -
fol d gauge set to the vehi cl e.
(2) Open the l ow and hi gh si de val ves and start
the vacuum pump. When the sucti on gauge reads 88
kPa (26 i n. Hg.) vacuum or greater, cl ose al l of the
val ves and turn off the vacuum pump. I f the system
fai l s to reach the speci fi ed vacuum, the system has a
l eak that must be corrected. I f the system mai ntai ns
the speci fi ed vacuum for fi ve mi nutes, restart the
vacuum pump. Then open the sucti on and di scharge
val ves and evacuate an addi ti onal ten mi nutes.
(3) Cl ose al l of the val ves. Turn off and di sconnect
the vacuum pump.
(4) The refri gerant system i s now ready to be
charged wi th refri gerant.
REFRIGERANT SYSTEM CHARGE
CHARGING THE REFRIGERANT SYSTEM.
After the system has been tested for l eaks and
evacuated, a refri gerant charge can be i njected i nto
the system. See Refri gerant Charge Capaci ty for the
proper amount of the refri gerant charge. Charge the
system usi ng a recovery/recycl i ng/chargi ng stati on
approved for R-134a refri gerant. Thi s devi ce must
meet SAE Standard J2210. Refer to the i nstructi ons
provi ded wi th the equi pment for proper operati on.
REFRIGERANT CHARGE CAPACITY
The R-134a system charge capaci ty i s 0.567 kg
(1.25 l bs.).
REFRIGERANT OIL LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components (except the compressor)
are refri gerant oi l free. After the system has been
charged and operated, the oi l i n the compressor i s
di spersed through the refri gerant system. The accu-
mul ator, evaporator, condenser, and compressor wi l l
retai n a si gni fi cant amount of oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s wi l l ensure proper l ubri -
cati on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the system.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. Thi s may be due to a rupture or l eak from a
refri gerant l i ne, a compressor shaft seal , an evapora-
tor, or a condenser. I f a rupture occurs, add 30 mi l l i -
l i ters (1 fl ui d ounce) of oi l to the system after the
repai r has been made. Oi l l oss at a l eak poi nt wi l l be
evi dent by the presence of a wet, shi ny surface
around the l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator, or condenser are repl aced. Refer to the
Refri gerant Oi l Capaci ti es chart. When a compressor
i s repl aced, the oi l must be drai ned from the ol d com-
pressor and measured. Drai n al l the oi l from the new
compressor, then fi l l the new compressor wi th the
same amount of oi l that was drai ned out of the ol d
compressor.
REFRIGERANT LINE COUPLER
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
(1) Recover the refri gerant from the refri gerant
system as descri bed i n thi s group.
(2) Remove the secondary cl i p from the coupl er. Fi t
the appropri ate spri ng l ock refri gerant l i ne coupl er
tool (Speci al Tool 7193) to the coupl er (Fi g. 12).
(3) Cl ose the tool and push i t i nto the open si de of
the cage to expand the garter spri ng and rel ease the
femal e fi tti ng.
NOTE: The garter spring may not release if the tool
is cocked while pushing it into the cage opening.
(4) After the garter spri ng i s expanded, pul l the
fi tti ngs apart wi thi n the tool .
(5) Remove the tool from the di sconnected coupl er.
(6) Separate the two ends of the coupl er.
INSTALLATION
(1) Check to ensure that the garter spri ng i s i n the
cage of the mal e coupl er fi tti ng. I f the garter spri ng
i s mi ssi ng, i nstal l a new spri ng by pushi ng i t i nto the
cage openi ng. I f the garter spri ng i s damaged,
remove i t from the cage wi th a smal l wi re hook (DO
NOT use a screwdri ver) and i nstal l a new garter
spri ng.
(2) Cl ean any di rt or forei gn materi al from both
hal ves of the coupl i ng.
(3) I nstal l new O-ri ngs on the mal e fi tti ng.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-ring may allow the con-
nection to leak intermittently during vehicle
operation.
(4) Lubri cate the mal e fi tti ng and O-ri ng, and the
i nsi de of the femal e fi tti ng wi th cl ean R-134a refri g-
erant oi l . Use onl y refri gerant oi l of the type recom-
mended for the compressor i n the vehi cl e.
(5) Fi t the femal e fi tti ng to the mal e fi tti ng and
push together unti l the garter spri ng snaps over the
fl ared end of the femal e fi tti ng.
(6) Ensure the coupl er i s ful l y engaged by pul l i ng
back on the l i nes on ei ther si de of the coupl er.
(7) I nstal l the secondary cl i p on the coupl er.
Refrigerant Oil Capacities
Component ml oz
A/C System 240 8.1
Accumulator 120 4
Condenser 30 1
Evaporator 60 2
Compressor drain and measure the oil from the
old compressor - see text.
Fig. 12 Spring Lock Coupler Disconnect
REMOVAL
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Unpl ug the wi re harness connector from the
hi gh pressure cut-off swi tch, whi ch i s l ocated i n a fi t-
ti ng on the di scharge l i ne between the compressor
and the condenser i nl et (Fi g. 13).
(3) Unscrew the hi gh pressure cut-off swi tch from
the di scharge l i ne fi tti ng.
(4) Remove the hi gh pressure cut-off swi tch from
the vehi cl e.
INSTALLATION
(1) I nstal l and ti ghten the hi gh pressure cut-off
swi tch on the di scharge l i ne fi tti ng.
(2) Pl ug the wi re harness connector i nto the hi gh
pressure cut-off swi tch.
SUCTION AND DISCHARGE LINE
ti ght.
properl y routed.
2.5L ENGINE
REMOVAL
cabl e.
hi gh pressure cut-off swi tch.
(4) Remove the radi ator gri l l e panel . Refer to
Group 23 - Body for the procedures.
(5) Reach through the gri l l e openi ng to remove the
screw that secures the di scharge l i ne bl ock fi tti ng at
the condenser i nl et (Fi g. 14) or (Fi g. 15). I nstal l pl ugs
i n, or tape over al l of the open refri gerant fi tti ngs.
(6) Remove the nut that secures the sucti on l i ne
bl ock fi tti ng to the accumul ator outl et. I nstal l pl ugs
Fig. 13 High Pressure Cut-Off Switch - Typical
Fig. 14 Suction and Discharge Line Remove/Install -
Left-Hand Drive 2.5L Engine
ACCUMULATOR SCREW COMPRESSOR SCREW CONDENSER SUCTION AND DISCHARGE LINE HEX NUT FWD
(7) Remove the screw that secures the sucti on and
di scharge l i ne mani fol d to the compressor. I nstal l
pl ugs i n, or tape over al l of the open refri gerant fi t-
ti ngs.
(8) Remove the sucti on and di scharge l i ne uni t
from the vehi cl e.
INSTALLATION
(1) Remove the tape or pl ugs from the sucti on and
di scharge l i ne mani fol d and the compressor. I nstal l
the sucti on and di scharge l i ne mani fol d to the com-
pressor. Ti ghten the mounti ng screw to 28 Nm (250
i n. l bs.).
(2) Remove the tape or pl ugs from the sucti on l i ne
and the accumul ator outl et bl ock fi tti ngs. I nstal l the
sucti on l i ne to the accumul ator outl et and ti ghten the
mounti ng nut to 9 Nm (80 i n. l bs.).
(3) Remove the tape or pl ugs from the di scharge
l i ne and the condenser i nl et bl ock fi tti ngs. I nstal l the
di scharge l i ne to the condenser i nl et and ti ghten the
mounti ng screw to 12 Nm (105 i n. l bs.).
(4) I nstal l the radi ator gri l l e panel . Refer to Group
23 - Body for the procedures.
(5) Pl ug i n the wi re harness connector to the hi gh
(7) Evacuate and charge the refri gerant system as
descri bed i n thi s group.
LEFT-HAND DRIVE 4.0L ENGINE
REMOVAL
cabl e.
hi gh pressure cut-off swi tch.
(4) Di sconnect the di scharge l i ne refri gerant l i ne
coupl er at the condenser i nl et (Fi g. 16). See Refri ger-
ant Li ne Coupl er i n thi s group for the procedures.
I nstal l pl ugs i n, or tape over al l of the open refri ger-
ant fi tti ngs.
(5) Remove the nut that secures the sucti on l i ne
bl ock fi tti ng to the accumul ator outl et. I nstal l pl ugs
(6) Remove the screw that secures the sucti on and
di scharge l i ne mani fol d to the compressor. I nstal l
ti ngs.
(7) Remove the sucti on and di scharge l i ne uni t
from the vehi cl e.
INSTALLATION
(1) Remove the tape or pl ugs from the sucti on and
di scharge l i ne mani fol d and the compressor. I nstal l
the sucti on and di scharge l i ne mani fol d to the com-
pressor. Ti ghten the mounti ng screw to 28 Nm (250
i n. l bs.).
(2) Remove the tape or pl ugs from the sucti on l i ne
and the accumul ator outl et bl ock fi tti ngs. I nstal l the
sucti on l i ne to the accumul ator outl et and ti ghten the
mounti ng nut to 9 Nm (80 i n. l bs.).
Right-Hand Drive 2.5L Engine
SCREW SUCTION AND DISCHARGE LINE COMPRESSOR HEX NUT ACCUMULATOR FWD CONDENSER
Left-Hand Drive 4.0L Engine
ACCUMULATOR SUCTION AND DISCHARGE LINE SCREW COMPRESSOR FWD CONDENSER INLET CLIP HEX NUT
(3) Remove the tape or pl ugs from the refri gerant
l i ne coupl ers on the di scharge l i ne and the condenser
i nl et. I nstal l the di scharge l i ne to the condenser
i nl et. See Refri gerant Li ne Coupl er i n thi s group for
the procedures.
(4) Pl ug i n the wi re harness connector to the hi gh
RIGHT-HAND DRIVE 4.0L ENGINE
The sucti on and di scharge l i nes for thi s model are
i ndi vi dual components and are secured to a mani fol d
bl ock on the compressor wi th bl ock fi tti ngs (Fi g. 17).
There i s al so a jumper l i ne i nstal l ed between the di s-
charge l i ne and the condenser i nl et that i s secured
wi th refri gerant l i ne coupl ers at each end. Each of
these components i s avai l abl e as a separate servi ce
part.
The sucti on and di scharge l i ne components can be
removed from or i nstal l ed on the vehi cl e i ndi vi dual l y,
or as a uni t. Otherwi se, the servi ce procedures are
the same as those for the Left-Hand Dri ve 4.0L
Engi ne appl i cati on. Ti ghten the addi ti onal mounti ng
hardware as fol l ows:
Sucti on l i ne to mani fol d bl ock nut - 9 Nm (80
i n. l bs.)
Di scharge l i ne to mani fol d bl ock nut - 9 Nm (80
i n. l bs.)
Mani fol d bl ock to compressor screw - 28 Nm
(250 i n. l bs.).
COMPRESSOR
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system. Di schargi ng i s not
necessary i f servi ci ng the compressor cl utch or cl utch
coi l , the engi ne, the cyl i nder head, or the generator.
REMOVAL
Fig. 17 Suction and Discharge Line Remove/Install - Right-Hand Drive 4.0L Engine
CLIP COMPRESSORFWD DISCHARGE LINE SUCTION LINE NUT ACCUMULATOR NUT SCREW MANIFOLD BLOCK CLIP DISCHARGE LINE JUMPER CONDENSER
cabl e.
(3) Loosen and remove the serpenti ne dri ve bel t.
Refer to Group 7 - Cool i ng System for the procedures.
(4) I f the vehi cl e i s equi pped wi th Ri ght-Hand
Dri ve (RHD) and the 4.0L engi ne, rai se and support
the vehi cl e.
(5) Unpl ug the compressor cl utch coi l wi re harness
connector.
(6) Remove the sucti on and di scharge refri gerant
l i nes from the compressor as descri bed i n thi s group.
I nstal l pl ugs i n, or tape over al l of the open refri ger-
ant fi tti ngs.
(7) Remove the four bol ts that secure the compres-
sor to the mounti ng bracket (Fi g. 18) or (Fi g. 19).
(8) Remove the compressor from the mounti ng
bracket.
INSTALLATION
NOTE: If a replacement compressor is being
installed, be certain to check the oil level. See
Refrigerant Oil Level in this group.
(1) I nstal l the compressor to the mounti ng bracket.
Ti ghten the four mounti ng bol ts as fol l ows:
Al l 2.5L engi nes and LHD 4.0L engi nes - 27 Nm
(20 ft. l bs.)
RHD 4.0L engi nes - 57 Nm (42 ft. l bs.).
(2) Remove the tape or pl ugs from al l of the open
refri gerant fi tti ngs, and i nstal l the sucti on and di s-
charge l i nes to the compressor as descri bed i n thi s
group.
(3) I nstal l the serpenti ne dri ve bel t. Refer to
Group 7 - Cool i ng System for the procedures.
(4) Pl ug i n the compressor cl utch coi l wi re harness
connector.
COMPRESSOR CLUTCH
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, pul l ey, or coi l repl acement.
The compressor cl utch can be servi ced i n the vehi cl e.
REMOVAL
cabl e.
(2) Remove the serpenti ne dri ve bel t. Refer to
Group 7 - Cool i ng System for the procedures.
(3) Remove the compressor mounti ng bol ts and l i ft
the compressor from the mounti ng bracket. Support
the compressor to work on the cl utch.
(4) I nsert the two pi ns of the spanner wrench
(Speci al Tool C-4489) i nto the hol es of the cl utch
pl ate. Hol d the cl utch pl ate stati onary and remove
the hex nut (Fi g. 20).
(5) Remove the cl utch pl ate wi th a pul l er (Speci al
Tool C-6461) (Fi g. 21).
(6) Remove the compressor shaft key and the
cl utch shi ms.
(7) Remove the external front housi ng snap ri ng
wi th snap ri ng pl i ers (Fi g. 22).
(8) I nstal l the l i p of the rotor pul l er (Speci al Tool
C-6141-1) i nto the snap ri ng groove exposed i n the
previ ous step, and i nstal l the shaft protector (Speci al
Tool C-6141-2) (Fi g. 23).
Fig. 18 Compressor Remove/Install - All 2.5L
Engines and LHD 4.0L Engines
Fig. 19 Compressor Remove/Install - RHD 4.0L
Engines
(9) I nstal l the pul l er through-bol ts (Speci al Tool
C-6461) through the pul l er fl ange and i nto the jaws
of the rotor pul l er and ti ghten (Fi g. 24). Turn the
pul l er center bol t cl ockwi se unti l the rotor pul l ey i s
free.
(10) Remove the screw and retai ner from the
cl utch coi l l ead wi re harness on the compressor front
(11) Remove the snap ri ng from the compressor
hub and remove the cl utch fi el d coi l (Fi g. 26). Sl i de
the cl utch fi el d coi l off of the compressor hub.
INSPECTION
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the front pl ate for wear. The pul l ey and front
pl ate shoul d be repl aced i f there i s excessi ve wear or
scori ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for oi l . Remove the
fel t from the front cover. I f the fel t i s saturated wi th
oi l , the shaft seal i s l eaki ng and the compressor must
be repl aced.
Fig. 20 Clutch Nut Remove
CLUTCH PLATE SPANNER
Fig. 21 Clutch Plate Remove
CLUTCH PLATE PULLER CLUTCH PLATE
Fig. 22 External Snap Ring Remove
PULLEY SNAP RING PLIERS
Fig. 23 Shaft Protector and Puller
PULLER JAW SHAFT PROTECTOR
Fig. 24 Install Puller Plate
PULLER JAW PULLER
Check the cl utch pul l ey beari ng for roughness or
excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) I nstal l the cl utch fi el d coi l and snap ri ng.
(2) I nstal l the cl utch coi l l ead wi re harness retai n-
i ng cl i p on the compressor front housi ng and ti ghten
the retai ni ng screw.
(3) Al i gn the rotor assembl y squarel y on the front
compressor housi ng hub.
(4) I nstal l the pul l ey beari ng assembl y wi th the
i nstal l er (Speci al Tool C-6871) (Fi g. 27). Thread the
i nstal l er on the shaft, then turn the nut unti l the
pul l ey assembl y i s seated.
(5) I nstal l the external front snap ri ng wi th snap
ri ng pl i ers. The bevel si de of the snap ri ng must be
faci ng outward. Press the snap ri ng to make sure i t
i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) I nstal l the compressor shaft key and the ori gi -
nal cl utch shi ms on the compressor shaft.
(7) I nstal l the cl utch pl ate wi th the dri ver (Speci al
Tool C-6463) (Fi g. 28). I nstal l the shaft hex nut and
ti ghten to 14.4 Nm (10.5 ft. l bs.).
(8) Check the cl utch ai r gap wi th a feel er gauge
(Fi g. 29). I f the ai r gap does not meet the speci fi ca-
ti on, add or subtract shi ms as requi red. The ai r gap
speci fi cati on i s 0.41 to 0.79 mm (0.016 to 0.031 i nch).
I f the ai r gap i s not consi stent around the ci rcumfer-
ence of the cl utch, l i ghtl y pry up at the mi ni mum
vari ati ons. Li ghtl y tap down at the poi nts of maxi -
mum vari ati on.
Fig. 25 Clutch Coil Lead Wire Harness
Fig. 26 Clutch Field Coil Snap Ring Remove
COIL SNAP RING PLIERS
Fig. 27 Clutch Pulley Install
PULLEY BEARING ASSEMBLY INSTALLER
Fig. 28 Clutch Plate Driver
CLUTCH PLATE DRIVER
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, 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 hardware package that is
provided with the new clutch.
(9) Reverse the remai ni ng removal procedures to
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the heater-A/C control to the
Reci rcul ati on Mode, the bl ower motor swi tch i n the
hi ghest speed posi ti on, and the engi ne speed at 1500
to 2000 rpm. Thi s procedure (burni shi ng) wi l l seat
the opposi ng fri cti on surfaces and provi de a hi gher
compressor cl utch torque capabi l i ty.
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 30).
(3) Refer to the l abel on the PDC for compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the compressor cl utch rel ay from the
PDC.
(5) I nstal l the compressor cl utch rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
(8) Test the rel ay operati on.
LIQUID LINE
ti ght.
properl y routed.
2.5L ENGINE
REMOVAL
cabl e.
(3) Di sconnect the l i qui d l i ne refri gerant l i ne cou-
pl ers at the evaporator i nl et and, on Ri ght-Hand
Fig. 29 Check Clutch Air Gap
FEELER GAUGE
Fig. 30 Power Distribution Center
RIGHT FENDER BATTERY POWER DISTRIBUTION CENTER
Dri ve model s onl y, the l i qui d l i ne jumper (Fi g. 31) or
(Fi g. 32). See Refri gerant Li ne Coupl er i n thi s group
for the procedures. I nstal l pl ugs i n, or tape over al l of
the open refri gerant fi tti ngs.
(4) On Left-Hand Dri ve model s onl y, remove the
screw that secures the l i qui d l i ne bl ock fi tti ng to the
l i qui d l i ne jumper. I nstal l pl ugs i n, or tape over al l of
(5) Remove the l i qui d l i ne from the vehi cl e.
screw that secures the l i qui d l i ne jumper bl ock fi tti ng
at the condenser outl et. I nstal l pl ugs i n, or tape over
al l of the open refri gerant fi tti ngs.
(8) Remove the l i qui d l i ne jumper from the vehi cl e.
INSTALLATION
(1) Remove the tape or pl ugs from the l i qui d l i ne
jumper and condenser outl et bl ock fi tti ngs. I nstal l
the l i qui d l i ne jumper to the condenser outl et.
Ti ghten the mounti ng screw to 12 Nm (105 i n. l bs.).
l i ne coupl ers on the l i qui d l i ne, the l i qui d l i ne
jumper, and the evaporator i nl et. I nstal l the l i qui d
l i ne to the l i qui d l i ne jumper and the evaporator
i nl et refri gerant l i ne coupl ers. See Refri gerant Li ne
Coupl er i n thi s group for the procedures.
(4) On Left-Hand Dri ve model s onl y, i nstal l the
screw that secures the l i qui d l i ne bl ock fi tti ng to the
l i qui d l i ne jumper. Ti ghten the mounti ng screw to 9
Nm (80 i n. l bs.).
4.0L ENGINE
REMOVAL
cabl e.
(3) Di sconnect the l i qui d l i ne refri gerant l i ne cou-
pl ers at the evaporator i nl et and the condenser outl et
(Left-Hand Dri ve) (Fi g. 33), or at the evaporator i nl et
and the l i qui d l i ne jumper (Ri ght-Hand Dri ve) (Fi g.
34). See Refri gerant Li ne Coupl er i n thi s group for
the procedures. I nstal l pl ugs i n, or tape over al l of
(4) Remove the l i qui d l i ne from the vehi cl e.
(5) On Ri ght-Hand Dri ve model s onl y, di sconnect
the l i qui d l i ne jumper refri gerant l i ne coupl er at the
condenser outl et. I nstal l pl ugs i n, or tape over al l of
(6) On Ri ght-Hand Dri ve model s onl y, remove the
l i qui d l i ne jumper from the vehi cl e.
Fig. 31 Liquid Line Remove/Install - Left-Hand Drive
2.5L Engine
EVAPORATOR INLET LIQUID LINE FWD CONDENSER LIQUID LINE JUMPER WITH ORIFICE TUBE SCREW STUD CLIP CLIP
Fig. 32 Liquid Line Remove/Install - Right-Hand
Drive 2.5L Engine
EVAPORATOR INLET CLIP LIQUID LINE FWD LIQUID LINE JUMPER WITH ORIFICE TUBE SCREW CONDENSER CLIP
INSTALLATION
(1) On Ri ght-Hand Dri ve model s onl y, remove the
tape or pl ugs from the refri gerant l i ne coupl ers on
the l i qui d l i ne jumper and the condenser outl et.
I nstal l the l i qui d l i ne jumper to the condenser outl et.
See Refri gerant Li ne Coupl er i n thi s group for the
procedures.
l i ne coupl ers on the condenser outl et (Left-Hand
Dri ve); or, on the l i qui d l i ne, the evaporator i nl et,
and the l i qui d l i ne jumper (Ri ght-Hand Dri ve).
I nstal l the l i qui d l i ne to the evaporator i nl et and the
condenser outl et or the l i qui d l i ne jumper. See
Refri gerant Li ne Coupl er i n thi s group for the proce-
dures.
FIXED ORIFICE TUBE
The fi xed ori fi ce tube i s l ocated i n the l i qui d l i ne
(Left-Hand Dri ve 4.0L engi ne) or the l i qui d l i ne
jumper (al l except Left-Hand Dri ve 4.0L engi ne) near
the condenser. The ori fi ce has fi l ter screens on the
i nl et and outl et ends of the tube body. I f the fi xed ori -
fi ce tube i s faul ty or pl ugged, the l i qui d l i ne uni t
must be repl aced. See the servi ce procedures for the
l i qui d l i ne i n thi s group.
cabl e.
l ow pressure cycl i ng cl utch swi tch on the top of the
accumul ator (Fi g. 35).
(3) Unscrew the l ow pressure cycl i ng cl utch swi tch
from the fi tti ng on the top of the accumul ator.
Fig. 33 Liquid Line Remove/Install - Left-Hand Drive
4.0L Engine
FWD LIQUID LINE WITH ORIFICE TUBE CLIP CONDENSER OUTLET TUBE STUD CLIP CLIP EVAPORATOR INLET
Fig. 34 Liquid Line Remove/Install - Right-Hand
Drive 4.0L Engine
EVAPORATOR INLET CLIP LIQUID LINE FWD LIQUID LINE JUMPER WITH ORIFICE TUBE OUTLET TUBE CLIP CONDENSER CLIP
Fig. 35 Low Pressure Cycling Clutch Switch
Remove/Install
WIRE HARNESS CONNEC- TOR ACCUMULATOR FWD LOW PRESSURE CYCLING CLUTCH SWITCH
(4) Reverse the removal procedures to i nstal l . The
swi tch shoul d be hand-ti ghtened onto the accumul a-
tor fi tti ng.
ACCUMULATOR
REMOVAL
cabl e.
l ow pressure cycl i ng cl utch swi tch.
(4) Loosen the screw that secures the accumul ator
retai ni ng band to the support bracket (Fi g. 36) or
(Fi g. 37).
(5) Di sconnect the sucti on l i ne from the accumul a-
tor as descri bed i n thi s group.
(6) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne coupl er from the evaporator outl et tube. See
dures. I nstal l pl ugs i n, or tape over al l of the open
refri gerant fi tti ngs.
(7) Sl i de the accumul ator out of the retai ni ng band
and remove the accumul ator from the vehi cl e.
INSTALLATION
(1) I nstal l the accumul ator i nto the retai ni ng
band.
(2) Remove the tape or pl ugs from accumul ator
i nl et and evaporator outl et tube fi tti ngs, and i nstal l
the accumul ator refri gerant l i ne coupl er to the evap-
orator outl et tube. See Refri gerant Li ne Coupl er i n
thi s group for the procedures.
(3) I nstal l the sucti on l i ne to the accumul ator as
(4) Ti ghten the accumul ator retai ni ng band screw
to 5 Nm (45 i n. l bs.).
(5) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
NOTE: If the accumulator is replaced, add 120 ml (4
oz.) of refrigerant oil to the refrigerant system.
CONDENSER
2.5L ENGINE
REMOVAL
Fig. 36 Accumulator Remove/Install - Left-Hand
Drive
LOW PRESSURE CYCLING CLUTCH SWITCH CLIP EVAPORATOR FWD STUDS BRACKET NUTS BAND ACCUMULATOR
Fig. 37 Accumulator Remove/Install - Right-Hand
Drive
LOW PRESSURE CLUTCH CYCLING SWITCH ACCUMULATOR BRACKET STUDS NUT BAND SCREWEVAPORATOR FWD CLIP
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
cabl e.
screw from the di scharge l i ne bl ock fi tti ng at the con-
denser i nl et and remove the di scharge l i ne from the
condenser. I nstal l pl ugs i n, or tape over, al l of the
open refri gerant fi tti ngs.
screw from the l i qui d l i ne jumper bl ock fi tti ng at the
condenser outl et and remove the l i qui d l i ne jumper
from the condenser. I nstal l pl ugs i n, or tape over, al l
of the open refri gerant fi tti ngs.
(6) Remove the radi ator and the condenser from
the vehi cl e as a uni t. Refer to Group 7 - Cool i ng Sys-
tem for the procedures.
(7) Remove the four screws that secure the con-
denser to the radi ator (Fi g. 38).
(8) Remove the condenser from the radi ator.
INSTALLATION
(1) I nstal l the condenser to the radi ator. Ti ghten
the mounti ng screws to 28 Nm (250 i n. l bs.).
(2) I nstal l the radi ator and condenser to the vehi -
cl e as a uni t. Refer to Group 7 - Cool i ng System for
the procedures.
(3) Remove the tape or pl ugs from the l i qui d l i ne
jumper and condenser outl et bl ock fi tti ngs. I nstal l
the l i qui d l i ne jumper to the condenser outl et.
Ti ghten the mounti ng screw to 12 Nm (105 i n. l bs.).
(4) Remove the tape or pl ugs from the di scharge
l i ne and condenser i nl et bl ock fi tti ngs. I nstal l the di s-
charge l i ne to the condenser i nl et. Ti ghten the
mounti ng screw to 12 Nm (105 i n. l bs.).
NOTE: If the condenser is replaced, add 30 ml (1
4.0L ENGINE
REMOVAL
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
cabl e.
(3) Di sconnect the di scharge l i ne (Left-Hand
Dri ve) or di scharge l i ne jumper (Ri ght-Hand Dri ve)
refri gerant l i ne coupl er at the condenser i nl et. See
dures. I nstal l pl ugs i n, or tape over al l of the open
refri gerant fi tti ngs.
(4) Di sconnect the l i qui d l i ne (Left-Hand Dri ve) or
l i qui d l i ne jumper (Ri ght-Hand Dri ve) refri gerant
l i ne coupl er at the condenser outl et. See Refri gerant
Li ne Coupl er i n thi s group for the procedures. I nstal l
ti ngs.
(5) Remove the radi ator and the condenser from
the vehi cl e as a uni t. Refer to Group 7 - Cool i ng Sys-
tem for the procedures.
Fig. 38 Condenser Remove/Install - 2.5L Engine
CONDENSER RADIATOR SCREW
(6) Remove the four nuts that secure the upper
brackets to the radi ator and the condenser (Fi g. 39).
(7) Remove the upper brackets from the radi ator
and the condenser.
(8) Sl i de the condenser l ower brackets off of the
dowel pi ns on the bottom of the radi ator.
(9) Remove the condenser from the radi ator.
INSTALLATION
(1) I nstal l the hol es of the condenser l ower brack-
ets over the dowel pi ns on the bottom of the radi ator.
(2) I nstal l the upper brackets over the studs on
the top of the radi ator and the condenser. Ti ghten
the mounti ng nuts to 5.3 Nm (47 i n. l bs.).
(3) I nstal l the radi ator and condenser to the vehi -
cl e as a uni t. Refer to Group 7 - Cool i ng System for
the procedures.
l i ne coupl ers on the condenser outl et and the l i qui d
l i ne (Left-Hand Dri ve) or the l i qui d l i ne jumper
(Ri ght-Hand Dri ve). I nstal l the l i qui d l i ne or the l i q-
ui d l i ne jumper to the condenser outl et. See Refri ger-
ant Li ne Coupl er i n thi s group for the procedures.
l i ne coupl ers on the condenser i nl et and the di s-
charge l i ne (Left-Hand Dri ve) or the di scharge l i ne
jumper (Ri ght-Hand Dri ve). I nstal l the di scharge l i ne
or the di scharge l i ne jumper to the condenser i nl et.
See Refri gerant Li ne Coupl er i n thi s group for the
procedures.
NOTE: If the condenser is replaced, add 30 ml (1
VACUUM CHECK VALVE
(1) Unpl ug the heater-A/C vacuum suppl y l i ne at
the vacuum check val ve (Fi g. 40).
(2) Note the ori entati on of the check val ve i n the
vacuum suppl y l i ne for correct rei nstal l ati on.
(3) Unpl ug the vacuum check val ve from the vac-
uum suppl y l i ne fi tti ngs.
(4) Reverse the removal procedures to i nstal l .
VACUUM RESERVOIR
(1) Remove the passenger si de bumper end cap
from the front bumper. Refer to Group 23 - Body for
the procedures.
(2) Unpl ug the vacuum suppl y l i ne connector from
the reservoi r (Fi g. 41).
(3) Remove the two screws that secure the reser-
voi r to the front bumper.
Fig. 39 Condenser Remove/Install - 4.0L Engine
UPPER BRACKET NUT RADIATOR GROMMET LOWER CROSSMEMBER CONDENSER
Fig. 40 Vacuum Supply
VACUUM CHECK VALVE TO ENGINE INTAKE MANIFOLD TO HEATER-A/C CONTROLS TO VACUUM RESERVOIR TO SPEED CON- TROL SERVO VACUUM SUPPLY LINE
Fig. 41 Vacuum Reservoir Remove/Install
VACUUM LINE RESERVOIR SCREWS VACUUM RESER- VOIR
(4) Remove the vacuum reservoi r from behi nd the
front bumper.
BLOWER MOTOR
REMOVAL
(1) I f the vehi cl e i s equi pped wi th ai r condi ti oni ng,
recover the refri gerant from the refri gerant system
as descri bed i n thi s group.
cabl e.
l oosen the accumul ator retai ni ng band screw, di scon-
nect the accumul ator i nl et tube from the evaporator
outl et tube and move the accumul ator far enough to
access and remove the bl ower motor.
(4) Unpl ug the bl ower motor wi re harness connec-
tor (Fi g. 42).
(5) Remove the three screws that secure the
bl ower motor and wheel assembl y to the heater-A/C
housi ng.
(6) Rotate and ti l t the bl ower motor uni t as needed
for cl earance to remove the bl ower motor and wheel
from the heater-A/C housi ng.
INSTALLATION
(1) Al i gn and i nstal l the bl ower motor and wheel
assembl y i nto the heater-A/C housi ng.
(2) I nstal l and ti ghten the three screws that secure
the bl ower motor to the heater A/C housi ng. Ti ghten
the mounti ng screws to 2.2 Nm (20 i n. l bs.).
(3) Pl ug i n the bl ower motor wi re harness connec-
tor.
connect the accumul ator i nl et tube to the evaporator
outl et tube and ti ghten the accumul ator retai ni ng
band screw.
evacuate and charge the refri gerant system as
HEATER-A/C CONTROL
INJURY.
REMOVAL
cabl e.
(2) Open the gl ove box and remove the gl ove box
stop bumpers to rol l down the gl ove box as descri bed
i n Group 8E - I nstrument Panel Systems.
(3) Reach through the gl ove box openi ng and
unpl ug the vacuum harness connector.
(4) Usi ng a tri m sti ck or another sui tabl e wi de-
bl aded fl at tool , gentl y pry the i nstrument panel cen-
ter bezel away from the i nstrument panel to rel ease
the si x snap cl i p retai ners (Fi g. 43).
(5) Remove the center bezel from the vehi cl e.
Fig. 42 Blower Motor Remove/Install
BLOWER MOTOR WIRE HARNESS CONNEC- TOR MOUNTING SCREWS
Fig. 43 Center Bezel Remove/Install
INSTRUMENT PANEL CENTER BEZEL
(6) Rel ease the vacuum harness push-i n retai ner
from the i nstrument panel di rectl y beneath the heat-
er-A/C control .
(7) Remove the four screws that secure the heater-
A/C control to the i nstrument panel (Fi g. 44).
(8) Pul l the heater-A/C control assembl y away
from the i nstrument panel far enough to access the
connecti ons.
back of the heater-A/C control assembl y (Fi g. 45).
(10) Rel ease the temperature control cabl e housi ng
fl ag retai ner l atch on the receptacl e on the back of
the heater-A/C control and di sengage the fl ag
retai ner from the receptacl e.
(11) Rotate the heater-A/C control assembl y to
al i gn the cabl e core wi th the sl ot on the end of the
temperature control l ever and remove the cabl e end
from the l ever.
(12) Reachi ng through the gl ove box openi ng, care-
ful l y gui de the heater-A/C control hal f of the vacuum
harness around any obstacl es whi l e removi ng the
heater-A/C control from the front of the i nstrument
panel .
INSTALLATION
(1) Connect the temperature control cabl e core end
to the temperature control l ever on the back of the
heater-A/C control s.
(2) Snap the temperature control cabl e housi ng
fl ag retai ner i nto the receptacl e on the back of the
heater-A/C control s.
(3) Pl ug i n the wi re harness connector to the back
of the heater-A/C control .
(4) Route the vacuum harness through the i nstru-
ment panel openi ng and rei nstal l the vacuum har-
ness push-i n retai ner.
(5) Reach through the gl ove box openi ng and pl ug
i n the vacuum harness connector.
(6) Rol l up the gl ove box and rei nstal l the gl ove
box stop bumpers.
(7) I nstal l the heater-A/C control s to the i nstru-
ment panel and secure wi th four screws. Ti ghten the
screws to 2.2 Nm (20 i n. l bs.).
(8) I nstal l the i nstrument panel center bezel .
TEMPERATURE CONTROL CABLE
INJURY.
REMOVAL
cabl e.
(2) Di sconnect the temperature control cabl e from
the heater-A/C control s. See Heater-A/C Control s i n
(3) Locate the temperature control cabl e housi ng
fl ag retai ner receptacl e on the bottom of the heater-
A/C housi ng towards the passenger si de of the fl oor
pan transmi ssi on tunnel (Fi g. 46). Locate the fl ag
retai ner l atch rel ease wi ndow on the si de of the
receptacl e. Whi l e depressi ng the l atch through the
l atch rel ease wi ndow, use a tri m sti ck or another
sui tabl e wi de fl at-bl aded tool to gentl y pry the fl ag
retai ner out of the receptacl e.
(4) Remove the screw that secures the bl end-ai r
door crank arm to the bl end-ai r door pi vot shaft.
Fig. 44 Heater-A/C Controls Remove/Install
INSTRUMENT PANEL HEATER-A/C CONTROLS SCREW
Fig. 45 Heater-A/C Control Connections
HEATER-A/C CONTROLS VACUUM HARNESS WIRE HARNESS CONNEC- TOR TEMPERATURE CONTROL CABLE FLAG RETAINERCABLE END
(5) Pul l the bl end-ai r door crank arm down from
the heater-A/C housi ng to remove i t from the bl end-
ai r door pi vot shaft.
(6) Remove the bl end-ai r door crank arm and tem-
perature control cabl e from the vehi cl e as a uni t.
(7) Remove the push nut that secures the temper-
ature control cabl e end to the pi n on the end of the
bl end-ai r door crank arm.
(8) Remove the temperature control cabl e from the
INSTALLATION
(1) I nstal l the bl end-ai r door crank arm onto the
bl end-ai r door pi vot shaft. Be certai n that the tensi on
band on the bottom of the heater-A/C housi ng i s
properl y posi ti oned agai nst the cam formati on on the
(2) I nstal l and ti ghten the screw that secures the
bl end-ai r door crank arm to the bl end-ai r door pi vot
shaft. Ti ghten the mounti ng screw to 1 Nm (10 i n.
l bs.).
(3) I nstal l the temperature control cabl e end over
the pi n on the end of the bl end-ai r door crank arm
and secure i t wi th a push nut.
(4) Snap the temperature control cabl e housi ng
fl ag retai ner i nto the receptacl e on the bottom of the
heater-A/C housi ng.
(5) Connect the temperature control cabl e to the
heater-A/C control s and rei nstal l the heater-A/C con-
trol s to the i nstrument panel . See Heater-A/C Con-
trol s i n thi s group for the procedures.
BLOWER MOTOR RELAY
cabl e.
(2) Open the gl ove box and remove the gl ove box
stop bumpers to rol l down the gl ove box as descri bed
i n Group 8E - I nstrument Panel Systems.
(3) Reach through the gl ove box openi ng to l ocate
the bl ower motor rel ay (Fi g. 47).
(4) Unpl ug the bl ower motor rel ay from i ts wi re
harness connector.
(5) I nstal l the bl ower motor rel ay by al i gni ng the
rel ay termi nal s wi th the cavi ti es i n the wi re harness
connector and pushi ng the rel ay fi rml y i nto pl ace.
(6) Rol l up the gl ove box and rei nstal l the gl ove
box stop bumpers.
KICK COVER
INJURY.
REMOVAL
cabl e.
(2) Loosen the two upper screws that secure the
ki ck cover to the heater-A/C housi ng under the pas-
senger si de of the i nstrument panel on the passenger
si de of the i nstrument panel (Fi g. 48).
(3) Remove the two l ower screws that secure the
ki ck cover to the heater-A/C housi ng.
(4) Pul l the ki ck cover down towards the fl oor to
di sengage the sl otted upper mounti ng tabs from
under the upper screws.
(5) Remove the ki ck cover from the vehi cl e.
Fig. 46 Temperature Control Cable Remove/Install
BOTTOM OF HEATER- A/C HOUSING TEMPERATURE CONTROL CABLE FLAG RETAINER CABLE END FWD PUSH NUT BLEND-AIR DOOR CRANK ARM SCREW FLOOR DUCT TENSION BAND
Fig. 47 Blower Motor Relay Remove/Install
BLOWER MOTOR RELAY VACUUM HARNESS HEATER-A/C WIRE HARNESS CONNEC- TOR HEATER-A/C HOUS- ING
INSTALLATION
(1) Posi ti on the sl otted upper mounti ng tabs of the
ki ck cover under the upper mounti ng screws on the
heater-A/C housi ng. Ti ghten the screws to 2.2 Nm
(20 i n. l bs.).
(2) I nstal l the two l ower ki ck cover mounti ng
screws to the heater-A/C housi ng. Ti ghten the screws
to 2.2 Nm (20 i n. l bs.).
INJURY.
cabl e.
(2) Remove the ki ck cover from the heater-A/C
housi ng as descri bed i n thi s group.
(3) Pul l out on the bl ower motor resi stor wi re har-
ness connector l ock to rel ease the connector l atch
(Fi g. 49).
(4) Depress the l atch on the bl ower motor resi stor
wi re harness connector and unpl ug i t from the resi s-
tor.
(5) Remove the two screws that secure the resi stor
to the heater-A/C housi ng.
(6) Remove the resi stor from the housi ng.
Ti ghten the mounti ng screws to 2.2 Nm (20 i n l bs.).
MODE DOOR VACUUM ACTUATOR
INJURY.
DEFROST DOOR ACTUATOR
cabl e.
(2) Remove the i nstrument panel assembl y as
descri bed i n Group 8E - I nstrument Panel Systems.
(3) Unpl ug the two vacuum harness connectors
from the defrost door actuator (Fi g. 50).
(4) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the heater-A/C
housi ng actuator mount to rel ease the actuator l atch
and pul l fi rml y outwards on the actuator to remove
the actuator from the mount (Fi g. 51).
(5) Move the vacuum actuator as requi red to di s-
engage the hol e on the end of the actuator l i nk from
the hooked pi n on the end of the defrost door crank
arm.
(6) Remove the defrost door vacuum actuator from
the vehi cl e.
FLOOR DOOR ACTUATOR
cabl e.
Fig. 48 Kick Cover Remove/Install
HEATER-A/C HOUS- ING MOUNTING SCREWS KICK COVER
Fig. 49 Blower Motor Resistor Remove/Install
SCREWS WIRE HARNESS CONNECTOR CONNECTOR LOCK HEATER-A/C HOUSING BLOWER MOTOR RESISTOR
(3) Unpl ug the vacuum harness connector from the
fl oor door actuator (Fi g. 50).
the hooked pi n on the end of the fl oor door crank
arm.
(6) Remove the fl oor door vacuum actuator from
the vehi cl e.
PANEL/DEMIST DOOR ACTUATOR
cabl e.
(3) Remove the defrost door actuator as descri bed
i n thi s group.
panel /demi st door actuator (Fi g. 50).
the hooked pi n on the end of the panel /demi st door
crank arm.
(7) Remove the panel /demi st door vacuum actuator
from the vehi cl e.
RECIRCULATION AIR DOOR ACTUATOR
A reci rcul ati on ai r door and vacuum actuator are
used onl y on model s wi th the opti onal ai r condi ti on-
i ng system.
cabl e.
(2) Remove the ki ck cover from the heater-A/C
housi ng as descri bed i n thi s group.
reci rcul ati on ai r door actuator (Fi g. 52).
the hooked pi n on the end of the reci rcul ati on ai r
door l ever.
(6) Remove the reci rcul ati on ai r door vacuum
actuator from the vehi cl e.
HEATER-A/C HOUSING
The heater-A/C housi ng assembl y must be removed
from the vehi cl e and the two hal ves of the housi ng
separated for servi ce access of the heater core, evap-
orator coi l , bl end-ai r door, and each of the vari ous
mode control doors.
Fig. 50 Defrost, Floor, and Panel/Demist Door
Vacuum Actuators
Fig. 51 Vacuum Actuator Remove/Install - Typical
ACTUATOR MOUNT LATCH HOLE TRIM STICK ACTUATOR LATCH
INJURY.
REMOVAL
cabl e.
(3) Unpl ug the heater-A/C uni t wi re harness con-
nector, whi ch i s fastened to the heater-A/C housi ng
next to the bl ower motor rel ay (Fi g. 53).
(4) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 6. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, recover the refri gerant from the
refri gerant system as descri bed i n thi s group.
(5) Di sconnect the refri gerant l i nes from the evap-
orator tubes. I nstal l pl ugs i n, or tape over al l of the
open refri gerant fi tti ngs.
(6) Drai n the cool i ng system. Refer to Group 7 -
Cool i ng System for the procedures.
(7) Di sconnect the heater hoses from the heater
core tubes.
(8) Unpl ug the heater-A/C system vacuum suppl y
l i ne from the tee fi tti ng near the heater core tubes.
remove and rel ocate the accumul ator and i ts mount-
i ng bracket.
(10) Remove the fi ve heater-A/C housi ng mounti ng
nuts from the studs on the engi ne compartment si de
of the dash panel (Fi g. 54). Remove or reposi ti on the
evaporati on cani ster for access, i f requi red.
(11) Pul l the heater-A/C housi ng rearward far
enough for the mounti ng studs and the evaporator
drai n tube to cl ear the dash panel hol es.
(12) Remove the heater-A/C housi ng from the vehi -
cl e.
DISASSEMBLY
(1) Remove the heater-A/C housi ng from the vehi -
cl e and pl ace i t on a work bench.
(2) Unpl ug the vacuum harness connectors from
the fl oor door actuator and, i f the uni t i s so equi pped,
the reci rcul ati on ai r door actuator.
Fig. 52 Recirculation Air Door Vacuum Actuator
Fig. 53 Heater-A/C Unit Connector
Fig. 54 Heater-A/C Housing Remove/Install
HEATER-A/C HOUSING STUD NUT STUD RIGHT FRONT FENDER
(3) Di sengage the vacuum harness from any rout-
i ng cl i ps l ocated on the l ower hal f of the heater-A/C
housi ng.
(4) Di sengage the heater-A/C uni t wi re harness
and bl ower motor rel ay wi re harness connector
push-i n retai ners from thei r mounti ng hol es on the
(5) Remove the bl ower motor and bl ower wheel
uni t from the heater-A/C housi ng as descri bed i n thi s
group.
(6) Pul l the vacuum suppl y l i ne and connector
through the foam gasket on the heater-A/C housi ng
heater core and evaporator coi l tube mounti ng fl ange
(Fi g. 55).
(7) Careful l y remove the bl ower motor housi ng
foam fl ange gasket from around the bl ower motor
openi ng i n the heater-A/C housi ng. I f the gasket i s
deformed or damaged, i t must be repl aced.
(8) I f the uni t i s equi pped wi th ai r condi ti oni ng,
remove the screw that secures the cl amp to the evap-
orator coi l tubes and remove the cl amp.
(9) Careful l y remove the foam gasket from the
heater-A/C housi ng heater core and evaporator coi l
tube mounti ng fl ange. I f the gasket i s deformed or
(10) Use a screwdri ver to pry off the two snap cl i ps
that hel p secure the upper and l ower heater-A/C
housi ng hal ves together.
(11) Remove the 14 screws that hel p secure the
upper and l ower heater-A/C housi ng hal ves together.
(12) Careful l y separate the upper heater-A/C hous-
i ng hal f from the l ower hal f.
ASSEMBLY
(1) Assembl e the upper heater-A/C housi ng hal f to
the l ower hal f. Be certai n that each of the door pi vot
shaft ends i s properl y engaged i n i ts pi vot hol e, that
the bl ower motor ri ng i s properl y i nstal l ed and, i f the
uni t i s so equi pped, that the evaporator coi l tube rub-
ber seal i s properl y posi ti oned (Fi g. 56).
(2) I nstal l the 14 screws and two snap cl i ps that
secure the upper and l ower heater-A/C housi ng
hal ves together.
(3) I nstal l the bl ower motor and wheel uni t to the
(4) I nstal l the bl ower motor housi ng fl ange and
heater core and evaporator coi l tube mounti ng fl ange
foam gaskets.
(5) I nsert the vacuum suppl y l i ne and connector
through the foam gasket on the heater-A/C housi ng
heater core and evaporator coi l tube mounti ng fl ange.
(6) I f the uni t i s equi pped wi th ai r condi ti oni ng,
rei nstal l the evaporator coi l tube cl amp.
(7) Engage the heater-A/C uni t wi re harness and
bl ower motor rel ay wi re harness connector push-i n
retai ners to thei r mounti ng hol es on the heater-A/C
housi ng.
(8) Rei nstal l the vacuum harness to the routi ng
cl i ps and pl ug i n the vacuum harness connector at
the fl oor door actuator and, i f the uni t i s so equi pped,
the reci rcul ati on ai r door actuator.
(9) I nstal l the heater-A/C housi ng i n the vehi cl e.
INSTALLATION
(1) Posi ti on the heater-A/C housi ng to the dash
panel . Be certai n that the evaporator drai n tube and
the housi ng mounti ng studs are i nserted i nto thei r
correct mounti ng hol es.
(2) I nstal l the fi ve nuts to the mounti ng studs on
the engi ne compartment si de of the dash panel .
Ti ghten the mounti ng nuts to 6.2 Nm (55 i n. l bs.).
(3) Rei nstal l the evaporati on cani ster i f i t was
reposi ti oned duri ng the removal procedure.
rei nstal l the accumul ator and i ts mounti ng bracket.
(5) Connect the heater-A/C system vacuum suppl y
l i ne to the tee fi tti ng near the heater core tubes.
(6) Connect the heater hoses to the heater core
tubes.
Fig. 55 Heater-A/C Housing Disassembly
GASKETS EVAPORATOR TUBE CLAMP CLIPS HEATER CORE TUBES VACUUM SUPPLY LINE BLOWER MOTOR
Fig. 56 Heater-A/C Housing Assembly
BLEND-AIR DOOR PIVOT EVAPORATOR COIL TUBE RUBBER SEAL RECIRCULATION AIR DOOR PIVOTS BLOWER MOTOR RING
unpl ug or remove the tape from the refri gerant fi t-
ti ngs, and connect the refri gerant l i nes to the evapo-
rator tubes.
(8) I nstal l the i nstrument panel assembl y as
(10) Fi l l the cool i ng system. Refer to Group 7 -
Cool i ng System for the procedures.
(11) I f the vehi cl e i s equi pped wi th ai r condi ti on-
i ng, evacuate and charge the refri gerant system as
(12) Start the vehi cl e and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
HEATER-A/C HOUSING DOOR
INJURY.
BLEND-AIR DOOR
(1) Remove and di sassembl e the heater-A/C hous-
i ng as descri bed i n thi s group.
NOTE: If the temperature control cable was not
removed with the blend-air door crank arm as a unit
during the instrument panel assembly removal pro-
cedures, the crank arm must be removed from the
blend-air door pivot shaft before the blend-air door
can be removed from the heater-A/C housing. See
Temperature Control Cable in this group for the pro-
cedures.
(2) Li ft the bl end-ai r door pi vot shaft out of the
pi vot hol e i n the bottom of the l ower hal f of the heat-
er-A/C housi ng (Fi g. 57).
PANEL/DEMIST DOOR AND CRANK ARM
(2) Remove the defrost and panel /demi st door vac-
uum actuators as descri bed i n thi s group.
(3) I nsert a screwdri ver i nto the l atch hol e (Fi g.
58) of the panel /demi st door pi vot shaft to rel ease the
l atch of the panel /demi st door crank arm, and pul l
the crank arm out of the pi vot shaft from the outsi de
of the upper hal f of the heater-A/C housi ng.
(4) Reach i nsi de the upper hal f of the heater-A/C
housi ng and careful l y fl ex the panel /defrost door (Fi g.
59) enough so that the door pi vot cl ears the pi vot
hol e i n the housi ng.
(5) Remove the panel /demi st door from the heater-
A/C housi ng.
DEFROST DOOR AND CRANK ARM
(2) Remove the panel /demi st door and crank arm
as descri bed i n thi s group.
58) of the defrost door pi vot shaft to rel ease the l atch
of the defrost door crank arm, and pul l the crank
arm out of the pi vot shaft from the outsi de of the
upper hal f of the heater-A/C housi ng.
(4) Reach i nsi de the upper hal f of the heater-A/C
housi ng and careful l y fl ex the defrost door (Fi g. 59)
Fig. 57 Blend-Air Door
Fig. 58 Mode Door Crank Arm Remove/Install -
Typical
DOOR PIVOT SHAFT LATCH HOLE CRANK ARM LATCH FLAT BLADE PRY TOOL
enough so that the door pi vot cl ears the pi vot hol e i n
the housi ng.
(5) Remove the defrost door from the heater-A/C
housi ng.
FLOOR DOOR AND CRANK ARM
(2) Remove the fl oor door vacuum actuator as
58) of the fl oor door pi vot shaft to rel ease the l atch of
the fl oor door crank arm, and pul l the crank arm out
of the pi vot shaft from the outsi de of the l ower hal f of
the heater-A/C housi ng.
(4) Reach i nsi de the l ower hal f of the heater-A/C
housi ng and careful l y fl ex the fl oor door (Fi g. 60)
enough so that the door pi vot cl ears the pi vot hol e i n
the housi ng.
(5) Remove the fl oor door from the heater-A/C
housi ng.
RECIRCULATION AIR DOOR
A reci rcul ati on ai r door and vacuum actuator are
used onl y on model s wi th the opti onal ai r condi ti on-
i ng system.
(2) Remove the reci rcul ati on ai r door vacuum
actuator as descri bed i n thi s group.
(3) Reach i nsi de the l ower hal f of the heater-A/C
housi ng and l i ft the bottom edge of the reci rcul ati on
ai r door upwards (Fi g. 61).
(4) Gui de the reci rcul ati on ai r door l ever through
the ai r i ntake gri l l e of the heater-A/C housi ng whi l e
removi ng the door from the housi ng.
EVAPORATOR COIL
INJURY.
(2) Li ft the evaporator coi l uni t out of the l ower
hal f of the heater-A/C housi ng (Fi g. 62).
(3) Reverse the removal procedures to i nstal l . Be
certai n that the evaporator foam i nsul ator wrap and
rubber tube seal are rei nstal l ed.
Fig. 59 Panel/Demist and Defrost Doors
Fig. 60 Floor Door
LOWER HEATER-A/C HOUSING
PIVOT SHAFT CRANK ARM FLOOR DOOR
Fig. 61 Recirculation Air Door
RECIRCULATION AIR DOOR LOWER HEATER-A/C HOUS- ING LEVER PIVOT SHAFT
NOTE: If the evaporator is replaced, add 60 ml (2
HEATER CORE
INJURY.
(2) Li ft the heater core out of the l ower hal f of the
heater-A/C housi ng (Fi g. 63).
certai n that the heater core foam i nsul ator i s rei n-
stal l ed.
DUCTS AND OUTLETS
INJURY.
PANEL OUTLET DUCTS
The panel outl et ducts are i ntegral to the i nstru-
ment panel assembl y. Refer to Group 8E - I nstru-
ment Panel Systems for the i nstrument panel
assembl y servi ce procedures.
PANEL OUTLET BARRELS
(1) Use a tri m sti ck or another sui tabl e wi de-
bl aded fl at tool to gentl y pry the panel outl et barrel
out of the panel outl et housi ng (Fi g. 64). The barrel
i s retai ned by a l i ght snap fi t.
(2) To i nstal l , posi ti on the barrel i n the panel out-
l et housi ng and press fi rml y unti l the barrel snaps
i nto pl ace.
Fig. 62 Evaporator Coil
EVAPORATOR COIL TUBE SEAL CONDENSATE DRAIN TUBE FOAM INSULA- TOR WRAP
Fig. 63 Heater Core
HEATER CORE LOWER HEATER-A/C HOUS- ING
Fig. 64 Panel Outlet Barrels
DEMISTER OUTLETS PANEL OUTLET BARRELS
DEMISTER OUTLETS
The si de wi ndow demi ster outl ets are i ntegral to
the i nstrument panel end caps. Refer to Group 8E -
I nstrument Panel Systems for the i nstrument panel
end cap servi ce procedures.
DEFROST DUCT/DEMISTER ADAPTER
(2) Di sconnect the demi ster hoses from the defrost
duct/demi ster adapter (Fi g. 65).
defrost duct/demi ster adapter to the i nstrument
panel .
(4) Remove the defrost duct/demi ster adapter from
the i nstrument panel .
Ti ghten the mounti ng screws to 2.2 Nm (20 i n. l bs.).
DEMISTER HOSES
(2) Di sconnect the ends of the demi ster hose from
the demi ster duct (Fi g. 66) and the defrost duct/de-
mi ster adapter (Fi g. 65).
DEMISTER DUCTS
(2) Remove the i nstrument panel end cap as
(3) Di sconnect the demi ster hoses from the demi s-
ter duct (Fi g. 66).
(4) Remove the two screws that secure the demi s-
ter duct to the top of the i nstrument panel .
(5) Remove the demi ster duct from the i nstrument
panel .
CONSOLE REAR DUCT
cabl e.
(2) Remove the fl oor consol e from the fl oor pan
transmi ssi on tunnel (Fi g. 67). Refer to Group 23 -
Body for the procedures.
(3) Li ft the rear of the consol e rear duct out of the
consol e rear mounti ng bracket on the fl oor pan trans-
mi ssi on tunnel and sl i de the duct rearward to di sen-
gage i t from the fl oor duct and adapter.
(4) Remove the consol e rear duct from the vehi cl e.
Fig. 65 Defrost Duct/Demister Adapter
HOSE FWD INSTRUMENT PANEL DEFROST DUCT/DEMISTER ADAPTER SCREW HOSE
Fig. 66 Demister Duct Remove/Install
DEMISTER DUCT SCREWS DEMISTERHOSE
Fig. 67 Floor Duct and Console Rear Duct Remove/
Install
FLOOR CONSOLE SCREW FLOOR DUCT AND ADAPTER CONSOLE REAR DUCT
FLOOR DUCT AND ADAPTER
(1) Remove the i nstrument panel as descri bed i n
Group 8E - I nstrument Panel Systems.
(2) Remove the heater-A/C housi ng as descri bed i n
thi s group.
(3) Remove the three screws that secure the fl oor
duct and adapter to the heater-A/C housi ng (Fi g. 67).
(4) Remove the fl oor duct and adapter from the
EMISSION CONTROL SYSTEMS
CONTENTS
page page
EVAPORATIVE EMISSION CONTROLS . . . . . . . 11 ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . . . 1
ON-BOARD DIAGNOSTICS
INDEX
page page
GENERAL INFORMATION
SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . 1
CIRCUIT ACTUATION TEST MODE . . . . . . . . . . 2
COMPONENT MONITORS . . . . . . . . . . . . . . . . . 9
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . . 2
HIGH AND LOW LIMITS . . . . . . . . . . . . . . . . . . 10
LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . . . 10
MALFUNCTION INDICATOR LAMP (MIL) . . . . . . 1
MONITORED SYSTEMS . . . . . . . . . . . . . . . . . . 7
NON-MONITORED CIRCUITS . . . . . . . . . . . . . . 9
STATE DISPLAY TEST MODE . . . . . . . . . . . . . . 2
TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
SYSTEM DESCRIPTION
The Powertrai n Control Modul e (PCM) moni tors
many di fferent ci rcui ts i n the fuel i njecti on, i gni ti on,
emi ssi on and engi ne systems. I f the PCM senses a
probl em wi th a moni tored ci rcui t often enough to
i ndi cate an actual probl em, i t stores a Di agnosti c
Troubl e Code (DTC) i n the PCMs memory. I f the
code appl i es to a non-emi ssi ons rel ated component or
system, and the probl em i s repai red or ceases to
exi st, the PCM cancel s the code after 40 warm-up
cycl es. Di agnosti c troubl e codes that affect vehi cl e
emi ssi ons i l l umi nate the Mal functi on I ndi cator
(check engi ne) Lamp. Refer to Mal functi on I ndi cator
Lamp i n thi s secti on.
Certai n cri teri a must be met before the PCM
stores a DTC i n memory. The cri teri a may be a spe-
ci fi c range of engi ne RPM, engi ne temperature,
and/or i nput vol tage to the PCM.
The PCM mi ght not store a DTC for a moni tored
ci rcui t even though a mal functi on has occurred. Thi s
may happen because one of the DTC cri teri a for the
ci rcui t has not been met. For example , assume the
di agnosti c troubl e code cri teri a requi res the PCM to
moni tor the ci rcui t onl y when the engi ne operates
between 750 and 2000 RPM. Suppose the sensors
output ci rcui t shorts to ground when engi ne operates
above 2400 RPM (resul ti ng i n 0 vol t i nput to the
PCM). Because the condi ti on happens at an engi ne
speed above the maxi mum threshol d (2000 rpm), the
PCM wi l l not store a DTC.
There are several operati ng condi ti ons for whi ch
the PCM moni tors and sets DTCs. Refer to Moni -
tored Systems, Components, and Non-Moni tored Ci r-
cui ts i n thi s secti on.
NOTE: Various diagnostic procedures may actually
cause a diagnostic monitor to set a DTC. For
instance, pulling a spark plug wire to perform a
spark test may set the misfire code. When a repair
is completed and verified, connect the DRB scan
tool to the 16way data link connector (Fig. 1) to
erase all DTCs and extinguish the MIL.
Techni ci ans can di spl ay stored DTCs by three di f-
ferent methods. Refer to Di agnosti c Troubl e Codes i n
thi s secti on. For DTC i nformati on, refer to charts i n
thi s secti on.
MALFUNCTION INDICATOR LAMP (MIL)
As a functi onal test, the MI L (check engi ne) i l l umi -
nates at key-on before engi ne cranki ng. Whenever
the Powertrai n Control Modul e (PCM) sets a Di ag-
nosti c Troubl e Code (DTC) that affects vehi cl e emi s-
si ons, i t i l l umi nates the MI L. I f a probl em i s
XJ EMISSION CONTROL SYSTEMS 25 - 1
detected, the PCM sends a message to the i nstru-
ment cl uster to i l l umi nate the l amp. The PCM i l l u-
mi nates the MI L onl y for DTCs that affect vehi cl e
emi ssi ons. There are some moni tors that may take
two consecuti ve tri ps, wi th a detected faul t, before
the MI L i s i l l umi nated. The MI L stays on conti nu-
ousl y when the PCM has entered a Li mp-I n mode or
i denti fi ed a fai l ed emi ssi on component. Refer to the
Di agnosti c Troubl e Code charts i n thi s group for
emi ssi on rel ated codes.
Al so, the MI L ei ther fl ashes or i l l umi nates conti n-
uousl y when the PCM detects acti ve engi ne mi sfi re.
Refer to Mi sfi re Moni tori ng i n thi s secti on.
Addi ti onal l y, the PCM may reset (turn off) the MI L
when one of the fol l owi ng occur:
PCM does not detect the mal functi on for 3 con-
secuti ve tri ps (except mi sfi re and Fuel system Moni -
tors).
PCM does not detect a mal functi on whi l e per-
formi ng three successi ve engi ne mi sfi re or fuel sys-
tem tests. The PCM performs these tests whi l e the
engi ne i s operati ng wi thi n 375 RPM of and wi thi n
10 % of the l oad of the operati ng condi ti on at whi ch
the mal functi on was fi rst detected.
STATE DISPLAY TEST MODE
The swi tch i nputs to the Powertrai n Control Mod-
ul e (PCM) have two recogni zed states; HI GH and
LOW. For thi s reason, the PCM cannot recogni ze the
di fference between a sel ected swi tch posi ti on versus
an open ci rcui t, a short ci rcui t, or a defecti ve swi tch.
I f the State Di spl ay screen shows the change from
HI GH to LOW or LOW to HI GH, assume the enti re
swi tch ci rcui t to the PCM functi ons properl y. Connect
the DRB scan tool to the data l i nk connector and
access the state di spl ay screen. Then access ei ther
State Di spl ay I nputs and Outputs or State Di spl ay
Sensors.
CIRCUIT ACTUATION TEST MODE
The Ci rcui t Actuati on Test Mode checks for proper
operati on of output ci rcui ts or devi ces the Powertrai n
Control Modul e (PCM) may not i nternal l y recogni ze.
The PCM attempts to acti vate these outputs and
al l ow an observer to veri fy proper operati on. Most of
the tests provi de an audi bl e or vi sual i ndi cati on of
devi ce operati on (cl i ck of rel ay contacts, fuel spray,
etc.). Except for i ntermi ttent condi ti ons, i f a devi ce
functi ons properl y duri ng testi ng, assume the devi ce,
i ts associ ated wi ri ng, and dri ver ci rcui t work cor-
rectl y. Connect the DRB scan tool to the data l i nk
connector and access the Actuators screen.
DIAGNOSTIC TROUBLE CODES
A Di agnosti c Troubl e Code (DTC) i ndi cates the
PCM has recogni zed an abnormal condi ti on i n the
system.
The techni ci an can retri eve and di spl ay DTCs i n
three di fferent ways:
The preferred and most accurate method of
retri evi ng a DTC i s by usi ng the DRB scan tool . The
scan tool suppl i es detai l ed di agnosti c i nformati on
whi ch can be used to more accuratel y di agnose
causes for a DTC.
The second method i s by observi ng the two-di gi t
number di spl ayed at the Mal functi on I ndi cator Lamp
(MI L). The MI L i s di spl ayed on the i nstrument panel
as the Check Engi ne l amp. Thi s method i s to be used
as a qui ck-test onl y. Al ways use the DRB scan tool
for detai l ed i nformati on.
The thi rd method i s by observi ng the two-di gi t
number di spl ayed at the vehi cl e odometer. Thi s
method, si mi l ar to the MI L l amp, i s al so to be used
as a qui ck-test onl y.
Remember that DTCs are the results of a sys-
tem or circuit failure, but do not directly iden-
tify the failed component or components.
NOTE: For a list of DTCs, refer to the charts in this
section.
BULB CHECK
Each ti me the i gni ti on key i s turned to the ON
posi ti on, the mal functi on i ndi cator (check engi ne)
l amp on the i nstrument panel shoul d i l l umi nate for
approxi matel y 2 seconds then go out. Thi s i s done for
a bul b check.
OBTAINING DTCS USING DRB SCAN TOOL
(1) Connect the DRB scan tool to the data l i nk
(di agnosti c) connector. Thi s connector i s l ocated i n
Fig. 1 Data Link (Diagnostic) Connector Location
16WAY DATA LINK CON- NECTOR
25 - 2 EMISSION CONTROL SYSTEMS XJ
the passenger compartment; at the l ower edge of
i nstrument panel ; near the steeri ng col umn.
(2) Turn the i gni ti on swi tch on and access the
Read Faul t screen.
(3) Record al l the DTCs and freeze frame i nfor-
mati on shown on the DRB scan tool .
(4) To erase DTCs, use the Erase Troubl e Code
data screen on the DRB scan tool . Do not erase any
DTCs until problems have been investigated
and repairs have been performed.
OBTAINING DTCS USING MIL LAMP
(1) Cycl e the i gni ti on key On - Off - On - Off - On
wi thi n 5 seconds.
(2) Count the number of ti mes the MI L (check
engi ne l amp) on the i nstrument panel fl ashes on and
off. The number of fl ashes represents the troubl e
code. There i s a sl i ght pause between the fl ashes rep-
resenti ng the fi rst and second di gi ts of the code.
Longer pauses separate i ndi vi dual two di gi t troubl e
codes.
An exampl e of a fl ashed DTC i s as fol l ows:
Lamp fl ashes 4 ti mes, pauses, and then fl ashes
6 more ti mes. Thi s i ndi cates a DTC code number 46.
Lamp fl ashes 5 ti mes, pauses, and fl ashes 5
more ti mes. Thi s i ndi cates a DTC code number 55. A
DTC 55 wi l l al ways be the l ast code to be di spl ayed.
Thi s i ndi cates the end of al l stored codes.
OBTAINING DTCS USING VEHICLE
ODOMETER
(1) Cycl e the i gni ti on key On - Off - On - Off - On
wi thi n 5 seconds.
(2) After a short pause, the mi l eage shown on the
vehi cl es di gi tal odometer wi l l be temporari l y del eted.
After thi s occurs, read the DTC number di spl ayed on
the odometer. Each twodi gi t number wi l l be di s-
pl ayed wi th a sl i ght del ay between numbers.
(3) A DTC number 55 wi l l al ways be the l ast code
to be di spl ayed. Thi s i ndi cates the end of al l stored
codes. After code 55 has been di spl ayed, the odometer
wi l l return to i ts normal mode.
DIAGNOSTIC TROUBLE CODE DESCRIPTIONS
HEX CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
DESCRIPTION OF DIAGNOSTIC TROUBLE
CODE
12* Battery Disconnect Direct battery input to PCM was disconnected
within the last 50 Key-on cycles.
55* Completion of fault code display on Check
Engine lamp.
01 54** P0340 No Cam Signal at
PCM
No camshaft signal detected during engine
cranking.
02 53** P0601 Internal Controller
Failure
PCM Internal fault condition detected.
05 47*** Charging System
Voltage Too Low
Battery voltage sense input below target
charging during engine operation. Also, no
significant change detected in battery voltage
during active test of generator output circuit.
06 46*** Charging System
Voltage Too High
Battery voltage sense input above target
charging voltage during engine operation.
0A 42* Auto Shutdown Relay
Control Circuit
An open or shorted condition detected in the
auto shutdown relay circuit.
0B 41*** Generator Field Not
Switching Properly
generator field control circuit.
0C 37** P0743 Torque Converter
Clutch Soleniod/Trans
Relay Circuits
torque converter part throttle unlock solenoid
control circuit (3 speed auto RH trans. only).
0E 35** P1491 Rad Fan Control
Relay Circuit
low speed radiator fan relay control circuit.
HEX CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
CODE
0F 34* Speed Control
Solenoid Circuits
Speed Control vacuum or vent solenoid circuits.
10 33* A/C Clutch Relay
Circuit
A/C clutch relay circuit.
12 31** P0443 EVAP Purge Solenoid
Circuit
duty cycle purge solenoid circuit.
13 27** P0203 Injector #3 Control
Circuit
Injector #3 output driver does not respond
properly to the control signal.
or
14 P0202 Injector #2 Control
Circuit
or
Circuit
19 25** P0505 Idle Air Control Motor
Circuits
A shorted or open condition detected in one or
more of the idle air control motor circuits.
1A 24** P0122 Throttle Position
Sensor Voltage Low
Throttle position sensor input below the
minimum acceptable voltage
or
1B P0123 Throttle Position
Sensor Voltage High
Throttle position sensor input above the
maximum acceptable voltage.
1E 22** P0117 ECT Sensor Voltage
Too Low
Engine coolant temperature sensor input below
minimum acceptable voltage.
or
1F P0118 ECT Sensor Voltage
Too High
Engine coolant temperature sensor input above
21 17* Engine Is Cold Too
Long
Engine did not reach operating temperature
within acceptable limits.
23 15** P0500 No Vehicle Speed
Sensor Signal
No vehicle speed sensor signal detected during
road load conditions.
24 14** P0107 MAP Sensor Voltage
Too Low
MAP sensor input below minimum acceptable
voltage.
or
25 P0108 MAP Sensor Voltage
Too High
MAP sensor input above maximum acceptable
voltage.
27 13** P1297 No Change in MAP
From Start to Run
No difference recognized between the engine
MAP reading and the barometric (atmospheric)
pressure reading from start-up.
28 11* No Crank Reference
Signal at PCM
No crank reference signal detected during
engine cranking.
2B P0351 Ignition Coil #1
Primary Circuit
Peak primary circuit current not achieved with
maximum dwell time.
2C 42* No ASD Relay Output
Voltage at PCM
An Open condition Detected In The ASD Relay
Output Circuit.
HEX CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
CODE
31 63** P1696 PCM Failure
EEPROM Write
Denied
Unsuccessful attempt to write to an EEPROM
location by the PCM.
39 23** P0112 Intake Air Temp
Sensor Voltage Low
Intake air temperature sensor input below the
or
3A P0113 Intake Air Temp
Sensor Voltage High
Intake air temperature sensor input above the
minimum acceptable voltage.
3D 27** P0204 Injector #4 Control
Circuit
3E 21** P0132 Upstream O2S
Shorted to Voltage
Oxygen sensor input voltage maintained above
the normal operating range.
44 53** PO600 PCM Failure SPI
Communications
PCM internal fault condition detected
45 27** P0205 Injector #5 Control
Circuit
or
Circuit
52 77* SPD CTRL PWR RLY;
or S/C 12V Driver
CKT
Malfuntion detected with power feed to speed
control servo solenoids
56 34* Speed Control Switch
Always High
Speed control switch input above the maximum
acceptable voltage.
or
57 Speed Control Switch
Always Low
Speed control switch input below the minimum
acceptable voltage.
65 42* Fuel Pump Relay
Control Circuit
fuel pump relay control circuit.
66 21** P0133 Upstream O2S Slow
Response
Oxygen sensor response slower than minimum
required switching frequency.
or
67 P0135 Upstream O2S Heater
Failure
Upstream oxygen sensor heating element
circuit malfunction
69 P0141 Downstream or
Pre-Catalyst Heater
Failure
Oxygen sensor heating element circuit
malfunction.
6A 43** P0300 Multiple Cylinder
Mis-fire
Misfire detected in multiple cylinders.
or
6B P0301 Cylinder #1 Mis-fire Misfire detected in cylinder #1.
or
6C P0302 Cylinder #2 Mis-fire Misfire detected in cylinder #2.
or
HEX CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
CODE
6D P0303 Cylinder #3 Mis-fire Misfire detected in cylinder #3.
or
6E P0304 Cylinder #4 Mis-fire Misfire detected in cylinder #4.
70 72** P0420 Efficency Failure Catalyst efficiency below required level.
71 31* P0441 Evap Purge Flow
Monitor Failure
Insufficient or excessive vapor flow detected
during evaporative emission system operation.
72 37** P1899 P/N Switch Stuck in
Park or in Gear
Incorrect input state detected for the Park/
Neutral switch, auto. trans. only.
76 52** P0172 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
77 51** P0171 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
7E 21** P0138 Downstream and
Pre-Catalyst O2S
Shorted to Voltage
Oxygen sensor input voltage maintained above
the normal operating range.
80 17** P0125 Closed Loop Temp
Not Reached
Engine does not reach 20F within 5 minutes
with a vehicle speed signal.
84 24** P0121 TPS Voltage Does
Not Agree With MAP
TPS signal does not correlate to MAP sensor
87 14** P1296 No 5 Volts To MAP
Sensor
5 Volt output to MAP sensor open.
8A 25** P1294 Target Idle Not
Reached
Actual idle speed does not equal target idle
speed.
94 37* P0740 Torq Conv Clu, No
RPM Drop At Lockup
Relationship between engine speed and vehicle
speed indicates no torque converter clutch
engagement (auto. trans. only).
95 42* Fuel Level Sending
Unit Volts Too Low
Open circuit between PCM and fuel gauge
sending unit.
or
96 Fuel Level Sending
Unit Volts Too High
Circuit shorted to voltage between PCM and
fuel gauge sending unit.
or
97 Fuel Level Unit No
Change Over Miles
No movement of fuel level sender detected.
99 44** P1493 Ambient/Batt Temp
Sen VoltsToo Low
Battery temperature sensor input voltage below
an acceptable range.
or
9A P1492 Ambient/Batt Temp
Sensor VoltsToo High
Battery temperature sensor input voltage above
an acceptable range.
9B 21** P0131 Upstream O2S
Shorted to Ground
O2 sensor voltage too low, tested after cold
start.
or
HEX CODE
MIL
CODE
GENERIC
SCAN
TOOL
CODE
DRB SCAN TOOL
DISPLAY
CODE
9C P0137 Downstream and
Pre-Catalyst O2S
Shorted to Ground
O2 sensor voltage too low, tested after cold
start.
9D 11** P1391 Intermittent Loss of
CMP or CKP
Intermittent loss of either camshaft or
crankshaft position sensor
AE 43** P0305 Cylinder #5 Mis-fire Misfire detected in cylinder #5.
or
AF P0306 Cylinder #6 Mis-fire Misfire detected in cylinder #6.
BA 11** P1398 Mis-fire Adaptive
Numerator at Limit
CKP sensor target windows have too much
variation
CO 21 P0133 CAT MON SLOW O2
1/1
A slow switching oxygen sensor has been
detected in bank 1/1 during catalyst monitor
test.
* Check Engi ne Lamp (MI L) wi l l not i l l umi nate i f thi s Di agnosti c Troubl e Code was recorded. Cycl e I gni ti on
key as descri bed i n manual and observe code fl ashed by Check Engi ne l amp.
** Check Engi ne Lamp (MI L) wi l l i l l umi nate duri ng engi ne operati on i f thi s Di agnosti c Troubl e Code was
recorded.
*** Generator Lamp i l l umi nated
MONITORED SYSTEMS
There are new el ectroni c ci rcui t moni tors that
check fuel , emi ssi on, engi ne and i gni ti on perfor-
mance. These moni tors use i nformati on from vari ous
sensor ci rcui ts to i ndi cate the overal l operati on of the
fuel , engi ne, i gni ti on and emi ssi on systems and thus
the emi ssi ons performance of the vehi cl e.
The fuel , engi ne, i gni ti on and emi ssi on systems
moni tors do not i ndi cate a speci fi c component prob-
l em. They do i ndi cate that there i s an i mpl i ed prob-
l em wi thi n one of the systems and that a speci fi c
probl em must be di agnosed.
I f any of these moni tors detect a probl em affecti ng
vehi cl e emi ssi ons, the Mal functi on I ndi cator (Check
Engi ne) Lamp wi l l be i l l umi nated. These moni tors
generate Di agnosti c Troubl e Codes that can be di s-
pl ayed wi th the check engi ne l amp or a scan tool .
The fol l owi ng i s a l i st of the system moni tors:
Mi sfi re Moni tor
Fuel System Moni tor
Oxygen Sensor Moni tor
Oxygen Sensor Heater Moni tor
Catal yst Moni tor
Al l these system moni tors requi re two consecuti ve
tri ps wi th the mal functi on present to set a faul t.
Fol l owi ng i s a descri pti on of each system moni tor,
and i ts DTC.
Refer to the appropriate Powertrain Diagnos-
tics Procedures manual for diagnostic proce-
dures.
MIL 21OXYGEN SENSOR (O2S) MONITOR
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The O2S i s al so the mai n sensi ng el ement for the
Catal yst and Fuel Moni tors.
The O2S can fai l i n any or al l of the fol l owi ng
manners:
sl ow response rate
reduced output vol tage
dynami c shi ft
shorted or open ci rcui ts
Response rate i s the ti me requi red for the sensor to
swi tch from l ean to ri ch once i t i s exposed to a ri cher
than opti mum A/F mi xture or vi ce versa. As the sen-
sor starts mal functi oni ng, i t coul d take l onger to
detect the changes i n the oxygen content of the
exhaust gas.
The output vol tage of the O2S ranges from 0 to 1
vol t. A good sensor can easi l y generate any output
vol tage i n thi s range as i t i s exposed to di fferent con-
centrati ons of oxygen. To detect a shi ft i n the A/F
mi xture (l ean or ri ch), the output vol tage has to
change beyond a threshol d val ue. A mal functi oni ng
sensor coul d have di ffi cul ty changi ng beyond the
threshol d val ue.
MIL 21OXYGEN SENSOR HEATER MONITOR
I f there i s an oxygen sensor (O2S) shorted to vol t-
age DTC, as wel l as a O2S heater DTC, the O2S
faul t MUST be repai red fi rst. Before checki ng the
O2S faul t, veri fy that the heater ci rcui t i s operati ng
correctl y.
Effecti ve control of exhaust emi ssi ons i s achi eved
by an oxygen feedback system. The most i mportant
el ement of the feedback system i s the O2S. The O2S
i s l ocated i n the exhaust path. Once i t reaches oper-
ati ng temperature 300 to 350C (572 to 662F), the
sensor generates a vol tage that i s i nversel y propor-
ti onal to the amount of oxygen i n the exhaust. The
i nformati on obtai ned by the sensor i s used to cal cu-
l ate the fuel i njector pul se wi dth. Thi s mai ntai ns a
14.7 to 1 Ai r Fuel (A/F) rati o. At thi s mi xture rati o,
the catal yst works best to remove hydrocarbons (HC),
carbon monoxi de (CO) and ni trogen oxi de (NOx) from
the exhaust.
The vol tage readi ngs taken from the O2S sensor
are very temperature sensi ti ve. The readi ngs are not
accurate bel ow 300C. Heati ng of the O2S sensor i s
done to al l ow the engi ne control l er to shi ft to cl osed
l oop control as soon as possi bl e. The heati ng el ement
used to heat the O2S sensor must be tested to ensure
that i t i s heati ng the sensor properl y.
The O2S sensor ci rcui t i s moni tored for a drop i n
vol tage. The sensor output i s used to test the heater
by i sol ati ng the effect of the heater el ement on the
O2S sensor output vol tage from the other effects.
MIL 43MISFIRE MONITOR
Excessi ve engi ne mi sfi re resul ts i n i ncreased cata-
l yst temperature and causes an i ncrease i n HC emi s-
si ons. Severe mi sfi res coul d cause catal yst damage.
To prevent catal yti c convertor damage, the PCM
moni tors engi ne mi sfi re.
for mi sfi re duri ng most engi ne operati ng condi ti ons
(posi ti ve torque) by l ooki ng at changes i n the crank-
shaft speed. I f a mi sfi re occurs the speed of the
crankshaft wi l l vary more than normal .
MIL 51/52FUEL SYSTEM MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de. The catal yst works best
when the Ai r Fuel (A/F) rati o i s at or near the opti -
mum of 14.7 to 1.
The PCM i s programmed to mai ntai n the opti mum
ai r/fuel rati o of 14.7 to 1. Thi s i s done by maki ng
short term correcti ons i n the fuel i njector pul se wi dth
based on the O2S sensor output. The programmed
memory acts as a sel f cal i brati on tool that the engi ne
control l er uses to compensate for vari ati ons i n engi ne
speci fi cati ons, sensor tol erances and engi ne fati gue
over the l i fe span of the engi ne. By moni tori ng the
actual fuel -ai r rati o wi th the O2S sensor (short term)
and mul ti pl yi ng that wi th the program l ong-term
(adapti ve) memory and compari ng that to the l i mi t,
i t can be determi ned whether i t wi l l pass an emi s-
si ons test. I f a mal functi on occurs such that the PCM
cannot mai ntai n the opti mum A/F rati o, then the
MI L wi l l be i l l umi nated.
MIL 64CATALYST MONITOR
To compl y wi th cl ean ai r regul ati ons, vehi cl es are
equi pped wi th catal yti c converters. These converters
reduce the emi ssi on of hydrocarbons, oxi des of ni tro-
gen and carbon monoxi de.
Normal vehi cl e mi l es or engi ne mi sfi re can cause a
catal yst to decay. A mel tdown of the cerami c core can
cause a reducti on of the exhaust passage. Thi s can
i ncrease vehi cl e emi ssi ons and deteri orate engi ne
performance, dri veabi l i ty and fuel economy.
The catal yst moni tor uses dual oxygen sensors
(O2Ss) to moni tor the effi ci ency of the converter. The
dual O2Ss sensor strategy i s based on the fact that
as a catal yst deteri orates, i ts oxygen storage capaci ty
and i ts effi ci ency are both reduced. By moni tori ng
the oxygen storage capaci ty of a catal yst, i ts effi -
ci ency can be i ndi rectl y cal cul ated. The upstream
O2S i s used to detect the amount of oxygen i n the
exhaust gas before the gas enters the catal yti c con-
verter. The PCM cal cul ates the A/F mi xture from the
output of the O2S. A l ow vol tage i ndi cates hi gh oxy-
gen content (l ean mi xture). A hi gh vol tage i ndi cates a
l ow content of oxygen (ri ch mi xture).
When the upstream O2S detects a l ean condi ti on,
there i s an abundance of oxygen i n the exhaust gas.
A functi oni ng converter woul d store thi s oxygen so i t
can use i t for the oxi dati on of HC and CO. As the
converter absorbs the oxygen, there wi l l be a l ack of
oxygen downstream of the converter. The output of
the downstream O2S wi l l i ndi cate l i mi ted acti vi ty i n
thi s condi ti on.
As the converter l oses the abi l i ty to store oxygen,
the condi ti on can be detected from the behavi or of
the downstream O2S. When the effi ci ency drops, no
chemi cal reacti on takes pl ace. Thi s means the con-
centrati on of oxygen wi l l be the same downstream as
upstream. The output vol tage of the downstream
O2S copi es the vol tage of the upstream sensor. The
onl y di fference i s a ti me l ag (seen by the PCM)
between the swi tchi ng of the O2Ss.
To moni tor the system, the number of l ean-to-ri ch
swi tches of upstream and downstream O2Ss i s
counted. The rati o of downstream swi tches to
upstream swi tches i s used to determi ne whether the
catal yst i s operati ng properl y. An effecti ve catal yst
wi l l have fewer downstream swi tches than i t has
upstream swi tches i .e., a rati o cl oser to zero. For a
total l y i neffecti ve catal yst, thi s rati o wi l l be one-to-
one, i ndi cati ng that no oxi dati on occurs i n the devi ce.
The system must be moni tored so that when cata-
l yst effi ci ency deteri orates and exhaust emi ssi ons
i ncrease to over the l egal l i mi t, the MI L (check
engi ne l amp) wi l l be i l l umi nated.
TRIP DEFINITION
The term Tri p has di fferent meani ngs dependi ng
on what the ci rcumstances are. I f the MI L (Mal func-
ti on I ndi cator Lamp) i s OFF, a Tri p i s defi ned as
when the Oxygen Sensor Moni tor and the Catal yst
Moni tor have been compl eted i n the same dri ve cycl e.
When any Emi ssi on DTC i s set, the MI L on the
dash i s turned ON. When the MI L i s ON, i t takes 3
good tri ps to turn the MI L OFF. I n thi s case, i t
depends on what type of DTC i s set to know what a
Tri p i s.
For the Fuel Moni tor or Mi s-Fi re Moni tor (conti n-
uous moni tor), the vehi cl e must be operated i n the
Si mi l ar Condi ti on Wi ndow for a speci fi ed amount of
ti me to be consi dered a Good Tri p.
I f a Non-Conti uous OBDI I Moni tor, such as:
Oxygen Sensor
Catal yst Moni tor
Purge Fl ow Moni tor
Leak Detecti on Pump Moni tor (i f equi pped)
EGR Moni tor (i f equi pped)
Oxygen Sensor Heater Moni tor
fai l s twi ce i n a row and turns ON the MI L, re-run-
ni ng that moni tor whi ch previ ousl y fai l ed, on the
next start-up and passi ng the moni tor i s consi dered
to be a Good Tri p.
I f any other Emi ssi on DTC i s set (not an OBDI I
Moni tor), a Good Tri p i s consi dered to be when the
Oxygen Sensor Moni tor and Catal yst Moni tor have
been compl eted; or 2 Mi nutes of engi ne run ti me i f
the Oxygen Sensor Moni tor or Catal yst Moni tor have
been stopped from runni ng.
I t can take up to 2 Fai l ures i n a row to turn on the
MI L. After the MI L i s ON, i t takes 3 Good Tri ps to
turn the MI L OFF. After the MI L i s OFF, the PCM
wi l l sel f-erase the DTC after 40 Warm-up cycl es. A
Warm-up cycl e i s counted when the ECT (Engi ne
Cool ant Temperature Sensor) has crossed 160F and
has ri sen by at l east 40F si nce the engi ne has been
started.
COMPONENT MONITORS
There are several components that wi l l affect vehi -
cl e emi ssi ons i f they mal functi on. I f one of these com-
ponents mal functi ons the Mal functi on I ndi cator
Lamp (Check Engi ne) wi l l i l l umi nate.
Some of the component moni tors are checki ng for
proper operati on of the part. El ectri cal l y operated
components now have i nput (rati onal i ty) and output
(functi onal i ty) checks. Previ ousl y, a component l i ke
the Throttl e Posi ti on sensor (TPS) was checked by
the PCM for an open or shorted ci rcui t. I f one of
these condi ti ons occurred, a DTC was set. Now there
i s a check to ensure that the component i s worki ng.
Thi s i s done by watchi ng for a TPS i ndi cati on of a
greater or l esser throttl e openi ng than MAP and
engi ne rpm i ndi cate. I n the case of the TPS, i f engi ne
vacuum i s hi gh and engi ne rpm i s 1600 or greater
and the TPS i ndi cates a l arge throttl e openi ng, a
DTC wi l l be set. The same appl i es to l ow vacuum i f
the TPS i ndi cates a smal l throttl e openi ng.
Al l open/short ci rcui t checks or any component that
has an associ ated l i mp i n wi l l set a faul t after 1 tri p
wi th the mal functi on present. Components wi thout
an associ ated l i mp i n wi l l take two tri ps to i l l umi -
nate the MI L.
Refer to the Di agnosti c Troubl e Codes Descri pti on
Charts i n thi s secti on and the appropri ate Power-
trai n Di agnosti c Procedure Manual for di agnosti c
procedures.
NON-MONITORED CIRCUITS
The PCM does not moni tor the fol l owi ng ci rcui ts,
systems and condi ti ons that coul d have mal functi ons
causi ng dri veabi l i ty probl ems. The PCM mi ght not
store di agnosti c troubl e codes for these condi ti ons.
However, probl ems wi th these systems may cause the
PCM to store di agnosti c troubl e codes for other sys-
tems or components. For exampl e, a fuel pressure
probl em wi l l not regi ster a faul t di rectl y, but coul d
cause a ri ch/l ean condi ti on or mi sfi re. Thi s coul d
cause the PCM to store an oxygen sensor or mi sfi re
di agnosti c troubl e code
FUEL PRESSURE
The fuel pressure regul ator control s fuel system
pressure. The PCM cannot detect a cl ogged fuel
pump i nl et fi l ter, cl ogged i n-l i ne fuel fi l ter, or a
pi nched fuel suppl y or return l i ne. However, these
coul d resul t i n a ri ch or l ean condi ti on causi ng the
PCM to store an oxygen sensor or fuel system di ag-
nosti c troubl e code.
SECONDARY IGNITION CIRCUIT
The PCM cannot detect an i noperati ve i gni ti on coi l ,
foul ed or worn spark pl ugs, i gni ti on cross fi ri ng, or
open spark pl ug cabl es.
CYLINDER COMPRESSION
The PCM cannot detect uneven, l ow, or hi gh engi ne
cyl i nder compressi on.
EXHAUST SYSTEM
The PCM cannot detect a pl ugged, restri cted or
l eaki ng exhaust system, al though i t may set a fuel
system faul t.
FUEL INJ ECTOR MECHANICAL
MALFUNCTIONS
The PCM cannot determi ne i f a fuel i njector i s
cl ogged, the needl e i s sti cki ng or i f the wrong i njector
i s i nstal l ed. However, these coul d resul t i n a ri ch or
l ean condi ti on causi ng the PCM to store a di agnosti c
troubl e code for ei ther mi sfi re, an oxygen sensor, or
the fuel system.
EXCESSIVE OIL CONSUMPTION
Al though the PCM moni tors engi ne exhaust oxygen
content when the system i s i n cl osed l oop, i t cannot
determi ne excessi ve oi l consumpti on.
THROTTLE BODY AIR FLOW
The PCM cannot detect a cl ogged or restri cted ai r
cl eaner i nl et or fi l ter el ement.
VACUUM ASSIST
The PCM cannot detect l eaks or restri cti ons i n the
vacuum ci rcui ts of vacuum assi sted engi ne control
system devi ces. However, these coul d cause the PCM
to store a MAP sensor di agnosti c troubl e code and
cause a hi gh i dl e condi ti on.
PCM SYSTEM GROUND
The PCM cannot determi ne a poor system ground.
However, one or more di agnosti c troubl e codes may
be generated as a resul t of thi s condi ti on. The mod-
ul e shoul d be mounted to the body at al l ti mes, al so
duri ng di agnosti c.
PCM CONNECTOR ENGAGEMENT
The PCM may not be abl e to determi ne spread or
damaged connector pi ns. However, i t mi ght store
di agnosti c troubl e codes as a resul t of spread connec-
tor pi ns.
HIGH AND LOW LIMITS
The PCM compares i nput si gnal vol tages from each
i nput devi ce wi th establ i shed hi gh and l ow l i mi ts for
the devi ce. I f the i nput vol tage i s not wi thi n l i mi ts
and other cri teri a are met, the PCM stores a di agnos-
ti c troubl e code i n memory. Other di agnosti c troubl e
code cri teri a mi ght i ncl ude engi ne RPM l i mi ts or
i nput vol tages from other sensors or swi tches that
must be present before veri fyi ng a di agnosti c troubl e
code condi ti on.
LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
All Engines 2% to 8% of Maximum Load 9% to 17% of Maximum Load
EVAPORATIVE EMISSION CONTROLS
INDEX
page page
CRANKCASE VENTILATION SYSTEM . . . . . . . 12
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 11
EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . . 11
EVAPORATION (EVAP) CONTROL SYSTEM . . 11
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . . . 11
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL . . . . . . . . . . . . . . . . . . . . . . . . 13
VACUUM SCHEMATICS . . . . . . . . . . . . . . . . . . 13
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 14
EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . . 13
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . 14
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 14
EVAPORATION (EVAP) CONTROL SYSTEM
The functi on of the EVAP control system i s to pre-
vent the emi ssi ons of gasol i ne vapors from the fuel
tank i nto the atmosphere. When fuel evaporates i n
the fuel tank, the vapors pass through vent hoses or
tubes to a carbon fi l l ed EVAP cani ster. They are tem-
porari l y hel d i n the cani ster unti l they can be drawn
i nto the i ntake mani fol d when the engi ne i s runni ng.
Al l engi nes use a duty cycl e purge system. The
PCM control s vapor fl ow by operati ng the duty cycl e
EVAP purge sol enoi d. Refer to Duty Cycl e EVAP
Cani ster Purge Sol enoi d for addi ti onal i nformati on.
The EVAP cani ster i s a feature on al l model s for
the storage of fuel vapors from the fuel tank.
NOTE: The hoses used in this system are specially
manufactured. If replacement becomes necessary, it
is important to use only fuel resistant hose.
ROLLOVER VALVE
The fuel tank i s equi pped wi th a rol l over val ve.
The val ve i s l ocated on the top of the fuel tank (Fi g.
1). The val ve wi l l prevent fuel fl ow through the fuel
tank vent (EVAP) hoses i n the event of an acci dental
vehi cl e rol l over. The EVAP cani ster draws fuel vapors
from the fuel tank through thi s val ve.
The val ve cannot be servi ced separatel y. I f repl ace-
ment i s necessary, the fuel tank must be repl aced.
Refer to Fuel Tank Removal /I nstal l ati on i n Group 14,
Fuel System.
EVAP CANISTER
A mai ntenance free, EVAP cani ster i s used on al l
vehi cl es. On conventi onal l eft hand dri ve (LHD) mod-
el s, the EVAP cani ster i s l ocated i n the engi ne com-
partment on the passenger si de frame rai l (Fi g. 2).
On RHD model s, the cani ster i s l ocated i n the l eft
si de of the engi ne compartment near the heater
bl ower motor (Fi g. 3). The EVAP cani ster i s fi l l ed
wi th granul es of an acti vated carbon mi xture. Fuel
vapors enteri ng the EVAP cani ster are absorbed by
the charcoal granul es.
Fuel tank pressure vents i nto the EVAP cani ster.
Fuel vapors are temporari l y hel d i n the cani ster unti l
they can be drawn i nto the i ntake mani fol d. The duty
cycl e EVAP cani ster purge sol enoi d al l ows the EVAP
cani ster to be purged at predetermi ned ti mes and at
certai n engi ne operati ng condi ti ons.
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
The Duty Cycl e EVAP Cani ster Purge Sol enoi d reg-
ul ates the rate of vapor fl ow from the EVAP cani ster
to the i ntake mani fol d. The Powertrai n Control Mod-
ul e (PCM) operates the sol enoi d.
Fig. 1 Rollover Valve Location
ROLLOVER VALVE RETAINERCLAMP LOCKNUT FUEL PUMP MODULE FUEL FILTER/FUEL PRES- SURE REGULATOR ALIGNMENT ARROW
PIGTAIL HARNESS
FWD FUEL SUPPLY TUBE EVAP CANISTER VENT LINE
Duri ng the col d start warm-up peri od and the hot
start ti me del ay, the PCM does not energi ze the sol e-
noi d. When de-energi zed, no vapors are purged. The
PCM de-energi zes the sol enoi d duri ng open l oop oper-
ati on.
The engi ne enters cl osed l oop operati on after i t
reaches a speci fi ed temperature and the ti me del ay
ends. Duri ng cl osed l oop operati on, the PCM cycl es
(energi zes and de-energi zes) the sol enoi d 5 or 10
ti mes per second, dependi ng upon operati ng condi -
ti ons. The PCM vari es the vapor fl ow rate by chang-
i ng sol enoi d pul se wi dth. Pul se wi dth i s the amount
of ti me that the sol enoi d i s energi zed. The PCM
adjusts sol enoi d pul se wi dth based on engi ne operat-
i ng condi ti on.
On vehi cl es equi pped wi th Left Hand Dri ve (LHD),
the sol enoi d attaches to a bracket l ocated i n the
ri ght-rear si de of engi ne compartment near the EVAP
cani ster (Fi g. 4). On vehi cl es equi pped wi th Ri ght
Hand Dri ve (RHD), the sol enoi d attaches to a bracket
l ocated i n the l eft-rear si de of engi ne compartment.
The top of the sol enoi d has the word UP or TOP on
i t. The sol enoi d wi l l not operate properl y unl ess i t i s
i nstal l ed correctl y.
CRANKCASE VENTILATION SYSTEM
Al l 2.5L 4cyl i nder and 4.0L 6cyl i nder engi nes
are equi pped wi th a Crankcase Venti l ati on (CCV)
system (Fi g. 5) or (Fi g. 6). The CCV system performs
the same functi on as a conventi onal PCV system, but
does not use a vacuum control l ed val ve.
On 4.0L 6 cyl i nder engi nes, a mol ded vacuum tube
connects mani fol d vacuum to top of cyl i nder head
(val ve) cover at dash panel end. The vacuum fi tti ng
contai ns a fi xed ori fi ce of a cal i brated si ze. I t meters
the amount of crankcase vapors drawn out of the
engi ne.
Fig. 2 EVAP Canister LocationLHD Models
FWD EVAP CANISTER STRAP MOUNTING BOLT MOUNTINGSTRAP
Fig. 3 EVAP Canister LocationRHD Models
MOUNTINGSTRAP EVAP CANISTER FWD MOUNTING STRAP BOLT
Fig. 4 Duty Cycle EVAP Purge Solenoid (LHD
Shown)
ELECTRICAL CONNECTOR VACUUM HARNESS PURGE SOLE- NOID MOUNTING BOLT
Fig. 5 CCV System2.5L EngineTypical
AIR INLET FIT- TING AIR FILTER COVER FIXED ORIFICE FITTING
On 2.5L 4 cyl i nder engi nes, a fi tti ng on dri vers
si de of cyl i nder head (val ve) cover contai ns the
metered ori fi ce. I t i s connected to mani fol d vacuum.
A fresh ai r suppl y hose from the ai r cl eaner i s con-
nected to front of cyl i nder head cover on 4.0L
engi nes. I t i s connected to rear of cover on 2.5L
engi nes.
When the engi ne i s operati ng, fresh ai r enters the
engi ne and mi xes wi th crankcase vapors. Mani fol d
vacuum draws the vapor/ai r mi xture through the
fi xed ori fi ce and i nto the i ntake mani fol d. The vapors
are then consumed duri ng combusti on.
VEHICLE EMISSION CONTROL INFORMATION
(VECI) LABEL
Al l vehi cl es are equi pped wi th a combi ned VECI
l abel . Thi s l abel i s l ocated i n the engi ne compart-
ment (Fi g. 7) and contai ns the fol l owi ng:
Engi ne fami l y and di spl acement
Evaporati ve fami l y
Emi ssi on control system schemati c
Certi fi cati on appl i cati on
Engi ne ti mi ng speci fi cati ons (i f adjustabl e)
I dl e speeds (i f adjustabl e)
Spark pl ug and gap
The l abel al so contai ns an engi ne vacuum sche-
mati c. There are uni que l abel s for vehi cl es bui l t for
sal e i n the state of Cal i forni a and the country of
Canada. Canadi an l abel s are wri tten i n both the
Engl i sh and French l anguages. These l abel s are per-
manentl y attached and cannot be removed wi thout
defaci ng i nformati on and destroyi ng l abel .
VACUUM SCHEMATICS
A vacuum schemati c for emi ssi on rel ated i tems can
be found on the Vehi cl e Emi ssi on Control I nforma-
ti on (VECI ) Label . Refer to VECI Label i n thi s group
for l abel l ocati on.
EVAP CANISTER
On vehi cl e equi pped wi th Left Hand Dri ve (LHD),
the EVAP cani ster i s l ocated i n engi ne compartment
on ri ght si de frame rai l (Fi g. 8). On vehi cl es equi pped
wi th Ri ght Hand Dri ve (RHD), the cani ster i s l ocated
on l eft si de of engi ne compartment near heater
bl ower motor (Fi g. 9).
REMOVAL
(1) Di sconnect vacuum l i nes at EVAP cani ster.
Note l ocati on of l i nes before removal .
Fig. 6 CCV System4.0L EngineTypical
AIR INLET FIT- TING FWD FIXED ORIFICE FITTING AIR FILTER COVER
Fig. 7 VECI Label LocationTypical
VECI LABEL
Fig. 8 EVAP Canister LocationLHD Models
FWD EVAP CANISTER STRAP MOUNTING BOLT MOUNTINGSTRAP
(2) Remove cani ster retai ni ng strap bol t.
(3) Remove cani ster from vehi cl e.
INSTALLATION
(1) Posi ti on cani ster i nto bracket.
(2) I nstal l and ti ghten strap bol t to 5 Nm (45 i n.
l bs.) torque.
(3) Connect vacuum l i nes at EVAP cani ster.
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
REMOVAL
On vehi cl es equi pped wi th Left Hand Dri ve (LHD),
the sol enoi d attaches to a bracket l ocated i n the
ri ght-rear si de of engi ne compartment near the EVAP
cani ster (Fi g. 10). On vehi cl es equi pped wi th Ri ght
Hand Dri ve (RHD), the sol enoi d attaches to a bracket
l ocated i n the l eft-rear si de of engi ne compartment.
The top of the sol enoi d has the word UP or TOP on
i t. The sol enoi d wi l l not operate properl y unl ess i t i s
i nstal l ed correctl y.
(1) Di sconnect el ectri cal wi ri ng connector at sol e-
noi d.
(2) Di sconnect vacuum harness at sol enoi d.
(3) Remove sol enoi d and i ts support bracket.
INSTALLATION
(1) I nstal l EVAP cani ster purge sol enoi d and i ts
mounti ng bracket to cowl panel .
(2) Ti ghten bol t to 5 Nm (45 i n. l bs.) torque.
(3) Connect vacuum harness and wi ri ng connector.
ROLLOVER VALVE(S)
The pressure rel i ef/rol l over val ves(s) are/i s mol ded
i nto the fuel tank and are not servi ced separatel y. I f
repl acement i s necessary, the fuel tank must be
repl aced. Refer to Fuel Tank Removal /I nstal l ati on i n
Group 14, Fuel System for procedures.
SPECIFICATIONS
TORQUE CHART
Description Torque
EVAP Cani ster Mounti ng Bol t . . . 5 Nm (45 i n. l bs.)
EVAP Cani ster Purge Sol enoi d
Bracket-to-Body Mounti ng Bol t . 5 Nm (45 i n. l bs.)
Fig. 9 EVAP Canister LocationRHD Models
MOUNTINGSTRAP EVAP CANISTER FWD MOUNTING STRAP BOLT
Fig. 10 Duty Cycle EVAP Canister Purge Solenoid
(LHD Shown)
DIFFERENTIAL AND DRIVELINE
CONTENTS
page page
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 47
8 1/4 REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . 83
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . 1
TUBE AND 181 FBI AXLE . . . . . . . . . . . . . . . . 15
PROPELLER SHAFTS
INDEX
page page
GENERAL INFORMATION
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PROPELLER SHAFT JOINT ANGLE . . . . . . . . . . 2
PROPELLER SHAFT JOINTS . . . . . . . . . . . . . . . 2
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . 1
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 5
PROPELLER SHAFT ANGLE MEASUREMENT . . 5
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . 6
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . 6
DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . . 9
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . 7
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 12
ADJUSTMENTS
ADJUSTMENT AT AXLE WITH
LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . 12
FRONT AXLE ANGLE ADJUSTMENT . . . . . . . . 13
SPECIFICATIONS
PROPELLER SHAFTS AND UJOINTS . . . . . . 14
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . 14
GENERAL INFORMATION
PROPELLER SHAFTS
The propel l er shaft (Fi g. 1) transmi ts power from
one poi nt to another i n a smooth and conti nuous
acti on. The shaft i s desi gned to send torque through
an angl e from the transmi ssi on (transfer case on
4WD vehi cl es) to the axl e.
The propel l er shaft must operate through con-
stantl y changi ng rel ati ve angl es between the trans-
mi ssi on and axl e. I t must al so be capabl e of changi ng
l ength whi l e transmi tti ng torque. The axl e ri des sus-
pended by spri ngs i n a fl oati ng moti on. Thi s means
the propel l er shaft must be abl e to contract, expand
and change operati ng angl es when goi ng over vari ous
road surfaces. Thi s i s accompl i shed through uni ver-
sal joi nts, whi ch permi t the propel l er shaft to operate
at di fferent angl es. The sl i p joi nts (or yokes) permi t
contracti on or expansi on.
Tubul ar propel l er shafts are bal anced by the man-
ufacturer wi th wei ghts spot wel ded to the tube.
The propel l er shaft i s desi gned and bui l t wi th the
yoke l ugs i n l i ne wi th each other. Thi s i s cal l ed phas-
i ng. Thi s desi gn produces the smoothest runni ng con-
di ti on. An out of phase shaft can cause a vi brati on.
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered. This
will prevent the undercoating from causing an
unbalanced condition.
CAUTION: Use exact replacement parts for attach-
ing the propeller shafts. This will ensure safe oper-
ation. The specified torque must always be applied
when tightening the fasteners.
LUBRICATION
The sl i p yoke on the front propel l er shaft i s
equi pped wi th a l ubri cati on fi tti ng. Use a mul ti -pur-
XJ DIFFERENTIAL AND DRIVELINE 3 - 1
pose NLGI Grade 2 EP l ubri cant. The factory
i nstal l ed uni versal joi nts are l ubri cated for the l i fe of
the vehi cl e and do not need l ubri cati on. Al l uni versal
joi nts shoul d be i nspected for l eakage and damage
each ti me the vehi cl e i s servi ced. I f seal l eakage or
damage exi sts, the uni versal joi nt shoul d be repl aced.
Refer to Group 0, Lubri cati on and Mai ntenance, for
PROPELLER SHAFT JOINT ANGLE
When two shafts come together at a common joi nt,
the bend that i s formed i s cal l ed the operati ng angl e.
The l arger the angl e, the l arger the amount of accel -
erati on and decel erati on of the joi nt. Thi s speedi ng
up and sl owi ng down of the joi nt must be cancel l ed
to produce a smooth power fl ow. Thi s i s done through
the phasi ng of a propel l er shaft and ensuri ng that
the proper propel l er shaft joi nt worki ng angl es are
mai ntai ned.
A propel l er shaft i s properl y phased when the yoke
ends are i n the same pl ane, or i n l i ne. A twi sted
shaft wi l l make the yokes out of phase and cause a
noti ceabl e vi brati on.
When taki ng propel l er shaft joi nt angl e measure-
ments, or checki ng the phasi ng, of two pi ece shafts,
consi der each shaft separatel y.
I deal l y the dri vel i ne system shoul d have;
Angl es that are equal or opposi te wi thi n 1
degree of each other.
Have a 3 degree maxi mum operati ng angl e.
Have at l east a 1/2 degree conti nuous operati ng
(propel l er shaft) angl e.
Engi ne speed (rpm) i s the mai n factor i n determi n-
i ng the maxi mum al l owabl e operati ng angl e. As a
gui de to the maxi mum normal operati ng angl es refer
to (Fi g. 2).
PROPELLER SHAFT JOINTS
Two di fferent types of propel l er shaft joi nts are
used:
Si ngl e cardan uni versal joi nt (Fi g. 3).
Fig. 1 Front & Rear Propeller Shafts4WD
FRONT AXLE FRONT PROPEL- LER SHAFT TRANSFER CASE BOOT REAR AXLE STRAP REAR PROPELLER SHAFT STRAP
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
Fig. 2 Maximum Angles And Engine Speed
3 - 2 DIFFERENTIAL AND DRIVELINE XJ
Doubl e cardan (CV) uni versal joi nt (Fi g. 4).
None of the uni versal joi nts are servi ci bl e. I f one
becomes worn or damaged, the compl ete uni versal
joi nt assembl y must be repl aced.
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
Refer to Group 22, Ti res and Wheel s, for addi ti onal
i nformati on.
Brake drums that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on. Refer to Group 5,
Brakes, for addi ti onal i nformati on.
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts. Refer to Group 9, Engi nes,
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve uni versal
joi nts, or an i ncorrect propel l er shaft angl e, are usu-
al l y the cause of such a vi brati on.
UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180 relative to the yoke may eliminate some
vibrations.
Fig. 3 Single Cardan Universal Joint
NEEDLE BEARING BEARING CAP SEAL SPIDER NEEDLE BEARING BEARING CAP RETAINING CLIP YOKE SEAL
Fig. 4 Double Cardan (CV) Universal Joint
1. LINK YOKE 2. SOCKET SPRING 3. SCOKET BALL RETAINER 4. THRUST WASHER 5. NEEDLE BEARINGS 6. SEAL 7. BEARING CAP 8. REAR SPIDER 9. SOCKET YOKE 10. SOCKET BALL 11. FRONT SPIDER 12. NEEDLE WASHER 13. THRUST WASHER 14. DRIVE SHAFT YOKE 15. RETAINING CLIP
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90 apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 5).
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 6) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 7).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt, and undercoati ng
from the propel l er shaft surface where the di al i ndi -
cator wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
PROPELLER SHAFT a. Undercoating or other foreign
material on shaft.
a. Clean exterior of shaft and wash
with solvent.
b. Loose U-joint clamp screws. b. Tighten screws properly.
c. Loose or bent U-joint yoke or
excessive runout.
c. Install replacement yoke.
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.
f. Worn U-joint bearings. f. Replace U-joint.
g. Propeller shaft damaged (bent
tube) or out of balance.
g. Install replacement propeller
shaft.
h. Broken rear spring. h. Replace rear spring.
i. Excessive runout or unbalanced
condition.
i. Reindex propeller shaft 180, test
and correct as necessary.
j. Excessive drive pinion gear shaft
yoke runout.
j. Reindex propeller shaft 180and
evaluate.
UNIVERSAL JOINT NOISE a. U-joint clamp screws loose. a. Tighten screws with specified
torque.
b. Lack of lubrication. Replace U-joint.
Fig. 5 Clamp Screw At Position 1
CLAMP SCREWDRIVER
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
that the effects of the wel d process wi l l not enter i nto
the measurements.
(4) Refer to Runout Speci fi cati ons chart.
(5) Repl ace the propel l er shaft i f the runout
exceeds the l i mi t.
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT PREPARATION
Before measuri ng uni versal joi nt angl es, the fol -
l owi ng must be done;
I nfl ate al l ti res to correct pressure.
Check the angl es i n the same l oaded or
unl oaded condi ti on as when the vi brati on occurred.
Propel l er shaft angl es change accordi ng to the
amount of l oad i n the vehi cl e.
Check the condi ti on of al l suspensi on compo-
nents and veri fy al l fasteners are torqued to speci fi -
cati ons.
Check the condi ti on of the engi ne and transmi s-
si on mounts and veri fy al l fasteners are torqued to
speci fi cati ons.
PROPELLER SHAFT ANGLE MEASUREMENT
To accuratel y check dri vel i ne al i gnment, rai se and
support the vehi cl e at the axl es as l evel as possi bl e.
Al l ow the wheel s and propel l er shaft to turn. Remove
any external beari ng snap ri ngs (i f equi pped) from
uni versal joi nt so that the i ncl i nometer base si ts fl at.
(1) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng cap i s faci ng downward.
Always make measurements from front to
rear.
(2) Pl ace I ncl i nometer on yoke beari ng cap (A) par-
al l el to the shaft (Fi g. 8). Center bubbl e i n si ght gl ass
and record measurement.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
(3) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng cap paral l el to the
Fig. 6 Two Clamp Screws At The Same Position
Fig. 7 Clamp Screws Separated
1
2 INCH
RUNOUT SPECIFICATIONS
Front of shaft 0.010 in. (0.25 mm)
Center of shaft 0.015 in. (0.38 mm)
Rear of shaft 0.010 in. (0.25 mm)
NOTE: Measure front/rear runout approximately 3
inches (76 mm) from the weld seam at each end of
the shaft tube for tube lengths over 30 inches. Under
30 inches the max. runout is 0.20 inch for full length
of the tube.
Fig. 8 Front (Output) Angle Measurement (A)
SLIP YOKE BEARING CAP SPECIAL TOOL 7663 (J-23498A)
shaft (Fi g. 9). Center bubbl e i n si ght gl ass and record
measurement. Thi s measurement can al so be taken
at the rear end of the shaft.
This measurement will give you the propeller
shaft angle (C).
(4) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n transmi ssi on output operati ng angl e.
(5) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng cap paral l el to
the shaft (Fi g. 10). Center bubbl e i n si ght gl ass and
record measurement.
This measurement will give you the pinion
shaft or input yoke angle (B).
(6) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n for
Good cancel l ati on of Ujoi nt operati ng angl es
(wi thi n 1).
Operati ng angl es l ess than 3.
At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
FRONT PROPELLER SHAFT
REMOVAL
(2) Scri be al i gnment marks on the yokes at the
transfer case. Pl ace marks at the pi ni on shaft and at
each end of the propel l er shaft. These marks wi l l be
used for i nstal l ati on reference (Fi g. 12).
(3) Remove the uni versal joi nt strap bol ts at the
pi ni on shaft yoke.
(4) Di sconnect the propel l er shaft at the transfer
case and remove the propel l er shaft.
INSTALLATION
(1) Posi ti on the propel l er shaft wi th the yoke ref-
erence marks al i gned (Fi g. 13). I nstal l the propel l er
shaft.
Replacement universal joint straps and bolts
must be installed.
(2) Ti ghten the uni versal joi nt strap/cl amp bol ts at
the axl e yoke to 19 Nm (14 ft. l bs.) torque.
(3) Ti ghten the fl ange to transfer case bol ts to 27
REAR PROPELLER SHAFT
REMOVAL
(1) Shi ft the transmi ssi on and transfer case i nto
Neutral .
(3) Scri be al i gnment marks at the pi ni on shaft and
at each end of the propel l er shaft. These marks wi l l
be used for i nstal l ati on reference.
(4) Remove the uni versal joi nt strap bol ts at the
pi ni on shaft yoke.
(5) Pry open cl amp hol di ng the dust boot to propel -
l er shaft yoke (Fi g. 14).
(6) Sl i de the sl i p yoke off of the transmi ssi on/
transfer case output shaft and remove the propel l er
shaft (Fi g. 15).
Fig. 9 Propeller Shaft Angle Measurement (C)
SHAFT YOKE BEARING CAP SPECIAL TOOL 7663 (J23498A)
Fig. 10 Rear (Input) Angle Measurement (B)
PINION YOKE BEARING CAP SPECIAL TOOL 7663 (J-23498A)
INSTALLATION
(1) Sl i de the sl i p yoke on the transmi ssi on/transfer
case output shaft. Al i gn the i nstal l ati on reference
marks at the axl e yoke and i nstal l the propel l er shaft
(Fi g. 15).
Replacement universal joint straps and bolts
must be installed.
(2) Ti ghten the uni versal joi nt strap/cl amp bol ts at
the axl e yoke to 19 Nm (14 ft. l bs.) torque.
(3) Cri mp cl amp to hol d dust boot to propel l er
shaft yoke (Fi g. 16).
SINGLE CARDAN UNIVERSAL JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
(1) Remove the propel l er shaft.
Fig. 11 Universal Joint Angle Example
4.9Angle (C) 3.2Angle (B) Input Yoke Horizontal Level (B) Axle Input Yoke = 3.2 4.9 or (C) Prop. Shaft = 4.9 3.2 Axle Input Operating Angle 1.7 Trans. Output Operating Angle 1.9 Axle Input Operating Angle 1.7 Amount of U-Joint Cancellation 0.2 (A) Output Yoke = 3.0 4.9 or (C) Prop. Shaft = 4.9 3.0 Transmission Output Operating Angle 1.9 3.0Angle (A) Output Yoke
Fig. 12 Front Propeller Shaft
FRONT AXLE BOOT PROPELLER SHAFT CV-JOINTTRANSFER CASE BOOT SLINGER CLAMP YOKE
Fig. 13 Reference Marks on Yokes
REFERENCE MARKS
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 17).
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 18).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
Fig. 14 Dust Boot Clamp
SLINGER BOOT AWL TRANSFER CASE
Fig. 15 Rear Propeller Shaft
CLAMP YOKE PROPELLER SHAFT AXLE YOKE CLAMP OUTPUTSHAFT BOOT
Fig. 16 Crimping Dust Boot ClampTypical
SPECIAL TOOL C-4975A SLINGER BOOT CLAMP
Fig. 17 Remove Snap Ring
SNAP RING
Fig. 18 Press Out Bearing
PRESS SOCKET
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 19).
CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.
ASSEMBLY
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 20).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 21). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4 to i nstal l the oppo-
si te beari ng cap. I f the joi nt i s sti ff or bi ndi ng, stri ke
the yoke wi th a soft hammer to seat the needl e bear-
i ngs.
(7) Add grease to l ube fi tti ng, i f equi pped.
(8) I nstal l the propel l er shaft.
DOUBLE CARDAN JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
Fig. 19 Press Out Remaining Bearing
CROSS BEARING CAP
Fig. 20 Install Cross In Yoke
CROSS YOKE
Fig. 21 Install Bearing On Trunnion
BEARING CAP TRUNNION
(3) Remove al l the beari ng cap snap ri ngs (Fi g.
22).
(4) Set the joi nt i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the l i nk
yoke.
(5) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and parti al l y press one beari ng cap from
the outboard si de of the l i nk yoke enough to grasp
the beari ng cap wi th vi se jaws (Fi g. 23). Be sure to
remove grease fi tti ngs that i nterfere wi th removal .
(6) Grasp the protrudi ng beari ng by vi se jaws. Tap
the l i nk yoke wi th a mal l et and dri ft to di sl odge the
beari ng cap from the yoke (Fi g. 24).
(7) Fl i p assembl y and repeat Step 4, Step 5, and
Step 6 to remove the opposi te beari ng cap. Thi s wi l l
then al l ow removal of the cross centeri ng ki t assem-
bl y and spri ng (Fi g. 25).
(8) Press the remai ni ng beari ng caps out the other
end of the l i nk yoke as descri bed above to compl ete
the di sassembl y.
Fig. 22 Remove Snap Rings
Fig. 23 Press Out Bearing
Fig. 24 Remove Bearing From Yoke
Fig. 25 Remove Centering Kit
ASSEMBLY
During assembly, ensure that the alignment
marks on the link yoke and propeller shaft
yoke are aligned.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Fi t a cross i nto the propel l er shaft yoke (Fi g.
26).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 27). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng (Fi g. 28).
(5) I nstal l a snap ri ng.
(6) Fl i p the propel l er shaft yoke and i nstal l the
beari ng cap onto the opposi te trunni on. I nstal l a
snap ri ng (Fi g. 29).
(7) Fi t the l i nk yoke on the remai ni ng two trun-
ni ons and press both beari ng caps i nto pl ace (Fi g.
30).
(8) I nstal l snap ri ngs.
Fig. 26 Install Cross In Yoke
Fig. 27 Install Bearing Cap
Fig. 28 Press In Bearing Cap
(9) I nstal l the centeri ng ki t assembl y i nsi de the
l i nk yoke maki ng sure the spri ng i s properl y posi -
ti oned (Fi g. 31).
(10) Pl ace two beari ng caps on opposi te trunni ons
of the remai ni ng cross. Fi t the open trunni ons i nto
the l i nk yoke bores and the beari ng caps i nto the
centeri ng ki t (Fi g. 32).
(11) Press the remai ni ng two beari ng caps i nto
pl ace and i nstal l snap ri ngs (Fi g. 33).
(12) Tap the snap ri ngs to al l ow them to seat i nto
the grooves (Fi g. 34).
(13) Check for proper assembl y. Fl ex the joi nt
beyond center, i t shoul d snap over-center i n both
di recti ons when correctl y assembl ed (Fi g. 35).
(14) I nstal l the propel l er shaft.
PROPELLER SHAFT
(1) Cl ean al l uni versal joi nt bores wi th cl eani ng
sol vent and a wi re brush.
(2) I nspect the yokes for di storti on, cracks, and
worn beari ng cap bores.
ADJ USTMENTS
ADJUSTMENT AT AXLE WITH LEAF SPRINGS
Adjust the pi ni on shaft angl e at the spri ngs wi th
tapered shi ms (Fi g. 36). I nstal l tapered shi ms
between the spri ngs and axl e pad to correct the
Fig. 30 Install Link Yoke
Fig. 31 Install Centering Kit
Fig. 32 Install Remaining Cross
angl e. Refer to Group 2, Suspensi on, for addi ti onal
i nformati on.
FRONT AXLE ANGLE ADJUSTMENT
Adjust the pi ni on gear angl e at the l ower suspen-
si on arms wi th shi ms (Fi g. 37). Addi ng shi ms wi l l
decrease the pi ni on gear shaft angl e but wi l l i ncrease
the caster angl e. The pi ni on gear shaft angl e has pri -
ori ty over the caster angl e. Refer to Group 2, Suspen-
si on, for addi ti onal i nformati on.
Fig. 34 Seat Snap Rings In Groove
Fig. 35 Check Assembly
Fig. 36 Angle Adjustment at Leaf Springs
WEDGE
Fig. 37 Front Axle Angle Adjustment
SHIM SUSPENSION ARM
SPECIFICATIONS
PROPELLER SHAFTS AND UJOINTS
DESCRIPTION TORQUE
Bol ts, Transfer Case Yoke . . . . . . 27 Nm (20 ft. l bs.)
Bol ts, Axl e Yoke . . . . . . . . . . . . . 19 Nm (14 ft. l bs.)
Bol ts, Axl e Yoke . . . . . . . . . . . . . 19 Nm (14 ft. l bs.)
SPECIAL TOOLS
PROPELLER SHAFT
Inclinometer7663
TUBE AND 181 FBI AXLE
INDEX
page page
GENERAL INFORMATION
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 15
LUBRICANT SPECIFICATIONS . . . . . . . . . . . . 15
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . 16
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . 17
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . 17
FRONT AXLES . . . . . . . . . . . . . . . . . . . . . . . . . 18
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 16
GENERAL INFORMATION . . . . . . . . . . . . . . . . 16
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . 17
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . 20
AXLE BUSHING REPLACEMENT . . . . . . . . . . . 26
AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . 29
AXLE SHAFTCARDAN U-JOINT . . . . . . . . . . 22
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . 28
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 26
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . 20
HUB BEARING AND AXLE SHAFT . . . . . . . . . . 24
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 30
PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . 23
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STEERING KNUCKLE AND BALL STUDS . . . . 25
TUBE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . 21
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 34
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . 35
CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . . 35
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 38
GEAR CONTACT PATTERN ANALYSIS . . . . . . 41
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 35
SPECIFICATIONS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 43
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 43
SPECIAL TOOLS
181 FBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . 43
GENERAL INFORMATION
181 FBI AXLE
The 181 Front Beam-desi gn I ron (FBI ) axl e con-
si sts of a cast i ron di fferenti al housi ng wi th axl e
shaft tubes extendi ng from ei ther si de. The tubes are
pressed i nto the di fferenti al housi ng and wel ded.
The i ntegral type housi ng, hypoi d gear desi gn has
the centerl i ne of the pi ni on set above the centerl i ne
of the ri ng gear.
The axl e has a fi tti ng for a vent hose used to
rel i eve i nternal pressure caused by l ubri cant vapor-
i zati on and i nternal expansi on.
The axl es are equi pped wi th semi fl oati ng axl e
shafts, meani ng that l oads are supported by the hub
beari ngs. The axl e shafts are retai ned by nuts at the
hub beari ngs. The hub beari ngs are bol ted to the
steeri ng knuckl e at the outboard end of the axl e tube
yoke. The hub beari ngs are servi ced as an assembl y.
For vehi cl es wi th ABS brakes, the ABS wheel
speed sensors are attached to the knuckl e assem-
bl i es. The tone ri ngs for the ABS system are pressed
onto the axl e shaft. Do not damage ABS tone
wheel or the sensor when removing axle shafts.
The stamped steel cover provi des a means for
i nspecti on and servi ci ng the di fferenti al .
The 181 FBI axl e has the assembl y part number
and gear rati o l i sted on a tag. The tag i s attached to
the housi ng cover by a cover bol t. Bui l d date i denti -
fi cati on codes are stamped on the cover si de of the
axl e shaft tube.
The di fferenti al case i s a onepi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a rol l
pi n. Di fferenti al beari ng prel oad and ri ng gear back-
l ash i s adjusted by the use of shi ms (sel ect thi ck-
ness). The shi ms are l ocated between the di fferenti al
beari ng cones and case. Pi ni on beari ng prel oad i s set
and mai ntai ned by the use of shi ms (sel ect thi ck-
ness).
LUBRICANT SPECIFICATIONS
A mul ti purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
The l ubri cant shoul d have MI LL2105C and
API GL 5 qual i ty speci fi cati ons.
Lubri cant i s a thermal l y stabl e SAE 80W90
gear l ubri cant.
Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W140 SYNTHETI C gear
l ubri cant.
The 181 FBI axl e l ubri cant capaci ty i s 1.48 L (3.13
pts.).
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
STANDARD DIFFERENTIAL
The di fferenti al gear system di vi des the torque
between the axl e shafts. I t al l ows the axl e shafts to
rotate at di fferent speeds when turni ng corners.
Each di fferenti al si de gear i s spl i ned to an axl e
shaft. The pi ni on gears are mounted on a pi ni on
mate shaft and are free to rotate on the shaft. The
pi ni on gear i s fi tted i n a bore i n the di fferenti al case
and i s posi ti oned at a ri ght angl e to the axl e shafts.
I n operati on, power fl ow occurs as fol l ows:
The pi ni on gear rotates the ri ng gear.
The ri ng gear (bol ted to the di fferenti al case)
rotates the case.
The di fferenti al pi ni on gears (mounted on the
pi ni on mate shaft i n the case) rotate the si de gears.
The si de gears (spl i ned to the axl e shafts) rotate
the shafts.
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
GENERAL INFORMATION
Axl e beari ng probl em condi ti ons are usual l y caused
by:
I nsuffi ci ent or i ncorrect l ubri cant.
Forei gn matter/water contami nati on.
I ncorrect beari ng prel oad torque adjustment.
I ncorrect backl ash.
Axl e gear probl em condi ti ons are usual l y the resul t
of:
I nsuffi ci ent l ubri cati on.
I ncorrect or contami nated l ubri cant.
Overl oadi ng (excessi ve engi ne torque) or exceed-
i ng vehi cl e wei ght capaci ty.
I ncorrect cl earance or backl ash adjustment.
Axl e component breakage i s most often the resul t
of:
Severe overl oadi ng.
I nsuffi ci ent l ubri cant.
I ncorrect l ubri cant.
I mproperl y ti ghtened components.
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, or worn/dam-
aged gears.
Gear noi se usual l y happens at a speci fi c speed
range. The range i s 30 to 40 mph, or above 50 mph.
The noi se can al so occur duri ng a speci fi c type of
dri vi ng condi ti on. These condi ti ons are accel erati on,
decel erati on, coast, or constant l oad.
Fig. 1 Differential OperationStraight Ahead Driving
IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE SPEED PINION GEAR SIDE GEAR PINION GEARS ROTATE WITH CASE
Fig. 2 Differential OperationOn Turns
AXLE
OUTER WHEEL 110% CASE
SPEED
100% DIFFERENTIAL CASE SPEED
INNER WHEEL 90% CASE
SPEED
PINION GEARS ROTATE ON PINION SHAFT
When road testi ng, accel erate the vehi cl e to the
speed range where the noi se i s the greatest. Shi ft
out-of-gear and coast through the peaknoi se range.
I f the noi se stops or changes greatl y:
Check for i nsuffi ci ent l ubri cant.
I ncorrect ri ng gear backl ash.
Gear damage.
Di fferenti al si de and pi ni on gears can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ghtahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on gear mate shaft can al so
cause a snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on gear bear-
i ngs can al l produce noi se when worn or damaged.
Beari ng noi se can be ei ther a whi ni ng, or a growl i ng
sound.
Pi ni on gear beari ngs have a constantpi tch noi se.
Thi s noi se changes onl y wi th vehi cl e speed. Pi ni on
beari ng noi se wi l l be hi gher because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
Ujoi nt or by worn si degear thrust washers. A worn
pi ni on gear shaft bore wi l l al so cause l ow speed
knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
Damaged dri ve shaft.
Mi ssi ng dri ve shaft bal ance wei ght(s).
Worn or outofbal ance wheel s.
Loose wheel l ug nuts.
Worn Ujoi nt(s).
Loose/broken spri ngs.
Damaged axl e shaft beari ng(s).
Loose pi ni on gear nut.
Excessi ve pi ni on yoke run out.
Bent axl e shaft(s).
Check for l oose or damaged frontend components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rearend
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Refer to Group 22, Wheel s and Ti res, for addi ti onal
vi brati on i nformati on.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
Hi gh engi ne i dl e speed.
Loose engi ne/transmi ssi on/transfer case mounts.
Worn Ujoi nts.
Loose spri ng mounts.
Loose pi ni on gear nut and yoke.
Excessi ve ri ng gear backl ash.
Excessi ve si de gear/case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
FRONT AXLES
DIAGNOSIS
WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must
be replaced.
AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1. Inspect axle shaft tube alignment.
Correct as necessary.
2. Bent or sprung axle shaft. 2. Replace bent or sprung axle
shaft.
3. End play in drive pinion bearings. 3. Refer to Drive Pinion Bearing
Pre-Load Adjustment.
4. Excessive gear backlash between
ring gear and pinion gear.
4. Check adjustment of ring gear
backlash and pinion gear. Correct as
necessary.
5. Improper adjustment of drive
pinion gear shaft bearings.
5. Adjust drive pinion shaft bearings.
6. Loose drive pinion gearshaft yoke
nut.
6. Tighten drive pinion gearshaft
yoke nut with specified torque.
7. Improper wheel bearing
adjustment.
7. Readjust as necessary.
8. Scuffed gear tooth contact
surfaces.
8. If necessary, replace scuffed
gears.
AXLE SHAFT BROKE 1. Misaligned axle shaft tube. 1. Replace broken axle shaft after
correcting axle shaft tube alignment.
2. Vehicle overloaded. 2. Replace broken axle shaft. Avoid
excessive weight on vehicle.
3. Erratic clutch operation. 3. Replace broken axle shaft after
inspecting for other possible casues.
Avoid erratic use of clutch.
4. Grabbing clutch. 4. Replace broken axle shaft.
Inspect clutch and make necessary
repairs or adjustments.
DIFFERENTIAL CASE CRACKED 1. Improper adjustment of differential
bearings.
1. Replace cracked case; examine
gears and bearings for possible
damage. At reassembly, adjust
differential bearings properly.
2. Excessive ring gear backlash. 2. Replace cracked case; examine
damage. At reassembly, adjust ring
gear backlash properly.
3. Vehicle overloaded. 3. Replace cracked case; examine
damage. Avoid excessive weight on
vehicle.
4. Erratic clutch operation. 4. Replace cracked case. After
inspecting for other possible causes,
examine gears and bearings for
possible damage. Avoid erratic use
of clutch.
DIFFERENTIAL GEARS SCORED 1. Insufficient lubrication. 1. Replace scored gears. Scoring
marks 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.
2. Improper grade of lubricant. 2. Replace scored gears. Inspect all
damage. Clean and refill differential
housing to required capacity with
proper lubricant.
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all
gears, pinion bores and shaft for
damage. Service as necessary.
LOSS OF LUBRICANT 1. Lubricant level too high. 1. Drain excess lubricant by
removing fill plug and allow lubricant
to level at lower edge of fill plug
hole.
2. Worn axle shaft seals. Replace worn seals.
3. Cracked differential housing. 3. Repair or replace housing as
necessary.
4. Worn drive pinion gear shaft seal. 4. Replace worn drive pinion gear
shaft seal.
5. Scored and worn yoke. 5. Replace worn or scored yoke and
seal.
6. Axle cover not properly sealed. 6. Remove cover and clean flange
and reseal.
AXLE OVERHEATING 1. Lubricant level too low. 1. Refill differential housing.
2. Incorrect grade of lubricant. 2. Drain, flush and refill with correct
amount of the correct lubricant.
3. Bearings adjusted too tight. 3. Readjust bearings.
4. Excessive gear wear. 4. Inspect gears for excessive wear
or scoring. Replace as necessary.
5. Insufficient ring gear backlash. 5. Readjust ring gear backlash and
inspect gears for possible scoring.
GEAR TEETH BROKE (RING GEAR
AND PINION)
1. Overloading. 1. Replace gears. Examine other
damage.
2. Erratic clutch operation. 2. Replace gears and examine the
remaining parts for possible
damage. Avoid erratic clutch
operation.
3. Ice-spotted pavements. 3. Replace gears. Examine the
damage. Replace parts as required.
4. Improper adjustments. 4. Replace gears. Examine other
parts for possible damage. Ensure
ring gear backlash is correct.
AXLE NOISE 1. Insufficient lubricant. 1. Refill axle with correct amount of
proper lubricant. Also inspect for
leaks and correct as necessary.
2. Improper ring gear and drive
pinion gear adjustment.
2. Check ring gear and pinion gear
teeth contact pattern.
3. Unmatched ring gear and drive
pinion gear.
3. Remove unmatched ring gear and
drive pinion gear. Replace with
matched gear and drive pinion gear
set.
4. Worn teeth on ring gear or drive
pinion gear.
4. Check teeth on ring gear and
drive pinion gear for correct contact.
If necessary, replace with new
matched set.
5. Loose drive pinion gear shaft
bearings.
5. Adjust drive pinion gearshaft
bearing preload torque.
6. Loose differential bearings. 6. Adjust differential bearing preload
torque.
7. Misaligned or sprung ring gear. 7. Measure ring gear runout.
8. Loose differential bearing cap
bolts.
8. Tighten with specified torque.
SERVICE PROCEDURES
LUBRICANT CHANGE
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
drai n the l ubri cant from the housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the seal ant from the housi ng and cover
surfaces. Use sol vent to cl ean the mati ng surfaces.
(6) Appl y a bead of Mopar Si l i cone Rubber Seal -
ant, or equi val ent, to the housi ng cover (Fi g. 3).
Install the housing cover within 5 minutes
after applying the sealant.
(7) I nstal l the cover and any i denti fi cati on tag.
Ti ghten the cover bol ts i n a cri sscross pattern to 41
(8) Refi l l the di fferenti al wi th Mopar Hypoi d
Gear Lubri cant, or equi val ent, to bottom of the fi l l
pl ug hol e. Refer to the Lubri cant Speci fi cati ons i n
thi s group for the quanti ty necessary.
(9) I nstal l the fi l l hol e pl ug and l ower the vehi cl e.
DRIVE AXLE ASSEMBLY
REMOVAL
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Remove the brake rotors and cal i pers from the
axl e. Refer to Group 5, Brakes, for proper procedures.
(6) Di sconnect the wheel sensor wi ri ng harness
from the vehi cl e wi ri ng harness, i f necessary.
Fig. 3 Typical Housing Cover With Sealant
SEALING SURFACE CONTOUR OF BEAD BEAD THICK- NESS 6.35MM (1/4)
(7) Di sconnect the vent hose from the axl e shaft
tube.
(8) Mark the propel l er shaft and yoke for i nstal l a-
ti on al i gnment reference.
(9) Remove propel l er shaft.
(10) Di sconnect stabi l i zer bar l i nks at the axl e.
(11) Di sconnect shock absorbers from axl e brack-
ets.
(12) Di sconnect track bar.
(13) Di sconnect the ti e rod and drag l i nk from the
steeri ng knuckl e. Refer to Group 2, Suspensi on, for
proper procedures.
(14) Di sconnect the steeri ng damper from the axl e
bracket.
(15) Di sconnect the upper and l ower suspensi on
arms from the axl e brackets.
(16) Lower the l i fti ng devi ce enough to remove the
axl e. The coi l spri ngs wi l l drop wi th the axl e.
(17) Remove the coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, ride height and
handling could be affected.
(1) I nstal l the spri ngs and retai ner cl i ps. Ti ghten
the retai ner bol ts to 21 Nm (16 ft. l bs.) torque.
(2) Support the axl e on a sui tabl e l i fti ng devi ce
and posi ti on axl e under the vehi cl e.
(3) Rai se the axl e and al i gn i t wi th the spri ng
pads.
(4) Posi ti on the upper and l ower suspensi on arms
i n the axl e brackets. Loosel y i nstal l bol ts and nuts to
hol d suspensi on arms to the axl e brackets.
(5) Connect the vent hose to the axl e shaft tube.
(6) Connect the track bar to the axl e bracket.
Loosel y i nstal l the bol t to hol d the track bar to the
axl e bracket.
(7) I nstal l the shock absorbers and ti ghten the
(8) I nstal l the stabi l i zer bar l i nks to the axl e
brackets. Ti ghten the nut to 95 Nm (70 ft. l bs.)
torque.
(9) I nstal l the drag l i nk and ti e rod to the steeri ng
knuckl es. Refer to Group 2, Suspensi on, for proper
procedures.
(10) I nstal l the steeri ng damper to the axl e
bracket and ti ghten the nut to 75 Nm (55 ft. l bs.)
torque.
(11) I nstal l the brake rotors and cal i pers. Refer to
Group 5, Brakes, for the proper procedures.
(12) Connect the wheel speed sensor wi ri ng har-
ness to the vehi cl e wi ri ng harness, i f necessary.
(13) Al i gn the previ ousl y made marks on the pro-
pel l er shaft and the yoke.
(14) I nstal l the straps and bol ts to hol d the propel -
l er shaft to the yoke.
(15) Check and fi l l axl e l ubri cant. Refer to the
Lubri cant Speci fi cati ons i n thi s group for the quan-
ti ty necessary.
(17) Remove the l i fti ng devi ce from the axl e and
(18) Ti ghten the upper suspensi on arm nuts to 75
Nm (55 ft. l bs.) torque. Ti ghten the l ower suspensi on
arm nuts to 115 Nm (85 ft. l bs.) torque.
(19) Ti ghten the track bar bol t at the axl e bracket
(20) Check the front wheel al i gnment.
TUBE AXLE ASSEMBLY
REMOVAL
axl e.
(5) Remove the brake rotors and cal i pers from the
axl e. Refer to Group 5, Brakes, for proper procedures.
(6) Di sconnect the wheel sensor wi ri ng harness
from the vehi cl e wi ri ng harness, i f necessary.
(7) Di sconnect stabi l i zer bar l i nks at the axl e.
(8) Di sconnect shock absorbers from axl e brackets.
(9) Di sconnect track bar.
(10) Di sconnect the ti e rod and drag l i nk from the
steeri ng knuckl e. Refer to Group 2, Suspensi on, for
proper procedures.
(11) Di sconnect the steeri ng damper from the axl e
bracket.
(12) Di sconnect the upper and l ower suspensi on
arms from the axl e brackets.
(13) Lower the l i fti ng devi ce enough to remove the
axl e. The coi l spri ngs wi l l drop wi th the axl e.
(14) Remove the coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
are not at their normal ride position, ride height and
handling could be affected.
(1) I nstal l the spri ngs and retai ner cl i ps. Ti ghten
the retai ner bol ts to 21 Nm (16 ft. l bs.) torque.
(2) Support the axl e on a sui tabl e l i fti ng devi ce
and posi ti on axl e under the vehi cl e.
(3) Rai se the axl e and al i gn i t wi th the spri ng
pads.
(4) Posi ti on the upper and l ower suspensi on arms
i n the axl e brackets. Loosel y i nstal l bol ts and nuts to
hol d suspensi on arms to the axl e brackets.
(5) Connect the track bar to the axl e bracket.
Loosel y i nstal l the bol t to hol d the track bar to the
axl e bracket.
(6) I nstal l the shock absorbers and ti ghten the
(7) I nstal l the stabi l i zer bar l i nks to the axl e
brackets. Ti ghten the nut to 95 Nm (70 ft. l bs.)
torque.
(8) I nstal l the drag l i nk and ti e rod to the steeri ng
knuckl es. Refer to Group 2, Suspensi on, for proper
procedures.
(9) I nstal l the steeri ng damper to the axl e bracket
and ti ghten the nut to 75 Nm (55 ft. l bs.) torque.
Group 5, Brakes, for the proper procedures.
(11) Connect the wheel speed sensor wi ri ng har-
ness to the vehi cl e wi ri ng harness, i f necessary.
(13) Remove the l i fti ng devi ce from the axl e and
(14) Ti ghten the upper suspensi on arm nuts to 75
Nm (55 ft. l bs.) torque. Ti ghten the l ower suspensi on
arm nuts to 115 Nm (85 ft. l bs.) torque.
(15) Ti ghten the track bar bol t at the axl e bracket
(16) Check the front wheel al i gnment.
AXLE SHAFTCARDAN U-JOINT
Si ngl e cardan Ujoi nt components are not servi ce-
abl e. I f defecti ve, they must be repl aced as a uni t. I f
the beari ngs, seal s, spi der, or beari ng caps are dam-
aged or worn, repl ace the compl ete Ujoi nt.
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Also, to avoid distorting the
yoke, do not over tighten the vise jaws.
(1) Remove axl e shaft.
(2) Remove the beari ng cap retai ni ng snap ri ngs
(Fi g. 4).
It can be helpful to saturate the bearing caps
with penetrating oil prior to removal.
(3) Locate a socket where the i nsi de di ameter i s
l arger i n di ameter than the beari ng cap. Pl ace the
socket (recei ver) agai nst the yoke and around the
peri meter of the beari ng cap to be removed.
(4) Locate a socket where the outsi de di ameter i s
smal l er i n di ameter than the beari ng cap. Pl ace the
socket (dri ver) agai nst the opposi te beari ng cap.
(5) Posi ti on the yoke wi th the sockets i n a vi se
(Fi g. 5).
(6) Compress the vi se jaws to force the beari ng cap
i nto the l arger socket (recei ver).
(7) Rel ease the vi se jaws. Remove the sockets and
beari ng cap that was parti al l y forced out of the yoke.
(8) Repeat the above procedure for the remai ni ng
beari ng cap.
(9) Remove the remai ni ng beari ng cap, beari ngs,
seal s and spi der from the propel l er shaft yoke.
Fig. 4 Axle Shaft Outer UJoint
SHAFT YOKE BEARING CAP SNAP RINGS BEARING CAP SPINDLE YOKE BEARING BEARING CAP SNAP RINGS BEARING CAP
Fig. 5 Yoke Bearing Cap Removal
LARGE-DIAMETER SOCKET WRENCH VISE SMALL-DIAMETER SOCKET WRENCH
INSTALLATION
(1) Pack the beari ng caps 1/3 ful l of wheel beari ng
l ubri cant. Appl y extreme pressure (EP), l i thi umbase
l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on the spi der i n the yoke. I nsert the seal s
and beari ngs. Tap the beari ng caps i nto the yoke
bores far enough to hol d the spi der i n posi ti on.
(3) Pl ace the socket (dri ver) agai nst one beari ng
cap. Posi ti on the yoke wi th the socket wrench i n a
vi se.
(4) Compress the vi se to force the beari ng caps
i nto the yoke. Force the caps enough to i nstal l the
retai ni ng cl i ps.
(5) I nstal l the beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
PINION SHAFT SEAL
REMOVAL
(2) Remove wheel and ti re assembl i es.
(3) Remove brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng Hol der 6958 to hol d the pi ni on yoke,
remove the pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke (Fi g. 6).
(10) Use a sui tabl e pry tool or a sl i de hammer
mounted screw to remove the pi ni on shaft seal .
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
W-162D, Cup 8109, and Hol der 6958 (Fi g. 8).
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.
(3) I nstal l the pi ni on washer and a new nut on the
pi ni on gear. Tighten the nut only enough to
remove the shaft end play.
(4) Ti ghten pi ni on nut to 217 Nm (160 ft. l bs.).
(5) Rotate the pi ni on shaft usi ng a (i n. l bs.) torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 9).
(6) I f the rotati ng torque i s l ow, use Hol der 6958 to
hol d the pi ni on yoke, and ti ghten the pi ni on shaft
Fig. 6 Pinion Yoke Removal
SPECIAL TOOL C-3281 YOKE SPECIAL TOOL C-452
Fig. 7 Pinion Seal Installation
SPECIAL TOOL C-4171 SPECIAL TOOL C-3972A
Fig. 8 Pinion Yoke Installation
PINION YOKE AXLE HOUSING
nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l proper
rotati ng torque i s achi eved.
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke, and i nstal l the propel l er
shaft.
(8) Check and fi l l the gear l ubri cant. Refer to the
Lubri cant Speci fi cati ons for gear l ubri cant requi re-
ments.
(10) I nstal l wheel and ti re assembl i es.
HUB BEARING AND AXLE SHAFT
I f the axl e shaft and hub beari ng are bei ng
removed i n order to servi ce another component, the
axl e shaft and hub beari ng can be removed as an
assembl y.
REMOVAL
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per and rotor. Refer to
(4) Remove ABS wheel speed sensor, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(5) Remove the cotter pi n, nut retai ner, and axl e
hub nut (Fi g. 10), i f necessary.
(6) Remove the hub to knuckl e bol ts (Fi g. 11).
(7) Remove the hub from the steeri ng knuckl e and
axl e shaft, i f necessary.
(8) Remove hub beari ng and axl e shaft assembl y
(Fi g. 12), or axl e shaft from axl e. Avoid damaging
the axle shaft oil seals in the axle housing.
(9) Remove the brake rotor shi el d from the hub
beari ng or knuckl e (Fi g. 10).
INSTALLATION
(1) Thoroughl y cl ean the axl e shaft (Fi g. 10) and
appl y a thi n fi l m of Mopar Wheel Beari ng Grease,
or equi val ent, to the shaft spl i nes, seal contact sur-
face, and hub bore.
(2) I nstal l the brake rotor shi el d to the knuckl e.
Fig. 10 Hub, Knuckle and Axle Shaft
BRAKE SHIELD WASHER RETAINER COTTER PIN NUT HUB AND BEARING ASSEMBLY STEERING KNUCKLE BOLT TONE WHEEL (ABS)
Fig. 9 Check Pinion Rotation Torque
PINION YOKE INCH POUND TORQUE WRENCH
(3) I nstal l the hub beari ng and axl e shaft assem-
bl y, or axl e shaft, i nto the housi ng and di fferenti al
si de gears. Avoi d damagi ng the axl e shaft oi l seal s i n
the axl e housi ng.
(4) I nstal l the hub beari ng, i f necessary.
(5) I nstal l the hub to knuckl e bol ts and ti ghten to
(6) I nstal l the hub washer and nut, i f necessary.
Ti ghten the hub nut to 237 Nm (175 ft. l bs.) torque.
I nstal l the nut retai ner and a new cotter pi n (Fi g.
10).
(7) I nstal l ABS wheel speed sensor, i f necessary.
(8) I nstal l the brake rotor and cal i per. Refer to
(9) I nstal l the wheel and ti re assembl y.
STEERING KNUCKLE AND BALL STUDS
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. Removal and
i nstal l ati on of upper and l ower bal l studs requi re the
use of Tool Ki t 6289.
KNUCKLE REMOVAL
(1) Remove hub beari ng and axl e shaft.
(2) Di sconnect the ti e-rod or drag l i nk from the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
(3) Remove the cotter pi ns from the upper and
l ower bal l studs.
(4) Remove the upper and l ower bal l stud nuts.
(5) Stri ke the steeri ng knuckl e wi th a brass ham-
mer to l oosen knuckl e from the bal l studs. Remove
knuckl e from bal l studs (Fi g. 13).
UPPER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 14).
LOWER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 15).
KNUCKLE INSTALLATION
(1) Posi ti on the steeri ng knuckl e on the bal l studs.
(2) I nstal l and ti ghten the bottom retai ni ng nut to
109 Nm (80 ft. l bs.) torque. I nstal l new cotter pi n.
(3) I nstal l and ti ghten the top retai ni ng nut to 101
Nm (75 ft. l bs.) torque. I nstal l new cotter pi n.
(4) I nstal l the hub beari ng and axl e shaft.
(5) Connect the ti e-rod or drag l i nk end to the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
Fig. 11 Hub Bearing Bolts
AXLESHAFT AXLE KNUCKLE HUB BEARING
Fig. 12 Hub Bearing and Axle Assembly
AXLE KNUCKLE HUB BEARING AXLE SHAFT
Fig. 13 Steering Knuckle Removal/Installation
AXLE YOKE UPPER BALL STUD LOWER BALL STUD STEERING KNUCKLE
AXLE BUSHING REPLACEMENT
Refer to Group 2, Suspensi on, for the proper axl e
bushi ng procedures.
DIFFERENTIAL
REMOVAL
al l ow fl ui d to drai n.
(4) Remove hub beari ngs and axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 16).
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Posi ti on Spreader W129B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 17). I nstal l the
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
gerti ght.
(8) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to gui de pi n. Load the l ever adapter agai nst the
opposi te si de of the housi ng (Fi g. 18) and zero the
i ndi cator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 19).
(10) Remove the di al i ndi cator.
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs (Fi g. 20).
(13) Mark or tag the di fferenti al beari ng cups to
i ndi cate whi ch si de of the di fferenti al they were
removed from.
(14) Remove spreader from housi ng.
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) Posi ti on Spreader W-129-B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
Fig. 14 Upper Ball Stud Remove/Install
REMOVAL INSTALLATION
pi ns seated i n the l ocati ng hol es (Fi g. 21). I nstal l the
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
gerti ght.
(2) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
to gui de pi n. Load the l ever adapter agai nst the
i ndi cator.
the housing is over-spread, it could be distorted or
damaged.
Fig. 15 Lower Ball Stud Remove/Install
SPECIAL TOOL 628912 SPECIAL TOOL 62894 SPECIAL TOOL 4212F INSTALLATION REMOVAL SPECIAL TOOL 4212F SPECIAL TOOL 62891 SPECIAL TOOL 62893
Fig. 16 Bearing Cap Identification
INSTALLATION REFER- ENCE LETTERS INSTALLATION REFER- ENCE LETTERS
Fig. 17 Install Axle Housing Spreader
AXLE HOUSING DOWEL SAFETY HOLD DOWN SPECIALTOOL W-129B TURNBUCKLE
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 19).
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs. Tap the di fferenti al case
to ensure the beari ngs cups are ful l y seated i n the
housi ng.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 22).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 61 Nm (45 ft.
l bs.) torque.
(10) I nstal l the hub beari ngs and axl e shafts.
DIFFERENTIAL SIDE BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove the beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, C-293-39 Adapter
Bl ocks, and Pl ug SP-3289 (Fi g. 23).
INSTALLATION
I f repl acement di fferenti al si de beari ngs or di ffer-
enti al case are bei ng i nstal l ed, di fferenti al si de bear-
i ng shi m requi rements may change. Refer to the
Di fferenti al Beari ng Prel oad and Gear Backl ash pro-
cedures i n thi s secti on to determi ne the proper shi m
sel ecti on.
Fig. 18 Install Dial Indicator
SPECIAL TOOL C-3339 DIAL INDICATOR LEVER ADAPTER SPECIAL TOOL W-129B SPECIAL TOOL C-3288B
Fig. 19 Spread Axle Housing
SPECIAL TOOL C-3339 SPECIALTOOL W-129B
Fig. 20 Differential Case Removal
AXLE HOUSING DIFFERENTIAL CASE BEARING CUPS
(1) I nstal l di fferenti al si de beari ng shi ms onto di f-
ferenti al case hubs.
(2) Usi ng I nstal l er C-3716-A and Handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 24).
(3) I nstal l di fferenti al i n axl e housi ng.
AXLE SHAFT OIL SEAL
REMOVAL
(2) Remove di fferenti al assembl y.
(3) Remove the i nner axl e shaft seal s wi th a pry
bay.
INSTALLATION
(1) Remove any seal er remai ni ng from ori gi nal
seal s.
(2) Remove seal er from axl e tube to housi ng junc-
ti on, i f necessary.
(3) I nstal l oi l seal s wi th Di scs 8110 and Turn-
buckl e 6797 (Fi g. 25). Ti ghten tool unti l di sc bottoms
i n housi ng.
(4) I nstal l di fferenti al assembl y.
RING GEAR
The ri ng and pi ni on gears are servi ce i n a matched
set. Do not repl ace the ri ng gear wi thout repl aci ng
the pi ni on gear.
REMOVAL
(1) Remove di fferenti al from axl e housi ng.
(2) Pl ace di fferenti al case i n a sui tabl e vi se wi th
soft metal jaw protectors. (Fi g. 26)
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Usi ng a soft hammer, dri ve ri ng gear from di f-
ferenti al case (Fi g. 26).
Fig. 22 Differential Bearing Cap Reference Letters
Fig. 23 Differential Bearing Removal
SPECIAL TOOL C-29339 BEARING DIFFERENTIAL SPECIAL TOOL SP-3289 SPECIAL TOOL C-293PA
Fig. 24 Differential Side Bearing Installation
SPECIAL TOOL C-3716A SPECIAL TOOL C-4171
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(2) I nvert the di fferenti al case i n the vi se.
(3) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 95122 Nm (7090 ft. l bs.) torque (Fi g.
27).
(4) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
PINION GEAR
The ri ng and pi ni on gears are servi ced as a
matched set. Do not repl ace the pi ni on gear wi thout
repl aci ng the ri ng gear.
REMOVAL
(1) Remove di fferenti al assembl y from axl e hous-
i ng.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke.
Usi ng sui tabl e wi re, ti e propel l er shaft to underbody.
(4) Usi ng Hol der 6958 to hol d yoke, remove the
pi ni on nut and washer.
(5) Usi ng Remover C-452 and Hol der C-3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 28).
Fig. 25 Axle Seal Installation
TURNBUCKLE 6797 DISCS 8110
Fig. 26 Ring Gear Removal
CASE RING GEAR RAWHIDE HAM- MER
Fig. 27 Ring Gear Bolt Installation
TORQUE WRENCH RING GEAR BOLT RING GEAR CASE
(6) Remove the pi ni on gear and prel oad shi ms
from housi ng (Fi g. 29). Catch the pi ni on wi th your
hand to prevent i t from fal l i ng and bei ng damaged.
(7) Remove the front pi ni on beari ng cup, beari ng,
oi l sl i nger, i f equi pped, and pi ni on seal wi th Remover
D-147 and Handl e C4171 (Fi g. 30).
(8) Remove the rear pi ni on beari ng cup from axl e
housi ng (Fi g. 31). Use Remover D-149 and Handl e
C4171.
(9) Remove the depth shi ms from rear pi ni on bear-
i ng cup bore i n axl e housi ng. Record the thi ckness of
the depth shi ms.
NOTE: The pinion depth shims can be very thin.
Verify that all shims have been removed before pro-
ceeding.
(10) Remove the rear pi ni on beari ng from the pi n-
i on wi th Pul l er/Press C293-PA and Adapters
C-293-39 (Fi g. 32).
Place 4 adapter blocks so they do not damage
the bearing cage.
INSTALLATION
NOTE: Pinion depth shims are placed between the
rear pinion bearing cup and axle housing to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement.
Refer to Pinion Gear Depth to select the proper
thickness shim before installing pinion gear.
(1) Pl ace proper thi ckness depth shi m i n rear pi n-
i on beari ng cup bore i n the axl e housi ng.
(2) Appl y Mopar Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of rear pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-146 and
Handl e C4171 (Fi g. 33). Veri fy cup i s correctl y
seated.
l ubri cant to outsi de surface of front pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-144 and
Handl e C4171 (Fi g. 34).
Fig. 29 Remove Pinion Gear
RAWHIDE HAM- MER
Fig. 30 Front Bearing Cup Removal
REMOVER HANDLE
Fig. 31 Rear Bearing Cup Removal
DRIVER HANDLE
(4) I nstal l front pi ni on beari ng, and oi l sl i nger, i f
equi pped.
and Handl e C4171 (Fi g. 35).
(6) I nstal l the rear pi ni on beari ng and oi l sl i nger,
i f equi pped, on the pi ni on gear wi th I nstal l er W-262
and a shop press (Fi g. 36).
(7) I nstal l pi ni on beari ng prel oad shi ms onto the
pi ni on gear (Fi g. 37).
(8) I nstal l pi ni on gear i n housi ng.
(9) I nstal l yoke wi th I nstal l er W-162-B, Cup 8109,
and Hol der 6958 (Fi g. 38).
(10) I nstal l the pi ni on washer and a new nut on
the pi ni on gear. Ti ghten the nut to 217 Nm (160 ft.
l bs.).
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload rotating torque.
(11) Check beari ng prel oad torque wi th an i nch
pound torque wrench (Fi g. 39). The torque necessary
to rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs1 to 3 Nm (10 to 20 i n. l bs.).
New Beari ngs2 to 5 Nm (15 to 35 i n. l bs.).
(12) I f rotati ng torque i s above the desi red
amount, remove the pi ni on yoke and i ncrease the
prel oad shi m pack thi ckness. I ncreasi ng the shi m
pack thi ckness 0.025 mm (0.001 i n.) wi l l decrease the
rotati ng torque approxi matel y 0.9 Nm (8 i n. l bs.).
Fig. 32 Inner Bearing Removal
SPECIAL TOOL C-293PA VISE ADAPTERS DRIVE PINION GEAR SHAFT
Fig. 33 Rear Pinion Bearing Cup Installation
INSTALLER HANDLE
Fig. 34 Pinion Outer Bearing Cup Installation
INSTALLER HANDLE
(13) Ti ghten pi ni on shaft nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l the maxi mum ti ghteni ng or desi red
rotati ng torque i s reached.
(14) I f the maxi mum ti ghteni ng torque i s reached
pri or to achi evi ng the desi red rotati ng torque, remove
the pi ni on yoke and decrease the thi ckness of the
prel oad shi m pack. Decreasi ng the shi m pack thi ck-
ness 0.025 mm (0.001 i n.) wi l l i ncrease the rotati ng
torque approxi matel y 0.9 Nm (8 i n. l bs.).
(15) I nstal l di fferenti al assembl y.
Fig. 37 Pinion Preload ShimsTypical
WASHER PINION NUT PINION OIL SEAL FRONT BEARING CONE SHOULDER FOR PINION PRELOAD SPACER PINION PRELOAD SPACER PINION PRELOAD SHIMS FRONT BEARING CUP SLINGER PINION YOKE
Fig. 36 Rear Pinion Bearing Installation
INSTALLA- TION TOOL OIL SLINGER DRIVE PINION GEAR DRIVE PINION GEAR SHAFT REAR BEARING
DISASSEMBLY
(1) Remove the ri ng gear.
(2) Usi ng a sui tabl e rol l pi n punch, dri ve out the
rol l pi n hol di ng pi ni on gear mate shaft i n the di ffer-
enti al case (Fi g. 40).
(3) Remove the pi ni on gear mate shaft from the
di fferenti al case and the pi ni on mate gears.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 41).
(5) Remove the di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l the di fferenti al si de gears and thrust
washers.
(2) I nstal l the pi ni on mate gears and thrust wash-
ers.
(3) I nstal l the pi ni on gear mate shaft. Al i gn the
rol l pi n hol es i n shaft and the di fferenti al case.
(4) I nstal l the rol l pi n to hol d the pi ni on mate
shaft i n the di fferenti al case (Fi g. 42).
(5) I nstal l the ri ng gear.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar Si l i cone
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 43).
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 Nm (30 ft. l bs.) torque.
Fig. 39 Check Pinion Gear Rotating Torque
in. lbs. TORQUE WRENCH PINION YOKE
Fig. 40 Mate Shaft Roll Pin Removal
DRIFT LOCKPIN MATE SHAFT
Fig. 41 Pinion Mate Gear Removal
THRUST WASHER SIDE GEAR PINION MATE GEAR
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
CARDAN U-JOINT
Cl ean al l the Ujoi nt yoke bores wi th cl eani ng sol -
vent and a wi re brush. Ensure that al l the rust and
forei gn matter are removed from the bores.
I nspect the yokes for di storti on, cracks and worn
beari ng cap bores.
Repl ace the compl ete Ujoi nt i f any of the compo-
nents are defecti ve.
AXLE COMPONENTS
Wash di fferenti al components wi th cl eani ng sol vent
and dry wi th compressed ai r. Do not steam clean
the differential components.
Wash beari ngs wi th sol vent and towel dry, or dry
wi th compressed ai r. DO NOT spi n beari ngs wi th
compressed ai r. Cup and bearing must be
replaced as matched sets only.
Cl ean axl e shaft tubes and oi l channel s i n housi ng.
I nspect for;
Smooth appearance wi th no broken/dented sur-
faces on the beari ng rol l ers or the rol l er contact sur-
faces.
Beari ng cups must not be di storted or cracked.
Machi ned surfaces shoul d be smooth and wi th-
out any rai sed edges.
Rai sed metal on shoul ders of cup bores shoul d
be removed wi th a hand stone.
Wear and damage to pi ni on gear mate shaft,
pi ni on gears, si de gears and thrust washers. Repl ace
as a matched set onl y.
Ri ng and pi ni on gear for worn and chi pped
teeth.
Ri ng gear for damaged bol t threads. Repl aced as
a matched set onl y.
Pi ni on yoke for cracks, worn spl i nes, pi tted
areas, and a rough/corroded seal contact surface.
Repai r or repl ace as necessary.
Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
44). A pl us (+) number, mi nus () number or zero (0)
i s etched i nto the face of the pi ni on gear. Thi s num-
ber i s the amount (i n thousandths of an i nch) the
depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
Fig. 42 Mate Shaft Roll Pin Installation
PUNCH PINION MATE SHAFT MATE SHAFT LOCKPIN
pi ni on i s 92.08 mm (3.625 i n.). The standard depth
provi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
thi s secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th sel ect shi ms. The shi ms are pl aced
behi nd the rear pi ni on beari ng cup (Fi g. 45).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (1, 2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
PINION DEPTH MEASUREMENT AND
ADJ USTMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the axl e housi ng
wi thout any shi ms pl aced behi nd the rear pi ni on
beari ng cup. Take measurements wi th Pi ni on Gauge
Set 6774 and Di al I ndi cator C-3339 (Fi g. 46).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6733, and rear pi ni on beari ng onto Screw 6741
(Fi g. 46).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 47).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
hand ti ght (Fi g. 46).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 48).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
hei ght bl ock (Fi g. 46). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator face to the poi nter. Ti ghten
di al i ndi cator face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 49). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
Fig. 44 Pinion Gear ID Numbers
PRODUCTION NUM- BERS DRIVE PINION GEAR DEPTH VARIANCE GEAR MATCHING NUMBER (SAME AS RING GEAR NUM- BER)
Fig. 45 Shim Locations
DRIVE PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on gear (Fi g. 44). For
exampl e, i f the depth vari ance i s 2, add +0.002 i n.
to the di al i ndi cator readi ng.
NOTE: If an oil slinger is used behind the inner pin-
ion bearing, deduct the thickness of the slinger
from the dial indicator reading and use that total for
shim selection.
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion 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 +0.006 +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 +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
Fig. 46 Pinion Gear Depth Gauge ToolsTypical
DIAL INDICATORARBOR PINION HEIGHT BLOCK CONE SCREW PINION BLOCK SCOOTER BLOCK ARBOR DISC
Fig. 47 Pinion Height BlockTypical
PINION BLOCK PINION HEIGHT BLOCK
Fig. 48 Gauge Tools In HousingTypical
ARBOR DISC PINION BLOCK ARBOR PINION HEIGHT BLOCK
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
INTRODUCTION
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms posi ti oned behi nd the
di fferenti al si de beari ng cones. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on gear for i nstal l ati on. Estab-
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng and the prel oad speci fi ca-
ti on added together. The gear backl ash measurement
determi nes the thi ckness of the shi m used on the
ri ng gear si de of the di fferenti al case. Subtract the
gear backl ash shi m thi ckness from the total overal l
shi m thi ckness and sel ect that amount for the pi ni on
gear si de of the di fferenti al (Fi g. 50). Di fferenti al
shi m measurements are performed wi th axl e
spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n axl e housi ng.
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 51).
(7) Usi ng a dead-bl ow type mal l et, seat the di ffer-
enti al dummy beari ngs to each si de of the axl e hous-
i ng (Fi g. 52) and (Fi g. 53).
(8) Thread gui de stud C-3288-B i nto rear cover
bol t hol e bel ow ri ng gear (Fi g. 54).
(9) Attach a di al i ndi cator C-3339 to gui de stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 54).
Fig. 49 Pinion Gear Depth MeasurementTypical
ARBOR SCOOTER BLOCK DIAL INDICATOR
Fig. 50 Axle Adjustment Shim Locations
DRIVE PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM
Fig. 51 Tighten Bolts Holding Bearing Caps
BEARING CAP AXLE HOUSING DIFFERENTIAL CASE
(10) Push and hol d di fferenti al case to pi ni on gear
si de of axl e housi ng (Fi g. 55).
(11) Zero di al i ndi cator face to poi nter (Fi g. 55).
(12) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng (Fi g. 56).
(13) Record di al i ndi cator readi ng (Fi g. 56).
(14) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(15) Rotate di al i ndi cator out of the way on the
gui de stud.
(16) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
(17) I nstal l the pi ni on gear i n axl e housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(18) I nstal l di fferenti al case and dummy beari ngs
D-348 i n axl e housi ng (wi thout shi ms), i nstal l bear-
i ng caps and ti ghten bol ts snug.
(19) Seat ri ng gear si de dummy beari ng (Fi g. 53).
(20) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads. (Fi g. 54).
(21) Push and hol d di fferenti al case toward pi ni on
gear (Fi g. 57).
(22) Zero di al i ndi cator face to poi nter (Fi g. 57).
si de of the axl e housi ng (Fi g. 58).
(24) Record di al i ndi cator readi ng (Fi g. 58).
(25) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(26) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
Fig. 52 Seat Pinion Gear Side Differential Dummy
Side Bearing
MALLET AXLE HOUSING DIFFERENTIAL CASE
Fig. 53 Seat Ring Gear Side Differential Dummy
Side Bearing
AXLE HOUSING MALLET DIFFERENTIAL CASE
Fig. 54 Differential Side play Measurement
DIFFEREN- TIAL CASE AXLE HOUSING SPECIAL TOOL C-3288B SPECIAL TOOL C-3339
Fig. 55 Hold Differential Case and Zero Dial
Indicator
FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE SPECIAL TOOL C-3288B SPECIAL TOOL C-3339 ZERO DIAL INDICATOR FACE
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(27) Rotate di al i ndi cator out of the way on gui de
stud.
(29) I nstal l si de beari ng shi ms on di fferenti al case
hubs.
(30) I nstal l si de beari ngs and cups on di fferenti al
case.
(31) I nstal l spreader W-129-B, uti l i zi ng some i tems
from Adapter Set 6987, on axl e housi ng and spread
axl e openi ng enough to recei ve di fferenti al case.
(33) Remove spreader from axl e housi ng.
(34) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(35) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 59).
(36) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(37) Zero di al i ndi cator face to poi nter.
(38) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the axl e housi ng to the other
(Fi g. 60).
(39) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at several
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
Fig. 56 Hold Differential Case and Read Dial
Indicator
READ DIAL INDICATOR FORCE DIFFERENTIAL CASE TO RING GEAR SIDE AXLE HOUSING
Fig. 57 Hold Differential Case and Zero Dial
Indicator
ZERO DIAL INDICATOR FACE
FORCE DIFFERENTIAL
CASE TO PINION GEAR
SIDE
PINION GEAR AXLE HOUSING DIFFERENTIAL CASE
Fig. 58 Hold Differential Case and Read Dial
Indicator
READ DIAL INDICATOR
FORCE DIFFEREN-
TIAL CASE TO RING
GEAR SIDE
PINION GEAR AXLE HOUSING DIFFERENTIAL CASE
Fig. 59 Ring Gear Backlash Measurement
DIAL INDI- CATOR
GEAR CONTACT PATTERN ANALYSIS
The ri ng and pi ni on gear teeth contact patterns
wi l l show i f the pi ni on gear depth i s correct i n the
axl e housi ng. I t wi l l al so show i f the ri ng gear back-
l ash has been adjusted correctl y. The backl ash can be
adjusted wi thi n speci fi cati ons to achi eve desi red
tooth contact patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de, or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on gear. Thi s wi l l provi de a more di sti nct contact
pattern.
(3) Usi ng a boxed end wrench on a ri ng gear bol t,
Rotate the di fferenti al case one compl ete revol uti on
i n both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on gear teeth wi l l
squeegee the compound to the areas wi th the l east
amount of contact. Note and compare patterns on the
ri ng gear teeth to Gear Tooth Contact Patterns chart
(Fi g. 61) and adjust pi ni on depth and gear backl ash
as necessary.
Fig. 60 Backlash Shim Adjustment
FOR MORE BACKLASH INCREASE SHIM THIS SIDE FOR MORE BACKLASH
DECREASE SHIM THIS
SIDE FOR LESS BACK-
LASH
FOR LESS BACKLASH
INCREASE SHIM THIS DIE
FOR LESS BACKLASH
DECREASE SHIM THIS
SIDE FOR MORE BACK-
LASH
Fig. 61 Gear Tooth Contact Patterns
DRIVE SIDE OF RING GEAR TEETH HEEL TOE COAST SIDE OF RING GEAR TEETH TOE HEEL DESIRABLE CONTACT PATTERN. PATTERN SHOULD BE CENTERED ON THE DRIVE SIDE OF TOOTH. PATTERN SHOULD BE CENTERED ON THE COAST SIDE OF TOOTH, BUT MAY BE SLIGHTLY TOWARD THE TOE. THERE SHOULD ALWAYS BE SOME CLEARANCE BETWEEN CONTACT PATTERN AND TOP OF THE TOOTH. RING GEAR BACKLASH CORRECT. THINNER PINION GEAR DEPTH SHIM REQUIRED. RING GEAR BACKLASH CORRECT. THICKER PINION GEAR DEPTH SHIM REQUIRED. PINION GEAR DEPTH SHIM CORRECT. DECREASE RING GEAR BACKLASH. PINION GEAR DEPTH SHIM CORRECT. INCREASE RING GEAR BACKLASH.
SPECIFICATIONS
181 FBI AXLE
Axl e Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W90
Lube Capaci ty . . . . . . . . . . . . . . . . . . 1.2 L (2.5 pts.)
Axl e Rati o . . . . . . . . 3.07, 3.31, 3.54, 3.55, 3.73, 4.10
Di fferenti al Si de Gear Cl earance . . . . 0.120.20 mm
(0.0050.008 i n.)
Ri ng Gear Di ameter . . . . . . . . . 18.09 cm (7.125 i n.)
Backl ash . . . . . . . . . . . 00.15 mm (0.0050.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . . 92.1 mm (3.625 i n.)
Pi ni on Beari ng Rotati ng Torque
Ori gi nal Beari ngs . . . . . . . . 12 Nm (1020 i n. l bs.)
New Beari ngs . . . . . . . . . 1.54 Nm (1535 i n. l bs.)
181 FBI AXLE
DESCRIPTION TORQUE
Fill Hole Plug . . . . . . . . . . . . . . 34 Nm (25 ft. l bs.)
Diff. Cover Bolt . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bearing Cap Bolt . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Ring Gear Bolt . . . . . . 95122 Nm (7090 ft. l bs.)
Axle Nut . . . . . . . . . . . . . . . . 237 Nm (175 ft. l bs.)
Hub Brg. Bolt . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Lower Ball Stud . . . . . . . . . . . 108 Nm (80 ft. l bs.)
Upper Ball Stud . . . . . . . . . . . 101 Nm (75 ft. l bs.)
SPECIAL TOOLS
181 FBI AXLE
PullerC-293-PA
PlugSP-3289
AdapterC-293-39
PullerC-452
WrenchC-3281
DriverC-3716-A
HandleC-4171
InstallerD-146
RemoverD-149
InstallerW-162-D
Cup8109
Remover/Installer6289
Installer6761
Installer6752
Installer Discs8110
Turnbuckle6797
Tool Set, Pinion Depth6774
Gauge Block6733
Spanner6958
InstallerC-3972-A
SpreaderW-129-B
Adapter Kit6987
Pilot StudC-3288-B
RemoverD-147
InstallerD-144
InstallerW-262
194 RBI AXLE
INDEX
page page
GENERAL INFORMATION
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 47
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . 48
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . 49
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . 50
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 49
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . 50
TRACLOK DIFFERENTIAL NOISE . . . . . . . . . 50
TRACLOK TEST . . . . . . . . . . . . . . . . . . . . . . . 53
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
SERVICE PROCEDURES
AXLE SHAFT SEAL AND BEARING . . . . . . . . . 59
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 58
COLLAPSIBLE SPACER . . . . . . . . . . . . . . . . . . 56
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 60
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 67
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 63
PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . . 55
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . 68
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . 72
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
ADJUSTMENTS
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . . 74
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . 72
SPECIFICATIONS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 78
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 78
SPECIAL TOOLS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . 78
GENERAL INFORMATION
194 RBI AXLE
The 194 Rear Beam-desi gn I ron (RBI ) axl e housi ng
has an i ron center casti ng (di fferenti al housi ng) wi th
axl e shaft tubes extendi ng from ei ther si de. The
tubes are pressed i nto and wel ded to the di fferenti al
housi ng to form a one-pi ece axl e housi ng.
The i ntegral type, hypoi d gear desi gn, housi ng has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
The axl es are equi pped wi th semi fl oati ng axl e
shafts, meani ng that l oads are supported by the axl e
shaft and beari ngs. The axl e shafts are retai ned by
Ccl i ps i n the di fferenti al si de gears.
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e.
For vehi cl es equi pped wi th ABS brakes, the axl es
have a tone ri ng pressed onto the axl e shaft. Use
care when removi ng axl e shafts to ensure that the
tone wheel or the wheel speed sensor are not dam-
aged.
The 194 RBI axl e has the assembl y part number
and gear rati o l i sted on a tag. The tag i s attached to
the di fferenti al housi ng by a cover bol t. Bui l d date
i denti fi cati on codes are stamped on the cover si de of
an axl e shaft tube.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash i s adjusted by the use of sel ecti ve
spacer shi ms. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer (Fi g. 1).
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
The l ubri cant shoul d have MI LL2105C and
API GL 5 qual i ty speci fi cati ons.
Lubri cant i s a thermal l y stabl e SAE 80W90
gear l ubri cant.
Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W140 SYNTHETI C gear
l ubri cant.
Trac-l ok di fferenti al s requi re the addi ti on of 4 oz.
of fri cti on modi fi er to the axl e l ubri cant. The 194 RBI
axl e l ubri cant capaci ty i s 1.66L (3.50 pts.) total ,
i ncl udi ng the fri cti on modi fi er i f necessary.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
rotates the case.
the shafts.
speed.
TRAC-LOK OPERATION
I n a conventi onal di fferenti al , i f one wheel spi ns,
the opposi te wheel wi l l generate onl y as much torque
as the spi nni ng wheel .
I n the Trac-l ok di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
I n operati on, the Trac-l ok cl utches are engaged by
two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 4).
PINION GEAR DEPTH SHIM DIFFERENTIAL BEARING SHIM- PINION GEAR SIDE RING GEAR DIFFERENTIAL BEARING SHIM-RING GEAR SIDE COLLAPSIBLE SPACER
AXLE
SPEED
SPEED
The Trac-l ok desi gn provi des the di fferenti al acti on
needed for turni ng corners and for dri vi ng strai ght
ahead duri ng peri ods of unequal tracti on. When one
wheel l ooses tracti on, the cl utch packs transfer addi -
ti onal torque to the wheel havi ng the most tracti on.
Trac-l ok di fferenti al s resi st wheel spi n on bumpy
roads and provi de more pul l i ng power when one
wheel l ooses tracti on. Pul l i ng power i s provi ded con-
ti nuousl y unti l both wheel s l oose tracti on. I f both
wheel s sl i p due to unequal tracti on, Trac-l ok opera-
ti on i s normal . I n extreme cases of di fferences of
tracti on, the wheel wi th the l east tracti on may spi n.
GENERAL INFORMATION
by:
of:
of:
GEAR NOISE
aged gears.
Gear damage.
BEARING NOISE
sound.
source.
Fig. 4 Trac-lok Limited Slip Differential Operation
CASE RING GEAR DRIVE PINION PINION GEAR MATE SHAFT CLUTCH PACK SIDE GEAR CLUTCH PACK
LOW SPEED KNOCK
knock.
VIBRATION
caused by a:
Worn Ujoi nt(s).
DRIVELINE SNAP
Worn Ujoi nts.
TRACLOK DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t for
repai r, drai n, fl ush and refi l l the axl e wi th the spec-
i fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar Trac-l ok Lubri cant (fri cti on
modi fi er) shoul d be added after repai r servi ce or dur-
i ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred
be replaced.
shaft.
necessary.
nut.
adjustment.
surfaces.
gears.
bearings.
vehicle.
of clutch.
proper lubricant.
wheel/tire.
hole.
2. Worn axle shaft seals. Replace worn seals.
necessary.
shaft seal.
seal.
and reseal.
AND PINION)
damage.
operation.
pinion gear.
set.
pinion gear.
matched set.
bearings.
torque.
bolts.
TRACLOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRACLOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRACLOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 5).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Fig. 5 Trac-lok Test Typical
SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE TORQUE WRENCH
Ti ghten the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(8) For Tracl ok di fferenti al s, a quanti ty of
Mopar Tracl ok l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
(11) Tracl ok di fferenti al equi pped vehi cl es shoul d
be road tested by maki ng 10 to 12 sl ow fi gure-ei ght
turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
REAR AXLE
REMOVAL
axl e.
(5) Remove the brake drums from the axl e. Refer
to Group 5, Brakes, for proper procedures.
(6) Di sconnect parki ng brake cabl es from brackets
and l ever.
(7) Remove wheel speed sensors, i f necessary.
(8) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Group 5, Brakes, for
proper procedures.
tube.
(10) Mark the propel l er shaft and yokes for i nstal -
l ati on al i gnment reference.
(12) Di sconnect stabi l i zer bar l i nks.
(13) Di sconnect shock absorbers from axl e.
(14) Remove the U-bol ts whi ch hol d the axl e to the
spri ng brackets.
(15) Separate the axl e from the vehi cl e.
INSTALLATION
NOTE: The weight of the vehicle must be sup-
are not at their normal ride position, vehicle ride
height and handling could be affected.
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn the
spri ng centeri ng bol ts wi th the mati ng hol es i n the
axl e spri ng perch.
(2) I nstal l the U-bol ts whi ch hol d the axl e to the
spri ng brackets. Ti ghten nuts to 70 Nm (52 ft. l bs.).
(3) I nstal l shock absorbers and ti ghten nuts to 60
(4) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
(5) I nstal l the wheel speed sensors, i f necessary.
(6) Connect parki ng brake cabl e to brackets and
l ever.
(7) I nstal l the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(8) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(9) I nstal l axl e vent hose.
(10) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and bol ts. Ti ghten
(11) I nstal l the wheel s and ti res.
(12) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(13) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
Fig. 6 Apply Sealant
SEALANT AXLE HOUSING COVER
PINION SHAFT SEAL
REMOVAL
(3) Remove the brake drums. Refer to Group 5,
i nstal l ati on al i gnment reference.
l ati on reference.
(10) Use a sui tabl e pry tool or sl i de hammer
mounted screw to remove the pi ni on gear seal .
INSTALLATION
(2) I nstal l yoke on the pi ni on gear wi th Screw
8112, Cup 8109, and Hol der 6958 (Fi g. 9).
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.
(3) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(4) Ti ghten the nut to 271 Nm (200 ft. l bs.).
never exceed specified preload torque. If preload
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
(5) Rotate the pi ni on shaft usi ng a (i n. l bs.) torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 10).
(6) I f the rotati ng torque i s l ow, use Hol der 6958 to
hol d the pi ni on yoke (Fi g. 11), and ti ghten the pi ni on
shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l the
proper rotati ng torque i s achi eved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke and i nstal l the propel l er
shaft.
(8) Add gear l ubri cant to the di fferenti al housi ng,
i f necessary. Refer to the Lubri cant Speci fi cati ons for
gear l ubri cant requi rements.
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
(3) Remove rear brake drums. Refer to Group 5,
l ati on reference.
(11) Remove the front pi ni on beari ng usi ng a pai r
of sui tabl e pi ck tool s to pul l the beari ng strai ght off
the pi ni on gear shaft. I t may be necessary to l i ghtl y
tap the end of the pi ni on gear wi th a rawhi de or rub-
ber mal l et i f the beari ng becomes bound on the pi n-
i on shaft.
(12) Remove the col l apsi bl e spacer.
REMOVAL W/PINION REMOVED
(3) Remove rear brake drums. Refer to Group 5,
l ati on reference.
(8) Remove di fferenti al assembl y from axl e hous-
i ng.
Fig. 11 Tightening Pinion Shaft NutTypical
SPECIAL TOOL 6958 1 in. PIPE 3/4 DRIVE TORQUE WRENCH
pi ni on yoke nut and washer.
(10) Usi ng Remover C452 and Wrench C3281,
(11) Remove the pi ni on gear from housi ng (Fi g.
13). Catch the pi ni on wi th your hand to prevent i t
from fal l i ng and bei ng damaged.
(12) Remove col l apsi bl e spacer from pi ni on shaft.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft (Fi g. 14).
(2) I f pi ni on gear was removed, i nstal l pi ni on gear
i n housi ng.
(3) I nstal l pi ni on front beari ng, i f necessary.
(5) I nstal l yoke wi th Screw 8112, Cup 8109, and
Hol der 6958 (Fi g. 16).
(6) I f the ori gi nal pi ni on beari ngs are bei ng used,
i nstal l di fferenti al assembl y and axl e shafts, i f neces-
sary.
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
pi ni on gear. Ti ghten the pi ni on nut unti l there i s zero
beari ng end-pl ay.
(9) Usi ng yoke hol der 6958 and a torque wrench
set at 474 Nm (350 ft. l bs.), crush col l apsi bl e spacer
unti l beari ng end pl ay i s taken up (Fi g. 17).
NOTE: If more than 474 Nm (350 ft. lbs.) of torque
is necessary to remove the bearing end play, the
collapsible spacer is defective and must be
replaced.
RAWHIDE HAM- MER
Fig. 14 Collapsible Preload Spacer
COLLAPS- IBLESPACER SHOULDER PINION GEAR OIL SLINGER REAR BEAR- ING
(10) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 18).
(11) Check rotati ng torque wi th a (i n. l bs.) torque
wrench (Fi g. 18). The torque necessary to rotate the
pi ni on gear shoul d be:
Ori gi nal Beari ngs The readi ng recorded dur-
i ng removal , pl us an addi ti onal 0.56 Nm (5 i n. l bs.).
New Beari ngs 2 to 5 Nm (15 to 35 i n. l bs.).
(12) I nstal l di fferenti al assembl y and axl e shafts,
i f necessary.
(13) Al i gn marks made previ ousl y on yoke and
propel l er shaft and i nstal l propel l er shaft.
(14) I nstal l rear brake drums. Refer to Group 5,
Lubri cant Speci fi cati ons of thi s secti on for l ubri cant
requi rements.
AXLE SHAFT
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure.
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Loosen housi ng cover bol ts. Drai n l ubri cant
from the housi ng and axl e shaft tubes. Remove hous-
i ng cover.
(6) Rotate di fferenti al case so that pi ni on mate
gear shaft l ock screw i s accessi bl e. Remove l ock
screw and pi ni on mate gear shaft from di fferenti al
case (Fi g. 19).
(7) Push axl e shaft i nward and remove axl e shaft
Ccl i p l ock from the axl e shaft (Fi g. 20).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e shaft tube. Al so, exerci se care not to damage the
wheel speed sensor on vehi cl es equi pped wi th ABS
brakes.
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
Fig. 17 Tightening Pinion NutTypical
Fig. 18 Check Pinion Gear Rotation Torque
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles
equipped with ABS brakes
(2) I nsert Ccl i p l ock i n end of axl e shaft. Push
axl e shaft outward to seat Ccl i p l ock i n si de gear.
(3) I nsert pi ni on mate shaft i nto di fferenti al case
and through thrust washers and pi ni on gears.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 19 Nm (14 ft. l bs.)
torque.
(5) I nstal l cover and add fl ui d. Refer to Lubri cant
Change procedure i n thi s secti on for procedure and
l ubri cant requi rements.
(6) I nstal l brake drum. Refer to Group 5, Brakes,
(7) I nstal l wheel and ti re.
AXLE SHAFT SEAL AND BEARING
REMOVAL
(1) Remove the axl e shaft.
(2) Remove the axl e shaft seal from the end of the
axl e shaft tube wi th a smal l pry bar.
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the axl e
tube wi th Beari ng Removal Tool Set 6310 usi ng
Adapter Foot 6310-5 (Fi g. 21).
(4) I nspect the axl e shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
Do not install the original axle shaft seal.
Always install a new seal.
(1) Wi pe the axl e shaft tube bore cl ean.
(2) I nstal l axl e shaft beari ng wi th I nstal l er 6436
and Handl e C4171. Ensure that the part number on
the beari ng i s agai nst the i nstal l er.
(3) I nstal l the new axl e shaft seal wi th I nstal l er
6437 and Handl e C4171 (Fi g. 22).
(4) I nstal l the axl e shaft.
Fig. 19 Mate Shaft Lock Screw
LOCK SCREW PINION GEAR MATE SHAFT
Fig. 20 Axle Shaft CClip Lock
C-CLIPLOCK AXLESHAFT SIDE GEAR
Fig. 21 Axle Shaft Bearing Removal
AXLE SHAFT TUBE NUT GUIDE PLATE GUIDE THREADED ROD ADAPTER FOOT
DIFFERENTIAL
REMOVAL
al l ow fl ui d to drai n.
(4) Remove axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 23).
(6) Loosen the di fferenti al beari ng cap bol ts.
i tems from Adapter set 6987, wi th the tool dowel pi ns
seated i n the l ocati ng hol es (Fi g. 24). I nstal l the hol d-
down cl amps and ti ghten the tool turnbuckl e fi nger-
ti ght.
(8) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
to pi l ot stud. Load the i ndi cator pl unger agai nst the
i ndi cator.
the housing is overspread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 26).
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
Fig. 22 Axle Shaft Seal Installation
SPECIAL TOOL 6437 SEAL AXLE SHAFT TUBE SPECIAL TOOL C-4171
Fig. 23 Bearing Cap Identification
Fig. 25 Install Dial Indicator
SPECIAL TOOL C-3339 DIAL INDICATOR LEVER ADAPTER SPECIAL TOOL W-129B SPECIAL TOOL C-3288B
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs (Fi g. 27).
(13) Mark or tag the di fferenti al beari ng cups to
i ndi cate whi ch si de of the di fferenti al they were
removed from.
(14) Retri eve di fferenti al case prel oad shi ms from
axl e housi ng. Mark or tag the di fferenti al case pre-
l oad shi ms to i ndi cate whi ch si de of the di fferenti al
they were removed from.
(15) Remove spreader from housi ng.
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
i tems from Adapter set 6987, wi th the tool dowel pi ns
seated i n the l ocati ng hol es (Fi g. 28). I nstal l the hol d-
down cl amps and ti ghten the tool turnbuckl e fi nger-
ti ght.
(2) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
to pi l ot stud. Load the i ndi cator pl unger agai nst the
i ndi cator.
the housing is overspread, it could be distorted or
damaged.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 26).
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs and that the prel oad
shi ms remai n between the face of the beari ng cup
and the housi ng. Tap the di fferenti al case to ensure
the beari ngs cups and shi ms are ful l y seated i n the
housi ng.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 29).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
Fig. 26 Spread Axle Housing
SPECIAL TOOL C-3339 SPECIALTOOL W-129B
Fig. 27 Differential Case Removal
AXLE HOUSING DIFFERENTIAL CASE BEARING CUPS
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 77 Nm (57 ft.
l bs.) torque.
(10) I nstal l the axl e shafts.
REMOVAL
wi th Pul l er/Press C-293-PA, C-293-39 Bl ocks, and
Pl ug SP-3289 (Fi g. 30).
INSTALLATION
(1) Usi ng tool C-3716-A wi th handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 31).
(2) I nstal l di fferenti al i n axl e housi ng.
RING GEAR
The ri ng and pi ni on gears are servi ce i n a matched
set. Do not repl ace the ri ng gear wi thout repl aci ng
the pi ni on gear.
REMOVAL
soft metal jaw protectors. (Fi g. 26)
case.
INSTALLATION
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
Fig. 29 Differential Bearing Cap Reference Letters
SPECIAL TOOL C-29339 BEARING DIFFERENTIAL SPECIAL TOOL SP-3289 SPECIAL TOOL C-293PA
Fig. 31 Install Differential Side Bearings
HANDLE C-4171 DIFFERENTIAL BEARING TOOL C-3716A
ti ghten to 95122 Nm (7090 ft. l bs.) torque (Fi g.
27).
PINION GEAR
The ri ng and pi ni on gears are servi ced i n a
REMOVAL
(1) Remove di fferenti al from the axl e housi ng.
pi ni on yoke nut and washer.
(5) Usi ng Remover C452 and Wrench C3281,
(6) Remove the pi ni on gear from housi ng (Fi g. 35).
Catch the pi ni on wi th your hand to prevent i t from
fal l i ng and bei ng damaged.
(8) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(9) Remove the front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C4171 (Fi g. 36).
(10) Remove the rear beari ng cup from housi ng
(Fi g. 37). Use Remover D-149 and Handl e C4171.
RAWHIDE HAM- MER
(11) Remove the col l apsi bl e prel oad spacer (Fi g.
38).
(12) Remove the rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-40 (Fi g.
39).
the bearing cage.
(13) Remove the depth shi ms from the pi ni on gear
shaft. Record the thi ckness of the depth shi ms.
INSTALLATION
l ubri cant to outsi de surface of beari ng cup.
(2) I nstal l the pi ni on rear beari ng cup wi th
I nstal l er D-146 and Dri ver Handl e C4171 (Fi g. 40).
Ensure cup i s correctl y seated.
REMOVER HANDLE
DRIVER HANDLE
Fig. 38 Collapsible Spacer
Fig. 39 Rear Bearing Removal
(4) I nstal l the pi ni on front beari ng cup wi th
I nstal l er D130 and Handl e C4171 (Fi g. 41).
(5) I nstal l pi ni on front beari ng, and oi l sl i nger, i f
equi pped.
rear pinion bearing cone and pinion gear to achieve
ion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.
(7) Pl ace the proper thi ckness depth shi m on the
pi ni on gear.
(8) I nstal l the rear beari ng and sl i nger, i f
equi pped, on the pi ni on gear wi th I nstal l er W-262
(Fi g. 43).
(9) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft and i nstal l pi ni on gear i n housi ng (Fi g. 44).
(11) I nstal l yoke wi th I nstal l er Screw 8112, Cup
8109, and hol der 6958 (Fi g. 45).
Fig. 40 Pinion Rear Bearing Cup Installation
INSTALLER HANDLE
Fig. 41 Pinion Front Bearing Cup Installation
INSTALLER HANDLE
Fig. 43 Shaft Rear Bearing Installation
PRESS INSTALLATION TOOL DRIVE PINION GEAR DRIVE PINION GEAR SHAFT REAR BEARING
zero beari ng end-pl ay.
(14) Usi ng yoke hol der 6958 and a torque wrench
set at 474 Nm (350 ft. l bs.), crush col l apsi bl e spacer
unti l beari ng end pl ay i s taken up (Fi g. 46).
NOTE: If the spacer requires more than 474 Nm
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 47).
(16) Check beari ng rotati ng torque wi th a (i n. l bs.)
torque wrench (Fi g. 47). The torque necessary to
rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs 1 to 3 Nm (10 to 20 i n.
l bs.).
(17) I nstal l di fferenti al i n housi ng.
Fig. 46 Tightening Pinion NutTypical
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar Si l i cone
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 43).
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
DISASSEMBLY
(1) Remove pi ni on gear mate shaft l ock screw (Fi g.
49).
(2) Remove pi ni on gear mate shaft.
(3) Rotate the di fferenti al si de gears and remove
the pi ni on mate gears and thrust washers (Fi g. 50).
washers.
ASSEMBLY
washers.
ers.
(3) I nstal l the pi ni on gear mate shaft.
(4) Al i gn the hol e i n the pi ni on gear mate shaft
wi th the hol e i n the di fferenti al case and i nstal l the
pi ni on gear mate shaft l ock screw.
Fig. 49 Pinion Gear Mate Shaft Lock Screw
TRAC-LOK DIFFERENTIAL
The Tracl ok di fferenti al components are i l l us-
trated i n (Fi g. 51). Refer to thi s i l l ustrati on duri ng
repai r servi ce.
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 6965 i n a vi se.
(2) Posi ti on the di fferenti al case on Si de Gear
Hol di ng Tool 6965 (Fi g. 52).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
Fig. 51 Traclok Differential Components
THRUST WASHER PINION SHAFT LOCK SCREW PINION MATE SHAFT SIDE GEAR RETAINER DISC CLUTCH PACK DIFFERENTIAL CASE RETAINER
Fig. 52 Differential Case Holding Tool
SPECIAL TOOL 6965 VISE DIFFERENTIAL
(4) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 53).
(5) Remove the pi ni on gear mate shaft. I f neces-
sary, use a dri ft and hammer (Fi g. 54).
(6) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
55).
(7) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter C-6960-1 (Fi g. 56) to prevent
adapter from turni ng.
Fig. 54 Mate Shaft Removal
PINION MATE SHAFT SIDE GEAR DRIFT PINION MATE GEAR
Fig. 55 Step Plate Tool Installation
LOWER SIDE GEAR DIFFERENTIAL CASE SPECIAL TOOL C-69603
Fig. 56 Threaded Adapter Installation
SOCKET SLOT IN ADAPTER SCREWDRIVER DISC C-69603 THREADED ROD C-69604 THREADED ADAPTER DISC C69601
(9) Ti ghten forci ng screw tool 122 Nm (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 57).
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the pi ni on gears
(Fi g. 58).
(11) I nsert Turni ng Bar C-6960-2 i n case (Fi g. 59).
(12) Loosen the Forci ng Screw C-6960-4 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar C-6960-2.
(13) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(14) Remove pi ni on gears from di fferenti al case.
(15) Remove Forci ng Screw C-6960-4, Step Pl ate
C-6960-3, and Threaded Adapter C-6960-1.
(16) Remove top si de gear, cl utch pack retai ner,
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 60).
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 6965. Remove si de gear, cl utch pack retai ner,
removal .
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Fig. 57 Tighten Belleville Spring Compressor Tool
TORQUE WRENCH TOOL ASSEM- BLED DIFFERENTIAL CASE
Fig. 58 Remove Pinion Gear Thrust Washer
THRUST WASHER FEELER GAUGE
Fig. 59 Pinion Gear Removal
PINION GEARS TOOL
Fig. 60 Side Gear & Clutch Disc Removal
DIFFERENTIAL CASE RETAINER SIDE GEAR AND CLUTCH DISC PACK
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 61).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 62). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Hol di ng Tool 6965.
(5) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 63).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 63).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
(8) I nsert Forci ng Screw C-6960-4.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
(11) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw C-6960-4, Step Pl ate
C-6960-3, and Threaded Adapter C-6960-1.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
Fig. 61 Clutch Disc Pack
CLUTCH PACK RETAINER SIDE GEAR RETAINER
Fig. 62 Clutch Discs & Lower Side Gear Installation
DIFFERENTIAL CASE LOWER SIDE GEAR AND CLUTCH DISC PACK
Fig. 63 Upper Side Gear & Clutch Disc Pack
Installation
UPPER SIDE GEAR AND CLUTCH DISC PACK DIFFERENTIAL CASE SPECIAL TOOLC-69603
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
AXLE COMPONENTS
I nspect for;
faces.
teeth.
Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
TRAC-LOK
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de and pi ni on gears. Repl ace any
gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
pi ni on gear are etched i nto the face of each gear (Fi g.
i s etched i nto the face of the pi ni on gear. Thi s num-
pi ni on etched wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
pi ni on i s 96.850 mm (3.813 i n.). The standard depth
provi des the best teeth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s Paragraph i n
thi s secti on for addi ti onal i nformati on.
under the i nner pi ni on beari ng cone (Fi g. 65).
vari ance etched i nto both the ori gi nal and repl ace-
ance charts.
mi nus amount needed.
Note the etched number on the face of the dri ve
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
ADJ USTMENT
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 6735,
Arbor Di scs 6732, and Di al I ndi cator C-3339 (Fi g.
66).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6735, and rear pi ni on beari ng onto Screw 6741
(Fi g. 66).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 67).
(3) I nstal l front pi ni on beari ng and Cone 6740
hand ti ght (Fi g. 66).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 68).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons
i n thi s secti on.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the surface of the pi ni on hei ght bl ock.
Hol d scooter bl ock i n pl ace and zero the di al i ndi ca-
tor face to the poi nter. Ti ghten di al i ndi cator face
l ock screw.
Original Pinion
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 +0.006 +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 +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
Fig. 66 Pinion Gear Depth Gauge ToolsTypical
DIAL INDICATORARBOR PINION HEIGHT BLOCK CONE SCREW PINION BLOCK SCOOTER BLOCK ARBOR DISC
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
Observe how many revol uti ons countercl ockwi se the
di al poi nter travel s (approxi matel y 0.125 i n.) to the
out-stop of the di al i ndi cator.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 69). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on gear (Fi g. 64) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s 2, add +0.002 i n. to the
di al i ndi cator readi ng.
(10) Remove the pi ni on depth gauge components
from the axl e housi ng
BACKLASH
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the axl e housi ng. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on gear for i nstal l ati on. Estab-
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng, starti ng poi nt shi m thi ck-
ness, and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
the di fferenti al case. Subtract the gear backl ash shi m
thi ckness from the total overal l shi m thi ckness and
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 70).
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove si de beari ngs from di fferenti al case.
Fig. 67 Pinion Height BlockTypical
PINION BLOCK PINION HEIGHT BLOCK
Fig. 68 Gauge Tools In HousingTypical
ARBOR DISC PINION BLOCK ARBOR PINION HEIGHT BLOCK
Fig. 69 Pinion Gear Depth MeasurementTypical
ARBOR SCOOTER BLOCK DIAL INDICATOR
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
(3) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(5) I nsert Dummy Shi ms 8107 (0.118 i n. (3.0 mm))
starti ng poi nt shi ms between the dummy beari ng
and the axl e housi ng (Fi g. 71).
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and ti ghten the bol ts.
(7) Thread gui de stud C-3288-B i nto rear cover
bol t hol e bel ow ri ng gear (Fi g. 72).
(8) Attach di al i ndi cator C-3339 to gui de stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
on a ri ng gear bol t head (Fi g. 72).
(9) Push fi rml y and hol d di fferenti al case to pi ni on
gear si de of axl e housi ng.
(11) Push fi rml y and hol d di fferenti al case to ri ng
gear si de of the axl e housi ng.
(12) Record di al i ndi cator readi ng.
(13) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
(14) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
stud.
(16) Remove di fferenti al case, dummy beari ngs,
and starti ng poi nt shi ms from axl e housi ng.
(17) I nstal l pi ni on gear i n axl e housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
(18) I nstal l di fferenti al case and dummy beari ngs
i n axl e housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts.
(19) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads (Fi g. 72).
(20) Push and hol d di fferenti al case toward pi ni on
gear.
si de of the axl e housi ng.
(23) Record di al i ndi cator readi ng.
(24) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
Fig. 70 Axle Adjustment Shim Locations
Fig. 71 Insert Starting Point Shims
SPECIAL TOOL 8107 AXLE HOUSING DIFFERENTIAL CASE SPECIAL TOOL D-348
Fig. 72 Differential Side play Measurement
DIFFEREN- TIAL CASE AXLE HOUSING SPECIAL TOOL C-3288B SPECIAL TOOL C-3339
ri ng and pi ni on gears. Thi s total i s the thi ckness of
shi m requi red to achi eve proper backl ash.
(25) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
stud.
(28) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(29) I nstal l spreader W-129-B, uti l i zi ng some com-
ponents of Adapter Set 6987, on axl e housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(30) Pl ace si de beari ng shi ms i n axl e housi ng
agai nst axl e tubes.
(32) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(33) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 73).
(34) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(36) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the di fferenti al housi ng to the
other (Fi g. 74).
(37) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at several
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform the
Gear Contact Pattern Anal ysi s procedure.
gear teeth.
pattern.
shop towel .
as necessary.
DIAL INDI- CATOR
Fig. 74 Backlash Shim Adjustment
FOR MORE BACKLASH INCREASE SHIM THIS SIDE FOR MORE BACKLASH
DECREASE SHIM THIS
SIDE FOR LESS BACK-
LASH
FOR LESS BACKLASH
INCREASE SHIM THIS DIE
FOR LESS BACKLASH
DECREASE SHIM THIS
SIDE FOR MORE BACK-
LASH
SPECIFICATIONS
194 RBI AXLE
DESCRIPTION SPECIFICATION
Axl e Type . . . . . . . . . . . . . . . Semi Fl oati ng Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W90
Lubri cant Trai l er Tow . . . . . . . . Syntheti c 75W140
Lube Capaci ty . . . . . . . . . . . . . . . . 1.66 L (3.50 pts.)
Axl e Rati os . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.11
Di fferenti al Beari ng Prel oad . . . . 0.1 mm (0.004 i n.)
Di fferenti al Si de Gear
Cl earance . . . . . . . . . . . . 00.15 mm (00.006 i n.)
Ri ng Gear Di ameter . . . . . . . . . . 19.2 cm (7.562 i n.)
Ri ng Gear Backl ash . . . 00.15 mm (0.0050.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . 92.08 mm (3.625 i n.)
Pi ni on Beari ng Prel oad-Ori gi nal
Beari ngs . . . . . . . . . . . . . 12 Nm (1020 i n. l bs.)
Pi ni on Beari ng Prel oad-New
Beari ngs . . . . . . . . . . . 1.54 Nm (1535 i n. l bs.)
194 RBI AXLE
DESCRIPTION TORQUE
Bol t, Di ff. Cover . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bol ot, Beari ng Cap . . . . . . . . . . . 77 Nm (57 ft. l bs.)
Nut, Pi ni on . . . . . . . 271474 Nm (200350 ft. l bs.)
Screw, Pi ni on Mate
Shaft Lock . . . . . . . . . . . . . 16.25 Nm (12 ft. l bs.)
Bol t, Ri ng Gear . . . . . . . 95122 Nm (7090 ft. l bs.)
Bol t, RWAL/ABS Sensor . . . . . . . 8 Nm (70 i n. l bs.)
SPECIAL TOOLS
194 RBI AXLE
PullerC-293-PA
AdapterC-293-39
AdapterC-293-40
PlugSP-3289
PullerC-452
WrenchC-3281
InstallerC-3972-A
Spanner6958
Installer Screw8112
Cup8109
HandleC-4171
DriverC-3716-A
InstallerD-130
InstallerD-146
RemoverC-4345
RemoverD-149
InstallerW-262
Installer6436
Installer6437
Disc, Axle Arbor6732
Gauge Block6735
Tool Set, Pinion Depth6774
Trac-lok Tool Set6960
Holder6965
Puller7794-A
Starting Point Shim8107
SpreaderW-129-B
Adapter Kit6987
Guide PinC-3288-B
Bearing Remover Tool Set6310
Hub Puller6790
8 1/4 REAR AXLE
INDEX
page page
GENERAL INFORMATION
8 1/4 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
AXLE IDENTIFICATION . . . . . . . . . . . . . . . . . . 83
TRAC-LOK OPERATION . . . . . . . . . . . . . . . . . . 85
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . 86
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . 86
GEAR NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 86
LOW SPEED KNOCK . . . . . . . . . . . . . . . . . . . . 86
TRACLOK DIFFERENTIAL NOISE . . . . . . . . . 87
TRACLOK TEST . . . . . . . . . . . . . . . . . . . . . . . 90
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
SERVICE PROCEDURES
AXLE SEAL AND BEARING . . . . . . . . . . . . . . . 92
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 91
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . 95
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 96
PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 93
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . 100
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . 101
8 1/4 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . 104
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
ADJUSTMENTS
8 1/4 AXLE PINION GEAR DEPTH . . . . . . . . . 105
GEAR BACKLASH . . . . . . . . . . . . . . . . . . . . 107
SIDE GEAR CLEARANCE . . . . . . . . . . . . . . . 108
SPECIFICATIONS
8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . 110
8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . 110
SPECIAL TOOLS
8 1/4 AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . 111
GENERAL INFORMATION
8 1/4 AXLES
The 8 1/4 i nch axl e housi ngs consi st of a cast i ron
center secti on wi th axl e shaft tubes extendi ng from
ei ther si de. The tubes are pressed i nto and wel ded to
the di fferenti al housi ng to form a one-pi ece axl e
housi ng (Fi g. 1).
The axl es have a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
The axl es are equi pped wi th semi -fl oati ng axl e
shafts, meani ng vehi cl e l oads are supported by the
axl e shaft and beari ngs. The axl e shafts are retai ned
by C-cl i ps i n the di fferenti al si de gears.
The removabl e, stamped steel cover provi des a
means for i nspecti on and servi ce wi thout removi ng
the compl ete axl e from the vehi cl e.
The 8 1/4 axl e have the assembl y part number and
gear rati o l i sted on tag. The tag i s attached to the
di fferenti al housi ng by a cover bol t.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash are set and mai ntai ned by threaded
adjusters at the outsi de of the di fferenti al housi ng.
Pi ni on beari ng prel oad i s set and mai ntai ned by the
use of a col l apsi bl e spacer.
Axl es equi pped wi th a Trac-Lok di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
AXLE IDENTIFICATION
The axl e di fferenti al cover can be used for i denti fi -
cati on of the axl e (Fi g. 2). A tag i s al so attached to
the cover.
Mul ti -purpose, hypoi d gear l ubri cant shoul d be
used for rear axl es wi th a standard di fferenti al . The
l ubri cant shoul d have a MI L-L-2105C and API GL 5
qual i ty speci fi cati ons.
Trac-Lok di fferenti al s requi re the addi ti on of 5 oz.
of fri cti on modi fi er to the axl e l ubri cant after servi ce.
The 8 1/4 axl e l ubri cant capaci ty i s 2.27 L (4.8 pts.)
total , i ncl udi ng the fri cti on modi fi er, i f necessary.
NOTE: If the rear axle is submerged in water, the
lubricant must be replaced immediately. Avoid the
possibility of premature axle failure resulting from
water contamination of the lubricant.
rotates the case.
the shafts.
Fig. 1 8 1/4 Axle
1. DIFFERENTIAL CASE 2. DIFFERENTIAL BEARING 3. BEARING CUP 4. PINION GEAR SHAFT 5. PINION GEAR DEPTH SHIMS 6. BEARING CUP 7. PINION GEAR SHAFT REAR BEARING 8. BEARING PRELOAD COLLAPSIBLE SPACER 9. DIFFERENTIAL HOUSING 10. PINION GEAR SHAFT FRONT BEARING 11. SEAL 12. YOKE 13. WASHER 14. NUT 15. LOCK 16. ADJUSTER 17. BEARING CAP 18. THRUST WASHER 19. SIDE GEAR 20. C-LOCK 21. PINION GEARS 22. THRUST WAHSERS 23. SHAFT LOCK BOLT 24. MAT SHAFT 25. RING GEAR BOLT 26. COVER 27. PLUG 28. RING GEAR
Fig. 2 Differential Cover 8 1/4 Inch Axle
DIFFERENTIAL COVER IDENTIFICATION TAG PUSH-IN FILL PLUG
speed.
TRAC-LOK OPERATION
I n a conventi onal di fferenti al , i f one wheel spi ns,
the opposi te wheel wi l l generate onl y as much torque
as the spi nni ng wheel .
I n the Trac-l ok di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
I n operati on, the Trac-l ok cl utches are engaged by
two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 4).
The Trac-l ok desi gn provi des the di fferenti al acti on
needed for turni ng corners and for dri vi ng strai ght
ahead duri ng peri ods of unequal tracti on. When one
wheel l ooses tracti on, the cl utch packs transfer addi -
ti onal torque to the wheel havi ng the most tracti on.
Trac-l ok di fferenti al s resi st wheel spi n on bumpy
roads and provi de more pul l i ng power when one
wheel l ooses tracti on. Pul l i ng power i s provi ded con-
ti nuousl y unti l both wheel s l oose tracti on. I f both
wheel s sl i p due to unequal tracti on, Trac-l ok opera-
ti on i s normal . I n extreme cases of di fferences of
tracti on, the wheel wi th the l east tracti on may spi n.
GENERAL INFORMATION
by:
AXLE
SPEED
SPEED
Fig. 5 Trac-lok Limited Slip Differential Operation
CASE RING GEAR DRIVE PINION PINION GEAR MATE SHAFT CLUTCH PACK SIDE GEAR CLUTCH PACK
of:
of:
GEAR NOISE
aged gears.
Gear damage.
BEARING NOISE
sound.
source.
LOW SPEED KNOCK
knock.
VIBRATION
caused by a:
Worn Ujoi nt(s).
DRIVELINE SNAP
Worn Ujoi nts.
TRACLOK DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t for
repai r, drai n, fl ush and refi l l the axl e wi th the spec-
i fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar Trac-l ok Lubri cant (fri cti on
modi fi er) shoul d be added after repai r servi ce or dur-
i ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
be replaced.
shaft.
necessary.
nut.
adjustment.
surfaces.
gears.
bearings.
vehicle.
of clutch.
proper lubricant.
wheel/tire.
hole.
LOSS OF LUBRICANT 2. Worn axle shaft seals. Replace worn seals.
necessary.
shaft seal.
seal.
and reseal.
AND PINION)
damage.
operation.
pinion gear.
set.
pinion gear.
matched set.
bearings.
torque.
bolts.
TRACLOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRACLOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRACLOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 5).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Fig. 6 Trac-lok Test Typical
SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE TORQUE WRENCH
Ti ghten the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(8) For Tracl ok di fferenti al s, a quanti ty of
Mopar Tracl ok l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
(11) Tracl ok di fferenti al equi pped vehi cl es shoul d
be road tested by maki ng 10 to 12 sl ow fi gure-ei ght
turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
REAR AXLE
REMOVAL
axl e.
(5) Secure brake drums to the axl e shaft.
(6) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Group 5, Brakes, for
proper procedures.
(7) Di sconnect the parki ng brake cabl es and cabl e
brackets.
tube.
(9) Mark the propel l er shaft and yoke for i nstal l a-
ti on al i gnment reference.
(11) Di sconnect shock absorbers from axl e.
(12) Remove the stabi l i zer l i nks.
(13) Remove the spri ng cl amps and spri ng brack-
ets. Refer to Group 2, Suspensi on, for proper proce-
dures.
(14) Separate the axl e from the vehi cl e.
INSTALLATION
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn to
the l eaf spri ng centeri ng bol ts.
(2) I nstal l the spri ng cl amps and spri ng brackets.
Refer to Group 2, Suspensi on, for proper procedures.
(3) I nstal l shock absorbers and ti ghten nuts to 60
(4) I nstal l the stabi l i zer l i nks. Ti ghten sway bar
l i nks to 74 Nm (55 ft. l bs.).
(5) Connect the parki ng brake cabl es and cabl e
brackets.
(7) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(8) I nstal l axl e vent hose.
(9) Al i gn propel l er shaft and pi ni on yoke reference
marks. I nstal l uni versal joi nt straps and bol ts.
Ti ghten to 19 Nm (14 ft. l bs.) torque.
(10) I nstal l the wheel s and ti res.
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(12) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
AXLE SHAFT
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure.
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Loosen housi ng cover bol ts. Drai n l ubri cant
from the housi ng and axl e shaft tubes. Remove hous-
i ng cover.
(6) Rotate di fferenti al case so that pi ni on mate
gear shaft l ock screw i s accessi bl e. Remove l ock
Fig. 7 Apply Sealant
SEALANT AXLE HOUSING COVER
screw and pi ni on mate gear shaft from di fferenti al
case (Fi g. 8).
(7) Push axl e shaft i nward and remove axl e shaft
Ccl i p l ock from the axl e shaft (Fi g. 9).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e shaft tube.
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
(2) I nsert Ccl i p l ock i n end of axl e shaft. Push
axl e shaft outward to seat Ccl i p l ock i n si de gear.
(3) I nsert pi ni on mate shaft i nto di fferenti al case
and through thrust washers and pi ni on gears.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 11 Nm (8 ft. l bs.)
torque.
(5) I nstal l cover and add fl ui d. Refer to Lubri cant
Change procedure i n thi s secti on for procedure and
l ubri cant requi rements.
(6) I nstal l brake drum. Refer to Group 5, Brakes,
(7) I nstal l wheel and ti re.
AXLE SEAL AND BEARING
REMOVAL
(1) Remove axl e shaft.
(2) Remove axl e shaft seal from the end of the axl e
tube wi th a smal l pry bar (Fi g. 10).
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the axl e
tube wi th Beari ng Removal Tool Set 6310, usi ng
Adapter Foot 6310-9 (Fi g. 11).
INSTALLATION
NOTE: Do not install the original axle shaft seal.
Always install a new seal.
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l the axl e shaft beari ng wi th I nstal l er
C-4198 and Handl e C-4171 (Fi g. 12). Ensure that the
beari ng part number i s agai nst the i nstal l er. Veri fy
Fig. 9 Axle Shaft CClip Lock
C-CLIPLOCK AXLESHAFT SIDE GEAR
Fig. 10 Axle Seal Removal
AXLE TUBE AXLE SEAL PRY BAR
that the beari ng i n i nstal l ed strai ght and the tool
ful l y contacts the axl e tube when seati ng the beari ng.
(3) I nstal l a new axl e seal wi th I nstal l er C-4076-B
and Handl e C-4735-1. When the tool contacts the
axl e tube, the seal i s i nstal l ed to the correct depth.
(4) Coat the l i p of the seal wi th axl e l ubri cant for
protecti on pri or to i nstal l i ng the axl e shaft.
(5) I nstal l the axl e shaft.
PINION SEAL
REMOVAL
(2) Scri be a mark on the uni versal joi nt, pi ni on
yoke, and pi ni on shaft for reference.
(3) Di sconnect the propel l er shaft from the pi ni on
yoke. Secure the propel l er shaft i n an upri ght posi -
ti on to prevent damage to the rear uni versal joi nt.
(5) Remove the brake drums to prevent any drag.
The drag may cause a fal se beari ng prel oad torque
measurement.
(6) Rotate the pi ni on yoke three or four ti mes.
l ati on reference.
(8) Hol d the yoke wi th Wrench 6719. Remove the
pi ni on shaft nut and washer.
(9) Remove the yoke wi th Remover C-452 (Fi g. 13).
(10) Remove the pi ni on shaft seal wi th sui tabl e
pry tool or sl i de-hammer mounted screw.
INSTALLATION
(1) Cl ean the seal contact surface i n the housi ng
bore.
(2) Exami ne the spl i nes on the pi ni on shaft for
burrs or wear. Remove any burrs and cl ean the shaft.
(3) I nspect pi ni on yoke for cracks, worn spl i nes
and worn seal contact surface. Repl ace yoke i f neces-
sary.
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
l i p of pi ni on seal .
(5) I nstal l the new pi ni on shaft seal wi th I nstal l er
C-4076-B and Handl e C-4735-1 (Fi g. 14).
NOTE: The seal is correctly installed when the seal
flange contacts the face of the differential housing
flange.
Fig. 11 Axle Shaft Bearing Removal Tool
AXLE SHAFT TUBE NUT GUIDE PLATE GUIDE THREADED ROD ADAPTER FOOT
Fig. 12 Axle Shaft Seal and Bearing Installation
HANDLE INSTALLER AXLE TUBE
PINION YOKE TOOL C452
(6) Posi ti on the pi ni on yoke on the end of the shaft
wi th the reference marks al i gned.
(7) Seat yoke on pi ni on shaft wi th I nstal l er C-3718
and Wrench 6719.
(8) Remove the tool s and i nstal l the pi ni on yoke
washer. The convex si de of the washer must face out-
ward.
torque when installing the pinion yoke retaining nut
at this point. Damage to collapsible spacer or bear-
ings may result.
(9) Hol d pi ni on yoke wi th Yoke Hol der 6719 and
ti ghten shaft nut to 285 Nm (210 ft. l bs.) (Fi g. 15).
Rotate pi ni on shaft several revol uti ons to ensure the
beari ng rol l ers are seated.
(10) Rotate the pi ni on shaft usi ng an (i n. l bs.)
torque wrench. Rotati ng torque shoul d be equal to
the readi ng recorded duri ng removal , pl us an addi -
ti onal 0.56 Nm (5 i n. l bs.) (Fi g. 16).
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
(11) I f the rotati ng torque i s l ow, use Yoke Hol der
6719 to hol d the pi ni on yoke (Fi g. 15) and ti ghten the
pi ni on shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements
unti l proper rotati ng torque i s achi eved.
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(12) The seal repl acement i s unacceptabl e i f the
fi nal pi ni on nut torque i s l ess than 285 Nm (210 ft.
l bs.).
(13) I nstal l the propel l er shaft wi th the i nstal l a-
ti on reference marks al i gned.
(14) Ti ghten the uni versal joi nt yoke cl amp screws
to 19 Nm (14 ft. l bs.).
(15) I nstal l the brake drums.
Fig. 14 8 1/4 Axle Pinion Seal Installation
SPECIAL TOOL C-4735 DIFFERENTIAL HOUSING SPECIAL TOOL C-4076-A
Fig. 15 Tightening Pinion Shaft Nut
DIFFERENTIAL HOUSING YOKE HOLDERTORQUE WRENCH
(16) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
(17) Check the di fferenti al housi ng l ubri cant l evel .
DIFFERENTIAL
REMOVAL
(1) Remove the axl e shafts.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
(2) Mark the di fferenti al housi ng and the di fferen-
ti al beari ng caps for i nstal l ati on reference (Fi g. 17).
(3) Remove beari ng threaded adjuster l ock from
each beari ng cap. Loosen the bol ts, but do not
remove the beari ng caps.
(4) Loosen the threaded adjusters wi th Wrench
C-4164 (Fi g. 18).
(5) Hol d the di fferenti al case whi l e removi ng bear-
i ng caps and adjusters.
(6) Remove the di fferenti al case.
NOTE: Each differential bearing cup and threaded
adjuster must be kept with their respective bearing.
INSTALLATION
(1) Appl y a coati ng of hypoi d gear l ubri cant to the
di fferenti al beari ngs, beari ng cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters i n posi ti on. Careful l y posi ti on the assem-
bl ed di fferenti al case i n the housi ng.
(2) Observe the reference marks and i nstal l the
di fferenti al beari ng caps at thei r ori gi nal l ocati ons
(Fi g. 19).
(3) I nstal l beari ng cap bol ts and ti ghten the upper
bol ts to 14 Nm (10 ft. l bs.). Ti ghten the l ower bol ts
fi nger-ti ght unti l the bol t head i s seated.
(4) Perform the di fferenti al beari ng prel oad and
adjustment procedure.
(5) I nstal l axl e shafts and di fferenti al housi ng
cover.
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
wi th Pul l er/Press C-293-PA and Adapters C-293-48
and Pl ug SP-3289 (Fi g. 20).
INSTALLATION
(1) I nstal l di fferenti al si de beari ngs. Use I nstal l er
C-4340 wi th handl e C-4171 (Fi g. 21).
Fig. 17 Mark For Installation Reference
INSTALLATION REFERENCE MARKS INSTALLATION REFERENCE MARKS DIFFERENTIAL HOUSING
BEARING
CAP
Fig. 18 Threaded Adjuster Tool
AXLE TUBE BACKING PLATE TOOL C-4164
Fig. 19 Bearing Caps & Bolts
INSTALLATION REFERENCE MARKS INSTALLATION REFERENCE MARKS DIFFERENTIAL HOUSING
BEARING
CAP
RING GEAR
matched set. Do not repl ace the ri ng gear wi thout
repl aci ng the pi ni on gear.
REMOVAL
soft metal jaw protectors. (Fi g. 22).
case.
INSTALLATION
(1) I nvert the di fferenti al case.
(2) Posi ti on ri ng gear on the di fferenti al case and
start two ri ng gear bol ts. Thi s wi l l provi de case-to-
ri ng gear bol t hol e al i gnment.
ti ghten to 102 Nm (75 ft. l bs.) torque (Fi g. 23).
PINION GEAR
REMOVAL
(1) Remove di fferenti al from the axl e housi ng.
SPECIAL TOOL C-293PA SPECIAL TOOL C-29348 BEARING DIFFERENTIAL SPECIAL TOOL SP-3289
Fig. 21 Install Differential Side Bearings
HANDLE C-4171 DIFFEREN- TIAL BEARING TOOLC-4340
(4) Usi ng Yoke Hol der 6719 to hol d yoke and
remove the pi ni on yoke nut and washer.
(5) Usi ng Remover C452, remove the pi ni on yoke
from pi ni on shaft (Fi g. 24).
(6) Parti al l y i nstal l pi ni on nut onto pi ni on to pro-
tect the threads.
(7) Remove the pi ni on gear from housi ng (Fi g. 25).
Catch the pi ni on wi th your hand to prevent i t from
fal l i ng and bei ng damaged.
(8) Remove the pi ni on shaft seal wi th sui tabl e pry
tool or sl i de-hammer mounted screw.
(9) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(10) Remove the front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C4171 (Fi g. 26).
PINION YOKE TOOL C452
RAWHIDE HAM- MER
REMOVER HANDLE
(11) Remove the rear beari ng cup from housi ng
(Fi g. 27). Use Remover C-4307 and Handl e C4171.
(12) Remove the col l apsi bl e prel oad spacer (Fi g.
28).
(13) Remove the rear beari ng from the pi ni on (Fi g.
29) wi th Pul l er/Press C-293-PA and Adapters C-293-
47.
the bearing cage.
(14) Remove the depth shi ms from the pi ni on gear
shaft. Record the thi ckness of the depth shi ms.
INSTALLATION
(2) I nstal l the pi ni on rear beari ng cup (Fi g. 30)
wi th I nstal l er C-4308 and Dri ver Handl e C4171.
(3) Ensure cup i s correctl y seated.
DRIVER HANDLE
Fig. 28 Collapsible Spacer
Fig. 29 Rear Bearing Removal
Fig. 30 Pinion Rear Bearing Cup Installation
INSTALLER HANDLE
(5) I nstal l the pi ni on front beari ng cup (Fi g. 31)
wi th I nstal l er D130 and Handl e C4171.
(6) I nstal l pi ni on front beari ng, and oi l sl i nger, i f
equi pped.
l i p of pi ni on seal . I nstal l seal wi th I nstal l er
C-4076B and Handl e C-4735-1 (Fi g. 32).
rear pinion bearing cone and pinion gear to achieve
ion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.
(8) Pl ace the proper thi ckness depth shi m on the
pi ni on gear.
(9) I nstal l the rear beari ng and sl i nger, i f
equi pped, on the pi ni on gear (Fi g. 33) wi th I nstal l er
6448.
(10) I nstal l a new col l apsi bl e prel oad spacer on
pi ni on shaft and i nstal l pi ni on gear i n housi ng (Fi g.
34).
(12) I nstal l yoke wi th I nstal l er C-3718 and Yoke
Hol der 6719.
Fig. 31 Pinion Front Bearing Cup Installation
INSTALLER HANDLE
SPECIAL TOOL C-4735 DIFFERENTIAL HOUSING SPECIAL TOOL C-4076-A
Fig. 33 Shaft Rear Bearing Installation
PRESS INSTALLATION TOOL DRIVE PINION GEAR DRIVE PINION GEAR SHAFT REAR BEARING
zero beari ng end-pl ay. I t wi l l not be possi bl e at thi s
poi nt to achi eve zero beari ng end-pl ay i f a new col -
l apsi bl e spacer was i nstal l ed.
(15) Usi ng Yoke Hol der 6719, crush col l apsi bl e
spacer unti l beari ng end pl ay i s taken up.
i ncrements unti l the desi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer (Fi g. 35).
(17) Check beari ng rotati ng torque wi th an i nch
pound torque wrench (Fi g. 35). The torque necessary
to rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs 1 to 3 Nm (10 to 20 i n.
l bs.).
(19) I nstal l di fferenti al i n housi ng.
DISASSEMBLY
(1) Remove pi ni on gear mate shaft l ock screw (Fi g.
49).
(2) Remove pi ni on gear mate shaft.
(3) Rotate the di fferenti al si de gears and remove
the pi ni on mate gears and thrust washers (Fi g. 50).
washers.
Fig. 36 Pinion Gear Mate Shaft Lock Screw
ASSEMBLY
washers.
ers.
(3) I nstal l the pi ni on gear mate shaft.
(4) Al i gn the hol e i n the pi ni on gear mate shaft
wi th the hol e i n the di fferenti al case and i nstal l the
pi ni on gear mate shaft l ock screw.
TRAC-LOK DIFFERENTIAL
The Tracl ok di fferenti al components are i l l us-
trated i n (Fi g. 38). Refer to thi s i l l ustrati on duri ng
repai r servi ce.
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 8138 i n a vi se.
Hol di ng Tool 8138 (Fi g. 39).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(4) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 40).
(5) Remove the pi ni on gear mate shaft. I f neces-
sary, use a dri ft and hammer (Fi g. 41).
(6) I nstal l and l ubri cate Step Pl ate 81402 (Fi g.
42).
(7) Assembl e Threaded Adapter 8140-1 i nto top
si de gear. Thread Forci ng Screw 6960-4 i nto adapter
unti l i t becomes centered i n adapter pl ate.
Fig. 38 Traclok Differential Components
THRUST WASHER PINION SHAFT LOCK SCREW PINION MATE SHAFT SIDE GEAR RETAINER DISC CLUTCH PACK DIFFERENTIAL CASE RETAINER
Fig. 39 Differential Case Holding Tool
SIDE GEAR HOLD- ING TOOL VISE DIFFERENTIAL
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter 8140-1 (Fi g. 43) to prevent adapter
from turni ng.
(9) Ti ghten forci ng screw tool 122 Nm (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 44).
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the pi ni on gears
(Fi g. 45).
(11) I nsert Turni ng Bar 6960-2 i n case (Fi g. 46).
(12) Loosen the Forci ng Screw 6960-4 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar 6960-2.
(13) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(14) Remove pi ni on gears from di fferenti al case.
(15) Remove Forci ng Screw 6960-4, Step Pl ate
81402, and Threaded Adapter 81401.
(16) Remove top si de gear, cl utch pack retai ner,
removal (Fi g. 47).
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 8138. Remove si de gear, cl utch pack retai ner,
removal .
Fig. 41 Mate Shaft Removal
PINION MATE SHAFT SIDE GEAR DRIFT PINION MATE GEAR
Fig. 42 Step Plate Tool Installation
SPECIAL TOOL 81402 LOWER SIDE GEAR DIFFERENTIAL CASE
Fig. 43 Threaded Adapter Installation
SOCKET SLOT IN ADAPTER SCREWDRIVER DISC 81402 THREADED ROD C-69604 THREADED ADAPTER DISC 81401
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 48).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 49). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Hol di ng Tool 8138.
(5) I nstal l l ubri cated Step Pl ate 81402 i n l ower
si de gear (Fi g. 50).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 50).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter 8140-1 i nto top si de gear.
(8) I nsert Forci ng Screw 6960-4.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol es are
al i gned.
(11) Rotate case wi th Turni ng Bar 6960-2 unti l the
pi ni on mate shaft hol es i n pi ni on gears al i gn wi th
Fig. 44 Tighten Belleville Spring Compressor Tool
TORQUE WRENCH TOOL ASSEM- BLED DIFFERENTIAL CASE
Fig. 45 Remove Pinion Gear Thrust Washer
THRUST WASHER FEELER GAUGE
Fig. 46 Pinion Gear Removal
PINION GEARS TOOL
Fig. 47 Side Gear & Clutch Disc Removal
DIFFERENTIAL CASE RETAINER SIDE GEAR AND CLUTCH DISC PACK
hol es i n case. I t may be necessary to sl i ghtl y ti ghten
the forci ng screw i n order to i nstal l the pi ni on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw 6960-4, Step Pl ate
81402, and Threaded Adapter 8140-1.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
8 1/4 AXLES
I nspect for:
faces.
Fig. 48 Clutch Disc Pack
CLUTCH PACK RETAINER SIDE GEAR RETAINER
Fig. 49 Clutch Discs & Lower Side Gear Installation
DIFFERENTIAL CASE LOWER SIDE GEAR AND CLUTCH DISC PACK
Fig. 50 Upper Side Gear & Clutch Disc Pack
Installation
UPPER SIDE GEAR AND CLUTCH DISC PACK DIFFERENTIALCASE SPECIAL TOOL 81402
teeth.
Pi ni on depth shi ms for damage and di storti on.
I nstal l new shi ms i f necessary.
The di fferenti al case. Repl ace the case i f cracked
or damaged.
The axl e shaft C-cl i p l ocks for cracks and exces-
si ve wear. Repl ace them i f necessary.
Each threaded adjuster to determi ne i f i t rotates
freel y. I f an adjuster bi nds, repai r the damaged
threads or repl ace the adjuster.
Pol i sh each axl e shaft seal i ng surface wi th No. 600
crocus cl oth. Thi s can remove sl i ght surface damage.
Do not reduce the di ameter of the axl e shaft seal con-
tact surface. When pol i shi ng, the crocus cl oth shoul d
be moved around the ci rcumference of the shaft (not
i n-l i ne wi th the shaft).
TRAC-LOK
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de and pi ni on gears. Repl ace any
gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
ADJ USTMENTS
8 1/4 AXLE PINION GEAR DEPTH
GENERAL INFORMATION
pi ni on gear are marked on the face of each gear (Fi g.
i s marked on the face of the pi ni on gear. Thi s num-
pi ni on marked wi th a (0). The standard depth pro-
vi des the best teeth contact pattern. Refer to Back-
l ash and Contact Pattern Anal ysi s Paragraph i n thi s
secti on for addi ti onal i nformati on.
under the rear pi ni on beari ng cone (Fi g. 52).
vari ance marked on both the ori gi nal and repl ace-
ance charts.
mi nus amount needed.
Note the marked number on the face of the dri ve
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
AXLE HOUSING COLLAPSIBLE SPACER PINION BEARING PINION DEPTH SHIM PINIONGEAR BEARING CUP
ADJ USTMENT
(1) I nstal l front pi ni on beari ng cup. Use I nstal l er
D-130 and Handl e C-4171.
(2) I nstal l rear pi ni on beari ng cup. Use I nstal l er
C-4308 and Handl e C-4171.
(3) Use Pi ni on Gear Adjustment Gauge Set
C-3715-B (Fi g. 53).
(4) Posi ti on Spacer SP-6030 over Shaft SP-5385.
(5) Posi ti on pi ni on rear beari ng on shaft.
(6) Posi ti on tool s (wi th beari ng) i n the housi ng.
(7) I nstal l Sl eeve SP-5382.
(8) I nstal l pi ni on front beari ng.
(9) I nstal l Spacer SP-6022.
(10) I nstal l Sl eeve SP-3194-B, Washer SP-534, and
Nut SP-3193.
(11) Ti ghten the nut to seat the pi ni on beari ngs i n
the housi ng. Al l ow the sl eeve to turn several ti mes
duri ng ti ghteni ng to prevent bri nel l i ng beari ng cups
or beari ngs.
(12) Loosen the compressi on nut tool .
(13) Lubri cate the pi ni on gear front and rear bear-
i ngs wi th gear l ubri cant.
(14) Re-ti ghten the compressi on nut tool to 1-3
Nm (15-25 i n. l bs.) torque.
(15) Rotate the pi ni on gear several compl ete revo-
l uti ons to al i gn the beari ng rol l ers.
(16) I nstal l Gauge Bl ock (Fi g. 54).
(17) I nstal l Gauge Bl ock SP-5383 at the end of
SP-5385.
(18) I nstal l Cap Screw SP-536 and ti ghten wi th
Wrench SP-531.
(19) Posi ti on Crossbore Arbor SP-6029 i n the di f-
ferenti al housi ng (Fi g. 55).
(20) Center the arbor tool .
(21) Posi ti on the beari ng caps on the arbor tool .
(22) I nstal l the attachi ng bol ts.
(23) Ti ghten the cap bol ts to 14 Nm (10 ft. l bs.).
(24) Tri al fi t depth shi m(s) between the crossbore
arbor and gauge bl ock (Fi g. 56). The depth shim(s)
fit must be snug but not tight (drag friction of a
feeler gauge blade).
Original Pinion
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 +0.006 +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 +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
Fig. 53 8 1/4 Axle Pinion Adjustment Tools
SPECIAL TOOL SET C-3715B
Fig. 54 Gauge Block
PINION BEARING GAUGE BLOCK AXLE HOUSING ADJUSTER
(25) Sel ect a shi m equal to the shi m sel ected above
pl us the dri ve pi ni on gear depth vari ance number
marked on the face of the pi ni on gear (Fi g. 51) usi ng
the opposi te si gn on the vari ance number. For exam-
pl e, i f the depth vari ance i s 2, add +0.002 i n. to the
di al i ndi cator readi ng.
NOTE: Depth shims are available in 0.001-inch
increments from 0.020 inch to 0.038 inch.
(26) Remove the tool s from the di fferenti al hous-
i ng.
BACKLASH
The fol l owi ng must be consi dered when adjusti ng
beari ng prel oad and gear backl ash:
The maxi mum ri ng gear backl ash vari ati on i s
0.003 i nch (0.076 mm).
Mark the gears so the same teeth are meshed
duri ng al l backl ash measurements.
Mai ntai n the torque whi l e adjusti ng the beari ng
prel oad and ri ng gear backl ash.
Excessi ve adjuster torque wi l l i ntroduce a hi gh
beari ng l oad and cause premature beari ng fai l ure.
I nsuffi ci ent adjuster torque can resul t i n excessi ve
di fferenti al case free-pl ay and ri ng gear noi se.
I nsuffi ci ent adjuster torque wi l l not support the
ri ng gear correctl y and can cause excessi ve di fferen-
ti al case free-pl ay and ri ng gear noi se.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
Maintain the gear teeth engaged (meshed) as
marked.
The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
Do this five to ten times each time the
threaded adjusters are adjusted.
(1) Use Wrench C-4164 to adjust each threaded
adjuster i nward unti l the di fferenti al beari ng free-
pl ay i s el i mi nated (Fi g. 57). Al l ow some ri ng gear
backl ash (approxi matel y 0.01 i nch/0.25 mm) between
the ri ng and pi ni on gear. Seat the beari ng cups wi th
the procedure descri bed above.
(2) I nstal l di al i ndi cator and posi ti on the pl unger
agai nst the dri ve si de of a ri ng gear tooth (Fi g. 58).
Measure the backl ash at 4 posi ti ons (90 degrees
apart) around the ri ng gear. Locate and mark the
area of mi ni mum backl ash.
(3) Rotate the ri ng gear to the posi ti on of the l east
backl ash. Mark the gear so that al l future backl ash
measurements wi l l be taken wi th the same gear
teeth meshed.
(4) Loosen the ri ght-si de, ti ghten the l eft-si de
threaded adjuster. Obtai n backl ash of 0.003 to 0.004
i nch (0.076 to 0.102 mm) wi th each adjuster ti ght-
Fig. 55 Crossbore Arbor
AXLE HOUSING CROSSBORE ARBOR
Fig. 56 Depth Shim(s) Selection
SHIMS CROSSBORE ARBORBEARING CAP
Fig. 57 Threaded Adjuster Tool
AXLE TUBE BACKING PLATE TOOL C-4164
ened to 14 Nm (10 ft. l bs.). Seat the beari ng cups
wi th the procedure descri bed above.
(5) Ti ghten the di fferenti al beari ng cap bol ts 95
Nm (70 ft. l bs.).
(6) Ti ghten the ri ght-si de threaded adjuster to 102
Nm (75 ft. l bs.). Seat the beari ng cups wi th the pro-
cedure descri bed above. Conti nue to ti ghten the
ri ght-si de adjuster and seat beari ng cups unti l the
torque remai ns constant at 102 Nm (75 ft. l bs.)
(7) Measure the ri ng gear backl ash. The range of
backl ash i s 0.006 to 0.008 i nch (0.15 to 0.203 mm).
(8) Conti nue i ncreasi ng the torque at the ri ght-
si de threaded adjuster unti l the speci fi ed backl ash i s
obtai ned.
NOTE: The left-side threaded adjuster torque
should have approximately 102 Nm (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Ti ghten the l eft-si de threaded adjuster unti l
102 Nm (75 ft. l bs.) torque i s i ndi cated. Seat the
beari ng rol l ers wi th the procedure descri bed above.
Do thi s unti l the torque remai ns constant.
(10) I nstal l the threaded adjuster l ocks and
ti ghten the l ock screws to 10 Nm (90 i n. l bs.).
After the proper backl ash i s achi eved, perform the
Gear Contact Anal ysi s procedure.
gear teeth.
pattern.
shop towel .
as necessary.
SIDE GEAR CLEARANCE
When measuri ng si de gear cl earance, check each
gear i ndependentl y. I f i t necessary to repl ace a si de
gear, repl ace both gears as a matched set.
(1) I nstal l the axl e shafts and C-cl i p l ocks and pi n-
i on mate shaft.
(2) Measure each si de gear cl earance. I nsert a
matched pai r of feel er gauge bl ades between the gear
and di fferenti al housi ng on opposi te si des of the hub
(Fi g. 60).
(3) I f si de gear cl earances i s no more than 0.005
i nch. Determi ne i f the shaft i s contacti ng the pi ni on
gear mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. I f the end of
the axl e shaft i s not contacti ng the pi ni on gear mate
shaft, the si de gear cl earance i s acceptabl e.
(4) I f cl earance i s more than 0.005 i nch (axl e shaft
not contacti ng mate shaft), record the si de gear cl ear-
ance. Remove the thrust washer and measure i ts
thi ckness wi th a mi crometer. Add the washer thi ck-
ness to the recorded si de gear cl earance. The sum of
gear cl earance and washer thi ckness wi l l determi ne
requi red thi ckness of repl acement thrust washer
(Fi g. 61).
I n some cases, the end of the axl e shaft wi l l move
and contact the mate shaft when the feel er gauge i s
i nserted. The C-cl i p l ock i s preventi ng the si de gear
from sl i di ng on the axl e shaft.
(5) I f there i s no si de gear cl earance, remove the
C-cl i p l ock from the axl e shaft. Use a mi crometer to
measure the thrust washer thi ckness. Record the
thi ckness and re-i nstal l the thrust washer. Assembl e
the di fferenti al case wi thout the C-cl i p l ock i nstal l ed
and re-measure the si de gear cl earance.
(6) Compare both cl earance measurements. I f the
di fference i s l ess than 0.012 i nch (0.305 mm), add
cl earance recorded when the C-cl i p l ock was i nstal l ed
to thrust washer thi ckness measured. The sum wi l l
DIAL INDICATOR RING GEAR EXCITER RING
determi ne the requi red thi ckness of the repl acement
thrust washer.
(7) I f cl earance i s 0.012 i nch (0.305 mm) or
greater, both si de gears must be repl aced (matched
set) and the cl earance measurements repeated.
(8) I f cl earance (above) conti nues to be 0.012 i nch
(0.305 mm) or greater, the case must be repl aced.
SPECIFICATIONS
8 1/4 INCH AXLE
Axl e Type . . . . . . . . . . . . . . . . Semi -fl oati ng, hypoi d
Lubri cant . . . . . . . . . . . . . . . . . . . . . . . SAE 80W-90
Lube Capaci ty . . . . . . . . . . . . . . . . . 2.27 L (4.8 pts.)
Trac-Lok Addi ti ve . . . . . . . . . . . . . . . . 148 ml (5 oz.)
Axl e Rati o . . . . . . . . . . . . . . . . . . . . . 3.21, 3.55, 3.90
Differential
Case Cl earance . . . . . . . . . . . . . 0.12 mm (0.005 i n.)
Case Fl ange Runout . . . . . . . . 0.076 mm (0.003 i n.)
Ring Gear
Di ameter . . . . . . . . . . . . . . . . . . . 20.95 cm (8.25 i n.)
Backl ash . . . . . . . . . . 0.12-0.20 mm (0.005-0.008 i n.)
Runout . . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 i n.)
Pinion Bearing
Prel oad . . . . . . . . . . . . . . . . . 1-2 Nm (10-20 i n.l bs.)
8 1/4 INCH AXLE
DESCRIPTION TORQUE
Di ff. Cover Bol t . . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Beari ng Cap Bol t . . . . . . . . . . 136 Nm (100 ft. l bs.)
Pi ni on NutMi ni mum . . . . . . . 285 Nm (210 ft. l bs.)
Ri ng Gear Bol t . . . . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Backi ng Pl ate Bol t . . . . . . . . . . . 64 Nm (48 ft. l bs.)
RWAL/ABS Sensor Bol t . . . . . . . 24 Nm (18. ft. l bs.)
Fig. 60 Side Gear Clearance Measurement
FEELER GAUGE
BLADES
SIDEGEAR
Fig. 61 Side Gear Calculations
SIDE GEAR CLEARANCE THRUST WASHER THICKNESS TOTAL 0.007 +0.033 0.040 0.040 0.037 0.003 REPLACEMENT WASHER THICKNESS NEW SIDE GEAR CLEARANCE
SPECIAL TOOLS
8 1/4 AXLES
Puller, Hub6790
Remover, Bearing6310
InstallerC-4198
HandleC-4171
InstallerC-4076-B
HandleC-4735-1
Holder6719
PullerC-452
InstallerC-3718
Adjustment RodC-4164
Puller/PressC-293PA
AdaptersC-293-48
PlugSP-3289
AdaptersC-293-47
InstallerC-4340
Holder8138
InstallerC-4345
RemoverC-4307
InstallerC-4308
InstallerD-130
Installer6448
Trac-lok Tools8140
Trac-lok Tools6960
Gauge SetC-3715-B
BRAKES
CONTENTS
page page
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 30 BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . 1
BASE BRAKE SYSTEM
INDEX
page page
GENERAL INFORMATION
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE WARNINGS & CAUTIONS . . . . . . . . . 2
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . . 5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 3
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . . 3
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . 2
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . . 3
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . 2
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 2
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . 5
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . 10
BRAKE FLUID CONTAMINATION . . . . . . . . . . . 11
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . 10
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . 9
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . 9
MASTER CYLINDER/POWER BOOSTER . . . . . . 8
RED BRAKE WARNING LAMP . . . . . . . . . . . . . . 8
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 8
SERVICE PROCEDURES
BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . 11
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . 12
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 11
BRAKE LINE . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DISC ROTOR MACHINING . . . . . . . . . . . . . . . . 12
MASTER CYLINDER BLEEDING . . . . . . . . . . . 11
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . 14
BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . 20
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . 14
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 16
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . 18
DISC BRAKE SHOES . . . . . . . . . . . . . . . . . . . . 17
DRUM BRAKE SHOES . . . . . . . . . . . . . . . . . . . 19
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . 15
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . 21
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . 15
REAR PARKING BRAKE CABLES . . . . . . . . . . 21
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 13
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . 20
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 23
MASTER CYLINDER RESERVOIR . . . . . . . . . . 22
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . 24
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . 25
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . 26
ADJUSTMENTS
PARKING BRAKE CABLE TENSIONER . . . . . . 28
REAR DRUM BRAKE . . . . . . . . . . . . . . . . . . . . 26
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 29
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . 28
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 29
XJ BRAKES 5 - 1
GENERAL INFORMATION
BRAKE SYSTEM
Power assi st front di sc and rear drum brakes are
standard equi pment. Di sc brake components consi st
of si ngl e pi ston cal i pers and venti l ated rotors. Rear
drum brakes are dual shoe uni ts wi th cast brake
drums.
The parki ng brake mechani sm i s l ever and cabl e
operated. The cabl es are attached to l evers on the
rear drum brake secondary shoes. The parki ng
brakes are operated by a hand l ever.
A dual di aphragm vacuum power brake booster i s
used for al l appl i cati ons. Al l model s have a two-pi ece
master cyl i nder wi th pl asti c reservoi r.
Al l model s are equi pped wi th a combi nati on val ve.
The val ve contai ns a pressure di fferenti al val ve and
swi tch and a fi xed rate rear proporti oni ng val ve.
Factory brake l i ni ng on al l model s consi sts of an
organi c base materi al combi ned wi th metal l i c parti -
cl es. The l i ni ng does not contai n asbestos.
SERVICE WARNINGS & CAUTIONS
WARNING: FACTORY INSTALLED BRAKE LININGS
DO NOT CONTAIN ASBESTOS FIBERS. DUST AND
DIRT ACCUMULATING ON BRAKE PARTS DURING
NORMAL USE MAY CONTAIN ASBESTOS FIBERS
FROM AFTER MARKET BRAKE LININGS. BREATH-
ING EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
PARTS. DO NOT CLEAN BRAKE PARTS WITH COM-
PRESSED AIR OR BY DRY BRUSHING. USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
THE REMOVAL OF ASBESTOS FIBERS FROM
BRAKE COMPONENTS. IF A SUITABLE VACUUM
CLEANER IS NOT AVAILABLE, CLEANING SHOULD
BE DONE WITH A WATER DAMPENED CLOTH. DO
NOT SAND, OR GRIND BRAKE LINING UNLESS
EQUIPMENT USED IS DESIGNED TO CONTAIN THE
DUST RESIDUE. DISPOSE OF ALL RESIDUE CON-
TAINING ASBESTOS FIBERS IN SEALED BAGS OR
CONTAINERS TO MINIMIZE EXPOSURE TO YOUR-
SELF AND OTHERS. FOLLOW PRACTICES PRE-
SCRIBED BY THE OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION AND THE ENVIRONMEN-
TAL PROTECTION AGENCY FOR THE HANDLING,
PROCESSING, AND DISPOSITION OF DUST OR
DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Drain and
flush the system with new brake fluid if contamina-
tion is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper bushings
and slide pins to ensure proper operation.
BRAKE PEDAL
A suspended-type brake pedal i s used, the pedal
pi vots on a shaft mounted i n the pedal support
bracket. The bracket i s attached to the dash panel
and steeri ng support bracket. The uni t i s servi ced as
an assembl y, except for the pedal pad.
STOP LAMP SWITCH
The pl unger type stop l amp swi tch i s mounted on a
bracket attached to the brake pedal support. The
swi tch can be adjusted when necessary.
RED BRAKE WARNING LAMP
A red warni ng l amp i s used for the servi ce brake
porti on of the hydraul i c system. The l amp i s l ocated
i n the i nstrument cl uster.
The red warni ng l i ght al erts the dri ver i f a pres-
sure di fferenti al exi sts between the front and rear
hydraul i c systems. The l i ght al so al erts the dri ver
when the parki ng brakes are appl i ed.
POWER BRAKE BOOSTER
The booster assembl y consi sts of a housi ng di vi ded
i nto separate chambers by two i nternal di aphragms.
The outer edge of each di aphragm i s attached to the
booster housi ng. The di aphragms are connected to
the booster pri mary push rod.
Two push rods are used i n the booster. The pri -
mary push rod connects the booster to the brake
pedal . The secondary push rod connects the booster
to the master cyl i nder to stroke the cyl i nder pi stons.
5 - 2 BRAKES XJ
The atmospheri c i nl et val ve i s opened and cl osed
by the pri mary push rod. Booster vacuum suppl y i s
through a hose attached to an i ntake mani fol d fi tti ng
at one end and to the booster check val ve at the
other. The vacuum check val ve i n the booster housi ng
i s a one-way devi ce that prevents vacuum l eak back.
Power assi st i s generated by uti l i zi ng the pressure
di fferenti al between normal atmospheri c pressure
and a vacuum. The vacuum needed for booster oper-
ati on i s taken di rectl y from the engi ne i ntake mani -
fol d. The entry poi nt for atmospheri c pressure i s
through a fi l ter and i nl et val ve at the rear of the
housi ng (Fi g. 1).
The chamber areas forward of the booster di a-
phragms are exposed to vacuum from the i ntake
mani fol d. The chamber areas to the rear of the di a-
phragms, are exposed to normal atmospheri c pres-
sure of 101.3 ki l opascal s (14.7 pounds/square i n.).
Brake pedal appl i cati on causes the pri mary push
rod to open the atmospheri c i nl et val ve. Thi s exposes
the area behi nd the di aphragms to atmospheri c pres-
sure. The resul ti ng pressure di fferenti al provi des the
extra appl y pressure for power assi st.
MASTER CYLINDER
The master cyl i nder has a removabl e nyl on reser-
voi r. The cyl i nder body i s made of al umi num and
contai ns a pri mary and secondary pi ston assembl y.
The cyl i nder body i ncl udi ng the pi ston assembl i es
are not servi ceabl e. I f di agnosi s i ndi cates an i nternal
probl em wi th the cyl i nder body, i t must be repl aced
as an assembl y. The reservoi r and grommets are the
onl y repl aceabl e parts on the master cyl i nder.
COMBINATION VALVE
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e. I t must be
repl aced i f di agnosi s i ndi cates thi s i s necessary.
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs are
made.
The rear proporti oni ng val ve i s used to bal ance
front-rear brake acti on. The val ve al l ows normal
fl ui d fl ow duri ng moderate effort brake stops. The
val ve onl y control s (meters) fl ui d fl ow duri ng hi gh
effort brake stops.
FRONT DISC BRAKES
The cal i pers are a si ngl e pi ston type. The cal i pers
are free to sl i de l ateral l y, thi s al l ows conti nuous com-
pensati on for l i ni ng wear.
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 2).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bore forces the cal i per to sl i de i nward on
the mounti ng bol ts. Thi s acti on bri ngs the outboard
brake shoe l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l stop the rotors from turni ng and bri ng the vehi -
cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake shoes do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g. 3).
When the brakes (and fl ui d pressure) are rel eased,
the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
brake l i ni ng wear. General l y the amount i s just
enough to mai ntai n contact between the pi ston and
i nboard brake shoe.
REAR DRUM BRAKE
The brake systems use a l eadi ng shoe (pri mary)
and trai l i ng shoe (secondary) (Fi g. 4). When the
brake pedal i s depressed hydraul i c pressure pushes
the rear brake wheel cyl i nder pi stons outward. The
wheel cyl i nder push rods then push the brake shoes
outward agai nst the brake drum. When the brake
pedal i s rel eased return spri ngs attached to the
brake shoes pul l the shoes back to there ori gi nal
posi ti on.
XJ BRAKES 5 - 3
PARKING BRAKE
Parki ng brake adjustment i s control l ed by a cabl e
tensi oner mechani sm. The cabl e tensi oner, once
adjusted at the factory, shoul d not need further
adjustment under normal ci rcumstances. Adjustment
may be requi red i f a new tensi oner, or cabl es are
i nstal l ed, or di sconnected.
PARKING BRAKE OPERATION
A hand operated l ever i n the passenger compart-
ment i s the mai n appl i cati on devi ce. The front cabl e
i s connected between the hand l ever and the ten-
si oner. The tensi oner rod i s attached to the equal i zer
whi ch i s the connecti ng poi nt for the rear cabl es (Fi g.
5).
The rear cabl es are connected to the actuati ng
l ever on each secondary brake shoe. The l evers are
attached to the brake shoes by a pi n ei ther pressed
i nto, or wel ded to the l ever. A cl i p i s used to secure
the pi n i n the brake shoe. The pi n al l ows each l ever
to pi vot i ndependentl y of the brake shoe.
To appl y the parki ng brakes, the hand l ever i s
pul l ed upward. Thi s pul l s the rear brake shoe actu-
ati ng l evers forward, by means tensi oner and cabl es.
As the actuati ng l ever i s pul l ed forward, the parki ng
brake strut (whi ch i s connected to both shoes), exerts
a l i near force agai nst the pri mary brake shoe. Thi s
acti on presses the pri mary shoe i nto contact wi th the
drum. Once the pri mary shoe contacts the drum,
force i s exerted through the strut. Thi s force i s trans-
ferred through the strut to the secondary brake shoe
causi ng i t to pi vot i nto the drum as wel l .
A gear type ratcheti ng mechani sm i s used to hol d
the l ever i n an appl i ed posi ti on. Parki ng brake
rel ease i s accompl i shed by the hand l ever rel ease
button.
Fig. 1 Power Brake BoosterTypical
VACUUM CHECK VALVE FRONT DIA- PHRAGM REAR DIA- PHRAGM HOUSING SEAL AIR FILTER PRIMARY PUSH ROD (TO BRAKE PEDAL) ATMOSPHERIC INLET VALVE ASSEMBLY BOOSTER MOUNTING STUDS (4) SECONDARY PUSH ROD (TO MASTER CYLINDER) MASTER CYLINDER MOUNTING STUD (2) SPRING
5 - 4 BRAKES XJ
A parki ng brake swi tch i s mounted on the parki ng
brake l ever and i s actuated by movement of the
l ever. The swi tch, whi ch i s i n ci rcui t wi th the red
warni ng l i ght i n the dash, wi l l i l l umi nate the warn-
i ng l i ght whenever the parki ng brakes are appl i ed.
BRAKE HOSES AND LINES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. Doubl e wal l ed
steel tubi ng i s used to connect the master cyl i nder to
the major hydraul i c braki ng components and then to
the fl exi bl e rubber hoses.
BASE BRAKE SYSTEM
Base brake components consi st of the brake shoes,
cal i pers, wheel cyl i nders, brake drums, rotors, brake
l i nes, master cyl i nder, booster, and parki ng brake
components.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, or vacuum
operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the front di sc brake reservoi r fl ui d l evel wi l l
decrease i n proporti on to normal l i ni ng wear. Also
note that brake fluid tends to darken over time.
This is normal and should not be mistaken for
contamination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, wheel cyl i nders, brake
l i nes, and master cyl i nder.
(b) I f fl ui d appears contami nated, drai n out a
sampl e. System wi l l have to be fl ushed i f fl ui d i s
separated i nto l ayers, or contai ns a substance
other than brake fl ui d. The system seal s and cups
wi l l al so have to be repl aced after fl ushi ng. Use
cl ean brake fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and pedal . Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
(2) Check brake pedal response wi th transmi ssi on
i n Neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
Fig. 2 Brake Caliper Operation
CALIPER PISTON PISTON BORE SEAL INBOARDSHOE OUTBOARDSHOE
Fig. 3 Lining Wear Compensation By Piston Seal
PISTON CYLINDER BORE PISTON SEAL BRAKE PRES- SURE OFF CALIPER HOUSING DUST BOOT PISTON SEAL BRAKE PRESSURE ON
XJ BRAKES 5 - 5
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak. The
l eak poi nt coul d be at a brake l i ne, fi tti ng, hose, or
cal i per/wheel cyl i nder. I nternal l eakage i n the master
cyl i nder caused by worn or damaged pi ston cups,
may al so be the probl em cause.
I f l eakage i s severe, fl ui d wi l l be evi dent at or
around the l eaki ng component. However, i nternal
l eakage i n the master cyl i nder may not be physi cal l y
evi dent.
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up worn l i ni ngs,
rotors, drums, or rear brakes out of adjustment are
the most l i kel y causes.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However, thi n brake drums or substandard
brake l i nes and hoses can al so cause a spongy pedal .
The proper course of acti on i s to bl eed the system, or
repl ace thi n drums and suspect qual i ty brake l i nes
and hoses.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster or check val ve coul d
al so be faul ty.
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on, or out of round brake drums. Other causes are
l oose wheel beari ngs or cal i pers and worn, damaged
ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Fig. 4 Brake Components
RIGHT REAR BRAKE ASSEMBLY ADJUSTER LEVER ADJUSTER CABLE HOLDDOWN SPRING AND RETAINERS ADJUSTER LEVERSPRING TRAILING SHOE CYLINDER-TO- SUPPORT SEAL HOLDDOWN PINS ACCESS PLUGS SUPPORT PLATE CABLE HOLE PLUG PARK BRAKE STRUT AND SPRING ADJUSTER SCREW ASSEMBLY HOLDDOWN SPRING AND RETAINERS LEADING SHOE CABLE GUIDE SHOE RETURN SPRINGS SHOE GUIDE PLATE PIN SHOESPRING PARK BRAKE LEVER
Fig. 5 Parking Brake Components
REAR CABLES EQUALIZER FRONT CABLE TENSIONER ROD
5 - 6 BRAKES XJ
Drag i s a product of i ncompl ete brake shoe rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and drums.
Mi nor drag wi l l usual l y cause sl i ght surface char-
ri ng of the l i ni ng. I t can al so generate hard spots i n
rotors and drums from the overheat-cool down pro-
cess. I n most cases, the rotors, drums, wheel s and
ti res are qui te warm to the touch after the vehi cl e i s
stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors and
drums to the poi nt of repl acement. The wheel s, ti res
and brake components wi l l be extremel y hot. I n
severe cases, the l i ni ng may generate smoke as i t
chars from overheati ng.
Common causes of brake drag are:
Sei zed or i mproperl y adjusted parki ng brake
cabl es.
Loose/worn wheel beari ng.
Sei zed cal i per or wheel cyl i nder pi ston.
Cal i per bi ndi ng on corroded bushi ngs or rusted
sl i de surfaces.
Loose cal i per mounti ng.
Drum brake shoes bi ndi ng on worn/damaged
support pl ates.
Mi sassembl ed components.
I f brake drag occurs at al l wheel s, the probl em
may be rel ated to a bl ocked master cyl i nder return
port, or faul ty power booster (bi nds-does not rel ease).
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Front brake pul l condi ti on coul d resul t from:
Contami nated l i ni ng i n one cal i per
Sei zed cal i per pi ston
Bi ndi ng cal i per
Loose cal i per
Rusty adapter/cal i per sl i de surfaces
I mproper brake shoes
Damaged rotor
A worn, damaged wheel beari ng or suspensi on
component are further causes of pul l . A damaged
front ti re (brui sed, pl y separati on) can al so cause
pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pul l i s usual l y caused by i mproperl y
adjusted or sei zed parki ng brake cabl es, contami -
nated l i ni ng, bent or bi ndi ng shoes and support
pl ates, or i mproperl y assembl ed components. Thi s i s
parti cul arl y true when onl y one rear wheel i s
i nvol ved. However, when both rear wheel s are
affected, the master cyl i nder, proporti oni ng val ve, or
RWAL val ve coul d be at faul t.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and/or repl acement wi l l
be necessary.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or
oi l . Gl azed l i ni ngs and rotors wi th hard spots can
al so contri bute to squeak. Di rt and forei gn materi al
embedded i n the brake l i ni ng wi l l al so cause squeak/
squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake shoes i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors and drums can become so scored that repl ace-
ment i s necessary.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components. However,
XJ BRAKES 5 - 7
cal i pers that bi nd on the sl i de surfaces can generate
a thump or cl unk noi se. I n addi ti on, worn out,
i mproperl y adjusted, or i mproperl y assembl ed rear
brake shoes can al so produce a thump noi se.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or wheel cyl i nders, worn seal s, dri v-
i ng through deep water puddl es, or l i ni ng that has
become covered wi th grease and gri t duri ng repai r.
Contami nated l i ni ng shoul d be repl aced to avoi d fur-
ther brake probl ems.
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on. A
ti re wi th i nternal damage such as a severe brui se,
cut, or pl y separati on can cause pul l and vi brati on.
STOP LAMP SWITCH
Stop l amp swi tch operati on can be tested wi th an
ohmmeter. The ohmmeter i s used to check conti nui ty
between the pi n termi nal s at di fferent pl unger posi -
ti ons (Fi g. 6).
NOTE: The switch wire harness must be discon-
nected before testing switch continuity.
SWITCH CIRCUIT IDENTIFICATION
Termi nal s 1 and 2 are for brake sensor ci rcui t.
Termi nal s 5 and 6 are for the stop l amp ci rcui t.
Termi nal s 3 and 4 are for the speed control ci r-
cui t.
SWITCH CONTINUITY TEST
(1) Check conti nui ty between termi nal pi ns 5 and
6 as fol l ows:
(a) Pul l pl unger al l the way out to ful l y extended
posi ti on.
(b) Attach test l eads to pi ns 5 and 6 and note
ohmmeter readi ng.
(c) I f conti nui ty exi sts, proceed to next test.
Repl ace swi tch i f meter i ndi cates l ack of conti nui ty
(shorted or open).
(2) Check conti nui ty between termi nal pi ns 1 and
2 and pi ns 3 and 4 as fol l ows:
(a) Push swi tch pl unger i nward to ful l y
retracted posi ti on.
(b) Attach test l eads to pi ns 1 and 2 and note
ohmmeter readi ng.
(c) I f conti nui ty exi sts, swi tch i s OK. Repl ace
swi tch i f meter i ndi cates l ack of conti nui ty (swi tch
i s open).
RED BRAKE WARNING LAMP
The red brake warni ng l i ght wi l l i l l umi nate under
the fol l owi ng condi ti ons:
2-3 seconds at start-up as part of normal bul b
check.
When parki ng brakes are appl i ed.
Low brake pedal caused by l eak i n front/rear
brake hydraul i c ci rcui t.
I f the red l i ght remai ns on after start-up, fi rst ver-
i fy that the parki ng brakes are ful l y rel eased. Then
check pedal acti on and fl ui d l evel . A red l i ght pl us
l ow pedal i ndi cates the pressure di fferenti al swi tch
and val ve have been actuated due to a system l eak.
On model s wi th ABS brakes, the amber warni ng
l i ght onl y i l l umi nates when an ABS mal functi on has
occurred. The ABS l i ght operates i ndependentl y of
the red warni ng l i ght.
For addi ti on i nformati on refer to Group 8W.
MASTER CYLINDER/POWER BOOSTER
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neu-
tral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away master cyl i nder i s faul ty (i nternal l eak-
age).
(5) Start engi ne and note pedal acti on i t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
Fig. 6 Stop Lamp Switch Terminal Identification
TERMINAL PINS PLUNGER TEST POSITIONS
5 - 8 BRAKES XJ
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and i mmedi atel y stop turn off
i gni ti on to stop engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 7).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm or
check val ve i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 15-20 i nches vacuum at l arge end of
check val ve (Fi g. 8).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss, check val ve i s faul ty and
shoul d be repl aced.
COMBINATION VALVE
PRESSURE DIFFERENTIAL SWITCH
(1) Have hel per si t i n dri vers seat to appl y brake
pedal and observe red brake warni ng l i ght.
(3) Connect bl eed hose to a rear wheel cyl i nder
and i mmerse hose end i n contai ner parti al l y fi l l ed
wi th brake fl ui d.
(4) Have hel per press and hol d brake pedal to fl oor
and observe warni ng l i ght.
(a) I f warni ng l i ght i l l umi nates, swi tch i s operat-
i ng correctl y.
(b) I f l i ght fai l s to i l l umi nate, check ci rcui t fuse,
bul b, and wi ri ng. The parki ng brake swi tch can be
used to ai d i n i denti fyi ng whether or not the brake
l i ght bul b and fuse i s functi onal . Repai r or repl ace
parts as necessary and test di fferenti al pressure
swi tch operati on agai n.
(5) I f warni ng l i ght sti l l does not i l l umi nate,
swi tch i s faul ty. Repl ace combi nati on val ve assembl y,
bl eed brake system and veri fy proper swi tch and
val ve operati on.
REAR PROPORTIONING VALVE
The val ve control s fl ui d fl ow. I f fl ui d enters the
val ve and does not exi t the val ve the combi nati on
val ve must be repl aced.
DISC BRAKE ROTOR
The rotor braki ng surfaces shoul d not be refi ni shed
unl ess necessary.
Li ght surface rust and scal e can be removed wi th a
l athe equi pped wi th dual sandi ng di scs. The rotor
surfaces can be restored by machi ni ng i n a di sc brake
l athe i f surface scori ng and wear are l i ght.
Fig. 7 Typical Booster Vacuum Test Connections
TEE FITTINGSHORT CONNECTING HOSE CHECK VALVE CHECK VALVE HOSE CLAMPTOOL INTAKE MANI- FOLD VACUUM GAUGE
Fig. 8 Vacuum Check Valve And Seal
BOOSTER CHECK VALVE APPLY TEST VACUUM HERE VALVE SEAL
XJ BRAKES 5 - 9
Repl ace the rotor under the fol l owi ng condi ti ons:
severel y scored
tapered
hard spots
cracked
bel ow mi ni mum thi ckness
ROTOR MINIMUM THICKNESS
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f machi ni ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
Rotor mi ni mum thi ckness i s usual l y speci fi ed on
the rotor hub. The speci fi cati on i s ei ther stamped or
cast i nto the hub surface.
ROTOR RUNOUT
Check rotor l ateral runout wi th di al i ndi cator
C-3339 (Fi g. 9). Excessi ve l ateral runout wi l l cause
brake pedal pul sati on and rapi d, uneven wear of the
brake shoes. Posi ti on the di al i ndi cator pl unger
approxi matel y 25.4 mm (1 i n.) i nward from the rotor
edge.
NOTE: Be sure wheel bearing has zero end play
before checking rotor runout.
Maxi mum al l owabl e rotor runout i s 0.102 mm
(0.004 i n.).
ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at 6 to 12 poi nts around
the rotor face (Fi g. 10).
Posi ti on the mi crometer approxi matel y 25.4 mm (1
i n.) from the rotor outer ci rcumference for each mea-
surement.
Thi ckness shoul d not vary by more than 0.013 mm
(0.0005 i n.) from poi nt-to-poi nt on the rotor. Machi ne
or repl ace the rotor i f necessary.
BRAKE DRUM
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s stamped or cast i nto the drum
outer edge. General l y, a drum can be machi ned to a
maxi mum of 1.52 mm (0.060 i n.) oversi ze. Al ways
repl ace the drum i f machi ni ng woul d cause drum
di ameter to exceed the si ze l i mi t i ndi cated on the
drum.
BRAKE DRUM RUNOUT
Measure drum di ameter and runout wi th an accu-
rate gauge. The most accurate method of measure-
ment i nvol ves mounti ng the drum i n a brake l athe
and checki ng vari ati on and runout wi th a di al i ndi -
cator.
Vari ati ons i n drum di ameter shoul d not exceed
0.076 mm (0.003 i n.). Drum runout shoul d not exceed
0.20 mm (0.008 i n.) out of round. Machi ne the drum
i f runout or vari ati on exceed these val ues. Repl ace
the drum i f machi ni ng causes the drum to exceed the
maxi mum al l owabl e di ameter.
BRAKE LINE AND HOSES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. I nspect the hoses
whenever the brake system i s servi ced, at every
engi ne oi l change, or whenever the vehi cl e i s i n for
servi ce.
I nspect the hoses for surface cracki ng, scuffi ng, or
worn spots. Repl ace any brake hose i mmedi atel y i f
Fig. 9 Checking Rotor Runout And Thickness
Variation
DIAL INDICATOR
Fig. 10 Measuring Rotor Thickness
MICROMETER TAKE MINIMUM OF 6 MEASUREMENTS AROUND ROTOR ROTOR
5 - 10 BRAKES XJ
the fabri c casi ng of the hose i s exposed due to cracks
or abrasi ons.
Al so check brake hose i nstal l ati on. Faul ty i nstal l a-
ti on can resul t i n ki nked, twi sted hoses, or contact
wi th the wheel s and ti res or other chassi s compo-
nents. Al l of these condi ti ons can l ead to scuffi ng,
cracki ng and eventual fai l ure.
The steel brake l i nes shoul d be i nspected peri odi -
cal l y for evi dence of corrosi on, twi sts, ki nks, l eaks, or
other damage. Heavi l y corroded l i nes wi l l eventual l y
rust through causi ng l eaks. I n any case, corroded or
damaged brake l i nes shoul d be repl aced.
Factory repl acement brake l i nes and hoses are rec-
ommended to ensure qual i ty, correct l ength and supe-
ri or fati gue l i fe. Care shoul d be taken to make sure
that brake l i ne and hose mati ng surfaces are cl ean
and free from ni cks and burrs. Al so remember that
ri ght and l eft brake hoses are not i nterchangeabl e.
Use new copper seal washers at al l cal i per connec-
ti ons. Be sure brake l i ne connecti ons are properl y
made (not cross threaded) and ti ghtened to recom-
mended torque.
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
SERVICE PROCEDURES
BRAKE FLUID LEVEL
Al ways cl ean the master cyl i nder reservoi r and cap
before addi ng fl ui d. Thi s wi l l prevent di rt from fal l -
i ng i n the reservoi r and contami nati ng the brake
fl ui d.
The reservoi r has a ADD and a FULL mark on the
si de (Fi g. 11) fi l l to the FULL mark.
MASTER CYLINDER BLEEDING
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
BLEEDING PROCEDURE
(1) Mount master cyl i nder i n vi se.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i n the reservoi r fl ui d
compartment (Fi g. 12).
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n the fl ui d reser-
voi r.
BRAKE BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
Fig. 11 Master Cylinder Fluid Level
FLUID LEVEL MARKS RESERVOIR
Fig. 12 Master Cylinder Bleeding
BLEEDING TUBES RESERVOIR
XJ BRAKES 5 - 11
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Bl eed onl y one brake component at a ti me. Recom-
mended bl eed sequence i s:
master cyl i nder
combi nati on val ve
ri ght rear wheel
l eft rear wheel
ri ght front wheel
l eft front wheel
MANUAL BLEEDING
(1) Remove reservoi r fi l l er caps and fi l l reservoi r
wi th Mopar, or equi val ent qual i ty DOT 3 brake fl ui d.
(2) I f cal i pers, or wheel cyl i nders were overhaul ed,
open al l cal i per and wheel cyl i nder bl eed screws.
Then cl ose each bl eed screw as fl ui d starts to dri p
from i t. Top off master cyl i nder reservoi r once more
before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
fi l l ed wi th brake fl ui d (Fi g. 13). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
PRESSURE BLEEDING
I f pressure bl eedi ng equi pment wi l l be used, the
front brake meteri ng val ve wi l l have to be hel d open
to bl eed the front brakes. The val ve stem i s l ocated
i n the forward end of the combi nati on val ve. The
stem must ei ther be pressed i nward, or hel d outward
sl i ghtl y. a spri ng cl i p tool or hel per i s needed to hol d
the val ve stem i n posi ti on.
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 15-20 psi i s suffi ci ent for
bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system.
DISC ROTOR MACHINING
Rotor braki ng surfaces can be sanded or machi ned
i n a di sc brake l athe.
The l athe must machi ne both si des of the rotor
si mul taneousl y wi th dual (two) cutter heads (Fi g.
14). Equi pment capabl e of machi ni ng onl y one si de at
a ti me wi l l produce a tapered rotor.
The l athe shoul d al so be equi pped wi th a gri nder
attachment or dual sandi ng di scs for fi nal cl eanup or
l i ght refi ni shi ng (Fi g. 15).
I f the rotor surfaces onl y need mi nor cl eanup of
rust, scal e, or mi nor scori ng, use abrasi ve di scs to
cl ean up the rotor surfaces. However, when a rotor i s
scored or worn, machi ni ng wi th cutti ng tool s wi l l be
requi red.
CAUTION: Do not machine the rotor if it will cause
the rotor to fall below minimum allowable thick-
ness.
BRAKE DRUM MACHINING
The brake drums can be machi ned on a drum l athe
when necessary. I ni ti al machi ni ng cuts shoul d be l i m-
i ted to 0.12 - 0.20 mm (0.005 - 0.008 i n.) at a ti me as
heavi er feed rates can produce taper and surface
vari ati on. Fi nal fi ni sh cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 i n.) are recommended and wi l l gen-
eral l y provi de the best surface fi ni sh.
Be sure the drum i s securel y mounted i n the l athe
before machi ni ng operati ons. A damper strap shoul d
al ways be used around the drum to reduce vi brati on
and avoi d chatter marks.
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s stamped or cast i nto the drum
outer edge. Al ways repl ace the drum i f machi ni ng
woul d cause drum di ameter to exceed the si ze l i mi t
i ndi cated on the drum.
BRAKE LINE
Mopar preformed metal brake l i ne i s recommended
and preferred for al l repai rs. However, doubl e-wal l
Fig. 13 Bleed Hose Setup
BLEED HOSE FLUID CON- TAINER PAR- TIALLY FILLED WITH FLUID
5 - 12 BRAKES XJ
steel l i ne can be used for emergency repai r when fac-
tory repl acement parts are not readi l y avai l abl e.
Speci al , heavy duty tube bendi ng and fl ari ng
equi pment i s requi red to prepare doubl e wal l brake
l i ne. Speci al bendi ng tool s are needed to avoi d ki nk-
i ng or twi sti ng metal brake l i ne. I n addi ti on, speci al
fl ari ng tool s are needed to provi de the i nverted-type,
doubl e fl are requi red on metal brake l i nes.
FLARING PROCEDURE
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
(3) I nstal l repl acement tube nut on secti on of tube
to be repai red.
(4) I nsert tube i n fl ari ng tool . Center tube i n area
between verti cal posts.
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Squeeze fl ari ng tool jaws to l ock tubi ng i n
pl ace.
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 16).
(9) Ti ghten tool handl e unti l pl ug gauge i s seated
on jaws of fl ari ng tool . Thi s wi l l start the i nverted
fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
(11) Remove the fl ari ng tool s and veri fy that the
i nverted fl are i s correct.
STOP LAMP SWITCH
REMOVAL
(1) Remove steeri ng col umn cover and l ower tri m
panel for swi tch access (i f necessary).
(2) Press brake pedal downward to ful l y appl i ed
posi ti on.
Fig. 14 Rotor Refinishing
BRAKING DISC DAMPER CUTTING TOOLS
Fig. 15 Rotor Grinder
BRAKING DISC GRINDER
Fig. 16 Inverted Flare Tools
XJ BRAKES 5 - 13
(3) Rotate swi tch approxi matel y 30 i n counter-
cl ockwi se di recti on to unl ock swi tch retai ner. Then
pul l swi tch rearward and out of bracket.
(4) Di sconnect swi tch wi re harness and remove
swi tch from vehi cl e (Fi g. 17).
INSTALLATION
(1) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(2) Connect harness wi res to swi tch.
(3) Press and hol d brake pedal i n appl i ed posi ti on.
(4) I nstal l swi tch as fol l ows: Al i gn tab on swi tch
wi th notch i n swi tch bracket. Then i nsert swi tch i n
bracket and turn i t cl ockwi se about 30 to l ock i t i n
pl ace.
(5) Rel ease brake pedal . Then pul l pedal ful l y rear-
ward. Pedal wi l l set pl unger to correct posi ti on as
pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make ratcheti ng sound as i t sel f adjusts.
BRAKE PEDAL
REMOVAL
(1) Remove knee bl ocker under the steeri ng col -
umn.
(2) Remove retai ner cl i p securi ng booster push rod
to pedal (Fi g. 18).
(3) Remove stop l amp swi tch.
(4) Remove nuts securi ng the booster to the pedal
support bracket and nuts to the col umn bracket.
(5) Remove pedal and support bracket as an
assembl y from the vehi cl e.
INSTALLATION
(1) I nstal l pedal and support bracket as an assem-
bl y i nto the vehi cl e.
(2) I nstal l nuts securi ng the booster to the pedal
support bracket and nuts to the col umn bracket.
(3) Ti ghten nuts to 39 Nm (29 ft. l bs.).
(4) I nstal l booster push rod on pedal pi n and
i nstal l new retai ner cl i p.
(5) I nstal l knee bl ocker.
COMBINATION VALVE
NOTE: The combination valve is not repairable. The
valve is serviced as an assembly only.
REMOVAL
(1) Remove ai r cl eaner cover and hose for access to
val ve.
(2) Unsnap connector l ock tabs and di sconnect di f-
ferenti al pressure swi tch wi re at combi nati on val ve
(Fi g. 19). Do not pul l swi tch wi re to di sconnect.
Fig. 17 Stop Lamp Switch
RETAINER TERMINALS SWITCHPLUNGER
Fig. 18 Booster Push Rod
BRAKEPEDAL BOOSTERROD BUSHING
Fig. 19 Differential Pressure Switch
SWITCH TERMI- NAL COMBINATION VALVE WIRE HARNESS CON- NECTOR
5 - 14 BRAKES XJ
(3) Di sconnect brake l i nes at combi nati on val ve
(Fi g. 20).
(4) Remove mounti ng nut and remove val ve.
INSTALLATION
(1) I nstal l val ve and ti ghten mounti ng nut to 17
Nm (155 i n. l bs.).
(2) Connect brake l i nes to repl acement val ve. Start
l i ne fi tti ngs by hand to avoi d cross threadi ng.
(3) Ti ghten brake l i ne fi tti ngs to 19 Nm (170 i n.
l bs.).
(4) Connect wi re to pressure di fferenti al swi tch.
(5) Bl eed brakes.
MASTER CYLINDER
REMOVAL
(1) On RHD vehi cl es remove the cool ant reserve/
overfl ow tank. Refer to Group 7 Cool i ng System.
(2) Remove brake l i nes at master cyl i nder and
combi nati on val ve (Fi g. 20).
(3) Di sconnect di fferenti al pressure swi tch wi re
from the combi nati on val ve.
(4) Remove mounti ng nuts from the combi nati on
val ve bracket and remove the val ve (Fi g. 20).
(5) Remove mounti ng nuts from the master cyl i n-
der.
(6) Remove master cyl i nder.
(7) Remove cyl i nder cover and drai n fl ui d.
(8) I f master cyl i nder reservoi r requi res servi ce,
refer to reservoi r repl acement procedure i n thi s sec-
ti on.
INSTALLATION
NOTE: Bleed master cylinder on bench before
installation.
(1) Remove protecti ve sl eeve from pri mary pi ston
shank on new master cyl i nder.
(2) Cl ean cyl i nder mounti ng surface of brake
booster.
(3) I nstal l master cyl i nder onto brake booster
studs.
(4) I nstal l mounti ng nuts and ti ghten to 17.5 Nm
(155 i n. l bs.).
(5) I nstal l combi nati on val ve and i nstal l mounti ng
nuts.
(6) Connect brake l i nes to master cyl i nder and
combi nati on val ve and ti ghten to 19 Nm (170 i n.
l bs.).
(7) Connect di fferenti al pressure swi tch wi re to the
combi nati on val ve.
(8) On RHD vehi cl es i nstal l the cool ant reserve/
(9) Fi l l and bl eed brake system.
POWER BRAKE BOOSTER
REMOVAL
(1) On RHD vehi cl es remove the cool ant reserve/
(2) Di sconnect brake l i nes at master cyl i nder.
(3) Di sconnect wi re at combi nati on val ve di fferen-
ti al pressure swi tch.
(4) Remove nut mounti ng combi nati on val ve
bracket to booster studs and remove val ve.
(5) Remove nuts mounti ng master cyl i nder to
booster studs and remove cyl i nder.
(6) Di sconnect vacuum hose from booster check
val ve.
(7) Remove knee bl ocker under the steeri ng col -
umn.
(8) Remove retai ni ng cl i p that secures booster
push rod to brake pedal (Fi g. 21).
(9) Remove nuts attachi ng booster to passenger
compartment si de of dash panel (Fi g. 22).
Fig. 20 Combination Valve
COMBINATION VALVE MASTER CYLINDER
Fig. 21 Booster Push Rod
BRAKEPEDAL BOOSTERROD BUSHING
XJ BRAKES 5 - 15
(10) I n engi ne compartment, sl i de booster studs
out of dash panel , ti l t booster upward, and remove
booster from engi ne compartment.
(11) Remove dash seal from booster.
INSTALLATION
(1) I nstal l dash seal on booster.
(2) Al i gn and posi ti on booster on dash panel .
(3) I n passenger compartment, i nstal l booster
mounti ng nuts. Ti ghten nuts just enough to hol d
booster i n pl ace.
(4) Sl i de booster push rod onto the brake pedal .
Then secure push rod to pedal pi n wi th retai ni ng
cl i p.
NOTE: Lubricate the pedal pin and bushing with
Mopar multi-mileage grease before installation.
(5) Ti ghten booster mounti ng nuts to 39 Nm (29
ft. l bs.).
(6) I nstal l the knee bl ocker.
(7) I f ori gi nal master cyl i nder i s bei ng i nstal l ed,
check condi ti on of seal at rear of master cyl i nder.
Repl ace seal i f cut, or torn.
(8) Cl ean cyl i nder mounti ng surface of brake
booster. Use shop towel wetted wi th brake cl eaner for
thi s purpose. Di rt, grease, or si mi l ar materi al s wi l l
prevent proper cyl i nder seati ng and coul d resul t i n
vacuum l eak.
(9) Al i gn and i nstal l master cyl i nder on booster
studs. I nstal l mounti ng nuts and ti ghten to 17.5 Nm
(155 i n. l bs.).
(10) Connect vacuum hose to booster check val ve.
(11) Connect and secure brake l i nes to combi nati on
val ve and master cyl i nder. Start al l brake l i ne fi t-
ti ngs by hand to avoi d cross threadi ng.
(12) I nstal l combi nati on val ve on booster studs.
Ti ghten bracket mounti ng nuts to 17.5 Nm (155 i n.
l bs.).
(13) Connect wi re to combi nati on val ve swi tch.
(14) On RHD vehi cl es i nstal l the cool ant reserve/
(15) Fi l l and bl eed brake system.
(16) Veri fy proper brake operati on before movi ng
vehi cl e.
DISC BRAKE CALIPER
REMOVAL
(2) Remove front wheel and ti re assembl y.
(3) Drai n smal l amount of fl ui d from master cyl i n-
der brake reservoi r wi th sucti on gun.
(4) Bottom cal i per pi ston i n bore wi th C-cl amp.
Posi ti on cl amp screw on outboard brake shoe and
cl amp frame on rear of cal i per (Fi g. 23). Do not
allow clamp screw to bear directly on outboard
shoe retainer spring. Use wood or metal spacer
between shoe and clamp screw.
(5) Remove brake hose mounti ng bol t and di scard
washers (Fi g. 24).
(6) Remove cal i per mounti ng bol ts (Fi g. 25).
(7) Ti l t top of cal i per outward wi th pry tool i f nec-
essary (Fi g. 26) and remove cal i per.
(8) Remove cal i per from vehi cl e.
INSTALLATION
(1) Cl ean brake shoe mounti ng l edges wi th wi re
brush and appl y l i ght coat of Mopar mul ti -mi l eage
grease to surfaces (Fi g. 27).
(2) Connect brake hose to cal i per wi th new
washer on both si des of hose fi tti ng. Do not ti ghten
fi tti ng bol t compl etel y at thi s ti me.
(3) I nstal l cal i per by posi ti on notches at l ower end
of brake shoes on bottom mounti ng l edge. Then
rotate cal i per over rotor and seat notches at upper
end of shoes on top mounti ng l edge (Fi g. 28).
Fig. 22 Booster Mounting
BOOSTER
Fig. 23 Bottoming Caliper Piston With C-Clamp
CALIPER BOSS OUTBOARD BRAKESHOE C-CLAMP
5 - 16 BRAKES XJ
(4) Coat cal i per mounti ng bol ts wi th si l i cone
grease. Then i nstal l and ti ghten bol ts to 15 Nm (11
ft. l bs.).
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. Bolts must not have a shank length greater
than 67.6 mm (2.66 in.) (Fig. 29).
(5) Ti ghten brake hose fi tti ng bol t to 31 Nm (23 ft.
l bs.).
CAUTION: Insure the brake hose is not twisted or
kinked and clear of all steering and suspension
components.
(6) I nstal l wheel and ti re assembl y.
(8) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated.
(9) Fi l l master cyl i nder and bl eed brake system.
DISC BRAKE SHOES
REMOVAL
(3) Remove cal i per.
(4) Pressi ng one end of outboard shoe i nward to
di sengage shoe l ug. Then rotate shoe upward unti l
retai ner spri ng cl ears cal i per. Press opposi te end of
shoe i nward to di sengage shoe l ug and rotate shoe up
and out of cal i per (Fi g. 30).
(5) Grasp ends of i nboard shoe and ti l t shoe out-
ward to rel ease spri ngs from cal i per pi ston (Fi g. 31)
and remove shoe from cal i per.
Fig. 24 Brake Hose And Bolt
FITTING WASHERS CALIPERS
Fig. 25 Caliper Mounting Bolts
CALIPER MOUNTER BOLT (2) CALIPER
Fig. 26 Caliper Removal
TILT CALIPER OUTBOARD TO REMOVE
Fig. 27 Caliper Lubrication Points
BUSHINGS
CALIPER
MOUNTING
BOLTS
MOUNTING LEDGES
XJ BRAKES 5 - 17
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter-
changeable.
(6) Secure cal i per to nearby suspensi on part wi th
wi re. Do not allow brake hose to support caliper
weight.
(7) Wi pe cal i per off wi th shop rags or towel s.
CAUTION: Do not use compressed air, this can
unseat dust boot and force dirt into piston bore.
INSTALLATION
(1) I nstal l i nboard shoe i n cal i per and veri fy shoe
retai ni ng i s ful l y seated i nto the pi ston.
(2) Starti ng one end of outboard shoe i n cal i per
and rotati ng shoe downward i nto pl ace. Veri fy shoe
l ocati ng l ugs and shoe spri ng are seated.
(3) I nstal l cal i per.
(6) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated.
(7) Top off brake fl ui d l evel i f necessary.
DISC BRAKE ROTOR
REMOVAL
(1) Remove wheel and ti re assembl e.
(2) Remove cal i per.
(3) Remove retai ners securi ng rotor to hub studs
(Fi g. 32).
(4) Remove rotor from hub.
(5) I f rotor shi el d requi res servi ce, remove front
hub and beari ng assembl y.
Fig. 28 Caliper Installation
TOP LEDGE BRAKESHOE TAB ON LEDGE OUTER SURFACE LEDGE SEATED IN BRAKESHOE NOTCH BOTTOMLEDGE
Fig. 29 Mounting Bolt Dimensions
CORRECT SHANK LENGTH: 67 mm ( 0.6 mm) 2.637 in. ( 0.0236 in.) 22 mm (0.866 in.) THREADLENGTH CALIPER BOLT
Fig. 30 Outboard Brake Shoe Removal
OUTBOARD BRAKESHOE SHOE SPRING LOCATING LUG CALIPER LOCATING LUG
Fig. 31 Inboard Brake Shoe Removal
CALIPER PISTON SHOE SPRINGS INBOARD BRAKE- SHOE
5 - 18 BRAKES XJ
INSTALLATION
(1) I f new rotor i s bei ng i nstal l ed, remove protec-
ti ve coati ng from rotor surfaces wi th carburetor
cl eaner.
(2) I nstal l rotor on hub.
(3) I nstal l cal i per.
(4) I nstal l new spri ng nuts on wheel studs.
DRUM BRAKE SHOES
REMOVAL
(1) Rai se vehi cl e and remove rear wheel s.
(2) Remove and di scard spri ng nuts securi ng
drums to wheel studs.
(3) Remove brake drums. I f drums prove di ffi cul t
to remove, retract brake shoes. Remove access pl ug
at the rear of backi ng pl ate and back off adjuster
screw wi th brake tool and screwdri ver.
(4) Remove U-cl i p and washer securi ng adjuster
cabl e to parki ng brake l ever (Fi g. 33).
(5) Remove pri mary and secondary return spri ngs
from anchor pi n wi th brake spri ng pl i ers.
(6) Remove hol d-down spri ngs, retai ners and pi ns
wi th standard retai ni ng spri ng tool .
(7) I nstal l spri ng cl amps on wheel cyl i nders to
hol d pi stons i n pl ace.
(8) Remove adjuster l ever, adjuster screw and
spri ng.
(9) Remove adjuster cabl e and cabl e gui de.
(10) Remove brake shoes and parki ng brake strut.
(11) Di sconnect cabl e from parki ng brake l ever and
remove l ever.
INSTALLATION
(1) Cl ean support pl ate wi th brake cl eaner.
(2) I f new drums are bei ng i nstal l ed, remove pro-
tecti ve coati ng wi th carburetor cl eaner fol l owed by
fi nal ri nse wi th brake cl eaner.
(3) Cl ean and l ubri cate anchor pi n wi th l i ght coat
of Mopar mul ti -mi l eage grease.
(4) Appl y Mopar mul ti -mi l eage grease to brake
shoe contact surfaces of support pl ate (Fi g. 34).
(5) Lubri cate adjuster screw threads and pi vot
wi th spray l ube.
(6) Attach parki ng brake l ever to secondary brake
shoe. Use new washer and U-cl i p to secure l ever.
(7) Remove wheel cyl i nder cl amps.
(8) Attach parki ng brake cabl e to l ever.
Fig. 33 Drum Brake ComponentsTypical
RIGHT REAR BRAKE ASSEMBLY ADJUSTER LEVER ADJUSTER CABLE HOLDDOWN SPRING AND RETAINERS ADJUSTER LEVERSPRING TRAILING SHOE CYLINDER-TO- SUPPORT SEAL HOLDDOWN PINS ACCESS PLUGS SUPPORT PLATE CABLE HOLE PLUG PARK BRAKE STRUT AND SPRING ADJUSTER SCREW ASSEMBLY HOLDDOWN SPRING AND RETAINERS LEADING SHOE CABLE GUIDE SHOE RETURN SPRINGS SHOE GUIDE PLATE PIN SHOESPRING PARK BRAKE LEVER
Fig. 32 Rotor & Hub
ROTOR RETAINER BEARING NUT NUT LOCK COTTER PIN WASHER
XJ BRAKES 5 - 19
(9) I nstal l brake shoes on support pl ate. Secure
shoes wi th new hol d-down spri ngs, pi ns and retai n-
ers.
(10) I nstal l parki ng brake strut and spri ng.
(11) I nstal l gui de pl ate and adjuster cabl e on
anchor pi n.
(12) I nstal l pri mary and secondary return spri ngs.
(13) I nstal l adjuster cabl e gui de on secondary
shoe.
(14) Lubri cate and assembl e adjuster screw.
(15) I nstal l adjuster screw, spri ng and l ever and
connect to adjuster cabl e.
(16) Adjust shoes to drum.
(17) I nstal l wheel /ti re assembl i es and l ower vehi -
cl e.
(18) Veri fy fi rm brake pedal before movi ng vehi cl e.
WHEEL CYLINDER
REMOVAL
(2) Remove brake drum.
(3) Di sconnect wheel cyl i nder brake l i ne.
(4) Remove brake shoe return spri ngs and move
shoes out of engagement wi th cyl i nder push rods.
(5) Remove cyl i nder attachi ng bol ts and remove
cyl i nder from support pl ate.
INSTALLATION
(1) Appl y bead of si l i cone seal er around cyl i nder
mounti ng surface of support pl ate.
(2) I nstal l cyl i nder mounti ng bol ts and ti ghten to
correct torque.
(3) Connect brake l i ne to cyl i nder.
(4) I nstal l brake shoe return spri ng.
(5) I nstal l brake drum.
(7) Bl eed brake system.
BRAKE SUPPORT PLATE
REMOVAL
(1) Remove wheel and ti re assembl y and brake
drum.
(2) Remove brake shoe assembl y.
(3) Remove parki ng brake cabl e from parki ng
brake l ever.
(4) Compress parki ng brake cabl e retai ner tabs
wi th a hose cl amp (Fi g. 35). Then push retai ner and
cabl e through and out of support pl ate.
(5) Di sconnect brake l i ne at wheel cyl i nder.
(6) Remove wheel cyl i nder from support pl ate.
(7) Remove axl e shaft, refer to Group 3 for proce-
dures.
(8) Remove bol ts attachi ng support pl ate to axl e
and remove support pl ate.
INSTALLATION
(1) Appl y bead of si l i cone seal er around axl e
mounti ng surface of support pl ate.
(2) I nstal l support pl ate on axl e fl ange. Ti ghten
attachi ng bol ts to 47-81 Nm (35-60 ft. l bs.).
(3) Appl y bead of si l i cone seal er around wheel cyl -
i nder mounti ng surface and i nstal l wheel cyl i nder.
(4) I nstal l brake l i ne i n wheel cyl i nder.
(5) I nstal l parki ng brake cabl e i n support pl ate.
(6) I nstal l axl e shaft, refer to Group 3 for proce-
dure.
(7) Connect parki ng brake cabl e to l ever on sec-
ondary shoe and i nstal l brake shoes on support pl ate.
(8) Adjust brake shoes to drum wi th brake gauge.
(9) I nstal l brake drum and wheel and ti re assem-
bl y.
(10) Bl eed brake system.
Fig. 34 Shoe Contact Surfaces
ANCHOR PIN SUPPORT PLATE SHOE CONTACT SURFACES
Fig. 35 Parking Brake Cable Removal
CABLE ASSEMBLY CABLE RETAINER AIRCRAFT TYPE HOSE CLAMP
5 - 20 BRAKES XJ
REAR PARKING BRAKE CABLES
REMOVAL
(1) Rai se vehi cl e and l oosen equal i zer nuts unti l
rear cabl es are sl ack.
(2) Di sengage cabl es from equal i zer and compress
cabl e retai ners wi th a worm dri ve hose cl amp.
(3) Remove cabl es from the cabl e bracket (Fi g. 36).
(4) Remove rear wheel and brake drums.
(5) Remove secondary brake shoe and di sconnect
cabl e from l ever on brake shoe.
(6) Compress cabl es retai ner wi th worm dri ve hose
cl amp (Fi g. 37) and remove cabl es from backi ng
pl ates.
INSTALLATION
(1) I nstal l new cabl es i n backi ng pl ates. Be sure
cabl e retai ner i s seated.
(2) Attach cabl e to l ever on brake shoe and i nstal l
brake shoe on backi ng pl ate.
(3) Adjust brake shoes to drum wi th brake gauge.
(4) I nstal l brake drums and wheel s.
(5) I nstal l cabl es i nto the cabl e bracket and i nsure
retai ners are seated i n the bracket.
(6) Engage the cabl e ends i nto the equal i zer and
i nstal l equal i zer nut.
(7) Adjust parki ng brakes.
PARKING BRAKE LEVER
The center consol e must be removed to servi ce the
parki ng brake l ever. Refer to Group 23 I nteri or Com-
ponents for servi ce procedures.
REMOVAL
(1) Rel ease parki ng brakes.
(3) Remove adjusti ng nut from tensi oner rod at the
equal i zer (Fi g. 38).
(5) Di sengage front cabl e from the cabl e l ever.
(6) Compress cabl e retai ner wi th worm dri ve hose
cl amp and remove the cabl e from the parki ng brake
l ever base.
(7) Di sconnect parki ng brake l amp swi tch wi re
(Fi g. 39).
(8) Remove parki ng brake l ever assembl y mount-
i ng bol ts (Fi g. 39).
(9) Remove l ever assembl y.
(10) Remove parki ng brake l amp swi tch.
INSTALLATION
(1) I nstal l parki ng brake l amp swi tch.
(2) Posi ti on l ever assembl y on fl oorpan and i nstal l
l ever mounti ng bol ts.
Fig. 36 Parking Brake Cables
Fig. 37 Cable Retainer
CABLE RETAINER REAR CABLE WORM DRIVE HOSE CLAMP
Fig. 38 Parking Brake Equalizer
XJ BRAKES 5 - 21
(3) I nsert front cabl e through the parki ng brake
l ever base. I nsure the cabl e retai ner i s seated i nto
the base.
(4) Attach the front cabl e to the cabl e l ever (Fi g.
39).
(5) Connect parki ng brake l amp swi tch wi re.
(7) I nstal l adjusti ng nut to the tensi oner rod and
adjust parki ng brakes.
(9) Veri fy correct parki ng brake operati on.
MASTER CYLINDER RESERVOIR
REMOVAL
(1) Remove reservoi r cap and empty fl ui d i nto
drai n contai ner.
(2) Remove pi ns that retai n reservoi r to master
cyl i nder. Use hammer and pi n punch to remove pi ns
(Fi g. 40).
(3) Cl amp cyl i nder body i n vi se wi th brass protec-
ti ve jaws.
(4) Loosen reservoi r from grommets wi th pry tool
(Fi g. 41).
(5) Remove reservoi r by rocki ng i t to one si de and
pul l i ng free of grommets (Fi g. 42).
(6) Remove ol d grommets from cyl i nder body (Fi g.
43).
INSTALLATION
CAUTION: Do not use any type of tool to install
the grommets. Tools may cut, or tear the grommets
creating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubri cate new grommets wi th cl ean brake fl ui d
and I nstal l new grommets i n cyl i nder body (Fi g. 44).
Use fi nger pressure to i nstal l and seat grommets.
(2) Start reservoi r i n grommets. Then rock reser-
voi r back and forth whi l e pressi ng downward to seat
i t i n grommets.
(3) I nstal l pi ns that retai n reservoi r to cyl i nder
body.
Fig. 39 Parking Brake Lever Assembly
MOUNTING BOLTS FRONT CABLE LEVER PARKING BRAKE SWITCH PARKING BRAKE LEVER
Fig. 40 Reservoir Retaining Pins
PIN PUNCH RESERVOIR BODY ROLL PINS
Fig. 41 Loosening Reservoir
PRY TOOL RESERVOIR GROMMET MASTER CYLINDER BODY
Fig. 42 Reservoir Removal
RESERVOIR GROMMETS
5 - 22 BRAKES XJ
(4) Fi l l and bl eed master cyl i nder on bench before
i nstal l ati on i n vehi cl e.
DISC BRAKE CALIPER
DISASSEMBLY
(1) Remove brake shoes from cal i per.
(2) Drai n brake fl ui d out of cal i per.
(3) Pad i nteri or of cal i per wi th mi ni mum, 2.54 cm
(1 i n.) thi ckness of shop towel s or rags (Fi g. 45). Tow-
el s are needed to protect cal i per pi ston duri ng
removal .
(4) Remove cal i per pi ston wi th short bursts of
l ow pressure compressed ai r. Di rect ai r through fl ui d
i nl et port and ease pi ston out of bore (Fi g. 46).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
(5) Remove cal i per pi ston dust boot wi th sui tabl e
tool (Fi g. 47) and di scard boot.
(6) Remove cal i per pi ston seal wi th wood or pl asti c
tool (Fi g. 48) and di scard seal . Do not use metal tool s
as they wi l l scratch pi ston bore.
(7) Remove cal i per mounti ng bol t bushi ngs and
boots (Fi g. 49).
ASSEMBLY
(1) Coat cal i per pi ston bore, new pi ston seal and
pi ston wi th cl ean brake fl ui d.
(2) Lubri cate cal i per bushi ngs and i nteri or of
bushi ng boots wi th si l i cone grease.
(3) I nstal l bushi ng boots i n cal i per, then i nsert
bushi ng i nto boot and push bushi ng i nto pl ace (Fi g.
50).
Fig. 43 Grommet Removal
MASTER CYLINDER BODY GROMMETS
Fig. 44 Grommet Installation
WORK NEW GROMMETS INTO PLACE USING FINGER PRES- SURE ONLY
Fig. 45 Padding Caliper Interior
SHOP TOWELS OR CLOTHS CALIPER
Fig. 46 Caliper Piston Removal
AIR GUN CALIPER PISTON PADDING MATERIAL
XJ BRAKES 5 - 23
(4) I nstal l new pi ston seal i nto seal groove wi th
fi nger (Fi g. 51).
(5) I nstal l dust boot on cal i per pi ston and seat boot
i n pi ston groove (Fi g. 52).
(6) Press pi ston i nto cal i per bore by hand, use a
turn and push moti on to work pi ston i nto seal (Fi g.
53).
(7) Press cal i per pi ston to bottom of bore.
(8) Seat dust boot i n cal i per wi th I nstal l er Tool
C-4842 and Tool Handl e C-4171 (Fi g. 54).
(9) Repl ace cal i per bl eed screw i f removed.
WHEEL CYLINDER
DISASSEMBLY
(1) Remove push rods and boots (Fi g. 55).
(2) Press pi stons, cups and spri ng and expander
out of cyl i nder bore.
(3) Remove bl eed screw.
Fig. 47 Caliper Piston Dust Boot Removal
COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER PISTON DUSTBOOT
Fig. 48 Piston Seal Removal
REMOVE SEAL WITH WOOD PEN- CIL OR SIM- ILAR TOOL
PISTON SEAL
Fig. 49 Mounting Bolt Bushing And Boot
CALIPER SLIDE BUSH- ING BOOT
Fig. 50 Bushings And Boots Installation
BUSHING BOOT
Fig. 51 Piston Seal Installation
SEAL GROOVE PISTON SEAL
Fig. 52 Dust Boot On Piston
PIS- TION DUST BOOT
5 - 24 BRAKES XJ
ASSEMBLY
(1) Lubri cate wheel cyl i nder bore, pi stons, pi ston
cups and spri ng and expander wi th cl ean brake fl ui d.
(2) I nstal l fi rst pi ston i n cyl i nder bore. Then
i nstal l fi rst cup i n bore and agai nst pi ston. Be sure
lip of piston cup is facing inward (toward
spring and expander) and flat side is against
piston.
(3) I nstal l spri ng and expander fol l owed by
remai ni ng pi ston cup and pi ston.
(4) I nstal l boots on each end of cyl i nder and i nsert
push rods i n boots.
(5) I nstal l cyl i nder bl eed screw.
CALIPER
CLEANING
Cl ean the cal i per components wi th cl ean brake
fl ui d or brake cl ean onl y. Wi pe the cal i per and pi ston
dry wi th l i nt free towel s or use l ow pressure com-
pressed ai r.
CAUTION: Do not use gasoline, kerosene, thinner,
or similar solvents. These products may leave a
residue that could damage the piston and seal.
INSPECTION
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
The pi ston must be repl aced i f cracked or scored.
Do not attempt to restore a scored pi ston surface by
sandi ng or pol i shi ng.
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly pol i shed wi th a brake
hone to remove very mi nor surface i mperfecti ons
(Fi g. 56). The cal i per shoul d be repl aced i f the bore i s
severel y corroded, rusted, scored, or i f pol i shi ng
woul d i ncrease bore di ameter more than 0.025 mm
(0.001 i nch).
REAR DRUM BRAKE
CLEANING
Cl ean the i ndi vi dual brake components, i ncl udi ng
the support pl ate and wheel cyl i nder exteri or, wi th a
water dampened cl oth or wi th brake cl eaner. Do not
use any other cl eani ng agents. Remove l i ght rust and
Fig. 53 Caliper Piston Installation
PISTON BOOT
Fig. 54 Piston Dust Boot Installation
HANDLE C-4171 INSTALLERC-4842 DUST BOOT
Fig. 55 Wheel Cylinder ComponentsTypical
SPRING CYLINDER PISTON CLIP BOOT PUSH ROD PISTON BLEED SCREW CUP EXPAND- ERS
XJ BRAKES 5 - 25
scal e from the brake shoe contact pads on the sup-
port pl ate wi th fi ne sandpaper.
INSPECTION
As a general rul e, ri veted brake shoes shoul d be
repl aced when worn to wi thi n 0.78 mm (1/32 i n.) of
the ri vet heads. Bonded l i ni ng shoul d be repl aced
when worn to a thi ckness of 1.6 mm (1/16 i n.).
Exami ne the l i ni ng contact pattern to determi ne i f
the shoes are bent or the drum i s tapered. The l i ni ng
shoul d exhi bi t contact across i ts enti re wi dth. Shoes
exhi bi ti ng contact onl y on one si de shoul d be
repl aced and the drum checked for runout or taper.
I nspect the adjuster screw assembl y. Repl ace the
assembl y i f the star wheel or threads are damaged,
or the components are severel y rusted or corroded.
Di scard the brake spri ngs and retai ner components
i f worn, di storted or col l apsed. Al so repl ace the
spri ngs i f a brake drag condi ti on had occurred. Over-
heati ng wi l l di stort and weaken the spri ngs.
I nspect the brake shoe contact pads on the support
pl ate, repl ace the support pl ate i f any of the pads are
worn or rusted through. Al so repl ace the pl ate i f i t i s
bent or di storted (Fi g. 57).
WHEEL CYLINDER
CLEANING
Cl ean the cyl i nder and pi stons wi th cl ean brake
fl ui d or brake cl eaner onl y. Do not use any other
cl eani ng agents.
Dry the cyl i nder and pi stons wi th compressed ai r.
Do not use rags or shop towel s to dry the cyl i nder
components. Li nt from cl oth materi al wi l l adhere to
the cyl i nder bores and pi stons.
INSPECTION
I nspect the cyl i nder bore. Li ght di scol orati on and
dark stai ns i n the bore are normal and wi l l not
i mpai r cyl i nder operati on.
The cyl i nder bore can be l i ghtl y pol i shed but onl y
wi th crocus cl oth. Repl ace the cyl i nder i f the bore i s
scored, pi tted or heavi l y corroded. Honi ng the bore to
restore the surface i s not recommended.
I nspect the cyl i nder pi stons. The pi ston surfaces
shoul d be smooth and free of scratches, scori ng and
corrosi on. Repl ace the pi stons i f worn, scored, or cor-
roded. Do attempt to restore the surface by sandi ng
or pol i shi ng.
Di scard the ol d pi ston cups and the spri ng and
expander. These parts are not reusabl e. The ori gi nal
dust boots may be reused but onl y i f they are i n good
condi ti on.
ADJ USTMENTS
STOP LAMP SWITCH
(1) Press and hol d brake pedal i n appl i ed posi ti on.
(2) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(3) Rel ease brake pedal . Then pul l pedal ful l y rear-
ward. Pedal wi l l set pl unger to correct posi ti on as
pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make ratcheti ng sound as i t sel f adjusts.
REAR DRUM BRAKE
The rear drum brakes are equi pped wi th a sel f-ad-
justi ng mechani sm. Under normal ci rcumstances, the
onl y ti me adjustment i s requi red i s when the shoes
are repl aced, removed for access to other parts, or
when one or both drums are repl aced.
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
ADJ USTMENT WITH BRAKE GAUGE
(1) Be sure parki ng brakes are ful l y rel eased.
Fig. 56 Polishing Piston Bore
SPECIAL HONE CALIPER PISTON BORE
Fig. 57 Shoe Contact Surfaces
ANCHOR PIN SUPPORT PLATE SHOE CONTACT SURFACES
5 - 26 BRAKES XJ
(2) Rai se rear of vehi cl e and remove wheel s and
brake drums.
(3) Veri fy that l eft and ri ght automati c adjuster
l evers and cabl es are properl y connected.
(4) I nsert brake gauge i n drum. Expand gauge
unti l gauge i nner l egs contact drum braki ng surface.
Then l ock gauge i n posi ti on (Fi g. 58).
(5) Reverse gauge and i nstal l i t on brake shoes.
Posi ti on gauge l egs at shoe centers as shown (Fi g.
59). I f gauge does not fi t (too l oose/too ti ght), adjust
shoes.
(6) Pul l shoe adjuster l ever away from adjuster
screw star wheel .
(7) Turn adjuster screw star wheel (by hand) to
expand or retract brake shoes. Conti nue adjustment
unti l gauge outsi de l egs are l i ght drag-fi t on shoes.
(8) I nstal l brake drums and wheel s and l ower
vehi cl e.
(9) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
ADJ USTMENT WITH ADJ USTING TOOL
(1) Be sure parki ng brake l ever i s ful l y rel eased.
(2) Rai se vehi cl e so rear wheel s can be rotated
freel y.
(3) Remove pl ug from each access hol e i n brake
support pl ates.
(4) Loosen parki ng brake cabl e adjustment nut
unti l there i s sl ack i n front cabl e.
(5) I nsert adjusti ng tool through support pl ate
access hol e and engage tool i n teeth of adjusti ng
screw star wheel (Fi g. 60).
(6) Rotate adjuster screw star wheel (move tool
handl e upward) unti l sl i ght drag can be fel t when
wheel i s rotated.
(7) Push and hol d adjuster l ever away from star
wheel wi th thi n screwdri ver.
(8) Back off adjuster screw star wheel unti l brake
drag i s el i mi nated.
(9) Repeat adjustment at opposi te wheel . Be sure
adjustment i s equal at both wheel s.
(10) I nstal l support pl ate access hol e pl ugs.
(11) Adjust parki ng brake cabl e and l ower vehi cl e.
(12) I nstal l brake drums and wheel s and l ower
vehi cl e.
(13) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
Fig. 58 Adjusting Gauge On Drum
BRAKEGAUGE BRAKE DRUM
Fig. 59 Adjusting Gauge On Brake Shoes
BRAKE GAUGE BRAKE SHOES
Fig. 60 Brake Adjustment
STAR WHEEL LEVER BRAKE SHOEWEB SCREWDRIVER ADJUSTING TOOL ADJUSTER SPRING
XJ BRAKES 5 - 27
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
PARKING BRAKE CABLE TENSIONER
NOTE: Parking brake adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected for service. When adjustment is nec-
essary, perform the following procedure for proper
parking brake operation.
ADJ USTMENT
(2) Back off tensi oner adjusti ng nut to create sl ack
i n cabl es.
(3) Remove rear wheel /ti re assembl i es and remove
brake drums.
(4) Check rear brake shoe adjustment wi th stan-
dard brake gauge. Excessive shoe-to-drum clear-
ance, or worn brake components will result in
faulty parking brake adjustment and operation.
(5) Veri fy that parki ng brake cabl es operate freel y
and are not bi ndi ng, or sei zed. Repl ace faul ty cabl es,
before proceedi ng.
(6) Rei nstal l brake drums and wheel /ti re assem-
bl i es after brake shoe adjustment i s compl ete.
(7) Lower vehi cl e enough for access to parki ng
brake l ever. Then fully appl y parki ng brakes. Leave
brakes appl i ed unti l adjustment i s compl ete.
(8) Rai se vehi cl e and mark tensi oner rod 6.5 mm
(1/4 i n.) from tensi oner bracket (Fi g. 61).
(9) Ti ghten adjusti ng nut at equal i zer unti l mark
on tensi oner rod moves i nto al i gnment wi th tensi oner
bracket.
(10) Lower vehi cl e unti l rear wheel s are 15-20 cm
(6-8 i n.) off shop fl oor.
(11) Rel ease parki ng brake l ever and veri fy that
rear wheel s rotate freel y wi thout drag.
NOTE: Do not loosen/tighten equalizer adjusting
nut for any reason after completing adjustment.
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid ect.
Fig. 61 Tensioner Rod Measurement
TENSIONER BRACKET 6.5 MM (1/4 in.) TENSIONER ROD ROD TO EQUALIZER
5 - 28 BRAKES XJ
BRAKE COMPONENTS
Disc Brake Caliper
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sl i di ng
Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . Venti l ated
Max. Runout . . . . . . . . . . . . . 0.12 mm (0.005 i n.)
Max. Thi ckness Vari ati on . . 0.013 mm (0.0005 i n.)
Brake Drum
Si ze . . . . . . . . . . . . . . . . . . . . . . . . . 9 i n. or 10 i n.
Brake Booster
Type . . . . . . . . . . . . . . . . . . . . . . Dual Di aphragm
TORQUE CHART
DESCRIPTION TORQUE
Brake Pedal
Pi vot Bol t/Nut . . . . . . . . . . . . . 35 Nm (26 ft. l bs.)
Brake Booster
Master Cylinder
Mounti ng Nuts . . . . . . . . . . 17.5 Nm (155 i n. l bs.)
Brake Li nes . . . . . . . . . . . . . 19 Nm (170 i n. l bs.)
Combination Valve
Caliper
Mounti ng Bol ts . . . . . . . . . . . . 15 Nm (11 ft. l bs.)
Brake Hose Bol t . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Wheel Cylinder
Mounti ng Bol ts . . . . . . . . . . . . . 10 Nm (7 ft. l bs.)
Brake Li ne . . . . . . . . . . . . . . . 16 Nm (12 ft. l bs.)
Parking Brake
Lever Screws . . . . . . . . . . 10-14 Nm (7-10 ft. l bs.)
Lever Bracket Screws . . . 10-14 Nm (7-10 ft. l bs.)
Cabl e Retai ner Nut . . . . . . . . 1.5 Nm (14 i n. l bs.)
SPCIAL TOOLS
BASE BRAKES
Installer Caliper Dust Boot C-4842
Handle C-4171
XJ BRAKES 5 - 29
ANTILOCK BRAKES
INDEX
page page
GENERAL INFORMATION
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 30
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . 33
ACCELERATION SWITCH . . . . . . . . . . . . . . . . 32
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 30
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . 32
CONTROLLER ANTILOCK BRAKES . . . . . . . . . 31
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . . 31
WHEEL SPEED SENSORS AND
TONE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 32
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 33
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . 33
ACCELERATION SWITCH . . . . . . . . . . . . . . . . 36
FRONT WHEEL SPEED SENSOR . . . . . . . . . . 34
HYDRAULIC CONTROL UNIT/
CONTROLLER ANTILOCK BRAKES . . . . . . . 33
REAR WHEEL SPEED SENSOR . . . . . . . . . . . 34
HYDRAULIC CONTROL UNIT/
CONTROLLER ANTILOCK BRAKE . . . . . . . . 36
SPECIFICATIONS
T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 37
GENERAL INFORMATION
ANTILOCK BRAKE SYSTEM
The anti l ock brake system (ABS) i s an el ectroni -
cal l y operated, al l wheel brake control system.
The system i s desi gned to prevent wheel l ockup
and mai ntai n steeri ng control duri ng peri ods of hi gh
wheel sl i p when braki ng. Preventi ng l ockup i s accom-
pl i shed by modul ati ng fl ui d pressure to the wheel
brake uni ts.
The hydraul i c system i s a three channel desi gn.
The front wheel brakes are control l ed i ndi vi dual l y
and the rear wheel brakes i n tandem (Fi g. 1). The
ABS el ectri cal system i s separate from other el ectri -
cal ci rcui ts i n the vehi cl e. A speci al l y programmed
control l er anti l ock brake uni t operates the system
components.
ABS system major components i ncl ude:
Control l er Anti l ock Brakes (CAB)
Hydraul i c Control Uni t (HCU)
Wheel Speed Sensors (WSS)
Accel erati on Swi tch
ABS Warni ng Li ght
ANTILOCK BRAKE SYSTEM
The purpose of the anti l ock system i s to prevent
wheel l ockup duri ng peri ods of hi gh wheel sl i p. Pre-
venti ng l ockup hel ps mai ntai n vehi cl e braki ng acti on
and steeri ng control .
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of hi gh wheel sl i p.
Hi gh wheel sl i p can be descri bed as the poi nt where
wheel rotati on begi ns approachi ng 20 to 30 percent of
actual vehi cl e speed duri ng braki ng. Peri ods of hi gh
wheel sl i p occur when brake stops i nvol ve hi gh pedal
pressure and rate of vehi cl e decel erati on.
Battery vol tage i s suppl i ed to the CAB i gni ti on ter-
mi nal when the i gni ti on swi tch i s turned to Run posi -
ti on. The CAB performs a system i ni ti al i zati on
procedure at thi s poi nt. I ni ti al i zati on consi sts of a
stati c and dynami c sel f check of system el ectri cal
components.
The stati c check occurs after the i gni ti on swi tch i s
turned to Run posi ti on. The dynami c check occurs
when vehi cl e road speed reaches approxi matel y 30
kph (18 mph). Duri ng the dynami c check, the CAB
Fig. 1 Antilock Brake System
MASTER CYLIN- DER POWER BRAKE BOOSTER HCU/CAB HAR- NESS ACCELERATION SWITCH
WIRES TO
WHEEL SPEED
SENSORS
RIGHT
REAR
WHEEL
LEFT REAR
WHEEL
LEFT
FRONT
WHEEL
RIGHT
FRONT
WHEEL
HYDRAULIC BRAKE
LINES TO WHEELS
HCU/CAB ASSEMBLY
5 - 30 BRAKES XJ
bri efl y cycl es the pump and sol enoi ds to veri fy oper-
ati on.
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
NORMAL BRAKING
Duri ng normal braki ng, the master cyl i nder, power
booster and wheel brake uni ts al l functi on as they
woul d i n a vehi cl e wi thout ABS. The HCU compo-
nents are not acti vated.
ANTILOCK BRAKING
The anti l ock system prevents l ockup duri ng hi gh
sl i p condi ti ons by modul ati ng fl ui d appl y pressure to
the wheel brake uni ts.
Brake fl ui d appl y pressure i s modul ated accordi ng
to wheel speed, degree of sl i p and rate of decel era-
ti on. A sensor at each wheel converts wheel speed
i nto el ectri cal si gnal s. These si gnal s are transmi tted
to the CAB for processi ng and determi nati on of
wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a hi gh sl i p condi ti on acti vates the
CAB anti l ock program.
Two sol enoi d val ves are used i n each anti l ock con-
trol channel . The val ves are al l l ocated wi thi n the
HCU val ve body and work i n pai rs to ei ther i ncrease,
hol d, or decrease appl y pressure as needed i n the
i ndi vi dual control channel s.
The sol enoi d val ves are not stati c duri ng anti l ock
braki ng. They are cycl ed conti nuousl y to modul ate
pressure. Sol enoi d cycl e ti me i n anti l ock mode can be
measured i n mi l l i seconds.
CONTROLLER ANTILOCK BRAKES
The CAB moni tors wheel speed sensor i nputs con-
ti nuousl y whi l e the vehi cl e i s i n moti on. However,
the CAB wi l l not acti vate any ABS components as
l ong as sensor i nputs and the accel erati on swi tch
i ndi cate normal braki ng.
The CAB i s mounted to the HCU and operates the
ABS system (Fi g. 2) separate from other vehi cl e el ec-
tri cal ci rcui ts. CAB vol tage source i s through the
i gni ti on swi tch i n the RUN posi ti on.
The CAB contai ns dual mi croprocessors. A l ogi c
bl ock i n each mi croprocessor recei ves i denti cal sensor
si gnal s. These si gnal s are processed and compared
si mul taneousl y.
The CAB contai ns a sel f check program that i l l u-
mi nates the ABS warni ng l i ght when a system faul t
i s detected. Faul ts are stored i n a di agnosti c program
memory and are accessi bl e wi th the DRB scan tool .
ABS faul ts remai n i n memory unti l cl eared, or
unti l after the vehi cl e i s started approxi matel y 50
ti mes. Stored faul ts are not erased i f the battery i s
di sconnected.
HYDRAULIC CONTROL UNIT
The HCU consi sts of a val ve body, pump body,
accumul ators, pump motor, and wi re harnesses (Fi g.
2).
The pump, motor, and accumul ators are combi ned
i nto an assembl y attached to the val ve body. The
accumul ators store the extra fl ui d rel eased to the
system for ABS mode operati on. The pump provi des
the fl ui d vol ume needed and i s operated by a DC
type motor. The motor i s control l ed by the CAB.
The val ve body contai ns the sol enoi d val ves. The
val ves modul ate brake pressure duri ng anti l ock brak-
i ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed. The val ves are not
stati c. They are cycl ed rapi dl y and conti nuousl y to
modul ate pressure and control wheel sl i p and decel -
erati on.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure i ncrease,
pressure hol d, and pressure decrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
Pressure Decrease
The outl et val ve i s opened and the i nl et val ve i s
cl osed duri ng the pressure decrease cycl e.
Fig. 2 Controller Antilock Brakes
HCU MOTORCAB
XJ BRAKES 5 - 31
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB cl oses the i nl et
then opens the outl et val ve, whi ch al so opens the
return ci rcui t to the accumul ators. Fl ui d pressure i s
al l owed to bl eed off (decrease) as needed to prevent
wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
Pressure Hold
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e. Fl ui d appl y pressure i n the control chan-
nel i s mai ntai ned at a constant rate. The CAB mai n-
tai ns the hol d cycl e unti l sensor i nputs i ndi cate a
pressure change i s necessary.
Pressure Increase
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to counteract unequal
wheel speeds. Thi s cycl e control s re-appl i cati on of
fl ui d appl y pressure due to changi ng road surfaces or
wheel speed.
WHEEL SPEED SENSORS AND TONE WHEEL
A speed sensor i s used at each wheel . The front
sensors are mounted to the steeri ng knuckl es. The
rear sensors at the outboard end of the axl e.
The sensors convert wheel speed i nto a smal l AC
el ectri cal si gnal . Thi s si gnal i s transmi tted to the
CAB. The CAB converts the AC si gnal i nto a di gi tal
si gnal for each wheel . Thi s vol tage i s generated by
magneti c i nducti on when a tone wheel passes by the
stati onary magnet of the wheel speed sensor.
A gear type tone ri ng serves as the tri gger mecha-
ni sm for each sensor. The tone ri ngs are mounted at
the outboard ends of the front and rear axl e shafts.
Di fferent sensors are used at the front and rear
wheel s (Fi g. 3). The front/rear sensors have the same
el ectri cal val ues but are not i nterchangeabl e. The
sensors have a resi stance between 900 and 1300
ohms.
SPEED SENSOR AIR GAP
Front Sensor
Front sensor ai r gap i s fi xed and not adjustabl e.
Onl y rear sensor ai r gap i s adjustabl e.
Al though front ai r gap i s not adjustabl e, i t can be
checked i f di agnosi s i ndi cates thi s i s necessary. Front
ai r gap shoul d be 0.36 to 1.5 mm (0.014 to 0.059 i n.).
I f gap i s i ncorrect, the sensor i s ei ther l oose, or dam-
aged.
Rear Sensor
A rear sensor ai r gap adjustment i s onl y needed
when rei nstal l i ng an ori gi nal sensor. Repl acement
sensors have an ai r gap spacer attached to the sensor
pi ckup face. The spacer establ i shes correct ai r gap
when pressed agai nst the tone ri ng duri ng i nstal l a-
ti on. As the tone ri ng rotates, i t peel s the spacer off
the sensor to create the requi red ai r gap. Rear sensor
ai r gap i s 0.92-1.275 mm (0.036-0.05 i n.).
Sensor ai r gap measurement, or adjustment proce-
dures are provi ded i n thi s secti on. Refer to the front,
or rear sensor removal and i nstal l ati on procedures as
requi red.
COMBINATION VALVE
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e. I t must be
repl aced i f di agnosi s i ndi cates thi s i s necessary.
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs are
made.
The rear proporti oni ng val ve i s used to bal ance
front-rear brake acti on. The val ve al l ows normal
fl ui d fl ow duri ng moderate effort brake stops. The
val ve onl y control s (meters) fl ui d fl ow duri ng hi gh
effort brake stops.
ACCELERATION SWITCH
The accel erati on swi tch i s l ocated under the rear
seat. The swi tch (Fi g. 4), provi des an addi ti onal vehi -
cl e decel erati on reference duri ng 4WD operati on. The
Fig. 3 Wheel Speed Sensors
FRONT SENSOR REAR SENSOR PICKUP FACE
5 - 32 BRAKES XJ
swi tch i s moni tored by the CAB at al l ti mes. The
swi tch reference si gnal i s uti l i zed by the CAB when
al l wheel s are decel erati ng at the same speed.
ABS WARNING LAMP
The amber ABS warni ng l amp i s l ocated i n the
i nstrument cl uster. The l amp i l l umi nates at start-up
to perform a sel f check. The l amp goes out when the
sel f check program determi nes the system i s operat-
i ng normal . I f an ABS component exhi bi ts a faul t the
CAB wi l l i l l umi nate the l amp and regi ster a troubl e
code i n the mi croprocessor.
The l amp i s control l ed by the CAB. The l amp i s
i l l umi nated when the CAB sends a ground si gnal to
the ABS rel ay. The ABS rel ay then grounds the l amp
ci rcui t and i l l umi nates the l amp.
ANTILOCK BRAKES
The ABS brake system performs several sel f-tests
every ti me the i gni ti on swi tch i s turned on and the
vehi cl e i s dri ven. The CAB moni tors the systems
i nput and output ci rcui ts to veri fy the system i s oper-
ati ng correctl y. I f the on board di agnosti c system
senses that a ci rcui t i s mal functi oni ng the system
wi l l set a troubl e code i n i ts memory.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng. Refer to base
brake secti on for procedure.
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then ABS BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me.
Refer to base brake secti on for procedure.
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
HYDRAULIC CONTROL UNIT/CONTROLLER
ANTILOCK BRAKES
REMOVAL
(1) Remove negati ve battery cabl e from the bat-
tery.
(2) Pul l up on the CAB harness connector rel ease
(Fi g. 5) and remove connector.
(3) Remove brake l i nes from the HCU.
(4) Remove HCU/CAB mounti ng nuts and bol t
(Fi g. 6) and remove HCU/CAB.
Fig. 4 Acceleration Switch
SWITCH PART NUMBER ARROW INDICATES FRONT OF SWITCH FOR PROPER MOUNTING
Fig. 5 CAB Harness Connector Release
CAB CAB HAR- NESS RELEASE FWD
XJ BRAKES 5 - 33
INSTALLATION
(1) I nstal l HCU/CAB on the mounti ng studs.
(2) I nstal l mounti ng nuts and bol t. Ti ghten to 11.5
Nm (102 i n. l bs.).
(3) I nstal l brake l i nes to the HCU and ti ghten to
19 Nm (170 i n. l bs.).
(4) I nstal l wi ri ng harness connector to the CAB
and push down on the rel ease to secure the connec-
tor.
(5) I nstal l negati ve battery cabl e to the battery.
(6) Bl eed ABS brake system.
FRONT WHEEL SPEED SENSOR
REMOVAL
(1) Rai se vehi cl e and turn wheel outward for eas-
i er access to sensor.
(2) Remove sensor wi re from mounti ng brackets.
(3) Cl ean sensor and surroundi ng area wi th shop
towel before removal .
(4) Remove bol t attachi ng sensor to steeri ng
knuckl e and remove sensor (Fi g. 7).
(5) Remove sensor wi re from brackets on body and
steeri ng knuckl e.
(6) Unseat sensor wi re grommet i n wheel house
panel .
(7) I n engi ne compartment, di sconnect sensor wi re
connector at harness pl ug. Then remove sensor and
wi re.
INSTALLATION
(1) I f original sensor wi l l be i nstal l ed, wi pe al l
traces of ol d spacer materi al off sensor pi ckup face.
Use a dry shop towel for thi s purpose.
(2) Appl y Mopar Lock N Seal or Locti te 242 to
bol t that secures sensor i n steeri ng knuckl e. Use new
sensor bol t i f ori gi nal bol t i s worn or damaged.
(3) Posi ti on sensor on steeri ng knuckl e. Seat sen-
sor l ocati ng tab i n hol e i n knuckl e and i nstal l sensor
attachi ng bol t fi nger ti ght.
(4) Ti ghten sensor attachi ng bol t to 4.7 Nm (42 i n.
l bs.).
(5) I f ori gi nal sensor has been i nstal l ed, check sen-
sor ai r gap. Ai r gap shoul d be 0.36 to 1.5 mm (0.014
to 0.059 i n.). I f gap i s i ncorrect, sensor i s ei ther l oose,
or damaged.
(6) Secure sensor wi re to steeri ng knuckl e and
body brackets.
(7) Route sensor wi re forward and behi nd shock
absorber. Then attach sensor wi re to spri ng seat
bracket wi th grommets on sensor wi re.
(8) Route sensor wi re to outer si l l bracket. Remove
al l twi sts or ki nks from wi re.
(9) Attach sensor wi re to si l l bracket wi th grom-
met. Be sure wi re i s free of twi sts and ki nks.
(10) Veri fy sensor wi re routi ng. Wi re shoul d l oop
forward and above si l l bracket. Loose end of wi re
shoul d be bel ow si l l bracket and towards brake hose.
(11) Seat sensor wi re grommet i n body panel and
cl i p wi re to brake l i ne at grommet l ocati on.
(12) Connect sensor wi re to harness i n engi ne com-
partment.
REAR WHEEL SPEED SENSOR
REMOVAL
(1) Rai se and fol d rear seat forward for access to
rear sensor connectors (Fi g. 8).
(2) Di sconnect sensors at rear harness connectors.
Fig. 6 HCU/CAB Mounting
HCU CAB HCU/CAB BRACKET FWD MOTOR
Fig. 7 Front Wheel Speed Sensor
WHEEL SPEED SENSOR PIGTAIL STEERING KNUCKLE TONE WHEEL FRONT WHEEL SPEED SEN- SOR
5 - 34 BRAKES XJ
(3) Push sensor grommets and sensor wi res
through fl oorpan.
(5) Di sconnect sensor wi res at rear axl e connec-
tors.
(7) Remove brake drum.
(8) Remove cl i ps securi ng sensor wi res to brake
l i nes, rear axl e and, brake hose.
(9) Unseat sensor wi re support pl ate grommet.
(10) Remove bol t attachi ng sensor to bracket and
remove sensor (Fi g. 9).
INSTALLATION
(1) I f original sensor i s bei ng i nstal l ed, remove
any remai ni ng pi eces of cardboard spacer from sen-
sor pi ckup face. Use dry shop towel onl y to remove
ol d spacer materi al .
(2) I nsert sensor wi re through support pl ate hol e.
Then seat sensor grommet i n support pl ate.
(3) Appl y Mopar Lock N Seal or Locti te 242 to
ori gi nal sensor bol t. Use new bol t i f ori gi nal i s worn
or damaged.
(4) I nstal l sensor bol t fi nger ti ght onl y at thi s
ti me.
(5) I f original rear sensor was i nstal l ed, adjust
sensor ai r gap to 0.92-1.275 mm (0.036-0.05 i n.). Use
feel er gauge to measure ai r gap (Fi g. 10). Ti ghten
sensor bol t to 13 Nm (115 i n. l bs.).
(6) I f new sensor was i nstal l ed, push cardboard
spacer on sensor face agai nst tone ri ng (Fi g. 11).
Then ti ghten sensor bol t to 13 Nm (115 i n. l bs.). Cor-
rect ai r gap wi l l be establ i shed as tone ri ng rotates
and peel s spacer off sensor face.
(7) Route sensor wi res to rear seat area.
(8) Feed sensor wi res through fl oorpan access hol e
and seat sensor grommets i n fl oorpan.
Fig. 8 Acceleration Switch And Rear Sensor
Connections
REAR SEAT CROSSMEMBER ACCELERATION SENSOR SENSOR MOUNTING BRACKET TO R.R. WHEEL SENSOR TO L.R. WHEEL SENSOR FLOORPAN SENSOR HAR- NESSFWD
Fig. 9 Rear Wheel Speed Sensor
TONEWHEEL WHEEL SPEED SENSOR
Fig. 10 Setting Air Gap On Original Rear Sensor
WHEEL SPEED SENSOR BRASS FEELER GAUGE TONE RING
Fig. 11 New Rear Sensor
REAR SENSOR AIR GAP SPACER ATTACHED TO SENSOR FACE
XJ BRAKES 5 - 35
(9) Veri fy that rear sensor wi res are secured to
rear brake hose and axl e wi th cl i ps. Veri fy that wi re
i s cl ear of rotati ng components.
(10) I nstal l brake drum and wheel and ti re assem-
bl y.
(12) Connect sensor wi re to harness connector.
Then reposi ti on carpet and fol d rear seat down.
ACCELERATION SWITCH
REMOVAL
(1) Rai se and fol d rear seat assembl y forward for
access to sensor.
(2) Di sconnect swi tch harness.
(3) Remove swi tch mounti ng screws (Fi g. 12)
(4) Remove the accel erati on swi tch.
INSTALLATION
CAUTION: The mercury switch (inside the acceler-
ation switch), will not function properly if the switch
is mispositioned. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig.
13).
(1) Posi ti on swi tch i n mounti ng bracket.
(2) I nstal l swi tch mounti ng bol ts and ti ghten to 3
Nm (27.5 i n. l bs.).
(3) Connect harness to swi tch. Be sure harness
connector i s fi rml y seated.
(4) Move seat back to normal posi ti on.
HYDRAULIC CONTROL UNIT/CONTROLLER
ANTILOCK BRAKE
DISASSEMBLY
(1) Remove pump motor connector from the CAB.
(2) Remove CAB mounti ng screws from the HCU
(Fi g. 14).
(3) Remove CAB from the HCU.
ASSEMBLY
(1) I nstal l the CAB onto the HCU.
(2) I nstal l the CAB mounti ng screws and ti ghten
to 1.8 Nm (16 i n. l bs.).
(3) I nstal l pump motor connector to the CAB.
Fig. 12 Acceleration Switch Mounting
ACCELERATION SWITCH SWITCHBRACKET REAR SEAT CROSSMEMBER FWD
Fig. 13 Acceleration Switch
SWITCH PART NUMBER ARROW INDICATES FRONT OF SWITCH FOR PROPER MOUNTING
Fig. 14 CAB Mounting Screws
MOUNTING SCREWS CAB
5 - 36 BRAKES XJ
SPECIFICATIONS
T0RQUE CHART
DESCRIPTION TORQUE
Acceleration Sensor
Sensor Bol t . . . . . . . . . . . . . . 3 Nm (27.5 i n. l bs.)
Bracket Bol t . . . . . . . . . . . . 1.7 Nm (15.5 i n. l bs.)
Hydraulic Control Unit/Controller Antilock
Brakes
Controller Antilock Brakes
Mounti ng Screws . . . . . . . . . . 1.8 Nm (16 i n. l bs.)
Wheel Speed Sensors
Front Mounti ng Bol t . . . . . . . 4.7 Nm (42 i n. l bs.)
Rear Mounti ng Bol t . . . . . . . 13 Nm (115 i n. l bs.)
XJ BRAKES 5 - 37
CLUTCH
CONTENTS
page page
GENERAL INFORMATION
CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . 1
CLUTCH HYDRAULIC FLUID . . . . . . . . . . . . . . . 2
CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . . 2
INSTALLATION METHODS AND PARTS
USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1
CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . 2
CLUTCH CONTAMINATION . . . . . . . . . . . . . . . . 3
CLUTCH RUNOUT . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSTIC CHARTS . . . . . . . . . . . . . . . . . . . 5
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 3
IMPROPER CLUTCH RELEASE OR
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . 3
MISALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION . . . . . . . 5
CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . 10
CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . 5
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH COVER AND DISC . . . . . . . . . . . . . . . 11
CLUTCH HOUSING REPLACEMENTAX15 . . 12
CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . 14
PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . 14
RELEASE BEARING . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION
CLUTCH COMPONENTS
The cl utch mechani sm consi sts of a si ngl e, dry-type
di sc and a di aphragm styl e cl utch cover. A hydraul i c
l i nkage i s used to operate the cl utch rel ease beari ng
and fork.
A needl e-type pi l ot beari ng i n the crankshaft
fl ange supports the transmi ssi on i nput shaft. A
sl eeve type rel ease beari ng i s used to engage and di s-
engage the cl utch cover pressure pl ate.
The rel ease beari ng i s operated by a rel ease fork i n
the cl utch housi ng. The fork pi vots on a bal l stud
mounted i n the housi ng. The rel ease fork i s actuated
by a hydraul i c sl ave cyl i nder mounted i n the hous-
i ng. The sl ave cyl i nder i s operated by a cl utch master
cyl i nder mounted on the dash panel . The cyl i nder
push rod i s connected to the cl utch pedal .
The cl utch di sc has cushi on spri ngs i n the di sc
hub. The cl utch di sc faci ng i s ri veted to the hub. The
faci ng i s made from a non-asbestos materi al . The
cl utch cover pressure pl ate i s a di aphragm type wi th
a one-pi ece spri ng and mul ti pl e rel ease fi ngers. The
pressure pl ate rel ease fi ngers are preset duri ng man-
ufacture and are not adjustabl e.
HYDRAULIC LINKAGE COMPONENTS
The hydraul i c l i nkage consi sts of a cl utch master
cyl i nder wi th i ntegral reservoi r, a cl utch sl ave cyl i n-
der and an i nterconnecti ng fl ui d l i ne.
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . The sl ave cyl i nder push rod i s
connected to the cl utch rel ease fork. The master cyl -
i nder i s mounted on the dri ver si de of the dash panel
adjacent to the brake master cyl i nder and booster
assembl y. Thi s posi ti oni ng i s si mi l ar for both l eft and
ri ght hand dri ve model s.
SAFETY PRECAUTIONS
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMAR-
KET COMPONENTS. BREATHING EXCESSIVE CON-
CENTRATIONS OF THESE FIBERS CAN CAUSE
SERIOUS BODILY HARM. WEAR A RESPIRATOR
DURING SERVICE AND NEVER CLEAN CLUTCH
COMPONENTS WITH COMPRESSED AIR OR WITH
A DRY BRUSH. EITHER CLEAN THE COMPONENTS
WITH A WATER DAMPENED RAGS OR USE A VAC-
UUM CLEANER SPECIFICALLY DESIGNED FOR
REMOVING ASBESTOS FIBERS AND DUST. DO NOT
CREATE DUST BY SANDING A CLUTCH DISC.
REPLACE THE DISC IF THE FRICTION MATERIAL IS
DAMAGED OR CONTAMINATED. DISPOSE OF ALL
DUST AND DIRT CONTAINING ASBESTOS FIBERS
IN SEALED BAGS OR CONTAINERS. THIS WILL
HELP MINIMIZE EXPOSURE TO YOURSELF AND TO
OTHERS. FOLLOW ALL RECOMMENDED SAFETY
PRACTICES PRESCRIBED BY THE OCCUPATIONAL
SAFETY AND HEALTH ADMINISTRATION (OSHA)
AND THE ENVIRONMENTAL SAFETY AGENCY
(EPA), FOR THE HANDLING AND DISPOSAL OF
PRODUCTS CONTAINING ASBESTOS.
XJ CLUTCH 6 - 1
CLUTCH HYDRAULIC FLUID
The cl utch hydraul i c l i nkage cyl i nders and l i nes
are prefi l l ed wi th fl ui d at the factory.
The hydraul i c system shoul d not requi re addi ti onal
fl ui d under normal ci rcumstances. I n fact, the reser-
voi r fl ui d l evel wi l l actual l y i ncrease as normal cl utch
wear occurs. For thi s reason, i t i s i mportant to avoi d
overfi l l i ng, or removi ng fl ui d from the reservoi r. Thi s
acti on wi l l cause cl utch rel ease probl ems.
I f i nspecti on or di agnosi s i ndi cates addi ti onal fl ui d
may be needed, use Mopar brake fl ui d, or an equi v-
al ent, meeti ng SAE J1703 and DOT 3 standards. Do
not use any other type of fl ui d.
CLUTCH LUBRICATION
Proper cl utch component l ubri cati on i s i mportant
to sati sfactory operati on. Usi ng the correct l ubri cant
and avoi di ng over l ubri cati on are al so equal l y i mpor-
tant.
Duri ng servi ce, appl y recommended l ubri cant spar-
i ngl y. Do not overl ubri cate as thi s coul d resul t i n
cl utch di sc and pressure pl ate contami nati on.
Cl utch and transmi ssi on components requi ri ng
l ubri cati on are:
pi l ot beari ng.
rel ease l ever pi vot bal l stud.
rel ease l ever pi vot surfaces.
rel ease beari ng bore.
cl utch pedal pi vot bore and bushi ngs.
transmi ssi on i nput shaft spl i nes and pi l ot hub.
rel ease beari ng sl i de surface of front beari ng
retai ner.
Do not apply grease to any part of the clutch
cover or disc.
Use Mopar mul ti -mi l eage grease or a si l i cone
grease for the cl utch pedal bushi ngs and pi vot shaft.
Use Mopar hi gh temperature beari ng grease or
equi val ent for the pi l ot beari ng, rel ease beari ng bore,
transmi ssi on i nput shaft and rel ease fork compo-
nents. Appl y recommended amounts onl y and do not
overl ubri cate.
INSTALLATION METHODS AND PARTS USAGE
Di storti on of cl utch components duri ng i nstal l ati on
and the use of non-standard components are common
causes of cl utch mal functi on.
I mproper cl utch cover bol t ti ghteni ng can di stort
the cover. The usual resul t i s cl utch grab, chatter
and rapi d wear.
An i mproperl y seated fl ywheel and/or cl utch hous-
i ng are addi ti onal causes of cl utch fai l ure. I mproper
seati ng wi l l produce mi sal i gnment and addi ti onal
cl utch probl ems.
The use of non-standard or l ow qual i ty parts wi l l
al so l ead to probl ems and wear. Use recommended
factory parts onl y.
A cocked pi l ot beari ng i s another cause of cl utch
noi se, drag, hard shi fti ng, and rapi d beari ng wear.
Al ways use an al i gnment tool to i nstal l a new bear-
i ng. Thi s practi ce hel ps avoi d cocki ng the beari ng
duri ng i nstal l ati on.
CLUTCH OPERATION
Leverage, cl ampi ng force, and fri cti on are what
make the cl utch work. The di sc serves as the fri cti on
el ement and a di aphragm spri ng and pressure pl ate
provi de the cl ampi ng force. The cl utch pedal , hydrau-
l i c l i nkage, rel ease l ever and beari ng provi de the
l everage.
The cl utch cover assembl y cl amps the di sc agai nst
the fl ywheel . The assembl y consi sts of the cover, di a-
phragm spri ng, pressure pl ate, and ful crum compo-
nents. The pressure pl ate cl amps the cl utch di sc
agai nst the fl ywheel and the spri ng provi des the
cl ampi ng force.
The cl utch di sc fri cti on materi al i s ri veted to the
di sc hub. The hub bore i s spl i ned for i nstal l ati on on
the transmi ssi on i nput shaft. The hub spl i nes con-
nect the di sc to the transmi ssi on.
The cl utch l i nkage uses hydraul i c pressure to oper-
ate the cl utch. The cl utch master cyl i nder push rod i s
connected to the cl utch pedal and the sl ave cyl i nder
push rod i s connected to the rel ease l ever i n the
cl utch housi ng.
Depressi ng the cl utch pedal devel ops fl ui d pressure
i n the cl utch master cyl i nder. Thi s pressure i s trans-
mi tted to the sl ave cyl i nder through a connecti ng
l i ne. I n turn, the sl ave cyl i nder operates the cl utch
rel ease l ever.
The cl utch rel ease beari ng i s mounted on the
transmi ssi on front beari ng retai ner. The beari ng i s
attached to the rel ease l ever, whi ch moves the bear-
i ng i nto contact wi th the cl utch cover di aphragm
spri ng.
Sl ave cyl i nder force causes the rel ease l ever to
move the rel ease beari ng i nto contact wi th the di a-
phragm spri ng. As addi ti onal force i s appl i ed, the
beari ng presses the di aphragm spri ng fi ngers i nward
on the ful crums. Thi s acti on moves the pressure
pl ate rearward rel i evi ng cl amp force on the di sc. The
cl utch di sc i s di sengaged and freewheel i ng at thi s
poi nt.
The process of cl utch re-engagement i s si mpl y the
reverse of what occurs duri ng di sengagement. Rel eas-
i ng pedal pressure removes cl utch l i nkage pressure.
The rel ease beari ng moves away from the di aphragm
spri ng whi ch al l ows the pressure pl ate to exert
cl ampi ng force on the cl utch di sc.
6 - 2 CLUTCH XJ
GENERAL INFORMATION
Probl em di agnosi s wi l l general l y requi re a road
test to determi ne the type of faul t. Component
i nspecti on wi l l then determi ne the probl em cause
after road testi ng.
Dri ve the vehi cl e at normal speeds duri ng the road
test. Shi ft the transmi ssi on through al l gear ranges
and observe cl utch acti on.
I f chatter, grab, sl i p, or i mproper rel ease i s experi -
enced, remove and i nspect the cl utch components.
However, i f the probl em i s noi se or hard shi fti ng, fur-
ther di agnosi s may be needed. The transmi ssi on or
another dri vel i ne component may actual l y be at
faul t. Careful observati on duri ng the test wi l l hel p
narrow the probl em area.
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , grease, water, or other fl ui ds on
the cl utch contact surfaces wi l l cause faul ty opera-
ti on. The usual resul t i s chatter, sl i p and grab.
Duri ng i nspecti on, note i f any components are con-
tami nated. Look for evi dence of oi l , grease, cl utch
hydraul i c fl ui d, or water/road spl ash on cl utch com-
ponents.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Oi l l eaks
produce a resi due of oi l on the housi ng i nteri or and
on the cl utch cover and fl ywheel . Heat bui l dup
caused by sl i ppage between the cl utch cover, di sc,
and fl ywheel can someti mes bake the oi l resi due onto
the components. The gl aze-l i ke resi due ranges i n
col or from amber to bl ack.
Road spl ash contami nati on means di rt/water i s
enteri ng the cl utch housi ng. Thi s may be due to l oose
bol ts, housi ng cracks, or through the sl ave cyl i nder
openi ng. Dri vi ng through deep water puddl es can
force water/road spl ash i nto the housi ng through
such openi ngs.
Cl utch fl ui d l eaks are from l oose or damaged
cl utch l i nkage fl ui d l i nes or connecti ons. However,
most cl utch fl ui d l eaks wi l l usual l y be noted and cor-
rected before severe contami nati on occurs.
Grease contami nati on i s usual l y a product of exces-
si ve l ubri cati on duri ng cl utch servi ce. Appl y onl y a
smal l amount of grease to the i nput shaft spl i nes,
beari ng retai ner, pi l ot beari ng, rel ease fork and pi vot
stud. Excess grease can be thrown off duri ng opera-
ti on and contami nate the di sc.
IMPROPER CLUTCH RELEASE OR ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear, or damage to one or more cl utch compo-
nents. A vi sual i nspecti on of the rel ease components
wi l l usual l y reveal the probl em part.
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. I tems to l ook for are: l eaks at the cl utch cyl i n-
ders and i nterconnecti ng l i ne; l oose sl ave cyl i nder
bol ts; worn/l oose rel ease fork and pi vot stud; dam-
aged rel ease beari ng; and a worn cl utch di sc, or pres-
sure pl ate.
Normal condensati on i n vehi cl es that are stored or
out of servi ce for l ong peri ods of ti me can generate
enough corrosi on to make the di sc sti ck to the fl ywheel ,
or pressure pl ate. I f thi s condi ti on i s experi enced, cor-
recti on onl y requi res that the di sc be l oosened manu-
al l y through the i nspecti on pl ate openi ng.
Engagement probl ems usual l y resul t i n sl i p, chat-
ter/shudder, and noi sy operati on. The pri mary causes
are cl utch di sc contami nati on; cl utch di sc wear; mi s-
al i gnment, or di storti on; fl ywheel damage; or a com-
bi nati on of the foregoi ng. A vi sual i nspecti on i s
requi red to determi ne the part actual l y causi ng the
probl em.
CLUTCH RUNOUT
CLUTCH DISC
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.5 mm
(0.020 i n.). Measure runout about 6 mm (1/4 i n.) from
the outer edge of the di sc faci ng. Obtai n another di sc
i f runout i s excessi ve.
CLUTCH COVER
Check condi ti on of the cl utch cover before i nstal l a-
ti on. A warped cover or di aphragm spri ng wi l l cause
grab and i ncompl ete rel ease or engagement. Be care-
ful when handl i ng the cover and di sc. I mpact can di s-
tort the cover, di aphragm spri ng, rel ease fi ngers and
the hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on i s
i mproper bol t ti ghteni ng. To avoi d warpi ng the cover,
the bol ts must be ti ghtened i n a di agonal pattern and
onl y 23 threads at a ti me to the speci fi ed torque.
FLYWHEEL
Fl ywheel runout shoul d not exceed 0.08 mm (0.003
i n.). Measure runout at the outer edge of the fl y-
wheel face wi th a di al i ndi cator. Mount the i ndi cator
on a stud i nstal l ed i n pl ace of one of the fl ywheel
bol ts.
Common causes of runout are:
heat warpage.
i mproper machi ni ng.
XJ CLUTCH 6 - 3
1 Check clutch housing bolts. Tighten if loose. Be
sure housing is fully seated on engine block.
2 Check flywheel. Scuff sand face to remove glaze.
Clean surface with wax and grease remover.
Replace flywheel if severely scored, worn or
cracked. Secure flywheel with new bolts (if
removed). Do not reuse old bolts. Use Mopar
Lock NSeal on bolts.
3 Tighten clutch cover bolts 2-3 threads at a time,
alternately and evenly (in a star pattern) to
specified torque. Failure to do so could wrap the
cover.
4 Check release fork. Replace fork if bent or worn.
Make sure pivot and bearing contact surfaces are
lubricated.
5 Check release fork pivot (in housing). Be sure
pivot is suecure and ball end is lubricated.
6 Transmission input shaft bearing will cause noise,
chatter, or improper release if damaged. Check
condition before installing transmission.
7 Check slave cylinder. Replace it if leaking. Be
sure cylinder is properly secured in housing and
cylinder piston is seated in release fork.
8 Check input shaft seal if clutch cover and disc
were oil covered. Replace seal if worn, or cut.
Clutch Components
9 Inspect release bearing slide surface of trans.
front bearing retainer. Surface should be smooth,
free of nicks, scores. Replace retainer if
necessary. Lubricate slide surface before
installing release bearing.
10 Do not replace release bearing unless actually
faulty. Replace bearing only if seized, noisy, or
damaged.
11 Check clutch cover diaphragmspring and release
fingers. Replace cover if spring or fingers are
bent, warped, broken, cracked. Do not tamper
with factory spring setting as clutch problems will
result.
12 Check condition of clutch cover. Replace clutch
cover if plate surface is deeply scored. warped,
worn, or cracked. Be sure cover is correct size
and properly aligned on disc and flywheel.
13 Inspect clutch housing. Be sure bolts are tight.
Replace housing if damaged.
14 Verify that housing alignment dowels are in
position before installing housing.
15 Clean engine block surface before installing
clutch housing. Dirt, grime can produce
misalignment.
16 Make sure side of clutch disc marked flywheel
side is toward flywheel.
17 Check rear main seal if clutch disc and cover were
oil covered. Replace seal if necessary.
18 Check crankshaft flange (if flywheel is removed).
Be sure flance is clean and flywheel bolt threads
are in good condition.
19 Check pilot bearing. Replace bearing if damaged.
Lube with Mopar high temp. bearing grease
before installation.
20 Check transmission input shaft. Disc must slide
freely on shaft splines. Lightly grease splines
before installation. Replace shaft if splines or pilot
bearing hub are damaged.
21 Check flywheel bolt torque. If bolts are loose,
replace them. Use Mopar Lock NSeal to secure
new bolts.
22 Check clutch disc facing. Replace disc if facing is
charred, scored, flaking off, or worn. Also check
runout of newdisc. Runout should not exceed 0.5
mm (0.02 in.).
6 - 4 CLUTCH XJ
i ncorrect bol t ti ghteni ng.
i mproper seati ng on crankshaft fl ange shoul der.
forei gn materi al on crankshaft fl ange.
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. However,
mi nor fl ywheel scori ng can be cl eaned up by hand
wi th 180 gri t emery, or wi th surface gri ndi ng equi p-
ment. Remove onl y enough materi al to reduce scor-
i ng (approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal . Ti ghten fl ywheel
bol ts to speci fi ed torque onl y. Overti ghteni ng can di s-
tort the fl ywheel hub causi ng runout.
MISALIGNMENT
Cl utch housi ng al i gnment i s i mportant to proper
cl utch operati on. The housi ng mai ntai ns al i gnment
between the crankshaft and transmi ssi on i nput
shaft. Mi sal i gnment can cause cl utch noi se, hard
shi fti ng, i ncompl ete rel ease and chatter. I t can al so
resul t i n premature wear of the pi l ot beari ng, cover
rel ease fi ngers and cl utch di sc. I n severe cases, mi s-
al i gnment can al so cause premature wear of the
transmi ssi on i nput shaft and front beari ng.
Housi ng mi sal i gnment i s general l y caused by
i ncorrect seati ng on the engi ne or transmi ssi on, l oose
housi ng bol ts, mi ssi ng al i gnment dowel s, or housi ng
damage. Ti ghten al l the cl utch housi ng bol ts to
proper torque before i nstal l i ng any struts. Al so be
sure al i gnment dowel s are i n pl ace and seated i n the
bl ock and housi ng before bol t ti ghteni ng. I nfre-
quentl y, mi sal i gnment may al so be caused by housi ng
mounti ng surfaces that are not compl etel y paral l el .
Mi sal i gnment can be corrected wi th shi ms.
DIAGNOSTIC CHARTS
The di agnosi s charts descri be common cl utch prob-
l ems, causes and correcti on. Faul t condi ti ons are
l i sted at the top of each chart. Condi ti ons, causes and
correcti ve acti on are outl i ned i n the i ndi cated col -
umns.
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION
Proper cl utch component l ubri cati on i s i mportant
to sati sfactory operati on. Usi ng the correct l ubri cant
and not over l ubri cati ng are equal l y i mportant. Appl y
recommended l ubri cant spari ngl y to avoi d di sc and
pressure pl ate contami nati on.
Cl utch and transmi ssi on components requi ri ng
l ubri cati on are:
Pi l ot beari ng.
Rel ease l ever pi vot bal l stud.
Rel ease l ever contact surfaces.
Rel ease beari ng bore.
Cl utch di sc hub spl i nes.
Cl utch pedal pi vot shaft bore.
Cl utch pedal bushi ngs.
I nput shaft spl i nes.
I nput shaft pi l ot hub.
Transmi ssi on front beari ng retai ner sl i de sur-
face.
NOTE: Never apply grease to any part of the clutch
cover, or disc.
RECOMMENDED LUBRICANTS
Use Mopar mul ti -purpose grease for the cl utch
pedal bushi ngs and pi vot shaft. Use Mopar hi gh
temperature grease (or equi val ent) for al l other l ubri -
cati on requi rements. Appl y recommended amounts
and do not over l ubri cate.
CLUTCH LINKAGE FLUID
The i ntegral cl utch master cyl i nder reservoi r, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed wi th fl ui d pri or
to assembl y operati ons.
voir fluid level will actually increase as normal
clutch wear occurs. For this reason, it is impor-
tant to avoid overfilling, or removing fluid from
the reservoir. This will cause clutch release
problems.
al ent meeti ng standards SAE J1703 and DOT 3. Do
XJ CLUTCH 6 - 5
DISC FACING WORN OUT 1. Normal wear. Driver frequently
rides (slips) clutch. Results in rapid
war overheating. Insufficient clutch
cover diaphragm spring tension.
1. Replace clutch disc. Also replace
cover if spring is weak or pressure
plate surface is damaged.
CLUTCH DISC FACING
CONTAMINATED WITH OIL,
GREASE, OR CLUTCH FLUID
1. Leak at rear main seal or at
transmission input shaft seal.
Excessive amount of grease
applied to input shaft splines. Road
splash, water entering housing.
Slave cylinder leaking.
1. Replace leaking seals. Apply less
grease to input shaft splines.
Replace clutch disc (do not clean
and reuse). Clean clutch cover
and reuse only if cover is in good
condition. Replace slave cylinder if
leaking.
CLUTCH IS RUNNING PARTIALLY
DISENGAGED
1. Release bearing sticking-binding.
Does not return to normal running
position.
1. Verify that bearing is actually
binding, the replace bearing and
transmission front bearing retainer
if sleeve surface is damaged.
FLYWHEEL HEIGHT INCORRECT 1. Flywheel surface improperly
machined. Too much stock
removed or surface is tapered.
1. Replace flywheel.
WRONG DISC OR PRESSURE
PLATE INSTALLED
1. Incorrect parts order or model
number.
1. Replace with correct parts.
Compare old and new parts before
installation.
CLUTCH DISC, COVER AND/OR
DIAPHRAGM SPRING, SARPED,
DISTORTED
1. Rough handling (impact) bent
cover, spring, or disc. Incorrect bolt
tightening sequence and method
caused warped cover.
1. Install new disc or cover as
needed. Follow installation/
tightening instructions.
FACING ON FLYWHEEL SIDE OF
DISC TORN, GOUGED, WORN
1. Flywheel surface scored and
nicked.
1. Reduce scores and nicks by
sanding or surface grinding.
Replace flywheel if scores-nicks
are deeper than .002-.004 inch.
CLUTCH DISC FACING BURN
(CHARRED). FLYWHEEL AND
COVER PRESSURE PLATE
SURFACES HEAVILY GLAZED
1. Frequent operation under high
loads or hard acceleration
conditions. Driver frequently rides
(slips) clutch. Results in rapid wear
and overheating of disc and cover.
1. Scuff sand flywheel. Replace
clutch cover and disc. Alert driver
to problem cause.
6 - 6 CLUTCH XJ
CLUTCH DISC WARPED 1. New disc not checked for axial
runout before installation.
1. Replace disc. Be sure runout of
new disc is less than .5 mm (.020
in.).
CLUTCH DISC BINDS ON INPUT
SHAFT SPLINES
1. Clutch disc hub splines damaged
during installation. Input shaft
splines rough, damaged.
Corrosion, rust formations on
splines of disc and input shaft.
1. Clean, smooth and lubricate disc
and shaft splines. Replace disc
and/or input shaft if splines are
severely damaged.
CLUTCH DISC RUSTED TO
FLYWHEEL AND/OR PRESSURE
PLATE
1. Occurs in vehicles stored, or not
driven for extended periods of
time. Also occurs after steam
cleaning if vehicle is not used for
extended period.
1. Remove clutch cover and disc.
Sand rusted surfaces clean with
180 grit paper. Replace disc cover,
and flywheel if corrosion is severe.
CLUTCH DISC FACING STICKS TO
FLYWHEEL
1. Vacuum may form in pockets over
rivet heads in clutch disc. Occurs
as clutch cools down after use.
1. Drill 1/16 inch diameter hole
through rivets and scuff sand disc
facing with 180 grit paper.
CLUTCH DISC TOO THICK 1. Wrong disc installed. 1. Replace disc.
PILOT BEARING SEIZED, LOOSE,
OR ROLLERS ARE WORN
1. Bearing cocked during installation.
Bearing defective. Bearing not
lubricated. Clutch misalignment.
1. Lubricate and install new bearing.
Check and correct any
misalignment.
CLUTCH WILL NOT DISENGAGE
PROPERLY
1. Low clutch fluid level. 1. Top off reservoir and check for
leaks.
2. Clutch cover loose. 2. Tighten bolts.
5. Clutch cover diaphragm spring
bent or warped during transmission
installation.
5. Replace cover.
6. Clutch disc installed backwards. 6. Remove and reinstall disc
correctly. Be sure disc side
marked to flywheel is actually
toward flywheel.
7. Release fork bent or fork pivot is
loose or damaged.
7. Replace fork and pivot if worn or
damaged.
8. Clutch master or slave cylinder
fault.
8. Replace master and slave cylinder
as assembly.
XJ CLUTCH 6 - 7
CLUTCH DISC FACING COVERED
WITH OIL, GREASE, OR CLUTCH
FLUID
1. Oil leak at rear main or input shaft
seal.
1. Correct leak and replace disc (do
not clean and reuse the disc).
2. Too much grease applied to
splines or disc and input shaft.
2. Apply lighter grease coating to
splines and replace disc (do not
clean and reuse the disc).
CLUTCH DISC AND/OR COVER
WARPED, OR DISC FACINGS
EXHIBIT UNUSUAL WRONG TYPE
1. Incorrect or substandard parts. 1. Replace disc and/or cover with
correct parts.
CLUTCH MASTER OR SLAVE
CYLINDER PLUNGER DRAGGING-
BINDING
1. Master or slave cylinder
components worn or corroded.
1. Replace both cylinders as
assembly (and reservoir).
NO FAULT FOUND WITH CLUTCH
COMPONENTS
1. Problem actually related to
suspension or driveline component.
1. Further diagnosis required. Check
engine/transmission mounts,
propeller shafts and U-joints, tires,
suspension attaching parts and
other driveline components as
needed.
2. Engine related problem. 2. Check EFI and ignition systems.
PARTIAL ENGAGEMENT OF
CLUTCH DISC (ONE SIDE
WORN-OPPOSITE SIDE GLAZED
AND LIGHTLY WORN)
1. Clutch pressure plate position
setting incorrect or modified.
1. Replace clutch cover and disc.
2. Clutch cover, spring, or release
fingers bent, distorted (rough
handling, improper assembly).
2. Replace clutch cover and disc.
3. Clutch disc damaged or distorted. 3. Replace disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, or cover and/or
clutch housing. Correct as
necessary.
6 - 8 CLUTCH XJ
Clutch components damaged or worn
out prematurely.
1. Incorrect or sub-standard clutch
parts.
1. Replace with parts of correct type
and quality.
Pilot bearing damaged. 1. Bearing cocked during installation.
Bearing not lubricated prior to
installation. Bearing defect.
1. Replace bearing. Be sure it is
properly seated and lubricated
before installing clutch.
2. Clutch misalignment. 2. Check and correct misalignment
caused by excessive runout of
flywheel, disc, cover or clutch
housing. Replace input shaft if
bearing hub is damaged.
Loose components. 1. Attaching bolts loose at flywheel,
cover, or clutch housing.
1. Tighten bolts to specified torque.
Replace any clutch bolts that are
damaged.
Components appear overheated.
Hub of disc cracked or torsion
damper springs are distorted or
broken.
1. Frequent high load, full throttle
operation.
1. Replace parts as needed. Alert
driver to condition causes.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect, or release
fingers are bent or distorted
causing damage.
1. Replace clutch cover and bearing.
2. Release bearing defect. 2. Replace bearing.
3. Release bearing misaligned. 3. Check and correct runout of clutch
components. Check front bearing
retainer sleeve surface. Replace if
damaged.
Release bearing is noisy. 1. Release bearing defect. 1. Replace bearing.
Clutch pedal squeak. 1. Pivot pin loose. Pedal bushings
worn out or cracked.
1. Tighten pivot pin. Replace
bushings if worn or damaged.
Lubricate pin and bushings with
silicone base lubricator chassis
grease.
XJ CLUTCH 6 - 9
CLUTCH FLUID LEVEL
The cl utch fl ui d reservoi r, master cyl i nder, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed wi th fl ui d at
the factory duri ng assembl y operati ons.
voir fluid level will actually increase as normal
clutch wear occurs. For this reason, it is impor-
tant to avoid overfilling, or removing fluid from
the reservoir.
al ent meeti ng standards SAE J1703 and DOT 3. Do
Cl utch fl ui d l evel i s checked at the master cyl i nder
reservoi r (Fi g. 1). An i ndi cator ri ng i s provi ded ei ther
on the si de, or i nteri or ri m of the reservoi r (Fi g. 2).
Be sure to wi pe the reservoi r and cover cl ean
before removi ng the cover. Thi s wi l l avoi d havi ng di rt
or forei gn materi al fal l i nto the reservoi r duri ng a
fl ui d l evel check.
FLYWHEEL
I nspect the fl ywheel whenever the cl utch di sc,
cover and housi ng are removed for servi ce. Check
condi ti on of the fl ywheel face, hub, ri ng gear teeth,
and fl ywheel bol ts.
Mi nor scratches, burrs, or gl azi ng on the fl ywheel
face can be reduced wi th 180 gri t emery cl oth. How-
ever, the fl ywheel shoul d be repl aced i f the di sc con-
tact surface i s severel y scored, heat checked, cracked,
or obvi ousl y worn.
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel surface i s manufactured wi th a uni que contour
that woul d be negated by machi ni ng. However,
cl eanup of mi nor fl ywheel scori ng can be performed
by hand wi th 180 gri t emery, or wi th surface gri nd-
i ng equi pment. Repl ace the fl ywheel i f scori ng i s
deeper than 0.0762 mm (0.003 i n.).
Heavy stock removal by gri ndi ng i s not recom-
mended. Excessi ve stock removal can resul t i n fl y-
wheel cracki ng or warpage after i nstal l ati on. I t can
al so weaken the fl ywheel and i nterfere wi th proper
cl utch rel ease.
Check fl ywheel runout i f mi sal i gnment i s sus-
pected. Runout shoul d not exceed 0.08 mm (0.003
i n.). Measure runout at the outer edge of the fl y-
wheel face wi th a di al i ndi cator. Mount the di al i ndi -
cator on a stud i nstal l ed i n pl ace of one of the cl utch
housi ng attachi ng bol ts.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout.
Check condi ti on of the fl ywheel hub and attachi ng
bol ts. Repl ace the fl ywheel i f the hub exhi bi ts cracks
i n the area of the attachi ng bol t hol es.
I nstal l new attachi ng bol ts whenever the fl ywheel
i s repl aced and use Mopar Lock N Seal , or Locti te
242 on the repl acement bol t threads.
Recommended fl ywheel bol t torques are:
142 Nm (105 ft. l bs.) for 6-cyl i nder fl ywheel s
68 Nm (50 ft. l bs.) pl us an addi ti onal turn of
60 for 4-cyl i nder fl ywheel s
I nspect the teeth on the starter ri ng gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
I n cases where a new fl ywheel i s not readi l y avai l -
abl e, a repl acement ri ng gear can be i nstal l ed. How-
ever, the fol l owi ng precauti ons must be observed to
avoi d damagi ng the fl ywheel and repl acement gear.
(1) Mark posi ti on of the ol d gear for al i gnment ref-
erence on the fl ywheel . Use a scri ber for thi s pur-
pose.
(2) Wear protecti ve goggl es or approved safety
gl asses. Al so wear heat resi stent gl oves when han-
dl i ng a heated ri ng gear.
Fig. 1 Clutch Master Cylinder Reservoir And Cap
RESERVOIR CAP CLUTCH MASTER CYLINDER RESERVOIR FLUID LINE
Fig. 2 Reservoir Fluid Level Indicator Ring
CLUTCH MASTER CYLINDER RESER- VOIR FLUID LEVEL INDICA- TOR RING
6 - 10 CLUTCH XJ
(3) Remove the ol d gear by cutti ng most of the way
through i t (at one poi nt) wi th an abrasi ve cut-off
wheel . Then compl ete removal wi th a col d chi sel or
punch.
(4) The ri ng gear i s a shri nk fi t on the fl ywheel .
Thi s means the gear must be expanded by heati ng i n
order to i nstal l i t. The method of heating and
expanding the gear is extremely important.
Every surface of the gear must be heated at the same
ti me to produce uni form expansi on. An oven or si mi -
l ar encl osed heati ng devi ce must be used. Tempera-
ture requi red for uni form expansi on i s approxi matel y
375 F.
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
(5) The heated gear must be i nstal l ed evenl y to
avoi d mi sal i gnment or di storti on. A shop press and
sui tabl e press pl ates shoul d be used to i nstal l the
gear i f at al l possi bl e.
(6) Be sure to wear eye and hand protecti on. Heat
resi stent gl oves and safety goggl es are needed for
personal safety. Al so use metal tongs, vi se gri ps, or
si mi l ar tool s to posi ti on the gear as necessary for
i nstal l ati on.
(7) Al l ow the fl ywheel and ri ng gear to cool down
before i nstal l ati on. Set the assembl y on a workbench
and l et i t cool i n normal shop ai r.
CAUTION: Do not use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.
CLUTCH COVER AND DISC
REMOVAL
(1) Remove transmi ssi on. Refer to Group 21,
Transmi ssi on and Transfer Case, for proper proce-
dures.
(2) I f ori gi nal cl utch cover wi l l be rei nstal l ed, mark
posi ti on of cover on fl ywheel for assembl y reference
(Fi g. 3). Use pai nt or a scri ber for thi s purpose.
(3) Loosen cover bol ts evenl y and i n rotati on to
rel i eve spri ng tensi on equal l y. Thi s i s necessary to
avoi d warpi ng cover.
(4) Remove cover bol ts and remove cover and di sc
(Fi g. 4).
INSTALLATION
(1) Li ghtl y scuff sand fl ywheel face wi th 180 gri t
emery cl oth. Then cl ean surface wi th a wax and
grease remover.
(2) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature beari ng grease.
(3) Check new cl utch for runout and free operati on
on i nput shaft spl i nes.
(4) Posi ti on cl utch di sc on fl ywheel . Be sure si de of
di sc marked fl ywheel si de i s posi ti oned agai nst fl y-
wheel (Fi g. 4). I f di sc i s not marked, be sure fl at si de
of di sc hub i s toward fl ywheel .
(5) I nspect condi ti on of pressure pl ate surface of
cl utch cover (Fi g. 4). Repl ace cover i f thi s surface i s
worn, heat checked, cracked, or scored.
(6) I nsert cl utch al i gnment tool i n cl utch di sc (Fi g.
5).
(7) I nsert al i gnment tool i n pi l ot beari ng and posi -
ti on di sc on fl ywheel . Be sure di sc hub i s posi ti oned
correctl y. Si de of hub marked Fl ywheel Si de shoul d
face fl ywheel (Fi g. 4). I f di sc i s not marked, pl ace fl at
si de of di sc agai nst fl ywheel .
(8) Posi ti on cl utch cover over di sc and on fl ywheel
(Fi g. 5).
(9) I nstal l cl utch cover bol ts fi nger ti ght.
(10) Ti ghten cover bol ts evenl y and i n rotati on a
few threads at a ti me. Cover bol ts must be ti ghtened
evenl y and to speci fi ed torque to avoi d di storti ng
cover. Ti ghteni ng torques are 31 Nm (23 ft. l bs.) on
2.5L engi nes and 54 Nm (40 ft. l bs.) on 4.0L engi nes.
Fig. 3 Typical Method Of Marking Clutch Cover
Position
CLUTCH COVER PUNCH MARKS FLYWHEEL
XJ CLUTCH 6 - 11
(11) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease to pi l ot beari ng hub and spl i nes of
transmi ssi on i nput shaft. Do not over l ubri cate shaft
spl i nes. Thi s wi l l resul t i n grease contami nati on of
di sc.
(12) I nstal l transmi ssi on (Fi g. 6) and (Fi g. 7).
Refer to Group 21, Transmi ssi on and Transfer Case,
CLUTCH HOUSING REPLACEMENTAX15
REMOVAL
(1) Rai se vehi cl e and support vehi cl e.
(2) Remove transmi ssi on and cl utch housi ng as
assembl y. Refer to Group 21, Transmi ssi on and
Transfer Case, for proper procedures.
(3) Remove rel ease beari ng, rel ease fork, and fork
boot from i nput shaft and cl utch housi ng.
(4) Remove bol ts attachi ng cl utch housi ng to trans-
mi ssi on (Fi g. 8).
INSTALLATION
(1) Cl ean mounti ng surfaces of transmi ssi on and
cl utch housi ng. Use a wi re brush i f necessary fol -
l owed by a wax and grease remover, or si mi l ar sol -
vent. Al so cl ean engi ne bl ock surface as wel l .
(2) Posi ti on cl utch housi ng on transmi ssi on and
i nstal l housi ng attachi ng bol ts. Ti ghten bol ts to 38
(3) I nstal l rel ease fork pi vot bal l stud to housi ng, i f
necessary.
Fig. 6 Manual Transmission Mounting4.0L
ENGINE (4.0L) TRANSFER CASE VENT TUBE CLUTCH HOUSING BRACKET
ITEM
TORQUE
Fig. 4 Clutch Disc And Pressure Plate Inspection
DISC INSPECT THIS SURFACE CLUTCH COVER FLYWHEEL SIDE STAMPED ON THIS SUR- FACE
Fig. 5 Typical Method Of Aligning Clutch Disc
FLYWHEEL CLUTCH COVER AND DISC CLUTCH DISC ALIGNMENT TOOL
6 - 12 CLUTCH XJ
(4) Lubri cate rel ease beari ng bore, rel ease fork
contact surfaces, and rel ease fork pi vot stud wi th
Mopar hi gh temperature beari ng grease. Al so l ubri -
cate transmi ssi on i nput shaft spl i nes, pi l ot hub and
beari ng retai ner sl i de surface wi th l i ght coat of same
grease.
(5) I nstal l rel ease fork, beari ng, and boot i n hous-
i ng. Be sure rel ease fork boot i s properl y seated i n
housi ng.
(6) I nstal l transmi ssi on. Refer to Group 21, Trans-
mi ssi on and Transfer Case, for proper procedures.
RELEASE BEARING
REMOVAL
dures.
(2) Di sconnect rel ease beari ng from fork and
remove beari ng (Fi g. 9).
Fig. 7 Manual Transmission Mounting2.5L
TORQUE
ITEM
ENGINE (2.5L) CLUTCH HOUSING COVER BRACKET FWD
Fig. 8 Clutch Housing Attachment
HOUSING TO- TRANSMISSION BOLTS (38 Nm/28 ft. lbs.) CLUTCH HOUSING TRANSMISSION
Fig. 9 Release Bearing And Release Fork Mounting
CONED WASHER CLUTCH HOUSING RELEASE FORK RELEASE BEARING AND SLEEVE PIVOT 23 Nm (200 IN. LBS.) SPRING
XJ CLUTCH 6 - 13
INSTALLATION
(1) I nspect rel ease beari ng sl i de surface of trans-
mi ssi on front beari ng retai ner. Repl ace retai ner i f
sl i de surface i s scored, worn or cracked.
(2) I nspect rel ease fork and fork pi vot (Fi g. 9). Be
sure pi vot i s secure and i n good condi ti on. Be sure
fork i s not di storted or worn. Repl ace rel ease fork
retai ner spri ng i f bent or damaged i n any way.
(3) Li ghtl y l ubri cate pi l ot beari ng, i nput shaft
spl i nes, beari ng retai ner sl i de surface, fork pi vot and
rel ease fork pi vot surface wi th Mopar hi gh temper-
ature beari ng grease.
(4) I nstal l rel ease fork and beari ng. Be sure fork
and beari ng are properl y secured.
PILOT BEARING
REMOVAL
dures.
(2) Remove cl utch cover and di sc.
(3) Use a sui tabl e bl i nd hol e pul l er to remove pi l ot
beari ng.
INSTALLATION
(1) Cl ean beari ng bore wi th sol vent and wi pe dry
wi th shop towel .
(2) Lubri cate new pi l ot beari ng wi th Mopar hi gh
temperature grease.
(3) Posi ti on and start new beari ng i n beari ng bore
by hand. Note that pi l ot beari ng has seal at one end.
I nstal l beari ng so seal i s faci ng outward toward
transmi ssi on.
(4) Seat pi l ot beari ng wi th cl utch al i gnment tool
(Fi g. 10). Keep beari ng strai ght duri ng i nstal l ati on.
Do not al l ow beari ng to become cocked. Tap beari ng
i nto pl ace unti l fl ush wi th edge of beari ng bore. Do
not recess beari ng.
CLUTCH HYDRAULIC LINKAGE
The cl utch master cyl i nder, sl ave cyl i nder and con-
necti ng l i ne are servi ced as an assembl y onl y. The
l i nkage components cannot be overhaul ed or servi ced
separatel y. The cyl i nders and connecti ng l i ne are
seal ed uni ts. Al so note that removal /i nstal l ati on pro-
cedures for ri ght and l eft hand dri ve model s are basi -
cal l y the same. Onl y master cyl i nder l ocati on i s
di fferent.
REMOVAL
(2) Remove fasteners attachi ng sl ave cyl i nder to
cl utch housi ng.
(3) Remove sl ave cyl i nder from cl utch housi ng
(Fi g. 11).
(4) Di sengage cl utch fl ui d l i ne from body cl i ps.
(6) Veri fy that cap on cl utch master cyl i nder reser-
voi r i s ti ght. Thi s i s necessary to avoi d undue spi l l -
age duri ng removal .
(7) Remove cl utch master cyl i nder attachi ng nuts.
Note that both nuts are accessi bl e from under i nstru-
ment panel (Fi g. 12) and (Fi g. 13).
(8) Remove cl utch master cyl i nder push rod from
pedal .
(9) Di sconnect cl utch pedal posi ti on swi tch wi res.
(10) I f pedal pi n i s equi pped wi th bushi ng, i nspect
condi ti on of bushi ng and repl ace i t i f worn or dam-
aged.
(11) Remove cl utch hydraul i c l i nkage through
INSTALLATION
(1) Be sure reservoi r cover on cl utch master cyl i n-
der i s ti ght to avoi d spi l l s.
(2) Posi ti on cl utch l i nkage components i n vehi cl e.
Work connecti ng l i ne and sl ave cyl i nder downward
past engi ne and adjacent to cl utch housi ng.
(3) Posi ti on cl utch master cyl i nder on dash panel .
(4) Attach cl utch master cyl i nder push rod to
cl utch pedal pi n.
Fig. 10 Typical Method Of Installing Pilot Bearing
PILOT BEARING ALIGNMENT TOOL BEARING SEAL MUST FACE TRANSMISSION KEEP BEARING STRAIGHT DUR- ING INSTALLATION TO AVOID DAMAGE
6 - 14 CLUTCH XJ
(5) I nstal l and ti ghten cl utch master cyl i nder
attachi ng nuts to 23-34 Nm (200-300 i n. l bs.) torque.
(7) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure cap
on end of rod i s securel y engaged i n l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
(8) I nstal l and ti ghten sl ave cyl i nder attachi ng
nuts to 23-34 Nm (200-300 i n. l bs.) torque.
(9) Secure cl utch fl ui d l i ne i n body cl i ps.
(11) Connect cl utch pedal posi ti on swi tch wi res.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Bol ts, cl utch cover 2.5 L . . . . . . . 31 Nm (23 ft. l bs)
Bol ts, cl utch cover 4.0 L . . . . . . . 52 Nm (38 ft. l bs)
Bol t/Nut, cl utch cyl . mount . . . . 23 Nm (200 i n. l bs)
Bol t, cl utch housi ng M12 . . . . . . . 75 Nm (55 ft. l bs)
Bol t, cl utch housi ng 3/8 . . . . . . . . 37 Nm (27 ft. l bs)
Bol t, cl utch housi ng 7/16 . . . . . . . 58 Nm (43 ft. l bs)
Bol t, cl utch housi ng/trans. . . . . . . 38 Nm (28 ft. l bs)
Bol t, dust shi el d M8 . . . . . . . . . . . 8 Nm (72 i n. l bs)
Bol t, dust shi el d l ower . . . . . . . . . 50 Nm (37 ft. l bs)
Bol t, X-member/frame . . . . . . . . . 41 Nm (30 ft. l bs)
Bol t, X-member/rear support . . . 45 Nm (33 ft. l bs.)
Bol ts, fl ywheel 4.0 L . . . . . . . . 142 Nm (105 ft. l bs)
Bol ts, fl ywheel 2.5 L . . 68 Nm (50 ft. l bs) +1/4 turn
Bol t, starter motor . . . . . . . . . . . . 45 Nm (33 ft. l bs)
Bol ts, U-joi nts . . . . . . . . . . . . . 19 Nm (170 i n. l bs.)
Fig. 11 Slave Cylinder Attachment
CLUTCH HOUSING SLAVE CYLIN- DER STUDS (2) CYLINDER FLUID LINE FWD
Fig. 12 Clutch Master Cylinder And Push Rod
AttachmentLeft Hand Drive Models
DASH PANEL PUSH ROD CLUTCH MASTER CYLINDER
Fig. 13 Clutch Master Cylinder LocationRight
Hand Drive Models
XJ CLUTCH 6 - 15
COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
ACCESSORY DRIVE BELT TENSION . . . . . . . . . 3
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COOLING SYSTEM COMPONENTS . . . . . . . . . . 2
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 1
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 3
RADIATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM COOLANT ROUTING . . . . . . . . . . . . . 2
WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 2
ACCESSORY DRIVE BELT TENSION . . . . . . . . . 4
AUTOMATIC TRANSMISSION OIL COOLER . . . 3
AUXILIARY ELECTRIC COOLING FAN . . . . . . . . 8
COOLANT PERFORMANCE . . . . . . . . . . . . . . . . 5
COOLANT RESERVE/OVERFLOW SYSTEM . . . 3
COOLANT SELECTION-ADDITIVES . . . . . . . . . . 5
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . 4
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . 6
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . . 4
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . . 5
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 4
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . . 7
WATER PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUXILIARY ELECTRIC COOLING FAN . . . . . . . 21
COOLING SYSTEM DIAGNOSIS . . . . . . . . . . . 12
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . . 9
LOW COOLANT LEVEL-AERATION . . . . . . . . . 22
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . 8
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . 10
PRESSURE TESTING RADIATOR CAPS . . . . . 22
RADIATOR CAP-TO-FILLER NECK SEAL
PRESSURE RELIEF CHECK . . . . . . . . . . . . . 21
RADIATOR COOLANT FLOW CHECK . . . . . . . 19
TESTING COOLING SYSTEM FOR LEAKS . . . 19
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . . . . 20
SERVICE PROCEDURES
ADDING ADDITIONAL COOLANTROUTINE . . 22
COOLANT LEVEL CHECKROUTINE . . . . . . . 22
COOLANT LEVEL CHECKSERVICE . . . . . . . 22
COOLANT SERVICE . . . . . . . . . . . . . . . . . . . . 22
DRAINING AND FILLING COOLING SYSTEM . . 23
REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . 23
AUXILIARY ELECTRIC COOLING FAN . . . . . . . 34
COOLANT RESERVE TANK . . . . . . . . . . . . . . . 25
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . 37
ENGINE ACCESSORY DRIVE BELTS . . . . . . . . 34
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . . 34
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . 29
TRANSMISSION OIL COOLERS . . . . . . . . . . . . 24
VISCOUS FAN DRIVE REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 38
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 25
COOLING SYSTEM CLEANING . . . . . . . . . . . . 38
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . 38
FAN BLADE INSPECTION . . . . . . . . . . . . . . . . 38
RADIATOR CLEANING . . . . . . . . . . . . . . . . . . . 38
RADIATOR PRESSURE CAP . . . . . . . . . . . . . . 38
SPECIFICATIONS
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . 38
COOLING SYSTEM CAPACITIES . . . . . . . . . . . 38
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . 39
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
GENERAL INFORMATION
ENGINE ACCESSORY DRIVE BELTS
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to water pump rotat-
ing in wrong direction. Refer to the appropriate
engine Belt Schematic in this group for the correct
belt routing. Or, refer to the Belt Routing Label
located in the engine compartment.
COOLING SYSTEM
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e, mai ntai ns
normal operati ng temperature and prevents over-
heati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
XJ COOLING SYSTEM 7 - 1
An opti onal factory i nstal l ed heavy duty cool i ng
package i s avai l abl e on most model s. The package
consi sts of a radi ator that has an i ncreased number
of cool i ng fi ns. Vehi cl es equi pped wi th a 4.0L 6- cyl -
i nder engi ne and heavy duty cool i ng and/or ai r con-
di ti oni ng al so have an auxi l i ary el ectri c cool i ng fan.
COOLING SYSTEM COMPONENTS
The cool i ng system consi sts of:
A radi ator
Cool i ng fan (mechani cal and/or el ectri cal )
Thermal vi scous fan dri ve
Fan shroud
Radi ator pressure cap
Thermostat
Cool ant reserve/overfl ow system
Transmi ssi on oi l cool er (i f equi pped wi th an
automati c transmi ssi on)
Cool ant
Water pump
Hoses and hose cl amps
SYSTEM COOLANT ROUTING
For cool i ng system fl ow routi ngs, refer to (Fi g. 1)
(Fi g. 2).
WATER PUMPS
A qui ck test to determi ne i f the pump i s worki ng i s
to check i f the heater warms properl y. A defecti ve
water pump wi l l not be abl e to ci rcul ate heated cool -
ant through the l ong heater hose to the heater core.
COOLANT
The cool i ng system i s desi gned around the cool ant.
Cool ant fl ows through the engi ne water jackets
absorbi ng heat produced duri ng engi ne operati on.
The cool ant carri es heat to the radi ator and heater
core. Here i t i s transferred to the ambi ent ai r pass-
i ng through the radi ator and heater core fi ns. The
cool ant al so removes heat from the automati c trans-
mi ssi on fl ui d i n vehi cl es equi pped wi th an automati c
transmi ssi on.
RADIATORS
2.5L 4cyl i nder engi ne radi ators are the down fl ow
type, 4.0L 6-cyl i nder engi ne radi ators are the cross
fl ow type. Pl asti c tanks are used on al l radi ators.
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches.
Fig. 1 Coolant Flow2.5L 4-Cylinder EngineTypical
TO COOLANT RECOVERY BOTTLE RADIATOR LOWER HOSE WATER PUMP PULLEY RADIATOR RADIATOR UPPER HOSE TO WATER PUMP HEATER CORE
7 - 2 COOLING SYSTEM XJ
I f the pl asti c tank has been damaged, the pl asti c
tank and/or o-ri ngs are avai l abl e for servi ce repai r.
Tank repl acement shoul d be done by a qual i fi ed per-
son wi th proper equi pment.
ACCESSORY DRIVE BELT TENSION
Correct accessory dri ve bel t tensi on i s requi red to
ensure opti mum performance of bel t dri ven engi ne
accessori es. I f speci fi ed tensi on i s not mai ntai ned,
bel t sl i ppage may cause: engi ne overheati ng, l ack of
power steeri ng assi st, l oss of ai r condi ti oni ng capac-
i ty, reduced generator output rate, greatl y reduced
bel t l i fe and objecti onabl e under hood noi se.
DOMESTIC LEFT HAND DRIVE VEHICLES
Bel t tensi on i s adjusted at the power steeri ng
pump bracket and i dl er pul l ey assembl y.
DOMESTIC RIGHT HAND DRIVE VEHICLES
I f equi pped wi th a 4.0L 6-cyl i nder engi ne; the ser-
penti ne bel t i s adjusted at the generator mounti ng
bracket. When equi pped wi th a 2.5L 4-cyl i nder
engi ne, the serpenti ne bel t i s adjusted at the power
steeri ng pump bracket and i dl er pul l ey assembl y.
ENGINE BLOCK HEATER
An opti onal engi ne bl ock heater i s avai l abl e for al l
model s. The heater i s equi pped wi th a power cord.
The cord i s attached to an engi ne compartment com-
ponent wi th ti e-straps. The heater warms the engi ne
provi di ng easi er engi ne starti ng and faster warm-up
i n l ow temperatures. The heater i s mounted i n a core
hol e of the engi ne cyl i nder bl ock (i n pl ace of a freeze
pl ug) wi th the heati ng el ement i mmersed i n engi ne
cool ant. Connect the power cord to a grounded 110-
120 vol t AC el ectri cal outl et wi th a grounded, three-
wi re extensi on cord.
AUTOMATIC TRANSMISSION OIL COOLER
WATER-TO-OIL COOLER
Al l model s equi pped wi th an automati c transmi s-
si on are equi pped wi th a transmi ssi on oi l cool er
mounted i nternal l y wi thi n the radi ator tank. Thi s
i nternal cool er i s suppl i ed as standard equi pment on
al l model s equi pped wi th an automati c transmi ssi on.
Transmi ssi on oi l i s cool ed when i t passes through
thi s separate cool er. I n case of a l eak i n the i nternal
radi ator mounted transmi ssi on oi l cool er, engi ne cool -
ant may become mi xed wi th transmi ssi on fl ui d or
transmi ssi on fl ui d may enter engi ne cool i ng system.
Both cool i ng system and transmi ssi on shoul d be
drai ned and i nspected i f the i nternal radi ator
mounted transmi ssi on cool er i s l eaki ng.
AIR-TO-OIL COOLER
An auxi l i ary ai r-to-oi l transmi ssi on oi l cool er i s
avai l abl e wi th most engi ne packages.
The auxi l i ary ai r-to-oi l transmi ssi on oi l cool er i s
l ocated i n front of the radi ator or A/C condenser (i f
equi pped) and behi nd the gri l l . I t i s mounted to the
front frame crossmember.
The auxi l i ary oi l cool ers on al l model s operate i n
conjuncti on wi th the i nternal radi ator mounted mai n
oi l cool er. The transmi ssi on oi l i s routed through the
mai n cool er fi rst, then the auxi l i ary cool er, before
returni ng to the transmi ssi on.
COOLANT RESERVE/OVERFLOW SYSTEM
The system works al ong wi th the radi ator pressure
cap. Thi s i s done by usi ng thermal expansi on and
contracti on of the cool ant to keep the cool ant free of
trapped ai r. I t provi des:
A vol ume for cool ant expansi on and contracti on.
A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
Fig. 2 Coolant Flow4.0L 6-Cylinder Engine
Typical
HEATER CORE TO COOLANT RESERVE/ OVERFLOW TANK THERMOSTAT HOUSING RADIATORWATER PUMP
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
The cool ant reserve/overfl ow system consi sts of a
radi ator mounted pressuri zed cap, a pl asti c reserve/
overfl ow tank (Fi g. 3) (Fi g. 4), a tube (hose) connect-
i ng the radi ator and tank, and an overfl ow tube on
the si de of the tank.
COOLING SYSTEM FANS
Al so refer to ei ther the Vi scous Fan Dri ve and/or
the Auxi l i ary El ectri c Cool i ng Fan.
Al l model s are equi pped wi th a mechani cal temper-
ature control l ed fan. Thi s thermal vi scous fan dri ve
i s a torque-and-temperature-sensi ti ve cl utch uni t. I t
automati cal l y i ncreases or decreases fan speed to
provi de proper engi ne cool i ng. Vehi cl es wi th a 4.0L
6-cyl i nder engi ne may al so have an auxi l i ary el ectri -
cal cool i ng fan; when equi pped ai r condi ti oni ng
and/or heavy duty cool i ng.
ACCESSORY DRIVE BELT TENSION
Both the 2.5l and 4.0l engi nes use one accessory
dri ve bel t. Correct dri ve bel t tensi on i s requi red to
ensure opti mum performance of the bel t dri ven
engi ne accessori es. There are di fferent types of
adjustment gauges for checki ng ei ther a serpenti ne
or a conventi onal V-type bel t. Refer to the i nstruc-
ti ons suppl i ed wi th the gauge. Make sure to use a
gauge desi gned speci fi cal l y for serpenti ne styl e bel ts.
Pl ace gauge i n the mi ddl e of the secti on of bel t bei ng
tested (between two pul l eys) to check tensi on. Do not
al l ow the gauge (or gauge adapter) to contact any-
thi ng but the bel t.
ENGINE BLOCK HEATER
An opti onal engi ne bl ock heater i s avai l abl e for al l
model s. The heater i s equi pped wi th a power cord.
The cord i s attached to an engi ne compartment com-
ponent wi th ti e-straps. The heater warms the engi ne
provi di ng easi er engi ne starti ng and faster warm-up
i n l ow temperatures. The heater i s mounted i n a core
hol e of the engi ne cyl i nder bl ock (i n pl ace of a freeze
pl ug) wi th the heati ng el ement i mmersed i n engi ne
cool ant. Connect the power cord to a grounded 110-
120 vol t AC el ectri cal outl et wi th a grounded, three-
wi re extensi on cord.
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
BLOCK HEATER SPECI FI CATI ONS
2.5L 4-Cyl i nder Engi ne: 115 Vol ts 400 Watts
4.0L 6-Cyl i nder Engi ne: 120 Vol ts 600 Watts
THERMOSTAT
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm-up and overal l
temperature control .
Fig. 3 Reserve/Overflow TankExcept Right Hand
Drive
Fig. 4 Reserve/Overflow TankWith Right Hand
Drive
CLAMP COOLANT RESERVE/ OVERFLOWTANK MOUNTINGBOLTS LOWER BRACKET TUBE TO RADIATOR
An arrow pl us the word UP i s stamped on the
front fl ange next to the ai r bl eed. The words TO
RAD are stamped on one arm of the thermostat.
They i ndi cate the proper i nstal l ed posi ti on.
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: l onger engi ne warm-up ti me, unre-
l i abl e warm-up performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
CAUTION: Do not operate an engine without a
thermostat, except for servicing or testing.
COOLANT PERFORMANCE
ETHYLENE-GLYCOL MIXTURES
The requi red ethyl ene-gl ycol (anti freeze) and water
mi xture depends upon the cl i mate and vehi cl e oper-
ati ng condi ti ons. The recommended mi xture of 50/50
ethyl ene-gl ycol and water wi l l provi de protecti on
agai nst freezi ng to -37 deg. C (-35 deg. F). The anti -
freeze concentrati on must always be a mi ni mum of
44 percent, year-round i n al l cl i mates. If percentage
is lower than 44 percent, engine parts may be
eroded by cavitation, and cooling system com-
ponents may be severely damaged by corrosion.
Maxi mum protecti on agai nst freezi ng i s provi ded
wi th a 68 percent anti freeze concentrati on, whi ch
prevents freezi ng down to -67.7 deg. C (-90 deg. F). A
hi gher percentage wi l l freeze at a warmer tempera-
ture. Al so, a hi gher percentage of anti freeze can
cause the engi ne to overheat because the speci fi c
heat of anti freeze i s l ower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used in
Chrysler Vehicles
Use of 100 percent ethyl ene-gl ycol wi l l cause for-
mati on of addi ti ve deposi ts i n the system, as the cor-
rosi on i nhi bi ti ve addi ti ves i n ethyl ene-gl ycol requi re
the presence of water to di ssol ve. The deposi ts act as
i nsul ati on, causi ng temperatures to ri se to as hi gh as
149 deg. C (300) deg. F). Thi s temperature i s hot
enough to mel t pl asti c and soften sol der. The
i ncreased temperature can resul t i n engi ne detona-
ti on. I n addi ti on, 100 percent ethyl ene-gl ycol freezes
at 22 deg. C (-8 deg. F ).
Propylene-glycol Formulations Should Not Be Used in
Chrysler Vehicles
Propylene-glycol formulations do not meet
Chrysler coolant specifications. I ts overal l effec-
ti ve temperature range i s smal l er than that of ethyl -
ene-gl ycol . The freeze poi nt of 50/50 propyl ene-gl ycol
and water i s -32 deg. C (-26 deg. F). 5 deg. C hi gher
than ethyl ene-gl ycol s freeze poi nt. The boi l i ng poi nt
(protecti on agai nst summer boi l -over) of propyl ene-
gl ycol i s 125 deg. C (257 deg. F ) at 96.5 kPa (14 psi ),
compared to 128 deg. C (263 deg. F) for ethyl ene-gl y-
col . Use of propyl ene-gl ycol can resul t i n boi l -over or
freeze-up i n Chrysl er vehi cl es, whi ch are desi gned for
ethyl ene-gl ycol . Propyl ene gl ycol al so has poorer heat
transfer characteri sti cs than ethyl ene gl ycol . Thi s
can i ncrease cyl i nder head temperatures under cer-
tai n condi ti ons.
Propylene-glycol/Ethylene-glycol Mixtures Should Not Be
Used in Chrysler Vehicles
Propyl ene-gl ycol /ethyl ene-gl ycol Mi xtures can
cause the destabi l i zati on of vari ous corrosi on i nhi bi -
tors, causi ng damage to the vari ous cool i ng system
components. Al so, once ethyl ene-gl ycol and propy-
l ene-gl ycol based cool ants are mi xed i n the vehi cl e,
conventi onal methods of determi ni ng freeze poi nt wi l l
not be accurate. Both the refracti ve i ndex and spe-
ci fi c gravi ty di ffer between ethyl ene gl ycol and propy-
l ene gl ycol .
CAUTION: Richer antifreeze mixtures cannot be
measured with normal field equipment and can
cause problems associated with 100 percent ethyl-
ene-glycol.
COOLANT SELECTION-ADDITIVES
Cool ant shoul d be mai ntai ned at the speci fi ed l evel
wi th a mi xture of ethyl ene gl ycol -based anti freeze
and l ow mi neral content water. Onl y use an anti -
freeze contai ni ng ALUGARD 340-2 .
CAUTION: Do not use coolant additives that are
claimed to improve engine cooling.
RADIATOR PRESSURE CAP
Al l radi ators are equi pped wi th a pressure cap.
Thi s cap rel eases pressure at some poi nt wi thi n a
range of 83-110 kPa (12-16 psi ). The pressure rel i ef
poi nt (i n pounds) i s engraved on top of the cap (Fi g.
5).
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
l oaded pressure rel i ef val ve that opens when system
pressure reaches rel ease range of 83-110 kPa (12-16
psi ).
A vent val ve i n the center of cap al l ows a smal l
cool ant fl ow through cap when cool ant i s bel ow boi l -
i ng temperature. The val ve i s compl etel y cl osed when
boi l i ng poi nt i s reached. As the cool ant cool s, i t con-
tracts and creates a vacuum i n the cool i ng system.
Thi s causes the vacuum val ve to open and cool ant i n
the reserve/overfl ow tank to be drawn through i ts
connecti ng hose i nto radi ator. I f the vacuum val ve i s
stuck shut, the radi ator hoses wi l l col l apse on cool -
down.
A rubber gasket seal s radi ator fi l l er neck. Thi s i s
done to mai ntai n vacuum duri ng cool ant cool -down
and to prevent l eakage when system i s under pres-
sure.
WATER PUMPS
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
dri ve bel t on al l engi nes.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has a smal l hol e to al l ow seep-
age to escape. The water pump seal s are l ubri cated
by the anti freeze i n the cool ant mi xture. No addi -
ti onal l ubri cati on i s necessary.
CAUTION: All engines are equipped with a reverse
(counter-clockwise) rotating water pump and vis-
cous fan drive assembly. REVERSE is stamped or
imprinted on the cover of the viscous fan drive and
inner side of the fan. The letter R is stamped into
the back of the water pump impeller (Fig. 6).
Engi nes from previ ous model years, dependi ng
upon appl i cati on, may have been equi pped wi th a for-
ward (cl ockwi se) rotati ng water pump. I nstal l ati on of
the wrong water pump wi l l cause engi ne overheati ng.
A qui ck test to determi ne i f the pump i s worki ng i s
to check i f the heater warms properl y. A defecti ve
water pump wi l l not be abl e to ci rcul ate heated cool -
ant through the l ong heater hose to the heater core.
COOLING SYSTEM HOSES
Rubber hoses route cool ant to and from the radi a-
tor, i ntake mani fol d and heater core. Radi ator l ower
hoses are spri ng-rei nforced to prevent col l apse from
water pump sucti on at moderate and hi gh engi ne
speeds.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 7). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
Fig. 5 Radiator Pressure Cap and Filler Neck
Typical
TOP VIEWPRESSURE RATING CROSS-SECTIONAL VIEW FILLER NECK SEAL PRESSURE VALVE VACUUM VENT VALVE (SHOWN IN SEAL- ING POSITION)
Fig. 6 Reverse Rotating Water PumpTypical
FRONT VIEW ROTATION DIRECTION AS VIEWED BACK VIEW ROTATION DIRECTION AS VIEWED R STAMPED INTO IMPELLER
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps (Fig. 8). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
I nspect the hoses at regul ar i nterval s. Repl ace
hoses that are cracked, feel bri ttl e when squeezed, or
swel l excessi vel y when the system i s pressuri zed.
For al l vehi cl es: I n areas where speci fi c routi ng
cl amps are not provi ded, be sure that hoses are posi -
ti oned wi th suffi ci ent cl earance. Check cl earance
from exhaust mani fol ds and pi pe, fan bl ades, dri ve
bel ts and sway bars. I mproperl y posi ti oned hoses can
be damaged, resul ti ng i n cool ant l oss and engi ne
overheati ng.
Ordi nary worm gear type hose cl amps (when
equi pped) can be removed wi th a strai ght screw-
dri ver or a hex socket. To prevent damage to
hoses or clamps, the hose clamps should be
tightened to 4 Nm (34 in. lbs.) torque. Do not
over tighten hose clamps.
VISCOUS FAN DRIVE
NOTE: Also refer to Cooling System Fans.
The thermal vi scous fan dri ve i s a si l i cone-fl ui d-
fi l l ed coupl i ng used to connect the fan bl ades to
ei ther the engi ne or the water pump shaft. The cou-
pl i ng al l ows the fan to be dri ven i n a normal manner.
Thi s i s done at l ow engi ne speeds whi l e l i mi ti ng the
top speed of the fan to a predetermi ned maxi mum
l evel at hi gher engi ne speeds.
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t. A typi cal
vi scous uni t i s shown i n (Fi g. 9). Thi s spri ng coi l
reacts to the temperature of the radi ator di scharge
ai r. I t engages the vi scous fan dri ve for hi gher fan
speed i f the ai r temperature from the radi ator ri ses
above a certai n poi nt. Unti l addi ti onal engi ne cool i ng
i s necessary, the fan wi l l remai n at a reduced rpm
regardl ess of engi ne speed.
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
Fig. 7 Hose Clamp ToolTypical
HOSE CLAMP TOOL 6094 HOSECLAMP
Fig. 8 Clamp Number/Letter Location
TYPICAL CONSTANT TENSION HOSE CLAMP CLAMP NUMBER/ LETTER LOCA- TION TYPICAL HOSE
Fig. 9 Typical Viscous Fan Drive
VISCOUS FAN DRIVE MOUNTING HUB THERMOSTATICSPRING
CAUTION: Engines equipped with serpentine drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
CAUTION: If the viscous fan drive is replaced
because of mechanical damage, the cooling fan
blades should also be inspected. Inspect for fatigue
cracks, loose blades, or loose rivets that could
have resulted from excessive vibration. Replace fan
blade assembly if any of these conditions are
found. Also inspect water pump bearing and shaft
assembly for any related damage due to a viscous
fan drive malfunction.
NOISE
It is normal for fan noise to be louder (roar-
ing) when:
The underhood temperature i s above the engage-
ment poi nt for the vi scous dri ve coupl i ng. Thi s may
occur when ambi ent (outsi de ai r temperature) i s very
hi gh.
Engi ne l oads and temperatures are hi gh such as
when towi ng a trai l er.
Cool si l i cone fl ui d wi thi n the fan dri ve uni t i s
bei ng redi stri buted back to i ts normal di sengaged
(warm) posi ti on. Thi s can occur duri ng the fi rst 15
seconds to one mi nute after engi ne start-up on a col d
engi ne.
AUXILIARY ELECTRIC COOLING FAN
Model s equi pped wi th a 4.0L 6-cyl i nder engi ne may
al so have an auxi l i ary el ectri cal cool i ng fan. Thi s i s
wi th model s that have ai r condi ti oni ng and/or heavy
duty cool i ng. The fan i s control l ed by the cool i ng fan
rel ay, whi ch i s l ocated i n the power di stri buti on cen-
ter (PDC) (Fi g. 10). For the l ocati on of rel ay wi thi n
the PDC, refer to the l abel on PDC cover.
When cool ant temperature reaches approxi matel y
103C (218F), or when ai r condi ti oni ng i s requested,
the powertrai n control modul e (PCM) provi des a
ground path for the fan rel ay. Thi s ground i s pro-
vi ded to the cool i ng fan rel ay through pi n C2 of PCM
connector C3. Battery vol tage i s then appl i ed to the
fan through the rel ay. When cool ant temperature
drops bel ow approxi matel y 98C (209F), the PCM
opens the ground path to the rel ay. Thi s wi l l prevent
the cool i ng fan from bei ng energi zed.
ON-BOARD DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Powertrai n Control Modul e (PCM) has been
programmed to moni tor the certai n fol l owi ng cool i ng
system components:
I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
I f an open or shorted condi ti on has devel oped i n
the rel ay ci rcui t control l i ng the el ectri c radi ator fan,
a Di agnosti c Troubl e Code (DTC) can be set.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cate an actual probl em, a DTC i s
stored. The DTC wi l l be stored i n the PCM memory
for eventual di spl ay to the servi ce techni ci an. (Refer
to Group 25, Emi ssi on Control Systems for proper
procedures)
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTCs and to obtai n cool i ng system data,
refer to Group 25, Emi ssi on Control Systems for
proper procedures.
DRB SCAN TOOL
For operati on of the DRB scan tool , refer to the
vi ce manual .
BELT DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 11), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 11). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to the Serpenti ne Dri ve Bel t Di agnosi s
charts for further bel t di agnosi s.
SERPENTINE BELT DIAGNOSIS CHART
RIB CHUNKING (One or more ribs has
separated from belt body)
1. Foreign objects imbedded in pulley
grooves.
1. Remove foreign objects from pulley
grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove tips 4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of insufficient
tension
1. Adjust tension
2. Belt or pulley exposed to substance
that has reduced friction (belt dressing,
oil, ethylene glycol)
2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)
3. Replace faulty component or bearing
4. Belt glazed or hardened from heat
and excessive slippage
4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member
2. Replace belt
Fig. 11 Serpentine Belt Wear Patterns
GROOVE JUMPING
(Belt does not maintain correct
position on pulley)
1. Belt tension either too low or too
high
1. Adjust belt tension
2. Pulley(s) not within design
tolerance
2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Excessive tension 1. Replace belt and adjust tension to
specification
2. Tensile member damaged during
belt installation
2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component and
belt
NOISE
(Objectional squeal, squeak, or
rumble is heard or felt while drive belt
is in operation)
1. Belt slippage 1. Adjust belt
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration
5. Locate defective driven component
and repair
6. System resonant frequency
induced vibration
6. Vary belt tension within
specifications.
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)
1. Tension sheeting contacting
stationary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges of
belt or separated from belt body)
1. Excessive tension 1. Adjust belt tension
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt and adjust tension to
specifications
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE,
SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC
JAMS, HIGH SPEED OR STEEP GRADES.
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
TRAILER TOWING:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maxi mum cool i ng package shoul d have been
ordered wi th vehi cl e i f add-on or after market A/C i s
i nstal l ed. I f not, maxi mum cool i ng system compo-
nents shoul d be i nstal l ed for model i nvol ved per
manufacturers speci fi cati ons.
RECENT SERVICE OR ACCIDENT REPAIR:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t(s)
Brakes (possi bl y draggi ng)
Changed parts. I ncorrect water pump or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a qui ck-reference
onl y. Refer to the group text for i nformati on.
COOLING SYSTEM DIAGNOSIS
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) number 17 been set indicating
a stuck open engine thermostat?
1. Refer to On-Board Diagnostics in
the service manual text. Replace
thermostat if necessary. If a
Diagnostic Trouble Code (DTC)
number 17 has not been set, the
problem may be with the temperature
gauge.
2. Is the temperature gauge (if
equipped) connected to the
temperature gauge coolant sensor on
the engine?
2. Check the engine temperature
sensor connector in the engine
compartment. Refer to Group 8E.
Repair as necessary.
3. Is the temperature gauge (if
equipped) operating OK?
3. Check gauge operation. Refer to
Group 8E. Repair as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with poor
heater performance.
4. Check coolant level in the coolant
reserve/overflow tank and the
radiator. Inspect system for leaks.
Repair leaks as necessary. Refer to
the Coolant section of the manual text
for WARNINGS and precautions
before removing the radiator cap.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. Refer to Group 24,
Heating and Air Conditioning for
procedures.
HIGH OR ENGINE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM
COOLING SYSTEM
1. Trailer is being towed, a steep hill is
being climbed, vehicle is operated in
slow moving traffic, or engine is being
idled with very high ambient (outside)
temperatures and the air conditioning
is on. Higher altitudes could aggravate
these conditions.
1. This may be a temporary condition
and repair is not necessary. Turn off
the air conditioning and attempt to
drive the vehicle without any of the
previous conditions. Observe the
temperature gauge. The gauge
should return to the normal range. If
the gauge does not return to normal
range, determine the cause for
overheating and repair. Refer to
POSSIBLE CAUSES (numbers 2
through 20).
2. Is temperature gauge (if equipped)
reading correctly?
2. Check gauge. Refer to Group 8E.
3. Is temperature warning lamp (if
equipped) illuminating unnecessarily?
3. Check warning lamp operation.
Refer to Group 8E. Repair as
necessary.
4. Coolant low in coolant reserve/
overflow tank and radiator.
4. Check for coolant leaks and repair
as necessary. Refer to Testing
Cooling System For Leaks in this
group.
5. Pressure cap not installed tightly. If
cap is loose, boiling point of coolant
will be lowered. Also refer to the
following step 6.
5. Tighten cap.
6. Poor seals at radiator cap. 6. (a) Check condition of cap and cap
seals. Refer to Radiator Cap. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
COOLING SYSTEM DIAGNOSIS
LOST OR LEAKING FROM COOLING
SYTEM (Continued)
7. Coolant level low in radiator but not
in coolant reserve/overflow tank. This
means the radiator is not drawing
coolant from the coolant reserve/
overflow tank as the engine cools.
As the engine cools, a vacuum is
formed in the cooling system of the
engine and radiator. If radiator cap
seals are defective, or cooling system
has leaks, a vacuum can not be
formed.
7. (a) Check condition of radiator cap
and cap seals. Refer to Radiator Cap
in this group. Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check the condition of the hose
from the radiator to the coolant tank. It
should fit tight at both ends without any
kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow
tank and tank hose for blockage.
8. Freeze point of antifreeze not
correct. Mixture may be too rich.
8. Check antifreeze. Refer to Coolant
section of this group. Adjust antifreeze-
to-water ratio as required.
9. Coolant not flowing through system. 9. Check for coolant flow at radiator
filler neck with some coolant removed,
engine warm and thermostat open.
Coolant should be observed flowing
through radiator. If flow is not
observed, determine reason for lack of
flow and repair as necessary.
10. Radiator or A/C condenser fins are
dirty or clogged.
10. Clean insects or debris. Refer to
Radiator Cleaning in this group.
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or replaced.
12. Aftermarket A/C installed without
proper radiator.
12. Install proper radiator.
13. Fuel or ignition system problems. 13. Refer to Fuel and Ignition System
groups for diagnosis. Also refer to the
appropriate Powertrain Diagnostic
Procedures service manual for
operation of the DRB scan tool.
14. Dragging brakes. 14. Check and correct as necessary.
Refer to Group 5, Brakes in this
manual text.
15. Bug screen is being used reducing
airflow.
15. Remove bug screen.
16. Thermostat partially or completely
shut. This is more prevalent on high
mileage vehicles.
16. Check thermostat operation and
replace as necessary. Refer to
Thermostats in this group.
17. Thermal viscous fan drive not
operating properly.
17. Check fan drive operation and
replace if necessary. Refer to Viscous
Fan Drive in this group.
18. Electric cooling fan not operating
properly (XJ models with 4.0L engine
equipped with heavy duty cooling
and/or air conditioning).
18. Check electric fan operation and
repair as necessary. Refer to Auxiliary
Electric Cooling Fan-XJ Models with
4.0L 6-cylinder engine in the manual
text.
COOLING SYSTEM DIAGNOSIS (CONT.)
LOST OR LEAKING FROM COOLING
SYSTEM (Continued)
19. Cylinder head gasket leaking 19. Check for cylinder head gasket
leaks. Refer to Testing Cooling System
for Leaks in this group. For repair refer
to Group 9, Engines.
20. Heater core leaking. 20. Check heater core for leaks. Refer
to Group 24, Heating and Air
Conditioning. Repair as necessary.
TEMPERATURE GUAGE READING IS
INCONSISTENT (FLUCTUATES,
CCLES OR IS ERRACTIC)
1. On XJ models equipped with a 4.0L
6-cylinder engine, heavy duty cooling
and/or air conditioning, the gauge may
cycle up and down. This is due to the
cycling of the electric radiator fan.
1. A normal condition. No correction is
necessary. If gauge cycling is going
into the hot zone, check electric fan
operation and repair as necessary.
Refer to Auxiliary Electric Cooling
Fan-XJ Models with 4.0L 6-cylinder
engine in the manual text.
2. During cold weather operation, with
the heater blower in the high position,
the gauge reading may drop slightly.
necessary.
3. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose wiring
in this circuit.
3. Check operation of gauge and repair
if necessary. Refer to Group 8E,
Instrument Panel and Gauges.
4. Gauge reading rises when vehicle is
brought to a stop after heavy use
(engine still running).
necessary. Gauge reading should
return to normal range after vehicle is
driven.
5. Gauge reading high after restarting a
warmed-up (hot) engine.
necessary. The gauge should return to
normal range after a few minutes of
engine operation.
6. Coolant level low in radiator (air will
build up in the cooling system causing
the thermostat to open late).
6. Check and correct coolant leaks.
Refer to Testing Cooling Sytem for
Leaks in this group.
7. Cylinder head gasket leaking
allowing exhaust gas to enter cooling
system causing thermostat to open late.
7. (a) Check for cylinder head gasket
leaks with a commercially available
Block Leak Tester. Repair as
necessary.
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from
exhaust system. Repair as necessary.
8. Water pump impeller loose on shaft. 8. Check water pump and replace as
necessary. Refer to Water Pumps in
this group.
9. Loose accessory drive belt (water
pump slipping).
9. Refer to Engine Accessory Drive
Belts in this group. Check and correct
as necessary.
10. Air leak on the suction side of water
pump allows air to build up in cooling
system causing thermostat to open late.
10. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING OFF
STEAM AND/OR COOLANT TO
COOLANT TANK. TEMPERATURE
GAUGE READING MAY BE ABOVE
NORMAL BUT NOT HIGH. COOLANT
LEVEL MAY BE HIGH IN COOLANT
RESERVE/OVERFLOW TANK
1. Pressure relief valve in radiator cap
is defective.
1. Check condition of radiator cap and
cap seals. Refer to Radiator Caps in
this group. Replace cap as necessary.
COOLANT LOSS TO THE GROUND
WITHOUT PRESSURE CAP
BLOWOFF. GAUGE IS READING
HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or engine.
1. Pressure test and repair as
necessary. Refer to Testing Cooling
System for Leaks in this group.
DETONATION OR PREIGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
1. Engine overheating. 1. Check reason for overheating and
repair as necessary.
2. Freeze point of antifreeze not
correct. Mixture is too rich or too lean.
2. Check antifreeze. Refer to the
Coolant section in this group. Adjust
antifreeze-to-water ratio as required.
HOSE OR HOSES COLLAPSE WHEN
ENGINE IS COOLING
1. Vacuum created in cooling system on
engine cool-down is not being relieved
through coolant reserve/overflow
system.
1. (a) Radiator cap relief valve stuck.
Refer to Radiator Cap in this group.
Replace if necessary.
(b) Hose between coolant reserve/
overflow tank and radiator is kinked.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and repair
as necessary.
(d) Reserve/overflow tank is internally
blocked or plugged. Check for
blockage and repair as necessary.
ELECTRIC RADIATOR FAN RUNS
ALL THE TIME (XJ MODELS WITH
4.0L ENGINE EQUIPPED WITH
HEAVY DUTY COOLING AND/OR AIR
CONDITIONING ONLY)
1. Fan relay, powertrain control module
(PCM) or engine coolant temperature
sensor defective.
1. Refer to Auxiliary Electric Cooling
Fan-XJ Models with 4.0L 6-Cylinder
engine in the manual text. Repair as
necessary. Also refer to appropriate
Powertrain Diagnostic Procedures
service manual for operation of the
DRB scan tool.
ELECTRIC RADIATOR FAN WILL NOT
RUN (XJ MODELS WITH 4.0L
ENGINE EQUIPPED WITH HEAVY
DUTY COOLING AND/OR AIR
CONDITIONING ONLY) GAUGE
READING HIGH OR HOT
1. Fan motor defective. 1. Refer to Auxiliary Electric Cooling
necessary.
2. Fan relay, powertrain control module
(PCM) or engine coolant temperature
sensor defective.
necessary. Also refer to the appropriate
Powertrain Diagnostic Procedures
service manual for operation of the
DRB scan tool
3. Blown fuse in power distribution
center (PDC).
3. Determine reason for blown fuse
NOISY FAN 1. Fan blades loose. Replace fan blade assembly. Refer to
Cooling System Fans in this group.
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or clean
debris or insects from radiator or A/C
condenser.
4. Electric fan motor defective (if
equipped).
4. Replace electric fan motor. Refer to
Auxiliary Electric Cooling Fan-XJ
Models with 4.0L 6-Cylinder engine in
the manual text.
5. Thermal viscous fan drive has
defective bearing.
5. Replace fan drive. Bearing is not
serviceable. Refer to Viscous Fan
Drive in this group.
6. A certain amount of fan noise
(roaring) may be evident on models
equipped with a thermal viscous fan
drive. Some of this noise is normal.
6. Refer to Viscous Fan Drive in this
group for an explanation of normal fan
noise.
INADEQUATE AIR CONDITIONER
PERFORMANCE (COOLING SYSTEM
SUSPECTED)
1. Radiator and/or A/C condenser is
restricted, obstructed or dirty (insects,
leaves etc.).
1. Remove restriction and/or clean as
necessary. Refer to Radiator Cleaning
in this group.
2. Electric radiator fan not operating
when A/C is operated (if equipped with
electric fan).
necessary.
3. Thermal viscous fan drive is
freewheeling.
3. Refer to Viscous Fan Drive for
diagnosis. Repair as necessary.
4. Engine is overheating (heat may be
transferred from radiator to A/C
condenser. High underhood
temperatures due to engine overheating
may also transfer heat to A/C
components).
4. Correct overheating condition. Refer
to text in Group 7, Cooling.
5. Some models with certain engines
are equipped with air seals at the
radiator and/or A/C condenser. If these
seals are missing or damaged, not
enough air flow will be pulled through
the radiator and A/C condenser.
5. Check for missing or damaged air
seals and repair as necessary.
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a diagnostic trouble code (DTC)
number 17 been set?
the manual text and replace thermostat
if necessary.
2. Coolant level low. 2. Refer to Testing Cooling System for
Leaks in the manual text. Repair as
necessary.
3. Obstructions in heater hose fittings at
engine.
3. Remove heater hoses at both ends
and check for obstructions. Repair as
necessary.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
(Continued)
5. Some models with certain engines
are equipped with a water control
valve located on one of the heater
hoses. This valve may be defective.
5. Refer to Group 24, Heating and
Air Conditioning for diagnosis. Repair
as necessary.
6. Water pump is not pumping water
to heater core. When the engine is
fully warmed up, both heater hoses
should be hot to the touch. If only
one of the hoses is hot, the water
pump may not be operating correctly.
The accessory drive belt may also be
slipping causing poor water pump
operation.
6. Refer to Water Pumps in this
group. Repair as necessary. If a
slipping belt is detected, refer to
Engine Accessory Drive Belts in this
group. Repair as necessary.
HEAT ODOR 1. Various heat shields are used at
certain drive line components. One or
more of these shields may be
missing.
1. Locate missing shields and
replace or repair as necessary.
2. Is temperature gauge reading
above the normal range?
2. Refer to the previous Temperature
Gauge Reads High in these
Diagnosis Charts. Repair as
necessary.
3. Is cooling fan operating correctly? 3. Refer to Cooling System Fan in
this group for diagnosis. Repair as
necessary.
4. Has undercoating been applied to
any unnecessary component?
4. Clean undercoating as necessary.
5. Engine may be running rich
causing the catalytic convertor to
overheat.
5. Refer to the DRB scan tool and
the appropriate Powertrain
Diagnostic Procedures service
manual. Repair as necessary.
POOR DRIVEABILITY
(THERMOSTAT POSSIBLY STUCK
OPEN) GAUGE READING MAY BE
LOW
1. For proper driveability, good
vehicle emissions and for preventing
build-up of engine oil sludge, the
thermostat must be operating
properly. Has a diagnostic trouble
code (DTC) number 17 been set?
this group. DTCs may also be
checked using the DRB scan tool.
Refer to the proper Powertrain
Diagnostics Procedures service
manual for checking the thermostat
using the DRB scan tool. Replace
thermostat if necessary.
STEAM IS COMING FROM FRONT
OF VEHICLE NEAR GRILL AREA
WHEN WEATHER IS WET, ENGINE
IS WARMED UP AND RUNNING,
AND VEHICLE IS STATIONARY.
TEMPERATURE GAUGE IS IN
NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the radiator.
When the moisture contacts the hot
radiator, steam may be emitted. This
usually occurs in cold weather with
no fan or airflow to blow it away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily an
indication of adequate corrosion or
temperature protection. Do not rely
on coolant color for determining
condition of coolant.
1. Refer to Coolant in this group for
antifreeze tests. Adjust antifreeze-to-
water ratio as necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. Level changes are to be expected
as coolant volume fluctuates with
engine temperature. If the level in the
tank was between the FULL and ADD
marks at normal engine operating
temperature, the level should return
to within that range after operation at
elevated temperatures.
1. A normal condition. No repair is
necessary.
RADIATOR COOLANT FLOW CHECK
The fol l owi ng procedure wi l l determi ne i f cool ant i s
fl owi ng through the cool i ng system.
I f engi ne i s col d, i dl e engi ne unti l normal operati ng
temperature i s reached. Then feel the upper radi ator
hose. I f hose i s hot, the thermostat i s open and water
i s ci rcul ati ng through cool i ng system.
TESTING COOLING SYSTEM FOR LEAKS
ULTRAVIOLET LIGHT METHOD
Al l Jeep model s have a l eak detecti on addi ti ve
added to the cool i ng system before they l eave the fac-
tory. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). I f the factory ori gi nal cool ant has
been drai ned, pour one ounce of addi ti ve i nto the
cool i ng system. The addi ti ve i s avai l abl e through the
parts department. Pl ace the heater control uni t i n
HEAT posi ti on. Start and operate the engi ne unti l
the radi ator upper hose i s warm to the touch. Ai m
the commerci al l y avai l abl e bl ack l i ght tool at the
components to be checked. I f l eaks are present, the
bl ack l i ght wi l l cause the addi ti ve to gl ow a bri ght
green col or.
The bl ack l i ght can be used al ong wi th a pressure
tester to determi ne i f any external l eaks exi st (Fi g.
12).
PRESSURE TESTER METHOD
The engi ne shoul d be at the normal operati ng tem-
perature. Recheck the system col d i f the cause of
cool ant l oss i s not l ocated duri ng warm engi ne exam-
i nati on.
CAUSE INJURY BY SCALDING.
Careful l y remove the radi ator pressure cap from
the fi l l er neck and check the cool ant l evel . Push
down on the cap to di sengage i t from the stop tabs.
Wi pe the i nner part of the fi l l er neck and exami ne
the l ower i nsi de seal i ng seat for ni cks, cracks, pai nt,
di rt and sol der resi due. I nspect the reserve/overfl ow
tank tube for i nternal obstructi ons. I nsert a wi re
through the tube to be sure i t i s not obstructed.
I nspect the cams on the outsi de part of the fi l l er
neck. I f the cams are bent, seati ng of pressure cap
val ve and tester seal wi l l be affected. Repl ace cap i f
cams are bent.
Attach pressure tester 7700 (or an equi val ent) to
the radi ator fi l l er neck (Fi g. 13).
Operate the tester pump to appl y 124 kPa (18 psi )
pressure to the system. I f the hoses enl arge exces-
si vel y or bul ge whi l e testi ng, repl ace as necessary.
Observe the gauge poi nter and determi ne the condi -
ti on of the cool i ng system accordi ng to the fol l owi ng
cri teri a:
Hol ds Steady: I f the poi nter remai ns steady for
two mi nutes, there are no seri ous cool ant l eaks i n
the system. However, there coul d be an i nternal l eak
that does not appear wi th normal system test pres-
sure. I nspect for i nteri or l eakage or do the I nternal
Leakage Test. Do thi s i f i t i s certai n that cool ant i s
bei ng l ost and no l eaks can be detected.
Drops Sl owl y: Shows a smal l l eak or seepage i s
occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect the radi ator,
hoses, gasket edges and heater. Seal any smal l l eak
hol es wi th a Seal er Lubri cant or equi val ent. Repai r
l eak hol es and rei nspect the system wi th pressure
appl i ed.
Drops Qui ckl y: Shows that a seri ous l eakage i s
occurri ng. Exami ne the system for seri ous external
Fig. 12 Leak Detection Using Black LightTypical
TYPICAL BLACK
LIGHT TOOL
Fig. 13 Pressurizing SystemTypical
TYPICAL COOLING SYTEM PRESSURE TESTER
l eakage. I f no l eaks are vi si bl e, i nspect for i nternal
l eakage. Large radi ator l eak hol es shoul d be repai red
by a reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove the engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . Cool ant, bei ng heavi er
than engi ne oi l , wi l l drai n fi rst. Another way of test-
i ng i s to operate the engi ne and check for water gl ob-
ul es on the engi ne oi l di psti ck. Al so i nspect the
automati c transmi ssi on oi l di psti ck for water gl ob-
ul es. I nspect the automati c transmi ssi on fl ui d cool er
for l eakage. Operate the engi ne wi thout the pressure
cap on the radi ator unti l thermostat opens.
Attach a pressure tester to the fi l l er neck. I f pres-
sure bui l ds up qui ckl y, a l eak exi sts as a resul t of a
faul ty cyl i nder head gasket or crack i n the engi ne.
Repai r as necessary.
WARNING: DO NOT ALLOW PRESSURE TO
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
I f there i s no i mmedi ate pressure i ncrease, pump
the pressure tester unti l the i ndi cated pressure i s
wi thi n the system range. Vi brati on of the gauge
poi nter i ndi cates compressi on or combusti on l eakage
i nto the cool i ng system.
WARNING: DO NOT DISCONNECT THE SPARK
PLUG WIRES WHILE THE ENGINE IS OPERATING.
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. The catalytic
converter may be damaged.
I sol ate the compressi on l eak by shorti ng each
spark pl ug to the cyl i nder bl ock. The gauge poi nter
shoul d stop or decrease vi brati on when spark pl ug
for l eaki ng cyl i nder i s shorted. Thi s happens because
of the absence of combusti on pressure.
COMBUSTION LEAKAGE TEST (WITHOUT
PRESSURE TESTER)
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow for thermostat
removal . Refer to Thermostat Repl acement. Di scon-
nect the water pump dri ve bel t.
Di sconnect the upper radi ator hose from the ther-
mostat housi ng. Remove the housi ng and thermostat.
I nstal l the thermostat housi ng.
Add cool ant to the radi ator to bri ng the l evel to
wi thi n 6.3 mm (1/4 i n) of the top of the thermostat
housi ng.
CAUTION: Avoid overheating. Do not operate the
engine for an excessive period of time. Open the
draincock immediately after the test to eliminate
boil over of coolant.
Start the engi ne and accel erate rapi dl y three ti mes
(to approxi matel y 3000 rpm) whi l e observi ng the
cool ant. I f i nternal engi ne combusti on gases are l eak-
i ng i nto the cool i ng system, bubbl es wi l l appear i n
the cool ant. I f bubbl es do not appear, there i s no
i nternal combusti on gas l eakage.
VISCOUS FAN DRIVE
LEAKS
Vi scous fan dri ve operati on i s not affected by smal l
oi l stai ns near the dri ve beari ng. I f l eakage appears
excessi ve, repl ace the fan dri ve uni t.
TESTING
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18-to-
105C (0-to-220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 88 C (190 F).
Fan dri ve engagement shoul d have started to occur
at between 74 to 82 C (165 to 180 F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi -
cate an i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 88 C (190
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 57 to
79 C (135 to 175 F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
ELECTRIC COOLING FAN AND RELAY
DIAGNOSIS
NOTE: Refer to Electrical Group 8W for electric
cooling fan and relay circuit schematic.
The powertrai n control modul e (PCM) wi l l enter a
di agnosti c troubl e code (DTC) i n memory i f i t detects
a probl em i n the auxi l i ary cool i ng fan rel ay or ci rcui t.
Refer to Group 25, Emi ssi on Control Systems for cor-
rect DTC retri eval procedures.
I f the el ectri c cool i ng fan i s i noperati ve, check fuse
#11 (20A) i n juncti on bl ock and fuse #5 (40A maxi -
fuse) i n the Power Di stri buti on Center (PDC) wi th a
12 vol t test l amp or DVOM. I f fuses are o.k., refer to
Group 8W for el ectri c cool i ng fan and rel ay ci rcui t
schemati c.
RADIATOR CAP-TO-FILLER NECK SEAL
PRESSURE RELIEF CHECK
Wi th radi ator cap i nstal l ed on fi l l er neck, remove
cool ant reserve/ overfl ow tank hose from ni ppl e on
fi l l er neck. Connect a hand operated vacuum pump
to ni ppl e. Operate pump unti l a readi ng of 47-to-61
kPa (14- to-18 i n. Hg) appears on gauge. I f the read-
i ng stays steady, or drops sl i ghtl y and then remai ns
steady, the pressure val ve seal i s good. Repl ace radi -
ator cap i f readi ng does not hol d.
WARNING: THE WARNING WORDS -DO NOT OPEN
HOT- ON THE RADIATOR PRESSURE CAP (Fig. 14)
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT AND/OR UNDER PRESSURE.
There i s no need to remove the radi ator cap
except for the fol l owi ng purposes:
(1) To check and adjust anti freeze freeze poi nt.
(2) To refi l l system wi th new anti freeze.
(3) For conducti ng servi ce procedures.
(4) When checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN
RECENTLY, WAIT AT LEAST 15 MINUTES BEFORE
REMOVING RADIATOR CAP. WITH A RAG,
SQUEEZE RADIATOR UPPER HOSE TO CHECK IF
SYSTEM IS UNDER PRESSURE. PLACE A RAG
OVER THE CAP AND WITHOUT PUSHING DOWN,
ROTATE CAP COUNTER-CLOCKWISE TO THE
FIRST STOP. ALLOW FLUID TO ESCAPE THROUGH
OVERFLOW HOSE INTO COOLANT RESERVE/
OVERFLOW TANK. SQUEEZE RADIATOR UPPER
HOSE TO DETERMINE WHEN PRESSURE HAS
BEEN RELEASED. WHEN COOLANT AND STEAM
STOP BEING PUSHED INTO TANK AND SYSTEM
PRESSURE DROPS, REMOVE RADIATOR CAP
COMPLETELY.
Fig. 14 Radiator Pressure Cap
PRESSURE RATING FILLER NECK SEAL PRESSURE VALVE VACUUM VENT VALVE (SHOWN IN SEAL- ING POSITION)
PRESSURE TESTING RADIATOR CAPS
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l the cap on pressure tester (tool 7700 or
an equi val ent) (Fi g. 15).
Operate the tester pump and observe the gauge
poi nter at i ts hi ghest poi nt. The cap rel ease pressure
shoul d be 83-to-110 kPa (12-to-16 psi ). The cap i s sat-
i sfactory when the pressure hol ds steady. I t i s al so
good i f i t hol ds pressure wi thi n the 83-to-110 kPa
(12-to-16 psi ) range for 30 seconds or more. I f the
poi nter drops qui ckl y, repl ace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CAP INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
LOW COOLANT LEVEL-AERATION
I f the cool ant l evel i n radi ator drops bel ow top of
radi ator core tubes, ai r wi l l enter cool i ng system.
Low cool ant l evel can cause thermostat pel l et to be
suspended i n ai r i nstead of cool ant. Thi s wi l l cause
thermostat to open l ater, whi ch i n turn causes hi gher
cool ant temperature. Ai r trapped i n cool i ng system
al so reduces amount of cool ant ci rcul ati ng i n heater
core resul ti ng i n l ow heat output.
DEAERATION
As the engi ne operates, any ai r trapped i n cool i ng
system gathers under the radi ator cap. The next ti me
the engi ne i s operated, thermal expansi on of cool ant
wi l l push any trapped ai r past radi ator cap i nto the
cool ant reserve/overfl ow tank. Here i t escapes to the
atmosphere i nto the tank. When the engi ne cool s
down the cool ant, i t wi l l be drawn from the reserve/
overfl ow tank i nto the radi ator to repl ace any
removed ai r.
SERVICE PROCEDURES
COOLANT LEVEL CHECK ROUTINE
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
The cool ant reserve/overfl ow system provi des a
qui ck vi sual method for determi ni ng cool ant l evel
wi thout removi ng radi ator pressure cap. Wi th engi ne
col d and not runni ng, observe cool ant l evel i n
reserve/overfl ow tank. The cool ant l evel shoul d be
between ADD and FULL marks.
COOLANT SERVICE
I t i s recommended that the cool i ng system be
drai ned and fl ushed at 84,000 ki l ometers (52,500
mi l es), or 3 years, whi chever occurs fi rst. Then every
two years, or 48,000 ki l ometers (30,000 mi l es),
whi chever occurs fi rst.
ADDING ADDITIONAL COOLANT ROUTINE
Do not remove radiator cap to add coolant to
system. When addi ng cool ant to mai ntai n correct
l evel , do so at cool ant reserve/overfl ow tank. Use a
50/50 mi xture of ethyl ene-gl ycol anti freeze contai ni ng
Al ugard 340-2 and l ow mi neral content water.
Remove radi ator cap onl y for testi ng or when refi l l -
i ng system after servi ce. Removi ng cap unnecessari l y
can cause l oss of cool ant and al l ow ai r to enter sys-
tem, whi ch produces corrosi on.
COOLANT LEVEL CHECK SERVICE
The cool i ng system i s cl osed and desi gned to mai n-
tai n cool ant l evel to top of radi ator.
Fig. 15 Pressure Testing Radiator Pressure
CapTypical
WARNING: DO NOT OPEN RADIATOR DRAINCOCK
WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
AND COOLING SYSTEM IS UNDER PRESSURE.
When vehi cl e servi ci ng requi res a cool ant l evel
check i n radi ator, drai n several ounces of cool ant
from radi ator drai n cock. Do thi s whi l e observi ng
cool ant reserve/overfl ow system tank. The cool ant
l evel i n reserve/overfl ow tank shoul d drop sl i ghtl y. I f
not, i nspect for a l eak between radi ator and cool ant
reserve/overfl ow system connecti on. Remove radi ator
cap. The cool ant l evel shoul d be to top of radi ator. I f
not and i f cool ant l evel i n reserve/overfl ow tank i s at
ADD mark, check for:
An ai r l eak i n cool ant reserve/overfl ow tank or
i ts hose
An ai r l eak i n radi ator fi l l er neck
Leak i n pressure cap seal to radi ator fi l l er neck
DRAINING AND FILLING COOLING SYSTEM
DRAINING 2.5L 4-CYLINDER ENGINE
WARNING: DO NOT REMOVE THE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
reuse.
DO NOT remove the radi ator cap when drai ni ng
the cool ant from the reserve/overfl ow tank. Open the
radi ator drai ncock and when the tank i s empty,
remove the radi ator cap. The cool ant does not have
to be removed from the tank unl ess the system i s
bei ng refi l l ed wi th a fresh mi xture.
(1) Drai n the cool ant from the radi ator by l oosen-
i ng the petcock.
(2) Drai n cool ant from engi ne by removi ng drai n
pl ug at l eft rear si de of bl ock.
DRAINING 4.0L 6-CYLINDER ENGINE
WARNING: DO NOT REMOVE THE CYLINDER BLOCK
DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND UNDER PRESSURE.
reuse.
(1) Remove radi ator pressure cap.
(2) For access to radi ator drai ncock (Fi g. 16),
remove radi ator gri l l e mounti ng screws and remove
gri l l . Refer to Group 23, Body for correct procedure.
(3) Attach one end of a 24 i nch l ong X 1/4 i nch I D
hose to the radi ator drai ncock. Put the other end i nto
a cl ean contai ner. Open drai ncock and drai n cool ant
from radi ator.
(4) Drai n cool ant from engi ne by removi ng the
drai n pl ug and cool ant temperature sensor on l eft
si de of bl ock.
REFILLING COOLING SYSTEM
(1) Ti ghten the radi ator petcock and the cyl i nder
bl ock drai n pl ug(s). I f removed, i nstal l cool ant tem-
perature sensor (4.0L 6-cyl i nder engi ne).
(2) Fi l l system usi ng a 50/50 mi xture of water and
anti freeze as descri bed i n the Cool ant secti on of thi s
group. Fi l l radi ator to top and i nstal l radi ator cap.
Add suffi ci ent cool ant to reserve/overfl ow tank to
rai se l evel to FULL mark.
(3) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th radi ator cap i n pl ace.
(4) After engi ne has reached normal operati ng
temperature, shut engi ne off and al l ow i t to cool .
(5) Add cool ant to reserve/overfl ow tank as neces-
sary. Only add coolant when the engine is cold.
Coolant level in a warm engine will be higher
due to thermal expansion.
REVERSE FLUSHING
CAUTION: The cooling system normally operates
at 97-to-124 kPa (14- to-18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
Fig. 16 Radiator Petcock4.0L (LHD/RHD)
RADIATOR PETCOCK
CHEMICAL CLEANING
I f vi sual i nspecti on i ndi cates the formati on of sl udge or
scal y deposi ts, use a radi ator cl eaner (Mopar Radi ator
Kl een or equi val ent) before fl ushi ng. Thi s wi l l soften
scal e and other deposi ts and ai d the fl ushi ng operati on.
CAUTION: Be sure instructions on the container
are followed.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
CAUTION: The cooling system normally operates
at 97-to-124 kPa (14- to-18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system. Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Remove the l ead away hose, fl ushi ng gun, water sup-
pl y hose and ai r suppl y hose. Remove the thermostat
housi ng and i nstal l thermostat. I nstal l the thermostat
housi ng wi th a repl acement gasket. Refer to Thermostat
Repl acement. Connect the radi ator hoses. Refi l l the
cool i ng system wi th the correct anti freeze/water mi x-
ture.
TRANSMISSION OIL COOLERS
WATER-TO-OIL COOLER
The i nternal transmi ssi on oi l cool er l ocated wi thi n
the radi ator i s not servi ceabl e. I f i t requi res servi ce,
the radi ator must be repl aced.
Once the repai red or repl acement radi ator has been
i nstal l ed, fi l l the cool i ng system and i nspect for l eaks.
Refer to the Refi l l i ng Cool i ng System and Testi ng Cool -
i ng System For Leaks secti ons i n thi s group. I f the
transmi ssi on operates properl y after repai ri ng the l eak,
drai n the transmi ssi on and remove the transmi ssi on oi l
pan. I nspect for sl udge and/or rust. I nspect for a di rty
or pl ugged i nl et fi l ter. I f none of these condi ti ons are
found, the transmi ssi on and torque convertor may not
requi re recondi ti oni ng. Refer to Group 21 for automati c
transmi ssi on servi ci ng.
AIR-TO-OIL COOLER
REMOVAL
(1) Remove the gri l l mounti ng screws and remove
the gri l l . Refer to Group 23, Body for procedures.
(2) Pl ace a drai n pan bel ow the transmi ssi on oi l
cool er.
(3) Remove the two hose cl amps at oi l cool er i nl et
and outl et tubes.
(4) Remove the two oi l cool er mounti ng bol ts (Fi g.
17) (Fi g. 18).
(5) Remove the oi l cool er from vehi cl e.
Fig. 17 Auxiliary Air-To-Oil Cooler4.0L Engine
AIR CONDITION- ING CONDENSER HOSE CLAMPS (2)
AUXILIARY AUTOMATIC TRANSMIS-
SION OIL COOLER
MOUNTING BOLT MOUNTING BOLT
INSTALLATION
(1) Posi ti on and secure oi l cool er to vehi cl e.
Ti ghten mounti ng bol ts to 8 Nm (72 i n. l bs.) torque.
(2) Secure i nl et and outl et tubes wi th hose cl amps.
Ti ghten the two cl amps to 2 Nm (15 i n. l bs.) torque.
COOLANT RESERVE TANK
REMOVAL
(1) Remove the tube cl amp at the tank and remove
tube.
(2) Remove the tank mounti ng bol ts and remove
tank (Fi g. 19) (Fi g. 20).
INSTALLATION
(1) Posi ti on tank and ti ghten to 2 Nm (17 i n. l bs.)
torque.
(2) Posi ti on tube and secure cl amp.
WATER PUMP
CAUTION: If the water pump is replaced because
of mechanical damage, the fan blades and viscous
fan drive should also be inspected. These compo-
nents could have been damaged due to excessive
vibration.
The water pump can be removed wi thout di scharg-
i ng the ai r condi ti oni ng system (i f equi pped).
CAUTION: All engines have a reverse (counter-
clockwise) rotating water pump. The letter R is
stamped into the back of the water pump impeller
(Fig. 21) to identify. Engines from previous model
years, depending upon application, may be
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump will
cause engine over heating.
The water pump i mpel l er i s pressed on the rear of
the pump shaft and beari ng assembl y. The water
pump i s servi ced onl y as a compl ete assembl y.
Fig. 18 Auxiliary Air-To-Oil Cooler2.5L Engine
AUTO. TRANS. OIL COOLER FRONT MOUNTING BOLTS HOSECLAMPS
Fig. 19 Reserve/Overflow TankExcept Right Hand
Drive
COOLANT RESERVE/OVER- FLOW TANK TUBE TO RADI- ATOR CLAMP MOUNTING BOLTS
Fig. 20 Reserve/Overflow TankWith Right Hand
Drive
CLAMP COOLANT RESERVE/ OVERFLOWTANK TUBE TO RADI- ATOR MOUNTING BOLTS LOWER BRACKET
WARNING: DO NOT REMOVE THE BLOCK DRAIN
PLUG(S) OR LOOSEN RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE.
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
REMOVAL-2.5L ENGINE (LHD/RHD)
(2) Drai n the cool i ng system.
(3) Remove upper radi ator hose.
(4) Loosen (but do not remove at thi s ti me) the
four fan hub-to-water pump pul l ey mounti ng nuts
(Fi g. 22).
(5) Remove accessory dri ve bel t (refer to Accessory
Dri ve Bel t, Removal and I nstal l ati on i n thi s secti on)
(6) Unbol t fan shroud
(7) Remove the four fan hub-to-water pump pul l ey
nuts and remove fan and shroud together
CAUTION: After removing fan blade/viscous fan
drive assembly, do not place thermal viscous fan
drive in horizontal position. If stored horizontally,
silicone fluid in viscous fan drive could drain into
its bearing assembly and contaminate lubricant.
(8) Remove power steeri ng pump and bracket (Fi g.
23), refer to Group 19 Steeri ng for correct procedure.
(9) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
(10) Remove the four pump mounti ng bol ts (Fi g.
24) and remove pump from vehi cl e. Di scard ol d gas-
ket. Note that one of the four bol ts i s l onger than the
other bol ts.
(11) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
INSTALLATION-2.5L ENGINE (LHD/RHD)
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar Thread Seal ant Wi th Tefl on. Refer
to the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
Fig. 21 Reverse Rotating Water PumpTypical
R STAMPED INTO IMPELLER
Fig. 22 Fan Mounting Nuts
THERMAL VIS- COUS FAN DRIVE (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS (4) FAB HUB-TO-PUMP PULLEY STUDS WATER PUMP WATER PUMP PUL- LEY FAN BLADE (4) FAN HUB-TO- PUMP PULLEY NUTS
Fig. 23 Power Steering Pump Attachment-2.5L
INTAKE MANIFOLD PUMP ASSEMBLY 2.5L PUMP BRACKET
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 30 Nm (22 ft. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) I nstal l power steeri ng pump and bracket. Refer
to Group 19, Steeri ng.
(6) Posi ti on water pump pul l ey to water pump
hub.
(7) I nstal l shroud and fan together and i nstal l four
nuts to water pump hub studs. Ti ghten nuts to 27
(8) I nstal l and ti ghten upper fan shroud nuts.
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installation in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
(9) I nstal l and tensi on accessory dri ve bel t, refer to
Accessory Dri ve Bel t removal and i nstal l ati on i n thi s
group.
(10) I nstal l upper radi ator hose.
(11) Fi l l cool i ng system wi th cool ant and check for
l eaks. Refer to Refi l l i ng Cool i ng System i n thi s
group.
(13) Start and warm the engi ne. Check for l eaks.
REMOVAL-4.0L ENGINE (LHD/RHD)
(2) Drai n the cool i ng system.
(3) Di sconnect el ectri c cool i ng fan connector.
(4) Remove el ectri c cool i ng fan/shroud assembl y (i f
equi pped).
(5) Unbol t vi scous fan shroud.
(6) Loosen (but do not remove at thi s ti me) the
four water pump pul l ey-to-water pump hub mounti ng
bol ts (Fi g. 25) and the four vi scous fan to i dl er pul l ey
nuts.
NOTE: The engine accessory drive belt must be
removed prior to removing the fan (if installed at
pump) or fan pulley.
(7) Remove accessory dri ve bel t (refer to Accessory
Dri ve Bel t, Removal and I nstal l ati on i n thi s secti on)
(8) Remove the four vi scous fan to i dl er pul l ey
nuts and remove the fan and shroud together.
CAUTION: After removing fan blade/viscous fan
drive assembly, do not place thermal viscous fan
drive in horizontal position. If stored horizontally,
silicone fluid in viscous fan drive could drain into
its bearing assembly and contaminate lubricant.
(9) Remove the four water pump pul l ey bol ts and
remove the pul l ey.
(10) Remove power steeri ng pump and bracket
(Fi g. 26), refer to Group 19 Steeri ng.
(11) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
Fig. 24 Water Pump Remove/InstallTypical
(4) PULLEY MOUNTING STUDS HEATER HOSE FITTING UPPER VENT HOLE PUMP GAS- KET WATER PUMP LOWER VENT HOLE LONG BOLT BOLTS (3) SHORT
Fig. 25 Water Pump Pulley Bolts
WATER PUMP HUB BOLTS (4) PUMP PULLEY
(12) Remove the four pump mounti ng bol ts (Fi g.
27) and remove pump from vehi cl e. Di scard ol d gas-
ket. Note that one of the four bol ts i s l onger than the
other bol ts.
(13) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
INSTALLATION-4.0L ENGINE (LHD/RHD)
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar Thread Seal ant Wi th Tefl on. Refer
to the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 30 Nm (22 ft. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) Posi ti on water pump pul l ey to water pump
hub.
(6) I nstal l four pump pul l ey bol ts. Ti ghten bol ts (or
nuts) to 27 Nm (20 ft. l bs.) torque.
(7) I nstal l power steeri ng pump. Refer to Group
19, Steeri ng for proper procedure and torque val ues.
(8) I nstal l the vi scous fan and shroud together.
I nstal l the four fan to i dl er pul l ey nuts and ti ghten
to 27 Nm (20 ft. l bs.).
Fig. 26 Power Steering Pump Attachment-4.0L
Fig. 27 Water Pump Remove/InstallTypical
(4) PULLEY MOUNTING STUDS HEATER HOSE FITTING UPPER VENT HOLE PUMP GAS- KET WATER PUMP LOWER VENT HOLE LONG BOLT BOLTS (3) SHORT
CAUTION: When installing the serpentine engine
accessory drive belt, the belt MUST be routed cor-
rectly. If not, the engine may overheat due to the
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installation in this group for
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
(9) I nstal l and ti ghten vi scous fan shroud bol ts.
(10) I nstal l and tensi on the accessory dri ve bel t,
refer to Accessory Dri ve Bel t removal and i nstal l a-
ti on i n thi s group.
(11) I nstal l the el ectri c cool i ng fan/shroud assy.
(12) I nstal l and ti ghten fan shroud bol ts and con-
nect el ectri cal fan connector.
(13) Fi l l cool i ng system wi th cool ant and check for
l eaks. Refer to Refi l l i ng Cool i ng System i n thi s
group.
THERMOSTAT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
reuse.
(1) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng.
(2) Remove radi ator upper hose and heater hose at
thermostat housi ng.
(3) Di sconnect wi ri ng connector at engi ne cool ant
temperature sensor.
(4) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 28).
Di scard ol d gasket.
(5) Cl ean the gasket mati ng surfaces.
INSTALLATION
(1) I nstal l the repl acement thermostat so that the
pel l et, whi ch i s enci rcl ed by a coi l spri ng, faces the
engi ne. Al l thermostats are marked on the outer
fl ange to i ndi cate the proper i nstal l ed posi ti on.
(a) Observe the recess groove i n the engi ne cyl -
i nder head (Fi g. 29).
(b) Posi ti on thermostat i nto thi s groove wi th
arrow and ai r bl eed hol e on outer fl ange poi nti ng
up.
(2) I nstal l repl acement gasket and thermostat
housi ng.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
may result in a cracked housing.
(3) Ti ghten the housi ng bol ts to 20 Nm (15 ft. l bs.)
torque.
(4) I nstal l hoses to thermostat housi ng.
(5) I nstal l el ectri cal connector to cool ant tempera-
ture sensor.
(6) Be sure that the radi ator drai ncock i s ti ghtl y
cl osed. Fi l l the cool i ng system to the correct l evel
wi th the requi red cool ant mi xture. Refer to Refi l l i ng
Cool i ng System i n thi s group.
Fig. 28 Thermostat Removal/Installation
LONGBOLT GASKET THERMOSTAT THERMOSTAT HOUSING SHORT BOLT
RADIATOR
BLOCK DRAIN PLUGS, RADIATOR CAP, OR
LOOSEN THE RADIATOR DRAINCOCK WITH THE
SYSTEM HOT AND PRESSURIZED. SERIOUS
BURNS FROM THE COOLANT CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
2.5L 4-CYLINDER ENGINE
REMOVAL
(2) Observe the previ ous WARNINGS. Remove
radi ator cap.
(3) Posi ti on drai n pan under drai ncock. Open radi -
ator drai ncock. Drai n radi ator.
(4) Remove radi ator upper and l ower hose cl amps
(Fi g. 7) (Fi g. 8). Remove hoses.
(5) Remove E-cl i p from al i gnment dowel at radi a-
tor l ower mounti ng bracket (Fi g. 30).
(6) Di sconnect cool ant reserve/overfl ow tank hose
from radi ator.
(7) Remove four radi ator fan shroud mounti ng
bol ts (Fi g. 30). Push shroud back agai nst front of
engi ne.
(8) I f equi pped, di sconnect and pl ug automati c
transmi ssi on fl ui d cool er l i nes. Refer to Group 21,
Transmi ssi on for procedures.
(9) Remove two radi ator top mounti ng bol ts (Fi g.
30).
(10) Ai r condi ti oni ng equi pped
(a) Remove the radi ator gri l l e mounti ng screws
and remove gri l l . Refer to Group 23, Body for pro-
cedures.
(b) Remove the ai r condi ti oni ng condenser-to-
radi ator mounti ng bol t. Use an open end wrench to
remove bottom bol ts (Fi g. 31).
(11) Li ft radi ator strai ght up and out of vehi cl e.
Take care not to damage radi ator fi ns. When remov-
i ng radi ator, note posi ti on of the rubber seal s l ocated
on the top, bottom and si des of radi ator (Fi g. 30). To
prevent possi bl e overheati ng, these seal s must be
i nstal l ed to thei r ori gi nal posi ti ons.
INSTALLATION
(1) I nstal l radi ator behi nd ai r condi ti oni ng con-
denser wi th bottom al i gnment dowel i nserted i nto
radi ator l ower mounti ng bracket (Fi g. 30).
(2) I nstal l E-cl i p to radi ator al i gnment dowel (Fi g.
30).
(3) Ti ghten the four condenser-to-radi ator mount-
i ng bol ts to 6.2 Nm (55 i n. l bs.) torque.
(4) I f removed, i nstal l radi ator gri l l e.
(5) Ti ghten radi ator top mounti ng bol ts to 6 Nm
(6) I f equi pped, connect automati c transmi ssi on
fl ui d cool er l i nes to radi ator. Refer to Group 21,
Transmi ssi on for procedures.
(7) I nstal l the radi ator fan shroud.
(8) Connect the cool ant reserve/overfl ow tank hose.
(9) Connect radi ator hoses and i nstal l hose cl amps.
(10) Connect negati ve battery cabl e.
(11) Cl ose the drai ncock.
(12) Fi l l cool i ng system wi th correct cool ant.
(13) I nstal l radi ator cap.
(14) Check and adjust automati c transmi ssi on
fl ui d l evel (i f equi pped).
Fig. 29 Thermostat Recess
GROOVE
4.0L 6-CYLINDER ENGINE
CAN OCCUR.
Fig. 30 Radiator Remove/Install2.5L 4-Cylinder Engine
UPPER CROSSMEMBER BOLTS (2) TOP MOUNTING BOLTS (2)UPPER RUBBER SEAL FAN SHROUDWELL NUTS (2) FAN SHROUD MOUNTING BOLTS (4) RADIATOR SUP- PORT LEFT SIDE RUBBER SEAL E-CLIP RADIATOR LOWER MOUNTINGBRACKET
ALIGN DOWEL
LOWER RUBBER SEAL A/C CONDENSER RIGHT SIDE RUBBER SEAL RADIATOR
Fig. 31 Condenser Mounting Bolts2.5L 4-Cylinder
EngineTypical
CONDENSER 6 Nm (55 IN. LBS.) RECEIVER/DRIER
REMOVAL
(2) Observe the previ ous WARNINGS.
(3) Remove pressure cap.
(4) For access to radi ator drai ncock, remove radi a-
tor gri l l e mounti ng screws and remove gri l l . Refer to
Group 23, Body for procedures.
(5) Attach one end of a 24 i nch l ong X 1/4 i nch I D
hose to the radi ator drai ncock. Put the other end i nto
a cl ean contai ner. Open drai ncock and drai n radi ator.
(6) I f equi pped, di sconnect auxi l i ary el ectri c cool -
i ng fan el ectri cal connector (Fi g. 32).
(7) I f equi pped, remove two el ectri c cool i ng fan
mounti ng bol ts. Li ft cool i ng fan strai ght up unti l
al i gnment tabs at the bottom are cl ear of sl ots i n
bracket at bottom of radi ator (Fi g. 33).
(8) Remove the two mechani cal (non-el ectri cal ) fan
shroud mounti ng bol ts. Li ft shroud strai ght up unti l
al i gnment tabs at the bottom are cl ear of sl ots i n
bracket at bottom of radi ator (Fi g. 33). Pl ace shroud
over mechani cal fan.
(9) I f equi pped, di sconnect and pl ug automati c
transmi ssi on fl ui d cool er l i nes. Refer to Group 21,
Transmi ssi ons for procedures. I f equi pped wi th
remote transmi ssi on cool er, remove l i ne to cool er
from bracket at bottom of radi ator.
(10) Di sconnect radi ator upper and l ower hoses
cl amps (Fi g. 7) (Fi g. 8). Di sconnect radi ator upper
and l ower hoses.
(11) Mark the posi ti on of the hood l atch stri ker on
the radi ator crossmember and remove hood l atch
stri ker.
(12) Remove two radi ator upper crossmember-to-
i sol ator nuts (Fi g. 33).
(13) Remove four radi ator upper crossmember
bol ts (Fi g. 33) and remove upper crossmember.
(14) I f equi pped wi th ai r condi ti oni ng, separate
radi ator from condenser by removi ng condenser-to-ra-
di ator mounti ng brackets (Fi g. 34).
(15) Li ft radi ator strai ght up and out of engi ne
compartment taki ng care not to damage fi ns.
INSTALLATION
The radi ator i s suppl i ed wi th two al i gnment dowel s
(Fi g. 33) xxxxxxx (Fi g. 35). They are l ocated on the
bottom tank and fi t i nto rubber grommets i n the
radi ator l ower crossmember.
(1) Lower radi ator i nto engi ne compartment. Posi -
ti on al i gnment dowel s i nto rubber grommets i n radi -
ator l ower crossmember (Fi g. 33) xxxxxxxx (Fi g. 35)
(2) I f equi pped wi th ai r condi ti oni ng, attach con-
denser to radi ator wi th mounti ng brackets (Fi g. 34).
(3) I nstal l radi ator upper crossmember and four
mounti ng bol ts.
(4) I nstal l radi ator upper crossmember-to-i sol ator
nuts. Ti ghten nuts to 10 Nm (86 i n. l bs.) torque. I f
i sol ator-to-radi ator nuts had been removed, ti ghten
them to 5 Nm (47 i n. l bs.) torque.
(5) I nstal l hood l atch stri ker. Note previ ousl y
marked posi ti on.
(6) Connect radi ator upper and l ower hoses.
(7) I f equi pped, connect automati c transmi ssi on
fl ui d cool er l i nes. Refer to Group 21, Transmi ssi ons
for procedures. I f equi pped wi th remote cool er, attach
cool er l i ne to bracket at bottom of radi ator.
(8) I nstal l el ectri c cool i ng fan (i f equi pped). I nsert
al i gnment tabs at bottom of fan shroud i nto sl ots i n
bracket at bottom of radi ator. Ti ghten mounti ng bol ts
(9) Connect el ectri c cool i ng fan el ectri cal connec-
tor.
(10) I nstal l mechani cal cool i ng fan shroud. I nsert
al i gnment tabs at bottom of shroud i nto sl ots i n
bracket at bottom of radi ator. Ti ghten mounti ng bol ts
(11) Cl ose radi ator drai ncock.
(12) I nstal l gri l l e.
(13) Connect negati ve battery cabl e.
(14) Fi l l cool i ng system wi th correct cool ant. Refer
to the Cool ant secti on of thi s group.
(15) I nstal l pressure cap.
(16) Check and adjust automati c transmi ssi on
fl ui d l evel (i f equi pped).
Fig. 32 Auxiliary Electric Cooling Fan Wiring
ConnectorTypical
ELECTRIC COOLING FAN MOUNTINGBOLT ELECTRIC COOLING FAN CONNECTOR MOUNTING BOLT
Fig. 33 Auxiliary Electric Cooling Fan and Fan ShroudTypical
UPPER CROSSMEMBER BOLTS (4) FAN SHROUD MOUNTING BOLTS (2) MECHANICAL FAN SHROUD ELECTRIC COOLING FAN WIRING HARNESS CLIPS COOLING FAN MOUNTING BOLTS (2) ALIGNMENT TABS RUBBER ISOLA- TORS (2) RADIATOR RADIATOR ALIGNMENT DOWELS (2) LOWER CROSS- MEMBER RUBBER GROM- METS (2) ALIGNMENT SLOTS (4) UPPER RADIATOR CROSS- MEMBER ISOLATORNUTS ALIGNMENT TABS
Fig. 34 Condenser-to-Radiator Mounting Brackets
4.0L 6- Cylinder Engine
Fig. 35 Radiator Installation 4.0L 6-Cylinder Engine
ALIGNMENT DOWEL RADIATOR AIR CONDI- TIONING CONDENSER GROMMET
REMOVAL
The auxi l i ary cool i ng fan i s attached to the radi a-
tor upper crossmember behi nd the radi ator.
(1) Remove the two fan mounti ng bol ts from radi -
ator upper crossmember (Fi g. 36).
(2) Di sconnect the el ectri c fan connector.
(3) Li ft fan strai ght up and out of vehi cl e.
INSTALLATION
(1) Al i gn l ower retai ni ng tabs of fan shroud wi th
sl ots i n bracket at bottom of radi ator. Push fan down
i nto posi ti on.
(2) Ti ghten the mounti ng bol ts to 4 Nm (31 i n.
l bs.) torque.
(3) Connect auxi l i ary cool i ng fan el ectri cal connec-
tor.
ENGINE BLOCK HEATER
REMOVAL
Refer to correct i l l ustrati on (Fi g. 37) (Fi g. 38)when
servi ci ng bl ock heater.
CAN OCCUR.
(1) Drai n cool ant from radi ator and engi ne cyl i n-
der bl ock.
(2) Unpl ug power cord from bl ock heater.
(3) Loosen screw i n center of bl ock heater (Fi g. 37)
(Fi g. 38).
(4) Remove bl ock heater from cyl i nder bl ock.
INSTALLATION
(1) Thoroughl y cl ean the engi ne core hol e and the
bl ock heater seat.
(2) I nsert bl ock heater assembl y i nto core hol e
wi th el ement l oop poi nti ng Up.
(3) Seat bl ock heater fl ush agai nst bl ock face.
Ti ghten mounti ng screw to 3.6 Nm (32 i n. l bs.)
torque.
(4) Fi l l cool i ng system wi th cool ant. Pressuri ze
system and i nspect for l eaks.
(5) Pl ug power cord i nto bl ock heater. Route cord
away from movi ng parts, l i nkages and exhaust sys-
tem components. Secure cord i n pl ace wi th ti e-straps.
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. There are di fferent types of adjustment
gauges for checki ng ei ther a serpenti ne or a V-type
bel t. Refer to the i nstructi ons suppl i ed wi th the
gauge. Use the correct gauge when checki ng bel t ten-
si on. Pl ace gauge i n the mi ddl e of the secti on of bel t
bei ng tested (between two pul l eys) to check tensi on.
Do not al l ow the gauge (or gauge adapter) to contact
anythi ng but the bel t.
BELT SCHEMATICS
The bel t routi ng schemati cs are publ i shed from the
l atest i nformati on avai l abl e at the ti me of publ i ca-
ti on. If anything differs between these schemat-
ics and the Belt Routing Label, use the
Fig. 36 Auxiliary Cooling FanRemove/Install
Typical
ELECTRIC COOLING FAN MOUNTINGBOLT ELECTRIC COOLING FAN CONNECTOR MOUNTING BOLT
Fig. 37 Heater and Cord 2.5L 4-Cylinder Engine
POWER CORD LOCATION BLOCKHEATER
schematics on Belt Routing Label. Thi s l abel i s
l ocated i n the engi ne compartment.
Refer to (Fi g. 39) xxxxx (Fi g. 40) xxxxxx (Fi g. 41)
xxxxx (Fi g. 42) for proper bel t routi ng on vehi cl es
wi th conventi onal l eft hand dri ve. Refer to (Fi g. 43)
xxxxx (Fi g. 44) for proper bel t routi ng on vehi cl es
wi th ri ght hand dri ve (RHD). Or, refer to the Bel t
Routi ng Label l ocated i n the vehi cl e engi ne compart-
ment.
BELT REPLACEMENT OR ADJ USTMENT
LEFT HAND DRIVE
Bel t tensi on i s adjusted at the power steeri ng
pump bracket and i dl er pul l ey assembl y.
(2) Loosen i dl er pul l ey bol t at the power steeri ng
bracket (Fi g. 45).
(3) Loosen adjusti ng bol t unti l bel t can be removed
from pul l eys.
(4) Remove bel t.
INSTALLATION
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine acces-
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction. Refer to (Fig.
39) xxxxx (Fig. 40) xxxx (Fig. 41) xxxxx (Fig. 42)
xxxx for correct belt routing.
(2) I nstal l new bel t.
(3) Usi ng serpenti ne bel t tensi on gauge, ti ghten
adjusti ng bol t unti l bel t reaches proper tensi on. Refer
Fig. 38 Heater and Cord4.0L 6-Cylinder Engine
POWER CORD LOCA- TION BLOCK HEATER
Fig. 39 Models with 2.5L EngineWith A/C
AC+
IDL
+
ALT+ WP & FAN+ PS+ IDL +
CRANK
+
Fig. 40 Models with 2.5L EngineWithout A/C
IDL + PS+ IDL + CRANK+ WP & FAN+
ALT
+
Fig. 41 Models with 4.0L EngineWithout A/C
Except RHD
IDL + FAN+
ALT
+
WP & FAN
+
PS+
IDL
+
CRANK+
to Bel t Tensi on at the rear of thi s secti on for proper
bel t tensi on.
(4) After bel t i s tensi oned correctl y, ti ghten i dl er
pul l ey bol t to 47 Nm (35 ft. l bs.)
(5) After i dl er pul l ey has been ti ghtened i nto posi -
ti on, recheck bel t tensi on. Adjust i f necessary.
BELT REPLACEMENT OR ADJ USTMENT
RIGHT HAND DRIVE (4.0L)
(2) Loosen l ower al ternator mounti ng bol t and nut.
(3) Loosen upper al ternator mounti ng nut.
(4) Loosen adjusti ng bol t at upper al ternator
bracket (Fi g. 46) unti l bel t can be removed from pul -
l eys.
(5) Remove bel t.
INSTALLATION
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine acces-
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction. Refer to (Fig.
43) xxxxx (Fig. 44) for correct belt routing.
Fig. 42 Models With 4.0L EngineWith A/CExcept
RHD
AC+ PS+ IDL + WP & FAN+ CRANK+ ALT+
FAN
+
Fig. 43 Models With 4.0L EngineWith A/CWith
RHD
ALT
+
IDL + IDL + WP+ CRANK+ PS+ FAN+ AC+
Fig. 44 Models With 4.0L EngineWithout A/C
With RHD
ALT
+
IDL + IDL + WP+ CRANK+ PS+ FAN+ IDL +
Fig. 45 Power Steering Pump Bracket and Idler
Pulley
ADJUSTING BOLT IDLER PULLEY BOLT
(2) I nstal l new bel t.
(3) Usi ng serpenti ne bel t tensi on gauge, ti ghten
adjusti ng bol t unti l bel t reaches proper tensi on. Refer
to Bel t Tensi on at the rear of thi s secti on for proper
bel t tensi on.
(4) Ti ghten al ternator upper and l ower mounti ng
bol ts.
(5) After generator and adjust bracket have been
ti ghtened i nto posi ti on, recheck bel t tensi on. Adjust i f
necessary.
COOLING SYSTEM FANS
REMOVAL
Some engi nes have the mechani cal fan/vi scous fan
dri ve assembl y mounted di rectl y to the water pump
hub (Fi g. 47). I t may al so be mounted to a hub/bear-
i ng attached to an al umi num bracket on the ri ght
front si de of engi ne (Fi g. 48).
(1) Loosen but do not remove at thi s ti me, the four
fan hub mounti ng nuts (Fi g. 47) xxxxxx (Fi g. 48).
(2) Remove accessory serpenti ne dri ve bel t. Refer
to Bel t Servi ce i n the Engi ne Accessory Dri ve Bel t
secti on of thi s group.
(3) Some model s wi th certai n engi nes may requi re
the removal of the fan shroud to remove the vi scous
fan dri ve. The fan shroud and fan bl ade/vi scous fan
dri ve shoul d be removed from the vehi cl e as one
assembl y.
(4) Remove four fan hub mounti ng nuts (Fi g. 47)
xxxxxxxxxx (Fi g. 48) and remove fan/vi scous fan
dri ve assembl y from vehi cl e.
(5) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
INSTALLATION
(1) Assembl e fan bl ade to vi scous fan dri ve.
Ti ghten mounti ng bol ts to 27 Nm (20 ft. l bs.) torque.
(2) Posi ti on mounti ng fl ange of fan bl ade/vi scous
fan dri ve assembl y onto hub. I nstal l four nuts and
ti ghten to 24 Nm (18 ft. l bs.) torque. Ti ghten the
Fig. 46 Generator Belt Tension Adjust Bracket
TENSION ADJUSTMENT BOLT UPPER ALTERNATOR NUT
Fig. 47 Water Pump Mounted Cooling Fan
THERMAL VIS- COUS FAN DRIVE (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS (4) FAB HUB-TO-PUMP PULLEY STUDS WATER PUMP WATER PUMP PUL- LEY FAN BLADE (4) FAN HUB-TO- PUMP PULLEY NUTS
Fig. 48 Bracket Mounted Cooling Fan
HUB/BEARING WATER PUMP PULLEY PULLEY NUTS BRACKET
fi rst two nuts 180 degrees apart. Then ti ghten l ast
two nuts.
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. Refer to appropriate
Engine Accessory Drive Belt Schematic in this
group for correct belt routing.
(3) I nstal l accessory dri ve bel ts. Tensi on bel ts to
speci fi cati ons. Refer to the Speci fi cati ons secti on at
the end of thi s group.
VISCOUS FAN DRIVE REMOVAL/INSTALLATION
Refer to Cool i ng System Fan for removal and
i nstal l ati on procedures of the vi scous dri ve uni t.
Visc ous Fan Drive Fluid Pump Out
Requirement:
After i nstal l i ng a new vi scous fan dri ve, bri ng the
engi ne speed up to approxi matel y 2000 rpm and hol d
for approxi matel y two mi nutes. Thi s wi l l ensure
proper fl ui d di stri buti on wi thi n the dri ve.
RADIATOR PRESSURE CAP
INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
RADIATOR CLEANING
The radi ator and ai r condi ti oni ng fi ns shoul d be
cl eaned when an accumul ati on of bugs, l eaves etc.
has occurred. Cl ean radi ator fi ns are necessary for
good heat transfer. Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
COOLING SYSTEM CLEANING
Drai n cool i ng system and refi l l wi th water. Run
engi ne wi th radi ator cap i nstal l ed unti l upper radi a-
tor hose i s hot. Stop engi ne and drai n water from
system. I f water i s di rty, fi l l system wi th water, run
engi ne and drai n system. Repeat unti l water drai ns
cl ean.
FAN BLADE INSPECTION
The fan bl ades cannot be repai red. I f fan i s dam-
aged, i t must be repl aced. I nspect fan as fol l ows:
(1) Remove fan bl ade and vi scous fan dri ve as an
assembl y from the engi ne. Refer to precedi ng
Removal procedure.
(2) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts).
(3) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI-
FICATIONS.
(4) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
COOLING SYSTEM HOSES
INSPECTION
I nspect the hoses at regul ar i nterval s. Repl ace
hoses that are cracked, feel bri ttl e when squeezed or
swel l excessi vel y when the system i s pressuri zed.
The use of mol ded repl acement hoses i s recom-
mended. When performi ng a hose i nspecti on, i nspect
the radi ator l ower hose for proper posi ti on and con-
di ti on of the spri ng.
SPECIFICATIONS
COOLING SYSTEM CAPACITIES
BELT TENSION
Bel t tensi on must be adjusted. Refer to the fol l ow-
i ng Bel t Tensi on chart for speci fi cati ons.
DESCRIPTION TORQUE
Auto. Trans. Auxiliary Oil Cooler
Mtg. Screws . . . . . . . . . . . . . . . . 2 Nm (18i n. l bs.)
Auxiliary Electric Cooling Fan
Mtg. Screws . . . . . . . . . . . . . . . 4 Nm (36 i n. l bs.)
Block Heater
Mounti ng Screw . . . . . . . . . . . . 4 Nm (20 i n. l bs.)
Condenser-to-Radiator
Screws . . . . . . . . . . . . . . . . . . . 6 Nm (55 i n. l bs.)
Fan BladeAssy.-to-Viscous Fan Drive
Bol ts . . . . . . . . . . . . . . . . . . . . 24 Nm (18 ft. l bs.)
Fan Shroud (2.5L Engine)
Mounti ng Bol ts . . . . . . . . . . . . . 2 Nm (20 i n. l bs.)
Fan Shroud (4.0L Engine)
Screws . . . . . . . . . . . . . . . . . . . 4 Nm (20 i n. l bs.)
Generator Pivot
Bol t . . . . . . . . . . . . . . . . . . . . . 38 Nm (28 ft. l bs.)
Generator Rear Adj.
Bol t . . . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Isolator-to-Crossmember
Nuts . . . . . . . . . . . . . . . . . . . . 10 Nm (86 i n. l bs.)
Isolator-to-Radiator
Nuts . . . . . . . . . . . . . . . . . . . . . 5 Nm (47 i n. l bs.)
Radiator (4.0L Engine)
Mounti ng Bol ts . . . . . . . . . . . . . . 8 Nm (6 ft. l bs.)
DESCRIPTION TORQUE
Radiator (2.5L Engine)
Mounti ng Bol ts . . . . . . . . . . . . . 6 Nm (55 i n. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . . 20 Nm (15 ft. l bs.)
Viscous Fan DriveAssy.-to-Water Pump
Nuts . . . . . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Water Pump
Bol ts . . . . . . . . . . . . . . . . . . . . 30 Nm (22 ft. l bs.)
SPECIAL TOOLS
COOLING
MODEL ENGINE
COOLING
CAPACITY
COOLING
PACKAGE
RADIATOR A/C
MECHANICAL
FAN
(VISCOUS DRIVE)
AUXILIARY*
ELECTRIC FAN
2.5L 4.0L QTS. LITERS STD. HD. ROWS
OF
TUBES
FINS
PER
INCH
DIA
(INCH)
NO.
OF
BLADE
BLADE
PITCH
(INCH)
DIA.
(INCH)
NO.
OF
BLADES
BLADE
PITCH
(INCH)
10.0 9.5 1 15 16.0 5 2.5
10.0 9.5 1 20 16.05 5 2.5
XJ 12.0 11.4 1 19 15.0 7 1.88
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
*4.0L ENGI NE WI TH HEAVY DUTY COOLI NG AND /OR AI R CONDI TI ONI NG
COOLING SYSTEM CAPACITIES
*800-900 N (180-200 lbs. force)
(With ** new serpentine belt)
*623-712 N (140-160 lbs. force)
(With ** used serpentine belt)
**Belt is considered new if it has been used 15
minutes or less.
*Specifications for use with a belt tension gauge.
Refer to operating instructions supplied with gauge.
Hose Clamp Tool6094
Cooling System Pressure Tester7700A
BATTERY
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY MOUNTING . . . . . . . . . . . . . . . . . . . . 3
BATTERY SIZE AND RATINGS . . . . . . . . . . . . . . 2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BUILT-IN TEST INDICATOR . . . . . . . . . . . . . . . . 4
HYDROMETER TEST . . . . . . . . . . . . . . . . . . . . . 6
IGNITION-OFF DRAW TEST . . . . . . . . . . . . . . . 9
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . . . 7
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . 10
SERVICE PROCEDURES
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . 11
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION
OVERVIEW
The battery, starti ng, and chargi ng systems oper-
ate wi th one another, and must be tested as a com-
pl ete system. I n order for the vehi cl e to start and
charge properl y, al l of the components i nvol ved i n
these systems must perform wi thi n speci fi cati ons.
Group 8A covers the battery, Group 8B covers the
starti ng system, and Group 8C covers the chargi ng
system. Refer to Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams. We have
separated these systems to make i t easi er to l ocate
the i nformati on you are seeki ng wi thi n thi s Servi ce
Manual . However, when attempti ng to di agnose any
of these systems, i t i s i mportant that you keep thei r
i nterdependency i n mi nd.
The di agnosti c procedures used i n these groups
i ncl ude the most basi c conventi onal di agnosti c meth-
ods, to the more sophi sti cated On-Board Di agnosti cs
(OBD) bui l t i nto the Powertrai n Control Modul e
(PCM). Use of a i nducti on mi l l i ampere ammeter, vol t/
ohmmeter, battery charger, carbon pi l e rheostat (l oad
tester), and 12-vol t test l amp may be requi red.
Al l OBD-sensed systems are moni tored by the
PCM. Each moni tored ci rcui t i s assi gned a Di agnos-
ti c Troubl e Code (DTC). The PCM wi l l store a DTC i n
el ectroni c memory for any fai l ure i t detects. See the
On-Board Di agnosti cs Test i n Group 8C - Chargi ng
System for more i nformati on.
INTRODUCTION
Thi s secti on covers onl y battery di agnosti c and ser-
vi ce procedures. For battery mai ntenance procedures,
refer to Group 0 - Lubri cati on and Mai ntenance.
Whi l e battery chargi ng can be consi dered a mai nte-
nance procedure, battery chargi ng i nformati on i s
l ocated i n thi s group. Thi s was done because the bat-
tery must be ful l y-charged before any di agnosi s can
be performed.
The factory-i nstal l ed l ow-mai ntenance battery has
removabl e battery cel l caps. Water can be added to
thi s battery. The battery i s not seal ed and has vent
hol es i n the cel l caps (Fi g. 1). The chemi cal composi -
ti on wi thi n the l ow-mai ntenance battery reduces bat-
tery gassi ng and water l oss, at normal charge and
di scharge rates.
Rapi d l oss of el ectrol yte can be caused by an over-
chargi ng condi ti on. Be certai n to di agnose the charg-
i ng system before returni ng the vehi cl e to servi ce.
Refer to Group 8C - Chargi ng System for more i nfor-
mati on.
The factory-i nstal l ed battery al so has a bui l t-i n
test i ndi cator (hydrometer). The col or vi si bl e i n the
si ght gl ass of the i ndi cator wi l l reveal the battery
Fig. 1 Low-Maintenance Battery - Typical
ELECTROLYTE LEVEL POSITIVE POST VENT TEST INDICA- TOR VENT NEGATIVE POST GREEN BALL PLATE GROUPS LOW-MAINTE- NANCE BAT- TERY
XJ BATTERY 8A - 1
condi ti on. See Bui l t-I n Test I ndi cator i n thi s group
for more i nformati on.
I t i s i mportant that the battery, starti ng, and
chargi ng systems be thoroughl y tested and i nspected
any ti me a battery needs to be charged or repl aced.
The cause of abnormal di scharge, overchargi ng, or
earl y battery fai l ure must be di agnosed and corrected
before a battery i s repl aced or returned to servi ce.
BATTERY
The storage battery i s a devi ce used to store el ec-
tri cal energy potenti al i n a chemi cal form. When an
el ectri cal l oad i s appl i ed to the battery termi nal s, an
el ectrochemi cal reacti on occurs wi thi n the battery.
Thi s reacti on causes the battery to di scharge el ectri -
cal current.
The battery i s made up of si x i ndi vi dual cel l s that
are connected i n seri es. Each cel l contai ns posi ti vel y
charged pl ate groups made of l ead oxi de, and nega-
ti vel y charged pl ate groups made of sponge l ead.
These di ssi mi l ar metal pl ates are submerged i n a
sul furi c aci d and water sol uti on cal l ed an el ectrol yte.
As the battery di scharges, a gradual chemi cal
change takes pl ace wi thi n each cel l . The sul furi c aci d
i n the el ectrol yte combi nes wi th the pl ate materi al s,
causi ng both pl ates to sl owl y change to l ead sul fate.
At the same ti me, oxygen from the posi ti ve pl ate
materi al combi nes wi th hydrogen from the sul furi c
aci d, causi ng the el ectrol yte to become mai nl y water.
The chemi cal changes wi thi n the battery are
caused by the movement of excess or free el ectrons
between the posi ti ve and negati ve pl ate groups. Thi s
movement of el ectrons produces a fl ow of el ectri cal
current through the l oad devi ce attached to the bat-
tery termi nal s.
As the pl ate materi al s become more si mi l ar chem-
i cal l y, and the el ectrol yte becomes l ess aci d, the vol t-
age potenti al of each cel l i s reduced. However, by
chargi ng the battery wi th a vol tage hi gher than that
of the battery, the battery di schargi ng process i s
reversed.
Chargi ng the battery gradual l y changes the sul -
fated l ead pl ates back i nto sponge l ead and l ead
oxi de, and the water back i nto sul furi c aci d. Thi s
acti on restores the di fference i n the el ectron charges
deposi ted on the pl ates, and the vol tage potenti al of
the battery cel l s.
For a battery to remai n useful , i t must be abl e to
produce hi gh-amperage current over an extended
peri od. A battery must al so be abl e to accept a
charge, so that i ts vol tage potenti al may be restored.
I n addi ti on to produci ng and stori ng el ectri cal
energy, the battery serves as a capaci tor, or vol tage
stabi l i zer, for a vehi cl es el ectri cal system. I t absorbs
most abnormal or transi ent vol tages caused by the
swi tchi ng of any of the vehi cl es el ectri cal compo-
nents.
The battery i s vented to rel ease excess hydrogen
gas that i s created when the battery i s bei ng charged
or di scharged. However, even wi th these vents, the
hydrogen gas can col l ect i n or around the battery. I f
hydrogen gas i s exposed to fl ame or sparks, i t may
i gni te.
I f the el ectrol yte l evel i s l ow, the battery may arc
i nternal l y and expl ode. I f the battery i s equi pped
wi th removabl e cel l caps, add di sti l l ed water when-
ever the el ectrol yte l evel i s bel ow the top of the
pl ates. I f the battery cel l caps cannot be removed, the
battery must be repl aced i f the el ectrol yte l evel
becomes l ow.
BATTERY SIZE AND RATINGS
The battery Group Si ze number, the Col d Cranki ng
Amperage (CCA) rati ng, and the Reserve Capaci ty
(RC) rati ng or Ampere-Hours (AH) rati ng can be
found on the ori gi nal equi pment battery l abel . Be
certai n that a repl acement battery has the correct
Group Si ze number, as wel l as CCA, and RC or AH
rati ngs that equal or exceed the ori gi nal equi pment
speci fi cati on for the vehi cl e bei ng servi ced.
See the Battery Cl assi fi cati ons and Rati ngs chart
i n Speci fi cati ons at the back of thi s group for more
i nformati on. Battery si zes and rati ngs are di scussed
i n more detai l bel ow.
GROUP SIZE
The outsi de di mensi ons and termi nal pl acement of
the battery conform to standards establ i shed by the
Battery Counci l I nternati onal (BCI ). Each battery i s
assi gned a BCI Group Si ze number to hel p i denti fy a
correctl y-si zed repl acement.
COLD CRANKING AMPERAGE
The Col d Cranki ng Amperage (CCA) rati ng speci -
fi es how much current (i n amperes) the battery can
del i ver for thi rty seconds at -18 C (0 F). Termi nal
vol tage must not fal l bel ow 7.2 vol ts duri ng or after
the thi rty second di scharge peri od. The CCA requi red
8A - 2 BATTERY XJ
i s general l y hi gher as engi ne di spl acement i ncreases,
dependi ng al so upon the starter current draw
requi rements.
RESERVE CAPACITY
The Reserve Capaci ty (RC) rati ng speci fi es the
ti me (i n mi nutes) i t takes for battery termi nal vol t-
age to fal l bel ow 10.5 vol ts, at a di scharge rate of 25
amperes. RC i s determi ned wi th the battery ful l y-
charged at 26.7 C (80 F). Thi s rati ng esti mates how
l ong the battery mi ght l ast after a chargi ng system
fai l ure, under mi ni mum el ectri cal l oad.
AMPERE-HOURS
The Ampere-Hours (AH) rati ng speci fi es the cur-
rent (i n amperes) that a battery can del i ver steadi l y
for twenty hours, wi th the vol tage i n the battery not
fal l i ng bel ow 10.5 vol ts. Thi s rati ng i s al so someti mes
referred to as the twenty-hour di scharge rati ng.
BATTERY MOUNTING
The battery i s mounted to a mol ded pl asti c tray
l ocated i n the ri ght front corner of the engi ne com-
partment. Two T-bol ts are hel d i n formati ons on each
si de of the tray by push-on retai ners, and extend
upward on each si de of the battery. A hol ddown strap
fi ts across the top of the battery case and thermo-
guard. The ends of the T-bol ts pass through the hol d-
down strap on each si de of the battery, and a nut
secures the hol ddown strap to the T-bol ts. One end of
a support strap i s l ocated under the forward-most
hol ddown strap nut, and the other end i s secured to
the upper radi ator crossmember by a bol t.
The battery tray i s secured wi th three nuts to
three studs that protrude from the wheel house i nner
panel , forward of the ri ght front wheel .
On some model s, a hol e i n the bottom of the bat-
tery tray i s fi tted wi th a battery temperature sensor.
Model s wi thout the battery temperature sensor have
a pl ug fi tted to thi s hol e. Refer to Group 8C - Charg-
i ng System for more i nformati on on the battery tem-
perature sensor.
When i nstal l i ng a battery, be certai n that the hol d-
down fasteners are ti ghtened to the proper speci fi ca-
ti ons. I mproper hol ddown fastener ti ghtness, whether
too l oose or too ti ght, can resul t i n damage to the
battery. See the Battery Removal and I nstal l ati on
procedures for the correct hol ddown fastener ti ght-
ness speci fi cati ons.
BATTERY
The battery must be compl etel y charged and the
top, posts, and termi nal cl amps shoul d be properl y
cl eaned before di agnosti c procedures are performed.
See the Battery Chargi ng procedure i n thi s group for
more i nformati on.
WARNING:
IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
OF THE REACH OF CHILDREN.
IF THE BATTERY IS EQUIPPED WITH REMOV-
ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
The condi ti on of a battery i s determi ned by two cri -
teri a:
1. State-Of-Charge - Thi s can be determi ned by
vi ewi ng the bui l t-i n test i ndi cator, by checki ng the
speci fi c gravi ty of the el ectrol yte (hydrometer test),
or by checki ng the battery vol tage (open-ci rcui t vol t-
age test).
2. Cranking Capacity - Thi s can be determi ned
by performi ng a battery l oad test, whi ch measures
the abi l i ty of the battery to suppl y hi gh-amperage
current.
Fi rst, determi ne the battery state-of-charge. Thi s
can be done i n one of three ways. I f the battery has a
bui l t-i n test i ndi cator, vi ew the test i ndi cator to
determi ne the state-of-charge. I f the battery has no
test i ndi cator, but has removabl e cel l caps, perform
the hydrometer test to determi ne the state-of-charge.
I f the cel l caps are not removabl e, or a hydrometer i s
not avai l abl e, perform the open-ci rcui t vol tage test to
determi ne the state-of-charge.
The battery must be charged before proceedi ng
wi th a l oad test i f:
The bui l t-i n test i ndi cator has a bl ack or dark
col or vi si bl e.
The temperature corrected speci fi c gravi ty i s
l ess than 1.235.
The open-ci rcui t vol tage i s l ess than 12.4 vol ts.
A battery that wi l l not accept a charge i s faul ty,
and must be repl aced. Further testi ng i s not
XJ BATTERY 8A - 3
requi red. A ful l y-charged battery must be l oad tested
to determi ne i ts cranki ng capaci ty. A battery that i s
ful l y-charged, but does not pass the l oad test, i s
faul ty and must be repl aced.
NOTE: Completely discharged batteries may take
several hours to accept a charge. See Charging A
Completely Discharged Battery in this group for
more information.
A battery i s ful l y-charged when:
Al l cel l s are gassi ng freel y duri ng chargi ng.
A green col or i s vi si bl e i n the si ght gl ass of the
bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty.
Open-ci rcui t vol tage i s 12.4 vol ts or greater.
ABNORMAL BATTERY DISCHARGING
Any of the fol l owi ng condi ti ons can resul t i n abnor-
mal battery di schargi ng:
1. Corroded or l oose battery posts and termi nal
cl amps.
2. A l oose or worn generator dri ve bel t.
3. El ectri cal l oads that exceed the output of the
chargi ng system. Thi s can be due to equi pment
i nstal l ed after manufacture, or repeated short tri p
use.
4. Sl ow dri vi ng speeds (heavy traffi c condi ti ons) or
prol onged i dl i ng, wi th hi gh-amperage draw systems
i n use.
5. A faul ty ci rcui t or component causi ng excessi ve
i gni ti on-off draw. See the I gni ti on-Off Draw Test pro-
cedure i n thi s group for more i nformati on.
6. A faul ty or i ncorrect chargi ng system compo-
nent. Refer to Group 8C - Chargi ng System for more
i nformati on.
7. A faul ty or i ncorrect battery.
BUILT-IN TEST INDICATOR
A test i ndi cator (hydrometer) bui l t i nto the top of
the battery case provi des vi sual i nformati on for bat-
tery testi ng (Fi g. 2). Li ke a hydrometer, the bui l t-i n
test i ndi cator measures the speci fi c gravi ty of the
el ectrol yte. The test i ndi cator reveal s the battery
state-of-charge; however, i t wi l l not reveal the crank-
i ng capaci ty of the battery. A l oad test must be per-
formed to determi ne the battery cranki ng capaci ty.
See the Load Test procedure i n thi s group for more
i nformati on.
WARNING:
MAY RESULT.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. I n order to
obtai n correct i ndi cati ons from the bui l t-i n test i ndi -
cator, i t i s i mportant that the battery be l evel and
have a cl ean si ght gl ass. Addi ti onal l i ght may be
requi red to vi ew the i ndi cator. Do not use open
flame as a source of additional light.
To read the bui l t-i n test i ndi cator, l ook i nto the
si ght gl ass and note the col or of the i ndi cator (Fi g. 3).
Refer to the fol l owi ng descri pti on, as the col or i ndi -
cates:
Green - i ndi cates 75% to 100% state-of-charge.
The battery i s adequatel y charged for further testi ng
or return to use. I f the vehi cl e wi l l not crank for a
mi ni mum of fi fteen seconds wi th a ful l y-charged bat-
tery, perform the Load Test procedure as descri bed i n
thi s group.
Black or Dark - i ndi cates 0% to 75% state-of-
charge. The battery i s i nadequatel y charged and
must be charged unti l a green i ndi cati on i s vi si bl e i n
the si ght gl ass (12.4 vol ts or more), before the bat-
tery i s tested further or returned to servi ce. See the
Battery Chargi ng procedure i n thi s group for more
i nformati on. Al so see Abnormal Battery Di schargi ng
i n thi s group for possi bl e causes of the di scharged
condi ti on.
Clear or Bright - i ndi cates a l ow el ectrol yte
l evel . The el ectrol yte l evel i n the battery i s bel ow the
test i ndi cator. A mai ntenance-free battery wi th non-
removabl e cel l caps must be repl aced i f the el ectro-
l yte l evel i s l ow. Water must be added to a l ow-
mai ntenance battery wi th removabl e cel l caps before
i t i s charged. See the Battery Chargi ng procedure i n
thi s group for more i nformati on. A l ow el ectrol yte
l evel may be caused by an overchargi ng condi ti on.
8A - 4 BATTERY XJ
Battery Diagnosis
The battery seems weak or
dead when attempting to start
the engine.
1. The battery has an
incorrect size or rating for
this vehicle.
2. The battery is physically
damaged.
3. The battery terminal
connections are loose or
corroded.
4. The battery is discharged.
5. The electrical system is
faulty.
6. The battery is faulty.
7. The starting system is
faulty.
8. The charging system is
faulty.
1. See Specifications in this group. Replace the
incorrect battery with the correct battery, if
required.
2. Inspect the battery for loose terminal posts or a
cracked and leaking case. Replace the battery, if
damaged.
3. See the Voltage Drop Test in this group. Clean
and tighten the battery terminal connections, if
required.
4. See the Test Indicator, the Hydrometer Test, or
the Open-Circuit Voltage Test in this group to
determine the battery state-of-charge. Charge the
battery, if required.
5. See the Ignition-Off Draw Test in this group.
Repair the electrical system, if required.
6. See the Load Test in this group to determine
the battery condition. Replace the battery, if
required.
7. Refer to Group 8B - Starting Systems for more
information. Repair the starting system, if
required.
8. Refer to Group 8C - Charging Systems for
more information. Repair the charging system, if
required.
The battery state-of-charge
cannot be maintained.
1. The battery has an
incorrect size or rating for
this vehicle.
2. The battery terminal
connections are loose or
corroded.
3. The generator drive belt is
loose or worn.
4. The electrical system is
faulty.
5. The battery is faulty.
6. The starting system is
faulty.
7. The charging system is
faulty.
8. Electrical loads exceed the
output of the charging
system.
9. Slow driving or prolonged
idling with high-amperage
draw systems in use.
1. See Specifications in this group. Replace the
incorrect battery with the correct battery, if
required.
2. See the Voltage Drop Test in this group. Clean
and tighten the battery terminal connections, if
required.
3. Refer to Group 7 - Cooling Systems for more
information. Replace or adjust the generator drive
belt, if required.
4. See the Ignition-Off Draw Test in this group.
Repair the electrical system, if required.
5. See the Load Test in this group to determine
the battery condition. Replace the battery, if
required.
6. Check whether the starting system is
performing to specifictions. Refer to Group 8B -
Starting Systems for more information. Repair the
starting system, if required.
7. Refer to Group 8C - Charging Systems for
more information. Repair the charging system, if
required.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Advise the vehicle operator, as required.
The battery will not accept a
charge.
1. The battery is faulty. 1. See Battery Charging in this group. Replace
the faulty battery, if required.
XJ BATTERY 8A - 5
Refer to Group 8C - Chargi ng System to di agnose an
overchargi ng condi ti on.
HYDROMETER TEST
The hydrometer test reveal s the battery state-of-
charge by measuri ng the speci fi c gravi ty of the el ec-
trol yte. Thi s test cannot be performed on
mai ntenance-free batteri es wi th non-removabl e cel l
caps. I f the battery has non-removabl e cel l caps, see
the Bui l t-I n Test I ndi cator or the Open-Ci rcui t Vol t-
age Test procedures i n thi s group.
Speci fi c gravi ty i s a compari son of the densi ty of
the el ectrol yte to the densi ty of pure water. Pure
water has a speci fi c gravi ty of 1.000, and sul furi c
aci d has a speci fi c gravi ty of 1.835. Sul furi c aci d
makes up approxi matel y 35% of the el ectrol yte by
wei ght, or 24% by vol ume.
I n a ful l y-charged battery the el ectrol yte wi l l have
a temperature-corrected speci fi c gravi ty of 1.260 to
1.290. However, a speci fi c gravi ty of 1.235 or above i s
sati sfactory for battery l oad testi ng and/or return to
servi ce.
WARNING:
MAY RESULT.
Before testi ng, vi sual l y i nspect the battery for any
damage (a cracked case or cover, l oose posts, etc.)
that woul d cause the battery to be faul ty. Then
remove the cel l caps and check the el ectrol yte l evel .
Add di sti l l ed water i f the el ectrol yte l evel i s bel ow
the top of the battery pl ates.
Refer to the i nstructi ons suppl i ed wi th the hydrom-
eter for recommendati ons on the correct use of the
hydrometer. Remove onl y enough el ectrol yte from the
battery cel l so that the fl oat i s off the bottom of the
hydrometer barrel wi th pressure on the bul b
rel eased.
CAUTION: Exercise care when inserting the tip of
the hydrometer into a cell to avoid damaging the
plate separators. Damaged plate separators can
cause early battery failure.
To read the hydrometer correctl y, hol d i t wi th the
top surface of the el ectrol yte at eye l evel (Fi g. 4).
Hydrometer fl oats are general l y cal i brated to i ndi -
cate the speci fi c gravi ty correctl y onl y at 26.7 C (80
F). When testi ng the speci fi c gravi ty at any other
temperature, a correcti on factor i s requi red.
The correcti on factor i s approxi matel y a speci fi c
gravi ty val ue of 0.004, referred to as four poi nts of
speci fi c gravi ty. For each 5.5 C above 26.7 C (10 F
above 80 F), add four poi nts. For each 5.5 C bel ow
26.7 C (10 F bel ow 80 F), subtract four poi nts.
Al ways correct the speci fi c gravi ty for temperature
vari ati on. Test the speci fi c gravi ty of the el ectrol yte
i n each battery cel l .
EXAMPLE: A battery i s tested at -12.2 C (10 F)
and has a speci fi c gravi ty of 1.240. Determi ne the
actual speci fi c gravi ty as fol l ows:
(1) Determi ne the number of degrees above or
bel ow 26.7 C (80 F):
Fig. 2 Built-In Test Indicator
SIGHT GLASS PLASTICROD BATTERYTOP GREEN BALL
Fig. 3 Built-In Test Indicator Sight Glass
TEST INDICATOR/STATE-OF- CHARGE LOW ELECTROLYTE CLEAR BLACK GREEN
8A - 6 BATTERY XJ
26.6 C - -12.2 C = 38.8 C (80 F -
10 F = 70 F)
(2) Di vi de the resul t from Step 1 by 5.5 (10):
38.8 C 5.5 = 7 (70 F 10 = 7)
(3) Mul ti pl y the resul t from Step 2 by the temper-
ature correcti on factor (0.004):
7 X 0.004 = 0.028
(4) The temperature at testi ng was bel ow 26.7 C
(80 F); therefore, the temperature correcti on factor
i s subtracted:
1.240 - 0.028 = 1.212
The corrected speci fi c gravi ty of the battery i n thi s
exampl e i s 1.212.
I f the speci fi c gravi ty of al l cel l s i s above 1.235, but
the vari ati on between cel l s i s more than fi fty poi nts
(0.050), the battery shoul d be repl aced. I f the speci fi c
gravi ty of one or more cel l s i s l ess than 1.235, charge
the battery at a rate of approxi matel y fi ve amperes.
Conti nue chargi ng the battery unti l three consecu-
ti ve speci fi c gravi ty tests, taken at one-hour i nter-
val s, are constant. I f the cel l speci fi c gravi ty
vari ati on i s more than fi fty poi nts (0.050) at the end
of the charge peri od, repl ace the battery.
When the speci fi c gravi ty of al l cel l s i s above 1.235,
and the cel l vari ati on i s l ess than fi fty poi nts (0.050),
the battery may be l oad tested to determi ne i ts
cranki ng capaci ty. See the Load Test procedure i n
thi s group for more i nformati on.
OPEN-CIRCUIT VOLTAGE TEST
A battery open-ci rcui t vol tage (no l oad) test wi l l
show the state-of-charge of a battery. Thi s test can be
used i n pl ace of the hydrometer test when a hydrom-
eter i s not avai l abl e, or for mai ntenance-free batter-
i es wi th non-removabl e cel l caps.
WARNING:
MAY RESULT.
Before proceedi ng wi th thi s test, compl etel y charge
the battery as descri bed i n the Battery Chargi ng pro-
cedure i n thi s group.
(1) Before measuri ng the open-ci rcui t vol tage, the
surface charge must be removed from the battery.
Turn on the head l amps for fi fteen seconds, then
al l ow up to fi ve mi nutes for the battery vol tage to
stabi l i ze.
(2) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst.
(3) Usi ng a vol tmeter connected to the battery
posts (refer to the i nstructi ons provi ded wi th the
vol tmeter), measure the open-ci rcui t vol tage (Fi g. 5).
Fig. 4 Hydrometer - Typical
BULB SURFACE COHESION SPECIFIC GRAVITY READING TEMPERATURE READING HYDROMETER BARREL FLOAT
Fig. 5 Testing Open-Circuit Voltage - Typical
XJ BATTERY 8A - 7
See the Open-Ci rcui t Vol tage chart. Thi s vol tage
readi ng wi l l i ndi cate the battery state-of-charge, but
wi l l not reveal i ts cranki ng capaci ty. I f a battery has
an open-ci rcui t vol tage readi ng of 12.4 vol ts or
greater, i t may be l oad tested to reveal i ts cranki ng
capaci ty. See the Load Test procedure i n thi s group
LOAD TEST
A battery l oad test wi l l veri fy the battery cranki ng
capaci ty. The test i s based on the Col d Cranki ng
Amperage (CCA) rati ng of the battery. Refer to the
battery l abel , or see the Battery Cl assi fi cati ons and
Rati ngs chart i n Speci fi cati ons at the back of thi s
group for the CCA rati ng of the factory-i nstal l ed bat-
tery.
WARNING:
MAY RESULT.
Before proceedi ng wi th thi s test, compl etel y charge
the battery as descri bed i n the Battery Chargi ng pro-
cedure i n thi s group.
(1) Di sconnect and i sol ate both battery cabl es, neg-
ati ve cabl e fi rst. The battery top and posts shoul d be
cl ean.
(2) Connect a sui tabl e vol t-ammeter-l oad tester
(Fi g. 6) to the battery posts (Fi g. 7). Refer to the
operati ng i nstructi ons provi ded wi th the tester bei ng
used. Check the open-ci rcui t vol tage (no l oad) of the
battery. Open-ci rcui t vol tage must be 12.4 vol ts or
greater.
(3) Rotate the l oad control knob (carbon pi l e rheo-
stat) to appl y a 300 ampere l oad to the battery for
fi fteen seconds, then return the control knob to the
Off posi ti on (Fi g. 8). Thi s wi l l remove the surface
charge from the battery.
(4) Al l ow the battery to stabi l i ze to open-ci rcui t
vol tage. I t may take up to fi ve mi nutes for the bat-
tery vol tage to stabi l i ze.
(5) Rotate the l oad control knob to mai ntai n a l oad
equal to 50% of the CCA rati ng of the battery (Fi g.
9). After fi fteen seconds, record the l oaded vol tage
readi ng, then return the l oad control knob to the Off
posi ti on.
Open Circuit Voltage
Open Circuit Volts Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
Fig. 6 Volt-Ammeter-Load Tester - Typical
Fig. 7 Volt-Ammeter-Load Tester Connections -
Typical
INDUCTION AMMETER CLAMP NEGATIVE CLAMP POSITIVE CLAMP
8A - 8 BATTERY XJ
(6) The vol tage drop wi l l vary wi th the battery
temperature at the ti me of the l oad test. The battery
temperature can be esti mated by usi ng the ambi ent
temperature duri ng the past several hours. I f the
battery has been charged, boosted, or l oaded a few
mi nutes pri or to the test, the battery wi l l be some-
what warmer. See the Load Test Temperature chart
for the proper l oaded vol tage readi ng.
(7) I f the vol tmeter readi ng fal l s bel ow 9.6 vol ts, at
a mi ni mum battery temperature of 21 C (70 F), the
battery i s faul ty and must be repl aced.
IGNITION-OFF DRAW TEST
I gni ti on-Off Draw (I OD) refers to power bei ng
drai ned from the battery wi th the i gni ti on swi tch i n
the Off posi ti on. A normal vehi cl e el ectri cal system
wi l l draw from fi ve to twenty-fi ve mi l l i amperes
(0.005 to 0.025 ampere) wi th the i gni ti on swi tch i n
the Off posi ti on, and al l non-i gni ti on control l ed ci r-
cui ts i n proper worki ng order. The twenty-fi ve mi l l i -
amperes are needed to enabl e the memory functi ons
for the Powertrai n Control Modul e (PCM), di gi tal
cl ock, el ectroni cal l y tuned radi o, and other modul es
whi ch may vary wi th the vehi cl e equi pment.
A vehi cl e that has not been operated for approxi -
matel y twenty days, may di scharge the battery to an
i nadequate l evel . When a vehi cl e wi l l not be used for
twenty days or more (stored), remove the I OD fuse
from the Power Di stri buti on Center (PDC). Thi s wi l l
reduce battery di schargi ng.
Excessi ve I OD can be caused by:
El ectri cal i tems l eft on
Faul ty or i mproperl y adjusted swi tches
Faul ty or shorted el ectroni c modul es and compo-
nents
An i nternal l y shorted generator
I ntermi ttent shorts i n the wi ri ng.
I f the I OD i s over twenty-fi ve mi l l i amperes, the
probl em must be found and corrected before repl ac-
i ng a battery. I n most cases, the battery can be
charged and returned to servi ce after the excessi ve
I OD condi ti on has been corrected.
DIAGNOSIS
(1) Veri fy that al l el ectri cal accessori es are off.
Turn off al l l amps, remove the i gni ti on key, and cl ose
al l doors. I f the vehi cl e i s equi pped wi th a i l l umi -
nated entry system or el ectroni cal l y tuned radi o,
al l ow the el ectroni c ti mer functi on of these systems
to automati cal l y shut off (ti me out). Thi s may take
up to three mi nutes.
(2) Determi ne that the underhood l amp i s operat-
i ng properl y, then unpl ug the l amp wi re harness con-
nector or remove the l amp bul b.
(3) Di sconnect the battery negati ve cabl e.
(4) Set an el ectroni c di gi tal mul ti -meter to i ts
hi ghest amperage scal e. Connect the mul ti -meter
between the di sconnected battery negati ve cabl e
cl amp and the battery negati ve termi nal post. Make
sure that the doors remai n cl osed so that the i l l umi -
nated entry system i s not acti vated. The mul ti -meter
amperage readi ng may remai n hi gh for up to three
mi nutes, or may not gi ve any readi ng at al l whi l e set
i n the hi ghest amperage scal e, dependi ng upon the
el ectri cal equi pment on the vehi cl e. The mul ti -meter
Fig. 8 Remove Surface Charge from Battery -
Typical
Fig. 9 Load 50% CCA Rating - Note Voltage - Typical
Load Test Temperature
Minimum Volt-
age
Temperature
F C
9.6 volts 70and above 21and above
9.5 volts 60 16
9.4 volts 50 10
9.3 volts 40 4
9.1 volts 30 -1
8.9 volts 20 -7
8.7 volts 10 -12
8.5 volts 0 -18
XJ BATTERY 8A - 9
l eads must be securel y cl amped to the battery nega-
ti ve cabl e cl amp and the battery negati ve termi nal
post. I f conti nui ty between the battery negati ve ter-
mi nal post and the negati ve cabl e cl amp i s l ost dur-
i ng any part of the I OD test, the el ectroni c ti mer
functi on wi l l be acti vated and al l of the tests wi l l
have to be repeated.
(5) After about three mi nutes, the hi gh-amperage
I OD readi ng on the mul ti -meter shoul d become very
l ow or nonexi stent, dependi ng upon the el ectri cal
equi pment on the vehi cl e. I f the amperage readi ng
remai ns hi gh, remove each fuse or ci rcui t breaker
(refer to Group 8W - Wi ri ng Di agrams for more i nfor-
mati on) unti l the amperage readi ng becomes very
l ow, or nonexi stent. Thi s wi l l i sol ate each ci rcui t and
i denti fy the source of the hi gh-amperage I OD. I f the
amperage readi ng remai ns hi gh after di sconnecti ng
each fuse and ci rcui t breaker, unpl ug the wi re har-
ness connector from the generator. I f the amperage
readi ng now becomes very l ow or nonexi stent, refer
to Group 8C - Chargi ng System to di agnose the
faul ty chargi ng system. After the hi gh-amperage I OD
has been corrected, swi tch the mul ti -meter to pro-
gressi vel y l ower amperage scal es and, i f necessary,
repeat the fuse and ci rcui t breaker removal process
to i denti fy and correct the sources of excessi ve I OD.
I t i s now safe to sel ect the l owest mi l l i ampere scal e
of the mul ti -meter to check the l ow-amperage I OD.
CAUTION: Do not open any doors, or turn on any
electrical accessories with the lowest milliampere
scale selected, or the multi-meter may be damaged.
(6) Observe the mul ti -meter readi ng. The l ow-am-
perage I OD shoul d not exceed twenty-fi ve mi l l i am-
peres (0.025 ampere). I f the draw exceeds twenty-fi ve
mi l l i amperes, i sol ate each ci rcui t by removi ng the
ci rcui t breakers and fuses. The mul ti -meter readi ng
wi l l drop to wi thi n the acceptabl e l i mi t when the
source of the excessi ve draw i s di sconnected. Repai r
thi s ci rcui t as requi red; whether a wi ri ng short,
i ncorrect swi tch adjustment, or a component fai l ure
i s at faul t.
VOLTAGE DROP TEST
The vol tage drop test wi l l determi ne i f there i s
excessi ve resi stance i n the battery termi nal connec-
ti ons or the battery cabl es. When performi ng these
tests, i t i s i mportant to remember that the vol tage
drop i s gi vi ng an i ndi cati on of the resi stance between
the two poi nts at whi ch the vol tmeter probes are
attached.
Example: When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e cl amp and the cabl e connector
at the starter sol enoi d. I f you probe the battery pos-
i ti ve termi nal post and the cabl e connector at the
starter sol enoi d, you are readi ng the combi ned vol t-
age drop i n the battery posi ti ve cabl e cl amp-to-termi -
nal post connecti on and the battery posi ti ve cabl e.
WARNING:
MAY RESULT.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng the
tests, be certai n the fol l owi ng procedures are accom-
pl i shed:
Battery i s ful l y-charged as descri bed i n thi s
group.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
transmi ssi on, pl ace the gearshi ft sel ector l ever i n the
Park posi ti on. I f the vehi cl e i s equi pped wi th a man-
ual transmi ssi on, pl ace the gearshi ft sel ector l ever i n
the Neutral posi ti on and ful l y depress the cl utch
pedal .
Unpl ug the Automati c ShutDown (ASD) rel ay to
prevent the engi ne from starti ng. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC).
Refer to the PDC l abel for ASD rel ay i denti fi cati on
and l ocati on.
(1) Connect the posi ti ve l ead of the vol tmeter to
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e cl amp (Fi g. 10). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor contact between
the cabl e cl amp and the termi nal post.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
cl amp (Fi g. 11). Rotate and hol d the i gni ti on swi tch
8A - 10 BATTERY XJ
i n the Start posi ti on. Observe the vol tmeter. I f vol t-
age i s detected, correct the poor contact between the
cabl e cl amp and the termi nal post.
(3) Connect the vol tmeter to measure between the
battery posi ti ve termi nal post and the starter sol e-
noi d battery termi nal stud (Fi g. 12). Rotate and hol d
the i gni ti on swi tch i n the Start posi ti on. Observe the
vol tmeter. I f the readi ng i s above 0.2 vol t, cl ean and
ti ghten the battery cabl e connecti on at the sol enoi d.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
battery negati ve termi nal post and a good cl ean
ground on the engi ne bl ock (Fi g. 13). Rotate and hol d
ti ghten the battery negati ve cabl e attachment on the
engi ne bl ock. Repeat the test. I f the readi ng i s sti l l
above 0.2 vol t, repl ace the faul ty battery negati ve
cabl e.
SERVICE PROCEDURES
BATTERY CHARGING
A battery i s ful l y-charged when:
Al l cel l s are gassi ng freel y duri ng battery charg-
i ng.
A green col or i s vi si bl e i n the si ght gl ass of the
bui l t-i n test i ndi cator.
Three corrected speci fi c gravi ty tests, taken at
one-hour i nterval s, i ndi cate no i ncrease i n the spe-
ci fi c gravi ty.
Open-ci rcui t vol tage i s 12.4 vol ts or above.
Fig. 10 Test Battery Negative Connection
Resistance - Typical
VOLTMETER BATTERY
Fig. 11 Test Battery Positive Connection Resistance
- Typical
VOLTMETER BATTERY
Fig. 12 Test Battery Positive Cable Resistance -
Typical
BATTERY VOLTMETER STARTER MOTOR
Fig. 13 Test Ground Circuit Resistance - Typical
VOLTMETER ENGINE GROUND BATTERY
XJ BATTERY 8A - 11
WARNING:
MAY RESULT.
CAUTION:
Always disconnect and isolate the battery neg-
ative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.
Battery electrolyte will bubble inside the bat-
tery case during normal battery charging. Electro-
lyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
The battery should not be hot to the touch. If
the battery feels hot to the touch, turn off the
charger and let the battery cool before continuing
the charging operation. Damage to the battery may
result.
Some battery chargers are equi pped wi th pol ari ty-
sensi ng ci rcui try. Thi s ci rcui try protects the charger
and/or the battery from bei ng damaged i f they are
i mproperl y connected. I f the battery state-of-charge
i s too l ow for the pol ari ty-sensi ng ci rcui try to detect,
the charger wi l l not operate. Thi s makes i t appear
that the battery wi l l not accept chargi ng current.
Refer to the i nstructi ons provi ded wi th the battery
charger to bypass the pol ari ty-sensi ng ci rcui try.
After the battery has been charged to 12.4 vol ts or
greater, perform a l oad test to determi ne the battery
cranki ng capaci ty. I f the battery wi l l endure a l oad
test, return the battery to use. I f the battery wi l l not
endure a l oad test, i t i s faul ty and must be repl aced.
Cl ean and i nspect the battery hol ddowns, tray, ter-
mi nal s, posts, and top before compl eti ng servi ce. See
the Battery Removal and I nstal l ati on procedures i n
CHARGING A COMPLETELY DISCHARGED
BATTERY
The fol l owi ng procedure shoul d be used to recharge
a compl etel y di scharged battery. Unl ess thi s proce-
dure i s properl y fol l owed, a good battery may be
needl essl y repl aced.
(1) Measure the vol tage at the battery posts wi th a
vol tmeter, accurate to 1/10 (0.10) vol t (Fi g. 14). I f the
readi ng i s bel ow ten vol ts, the charge current wi l l be
l ow. I t coul d take some ti me before the battery
accepts a current greater than a few mi l l i amperes.
Such l ow current may not be detectabl e on the
ammeters bui l t i nto many chargers.
cabl e. Connect the battery charger l eads. Some bat-
tery chargers are equi pped wi th pol ari ty-sensi ng ci r-
cui try. Thi s ci rcui try protects the charger and/or the
battery from bei ng damaged i f they are i mproperl y
connected. I f the battery state-of-charge i s too l ow for
the pol ari ty-sensi ng ci rcui try to detect, the charger
wi l l not operate. Thi s makes i t appear that the bat-
tery wi l l not accept chargi ng current. Refer to the
i nstructi ons provi ded wi th the battery charger to
bypass the pol ari ty-sensi ng ci rcui try.
(3) Battery chargers vary i n the amount of vol tage
and current they provi de. The amount of ti me
requi red for a battery to accept measurabl e charger
current at vari ous vol tages i s shown i n the Charge
Rate chart. I f the charge current i s sti l l not measur-
abl e at the end of the chargi ng ti me, the battery i s
faul ty and must be repl aced. I f the charge current i s
measurabl e duri ng the chargi ng ti me, the battery
Fig. 14 Voltmeter Accurate to 1/10 Volt Connected -
Typical
8A - 12 BATTERY XJ
may be good and the chargi ng shoul d be compl eted i n
the normal manner.
CHARGING TIME REQUIRED
The ti me requi red to charge a battery wi l l vary,
dependi ng upon the fol l owi ng factors:
Battery Capacity - A compl etel y di scharged
heavy-duty battery requi res twi ce the chargi ng ti me
of a smal l capaci ty battery.
Temperature - A l onger ti me wi l l be needed to
charge a battery at -18 C (0 F) than at 27 C (80
F). When a fast charger i s connected to a col d bat-
tery, the current accepted by the battery wi l l be very
l ow at fi rst. As the battery warms, i t wi l l accept a
hi gher chargi ng current rate (amperage).
Charger Capacity - A charger that suppl i es
onl y fi ve amperes wi l l requi re a l onger chargi ng
ti me. A charger that suppl i es twenty amperes or
more wi l l requi re a shorter chargi ng ti me.
State-Of-Charge - A compl etel y di scharged
battery requi res more chargi ng ti me than a parti al l y
di scharged battery. El ectrol yte i s nearl y pure water
i n a compl etel y di scharged battery. At fi rst, the
chargi ng current (amperage) wi l l be l ow. As the bat-
tery charges, the speci fi c gravi ty of the el ectrol yte
wi l l gradual l y ri se.
WARNING: NEVER EXCEED TWENTY AMPERES
WHEN CHARGING A COLD (-1 C/30 F) BATTERY.
THE BATTERY MAY ARC INTERNALLY AND
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
DAMAGE MAY RESULT.
BATTERY
Make sure al l el ectri cal accessori es are turned off.
(2) Loosen the cabl e termi nal cl amps and di scon-
nect both battery cabl es, negati ve cabl e fi rst. I f nec-
essary, use a pul l er to remove the termi nal cl amps
from the battery posts (Fi g. 15).
(3) I nspect the cabl e termi nal cl amps for corrosi on
and damage. Remove any corrosi on usi ng a wi re
brush or a post and termi nal cl eani ng tool , and a
sodi um bi carbonate (baki ng soda) and warm water
cl eani ng sol uti on (Fi g. 16). Repl ace any cabl e that
has damaged or deformed termi nal cl amps.
WARNING: WEAR A SUITABLE PAIR OF RUBBER
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
REMOVING A BATTERY BY HAND. SAFETY
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
(4) Remove the battery hol ddowns and remove the
battery from the vehi cl e (Fi g. 17).
(5) I nspect the battery tray and hol ddowns for cor-
rosi on or damage. Remove any corrosi on usi ng a wi re
brush and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on. Pai nt any exposed
bare metal and repl ace any damaged parts.
(6) Sl i de the thermoguard off of the battery case.
I nspect the battery case for cracks or other damage
that coul d resul t i n el ectrol yte l eaks. Al so, check the
battery termi nal posts for l ooseness. Batteri es wi th
damaged cases or l oose posts must be repl aced.
(7) Check the el ectrol yte l evel i n the battery. Use a
putty kni fe or another sui tabl e wi de fl at-bl aded tool
to pry the cel l caps off (Fi g. 18). Do not use a screw-
Charge Rate
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
Battery Charging Timetable
Charging
Amperage
5
Amperes
10
Amperes
20
Amperes
Open Cir-
cuit Volt-
age
Hours Charging at 21C (70F)
12.25 to
12.39
6 hours 3 hours 1.5 hours
12.00 to
12.24
8 hours 4 hours 2 hours
11.95 to
11.99
12 hours 6 hours 3 hours
10.00 to
11.94
14 hours 7 hours 3.5 hours
less than
10.00
See Charging Completely Discharged
Battery
Fig. 15 Remove Battery Cable Terminal Clamp -
Typical
BATTERY BATTERY TERMINAL PULLER
XJ BATTERY 8A - 13
dri ver. Add di sti l l ed water to each cel l unti l the l i q-
ui d reaches the bottom of the vent wel l . DO NOT
OVERFI LL.
(8) I nspect the battery bui l t-i n test i ndi cator si ght
gl ass for an i ndi cati on of the battery condi ti on. I f the
battery i s di scharged, charge as requi red. See the
Bui l t-I n Test I ndi cator and the Battery Chargi ng pro-
cedures i n thi s group for more i nformati on.
(9) I f the battery i s to be rei nstal l ed, cl ean the out-
si de of the battery case and the top cover wi th a
sodi um bi carbonate (baki ng soda) and warm water
cl eani ng sol uti on to remove any aci d fi l m (Fi g. 19).
Ri nse the battery wi th cl ean water. Ensure that the
cl eani ng sol uti on does not enter the battery cel l s
through the vent hol es. I f the battery i s bei ng
repl aced, see the Battery Rati ngs and Cl assi fi cati ons
chart i n Speci fi cati ons at the back of thi s group. Con-
fi rm that the repl acement battery i s the correct si ze
and has the correct rati ngs for the vehi cl e.
(10) Cl ean any corrosi on from the battery termi nal
posts wi th a wi re brush or a post and termi nal
cl eaner, and a sodi um bi carbonate (baki ng soda) and
warm water cl eani ng sol uti on (Fi g. 20).
(11) Rei nstal l the battery thermoguard by sl i di ng
i t over the battery case.
(12) Posi ti on the battery i n the tray. Ensure that
the posi ti ve and negati ve termi nal posts are correctl y
posi ti oned. The cabl e termi nal cl amps must reach the
correct battery post wi thout stretchi ng the cabl es
(Fi g. 21).
(13) Loosel y i nstal l the battery hol ddown hard-
ware. Ensure that the battery base i s correctl y posi -
ti oned i n the tray, then ti ghten the hol ddown nuts to
2.2 Nm (20 i n. l bs.). Ti ghten the hol ddown support
strap bol t to 9 Nm (77 i n. l bs.).
CAUTION: Be certain that the battery cables are
connected to the correct battery terminals. Reverse
polarity may damage electrical components.
Fig. 16 Clean Battery Cable Terminal Clamp -
Typical
TERMINAL BRUSH BATTERY CABLE TEST INDICA- TOR
Fig. 17 Battery Holddowns
BOLT NUTS HOLD DOWN THERMOGUARD NUTSENSOR PUSH-ON RETAINERT-BOLT WHEELHOUSE INNER PANEL STUD FWD TRAY RADIATOR CROSS- MEMBER BATTERY SUPPORTSTRAP
Fig. 18 Removing Cell Caps - Typical
8A - 14 BATTERY XJ
(14) I nstal l and ti ghten the battery posi ti ve cabl e
termi nal cl amp. Then i nstal l and ti ghten the battery
negati ve cabl e termi nal cl amp. Ti ghten both cabl e
termi nal cl amp bol ts to 8.5 Nm (75 i n. l bs.).
(15) Appl y a thi n coati ng of petrol eum jel l y or
chassi s grease to the exposed surfaces of the battery
cabl e termi nal cl amps and the battery termi nal
posts.
SPECIFICATIONS
BATTERY
Fig. 19 Clean Battery - Typical
TEST INDICA- TOR BATTERY CLEANING BRUSH WARM WATER AND BAKING SODA SOLU- TION
Fig. 20 Clean Battery Terminal Post - Typical
BATTERY TEST INDI- CATOR TERMINAL BRUSH BATTERY CABLE
Fig. 21 Battery Cables
RADIATOR CROSSMEMBER WHEELHOUSE INNER PANEL NEGATIVE CABLE POSITIVE CABLE FWD BATTERY
Battery Classifications and Ratings
Part Number
BCI Group Size
Classification
Cold Cranking
Amperage
Reserve Capac-
ity
Ampere-Hours
Load Test
Amperage
56041105 58 500 85 Minutes 42 250
XJ BATTERY 8A - 15
STARTING SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
COLD CRANKING TEST . . . . . . . . . . . . . . . . . . 3
CONTROL CIRCUIT TEST . . . . . . . . . . . . . . . . . 6
FEED CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . 3
STARTER NOISE - 2.5L ENGINE . . . . . . . . . . . . 7
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . 9
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
OVERVIEW
ods, to the more sophi sti cated On-Board Di agnosti cs
INTRODUCTION
The starti ng system consi sts of:
Battery
Starter rel ay
Starter wi th an i ntegral sol enoi d
I gni ti on swi tch
Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Wi re harness and connecti ons.
Thi s group covers di agnosi s of the compl ete start-
i ng system, except the battery. However, thi s group
onl y covers servi ce procedures for the starter and
starter rel ay. Servi ce procedures for other starti ng
system components can be l ocated as fol l ows:
Battery - refer to Group 8A - Battery for the
di agnosti c and servi ce procedures
I gni ti on swi tch - refer to Group 8D - I gni ti on
Systems for the servi ce procedures
Cl utch pedal posi ti on swi tch - refer to Group 6 -
Cl utch for the servi ce procedures
Park/neutral posi ti on swi tch - refer to Group 21
- Transmi ssi on for the servi ce procedures
Wi re harness and connecti ons - refer to Group
8W - Wi ri ng Di agrams for the servi ce procedures.
XJ STARTING SYSTEMS 8B - 1
STARTING SYSTEM
The starti ng system components form two separate
ci rcui ts. A hi gh-amperage feed ci rcui t that feeds the
starter between 150 and 350 amperes, and a l ow-am-
perage control ci rcui t that operates on l ess than 20
amperes.
I f the vehi cl e i s equi pped wi th an automati c trans-
mi ssi on, battery vol tage i s suppl i ed through the l ow-
amperage control ci rcui t to the coi l battery termi nal
of the starter rel ay when the i gni ti on swi tch i s
turned to the Start posi ti on. The park/neutral posi -
ti on swi tch i s i nstal l ed i n seri es between the starter
rel ay coi l ground termi nal and ground. Thi s normal l y
open swi tch prevents the starter rel ay from bei ng
energi zed unl ess the automati c transmi ssi on gear
sel ector i s i n the Neutral or Park posi ti ons.
I f the vehi cl e i s equi pped wi th a manual transmi s-
si on, i t has a cl utch pedal posi ti on swi tch i nstal l ed i n
seri es between the i gni ti on swi tch and the coi l bat-
tery termi nal of the starter rel ay. Thi s normal l y open
swi tch prevents the starter rel ay from bei ng ener-
gi zed unl ess the cl utch pedal i s depressed, preventi ng
starter operati on whi l e the cl utch di sc and the fl y-
wheel are engaged. The starter rel ay coi l ground ter-
mi nal i s al ways grounded on vehi cl es wi th a manual
transmi ssi on.
When the starter rel ay coi l i s energi zed, the nor-
mal l y open rel ay contacts cl ose. The rel ay contacts
connect the rel ay common feed termi nal to the rel ay
normal l y open termi nal . The cl osed rel ay contacts
energi ze the starter sol enoi d coi l wi ndi ngs.
The energi zed sol enoi d pul l -i n coi l pul l s i n the sol e-
noi d pl unger. The sol enoi d pl unger pul l s the shi ft
l ever i n the starter. Thi s engages the starter overrun-
ni ng cl utch and pi ni on gear wi th the starter ri ng
gear on the manual transmi ssi on fl ywheel , or on the
automati c transmi ssi on torque converter dri ve pl ate.
As the sol enoi d pl unger reaches the end of i ts
travel , the sol enoi d contact di sc compl etes the hi gh-
amperage starter feed ci rcui t and energi zes the sol e-
noi d pl unger hol d-i n coi l . Current now fl ows between
the sol enoi d battery termi nal and the starter motor,
energi zi ng the starter.
Once the engi ne starts, the overrunni ng cl utch pro-
tects the starter from damage by al l owi ng the starter
pi ni on gear to spi n faster than the pi ni on shaft.
When the dri ver rel eases the i gni ti on swi tch to the
On posi ti on, the starter rel ay coi l i s de-energi zed.
Thi s causes the rel ay contacts to open. When the
rel ay contacts open, the starter sol enoi d pl unger
hol d-i n coi l i s de-energi zed.
When the sol enoi d pl unger hol d-i n coi l i s de-ener-
gi zed, the sol enoi d pl unger return spri ng returns the
pl unger to i ts rel axed posi ti on. Thi s causes the con-
tact di sc to open the starter feed ci rcui t, and the shi ft
l ever to di sengage the overrunni ng cl utch and pi ni on
gear from the starter ri ng gear.
STARTER
The starter motor i ncorporates several features to
create a rel i abl e, effi ci ent, compact, and l i ghtwei ght
uni t. A pl anetary gear system (i ntermedi ate trans-
mi ssi on) i s used between the el ectri c motor and the
pi ni on gear. Thi s feature makes i t possi bl e to reduce
the di mensi ons of the starter. At the same ti me, i t
al l ows hi gher armature rotati onal speed and del i vers
i ncreased torque through the pi ni on gear to the
starter ri ng gear on the automati c transmi ssi on
torque converter or torque converter dri ve pl ate, or
on the manual transmi ssi on fl ywheel .
The use of a permanent magnet fi el d al so reduces
the si ze and wei ght of the starter. The permanent
magnet fi el d consi sts of four hi gh-strength perma-
nent magnets. The magnets are al i gned accordi ng to
thei r pol ari ty, and are permanentl y mounted i n the
starter fi el d frame.
The starter motors for al l engi nes are acti vated by
a sol enoi d mounted to the overrunni ng cl utch hous-
i ng. However, the starter motor and sol enoi d are ser-
vi ced onl y as a compl ete assembl y. I f ei ther
component i s faul ty or damaged, the enti re starter
assembl y must be repl aced.
CAUTION:
Permanent magnet starters are highly sensi-
tive to hammering, shocks, and external pressure.
The permanent magnets may be damaged and the
starter rendered unserviceable, if subjected to any
of these conditions.
The starter motor must not be clamped in a
vise by the starter field frame. Doing so may dam-
age the permanent magnets. The starter should
only be clamped by the mounting flange.
Do not connect the starter motor incorrectly
when testing. Reverse polarity may damage the per-
manent magnets and render the starter unservice-
able.
STARTER RELAY
The starter rel ay i s a I nternati onal Standards
Organi zati on (I SO)-type rel ay. The starter rel ay i s a
el ectromechani cal devi ce that swi tches battery cur-
rent to the pul l -i n coi l of the starter sol enoi d when
the i gni ti on swi tch i s turned to the Start posi ti on.
See the Di agnosi s and Testi ng secti on of thi s group
for more i nformati on on the operati on of the starter
rel ay.
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC), i n the engi ne compartment. Refer
to the PDC l abel for rel ay i denti fi cati on and l ocati on.
8B - 2 STARTING SYSTEMS XJ
The starter rel ay cannot be repai red and, i f faul ty
or damaged, i t must be repl aced.
STARTING SYSTEM
8W-21 - Starti ng System i n Group 8W - Wi ri ng Di a-
grams.
INJURY.
INSPECTION
Before removi ng any uni t from the starti ng system
for repai r or di agnosi s, perform the fol l owi ng i nspec-
ti ons:
Battery - Vi sual l y i nspect the battery for i ndi -
cati ons of physi cal damage and l oose or corroded
cabl e connecti ons. Determi ne the state-of-charge and
cranki ng capaci ty of the battery. Charge or repl ace
the battery, i f requi red. Refer to Group 8A - Battery
Ignition Switch - Vi sual l y i nspect the i gni ti on
swi tch for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons.
Clutch Pedal Position Switch - Vi sual l y
i nspect the cl utch pedal posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
harness connecti ons.
Park/Neutral Position Switch - Vi sual l y
i nspect the park/neutral posi ti on swi tch for i ndi ca-
ti ons of physi cal damage and l oose or corroded wi re
Starter Relay - Vi sual l y i nspect the starter
rel ay for i ndi cati ons of physi cal damage and l oose or
corroded wi re harness connecti ons.
Starter - Vi sual l y i nspect the starter for i ndi -
cati ons of physi cal damage and l oose or corroded wi re
Starter Solenoid - Vi sual l y i nspect the starter
sol enoi d for i ndi cati ons of physi cal damage and l oose
or corroded wi re harness connecti ons.
Wiring - Vi sual l y i nspect the wi re harness for
damage. Repai r or repl ace any faul ty wi ri ng, as
requi red.
COLD CRANKING TEST
grams. The battery must be ful l y-charged and l oad-
tested before proceedi ng. Refer to Group 8A - Battery
(1) Connect a sui tabl e vol t-ampere tester to the
battery termi nal s (Fi g. 1). Refer to the operati ng
i nstructi ons provi ded wi th the tester bei ng used.
(2) Ful l y engage the parki ng brake.
(3) I f the vehi cl e i s equi pped wi th an automati c
pedal .
(4) Veri fy that al l l amps and accessori es are
turned off.
(5) To prevent the engi ne from starti ng, unpl ug
the Automati c ShutDown (ASD) rel ay. The ASD rel ay
i s l ocated i n the Power Di stri buti on Center (PDC).
Refer to the PDC l abel for rel ay i denti fi cati on and
l ocati on.
(6) Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Note the cranki ng vol tage and current
(amperage) draw.
(a) I f the vol tage reads bel ow 9.6 vol ts, remove
the starter for bench testi ng. I f the starter bench
test i s OK, refer to Group 9 - Engi ne for further
di agnosi s of the engi ne. I f the starter bench test i s
not OK, repl ace the faul ty starter.
(b) I f the vol tage reads above 9.6 vol ts and the
current (amperage) draw reads bel ow speci fi ca-
ti ons, see the Feed Ci rcui t Test procedures i n thi s
group.
(c) I f the vol tage reads 12.5 vol ts or greater and
the starter does not turn, see the Control Ci rcui t
Test procedures i n thi s group.
(d) I f the vol tage reads 12.5 vol ts or greater and
the starter turns very sl owl y, see the Feed Ci rcui t
Test procedures i n thi s group.
NOTE: A cold engine will increase the starter cur-
rent (amperage) draw reading, and reduce the bat-
tery voltage reading.
FEED CIRCUIT TEST
The starter feed ci rcui t test (vol tage drop method)
wi l l determi ne i f there i s excessi ve resi stance i n the
hi gh-amperage ci rcui t. For ci rcui t descri pti ons and
di agrams, refer to 8W-21 - Starti ng System i n Group
8W - Wi ri ng Di agrams.
When performi ng these tests, i t i s i mportant to
remember that the vol tage drop i s gi vi ng an i ndi ca-
ti on of the resi stance between the two poi nts at
whi ch the vol tmeter probes are attached.
Example: When testi ng the resi stance of the bat-
tery posi ti ve cabl e, touch the vol tmeter l eads to the
battery posi ti ve cabl e cl amp and the cabl e connector
at the starter sol enoi d. I f you probe the battery pos-
i ti ve termi nal post and the cabl e connector at the
starter sol enoi d, you are readi ng the combi ned vol t-
age drop i n the battery posi ti ve cabl e cl amp-to-termi -
nal post connecti on and the battery posi ti ve cabl e.
The fol l owi ng operati on wi l l requi re a vol tmeter
accurate to 1/10 (0.10) vol t. Before performi ng the
tests, be certai n the fol l owi ng procedures are accom-
pl i shed:
Battery i s ful l y-charged. Refer to Group 8A -
Battery for more i nformati on.
Ful l y engage the parki ng brake.
I f the vehi cl e i s equi pped wi th an automati c
pedal .
Unpl ug the Automati c ShutDown (ASD) rel ay to
prevent the engi ne from starti ng. The ASD rel ay i s
Starting System Diagnosis
STARTER FAILS
TO ENGAGE.
1. Battery discharged or
faulty.
2. Starting circuit wiring
faulty.
3. Starter relay faulty.
4. Ignition switch faulty.
5. Park/Neutral position
switch (auto trans) faulty
or misadjusted.
6. Clutch pedal position
switch (man trans) faulty.
7. Starter solenoid faulty.
8. Starter assembly
faulty.
1. Refer to Group 8A - Battery. Charge or replace battery, if
required.
2. See Cold Cranking Test, in this group. Test and repair feed
and/or control circuits, if required.
3. See Relay Test, in this group. Replace relay, if required.
4. See Ignition Switch Test, in this group. Replace switch, if
required.
5. See Park/Neutral Position Switch, in Group 21 - Transmission
and Transfer Case for the diagnosis and service of this
component. Replace switch, if required.
6. See Clutch Pedal Position Switch Test, in this group. Replace
switch, if required.
7. See Solenoid Test, in this Group. Replace starter assembly, if
required.
8. If all other starting system components and circuits check OK,
replace starter assembly.
STARTER
ENGAGES,
FAILS TO TURN
ENGINE.
1. Battery discharged or
faulty.
2. Starting circuit wiring
faulty.
3. Starter assembly
faulty.
4. Engine seized.
1. Refer to Group 8A - Battery. Charge or replace battery, if
required.
2. See Cold Cranking Test, in this group. Test and repair feed
and/or control circuits, if required.
4. Refer to Group 9 - Engine, for diagnostic and service
procedures.
STARTER
ENGAGES,
SPINS OUT
BEFORE
ENGINE
STARTS.
1. Broken teeth on
starter ring gear.
2. Starter assembly
faulty.
1. Remove starter as described in this group. Inspect ring gear
and replace, if required.
STARTER DOES
NOT
DISENGAGE.
1. Starter improperly
installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter assembly
faulty.
1. Install starter as described in this group. Tighten starter
mounting hardware to correct torque specifications.
2. See Relay Test, in this group. Replace relay, if required.
3. See Ignition Switch Test, in this group. Replace switch, if
required.
Refer to the PDC l abel for ASD rel ay i denti fi cati on
and l ocati on.
the battery negati ve termi nal post. Connect the neg-
ati ve l ead of the vol tmeter to the battery negati ve
cabl e cl amp (Fi g. 2). Rotate and hol d the i gni ti on
swi tch i n the Start posi ti on. Observe the vol tmeter. I f
vol tage i s detected, correct the poor contact between
the cabl e cl amp and the termi nal post.
the battery posi ti ve termi nal post. Connect the nega-
ti ve l ead of the vol tmeter to the battery posi ti ve cabl e
cl amp (Fi g. 3). Rotate and hol d the i gni ti on swi tch i n
the Start posi ti on. Observe the vol tmeter. I f vol tage
i s detected, correct the poor contact between the
cabl e cl amp and the termi nal post.
battery posi ti ve termi nal post and the starter sol e-
noi d battery termi nal stud (Fi g. 4). Rotate and hol d
ti ghten the battery cabl e connecti on at the sol enoi d.
Repeat the test. I f the readi ng i s sti l l above 0.2 vol t,
repl ace the faul ty battery posi ti ve cabl e.
battery negati ve termi nal post and a good cl ean
ground on the engi ne bl ock (Fi g. 5). Rotate and hol d
ti ghten the battery negati ve cabl e attachment on the
engi ne bl ock. Repeat the test. I f the readi ng i s sti l l
above 0.2 vol t, repl ace the faul ty battery negati ve
cabl e.
the starter housi ng. Connect the negati ve l ead of the
vol tmeter to the battery negati ve termi nal post (Fi g.
6). Rotate and hol d the i gni ti on swi tch i n the Start
posi ti on. Observe the vol tmeter. I f the readi ng i s
above 0.2 vol t, correct the poor starter to engi ne
bl ock ground contact.
I f the resi stance tests detect no feed ci rcui t prob-
l ems, remove the starter and see the Sol enoi d Test
procedure i n thi s group.
Fig. 1 Volts-Amps Tester Connections - Typical
POSITIVE CLAMP NEGATIVE CLAMP INDUCTION AMMETER CLAMP
Fig. 2 Test Battery Negative Connection Resistance
- Typical
VOLTMETER BATTERY
Fig. 3 Test Battery Positive Connection Resistance -
Typical
Fig. 4 Test Battery Positive Cable Resistance -
Typical
BATTERY VOLTMETER STARTER MOTOR
CONTROL CIRCUIT TEST
grams. The starter control ci rcui t consi sts of:
Battery
Starter rel ay
Starter sol enoi d
I gni ti on swi tch
Park/neutral posi ti on swi tch (automati c trans-
mi ssi on)
Cl utch pedal posi ti on swi tch (manual transmi s-
si on)
Wi re harness and connecti ons.
Test procedures for these components shoul d be
performed i n the order i n whi ch they are l i sted, as
fol l ows:
SOLENOID TEST
Remove the starter as descri bed i n thi s group.
Then proceed as fol l ows:
(1) Remove the wi re from the sol enoi d fi el d coi l
termi nal .
(2) Check for conti nui ty between the sol enoi d ter-
mi nal and the fi el d coi l termi nal wi th a conti nui ty
tester (Fi g. 7). There shoul d be conti nui ty. I f OK, go
to Step 3. I f not OK, repl ace the faul ty starter assem-
bl y.
(3) Check for conti nui ty between the sol enoi d ter-
mi nal and the sol enoi d case (Fi g. 8). There shoul d be
conti nui ty. I f OK, go to Step 4. I f not OK, repl ace the
faul ty starter assembl y.
(4) Connect the sol enoi d fi el d coi l wi re to the fi el d
coi l termi nal .
(5) I nstal l the starter as descri bed i n thi s group.
RELAY TEST
The starter rel ay i s l ocated i n the Power Di stri bu-
ti on Center (PDC) i n the engi ne compartment. Refer
to the PDC l abel for starter rel ay i denti fi cati on and
l ocati on.
Remove the starter rel ay from the PDC as
descri bed i n thi s group to perform the fol l owi ng tests:
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
connected to battery vol tage and shoul d be hot at al l
Fig. 5 Test Ground Circuit Resistance - Typical
VOLTMETER ENGINE GROUND BATTERY
Fig. 6 Test Starter Ground - Typical
STARTER MOTOR BATTERY VOLTMETER
Fig. 7 Continuity Test Between Solenoid Terminal
and Field Coil Terminal
SOLENOID SOLENOID TERMINAL OHMMETER FIELD COIL TERMI- NAL
Fig. 8 Continuity Test Between Solenoid Terminal
and Solenoid Case
SOLENOID SOLENOID TER- MINAL OHMMETER
ci rcui t to the PDC fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the starter sol enoi d fi el d coi l s. There shoul d be
conti nui ty between the cavi ty for rel ay termi nal 87
and the starter sol enoi d termi nal at al l ti mes. I f OK,
go to Step 4. I f not OK, repai r the open ci rcui t to the
starter sol enoi d as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s energi zed when
the i gni ti on swi tch i s hel d i n the Start posi ti on. On
vehi cl es wi th a manual transmi ssi on, the cl utch
pedal must be ful l y depressed for thi s test. Check for
battery vol tage at the cavi ty for rel ay termi nal 86
wi th the i gni ti on swi tch i n the Start posi ti on, and no
vol tage when the i gni ti on swi tch i s rel eased to the
On posi ti on. I f OK, go to Step 5. I f not OK wi th an
automati c transmi ssi on, check for an open or short
ci rcui t to the i gni ti on swi tch and repai r, i f requi red.
I f the ci rcui t to the i gni ti on swi tch i s OK, see the
I gni ti on Swi tch Test procedure i n thi s group. I f not
OK wi th a manual transmi ssi on, check the ci rcui t
between the rel ay and the cl utch pedal posi ti on
swi tch for an open or a short. I f the ci rcui t i s OK, see
the Cl utch Pedal Posi ti on Swi tch Test procedure i n
thi s group.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. On vehi cl es wi th an
automati c transmi ssi on, i t i s grounded through the
park/neutral posi ti on swi tch onl y when the gearshi ft
sel ector l ever i s i n the Park or Neutral posi ti ons. On
vehi cl es wi th a manual transmi ssi on, i t i s grounded
at al l ti mes. Check for conti nui ty to ground at the
cavi ty for rel ay termi nal 85. I f not OK wi th an auto-
mati c transmi ssi on, check for an open or short ci rcui t
to the park/neutral posi ti on swi tch and repai r, i f
requi red. I f the ci rcui t i s OK, see the Park/Neutral
Posi ti on Swi tch Test procedure i n thi s group. I f not
OK wi th a manual transmi ssi on, repai r the ci rcui t to
ground as requi red.
PARK/NEUTRAL POSITION SWITCH TEST
For testi ng of the park/neutral posi ti on swi tch,
refer to Group 21 - Transmi ssi on and Transfer Case.
IGNITION SWITCH TEST
INJURY.
cabl e.
(2) Remove the steeri ng col umn shrouds and
unpl ug the i gni ti on swi tch wi re harness connector.
Refer to Group 8D - I gni ti on Systems for the proce-
dures.
(3) Wi th the i gni ti on swi tch i n the On posi ti on,
check for conti nui ty between the i gni ti on swi tch
fused B(+) ci rcui t termi nal and the i gni ti on swi tch
output (start) ci rcui t termi nal . There shoul d be no
conti nui ty. I f OK, go to Step 4. I f not OK, repl ace the
faul ty swi tch.
(4) Wi th the i gni ti on swi tch hel d i n the Start posi -
ti on, check for conti nui ty between the i gni ti on swi tch
fused B(+) ci rcui t termi nal and the i gni ti on swi tch
output (start) ci rcui t termi nal . There shoul d now be
conti nui ty. I f not OK, repl ace the faul ty swi tch.
STARTER NOISE - 2. 5L ENGINE
See the Starter Noi se Di agnosi s chart (Fi g. 9). I f
the compl ai nt i s si mi l ar to Condi ti ons 1 and 2 i n the
chart, correcti on can be made by shi mmi ng the
starter usi ng the fol l owi ng procedures:
CAUTION: Disconnect the battery negative cable to
prevent the engine from starting.
(1) I f the compl ai nt i s si mi l ar to Condi ti on 1, the
starter must be moved toward the starter ri ng gear
by removi ng shi ms (Fi g. 10).
NOTE: The shim thickness is 0.381 mm (0.015 in.),
and the shims may be stacked if additional thick-
ness is required.
Starter Relay
TERMINAL LEGEND NUMBER IDENTIFICATION COMMON FEED
COIL GROUND
COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
(2) I f the compl ai nt i s si mi l ar to Condi ti on 2, the
starter must be moved away from the starter ri ng
gear. Thi s i s done by i nstal l i ng shi m(s) across both
starter mounti ng pads. More than one shi m may be
requi red.
NOTE: This is a condition that will generally cause
broken starter (flywheel/drive plate) ring gear teeth
or broken starter housings.
STARTER
2.5L ENGINE
cabl e.
(3) Di sconnect the battery cabl e and sol enoi d feed
wi re from the starter sol enoi d (Fi g. 11).
Fig. 9 Starter Noise Diagnosis
Fig. 10 Starter Shim
STARTER MOTOR SHIM FWD
Fig. 11 Starter Remove/Install - 2.5L Engine
FWD STARTER NUTS CONNECTORS SCREW SHIM
(4) Remove the two starter mounti ng screws, the
starter motor, and any starter motor shi ms.
NOTE: Shim thickness available is 0.381 mm (0.015
in.). See Starter Noise - 2.5L Engine in this group
for more information.
Ti ghten the starter hardware as fol l ows:
Mounti ng screws - 45 Nm (33 ft. l bs.)
Sol enoi d battery cabl e nut - 10 Nm (90 i n. l bs.)
Sol enoi d termi nal nut - 6 Nm (55 i n. l bs.).
4.0L ENGINE
cabl e.
(3) Di sconnect the battery cabl e and sol enoi d feed
wi re from the starter sol enoi d (Fi g. 12).
(4) Remove the l ower starter mounti ng screw.
(5) Remove the upper starter mounti ng screw and
the starter motor.
Ti ghten the starter hardware as fol l ows:
Upper mounti ng screw (rear screw) - 55 Nm (40
ft. l bs.)
Lower mounti ng screw (front screw) - 41 Nm
(30 ft. l bs.)
Sol enoi d battery cabl e nut - 10 Nm (90 i n. l bs.)
Sol enoi d termi nal nut - 6 Nm (55 i n. l bs.).
STARTER RELAY
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 13).
(3) Refer to the l abel on the PDC for starter rel ay
i denti fi cati on and l ocati on.
(4) Unpl ug the starter rel ay from the PDC.
(5) I nstal l the starter rel ay by al i gni ng the rel ay
termi nal s wi th the cavi ti es i n the PDC and pushi ng
the rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
Fig. 12 Starter Remove/Install - 4.0L Engine
SCREW FWD SCREW NUTS CONNECTOR STARTER
Fig. 13 Power Distribution Center
SPECIFICATIONS
STARTING SYSTEM
Starter and Solenoid
Manufacturer Mitsubishi
Engine Application 2.5L, 4.0L
Power Rating 1.2 Kilowatt - 2.5L
1.4 Kilowatt - 4.0L
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test
Voltage
11.2 Volts
Free Running Test
Maximum Amperage
Draw
90 Amperes
Free Running Test
Minimum Speed
2600 rpm - 2.5L
2500 rpm - 4.0L
Solenoid Closing
Maximum Voltage
7.8 Volts
*Cranking Amperage
Draw Test
130 Amperes - 2.5L
160 Amperes - 4.0L
*Test at operating temperature. Cold engine, tight
(new) engine, or heavy oil will increase starter
amperage draw.
CHARGING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BATTERY TEMPERATURE SENSOR . . . . . . . . . 2
CHARGING SYSTEM OPERATION . . . . . . . . . . 1
ELECTRONIC VOLTAGE REGULATOR . . . . . . . 2
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHARGING SYSTEM RESISTANCE TESTS . . . . 3
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
CURRENT OUTPUT TEST . . . . . . . . . . . . . . . . . 3
ON-BOARD DIAGNOSTIC TEST FOR
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . 5
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
GENERATOR RATINGS . . . . . . . . . . . . . . . . . . . 7
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
OVERVIEW
ods to the more sophi sti cated On-Board Di agnosti cs
CHARGING SYSTEM OPERATION
The chargi ng system consi sts of:
Generator
El ectroni c Vol tage Regul ator (EVR) ci rcui try
wi thi n the Powertrai n Control Modul e (PCM)
I gni ti on swi tch (refer to Group 8D, I gni ti on Sys-
tem for i nformati on)
Battery (refer to Group 8A, Battery for i nforma-
ti on)
Battery temperature sensor
Generator Lamp (i f equi pped)
Check Gauges Lamp (i f equi pped)
Vol tmeter (refer to Group 8E, I nstrument Panel
and Gauges for i nformati on)
Wi ri ng harness and connecti ons (refer to Group
8W, Wi ri ng for i nformati on)
The chargi ng system i s turned on and off wi th the
i gni ti on swi tch. When the i gni ti on swi tch i s turned to
the ON posi ti on, battery vol tage from the powertrai n
control modul e (PCM) i s suppl i ed to the generator
rotor to produce a magneti c fi el d. Thi s i s done
through one of the two fi el d termi nal s at the rear of
generator. On models of previous years, battery
voltage to this field terminal was supplied
directly from the ASD relay.
The amount of DC current produced by the gener-
ator i s control l ed by the EVR (fi el d control ) ci rcui try
contai ned wi thi n the PCM. Thi s ci rcui try i s con-
nected i n seri es wi th the second rotor fi el d termi nal
and ground.
A battery temperature sensor, l ocated i n the bat-
tery tray housi ng, i s used to sense battery tempera-
ture. Thi s temperature data, al ong wi th data from
moni tored l i ne vol tage, i s used by the PCM to vary
the battery chargi ng rate. Thi s i s done by cycl i ng the
ground path to control the strength of the rotor mag-
neti c fi el d. The PCM then compensates and regul ates
generator current output accordi ngl y.
Al l vehi cl es are equi pped wi th On-Board Di agnos-
ti cs (OBD). Al l OBD-sensed systems, i ncl udi ng the
EVR (fi el d control ) ci rcui try, are moni tored by the
XJ CHARGING SYSTEM 8C - 1
el ectroni c memory for any fai l ure i t detects. Refer to
On-Board Di agnosti c Test For Chargi ng System i n
The Check Gauges Lamp moni tors: charging sys-
tem voltage, engi ne cool ant temperature and engi ne
oi l pressure. I f an extreme condi ti on i s i ndi cated, the
l amp wi l l be i l l umi nated. Thi s i s done as remi nder to
check the three gauges. The si gnal to acti vate the
l amp i s sent vi a the CCD bus ci rcui ts. The l amp i s
l ocated on the i nstrument panel . Refer to Group 8E,
I nstrument Panel and Gauges for addi ti onal i nforma-
ti on.
GENERATOR
The generator i s bel t-dri ven by the engi ne usi ng a
serpenti ne type dri ve bel t. I t i s servi ced onl y as a
compl ete assembl y. I f the generator fai l s for any rea-
son, the enti re assembl y must be repl aced.
As the energi zed rotor begi ns to rotate wi thi n the
generator, the spi nni ng magneti c fi el d i nduces a cur-
rent i nto the wi ndi ngs of the stator coi l . Once the
generator begi ns produci ng suffi ci ent current, i t al so
provi des the current needed to energi ze the rotor.
The Y type stator wi ndi ng connecti ons del i ver the
i nduced AC current to 3 posi ti ve and 3 negati ve
di odes for recti fi cati on. From the di odes, recti fi ed DC
current i s del i vered to the vehi cl e el ectri cal system
through the generator battery and ground termi nal s.
Al though the generators appear the same exter-
nal l y, di fferent generators wi th di fferent output rat-
i ngs are used on thi s vehi cl e. Be certai n that the
repl acement generator has the same output rati ng
and part number as the ori gi nal uni t. Refer to Gen-
erator Rati ngs i n the Speci fi cati ons secti on at the
back of thi s group for amperage rati ngs and part
numbers.
Noi se emi tti ng from the generator may be caused
by: worn, l oose or defecti ve beari ngs; a l oose or defec-
ti ve dri ve pul l ey; i ncorrect, worn, damaged or mi sad-
justed fan dri ve bel t; l oose mounti ng bol ts; a
mi sal i gned dri ve pul l ey or a defecti ve stator or di ode.
BATTERY TEMPERATURE SENSOR
The battery temperature sensor i s used to deter-
mi ne the battery temperature and control battery
chargi ng rate. Thi s temperature data, al ong wi th
data from moni tored l i ne vol tage, i s used by the PCM
to vary the battery chargi ng rate. System vol tage wi l l
be hi gher at col der temperatures and i s gradual l y
reduced at warmer temperatures.
ELECTRONIC VOLTAGE REGULATOR
The El ectroni c Vol tage Regul ator (EVR) i s not a
separate component. I t i s actual l y a vol tage regul at-
i ng ci rcui t l ocated wi thi n the Powertrai n Control
Modul e (PCM). The EVR i s not servi ced separatel y. I f
repl acement i s necessary, the PCM must be repl aced.
Operation: The amount of DC current produced
by the generator i s control l ed by EVR ci rcui try con-
tai ned wi thi n the PCM. Thi s ci rcui try i s connected i n
seri es wi th the generators second rotor fi el d termi nal
and i ts ground.
Vol tage i s regul ated by cycl i ng the ground path to
control the strength of the rotor magneti c fi el d. The
EVR ci rcui try moni tors system l i ne vol tage and bat-
tery temperature (refer to Battery Temperature Sen-
sor for more i nformati on). I t then compensates and
regul ates generator current output accordi ngl y. Al so
see Chargi ng System Operati on for addi ti onal i nfor-
mati on.
CHARGING SYSTEM
The fol l owi ng procedures may be used to di agnose
the chargi ng system i f:
the generator l amp (i f equi pped) i s i l l umi nated
wi th the engi ne runni ng
the vol tmeter (i f equi pped) does not regi ster
properl y
an undercharged or overcharged battery condi -
ti on occurs.
Remember that an undercharged battery i s often
caused by:
accessori es bei ng l eft on wi th the engi ne not
runni ng
a faul ty or i mproperl y adjusted swi tch that
al l ows a l amp to stay on. See I gni ti on-Off Draw Test
i n Group 8A, Battery for more i nformati on.
INSPECTION
To perform a compl ete test of the chargi ng system,
refer to the appropri ate Powertrai n Di agnosti c Proce-
dures servi ce manual and the DRB scan tool . Per-
form the fol l owi ng i nspecti ons before attachi ng the
scan tool .
(1) I nspect the battery condi ti on. Refer to Group
8A, Battery for procedures.
(2) I nspect condi ti on of battery cabl e termi nal s,
battery posts, connecti ons at engi ne bl ock, starter
sol enoi d and rel ay. They shoul d be cl ean and ti ght.
Repai r as requi red.
(3) I nspect al l fuses i n both the fusebl ock and
Power Di stri buti on Center (PDC) for ti ghtness i n
receptacl es. They shoul d be properl y i nstal l ed and
ti ght. Repai r or repl ace as requi red.
(4) I nspect generator mounti ng bol ts for ti ghtness.
Repl ace or ti ghten bol ts i f requi red. Refer to the Gen-
erator Removal /I nstal l ati on secti on of thi s group for
torque speci fi cati ons.
8C - 2 CHARGING SYSTEM XJ
(5) I nspect generator dri ve bel t condi ti on and ten-
si on. Ti ghten or repl ace bel t as requi red. Refer to
Bel t Tensi on Speci fi cati ons i n Group 7, Cool i ng Sys-
tem.
(6) I nspect automati c bel t tensi oner (i f equi pped).
Refer to Group 7, Cool i ng System for i nformati on.
(7) I nspect connecti ons at generator fi el d, battery
output, and ground termi nal s. Al so check ground con-
necti on at engi ne. They shoul d al l be cl ean and ti ght.
Repai r as requi red.
CHARGING SYSTEM RESISTANCE TESTS
These tests wi l l show the amount of vol tage drop
across the generator output wi re, from the generator
output (B+) termi nal to the battery posi ti ve post.
They wi l l al so show the amount of vol tage drop from
the ground (-) termi nal on the generator to the bat-
tery negati ve post. A typi cal generator wi ri ng har-
ness i s shown i n (Fi g. 1). Wi ri ng harness routi ng as
shown i n (Fi g. 1) may be sl i ghtl y di fferent dependi ng
on vehi cl e model and/or engi ne. Refer to Group 8W,
Wi ri ng Di agrams for addi ti onal i nformati on.
A vol tmeter wi th a 018 vol t DC scal e shoul d be
used for these tests. By reposi ti oni ng the vol tmeter
test l eads, the poi nt of hi gh resi stance (vol tage drop)
can easi l y be found.
PREPARATION
(1) Before starti ng test, make sure battery i s i n
good condi ti on and i s ful l y-charged. See Group 8A,
(2) Check condi ti on of battery cabl es at battery.
Cl ean i f necessary.
(3) Start the engi ne and al l ow i t to reach normal
operati ng temperature.
(5) Connect an engi ne tachometer.
TEST
(1) Start engi ne.
(2) Pl ace heater bl ower i n hi gh posi ti on.
(3) Turn on headl amps and pl ace i n hi gh-beam
posi ti on.
(4) Turn vehi cl e i nteri or l amps on.
(5) Bri ng engi ne speed up to 2400 rpm and hol d.
(6) Testi ng (+) ci rcui try:
(a) Touch the negati ve l ead of vol tmeter di rectl y
to battery posi ti ve post.
(b) Touch the posi ti ve l ead of vol tmeter to the
B+ output termi nal stud on the generator (not the
termi nal mounti ng nut). Vol tage shoul d be no
hi gher than 0.6 vol ts. I f vol tage i s hi gher than 0.6
vol ts, touch test l ead to termi nal mounti ng stud
nut and then to the wi ri ng connector. I f vol tage i s
now bel ow 0.6 vol ts, l ook for di rty, l oose or poor
connecti on at thi s poi nt. Al so check condi ti on of the
generator output wi re-to-battery bul l et connector
(i f equi pped). Refer to Group 8, Wi ri ng for connec-
tor l ocati on. A vol tage drop test may be performed
at each (+) connecti on i n thi s ci rcui t to l ocate the
excessi ve resi stance.
(7) Testi ng (-) ci rcui try:
(a) Touch the negati ve l ead of vol tmeter di rectl y
to battery negati ve post.
(b) Touch the posi ti ve l ead of vol tmeter to the
ground termi nal stud on the generator case (not
the termi nal mounti ng nut). Vol tage shoul d be no
hi gher than 0.3 vol ts. I f vol tage i s hi gher than 0.3
vol ts, touch test l ead to termi nal mounti ng stud
nut and then to the wi ri ng connector. I f vol tage i s
now bel ow 0.3 vol ts, l ook for di rty, l oose or poor
connecti on at thi s poi nt. A vol tage drop test may be
performed at each (-) connecti on i n thi s ci rcui t to
l ocate the excessi ve resi stance. Thi s test can al so
be performed between the generator case and the
engi ne. I f test vol tage i s hi gher than 0.3 vol ts,
check for corrosi on at generator mounti ng poi nts or
l oose generator mounti ng.
CURRENT OUTPUT TEST
The current output test wi l l determi ne i f the
chargi ng system can del i ver i ts mi ni mum test cur-
rent (amperage) output. Refer to the Speci fi cati ons
secti on at the end of thi s group for mi ni mum test
current (amperage) requi rements.
The fi rst part of thi s test (Test 1) wi l l determi ne
the combi ned amperage output of both the generator
Fig. 1 Generator Terminals (Typical Wiring Harness
Shown)
GROUND TERMINAL B+ (OUTPUT TERMINAL) FIELD TERMI- NALS
and the El ectroni c Vol tage Regul ator (EVR) ci rcui try.
The second part of thi s test (Test 2) wi l l determi ne
onl y generator amperage and will not i ncl ude anal -
ysi s of EVR ci rcui try. EVR ci rcui try i s l ocated wi thi n
the Powertrai n Control Modul e (PCM). To test vol t-
age regul ator ci rcui try, refer to the appropri ate Pow-
ertrai n Di agnosti c Procedures servi ce manual .
PREPARATION
(1) Determi ne i f any Di agnosti c Troubl e Codes
(DTCs) exi st. To determi ne a DTC, refer to On-Board
Di agnosti cs i n thi s group. For repai r, refer to the
appropri ate Powertrai n Di agnosti c Procedures man-
ual .
(2) Before starti ng test, make sure battery i s i n
good condi ti on and i s ful l y-charged. See Group 8A,
(3) Check condi ti on of battery cabl es at battery.
Cl ean i f necessary.
(4) Perform the previ ous Chargi ng System Resi s-
tance Tests (vol tage drop tests). Thi s wi l l ensure
cl ean and ti ght generator/battery el ectri cal connec-
ti ons.
(5) Be sure the generator dri ve bel t i s properl y
tensi oned. Refer to Group 7, Cool i ng System for
i nformati on.
(6) A vol t/amp tester equi pped wi th both a battery
l oad control (carbon pi l e rheostat) and an i nducti ve-
type pi ckup cl amp (ammeter probe) wi l l be used for
thi s test. Refer to operati ng i nstructi ons suppl i ed
wi th tester. When usi ng a tester equi pped wi th an
i nducti ve-type cl amp, removal of wi ri ng at the gener-
ator wi l l not be necessary.
(7) Start the engi ne and al l ow i t to reach operati ng
temperature.
(9) Turn off al l el ectri cal accessori es and al l vehi cl e
l i ghti ng.
(10) Connect the vol t/amp tester l eads to the bat-
tery. Be sure the carbon pi l e rheostat control i s i n the
OPEN or OFF posi ti on before connecti ng l eads. See
Load Test i n Group 8A, Battery for more i nformati on.
Al so refer to the operati ng i nstructi ons suppl i ed wi th
test equi pment.
(11) Connect the i nducti ve cl amp (ammeter probe).
Refer to the operati ng i nstructi ons suppl i ed wi th test
equi pment.
(12) I f vol t/amp tester i s not equi pped wi th an
engi ne tachometer, connect a separate tachometer to
the engi ne.
TEST 1
(1) Perform the previ ous test Preparati on.
(3) Start engi ne.
(4) Bri ng engi ne speed to 2500 rpm.
(5) Wi th engi ne speed hel d at 2500 rpm, sl owl y
adjust the rheostat control (l oad) on the tester to
obtai n the hi ghest amperage readi ng. Do not al l ow
vol tage to drop bel ow 12 vol ts. Record the readi ng.
This load test must be performed within 15 sec-
onds to prevent damage to test equipment. On
certai n brands of test equi pment, thi s l oad wi l l be
appl i ed automati cal l y. Refer to the operati ng manual
suppl i ed wi th test equi pment.
(6) The ammeter readi ng must meet the Mi ni mum
Test Amps speci fi cati ons as di spl ayed i n the Genera-
tor Rati ngs chart. Thi s can be found i n the Speci fi ca-
ti ons secti on at the end of thi s group. A l abel stati ng
a part reference number i s attached to the generator
case. On some engi nes thi s l abel may be l ocated on
the bottom of the case. Compare thi s reference num-
ber to the Generator Rati ngs chart.
(7) Rotate the l oad control to the OFF posi ti on.
(8) Conti nue hol di ng engi ne speed at 2500. I f EVR
ci rcui try i s OK, amperage shoul d drop bel ow 1520
amps. Wi th al l el ectri cal accessori es and vehi cl e
l i ghti ng off, thi s coul d take several mi nutes of engi ne
operati on. I f amperage di d not drop, refer to the
ual for testi ng.
(9) Remove vol t/amp tester.
I f mi ni mum amperage coul d not be met, proceed to
Test 2. Thi s test wi l l determi ne i f the generator i s
faul ty, or i f EVR ci rcui try i s defecti ve.
TEST 2
(1) Perform the previ ous test preparati on.
(3) Connect one end of a jumper wi re to a good
ground. Connect the other end of jumper wi re to the
generator fi el d dri ver (-) termi nal . The 2 fi el d termi -
nal s (+ and -) are l ocated on the back of the genera-
tor (Fi g. 1). To l ocate and i denti fy the (-) termi nal
and ci rcui t, refer to Group 8W, Wi ri ng Di agrams.
Another way to i denti fy the (-) termi nal i s to start
the engi ne and measure vol tage at both fi el d termi -
nal s. The (+) termi nal wi l l show battery vol tage
(12.514.5 vol ts). The (-) termi nal wi l l show 35 vol ts
l ess than battery vol tage.
CAUTION: Do not connect the jumper ground wire
to the generator field source (+) field terminal. Dam-
age to electrical system components may result.
Connecti ng the jumper wi re wi l l remove the vol t-
age regul ator ci rcui try from the test. I t wi l l al so gen-
erate a Di agnosti c Troubl e Code (DTC).
(4) Start engi ne. Immediately after starti ng,
reduce engi ne speed to i dl e. Thi s wi l l prevent any
el ectri cal accessory damage from hi gh vol tage.
(5) Adjust carbon pi l e rheostat (l oad) and engi ne
speed i n sl ow i ncrements unti l a speed of 1250 rpm,
and a vol tmeter readi ng of 15 vol ts i s obtai ned.
I mmedi atel y record ammeter readi ng. Do not appl y
l oad to system l onger than 15 seconds as damage to
test equi pment may resul t.
CAUTION: When adjusting rheostat load, do not
allow voltage to rise above 16 volts. Damage to the
battery and electrical system components may
result.
(6) The ammeter readi ng must meet the Mi ni mum
Test Amps speci fi cati ons as di spl ayed i n the Genera-
tor Rati ngs chart. Thi s can be found i n the Speci fi ca-
ti ons secti on at the end of thi s group. A l abel stati ng
a part reference number i s attached to the generator
case. On some engi nes thi s l abel may be l ocated on
the bottom of the case. Compare thi s reference num-
ber to the Generator Rati ng chart.
(7) Remove vol t/amp tester.
(8) Remove jumper wi re.
(9) Use the DRB scan tool to erase the DTC. Refer
to the DRB screen for procedures.
RESULTS
I f amp readi ng meets speci fi cati ons i n Test 2,
generator i s OK.
I f amp readi ng i s l ess than speci fi ed i n Test 2,
and wi re resi stance (vol tage drop) tests were OK, the
generator shoul d be repl aced. Refer to Removal and
I nstal l ati on i n thi s group for procedures.
I f Test 2 resul ts were OK, but Test 1 resul ts
were not, the probl em i s i n EVR ci rcui try. Refer to
ual for di agnosi s.
To perform a compl ete test of thi s sensor and i ts
ci rcui try, refer to the appropri ate Powertrai n Di ag-
nosti c Procedures manual . To test the sensor onl y,
refer to the fol l owi ng:
(1) The sensor i s l ocated under the battery and i s
attached to the battery tray (Fi g. 2). A two-wi re pi g-
tai l harness i s attached di rectl y to the sensor. The
opposi te end of thi s harness connects the sensor to
the engi ne wi ri ng harness.
(2) Di sconnect the two-wi re pi gtai l harness from
the engi ne harness.
(3) Attach ohmmeter l eads to the wi re termi nal s of
the pi gtai l harness.
(4) At room temperature of 25 C (7580 F), an
ohmmeter readi ng of 9,000 (9K) to 11,000 (11K) ohms
shoul d be observed.
(5) I f readi ng i s above or bel ow the speci fi cati on,
repl ace the sensor.
(6) Refer to the Removal and I nstal l ati on secti on
for procedures.
ON-BOARD DIAGNOSTIC TEST FOR CHARGING
SYSTEM
cri ti cal i nput and output ci rcui ts of the chargi ng sys-
tem, maki ng sure they are operati onal . A Di agnosti c
Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some ci rcui ts are checked conti nu-
ousl y and some are checked onl y under certai n con-
di ti ons.
For DTC i nformati on, refer to Di agnosti c Troubl e
Codes i n Group 25, Emi ssi on Control System. Thi s
wi l l i ncl ude a compl ete l i st of DTCs i ncl udi ng DTCs
for the chargi ng system.
GENERATOR
REMOVAL
WARNING: DISCONNECT NEGATIVE CABLE FROM
BATTERY BEFORE REMOVING BATTERY OUTPUT
WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO
DO SO CAN RESULT IN INJURY OR DAMAGE TO
ELECTRICAL SYSTEM.
(2) Remove generator dri ve bel t. Refer to Group 7,
Cool i ng System for procedures.
(3) Left Hand Dri ve (LHD) Vehi cl es Onl y: Remove
generator pi vot and mounti ng bol ts/nut (Fi g. 3) or
Fig. 2 Battery Temperature Sensor
BATTERY TEMPERATURE SENSOR BATTERY TRAY
(Fi g. 4). Posi ti on generator for access to wi re connec-
tors.
(4) Ri ght Hand Dri ve (RHD) Vehi cl es Onl y:
Remove upper nut (generator adjustment nut) and
both bel t adjustment bol ts (Fi g. 5). Remove generator
l ower nut/bol t. Posi ti on generator for access to wi re
connectors.
(5) Remove nuts from harness hol d-down, battery
termi nal , ground termi nal and 2 fi el d termi nal s.
Remove wi re connectors. A typi cal generator wi ri ng
harness i s shown i n (Fi g. 6). Wi ri ng harness routi ng
as shown may be sl i ghtl y di fferent dependi ng on
vehi cl e model and/or engi ne. Refer to Group 8W, Wi r-
i ng Di agrams for addi ti onal i nformati on.
(6) Remove generator from vehi cl e.
INSTALLATION
(1) Posi ti on generator to engi ne and i nstal l wi ri ng
to rear of generator. Ti ghten al l wi ri ng fasteners as
fol l ows:
Battery termi nal nut-8.5 Nm (75 i n. l bs.)
Ground termi nal nut-8.5 Nm (75 i n. l bs.)
Harness hol d-down nut-8.5 Nm (75 i n. l bs.)
Fi el d termi nal nuts-2.8 Nm (25 i n. l bs.)
Fig. 3 Remove/Install Generator2.5L Engine
UPPER MOUNTING BRACKET GENERATOR UPPER BOLT LOWER BOLT SPACER
Fig. 4 Remove/Install Generator4.0L EngineLHD
UPPER MOUNTING BRACKET GENERATOR UPPER BOLT LOWER BOLT SPACER
Fig. 5 Remove/Install Generator4.0L EngineRHD
UPPER NUT LOWER BOLT GENERATOR BELT ADJUSTMENT BOLTS
Fig. 6 Remove/Install Generator Connectors
Typical
B+ TERMINAL FWD FIELD TERMI- NALS GROUND (-) TERMINAL WIRE HARNESS HOLDOWN NUT
(2) LHD Vehi cl es: I nstal l generator fasteners and
ti ghten as fol l ows:
Generator upper mounti ng bol t-55 Nm (41 ft.
l bs.)
Generator l ower pi vot bol t/nut-55 Nm (41 ft.
l bs.)
CAUTION: Never force a belt over a pulley rim
using a screwdriver. The synthetic fiber of the belt
can be damaged.
drive belt, the belt MUST be routed correctly. The
water pump will be rotating in the wrong direction if
the belt is installed incorrectly, causing the engine
to overheat. Refer to belt routing label in engine
compartment, or refer to Belt Schematics in Group
7, Cooling System.
(3) LHD Vehi cl es: I nstal l generator dri ve bel t.
Refer to Group 7, Cool i ng System for procedures.
(4) RHD Vehi cl es: I nstal l upper nut (generator
adjustment nut) and both bel t adjustment bol ts.
I nstal l generator l ower nut/bol t.
(5) RHD Vehi cl es: On vehi cl es equi pped wi th RHD,
the generator i s used to adjust the serpenti ne bel t.
Refer to Group 7, Cool i ng System for bel t routi ng,
bel t adjustment and bol t ti ghteni ng procedures.
(6) I nstal l negati ve battery cabl e to battery.
The battery temperature sensor i s l ocated under
vehi cl e battery and i s attached to a mounti ng hol e on
battery tray.
REMOVAL
(1) Remove battery. Refer to Group 8A, Battery for
procedures.
(2) Di sconnect sensor pi gtai l harness from engi ne
wi re harness.
(3) Pry sensor strai ght up from battery tray
mounti ng hol e.
INSTALLATION
(1) Feed pi gtai l harness through hol e i n top of bat-
tery tray and press sensor i nto top of battery tray.
(2) Connect pi gtai l harness.
(3) I nstal l battery. Refer to Group 8A, Battery for
procedures.
SPECIFICATIONS
GENERATOR RATINGS
TORQUE CHART
Ri ght Hand Dri ve= RHD, Left Hand Dri ve= LHD.
Description Torque
Generator Mounti ng
Bol tLHD2.5L/4.0L
Engi ne . . . . . . . . . . . . . . . . . . 55 Nm (41 ft. l bs.)
Generator Pi vot Bol t/
NutLHD2.5L/4.0L Engi ne . 55 Nm (41 ft. l bs.)
Description Torque
Battery Termi nal NutLHD or
RHD . . . . . . . . . . . . . . . . . . . 8.5 Nm (75 i n. l bs.)
Ground Termi nal NutLHD or
RHD . . . . . . . . . . . . . . . . . . . 8.5 Nm (75 i n. l bs.)
Harness Hol d-down NutLHD or
RHD . . . . . . . . . . . . . . . . . . . 8.5 Nm (75 i n. l bs.)
Fi el d Termi nal NutsLHD or
RHD . . . . . . . . . . . . . . . . . . . 2.8 Nm (25 i n. l bs.)
Fig. 7 Battery Temperature Sensor
BATTERY TEMPERATURE SENSOR BATTERY TRAY
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56005685AB 119 2.5L/4.0L 90
IGNITION SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 3
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 3
CRANKSHAFT POSITION SENSOR . . . . . . . . . . 3
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 3
IGNITION SWITCH AND KEY LOCK
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
POWERTRAIN CONTROL MODULE . . . . . . . . . . 2
SPARK PLUG CABLES . . . . . . . . . . . . . . . . . . . 2
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 2
THROTTLE POSITION SENSOR . . . . . . . . . . . . 4
AUTOMATIC SHUTDOWN
(ASD) RELAY TEST . . . . . . . . . . . . . . . . . . . . 4
DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . . . 7
DISTRIBUTOR ROTOR . . . . . . . . . . . . . . . . . . . 7
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FAILURE TO START TEST . . . . . . . . . . . . . . . . . 6
IGNITION COIL TEST . . . . . . . . . . . . . . . . . . . . . 5
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . 7
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPARK PLUG CONDITIONS . . . . . . . . . . . . . . . 9
TESTING FOR SPARK AT COIL . . . . . . . . . . . . . 4
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . 13
CAMSHAFT POSITION SENSOR . . . . . . . . . . . 14
CRANKSHAFT POSITION SENSOR . . . . . . . . . 13
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . 15
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . 12
IGNITION SWITCH AND KEY CYLINDER . . . . . 18
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
POWERTRAIN CONTROL MODULE (PCM) . . . 18
SHIFTER/IGNITION INTERLOCK . . . . . . . . . . . 20
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 12
THROTTLE POSITION SENSOR . . . . . . . . . . . 15
SPECIFICATIONS
ENGINE FIRING ORDER2.5L 4-CYLINDER
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ENGINE FIRING ORDER4.0L 6-CYLINDER
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
IGNITION COIL RESISTANCE . . . . . . . . . . . . . 21
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . 20
SPARK PLUG CABLE RESISTANCE . . . . . . . . 21
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 21
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 21
VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
GENERAL INFORMATION
INTRODUCTION
Thi s group descri bes the i gni ti on systems for both
the 2.5L 4cyl i nder and the 4.0L 6cyl i nder engi nes.
On Board Di agnosti cs i s descri bed i n Group 25,
Emi ssi on Control Systems.
Group 0, Lubri cati on and Mai ntenance, contai ns
general mai ntenance i nformati on (i n ti me or mi l eage
i nterval s) for i gni ti on rel ated i tems. The Owners
Manual al so contai ns mai ntenance i nformati on.
IGNITION SYSTEM
The i gni ti on systems used on the 2.5L 4cyl i nder
and the 4.0L 6cyl i nder engi ne are basi cal l y i denti -
cal . Si mi l ari ti es and di fferences between the systems
wi l l be di scussed.
The i gni ti on system i s control l ed by the powertrai n
control modul e (PCM) on al l engi nes.
The i gni ti on system consi sts of:
Spark Pl ugs
I gni ti on Coi l
XJ IGNITION SYSTEM 8D - 1
Secondary I gni ti on Cabl es
Di stri butor (contai ns rotor and camshaft posi ti on
sensor)
Powertrai n Control Modul e (PCM)
Crankshaft Posi ti on, Camshaft Posi ti on, Throt-
tl e Posi ti on and MAP Sensors
POWERTRAIN CONTROL MODULE
The Powertrai n Control Modul e (PCM) i s l ocated
i n the engi ne compartment (Fi g. 1).
The i gni ti on system i s control l ed by the PCM.
NOTE: Base ignition timing by rotation of distribu-
tor is not adjustable.
The PCM opens and cl oses the i gni ti on coi l ground
ci rcui t to operate the i gni ti on coi l . Thi s i s done to
adjust i gni ti on ti mi ng, both i ni ti al (base) and
advance, and for changi ng engi ne operati ng condi -
ti ons.
The amount of el ectroni c spark advance provi ded
by the PCM i s determi ned by fi ve i nput factors:
engi ne cool ant temperature, engi ne rpm, i ntake man-
i fol d temperature, mani fol d absol ute pressure and
throttl e posi ti on.
DISTRIBUTOR
Al l engi nes are equi pped wi th a camshaft dri ven
mechani cal di stri butor contai ni ng a shaft dri ven di s-
tri butor rotor. Al l di stri butors are equi pped wi th an
i nternal camshaft posi ti on (fuel sync) sensor (Fi g. 2).
Thi s sensor provi des fuel i njecti on synchroni zati on
and cyl i nder i denti fi cati on.
The di stri butors on both the 2.5L 4-cyl i nder and
the 4.0L-6 cyl i nder engi nes do not have bui l t i n cen-
tri fugal or vacuum assi sted advance. Base i gni ti on
ti mi ng and al l ti mi ng advance i s control l ed by the
powertrai n control modul e (PCM). Because i gni ti on
ti mi ng i s control l ed by the PCM, base ignition tim-
ing is not adjustable on any of these engines.
The di stri butor i s l ocked i n pl ace by a fork wi th a
sl ot l ocated on the di stri butor housi ng base. The di s-
tri butor hol ddown cl amp bol t passes through thi s sl ot
when i nstal l ed. Because the di stri butor posi ti on i s
l ocked when i nstal l ed, i ts rotati onal posi ti on can not
be changed. Do not attempt to modify the dis-
tributor housing to get distributor rotation.
Distributor position will have no effect on igni-
tion timing. The position of the distributor will
determine fuel synchronization only.
Al l di stri butors contai n an i nternal oi l seal that
prevents oi l from enteri ng the di stri butor housi ng.
The seal i s not servi ceabl e.
SPARK PLUGS
Al l engi nes use resi stor type spark pl ugs. Remove
the spark pl ugs and exami ne them for burned el ec-
trodes and foul ed, cracked or broken porcel ai n i nsu-
l ators. Keep pl ugs arranged i n the order i n whi ch
they were removed from the engi ne. A si ngl e pl ug
di spl ayi ng an abnormal condi ti on i ndi cates that a
probl em exi sts i n the correspondi ng cyl i nder. Repl ace
spark pl ugs at the i nterval s recommended i n Group
O, Lubri cati on and Mai ntenance
Spark pl ugs that have l ow mi l age may be cl eaned
and reused i f not otherwi se defecti ve, carbon or oi l
foul ed. Refer to the Spark Pl ug Condi ti on secti on of
thi s group.
SPARK PLUG CABLES
Spark pl ug cabl es are someti mes referred to as sec-
ondary i gni ti on wi res. These cabl es transfer el ectri cal
current from the i gni ti on coi l (s) and/or di stri butor, to
i ndi vi dual spark pl ugs at each cyl i nder. The resi sti ve
spark pl ug cabl es are of nonmetal l i c constructi on.
Fig. 1 Powertrain Control Module (PCM) Location
(3) 32-WAY CONNEC- TORS PCM
Fig. 2 Distributor and Camshaft Position Sensor-
Typical
SYNC SIGNAL GENERATOR CAMSHAFT POSITION SEN- SOR PULSE RING DISTRIBUTOR ASSEMBLY
8D - 2 IGNITION SYSTEM XJ
The cabl es provi de suppressi on of radi o frequency
emi ssi ons from the i gni ti on system.
IGNITION COIL
Battery vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal from the ASD rel ay.
The Powertrai n Control Modul e (PCM) opens and
cl oses the i gni ti on coi l ground ci rcui t for i gni ti on coi l
operati on.
Base ignition timing is not adjustable on any
engine. By control l i ng the coi l ground ci rcui t, the
PCM i s abl e to set the base ti mi ng and adjust the
i gni ti on ti mi ng advance. Thi s i s done to meet chang-
i ng engi ne operati ng condi ti ons.
The i gni ti on coi l i s not oi l fi l l ed. The wi ndi ngs are
embedded i n an epoxy compound. Thi s provi des heat
and vi brati on resi stance that al l ows the i gni ti on coi l
to be mounted on the engi ne.
As one of i ts functi ons, the ASD rel ay wi l l suppl y
battery vol tage to the i gni ti on coi l . The ground ci r-
cui t for the ASD rel ay i s control l ed by the Powertrai n
Control Modul e (PCM). The PCM regul ates ASD
rel ay operati on by swi tchi ng the ground ci rcui t
on-and-off.
CRANKSHAFT POSITION SENSOR
The crankshaft posi ti on sensor i s mounted to the
transmi ssi on bel l housi ng at the l eft/rear si de of
Engi ne speed and crankshaft posi ti on are provi ded
through the crankshaft posi ti on sensor. The sensor
generates pul ses that are the i nput sent to the pow-
ertrai n control modul e (PCM). The PCM i nterprets
the sensor i nput to determi ne the crankshaft posi -
ti on. The PCM then uses thi s posi ti on, al ong wi th
other i nputs, to determi ne i njector sequence and i gni -
ti on ti mi ng.
The sensor i s a hal l effect devi ce combi ned wi th an
i nternal magnet. I t i s al so sensi ti ve to steel wi thi n a
certai n di stance from i t.
SENSOR OPERATION
The fl ywheel /dri ve pl ate has groups of four notches
at i ts outer edge. On 4.0L 6-cyl i nder engi nes there
are three sets of notches (Fi g. 5). On 2.5L 4-cyl i nder
engi nes there are two sets of notches (Fi g. 4).
The notches cause a pul se to be generated when
they pass under the sensor. The pul ses are the i nput
to the PCM. For each engi ne revol uti on there are two
groups of four pul ses generated on 2.5L 4-cyl i nder
engi nes. There are 3 groups of four pul ses generated
on 4.0L 6-cyl i nder engi nes.
The trai l i ng edge of the fourth notch, whi ch causes
the pul se, i s four degrees before top dead center
(TDC) of the correspondi ng pi ston.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
CAMSHAFT POSITION SENSOR
The camshaft posi ti on sensor i s l ocated i n the di s-
tri butor on al l engi nes.
The sensor contai ns a hal l effect devi ce cal l ed a
sync si gnal generator to generate a fuel sync si gnal .
Thi s sync si gnal generator detects a rotati ng pul se
ri ng (shutter) on the di stri butor shaft. The pul se ri ng
Fig. 3 Crankshaft Position SensorTypical
ELECTRICAL CONNECTOR CLAMP NUT TRANSMISSION BELL- HOUSING MOUNTING BOLTS (2) CRANKSHAFT POSITION SEN- SOR RUBBER GROMMET PIGTAIL HAR- NESS
Fig. 4 Sensor Operation2.5L 4-Cyl. Engine
CRANKSHAFT POSI- TION SENSOR NOTCHES FLYWHEEL
rotates 180 degrees through the sync si gnal genera-
tor. I ts si gnal i s used i n conjuncti on wi th the crank-
shaft posi ti on sensor to di fferenti ate between fuel
i njecti on and spark events. I t i s al so used to synchro-
ni ze the fuel i njectors wi th thei r respecti ve cyl i nders.
When the l eadi ng edge of the pul se ri ng (shutter)
enters the sync si gnal generator, the fol l owi ng occurs:
The i nterrupti on of magneti c fi el d causes the vol tage
to swi tch hi gh resul ti ng i n a sync si gnal of approxi -
matel y 5 vol ts.
When the trai l i ng edge of the pul se ri ng (shutter)
l eaves the sync si gnal generator, the fol l owi ng occurs:
The change of the magneti c fi el d causes the sync si g-
nal vol tage to swi tch l ow to 0 vol ts.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
For an operati onal descri pti on, di agnosi s and
removal /i nstal l ati on procedures, refer to Group 14,
Fuel System.
Fuel System.
THROTTLE POSITION SENSOR
Fuel System.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
Fuel System.
IGNITION SWITCH AND KEY LOCK CYLINDER
The i gni ti on swi tch i s l ocated on the steeri ng col -
umn. The Key-I n-Swi tch i s l ocated i n the i gni ti on
swi tch modul e. For el ectri cal di agnosi s of the Key-I n-
Swi tch, refer to Group 8U, Chi me/Buzzer Warni ng
Systems. For removal /i nstal l ati on of ei ther the key
l ock cyl i nder or i gni ti on swi tch, refer to I gni ti on
Swi tch and Key Cyl i nder Removal /I nstal l ati on i n thi s
group.
On vehi cl es equi pped wi th an automati c transmi s-
si on, a cabl e connects an i nterl ock devi ce wi thi n the
steeri ng col umn assembl y to the transmi ssi on fl oor
shi ft l ever. Thi s i nterl ock devi ce i s used to l ock the
transmi ssi on shi fter i n the PARK posi ti on when the
key i s i n the LOCKED or ACCESSORY posi ti on. The
i nterl ock devi ce i s not servi ceabl e. I f repai r i s neces-
sary, the steeri ng col umn assembl y must be repl aced.
Refer to Group 19, Steeri ng for procedures. The
shi fter i nterl ock cabl e can be adjusted or repl aced.
Refer to Group 21, Transmi ssi ons for procedures.
AUTOMATIC SHUTDOWN (ASD) RELAY TEST
To perform a compl ete test of thi s rel ay and i ts ci r-
cui try, refer to the DRB scan tool . Al so refer to the
ual . To test the rel ay onl y, refer to Rel aysOpera-
ti on/Testi ng i n the Group 14, Fuel Systems secti on.
TESTING FOR SPARK AT COIL
CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 6). Grasp the boot (not the cable) and
pull it off with a steady, even force.
(1) Di sconnect the i gni ti on coi l secondary cabl e
from center tower of the di stri butor cap. Hol d the
cabl e termi nal approxi matel y 12 mm (1/2 i n.) from a
good engi ne ground (Fi g. 7).
WARNING: BE VERY CAREFUL WHEN THE
ENGINE IS CRANKING. DO NOT PUT YOUR HANDS
NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT
WEAR LOOSE FITTING CLOTHING.
Fig. 5 Sensor Operation4.0L 6-Cyl. Engine
CRANKSHAFT POSITION SENSOR NOTCHES FLYWHEEL
(2) Rotate (crank) the engi ne wi th the starter
motor and observe the cabl e termi nal for a steady
arc. I f steady arci ng does not occur, i nspect the sec-
ondary coi l cabl e. Refer to Spark Pl ug Cabl es i n thi s
group. Al so i nspect the di stri butor cap and rotor for
cracks or burn marks. Repai r as necessary. I f steady
arci ng occurs, connect i gni ti on coi l cabl e to the di s-
tri butor cap.
(3) Remove a cabl e from one spark pl ug.
(4) Usi ng i nsul ated pl i ers, hol d the cabl e termi nal
approxi matel y 12 mm (1/2 i n.) from the engi ne cyl i n-
der head or bl ock whi l e rotati ng the engi ne wi th the
starter motor. Observe the spark pl ug cabl e termi nal
for an arc. I f steady arci ng occurs, i t can be expected
that the i gni ti on secondary system i s operati ng cor-
rectl y. (If the ignition coil cable is removed for
this test, instead of a spark plug cable, the
spark intensity will be much higher). I f steady
arci ng occurs at the spark pl ug cabl es, but the engi ne
wi l l not start, connect the DRB scan tool . Refer to
the appropri ate Powertrai n Di agnosti c Procedures
servi ce manual .
IGNITION COIL TEST
To perform a compl ete test of the i gni ti on coi l and
i ts ci rcui try, refer to the DRB scan tool . Al so refer to
the appropri ate Powertrai n Di agnosti cs Procedures
manual . To test the coi l onl y, refer to the fol l owi ng:
The i gni ti on coi l (Fi g. 8) or (Fi g. 9) i s desi gned to
operate wi thout an external bal l ast resi stor.
I nspect the i gni ti on coi l for arci ng. Test the coi l
accordi ng to coi l tester manufacturers i nstructi ons.
Test the coi l pri mary and secondary resi stance.
Repl ace any coi l that does not meet speci fi cati ons.
Refer to the I gni ti on Coi l Resi stance chart.
I f the i gni ti on coi l i s bei ng repl aced, the secondary
spark pl ug cabl e must al so be checked. Repl ace cabl e
i f i t has been burned or damaged.
Arci ng at the tower wi l l carboni ze the cabl e boot,
whi ch i f i t i s connected to a new i gni ti on coi l , wi l l
cause the coi l to fai l .
I f the secondary coi l cabl e shows any si gns of dam-
age, i t shoul d be repl aced wi th a new cabl e and new
Fig. 6 Cable Removal
SPARK PLUG CABLE AND BOOT SPARK PLUG BOOT PULLER TWIST AND PULL SPARK PLUG
Fig. 7 Checking for SparkTypical
A GOOD ENGINE GROUND CHECK HERE FOR SPARK IGNITION COIL
IGNITION COIL ELECTRICAL CON- NECTOR MOUNTING BOLTS SECONDARY CABLE
ELECTRICAL CON- NECTOR IGNITION COIL MOUNTING BOLTS (2) SECONDARY CABLE
termi nal . Carbon tracki ng on the ol d cabl e can cause
arci ng and the fai l ure of a new i gni ti on coi l .
FAILURE TO START TEST
To prevent unnecessary di agnosti c ti me and wrong
test resul ts, the Testi ng For Spark At Coi l test
shoul d be performed pri or to thi s test.
WARNING: SET PARKING BRAKE OR BLOCK THE
DRIVE WHEELS BEFORE PROCEEDING WITH THIS
TEST.
(1) Unpl ug the i gni ti on coi l harness connector at
the coi l (Fi g. 9).
(2) Connect a set of smal l jumper wi res (18 gauge
or smal l er) between the di sconnected harness termi -
nal s and the i gni ti on coi l termi nal s. To determi ne
pol ari ty at connector and coi l , refer to the Wi ri ng
Di agrams secti on.
(3) Attach one l ead of a vol tmeter to the posi ti ve
(12 vol t) jumper wi re. Attach the negati ve si de of
vol tmeter to a good ground.
(4) Determi ne that suffi ci ent battery vol tage (12.4
vol ts) i s present for the starti ng and i gni ti on sys-
tems.
(5) Crank the engi ne for 5 seconds whi l e moni tor-
i ng the vol tage at the coi l posi ti ve termi nal :
I f the vol tage remai ns near zero duri ng the
enti re peri od of cranki ng, refer to On-Board Di agnos-
ti cs i n Group 14, Fuel Systems. Check the Power-
trai n Control Modul e (PCM) and auto shutdown
rel ay.
I f vol tage i s at or near battery vol tage and drops
to zero after 1-2 seconds of cranki ng, check the pow-
ertrai n control modul e ci rcui t. Refer to On-Board
Di agnosti cs i n Group 14, Fuel Systems.
I f vol tage remai ns at or near battery vol tage
duri ng the enti re 5 seconds, turn the key off. Remove
the three 32-way connectors (Fi g. 10) from the PCM.
Check 32-way connectors for any spread termi nal s or
corrosi on.
(6) Remove test l ead from the coi l posi ti ve termi -
nal . Connect an 18 gauge jumper wi re between the
battery posi ti ve termi nal and the coi l posi ti ve termi -
nal .
(7) Make the speci al jumper shown i n (Fi g. 11).
Usi ng the jumper, momentarily ground the i gni ti on
coi l dri ver ci rcui t at the PCM connector (cavi ty A-7).
For cavi ty/termi nal l ocati on of thi s ci rcui t, refer to
Group 8W, Wi ri ng. A spark shoul d be generated at
the coi l cabl e when the ground i s removed.
(8) I f spark i s generated, repl ace the PCM.
(9) I f spark i s not seen, use the speci al jumper to
ground the coi l negati ve termi nal di rectl y.
(10) I f spark i s produced, repai r wi ri ng harness for
an open condi ti on.
IGNITION COIL RESISTANCE
Fig. 10 PCM and Three 32Way Connectors
Fig. 11 Special Jumper Ground-to-Coil Negative
Terminal
(11) I f spark i s not produced, repl ace the i gni ti on
coi l .
DISTRIBUTOR CAP
Remove the di stri butor cap and wi pe i t cl ean wi th
a dry l i nt free cl oth. Vi sual l y i nspect the cap for
cracks, carbon paths, broken towers or damaged
rotor button (Fi g. 12) or (Fi g. 13). Al so check for
whi te deposi ts on the i nsi de (caused by condensati on
enteri ng the cap through cracks). Repl ace any cap
that di spl ays charred or eroded termi nal s. The
machi ned surface of a termi nal end (faces toward
rotor) wi l l i ndi cate some evi dence of erosi on from
normal operati on. Exami ne the termi nal ends for evi -
dence of mechani cal i nterference wi th the rotor ti p.
DISTRIBUTOR ROTOR
Vi sual l y i nspect the rotor (Fi g. 14) for cracks, evi -
dence of corrosi on or the effects of arci ng on the
metal ti p. Al so check for evi dence of mechani cal
i nterference wi th the cap. Some charri ng i s normal
on the end of the metal ti p. The si l i cone-di el ectri c-
varni sh-compound appl i ed to the rotor ti p for radi o
i nterference noi se suppressi on, wi l l appear charred.
Thi s i s normal . Do not remove the charred com-
pound. Test the spri ng for i nsuffi ci ent tensi on.
Repl ace a rotor that di spl ays any of these adverse
condi ti ons.
IGNITION TIMING
NOTE: Base (initial) ignition timing is NOT adjust-
able on any 2.5L 4-cylinder or 4.0L 6-cylinder
engine. Do not attempt to adjust ignition timing by
rotating the distributor.
NOTE: Do not attempt to modify the distributor
housing to get distributor rotation. Distributor posi-
tion will have no effect on ignition timing.
Al l i gni ti on ti mi ng functi ons are control l ed by the
powertrai n control modul e (PCM). For addi ti onal
i nformati on, refer to the appropri ate Powertrai n
Di agnosti cs Procedures servi ce manual for operati on
of the DRB Scan Tool .
MAP SENSOR
For an operati onal descri pti on, di agnosi s or remov-
al / i nstal l ati on procedures, refer to Group 14, Fuel
Systems.
ci rcui try, refer to the DRB scan tool . Al so refer to the
ual .
Fig. 12 Cap InspectionExternalTypical
Fig. 13 Cap InspectionInternalTypical
Fig. 14 Rotor InspectionTypical
tri butor (Fi g. 15) on al l engi nes.
ci rcui try, refer to the appropri ate Powertrai n Di ag-
nosti cs Procedures servi ce manual . To test the sensor
onl y, refer to the fol l owi ng:
For this test, an analog (non-digital) voltme-
ter is needed. Do not remove the di stri butor connec-
tor from the di stri butor. Usi ng smal l paper cl i ps,
i nsert them i nto the backsi de of the di stri butor wi re
harness connector to make contact wi th the termi -
nal s. Be sure that the connector i s not damaged
when i nserti ng the paper cl i ps. Attach vol tmeter
l eads to these paper cl i ps.
(1) Connect the posi ti ve (+) vol tmeter l ead i nto the
sensor output wi re. Thi s i s at done the di stri butor
wi re harness connector. For wi re i denti fi cati on, refer
to Group 8W, Wi ri ng Di agrams.
(2) Connect the negati ve (-) vol tmeter l ead i nto the
ground wi re. For wi re i denti fi cati on, refer to Group
8W, Wi ri ng Di agrams.
(3) Set the vol tmeter to the 15 Vol t DC scal e.
(4) Remove di stri butor cap from di stri butor (two
screws). Rotate (crank) the engi ne unti l the di stri bu-
tor rotor i s approxi matel y i n the 11 ocl ock posi ti on.
The movabl e pul se ri ng shoul d now be wi thi n the
sensor pi ckup.
(5) Turn i gni ti on key to ON posi ti on. Vol tmeter
shoul d read approxi matel y 5.0 vol ts.
(6) I f vol tage i s not present, check the vol tmeter
l eads for a good connecti on.
(7) I f vol tage i s sti l l not present, check for vol tage
at the suppl y wi re. For wi re i denti fi cati on, refer to
Group 8W, Wi ri ng Di agrams.
(8) I f 5 vol ts i s not present at suppl y wi re, check
for vol tage at PCM 32-way connector (cavi ty A-17).
Refer to Group 8W, Wi ri ng for l ocati on of connector/
termi nal . Leave the PCM connector connected for
thi s test.
(9) I f vol tage i s sti l l not present, perform vehi cl e
test usi ng the DRB scan tool .
(10) I f vol tage i s present at cavi ty A-17, but not at
the suppl y wi re:
(a) Check conti nui ty between the suppl y wi re.
Thi s i s checked between the di stri butor connector
and cavi ty A-17 at the PCM. I f conti nui ty i s not
present, repai r the harness as necessary.
(b) Check for conti nui ty between the camshaft
posi ti on sensor output wi re and cavi ty A-18 at the
PCM. I f conti nui ty i s not present, repai r the har-
ness as necessary.
(c) Check for conti nui ty between the ground ci r-
cui t wi re at the di stri butor connector and ground.
I f conti nui ty i s not present, repai r the harness as
necessary.
(11) Whi l e observi ng the vol tmeter, crank the
engi ne wi th i gni ti on swi tch. The vol tmeter needl e
shoul d fl uctuate between 0 and 5 vol ts whi l e the
engi ne i s cranki ng. Thi s veri fi es that the camshaft
posi ti on sensor i n the di stri butor i s operati ng prop-
erl y and a sync pul se si gnal i s bei ng generated.
I f sync pul se si gnal i s not present, repl acement of
the camshaft posi ti on sensor i s necessary
Fuel System.
Fuel System.
SPARK PLUG CABLES
Check the spark pl ug cabl e connecti ons for good
contact at the coi l (s), di stri butor cap towers, and
spark pl ugs. Termi nal s shoul d be ful l y seated. The
i nsul ators shoul d be i n good condi ti on and shoul d fi t
ti ghtl y on the coi l , di stri butor and spark pl ugs. Spark
pl ug cabl es wi th i nsul ators that are cracked or torn
must be repl aced.
Cl ean hi gh vol tage i gni ti on cabl es wi th a cl oth
moi stened wi th a non-fl ammabl e sol vent. Wi pe the
cabl es dry. Check for bri ttl e or cracked i nsul ati on.
TESTING
When testi ng secondary cabl es for damage wi th an
osci l l oscope, fol l ow the i nstructi ons of the equi pment
manufacturer.
I f an osci l l oscope i s not avai l abl e, spark pl ug cabl es
may be tested as fol l ows:
Fig. 15 Camshaft Position SensorTypical
CAUTION: Do not leave any one spark plug cable
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.
Wi th the engi ne runni ng, remove spark pl ug cabl e
from spark pl ug (one at a ti me) and hol d next to a
good engi ne ground. I f the cabl e and spark pl ug are
i n good condi ti on, the engi ne rpm shoul d drop and
the engi ne wi l l run poorl y. I f engi ne rpm does not
drop, the cabl e and/or spark pl ug may not be operat-
i ng properl y and shoul d be repl aced. Al so check
engi ne cyl i nder compressi on.
Wi th the engi ne not runni ng, connect one end of a
test probe to a good ground. Start the engi ne and run
the other end of the test probe al ong the enti re
l ength of al l spark pl ug cabl es. I f cabl es are cracked
or punctured, there wi l l be a noti ceabl e spark jump
from the damaged area to the test probe. The cabl e
runni ng from the i gni ti on coi l to the di stri butor cap
can be checked i n the same manner. Cracked, dam-
aged or faul ty cabl es shoul d be repl aced wi th resi s-
tance type cabl e. Thi s can be i denti fi ed by the words
ELECTRONI C SUPPRESSI ON pri nted on the cabl e
jacket.
Use an ohmmeter to test for open ci rcui ts, exces-
si ve resi stance or l oose termi nal s. Remove the di s-
tri butor cap from the di stri butor. Do not remove
cables from cap. Remove cabl e from spark pl ug.
Connect ohmmeter to spark pl ug termi nal end of
cabl e and to correspondi ng el ectrode i n di stri butor
cap. Resi stance shoul d be 250 to 1000 Ohms per i nch
of cabl e. I f not, remove cabl e from di stri butor cap
tower and connect ohmmeter to the termi nal ends of
cabl e. I f resi stance i s not wi thi n speci fi cati ons as
found i n the Spark Pl ug Cabl e Resi stance chart,
repl ace the cabl e. Test al l spark pl ug cabl es i n thi s
manner.
To test i gni ti on coi l -to-di stri butor cap cabl e, do not
remove the cabl e from the cap. Connect ohmmeter to
rotor button (center contact) of di stri butor cap and
termi nal at i gni ti on coi l end of cabl e. I f resi stance i s
not wi thi n speci fi cati ons as found i n the Spark Pl ug
Cabl e Resi stance chart, remove the cabl e from the
di stri butor cap. Connect the ohmmeter to the termi -
nal ends of the cabl e. I f resi stance i s not wi thi n spec-
i fi cati ons as found i n the Spark Pl ug Cabl e
Resi stance chart, repl ace the cabl e. I nspect the i gni -
ti on coi l tower for cracks, burns or corrosi on.
SPARK PLUG CONDITIONS
NORMAL OPERATING
The few deposi ts present on the spark pl ug wi l l
probabl y be l i ght tan or sl i ghtl y gray i n col or. Thi s i s
evi dent wi th most grades of commerci al gasol i ne
(Fi g. 16). There wi l l not be evi dence of el ectrode
burni ng. Gap growth wi l l not average more than
approxi matel y 0.025 mm (.001 i n) per 1600 km (1000
mi l es) of operati on. Spark pl ugs that have normal
wear can usual l y be cl eaned, have the el ectrodes
fi l ed, have the gap set and then be i nstal l ed.
Some fuel refi ners i n several areas of the Uni ted
States have i ntroduced a manganese addi ti ve (MMT)
for unl eaded fuel . Duri ng combusti on, fuel wi th MMT
causes the enti re ti p of the spark pl ug to be coated
wi th a rust col ored deposi t. Thi s rust col or can be
mi sdi agnosed as bei ng caused by cool ant i n the com-
busti on chamber. Spark pl ug performance i s not
affected by MMT deposi ts.
COLD FOULING/CARBON FOULING
Col d foul i ng i s someti mes referred to as carbon
foul i ng. The deposi ts that cause col d foul i ng are basi -
cal l y carbon (Fi g. 16). A dry, bl ack deposi t on one or
two pl ugs i n a set may be caused by sti cki ng val ves
or defecti ve spark pl ug cabl es. Col d (carbon) foul i ng
of the enti re set of spark pl ugs may be caused by a
cl ogged ai r cl eaner el ement or repeated short operat-
i ng ti mes (short tri ps).
WET FOULING OR GAS FOULING
A spark pl ug coated wi th excessi ve wet fuel or oi l
i s wet foul ed. I n ol der engi nes, worn pi ston ri ngs,
l eaki ng val ve gui de seal s or excessi ve cyl i nder wear
can cause wet foul i ng. I n new or recentl y overhaul ed
engi nes, wet foul i ng may occur before break-i n (nor-
mal oi l control ) i s achi eved. Thi s condi ti on can usu-
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
SPARK PLUG CABLE RESISTANCE
Fig. 16 Normal Operation and Cold (Carbon) Fouling
NORMAL DRY BLACK DEPOSITS COLD (CARBON) FOULING
al l y be resol ved by cl eani ng and rei nstal l i ng the
foul ed pl ugs.
OIL OR ASH ENCRUSTED
I f one or more spark pl ugs are oi l or oi l ash
encrusted (Fi g. 17), eval uate engi ne condi ti on for the
cause of oi l entry i nto that parti cul ar combusti on
chamber.
ELECTRODE GAP BRIDGING
El ectrode gap bri dgi ng may be traced to l oose
deposi ts i n the combusti on chamber. These deposi ts
accumul ate on the spark pl ugs duri ng conti nuous
stop-and-go dri vi ng. When the engi ne i s suddenl y
subjected to a hi gh torque l oad, deposi ts parti al l y l i q-
uefy and bri dge the gap between el ectrodes (Fi g. 18).
Thi s short ci rcui ts the el ectrodes. Spark pl ugs wi th
el ectrode gap bri dgi ng can be cl eaned usi ng standard
procedures.
SCAVENGER DEPOSITS
Fuel scavenger deposi ts may be ei ther whi te or yel -
l ow (Fi g. 19). They may appear to be harmful , but
thi s i s a normal condi ti on caused by chemi cal addi -
ti ves i n certai n fuel s. These addi ti ves are desi gned to
change the chemi cal nature of deposi ts and decrease
spark pl ug mi sfi re tendenci es. Noti ce that accumul a-
ti on on the ground el ectrode and shel l area may be
heavy, but the deposi ts are easi l y removed. Spark
pl ugs wi th scavenger deposi ts can be consi dered nor-
mal i n condi ti on and can be cl eaned usi ng standard
procedures.
CHIPPED ELECTRODE INSULATOR
A chi pped el ectrode i nsul ator usual l y resul ts from
bendi ng the center el ectrode whi l e adjusti ng the
spark pl ug el ectrode gap. Under certai n condi ti ons,
severe detonati on can al so separate the i nsul ator
from the center el ectrode (Fi g. 20). Spark pl ugs wi th
thi s condi ti on must be repl aced.
PREIGNITION DAMAGE
Prei gni ti on damage i s usual l y caused by excessi ve
combusti on chamber temperature. The center el ec-
trode di ssol ves fi rst and the ground el ectrode di s-
sol ves somewhat l atter (Fi g. 21). I nsul ators appear
rel ati vel y deposi t free. Determi ne i f the spark pl ug
has the correct heat range rati ng for the engi ne.
Determi ne i f i gni ti on ti mi ng i s over advanced or i f
other operati ng condi ti ons are causi ng engi ne over-
heati ng. (The heat range rati ng refers to the operat-
i ng temperature of a parti cul ar type spark pl ug.
Spark pl ugs are desi gned to operate wi thi n speci fi c
temperature ranges. Thi s depends upon the thi ck-
Fig. 17 Oil or Ash Encrusted
Fig. 18 Electrode Gap Bridging
GROUND ELECTRODE DEPOSITS CENTER ELECTRODE
Fig. 19 Scavenger Deposits
GROUND ELECTRODE COVERED WITH WHITE OR YELLOW DEPOSITS CENTER ELEC- TRODE
ness and l ength of the center el ectrodes porcel ai n
i nsul ator.)
SPARK PLUG OVERHEATING
Overheati ng i s i ndi cated by a whi te or gray center
el ectrode i nsul ator that al so appears bl i stered (Fi g.
22). The i ncrease i n el ectrode gap wi l l be consi der-
abl y i n excess of 0.001 i nch per 1000 mi l es of opera-
ti on. Thi s suggests that a pl ug wi th a cool er heat
range rati ng shoul d be used. Over advanced i gni ti on
ti mi ng, detonati on and cool i ng system mal functi ons
can al so cause spark pl ug overheati ng.
SPARK PLUG CABLES
CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
loose (Fig. 23). Grasp the boot (not the cable) and
pull it off with a steady, even force.
I nstal l cabl es i nto the proper engi ne cyl i nder fi ri ng
order (Fi g. 24) or (Fi g. 25).
Fig. 20 Chipped Electrode Insulator
GROUND ELECTRODE CENTER ELECTRODE CHIPPED INSULATOR
Fig. 21 Preignition Damage
GROUND ELECTRODE STARTING TO DISSOLVE CENTER ELECTRODE DISSOLVED
Fig. 22 Spark Plug Overheating
BLISTERED WHITE OR GRAY COLORED INSULATOR
Fig. 23 Cable Removal
SPARK PLUG CABLE AND BOOT SPARK PLUG BOOT PULLER TWIST AND PULL SPARK PLUG
Fig. 24 Engine Firing Order2.5L 4-Cylinder Engine
FIRING ORDER: 1 3 4 2 CLOCKWISE ROTA- TION FRONT
When repl aci ng the spark pl ug and coi l cabl es,
route the cabl es correctl y and secure i n the proper
retai ners. Fai l ure to route the cabl es properl y can
cause the radi o to reproduce i gni ti on noi se. I t coul d
al so cause cross i gni ti on of the pl ugs or short ci rcui t
the cabl es to ground.
When i nstal l i ng new cabl es, make sure a posi ti ve
connecti on i s made. A snap shoul d be fel t when a
good connecti on i s made between the pl ug cabl e and
the di stri butor cap tower.
SPARK PLUGS
PLUG REMOVAL
(1) Al ways remove spark pl ug or i gni ti on coi l
cabl es by graspi ng at the cabl e boot (Fi g. 23). Turn
the cabl e boot 1/2 turn and pul l strai ght back i n a
steady moti on. Never pul l di rectl y on the cabl e.
I nternal damage to cabl e wi l l resul t.
(2) Pri or to removi ng the spark pl ug, spray com-
pressed ai r around the spark pl ug hol e and the area
around the spark pl ug. Thi s wi l l hel p prevent forei gn
materi al from enteri ng the combusti on chamber.
(3) Remove the spark pl ug usi ng a qual i ty socket
wi th a rubber or foam i nsert.
(4) I nspect the spark pl ug condi ti on. Refer to
Spark Pl ugs i n the Di agnosti cs/Servi ce Procedures
secti on of thi s group.
PLUG CLEANING
The pl ugs may be cl eaned usi ng commerci al l y
avai l abl e spark pl ug cl eani ng equi pment. After cl ean-
i ng, fi l e the center el ectrode fl at wi th a smal l poi nt
fi l e or jewel ers fi l e before adjusti ng gap.
CAUTION: Never use a motorized wire wheel brush
to clean the spark plugs. Metallic deposits will
remain on the spark plug insulator and will cause
plug misfire.
PLUG GAP ADJ USTMENT
Check the spark pl ug gap wi th a gap gauge tool . I f
the gap i s not correct, adjust i t by bendi ng the
ground el ectrode (Fi g. 26). Never attempt to adjust
the gap by bending the center electrode.
SPARK PLUG GAP
2.5L 4-Cyl i nder Engi ne Spark Pl ug Gap: .89 mm
(.035 i n).
4.0L 6-Cyl i nder Engi ne Spark Pl ug Gap: .89 mm
(.035 i n).
PLUG INSTALLATION
Al ways ti ghten spark pl ugs to the speci fi ed torque.
Over ti ghteni ng can cause di storti on. Thi s may resul t
i n a change i n the spark pl ug gap, or a cracked por-
cel ai n i nsul ator.
When repl aci ng the spark pl ug and i gni ti on coi l
cabl es, route the cabl es correctl y and secure them i n
the appropri ate retai ners. Fai l ure to route the cabl es
properl y can cause the radi o to reproduce i gni ti on
noi se. I t coul d cause cross i gni ti on of the spark pl ugs,
or short ci rcui t the cabl es to ground.
(1) Start the spark pl ug i nto the cyl i nder head by
hand to avoi d cross threadi ng.
(2) Ti ghten the spark pl ugs to 35-41 Nm (26-30 ft.
l bs.) torque.
(3) I nstal l spark pl ug cabl es over spark pl ugs.
IGNITION COIL
The i gni ti on coi l i s an epoxy fi l l ed type. I f the coi l
i s repl aced, i t must be repl aced wi th the same type.
Fig. 25 Engine Firing Order4.0L 6-Cylinder Engine
Fig. 26 Setting Spark Plug GapTypical
REMOVAL
On the 2.5L 4-cyl i nder engi ne, the i gni ti on coi l i s
mounted to a bracket on si de of engi ne (to rear of
di stri butor) (Fi g. 27).
On the 4.0L 6-cyl i nder engi ne, the i gni ti on coi l i s
mounted to a bracket on si de of engi ne (to front of
di stri butor) (Fi g. 28).
(1) Di sconnect i gni ti on coi l secondary cabl e from
i gni ti on coi l .
(2) Di sconnect engi ne harness connector from i gni -
ti on coi l .
(3) Remove i gni ti on coi l mounti ng bol ts (nuts are
used on back si de of bracket on some coi l s).
(4) Remove coi l from vehi cl e.
INSTALLATION
(1) I nstal l i gni ti on coi l to bracket on cyl i nder bl ock
wi th mounti ng bol ts (and nuts i f equi pped). I f
equi pped wi th nuts and bol ts, ti ghten to 11 Nm (100
i n. l bs.) torque. I f equi pped wi th bol ts onl y, ti ghten to
(2) Connect engi ne harness connector to coi l .
(3) Connect i gni ti on coi l cabl e to i gni ti on coi l .
The ASD rel ay i s l ocated i n the power di stri buti on
center (PDC). The PDC i s l ocated i n engi ne compart-
ment (Fi g. 29). Refer to l abel on PDC cover for rel ay
l ocati on .
REMOVAL
(2) Remove rel ay by l i fti ng strai ght up.
INSTALLATION
(1) Check condi ti on of rel ay wi re termi nal s at PDC
for corrosi on or damage. Al so check hei ghts of rel ay
termi nal pi ns at PDC. Pi n hei ght shoul d be the same
for al l pi ns. Repai r as necessary before i nstal l i ng
rel ay.
(2) Push rel ay i nto connector.
(3) I nstal l rel ay cover.
The crankshaft posi ti on sensor i s mounted to the
transmi ssi on bel l housi ng at the l eft/rear si de of
engi ne bl ock (Fi g. 30) or (Fi g. 31).
On 2.5L 4-cyl i nder equi pped wi th a manual trans-
mi ssi on, the sensor i s attached wi th two bol ts. On
2.5L engi nes equi pped wi th an automati c transmi s-
si on, the sensor i s attached wi th two nuts. Al l 4.0L
6-cyl i nder engi nes have the sensor attached wi th two
bol ts.
IGNITION COIL ELECTRICAL CON- NECTOR MOUNTING BOLTS SECONDARY CABLE
ELECTRICAL CON- NECTOR IGNITION COIL MOUNTING BOLTS (2) SECONDARY CABLE
Fig. 29 PDC Location
POWER DISTRIBUTION CEN- TER (PDC)
REMOVAL
Some model /engi ne combi nati ons may requi re
removal of ai r cl eaner tubes for access to sensor.
(1) Remove ai r cl eaner tube(s) at throttl e body (i f
necessary).
(2) Near rear of i ntake mani fol d, di sconnect pi gtai l
harness (el ectri cal connector) from mai n el ectri cal
harness.
(3) Remove nut hol di ng sensor harness wi re cl amp
to fuel rai l mounti ng stud.
(4) Dependi ng upon appl i cati on, remove ei ther sen-
sor mounti ng bol ts or nuts.
(5) Remove sensor.
(6) Remove cl amp from sensor wi re harness.
INSTALLATION
(1) I nstal l sensor fl ush agai nst openi ng i n trans-
mi ssi on housi ng.
(2) 2.5L engi nes equi pped wi th automati c trans-
mi ssi on: I nstal l and ti ghten two sensor mounti ng
nuts to 19 Nm (14 ft. l bs.) torque.
(3) 2.5L engi nes equi pped wi th manual transmi s-
si on or any 4.0L engi nes: I nstal l and ti ghten two sen-
sor mounti ng bol ts to 19 Nm (14 ft. l bs.) torque. The
two sensor mounting bolts are specially
machined to correctly space unit to flywheel.
Do not attempt to install any other bolts.
(4) Connect sensor pi gtai l harness el ectri cal con-
nector to mai n wi ri ng harness.
(5) I nstal l cl amp on sensor wi re harness.
(6) I nstal l cl amp over fuel rai l mounti ng stud.
(7) I nstal l cl amp mounti ng nut.
(8) I nstal l ai r cl eaner tube to throttl e body (i f nec-
essary).
tri butor (Fi g. 32).
REMOVAL
Di stri butor removal i s not necessary to remove
camshaft posi ti on sensor.
(2) Remove di stri butor cap from di stri butor (two
screws).
(3) Di sconnect camshaft posi ti on sensor wi ri ng
harness from mai n engi ne wi ri ng harness.
Fig. 30 Crankshaft Position Sensor2.5L 4-Cyl.
Engine With Auto. Trans.
Fig. 31 Crankshaft Position SensorExcept 2.5L
4-Cyl. Engine With Auto. Trans.
Fig. 32 Camshaft Position Sensor
(4) Remove di stri butor rotor from di stri butor shaft.
(5) Li ft camshaft posi ti on sensor assembl y from
di stri butor housi ng (Fi g. 32).
INSTALLATION
(1) I nstal l camshaft posi ti on sensor to di stri butor.
Al i gn sensor i nto notch on di stri butor housi ng.
(2) Connect wi ri ng harness.
(3) I nstal l rotor.
(4) I nstal l di stri butor cap. Ti ghten mounti ng
screws.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
For removal and i nstal l ati on, refer to Mani fol d
Absol ute Pressure Sensor i n group 14, Fuel Systems.
Fuel System.
Fuel System.
Fuel System.
DISTRIBUTOR
Al l di stri butors contai n an i nternal oi l seal that
prevents oi l from enteri ng the di stri butor housi ng.
The seal i s not servi ceabl e.
Factory repl acement di stri butors are equi pped wi th
a pl asti c al i gnment pi n al ready i nstal l ed. The pi n i s
l ocated i n an access hol e on the bottom of the di stri b-
utor housi ng (Fi g. 33). I t i s used to temporari l y l ock
the rotor to the cyl i nder number 1 posi ti on duri ng
i nstal l ati on. The pi n must be removed after i nstal l -
i ng the di stri butor.
tri butor on al l engi nes (Fi g. 34). For removal /i nstal -
l ati on procedures, refer to Camshaft Posi ti on Sensor.
Di stri butor removal i s not necessary for sensor
removal .
Refer to (Fi g. 34) for an expl oded vi ew of the di s-
tri butor.
A fork wi th a sl ot i s suppl i ed on the bottom of the
di stri butor housi ng where the housi ng base seats
agai nst the engi ne bl ock (Fi g. 34). The centerl i ne of
the sl ot al i gns wi th the di stri butor hol ddown bol t
hol e i n the engi ne bl ock. Because of the fork, the di s-
tri butor cannot be rotated. Di stri butor rotati on i s not
necessary as al l i gni ti on ti mi ng requi rements are
handl ed by the powertrai n control modul e (PCM).
The posi ti on of the di stri butor determi nes fuel syn-
chroni zati on onl y. I t does not determi ne i gni ti on ti m-
i ng.
Fig. 33 Plastic Alignment Pin
PLASTIC ALIGN- MENT PIN
Fig. 34 Distributor2.5L Or 4.0L EnginesTypical
CAP CAMSHAFT POSITION SENSOR HOUSING HOLDDOWNBOLT HOLDDOWN CLAMP FORK WITH SLOT GASKET WASHER ROLL PIN DRIVE GEAR SHAFT PULSE RING ROTOR
NOTE: Do not attempt to modify this fork to attain
ignition timing.
REMOVAL2.5L OR 4.0L ENGINE
battery.
(2) Di sconnect coi l secondary cabl e at coi l .
(3) Remove di stri butor cap from di stri butor (2
screws). Do not remove cabl es from cap. Do not
remove rotor.
(4) Di sconnect the di stri butor wi ri ng harness from
the mai n engi ne harness.
(5) Remove the cyl i nder number 1 spark pl ug.
(6) Hol d a fi nger over the open spark pl ug hol e.
Rotate the engi ne at the vi brati on dampener bol t
unti l compressi on (pressure) i s fel t.
(7) Sl owl y conti nue to rotate the engi ne. Do thi s
unti l the ti mi ng i ndex mark on the vi brati on damper
pul l ey al i gns wi th the top dead center (TDC) mark (0
degree) on ti mi ng degree scal e (Fi g. 35). Al ways
rotate the engi ne i n di recti on of normal rotati on. Do
not rotate the engi ne backward to al i gn the ti mi ng
marks.
(8) On model s equi pped wi th A/C, remove the el ec-
tri cal cool i ng fan and shroud assembl y from the radi -
ator. Refer to Group 7, Cool i ng System for
procedures.
(9) Thi s wi l l provi de room to turn the engi ne
crankshaft wi th a socket and ratchet usi ng the vi bra-
ti on damper bol t.
(10) Remove the di stri butor hol ddown bol t and
cl amp.
(11) Remove the di stri butor from engi ne by sl owl y
l i fti ng strai ght up.
(12) Note that the rotor wi l l rotate sl i ghtl y i n a
countercl ockwi se di recti on whi l e l i fti ng up the di s-
tri butor. The oi l pump gear wi l l al so rotate sl i ghtl y i n
a countercl ockwi se di recti on whi l e l i fti ng up the di s-
tri butor. Thi s i s due to the hel i cal cut gears on the
di stri butor and camshaft.
(13) Note the removed posi ti on of the rotor duri ng
di stri butor removal . Duri ng i nstal l ati on, thi s wi l l be
referred to as the Pre-posi ti on.
(14) 2.5L 4-Cylinder Engine: Observe the sl ot i n
the oi l pump gear through the hol e on the si de of the
engi ne. I t shoul d be sl i ghtl y before (countercl ockwi se
of) the 10 ocl ock posi ti on (Fi g. 36).
(15) 4.0L 6-Cylinder Engine: Observe the sl ot i n
the oi l pump gear through the hol e on the si de of the
engi ne. I t shoul d be sl i ghtl y before (countercl ockwi se
of) the 11 ocl ock posi ti on (Fi g. 37).
(16) Remove and di scard the ol d di stri butor-to-en-
gi ne bl ock gasket.
Fig. 35 Align Timing Marks
CRANKSHAFT VIBRATION DAMPER TIMING MARK
Fig. 36 Slot At 10 Oclock Position2.5L Engine
Fig. 37 Slot At 11 Oclock Position4.0L Engine
FRONT 11 OCLOCK POSITION OIL PUMP SLOT
INSTALLATION
(1) I f the engi ne crankshaft has been rotated after
di stri butor removal , cyl i nder number 1 must be
returned to i ts proper fi ri ng stroke. Refer to previ ous
REMOVAL Step 5 and Step 6. These steps must be
done before i nstal l i ng di stri butor.
(2) Check the posi ti on of the sl ot on the oi l pump
gear. On the 2.5L engi ne, i t shoul d be just sl i ghtl y
before (countercl ockwi se of) the 10 ocl ock posi ti on
(Fi g. 36). On the 4.0L engi ne, i t shoul d be just
sl i ghtl y before (countercl ockwi se of) the 11 ocl ock
posi ti on (Fi g. 37). I f not, pl ace a fl at bl ade screw-
dri ver i nto the oi l pump gear and rotate i t i nto the
proper posi ti on.
(3) Factory repl acement di stri butors are equi pped
wi th a pl asti c al i gnment pi n al ready i nstal l ed (Fi g.
33). Thi s pi n i s used to temporari l y hol d the rotor to
the cyl i nder number 1 fi ri ng posi ti on duri ng di stri b-
utor i nstal l ati on. I f thi s pi n i s i n pl ace, proceed to
Step 8. I f not, proceed to next step.
(4) I f the ori gi nal di stri butor i s to be rei nstal l ed,
such as duri ng engi ne overhaul , the pl asti c pi n wi l l
not be avai l abl e. A 3/16 i nch dri ft pi n punch tool may
be substi tuted for the pl asti c pi n.
(5) Remove the camshaft posi ti on sensor from the
di stri butor housi ng. Li ft strai ght up.
(6) Four di fferent al i gnment hol es are provi ded on
the pl asti c ri ng (Fi g. 38). Note that 2.5L and 4.0L
engines have different alignment holes (Fig.
38).
(7) Rotate the di stri butor shaft and i nstal l the pi n
punch tool through the proper al i gnment hol e i n the
pl asti c ri ng (Fi g. 38) and i nto the mati ng access hol e
i n the di stri butor housi ng. Thi s wi l l prevent the di s-
tri butor shaft and rotor from rotati ng.
(8) Cl ean the di stri butor mounti ng hol e area of the
engi ne bl ock.
(9) I nstal l a new di stri butor-to-engi ne bl ock gasket
(Fi g. 34).
(10) I nstal l the rotor to the di stri butor shaft.
(11) 2.5L 4-Cylinder Engine: Pre-posi ti on the
di stri butor i nto the engi ne whi l e hol di ng the center-
l i ne of the base sl ot i n the 1 ocl ock posi ti on (Fi g. 39).
Conti nue to engage the di stri butor i nto the engi ne.
The rotor and di stri butor wi l l rotate cl ockwi se duri ng
i nstal l ati on. Thi s i s due to the hel i cal cut gears on
the di stri butor and camshaft. When the di stri butor i s
ful l y seated to the engi ne bl ock, the centerl i ne of the
base sl ot shoul d be al i gned to the cl amp bol t mount-
i ng hol e on the engi ne (Fi g. 40). The rotor shoul d
al so be poi nted sl i ghtl y past (cl ockwi se of) the 3
ocl ock posi ti on.
4.0L 6-Cylinder Engine: Pre-posi ti on the di stri b-
utor i nto the engi ne whi l e hol di ng the centerl i ne of
the base sl ot i n the 1 ocl ock posi ti on (Fi g. 39). Con-
ti nue to engage the di stri butor i nto the engi ne. The
rotor and di stri butor wi l l rotate cl ockwi se duri ng
i nstal l ati on. Thi s i s due to the hel i cal cut gears on
the di stri butor and camshaft. When the di stri butor i s
ful l y seated to the engi ne bl ock, the centerl i ne of the
base sl ot shoul d be al i gned to the cl amp bol t mount-
i ng hol e on the engi ne (Fi g. 41). The rotor shoul d
al so be poi nted at the 5 ocl ock posi ti on.
I t may be necessary to rotate the rotor and di stri b-
utor shaft (very sl i ghtl y) to engage the di stri butor
shaft wi th the sl ot i n the oi l pump gear. The same
may have to be done to engage the di stri butor gear
wi th the camshaft gear.
The distributor is correctly installed when:
the rotor i s poi nted at the 3 ocl ock posi ti on
(2.5L engi ne), or at the 5 ocl ock posi ti on (4.0L
engi ne).
the pl asti c al i gnment pi n (or pi n punch tool ) i s
sti l l i nstal l ed to di stri butor.
the number 1 cyl i nder pi ston i s set at top dead
center (TDC) (compressi on stroke).
the centerl i ne of the sl ot at the base of the di s-
tri butor i s al i gned to the centerl i ne of the di stri butor
hol ddown bol t hol e on the engi ne. I n thi s posi ti on,
the hol ddown bol t shoul d easi l y pass through the sl ot
and i nto the engi ne.
No adjustments are necessary. Proceed to next
step.
(12) I nstal l the di stri butor hol ddown cl amp and
bol t. Ti ghten the bol t to 23 Nm (17 ft. l bs.) torque.
(13) Remove the pi n punch tool from the di stri bu-
tor. Or, i f the pl asti c al i gnment pi n was used, remove
i t strai ght down from the bottom of the di stri butor.
Di scard pl asti c pi n.
Fig. 38 Pin Alignment Holes
DISTRIBUTOR HOUSING (TOP VIEW) PULSE RING 4.0L 6-CYLIN- DER ENGINE ALIGN. HOLE 2.5L 4-CYLIN- DER ENGINE ALIGN. HOLE MATING ACCESS HOLE IN DISTRIBUTOR HOUSING PLASTIC RING
(14) I f removed, i nstal l the camshaft posi ti on sen-
sor to the di stri butor. Al i gn the wi ri ng harness grom-
met to the notch i n the di stri butor housi ng.
(15) I nstal l the rotor.
CAUTION: If the distributor cap is incorrectly posi-
tioned on distributor housing, the cap or rotor may
be damaged when engine is started.
(16) I nstal l the di stri butor cap. Ti ghten di stri butor
cap hol ddown screws to 3 Nm (26 i n. l bs.) torque.
(17) I f removed, i nstal l the spark pl ug cabl es to
the di stri butor cap. For proper fi ri ng order, refer to
the Speci fi cati ons secti on at the end of thi s group.
See Engi ne Fi ri ng Order.
(18) Connect the di stri butor wi ri ng harness to the
mai n engi ne harness.
Refer to Group 14, Fuel System for procedures.
IGNITION SWITCH AND KEY CYLINDER
The i gni ti on key must be i n the key cyl i nder for
cyl i nder removal . The key cyl i nder must be removed
fi rst before removi ng i gni ti on swi tch.
KEY CYLINDER REMOVAL
(2) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(3) Rotate key to ON posi ti on.
(4) A rel ease tang i s l ocated on bottom of key cyl -
i nder (Fi g. 42).
(5) Posi ti on a smal l screwdri ver or pi n punch i nto
tang access hol e on bottom of steeri ng col umn l ower
cover (Fi g. 43).
(6) Push the pi n punch up whi l e pul l i ng key cyl i n-
der from steeri ng col umn.
Fig. 39 Distributor Pre-positionAll Engines
1 OCLOCK POSITION FRONT BASE SLOT DISTRIBUTOR BASE
Fig. 40 Distributor Engaged Position2.5L
4-Cylinder Engine
DISTRIBUTOR BASE SLOTCLAMP BOLT MOUNTING HOLE (ON ENGINE) DISTRIBUTOR BASE FRONT
Fig. 41 Distributor Engaged Position4.0L
6-Cylinder Engine
DISTRIBUTOR BASE SLOT CLAMP BOLT MOUNTING HOLE (ON ENGINE) DISTRIBUTOR BASE FRONT
IGNITION SWITCH REMOVAL
(1) Remove key cyl i nder. Refer to previ ous steps.
(2) Remove l ower steeri ng col umn cover screws
and remove cover (Fi g. 43).
(3) Remove i gni ti on swi tch mounti ng screw (Fi g.
46). Use tamper proof torx bi t (Snap-On SDMTR10
or equi val ent) to remove the screw.
(4) Usi ng a smal l screwdri ver, push on l ocki ng tab
(Fi g. 44) and remove swi tch from steeri ng col umn.
(5) Di sconnect two el ectri cal connectors at rear of
i gni ti on swi tch (Fi g. 46).
IGNITION SWITCH INSTALLATION
(1) Before i nstal l i ng i gni ti on swi tch, rotate the sl ot
i n the swi tch to the ON posi ti on (Fi g. 45).
(2) Connect two el ectri cal connectors to rear of
i gni ti on swi tch. Make sure that l ocki ng tabs are ful l y
seated i nto wi ri ng connectors.
(3) Posi ti on swi tch to col umn and i nstal l tamper
proof screw. Ti ghten screw to 3 Nm (26 i n. l bs.).
(4) I nstal l steeri ng col umn l ower cover.
KEY CYLINDER INSTALLATION
(1) I f equi pped wi th an automati c transmi ssi on,
pl ace shi fter i n PARK posi ti on.
(2) Posi ti on key cyl i nder i nto steeri ng col umn as i t
woul d normal l y be i n the ON posi ti on.
(3) Press key cyl i nder i nto col umn unti l i t snaps
i nto posi ti on.
(4) Check mechani cal operati on of swi tch. Auto-
matic Transmission: Be sure transmi ssi on l ever i s
Fig. 42 Key Cylinder Release Tang
KEY CYLINDER RELEASE TANG
Fig. 43 Key Cylinder and Cover Removal
LOWER COVER ACCESS HOLE PIN PUNCH COVER SCREWS (3)
Fig. 44 Ignition Switch Lock Tab
LOCK TAB IGNITION SWITCH SCREWDRIVER
Fig. 45 Switch In ON Position
IGNITION SWITCH ROTATE TO ON POSITION
l ocked i n PARK posi ti on after key removal . I f key i s
di ffi cul t to rotate or i s di ffi cul t to remove, the shi ft
l ever-to-steeri ng col umn cabl e may be out of adjust-
ment or defecti ve. Refer to Group 21, Transmi ssi on
for procedures. Manual Transmission: Be sure key
cannot be removed unti l rel ease l ever i s operated. I f
key can be removed, rel ease l ever mechani sm may be
defecti ve. Rel ease l ever mechani sm i s not servi ced
separatel y. I f repai r i s necessary, the steeri ng col umn
must be repl aced. Refer to Group 19, Steeri ng for
procedures.
(6) Check el ectri cal operati on of swi tch.
SHIFTER/IGNITION INTERLOCK
On model s equi pped wi th an automati c transmi s-
si on, a cabl e connects the i gni ti on swi tch wi th the
fl oor shi ft l ever. The shi fter wi l l be l ocked i n the
PARK posi ti on when the i gni ti on key i s i n the LOCK
or ACCESSORY posi ti ons. The cabl e can be adjusted
or repl aced. Refer to Group 21, Transmi ssi ons for
procedures. The i gni ti on i nterl ock devi ce wi thi n the
steeri ng col umn i s not servi ceabl e. I f servi ce i s nec-
essary, the steeri ng col umn must be repl aced. Refer
to Group 19, Steeri ng for procedures.
SPECIFICATIONS
VECI LABEL
I f anythi ng di ffers between the speci fi cati ons found
on the Vehi cl e Emi ssi on Control I nformati on (VECI )
l abel and the fol l owi ng speci fi cati ons, use speci fi ca-
ti ons on VECI l abel . The VECI l abel i s l ocated i n the
IGNITION TIMING
I gni ti on ti mi ng i s not adjustabl e on any engi ne.
Refer to I gni ti on Ti mi ng i n the Di agnosti cs/Servi ce
Procedures secti on of thi s group for more i nforma-
ti on.
ENGINE FIRING ORDER2. 5L 4-CYLINDER
ENGINE
ENGINE FIRING ORDER4. 0L 6-CYLINDER
ENGINE
Fig. 46 Ignition Switch Removal/Installation
TAMPER PROOF SCREW IGNITIONSWITCH ELECTRICAL CONNECTORS FIRING ORDER: 1 3 4 2 CLOCKWISE ROTA- TION FRONT
FIRING ORDER: 1 5 3 6 2 4 CLOCKWISE ROTATION FRONT
SPARK PLUGS SPARK PLUG CABLE RESISTANCE
IGNITION COIL RESISTANCE
TORQUE CHART
DESCRIPTION TORQUE
Crankshaft Posi ti on Sensor
Mounti ng Bol ts . . . . . . . . . . . . 19 Nm (14 ft. l bs.)
Crankshaft Posi ti on Sensor
Di stri butor Hol d Down Bol t . . . . 23 Nm (17 ft. l bs.)
I gni ti on Coi l Mounti ng
(i f tapped bol ts are used) . . . . . 5 Nm (50 i n. l bs.)
I gni ti on Coi l Mounti ng
(i f nuts/bol ts are used) . . . . . 11 Nm (100 i n. l bs.)
Powertrai n Control Modul e (PCM)
Mounti ng Screws . . . . . . . . . . . . 1 Nm (9 i n. l bs.)
Spark Pl ugs (al l engi nes) . . . . . . 41 Nm (30 ft. l bs.)
ENGINE PLUG TYPE
ELECTRODE
GAP
2.5/4.0L RC12LYC 0.89 mm
(0.035 in.)
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
COIL TOYODENSO DIAMOND
Primary Resistance .95 - 1.20 Ohms .96 - 1.18 Ohms
Secondary Resistance at 70- 80F 11,300 - 13,300 Ohms 11,300 - 15,300 Ohms
INSTRUMENT PANEL SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . . . 3
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 2
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 3
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . . 6
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . . 6
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . 6
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . . 6
CIGAR LIGHTER AND POWER OUTLET . . . . . . 6
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . . 6
CLUSTER ILLUMINATION LAMP . . . . . . . . . . . . 7
COOLANT TEMPERATURE GAUGE . . . . . . . . . . 4
COOLANT TEMPERATURE WARNING LAMP . . 7
CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . . 7
FOUR-WHEEL DRIVE INDICATOR LAMP . . . . . . 7
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEADLAMP HIGH BEAM INDICATOR LAMP . . . 7
LOW FUEL WARNING LAMP . . . . . . . . . . . . . . . 8
LOW OIL PRESSURE WARNING LAMP . . . . . . . 8
LOW WASHER FLUID WARNING LAMP . . . . . . . 8
MALFUNCTION INDICATOR LAMP . . . . . . . . . . 8
ODOMETER AND TRIP ODOMETER . . . . . . . . . 4
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . . 5
SEAT BELT REMINDER LAMP . . . . . . . . . . . . . . 9
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . 5
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . . 9
UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . . 9
VOLTAGE WARNING LAMP . . . . . . . . . . . . . . . . 9
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIRBAG INDICATOR LAMP . . . . . . . . . . . . . . . 14
ANTI-LOCK BRAKE SYSTEM LAMP . . . . . . . . . 14
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . 15
CHECK GAUGES LAMP . . . . . . . . . . . . . . . . . . 16
CIGAR LIGHTER AND POWER OUTLET . . . . . 16
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . 16
CLUSTER ILLUMINATION LAMP . . . . . . . . . . . 17
COOLANT TEMPERATURE GAUGE . . . . . . . . . 10
COOLANT TEMPERATURE WARNING LAMP . . 18
CRUISE-ON INDICATOR LAMP . . . . . . . . . . . . 18
FOUR-WHEEL DRIVE INDICATOR LAMP . . . . . 18
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . 13
HEADLAMP HIGH BEAM INDICATOR LAMP . . 19
LOW FUEL WARNING LAMP . . . . . . . . . . . . . . 20
LOW OIL PRESSURE WARNING LAMP . . . . . . 20
LOW WASHER FLUID WARNING LAMP . . . . . . 20
MALFUNCTION INDICATOR LAMP . . . . . . . . . . 21
ODOMETER AND TRIP ODOMETER . . . . . . . . 13
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . 13
SEAT BELT REMINDER LAMP . . . . . . . . . . . . . 21
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . 14
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 14
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . 21
UPSHIFT INDICATOR LAMP . . . . . . . . . . . . . . 22
VOLTAGE WARNING LAMP . . . . . . . . . . . . . . . 22
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ACCESSORY SWITCH BEZEL . . . . . . . . . . . . . 24
CENTER SUPPORT BRACKET . . . . . . . . . . . . 32
CIGAR LIGHTER RELAY . . . . . . . . . . . . . . . . . 24
CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . . . 25
CLUSTER BULB . . . . . . . . . . . . . . . . . . . . . . . . 28
CLUSTER COMPONENTS . . . . . . . . . . . . . . . . 27
GLOVE BOX COMPONENTS . . . . . . . . . . . . . . 30
GLOVE BOX LAMP AND SWITCH . . . . . . . . . . 29
GLOVE BOX LATCH STRIKER . . . . . . . . . . . . . 31
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . 25
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . 26
INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . 33
INSTRUMENT PANEL CENTER BEZEL . . . . . . 23
INSTRUMENT PANEL END CAP . . . . . . . . . . . 31
INSTRUMENT PANEL TOP COVER . . . . . . . . . 28
JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . 32
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . . 23
STEERING COLUMN OPENING COVER . . . . . 22
GENERAL INFORMATION
INTRODUCTION
Thi s group i s responsi bl e for coveri ng the vehi cl e
i nstrument panel . However, because the i nstrument
panel serves as the command center of the vehi cl e, i t
i s a very compl ex uni t. The i nstrument panel i s
desi gned to house the control s and moni tors for stan-
dard and opti onal powertrai ns, cl i mate control sys-
tems, audi o systems, l i ghti ng systems, safety
systems, and many other comfort or conveni ence
i tems. I t i s al so desi gned so that al l of the control s
and moni tors can be safel y reached and vi ewed by
XJ INSTRUMENT PANEL SYSTEMS 8E - 1
the vehi cl e operator, whi l e sti l l al l owi ng rel ati ve ease
of access to these i tems for servi ce.
Compl ete servi ce i nformati on coverage for al l of the
systems and components housed i n the i nstrument
panel i n thi s secti on of the servi ce manual woul d not
be practi cal . I t woul d resul t i n a great deal of dupl i -
cati on and make thi s group too l arge for the i nforma-
ti on to be easi l y accessed and used. Therefore, the
i nformati on found i n thi s group has been l i mi ted as
fol l ows:
General I nformati on - Covers non-el ectri cal com-
ponents and features of the i nstrument panel that
are not rel ated to other systems.
Descri pti on and Operati on - Covers gauges and
thei r sendi ng uni ts, warni ng l amps and thei r
swi tches, and i nstrument panel i l l umi nati on l amps.
Di agnosi s and Testi ng - Covers gauges and thei r
sendi ng uni ts, warni ng l amps and thei r swi tches,
and i nstrument panel i l l umi nati on l amps.
Removal and I nstal l ati on - Covers components
i nstal l ed on or i n the i nstrument panel that requi re
removal for di agnosi s or servi ce of i nstrument panel
components covered i n thi s group.
For more i nformati on on components or systems
not covered above, refer to the proper group i n thi s
manual . I f you are uncertai n as to the proper group,
refer to the Component and System I ndex at the
back of thi s manual . Refer to Group 8W - Wi ri ng
Di agrams for compl ete ci rcui t descri pti ons and di a-
grams.
INSTRUMENT PANEL
Thi s i nstrument panel uses a ful l -wi dth structural
pl asti c foundati on as i ts pri mary support. When the
two pri mary mol ded pl asti c components of thi s struc-
ture are vi brati on wel ded together they provi de supe-
ri or i nstrument panel sti ffness and i ntegri ty to hel p
reduce buzzes, squeaks, and rattl es even on the
bumpi est roads.
Thi s type of constructi on al so provi des i mproved
energy absorpti on whi ch, i n conjuncti on wi th the
dual ai rbag modul es and seat bel ts, hel ps to i mprove
occupant protecti on. Thi s foundati on structure al so
serves as the ducti ng for the heati ng and ai r condi -
ti oni ng system panel outl ets, whi ch greatl y reduces
the number of components used over conventi onal
i nstrument panel constructi on.
Modul ar i nstrument panel constructi on al l ows al l
of the gauges and control s to be servi ced from the
front of the panel . I n addi ti on, most of the i nstru-
ment panel el ectri cal components can be accessed
wi thout compl ete i nstrument panel removal . I f neces-
sary, the i nstrument panel can be removed from the
vehi cl e as an assembl y.
Removal of the steeri ng col umn openi ng cover and
knee bl ocker provi des access to the steeri ng col umn
mounts, the steeri ng col umn wi ri ng, the headl amp
swi tch, the el ectroni c combi nati on fl asher, and much
of the i nstrument panel wi ri ng. Removal of the gl ove
box provi des access to the heati ng and ai r condi ti on-
i ng el ectri cal and vacuum harnesses, the bl ower
motor rel ay, the radi o antenna coaxi al cabl e, the
l ower passenger si de ai rbag mounts, and addi ti onal
i nstrument panel wi ri ng.
Removal of the i nstrument panel center bezel
al l ows access to the radi o, the heati ng and ai r condi -
ti oni ng control s, the accessory swi tches, the ci gar
l i ghter, and the accessory power outl et. Removal of
the i nstrument cl uster bezel al l ows access to the
i nstrument cl uster. Removal of the cl uster assembl y
al l ows access to the cl uster i l l umi nati on and i ndi ca-
tor l amp bul bs, and more of the i nstrument panel
wi ri ng.
Removal of the i nstrument panel top cover al l ows
access to the upper passenger si de ai rbag mounts.
I nstrument panel removal i s requi red for servi ce of
most i nternal components of the heati ng and ai r con-
di ti oni ng housi ng.
INSTRUMENT CLUSTER
Two basi c i nstrument cl usters are offered on thi s
model : l ow-l i ne or hi gh-l i ne. Both cl usters are el ectro-
mechani cal uni ts that uti l i ze i ntegrated ci rcui try and
i nformati on carri ed on the Chrysl er Col l i si on Detec-
ti on (CCD) data bus network for control of al l gauges
and many of the i ndi cator l amps. These cl usters al so
i ncorporate a vacuum fl uorescent di spl ay tube for the
di gi tal odometer/tri p odometer di spl ay functi ons.
Some vari ati ons of each cl uster exi st due to opti onal
equi pment and regul atory requi rements.
The l ow-l i ne cl uster i ncl udes the fol l owi ng anal og
gauges:
Fuel gauge
Speedometer.
Thi s cl uster i ncl udes provi si ons for the fol l owi ng
i ndi cator l amps:
Ai rbag i ndi cator l amp
Anti -l ock brake system l amp
Brake warni ng l amp
Cool ant temperature warni ng l amp
8E - 2 INSTRUMENT PANEL SYSTEMS XJ
Crui se-on i ndi cator l amp
Four-wheel dri ve (Part Ti me and/or Ful l Ti me)
i ndi cator l amps
Headl amp hi gh beam i ndi cator l amp
Low oi l pressure warni ng l amp
Low washer fl ui d warni ng l amp
Mal functi on i ndi cator (Check Engi ne) l amp
Seat bel t remi nder l amp
Turn si gnal i ndi cator l amps
Upshi ft i ndi cator l amp (manual transmi ssi on)
Vol tage warni ng l amp.
The hi gh-l i ne cl uster repl aces some of the i ndi cator
l amps found i n the l ow-l i ne cl uster wi th anal og
gauges. The hi gh-l i ne cl uster i ncl udes the fol l owi ng
anal og gauges:
Cool ant temperature gauge
Fuel gauge
Oi l pressure gauge
Speedometer
Tachometer
Vol tmeter.
The hi gh-l i ne cl uster al so adds a check gauges
l amp and a l ow fuel warni ng l amp to the remai ni ng
i ndi cator l amps found i n the l ow-l i ne cl uster.
Both i nstrument cl usters feature ci rcui try that has
a sel f-di agnosti c actuator test capabi l i ty, whi ch wi l l
test each of the CCD bus message-control l ed func-
ti ons of the cl uster by l i ghti ng the appropri ate i ndi -
cator l amps and posi ti oni ng the gauge needl es at
several predetermi ned l ocati ons on the gauge faces i n
a prescri bed sequence. For more i nformati on on thi s
functi on, see I nstrument Cl uster i n the Di agnosi s
and Testi ng secti on of thi s group.
The i nstrument cl uster ci rcui try al so i ntegrates a
chi me tone generator and a ti mer ci rcui t. These
i tems repl ace the chi me or buzzer modul e, and the
separate ti mer ci rcui t for the rear wi ndow defogger
system. Refer to Group 8U - Chi me/Buzzer Warni ng
Systems or Group 8N - El ectri cal l y Heated Systems
for more i nformati on on these cl uster ci rcui try func-
ti ons.
The i nstrument cl usters for thi s model are servi ced
onl y as compl ete uni ts. I f a cl uster gauge or the cl us-
ter ci rcui t board are faul ty, the enti re cl uster must be
repl aced. The cl uster l ens, the hood and mask, the
rear housi ng cover and the odometer reset knob boot
are avai l abl e for servi ce. Al so, the i ndi vi dual cl uster
l amp bul bs and bul b hol ders can be servi ced.
GAUGE
Wi th the i gni ti on swi tch i n the On or Start posi -
ti ons, vol tage i s suppl i ed to al l gauges through the
i nstrument cl uster el ectroni c ci rcui t board. Wi th the
i gni ti on swi tch i n the Off posi ti on, vol tage i s not sup-
pl i ed to the gauges. The gauges do not accuratel y
i ndi cate any vehi cl e condi ti on unl ess the i gni ti on
swi tch i s i n the On or Start posi ti ons.
Al l gauges, except the odometer, are ai r core mag-
neti c uni ts. Two fi xed el ectromagneti c coi l s are
l ocated wi thi n the gauge. These coi l s are wrapped at
ri ght angl es to each other around a movabl e perma-
nent magnet. The movabl e magnet i s suspended
wi thi n the coi l s on one end of a shaft. The gauge nee-
dl e i s attached to the other end of the shaft.
One of the coi l s has a fi xed current fl owi ng
through i t to mai ntai n a constant magneti c fi el d
strength. Current fl ow through the second coi l
changes, whi ch causes changes i n i ts magneti c fi el d
strength. The current fl owi ng through the second coi l
i s changed by the i nstrument cl uster el ectroni c ci r-
cui try i n response to messages recei ved on the
Chrysl er Col l i si on Detecti on (CCD) data bus network.
The gauge needl e moves as the movabl e permanent
magnet al i gns i tsel f to the changi ng magneti c fi el ds
created around i t by the el ectromagnets. The i nstru-
ment cl uster ci rcui try i s programmed to move al l of
the gauge needl es back to the l ow end of thei r respec-
ti ve scal es after the i gni ti on swi tch i s turned to the
Off posi ti on.
INDICATOR LAMP
I ndi cator l amps are l ocated i n the i nstrument cl us-
ter and are served by the cl uster ci rcui t board and
connectors. Many of the i ndi cator l amps i n the
i nstrument cl uster are control l ed by the i nstrument
cl uster ci rcui try i n response to messages recei ved
over the Chrysl er Col l i si on Detecti on (CCD) data bus
network.
The anti -l ock brake system l amp, brake warni ng
l amp, four-wheel dri ve i ndi cator l amps, headl amp
hi gh beam i ndi cator l amp, l ow washer fl ui d warni ng
l amp, seat bel t remi nder l amp dri ver seat bel t swi tch
i nput, and turn si gnal i ndi cator l amps are hard-
wi red. The i nstrument cl uster ci rcui try uses CCD
data bus messages from the Powertrai n Control Mod-
ul e (PCM) and Ai rbag Control Modul e (ACM) to con-
trol al l of the remai ni ng i ndi cator l amps.
JUNCTION BLOCK
The juncti on bl ock i s mounted on the ri ght cowl
si de i nner panel under the i nstrument panel . I t i s
conceal ed behi nd the ri ght cowl si de tri m panel . The
juncti on bl ock serves to si mpl i fy and central i ze
numerous el ectri cal components.
The juncti on bl ock combi nes the functi ons previ -
ousl y provi ded by a separate fusebl ock modul e and
rel ay center. I t contai ns fuses, ci rcui t breakers and
rel ays. I t al so el i mi nates the need for numerous
spl i ce connecti ons and serves i n pl ace of a bul khead
connector between many of the engi ne compartment,
i nstrument panel , and body wi re harnesses.
The ri ght cowl si de tri m panel has a snap-fi t fuse
access cover that can be removed for servi ce of the
juncti on bl ock fuses. A fuse pul l er and spare fuse
hol ders are l ocated on the back of the fuse access
panel . The ri ght cowl si de tri m panel must be
removed to access the rel ays i n the juncti on bl ock.
The juncti on bl ock cannot be repai red and, i f faul ty
COOLANT TEMPERATURE GAUGE
The cool ant temperature gauge gi ves an i ndi cati on
of the engi ne cool ant temperature. The i nstrument
cl uster ci rcui try control s the gauge poi nter posi ti on.
The i nstrument cl uster ci rcui try cal cul ates the
proper gauge poi nter posi ti on based upon an engi ne
cool ant temperature message recei ved from the Pow-
ertrai n Control Modul e (PCM) on the Chrysl er Col l i -
si on Detecti on (CCD) data bus.
The PCM uses an i nput from the engi ne cool ant
temperature sensor and i nternal programmi ng to
deci de what engi ne cool ant temperature message i s
requi red. The PCM then sends the proper message to
the i nstrument cl uster on the CCD data bus.
I f the PCM message i ndi cates that cool ant temper-
ature i s hi gh, the i nstrument cl uster ci rcui try moves
the gauge needl e i nto the begi nni ng of the red zone
on the gauge face, turns on the Check Gauges l amp,
and generates a si ngl e chi me tone. I f the PCM mes-
sage i ndi cates that cool ant temperature i s cri ti cal ,
the i nstrument cl uster ci rcui try moves the gauge
needl e to the stop at the end of the red zone on the
gauge face.
i n a threaded hol e that penetrates a cool ant passage
of the engi ne. I t i s a thermi stor-type sensor that
changes i ts i nternal resi stance wi th changes i n
engi ne cool ant temperature. Refer to Group 14 - Fuel
Systems for more i nformati on on the PCM and the
cool ant temperature sensor.
FUEL GAUGE
The fuel gauge gi ves an i ndi cati on of the l evel of
fuel i n the fuel tank. The i nstrument cl uster ci rcui try
control s the gauge poi nter posi ti on. The i nstrument
cl uster ci rcui try cal cul ates the proper gauge poi nter
posi ti on based upon a fuel l evel message recei ved
from the Powertrai n Control Modul e (PCM) on the
Chrysl er Col l i si on Detecti on (CCD) data bus.
The PCM uses an i nput from the fuel gauge send-
i ng uni t and i nternal programmi ng to deci de what
fuel l evel message i s requi red. The PCM then sends
the proper message to the i nstrument cl uster on the
CCD data bus. I f the vehi cl e i s equi pped wi th the
hi gh-l i ne i nstrument cl uster, when the PCM message
i ndi cates that the fuel l evel i s bel ow one-ei ghth of a
ful l tank, the i nstrument cl uster ci rcui try turns on
the l ow fuel warni ng l amp and generates a si ngl e
chi me tone.
The fuel gauge sendi ng uni t i s mounted to the el ec-
tri c fuel pump modul e l ocated i nsi de the fuel tank.
The sendi ng uni t has a fl oat attached to the end of a
swi ng-arm. The fl oat moves up or down wi thi n the
fuel tank as the fuel l evel changes. As the fl oat
moves, an el ectri cal contact on the pi vot end of the
swi ng-arm wi pes across a resi stor coi l , whi ch changes
the i nternal el ectri cal resi stance of the sendi ng uni t.
Refer to Group 14 - Fuel Systems for more i nforma-
ti on on the PCM and the fuel gauge sendi ng uni t ser-
vi ce procedures.
ODOMETER AND TRIP ODOMETER
The odometer and the tri p odometer share the
same vacuum fl uorescent di gi tal di spl ay tube i n the
i nstrument cl uster ci rcui t board. Each gi ves an i ndi -
cati on of the di stance the vehi cl e has travel l ed. How-
ever, by depressi ng the reset knob on the face of the
i nstrument cl uster, the di spl ay can be swi tched from
odometer to tri p odometer. Depressi ng the reset knob
for l onger than two seconds whi l e i n the tri p odome-
ter mode wi l l reset the tri p odometer to zero. The
odometer and tri p odometer di spl ay val ues are based
on di stance pul se messages recei ved from the Power-
trai n Control Modul e (PCM) on the Chrysl er Col l i -
The PCM uses an i nput from the Vehi cl e Speed
Sensor (VSS) and i nternal programmi ng to deci de
what di stance pul se si gnal i s requi red. The PCM
then sends the proper message to the i nstrument
cl uster ci rcui try on the CCD data bus. The i nstru-
ment cl uster stores both the odometer and tri p odom-
eter di stance i nformati on and di spl ays the proper
val ue based upon i gni ti on key-on and tri p odometer
reset knob i nputs. The i nstrument cl uster al so stores
the odometer di spl ay mode (odometer or tri p odome-
ter), and wi l l return to the mode that was sel ected
pri or to the i gni ti on swi tch bei ng turned off.
I f the i nstrument cl uster i s not recei vi ng di stance
i nformati on on the CCD data bus when the i gni ti on
swi tch i s turned to the On posi ti on, the odometer di s-
pl ay wi l l remai n bl ank. I f the i nstrument cl uster
does not recei ve a di stance message on the CCD data
bus after the i gni ti on swi tch has been turned to the
On posi ti on, the i nstrument panel ci rcui try wi l l
i nsert the l ast normal l y di spl ayed di stance i n the
odometer di spl ay. I f the i nstrument cl uster i s recei v-
i ng CCD messages, but cannot di spl ay odometer val -
ues due to an i nternal error, the odometer di spl ay
wi l l be bl ank.
The VSS i s a hal l -effect sensor that i s i nstal l ed i n
the transmi ssi on (two-wheel dri ve) or transfer case
(four-wheel dri ve), and i s dri ven by the output shaft
through a speedometer pi ni on gear. I ncorrect ti re
si ze, i ncorrect axl e rati o, a faul ty or i ncorrect speed-
ometer pi ni on gear, or a faul ty VSS can each resul t
i n i naccurate odometer readi ngs. Refer to Group 14 -
Fuel Systems for more i nformati on on the PCM and
the VSS. Refer to Group 21 - Transmi ssi on for more
i nformati on on the speedometer pi ni on gear.
The odometer and tri p odometer can al so be used
to di gi tal l y di spl ay a stored DTC. Refer to Group 25 -
Emi ssi on Control Systems for more i nformati on on
DTCs and thei r retri eval .
OIL PRESSURE GAUGE
The oi l pressure gauge gi ves an i ndi cati on of the
engi ne oi l pressure. The i nstrument cl uster ci rcui try
control s the gauge poi nter posi ti on. The i nstrument
cl uster ci rcui try cal cul ates the proper gauge poi nter
posi ti on based upon an engi ne oi l pressure message
recei ved from the Powertrai n Control Modul e (PCM)
on the Chrysl er Col l i si on Detecti on (CCD) data bus.
The PCM uses an i nput from the engi ne oi l pres-
sure sensor and i nternal programmi ng to deci de
what engi ne oi l pressure message i s requi red. The
PCM then sends the proper message to the i nstru-
ment cl uster on the CCD data bus. I f the PCM mes-
sage i ndi cates that oi l pressure i s l ow, the
i nstrument cl uster ci rcui try moves the gauge needl e
to bel ow the zero graduati on on the gauge face, and
turns on the Check Gauges l amp.
The engi ne oi l pressure sensor i s i nstal l ed i n a
threaded hol e that penetrates an oi l passage of the
engi ne. The engi ne oi l pressure sensor contai ns a
fl exi bl e di aphragm and a vari abl e resi stor coi l . The
di aphragm moves i n response to changes i n the
engi ne oi l pressure, whi ch changes the i nternal el ec-
tri cal resi stance of the sensor. Refer to Group 14 -
the engi ne oi l pressure sensor.
SPEEDOMETER
The speedometer gi ves an i ndi cati on of the current
vehi cl e speed. The i nstrument cl uster ci rcui try con-
trol s the gauge poi nter posi ti on. The i nstrument cl us-
ter ci rcui try cal cul ates the proper gauge poi nter
posi ti on based upon a vehi cl e speed message recei ved
from the Powertrai n Control Modul e (PCM) on the
Chrysl er Col l i si on Detecti on (CCD) data bus.
The PCM uses an i nput from the Vehi cl e Speed
Sensor (VSS) and i nternal programmi ng to deci de
what vehi cl e speed message i s requi red. The PCM
cl uster on the CCD data bus.
The VSS i s a hal l -effect sensor that i s i nstal l ed i n
the transmi ssi on (two-wheel dri ve) or transfer case
(four-wheel dri ve), and i s dri ven by the output shaft
through a speedometer pi ni on gear. I ncorrect ti re
si ze, i ncorrect axl e rati o, a faul ty or i ncorrect speed-
ometer pi ni on gear, or a faul ty VSS can each resul t
i n i naccurate speedometer readi ngs. Refer to Group
14 - Fuel Systems for more i nformati on on the PCM
and the VSS. Refer to Group 21 - Transmi ssi on for
more i nformati on on the speedometer pi ni on gear.
TACHOMETER
The tachometer gi ves an i ndi cati on of the engi ne
speed i n revol uti ons-per-mi nute (RPM). The i nstru-
ment cl uster ci rcui try control s the gauge poi nter
posi ti on. The i nstrument cl uster ci rcui try cal cul ates
the proper gauge poi nter posi ti on based upon an
engi ne speed message recei ved from the Powertrai n
Control Modul e (PCM) on the Chrysl er Col l i si on
Detecti on (CCD) data bus.
The PCM uses an i nput from the crankshaft posi -
ti on sensor and i nternal programmi ng to cal cul ate
what engi ne speed message i s requi red. The PCM
cl uster on the CCD data bus. The crankshaft posi ti on
sensor i s a hal l -effect sensor i nstal l ed near the rear
of the engi ne, where i t i s ai med at the tri gger wheel
attached to the rear fl ange of the crankshaft.
Refer to Group 14 - Fuel Systems for more i nfor-
mati on on the PCM. Refer to Group 8D - I gni ti on
Systems for more i nformati on on the crankshaft posi -
ti on sensor.
VOLTMETER
The vol tmeter gi ves an i ndi cati on of the el ectri cal
system vol tage. The i nstrument cl uster ci rcui try con-
trol s the gauge poi nter posi ti on. The i nstrument cl us-
ter ci rcui try cal cul ates the proper gauge poi nter
posi ti on based upon a system vol tage message
The PCM uses an i nput from the el ectri cal system
and i nternal programmi ng to deci de what system
vol tage message i s requi red. The PCM then sends
CCD data bus.
I f the PCM message i ndi cates that the chargi ng
system has fai l ed, the i nstrument cl uster ci rcui try
moves the gauge needl e to the 9 vol t graduati on on
the gauge face, and turns on the Check Gauges l amp.
I f the PCM message i ndi cates that system vol tage i s
hi gh, the i nstrument cl uster ci rcui try moves the
gauge needl e to the 19 vol t graduati on on the gauge
face, and turns on the Check Gauges l amp.
mati on on the PCM. Refer to Group 8C - Chargi ng
Systems for more i nformati on on chargi ng system
components and di agnosi s.
AIRBAG INDICATOR LAMP
The ai rbag i ndi cator l amp gi ves an i ndi cati on when
the ai rbag system i s faul ty or i noperati ve. The l amp
i s turned on by the i nstrument cl uster ci rcui try for
about seven seconds when the i gni ti on swi tch i s
turned to the On posi ti on as a bul b test. After the
bul b test, the l amp i s control l ed by the i nstrument
cl uster ci rcui try based upon a message recei ved from
the Ai rbag Control Modul e (ACM) on the Chrysl er
Col l i si on Detecti on (CCD) data bus.
The ACM conti nual l y moni tors the ai rbag system
ci rcui ts and sensors to deci de whether the system i s
i n good operati ng condi ti on. The ACM then sends the
proper message to the i nstrument cl uster on the
CCD data bus to turn the l amp on or off. I f the ACM
sends a l amp-on message after the bul b test, i t i ndi -
cates that the ACM has detected a system mal func-
ti on and/or that the ai rbag system has become
i noperati ve.
Each ti me the i nstrument cl uster ci rcui try recei ves
a l amp-on message from the ACM, i t wi l l l i ght the
l amp for twel ve seconds or the durati on of the ai rbag
system mal functi on, whi chever i s l onger. I f the
i nstrument cl uster recei ves no l amp messages from
the ACM for more than fi ve seconds, i t wi l l l i ght the
l amp for twel ve seconds or unti l another l amp-off
message from the ACM, whi chever i s l onger.
Refer to Group 8M - Passi ve Restrai nt Systems for
more i nformati on on the ai rbag system.
ANTI-LOCK BRAKE SYSTEM LAMP
The Anti -Lock Brake System (ABS) l amp gi ves an
i ndi cati on when the ABS system i s faul ty or i noper-
ati ve. The l amp i s hard-wi red i n the i nstrument cl us-
ter, and i s compl etel y control l ed by the Control l er
Anti -l ock Brake (CAB). I t recei ves battery vol tage
through the i nstrument cl uster fused i gni ti on swi tch
output feed ci rcui t, and i s grounded by the CAB. The
l amp i s turned on by the CAB for about two seconds
when the i gni ti on swi tch i s turned to the On posi ti on
as a bul b test. After the bul b test, the CAB turns the
l amp on or off based upon the resul ts of the ABS sys-
tem sel f-tests.
The CAB conti nual l y moni tors the ABS ci rcui ts
and sensors to deci de whether the system i s i n good
operati ng condi ti on. I f the CAB turns the l amp on
after the bul b test, i t i ndi cates that the CAB has
detected a system mal functi on and/or that the ABS
system has become i noperati ve. Refer to Group 5 -
Brakes for more i nformati on.
BRAKE WARNING LAMP
The brake warni ng l amp gi ves an i ndi cati on when
the parki ng brake i s appl i ed, or when the pressures
i n the two hal ves of the spl i t brake hydraul i c system
are unequal . The l amp i s turned on when the i gni -
ti on swi tch i s i n the Start posi ti on as a bul b test.
After the bul b test, the l amp i s control l ed by hard-
wi red i nputs from the parki ng brake swi tch and/or
the brake warni ng swi tch.
The brake warni ng swi tch cl oses to ground when i t
senses unequal hydraul i c pressures i n the two hal ves
of the spl i t brake hydraul i c system, possi bl y due to
l ow brake fl ui d l evel or brake fl ui d l eakage. The
parki ng brake swi tch cl oses to ground when the
parki ng brake i s appl i ed. Refer to Group 5 - Brakes
CHECK GAUGES LAMP
The check gauges l amp gi ves an i ndi cati on when
certai n gauges refl ect a condi ti on requi ri ng i mmedi -
ate attenti on. The l amp i s turned on by the i nstru-
ment cl uster ci rcui try for about three seconds after
the i gni ti on swi tch i s turned to the On posi ti on as a
bul b test. After the bul b test, the l amp i s control l ed
by the i nstrument cl uster ci rcui try based upon gauge
data messages recei ved from the Powertrai n Control
Modul e (PCM) on the Chrysl er Col l i si on Detecti on
(CCD) data bus.
The PCM uses several i nputs to deci de what gauge
data messages are requi red. The PCM then sends the
proper message to the i nstrument cl uster on the
CCD data bus. The gauge data messages for whi ch
the i nstrument cl uster i s programmed to turn on the
check gauges l amp are:
Engi ne cool ant temperature i s hi gh or cri ti cal
Engi ne oi l pressure i s l ow
Chargi ng system fai l ure
System vol tage i s hi gh.
CIGAR LIGHTER AND POWER OUTLET
A ci gar l i ghter and an accessory power outl et are
standard equi pment on thi s model . Power to the
accessory power outl et i s provi ded at al l ti mes,
regardl ess of the i gni ti on swi tch posi ti on. Power to
the ci gar l i ghter i s swi tched by a ci gar l i ghter rel ay,
whi ch i s onl y energi zed when the i gni ti on swi tch i s
i n the Accessory or On posi ti ons.
The ci gar l i ghter and accessory power outl et recep-
tacl es are l ocated i n, and servi ced onl y as a part of,
the accessory swi tch bezel uni t. I f ei ther receptacl e i s
faul ty or damaged, the accessory swi tch bezel must
be repl aced.
CIGAR LIGHTER RELAY
The ci gar l i ghter rel ay i s a I nternati onal Standards
Organi zati on (I SO)-type rel ay. The ci gar l i ghter rel ay
i s a el ectromechani cal devi ce that swi tches fused bat-
tery current to the ci gar l i ghter when the i gni ti on
swi tch i s turned to the Accessory or On posi ti ons. See
the Di agnosi s and Testi ng secti on of thi s group for
more i nformati on on the operati on of the ci gar l i ghter
rel ay.
The ci gar l i ghter rel ay i s l ocated i n the juncti on
bl ock, on the ri ght cowl si de panel bel ow the i nstru-
ment panel i n the passenger compartment. The ci gar
l i ghter rel ay cannot be repai red and, i f faul ty or
CLUSTER ILLUMINATION LAMP
The cl uster i l l umi nati on l amps are hard-wi red i n
the i nstrument cl uster. When the park or head l amps
are turned on, the cl uster i l l umi nati on l amps l i ght.
I l l umi nati on bri ghtness i s adjusted by rotati ng the
headl amp swi tch knob (cl ockwi se to di m, counter-
cl ockwi se to bri ghten). The i nstrument cl uster i l l umi -
nati on l amps recei ve battery feed from the panel
di mmer rheostat i n the headl amp swi tch through a
fuse i n the juncti on bl ock.
Each of the i l l umi nati on l amps i s l ocated on the
i nstrument cl uster ci rcui t board. Each l amp has a
repl aceabl e bul b and bul b hol der. Refer to Group 8L -
Lamps for more i nformati on.
COOLANT TEMPERATURE WARNING LAMP
The cool ant temperature warni ng l amp gi ves an
i ndi cati on when the engi ne cool ant temperature i s
hi gh. The l amp i s turned on by the i nstrument cl us-
ter ci rcui try for about three seconds after the i gni ti on
swi tch i s turned to the On posi ti on as a bul b test.
After the bul b test, the l amp i s control l ed by the
i nstrument cl uster ci rcui try based upon an engi ne
cool ant temperature message recei ved from the Pow-
ertrai n Control Modul e (PCM) on the Chrysl er Col l i -
The PCM uses an i nput from the engi ne cool ant
temperature sensor and i nternal programmi ng to
deci de what engi ne cool ant temperature message i s
requi red. The PCM then sends the proper message to
the i nstrument cl uster on the CCD data bus. I f the
PCM message i ndi cates that cool ant temperature i s
hi gh, the i nstrument cl uster ci rcui try turns on the
cool ant temperature warni ng l amp and generates a
si ngl e chi me tone.
i n a threaded hol e that penetrates a cool ant passage
of the engi ne. I t i s a thermi stor-type sensor that
changes i ts i nternal resi stance wi th changes i n
engi ne cool ant temperature. Refer to Group 14 - Fuel
cool ant temperature sensor.
CRUISE-ON INDICATOR LAMP
The crui se-on i ndi cator l amp gi ves an i ndi cati on
when the vehi cl e speed control system i s turned on,
even when the system i s not currentl y engaged. The
l amp i s control l ed by the i nstrument cl uster ci rcui try
based upon a message recei ved from the Powertrai n
Control Modul e (PCM) on the Chrysl er Col l i si on
Detecti on (CCD) data bus.
The PCM uses an i nput from the anal og resi stor-
mul ti pl exed vehi cl e speed control swi tches i n the
steeri ng wheel to deci de whether to turn the l amp on
or off. The PCM then sends the proper message to
the i nstrument cl uster on the CCD data bus. Refer to
Group 8H - Vehi cl e Speed Control System for more
i nformati on.
FOUR-WHEEL DRIVE INDICATOR LAMP
PART TIME
On vehi cl es wi th the opti onal Command-Trac four-
wheel dri ve system, the Part Ti me i ndi cator l amp
l i ghts when the transfer case i s engaged i n the 4H or
4L posi ti ons. On vehi cl es wi th the opti onal Sel ec-Trac
four-wheel dri ve system, the Part Ti me i ndi cator
l amp l i ghts when the transfer case i s engaged i n the
4 X 4 Part Ti me or 4 Lo posi ti ons.
When the i gni ti on swi tch i s i n the On posi ti on, bat-
tery vol tage i s suppl i ed to one si de of the i ndi cator
l amp bul b. A normal l y-open, pl unger-type, four-wheel
dri ve swi tch threaded i nto the transfer case i s hard-
wi red i n seri es between the other si de of the i ndi ca-
tor l amp bul b and ground. When the transfer case i s
shi fted i nto the proper posi ti on, the pl unger of the
four-wheel dri ve swi tch i s moved, cl osi ng the swi tch
and provi di ng a path to ground. Thi s causes the Part
Ti me i ndi cator l amp bul b to l i ght.
Refer to Group 21 - Transmi ssi on for more i nfor-
mati on on the transfer case shi ft mechani sm.
FULL TIME
The Ful l Ti me i ndi cator l amp i s onl y operati onal
on vehi cl es equi pped wi th the opti onal Sel ec-Trac
four-wheel dri ve system. The Ful l Ti me i ndi cator
l amp l i ghts when the transfer case i s engaged i n the
4 X 4 Ful l Ti me posi ti on.
When the i gni ti on swi tch i s i n the On posi ti on, bat-
tery vol tage i s suppl i ed to one si de of the i ndi cator
l amp bul b. A normal l y-open, pl unger-type, four-wheel
dri ve swi tch threaded i nto the transfer case i s hard-
wi red i n seri es between the other si de of the i ndi ca-
tor l amp bul b and ground. When the transfer case i s
shi fted i nto the proper posi ti on, the pl unger of the
four-wheel dri ve swi tch i s moved, cl osi ng the swi tch
and provi di ng a path to ground. Thi s causes the Ful l
Ti me i ndi cator l amp bul b to l i ght.
Refer to Group 21 - Transmi ssi on for more i nfor-
mati on on the transfer case shi ft mechani sm.
HEADLAMP HIGH BEAM INDICATOR LAMP
The headl amp hi gh beam i ndi cator l amp gi ves an
i ndi cati on when the headl amp hi gh beams are turned
on. The l amp i s control l ed by a hard-wi red i nput
from the headl amp di mmer (mul ti -functi on) swi tch.
One si de of the i ndi cator bul b i s grounded at al l
ti mes. The other si de of the bul b recei ves a battery
feed through the contacts of the di mmer swi tch when
the mul ti -functi on swi tch stal k i s actuated to turn on
the headl amp hi gh beams. Refer to Group 8L -
Lamps for more i nformati on.
LOW FUEL WARNING LAMP
The l ow fuel warni ng l amp gi ves an i ndi cati on
when the fuel l evel i n the fuel tank has fal l en bel ow
about one-ei ghth of a ful l tank, as regi stered on the
fuel gauge. The i nstrument cl uster ci rcui try l i ghts
the l amp for about three seconds when the i gni ti on
After the bul b test, the i nstrument cl uster ci rcui try
control s the l amp based upon a fuel l evel message
The PCM uses an i nput from the fuel gauge send-
i ng uni t and i nternal programmi ng to deci de what
fuel l evel message i s requi red. The PCM then sends
CCD data bus. I f the PCM message i ndi cates that
the fuel l evel i s bel ow one-ei ghth of a ful l tank for
more than ten seconds, the i nstrument cl uster ci r-
cui try turns on the l ow fuel warni ng l amp and gen-
erates a si ngl e chi me tone. Once the l amp i s turned
on, an i ncrease i n the fuel l evel message of at l east
one ful l needl e wi dth for more than twenty seconds i s
requi red before the cl uster wi l l turn the l amp off.
The fuel gauge sendi ng uni t i s mounted to the el ec-
tri c fuel pump modul e i nsi de the fuel tank. The send-
i ng uni t has a fl oat attached to the end of a swi ng-
arm. The fl oat moves up or down wi thi n the fuel
tank as the fuel l evel changes. As the fl oat moves, an
el ectri cal contact on the pi vot end of the swi ng-arm
wi pes across a resi stor coi l , whi ch changes the resi s-
tance of the sendi ng uni t. Refer to Group 14 - Fuel
fuel gauge sendi ng uni t.
LOW OIL PRESSURE WARNING LAMP
The l ow oi l pressure warni ng l amp gi ves an i ndi ca-
ti on when the engi ne oi l pressure i s l ow. The l amp i s
turned on by the i nstrument cl uster ci rcui try for
about three seconds after the i gni ti on swi tch i s
turned to the On posi ti on as a bul b test. After the
bul b test, the l amp i s control l ed by the i nstrument
cl uster ci rcui try based upon an engi ne oi l pressure
message recei ved from the Powertrai n Control Mod-
ul e (PCM) on the Chrysl er Col l i si on Detecti on (CCD)
data bus.
The PCM uses an i nput from the engi ne oi l pres-
sure sensor and i nternal programmi ng to deci de
what engi ne oi l pressure message i s requi red. The
PCM then sends the proper message to the i nstru-
ment cl uster on the CCD data bus. I f the PCM mes-
sage i ndi cates that oi l pressure i s l ow, the
i nstrument cl uster ci rcui try turns on the l ow oi l pres-
sure warni ng l amp.
The engi ne oi l pressure sensor i s i nstal l ed i n a
threaded hol e that penetrates an oi l passage of the
engi ne. The engi ne oi l pressure sensor contai ns a
fl exi bl e di aphragm and a vari abl e resi stor coi l . The
di aphragm moves i n response to changes i n the
engi ne oi l pressure, whi ch changes the i nternal el ec-
tri cal resi stance of the sensor. Refer to Group 14 -
the engi ne oi l pressure sensor.
LOW WASHER FLUID WARNING LAMP
The l ow washer fl ui d warni ng l amp gi ves an i ndi -
cati on when the fl ui d l evel i n the washer fl ui d reser-
voi r i s too l ow. The i nstrument cl uster ci rcui try
control s the l amp based upon a hard-wi red i nput
from the washer fl ui d l evel sensor.
The washer fl ui d l evel sensor uses a fl oat i n the
reservoi r to moni tor the fl ui d l evel . The up and down
acti on of the fl oat opens or cl oses the swi tch wi thi n
the washer fl ui d l evel sensor that provi des a ground
si gnal to the i nstrument cl uster ci rcui try.
I f the i nstrument cl uster ci rcui try senses a ground
i nput from the washer fl ui d l evel sensor for more
than about thi rty seconds, i t turns on the l ow washer
fl ui d warni ng l amp. Thi s hel ps to reduce the effects
of fl ui d sl oshi ng wi thi n the reservoi r. Thi s l amp al so
l atches. Once the l amp has been turned on, i t wi l l
remai n on unti l washer fl ui d i s added to the reser-
voi r and the i gni ti on swi tch i s cycl ed.
Refer to Group 8K - Wi per and Washer Systems for
more i nformati on on the washer fl ui d l evel sensor.
MALFUNCTION INDICATOR LAMP
The Check Engi ne or Mal functi on I ndi cator Lamp
(MI L) gi ves an i ndi cati on when the Powertrai n Con-
trol Modul e (PCM) has recorded a Di agnosti c Troubl e
Code (DTC) for an On-Board Di agnosti cs I I (OBDI I )
emi ssi ons-rel ated ci rcui t or component mal functi on.
The l amp i s control l ed by the i nstrument cl uster ci r-
cui try based upon messages recei ved from the PCM
The PCM sends a l amp-on message for about three
seconds when the i gni ti on swi tch i s turned to the On
posi ti on as a bul b test.
Fol l owi ng the bul b test, the PCM uses i nputs from
many emi ssi ons-rel ated ci rcui ts and sensors, al ong
wi th i ts i nternal programmi ng, to deci de whether a
condi ti on exi sts that requi res the MI L l amp to be
turned on. The PCM then sends the proper message
to the i nstrument cl uster on the CCD data bus to
turn the l amp on or off.
The MI L l amp can al so be used to di spl ay a stored
DTC by fl ashi ng on and off. Refer to Group 14 - Fuel
Systems for more i nformati on on the PCM or the
PCM i nputs. Refer to Group 25 - Emi ssi on Control
Systems for more i nformati on on DTCs and thei r
retri eval .
SEAT BELT REMINDER LAMP
The seat bel t remi nder l amp gi ves a vi sual
remi nder to the vehi cl e occupants to fasten thei r seat
bel ts. The l amp i s turned on by the i nstrument cl us-
ter ci rcui try for about seven seconds when the i gni -
ti on swi tch i s turned to the On posi ti on. The
i nstrument cl uster al so recei ves a hard-wi red i nput
from the dri ver seat bel t swi tch. I f the dri ver seat
bel t swi tch i s cl osed (seat bel t i s not buckl ed), the
i nstrument cl uster wi l l generate a chi me warni ng for
the durati on of the seat bel t remi nder l amp i l l umi na-
ti on. The chi me warni ng wi l l stop when the dri ver
seat bel t swi tch i s open (seat bel t i s buckl ed).
Refer to Group 8U - Chi me/Buzzer Warni ng Sys-
tems for more i nformati on on the dri ver seat bel t
swi tch.
TURN SIGNAL INDICATOR LAMP
The l eft and ri ght turn si gnal i ndi cator l amps gi ve
an i ndi cati on when the turn si gnal ci rcui ts are acti -
vated. The l amps are hard-wi red i n the i nstrument
cl uster, and are compl etel y control l ed by the turn si g-
nal and hazard warni ng (mul ti -functi on) swi tches.
The i ndi cator l amps are grounded at al l ti mes and
recei ve battery feed through the contacts of the
mul ti -functi on swi tch when the turn si gnal l ever
(mul ti -functi on swi tch stal k) or hazard warni ng but-
ton are actuated to the On posi ti on. The i nstrument
cl uster ci rcui try does not perform a bul b test of these
l amps. Refer to Group 8J - Turn Si gnal and Hazard
Warni ng Systems for more i nformati on.
UPSHIFT INDICATOR LAMP
Vehi cl es equi pped wi th a manual transmi ssi on
have an upshi ft i ndi cator l amp. The upshi ft i ndi cator
l amp gi ves an i ndi cati on when the dri ver shoul d shi ft
to the next hi ghest gear for the best fuel economy.
The l amp i s control l ed by the i nstrument cl uster ci r-
cui try based upon a message recei ved from the Pow-
ertrai n Control Modul e (PCM) on the Chrysl er
Col l i si on Detecti on (CCD) data bus.
The PCM uses i nputs from many sensors and i ts
i nternal programmi ng to deci de whether the engi ne
speed and l oad condi ti ons are correct for a transmi s-
si on upshi ft. The PCM then sends the proper mes-
sage to the i nstrument cl uster on the CCD data bus
to turn the l amp on or off. The PCM wi l l send a
l amp-off message three to fi ve seconds after a
l amp-on message, i f an upshi ft i s not performed. The
l amp wi l l then remai n off unti l the vehi cl e stops
accel erati ng and i s brought back i nto the range of
l amp operati on, or unti l the transmi ssi on i s shi fted
i nto another gear. Refer to Group 14 - Fuel Systems
for more i nformati on on the PCM and the PCM
i nputs.
VOLTAGE WARNING LAMP
The vol tage warni ng l amp gi ves an i ndi cati on
when the el ectri cal system vol tage i s too l ow or too
hi gh. The l amp i s turned on by the i nstrument cl us-
ter ci rcui try for about three seconds after the i gni ti on
After the bul b test, the l amp i s control l ed by the
i nstrument cl uster ci rcui try based upon a system
vol tage message recei ved from the Powertrai n Con-
trol Modul e (PCM) on the Chrysl er Col l i si on Detec-
ti on (CCD) data bus.
The PCM uses an i nput from the el ectri cal system
and i nternal programmi ng to deci de what system
vol tage message i s requi red. The PCM then sends
CCD data bus. I f the PCM message i ndi cates that
the chargi ng system i s too l ow or too hi gh, the
i nstrument cl uster ci rcui try turns on the vol tage
warni ng l amp.
mati on on the PCM. Refer to Group 8C - Chargi ng
Systems for more i nformati on on chargi ng system
components and di agnosi s.
INSTRUMENT CLUSTER
I f al l of the gauges and/or i ndi cator l amps are i nop-
erati ve, perform the Prel i mi nary Di agnosi s. I f an
i ndi vi dual gauge or Chrysl er Col l i si on Detecti on
(CCD) data bus message-control l ed i ndi cator l amp i s
i noperati ve, go di rectl y to the Actuator Test. I f an
i ndi vi dual hard-wi red i ndi cator l amp i s i noperati ve,
go di rectl y to the di agnosi s for that l amp. For ci rcui t
descri pti ons and di agrams, refer to 8W-40 - I nstru-
ment Cl uster i n Group 8W - Wi ri ng Di agrams.
INJURY.
PRELIMINARY DIAGNOSIS
(1) I f the i ndi cator l amps operate, but none of the
gauges operate, go to Step 2. I f al l of the gauges and
the data bus message-control l ed i ndi cator l amps are
i noperati ve, go to Step 5.
(2) Check the I gni ti on-Off Draw (I OD) fuse i n the
Power Di stri buti on Center (PDC). I f OK, go to Step
3. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(3) Check for battery vol tage at the I OD fuse i n
the PDC. I f OK, go to Step 4. I f not OK, repai r the
open ci rcui t as requi red.
cabl e. Remove the i nstrument cl uster as descri bed i n
thi s group. Connect the battery negati ve cabl e. Check
for battery vol tage at the fused B(+) ci rcui t cavi ty of
the l eft i nstrument cl uster wi re harness connector
(connector A). I f OK, go to the Actuator Test. I f not
OK, repai r the open ci rcui t to the I OD fuse as
requi red.
(5) Check the swi tched i gni ti on fuse i n the junc-
ti on bl ock. I f OK, go to Step 6. I f not OK, repai r the
shorted ci rcui t or component as requi red and repl ace
the faul ty fuse.
(6) Turn the i gni ti on swi tch to the On posi ti on and
check for battery vol tage at the swi tched i gni ti on
fuse i n the juncti on bl ock. I f OK, go to Step 7. I f not
OK, repai r the open ci rcui t to the i gni ti on swi tch as
requi red.
Di sconnect and i sol ate the battery negati ve cabl e.
Rei nstal l the i nstrument cl uster. Connect the battery
negati ve cabl e. Turn the i gni ti on swi tch to the On
posi ti on. Set the parki ng brake. The brake warni ng
l amp shoul d l i ght. I f OK, go to Step 8. I f not OK, go
to Step 9.
Turn on the park l amps and adjust the panel l amps
di mmer rheostat to the ful l bri ght posi ti on. The cl us-
ter i l l umi nati on l amps shoul d l i ght. I f OK, go to the
Actuator Test. I f not OK, go to Step 10.
Remove the i nstrument cl uster as descri bed i n thi s
group. Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on. Check for battery
vol tage at the fused i gni ti on swi tch output (run/start)
ci rcui t cavi ty of the l eft i nstrument cl uster wi re har-
ness connector (connector A). I f OK, go to the Actua-
tor Test. I f not OK, repai r the open ci rcui t to the
juncti on bl ock as requi red.
thi s group. Check for conti nui ty between the ground
ci rcui t cavi ty of the l eft i nstrument cl uster wi re har-
ness connector (connector A) and a good ground.
There shoul d be conti nui ty. I f OK, go to the Actuator
Test. I f not OK, repai r the open ci rcui t to ground as
requi red.
ACTUATOR TEST
The i nstrument cl uster actuator test wi l l put the
cl uster i nto i ts sel f-di agnosti c mode. I n thi s mode the
cl uster wi l l posi ti on each of the gauge needl es at var-
i ous speci fi ed cal i brati on poi nts, and turn al l of the
CCD data bus message-control l ed l amps on and off at
speci fi ed ti me i nterval s (Fi g. 1) or (Fi g. 2).
Successful compl eti on of the actuator test wi l l con-
fi rm that the cl uster ci rcui try, gauges, and l amps are
capabl e of operati ng as desi gned. However, there may
sti l l be a probl em wi th the CCD data bus, the Pow-
ertrai n Control Modul e (PCM), the Ai rbag Control
Modul e (ACM), or the i nputs to one of these modul es.
Use a DRB scan tool and the proper Di agnosti c Pro-
cedures manual for testi ng of these components.
I f an i ndi vi dual gauge does not respond properl y or
at al l duri ng the Actuator Test, the i nstrument cl us-
ter shoul d be removed. However, check the gauge
mounti ng screws on the pri nted ci rcui t board for
proper ti ghtness before consi deri ng i nstrument cl us-
ter repl acement. I f the mounti ng screws check OK,
repl ace the faul ty cl uster.
I f an i ndi vi dual i ndi cator l amp does not i l l umi nate
duri ng the Actuator Test, the i nstrument cl uster
shoul d be removed. However, check that the i ncan-
descent l amp bul b i s not faul ty and that the bul b
hol der i s properl y i nstal l ed on the ci rcui t board
before consi deri ng i nstrument cl uster repl acement. I f
the bul b and bul b hol der check OK, repl ace the
faul ty i nstrument cl uster.
(1) Begi n the test wi th the i gni ti on swi tch i n the
Off posi ti on.
(2) Depress the tri p odometer reset button.
(3) Whi l e hol di ng the tri p odometer reset button
depressed, turn the i gni ti on swi tch to the On posi -
ti on, but do not start the engi ne.
(4) Rel ease the tri p odometer reset button.
(5) Compare the operati on of the suspect gauge(s)
and/or l amp(s) wi th the chart (Fi g. 1) or (Fi g. 2).
(6) The cl uster wi l l exi t the sel f-di agnosti c mode at
the compl eti on of the test, or i f the i gni ti on swi tch i s
turned to the Off posi ti on.
(7) Go back to Step 1 to repeat the test, i f
requi red.
COOLANT TEMPERATURE GAUGE
I f the probl em bei ng di agnosed i s rel ated to cool ant
temperature gauge accuracy, be certai n to confi rm
that the probl em i s wi th the gauge and not wi th cool -
i ng system performance. The actual engi ne cool ant
temperature shoul d be checked wi th a test gauge or
thermometer and compared to the i nstrument cl uster
cool ant temperature gauge readi ngs before you pro-
Fig. 1 Low-Line Instrument Cluster Actuator Test
AIRBAG SEAT BELT UPSHIFT CHECK ENGINE (MIL) CRUISE ON LOW WASHER LOW OIL PRESSURE WARNING BATTERY WARNING COOLANT TEMPERATURE WARNING SPEEDOMETER (MILES PER HOUR) (KILOMETERS PER HOUR) FUEL ODOMETER 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC.
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
COMPLETE DIAGNOSTICS START DIAGNOSTICS NOTE: 1.5 SECONDS AFTER COMPLETING TEST, ALL POINTERS SHOULD RETURN TO POINTER STOP AND ODOMETER SHOULD BE TURNED OFF.
Fig. 2 High-Line Instrument Cluster Actuator Test
LOW FUEL WARNING AIRBAG SEAT BELT UPSHIFT CHECK ENGINE (MIL) CHECK GAUGES CRUISE ON LOW WASHER SPEEDOMETER (MILES PER HOUR POLICE ONLY) (MILES PER HOUR EXCEPT POLICE) (KILOMETERS PER HOUR) TACHOMETER FUEL TEMPERATURE OIL VOLT ODOMETER 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC. 2 SEC.
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
COMPLETE DIAGNOSTICS START DIAGNOSTICS NOTE: 1.5 SECONDS AFTER COMPLETING TEST, ALL POINTERS SHOULD RETURN TO POINTER STOP AND ODOMETER SHOULD BE TURNED OFF.
ceed wi th gauge di agnosi s. Refer to Group 7 - Cool i ng
System for more i nformati on. Refer to Group 8W -
Wi ri ng Di agrams for ci rcui t descri pti ons and di a-
grams.
INJURY.
Di agnosi s of the cool ant temperature sensor and
ci rcui t, the Chrysl er Col l i si on Detecti on (CCD) data
bus, and/or the Powertrai n Control Modul e (PCM)
shoul d be performed wi th a DRB scan tool as
descri bed i n the proper Di agnosti c Procedures man-
ual . For di agnosi s of the cool ant temperature gauge
and the i nstrument cl uster ci rcui try, see I nstrument
Cl uster i n thi s group.
FUEL GAUGE
I f the probl em bei ng di agnosed i s rel ated to fuel
gauge accuracy, be certai n to confi rm that the prob-
l em i s wi th the gauge or sendi ng uni t and not wi th
the fuel tank. I nspect the fuel tank for si gns of dam-
age or di storti on that coul d affect the sendi ng uni t
performance before you proceed wi th fuel gauge di ag-
nosi s. Refer to Group 8W - Wi ri ng Di agrams for ci r-
cui t descri pti ons and di agrams.
INJURY.
Di agnosi s of the fuel gauge sendi ng uni t and ci r-
cui t, the Chrysl er Col l i si on Detecti on (CCD) data
bus, and/or the Powertrai n Control Modul e (PCM)
ual . For di agnosi s of the fuel gauge and the i nstru-
ment cl uster ci rcui try, see I nstrument Cl uster i n thi s
group.
ODOMETER AND TRIP ODOMETER
I f the probl em bei ng di agnosed i s rel ated to odom-
eter and/or tri p odometer accuracy, be certai n to con-
fi rm that the probl em i s wi th the di spl ay and not
wi th an i ncorrect speedometer pi ni on gear, axl e rati o,
or ti re si ze. Refer to Group 21 - Transmi ssi on for
more i nformati on on the speedometer pi ni on gear.
Refer to Group 8W - Wi ri ng Di agrams for ci rcui t
descri pti ons and di agrams.
INJURY.
Di agnosi s of the vehi cl e speed sensor and ci rcui t,
the Chrysl er Col l i si on Detecti on (CCD) data bus,
and/or the Powertrai n Control Modul e (PCM) shoul d
be performed wi th a DRB scan tool as descri bed i n
the proper Di agnosti c Procedures manual . For di ag-
nosi s of the odometer and/or tri p odometer and the
i nstrument cl uster ci rcui try, see I nstrument Cl uster
i n thi s group.
OIL PRESSURE GAUGE
I f the probl em bei ng di agnosed i s rel ated to oi l
pressure gauge accuracy, be certai n to confi rm that
the probl em i s wi th the gauge and not wi th the
engi ne oi l i ng system performance. The actual engi ne
oi l pressure shoul d be checked wi th a test gauge and
compared to the i nstrument cl uster oi l pressure
gauge readi ngs before you proceed wi th gauge di ag-
nosi s. Refer to Group 9 - Engi nes for more i nforma-
ti on. Refer to Group 8W - Wi ri ng Di agrams for ci rcui t
INJURY.
Di agnosi s of the oi l pressure sensor and ci rcui t, the
Chrysl er Col l i si on Detecti on (CCD) data bus, and/or
the Powertrai n Control Modul e (PCM) shoul d be per-
formed wi th a DRB scan tool as descri bed i n the
proper Di agnosti c Procedures manual . For di agnosi s
of the oi l pressure gauge and the i nstrument cl uster
ci rcui try, see I nstrument Cl uster i n thi s group.
SPEEDOMETER
I f the probl em bei ng di agnosed i s rel ated to speed-
ometer accuracy, be certai n to confi rm that the prob-
l em i s wi th the speedometer gauge and not wi th an
i ncorrect speedometer pi ni on gear, axl e rati o, or ti re
si ze. Refer to Group 21 - Transmi ssi on for more i nfor-
mati on on the speedometer pi ni on gear. Refer to
Group 8W - Wi ri ng Di agrams for ci rcui t descri pti ons
and di agrams.
INJURY.
Di agnosi s of the vehi cl e speed sensor and ci rcui t,
the Chrysl er Col l i si on Detecti on (CCD) data bus,
and/or the Powertrai n Control Modul e (PCM) shoul d
be performed wi th a DRB scan tool as descri bed i n
the proper Di agnosti c Procedures manual . For di ag-
nosi s of the speedometer and the i nstrument cl uster
ci rcui try, see I nstrument Cl uster i n thi s group.
TACHOMETER
INJURY.
descri pti ons and di agrams. Di agnosi s of the crank-
shaft posi ti on sensor and ci rcui t, the Chrysl er Col l i -
si on Detecti on (CCD) data bus, and/or the Powertrai n
Control Modul e (PCM) shoul d be performed wi th a
DRB scan tool as descri bed i n the proper Di agnosti c
Procedures manual . For di agnosi s of the tachometer
VOLTMETER
I f the probl em bei ng di agnosed i s rel ated to vol t-
meter gauge accuracy, be certai n to confi rm proper
chargi ng system operati on before consi deri ng i nstru-
ment cl uster repl acement. Refer to Group 8C -
Chargi ng System for more i nformati on. Refer to
Group 8W - Wi ri ng Di agrams for ci rcui t descri pti ons
and di agrams.
INJURY.
Di agnosi s of the system vol tage i nput ci rcui t, the
Chrysl er Col l i si on Detecti on (CCD) data bus, and/or
the Powertrai n Control Modul e (PCM) shoul d be per-
formed wi th a DRB scan tool as descri bed i n the
proper Di agnosti c Procedures manual . For di agnosi s
of the vol tmeter and the i nstrument cl uster ci rcui try,
see I nstrument Cl uster i n thi s group.
AIRBAG INDICATOR LAMP
The di agnosi s found here addresses an i noperati ve
ai rbag i ndi cator l amp condi ti on. I f the ai rbag i ndi ca-
tor l amp stays on wi th the i gni ti on swi tch i n the On
posi ti on, or comes on and stays on whi l e dri vi ng,
refer to Group 8M - Passi ve Restrai nt Systems for
di agnosi s. For ci rcui t descri pti ons and di agrams,
refer to 8W-40 - I nstrument Cl uster, and 8W-43 - Ai r-
bag System i n Group 8W - Wi ri ng Di agrams.
INJURY.
I f the ai rbag i ndi cator l amp fai l s to l i ght when the
i gni ti on swi tch i s turned to the On posi ti on, repl ace
the ai rbag i ndi cator l amp bul b wi th a known good
uni t. I f the ai rbag i ndi cator l amp sti l l fai l s to oper-
ate, di agnosi s of the ai rbag l amp and the i nstrument
cl uster ci rcui try shoul d be performed as descri bed i n
I nstrument Cl uster i n thi s group. I f the ai rbag l amp
and i nstrument cl uster ci rcui try are OK, di agnosi s of
the ai rbag system and the CCD data bus shoul d be
performed wi th a DRB scan tool as descri bed i n the
proper Di agnosti c Procedures manual .
ANTI-LOCK BRAKE SYSTEM LAMP
Anti -l ock Brake System (ABS) l amp condi ti on. I f the
ABS l amp stays on wi th the i gni ti on swi tch i n the
On posi ti on, or comes on and stays on whi l e dri vi ng,
refer to Group 5 - Brakes for di agnosi s. I f no ABS
probl em i s found, the fol l owi ng procedure wi l l hel p
l ocate a short or open i n the ABS l amp ci rcui t. For
ci rcui t descri pti ons and di agrams, refer to 8W-40 -
I nstrument Cl uster, and 8W-35 - Al l -Wheel Anti -Lock
Brakes i n Group 8W - Wi ri ng Di agrams.
INJURY.
(1) Check the fuse i n the juncti on bl ock. I f OK, go
to Step 2. I f not OK, repai r the shorted ci rcui t or
component as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch i n the On posi ti on.
Check for battery vol tage at the fuse i n the juncti on
bl ock. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the i gni ti on swi tch as requi red.
group. Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the On posi ti on and wi thi n fi ve
seconds check for conti nui ty between the ABS warn-
i ng l amp dri ver ci rcui t cavi ty of the l eft i nstrument
cl uster wi re harness connector (connector A) and a
good ground. There shoul d be conti nui ty for fi ve sec-
onds after i gni ti on On, and then an open ci rcui t. I f
OK, repl ace the faul ty bul b. I f not OK, go to Step 4.
Di sconnect the Control l er Anti -l ock Brake (CAB) wi re
harness connector. Check for conti nui ty between the
ABS warni ng l amp dri ver ci rcui t cavi ty of the l eft
i nstrument cl uster wi re harness connector (connector
A) and a good ground. There shoul d be no conti nui ty.
I f OK, go to Step 5. I f not OK, repai r the short ci rcui t
as requi red.
(5) Check for conti nui ty between the ABS warni ng
l amp dri ver ci rcui t cavi ti es of the l eft i nstrument
cl uster wi re harness connector (connector A) and the
CAB wi re harness connector. There shoul d be conti -
nui ty. I f OK, refer to Group 5 - Brakes for di agnosi s
of the CAB. I f not OK, repai r the open ci rcui t as
requi red.
BRAKE WARNING LAMP
brake warni ng l amp condi ti on. I f the brake warni ng
l amp stays on wi th the i gni ti on swi tch i n the On
posi ti on and the parki ng brake rel eased, or comes on
whi l e dri vi ng, refer to Group 5 - Brakes for di agnosi s.
I f no servi ce brake or parki ng brake probl em i s
found, the fol l owi ng procedure wi l l hel p l ocate a
short or open ci rcui t, or a faul ty swi tch. Refer to
8W-40 - I nstrument Cl uster, and 8W-35 - Al l -Wheel
Anti -Lock Brakes i n Group 8W - Wi ri ng Di agrams for
ci rcui t descri pti ons and di agrams.
INJURY.
(2) Turn the i gni ti on swi tch to the On posi ti on.
Unpl ug the wi re harness connector at the park brake
swi tch. Wi th the park brake rel eased, check for con-
ti nui ty between the park brake swi tch termi nal and
a good ground. There shoul d be no conti nui ty. I f OK,
go to Step 4. I f not OK, adjust or repl ace the faul ty
park brake swi tch.
(4) Unpl ug the wi re harness connector at the
brake warni ng swi tch. Check for conti nui ty between
the two termi nal s of the brake warni ng swi tch. There
shoul d be conti nui ty. I f OK, go to Step 5. I f not OK,
repl ace the faul ty brake warni ng swi tch.
(5) Check for conti nui ty between each of the two
brake warni ng swi tch termi nal s and a good ground.
I n each case, there shoul d be no conti nui ty. I f OK, go
to Step 6. I f not OK, repl ace the faul ty brake warn-
i ng swi tch.
(6) Wi th both the park brake swi tch and the brake
warni ng swi tch wi re harness connectors sti l l
unpl ugged, check for conti nui ty between the park
brake swi tch wi re harness connector cavi ty and a
good ground. There shoul d be no conti nui ty. I f OK, go
to Step 7. I f not OK, repai r the short ci rcui t as
requi red.
(7) Wi th the i gni ti on swi tch hel d i n the Start posi -
ti on, check for conti nui ty between the park brake
swi tch wi re harness connector cavi ty and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
8. I f not OK, refer to Group 8D - I gni ti on Systems for
di agnosi s of the i gni ti on swi tch.
group. Check for conti nui ty between the red brake
warni ng l amp dri ver ci rcui t cavi ty of the l eft i nstru-
ment cl uster wi re harness connector (connector A)
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 9. I f not OK, repai r the short ci rcui t
as requi red.
(9) Check for conti nui ty between the red brake
warni ng l amp dri ver (G99) ci rcui t cavi ti es of the l eft
i nstrument cl uster wi re harness connector (connector
A) and the brake warni ng swi tch wi re harness con-
nector. There shoul d be conti nui ty. I f OK, repl ace the
faul ty bul b. I f not OK, repai r the open ci rcui t as
requi red.
CHECK GAUGES LAMP
check gauges l amp condi ti on. I f the check gauges
l amp stays on wi th the i gni ti on swi tch i n the On
posi ti on, or comes on whi l e dri vi ng wi th no unusual
gauge readi ngs evi dent, di agnosi s of the Powertrai n
Control Modul e (PCM) and the Chrysl er Col l i si on
Detecti on (CCD) data bus shoul d be performed wi th
a DRB scan tool as descri bed i n the proper Di agnos-
ti c Procedures manual . For ci rcui t descri pti ons and
di agrams, refer to 8W-40 - I nstrument Cl uster i n
Group 8W - Wi ri ng Di agrams.
INJURY.
I f the check gauges l amp fai l s to l i ght duri ng the
bul b test (about three seconds after the i gni ti on
swi tch i s turned to the On posi ti on), repl ace the
check gauges l amp bul b wi th a known good uni t. I f
the cool ant temperature gauge, oi l pressure gauge, or
vol tmeter are gi vi ng an i ndi cati on that shoul d tri gger
the check gauges l amp, but the check gauges l amp
sti l l fai l s to operate, see I nstrument Cl uster i n thi s
group for di agnosi s of the check gauges l amp and the
i nstrument cl uster ci rcui try.
CIGAR LIGHTER AND POWER OUTLET
INJURY.
ACCESSORY POWER OUTLET
(2) Check for battery vol tage at the fuse i n the
juncti on bl ock. I f OK, go to Step 3. I f not OK, repai r
the open ci rcui t to the Power Di stri buti on Center
(PDC) as requi red.
cabl e. Remove the accessory swi tch bezel as
descri bed i n thi s group. Check for conti nui ty between
the ground ci rcui t cavi ty of the accessory power out-
l et wi re harness connector and a good ground. There
repai r the open ci rcui t to ground as requi red.
(4) Connect the battery negati ve cabl e. Check for
battery vol tage at the fused B(+) ci rcui t cavi ty of the
accessory power outl et wi re harness connector. I f OK,
repl ace the faul ty accessory swi tch bezel . I f not OK,
repai r the open ci rcui t to the juncti on bl ock fuse as
requi red.
CIGAR LIGHTER
cabl e. Remove the accessory swi tch bezel as
the ground ci rcui t cavi ty of the ci gar l i ghter wi re
harness connector and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 2. I f not OK, repai r
the open ci rcui t to ground as requi red.
(2) Connect the battery negati ve cabl e. Turn the
i gni ti on swi tch to the Accessory or On posi ti ons.
Check for battery vol tage at the ci gar l i ghter rel ay
output ci rcui t cavi ty of the ci gar l i ghter wi re harness
connector. I f OK, repl ace the faul ty accessory swi tch
bezel . I f not OK, see the di agnosi s for the ci gar
l i ghter rel ay i n thi s group.
CIGAR LIGHTER RELAY
8W-41 - Horns/Ci gar Li ghter i n Group 8W - Wi ri ng
Di agrams.
INJURY.
RELAY TEST
The ci gar l i ghter rel ay i s l ocated i n the juncti on
bl ock. The juncti on bl ock i s attached to the ri ght cowl
si de i nner panel , bel ow the i nstrument panel and
behi nd the ri ght cowl si de tri m panel .
Remove the ci gar l i ghter rel ay from the juncti on
bl ock as descri bed i n thi s group to perform the fol -
l owi ng tests:
and 30. I f OK, see the Rel ay Ci rcui t Test i n thi s
group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
ci rcui t to the fuse i n the juncti on bl ock as requi red.
to the ci gar l i ghter. There shoul d be conti nui ty
between the cavi ty for rel ay termi nal 87 and the
ci gar l i ghter rel ay output ci rcui t cavi ty of the ci gar
l i ghter wi re harness connector at al l ti mes. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t to the
ci gar l i ghter as requi red.
the el ectromagnet i n the rel ay. I t i s connected to
fused i gni ti on swi tch output and shoul d be hot when
the i gni ti on swi tch i s i n the On or Accessory posi -
ti ons. Check for battery vol tage at the cavi ty for
rel ay termi nal 86 wi th the i gni ti on swi tch i n the On
or Accessory posi ti ons. I f OK, go to Step 5. I f not OK,
repai r the open ci rcui t to the i gni ti on swi tch as
requi red.
the el ectromagnet i n the rel ay. I t i s grounded at al l
ti mes. Check for conti nui ty to ground at the cavi ty
for rel ay termi nal 85. There shoul d be conti nui ty. I f
not OK, repai r the open ci rcui t to ground as
requi red.
CLUSTER ILLUMINATION LAMP
i nstrument cl uster i l l umi nati on l amp condi ti on. I f
the probl em bei ng di agnosed i ncl udes i noperati ve
exteri or l i ghti ng control l ed by the headl amp swi tch,
that system needs to be repai red fi rst. I f the exteri or
l amps control l ed by the headl amp swi tch are i noper-
ati ve, refer to Group 8L - Lamps for di agnosi s. I f no
exteri or l i ghti ng system probl ems are found, the fol -
l owi ng procedure wi l l hel p l ocate a short or open i n
the cl uster i l l umi nati on l amp ci rcui t. For ci rcui t
INJURY.
(2) Turn the park l amps on wi th the headl amp
swi tch. Rotate the headl amp swi tch knob counter-
cl ockwi se to just before the i nteri or l amps detent.
bl ock. Rotate the headl amp swi tch knob cl ockwi se
Cigar Lighter Relay
whi l e observi ng the test vol tmeter. The readi ng
shoul d go from battery vol tage to zero vol ts. I f OK,
go to Step 3. I f not OK, repai r the open ci rcui t to the
headl amp swi tch or refer to Group 8L - Lamps to
di agnose the headl amp swi tch.
thi s group. Turn the headl amp swi tch off. Remove
the fuse from the juncti on bl ock. Probe the fused
panel l amp di mmer swi tch si gnal ci rcui t cavi ty of the
l eft i nstrument cl uster wi re harness connector (con-
nector A). Check for conti nui ty to a good ground.
There shoul d be no conti nui ty. I f OK, go to Step 4. I f
not OK, repai r the short ci rcui t as requi red.
(4) Rei nstal l the fuse i n the juncti on bl ock. Con-
nect the battery negati ve cabl e. Turn the park l amps
on wi th the headl amp swi tch. Rotate the headl amp
swi tch knob countercl ockwi se to just before the i nte-
ri or l amps detent. Check for battery vol tage at the
fused panel l amp di mmer swi tch si gnal ci rcui t cavi ty
of the l eft i nstrument cl uster wi re harness connector
(connector A). I f OK, repl ace the faul ty bul b(s) and
bul b hol der(s). I f not OK, repai r the open ci rcui t as
requi red.
COOLANT TEMPERATURE WARNING LAMP
I f the probl em bei ng di agnosed i s rel ated to cool ant
temperature warni ng l amp accuracy, be certai n to
confi rm that the probl em i s wi th the l amp and not
wi th cool i ng system performance. The actual engi ne
cool ant temperature shoul d be checked wi th a test
gauge or thermometer and compared to the cool ant
temperature warni ng l amp operati on before you pro-
ceed wi th l amp di agnosi s. Refer to Group 7 - Cool i ng
System for more i nformati on. Refer to Group 8W -
Wi ri ng Di agrams for ci rcui t descri pti ons and di a-
grams.
INJURY.
I f the cool ant temperature warni ng l amp fai l s to
l i ght duri ng the bul b test (about two seconds after
the i gni ti on swi tch i s turned to the On posi ti on),
repl ace the cool ant temperature warni ng l amp bul b
wi th a known good uni t. I f the cool ant temperature
warni ng l amp sti l l fai l s to operate, di agnosi s of the
cool ant temperature sensor and ci rcui t, the Chrysl er
Col l i si on Detecti on (CCD) data bus, and/or the Pow-
ertrai n Control Modul e (PCM) shoul d be performed
wi th a DRB scan tool as descri bed i n the proper
Di agnosti c Procedures manual . For di agnosi s of the
cool ant temperature warni ng l amp and the i nstru-
ment cl uster ci rcui try, see I nstrument Cl uster i n thi s
group.
CRUISE-ON INDICATOR LAMP
crui se-on i ndi cator l amp condi ti on. I f the probl em
bei ng di agnosed i s an i naccurate crui se-on i ndi cator
l amp, refer to Group 8H - Vehi cl e Speed Control for
di agnosi s of the vehi cl e speed control system. For ci r-
cui t descri pti ons and di agrams, refer to 8W-33 - Vehi -
cl e Speed Control and 8W-40 - I nstrument Cl uster i n
INJURY.
I f the crui se-on i ndi cator l amp fai l s to l i ght when
the vehi cl e speed control i s turned on, repl ace the
crui se-on i ndi cator l amp bul b wi th a known good
uni t. I f the crui se-on l amp sti l l fai l s to operate, di ag-
nosi s of the Powertrai n Control Modul e (PCM) and
the Chrysl er Col l i si on Detecti on (CCD) data bus
ual . For di agnosi s of the crui se-on i ndi cator l amp and
the i nstrument cl uster ci rcui try, see I nstrument
FOUR-WHEEL DRIVE INDICATOR LAMP
four-wheel dri ve i ndi cator l amp condi ti on. I f the
probl em bei ng di agnosed i s rel ated to l amp accuracy,
be certai n to confi rm that the probl em i s wi th the
l amp or swi tch and not wi th a damaged or i nopera-
ti ve transfer case or transfer case l i nkage. Refer to
Group 21 - Transmi ssi on for more i nformati on. I f no
transfer case probl em i s found, the fol l owi ng proce-
dure wi l l hel p l ocate a short or open i n the i ndi cator
l amp ci rcui t. For ci rcui t di agrams and descri pti ons,
refer to 8W-40 - I nstrument Cl uster i n Group 8W -
Wi ri ng Di agrams.
INJURY.
PART TIME
Unpl ug the transfer case swi tch wi re harness connec-
tor. Check for conti nui ty between the ground ci rcui t
cavi ty of the transfer case swi tch wi re harness con-
nector and a good ground. There shoul d be conti nu-
i ty. I f OK, go to Step 4. I f not OK, repai r the open
ci rcui t to ground as requi red.
i gni ti on swi tch to the On posi ti on. I nstal l a jumper
wi re between the part ti me four wheel dri ve i ndi cator
l amp dri ver ci rcui t cavi ty of the transfer case swi tch
wi re harness connector and a good ground. The four-
wheel dri ve i ndi cator l amp shoul d l i ght. I f OK,
repl ace the faul ty transfer case swi tch. I f not OK, go
to Step 5.
group. Wi th the transfer case swi tch wi re harness
connector sti l l unpl ugged, check for conti nui ty
between the part ti me four wheel dri ve i ndi cator
l amp dri ver ci rcui t cavi ty of the ri ght i nstrument
cl uster wi re harness connector (connector B) and a
requi red.
(6) Check for conti nui ty between the part ti me
four wheel dri ve i ndi cator l amp dri ver ci rcui t cavi ti es
of the ri ght i nstrument cl uster wi re harness connec-
tor (connector B) and the transfer case swi tch wi re
harness connector. There shoul d be conti nui ty. I f OK,
repl ace the faul ty bul b. I f not OK, repai r the open
FULL TIME
Unpl ug the transfer case swi tch wi re harness connec-
cavi ty of the transfer case swi tch wi re harness con-
nector and a good ground. There shoul d be conti nu-
i ty. I f OK, go to Step 4. I f not OK, repai r the open
i gni ti on swi tch to the On posi ti on. I nstal l a jumper
wi re between the ful l ti me four wheel dri ve i ndi cator
l amp dri ver ci rcui t cavi ty of the transfer case swi tch
wi re harness connector and a good ground. The four-
wheel dri ve i ndi cator l amp shoul d l i ght. I f OK,
repl ace the faul ty transfer case swi tch. I f not OK, go
to Step 5.
group. Wi th the transfer case swi tch wi re harness
connector sti l l unpl ugged, check for conti nui ty
between the ful l ti me four wheel dri ve i ndi cator l amp
dri ver ci rcui t cavi ty of the ri ght i nstrument cl uster
wi re harness connector (connector B) and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 6. I f not OK, repai r the short ci rcui t as
requi red.
(6) Check for conti nui ty between the ful l ti me four
wheel dri ve i ndi cator l amp dri ver ci rcui t cavi ti es of
the ri ght i nstrument cl uster wi re harness connector
(connector B) and the transfer case swi tch wi re har-
ness connector. There shoul d be conti nui ty. I f OK,
repl ace the faul ty bul b. I f not OK, repai r the open
HEADLAMP HIGH BEAM INDICATOR LAMP
headl amp hi gh beam i ndi cator l amp condi ti on. I f the
probl em bei ng di agnosed i s rel ated to i noperati ve
headl amp hi gh beams, refer to Group 8L - Lamps for
di agnosi s of the headl amp system. I f no headl amp
system probl ems are found, the fol l owi ng procedure
wi l l hel p l ocate an open i n the hi gh beam i ndi cator
l amp ci rcui t. For ci rcui t descri pti ons and di agrams,
refer to 8W-40 - I nstrument Cl uster and 8W-50 -
Front Li ghti ng i n Group 8W - Wi ri ng Di agrams.
INJURY.
thi s group.
headl amps on and sel ect the hi gh beams wi th the
mul ti -functi on swi tch stal k. Check for battery vol tage
at the hi gh beam i ndi cator dri ver ci rcui t cavi ty of the
l eft i nstrument cl uster wi re harness connector (con-
nector A). I f OK, repl ace the faul ty bul b. I f not OK,
repai r the open ci rcui t to the headl amp di mmer
(mul ti -functi on) swi tch as requi red.
LOW FUEL WARNING LAMP
l ow fuel warni ng l amp condi ti on. I f the probl em
bei ng di agnosed i s rel ated to l amp accuracy, be cer-
tai n to confi rm the probl em i s the wi th the l ow fuel
warni ng l amp and not wi th the fuel gauge ci rcui t.
See the di agnosi s for the Fuel Gauge i n thi s group. I f
no fuel gauge probl em i s found, refer to the I nstru-
ment Cl uster di agnosi s i n thi s group. For ci rcui t
INJURY.
I f the l ow fuel warni ng l amp fai l s to l i ght when the
fuel l evel i s bel ow about one-ei ghth of a ful l tank as
i ndi cated by the fuel gauge, repl ace the l ow fuel
warni ng l amp bul b wi th a known good uni t. I f the
i ndi cator l amp sti l l fai l s to operate, di agnosi s of the
fuel gauge sendi ng uni t and ci rcui t, the Powertrai n
Control Modul e (PCM), and the Chrysl er Col l i si on
Detecti on (CCD) data bus shoul d be performed wi th
a DRB scan tool as descri bed i n the proper Di agnos-
ti c Procedures manual . For di agnosi s of the l ow fuel
warni ng l amp and the i nstrument cl uster ci rcui try,
see I nstrument Cl uster i n thi s group.
LOW OIL PRESSURE WARNING LAMP
I f the probl em bei ng di agnosed i s rel ated to l ow oi l
pressure warni ng l amp accuracy, be certai n to con-
fi rm that the probl em i s wi th the l amp and not wi th
the engi ne oi l i ng system performance. The actual
engi ne oi l pressure shoul d be checked wi th a test
gauge and compared to the l ow oi l pressure warni ng
l amp operati on before you proceed wi th l amp di agno-
si s. Refer to Group 9 - Engi nes for more i nformati on.
INJURY.
I f the l ow oi l pressure warni ng l amp fai l s to l i ght
duri ng the bul b test (about two seconds after the
i gni ti on swi tch i s turned to the On posi ti on), repl ace
the l ow oi l pressure warni ng l amp bul b wi th a known
good uni t. I f the l ow oi l pressure warni ng l amp sti l l
fai l s to operate, di agnosi s of the oi l pressure sensor
and ci rcui t, the Chrysl er Col l i si on Detecti on (CCD)
data bus, and/or the Powertrai n Control Modul e
(PCM) shoul d be performed wi th a DRB scan tool as
ual . For di agnosi s of the l ow oi l pressure warni ng
l amp and the i nstrument cl uster ci rcui try, see I nstru-
ment Cl uster i n thi s group.
LOW WASHER FLUID WARNING LAMP
l ow washer fl ui d warni ng l amp condi ti on. I f the prob-
l em bei ng di agnosed i s rel ated to l amp accuracy, be
certai n to confi rm that the probl em i s wi th the l amp
or washer fl ui d l evel sensor and not wi th a damaged
or empty washer fl ui d reservoi r. I nspect the reservoi r
for proper fl ui d l evel and si gns of damage or di stor-
ti on that coul d affect sensor performance before you
proceed wi th l amp di agnosi s. Refer to Group 8K -
Wi per and Washer Systems for more i nformati on. For
ci rcui t descri pti ons and di agrams, refer to 8W-40 -
I nstrument Cl uster i n Group 8W - Wi ri ng Di agrams.
INJURY.
Unpl ug the wi re harness connector from the washer
fl ui d l evel sensor. I nstal l a jumper wi re between the
two cavi ti es of the sensor wi re harness connector.
Turn the i gni ti on swi tch to the On posi ti on. The l ow
washer fl ui d warni ng l amp shoul d l i ght. Remove the
jumper wi re and the l amp shoul d go off. I f OK,
repl ace the faul ty washer fl ui d l evel sensor. I f not
OK, go to Step 4.
Check for conti nui ty between the ground ci rcui t cav-
i ty of the washer fl ui d l evel sensor wi re harness con-
nector and a good ground. There shoul d be
conti nui ty. I f OK, go to Step 5. I f not OK, repai r the
thi s group. The washer fl ui d l evel sensor wi re har-
ness connector i s sti l l unpl ugged. Check for conti nu-
i ty between the washer fl ui d l evel sense ci rcui t cavi ty
of the ri ght i nstrument cl uster wi re harness connec-
tor (connector B) and a good ground. There shoul d be
no conti nui ty. I f OK, go to Step 6. I f not OK, repai r
the short ci rcui t as requi red.
(6) Check for conti nui ty between the washer fl ui d
l evel sense ci rcui t cavi ti es of the ri ght i nstrument
cl uster wi re harness connector (connector B) and the
washer fl ui d l evel sensor wi re harness connector.
There shoul d be conti nui ty. I f OK, repl ace the faul ty
bul b. I f not OK, repai r the open ci rcui t as requi red.
MALFUNCTION INDICATOR LAMP
mal functi on i ndi cator l amp condi ti on. I f the l amp
comes on and stays on wi th the engi ne runni ng, refer
to Group 14 - Fuel Systems for di agnosi s. For ci rcui t
INJURY.
I f the mal functi on i ndi cator l amp fai l s to l i ght dur-
i ng the bul b test (about three seconds after the i gni -
ti on swi tch i s turned to the On posi ti on), repl ace the
mal functi on i ndi cator l amp bul b wi th a known good
uni t. I f the i ndi cator l amp sti l l fai l s to operate, di ag-
ual . For di agnosi s of the mal functi on i ndi cator l amp
SEAT BELT REMINDER LAMP
seat bel t remi nder l amp condi ti on. I f the l amp comes
on and fl ashes fol l owi ng i ts di spl ay functi on (for
about seven seconds after the i gni ti on swi tch i s
turned to the On posi ti on), refer to the di agnosi s for
the ai rbag i ndi cator l amp i n thi s group. For ci rcui t
INJURY.
I f the seat bel t remi nder l amp fai l s to l i ght duri ng
i ts di spl ay functi on, repl ace the seat bel t remi nder
l amp bul b wi th a known good uni t. I f the remi nder
l amp sti l l fai l s to operate, see I nstrument Cl uster i n
thi s group for di agnosi s of the seat bel t remi nder
l amp and the i nstrument cl uster ci rcui try. Refer to
Group 8U - Chi me/Buzzer Warni ng Systems for di ag-
nosi s of the dri ver seat bel t swi tch and ci rcui t.
turn si gnal i ndi cator l amp condi ti on. For any other
turn si gnal probl em, refer to Group 8J - Turn Si gnal
and Hazard Warni ng Systems for di agnosi s. I f no
turn si gnal or hazard warni ng system probl em i s
found, the fol l owi ng procedure wi l l hel p l ocate a
short or open i n the i ndi cator l amp ci rcui t. For ci r-
cui t descri pti ons and di agrams, refer to 8W-40 -
I nstrument Cl uster and 8W-50 - Front Li ghti ng i n
INJURY.
cabl e. Remove the i nstrument cl uster bezel and the
cl uster as descri bed i n thi s group.
(2) Connect the battery negati ve cabl e. Acti vate
the hazard warni ng system by movi ng the hazard
warni ng swi tch button to the On posi ti on. Check for
battery vol tage at the i noperati ve (ri ght or l eft) turn
si gnal ci rcui t cavi ty of the cl uster wi re harness con-
nector (connector A - l eft, or connector B - ri ght).
There shoul d be a swi tchi ng (on and off) battery vol t-
age si gnal . I f OK, repl ace the faul ty (ri ght or l eft)
i ndi cator l amp bul b. I f not OK, repai r the open ci r-
cui t to the turn si gnal /hazard warni ng (mul ti -func-
ti on) swi tch as requi red.
UPSHIFT INDICATOR LAMP
upshi ft i ndi cator l amp condi ti on. I f l amp accuracy i s
suspect, di agnosi s shoul d be performed wi th a DRB
scan tool as descri bed i n the proper Di agnosti c Pro-
cedures manual . For ci rcui t descri pti ons and di a-
grams, refer to 8W-40 - I nstrument Cl uster i n Group
INJURY.
I f the upshi ft i ndi cator l amp fai l s to l i ght when a
transmi ssi on upshi ft i s obvi ousl y requi red, repl ace
the upshi ft i ndi cator l amp bul b wi th a known good
uni t. I f the i ndi cator l amp sti l l fai l s to operate, di ag-
ual . For di agnosi s of the upshi ft i ndi cator l amp and
the i nstrument cl uster ci rcui try, see I nstrument
VOLTAGE WARNING LAMP
I f the probl em bei ng di agnosed i s rel ated to vol tage
warni ng l amp accuracy, be certai n to confi rm proper
chargi ng system operati on before consi deri ng vol tage
warni ng l amp di agnosi s. Refer to Group 8C - Charg-
i ng System for more i nformati on. Refer to Group 8W
- Wi ri ng Di agrams for ci rcui t descri pti ons and di a-
grams.
INJURY.
I f the vol tage warni ng l amp fai l s to l i ght duri ng
the bul b test (about two seconds after the i gni ti on
swi tch i s turned to the On posi ti on), repl ace the vol t-
age warni ng l amp bul b wi th a known good uni t. I f
the vol tage warni ng l amp sti l l fai l s to operate, di ag-
nosi s of the system vol tage i nput ci rcui t, the Chrysl er
Col l i si on Detecti on (CCD) data bus, and/or the Pow-
ertrai n Control Modul e (PCM) shoul d be performed
wi th a DRB scan tool as descri bed i n the proper
Di agnosti c Procedures manual . For di agnosi s of the
vol tage warni ng l amp and the i nstrument cl uster ci r-
cui try, see I nstrument Cl uster i n thi s group.
STEERING COLUMN OPENING COVER
INJURY.
cabl e.
(2) I f the vehi cl e i s so equi pped, move the ti l t
steeri ng col umn to the ful l y rai sed posi ti on.
(3) Remove the three screws that secure the steer-
i ng col umn openi ng cover to the l ower i nstrument
panel rei nforcement (Fi g. 3).
(4) Usi ng a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool , gentl y pry the upper edge of the
steeri ng col umn openi ng cover away from the i nstru-
ment panel on each si de of the steeri ng col umn to
rel ease the two snap cl i p retai ners that secure the
cover to the i nstrument panel .
(5) Remove the steeri ng col umn openi ng cover
from the vehi cl e.
KNEE BLOCKER
INJURY.
cabl e.
(2) Remove the steeri ng col umn openi ng cover as
(3) Remove the two screws that secure the knee
bl ocker to the i nstrument panel (Fi g. 4).
(4) Pul l the knee bl ocker away from the i nstru-
ment panel far enough to di sengage the two mount-
i ng tabs from the sl ots i n the l ower i nstrument panel
rei nforcement.
(5) Remove the knee bl ocker from the vehi cl e.
certai n that the mounti ng screws are l ocated i n the
screw hol e on each si de of the steeri ng col umn that i s
cl osest to the dri ver si de front door of the vehi cl e
(Fi g. 5). Ti ghten the mounti ng screws to 2.2 Nm (20
i n. l bs.).
INJURY.
cabl e.
fl at-bl aded tool , gentl y pry the i nstrument panel cen-
Fig. 3 Steering Column Opening Cover Remove/
Install
Fig. 4 Knee Blocker Remove/Install
Fig. 5 Knee Blocker Mounting Screw Location
ACCESSORY SWITCH BEZEL
INJURY.
cabl e.
(2) Remove the i nstrument panel center bezel as
(3) Remove the three screws that secure the acces-
sory swi tch bezel to the i nstrument panel (Fi g. 7).
(4) Pul l the accessory swi tch bezel out from the
i nstrument panel far enough to unpl ug the wi re har-
ness connectors.
(5) Remove the accessory swi tch bezel from the
i nstrument panel .
(6) Careful l y pry the snap retai ners at the top and
bottom of the accessory swi tch (fog l amp swi tch, rear
wi ndow defogger swi tch, rear wi per and washer
swi tch) receptacl es on the back of the accessory
swi tch bezel wi th a smal l thi n-bl aded screwdri ver
and pul l the swi tches out of the receptacl es.
certai n that both of the swi tch snap retai ners i n the
receptacl es on the back of the accessory swi tch bezel
are ful l y engaged. Ti ghten the mounti ng screws to
2.2 Nm (20 i n. l bs.).
CIGAR LIGHTER RELAY
INJURY.
cabl e.
(2) Remove the fuse access panel by unsnappi ng i t
from the ri ght cowl si de tri m panel .
(3) Remove the stamped nut that secures the ri ght
cowl si de tri m to the juncti on bl ock stud (Fi g. 8).
(4) Remove the screw l ocated above the fuse access
openi ng that secures the ri ght cowl si de tri m to the
ri ght cowl si de i nner panel .
(5) Remove the screw that secures the ri ght door
si l l tri m and the ri ght cowl si de tri m to the ri ght
door openi ng si l l .
(6) Remove the ri ght cowl si de tri m panel from the
vehi cl e.
(7) Unpl ug the ci gar l i ghter rel ay from the junc-
ti on bl ock.
(8) I nstal l the ci gar l i ghter rel ay by al i gni ng the
rel ay termi nal s wi th the cavi ti es i n the juncti on
bl ock and pushi ng the rel ay fi rml y i nto pl ace.
Fig. 7 Accessory Switch Bezel Remove/Install
(11) I nstal l the ri ght cowl si de tri m and the fuse
access panel .
CLUSTER BEZEL
INJURY.
cabl e.
(2) Remove the knee bl ocker and the i nstrument
panel center bezel , as descri bed i n thi s group.
(3) Remove the headl amp swi tch knob and shaft
from the headl amp swi tch. See Headl amp Swi tch i n
(4) Di sengage the two ends of the steeri ng col umn
si ght shi el d from each other at the connector l ocated
bel ow the l ower steeri ng col umn shroud (Fi g. 9).
(5) I f the vehi cl e i s so equi pped, set the ti l t steer-
i ng col umn i n i ts l owest posi ti on.
(6) Remove the four screws that secure the cl uster
bezel to the i nstrument panel behi nd the center
bezel .
fl at-bl aded tool , gentl y pry around the peri meter of
the cl uster bezel to di sengage the fi ve snap cl i p
retai ners that secure the bezel to the i nstrument
panel .
(8) Remove the cl uster bezel from the vehi cl e.
Be certai n to engage the two ends of the steeri ng col -
umn si ght shi el d connector wi th each other before
rei nstal l i ng the knee bl ocker and steeri ng col umn
openi ng cover.
HEADLAMP SWITCH
INJURY.
WARNING: IF THE HEADLAMP SWITCH WAS ON,
WAIT FIVE MINUTES TO ALLOW THE CERAMIC
DIMMER RESISTOR TO COOL. IF THE CERAMIC
DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT
CAN BURN YOUR FINGERS.
cabl e.
Fig. 8 Right Cowl Side Trim Remove/Install
Fig. 9 Cluster Bezel Remove/Install
(2) Remove the knee bl ocker as descri bed i n thi s
group.
(3) Pul l the headl amp swi tch control knob out to
the On posi ti on stop.
WARNING: IF THE HEADLAMP SWITCH WAS ON,
WAIT FIVE MINUTES TO ALLOW THE CERAMIC
DIMMER RESISTOR TO COOL. IF THE CERAMIC
DIMMER RESISTOR IS NOT ALLOWED TO COOL, IT
CAN BURN YOUR FINGERS.
(4) Reach up through the outboard si de of the
steeri ng col umn openi ng and depress the headl amp
swi tch knob and shaft rel ease button on the i nboard
si de of the swi tch (Fi g. 10).
(5) Pul l the swi tch knob and shaft out of the head-
l amp swi tch.
(6) Remove the spanner nut that secures the head-
l amp swi tch to the i nstrument panel (Fi g. 11).
(7) Move the headl amp swi tch i nto the steeri ng
col umn openi ng far enough to access the wi re har-
ness connectors.
(8) Unpl ug the two wi re harness connectors from
the headl amp swi tch.
(9) Remove the headl amp swi tch from the i nstru-
ment panel .
Ti ghten the spanner nut to 2.7 Nm (24 i n. l bs.).
INSTRUMENT CLUSTER
INJURY.
(1) Remove the cl uster bezel as descri bed i n thi s
group.
(2) Remove the four screws that secure the cl uster
to the i nstrument panel (Fi g. 12).
(3) Pul l the cl uster rearward to di sengage the two
sel f-docki ng wi re harness connectors.
NOTE: The instrument cluster has two self-docking
wire harness connectors that will be automatically
aligned with, and connected to the instrument panel
wire harness when the cluster is installed in the
instrument panel.
Fig. 10 Headlamp Switch Knob and Shaft Remove/
Install - Typical
PUSH RETAINER BUTTON VIEWED FROM UNDERSIDE OF DASH
Fig. 11 Headlamp Switch Remove/Install
Fig. 12 Instrument Cluster Remove/Install
INSTRUMENT PANEL SELF-DOCKING WIRE HARNESS CONNECTORS INSTRUMENT CLUSTER SCREW
(4) Remove the i nstrument cl uster from the vehi -
cl e.
CLUSTER COMPONENTS
CLUSTER LENS AND ODOMETER RESET
KNOB BOOT
INJURY.
cabl e.
(2) Remove the i nstrument cl uster as descri bed i n
thi s group.
(3) Work around the peri meter of the cl uster
depressi ng the snap cl i ps that secure the cl uster l ens
to the cl uster housi ng, and gentl y pul l the l ens away
from the cl uster (Fi g. 13).
(4) Remove the tri p odometer reset knob boot by
pul l i ng i t out of the l ens.
CLUSTER HOOD AND MASK
INJURY.
cabl e.
thi s group.
(3) Remove the cl uster l ens as descri bed i n thi s
group.
depressi ng the snap cl i ps that secure the cl uster
hood and mask to the cl uster housi ng, and gentl y
pul l the hood and mask away from the cl uster (Fi g.
13).
Fig. 13 Instrument Cluster Components
CLUSTER REAR COVER CLUSTER HOOD AND MASK CLUSTER LENS ODOMETER RESET KNOB BOOT INSTRUMENT CLUSTER HOUSING
CLUSTER REAR COVER
INJURY.
cabl e.
thi s group.
rel easi ng the snap cl i ps that secure the rear cover to
the cl uster housi ng, and gentl y pul l the rear cover
away from the cl uster (Fi g. 13).
CLUSTER BULB
INJURY.
thi s group.
(2) Remove the bul b and bul b hol der from the ci r-
cui t board on the rear of the cl uster housi ng by turn-
i ng the hol der countercl ockwi se (Fi g. 14).
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the instrument
cluster printed circuit and/or the gauges.
INSTRUMENT PANEL TOP COVER
INJURY.
cabl e.
(2) Remove the i nstrument cl uster bezel as
fl at-bl aded tool , gentl y pry the rear edge (nearest the
passenger compartment) of the i nstrument panel top
cover up and away from the top of the i nstrument
panel to rel ease the seven rear snap cl i p retai ners
(Fi g. 15).
(4) Li ft the rear edge of the top cover up and away
from the i nstrument panel unti l al l of the rear snap
cl i p retai ners (seven) on the top cover are di sengaged
from the receptacl es i n the top of the i nstrument
panel .
(5) Pul l the top cover sharpl y rearwards to di sen-
gage the four front snap cl i p retai ners from the
receptacl es near the base of the wi ndshi el d.
(6) Remove the top cover from the vehi cl e.
When i nstal l i ng the top cover, be certai n to engage
the four front (nearest the wi ndshi el d) snap cl i p
Fig. 14 Cluster Bulb Locations
CLUSTER ILLUMINATION BULBS
Fig. 15 Instrument Panel Top Cover Remove/Install
INSTRUMENT PANEL TOP COVER FRONT EDGE REAR EDGE FWD
retai ners fi rst, then engage the seven rear snap cl i p
retai ners.
GLOVE BOX
ROLL DOWN
INJURY.
cabl e.
(2) Open the gl ove box.
(3) Locate the two rubber stop bumpers on the
upper edge of the gl ove box openi ng (Fi g. 16).
(4) Remove the two gl ove box stop bumpers by
sl i di ng them downward and out of the sl ots i n the
i nstrument panel upper gl ove box openi ng rei nforce-
ment.
(5) Rol l the gl ove box downward so that the stops
on the gl ove box bi n pass through the stop bumper
sl ots i n the i nstrument panel upper gl ove box open-
i ng rei nforcement.
(6) Reverse the rol l down procedure to rol l the
gl ove box back up.
REMOVAL
INJURY.
cabl e.
(2) Remove the three screws that secure the gl ove
box hi nge to the i nstrument panel l ower gl ove box
openi ng rei nforcement (Fi g. 17).
(3) Rel ease the gl ove box l atch.
(4) Remove the gl ove box from the i nstrument
panel .
When rei nstal l i ng the gl ove box, be certai n that the
stops on the gl ove box bi n are ori ented behi nd the
gl ove box stop bumpers on the i nstrument panel
upper gl ove box openi ng rei nforcement.
GLOVE BOX LAMP AND SWITCH
INJURY.
cabl e.
(2) Rol l down the gl ove box as descri bed i n thi s
group.
(3) Reach i nsi de and above the gl ove box openi ng
to unl atch and unpl ug the wi re harness connector
from the gl ove box l amp and swi tch (Fi g. 18).
(4) From i nsi de and above the gl ove box openi ng,
squeeze the retai ni ng tabs on the top and bottom of
the gl ove box l amp and swi tch housi ng together and
Fig. 16 Glove Box Stop Bumpers Remove/Install
GLOVE BOX OPENING UPPER REINFORCEMENT GLOVE BOX LATCH STRIKER STOP BUMPERS GLOVE BOXDOOR
Fig. 17 Glove Box Remove/Install
GLOVE BOX LATCH SCREWS
push the uni t out through the i nstrument panel
mounti ng hol e.
GLOVE BOX COMPONENTS
The gl ove box hi nge, bi n, i nner door and l atch are
servi ced onl y as a compl ete uni t. The gl ove box outer
door and l ock cyl i nder are servi ced separatel y.
HINGE, BIN, INNER DOOR AND LATCH
INJURY.
cabl e.
panel as descri bed i n thi s group.
(3) Remove the seven screws that secure the i nner
gl ove box door to the outer gl ove box door (Fi g. 19).
(4) Separate the i nner gl ove box door assembl y
from the outer gl ove box door.
OUTER DOOR
INJURY.
cabl e.
(3) Remove the seven screws that secure the i nner
gl ove box door to the outer gl ove box door (Fi g. 19).
(4) Separate the outer gl ove box door from the
i nner gl ove box door assembl y.
LOCK CYLINDER
(1) I nsert the key i nto the gl ove box l ock cyl i nder
and turn the l ock cyl i nder to the unl ocked posi ti on.
(2) Open the gl ove box.
(3) Wi th the key sti l l i n the l ock cyl i nder, i nsert a
smal l pi n punch or a sti ff wi re i nto the l ock cyl i nder
rel ease hol e (Fi g. 20) and depress the l ock cyl i nder
retai ni ng tumbl er.
(4) Whi l e hol di ng the retai ni ng tumbl er depressed,
rotate the key i n the l ock cyl i nder cl ockwi se and
press outward on the back of the l ock cyl i nder from
the i nsi de of the gl ove box door unti l the l ock cyl i n-
der comes out of the gl ove box l atch l ock cyl i nder
bore.
(5) To i nstal l the l ock cyl i nder, i nsert the key i n
the cyl i nder and al i gn the l ock cyl i nder tumbl ers
wi th the ramp i n the gl ove box l atch l ock cyl i nder
bore. The ramp i s l ocated at about the 7 ocl ock posi -
Fig. 18 Glove Box Lamp and Switch Remove/Install
LATCH STRIKER STOP BUMPER SLOT LAMP AND SWITCH MOUNTING HOLE WIRE HARNESS CONNEC- TOR
Fig. 19 Glove Box Components Remove/Install
OUTER DOOR STOPS INNER DOOR LATCH BIN HINGE SCREWS
ti on. Push the l ock cyl i nder fi rml y i nto the l ock cyl -
i nder bore whi l e rotati ng the key and cyl i nder
countercl ockwi se to the 6 ocl ock posi ti on, where the
l ock cyl i nder retai ni ng tumbl er wi l l snap back i nto
pl ace.
GLOVE BOX LATCH STRIKER
INJURY.
cabl e.
(2) Remove the passenger si de ai rbag modul e.
the procedures.
(3) Remove the two screws that secure the gl ove
box l atch stri ker to the i nstrument panel on the top
of the upper gl ove box openi ng rei nforcement (Fi g.
21).
(4) Remove the l atch stri ker from the gl ove box
openi ng.
INSTRUMENT PANEL END CAP
INJURY.
DRIVER SIDE
cabl e.
(2) Remove the knee bl ocker as descri bed i n thi s
group.
(3) Remove the i nstrument panel top cover as
(4) Remove the fi ve screws that secure the end cap
(5) Remove the end cap from the i nstrument
panel .
PASSENGER SIDE
cabl e.
group.
(3) Remove the i nstrument panel top cover as
Fig. 20 Glove Box Lock Cylinder Remove/Install
LOCK CYLINDER LATCH HANDLE RELEASE HOLE
Fig. 21 Glove Box Latch Striker Remove/Install
GLOVE BOX OPENING UPPER REINFORCEMENT SCREWS LATCH STRIKERSTOP BUMPER SLOTS
Fig. 22 Instrument Panel End Cap Remove/Install
END CAP INSTRUMENT PANEL SCREW
(4) Remove the passenger si de ai rbag modul e.
the procedures.
(5) Remove the si x screws that secure the end cap
(6) Remove the end cap from the i nstrument
panel .
CENTER SUPPORT BRACKET
INJURY.
cabl e.
(2) Remove the i nstrument panel center bezel as
(3) Remove the fl oor consol e from the fl oor pan
transmi ssi on tunnel . Refer to Group 23 - Body for the
procedures.
(4) Pul l the carpet back from the front of the fl oor
pan transmi ssi on tunnel far enough to access the
center support bracket mounti ng nuts.
(5) Remove the two nuts that secure the center
support bracket to the studs on the l ower i nstrument
panel (Fi g. 23).
(6) Remove the two nuts that secure the center
support bracket to the studs on the fl oor pan trans-
mi ssi on tunnel .
(7) Remove the center support bracket from the
vehi cl e.
Ti ghten the mounti ng nuts to 28 Nm (250 i n. l bs.).
JUNCTION BLOCK
INJURY.
cabl e.
Fig. 23 Center Support Bracket Remove/Install
INSTRUMENT PANEL NUT BRACKET FLOOR PAN TRANSMISSION TUNNEL STUDS
RIGHT FRONT DOOR SILLCOWL SIDE TRIM PANEL SCREWSILL TRIM FUSE ACCESS PANEL FWD PUSH-NUT
vehi cl e.
(7) Unpl ug al l of the wi re harness connectors from
the juncti on bl ock cavi ti es.
(8) Remove the three nuts that secure the juncti on
bl ock to the studs on the ri ght cowl si de i nner panel
(Fi g. 25).
(9) Remove the juncti on bl ock from the vehi cl e.
Ti ghten the mounti ng nuts to 2.7 Nm (24 i n. l bs.).
INSTRUMENT PANEL ASSEMBLY
INJURY.
(1) Pl ace the front wheel s i n the strai ght-ahead
posi ti on.
cabl e.
(3) Remove the l eft and ri ght cowl si de i nner tri m
panel s. Refer to Group 23 - Body for the procedures.
(4) Remove the steeri ng col umn openi ng cover and
the knee bl ocker as descri bed i n thi s group.
(5) Remove the i nstrument panel center bezel , the
cl uster bezel and the i nstrument panel top cover as
(6) Remove the center support bracket as
(7) Remove the steeri ng col umn. Refer to Group 19
- Steeri ng for the procedures.
(8) Remove the screws from the centers of the
i nstrument panel -to-body and i nstrument panel -to-
headl amp and dash wi re harness connectors near the
l eft cowl si de i nner panel and unpl ug the connectors.
(9) Remove the screw from the center of the
i nstrument panel -to-fl oor wi re harness connector
near the fl oor pan transmi ssi on tunnel under the
i nstrument panel and unpl ug the connector.
(10) Unpl ug the two wi re harness connectors
l ocated near the i nstrument panel -to-fl oor wi re har-
ness connector at the fl oor pan transmi ssi on tunnel
under the i nstrument panel .
group.
(12) Reach through the i nboard si de of the i nstru-
ment panel gl ove box openi ng to unpl ug the vacuum
harness connector between the heater-A/C control
and the heater-A/C housi ng hal ves of the vacuum
harness.
(13) Reach under the ri ght end of the i nstrument
panel to unpl ug the coaxi al cabl e connector between
the radi o and antenna hal ves of the antenna coaxi al
cabl e. On Left-Hand Dri ve model s onl y, al so di sen-
gage the retai ner on the radi o hal f of the coaxi al
cabl e from the heater-A/C housi ng ki ck cover.
(14) Remove the temperature control cabl e and
bl end-ai r door crank arm from the heater-A/C hous-
i ng as a uni t. Refer to Group 24 - Heati ng and Ai r
Condi ti oni ng for the temperature control cabl e ser-
vi ce procedures.
(15) Loosen the ri ght and l eft i nstrument panel
cowl si de rol l down screws about 6 mm (0.25 i nch)
(Fi g. 26).
(16) Remove the four screws and two nuts that
secure the top of the i nstrument panel to the top of
the dash panel near the base of the wi ndshi el d.
(17) Wi th the ai d of an assi stant, l i ft the top of the
i nstrument panel assembl y off of the two dash panel
studs. Then pul l the l ower i nstrument panel rear-
ward to cl ear the cowl si de rol l down screws.
(18) Remove the i nstrument panel assembl y from
the vehi cl e.
Ti ghten the mounti ng hardware as fol l ows:
I nstrument panel top to dash panel screws - 7
Nm (60 i n. l bs.)
I nstrument panel top to dash panel nuts - 7 Nm
(60 i n. l bs.)
Fig. 25 Junction Block Remove/Install
JUNCTIONBLOCK STUD RIGHT COWL SIDE INNER PANEL NUT
I nstrument panel cowl si de rol l down screws - 28
Nm (250 i n. l bs.)
Wi re harness connector screws - 4 Nm (35 i n.
l bs.).
Fig. 26 Instrument Panel Assembly Remove/Install
SCREW NUT INSTRUMENT PANEL COWL SIDE ROLL DOWN SCREWS
AUDIO SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . . 1
RADIO NOISE SUPPRESSION . . . . . . . . . . . . . . 2
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 2
RADIO FREQUENCY INTERFERENCE . . . . . . . 7
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SOUND BAR . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION
INTRODUCTION
Fol l owi ng are general descri pti ons of the major
components used i n both the standard and opti onal
factory-i nstal l ed audi o systems. Refer to 8W-47 Audi o
System i n Group 8W - Wi ri ng Di agrams for compl ete
ci rcui t descri pti ons and di agrams.
RADIO
Avai l abl e factory-i nstal l ed radi o recei vers for thi s
model i ncl ude an AM/FM (RAL sal es code), an
AM/FM/cassette (RAS sal es code), and an AM/FM/
CD/cassette/3-band graphi c equal i zer (RAZ sal es
code). Al l factory-i nstal l ed radi o recei vers are stereo
El ectroni cal l y Tuned Radi os (ETR) and i ncl ude an
el ectroni c di gi tal cl ock functi on.
For more i nformati on on radi o features, setti ng
procedures, and control functi ons refer to the owners
manual i n the vehi cl e gl ove box.
IGNITION-OFF DRAW FUSE
Al l vehi cl es are equi pped wi th an I gni ti on-Off
Draw (I OD) fuse that i s removed when the vehi cl e i s
shi pped from the factory. Thi s fuse feeds vari ous
accessori es that requi re battery current when the
i gni ti on swi tch i s i n the Off posi ti on, i ncl udi ng the
cl ock and radi o stati on preset memory functi ons. The
fuse i s removed to prevent battery di scharge duri ng
vehi cl e storage.
When removi ng or i nstal l i ng the I OD fuse, i t i s
i mportant that the i gni ti on swi tch be i n the Off posi -
ti on. Fai l ure to pl ace the i gni ti on swi tch i n the Off
posi ti on can cause the radi o di spl ay to become scram-
bl ed when the I OD fuse i s removed and repl aced.
Removi ng and repl aci ng the I OD fuse agai n, wi th the
i gni ti on swi tch i n the Off posi ti on, wi l l correct the
scrambl ed di spl ay condi ti on.
The I OD fuse shoul d be checked i f the radi o stati on
preset memory or cl ock functi ons are errati c or i nop-
erati ve. The I OD fuse i s l ocated i n the Power Di stri -
buti on Center (PDC). Refer to the PDC l abel for I OD
fuse i denti fi cati on and l ocati on.
SPEAKER
The standard equi pment speaker system i ncl udes
two 13.3 centi meter (5.25 i nch) di ameter ful l -range
speakers. Each speaker i s mounted to the front l ower
i nner door panel behi nd the door tri m panel .
The sound bar opti on adds two 13.3 centi meter
(5.25 i nch) di ameter ful l -range speakers to the stan-
dard speaker system, for a total of four speakers.
Each of the addi ti onal speakers i s mounted behi nd a
gri l l e l ocated on the outboard ends of the sound bar,
whi ch i s l ocated on the headl i ner just forward of the
upper l i ftgate openi ng rei nforcement near the rear of
the vehi cl e cargo area.
XJ AUDIO SYSTEMS 8F - 1
The premi um speaker opti on upgrades al l of the
speakers to I nfi ni ty model s, and i ncl udes a 100 watt
I nfi ni ty ampl i fi er. Each front door has two separate
I nfi ni ty speakers: a woofer mounted l ow i n the door,
and a tweeter mounted behi nd the door fl ag tri m
panel . I nfi ni ty coaxi al speakers are mounted i n the
sound bar. The I nfi ni ty ampl i fi er i s mounted to the
fl oor pan under the l eft rear seat cushi on.
ANTENNA
Al l model s use a fi xed-l ength stai nl ess steel rod-
type antenna mast, i nstal l ed at the ri ght front fender
of the vehi cl e. The antenna mast i s connected to the
center wi re of the coaxi al antenna cabl e, and i s not
grounded to any part of the vehi cl e.
To el i mi nate stati c, the antenna base must have a
good ground. The coaxi al antenna cabl e shi el d (the
outer wi re mesh of the cabl e) i s grounded to the
antenna base and the radi o chassi s.
The antenna coaxi al cabl e has an addi ti onal di s-
connect, l ocated near the ri ght cowl si de panel
behi nd the i nstrument panel . Thi s addi ti onal di scon-
nect al l ows the i nstrument panel assembl y to be
removed and i nstal l ed wi thout removi ng the radi o.
The factory-i nstal l ed El ectroni cal l y Tuned Radi os
(ETRs) automati cal l y compensate for radi o antenna
tri m. Therefore, no antenna tri mmer adjustment i s
requi red or possi bl e when repl aci ng the recei ver or
the antenna.
RADIO NOISE SUPPRESSION
Radi o Frequency I nterference (RFI ) and El ectro-
Magneti c I nterference (EMI ) noi se suppressi on i s
accompl i shed pri mari l y through ci rcui try i nternal to
the radi o recei vers. These i nternal suppressi on
devi ces are onl y servi ced as part of the radi o recei ver.
External suppressi on devi ces that are servi ced, and
shoul d be checked i n the case of RFI or EMI noi se
compl ai nts, i ncl ude the fol l owi ng:
Radi o antenna base ground
Radi o chassi s ground wi re, strap, or bracket
Engi ne-to-body ground strap (i f the vehi cl e i s so
equi pped)
Cab-to-bed ground strap (i f the vehi cl e i s so
equi pped)
Heater core ground strap (i f the vehi cl e i s so
equi pped)
Resi stor-type spark pl ugs
Radi o suppressi on-type secondary i gni ti on wi r-
i ng.
I n addi ti on, i f the source of RFI or EMI noi se i s
i denti fi ed as a component on the vehi cl e (i .e., gener-
ator, bl ower motor, etc.), the ground path for that
component shoul d be checked. I f excessi ve resi stance
i s found i n that ci rcui t, repai r that ci rcui t as
requi red before consi deri ng any component repl ace-
ment.
I f the source of the noi se i s i denti fi ed as two-way
mobi l e radi o or tel ephone equi pment, check the
equi pment i nstal l ati on for the fol l owi ng:
Power connecti ons shoul d be made di rectl y to
the battery, and fused as cl osel y to the battery as
possi bl e.
The antenna shoul d be mounted on the roof or
toward the rear of the vehi cl e. Remember that mag-
neti c antenna mounts on the roof panel can adversel y
affect the operati on of an overhead consol e compass,
i f the vehi cl e i s so equi pped.
The antenna cabl e shoul d be ful l y shi el ded coax-
i al cabl e, shoul d be as short as i s practi cal , and
shoul d be routed away from the factory-i nstal l ed
vehi cl e wi re harnesses whenever possi bl e.
The antenna and cabl e must be careful l y
matched to ensure a l ow Standi ng Wave Rati o
(SWR).
Fl eet vehi cl es are avai l abl e wi th an extra-cost RFI -
suppressed Powertrai n Control Modul e (PCM). Thi s
uni t reduces i nterference generated by the PCM on
some radi o frequenci es used i n two-way radi o com-
muni cati ons. However, thi s uni t wi l l not resol ve com-
pl ai nts of RFI i n the commerci al AM or FM radi o
frequency ranges.
AUDIO SYSTEM
INJURY.
8F - 2 AUDIO SYSTEMS XJ
AUDIO SYSTEM DIAGNOSIS
NO AUDIO. 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
6. Speakers faulty.
1. Check radio fuses in fuseblock
module. Replace fuses, if required.
2. Check for loose or corroded radio
connector. Repair, if required.
3. Check for battery voltage at radio
connector. Repair wiring, if required.
4. Check for continuity between
radio chassis and a known good
ground. There should be continuity.
Repair ground, if required.
5. Exchange or replace radio, if
required.
6. See speaker diagnosis, in this
group.
NO DISPLAY. 1. Fuse faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
required.
CLOCK WILL NOT KEEP SET
TIME.
1. Fuse faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
1. Check ignition-off draw fuse.
Replace fuse, if required.
required.
POOR RADIO RECEPTION. 1. Antenna faulty.
2. Ground faulty.
3. Radio faulty.
1. See antenna diagnosis, in this
group. Repair or replace antenna, if
required.
Repair ground, if required..
required.
NO AUDIO. 1. Fuse faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
6. Speakers faulty.
required.
6. See speaker diagnosis, in this
group.
NO/POOR TAPE OPERATION. 1. Faulty tape.
2. Foreign objects behind tape door.
3. Dirty cassette tape head.
4. Faulty tape deck.
1. Insert known good tape and test
operation.
2. Remove foreign objects and test
operation.
3. Clean head with Mopar Cassette
Head Cleaner.
required.
NO COMPACT DISC OPERATION 1. Faulty CD.
2. Foreign material on CD.
3. Condensation on CD or optics.
4. Faulty CD player.
1. Insert known good CD and test
operation.
2. Clean CD and test operation.
3. Allow temperature of vehicle
interior to stabilize and test
operation.
required.
RADIO
8W-47 - Audi o System i n Group 8W - Wi ri ng Di a-
grams.
INJURY.
CAUTION: The speaker output of the radio is a
floating ground system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Check the fuse(s) i n the juncti on bl ock and the
as requi red and repl ace the faul ty fuse(s).
(2) Check for battery vol tage at the fuse i n the
PDC. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to the battery as requi red.
Remove the radi o as descri bed i n thi s group, but do
not unpl ug the radi o wi re harness connectors. Check
for conti nui ty between the radi o chassi s and a good
ground. There shoul d be conti nui ty. I f OK, go to Step
5. I f not OK, repai r the open radi o chassi s ground
vol tage at the fused i gni ti on swi tch output ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, go to Step 6. I f not OK, repai r the open ci rcui t
as requi red.
Check for battery vol tage at the fused B(+) ci rcui t
cavi ty of the l eft (gray) radi o wi re harness connector.
I f OK, repl ace the faul ty radi o. I f not OK, repai r the
open ci rcui t to the I gni ti on-Off Draw (I OD) fuse as
requi red.
SPEAKER
8W-47 - Audi o System i n Group 8W - Wi ri ng Di a-
grams.
INJURY.
CAUTION: The speaker output of the radio is a
floating ground system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
Turn the radi o on. Adjust the bal ance and fader con-
trol s to check the performance of each i ndi vi dual
speaker. Note the speaker l ocati ons that are not per-
formi ng correctl y. Go to Step 2.
(2) Turn the radi o off. Turn the i gni ti on swi tch to
the Off posi ti on. Di sconnect and i sol ate the battery
negati ve cabl e. Remove the radi o as descri bed i n thi s
group. I f the vehi cl e i s equi pped wi th the I nfi ni ty
speaker package, al so unpl ug the wi re harness con-
nectors at the ampl i fi er. Check both the speaker feed
(+) ci rcui t and return () ci rcui t cavi ti es for the i nop-
erati ve speaker l ocati on(s) at the radi o wi re harness
connectors for conti nui ty to ground. I n each case,
there shoul d be no conti nui ty. I f OK, go to Step 3. I f
not OK, repai r the shorted speaker ci rcui t(s) as
requi red.
(3) I f the vehi cl e i s equi pped wi th the I nfi ni ty
speaker package, go to Step 6. I f the vehi cl e i s
equi pped wi th the standard speaker system, check
the resi stance between the speaker feed (+) ci rcui t
and return () ci rcui t cavi ti es of the radi o wi re har-
ness connectors for the i noperati ve speaker l oca-
ti on(s). The meter shoul d read between 2 and 12
ohms (speaker resi stance). I f OK, go to Step 4. I f not
OK, go to Step 5.
(4) I nstal l a known good radi o. Connect the bat-
tery negati ve cabl e. Turn the i gni ti on swi tch to the
On posi ti on. Turn on the radi o and test the speaker
operati on. I f OK, repl ace the faul ty radi o. I f not OK,
turn the radi o off, turn the i gni ti on swi tch to the Off
posi ti on, di sconnect and i sol ate the battery negati ve
cabl e, remove the test radi o, and go to Step 5.
(5) Unpl ug the speaker wi re harness connector at
the i noperati ve speaker. Check for conti nui ty
between the speaker feed (+) ci rcui t cavi ti es of the
radi o wi re harness connector and the speaker wi re
harness connector. Repeat the check between the
speaker return () ci rcui t cavi ti es of the radi o wi re
harness connector and the speaker wi re harness con-
nector. I n each case, there shoul d be conti nui ty. I f
OK, repl ace the faul ty speaker. I f not OK, repai r the
open ci rcui t(s) as requi red.
(6) For each i noperati ve speaker l ocati on, check for
conti nui ty between the speaker feed (+) ci rcui t cavi -
ti es of the radi o wi re harness connectors and the
ampl i fi er wi re harness connectors. Repeat the check
for each i noperati ve speaker l ocati on between the
speaker return () ci rcui t cavi ti es of the radi o wi re
harness connectors and the ampl i fi er wi re harness
connectors. I n each case, there shoul d be conti nui ty.
as requi red.
(7) Check for conti nui ty between the two ground
ci rcui t cavi ti es of the ampl i fi er wi re harness connec-
tor and a good ground. There shoul d be conti nui ty. I f
OK, go to Step 8. I f not OK, repai r the open ci rcui t(s)
as requi red.
(8) Check the ampl i fi er fuse i n the juncti on bl ock.
I f OK, go to Step 9. I f not OK, repai r the shorted ci r-
cui t or component as requi red and repl ace the faul ty
fuse.
(9) Check for battery vol tage at the ampl i fi er fuse
i n the juncti on bl ock. I f OK, go to Step 10. I f not OK,
repai r the open ci rcui t to the PDC as requi red.
(10) I nstal l the radi o. Connect the battery negati ve
cabl e. Check for battery vol tage at the two fused B(+)
ci rcui t cavi ti es of the ampl i fi er wi re harness connec-
tor. I f OK, go to Step 11. I f not OK, repai r the open
Turn the radi o on. Check for battery vol tage at the
radi o 12 vol t output ci rcui t cavi ty of the ampl i fi er
wi re harness connector. I f OK, go to Step 12. I f not
OK, repai r the open ci rcui t to the radi o as requi red.
(12) Turn the radi o off. Turn the i gni ti on swi tch to
the Off posi ti on. Di sconnect and i sol ate the battery
negati ve cabl e. For each i noperati ve speaker l ocati on,
check both the ampl i fi ed feed (+) ci rcui t and the
ampl i fi ed return () ci rcui t cavi ti es of the ampl i fi er
wi re harness connectors for conti nui ty to ground. I n
each case there shoul d be no conti nui ty. I f OK, go to
requi red.
(13) For each i noperati ve speaker l ocati on, check
the resi stance between the ampl i fi ed feed (+) ci rcui t
and the ampl i fi ed return () ci rcui t cavi ti es of the
ampl i fi er wi re harness connectors. The meter shoul d
read between 2 and 12 ohms (speaker resi stance). I f
OK, repl ace the faul ty ampl i fi er. I f not OK, go to
Step 14.
(14) Unpl ug the speaker wi re harness connector at
the i noperati ve speaker. Check for conti nui ty
between the ampl i fi ed feed (+) ci rcui t cavi ti es of the
speaker wi re harness connector and the ampl i fi er
wi re harness connector. Repeat the check between
the ampl i fi ed return () ci rcui t cavi ti es of the speaker
wi re harness connector and the ampl i fi er wi re har-
ness connector. I n each case there shoul d be conti nu-
i ty. I f OK, repl ace the faul ty speaker. I f not OK,
repai r the open ci rcui t as requi red.
ANTENNA
INJURY.
The fol l owi ng four tests are used to di agnose the
antenna wi th an ohmmeter:
Test 1 - Mast to ground test
Test 2 - Ti p-of-mast to ti p-of-conductor test
Test 3 - Body ground to battery ground test
Test 4 - Body ground to coaxi al shi el d test.
The ohmmeter test l ead connecti ons for each test
are shown i n Antenna Tests (Fi g. 1).
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the
instrument panel near the right cowl side panel to
the antenna base, and then from the coaxial cable
connection to the radio chassis connection.
TEST 1
Test 1 determi nes i f the antenna mast i s i nsul ated
from the base. Proceed as fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s and i sol ate.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
antenna base. Check for conti nui ty.
(3) There shoul d be no conti nui ty. I f conti nui ty i s
found, repl ace the faul ty or damaged antenna base
and cabl e assembl y.
TEST 2
Test 2 checks the antenna for an open ci rcui t as
fol l ows:
(1) Unpl ug the antenna coaxi al cabl e connector
from the radi o chassi s.
(2) Connect one ohmmeter test l ead to the ti p of
the antenna mast. Connect the other test l ead to the
center pi n of the antenna coaxi al cabl e connector.
(3) Conti nui ty shoul d exi st (the ohmmeter shoul d
onl y regi ster a fracti on of an ohm). Hi gh or i nfi ni te
resi stance i ndi cates damage to the base and cabl e
assembl y. Repl ace the faul ty base and cabl e, i f
requi red.
TEST 3
Test 3 checks the condi ti on of the vehi cl e body
ground connecti on. Thi s test shoul d be performed
wi th the battery posi ti ve cabl e removed from the bat-
tery. Di sconnect both battery cabl es, the negati ve
cabl e fi rst. Reconnect the battery negati ve cabl e and
perform the test as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the battery
negati ve post.
(2) The resi stance shoul d be l ess than one ohm.
(3) I f the resi stance i s more than one ohm, check
the brai ded ground strap connected to the engi ne and
Fig. 1 Antenna Tests
the vehi cl e body for bei ng l oose, corroded, or dam-
aged. Repai r the ground strap connecti on, i f requi red.
TEST 4
Test 4 checks the condi ti on of the ground between
the antenna base and the vehi cl e body as fol l ows:
(1) Connect one ohmmeter test l ead to the vehi cl e
fender. Connect the other test l ead to the outer cri mp
on the antenna coaxi al cabl e connector.
(2) The resi stance shoul d be l ess then one ohm.
(3) I f the resi stance i s more then one ohm, cl ean
and/or ti ghten the antenna base to fender mounti ng
hardware.
RADIO FREQUENCY INTERFERENCE
INJURY.
I nspect the ground connecti ons at the fol l owi ng:
Bl ower motor
El ectri c fuel pump
Generator
I gni ti on modul e
Wi per motor
Antenna coaxi al ground
Radi o ground
Body-to-engi ne brai ded ground strap (i f the vehi -
cl e i s so equi pped).
Cl ean, ti ghten, or repai r the connecti ons as
requi red.
Al so i nspect the fol l owi ng secondary i gni ti on sys-
tem components, as descri bed i n Group 8D - I gni ti on
Systems:
Spark pl ug wi re routi ng and condi ti on
Di stri butor cap and rotor
I gni ti on coi l
Spark pl ugs.
Reroute the spark pl ug wi res or repl ace the faul ty
components as requi red.
RADIO
INJURY.
cabl e.
(4) Remove the two screws from the front of the
radi o that secure i t to the i nstrument panel (Fi g. 3).
Fig. 3 Radio Remove/Install
FWD RADIO SCREW
(5) Pul l the radi o out from the i nstrument panel
far enough to unpl ug the wi re harness connectors
and the antenna coaxi al cabl e connector (Fi g. 4).
(6) Remove the radi o from the vehi cl e.
Ti ghten the radi o mounti ng screws to 5 Nm (45 i n.
l bs.).
AMPLIFIER
cabl e.
(2) Di sengage the rear seat cushi on l atch by pul l -
i ng upward on the rel ease strap. Ti l t the seat cush-
i on forward.
(3) Li ft the carpeti ng on the rear fl oor pan under
the l eft end of the seat cushi on as requi red to access
the ampl i fi er.
the ampl i fi er (Fi g. 5).
(5) Remove the four screws that secure the ampl i -
fi er to the rear fl oor pan.
(6) Remove the ampl i fi er from the vehi cl e.
Ti ghten the ampl i fi er mounti ng screws to 2.8 Nm
(25 i n. l bs.).
SPEAKER
FRONT DOOR
LOWER
cabl e.
(2) I f the vehi cl e i s so equi pped, remove the man-
ual wi ndow regul ator crank handl e wi th a removal
tool (Fi g. 6).
(3) Remove the screws that secure the door tri m
panel to the i nner door panel (Fi g. 7) or (Fi g. 8).
fl at-bl aded tool , gentl y pry the tri m panel away from
Fig. 4 Radio Connections - Typical
Fig. 5 Amplifier Remove/Install
AMPLIFIER WIRE HARNESS CONNEC- TORS FWD REAR FLOOR PAN SCREW
Fig. 6 Window Regulator Crank Handle Remove -
Typical
Fig. 7 Front Door Trim Panel Remove/Install -
Manual Window
U-NUT DOORTRIM PANEL WINDOWCRANK SPACER PUSH-IN FAS- TENER
the door around the peri meter to rel ease the tri m
panel retai ners.
NOTE: To aid in the removal of the trim panel, start
at the bottom of the panel.
(5) Li ft the door tri m panel upwards and away
from the door to di sengage the top of the panel from
the i nner bel t weatherstri p.
(6) Pul l the door tri m panel away from the i nner
door far enough to access the i nsi de door l atch
rel ease and l ock l i nkage rods near the back of the
i nsi de door remote control .
(7) Unsnap the pl asti c retai ner cl i ps from the
i nsi de door remote control ends of the l atch rel ease
and l ock l i nkage rods, and remove the rod ends from
the i nsi de door remote control .
(8) I f the vehi cl e i s so equi pped, unpl ug the wi re
harness connectors from the door power swi tch mod-
ul e or, on the dri ver si de onl y, the power mi rror
swi tch.
(9) Remove the front door tri m panel from the
vehi cl e.
(10) Remove the two screws that secure the
speaker to the l ower front corner of the i nner door
panel (Fi g. 9).
(11) Pul l the speaker away from the i nner door
panel far enough to unpl ug the speaker wi re harness
connector.
(12) Remove the speaker from the door.
UPPER
(1) Remove the front door tri m panel as descri bed
under Lower Front Door Speaker, i n thi s group.
(2) Remove the one screw that secures the door
fl ag tri m to the i nner door panel (Fi g. 10).
fl at-bl aded tool , gentl y pry the door fl ag tri m away
from the i nner door to rel ease the tri m panel
retai ner.
(4) Unpl ug the upper speaker wi re harness connec-
tor.
(5) Unsnap the speaker from the retai ners mol ded
i nto the back si de of the door fl ag tri m panel .
SOUND BAR
(1) Remove the sound bar from the vehi cl e as
(2) From the i nsi de of the sound bar, strai ghten
the tabs that secure the speaker gri l l e to the sound
bar (Fi g. 11).
(3) From the outsi de of the sound bar, remove the
speaker gri l l e.
Fig. 8 Front Door Trim Panel Remove/Install - Power
Window
Fig. 9 Front Door Lower Speaker Remove/Install
SPEAKER WIRE HARNESS CONNEC- TORS FWD NUT SCREW
Fig. 10 Front Door Flag Trim Panel Remove/Install
(4) Careful l y dri l l out the ri vets that secure the
speaker to the sound bar.
(5) Remove the speaker from the sound bar.
(6) Reverse the removal procedures to i nstal l . Use
new ri vets i nstal l ed from the i nsi de of the sound bar
to secure the speaker.
SOUND BAR
cabl e.
(2) I f the vehi cl e i s so equi pped, remove the cargo
compartment-mounted spare ti re.
(3) Remove the l i ftgate openi ng upper garni sh
moul di ng and the l i ftgate pi l l ar tri m panel s. Refer to
(4) Remove the l ens from the cargo l amp housi ng
(Fi g. 12).
(5) I f the vehi cl e i s so equi pped, remove the rear
roof si de rai l -mounted assi st handl es.
(6) Remove the screws that secure the rear roof
si de rai l garni sh mol di ngs.
(7) Remove the l eft and ri ght rear roof si de rai l
garni sh mol di ngs.
(8) Remove and di scard the two push nut retai ners
from the studs i nsi de the front and rear of the cargo
l amp housi ng.
(9) Lower the sound bar far enough to unpl ug the
wi re harness connectors from both speakers and the
cargo l amp.
(10) Remove the adhesi ve tape that secures the
wi re harness to the i nsi de of the sound bar.
(11) Remove the sound bar from the vehi cl e.
(12) Reverse the removal procedures to i nstal l . Use
two new push nuts on the studs i n the cargo l amp
housi ng when rei nstal l i ng the sound bar.
ANTENNA
INJURY.
cabl e.
(2) Remove the ri ght front fender i nner spl ash
shi el d. Refer to Group 23 - Body for the procedures.
(3) Reach under the ri ght end of the i nstrument
panel to unpl ug the coaxi al cabl e connector (Fi g. 13).
Unpl ug the connector by pul l i ng i t apart whi l e twi st-
i ng the metal connector hal ves. Do not pul l on the
cabl e.
(4) Unscrew the antenna mast from the antenna
body (Fi g. 14).
(5) Remove the antenna cap nut and adapter usi ng
an antenna nut wrench (Speci al Tool C-4816) (Fi g.
15).
(6) Lower the antenna body and cabl e assembl y
through the fender far enough to access the antenna
body by reachi ng up i nto the rear of the ri ght front
Fig. 11 Sound Bar Speaker Remove/Install - Typical Fig. 12 Sound Bar Remove/Install
WIRE HARNESS STUDS LIFTGATE OPENING UPPER REINFORCEMENT SOUND BAR PUSH NUTS LENS FWD
fender wheel openi ng between the ri ght cowl si de
outer panel and the fender (Fi g. 16).
(7) Di sengage the coaxi al cabl e grommet from the
hol e i n the ri ght cowl si de outer panel .
(8) Pul l the coaxi al cabl e out through the ri ght
cowl si de outer panel .
(9) Remove the antenna body and cabl e from the
vehi cl e.
Ti ghten the antenna cap nut to 8 Nm (70 i n. l bs.).
Ti ghten the antenna mast to 3.3 Nm (30 i n. l bs.).
Fig. 13 Antenna Cable Routing
INSTRUMENT PANEL ANTENNA COAXIAL CABLE RIGHT-HAND DRIVE FWD LEFT-HAND DRIVE FWD ANTENNA COAXIAL CABLE HEATER-A/C HOUSING KICK COVER INSTRUMENT PANEL
Fig. 14 Antenna Mast Remove/Install - Typical
ANTENNA MAST ADAPTER CAP NUT
Fig. 15 Antenna Cap Nut and Adapter Remove/
Install - Typical
CAP NUT ANTENNA ADAPTER TOOL
Fig. 16 Antenna Mounting
NUT MAST RIGHT FRONT FENDER FWD ANTENNA BODY AND CABLE GROMMET ADAPTER
HORN SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
components i n the factory-i nstal l ed horn systems.
Refer to 8W-41 - Horns/Ci gar Li ghter i n Group 8W -
Wi ri ng Di agrams for compl ete ci rcui t descri pti ons
and di agrams.
HORN RELAY
The horn rel ay i s a I nternati onal Standards Orga-
ni zati on (I SO) rel ay. The rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the horn
when the horn swi tch grounds the rel ay coi l . See the
Di agnosi s and Testi ng secti on of thi s group for more
i nformati on on the operati on of the horn rel ay.
The horn rel ay i s l ocated i n the juncti on bl ock, on
the ri ght cowl si de panel bel ow the i nstrument panel
i n the passenger compartment. I f a probl em i s
encountered wi th a conti nuousl y soundi ng horn, i t
can usual l y be qui ckl y resol ved by removi ng the horn
rel ay from the juncti on bl ock unti l further di agnosi s
i s compl eted.
The horn rel ay cannot be repai red and, i f faul ty or
HORN SWITCH
A center-bl ow, resi sti ve membrane type horn
swi tch i s i nstal l ed on the back si de of the dri ver si de
ai rbag modul e tri m cover i n the center of the steer-
i ng wheel . When the center area of the ai rbag tri m
cover i s depressed, the horn swi tch compl etes a ci r-
cui t to ground for the coi l si de of the horn rel ay. The
steeri ng wheel and steeri ng col umn must be properl y
grounded for the horn swi tch to functi on.
The horn swi tch i s onl y servi ced as a part of the
ai rbag modul e tri m cover. I f the horn swi tch shoul d
fai l , or i f the ai rbag i s depl oyed, the ai rbag modul e
tri m cover and horn swi tch uni t must be repl aced.
HORN
Dual -note, el ectromagneti c di aphragm-type horns
are standard equi pment. The l ow-note horn i s
mounted and grounded to the l eft radi ator cl osure
panel brace, behi nd the front bumper. The hi gh-note
horn i s connected i n paral l el wi th the l ow-note horn.
The hi gh-note horn i s mounted and grounded to the
ri ght radi ator cl osure panel brace, behi nd the front
bumper. Both horns recei ve battery feed through the
cl osed contacts of the horn rel ay.
The horns cannot be repai red or adjusted and, i f
faul ty or damaged, they must be repl aced.
NOTE: A cadmium-plated screw is used to mount
the horns. Do not substitute other types of screws,
as they may become corroded and cause a loss of
horn ground.
XJ HORN SYSTEMS 8G - 1
HORN RELAY
Di agrams.
INJURY.
RELAY TEST
The horn rel ay i s l ocated i n the juncti on bl ock. The
juncti on bl ock i s attached to the ri ght cowl si de i nner
panel , bel ow the i nstrument panel and behi nd the
ri ght cowl si de tri m panel .
Remove the horn rel ay from the juncti on bl ock as
descri bed i n thi s group to perform the fol l owi ng tests:
RELAY CIRCUIT TEST
to the horn(s). There shoul d be conti nui ty between
the cavi ty for rel ay termi nal 87 and the rel ay output
ci rcui t cavi ty of each horn wi re harness connector at
al l ti mes. I f OK, go to Step 4. I f not OK, repai r the
open ci rcui t to the horn(s) as requi red.
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. I f
OK, go to Step 5. I f not OK, repai r the open ci rcui t to
the fuse i n the juncti on bl ock as requi red.
the el ectromagnet i n the rel ay. I t i s grounded
through the horn swi tch when the horn swi tch i s
depressed. Check for conti nui ty to ground at the cav-
i ty for rel ay termi nal 85. There shoul d be conti nui ty
wi th the horn swi tch depressed, and no conti nui ty
wi th the horn swi tch rel eased. I f not OK, see the
di agnosi s for the Horn Swi tch i n thi s group.
HORN SWITCH
Di agrams.
INJURY.
cabl e. Remove the steeri ng col umn openi ng cover and
knee bl ocker. Check for conti nui ty between the metal
steeri ng col umn jacket and a good ground. There
refer to Group 19 - Steeri ng and check for proper
i nstal l ati on of the steeri ng col umn mounti ng nuts.
(2) Remove the dri ver si de ai rbag modul e as
descri bed i n Group 8M - Passi ve Restrai nt Systems.
Unpl ug the horn swi tch wi re harness connector from
the ai rbag modul e. Unpl ug the horn rel ay from the
Horn Relay
8G - 2 HORN SYSTEMS XJ
juncti on bl ock. Check for conti nui ty between the
steeri ng col umn hal f of the horn swi tch feed wi re
harness connector and a good ground. There shoul d
be no conti nui ty. I f OK, go to Step 3. I f not OK,
repai r the short ci rcui t as requi red.
(3) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the juncti on bl ock. There shoul d be
(4) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
ai rbag modul e. There shoul d be no conti nui ty. I f OK,
go to Step 5. I f not OK, repl ace the faul ty horn
swi tch.
(5) Depress the center of the ai rbag modul e cover
and check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
ai rbag modul e. There shoul d now be conti nui ty. I f not
OK, repl ace the faul ty horn swi tch.
HORN
Di agrams.
(1) Measure the resi stance between the horn
mounti ng bracket and a good ground. There shoul d
be zero ohms resi stance. I f OK, go to Step 2. I f not
OK, repai r the horn ground connecti on as requi red.
(2) Unpl ug the horn wi re harness connector.
Depress the horn swi tch. There shoul d be battery
vol tage at the horn wi re harness connector. I f OK,
repl ace the faul ty horn. I f not OK, repai r the open
ci rcui t to the horn rel ay as requi red.
HORN RELAY
INJURY.
cabl e.
vehi cl e.
(7) Unpl ug the horn rel ay from the juncti on bl ock.
(8) I nstal l the horn rel ay by al i gni ng the rel ay ter-
mi nal s wi th the cavi ti es i n the juncti on bl ock and
access panel .
RIGHT FRONT DOOR SILLCOWL SIDE TRIM PANEL SCREWSILL TRIM FUSE ACCESS PANEL FWD PUSH-NUT
XJ HORN SYSTEMS 8G - 3
HORN SWITCH
WARNING: ON VEHICLES EQUIPPED WITH A
DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTE-
GRAL TO THE AIRBAG MODULE TRIM COVER.
SERVICE OF THIS COMPONENT SHOULD BE PER-
FORMED ONLY BY CHRYSLER-TRAINED AND
AUTHORIZED DEALER SERVICE TECHNICIANS.
FAILURE TO TAKE THE PROPER PRECAUTIONS
OR TO FOLLOW THE PROPER PROCEDURES
COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY. REFER TO GROUP 8M - PAS-
SIVE RESTRAINT SYSTEMS FOR THE SERVICE
PROCEDURES.
HORN
cabl e.
(3) Remove the front underbody spl ash shi el d.
NOTE: Do not remove the horn from its mounting
bracket.
(4) Remove the horn mounti ng bracket screw and
l ower the horn and mounti ng bracket uni t far enough
to access the wi re harness connector (Fi g. 2).
horn.
(6) Remove the horn and mounti ng bracket from
the vehi cl e.
Ti ghten the horn mounti ng bracket screw to 28.5
Nm (21 ft. l bs.).
Fig. 2 Horns Remove/Install
MOUNTING BOLT HORN
8G - 4 HORN SYSTEMS XJ
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED CONTROL SERVO . . . . . . . . . . . . . . . . 1
SPEED CONTROL SWITCHES . . . . . . . . . . . . . 1
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 1
ON-BOARD DIAGNOSTIC TEST FOR SPEED
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 2
OVERSHOOT/UNDERSHOOT FOLLOWING
SPEED CONTROL SET . . . . . . . . . . . . . . . . . . 4
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPEED CONTROL ELECTRICAL TEST . . . . . . . 2
SPEED CONTROL SWITCHES . . . . . . . . . . . . . 3
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 3
VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . 3
SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . . 5
SPEED CONTROL SWITCH . . . . . . . . . . . . . . . . 5
STOP LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 5
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL INFORMATION
INTRODUCTION
The vehi cl e speed control system i s el ectroni cal l y
control l ed and vacuum operated. The system i s
desi gned to operate between approxi matel y 35 and
85 mph (56 and 137 km/h). Fol l owi ng are general
descri pti ons of the major components i n the speed
control system. For di agnosi s of the enti re speed con-
trol system, refer to the appropri ate Powertrai n
Di agnosti c Procedures servi ce manual and the DRB
scan tool . Refer to Group 8W, Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and wi ri ng di agrams.
SPEED CONTROL SERVO
The servo uni t consi sts of a sol enoi d val ve body, a
vacuum servo and the mounti ng bracket. The Power-
trai n Control Modul e (PCM) control s the sol enoi d
val ve body. The sol enoi d val ve body control s the
appl i cati on and rel ease of vacuum to the di aphragm
of the vacuum servo. A cabl e connects the servo wi th
the throttl e l i nkage. The servo uni t cannot be
repai red and i s servi ced onl y as a compl ete assembl y.
SPEED CONTROL SWITCHES
Two separate speed control swi tch modul es are
mounted on the steeri ng wheel to the l eft and ri ght
si de of the dri vers ai rbag modul e. Wi thi n the two
swi tch modul es, fi ve momentary contact swi tches,
supporti ng seven di fferent speed control functi ons
are used. The outputs from these swi tches are fi l -
tered i nto one i nput. The Powertrai n Control Modul e
(PCM) determi nes whi ch output has been appl i ed
through resistive multiplexing. The i nput ci rcui t
vol tage i s measured by the PCM to determi ne whi ch
swi tch functi on has been sel ected.
A speed control i ndi cator l amp, l ocated on the
i nstrument panel cl uster i s energi zed by the PCM vi a
the CCD Bus. Thi s occurs when speed control system
power has been turned ON, and the engi ne i s run-
ni ng.
The two swi tch modul es are l abel ed: ON/OFF, SET,
RESUME/ACCEL, CANCEL and COAST. Refer to
the owners manual for more i nformati on on speed
control swi tch functi ons and setti ng procedures. The
i ndi vi dual swi tches cannot be repai red. I f one i ndi -
vi dual swi tch fai l s, the swi tch modul e must be
repl aced.
STOP LAMP SWITCH
Vehi cl es equi pped wi th the speed control opti on use
a dual functi on stop l amp swi tch. The swi tch i s
mounted i n the same l ocati on as the conventi onal
stop l amp swi tch, on the brake pedal mounti ng
bracket under the i nstrument panel . The PCM mon-
i tors the state of the dual functi on stop l amp swi tch.
Refer to Group 5, Brakes for more i nformati on on
stop l amp swi tch servi ce and adjustment procedures.
XJ VEHICLE SPEED CONTROL SYSTEM 8H - 1
SERVO CABLE
The speed control servo cabl e i s connected between
the speed control vacuum servo di aphragm and the
throttl e body control l i nkage. Thi s cabl e causes the
throttl e control l i nkage to open or cl ose the throttl e
val ve i n response to movement of the vacuum servo
di aphragm.
The speed control el ectroni c control ci rcui try i s
i ntegrated i nto the Powertrai n Control Modul e
(PCM). The PCM i s l ocated i n the engi ne compart-
ment. The PCM speed control functi ons are moni -
tored by the On-Board Di agnosti cs (OBD). Al l OBD-
sensed systems are moni tored by the PCM. Each
moni tored ci rcui t i s assi gned a Di agnosti c Troubl e
Code (DTC). The PCM wi l l store a DTC i n el ectroni c
memory for certai n fai l ures i t detects. See On-Board
Di agnosti c Test For Speed Control System i n thi s
group for more i nformati on. The PCM cannot be
repai red and must be repl aced i f faul ty.
VACUUM RESERVOIR
The vacuum reservoi r contai ns a one-way check
val ve to trap engi ne vacuum i n the reservoi r. When
engi ne vacuum drops, as i n cl i mbi ng a grade whi l e
dri vi ng, the reservoi r suppl i es the vacuum needed to
mai ntai n proper speed control operati on. The vacuum
reservoi r cannot be repai red and must be repl aced i f
faul ty.
The Vehi cl e Speed Sensor (VSS) i s a pul se genera-
tor mounted to an adapter near the transmi ssi on out-
put shaft. The sensor i s dri ven through the adapter
by a speedometer pi ni on gear. The VSS pul se si gnal
to the speedometer/odometer i s moni tored by the
PCM speed control ci rcui try to determi ne vehi cl e
speed and to mai ntai n speed control set speed. Refer
to the appropri ate Powertrai n Di agnosti c Procedures
manual for di agnosi s and testi ng of thi s component.
Refer to Group 14, Fuel System for removal /i nstal l a-
ti on procedures.
ROAD TEST
Perform a vehi cl e road test to veri fy reports of
speed control system mal functi on. The road test
shoul d i ncl ude attenti on to the speedometer. Speed-
ometer operati on shoul d be smooth and wi thout fl ut-
ter at al l speeds.
Fl utter i n the speedometer i ndi cates a probl em
whi ch mi ght cause surgi ng i n the speed control sys-
tem. The cause of any speedometer probl ems shoul d
be corrected before proceedi ng. Refer to Group 8E,
I nstrument Panel and Gauges for speedometer di ag-
nosi s.
I f a road test veri fi es a system probl em and the
speedometer operates properl y, check for:
A Di agnosti c Troubl e Code (DTC). I f a fl ash
l amp code 15, 34 or 77 exi sts at the Check Engi ne
Lamp (MI L), conduct tests per the Powertrai n Di ag-
nosti c Procedures servi ce manual .
A mi sadjusted brake (stop) l amp swi tch. Thi s
coul d al so cause an i ntermi ttent probl em.
Loose or corroded el ectri cal connecti ons at the
servo. Corrosi on shoul d be removed from el ectri cal
termi nal s and a l i ght coati ng of Mopar Mul ti Purpose
Grease, or equi val ent, appl i ed.
Loose or l eaki ng vacuum hoses or connecti ons.
Secure attachment of both ends of the speed con-
trol servo cabl e.
Smooth operati on of throttl e l i nkage and throttl e
body ai r val ve.
Fai l ed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
ON-BOARD DIAGNOSTIC TEST FOR SPEED
CONTROL SYSTEM
cri ti cal i nput and output ci rcui ts of the speed control
system, maki ng sure they are operati onal . A Di agnos-
ti c Troubl e Code (DTC) i s assi gned to each i nput and
output ci rcui t moni tored by the On-Board Di agnosti c
(OBD) system. Some ci rcui ts are checked conti nu-
ousl y and some are checked onl y under certai n con-
di ti ons.
For DTC i nformati on, refer to Di agnosti c Troubl e
Codes i n Group 25, Emi ssi on Control System. Thi s
wi l l i ncl ude a compl ete l i st of DTCs i ncl udi ng DTCs
for the speed control system.
SPEED CONTROL ELECTRICAL TEST
Two di fferent test methods may be used to check
the el ectroni c speed control system. One i nvol ves
usi ng the DRB scan tool . I f thi s test method i s
desi red, refer to the appropri ate Powertrai n Di agnos-
ti c Procedures servi ce manual .
The other test method wi l l i nvol ve the use of a
vol t/ohm meter. The vol t/ohm meter method i s
descri bed wi thi n the tests on the fol l owi ng pages.
Refer to Group 8W, Wi ri ng Di agrams for speed con-
trol el ectri cal schemati cs and connector l ocati on.
8H - 2 VEHICLE SPEED CONTROL SYSTEM XJ
CAUTION: When test probing for voltage or conti-
nuity at electrical connectors, care must be taken
not to damage connector, terminals or seals. If
these components are damaged, intermittent or
complete system failure may occur.
When el ectri cal connecti ons are removed, corrosi on
shoul d be removed from el ectri cal termi nal s and a
l i ght coati ng of Mopar Mul ti -Purpose Grease, or
equi val ent, shoul d be appl i ed.
I nspect connectors for damaged termi nal s. A poor
el ectri cal connecti on can cause a compl ete or i nter-
mi ttent mal functi on. For thi s reason, a poor connec-
ti on may be mi sdi agnosed as a component
mal functi on.
For di agnosi s and testi ng of the Vehi cl e Speed Sen-
sor (VSS), refer to the appropri ate Powertrai n Di ag-
nosti c Procedures servi ce manual . Al so refer to the
DRB scan tool .
SPEED CONTROL SWITCHES
For compl ete speed control system di agnosi s, refer
manual . To test each of the speed control swi tches
onl y, refer to the fol l owi ng:
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
RELATED STEERING WHEEL AND STEERING COL-
UMN COMPONENTS, YOU MUST FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM
CAPACITOR TO DISCHARGE BEFORE FURTHER
SYSTEM SERVICE. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Di sconnect negati ve battery cabl e. Wai t 2 mi n-
utes for ai rbag system capaci tor to di scharge.
(2) Remove the two speed control swi tch modul es
from steeri ng wheel . Refer to the removal /i nstal l ati on
secti on for procedures.
(3) Check conti nui ty of each i ndi vi dual speed con-
trol swi tch modul e as shown i n chart (Fi g. 1). I f OK,
rei nstal l swi tch. I f not OK, repl ace swi tch modul e
assembl y.
STOP LAMP SWITCH
For conti nui ty checks and swi tch adjustment, refer
to Group 5, Brakes.
VACUUM SUPPLY TEST
(1) Di sconnect vacuum hose at speed control servo
and i nstal l a vacuum gauge i nto the di sconnected
hose.
(2) Start engi ne and observe gauge at i dl e. Vac-
uum gauge shoul d read at l east ten i nches of mer-
cury.
(3) I f vacuum i s l ess than ten i nches of mercury,
determi ne source of l eak. Check vacuum l i ne to
engi ne for l eaks. Al so check actual engi ne i ntake
mani fol d vacuum. I f mani fol d vacuum does not meet
thi s requi rement, check for poor engi ne performance
and repai r as necessary.
(4) I f vacuum l i ne to engi ne i s not l eaki ng, check
for l eak at vacuum reservoi r. To l ocate and gai n
access to reservoi r, refer to Vacuum Reservoi r Remov-
al /I nstal l ati on i n thi s group. Di sconnect vacuum l i ne
at reservoi r and connect a hand-operated vacuum
pump to reservoi r fi tti ng. Reservoi r vacuum shoul d
not bl eed off. I f vacuum i s bei ng l ost, repl ace reser-
voi r.
SPEED CONTROL SERVO
For compl ete speed control system di agnosi s, refer
manual . To test the speed control servo onl y, refer to
the fol l owi ng:
The engi ne must be started and runni ng for the
fol l owi ng vol tage tests.
(1) Start engi ne.
(2) Di sconnect 4way el ectri cal connector at servo.
(3) Turn speed control swi tch to ON posi ti on.
(4) Check for battery vol tage at pi n3 of wi ri ng
harness 4way connector (Fi g. 2). Thi s i s the 12 vol t
feed from the stopl amp swi tch. When the brake pedal
i s depressed, vol tage shoul d not be present at pi n3.
I f vol tage i s not present wi th brake pedal not
depressed, check for conti nui ty between servo and
stop l amp swi tch. Al so check stop l amp swi tch
adjustment. Refer to Group 5, Brakes for procedures.
Fig. 1 Speed Control Switch Continuity Tests
SWITCH PIN 1 PIN 2
(5) Connect a smal l gauge jumper wi re between
the di sconnected servo harness 4way connector
pi n3, and pi n3 on the servo. Check for battery vol t-
age at pi ns1, 2 and 4 of the servo. I f battery vol tage
i s not at these pi ns, repl ace the servo.
(6) Turn i gni ti on swi tch to OFF posi ti on. Check for
conti nui ty between di sconnected servo harness
4way connector pi n4 and a good ground. There
shoul d be conti nui ty. I f not OK, repai r open ci rcui t to
For compl ete PCM di agnosi s of the speed control
system, refer to the DRB scan tool and the appropri -
ate Powertrai n Di agnosti c Procedures servi ce man-
ual .
OVERSHOOT/UNDERSHOOT FOLLOWING SPEED
CONTROL SET
I f the operator repeatedl y presses and rel eases the
set button wi th thei r foot off of the accel erator (a l i ft
foot set to begi n speed control operati on), the vehi cl e
may accel erate and exceed the desi red set speed by
up to 5 MPH (8 km/h) and then decel erate to l ess
than the desi red set speed before fi nal l y achi evi ng
the desi red set speed.
The Speed Control has an adapti ve strategy that
compensates for vehi cl e-to-vehi cl e vari ati ons i n speed
control cabl e l engths. When the speed control i s set
wi th the vehi cl e operators foot off of the accel erator
pedal , the speed control thi nks there i s excessi ve
speed control cabl e sl ack and adapts. I f the l i ft foot
sets are conti nual l y used, the speed control over-
shoot/undershoot condi ti on wi l l devel op.
To unl earn the overshoot/undershoot condi ti on,
the vehi cl e operator has to press and rel ease the set
button whi l e mai ntai ni ng the desi red set speed wi th
the accel erator pedal (not decel erati ng or accel erat-
i ng), and then turn the crui se control swi tch to the
OFF posi ti on (or press the CANCEL button i f
equi pped) after wai ti ng 10 seconds. Thi s procedure
must be performed approxi matel y 1015 ti mes to
compl etel y unl earn the overshoot/undershoot condi -
ti on.
SPEED CONTROL SERVO
REMOVAL
(2) Di sconnect vacuum hose at servo.
(3) Di sconnect el ectri cal connector at servo.
(4) Bl ock throttl e to ful l open posi ti on.
(5) Remove 2 servo mounti ng nuts hol di ng cabl e
and cabl e sl eeve to mounti ng bracket.
(6) Pul l servo away from mounti ng bracket to
expose cabl e retai ni ng cl i p (Fi g. 3) and remove cl i p.
(7) Pul l servo away from cabl e and remove from
vehi cl e.
INSTALLATION
(1) Posi ti on servo near end of servo cabl e.
(2) Bl ock throttl e to ful l open posi ti on. Al i gn hol e
i n cabl e sl eeve wi th hol e i n servo pi n and i nstal l
cabl e retai ni ng cl i p (Fi g. 3).
(3) I nsert servo studs through hol es i n servo
mounti ng bracket.
(4) I nstal l servo mounti ng nuts. Ti ghten to 8.5
(5) Connect vacuum hose at servo.
(6) Connect el ectri cal connector at servo.
Fig. 2 Servo 4Way Harness Connector
Fig. 3 Servo Cable Clip Remove/Install
(7) Remove throttl e bl ock.
SPEED CONTROL SWITCH
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR
RELATED STEERING WHEEL AND STEERING COL-
UMN COMPONENTS YOU MUST FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM
SYSTEM SERVICE. FAILURE TO DO SO COULD
RESULT IN ACCIDENTAL DEPLOYMENT AND POS-
SIBLE PERSONAL INJURY.
REMOVAL
(1) Di sconnect and i sol ate negati ve battery cabl e
from battery.
(2) Remove ai rbag modul e. Refer to Group 8M,
Passi ve Restrai nt Systems for procedures.
(3) From undersi de of steeri ng wheel , remove
speed control swi tch mounti ng screw (Fi g. 4).
(4) Remove swi tch from steeri ng wheel and unpl ug
el ectri cal connector.
INSTALLATION
(1) Pl ug el ectri cal connector i nto swi tch.
(2) Posi ti on swi tch to steeri ng wheel .
(3) I nstal l swi tch mounti ng screw and ti ghten to
1.5 Nm (14 i n. l bs.) torque.
(4) I nstal l ai rbag modul e. Refer to Group 8M, Pas-
si ve Restrai nt Systems for procedures.
STOP LAMP SWITCH
Refer to Stop Lamp Swi tch i n Group 5, Brakes for
removal /i nstal l ati on and adjustment procedures.
SERVO CABLE
REMOVAL
(2) Usi ng fi nger pressure onl y, remove cabl e con-
nector by pushi ng connector off the throttl e body
bel l crank pi n (Fi g. 5). DO NOT try to pull cable
connector off perpendicular to the bellcrank
pin. Connector will be broken.
(3) Two squeeze tabs are l ocated on si des of speed
control cabl e at cabl e l ocki ng pl ate (Fi g. 6). Squeeze
the tabs together and push cabl e out of cabl e l ocki ng
pl ate.
(4) Uncl i p cabl e from cabl e gui de at val ve cover
(Fi g. 6).
(5) Di sconnect servo cabl e at servo. Refer to Speed
Control ServoRemoval /I nstal l ati on.
INSTALLATION
(1) Attach end of cabl e to speed control servo.
Refer to Speed Control Servo Removal /I nstal l ati on.
(2) I nstal l cabl e i nto cabl e l ocki ng pl ate (snaps i n).
(3) I nstal l cabl e connector at throttl e body
bel l crank pi n (snaps on).
Fig. 4 Speed Control Switch Remove/Install
Fig. 5 Servo Cable to BellcrankRemove/Install
BELLCRANK CABLE CONNEC- TOR PUSH SPEED CONTROL CABLE
(4) Cl i p cabl e to cabl e gui de at val ve cover.
For Removal /I nstal l ati on refer to Powertrai n Con-
trol Modul e i n Group 14, Fuel I njecti on System.
VACUUM RESERVOIR
REMOVAL
The vacuum reservoi r i s l ocated behi nd ri ght front
bumper end cap on vehi cl es equi pped wi th LHD (Left
Hand Dri ve) (Fi g. 7). I t i s l ocated behi nd l eft front
bumper end cap on vehi cl es equi pped wi th RHD
(Ri ght Hand Dri ve).
(1) Remove front bumper end cap. Refer to Front
Bumper End Cap i n Group 23, Body for procedures.
(2) Remove vacuum l i ne at reservoi r (Fi g. 8).
(3) Remove 2 reservoi r mounti ng screws.
(4) Remove reservoi r from bumper bar.
INSTALLATION
(1) Posi ti on reservoi r to bumper bar and i nstal l
mounti ng screws. Ti ghten screws to 8 Nm (72 i n.
l bs.) torque.
(2) I nstal l vacuum l i ne to reservoi r
(3) I nstal l front bumper end cap. Refer to Group
23, Body for procedures.
For removal /i nstal l ati on, refer to Vehi cl e Speed
Sensor i n Group 14, Fuel System.
SPECIFICATIONS
TORQUE CHART
Description Torque
Servo Mounti ng Bracket-to-
Servo Nuts . . . . . . . . . . . . . . 8.5 Nm (75 i n. l bs.)
Servo Mounti ng Bracket-to-
Body Bol ts . . . . . . . . . . . . . . . . 2 Nm (20 i n. l bs.)
Speed Control Swi tch Mounti ng
Screws . . . . . . . . . . . . . . . . . . 1.5 Nm (14 i n. l bs.)
Vacuum Reservoi r Mounti ng
Bol ts . . . . . . . . . . . . . . . . . . . . 8 Nm (72 i n. l bs.)
Fig. 6 Squeeze Tabs at Cable Locking Plate
CABLE
GUIDE
SPEED CONTROL CABLEACCELERATOR CABLE
SQUEEZE
TABS
LOCKING
PLATE
TRANSMISSION CABLE
Fig. 7 Vacuum Reservoir Location
BUMPER END CAP VACUUM RESERVOIR
Fig. 8 Vacuum Reservoir Removal/Installation
VACUUM LINE RESERVOIR SCREWS VACUUM RESER- VOIR
TURN SIGNAL AND HAZARD WARNING SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
COMBINATION FLASHER . . . . . . . . . . . . . . . . . 1
HAZARD WARNING SYSTEM . . . . . . . . . . . . . . 1
TURN SIGNAL INDICATOR LAMP . . . . . . . . . . . 2
TURN SIGNAL LAMP . . . . . . . . . . . . . . . . . . . . . 2
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH . . . . . . . . . . . . . . . . . . . . 2
TURN SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 2
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . 3
TURN SIGNAL AND HAZARD WARNING
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMBINATION FLASHER . . . . . . . . . . . . . . . . . 3
MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
components i n the turn si gnal and hazard warni ng
systems. Refer to 8W-52 - Turn Si gnal s i n Group 8W
- Wi ri ng Di agrams for compl ete ci rcui t descri pti ons
and di agrams.
TURN SIGNAL SYSTEM
Wi th the i gni ti on swi tch i n the On posi ti on, and
the mul ti -functi on swi tch control l ever moved up
(ri ght turn) or down (l eft turn), the turn si gnal sys-
tem i s acti vated. The swi tch has a detent posi ti on i n
each di recti on that provi des turn si gnal s wi th auto-
mati c cancel l ati on, and an i ntermedi ate momentary
posi ti on that provi des turn si gnal s onl y unti l the
mul ti -functi on swi tch l ever i s rel eased.
When the turn si gnal swi tch i s i n a detent posi -
ti on, i t i s turned off by one of two cancel l i ng cam
l obes mol ded i nto the hub of the cl ockspri ng mecha-
ni sm. When turni ng the steeri ng wheel causes one of
the cam l obes to contact a cancel actuator i n the
mul ti -functi on swi tch, the turn si gnal swi tch auto-
mati cal l y returns to the off posi ti on.
When the turn si gnal system i s acti vated, the
sel ected (ri ght or l eft) turn si gnal i ndi cator l amp,
front park/turn si gnal l amp, front si de marker l amp,
and rear tai l /stop/turn si gnal l amp bul bs wi l l fl ash.
Wi th the headl amp swi tch i n the Off posi ti on, the
front turn si gnal and front si de marker l amps fl ash
i n uni son. Wi th the headl amp swi tch i n the On posi -
ti on, the front turn si gnal and front si de marker
l amps fl ash al ternatel y.
HAZARD WARNING SYSTEM
The hazard warni ng system i s acti vated by a
swi tch button i n the mul ti -functi on swi tch. The but-
ton i s l ocated on the top of the steeri ng col umn
between the steeri ng wheel and the i nstrument
panel . The hazard warni ng swi tch button i s i denti -
fi ed wi th a doubl e tri angl e.
The hazard warni ng system i s connected to a non-
swi tched battery feed so that the system remai ns
functi onal , regardl ess of the i gni ti on swi tch posi ti on.
Sl i de the swi tch button to the l eft to acti vate the haz-
ard warni ng system, and sl i de the swi tch button to
the ri ght to turn the system off.
When the hazard warni ng system i s acti vated, the
ri ght and l eft turn si gnal i ndi cators, front park/turn
si gnal l amps, front si de marker l amps, and rear tai l /
stop/turn si gnal l amps wi l l fl ash. Wi th the headl amp
swi tch i n the Off posi ti on, the front turn si gnal and
front si de marker l amps fl ash i n uni son. Wi th the
head or park l amps turned on, the front turn si gnal
and front si de marker l amps fl ash al ternatel y.
COMBINATION FLASHER
The combi nati on fl asher i s a smart rel ay that func-
ti ons as both the turn si gnal system and hazard
warni ng system fl asher. The combi nati on fl asher i s
XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1
desi gned to handl e the current fl ow requi rements of
the factory-i nstal l ed l i ghti ng.
I f suppl emental l i ghti ng i s added to the turn si gnal
l amp ci rcui ts, such as when towi ng a trai l er wi th
l i ghts, the combi nati on fl asher wi l l automati cal l y
compensate. Thi s al l ows the fl ash rate to remai n the
same, regardl ess of el ectri cal l oad i ncreases. How-
ever, i f a bul b fai l s i n the turn si gnal l amp ci rcui ts,
the fl ash rate of the remai ni ng bul bs i n that ci rcui t
wi l l i ncrease to 120 fl ashes-per-mi nute, or hi gher.
Whi l e the combi nati on fl asher shares the termi nal
ori entati on (footpri nt) of a I nternati onal Standards
Organi zati on (I SO)-type rel ay, the i nternal ci rcui try
i s much di fferent. The combi nati on fl asher contai ns
acti ve el ectroni c i ntegrated ci rcui try el ements. Do not
substi tute any other rel ay for the combi nati on
fl asher.
Because of the acti ve el ectroni c el ements wi thi n
the combi nati on fl asher, i t cannot be tested wi th con-
venti onal automoti ve el ectri cal test equi pment. I f the
combi nati on fl asher i s bel i eved to be faul ty, test the
turn si gnal and hazard warni ng system ci rcui ts as
descri bed i n thi s group. Then repl ace the combi na-
ti on fl asher wi th a known good uni t to confi rm sys-
tem operati on.
The combi nati on fl asher cannot be repai red and, i f
faul ty, i t must be repl aced.
TURN SIGNAL SWITCH AND HAZARD WARNING
SWITCH
The turn si gnal and hazard warni ng swi tches are
i ntegral to the mul ti -functi on swi tch assembl y. The
mul ti -functi on swi tch assembl y i s mounted to the l eft
si de of the steeri ng col umn (Fi g. 1). Thi s swi tch con-
tai ns ci rcui try for the fol l owi ng functi ons:
Turn si gnal s
Hazard warni ng
Headl amp beam sel ecti on
Headl amp opti cal horn.
The i nformati on contai ned i n thi s group addresses
onl y the mul ti -functi on swi tch functi ons for the turn
si gnal and hazard warni ng ci rcui ts. For i nformati on
rel ati ve to the other swi tch functi ons, refer to the
proper group. However, the mul ti -functi on swi tch
cannot be repai red. I f any functi on of the mul ti -func-
ti on swi tch i s faul ty, or i f the swi tch i s damaged, the
enti re swi tch assembl y must be repl aced.
The turn si gnal i ndi cator l amps are l ocated i n the
i nstrument cl uster. They fl ash wi th the exteri or turn
si gnal l amps to gi ve the dri ver a vi sual i ndi cati on
that a turn si gnal or the hazard warni ng system i s
operati ng. For di agnosi s and servi ce of these l amps,
refer to Group 8E - I nstrument Panel Systems.
TURN SIGNAL LAMP
The exteri or l amps i n the turn si gnal and hazard
warni ng ci rcui ts i ncl ude the front park/turn si gnal ,
the front si de marker, and the rear tai l /stop/turn si g-
nal . For di agnosi s and servi ce of these l amps, refer to
Group 8L - Lamps.
INTRODUCTION
When di agnosi ng the turn si gnal or hazard warn-
i ng ci rcui ts, remember that hi gh generator output
can burn out bul bs rapi dl y and repeatedl y. I f thi s i s a
probl em on the vehi cl e bei ng di agnosed, refer to
Group 8C - Chargi ng System for further di agnosi s of
a possi bl e generator overchargi ng condi ti on.
INJURY.
TURN SIGNAL AND HAZARD WARNING SYSTEMS
8W-52 - Turn Si gnal s i n Group 8W - Wi ri ng Di a-
grams.
Fig. 1 Multi-Function Switch
HAZARD WARNING BUTTON CANCEL ACTUATOR CONTROL STALK
8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ
INJURY.
Actuate the turn si gnal l ever or hazard warni ng but-
ton. Observe the turn si gnal i ndi cator l amp(s) i n the
i nstrument cl uster. I f the fl ash rate i s very hi gh,
check for a turn si gnal bul b that i s not l i t or i s very
di ml y l i t. Repai r the ci rcui ts to that l amp or repl ace
the faul ty bul b, as requi red. Test the operati on of the
turn si gnal and hazard warni ng systems agai n. I f the
turn si gnal i ndi cator(s) fai l to l i ght, go to Step 2.
Check the turn si gnal fuse i n the juncti on bl ock
and/or the hazard warni ng fuse i n the Power Di stri -
buti on Center (PDC). I f OK, go to Step 3. I f not OK,
repai r the shorted ci rcui t or component as requi red
and repl ace the faul ty fuse(s).
(3) Turn the i gni ti on swi tch to the On posi ti on to
check for battery vol tage at the turn si gnal fuse i n
the juncti on bl ock; or, l eave the i gni ti on swi tch i n the
Off posi ti on to check for battery vol tage at the haz-
ard warni ng fuse i n the PDC. I f OK, go to Step 4. I f
not OK, repai r the open ci rcui t as requi red.
Unpl ug the combi nati on fl asher from i ts wi re har-
ness connector and repl ace i t wi th a known good
uni t. Connect the battery negati ve cabl e. Test the
operati on of the turn si gnal and hazard warni ng sys-
tems. I f OK, di scard the faul ty combi nati on fl asher.
I f not OK, remove the test fl asher and go to Step 5.
Check for battery vol tage at the combi nati on fl asher
fused i gni ti on ci rcui t cavi ty i n the combi nati on
fl asher wi re harness connector. I f OK, go to Step 6. I f
not OK, go to Step 8.
Check for battery vol tage agai n at the combi nati on
fl asher fused B+ ci rcui t cavi ty i n the combi nati on
fl asher wi re harness connector. I f OK, go to Step 7. I f
not OK, go to Step 8.
cabl e. Check for conti nui ty between the ground ci r-
cui t cavi ty of the combi nati on fl asher wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 8. I f not OK, repai r the ci r-
cui t to ground as requi red.
(8) Unpl ug the mul ti -functi on swi tch wi re harness
connector as descri bed i n thi s group. Check for con-
ti nui ty between the combi nati on fl asher turn si gnal
ci rcui t cavi ti es i n the combi nati on fl asher wi re har-
ness connector and i n the mul ti -functi on swi tch wi re
harness connector. There shoul d be conti nui ty. I f OK,
go to Step 9. I f not OK, repai r the open ci rcui t as
requi red.
(9) Check for conti nui ty between the combi nati on
fl asher hazard warni ng ci rcui t cavi ti es i n the combi -
nati on fl asher wi re harness connector and i n the
mul ti -functi on swi tch wi re harness connector. There
shoul d be conti nui ty. I f OK, test the mul ti -functi on
swi tch as descri bed i n thi s group. I f not OK, repai r
the open ci rcui t as requi red.
MULTI-FUNCTION SWITCH
Perform the di agnosi s of the hazard warni ng
and/or turn si gnal systems as descri bed i n thi s group
before testi ng the mul ti -functi on swi tch. For ci rcui t
descri pti ons and di agrams, refer to 8W-52 - Turn Si g-
nal s i n Group 8W - Wi ri ng Di agrams.
INJURY.
(1) Unpl ug the mul ti -functi on swi tch wi re harness
connector as descri bed i n thi s group.
(2) Usi ng an ohmmeter, perform the swi tch conti -
nui ty checks at the swi tch termi nal s as shown i n the
Mul ti -Functi on Swi tch Conti nui ty chart (Fi g. 2).
(3) I f the swi tch fai l s any of the conti nui ty checks,
repl ace the faul ty swi tch. I f the swi tch i s OK, repai r
the l i ghti ng ci rcui ts as requi red.
COMBINATION FLASHER
INJURY.
cabl e.
(2) Remove the steeri ng col umn openi ng cover and
the knee bl ocker as descri bed i n Group 8E - I nstru-
ment Panel Systems.
(3) Reach through the outboard si de of the steer-
i ng col umn openi ng and remove the combi nati on
fl asher and wi re harness connector from the i nstru-
ment panel di agonal mounti ng bracket by gentl y pry-
i ng the connector retai ner from the bracket mounti ng
hol e (Fi g. 3).
(4) Pul l the combi nati on fl asher and wi re harness
connector i nto the steeri ng col umn openi ng far
enough to unpl ug the fl asher from the wi re harness
connector.
(5) I nstal l the combi nati on fl asher by al i gni ng the
fl asher termi nal s wi th the cavi ti es i n the wi re har-
ness connector and pushi ng the fl asher fi rml y i nto
pl ace.
(6) Rei nstal l the retai ner that secures the combi -
nati on fl asher and wi re harness connector to the
i nstrument panel di agonal mounti ng bracket.
(7) Rei nstal l the knee bl ocker and the steeri ng col -
umn openi ng cover as descri bed i n Group 8E -
I nstrument Panel Systems.
(9) Test the fl asher operati on.
MULTI-FUNCTION SWITCH
INJURY.
cabl e.
(4) I nsert the key i n the i gni ti on l ock cyl i nder and
turn the i gni ti on swi tch to the On posi ti on.
(5) I nsert a smal l screwdri ver or pi n punch
through the access hol e i n the l ower steeri ng col umn
shroud and depress the i gni ti on l ock cyl i nder retai n-
i ng tumbl er (Fi g. 4).
pul l the i gni ti on l ock cyl i nder and key out of the i gni -
ti on l ock housi ng.
(7) Remove the three screws that secure the l ower
steeri ng col umn shroud to the upper shroud.
(8) I f the vehi cl e i s equi pped wi th a standard non-
ti l t steeri ng col umn, l oosen the two upper steeri ng
col umn mounti ng nuts. I f the vehi cl e i s equi pped
wi th the opti onal ti l t steeri ng col umn, move the ti l t
steeri ng col umn to the ful l y l owered posi ti on.
(9) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(10) Remove the two screws that secure the swi tch
water shi el d and bracket to the top of the steeri ng
col umn (Fi g. 5).
Fig. 2 Multi-Function Switch Continuity
H RIGHT REAR I LEFT FRONT J RIGHT FRONT K LEFT REAR
Fig. 3 Combination Flasher Remove/Install
DIAGNOSTICS SPLICE BLOCK DIAGNOSTICS MOUNTING BRACKET COMBINATION FLASHER AND CONNECTOR FWD INSTRUMENT PANEL COUR- TESY LAMP DATA LINK CONNECTOR OUTBOARD STEERING COL- UMN OPENING
8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ
(11) Remove the one screw l ocated bel ow the
mul ti -functi on swi tch l ever that secures the swi tch
water shi el d and bracket to the steeri ng col umn (Fi g.
6).
(12) Gentl y pul l the l ower mounti ng tab of the
swi tch water shi el d bracket away from the steeri ng
col umn far enough to cl ear the screw boss bel ow the
mul ti -functi on swi tch l ever.
(13) Li ft the water shi el d and bracket wi th the
mul ti -functi on swi tch away from the steeri ng col umn
far enough to access the two mul ti -functi on swi tch
wi re harness connectors. I f the vehi cl e i s equi pped
wi th the opti onal ti l t steeri ng col umn, l i fti ng gentl y
upward on the ti l t rel ease l ever wi l l provi de addi -
ti onal cl earance to ease mul ti -functi on swi tch
removal .
(14) Unpl ug the wi re harness connectors from the
mul ti -functi on swi tch.
(15) Remove the mul ti -functi on swi tch and water
shi el d from the steeri ng col umn as a uni t.
(16) Gentl y pul l the water shi el d over the hazard
warni ng swi tch knob and the mul ti -functi on swi tch
l ever.
Fig. 4 Steering Column Shrouds Remove/Install
LOWER SHROUD ACCESS HOLE STEERINGWHEEL PIN PUNCH SCREWS (3)
Fig. 5 Water Shield Upper Screws Remove/Install
MOUNTING SCREWS HAZARD WARNING SWITCHKNOB MULTI-FUNCTION SWITCH LEVER WATER SHIELD AND BRACKET WIPER SWITCHLEVER
Fig. 6 Water Shield Lower Screw Remove/Install
MULTI-FUNCTION SWITCH LEVER WATER SHIELD AND BRACKET LOWER MOUNTING SCREW LOWER MOUNTING TAB
WIPER AND WASHER SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
REAR WIPER AND WASHER SYSTEM . . . . . . . 2
WASHER FLUID LEVEL SENSOR . . . . . . . . . . . 4
WASHER NOZZLE AND PLUMBING . . . . . . . . . 4
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . 3
WASHER RESERVOIR . . . . . . . . . . . . . . . . . . . . 3
WINDSHIELD WASHER SYSTEM . . . . . . . . . . . 1
WINDSHIELD WIPER SYSTEM . . . . . . . . . . . . . 1
WIPER ARM AND BLADE . . . . . . . . . . . . . . . . . 2
WIPER LINKAGE AND PIVOT . . . . . . . . . . . . . . 2
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . 2
WIPER SWITCH AND WASHER SWITCH . . . . . . 3
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 5
WIPER SWITCH AND WASHER SWITCH . . . . . . 6
WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 4
WASHER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 13
WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIPER BLADE AND ELEMENT . . . . . . . . . . . . . 7
WIPER LINKAGE AND PIVOT . . . . . . . . . . . . . . 9
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . 9
WIPER SWITCH AND WASHER SWITCH . . . . . 11
GENERAL INFORMATION
INTRODUCTION
components i n the wi per and washer systems. Refer
to 8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams
for compl ete ci rcui t descri pti ons and di agrams.
WINDSHIELD WIPER SYSTEM
An i ntermi ttent wi ndshi el d wi per system i s stan-
dard equi pment. Thi s system l ets the dri ver sel ect
from ei ther of two wi per speeds, or the i ntermi ttent
wi pe mode.
The i ntermi ttent wi pe mode del ay ti mes are dri ver
adjustabl e from about one second to about fi fteen sec-
onds. The i ntermi ttent wi pe mode i s provi ded by
del ay l ogi c and rel ay control ci rcui try contai ned
wi thi n the i ntermi ttent wi per/washer swi tch. The
i ntermi ttent wi pe rel ay i s al so contai ned wi thi n the
swi tch.
The wi ndshi el d wi pers wi l l operate onl y when the
i gni ti on swi tch i s i n the Accessory or On posi ti ons. A
ci rcui t breaker l ocated i n the juncti on bl ock protects
the ci rcui try of the wi ndshi el d wi per system. Refer to
the owners manual for more i nformati on on the
wi ndshi el d wi per system control s and operati on.
WINDSHIELD WASHER SYSTEM
A el ectri cal l y operated wi ndshi el d washer system i s
standard equi pment. The washer reservoi r i s l ocated
between the i nner and outer front fenders, above and
forward of the l eft front wheel housi ng. The reservoi r
fi l l er neck i s l ocated i n the engi ne compartment on
the l eft i nner fender shi el d.
The reservoi r hol ds the washer fl ui d, whi ch i s pres-
suri zed by a pump when the wi ndshi el d washer
swi tch l ever i s actuated. The wi ndshi el d washer
pump feeds the pressuri zed washer fl ui d through the
washer system pl umbi ng to the wi ndshi el d washer
nozzl es.
A l ow washer fl ui d warni ng l amp i s standard
equi pment on al l model s equi pped wi th the opti onal
rear wi per and washer system. Thi s warni ng l amp i n
the i nstrument cl uster wi l l warn the dri ver when the
washer fl ui d l evel needs to be checked. Refer to
Group 8E - I nstrument Panel Systems for more i nfor-
mati on on thi s feature.
The washers wi l l operate onl y when the i gni ti on
swi tch i s i n the Accessory or On posi ti ons. A fuse
l ocated i n the juncti on bl ock protects the ci rcui try of
the washer system. Refer to the owners manual for
more i nformati on on the wi ndshi el d washer system
control s and operati on.
XJ WIPER AND WASHER SYSTEMS 8K - 1
REAR WIPER AND WASHER SYSTEM
A rear wi per and washer system i s an avai l abl e
opti on on thi s model . The rear wi per system i s a
fi xed-cycl e wi per system. A si ngl e swi tch i n the
i nstrument panel center bezel control s both the rear
wi per and washer functi ons. The rear washer system
shares the reservoi r of the wi ndshi el d washer sys-
tem, but has i ts own dedi cated washer pump and
pl umbi ng.
The rear wi per and washer systems wi l l operate
onl y when the i gni ti on swi tch i s i n the Accessory or
On posi ti ons. A fuse i n the juncti on bl ock protects the
ci rcui try of both the rear wi per and washer systems.
Refer to the owners manual for more i nformati on
on the rear wi per and washer system control s and
operati on.
WIPER ARM AND BLADE
Al l Cherokee model s have two 45.72-centi meter
(18-i nch) wi ndshi el d wi per bl ades wi th repl aceabl e
rubber el ements (squeegees). The opti onal rear wi per
uses a si ngl e 34.8-centi meter (13.7-i nch) wi per bl ade
wi th a repl aceabl e rubber el ement (squeegee).
Cauti on shoul d be exerci sed to protect the rubber
squeegees from any petrol eum-based cl eaners or con-
tami nants, whi ch wi l l rapi dl y deteri orate the rubber.
I f the squeegees are damaged, worn, or contami -
nated, they must be repl aced.
Wi per squeegees exposed to the el ements for a l ong
ti me tend to l ose thei r wi pi ng effecti veness. Peri odi c
cl eani ng of the squeegees i s suggested to remove
deposi ts of sal t and road fi l m. The wi per bl ades,
arms, and wi ndshi el d or rear gl ass shoul d be cl eaned
wi th a sponge or cl oth and wi ndshi el d washer fl ui d, a
mi l d detergent, or a non-abrasi ve cl eaner. I f the
squeegees conti nue to streak or smear, they shoul d
be repl aced.
The bl ades are mounted to spri ng-l oaded wi per
arms. The spri ng tensi on of the wi per arms control s
the pressure appl i ed to the bl ades on the gl ass. The
wi ndshi el d wi per arms are secured by an i ntegral
l atch to the two wi per pi vots on the cowl pl enum cov-
er/gri l l e panel at the base of the wi ndshi el d. The rear
wi per arm i s secured by a nut di rectl y to the rear
wi per motor output shaft on the l i ftgate bel ow the
l i ftgate gl ass.
The wi per arms and bl ades cannot be adjusted or
repai red. I f faul ty or damaged, they must be
repl aced.
WIPER LINKAGE AND PIVOT
The wi per l i nkage and pi vot modul e i s secured
wi th screws to the cowl top panel beneath the cowl
pl enum cover/gri l l e panel . The wi per motor i s
secured wi th screws to the center of the l i nkage and
pi vot modul e bracket. The wi per pi vots are secured
to the ends of the modul e bracket.
The two wi per pi vot crank arms and the wi per
motor crank arm each have bal l studs on thei r ends.
The l eft pi vot bal l stud i s the l onger of the three. A
connecti ng l i nk wi th a pl asti c socket-type bushi ng i n
the ri ght end, and a pl asti c sl eeve-type bushi ng i n
the l eft end, i s fi t over the pi vot bal l studs to joi n the
two pi vots.
The wi per dri ve l i nk has a pl asti c socket-type
bushi ng on each end. One end of the dri ve l i nk i s fi t
over the exposed end of the l onger l eft pi vot bal l
stud, whi l e the other end i s snap-fi t over the bal l
stud on the wi per motor crank arm.
The wi per l i nkage, pi vots, bushi ngs, and mounti ng
bracket are onl y servi ced as a compl ete uni t. I f any
part of thi s assembl y i s faul ty or damaged, the enti re
l i nkage and pi vot modul e must be repl aced. The
wi per motor and motor crank arm are servi ced sepa-
ratel y.
WIPER MOTOR
FRONT
The two-speed permanent magnet wi per motor has
an i ntegral transmi ssi on and park swi tch. The motor
al so contai ns an i nternal automati c resetti ng ci rcui t
breaker to protect the motor from overl oads. The
motor i s secured to a bracket on the l i nkage and
pi vot modul e i n the cowl pl enum area. A rei nforce-
ment/stud pl ate wi th a rubber-i sol ated mounti ng
bracket extends from the cowl pl enum si de of the
dash panel to the motor mounti ng bracket to provi de
addi ti onal support. The wi per motor output shaft
passes through a hol e i n the modul e bracket, where a
nut secures the wi per motor crank arm to the motor
output shaft.
Wi per speed i s control l ed by current fl ow to the
proper set of brushes. The wi per motor compl etes i ts
wi pe cycl e when the wi ndshi el d wi per swi tch stal k i s
moved to the Off posi ti on, and parks the bl ades i n
the l owest porti on of the wi pe pattern.
The wi ndshi el d wi per motor cannot be repai red. I f
faul ty or damaged, the enti re wi per motor assembl y
must be repl aced. The motor crank arm, the l i nkage
and pi vot modul e, and the rei nforcement/stud pl ate
are avai l abl e for servi ce.
REAR
The rear wi per motor i s secured wi th a bracket to
the l i ftgate i nner panel , bel ow the l i ftgate gl ass and
behi nd the l i ftgate tri m panel . The motor output
shaft passes through the l i ftgate outer panel where a
gasket, bezel , and nut, seal and secure the uni t to
the l i ftgate outer panel . The rear wi per arm i s
secured di rectl y to the motor output shaft.
8K - 2 WIPER AND WASHER SYSTEMS XJ
The rear wi per motor uni t provi des three operati ng
modes:
Constant wi pe that operates when the rear
wi per swi tch i s turned to the On posi ti on.
Constant wi pe that operates when the rear
washer swi tch i s depressed.
A park mode that operates the wi per motor unti l
the bl ade reaches i ts park posi ti on when ei ther the
rear wi per swi tch or the i gni ti on swi tch i s pl aced i n
the Off posi ti on.
The rear wi per motor cannot be repai red. I f faul ty
or damaged, the enti re rear wi per motor assembl y
must be repl aced.
WIPER SWITCH AND WASHER SWITCH
FRONT
The wi ndshi el d wi per and washer swi tches are
mounted on the ri ght si de of the steeri ng col umn
(Fi g. 1). The swi tch stal k i s moved up or down to
sel ect the wi per swi tch mode, and pul l ed towards the
steeri ng wheel to acti vate the washer system. An
i ntermi ttent wi pe system control knob on the end of
the swi tch stal k i s rotated to sel ect the desi red del ay
i nterval . The wi ndshi el d wi per and washer swi tch
contai ns ci rcui try for the fol l owi ng functi ons:
Wi ndshi el d wi pers
I ntermi ttent wi per del ay rel ay control and l ogi c
I ntermi ttent wi pe rel ay
Wi ndshi el d washers.
The wi ndshi el d wi per and washer swi tch cannot be
repai red. I f any functi on of the swi tch i s faul ty, or i f
the swi tch i s damaged, the enti re swi tch assembl y
must be repl aced.
REAR
The si ngl e two-functi on rear wi per and washer
swi tch i s i nstal l ed near the bottom of the i nstrument
panel center bezel , bel ow the heater-A/C control s.
The rear wi per and washer swi tch control s the rear
wi per and washer functi ons.
The toggl e-type swi tch features a detent i n the On
posi ti on, and a momentary wash posi ti on. The rear
wi per and washer swi tch al so has an i ntegral i l l umi -
nati on l amp wi th a servi ceabl e bul b. The swi tch knob
i s pushed down to i ts detent to acti vate the rear
wi per system, and down agai n to the momentary
posi ti on to acti vate the rear washer system. Both the
rear wi per and rear washer motors wi l l operate con-
ti nuousl y for as l ong as the swi tch i s hel d i n the
momentary Wash posi ti on.
The rear wi per and washer swi tch cannot be
repai red and, i f faul ty or damaged, the enti re swi tch
uni t must be repl aced.
WASHER RESERVOIR
A si ngl e washer fl ui d reservoi r i s used for both the
standard front and opti onal rear washer systems.
The washer fl ui d reservoi r i s secured between the
l eft front i nner and outer fender panel s, above and i n
front of the l eft front wheel house.
Each washer pump and motor uni t has a barbed
ni ppl e, whi ch i s i nstal l ed through a rubber grommet
seal i nserted i n a hol e near the bottom of the reser-
voi r. The washer pumps are retai ned by an i nterfer-
ence fi t between the barbed ni ppl e and the grommet
seal , whi ch i s a l i ght press fi t.
The washer reservoi r has a separate fi l l er neck.
The fi l l er neck snaps i nto the reservoi r from the
engi ne compartment si de of the l eft i nner fender
shi el d. The reservoi r al so has a provi si on for a
washer fl ui d l evel sensor.
The washer reservoi r, fi l l er neck, fi l l er cap, and
sensor are each avai l abl e for servi ce.
WASHER PUMP
The washer pumps and motors are mounted near
the bottom of the washer reservoi r. A barbed ni ppl e
on the pump housi ng passes through a rubber grom-
met seal i nstal l ed i n a hol e near the bottom of the
reservoi r. The washer pump i s retai ned by an i nter-
ference fi t between the barbed pump ni ppl e and the
grommet seal , whi ch i s a l i ght press fi t.
A permanentl y l ubri cated and seal ed motor i s cou-
pl ed to a rotor-type pump. Washer fl ui d i s gravi ty-fed
from the reservoi r to the pump. When the motor i s
energi zed, the pump pressuri zes the washer fl ui d
and forces i t through the pl umbi ng to the nozzl es.
On vehi cl es wi th the opti onal rear wi per/washer
system, the front washer pump and motor i s al ways
mounted i n the l ower hol e of the reservoi r. The
Fig. 1 Windshield Wiper and Washer Switch
washer pump and motor uni t cannot be repai red. I f
faul ty, the enti re washer pump and motor uni t must
be repl aced.
WASHER FLUID LEVEL SENSOR
The washer fl ui d l evel sensor i s mounted near the
front of the washer reservoi r, above the two washer
pumps. A barbed ni ppl e on the sensor i s press-fi t i nto
a rubber grommet seal i nstal l ed i n a hol e i n the front
of the reservoi r.
When the fl ui d l evel i n the reservoi r fal l s bel ow
the pi voti ng fl oat on the sensor, the fl oat changes
posi ti on and cl oses the i nternal swi tch contacts of the
sensor. Refer to Group 8E - I nstrument Panel Sys-
tems for di agnosi s of the l ow washer fl ui d warni ng
l amp and ci rcui t, i ncl udi ng the sensor.
The washer fl ui d l evel sensor cannot be repai red. I f
faul ty or damaged, the sensor uni t must be repl aced.
WASHER NOZZLE AND PLUMBING
FRONT
Pressuri zed washer fl ui d i s fed through a si ngl e
hose, attached to a barbed ni ppl e on the front washer
pump. The hose i s routed to a tee fi tti ng l ocated i n
the cowl pl enum area, beneath the cowl pl enum cov-
er/gri l l e panel . Hoses from the tee fi tti ng are routed
to the two nozzl es, whi ch are ri veted i nto openi ngs i n
the cowl pl enum cover/gri l l e panel bel ow the wi nd-
shi el d.
The two fl ui di c washer nozzl es are not adjustabl e.
The nozzl es and hose fi tti ngs cannot be repai red and,
i f faul ty or damaged, they must be repl aced.
REAR
Pressuri zed washer fl ui d i s fed through a si ngl e
hose, attached to a barbed ni ppl e on the rear washer
pump. The hose i s routed from the front of the vehi -
cl e to the l i ftgate wi th the body wi re harness.
Located at the hi ghest poi nt of the suppl y hose
routi ng, beneath the l i ftgate openi ng upper header
garni sh moul di ng, a check val ve prevents washer
fl ui d drai n-back or si phoni ng from occurri ng. From
the check val ve, another si ngl e hose i s routed
through a grommet to the l i ftgate, where i t i s con-
nected to a ni ppl e that protrudes from the i nsi de of
the rear wi per motor output shaft bezel .
The washer fl ui d passes through the bezel ni ppl e
to the outsi de of the l i ftgate. There a si ngl e hose i s
routed through a pl asti c trough-l i ke guard snapped
to the undersi de of the rear wi per arm. The hose i s
then attached to the si ngl e rear washer nozzl e. The
nozzl e snaps i nto pl ace on the rear wi per arm.
The rear washer nozzl e cannot be adjusted. The
nozzl e, bezel , check val ve, and hose fi tti ngs cannot be
repai red and, i f faul ty or damaged, they must be
repl aced.
WIPER SYSTEM
FRONT
8W-53 - Wi pers i n Group 8W - Wi ri ng Di agrams.
INJURY.
(1) Check the ci rcui t breaker i n the juncti on bl ock.
I f OK, go to Step 2. I f not OK, repl ace the faul ty ci r-
cui t breaker.
cabl e. Unpl ug the wi ndshi el d wi per swi tch wi re har-
ness connector. Connect the battery negati ve cabl e.
Turn the i gni ti on swi tch to the On posi ti on. Check
for battery vol tage at the fused i gni ti on swi tch out-
put ci rcui t cavi ty of the wi per swi tch wi re harness
connector. I f OK, go to Step 3. I f not OK, repai r the
open ci rcui t to the juncti on bl ock as requi red.
(3) I f the probl em bei ng di agnosed i nvol ves onl y
the pul se wi pe, wi pe-after-wash, or i ntermi ttent wi pe
modes, go to Step 4. I f not, go to Step 5.
i ty of the wi per swi tch wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK,
repl ace the faul ty swi tch. I f not OK, repai r the open
Remove and check the wi ndshi el d wi per and washer
swi tch conti nui ty as descri bed i n thi s group. I f OK,
go to Step 6. I f not OK, repl ace the faul ty swi tch.
(6) Unpl ug the wi ndshi el d wi per motor wi re har-
ness connector. Check for conti nui ty between the
ground ci rcui t cavi ty i n the body hal f of the wi per
motor wi re harness connector and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 7. I f not
OK, repai r the open ci rcui t to ground as requi red.
vol tage at the fused i gni ti on swi tch output ci rcui t
cavi ty i n the body hal f of the wi per motor wi re har-
ness connector. I f OK, go to Step 8. I f not OK, repai r
the open ci rcui t to the juncti on bl ock as requi red.
Wi th the wi ndshi el d wi per and washer swi tch wi re
harness connector sti l l unpl ugged, check the cavi ti es
for each of the fol l owi ng ci rcui ts i n the body hal f of
the wi per motor wi re harness connector for conti nu-
i ty to ground. I n each case, there shoul d be no conti -
nui ty. I f OK, go to Step 9. I f not OK, repai r the short
Wi per park swi tch sense
Wi per swi tch l ow speed output
Wi per swi tch hi gh speed output.
(9) Check for conti nui ty between the cavi ti es i n
the body hal f of the wi per motor wi re harness con-
nector and the cavi ti es i n the wi ndshi el d wi per and
washer swi tch wi re harness connector for each of the
fol l owi ng ci rcui ts. I n each case, there shoul d be con-
ti nui ty. I f OK, repl ace the faul ty wi per motor. I f not
OK, repai r the open ci rcui t as requi red.
Wi per park swi tch sense
Wi per swi tch l ow speed output
Wi per swi tch hi gh speed output.
REAR
INJURY.
cabl e. Remove the rear wi per and washer swi tch and
unpl ug the wi re harness connector as descri bed i n
thi s group. Connect the battery negati ve cabl e. Turn
the i gni ti on swi tch to the On posi ti on. Check for bat-
tery vol tage at the fused i gni ti on swi tch output ci r-
cui t cavi ty of the rear wi per and washer swi tch wi re
harness connector. I f OK, go to Step 3. I f not OK,
repai r the open ci rcui t to the juncti on bl ock as
requi red.
i ty of the rear wi per and washer swi tch wi re harness
nui ty. I f OK, go to Step 4. I f not OK, repai r the open
(4) Test the rear wi per and washer swi tch as
descri bed i n thi s group. I f OK, go to Step 5. I f not
OK, repl ace the faul ty swi tch.
(5) Remove the l i ftgate tri m panel and unpl ug the
rear wi per motor wi re harness connector. Connect
the battery negati ve cabl e. Turn the i gni ti on swi tch
to the On posi ti on. Check for battery vol tage at the
fused i gni ti on swi tch output ci rcui t cavi ty of the rear
wi per motor wi re harness connector. I f OK, go to
Step 6. I f not OK, repai r the open ci rcui t to the junc-
ti on bl ock as requi red.
i ty of the rear wi per motor wi re harness connector
and a good ground. There shoul d be conti nui ty. I f
(7) Check for conti nui ty between the rear wi per
motor control ci rcui t cavi ty of the rear wi per motor
wi re harness connector and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 8. I f not
OK, repai r the short ci rcui t as requi red.
(8) Check for conti nui ty between the rear wi per
motor control ci rcui t cavi ti es of the rear wi per motor
wi re harness connector and the rear wi per and
washer swi tch wi re harness connector. There shoul d
be conti nui ty. I f OK, repl ace the faul ty rear wi per
motor. I f not OK, repai r the open ci rcui t as requi red.
WASHER SYSTEM
FRONT
washer pump. I f the washer pump operates, but no
washer fl ui d i s emi tted from the washer nozzl es, be
certai n to check the fl ui d l evel i n the reservoi r. Check
for i ce or other forei gn materi al i n the reservoi r, and
for pi nched, di sconnected, broken, or i ncorrectl y
routed washer system pl umbi ng. For ci rcui t descri p-
ti ons and di agrams, refer to 8W-53 - Wi pers i n Group
INJURY.
Turn the wi per swi tch to the Low or Hi gh speed posi -
ti on. Check whether the wi pers operate. I f OK, go to
Step 2. I f not OK, see the Wi per System di agnosi s i n
thi s group.
Unpl ug the front washer pump wi re harness connec-
cavi ty of the front washer pump wi re harness connec-
vol tage at the front washer swi tch output ci rcui t cav-
i ty of the front washer pump wi re harness connector
whi l e actuati ng the washer swi tch. I f OK, repl ace the
faul ty washer pump. I f not OK, go to Step 4.
Unpl ug the wi ndshi el d wi per/washer swi tch wi re
harness connector. Check for conti nui ty between the
front washer swi tch output ci rcui t cavi ty of the front
washer pump wi re harness connector and a good
Step 5 I f not OK, repai r the short ci rcui t as requi red.
(5) Check for conti nui ty between the front washer
swi tch output ci rcui t cavi ti es of the front washer
pump wi re harness connector and the wi per/washer
swi tch wi re harness connector. There shoul d be con-
ti nui ty. I f OK, repl ace the faul ty swi tch. I f not OK,
REAR
washer pump. I f the washer pump operates, but no
washer fl ui d i s emi tted from the washer nozzl es, be
certai n to check the fl ui d l evel i n the reservoi r. Check
for i ce or other forei gn materi al i n the reservoi r, and
for pi nched, di sconnected, broken, or i ncorrectl y
routed washer system pl umbi ng. For ci rcui t descri p-
ti ons and di agrams, refer to 8W-53 - Wi pers i n Group
INJURY.
Pl ace the rear wi per/washer swi tch i n the Wi pe posi -
ti on. Check whether the rear wi per i s operati ng. I f
OK, go to Step 2. I f not OK, see the Wi per System
di agnosi s i n thi s group.
Unpl ug the rear washer pump wi re harness connec-
cavi ty of the rear washer pump wi re harness connec-
i gni ti on swi tch to the On posi ti on. Depress the rear
washer swi tch. Check for battery vol tage at the rear
washer motor control ci rcui t cavi ty of the rear
washer pump wi re harness connector. I f OK, repl ace
the faul ty pump. I f not OK, go to Step 4.
Unpl ug the rear wi per/washer swi tch wi re harness
connector. Check for conti nui ty between the rear
washer motor control ci rcui t cavi ty of the rear
washer pump wi re harness connector and a good
requi red.
(5) Check for conti nui ty between the rear washer
motor control ci rcui t cavi ti es of the rear washer
pump wi re harness connector and the rear wi per/
washer swi tch wi re harness connector. There shoul d
be conti nui ty. I f OK, repl ace the faul ty swi tch. I f not
OK, repai r the open ci rcui t as requi red.
FRONT
Perform the di agnosi s for the wi ndshi el d wi per sys-
tem and/or washer system as descri bed i n thi s group
before testi ng the wi ndshi el d wi per and washer
swi tch. For ci rcui t descri pti ons and di agrams, see
INJURY.
cabl e.
(2) Unpl ug the wi ndshi el d wi per and washer
swi tch wi re harness connector as descri bed i n thi s
group.
(3) Usi ng an ohmmeter, perform the swi tch conti -
nui ty checks at the swi tch termi nal s as shown i n the
Wi ndshi el d Wi per and Washer Swi tch Conti nui ty
chart (Fi g. 2).
the wi per system and/or washer system wi re harness
ci rcui ts as requi red.
REAR
Perform the di agnosi s for the rear wi per system
and/or washer system as descri bed i n thi s group
before testi ng the rear wi per and washer swi tch. For
ci rcui t descri pti ons and di agrams, see 8W-53 - Wi p-
ers i n Group 8W - Wi ri ng Di agrams.
INJURY.
(1) Remove the rear wi per and washer swi tch as
(2) Usi ng an ohmmeter, check the swi tch conti nu-
i ty at the swi tch termi nal s as shown i n the Rear
Wi per and Washer Swi tch Conti nui ty chart (Fi g. 3).
the rear wi per system and/or washer system wi re
harness ci rcui ts as requi red.
WIPER BLADE AND ELEMENT
FRONT
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.
To remove the wi ndshi el d wi per bl ade and/or el e-
ment, proceed as fol l ows:
(1) Li ft the wi per arm to rai se the wi per bl ade and
el ement off of the wi ndshi el d gl ass.
(2) Remove the wi per bl ade from the wi per arm, or
the wi per el ement from the wi per bl ade as fol l ows:
(a) To remove the wi per bl ade from the wi per
arm, push the rel ease tab under the arm ti p and
sl i de the bl ade away from the ti p towards the pi vot
end of the arm (Fi g. 4).
(b) To remove the wi per el ement from the wi per
bl ade, pi nch the notched retai ner (pi vot) end of the
wi per el ement ti ghtl y between the thumb and fore-
fi nger. Then, pul l the el ement fi rml y towards the
wi per pi vot unti l the notched retai ner of the wi per
el ement cl ears the wi per bl ade cl aws. Once the
notched retai ner i s rel eased from the cl aws, the
el ement wi l l sl i de easi l y out of the remai ni ng
cl aws.
(3) I nstal l the wi per bl ade on the wi per arm, or
the wi per el ement i n the wi per bl ade as fol l ows:
(a) To i nstal l the wi per bl ade on the wi per arm,
sl i de the bl ade retai ner i nto the U-shaped forma-
Fig. 2 Windshield Wiper and Washer Switch
Continuity
TWO SPEED WIPER SWITCH PINS INTERMITTENT WIPER SWITCH PINS
Fig. 3 Rear Wiper and Washer Switch Continuity
ti on on the ti p of the wi per arm unti l the rel ease
tab snaps i nto i ts l ocked posi ti on. Be certai n that
the notched retai ner for the wi per el ement i s ori -
ented towards the end of the wi per bl ade that i s
nearest to the wi per pi vot.
(b) To i nstal l the wi per el ement i n the wi per
bl ade, start at the wi per pi vot end of the bl ade and
sl i de the el ement through each pai r of wi per bl ade
cl aws. The el ement i s ful l y i nstal l ed when the
notched retai ner on the wi per el ement i s engaged
wi th the cl aws on the wi per pi vot end of the wi per
bl ade.
REAR
NOTE: The notched retainer end of the wiper ele-
ment should always be oriented towards the end of
the wiper blade that is nearest to the wiper pivot.
To remove the rear wi per bl ade and/or el ement,
proceed as fol l ows:
(1) Li ft the rear wi per arm to rai se the wi per bl ade
and el ement off of the rear wi ndow gl ass.
(2) Remove the wi per bl ade from the wi per arm, or
the wi per el ement from the wi per bl ade as fol l ows:
(a) To remove the wi per bl ade from the wi per
arm, push the rel ease tab under the arm ti p and
sl i de the bl ade away from the ti p towards the rear
wi per motor output shaft end of the arm (Fi g. 4).
(b) To remove the wi per el ement from the wi per
bl ade, pi nch the notched (pi vot) end rel ease cl i p of
the wi per el ement ti ghtl y between the thumb and
forefi nger. Then, pul l the el ement fi rml y towards
the rear wi per motor output shaft to rel ease the
wi per el ement pi nch-rel ease cl i p from the wi per
bl ade cl aws. Once the cl i p i s rel eased from the
cl aws, the el ement wi l l sl i de easi l y out of the
remai ni ng cl aws.
(3) I nstal l the wi per bl ade on the wi per arm, or
the wi per el ement i n the wi per bl ade as fol l ows:
(a) To i nstal l the wi per bl ade on the wi per arm,
sl i de the bl ade retai ner i nto the U-shaped forma-
ti on on the ti p of the wi per arm unti l the rel ease
tab snaps i nto i ts l ocked posi ti on. Be certai n that
the pi nch-rel ease cl i p for the wi per el ement i s ori -
ented towards the end of the wi per bl ade that i s
nearest to the rear wi per motor output shaft.
(b) To i nstal l the wi per el ement i n the wi per
bl ade, start at the rear wi per motor output shaft
end of the bl ade and sl i de the el ement through
each pai r of wi per bl ade cl aws. The el ement i s ful l y
i nstal l ed when the cl aws on the rear wi per motor
output shaft end of the bl ade are engaged i n the
wi per el ement retai ni ng cl i p notches.
WIPER ARM
FRONT
CAUTION: The use of a screwdriver or other prying
tool to remove a wiper arm may distort it. This dis-
tortion could allow the arm to come off of the pivot
shaft, regardless of how carefully it is installed.
(1) Li ft the wi per arm to permi t the l atch to be
pul l ed out to i ts hol di ng posi ti on, then rel ease the
arm (Fi g. 5). The arm wi l l remai n off the wi ndshi el d
wi th the l atch i n thi s posi ti on.
(2) Remove the arm from the pi vot usi ng a rocki ng
moti on.
(3) I nstal l the arm and bl ade wi th the wi per motor
i n the Park posi ti on. See the Wi per Arm I nstal l ati on
i l l ustrati on
(4) (Fi g. 6). Mount the arms on the pi vot shafts so
that the di stance from the l ower edge of the wi per
arm ti p to the upper edge of the l ower wi ndshi el d
moul di ng i s:
23 to 52 mm (0.90 to 2.04 i nch) on the dri ver
si de
33 to 62 mm (1.29 to 2.44 i nch) on the passenger
si de.
(5) Li ft the wi per arm away from the wi ndshi el d
sl i ghtl y to rel i eve the spri ng tensi on on the l atch.
Fig. 4 Wiper Blade Remove/Install - Typical
Fig. 5 Wiper Arm Remove/Install
LOCKING LATCH ARM
Push the l atch i nto the l ocked posi ti on and sl owl y
rel ease the arm unti l the wi per bl ade rests on the
wi ndshi el d.
(6) Operate the wi pers wi th the wi ndshi el d gl ass
wet, then turn the wi per swi tch to the Off posi ti on.
Check for the correct wi per arm posi ti oni ng and
readjust i f requi red.
REAR
(1) Di sconnect the washer nozzl e hose and cl i p
from the external ni ppl e of the rear wi per motor out-
put shaft bezel .
(2) Li ft the wi per arm pi vot cover and remove the
retai ni ng nut (Fi g. 7).
(3) Remove the wi per arm from the motor output
shaft usi ng a rocki ng moti on.
(4) I nstal l the rear wi per arm wi th the wi per
motor i n the Park posi ti on. Pl ace the rear wi per
bl ade on the gl ass so that i t i s paral l el to the l i ftgate
gl ass openi ng, and i nstal l the wi per arm retai ni ng
nut.
(5) Operate the rear wi per on the wet l i ftgate
gl ass, then turn the rear wi per swi tch to the Off posi -
ti on so that the bl ade moves to the Park posi ti on.
The ti p of the bl ade shoul d now be from 27 to 35 mm
(1.06 to 1.38 i nch) above the upper edge of the l ower
l i ftgate gl ass seal (Fi g. 8). Check for the correct
wi per arm posi ti oni ng and readjust i f requi red.
(6) Ti ghten the wi per arm retai ni ng nut to 18 Nm
(160 i n. l bs.) and cl ose the pi vot cover.
WIPER LINKAGE AND PIVOT
The wi per l i nkage and pi vots modul e can onl y be
removed from or i nstal l ed i n the vehi cl e as a uni t
wi th the wi per motor. See Wi per Motor i n thi s group
for the servi ce procedures.
WIPER MOTOR
FRONT
cabl e.
(2) Remove the wi per arms as descri bed i n thi s
group.
(3) Remove the ei ght screws that secure the cowl
pl enum cover/gri l l e panel and screen to the cowl top
panel (Fi g. 9).
(4) Li ft the cowl pl enum cover/gri l l e panel and
screen from the vehi cl e far enough to access the
wi ndshi el d washer pl umbi ng. Use care so as not to
damage the pai nt around the pi vot openi ngs of the
panel .
(5) Di sconnect the wi ndshi el d washer suppl y hose
and the passenger si de washer nozzl e hose from the
washer nozzl e hose tee fi tti ng.
(6) Remove the cowl pl enum cover/gri l l e panel and
screen from the vehi cl e.
(7) Reach i nto the cowl pl enum and unpl ug the
wi per motor wi re harness connector.
Fig. 6 Front Wiper Arm Installation
Fig. 7 Rear Wiper Arm Remove/Install
PIVOT COVER WIPER ARM RETAINING NUT
Fig. 8 Rear Wiper Arm Installation
IN PARKED POSITION 27 TO 35 mm (1.06 TO 1.38 INCH) ABOVE UPPER EDGE OF LOWER GLASS SEAL AT TIP OF WIPER BLADE
(8) Open the hood and remove the two nuts that
secure the studs of the wi per modul e mounti ng
bracket and grommet to the cowl pl enum panel (Fi g.
10).
(9) Remove the four screws near the wi per pi vots that
secure the wi per modul e to the cowl pl enum panel .
(10) Remove the wi per modul e from the cowl pl e-
num as a uni t.
wi per motor to the wi per l i nkage modul e and remove
the motor.
Wi per motor mounti ng screws - 4 Nm (35 i n. l bs.)
Wi per modul e mounti ng screws - 6 Nm (50 i n. l bs.)
Wi per modul e mounti ng bracket nuts - 6 Nm (50 i n.
l bs.).
REAR
cabl e.
(2) From the outsi de of the l i ftgate gl ass, remove
the rear wi per arm as descri bed i n thi s group.
(3) Remove the motor output shaft retai ni ng nut
(Fi g. 11).
(4) Pul l the bezel and seal away from the l i ftgate
far enough to access the washer suppl y hose.
(5) Di sconnect the washer suppl y hose from the
i nternal ni ppl e on the bezel .
(6) Remove the bezel and seal from the motor out-
put shaft.
fl at-bl aded tool , gentl y pry the two screw cover pl ugs
out of the l i ftgate assi st handl e.
(9) Remove the two screws that secure the l i ftgate
assi st handl e to the l i ftgate i nner panel (Fi g. 12).
Fig. 9 Cowl Plenum Cover/Grille Panel Remove/Install
SCREW SCREW GRILLE PANEL SCREEN WASHER HOSE NUT BRACKET NUT FWD
Fig. 10 Wiper Linkage Module Remove/Install
BRACKET AND GROMMET SCREW FWD NUT LINKAGE AND PIVOT MOD- ULE
Fig. 11 Rear Wiper Motor Remove/Install
LIFTGATE ARM NUT NUT SCREW MOTOR AND BRACKET BLADE BEZEL CLIPHOSE
Fig. 12 Liftgate Trim Panel Remove/Install
TRIM PANEL PUSH NUT LIFTGATE ASSIST HANDLE PLUG
(10) Remove the ei ght screws that secure the l i ft-
gate tri m panel to the l i ftgate i nner panel on both
si des and above the l i ftgate gl ass.
fl at-bl aded tool , gentl y pry the l ower edges of the
tri m panel away from the l i ftgate i nner panel around
the peri meter to rel ease the tri m panel retai ners.
(12) Remove the l i ftgate tri m panel from the vehi -
cl e.
(13) Unpl ug the rear wi per motor wi re harness
connector.
(14) Remove the two screws that secure the rear
wi per motor mounti ng bracket to the l i ftgate i nner
panel .
(15) Remove the rear wi per motor and mounti ng
bracket from the l i ftgate as a uni t.
Rear wi per motor mounti ng bracket screws - 5
Nm (45 i n. l bs.)
Rear wi per motor output shaft retai ni ng nut - 3
Nm (27 i n. l bs.).
FRONT
INJURY.
cabl e.
pul l the i gni ti on l ock cyl i nder and key out of the i gni -
ti on l ock housi ng.
(7) Remove the three screws that secure the l ower
steeri ng col umn shroud to the upper shroud.
(8) I f the vehi cl e i s equi pped wi th a standard non-
ti l t steeri ng col umn, l oosen the two upper steeri ng
col umn mounti ng nuts. I f the vehi cl e i s equi pped
(9) Remove both the upper and l ower shrouds from
the steeri ng col umn.
(10) Remove the two screws that secure the swi tch
water shi el d and bracket to the top of the steeri ng
col umn (Fi g. 14).
(11) Remove the one screw l ocated bel ow the
mul ti -functi on swi tch l ever that secures the swi tch
Fig. 14 Water Shield Upper Screws Remove/Install
MOUNTING SCREWS HAZARD WARNING SWITCHKNOB MULTI-FUNCTION SWITCH LEVER WATER SHIELD AND BRACKET WIPER SWITCHLEVER
water shi el d and bracket to the steeri ng col umn (Fi g.
15).
(12) Gentl y pul l the l ower mounti ng tab of the
swi tch water shi el d bracket away from the steeri ng
col umn far enough to cl ear the screw boss bel ow the
mul ti -functi on swi tch l ever.
(13) Li ft the water shi el d and bracket wi th the
mul ti -functi on swi tch off of the l eft si de of the steer-
i ng col umn as a uni t and move i t out of the way. I f
the vehi cl e i s equi pped wi th the opti onal ti l t steeri ng
col umn, l i fti ng gentl y upward on the ti l t rel ease l ever
wi l l provi de addi ti onal cl earance to ease mul ti -func-
ti on swi tch removal .
(14) Gentl y pul l the wi ndshi el d wi per and washer
swi tch up and away from the ri ght si de of the steer-
i ng col umn far enough to access the wi re harness
connector.
wi ndshi el d wi per and washer swi tch.
(16) Remove the wi ndshi el d wi per and washer
swi tch from the steeri ng col umn.
REAR
INJURY.
cabl e.
ness connectors.
i nstrument panel .
bottom of the rear wi per and washer swi tch recepta-
cl e on the back of the accessory swi tch bezel wi th a
smal l thi n-bl aded screwdri ver and pul l the swi tch out
of the receptacl e.
Fig. 15 Water Shield Lower Screw Remove/Install
MULTI-FUNCTION SWITCH LEVER WATER SHIELD AND BRACKET LOWER MOUNTING SCREW LOWER MOUNTING TAB
ACCESSORY SWITCH BEZEL SCREW
receptacl e on the back of the accessory swi tch bezel
2.2 Nm (20 i n. l bs.).
WASHER SYSTEM
WASHER RESERVOIR
cabl e.
(2) The washer reservoi r fi l l er neck i s hel d i n the
reservoi r by an i nterference fi t. Remove the fi l l er
neck from the reservoi r usi ng a pul l i ng and twi sti ng
acti on (Fi g. 18).
(3) Remove the engi ne ai r fi l ter housi ng. Refer to
Group 14 - Fuel System for the procedures.
(4) Remove the two screws that secure the reser-
voi r to the i nner fender shi el d (Fi g. 19).
(6) Remove the l eft front i nner wheel house spl ash
(7) Remove the washer suppl y hose(s) from the
washer pump(s) and drai n the washer fl ui d from the
reservoi r i nto a cl ean contai ner for reuse.
washer pump(s) and the washer fl ui d l evel sensor.
(9) Sl i de the reservoi r sl i ghtl y towards the rear of
the vehi cl e to rel ease the two hooks from the i nner
fender l edge sl ots.
(10) Lower the front of the reservoi r and sl i de the
uni t forward to remove i t from the vehi cl e.
Ti ghten the reservoi r mounti ng screws to 3 Nm (26
i n. l bs.).
WASHER PUMP
cabl e.
(3) Remove the l eft front i nner wheel house spl ash
(4) Remove the washer suppl y hose(s) from the
washer pump(s) and drai n the washer fl ui d from the
reservoi r i nto a cl ean contai ner for reuse.
washer pump(s).
fl at-bl aded tool , gentl y pry the washer pump out of
the rubber grommet seal . Care must be taken not to
damage the reservoi r.
(7) Remove the rubber grommet seal from the res-
ervoi r and di scard.
Al ways use a new rubber grommet seal on the reser-
voi r.
WASHER FLUID LEVEL SENSOR
(1) Remove the washer reservoi r as descri bed i n
thi s group.
NOTE: The pivoting float of the washer fluid sensor
must be in a horizontal position within the reservoir
in order to be removed. With the reservoir empty
and held in an upright position, the pivoting float
will be oriented to the horizontal position when the
sensor connector is pointed straight downwards.
fl at-bl aded tool , gentl y pry the washer fl ui d l evel sen-
sor out of the rubber grommet seal . Care must be
taken not to damage the reservoi r.
Fig. 18 Washer Reservoir Filler Neck Remove/Install
RESERVOIR LEFT FENDERFWD FILLER NECK AND CAP
Fig. 19 Washer Reservoir Remove/Install
(3) Remove the rubber grommet seal from the res-
ervoi r and di scard.
Al ways use a new rubber grommet seal on the reser-
voi r.
WASHER NOZZLE
FRONT
(1) Remove the wi per arms as descri bed i n thi s
group.
(2) Remove the ei ght screws that secure the cowl
pl enum cover/gri l l e panel and screen to the cowl top
panel (Fi g. 20).
(3) Li ft the cowl pl enum cover/gri l l e panel and
screen from the vehi cl e far enough to access the
wi ndshi el d washer pl umbi ng. Use care so as not to
damage the pai nt around the pi vot openi ngs of the
panel .
(4) Di sconnect the wi ndshi el d washer suppl y hose
and the passenger si de washer nozzl e hose from the
washer nozzl e hose tee fi tti ng.
(5) Remove the cowl pl enum cover/gri l l e panel and
screen from the vehi cl e.
(6) From the undersi de of the cowl pl enum cover/
gri l l e panel , di sconnect the washer hose from the
nozzl e fi tti ng.
(7) From the undersi de of the cowl pl enum cover/
gri l l e panel , remove the ri vet that secures the nozzl e
to the openi ng i n the cowl pl enum cover/gri l l e panel .
(8) Remove the washer nozzl e from the cowl pl e-
num cover/gri l l e panel .
REAR
(1) Unsnap the rear washer nozzl e from the rear
wi per arm (Fi g. 21).
(2) Di sconnect the washer hose from the nozzl e fi t-
ti ng.
CHECK VALVE
(1) Remove the four screws that secure the l i ftgate
openi ng upper garni sh moul di ng to the upper l i ftgate
openi ng rei nforcement.
(2) Usi ng a tri m sti ck or another sui tabl e wi de-
bl aded fl at tool , gentl y pry the l i ftgate openi ng upper
garni sh moul di ng away from the upper l i ftgate open-
i ng rei nforcement to rel ease the snap cl i p retai ners.
(3) Remove the upper l i ftgate openi ng garni sh
moul di ng from the vehi cl e.
(4) Di sconnect the l i ftgate hal f of the washer sup-
pl y hose from the check val ve.
(5) Di sconnect the body hal f of the washer suppl y
hose from the check val ve.
(6) Remove the check val ve from the vehi cl e.
(7) When rei nstal l i ng the check val ve, be certai n
the val ve i s properl y ori ented wi thi n the system fl ow
(Fi g. 22).
Fig. 20 Front Washer Nozzles Remove/Install
RIVET GRILLE PANELSCREW SCREEN WASHER HOSE TEE NOZZLE
Fig. 21 Rear Washer Nozzle Remove/Install
TO CHECK VALVE AND BODY SUP- PLY HOSE LIFTGATE GROMMET NOZZLE GUARD HOSE CLIP BEZEL LIFTGATE SUPPLY HOSE
Fig. 22 Rear Washer System Check Valve
TO RESER- VOIR CHECKBALL SPRING TO NOZZLE FLOW
LAMPS
CONTENTS
page page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . 15
HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . . . 4
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . . . . 7
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 1
LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 10
LAMP SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 14
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
DAYTIME RUNNING LAMP MODULE . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . 1
SENTINEL HEADLAMP DELAY MODULE . . . . . . 1
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 2
FOG LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . 3
HEADLAMP DELAY MODULE . . . . . . . . . . . . . . 3
HEADLAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
GENERAL INFORMATION
Each vehi cl e i s equi pped wi th vari ous l amp assem-
bl i es. A good ground i s necessary for proper l i ghti ng
operati on. Groundi ng i s provi ded by the l amp socket
when i t comes i n contact wi th the metal body, or
through a separate ground wi re.
When changi ng l amp bul bs check the socket for
corrosi on. I f corrosi on i s present, cl ean i t wi th a wi re
brush and coat the i nsi de of the socket l i ghtl y wi th
Mopar Mul ti -Purpose Grease or equi val ent.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges are not hol di ng the com-
ponent i n pl ace.
SENTINEL HEADLAMP DELAY MODULE
The Headl amp Modul e del ays the de-acti vati on of
the headl amps for 45 15 seconds after the i gni ti on
swi tch i s turned OFF. The dri ver engages the modul e
by turni ng the i gni ti on swi tch OFF, then turni ng the
headl amps OFF.
DAYTIME RUNNING LAMP MODULE
The Dayti me Runni ng Li ghts (Headl amps) System
i s i nstal l ed on vehi cl es manufactured for sal e i n Can-
ada onl y. The headl amps are i l l umi nated when the
i gni ti on swi tch i s turned to the ON posi ti on and the
vehi cl e i s put i nto moti on. The DRL modul e recei ves
a vehi cl e-movi ng si gnal from the vehi cl e speed sen-
sor. Thi s provi des a constant headlamps-on condi -
ti on as l ong as the vehi cl e i s movi ng. The l amps are
i l l umi nated at approxi matel y 30 percent of normal
i ntensi ty.
XJ LAMPS 8L - 1
DIAGNOSTIC PROCEDURES
When a vehi cl e experi ences probl ems wi th the
headl amp system, veri fy the condi ti on of the battery
connecti ons, chargi ng system, headl amp bul bs, wi re
connectors, rel ay, hi gh beam di mmer swi tch and
headl amp swi tch. Refer to Group 8W, Wi ri ng Di a-
grams for component l ocati ons and ci rcui t i nforma-
ti on.
HEADLAMP DIAGNOSIS
Al ways begi n any di agnosi s by testi ng al l of the
fuses and ci rcui t breakers i n the system. Refer to
Group 8W, Wi ri ng Di agrams.
Conventi onal and hal ogen headl amps are i nter-
changeabl e. I t i s recommended that they not be
i ntermi xed on a gi ven vehi cl e.
HEADLAMP DIAGNOSIS
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF.
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Group 8A
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Group 8A
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.
1. Charging system output too high. 1. Test and repair charging system, refer to
Group 8A
2. Loose or corroded terminals or
splices in circuit.
2. Inspect and repair all connectors and
splices, refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE.*
Group 8A.
2. Poor headlamp circuit ground. 2. Test voltage drop across Z1-ground,
refer to Group 8W.
3. High resistance in headlamp circuit. 3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASH
RANDOMLY.
1. Poor headlamp circuit ground. 1. Repair circuit ground, refer to Group 8W.
2. High resistance in headlamp circuit. 2. Test amperage draw of headlamp circuit.
3. Faulty headlamp switch circuit
breaker.
3. Replace headlamp switch.
splices in circuit.
4. Repair connector terminals or splices,
refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE.
1. No voltage to headlamps. 1. Replace fuse, refer to group 8W.
2. No ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer switch. 4. Replace headlamp dimmer switch.
5. Broken connector terminal or wire
splice in headlamp circuit.
5. Repair connector terminal or wire
splices.
* Canada vehicles must have lamps ON.
8L - 2 LAMPS XJ
FOG LAMP DIAGNOSIS
HEADLAMP DELAY MODULE
DELAY FUNCTION INOPERATIVE
(1) Ensure headl amps operate before proceedi ng.
(2) Remove, i nspect and test the HDLP del ay 10
amp fuse i n juncti on box. Repl ace i f defecti ve.
(3) Wi th the key off and the connector di scon-
nected, measure the resi stance from the del ay mod-
ul e termi nal 4 to vehi cl e body ground. The ohmmeter
shoul d i ndi cate zero ohms. I f not, repai r the open ci r-
cui t i n the wi re harness to vehi cl e body ground.
(4) Wi th the key on measure the vol tage between
the del ay modul e termi nal 8 and vehi cl e body
ground. The vol tmeter shoul d i ndi cate battery vol t-
age. I f not, repai r the open ci rcui t i n the wi re har-
ness from i gni ti on swi tch to HDLP del ay modul e.
(5) Turn headl amps on and measure vol tage at ter-
mi nal 6. The vol tmete shoul d i ndi cate battery vol t-
age. I f not repai r open ci rcui t between L2 and HDLP
del ay modul e.
(6) Measure the vol tage between the del ay modul e
termi nal 2 and vehi cl e body ground. The vol tmeter
shoul d i ndi cate battery vol tage. I f not, repai r the
open ci rcui t i n the wi re harness to the HDLP fuse i n
the PDC.
(7) I f steps 1 through 6 prove out good, repl ace
headl amp del ay modul e.
FOG LAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF.
1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
Group 8A
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
7. Both fog lamp bulbs defective. 7. Replace both lamp bulbs.
FOG LAMP BULBS BURN
OUT FREQUENTLY.
1. Charging system output too high. 1. Test and repair charging system, refer to
Group 8A.
splices in circuit.
2. Inspect and repair all connectors and
splices, refer to Group 8W.
FOG LAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE.
Group 8A.
2. Poor fog lamp circuit ground. 2. Test voltage drop across Z1-ground,
refer to Group 8W.
3. High resistance in fog lamp circuit. 3. Test amperage draw of fog lamp circuit.
4. Both fog lamp bulbs defective. 4. Replace both fog lamp bulbs.
FOG LAMPS FLASH
RANDOMLY.
1. Poor fog lamp circuit ground. 1. Repair circuit ground, refer to Group 8W.
2. High resistance in fog lamp circuit. 2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch circuit
breaker.
3. Replace fog lamp switch.
splices in circuit.
4. Repair connector terminals or splices,
refer to Group 8W.
FOG LAMPS DO NOT
ILLUMINATE.
1. Blown fuse for fog lamps. 1. Replace fuse, refer to group 8W.
2. No ground at fog lamps. 2. Repair circuit ground, refer to Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.
4. Repair connector terminal or wire
splices.
XJ LAMPS 8L - 3
HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
SERVICE PROCEDURES
FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . . . 6
HEADLAMP ADJUSTMENT . . . . . . . . . . . . . . . . 5
HEADLAMP ALIGNMENT PREPARATION . . . . . . 4
SPECIAL TOOLS
GENERAL INFORMATION
HEADLAMP ALIGNMENT
Headl amps can be al i gned usi ng the screen method
provi ded i n thi s secti on. Al i gnment Tool C-4466-A or
equi val ent can al so be used. Refer to i nstructi ons
provi ded wi th the tool for proper procedures. The
preferred headlamp alignment setting is 0 for
the left/right adjustment and 1 down for the
up/down adjustment.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Veri fy headl amp di mmer swi tch and hi gh beam
i ndi cator operati on.
(2) Correct defecti ve components that coul d hi nder
proper headl amp al i gnment.
(3) Veri fy proper ti re i nfl ati on.
(4) Cl ean headl amp l enses.
(5) Veri fy that l uggage area i s not heavi l y l oaded.
(6) Fuel tank shoul d be FULL. Add 2.94 kg (6.5
l bs.) of wei ght over the fuel tank for each esti mated
gal l on of mi ssi ng fuel .
Fig. 1 Headlamp Alignment ScreenTypical
CENTER OF VEHICLE TO CENTER OF HEAD- LAMP LENS TOP EDGE OF HIGH INTENSITY ZONE FLOOR TO CENTER OF HEADLAMP LENS 7.62 METERS (25 FEET) FRONT OF HEADLAMP VEHICLE CENTERLINE LEFT EDGE OF HIGH INTEN- SITY ZONE
8L - 4 LAMPS XJ
ALIGNMENT SCREEN PREPARATION
(1) Posi ti on vehi cl e on a l evel surface perpendi cu-
l ar to a fl at wal l 7.62 meters (25 ft) away from front
of headl amp l ens (Fi g. 1).
(2) I f necessary, tape a l i ne on the fl oor 7.62
meters (25 ft) away from and paral l el to the wal l .
(3) Measure from the fl oor up 1.27 meters (5 ft)
and tape a l i ne on the wal l at the centerl i ne of the
vehi cl e. Si ght al ong the centerl i ne of the vehi cl e
(from rear of vehi cl e forward) to veri fy accuracy of
the l i ne pl acement.
(4) Rock vehi cl e si de-to-si de three ti mes to al l ow
suspensi on to stabi l i ze.
(5) Jounce front suspensi on three ti mes by pushi ng
downward on front bumper and rel easi ng.
(6) Measure the di stance from the center of head-
l amp l ens to the fl oor. Transfer measurement to the
al i gnment screen (wi th tape). Use thi s l i ne for
up/down adjustment reference.
(7) Measure di stance from the centerl i ne of the
vehi cl e to the center of each headl amp bei ng al i gned.
Transfer measurements to screen (wi th tape) to each
si de of vehi cl e centerl i ne. Use these l i nes for l eft/
ri ght adjustment reference.
HEADLAMP ADJUSTMENT
A properl y ai med l ow beam wi l l project the top
edge of hi gh i ntensi ty pattern on the screen from 50
mm (2 i n.) above to 50 mm (2 i n.) bel ow headl amp
centerl i ne. The si de-to-si de l eft edge of hi gh i ntensi ty
pattern shoul d be from 50 mm (2 i n.) l eft to 50 mm
(2 i n.) ri ght of headl amp centerl i ne). The preferred
headlamp alignment is 0 for the left/right
adjustment and 1 down for the up/down
adjustment. The hi gh beams on a vehi cl e wi th dual
headl amps cannot be al i gned. The hi gh beam pattern
shoul d be correct when the l ow beams are al i gned
properl y.
(1) Remove screws and both headl amp bezel s.
(2) Cl ean front of the headl amps.
(3) Pl ace headl amps on LOW beam.
(4) Cover front of the headl amp that i s not bei ng
adjusted.
(5) Turn verti cal adjustment screw (Fi g. 2) unti l
the headl amp beam pattern on screen/wal l i s si mi l ar
to the pattern depi cted i n the al i gnment screen fi g-
ure.
NOTE: When using a headlamp aiming screen:
Adjust the headl amps so that the beam hori zon-
tal posi ti on i s at 0.
Adjust the beam verti cal posi ti on i s 25 mm (1
i n) downward from the l amp hori zontal centerl i ne.
(6) Rotate the hori zontal adjustment screw unti l
the headl amp beam pattern on the ai mi ng screen/
wal l si mi l ar to the pattern i n the al i gnment screen
fi gure.
(7) Cover front of the headl amp that has been
adjusted and adjust the other headl amp beam as
i nstructed above.
(8) I nstal l headl amp bezel s. Ti ghten the screws
securel y.
Fig. 2 Headlamp Beam Adjustment Screws
LEFT/RIGHT ADJUSTMENT SCREW UP/DOWN ADJUST- MENT SCREW HEADLAMP
XJ LAMPS 8L - 5
FOG LAMP ADJUSTMENT
Prepare an al i gnment screen. Refer to Al i gnment
Screen Preparati on paragraph i n thi s secti on. A prop-
erl y al i gned fog l amp wi l l project a pattern on the
al i gnment screen 100 mm (4 i n.) bel ow the fog l amp
centerl i ne and strai ght ahead (Fi g. 3).
Rotate the adjustment screw to adjust beam hei ght
(Fi g. 4).
SPECIAL TOOLS
HEADLAMP ALIGNMENT
Fig. 3 Fog Lamp Alignment Typical
VEHICLE CENTERLINE CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS HIGH-INTENSITY AREA FLOOR TO CENTER OF FOG LAMP LENS 100 mm (4 in.) 7.62 METERS (25 FEET) FRONT OF FOG LAMP
Fig. 4 Fog Lamp Adjustment
ADJUSTMENT SCREW MOUNTING BRACKET FOG LAMP
Headlamp Aiming Kit C-4466A
8L - 6 LAMPS XJ
LAMP BULB SERVICE
INDEX
page page
BACK-UP/REAR TURN SIGNAL/TAIL LAMP
BULB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . . . 8
DOME LAMP BULB . . . . . . . . . . . . . . . . . . . . . . 9
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . . . . 7
FRONT PARK/TURN SIGNAL LAMP BULB . . . . . 7
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . . . . 7
LICENSE PLATE LAMP BULB . . . . . . . . . . . . . . 8
MAP READING LAMP BULB . . . . . . . . . . . . . . . 9
SIDE MARKER LAMP BULB . . . . . . . . . . . . . . . . 8
UNDERHOOD LAMP BULB . . . . . . . . . . . . . . . . 9
VISOR VANITY LAMP BULB . . . . . . . . . . . . . . . . 9
HEADLAMP BULB
REMOVAL
(1) Remove the screws attachi ng the bezel to the
gri l l e openi ng panel (Fi g. 1).
(2) Remove the screws attachi ng the retai ni ng ri ng
to the headl amp bucket.
(3) Di sconnect the headl amp bul b wi re harness
connector.
(4) Separate the bul b from the vehi cl e.
INSTALLATION
(1) Connect wi re harness connector.
(2) Posi ti on bul b i n bucket.
(3) Posi ti on retai ni ng ri ng on headl amp bul b and
i nstal l screws.
(4) I nstal l headl amp bezel .
FOG LAMP BULB
REMOVAL
(1) Remove the screws attachi ng the access cover
to the bottom of the fog l amp (Fi g. 2).
(2) Remove spri ng cl i p securi ng bul b to fog l amp.
(3) Di sconnect wi re connectors at bul b.
(4) Remove bul b el ement from fog l amp.
INSTALLATION
CAUTION: Do not touch the bulb glass with fin-
gers or other oily surfaces. Reduced bulb life will
result.
(1) Posi ti on bul b el ement i n fog l amp.
(2) Connect wi re connectors at bul b.
(3) I nstal l spri ng cl i p securi ng bul b to fog l amp.
(4) I nstal l screws attachi ng the access cover to the
bottom of the fog l amp.
FRONT PARK/TURN SIGNAL LAMP BULB
REMOVAL
(1) Remove headl amp bezel .
Fig. 1 Headlamp Bezel
HEADLAMP ADJUSTMENT NUT HEADLAMP BEZEL PARK/TURN LAMP SPRING BUMPER
Fig. 2 Fog Lamp Components
FOG LAMP CLIP BULB ACCESS COVER BULBSOCKET
XJ LAMPS 8L - 7
(2) Remove screws attachi ng park/turn si gnal
l amp to gri l l e openi ng panel .
(3) Rotate bul b socket one-thi rd turn and remove
i t from l amp (Fi g. 3).
(4) Remove bul b from socket.
INSTALLATION
(1) I nstal l bul b i n socket.
(2) I nstal l socket i n l amp.
(3) I nstal l park/turn si gnal l amp.
(4) I nstal l headl amp bezel .
SIDE MARKER LAMP BULB
REMOVAL
(1) Remove si de marker l amp.
(2) Remove bul b and socket from back si de of l amp
housi ng (Fi g. 4).
INSTALLATION
(2) I nstal l bul b and socket i n back of si de marker
l amp.
(3) I nstal l si de marker l amp.
BACK-UP/REAR TURN SIGNAL/TAIL LAMP BULB
REMOVAL
(1) Remove tai l l amp.
(2) Rotate bul b socket one-thi rd turn and remove
bul b socket from l amp (Fi g. 5).
INSTALLATION
(2) I nstal l bul b and socket i n l amp.
(3) I nstal l l amp.
LICENSE PLATE LAMP BULB
REMOVAL
(1) Remove screws attachi ng l i cense pl ate l amp to
l i ftgate.
(2) Remove bul b from l amp socket.
INSTALLATION
(1) I nstal l a repl acement bul b i n l amp socket.
(2) I nstal l screws attachi ng l i cense pl ate l amp to
l i ftgate.
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
BULB
REMOVAL
(1) Remove the screws attachi ng the l amp housi ng
to the l i ftgate.
(2) Rotate bul b socket 1/4 turn and pul l from hous-
i ng (Fi g. 6).
(3) Grasp bul b and pul l from socket.
Fig. 3 Park/Turn Signal Lamp Bulb
PARK LAMP PARK LAMP BULB
Fig. 4 Side Marker Lamp
SIDE MARKER LAMP SIDE MARKER LAMP BULB
Fig. 5 Bulb Socket Removal
TAIL LAMP BULB TAIL LAMP
8L - 8 LAMPS XJ
INSTALLATION
(1) Push bul b i nto socket.
(2) Posi ti on socket i n l amp and rotate 1/4 turn.
(3) I nstal l the screws attachi ng the l amp housi ng
to the l i ftgate.
UNDERHOOD LAMP BULB
REMOVAL
underhood l amp.
(2) Rotate the bul b countercl ock-wi se. Remove i t
from the l amp socket.
INSTALLATION
(1) I nsert the repl acement bul b i n the l amp base
socket. Rotate i t cl ockwi se.
(2) Connect the wi re harness connector to the
l amp.
DOME LAMP BULB
REMOVAL
(1) Remove the dome l amp l ens by squeezi ng i t at
both si des. Thi s wi l l separate the l ens retai ner tabs
from the l amp housi ng shoul ders.
(2) Pul l the l ens downward to remove i t from the
l amp housi ng.
(3) Grasp bul b and pul l from l amp.
INSTALLATION
(1) Posi ti on bul b i n l amp and snap i nto pl ace.
(2) Posi ti on the l ens at the l amp housi ng and force
i t upward i nto the housi ng unti l the retai ner tabs are
seated on the l amp housi ng shoul ders.
MAP READING LAMP BULB
REMOVAL
(1) I nsert a fl at bl ade screwdri ver i n sl ot at front
of l ens (Fi g. 7).
(2) Rotate the screwdri ver unti l l ens snaps out of
the housi ng.
(3) Remove l ens from housi ng.
(4) Remove bul b from termi nal s.
INSTALLATION
(1) I nsert bul b i nto readi ng l amp termi nal s.
(2) Repl ace l ens by hol di ng l ens l evel and pushi ng
rearward i nto housi ng.
(3) Push l ens up to snap i nto housi ng.
VISOR VANITY LAMP BULB
REMOVAL
(1) Usi ng a smal l fl at bl ade, careful l y pry each cor-
ner of l ens outward from l amp.
(2) Separate l ens from l amp.
(3) Grasp bul b and pul l outward.
INSTALLATION
(1) Posi ti on bul b i n socket and push i nto pl ace.
(2) Posi ti on l ens on l amp and snap i nto pl ace.
Fig. 6 CHMSL Bulb
CHMSL CHMSLBULB
Fig. 7 Reading Lamp Bulb
LENS FLAT BLADE CONSOLE
XJ LAMPS 8L - 9
LAMP SERVICE
INDEX
page page
BACK-UP/REAR TURN SIGNAL/TAIL LAMP . . . 11
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DOME LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FRONT PARK/TURN SIGNAL LAMP . . . . . . . . . 10
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LICENSE PLATE LAMP . . . . . . . . . . . . . . . . . . 12
MAP/READING LAMP . . . . . . . . . . . . . . . . . . . 13
SIDE MARKER LAMP . . . . . . . . . . . . . . . . . . . . 11
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . 12
VISOR VANITY LAMP . . . . . . . . . . . . . . . . . . . . 13
HEADLAMP
REMOVAL
(1) Remove the screws attachi ng the bezel to the
gri l l e openi ng panel
(2) Remove the screws attachi ng the retai ni ng ri ng
to the headl amp bucket.
(3) Di sconnect the headl amp bul b wi re harness
connector.
(4) Separate the bul b from the vehi cl e.
(5) Remove the spri ng attachi ng the headl amp
bucket to the gri l l e openi ng panel (Fi g. 1).
(6) Sl i de the headl amp bucket downward to di sen-
gage i t from the headl amp adjusti ng screws.
INSTALLATION
(1) Posi ti on the headl amp bucket i n the gri l l e
openi ng panel and sl i de the headl amp bucket upward
to engage i t wi th the headl amp adjusti ng screws.
(2) I nstal l the spri ng attachi ng the headl amp
bucket to the gri l l e openi ng panel .
(3) Connect the wi re harness connector.
(4) Posi ti on the bul b i n the bucket.
(5) Posi ti on retai ni ng ri ng on the headl amp bul b
and i nstal l screws.
FOG LAMP
REMOVAL
(1) Di sconnect the fog l amp wi re harness connec-
tor.
(2) Remove the screws attachi ng the fog l amp to
the support (Fi g. 2).
(3) Separate the fog l amp from the vehi cl e.
INSTALLATION
(1) Posi ti on the fog l amp i n the support bracket
and i nstal l the screws.
(2) Connect the fog l amp wi re harness connector.
FRONT PARK/TURN SIGNAL LAMP
REMOVAL
(1) Remove the headl amp bezel .
Fig. 1 Headlamp
HEADLAMP ADJUSTMENT NUT HEADLAMP BEZEL PARK/TURN LAMP SPRING BUMPER
Fig. 2 Fog Lamp
FOG LAMP BUMPER
8L - 10 LAMPS XJ
(2) Remove the screws attachi ng the park/turn si g-
nal l amp housi ng to the gri l l e openi ng panel (Fi g. 3).
(3) Remove the bul b sockets and separate from the
vehi cl e.
INSTALLATION
(1) I nstal l bul bs and sockets i n the l amp housi ng.
(2) Posi ti on the park/turn si gnal l amp housi ng on
the gri l l e openi ng panel and i nstal l the screws.
SIDE MARKER LAMP
REMOVAL
(1) Remove screws attachi ng si de marker l amp
l ens to gri l l e openi ng panel (Fi g. 4).
(2) Remove bul b and socket from back si de of
l amp.
INSTALLATION
(1) I nstal l bul b and socket i n back of si de marker
l amp.
(2) I nstal l si de marker l amp i n gri l l e openi ng
panel .
BACK-UP/REAR TURN SIGNAL/TAIL LAMP
REMOVAL
(2) Remove the bol ts attachi ng the tai l l amp hous-
i ng to the quarter panel (Fi g. 5).
(3) Grasp the l amp and pul l to di sengage i t from
the grommet at the base of the l amp.
(4) Rotate the bul b sockets one-thi rd turn and
remove the bul b sockets from the l amp housi ng.
INSTALLATION
(1) I nstal l the bul b and sockets i n the l amp hous-
i ng.
(2) Posi ti on the l amp housi ng i n the quarter panel
and push to engage the grommet.
(3) I nstal l the l amp housi ng screws. Ti ghten the
screws securel y.
(4) I nstal l the bol ts attachi ng the tai l l amp hous-
i ng to the quarter panel .
(5) Cl ose the l i ftgate.
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
REMOVAL
(1) Remove the screws attachi ng the CHMSL to
the l i ftgate (Fi g. 6).
(3) Separate the CHMSL from the vehi cl e.
INSTALLATION
(2) Posi ti on the CHMSL on the l i ftgate.
(3) I nstal l the screws attachi ng the CHMSL to the
l i ftgate.
Fig. 3 Park/Turn Signal Lamp
NUT BEZEL PARK/TURN LAMP BUMPER
Fig. 4 Side Marker Lamp
GRILLE OPEN- ING PANEL FENDER SIDE MARKER LAMP
Fig. 5 Tail Lamp
TAIL LAMPREAR BUMPER GROMMET
XJ LAMPS 8L - 11
LICENSE PLATE LAMP
REMOVAL
(1) Remove screws attachi ng the l i cense pl ate
l amp to the l i ftgate.
(2) Remove the bul b from the l amp socket.
INSTALLATION
(1) I nstal l bul b i n the l amp socket.
(2) Posi ti on the l i cense pl ate l amp on the l i ftgate
and i nstal l screws.
UNDERHOOD LAMP
The underhood l amp i s i nstal l ed on the hood i nner
panel . The l amp i l l umi nates when the hood i s
opened. The l i qui d ON/OFF swi tch that i s i ntegral
wi th the l amp base control s the operati on. The
swi tch provi des automati c ON/OFF functi ons each
ti me the hood i s opened and cl osed.
REMOVAL
l amp.
(2) Rotate the bul b countercl ock-wi se. Remove i t
from the l amp base socket.
(3) Remove the screw that attaches the l amp
refl ector and support bracket (Fi g. 7).
(4) Remove the l amp from the hood i nner panel .
INSTALLATION
(1) Posi ti on the underhood l amp on the hood i nner
panel .
(2) I nstal l the screw through the l amp and i nto
the hood panel . Ti ghten the screw securel y.
(3) I nsert a repl acement bul b i n the l amp base
socket. Rotate i t cl ockwi se.
(4) Connect the wi re harness connector to the
l amp.
DOME LAMP
REMOVAL
(1) Remove the dome l amp l ens by squeezi ng i t at
both si des. Thi s wi l l separate the l ens retai ner tabs
from the l amp housi ng shoul ders.
(2) Pul l the l ens downward to remove i t from the
l amp housi ng.
(3) Remove the fasteners attachi ng the l amp to the
roof (Fi g. 8).
(5) Remove the l amp housi ng from the headl i ner
cavi ty.
INSTALLATION
(1) Posi ti on the dome l amp housi ng at the head-
l i ner cavi ty.
(3) I nstal l the fasteners attachi ng the l amp to the
roof.
Fig. 6 Center High Mounted Stop lamp
U-NUT LIFTGATE CHMSL
Fig. 7 Underhood Lamp
WIRE CONNEC- TOR UNDERHOOD LAMP AND SWITCH SCREWHOOD INNER PANEL CONVOLUTED WIRE HAR- NESS COVER GROMMET WIRE HOLE
Fig. 8 Dome Lamp
HEADLINER DOME LAMP BULB LENS NUT FWD
8L - 12 LAMPS XJ
(4) Posi ti on the l ens at the l amp housi ng and force
i t upward i nto the housi ng unti l the retai ner tabs are
seated on the l amp housi ng shoul ders.
MAP/READING LAMP
The map/readi ng l amp can be servi ced by removi ng
the overhead consol e. Refer to Group 8C, Overhead
Consol e for removal /i nstal l ati on procedures.
VISOR VANITY LAMP
REMOVAL
(1) Fol d down sunvi sor.
(2) Starti ng at the base of the l amp assembl y and
worki ng ri ght-to-l eft, use a smal l fl at bl ade, careful l y
pry l amp from vi sor.
(3) Di sconnect vi sor l amp wi re connector and
remove from vehi cl e.
INSTALLATION
(1) Posi ti on vi sor l amp at vi sor and connect vi sor
l amp wi re connector.
(2) Posi ti on vi sor l amp i n vi sor and press i nto
pl ace.
XJ LAMPS 8L - 13
LAMP SYSTEMS
INDEX
page page
DAYTIME RUNNING LAMP MODULE . . . . . . . . 14
SENTINEL HEADLAMP DELAY MODULE . . . . . 14
SENTINEL HEADLAMP DELAY MODULE
REMOVAL
(1) Remove the knee bl ocker.
(2) Remove the screw that attaches the modul e to
the i nsi de of the i nstrument panel (Fi g. 1).
(3) Di sconnect the wi re harness connector and
remove the modul e from the i nstrument panel .
INSTALLATION
(1) Posi ti on the modul e i nsi de the I /P and connect
the wi re harness connector to the modul e.
(2) I nstal l the screw that attaches the modul e to
the i nsi de of the i nstrument panel .
(3) I nstal l the knee bl ocker.
DAYTIME RUNNING LAMP MODULE
REMOVAL
The Dayti me Runni ng Li ghts (DRL) modul e i s
l ocated on the ri ght fender i nner panel adjacent to
the dash panel (Fi g. 2).
modul e.
(2) Remove the screws that attach the modul e to
the fender i nner panel .
(3) Remove the modul e from the fender i nner
panel .
INSTALLATION
(1) Posi ti on the modul e on the ri ght fender i nner
panel .
(2) I nstal l the attachi ng screws. Ti ghten the
screws securel y.
(3) Connect the wi re harness connector to the mod-
ul e.
Fig. 1 Headlamp Delay Module
HEADLAMP DELAY MOD- ULE BRACKET
Fig. 2 Daytime Running Lamp Module
DAYTIME RUNNING LIGHT MODULE
8L - 14 LAMPS XJ
BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
SPECIFICATIONS
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 15
INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . . 15
GENERAL INFORMATION
GENERAL INFORMATION
The fol l owi ng Bul b Appl i cati on Tabl es l i sts the
l amp ti tl e on the l eft si de of the col umn and trade
number or part number on the ri ght.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result. Do not
touch halogen bulbs with fingers or other oily sur-
faces. Bulb life will be reduced.
SPECIFICATIONS
EXTERIOR LAMPS
LAMP BULB
Back-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3157
Center Hi gh Mounted Stopl amp . . . . . . . . . . . . . 921
Fog l amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H3
Front Si de Marker . . . . . . . . . . . . . . . . . . . . . . . 168
Headl amp/Seal ed Beam . . . . . . . . . . . . . . . . . H6054
Li cense Pl ate . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Park/Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . . 3157
Tai l /Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3157
Rear Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . . 3157
INTERIOR LAMPS
Servi ce procedures for most of the l amps i n the
i nstrument panel , I nstrument cl uster and swi tches
are l ocated i n Group 8E, I nstrument Panel and
Gauges. Some components have l amps that can onl y
be servi ced by an Authori zed Servi ce Center (ASC)
after the component i s removed from the vehi cl e.
Contact l ocal deal er for l ocati on of nearest ASC.
LAMP BULB
Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Dome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
LAMP BULB
Dome/Readi ng . . . . . . . . . . . . . . . . . . . . . . . . . . 906
Gl ove Compartment . . . . . . . . . . . . . . . . . . . . . . 194
Overhead Consol e . . . . . . . . . . . . . . . . . . . . . . . . 912
Under Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Vani ty Mi rror . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Underpanel Courtesy . . . . . . . . . . . . . . . . . . . . . 168
INDICATOR LAMPS
Servi ce procedures for most of the l amps i n the
i nstrument panel , i nstrument cl uster and swi tches
are l ocated i n Group 8E, I nstrument Panel and
Gauges.
LAMP BULB
A/C Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ai rbag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Anti -l ock Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Brake Warni ng . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Check Engi ne . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Check Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Cool ant Temp Hi gh . . . . . . . . . . . . . . . . . . . . . . 194
Crui se . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fasten Seat Bel ts . . . . . . . . . . . . . . . . . . . . . . . . . 74
Four Wheel Dri ve . . . . . . . . . . . . . . . . . . . . . . . . . 74
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Hi gh Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
I l l umi nati on . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Low Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Low Oi l Pressure . . . . . . . . . . . . . . . . . . . . . . . . 194
Low Washer Fl ui d . . . . . . . . . . . . . . . . . . . . . . . . 74
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASC
Securi ty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
Transmi ssi on Fl oor Shi ft . . . . . . . . . . . . . . . . . . 658
Turn Si gnal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Upshi ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
XJ LAMPS 8L - 15
PASSIVE RESTRAINT SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . 3
AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . 2
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . 3
IMPACT SENSOR . . . . . . . . . . . . . . . . . . . . . . . 3
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 4
CLEANUP PROCEDURE . . . . . . . . . . . . . . . . . . 4
AIRBAG CONTROL MODULE . . . . . . . . . . . . . . 8
AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . . . 5
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . 9
DRIVER SIDE AIRBAG TRIM COVER AND
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 6
PASSENGER SIDE AIRBAG DOOR . . . . . . . . . . 7
ADJUSTMENTS
CLOCKSPRING CENTERING . . . . . . . . . . . . . . 10
GENERAL INFORMATION
INTRODUCTION
A dual front ai rbag system i s a standard equi p-
ment safety feature on thi s model . The system
i ncl udes an i nfl atabl e ai rbag modul e i n the center of
the steeri ng wheel , and a second i nfl atabl e ai rbag
modul e i n the i nstrument panel above the gl ove box.
Thi s system i s desi gned to reduce seri ous i njuri es to
the dri ver and front seat passenger duri ng a frontal
i mpact of the vehi cl e.
To test thi s passi ve restrai nt system, refer to the
proper Di agnosti c Procedures manual . I f an ai rbag
modul e assembl y i s defecti ve and non-depl oyed, refer
to the Chrysl er Corporati on current parts return l i st
i n the Warranty Pol i ci es and Procedures manual for
the proper handl i ng procedures.
components i n the ai rbag system. Refer to 8W-43 -
Ai rbag System i n Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams.
XJ PASSIVE RESTRAINT SYSTEMS 8M - 1
WARNING:
THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS-
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
TO DO THIS COULD RESULT IN ACCIDENTAL AIR-
INJURY.
THE AIRBAG MODULE INFLATOR ASSEMBLY
CONTAINS SODIUM AZIDE AND POTASSIUM
NITRATE. THESE MATERIALS ARE POISONOUS
AND EXTREMELY FLAMMABLE. CONTACT WITH
ACID, WATER, OR HEAVY METALS MAY PRODUCE
HARMFUL AND IRRITATING GASES (SODIUM
HYDROXIDE IS FORMED IN THE PRESENCE OF
MOISTURE) OR COMBUSTIBLE COMPOUNDS. IN
ADDITION, THE PASSENGER AIRBAG MODULE
CONTAINS ARGON GAS PRESSURIZED TO OVER
2500 PSI. DO NOT ATTEMPT TO DISMANTLE AN
AIRBAG MODULE OR TAMPER WITH ITS INFLA-
TOR. DO NOT PUNCTURE, INCINERATE, OR BRING
INTO CONTACT WITH ELECTRICITY. DO NOT
STORE AT TEMPERATURES EXCEEDING 93 C
(200 F).
REPLACE AIRBAG SYSTEM COMPONENTS
ONLY WITH PARTS SPECIFIED IN THE CHRYSLER
MOPAR PARTS CATALOG. SUBSTITUTE PARTS
MAY APPEAR INTERCHANGEABLE, BUT INTERNAL
DIFFERENCES MAY RESULT IN INFERIOR OCCU-
PANT PROTECTION.
THE FASTENERS, SCREWS, AND BOLTS
ORIGINALLY USED FOR THE AIRBAG SYSTEM
COMPONENTS HAVE SPECIAL COATINGS AND
ARE SPECIFICALLY DESIGNED FOR THE AIRBAG
SYSTEM. THEY MUST NEVER BE REPLACED WITH
ANY SUBSTITUTES. ANY TIME A NEW FASTENER
IS NEEDED, REPLACE IT WITH THE CORRECT FAS-
TENERS PROVIDED IN THE SERVICE PACKAGE OR
SPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-
ALOG.
WHEN A STEERING COLUMN HAS AN AIRBAG
MODULE ATTACHED, NEVER PLACE THE COLUMN
ON THE FLOOR OR ANY OTHER SURFACE WITH
THE STEERING WHEEL OR AIRBAG MODULE FACE
DOWN.
AIRBAG MODULE
DRIVER SIDE
The ai rbag modul e protecti ve tri m cover i s the
most vi si bl e part of the dri ver si de ai rbag system.
The modul e i s mounted di rectl y to the steeri ng
wheel . Located under the ai rbag modul e tri m cover
are the horn swi tch, the ai rbag cushi on, and the ai r-
bag cushi on supporti ng components. The ai rbag mod-
ul e i ncl udes a housi ng to whi ch the cushi on and
i nfl ator are attached and seal ed. The ai rbag modul e
cannot be repai red, and must be repl aced i f depl oyed
or i n any way damaged.
The i nfl ator assembl y i s mounted to the back of
the ai rbag modul e. The i nfl ator seal s the hol e i n the
ai rbag cushi on so i t can di scharge the gas i t produces
di rectl y i nto the cushi on when suppl i ed wi th the
proper el ectri cal si gnal . The protecti ve tri m cover i s
fi tted to the front of the ai rbag modul e and forms a
decorati ve cover i n the center of the steeri ng wheel .
Upon ai rbag depl oyment, thi s cover wi l l spl i t at a
predetermi ned breakout l i ne.
PASSENGER SIDE
The ai rbag door on the i nstrument panel above the
gl ove box i s the most vi si bl e part of the passenger
si de ai rbag system. Located under the ai rbag door
are the ai rbag cushi on and i ts supporti ng compo-
nents. The ai rbag modul e i ncl udes a housi ng to
whi ch the cushi on and i nfl ator are attached and
seal ed. The ai rbag modul e cannot be repai red, and
must be repl aced i f depl oyed or i n any way damaged.
The i nfl ator assembl y i s mounted to the back of
the ai rbag modul e. The i nfl ator seal s the hol e i n the
ai rbag cushi on so i t can di scharge the gas i t produces
di rectl y i nto the cushi on when suppl i ed wi th the
proper el ectri cal si gnal . The ai rbag door i s secured to
the ai rbag modul e and the i nstrument panel base,
and has predetermi ned breakout l i nes conceal ed
beneath i ts decorati ve cover. Upon ai rbag depl oy-
ment, the ai rbag door wi l l spl i t at the breakout l i nes
and the door wi l l pi vot out of the way.
The ai rbag modul e i s secured wi th screws at the
bottom to the i nstrument panel base above the gl ove
box openi ng, and at the top to the i nstrument panel
base underneath the i nstrument panel top cover. The
ai rbag modul e and ai rbag door are avai l abl e as sep-
arate servi ce i tems. Fol l owi ng an ai rbag depl oyment,
the ai rbag modul e and ai rbag door must be repl aced.
STORAGE
An ai rbag modul e must be stored i n i ts ori gi nal ,
speci al contai ner unti l used for servi ce. Al so, i t must
be stored i n a cl ean, dry envi ronment; away from
sources of extreme heat, sparks, and hi gh el ectri cal
8M - 2 PASSIVE RESTRAINT SYSTEMS XJ
energy. Al ways pl ace or store an ai rbag modul e on a
surface wi th i ts tri m cover or ai rbag si de faci ng up,
to mi ni mi ze movement i n case of an acci dental
depl oyment.
IMPACT SENSOR
The i mpact sensor provi des veri fi cati on of the
di recti on and severi ty of an i mpact. One i mpact sen-
sor i s used. I t i s l ocated i nsi de the Ai rbag Control
Modul e (ACM), whi ch i s secured to a bracket under
the l eft si de front bucket seat i nsi de the vehi cl e.
The i mpact sensor i s an accel erometer that senses
the rate of decel erati on. The mi croprocessor i n the
ACM moni tors the i mpact sensor si gnal . A pre-pro-
grammed deci si on al gori thm i n the mi croprocessor
determi nes when the decel erati on rate i ndi cates an
i mpact i s severe enough to requi re ai rbag system
protecti on. When the programmed condi ti ons are
met, the ACM sends an el ectri cal si gnal to depl oy the
ai rbag system components.
The i mpact sensor i s cal i brated for the speci fi c
vehi cl e. The sensor i s onl y servi ced as a uni t wi th the
ACM. The sensor cannot be repai red or adjusted and,
i f faul ty or damaged, the ACM uni t must be repl aced.
CLOCKSPRING
The cl ockspri ng i s mounted on the steeri ng col umn
behi nd the steeri ng wheel . Thi s assembl y consi sts of
a pl asti c housi ng whi ch contai ns a fl at, ri bbon-l i ke,
el ectri cal l y conducti ve tape that wi nds and unwi nds
wi th the steeri ng wheel rotati on.
The cl ockspri ng i s used to mai ntai n a conti nuous
el ectri cal ci rcui t between the wi re harness and the
dri ver si de ai rbag modul e, the horn swi tch, and the
vehi cl e speed control swi tches on vehi cl es that are so
equi pped.
The cl ockspri ng must be properl y centered when i t
i s i nstal l ed on the steeri ng col umn fol l owi ng any ser-
vi ce removal , or i t wi l l be damaged. See the Cl ock-
spri ng Centeri ng procedure i n thi s group for more
i nformati on.
The cl ockspri ng cannot be repai red. I f the cl ock-
spri ng i s faul ty, damaged, or i f the ai rbag has been
depl oyed, the cl ockspri ng must be repl aced.
AIRBAG CONTROL MODULE
The Ai rbag Control Modul e (ACM) contai ns the
i mpact sensor, and a mi croprocessor that moni tors
the i mpact sensor and the ai rbag system el ectri cal
ci rcui ts to determi ne the system readi ness. The ACM
contai ns On-Board Di agnosti cs (OBD), and wi l l send
an ai rbag l amp-on message to the i nstrument cl uster
on the Chrysl er Col l i si on Detecti on (CCD) data bus
to l i ght the ai rbag i ndi cator l amp i n the i nstrument
cl uster when a moni tored ai rbag system faul t occurs.
The ACM al so contai ns an energy-storage capaci -
tor. Thi s capaci tor stores enough el ectri cal energy to
depl oy the ai rbags for up to one second fol l owi ng a
battery di sconnect or fai l ure duri ng an i mpact. The
purpose of the capaci tor i s to provi de ai rbag system
protecti on i n a severe secondary i mpact, i f the i ni ti al
i mpact has damaged or di sconnected the battery, but
was not severe enough to depl oy the ai rbags.
The ACM cannot be repai red and, i f damaged or
AIRBAG SYSTEM
A DRB scan tool i s requi red for di agnosi s of the
ai rbag system. Refer to the proper Di agnosti c Proce-
dures manual for more i nformati on.
cabl e. I f the ai rbag has not been depl oyed, wai t two
mi nutes for the system capaci tor to di scharge before
further servi ce.
(2) Connect the DRB scan tool to the 16-way data
l i nk wi re harness connector. The connector i s l ocated
on the dri ver si de l ower edge of the i nstrument
panel , outboard of the steeri ng col umn (Fi g. 1).
Exi t the vehi cl e wi th the DRB. Use the l atest versi on
of the proper DRB cartri dge.
(4) After checki ng that nobody i s i nsi de the vehi -
cl e, reconnect the battery negati ve cabl e.
(5) Usi ng the DRB, read and record the acti ve
Di agnosti c Troubl e Code (DTC) data.
Fig. 1 16-Way Data Link Connector - Typical
16WAY DATA LINK CONNECTOR BOTTOM OF INSTRU- MENT PANEL
(6) Read and record any stored DTC data.
(7) Refer to the proper Di agnosti c Procedures man-
ual , i f any DTC i s found i n Step 5 or Step 6.
(8) Erase the stored DTC data. I f any probl ems
remai n, the stored DTC data wi l l not erase.
(9) Wi th the i gni ti on swi tch sti l l i n the On posi -
ti on, make sure nobody i s i n the vehi cl e.
(10) From outsi de of the vehi cl e (away from the
ai rbag modul es i n case of an acci dental depl oyment)
turn the i gni ti on swi tch to the Off posi ti on for about
ten seconds, and then back to the On posi ti on.
Observe the ai rbag i ndi cator l amp i n the i nstrument
cl uster. I t shoul d l i ght for si x to ei ght seconds, and
then go out. Thi s i ndi cates that the ai rbag system i s
functi oni ng normal l y.
NOTE: If the airbag indicator lamp fails to light, or
lights and stays on, there is an airbag system mal-
function. Refer to the proper Diagnostic Procedures
manual to diagnose the problem.
SERVICE PROCEDURES
AIRBAG SYSTEM
NON-DEPLOYED
At no ti me shoul d any source of el ectri ci ty be per-
mi tted near the i nfl ator on the back of an ai rbag
modul e. When carryi ng a non-depl oyed ai rbag mod-
ul e, the tri m cover or ai rbag si de of the modul e
shoul d be poi nted away from the body to mi ni mi ze
i njury i n the event of an acci dental depl oyment. I f
the modul e i s pl aced on a bench or any other surface,
the tri m cover or ai rbag si de of the modul e shoul d be
face up to mi ni mi ze movement i n the event of an
acci dental depl oyment.
I n addi ti on, the ai rbag system shoul d be di sarmed
whenever any steeri ng wheel , steeri ng col umn, or
i nstrument panel components requi re di agnosi s or
servi ce. Fai l ure to observe thi s warni ng coul d resul t
i n acci dental ai rbag depl oyment and possi bl e per-
sonal i njury. Refer to Group 8E - I nstrument Panel
Systems for addi ti onal servi ce procedures on the
i nstrument panel . Refer to Group 19 - Steeri ng for
addi ti onal servi ce procedures on the steeri ng wheel
and steeri ng col umn.
DEPLOYED
Any vehi cl e whi ch i s to be returned to use after an
ai rbag depl oyment, must have both ai rbag modul es,
and the cl ockspri ng repl aced. These components wi l l
be damaged or weakened as a resul t of an ai rbag
depl oyment, whi ch may or may not be obvi ous duri ng
a vi sual i nspecti on, and are not i ntended for reuse.
Other vehi cl e components shoul d be cl osel y
i nspected, but are to be repl aced onl y as requi red by
the extent of the vi si bl e damage i ncurred.
CLEANUP PROCEDURE
Fol l owi ng an ai rbag system depl oyment, the vehi -
cl e i nteri or wi l l contai n a powdery resi due. Thi s res-
i due i s pri mari l y sodi um bi carbonate (baki ng soda),
used as an ai rbag cushi on l ubri cant. However, there
wi l l al so be traces of sodi um hydroxi de powder, a
chemi cal by-product of the generant used for ai rbag
depl oyment. Si nce thi s powder can i rri tate the ski n,
eyes, nose, or throat, be sure to wear safety gl asses,
rubber gl oves, and a l ong-sl eeved shi rt duri ng
cl eanup (Fi g. 2).
WARNING: IF YOU EXPERIENCE SKIN IRRITATION
DURING CLEANUP, RUN COOL WATER OVER THE
AFFECTED AREA. ALSO, IF YOU EXPERIENCE
IRRITATION OF THE NOSE OR THROAT, EXIT THE
VEHICLE FOR FRESH AIR UNTIL THE IRRITATION
CEASES. IF IRRITATION CONTINUES, SEE A PHYSI-
CIAN.
Begi n the cl eanup by removi ng the ai rbag modul es
from the vehi cl e as descri bed i n thi s group.
Use a vacuum cl eaner to remove any resi dual pow-
der from the vehi cl e i nteri or. Cl ean from outsi de the
vehi cl e and work your way i nsi de, so that you avoi d
kneel i ng or si tti ng on a non-cl eaned area.
Be sure to vacuum the heater and ai r condi ti oni ng
outl ets as wel l (Fi g. 3). Run the heater and ai r con-
di ti oni ng bl ower on the l owest speed setti ng and vac-
uum any powder expel l ed from the outl ets. You may
need to vacuum the i nteri or of the vehi cl e a second
ti me to recover al l of the powder.
Pl ace the depl oyed ai rbag modul es i n your vehi cu-
l ar scrap pi l e.
Fig. 2 Wear Safety Glasses and Rubber Gloves
AIRBAG MODULE
WARNING:
INJURY.
WHEN REMOVING A DEPLOYED AIRBAG
MODULE, RUBBER GLOVES, EYE PROTECTION,
AND A LONG-SLEEVED SHIRT SHOULD BE WORN.
THERE MAY BE DEPOSITS ON THE AIRBAG MOD-
ULE AND OTHER INTERIOR SURFACES. IN LARGE
DOSES, THESE DEPOSITS MAY CAUSE IRRITATION
TO THE SKIN AND EYES.
DRIVER SIDE
cabl e. I f the ai rbag modul e has not been depl oyed,
wai t two mi nutes for the system capaci tor to di s-
charge before further servi ce.
(2) From the undersi de of the steeri ng wheel ,
remove the two screws that secure the dri ver si de
ai rbag modul e to the steeri ng wheel (Fi g. 4).
(3) Pul l the ai rbag modul e away from the steeri ng
wheel far enough to access the wi re harness connec-
tors on the back of the ai rbag modul e.
(4) Unpl ug the ai rbag modul e and horn swi tch
wi re harness connectors from the back of the ai rbag
modul e.
(5) Remove the dri ver si de ai rbag modul e from the
vehi cl e.
(6) I f the ai rbag has been depl oyed, see the proce-
dure for repl aci ng the cl ockspri ng i n thi s group.
(7) When i nstal l i ng the ai rbag modul e, connect the
cl ockspri ng wi re harness connector to the modul e by
pressi ng strai ght i n on the connector. Be certai n that
the connector i s ful l y engaged by observi ng the l atch-
i ng cl i p arms on the top of the connector.
(8) I nstal l the two ai rbag modul e mounti ng screws
and ti ghten to 10.2 Nm (90 i n. l bs.).
(9) Do not connect the battery negati ve cabl e at
thi s ti me. See Ai rbag System i n Di agnosi s and Test-
i ng for the proper procedures.
PASSENGER SIDE
(2) Remove the i nstrument panel top cover. Refer
to Group 8E - I nstrument Panel Systems for the pro-
cedures.
(3) Unpl ug the passenger si de ai rbag modul e wi re
harness connector l ocated on the top of the i nstru-
ment panel between the ai rbag modul e and the wi nd-
shi el d (Fi g. 5).
(4) Di sengage the passenger si de ai rbag modul e
wi re harness connector retai ner from the hol e on the
top of the i nstrument panel .
(5) Remove the four screws that secure the upper
fl ange of the passenger si de ai rbag door to the
i nstrument panel (Fi g. 6).
(6) Remove the two screws that secure the upper
ai rbag modul e mounti ng brackets to the top of the
i nstrument panel .
Fig. 3 Vacuum Heater and A/C Outlets
Fig. 4 Driver Side Airbag Module Remove/Install
CLOCKSPRING FWD SCREW HORN SWITCH WIRE NUT DRIVER AIRBAG MODULE STEERING WHEEL SPEED CONTROL WIRE AIRBAG WIRE
(7) Open the gl ove box door and remove the two
gl ove box door stop bumpers by sl i di ng them down
towards the gl ove box bi n and out of thei r sl otted
hol es i n the i nstrument panel . Rol l the gl ove box
door down to i ts ful l y opened posi ti on.
(8) Remove the four screws that secure the l ower
fl ange of the passenger si de ai rbag door to the
i nstrument panel near the upper edge of the gl ove
box openi ng.
(9) Reach through the gl ove box openi ng and up to
remove the two screws that secure the l ower ai rbag
modul e mounti ng brackets to the i nstrument panel .
(10) Remove the passenger si de ai rbag modul e and
ai rbag door from the i nstrument panel as a uni t.
Ti ghten the hardware as fol l ows:
Ai rbag modul e mounti ng bracket screws - 11.8
Nm (105 i n. l bs.)
Ai rbag door mounti ng screws - 2.2 Nm (20 i n.
l bs.).
(12) Before rei nstal l i ng the i nstrument panel top
cover, be certai n that the ai rbag modul e wi re harness
connector l atches are ful l y engaged.
DRIVER SIDE AIRBAG TRIM COVER AND HORN
SWITCH
WARNING:
INJURY.
THE HORN SWITCH IS INTEGRAL TO THE AIR-
BAG MODULE TRIM COVER. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
(3) Remove the pl asti c horn swi tch feed wi re
retai ner from the stud on the ai rbag housi ng (Fi g. 7).
Fig. 5 Passenger Side Airbag Connector Remove/
Install
AIRBAG
DOOR
PASSENGER SIDE AIRBAG WIRE HARNESS CONNECTOR
AIRBAG HOUS-
ING
Fig. 6 Passenger Side Airbag Module Remove/Install
INSTRUMENT PANEL SCREW PASSENGER AIRBAG MODULE SCREW GLOVE BOX DOOR
Fig. 7 Horn Switch Feed Wire Remove/Install
HORN SWITCH FEED WIRE HORN SWITCH GROUND WIRE WIRE RETAINER
(4) Remove the four nuts that secure the upper
and l ower tri m cover retai ners to the studs on the
ai rbag housi ng (Fi g. 8).
(5) Remove the upper and l ower tri m cover retai n-
ers from the ai rbag housi ng studs.
(6) Remove the horn swi tch ground wi re eyel et
from the upper ai rbag housi ng stud.
(7) Di sengage the four tri m cover l ocki ng bl ocks from
the l i p around the outsi de edge of the ai rbag housi ng
and remove the housi ng from the cover (Fi g. 9).
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
DRIVER SIDE AIRBAG MODULE, OR BECOMING
ENTRAPPED BETWEEN THE DRIVER SIDE AIRBAG
MODULE TRIM COVER AND THE DRIVER SIDE AIR-
BAG MODULE. FAILURE TO OBSERVE THIS WARN-
ING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(8) When i nstal l i ng the tri m cover and horn
swi tch, be certai n that the l ocki ng bl ocks are ful l y
engaged on the l i p of the ai rbag housi ng (Fi g. 10).
(9) When i nstal l i ng the upper and l ower tri m cover
retai ners, be certai n that the tabs on each retai ner are
engaged i n the retai ner sl ots of the tri m cover (Fi g. 9).
(10) I nstal l and ti ghten the tri m cover retai ner
nuts to 10 Nm (90 i n. l bs.).
compl ete the i nstal l ati on, but do not connect the bat-
tery negati ve cabl e at thi s ti me. See Ai rbag System
i n Di agnosi s and Testi ng for the proper procedures.
PASSENGER SIDE AIRBAG DOOR
WARNING:
STEERING COLUMN, OR INSTRUMENT PANEL COM-
PONENTS YOU MUST FIRST DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE.
THEN WAIT TWO MINUTES FOR THE SYSTEM
SYSTEM SERVICE. THIS IS THE ONLY SURE WAY TO
DISABLE THE AIRBAG SYSTEM. FAILURE TO DO
THIS COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WHEN REMOVING A DEPLOYED AIRBAG
MODULE, RUBBER GLOVES, EYE PROTECTION,
AND A LONG-SLEEVED SHIRT SHOULD BE WORN.
THERE MAY BE DEPOSITS ON THE AIRBAG MOD-
ULE AND OTHER INTERIOR SURFACES. IN LARGE
DOSES, THESE DEPOSITS MAY CAUSE IRRITATION
TO THE SKIN AND EYES.
Fig. 8 Airbag Trim Cover Retainers Remove/Install
UPPER RETAINER AIRBAG HOUSING NUT (4) RETAINER SLOTS LOWERRETAINER TRIM COVER STUDS INFLATOR
Fig. 9 Airbag Trim Cover Remove/Install
RETAINER SLOTS TRIM COVER LOCKING BLOCKS RETAINER SLOTS HORN SWITCH
Fig. 10 Airbag Trim Cover Locking Blocks Installed
LIP TRIM COVER HORN SWITCH AIRBAG HOUSING LOCKINGBLOCK
(2) Remove the passenger si de ai rbag modul e from
the i nstrument panel as descri bed i n thi s group.
(3) Wi th the ai rbag modul e on a bench, sl i de the
ai rbag door si deways unti l the keyed sl ots i n the
upper and l ower ai rbag door fl anges cl ear the three
tabs on the top and the bottom of the ai rbag housi ng
(Fi g. 11).
(4) Remove the passenger si de ai rbag door from
the ai rbag modul e.
WARNING: USE EXTREME CARE TO PREVENT
ANY FOREIGN MATERIAL FROM ENTERING THE
PASSENGER SIDE AIRBAG MODULE, OR BECOM-
ING ENTRAPPED BETWEEN THE PASSENGER SIDE
AIRBAG DOOR AND THE PASSENGER SIDE AIR-
BAG MODULE. FAILURE TO OBSERVE THIS WARN-
ING COULD RESULT IN OCCUPANT INJURIES
UPON AIRBAG DEPLOYMENT.
(5) Reverse the removal procedures to compl ete
the i nstal l ati on, but do not connect the battery neg-
ati ve cabl e at thi s ti me. See Ai rbag System i n Di ag-
nosi s and Testi ng for the proper procedures.
AIRBAG CONTROL MODULE
WARNING:
THE AIRBAG CONTROL MODULE CONTAINS
THE IMPACT SENSOR, WHICH ENABLES THE SYS-
TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT-
ING TO DIAGNOSE OR SERVICE ANY AIRBAG
SYSTEM OR RELATED STEERING WHEEL, STEER-
ING COLUMN, OR INSTRUMENT PANEL COMPO-
NENTS YOU MUST FIRST DISCONNECT AND
ISOLATE THE BATTERY NEGATIVE (GROUND)
INJURY.
NEVER STRIKE OR KICK THE AIRBAG CON-
TROL MODULE, AS IT CAN DAMAGE THE IMPACT
SENSOR OR AFFECT ITS CALIBRATION. IF AN AIR-
BAG CONTROL MODULE IS ACCIDENTALLY
DROPPED DURING SERVICE, THE MODULE MUST
BE SCRAPPED AND REPLACED WITH A NEW UNIT.
ALWAYS REINSTALL THE AIRBAG CONTROL MOD-
ULE PROTECTIVE COVER.
further servi ce.
(2) Remove the l eft front bucket seat assembl y as
descri bed i n Group 23 - Body.
(3) Remove the three screws that secure the Ai r-
bag Control Modul e (ACM) protecti ve cover to the
l eft front fl oor pan and the ACM mounti ng bracket
(Fi g. 12).
(4) Pul l the ACM protecti ve cover away from the
ACM far enough to access and rel ease the ACM wi re
harness retai ner from the sl otted hol e near the rear
of the cover.
(5) Remove the ACM protecti ve cover from the
vehi cl e.
(6) Unpl ug the ACM wi re harness connector. To
unpl ug the connector, squeeze the two connector
l atch tabs between the thumb and forefi nger, whi l e
pul l i ng the connector out from the ACM.
Fig. 11 Passenger Side Airbag Door Remove/Install
CONNECTOR AIRBAG MODULE HOUSING AIRBAG DOORFLANGE AIRBAG DOOR TABS KEYED SLOTS
Fig. 12 Airbag Control Module Remove/Install
LEFT FRONT FLOOR PAN SEAT MOUNTING BRACKET FWD SCREW RETAINER COVER BRACKET AIRBAG CONTROL MODULE NUT
(7) Remove the three nuts that secure the ACM
mounti ng bracket to the fl oor pan mounti ng bracket.
(8) Remove the ACM from the vehi cl e.
(9) When i nstal l i ng the ACM, posi ti on the uni t
wi th the arrow on the ACM housi ng poi nti ng for-
ward.
(10) Attach the ACM to the fl oor pan ACM mount-
i ng bracket wi th the three mounti ng nuts. Ti ghten
the mounti ng nuts to 7.3 Nm (65 i n. l bs.).
(11) Pl ug i n the wi re harness connector to the
ACM. Be certai n that the connector l atches are ful l y
engaged.
(12) Posi ti on the ACM protecti ve cover over the
ACM. Be certai n that the wi re harness retai ner i s
correctl y rei nstal l ed i n the sl otted hol e of the ACM
protecti ve cover. Ti ghten the mounti ng screws to 4
Nm (35 i n. l bs.).
CLOCKSPRING
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
INJURY.
(1) Turn the steeri ng wheel unti l the front wheel s
are i n the strai ght-ahead posi ti on before starti ng the
procedure.
further servi ce.
(4) I f the vehi cl e i s equi pped wi th the opti onal
vehi cl e speed control , unpl ug the speed control
swi tch wi re harness connector i n the steeri ng wheel .
(5) Remove the nut that secures the steeri ng wheel
to the steeri ng col umn upper shaft.
(6) Remove the steeri ng wheel wi th a steeri ng
wheel pul l er (Speci al Tool C-3428B).
(11) Whi l e hol di ng the retai ni ng tumbl er
depressed, pul l the i gni ti on l ock cyl i nder and key out
of the i gni ti on l ock housi ng.
l ower steeri ng col umn shroud to the upper shroud.
(13) I f the vehi cl e i s equi pped wi th a standard
non-ti l t steeri ng col umn, l oosen the two upper steer-
i ng col umn mounti ng nuts. I f the vehi cl e i s equi pped
(14) Remove both the upper and l ower shrouds
from the steeri ng col umn.
the steeri ng col umn si de of the cl ockspri ng.
(16) To remove the cl ockspri ng, careful l y l i ft the
l ocati ng fi ngers of the cl ockspri ng assembl y from the
steeri ng col umn as necessary. I f the cl ockspri ng l ocat-
i ng fi ngers are broken, be certai n to remove the bro-
ken pi eces from the upper steeri ng col umn housi ng.
The cl ockspri ng cannot be repai red. I t must be
repl aced i f faul ty or damaged, or i f the ai rbag has
been depl oyed.
LOWER SHROUD ACCESS HOLE STEERINGWHEEL PIN PUNCH SCREWS (3)
(17) When i nstal l i ng the cl ockspri ng, snap the
cl ockspri ng onto the steeri ng col umn. I f the cl ock-
spri ng i s not properl y posi ti oned, see Cl ockspri ng
Centeri ng i n thi s group before i nstal l i ng the steeri ng
wheel .
(18) Pl ug the two cl ockspri ng wi re harness connec-
tors i nto the steeri ng col umn si de of the cl ockspri ng.
Be certai n that the wi re harness connector l atches
are ful l y engaged.
(19) Rei nstal l the steeri ng col umn shrouds and
i gni ti on l ock cyl i nder.
(20) Rei nstal l the steeri ng col umn openi ng cover
as descri bed i n Group 8E - I nstrument Panel Sys-
tems.
(21) The front wheel s shoul d sti l l be i n the
strai ght-ahead posi ti on. I nstal l the steeri ng wheel
bei ng certai n to fi t the fl ats on the hub of the steer-
i ng wheel onto the formati ons on the i nsi de of the
cl ockspri ng. Pul l the wi re harness through the l ower
hol e i n the steeri ng wheel hub. Ti ghten the steeri ng
wheel nut to 61 Nm (45 ft. l bs.). Be certai n not to
pi nch the wi ri ng between the steeri ng wheel and the
nut.
(22) I nstal l the ai rbag modul e as descri bed i n thi s
group.
ADJ USTMENTS
CLOCKSPRING CENTERING
I f the rotati ng tape wi thi n the cl ockspri ng i s not
posi ti oned properl y i n rel ati on to the steeri ng wheel
and the front wheel s, the cl ockspri ng may fai l duri ng
use. The cl ockspri ng must be centered i f i t i s not
known to be properl y posi ti oned, or i f the front
wheel s were moved from the strai ght-ahead posi ti on
wi th the cl ockspri ng removed duri ng any servi ce pro-
cedure.
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
INJURY.
(1) Turn the steeri ng wheel unti l the front wheel s
are i n the strai ght-ahead posi ti on before starti ng the
centeri ng procedure.
further servi ce.
(3) Remove the ai rbag modul e as descri bed i n thi s
group.
(4) I f the vehi cl e i s equi pped wi th the opti onal
vehi cl e speed control , unpl ug the speed control
swi tch wi re harness connector i n the steeri ng wheel .
(5) Remove the nut that secures the steeri ng wheel
to the steeri ng col umn upper shaft.
(6) Remove the steeri ng wheel wi th a steeri ng
wheel pul l er (Speci al Tool C-3428B).
(7) Rotate the cl ockspri ng rotor cl ockwi se to the
end of i ts travel (Fi g. 14). Do not apply excessive
torque.
(8) From the end of the cl ockwi se travel , rotate the
rotor about two and one-hal f turns countercl ockwi se,
unti l the rotor fl ats are hori zontal . I f the cl ockspri ng
wi re harness i s not at the bottom, rotate another
one-hal f turn.
(9) The front wheel s shoul d sti l l be i n the strai ght-
ahead posi ti on. I nstal l the steeri ng wheel bei ng cer-
tai n to fi t the fl ats on the hub of the steeri ng wheel
onto the formati ons on the i nsi de of the cl ockspri ng.
Pul l the wi re harness from the cl ockspri ng through
the l ower hol e i n the steeri ng wheel hub. Ti ghten the
steeri ng wheel nut to 61 Nm (45 ft. l bs.). Be certai n
not to pi nch any of the wi ri ng between the steeri ng
wheel and the nut.
(10) I nstal l the ai rbag modul e as descri bed i n thi s
group.
Fig. 14 Clockspring
ELECTRICALLY HEATED SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 2
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 2
OUTSIDE MIRROR HEATING GRID . . . . . . . . . . 2
REAR GLASS HEATING GRID . . . . . . . . . . . . . . 1
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 4
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 3
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . . 2
REAR GLASS HEATING GRID . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
REAR GLASS HEATING GRID REPAIR . . . . . . . 5
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 7
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . 6
GENERAL INFORMATION
INTRODUCTION
An el ectri cal l y heated rear wi ndow defogger and
el ectri cal l y heated outsi de rear vi ew mi rrors are
avai l abl e factory-i nstal l ed opti ons on thi s model . The
defogger wi l l onl y operate when the i gni ti on swi tch i s
i n the On posi ti on. When the defogger swi tch i s i n
the On posi ti on, el ectri c heater gri ds on the rear wi n-
dow gl ass and behi nd the outsi de rear vi ew mi rror
gl ass are energi zed. These gri ds produce heat to hel p
cl ear the rear wi ndow gl ass and outsi de rear vi ew
mi rrors of i ce, snow, or fog.
The defogger system i s control l ed by a swi tch
l ocated i n the accessory swi tch bezel , whi ch i s near
the bottom of the i nstrument panel center bezel . An
amber i ndi cator l amp i n the swi tch button wi l l l i ght
to i ndi cate when the defogger system i s turned on.
The i nstrument cl uster ci rcui try, whi ch contai ns the
defogger system ti mer l ogi c, moni tors the state of the
defogger swi tch through a hard-wi red i nput. The
i nstrument cl uster ci rcui try control s the defogger
system through a hard-wi red control output to the
defogger rel ay.
The defogger system wi l l be automati cal l y turned
off after a programmed ti me i nterval of about ten
mi nutes. After the i ni ti al ti me i nterval has expi red, i f
the defogger swi tch i s turned on agai n duri ng the
same i gni ti on cycl e, the defogger system wi l l auto-
mati cal l y turn off after about fi ve mi nutes.
The defogger system wi l l automati cal l y shut off i f
the i gni ti on swi tch i s turned to the Off posi ti on, or i t
can be turned off manual l y by depressi ng the i nstru-
ment panel swi tch. Refer to the owners manual for
more i nformati on on the defogger system control s
and operati on.
components i n the defogger system. Refer to 8W-48 -
Rear Wi ndow Defogger and 8W-62 - Power Mi rrors i n
Group 8W - Wi ri ng Di agrams for compl ete ci rcui t
REAR GLASS HEATING GRID
The heated rear wi ndow gl ass has two el ectri cal l y
conducti ve verti cal bus bars and a seri es of hori zon-
tal gri d l i nes made of a si l ver-cerami c materi al ,
whi ch i s baked on and bonded to the i nsi de surface of
the gl ass. The gri d l i nes and bus bars compri se a
paral l el el ectri cal ci rcui t.
When the rear wi ndow defogger swi tch i s pl aced i n
the On posi ti on, el ectri cal current i s di rected to the
rear wi ndow gri d l i nes through the bus bars. The
gri d l i nes heat the rear wi ndow to cl ear the surface
of fog or snow. Protecti on for the heated gri d ci rcui t
i s provi ded by a fuse i n the Power Di stri buti on Cen-
ter (PDC).
The gri d l i nes and bus bars are hi ghl y resi stant to
abrasi on. However, i t i s possi bl e for an open ci rcui t
XJ ELECTRICALLY HEATED SYSTEMS 8N - 1
to occur i n an i ndi vi dual gri d l i ne, resul ti ng i n no
current fl ow through the l i ne.
The gri d l i nes can be damaged or scraped off wi th
sharp i nstruments. Care shoul d be taken when cl ean-
i ng the gl ass or removi ng forei gn materi al s, decal s,
or sti ckers from the gl ass. Normal gl ass cl eani ng sol -
vents or hot water used wi th rags or towel i ng i s rec-
ommended.
A repai r ki t i s avai l abl e to repai r the gri d l i nes and
bus bars, or to rei nstal l the heated gl ass pi gtai l
wi res.
OUTSIDE MIRROR HEATING GRID
The heated mi rrors are control l ed by the rear wi n-
dow defogger swi tch. The heati ng gri ds behi nd the
mi rror gl ass i nsi de the mi rror are acti vated onl y
when the rear wi ndow defogger swi tch i s i n the On
posi ti on. The heati ng gri ds i nsi de the mi rrors cannot
be repai red and, i f faul ty, the enti re mi rror uni t must
be repl aced. Refer to Group 8T - Power Mi rrors for
the di agnosi s and servi ce of thi s component.
DEFOGGER SWITCH
The rear wi ndow defogger swi tch i s mounted i n the
accessory swi tch bezel , whi ch i s l ocated i n the l ower
i nstrument panel center bezel . The momentary-type
swi tch provi des a hard-wi red ground si gnal to the
i nstrument cl uster each ti me i t i s depressed. The
i nstrument cl uster rear wi ndow defogger ti mer and
l ogi c ci rcui try responds by energi zi ng or de-energi z-
i ng the rear wi ndow defogger rel ay.
Energi zi ng the rear wi ndow defogger rel ay pro-
vi des el ectri cal current to the rear wi ndow defogger
gri d, the heated outsi de rear vi ew mi rror gri ds, and
the amber i ndi cator l amp i n the swi tch, whi ch l i ghts
to i ndi cate when the defogger system i s turned On.
The defogger i l l umi nati on l amp and i ndi cator l amp
bul bs are servi ceabl e. The defogger swi tch cannot be
repai red and, i f faul ty, i t must be repl aced.
INSTRUMENT CLUSTER
The i nstrument cl uster i s an el ectromechani cal
uni t that contai ns i ntegrated ci rcui try and i nternal
programmi ng to perform a vari ety of functi ons. The
i nstrument cl uster ci rcui try moni tors hard-wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c control modul es on the
The i nstrument cl uster uses these many i nputs
al ong wi th i ts i nternal programmi ng and i ntegral
ti mer and l ogi c ci rcui try to perform the functi ons of
the rear wi ndow defogger ti mer on thi s model . The
i nstrument cl uster ci rcui try al so has a sel f-di agnosti c
capabi l i ty. Refer to Group 8E - I nstrument Panel
Systems for more i nformati on on thi s feature.
However, there are no di agnosti cs avai l abl e for the
rear wi ndow defogger ti mer and l ogi c ci rcui try.
Therefore, the di agnosi s for thi s system consi sts of
confi rmi ng the presence of a rear wi ndow defogger
swi tch i nput si gnal at the i nstrument cl uster connec-
tor, and the resul ti ng rear wi ndow defogger rel ay
control output si gnal at the defogger rel ay. For di ag-
nosi s of the CCD data bus and the data bus message
i nputs, a DRB scan tool and the proper Di agnosti c
Procedures manual are recommended.
Refer to Group 8E - I nstrument Panel Systems for
the servi ce procedures for the i nstrument cl uster.
The rear wi ndow defogger ti mer and l ogi c ci rcui try
cannot be adjusted or repai red and, i f faul ty, the
i nstrument cl uster assembl y must be repl aced.
DEFOGGER RELAY
The rear wi ndow defogger rel ay i s a I nternati onal
Standards Organi zati on (I SO)-type rel ay. The rear
wi ndow defogger rel ay i s a el ectromechani cal devi ce
that swi tches fused battery current to the rear gl ass
and outsi de mi rror heati ng gri ds and the i ndi cator
l amp of the defogger swi tch, when the i nstrument
cl uster rear wi ndow defogger ti mer and l ogi c ci r-
cui try grounds the rel ay coi l . See the Di agnosi s and
Testi ng secti on of thi s group for more i nformati on on
the operati on of the rear wi ndow defogger rel ay.
The rear wi ndow defogger rel ay i s l ocated i n the
juncti on bl ock, on the ri ght cowl si de panel bel ow the
i nstrument panel i n the passenger compartment. The
rear wi ndow defogger rel ay cannot be repai red and, i f
DEFOGGER SYSTEM
8W-48 - Rear Wi ndow Defogger or 8W-62 Power Mi r-
rors i n Group 8W - Wi ri ng Di agrams. The operati on
of the el ectri cal l y heated rear wi ndow defogger sys-
tem can be confi rmed i n one of the fol l owi ng man-
ners:
1. Turn the i gni ti on swi tch to the On posi ti on.
Whi l e moni tori ng the i nstrument panel vol tmeter, set
the defogger swi tch i n the On posi ti on. When the
defogger swi tch i s turned On, a di sti nct vol tmeter
needl e defl ecti on shoul d be noted.
2. Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The rear wi n-
dow defogger operati on can be checked by feel i ng the
rear wi ndow or outsi de rear vi ew mi rror gl ass. A di s-
ti nct di fference i n temperature between the gri d l i nes
and the adjacent cl ear gl ass or the mi rror gl ass can
be detected wi thi n three to four mi nutes of operati on.
3. Usi ng a 12-vol t DC vol tmeter, contact the rear
gl ass heati ng gri d termi nal A (ri ght si de) wi th the
8N - 2 ELECTRICALLY HEATED SYSTEMS XJ
negati ve l ead, and termi nal B (l eft si de) wi th the pos-
i ti ve l ead (Fi g. 1). The vol tmeter shoul d read battery
vol tage.
The above checks wi l l confi rm system operati on.
I l l umi nati on of the defogger swi tch i ndi cator l amp
means that there i s el ectri cal current avai l abl e at the
output of the defogger rel ay, but does not confi rm
that the el ectri cal current i s reachi ng the rear gl ass
heati ng gri d l i nes.
I f the defogger system does not operate, the prob-
l em shoul d be i sol ated i n the fol l owi ng manner:
(1) Confi rm that the i gni ti on swi tch i s i n the On
posi ti on.
(2) Ensure that the rear gl ass heati ng gri d feed
and ground wi res are connected to the gl ass. Confi rm
that the ground wi re has conti nui ty to ground.
(3) Check the fuses i n the Power Di stri buti on Cen-
ter (PDC) and i n the juncti on bl ock. The fuses must
be ti ght i n thei r receptacl es and al l el ectri cal connec-
ti ons must be secure.
When the above steps have been compl eted and the
rear gl ass or outsi de rear vi ew mi rror heati ng gri d i s
sti l l i noperati ve, one or more of the fol l owi ng i s
faul ty:
Defogger swi tch
Defogger rel ay
I nstrument cl uster ci rcui try
Rear wi ndow gri d l i nes (al l gri d l i nes woul d
have to be broken or one of the feed wi res di scon-
nected for the enti re system to be i noperati ve)
Outsi de rear vi ew mi rror heati ng gri d.
I f setti ng the defogger swi tch to the On posi ti on
produces a severe vol tmeter defl ecti on, check for a
short ci rcui t between the defogger rel ay output and
the rear gl ass or outsi de rear vi ew mi rror heati ng
gri ds.
REAR GLASS HEATING GRID
8W-48 - Rear Wi ndow Defogger i n Group 8W - Wi r-
i ng Di agrams. To detect breaks i n the gri d l i nes, the
fol l owi ng procedure i s requi red:
(1) Turn the i gni ti on swi tch to the On posi ti on. Set
the defogger swi tch i n the On posi ti on. The i ndi cator
l amp shoul d l i ght. I f OK, go to Step 2. I f not OK, see
the Defogger Rel ay di agnosi s i n thi s group.
(2) Usi ng a 12-vol t DC vol tmeter, contact the ver-
ti cal bus bar on the ri ght si de of the vehi cl e wi th the
negati ve l ead. Wi th the posi ti ve l ead, contact the ver-
ti cal bus bar on the l eft si de of the vehi cl e. The vol t-
meter shoul d read battery vol tage. I f OK, go to Step
3. I f not OK, repai r the open ci rcui t to the defogger
rel ay as requi red.
(3) Wi th the negati ve l ead of the vol tmeter, contact
a good body ground poi nt. The vol tage readi ng shoul d
not change. I f OK, go to Step 4. I f not OK, repai r the
(4) Connect the negati ve l ead of the vol tmeter to
the ri ght si de bus bar and touch each gri d l i ne at
mi dpoi nt C wi th the posi ti ve l ead. A readi ng of
approxi matel y si x vol ts i ndi cates a l i ne i s good. A
readi ng of zero vol ts i ndi cates a break i n the gri d
l i ne between mi dpoi nt C and the l eft si de bus bar. A
readi ng of ten to fourteen vol ts i ndi cates a break
between mi dpoi nt C and the ri ght si de bus bar. Move
the posi ti ve l ead on the gri d l i ne towards the break
and the vol tage readi ng wi l l change as soon as the
break i s crossed.
DEFOGGER SWITCH
8W-48 - Rear Wi ndow Defogger i n Group 8W - Wi r-
i ng Di agrams.
INJURY.
cabl e. Remove the defogger swi tch and unpl ug the
swi tch wi re harness connector.
(2) Check for conti nui ty between the ground ci r-
cui t cavi ty of the swi tch wi re harness connector and
a good ground. There shoul d be conti nui ty. I f OK, go
to Step 3. I f not OK, repai r the open ci rcui t as
requi red.
cui t and rear wi ndow defogger swi tch sense ci rcui t
termi nal s on the back of the swi tch housi ng (Fi g. 2).
There shoul d be momentary conti nui ty as the defog-
ger swi tch button i s depressed, and then no conti nu-
Fig. 1 Rear Window Glass Grid Test
TERMINALA VOLTMETER TERMINALB FEED WIRE MID-POINT C (TYPICAL) HEATED REAR WINDOW DEFOGGER GRID GROUND WIRE
i ty. I f OK, see the di agnosi s for the I nstrument
Cl uster i n thi s group. I f not OK, repl ace the faul ty
swi tch.
DEFOGGER RELAY
INJURY.
RELAY TEST
The defogger rel ay i s l ocated i n the juncti on bl ock,
on the ri ght cowl si de panel bel ow the i nstrument
panel i n the passenger compartment. Remove the
defogger rel ay from the juncti on bl ock as descri bed i n
thi s group to perform the fol l owi ng tests:
tromagnet) shoul d be 75 10 ohms. I f OK, go to
Step 3. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
ci rcui t to the PDC fuse as requi red.
to the rear gl ass and outsi de rear vi ew mi rror heat-
i ng gri ds and the defogger swi tch i ndi cator l amp.
There shoul d be conti nui ty between the cavi ty for
rel ay termi nal 87 and the rear wi ndow defogger rel ay
output ci rcui t cavi ti es of the rear gl ass and outsi de
rear vi ew mi rror heati ng gri ds and the defogger
swi tch i ndi cator l amp at al l ti mes. I f OK, go to Step
4. I f not OK, repai r the open ci rcui t(s) as requi red.
the el ectromagnet i n the rel ay. Thi s termi nal i s pro-
vi ded wi th ground by the i nstrument cl uster rear
wi ndow defogger ti mer and l ogi c ci rcui try to energi ze
the defogger rel ay. There shoul d be conti nui ty to
ground at the cavi ty for rel ay termi nal 85 when the
defogger swi tch i s turned On. However, wi th the
defogger rel ay removed, the defogger swi tch i ndi cator
l amp wi l l not l i ght to show that the defogger system
i s turned On. Be certai n that you depress the defog-
ger swi tch at l east twi ce to confi rm that the system
i s turned on duri ng thi s test. I f OK, go to Step 5. I f
not OK, repai r the open ci rcui t to the i nstrument
cl uster as requi red.
the el ectromagnet i n the rel ay. I t i s connected to
fused i gni ti on swi tch output vol tage and shoul d be
hot when the i gni ti on swi tch i s i n the On posi ti on.
Check for battery vol tage at the cavi ty for rel ay ter-
mi nal 86 wi th the i gni ti on swi tch i n the On posi ti on.
SWITCH
POSITION
CONTINUITY
BETWEEN
OFF LAMPS
ON MOMENTARY 1 AND 2
ILLUMINATION LAMP 1 AND 4
INDICATOR LAMP 1 AND 3
Fig. 2 Defogger Switch Continuity
Defogger Relay
I f OK, see the di agnosi s for I nstrument Cl uster i n
thi s group. I f not OK, repai r the open ci rcui t to the
fuse i n the juncti on bl ock as requi red.
INSTRUMENT CLUSTER
Before performi ng thi s test, compl ete the Defogger
Swi tch and the Defogger Rel ay tests as descri bed i n
thi s group. For ci rcui t descri pti ons and di agrams,
refer to 8W-48 - Rear Wi ndow Defogger i n Group 8W
- Wi ri ng Di agrams.
INJURY.
cabl e. Remove the defogger rel ay from the juncti on
bl ock and unpl ug the defogger swi tch wi re harness
connector.
(2) Remove the i nstrument cl uster from the i nstru-
ment panel . Refer to Group 8E - I nstrument Panel
Systems for the procedures.
(3) Check for conti nui ty between the rear wi ndow
defogger swi tch sense ci rcui t cavi ty of the ri ght
i nstrument cl uster wi re harness connector and a
requi red.
defogger swi tch sense ci rcui t cavi ti es of the ri ght
i nstrument cl uster wi re harness connector and the
defogger swi tch wi re harness connector. There shoul d
be conti nui ty. I f OK, go to Step 5. I f not OK, repai r
the open ci rcui t as requi red.
defogger rel ay control ci rcui t cavi ty of the ri ght
i nstrument cl uster wi re harness connector and a
requi red.
defogger rel ay control ci rcui t cavi ti es of the ri ght
i nstrument cl uster wi re harness connector and the
defogger rel ay receptacl e (I SO rel ay cavi ty 85) i n the
juncti on bl ock. There shoul d be conti nui ty. I f OK,
repl ace the faul ty i nstrument cl uster. I f not OK,
SERVICE PROCEDURES
REAR GLASS HEATING GRID REPAIR
Repai r of the gri d l i nes, bus bars, or pi gtai l wi res
can be accompl i shed usi ng a Mopar Rear Wi ndow
Defogger Repai r Ki t (P/N 4267922) or equi val ent.
WARNING: MATERIALS CONTAINED IN THE
REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.
THE KIT CONTAINS EPOXY RESIN AND AMINE
TYPE HARDENER, WHICH ARE HARMFUL IF SWAL-
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED
AREAS WITH SOAP AND WATER. FOR CONTACT
WITH THE EYES, FLUSH WITH PLENTY OF WATER.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN
IMMEDIATELY. USE WITH ADEQUATE VENTILA-
TION. DO NOT USE NEAR FIRE OR FLAME. CON-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE
REACH OF CHILDREN.
(1) Mask the repai r area so that the conducti ve
epoxy can be appl i ed neatl y. Extend the epoxy appl i -
cati on onto the gri d l i ne or the bus bar on each si de
of the break (Fi g. 3).
(2) Fol l ow the i nstructi ons i n the repai r ki t for
prepari ng the damaged area.
(3) Remove the package separator cl amp and mi x
the two conducti ve epoxy components thoroughl y
wi thi n the packagi ng. Fol d the package i n hal f and
cut the center corner to di spense the epoxy.
(4) For gri d l i ne repai rs, mask the area to be
repai red wi th maski ng tape or a templ ate.
(5) Appl y the epoxy through the sl i t i n the mask-
i ng tape or templ ate. Overl ap both ends of the break
by at l east 19 mm (0.75 i n.).
(6) For a termi nal or pi gtai l wi re repl acement,
mask the adjacent areas so the epoxy can be
extended onto the adjacent gri d l i ne as wel l as the
bus bar. Appl y a thi n l ayer of epoxy to the area
Fig. 3 Grid Line Repair - Typical
BREAK GRID LINE MASKING TAPE
where the termi nal or pi gtai l wi re was fastened and
onto the adjacent gri d l i ne.
(7) Appl y a thi n l ayer of conducti ve epoxy to the
termi nal or bare wi re end of the pi gtai l and pl ace i t
i n the proper l ocati on on the bus bar. To prevent the
termi nal or pi gtai l wi re from movi ng whi l e the epoxy
i s curi ng, i t must be wedged or cl amped.
(8) Careful l y remove the maski ng tape or tem-
pl ate.
CAUTION: Do not allow the glass surface to exceed
204 C (400 F) or the glass may fracture.
(9) Al l ow the epoxy to cure 24 hours at room tem-
perature, or use a heat gun wi th a 260 to 371 C
(500 to 700 F) range for fi fteen mi nutes. Hol d the
heat gun approxi matel y 25.4 cm (10 i n.) from the
repai r.
(10) After the conducti ve epoxy i s properl y cured,
remove the wedge or cl amp from the termi nal or pi g-
tai l wi re. Do not attach the wi re harness connectors
unti l the curi ng process i s compl ete.
(11) Check the operati on of the rear wi ndow defog-
ger rear gl ass heati ng gri d.
DEFOGGER SWITCH
INJURY.
cabl e.
ness connectors.
i nstrument panel .
bottom of the rear wi ndow defogger swi tch receptacl e
on the back of the accessory swi tch bezel wi th a
smal l thi n-bl aded screwdri ver and pul l the swi tch out
of the receptacl e.
receptacl e on the back of the accessory swi tch bezel
2.2 Nm (20 i n. l bs.).
ACCESSORY SWITCH BEZEL SCREW
DEFOGGER RELAY
INJURY.
cabl e.
vehi cl e.
(7) Unpl ug the rear wi ndow defogger rel ay from
the juncti on bl ock.
(8) I nstal l the defogger rel ay by al i gni ng the rel ay
termi nal s wi th the cavi ti es i n the juncti on bl ock and
access panel .
POWER LOCK SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER LOCK SYSTEM . . . . . . . . . . . . . . . . . . 1
REMOTE KEYLESS ENTRY SYSTEM . . . . . . . . 1
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 2
POWER LOCK SWITCH . . . . . . . . . . . . . . . . . . . 2
REMOTE KEYLESS ENTRY RECEIVER . . . . . . . 2
REMOTE KEYLESS ENTRY TRANSMITTER . . . 2
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 5
POWER LOCK SYSTEM AND REMOTE
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . . 3
REMOTE KEYLESS ENTRY TRANSMITTER . . . 5
SERVICE PROCEDURES
REMOTE KEYLESS ENTRY RECEIVER
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE KEYLESS ENTRY TRANSMITTER
BATTERY REPLACEMENT . . . . . . . . . . . . . . . 6
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 6
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
INTRODUCTION
Power l ocks are opti onal factory-i nstal l ed equi p-
ment on these model s. The power wi ndow system
and the power mi rror system are i ncl uded on vehi -
cl es equi pped wi th the power l ock opti on. On vehi cl es
equi pped wi th the power l ock opti on, al l of the doors
and the l i ftgate can be l ocked and unl ocked el ectri -
cal l y by operati ng the swi tch on ei ther front door
tri m panel . The power l ock system i ncl udes a l ock
i nhi bi t feature, whi ch prevents the doors from bei ng
l ocked by the power l ock system i f the dri ver door i s
open wi th the key i n the i gni ti on swi tch or wi th the
headl amp swi tch i n the On posi ti on. However, the
doors can sti l l be l ocked manual l y.
The Remote Keyl ess Entry (RKE) system i s an
addi ti onal opti on avai l abl e on vehi cl es equi pped wi th
the power l ock opti on. On vehi cl es wi th the RKE
opti on, the power l ocks can al so be operated by
depressi ng the Lock or Unl ock buttons of the RKE
radi o transmi tter. The RKE system i ncl udes an i l l u-
mi nated entry feature, whi ch turns on the courtesy
l amps for a ti med i nterval (about thi rty seconds),
when the power l ocks are unl ocked usi ng the RKE
transmi tter.
The power l ocks and RKE systems operate wi th
battery power suppl i ed i ndependent of the i gni ti on
swi tch. Fol l owi ng are general descri pti ons of the
major components i n the power l ock, and RKE sys-
tems. Refer to 8W-61 - Power Door Locks i n Group
8W - Wi ri ng Di agrams for compl ete ci rcui t descri p-
ti ons and di agrams. Refer to the owners manual for
more i nformati on on the features and use of these
systems.
POWER LOCK SYSTEM
The power l ock system al l ows al l of the doors and
the l i ftgate to be l ocked or unl ocked el ectri cal l y by
operati ng the swi tch on ei ther front door tri m panel .
Thi s system operates wi th battery power suppl i ed
through a fuse i n the juncti on bl ock, i ndependent of
the i gni ti on swi tch.
The power l ock system i ncl udes the front door
power l ock swi tches i ntegral to the dri ver and pas-
senger door modul es, and the power l ock motors
mounted i n each door and the l i ftgate. The power
l ock control ci rcui try and the power l ock and unl ock
rel ays are i ntegral to the Passenger Door Modul e
(PDM).
REMOTE KEYLESS ENTRY SYSTEM
The Remote Keyl ess Entry (RKE) system i s a radi o
frequency system that al l ows the use of a remote
radi o transmi tter to control the power l ock and i l l u-
mi nated entry systems. The RKE system consi sts of
the remote key fob transmi tter and a radi o recei ver
wi th program l ogi c, whi ch i s i nstal l ed i n an RKE
housi ng on the headl i ner of the vehi cl e, or i n the
housi ng of the opti onal overhead consol e, dependi ng
upon how the vehi cl e i s equi pped.
The RKE system can retai n the vehi cl e access
codes of up to four transmi tters. The transmi tter
codes are retai ned i n memory, even i f the battery i s
di sconnected. I f a transmi tter i s faul ty or l ost, new
transmi tter vehi cl e access codes can be programmed
XJ POWER LOCK SYSTEMS 8P - 1
i nto the system usi ng a DRB scan tool and the
proper Di agnosti c Procedures manual .
The RKE system for thi s vehi cl e al so features a
customer-programmabl e horn chi rp feature. Thi s fea-
ture al l ows the customer the opti on of enabl i ng or
di sabl i ng the horn chi rp request that the RKE
recei ver i ssues as an audi bl e i ndi cati on that a val i d
Lock si gnal has been recei ved from the RKE trans-
mi tter. See Remote Keyl ess Entry Recei ver Program-
mi ng i n thi s group for more i nformati on on thi s
feature.
POWER LOCK SWITCH
The power l ocks are control l ed by a two-way swi tch
that i s i ntegral to the Dri ver Door Modul e (DDM)
and the Passenger Door Modul e (PDM) mounted i n
the tri m panel of i ts respecti ve front door. Each
swi tch i s i l l umi nated by a l i ght-emi tti ng di ode when
the i gni ti on swi tch i s turned to the On posi ti on. The
power l ock swi tches provi de a hard-wi red l ock or
unl ock si gnal to the power l ock system control ci r-
cui try, whi ch i s l ocated i n the PDM.
The power l ock swi tches and thei r l amps cannot be
repai red. I f the swi tches are damaged or faul ty, the
enti re PDM or DDM must be repl aced.
DOOR MODULE
A Dri ver Door Modul e (DDM) and a Passenger
Door Modul e (PDM) are used on al l model s equi pped
wi th power l ocks and power wi ndows. Each door
modul e houses both the front power l ock and power
wi ndow swi tches. The DDM al so houses i ndi vi dual
swi tches for each passenger door power wi ndow, a
power wi ndow l ockout swi tch and the power mi rror
swi tch. The PDM al so houses the control ci rcui try
and the power l ock and unl ock rel ays for the power
l ock system.
I n i ts rol e as the power l ock control modul e, the
PDM recei ves i nputs from the battery, the i gni ti on
swi tch, the DDM, the dri ver door ajar swi tch, the
key-i n i gni ti on swi tch, and the headl amp swi tch. I t
al so recei ves a hard-wi red i nput from the RKE
recei ver, i f the vehi cl e i s so equi pped. I n response to
these i nputs, the PDM sends the proper outputs to
control the power l ock motors through i ts i ntegral
power l ock and unl ock rel ays.
The DDM and the PDM are mounted to thei r
respecti ve front door tri m panel s. The DDM and
PDM are servi ced i ndi vi dual l y and cannot be
repai red. I f the DDM or PDM, or any of the swi tches
and ci rcui try they contai n are faul ty or damaged, the
compl ete modul e must be repl aced.
POWER LOCK MOTOR
I n the power l ock and Remote Keyl ess Entry
(RKE) systems, the l ocks are actuated by a reversi bl e
motor mounted wi thi n each door and the l i ftgate.
The power l ock motor di recti on i s control l ed by the
battery and ground feeds from the power l ock and
unl ock rel ays i ntegral to the Passenger Door Modul e
(PDM).
The power l ock motors cannot be repai red and, i f
faul ty or damaged, the enti re motor must be
repl aced.
The Remote Keyl ess Entry (RKE) system transmi t-
ter i s equi pped wi th two buttons, l abel ed Lock and
Unl ock. I t i s al so equi pped wi th a key ri ng and i s
desi gned to serve as a key fob. The operati ng range
of the transmi tter radi o si gnal i s up to 7 meters (23
feet) from the RKE recei ver.
Each transmi tter has a di fferent vehi cl e access
code, whi ch must be programmed i nto the memory of
the RKE recei ver i n the vehi cl e i n order to operate
the RKE system. Refer to the servi ce procedure for
Remote Keyl ess Entry Transmi tter Programmi ng i n
The transmi tter operates on two Duracel l DL2016
(or equi val ent) batteri es. Typi cal battery l i fe i s from
one to two years. The transmi tter cannot be repai red
On model s wi th the Remote Keyl ess Entry (RKE)
opti on, an RKE recei ver i s mounted i n an RKE hous-
i ng, or i n the overhead consol e housi ng on the vehi cl e
headl i ner. The RKE recei ver i s a radi o frequency uni t
that al so contai ns the RKE system program l ogi c.
The RKE recei ver al so performs as a smart rel ay for
the i l l umi nated entry feature.
The RKE recei ver has a memory functi on to retai n
the vehi cl e access code of at l east one, but no more
than four transmi tters. The recei ver i s desi gned to
retai n the transmi tter codes i n memory, even i f the
battery i s di sconnected.
The RKE modul e recei ves i nputs from the battery,
the dri ver door ajar swi tch, and the Chrysl er Col l i -
si on Detecti on (CCD) data bus. I t al so recei ves the
radi o si gnal i nput from the RKE transmi tter. I n
response to those i nputs, i t i s programmed to control
outputs to the power l ock motors, the courtesy l amp
ci rcui ts, and the vehi cl e horn.
The RKE system for thi s vehi cl e al so features a
customer-programmabl e horn chi rp feature. Thi s fea-
ture al l ows the customer the opti on of enabl i ng or
di sabl i ng the horn chi rp request that the RKE
recei ver i ssues as an audi bl e i ndi cati on that a val i d
Lock si gnal has been recei ved from the RKE trans-
8P - 2 POWER LOCK SYSTEMS XJ
mi tter. See Remote Keyl ess Entry Recei ver Program-
mi ng i n thi s group for more i nformati on on thi s
feature.
The RKE recei ver cannot be repai red and, i f faul ty
POWER LOCK SYSTEM AND REMOTE KEYLESS
ENTRY SYSTEM
On model s wi thout the Remote Keyl ess Entry
(RKE) opti on, proceed di rectl y to the Door Modul e
di agnosi s. As a prel i mi nary di agnosi s for model s wi th
the RKE system, note the power l ock system and
i l l umi nated entry system operati on whi l e you actuate
both the Lock and Unl ock functi ons wi th the power
l ock swi tches and the RKE transmi tter. Then, pro-
ceed as fol l ows:
I f the enti re power l ock system fai l s to functi on
wi th ei ther the power l ock swi tches or the RKE
transmi tter, see the Door Modul e di agnosi s i n thi s
group.
I f the system functi ons wi th both power l ock
swi tches, but not wi th the RKE transmi tter, see the
Remote Keyl ess Entry Transmi tter di agnosi s i n thi s
group.
I f one power l ock motor fai l s to operate wi th
both of the power l ock swi tches and/or the RKE
transmi tter, see the Power Lock Motor di agnosi s i n
thi s group.
I f the RKE and power l ock systems are functi on-
i ng, but the i l l umi nated entry system fai l s to operate,
see the Remote Keyl ess Entry Recei ver di agnosi s i n
thi s group.
DOOR MODULE
I f the power l ock system i s i noperati ve wi th ei ther
front door power l ock swi tch, test the Passenger Door
Modul e (PDM). I f the power l ock system i s i nopera-
ti ve wi th onl y the dri ver si de front door power l ock
swi tch, test the Dri ver Door Modul e (DDM). For ci r-
cui t descri pti ons and di agrams, refer to 8W-61 -
Power Door Locks i n Group 8W - Wi ri ng Di agrams.
DRIVER DOOR MODULE
The onl y functi on of the Dri ver Door Modul e
(DDM) i n the power l ock system i s to provi de a Lock
or Unl ock si gnal to the power l ock system control ci r-
cui try contai ned wi thi n the Passenger Door Modul e
(PDM). The DDM si gnal s the PDM by provi di ng a
hard-wi red ground path through the DDM ground
ci rcui t and the dri ver si de power l ock swi tch contacts
to the l ock request or unl ock request termi nal s of the
PDM. The DDM power l ock swi tch functi on can be
tested as fol l ows:
cabl e. Remove the dri ver si de front door tri m panel
and unpl ug the 12-way DDM wi re harness connec-
tor (C-2) from the DDM. Check for conti nui ty
between the ground ci rcui t cavi ty of the 12-way
DDM wi re harness connector and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 2. I f
not OK, repai r the open ci rcui t to ground as
requi red.
(2) I f the probl em bei ng di agnosed i s i noperati ve
power l ock swi tch i l l umi nati on, proceed as fol l ows.
I f the probl em i s not power l ock swi tch i l l umi na-
ti on, go to Step 4. Connect the battery negati ve
cabl e. Turn the i gni ti on swi tch to the Accessory or
On posi ti ons. Check for battery vol tage at both
si des of the power wi ndow ci rcui t breaker i n the
juncti on bl ock. I f OK, go to Step 3. I f not OK,
repl ace the faul ty ci rcui t breaker.
(3) Wi th the i gni ti on swi tch sti l l i n the On or
Accessory posi ti on, check for battery vol tage at the
fused i gni ti on swi tch output ci rcui t cavi ty of the
12-way DDM wi re harness connector. I f OK, repl ace
the faul ty DDM. I f not OK, repai r the open ci rcui t
to the juncti on bl ock as requi red.
(4) Test the power l ock swi tch conti nui ty through
the DDM 12-way wi re harness connector receptacl e.
See the DDM Power Lock Swi tch Conti nui ty chart
(Fi g. 1) to determi ne i f the conti nui ty i s correct i n
the Lock and Unl ock swi tch posi ti ons. I f OK, repai r
the l ock request ci rcui t and/or the unl ock request
ci rcui t between the DDM and the PDM as requi red.
I f not OK, repl ace the faul ty DDM.
PASSENGER DOOR MODULE
The Passenger Door Modul e (PDM) contai ns the
passenger si de front door power l ock swi tch and the
power l ock system control ci rcui try. I n i ts rol e as a
power l ock swi tch, i t provi des the power l ock system
control ci rcui try wi th a ground path through the
PDM ground ci rcui t and the dri ver si de power l ock
CONNECTOR 2 (C2)
SWITCH POSITION CONTINUITY BETWEEN
LOCK 7 & 8
UNLOCK 11 & 8
Fig. 1 DDM Power Lock Switch Continuity $$1$
CONNECTOR 2 (C2)
swi tch contacts to i ndi cate a l ock request or unl ock
request.
I n i ts rol e as the power l ock control modul e, the
PDM recei ves i nputs from the battery, the i gni ti on
swi tch, the DDM, the dri ver door ajar swi tch, the
key-i n i gni ti on swi tch, and the headl amp swi tch. I t
al so recei ves a hard-wi red i nput from the RKE
recei ver, i f the vehi cl e i s so equi pped. I n response to
these i nputs, the PDM sends the proper outputs to
control the power l ock motors through i ts i ntegral
power l ock and unl ock rel ays. The PDM power l ock
system functi ons can be tested as outl i ned bel ow. I f
the power l ock system operates, but the RKE system
l ock and/or unl ock functi ons are i noperati ve, see the
di agnosi s for the Remote Keyl ess Entry Transmi tter
i n thi s group.
cabl e. Remove the passenger si de front door tri m
panel and unpl ug the 8-way PDM wi re harness con-
nector (C-1) from the PDM. Check for conti nui ty
between the ground ci rcui t cavi ty of the 8-way PDM
repai r the open ci rcui t to ground as requi red.
power l ock swi tch i l l umi nati on, proceed as fol l ows. I f
the probl em i s not power l ock swi tch i l l umi nati on, go
to Step 5. Connect the battery negati ve cabl e. Turn
the i gni ti on swi tch to the Accessory or On posi ti ons.
Check for battery vol tage at both si des of the power
wi ndow ci rcui t breaker i n the juncti on bl ock. I f OK,
go to Step 4. I f not OK, repl ace the faul ty ci rcui t
breaker.
(4) Wi th the i gni ti on swi tch sti l l i n the Accessory
or On posi ti ons, check for battery vol tage at the
fused i gni ti on swi tch output ci rcui t cavi ty of the
8-way PDM wi re harness connector. I f OK, repl ace
the faul ty PDM. I f not OK, repai r the open ci rcui t to
the juncti on bl ock as requi red.
(5) I f the probl em bei ng di agnosed i s an i nopera-
ti ve door l ock i nhi bi t feature or a power l ock system
that responds to an Unl ock command, but not a Lock
command, proceed as fol l ows. Otherwi se, go to Step
7. Wi th the dri ver si de front door cl osed, check for
conti nui ty between the door ajar/key-i n ci rcui t cavi ty
of the 8-way PDM wi re harness connector and a good
Step 6. I f not OK, repai r the shorted door ajar and/or
key-i n i gni ti on ci rcui ts as requi red. Refer to Group
8U - Chi me/Buzzer Warni ng Systems for more i nfor-
mati on.
(6) Open the dri ver si de front door wi th the key i n
the i gni ti on swi tch or wi th the headl amp swi tch i n
the On posi ti on. Check for conti nui ty between the
door ajar/key-i n ci rcui t cavi ty of the 8-way PDM
repai r the open door ajar and/or key-i n i gni ti on ci r-
cui ts as requi red. Refer to Group 8U - Chi me/
Buzzer Warni ng Systems for more i nformati on.
battery vol tage at the fused B(+) ci rcui t cavi ty of
the 8-way PDM wi re harness connector. I f OK, go to
Step 8. I f not OK, repai r the open ci rcui t to the fuse
i n the juncti on bl ock as requi red.
(8) Test the PDM power l ock swi tch conti nui ty
through the two PDM wi re harness connector recep-
tacl es. See the PDM Power Lock Swi tch Conti nui ty
chart (Fi g. 2) to determi ne i f the conti nui ty i s cor-
rect i n the Lock and Unl ock swi tch posi ti ons. I f OK,
see the di agnosi s for Power Lock Motors i n thi s
group. I f not OK, repl ace the faul ty PDM.
LEFT-HAND DRIVE (LHD)
LOCK C1 PIN 3 & C1 PIN 6
C1 PIN 3 & C2 PIN 1
C1 PIN 3 & C2 PIN 5
UNLOCK C1 PIN 6 & C1 PIN 7
C1 PIN 7 & C2 PIN 1
C1 PIN 7 & C2 PIN 5
RIGHT-HAND DRIVE (RHD)
LOCK C1 PIN 7 & C1 PIN 6
C1 PIN 7 & C2 PIN 1
C1 PIN 7 & C2 PIN 5
UNLOCK C1 PIN 6 & C1 PIN 3
C1 PIN 3 & C2 PIN 1
C1 PIN 3 & C2 PIN 5
Fig. 2 PDM Power Lock Switch Continuity
CONNECTOR 1 (C-1) $$2$ CONNECTOR 2 (C-2)
POWER LOCK MOTOR
Before you proceed wi th thi s di agnosi s, confi rm
proper power door l ock swi tch operati on. See Door
Modul e i n thi s group for the di agnosti c procedures.
Remember, the Passenger Door Modul e (PDM) ci r-
cui try control s the output to each of the power l ock
motors. For ci rcui t descri pti ons and di agrams, refer
to 8W-61 - Power Door Locks i n Group 8W - Wi ri ng
Di agrams.
(1) Check each power l ock motor for correct opera-
ti on whi l e movi ng the power l ock swi tch to both the
Lock and Unl ock posi ti ons. I f al l of the power l ock
motors are i noperati ve, go to Step 2. I f one power
l ock motor i s i noperati ve, go to Step 3.
(2) I f al l of the power l ock motors are i noperati ve,
the probl em may be caused by one shorted motor.
Unpl uggi ng a shorted power l ock motor from the
power l ock ci rcui t wi l l al l ow the good power l ock
motor to operate. Unpl ug each power l ock motor wi re
harness connector, one at a ti me, and recheck both
the l ock and unl ock functi ons by operati ng the power
l ock swi tch. I f al l of the power l ock motors are sti l l
i noperati ve after the above test, check for a short or
open ci rcui t between the power l ock motors and the
PDM. I f unpl uggi ng one power l ock motor causes the
other motors to become functi onal , go to Step 3 to
test the unpl ugged motor.
(3) Once i t i s determi ned whi ch l ock motor i s i nop-
erati ve, that motor can be tested as fol l ows. Unpl ug
the wi re harness connector at the i noperati ve motor.
Appl y 12 vol ts to the motor termi nal s to check i ts
operati on i n one di recti on. Reverse the pol ari ty to
check the operati on i n the other di recti on. I f OK,
repai r the short or open ci rcui ts to the PDM as
requi red. I f not OK, repl ace the faul ty power l ock
motor.
(1) Repl ace the Remote Keyl ess Entry (RKE)
transmi tter batteri es as descri bed i n thi s group. Test
each of the transmi tter functi ons. I f OK, di scard the
faul ty batteri es. I f not OK, go to Step 2.
(2) Perform the Remote Keyl ess Entry Transmi tter
Programmi ng procedure wi th the suspect transmi tter
and another known good transmi tter usi ng a DRB
scan tool , as descri bed i n the proper Di agnosti c Pro-
cedures manual .
(3) Test the RKE system operati on wi th both
transmi tters. I f both transmi tters fai l to operate the
power l ock system, see the di agnosi s for the Remote
Keyl ess Entry Recei ver i n thi s group. I f the known
good transmi tter operates the power l ocks and the
suspect transmi tter does not, repl ace the faul ty
transmi tter.
NOTE: Be certain to perform the Remote Keyless
Entry Transmitter Programming procedure again
following this test. This procedure will erase the
access code of the test transmitter from the RKE
receiver.
I f the probl em bei ng di agnosed i s an i noperati ve
RKE horn chi rp feature, be certai n that the horn
chi rp feature has not been di sabl ed by performi ng
the Remote Keyl ess Entry Recei ver Programmi ng
procedure as descri bed i n thi s group. Al so be certai n
that the vehi cl e horn system i s operati onal . See
Group 8G - Horn Systems for more i nformati on.
RKE i l l umi nated entry system, be certai n that the
i nteri or courtesy l amp system i s operati onal . See
Group 8L - Lamps for more i nformati on.
Before you proceed wi th di agnosi s of the RKE
recei ver, see the di agnosi s for Remote Keyl ess Entry
Transmi tter i n thi s group. For ci rcui t descri pti ons
and di agrams, refer to 8W-61 - Power Door Locks i n
(1) Check the fuses i n the Power Di stri buti on Cen-
ter (PDC) and the juncti on bl ock. I f OK, go to Step 2.
I f not OK, repai r the shorted ci rcui t or component as
requi red and repl ace the faul ty fuse.
cabl e. Remove the Remote Keyl ess Entry (RKE)
recei ver as descri bed i n thi s group. Unpl ug the wi re
harness connector from the RKE recei ver.
(3) Check the wi re harness connector and the
receptacl e i n the recei ver for l oose, corroded, or dam-
aged termi nal s and pi ns. I f OK, go to Step 4. I f not
OK, repai r as requi red.
(4) Check for conti nui ty between each of the two
ground ci rcui t cavi ti es of the RKE recei ver wi re har-
ness connector and a good ground. I n each case,
there shoul d be conti nui ty. I f OK, go to Step 5. I f not
OK, repai r the ci rcui t to ground as requi red.
battery vol tage at each of the two fused B(+) ci rcui t
cavi ti es of the RKE recei ver wi re harness connector.
to the PDC or the juncti on bl ock as requi red.
(6) I f the probl em bei ng di agnosed i nvol ves onl y
the RKE horn chi rp feature, go to Step 10. I f the
probl em bei ng di agnosed i nvol ves onl y the RKE i l l u-
mi nated entry feature, go to Step 9. I f the probl em
bei ng di agnosed i nvol ves onl y the RKE power l ocks
feature, go to Step 7.
cabl e. Unpl ug the 8-way Passenger Door Modul e
(PDM) wi re harness connector. Check for conti nui ty
between the l ock request ci rcui t cavi ty of the RKE
recei ver wi re harness connector and a good ground.
Repeat the test between the unl ock request ci rcui t
cavi ty of the RKE recei ver wi re harness connector
and a good ground. I n each case, there shoul d be no
shorted ci rcui t as requi red.
(8) Check for conti nui ty between the l ock request
ci rcui t cavi ti es of the RKE recei ver wi re harness con-
nector and the 8-way PDM wi re harness connector.
Repeat the test between the unl ock request ci rcui t
cavi ti es of the RKE recei ver wi re harness connector
and the 8-way PDM wi re harness connector. I n each
case, there shoul d be conti nui ty. I f OK, repl ace the
faul ty RKE recei ver. I f not OK, repai r the open ci r-
cui t as requi red.
(9) Check for conti nui ty between the door ajar ci r-
cui t cavi ty of the RKE recei ver wi re harness connec-
tor and a good ground wi th the dri ver door cl osed.
There shoul d be no conti nui ty unti l the dri ver door i s
opened. I f OK, repl ace the faul ty RKE recei ver. I f not
OK, repai r the ci rcui t or repl ace the faul ty dri ver
door ajar swi tch as requi red.
(10) Unpl ug the horn rel ay from the juncti on
bl ock. Check for conti nui ty between the horn rel ay
output ci rcui t cavi ty of the RKE recei ver wi re har-
ness connector and a good ground. There shoul d be
no conti nui ty. I f OK, go to Step 11. I f not OK, repai r
the short ci rcui t to the horn rel ay as requi red.
(11) Check for conti nui ty between the horn rel ay
output ci rcui t cavi ty of the RKE recei ver wi re har-
ness connector and the juncti on bl ock cavi ty for the
horn rel ay coi l ground termi nal (85). There shoul d be
conti nui ty. I f OK, repl ace the faul ty RKE recei ver. I f
not OK, repai r the open ci rcui t to the juncti on bl ock
as requi red.
SERVICE PROCEDURES
BATTERY REPLACEMENT
To repl ace the Remote Keyl ess Entry (RKE) trans-
mi tter batteri es, separate the transmi tter case hal ves
at the center seam by pryi ng gentl y wi th a tri m
sti ck, or another sui tabl e wi de fl at-bl aded tool . The
case snaps open and shut.
Repl ace the two batteri es wi th new Duracel l
DL2016, or thei r equi val ent. Be certai n that the bat-
teri es are i nstal l ed wi th thei r pol ari ty correctl y ori -
ented. Then, al i gn the two transmi tter case hal ves
wi th each other, and squeeze them fi rml y together
unti l they snap back i nto pl ace.
PROGRAMMING
To program the Remote Keyl ess Entry (RKE)
transmi tter access codes i nto the RKE recei ver
requi res the use of a DRB scan tool . Refer to the
proper Di agnosti c Procedures manual for more i nfor-
mati on.
PROGRAMMING
The opti onal Remote Keyl ess Entry (RKE) system
for thi s vehi cl e has a customer-programmabl e horn
chi rp feature. The horn chi rp i s requested by the
RKE recei ver through a hard-wi red ci rcui t to the
horn rel ay whenever a val i d Lock message i s
recei ved from a programmed RKE radi o transmi tter.
The purpose of the horn chi rp i s to provi de the
vehi cl e operator wi th an audi bl e veri fi cati on that the
Lock request has been recei ved by the RKE recei ver.
However, for any number of reasons, some customers
may prefer that thi s feature be di sabl ed. Thi s RKE
system al l ows them that opti on.
To program the Remote Keyl ess Entry (RKE)
recei ver to di sabl e the horn chi rp feature, proceed as
fol l ows:
(1) Press and hol d the Lock button of a pro-
grammed RKE transmi tter depressed for fi ve to ten
seconds.
(2) Whi l e hol di ng the RKE transmi tter Lock but-
ton depressed, press and rel ease the RKE transmi t-
ter Unl ock button.
(3) The horn chi rp feature i s now di sabl ed.
Repeati ng the precedi ng steps wi l l agai n enabl e
the horn chi rp feature.
DOOR MODULE
cabl e.
panel to the i nner door panel (Fi g. 3).
Fig. 3 Front Door Trim Panel Remove/Install
U-NUT DOORTRIM PANEL PUSH-IN FAS- TENER
panel retai ners.
i nsi de door remote control s.
the i nsi de door remote control s.
door modul e.
vehi cl e.
(9) Remove the three screws that secure the door
modul e to the door tri m panel (Fi g. 4).
(10) Remove the door modul e from the tri m panel .
POWER LOCK MOTOR
FRONT DOOR
The front door power l ock motor i s i ntegral to the
front door l atch uni t. I f the front door power l ock
motor i s faul ty or damaged, the enti re l atch uni t
must be repl aced. Refer to Group 23 - Body for the
front door l atch servi ce procedures.
REAR DOOR
The rear door power l ock motor i s i ntegral to the
rear door l atch uni t. I f the rear door power l ock
motor i s faul ty or damaged, the enti re l atch uni t
must be repl aced. Refer to Group 23 - Body for the
rear door l atch servi ce procedures.
LIFTGATE
cabl e.
fl at-bl aded tool , gentl y pry the two screw cover pl ugs
out of the l i ftgate assi st handl e.
(4) Remove the two screws that secure the l i ftgate
assi st handl e to the l i ftgate i nner panel (Fi g. 5).
(5) Remove the ei ght screws that secure the l i ft-
gate tri m panel to the l i ftgate i nner panel on both
si des and above the l i ftgate gl ass.
fl at-bl aded tool , gentl y pry the l ower edges of the
tri m panel away from the l i ftgate i nner panel around
the peri meter to rel ease the tri m panel retai ners.
(7) Remove the l i ftgate tri m panel from the vehi cl e.
(8) Reach through the l i ftgate i nner panel access
hol e and di sconnect the l i nk from the cl i p on the
power l ock motor (Fi g. 6).
(9) Remove the two screws that secure the power
l ock motor to the l i ftgate i nner panel .
(10) Pul l the power l ock motor out through the l i ft-
gate i nner panel access hol e far enough to reach the
wi re harness connector.
power l ock motor.
(12) Remove the power l ock motor from the l i ft-
gate.
Ti ghten the power l ock motor mounti ng screws to 3
Nm (28 i n. l bs.).
Fig. 4 Door Module Remove/Install
INSIDE DOOR LATCH AND LOCK REMOTE CONTROLS CONNECTOR 1 RECEPTA- CLE DOOR MODULE CONNECTOR 2 RECEP- TACLE SCREWS DOOR TRIM PANEL
Fig. 5 Liftgate Trim Panel Remove/Install
TRIM PANEL PUSH NUT LIFTGATE ASSIST HANDLE PLUG
MINI-DOME MOUNTED TYPE
cabl e.
(2) Remove the two screws that secure the Remote
Keyl ess Entry (RKE) mi ni -dome housi ng to the roof
panel rei nforcement (Fi g. 7).
(3) Lower the front of the mi ni -dome housi ng and
sl i de the uni t forward to di sengage the rear mount-
i ng tab from the headl i ner.
(4) Lower the mi ni -dome housi ng far enough to
reach the RKE recei ver wi re harness connector.
RKE recei ver.
(6) Remove the RKE mi ni -dome uni t from the
vehi cl e.
(7) Remove the two screws that secure the RKE
recei ver ci rcui t board to the mi ni -dome housi ng.
(8) Remove the RKE recei ver ci rcui t board from
the mi ni -dome housi ng.
OVERHEAD CONSOLE MOUNTED TYPE
cabl e.
(2) Remove the two screws l ocated forward of the
di spl ay modul e that secure the overhead consol e to
the upper wi ndshi el d openi ng rei nforcement (Fi g. 8).
(3) To rel ease the overhead consol e from the rear
mounti ng bracket, use your fi ngerti ps to gentl y pul l
the si des of the overhead consol e housi ng outward
near the rear mounti ng bracket.
(4) Move the overhead consol e forward to di sen-
gage the rear mounti ng tab from the headl i ner.
(5) Lower the overhead consol e far enough to
access the two wi re harness connectors.
(6) Unpl ug one wi re harness connector near the
push button modul e towards the front of the over-
head consol e.
(7) Unpl ug one wi re harness connector from the
Remote Keyl ess Entry (RKE) recei ver near the center
of the overhead consol e.
(8) Remove the overhead consol e from the vehi cl e.
(9) Remove the si x screws that secure the rear
overhead consol e housi ng to the overhead consol e
bezel (Fi g. 9).
(10) Gentl y fl ex the si des of the overhead consol e
bezel far enough to cl ear the tabs on the rear consol e
housi ng and remove the housi ng from the bezel .
Fig. 6 Liftgate Power Lock Motor Remove/Install
CLIPS LOCK LEVER LINK MOTOR LIFTGATE INNER PANEL SCREW CONNECTORS
Fig. 7 Mini-Dome Housing Remove/Install
Fig. 8 Overhead Console Remove/Install
(11) Remove the two screws that secure the RKE
recei ver ci rcui t board to the rear overhead consol e
housi ng.
(12) Remove the RKE ci rcui t board from the rear
overhead consol e housi ng.
Fig. 9 RKE Receiver Remove/Install
REAR OVERHEAD CONSOLE HOUSING RKE RECEIVER TABS OVERHEAD CONSOLE BEZEL SCREWS
POWER SEAT SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 2
POWER SEAT ADJUSTER AND MOTORS . . . . . 1
POWER SEAT SWITCH . . . . . . . . . . . . . . . . . . . 1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 2
POWER SEAT SYSTEM . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION
INTRODUCTION
A si x-way dri ver si de power seat i s an avai l abl e
factory-i nstal l ed opti on for Left-Hand Dri ve (LHD)
versi ons of thi s model . The power seat system
recei ves battery feed through a fuse i n the Power
Di stri buti on Center and a ci rcui t breaker i n the junc-
ti on bl ock at al l ti mes.
components i n the power seat system. Refer to 8W-63
- Power Seat i n Group 8W - Wi ri ng Di agrams for
compl ete ci rcui t descri pti ons and di agrams.
POWER SEAT SWITCH
The power seat can be adjusted i n si x di fferent
ways usi ng the power seat swi tch. The swi tch i s
l ocated on the l ower outboard si de of the seat cushi on
frame. Refer to the owners manual for more i nforma-
ti on on power seat swi tch functi ons and seat adjust-
i ng procedures.
The i ndi vi dual swi tches i n the power seat swi tch
modul e cannot be repai red. I f one swi tch i s damaged
or faul ty, the enti re power seat swi tch modul e must
be repl aced.
POWER SEAT ADJUSTER AND MOTORS
There are three reversi bl e motors that operate the
power seat adjuster. The motors are connected to
worm-dri ve gearboxes that move the seat adjuster
through a combi nati on of screw-type dri ve uni ts.
The front and rear of a seat are operated by di ffer-
ent motors. They can be rai sed or l owered i ndepen-
dentl y of each other. When the center seat swi tch i s
pushed to the Up or Down posi ti on, both the front
and rear motors operate i n uni son, movi ng the enti re
seat up or down. The forward-rearward motor i s
operated by pushi ng the center seat swi tch to the
Forward or Rearward posi ti on.
When a swi tch i s actuated, a battery feed and a
ground path are appl i ed through the swi tch contacts
to the motor(s). The motor(s) and dri ves operate to
move the seat i n the sel ected di recti on unti l the
swi tch i s rel eased, or unti l the travel l i mi t of the
power seat adjuster i s reached. When the swi tch i s
moved i n the opposi te di recti on, the battery feed and
ground path to the motor(s) are reversed through the
swi tch contacts. Thi s causes the motor to run i n the
opposi te di recti on.
Each motor contai ns a sel f-resetti ng ci rcui t breaker
to protect i t from overl oad. Consecuti ve or frequent
resetti ng of the ci rcui t breakers must not be al l owed
to conti nue, or the motors may be damaged. Make
the necessary repai rs.
The power seat adjuster and motors cannot be
repai red, and are servi ced onl y as a compl ete uni t. I f
any component i n thi s uni t i s faul ty or damaged, the
enti re power seat adjuster and motors assembl y must
be repl aced.
XJ POWER SEAT SYSTEMS 8R - 1
CIRCUIT BREAKER
An automati c resetti ng ci rcui t breaker i n the junc-
ti on bl ock i s used to protect the power seat system
ci rcui t. The ci rcui t breaker can protect the system
from a short ci rcui t, or from an overl oad condi ti on
caused by an obstructed or stuck seat adjuster.
The ci rcui t breaker cannot be repai red and, i f
POWER SEAT SYSTEM
Before any testi ng of the power seat system i s
attempted, the battery shoul d be ful l y-charged and
al l wi re harness connecti ons and pi ns cl eaned and
ti ghtened to ensure proper conti nui ty and grounds.
For ci rcui t descri pti ons and di agrams, refer to 8W-63
- Power Seat i n Group 8W - Wi ri ng Di agrams.
Wi th the dome l amp on, appl y the power seat
swi tch i n the di recti on of the fai l ure. I f the dome
l amp di ms, the seat may be jammi ng. Check under
and behi nd the seat for bi ndi ng or obstructi ons. I f
the dome l amp does not di m, proceed wi th testi ng of
the i ndi vi dual components and ci rcui ts.
CIRCUIT BREAKER
8W-63 - Power Seat i n Group 8W - Wi ri ng Di agrams.
(1) Locate the correct ci rcui t breaker i n the junc-
ti on bl ock. Pul l out the ci rcui t breaker sl i ghtl y, but
be sure that the termi nal s sti l l contact the termi nal s
i n the juncti on bl ock cavi ti es.
(2) Connect the negati ve l ead of a 12-vol t DC vol t-
meter to a good ground.
(3) Wi th the vol tmeter posi ti ve l ead, check both
termi nal s of the ci rcui t breaker for battery vol tage.
I f onl y one termi nal has battery vol tage, the ci rcui t
breaker i s faul ty and must be repl aced. I f nei ther ter-
mi nal has battery vol tage, repai r the open ci rcui t
from the Power Di stri buti on Center (PDC) as
requi red.
Operate the power seat swi tch to move al l three
seat motors. The seat shoul d move i n each sel ected
di recti on. I f a motor fai l s to operate i n onl y one di rec-
ti on, move the seat a short di stance i n the opposi te
di recti on and test agai n to be certai n the adjuster i s
not at i ts travel l i mi t. I f one or more of the motors
operate, see the di agnosi s for the Power Seat Swi tch
i n thi s group. I f no motors operate, proceed as fol -
l ows:
(1) Test the ci rcui t breaker i n the juncti on bl ock as
descri bed i n thi s group. I f OK, go to Step 2. I f not
OK, repl ace the faul ty ci rcui t breaker.
(2) Remove the power seat swi tch as descri bed i n
thi s group. Check for battery vol tage at the fused
B(+) ci rcui t cavi ty of the power seat swi tch wi re har-
ness connector. I f OK, go to Step 3. I f not OK, repai r
the open ci rcui t to the juncti on bl ock as requi red.
cui t cavi ty of the power seat swi tch wi re harness con-
nector and a good ground. There shoul d be
open ci rcui t to ground as requi red.
(4) Test the power seat swi tch as descri bed i n thi s
group. I f the swi tch tests OK, check the wi re harness
for the i noperati ve motor between the swi tch and the
motor for shorts or opens. I f the ci rcui ts check OK,
repl ace the faul ty power seat adjuster and motors
assembl y. I f the ci rcui ts are not OK, repai r the wi re
harness as requi red.
POWER SEAT SWITCH
(1) Remove the power seat swi tch as descri bed i n
thi s group.
(2) Use an ohmmeter to test the conti nui ty of the
swi tches i n each posi ti on. See the Power Seat Swi tch
Conti nui ty chart (Fi g. 1). I f OK, see the di agnosi s for
the Power Seat Adjuster and Motors i n thi s group. I f
not OK, repl ace the faul ty power seat swi tch modul e.
POWER SEAT SWITCH
cabl e.
(2) Remove the three screws that secure the seat
si de shi el d to the outboard seat cushi on frame.
(3) Pul l the seat si de shi el d away from the seat
cushi on frame far enough to access the power seat
swi tch wi re harness connector.
(4) Unpl ug the power seat swi tch wi re harness
connector from the swi tch.
(5) Remove the seat si de shi el d from the vehi cl e.
(6) Remove the two screws that secure the power
seat swi tch to the i nsi de of the seat si de shi el d (Fi g.
2).
(7) Remove the power seat swi tch from the seat
si de shi el d.
8R - 2 POWER SEAT SYSTEMS XJ
(1) Move the seat to i ts ful l y rai sed and ful l y for-
ward posi ti on, i f possi bl e.
cabl e.
(3) Unpl ug the seat bel t swi tch wi re harness con-
nector from the dri ver si de seat bel t buckl e hal f on
the i nboard si de of the seat (Fi g. 3).
(4) Remove the two screws that secure the front of
the seat adjuster frame to the fl oor pan seat mount-
i ng rei nforcement (Fi g. 4).
(5) Remove the screw that secures the outboard
rear of the seat adjuster frame to the fl oor pan.
(6) Remove the nut that secures the i nboard rear
of the seat adjuster frame to the stud on the fl oor
pan.
(7) Unpl ug the power seat wi re harness connector
from the body wi re harness connector.
(8) Remove the dri ver si de power seat and adjuster
assembl y from the vehi cl e.
(9) Unpl ug the power seat wi re harness connectors
at each of the three power seat motors.
(10) Remove the four nuts that secure the seat
adjuster and motors assembl y to the seat cushi on
frame and remove the adjuster and motors assembl y
from the seat (Fi g. 5).
Ti ghten the seat mounti ng hardware as fol l ows:
Fig. 1 Power Seat Switch Continuity
SWITCH POSITION OFF
VERTICAL UP
VERTICAL DOWN
HORIZONTAL FORWARD
HORIZONTAL AFT
FRONT TILT UP
FRONT TILT DOWN
REAR TILT UP
REAR TILT DOWN
CONTINUITY BETWEEN AFT/FORWARD DOWN TERMINALS SHOWN AS VIEWED FROM REAR OF SWITCH UP
Fig. 2 Power Seat Switch Remove/Install
SEAT SIDE SHIELD POWER SEAT SWITCH SCREWS
Fig. 3 Driver Seat Belt Switch Connector
DRIVER SIDE FRONT SEAT SEAT BELT SWITCH CONNECTOR BODY WIRE HAR- NESS CONNECTOR
XJ POWER SEAT SYSTEMS 8R - 3
Seat adjuster to seat cushi on frame nuts - 25
Nm (18 ft. l bs.)
Seat adjuster to fl oor panel screws - 27 Nm (20
ft. l bs.)
Seat adjuster to fl oor panel nut - 40 Nm (30 ft.
l bs.).
Fig. 4 Power Seat Remove/Install
NUT DRIVER SIDE FRONT SEAT SCREW STUD SCREW
Fig. 5 Power Seat Adjuster and Motors Remove/
Install
POWER SEAT ADJUSTER AND MOTORS SEAT CUSHION FRAME SEAT CUSHION FRAME
8R - 4 POWER SEAT SYSTEMS XJ
POWER WINDOW SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 2
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 2
POWER WINDOW MOTOR . . . . . . . . . . . . . . . . 2
POWER WINDOW SWITCH . . . . . . . . . . . . . . . . 1
CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . 3
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 3
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . 2
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
Power wi ndows are avai l abl e as factory-i nstal l ed
opti onal equi pment on thi s model . The power l ock
system and power mi rror system are i ncl uded on
vehi cl es equi pped wi th the power wi ndow opti on.
Thi s group covers di agnosi s and servi ce of onl y the
el ectri cal components i n the power wi ndow system.
For servi ce of mechani cal components, such as the
regul ator, l i ft pl ate, wi ndow tracks, or gl ass refer to
Group 23 - Body.
components i n the power wi ndow system. Refer to
8W-60 - Power Wi ndows i n Group 8W - Wi ri ng Di a-
grams for compl ete ci rcui t descri pti ons and di agrams.
Refer to the owners manual for more i nformati on on
the features and use of thi s system.
POWER WINDOW SWITCH
The i ndi vi dual power wi ndows are control l ed by a
two-way momentary swi tch mounted on the tri m
panel of the passenger si de front door tri m panel
and, on four-door model s, on each of the rear door
tri m panel s. Two-way momentary master swi tches on
the dri ver si de front door tri m panel control al l of the
power wi ndows i n the vehi cl e. The dri ver si de front
door tri m panel al so has a two-posi ti on power wi n-
dow l ockout swi tch.
The front door power wi ndow swi tches and the
power wi ndow l ockout swi tch are i ntegral to the
Dri ver Door Modul e (DDM) or Passenger Door Mod-
ul e (PDM), respecti vel y. The rear door power wi ndow
swi tches are stand-al one uni ts.
Each power wi ndow swi tch control s i ts power wi n-
dow motor by swi tchi ng battery current and ground
between the termi nal s of the power wi ndow motor.
The passenger si de front door and, on four-door mod-
el s, both rear door power wi ndow swi tches recei ve
thei r battery feed through the power wi ndow l ockout
swi tch or through the master swi tches i n the DDM.
Al so, each of the i ndi vi dual power wi ndow swi tches
recei ves i ts ground through the DDM. When the l ock-
out swi tch i s pl aced i n the Lock posi ti on, the i ndi vi d-
ual power wi ndow swi tches become i noperati ve
because they have no battery current avai l abl e to
them. However, the master swi tches are unaffected
by the l ockout swi tch posi ti on.
Each power wi ndow swi tch, except the l ockout
swi tch, i s i l l umi nated by a Li ght-Emi tti ng Di ode
(LED) when the i gni ti on swi tch i s turned to the On
posi ti on. However, when the l ockout swi tch i s pl aced
i n the Lock posi ti on, the LED for the l ocked-out pas-
senger si de front and, on four-door model s, the rear
passenger door power wi ndow swi tches i s turned off.
The front door power wi ndow swi tches and thei r
l amps cannot be repai red and, i f faul ty or damaged,
the enti re door modul e must be repl aced. The rear
door power wi ndow swi tches and thei r l amps cannot
be repai red but, i f faul ty or damaged, onl y the
affected swi tch uni t must be repl aced.
XJ POWER WINDOW SYSTEMS 8S - 1
DOOR MODULE
modul e houses both the front door power l ock and
power wi ndow swi tches. The DDM al so houses i ndi -
vi dual swi tches for each passenger door power wi n-
dow, a power wi ndow l ockout swi tch, a power mi rror
swi tch, and ci rcui try to support the one-touch down
feature of the dri ver si de front door power wi ndow.
The PDM al so houses the control ci rcui try and the
power l ock and unl ock rel ays for the power l ock sys-
tem.
POWER WINDOW MOTOR
A permanent magnet reversi bl e motor moves the
wi ndow regul ator through an i ntegral gearbox mech-
ani sm. A posi ti ve and negati ve battery connecti on to
the two motor termi nal s wi l l cause the motor to
rotate i n one di recti on. Reversi ng current through
these same two connecti ons wi l l cause the motor to
rotate i n the opposi te di recti on.
I n addi ti on, each power wi ndow motor i s equi pped
wi th an i ntegral sel f-resetti ng ci rcui t breaker to pro-
tect the motor from overl oads. The power wi ndow
motor and gearbox assembl y cannot be repai red and,
i f faul ty or damaged, the enti re power wi ndow regu-
l ator assembl y must be repl aced.
CIRCUIT BREAKER
An automati c resetti ng ci rcui t breaker i n the junc-
ti on bl ock i s used to protect the power wi ndow sys-
tem ci rcui t. The ci rcui t breaker can protect the
system from a short ci rcui t, or from an overl oad con-
di ti on caused by an obstructed or stuck wi ndow gl ass
or regul ator.
The ci rcui t breaker cannot be repai red and, i f
POWER WINDOW SYSTEM
grams.
ALL WINDOWS INOPERATIVE
(1) Check the ci rcui t breaker i n the juncti on bl ock,
as descri bed i n thi s group. I f OK, go to Step 2. I f not
OK, repl ace the faul ty ci rcui t breaker.
(2) Remove the Dri ver Door Modul e (DDM) as
the ground ci rcui t cavi ty of the swi tch wi re harness
connector and a good ground. I f OK, go to Step 3. I f
not OK, repai r the ci rcui t to ground as requi red.
Check for battery vol tage at the fused i gni ti on swi tch
output ci rcui t cavi ty of the DDM wi re harness con-
nector. I f OK, see the di agnosi s for the Door Modul e
i n thi s group. I f not OK, repai r the open ci rcui t to
the ci rcui t breaker i n the juncti on bl ock as requi red.
ONE WINDOW INOPERATIVE
The wi ndow gl ass must be free to sl i de up and
down for the power wi ndow motor to functi on prop-
erl y. I f the gl ass i s not free to move up and down, the
motor wi l l overl oad and tri p the i ntegral ci rcui t
breaker. To determi ne i f the gl ass i s free, di sconnect
the regul ator pl ate from the gl ass. Then sl i de the
wi ndow up and down by hand.
There i s an al ternate method to check i f the gl ass
i s free. Posi ti on the gl ass between the up and down
stops. Then, shake the gl ass i n the door. Check that
the gl ass can be moved sl i ghtl y from si de to si de,
front to rear, and up and down. Then check that the
gl ass i s not bound ti ght i n the tracks. I f the gl ass i s
free, proceed wi th the di agnosi s that fol l ows. I f the
gl ass i s not free, refer to Group 23 - Body for the
door wi ndow gl ass and hardware servi ce and adjust-
ment procedures.
(1) Check the power wi ndow swi tch conti nui ty as
descri bed i n the di agnosi s for the Door Modul e (front
doors) or Power Wi ndow Swi tch (rear doors) i n thi s
group. I f OK and the dri ver si de front wi ndow i s
i noperati ve, see the Power Wi ndow Motor di agnosi s
i n thi s group. I f OK and the i noperati ve wi ndow i s
other than the dri ver si de front, go to Step 2. I f not
OK, repl ace the faul ty door modul e or swi tch.
(2) Refer to the ci rcui t di agrams i n 8W-60 - Power
Wi ndows i n Group 8W - Wi ri ng Di agrams. Check the
conti nui ty i n each ci rcui t between the i noperati ve
Passenger Door Modul e (PDM) or power wi ndow
swi tch wi re harness connector cavi ti es and the corre-
spondi ng Dri ver Door Modul e (DDM) wi re harness
connector cavi ti es. I f OK, see the di agnosi s for the
Power Wi ndow Motor i n thi s group. I f not OK, repai r
the open ci rcui t(s) as requi red.
NOTE: All individual power window switches
receive their battery and ground feeds through the
Driver Door Module (DDM) and wire harness con-
nectors.
8S - 2 POWER WINDOW SYSTEMS XJ
CIRCUIT BREAKER
grams.
(1) Locate the ci rcui t breaker i n the juncti on bl ock.
Pul l out the ci rcui t breaker sl i ghtl y, but be sure that
the termi nal s sti l l contact the termi nal s i n the junc-
ti on bl ock cavi ti es.
(2) Connect the negati ve l ead of a 12-vol t DC vol t-
meter to a good ground.
(3) Wi th the vol tmeter posi ti ve l ead, check both
termi nal s of the ci rcui t breaker for battery vol tage.
I f onl y one termi nal has battery vol tage, the ci rcui t
breaker i s faul ty and must be repl aced. I f nei ther ter-
mi nal has battery vol tage, repai r the open ci rcui t
from the Power Di stri buti on Center (PDC) as
requi red.
DOOR MODULE
The Dri ver Door Modul e (DDM) contai ns the mas-
ter swi tches and the l ockout swi tch i n the power wi n-
dow system. The DDM al so contai ns an i ntegrated
ci rcui t to support the one-touch down feature of the
dri ver si de front door power wi ndow. Remember that
the passenger si de front door power wi ndow swi tch
and, on four-door model s, the rear door power wi n-
dow swi tches get thei r battery current through the
power wi ndow l ockout swi tch i n the Dri ver Door
Modul e (DDM). I n addi ti on, each i ndi vi dual power
wi ndow swi tch gets i ts ground through the master
swi tch i n the DDM.
The one-touch down feature ci rcui try wi thi n the
DDM wi l l not operate the power wi ndow motor i f the
door gl ass, wi ndow regul ator, or gearbox mechani sm
are stuck, obstructed, or bi ndi ng. I f the dri ver si de
front door power wi ndow operates as desi gned, but
the one-touch down feature i s i noperati ve, repl ace
the faul ty DDM.
power wi ndow swi tch i l l umi nati on l amp, but the
power wi ndow swi tch operates as desi gned, repl ace
the faul ty door modul e. For ci rcui t descri pti ons and
di agrams, refer to 8W-60 - Power Wi ndows i n Group
(1) Remove the door modul e from the door tri m
(2) Check the door modul e power wi ndow swi tch
and/or power wi ndow l ockout swi tch conti nui ty i n
each posi ti on, as shown i n the proper chart (Fi g. 1)
or (Fi g. 2). I f OK, see the Power Wi ndow Motor di ag-
nosi s i n thi s group. I f not OK, repl ace the faul ty door
modul e.
POWER WINDOW SWITCH
The di agnosi s found here appl i es onl y to the rear
door power wi ndow swi tches. For di agnosi s of the
front door swi tches, see Door Modul e i n thi s group. I f
the probl em bei ng di agnosed i s an i noperati ve power
wi ndow swi tch i l l umi nati on l amp, but the power wi n-
dow swi tch operates as desi gned, repl ace the faul ty
swi tch. For ci rcui t descri pti ons and di agrams, refer
to 8W-60 - Power Wi ndows i n Group 8W - Wi ri ng
Di agrams.
(1) Remove the power wi ndow swi tch from the
rear door tri m panel as descri bed i n thi s group.
(2) Check the power wi ndow swi tch conti nui ty i n
each posi ti on as shown i n the Rear Door Power Wi n-
dow Swi tch Conti nui ty chart (Fi g. 3). I f OK, see the
Power Wi ndow Motor di agnosi s i n thi s group. I f not
OK, repl ace the faul ty swi tch.
POWER WINDOWS
CONNECTOR 2 (C2)
OFF (NORMAL) 1&8, 2&8, 3&8, 4&8, 5&8, 6&8, 10&8, 12&8
RIGHT REAR DOWN 1&9
RIGHT REAR UP 2&9
RIGHT FRONT UP 3&9
LEFT REAR UP 4&9
LEFT FRONT UP 5&9
RIGHT FRONT DOWN 6&9
LEFT REAR DOWN 10&9
LEFT FRONT DOWN 12&9
WINDOW LOCKOUT
CONNECTOR 1 (C1), CONNECTOR 2 (C2)
LOCKOUT OFF (UP) C1 PIN 8 & C2 PIN 9
LOCKOUT ON
(DOWN)
NO CONTINUITY BETWEEN C1 PIN 8
& C2 PIN 9
Fig. 1 DDM Power Window Switch Continuity
CONNECTOR 1 (C-1) CONNECTOR 2 (C-2)
POWER WINDOWS
OFF (NORMAL) C2 PIN 2 & C2 PIN 3
C2 PIN 4 & C2 PIN 9
UP C2 PIN 2 & C2 PIN 3
C2 PIN 9 & C2 PIN 10
DOWN C2 PIN 2 & C2 PIN 10
C2 PIN 4 & C2 PIN 9
Fig. 2 PDM Power Window Switch Continuity
CONNECTOR 2 (C-2)
POWER WINDOW MOTOR
grams. Before you proceed wi th thi s di agnosi s, con-
fi rm proper swi tch operati on. See the Door Modul e
and/or Power Wi ndow Swi tch di agnosi s i n thi s group.
(1) Remove the door tri m panel as descri bed i n
Door Modul e (front door) or Power Wi ndow Swi tch
(rear door) i n thi s group.
(2) Unpl ug the power wi ndow motor wi re harness
connector. Appl y 12 vol ts across the motor termi nal s
to check i ts operati on i n one di recti on. Reverse the
connecti ons across the motor termi nal s to check the
operati on i n the other di recti on. Remember, i f the
wi ndow i s i n the ful l up or ful l down posi ti on, the
motor wi l l not operate i n that di recti on by desi gn. I f
OK, repai r the ci rcui ts from the motor to the door
modul e or the swi tch as requi red. I f not OK, repl ace
the faul ty motor.
(3) I f the motor operates i n both di recti ons, check
the operati on of the wi ndow gl ass and l i ft mechani sm
through i ts compl ete up and down travel . There
shoul d be no bi ndi ng or sti cki ng of the wi ndow gl ass
or l i ft mechani sm through the enti re travel range. I f
not OK, refer to Group 23 - Body to check the wi n-
dow gl ass, tracks, and regul ator for sti cki ng, bi ndi ng,
or i mproper adjustment.
DOOR MODULE
cabl e.
panel retai ners.
door modul e.
vehi cl e.
OFF (NORMAL) 1&4
2&5
UP 1&6
2&5
DOWN 1&4
5&6
Fig. 3 Rear Door Power Window Switch Continuity
INSIDE DOOR LATCH AND LOCK REMOTE CONTROLS CONNECTOR 1 RECEPTA- CLE DOOR MODULE CONNECTOR 2 RECEP- TACLE SCREWS DOOR TRIM PANEL
8S - 4 POWER WINDOW SYSTEMS XJ
POWER WINDOW SWITCH
cabl e.
panel retai ners.
rear door power wi ndow swi tch.
(8) Remove the rear door tri m panel from the vehi -
cl e.
(9) Careful l y pry the snap retai ners at each si de of
the swi tch receptacl e i n the tri m panel and pul l the
swi tch out of the receptacl e (Fi g. 7).
POWER WINDOW MOTOR
FRONT DOOR
The front door power wi ndow motor and mecha-
ni sm i s i ntegral to the front door power wi ndow reg-
ul ator uni t. I f the front door power wi ndow motor or
mechani sm i s faul ty or damaged, the enti re power
wi ndow regul ator uni t must be repl aced. Refer to
Group 23 - Body for the front door wi ndow regul ator
REAR DOOR
The rear door power wi ndow motor and mechani sm
i s i ntegral to the rear door power wi ndow regul ator
uni t. I f the rear door power wi ndow motor or mech-
ani sm i s faul ty or damaged, the enti re power wi ndow
regul ator uni t must be repl aced. Refer to Group 23 -
Body for the rear door wi ndow regul ator servi ce
procedures.
Fig. 6 Rear Door Trim Panel Remove/Install
U-NUT REAR DOOR TRIM PANEL PUSH-IN FAS- TENER
Fig. 7 Rear Door Power Window Switch Remove/
Install
REAR DOOR POWER WINDOW SWITCH TRIM PANEL SWITCH RECEPTACLE
POWER MIRROR SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER MIRROR SWITCH . . . . . . . . . . . . . . . . 1
POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER MIRROR SYSTEM . . . . . . . . . . . . . . . . 2
DOOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . 4
POWER MIRROR SWITCH . . . . . . . . . . . . . . . . 2
POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
Power operated or power operated and heated out-
si de rear vi ew mi rrors are avai l abl e factory-i nstal l ed
opti ons on thi s model . Fol l owi ng are general descri p-
ti ons of the major components i n the power mi rror
system.
Refer to 8W-62 - Power Mi rrors i n Group 8W - Wi r-
i ng Di agrams for compl ete ci rcui t descri pti ons and
di agrams. Refer to the owners manual for more
i nformati on on the features and use of thi s system.
POWER MIRROR
The power mi rrors are connected to an i gni ti on-
swi tched battery feed so that the mi rrors wi l l onl y
operate wi th the i gni ti on swi tch i n the On posi ti on.
Each mi rror head contai ns two el ectri c motors, two
dri ve mechani sms, and the mi rror gl ass. One motor
and dri ve control s mi rror up-and-down movement,
and the other control s ri ght-and-l eft movement.
The power mi rrors i n vehi cl es equi pped wi th the
avai l abl e heated mi rror opti on al so i ncl ude an el ec-
tri c heati ng gri d l ocated behi nd the mi rror gl ass.
Thi s heati ng gri d i s energi zed by the rear wi ndow
defogger rel ay whenever the rear wi ndow defogger
system i s turned on. Refer to Group 8N - El ectri cal l y
Heated Systems for more i nformati on on the opera-
ti on of the rear wi ndow defogger system.
The power mi rror assembl y cannot be repai red.
Onl y the mi rror gl ass i s servi ced separatel y. I f any
other component of the power mi rror uni t i s faul ty or
damaged, the enti re assembl y must be repl aced.
POWER MIRROR SWITCH
Both the ri ght and l eft power outsi de mi rrors are
control l ed by a si ngl e mul ti -functi on swi tch uni t
l ocated on the dri ver si de front door tri m panel . Two
versi ons of thi s swi tch are offered. Model s wi thout
power wi ndows or power l ocks have a stand-al one
swi tch mounted i n the dri ver si de front door tri m
panel . Model s equi pped wi th power wi ndows and
power l ocks have a power mi rror swi tch that i s i nte-
gral to the Dri ver Door Modul e (DDM).
Both versi ons of the swi tch are operated i n the
same manner. A three posi ti on rocker-type mi rror
sel ector swi tch i s moved ri ght (ri ght mi rror control ),
l eft (l eft mi rror control ), or center to turn the power
mi rrors off. Then one of four di recti onal control but-
tons i s depressed to control movement of the sel ected
mi rror up, down, ri ght, or l eft. The di recti onal control
buttons of the DDM-mounted swi tch are i l l umi nated
when the i gni ti on swi tch i s i n the On posi ti on. The
stand-al one swi tch i s not i l l umi nated.
The stand-al one power mi rror swi tch cannot be
repai red and, i f faul ty or damaged, i t must be
repl aced as a compl ete uni t. The DDM power mi rror
swi tch requi res repl acement of the enti re DDM i f the
swi tch i s faul ty or damaged.
DOOR MODULE
modul e houses both the front door power l ock and
power wi ndow swi tches. The DDM al so houses i ndi -
vi dual swi tches for each passenger door power wi n-
dow, a power wi ndow l ockout swi tch, a power mi rror
XJ POWER MIRROR SYSTEMS 8T - 1
swi tch, and ci rcui try to support the one-touch down
feature of the dri ver si de front door power wi ndow.
The PDM al so houses the control ci rcui try and the
power l ock and unl ock rel ays for the power l ock sys-
tem.
POWER MIRROR SYSTEM
8W-62 - Power Mi rrors i n Group 8W - Wi ri ng Di a-
grams.
power mi rror swi tch di recti onal button i l l umi nati on
for the Dri ver Door Modul e (DDM)-type swi tch, pro-
ceed as fol l ows. I f not, go to Step 4. Check the power
wi ndow ci rcui t breaker i n the juncti on bl ock. I f OK,
go to Step 3. I f not OK, repl ace the faul ty ci rcui t
breaker.
(3) Check for battery vol tage at the fused i gni ti on
swi tch output ci rcui t cavi ty of the 12-way DDM wi re
harness connector wi th the i gni ti on swi tch i n the On
posi ti on. I f OK, repl ace the faul ty DDM. I f not OK,
repai r the open ci rcui t to the power wi ndow ci rcui t
breaker i n the juncti on bl ock as requi red.
(4) I f the probl em bei ng di agnosed i s an i nopera-
ti ve power mi rror el ectri c heati ng gri d, proceed as
fol l ows. I f not, go to Step 7. Di sconnect and i sol ate
the battery negati ve cabl e. Unpl ug the wi re harness
connector at the i noperati ve mi rror as descri bed i n
thi s group. Check for conti nui ty between the ground
ci rcui t cavi ty i n the body hal f of the power mi rror
wi re harness connector and a good ground. I f OK, go
to Step 5. I f not OK, repai r the open ci rcui t to ground
as requi red.
i gni ti on swi tch to the On posi ti on. Turn on the rear
wi ndow defogger system. Check for battery vol tage at
the rear wi ndow defogger rel ay output ci rcui t cavi ty
i n the body hal f of the power mi rror wi re harness
connector. I f OK, go to Step 6. I f not OK, repai r the
open ci rcui t to the rear wi ndow defogger rel ay as
requi red.
cui t and the rear wi ndow defogger rel ay output ci r-
cui t cavi ti es i n the mi rror hal f of the power mi rror
wi re harness connector. There shoul d be conti nui ty. I f
not OK, repl ace the faul ty power mi rror. I f OK, check
the resi stance through the el ectri c heati ng gri d ci r-
cui t. Correct resi stance through the el ectri c heati ng
gri d shoul d be from 10 to 16 ohms when measured at
an ambi ent temperature of 21C (70F). I f not OK,
repl ace the faul ty power mi rror.
cabl e. Remove the stand-al one power mi rror swi tch
or the DDM as descri bed i n thi s group. Unpl ug the
wi re harness connector from the stand-al one swi tch
or the 8-way wi re harness connector from the DDM.
Connect the battery negati ve cabl e. Turn the i gni ti on
swi tch to the On posi ti on. Check for battery vol tage
at the fused i gni ti on swi tch output ci rcui t cavi ty of
the stand-al one swi tch wi re harness connector or the
8-way DDM wi re harness connector. I f OK, go to Step
8. I f not OK, repai r the open ci rcui t to the juncti on
bl ock as requi red.
i ty of the stand-al one swi tch wi re harness connector
or the 8-way DDM wi re harness connector and a
good ground. There shoul d be conti nui ty. I f OK, go to
Step 9. I f not OK, repai r the ci rcui t to ground as
requi red.
(9) Check the stand-al one power mi rror swi tch or
DDM-mounted power mi rror swi tch conti nui ty as
shown i n (Fi g. 1) or (Fi g. 2). I f OK, go to Step 10. I f
not OK, repl ace the faul ty stand-al one power mi rror
swi tch or the faul ty DDM.
(10) Connect the battery negati ve cabl e. Use two
jumper wi res, one connected to a 12-vol t battery feed,
and the other connected to a good body ground. See
the Power Mi rror Test chart for the correct jumper
wi re connecti ons at the mi rror hal f of the power mi r-
ror wi re harness connector (Fi g. 3). I f the mi rror
reacti ons are OK, repai r the wi re harness between
the mi rror and the stand-al one power mi rror swi tch
or the DDM as requi red. I f the mi rror reacti ons are
not OK, repl ace the faul ty power outsi de mi rror
assembl y.
POWER MIRROR SWITCH
Thi s procedure covers removal of onl y the stand-
al one power mi rror swi tch. Vehi cl es wi th power wi n-
dows and power l ocks have the a power mi rror
swi tch i ntegral to the Dri ver Door Modul e (DDM).
See Door Modul e i n thi s group for the servi ce proce-
dures.
cabl e.
fl at-bl aded tool , gentl y pry the edge of the swi tch out
8T - 2 POWER MIRROR SYSTEMS XJ
of the tri m panel to rel ease the snap cl i p retai ners
(Fi g. 4).
(3) Pul l the power mi rror swi tch away from the
tri m panel far enough to access the wi re harness con-
nector.
(4) Unpl ug the power mi rror swi tch wi re harness
connector.
Fig. 1 Stand-Alone Power Mirror Switch Continuity
Fig. 2 Driver Door Module Power Mirror Switch
Continuity
Fig. 3 Power Mirror Test
Fig. 4 Stand-Alone Power Mirror Switch Remove/
Install
STAND-ALONE POWER MIR- ROR SWITCH CONNECTOR FWD DOOR TRIM PANEL
(5) Remove the power mi rror swi tch from the vehi -
cl e.
DOOR MODULE
cabl e.
panel retai ners.
door modul e.
vehi cl e.
POWER MIRROR
cabl e.
(2) I f the vehi cl e i s so equi pped, remove the man-
ual wi ndow regul ator crank handl e wi th a removal
tool (Fi g. 7).
panel to the i nner door panel (Fi g. 8) or (Fi g. 9).
panel retai ners.
i nsi de door remote control .
Fig. 7 Window Regulator Crank Handle Remove -
Typical
8T - 4 POWER MIRROR SYSTEMS XJ
the i nsi de door remote control .
door power swi tch modul e or, on the dri ver si de onl y,
the stand-al one power mi rror swi tch.
vehi cl e.
(10) Remove the one screw that secures the door
fl ag tri m to the i nner door panel (Fi g. 10).
fl at-bl aded tool , gentl y pry the door fl ag tri m away
from the i nner door to rel ease the tri m panel
retai ner.
(12) Unpl ug the power mi rror wi re harness con-
nector.
power mi rror to the i nner door panel (Fi g. 11).
(14) Unseat the power mi rror wi re harness grom-
met by pushi ng i t out through the hol e i n the door
fl ag from the i nsi de.
(15) Pul l the mi rror and seal from the outsi de of
the door whi l e feedi ng the wi re harness, grommet,
and connector out through the hol e from the i nsi de of
the door.
Ti ghten the mi rror mounti ng screws to 4.3 Nm (38
i n. l bs.).
Fig. 8 Front Door Trim Panel Remove/Install -
Manual Window
U-NUT DOORTRIM PANEL WINDOWCRANK SPACER PUSH-IN FAS- TENER
Fig. 9 Front Door Trim Panel Remove/Install - Power
Window
Fig. 10 Front Door Flag Trim Panel Remove/Install
FRONT DOOR DOOR FLAG TRIM PANEL RETAINER SCREW UPPER SPEAKER WIRE HARNESS
Fig. 11 Power Mirror Remove/Install
SIDE VIEW MIRROR WIRE HAR- NESS SEALGROMMET DOOR
CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
DRIVER DOOR JAMB SWITCH . . . . . . . . . . . . . 2
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . 2
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . 2
DRIVER DOOR JAMB SWITCH . . . . . . . . . . . . . 2
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . . . 2
HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 3
KEY-IN IGNITION SWITCH . . . . . . . . . . . . . . . . . 3
CHIME WARNING SYSTEM SWITCHES . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
Thi s group covers the chi me warni ng system,
whi ch i s standard factory-i nstal l ed equi pment on thi s
model . The chi me warni ng system provi des an audi -
bl e warni ng to the dri ver under the fol l owi ng condi -
ti ons:
Dri ver si de seat bel t i s not fastened wi th the
i gni ti on swi tch i n the On posi ti on
Engi ne cool ant temperature i s hi gh
Head or park l amps are turned on wi th the i gni -
ti on swi tch Off and the dri ver si de front door open
Key i s i n the i gni ti on swi tch wi th the i gni ti on
swi tch Off and the dri ver si de front door open
Low fuel warni ng l amp i l l umi nati on - l ess than
about one-ei ghth tank of fuel remai ni ng
Overhead consol e tri p computer i s reset.
components i n the chi me warni ng system. Refer to
8W-40 I nstrument Cl uster or 8W-44 - I nteri or Li ght-
i ng i n Group 8W - Wi ri ng Di agrams for compl ete ci r-
cui t descri pti ons and di agrams.
INSTRUMENT CLUSTER
The i nstrument cl uster i s an el ectromechani cal
uni t that contai ns i ntegrated ci rcui try and i nternal
programmi ng to perform a vari ety of functi ons. The
i nstrument cl uster ci rcui try moni tors hard-wi red
swi tch i nputs, as wel l as message i nputs recei ved
from other vehi cl e el ectroni c modul es on the Chrysl er
Col l i si on Detecti on (CCD) data bus network.
The i nstrument cl uster uses these many i nputs
al ong wi th i ts i nternal programmi ng and an i ntegral
chi me tone generator to perform the functi ons of the
chi me warni ng modul e on thi s model . The i nstru-
ment cl uster ci rcui try al so has a sel f-di agnosti c capa-
bi l i ty. Refer to Group 8E - I nstrument Panel Systems
for more i nformati on on thi s feature.
Hard-wi red chi me warni ng system i nputs to the
i nstrument cl uster i ncl ude the fol l owi ng:
Dri ver door jamb swi tch
Dri ver seat bel t swi tch
Headl amp swi tch
Key-i n i gni ti on swi tch.
The onl y i nstrument cl uster di agnosi s found i n thi s
group consi sts of confi rmi ng the vi abi l i ty of the hard-
wi red chi me request i nputs to the i nstrument cl uster
ci rcui try. For di agnosi s of the CCD data bus and the
data bus message i nputs, a DRB scan tool and the
proper Di agnosti c Procedures manual are recom-
mended.
Refer to Group 8E - I nstrument Panel Systems for
the servi ce procedures for the i nstrument cl uster.
The i nstrument cl uster chi me warni ng ci rcui try and
chi me tone generator cannot be repai red and, i f
faul ty, the i nstrument cl uster assembl y must be
repl aced.
XJ CHIME/BUZZER WARNING SYSTEMS 8U - 1
DRIVER DOOR JAMB SWITCH
The dri ver door jamb swi tch i s mounted to the
dri ver si de front door hi nge pi l l ar. The swi tch cl oses
a path to ground for the i nstrument cl uster chi me
warni ng ci rcui try through the key-i n i gni ti on swi tch
and/or the headl amp swi tch when the dri ver door i s
opened, and opens the ground path when the dri ver
door i s cl osed.
The dri ver door jamb swi tch cannot be repai red
and, i f faul ty or damaged, i t must be repl aced. Refer
to Group 8L - Lamps for the servi ce procedures.
DRIVER SEAT BELT SWITCH
The dri ver seat bel t swi tch i s i ntegral to the dri ver
seat bel t buckl e-hal f assembl y. The swi tch i s nor-
mal l y cl osed, provi di ng a ground path to the i nstru-
ment panel chi me warni ng ci rcui try. When the ti p-
hal f of the seat bel t i s i nserted i nto the seat bel t
buckl e, the swi tch opens the ground path.
The dri ver seat bel t swi tch cannot be repai red and,
i f faul ty or damaged, the enti re dri ver seat bel t buck-
l e-hal f uni t must be repl aced. Refer to Group 23 -
Body for the servi ce procedures.
KEY-IN IGNITION SWITCH
The key-i n i gni ti on swi tch i s i ntegral to the i gni -
ti on swi tch, whi ch i s mounted on the l eft si de of the
steeri ng col umn, opposi te the i gni ti on l ock cyl i nder.
I t cl oses a path to ground for the i nstrument cl uster
chi me warni ng ci rcui try when the i gni ti on key i s
i nserted i n the i gni ti on l ock cyl i nder and the dri ver
door jamb swi tch i s cl osed (dri ver door i s open). The
key-i n i gni ti on swi tch opens the ground path when
the key i s removed from the i gni ti on l ock cyl i nder.
The key-i n i gni ti on swi tch cannot be repai red and,
i f faul ty or damaged, the enti re i gni ti on swi tch must
be repl aced. Refer to Group 8D - I gni ti on Systems for
the servi ce procedures.
HEADLAMP SWITCH
The headl amp swi tch i s l ocated i n the i nstrument
panel , outboard of the steeri ng col umn. I t cl oses a
path to ground for the i nstrument cl uster chi me
warni ng ci rcui try when the park or head l amps are
on and the dri ver door jamb swi tch i s cl osed (dri ver
door i s open). The headl amp swi tch opens the ground
path when the headl amp swi tch i s turned off.
The headl amp swi tch cannot be repai red and, i f
faul ty or damaged, i t must be repl aced. Refer to
Group 8E - I nstrument Panel Systems for the servi ce
procedures.
DRIVER DOOR JAMB SWITCH
8W-40 - I nstrument Cl uster or 8W-44 - I nteri or
Li ghti ng i n Group 8W - Wi ri ng Di agrams.
INJURY.
(1) Rotate the headl amp swi tch knob countercl ock-
wi se to ensure that the dome l amps are not swi tched
off. Open the dri ver door and note whether the i nte-
ri or l amps l i ght. They shoul d l i ght. I f OK, see the
di agnosi s for the Key-I n I gni ti on Swi tch or the Head-
l amp Swi tch i n thi s group. I f not OK, go to Step 2.
cabl e. Unpl ug the dri ver door jamb swi tch from i ts
wi re harness connector. Check for conti nui ty between
the ground ci rcui t cavi ty of the dri ver door jamb
swi tch wi re harness connector and a good ground.
There shoul d be conti nui ty. I f OK, go to Step 3. I f not
OK, repai r the ci rcui t to ground as requi red.
(3) Check for conti nui ty between the door jamb
swi tch ground ci rcui t termi nal and the l eft front door
jamb swi tch sense termi nal of the door jamb swi tch.
There shoul d be conti nui ty wi th the swi tch pl unger
rel eased, and no conti nui ty wi th the swi tch pl unger
depressed. I f not OK, repl ace the faul ty swi tch.
DRIVER SEAT BELT SWITCH
INJURY.
8U - 2 CHIME/BUZZER WARNING SYSTEMS XJ
cabl e. Unpl ug the dri ver seat bel t swi tch wi re har-
ness connector on the fl oor under the dri ver seat
near the seat bel t buckl e-hal f anchor. Check for con-
ti nui ty between the seat bel t swi tch sense ci rcui t and
the ground ci rcui t cavi ti es of the seat bel t hal f of the
dri ver seat bel t swi tch wi re harness connector. There
shoul d be conti nui ty wi th the seat bel t unbuckl ed,
and no conti nui ty wi th the seat bel t buckl ed. I f OK,
go to Step 2. I f not OK, repl ace the faul ty seat bel t
buckl e-hal f assembl y.
cui t cavi ty i n the body hal f of the dri ver seat bel t
There shoul d be conti nui ty. I f OK, see the I nstru-
ment Cl uster di agnosi s i n thi s group. I f not OK,
repai r the ci rcui t to ground as requi red.
KEY-IN IGNITION SWITCH
INJURY.
cabl e. Remove the steeri ng col umn shrouds. Refer to
Group 8D - I gni ti on Systems for the procedures.
Unpl ug the key-i n i gni ti on swi tch wi re harness con-
nector from the i gni ti on swi tch.
(2) Check for conti nui ty between the key-i n swi tch
sense ci rcui t and the l eft front door jamb swi tch
sense ci rcui t termi nal s of the key-i n i gni ti on swi tch.
There shoul d be conti nui ty wi th the key i n the i gni -
ti on l ock cyl i nder, and no conti nui ty wi th the key
removed from the i gni ti on l ock cyl i nder. I f OK, go to
Step 3. I f not OK, repl ace the faul ty i gni ti on swi tch
assembl y.
(3) Check for conti nui ty between the l eft front door
jamb swi tch sense ci rcui t cavi ty of the key-i n i gni ti on
There shoul d be conti nui ty wi th the dri ver door open,
and no conti nui ty wi th the dri ver door cl osed. I f OK,
see the di agnosi s for I nstrument Cl uster i n thi s
group. I f not OK, repai r the ci rcui t to the dri ver door
jamb swi tch as requi red.
HEADLAMP SWITCH
INJURY.
cabl e. Remove the headl amp swi tch from the i nstru-
ment panel . Refer to Group 8E - I nstrument Panel
Systems for the procedures. Unpl ug the headl amp
swi tch wi re harness connectors. Check for conti nui ty
between the l eft front door jamb swi tch sense ci rcui t
cavi ty of the headl amp swi tch wi re harness connector
and a good ground. There shoul d be conti nui ty wi th
the dri ver door cl osed, and no conti nui ty wi th the
dri ver door open. I f OK, go to Step 2. I f not OK,
repai r the ci rcui t to the dri ver door jamb swi tch as
requi red.
sense ci rcui t termi nal and the l eft front door jamb
swi tch sense termi nal of the headl amp swi tch. There
shoul d be no conti nui ty wi th the swi tch i n the Off
posi ti on, and conti nui ty wi th the swi tch i n the park
or head l amps On posi ti on. I f OK, see the di agnosi s
for the I nstrument Cl uster i n thi s group. I f not OK,
repl ace the faul ty headl amp swi tch.
INSTRUMENT CLUSTER
Before performi ng thi s test, compl ete the testi ng of
the hard-wi red chi me warni ng system swi tches as
descri bed i n thi s group. For ci rcui t descri pti ons and
di agrams, refer to 8W-40 - I nstrument Cl uster or
8W-44 - I nteri or Li ghti ng i n Group 8W - Wi ri ng Di a-
grams.
INJURY.
cabl e. Remove the i nstrument cl uster from the
XJ CHIME/BUZZER WARNING SYSTEMS 8U - 3
i nstrument panel . Refer to Group 8E - I nstrument
Panel Systems for the procedures.
(2) Unpl ug the headl amp swi tch and the key-i n
i gni ti on swi tch wi re harness connectors. Check for
conti nui ty between the key-i n swi tch sense ci rcui t
cavi ty of the ri ght i nstrument cl uster wi re harness
connector (connector B) and a good ground. There
shoul d be no conti nui ty. I f OK, go to Step 3. I f not
OK, repai r the short ci rcui t as requi red.
sense ci rcui t cavi ti es of the ri ght i nstrument cl uster
wi re harness connector (connector B) and the head-
l amp swi tch wi re harness connector. There shoul d be
(4) Unpl ug the dri ver seat bel t swi tch wi re har-
ness connector. Check for conti nui ty between the seat
bel t swi tch sense ci rcui t cavi ty of the ri ght i nstru-
ment cl uster wi re harness connector (connector B)
and a good ground. There shoul d be no conti nui ty. I f
OK, go to Step 5. I f not OK, repai r the short ci rcui t
as requi red.
(5) Check for conti nui ty between the seat bel t
swi tch sense ci rcui t cavi ti es of the ri ght i nstrument
cl uster wi re harness connector (connector B) and the
dri ver seat bel t swi tch wi re harness connector. There
shoul d be conti nui ty. I f OK, test the i nstrument cl us-
ter as descri bed i n Group 8E - I nstrument Panel Sys-
tems. I f not OK, repai r the open ci rcui t as requi red.
CHIME WARNING SYSTEM SWITCHES
Servi ce procedures for the vari ous hard-wi red
swi tches used i n the chi me warni ng system can be
found i n the proper group as fol l ows:
Dri ver door jamb swi tch - refer to Group 8L -
Lamps
Dri ver seat bel t swi tch - refer to Group 23 -
Body
Headl amp swi tch - refer to Group 8E - I nstru-
ment Panel Systems
Key-i n i gni ti on swi tch - refer to Group 8D - I gni -
ti on Systems.
8U - 4 CHIME/BUZZER WARNING SYSTEMS XJ
OVERHEAD CONSOLE SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . 1
COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GARAGE DOOR OPENER STORAGE BIN . . . . . 2
READING AND COURTESY LAMP . . . . . . . . . . . 2
SUNGLASSES STORAGE BIN . . . . . . . . . . . . . . 3
THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . 2
TRIP COMPUTER . . . . . . . . . . . . . . . . . . . . . . . 1
THERMOMETER . . . . . . . . . . . . . . . . . . . . . . . . 4
TRIP COMPUTER, COMPASS, AND
THERMOMETER DISPLAY MODULE . . . . . . . 3
SERVICE PROCEDURES
COMPASS CALIBRATION . . . . . . . . . . . . . . . . . 5
COMPASS DEMAGNETIZING . . . . . . . . . . . . . . 5
COMPASS VARIATION ADJUSTMENT . . . . . . . . 4
AMBIENT TEMPERATURE SENSOR . . . . . . . . . 8
GARAGE DOOR OPENER STORAGE BIN
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . 6
PUSH BUTTON MODULE . . . . . . . . . . . . . . . . . 7
READING AND COURTESY LAMP BULB . . . . . . 7
SUNGLASSES STORAGE BIN . . . . . . . . . . . . . . 8
THERMOMETER DISPLAY MODULE . . . . . . . 7
GENERAL INFORMATION
INTRODUCTION
An overhead consol e featuri ng a mi ni tri p com-
puter, an el ectroni c compass, and an outsi de ambi ent
temperature thermometer are avai l abl e factory-i n-
stal l ed opti ons on thi s model . The overhead consol e
al so i ncl udes two front-mounted and two rear-
mounted readi ng and courtesy l amps, a garage door
opener storage bi n, and a sungl asses storage bi n.
On model s equi pped wi th the Remote Keyl ess
Entry (RKE) opti on, the overhead consol e al so houses
the RKE recei ver. Refer to Group 8P - Power Lock
Systems for more i nformati on on thi s feature.
components used i n the overhead consol e. Refer to
8W-49 - Overhead Consol e i n Group 8W - Wi ri ng
Di agrams for compl ete ci rcui t descri pti ons and di a-
grams.
have been clearly identified as
TRIP COMPUTER
A mi ni tri p computer i s avai l abl e on thi s model to
provi de several el ectroni c functi ons and features. The
tri p computer contai ns a central processi ng uni t and
i nterfaces wi th other modul es i n the vehi cl e on the
The CCD data bus network al l ows the shari ng of
sensor i nformati on. Thi s hel ps to reduce wi re har-
ness compl exi ty, reduce i nternal control l er hardware,
and reduce component sensor current l oads. At the
same ti me, thi s system provi des i ncreased rel i abi l i ty,
enhanced di agnosti cs, and al l ows the addi ti on of
many new feature capabi l i ti es.
Some of the functi ons and features that the tri p
computer supports and/or control s, i ncl ude the fol -
l owi ng di spl ay opti ons:
Compass and temperature
Tri p odometer (ODO)
Average fuel economy (AVG ECO)
I nstant fuel economy (ECO)
Di stance to empty (DTE)
El apsed ti me (ET)
Bl ank di spl ay.
Momentari l y depressi ng and rel easi ng the Step
button when the i gni ti on swi tch i s i n the On posi ti on
wi l l cause the overhead consol e di spl ay to step
sequenti al l y through the l i sted di spl ay opti ons.
Momentari l y depressi ng and rel easi ng the U.S./Met-
ri c button toggl es the di spl ay between U.S. and Met-
ri c measurements. For more i nformati on on the tri p
XJ OVERHEAD CONSOLE SYSTEMS 8V - 1
computer features and functi ons, refer to the owners
manual i n the vehi cl e gl ove box.
The push button (Step and U.S./Metri c) swi tch
modul e i n the overhead consol e i s hard-wi red to the
tri p computer. The compass fl ux-gate uni t i s i ntegral
to the tri p computer, compass, and thermometer di s-
pl ay modul e uni t. Data i nput for al l other tri p com-
puter functi ons i s recei ved through CCD data bus
messages. The tri p computer uses i ts i nternal pro-
grammi ng and al l of these i nputs to cal cul ate and
di spl ay the requested data. I f the data di spl ayed i s
i ncorrect, perform the sel f-di agnosti c tests as
descri bed i n thi s group. I f these tests prove i nconcl u-
si ve, the use of a DRB scan tool and the proper Di ag-
nosti c Procedures manual are recommended for
further testi ng of the tri p computer and the CCD
data bus.
The tri p computer, compass, and thermometer di s-
pl ay modul e cannot be repai red, and are onl y avai l -
abl e for servi ce as a uni t. I f faul ty, the compl ete
modul e must be repl aced. The push button (Step and
U.S./Metri c) swi tch modul e i s servi ced separatel y.
COMPASS
The compass wi l l di spl ay the di recti on i n whi ch the
vehi cl e i s poi nted usi ng the ei ght major compass
headi ngs (Exampl es: north i s N, northeast i s NE). I t
does not di spl ay the headi ngs i n actual degrees.
The sel f-cal i brati ng compass uni t requi res no
adjusti ng i n normal use. The onl y cal i brati on that
may prove necessary i s to dri ve the vehi cl e i n three
compl ete ci rcl es, on l evel ground, i n not l ess than 48
seconds. Thi s wi l l reori ent the compass uni t to i ts
vehi cl e.
The compass uni t al so wi l l compensate for magne-
ti sm the body of the vehi cl e may acqui re duri ng nor-
mal use. However, avoi d pl aci ng anythi ng magneti c
di rectl y on the roof of the vehi cl e. Magneti c mounts
for an antenna, a repai r order hat, or a funeral pro-
cessi on fl ag can exceed the compensati ng abi l i ty of
the compass uni t i f pl aced on the roof panel . Mag-
neti c bi t dri vers used on the fasteners that hol d the
assembl y to the roof header can al so affect compass
operati on. I f the vehi cl e roof shoul d become magne-
ti zed, the demagneti zi ng and cal i brati on procedures
found i n thi s group may be requi red to restore proper
compass operati on.
The compass, tri p computer, and thermometer di s-
abl e for servi ce as a uni t. I f faul ty, the compl ete
modul e must be repl aced. The push button (Step and
U.S./Metri c) swi tch modul e i s servi ced separatel y.
THERMOMETER
The thermometer di spl ays the outsi de ambi ent
temperature. The temperature di spl ay can be
changed from Fahrenhei t to Cel si us usi ng the U.S./
Metri c button, l ocated just rearward of the di spl ay
modul e. The di spl ayed temperature i s not an i nstant
readi ng of condi ti ons, but an average temperature. I t
may take the thermometer di spl ay several mi nutes
to respond to a major temperature change, such as
dri vi ng out of a heated garage i nto wi nter tempera-
tures.
When the i gni ti on swi tch i s turned to the Off posi -
ti on, the l ast di spl ayed temperature readi ng stays i n
the thermometer uni t memory. When the i gni ti on
swi tch i s turned to the On posi ti on agai n, the ther-
mometer wi l l di spl ay the memory temperature i f the
engi ne cool ant temperature i s above about 52 C
(125 F). I f the engi ne cool ant temperature i s bel ow
about 52 C (125 F), the thermometer wi l l di spl ay
the actual temperature sensed by the ambi ent tem-
perature sensor. The thermometer temperature di s-
pl ay update i nterval vari es wi th the vehi cl e speed.
The thermometer functi on i s supported by an
ambi ent temperature sensor. The sensor i s mounted
outsi de the passenger compartment near the front
and center of the vehi cl e and i s hard-wi red to the
modul e. The ambi ent temperature sensor i s avai l abl e
as a separate servi ce i tem.
The thermometer, compass, and tri p computer di s-
abl e for servi ce as a uni t. I f faul ty or damaged, the
compl ete modul e must be repl aced. The push button
(Step and U.S./Metri c) swi tch modul e and ambi ent
temperature sensor are servi ced separatel y.
READING AND COURTESY LAMP
Al l readi ng and courtesy l amps l ocated i n the over-
head consol e are acti vated by the door ajar swi tches.
When the doors are cl osed, the l amps can be i ndi vi d-
ual l y acti vated by depressi ng the correspondi ng l ens.
When a door i s open, depressi ng the l amp l ens
swi tches wi l l not turn the l amps off. Refer to Group
8L - Lamps, for di agnosi s of the readi ng and courtesy
l amps.
The readi ng and courtesy l amp l ens, and bul bs are
avai l abl e for servi ce repl acement. The readi ng and
courtesy l amp hol ders and swi tches are onl y avai l -
abl e as part of the overhead consol e wi re harness. I f
any readi ng l amp swi tch i s faul ty or damaged, the
wi re harness and al l four swi tches must be repl aced.
GARAGE DOOR OPENER STORAGE BIN
A compartment i n the overhead consol e i s desi gned
to hol d most garage door opener remote control
transmi tters. The transmi tter i s mounted wi thi n the
compartment wi th an adhesi ve-backed hook and l oop
fastener patch.
Wi th the transmi tter mounted i n the storage bi n,
adapter pegs l ocated on the front of the storage bi n
8V - 2 OVERHEAD CONSOLE SYSTEMS XJ
door are sel ected and mounted on a post near the
center of the storage bi n door. The peg(s) sel ected
and/or the post must be l ong enough to depress the
button of the transmi tter when the garage door
opener storage bi n door i s depressed. The pegs may
be stacked, i f necessary. Refer to the owners manual
i n the vehi cl e gl ove box for more i nformati on.
A transmi tter mounti ng ki t i ncl udi ng the adhesi ve-
backed hook and l oop fastener materi al and a sel ec-
ti on of pegs i s avai l abl e for servi ce. The garage door
opener storage bi n door assembl y i s al so avai l abl e for
servi ce repl acement.
SUNGLASSES STORAGE BIN
A sungl asses storage bi n i s i ncl uded i n the over-
head consol e. The i nteri or of the bi n i s l i ned wi th a
foam rubber paddi ng materi al to protect the sun-
gl asses from bei ng scratched. Thi s bi n features a
push/push-type l atchi ng mechani sm, and a vi scous
dampeni ng system for a fl ui d openi ng acti on.
The sungl asses storage bi n door, l atch, vi scous
damper, hi nge spri ng and housi ng are avai l abl e for
servi ce onl y as a compl ete modul e. I f any part of thi s
uni t i s faul ty or damaged, the enti re modul e must be
repl aced.
THERMOMETER DISPLAY MODULE
I f the probl em wi th the tri p computer, compass,
and thermometer di spl ay modul e i s an i naccurate or
scrambl ed di spl ay, use the Sel f-Di agnosti c Test proce-
dures. I f the probl em i s i ncorrect di spl ay l i ghti ng l ev-
el s, use a DRB scan tool and the proper Di agnosti c
Procedures manual to test for the correct di mmi ng
message i nputs bei ng recei ved from the i nstrument
cl uster over the Chrysl er Col l i si on Detecti on (CCD)
data bus. I f the probl em i s a no-di spl ay condi ti on,
use the fol l owi ng procedures. For ci rcui t descri pti ons
and di agrams, refer to 8W-49 - Overhead Consol e i n
(1) Check the fuses i n the juncti on bl ock and the
as requi red and repl ace the faul ty fuse(s).
output fuse i n the juncti on bl ock. I f OK, go to Step 3.
I f not OK, repai r the open ci rcui t to the i gni ti on
swi tch as requi red.
Remove the overhead consol e as descri bed i n thi s
group. Check for conti nui ty between the ground ci r-
cui t cavi ti es of the overhead consol e wi re harness
nui ty. I f OK, go to Step 4. I f not OK, repai r the open
battery vol tage at the fused B(+) ci rcui t cavi ty of the
overhead consol e wi re harness connector. I f OK, go to
Step 5. I f not OK, repai r the open ci rcui t to the junc-
ti on bl ock as requi red.
output ci rcui t cavi ty of the overhead consol e wi re
harness connector. I f OK, proceed to the Sel f-Di ag-
nosti c Test i n thi s group for further di agnosi s of the
modul e and the CCD data bus. I f not OK, repai r the
open ci rcui t to the juncti on bl ock as requi red.
SELF-DIAGNOSTIC TEST
A sel f-di agnosti c test i s used to determi ne that the
tri p computer, compass, thermometer, and al l of the
di spl ay modul e segments are operati ng properl y el ec-
tri cal l y. I ni ti ate the sel f-di agnosti c test as fol l ows:
(1) Wi th the i gni ti on swi tch i n the Off posi ti on,
si mul taneousl y press and hol d the Step button and
the U.S./Metri c button.
(3) Conti nue to hol d both buttons unti l the di spl ay
modul e performs a di spl ay segment test. I n thi s test,
al l of the vacuum fl uorescent di spl ay segments are
l i ghted. Thi s test wi l l :
a. Veri fy that al l di spl ay segments are functi onal
b. Check the i nternal ci rcui try of the modul e
c. Check that al l of the CCD data bus messages
needed are bei ng recei ved.
(4) Respond to the respecti ve test resul ts as fol -
l ows. I f al l tests are passed, the modul e wi l l automat-
i cal l y return to normal operati on.
d. I n the di spl ay segment test, i f any segment
shoul d fai l to l i ght the uni t i s faul ty and must be
repl aced.
e. I f the i nternal ci rcui try test i s fai l ed, the modul e
wi l l di spl ay FAI L. I f FAI L i s di spl ayed, the uni t i s
faul ty and must be repl aced.
f. I f the CCD data bus message test i s fai l ed, the
modul e wi l l di spl ay CCD. I f CCD i s di spl ayed, the
use of a DRB scan tool and the proper Di agnosti c
Procedures manual are requi red for further di agno-
si s.
(5) Momentari l y depress and rel ease ei ther button
one ti me to exi t the sel f-di agnosti c test mode and
return the tri p computer, compass, and thermometer
di spl ay modul e to normal operati on.
NOTE: If the compass functions, but accuracy is
suspect, it may be necessary to perform a variation
adjustment. This procedure allows the compass
unit to accommodate variations in the earths mag-
netic field strength, based on geographic location.
See the Compass Variation Adjustment procedures,
in this group.
NOTE: If the compass reading has blanked out, and
only CAL appears in the display module, demag-
netizing may be necessary to remove excessive
residual magnetic fields from the vehicle. See the
Compass Demagnetizing procedure, in this group.
THERMOMETER
The thermometer functi on i s supported by a ambi -
ent temperature sensor, a wi ri ng ci rcui t, and a por-
ti on of the overhead consol e tri p computer, compass,
and thermometer di spl ay modul e di spl ay. The sensor
i s mounted outsi de the passenger compartment near
the front and center of the vehi cl e.
I f any porti on of the ambi ent temperature sensor
ci rcui t fai l s, the thermometer di spl ay wi l l sel f-di ag-
nose the ci rcui t. An SC (short ci rcui t) wi l l appear i n
the di spl ay i n pl ace of the temperature, when the
sensor i s exposed to temperatures above 55 C (131
F), or i f the sensor ci rcui t i s shorted. An OC (open
ci rcui t) wi l l appear i n the di spl ay i n pl ace of the tem-
perature, when the sensor i s exposed to temperatures
bel ow -40 C (-40 F), or i f the sensor ci rcui t i s open.
The ambi ent temperature sensor ci rcui t can al so be
di agnosed usi ng the fol l owi ng Sensor Test, and Sen-
sor Ci rcui t Test. I f the temperature sensor and ci r-
cui t are confi rmed to be OK, but the temperature
di spl ay i s i noperati ve or i ncorrect, see the Tri p Com-
puter, Compass, and Thermometer Di spl ay Modul e
di agnosi s i n thi s group. For ci rcui t descri pti ons and
di agrams, refer to 8W-49 - Overhead Consol e i n
SENSOR TEST
Unpl ug the temperature sensor wi re harness connec-
tor.
(2) Measure the resi stance of the temperature sen-
sor. At -40 C (-40 F), the sensor resi stance i s 336
ki l ohms. At 55 C (131 F), the sensor resi stance i s
2.986 ki l ohms. The sensor resi stance shoul d read
between these two val ues. I f OK, go to the Sensor
Ci rcui t Test. I f not OK, repl ace the faul ty sensor.
SENSOR CIRCUIT TEST
Unpl ug the ambi ent temperature sensor wi re har-
ness connector and the overhead consol e wi re har-
ness connector.
(2) Connect a jumper wi re between the two termi -
nal s i n the body hal f of the sensor wi re harness con-
nector.
(3) Check for conti nui ty between the sensor return
ci rcui t and the ambi ent temperature sensor si gnal
ci rcui t cavi ti es of the overhead consol e wi re harness
connector. There shoul d be conti nui ty. I f OK, go to
Step 4. I f not OK, repai r the open ci rcui t as requi red.
(4) Remove the jumper wi re from the ambi ent tem-
perature sensor wi re harness connector. Check for
conti nui ty between the sensor return ci rcui t cavi ty of
the overhead consol e wi re harness connector and a
requi red.
(5) Check for conti nui ty between the ambi ent tem-
perature sensor si gnal ci rcui t cavi ty of the overhead
consol e wi re harness connector and a good ground.
There shoul d be no conti nui ty. I f OK, see the Tri p
Computer, Compass, and Thermometer Di spl ay Mod-
ul e di agnosi s i n thi s group. I f not OK, repai r the
short ci rcui t as requi red.
SERVICE PROCEDURES
COMPASS VARIATION ADJUSTMENT
Vari ance i s the di fference between magneti c north
and geographi c north. I n some geographi c l ocati ons,
the di fference between magneti c and geographi c
north i s great enough to cause the compass to gi ve
fal se readi ngs. I f thi s probl em occurs, the compass
vari ance must be set.
To set the compass vari ance:
(1) Usi ng the Vari ance Setti ngs map, fi nd your
geographi c l ocati on and note the zone number (Fi g.
1).
(2) Turn the i gni ti on swi tch to the On posi ti on. I f
the compass/temperature data i s not currentl y bei ng
di spl ayed, momentari l y depress and rel ease the Step
button to step through the di spl ay opti ons unti l you
have reached the compass/temperature di spl ay.
(3) Depress both the U.S./Metri c, and the Step but-
tons. Hol d the buttons down unti l VAR appears i n
the di spl ay. Thi s takes about fi ve seconds.
(4) Rel ease both of the buttons. The current vari -
ance zone number setti ng wi l l appear i n the di spl ay.
(5) Press and rel ease the U.S./Metri c button to
step through the zone numbers, unti l the zone num-
ber for your geographi c l ocati on appears i n the di s-
pl ay.
(6) Press the Step button to enter thi s zone num-
ber i nto the compass uni t memory.
(7) Confi rm that the correct di recti ons are now
i ndi cated by the compass.
COMPASS CALIBRATION
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of
the compass. Do not use magnetic tools when ser-
vicing the overhead console.
The el ectroni c compass uni t features a sel f-cal i -
brati ng desi gn, whi ch si mpl i fi es the cal i brati on pro-
cedure. Thi s feature automati cal l y updates the
compass cal i brati on whi l e the vehi cl e i s bei ng dri ven.
Thi s al l ows the compass uni t to compensate for smal l
changes i n the resi dual magneti sm that the vehi cl e
may acqui re duri ng normal use. Do not attempt to
cal i brate the compass near l arge metal objects such
as other vehi cl es, l arge bui l di ngs, or bri dges.
NOTE: Whenever the compass is calibrated manu-
ally, the variation number must also be reset. See
the Compass Variation Adjustment procedure, in
this group.
Cal i brate the compass manual l y as fol l ows:
(1) Start the engi ne. I f the compass/temperature
data i s not currentl y bei ng di spl ayed, momentari l y
depress and rel ease the Step button to step through
the di spl ay opti ons unti l you have reached the com-
pass/temperature di spl ay.
(2) Depress both the U.S./Metri c, and the Step but-
tons. Hol d the buttons down unti l CAL appears i n
the di spl ay. Thi s takes about ten seconds, and
appears about fi ve seconds after VAR i s di spl ayed.
(3) Rel ease both of the buttons.
(4) Dri ve the vehi cl e on a l evel surface, away from
l arge metal objects, through three or more compl ete
ci rcl es i n not l ess than 48 seconds. The CAL mes-
sage wi l l di sappear from the di spl ay to i ndi cate that
the compass i s now cal i brated.
NOTE: If the CAL message remains in the dis-
play, either there is excessive magnetism near the
compass, or the unit is faulty. Repeat the demagne-
tizing and calibration procedures at least one more
time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
COMPASS DEMAGNETIZING
A degaussi ng tool (Speci al Tool 6029) i s used to
demagneti ze, or degauss, the overhead consol e for-
ward mounti ng screw(s) and the roof panel . Equi va-
l ent uni ts must be rated as conti nuous duty for 110/
115 vol ts and 60 Hz. They must al so have a fi el d
Fig. 1 Variance Settings
strength of over 350 gauss at 7 mi l l i meters (0.25
i nch) beyond the ti p of the probe.
To demagneti ze the roof panel and the overhead
consol e forward mounti ng screw(s), proceed as fol -
l ows:
(1) Be certai n the i gni ti on swi tch i s i n the Off posi -
ti on, before you begi n the demagneti zi ng procedure.
(2) Pl ug i n the degaussi ng tool , whi l e keepi ng the
tool at l east 61 centi meters (2 feet) away from the
compass uni t.
(3) Sl owl y approach the head of the overhead con-
sol e forward mounti ng screw wi th the degaussi ng
tool pl ugged i n.
(4) Contact the head of each screw wi th the pl asti c
coated ti p of the degaussi ng tool for about two sec-
onds.
(5) Wi th the degaussi ng tool sti l l energi zed, sl owl y
back i t away from the screw. When the ti p of the tool
i s at l east 61 centi meters (2 feet) from the screw
head, unpl ug the tool .
(6) Pl ace a pi ece of paper approxi matel y 22 by 28
centi meters (8.5 by 11 i nches), ori ented on the vehi cl e
l engthwi se from front to rear, on the center l i ne of
the roof at the wi ndshi el d header (Fi g. 2). The pur-
pose of the paper i s to protect the roof panel from
scratches, and to defi ne the area to be demagneti zed.
(7) Pl ug i n the degaussi ng tool , whi l e keepi ng the
tool at l east 61 centi meters (2 feet) away from the
compass uni t.
(8) Sl owl y approach the center l i ne of the roof
panel at the wi ndshi el d header, wi th the degaussi ng
tool pl ugged i n.
(9) Contact the roof panel wi th the pl asti c coated
ti p of the degaussi ng tool . Be sure the templ ate i s i n
pl ace to avoi d scratchi ng the roof panel . Usi ng a
sl ow, back-and-forth sweepi ng moti on, and al l owi ng
13 mi l l i meters (0.50 i nch) between passes, move the
tool at l east 11 centi meters (4 i nches) to each si de of
the roof center l i ne, and 28 centi meters (11 i nches)
back from the wi ndshi el d header.
(10) Wi th the degaussi ng tool sti l l energi zed,
sl owl y back i t away from the roof panel . When the
ti p of the tool i s at l east 61 centi meters (2 feet) from
the roof panel , unpl ug the tool .
(11) Cal i brate the compass and adjust the compass
vari ance as descri bed i n thi s group.
OVERHEAD CONSOLE
cabl e.
(2) Remove the two screws l ocated forward of the
di spl ay modul e that secure the overhead consol e to
the upper wi ndshi el d openi ng rei nforcement (Fi g. 3).
(3) To rel ease the overhead consol e from the rear
mounti ng bracket, use your fi ngerti ps to gentl y pul l
the si des of the overhead consol e housi ng outward
near the rear mounti ng bracket.
(4) Move the overhead consol e forward to di sen-
gage the rear mounti ng tab from the headl i ner.
Fig. 2 Roof Demagnetizing Pattern
RH PULL TIP OF DEGAUSSING TOOL AWAY AT LEAST TWO FEET AND DISCONNECT START WINDSHIELD EDGE 1/2 L H
Fig. 3 Overhead Console Remove/Install
HEADLINER REAR BRACKET REAR MOUNT- ING TAB OVERHEAD CONSOLE FWD SCREW SCREW
(5) Lower the overhead consol e far enough to
access the two wi re harness connectors.
(6) Unpl ug one wi re harness connector near the
push button modul e towards the front of the over-
head consol e.
(7) Unpl ug one wi re harness connector from the
Remote Keyl ess Entry (RKE) recei ver near the center
of the overhead consol e.
(8) Remove the overhead consol e from the vehi cl e.
Ti ghten the overhead consol e mounti ng screws to 2.7
Nm (24 i n. l bs.).
THERMOMETER DISPLAY MODULE
(1) Remove the overhead consol e as descri bed i n
thi s group.
(2) Remove the two screws that secure the forward
end of the tri p computer, compass, and thermometer
di spl ay modul e to the overhead consol e housi ng (Fi g.
4).
(3) Gentl y fl ex the si des of the overhead consol e
housi ng as requi red to rel ease the tri p computer,
compass, and thermometer di spl ay modul e mounti ng
pi ns.
(4) Pul l the tri p computer, compass, and thermom-
eter di spl ay modul e away from the overhead consol e
housi ng far enough to access the two wi re harness
connectors.
(5) Unpl ug the overhead consol e and push button
modul e wi re harness connectors from the tri p com-
puter, compass, and thermometer di spl ay modul e.
(6) Remove the tri p computer, compass, and ther-
mometer di spl ay modul e from the overhead consol e
housi ng.
PUSH BUTTON MODULE
thi s group.
(2) Unpl ug the push button modul e wi re harness
connector from the tri p computer, compass, and ther-
mometer di spl ay modul e.
(3) Remove the four screws that secure the push
button modul e to the overhead consol e housi ng (Fi g.
5).
(4) Remove the push button modul e from the over-
head consol e.
READING AND COURTESY LAMP BULB
cabl e.
(2) I nsert a l ong, narrow, fl at-bl aded tool i n the
notch on the edge of the readi ng and courtesy l amp
l ens.
(3) Gentl y pry the l ens downward from the over-
head consol e housi ng and pi vot the l ens down. I t may
be necessary to move the tool al ong the edge of the
l ens to free the l ens from the consol e housi ng.
(4) Unsnap the bul b from the bul b hol ders by pul l -
i ng the bul b gentl y downwards.
(5) I nstal l a new bul b by al i gni ng i ts base wi th the
bul b hol ders and pushi ng the bul b fi rml y i nto pl ace.
(6) Pi vot the l ens back up i nto posi ti on and press
upward fi rml y unti l i t snaps i nto pl ace.
(8) Test the l amp by depressi ng the l ens to check
for proper l amp swi tchi ng and l i ghti ng.
GARAGE DOOR OPENER STORAGE BIN DOOR
(1) Open the garage door opener storage bi n door.
Fig. 4 Trip Computer, Compass, and Thermometer
Display Module Remove/Install
TRIP COMPUTER, COM- PASS AND THERMOME- TER DISPLAY MODULE OVERHEAD CONSOLE HOUSING PUSH BUTTON MODULE CONNECTOR OVERHEAD CONSOLE WIRE HARNESS CONNECTOR MOUNTING SCREWS MOUNTING PINS
Fig. 5 Push Button Module Remove/Install
PUSH BUTTON MODULE MOUNTING SCREWS
fl at-bl aded tool , gentl y pry between the door pi vot
pi n and the pi vot hol e on one si de of the overhead
consol e housi ng unti l the pi vot pi n cl ears the pi vot
hol e.
(3) Use a gentl e twi sti ng acti on to remove the
garage door opener storage bi n door from the over-
head consol e housi ng.
(4) To i nstal l , i nsert the pi vot pi n on one si de of
the door i nto the pi vot hol e i n the overhead consol e
housi ng. Gentl y depress the pi vot pi n tab on the
other si de of the door unti l i t cl ears the si de of the
garage door opener storage bi n openi ng and push the
door i nto the openi ng. Gui de the door i nto the open-
i ng so that the pi vot pi n snaps i nto the pi vot hol e.
SUNGLASSES STORAGE BIN
The sungl asses storage bi n door and bi n, housi ng,
damper, spri ng and l atch are servi ced onl y as a uni t.
Remove the sungl asses storage bi n modul e from the
overhead consol e as fol l ows:
thi s group.
(2) Di sengage the overhead consol e courtesy l amp
wi re harness from the retai ners mol ded i nto the sun-
gl asses storage bi n housi ng.
(3) Remove the si x screws that secure the sun-
gl asses storage bi n modul e to the overhead consol e
housi ng (Fi g. 6).
(4) Remove the sungl asses storage bi n modul e
from the overhead consol e.
AMBIENT TEMPERATURE SENSOR
cabl e.
(2) Locate the ambi ent temperature sensor, bel ow
the gri l l e and behi nd the front bumper (Fi g. 7).
(3) Unpl ug the sensor wi re harness connector.
(4) Remove the screw that secures the ambi ent
temperature sensor to the radi ator support.
(5) Remove the ambi ent temperature sensor.
Ti ghten the ambi ent temperature sensor mounti ng
screw to 3.4 Nm (30 i n l bs.).
Fig. 6 Sunglasses Storage Bin Module Remove/
Install
SUNGLASSES STORAGE BIN MODULE MOUNTING SCREWS WIRE HARNESS RETAINERS
Fig. 7 Ambient Temperature Sensor Remove/Install
FWD WIRE HARNESS SCREWSENSOR RADIATOR SUPPORT CROSSMEMBER CLIPS HORN
WIRING DIAGRAMS
CONTENTS
page page
8W-01 GENERAL INFORMATION . . . . . . . 8W-01-1
8W-02 COMPONENT INDEX . . . . . . . . . . . 8W-02-1
8W-10 POWER DISTRIBUTION . . . . . . . . 8W-10-1
8W-12 JUNCTION BLOCK . . . . . . . . . . . . . 8W-12-1
8W-15 GROUND DISTRIBUTION . . . . . . . 8W-15-1
8W-20 CHARGING SYSTEM . . . . . . . . . . . 8W-20-1
8W-21 STARTING SYSTEM . . . . . . . . . . . 8W-21-1
8W-30 FUEL/IGNITION SYSTEMS . . . . . . 8W-30-1
8W-31 TRANSMISSION CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-1
8W-33 VEHICLE SPEED CONTROL . . . . . 8W-33-1
8W-35 ALL-WHEEL ANTI-LOCK BRAKES . 8W-35-1
8W-39 VEHICLE THEFT SECURITY
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-1
8W-40 INSTRUMENT CLUSTER . . . . . . . . 8W-40-1
8W-41 HORN/CIGAR LIGHTER . . . . . . . . . 8W-41-1
8W-42 AIR CONDITIONING/HEATER . . . . 8W-42-1
8W-43 AIRBAG SYSTEM . . . . . . . . . . . . . 8W-43-1
8W-44 INTERIOR LIGHTING . . . . . . . . . . . 8W-44-1
8W-47 AUDIO SYSTEM . . . . . . . . . . . . . . 8W-47-1
8W-48 REAR WINDOW DEFOGGER . . . . . 8W-48-1
8W-49 OVERHEAD CONSOLE . . . . . . . . . . 8W-49-1
8W-50 FRONT LIGHTING . . . . . . . . . . . . . 8W-50-1
8W-51 REAR LIGHTING . . . . . . . . . . . . . . 8W-51-1
8W-52 TURN SIGNALS . . . . . . . . . . . . . . . 8W-52-1
8W-53 WIPERS . . . . . . . . . . . . . . . . . . . . . 8W-53-1
8W-54 TRAILER TOW . . . . . . . . . . . . . . . . 8W-54-1
8W-60 POWER WINDOWS . . . . . . . . . . . . 8W-60-1
8W-61 POWER DOOR LOCKS . . . . . . . . . 8W-61-1
8W-62 POWER MIRRORS . . . . . . . . . . . . 8W-62-1
8W-63 POWER SEAT . . . . . . . . . . . . . . . . 8W-63-1
8W-70 SPLICE INFORMATION . . . . . . . . . 8W-70-1
8W-80 CONNECTOR PIN-OUTS . . . . . . . . 8W-80-1
8W-90 CONNECTOR LOCATIONS . . . . . . . 8W-90-1
8W-95 SPLICE LOCATIONS . . . . . . . . . . . 8W-95-1
XJ WIRING DIAGRAMS 8W - 1
8W-01 GENERAL INFORMATION
INDEX
page page
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . 5
HOW TO USE THIS GROUP . . . . . . . . . . . . . . . . 1
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . 1
CONNECTOR/GROUND LOCATIONS . . . . . . . . . . 1
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 1
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . 1
WIRE CODE IDENTIFICATION . . . . . . . . . . . . . . . 2
CIRCUIT IDENTIFICATION . . . . . . . . . . . . . . . . . . 3
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . 5
INTERMITTENT AND POOR CONNECTIONS . . . . 5
TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 6
TROUBLESHOOTING WIRING PROBLEMS . . . . . 6
SERVICE PROCEDURES
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 7
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 7
TERMINAL/CONNECTOR REPAIRTHOMAS
AND BETTS CONNECTORS . . . . . . . . . . . . . . . 8
CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 8
CONNECTOR AND TERMINAL REPLACEMENT . . 9
TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . . 9
DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . 11
HOW TO USE THIS GROUP
The purpose of thi s group i s to show the el ectri cal
ci rcui ts i n a cl ear, si mpl e fashi on and to make trou-
bl eshooti ng easi er. Components that work together
are shown together. Al l el ectri cal components used i n
a speci fi c system are shown on one di agram. The feed
for a system i s shown at the top of the page. Al l
wi res, connectors, spl i ces, and components are shown
i n the fl ow of current to the bottom of the page. Wi r-
i ng whi ch i s not part of the ci rcui t represented i s ref-
erenced to another page/secti on, where the compl ete
ci rcui t i s shown. I n addi ti on, al l swi tches, compo-
nents, and modul es are shown i n the at rest posi-
tion with the doors closed and the key removed
from the ignition.
I f a component i s part of several di fferent ci rcui ts,
i t i s shown i n the di agram for each. For exampl e, the
headl amp swi tch i s the mai n part of the exteri or
l i ghti ng, but i t al so affects the i nteri or l i ghti ng and
the chi me warni ng system. It is important to real-
ize that no attempt is made on the diagrams to
represent components and wiring as they
appear on the vehicle. For example, a short
piece of wire is treated the same as a long one.
In addition, switches and other components are
shown as simply as possible, with regard to
function only.
SECTION IDENTIFICATION
Secti ons i n Group 8W are organi zed by sub-sys-
tems. The secti ons contai n ci rcui t operati on descri p-
ti ons, hel pful i nformati on, and system di agrams. The
i ntenti on i s to organi ze i nformati on by system, con-
si stentl y from year to year.
CONNECTOR/GROUND LOCATIONS
Secti on 8W-90 contai ns connector/ground l ocati on
i l l ustrati ons. The i l l ustrati ons contai n the connector
name (or number)/ground number and component
i denti fi cati on. Connector/ground l ocati on charts i n
Secti on 8W-90 reference the i l l ustrati on number for
components and connectors.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the Di a-
gram pages.
SPLICE LOCATIONS
Spl i ce Locati on charts i n Secti on 8W-70 show the
enti re spl i ce, and provi de references to other secti ons
the spl i ce serves.
Secti on 8W-95 contai ns i l l ustrati ons that show the
general l ocati on of the spl i ces i n each harness. The
i l l ustrati ons show the spl i ce by number, and provi de
a wri tten l ocati on.
NOTES, CAUTIONS, and WARNINGS
Throughout thi s group addi ti onal i mportant i nfor-
mati on i s presented i n three ways; Notes, Cauti ons,
and Warni ngs.
NOTES are used to hel p descri be how swi tches or
components operate to compl ete a parti cul ar ci rcui t.
They are al so used to i ndi cate di fferent condi ti ons
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 1
that may appear on the vehi cl e. For exampl e, an
up-to and after condi ti on.
CAUTIONS are used to i ndi cate i nformati on that
coul d prevent maki ng an error that may damage the
vehi cl e.
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
WIRE CODE IDENTIFICATION
Each wi re shown i n the di agrams contai ns a code
(Fi g. 1) whi ch i denti fi es the mai n ci rcui t, part of the
mai n ci rcui t, gauge of wi re, and col or. The col or i s
shown as a two l etter code whi ch can be i denti fi ed by
referri ng to the Wi re Col or Code Chart (Fi g. 2)
Fig. 1 Wire Code Identification
Fig. 2 Wire Color Code Chart
8W - 01 - 2 8W - 01 GENERAL INFORMATION XJ
CIRCUIT IDENTIFICATION
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on (Fi g. 3). To
i denti fy whi ch ci rcui t code appl i es to a system, refer
to the Ci rcui t I denti fi cati on Code Chart. Thi s chart
shows the mai n ci rcui ts onl y and does not show the
secondary codes that may appl y to some model s.
CONNECTORS
Connectors shown i n the di agrams are i denti fi ed
usi ng the i nternati onal standard arrows for mal e and
femal e termi nal s (Fi g. 4). A connector i denti fi er i s
pl aced next to the arrows to i ndi cate the connector
number (Fi g. 4).
For vi ewi ng connector pi n outs, wi th two termi nal s
or greater, refer to secti on 8W-80. Thi s secti on i den-
ti fi es i n-l i ne connectors by number, and component
connectors by name. I f a component has two or more
connectors they wi l l be i denti fi ed as C1, C2, C3...etc.
Thi s secti ons al so provi des termi nal numberi ng, ci r-
cui t i denti fi cati on, wi re col ors, and functi ons.
Al l connectors are vi ewed from the termi nal end
unl ess otherwi se speci fi ed. To fi nd the connector l oca-
ti on i n the vehi cl e refer to secti on 8W-90. Thi s sec-
ti on uses the connector i denti fi cati on number from
the wi ri ng di agrams to provi de a fi gure number ref-
erence.
TAKE OUTS
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component.
SYMBOLS
Vari ous symbol s are used throughout the Wi ri ng
Di agrams. These symbol s can be i denti fi ed by refer-
ri ng to the symbol i denti fi cati on chart (Fi g. 5).
Fig. 3 Circuit Identification
Fig. 4 Connector Identification
Fig. 5 Symbol Identification
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 6) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part from i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts package,
ground the package to a known good ground on the
vehi cl e.
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: - Most of the electrical components used
in todays vehicle are Solid State. When checking
resistance in these circuits use a meter with a
10-megohm or greater impedance. In addition, make
sure the power is disconnected from the circuit.
Circuits that are powered up by the vehicle electri-
cal system can cause damage to the equipment and
provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 7). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i n
posi ti on
Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
Damaged connector/component casi ng exposi ng
the i tem to di rt and moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Wi ri ng broke i nsi de of the i nsul ati on
Fig. 6 Electrostatic Discharge Symbol
Fig. 7 Probing Tool
TROUBLESHOOTING TESTS
Before begi nni ng any tests on a vehi cl es el ectri cal
system use the Wi ri ng Di agrams and study the ci r-
cui t. Al so refer to the Troubl eshooti ng Wi ri ng Prob-
l ems secti on i n thi s secti on.
TESTING FOR VOLTAGE
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 8).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 9).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the fused ci rcui t.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng the i tems i n the fuse ci rcui t
one at a ti me. When the fuse bl ows the ci rcui t wi th
the short to ground has been i sol ated.
TESTING FOR A VOLTAGE DROP
the si de of the ci rcui t cl osest to the battery (Fi g. 10).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch or component.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
Fig. 8 Testing for Voltage
Fig. 9 Testing for Continuity
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em.
(6) Veri fy proper operati on. For thi s step check for
proper operati on of al l i tems on the repai red ci rcui t.
Refer to the wi ri ng di agrams.
SERVICE PROCEDURES
WIRING REPAIR
When repl aci ng or repai ri ng a wi re, i t i s i mportant
that the correct gauge be used as shown i n the wi r-
i ng di agrams. The wi res must al so be hel d securel y
i n pl ace to prevent damage to the i nsul ati on.
(1) Di sconnect battery negati ve cabl e
(2) Remove 1 i nch of i nsul ati on from each end of
the wi re.
(3) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(4) Spread the strands of the wi re apart on each
part of the exposed wi re (exampl e 1). (Fi g. 11)
(5) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on (exampl e
2) (Fi g. 11)
(6) Twi st the wi res together (exampl e 3) (Fi g. 11)
(7) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(8) Center the heat shri nk tubi ng over the joi nt,
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng.
(9) Secure the wi re to the exi sti ng ones to prevent
chafi ng or damage to the i nsul ati on
(10) Connect battery and test al l affected systems.
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) I nsert the termi nal rel easi ng speci al tool 6742
i nto the termi nal end of the connector (Fi g. 12).
Fig. 10 Testing for Voltage Drop
Fig. 11 Wire Repair
Fig. 12 Molex Connector Repair
(4) Usi ng speci al tool 6742 rel ease the l ocki ng fi n-
gers on the termi nal (Fi g. 13).
(5) Pul l on the wi re to remove i t from the connec-
tor.
(6) Repai r or repl ace the connector or termi nal , as
necessary.
TERMINAL/CONNECTOR REPAIR THOMAS AND
BETTS CONNECTORS
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) Push i n the two l ock tabs on the si de of the
connector (Fi g. 14).
(4) I nsert the probe end of speci al tool 6934 i nto
the back of the connector cavi ty (Fi g. 15).
(5) Grasp the wi re and tool 6934 and sl owl y
remove the wi re and termi nal from the connector.
(6) Repai r or repl ace the termi nal .
(7) I nstal l the wi re and termi nal i n the connector.
Ful l y seat the termi nal i n the connector.
(8) Push i n the si ngl e l ock tab on the si de of the
connector (Fi g. 16).
CONNECTOR REPLACEMENT
(2) Di sconnect the connector that i s to be repai red
from i ts mati ng hal f/component
(3) Remove the connector l ocki ng wedge, i f
requi red (Fi g. 17)
Fig. 13 Using Special Tool 6742
Fig. 14 Thomas and Betts Connector Lock Release
Tabs
Fig. 15 Removing Wire Terminal
Fig. 16 Single Lock Tab
Fig. 17 Connector Locking Wedge
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 18) (Fi g. 19).
(5) Reset the termi nal l ocki ng tang, i f i t has one.
(6) I nsert the removed wi re i n the same cavi ty on
the repai r connector.
(7) Repeat steps four through si x for each wi re i n
the connector, bei ng sure that al l wi res are i nserted
i nto the proper cavi ti es. For addi ti onal connector pi n-
out i denti fi cati on, refer to the wi ri ng di agrams.
(8) I nsert the connector l ocki ng wedge i nto the
repai red connector, i f requi red.
(9) Connect connector to i ts mati ng hal f/compo-
nent.
(10) Connect battery and test al l affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(2) Di sconnect the connector (that i s to be
repai red) from i ts mati ng hal f/component.
(3) Cut off the exi sti ng wi re connector di rectl y
behi nd the i nsul ator. Remove si x i nches of tape from
the harness.
(4) Stagger cut al l wi res on the harness si de at
1/2 i nch i nterval s (Fi g. 20).
(5) Remove 1 i nch of i nsul ati on from each wi re on
the harness si de.
(6) Stagger cut the matchi ng wi res on the repai r
connector assembl y i n the opposi te order as was done
on the harness si de of the repai r. Al l ow extra l ength
for sol dered connecti ons. Check that the overal l
l ength i s the same as the ori gi nal (Fi g. 20).
(7) Remove 1 i nch of i nsul ati on from each wi re.
si de of the wi re. Be sure the tubi ng wi l l be l ong
part of the exposed wi res.
strands of wi re are cl ose to the i nsul ati on.
(11) Twi st the wi res together.
(12) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(13) Center the heat shri nk tubi ng over the joi nt
ends of the tubi ng
(14) Repeat steps 8 through 13 for each wi re.
(15) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(16) Re-connect the repai red connector.
(17) Connect the battery, and test al l affected sys-
tems.
TERMINAL REPLACEMENT
(2) Di sconnect the connector bei ng repai red from
i ts mati ng hal f. Remove connector l ocki ng wedge, i f
requi red (Fi g. 21).
Fig. 18 Terminal Removal
Fig. 19 Terminal Removal Using Special Tool
Fig. 20 Stagger Cutting Wires
(3) Remove connector l ocki ng wedge, i f requi red
(Fi g. 21).
(4) Posi ti on the connector l ocki ng fi nger away
from the termi nal usi ng the proper pi ck from speci al
tool ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 22) (Fi g. 23).
(5) Cut the wi re 6 i nches from the back of the
connector.
(6) Remove 1 i nch of i nsul ati on from the wi re on
the harness si de.
(7) Sel ect a wi re from the termi nal repai r assem-
bl y that best matches the col or wi re bei ng repai red.
(8) Cut the repai r wi re to the proper l ength and
remove 1 i nch of i nsul ati on.
si de of the wi re. Make sure the tubi ng wi l l be l ong
part of the exposed wi res.
strands of wi re are cl ose to the i nsul ati on.
(12) Twi st the wi res together.
(13) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(14) Center the heat shri nk tubi ng over the joi nt
ends of the tubi ng.
(15) I nsert the repai red wi re i nto the connector.
(16) I nstal l the connector l ocki ng wedge, i f
requi red, and reconnect the connector to i ts mati ng
hal f/component.
(17) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(18) Connect battery, and test al l affected systems.
DIODE REPLACEMENT
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 24).
Fig. 21 Connector Locking Wedge Tab (Typical)
Fig. 22 Terminal Removal
Fig. 23 Terminal Removal Using Special Tool
Fig. 24 Diode Identification
(4) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(5) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary refer to the
appropri ate wi ri ng di agram for current fl ow.
(6) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(7) Tape the di ode to the harness usi ng el ectri cal
tape maki ng, sure the di ode i s compl etel y seal ed
from the el ements
(8) Re-connect the battery, and test affected sys-
tems.
SPECIAL TOOLS
WIRING/TERMINAL
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
8W-02 COMPONENT INDEX
INDEX
page
SCHEMATICS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Page
4WD Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
4WD Swi tch I l l umi nati on . . . . . . . . . . . . . . . . .8W-44
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . .8W-42
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . .8W-42
A/C Heater Control . . . . . . . . . . . . . . . . . . . . .8W-42
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . . .8W-42
A/C Low Pressure Swi tch . . . . . . . . . . . . . . . . .8W-42
Accel erator Pedal Posi ti on Sensor . . . . . . . . . .8W-30
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . .8W-43
Ambi ent Temperature Sensor . . . . . . . . . . . . . .8W-49
Automati c Shut Down Rel ay . . . . . . . . . . . . . .8W-30
Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Back-Up Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20
Battery Temperature Sensor . . . . . . . . . . . . . .8W-30
Beam Sel ect Swi tch . . . . . . . . . . . . . . . . . . . . .8W-50
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . . .8W-42
Brake Pressure Warni ng Swi tch. . . . . . . . . . . .8W-40
Brake Warni ng I ndi cator . . . . . . . . . . . . . . . . .8W-40
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . .8W-30
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . . . . .8W-44
Center Hi gh Mounted Stop Lamp . . . . . . . . . .8W-51
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . .8W-41
Ci rcui t Breakers . . . . . . . . . . . . . . . . . . . . . . . .8W-12
Cl ockspri ng . . . . . . . . . . . . .8W-12, 30, 33, 40, 41, 70
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . . . .8W-40
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . .8W-12, 21
Cl utch I nterl ock Swi tch Jumper . . . . . . . . .8W-12, 21
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . .8W-52
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49
Control Sl eeve . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Control l er Anti -Lock Brake . . . . . . . . . . . . . . .8W-35
Control l er Anti -Lock Brake Rel ay . . . . . . . . . .8W-35
Cool i ng Fan Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-42
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . .8W-44
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . .8W-30
Data Li nk Connector . . . . . . . . . . . . . . . . . . . .8W-30
Di agnosti c Spl i ce Bl ock . . . . . . . . . . . . . . . . . .8W-30
Di esel Power Rel ay. . . . . . . . . . . . . . . . . . . . . .8W-30
Dome Lamp/Swi tch . . . . . . . . . . . . . . . . . . . . .8W-44
Door Jamb Swi tches . . . . . . . . . . . . . . . . . .8W-39, 44
Door Lock Motors . . . . . . . . . . . . . . . . . . . . . . .8W-61
Component Page
Dri ver Ai rbag . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43
Dri ver Power Seat Motor . . . . . . . . . . . . . . . . .8W-63
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . . .8W-63
Dri vers Door Speaker . . . . . . . . . . . . . . . . . . .8W-47
Dri vers Door Tweeter . . . . . . . . . . . . . . . . . . .8W-47
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . .8W-30
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . . .8W-54
El ectroni c Vacuum Modul ator . . . . . . . . . . . . .8W-30
Engi ne Cool ant Temperature Gauge. . . . . . . . .8W-40
Engi ne Cool ant Temperature Sensor . . . . . . . .8W-30
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . . .8W-21
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . .8W-21
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . .8W-50, 51
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . . . .8W-50
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . . .8W-53
Fuel Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-30
Fuel Quanti ty Actuator . . . . . . . . . . . . . . . . . .8W-30
Fuel Shutdown Sol enoi d. . . . . . . . . . . . . . . . . .8W-30
Fuel Temperature Sensor . . . . . . . . . . . . . . . . .8W-30
Fuel Ti mi ng Sol enoi d . . . . . . . . . . . . . . . . . . . .8W-30
Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12
Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10
G Swi tch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20
Gl ove Box Lamp Swi tch . . . . . . . . . . . . . . . . . .8W-44
Gl ow Pl ug Assembl y . . . . . . . . . . . . . . . . . . . . .8W-30
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Ground Di stri buti on . . . . . . . . . . . . . . . . . . . . .8W-15
Headl amp Del ay Modul e . . . . . . . . . . . . . . . . .8W-50
Headl amp Level i ng Motors . . . . . . . . . . . . . . .8W-50
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . .8W-50
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Heated Oxygen Sensors . . . . . . . . . . . . . . . . . .8W-30
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-12, 41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41
XJ 8W - 02 COMPONENT INDEX 8W - 02 - 1
Component Page
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41
HVAC Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . .8W-30
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-10
I ndi cator Lamps . . . . . . . . . . . . . . . . . . . . . . . .8W-40
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . .8W-40
I ntake Ai r Temperature Sensor . . . . . . . . . . . .8W-30
I nteri or Li ghts On Swi tch . . . . . . . . . . . . . . . .8W-44
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . .8W-12
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Li ft Gate Door Lock Motor . . . . . . . . . . . . . . . .8W-61
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-39, 44
Low Cool ant Swi tch . . . . . . . . . . . . . . . . . . . . .8W-30
Low Washer Fl ui d Swi tch. . . . . . . . . . . . . . . . .8W-40
Mani fol d Absol ute Pressure Sensor . . . . . . . . .8W-30
Mass Ai r Fl ow Sensor . . . . . . . . . . . . . . . . . . . .8W-30
Measure Coi l . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30
Needl e Movement Sensor . . . . . . . . . . . . . . . . .8W-30
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Oi l Pressure Gauge . . . . . . . . . . . . . . . . . . . . .8W-40
Oi l Pressure Sensor . . . . . . . . . . . . . . . . . . . . .8W-30
Output Shaft Speed Sensor . . . . . . . . . . . . . . .8W-31
Overhead Modul e . . . . . . . . . . . . . . . . . . . . . . .8W-39
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-40
Part Ti me 4WD Swi tch . . . . . . . . . . . . . . . . . .8W-40
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . . . .8W-43
Passenger Power Seat Motor . . . . . . . . . . . . . .8W-63
Passenger Power Seat Swi tch. . . . . . . . . . . . . .8W-63
Passengers Door Speaker . . . . . . . . . . . . . . . .8W-47
Passengers Door Tweeter . . . . . . . . . . . . . . . . .8W-47
Posi ti on Lamps. . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . .8W-47
Power Di stri buti on Center . . . . . . . . . . . . . . . .8W-10
Power Lock/Wi ndow Swi tch/Modul es . . . . .8W-60, 61
Power Lock/Wi ndow Swi tches . . . . . . . .8W-60, 61, 62
Power Mi rrors . . . . . . . . . . . . . . . . . . . . . .8W-48, 62
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41
Power Steeri ng Pressure Swi tch. . . . . . . . . . . .8W-30
Powertrai n Control Modul e . . . . . . . . . . . .8W-30, 31
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . . . . .8W-44
Radi ator Cool i ng Fan . . . . . . . . . . . . . . . . . . . .8W-42
Component Page
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47
Rear Fog Lamp Rel ay. . . . . . . . . . . . . . . . . . . .8W-51
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . .8W-51
Rear Washer Pump Motor . . . . . . . . . . . . . . . .8W-53
Rear Wi ndow Defogger Gri d. . . . . . . . . . . . . . .8W-48
Rear Wi ndow Defogger Rel ay . . . . . . . . . . .8W-12, 48
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . . .8W-48
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . . .8W-53
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . . . .8W-53
Repeater Lamps . . . . . . . . . . . . . . . . . . . . . . . .8W-50
Seat Bel t Swi tch. . . . . . . . . . . . . . . . . . . . . . . .8W-40
Seat Bel t Warni ng I ndi cator . . . . . . . . . . . . . . .8W-40
Speakers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47
Speed Control Swi tches . . . . . . . . . . . . . . .8W-30, 33
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Spl i ce Detai l s . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . .8W-30, 33
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Tai l /Stop Lamps . . . . . . . . . . . . . . . . . . . . . . . .8W-51
Tel l Tal e Modul e . . . . . . . . . . . . . . . . . . . . .8W-30, 40
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . .8W-30, 31
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . .8W-54
Transmi ssi on Control Modul e. . . . . . . . . . . . . .8W-31
Transmi ssi on Control Sol enoi ds . . . . . . . . . . . .8W-31
Transmi ssi on Range Swi tch . . . . . . . . . . . . . . .8W-31
Tri p Reset Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-40
Turn Si gnal Rel ays . . . . . . . . . . . . . . . . . . . . . .8W-54
Turn Si gnal Lamps . . . . . . . . . . . . . . . . . . .8W-50, 51
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . . .8W-52
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-44
Vani ty Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44
Vehi cl e Speed Control Servo. . . . . . . . . . . . . . .8W-33
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . .8W-30
Vol tmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40
Warni ng I ndi cator Lamps. . . . . . . . . . . . . . . . .8W-40
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . . .8W-30
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . . . .8W-35
Wi ndow Motors . . . . . . . . . . . . . . . . . . . . . . . .8W-60
Wi ndow Swi tches . . . . . . . . . . . . . . . . . . . . . . .8W-60
Wi ndshi el d Washer Pump Motor . . . . . . . . . . .8W-53
Wi ndshi el d Wi per/Washer Swi tch . . . . . . . . . . .8W-53
8W - 02 - 2 8W - 02 COMPONENT INDEX XJ
8W-02 COMPONENT INDEX
GENERAL INFORMATION
INTRODUCTION
Thi s secti on provi des an al phabeti cal l i sti ng of al l
the components covered i n group 8W. For i nformati on
on system operati on, refer to the appropri ate secti on
of the wi ri ng di agrams.
XJ 8W - 02 COMPONENT INDEX 8W - 02 - 3
8W-10 POWER DISTRIBUTION
INDEX
page
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . . . . . .8W-10-12, 35
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . .8W-10-6, 12, 26, 34, 35
Automati c Shut Down Rel ay . . . . . . . . . . . . . . . . . . . .8W-10-7, 17
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 25
Brake Pressure Warni ng Swi tch . . . . . . . . . . . . . . . . . .8W-10-8, 28
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
Center Hi gh Mounted Stop Lamp . . . . . . . . . . . . . . . .8W-10-20, 34
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . .8W-10-8, 11, 28, 32
Ci rcui t Breaker 28 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
Ci rcui t Breaker 29 (JB). . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Ci rcui t Breaker 30 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . . . . .8W-10-19, 36
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-15, 33
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . .8W-10-13, 20, 32, 34
Cool i ng Fan Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 11
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
Di esel Power Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
Dome Lamp/Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-10-15, 33
Downstream Heated Oxygen Sensor . . . . . . . . . . . . . . . . .8W-10-17
El ectroni c Vacuum Modul ator . . . . . . . . . . . . . . . . . . . .8W-10-35
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . .8W-10-6, 13, 25, 31
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . .8W-10-6, 13, 25, 31
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 20, 26, 36
Front Fog Lamp Swi tch. . . . . . . . . . . . . . . . . . . . . .8W-10-20, 36
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-31
Fuel Heater Rel ay. . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25, 31
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-18
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . .8W-10-19, 27, 35
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 19
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 8, 25, 27
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 8, 25, 27
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 11, 25, 27
Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 11, 25, 28
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 11, 25, 31
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 12, 25, 31
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 29
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25, 31
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 29
Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 12, 25, 32
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 29
Fuse 10 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 13, 25, 28
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 29
Fuse 11 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-25, 32
Fuse 12 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Fuse 12 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 13, 25, 32
Fuse 13 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-13, 31
Fuse 13 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 13
Fuse 14 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-13, 31
Fuse 14 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-26, 32
Fuse 15 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 14, 26, 33
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 16
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 17
Fuse 19 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 19, 26, 34
Fuse 20 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Fuse 20 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17, 26, 34
Fuse 21 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Fuse 21 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 19, 35
Fuse 22 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 20, 26, 35
Fuse 23 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17, 26, 36
Fuse 24 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Fuse 24 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 20, 27
Fuse 25 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-7, 20, 26, 36
Fuse 26 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-10, 30
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 12, 26, 37
Component Page
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-9, 29
Fuse 27 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-26, 34
Fusi bl e Li nk A11 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 25
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 25,27
Gl ove Box Lamp Swi tch . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
Gl ow Pl ug Assembl y . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27, 35
Headl amp Del ay Modul e . . . . . . . . . . . . . . . . . . . . .8W-10-12, 31
Headl amp Swi tch . . . . . . . . . . . . . . . . .8W-10-9, 12, 16, 29, 31, 37
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
HVAC Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . .8W-10-8, 9, 10, 28, 29, 30
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . .8W-10-9, 14, 29, 33
Juncti on Bl ock . . . . . . . .8W-10-8, 9, 10, 11, 13, 14, 28, 29, 30, 31, 32, 33
Left Courtesy Lamp. . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 36
Left Front Door Jamb Swi tch . . . . . . . . . . . . . . . . . . .8W-10-9, 29
Left Front Power Lock/Wi ndow Swi tch . . . . . . . . . . . . .8W-10-14, 33
Left Front Power Lock/Wi ndow Swi tch/Modul e . . . . . . . . . .8W-10-9, 29
Left Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Left Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
Left Tai l /Stop Lamp. . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 34
Left Vani ty Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-15, 33
Mass Ai r Fl ow Sensor . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-35
Overhead Modul e . . . . . . . . . . . . . . . . . . . . .8W-10-12, 15, 33, 34
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 35
Power Di stri buti on Center . . . . . . . . . . . .8W-10-6, 7, 8, 11, 12, 13, 14,
16, 17, 19, 20, 25, 26, 27, 28, 31, 32, 33, 34, 35, 36, 37
Powertrai n Control Modul e. . . . . . . . . . . . . . . .8W-10-17, 19, 27, 34
Radi ator Cool i ng Fan . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
Rear Wi ndow Defogger Gri d . . . . . . . . . . . . . . . . . . .8W-10-13, 31
Rear Wi ndow Defogger Rel ay. . . . . . . . . . . . . . .8W-10-10, 13, 30, 31
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 36
Ri ght Front Door Jamb Swi tch . . . . . . . . . . . . . . . . . .8W-10-9, 29
Ri ght Front Power Lock/Wi ndow Swi tch . . . . . . . . . . . . .8W-10-14, 33
Ri ght Front Power Lock/Wi ndow Swi tch/Modul e . . . . . . . . .8W-10-9, 29
Ri ght Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
Ri ght Rear Fog Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 34
Ri ght Vani ty Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-10-15, 33
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 36
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-18
S118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-6, 25
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-11, 32
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-17, 27
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-34
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
S153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-27
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-35
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 9, 28, 29
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 34
S207. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 9, 28, 29
S211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-8, 28
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 35
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 34
S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-16, 37
S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-15, 33
Stop Lamp Swi tch. . . . . . . . . . . . . . . . . . . . . . . . .8W-10-20, 34
Transmi ssi on Control Modul e . . . . . . . . . . . . . . . . . . . .8W-10-14
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-10-14, 33
Upstream Heated Oxygen Sensor . . . . . . . . . . . . . . . . . .8W-10-17
XJ 8W - 10 POWER DISTRIBUTION 8W - 10 - 1
16
19 18 20
17
11
13 15 14
12 2
4 5 3
1
7
10 8 9
6
13
12 14
11
10 2
4
8 5
6
FUEL
PUMP
RELAY
POWER DISTRIBUTION CENTER
MOTOR
STARTER
ENGINE
RELAY
D
C
10
11
14 12
13
RELAY
COOLING
FAN
6
5 8
4
2
DOWN
SHUT
AUTOMATIC
RELAY
B
LAMP
FOG
RELAY
RELAY
CLUTCH
A/C
COMPRESSOR
RELAY
CONTROLLER
ANTI-LOCK
BRAKE
A
FUSES
8 14 7
6
7
30A
13
5
6
40A
12
4
5
40A
11
3
4
50A
10
2
3
40A
9
1
2
40A
8
21
15
16
17
18
19
20
22
23
24
25
26
27
28 15
14
13
20A
12
40A
11
10
30A
9
20A
F20 20A F26 10A
1 2
F23 15A
F22 15A
4 3
F25 20A F19 15A F17 20A
F16 15A F18 25A F24 15A
5 6
F21 15A
8 7
9 10
12 11
14 13
15 16
18 17
20 19
21 22
24 23
BATTERY
M1
8W - 10 - 2 8W-10 POWER DISTRIBUTION
GAS
XJ
J978W-7 XJI01001
FUSES
FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT
1
- - -
A1 12RD IGNITION SWITCH 40A
2
3
40A A2 12PK/BK IGNITION SWITCH
A7 10RD/BK 40A
4
F141 12LG/RD COOLING FAN RELAY 40A
5
6
40A A111 12RD/LG A/C HEATER CONTROL
7
30A A3 16RD/WT
8
10
30A
-
9
20A
A4 14BK/PK
A10 12RD/DG ABS CONTROL MODULE
-
11
A20 14RD/DB ABS CONTROL MODULE
40A
12
-
20A
13
14
-
-
15
M1 20PK
F34 18TN/BK
L9 20BK/PK COMBINATION FLASHER
A16 16RD/LG
15A
16
17
20A
25A
18
19
15A
-
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
-
A0 6RD
A0 6RD
-
-
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A17 16RD/BK
- - -
A0 6RD A17 16RD/BK
26
10A F1 20DB/GY A17 16RD/BK
20
20A A142 18DG/OR A999 16RD
21
15A A61 14DG/BK A0 6RD
22
15A F32 20PK/DB STOP LAMP SWITCH A0 6RD
23
15A F142 20DG/WT A999 16RD
24
15A F61 20WT/OR FOG LAMP RELAY NO. 1 A0 6RD
25
20A F75 16VT POWER AMPLIFIER A0 6RD
AUTOMATIC SHUT DOWN RELAY
A4 14BK/PK
XJ 8W-10 POWER DISTRIBUTION
GAS
8W - 10 - 3
XJI01002 J978W-7
CONTROLLER ANTI-LOCK BRAKE INDICATOR OUTPUT G19 20LG/OR
CIRCUIT CAVITY FUNCTION
CONTROLLER ANTI-LOCK BRAKE RELAY
B19
B16
B20
B18
Z1 20BK GROUND
- -
F15 20DB/WT FUSED IGNITION (RUN)
G83 20GY/BK CONTROLLER ANTI-LOCK BRAKE RELAY CONTROL
A/C COMPRESSOR CLUTCH RELAY
B5
B3
B1
B4
B2
FUSED IGN. (ST-RUN) F12 18DB/WT
C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
A17 16RD/BK FUSED B(+)
-
A/C COMPRESSOR CLUTCH RELAY OUTPUT C3 16DB/BK
-
FUNCTION CAVITY CIRCUIT
- -
FUSED B(+) F61 20WT/OR
GROUND L35 20BR/WT
L77 20BR/YL FUSED HEADLAMP SWITCH OUTPUT
B9
B6
B8
FOG LAMP RELAY
B10
B17
B7
L139 20VT FOG LAMP RELAY OUTPUT
GAS
XJ
J978W-7 XJI01003
FUSED B(+) A4 14BK/PK
ENGINE STARTER MOTOR RELAY
D13 (A/T)
D10
D14
D12
F45 20YL/RD FUSED IGN. (ST)
T41 20BK/WT ENGINE STARTER MOTOR RELAY CONTROL
T40 14BR ENGINE STARTER MOTOR RELAY OUTPUT
- -
AUTOMATIC SHUT DOWN RELAY
C8
C5
C2
C6
C4
AUTOMATIC SHUT DOWN RELAY OUTPUT A999 16RD
- -
A16 16RD/LG FUSED B(+)
K51 18DB/YL
AUTOMATIC SHUT DOWN RELAY CONTROL
FUEL PUMP RELAY
D8
D5
D2
D6
D4
FUEL PUMP RELAY CONTROL K31 18BR
F12 18DB/WT FUSED IGN. (ST-RUN)
A61 14DG/BK FUSED B(+)
- -
A141 14DG/WT FUEL PUMP RELAY OUTPUT
- -
FUSED B(+) F141 12LG/RD
C11
C13
C10
C12
COOLING FAN RELAY
C14
C27 18DB/PK COOLING FAN RELAY CONTROL
D11 (A/T)
AUTOMATIC SHUT DOWN RELAY OUTPUT A999 16RD
C25 12LB COOLING FAN RELAY OUTPUT
A61 14DG/BK FUSED B(+)
T41 20BK/WT ENGINE STARTER MOTOR RELAY CONTROL
D11 (M/T)
D13 (M/T)
SWITCHED FUSED IGN. (ST) T141 20YL
T41 20BR/LB ENGINE STARTER MOTOR RELAY CONTROL
GAS
8W - 10 - 5
XJI01004 J978W-7
CENTER
DISTRIBUTION
POWER
BATTERY
ENGINE
STARTER
MOTOR
A0
6
RD RD
6
A0
2
FUSE
40A 40A
FUSE
3 4
FUSE
40A
5
FUSE
40A
C10
30A
FUSE
7 9
FUSE
20A
GENERATOR
A11
6
BK/WT
S118
A11
LINK
FUSIBLE
10
DG
A
(8W-10-7)
TO
FUSE
12 (PDC)
1
8 9
2
A2
12
PK/BK
10
3
11
4
13
6
A3
16
RD/WT
SWITCH
HEADLAMP
TO
22
15
RD
12
A1
SWITCH
IGNITION
TO TO
IGNITION
SWITCH
TO
JUNCTION
BLOCK
RD/BK
10
A7
COOLING
FAN
RELAY
5
12
40A
FUSE
6
A111
12
RD/LG
UNIT
HVAC
TO
RELAY
COMPRESSOR
A/C
B1
CLUTCH
A2
A1
10A
FUSE
26
TO
OVERHEAD
MODULE
DB/GY
20
F1
MOTOR
D10
ENGINE
STARTER
RELAY
23
16
30A
FUSE
10
A4
14
BK/PK
BLOCK
JUNCTION
TO
1 1 C2
(8W-20-2)
(8W-20-3)
(8W-21-2)
(8W-21-3)
(8W-10-8) (8W-10-8) (8W-10-11) (8W-10-11)
(8W-10-12)
(8W-20-2)
(8W-20-3)
(8W-10-12)
(8W-42-7)
(8W-10-11)
(8W-42-7)
(8W-10-12)
(8W-21-2)
(8W-21-3)
(8W-10-13)
GAS
XJ
J978W-7 XJI01005
A15
A16
A22
A21
A24
A23
26
19
25
18
17
FUSE
20A
SWITCH
HEADLAMP
TO
TN/BK
18
F34
10 (PDC)
FUSE
FROM
RD/DG
12
A10
12
FUSE
40A
40A
FUSE
13
A20
14
RD/DB
TO
15A
FUSE
16
19
FUSE
15A
TO
CONTROLLER
ANTI-LOCK
POWER
DISTRIBUTION
CENTER
A
(8W-10-6)
BRAKE BRAKE
ANTI-LOCK
CONTROLLER S135
TO
PK
20
M1
C2
25A
FUSE
18
DOWN
SHUT
AUTOMATIC
A18
A17
RELAY
D2
15A
FUSE
21
RELAY
PUMP
FUEL
A11
A12
L9
20
BK/PK
TO
COMBINATION
FLASHER CONTROL
POWERTRAIN
TO
DG/BK
16
A61
MODULE
A5
A6
FOG
LAMP
RELAY
24
FUSE
15A
B6
20A
FUSE
25
A4
A3 A10
A9
22
FUSE
15A
SWITCH
F32
20
PK/DB
TO
STOP
LAMP AMPLIFIER
POWER
TO
VT
16
F75
(8W-10-14)
(8W-10-16)
(8W-10-13)
(8W-10-13)
(8W-10-19)
(8W-10-17)
(8W-30-2)
(8W-10-19)
(8W-30-3)
(8W-30-4)
(8W-10-20) (8W-10-20) (8W-10-20)
(8W-50-7)
GAS
8W - 10 - 7
XJI01006 J978W-7
POWER
DISTRIBUTION
CENTER
BATT A0
1
2
FUSE
40A
A1
12
RD
C2
RD
12
A1
2
C2
1 C2
G26
20
LB
SWITCH
KEY-IN
C1
3
0
2
1 4
4
C1
3 C1
4 1
2
0
3
C1
10
C1 7
3
0
2
1 4
C1
9
3
0
2
1 4
8
C1
2 C1
G9
20
GY/BK
A2
12
PK/BK
C100
C6
PK/BK
12
A2
40A
FUSE
3
2
1
BK
20
Z1
3
0
2
1 4
YL
14
A41 A22
12
BK/OR
A21
12
DB
ST-RUN A21
BK/WT
12
A31
BK/LB
20
G16
8 9
PARK
BRAKE
SWITCH
SWITCH
PRESSURE
BRAKE
1
WARNING
G9
20
GY/BK
A14 C100
1
G9
18
GY/BK
66 C201
S211
S210
FROM
TO
S200
15A
FUSE
17
BLOCK
JUNCTION
L1 C4
18
FUSE
SPARE
30A
28
BREAKER
CIRCUIT CIRCUIT
BREAKER
30
20A
RUN A22
G108
G9
20
GY/BK
A31
12
BK/WT
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
SWITCH
IGNITION
S207
Z1
14
BK
86
ST A41
CIGAR
LIGHTER
RELAY
C203 10
LHD RHD
RHD LHD
C201 10
GY/BK
20
G9
(8W-10-6)
(8W-10-6)
(8W-10-9)
(8W-40-12)
(8W-40-12)
(8W-10-9)
(8W-10-9)
(8W-12-17)
(8W-12-18)
(8W-12-2)
(8W-12-17)
(8W-12-18) (8W-12-23)
(8W-12-24)
(8W-12-25)
(8W-10-10)
(8W-15-10)
(8W-15-10)
(8W-10-10)
(8W-41-2)
(8W-41-3)
GAS
XJ
J978W-7 XJI01007
A31
12
BK/WT
RUN-ACC A31
3
0
2
1 4
8
C1
29 C201
5 C300
G26
20
LB
LB
20
G26
5 C1
DB
12
A21
C201 64
27
FUSE
10A 20A
FUSE
11 10
FUSE
SPARE
BLOCK
JUNCTION
SPARE
FUSE
8
L2 C4
9
FUSE
10A
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
LEFT
FRONT
DOOR
JAMB
SWITCH
2
BK/LB
18
G16
C317 2
C200 17
S200
S210
LB
20
G26
RIGHT
FRONT
POWER
LOCK/
WINDOW
SWITCH/
C2
8
CLUSTER
INSTRUMENT
BATT A1
G26
20
LB
RD
12
A1
2
C2
1 C2
SWITCH
KEY-IN
C1 7
SWITCH
IGNITION
C1
9
3
0
2
1 4
A21
12
DB BK/LB
20
G16
RHD LHD
C305 13
C203 20
LHD RHD
19 C203
2 C318
G16
18
BK/LB
2
SWITCH
JAMB
DOOR
FRONT
RIGHT
LHD RHD
BK/LB
20
G16
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
C1
6
0
1
2
CHIME
MODULE
8
C2 C2
8
MODULE
SWITCH/
WINDOW
LOCK/
POWER
FRONT
LEFT
LB
20
G26
(8W-10-8)
(8W-12-23)
(8W-12-24)
(8W-12-14) (8W-12-11)
(8W-12-12)
(8W-12-2)
(8W-12-11)
(8W-12-12)
(8W-12-11)
(8W-12-12)
(8W-39-6)
(8W-39-7)
(8W-61-4)
(8W-40-14)
(8W-10-8)
(8W-10-8)
(8W-39-6)
(8W-39-7)
(8W-50-2)
(8W-50-3)
(8W-61-4)
GAS
8W - 10 - 9
XJI01008 J978W-7
BK/OR
12
A22
62
RELAY
DEFOGGER
WINDOW
REAR
86
20A
FUSE
22
C4 M2
12
FUSE
10A
JUNCTION
BLOCK
15A
FUSE
25 26
FUSE
10A
IGNITION
SWITCH
1 START
2 RUN
0 OFF
3 LOCK
4 ACC
BK/OR
12
A22 A41
14
YL
4 1
2
0
3
10
C1
3
0
2
1 4
C1 3
C1
4
PK/BK
12
A2
BATT A2
C201
63
A41
12
YL
10A
FUSE
19
M1 C4
LHD RHD RHD LHD
YL
14
A41
24
FUSE
SPARE
(8W-48-2)
(8W-48-3)
(8W-12-20)
(8W-12-21)
(8W-12-15)
(8W-12-16)
(8W-12-2)
(8W-12-20)
(8W-12-21)
(8W-12-23)
(8W-12-24)
(8W-10-8)
(8W-10-8)
(8W-12-17)
(8W-12-18)
(8W-12-20)
(8W-12-21)
GAS
XJ
J978W-7 XJI01009
12 11 10
8
HVAC
UNIT
11 C201
C100 D5
RD/LG
12
A111
40A
FUSE
6
5
1
RADIATOR
COOLING
FAN
C25
12
LB
COOLING
FAN
RELAY
C10
C14
JUNCTION
BLOCK
HORN
RELAY
RELAY
LIGHTER
CIGAR
CIRCUIT
BREAKER
29
30A
10A
FUSE
20
15A
FUSE
21 15
FUSE
25A
2
FUSE
25A
25A
FUSE
1
C2 2
A7
10
RD/BK
3
4
FUSE
40A 40A
FUSE
5
4
BATT A0
POWER
DISTRIBUTION
CENTER
30
87 87
30 86
M6
C4
1
LIGHTER
CIGAR
50 C201
F30
16
RD
DG/RD
20
X2
C2
4
RIGHT
HORN
1 1
HORN
LEFT
S131
LHD RHD
RHD LHD
C202 7
(8W-42-2)
(8W-42-3)
(8W-42-7)
(8W-42-7)
(8W-12-2)
(8W-41-2)
(8W-41-3) (8W-41-2)
(8W-41-3)
(8W-12-25)
(8W-12-19)
(8W-12-19)
(8W-12-5)
(8W-12-5)
(8W-12-17)
(8W-12-18)
(8W-10-6)
(8W-10-6)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
GAS
8W - 10 - 11
XJI01010 J978W-7
CLUTCH
COMPRESSOR
A/C
1
DB/BK
16
C3
C108 4
DB/GY
20
F1
OVERHEAD
MODULE
DB/GY
20
F1
C201 19
8
C100 E10
DB/GY
20
F1
10A
FUSE
26
A2
A1
C3
16
DB/BK
A17
16
RD/BK
B2
B1
22 13
15
9
FUSE
20A
RD/WT
16
A3
MODULE
DELAY
HEADLAMP
2
SWITCH
HEADLAMP
8 C1
RD/WT
16
A3
D1 C100
A3
16
RD/WT
CENTER
DISTRIBUTION
POWER
BATT A0
30A
FUSE
7
6
A/C
COMPRESSOR
CLUTCH
RELAY
LHD RHD
2 C302
F1
20
DB/GY
(8W-42-7)
(8W-39-2)
(8W-39-3)
(8W-50-2)
(8W-50-3)
(8W-50-2)
(8W-50-3)
(8W-10-6)
(8W-10-6)
(8W-42-7)
GAS
XJ
J978W-7 XJI01011
BK/WT
12
C15
C310
C313
3
C315 1
9 25
RD/DB
14
A20 A10
12
RD/DG
20A
FUSE
13
26
19 18
25
12
FUSE
40A
BR
14
T40
1 C108
T40
14
BR
2
ENGINE
STARTER
MOTOR
REAR
WINDOW
DEFOGGER
GRID
1
BK/WT
12
C15
C6
1
SPARE
FUSE
13 14
FUSE
10A
REAR
WINDOW
DEFOGGER
RELAY
BK/PK
14
A4
C2 1
BLOCK
JUNCTION
BATT A0
30A
FUSE
10
23
16
RELAY
MOTOR
STARTER
ENGINE
D10
D14
POWER
DISTRIBUTION
CENTER
30
87
(4.0L)
BRAKE
ANTI-LOCK
CONTROLLER
C1
2
(8W-21-2)
(8W-21-3)
(8W-48-2)
(8W-48-3)
(8W-48-2)
(8W-48-3)
(8W-12-2)
(8W-10-6)
(8W-21-2)
(8W-21-3)
(8W-10-6)
(8W-35-2)
(8W-12-15)
(8W-12-16)
(8W-12-15)
(8W-12-16)
GAS
8W - 10 - 13
XJI01012 J978W-7
1
GLOVE
BOX
LAMP
PK
20
M1
M1
20
PK
PK
20
M1
RADIO
7 C2
M1
20
PK
4
C7
12 C1
JUNCTION
BLOCK
UNDERHOOD
LAMP
2
MODULE
CONTROL
TRANSMISSION
25
S135
PK
20
M1
M1
20
PK
A23
A24
16
FUSE
15A
CENTER
DISTRIBUTION
POWER
BATT A0
C1 9
S214
INSTRUMENT
CLUSTER
RIGHT
COURTESY
LAMP
COURTESY
LEFT
LAMP
1 1
M1
20
PK
M1
20
PK
6 C201
M1
20
PK
S18
C4
M1
20
PK
M1
20
PK
PK
20
M1
PK
20
M1
PK
20
M1
S300
A C207
M1
18
PK
C208 A
PK
18
M1
5 C314
C305 3
M1
18
PK
3
SWITCH
WINDOW
LOCK/
POWER
FRONT
LEFT
M1
20
PK
A
LAMP/
CARGO
C3
3
PK
20
M1
B
(8W-10-15)
TO
S347
(4.0L A/T)
PK
18
M1
C314 5
M1
20
PK
LHD RHD RHD LHD
SWITCH
SWITCH
C2
C2
RIGHT
FRONT
POWER
LOCK/
WINDOW
SWITCH
3
PK
18
M1
(RHD)
(8W-44-5)
(8W-47-2)
(8W-12-2) (8W-44-4)
(8W-31-2)
(8W-10-7)
(8W-10-6)
(8W-40-2)
(8W-44-5) (8W-44-5)
(8W-62-2)
(8W-44-6)
(8W-62-4)
GAS
XJ
J978W-7 XJI01013
2
COMPASS
PK
20
M1
PK
20
M1
A
DOME
LAMP/
OVERHEAD
MODULE
2
PK
20
M1
1
RIGHT
VANITY
LAMP LAMP
VANITY
LEFT
1
S347
M1
20
PK
M1
20
PK
PK
20
M1
JUNCTION
BLOCK
FROM
B
(8W-10-14)
SWITCH
(8W-49-2)
(8W-49-3)
(8W-39-2)
(8W-39-3)
(8W-44-4) (8W-44-4) (8W-44-5)
GAS
8W - 10 - 15
XJI01014 J978W-7
IND.
LAMP
FOG
REAR
RIGHT LEFT
REAR
FOG
LAMP
C321 4 4 C322
BR/WT
16
L38
S308
L38
16
BR/WT
L38
18
BR/WT
C203 15
SWITCH
LAMP
FOG
REAR
3
BR/WT
18
L38
BR/WT
18
L38
S220
L38
18
BR/WT
REAR
FOG
LAMP
RELAY
4
1
TN/BK
18
F34
TN/BK
18
F34
S218
RHD LHD
C1 4
SWITCH
HEADLAMP
16
CONNECTOR
LINK
DATA
F34
18
TN/BK
TN/BK
18
F34
DATA
LINK
CONNECTOR
16
HEADLAMP
SWITCH
4 C1
TN/BK
18
F34
C100 A18
F34
18
TN/BK
A21
A22
17
FUSE
20A
POWER
DISTRIBUTION
CENTER
BATT A0
(8W-51-6) (8W-51-6) (8W-51-6)
(8W-51-6)
(8W-50-2)
(8W-50-3)
(8W-30-15)
(8W-30-15)
(8W-50-2)
(8W-50-3)
(8W-10-7)
(8W-10-6)
GAS
XJ
J978W-7 XJI01015
16 RD A999
S113
TO
C
(8W-10-18)
DG/OR
18
A142
IGNITION
COIL
2
S109
A142
18
DG/OR
A142
18
DG/OR
DG/WT
20
F142
DG/WT
20
F142
DG/WT
20
F142
1
SENSOR
OXYGEN
HEATED
DOWNSTREAM UPSTREAM
HEATED
OXYGEN
SENSOR
1
S110
DG/OR
18
A142
1
S137
DG/OR
18
A142
C3 C12
C107
7
POWERTRAIN
CONTROL
MODULE
DG/WT
20
F142
15A
FUSE
23
A8
A7 A14
A13
20
FUSE
20A
A142
18
DG/OR
C8
C2
AUTOMATIC
SHUT
DOWN
RELAY
RD/LG
16
A16
25A
FUSE
18
A17
A18
CENTER
DISTRIBUTION
POWER
BATT A0
(8W-30-5)
(8W-30-8) (8W-30-8)
(8W-30-2)
(8W-30-2)
(8W-10-6)
(8W-10-6)
GAS
8W - 10 - 17
XJI01016 J978W-7
A142
DG/OR
18 18
DG/OR
A142 A142
DG/OR
18
1 1 1
A142
DG/OR
18 18
DG/OR
A142
FUEL
INJECTOR
NO. 6
NO. 5
INJECTOR
FUEL
1 1
FUEL
INJECTOR
NO. 3
NO. 4
INJECTOR
FUEL FUEL
INJECTOR
NO. 2
NO. 1
INJECTOR
FUEL
1
18
DG/OR
A142
DG/OR
18
A142
S113
C
(8W-10-17)
FROM
S109
(8W-30-6)
(8W-30-6) (8W-30-6)
(8W-30-6) (8W-30-6)
(8W-30-6)
GAS
XJ
J978W-7 XJI01017
DG/BK
16
A61
C1 A22
MODULE
PUMP
FUEL
1
DG/WT
16
A141
DG/WT
16
A141
C200 13
DG/BK
16
A61
14 C107 C100
D2
A141
14
DG/WT
MODULE
CONTROL
POWERTRAIN
A11
A12
21
FUSE
15A
RELAY
PUMP
FUEL
D2
D8
2
COMBINATION
FLASHER
BATT A0
CENTER
DISTRIBUTION
POWER
15A
FUSE
19
A15
A16
BK/PK
20
L9
B11
L9
20
BK/PK
LHD RHD
4 C204
(8W-30-3)
(8W-30-4)
(8W-30-2)
(8W-30-3)
(8W-30-4)
(8W-52-2)
(8W-52-3)
(8W-10-6)
(8W-10-7)
GAS
8W - 10 - 19
XJI01018 J978W-7
POWER
DISTRIBUTION
CENTER
BATT A0
15A
FUSE
22
A10
A9
F32
20
PK/DB
F8
5
6
STOP
LAMP
SWITCH
L50
20
WT/TN
S203
B4 C100
12
CONTROLLER
ANTI-LOCK
BRAKE
C200 24
L50
18
WT/TN
MOUNTED
HIGH
CENTER
2
STOP
LAMP
D C308
L50
20
WT/TN
WT/TN
20
L50
S302
LAMP
STOP
TAIL/
LEFT
C322 6
WT/TN
18
L50
3 3
L50
18
WT/TN
6 C321
RIGHT
TAIL/
STOP
LAMP
A6
A5
24
FUSE
15A
B7
B6
FOG
LAMP
RELAY
VT
20
L139
A5
3
SWITCH
LAMP
FOG
FRONT
2
2 2
LEFT RIGHT
S106
8 C106
C100 A4
L39
20
LB
L39
20
LB
L39
20
LB
A4
A3
25
FUSE
20A
VT
16
F75
C100
C4
VT
14
F75
VT
16
F75
VT
16
F75
S301
AMPLIFIER
POWER
(4.0L)
1 C2 C2 2
RHD LHD
6 C204
C204 3
LHD RHD
14 C200
C427 1
LAMP
FOG FOG
LAMP
LAMP
STOP
CENTER
HIGH
MOUNTED
2
PK/DB
20
F32
L50
20
WT/TN
L50
20
WT/TN
(8W-10-7)
(8W-10-6)
(8W-33-3)
(8W-35-2)
(8W-51-2) (8W-51-2) (8W-51-2)
(8W-51-3)
(8W-50-7)
(8W-50-7)
(8W-47-5)
(8W-50-7) (8W-50-7)
(8W-51-2)
GAS
XJ
J978W-7 XJI01019
16
19 18 20
17
11
13 15 14
12 2
4 5 3
1
7
10 8 9
6
13
12 14
11
10 2
4
8 5
6
FUEL
HEATER
RELAY
POWER DISTRIBUTION CENTER
MOTOR
STARTER
ENGINE
RELAY
D
C
10
11
14 12
13 6
5 8
4
2
RELAY
POWER
DIESEL
B
LAMP
FOG
RELAY
RELAY
CLUTCH
A/C
COMPRESSOR
RELAY
CONTROLLER
ANTI-LOCK
BRAKE
A
FUSES
14 7
6
7
30A
13
5
6
30A
12
4
5
40A
11
3
4
30A
10
2
3
50A
9
1
2
50A
8
21
15
16
17
18
19
20
22
23
24
25
26
27
28 15
12
40A
10
40A
9
50A
F21 20A F27 10A
1 2
F24 10A
F23 15A
4 3
F26 20A F20 20A
F16 15A F19 15A F25 15A
5 6
F22 20A
8 7
9 10
12 11
14 13
15 16
18 17
20 19
21 22
24 23
BATTERY
M1
8
30A
14
20A
13
11
40A
DIESEL
8W - 10 - 21
XJI01020 J978W-7
FUSES
1
- - -
A54 12RD/GY GLOW PLUG RELAY 50A
2
3
50A A54 12RD/GY GLOW PLUG RELAY
A16 12RD/LG 30A
4
A1 12RD IGNITION SWITCH 40A
5
6
30A A61 14LG/RD FUEL HEATER RELAY
7
30A
A4 12BK/PK
8
10
40A
A111 12RD/LG
9
50A
A2 12PK/BK IGNITION SWITCH
40A
11
-
40A
12
-
13
14
20A
-
15
M1 20PK
-
F32 20PK/DB
-
15A
16
17
-
-
18
19
15A
-
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
-
A0 6RD
-
-
A0 6RD
A7 10RD/BK
30A A3 16RD/WT A0 6RD
A4 14BK/PK (RHD)
26
20A F34 18TN/BK A0 6RD
20
20A
A17 20RD/BK
A0 6RD
21
20A F142 16DG/OR A142 16DG/OR
22
20A F75 16VT A0 6RD
23
15A L9 20BK/WT A0 6RD
24
10A F16 16RD/LG A16 12RD/LG
25
15A F61 20WT/OR FOG LAMP RELAY A0 6RD
27
10A F1 20DB/GY A17 20RD/BK
M1 20PK
A17 16RD/BK
A4 12BK/PK (LHD)
DIESEL
XJ
J978W-7 XJI01021
CONTROLLER ANTI-LOCK BRAKE INDICATOR OUTPUT G19 20LG/OR
CONTROLLER ANTI-LOCK BRAKE RELAY
B19
B16
B20
B18
Z1 20BK GROUND
- -
G83 20GY/WT
FUSED IGNITION (RUN)
F15 20DB/WT
A/C COMPRESSOR CLUTCH RELAY
B5
B3
B1
B4
B2
SWITCHED IGN. (ST-RUN) F142 18DG/OR
C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
A17 16RD/BK FUSED B(+)
-
A/C COMPRESSOR CLUTCH RELAY OUTPUT C3 12DB/BK
-
FOG LAMP RELAY OUTPUT L139 20WT
- -
FUSED B(+) F61 20WT/OR
GROUND Z1 20BK
B7
B9
B6
B8
FOG LAMP RELAY
B10
Z1 20BK GROUND
B17
F15 20DB/WT
FUSED IGNITION (RUN)
CONTROLLER ANTI-LOCK BRAKE RELAY CONTROL
DIESEL
8W - 10 - 23
XJI01022 J978W-7
FUSED B(+) A4 12BK/PK
ENGINE STARTER MOTOR RELAY
D10 (LHD)
D14
DIESEL POWER RELAY
C8
C5
C2
C6
C4
DIESEL POWER RELAY OUTPUT A142 16DG/OR
- -
K51 20DB/YL DIESEL POWER RELAY CONTROL
FUEL HEATER RELAY
D8
D5
D2
D6
D4
GROUND Z1 18BK
F12 18DB/WT FUSED IGN. (ST-RUN)
A61 14LG/RD FUSED B(+)
- -
A93 14RD/BK FUEL HEATER RELAY OUTPUT
D11
T141 20YL SWITCHED FUSED IGN. (ST)
D13
Z1 20BK GROUND
D12
- -
T40 14BR ENGINE STARTER MOTOR RELAY OUTPUT
A4 14BK/PK FUSED B(+)
D10 (RHD)
DIESEL
XJ
J978W-7 XJI01023
CENTER
DISTRIBUTION
POWER
BATTERY
ENGINE
STARTER
MOTOR
A0
2/0
RD RD
6
A0
2
FUSE
50A
50A
FUSE
3
4
FUSE
40A
5
FUSE
40A
D2
30A
FUSE
7
9
FUSE
50A
GENERATOR
A11
6
BK/WT
S118
A11
LINK
FUSIBLE
10
DG
D
(8W-10-26)
TO
FUSE
14 (PDC)
1
8
9
2
10
3
11
4
13
6
A4
12
BK/PK
22
15
RD/GY
12
A54
S153
TO TO
S153
TO
HEADLAMP
SWITCH
RD/WT
16
A3
FUEL
HEATER
RELAY
5
12
30A
FUSE
6
TO
JUNCTION
BLOCK
23
16
40A
FUSE
10
1 C2
A54
12
RD/GY
7
14
30A
FUSE
8
MOTOR
D10
ENGINE
STARTER
RELAY
RD/LG
12
A16 A1
12
RD
SWITCH
IGNITION
TO
TO
S151
A7
10
RD/BK
BLOCK
JUNCTION
TO
A2
12
PK/BK
SWITCH
IGNITION
TO TO
HVAC
UNIT
RD/LG
12
A111
24
17
40A
FUSE
11
12
FUSE
40A
18
25
A10
12
RD/DG
TO
BRAKE
ANTI-LOCK
CONTROLLER
1 C2
(8W-20-4)
(8W-21-4)
(8W-10-27)
(8W-10-27)
(8W-10-27)
(8W-10-28)
(8W-10-31)
(8W-20-4)
(8W-10-32)
(8W-30-19)
(8W-10-31)
(8W-10-28) (8W-10-31)
(8W-21-4)
(8W-10-32)
(8W-10-32)
DIESEL
8W - 10 - 25
XJI01024 J978W-7
SWITCH
HEADLAMP
TO
TN/BK
18
F34
A10
A9
23
FUSE
15A
A2
A1
10A
FUSE
27
A/C
COMPRESSOR
CLUTCH
RELAY
LAMP
UNDERHOOD
TO
PK
20
M1
F75
16
VT
TO
POWER
AMPLIFIER
LAMP
STOP
TO
PK/DB
20
F32
SWITCH
20A
FUSE
22
A11
A12 A3
A4
26
FUSE
20A
B6
15A
FUSE
25
RELAY
LAMP
FOG
A6
A5
F1
20
DB/GY
TO
OVERHEAD
MODULE FLASHER
COMBINATION
TO
BK/WT
20
L9
A15
A16
20
FUSE
20A
B1
M1
20
PK
TO
JUNCTION
BRAKE
D
(8W-10-25)
CENTER
DISTRIBUTION
POWER
ANTI-LOCK
CONTROLLER
TO
15A
FUSE
19 16
FUSE
15A 20A
FUSE
14
A20
14
RD/DG
FROM
FUSE
12 (PDC)
20
27
A23
A24
A18
A17
BLOCK
(8W-10-36) (8W-10-34)
(8W-42-8)
(8W-10-35) (8W-10-37) (8W-10-36)
(8W-50-8)
(8W-10-34)
(8W-10-34) (8W-10-32) (8W-10-35)
DIESEL
XJ
J978W-7 XJI01025
POWER
DISTRIBUTION
CENTER
BATT A0
1
2
FUSE
50A
A54
12
RD/GY
50A
FUSE
3
2
8 9
RD/GY
12
A54
S153
A54
10
RD/GY
GLOW
PLUG
RELAY
1
4
GY
10
K154
1
PLUG
GLOW
A16
12
RD/LG
10
3
4
FUSE
30A
RD/LG
12
A16
S151
A16
12
RD/LG RD/LG
12
A16
C8
C2 C4
DIESEL
POWER
RELAY
CENTER
DISTRIBUTION
POWER
10A
FUSE
24
A7
A8
C2 3
POWERTRAIN
CONTROL
MODULE
F16
16
RD/LG
A142
16
DG/OR DG/OR
16
A142
S137
A142
16
DG/OR
DG/OR
16
A142
45 C1 23 C1 C1 68 C2 57
DG/OR
A142
16 16
A142
DG/OR
E
(8W-10-35)
FUSE
21 (PDC)
TO
9
MODULE
PUMP
FUEL
DG/OR
16
A142 A142
16
DG/OR
7 C120
C2 2
GENERATOR
A142
16
DG/OR
ASSEMBLY
(8W-10-25)
(8W-10-25)
(8W-30-20)
(8W-30-18)
(8W-10-26)
(8W-30-18)
(8W-30-21)
(8W-30-22)
(8W-20-4)
(8W-30-20)
DIESEL
8W - 10 - 27
XJI01026 J978W-7
POWER
DISTRIBUTION
CENTER
BATT A0
4
5
FUSE
40A
A1
12
RD
C2
RD
12
A1
2
C2
1 C2
G26
20
LB
SWITCH
KEY-IN
C1
3
0
2
1 4
4
C1
3 C1
4 1
2
0
3
C1
10
C1 7
3
0
2
1 4
C1
9
3
0
2
1 4
8
C1
2 C1
G9
20
GY/BK
A2
12
PK/BK
C100
C6
PK/BK
12
A2
40A
FUSE
10
23
1
BK
20
Z1
3
0
2
1 4
YL
14
A41 A22
12
BK/OR
A21
12
DB
ST-RUN A21
BK/WT
12
A31
BK/LB
20
G16
11 16
PARK
BRAKE
SWITCH
SWITCH
PRESSURE
BRAKE
1
WARNING
G9
20
GY/BK
A14 C100
1
G9
18
GY/BK
66 C201
S211
S210
FROM
TO
S200
15A
FUSE
17
BLOCK
JUNCTION
L1 C4
18
FUSE
SPARE
30A
28
BREAKER
CIRCUIT CIRCUIT
BREAKER
30
20A
RUN A22
G108
G9
20
GY/BK
10 C201
A31
12
BK/WT
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
SWITCH
IGNITION
S207
Z1
14
BK
86
ST A41
CIGAR
LIGHTER
RELAY
RHD LHD
C203 10
LHD RHD
GY/BK
20
G9
(8W-10-25)
(8W-10-25)
(8W-10-29)
(8W-40-13)
(8W-40-13)
(8W-10-29)
(8W-10-29)
(8W-12-17)
(8W-12-18)
(8W-12-2)
(8W-12-17)
(8W-12-18) (8W-12-23)
(8W-12-24)
(8W-12-25)
(8W-10-30)
(8W-15-10)
(8W-15-10)
(8W-10-30)
(8W-41-2)
(8W-41-3)
DIESEL
XJ
J978W-7 XJI01027
A31
12
BK/WT
RUN-ACC A31
3
0
2
1 4
8
C1
29 C201
5 C300
G26
20
LB
LB
20
G26
5 C1
DB
12
A21
C201 64
27
FUSE
10A 20A
FUSE
11 10
FUSE
SPARE
BLOCK
JUNCTION
SPARE
FUSE
8
L2 C4
9
FUSE
10A
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
LEFT
FRONT
DOOR
JAMB
SWITCH
2
BK/LB
18
G16
C317 2
C200 17
S200
S210
LB
20
G26
RIGHT
FRONT
POWER
LOCK/
WINDOW
SWITCH/
C2
8
CLUSTER
INSTRUMENT
BATT A1
G26
20
LB
RD
12
A1
2
C2
1 C2
SWITCH
KEY-IN
C1 7
SWITCH
IGNITION
C1
9
3
0
2
1 4
A21
12
DB BK/LB
20
G16
RHD LHD
C305 13
C203 20
LHD RHD
19 C203
2 C318
G16
18
BK/LB
2
SWITCH
JAMB
DOOR
FRONT
RIGHT
LHD RHD
BK/LB
20
G16
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
C1
6
0
1
2
CHIME
MODULE
8
C2 C2
8
MODULE
SWITCH/
WINDOW
LOCK/
POWER
FRONT
LEFT
LB
20
G26
(8W-10-28)
(8W-12-23)
(8W-12-24)
(8W-12-13)
(8W-12-14)
(8W-12-11)
(8W-12-12)
(8W-12-2)
(8W-12-11)
(8W-12-12)
(8W-39-6)
(8W-39-7)
(8W-61-4)
(8W-40-14)
(8W-10-28)
(8W-10-28)
(8W-39-6)
(8W-39-7)
(8W-50-2)
(8W-50-3)
(8W-61-4)
(8W-12-11)
(8W-12-12)
DIESEL
8W - 10 - 29
XJI01028 J978W-7
BK/OR
12
A22
62
RELAY
DEFOGGER
WINDOW
REAR
86
20A
FUSE
22
C4 M2
12
FUSE
10A
JUNCTION
BLOCK
15A
FUSE
25 26
FUSE
10A
IGNITION
SWITCH
1 START
2 RUN
0 OFF
3 LOCK
4 ACC
BK/OR
12
A22 A41
14
YL
4 1
2
0
3
10
C1
3
0
2
1 4
C1 3
C1
4
PK/BK
12
A2
BATT A2
C201
63
A41
12
YL
10A
FUSE
19
M1 C4
LHD RHD RHD LHD
YL
14
A41
24
FUSE
SPARE
(8W-48-2)
(8W-48-3)
(8W-12-20)
(8W-12-21)
(8W-12-15)
(8W-12-16)
(8W-12-2)
(8W-12-20)
(8W-12-21)
(8W-12-23)
(8W-12-24)
(8W-10-28)
(8W-10-28)
(8W-12-17)
(8W-12-18)
(8W-12-20)
(8W-12-21)
DIESEL
XJ
J978W-7 XJI01029
12
30A
FUSE
6
5
1
FUEL
HEATER
A93
14
RD/BK
FUEL
HEATER
RELAY
D2
D8
CENTER
DISTRIBUTION
POWER
BATT A0
D14
D10
6
7
FUSE
30A
13
ENGINE
STARTER
MOTOR
RELAY
T40
14
BR
10
MOTOR
STARTER
ENGINE
BK/PK
12
A4
C1
87
30
JUNCTION
BLOCK
1 C2
RELAY
DEFOGGER
WINDOW
REAR
10A
FUSE
14 13
FUSE
SPARE
1
C6
C15
12
BK/WT
1
GRID
DEFOGGER
WINDOW
REAR
1 C315
3
C313
C310
C15
12
BK/WT
7
8
FUSE
30A
14
A3
16
RD/WT
D1 C100
A3
16
RD/WT
C1 8
SWITCH
HEADLAMP
A3
16
RD/WT
2
HEADLAMP
DELAY
MODULE
C110
1 C1
2
(8W-30-19)
(8W-30-19)
(8W-10-25)
(8W-10-25)
(8W-21-4)
(8W-21-4)
(8W-12-2)
(8W-48-2)
(8W-48-3)
(8W-48-2)
(8W-48-3)
(8W-50-2)
(8W-50-3)
(8W-50-2)
(8W-50-3)
(8W-12-15)
(8W-12-16)
(8W-12-15)
(8W-12-16)
DIESEL
8W - 10 - 31
XJI01030 J978W-7
9
A20
14
RD/DG RD/DG
12
A10
25
CONTROLLER
ANTI-LOCK
BRAKE
20
27
14
FUSE
20A 40A
FUSE
12
25
18 17
24
11
FUSE
40A
S131
LEFT
HORN
1 1
HORN
RIGHT
4
C2
X2
18
DG/RD RD
16
F30
CIGAR
LIGHTER
1
C4
M6
86 30
87 87
30
CENTER
DISTRIBUTION
POWER
BATT A0
50A
FUSE
9
15
RD/BK
10
A7
2 C2
1
FUSE
25A
25A
FUSE
2
25A
FUSE
15 21
FUSE
15A
20
FUSE
10A
30A
29
BREAKER
CIRCUIT
CIGAR
LIGHTER
RELAY
RELAY
HORN
BLOCK
JUNCTION
A111
12
RD/LG
D5 C100
C201 11
UNIT
HVAC
8
22
RHD LHD
7 C202
X2
20
DG/RD
X2
20
DG/RD
LHD
50 C201
RHD
(8W-35-4)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-10-25)
(8W-10-26)
(8W-10-25)
(8W-12-17)
(8W-12-18)
(8W-12-5)
(8W-12-5)
(8W-12-19)
(8W-12-19)
(8W-12-25)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-12-2)
(8W-42-5)
(8W-42-6)
DIESEL
XJ
J978W-7 XJI01031
1
GLOVE
BOX
LAMP
PK
20
M1 M1
20
PK PK
20
M1
RADIO
7 C2
M1
20
PK
4
C7
12 C1
JUNCTION
BLOCK
UNDERHOOD
LAMP
2
PK
20
M1
A23
A24
16
FUSE
15A
CENTER
DISTRIBUTION
POWER
BATT A0
C1 9
S214
INSTRUMENT
CLUSTER
RIGHT
COURTESY
LAMP
COURTESY
LEFT
LAMP
1 1
M1
20
PK
M1
20
PK
6 C201
M1
20
PK
S18
C4
M1
20
PK
PK
20
M1
PK
20
M1
PK
20
M1
S300
A C207
M1
18
PK
C208 A
PK
18
M1
5 C314
C305 3
M1
18
PK
3
SWITCH
WINDOW
LOCK/
POWER
FRONT
LEFT
M1
20
PK
A
LAMP/
CARGO
C3
3
2
COMPASS
PK
20
M1
PK
20
M1
A
DOME
LAMP/
OVERHEAD
MODULE
2 1
RIGHT
VANITY
LAMP
LAMP
VANITY
LEFT
1
S347
M1
20
PK
M1
20
PK
RHD LHD LHD RHD
PK
18
M1
C314 5
SWITCH
SWITCH
SWITCH
RIGHT
FRONT
POWER
LOCK/
WINDOW
SWITCH
3
C2
C2
M1
20
PK
(RHD)
(8W-44-5)
(8W-47-2)
(8W-12-2) (8W-44-4)
(8W-10-26)
(8W-10-25)
(8W-40-2)
(8W-44-5) (8W-44-5)
(8W-62-2)
(8W-49-2)
(8W-49-3)
(8W-39-4)
(8W-44-4)
(8W-44-4)
(8W-44-6)
(8W-44-5)
(8W-62-4)
DIESEL
8W - 10 - 33
XJI01032 J978W-7
POWER
DISTRIBUTION
CENTER
BATT A0
15A
FUSE
19
A17
A18
F32
20
PK/DB
F8
5
6
STOP
LAMP
SWITCH
L50
20
WT/TN
S203
B4 C100
12
CONTROLLER
ANTI-LOCK
BRAKE
C200 24
L50
18
WT/TN
MOUNTED
HIGH
CENTER
2
STOP
LAMP
D C308
L50
20
WT/TN
S302
LAMP
STOP
TAIL/
LEFT
C322 6
WT/TN
18
L50
3
3
L50
18
WT/TN
6 C321
RIGHT
TAIL/
STOP
LAMP
C100
WT/TN
20
L50
L50
20
WT/TN WT/TN
20
L50
WT/TN
20
L50
S147
C1 44
MODULE
CONTROL
POWERTRAIN
RELAY
CLUTCH
COMPRESSOR
A/C
20A
FUSE
20
A15
A16
B1
B2
DB/BK
12
C3
A1
A2
27
FUSE
10A
F1
20
DB/GY
E10 C100
8
19 C201
F1
20
DB/GY
MODULE
OVERHEAD
F1
20
DB/GY
6 C120
C3
14
DB/BK
1
A/C
COMPRESSOR
CLUTCH
C302 2
LHD RHD
LHD RHD
6 C204
C427 1
LAMP
STOP
2
CENTER
HIGH
MOUNTED
L50
20
WT/TN
(8W-10-26)
(8W-10-25)
(8W-33-5)
(8W-35-4)
(8W-51-3) (8W-51-3)
(8W-51-3)
(8W-30-26)
(8W-42-8)
(8W-39-4)
(8W-42-8)
(8W-51-3)
DIESEL
XJ
J978W-7 XJI01033
S301
F75
16
VT VT
16
F75
POWER
AMPLIFIER
F75
14
VT
C200 14
VT
16
F75
C100 C4
F75
16
VT
BATT A0
A11
A12
22
FUSE
20A
DG/OR
18
F142 F142
18
DG/OR
MASS
AIR
FLOW
SENSOR
3
RELAY
CLUTCH
COMPRESSOR
A/C
B5
GLOW
PLUG
RELAY
2
10
MODULE
PUMP
FUEL
A
S156
F142
18
DG/OR DG/OR
18
F142 F142
16
DG/OR
CENTER
DISTRIBUTION
POWER
A142
16
DG/OR
FROM
S137
E
(8W-10-27)
DG/OR
16
F142
20A
FUSE
21
A13
A14
3 C204
LHD RHD
1 C2 C2 2
MODULATOR
VACUUM
ELECTRONIC
(8W-47-5)
(8W-10-25)
(8W-30-22)
(8W-42-8)
(8W-30-20)
(8W-30-21)
(8W-30-22)
(8W-10-26)
(8W-30-19)
DIESEL
8W - 10 - 35
XJI01034 J978W-7
LB
20
L39
LB
20
L39
LB
20
L39
LB
20
L39
LB
20
L39
VT
20
L139
A4 C100
C106 8
S106
RIGHT
LAMP LAMP
LEFT
2 2
2
FRONT
FOG
LAMP
SWITCH
3
A5
L139
20
WT
RELAY
LAMP
FOG
B6
B7
15A
FUSE
25
A5
A6
C100
POWER
DISTRIBUTION
CENTER
BATT A0
A9
A10
23
FUSE
15A
BK/WT
20
L9
B11
L9
20
BK/PK
2
COMBINATION
FLASHER FOG FOG
(8W-50-8) (8W-50-8)
(8W-50-8)
(8W-50-8)
(8W-10-26)
(8W-10-25)
(8W-52-2)
(8W-52-3)
DIESEL
XJ
J978W-7 XJI01035
IND.
LAMP
FOG
REAR
RIGHT LEFT
REAR
FOG
LAMP
C321 4 4 C322
BR/WT
16
L38
S308
L38
16
BR/WT
L38
18
BR/WT
C203 15
SWITCH
LAMP
FOG
REAR
3
BR/WT
18
L38
BR/WT
18
L38
S220
L38
18
BR/WT
REAR
FOG
LAMP
RELAY
4
1
TN/BK
18
F34
TN/BK
18
F34
S218
RHD LHD
C1 4
SWITCH
HEADLAMP
16
CONNECTOR
LINK
DATA
F34
18
TN/BK
TN/BK
18
F34
DATA
LINK
CONNECTOR
16
HEADLAMP
SWITCH
4 C1
TN/BK
18
F34
C100 A18
F34
18
TN/BK
A4
A3
26
FUSE
20A
POWER
DISTRIBUTION
CENTER
BATT A0
(8W-51-6) (8W-51-6) (8W-51-6)
(8W-51-6)
(8W-50-3)
(8W-30-29)
(8W-30-29)
(8W-50-2)
(8W-10-26)
(8W-10-25)
DIESEL
8W - 10 - 37
XJI01036 J978W-7
8W-12 J UNCTION BLOCK
INDEX
page
Component Page
4WD Swi tch I l l umi nati on . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 9
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . . . . . . . .8W-12-14
A/C Heater Control . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 9
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . . . .8W-12-23, 24
Automati c Shut Down Rel ay . . . . . . . . . . . . . . . . . . . . .8W-12-14
Back-Up Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13, 14
Beam Sel ect Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-6, 7
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-12-27, 32
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-5
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-12-5, 33
Ci rcui t Breaker 28 (JB). . . . . . . . . . . . . . . . . . . . . .8W-12-23, 24
Ci rcui t Breaker 29 (JB). . . . . . . . . . . . . . . . . . . . . . . .8W-12-25
Ci rcui t Breaker 30 (JB). . . . . . . . . . . . . . . . . . . . . . . .8W-12-25
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Cl utch I nterl ock Swi tch. . . . . . . . . . . . . . . . . . . . . .8W-12-17, 18
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . . . . . . . . . . .8W-12-18
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . . . . .8W-12-15, 16
Compass . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 12, 26, 33
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . . . . . .8W-12-20, 21
Control l er Anti -Lock Brake Rel ay . . . . . . . . . . . . . . . .8W-12-20, 21
Cool i ng Fan Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-14
Dome Lamp/Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-12-26, 33
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-12-25
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . . . .8W-12-14
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . . . . .8W-12-17, 18
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 9
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-25
Fuel Heater Rel ay. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-14
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-5
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-5
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-6
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-7
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-7
Fuse 6 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 9
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 12
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 12
Fuse 10 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 12
Fuse 11 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13, 14
Fuse 12 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-15, 16
Fuse 13 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-15, 16
Fuse 14 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-15, 16
Fuse 15 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-17, 18
Fuse 16 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-6
Fuse 16 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-32
Fuse 17 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-17, 18
Fuse 18 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-17, 18
Fuse 19 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-17, 18
Fuse 20 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Fuse 21 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Fuse 22 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-20, 21
Fuse 23 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-22
Fuse 24 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-20, 21
Fuse 25 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-20, 21
Fuse 26 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-23, 24
Fuse 27 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-23, 24
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-33
Headl amp Del ay Modul e . . . . . . . . . . . . . . . . . . . . .8W-12-11, 12
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-12-7
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . .8W-12-8, 9, 10, 22, 26
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
HVAC Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-20, 21
I nstrument Cl uster . . . . . . . . . . . . . . . . .8W-12-8, 9, 11, 12, 15, 16
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-2
Left Courtesy Lamp. . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-26
Left Front Door Jamb Swi tch . . . . . . . . . . . . . . . . . . . .8W-12-27
Left Front Door Lock Motor . . . . . . . . . . . . . . . . . . .8W-12-28, 29
Left Front Power Lock/Wi ndow Swi tch . . . . . . . . .8W-12-23, 30, 31, 32
Left Front Power Lock/Wi ndow Swi tch/Modul e . . . . .8W-12-18, 24, 29, 30
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-6, 7
Left Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Left Posi ti on Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
Left Power Mi rror . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-15, 31
Component Page
Left Rear Door Jamb Swi tch . . . . . . . . . . . . . . . . . . . . .8W-12-27
Left Rear Door Lock Motor . . . . . . . . . . . . . . . . . . . .8W-12-28, 29
Left Rear Wi ndow Swi tch. . . . . . . . . . . . . . . . . . . . . . .8W-12-30
Left Tai l /Stop Lamp. . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
Left Turn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
Li ft Gate Door Lock Motor . . . . . . . . . . . . . . . . . . . .8W-12-28, 29
Overhead Modul e . . . . . . . . . . . . . . . . . . . . . . .8W-12-19, 26, 33
Passenger Power Seat Swi tch . . . . . . . . . . . . . . . . . . . .8W-12-25
Power Di stri buti on Center . . . . . . . . . . . . . . . . . . . . . .8W-12-32
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-5
Powertrai n Control Modul e. . . . . . . . . . . . . . . . . . . .8W-12-13, 14
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 9
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 9, 17, 18
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-9
Rear Wi ndow Defogger Gri d . . . . . . . . . . . . . . . . . . .8W-12-15, 16
Rear Wi ndow Defogger Rel ay. . . . . . . . . . . . . . . . . . .8W-12-15, 16
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . . . . .8W-12-8, 9, 15, 16
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-20, 21
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . . . . .8W-12-8, 9, 20, 21
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-26
Ri ght Front Door Jamb Swi tch . . . . . . . . . . . . . . . . . . . .8W-12-27
Ri ght Front Door Lock Motor . . . . . . . . . . . . . . . . . . .8W-12-28, 29
Ri ght Front Power Lock/Wi ndow Swi tch . . . . . . . . . . .8W-12-24, 30, 33
Ri ght Front Power Lock/Wi ndow Swi tch/Modul e . .8W-12-17, 23, 28, 30, 33
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-6, 7
Ri ght Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
Ri ght Posi ti on Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-22
Ri ght Power Mi rror . . . . . . . . . . . . . . . . . . . .8W-12-15, 16, 31, 33
Ri ght Rear Door Jamb Swi tch . . . . . . . . . . . . . . . . . . . .8W-12-27
Ri ght Rear Door Lock Motor . . . . . . . . . . . . . . . . . . .8W-12-28, 29
Ri ght Rear Wi ndow Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-12-30
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-22
Ri ght Turn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-14
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-13, 14
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
S133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-7
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-20, 21
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-32
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-14
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-26
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-15
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10, 22
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-33
S213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-6
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-32
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8, 9
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 12
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-32
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-27
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-30
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-28, 29
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-28, 29
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-33
S315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-8
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-28
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-28
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-31
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-33
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-29
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-29
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-31
S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-19
S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-10
S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-33
S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-26
S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-32
Tel l Tal e Modul e. . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-11, 12
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . . . . .8W-12-10, 19
Transmi ssi on Control Modul e . . . . . . . . . . . . . . . . . .8W-12-14, 32
Transmi ssi on Range Swi tch . . . . . . . . . . . . . . . . . . . . .8W-12-14
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-12-32
Wi ndshi el d Wi per/Washer Swi tch . . . . . . . . . . . . . . . . . .8W-12-25
XJ 8W - 12 JUNCTION BLOCK 8W - 12 - 1
JUNCTION BLOCK
FRONT OF
27 10A 14
13 26
12 10A 25 15A
10A 23 10
24 20A 11
9 10A 22 20A
8 21 15A
10A 16 10A 3
5 10A 18
4 10A 17 15A
10A 19 5A 6
10A 20 10A 7
C1
C2
C8
C4
C5
C7 C6
C9
C3
1 25A
25A 2 25A 15
SPARE
RELAY
30
28
29
10A
10A
30A 30A
20A
CIGAR
LIGHTER
RELAY
HORN
WINDOW
REAR
RELAY
RELAY
DEFOGGER
8W - 12 - 2 8W-12 JUNCTION BLOCK XJ
J978W-7 XJI01201
FUSES
1
25A F38 16RD/LB A7 10RD/BK
2
3
L33
L43
4
5
6
E2 20OR
7
L77
8
10
F12 18DB/WT
9
F87 20WT/BK
L5 20BK
11
12
L3 16RD/OR
L7 18BK/YL
A21 12DB
25A
10A
10A
5A
10A
10A
20A
10A
E1 20TN
A22 12BK/OR
A7 10RD/BK -
A21 12DB
A21 12DB
A21 12DB
- -
- -
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
L4 16VT/WT
10A L44 L4 16VT/WT
A22 12BK/OR
A22 12BK/OR
A22 12BK/OR
A41
A7 10RD/BK
A7 10RD/BK
A7 10RD/BK
A4 14PK/BK
C15
A31 12BK/WT
A31 12BK/WT
A31 12BK/WT
A31 12BK/WT
A21 12DB
A7 10RD/BK
L3 16RD/OR
L7 18BK/YL
C16
- -
10A
25A F35 16RD
15A X12 16RD/WT
- -
10A F45 20YL/RD
10A A6 20RD/OR
- 15A
20A V23 18BR/PK
- -
15A F15 20DB/WT
10A F14 18LG/YL
10A F23 18DB/YL
30A F81 12TN
30A F37 14RD/LB
20A V6 16DB
10A L34
10A L78
CB NO. AMPS FUSED CIRCUIT FEED CIRCUIT
CIRCUIT BREAKERS
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 3
XJI01202 J978W-7
HORN RELAY CONTROL
FUSED B (+)
HORN RELAY
30
85
86
87
X3 20BK/RD
A2
X2
- -
-
REAR WINDOW DEFOGGER RELAY
30
85
86
87
A4 12PK/BK
C81 20LB/WT
L5
C15
FUSED B (+)
FUSED B (+)
REAR WINDOW DEFOGGER RELAY OUTPUT
REAR WINDOW DEFOGGER RELAY CONTROL
FUSED B (+) -
HORN RELAY OUTPUT
-
- -
GROUND
CIGAR LIGHTER RELAY OUTPUT
FUSED B (+)
FUSED B (+)
F30 16RD
A31 12BK/WT
C81 20LB/WT
87
86
85
30
CIGAR LIGHTER RELAY
-
- -
- -
SPARE RELAY
30
85
86
87
87A
- -
- -
- -
- -
-
J978W-7 XJI01203
JUNCTION
BLOCK
1
FUSE
25A
BATT A7
F38
16
RD/LB
2
POWER
OUTLET
M5
C4
RD/LB
16
F38
87
30
BATT A7
25A
FUSE
2
M6
C4
RD
16
F30
F30
16
RD
LIGHTER
CIGAR
1
CIGAR
LIGHTER
RELAY
65 C201 C201 50
LHD RHD LHD RHD
(8W-12-2)
(8W-10-11)
(8W-41-2)
(8W-41-3)
(8W-10-11)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
XJI01204 J978W-7
JUNCTION
BLOCK
3
FUSE
10A
9
C1
10A
FUSE
16
C1
11
2
A
LEFT
HEADLAMP
C106 6
L34
18
RD/OR RD
20
L33
HEADLAMP
RIGHT
A
L34
18
BEAM
SELECT
S7 C4
RD/OR
16
L3
SWITCH
2
C201 16
L3
16
RD/OR
S213
RD/OR
16
L3
LHD RHD
RD/OR
20
L34
DIESEL GAS
RD/OR RD
GAS DIESEL
L33
20
RD
18
L33
(8W-12-2)
(8W-50-4) (8W-50-4)
(8W-50-2)
(8W-50-3)
(8W-50-2)
(8W-50-3)
J978W-7 XJI01205
JUNCTION
BLOCK
4
FUSE
10A
10
C1
10A
FUSE
5
C1
1
9
B
LEFT
HEADLAMP
C106 13
L44
18
VT/RD VT
20
L43
HEADLAMP
RIGHT
B
BEAM
SELECT
S3 C4
SWITCH
4
VT/WT
16
L4
L4
16
VT/WT
S133
LHD RHD
LHD RHD
C201 22
GAS
L43
20
VT VT
DIESEL
18
L43
USED
NOT
C100 B12
GAS
L44
20
VT/RD VT/RD
DIESEL
18
L44
L44
18
DIESEL
VT/RD VT/RD
20
L44
GAS GAS
L44
20
VT/RD VT/RD
DIESEL
18
L44
B12 C100
VT/RD
18
L44
B
HEADLAMP
LEVELING
SWITCH
(8W-12-2)
(8W-50-4) (8W-50-4)
(8W-50-2)
(8W-50-3)
(8W-50-9)
XJI01206 J978W-7
43 C201
JUNCTION
BLOCK
6
FUSE
5A
S2
C4
E2
20
OR
S1 C4
42 C201
E1
20
TN
HEADLAMP
SWITCH
1
S315
E2
20
OR OR
20
E2
1 C206
E2
20
OR
E2
20
OR
1 1
4WD
SWITCH ILLUMINATION
PRNDL
(A/T)
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
S215
E2
20
OR
RADIO
C2 5
LAMP
1
FRONT
FOG
SWITCH
SWITCH
WINDOW
REAR
4
DEFOGGER
3 C1
INSTRUMENT
CLUSTER
HEATER
A/C
1
CONTROL
WASHER
3
REAR
WIPER/
TN
20
E1
C1
ILLUMINATION
SWITCH
(8W-12-2)
(8W-50-2)
(8W-44-2)
(8W-47-2)
(8W-50-7)
(8W-50-8)
(8W-48-2)
(8W-40-17)
(8W-44-2)
(8W-44-5)
(8W-53-3)
(8W-44-2)
8W - 12 - 8 8W-12 JUNCTION BLOCK
LHD
XJ
J978W-7 XJI01207
OR/BK
20
E2
C203 11
OR
20
E2
1 C206
E2
20
OR
E2
20
OR
1 1
4WD
SWITCH ILLUMINATION
PRNDL
(A/T)
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
S215
RADIO
C2 5
LAMP
1
FRONT
FOG
SWITCH
SWITCH
WINDOW
REAR
4
DEFOGGER
3 C1
INSTRUMENT
CLUSTER
HEATER
A/C
1
CONTROL
WASHER
3
REAR
WIPER/
JUNCTION
BLOCK
6
FUSE
5A
S2
C4
E2
20
OR
S1 C4
E1
20
TN
HEADLAMP
SWITCH
1
C1
OR
20
E2
SWITCH
FOG
REAR
4
LAMP
ILLUMINATION
SWITCH
(8W-44-3)
(8W-47-2)
(8W-50-7)
(8W-50-8)
(8W-48-3)
(8W-40-17)
(8W-42-3)
(8W-42-4)
(8W-42-6)
(8W-53-3)
(8W-12-2)
(8W-50-3)
(8W-51-6)
(8W-44-3)
XJ 8W-12 JUNCTION BLOCK
RHD
8W - 12 - 9
XJI01208 J978W-7
JUNCTION
BLOCK
7
FUSE
10A
6
C2 C7
2
M3 C4
BR
18
L77
45 C201
RHD LHD
L7
18
BK/YL
HEADLAMP
SWITCH
9
B8
RELAY
LAMP
FOG
L77
20
BR/YL
7 C106
1
LICENSE
LAMP
L77
20
BR
POSITION
LEFT
1
LAMP
BR
18
L77 L77
18
BR
S311
7 C322
C308 H
BR
18
L77
C310
C311 4
11
L77
20
BR
3
TRAILER
TOW
CONNECTOR
S340
LAMP
STOP
TAIL/
LEFT
2
OTHERS TOW
TRAILER
L77
18
BR
7 C323
L77
18
BR
L77
20
BR
L77
20
BR
S206
C1
GAS
L77
20
BR/YL BR/YL
DIESEL
18
L77
FOG
LAMP
RELAY
B10
BR/YL
20
L77
(8W-12-2)
(8W-50-2)
(8W-50-3)
(8W-50-8)
(8W-51-2)
(8W-51-3)
(8W-50-5)
(8W-50-6)
(8W-54-2)
(8W-51-2)
(8W-51-3)
(8W-70-6)
(8W-50-7)
J978W-7 XJI01209
JUNCTION
BLOCK
8
FUSE
SPARE
ST-RUN A21
C4
S13
COMPASS
6
SPARE
FUSE
10 9
FUSE
10A
F87
20
WT/BK
6 C301
WT/BK
20
F87 F87
20
WT/BK
C201 5
F87
20
WT/BK
DELAY
HEADLAMP
8
MODULE
CLUSTER
INSTRUMENT
8 C1
F87
20
WT/BK WT/BK
20
F87
S216
F87
20
WT/BK
OPTIONS
FULL
BASE
WT/BK
20
F87
F87
20
WT/BK
1
TELL
TALE
(DIESEL)
MODULE
(8W-12-2)
(8W-10-9)
(8W-49-2)
(8W-50-2)
(8W-40-2)
(8W-40-7)
LHD
8W - 12 - 11
XJI01210 J978W-7
WT/BK
20
F87
JUNCTION
BLOCK
8
FUSE
SPARE
ST-RUN A21
C4
S13
COMPASS
6
SPARE
FUSE
10 9
FUSE
10A
6 C301
WT/BK
20
F87
DELAY
HEADLAMP
8
MODULE
CLUSTER
INSTRUMENT
8 C1
F87
20
WT/BK
WT/BK
20
F87
S216
F87
20
WT/BK
WT/BK
20
F87
MODULE
1
TALE
TELL
(DIESEL)
(8W-12-2)
(8W-10-9)
(8W-49-2)
(8W-50-3)
(8W-40-2)
(8W-40-7)
RHD
XJ
J978W-7 XJI01211
JUNCTION
BLOCK
11
FUSE
20A
ST-RUN A21
C2
5
F12
18
DB/WT
S130
D4
RELAY
FUEL
HEATER
(IN PDC)
F12
18
DB/WT
DB/WT
18
F12
7 C110
F12
18
DB/WT
B
BACK-UP
SWITCH
MODULE
POWERTRAIN
CONTROL
38 C1 C2 9
DB/WT
18
F12 F12
18
DB/WT
(8W-12-2)
(8W-10-29)
(8W-30-19)
(8W-51-5)
(8W-30-18)
DIESEL
8W - 12 - 13
XJI01212 J978W-7
JUNCTION
BLOCK
11
FUSE
20A
ST-RUN A21
C2
5
F12
18
DB/WT
CONTROL
TRANSMISSION
26
MODULE
CONTROL
POWERTRAIN
A2 C1
S130
S136
DB/WT
18
F12
MODULE
F12
18
DB/WT
DB/WT
18
F12
10 C107
F12
18
DB/WT
PURGE
2
DUTY
CYCLE
SOLENOID
F12
18
DB/WT
SWITCH
3
TRANSMISSION
RANGE
C4
RELAY
DOWN
AUTOMATIC
SHUT
(IN PDC)
(IN PDC)
FAN
COOLING
RELAY
C11 D4
RELAY
FUEL
PUMP
(IN PDC)
(IN PDC)
COMPRESSOR
A/C
CLUTCH
RELAY
B5
F12
18
DB/WT
F12
18
DB/WT
F12
18
DB/WT
F12
18
DB/WT DB/WT
18
F12
(A/T) (A/T)
DB/WT
18
F12
A
BACK-UP
SWITCH
S116
A/T M/T
LHD RHD
LHD RHD
F12
18
DB/WT
F12
18
DB/WT DB/WT
18
F12
DB/WT
18
F12
EVAP/
(8W-12-2)
(8W-10-9)
(8W-30-2)
(8W-30-12)
(8W-30-2)
(8W-42-7) (8W-30-3)
(8W-30-4)
(8W-42-7)
(8W-31-3) (8W-31-2)
(8W-51-5)
GAS
XJ
J978W-7 XJI01213
JUNCTION
BLOCK
12
FUSE
10A
RUN A22
S20
C4
85 87
30 86
BATT A4
10A
FUSE
14
C4
S26 3
C9
REAR
WINDOW
DEFOGGER
C81
20
LB/WT
L5
20
BK
RELAY
13
FUSE
SPARE
C4
S19
BK/WT
20
C16
1
C6
BK/WT
12
C15
3
BK
20
L5
1
COMBINATION
FLASHER
LB/YL
20
C16
S202
C16
20
LB/YL
WINDOW
REAR
3
DEFOGGER
SWITCH
LB/YL
20
C16
37 C200
11 C305
MIRROR
5
LEFT
POWER
CLUSTER
INSTRUMENT
3
C16
20
LB/YL
POWER
RIGHT
5
MIRROR
GRID
DEFOGGER
1
REAR
WINDOW
1 C315
C313 2
C310
C15
12
BK/WT
BK/WT
12
C15
C1
C2
17
LB/WT
20
C81
BK/WT
20
C16
2 C201
3
(8W-12-2)
(8W-10-10) (8W-10-13)
(8W-52-2)
(8W-52-3)
(8W-48-2)
(8W-48-2)
(8W-40-15)
(8W-48-2)
(8W-48-2)
LHD
8W - 12 - 15
XJI01214 J978W-7
5
C5
LB/YL
20
C16
JUNCTION
BLOCK
12
FUSE
10A
RUN A22
S20
C4
85 87
30 86
BATT A4
10A
FUSE
14
C4
S26
REAR
WINDOW
DEFOGGER
C81
20
LB/WT
RELAY
13
FUSE
SPARE
C16
20
BK/WT
C4
S19 1
C6
BK/WT
12
C15
BK
20
L5
1
COMBINATION
FLASHER
C16
20
LB/YL
WINDOW
REAR
3
DEFOGGER
SWITCH
22 C204
11 C305
MIRROR
5
RIGHT
POWER
CLUSTER
INSTRUMENT
3
C16
20
LB/YL
GRID
DEFOGGER
1
REAR
WINDOW
1 C315
C313 2
C310
C15
12
BK/WT
BK/WT
12
C15
C1
C2
3
(8W-12-2)
(8W-10-10) (8W-10-13)
(8W-52-2)
(8W-52-3)
(8W-48-3)
(8W-48-3)
(8W-40-15)
(8W-48-3)
RHD
XJ
J978W-7 XJI01215
JUNCTION
BLOCK
15
FUSE
25A
BATT A7
9
C9
RUN-ACC A31
15A
FUSE
17 19
FUSE
10A
C4
S9 3
C1
F35
16
RD
SWITCH/
WINDOW
5
RIGHT
FRONT
C2
LOCK/
POWER
RD/WT
16
X12
18
FUSE
SPARE
F45
20
YL/RD
ST A41
C201 54
X12
16
RD/WT
C2
RADIO
6
M/T A/T
MOTOR
RELAY
STARTER
ENGINE
(IN PDC)
D13
2
1
SWITCH
INTERLOCK
CLUTCH
YL/RD
20
F45 F45
20
YL/RD
YL
20
T141
D13
(IN PDC)
ENGINE
STARTER
RELAY
MOTOR
MODULE
GAS DIESEL
MOTOR
RELAY
STARTER
ENGINE
(IN PDC)
D11
(8W-12-2)
(8W-10-11) (8W-10-8) (8W-10-10)
(8W-47-2)
(8W-21-2)
(8W-21-3)
(8W-61-2)
(8W-21-4)
LHD
8W - 12 - 17
XJI01216 J978W-7
JUNCTION
BLOCK
15
FUSE
25A
BATT A7 RUN-ACC A31
15A
FUSE
17 19
FUSE
10A
C4
S9 3
C1
18
FUSE
SPARE
F45
20
YL/RD
ST A41
X12
16
RD/WT
C2
RADIO
6
M/T A/T
2
1
SWITCH
INTERLOCK
CLUTCH
F45
20
YL/RD
YL
20
T141
E7 C100
YL/RD
20
F45
CLUTCH
INTERLOCK
SWITCH
1
2
YL/RD
20
F45
JUMPER
T141
20
YL
T141
20
YL
POWER
C2
FRONT
LEFT
5
SWITCH/
RD
16
F35
C5
7
12 C204
1 C306
F35
16
RD
RD
16
F35
LOCK/
WINDOW
MODULE
C100 E8
D13
(IN PDC)
ENGINE
STARTER
RELAY
MOTOR
GAS DIESEL
MOTOR
RELAY
STARTER
ENGINE
(IN PDC)
D11
(8W-12-2)
(8W-10-11) (8W-10-8) (8W-10-10)
(8W-47-2)
(8W-61-3)
(8W-21-2)
(8W-21-3)
(8W-21-4)
RHD
XJ
J978W-7 XJI01217
JUNCTION
BLOCK
20
FUSE
10A
BATT A7
8
C7
21
FUSE
15A
85 87
30 86
HORN
RELAY
C5
1 S22
C4 C2
4
C322
A6
20
RD/OR
3
RD/OR
20
A6
BK/RD
20
X3
1 C302
X3
20
BK/RD
X3
20
BK/RD
26 C201
BK/RD
20
X3
X2
20
DG/RD DG/RD
20
X2
S131
4
TRAILER
TOW
CONNECTOR
10
OVERHEAD
MODULE HORN
LEFT
1 1
RIGHT
HORN SWITCH
HORN
CLOCKSPRING
1
1
C5
RHD LHD LHD RHD
S22
C4
BK/RD
20
X3
TURN
LEFT
3
RELAY RELAY
3
RIGHT
TURN
A6
20
RD/OR
S338
RD/OR
20
A6
RD/OR
20
A6
GAS
X2
20
DG/RD DG/RD
DIESEL
18
X2
(8W-12-2)
(8W-10-11)
(8W-54-2)
(8W-39-8) (8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-54-2) (8W-54-2)
XJI01218 J978W-7
JUNCTION
BLOCK
22
FUSE
20A
RUN A22
S11
C4
6
C1
SPARE
FUSE
24 25
FUSE
15A
C4
S8
V23
18
BR/PK
39 C201
BR/PK
18
V23
9
HVAC
UNIT
DB/WT
20
F15
WASHER
5
REAR
WIPER/
6
V23
18
BR/PK
C200 29
BR/PK
18
V23
F C308
V23
18
BR/PK
2 C312
C310 7
BR/PK
18
V23
MOTOR
4
REAR
WIPER
BRAKE
CONTROLLER
ANTI-LOCK
23
RELAY
BRAKE
CONTROLLER
ANTI-LOCK
B20
F15
20
DB/WT
S134
DB/WT
20
F15
F15
20
DB/WT
(IN PDC)
(IN PDC)
DB/WT
20
F15
B18
ANTI-LOCK
CONTROLLER
BRAKE
RELAY
23
ANTI-LOCK
CONTROLLER
BRAKE
F15
20
BK/WT
F15
20
BK/WT
DIESEL GAS
SWITCH
(8W-12-2)
(8W-10-10)
(8W-42-2)
(8W-42-5)
(8W-53-3)
(8W-53-3)
(8W-35-3)
(8W-35-3)
(8W-35-5)
(8W-35-5)
LHD
XJ
J978W-7 XJI01219
JUNCTION
BLOCK
22
FUSE
20A
RUN A22
S11
C4
6
C1
SPARE
FUSE
24 25
FUSE
15A
C4
S8
BR/PK
18
V23
9
HVAC
UNIT
SWITCH
6
REAR
WIPER/
5
V23
18
BR/PK
C203 17
BR/PK
18
V23
F C308
V23
18
BR/PK
2 C312
C310 7
BR/PK
18
V23
MOTOR
4
REAR
WIPER
DB/WT
20
F15
F15
20
DB/WT
BRAKE
CONTROLLER
ANTI-LOCK
23
RELAY
BRAKE
CONTROLLER
ANTI-LOCK
B20
F15
20
DB/WT
S134
DB/WT
20
F15
F15
20
DB/WT
(IN PDC)
(IN PDC)
DB/WT
20
F15
B18
ANTI-LOCK
CONTROLLER
BRAKE
RELAY
23
ANTI-LOCK
CONTROLLER
BRAKE
F15
20
BK/WT
F15
20
BK/WT
DIESEL GAS
WASHER
(8W-12-2)
(8W-10-10)
(8W-42-3)
(8W-42-4)
(8W-42-6)
(8W-53-3)
(8W-53-3)
(8W-35-3)
(8W-35-3)
(8W-35-5)
(8W-35-5)
RHD
8W - 12 - 21
XJI01220 J978W-7
7 C321
DG/YL
18
L78
DG/YL
L78
20
POSITION
RIGHT
1
LAMP
14 C106
JUNCTION
BLOCK
23
FUSE
10A
5
C1 C7
6
DG/YL
18
L78
M3 C4
BK/YL
18
L7
45 C201
RHD LHD
L7
18
BK/YL
HEADLAMP
SWITCH
9
2
RIGHT
TAIL/
STOP
LAMP
S206
GAS
L78
20
DG/YL DG/YL
DIESEL
18
L78
(8W-50-5)
(8W-50-6)
(8W-12-2)
(8W-50-2)
(8W-50-3)
(8W-51-2)
(8W-51-3)
(8W-70-6)
J978W-7 XJI01221
RUN A22
MODULE
AIRBAG
CONTROL
JUNCTION
BLOCK
27
FUSE
10A
ST-RUN A21
C4
S23
17 20
S21
C4
10A
FUSE
26
30A
28
BREAKER
CIRCUIT
RUN-ACC A31
8
C5 C8
1
F81
12
TN
4
FRONT
RIGHT
POWER
C2
LOCK/
WINDOW
SWITCH/ SWITCH
WINDOW
LOCK/
C1
POWER
LEFT
FRONT
9
1 C307
TN
12
F81
TN
12
F81
LG/YL
18
F14 F23
18
DB/YL
13 C201
F81
12
TN
33 C200
TN
12
F81
MODULE
(8W-10-10)
(8W-43-2)
(8W-12-2)
(8W-10-9) (8W-10-8)
(8W-60-2)
(8W-61-2)
LHD
8W - 12 - 23
XJI01222 J978W-7
TN
12
F81
RUN A22
MODULE
AIRBAG
CONTROL
JUNCTION
BLOCK
27
FUSE
10A
ST-RUN A21
C4
S23
DB/YL
18
F23
17
F14
18
LG/YL
20
S21
C4
10A
FUSE
26
30A
28
BREAKER
CIRCUIT
RUN-ACC A31
8
C5 C8
1
F81
12
TN TN
12
F81
11 C204 10
LG/YL
18
F14 F23
18
DB/YL
C202 3
SWITCH/
WINDOW
LOCK/
C2
POWER
LEFT
FRONT
4
F81
12
TN
C307 1
SWITCH
WINDOW
LOCK/
C1
POWER
RIGHT
FRONT
9
MODULE
(8W-10-10)
(8W-43-3)
(8W-12-2)
(8W-10-9) (8W-10-8)
(8W-60-4)
(8W-61-3)
RHD
XJ
J978W-7 XJI01223
(PART OF
SWITCH)
FUNCTION
MULTI-
5
FRONT
SWITCH
MOTOR
WINDSHIELD
WIPER
1
DB
16
V6
DB
16
V6
SEAT
DRIVER
POWER
1
F37
14
RD/LB
C316 1
RD/LB
14
F37
CIRCUIT
BREAKER
30
20A
BATT A7
JUNCTION
BLOCK
C4
M4 2
C6
30A
29
BREAKER
CIRCUIT
RUN-ACC A31
C1
8
RHD LHD
C201 8
SWITCH
WASHER
4
MULTI-
FUNCTION
SWITCH)
(PART OF
V6
18
DB
DB
16
V6
1
POWER
PASSENGER
SEAT
F37
14
RD/LB
SWITCH SWITCH
WINDSHIELD
WIPER/ WIPER/
WASHER
(8W-53-2)
(8W-53-2)
(8W-63-2)
(8W-10-11)
(8W-12-2)
(8W-10-8)
(8W-53-2)
(8W-63-3)
XJI01224 J978W-7
JUNCTION
BLOCK
7
C7
HEADLAMP
SWITCH
3
C1
M2
20
YL
YL
20
M2
2
LAMP
LEFT
COURTESY COURTESY
RIGHT
LAMP
2
M2
20
YL
B C207 C208 B
YL
20
M2 M2
20
YL
YL
20
M2
46 C201
S25 C4
S201
LHD RHD
YL
20
M2
A
(8W-12-27)
TO
S304
C3
1
COMPASS
7 1
OVERHEAD
MODULE
B
IMMOBILZER OTHERS
COMPASS OTHERS
S345
M2
20
YL
M2
20
YL
M2
20
YL
M2
20
YL
M2
20
YL
SWITCH
LAMP/
DOME
(8W-12-2)
(8W-50-2)
(8W-50-3)
(8W-44-5) (8W-44-5)
(8W-49-2)
(8W-49-3)
(8W-39-6)
(8W-39-7)
(8W-44-5)
J978W-7 XJI01225
JUNCTION
BLOCK
FROM
A
(8W-12-26)
S304
YL
20
M2
YL
20
M2
YL
20
M2
YL
20
M2
YL
20
M2 M2
20
YL
YL
18
M2
C314 6
B
CARGO
LAMP/
1 C318 1 C317 A C320
DOOR
1
RIGHT
FRONT
JAMB
M2
18
YL
SWITCH SWITCH
YL
18
M2
JAMB
FRONT
LEFT
1
DOOR DOOR
3
LEFT
REAR
JAMB
M2
18
YL
SWITCH SWITCH
YL
18
M2
JAMB
REAR
RIGHT
3
DOOR
C319 A
SWITCH
(8W-39-6)
(8W-39-7)
(8W-39-6)
(8W-39-7)
(8W-39-6)
(8W-39-7)
(8W-44-6)
(8W-39-6)
(8W-39-7)
(8W-44-6)
(8W-44-6)
XJI01226 J978W-7
JUNCTION
BLOCK
1
C7
P33
16
OR/BK
LOCK/
FRONT
RIGHT
POWER
WINDOW
SWITCH/
C1
5
OR/BK
16
P33 P33
16
OR/BK
2
MOTOR
DOOR
RIGHT
FRONT
LOCK
S317
1 C9
P33
16
OR/BK
4 C305
S306
OR/BK
16
P33 P33
16
OR/BK
C309 4
P33
16
OR/BK
C304 4
A
C308
OR/BK
16
P33
OR/BK
16
P33
OR/BK
16
P33 P33
16
OR/BK
C310
C311
1
4
OR/BK
16
P33
LOCK
FRONT
LEFT
DOOR
MOTOR
2 2
MOTOR
DOOR
LEFT
REAR
LOCK LOCK
REAR
RIGHT
DOOR
MOTOR
2 2
MOTOR
DOOR
LIFT
GATE
LOCK
1
PK/BK
16
P34
1
C1
P34
16
PK/BK
S316
PK/BK
16
P34
C9 12
C7
5
PK/BK
16
P34
1 1
P34
16
PK/BK
1
P34
16
PK/BK
1
P34
16
PK/BK
5 5 5
P34
16
PK/BK PK/BK
16
P34
PK/BK
16
P34
PK/BK
16
P34
5
2
B
S307
PK/BK
16
P34
MODULE
(8W-12-2)
(8W-61-5)
(8W-61-5) (8W-61-5) (8W-61-5) (8W-61-5)
(8W-61-5)
LHD
XJ
J978W-7 XJI01227
JUNCTION
BLOCK
1
C7
P33
16
OR/BK
LOCK/
FRONT
LEFT
POWER
WINDOW
C1
5
OR/BK
16
P33 P33
16
OR/BK
2
MOTOR
DOOR
LEFT
FRONT
LOCK
S323
P33
16
OR/BK
4 C305
S306
OR/BK
16
P33
P33
16
OR/BK
C309 4
P33
16
OR/BK
C304 4
A
C308
OR/BK
16
P33
OR/BK
16
P33
OR/BK
16
P33
C310
C311
1
4
OR/BK
16
P33
LOCK
FRONT
RIGHT
DOOR
MOTOR
2 2
MOTOR
DOOR
LEFT
REAR
LOCK LOCK
REAR
RIGHT
DOOR
MOTOR
2 2
MOTOR
DOOR
LIFT
GATE
LOCK
1
PK/BK
16
P34
1
C1
P34
16
PK/BK
S322
PK/BK
16
P34
C7
5
1 1
P34
16
PK/BK
1
P34
16
PK/BK
1
P34
16
PK/BK
5
5 5
P34
16
PK/BK
PK/BK
16
P34
PK/BK
16
P34
PK/BK
16
P34
5
2
B
S307
PK/BK
16
P34 P34
16
PK/BK OR/BK
16
P33
NOT
USED USED
NOT
SWITCH/
MODULE
(8W-12-2)
(8W-61-6)
(8W-61-6) (8W-61-6) (8W-61-6) (8W-61-6)
(8W-61-6)
RHD
8W - 12 - 29
XJI01228 J978W-7
JUNCTION
BLOCK
3
C7
LOCK/
FRONT
RIGHT
POWER
WINDOW
SWITCH/
7 C9
2 C307
S305
C309
Q1
14
YL
C304 3
LEFT
WINDOW
REAR
RIGHT
SWITCH
6
10
C1
Q1
14
YL YL
14
Q1
C1
10
WINDOW
POWER
LEFT
FRONT
LOCK/
LHD RHD
YL
14
Q1
SWITCH
REAR
WINDOW
Q1
14
YL
6
3
YL
14
Q1 Q1
14
YL
YL
14
Q1
LHD RHD
SWITCH
WINDOW
POWER
LEFT
FRONT
LOCK/
C2 8 8 C2
LOCK/
FRONT
RIGHT
POWER
WINDOW
SWITCH
Q1
14
YL
YL
14
Q1
YL
14
Q1
C307 2
Q1
14
YL
MODULE MODULE
SWITCH/
(8W-12-2)
(8W-60-3)
(8W-60-5)
(8W-60-3)
(8W-60-5)
(8W-60-2) (8W-60-4)
(8W-60-2) (8W-60-4)
J978W-7 XJI01229
JUNCTION
BLOCK
2
C9
LOCK/
FRONT
LEFT
POWER
WINDOW
SWITCH
C2
4
9 C5
DB
20
P74
9
35
24
P74
20
DB
P74
20
DB
P74
20
DB
3
MIRROR
RIGHT
POWER
DB
20
P74 P72
20
YL/BK
1
C9
6
C5 10
20
34
8
P72
20
YL/BK
7
C2
YL/BK
20
P72
YL/BK
20
P72
YL/BK
20
P72
POWER
LEFT
MIRROR
C2
2
OR/YL
20
P76 P76
20
OR/YL
2 4
OR/YL
20
P76
S328
P76
20
OR/YL
10 C305
36 C200
OR/YL
20
P76
28 C201
P76
20
OR/YL
OR/YL
20
P76
2 C5
10
C9
2
OR/YL
20
P76
S318
P76
20
OR/YL OR/YL
20
P76
4
(8W-12-2)
(8W-62-2)
(8W-62-3)
(8W-62-3)
(8W-62-2)
LHD
8W - 12 - 31
XJI01230 J978W-7
M1
20
PK
4
C7
12 C1
JUNCTION
BLOCK
UNDERHOOD
LAMP
2
MODULE
CONTROL
TRANSMISSION
25
S135
M1
20
PK
A23
A24
16
FUSE
15A
CENTER
DISTRIBUTION
POWER
BATT A0
6 C201
M1
20
PK
S18
C4
M1
20
PK
M1
20
PK
PK
20
M1
PK
20
M1
PK
20
M1
S300
5 C314 C305 3
M1
18
PK
3
SWITCH
WINDOW
LOCK/
POWER
FRONT
LEFT
M1
20
PK
A
LAMP/
CARGO
C3
3
PK
20
M1
(4.0L A/T)
PK
18
M1
C314 5
M1
20
PK
LHD RHD RHD LHD
SWITCH
TO
S347
S214
TO
C2
GAS DIESEL
PK
20
M1
GAS DIESEL
M1
20
PK
(8W-12-2)
(8W-44-4)
(8W-31-2)
(8W-10-7)
(8W-10-6)
(8W-62-2)
(8W-44-6)
(8W-10-15)
(8W-10-33)
(8W-10-14)
(8W-10-33)
(8W-10-14)
(8W-10-33)
J978W-7 XJI01231
JUNCTION
BLOCK
S5
C4
Z1
14
BK
11 C9
S314
BK
14
Z1
LHD RHD
C201 14
G107
Z1
14
BK
85
CIGAR
LIGHTER
RELAY
Z1
16
BK
S319
BK
16
Z1 Z1
18
BK
LOCK/
FRONT
RIGHT
POWER
C2
6
WINDOW
SWITCH/
6
MIRROR
RIGHT
POWER
C3
2
(LHD)
(LHD)
MODULE (RHD)
SWITCH
WINDOW
8
C1
POWER
RIGHT
FRONT
LOCK/
Z1
12
BK BK
12
Z1
C2
5
BK
12
Z1
Z1
12
BK
Z1
14
BK
S208
RHD LHD
Z1
20
BK
BK
20
Z1
BK
20
Z1
BK
20
Z1
S342
OTHERS COMPASS
IMMOBILIZER
C
MODULE
OVERHEAD
1
COMPASS
3
DOME
LAMP/
BK
20
Z1
OTHERS
SWITCH
BK
20
Z1
Z1
14
BK
Z1
14
BK
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-41-2)
(8W-41-3)
(8W-61-2)
(8W-48-2)
(8W-48-3)
(8W-61-3)
(8W-15-8)
(8W-39-2)
(8W-39-3)
(8W-39-4)
(8W-39-5)
(8W-49-2)
(8W-44-5)
XJI01232 J978W-7
8W-15 GROUND DISTRIBUTION
INDEX
page
Component Page
4WD Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
4WD Swi tch I l l umi nati on . . . . . . . . . . . . . . . . . . . . .8W-15-8, 12
A/C Heater Control . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
Center Hi gh Mounted Stop Lamp . . . . . . . . . . . . . . . . . .8W-15-15
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7, 9
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
Control l er Anti -Lock Brake Rel ay. . . . . . . . . . . . . . . . . .8W-15-4, 5
Data Li nk Connector . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
Dome Lamp/Swi tch. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
Dri ver Power Seat Swi tch . . . . . . . . . . . . . . . . . . . .8W-15-13, 14
El ectroni c Vacuum Modul ator . . . . . . . . . . . . . . . . . . . . .8W-15-6
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . . . . .8W-15-2, 5, 6
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5, 6
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Fuel Heater Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-12
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13, 14
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-15
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
Gl ove Box Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Headl amp Del ay Modul e . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Headl amp Level i ng Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
HVAC Uni t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4, 12
Left Front Door Jamb Swi tch. . . . . . . . . . . . . . . . . . .8W-15-11, 12
Left Front Power Lock/Wi ndow Swi tch. . . . . . . . . . . . . . . .8W-15-11
Left Front Power Lock/Wi ndow Swi tch/Modul e . . . . . . . . . . .8W-15-12
Left Front Turn Si gnal Lamp . . . . . . . . . . . . . . . . . . . . .8W-15-4
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Left Headl amp Level i ng Motor . . . . . . . . . . . . . . . . . . . .8W-15-4
Left Posi ti on Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Left Power Mi rror . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Left Rear Door Jamb Swi tch . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Left Repeater Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Left Turn Si gnal Lamp . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-15
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-15
Low Washer Fl ui d Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-15-5, 6
Overhead Modul e . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7, 9
Component Page
Part Ti me 4WD Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-15-2, 6
Passenger Power Seat Swi tch . . . . . . . . . . . . . . . . . .8W-15-13, 14
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Power Steeri ng Pressure Swi tch . . . . . . . . . . . . . . . . . . . .8W-15-2
Powertrai n Control Modul e . . . . . . . . . . . . . . . . . . . . .8W-15-2, 3
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8, 12
Radi ator Cool i ng Fan . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Rear Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . .8W-15-5, 6
Rear Wi ndow Defogger Gri d . . . . . . . . . . . . . . . . . . . . .8W-15-15
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . . . . . . . . . . .8W-15-8
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-15
Rear Wi per/Washer Swi tch. . . . . . . . . . . . . . . . . . . . . . .8W-15-8
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-15-13, 14
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4, 14
Ri ght Front Door Jamb Swi tch . . . . . . . . . . . . . . . . . .8W-15-13, 14
Ri ght Front Power Lock/Wi ndow Swi tch . . . . . . . . . . . . . . .8W-15-7
Ri ght Front Power Lock/Wi ndow Swi tch/Modul e . . . . . . . . . . .8W-15-7
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . . . . . . . . . . .8W-15-4
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Ri ght Headl amp Level i ng Motor . . . . . . . . . . . . . . . . . . . .8W-15-4
Ri ght Posi ti on Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Ri ght Power Mi rror . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
Ri ght Rear Door Jamb Swi tch . . . . . . . . . . . . . . . . . .8W-15-13, 14
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-15-13, 14
Ri ght Turn Si gnal Lamp . . . . . . . . . . . . . . . . . . . . .8W-15-13, 14
S102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
S103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-4
S107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
S119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-2
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5, 6
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5, 6
S146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
S150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-3
S157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-6
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
S208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13, 14
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-12
S314. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8
S319. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-12
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-15
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-15
S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
S341 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
S342. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-7
S343. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-9
S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-13, 14
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-8, 12
Stop Lamp Swi tch. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-10
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . . . . .8W-15-11, 12
Transmi ssi on Control Modul e . . . . . . . . . . . . . . . . . . . . .8W-15-2
Transmi ssi on Control Sol enoi ds . . . . . . . . . . . . . . . . . . . .8W-15-5
Transmi ssi on Range Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-15-5, 6
Upstream Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . .8W-15-2
Vehi cl e Speed Control Servo . . . . . . . . . . . . . . . . . . . . . .8W-15-5
Wi ndshi el d Washer Pump Motor . . . . . . . . . . . . . . . . . .8W-15-5, 6
Wi ndshi el d Wi per/Washer Swi tch . . . . . . . . . . . . . . . . . .8W-15-10
XJ 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1
24
MODULE
TRANSMISSION
CONTROL
(A/T)
Z12
18
BK/TN
9 C107
BK/TN
16
Z12
Z1
16
BK
S107
Z12
14
BK/TN
BK/TN
14
Z12
CONTROL
POWERTRAIN
MODULE
A31 A32
Z1
18
BK
SWITCH
TIME
PART
4WD
B A
4WD
SWITCH
PART-TIME/
FULL-TIME
4WD
4WD
PART-TIME
2
OXYGEN
DOWNSTREAM
HEATED
SENSOR
SENSOR
HEATED
UPSTREAM
OXYGEN
2
BK
18
Z1 Z1
20
BK
(2.5L)
STEERING
POWER
SWITCH
1
BK
20
Z1
A6
MODULE
POWERTRAIN
CONTROL
(M/T)
Z1
18
BK
Z1
20
BK
5 C107
4
Z0
6
BK
BATTERY
BK
8
Z0
G100
2.5L 4.0L
Z0
4
BK
BK
6
Z0
GENERATOR
G103
C1
2.5L 4.0L
S119
BK
8
Z0
G101
Z0
4
BK
LHD RHD
8
BRAKE
CONTROLLER
ANTI-LOCK
24
BK
12
Z1
G102
Z1
12
BK
BK
18
Z1 Z12
18
BK/TN
A1 C100 A7
BK/LB
18
Z12 Z1
18
BK
4 5
LINK
DATA
CONNECTOR
C1
D11
(IN PDC)
(4WD)
(2.5L M/T)
RELAY
MOTOR
STARTER
ENGINE
T41
20
BR/LB
PRESSURE
C1 C1
(8W-31-2)
(8W-30-2)
(8W-40-12)
(8W-40-12)
(8W-30-8)
(8W-30-8)
(8W-30-14)
(8W-30-2)
(8W-20-2)
(8W-20-3)
(8W-20-2)
(8W-20-3)
(8W-35-2)
(8W-30-15)
(8W-21-2)
(8W-21-3)
8W - 15 - 2 8W-15 GROUND DISTRIBUTION
GAS
XJ
J978W-7 XJI01501
G102
BK/LG
12
Z12
BK/LG
12
Z12
S150
1 24 46
POWERTRAIN
CONTROL
MODULE
Z12
14
BK/LG
Z12
16
BK/LG
Z12
16
BK/LG
C1 C1 C1
Z12
20
BK/LG
C100 A7
BK/LB
18
Z12
5
S146
C2 C2
12 11
BK/TN
14
Z12
BK/TN
14
Z12
8
BRAKE
CONTROLLER
ANTI-LOCK
24
BK
12
Z1 Z1
12
BK
BK
16
Z1
A1
Z1
18
BK
4
LINK
DATA
CONNECTOR
BATTERY
BK
6
Z0
G104 G105
Z0
2/0
BK
(8W-30-18) (8W-35-4)
(8W-30-29)
(8W-20-4)
XJ 8W-15 GROUND DISTRIBUTION
DIESEL
8W - 15 - 3
XJI01502 J978W-7
FROM
S141
FROM
S132
BK
16
Z1
B
(8W-15-5)
A
(8W-15-5)
Z1
14
BK
G106
BK
12
Z1
FAN
RADIATOR
2
1
TURN
RIGHT
FRONT
Z1
18
BK
SIGNAL
LAMP
LAMP
SIGNAL
BK
18
Z1
FRONT
RIGHT
TURN
1
C
RIGHT
HEADLAMP
Z1
18
BK BK
20
Z1
FOG
RIGHT
1
LAMP
S102
BK
18
Z1
4
Z1
18
BK BK
18
Z1
11
Z1
18
BK
S103
LAMP
1
LEFT
FOG
Z1
20
BK BK
20
Z1
HEADLAMP
LEFT
C
1
TURN
LEFT
FRONT
Z1
18
BK
SIGNAL
LAMP
LAMP
SIGNAL
BK
18
Z1
FRONT
LEFT
TURN
1
COOLING
2
LEFT
POSITION
LAMP
LAMP
REPEATER
LEFT
2
BK
20
Z1 Z1
18
BK
2
RIGHT
Z1
20
BK
RIGHT
2
BK
18
Z1
ANTI-LOCK
CONTROLLER
(IN PDC)
B19
RELAY
BRAKE
RELAY
B10
(IN PDC)
FOG
LAMP
Z1
20
BK
Z1
20
BK
12 C106
BK
20
Z1
AIR
1
MASS
FLOW
Z2
18
BK/LG
SENSOR
REPEATER
LAMP
LAMP
POSITION
GAS DIESEL
BK
12
Z1
(GAS)
(DIESEL)
(DIESEL)
(GAS)
LAMP
FOG
(IN PDC)
B8
RELAY
Z1
20
BK
C106
BR/WT
20
L35
12
MOTOR
LEVELING
RIGHT
3
HEADLAMP
Z15
18
BK/GY BK/GY
18
Z15
HEADLAMP
3
LEFT
LEVELING
MOTOR
5
C106
Z15
16
BKGY
(8W-42-7)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-4)
(8W-50-7)
(8W-50-8)
(8W-50-7)
(8W-50-8)
(8W-50-4)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-35-5)
(8W-50-8)
(8W-30-22)
(8W-50-7)
(8W-50-9)
(8W-50-9)
(8W-15-6)
8W - 15 - 4 8W-15 GROUND DISTRIBUTION XJ
J978W-7 XJI01503
S141
BK
16
Z1
BK
16
Z1
BK
18
Z1 Z1
18
BK
2
PUMP
REAR
WASHER
MOTOR
B
PUMP
WINDSHIELD
WASHER
MOTOR
BK
18
Z1
WIPER
FRONT
MOTOR
4
SWITCH
WASHER
LOW
FLUID
A 8
TRANSMISSION
RANGE
(A/T)
SWITCH SOLENOIDS
(A/T)
CONTROL
TRANSMISSION
1
BK
20
Z1
BK
18
Z1
BK
20
Z1
Z1
14
BK
S132
1
UNDERHOOD
LAMP
4
CONTROL
VEHICLE
SPEED
SERVO
RELAY
ANTI-LOCK
CONTROLLER
BRAKE
(IN PDC)
(IN PDC)
D11
MOTOR
ENGINE
STARTER
RELAY
Z1
20
BK
(M/T)
BK
20
Z1
BK
18
Z1
A
(8W-15-4)
TO
G106
B
(8W-15-4)
TO
G106
Z1
20
BK
LHD RHD
B19
(8W-53-3) (8W-53-2)
(8W-53-2)
(8W-40-8)
(8W-40-9)
(8W-31-3) (8W-31-2)
(8W-44-4)
(8W-33-3)
(8W-35-3)
(8W-21-3)
GAS
8W - 15 - 5
XJI01504 J978W-7
Z1
12
BK
S132
BK
12
Z1
BK
12
Z1
S157
S141
MOTOR
WASHER
WINDSHIELD
PUMP
B
MOTOR
WASHER
REAR
PUMP
2 A
FLUID
LOW
WASHER
SWITCH
D6
(IN PDC)
HEATER
FUEL
RELAY
MOTOR
ENGINE
STARTER
D13
RELAY
(IN PDC)
SWITCH
4WD
B
4 C110
Z1
20
BK
Z1
18
BK BK
20
Z1 Z1
18
BK
Z1
18
BK BK
18
Z1
BK
20
Z1
1
UNDERHOOD
LAMP HEATER
FUEL
2 D
MODULATOR
ELECTRONIC
VACUUM
4
FRONT
WIPER
MOTOR
Z1
20
BK BK
14
Z1
BK
16
Z1
BK
18
Z1
A
(8W-15-4)
TO
G106
PART
TIME
(8W-53-2)
(8W-53-3) (8W-40-10)
(8W-40-11)
(8W-30-19)
(8W-21-4)
(8W-40-13)
(8W-44-4) (8W-30-19)
(8W-53-2) (8W-30-19)
DIESEL
XJ
J978W-7 XJI01505
JUNCTION
BLOCK
S5
C4
Z1
14
BK
11 C9
85
CIGAR
LIGHTER
RELAY
Z1
16
BK
BK
16
Z1 Z1
18
BK
LOCK/
FRONT
RIGHT
POWER
C2
6
WINDOW
SWITCH/
6
MIRROR
RIGHT
POWER
3
C3
2
COMPASS
1
OVERHEAD
MODULE
C
IMMOBILIZER OTHERS
COMPASS OTHERS
S342
Z1
20
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
BK
20
Z1
(LHD)
(LHD)
MODULE
C
(8W-15-8)
TO
S208
BK
12
Z1
Z1
12
BK
RHD
5
C2
Z1
12
BK BK
12
Z1
LOCK/
FRONT
RIGHT
POWER
C1
8
WINDOW
SWITCH
(RHD)
S319
LHD
SWITCH
LAMP/
DOME
(8W-12-2)
(8W-41-2)
(8W-41-3)
(8W-61-2)
(8W-48-2)
(8W-48-3)
(8W-49-2)
(8W-39-2)
(8W-39-3)
(8W-39-4)
(8W-39-5)
(8W-60-5)
(8W-62-4)
(8W-44-5)
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 7
XJI01506 J978W-7
2
CIGAR
LIGHTER
BK
16
Z1
G107
Z1
16
BK
OUTLET
POWER
2
2
GLOVE
BOX
BK
18
Z1
LAMP
SWITCH
Z1
14
BK
S208
Z1
18
BK
BK
18
Z1
Z1
18
BK
Z1
18
BK
SWITCH
DEFOGGER
WINDOW
REAR
1
4 1
REAR
WIPER/
WASHER
SWITCH
FLASHER
COMBINATION
5
SWITCH
BELT
SEAT
B
Z1
20
BK
BK
14
Z1
Z1
12
BK
S314
14 C201
BK
14
Z1
C
(8W-15-7)
FROM
BLOCK
JUNCTION
LHD RHD
Z1
14
BK
2 C206
BK
20
Z1 Z1
20
BK
(A/T)
ILLUMINATION
PRNDL
2 2
4WD
SWITCH
SWITCH
LAMP
FOG
FRONT
Z1
18
BK
BK
18
Z1
LHD RHD
1
REAR
FOG
LAMP
SWITCH
Z15
18
BK
SWITCH
LEVELING
HEADLAMP
2
BK
20
Z15
RELAY
LAMP
FOG
REAR
3
BK
16
Z1
ILLUMINATION
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-44-5)
(8W-48-2)
(8W-48-3)
(8W-53-3)
(8W-52-2)
(8W-52-3)
(8W-40-8)
(8W-40-9)
(8W-40-10)
(8W-40-11)
(8W-44-2)
(8W-44-3)
(8W-50-7)
(8W-50-8)
(8W-51-6)
(8W-50-9)
(8W-51-6)
(8W-44-2)
(8W-44-3)
J978W-7 XJI01507
Z2
18
BK/LG
RHD LHD
58 C201
BK/LG
18
Z2
5 C301
Z2
20
BK/LG
9
OVERHEAD
MODULE
BK/LG
20
Z2
S343
Z2
20
BK/LG
COMPASS
12
12
COMPASS
BK/LG
20
Z2
MODULE
OVERHEAD
6
Z2
20
BK/LG
IMMOBILIZER OTHERS
BK/LG
20
Z2
COMPASS OTHERS
Z2
20
BK/LG
D
(8W-15-10)
TO
G108
(8W-39-2)
(8W-39-3)
(8W-39-4)
(8W-39-5)
(8W-49-2)
(8W-49-2)
(8W-39-2)
(8W-39-3)
(8W-39-4)
(8W-39-5)
XJI01508 J978W-7
FROM
C301
D
(8W-15-9)
C201 25
Z8
20
BK/VT BK/VT
18
Z8
OPTIONS BASE
FULL
C202 6
Z8
12
BK/PK
LHD RHD
10
HVAC
UNIT
BK/VT
16
Z8 Z2
18
BK/LG
CONTROL
HEATER
A/C
7
Z2
18
BK/LG
1
C1
CLUSTER
INSTRUMENT
C1
6
BK/VT
12
Z8
BK/LG
18
Z2
BK
18
Z1
4
HEADLAMP
DELAY
MODULE
SWITCH
HEADLAMP
C2
1
1
C1
2
(PART OF
SWITCH)
FUNCTION
MULTI-
1
WINDSHIELD
WIPER/
SWITCH
BK
18
Z1 Z1
18
BK
C3
1
IGNITION
SWITCH
BK
20
Z1
BK
18
Z1
S207
BK
14
Z1 Z9
14
BK
RADIO
G108
WASHER SWITCH
LAMP
STOP
(8W-42-2)
(8W-42-3)
(8W-42-4)
(8W-42-5)
(8W-42-6)
(8W-42-2)
(8W-42-3)
(8W-42-4)
(8W-42-5)
(8W-42-6)
(8W-40-2)
(8W-50-2)
(8W-50-3)
(8W-50-2)
(8W-50-3)
(8W-53-2)
(8W-10-8)
(8W-10-28)
(8W-47-2)
(8W-33-3)
(8W-33-5)
J978W-7 XJI01509
10
AIRBAG
CONTROL
MODULE
BK/YL
18
Z6
BASE
Z6
18
BK/PK
OPTIONS
FULL
G200
7
C2
AMPLIFIER
POWER
C2
8
Z5
16
BK
G301
BK
16
Z5
BK
12
Z1
BK
20
Z1
S309
G302
Z1
12
BK
Z1
20
BK
Z1
14
BK BK
14
Z1
2 C322
Z1
14
BK MODULE
PUMP
FUEL
6
B C320
BK
18
Z1
2
LEFT
REAR
DOOR
JAMB
SWITCH SWITCH
JAMB
DOOR
FRONT
LEFT
3
Z1
18
BK
C317 3 3 C307
BK
12
Z1
S329
Z1
16
BK BK
12
Z1 Z1
12
BK
MIRROR
POWER
LEFT
6
WINDOW
LOCK/
POWER
FRONT
LEFT
C2
5
C1
8
SWITCH
Z1
14
BK BK
18
Z1
1
TRAILER
TOW
CONNECTOR
S337
LAMP
STOP
TAIL/
LEFT
1 1
LEFT
TURN
SIGNAL
LAMP
LAMP
BACK-UP
LEFT
1
Z1
18
BK BK
18
Z1
BK
18
Z1
C323 2
S341
Z1
18
BK
BK
18
Z1
TRAILER
TOW OTHERS
(8W-43-2)
(8W-47-3)
(8W-30-2)
(8W-30-21)
(8W-39-6) (8W-39-6)
(8W-48-2)
(8W-60-2)
(8W-62-2)
(8W-54-2)
(8W-51-2) (8W-51-4)
(8W-51-5)
LHD
8W - 15 - 11
XJI01510 J978W-7
SWITCH
4WD
2
2
PRNDL
ILLUMINATION
(A/T)
BK
20
Z1
Z1
20
BK
WINDOW
LOCK/
POWER
FRONT
LEFT
C2
6
SWITCH/
MIRROR
POWER
LEFT
6
SWITCH
BELT
SEAT
B
C206 2
S313
BK
20
Z1
BK
20
Z1
BK
20
Z1
S325
Z1
16
BK
Z1
12
BK
SWITCH
JAMB
DOOR
FRONT
LEFT
3
Z1
18
BK
C317 3 3 C307
BK
12
Z1
B C320
BK
18
Z1
2
LEFT
REAR
DOOR
JAMB
SWITCH
MODULE
PUMP
FUEL
6
2 C322
BK
20
Z1
G302
BK
20
Z1
S309
Z1
12
BK
Z1
20
BK
Z1
14
BK BK
14
Z1
7
C2
AMPLIFIER
POWER
C2
8
Z5
16
BK
G301
BK
16
Z5
G300
Z6
18
BK/PK
10
AIRBAG
CONTROL
MODULE
Z1
14
BK
Z1
14
BK BK
18
Z1
1
TRAILER
TOW
CONNECTOR
S337
LAMP
STOP
TAIL/
LEFT
1 1
LEFT
TURN
SIGNAL
LAMP
LAMP
BACK-UP
LEFT
1
Z1
18
BK BK
18
Z1
BK
18
Z1
C323 2
S341
Z1
18
BK
BK
18
Z1
TRAILER
TOW OTHERS
MODULE
ILLUMINATION
Z1
18
BK
1
LEFT
FOG
LAMP
(8W-44-3)
(8W-48-3)
(8W-40-9)
(8W-40-11)
(8W-39-7) (8W-39-7)
(8W-30-4)
(8W-30-22)
(8W-47-4)
(8W-43-3)
(8W-54-2)
(8W-51-3) (8W-51-4)
(8W-51-5)
(8W-60-4)
(8W-61-3)
(8W-44-3)
(8W-50-7)
(8W-50-8)
RHD
XJ
J978W-7 XJI01511
BK
16
Z1
BK
20
Z1
S310
G303
Z1
20
BK BK
18
Z1
2 C321
Z1
18
BK
B C319
BK
18
Z1
2
RIGHT
REAR
DOOR
JAMB
SWITCH SWITCH
JAMB
DOOR
FRONT
RIGHT
3
Z1
18
BK
C318 3
Z1
12
BK
2 C316
LAMP
STOP
TAIL/
RIGHT
1 1
RIGHT
TURN
SIGNAL
LAMP
LAMP
BACK-UP
RIGHT
1
Z1
18
BK BK
18
Z1
BK
18
Z1
S348
SWITCH
SEAT
POWER
2
BK
14
Z1
DRIVER PASSENGER
Z1
14
BK
2
POWER
SEAT
SWITCH
(8W-39-6) (8W-39-6)
(8W-51-2) (8W-51-4)
(8W-51-5)
(8W-63-2) (8W-63-3)
LHD
8W - 15 - 13
XJI01512 J978W-7
1 C324
Z1
12
BK
2 C316
SWITCH
SEAT
POWER
2
BK
14
Z1
Z1
16
BK
BK
12
Z1
BK
20
Z1
S310
G303
Z1
20
BK BK
18
Z1
2 C321 B C319
BK
18
Z1
2
RIGHT
REAR
DOOR
JAMB
SWITCH
C318 3
Z1
18
BK
LAMP
STOP
TAIL/
RIGHT
1 1
RIGHT
TURN
SIGNAL
LAMP
LAMP
BACK-UP
RIGHT
1
Z1
18
BK BK
18
Z1
BK
18
Z1
S348
SWITCH
JAMB
DOOR
FRONT
RIGHT
3
Z1
18
BK
NOT
USED
DRIVER PASSENGER
Z1
14
BK
2
POWER
SEAT
SWITCH
Z1
18
BK
1
RIGHT
FOG
LAMP
(8W-63-2)
(8W-39-7)
(8W-51-3) (8W-51-4)
(8W-51-5)
(8W-39-7)
(8W-63-3)
(8W-50-7)
(8W-50-8)
RHD
XJ
J978W-7 XJI01513
BK
16
Z1
BK
18
Z1
S333
G304
BK
18
Z1
2 C427
Z1
18
BK
Z1
18
BK
Z1
12
BK
DEFOGGER
WINDOW
REAR
BK
12
Z1
1
C310
C313
2
1
C2
GRID
9
C311
C310
6
S334
BK
18
Z1 Z1
20
BK
Z1
18
BK
2
LICENSE
LAMP SWITCH
LIFTGATE
1
MOTOR
1
REAR
WIPER
STOP
1
CENTER
HIGH
MOUNTED
LAMP LAMP
MOUNTED
HIGH
CENTER
1
STOP
BK
18
Z1
(8W-48-2)
(8W-48-3)
(8W-51-2)
(8W-51-3)
(8W-53-3)
(8W-39-6)
(8W-39-7)
(8W-44-6)
(8W-51-2)
(8W-51-3)
(8W-51-2)
(8W-51-3)
XJI01514 J978W-7
8W-20 CHARGING SYSTEM
INDEX
page
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Page
Automati c Shut Down Rel ay . . . . . . . . . . .8W-20-2, 3
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Di esel Power Rel ay . . . . . . . . . . . . . . . . . . . .8W-20-3
Engi ne Starter Motor . . . . . . . . . . . . . . . .8W-20-2, 3
Fuse 4 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
Fuse 18 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Fuse 20 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Fuse 23 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Component Page
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2
G104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
G105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
Generator . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
Power Di stri buti on Center . . . . . . . . . . . . .8W-20-2, 3
Powertrai n Control Modul e . . . . . . . . . . . .8W-20-2, 3
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-2, 3
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-20-3
XJ 8W - 20 CHARGING SYSTEM 8W - 20 - 1
BK/WT
6
A11
4
BK
A0
6
RD
4
DG
18
K20
B10 C2
GENERATOR
FIELD
DRIVER
G103
BK
6
Z0
BK
8
Z0
G100
BATTERY
GENERATOR
1
MODULE
CONTROL
POWERTRAIN
18
FUSE
25A
16
A16
RD/LG
CENTER
DISTRIBUTION
POWER
A17
A18
C2
C8
RELAY
DOWN
SHUT
AUTOMATIC
RD
A999
16 16
A999
RD
TO
23 (PDC)
FUSE
C12 C3
OUTPUT
RELAY
DOWN
SHUT
AUTOMATIC
A14
A13
POWER
DISTRIBUTION
CENTER
DG/OR
A142
18
20A
FUSE
20
2
S137
18
A142
DG/OR
3
C108
C107 2
K20
18
DG
DG
18
K20
2
K72
18
DG/OR
DG/OR
18
K72
C25 C3
SOURCE
FIELD
GENERATOR
DG
10
A11
FUSIBLE
LINK
S118
1
ENGINE
STARTER
MOTOR
RD
6
A0
BK
6
Z0 Z0
2.5L 4.0L
C1 C1 C1
1 C2
4.0L 2.5L
Z0
BK
4
S119
BK
8
Z0
G101
Z0
BK
4
S119
G101
(8W-30-2)
(8W-30-13)
(8W-10-17)
(8W-10-7)
(8W-30-2)
(8W-10-17)
(8W-10-7)
(8W-10-17)
(8W-10-17)
(8W-21-2)
(8W-21-3)
(8W-15-2)
(8W-15-2)
(8W-15-2)
(8W-15-2)
8W - 20 - 2 8W-20 CHARGING SYSTEM
GAS LHD
XJ
J978W-7 XJI02001
BK/WT
6
A11
4
BK
A0
6
RD
DG
18
K20
B10 C2
GENERATOR
FIELD
DRIVER
BK
8
Z0
G100
BATTERY
GENERATOR
1
MODULE
CONTROL
POWERTRAIN
18
FUSE
25A
16
A16
RD/LG
CENTER
DISTRIBUTION
POWER
A17
A18
C2
C8
RELAY
DOWN
SHUT
AUTOMATIC
RD
A999
16 16
A999
RD
TO
23 (PDC)
FUSE
C12 C3
OUTPUT
RELAY
DOWN
SHUT
AUTOMATIC
A14
A13
POWER
DISTRIBUTION
CENTER
DG/OR
A142
18
20A
FUSE
20
2
S137
18
A142
DG/OR
3
C108
C107 2
K20
18
DG
DG
18
K20
2
K72
18
DG/OR
DG/OR
18
K72
C25 C3
SOURCE
FIELD
GENERATOR
DG
10
A11
FUSIBLE
LINK
S118
1
ENGINE
STARTER
MOTOR
RD
6
A0
BK
6
G101
Z0 Z0
2.5L 4.0L
C1 C1
1 C2
(8W-30-2)
(8W-30-13)
(8W-10-17)
(8W-10-7)
(8W-30-2)
(8W-10-17)
(8W-10-7)
(8W-10-17)
(8W-10-17)
(8W-21-2)
(8W-21-3)
XJ 8W-20 CHARGING SYSTEM
GAS RHD
8W - 20 - 3
XJI02002 J978W-7
8W-20 CHARGING SYSTEM
CHARGING SYSTEM
The chargi ng system i s an i ntegral part of the bat-
tery and starti ng systems. Because al l these systems
work i n conjuncti on, di agnose and test them together.
Ci rcui t A11 connects to the generator output termi -
nal and the Power Di stri buti on Center (PDC). Ci rcui t
A0 connects the battery to the PDC. Ci rcui t Z0 pro-
vi des ground for the generator.
When the i gni ti on swi tch i s i n ei ther the START or
RUN posi ti ons, i t connects ci rcui t A1 from fuse 2 i n
the PDC to ci rcui t A21. Ci rcui t A21 spl i ces to ci rcui t
F12 aned suppl i es current to the coi l si de of the
Automati c Shut Down (ASD) rel ay. The Powertrai n
Control Modul e (PCM) provi des ground for the rel ay
on ci rcui t K51. Ci rcui t K51 connects to cavi ty C3 of
the PCM.
When the PCM grounds the ASD rel ay, contacts
i nsi de the rel ay cl ose and connect ci rcui t A16 from
fuse 18 i n the PDC to ci rcui t A142. Ci rcui t A142 con-
nects to cavi ty C12 of the PCM.
The PCM has an i nternal vol tage regul ator that
control s generator output. The PCM control s the gen-
erator fi el d on ci rcui t K20. Ci rcui t K20 connects to
PCM cavi ty B10.
When the engi ne operates and there i s current i n
the generator fi el d, the generator produces a B+ vol t-
age. The generator suppl i es B+ vol tage to the battery
through the A11 and A0 ci rcui ts.
HELPFUL INFORMATION
The i gni ti on swi tch al so connects ci rcui t A1 wi th
ci rcui t A31.
Ci rcui t F12 al so powers the coi l si de of the fuel
pump rel ay.
CHARGING SYSTEM (DIESEL)
The chargi ng system i s an i ntegral part of the bat-
tery and starti ng systems. Because al l these systems
work i n conjuncti on, di agnose and test them together.
Ci rcui t A11 connects to the generator output termi -
nal and the Power Di stri buti on Center (PDC). Ci rcui t
A0 connects the battery to the PDC.The generator i s
case grounded.
Power for the fi el d termi nal i n the generator i s
suppl i ed on ci rcui t A142. Thi s ci rcui t i s HOT when
the contacts i n the Di esel Power rel ay are CLOSED.
The PCM has an i nternal vol tage regul ator that
control s generator output. The PCM control s the gen-
erator fi el d on ci rcui t K20.
When the engi ne operates and there i s current i n
the generator fi el d, the generator produces a B+ vol t-
age. The generator suppl i es B+ vol tage to the battery
through the A11 and A0 ci rcui ts.
8W - 20 - 4 8W - 20 CHARGING SYSTEM XJ
8W-21 STARTING SYSTEM
INDEX
page
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . . .8W-21-3
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . .8W-21-2
Engi ne Starter Motor . . . . . . . . . . . . . . . .8W-21-2, 3
Engi ne Starter Motor Rel ay . . . . . . . . . . .8W-21-2, 3
Fuse 7 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
Fuse 10 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
Component Page
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Powertrai n Control Modul e . . . . . . . . . . . . . .8W-21-2
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-3
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-2, 3
Transmi ssi on Range Swi tch . . . . . . . . . . . . .8W-21-2
XJ 8W - 21 STARTING SYSTEM 8W - 21 - 1
D11 D14
D10 D13
T40
14
BR
MOTOR
STARTER
ENGINE
7
30A
FUSE
10
23
A0
6
RD
CENTER
DISTRIBUTION
POWER
1 2
P/N
BATTERY
YL/RD
20
F45
BK/WT
18
T41
RD
6
A0
BK/PK
14
A4
SWITCH
RANGE
TRANSMISSION
WT/BK
20
T41
C1 A6
POWERTRAIN
CONTROL
MODULE
SENSE
SWITCH
POSITION
NEUTRAL
PARK/
19
FUSE
10A
ST A41
3
C1
JUNCTION
BLOCK
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
8
Z1
18
BK
BK
16
Z1
S141
G106
5 C107
T41
20
BK/WT
1 C108
LG/BK
14
T40
16
C2
1
BK/PK
12
A4
2 1
E7 C100
2
1
JUMPER
SWITCH
INTERLOCK
CLUTCH
E8 C100
T141
20
YL
LHD RHD
1 PULL-IN
2 HOLD-IN
M
(8W-10-13)
(8W-10-6)
(8W-20-2)
(8W-20-3)
(8W-31-3)
(8W-30-11)
(8W-12-17)
(8W-12-18)
(8W-10-10)
(8W-12-2)
(8W-15-5)
(8W-15-4)
8W - 21 - 2 8W-21 STARTING SYSTEM
GAS A/T
XJ
J978W-7 XJI02101
D11 D14
D10 D13
T40
14
BR
MOTOR
STARTER
ENGINE
30A
FUSE
10
23
A0
6
RD
CENTER
DISTRIBUTION
POWER
1 2
BATTERY
YL/RD
20
F45
RD
6
A0
BK/PK
14
A4
19
FUSE
10A
ST A41
3
C1
JUNCTION
BLOCK
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
Z1
20
BK
BK
14
Z1
S132
G106
1 C108
BR
14
T40
16
C2
1
BK/PK
12
A4
2 1
CLUTCH
INTERLOCK
SWITCH
2.5L (LHD)
G101
S107
Z1
16
BK
BR/LB
20
T41
5 C107
Z1
20
BK
RHD LHD
RHD LHD
YL
20
T141
C100 E8
1
2
C100 E7
2.5L (RHD)
4.0L &
2.5L 4.0L
T40
14
LG/BK
1 PULL-IN
2 HOLD-IN
M
(8W-10-13)
(8W-10-6)
(8W-20-2)
(8W-20-3)
(8W-12-17)
(8W-12-18)
(8W-10-10)
(8W-12-2)
(8W-15-5)
(8W-15-4) (8W-15-2)
(8W-15-2)
XJ 8W-21 STARTING SYSTEM
GAS M/T
8W - 21 - 3
XJI02102 J978W-7
D13 D14
D10 D11
T40
14
BR
MOTOR
STARTER
ENGINE
30A
FUSE
7
6
A0
2/0
RD
CENTER
DISTRIBUTION
POWER
1 2
BATTERY
RD
6
A0
BK/PK
14
A4
19
FUSE
10A
ST A41
3
C1
JUNCTION
BLOCK
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
Z1
20
BK
BK
12
Z1
S141
G106
10 C110
BR
14
T40
13
C2
1
BK/PK
12
A4
S132
Z1
12
BK
1 PULL-IN
2 HOLD-IN
YL/RD
20
F45
CLUTCH
INTERLOCK
SWITCH
RHD LHD
RHD LHD
YL
20
T141
C100 E8
1
2
C100 E7
M
(8W-10-31)
(8W-10-25)
(8W-20-4)
(8W-12-17)
(8W-12-18)
(8W-10-30)
(8W-12-2)
(8W-15-6)
(8W-15-4)
(8W-15-6)
8W - 21 - 4 8W-21 STARTING SYSTEM
DIESEL
XJ
J978W-7 XJI02103
8W-21 STARTING SYSTEM
STARTING SYSTEM AUTOMATIC
TRANSMISSIONS
Ci rcui t A0 from the battery i s doubl e cri mped at
the posi ti ve battery post. One branch of ci rcui t A0
(battery posi ti ve cabl e) connects to the engi ne starter
motor. The other A0 branch suppl i es vol tage to the
bus bar i n the Power Di stri buti on Center (PDC).
Fuse 10 i n the PDC suppl i es battery vol tage to the
contact si de of the engi ne starter motor rel ay on ci r-
cui t A4. When the coi l si de of the engi ne starter
motor rel ay energi zes, the contacts cl ose and connect
ci rcui t A4 to ci rcui t T40. Ci rcui t T40 suppl i es battery
vol tage to the starter motor sol enoi d.
The i gni ti on swi tch suppl i es battery vol tage to the
coi l si de of the starter motor rel ay on ci rcui t A41
when the key i s moved to the START posi ti on and
the PARK/NEUTRAL posi ti on swi tch i s cl osed.
Ground for the coi l si de of the starter motor rel ay i s
suppl i ed by the PARK/NEUTRAL posi ti on swi tch.
Ci rcui t T41 connects the coi l si de of the rel ay to the
PARK/NEUTRAL posi ti on swi tch.
When the starter motor rel ay energi zes and the
contacts cl ose, ci rcui t T40 suppl i es battery vol tage to
the starter motor sol enoi d. Ci rcui t A0 from the bat-
tery suppl i es vol tage to the starter motor when the
sol enoi d energi zes.
STARTING SYSTEM MANUAL TRANSMISSION
Ci rcui t A0 from the battery i s doubl e cri mped at
the posi ti ve battery post. One branch of ci rcui t A0
(battery posi ti ve cabl e) connects to the battery
starter motor. The other A0 branch suppl i es vol tage
to the bus bar i n the Power Di stri buti on Center
(PDC).
Fuse 10 i n the PDC suppl i es battery vol tage to the
contact si de of the engi ne starter motor rel ay on ci r-
cui t A4. When the coi l si de of the engi ne starter
motor rel ay energi zes, the contacts cl ose and connect
ci rcui t A4 to ci rcui t T40. Ci rcui t T40 suppl i es battery
vol tage to the starter motor sol enoi d.
The i gni ti on swi tch suppl i es battery vol tage to the
coi l si de of the starter motor rel ay on ci rcui t A41
when the key i s moved to the START posi ti on. Ci r-
cui t Z1 provi des ground for the coi l si de of the rel ay.
When the starter motor rel ay energi zes and the
contacts cl ose, ci rcui t T40 suppl i es battery vol tage to
the starter motor sol enoi d. Ci rcui t A0 from the bat-
tery suppl i es vol tage to the starter motor when the
sol enoi d energi zes.
STARTING SYSTEM (DIESEL)
Power for the coi l si de of the engi ne starter motor
rel ay i s suppl i ed on ci rcui t T141. Thi s ci rcui t i s HOT
when the operator has moved the i gni ti on key to the
START posi ti on and the cl utch pedal posi ti on swi tch
i s CLOSED.
Ground for the coi l si de of the rel ay i s suppl i ed by
ci rcui t Z1.
When the coi l si de of the rel ay energi zes the con-
tacts i n the rel ay CLOSE connecti ng ci rcui ts A4 and
T40. The A4 ci rcui t i s protected by a 30 amp fuse
l ocated i n the Power Di stri buti on Center (PDC). Ci r-
cui t T40 connects from the rel ay to the sol enoi d i n
the engi ne starter motor.
Power for the motor i n the starter i s suppl i ed on
ci rcui t A0. Thi s i s a di rect feed from the battery.
Ground for the engi ne starter motor i s suppl i ed
through a case ground.
HELPFUL INFORMATION (DIESEL)
Check the 30 amp fuse l ocated i n the PDC
Check the cl utch pedal posi ti on swi tch for proper
operati on
Check the case ground of the engi ne starter
motor
XJ 8W - 21 STARTING SYSTEM 8W - 21 - 5
8W-30 FUEL/IGNITION SYSTEMS
INDEX
page
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . . . . . . . .8W-30-13
A/C Heater Control . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13, 28
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . . . . . . .8W-30-13, 28
A/C Low Pressure Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
Accel erator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-23
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . .8W-30-16, 17, 30, 31
Automati c Shut Down Rel ay. . . . . . . . . . . . . . . . . .8W-30-2, 5, 6, 8
Battery Temperature Sensor . . . . . . . . . . . . . . . . . . . . .8W-30-10
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-30-5
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-10, 26
Compass . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16, 17, 20, 30, 31
Control Sl eeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22
Control l er Anti -Lock Brake . . . . . . . . . . . . . . . . . . . .8W-30-15, 29
Cool i ng Fan Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . . . . . . .8W-30-5, 25
Data Li nk Connector . . . . . . . . . . . . . . .8W-30-15, 16, 17, 29, 30, 31
Di agnosti c Spl i ce Bl ock . . . . . . . . . . . . . . . . . .8W-30-16, 17, 30, 31
Di esel Power Rel ay . . . . . . . . . . . . . . . . . .8W-30-18, 19, 20, 21, 22
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . . . .8W-30-12
El ectroni c Vacuum Modul ator . . . . . . . . . . . . . . . . . . . .8W-30-19
Engi ne Cool ant Temperature Sensor . . . . . . . . . . . . . . .8W-30-7, 24
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . . . . . . . . .8W-30-11
Fuel Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19
Fuel Heater Rel ay. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-6
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-27
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . .8W-30-3, 4, 21, 22
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 3, 4
Fuel Quanti ty Actuator . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuel Shutdown Sol enoi d . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuel Ti mi ng Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-18, 21, 22
Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Fuse 11 (JB). . . . . . . . . . . . . . . . . . . . . .8W-30-2, 3, 4, 12, 18, 19
Fuse 17 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-15
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2
Fuse 19 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-26
Fuse 20 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 5, 6, 8
Fuse 21 (PDC) . . . . . . . . . . . . . . . . . .8W-30-2, 3, 4, 19, 20, 21, 22
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 5, 6, 8
Fuse 24 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-18
Fuse 26 (PDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-29
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 8, 11, 14
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-15, 18, 29
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-11, 19, 22
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-14, 26
G123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-27
G154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3, 4
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13, 28
Gl ow Pl ug Assembl y . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Gl ow Pl ug No.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Gl ow Pl ug No.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Gl ow Pl ug No.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Gl ow Pl ug No.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Gl ow Pl ug Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-15, 29
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-5
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . .8W-30-16, 17, 30, 31
Component Page
I ntake Ai r Temperature Sensor . . . . . . . . . . . . . . . . . . . .8W-30-7
Juncti on Bl ock . . . . . . . . . . . . . . . . . .8W-30-2, 3, 4, 12, 18, 19, 20
Left Speed Control Swi tch . . . . . . . . . . . . . . . . . . . .8W-30-10, 26
Low Cool ant Level Warni ng I ndi cator . . . . . . . . . . . . . . . .8W-30-20
Low Cool ant Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-27
Mani fol d Absol ute Pressure Sensor . . . . . . . . . . . . . . . . . .8W-30-9
Measure Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22
Needl e Movement Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-30-25
Oi l Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . .8W-30-10, 27
Overhead Modul e . . . . . . . . . . . . . . . . . . . . .8W-30-16, 17, 30, 31
Power Di stri buti on Center . . . . . . . . . . . .8W-30-2, 3, 4, 5, 6, 8, 11, 13,
15, 18, 19, 20, 21, 22, 26, 29
Power Steeri ng Pressure Swi tch . . . . . . . . . . . . . . . . . . .8W-30-14
Powertrai n Control Modul e . . . . . . . . . . . . . . . . . . . . . .8W-30-2
Ri ght Speed Control Swi tch . . . . . . . . . . . . . . . . . . .8W-30-10, 26
S107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-8, 11, 14
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-5, 6
S110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-8
S111 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3, 4, 5, 7, 8, 9, 10
S112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-7
S113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-6
S114. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-5, 7, 8, 9
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-5, 7, 9
S116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-24
S130 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 3, 4, 12, 18, 19
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-11, 19
S136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 12
S137. . . . . . . . . . . . . . . . . . . . . . .8W-30-2, 5,6,18, 19, 20, 21, 22
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3, 4, 10, 24, 27
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-15, 29
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-14
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-11
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16, 17
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16, 17
S146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-18, 29
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-26
S148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21
S149. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21, 22,23,24, 26
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-18, 29
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-18, 21, 22
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-24
S153 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19, 20, 21, 22
S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-26
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-14, 26
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-14, 26
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-15, 29
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-10, 26
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-10, 26
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-3, 4
S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16, 17, 30, 31
S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16, 17, 30, 31
Stop Lamp Swi tch. . . . . . . . . . . . . . . . . . . . . . .8W-30-11, 14, 26
Tel l Tal e Modul e . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . . . . . . . . .8W-30-7
Transmi ssi on Control Modul e . . . . . . . . . . . . . . .8W-30-7, 15, 16, 17
Transmi ssi on Range Swi tch . . . . . . . . . . . . . . . . . . . . .8W-30-11
Upstream Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . .8W-30-8
Vehi cl e Speed Control Servo . . . . . . . . . . . . . . . . . . . . .8W-30-11
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .8W-30-9, 24
Wai t To Start Warni ng I ndi cator . . . . . . . . . . . . . . . . . . .8W-30-20
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-27
Water I n Fuel Warni ng I ndi cator . . . . . . . . . . . . . . . . . . .8W-30-20
XJ 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 1
POWERTRAIN
CONTROL
MODULE
20A
FUSE
11
C1 A2
DB/WT
18
F12
F12
18
DB/WT
18
FUSE
25A
RD/LG
16
A16
C6 C8
C2 C4
K51
18
DB/YL
C3 C3 C3 C12
DG/OR
18
A142
AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)
CONTROL
RELAY
DOWN
SHUT
AUTOMATIC
SHUT
DOWN
RELAY
OUTPUT
5
S130
10 C107
(ST-RUN)
IGN.
FUSED
CENTER
DISTRIBUTION
POWER
A17
ST-RUN A21
A18
JUNCTION
BLOCK
C2
S136
DB/WT
18
F12
AUTOMATIC
BATT A0
F12
18
DB/WT
RD
16
A999
A14
A13
POWER
DISTRIBUTION
CENTER
20A
FUSE
20
A142
18
DG/OR
A11
A12
A61
14
DG/BK
15A
FUSE
21
D2
FUEL
PUMP
RELAY
14 C107
A61
16
DG/BK
DG/BK
16
A61
A22 C1
B(+)
FUSED
A31
Z12
14 14
Z12
A32
G101
GROUND
C1 C1
GROUND
BK/TN BK/TN
A999
16
RD
TO
23 (PDC)
FUSE
A/T M/T
S116
S137
DB/WT
18
F12
(8W-12-13)
(8W-12-14)
(8W-10-17)
(8W-12-14)
(8W-10-7)
(8W-10-9)
(8W-12-2)
(8W-12-14)
(8W-10-6)
(8W-10-7)
(8W-10-17)
(8W-10-19)
(8W-30-3)
(8W-30-4)
(8W-15-2)
(8W-10-17)
(8W-12-14)
(8W-10-17)
8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM
GAS
XJ
J978W-7 XJI03001
POWERTRAIN
CONTROL
MODULE
20A
FUSE
11
F12
18
DB/WT
D6 D8
D2 D4
K31
18
BR
C19 C3
CONTROL
RELAY
PUMP
FUEL
5
S130
CENTER
DISTRIBUTION
POWER
ST-RUN A21
JUNCTION
BLOCK
C2
BATT A0
A11
A12
A61
14
DB/BK
15A
FUSE
21
FUEL
PUMP
RELAY
(IN PDC)
1
6
D2 C100
A141
14
DG/WT
M
FUEL
PUMP
MODULE
G302
S309
Z1
14
BK
BK
12
Z1
4
SENSOR
GROUND
C1 A4
BR/YL
18
K167
K226
18
DB/LG
3 C107
30
C200
S138
B3 C100
K167
20
BR/YL
FUSED
B(+)
C1
A61
16
DG/BK
A22
14 C107
DG/BK
16
A61
3
C26 C3
FUEL
LEVEL
SENSOR
SIGNAL
B2 C100
15
DB/LG
20
K226
K226
20
DB/LG
S111
13 C200
DG/WT
16
A141
BR/YL
20
K167
(8W-12-14)
(8W-12-14)
(8W-10-7)
(8W-10-9)
(8W-12-2)
(8W-10-6)
(8W-10-19)
(8W-15-11)
(8W-15-11)
(8W-70-2)
(8W-70-2)
XJ 8W-30 FUEL/IGNITION SYSTEM
GAS LHD
8W - 30 - 3
XJI03002 J978W-7
POWERTRAIN
CONTROL
MODULE
20A
FUSE
11
F12
18
DB/WT
D6 D8
D2 D4
K31
18
BR
C19 C3
CONTROL
RELAY
PUMP
FUEL
5
S130
CENTER
DISTRIBUTION
POWER
ST-RUN A21
JUNCTION
BLOCK
C2
BATT A0
A11
A12
A61
14
DB/BK
15A
FUSE
21
FUEL
PUMP
RELAY
(IN PDC)
1
6
D2 C100
A141
14
DG/WT
M
FUEL
PUMP
MODULE
G302
S309
Z1
14
BK
BK
12
Z1
4
SENSOR
GROUND
C1 A4
BR/YL
18
K167
K226
18
DB/LG
3 C107
17
C204
S138
B3 C100
K167
20
BR/YL
FUSED
B(+)
C1
A61
16
DG/BK
A22
14 C107
DG/BK
16
A61
3
C26 C3
FUEL
LEVEL
SENSOR
SIGNAL
B2 C100
16
DB/LG
20
K226
K226
20
DB/LG
S111
4 C204
DG/WT
16
A141
BR/YL
20
K167
(8W-12-14)
(8W-12-14)
(8W-10-6)
(8W-10-9)
(8W-12-2)
(8W-10-6)
(8W-10-19)
(8W-15-11)
(8W-15-11)
(8W-70-2)
(8W-70-2)
GAS RHD
XJ
J978W-7 XJI03003
POWERTRAIN
CONTROL
MODULE
DRIVER
COIL
IGNITION
A7 C1
C8
BATT A16
GY
18
K19
POWER
DISTRIBUTION
CENTER
AUTOMATIC
SHUT
DOWN
RELAY
C2
1
2
IGNITION
COIL
DG/OR
18
A142
2 1
3
1
SENSOR
POSITION
CRANKSHAFT
C1 A4
SENSOR
GROUND
S114
S111
K24
18
GY/BK
C1 A8
SIGNAL
SENSOR
POSITION
CRANKSHAFT
CKP
SENSOR
SIGNAL GROUND
SENSOR
SENSOR
GROUND
2
3
5V
SUPPLY
A17 C1
SIGNAL
SENSOR
CMP
CAMSHAFT
POSITION
SENSOR
SIGNAL
A18 C1
TN/YL
18
K44
SENSOR
POSITION
CAMSHAFT
S115
K7
20
OR
K167
20
BR/YL
SUPPLY
5V
5V
SUPPLY
S109
S137
DG/OR
18
A142
1 C107
20
FUSE
20A
A14
A13
POWER
DISTRIBUTION
CENTER
A999
16
RD
TO
23 (PDC)
FUSE
A999 16 RD
BR/YL
18
K167 K167
20
BR/YL
K167
18
BR/YL
A142
18
DG/OR
A142
18
DG/OR
OR
18
K7
OR
18
K7
(8W-10-17)
(8W-10-6)
(8W-10-7)
(8W-30-2)
(8W-70-2)
(8W-70-2)
(8W-70-5)
(8W-10-17)
(8W-10-17)
(8W-10-17)
(8W-10-7)
(8W-10-17)
GAS
8W - 30 - 5
XJI03004 J978W-7
POWERTRAIN
CONTROL
MODULE
2
1
DRIVER
NO. 1
INJ.
C2 B4
NO. 1
INJECTOR
FUEL
FUEL
INJECTOR
NO. 2
B15
NO. 2
DRIVER
2
K11
18
WT/DB YL/WT
K13
2
1
DRIVER
NO. 3
B5
NO. 3
INJECTOR
FUEL
K15
PK/BK
FUEL
INJECTOR
NO. 4
B16
NO. 4
DRIVER
K14
LB/BR
1
2 2
1
LG/BK
K16
DRIVER
NO. 6
B12
NO. 6
INJECTOR
FUEL
INJ. INJ. INJ. INJ. INJ.
2
1
TN
K12
DRIVER
NO. 5
B6
NO. 5
INJECTOR
FUEL
1
S113
18 18 18 18 18
A142
18
DG/OR DG/OR
18
A142
DG/OR
18
A142
DG/OR
18
A142
DG/OR
18
A142
DG/OR
18
A142
C2 C2 C2 C2 C2
C8
BATT A16
POWER
DISTRIBUTION
CENTER
AUTOMATIC
SHUT
DOWN
RELAY
C2
S109
S137
DG/OR
18
A142
1 C107
20
FUSE
20A
A14
A13
TO
23 (PDC)
FUSE
A142
18
DG/OR
RD
16
A999 A999
16
RD
(4.0L)
(4.0L)
(8W-10-18)
(8W-10-17)
(8W-10-6)
(8W-10-7)
(8W-30-2)
(8W-10-17)
(8W-10-17)
(8W-10-17)
(8W-10-17)
GAS
XJ
J978W-7 XJI03005
MODULE
CONTROL
POWERTRAIN
GROUND
SENSOR
A4 C1
SENSOR
POSITION
THROTTLE
3
1
K21
18
BK/RD
A15 C1
2
1
SENSOR
TEMPERATURE
AIR
INTAKE
2
BR/YL
20
K167
S115
ENGINE
COOLANT
TEMPERATURE
SENSOR
1
2
C1 A16
TN/BK
18
K2
S114
A23 C1
K22
18
OR/DB
SUPPLY
5V
C1 A17
K7
20
OR
SIGNAL
SENSOR
TEMPERATURE
AIR
INTAKE ENGINE
COOLANT
TEMPERATURE
SENSOR
SIGNAL
20
BR/YL
K167
S111
K167
18
BR/YL
BR/YL
20
K167
SIGNAL
SENSOR
POSITION
THROTTLE
(4WD)
S112
OR/DB
20
K22
17
TRANSMISSION
CONTROL
MODULE
6 C107
A/T M/T
K22
20
OR/DB
USED)
(NOT
OR
18
K7
OR/DB
20
K22
K167
BR/YL
20
2.5L 4.0L
(8W-70-5)
(8W-70-2)
(8W-70-2)
(8W-31-3)
GAS
8W - 30 - 7
XJI03006 J978W-7
POWERTRAIN
CONTROL
MODULE
A24 C1
BK
18
Z1
1 4
2 3
Z1
20
BK
C1 A4
K41
18
BK/DG
K167
18
BR/YL
S111
GROUND
SENSOR DOWNSTREAM
HEATED
OXYGEN
SENSOR
C1 A25
TN/BK
18
K141
UPSTREAM
HEATED
OXYGEN
SENSOR SENSOR
OXYGEN
HEATED
DOWNSTREAM
S110
G101
SIGNAL SIGNAL
SENSOR
OXYGEN
HEATED
UPSTREAM
BK
16
Z1
S107
S114
BR/YL
20
K167
K167
20
BR/YL
K167
18
BR/YL
C8
BATT A16
POWER
DISTRIBUTION
CENTER
AUTOMATIC
SHUT
DOWN
RELAY
C2
DG/WT
20
F142
7 C107
23
FUSE
15A
A8
A7
TO
20 (PDC)
FUSE
RD
16
A999 A999
16
RD
F142
20
DG/WT
DG/WT
20
F142 F142
20
DG/WT
1 4
2 3
(8W-70-2)
(8W-15-2)
(8W-15-2)
(8W-70-2)
(8W-10-17)
(8W-10-6)
(8W-10-7)
(8W-30-2)
(8W-10-17)
(8W-10-17)
GAS
XJ
J978W-7 XJI03007
MODULE
CONTROL
POWERTRAIN
1
C2 B31
VT/OR
18
K6
C1 A27
2
3
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
K1
18
DG/RD
OR
20
K7
S115
K7
18
OR
SUPPLY
5V
A17 C1
2 1
BR/YL
20
K167
SENSOR
SPEED
VEHICLE
5V
SUPPLY
G7
18
WT/OR
B27 C2
3
SIGNAL
SENSOR
SPEED
VEHICLE
K167
18
BR/YL
A4 C1
SENSOR
GROUND
S114
SIGNAL
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
S111
BR/YL
20
K167
K167
18
BR/YL
(8W-70-5)
(8W-70-2)
(8W-70-2)
GAS
8W - 30 - 9
XJI03008 J978W-7
MODULE
CONTROL
POWERTRAIN
K167
18
BR/YL
A4 C1
SENSOR
GROUND
S138
C3 C32
SENSE
SWITCH
CONTROL
SPEED
V37
18
RD/LG
B5 C100
20
1
2
BATTERY
TEMPERATURE
SENSOR
C3 C15
PK/YL
18
K118
SIGNAL
SENSOR
TEMPERATURE
BATTERY
CLOCKSPRING
C107 3
S111
V37
RD/LG
2 3
BK/LB
20
K4
B6 C100
K167
20
BR/YL
BR/YL
20
K167
OIL
PRESSURE
SENSOR
SIGNAL
G60
18
GY/YL
B23 C2
SENSOR
PRESSURE
OIL
1
2
LHD RHD
K4
20
BK/RD
SWITCH
CONTROL
SPEED
LEFT
2 1 1 2
RIGHT
SPEED
CONTROL
SWITCH
3
3 COAST
2 CANCEL
1 RESUME/ACCEL
2 ON/OFF
1 SET
1 2 2 1
B A
S222
S221
V37
20
RD/LG
K167
20
BR/YL RD/LG
20
V37
BR/YL
20
K167
(8W-70-2)
(8W-70-2)
GAS
XJ
J978W-7 XJI03009
POWERTRAIN
CONTROL
MODULE
SOLENOID
VACUUM
CONTROL
SPEED
C4 C3
TN/RD
18
V36
1 2
V35
18
LG/RD
C3 C5
SERVO
CONTROL
SPEED
VEHICLE
A6 C1
D11
D13
CENTER
DISTRIBUTION
POWER
7
P/N
T41
20
ST F45
CONTROL CONTROL
SPEED
CONTROL
VENT
SOLENOID SENSE
SWITCH
RANGE
TRANSMISSION
SWITCH
RANGE
TRANSMISSION
ENGINE
STARTER
MOTOR
RELAY
8
BK/WT
Z1
18
BK
BK
16
Z1
S141
G106
M/T A/T
S107
G101
Z1
16
BK
A/T M/T
(A/T)
BK/WT
18
T41
BK
14
Z1
G106
S132
Z1
20
BK
C107 5
T41
18
BK/WT
3
YL/RD
4
20
V32
3
DB/RD
20
V30
C100
V30
20
DB/RD
V32
18
YL/RD
C11
SPEED
CONTROL
SOURCE
C3
F9 F7
4.0L 2.5L
BK
20
Z1
S107
G101
Z1
16
BK
5 C107
T41
20
BR/LB
Z1
18
BK
STOP
LAMP
SWITCH
(8W-33-3)
(8W-10-6)
(8W-10-7)
(8W-12-17)
(8W-31-3)
(8W-21-2)
(8W-21-3)
(8W-15-5)
(8W-15-4)
(8W-15-2)
(8W-15-2)
(8W-15-4)
(8W-15-5) (8W-15-2)
(8W-15-2)
(8W-33-3)
GAS
8W - 30 - 11
XJI03010 J978W-7
GY/RD
18
K39
A11
2
MODULE
CONTROL
POWERTRAIN
C1
IAC
MOTOR
NO. 1
DRIVER
3
A10
IAC
MOTOR
NO. 2
DRIVER
YL/BK
K60
1
K59
VT/BK
DRIVER
NO. 4
MOTOR
IAC
A20 A19
IAC
MOTOR
NO. 3
DRIVER
BR/WT
K40
4
MOTOR
CONTROL
AIR
IDLE
F12
18
DB/WT
DB/WT
18
F12
11
FUSE
20A
ST-RUN A21
1
2
C3 C20
CONTROL
SOLENOID
PURGE
EVAP/
K52
18
PK/BK
PURGE
EVAP/
CYCLE
DUTY
18 18 18
IAC
MOTOR
NO. 3 NO. 4
MOTOR
IAC IAC
MOTOR
NO. 2 NO. 1
MOTOR
IAC
SOLENOID
S136
C1 C1 C1
5
C2
JUNCTION
BLOCK
S130
DB/WT
18
F12
(8W-12-14)
(8W-10-9)
(8W-12-14)
(8W-12-2)
(8W-12-14)
GAS
XJ
J978W-7 XJI03011
C3 C1
POWERTRAIN
CONTROL
MODULE
B1
B3
ST-RUN A17
CONTROL
RELAY
CLUTCH
COMPRESSOR
A/C
C13
18
DB/OR
CENTER
DISTRIBUTION
POWER
RELAY
CLUTCH
COMPRESSOR
A/C
C22
18
DB/WT
1
C22
C3 C1
C23
2
LG
18
C90
A6 C100
C90
20
LG
CONTROL
HEATER
A/C
SWITCH
PRESSURE
LOW
A/C A/C
HIGH
PRESSURE
SWITCH
A/C
SELECT
SIGNAL SIGNAL
REGUEST
A/C
LG
20
C90
S143
LG
20
C90
C1 C1
GENERATOR
FIELD
SOURCE
C3 C25
K72
18
DG/OR
DG/OR
18
K72
2
K20
18
DG
2 C107
C108
3
2 1
DRIVER
FIELD
GENERATOR
C2 B10
K20
18
DG
GENERATOR
DB/BK
18
C27
COOLING
FAN
RELAY
CONTROL
C13
C11
C2 C3
BATT A0
COOLING
FAN
RELAY
2
GENERATOR
1 2
C1 C1
RHD LHD
(8W-10-12)
(8W-10-6)
(8W-10-7)
(8W-42-7)
(8W-42-2)
(8W-42-3)
(8W-42-4)
(8W-42-2)
(8W-42-3)
(8W-42-4)
(8W-42-2)
(8W-42-3)
(8W-42-4)
(8W-20-2)
(8W-10-6)
(8W-42-7)
(8W-20-3)
GAS
8W - 30 - 13
XJI03012 J978W-7
POWERTRAIN
CONTROL
MODULE
SENSE
SWITCH
IDLE
EXTENDED
C100 F16
OTHERS
POLICE
PACKAGE
(NOT
USED)
C24
C3
WT/PK
18
K29
M/T A/T
B1 C100
2
1
K29
20
WT/PK
WT/PK
20
K29
C100 B1
S140
WT/PK
20
K29
S204
BK
18
Z1
Z1
14
BK
S207
G108
A12
C1
K78
18
GY
11 C107
GY
20
K78
C107 11
WT/PK
18
K29
C1
A12
POWER
STEERING
PRESSURE
SWITCH
SENSE
4.0L 2.5L
4.0L 2.5L
2
K10
18
DB/BR
SWITCH
PRESSURE
STEERING
POWER
STOP
LAMP
SWITCH
SENSE
STOP
LAMP
SWITCH
LHD RHD
K29
18
WT/PK
1
Z1
20
BK
S107
G101
BK
16
Z1
USED)
(NOT
(8W-15-10)
(8W-15-10)
(8W-33-3)
(8W-15-2)
(8W-15-2)
(8W-31-4)
GAS
XJ
J978W-7 XJI03013
C3 C29
POWERTRAIN
CONTROL
MODULE
C27 C3
CONNECTOR
LINK
DATA
PK
18
D21
17
FUSE
20A
A22
POWER
DISTRIBUTION
CENTER
BATT A0
A21
16
A18 C100
F34
18
TN/BK
Z12
18
BK/LB
5
A7 C100 A1
4
BK
18
Z1
Z12
18
BK/TN
G102
6 7
LG/BK
20
D20 D21
20
PK
BK/TN
18
Z12
TRANSMIT
SCI SCI
RECEIVE
C1 4
F34
18
TN/BK
SWITCH
HEADLAMP
B7 B8
D20
18
LG/BK
SCI
TRANSMIT
D21
20
PK
20
BRAKE
ANTI-LOCK
CONTROLLER
14
PK
20
D21
TRANSMIT
SCI
S139
TRANSMISSION
CONTROL
MODULE
D21
20
PK
2.5L 4.0L
HEADLAMP
SWITCH
4 C1
LHD RHD
TN/BK
18
F34
S218
(8W-10-16)
(8W-10-7)
(8W-10-6)
(8W-15-2)
(8W-50-2)
(8W-35-2)
(8W-31-4)
(8W-50-3)
(8W-10-16)
GAS
8W - 30 - 15
XJI03014 J978W-7
CONNECTOR
LINK
DATA
2 6
14
BLOCK
SPLICE
DIAGNOSTIC
8
VT/BR
18
D1 D2
18
WT/BK
11 3
6
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
12
INSTRUMENT
CLUSTER
1 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
2 C2
9 13
5 11
6 7
5 3
19
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
18
C28 C3
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
C30 C3
1 7
OVERHEAD
MODULE
(IMMOBILIZER)
D2
20
WT/BK VT/BR
20
D1
CCD
BUS
(+) (-)
BUS
CCD
COMPASS
D1
20
VT/BR WT/BK
20
D2
55
1
VT/BR
20
D1
D1
20
VT/BR
S346
S344
C301 2
C201 56
D2
20
WT/BK
D2
20
WT/BK
S144 S145
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
TRANSMISSION
(+)
BUS
CCD CCD
BUS
(-)
(A/T) (A/T)
D1
18
VT/BR WT/BK
18
D2
A11 C100
A12
51 C201 52
D2
18
WT/BK VT/BR
18
D1
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
WT/BK
20
D2
VT/BR
20
D1
PAIR
TWISTED
D1
20
VT/BR
D2
20
WT/BK
(IMMOBILIZER)
(IMMOBILIZER)
(8W-40-3)
(8W-39-8)
(8W-49-3)
(8W-31-4)
(8W-43-2)
GAS LHD
XJ
J978W-7 XJI03015
CONNECTOR
LINK
DATA
2 6
14
BLOCK
SPLICE
DIAGNOSTIC
8
VT/BR
18
D1 D2
18
WT/BK
11 3
6
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
12
INSTRUMENT
CLUSTER
1 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
2 C2
9 13
5 11
6 7
5 3
19
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
18
C28 C3
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
C30 C3
1 7
OVERHEAD
MODULE
(IMMOBILIZER)
D2
20
WT/BK VT/BR
20
D1
CCD
BUS
(+) (-)
BUS
CCD
COMPASS
D1
20
VT/BR WT/BK
20
D2
1
VT/BR
20
D1
D1
20
VT/BR
S346
S344
C301 2
D2
20
WT/BK
D2
20
WT/BK
S144 S145
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
TRANSMISSION
(+)
BUS
CCD CCD
BUS
(-)
(A/T) (A/T)
D1
18
VT/BR WT/BK
18
D2
A11 C100
A12
1 C204 2
D2
18
WT/BK VT/BR
18
D1
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
WT/BK
20
D2
VT/BR
20
D1
PAIR
TWISTED
D1
20
VT/BR
D2
20
WT/BK
(IMMOBILIZER)
(IMMOBILIZER)
(8W-40-3)
(8W-39-8)
(8W-49-3)
(8W-31-4)
(8W-43-3)
GAS RHD
8W - 30 - 17
XJI03016 J978W-7
POWERTRAIN
CONTROL
MODULE
46
12
Z12
1
GROUND
20A
FUSE
11
38
GROUND
C6 C8
C2 C4
K51
20
DB/YL
42 23
DG/OR
16
A142
RELAY
POWER
DIESEL
OUTPUT
(ST-RUN)
IGN.
FUSED
BK/LG
ST-RUN A21
S137
JUNCTION
BLOCK
5
C2
4
FUSE
30A
POWER
DISTRIBUTION
CENTER
BATT A0
A142
18
DG/OR
DIESEL
POWER
RELAY
A142
16
DG/OR
45
RELAY
POWER
DIESEL
OUTPUT
A142
16
DG/OR
68
RELAY
POWER
DIESEL
OUTPUT
24
GROUND
Z12
14 16
Z12 Z12
16
S150
S130
DB/WT
18
F12
9
FUSED
IGN.
(ST-RUN)
F12
18
DB/WT
F12
18
DB/WT
C1 C2
C1 C1 C1
BK/LG BK/LG BK/LG
G102
BK/LG
C2
14
Z12
GROUND
12
S146
BK/LG
Z12
12
11
Z12
14
C2
BK/LG
GROUND
DIESEL
POWER
RELAY
10
3
S151
A16
12
RD/LG
RD/LG
16
F16
A7
A8
10A
FUSE
24
BATT A16
FUSED
B(+)
3 C2 C1 C1 C1 C1
CONTROL
C2
OUTPUT
DIESEL
POWER
RELAY
DG/OR
16
A142
57
RD/LG
12
A16 A16
12
RD/LG
(8W-12-13)
(8W-10-29)
(8W-10-27)
(8W-12-2)
(8W-10-27)
(8W-10-25)
(8W-10-26)
(8W-10-25)
(8W-15-3)
(8W-12-13)
(8W-15-3)
(8W-15-3)
(8W-10-27)
(8W-10-27)
(8W-10-27)
DIESEL
XJ
J978W-7 XJI03017
20A
FUSE
11
D6 D8
D2 D4
RD/BK
14
A93
ST-RUN A21
5
C2
F12
18
DB/WT
6
FUSE
30A
POWER
DISTRIBUTION
CENTER
BATT A0
1
HEATER
FUEL
FUEL
HEATER
RELAY
2
Z1
18
BK
G106
BK
18
Z1
POWERTRAIN
CONTROL
MODULE
K35
18
GY/YL
25
RELAY
POWER
DIESEL
OUTPUT
F142
16
DG/OR
JUNCTION
BLOCK
B
A
S156
D
MODULATOR
VACUUM
ELECTRONIC
MODULATOR
VACUUM
ELECTRONIC
BK
18
Z1
ELECTRONIC
VACUUM
MODULATOR GROUND
5
12
A14
A13
20A
FUSE
21
C2
C8
BATT A16
CENTER
DISTRIBUTION
POWER
DIESEL
POWER
RELAY
A61
14
LG/RD
S137
DG/OR
16
A142
A142
16
DG/OR
DG/OR
18
F142
S157
Z1
12
BK
CONTROL
S132
BK
12
Z1
S130
DB/WT
18
F12
C1
(8W-12-13)
(8W-10-29)
(8W-10-31)
(8W-10-25)
(8W-10-26)
(8W-10-25)
(8W-15-4)
(8W-12-2)
(8W-10-35)
(8W-10-35)
(8W-10-27)
(8W-10-25)
(8W-10-26)
(8W-30-18)
(8W-10-27)
(8W-15-6)
(8W-15-6)
(8W-12-13)
DIESEL
8W - 30 - 19
XJI03018 J978W-7
GY
10
K154
POWER
DISTRIBUTION
CENTER
BATT A16
POWERTRAIN
CONTROL
MODULE
50
20A
FUSE
21
F142
18
DG/OR
C2
C8
RELAY
POWER
DIESEL
3 4
1 2
RELAY
PLUG
GLOW
K152
18
WT
CONTROL
RELAY
PLUG
LOW
S153
A54
10
RD/GY
20
K185
OR/LB
3
CONTROL
INDICATOR
START
TO
WAIT
4
1
9
FUSE
10A
JUNCTION
BLOCK
C4
S13
ST-RUN A21
GLOW
PLUG
ASSEMBLY
GLOW
PLUG
NO.1 NO.2
PLUG
GLOW
NO.3
PLUG
GLOW
NO.4
PLUG
GLOW
1
2
FUSE
50A
50A
FUSE
3
RD/GY
12
A54 A54
12
RD/GY
BATT A0
8
1
9
2
S137
A14
A13
DG/OR
16
A142
DG/OR
16
F142
S156
BASE
FULL
OPTIONS
LHD RHD
6 C301
5 C201
6
F87
20
WT/BK
COMPASS
WT/BK
20
F87
S216
WAIT
TO
START
WARNING
INDICATOR
WARNING
FUEL
IN
WATER
INDICATOR
7
31
TN/OR
G86
20
E15
E16
C2 C1
WATER
IN
FUEL
INDICATOR
CONTROL
TELL
TALE
MODULE
CONTROL
INDICATOR
LEVEL
COOLANT
LOW
C2
E17
C100
20
G154
VT/LG
54
8
INDICATOR
LOW
COOLANT
LEVEL
WARNING
WT/BK
20
F87
C1
(8W-10-25)
(8W-10-26)
(8W-10-27)
(8W-10-35)
(8W-12-11)
(8W-12-12)
(8W-12-2)
(8W-10-29)
(8W-10-27)
(8W-10-27)
(8W-10-25)
(8W-10-27)
(8W-10-35)
(8W-30-18)
(8W-49-2)
(8W-12-11)
(8W-12-12)
DIESEL
XJ
J978W-7 XJI03019
POWERTRAIN
CONTROL
MODULE
33
SENSOR
GROUND
7 4
SENSOR
TEMPERATURE
FUEL FUEL
QUANTITY
ACTUATOR
8 6 5
SOLENOID
TIMING
FUEL FUEL
SHUTDOWN
SOLENOID
9 10
POWER
DISTRIBUTION
CENTER
BATT A0
30A
FUSE
4
C2
C8
RELAY
POWER
DIESEL
S137
DG/OR
16
A142
GY
20
K156
63
FUEL
TEMP.
SENSOR
K4
20
BK/LB
BK/LB
20
K4
S149
TN/WT
16
K140
K140
TN/WT
5 4
TN/WT
16
K140
49
TN/WT
K140
S148
(TWISTED PAIR)
FUEL QUANTITY ACTUATOR
16 16
LG
16
K126
51
CONTROL
SOLENOID
TIMING
FUEL
53
FUEL
SHUTDOWN
SOLENOID
CONTROL
K153
16
OR
C1 C1
FUEL
PUMP
MODULE
S151
A16
12
RD/LG
10
3 A14
A13
21
FUSE
20A
F142
16
DG/OR
S156
DG/OR
16
F142 A142
16
DG/OR
C1 C1 C1 C1 C1
DG/OR
16
A142
(8W-10-25)
(8W-10-26)
(8W-10-25)
(8W-10-27)
(8W-10-27)
(8W-70-3)
(8W-10-27)
(8W-30-18)
(8W-10-35)
(8W-10-35)
DIESEL
8W - 30 - 21
XJI03020 J978W-7
POWERTRAIN
CONTROL
MODULE
7
LB/BK
20
K134
20
1
MEASURE
COIL
3 2
20
K135
WT/BK
52
FUEL
PUMP
CONTROL
29
K57
LG/OR
2
3
GROUND
SENSOR
BK/LB
20
K4
20
K155
DB
4
K4
20
BK/LB
S149
SENSOR
FLOW
AIR
MASS
G106
Z2
18
BK/LG
1
13 33
RELAY OUTPUT
DIESEL POWER
SENSOR
GROUND GROUND
AIR
FLOW
METER
SIGNAL
C1 C1 C1 C1 C1
SLEEVE
CONTROL
FUEL
PUMP
MODULE
SLEEVE
SIGNAL SIGNAL
COIL
REFERENCE
PUMP
FUEL FUEL
PUMP
MEASURE
COIL
SIGNAL SIGNAL
SENSOR
FLOW
AIR
MASS
POWER
DISTRIBUTION
CENTER
BATT A0
30A
FUSE
4
C2
C8
RELAY
POWER
DIESEL
S137
S151
A16
12
RD/LG
10
3 A14
A13
21
FUSE
20A
F142
16
DG/OR
S156
DG/OR
16
F142 A142
16
DG/OR DG/OR
16
A142
(8W-70-3)
(8W-15-4)
(8W-10-25)
(8W-10-26)
(8W-10-25)
(8W-10-27)
(8W-10-27)
(8W-10-27)
(8W-30-18)
(8W-10-35)
(8W-10-35)
DIESEL
XJ
J978W-7 XJI03021
POWERTRAIN
CONTROL
MODULE
7
15
OR/DB
K22
20 20
K225
WT/DG
55
8
20
K6
VT/WT
57
10
33
SENSOR
GROUND
ACCELERATOR
PEDAL
3
S149
20
K151
WT
65
5
BK/LB
K4
20
SENSOR
GROUND
LOW
IDLE
POSITION
SWITCH SIGNAL
SENSOR
PEDAL
ACCELERATOR
GROUND
SENSOR
PEDAL
ACCELERATOR
SUPPLY
5V
SWITCH
POSITION
IDLE
LOW ACCELERATOR
PEDAL
SENSOR
SIGNAL
SUPPLY
5V
GROUND
SENSOR
PEDAL
ACCELERATOR
20
K4
BK/LB
C1 C1 C1 C1 C1 C1
VTA
59
OR/BK
G55
20
C2 15
VTA
20
G55
OR/BK
(8W-70-3)
DIESEL
8W - 30 - 23
XJI03022 J978W-7
POWERTRAIN
CONTROL
MODULE
3
SENSOR
SPEED
VEHICLE
2
WT/OR
20
G7
43
TN/RD
20
K222
21
A
COOLANT
TEMPERATURE
SENSOR
C
14
B
33
GROUND
SENSOR
9
C120
K4
20
BK/LB
S149
BK/LB
20
K4
TN/BK
20
K2
K2
20
TN/BK
SENSOR
GROUND
GROUND
SENSOR
K167
18
BR/YL
COOLANT
TEMP.
SENSOR SENSOR
TEMP.
COOLANT
SENSOR
SPEED
VEHICLE
SIGNAL
SENSOR
SPEED
VEHICLE
1
C110
3
5V
SUPPLY
6
SUPPLY
8V
1
OR
20
K7
C2
K7
20
OR
G7
18
WT/OR
SIGNAL
S152
C1
VEHICLE
SPEED
SENSOR
SIGNAL
C2 47
G7
20
WT/OR
G7
20
WT/OR
8
BR/YL
20
K167
S138
4 C2
SENSOR
GROUND
K167
20
BR/YL
C1
S117
SIGNAL
SENSOR
TEMPERATURE
COOLANT COOLANT
TEMPERATURE
SENSOR
SIGNAL
10 8
K222
20
TN/RD
C1 C2
BK/LB
20
K4
BK/LB
20
K4
ENGINE ENGINE
ENGINE
ENGINE ENGINE
(8W-70-3) (8W-70-3)
(8W-70-3)
DIESEL
XJ
J978W-7 XJI03023
POWERTRAIN
CONTROL
MODULE
1 2
12
SENSOR
MOVEMENT
NEEDLE
BR/BK
18
K67
B(+)
SENSOR
MOVEMENT
NEEDLE
11
LG/YL
18
K68
GY/BK
20
K24
4
8
3
C120
K3
20
LG/BK
1
K24
20
GY/BK
C1
NEEDLE
MOVEMENT
SENSOR
B(-)
C1
B(-)
SENSOR
MOVEMENT
NEEDLE NEEDLE
MOVEMENT
SENSOR
B(+)
C1
SENSOR
POSITION
CRANKSHAFT
1
CRANKSHAFT
POSITION
SENSOR
GROUND SIGNAL
SENSOR
POSITION
CRANKSHAFT
C1 21
LG/BK
20
K3
CRANKSHAFT
POSITION
SENSOR
SIGNAL GROUND
SENSOR
POSITION
CRANKSHAFT
PAIR
TWISTED
DIESEL
8W - 30 - 25
XJI03024 J978W-7
POWERTRAIN
CONTROL
MODULE
15A
FUSE
19
F32
20
PK/DB
CENTER
DISTRIBUTION
POWER
BATT A0
2
1
SWITCH
LAMP
STOP
WT
20
V37
2
CLOCKSPRING
20
WT/PK
20
K29
6 5
44
BRAKE
SWITCH
PRIMARY
SIGNAL SIGNAL
SECONDARY
SWITCH
BRAKE
S147
L50
20
WT/TN
WT/TN
20
L50
27 36
V37
20
RD/LG
SPEED
CONTROL
SWITCH
SENSE
RD/LG
20
V37
B4 C100
WT/TN
20
L50
S203
L50
20
WT/TN
B1
S204
K29
18
WT/PK
K29
18
WT/PK
BLK
18
Z1
S207
Z1
14
BLK
G108
A18
A17
C1 C1 C1 C1
B5
C100
41
C2
LAMP
ON
CONTROL
SPEED
RD/LG
20
V66 V66
20
RD/LG
SPEED
CONTROL
ON
LAMP
SWITCH
CONTROL
SPEED
LEFT RIGHT
SPEED
CONTROL
SWITCH
B A
B6
C1
GROUND
SENSOR
BK/LB
20
K4
33
3
S149
K4
20
BK/RD
RHD LHD
BK/LB
20
K4
1 2
K167
20
BR/YL
2 1
S221
S222
BR/YL
20
K167 V37
20
WT WT
20
V37 K167
20
BR/YL
(8W-10-34)
(8W-10-26)
(8W-10-25)
(8W-10-34)
(8W-33-4)
(8W-10-34)
(8W-15-10)
(8W-15-10)
(8W-70-3)
(8W-33-4) (8W-33-4)
DIESEL
XJ
J978W-7 XJI03025
42
POWERTRAIN
CONTROL
MODULE
SIGNAL
SENSOR
PRESSURE
OIL
G60
20
GY/YL
C2
2
1
OIL
PRESSURE
SENSOR
C2
BR/YL
20
K167
SENSOR
GROUND
4
S138
K167
20
BR/YL
BR/YL
20
K167
SENSOR
LEVEL
FUEL
4
3
C2
DB/LG
20
K226
FUEL
LEVEL
SENSOR
SIGNAL
1
B2
K226
20
DB/LG
C204 16
RHD LHD
LHD RHD
17 C204
15 C200
C200 30
BR/YL
20
K167
2
1
C2
DG/WT
20
G123
WATER
IN FUEL
SENSOR
SIGNAL
23
SENSOR
FUEL
IN
WATER
8
SIGNAL
SWITCH
COOLANT
LOW
G18
20
PK/BK
C2
LOW
COOLANT
SWITCH
2
K167
20
BR/YL
1
B3 C100
K167
20
BR/YL
(8W-70-3)
DIESEL
8W - 30 - 27
XJI03026 J978W-7
28
POWERTRAIN
CONTROL
MODULE
CONTROL
RELAY
CLUTCH
COMPRESSOR
A/C
C22
20
DB/WT
SIGNAL
59
SWITCH
ON/OFF
A/C
DG
20
C103
C100
DB/PK
20
C22
A6
28
C90
20
LG
2
LG
20
C90
C2 C1
C103
20
DG
A/C
ON/OFF
SWITCH
37
SIGNAL
2
SIGNAL
TACH
GY/LB
20
G21
C1 C2
G21
20
GY/LB
24
TACH
SIGNAL
C2 C1
3 C120
2
SWITCH
PRESSURE
HIGH
A/C
A/C
HEATER
CONTROL
A/C
SELECT
SIGNAL DRIVER
FIELD
GENERATOR
C2
DG
18
K20
20
3
GENERATOR
1
K20
18
DG
C1
(8W-42-8)
(8W-42-5)
(8W-42-6)
(8W-20-4)
DIESEL
XJ
J978W-7 XJI03027
C2 45
POWERTRAIN
CONTROL
MODULE
61 C1
CONNECTOR
LINK
DATA
PK
20
D21
26
FUSE
20A
A3
POWER
DISTRIBUTION
CENTER
BATT A0
A4
16
A18 C100
F34
18
TN/BK
Z12
18
BK/LB
5
A7 C100 A1
4
BK
18
Z1
Z12
18
BK/TN
G102
6 7
LG/BK
20
D20 D21
20
PK
BK/LG
20
Z12
TRANSMIT
SCI SCI
RECEIVE
C1 4
F34
18
TN/BK
SWITCH
HEADLAMP
B7 B8
D20
20
LG/BK
SCI
TRANSMIT
D21
20
PK
20
BRAKE
ANTI-LOCK
CONTROLLER
S139
D21
20
PK
HEADLAMP
SWITCH
4 C1
LHD RHD
TN/BK
18
F34
S218
SCI
TRANSMIT
D21
20
PK
C2 25
S146
S150
Z12
12
BK/LG
Z12
12
BK/LG
(8W-10-37)
(8W-10-26)
(8W-10-25)
(8W-15-3)
(8W-50-2)
(8W-35-4)
(8W-50-3)
(8W-10-37)
(8W-15-3)
(8W-15-3)
DIESEL
8W - 30 - 29
XJI03028 J978W-7
CONNECTOR
LINK
DATA
2 6
14
BLOCK
SPLICE
DIAGNOSTIC
8
VT/BR
18
D1 D2
18
WT/BK
11 3
6
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
12
INSTRUMENT
CLUSTER
1 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
2 C2
9 13
5 11
5 3
19
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
18
46 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
26 C2
1 7
OVERHEAD
MODULE
(IMMOBILIZER)
D2
20
WT/BK VT/BR
20
D1
CCD
BUS
(+) (-)
BUS
CCD
COMPASS
D1
20
VT/BR WT/BK
20
D2
55
1
VT/BR
20
D1
D1
20
VT/BR
S346
S344
C301 2
56
D2
20
WT/BK
D2
20
WT/BK
POWERTRAIN
CONTROL
MODULE
D1
20
VT/BR WT/BK
20
D2
A11 C100
A12
51 C201 52
D2
18
WT/BK VT/BR
18
D1
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
(IMMOBILIZER)
(IMMOBILIZER)
TWISTED
PAIR
PAIR
TWISTED
(8W-40-4)
(8W-39-8)
(8W-49-2)
(8W-43-2)
DIESEL LHD
XJ
J978W-7 XJI03029
CONNECTOR
LINK
DATA
2 6
14
BLOCK
SPLICE
DIAGNOSTIC
8
VT/BR
18
D1 D2
18
WT/BK
11 3
6
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
12
INSTRUMENT
CLUSTER
1 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
2 C2
9 13
5 11
5 3
19
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
18
46 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
26 C2
1 7
OVERHEAD
MODULE
(IMMOBILIZER)
D2
20
WT/BK VT/BR
20
D1
CCD
BUS
(+) (-)
BUS
CCD
COMPASS
D1
20
VT/BR WT/BK
20
D2
1
VT/BR
20
D1
D1
20
VT/BR
S346
S344
C301 2
D2
20
WT/BK
D2
20
WT/BK
POWERTRAIN
CONTROL
MODULE
D1
20
VT/BR WT/BK
20
D2
A11 C100
A12
1 C204 2
D2
18
WT/BK VT/BR
18
D1
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
(IMMOBILIZER)
(IMMOBILIZER)
TWISTED
PAIR
PAIR
TWISTED
(8W-40-4)
(8W-39-8)
(8W-49-2)
(8W-43-3)
DIESEL RHD
8W - 30 - 31
XJI03030 J978W-7
8W-30 FUEL/IGNITION SYSTEMS
INDEX
page page
IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . 32
BATTERY FEED . . . . . . . . . . . . . . . . . . . . . . . . . 32
BATTERY FEED (DIESEL) . . . . . . . . . . . . . . . . . 32
GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
POWER GROUND (DIESEL) . . . . . . . . . . . . . . . 33
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . 33
AUTOMATIC SHUT DOWN (ASD) RELAY . . . . . . 33
DIESEL POWER RELAY . . . . . . . . . . . . . . . . . . . 33
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . 33
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 33
FUEL PUMP MODULE (DIESEL) . . . . . . . . . . . . 34
VEHICLE SPEED SENSOR (DIESEL) . . . . . . . . . 34
HEATED OXYGEN SENSORS . . . . . . . . . . . . . . 34
CRANKSHAFT POSITION SENSOR (DIESEL) . . 35
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
THROTTLE POSITION SENSOR . . . . . . . . . . . . 35
ACCELERATOR PEDAL POSITION SENSOR
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LOW IDLE POSITION SWITCH (DIESEL) . . . . . . 36
MANIFOLD ABSOLUTE PRESSURE SENSOR . . 36
MASS AIR FLOW SENSOR (DIESEL) . . . . . . . . . 36
INTAKE AIR TEMPERATURE SENSOR . . . . . . . . 36
OIL PRESSURE SENSOR (DIESEL) . . . . . . . . . . 36
WATER IN FUEL SENSOR (DIESEL) . . . . . . . . . 36
POWER STEERING PRESSURE SWITCH . . . . . 37
STOP LAMP SWITCH INPUT . . . . . . . . . . . . . . . 37
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 37
FUEL INJECTION PUMP (DIESEL) . . . . . . . . . . . 37
FUEL HEATER (DIESEL) . . . . . . . . . . . . . . . . . . 37
NEEDLE MOVEMENT SENSOR (DIESEL) . . . . . 38
GLOW PLUGS (DIESEL) . . . . . . . . . . . . . . . . . . 38
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 38
DUTY CYCLE EVAP\PURGE SOLENOID . . . . . . 38
ELECTRIC VACUUM MODULATOR (DIESEL) . . . 38
LOW COOLANT LEVEL SWITCH (DIESEL) . . . . . 38
TORQUE CONVERTER CLUTCH (TCC)
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
EXTENDED IDLE SWITCH . . . . . . . . . . . . . . . . . 38
CCD BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
IGNITION SWITCH
Ci rcui t A1 from fuse 2 and ci rcui t A2 from fuse 3,
i n the power di stri buti on center (PDC), suppl y bat-
tery vol tage to the i gni ti on swi tch. Dependi ng upon
posi ti on, the i gni ti on swi tch powers ci rcui ts A21, A22,
A31, A41, G9, G26, and G99.
START POSITION
I n the START posi ti on, the i gni ti on swi tch connects
ci rcui t A1 to ci rcui t A21 and ci rcui t A2 to ci rcui t A41.
Addi ti onal l y i n the START posi ti on, the case
grounded i gni ti on swi tch provi des ground for the
brake l amp swi tch and the warni ng l amps i n the
i nstrument cl uster.
START OR RUN POSITION
I n the START or RUN posi ti on, the i gni ti on swi tch
connects ci rcui t A1 to ci rcui t A21.
RUN (ONLY) POSITION
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A1 to ci rcui t A21 and ci rcui t A2 to
ci rcui t A22.
ACCESSORY OR RUN POSITIONS
I n the ACCESSORY or RUN posi ti ons, the i gni ti on
swi tch connects ci rcui t A1 to ci rcui t A31.
BATTERY FEED
Ci rcui t A61 from fuse 21 i n the Power Di stri buti on
Center (PDC) suppl i es battery vol tage to cavi ty A22
of the Powertrai n Control Modul e (PCM).
HELPFUL INFORMATION
Ci rcui t A61 al so suppl i es power to the contact si de
of the fuel pump rel ay.
BATTERY FEED (DIESEL)
Battery feed for the Powertrai n Control Modul e
(PCM) i s suppl i ed from several sources. One i s a con-
stant battery feed on ci rcui t F16. Thi s ci rcui t i s pro-
tected by a 10 amp fuse l ocated i n the Power
Di stri buti on Center (PDC)
8W - 30 - 32 8W - 30 FUEL/IGNITION SYSTEMS XJ
Battery vol tage i s al so provi ded on ci rcui t F12.
Thi s ci rcui t i s HOT i n the START and RUN posi ti on
and protected by a 20 amp fuse l ocated i n the Junc-
ti on Bl ock. Power for the fuse i s suppl i ed on ci rcui t
A21 from the i gni ti on swi tch.
GROUND
Ci rcui t Z12 connects to cavi ti es A31 and A32 of the
PCM. The Z12 ci rcui t provi des ground for PCM i nter-
nal dri vers that operate hi gh current devi ces l i ke the
i njectors and i gni ti on coi l .
I nternal to the PCM, the power (devi ce) ground ci r-
cui t connects to the PCM sensor return ci rcui t (from
ci rcui t K167).
HELPFUL INFORMATION
The groundi ng poi nt for ci rcui t Z12 i s the ri ght
front of the engi ne.
I f the system l oses ground for the Z12 ci rcui ts at
the front of the engi ne, the vehi cl e wi l l not operate.
Check the connecti on at the ganged-ground ci rcui t
eyel et.
POWER GROUND (DIESEL)
Ci rcui t Z12 attaches to cavi ti es 11 and 12 of the
Powertrai n Control Modul e (PCM) and caci ti es 1, 24
and 46 of the MSA Control l er. Ci rcui t Z12 termi nates
at the battery ground at the engi ne.
DATA LINK CONNECTOR
Ci rcui t F39 from the Power Di stri buti on Center
(PDC) suppl i es battery vol tage to the data l i nk con-
nector.
Ci rcui t D20 connects to cavi ty C29 of the PCM.
Ci rcui t D20 i s the SCI recei ve ci rcui t for the Power-
trai n Control Modul e (PCM). Ci rcui t D21 connects to
cavi ty C27 of the PCM and cavi ty A3 of the Control -
l er- Anti Lock Brakes. Ci rcui t D21 i s the SCI trans-
mi t ci rcui t for the PCM. CCD Bus Ci rcui ts D1 and
D2 connect to the data l i nk connector.
Ci rcui ts Z1 and Z12 provi de ground for the data
l i nk connector. Ci rcui t Z12 al so connects to cavi ti es
A31 and A32 of the PCM.
AUTOMATIC SHUT DOWN (ASD) RELAY
RUN posi ti on, i t connects ci rcui t A1 from fuse 8 i n
the Power Di stri buti on Center (PDC) to ci rcui t A21.
Ci rcui t A21 spl i ces to ci rcui t F12 and suppl i es bat-
tery vol tage to the coi l si de of the Automati c Shut
Down (ASD) rel ay. The Powertrai n Control Modul e
(PCM) provi des ground for the rel ay on ci rcui t K51.
Ci rcui t K51 connects to cavi ty C3 of the PCM.
When the PCM grounds the ASD rel ay, contacts
i nsi de the rel ay cl ose and connect ci rcui t A16 from
fuse 18 i n the PDC to ci rcui t A142. Ci rcui t A142 con-
HELPFUL INFORMATION
Al ong wi th suppl yi ng vol tage to the coi l si de of the
ASD rel ay, ci rcui t F12 al so suppl i es vol tage to the
coi l si de of the fuel pump rel ay.
DIESEL POWER RELAY
Power for the coi l and contact si de of the di esel
power rel ay i s suppl i ed on ci rcui t A16. Thi s ci rcui t i s
HOT at al l ti mes and protected by a 30 amp fuse
Ground for the coi l si de of the rel ay i s control l ed by
the MSA Control l er on ci rcui t K51.
When the MSA Control l er provi des a ground for
the coi l si de of the rel ay, the contacts i n the rel ay
CLOSE and connect ci rcui ts A16 to ci rcui ts A142 and
F142. The A142 and F142 ci rcui ts suppl y power to
vari ous components and modul es i n the fuel system.
HELPFUL INFORMATION
Check the 30 amp fuse l ocated i n the PDC
Refer to the appropri ate secti on of the servi ce
manual or Di agnosti c Test Procedures manual
FUEL PUMP RELAY
RUN posi ti ons, i t connects ci rcui t A1 from fuse 2 i n
Ci rcui t A21 spl i ces to ci rcui t F12 and suppl i es bat-
tery vol tage to the coi l si de of the fuel pump rel ay.
The Powertrai n Control Modul e (PCM) provi des
ground for the rel ay on ci rcui t K31. Ci rcui t K31 con-
When the PCM grounds the fuel pump rel ay, con-
tacts i nsi de the rel ay cl ose and connect ci rcui t A61
from fuse 21 i n the PDC to ci rcui t A141. Ci rcui t A141
suppl i es vol tage to the fuel pump motor (part of the
i n-tank fuel pump modul e).
HELPFUL INFORMATION
Ci rcui t A61 al so spl i ces to suppl y battery vol tage to
cavi ty A22 of the PCM.
FUEL PUMP MODULE
The i n-tank fuel pump modul e contai ns the fuel
pump motor and fuel l evel sensor.
FUEL PUMP MOTOR
When the fuel pump rel ay contacts cl ose, ci rcui t
A141 suppl i es vol tage to the fuel pump modul e. Ci r-
cui t Z1 provi des ground for the fuel pump motor.
FUEL LEVEL SENSOR
The fuel l evel sensor i s a vari abl e resi stor. Ci rcui t
K226 provi des the fuel l evel i nput to cavi ty C26 of
the Powertrai n Control Modul e (PCM). The PCM
broadcasts fuel l evel data on the CCD bus. The
mi cro-processor i n the i nstrument cl uster recei ves
the message on the CCD bus, cal cul ates fuel gauge
needl e posi ti on and adjusts the gauge.
FUEL PUMP MODULE (DIESEL)
The fuel pump modul e used on thi s engi ne package
contai ns the fuel gauge l evel sendi ng uni t.The fuel
l evel sensor i s a vari abl e resi stor. Ci rcui t K226 pro-
vi des the fuel l evel i nput to the Powertrai n Control
Modul e (PCM). The PCM broadcasts fuel l evel data
on the CCD bus. The mi cro-processor i n the i nstru-
ment cl uster recei ves the message on the CCD bus,
cal cul ates fuel gauge needl e posi ti on and adjusts the
gauge.
Ground for the modul e i s suppl i ed on ci rcui t K167.
Ci rcui t K6 suppl i es 5 vol ts from the Powertrai n
Control Modul e (PCM) to the vehi cl e speed sensor.
The K6 ci rcui t connects to cavi ty B31 of the PCM.
Ci rcui t G7 from the vehi cl e speed sensor provi des
an i nput si gnal to the PCM. The G7 ci rcui t connects
to cavi ty B27 of the PCM.
The PCM provi des a ground for the vehi cl e speed
sensor si gnal (ci rcui t G7) through ci rcui t K167. Ci r-
cui t K167 connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Ci rcui t K167 spl i ces to suppl y ground for the si g-
nal s from the fol l owi ng:
Camshaft posi ti on sensor
Engi ne oi l pressure sensor
Fuel l evel sensor
Heated oxygen sensor
I ntake ai r temperature sensor
Mani fol d absol ute pressure sensor
Vehi cl e speed control modul e
VEHICLE SPEED SENSOR (DIESEL)
Ci rcui t K7 suppl i es vol tage from the Powertrai n
Control Modul e (PCM) to the vehi cl e speed sensor.
Ci rcui t G7 from the vehi cl e speed sensor provi des
an i nput si gnal to the PCM.
The PCM provi des a ground for the vehi cl e speed
sensor si gnal (ci rcui t G7) through ci rcui t K167.
HEATED OXYGEN SENSORS
When the Automati c Shut Down (ASD) rel ay con-
tacts cl ose, they connect ci rcui ts A16 and F142. Ci r-
cui t F142 suppl i es vol tage to the upstream and
downstream heated oxygen sensors.
Ci rcui t K41 del i vers the si gnal from the upstream
heated oxygen sensor to the Powertrai n Control Mod-
ul e (PCM). Ci rcui t K41 connects to cavi ty A24 of the
PCM. Ci rcui t K141 suppl i es the si gnal from the
downstream heated oxygen sensor to the PCM. Ci r-
cui t K141 connects to PCM cavi ty A25.
The PCM provi des a ground for the heated oxygen
sensor si gnal s (ci rcui ts K41 and K141) through ci r-
cui t K167. Ci rcui t H167 connects to cavi ty A4 of the
PCM connector.
Ci rcui t Z1 provi des ground for the heater ci rcui t i n
each sensor.
HELPFUL INFORMATION
Fuel l evel sensor
The Powertrai n Control Modul e (PCM) determi nes
battery temperature on ci rcui t K15. Ci rcui t K15 con-
nects the PCM to the battery temperature sensor.
Ci rcui t K15 connects to cavi ty C15 of the PCM. Ci r-
cui t K167 provi des ground for the sensor and con-
nects to PCM cavi ty A4.
The Powertrai n Control Modul e (PCM) suppl i es 5
vol ts to the crankshaft posi ti on sensor on ci rcui t K7.
Ci rcui t K7 connects to cavi ty A17 of the PCM.
The PCM recei ves the crankshaft posi ti on sensor
si gnal on ci rcui t K24. Ci rcui t K24 connects to cavi ty
A8 of the PCM.
The PCM provi des a ground for the crankshaft
posi ti on sensor (ci rcui t K24) through ci rcui t K167.
HELPFUL INFORMATION
Ci rcui t K7 spl i ces to suppl y 5 vol ts to the cam-
shaft posi ti on sensor.
Fuel l evel sensor
CRANKSHAFT POSITION SENSOR (DIESEL)
The MSA Control l er suppl i es vol tage to the crank-
shaft posi ti on sensor on ci rcui t K24.
The MSA Control l er provi des a ground for the
crankshaft posi ti on sensor (ci rcui t K24) through ci r-
cui t K3.
The Powertrai n Control Modul e (PCM) suppl i es 5
vol ts to the camshaft posi ti on sensor (i n di stri butor)
on ci rcui t K7. Ci rcui t K7 connects to cavi ty A17 of
the PCM.
The PCM recei ves the camshaft posi ti on sensor si g-
nal on ci rcui t K44. Ci rcui t K44 connects to cavi ty
A18 of the PCM.
The PCM provi des a ground for the camshaft posi -
ti on sensor si gnal (ci rcui t K44) through ci rcui t K167.
HELPFUL INFORMATION
Ci rcui t K7 spl i ces to suppl y 5 vol ts to the crank-
shaft posi ti on sensor.
Fuel l evel sensor
The engi ne cool ant temperature sensor provi des an
i nput to the Powertrai n Control Modul e (PCM) on
ci rcui t K2. From ci rcui t K2, the engi ne cool ant tem-
perature sensor draws up to 5 vol ts from the PCM.
The sensor i s a vari abl e resi stor. As cool ant temper-
ature changes, the resi stance i n the sensor changes,
causi ng a change i n current draw. The K2 ci rcui t
connects to cavi ty A16 of the PCM.
The PCM provi des a ground for the engi ne cool ant
temperature sensor si gnal (ci rcui t K2) through ci rcui t
K167. Ci rcui t K167 connects to cavi ty A4 of the PCM
connector.
HELPFUL INFORMATION
Fuel l evel sensor
(DIESEL)
The Engi ne Cool ant Temperature (ECT) sensor on
thi s engi ne appl i cati on i s a dual functi on sensor. I t
provi des an engi ne cool ant temperature i nput to the
Powertrai n Control Modul e (PCM) on Ci rcui t K222
and to the MSA Control l er on ci rcui t K2.
Ground for the sensor i s suppl i ed on ci rcui t K4.
The sensor i s a vari abl e resi stor. As engi ne cool ant
temperature changes the resi stance on the K4 ci rcui t
changes.
From the Powertrai n Control Modul e (PCM), ci r-
cui t K7 suppl i es 5 vol ts to the throttl e posi ti on sen-
sor (TPS). Ci rcui t K7 connects to cavi ty A17 of the
PCM.
Ci rcui t K22 del i vers the TPS si gnal to the PCM.
The PCM provi des a ground for the throttl e posi -
ti on sensor si gnal (ci rcui t K22) through ci rcui t K167.
HELPFUL INFORMATION
Refer to Group 14 for throttl e posi ti on sensor oper-
ati on.
Ci rcui t K7 spl i ces to suppl y 5 vol ts to the mani fol d
absol ute pressure sensor, battery temperature sensor,
camshaft posi ti on sensor, and crankshaft posi ti on
sensor.
On vehi cl es equi pped wi th the 4.0L engi ne and
automati c transmi ssi on, ci rcui t K22 spl i ces to the
transmi ssi on control modul e.
Fuel l evel sensor
ACCELERATOR PEDAL POSITION SENSOR
(DIESEL)
Power for the accel erator pedal posi ti on sensor i s
suppl i ed by the MSA Control l er on ci rcui t K6. Thi s i s
a 5 vol t feed from the MSA Control l er.
Ci rcui t K22 provi des the pedal posi ti on i nput to
the MSA Control l er. Ground for the sensor i s sup-
pl i ed from the MSA Control l er on ci rcui t K255.
LOW IDLE POSITION SWITCH (DIESEL)
Ci rcui t K151 connects from the MSA Control l er to
the Accel erator Pedal Posi ti on Sensor. Thi s ci rcui t
provi des the l ow i dl e swi tch i nput.
Ground for the Accel erator Pedal Posi ti on Sensor i s
provi ded on ci rcui t K255.
MANIFOLD ABSOLUTE PRESSURE SENSOR
From the Powertrai n Control Modul e (PCM), ci r-
cui t K7 suppl i es 5 vol ts to the mani fol d absol ute
pressure (MAP) sensor. Ci rcui t K7 connects to cavi ty
A17 of the PCM.
Ci rcui t K1 del i vers the MAP si gnal to the PCM.
The PCM provi des a ground for the MAP sensor
si gnal (ci rcui t K1) through ci rcui t K167. Ci rcui t K167
connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Refer to Group 14 for MAP sensor operati on.
Ci rcui t K7 spl i ces to suppl y 5 vol ts to the camshaft
posi ti on sensor, crankshaft posi ti on sensor and throt-
tl e posi ti on sensor.
Fuel l evel sensor
MASS AIR FLOW SENSOR (DIESEL)
Power for the mass ai r fl ow sensor i s suppl i ed on
ci rcui t F142. Thi s ci rcui t i s HOT when the contacts
i n the Di esel Power Rel ay are CLOSED.
Ci rcui t K155 provi des the i nput to the MSA Con-
trol l er. A sensor ground i s provi ded by the MSA Con-
trol l er on ci rcui t K4.
Ground i s al so provi ded on ci rcui t Z2.
INTAKE AIR TEMPERATURE SENSOR
The i ntake ai r temperature sensor provi des an
i nput to the Powertrai n Control Modul e (PCM) on
ci rcui t K21. Ci rcui t K21 connects to cavi ty A15 of the
PCM.
From ci rcui t K21, the i ntake ai r temperature sen-
sor draws vol tage from the PCM. The sensor i s a
vari abl e resi stor. As i ntake ai r temperature changes,
the resi stance i n the sensor changes, causi ng a
change i n current draw.
The PCM provi des a ground for the i ntake ai r tem-
perature sensor si gnal (ci rcui t K21) through ci rcui t
K167. Ci rcui t K167 connects to cavi ty A4 of the PCM.
HELPFUL INFORMATION
Fuel l evel sensor
OIL PRESSURE SENSOR (DIESEL)
The oi l pressure sensor i s a vari abl e resi stor. A
change i n engi ne oi l pressure changes the resi stance
i n the sendi ng uni t whi ch al ters the si gnal sensed by
the Powertrai n Control Modul e on ci rcui t G60.
The PCM provi des ground for the oi l pressure sen-
sor on ci rcui t K167.
The PCM broadcasts the oi l pressure data on the
CCD bus. The mi cro-processor i n the i nstrument
cl uster recei ves the si gnal from the CCD bus, cal cu-
l ates oi l pressure and adjusts the gauge needl e posi -
ti on.
WATER IN FUEL SENSOR (DIESEL)
The water i n fuel sensor provi des an i nput to the
Powertrai n Control Modul e (PCM) on ci rcui t G123.
The PCM provi des ground for the water i n fuel
sensor si gnal (ci rcui t G123) through ci rcui t K167.
When cl osed, the park/neutral posi ti on swi tch pro-
vi des a ground path on ci rcui t T41 for the coi l si de of
the starter motor rel ay. Ci rcui t T141 from the i gni -
ti on swi tch provi des battery vol tage to the coi l si de of
the rel ay.
Ci rcui t T41 i s doubl e cri mped at the coi l si de of the
rel ay and connects to cavi ty A6 of the Powertrai n
Control Modul e (PCM). The park/neutral posi ti on
swi tch provi des an i nput to the PCM.
The Powertrai n Control Modul e (PCM) connects to
the power steeri ng pressure swi tch on ci rcui t K10.
On vehi cl es equi pped wi th a manual transmi ssi on,
ci rcui t Z12 provi des ground for the swi tch. I f the
vehi cl e has an automati c transmi ssi on, ci rcui t Z1
provi des ground. When the swi tch cl oses, i t connects
ci rcui t K10 to ground. The swi tch cl oses duri ng peri -
ods of hi gh power steeri ng pump l oad and l ow engi ne
speed; such as parki ng maneuvers.
Ci rcui t Z12 al so connects to cavi ti es A31 and A32 of
the PCM.
STOP LAMP SWITCH INPUT
Ci rcui t K29 provi des the stop l amp swi tch i nput to
the PCM. Ci rcui t K29 connects to cavi ty C24 of the
PCM. Ci rcui t K29 al so connects to the Transmi ssi on
Control Modul e (TCM) and the shi ft i nterl ock.
FUEL INJECTORS
tacts cl ose, they connect ci rcui ts A16 and A142. Ci r-
cui t A142 suppl i es vol tage to the fuel i njectors. Each
i njector has a separate ground ci rcui t control l ed by
the Powertrai n Control Modul e (PCM).
Ci rcui t K11 provi des ground for i njector number
one. The K11 ci rcui t connects to cavi ty B4 of the
PCM.
two. The K12 ci rcui t connects to cavi ty B15 of the
PCM.
three. The K13 ci rcui t connects to cavi ty B5 of the
PCM.
four. The K14 ci rcui t connects to cavi ty B16 of the
PCM.
On the 4.0L engi ne, ci rcui t K15 provi des ground
for i njector number fi ve. The K15 ci rcui t connects to
cavi ty B6 of the PCM.
Al so on the 4.0L engi ne, ci rcui t K16 provi des
ground for i njector number si x. The K16 ci rcui t con-
nects to cavi ty B12 of the PCM.
HELPFUL INFORMATION
For i nformati on about fuel i njector operati on,
refer to Group 14.
FUEL INJECTION PUMP (DIESEL)
The fuel i njecti on pump used on thi s engi ne appl i -
cati on performs several functi ons. Each of these i s
descri bed as fol l ows.
Power for the fuel shutdown sol enoi d i s suppl i ed by
the MSA Control l l er on ci rcui t K153. The sol enoi d i s
case grounded
FUEL TIMING SOLENOID
Power for the sol enoi d i s suppl i ed on ci rcui t F142.
Thi s ci rcui t i s HOT when the contacts i n the Di esel
Power Rel ay are CLOSED. Ground for the sol enoi d i s
control l ed by the MSA Control l er on ci rcui t K126.
FUEL TEMPERATURE SENSOR
Ci rcui t K156 connects between the MSA Control l er
and the fuel temperature sensor. The sensor i s a
vari abl e resi stor. As fuel temperature changes the
resi stance on ci rcui t K156 changes. Ground for the
sensor i s suppl i ed on ci rcui t K4.
CONTROL SLEEVE POSITION SENSOR
Ci rcui t K134 connects between the MSA Control l er
and the control sl eeve posi ti on sensor. Thi s ci rcui t i s
the posi ti on i nput to the MSA Control l er.
Ci rcui t K57 i s used for the mi ddl e tap, and ci rcui t
K135 i s used for the measure coi l .
Power for the fuel quanti ty Actuator i s suppl i ed on
ci rcui t A142. Thi s ci rcui t i s HOT when the contacts
i n the Di esel Power Rel ay are CLOSED. Ground for
the Actuator i s control l ed by the MSA Control l er on
ci rcui t K140.
FUEL HEATER (DIESEL)
When the i gni ti on swi tch i s i n the START or RUN
posi ti on, i t connects ci rcui t A1 from fuse 2 i n the
Power Di stri buti on Center (PDC) to ci rcui t A21. Ci r-
cui t A21 powers ci rcui t F12 through PDC fuse 11.
Ci rcui t F12 feeds the coi l si de of the fuel heater
rel ay. Ground for the rel ay i s suppl i ed by ci rcui t Z1.
When the contacts of the fuel heater rel ay are
cl osed they connect ci rcui t A61 from fuse 6 of the
PDC and ci rcui t A93. Ci rcui t A93 suppl i es vol tage to
the fuel heater. Ground for the fuel heater i s sup-
pl i ed on ci rcui t Z1.
NEEDLE MOVEMENT SENSOR (DIESEL)
The needl e movement sensor i s used to provi de an
i nput to the MSA Control l er. Ci rcui t K67 connects
from the MSA Control l er, cavi ty 12, to the i njector
and i s used as the si gnal wi re.
Ci rcui t K68, from cavi ty 11 of the MSA Control l er
connector, i s used for a return from the i njector.
GLOW PLUGS (DIESEL)
The gl ow pl ugs used on thi s vehi cl e are control l ed
by the MSA Control l er and the gl ow pl ug rel ay.
Power for the coi l si de of the rel ay i s suppl i ed on ci r-
cui t F142. Thi s ci rcui t i s HOT when the contacts i n
the Di esel Power Rel ay are CLOSED.
The ground si de of the rel ay i s control l ed by the
MSA Control l er on ci rcui t K152. Thi s ci rcui t connects
to cavi ty 50 of the MSA Control l er.
When the MSA Control l er determi nes a need for
gl ow pl ug operati on i t suppl i es a ground path on ci r-
cui t K152. Thi s causes the contacts i n the rel ay to
CLOSE connecti ng ci rcui t A54 and K154. The A54
ci rcui t i s HOT at al l ti mes. Ci rcui t K154 connects
from the rel ay to the gl ow pl ugs.
The gl ow pl ugs are case grounded.
IGNITION COIL
tacts cl ose, they connect ci rcui ts A16 and A142. Ci r-
cui t A142 spl i ces to suppl y vol tage to the i gni ti on
coi l . The Powertrai n Control Modul e (PCM) control s
the ground path for the i gni ti on coi l on ci rcui t K19.
HELPFUL INFORMATION
Ci rcui t A142 spl i ces to suppl y vol tage to the fuel
i njectors, PCM, and heated oxygen sensors.
The Powertrai n Control Modul e (PCM) operates
the i dl e ai r control motor through 4 ci rcui ts; K39,
K40, K59, and K60. Each ci rcui t connects to separate
cavi ti es i n the PCM connector.
Ci rcui t K39 connects to cavi ty A19 of the PCM
DUTY CYCLE EVAP\PURGE SOLENOID
cui t A21 powers ci rcui t F12 through fuse 11 i n the
juncti on bl ock. Ci rcui t F12 suppl i es power to the
Duty Cycl e EVAP/Purge sol enoi d.
The Powertrai n Control Modul e (PCM) provi des
the ground path for the sol enoi d on ci rcui t K52. Ci r-
cui t K52 connects to cavi ty C20 of the PCM.
ELECTRIC VACUUM MODULATOR (DIESEL)
Power for the El ectri c Vacuum Modul ator i s sup-
pl i ed on ci rcui t F142. Thi s ci rcui t i s HOT when the
contacts i n the Di esel Power Rel ay are CLOSED. The
El ectri c Vacuum Modul ator i s case grounded.
The MSA Control l er control s the operati on of the
modul ator by suppl yi ng a ground path for ci rcui t
K35. Thi s ci rcui t connects to cavi ty 25 of the MSA
Control l er.
LOW COOLANT LEVEL SWITCH (DIESEL)
When the l ow cool ant l evel swi tch cl oses, i t con-
nects ci rcui t G18 from the Powertrai n Control Mod-
ul e (PCM) and ci rcui t K167. Ci rcui t K167 i s the
sensor ground ci rcui t.
When the l ow cool ant l evel swi tch i s cl osed the
PCM recei ves a si gnal from ci rcui t G18.
TORQUE CONVERTER CLUTCH (TCC) SOLENOID
The TCC sol enoi d i s onl y used on 2.5L engi nes
wi th the three-speed automati c transmi ssi ons. When
the i gni ti on swi tch i s i n the START or RUN posi ti on,
i t connects ci rcui t A1 from fuse 2 i n the Power Di s-
tri buti on Center (PDC) to ci rcui t A21. Ci rcui t A21
powers ci rcui t F12 through fuse 11 i n the juncti on
bl ock. Ci rcui t F12 suppl i es power to the TCC sol e-
noi d. The Powertrai n Control Modul e (PCM) provi des
ground for the sol enoi d on ci rcui t K54. Ci rcui t K54
connects to cavi ty B11 of the PCM.
EXTENDED IDLE SWITCH
On Pol i ce Package vehi cl es, an opti onal extended
i dl e swi tch provi des an i nput to the Powertrai n Con-
trol Modul e (PCM) on ci rcui t K78. Ci rcui t K78 con-
nects to cavi ty A12 of the PCM. When the i gni ti on
swi tch i s i n the RUN posi ti on, ci rcui t F15 from fuse
25 i n the juncti on bl ock suppl i es battery vol tage to
the extended i dl e swi tch. Ci rcui t Z1 grounds the
swi tch.
CCD BUS
Ci rcui ts D1 and D2 connect the Powertrai n Control
Modul e (PCM) to the CCD Bus. Ci rcui t D1 connects
to cavi ty C30 of the PCM. Ci rcui t D2 connects to cav-
i ty C28 of the PCM. Ci rcui ts D1 and D2 are a
twi sted pai r of wi res.
Several modul es and control l ers broadcast and
recei ve data on the CCD Bus.
8W-31 TRANSMISSION CONTROL SYSTEM
INDEX
page
Component Page
1-2 And 3-4 Sol enoi d . . . . . . . . . . . . . . . . . . .8W-31-2
2-3 Sol enoi d. . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
Data Li nk Connector . . . . . . . . . . . . . . . . . . .8W-31-4
Di agnosti c Spl i ce Bl ock . . . . . . . . . . . . . . . . .8W-31-4
Engi ne Starter Motor Rel ay . . . . . . . . . . . . .8W-31-3
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3
Fuse 16 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3
Lock-Up Sol enoi d . . . . . . . . . . . . . . . . . . . . .8W-31-2
Output Shaft Speed Sensor . . . . . . . . . . . . . .8W-31-2
Power Di stri buti on Center . . . . . . . . . . . . . .8W-31-2
Powertrai n Control Modul e . . . . . . . . . . . .8W-31-3, 4
S111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
Component Page
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-4
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . . . .8W-31-4
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . .8W-31-3
Transmi ssi on Control Modul e . . . . . . . .8W-31-2, 3, 4
Transmi ssi on Control Sol enoi ds. . . . . . . . . . .8W-31-2
Transmi ssi on Range Swi tch . . . . . . . . . . . . .8W-31-3
XJ 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
TRANSMISSION
CONTROL
MODULE
20A
FUSE
11
26
DB/WT
18
F12
F12
18
DB/WT
16
FUSE
15A
PK
20
M1
5
(ST-RUN)
IGN.
FUSED
CENTER
DISTRIBUTION
POWER
A24
ST-RUN A21
A23
JUNCTION
BLOCK
C2
S136
BATT A0
24
Z12
16
G101
GROUND
BK/TN
9 C107
BK/TN
18
Z12
FUSED
B(+)
25
S135
M1
20
PK
12
WT
20
T19
3
1
6
T60
20
OR/WT
13
5
T22
20
DB/WT
11
4
T14
20
LG/WT
4
BK
18
Z1
SOLENOIDS
CONTROL
TRANSMISSION
3-4
AND
1-2
SOLENOID
2-3
SOLENOID
LOCK-UP
SOLENOID
SENSOR
OUTPUT
SHAFT
SPEED
BK
G106
16
Z1
SOLENOID
1-2
AND
3-4
SOLENOID
2-3
SOLENOID
LOCK-UP SPEED
SHAFT
OUTPUT
SENSOR
CONTROL CONTROL CONTROL SIGNAL
LHD RHD
S130
S141
(8W-12-14) (8W-10-14)
(8W-10-7)
(8W-10-9)
(8W-12-2)
(8W-12-14)
(8W-10-6)
(8W-15-2)
(8W-10-14)
(8W-15-4)
(8W-12-14)
(8W-15-5)
8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM XJ
J978W-7 XJI03101
TRANSMISSION
CONTROL
MODULE
4.0L 2.5L
OR/DB
20
K22 K22
18
OR/DB
THROTTLE
POSITION
SENSOR
3
R D D3 1-2
TRANSMISSION
RANGE
SWITCH
P/N
8 6 4 2 1
BK
18
Z1 L10
18
BR/LG
T1
18
LG/BK
T3
18
VT
T42
18
VT/WT
T41
20
BK/WT
7
18 22 9 21
SENSE
R
SENSOR
RANGE
SENSE
D
SENSOR
RANGE
SENSE
D3
SENSOR
RANGE
SENSE
LOW
SENSOR
RANGE
20A
FUSE
11
F12
18
DB/WT
5
ST-RUN A21
JUNCTION
BLOCK
C2
S130
S136
6 C107
OR/DB
20
K22
17
3 2 1
S112
C1
A17
K7
20
OR
OR
18
K7
S115
16
K167
20
BR/YL
S138
3 C107
S111
S114
K167
18
BR/YL
A4
C1
POWERTRAIN
CONTROL
MODULE
SUPPLY
5V SENSOR
GROUND
THROLLE
POSITION
SENSOR
SIGNAL
BR/YL
20
K167
K167
20
BR/YL
GROUND
SENSOR
STARTER
ENGINE
FROM
RELAY
S141
Z1
16
BK
G106
LHD RHD
MOTOR
(8W-12-14)
(8W-10-9)
(8W-12-2)
(8W-12-14)
(8W-12-14)
(8W-30-7)
(8W-70-5)
(8W-70-2)
(8W-70-2)
(8W-70-2)
(8W-30-7)
(8W-21-2)
(8W-21-3)
(8W-15-5)
(8W-15-4)
XJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3
XJI03102 J978W-7
TRANSMISSION
CONTROL
MODULE
14
2
1
BK
18
Z1
Z1
14
BK
S207
G108
K29
18
WT/PK
S204
K29
20
WT/PK
23
WT/PK
20
K29
7
D21
20
PK
B8
D21
20
PK
S139
SCI
TRANSMIT
PK
20
D21
CONNECTOR
LINK
DATA
2 6
BLOCK
SPLICE
DIAGNOSTIC
VT/BR
18
D1 D2
18
WT/BK
11 3
6 7
D2
20
WT/BK VT/BR
20
D1
1 7
S144 S145
(+)
BUS
CCD CCD
BUS
(-)
A11 A12
PAIR
TWISTED
WT/BK
20
D2
VT/BR
20
D1
D1
20
VT/BR
D2
20
WT/BK
S140
C100
B1
WT/PK
20
K29
TWISTED
PAIR
SENSE
SWITCH
LAMP
STOP
STOP
LAMP
SWITCH
LHD RHD
WT/PK
18
K29
S204
WT/PK
20
K29
WT/PK
18
K29
MODULE
CONTROL
POWERTRAIN
STOP
LAMP
SWITCH
SENSE
C24 C3
(8W-15-10)
(8W-15-10)
(8W-30-15)
(8W-30-16)
(8W-30-17)
(8W-30-15)
(8W-30-16)
(8W-30-17)
(8W-30-16)
(8W-30-17)
(8W-30-16)
(8W-30-17)
(8W-33-3)
8W - 31 - 4 8W-31 TRANSMISSION CONTROL SYSTEM XJ
J978W-7 XJI03103
8W-31 TRANSMISSION CONTROL SYSTEM
TORQUE CONVERTER CLUTCH (TCC) SOLENOID
The TCC sol enoi d i s onl y used on 2.5L engi nes
wi th the three-speed automati c transmi ssi ons. When
the i gni ti on swi tch i s i n the START or RUN posi ti on,
tri buti on Center (PDC) to ci rcui t A21. Ci rcui t A21
powers ci rcui t F12 through fuse 11 i n the juncti on
bl ock. Ci rcui t F12 suppl i es power to the TCC sol e-
noi d. The Powertrai n Control Modul e (PCM) provi des
ground for the sol enoi d on ci rcui t K54. Ci rcui t K54
connects to cavi ty B11 of the PCM.
FOUR-WHEEL DRIVE (4WD) SWITCH
When the 4WD swi tch CLOSES, ci rcui t Z1 pro-
vi des ground for the 4WD i ndi cator l amp i n the
i nstrument cl uster. Ci rcui t F87 connects to the
i nstrument cl uster and suppl i es battery vol tage to
the 4WD i ndi cator l amp. Ci rcui t G107 connects the
i ndi cator l amp to the 4WD swi tch.
On vehi cl es equi pped wi th the 4.0L engi ne and an
automati c transmi ssi on, ci rcui t G107 connects to the
sol enoi d assembl y i n the transmi ssi on. Ci rcui t G106
from the sol enoi d assembl y provi des ground duri ng
4WD Ful l Ti me operati on.
SHIFT INTERLOCK
The shi ft i nterl ock prevents the operator from
shi fti ng the vehi cl e out of PARK unl ess the brake
pedal i s pressed. When the i gni ti on swi tch i s i n the
START or RUN posi ti on, ci rcui t A22 feeds ci rcui t F15
through fuse 25 i n the juncti on bl ock. Ci rcui t F15
spl i ces to power the shi ft i nterl ock.
When the brake pedal i s not depressed, the stop
l amp swi tch provi des ground for i nterl ock by connect-
i ng ci rcui t K29 to ground ci rcui t Z1. When grounded,
the i nterl ock prevents shi fti ng the transmi ssi on out
of PARK. When the brake pedal i s pressed, the stop
l amp swi tch di sconnects ci rcui ts K29 and Z1, remov-
i ng ground from the shi ft i nterl ock.
TRANSMISSION CONTROL MODULE 4. 0L
ENGINE ONLY
Vehi cl es equi pped wi th the 4.0L engi ne have el ec-
troni cal l y control l ed sol enoi ds i n the automati c trans-
mi ssi on val ve body.
The Transmi ssi on Control Modul e (TCM) recei ves
i nputs from the Throttl e Posi ti on Sensor (TPS) on
ci rcui t K22 and the stop l amp swi tch on ci rcui t K29.
Ci rcui t K167 connects to the TCM to provi de ground
for the TPS si gnal . The TCM recei ves the transmi s-
si on output speed sensor si gnal on ci rcui t T14. Ci r-
cui t M1 from fuse 16 i n the Power Di stri buti on
Center (PDC) suppl i es battery vol tage to the TCM.
Ci rcui t Z12 provi des ground for the TCM.
The TCM powers the S1 sol enoi d on ci rcui t T19,
the S2 sol enoi d on ci rcui t T60, and the S3 sol enoi d
on ci rcui t T22. The S1, S2, and S3 sol enoi ds are case
grounded.
XJ 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5
8W-33 VEHICLE SPEED CONTROL
INDEX
page
Component Page
Accel erator Pedal . . . . . . . . . . . . . . . . . . . . .8W-33-5
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2, 4
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . .8W-33-5
Fuel Quanti ty Actuator . . . . . . . . . . . . . . . . .8W-33-5
Fuse 19 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3, 5
Left Speed Control Swi tch . . . . . . . . . . . . .8W-33-2, 4
Powertrai n Control Modul e . . . . . . . .8W-33-2, 3, 4, 5
Ri ght Speed Control Swi tch. . . . . . . . . . . .8W-33-2, 4
S111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
Component Page
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
S148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-4
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-5
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3, 5
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3, 5
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2, 4
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2, 4
Stop Lamp Swi tch . . . . . . . . . . . . . . . . . . .8W-33-3, 5
Vehi cl e Speed Control Servo . . . . . . . . . . . . .8W-33-3
XJ 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1
MODULE
CONTROL
POWERTRAIN
K167
18
BR/YL
A4 C1
SENSOR
GROUND
S138
C3 C32
SENSE
SWITCH
CONTROL
SPEED
V37
18
RD/LG
B5
CLOCKSPRING
C107 3
S111
V37
2 3
BK/LB
20
K4
B6 C100
K167
20
BR/YL
K4
20
BK/RD
LHD RHD
SWITCH
CONTROL
SPEED
LEFT
2 1 1 2
RIGHT
SPEED
CONTROL
SWITCH
3
3 COAST
2 CANCEL
1 RESUME/ACCEL
2 ON/OFF
1 SET
1 2 2 1
B A
S222
S221
V37
20
RD/LG
K167
20
BR/YL RD/LG
20
V37
BR/YL
20
K167
K167
20
BR/YL
V37
20
RD/LG
RD/LG
20
(8W-70-2)
(8W-70-2)
(8W-30-10)
8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL
GAS
XJ
J978W-7 XJI03301
POWERTRAIN
CONTROL
MODULE
SOLENOID
VACUUM
CONTROL
SPEED
C4 C3
TN/RD
18
V36
1 2
V35
18
LG/RD
C3 C5
SERVO
CONTROL
SPEED
VEHICLE
CONTROL CONTROL
SPEED
CONTROL
VENT
SOLENOID
3
YL/RD
4
20
V32
3
DB/RD
20
V30
C100
V30
20
DB/RD
V32
18
YL/RD
C11
SPEED
CONTROL
SOURCE
C3
F9
F7
4
BK
18
Z1
G106
C3 C24
YL/RD
18
K29
SENSE
SWITCH
LAMP
STOP
M/T A/T
S140
B1 C100 B1 C100
S204
WT/PK
20
K29
1
2
Z1
18
BK
S207
BK
14
Z1
G108
STOP
LAMP
SWITCH
S132
Z1
14
BK
LHD RHD
WT/PK
18
K29 K29
20
WT/PK
C100
WT/PK
18
K29 K29
20
WT/PK
RHD LHD
(8W-15-4)
(8W-31-4)
(8W-15-10)
(8W-15-10)
(8W-15-5)
(8W-30-11)
XJ 8W-33 VEHICLE SPEED CONTROL
GAS
8W - 33 - 3
XJI03302 J978W-7
MODULE
CONTROL
POWERTRAIN
K4
20
BK/LB
33 C1
SENSOR
GROUND
C1 36
SENSE
SWITCH
CONTROL
SPEED
V37
20
RD/LG
B5
CLOCKSPRING
S149
2 3
BK/LB
20
K4
B6
C100
K167
20
BR/YL
K4
20
BK/RD
LHD RHD
SWITCH
CONTROL
SPEED
LEFT
2 1 1 2
RIGHT
SPEED
CONTROL
SWITCH
3
3 COAST
2 CANCEL
1 RESUME/ACCEL
2 ON/OFF
1 SET
1 2 2 1
B A
S222
S221
V37
20
RD/LG
K167
20
BR/YL RD/LG
20
V37
BR/YL
20
K167
K167
20
BR/YL
V37
20
RD/LG
RD/LG
20
V37
(8W-70-3)
(8W-30-26)
8W - 33 - 4 8W-33 VEHICLE SPEED CONTROL
DIESEL
XJ
J978W-7 XJI03303
POWERTRAIN
CONTROL
MODULE
7
K22
20
OR/DB
C1 15
PEDAL
ACCELERATOR
SIGNAL
SENSOR
PEDAL
ACCELERATOR ACCELERATOR
PEDAL
SENSOR
GROUND
55 C1
WT/DG
20
K225
8 10
K6
20
VT/WT
C1 57
5V
SUPPLY
ACCELERATOR
PEDAL
SENSOR
SIGNAL GROUND
SENSOR
PEDAL
ACCELERATOR
5V
SUPPLY
15A
FUSE
19
F32
20
PK/DB
CENTER
DISTRIBUTION
POWER
BATT A0
2
1
SWITCH
LAMP
STOP
20
WT/PK
20
K29
6 5
44
BRAKE
SWITCH
PRIMARY
SIGNAL SIGNAL
SECONDARY
SWITCH
BRAKE
S147
WT/TN
20
L50
B4 C100
WT/TN
20
L50
S203
L50
20
WT/TN
B1
S204
K29
18
WT/PK
K29
18
WT/PK
BLK
18
Z1
S207
Z1
14
BLK
G108
A18
A17
C1 C1 C1 C1
V66
20
RD/LG
LAMP
ON
CONTROL
SPEED
27 41
SPEED
CONTROL
ON
LAMP
C1
(TWISTED PAIR)
K140
16
TN/WT
4 5
TN/WT
16
K140
C1 C1
K140
16
TN/WT
49
S148
MODULE
PUMP
FUEL
8
K140
16
TN/WT
FUEL
QUANTITY
ACTUATOR
(8W-30-21)
(8W-30-23)
(8W-30-26)
(8W-30-23)
(8W-10-34)
(8W-10-26)
(8W-10-25)
(8W-10-34)
(8W-10-34)
(8W-15-10)
(8W-15-10)
(8W-30-21) (8W-30-21)
XJ 8W-33 VEHICLE SPEED CONTROL
DIESEL
8W - 33 - 5
XJI03304 J978W-7
8W-33 VEHICLE SPEED CONTROL
VEHICLE SPEED CONTROL
The Powertrai n Control Modul e (PCM) operates
the vehi cl e speed control system. The vehi cl e speed
control swi tches are l ocated i n the steeri ng wheel .
Ci rcui t V32 from cavi ty C11 of the PCM suppl i es
12 vol ts to the Li ght Emi tti ng Di ode (LED) used for
the speed control i ndi cator l amp and the speed con-
trol swi tches. Ci rcui t V32 al so connects to ci rcui t V30
through the stop l amp swi tch. Ci rcui t V30 powers
the vehi cl e speed control servo.
Ci rcui t V37 from PCM cavi ty C32 connects to the
vehi cl e speed control swi tches. The swi tches are
wi red i n paral l el and each contai ns a separate resi s-
tor. The vol tage l evel present on ci rcui t V37 (at PCM
cavi ty C32) depends on whi ch speed control swi tch i s
sel ected. Ci rcui t K167 from PCM cavi ty A4 suppl i es
ground for the speed control swi tches.
When the ON/OFF swi tch i s open, the vol tage
l evel on ci rcui t V37 at PCM cavi ty C32 has a nomi -
nal val ue of 5.0 vol ts wi th a range from 4.8 to 5.0
vol ts.
When the ON/OFF swi tch cl oses, the vol tage
l evel on ci rcui t V37 at PCM cavi ty C32 has nomi nal
val ue of 1.51 vol ts wi th a range from 1.31 to 1.61
vol ts.
When the SET/COAST swi tch cl oses, the vol tage
l evel on ci rcui t V37 at PCM cavi ty C32 has nomi nal
val ue of 3.8 vol ts wi th a range from 3.6 to 3.9 vol ts.
When the RESUME/ACCEL swi tch cl oses, the
vol tage l evel on ci rcui t V37 at PCM cavi ty C32 has
nomi nal val ue of 4.4 vol ts wi th a range from 4.2 to
4.5 vol ts.
The PCM control s the vent and vacuum functi ons
of the vehi cl e speed control servo on ci rcui ts V35 and
V36. Dependi ng on the si gnal i t recei ves from vehi cl e
speed control swi tches, the PCM ei ther appl i es vac-
uum to or vents vacuum from the servo. Ci rcui t V36
from cavi ty C4 of the PCM sends the vacuum si gnal
to the servo. Ci rcui t V35 from cavi ty C5 sends the
vent si gnal .
Ci rcui t K29 provi des the stop l amp swi tch sense
i nput to the PCM at cavi ty C24. The stop l amp
swi tch connects ci rcui t K29 to ground on ci rcui t Z1.
When the brake pedal i s depressed, the stop l amp
swi tch opens and di sconnects ci rcui ts K29 and Z1,
and ci rcui ts V32 and V30. When the stop l amp
swi tch di sconnects ci rcui ts V32 and V30, power i s
removed from the speed control servo.
HELPFUL INFORMATION
Ci rcui t K167 al so provi des ground for some of the
engi ne control sensors that provi de i nputs to the
PCM.
VEHICLE SPEED CONTROL (DIESEL)
The MSA Control l er operates the vehi cl e speed
control system. The vehi cl e speed control swi tches
are l ocated i n the steeri ng wheel .
Ci rcui t V32 from the Powertrai n Control Modul e
(PCM) connects to ci rcui t V30 through the stop l amp
swi tch. Ci rcui t V30 provi des power to the speed con-
trol servo.
Ci rcui t V37 from the MSA Control l er suppl i es vol t-
age to the vehi cl e speed control swi tches. The
swi tches are wi red i n paral l el and each contai ns a
separate resi stor. The vol tage l evel present on ci rcui t
V37 at the MSA Control l er depends on whi ch speed
control swi tch i s sel ected. Ci rcui t K4 from MSA Con-
trol l er suppl i es ground for the speed control swi tches.
8W - 33 - 6 8W - 33 VEHICLE SPEED CONTROL XJ
8W-35 ALL-WHEEL ANTI-LOCK BRAKES
INDEX
page
Component Page
ABS I ndi cator . . . . . . . . . . . . . . . . . . . . . .8W-35-3, 5
Control l er Anti -Lock Brake . . . . . .8W-35-2, 3, 4, 5, 6
Control l er Anti -Lock Brake Rel ay . . . . . . .8W-35-3, 5
Data Li nk Connector . . . . . . . . . . . . . . . . .8W-35-2, 4
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . .8W-35-5
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3, 5
Fuse 12 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-35-2, 4
Fuse 13 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-35-2
Fuse 14 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-35-4
Fuse 19 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-35-4
Fuse 22 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-35-2
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-35-3, 5
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-2, 4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-2, 4
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3, 5
I nstrument Cl uster . . . . . . . . . . . . . . . . . .8W-35-3, 5
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-35-3, 5
Left Front Wheel Speed Sensor . . . . . . . . . . .8W-35-6
Left Rear Wheel Speed Sensor . . . . . . . . . . .8W-35-6
Overhead Modul e . . . . . . . . . . . . . . . . . . .8W-35-3, 5
Ri ght Front Wheel Speed Sensor . . . . . . . . . .8W-35-6
Ri ght Rear Wheel Speed Sensor . . . . . . . . . .8W-35-6
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-5
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-2, 4
S147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-4
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-2, 4
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-35-3, 5
XJ 8W - 35 ALL-WHEEL ANTI-LOCK BRAKES 8W - 35 - 1
12
FUSE
40A
25
POWER
DISTRIBUTION
CENTER
BATT A0
BRAKE
ANTI-LOCK
CONTROLLER
B(+)
FUSED
25
RD/DG
12
A10
8 24
GROUND GROUND
Z1
12
BK
Z1
12
BK
G102
18 19
26
20A
FUSE
13
A20
14
RD/DB
9
FUSED
B(+)
3 2 1
SWITCH
G
C C109
13 7
B43
20
PK/OR YL/VT
20
B41
6
A
B42
20
TN/WT
B
TN/WT
20
B516 B515
20
YL/VT PK/OR
20
B517
SIGNAL
TEST
SENSOR
ACCEL
NO.1
SENSOR
ACCEL
NO.2
SENSOR
ACCEL
PK
20
D21
20
B8 C100
SCI
TRANSMIT
S139
D21
20
PK
DATA
LINK
CONNECTOR
12
PK/DB
20
F32
22
FUSE
15A
A10
A9
F8 C100
F32
20
PK/DB
5
6
STOP
LAMP
SWITCH
B4 C100
S203
STOP
LAMP
SWITCH
SENSE
7
L50
20
WT/TN
(8W-10-13)
(8W-10-7)
(8W-10-6)
(8W-15-2)
(8W-10-13)
(8W-30-15)
(8W-30-15)
(8W-10-20)
(8W-33-3)
(8W-10-20)
8W - 35 - 2 8W-35 ANTI-LOCK BRAKES
GAS
XJ
J978W-7 XJI03501
(RUN)
IGN.
FUSED
23
BRAKE
ANTI-LOCK
CONTROLLER
6
C1
F15
20
DB/WT
BLOCK
JUNCTION
15A
FUSE
25
RUN A22
G83
20
GY/BK
16
S134
B19 B18
B20 B16
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
DB/WT
20
F15
CONTROL
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
BK
20
Z1
S132
G106
Z1
14
BK
C1
4
C1 8
CLUSTER
INSTRUMENT
ABS
INDICATOR
9
FUSE
10A
WT/BK
20
F87
C4
S13
ST-RUN A21
6 C301
F13 C100
G19
20
LG/OR
F15
20
DB/WT
RHD LHD
BASE
FULL
OPTIONS
C201 5
TO
COMPASS
WT/BK
20
F87
S216
F87
20
WT/BK
(8W-12-2)
(8W-12-20)
(8W-12-21)
(8W-10-10)
(8W-15-5)
(8W-15-4)
(8W-40-8)
(8W-40-9)
(8W-12-11)
(8W-12-12)
(8W-10-9)
(8W-49-2)
(8W-49-3)
(8W-12-11)
(8W-12-12)
XJ 8W-35 ANTI-LOCK BRAKES
GAS
8W - 35 - 3
XJI03502 J978W-7
12
FUSE
40A
25
POWER
DISTRIBUTION
CENTER
BATT A0
BRAKE
ANTI-LOCK
CONTROLLER
B(+)
FUSED
25
RD/DG
12
A10
8 24
GROUND GROUND
Z1
12
BK
Z1
12
BK
G102
18 20
27
20A
FUSE
14
A20
14
RD/DG
9
FUSED
B(+)
3 2 1
SWITCH
G
C C109
13 7
B43
20
PK/OR YL/VT
20
B41
6
A
B42
20
TN/WT
B
TN/WT
20
B516 B515
20
YL/VT PK/OR
20
B517
SIGNAL
TEST
SENSOR
ACCEL
NO.1
SENSOR
ACCEL
NO.2
SENSOR
ACCEL
PK
20
D21
20
B8 C100
SCI
TRANSMIT
S139
D21
20
PK
DATA
LINK
CONNECTOR
12
PK/DB
20
F32
19
FUSE
15A
A17
A18
F8 C100
F32
20
PK/DB
5
6
STOP
LAMP
SWITCH
B4 C100
S203
STOP
LAMP
SWITCH
SENSE
7
L50
20
WT/TN
S147
(8W-10-32)
(8W-10-26)
(8W-10-25)
(8W-15-3)
(8W-10-32)
(8W-30-29)
(8W-30-29)
(8W-10-34)
(8W-33-5)
(8W-10-34)
(8W-10-34)
8W - 35 - 4 8W-35 ANTI-LOCK BRAKES
DIESEL
XJ
J978W-7 XJI03503
(RUN)
IGN.
FUSED
23
BRAKE
ANTI-LOCK
CONTROLLER
6
C1
F15
20
DB/WT
BLOCK
JUNCTION
15A
FUSE
25
RUN A22
G83
20
GY/WT
16
B19 B20
B18 B16
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
BK/WT
20
F15
CONTROL
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
C1
4
C1 8
CLUSTER
INSTRUMENT
ABS
INDICATOR
9
FUSE
10A
WT/BK
20
F87
C4
S13
ST-RUN A21
6 C301
F13 C100
G19
20
LG/OR
RHD LHD
BASE
FULL
OPTIONS
C201 5
TO
COMPASS
WT/BK
20
F87
S216
B10
(IN PDC)
RELAY
LAMP
FOG
G106
Z1
20
BK
Z1
20
BK
Z1
18
BK
Z1
18
BK
11 C106
S103
12 C106
Z1
20
BK
(8W-12-2)
(8W-12-20)
(8W-12-21)
(8W-10-30)
(8W-40-10)
(8W-40-11)
(8W-12-11)
(8W-12-12)
(8W-10-29)
(8W-49-2)
(8W-49-3)
(8W-12-11)
(8W-12-12)
(8W-50-7)
(8W-50-8)
(8W-15-4)
(8W-15-4)
XJ 8W-35 ANTI-LOCK BRAKES
DIESEL
8W - 35 - 5
XJI03504 J978W-7
CONTROLLER
ANTI-LOCK
BRAKE
LEFT
FRONT
WHEEL
SPEED
SENSOR
4
LEFT
FRONT
WHEEL
SPEED
SENSOR
(+) (-)
SENSOR
SPEED
WHEEL
FRONT
LEFT
11
1 2
B A
2
LEFT
REAR
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
REAR
LEFT
10
SENSOR
SPEED
WHEEL
REAR
LEFT
2 1
6
RIGHT
FRONT
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
FRONT
RIGHT
1
SENSOR
SPEED
WHEEL
FRONT
RIGHT
A B
17
RIGHT
REAR
WHEEL
SPEED
SENSOR
(+)
SENSOR
SPEED
WHEEL
REAR
RIGHT
B8
20
RD/DB RD
20
B9
WT/DB
20
B6
WT
20
B7 B3
20
LG/DB
B3
20
LG/DB
F
C109
G
LG
20
B4
LG
20
B4
YL
20
B2
YL
20
B2 B1
20
YL/DB
B1
20
YL/DB
1
RIGHT
REAR
WHEEL
SPEED
SENSOR
(-)
D
C109
E
8W - 35 - 6 8W-35 ANTI-LOCK BRAKES XJ
J978W-7 XJI03505
8W-35 ALL-WHEEL ANTI-LOCK BRAKES
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 7
WHEEL SPEED SENSORS . . . . . . . . . . . . . . . . . 7
G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ABS RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 7
STOP LAMP SWITCH INPUT . . . . . . . . . . . . . . . . 7
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . . 7
INTRODUCTION
Four fuses suppl y power for the Anti -Lock Brake Sys-
tem (ABS); fuses 5, 8 and 14 i n the Power Di stri buti on
Center (PDC) and fuse 18 i n the fuse bl ock. Fuses 5, 8
and 14 i n the PDC are connected di rectl y to battery vol t-
age and are HOT al l ti mes. Fuse 18 i n the fuse bl ock i s
HOT when the i gni ti on swi tch i s the RUN Posi ti on.
I n the RUN posi ti on, the i gni ti on swi tch connects ci rcui t
A1 from fuse 8 i n the PDC wi th ci rcui t A38. Ci rcui t A38
connects to a bus bar i n the fuse bl ock. The bus bar feeds
ci rcui t B236 through fuse 18. Fuse 18 i s a 2 amp fuse.
Ci rcui t B236 connects to the coi l si de of the ABS mai n
rel ay and the Control l er, Anti -Lock Brakes (CAB).
Ci rcui t Z1 provi des ground for the CAB. Ci rcui t Z1
connects to cavi ti es B14 and B13 of the CAB.
Refer to group 5, Brakes for operati onal descri p-
ti ons of ABS system components.
WHEEL SPEED SENSORS
The al l wheel anti -l ock system uses four wheel
speed sensors; one for each wheel . Each sensor con-
verts wheel speed i nto an el ectri cal si gnal that i t
transmi ts to the Control l er, Anti -Lock Brakes (CAB).
A pai r of twi sted wi res connect to each sensor to pro-
vi de si gnal s to the CAB.
Ci rcui ts B6 and B7 provi de si gnal s to the CAB
from the ri ght front wheel speed sensor. Ci rcui t B6
whi ch provi des the LOW si gnal connects to cavi ty 18
of the CAB. Ci rcui t B7 connects to cavi ty 3 of the
CAB and provi des the HI GH si gnal .
Ci rcui ts B8 and B9 provi de si gnal s to the CAB
from the l eft front wheel speed sensor. Ci rcui t B8,
whi ch provi des the LOW si gnal , connects to cavi ty 11
of the CAB. Ci rcui t B9 connects to cavi ty 4 of the
CAB and provi des the HI GH si gnal .
Ci rcui ts B1 and B2 provi de si gnal s to the CAB from
ri ght rear wheel speed sensor. Ci rcui t B1 whi ch provi des
the LOW si gnal connects to cavi ty 1 of the CAB. Ci rcui t
B2 connects to cavi ty 17 and provi des the HI GH si gnal .
Ci rcui ts B3 and B4 provi de si gnal s to the CAB from the
l eft rear wheel speed sensor. Ci rcui t B3, whi ch provi des
the LOW si gnal , connects to cavi ty 2 of the CAB. Ci rcui t
B4 connects to cavi ty 10 and provi des the HI GH si gnal .
G-SWITCH
Duri ng four-wheel dri ve operati on, the G-swi tch
provi des decel erati on data to the Control l er, Anti -
Lock Brakes (CAB). Refer to Group 5, Brakes for
Ci rcui ts B41, B42, and B43 connect the G-Swi tch
to the CAB. Ci rcui ts B41 and B42 provi de swi tch
states whi l e ci rcui t B43 provi des ground.
ABS RELAY
Ci rcui t F15 from fuse 25 of the juncti on bl ock sup-
pl i es vol tage to the coi l si de of the ABS rel ay. Ground
for the coi l si de of the rel ay i s suppl i ed by the Con-
trol l er, Anti -Lock Brake (CAB).
When the rel ay contacts cl ose, the ground ci rcui t
for the ABS warni ng l amp i s compl eted on ci rcui t Z1.
ABS WARNING LAMP
Ci rcui t F87 provi des power for the ABS warni ng
l amp at the i nstrument cl uster. Ground for the ABS
warni ng l amp i s provi ded by ci rcui t Z1 when the
ABS rel ay i s not energi zed.
STOP LAMP SWITCH INPUT
Ci rcui t L50 from the stop l amp swi tch provi des the
brake swi tch i nput to the Control l er, Anti -Lock
Brakes (CAB). When the brake pedal i s depressed,
the stop l amp swi tch cl oses to suppl y battery vol tage
from ci rcui t F32 to ci rcui t L50. Ci rcui t L50 connects
to cavi ty 12 of the CAB. Ci rcui t F32 ori gi nates at
fuse 22 i n the Power Di stri buti on Center (PDC).
DATA LINK CONNECTOR
Ci rcui t D21 from cavi ty 20 of the Control l er, Anti -
Lock Brakes (CAB) transmi ts data to the DRB scan tool
through the data l i nk connector. Ci rcui t D21 i s doubl e
cri mped at the data l i nk connector and connects to cav-
i ty C27 of the Powertrai n Control Modul e (PCM).
Through the data l i nk connector, ci rcui t Z1 pro-
vi des ground for the DRB scan tool .
Ci rcui t F34 from fuse 17 i n the Power Di stri buti on
Center (PDC) suppl i es battery vol tage to the scan
tool through the di agnosti c connector.
XJ 8W - 35 ALL-WHEEL ANTI-LOCK BRAKES 8W - 35 - 7
8W-39 VEHICLE THEFT SECURITY SYSTEM
INDEX
page
Component Page
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . .8W-39-6, 7
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
Fuse 26 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3
Fuse 27 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-39-4, 5
G107 . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
G108 . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
Headl amp Swi tch . . . . . . . . . . . . . . . . . . .8W-39-6, 7
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-8
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
I nstrument Cl uster . . . . . . . . . . . .8W-39-2, 3, 4, 5, 8
Juncti on Bl ock . . . . . . . . . . . .8W-39-2, 3, 4, 5, 6, 7, 8
Left Front Door Jamb Swi tch . . . . . . . . . .8W-39-6, 7
Left Front Power Lock/Wi ndow
Swi tch/Modul e . . . . . . . . . . . . . . . . . . . .8W-39-3, 5
Left Rear Door Jamb Swi tch . . . . . . . . . . .8W-39-6, 7
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
Overhead Modul e . . . . . . . . . .8W-39-2, 3, 4, 5, 6, 7, 8
Power Di stri buti on Center . . . . . . . . .8W-39-2, 3, 4, 5
Powertrai n Control Modul e . . . . . . . . . . . . . .8W-39-8
Component Page
Ri ght Front Door Jamb Swi tch . . . . . . . . .8W-39-6, 7
Ri ght Front Power Lock/Wi ndow
Swi tch/Modul e . . . . . . . . . . . . . . . . . . . .8W-39-2, 4
Ri ght Rear Door Jamb Swi tch . . . . . . . . . .8W-39-6, 7
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-8
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-8
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
S208 . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 4
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
S342 . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
S343 . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-8
S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-6, 7
S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-8
S347 . . . . . . . . . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
Underhood Lamp. . . . . . . . . . . . . . . . . . . .8W-39-4, 5
VTSS I ndi cator . . . . . . . . . . . . . . . . .8W-39-2, 3, 4, 5
XJ 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
MODULE
OVERHEAD
11
10A
FUSE
26
DB/GY
20
F1
8
B(+)
FUSED
BATT A0
Z2
20
BK/LG
9
G108
GROUND
LOGIC
3
BK
20
Z1
GROUND
16
FUSE
15A
2
M1
20
PK
12
3
FUSED
B(+)
A24
A23
S135
C1
C3
M1
20
PK
S347
CENTER
DISTRIBUTION
POWER
BATT A17
A1
A2
19 C201
DB/GY
20
F1
C100 E10
F1
20
DB/GY
S342
JUNCTION
BLOCK
BLOCK
JUNCTION
C4
C3
S5
2
5 C301
58 C201
Z2
18
BK/LG
BK/LG
18
Z2
P59
20
LB/RD
SENSE
REQUEST
LOCK
DOOR DOOR
UNLOCK
REQUEST
SENSE
DB
20
P55
5
5 C302 4
P55
20
DB LB/RD
20
P59
3
C300
4
1
P59
20
LB/RD DB
20
P55
2
SWITCH/
WINDOW
LOCK/
POWER
FRONT
RIGHT
14
G107
S314
S208
CONTROL
INDICATOR
VTSS
GY
20
G38
4
C1 7
49 C201
6 C302
CLUSTER
INSTRUMENT
VTSS
INDICATOR
1
C1 C1
6
Z2
20
BK/LG BK/LG
20
Z2
G108
C2 C2
MODULE
BK/LG
20
Z2
(COMPASS)
S343
C302 2
Z1
14
BK
(8W-10-12)
(8W-15-10)
(8W-10-14)
(8W-10-6)
(8W-10-14)
(8W-10-15)
(8W-10-7)
(8W-10-12)
(8W-15-7)
(8W-12-2)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-40-16)
(8W-15-10)
(8W-61-2)
(8W-15-9)
(8W-12-33)
(8W-12-32)
8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM
GAS LHD
XJ
J978W-7 XJI03901
MODULE
OVERHEAD
11
10A
FUSE
26
DB/GY
20
F1
8
B(+)
FUSED
BATT A0
Z2
20
BK/LG
9
G108
GROUND
LOGIC
3
BK
20
Z1
GROUND
16
FUSE
15A
2
M1
20
PK
12
3
FUSED
B(+)
A24
A23
S135
C1
C3
M1
20
PK
S347
CENTER
DISTRIBUTION
POWER
BATT A17
A1
A2
DB/GY
20
F1
C100 E10
S342
JUNCTION
BLOCK
BLOCK
JUNCTION
C4
C3
S5
2
5 C301
Z2
18
BK/LG
P59
20
LB/RD
SENSE
REQUEST
LOCK
DOOR DOOR
UNLOCK
REQUEST
SENSE
DB
20
P55
5
5 C302 4
12
C305
3
1
P59
20
LB/RD DB
20
P55
2
SWITCH/
WINDOW
LOCK/
POWER
FRONT
LEFT
BK
14
Z1
G107
S208
CONTROL
INDICATOR
VTSS
GY
20
G38
4
C1 7
6 C302
CLUSTER
INSTRUMENT
VTSS
INDICATOR
1
C1 C1
6
Z2
18
BK/LG BK/LG
18
Z2
G108
C2 C2
MODULE
BK/LG
20
Z2
S343
(COMPASS)
C203
22 21
Z1
14
BK
G38
20
GY
C302 2
F1
20
DB/GY
(8W-10-12)
(8W-15-10)
(8W-10-14)
(8W-10-6)
(8W-10-14)
(8W-10-15)
(8W-10-7)
(8W-10-12)
(8W-15-7)
(8W-12-2)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-40-16)
(8W-15-10)
(8W-61-3)
(8W-15-9)
(8W-12-33)
(8W-12-32)
XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM
GAS RHD
8W - 39 - 3
XJI03904 J978W-7
MODULE
OVERHEAD
11
10A
FUSE
27
DB/GY
20
F1
8
B(+)
FUSED
BATT A0
Z2
20
BK/LG
9
G108
GROUND
LOGIC
3
BK
20
Z1
GROUND
16
FUSE
15A
2
12
3
FUSED
B(+)
A24
A23
C1
C3
M1
20
PK
S347
CENTER
DISTRIBUTION
POWER
BATT A17
A1
A2
19 C201
DB/GY
20
F1
C100 E10
F1
20
DB/GY
S342
JUNCTION
BLOCK
BLOCK
JUNCTION
C4
C3
S5
2
5 C301
58 C201
Z2
18
BK/LG
BK/LG
18
Z2
P59
20
LB/RD
SENSE
REQUEST
LOCK
DOOR DOOR
UNLOCK
REQUEST
SENSE
DB
20
P55
5
5 C302 4
P55
20
DB LB/RD
20
P59
3
C300
4
1
P59
20
LB/RD DB
20
P55
2
SWITCH/
WINDOW
LOCK/
POWER
FRONT
RIGHT
14
G107
S314
S208
CONTROL
INDICATOR
VTSS
GY
20
G38
4
C1 7
49 C201
6 C302
CLUSTER
INSTRUMENT
VTSS
INDICATOR
1
C1 C1
6
Z2
20
BK/LG BK/LG
20
Z2
G108
C2 C2
MODULE
BK/LG
20
Z2
(COMPASS)
S343
C302 2
Z1
14
BK
M1
20
PK
2
LAMP
UNDERHOOD
(8W-10-34)
(8W-15-10)
(8W-10-33)
(8W-10-25)
(8W-10-33)
(8W-10-26)
(8W-10-12)
(8W-15-7)
(8W-12-2)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-40-16)
(8W-15-10)
(8W-61-2)
(8W-15-9)
(8W-44-4)
(8W-12-33)
(8W-12-32)
LHD DIESEL
XJ
J978W-7 XJI03906
MODULE
OVERHEAD
11
10A
FUSE
27
DB/GY
20
F1
8
B(+)
FUSED
BATT A0
Z2
20
BK/LG
9
G108
GROUND
LOGIC
3
BK
20
Z1
GROUND
16
FUSE
15A
2
12
3
FUSED
B(+)
A24
A23
C1
C3
M1
20
PK
S347
CENTER
DISTRIBUTION
POWER
BATT A17
A1
A2
DB/GY
20
F1
C100 E10
S342
JUNCTION
BLOCK
BLOCK
JUNCTION
C4
C3
S5
2
5 C301
Z2
18
BK/LG
P59
20
LB/RD
SENSE
REQUEST
LOCK
DOOR DOOR
UNLOCK
REQUEST
SENSE
DB
20
P55
5
5 C302 4
12
C305
3
1
P59
20
LB/RD DB
20
P55
2
SWITCH/
WINDOW
LOCK/
POWER
FRONT
LEFT
BK
14
Z1
G107
S208
CONTROL
INDICATOR
VTSS
GY
20
G38
4
C1 7
6 C302
CLUSTER
INSTRUMENT
VTSS
INDICATOR
1
C1 C1
6
Z2
18
BK/LG BK/LG
18
Z2
G108
C2 C2
MODULE
BK/LG
20
Z2
S343
(COMPASS)
C203
22 21
Z1
14
BK
G38
20
GY
C302 2
F1
20
DB/GY
UNDERHOOD
LAMP
2
PK
20
M1
(8W-10-34)
(8W-15-10)
(8W-10-33)
(8W-10-25)
(8W-10-33)
(8W-10-26)
(8W-10-12)
(8W-15-7)
(8W-12-2)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-40-16)
(8W-15-10)
(8W-61-3)
(8W-15-9)
(8W-44-4)
(8W-12-33)
(8W-12-32)
RHD DIESEL
8W - 39 - 5
XJI03907 J978W-7
MODULE
OVERHEAD
1
M2
20
YL
S345
3
1
SWITCH
JAMB
DOOR
FRONT
LEFT
1
JUNCTION
BLOCK
C3
7
C7
DOOR
AJAR/
ILLUMINATION
SENSE
1 C317
M2
18
YL
2
3
SWITCH
JAMB
DOOR
REAR
LEFT
3 C317
BK
18
Z1
Z1
20
BK
G303
BK
12
Z1
S309
BK
20
Z1
Z1
18
BK
C320 B
YL
18
M2
C320 A
M2
20
YL YL
20
M2 M2
20
YL YL
20
M2
A C319
M2
18
YL
B C319
BK
18
Z1
Z1
20
BK
S310
Z1
16
BK
BK
20
Z1
Z1
18
BK
C318 3
RIGHT
REAR
DOOR
JAMB
SWITCH
3
2
YL
18
M2
C318 1
RIGHT
FRONT
DOOR
JAMB
SWITCH
1
3
C
B
LAMP/
CARGO
GY/BK
20
M4
7 C314
M4
20
GY/BK
GY/BK
20
M4
C311
C310
5
10
1
3
LIFTGATE
SWITCH
Z1
20
BK
BK
16
Z1
G304
S304
S334
9 C310
6
S333
Z1
18
BK
C311
BK
18
Z1
M2
20
YL
BK/LB
18
G16
2
17 C200
S200
BK/LB
20
G16
6
SWITCH
HEADLAMP
C1
C2
IGNITION
SWITCH
2
G16
20
BK/LB
G16
20
BK/LB
2
SWITCH
6 C314
YL
18
M2
G302
(8W-12-26)
(8W-12-2)
(8W-15-13)
(8W-15-11) (8W-15-13)
(8W-15-15)
(8W-12-27)
(8W-15-15)
(8W-15-15)
(8W-50-2)
(8W-10-8)
(8W-10-28)
(8W-44-6)
(8W-15-11)
(8W-12-26)
LHD
XJ
J978W-7 XJI03902
MODULE
OVERHEAD
1
M2
20
YL
S345
3
1
SWITCH
JAMB
DOOR
FRONT
LEFT
1
JUNCTION
BLOCK
C3
7
C7
DOOR
AJAR/
ILLUMINATION
SENSE
1 C317
M2
18
YL
2
3
SWITCH
JAMB
DOOR
REAR
LEFT
3 C317
BK
18
Z1
Z1
20
BK
G303
BK
20
Z1
S309
BK
20
Z1
Z1
18
BK
C320 B
YL
18
M2
C320 A
M2
20
YL YL
20
M2 M2
20
YL YL
20
M2
A C319
M2
18
YL
B C319
BK
18
Z1
Z1
20
BK
Z1
20
BK
BK
20
Z1
Z1
18
BK
C318 3
RIGHT
REAR
DOOR
JAMB
SWITCH
3
2
YL
18
M2
1
RIGHT
FRONT
DOOR
JAMB
SWITCH
1
3
C
B
LAMP/
CARGO
GY/BK
20
M4
7 C314
M4
20
GY/BK
GY/BK
20
M4
C311
C310
5
10
1
3
LIFTGATE
SWITCH
Z1
20
BK
BK
16
Z1
G304
S304
S334
9 C310
6
S333
C311
BK
18
Z1
M2
20
YL
BK/LB
18
G16
19 C203
S200
BK/LB
20
G16
6
SWITCH
HEADLAMP
C1 C2
IGNITION
SWITCH
2
G16
20
BK/LB
G16
20
BK/LB
2
SWITCH
6 C314
YL
18
M2
G302
C318
2
S310
Z1
18
BK
(8W-12-26)
(8W-12-2)
(8W-15-14)
(8W-15-12)
(8W-15-15)
(8W-12-27)
(8W-15-15)
(8W-15-15)
(8W-50-3) (8W-10-8)
(8W-10-28)
(8W-44-6)
(8W-15-12)
(8W-15-14)
(8W-12-26)
RHD
8W - 39 - 7
XJI03905 J978W-7
1
2
D1
18
VT/BR
C30 C3
A11
VT/BR
20
D1
D1
20
VT/BR
CCD
BUS
(+)
A12
C100
C3 C28
WT/BK
18
D2
6
7
CCD
BUS
(-)
D2
20
WT/BK
WT/BK
20
D2
3 11
DATA LINK
CONNECTOR
D2
20
WT/BK
13
C2
1 2
C2
9
VT/BR
20
D1
CLUSTER
INSTRUMENT
(-)
BUS
CCD
(+)
BUS
CCD
POWERTRAIN
CONTROL
MODULE
DIAGNOSTIC
SPLICE
BLOCK
CCD
BUS
(+)
CCD
BUS
(-)
6 12
WT/BK
20
D2
VT/BR
20
D1
14 8
1
BK/RD
20
X3
10
HORN
RELAY
CONTROL
1 C302
2 C301 1
S344 S346
D1
20
VT/BR
D2
20
WT/BK
D1
20
VT/BR
D2
20
WT/BK
D1
20
VT/BR
S144
WT/BK
D2
20
S145
BK/RD
20
X3
JUNCTION
BLOCK
86
85
BATT A7
C5
RELAY
HORN
MODULE
OVERHEAD
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
(A/T) (A/T)
C4
S22
LHD RHD
LHD RHD
56 C201 C201 55
RHD LHD
PAIR
TWISTED
(-)
BUS
CCD
D2
20
WT/BK
46 C2
(+)
BUS
CCD
C2 26
VT/BR
20
D1
DIESEL GAS
TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-40-16)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-12-2)
(8W-10-11)
(8W-41-2)
(8W-41-3)
(8W-30-16)
(8W-30-17)
(8W-30-16)
(8W-30-17)
(8W-41-2)
(8W-41-3)
8W - 39 - 8 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
J978W-7 XJI03903
8W-39 VEHICLE THEFT SECURITY SYSTEM
IMMOBILIZER
The I mmobi l i zer provi des protecti on agai nst unau-
thori zed vehi cl e use by preventi ng the engi ne from
operati ng when the system i s armed. The system i s
operated by radi o si gnal s sent from a hand-hel d
i mmobi l i zer transmi tter to a recei ver i n the vehi cl e.
REMOTE KEYLESS ENTRY
I mmobi l i zers use key-fob radi o si gnal transmi tters
and vehi cl e-mounted recei vers to l ock and unl ock the
system. I n most cases, the transmi tters and recei vers
al so operate the Remote Keyl ess Entry (RKE) system
for l ocki ng and unl ocki ng doors.
OVERHEAD MODULE
The Overhead Modul e operates the Remote Keyl es
Entry and the I mobi l i zer system.
Power for the Overhead Modul e i s suppl i ed by ci r-
cui t F1 from fuse 26 i n the Power Di stri buti on Cen-
ter. I nputs to the overhead modul e i ncl ude; door ajar
i l l umi nati on sense, door l ock and unl ock request, and
horn rel ay control .
The Overhead Modul e control s systems based on
i nputs broadcast on the CCD bus.
XJ 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 9
8W-40 INSTRUMENT CLUSTER
INDEX
page
Component Page
4WD Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-12
ABS I ndi cator . . . . . . . . . . . . . . . . . . . . . .8W-40-8, 9, 10, 11
Ai rbag Control Modul e . . . . . . . . . . . . . . . .8W-40-8, 9, 10, 11
Ai rbag Warni ng I ndi cator . . . . . . . . . . . . . .8W-40-8, 9, 10, 11
Beam Sel ect Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-40-16
Brake Pressure Warni ng Swi tch . . . . . . . . . . . . .8W-40-12, 13
Brake Warni ng I ndi cator . . . . . . . . . . . . . . . . . .8W-40-12, 13
Check Engi ne Warni ng I ndi cator . . . . . . . . . . . . . .8W-40-5, 6
Check Gauges Warni ng I ndi cator . . . . . . . . . . . . . .8W-40-3, 4
Cl ockspri ng. . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . . . . . . .8W-40-17
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2, 7
Control l er Anti -Lock Brake Rel ay. . . . . . . . . .8W-40-8, 9, 10, 11
Crui se On I ndi cator. . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6
Di agnosti c Spl i ce Bl ock . . . . . . .8W-40-3, 4, 5, 6, 8, 9, 10, 11, 16
Engi ne Cool ant Temperature Gauge. . . . . . . . . . . . .8W-40-5, 6
Engi ne Cool ant Temperature Sensor . . . . . . . . . . . .8W-40-5, 6
Engi ne Cool ant Temperature Warni ng I ndi cator . . . . .8W-40-5, 6
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . . . . . . .8W-40-10, 11
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3, 4
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-4
Fuel Pump Modul e. . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3
Ful l Ti me 4WD I ndi cator . . . . . . . . . . . . . . . . . .8W-40-12, 13
Fuse 6 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-17
Fuse 9 (JB). . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2, 7
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-15
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
G101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-12
G106. . . . . . . . . . . . . . . . . . . . . . .8W-40-8, 9, 10, 11, 12, 13
G107 . . . . . . . . . . . . . . . . . . . . . . . .8W-40-8, 10, 12, 13, 15
G108 . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2, 12, 13, 15, 16
G123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
G154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-9, 11, 14
G303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-14
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-40-14, 17
Hi gh Beam I ndi cator Lamp. . . . . . . . . . . . . . . . . . .8W-40-16
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-40-12, 13, 14
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . .8W-40-2, 7, 15, 17
Left Front Door Jamb Swi tch . . . . . . . . . . . . . . . . .8W-40-14
Left Speed Control Swi tch. . . . . . . . . . . . . . . . . . .8W-40-5, 6
Left Turn Si gnal I ndi cator Lamp . . . . . . . . . . . . . . .8W-40-15
Low Cool ant Level Warni ng I ndi cator . . . . . . . . . . . . .8W-40-7
Low Cool ant Swi tch . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
Low Fuel Warni ng I ndi cator . . . . . . . . . . . . . . . . .8W-40-3, 4
Low Washer Fl ui d I ndi cator . . . . . . . . . . . . .8W-40-8, 9, 10, 11
Low Washer Fl ui d Swi tch . . . . . . . . . . . . . .8W-40-8, 9, 10, 11
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-17
Oi l Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6
Oi l Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6
Oi l Pressure Warni ng I ndi cator . . . . . . . . . . . . . . .8W-40-5, 6
Overhead Modul e . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-16
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . . .8W-40-12, 13
Component Page
Part Ti me 4WD I ndi cator . . . . . . . . . . . . . . . . . .8W-40-12, 13
Part Ti me 4WD Swi tch . . . . . . . . . . . . . . . . . . .8W-40-12, 13
Power Di stri buti on Center . . . . . . . . . . . . . . . . . . . .8W-40-2
Powertrai n Control Modul e . . . . . . . . . . . . .8W-40-3, 4, 5, 6, 7
Rear Wi ndow Defogger Rel ay. . . . . . . . . . . . . . . . . .8W-40-15
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . . . . . . .8W-40-15
Ri ght Front Door Jamb Swi tch. . . . . . . . . . . . . . . . .8W-40-14
Ri ght Turn Si gnal I ndi cator Lamp . . . . . . . . . . . . . .8W-40-15
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-10, 11
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-12
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3
S132 . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-8, 9, 10, 11, 13
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
S141. . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-9, 10, 11, 13
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3, 5
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3, 5
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-4
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-14
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-12, 13
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-8, 10, 15
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-15
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-14
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-12, 13
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-15
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-16
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-17
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2, 7
S221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-5, 6
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-9, 11, 14
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-14
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-9, 11
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-8, 10
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-17
S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-16
S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-16
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . .8W-40-8, 9, 10, 11
Seat Bel t Warni ng I ndi cator . . . . . . . . . . . . .8W-40-8, 9, 10, 11
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3, 4
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3, 4
Tel l Tal e Modul e . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
Transmi ssi on Control Modul e. . . . . . . . . . . . . . . . .8W-40-3, 5
Tri p Reset Swi tch . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-17
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . . . . . . .8W-40-15
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-2
Upshi ft Warni ng I ndi cator . . . . . . . . . . . . . . . . . .8W-40-3, 4
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . . . .8W-40-3, 4
Vol tmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-3, 4
VTSS I ndi cator . . . . . . . . . . . . . . . . . . . . . . . . . .8W-40-16
Wai t To Start Warni ng I ndi cator . . . . . . . . . . . . . . . .8W-40-7
Water I n Fuel Sensor . . . . . . . . . . . . . . . . . . . . . . .8W-40-7
Water I n Fuel Warni ng I ndi cator . . . . . . . . . . . . . . . .8W-40-7
XJ 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1
JUNCTION
BLOCK
ST-RUN A21
10A
FUSE
9
CLUSTER
INSTRUMENT
S13
C4
8
(ST-RUN)
IGN.
FUSED
F87
20
WT/BK
C1
FULL
OPTIONS BASE
S216
5 C201
6 C301
COMPASS
TO
F87
20
WT/BK
F87
20
WT/BK
6
C1 C1
1
Z2
18
BK/LG
Z2
18
BK/LG
G108
LHD RHD
F87
20
WT/BK
GROUND
16
FUSE
15A
BATT A0
POWER
DISTRIBUTION
CENTER
A24
A23
PK
20
M1
S135
C4
S18
C1 12
BLOCK
JUNCTION
PK
20
M1
RHD LHD
C201 6
PK
20
M1
S214
C1 9
FUSED
B(+)
GAS DIESEL
M1
20
PK
2
LAMP
UNDERHOOD
M1
20
PK
(8W-12-2)
(8W-10-9)
(8W-12-11)
(8W-12-12)
(8W-12-11)
(8W-12-12)
(8W-49-2)
(8W-15-10)
(8W-10-14)
(8W-10-33)
(8W-10-6)
(8W-10-7)
(8W-10-26)
(8W-10-14)
(8W-12-32)
(8W-12-2)
(8W-10-14)
(8W-10-33)
(8W-44-4)
(8W-12-32)
8W - 40 - 2 8W-40 INSTRUMENT CLUSTER XJ
J978W-7 XJI04001
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
TACHOMETER
CONTROL CONTROL
GAUGE
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
1 7
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
A12
C100
A11
S145
S144
(A/T)
(A/T)
D1
18
VT/BR
D2
18
WT/BK
C3 C30 C28 C3
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
TRANSMISSION
PAIR
TWISTED TWISTED
PAIR
CCD
BUS
(+) (-)
BUS
CCD
FUEL
VOLTMETER
CONTROL
3 3
FUEL
PUMP
MODULE SENSOR
SPEED
VEHICLE
K226
20
DB/LG
15 C200
B2 C100
K226
18
DB/LG
C26 C3
FUEL
LEVEL
SENSOR
SIGNAL
K226
20
DB/LG
WT/OR
18
G7
C2 B27
WT/OR
18
G7
VEHICLE
SPEED
SENSOR
SIGNAL
S108
6 7
20
D2
VT/BR
20
D1
WT/BK
CCD
BUS
(-) (+)
BUS
CCD
FUEL
GAUGE
TACHOMETER VOLTMETER SPEEDOMETER
CONTROL
SPEEDOMETER
LOW
FUEL
WARNING
INDICATOR INDICATOR
WARNING
GAUGES
CHECK
LOW FUEL
WARNING
INDICATOR INDICATOR
WARNING
CHECK GAUGES
CONTROL CONTROL
UPSHIFT
INDICATOR
CONTROL
UPSHIFT
WARNING
INDICATOR
(M/T)
LHD RHD
C204 16
(8W-12-11)
(8W-30-16)
(8W-30-17)
(8W-30-3)
(8W-30-4)
(8W-30-9)
(8W-30-16)
(8W-30-17)
(8W-31-4)
(8W-30-3)
(8W-30-4)
(8W-30-9)
(8W-30-9)
XJ 8W-40 INSTRUMENT CLUSTER
GAS
8W - 40 - 3
XJI04002 J978W-7
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
TACHOMETER
CONTROL CONTROL
GAUGE
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
1 7
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
A12
A11
D1
20
VT/BR
D2
20
WT/BK
C2 26 46 C2
POWERTRAIN
CONTROL
MODULE
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
FUEL
VOLTMETER
CONTROL
3 3
FUEL
LEVEL
SENSOR SENSOR
SPEED
VEHICLE
K226
20
DB/LG
15 C200
B2
C100
K226
20
DB/LG
1 C2
FUEL
LEVEL
SENSOR
SIGNAL
K226
20
DB/LG
WT/OR
18
G7
C2 47
WT/OR
20
G7
VEHICLE
SPEED
SENSOR
SIGNAL
S152
FUEL
GAUGE
TACHOMETER VOLTMETER SPEEDOMETER
CONTROL
SPEEDOMETER
LOW
FUEL
WARNING
INDICATOR INDICATOR
WARNING
GAUGES
CHECK
LOW FUEL
WARNING
INDICATOR INDICATOR
WARNING
CHECK GAUGES
CONTROL CONTROL
UPSHIFT
INDICATOR
CONTROL
UPSHIFT
WARNING
INDICATOR
(M/T)
LHD RHD
C204 16 1 C110
G7
18
WT/OR
TWISTED
PAIR
G7
20
WT/OR
43 C1
SIGNAL
SENSOR
SPEED
VEHICLE
(8W-12-11)
(8W-30-16)
(8W-30-17)
(8W-30-24)
(8W-30-27)
(8W-30-30)
(8W-30-31)
(8W-30-27) (8W-30-24)
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER
DIESEL
XJ
J978W-7 XJI04003
INDICATOR
WARNING
ENGINE
CHECK
INDICATOR
WARNING
CHECK ENGINE
MODULE
CONTROL
TRANSMISSION
TWISTED
PAIR
6 7
20
D2
VT/BR
20
D1
WT/BK
CCD
BUS
(-) (+)
BUS
CCD
SENSOR
SIGNAL
OIL
PRESSURE
GAUGE
PRESSURE
GAUGE
TEMPERATURE
COOLANT
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
GAUGE
CONTROL CONTROL
GAUGE
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
1 7
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
A12
C100 A11
S145
S144
(A/T)
(A/T)
D1
18
VT/BR
D2
18
WT/BK
C3 C30 C28 C3
POWERTRAIN
CONTROL
MODULE
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
TEMPERATURE
2
2
COOLANT
TEMPERATURE
SENSOR
PRESSURE
OIL
K2
18
TN/BK
A16 C1
COOLANT
TEMPERATURE
SENSOR
C2 B23
GY/YL
18
G60
OIL
PRESSURE
SENSOR
SIGNAL
COOLANT
OIL
CONTROL CONTROL
OIL
PRESSURE
INDICATOR
OIL
PRESSURE
WARNING
INDICATOR
INDICATOR
WARNING
TEMPERATURE
COOLANT
INDICATOR
TEMPERATURE
COOLANT
CONTROL
WARNING
SENSE
SWITCH
CONTROL
SPEED
V37
18
RD/LG
C32 C3
B5 C100
RD/LG
20
V37
2
B
CLOCKSPRING
LEFT
SPEED
CONTROL
2
SWITCH
S221
V37
20
RD/LG
CRUISE
ON
INDICATOR
CONTROL
INDICATOR
CRUISE ON
ENGINE
ENGINE
ENGINE
ENGINE
ENGINE
ENGINE
(8W-31-4)
(8W-12-11)
(8W-30-16)
(8W-30-17)
(8W-30-7)
(8W-30-10)
(8W-30-16)
(8W-30-17)
(8W-30-7)
(8W-30-10)
(8W-33-2)
(8W-33-2)
GAS
8W - 40 - 5
XJI04004 J978W-7
INDICATOR
WARNING
ENGINE
CHECK
INDICATOR
WARNING
CHECK ENGINE
SENSOR
SIGNAL
OIL
PRESSURE
GAUGE
PRESSURE
GAUGE
TEMPERATURE
COOLANT
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
GAUGE
CONTROL CONTROL
GAUGE
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
1 7
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
A12
C100
A11
D1
20
VT/BR
D2
20
WT/BK
C2 26 46 C2
POWERTRAIN
CONTROL
MODULE
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
TEMPERATURE
A
2
COOLANT
TEMPERATURE
SENSOR
PRESSURE
OIL
K2
20
TN/BK
14 C1
COOLANT
TEMPERATURE
SENSOR
C2 42
GY/YL
20
G60
OIL
PRESSURE
SENSOR
SIGNAL
COOLANT
OIL
CONTROL
8 C120
K2
20
TN/BK
TWISTED
PAIR
RD/LG
20
V37
S221
SWITCH
2
CONTROL
SPEED
LEFT
CLOCKSPRING
B
2
V37
20
RD/LG
C100 B5
C1 36
RD/LG
20
V37
SPEED
CONTROL
SWITCH
SENSE
CRUISE ON
INDICATOR
CONTROL
INDICATOR
ON
CRUISE
WARNING
COOLANT
TEMPERATURE
INDICATOR
COOLANT
TEMPERATURE
WARNING
INDICATOR
INDICATOR
WARNING
PRESSURE
OIL
INDICATOR
PRESSURE
OIL
CONTROL
CONTROL
ENGINE
ENGINE
ENGINE
ENGINE
ENGINE
ENGINE
(8W-12-11)
(8W-30-30)
(8W-30-31)
(8W-30-24)
(8W-30-26)
(8W-30-27)
(8W-30-30)
(8W-30-31)
(8W-30-24)
(8W-30-27)
(8W-33-4)
(8W-33-4)
DIESEL
XJ
J978W-7 XJI04005
JUNCTION
BLOCK
ST-RUN A21
10A
FUSE
9
TALE
TELL
S13
C4
1
F87
20
WT/BK
FULL
OPTIONS BASE
S216
5 C201
6 C301
COMPASS
TO
F87
20
WT/BK
F87
20
WT/BK
7 4
G86
20
TN/OR
K185
20
OR/LB
LHD RHD
F87
20
WT/BK
VT/LG
20
G154
8
WAIT
TO
START
WARNING
INDICATOR INDICATOR
WARNING
FUEL
IN
WATER LOW
COOLANT
LEVEL
WARNING
INDICATOR
E15 C100
E16 E17
C1 3
POWERTRAIN
CONTROL
MODULE
31 C2 54 C2
G154
20
VT/LG OR/LB
20
K185
TN/OR
20
G86
WAIT TO
START
INDICATOR
CONTROL CONTROL
INDICATOR
IN FUEL
WATER LOW
LEVEL
INDICATOR
CONTROL
SIGNAL
SENSOR
IN FUEL
WATER
DG/WT
20
G123
C2 23
1
SENSOR
FUEL
IN
WATER
LOW
COOLANT
SWITCH
1
8 C2
G18
20
PK/BK
LOW
COOLANT
SWITCH
SENSE
COOLANT
MODULE
(8W-12-2)
(8W-10-29)
(8W-12-11)
(8W-12-11)
(8W-49-2)
(8W-30-27)
(8W-30-27)
(8W-30-27)
DIESEL
8W - 40 - 7
XJI04006 J978W-7
INDICATOR
WARNING
AIRBAG
INDICATOR
WARNING
AIRBAG
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
3 5
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
52
C201 51
D1
18
VT/BR
D2
18
WT/BK
19 18
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
TWISTED
PAIR
ABS
INDICATOR
B16
B19
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
4
C1
G19
20
LG/OR
F13
C100
Z1
20
BK
S132
Z1
14
BK
CONTROL
G19
20
LG/OR
CONTROL
INDICATOR
INDICATOR
FLUID
WASHER
LOW
FLUID
WASHER
LOW
BK/TN
20
G29
LOW
WASHER
FLUID
SWITCH
SENSE
A8
BK/TN
20
G29
C2
9
A
B
SWITCH
FLUID
WASHER
LOW
G106
BK
20
Z1
SEAT
BELT
SWITCH
A
B
10
C2
G10
20
LG/RD
69 C201
SENSE
SWITCH
BELT
SEAT
G10
20
LG/RD
Z1
20
BK
S314
Z1
14
BK
BK
14
Z1
S208
G107
14 C201
Z1
14
BK
SEAT
BELT
WARNING
SEAT
BELT
WARNING
INDICATOR
INDICATOR
CONTROL
(8W-12-11)
(8W-30-16)
(8W-43-2)
(8W-35-3)
(8W-15-5)
(8W-15-4)
(8W-15-8)
(8W-15-8)
(8W-15-8)
GAS LHD
XJ
J978W-7 XJI04007
BK
20
Z1
INDICATOR
WARNING
AIRBAG
INDICATOR
WARNING
AIRBAG
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
3 5
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
2
C204 1
D1
20
VT/BR
D2
20
WT/BK
19 18
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
TWISTED
PAIR
ABS
INDICATOR
B16
B19
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
4
C1
G19
20
LG/OR
F13
C100
Z1
20
BK
S132
Z1
14
BK
CONTROL
G19
20
LG/OR
CONTROL
INDICATOR
INDICATOR
FLUID
WASHER
LOW
FLUID
WASHER
LOW
BK/LB
20
G29
LOW
WASHER
FLUID
SWITCH
SENSE
A8
BK/TN
20
G29
C2
9
A
B
SWITCH
FLUID
WASHER
LOW
BK
16
Z1
G106
S141
BK
20
Z1
SEAT
BELT
SWITCH
A
B
10
C2
G10
20
LG/RD
12 C203
SENSE
SWITCH
BELT
SEAT
G10
20
LG/RD
Z1
20
BK
S313
BK
20
Z1
S309
G302
SEAT
BELT
WARNING
SEAT
BELT
WARNING
INDICATOR
INDICATOR
CONTROL
(8W-12-12)
(8W-30-17)
(8W-43-3)
(8W-35-3)
(8W-15-5)
(8W-15-4)
(8W-15-5)
(8W-15-12)
(8W-15-12)
(8W-15-12)
GAS RHD
8W - 40 - 9
XJI04008 J978W-7
INDICATOR
WARNING
AIRBAG
INDICATOR
WARNING
AIRBAG
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
3 5
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
52
C201 51
D1
18
VT/BR
D2
18
WT/BK
19 18
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
TWISTED
PAIR
ABS
INDICATOR
4
C1
G19
20
LG/OR
F13
C100
CONTROL
CONTROL
INDICATOR
INDICATOR
FLUID
WASHER
LOW
FLUID
WASHER
LOW
LOW
WASHER
FLUID
SWITCH
SENSE
A8
BK/TN
20
G29
C2
9
SEAT
BELT
SWITCH
A
B
10
C2
G10
20
LG/RD
69 C201
SENSE
SWITCH
BELT
SEAT
G10
20
LG/RD
Z1
20
BK
S314
Z1
14
BK
BK
14
Z1
S208
G107
14 C201
Z1
14
BK
SEAT
BELT
WARNING
SEAT
BELT
WARNING
INDICATOR
INDICATOR
CONTROL
BK
20
Z1
BK/TN
20
G29
Z1
20
BK
C106 12
Z1
18
BK
S103
C106 11
FOG
LAMP
RELAY
(IN PDC)
BK
18
Z1
G106
B10
S141
BK
12
Z1
Z1
20
BK
S132
Z1
12
BK
LOW
WASHER
FLUID
SWITCH
B
A
CONTROLLER
ANTI-LOCK
BRAKE
RELAY
(IN PDC)
B19
B16
(8W-12-11)
(8W-30-30)
(8W-43-2)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-15-4)
(8W-50-8)
(8W-15-4)
(8W-15-6)
(8W-15-6)
(8W-35-5)
DIESEL LHD
XJ
J978W-7 XJI04009
BK
20
Z1
INDICATOR
WARNING
AIRBAG
INDICATOR
WARNING
AIRBAG
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
TWISTED
PAIR
13 9
3 5
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
2
C204 1
D1
20
VT/BR
D2
20
WT/BK
19 18
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
TWISTED
PAIR
ABS
INDICATOR
B16
B19
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
4
C1
G19
20
LG/OR
F13
C100
CONTROL
CONTROL
INDICATOR
INDICATOR
FLUID
WASHER
LOW
FLUID
WASHER
LOW
LOW
WASHER
FLUID
SWITCH
SENSE
A8
BK/TN
20
G29
C2
9
A
B
SWITCH
FLUID
WASHER
LOW
BK
12
Z1
S132
BK
20
Z1
SEAT
BELT
SWITCH
A
B
10
C2
G10
20
LG/RD
12 C203
SENSE
SWITCH
BELT
SEAT
Z1
20
BK
S313
BK
20
Z1
S309
G302
SEAT
BELT
WARNING
SEAT
BELT
WARNING
INDICATOR
INDICATOR
CONTROL
Z1
12
BK
S141
B10
G106
Z1
18
BK
(IN PDC)
RELAY
LAMP
FOG
11 C106
S103
BK
18
Z1
12 C106
BK
20
Z1
LG/RD
20
G10 G29
20
BK/TN
Z1
20
BK
(8W-12-12)
(8W-30-31)
(8W-43-3)
(8W-35-5)
(8W-15-6)
(8W-15-12)
(8W-15-12)
(8W-15-12)
(8W-15-6)
(8W-15-4)
(8W-50-8)
(8W-15-4)
DIESEL RHD
8W - 40 - 11
XJI04010 J978W-7
4WD
TIME
PART
ST-RUN F87
CLUSTER
INSTRUMENT
INDICATOR
7
C2
G106
20
BK/WT
A2
INDICATOR
WARNING
BRAKE
A3
BK/RD
20
G107
C2
5
INDICATOR
FULL
TIME
4WD
G107
20
BK/RD BK/WT
20
G106
G106
18
BK/WT BK/RD
18
G107
8
C107 13
B
A
SWITCH
4WD
TIME
PART
FULL-TIME
4WD 4WD
PART-TIME
4WD
SWITCH
D
A
B
PART
TIME TIME
FULL
G101
S107
Z1
18
BK
Z1
16
BK
2
C1
G99
20
GY/WT
A10
C100
2
1
SWITCH
WARNING
PRESSURE
BRAKE
G9
20
GY/BK
A14 C100
G9
20
GY/BK GY/BK
20
G9
S211
C1
1
C1 2
3
0
2
1 4
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
SWITCH
IGNITION
BK
14
Z1
BK
20
Z1
S207
G108
PARK
BRAKE
SWITCH
1
G9
20
GY/BK
66 C201
LHD RHD
C203 10
PART-TIME/
GY/BK
18
G9
RHD 2.5L
GAS OTHERS
A2 C100
(NOT
USED)
(8W-12-11)
(8W-15-2)
(8W-15-2)
(8W-10-8)
(8W-15-10)
(8W-15-10)
GAS
XJ
J978W-7 XJI04011
4WD
TIME
PART
ST-RUN F87
CLUSTER
INSTRUMENT
INDICATOR
7
C2
G106
20
BK/WT
A2
INDICATOR
WARNING
BRAKE
A3
BK/RD
20
G107
C2
5
INDICATOR
FULL
TIME
4WD
G107
20
BK/RD BK/WT
20
G106
BK/RD
20
G107
3
C110 2
B
A
SWITCH
4WD
TIME
PART
G106
S141
Z1
18
BK
Z1
12
BK
2
C1
G99
20
GY/WT
A10
C100
GY/WT
20
G99
2
1
SWITCH
WARNING
PRESSURE
BRAKE
G9
20
GY/BK
A14 C100
G9
20
GY/BK GY/BK
20
G9
S211
C1
1
C1 2
3
0
2
1 4
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
SWITCH
IGNITION
BK
14
Z1
BK
20
Z1
S207
G108
PARK
BRAKE
SWITCH
1
G9
20
GY/BK
66 C201
LHD RHD
C203 10
(NOT
USED)
Z1
20
BK
4 C110
S132
Z1
12
BK
GY/BK
18
G9
(8W-12-11)
(8W-15-4)
(8W-15-6)
(8W-10-28)
(8W-15-10)
(8W-15-10)
(8W-15-6)
DIESEL
8W - 40 - 13
XJI04012 J978W-7
5 C1
LEFT
FRONT
DOOR
JAMB
SWITCH
2
BK/LB
18
G16
C317 2
C200 17
S200
LB
20
G26
C2
8
CLUSTER
INSTRUMENT
2
C2
1 C2
SWITCH
KEY-IN
SWITCH
IGNITION
BK/LB
20
G16
19 C203
2 C318
G16
18
BK/LB
2
SWITCH
JAMB
DOOR
FRONT
RIGHT
LHD RHD
BK/LB
20
G16
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
C1
6
0
1
2
S210
CHIME
CONTROL
BATT M1
FUSED
B(+)
3 C317
G302
S309
Z1
18
BK
Z1
20
BK
Z1
12
BK
3 3
BK
20
Z1
BK
20
Z1
BK
18
Z1
S310
G303
C318 3
(8W-39-6)
(8W-39-7)
(8W-39-6)
(8W-39-7)
(8W-50-2)
(8W-50-3)
(8W-10-9)
(8W-10-29)
(8W-10-8)
(8W-10-28)
(8W-10-14)
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-13)
(8W-15-14)
J978W-7 XJI04013
G108
C1
6
BK/LG
18
Z2
1
C1
Z2
18
BK/LG
GROUND
IGN.
FUSED
(ST-RUN)
ST-RUN F87
L60
20
TN
L60
20
TN
S212 S209
LG/WT
20
L61
LG/WT
20
L61
C2 6 10 C1
RIGHT
TURN
SIGNAL
INDICATOR
LAMP LAMP
INDICATOR
SIGNAL
TURN
LEFT
1 10
SWITCH)
(PART OF
MULTI-
FUNCTION
TURN
SIGNAL/
HAZARD
SWITCH
BLOCK
JUNCTION
BK
14
Z1
BK
18
Z1
S208
G107
DB/WT
20
C80
C2
4
WINDOW
REAR
DEFOGGER
SENSE
SWITCH
REAR
WINDOW
DEFOGGER
SWITCH
2
1
RELAY
CONTROL
DEFOGGER
REAR
WINDOW
C2 3
CLUSTER
INSTRUMENT
C201 17
LHD RHD
LB/WT
20
C81
C4
S26
RELAY
DEFOGGER
WINDOW
REAR
85
86
12
FUSE
10A
RUN A22
(8W-15-10)
(8W-12-11)
(8W-70-4) (8W-70-4)
(8W-52-2)
(8W-52-3)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-48-2)
(8W-48-3)
(8W-48-2)
(8W-48-3)
(8W-12-15)
(8W-12-16)
(8W-10-10)
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 15
XJI04014 J978W-7
RD/OR
16
L3
INDICATOR
VTSS
CONTROL (+)
CCD
BUS BUS
CCD
(-)
12
WT/BK
20
D2
WT/BK
20
D2
C301
2
C201 56
S346
D2
20
WT/BK VT/BR
20
D1
6
S344
D1
20
VT/BR
VT/BR
20
D1
55
1
WT/BK
20
D2
VT/BR
20
D1
BLOCK
SPLICE
DIAGNOSTIC
13
14 8
9
C2 1 2 C2
(-)
CCD
BUS BUS
CCD
(+)
GY
20
G38
GY
20
G38
C302 6
49
OVERHEAD
MODULE
4
G38
20
GY
C1 7
VTSS
INDICATOR
RD/OR
16
L3
S213
RD/OR
16
L3
FUNCTION
MULTI-
(PART OF
SWITCH)
SWITCH
SELECT
BEAM
2
RHD LHD
L3
16
RD/OR
C100 D4
RD/GY
16
G34
BK/LG
18
Z2
C1
1
Z2
18
BK/LG
6
C1
G108
ST-RUN F87
(ST-RUN)
FUSED
IGN.
GROUND
INSTRUMENT
CLUSTER
LAMP
INDICATOR
BEAM
HIGH
5 C1
RHD LHD LHD RHD
C201
RHD LHD
IMMOBILIZER VISOR IMMOBILIZER
LIGHTED LIGHTED
VISOR
PAIR
TWISTED
D3 C100
G34
16
RD/GY
TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-39-8)
(8W-50-2)
(8W-50-3)
(8W-50-2)
(8W-50-3)
(8W-15-10)
(8W-12-11)
J978W-7 XJI04015
IGN.
FUSED
(ST-RUN)
ST-RUN F87
3 C1
BLOCK
JUNCTION
TRIP
RESET
SENSE
SWITCH
CLUSTER
INSTRUMENT
6
FUSE
5A
BATT F34
TRIP
RESET
SWITCH
CLUSTER
ILLUMINATION
LAMPS
ODOMETER
CONTROL
ODOMETER
S2
C4
E2
20
OR
S315
43 C201
E2
20
OR
LHD RHD
S215
TN
20
E1
C4 S1
C201 42
RHD LHD
2
1
0
C1
1
3 4
4 BRIGHT
3 DIM
2 HEAD
1 PARK
0 OFF
SWITCH
HEADLAMP
BATT M1
FUSED
B(+)
(8W-12-11)
(8W-12-2)
(8W-12-8)
(8W-12-9)
(8W-10-16)
(8W-12-8)
(8W-12-8)
(8W-12-9)
(8W-50-2)
(8W-50-3)
(8W-10-14)
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 17
XJI04016 J978W-7
8W-40 INSTRUMENT CLUSTER
INDEX
page page
OIL PRESSURE GAUGE . . . . . . . . . . . . . . . . . . 19
SEAT BELT WARNING LAMP . . . . . . . . . . . . . . . 19
HIGH BEAM INDICATOR LAMP . . . . . . . . . . . . . 19
TURN SIGNAL INDICATOR LAMPS . . . . . . . . . . 19
MANUAL TRANSMISSION UP-SHIFT LAMP . . . . 19
FOUR-WHEEL DRIVE (4WD) SWITCH . . . . . . . . 19
CHIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
TELL TALE MODULE . . . . . . . . . . . . . . . . . . . . . 20
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
ILLUMINATION LAMPS . . . . . . . . . . . . . . . . . . . . 18
WARNING LAMPSEXCEPT ABS and BRAKE . 18
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . 18
BRAKE WARNING LAMP . . . . . . . . . . . . . . . . . . 18
SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . . . 18
TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . 18
VOLTMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ENGINE COOLANT TEMPERATURE GAUGE . . . 19
INTRODUCTION
The el ectroni c i nstrument cl uster contai ns a mi cro-
processor whi ch control s cl uster functi ons based on
data i t recei ves from the CCD bus. Ci rcui t M1 from
fuse 16 i n the Power Di stri buti on Center (PDC) sup-
pl i es power to the cl uster mi croprocessor. When the
i gni ti on swi tch i s i n the START or RUN posi ti on, i t
connects ci rcui t A1 from fuse 2 i n the PDC to ci rcui t
A21. Ci rcui t A21 powers ci rcui t F87 through fuse 9
i n the juncti on bl ock. Ci rcui t F87 powers the cl uster
mi croprocessor pl us the warni ng l amps i n the cl uster.
The cl uster mi croprocessor swi tches the warni ng
l amps on and off by control l i ng the ground path for
each l amp.
ILLUMINATION LAMPS
When the headl amp swi tch i s i n the PARK or ON
posi ti on, ci rcui t E1 from the di mmer swi tch ci rcui try
feeds ci rcui t E2 through fuse 6 i n the juncti on bl ock.
Ci rcui t E2 powers the i l l umi nati on l amps. Ci rcui t Z2
provi des ground for the l amps.
WARNING LAMPS EXCEPT ABS and BRAKE
Ci rcui t F87 feeds al l the warni ng l amps i n the
i nstrument cl uster. The mi croprocessor turns on and
off al l the warni ng l amps except the seat bel t warn-
i ng l amp, ABS warni ng l amp, and brake warni ng
l amp based on i nputs broadcast on the CCD bus. The
mi croprocessor control s the ground path for these
l amps. Ci rcui ts Z2 provi de ground for the mi cropro-
cessor.
ABS WARNING LAMP
Ci rcui t F87 from fuse 9 i n the juncti on bl ock pro-
vi des power for the ABS warni ng l amp i n the i nstru-
ment cl uster. Ground for the ABS warni ng l amp i s
provi ded by the ABS rel ay when the rel ay i s not
energi zed. When the ABS rel ay i s not energi zed ci r-
cui t G19 i s connected to ci rcui t Z1 ground, through
the ABS rel ay.
HELPFUL INFORMATION
cui t A21 powers ci rcui t F87 through fuse 9 i n the
juncti on bl ock.
Ci rcui t F87 suppl i es vol tage to the coi l si de of ABS
rel ay and ci rcui t G83 provi des the ground. Ci rcui t
G83 connects to cavi ty 16 of the Control l er, Anti -Lock
Brakes (CAB).
BRAKE WARNING LAMP
Ci rcui t F87 from fuse 9 i n the juncti on bl ock sup-
pl i es power to the brake warni ng l amp. Ground for
the brake warni ng l amp i s suppl i ed through the case
grounded park brake swi tch, i gni ti on swi tch (i n the
START posi ti on) or brake warni ng swi tch. Ci rcui t
G99 from the l amp connects to the brake warni ng
swi tch. Ci rcui t G9 connects the brake warni ng swi tch
to the park brake swi tch and i gni ti on swi tch.
SPEEDOMETER
The i nstrument cl uster mi croprocessor cal cul ates
speedometer needl e posi ti on based on the vehi cl e
speed si gnal broadcast on the CCD bus by the Pow-
ertrai n Control Modul e (PCM). The PCM determi nes
vehi cl e speed from the i nput provi ded by the vehi cl e
speed sensor.
TACHOMETER
The Powertrai n Control Modul e (PCM) broadcasts
the engi ne RPM data on the CCD bus. From the
8W - 40 - 18 8W - 40 INSTRUMENT CLUSTER XJ
RPM message on the CCD bus, the i nstrument cl us-
ter cal cul ates tachometer needl e posi ti on.
VOLTMETER
system vol tage data on the CCD bus. The mi cropro-
cessor i n the i nstrument cl uster cal cul ate vol tmeter
needl e posi ti on based on the si gnal recei ved from the
CCD bus.
FUEL GAUGE
The Powertrai n Control Modul e (PCM) transmi ts
the fuel percentage data over the CCD bus. The
mi croprocessor i n the i nstrument cl uster cal cul ates
posi ti on of the fuel gauge needl e based on the si gnal
from the PCM.
ENGINE COOLANT TEMPERATURE GAUGE
the engi ne cool ant temperature data over the CCD
bus. From the data message on the CCD bus, the
i nstrument cl uster mi croprocessor cal cul ates cool ant
temperature gauge needl e posi ti on.
OIL PRESSURE GAUGE
On ci rcui t G60, the Powertrai n Control Modul e
(PCM) provi des current to the oi l pressure sensor.
The sensor i s a vari abl e resi stor. As engi ne oi l pres-
sure changes, the resi stance i n the sensor changes
resul ti ng i n a change i n current draw. The PCM pro-
vi des ground for the sensor on ci rcui t K167. Ci rcui t
K167 connects to cavi ty A4 of the PCM.
The i nstrument cl uster mi croprocessor cal cul ates
engi ne oi l pressure gauge needl e posi ti on based on
the oi l pressure data message on the CCD bus. The
Powertrai n Control Modul e (PCM) broadcasts the
data message over the CCD bus.
Upstream and downstream heated oxygen sen-
sors
SEAT BELT WARNING LAMP
Ci rcui t F87 feeds al l the warni ng l amps i n the
i nstrument cl uster. The mi croprocessor turns on and
off al l the warni ng l amps except the seat bel t warn-
i ng l amp, ABS warni ng l amp, and brake warni ng
l amp based on i nputs broadcast on the CCD bus. The
mi croprocessor control s the ground path for these
l amps. Ci rcui ts Z2 provi de ground for the mi cropro-
cessor.
Ci rcui t G10 from the i nstrument cl uster mi cropro-
cessor connects to the seat bel t swi tch. The swi tch i s
cl osed when the seat bel t i s removed from the seat
bel t cl asp. When the seat bel t i s i nserted i nto the
cl asp, i t opens the swi tch. When cl osed, the seat bel t
swi tch connects ci rcui t G10 to ground on ci rcui t Z1.
I f the i gni ti on swi tch i s i n the START or RUN posi -
ti on, the i nstrument cl uster mi croprocessor grounds
the seat bel t warni ng l amp i f i t senses a cl osed seat
bel t swi tch.
HIGH BEAM INDICATOR LAMP
When the operator sel ects hi gh beam operati on,
the mul ti -functi on swi tch powers the headl amp hi gh
beams on ci rcui t L3. Ci rcui t L3 connects to ci rcui t
G34. Ci rcui t G34 suppl i es power for the hi gh-beam
i ndi cator l amp. Ci rcui t Z2 provi des ground for the
hi gh beam i ndi cator l amp at the cl uster.
TURN SIGNAL INDICATOR LAMPS
Ci rcui ts L60 and L61 from the turn si gnal /hazard
fl asher ci rcui try i n the mul ti -functi on swi tch power
the turn si gnal i ndi cator l amps. Ci rcui t L60 powers
the ri ght turn si gnal i ndi cator l amp. Ci rcui t L61
powers the l eft i ndi cator l amp. Ci rcui t Z2 provi des
ground for the l amps.
MANUAL TRANSMISSION UP-SHIFT LAMP
the transmi ssi on up-shi ft message on the CCD bus.
The mi croprocessor i n the i nstrument cl uster moni -
tors the CCD bus and swi tches the up-shi ft l amp on
or off by suppl yi ng or removi ng ground from the
l amp. Ci rcui t F87 from fuse 9 i n the juncti on bl ock
powers the l amp.
FOUR-WHEEL DRIVE (4WD) SWITCH
Ci rcui t F87 from fuse 9 i n the juncti on bl ock pow-
ers the 4WD i ndi cator l amp. Ci rcui t G107 connects
the i ndi cator l amp to the 4WD swi tch. When the
4WD swi tch cl oses, i t connects ci rcui t G107 to ci rcui t
G106. Ci rcui t G106 connects to ci rcui t Z1. Ci rcui t Z1
provi des ground for the 4WD i ndi cator l amp.
CHIME
The i nstrument cl uster mi croprocessor sounds the
audi bl e warni ng chi me. The chi me sounds for seat
bel t warni ng and when the i gni ti on key i s i n the
i gni ti on swi tch whi l e the dri vers door i s open. The
chi me sounds when the i gni ti on key i s i n the ON
posi ti on whi l e the dri vers si de seat bel t i s not buck-
l ed. Lastl y, the chi me sounds when the headl amps
are ON when the i gni ti on i s OFF.
XJ 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 19
When the parki ng l amps or headl amps are ON, the
headl amp swi tch connects ci rcui t G26 from the
i nstrument cl uster mi croprocessor to ci rcui t G16. Ci r-
cui t G16 connects to the dri vers si de door jamb
swi tch. Ci rcui t G16 al so connects to the key-i n
swi tch. When the cl uster mi croprocessor senses
ground on ci rcui t G26, i t sounds the chi me.
I f the headl amps are ON, and the dri vers door
opens, the dri vers door jamb swi tch connects ci rcui t
G16 to ground. When the i nstrument cl uster senses
ground on ci rcui t G26, i t sounds the chi me.
I f the headl amps are OFF wi th the key i n the i gni -
ti on swi tch whi l e the dri vers si de door i s open, the
cl uster sounds the chi me. I n thi s case, the cl osed
key-i n swi tch and dri vers door jamb connect the cl us-
ter mi croprocessor to ground.
Ci rcui t G10 connects the cl uster mi croprocessor to
the seat bel t swi tch. When the seat bel t swi tch
cl oses, a path to ground i s compl eted on ci rcui t Z1
and the cl uster momentari l y sounds the chi me.
TELL TALE MODULE
Ci rcui t F87 from fuse 9 i n the juncti on bl ock pow-
ers the tel l tal e modul e. The warni ng l amps wi thi n
the tel l tal e modul e recei ve ground from the power-
trai n control modul e and the MSA control l er.
Ci rcui t K185 from cavi ty 3 of the MSA control l er
provi des the ground for the Di esel Wai t l amp.
Ci rcui t G86 from cavi ty 31 of the powertrai n con-
trol modul e provi des the ground for the Water I n
Fuel l am.
Ci rcui t G154 from cavi ty 54 of the powertrai n con-
trol modul e provi des groung for the Low Cool ant
l amp.
8W - 40 - 20 8W - 40 INSTRUMENT CLUSTER XJ
8W-41 HORN/CIGAR LIGHTER
INDEX
page
Component Page
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . .8W-41-2, 3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Left Horn. . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Power Outl et . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
Ri ght Horn . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2, 3
XJ 8W - 41 HORN/CIGAR LIGHTER 8W - 41 - 1
C4
M6
BLOCK
JUNCTION
M5
C4
25A
FUSE
1
25A
FUSE
2
2
1
CIGAR
LIGHTER
F30
16
RD
F30
16
RD
50
Z1
16
BK
65
BK
16
Z1
OUTLET
POWER
1
2
F38
16
RD/LB
F38
16
RD/LB
4
C2
1
LEFT
HORN HORN
RIGHT
1
S131
X2
20
DG/RD
X2
20
DG/RD
X2
20
DG/RD
85 87
30 86
CIGAR
LIGHTER
RELAY
RUN-ACC A31 BATT A7
RELAY
HORN
86 30
87 85
C4
S22
CLOCKSPRING
HORN
SWITCH
C201
26
BK/RD
20
X3
X3
20
BK/RD
21
FUSE
15A
G107
S5
C4
1
C5
1
14
Z1
14
BK
Z1
14
BK
Z1
14
BK
Z1
14
BK
S314
S208
10
MODULE
OVERHEAD
X3
20
BK/RD
X3
20
BK/RD
1 C302
(8W-12-2)
(8W-12-5) (8W-12-5) (8W-12-19)
(8W-10-8) (8W-10-11)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-39-8)
8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
LHD
XJ
J978W-7 XJI04101
C4
M6
BLOCK
JUNCTION
M5
C4
25A
FUSE
1
25A
FUSE
2
2
1
CIGAR
LIGHTER
F30
16
RD
Z1
16
BK BK
16
Z1
OUTLET
POWER
1
2
F38
16
RD/LB
4
C2
1
LEFT
HORN HORN
RIGHT
1
S131
X2
20
DG/RD
X2
20
DG/RD
X2
20
DG/RD
85 87
30 86
CIGAR
LIGHTER
RELAY
RUN-ACC A31 BATT A7
RELAY
HORN
86 30
87 85
C5
1
CLOCKSPRING
HORN
SWITCH
BK/RD
20
X3
21
FUSE
15A
G107
S5
C4
S22
C4
1
Z1
14
BK
Z1
14
BK
Z1
14
BK
S314
S208
10
MODULE
OVERHEAD
X3
20
BK/RD
X3
20
BK/RD
1 C302
(8W-12-2)
(8W-12-5) (8W-12-5) (8W-12-19)
(8W-10-8) (8W-10-11)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-3-8)
XJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
RHD
8W - 41 - 3
XJI04102 J978W-7
8W-41 HORN/CIGAR LIGHTER
HORN
The horn system uses a si ngl e horn swi tch and
horn rel ay. The horn swi tch i s i nstal l ed i n the center
of the steeri ng wheel .
Center (PDC) feeds a juncti on bl ock bus bar. The bus
bar powers the coi l si de of the horn rel ay, and the
contact si de through fuse 21 i n the juncti on bl ock..
When the case grounded horn swi tch i s depressed,
ci rcui t X3 provi des ground for the coi l si de of the
rel ay and the contacts CLOSE. When the contacts
CLOSE, ci rcui t X2 suppl i es vol tage to the case
grounded horns.
HELPFUL INFORMATION
The horn swi tch i s grounded to the steeri ng
wheel .
Check fuse 4 i n the PDC and fuse 21 i n the
juncti on bl ock.
CIGAR LIGHTER
The ci gar l i ghter rel ay powers the ci gar l i ghter.
The rel ay energi zes when the i gni ti on swi tch i s i n
the ACCESSORY or RUN posi ti on. I n the ACCES-
SORY or RUN posi ti on, the swi tch connects ci rcui t
A1 from fuse 2 i n the Power Di stri buti on Center
(PDC) to ci rcui t A31. Ci rcui t A31 powers rel ay coi l .
Ci rcui t Z1 provi des ground for the rel ay coi l .
When the rel ay energi zes, i ts connects ci rcui t A7
from fuse 4 i n the PDC to ci rcui t F30. Ci rcui t F30
powers the ci gar l i ghter.
When the operator depresses the l i ghter, contacts
i nsi de the l i ghter el ement cl ose, and vol tage from ci r-
cui t F30 fl ows through the heati ng el ement to
ground. Ci rcui t Z1 provi des ground for the l i ghter.
HELPFUL INFORMATION
Ci rcui t Z1 al so grounds the power outl et.
POWER OUTLET
Ci rcui t A7 from FUSE 4 i n the Power Di stri buti on
Center (PDC) powers ci rcui t F38 through fuse 1 i n
the juncti on bl ock. Ci rcui t F38 feeds the power out-
l et. Ci rcui ts A7 and F38 are HOT at al l ti mes. Ci r-
cui t Z1 provi des ground for the power outl et.
8W - 41 - 4 8W - 41 HORN/CIGAR LIGHTER XJ
8W-42 AIR CONDITIONING/HEATER
INDEX
page
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . .8W-42-7, 8
A/C Compressor Cl utch Rel ay . . . . . . . . . .8W-42-7, 8
A/C Heater Control . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6
A/C Hi gh Pressure Swi tch . . . . . . . . .8W-42-2, 3, 4, 8
A/C Low Pressure Swi tch . . . . . . . . .8W-42-2, 3, 4, 8
Bl ower Motor . . . . . . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6
Bl ower Motor Rel ay . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6
Cool i ng Fan Rel ay . . . . . . . . . . . . . . . . . . . . .8W-42-7
Di esel Power Rel ay . . . . . . . . . . . . . . . . . . . .8W-42-8
Fuse 5 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
Fuse 6 (PDC). . . . . . . . . . . . . . . . . . . . .8W-42-2, 3, 4
Fuse 9 (PDC). . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . . . .8W-42-5, 6
Fuse 20 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
Component Page
Fuse 21 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
Fuse 25 (JB) . . . . . . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7
G108 . . . . . . . . . . . . . . . . . . . . . . . .8W-42-2, 3,4, 5, 6
HVAC Uni t . . . . . . . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6
I l l umi nati on Lamps . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6
Juncti on Bl ock . . . . . . . . . . . . . .8W-42-2, 3, 4, 5, 6, 7
Power Di stri buti on Center . . .8W-42-2, 3, 4, 5, 6, 7, 8
Powertrai n Control Modul e . .8W-42-2, 3, 4, 5, 6, 7, 8
Radi ator Cool i ng Fan . . . . . . . . . . . . . . . . . .8W-42-7
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-2, 3, 4
S156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8
S219 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-3, 4, 6
XJ 8W - 42 AIR CONDITIONING/HEATER 8W - 42 - 1
BLOCK
JUNCTION
ILLUMINATION
LAMPS
NORM
MAX
OFF DEF
HEAT DEF
VENT
BI-LEVEL
HEAT
CONTROL
HEATER
A/C
HIGH
M2 M1
LOW
3 6 5 4
2
10
3 4 7 8 9
HVAC
UNIT
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
12
C201
61 60 59
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
POWER
DISTRIBUTION
CENTER
S8
C4
2
1
2 2
1
C3 C22
POWERTRAIN
CONTROL
MODULE
C23 C3
SWITCH
PRESSURE
HIGH
A/C
SWITCH
PRESSURE
LOW
A/C
C22
18
DB/WT
S143
A6 C100
C90
20
LG
C90
20
LG
A/C
SWITCH
SENSE SIGNAL
SELECT
A/C
C90
18
LG
C21
20
DB/OR
C90
20
LG
F15
20
DB/WT
BATT A0 RUN A22
40A
FUSE
6
15A
FUSE
25
G108
25 C201
A111
12
RD/LG
11 C201
A111
12
RD/LG
BK/VT
20
Z8
5
12
C100 D5
Z8
16
BK/VT
M
(8W-12-2)
(8W-10-6)
(8W-30-13)
(8W-10-6) (8W-10-10)
(8W-10-11) (8W-12-20)
(8W-15-10)
8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER
LHD
XJ
J978W-7 XJI04201
BLOCK
JUNCTION
ILLUMINATION
LAMPS
NORM
MAX
OFF DEF
HEAT DEF
VENT
BI-LEVEL
HEAT
CONTROL
HEATER
A/C
HIGH
M2 M1
LOW
3 6 5 4
2
10
3 4 7 8 9
HVAC
UNIT
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
1
C202
8 13 14
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
POWER
DISTRIBUTION
CENTER
S8
C4
2
1
2 2
1
C3 C22
POWERTRAIN
CONTROL
MODULE
C23 C3
SWITCH
PRESSURE
HIGH
A/C
SWITCH
PRESSURE
LOW
A/C
C22
18
DB/WT
S143
A6 C100
C90
20
LG
C90
20
LG
A/C
SWITCH
SENSE SIGNAL
SELECT
A/C
C90
18
LG
C21
20
DB/OR
C90
20
LG
F15
20
DB/WT
BATT A0 RUN A22
40A
FUSE
6
15A
FUSE
25
G108
6 C202
A111
12
RD/LG
7 C202
A111
12
RD/LG
BK/PK
20
Z8
5
12
C100 D5
Z8
12
BK/WT
S219
M
(8W-12-2)
(8W-10-6)
(8W-30-13)
(8W-10-6) (8W-10-10)
(8W-10-11) (8W-12-21)
(8W-15-10)
(8W-12-21)
XJ 8W-42 AIR CONDITIONING-HEATER
RHD
8W - 42 - 3
XJI04202 J978W-7
BLOCK
JUNCTION
ILLUMINATION
LAMPS
NORM
MAX
OFF DEF
HEAT DEF
VENT
BI-LEVEL
HEAT
CONTROL
HEATER
A/C
HIGH
M2 M1
LOW
3 6 5 4
2
10
3 4 7 8 9
HVAC
UNIT
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
1
C202
8 13 14
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
POWER
DISTRIBUTION
CENTER
S8
C4
2
1
2 2
1
C3 C22
POWERTRAIN
CONTROL
MODULE
C23 C3
SWITCH
PRESSURE
HIGH
A/C
SWITCH
PRESSURE
LOW
A/C
C22
18
DB/WT
S143
A6 C100
C90
20
LG
C90
20
LG
A/C
SWITCH
SENSE SIGNAL
SELECT
A/C
C90
18
LG/RD
C21
20
DB/OR
C90
20
LG/RD
F15
20
DB/WT
BATT A0 RUN A22
40A
FUSE
6
15A
FUSE
25
G108
6 C202
A111
12
RD/LG
7 C202
A111
12
RD/LG
BK/PK
20
Z8
5
12
C100 D5
Z8
12
BK/WT
S219
M
(8W-12-2)
(8W-10-6)
(8W-30-13)
(8W-10-6) (8W-10-10)
(8W-10-11) (8W-12-21)
(8W-15-10)
(8W-12-21)
2.5L M/T RHD
XJ
J978W-7 XJI04203
BLOCK
JUNCTION
ILLUMINATION
LAMPS
NORM
MAX
OFF DEF
HEAT DEF
VENT
BI-LEVEL
HEAT
CONTROL
HEATER
A/C
HIGH
M2 M1
LOW
3 6 5 4
2
10
3 4 7 8 9
HVAC
UNIT
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
12
C201
61 60 59
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
POWER
DISTRIBUTION
CENTER
S8
C4
2
POWERTRAIN
CONTROL
MODULE
28 C2
A6 C106
C90
20
LG
SIGNAL
SELECT
A/C
C90
20
LG
F15
20
DB/WT
BATT A0 RUN A22
40A
FUSE
11
15A
FUSE
25
G108
25 C201
A111
12
RD/LG
11 C201
A111
12
RD/LG
BK/VT
20
Z8
24
17
C100 D5
Z8
16
BK/VT
M
(8W-12-2)
(8W-10-26)
(8W-30-28)
(8W-10-25) (8W-10-30)
(8W-10-32) (8W-12-20)
(8W-15-10)
XJ 8W-42 AIR CONDITIONING-HEATER
LHD DIESEL
8W - 42 - 5
XJI04204 J978W-7
BLOCK
JUNCTION
ILLUMINATION
LAMPS
NORM
MAX
OFF DEF
HEAT DEF
VENT
BI-LEVEL
HEAT
CONTROL
HEATER
A/C
HIGH
M2 M1
LOW
3 6 5 4
2
10
3 4 7 8 9
HVAC
UNIT
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
1
C202
8 13 14
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
POWER
DISTRIBUTION
CENTER
S8
C4
2
POWERTRAIN
CONTROL
MODULE
28 C2
A6 C100
C90
20
LG
SIGNAL
SELECT
A/C
C90
18
LG/RD
F15
20
DB/WT
BATT A0 RUN A22
40A
FUSE
11
15A
FUSE
25
G108
6 C202
A111
12
RD/LG
7 C202
A111
12
RD/LG
BK/PK
20
Z8
24
17
C100 D5
Z8
12
BK/WT
S219
M
(8W-12-2)
(8W-10-26)
(8W-30-28)
(8W-10-25) (8W-10-30)
(8W-10-32) (8W-12-21)
(8W-15-10)
(8W-12-21)
RHD DIESEL
XJ
J978W-7 XJI04205
POWER
DISTRIBUTION
CENTER
C3 C2
POWERTRAIN
CONTROL
MODULE
RADIATOR
FAN
SELECT
C13 C14
C10 C11
5
FUSE
40A
COOLING
FAN
RELAY
B5
20A
FUSE
9
B1
B2 B3
A/C
COMPRESSOR
CLUTCH
RELAY
1
2
COIL
RELAY
A/C
C1 C3
1
CLUTCH
COMPRESSOR
A/C
4 C108
C27
18
DB/PK
C25
12
LB
C13
18
DB/OR
C3
16
DB/BK
15
22
FAN
COOLING
RADIATOR
G106
Z1
12
BK
BATT A0
4
11
C2
5
BLOCK
JUNCTION
20A
FUSE
11
ST-RUN A21
F12
18
DB/WT
M
(8W-10-6)
(8W-30-13)
(8W-10-11) (8W-10-12)
(8W-15-4)
(8W-10-6)
(8W-12-2)
(8W-12-13)
(8W-12-14)
(8W-10-9)
XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7
XJI04206 J978W-7
POWER
DISTRIBUTION
CENTER
POWERTRAIN
CONTROL
MODULE
B5
20A
FUSE
20
B1
B2 B3
A/C
COMPRESSOR
CLUTCH
RELAY
COIL
RELAY
A/C
28 C1
1
CLUTCH
COMPRESSOR
A/C
6
C120
C13
20
DB/OR
C3
16
DB/BK
A15
A16
BATT A0
2
1
SWITCH
PRESSURE
LOW
A/C
A/C
HIGH
PRESSURE
SWITCH
1
2
C22
20
DB/WT
3 C120
2
C21
20
DB/OR
S156
A14
A13
21
FUSE
20A
C2
C8
BATT A16
DIESEL
POWER
RELAY
F142
18
DG/OR
F142
16
DG/OR
A142
16
DG/OR
S137
A142
16
DG/OR
DB/OR
20
C21
DB/WT
20
C22
(8W-10-26)
(8W-30-28)
(8W-10-34)
(8W-10-25)
(8W-10-35)
(8W-10-35)
(8W-10-27)
(8W-30-18)
(8W-10-27)
DIESEL
XJ
J978W-7 XJI04207
8W-42 AIR CONDITIONING/HEATER
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 9
BLOWER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 9
A/C OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 9
A/C OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION
INTRODUCTION
The wi ri ng di agrams i n thi s secti on are di vi ded
i nto two sub-secti ons; Heater onl y, and A/C and
Heater. When referri ng to the wi ri ng di agrams,
ensure that you use the correct sub-secti on.
BLOWER MOTOR
I n the RUN posi ti on, the i gni ti on swi tch connects
ci rcui t A2 from fuse 3 i n the Power Di stri buti on Cen-
ter (PDC) to ci rcui t A22. Ci rcui t A22 feeds ci rcui t F15
through fuse 25 i n the juncti on bl ock. Ci rcui t F15
suppl i es vol tage to coi l si de of the bl ower motor rel ay.
Ground for the coi l si de of the rel ay i s ci rcui t Z8.
When the rel ay contacts cl ose they connect ci rcui t
A111 from fuse 6 of the PDC to ci rcui t C1. Ci rcui t C1
suppl i es vol tage to the bl ower motor. Ci rcui t C7 con-
nects the ground si de of the bl ower motor to the
bl ower resi stor bl ock.
The bl ower swi tch recei ves ground through the
control swi tch on ci rcui t Z8. The bl ower swi tch con-
nects to ci rcui t C4. Ci rcui t C4 connects to the bl ower
resi stor bl ock. The bl ower resi stor bl ock control s
bl ower motor speed i n al l posi ti ons except HI GH. The
bl ower motor swi tch has four posi ti ons; LOW,
MEDI UM 1, MEDI UM 2, AND HI GH.
I n the LOW posi ti on, ci rcui t C4 passes through al l
three resi stors i n the bl ower resi stor bl ock, to the
bl ower motor.
I n the MEDI UM 1 posi ti on, ci rcui t C5 passes
through two resi stors i n the bl ower resi stor bl ock, to
the bl ower motor.
I n the MEDI UM 2 posi ti on, ci rcui t C6 passes
through one resi stor i n the bl ower resi stor bl ock, to
the bl ower motor.
When the bl ower motor swi tch i s i n the HI GH
posi ti on i t connects ci rcui t C7 di rectl y to the bl ower
motor.
Ci rcui t Z8 provi des ground for the bl ower motor
swi tch. Ci rcui t Z8 al so suppl i es ground for the coi l
si de of the bl ower motor rel ay.
A/C OPERATION
When the A/C-heater control swi tch i s moved to an
A/C posi ti on or the defrost posi ti on, i t connects ci r-
cui t C90 to ground on ci rcui t Z8. Ci rcui t C90 con-
nects to cavi ty C23 of the Powertrai n Control Modul e
(PCM). When ci rcui t C90 connects to ground ci rcui t
Z8, i t provi des the A/C sel ect si gnal to the PCM.
When the A/C hi gh pressure and l ow pressure
swi tches are cl osed, ci rcui t C90 connects to ci rcui t
C21, and ci rcui t C21 connects to ci rcui t C22. Ci rcui t
C22 connects to cavi ty C22 of the PCM. The PCM
senses the A/C request si gnal on ci rcui t C22 when
the A/C-heater control swi tch i s i n defrost or an A/C
posi ti on.
After sensi ng the A/C request si gnal , the PCM sup-
pl i es ground for the coi l si de of A/C compressor cl utch
rel ay on ci rcui t C13. Ci rcui t C13 ori gi nates at cavi ty
C1 of the PCM. Ci rcui t F12 from fuse 11 i n the fuse
bl ock powers the coi l si de of the A/C compressor
cl utch rel ay.
When the PCM grounds the A/C compressor cl utch
rel ay, the contacts cl ose and connect ci rcui t A17 from
fuse 9 i n the PDC to ci rcui t C3. Ci rcui t C3 suppl i es
power to the case grounded A/C compressor cl utch.
The A/C compressor cl utch has a bui l t-i n di ode.
The di ode control s the i nduced vol tage that resul ts
from the magneti c fi el d col l apsi ng when the cl utch
di sengages. The di ode provi des a current path to pro-
tect other components and systems.
A/C OPERATION
When the A/C-heater control swi tch i s moved to an
A/C posi ti on or the defrost posi ti on, i t connects ci r-
cui t C90 to ground on ci rcui t Z8. Ci rcui t C90 con-
nects to cavi ty C28 of the Powertrai n Control Modul e
(PCM). When ci rcui t C90 connects to ground ci rcui t
Z8, i t provi des the A/C i nput si gnal to the PCM.
Ci rcui t F142 from the di esel power rel ay powers
the coi l si de of the A/C compresser rel ay. Ci rcui t C13
provi des ground for the coi l si de of the A/C com-
XJ 8W - 42 AIR CONDITIONING/HEATER 8W - 42 - 9
presser rel ay. When the A/C hi gh pressure and l ow
pressure swi tches are cl osed, they connect ci rcui t C13
to to ci rcui t C22 whi ch connects to cavi ty 28 of the
MSA Control l er and provi des A/C compresser rel ay
ground.
When the MSA Control l er grounds the A/C com-
pressor cl utch rel ay, the contacts cl ose and connect
ci rcui t A17 from fuse 20 i n the PDC to ci rcui t C3.
Ci rcui t C3 suppl i es power to the A/C compressor
cl utch. Ci rcui t Z0 provi des ground for the compresser
cl utch.
The A/C compressor cl utch has a bui l t-i n di ode.
The di ode control s the i nduced vol tage that resul ts
from the magneti c fi el d col l apsi ng when the cl utch
di sengages. The di ode provi des a current path to pro-
tect other components and systems.
8W - 42 - 10 8W - 42 AIR CONDITIONING/HEATER XJ
8W-43 AIRBAG SYSTEM
INDEX
page
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . . . .8W-43-2, 3
Data Li nk Connector . . . . . . . . . . . . . . . . .8W-43-2, 3
Di agnosti c Spl i ce Bl ock . . . . . . . . . . . . . . .8W-43-2, 3
Dri ver Ai rbag . . . . . . . . . . . . . . . . . . . . . .8W-43-2, 3
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-43-2, 3
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-43-2, 3
Component Page
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-43-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-43-2, 3
Passenger Ai rbag. . . . . . . . . . . . . . . . . . . .8W-43-2, 3
XJ 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
C4
S21
BLOCK
JUNCTION
S23
C4
10A
FUSE
26
10A
FUSE
27
20
1
MODULE
CONTROL
AIRBAG
FUSED
IGN.
(RUN)
17
(ST-RUN)
IGN.
FUSED
F14
18
LG/YL
F23
18
DB/YL
DRIVER
AIRBAG
SQUIB
1
AIRBAG
SQUIB
DRIVER
2
2
DRIVER
SQUIB
AIRBAG
SQUIB
AIRBAG
DRIVER
DRIVER
AIRBAG
TWISTED
PAIR PAIR
TWISTED
AIRBAG
PASSENGER
AIRBAG
SQUIB
PASSENGER
6
4
PASSENGER
SQUIB
AIRBAG
3
5
PASSENGER
AIRBAG
SQUIB SQUIB
AIRBAG
PASSENGER PRESSURE
SENSE
(-)
12
1
SENSE
(-)
PRESSURE
(+)
SENSE
PRESSURE
11
2
PRESSURE
(-)
SENSE
TWISTED
PAIR
10
GROUND
18 19
PAIR
TWISTED
52 51
C201
6
3
2
5
11 3
DATA
LINK
CONNECTOR
DIAGNOSTIC
SPLICE
BLOCK
G200
RUN A22 ST-RUN A21
R45
18
DG/LB
R43
18
BK/LB
Z6
18
BK/PK
R42
18
BK/YL
R44
18
DG/YL
R51
18
VT/YL
R50
18
BR/YL
D2
18
WT/BK
D1
18
VT/BR
PAIR
TWISTED TWISTED
PAIR PAIR
TWISTED
VT/BR
20
D1
WT/BK
20
D2
D2
18
WT/BK
D1
18
VT/BR
TWISTED
PAIR
48 47
BR/YL
20
R50
WT/YL
20
R51
2
C205
1 3 4
C205
DG/YL
18
R44
BK/YL
18
R42
BK/LB
18
R43
DG/LB
18
R45
PAIR
TWISTED
(8W-12-2)
(8W-12-23) (8W-12-23)
(8W-30-16)
(8W-30-30)
(8W-30-16)
(8W-30-30)
(8W-15-11)
(8W-10-10) (8W-10-9)
8W - 43 - 2 8W-43 AIRBAG SYSTEM
LHD
XJ
J978W-7 XJI04301
C4
S21
BLOCK
JUNCTION
S23
C4
10A
FUSE
26
10A
FUSE
27
20
1
MODULE
CONTROL
AIRBAG
FUSED
IGN.
(RUN)
17
(ST-RUN)
IGN.
FUSED
F14
18
LG/YL
F23
18
DB/YL
DRIVER
AIRBAG
SQUIB
1
AIRBAG
SQUIB
DRIVER
2
2
DRIVER
SQUIB
AIRBAG
SQUIB
AIRBAG
DRIVER
DRIVER
AIRBAG
TWISTED
PAIR PAIR
TWISTED
AIRBAG
PASSENGER
AIRBAG
SQUIB
PASSENGER
6
4
PASSENGER
SQUIB
AIRBAG
3
5
PASSENGER
AIRBAG
SQUIB SQUIB
AIRBAG
PASSENGER PRESSURE
SENSE
(-)
12
1
SENSE
(-)
PRESSURE
(+)
SENSE
PRESSURE
11
2
PRESSURE
(-)
SENSE
TWISTED
PAIR
10
GROUND
18 19
PAIR
TWISTED
2 1
C204
6
3
2
5
11 3
DATA
LINK
CONNECTOR
DIAGNOSTIC
SPLICE
BLOCK
G300
RUN A22 ST-RUN A21
R45
18
DG/LB
R43
18
BK/LB
Z6
18
BK/PK
R42
18
BK/YL
R44
18
DG/YL
R51
18
VT/YL
R50
18
BR/YL
D2
18
WT/BK
D1
18
VT/BR
PAIR
TWISTED TWISTED
PAIR PAIR
TWISTED
VT/BR
20
D1
WT/BK
20
D2
D2
18
WT/BK
D1
18
VT/BR
TWISTED
PAIR
14 13
BR/YL
20
R50
WT/YL
20
R51
2
C205
1 3 4
DG/YL
18
R44
BK/YL
18
R42
BK/LB
18
R43
DG/LB
18
R45
PAIR
TWISTED
C203
(8W-12-2)
(8W-12-24) (8W-12-24)
(8W-30-17)
(8W-30-31)
(8W-30-17)
(8W-30-31)
(8W-15-12)
(8W-10-10) (8W-10-9)
XJ 8W-43 AIRBAG SYSTEM
RHD
8W - 43 - 3
XJI04302 J978W-7
8W-43 AIRBAG SYSTEM
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 4
AIRBAG IMPACT SENSOR . . . . . . . . . . . . . . . . . . 4
AIRBAG SQUIB (AIRBAG IGNITER) . . . . . . . . . . . 4
INTRODUCTION
Thi s vehi cl e has a dri vers ai rbag and a passengers
ai rbag. The Ai rbag Control Modul e (ACM) operates
both. The ai rbag system has one i mpact sensor
l ocated i nsi de the Ai rbag Control Modul e (ACM). The
ACM i s secured to a bracket under the l eft si de front
seat i nsi de the vehi cl e.
The ACM has two i gni ti on swi tch feeds. I n the
START or RUN posi ti on, the i gni ti on swi tch connects
ter (PDC) to ci rcui t A21. Ci rcui t A21 powers ci rcui t
F23 through fuse 27 i n the juncti on bl ock. Ci rcui t
F23 connects to the ACM.
When the i gni ti on swi tch i s i n the RUN posi ti on, i t
connects ci rcui t A2 to ci rcui t A22. Ci rcui t A22 powers
ci rcui t F14 through fuse 26 i n the juncti on bl ock. Ci r-
cui t F14 connects to the ACM. Ci rcui t Z6 provi des
ground for the ACM.
AIRBAG IMPACT SENSOR
The Ai rbag system uses a sensor i nternal to the
Ai rbag Control Modul e (ACM) to detect i mpact. For
i nformati on regardi ng operati on of thi s sensor, refer
to the appropri ate group of the Servi ce Manual .
AIRBAG SQUIB (AIRBAG IGNITER)
Ci rcui ts, R43 and R45, connect the ACM to the
dri vers ai rbag squi b (i gni ter) after passi ng through
the cl ock spri ng connector. Ci rcui t R43 from cavi ty 2
of the ACM 4-way connector connects to the squi b.
Ci rcui t R45 from cavi ty 1 of the ACM 4-way connec-
tor connects to the squi b.
Ci rcui ts, R42 and R44, connect the ACM to the
passenger ai rbag squi b (i gni ter). Ci rcui t R42 from
cavi ty 5 of the ACM 4-way connector connects to the
squi b. Ci rcui t R44 from cavi ty 6 of the ACM 4-way
connector connects to the squi b.
8W - 43 - 4 8W - 43 AIRBAG SYSTEM XJ
8W-44 INTERIOR LIGHTING
INDEX
page
Component Page
4wWD Swi tch I l l umi nati on . . . . . . . . . . . .8W-44-2, 3
A/C Heater Control . . . . . . . . . . . . . . . . . .8W-44-2, 3
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . . . .8W-44-6
Dome Lamp/Swi tch . . . . . . . . . . . . . . . . . . . .8W-44-5
Front Fog Lamp Swi tch. . . . . . . . . . . . . . .8W-44-2, 3
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3
Fuse 16 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 5
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 6
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
Gl ove Box Lamp Swi tch . . . . . . . . . . . . . . . .8W-44-5
Headl amp Del ay Modul e . . . . . . . . . . . . . . . .8W-44-5
Headl amp Swi tch . . . . . . . . . . . . . . . . .8W-44-2, 3, 5
I nteri or Li ghts On Swi tch . . . . . . . . . . . . . . .8W-44-5
Juncti on Bl ock . . . . . . . . . . . . . . . . . .8W-44-2, 3, 4, 5
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . .8W-44-5
Left Front Door Jamb Swi tch . . . . . . . . . . . .8W-44-6
Left Rear Door Jamb Swi tch . . . . . . . . . . . . .8W-44-6
Left Vani ty Lamp . . . . . . . . . . . . . . . . . . . . .8W-44-4
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . .8W-44-2, 3
Radi o. . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . .8W-44-2, 3
Component Page
Rear Wi ndow Defogger Swi tch . . . . . . . . .8W-44-2, 3
Rear Wi per/Washer Swi tch . . . . . . . . . . . .8W-44-2, 3
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . .8W-44-5
Ri ght Front Door Jamb Swi tch . . . . . . . . . . .8W-44-6
Ri ght Rear Door Jamb Swi tch . . . . . . . . . . . .8W-44-6
Ri ght Vani ty Lamp . . . . . . . . . . . . . . . . . . . .8W-44-4
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 5
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3, 6
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2, 3
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-2
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6
S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5
S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4, 5
Underhood Lamp. . . . . . . . . . . . . . . . . . . . . .8W-44-4
XJ 8W - 44 INTERIOR LIGHTING 8W - 44 - 1
43 C201
JUNCTION
BLOCK
6
FUSE
5A
S2
C4
E2
20
OR
S1 C4
42 C201
E1
20
TN
HEADLAMP
SWITCH
1
S315
1 C206
1 1
4WD
SWITCH ILLUMINATION
PRNDL
(A/T)
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
S215
E2
20
OR
RADIO
C2 5
LAMP
1
FRONT
FOG
SWITCH
SWITCH
WINDOW
REAR
4
DEFOGGER
3 C1
INSTRUMENT
CLUSTER
HEATER
A/C
1
CONTROL
3
C1
2 2
2 C206
Z1
20
BK
S313
S309
G302
Z1
20
BK
7
1 4
SWITCH
WASHER
WIPER/
REAR
G107
Z1
18
BK
Z1
14
BK
Z1
BK
18
1
Z1
18
BK
S208
BK/VT
12
Z8
G108
REAR
FOG
LAMP
SWITCH
1
4
BK
18
Z15
OR
20
E2
ILLUMINATION
(8W-12-2)
(8W-50-2)
(8W-47-2)
(8W-50-7)
(8W-50-8)
(8W-48-2)
(8W-40-17)
(8W-42-2)
(8W-42-5)
(8W-15-12)
(8W-15-11)
(8W-15-11)
(8W-53-3)
(8W-15-8)
(8W-15-8)
(8W-15-10)
(8W-51-6)
8W - 44 - 2 8W-44 INTERIOR LIGHTS
LHD
XJ
J978W-7 XJI04401
JUNCTION
BLOCK
6
FUSE
5A
S2
C4
S1 C4
E1
20
TN
HEADLAMP
SWITCH
1
1 C206
1 1
4WD
SWITCH ILLUMINATION
PRNDL
(A/T)
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
S215
E2
20
OR
RADIO
C2 5
LAMP
1
FRONT
FOG
SWITCH
SWITCH
WINDOW
REAR
4
DEFOGGER
3 C1
INSTRUMENT
CLUSTER
HEATER
A/C
1
CONTROL
3
C1
2 2
2 C206
Z1
20
BK
S313
S309
G302
Z1
20
BK
7
1 4
SWITCH
WASHER
WIPER/
REAR
G107
Z1
18
BK
Z1
14
BK
Z1
BK
18
1
Z1
18
BK
S208
BK/VT
12
Z8
G108
11 C203
BK
18
Z15
REAR
FOG
LAMP
SWITCH
1
4
OR
20
E2
ILLUMINATION
(8W-12-2)
(8W-50-3)
(8W-47-2)
(8W-50-7)
(8W-50-8)
(8W-48-3)
(8W-40-17)
(8W-42-3)
(8W-42-4)
(8W-42-6)
(8W-15-12)
(8W-15-12)
(8W-15-12)
(8W-53-3)
(8W-15-8)
(8W-15-8)
(8W-15-10)
(8W-51-6)
XJ 8W-44 INTERIOR LIGHTS
RHD
8W - 44 - 3
XJI04402 J978W-7
4
C7
12 C1
PK
20
M1
S300
5 C314
M1
20
PK PK
18
M1
C314 5
LHD RHD
A
(8W-44-6)
TO
SWITCH
LAMP/
CARGO
GAS DIESEL
PK
20
M1 M1
20
PK
15A
FUSE
16
A24
A23
POWER
DISTRIBUTION
CENTER
BATT A0
2
JUNCTION
BLOCK
UNDERHOOD
LAMP
1
G106
Z1
20
BK
S132
Z1
14
BK
M1
20
PK
S135
GAS DIESEL
1
LEFT
VANITY
LAMP
PK
20
M1
S347
M1
20
PK
LAMP
VANITY
RIGHT
1
C3
3
PK
20
M1
M1
20
PK
M1
20
PK
BK
12
Z1
S132
G106
DIESEL GAS
S157
Z1
20
BK
Z1
12
BK
(8W-12-32)
(8W-10-14)
(8W-10-33)
(8W-10-7)
(8W-10-26)
(8W-10-6)
(8W-12-2)
(8W-15-4)
(8W-15-5)
(8W-10-14)
(8W-10-15)
(8W-10-33)
(8W-15-6)
(8W-15-4)
(8W-15-6)
(8W-12-32)
8W - 44 - 4 8W-44 INTERIOR LIGHTS XJ
J978W-7 XJI04403
S208
G107
S314
14 C201
LHD RHD
S5
C4
C3 2
BK
20
Z1
YL
20
M2
M1
20
PK
S347
S342 S345
IMMOBILIZER OTHERS
1 C3
B C
SWITCH
LAMP/
DOME
A
C3
3
PK
20
M1
MODULE
FROM
HEADLAMP
DELAY
1
GLOVE
BOX
LAMP
PK
20
M1
SWITCH
2
G107
Z1
18
BK
M2
20
YL
C2
1
C1 3
SWITCH
HEADLAMP
INTERIOR
LIGHTS
ON
SWITCH
BK
14
Z1
G108
Z1
18
BK
S207
Z1
18
BK
BATT M1
S214
COURTESY
RIGHT
LAMP
1
2
B C207
A C207
M1
18
PK
M2
20
YL
S201
RHD LHD
C201 46
YL
20
M2
C7
7
YL
20
M2
C4 S25
BLOCK
JUNCTION
PK
18
M1
C201
M1
20
PK
6
S18
C4
RHD LHD
JUNCTION
BLOCK
C208 A
C208 B
2
1
LAMP
LEFT
COURTESY
B
(8W-44-6)
TO
S304
BK
14
Z1
BK
14
Z1
G107
S208
BK
18
Z1
RHD LHD
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-10-15)
(8W-10-33)
(8W-15-7) (8W-12-26)
(8W-50-2)
(8W-50-3)
(8W-15-8)
(8W-50-2)
(8W-50-3)
(8W-15-10)
(8W-15-10)
(8W-10-14)
(8W-10-14)
(8W-10-33)
(8W-12-2)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-12-32)
(8W-12-33)
XJ 8W-44 INTERIOR LIGHTS 8W - 44 - 5
XJI04404 J978W-7
G303
LHD RHD RHD LHD
G302
BK
20
Z1 Z1
12
BK
Z1
20
BK
G304
S334
9 C310
6
S333
C311
BK
18
Z1
Z1
16
BK
RIGHT
FRONT
DOOR
JAMB
SWITCH
1
3 3
1
SWITCH
JAMB
DOOR
FRONT
LEFT
1 C317
M2
18
YL
2
3
SWITCH
JAMB
DOOR
REAR
LEFT
3 C317
BK
18
Z1
Z1
20
BK
G303
BK
12
Z1
S309
BK
20
Z1
Z1
18
BK
C320 B
YL
18
M2
C320 A
M2
20
YL YL
20
M2 M2
20
YL YL
20
M2
A C319
M2
18
YL
B C319
BK
18
Z1
Z1
20
BK
S310
Z1
16
BK
BK
20
Z1
Z1
18
BK
C318 3
RIGHT
REAR
DOOR
JAMB
SWITCH
3
2
YL
18
M2
C318 1
C
B
LAMP/
CARGO
GY/BK
20
M4
7 C314
C311
C310
5
10
1
3
LIFTGATE
SWITCH
S304
SWITCH
G302
A
YL
18
M2
C314 6
M2
20
YL
B
(8W-44-5)
FROM
BLOCK
JUNCTION JUNCTION
BLOCK
FROM
A
(8W-44-4)
(8W-15-14) (8W-15-12)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-39-6)
(8W-39-7)
(8W-15-13)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-11)
(8W-39-6)
(8W-39-7)
8W - 44 - 6 8W-44 INTERIOR LIGHTS XJ
J978W-7 XJI04405
8W-44 INTERIOR LIGHTING
INDEX
page page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTRUMENT PANEL ILLUMINATION LAMPS . . . 7
GLOVE BOX LAMP . . . . . . . . . . . . . . . . . . . . . . . 7
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . . . 7
CARGO LAMP, COURTESY LAMPS AND DOME
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VISOR VANITY MIRROR LAMPS . . . . . . . . . . . . . 7
READING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION
Ci rcui t M1 from the I gni ti on Off Draw (I OD)fuse
i n cavi ty 16 of the Power Di stri buti on Center (PDC)
suppl i es power to the gl ove box l amp, l eft courtesy
l amp, ri ght courtesy l amp, dome l amp, cargo l amp,
and vi sor vani ty mi rror l amps. The M1 ci rcui t al so
feeds the radi o and i nstrument cl uster mi croproces-
sor.
Ci rcui t E2 suppl i es power for the i nstrument panel
i l l umi nati on l amps.
INSTRUMENT PANEL ILLUMINATION LAMPS
When parki ng l amps or headl amps are ON, the
headl amp swi tch connects ci rcui t F34 from fuse 17 i n
the Power Di stri buti on Center (PDC) to ci rcui t E1
through the di mmer swi tch ci rcui try. Ci rcui t E1 feeds
ci rcui t E2 through fuse 6 i n the juncti on bl ock. Ci r-
cui t E2 powers to the fol l owi ng i l l umi nati on l amps:
I nstrument cl uster
A/C-Heater control l amp
Fog l amp swi tch l amp
Rear wi per swi tch l amp
Rear wi ndow defogger swi tch l amp
Transmi ssi on range (PRNDL) i ndi cator l amp
Radi o
Ci rcui t Z1 provi des ground for al l of the i l l umi na-
ti on l amps except the i nstrument cl uster, radi o, and
A/C-Heater control . Ci rcui t Z2 provi des ground for
the i nstrument cl uster i l l umi nati on l amps. Ci rcui t Z5
provi des ground for the radi o, and ci rcui t Z8 provi des
ground for the A/C-Heater control l amp.
GLOVE BOX LAMP
Ci rcui t M1 from the I gni ti on Off Draw (I OD) fuse
powers the gl ove box l amp. A case grounded swi tch,
i n seri es after the l amp, CLOSES when the gl ove box
door i s opened. The swi tch compl etes a path to
ground on ci rcui t Z1.
UNDERHOOD LAMP
suppl i es battery vol tage for the underhood l amp. A
mercury swi tch, i n seri es after the l amp, connects
the l amp to ground on ci rcui t Z1. When the hood i s
rai sed, mercury i nsi de the swi tch moves to a posi ti on
where i t connects ci rcui t M1 to ground ci rcui t Z1,
i l l umi nati ng the l amp.
CARGO LAMP, COURTESY LAMPS AND DOME
LAMP
suppl i es power to the cargo l amp, courtesy l amps and
dome l amp. Thi s ci rcui t i s HOT at al l ti mes. The
ground path for the l amp i s provi ded i n three di ffer-
ent ways.
One way i s through the door jamb swi tches. Ci rcui t
M2 connects to the door jamb swi tches from the cour-
tesy and dome l amps. The swi tches are connected to
ground ci rcui t Z1. When a door i s opened, the
pl unger i n the swi tch CLOSES, compl eti ng a path to
ground.
The second way i s through the l i ftgate swi tch. Ci r-
cui t M2 connects to ci rcui t M4 through the l i ftgate
swi tch. The l i ftgate swi tch connects to ground ci rcui t
Z1. When the l i ft gate opens, the pl unger i n the
swi tch CLOSES, compl eti ng a path to ground.
The thi rd ground path i s through the headl amp
swi tch. Ci rcui t M2 i s spl i ced i n wi th the headl amp
swi tch. When the operator turns the headl amp
swi tch to the dome l amp ON posi ti on, a ground path
i s provi ded through the swi tch.
VISOR VANITY MIRROR LAMPS
suppl i es power to the vani ty l amps. Ci rcui t M1 i s
HOT at al l ti mes. When the vani ty l amps swi tch
cl oses, vol tage fl ows to vani ty mi rror l amps. Ci rcui t
Z1 suppl i es ground for the vani ty mi rror l amps.
XJ 8W - 44 INTERIOR LIGHTING 8W - 44 - 7
READING LAMPS
suppl i es power to the readi ng l amps. Ci rcui t M1 i s
HOT at al l ti mes. When the operator depresses the
readi ng l amp, the readi ng l amp swi tch cl oses and
suppl i es ground on ci rcui t Z1.
8W - 44 - 8 8W - 44 INTERIOR LIGHTING XJ
8W-47 AUDIO SYSTEM
INDEX
page
Component Page
Dri vers Door Speaker . . . . . . . . . . . . . . . .8W-47-3, 4
Dri vers Door Tweeter . . . . . . . . . . . . . . . .8W-47-3, 4
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
Fuse 16 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
Fuse 25 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-47-3, 4
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 4
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . .8W-47-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
Left Rear Speaker . . . . . . . . . . . . . . . . . . .8W-47-3, 4
Passengers Door Speaker . . . . . . . . . . . . .8W-47-3, 4
Passengers Door Tweeter . . . . . . . . . . . . .8W-47-3, 4
Power Ampl i fi er . . . . . . . . . . . . . . . . . . .8W-47-2, 3, 4
Power Di stri buti on Center . . . . . . . . . . .8W-47-2, 3, 4
Component Page
Radi o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
Ri ght Rear Speaker . . . . . . . . . . . . . . . . . .8W-47-3, 4
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
S215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 4
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2
S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 4
S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 4
S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-4
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-4
S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3
S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3
XJ 8W - 47 AUDIO SYSTEM 8W - 47 - 1
7 C1
RADIO
POWER
AMPLIFIER
LEFT
SOUNDBAR
SPEAKER
(+)
B(+)
SPEAKER
REAR
LEFT
ILLUMINATION
RADIO
MASTER
C1
2
C2 4
6
C200
11
3
C2
C1 2
7
6
C1
C1 8
(-)
SPEAKER
SOUNDBAR
LEFT
LEFT
REAR
SPEAKER
B(-)
1
4
C1
C1 5
DOOR
FRONT
LEFT
DRIVERS
DOOR
SPEAKER
B(+)
2
2
C2
C1 1 3 C1
C1
7
10
9 C1
C1
3
9
RIGHT
SOUNDBAR
SPEAKER
(-)
RIGHT
SOUNDBAR
SPEAKER
(+)
B(+)
SPEAKER
REAR
RIGHT
4
5
C1
C1 6
S206
2
1
0
9
SWITCH
HEADLAMP
C1
BATT F34
L7
18
BK/YL
X51
16
BR/YL
X57
16
BR/LB
X57
16
BR/LB BR/YL
16
X51
B(-)
SPEAKER
DOOR
DRIVERS
SPEAKER
(+) (-)
SPEAKER
LEFT
FRONT
DOOR
X53
16
DG
X55
16
BR/RD
X55
16
BR/RD DG
16
X53
RIGHT
REAR
SPEAKER
B(-)
DOOR
FRONT
RIGHT
SPEAKER
(-) (+)
SPEAKER
RIGHT
FRONT
DOOR
DOOR
SPEAKER
B(-) B(+)
SPEAKER
DOOR
PASSENGERS
X52
16
DB/WT
X58
16
DB/OR
X54
16
VT
X56
16
DB/RD
DB/RD
16
X56
VT
16
X54
DB/OR
16
X58
DB/WT
16
X52
FEED
POWER
RADIO
C3
1
GROUND
Z9
14
BK
G108
DG/RD
16
X60
C1
1
5
4 C1
X60
16
DG/RD
POWER
AMP
FEED
RELAY
FEED
RELAY
AMP
POWER
4 5
1 PARK
2 HEAD
3 DIM
4 BRIGHT
0 OFF
1 C1
42 C201
C4
S2
C4 S1
BLOCK
JUNCTION
5A
FUSE
6
RADIO
ILLUMINATION
C2 5
43
S215
E2
20
OR
E1
20
TN
L7
18
BK/YL
17
FUSE
15A
S9
C4
6 C2
RD/WT
16
X12
54
POWER
DISTRIBUTION
CENTER
16
FUSE
15A
A23
A24
BATT A0
PK
20
M1
S214
C201
6
7 C2
B(+)
FUSED
S135
C1 12
S18
C4
M1
20
PK
PASSENGERS
RUN-ACC A31
S315
(8W-70-6)
(8W-10-16)
(8W-15-10)
(8W-50-2)
(8W-12-2)
(8W-12-8)
(8W-12-8)
(8W-12-17)
(8W-10-8)
(8W-10-7)
(8W-10-26)
(8W-12-6)
(8W-10-6)
(8W-10-14)
(8W-10-14)
(8W-12-8)
(8W-12-32)
8W - 47 - 2 8W-47 AUDIO SYSTEM XJ
J978W-7 XJI04701
7 C1
RADIO
POWER
AMPLIFIER
LEFT
SOUNDBAR
SPEAKER
(+)
B(+)
SPEAKER
REAR
LEFT
ILLUMINATION
RADIO
MASTER
C1
2
C2 4
1
C203
9
3
C2
C1 2
7
6
C1
C1 8
(-)
SPEAKER
SOUNDBAR
LEFT
LEFT
REAR
SPEAKER
B(-)
3
4
C1
C1 5
DOOR
FRONT
LEFT
DRIVERS
DOOR
SPEAKER
B(+)
5
2
C2
C1 1 3 C1
C1
7
8
9 C1
C1
3
2
RIGHT
SOUNDBAR
SPEAKER
(-)
RIGHT
SOUNDBAR
SPEAKER
(+)
B(+)
SPEAKER
REAR
RIGHT
4
5
C1
C1 6
S206
2
1
0
9
SWITCH
HEADLAMP
C1
BATT F34
L7
18
BK/YL
X51
16
BR/YL
X57
16
BR/LB
X57
16
BR/LB BR/YL
16
X51
B(-)
SPEAKER
DOOR
DRIVERS
SPEAKER
(+) (-)
SPEAKER
LEFT
FRONT
DOOR
X53
16
DG
X55
16
BR/RD
X55
16
BR/RD DG
16
X53
RIGHT
REAR
SPEAKER
B(-)
DOOR
FRONT
RIGHT
SPEAKER
(-) (+)
SPEAKER
RIGHT
FRONT
DOOR
DOOR
SPEAKER
B(-) B(+)
SPEAKER
DOOR
PASSENGERS
X52
16
DB/WT
X58
16
DB/OR
X54
16
VT
X56
16
DB/RD
DB/RD
16
X56
VT
16
X54
DB/OR
16
X58
DB/WT
16
X52
FEED
POWER
RADIO
C3
1
GROUND
Z9
14
BK
G108
DG/RD
16
X60
C1
1
6
4 C1
X60
16
DG/RD
POWER
AMP
FEED
RELAY
FEED
RELAY
AMP
POWER
4 5
1 PARK
2 HEAD
3 DIM
4 BRIGHT
0 OFF
1 C1
C4
S2
C4 S1
BLOCK
JUNCTION
5A
FUSE
6
RADIO
ILLUMINATION
C2 5
S215
E2
20
OR
E1
20
TN
L7
18
BK/YL
17
FUSE
15A
S9
C4
6 C2
RD/WT
16
X12
POWER
DISTRIBUTION
CENTER
16
FUSE
15A
A23
A24
BATT A0
PK
20
M1
S214
7 C2
B(+)
FUSED
S135
C1 12
S18
C4
M1
20
PK
PASSENGERS
RUN-ACC A31
(8W-70-6)
(8W-10-16)
(8W-15-10)
(8W-50-3)
(8W-12-2)
(8W-12-9)
(8W-12-9)
(8W-12-18)
(8W-10-8)
(8W-10-7)
(8W-10-26)
(8W-12-6)
(8W-10-6)
(8W-10-14)
(8W-10-14)
(8W-12-32)
XJ 8W-47 AUDIO SYSTEM
RHD
8W - 47 - 3
XJI04702 J978W-7
6
C2
POWER
AMPLIFIER
LEFT
SOUNDBAR
SPEAKER
B(+)
A
B
C2 5
SPEAKER
SOUNDBAR
RIGHT
B(+)
C2
14
B(-)
SPEAKER
SOUNDBAR
LEFT
3
C314
4
X93
16
WT/TN
X93
16
WT/TN
X91
16
WT/BK
X91
16
WT/BK
LG/RD
16
X85
DG
16
X87
C305
12
C2
2
1
C2
4
SPEAKER
REAR
LEFT
B(+)
SPEAKER
DOOR
DRIVERS
DOOR
SPEAKER
B(-)
X87
16
DG
X85
16
BR/RD
SPEAKER
DOOR
DRIVERS
1
2
1
2
PASSENGERS
DOOR
SPEAKER
2
1
RIGHT
REAR
SPEAKER
A
B
X85
16
LG/RD
X87
16
LG/BK
13 C2
1
C314
2
X94
16
TN/RD
X94
16
TN/RD
X92
16
TN/BK
X92
16
TN/BK
C303
LB/BK
16
X80
C2 10
DOOR
SPEAKER
B(-)
LB/RD
16
X82
11 C2
B(+)
SPEAKER
PASSENGERS
DOOR
B(-)
RIGHT
SOUNDBAR
SPEAKER
X82
16
LB/RD
X80
16
LB/BK
POWER
AMP
FEED
C2 1
FEED
AMP
POWER
2 C2
14 C200
S301
C4 C100
POWER
DISTRIBUTION
CENTER
20A
FUSE
25
BATT A0
A3
A4
F75
16
VT
F75
16
VT
F75
16
VT
5 4
2 1
AMP
POWER
GROUND
C2
8
Z5
16
BK
G301
7
C2
BK
16
Z5
GROUND
POWER
AMP
S330
S331
X85
16
BK/RD
X87
16
DG/BK
S320
S321
X80
16
LB/BR
X80
16
LB/BR
DRIVERS
DOOR
TWEETER
TWEETER
DOOR
PASSENGERS
PASSENGERS
DRIVERS
(8W-10-7)
(8W-10-26)
(8W-10-20)
(8W-10-36)
(8W-10-6)
(8W-15-11)
8W - 47 - 4 8W-47 AUDIO SYSTEM
LHD
XJ
J978W-7 XJI04703
6
C2
POWER
AMPLIFIER
LEFT
SOUNDBAR
SPEAKER
B(+)
A
B
C2 5
SPEAKER
SOUNDBAR
RIGHT
B(+)
C2
14
B(-)
SPEAKER
SOUNDBAR
LEFT
3
C314
4
X93
16
WT/TN
X93
16
WT/TN
X91
16
WT/BK
X91
16
WT/BK
BR/RD
16
X85
DG
16
X87
C305
12
C2
2
1
C2
4
SPEAKER
REAR
LEFT
B(+)
SPEAKER
DOOR
DRIVERS
DOOR
SPEAKER
B(-)
X87
16
DG
X85
16
BR/RD
SPEAKER
DOOR
DRIVERS
1
2
1
2
PASSENGERS
DOOR
SPEAKER
2
1
RIGHT
REAR
SPEAKER
A
B
X85
16
LG/RD
X87
16
LG/BK
13 C2
1
C314
2
X94
16
TN/RD
X94
16
TN/RD
X92
16
TN/BK
X92
16
TN/BK
C303
LB/BK
16
X80
C2 10
DOOR
SPEAKER
B(-)
LB/RD
16
X82
11 C2
B(+)
SPEAKER
PASSENGERS
DOOR
B(-)
RIGHT
SOUNDBAR
SPEAKER
X82
16
LB/RD
X80
16
LB/BK
POWER
AMP
FEED
C2 1
FEED
AMP
POWER
2 C2
3 C204
S301
C4 C100
POWER
DISTRIBUTION
CENTER
20A
FUSE
22
BATT A0
A3
A4
F75
16
VT
F75
16
VT
F75
16
VT
5 4
2 1
AMP
POWER
GROUND
C2
8
Z5
16
BK
G301
7
C2
BK
16
Z5
GROUND
POWER
AMP
S326
S327
X85
16
BK/RD
X87
16
DG/BK
S320
S321
X80
16
LB/BR
X80
16
LB/BR
DRIVERS
DOOR
TWEETER
TWEETER
DOOR
PASSENGERS
PASSENGERS
DRIVERS
(8W-10-7)
(8W-10-26)
(8W-10-20)
(8W-10-36)
(8W-10-6)
(8W-15-12)
XJ 8W-47 AUDIO SYSTEM
RHD
8W - 47 - 5
XJI04704 J978W-7
8W-47 AUDIO SYSTEM
RADIO
When the i gni ti on swi tch i s i n the ACCESSORY or
RUN posi ti on, i t connects ci rcui t A1 from fuse 2 i n
Ci rcui t A31 feeds ci rcui t X12 through fuse 15 i n the
juncti on bl ock. Ci rcui t X12 powers the radi o.
Ci rcui t Z5 provi des ground for the radi o. The
antenna connects to the rear of the radi o.
RADIO MEMORY
suppl i es power for the radi o memory. Ci rcui t M1 i s
HOT at al l ti mes.
The I OD fuse i s removed duri ng vehi cl e shi ppi ng
to prevent excessi ve battery draw.
RADIO ILLUMINATION
When the parki ng l amps or headl amps are ON, ci r-
cui t L7 provi des the i l l umi nati on si gnal to the radi o.
Al so when the headl amps or parki ng l amps are ON,
ci rcui t E2 provi des the i l l umi nati on i ntensi ty si gnal
to the radi o.
SPEAKERS STANDARD SYSTEM
The standard system uses four speakers. Ci rcui t
X53 feeds the speaker i n the l eft front door. Ci rcui t
X55 i s the return from the speaker to the radi o.
Ci rcui t X54 feeds the ri ght front door speaker. Ci r-
cui t X56 i s the return from the speaker to the radi o.
Ci rcui t X51 feeds the l eft rear door speaker. Ci rcui t
X57 i s the return from the speaker to the radi o.
Ci rcui t X52 feeds the ri ght rear door speaker. Ci r-
cui t X58 i s the return from the speaker to the radi o.
AMPLIFIER AND SPEAKERS PREMIUM
A power ampl i fi er i s used on premi um systems
onl y. The ampl i fi er i s connected between the radi o
and the speakers.
Center (PDC) feeds the radi o ampl i fi er. Ci rcui t Z5
provi des ground for the ampl i fi er. Ci rcui t X60 from
the radi o suppl i es power to the ampl i fi er.
From the radi o, ci rcui ts X54 and X56 are the ri ght
front speaker i nputs to the power ampl i fi er; ci rcui ts
X53 and X55 the l eft front i nputs, ci rcui ts X51 and
X57 the l eft rear i nputs, and ci rcui ts X52 and X58
the ri ght rear i nputs.
From the power ampl i fi er, ci rcui ts X80 and X82
feed the ri ght front door and i nstrument panel . Ci r-
cui ts X85 and X87 feed the l eft front door and i nstru-
ment panel . Ci rcui ts X92 and X94 feed the ri ght
sound bar. Ci rcui ts X91 and X93 feed the l eft sound
bar.
8W - 47 - 6 8W - 47 AUDIO SYSTEM XJ
8W-48 REAR WINDOW DEFOGGER
INDEX
page
Component Page
Defogger On I ndi cator . . . . . . . . . . . . . . . .8W-48-2, 3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
I l l umi nati on Lamp . . . . . . . . . . . . . . . . . .8W-48-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
Left Power Mi rror . . . . . . . . . . . . . . . . . . .8W-48-2, 3
Rear Wi ndow Defogger Gri d . . . . . . . . . . .8W-48-2, 3
Component Page
Rear Wi ndow Defogger Rel ay . . . . . . . . . .8W-48-2, 3
Rear Wi ndow Defogger Swi tch . . . . . . . . .8W-48-2, 3
Ri ght Power Mi rror . . . . . . . . . . . . . . . . . .8W-48-2, 3
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-48-2, 3
XJ 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1
BLOCK
JUNCTION
S19
C4
10A
FUSE
12
86 30
87 85
REAR
WINDOW
DEFOGGER
RELAY
RUN A22 BATT A4
14
FUSE
10A
C4
S26 3
C9
6
5
RIGHT
POWER
MIRROR
5
6
1
C6
2 C313
C310 3
1
1
C313
C310 2
1
DEFOGGER
WINDOW
REAR
C15
12
BK/WT
C16
20
BK/WT
3
1
SWITCH
DEFOGGER
WINDOW
REAR
DEFOGGER
ON
INDICATOR
2
Z1
20
BK
2 C201
S202
37 C200
11 C305
LAMP
ILLUMINATION
C2
4
C2 3
CLUSTER
INSTRUMENT
17
C81
20
DB/WT
G302 G107
G304
G107
C2
C1
S208
GRID
MIRROR
POWER
LEFT
1 C315
BASE FULL OPTIONS
C16
20
BK/WT
C16
20
LB/YL
C16
20
LB/YL
HEATED MIRRORS/
REAR WINDOW
DEFOGGER TIMER
HEATED MIRRORS/
REAR WINDOW
DEFOGGER ON
BK
12
Z1
Z1
16
BK
S329
Z1
12
BK
C4
S5
C9 11
BLOCK
JUNCTION
Z1
18
BK
C201
S309
3 C307
S319
Z1
16
BK
C80
20
DB/WT
Z1
14
BK
Z1
14
BK
C201 14
S314
S208
(8W-12-2)
(8W-12-15)
(8W-10-10) (8W-10-13)
(8W-12-15)
(8W-40-15)
(8W-15-11) (8W-15-8)
(8W-15-15)
(8W-15-8)
(8W-15-8)
(8W-15-11)
(8W-12-2)
(8W-15-11)
(8W-15-7)
(8W-15-8)
(8W-15-8)
(8W-12-33)
8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER
LHD
XJ
J978W-7 XJI04801
BLOCK
JUNCTION
S19
C4
10A
FUSE
12
86 30
87 85
REAR
WINDOW
DEFOGGER
RELAY
RUN A22 BATT A4
14
FUSE
10A
C4
S26 3
C9
6
5
LEFT
POWER
MIRROR
5
6
1
C6
2 C313
C310 3
1
1
C313
C310 2
1
DEFOGGER
WINDOW
REAR
C15
12
BK/WT
C16
20
BK/WT
3
1
SWITCH
DEFOGGER
WINDOW
REAR
DEFOGGER
ON
INDICATOR
2
Z1
20
BK
2 C201
S202
37 C200
11 C305
LAMP
ILLUMINATION
C2
4
C2 3
CLUSTER
INSTRUMENT
17
C81
20
DB/WT
G302 G107
G304
G107
C2
C1
S208
GRID
MIRROR
POWER
RIGHT
1 C315
BASE FULL OPTIONS
C16
20
BK/WT
C16
20
LB/YL
C16
20
LB/YL
HEATED MIRRORS/
REAR WINDOW
DEFOGGER TIMER
HEATED MIRRORS/
REAR WINDOW
DEFOGGER ON
BK
12
Z1
Z1
16
BK
S329
Z1
12
BK
C4
S5
C9 11
BLOCK
JUNCTION
Z1
18
BK
C201
S309
3 C307
S319
Z1
16
BK
C80
20
DB/WT
Z1
14
BK
Z1
14
BK
C201 14
S314
S208
(8W-12-2)
(8W-12-16)
(8W-10-10) (8W-10-13)
(8W-12-16)
(8W-40-15)
(8W-15-12) (8W-15-8)
(8W-15-15)
(8W-15-8)
(8W-15-8)
(8W-15-11)
(8W-12-2)
(8W-15-12)
(8W-15-7)
(8W-15-8)
(8W-15-8)
(8W-12-33)
XJ 8W-48 REAR WINDOW DEFOGGER
RHD
8W - 48 - 3
XJI04802 J978W-7
8W-48 REAR WINDOW DEFOGGER
REAR WINDOW DEFOGGER
cui t A22 powers the coi l si de of the rear wi ndow
defogger rel ay through fuse 12 i n the juncti on bl ock..
When the operator presses the rear wi ndow defog-
ger swi tch, the swi tch contacts momentari l y CLOSE.
When cl osed, the swi tch contacts connect ci rcui t C80
from the i nstrument cl uster mi croprocessor to ground
on ci rcui t Z1. After i t senses ground on ci rcui t C80,
the mi croprocessor energi zes the rear wi ndow defog-
ger rel ay by provi di ng ground for the rel ay coi l on
ci rcui t C81.
When the rear wi ndow defogger rel ay energi zes, i t
connects ci rcui t A4 from PDC fuse 10 to ci rcui t C15.
Ci rcui t C15 suppl i es power the rear wi ndow defogger
gri d. Ci rcui t Z1 provi des ground for the rear wi ndow
defogger gri d.
HELPFUL INFORMATION
Check for broken gri d l i nes on the wi ndow.
Check for a broken bus bar or di sconnected
l eads at the rear wi ndow.
Check for a good ground at the rear wi ndow
defogger gri d.
8W - 48 - 4 8W - 48 REAR WINDOW DEFOGGER XJ
8W-49 OVERHEAD CONSOLE
INDEX
page
Component Page
Ambi ent Temperature Sensor (4.0L) . . . . . . .8W-49-2
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2,3
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
Fuse 16 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-49-2,3
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
Component Page
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
S343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2
S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-3
XJ 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1
COMPASS
10A
FUSE
9
WT/BK
20
F87
6
Z2
20
BK/LG
12
G108
GROUND
LOGIC
1
BK
20
Z1
GROUND
S342
BLOCK
JUNCTION
C4
C3
S5
2
5 C301
58 C201
Z2
18
BK/LG BK
14
Z1
14
G107
S314
S208
BK/LG
20
Z2
JUNCTION
BLOCK
ST-RUN A21
S13
C4
6 C301
S216
(ST-RUN)
IGN.
FUSED
LHD RHD
Z1
14
BK
C201
S343
IMMOBILIZER OTHERS
LHD RHD
Z2
18
BK/LG
4
VT/LG
20
G31
1
4
32
RHD LHD
35 C201
G31
20
VT/LG
C301
3
G32
20
BK/LG
10
BK/LG
20
G32
G31
20
VT/LG
2
BK/LG
20
G32
AMBIENT
TEMPERATURE
SENSOR
F14 C100 F15
G32
20
BK/LG VT/LG
20
G31
AMBIENT
TEMPERATURE
SENSOR
SIGNAL
(4.0L)
GROUND
SENSOR
TEMPERATURE
AMBIENT
TO
MODULE
DELAY
HEADLAMP
F87 20 WT/BK
(8W-12-11)
(8W-12-12)
(8W-15-10)
(8W-15-7)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-12-2)
(8W-10-9)
(8W-12-11)
(8W-12-12)
(8W-15-9)
(8W-50-2)
(8W-50-3)
(8W-12-33)
8W - 49 - 2 8W-49 OVERHEAD CONSOLE XJ
J978W-7 XJI04901
COMPASS
15A
FUSE
16
2
S135
(ST-RUN)
IGN.
FUSED
BATT A0
CENTER
DISTRIBUTION
POWER
A23
A24
PK
20
M1
12
3
C1
C3
JUNCTION
BLOCK
M1
20
PK
S347
5 11
(+)
BUS
CCD CCD
BUS
(-)
VT/BR
20
D1 D2
20
WT/BK
IMMOBILIZER OTHERS
S344 S346
WT/BK
20
D2 D1
20
VT/BR
2 C301 1
LHD RHD
55 C201 56
8
2 6
14
DIAGNOSTIC
SPLICE
BLOCK
VT/BR
20
D1 D2
20
WT/BK
3 11
DATA
LINK
CONNECTOR
7
DOOR
AJAR/
ILLUMINATION
SENSE
YL
20
M2
BLOCK
JUNCTION
C3 1
IMMOBILIZER OTHERS
S345
M2
20
YL
M1
20
PK
PK
20
M1
PAIR
TWISTED
PAIR
TWISTED
(8W-10-14)
(8W-10-33)
(8W-10-14)
(8W-12-32)
(8W-10-6)
(8W-10-7)
(8W-10-26)
(8W-12-2)
(8W-10-15)
(8W-10-33)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-30-16)
(8W-30-17)
(8W-30-30)
(8W-30-31)
(8W-12-2)
(8W-12-26)
(8W-12-26)
(8W-12-32)
XJ 8W-49 OVERHEAD CONSOLE 8W - 49 - 3
XJI04902 J978W-7
8W-49 OVERHEAD CONSOLE
INTRODUCTION
cui t A21 suppl i es power to ci rcui t F87 through fuse 9
i n the juncti on bl ock. Ci rcui t F87 suppl i es power to
the overhead consol e.
To al l ow the overhead consol e to communi cate wi th
other modul es and control l ers the CCD Bus i s used.
The ci rcui ts i nvol ved are D1 for CCD (+), and D2 for
CCD (-).
Ci rcui ts Z1 and Z2 provi des ground for the over-
head consol e. Ci rcui t M2 from the door jamb swi tches
al so connects to the overhead consol e.
AMBIENT TEMPERATURE SENSOR
The ambi ent temperature sensor i s a vari abl e
resi stor. Ci rcui t G31 suppl i es vol tage from the over-
head consol e to the sensor. Ci rcui t G32 i s the si gnal
return from the sensor to the overhead consol e.
8W - 49 - 4 8W - 49 OVERHEAD CONSOLE XJ
8W-50 FRONT LIGHTING
INDEX
page
Component Page
Beam Sel ect Swi tch . . . . . . . . . . . . . .8W-50-2, 3, 4, 9
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-2
Control l er Anti -Lock Brake Rel ay . . . . . . . . .8W-50-8
Fog Lamp Rel ay . . . . . . . . . . . . . . . . . .8W-50-5, 7, 8
Front Fog Lamp Swi tch. . . . . . . . . . . . . . .8W-50-7, 8
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3, 4
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3, 4
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . .8W-50-2, 3, 4, 9
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . .8W-50-5, 6, 7, 8
Fuse 7 (PDC). . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3
Fuse 16 (JB) . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3, 4
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-50-5, 6
Fuse 24 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-50-7, 8
G106 . . . . . . . . . . . . . . . . . . . . .8W-50-4, 5, 6, 7, 8, 9
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-9
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3
Headl amp Del ay Modul e . . . . . . . . . . . . . .8W-50-2, 3
Headl amp Level i ng Swi tch . . . . . . . . . . . .8W-50-4, 9
Headl amp Swi tch . . . . . . . . . . . .8W-50-2, 3, 5, 6, 7, 8
I l l umi nati on Lamp . . . . . . . . . . . . . . . . . .8W-50-7, 8
Juncti on Bl ock . . . . . . . . . .8W-50-2, 3, 4, 5, 6, 7, 8, 9
Left Fog Lamp. . . . . . . . . . . . . . . . . . . . . .8W-50-7, 8
Left Front Turn Si gnal Lamp . . . . . . . . . .8W-50-5, 6
Component Page
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . .8W-50-4
Left Headl amp Level i ng Motor . . . . . . . . . . .8W-50-9
Left Posi ti on Lamp . . . . . . . . . . . . . . . . . .8W-50-5, 6
Left Repeater Lamp. . . . . . . . . . . . . . . . . .8W-50-5, 6
Power Di stri buti on Center . . . . . . . . .8W-50-2, 3, 7, 8
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . . .8W-50-3
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . .8W-50-7, 8
Ri ght Front Turn Si gnal Lamp . . . . . . . . .8W-50-5, 6
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . .8W-50-4, 9
Ri ght Headl amp Level i ng Motor . . . . . . . . . .8W-50-9
Ri ght Posi ti on Lamp . . . . . . . . . . . . . . . . .8W-50-5, 6
Ri ght Repeater Lamp . . . . . . . . . . . . . . . .8W-50-5, 6
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-5, 6
S102. . . . . . . . . . . . . . . . . . . . . . . .8W-50-4, 5, 6, 7, 8
S103. . . . . . . . . . . . . . . . . . . . . . . .8W-50-4, 5, 6, 7, 8
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-5, 6
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7, 8
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-4, 9
S206 . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-5, 6, 7, 8
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-5, 6
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-5, 6
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3, 4
S216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-2, 3
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . .8W-50-5, 6
XJ 8W - 50 FRONT LIGHTING 8W - 50 - 1
2
1
0
HEADLAMP
SWITCH
1 PARK
2 HEAD
3 ON
4 DIM
5 BRIGHT
0 OFF
1
2
0
C1
2
C1 8
0 1 2
C1
7
0 3 5
4
6
HEADLAMP
SWITCH
OUTPUT
4
3
2
1
SWITCH
SELECT
BEAM
POWER
DISTRIBUTION
CENTER
BATT A0
30A
FUSE
7
D1 C100
A3
16
RD/WT
A3
16
RD/WT
6
13
2
HEADLAMP
DELAY
MODULE
L2
16
LG
L20
16
LG/WT
L2
16
LG
A3
16
RD/WT
B(+)
FUSED
L3
16
RD/OR
L4
16
VT/WT
S213
22 C201 16
C4 S3
BLOCK
JUNCTION
S7 C4
10A
FUSE
16 4
FUSE
10A
3
FUSE
10A 10A
FUSE
5
FUSED
IGN.
(ST-RUN)
8
5 C201
F87
20
WT/BK
F87
20
WT/BK
S216
C4
S13
BLOCK
JUNCTION
9
FUSE
10A
ST-RUN A21
6 C301
FULL OPTIONS BASE
6
F87
20
WT/BK
1
C2
BK
18
Z1
G108
S207
4
Z1
18
BK
GROUND
Z1
14
BK
C1 5
INSTRUMENT
CLUSTER
HIGH
BEAM
INDIC.
LAMP
C100 D4
G34
16
RD/GY
COMPASS
BATT A0
13
6
7
FUSE
30A
BK/PK
12
A4
DIESEL GAS
(8W-10-6)
(8W-10-25)
(8W-10-6)
(8W-10-12)
(8W-12-2)
(8W-12-6) (8W-12-7) (8W-12-6) (8W-12-7)
(8W-12-11)
(8W-12-2)
(8W-12-11)
(8W-10-9)
(8W-15-10)
(8W-15-10)
(8W-40-16)
(8W-49-2)
(8W-10-25)
(8W-10-31)
8W - 50 - 2 8W-50 FRONT LIGHTING
LHD
XJ
J978W-7 XJI05001
2
1
0
HEADLAMP
SWITCH
1 PARK
2 HEAD
3 ON
4 DIM
5 BRIGHT
0 OFF
1
2
0
C1
2
C1 8
0 1 2
C1
7
0 3 5
4
6
HEADLAMP
SWITCH
OUTPUT
4
3
2
1
SWITCH
SELECT
BEAM
POWER
DISTRIBUTION
CENTER
BATT A0
30A
FUSE
7
D1 C100
A4
12
BK/PK
6
13
2
HEADLAMP
DELAY
MODULE
L2
16
LG
L20
16
LG/WT
L2
16
LG
A3
16
RD/WT
B(+)
FUSED
L3
16
RD/OR
L4
16
VT/WT
S213
C4 S3
BLOCK
JUNCTION
S7 C4
10A
FUSE
16 4
FUSE
10A
3
FUSE
10A 10A
FUSE
5
FUSED
IGN.
(ST-RUN)
8
F87
20
WT/BK
S216
C4
S13
BLOCK
JUNCTION
9
FUSE
10A
ST-RUN A21
F87
20
WT/BK
1
C2
BK
18
Z1
G108
S207
4
Z1
18
BK
GROUND
L3
16
RD/OR
Z1
14
BK
C1 5
INSTRUMENT
CLUSTER
HIGH
BEAM
INDIC.
LAMP
13
6
7
FUSE
30A
RD/WT
16
A3
BATT A0
5
RELAY
LAMP
FOG
REAR
A3
16
RD/WT
DIESEL GAS
(8W-10-6)
(8W-10-25)
(8W-10-25)
(8W-10-31)
(8W-12-2)
(8W-12-6) (8W-12-7) (8W-12-6) (8W-12-7)
(8W-12-12)
(8W-12-2)
(8W-12-12)
(8W-10-9)
(8W-15-10)
(8W-15-10)
(8W-40-16)
(8W-10-12)
(8W-10-6)
(8W-51-6)
XJ 8W-50 FRONT LIGHTING
RHD
8W - 50 - 3
XJI05002 J978W-7
A
C
B
LEFT
HEADLAMP HEADLAMP
RIGHT
B
C
A
11
C106
4
9 2 6
C106
13
L43
20
VT
L33
20
RD
Z1
20
BK
Z1
18
BK
L44
18
VT/RD
L34
18
RD/OR
Z1
18
BK
Z1
18
BK
C1
10
C4 S7
10A
FUSE
4 3
FUSE
10A
9
C1
10A
FUSE
16 5
FUSE
10A
C1
11 1
C1
BLOCK
JUNCTION
S3 C4
16
2 4
BEAM
SELECT
SWITCH
L3
16
RD/OR
L4
16
VT/WT
S102 S103
16
L3
RD/OR VT/WT
16
L4
G106
S213
C201
LHD RHD LHD
C201 22
RHD
GAS DIESEL
L33
18
RD
L33
20
RD RD/OR
18
L34
DIESEL
RD/OR
20
L33
GAS GAS
L44
20
VT/RD
DIESEL
L44
18
VT/RD VT
20
L43
VT
18
L43
DIESEL GAS
C106
LHD RHD
B12 C100
C100 B12
NOT
USED
B
HEADLAMP
LEVELING
SWITCH
S133
(8W-12-7) (8W-12-6) (8W-12-6) (8W-12-7)
(8W-12-2)
(8W-50-2)
(8W-15-4) (8W-15-4)
(8W-15-4)
(8W-50-2)
(8W-50-9)
LHD
XJ
J978W-7 XJI05003
11
C106
4
S100
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
L77
20
BR
L61
18
LG
L61
18
LG
L61
20
LG
L60
18
TN
L60
18
TN
L60
20
TN
C2
6
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
S102
5
C1
23
FUSE
10A
G106
L7
18
BK/YL
45 C201
S206
2
1
0
9
SWITCH
HEADLAMP
C1
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
3
C106
10
B10
C100
B9
L61
20
LG/WT TN
20
L60
1 10
S209 S212
L61
20
LG/WT
L60
20
TN
SWITCH
HAZARD
SIGNAL/
TURN
(PART OF
MULTI-
FUNCTION
SWITCH)
B8
(IN PDC)
RELAY
LAMP
FOG
S105
L77
18
BR/YL
C106 7
BR/YL
20
L77
1
3
1
3
3
1
3
1
LEFT
FRONT
TURN
SIGNAL
LAMP
S103
LAMP
SIGNAL
TURN
FRONT
LEFT
Z1
18
BK
2
1
LAMP
POSITION
LEFT
RIGHT
FRONT
TURN
SIGNAL
LAMP
LAMP
SIGNAL
TURN
FRONT
RIGHT
1
RIGHT
LAMP
2
BK
18
Z1
L77
20
BR/YL
BR/YL
20
L77
FOG
LAMP
RELAY
(IN PDC)
B10
DIESEL GAS
DIESEL GAS
L78
18
DG/YL DG/YL
20
L78
L78
20
DG/YL
14 C106
LHD RHD
POSITION
TN
18
L60
REPEATER
2
LAMP
RIGHT
1
18
Z1
BK
REPEATER
LEFT
1
2
Z1
18
BK
LAMP
LG
18
L61
(8W-12-10)
(8W-12-2)
(8W-15-4)
(8W-12-22)
(8W-15-4)
(8W-70-6)
(8W-50-2)
(8W-50-3)
(8W-10-16)
(8W-70-4) (8W-70-4)
(8W-52-2)
(8W-52-3)
(8W-50-7)
(8W-50-8)
(8W-15-4)
(8W-50-7)
(8W-50-8)
FOG LAMPS
8W - 50 - 5
XJI05005 J978W-7
11
C106
4
S100
Z1
18
BK
Z1
18
BK
Z1
18
BK
Z1
18
BK
L77
20
BR
L61
18
LG
L61
18
LG
L61
20
LG
L60
18
TN
L60
18
TN
L60
20
TN
C2
6
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
S102
5
C1
23
FUSE
10A
G106
L7
18
BK/YL
45 C201
S206
2
1
0
9
SWITCH
HEADLAMP
C1
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
3
C106
10
B10
C100
B9
L61
20
LG/WT TN
20
L60
1 10
S209 S212
L61
20
LG/WT
L60
20
TN
SWITCH
HAZARD
SIGNAL/
TURN
(PART OF
MULTI-
FUNCTION
SWITCH)
S105
L77
18
BR/YL
C106 7
1
3
1
3
3
1
3
1
LEFT
FRONT
TURN
SIGNAL
LAMP
S103
LAMP
SIGNAL
TURN
FRONT
LEFT
Z1
18
BK
2
1
LAMP
POSITION
LEFT
RIGHT
FRONT
TURN
SIGNAL
LAMP
LAMP
SIGNAL
TURN
FRONT
RIGHT
1
RIGHT
LAMP
2
BK
18
Z1
BR/YL
20
L77
DIESEL GAS
L78
18
DG/YL DG/YL
20
L78
L78
20
DG/YL
14 C106
LHD RHD
POSITION
TN
18
L60
REPEATER
2
LAMP
RIGHT
1
18
Z1
BK
REPEATER
LEFT
1
2
Z1
18
BK
LAMP
LG
18
L61
DIESEL GAS
(8W-12-10)
(8W-12-2)
(8W-15-4)
(8W-12-22)
(8W-15-4)
(8W-70-6)
(8W-50-2)
(8W-50-3)
(8W-10-16)
(8W-70-4) (8W-70-4)
(8W-52-2)
(8W-52-3)
(8W-15-4)
8W - 50 - 6 8W-50 FRONT LIGHTING XJ
J978W-7 XJI05006
11
C106
4
Z1
18
BK
Z1
18
BK
S102 S103
G106
1
2
LAMP
FOG
LEFT
2
1
RIGHT
FOG
LAMP
Z1
20
BK
Z1
20
BK
S106
8
C106
A4 C100
3
2
SWITCH
LAMP
FOG
FRONT
L139
20
VT
A5 C100
POWER
DISTRIBUTION
CENTER
RELAY
LAMP
FOG
B10 B6
B7 B8
BATT A0
15A
FUSE
24
A6
A5
LAMP
ILLUMINATION
INDICATOR
ON
L39
20
LB
L35
20
BR/WT
C2
6
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
2
1
0
9
SWITCH
HEADLAMP
C1
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
S206
45 C201
RHD LHD
VT
20
L139
L77
20
BR/YL
BK/YL
18
L7
TO
S103
L77
20
BR/YL
12
Z1
20
BK
(8W-15-4) (8W-15-4)
(8W-15-4)
(8W-10-7)
(8W-10-6)
(8W-10-20)
(8W-12-10)
(8W-12-2)
(8W-50-2)
(8W-50-3)
(8W-10-16)
(8W-70-6)
(8W-15-4)
FOG LAMPS (GAS)
8W - 50 - 7
XJI05007 J978W-7
11
C106
4
Z1
18
BK
Z1
18
BK
S102 S103
G106
1
2
LAMP
FOG
LEFT
2
1
RIGHT
FOG
LAMP
Z1
20
BK
Z1
20
BK
S106
8
C106
A4 C100
3
2
SWITCH
LAMP
FOG
FRONT
L139
20
VT
A5 C100
POWER
DISTRIBUTION
CENTER
RELAY
LAMP
FOG
B8 B6
B7 B10
BATT A0
15A
FUSE
24
A6
A5
LAMP
ILLUMINATION
INDICATOR
ON
L39
20
LB
L35
20
BR/WT
C2
6
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
2
1
0
9
SWITCH
HEADLAMP
C1
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
S206
45 C201
RHD LHD
VT
20
L139
L77
20
BR/YL
BK/YL
18
L7
TO
S103
L77
20
BR/YL
12
Z1
20
BK
B19
CONTROLLER
ANTI-LOCK
BRAKE
RELAY
(8W-15-4) (8W-15-4)
(8W-15-4)
(8W-10-26)
(8W-10-25)
(8W-10-27)
(8W-12-10)
(8W-12-2)
(8W-50-2)
(8W-50-3)
(8W-10-37)
(8W-70-6)
(8W-15-4)
(8W-35-5)
FOG LAMPS (DIESEL)
XJ
J978W-7 XJI05008
5
2
M
2
3
MOTOR
LEVELING
HEADLAMP
LEFT RIGHT
HEADLAMP
LEVELING
MOTOR
3
2
M
BK/GY
18
Z15
4
SWITCH
LEVELING
HEADLAMP
BLOCK
JUNCTION
C1
1
10A
FUSE
5
G107
Z15
20
BK
DIESEL GAS
L44
18
VT/RD VT/RD
20
L44
B
HEADLAMP
RIGHT
S133
B12
C100
LHD RHD
S3 C4
4
BEAM
SELECT
SWITCH
22 C201
L4
16
VT/WT
L13
20
BR/YL
E18
13 C106
1 C106
G106
5 C106
Z15
18
BK/GY
Z15
16
BK/GY
(8W-12-2)
(8W-12-7)
(8W-15-8)
(8W-50-4)
(8W-50-2)
(8W-50-3)
(8W-15-4)
HEADLAMP LEVELING
8W - 50 - 9
XJI05009 J978W-7
8W-50 FRONT LIGHTING
INDEX
page page
PARKING LAMPS . . . . . . . . . . . . . . . . . . . . . . . . 10
HEADLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HEADLAMP LEVELING . . . . . . . . . . . . . . . . . . . 10
HEADLAMP DELAY MODULE . . . . . . . . . . . . . . . 10
FOG LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DAYTIME RUNNING LAMP (DRL) MODULE . . . . 11
PARKING LAMPS
Center (PDC) connects to ci rcui t L7 through the
headl amp swi tch. Ci rcui t L7 powers ci rcui ts L77 and
L78 through fuses 7 and 23 i n the juncti on bl ock.
Ci rcui t L78 powers the ri ght park and marker l amps.
Ci rcui t L77 powers the l eft park and marker l amps.
HELPFUL INFORMATION
Ci rcui ts L77 and L78 al so power the rear tai l
l amps.
Ci rcui t L77 powers the coi l si de of the fog l amp
rel ay.
Ci rcui t L77 provi des the i l l umi nati on l amp si g-
nal to the radi o.
Ci rcui t L78 feeds the l i cense pl ate l amp.
Ci rcui t Z1 provi des ground for the parki ng
l amps, marker l amps, rear tai l l amps, and l i cense
l amp.
HEADLAMPS
HEADLAMP SWITCH IN ON POSITION
The headl amp swi tch has three posi ti ons: ON,
PARK (parki ng l amps) and OFF. I n the ON posi ti on,
the headl amp swi tch connects ci rcui t A3 from fuse 7
i n the Power Di stri buti on Center (PDC) to ci rcui t L2.
Ci rcui t L2 connects to ci rcui t L4 through the di mmer
swi tch ci rcui try i n the mul ti -functi on swi tch. Ci rcui t
L4 connects to ci rcui ts L43 and L44 through fuses 4
and 5 i n the juncti on bl ock. Ci rcui ts L43 and L44
power the l ow beams of the headl amps.
When the operator sel ects hi gh beam operati on,
the mul ti -functi on swi tch connects ci rcui t L2 to ci r-
cui t L3. Ci rcui t L3connects to ci rcui ts L33 and L34
through fuses 3 and 16 i n the juncti on bl ock. Ci rcui ts
L33 and L34 power hi gh beam operati on. Ci rcui t Z1
provi des ground for the headl amps.
HEADLAMP SWITCH IN OFF OR PARKING
LAMP POSITION
The headl amps swi tch contai ns an i nternal ci rcui t
breaker that connects ci rcui t A3 to ci rcui t L20. Ci r-
cui t L20 connects to the mul ti -functi on swi tch. When
the operator momentari l y fl ashes the hi gh beams of
the headl amps wi th the turn si gnal l ever, ci rcui t L20
connects to ci rcui t L3. Ci rcui t L3 feeds the hi gh
beams of the headl amps.
HEADLAMP GROUND
Ci rcui t Z1 provi des ground for both ri ght and l eft
headl amps.
HEADLAMP LEVELING
When the headl amp swi tch i s i n the ON or Head-
l amp posi ti on, i t connects ci rcui t A3 from fuse 7 i n
the Power Di stri buti on Center (PDC) to ci rcui t L2.
Ci rcui t L2 connects to ci rcui t L4 through the mul ti -
functi on swi tch. Ci rcui t L4 feeds the headl amp l evel -
i ng swi tch. Ci rcui t Z15 grounds the swi tch.
HEADLAMP DELAY MODULE
When the operator turns OFF the i gni ti on swi tch
and then turns OFF the headl amp swi tch, the head-
l amp del ay modul e powers the headl amps for approx-
i matel y 45 seconds.
posi ti on, ci rcui t A22 powers ci rcui t F87 through fuse
9 i n the juncti on bl ock. Ci rcui t F87 suppl i es the
I GNI TI ON ON/OFF si gnal to the headl amp del ay
modul e. Ci rcui t Z1 provi des ground for the modul e.
When the headl amp del ay modul e acti vates, i t con-
nects ci rcui t A3 from fuse 7 i n the Power Di stri bu-
ti on Center (PDC) to ci rcui t L2. Ci rcui t L2 powers
the headl amps through the mul ti functi on swi tch.
FOG LAMPS
WITHOUT DAYTIME RUNNING LAMPS
The fog l amps are control l ed by the fog l amp
swi tch and fog l amp rel ay. The fog l amps operate
onl y when the headl amp swi tch i s i n the PARK or
ON posi ti on, and the operator has sel ected l ow-beam
8W - 50 - 10 8W - 50 FRONT LIGHTING XJ
operati on. When the headl amps are i n hi gh-beam
operati on, the fog l amps wi l l not operate.
Center (PDC) powers the contact si de of fog l amp
rel ay. Ci rcui t F61 connects to ci rcui t L139 through
the contacts of the fog l amp rel ay. Ci rcui t L139 con-
nects to ci rcui t L39 through the contacts of the fog
l amp swi tch. When the contacts i n the fog l amp rel ay
and the fog l amp swi tch are cl osed, ci rcui t L39 feeds
the fog l amps. Ci rcui t Z1 provi des ground for the fog
l amps.
Ci rcui t E2 provi des vol tage for the i l l umi nati on
l amp i n the fog l amp swi tch.
WITH DAYTIME RUNNING LAMPS
The fog l amps are control l ed by the fog l amp
swi tch and two fog l amp rel ays. The fog l amps oper-
ate onl y when the headl amp swi tch i s i n the PARK
or ON posi ti on, and the operator has sel ected l ow-
beam operati on. When the headl amps are i n hi gh-
beam operati on, the fog l amps wi l l not operate.
Center (PDC) powers the contact si de of fog l amp
rel ay number one (1).
When the headl amp swi tch i s i n the PARK or ON
posi ti on, ci rcui t L77 from the swi tch suppl i es vol tage
to the coi l si de of rel ay number one (1). Ci rcui t Z1
provi des ground for the coi l si de of rel ay number one
(1). When the contacts i n rel ay number one are
cl osed ci rcui t F61 i s connected to ci rcui t L34. Ci rcui t
L34 connects to ci rcui t L139 through the contacts i n
fog l amp rel ay number two (2). When the fog l amp
swi tch cl oses, i t connects ci rcui t L139 to ci rcui t L39.
When the contacts i n the fog l amp rel ays and the fog
l amp swi tch are cl osed, ci rcui t L39 feeds the fog
l amps. Ci rcui t Z1 provi des ground for the fog l amps.
I f the hi gh beam l amps are ON, ci rcui t G34 ener-
gi zes fog l amp rel ay number two (2). When fog l amp
rel ay number two (2) energi zes, i ts contacts open and
di sconnect ci rcui ts L34 and L139. When ci rcui ts L34
and L139 are di sconnected, power i s not suppl i ed to
the fog l amps.
Ci rcui t E2 provi des vol tage for the i l l umi nati on
l amp i n the fog l amp swi tch.
HELPFUL INFORMATION
The fog l amp swi tch contai ns a l i ght emi tti ng
di ode (LED) that i l l umi nates duri ng fog l amp opera-
ti on.
DAYTIME RUNNING LAMP (DRL) MODULE
On vehi cl es bui l t for sal e i n Canada, the head-
l amps operate when the i gni ti on swi tch i s i n the
RUN posi ti on.
posi ti on, ci rcui t A1 from fuse 2 i n the Power Di stri -
buti on Center (PDC) connects to ci rcui t A21. Ci rcui t
A21 powers ci rcui t F12 through fuse 11 i n the junc-
ti on bl ock. Ci rcui t F12 spl i ces to suppl y power to the
DRL modul e.
The headl amp swi tch connects ci rcui t A3 from fuse
7 i n the PDC to ci rcui t L20. Ci rcui ts A3 and L20 are
HOT at al l ti mes. Ci rcui t L20 connects to the head-
l amp di mmer swi tch ci rcui try i n the mul ti -functi on
swi tch and to the DRL modul e.
The DRL modul e recei ves the vehi cl e speed sensor
i nput from ci rcui t G7. Ci rcui t G34 from the DRL
modul e provi des power for the hi gh beam i ndi cator
l amp i n the i nstrument cl uster.
When the headl amp swi tch i s OFF and the i gni ti on
swi tch i s i n the START or RUN posi ti on, the DRL
modul e powers the headl amps on ci rcui t L3 at
reduced i ntensi ty. When the headl amps are ON, the
di mmer swi tch i n the mul ti -functi on swi tch powers
the l ow beams on ci rcui t L4.
Ci rcui t L3 feeds the hi gh beams of the headl amps.
When the operator fl ashes the headl amps wi th the
stal k of the mul ti -functi on swi tch, the DRL senses
vol tage on ci rcui t L3.
Ci rcui t Z1 provi des ground for the DRL modul e.
XJ 8W - 50 FRONT LIGHTING 8W - 50 - 11
8W-51 REAR LIGHTING
INDEX
page
Component Page
Back-Up Swi tch. . . . . . . . . . . . . . . . . . . . . . .8W-51-5
Beam Sel ect Swi tch . . . . . . . . . . . . . . . . . . . .8W-51-6
Center Hi gh Mounted Stop Lamp . . . . . . .8W-51-2, 3
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-5
Fuse 17 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-51-6
Fuse 19 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-51-3
Fuse 22 (PDC). . . . . . . . . . . . . . . . . . . . . . . .8W-51-2
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-6
G302 . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5, 6
G303 . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5, 6
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
Headl amp Del ay Modul e . . . . . . . . . . . . . . . .8W-51-6
Headl amp Swi tch . . . . . . . . . . . . . . . . .8W-51-2, 3, 6
I l l umi nati on Lamp . . . . . . . . . . . . . . . . . . . .8W-51-6
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 5
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . .8W-51-5
Left Rear Fog Lamp . . . . . . . . . . . . . . . . . . .8W-51-6
Left Tai l /Stop Lamp. . . . . . . . . . . . . . . . . .8W-51-2, 3
Left Turn Si gnal Lamp . . . . . . . . . . . . . . . . .8W-51-4
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
Power Di stri buti on Center . . . . . . . . . . .8W-51-2, 3, 6
Rear Defogger On I ndi cator . . . . . . . . . . . . . .8W-51-6
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . . .8W-51-6
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . . .8W-51-6
Ri ght Back-Up Lamp. . . . . . . . . . . . . . . . . . .8W-51-5
Ri ght Rear Fog Lamp . . . . . . . . . . . . . . . . . .8W-51-6
Component Page
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . .8W-51-2, 3
Ri ght Turn Si gnal Lamp . . . . . . . . . . . . . . . .8W-51-4
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-5
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-5
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-5
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
S218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-6
S220 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-6
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-5
S308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-6
S309. . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5, 6
S310. . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5, 6
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-4
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
S337 . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5
S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3
S341. . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5, 6
S348. . . . . . . . . . . . . . . . . . . . . . . .8W-51-2, 3, 4, 5, 6
Trai l er Tow Connector . . . . . . . . . . . .8W-51-2, 3, 4, 5
Transmi ssi on Control Modul e . . . . . . . . . . . .8W-51-5
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . .8W-51-4
XJ 8W - 51 REAR LIGHTING 8W - 51 - 1
3
1
2 LEFT
TAIL/
STOP
LAMP
2 3
1
L77
18
BR
L78
20
DG/YL
C7
2
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
6
C7
23
FUSE
10A
Z1
18
BK
L7
18
BK/YL
S206
2
1
0
9
SWITCH
HEADLAMP
C1
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
LAMP
STOP
TAIL/
RIGHT
G302
S309
BK
18
Z1
BK
16
Z1
S310
G303
5
6
STOP
LAMP
SWITCH
15A
FUSE
22
S341
1
TRAILER
TOW
CONNECTOR
Z1
14
BK
Z1
14
BK
Z1
12
BK
Z1
14
BK
2 C322
2 C323
OTHERS
TRAILER TOW
S348
2 C321
POWER
DISTRIBUTION
CENTER
BATT A0
A10
A9
F8 C100
F32
20
PK/DB
F32
20
PK/DB
L50
20
WT/TN
S203
LAMP
STOP
MOUNTED
HIGH
CENTER
1
2
S333
Z1
16
BK
G304
2 C427
Z1
18
BK
S337
6 C204 C200 24
S302
D C308
C321 6
C322 6
LHD RHD
2
1
LICENSE
LAMP
S334
9 C310
C311 6
Z1
18
BK
S311
7 C321
7 C322
C308 H
C310
C311 4
11
LHD
45 C201
RHD
OTHERS TRAILER TOW
BR
18
L77
S340
C323 7
3
L78
20
BR
L78
20
BR
L78
18
BR
C427 1
1
CENTER
HIGH
MOUNTED
STOP
LAMP
Z1
18
BK
(8W-12-10)
(8W-12-2)
(8W-12-22)
(8W-70-6)
(8W-50-2)
(8W-50-3)
(8W-10-16)
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-13)
(8W-15-14)
(8W-33-3)
(8W-10-20)
(8W-15-11)
(8W-15-12)
(8W-54-2)
(8W-15-13)
(8W-15-14)
(8W-10-7)
(8W-10-6)
(8W-10-20)
(8W-15-15)
(8W-15-15)
8W - 51 - 2 8W-51 REAR LIGHTING
GAS
XJ
J978W-7 XJI05101
3
1
2 LEFT
TAIL/
STOP
LAMP
2 3
1
L77
18
BR
L78
20
DG/YL
C7
2
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
6
C7
23
FUSE
10A
Z1
18
BK
L7
18
BK/YL
S206
2
1
0
9
SWITCH
HEADLAMP
C1
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
LAMP
STOP
TAIL/
RIGHT
G302
S309
BK
18
Z1
BK
16
Z1
S310
G303
5
6
STOP
LAMP
SWITCH
15A
FUSE
19
S341
1
TRAILER
TOW
CONNECTOR
Z1
14
BK
Z1
14
BK
Z1
12
BK
Z1
14
BK
2 C322
2 C323
OTHERS
TRAILER TOW
S348
2 C321
POWER
DISTRIBUTION
CENTER
BATT A0
A17
A18
F8 C100
F32
20
PK/DB
F32
20
PK/DB
L50
20
WT/TN
S203
LAMP
STOP
MOUNTED
HIGH
CENTER
1
2
S333
Z1
16
BK
G304
2 C427
Z1
18
BK
S337
6 C204 C200 24
S302
D C308
C321 6
C322 6
LHD RHD
2
1
LICENSE
LAMP
S334
9 C310
C311 6
Z1
18
BK
S311
7 C321
7 C322
C308 H
C310
C311 4
11
LHD
45 C201
RHD
OTHERS TRAILER TOW
BR
18
L77
S340
C323 7
3
L78
20
BR
L78
20
BR
L78
18
BR
C427 1
1
CENTER
HIGH
MOUNTED
STOP
LAMP
Z1
18
BK
(8W-12-10)
(8W-12-2)
(8W-12-22)
(8W-70-6)
(8W-50-2)
(8W-50-3)
(8W-10-37)
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-13)
(8W-15-14)
(8W-33-5)
(8W-10-34)
(8W-15-11)
(8W-15-12)
(8W-54-2)
(8W-15-13)
(8W-15-14)
(8W-10-26)
(8W-10-25)
(8W-10-34)
(8W-15-15)
(8W-15-15)
XJ 8W-51 REAR LIGHTING
DIESEL
8W - 51 - 3
XJI05102 J978W-7
9 3
SWITCH
HAZARD
SIGNAL/
TURN
(PART OF
MULTI-
FUNCTION
SWITCH)
1
2
LAMP
SIGNAL
TURN
LEFT RIGHT
TURN
SIGNAL
LAMP
2
1
L62
20
BR/RD
25
S312
C322 8
L63
20
DG/RD
C200 26
C321 1
Z1
18
BK
G302
S309
BK
18
Z1
BK
12
Z1
S310
G303
S341
1
TRAILER
TOW
CONNECTOR
Z1
14
BK
Z1
14
BK
Z1
20
BK
Z1
14
BK
2 C322
2 C323
OTHERS
TRAILER
TOW
S348
2 C321
S337
LHD RHD LHD RHD
C200 C204 7 8 C204
(8W-52-2)
(8W-52-3)
(8W-70-5)
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-13)
(8W-15-14)
(8W-15-11)
(8W-15-12)
(8W-54-2)
(8W-15-13)
(8W-15-14)
8W - 51 - 4 8W-51 REAR LIGHTING XJ
J978W-7 XJI05103
1
2 2
1
Z1
18
BK
G302
S309
BK
18
Z1
BK
16
Z1
S310
G303
S341
1
TRAILER
TOW
CONNECTOR
Z1
14
BK
Z1
14
BK
Z1
12
BK
Z1
14
BK
2 C322
2 C323
OTHERS
TRAILER TOW
S348
2 C321
S337
LAMP
BACK-UP
LEFT RIGHT
BACK-UP
LAMP
A
B
BACK-UP
SWITCH
C2
5
BLOCK
JUNCTION
20A
FUSE
11
(M/T)
ST-RUN A21
S116
7 C107
18
TRANSMISSION
CONTROL
MODULE
L10
18
BR/LG
S142 S130
DB/WT
18
F12
S303
5 C321 5 C322
A/T M/T
LHD RHD
5 C204 16 C200
A15 C100
12 C107
L10
18
BR/LG
L10
18
BR/LG
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-13)
(8W-15-14)
(8W-15-11)
(8W-15-12)
(8W-54-2)
(8W-15-13)
(8W-15-14)
(8W-12-2)
(8W-12-13)
(8W-12-14)
(8W-10-9)
(8W-12-14)
(8W-31-3)
(8W-70-7) (8W-12-13)
(8W-12-14)
XJ 8W-51 REAR LIGHTING 8W - 51 - 5
XJI05104 J978W-7
5
2
RELAY
LAMP
FOG
REAR
REAR
FOG
LAMP
SWITCH
1
3
4
1
85 87
30 86
BATT A0
POWER
DISTRIBUTION
CENTER
A22
A21
20A
FUSE
17
A18 C100
F34
18
TN/BK
F34
18
TN/BK
S218
F34
18
TN/BK
L38
18
BR/WT
REAR
DEFOGGER
ON
INDICATOR
Z15
18
BK
ILLUMINATION
LAMP
G107
2
L36
16
LG/BK
S220
15 C203
4 C322
LAMP
FOG
REAR
LEFT RIGHT
REAR
FOG
LAMP
C321 4
S308
3
Z1
16
BK
BR/WT
18
L38
L38
18
BR/WT
C1
2
SWITCH
HEADLAMP
6
HEADLAMP
DELAY
MODULE
3
SWITCH
SELECT
BEAM
L2
16
LG
L2
16
LG
2
1
2
1
2 C321 2 C322
G302 G303
S310 S309
S348 S341
Z1
18
BK
Z1
14
BK
Z1
20
BK
Z1
18
BK
Z1
12
BK
(8W-10-7)
(8W-10-26)
(8W-10-16)
(8W-10-16)
(8W-10-37)
(8W-15-8)
(8W-50-2)
(8W-50-3)
(8W-50-2)
(8W-50-3)
(8W-50-2)
(8W-50-3)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-13)
(8W-15-14)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-14)
(8W-15-11)
(8W-15-12)
(8W-10-6)
8W - 51 - 6 8W-51 REAR LIGHTING
REAR FOG LAMPS
XJ
J978W-7 XJI05105
8W-51 REAR LIGHTING
TAIL LAMPS AND REAR LICENSE PLATE LAMPS
Center (PDC) connects to ci rcui t L7 through the
headl amp swi tch. Ci rcui t L7 powers ci rcui ts L77 and
L78 through fuses 7 and 23 i n the juncti on bl ock.
Ci rcui t L78 powers the ri ght tai l l amps, the ri ght
park and marker l amps, and the l i cense l amp. Ci r-
cui t L77 powers the l eft tai l l amps, and the l eft l eft
park and marker l amps.
GROUND CIRCUIT
Ci rcui t Z1 provi des a ground for the tai l l amps,
parki ng l amps, marker l amps, and rear l i cense pl ate
l amp.
STOP LAMPS AND CHMSL LAMPS
Center (PDC). Ci rcui t F32 connects to the stop l amp
swi tch.
When the operator presses the brake pedal , the
stop l amp swi tch CLOSES and connects ci rcui t F32
to ci rcui t L50. Ci rcui t L50 connects to the stop l amps
and Center Hi gh Mounted Stop Lamps (CHMSL).
Ci rcui t Z1 provi des a ground for the CHMSL l amps
and stop l amps.
HELPFUL INFORMATION
Check fuse 22 i n the PDC.
Check for conti nui ty across the stop l amp swi tch
when i t i s cl osed.
REAR FOG LAMPS
The rear fog l amps are powered by the rear fog
l amp rel ay on ci rcui t L38. Ci rcui t L2 suppl i es vol tage
to the coi l si de of the rel ay (onl y when the headl amps
operate on Low beam. The rel ay coi l ground i s sup-
pl i ed by ci rcui t Z!.
l When the rel ay contacts cl ose they connect ci rcui t
F34 and L38. Ci rcui t L38 feeds the ri ght and l eft
rear fog l amps.
BACK-UP LAMPS
ter (PDC) to ci rcui t A21. Ci rcui t A21 feeds ci rcui t F12
through fuse 11 i n the juncti on bl ock.
Ci rcui t F12 suppl i es power to the back-up l amp
swi tch. On automati c transmi ssi on equi pped vehi cl es,
the back-up l amp swi tch ci rcui try i s part of the
PARK/NEUTRAL posi ti on swi tch. When the operator
puts the transmi ssi on i n REVERSE, the back-up
l amp swi tch connects ci rcui t F12 to ci rcui t L10. Ci r-
cui t L10 feeds the back-up l amps. Ci rcui t Z1 provi des
ground for the back-up l amps.
HELPFUL INFORMATION
Check fuse 2 i n the PDC and fuse 11 i n the junc-
ti on bl ock.
Check for conti nui ty across the back-up l amp
swi tch when i t i s cl osed.
XJ 8W - 51 REAR LIGHTING 8W - 51 - 7
8W-52 TURN SIGNALS
INDEX
page
Component Page
Combi nati on Fl asher . . . . . . . . . . . . . . . . .8W-52-2, 3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
Fuse 19 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . .8W-52-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
Left Front Turn Si gnal Lamp . . . . . . . . . . . .8W-52-2
Left Repeater Lamp . . . . . . . . . . . . . . . . . . .8W-52-2
Ri ght Front Turn Si gnal Lamp . . . . . . . . . . .8W-52-2
Component Page
Ri ght Repeater Lamp . . . . . . . . . . . . . . . . . .8W-52-2
Ri ght Turn Si gnal Lamp . . . . . . . . . . . . . . . .8W-52-3
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2, 3
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-2
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-52-3
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . .8W-52-2, 3
XJ 8W - 52 TURN SIGNALS 8W - 52 - 1
B10
C100
B9
1 10
S209
L61
20
LG/WT
L60
20
TN
SWITCH
HAZARD
SIGNAL/
TURN
(PART OF
MULTI-
FUNCTION
SWITCH)
1
3
COMBINATION
FLASHER
5
2
4
C4
S20
BLOCK
JUNCTION
10A
FUSE
12
POWER
DISTRIBUTION
CENTER
19
FUSE
15A
A15
A16
BATT A0
B11 C100
L5
20
BK
L9
20
BK/PK
S208
G107
Z1
18
BK
Z1
14
BK
6 5
L12
20
VT/TN
L6
20
RD/WT
3
LAMP
SIGNAL
TURN
FRONT
LEFT LEFT
FRONT
TURN
SIGNAL
LAMP
3 3
S105
L61
18
LG/WT
L61
18
LG/WT
L61
18
LG/WT LG/WT
18
L60
LG/WT
18
L60
LG/WT
18
L60
S100
3
3
LAMP
SIGNAL
TURN
FRONT
RIGHT RIGHT
FRONT
TURN
SIGNAL
3
LAMP
C1 10
CLUSTER
INSTRUMENT
LEFT
TURN
SIGNAL
INDICATOR INDICATOR
SIGNAL
TURN
RIGHT
INSTRUMENT
CLUSTER
6 C2
S212
R L L R R L L R
FUSED
IGN.
(ACC.-RUN)
RUN-ACC A22
FUSED
B(+) COMBINATION
FLASHER
OUTPUT
(HAZARD) (TURN SIGNAL)
OUTPUT
FLASHER
COMBINATION
GROUND
4 11
L55
18
WT/RD
LHD RHD
C201 3
3 10
C106
LEFT
REPEATER
LAMP
LAMP
REPEATER
RIGHT
(8W-12-2)
(8W-12-15)
(8W-12-16)
(8W-10-10)
(8W-10-7)
(8W-10-26)
(8W-10-19)
(8W-10-34)
(8W-10-6)
(8W-15-8)
(8W-15-8)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-40-15) (8W-40-15)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
8W - 52 - 2 8W-52 TURN SIGNALS XJ
J978W-7 XJI05201
9 3
SWITCH
HAZARD
SIGNAL/
TURN
(PART OF
MULTI-
FUNCTION
SWITCH)
1
3
COMBINATION
FLASHER
5
2
4
C4
S20
BLOCK
JUNCTION
10A
FUSE
12
POWER
DISTRIBUTION
CENTER
19
FUSE
15A
A15
A16
BATT A0
B11 C100
L5
20
BK
L9
20
BK/PK
S208
G107
Z1
18
BK
Z1
14
BK
6 5
L12
20
VT/TN
L6
20
RD/WT
R L L R R L L R
FUSED
IGN.
(ACC.-RUN)
RUN-ACC A22
FUSED
B(+) COMBINATION
FLASHER
OUTPUT
(HAZARD) (TURN SIGNAL)
OUTPUT
FLASHER
COMBINATION
GROUND
4 11
L55
18
WT/RD
LHD RHD
C201 3
L62
20
BR/RD
L63
20
DG/RD
LHD RHD
25 C200 C204 7
S312
8 C322
2
LAMP
SIGNAL
TURN
LEFT
26
LHD
8 C204
RHD
RIGHT
TURN
SIGNAL
LAMP
2
C321 1
C200
A9
A10
15A
FUSE
19
BK/WT
20
L9
BATT A0
DIESEL GAS
(8W-12-2)
(8W-12-15)
(8W-12-16)
(8W-10-10)
(8W-10-7)
(8W-10-26)
(8W-10-19)
(8W-10-6)
(8W-15-8)
(8W-15-8)
(8W-70-5)
(8W-51-4) (8W-51-4)
(8W-10-34)
(8W-10-25)
XJ 8W-52 TURN SIGNALS 8W - 52 - 3
XJI05202 J978W-7
8W-52 TURN SIGNALS
TURN SIGNALS
When the operator sel ects the ri ght turn si gnal ,
the mul ti -functi on swi tch connects power from ci rcui t
L55 to ci rcui t L60 and L62. Ci rcui t L60 feeds the
ri ght front turn si gnal l amps and the ri ght turn si g-
nal i ndi cator l amp on the i nstrument cl uster. Ci rcui t
L62 feeds the ri ght rear turn si gnal l amp.
When the operator sel ects the l eft turn si gnal , the
mul ti -functi on swi tch connects power from ci rcui t
L55 to ci rcui t L61 and L63. Ci rcui t L61 feeds the l eft
front turn si gnal l amp and the l eft turn si gnal i ndi -
cator l amp on the i nstrument cl uster. Ci rcui t L63
feeds the l eft rear turn si gnal l amp.
Ci rcui t Z1 provi des ground for the turn si gnal
l amps.
HELPFUL INFORMATION
The turn si gnal l amps are the same l amps used
for the hazard fl asher.
Check fuse 19 i n the PDC i f the turn si gnal s do
not operate.
COMBINATION FLASHER
I n the ACCESSORY or RUN posi ti on, the i gni ti on
swi tch connects ci rcui t A2 from fuse 3 i n the Power
Di stri buti on Center (PDC) to ci rcui t A22. Ci rcui t A22
feeds ci rcui t L5 through fuse 12 i n the juncti on bl ock.
Ci rcui t L5 powers the combi nati on fl asher for the
turn si gnal s. Ci rcui t L9 from fuse 19 i n the PDC sup-
pl i es battery vol tage to the combi nati on fl asher for
the hazard l amps. Ci rcui t Z1 provi des ground for the
combi nati on fl asher.
Ci rcui t L6 from the fl asher connects to the mul ti -
functi on swi tch to suppl y power to the turn si gnal s
on ci rcui t L55. The mul ti -functi on swi tch suppl i es
vol tage to the turn si gnal s and si de marker l amps on
ci rcui ts L60 and L61.
Ci rcui t L12 from the fl asher connects to the mul ti -
functi on swi tch to suppl y power to the hazard fl asher
ci rcui ts. The mul ti -functi on swi tch connects to the
turn si gnal and si de marker l amps on ci rcui ts L62
and L63.
HAZARD FLASHERS
When the operator sel ects the hazard fl ashers, the
mul ti -functi on swi tch connects ci rcui t L12 from the
combi nati on fl asher to ci rcui ts L60, L61, L62 and
L63.
Ci rcui ts L60 and L61feed the front turn si gnal
l amps and the turn si gnal i ndi cator l amps on the
i nstrument cl uster.
Ci rcui ts L62 and L63 feed the rear turn si gnal
l amps
Ci rcui t Z1 provi des ground for the hazard fl asher
l amps.
HELPFUL INFORMATION
The hazard fl asher l amps are the same l amps
used for the turn si gnal s.
Ci rcui t L9 powers ci rcui t L12 through the com-
bi nati on fl asher.
8W - 52 - 4 8W - 52 TURN SIGNALS XJ
8W-53 WIPERS
INDEX
page
Component Page
Ci rcui t Breaker 30 (JB). . . . . . . . . . . . . . . . .8W-53-2
Front Wi per Motor . . . . . . . . . . . . . . . . . . . .8W-53-2
Fuse 22 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
Rear Washer Pump Motor . . . . . . . . . . . . .8W-53-2, 3
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . .8W-53-3
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . .8W-53-3
Component Page
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2, 3
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-2
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3
S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-53-3
Wi ndshi el d Washer Pump Motor . . . . . . . .8W-53-2, 3
Wi ndshi el d Wi per/Washer Swi tch . . . . . . . . .8W-53-2
XJ 8W - 53 WIPERS 8W - 53 - 1
C4
M4
BLOCK
JUNCTION
5
4
SWITCH
WASHER
WIPER/
WINDSHIELD
INTERMITTENT
WIPER
LOGIC
OFF
DELAY LOW
HIGH HIGH
LOW DELAY
OFF
OFF
DELAY
LOW
HIGH
1 3
MAX
MIN
ON OFF
2 6
V6
18
DB
V10
18
BR
Z1
18
BK
V5
16
DG/YL
V4
16
BR/YL
V3
16
BR/WT
A
B
2
S132
C1
C100
C3 C5
6
4
M
2
RUN
PARK
5
MOTOR
WIPER
FRONT
S207
G108
Z1
18
BK
Z1
18
BK
SWITCH
WASHER
RELAY
MOTOR
WIPER
20A
30
BREAKER
CIRCUIT
RUN-ACC A31
8
C1
1
(PART OF
MULTI-
FUNCTION
SWITCH)
V6
18
DB
Z1
16
BK
G106
S141
OTHERS ABS LHD
MOTOR
PUMP
WASHER
WINDSHIELD
Z1
14
BK
Z1
16
BK
MOTOR
PUMP
WASHER
REAR
LHD RHD
C201 8
RD/YL
16
V4
2.5L,DIESEL OTHERS
M
(8W-12-2)
(8W-15-5)
(8W-15-6)
(8W-15-10)
(8W-15-10)
(8W-12-25)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-53-3)
8W - 53 - 2 8W-53 WIPERS XJ
J978W-7 XJI05301
C4
S11
20A
FUSE
22
BLOCK
JUNCTION
RUN A22
39 C201
V23
18
PK
6
SWITCH
WASHER
WIPER/
REAR
5
WIPE
OFF WASH
1
G107
Z1
18
BK
4
1
MOTOR
WIPER
REAR
V13
18
BR/LG
V23
18
BR/PK
29 C200
C308 F
C312 2
C310 7
S208
Z1
14
BK
2 4
WIPER
MODULE
8
PARK
RUN
M
1
2
MOTOR
PUMP
WASHER
REAR
LHD RHD
G304
S333
S334
Z1
18
BK
Z1
16
BK
9 C310
C311 6
2
MOTOR
PUMP
WASHER
WINDSHIELD
Z1
18
BK
Z1
18
BK
OTHERS ABS LHD
G106 G106
S132 S141
Z1
16
BK
Z1
14
BK
WASH
WIPE
OFF
LHD
C200 27
RHD
16 C203
S205
G C308 A17 C100
2
29
LHD
C203 18
RHD
C308 G
C200
BK/WT
18
V20 V20
18
VT/OR
2.5L,DIESEL OTHERS
M
(8W-12-20)
(8W-12-21)
(8W-12-2)
(8W-10-10)
(8W-15-8)
(8W-15-8)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-53-2)
(8W-15-4) (8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-15-5)
(8W-15-6)
XJ 8W-53 WIPERS 8W - 53 - 3
XJI05302 J978W-7
8W-53 WIPERS
INTERMITTENT WIPERS
A ci rcui t breaker powers the i ntermi ttent wi per
system. The i ntermi ttent wi per system operates at
ei ther LOW or HI GH or DELAY speeds.
I n the ACCESSORY or RUN posi ti on, the i gni ti on
swi tch connects ci rcui t A1 from fuse 8 i n the Power
Di stri buti on Center (PDC) wi th ci rcui t A48. Ci rcui t
A48 suppl i es vol tage to ci rcui t F86 through the ci r-
cui t breaker near the l eft ki ck panel .
Ci rcui t F86 suppl i es power to the front wi per
motor and the i ntermi ttent wi per control modul e.
Ci rcui t Z1 provi des ground for the front wi per motor
and the i ntermi ttent wi per control modul e.
When the operator moves the wi per swi tch to the
LOW posi ti on, battery vol tage passes through the
swi tch to ci rcui t V3. Ci rcui t V3 feeds the wi per motor
l ow speed brushes. I f the operator sel ects wi per
HI GH speed operati on, the wi per swi tch passes cur-
rent to ci rcui t V4. Ci rcui t V4 feeds the wi per motor
hi gh speed brushes.
The DELAY porti on of the wi per swi tch contai ns a
vari abl e resi stor. The vari abl e resi stor connects to
the i ntermi ttent wi per modul e on ci rcui t V51. The
amount of del ay sel ected by the operator determi nes
the vol tage drop through the resi stor and the vol tage
l evel recei ved by the i ntermi ttent wi per modul e.
After the i ntermi ttent wi per control modul e deter-
mi nes the amount of del ay sel ected, i t cycl es the wi p-
ers by peri odi cal l y energi zi ng ci rcui t V3. Ci rcui t V3
powers the wi per motor l ow speed brushes.
As the wi ndshi el d wi per motor turns, the park
swi tch, i nternal to the motor, moves from i ts DOWN
posi ti on to the UP posi ti on. When the wi per swi tch i s
turned OFF, the V55 ci rcui t prevents the wi pers from
stoppi ng i n any posi ti on but park.
The wi ndshi el d washer uses a pump motor l ocated
i nsi de the wi ndshi el d washer fl ui d reservoi r. When
the washer swi tch i s pressed, ci rcui t V11 provi des an
i nput to the i ntermi ttent wi per modul e. The modul e
powers the pump motor on ci rcui t V10. Ci rcui t Z1
provi des ground for the pump motor.
HELPFUL INFORMATION
Ci rcui t Z1 al so provi des ground for the rear wi per
washer pump.
REAR WIPER SYSTEM
ci rcui t A1 from fuse 8 i n the PDC wi th ci rcui t A38.
Ci rcui t A38 connects to a fuse bl ock bus bar that
powers ci rcui t V15 through the fuse i n cavi ty 1. Ci r-
cui t V15 suppl i es power to the rear wi per swi tch.
I n the WI PE or WASH posi ti ons, the rear wi per
swi tch suppl i es vol tage to the wi per motor on ci rcui t
V13. Ci rcui t Z1 provi des ground for the wi per motor.
The rear wi ndshi el d washer uses a pump motor
l ocated i nsi de the wi ndshi el d washer fl ui d reservoi r.
When the rear wi per swi tch i s i n the WASH posi ti on,
power i s suppl i ed through the wi per swi tch to the
rear wi per on ci rcui t V13 and the rear washer pump
motor on ci rcui t V20. Ci rcui t Z1 provi des ground for
the rear washer pump motor.
As the rear wi per motor turns, the park swi tch,
i nternal to the motor, moves from the RUN posi ti on
to the PARK posi ti on. When the wi per swi tch i s
turned OFF, the F20 ci rcui t prevents the wi pers from
stoppi ng i n any posi ti on but park.
8W - 53 - 4 8W - 53 WIPERS XJ
8W-54 TRAILER TOW
INDEX
page
Component Page
El ectri c Brake . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . .8W-54-3
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . .8W-54-3
Left Turn Rel ay . . . . . . . . . . . . . . . . . . . . .8W-54-2, 3
Ri ght Turn Rel ay . . . . . . . . . . . . . . . . . . . .8W-54-2, 3
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
Component Page
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2, 3
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2, 3
S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-3
S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
Trai l er Tow Connector . . . . . . . . . . . . . . . .8W-54-2, 3
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . .8W-54-3
XJ 8W - 54 TRAILER TOW 8W - 54 - 1
C7
8
BLOCK
JUNCTION
10A
FUSE
20
RELAY
TURN
LEFT RIGHT
TURN
RELAY
5
3
5
3
6 5
TRAILER
TOW
CONNECTOR
BATT A7
4
1
G302
S309
2 C322
Z1
14
BK
S337
Z1
20
BK
L73
20
YL
L74
20
LG
A6
20
RD/OR
7
FUSE
10A
C7
2
RHD
C201 45
LHD
BK/YL
18
L7
BATT F34
0 OFF
2 HEAD
1 PARK
C1
HEADLAMP
SWITCH
9
0
1
2
S206
BK/YL
18
L7
C4 M3
S338
3 C322
3
L77
18
BR
S311
S340
BR
20
L77
7 C322
L77
20
BR
BR
18
L77
(8W-12-2)
(8W-12-19)
(8W-10-11)
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-12)
(8W-15-11)
(8W-15-12)
(8W-12-10)
(8W-10-16)
(8W-50-2)
(8W-50-3)
(8W-70-6)
(8W-12-10)
(8W-12-10)
8W - 54 - 2 8W-54 TRAILER TOW XJ
J978W-7 XJI05401
RELAY
TURN
LEFT RIGHT
TURN
RELAY
2
1
2
1
TRAILER
TOW
CONNECTOR
1
S335
1 C323
L62
20
BR/RD
8
S336
6
S302
TO
L50
20
WT/TN
C323 6
3
LAMP
STOP
TAIL/
LEFT
TO
S312
LEFT
TURN
SIGNAL
LAMP
2
9
SWITCH
HAZARD
SIGNAL/
TURN
LHD
26 C200
RHD
C204 8
L63
20
DG/RD
(PART OF
MULTI-FUNCTION
SWITCH)
C322
C322
2
1
ELECTRIC
BRAKE
B40
14
LB
7
S339
2
LEFT
BACK-UP
LAMP
C322
5
TO
S303
L10
18
BR/LG
5 C323
(8W-10-34)
(8W-51-2)
(8W-51-3)
(8W-70-5)
(8W-51-4)
(8W-52-2)
(8W-52-3)
(8W-51-5)
(8W-70-7)
XJ 8W-54 TRAILER TOW 8W - 54 - 3
XJI05402 J978W-7
8W-54 TRAILER TOW
TRAILER TOW
The factory i nstal l ed trai l er tow system i n thi s
vehi cl e uses two rel ays wi th the trai l er tow wi ri ng
connector l ocated bel ow the rear bumper.
Battery vol tage for the trai l er tow system i s sup-
pl i ed on ci rcui t A7. Thi s ci rcui t i s HOT at al l ti mes
and connects to ci rcui tr A6 through fuse 20 i n the
juncti on bl ock.
RIGHT TURN RELAY
Ci rcui t A6 i s the feed for the contact si de of the
rel ay. When the contacts are cl osed they connect ci r-
cui t A6 and ci rcui t L74. Ci rcui t L74 suppl i es vol tage
to the trai l er connecter for the ri ght turn and stop
l amps.
Power and ground for the coi l si des of the rel ay are
suppl i ed by ci rcui ts L50 and L62. When the brakes
are depressed ci rcui t L50 suppl i es vol tage to the coi l
si de of the rel ay through the stop l amp swi tch. When
the stop l amp swi tch i s open ci rcui t L50 suppl i es
ground to the coi l si de of the rel ay.
HELPFUL INFORMATION
Ci rcui t L62 suppl i es vol tage to the ri ght rear turn
si gnal l amps and the coi l si de of the rel ay, through
the combi nati on fl asher.
LEFT TURN RELAY
Ci rcui t A6 i s the feed for the contact si de of the
rel ay. When the contacts are cl osed they connect ci r-
cui t A6 and ci rcui t L73. Ci rcui t L73 suppl i es vol tage
to the trai l er connecter for the l eft turn and stop
l amps.
Power and ground for the coi l si des of the rel ay are
suppl i ed by ci rcui ts L50 and L63. When the brakes
are depressed ci rcui t L50 suppl i es vol tage to the coi l
si de of the rel ay through the stop l amp swi tch. When
the stop l amp swi tch i s open ci rcui t L50 suppl i es
ground to the coi l si de of the rel ay.
HELPFUL INFORMATION
Ci rcui t L63 suppl i es vol tage to the ri ght rear turn
si gnal l amps and the coi l si de of the rel ay, through
the combi nati on fl asher.
HELPFUL INFORMATION
Ci rcui t L1 suppl i es vol tage for the trai l er
back-up l amps.
Ci rcui t L77 suppl i es vol tage for the runni ng
l amps.
Ci rcui t A6 suppl i es trai l er battery vol tage.
8W - 54 - 4 8W - 54 TRAILER TOW XJ
8W-60 POWER WINDOWS
INDEX
page
Component Page
Ci rcui t Breaker 28 (JB). . . . . . . . . . . . . . .8W-60-2, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-4, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 4
Left Front Power Lock/Wi ndow Swi tch . . .8W-60-2, 3
Swi tch/Modul e. . . . . . . . . . . . . . . . . . . . . .8W-60-4
Left Front Wi ndow Motor . . . . . . . . . . . . .8W-60-2, 4
Left Rear Wi ndow Motor . . . . . . . . . . . . . .8W-60-3, 5
Left Rear Wi ndow Swi tch . . . . . . . . .8W-60-2, 3, 4, 5
Ri ght Front Power Lock/Wi ndow Swi tch . .8W-60-4, 5
Component Page
Swi tch/Modul e. . . . . . . . . . . . . . . . . . . . . .8W-60-2
Ri ght Front Wi ndow Motor . . . . . . . . . . . .8W-60-2, 4
Ri ght Rear Wi ndow Motor . . . . . . . . . . . . .8W-60-3, 5
Ri ght Rear Wi ndow Swi tch . . . . . . . .8W-60-2, 3, 4, 5
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-4, 5
S305 . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3, 4, 5
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-4, 5
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3
XJ 8W - 60 POWER WINDOWS 8W - 60 - 1
C1 C1 C1 C1 C1 C2
C1
3 6 5 12 8 8
3 4
2 1 2 1 2 1 1
9
2
SWITCH
WINDOW
LOCK/
POWER
FRONT
LEFT
4 UNLOCK
3 LOCK
2 DOWN
1 UP
30A
28
BREAKER
CIRCUIT
C5
8
RUN-ACC A31
BLOCK
JUNCTION
F81
12
TN
13 C201
C200 33
1 C307
BR
16
Q12
2 1
VT
16
Q22
MOTOR
WINDOW
FRONT
RIGHT
3
2 9
4
2 1
10
1 2
LEFT
FRONT
WINDOW
MOTOR
Q21
16
WT
Q11
16
LB
1
3
BR/WT
14
Q16 Q26
14
VT/WT
4
C306
C303
2
Z1
12
BK
S329
Z1
12
BK
3
C307
S309
Z1
12
BK
Z1
12
BK
G302
C7
3 7
C9
JUNCTION
BLOCK
6
SWITCH
WINDOW
REAR
RIGHT LEFT
REAR
WINDOW
SWITCH
6
2
Q1
14
YL
S305
YL
14
Q1
3 C304
Q1
14
YL YL
14
Q1
C309 3
Q1
14
YL
Q1
14
YL
Q1
14
YL
1 UP
2 DOWN
3 LOCK
4 UNLOCK
RIGHT
FRONT
POWER
LOCK/
WINDOW
SWITCH/
MODULE
C1 C1
C1 C1 C1
M
(8W-12-23)
(8W-10-8)
(8W-12-2)
(8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-12-2)
(8W-60-3) (8W-60-3)
8W - 60 - 2 8W-60 POWER WINDOWS
LHD
XJ
J978W-7 XJI06001
2 DOWN
1 UP
2 DOWN
1 UP
S305
Q27
14
RD/BK
Q17
14
DB/WT
DB/WT
14
Q17
RD/BK
14
Q27
DG/WT
14
Q28
GY/BK
14
Q18
YL
14
Q1
6
5
C309
3 2
1
1 5
Q23
16
RD/WT
Q13
16
DB
6 4 2
SWITCH
WINDOW
REAR
LEFT
1 2
1 2
LEFT
REAR
WINDOW
MOTOR
GY/BK
14
Q18
1
1
Q28
14
DG/WT
2
C306
2
Z1
12
BK
S329
3
C307
S309
Z1
12
BK
G302
2
Q1
14
YL
YL
14
Q1
3
C304
Q1
14
YL
MOTOR
WINDOW
REAR
RIGHT
2 1
2 1
RIGHT
REAR
WINDOW
SWITCH
2 4 6
RUN-ACC F81
C1 C1 C1 C1 C1 C2
2 1 4 10 8 8
3 4
2 1 2 1 2 1 1 2
SWITCH
WINDOW
LOCK/
POWER
FRONT
LEFT
4 UNLOCK
3 LOCK
2 DOWN
1 UP
GY
16
Q14
DG
16
Q24
5 1
M M
(8W-12-30)
(8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-12-23)
XJ 8W-60 POWER WINDOWS
LHD
8W - 60 - 3
XJI06002 J978W-7
C1 C1 C1 C1 C1 C2
C1
3 6 5 12 8 8
3 4
2 1 2 1 2 1 1
9
2
SWITCH
WINDOW
LOCK/
POWER
FRONT
RIGHT
4 UNLOCK
3 LOCK
2 DOWN
1 UP
30A
28
BREAKER
CIRCUIT
C8
1
RUN-ACC A31
BLOCK
JUNCTION
F81
12
TN
BR
16
Q12
2 1
VT
16
Q22
MOTOR
WINDOW
FRONT
LEFT
3
2 9
4
2 1
10
1 2
RIGHT
FRONT
WINDOW
MOTOR
Q21
16
WT
Q11
16
LB
3
BR/WT
14
Q16 Q26
14
VT/WT
4
C306
Z1
12
BK
S319
Z1
12
BK
S208
G107
6
SWITCH
WINDOW
REAR
RIGHT
LEFT
REAR
WINDOW
SWITCH
6
Q1
14
YL
S305
3 C304
Q1
14
YL
YL
14
Q1
C309 3
Q1
14
YL
1 UP
2 DOWN
3 LOCK
4 UNLOCK
LEFT
FRONT
POWER
LOCK/
WINDOW
SWITCH/
MODULE
C1 C1
C1 C1 C1
8
7
Z1
14
BK
Q1
14
YL
C307 2
C303R
M
(8W-12-24)
(8W-10-8)
(8W-12-2)
(8W-12-33)
(8W-15-8)
(8W-15-8)
(8W-60-5)
(8W-60-5)
8W - 60 - 4 8W-60 POWER WINDOWS
RHD
XJ
J978W-7 XJI06003
2 DOWN
1 UP
2 DOWN
1 UP
S305
Q27
14
RD/BK
Q17
14
DB/WT
DB/WT
14
Q17
RD/BK
14
Q27
DG/WT
14
Q28
GY/BK
14
Q18
YL
14
Q1
6
5
C309
3 2
1
1 5
Q23
16
RD/WT
Q13
16
DB
6 4 2
SWITCH
WINDOW
REAR
LEFT
1 2
1 2
LEFT
REAR
WINDOW
MOTOR
GY/BK
14
Q18
1
1
Q28
14
DG/WT
2
C306
2
Z1
12
BK
S319
S208
Z1
14
BK
G107
Q1
14
YL
3
C304
Q1
14
YL
MOTOR
WINDOW
REAR
RIGHT
2 1
2 1
RIGHT
REAR
WINDOW
SWITCH
2 4 6
RUN-ACC F81
C1 C1 C1 C1 C1 C2
2 1 4 10 8 8
3 4
2 1 2 1 2 1 1 2
SWITCH
WINDOW
LOCK/
POWER
FRONT
RIGHT
4 UNLOCK
3 LOCK
2 DOWN
1 UP
GY
16
Q14
DG
16
Q24
5 1
BK
12
Z1
M M
(8W-12-30)
(8W-12-33)
(8W-15-8)
(8W-15-8)
(8W-12-24)
XJ 8W-60 POWER WINDOWS
RHD
8W - 60 - 5
XJI06004 J978W-7
8W-60 POWER WINDOWS
INDEX
page page
POWER WINDOW OPERATION . . . . . . . . . . . . . . 6
HELPFUL INFORMATION . . . . . . . . . . . . . . . . . . . 7
POWER WINDOW OPERATION
When the i gni ti on swi tch i s i n the RUN or ACCES-
SORY posi ti on i t connects ci rcui t A1 from fuse 2 i n
Ci rcui t A31 i s connected to ci rcui t F81 through a 20
amp. ci rcui t breaker l ocated i n cavi ty 28 of the junc-
ti on bl ock. The power wi ndow system i s powered by
ci rcui t F81.
Ci rcui t F81 connects to the master wi ndow swi tch.
Ci rcui t Z1 provi des ground for the power wi ndows.
A LOCK-OUT feature i s provi ded on the dri vers
door wi ndow swi tch. When thi s feature i s engaged
the other wi ndows i n the system wi l l not operate.
LEFT FRONT WINDOW OPERATION
When the operator sel ects wi ndow DOWN opera-
ti on, power i s suppl i ed on the F81 ci rcui t through the
swi tch to ci rcui t Q21. Ci rcui t Q21 connects the
swi tch to the power wi ndow motor. Ground for the
motor i s suppl i ed on the Q11 ci rcui t back to the
swi tch. A bus bar, i nternal to the swi tch, connects the
Q11 ci rcui t to the Z1 ground ci rcui t.
For wi ndow UP operati on the ci rcui ts are reversed.
Ci rcui t Q11 i s the feed, and ci rcui t Q21 i s the
ground.
RIGHT FRONT WINDOW OPERATION
When the DRI VER sel ects wi ndow DOWN opera-
swi tch to ci rcui t Q26. Ci rcui t Q26 connects the dri v-
ers door swi tch to the ri ght front door swi tch. Power
i s passed through thi s swi tch to ci rcui t Q22. The Q22
ci rcui t then goes to the ri ght front wi ndow motor.
Ground for the wi ndow motor i s suppl i ed on the
Q12 ci rcui t back to the ri ght front door swi tch. Ci r-
cui ty i nternal to the swi tch then passes the ground
to ci rcui t Q16. Ci rcui t Q16 connects the ri ght front
door swi tch to the master swi tch. A bus bar, i nternal
to the swi tch, connects the Q16 ci rcui t to the Z1
ground ci rcui t.
Ci rcui ts Q16 and Q12 are the feeds, and ci rcui ts Q22
and Q26 are the grounds.
I f the swi tch i s bei ng operated from the RI GHT
FRONT door, and the operator i s requesti ng wi ndow
DOWN operati on, power i s suppl i ed on the Q1 ci rcui t
from the dri vers master swi tch ci rcui t through the
swi tch to the Q22 ci rcui t.
Ground for the motor i s suppl i ed on the Q12 ci rcui t
through the swi tch and back to the master swi tch on
ci rcui t Q16. A bus bar, i nternal to the swi tch, con-
nects the Q16 ci rcui t to the Z1 ground ci rcui t.
For wi ndow UP operati on, the ci rcui ts are
reversed. Ci rcui t Q12 i s the power and ci rcui t Q22 i s
the ground.
LEFT REAR WINDOW
ers door swi tch to the l eft rear door swi tch. Power i s
passed through thi s swi tch to ci rcui t Q23. The Q23
ci rcui t then goes to the l eft rear wi ndow motor.
Q13 ci rcui t back to the l eft rear door swi tch. Ci rcui ty
i nternal to the swi tch then passes the ground to ci r-
cui t Q17. Ci rcui t Q17 connects the ri ght front door
swi tch to the master swi tch. A bus bar, i nternal to
the swi tch, connects the Q17 ci rcui t to the Z1 ground
ci rcui t.
I f the swi tch i s bei ng operated from the LEFT
REAR door, and the operator i s requesti ng wi ndow
the ground.
RIGHT REAR WINDOW
8W - 60 - 6 8W - 60 POWER WINDOWS XJ
ers door swi tch to the ri ght rear door swi tch. Power
i s passed through thi s swi tch to ci rcui t Q24. The Q24
ci rcui t then goes to the ri ght rear wi ndow motor.
Q14 ci rcui t back to the ri ght rear door swi tch. Ci rcu-
i ty i nternal to the swi tch then passes the ground to
ci rcui t Q18. Ci rcui t Q18 connects the ri ght rear door
swi tch to the master swi tch. A bus bar, i nternal to
the swi tch, connects the Q18 ci rcui t to the Z1 ground
ci rcui t.
I f the swi tch i s bei ng operated from the RI GHT
REAR door, and the operator i s requesti ng wi ndow
the ground.
HELPFUL INFORMATION
When the i gni ti on swi tch i s i n the RUN posi ti on,
tri buti on Center (PDC) to ci rcui t A38.
Refer to the appropri ate group of the Servi ce
Manual for test procedures.
XJ 8W - 60 POWER WINDOWS 8W - 60 - 7
8W-61 POWER DOOR LOCKS
INDEX
page
Component Page
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3, 4
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-4
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-61-4
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . .8W-61-4
Juncti on Bl ock . . . . . . . . . . . . . . . . . .8W-61-2, 3, 5, 6
Left Front Door Jamb Swi tch . . . . . . . . . . . .8W-61-4
Left Front Door Lock Motor . . . . . . . . . . .8W-61-5, 6
Left Front Power Lock/Wi ndow Swi tch . . . . .8W-61-2
Swi tch/Modul e . . . . . . . . . . . . . . . . . .8W-61-3, 4, 6
Left Rear Door Lock Motor . . . . . . . . . . . .8W-61-5, 6
Li ft Gate Door Lock Motor . . . . . . . . . . . .8W-61-5, 6
Ri ght Front Door Jamb Swi tch . . . . . . . . . . .8W-61-4
Ri ght Front Door Lock Motor . . . . . . . . . .8W-61-5, 6
Ri ght Front Power Lock/Wi ndow Swi tch . . . .8W-61-3
Component Page
Swi tch/Modul e . . . . . . . . . . . . . . . . . .8W-61-2, 4, 5
Ri ght Rear Door Lock Motor . . . . . . . . . . .8W-61-5, 6
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-4
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-4
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-5, 6
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-5, 6
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3, 4
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-4
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-5
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-5
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-6
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-6
S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-3
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2
XJ 8W - 61 POWER DOOR LOCKS 8W - 61 - 1
BATT A7
25A
FUSE
15
C9
9
BLOCK
JUNCTION
F35
16
RD
C2
3
C2 5
SWITCH/
MODULE
RIGHT
FRONT
POWER
LOCK/
WINDOW
FUSED
B(+)
LOCK
REQUEST REQUEST
UNLOCK
7
C2
P35
20
PK/VT
P35
18
PK/VT
7 C1
1
23
31
6 C305
7
C200
39
C201
9
C300
2
C1 11
OR/VT
18
P36
OR/VT
20
P36
SWITCH
LEFT
FRONT
POWER
LOCK/
WINDOW
5
C2
G302
3 C307
S309
S329
Z1
12
BK
BK
16
Z1
S319
C2
6
Z1
16
BK
C4
S5
C9 11
JUNCTION
BLOCK
BK
14
Z1
S208
Z1
14
BK
G107
14 C201
S314
Z1
14
BK
GROUND
30A
28
BREAKER
CIRCUIT
RUN-ACC A31
TN
12
F81
1
C8
IGN.
FUSED
4 C2
(RUN-ACC)
C2 1
LOCK
CONTROL CONTROL
UNLOCK
2 C2
P59
20
LB/RD DB
20
P55
5 11
MODULE
OVERHEAD
4
C300 3
P55
20
DB LB/RD
20
P59
5 C302
4
P55
20
DB LB/RD
20
P59
SENSE
REQUEST
DOOR
UNLOCK LOCK
DOOR
REQUEST
SENSE
(8W-10-11)
(8W-12-17)
(8W-12-2)
(8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-15-7)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-15-8)
(8W-12-23)
(8W-10-8)
(8W-39-2)
(8W-12-33)
8W - 61 - 2 8W-61 POWER DOOR LOCKS
LHD
XJ
J978W-7 XJI06101
12 C204
C306 1
RD
16
F35 F81
12
TN
1 C307
C202 3
12 C305
3
BK
14
Z1
C307 3
BATT A7
25A
FUSE
15
C5
7
BLOCK
JUNCTION
F35
16
RD
C2
3
C2 5
SWITCH/
MODULE
LEFT
FRONT
POWER
LOCK/
WINDOW
FUSED
B(+)
LOCK
REQUEST REQUEST
UNLOCK
7
C2
P35
18
PK/VT
P35
20
PK/VT
7 C1
6
23
1 C300
2
C204
24
C305
7
C1 11
OR/VT
20
P36
OR/VT
18
P36
SWITCH
RIGHT
FRONT
POWER
LOCK/
WINDOW
5
C2
G107
S208
S319
Z1
12
BK
BK
12
Z1
S325
C2
6
Z1
12
BK
BK
20
Z1
Z1
12
BK
G302
S309
GROUND
30A
28
BREAKER
CIRCUIT
RUN-ACC A31
TN
12
F81
8
C5
IGN.
FUSED
4 C2
(RUN-ACC)
C2 1
LOCK
CONTROL CONTROL
UNLOCK
2 C2
P59
20
LB/RD DB
20
P55
5 11
MODULE
OVERHEAD
21
C203 22
5 C302
4
P55
20
DB LB/RD
20
P59
SENSE
REQUEST
DOOR
UNLOCK LOCK
DOOR
REQUEST
SENSE
(8W-10-11)
(8W-12-18)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-15-7)
(8W-15-12)
(8W-15-12)
(8W-15-12)
(8W-12-24)
(8W-10-8)
(8W-39-3)
XJ 8W-61 POWER DOOR LOCKS
RHD
8W - 61 - 3
XJI06102 J978W-7
3
Z1
18
BK
3 C318
Z1
20
BK
S310
SWITCH
JAMB
DOOR
FRONT
RIGHT
19 C203
2 C318
2
G16
18
BK/LB
RHD LHD
RHD LHD
AJAR/
DOOR
KEY-IN
SIGNAL
G26
20
LB
13 C305
20 C203
C2
8
SWITCH/
MODULE
LEFT
FRONT
POWER
LOCK/
WINDOW WINDOW
LOCK/
POWER
FRONT
RIGHT
MODULE
SWITCH/
S309
BK
20
Z1
C317 3
BK
18
Z1
3
BK/LB
18
G16
LEFT
FRONT
DOOR
JAMB
SWITCH
2
C317 2
C200 17
BK/LB
20
G16 G16
20
BK/LB
S200
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
C1
6
C1 5
0
1
2
IGNITION
SWITCH
SWITCH
KEY-IN
1 C2
2
C2
G26
20
LB
CHIME
C2
8
CLUSTER
INSTRUMENT
LB
20
G26 G26
20
LB
S210
8
C2
C201 29
C300 5
LB
20
G26
SIGNAL
KEY-IN
DOOR
AJAR/
G302
Z1
12
BK
G303
Z1
20
BK
(8W-39-7) (8W-39-6)
(8W-15-14) (8W-15-11)
(8W-50-2)
(8W-50-3)
(8W-10-8)
(8W-10-28)
(8W-40-14)
(8W-15-11) (8W-15-14)
8W - 61 - 4 8W-61 POWER DOOR LOCKS XJ
J978W-7 XJI06103
P34
16
PK/BK
S307
B
2
5
P34
16
PK/BK
P34
16
PK/BK
P34
16
PK/BK PK/BK
16
P34
5 5 5
PK/BK
16
P34
1
PK/BK
16
P34
1
PK/BK
16
P34
1 1
P34
16
PK/BK
LOCK
GATE
LIFT
DOOR
MOTOR
2 2
MOTOR
DOOR
RIGHT
REAR
LOCK LOCK
REAR
LEFT
DOOR
MOTOR
2 2
MOTOR
DOOR
LEFT
FRONT
LOCK
P33
16
OR/BK
4
1
C311
C310
OR/BK
16
P33 P33
16
OR/BK
P33
16
OR/BK
P33
16
OR/BK
C308
A
4 C304
OR/BK
16
P33
4 C309
OR/BK
16
P33 P33
16
OR/BK
S306
C305 4
OR/BK
16
P33
12 C9
5
C7 C7
1
C9 1
BLOCK
JUNCTION
MOTOR
LOCK
DOOR
FRONT
RIGHT
2 1
P33
16
OR/BK
S317
P33
16
OR/BK OR/BK
16
P33 P34
16
PK/BK PK/BK
16
P34
S316
PK/BK
16
P34
5
C1
DOOR
LOCK
SIGNAL SIGNAL
UNLOCK
DOOR
C1
1
SWITCH/
MODULE
RIGHT
FRONT
POWER
LOCK/
WINDOW
M
M M M M
(8W-12-2)
XJ 8W-61 POWER DOOR LOCKS
LHD
8W - 61 - 5
XJI06104 J978W-7
WINDOW
LOCK/
POWER
FRONT
LEFT
MODULE
SWITCH/
1
C1
DOOR
UNLOCK
SIGNAL SIGNAL
LOCK
DOOR
C1
5
P34
16
PK/BK
S322
P34
16
PK/BK PK/BK
16
P34 P33
16
OR/BK OR/BK
16
P33
S323
OR/BK
16
P33
1 2
LEFT
FRONT
DOOR
LOCK
MOTOR
JUNCTION
BLOCK
1
C7 C7
5
P33
16
OR/BK
S306
OR/BK
16
P33 P33
16
OR/BK
C309 4
P33
16
OR/BK
C304 4
A
C308
OR/BK
16
P33
OR/BK
16
P33
OR/BK
16
P33
C310
C311
1
4
OR/BK
16
P33
LOCK
FRONT
RIGHT
DOOR
MOTOR
2 2
MOTOR
DOOR
LEFT
REAR
LOCK LOCK
REAR
RIGHT
DOOR
MOTOR
2 2
MOTOR
DOOR
LIFT
GATE
LOCK
1 1
P34
16
PK/BK
1
P34
16
PK/BK
1
P34
16
PK/BK
5 5
P34
16
PK/BK PK/BK
16
P34
PK/BK
16
P34
PK/BK
16
P34
5
2
B
S307
PK/BK
16
P34
OR/BK
16
P33 P34
16
PK/BK
4 C305
5
NOT
USED USED
NOT
M M M M
M
(8W-12-2)
8W - 61 - 6 8W-61 POWER DOOR LOCKS
RHD
XJ
J978W-7 XJI06105
8W-61 POWER DOOR LOCKS
INTRODUCTION
The Passenger Door Modul e and the l eft door l ock
swi tch, control the door l ocks, keyl ess entry, and i l l u-
mi nated entry systems.
POWER DOOR LOCK OPERATION
Center (PDC) suppl i es vol tage to ci rcui t F35 through
fuse 15 i n the juncti on bl ock. Ci rcui t F35 suppl i es
vol tage to the passenger door l ock modul e.
When the i gni ti on swi tch i s i n the ACCESSORY or
RUN posi ti on i t connects ci rcui t A1 from fuse 2 i n
Ci rcui t A31 suppl i es power to ci rcui t F81 through a
ci rcui t breaker i n cavi ty 28 of the juncti on bl ock.
DOOR LOCK SWITCH OPERATIONLOCK
POSITION
When ei ther door l ock swi tch i s put i n the LOCK
posi ti on, the swi tch connects vol tage from ci rcui t F35
to ci rcui t P35. Ci rcui t P35 provi des the LOCK i nput
to the door l ock modul e. After recei vi ng the LOCK
i nput, the door l ock modul e suppl i es power to the
door l ocks on ci rcui t P33. Ci rcui t P33 i s spl i ced to
provi de power for al l the door l ock motors.
I n the LOCK posi ti on, ground for the door l ock
motors i s on ci rcui t P34, through the door l ock mod-
ul e to ground on ci rcui t Z1.
DOOR LOCK SWITCH OPERATIONUNLOCK
POSITION
When ei ther door l ock swi tch i s put i n the
UNLOCK posi ti on, the swi tch connects vol tage from
ci rcui t F35 to ci rcui t P36. Ci rcui t P36 provi des the
UNLOCK i nput to the door l ock modul e. After recei v-
i ng the UNLOCK i nput, the door l ock modul e sup-
pl i es power to the door l ocks on ci rcui t P34. Ci rcui t
P34 i s spl i ced to provi de power to al l the door l ock
motors.
I n the UNLOCK posi ti on, ground for the door l ock
motors i s on ci rcui t P33, through the door l ock mod-
ul e to ground on ci rcui t Z1.
REMOTE KEYLESS ENTRY AND ILLUMINATED
ENTRY
The PDM control s the remote keyl ess entry and
i l l umi nated entry systems. When the modul e recei ves
i nput from the transmi tter, i t operates the door l ocks
and provi des ground for courtesy l amps.
GROUND CIRCUIT
Ci rcui t Z1 provi des ground for the door l ock mod-
ul e and dri vers door l ock swi tch..
HELPFUL INFORMATION
Each door l ock motor has an i nternal ci rcui t
breaker.
XJ 8W - 61 POWER DOOR LOCKS 8W - 61 - 7
8W-62 POWER MIRRORS
INDEX
page
Component Page
Fuse 16 (PDC). . . . . . . . . . . . . . . . . . . . . .8W-62-2, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-4, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . .8W-62-2, 3, 4
Left Front Power Lock/Wi ndow Swi tch . . .8W-62-2, 3
Left Power Mi rror . . . . . . . . . . . . . . . . .8W-62-2, 3, 5
Ri ght Front Power Lock/Wi ndow Swi tch . .8W-62-4, 5
Ri ght Power Mi rror . . . . . . . . . . . . . . . .8W-62-3, 4, 5
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-2, 4
Component Page
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-4, 5
S214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-4
S300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-2
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-2, 3
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-3, 4, 5
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-4, 5
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-2, 3, 5
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-62-2, 3
Underhood Lamp. . . . . . . . . . . . . . . . . . . .8W-62-2, 4
XJ 8W - 62 POWER MIRRORS 8W - 62 - 1
BATT A0
MIRROR
POWER
LEFT
3 1
A24
16
FUSE
15A
POWER
DISTRIBUTION
CENTER
M M
4 DOWN
3 UP
2 RIGHT
1 LEFT
3 2
1 4
2
C2
2 1 1 2
C2
6 1
C2
5
C2
3 C2
0 0 REST
0
4 1
2 3 3 2
1 4
0
A23
S135
M1
20
PK
C7
4
C1 12
BLOCK
JUNCTION
PK
20
M1
S300
3 C305
SWITCH
LEFT
FRONT
POWER
LOCK/
WINDOW
P76
20
OR/YL BK
12
Z1
DB/WT
20
P75 P71
20
YL
2 4
OR/YL
20
P76 P76
20
OR/YL
G302 S328
S329
3 C307
S309
Z1
12
BK
M1
18
PK
GAS DIESEL
PK
20
M1
2
UNDERHOOD
LAMP
M1
20
PK
(8W-10-6)
(8W-10-14)
(8W-10-33)
(8W-10-7)
(8W-10-26)
(8W-10-14)
(8W-12-2)
(8W-10-14)
(8W-10-33)
(8W-15-11) (8W-12-31)
(8W-15-11)
(8W-15-11)
(8W-44-4)
(8W-12-32)
8W - 62 - 2 8W-62 POWER MIRRORS
LHD
XJ
J978W-7 XJI06201
BK
12
Z1
BK
12
Z1
OR/YL
20
P76
OR/YL
20
P76
4 2
MIRROR
POWER
LEFT
OR/YL
20
P76
OR/YL
20
P76
OR/YL
20
P76
10
36
28
S328
DB
20
P74
DB
20
P74
DB
20
P74
YL/BK
20
P72
YL/BK
20
P72
YL/BK
20
P72
BK
12
Z1
G302
S329
3 C307
S309
Z1
12
BK
P76
20
OR/YL
2 C5
10
C9
P72
20
YL/BK DB
20
P74
24
C201
20
34
C200
35
9
C305
8
9 C5
2
C9 C9
6
C5 10
BLOCK
JUNCTION
BATT M1
5
C2
OR/YL
20
P76 P76
20
OR/YL
S318
MIRROR
POWER
RIGHT
3 1
M M
4 DOWN
3 UP
2 RIGHT
1 LEFT
3 2
1 4
2
C2
2 1 1 2
4
C2 C2
7
0
0 REST
0
4 1
2 3 3 2
1 4
0
SWITCH
LEFT
FRONT
POWER
LOCK/
WINDOW
P76
20
OR/YL
P74
20
DB YL/BK
20
P72
2 4
(8W-62-2)
(8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-12-2)
(8W-10-14)
XJ 8W-62 POWER MIRRORS
LHD
8W - 62 - 3
XJI06202 J978W-7
BATT A0
MIRROR
POWER
RIGHT
3 1
A24
16
FUSE
15A
POWER
DISTRIBUTION
CENTER
M M
4 DOWN
3 UP
2 RIGHT
1 LEFT
3 2
1 4
2
C2
2 1 1 2
C2
6 1
C2
5
C2
3 C2
0 0 REST
0
4 1
2 3 3 2
1 4
0
A23
C4
S18
C1 12
BLOCK
JUNCTION
PK
20
M1
S214
SWITCH
RIGHT
FRONT
POWER
LOCK/
WINDOW
P76
20
OR/YL BK
12
Z1
DB
20
P74 P72
20
YL/BK
2 4
OR/YL
20
P76 P76
20
OR/YL
G107 S318
S319
S208
Z1
14
BK
M1
18
PK
DIESEL GAS
PK
20
M1
M1
20
PK PK
20
M1
S135
LAMP
UNDERHOOD
2
Z1
12
BK
(8W-10-6)
(8W-10-14)
(8W-10-33)
(8W-10-7)
(8W-10-26)
(8W-12-2)
(8W-10-14)
(8W-10-33)
(8W-15-8) (8W-12-31)
(8W-15-7)
(8W-15-8)
(8W-10-14)
(8W-44-4)
(8W-12-32)
8W - 62 - 4 8W-62 POWER MIRRORS
RHD
XJ
J978W-7 XJI06203
OR/YL
20
P76
P71
20
YL DB/WT
20
P75
P75
20
DB/WT YL
20
P71
P71
20
YL DB/WT
20
P75
BK
12
Z1
BK
12
Z1
G107
S319
S208
Z1
14
BK
2 4
OR/YL
20
P76
WINDOW
LOCK/
POWER
FRONT
RIGHT
SWITCH
0
4 1
2 3 3 2
1 4
0
0 REST
0
7
C2 C2
4
2 1 1 2
C2
2
4 1
2 3
1 LEFT
2 RIGHT
3 UP
4 DOWN
M M
1 3
LEFT
POWER
MIRROR
S328
OR/YL
20
P76 P76
20
OR/YL
C2
5
BATT M1
19
C204
18
8
C305
9
S318
10
20
P76
20
OR/YL
P76
20
OR/YL
RIGHT
POWER
MIRROR
2 4
P76
20
OR/YL
P76
20
OR/YL
(8W-15-8)
(8W-15-7)
(8W-15-8)
(8W-10-14)
(8W-62-4)
XJ 8W-62 POWER MIRRORS
RHD
8W - 62 - 5
XJI06204 J978W-7
8W-62 POWER MIRRORS
POWER MIRRORS
Two power mi rror systems are avai l abl e. One
power mi rror system i s used i f the vehi cl e i s al so
equi pped wi th power wi ndows and l ocks, and another
system i s used i f the vehi cl e i s not equi pped wi th
power wi ndows and l ocks.
Each power mi rror system uses a di fferent swi tch
and ci rcui ty; however, on both systems have a si ngl e
swi tch that operates both the l eft and ri ght power
mi rrors. Each mi rror has two motors; a LEFT/RI GHT
motor and a UP/DOWN motor. The motors swi tch
pol ari ty to al l ow mi rror adjustment.
Battery vol tage for each system i s suppl i ed on ci r-
cui t M1. Thi s i s the I gni ti on-Off Draw (I OD) ci rcui t
and protected by a 15 amp fuse l ocated i n the junc-
ti on bl ock.
Ci rcui t Z1 connects to the power mi rror swi tch and
suppl i es ground for the power mi rror system.
RIGHT POWER MIRROR OPERATION
WITH POWER WINDOWS AND LOCKS
I n the RI GHT posi ti on, the power mi rror swi tch
suppl i es power to the ri ght mi rror LEFT/RI GHT
motor on ci rcui t P74 when a RI GHTWARD adjust-
ment i s made. Ci rcui t P76 provi des the ground path
the for RI GHTWARD adjustments.
When the operator makes a LEFTWARD adjust-
ment, pol ari ty reverses. For LEFTWARD adjust-
ments, the swi tch suppl i es battery vol tage the ri ght
mi rror LEFT/RI GHT motor on ci rcui t P76. Ci rcui t
P74 suppl i es ground for LEFTWARD adjustments.
Duri ng UPWARD adjustments, the swi tch suppl i es
vol tage to the ri ght mi rror UP/DOWN motor on ci r-
cui t P72. Ci rcui t P76 suppl i es ground duri ng
UPWARD adjustments.
For DOWNWARD adjustments, the pol ari ty i s
reversed, the swi tch powers the ri ght mi rror
UP/DOWN motor on ci rcui t P76. Ci rcui t P72 suppl i es
the ground path.
WITHOUT POWER WINDOWS AND LOCKS
I n the RI GHT posi ti on, the power mi rror swi tch
suppl i es power to the ri ght mi rror LEFT/RI GHT
motor on ci rcui t P91 when a RI GHTWARD adjust-
ment i s made. Ci rcui t P74 provi des the ground path
the for RI GHTWARD adjustments.
When the operator makes a LEFTWARD adjust-
ment, pol ari ty reverses. For LEFTWARD adjust-
ments, the swi tch suppl i es battery vol tage the ri ght
mi rror LEFT/RI GHT motor on ci rcui t P74. Ci rcui t
P91 suppl i es ground for LEFTWARD adjustments.
vol tage to the ri ght mi rror UP/DOWN motor on ci r-
cui t P72. Ci rcui t P90 suppl i es ground duri ng
UPWARD adjustments.
reversed, the swi tch powers the ri ght mi rror
the ground path.
LEFT POWER MIRROR OPERATION
WITH POWER WINDOWS AND LOCKS
I n the LEFT posi ti on, the power mi rror swi tch sup-
pl i es power to the l eft mi rror LEFT/RI GHT motor on
ci rcui t P75 when a RI GHTWARD adjustment i s
made. Ci rcui t P76 provi des the ground path for the
RI GHTWARD adjustments.
When the operator makes LEFTWARD adjustment,
pol ari ty reverses. For LEFTWARD adjustments, the
swi tch suppl i es battery vol tage to the l eft mi rror
LEFT/RI GHT motor on ci rcui t P76. Ci rcui t P75 sup-
pl i es ground for LEFTWARD adjustments.
vol tage to the l eft mi rror UP/DOWN motor on ci rcui t
P71. Ci rcui t P76 suppl i es ground duri ng UPWARD
adjustments.
reversed, the swi tch powers the l eft mi rror
the ground path.
WITHOUT POWER WINDOWS AND LOCKS
I n the LEFT posi ti on, the power mi rror swi tch sup-
pl i es power to the l eft mi rror LEFT/RI GHT motor on
ci rcui t P91 when a RI GHTWARD adjustment i s
made. Ci rcui t P75 provi des the ground path the for
RI GHTWARD adjustments.
When the operator makes LEFTWARD adjustment,
pol ari ty reverses. For LEFTWARD adjustments, the
swi tch suppl i es battery vol tage to the l eft mi rror
LEFT/RI GHT motor on ci rcui t P775. Ci rcui t P91 sup-
pl i es ground for LEFTWARD adjustments.
vol tage to the l eft mi rror UP/DOWN motor on ci rcui t
P71. Ci rcui t P90 suppl i es ground duri ng UPWARD
adjustments.
reversed, the swi tch powers the l eft mi rror
the ground path.
HELPFUL INFORMATION
Check the I OD fuse i n cavi ty 16 of the juncti on
bl ock
8W - 62 - 6 8W - 62 POWER MIRRORS XJ
Ci rcui t M1 suppl i es vol tage to the radi o memory,
l amp, underhood l amp, dome l amp, overhead consol e
l amps and gl ove box l amp. Check for proper opera-
ti on of these i tems.
Move the swi tch to i ts vari ous posi ti ons and l i s-
ten for the motors to cl i ck or try to move. Some
movement or cl i cki ng i ndi cates a poor connecti on or a
mechani cal probl em wi th a mi rror.
HEATER ELEMENTS
The rear wi ndow defogger rel ay powers the heater
el ements i n power mi rrors. When the rel ay energi zes,
i t suppl i es power to the heater el ements on ci rcui t
C15. Ci rcui t Z1 provi des ground for the power mi rror
heater el ements.
HELPFUL INFORMATION
Ci rcui t F82 from fuse 2 i n the fuse bl ock powers
ci rcui t C15 when the rear wi ndow defogger rel ay
energi zes.
Center (PDC) suppl i es battery vol tage to the fuse
bl ock for fuse 2 and ci rcui t F82.
Check fuse 2 i n the fuse bl ock.
Check fuse 3 i n the PDC.
XJ 8W - 62 POWER MIRRORS 8W - 62 - 7
8W-63 POWER SEAT
INDEX
page
Component Page
Dri ver Power Seat Motor . . . . . . . . . . . . . . . .8W-63-2
Dri ver Power Seat Swi tch . . . . . . . . . . . . .8W-63-2, 3
Forward/Rearward Motor . . . . . . . . . . . . .8W-63-2, 3
Front Motor . . . . . . . . . . . . . . . . . . . . . . . .8W-63-2, 3
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-2, 3
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . .8W-63-2, 3
Passenger Power Seat Motor . . . . . . . . . . . . .8W-63-3
Passenger Power Seat Swi tch . . . . . . . . . .8W-63-2, 3
Rear Motor . . . . . . . . . . . . . . . . . . . . . . . .8W-63-2, 3
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-63-2, 3
XJ 8W - 63 POWER SEAT 8W - 63 - 1
2
BLOCK
JUNCTION
25A
29
BREAKER
CIRCUIT
Z1
14
BK
2 C316
Z1
12
BK
G303
F37
14
RD/LB
BATT A7
POWER
SEAT
SWITCH
E
1
M J N K L 2
1 2 4 3 5 6
P19
16
YL/LG
P21
16
RD/LG
P11
16
YL/WT
P13
16
RD/WT
P15
16
YL/LB
P17
16
RD/LB
FORWARD/
REARWARD
MOTOR
MOTOR
FRONT REAR
MOTOR
MOTOR
SEAT
POWER
C6
1 FRONT UP
2 FRONT DOWN
3 REAR UP
4 REAR DOWN
5 FORWARD
6 REARWARD
C2 C2 C2 C2 C2 C2 C1
C1
C316 1
RD/LB
14
F37
DRIVER
PASSENGER
SWITCH
SEAT
POWER
C1 1
RD/LB
14
F37
POWER
SEAT
SWITCH
PASSENGER
C1
2
BK
14
Z1
DRIVER
BK
16
Z1
S310
M M M
(8W-12-2)
(8W-12-25)
(8W-10-11)
(8W-63-3)
(8W-63-3)
(8W-15-13)
(8W-15-14)
8W - 63 - 2 8W-63 POWER SEATS XJ
J978W-7 XJI06301
2
BLOCK
JUNCTION
25A
29
BREAKER
CIRCUIT
Z1
14
BK
2 C316
Z1
12
BK
G303
F37
14
RD/LB
BATT A7
POWER
SEAT
SWITCH
J
1
N E M L K 2
1 2 4 3 5 6
P18
16
YL/LG
P20
16
RD/LG
P10
16
YL/WT
P12
16
RD/WT
P14
16
YL/LB
P16
16
RD/LB
FORWARD/
REARWARD
MOTOR
MOTOR
FRONT REAR
MOTOR
MOTOR
SEAT
POWER
C6
1 FRONT UP
2 FRONT DOWN
3 REAR UP
4 REAR DOWN
5 FORWARD
6 REARWARD
C2 C2 C2 C2 C2 C2 C1
C1
C316 1
RD/LB
14
F37
PASSENGER
DRIVER
SWITCH
SEAT
POWER
C1 1
RD/LB
14
F37
POWER
SEAT
SWITCH
DRIVER
C1
2
BK
14
Z1
PASSENGER
BK
16
Z1
S310
M M M
(8W-12-2)
(8W-12-25)
(8W-10-11)
(8W-63-2)
(8W-63-2)
(8W-15-13)
(8W-15-14)
XJ 8W-63 POWER SEATS 8W - 63 - 3
XJI06302 J978W-7
8W-63 POWER SEAT
POWER SEAT OPERATION
Battery vol tage for the power seat system i s sup-
pl i ed by ci rcui t A7 from fuse 4 i n the Power Di stri -
buti on Center (PDC). Ci rcui t A7 connects to ci rcui t
F37 through a ci rcui t breaker i n cavi ty 29 of the
juncti on bl ock. Ci rcui t F37 connects to the power seat
swi tch.
A bus bar i nternal to the power seat swi tch con-
nects the power from ci rcui t F37 to the swi tches.
Groundi ng for the seat system i s suppl i ed on ci rcui t
Z1.
The motors l ocated under the seat are protected by
ci rcui t breakers wi red i n wi th the motors. Each
motor has i ts own ci rcui t breaker.
When the operator sel ects the FRONT UP func-
ti on, power i s passed on the F37 ci rcui t through the
CLOSED contacts i n the swi tch to the P19 ci rcui t.
The P19 ci rcui t connects to the motor. Ground i s pro-
vi ded on the P21 ci rcui t back to the swi tch. A ground
bus bar i nternal to the swi tch then connects to the
Z1 ground ci rcui t.
For FRONT DOWN functi on the ci rcui ts are
reversed. P21 i s the feed and P19 i s the ground.
When the operator sel ects the SEAT FORWARD
functi on, power i s passed on the F37 ci rcui t through
the CLOSED contacts i n the swi tch to the P15 ci r-
cui t. The P15 ci rcui t connects to the motor. Ground i s
provi ded on the P17 ci rcui t back to the swi tch. A
ground bus bar i nternal to the swi tch then connects
to the Z1 ground ci rcui t.
For SEAT REARWARD functi on the ci rcui ts are
When the operator sel ects the REAR UP functi on,
power i s passed on the F37 ci rcui t through the
CLOSED contacts i n the swi tch to the P11 ci rcui t.
The P11 ci rcui t connects to the motor. Ground i s pro-
vi ded on the P13 ci rcui t back to the swi tch. A ground
bus bar i nternal to the swi tch then connects to the
Z1 ground ci rcui t.
For REAR DOWN functi on the ci rcui ts are
When the operator sel ects the SEAT UP functi on
power i s passed on the F37 ci rcui t through the
CLOSED contacts i n the swi tch to the P11 and P19
ci rcui ts. The P11 ci rcui t connects to the REAR UP
motor, and P19 connects to the FRONT UP motor.
Ground i s provi ded on the P13 and P21 ci rcui ts back
to the swi tch. A ground bus bar i nternal to the swi tch
then connects to the Z1 ground ci rcui t.
For SEAT DOWN functi on the ci rcui ts are
reversed. P13 and P21 ci rcui ts are the feeds and P11
and P19 are the grounds.
HELPFUL INFORMATION
Check the ci rcui t breaker l ocated i n cavi ty 29 of
the juncti on bl ock
8W - 63 - 4 8W - 63 POWER SEAT XJ
8W-70 SPLICE INFORMATION
Component Page
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2, 3
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
S149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3
Component Page
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-706
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2, 3
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5
S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7
XJ 8W - 70 SPLICE INFORMATION 8W - 70 - 1
S111
BR/YL
18
K167 K167
18
BR/YL
K167
18
BR/YL
K167
20
BR/YL
K167
18
BR/YL
K167
20
BR/YL
A4
POWERTRAIN
CONTROL
MODULE
C1
SENSOR
POSITION
CAMSHAFT
2 2
K167
20
BR/YL
S114
3 C107
1
OIL
PRESSURE
SENSOR OXYGEN
HEATED
DOWNSTREAM
1
SENSOR
K167
20
BR/YL BR/YL
20
K167
BR/YL
20
K167
BR/YL
20
K167
BR/YL
20
K167
BR/YL
20
K167
1
AIR
TEMPERATURE
SENSOR
INTAKE
CRANKSHAFT
SENSOR
POSITION
2
VEHICLE
SPEED
SENSOR
SENSOR
1
MANIFOLD
ABSOLUTE
PRESSURE
1
POSITION
SENSOR
THROTTLE
COOLANT
SENSOR
TEMPERATURE
1
SENSOR
1
UPSTREAM
HEATED
OXYGEN
BR/YL
20
K167
S138
K167
20
BR/YL
MODULE
CONTROL
TRANSMISSION
16
C100 B6 B3 C100
SENSOR
TEMPERATURE
BATTERY
2
BR/YL
20
K167
C204 17 30 C200
BR/YL
20
K167
5
FUEL
MODULE
PUMP
K167
20
BR/YL
LHD RHD
BR/YL
20
K167
(A/T)
CLOCKSPRING
3
SWITCH
CONTROL
SPEED
LEFT
1 1
RIGHT
SPEED
CONTROL
SWITCH
A
BK/YL
20
K167
S222
RHD LHD
BK/RD
20
K4 K4
20
BK/LB
ENGINE
(8W-30-5)
(8W-30-8)
(8W-30-9)
(8W-30-10)
(8W-30-5)
(8W-30-10)
(8W-30-8)
(8W-30-7)
(8W-30-5)
(8W-30-9)
(8W-30-9)
(8W-30-7)
(8W-30-7)
(8W-30-8)
(8W-30-10)
(8W-30-3)
(8W-30-4)
(8W-31-3)
(8W-30-10) (8W-33-2)
8W - 70 - 2 8W-70 SPLICE DETAILS
GAS
XJ
J978W-7 XJI07001
S138
BR/YL
20
K167 K167
20
BR/YL
K167
BR/YL
K167
20
BR/YL
K167
BR/YL
K167
BR/YL
POWERTRAIN
CONTROL
MODULE
2
B3 C100
1
OIL
PRESSURE
SENSOR
LOW
COOLANT
SWITCH
C204 17 30 C200
BR/YL
20
K167
5
FUEL
MODULE
PUMP
K167
20
BR/YL
LHD RHD
20 20 20
C2
4
C110 8
FUEL
IN
WATER
2
SENSOR
BR/YL
18
K167
2
VEHICLE
SPEED
SENSOR
S149
K4
20
BK/LB
3
PEDAL
ACCELERATOR
4
SENSOR
2
MASS
AIR
FLOW
33
CONTROL
MODULE
POWERTRAIN
CLOCKSPRING
3
SWITCH
CONTROL
SPEED
LEFT
1
BK/LB
20
K4
BK/LB
20
K4
BK/LB
20
K4
BK/LB
20
K4
BK/LB
20
K4
FUEL
PUMP
C1
C100 B6
K4
20
BK/LB
9 C120
S117
BK/LB
20
K4
COOLANT
SENSOR
TEMPERATURE
B
MODULE
1
RIGHT
SPEED
CONTROL
SWITCH
A
BK/YL
20
K167
S222
RHD LHD
BK/RD
20
K4 K4
20
BK/LB
ENGINE
(8W-30-21)
(8W-30-22)
(8W-30-24)
(8W-30-27)
(8W-30-27)
(8W-30-27)
(8W-30-21)
(8W-30-22)
(8W-30-27)
(8W-30-24)
(8W-30-23)
(8W-30-22)
(8W-30-21)
(8W-30-22)
(8W-30-23)
(8W-30-24)
(8W-33-4)
(8W-30-24)
(8W-30-21)
(8W-30-22)
(8W-33-4)
XJ 8W-70 SPLICE DETAILS
DIESEL
8W - 70 - 3
XJI07002 J978W-7
S212
TN
20
L60
1
L60
20
TN
L60
20
TN
SWITCH
HAZARD
SIGNAL/
TURN
(PART OF
MULTI-
FUNCTION
SWITCH)
C2 6
INSTRUMENT
CLUSTER
B9 C100
TN
20
L60
C106 10
L60
20
TN
TN
18
L60
S100
L60
20
TN
2
RIGHT
3
LAMP
SIGNAL
TURN
FRONT
RIGHT
RIGHT
FRONT
TURN
SIGNAL
LAMP
3
L60
18
TN LG
18
L61
3
LAMP
SIGNAL
TURN
FRONT
LEFT
LEFT
FRONT
TURN
SIGNAL
LAMP
3
LEFT
REPEATER
LAMP
2
LG
20
L61
S105
L61
18
LG
LG
20
L61
3 C106
L61
20
LG/WT
C100 B10
CLUSTER
INSTRUMENT
10 C1
SWITCH)
FUNCTION
MULTI-
(PART OF
TURN
SIGNAL/
HAZARD
SWITCH
LG/WT
20
L61
LG/WT
20
L61
10
L61
20
LG/WT
S209
LAMP
REPEATER
(8W-52-2)
(8W-52-3)
(8W-40-14)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
(8W-40-14)
(8W-52-2)
(8W-52-3)
(8W-50-5)
(8W-50-6)
(8W-50-5)
(8W-50-6)
8W - 70 - 4 8W-70 SPLICE DETAILS XJ
J978W-7 XJI07003
TOW
TRAILER
BK/RD
20
L62
1
RIGHT
TURN
RELAY
OTHERS
LAMP
SIGNAL
TURN
LEFT
2 2
RIGHT
TURN
SIGNAL
LAMP
POSITION
SENSOR
THROTTLE
ABSOLUTE
SENSOR
PRESSURE
MANIFOLD
CRANKSHAFT
SENSOR
POSITION
POWERTRAIN
MODULE
CONTROL
C1
A17
K7
20
OR
K7
20
OR
K7
20
OR
K7
18
OR
3
3
3
1
POSITION
SENSOR
CAMSHAFT
OR
18
K7
S115
L62
18
BK/RD
L62
18
BK/RD
1 C321 C322 8
BK/RD
18
L62
BR/RD
18
L62
7 C204 C200 25
RHD LHD
SWITCH)
FUNCTION
MULTI-
(PART OF
TURN
SIGNAL/
HAZARD
SWITCH
BK/RD
18
L62
BK/RD
18
L62
3
L62
20
BR/RD
S312
(8W-54-2)
(8W-54-3)
(8W-51-4) (8W-51-4)
(8W-30-7)
(8W-30-9)
(8W-30-5)
(8W-30-25)
(8W-30-5)
(8W-30-7)
(8W-30-9)
(8W-30-25)
(8W-30-5)
(8W-52-2)
(8W-52-3)
XJ 8W-70 SPLICE DETAILS 8W - 70 - 5
XJI07004 J978W-7
C1
9
4 C2 C4 M3
SWITCH
HEADLAMP
10A
FUSE
7 23
FUSE
10A
JUNCTION
BLOCK
RADIO
L7
18
BK/YL
L7
18
BK/YL
45 C201
LHD RHD
L7
18
BK/YL
S206
18
V20
2
BK/WT
REAR
WIPER/
WASHER
BK/WT
18
V20
A17 C100
BK/WT
18
V20
RHD LHD
S205
28 C200 C203 18
V20
18
VT/OR
G C308
3 C312
1 C310
V20
18
BK/WT
2
REAR
WIPER
MOTOR
V20
18
BK/WT
1
MOTOR
PUMP
WASHER
REAR
SWITCH
(8W-50-2)
(8W-50-3)
(8W-12-10) (8W-12-22)
(8W-12-2)
(8W-47-2)
(8W-53-3)
(8W-53-3)
(8W-53-3)
8W - 70 - 6 8W-70 SPLICE DETAILS XJ
J978W-7 XJI07005
BR/LG
18
L10
18
TRANSMISSION
CONTROL
MODULE
S142
6
TRANSMISSION
RANGE
SWITCH
L10
18
BR/LG
BR/LG
18
L10
C100 A15
L10
18
BR/LG
16 C200 C205 5
TRAILER TOW OTHERS
BR/LG
18
L10
L10
18
BR/LG BR/LG
18
L10
5 C321 C322 5
S303
BR/LG
18
L10 L10
18
BR/LG
L10
18
BR/LG
S339
BR/LG
18
L10
5 C323
BR/LG
18
L10
7
2
2
LEFT
BACK-UP
LAMP
LAMP
BACK-UP
RIGHT
TRAILER
TOW
CONNECTOR
(8W-31-3)
(8W-51-5)
(8W-51-5)
(8W-54-2)
(8W-54-3)
(8W-31-3)
XJ 8W-70 SPLICE DETAILS 8W - 70 - 7
XJI07006 J978W-7
8W-80 CONNECTOR PIN-OUTS
Component Page
4WD Swi tch (231) . . . . . . . . . . . . . . . . . . . . .8W-80-4
4WD Swi tch (242) . . . . . . . . . . . . . . . . . . . . .8W-80-4
A/C Compressor Cl utch . . . . . . . . . . . . . . . . .8W-80-4
A/C Heater Control (LHD). . . . . . . . . . . . . . .8W-80-4
A/C Heater Control (RHD) . . . . . . . . . . . . . .8W-80-4
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . .8W-80-5
A/C Low Pressure Swi tch (Di esel ). . . . . . . . .8W-80-5
A/C Low Pressure Swi tch (LHD). . . . . . . . . .8W-80-5
A/C Low Pressure Swi tch (2.5L M/T RHD) . .8W-80-5
A/C Low Pressure Swi tch (RHD, Al l Others).8W-80-5
Ai rbag Control Modul e (LHD). . . . . . . . . . . .8W-80-6
Ai rbag Control Modul e (RHD). . . . . . . . . . . .8W-80-6
Al ternator . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-7
Ambi ent Temperature Sensor . . . . . . . . . . . .8W-80-7
Back-Up Lamp Swi tch (M/T). . . . . . . . . . . . .8W-80-7
Battery Temperature Sensor . . . . . . . . . . . . .8W-80-7
Beam Sel ect Swi tch (LHD) . . . . . . . . . . . . . .8W-80-7
Beam Sel ect Swi tch (RHD) . . . . . . . . . . . . . .8W-80-8
Brake Pressure Swi tch . . . . . . . . . . . . . . . . .8W-80-8
Brake Shi ft I nterl ock Sol enoi d (LHD) . . . . . .8W-80-8
Brake Shi ft I nterl ock Sol enoi d (RHD) . . . . . .8W-80-8
C100 (LHD, 2.5L Di esel ) . . . . . . . . . . . . . . . .8W-80-9
C100 (LHD, 4.0L, A/T, Fog, Amp,
Headl amp Level i ng). . . . . . . . . . . . . . . . .8W-80-11
C100 (LHD, 4.0L, M/T, ABS, DRL) . . . . . . .8W-80-13
C100 (LHD, A/T, ABS, DRL) . . . . . . . . . . . .8W-80-15
C100 (RHD, 2.5L, M/T) . . . . . . . . . . . . . . . .8W-80-17
C100 (RHD, 4.0L, A/T, ABS) . . . . . . . . . . . .8W-80-19
C100 (RHD, VM Di esel ). . . . . . . . . . . . . . . .8W-80-21
C102 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-23
C103 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-23
C104 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-23
C106 (2.5L, Di esel ) . . . . . . . . . . . . . . . . . . .8W-80-24
C106 (4.0L, DRL). . . . . . . . . . . . . . . . . . . . .8W-80-24
C106 (4.0L, DRL, Fog Lamps) . . . . . . . . . . .8W-80-25
C106 (Al l Others W/Fog Lamps) . . . . . . . . .8W-80-25
C106 (Al l Others) . . . . . . . . . . . . . . . . . . . .8W-80-25
C107 (Di esel ). . . . . . . . . . . . . . . . . . . . . . . .8W-80-26
C107 (2.5L M/T 231,2WD). . . . . . . . . . . . . .8W-80-26
C107 (2.5L M/T 231,2WD W/DRL). . . . . . . .8W-80-26
C107 (4.0L A/T 231,242) . . . . . . . . . . . . . . .8W-80-27
C107 (4.0L A/T 231,242,DRL) . . . . . . . . . . .8W-80-27
C107 (4.0L A/T 2WD). . . . . . . . . . . . . . . . . .8W-80-27
C107 (4.0L A/T 2WD DRL) . . . . . . . . . . . . .8W-80-28
C107 (4.0L M/T 231,242) . . . . . . . . . . . . . . .8W-80-28
C107 (4.0L M/T 2WD) . . . . . . . . . . . . . . . . .8W-80-28
C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-29
C109 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-29
C109 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-29
C110 (Di esel ) . . . . . . . . . . . . . . . . . . . . . . . .8W-80-29
C200 (LHD, Ful l Opti ons) . . . . . . . . . . . . . .8W-80-30
C200 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-30
Component Page
C201 (LHD Base) . . . . . . . . . . . . . . . . . . . .8W-80-31
C201 (LHD Ful l Opti ons) . . . . . . . . . . . . . .8W-80-32
C202 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-34
C203 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-34
C204 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-34
C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-35
C206 (A/T). . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-35
C206 (M/T) . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-35
C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-35
C208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-36
C300 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-36
C301 (W/Vani ty Lamps). . . . . . . . . . . . . . . .8W-80-36
C301 (W/I mmobi l i zer) . . . . . . . . . . . . . . . . .8W-80-36
C302 (W/I mmobi l i zer) . . . . . . . . . . . . . . . . .8W-80-36
C303 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-37
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-37
C305 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-37
C305 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-37
C306 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
C306 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
C307 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
C307 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
C308 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-38
C308 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
C310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
C312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-39
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-40
C314 (Wi th Sound Bar) . . . . . . . . . . . . . . . .8W-80-40
C315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-40
C316 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-40
C316 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-40
C317 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-41
C317 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-41
C318 (LHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-41
C318 (RHD). . . . . . . . . . . . . . . . . . . . . . . . .8W-80-41
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-41
C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-41
C321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-42
C322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-42
Camshaft Posi ti on Sensor . . . . . . . . . . . . . .8W-80-42
Cargo Lamp (Al l Others). . . . . . . . . . . . . . .8W-80-42
Cargo Lamp (Wi th Sound Bar) . . . . . . . . . .8W-80-42
Center Hi gh Mounted Stop Lamp . . . . . . . .8W-80-43
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . .8W-80-43
Cl ock Spri ng (LHD). . . . . . . . . . . . . . . . . . .8W-80-43
Cl ock Spri ng (RHD). . . . . . . . . . . . . . . . . . .8W-80-43
Cl utch I nterl ock Swi tch (RHD M/T) . . . . . .8W-80-43
Cl utch I nterl ock Swi tch (RHD, M/T) . . . . . .8W-80-44
Cl utch I nterl ock Swi tch Jumper (RHD, A/T).8W-80-44
XJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1
Component Page
Combi nati on Fl asher (Wi th Li ghted Vi sor) .8W-80-44
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-44
Consol e I l l umi nati on . . . . . . . . . . . . . . . . . .8W-80-44
Control l er Anti -Lock Brake (LHD). . . . . . . .8W-80-45
Control l er Anti -Lock Brake (RHD) . . . . . . .8W-80-45
Cool ant Temperature Sensor (Di esel ) . . . . .8W-80-46
Crankshaft Posi ti on Sensor . . . . . . . . . . . . .8W-80-46
Crankshaft Posi ti on Sensor (Di esel ) . . . . . .8W-80-46
Data Li nk Connector . . . . . . . . . . . . . . . . . .8W-80-46
Dayti me Runni ng Lamp Modul e . . . . . . . . .8W-80-47
Di agnosti cs Spl i ce Bl ock . . . . . . . . . . . . . . .8W-80-47
Dome Lamp (W/Vani ty Lamps, I mmobi l i zer).8W-80-47
Downstream Heated Oxygen Sensor . . . . . .8W-80-47
Dri ver Ai rbag. . . . . . . . . . . . . . . . . . . . . . . .8W-80-48
EGR Sol enoi d (Di esel ) . . . . . . . . . . . . . . . . .8W-80-48
Engi ne Cool ant Temperature Sensor . . . . . .8W-80-48
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . .8W-80-48
Evap/Purge Sol enoi d . . . . . . . . . . . . . . . . . .8W-80-48
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . .8W-80-48
Front Washer Pump Motor . . . . . . . . . . . . .8W-80-49
Front Wi per Motor. . . . . . . . . . . . . . . . . . . .8W-80-49
Fuel Heater (Di esel ) . . . . . . . . . . . . . . . . . .8W-80-49
Fuel Pump Modul e (Di esel ) . . . . . . . . . . . . .8W-80-49
Fuel Pump Modul e (LHD) . . . . . . . . . . . . . .8W-80-50
Fuel Pump Modul e (RHD). . . . . . . . . . . . . .8W-80-50
G Swi tch (LHD). . . . . . . . . . . . . . . . . . . . . .8W-80-50
Generator . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-50
Gl ove Box Lamp Swi tch . . . . . . . . . . . . . . .8W-80-50
Gl ow Pl ug Rel ay (Di esel ). . . . . . . . . . . . . . .8W-80-51
Headl amp Del ay Modul e (LHD) . . . . . . . . .8W-80-51
Headl amp Del ay Modul e (RHD) . . . . . . . . .8W-80-51
Headl amp Level i ng Swi tch (RHD). . . . . . . .8W-80-51
Headl amp Swi tch C1 (LHD) . . . . . . . . . . . .8W-80-52
Headl amp Swi tch C1 (RHD) . . . . . . . . . . . .8W-80-52
Headl amp Swi tch (C2). . . . . . . . . . . . . . . . .8W-80-52
HVAC Uni t (LHD) . . . . . . . . . . . . . . . . . . . .8W-80-52
HVAC Uni t (RHD). . . . . . . . . . . . . . . . . . . .8W-80-53
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . .8W-80-53
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . .8W-80-53
I gni ti on Swi tch (LHD). . . . . . . . . . . . . . . . .8W-80-53
I gni ti on Swi tch (RHD). . . . . . . . . . . . . . . . .8W-80-53
I njector No. 1. . . . . . . . . . . . . . . . . . . . . . . .8W-80-54
I njector No. 2. . . . . . . . . . . . . . . . . . . . . . . .8W-80-54
I njector No. 3. . . . . . . . . . . . . . . . . . . . . . . .8W-80-54
I njector No. 4. . . . . . . . . . . . . . . . . . . . . . . .8W-80-54
I njector No. 5. . . . . . . . . . . . . . . . . . . . . . . .8W-80-54
I njector No. 6. . . . . . . . . . . . . . . . . . . . . . . .8W-80-54
I nstrument Cl uster-C1 (LHD) . . . . . . . . . . .8W-80-55
I nstrument Cl uster-C1 (RHD) . . . . . . . . . . .8W-80-55
I nstrument Cl uster-C2 . . . . . . . . . . . . . . . .8W-80-55
I ntake Ai r Temperature Sensor . . . . . . . . . .8W-80-55
Juncti on Bl ock - C1 . . . . . . . . . . . . . . . . . . .8W-80-56
Component Page
Key-I n Swi tch . . . . . . . . . . . . . . . . . . . . . . .8W-80-58
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . .8W-80-58
Left Courtesy Lamp. . . . . . . . . . . . . . . . . . .8W-80-58
Left Fog Lamp. . . . . . . . . . . . . . . . . . . . . . .8W-80-59
Left Front Door Jamb Swi tch . . . . . . . . . . .8W-80-59
Left Front Door Speaker (LHD). . . . . . . . . .8W-80-59
Left Front Door Speaker (RHD) . . . . . . . . .8W-80-59
Left Front Door Tweeter (LHD). . . . . . . . . .8W-80-59
Left Front Door Tweeter (RHD). . . . . . . . . .8W-80-59
Left Front Power Door Lock Motor (LHD). .8W-80-60
Swi tch-C1 (LHD). . . . . . . . . . . . . . . . . . .8W-80-60
Swi tch-C2 (LHD). . . . . . . . . . . . . . . . . . .8W-80-60
Left Front Power Wi ndow Motor (LHD) . . .8W-80-60
Left Front Si de Marker Lamp . . . . . . . . . . .8W-80-60
Left Front Wheel Speed Sensor (LHD) . . . .8W-80-61
Left Front Wheel Speed Sensor (RHD) . . . .8W-80-61
Left Headl amp. . . . . . . . . . . . . . . . . . . . . . .8W-80-61
Left Park Lamp . . . . . . . . . . . . . . . . . . . . . .8W-80-61
Left Power Mi rror . . . . . . . . . . . . . . . . . . . .8W-80-61
Left Power Seat . . . . . . . . . . . . . . . . . . . . . .8W-80-62
Left Rear Door Jamb Swi tch . . . . . . . . . . . .8W-80-62
Left Rear Power Door Lock Motor . . . . . . . .8W-80-62
Left Rear Power Wi ndow Motor. . . . . . . . . .8W-80-62
Left Rear Power Wi ndow Swi tch . . . . . . . . .8W-80-62
Left Rear Si de Marker Lamp. . . . . . . . . . . .8W-80-63
Left Rear Turn Si gnal Lamp . . . . . . . . . . . .8W-80-63
Left Rear Wheel Speed Sensor (LHD) . . . . .8W-80-63
Left Rear Wheel Speed Sensor (RHD) . . . . .8W-80-63
Left Sound Bar Speaker . . . . . . . . . . . . . . .8W-80-63
Left Speaker (Wi th Sound Bar) . . . . . . . . . .8W-80-63
Left Tai l /Stop Lamp. . . . . . . . . . . . . . . . . . .8W-80-64
Left Turn Jumper . . . . . . . . . . . . . . . . . . . .8W-80-64
Left Turn Si gnal . . . . . . . . . . . . . . . . . . . . .8W-80-64
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-80-64
Li ftgate Jamb Swi tch . . . . . . . . . . . . . . . . .8W-80-64
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . .8W-80-65
Low Cool ant Sensor (Di esel ) . . . . . . . . . . . .8W-80-65
Low Washer Fl ui d Level Swi tch . . . . . . . . .8W-80-65
Mani fol d Absol ute Pressure Sensor . . . . . . .8W-80-65
Mass Ai r Fl ow Sensor (Di esel ). . . . . . . . . . .8W-80-65
MSA Control l er (Di esel ). . . . . . . . . . . . . . . .8W-80-66
Needl e Movement Sensor (Di esel ) . . . . . . . .8W-80-67
Oi l Pressure Swi tch (Di esel ) . . . . . . . . . . . .8W-80-67
Overhead Modul e (Wi th I mmobi l i zer) . . . . .8W-80-67
Park Brake Swi tch (LHD) . . . . . . . . . . . . . .8W-80-68
Park Brake Swi tch (RHD). . . . . . . . . . . . . .8W-80-68
8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS XJ
Component Page
Passenger Ai r Bag . . . . . . . . . . . . . . . . . . . .8W-80-68
Pedal Posi ti on Sensor (Di esel ). . . . . . . . . . .8W-80-68
Power Ampl i fi er-C1 . . . . . . . . . . . . . . . . . . .8W-80-68
Power Ampl i fi er-C2 (LHD) . . . . . . . . . . . . .8W-80-69
Power Ampl i fi er C2 (RHD) . . . . . . . . . . . . .8W-80-69
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . .8W-80-69
Power Steeri ng Pressure Swi tch (2.5L) . . . .8W-80-69
Powertrai n Control Modul e - C1 . . . . . . . . .8W-80-70
Powertrai n Control Modul e - C1 (Di esel ). . .8W-80-71
Powertrai n Control Modul e - C2 . . . . . . . . .8W-80-72
Powertrai n Control Modul e - C3
(2.5L, RHD, M/T). . . . . . . . . . . . . . . . . . .8W-80-73
Powertrai n Control Modul e - C3
(Al l Others) . . . . . . . . . . . . . . . . . . . . . . .8W-80-74
PRNDL Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-80-75
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . .8W-80-75
Radi o-C1 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75
Radi o-C2 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75
Radi o-C3 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-75
Rear Door Jamb Swi tch (LHD) . . . . . . . . . .8W-80-76
Rear Door Jamb Swi tch (RHD) . . . . . . . . . .8W-80-76
Rear Fog Lamp Rel ay . . . . . . . . . . . . . . . . .8W-80-76
Rear Fog Lamp Swi tch . . . . . . . . . . . . . . . .8W-80-76
Rear Washer Pump Motor (2.5L, Di esel ) . . .8W-80-76
Rear Washer Pump Motor (Al l Others) . . . .8W-80-77
Rear Wi ndow Defogger - C1. . . . . . . . . . . . .8W-80-77
Rear Wi ndow Defogger - C2. . . . . . . . . . . . .8W-80-77
Rear Wi ndow Defogger Swi tch . . . . . . . . . .8W-80-77
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . .8W-80-77
Rear Wi per Swi tch. . . . . . . . . . . . . . . . . . . .8W-80-78
Ri ght Back-Up Lamp. . . . . . . . . . . . . . . . . .8W-80-78
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . .8W-80-78
Ri ght Fog Lamp. . . . . . . . . . . . . . . . . . . . . .8W-80-78
Ri ght Front Door Jamb Swi tch . . . . . . . . . .8W-80-79
Ri ght Front Door Speaker (LHD) . . . . . . . .8W-80-79
Ri ght Front Door Speaker (RHD) . . . . . . . .8W-80-79
Ri ght Front Door Tweeter (LHD). . . . . . . . .8W-80-79
Ri ght Front Door Tweeter (RHD) . . . . . . . .8W-80-79
Ri ght Front Power Door Lock
Motor (LHD) . . . . . . . . . . . . . . . . . . . . . .8W-80-80
Swi tch-C1 (LHD). . . . . . . . . . . . . . . . . . .8W-80-80
Swi tch-C1 (RHD). . . . . . . . . . . . . . . . . . .8W-80-80
Swi tch-C2 (LHD) . . . . . . . . . . . . . . . . . .8W-80-80
Swi tch-C2 (RHD). . . . . . . . . . . . . . . . . . .8W-80-81
Component Page
Ri ght Front Power Wi ndow Motor . . . . . . . .8W-80-81
Ri ght Front Si de Marker Lamp . . . . . . . . . .8W-80-81
Ri ght Front Wheel Speed Sensor (LHD) . . .8W-80-81
Ri ght Front Wheel Speed Sensor (RHD) . . .8W-80-81
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . .8W-80-82
Ri ght Park Lamp. . . . . . . . . . . . . . . . . . . . .8W-80-82
Ri ght Power Mi rror (LHD) . . . . . . . . . . . . .8W-80-82
Ri ght Power Mi rror (RHD) . . . . . . . . . . . . .8W-80-82
Ri ght Power Seat (Wi th ECE) . . . . . . . . . . .8W-80-82
Ri ght Rear Door Jamb Swi tch . . . . . . . . . . .8W-80-83
Ri ght Rear Power Door Lock Motor . . . . . . .8W-80-83
Ri ght Rear Power Wi ndow Motor . . . . . . . .8W-80-83
Ri ght Rear Power Wi ndow Swi tch . . . . . . . .8W-80-83
Ri ght Rear Si de Marker Lamp . . . . . . . . . .8W-80-83
Ri ght Rear Turn Si gnal Lamp . . . . . . . . . . .8W-80-84
Ri ght Rear Wheel Speed Sensor (LHD) . . . .8W-80-84
Ri ght Rear Wheel Speed Sensor (RHD). . . .8W-80-84
Ri ght Sound Bar Speaker . . . . . . . . . . . . . .8W-80-84
Ri ght Speaker (Wi th Sound Bar). . . . . . . . .8W-80-84
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . .8W-80-85
Ri ght Turn Jumper . . . . . . . . . . . . . . . . . . .8W-80-85
Ri ght Turn Si gnal . . . . . . . . . . . . . . . . . . . .8W-80-85
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . .8W-80-85
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-85
Stop Lamp Swi tch (LHD) . . . . . . . . . . . . . .8W-80-86
Stop Lamp Swi tch (RHD) . . . . . . . . . . . . . .8W-80-86
Tel l Tal e Modul e (Di esel ). . . . . . . . . . . . . . .8W-80-86
Throttl e Posi ti on Sensor (4.0L 2WD). . . . . .8W-80-86
Throttl e Posi ti on Sensor (Al l Others) . . . . .8W-80-87
Tracti on Control Swi tch. . . . . . . . . . . . . . . .8W-80-87
Trai l er Tow El ectri c Brake. . . . . . . . . . . . . .8W-80-87
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . .8W-80-87
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . .8W-80-87
Transmi ssi on Control Modul e . . . . . . . . . . .8W-80-88
Transmi ssi on Control Sol enoi ds. . . . . . . . . .8W-80-88
Transmi ssi on Range Sensors . . . . . . . . . . . .8W-80-88
Turn Si gnal Hazard Swi tch . . . . . . . . . . . . .8W-80-89
Underhood Lamp. . . . . . . . . . . . . . . . . . . . .8W-80-89
Upstream Heated Oxygen Sensor . . . . . . . .8W-80-89
Vehi cl e Speed Control Servo (LHD). . . . . . .8W-80-89
Vehi cl e Speed Control Servo (RHD). . . . . . .8W-80-89
Vehi cl e Speed Sensor (LHD) . . . . . . . . . . . .8W-80-90
Vehi cl e Speed Sensor (RHD) . . . . . . . . . . . .8W-80-90
Water I n Fuel Sensor (Di esel ) . . . . . . . . . . .8W-80-90
Wi per/Washer Swi tch (LHD) . . . . . . . . . . . .8W-80-90
Wi per/Washer Swi tch (RHD) . . . . . . . . . . . .8W-80-90
J978W-7
XJ 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS
XJI08004
CAV CIRCUIT FUNCTION
A G107 18BK/RD 4WD PART TIME INDICATOR
B Z1 18BK GROUND
4WD SWITCH
(WITH 231)
A Z1 18BK GROUND
B G106 18BK/WT 4WD FULL TIME INDICATOR
C
D G107 18BK/RD 4WD PART TIME INDICATOR
4WD SWITCH
(WITH 242)
BLACK
A
B
C D
A B
BLACK
1 C3 16DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT
2
A/C COMPRESSOR
CLUTCH
BLACK
1 2
1 E2 20OR A/C HEATER CONTROL ILLUMINATION
2 C90 20LG A/C JTEC SELECT SIGNAL
3 C4 14TN HVAC MOTOR LOW
4 C5 14LG HVAC MOTOR M1
5 C6 14LB HVAC MOTOR M2
6 C7 12BK/TN HVAC MOTOR HIGH
7 Z8 12 BK/VT GROUND
A/C HEATER
CONTROL (LHD)
1
E2 20OR REAR WIPER SWITCH ILLUMINATION
E2 20OR A/C HEATER CONTROL ILLUMINATION
2 C90 20LG A/C JTEC SELECT SIGNAL
3 C4 14TN HVAC MOTOR LOW
4 C5 14LG HVAC MOTOR M1
5 C6 14LB HVAC MOTOR M2
6 C7 12BK/TN HVAC MOTOR HIGH
7 Z8 12 BK/VT GROUND
A/C HEATER
CONTROL (RHD)
BLACK
1 7
BLACK
1 7
J978W-7
8W - 80 - 5 XJ 8W-80 CONNECTOR PIN-OUTS
XJI08005
1 C22 18DB/WT A/C REQUEST TO JTEC
2 C21 20DB/OR A/C REQUEST
A/C HIGH
PRESSURE SWITCH
BLACK
1 2
1 C13 20DB/OR A/C SWITCH SENSE
2 C21 20DB/PK A/C LOW PRESSURE SWITCH OUTPUT
A/C LOW
PRESSURE SWITCH
(DIESEL)
2 1
BLACK
1 C21 20DB/OR A/C LOW PRESSURE SWITCH OUTPUT
2 C90 20LG A/C SWITCH SENSE
A/C LOW
PRESSURE SWITCH
(LHD)
2 C90 20LG/RD A/C SWITCH SENSE A/C LOW
PRESSURE SWITCH
(WITH 2.5L ENGNE,MANUAL
TRANSMISSION RHD)
A/C LOW
PRESSURE SWITCH
(RHD ALL OTHERS)
BLACK
1 2
BLACK
1 2
BLACK
1 2
J978W-7
XJI08006
1 R45 18DG/LB DRIVER AIRBAG
2 R43 18BK/LB DRIVER AIRBAG
3
4
5 R42 18BK/YL PASSENGER AIRBAG
6 R44 18DG/YL PASSENGER AIRBAG
7
8
9
10 Z6 18BK/PK GROUND
*
10 Z6 18BK/YL GROUND
**
11 R50 18BR/YL PASSENGER AIRBAG
12 R51 18VT/YL PASSENGER AIRBAG
13
14
15
16
17 F23 18DB/YL FUSED IGNITION (START)
18 D2 18WT/BK CCD BUS()
19 D1 18VT/BR CCD BUS(+)
20 F14 18LG/YL FUSED IGNITION (START/RUN)
AIRBAG
CONTROL MODULE
(LHD)
*
FULL OPTIONS
**
BASE
BLACK
1 12
11 22
1 R45 18DG/LB PASSENGER AIRBAG
2 R43 18BK/LB PASSENGER AIRBAG
3
4
5 R42 18BK/YL PASSENGER AIRBAG
6 R44 18DG/YL PASSENGER AIRBAG
7
8
9
11 R50 20BR/YL DRIVER AIRBAG
12 R51 20WT/YL DRIVER AIRBAG
13
14
15
16
17 F23 18DB/YL FUSED IGNITION (START)
20 F14 18LG/YL FUSED IGNITION (START/RUN)
AIRBAG
CONTROL MODULE
(RHD)
BLACK
1 12
11 22
J978W-7
BLACK
1
3 2
XJI08007
1 G31 20VT/LG AMBIENT TEMP SENSOR SIGNAL
2 G32 20BK/LG AMBIENT TEMP SENSOR GROUND AMBIENT
TEMPERATURE SENSOR
(WITH 4.0L, A/T, LHD,
4.0L M/T, 2.5L M/T, LHD)
A F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN/ACC)
B L10 18BR/LG BACK-UP LAMP SWITCH OUTPUT
BACK-UP
LAMP SWITCH
(WITH MANUAL
TRANSMISSION)
1 K118 18PK/YL BATTERY TEMP SENSOR SIGNAL
2 K167 20BR/YL SENSOR RETURN
BATTERY
TEMPERATURE SENSOR
BLACK
2 1
BLACK
1 2
A B
BLACK
1 K20 18DG GENERATOR FIELD DRIVER
2 A142 16DG/OR IGNITION (RUN/START)
3
ALTERNATOR
1 L20 16LG/WT BEAM SELECT SWITCH FEED
2 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
3 L2 16LG FUSED B(+)
4 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
BEAM
SELECT SWITCH
(LHD)
1 4
BLACK
J978W-7
XJI08008
1 L20 16LG/WT BEAM SELECT SWITCH FEED
2 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
3
4 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
BEAM
SELECT SWITCH
(RHD)
1 G9 20GY/BK BRAKE WARNING LAMP DRIVER
2 G99 20GY/WT BRAKE PRESSURE WARNING SWITCH SIGNAL
BRAKE
PRESSURE SWITCH
1 K29 20WT/PK STOP LAMP SWITCH SENSE
2 F15 20DB/WT FUSED B(+)
BRAKE SHIFT
INTERLOCK SOLENOID
(LHD)
2 F15 20DB/WT FUSED B(+)
BRAKE SHIFT
INTERLOCK SOLENOID
(RHD)
BLACK
2 1
BLACK
2 1
1 2
BLACK
1 4
BLACK
J978W-7
XJI08009
CAV CIRCUIT
A1 Z1 16BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20WT
A6 C90 20LG
A7 Z12 20BK/LG
A8 G29 20BK/TN
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18VT/OR
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 20DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K4 20BK/LB
B7 D20 20LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/WT
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16RD/YL
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
C100
(LHD, 2.5 DIESEL)
CAV CIRCUIT
A1 Z1 16BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20WT
A6 C90 20LG
A7 Z12 20BK/LG
A8 G29 20BK/TN
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18VT/OR
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 20DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K4 20BK/LB
B7 D20 20LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/WT
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16RD/YL
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
BLACK
B12
F6
F18
F12
B18
B6
D4
D2
D6
A7
E13
E7
A1
C3
C1
C5
A13
E1
BLACK
A7
E13
E7
A1
C3
C1
C5
A13 B18
B12
F18
F12
B6
D4
D2
D6
E1 F6
(CONTINUED ON NEXT PAGE)
C100
(LHD, 2.5 DIESEL)
J978W-7
XJI08010
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15 K185 20OR/LB
E16 G86 20TN/OR
E17 G154 20VT/LG
E18 L13 18BR/YL
F1
F2
F3
F4
F5
F6
F7
F8 F32 20PK/DB
F9
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LB
F16
F17
F18
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15 K185 20OR/LB
E16 G86 20TN/OR
E17 G154 20VT/LG
E18 L13 18BR/YL
F1
F2
F3
F4
F5
F6
F7
F8 F32 20PK/DB
F9
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LB
F16
F17
F18
(CONTINUED )
J978W-7
XJI08011
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 20BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3 L3 16RD
D4 G34 16RD/GY
D5 A111 12RD/LG
D6
E1
E2
E3
C100
(LHD, 4.0L, A/T,
W/FOG, AMP,
HEADLAMP LEVELING)
CAV CIRCUIT
A1 Z1 16BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 20BK/TN
A8 G29 20BK/TN
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/RD
D1 A3 16RD/WT
D2 A141 14DG/WT
D3 L3 16RD/OR
D4 G34 16RD/GY
D5 A111 12RD/LG
D6
E1
E2
E3
BLACK
B12
F6
F18
F12
B18
B6
D4
D2
D6
A7
E13
E7
A1
C3
C1
C5
A13
E1
BLACK
A7
E13
E7
A1
C3
C1
C5
A13 B18
B12
F18
F12
B6
D4
D2
D6
E1 F6
C100
(LHD, 4.0L, A/T,
W/FOG, AMP,
HEADLAMP LEVELING)
J978W-7
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LG
F16 K78 20GY
*
F17
F18
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LG
F16 K78 20GY
*
F17
F18
(CONTINUED )
*
POLICE PACKAGE
XJI08012
J978W-7
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 18VT/BR
A12 D2 18WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3 G34 16RD
D4 G34 16RD/GY
D5 A111 12RD/LG
D6
E1
E2
E3
C100
(LHD, 4.0L, M/T,
ABS, DRL)
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 18VT/BR
A12 D2 18WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 18WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 20RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3 L3 16RD
D4 G34 16RD/GY
D5 A111 12RD/LG
D6
E1
E2
E3
BLACK
B12
F6
F18
F12
B18
B6
D4
D2
D6
A7
E13
E7
A1
C3
C1
C5
A13
E1
BLACK
A7
E13
E7
A1
C3
C1
C5
A13 B18
B12
F18
F12
B6
D4
D2
D6
E1 F6
C100
(LHD, 4.0L, M/T,
ABS, DRL)
XJI08013
J978W-7
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LG
F16
F17
F18
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LG
F16
F17
F18
(CONTINUED )
XJI08014
J978W-7
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3 G34 16RD/GY
D4 G34 16RD/GY
D5 A111 12RD/LG
D6
E1
E2
E3
C100
(LHD, A/T, ABS, DRL)
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/RD
D1 A3 16RD/WT
D2 A141 14DG/WT
D3 G34 16RD/GY
D4 G34 16RD/GY
D5 A111 12RD/LG
D6
E1
E2
E3
BLACK
B12
F6
F18
F12
B18
B6
D4
D2
D6
A7
E13
E7
A1
C3
C1
C5
A13
E1
BLACK
A7
E13
E7
A1
C3
C1
C5
A13 B18
B12
F18
F12
B6
D4
D2
D6
E1 F6
C100
(LHD, A/T, ABS, DRL)
XJI08015
J978W-7
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18 L13 20BR/YL
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13
F14 G31 20VT/LG
F15 G32 20BK/LG
F16
F17
F18
CAV CIRCUIT
E4
E5
E6
E7
E8
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18 L13 20BR/YL
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13
F14 G31 20VT/LG
F15 G32 20BK/LG
F16
F17
F18
(CONTINUED )
XJI08016
J978W-7
CAV CIRCUIT
A1 Z1 18BK
A2
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 18VT/BR
A12 D2 18WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 18PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
C100
(RHD, 2.5L, M/T)
CAV CIRCUIT
A1 Z1 18BK
A2
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 18VT/BR
A12 D2 18WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 18PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
BLACK
B12
F6
F18
F12
B18
B6
D4
D2
D6
A7
E13
E7
A1
C3
C1
C5
A13
E1
BLACK
A7
E13
E7
A1
C3
C1
C5
A13 B18
B12
F18
F12
B6
D4
D2
D6
E1 F6
C100
(RHD, 2.5L, M/T)
XJI08017
J978W-7
CAV CIRCUIT
E4
E5
E6
E7 F45 20YL/RD
E8 T141 20YL
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18 L13 20BR/YL
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13
F14
F15
F16
F17
F18
CAV CIRCUIT
E4
E5
E6
E7 F45 20YL/RD
E8 T141 20YL
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18 L13 20BR/YL
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13
F14
F15
F16
F17
F18
(CONTINUED )
XJI08018
J978W-7
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
C100
(RHD, 4.0L, A/T, ABS)
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20VT
A6 C90 20LG
A7 Z12 18BK/TN
A8 G29 20BK/LB
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18BK/WT
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K167 20BR/YL
B7 D20 18LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/PK
B12 L44 20VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2 A141 14DG/WT
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
BLACK
B12
F6
F18
F12
B18
B6
D4
D2
D6
A7
E13
E7
A1
C3
C1
C5
A13
E1
BLACK
A7
E13
E7
A1
C3
C1
C5
A13 B18
B12
F18
F12
B6
D4
D2
D6
E1 F6
C100
(RHD, 4.0L, A/T, ABS)
XJI08019
J978W-7
CAV CIRCUIT
E4
E5
E6
E7 F45 20YL/RD
E8 T141 20YL
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18 L13 20BR/YL
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LG
F16
F17
F18
CAV CIRCUIT
E4
E5
E6
E7 F45 20YL/RD
E8 T141 20YL
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15
E16
E17
E18 L13 20BR/YL
F1
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LG
F16
F17
F18
(CONTINUED )
XJI08020
J978W-7
CAV CIRCUIT
A1 Z1 16BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20WT
A6 C90 20LG
A7 Z12 20BK/LG
A8 G29 20BK/TN
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18VT/OR
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 20DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K4 20BK/LB
B7 D20 20LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/WT
B12 L44 18VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16RD/YL
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
C100
(RHD, VM DIESEL)
CAV CIRCUIT
A1 Z1 16BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L39 20LB
A5 L139 20WT
A6 C90 20LG
A7 Z12 20BK/LG
A8 G29 20BK/TN
A9
A10 G99 20GY/WT
A11 D1 20VT/BR
A12 D2 20WT/BK
A13
A14 G9 20GY/BK
A15 L10 18BR/LG
A16 V10 18BR
A17 V20 18VT/OR
A18 F34 18TN/BK
B1 K29 20WT/PK
B2 K226 18DB/LG
B3 K167 20BR/YL
B4 L50 20WT/TN
B5 V37 18RD/LG
B6 K4 20BK/LB
B7 D20 20LG/BK
B8 D21 20PK
B9 L60 20TN
B10 L61 20LG/WT
B11 L9 20BK/WT
B12 L44 18VT/RD
B13
B14
B15
B16
B17
B18
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16RD/YL
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 16RD/WT
D2
D3
D4
D5 A111 12RD/LG
D6
E1
E2
E3
BLACK
B12
F6
F18
F12
B18
B6
D4
D2
D6
A7
E13
E7
A1
C3
C1
C5
A13
E1
BLACK
A7
E13
E7
A1
C3
C1
C5
A13 B18
B12
F18
F12
B6
D4
D2
D6
E1 F6
C100
(RHD, VM DIESEL)
XJI08021
J978W-7
CAV CIRCUIT
E4
E5
E6
E7 F45 20YL/RD
E8 T141 20YL
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15 K185 20OR/LB
E16 G86 20TN/OR
E17 G154 20VT/LG
E18 L13 18BR/YL
F1
F2
F3
F4
F5
F6
F7
F8 F32 20PK/DB
F9
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LB
F16
F17
F18
CAV CIRCUIT
E4
E5
E6
E7 F45 20YL/RD
E8 T141 20YL
E9
E10 F1 20DB/GY
E11
E12
E13
E14
E15 K185 20OR/LB
E16 G86 20TN/OR
E17 G154 20VT/LG
E18 L13 18BR/YL
F1
F2
F3
F4
F5
F6
F7
F8 F32 20PK/DB
F9
F10
F11
F12
F13 G19 20LG/OR
F14 G31 20VT/LG
F15 G32 20BK/LB
F16
F17
F18
(CONTINUED )
XJI08023
J978W-7
XJI08023
CAV CIRCUIT
1 C7 12BK/TN
2
3 F81 12TN
4
5
6 Z8 16BK/VT
7 A111 12RD/LG
8 C6 14LB
9
10
11
12
13 C5 14LG/
14 C4 14TN
C102 (RHD)
CAV CIRCUIT
1 C7 12BK/TN
2
3 F81 12TN
4
5
6 Z8 12BK/PK
7 A111 12RD/LG
8 C6 14LB
9
10
11
12
13 C5 14LG
14 C4 14TN
C102 (RHD)
7
GRAY GRAY
1
14 8
1
8
7
14
CAV CIRCUIT
1 X51 16BR/YL
2 X52 16DB/WT
3 X53 16DG
4 X54 16VT
5 X55 16BR/RD
6 X56 16DB/RD
7 X57 16BR/LB
8 X58 16DB/OR
9 X60 16DG/RD
10 G9 20GY/BK
11 E2 20OR
12 G10 20LG/RD
13 R50 20BR/YL
14 R51 20WT/YL
15 L38 18BR/WT
16 V13 18BR/LG
17 V23 18BR/PK
18 V20 18BK/WT
19 G16 20BK/LB
20 G26 20LB
21 P59 20LB/RD
22 P55 20DB
C103 (RHD)
CAV CIRCUIT
1 X51 16BR/YL
2 X52 16DB/WT
3 X53 16DG
4 X54 16VT
5 X55 16BR/RD
6 X56 16DB/RD
7 X57 16BR/LB
8 X58 16DB/OR
9 X60 16DG/RD
10 G9 20GY/BK
11 E2 20OR/BK
12 G10 20LG/RD
13 R50 20BR/YL
14 R51 20WT/YL
15 L38 18BR/WT
16 V13 18BR/RD
17 V23 18BR/PK
18 V20 18VT/OR
19 G16 20BK/LB
20 G26 20LB
21 P59 20LB/RD
22 P55 20DB
C103 (RHD)
BLUE
1
9
15
19
8
14
18
22
BLUE
1
9
15
19
8
14
18
22
C104 (RHD) C104 (RHD)
1
7
15
21
5
14
20
24
WHITE WHITE
1
7
15
21
5
14
20
24
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BR
3 F75 16VT
4 A141 16DG/WT
5 L10 18BR/LG
6 L50 20WT/TN
7 L62 20BR/RD
8 L63 20DG/RD
9 F15 20DB/WT
10 F23 18DB/YL
11 F14 18LG/YL
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BR
3 F75 16VT
4 A141 16DG/WT
5 L10 18BR/LG
6 L50 20WT/TN
7 L62 20BR/RD
8 L63 20DG/RD
9 F15 20DB/WT
10 F23 18DB/YL
11 F14 18LG/YL
J978W-7
XJI08024
CAV CIRCUIT
12 F35 16RD
13
14
15
16 K226 20DB/LG
17 K167 20BR/YL
18 P72 20YL/BK
19 P74 20DB
20 P76 20OR/YL
21
22 C16 20BK/WT
23 P35 20OR/VT
24 P36 20PK/VT
CAV CIRCUIT
12 F35 16RD
13
14
15
16 K226 20DB/LG
17 K167 20BR/YL
18 P71 20YL
19 P75 20DB/WT
20 P76 20OR/YL
21
22 C16 20LB/YL
23 P35 20OR/VT
24 P36 20PK/VT
CAV CIRCUIT
1 L13 18BR/YL
2 L33 18RD
3 L61 20LG/WT
4 Z1 18BK
5 Z15 16BK/GY
6 L34 18RD/OR
7 L77 20BR/YL
8 L39 20LB
9 L43 18VT
10 L60 20TN
11 Z1 18BK
12 Z1 20BK
13 L44 18VT/RD
14 L78 18DG/YL
C106
(2.5L DIESEL)
CAV CIRCUIT
1
2 L33 20RD
3 L61 20LG
4 Z1 18BK
5
6 L34 18RD/OR
7 L77 20BR
8
9 L43 20VT
10 L60 20TN
11 Z1 18BK
12
13 L44 18VT/RD
14 L78 20DG/YL
C106
(2.5L DIESEL)
(CONTINUED)
CAV CIRCUIT
1
2 L33 20RD
3 L61 20LG/WT
4 Z1 18BK
5
6 L34 20DG/OR
7 L77 20BR/YL
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 20BK
12
13 L44 20VT/RD
14 L78 20DG/YL
C106
(4.0L ENGINE, DRL)
CAV CIRCUIT
1
2 L33 20RD
3 L61 20LG
4 Z1 18BK
5
6 L34 18RD/OR
7 L77 20BR
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 18BK
12 Z1 20BK
13 L44 18VT/RD
14 L78 20DG/YL
C106
(4.0L ENGINE, DRL)
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK BLACK
7
GRAY GRAY
1
14 8
1
8
7
14
J978W-7
XJI08025
CAV CIRCUIT
1
2 L33 20RD
3 L61 20LG/WT
4 Z1 18BK
5
6 L34 20DG/OR
7 L77 20BR/YL
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 20BK
12
13 L44 20VT/RD
14 L78 20DG/YL
C106
(4.0L ENGINE,
DRL, FOG LAMPS)
CAV CIRCUIT
1
2 L33 20RD
3 L61 20LG
4 Z1 18BK
5
6 L34 18RD/OR
7 L77 20BR
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 18BK
12 Z1 20BK
13 L44 18VT/RD
14 L78 20DG/YL
C106
(4.0L ENGINE,
DRL, FOG LAMPS)
CAV CIRCUIT
1 L13 20BR/YL
2 L33 20RD
3 L61 20LG/WT
4 Z1 18BK
5 Z15 16BK/GY
6 L34 20DG/OR
7 L77 20BR/YL
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 20BK
12 L35 20BR/WT
13 L44 20VT/RD
14 L78 20DG/YL
C106
(ALL OTHERS
WITH FOG LAMPS)
CAV CIRCUIT
1
2 L33 20RD
3 L61 20LG
4 Z1 18BK
5
6 L34 18RD/OR
7 L77 20BR
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 18BK
12 Z1 20BK
13 L44 18VT/RD
14 L78 20DG/YL
C106
(ALL OTHERS
WITH FOG LAMPS)
GRAY
1
8
GRAY
7
14
1
8
7
14
GRAY
1
8
GRAY
7
14
1
8
7
14
CAV CIRCUIT
1 L13 20BR/YL
2 L33 20RD
3 L61 20LG/WT
4 Z1 18BK
5 Z15 16BK/GY
6 L34 20DG/OR
7 L77 20BR/YL
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 20BK
12 L35 20BR/WT
13 L44 20VT/RD
14 L78 20DG/YL
C106
(ALL OTHERS)
CAV CIRCUIT
1
2 L33 20RD
3 L61 20LG
4 Z1 18BK
5
6 L34 18RD/OR
7 L77 20BR
8 L39 20LB
9 L43 20VT
10 L60 20TN
11 Z1 18BK
12 Z1 20BK
13 L44 18VT/RD
14 L78 20DG/YL
C106
(ALL OTHERS)
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK BLACK
BLACK BLACK
BLACK BLACK
J978W-7
XJI08026
CAV CIRCUIT
1 K3 20LG/BK
2 C21 20DB/PK
3 C22 20DB/WT
4 K24 20GY/BK
5 K20 18DG
6 C3 14DB/BK
7 A142 16DG/OR
8 K2 20TN/BK
9 K4 20BK/LB
10 K222 20TN/RD
C107
(DIESEL)
CAV CIRCUIT
1 K3 20LG/BK
2 C21 20DB/PK
3 C22 20DB/WT
4 K24 20GY/BK
5 K20 18DG
6 C3 14DB/BK
7 A142 16DG/OR
8 K2 20TN/BK
9 K4 20BK/LB
10 K222 20TN/RD
C107
(DIESEL)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4
5
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 18BK/RD
9 Z12 18BK/TN
10 F12 18DB/WT
11
12 L10 18BR/LG
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 2.5L
ENGINE, MANUAL
TRANSMISSION, 231, 2WD)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 Z1 20BK
6
7 F142 20DG/WT
8 G107 18BK/RD
9
10 F12 18DB/WT
11
12 L10 18BR/LG
13
14 A61 16DG/BK
C107
(WITH 2.5L
ENGINE, MANUAL
TRANSMISSION, 231, 2WD)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 20BR/LB
6
7 F142 20DG/WT
8 G107 18BK/RD
9
10 F12 18DB/WT
11
12
13
14 A61 16DG/BK
C107
(WITH 2.5L ENGINE,
MANUAL TRANSMISSION,
231, 2WD, DRL)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 Z1 20BK
6
7 F142 20DG/WT
8 G107 18BK/RD
9
10 F12 18DB/WT
11
12 L10 18BR/LG
13
14 A61 16DG/BK
C107
(WITH 2.5L ENGINE,
231, 2WD, DRL)
GRAY
1
8
GRAY
7
14
1
8
7
14
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK BLACK
BLACK BLACK
BLACK
1
8
7
14
5
10
1
6
BLACK
J978W-7
XJI08027
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 20BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 20BK/RD
9 Z12 18BK/TN
10 F12 18DB/WT
11 K78 20GY
12
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION,
231, 242)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 18BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 18BK/RD
9 Z12 16BK/TN
10 F12 18DB/WT
11 K78 18GY
12
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION,
231, 242)
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK BLACK
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4
5 T41 20BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 20BK/RD
9 Z12 18BK/TN
10 F12 18DB/WT
11 K78 20GY
12
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION,
231, 242, DRL)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 18BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 18BK/RD
9 Z12 16BK/TN
10 F12 18DB/WT
11 K78 18GY
12
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION,
231, 242, DRL)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 20BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8
9 Z12 18BK/TN
10 F12 18DB/WT
11 K78 20GY
12
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION, 2WD)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 18BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8
9 Z12 16BK/TN
10 F12 18DB/WT
11 K78 18GY
12
13
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION, 2WD)
GRAY
1
8
GRAY
7
14
1
8
7
14
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK BLACK
BLACK BLACK
J978W-7
XJI08028
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4
5 T41 20BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8
9 Z12 18BK/TN
10 F12 18DB/WT
11 K78 20GY
12
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION, 2WD, DRL)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 18BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8
9 Z12 16BK/TN
10 F12 18DB/WT
11 K78 18GY
12
13
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
AUTOMATIC
TRANSMISSION, 2WD, DRL)
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK BLACK
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4
5
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 20BK/RD
9 Z12 18BK/TN
10 F12 18DB/WT
11
12 L10 18BR/LG
13 G106 20BK/WT
*
14 A61 16DG/BK
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 18BK/RD
9 Z12 16BK/TN
10 F12 18DB/WT
11
12 L10 18BR/LG
13 G106 20BK/WT
*
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
231, 242)
C107
(WITH 4.0L ENGINE,
231, 242)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4
5 T41 20BK/WT
6 K22 20OR/DB
7 F142 20DG/WT
8 G107 20BK/RD
9 Z12 18BK/TN
10 F12 18DB/WT
11
12
13 G106 20BK/WT
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
MANUAL
TRANSMISSION, 2WD)
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5
6
7 F142 20DG/WT
8
9
10 F12 18DB/WT
11
12 L10 18BR/LG
13
14 A61 16DG/BK
C107
(WITH 4.0L ENGINE,
MANUAL
TRANSMISSION, 2WD)
GRAY
1
8
GRAY
7
14
1
8
7
14
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK BLACK
BLACK BLACK
*
242 ONLY
**
4.0L AUTOMATIC TRANSMISSION LHD
4.0L MANUAL TRANSMISSION
J978W-7
XJI08029
CAV CIRCUIT
1 T40 14BR
2 K72 18DG/OR
3 K20 18DG
4 C3 16DB/BK
**
C108
CAV CIRCUIT
1 T40 14LG/BK
2 K72 18DG/OR
3 K20 18DG
4 C3 16DB/BK
**
C108
CAV CIRCUIT
A B41 20YL/VT
B B42 20TN/WT
C B43 20PK/OR
D B1 20YL/DB
E B2 20YL
F B3 20LG/DB
G B4 20LG
C109 (LHD)
CAV CIRCUIT
A B515 20YL/VT
B B516 20TN/WT
C B517 20PK/OR
D B1 20YL/DB
E B2 20YL
F B3 20LG/DB
G B4 20LG
C109 (LHD)
LT. GRAY
1 4
LT. GRAY
1 4
A
H
D
E
BLACK
A
H
D
E
BLACK
BLACK BLACK
CAV CIRCUIT
A B41 20YL/VT
B B42 20TN/WT
C B43 20PK/OR
D B1 20YL/DB
E B2 20YL
F B3 20LG/DB
G B4 20LG
C109 (RHD)
CAV CIRCUIT
A B515 18YL/VT
B B516 18TN/WT
C B517 18PK/OR
D B1 18YL/DB
E B2 18YL
F B3 18LG/DB
G B4 18LG
C109 (RHD)
A
H
D
E
BLACK
A
H
D
E
BLACK
CAV CIRCUIT
1 G7 20WT/OR
2 G106 20BK/WT
3 G107 20BK/RD
4 Z1 18BK
5 L10 18BR/LG
6 K7 20OR
7 F12 18DB/WT
8 K167 20BR/YL
9
10 T40 14BR
C110 (DIESEL)
CAV CIRCUIT
1 G7 20WT/OR
2 G106 20BK/WT
3 G107 20BK/RD
4 Z1 18BK
5 L10 18BR/LG
6 K7 20OR
7 F12 18DB/WT
8 K167 20BR/YL
9
10 T40 14BR
C110 (DIESEL)
5
10
1
6
BLACK
*
242 ONLY
**
4.0L AUTOMATIC TRANSMISSION LHD
BLACK
1
8
7
14
J978W-7
XJI08030
CAV CIRCUIT
1 X53 16DG
2 X55 16BR/RD
3
4 X54 16VT
5 X56 16DB/RD
6 X51 16BR/YL
7 X57 16BR/LB
8
9 X52 16DB/WT
10 X58 16DB/OR
11 X60 16DG/RD
12
13 A141 16DG/WT
14 F75 14VT
15 K226 20DB/LG
16 L10 18BR/LG
17 G16 20BK/LB
18
19
20
21
22
23 L38 16BR/WT
24 L50 20WT/TN
25 L62 18BK/RD
26 L63 18DG/RD
27 V13 18BR/LG
28 V20 18VT/OR
29 V23 18BR/PK
30 K167 20BR/YL
31 P35 18OR/VT
32 P36 18PK/VT
33 F81 12TN
34 P72 20YL/BK
35 P74 20DB
36 P76 20OR/YL
37 C16 20LB/YL
C200
(LHD FULL OPTIONS)
C200
(LHD FULL OPTIONS)
CAV CIRCUIT
1 X53 16DG
2 X55 16BR/RD
3
4 X54 16VT
5 X56 16DB/RD
6 X51 16BR/YL
7 X57 16BR/LB
8
9 X52 16DB/WT
10 X58 16DB/OR
11 X60 16DG/RD
12
13 A141 16DG/WT
14 F75 16VT
15 K226 20DB/LG
16 L10 18BR/LG
17 G16 20BK/LB
18
19
20
21
22
23
24 L50 20WT/TN
25 L62 20BR/RD
26 L63 20DG/RD
27 V13 18BR/LG
28 V20 18BK/WT
29 V23 18BR/PK
30 K167 20BR/YL
31 P35 20OR/VT
32 P36 18PK/VT
33 F81 12TN
34 P72 20YL/BK
35 P74 20DB
36 P76 20OR/YL
37 C16 20LB/YL
*
4.0L, LHD, AUTOMATIC TRANSMISSION
4.0L, MANUAL TRANSMISSION
2.5L, MANUAL TRANSMISSION
1
18
22
30
40
11
19
23
31
BLACK
22
30
40
11
19
23
31
BLACK
10
18
10 1
CAV CIRCUIT
1 P35 20OR/VT
2 P36 20PK/VT
3
4
5
C200 (RHD) C200 (RHD)
CAV CIRCUIT
1 P35 20OR/VT
2 P36 20PK/VT
3 P55 20DB
4 P59 20LB/RD
5 G26 20LB
NATURAL
1
4
3
6
1
NATURAL
4
3
6
WHITE
J978W-7
XJI08031
CAV CIRCUIT
1
2 C16 20LB/YL
3 L5 20BK
4
5 F87 20WT/BK
6 M1 20PK
7
8 V6 18PK/VT
9
10 A31 12BK/VT
11 A111 12RD/LG
12 C7 12BK/TN
13
14 Z1 14BK
15
16 L3 16RD/OR
17 C81 20LB/WT
18
19
20
21
22 L4 16VT/WT
23
24
25 Z8 20BK/VT
26 X3 20BK/RD
27
28
29
30
31
32
33
34
35
36
37
38
39 V23 18BR/PK
40 F15 20DB/WT
41
42 E1 20TN
43 E2 20OR
44
45 L7 18BR/YL
46 M2 20YL
47 R50 18BR/YL
48 R51 18WT/YL
49
50 F30 16RD
51 D1 18VT/BR
52 D2 18WT/BK
53
C201
(LHD BASE)
C201
(LHD BASE)
CAV CIRCUIT
1
2 C16 20LB/YL
3 L5 20BK
4
5 F87 20WT/BK
6 M1 20PK
7
8 V6 18PK/VT
9 P36 18PK/WT
10 A31 12BK/WT
11 A111 12RD/LG
12 C7 12BK/TN
13 F81 12TN
14 Z1 14BK
15
16 L3 16RD/OR
17 C81 20LB/WT
18
19 F1 20DB/GY
20 P72 20YL/BK
21
22 L4 16VT/WT
23 P35 20OR/VT
24 P74 20DB
25 Z8 16BK/VT
26 X3 20BK/RD
27
28 P76 20OR/YL
29 G26 20LB
30
31
32 G31 20VT/LG
33
34
35 G32 20BK/LB
36
37
38
39 V23 18BR/PK
40 F15 20DB/WT
41
42 E1 20TN
43 E2 20OR
44
45 L7 18BK/YL
46 M2 20YL
47 R50 18BR/YL
48 R51 20WT/YL
49 G38 20GY
50 F30 16RD
51 D1 20VT/BR
52 D2 20WT/BK
53
NATURAL
46
55
47
58
64
62
61
59
65
63
72
50
3
1
12
10
13
11
14
16
17
20
29
68 37
38
WHITE
1 7 38 44
46
55
58
59
60
61
64
65
72
74
68 37 31
29
20
17
16
15
14
11
10
NATURAL
J978W-7
WHITE
1 7 38 44
46
55
58
59
60
61
64
65
72
74
68 37 31
29
20
17
16
15
14
11
10
XJI08032
CAV CIRCUIT
53
54 X12 16RD/WT
55
56
57
58
59 C4 14TN
60 C5 14LG
61 C6 14LB
62 A22 12BK/OR
63 A41 12YL
64 A21 12DB
65 F38 16RD/LB
66 G9 18GY/BK
67
68
69 G10 20LG/RD
70
71
72
CAV CIRCUIT
53
54 X12 16RD/WT
55 D1 20VT/BR
56 D2 20WT/BK
57
58 Z2 18BK/LG
59 C4 14TN
60 C5 14LG
61 C6 14LB
62 A22 12BK/OR
63 A41 14YL
64 A21 12DB
65 F38 16RD/LB
66 G9 20GY/BK
67
68
69 G10 20LG/RD
70
71
72
(CONTINUED)
C201
(LHD FULL OPTIONS)
C201
(LHD FULL OPTIONS)
NATURAL
46
55
47
58
64
62
61
59
65
63
72
50
3
1
12
10
13
11
14
16
17
20
29
68 37
38
CAV CIRCUIT
1
2 C16 20LB/YL
3 L5 20BK
4
5 F87 20WT/BK
6 M1 20PK
7
8 V6 18PK/VT
9 P36 20PK/WT
10 A31 12BK/VT
11 A111 12RD/LG
12 C7 12BK/TN
13 F81 12TN
14 Z1 14BK
15
16 L3 16RD/OR
17 C81 20LB/WT
18
19 F1 20DB/GY
20 P72 20YL/BK
21
22 L4 16VT/WT
23 P35 20OR/VT
24 P74 20DB
25 Z8 20BK/VT
26 X3 20BK/RD
27
28 P76 20OR/YL
29 G26 20LB
CAV CIRCUIT
1
2 C16 20LB/YL
3 L5 20BK
4
5 F87 20WT/BK
6 M1 20PK
7
8 V6 18PK/VT
9 P36 18PK/WT
10 A31 12BK/WT
11 A111 12RD/LG
12 C7 12BK/TN
13 F81 12TN
14 Z1 14BK
15
16 L3 16RD/OR
17 C81 20LB/WT
18
19 F1 20DB/GY
20 P72 20YL/BK
21
22 L4 16VT/WT
23 P35 20OR/VT
24 P74 20DB
25 Z8 16BK/VT
26 X3 20BK/RD
27
28 P76 20OR/YL
29 G26 20LB
NATURAL
J978W-7
CAV CIRCUIT
30
31
32 G31 20VT/LG
33
34
35 G32 20BK/LB
36
37
38
39 V23 18BR/PK
40 F15 20DB/WT
41
42 E1 20TN
43 E2 20OR
44
45 L7 18BR/YL
46 M2 20YL
47 R50 18BR/YL
48 R51 18WT/YL
49 G38 20GY
50 F30 16RD
51 D1 18VT/BR
52 D2 18WT/BK
53
54 X12 16RD/WT
55 D1 20VT/BR
56 D2 20WT/BK
57
58 Z2 18BK/LG
59 C4 14TN
60 C5 14LG
61 C6 14LB
62 A22 12BK/OR
63 A41 12YL
64 A21 12DB
65 F38 16RD/LB
66 G9 18GY/BK
67
68
69 G10 20LG/RD
70
71
72
CAV CIRCUIT
30
31
32 G31 20VT/LG
33
34
35 G32 20BK/LB
36
37
38
39 V23 18BR/PK
40 F15 20DB/WT
41
42 E1 20TN
43 E2 20OR
44
45 L7 18BK/YL
46 M2 20YL
47 R50 18BR/YL
48 R51 20WT/YL
49 G38 20GY
50 F30 16RD
51 D1 20VT/BR
52 D2 20WT/BK
53
54 X12 16RD/WT
55 D1 20VT/BR
56 D2 20WT/BK
57
58 Z2 18BK/LG
59 C4 14TN
60 C5 14LG
61 C6 14LB
62 A22 12BK/OR
63 A41 14YL
64 A21 12DB
65 F38 16RD/LB
66 G9 20GY/BK
67
68
69 G10 20LG/RD
70
71
72
(CONTINUED)
XJI08033
J978W-7
XJI08034
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BK
3 F75 14VT
4 A141 16DG/WT
5 L10 18BR/LG
6 L50 20WT/TN
7 L62 18BR/RD
8 L63 20DG/RD
9 F15 20DB/WT
10 F23 18DB/YL
C204 (RHD) C204 (RHD)
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BR
3 F75 14VT
4 A141 16DG/WT
5 L10 18BR/LG
6 L50 20WT/TN
7 L62 20BR/RD
8 L63 20DG/RD
9 F15 20DB/WT
10 F23 18DB/YL
21
15
7
1
24
20
14
6
BLACK
21
15
7
1
24
20
14
6
BLACK
CAV CIRCUIT
1 C7 12BK/TN
2
3 F81 12TN
4
5
6 Z8 12BK/PK
7 A111 12RD/LG
8 C6 14LB
9
10
11
12
13 C5 14LG
14 C4 14TN
C202 (RHD) C202 (RHD)
CAV CIRCUIT
1 C7 12BK/TN
2
3 F81 12TN
4
5
6 Z8 16BK/VT
7 A111 12RD/LG
8 C6 14LB
9
10
11
12
13 C5 14LG
14 C4 14TN
CAV CIRCUIT
1 X51 16BR/YL
2 X52 16DB/WT
3 X53 16DG
4 X54 16VT
5 X55 16BR/RD
6 X56 16DB/RD
7 X57 16BR/LB
8 X58 16DB/OR
9 X60 16DG/RD
10 G9 20GY/BK
11 E2 20OR/BK
12 G10 20LG/RD
13 R50 20BR/YL
14 R51 20WT/YL
15 L38 18BR/WT
16 V13 18BR/RD
17 V23 18BR/PK
18 V20 18VT/OR
19 G16 20BK/LB
20 G26 20LB
21 P59 20LB/RD
22 P55 20DB
C203 (RHD) C203 (RHD)
CAV CIRCUIT
1 X51 16BR/YL
2 X52 16DB/WT
3 X53 16DG
4 X54 16VT
5 X55 16BR/RD
6 X56 16DB/RD
7 X57 16BR/LB
8 X58 16DB/OR
9 X60 16DG/RD
10 G9 20GY/BK
11 E2 20OR
12 G10 20LG/RD
13 R50 20BR/YL
14 R51 20WT/YL
15
16 V13 18BR/LG
17 V23 18BR/PK
18 V20 18BK/WT
19 G16 20BK/LB
20 G26 20LB
21 P59 20LB/RD
22 P55 20DB
GRAY
1
8
GRAY
7
14
1
8
7
14
BLACK
1
9
15
19
8
14
18
22
BLACK BLACK
BLUE
1
9
15
19
6
14
18
22
BLACK
J978W-7
XJI08035
CAV CIRCUIT
1 R42 18BK/YL
2 R44 18DG/YL
3 R43 18BK/LB
4 R45 18DG/LB
C205
CAV CIRCUIT
1 R42 18BK/YL
2 R44 18DG/YL
3 R43 18BK/LB
4 R45 18DG/LB
C205
CAV CIRCUIT
1 E2 20OR
2 Z1 20BK
C206
(AUTOMATIC
TRANSMISSION)
CAV CIRCUIT
1 E2 20OR
1 E2 20OR
2 Z1 20BK
2 Z1 20BK
C206
(AUTOMATIC
TRANSMISSION)
4 1
YELLOW
1 2
BLACK
2 1
CAV CIRCUIT
11 F14 18LG/YL
12 F35 16RD
13
14
15
16 K226 20DB/LG
17 K167 20BR/YL
18 P71 20YL
19 P75 20DB/WT
20 P76 20OR/YL
21
22 C16 20LB/YL
23 P35 18OR/VT
24 P36 18PK/VT
CAV CIRCUIT
11 F14 18LG/YL
12 F35 16RD
13
14
15
16 K226 20DB/LG
17 K167 20BR/YL
18 P72 20YL/BK
19 P74 20DB
20 P76 20OR/YL
21
22 C16 20BK/WT
23 P35 20OR/VT
24 P36 20PK/VT
(CONTINUED)
C206
(MANUAL
TRANSMISSION)
CAV CIRCUIT
1 E2 20OR
2 Z1 20BK
C206
(MANUAL
TRANSMISSION)
CAV CIRCUIT
1 E2 20OR
2 Z1 20BK
C207
CAV CIRCUIT
A M1 18PK
B M2 18BK/WT
C207
CAV CIRCUIT
A M1 20PK
B M2 20YL
1 2
BLACK
2 1
BLACK
RED
B A
RED
A B
BLACK BLACK
YELLOW
1 4
BLACK
J978W-7
XJI08036
C302
(WITH IMMOBILIZER)
CAV CIRCUIT
1 X3 20BK/RD
2 F1 20DB/GY
3
4 P59 20LB/RD
5 P55 20DB
6 G38 20GY
CAV CIRCUIT
1 X3A 20BK/RD
2 F1 20DB/GY
3
4 P59 20LB/RD
5 P55 20DB
6 G38 20GY
C302
(WITH IMMOBILIZER)
C301
(WITH IMMOBILIZER)
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BK
3
4
5 Z2 20BK/LG
6
7
8
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BK
3 G32 20BK/LB
4 G61 20VT/LG
5 Z2 18BK/LG
6 F87 20WT/BK
6 F87 20WT/BK
7
8
C208
CAV CIRCUIT
A M1 18PK
B M2 18BK/WT
C208
CAV CIRCUIT
A M1 20PK
B M2 20YL
C300 (LHD) C300 (LHD)
CAV CIRCUIT
1 P35 20OR/VT
2 P36 20PK/VT
3 P55 20DB
4 P59 20LB/RD
5 G26 20LB
6
CAV CIRCUIT
1 P35 20OR/VT
2 P36 20PK/VT
3 P55 20DB
4 P59 20LB/RD
5 G26 20LB
6
C301
(WITH VANITY LAMPS)
C301
(WITH VANITY LAMPS)
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BK
3 G32 20BK/LG
4 G31 20VT/LG
5 Z2 20BK/LG
6 F87 20WT/BK
7
8
CAV CIRCUIT
1 D1 20VT/BR
2 D2 20WT/BK
3 G32 20BK/LB
4 G31 20VT/LG
5 Z2 18BK/LG
6 F87 20WT/BK
6 F87 20WT/BK
7
8
RED
B A
RED
A B
BLACK BLACK
NATURAL
1
4
3
6
1
NATURAL
4
3
6
1 3
4
4 8
1 3
8
1 3
4
4 8
1 3
8
8 5
4 1
1 2 3 4
5 6 7 8
BLACK
BLACK
BLACK
BLACK
BLACK
BLACK
C301
(WITH IMMOBILIZER)
J978W-7
XJI08037
C303 (LHD)
CAV CIRCUIT
1 Q16 14BR/WT
2 Q26 14VT/WT
3
4 X80 16LB/BK
5 X82 16LB/RD
CAV CIRCUIT
1 Q16 14BR/WT
2 Q26 14VT/WT
3
4 X80 16LB/BK
5 X82 16LB/RD
C303 (LHD)
C304
CAV CIRCUIT
1 Q18 14GY/BK
2 Q28 14DG/WT
3 Q1 14YL
4 P33 16OR/BK
5 P34 16PK/BK
CAV CIRCUIT
1 Q18 14GY/BK
2 Q28 14DG/WT
3 Q1 14YL
4 P33 16OR/BK
5 P34 16PK/BK C304
C305 (LHD)
CAV CIRCUIT
1 X85 16BR/RD
2 X87 16DG
3 M1 20PK
4 P33 16OR/BK
5 P34 16PK/BK
6 P35 18OR/VT
7 P36 18PK/VT
8 P72 20YL/BK
9 P74 20DB
10 P76 20OR/YL
11 C16 20LB/YL
12
13
CAV CIRCUIT
1 X85 16BR/RD
2 X87 16DG
3 M1 18PK
4 P33 16OR/BK
5 P34 16PK/BK
6 P35 18OR/VT
7 P36 18PK/VT
8 P72 20YL/BK
9 P74 20DB
10 P76 20OR/YL
11 C16 20LB/YL
12
13
4
1
9
8
3
13
WHITE
C305 (LHD)
1
4
9
3
8
13
WHITE
C305 (RHD)
CAV CIRCUIT
1 X85 16LG/RD
2 X87 16DG
3 M1 20PK
4 P33 16OR/BK
5 P34 16PK/BK
6 P35 18OR/VT
7 P36 18PK/VT
8 P72 20YL/BK
9 P74 20DB
10 P76 20OR/YL
11 C16 20LB/YL
12 P90 20LG/BK
13 P91 20WT/BK
C305 (RHD)
CAV CIRCUIT
1 X85 16BR/RD
2 X87 16DG
3 P59 20LB/RD
4 P33 16OR/BK
5 P34 16PK/BK
6 P35 18OR/VT
7 P36 18PK/VT
8 P71 20YL
9 P75 20DB/RD
10 P76 20OR/YL
11 C16 20LB/YL
12 P55 20DB
13 G26 20LB
4
1
9
8
3
13
WHITE
1
4
9
3
8
13
WHITE
3 1
6 4
BLACK
BLACK
1
4
3
6
3 1
6 4
BLACK
BLACK
1
4
3
6
J978W-7
XJI08038
C306 (LHD)
CAV CIRCUIT
1 Q18 14GY/BK
2 Q28 14DG/WT
3 Q16 14BR/WT
4 Q26 14VT/WT
5 Q17 14DB/WT
6 Q27 14RD/BK
C306 (LHD)
CAV CIRCUIT
1 Q18 14GY/BK
2 Q28 14DG/WT
3 Q16 14BR/WT
4 Q26 14VT/WT
5 Q17 14DB/WT
6 Q27 14RD/BK
C306 (RHD)
CAV CIRCUIT
1 F35 16RD
2
3 Q16 14BR/WT
4 Q26 14VT/WT
5
6
C306 (RHD)
CAV CIRCUIT
1 F35 16RD
2
3 Q16 14BR/WT
4 Q26 14VT/WT
5
6
C307 (LHD)
CAV CIRCUIT
1 F81 12TN
2 Q1 14YL
3 Z1 12BK
C307 (LHD)
CAV CIRCUIT
1 F81 12TN
2 Q1 14YL
3 Z1 12BK
C308 (LHD)
CAV CIRCUIT
A P33 16OR/BK
B P34 16PK/BK
C M4 20GY/BK
D L50 18WT/TN
E V13 18BR/LG
F V23 18BR/PK
G V20 18BK/WT
H L77 18BR
C308 (LHD)
CAV CIRCUIT
A P33 16OR/BK
B P34 16PK/BK
C M4 20GY/BK
D L50 20WT/TN
E V13 18BR/LG
F V23 18BR/PK
G V20 18VT/OR
H L77 18BR
C307 (RHD)
CAV CIRCUIT
1 F81 12TN
2 Q1 14YL
3 Z1 12BK
C307 (RHD)
CAV CIRCUIT
1 F81 12TN
2 Q1 14YL
3 Z1 12BK
A
H
D
E
BLACK
A
H
D
E
BLACK
1
3 6
2
WHITE
1 2
6
3
WHITE
1
3 6
2
WHITE
1 2
6
3
WHITE
3 1
WHITE
3 1
WHITE
3 1
WHITE
3 1
WHITE
J978W-7
XJI08039
C308 (RHD)
CAV CIRCUIT
A P33 16OR/BK
B P34 16PK/BK
C M4 20GY/BK
D L50 18WT/TN
E V13 18BR/LG
F V23 18BR/PK
G V20 18BK/WT
H L77 18BR
C308 (RHD)
CAV CIRCUIT
A P33 16OR/BK
B P34 16PK/BK
C M4 20GY/BK
D L50 20WT/TN
E V13 18BR/LG
F V23 18BR/PK
G V20 18VT/OR
H L77 18BR
C309
CAV CIRCUIT
1 Q17 14DB/WT
2 Q27 14RD/BK
3 Q1 14YL
4 P33 16OR/BK
5 P34 16PK/BK
C309
CAV CIRCUIT
1 Q17 14DB/WT
2 Q27 14RD/BK
3 Q1 14YL
4 P33 16OR/BK
5 P34 16PK/BK
C310
CAV CIRCUIT
1 V20 18BK/WT
2 Z1 12 BK
3 C15 12BK/WT
4 P33 16BR/BK
5 P34 16PK/BK
6
7 V23 18BR/PK
8 V13 18BR/LG
9 Z1 18BK
10 M4 20VT/YL
11 L77 18BR
C311
CAV CIRCUIT
1 P33 16OR/BK
2 P34 16PK/BK
3
4 L77 18BR
5 M4 20GY/BK
6 Z1 18BK
C312
CAV CIRCUIT
1 V13 18BR/LG
2 V23 18BR/PK
3 V20 BR/WT
CONNECTOR
RETAINER
BLACK
2 3
A
H
D
E
BLACK
A
H
D
E
BLACK
3 1
6 4
BLACK
BLACK
1
4
3
6
C313
CAV CIRCUIT
1 Z1 12 BK
2 C15 12BK/WT
BLACK
1
6
3
4
BLACK
1 2
1 2
3
GRAY
GRAY
GREEN
BLACK
J978W-7
XJI08040
C314
CAV CIRCUIT
1 X92 16TN/BK
2 X94 16TN/RD
3 X91 16WT/BK
4 X93 16WT/RD
5 M1 20PK
6 M2 20YL
7 M4 20GY/BK
8
C314
CAV CIRCUIT
1 X92 16TN/BR
2 X94 16TN/RD
3 X91 16WT/BK
4 X93 16WT/RD
5 M1 18PK
6 M2 18YL
7 M4 18GY/BK
8
C314
(WITH SOUND BAR)
CAV CIRCUIT
1 X92 16TN/BK
2 X94 16TN/RD
3 X91 16WT/BK
4 X93 16WT/RD
5 M1 18PK
6 M2 18YL
7 M4 18GY/BK
8
C314
(WITH SOUND BAR)
CAV CIRCUIT
1 X92 16TN/BK
2 X94 16TN/RD
3 X91 16WT/BK
4 X93 16WT/RD
5 M1 20PK
6 M2 20YL
7 M4 20GY/BK
8
C315
CAV CIRCUIT
1 C15 12BK/WT
2
C315
CAV CIRCUIT
1 C15 12BK/WT
2
C316 (LHD)
CAV CIRCUIT
1 F37 14RD/LB*
1
F37 14RD/LB**
F37 14RD/LB**
2 Z1 14BK*
2
Z1 14BK**
Z1 14BK**
C316 (LHD)
C316 (RHD)
CAV CIRCUIT
A M2 18YL
B Z1 18BK
C316 (RHD)
CAV CIRCUIT
A M2 20YL
B Z1 20BK
1 2
BLACK BLACK
BLACK
1 2
1 2
BLACK BLACK
BLACK
1 2
8 5
4 1
1 2 3 4
5 6 7 8
8 5
4 1
1 2 3 4
5 6 7 8
WHITE WHITE
WHITE WHITE
RED
B A
RED
A B
CAV CIRCUIT
1 F37 14RD/LB*
1
F37 14RD/LB**
F37 14RD/LB**
2 Z1 16BK*
2
Z1 16BK**
Z1 16BK**
*
WITHOUT ECE
**
WITH ECE
J978W-7
XJI08041
C317 (LHD)
CAV CIRCUIT
1 M2 20YL
2 G16 20BK/LB
3 Z1 20BK
C317 (LHD)
CAV CIRCUIT
1 M2 18YL
2 G16 18BK/LB
3 Z1 18BK
C317 (RHD)
CAV CIRCUIT
1 M2 20YL
2
3 Z1 20BK
C317 (RHD)
CAV CIRCUIT
1 M2 18YL
2 G16 18BK/LB
3 Z1 18BK
C318 (LHD)
CAV CIRCUIT
1 M2 20YL
2
3 Z1 20BK
C318 (LHD)
CAV CIRCUIT
1 M2 18YL
2 G16 18BK/LB
3 Z1 18BK
C318 (RHD)
CAV CIRCUIT
1 M2 20YL
2 G16 20BK/LB
3 Z1 20BK
C318 (RHD)
CAV CIRCUIT
1 M2 18YL
2 G16 18BK/LB
3 Z1 18BK
C319
CAV CIRCUIT
A M2 20YL
B Z1 20BK
C319
CAV CIRCUIT
A M2 18YL
B Z1 18BK
C320
CAV CIRCUIT
A M2 20YL
B Z1 20BK
C320
CAV CIRCUIT
A M2 18YL
B Z1 18BK
GRAY
2 1 3
BLACK
3 1
GRAY
2 1 3
BLACK
3 1
GRAY
2 1 3
BLACK
3 1
GRAY
2 1 3
BLACK
3 1
GRAY
GRAY
GRAY
BLACK
B A
BLACK
A B
BLACK
B A
BLACK
A B
GRAY
J978W-7
XJI08042
A M1 20PK COURTESY LAMP B(+)
B M2 20YL SWITCHED GROUND
C M4 20GY/BR GATE GROUND
CARGO LAMP
(ALL OTHERS)
A M1 18PK COURTESY LAMP B(+)
C M4 18GY/BK GATE GROUND
CARGO LAMP
(WITH SOUND BAR)
BLACK
C A
BLACK
C A
C321
CAV CIRCUIT
1 L62 18BR/RD
2 Z1 18BK
3
4 L38 16LG/BK
5 L10 18BR/LG
6 L50 20WT/TN
7 L78 18DG/YL
8
C321
CAV CIRCUIT
1 L62 18BR/RD
2 Z1 18BK
3
4 L38 16LG/BK
5 L10 18BR/LG
6 L50 20WT/TN
7 L78 18DG/YL
8
C322
CAV CIRCUIT
1 L63 18DG/RD
*
1 L63 20DG/RD
**
2 Z1 14BK
3 A6 20RD/OR
4 L38 16LG/BK
5 L10 18BR/LG
6 L50 20WT/TN
7 L77 18BR
8 L62 18BK/RD
C322
CAV CIRCUIT
1 L63 20DG/RD
2 Z1 14BK
3 A6 20RD/OR
4 L38 20LG/BK
5 L10 18BK/LG
6 L50 20WT/TN
7 L77 20BR
8 L62 20BK/RD
1 K7 18OR 5 VOLT SUPPLY
3 K44 18TN/YL CAMSHAFT POSITION SENSOR
CAMSHAFT
POSITION SENSOR
BLACK
1 3
1 3
4
4 8
1 3
8
1 3
4
4 8
1 3
8
BLACK
BLACK
BLACK
BLACK
*
LHD
**
RHD
J978W-7
XJI08043
1 L50 18WT/TN STOP LAMP SWITCH OUTPUT
2 Z1 18BK GROUND
CENTER HIGH
MOUNTED STOP LAMP
1 F30 16RD CIGAR LIGHTER FEED
2 Z1 16BK GROUND
CIGAR
LIGHTER
1 X3 20BK/RD HORN SWITCH
2 V37 20RD/LG VEHICLE SPEED CONTROL SWITCH JTEC
3 K4 20BK/LB VEHICLE SPEED CONTROL SIGNAL
4
CLOCK SPRING
(LHD)
1 X3 20BK/RD HORN SWITCH
2 V37 20RD/LG VEHICLE SPEED CONTROL SWITCH TO JTEC
3 K4 20BK/RD VEHICLE SPEED CONTROL SIGNAL
4
CLOCK SPRING
(RHD)
BLACK
2
1
NATURAL
1 4
NATURAL
1 4
BLACK
1 2
1 F45 20YL/RD FUSED IGNITION (START)
2 T141 20YL ENGINE STARTER MOTOR RELAY
CLUTCH INTERLOCK
SWITCH (RHD MANUAL
TRANSMISSION)
GREEN
2 1
J978W-7
XJI08044
1 E2 20OR CONSOLE ILLUMINATION
2 Z1 20BK GROUND
CONSOLE
ILLUMINATION
BLACK
1 2
1 F45 20YL/RD STARTER RELAY COIL FEED
2 T141 20YL CLUTCH INTERLOCK CLUTCH INTERLOCK
SWITCH (RHD, MANUAL
TRANSMISSION)
1 F45 18YL FUSED IGNITION (START)
2 F45 18YL FUSED IGNITION (START)
CLUTCH INTERLOCK
SWITCH JUMPER
(RHD AUTOMATIC
TRANSMISSION)
1 L5 20BK FUSED IGNITION (ACC/RUN)
2 L9 20BK/PK FUSED B(+)
3 L12 20VT/TN COMBINATION FLAHSER OUTPUT (HAZARD)
4 L6 20RD/WT COMBINATION FLASHER OUTPUT (TURN SIGNALS)
5 Z1 18BK GROUND
COMBINATION
FLASHER
(WITH LIGHTER VISOR)
1 F87 20WT/BK FUSED IGNITION
2 D1 20VT/BR CCD(+)
3 G31 20VT/LG TEMP SENSOR FEED
4
5 M1 20PK COURTESY LAMPS
6 Z1 20BK GROUND
7 Z2 20BK/LG LOGIC GROUND
8 D2 20WT/BK CCD()
9 G32 20BK/LG TEMP SENSOR RETURN
10
11
12 M2 20YL SWITCHED GROUND
COMPASS
1 2
GREEN
GREEN
2 1
BLACK
2 5
4
3
1
6 1
12 7
BLACK
J978W-7
XJI08045
1 B1 20YL/DB RIGHT REAR WHEEL SENSOR ()
2 B3 20LG/DB LEFT REAR WHEEL SENSOR ()
3 B7 20WT RIGHT FRONT WHEEL SENSOR (+)
4 B9 20RD LEFT FRONT WHEEL SENSOR (+)
5
6 B41 20YL/VT (ABS) ACCEL SENSOR 1
7 B42 20TN/WT (ABS) ACCEL SENSOR 2
8 Z1 12BK GROUND
9 A20 14RD/DB ABS SOLENOIDS
10 B4 20LG LEFT REAR WHEEL SENSOR (+)
11 B8 20RD/DB LEFT FRONT WHEEL SENSOR ()
12 L50 20WT/TN STOP LAMPS
13 B43 20PK/OR ACCEL SENSOR TEST SIGNAL
14
15
16 G83 20GY/BK FEED TO ABS MODULE
17 B2 20YL RIGHT REAR WHEEL SENSOR (+)
18 B6 20WT/DB RIGHT FRONT WHEEL SENSOR ()
19
20 D21 20PK DATA LINK TRANSMIT
21
22
23 F15 20DB/WT IGNITION RUN
24 Z1 12BK GROUND
25 A10 12RD/DG ABS PUMP
CONTROLLER
ANTI-LOCK BRAKE
(LHD)
1 B1 20YL/DB RIGHT REAR WHEEL SENSOR ()
2 B3 20LG/DB LEFT REAR WHEEL SENSOR ()
3 B7 20WT RIGHT FRONT WHEEL SENSOR (+)
4 B9 20RD LEFT FRONT WHEEL SENSOR (+)
5
6 B41 20YL/VT (ABS) ACCEL SENSOR 1
7 B42 20TN/WT (ABS) ACCEL SENSOR 2
8 Z1 12BK GROUND
9 A20 14RD/DB ABS SOLENOIDS
10 B4 20LG LEFT REAR WHEEL SENSOR (+)
11 B8 20RD/DB LEFT FRONT WHEEL SENSOR ()
13 B43 20PK/OR ACCEL SENSOR TEST SIGNAL
14
15
16 G83 20GY/BK FEED TO ABS MODULE
17 B2 20YL RIGHT REAR WHEEL SENSOR (+)
18 B6 20WT/DB RIGHT FRONT WHEEL SENSOR ()
19
20 D21 20PK DATA LINK TRANSMIT
21
22
23 F15 20DB/WT IGNITION RUN
24 Z1 12BK GROUND
25 A10 12RD/DG ABS PUMP
CONTROLLER
ANTI-LOCK BRAKE
(RHD)
10
16
1 17
9 25
BLACK
10
16
1 17
9 25
BLACK
J978W-7
XJI08046
1 K24 18GY/BK CRANKSHAFT POSITION SENSOR
2 K167 20BR/YL SENSOR GROUND
3 K7 20OR 5 VOLT SUPLY
CRANKSHAFT
POSITION SENSOR
BLACK
3 1 1 3
A K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
B K4 20BK/LB SENSOR GROUND
C K222 20TN/RD SECONDARY ENGINE COOLANT TEMPERATURE SENSOR
COOLANT
TEMPERATURE
SENSOR (DIESEL)
1 K3 20LG/BK SENSOR GROUND
2
3 K24 20GY/BK CRANK POSITION SENSOR SIGNAL
CRANKSHAFT
POSITION SENSOR
(DIESEL)
1
2
3 D1 18VT/BR CCD BUS (+)
4 Z1 18BK GROUND
5 Z12 18BK/LB GROUND
6 D20 20LG/BK SCI RECEIVE
7 D21 20PK SCI TRANSMIT
8
9
10
11 D2 18WT/BK CCD BUS ()
12
13
14
15
16 F34 18TN/BK FUSED B(+)
DATA LINK
CONNECTOR
16 9
8 1
BLACK
BLACK
B A
C
BLACK
3 1
J978W-7
XJI08047
1 L3 16RD DIMMER SWITCH HIGH BEAM OUTPUT
2
3
4 G34 16RD/GY HIGH BEAM INDICATOR DRIVER
5 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN/START)
6 A3 16RD/WT FUSED B(+)
7 G7 20WT/OR VEHICLE SPEED SENSOR SIGNAL
8 Z12 16BK/TN GROUND
9
10 L44 18VT/RD DIMMER SWITCH LOW BEAM OUTPUT
DAYTIME RUNNING
LAMP MODULE
BLACK
1
6
5
10
1 D1 20VT/BR UNDERHOOD CCD BUS (+)
2 D1 18VT/BR DATA LINK CCD BUS (+)
3 D1 20VT/BR AIRBAG CONTROL MODULE CCD BUS (+)
4
5 D2 20WT/BK AIRBAG CONTROL MODULE CCD BUS ()
6 D2 18WT/BK DATA LINK CCD BUS ()
7 D2 20WT/BK UNDERHOOD CCD BUS ()
8 D1 20VT/BR OVERHEAD CONSOLE CCD BUS (+)
9 D1 20VT/BR INSTRUMENT CLUSTER CCD BUS (+)
10
11
12
13 D2 20WT/BK INSTRUMENT CLUSTER CCD BUS ()
14 D2 20WT/BK OVERHEAD CONSOLE CCD BUS ()
A M1 20PK COURTESY LAMPS
C Z1 20BK GROUND
DOME LAMP
(WITH VANITY LAMPS
IMMOBILIZER)
1 K142 20DG/WT AUTOMATIC SHUT DOWN RELAY OUTPUT
2 Z1 20BK GROUND
4 K141 18TN/BK DOWNSTREAM HEATED OXYGEN SENSOR SIGNAL
DOWNSTREAM HEATED
OXYGEN SENSOR
NATURAL
A C
BLACK
2
4
1
3
BLACK
GRAY
1
8
7
1 7
14
8 14
DIAGNOSTICS
SPLICE BLOCK
GRAY
J978W-7
XJI08048
1 R45 18DG/LB DRIVER AIRBAG SQUIB
2 R43 18BK/LB DRIVER AIRBAG SQUIB
DRIVER AIRBAG
YELLOW
2 1
1 2
A F142 18DG/OR FUSED ASD RELAY FEED TO EGR SOLENOID
B K35 18GY/YL EGR ACTUATOR SIGNAL
C
D Z1 18BK GROUND
EGR SOLENOID
(DIESEL)
2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR
ENGINE COOLANT
TEMPERATURE SENSOR
2 G60 18GY/YL OIL PRESSURE SENSOR
ENGINE OIL
PRESSURE SENSOR
1 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
2 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN/START)
EVAP/PURGE
SOLENOID
BLACK
1 2
BLACK
2 1
BLACK
2 1
1
BLACK
2
1 E2 20OR FOG LAMP SWITCH ILLUMINATION
2 L39 20LB FOG LAMP FEED FROM SWITCH
3 L139 20VT SIGNAL FROM SWITCH TO RELAY
4 Z1 18BK GROUND
FRONT FOG
LAMP SWITCH
BLACK
1 4
A B
J978W-7
XJI08049
A V10 18BR WINDSHIELD WASHER SWITCH OUTUT
B Z1 18BK GROUND
FRONT WASHER
PUMP MOTOR
1 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN)
2 V5 16DG/YL WIPER PARK SWITCH SENSE
3
4 Z1 16BK GROUND
5 V3 16BR/WT WIPER SWITCH LOW SPEED OUTPUT
6 V4 16BR/VT
*
WIPER SWITCH HIGH SPEED OUTPUT
6 V4 16RD/YL
**
WIPER SWITCH HIGH SPEED OUTPUT
FRONT WIPER
MOTOR
BLACK
1
4
3
6
BLACK
A B
1 A93 14RD/BK FUEL HEATER RELAY FEED TO FUEL HEATER
2 Z1 14BK GROUND
FUEL HEATER
(DIESEL)
1 K134 20LB/BK FUEL PUMP REFERENCE COIL SIGNAL
2 K57 20LG/OR FUEL PUMP CONT. SLEEVE SIGNAL
3 K135 20WT/BK FUEL PUMP MEASURE COIL SIGNAL
4 K4 20BK/LB SIGNAL GROUND FUEL TEMP SENSOR
5 K126 16LG FUEL TIMING SOLENOID SIGNAL
6 K153 16OR FUEL SHUTOFF SOLENOID SIGNAL
7 K156 20GY FUEL TEMP SENSOR SIGNAL
8 K140 16TN/WT FUEL QUANTITY ACTUATOR
9 A142 16DG/OR ASD RELAY FEED TO FUEL ACTUATOR SOLENOID
10 F142 16DG/OR FUSED ASD RELAY FEED TO FUEL TIMING SOLENOID
FUEL PUMP
MODULE (DIESEL)
*
GAS
**
DIESEL
BLACK
1 2
5
10
1
6
BLACK
J978W-7
XJI08050
1 A141 16DG/WT FUEL PUMP FEED
2
3 K226 20DB/LG FUEL LEVEL SENSOR
4 K167 20BR/YL FUEL RETURN SENSOR
5
6 Z1 14BK GROUND FUEL PUMP
MODULE (LHD)
1 A141 16DG/WT FUEL PUMP FEED
2
4 K167 20BR/YL FUEL RETURN SENSOR
5
6 Z1 16BK GROU ND
FUEL PUMP
MODULE (RHD)
1 B517 20PK/OR ACCEL SENSOR
2 B515 20YL/VT ACCEL SENSOR
3 B516 20TN/WT ACCEL SENSOR
G-SWITCH (LHD)
BLACK
6 5 4
3 2 1
1 3
BLACK
BLACK
4
BLACK
6 5 4
3 2 1
BLACK
4
1 K20 18DG GENERATOR FIELD
2 K72 18DG/OR GENERATOR SOURCE
3
4 Z006BK
**
ALTERNATOR GROUND
4 Z0 08BK
*
BATTERY CABLE NEGATIVE B()
GENERATOR
1 M120 PK FUSED B(+)
2 Z1 20BK GROUND
GLOVE BOX
LAMP SWITCH
2
BLACK
1
GRAY
*
2.5L DIESEL
**
4.0L
2.5L DIESEL/4.0L
3
4
1
2
BLACK
J978W-7
XJI08051
1 A54 10RD/GY BATTERY FEED TO GLOW PLUG RELAY
2 F142 18DG/OR FUSED ASD RELAY FEED TO GLOW PLUG RELAY
3 K152 18WT GLOW PLUG RELAY CONTROL SENSE
4 K154 10GY GLOW PLUG FEED
GLOW PLUG
RELAY (DIESEL)
1
3
4 Z1 18BK GROUND
5
6 L2 16LG HEADLAMP SWITCH OUTPUT
7
8 F87 20WT/BK FUSED IGNITION (START/RUN)
HEADLAMP
DELAY MODULE
(LHD)
1
3
4 Z1 18BK GROUND
5
7
HEADLAMP
DELAY MODULE
(RHD)
1 3 5 7
2 4 6 8
BLACK
1 3 5 7
2 4 6 8
BLACK
1
2 Z15 20BK GROUND
3
4 L44 20BK/RD HEADLAMP LEVELING SWITCH FEED
5 L13 20BR/YL HEADLAMP LEVELING MOTOR FEED
6
HEADLAMP LEVELING
SWTICH (RHD)
1
2 3
4
1 6
BLACK
J978W-7
XJI08052
1 E1 20TN FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 L2 16LG FEED TO DELAY MODULE
3 M2 20YL COURTESY LAMP DRIVER
4
F34 18TN/BK FUSED B(+)
F34 18TN/BK FUSED B(+)
5 G26 20LB HEADLAMPS ON SIGNAL
6 G16 20BK/LB KEY-IN IGNITION SWITCH SENSE
7 L20 16LG/WT FEED TO BEAM SELECT SWITCH
8
A3 16RD/WT FUSED B(+)
9 L7 18BK/YL PARKLAMP OUTPUT
HEADLAMP SWITCH
C1 (LHD)
BLACK
2
9
7
6
3
4
5 8
1
1 E1 20TN FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
2 L2 16LG FEED TO DELAY MODULE
5 G26 20LB KEY-IN IGNITION SWITCH SENSE
6 G16 20BK/LB HEADLAMP ON SIGNAL
7 L20 16LG/WT FEED TO BEAM SELECT SWITCH
8
9 L7 18BK/YL PARKLAMP OUTPUT
HEADLAMP SWITCH
C1 (RHD)
1
Z1 18BK GROUND
Z1 18BK GROUND
HEADLAMP
SWITCH C2
1
2 C4 14TN LOW MOTOR BLOWER DRIVER
3 C5 14LG M1 MOTOR BLOWER DRIVER
4 C6 14LB M2 MOTOR BLOWER DRIVER
5
6
7 C7 12BK/TN HIGH MOTOR BLOWER DRIVER
8 A111 12RD/LG BLOWER MOTOR FEED
9
F15 20DB/WT FUSED IGNITION (START/RUN)
F15 20DB/WT FUSED IGNITION (START/RUN)
10 Z8 12BK/VT GROUND
HVAC UNIT
(LHD)
BLACK
2
9
7
6
3
4
5 8
1
BLACK
2
1
5
10
1
6
BLACK
J978W-7
XJI08053
1
2 C4 14TN LOW MOTOR BLOWER DRIVER
3 C5 14LG M1 MOTOR BLOWER DRIVER
4 C6 14LB M2 MOTOR BLOWER DRIVER
5
6
7 C7 12BK/TN HIGH MOTOR BLOWER DRIVER
8 A111 12RD/LG BLOWER MOTOR FEED
9 F15 20DB/WT FUSED IGNITION (START/RUN)
HVAC UNIT
(RHD)
5
10
1
6
LT. GREEN
1 K59 18VT/BK IDLE AIR CONTROL MOTOR CLOSE SIGNAL
2 K40 18BR/WT IDLE AIR CONTROL MOTOR CLOSE SIGNAL
3 K60 18YL/BK IDLE AIR CONTROL MOTOR CLOSE SIGNAL
4 K39 18GY/RD IDLE AIR CONTROL MOTOR OPEN SIGNAL
IDLE AIR
CONTROL MOTOR
1 K19 18GY IGNITION COIL NO. 1 DRIVER
2 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
IGNITION COIL
1 Z1 20BK GROUND
2 G9 20GY/BK BRAKE INDICATOR LAMP
3 A2 12PK/RD FUSED B(+)
4 A22 12BK/OR IGNITION OUTPUT (RUN)
5
6
7 A1 12RD FUSED B(+)
8 A31 12BK/WT IGNITION OUTPUT (RUN/START)
9 A21 12DB IGNITION OUTPUT (START/RUN)
10 A41 14YL IGNITION OUTPUT (START)
IGNITION
SWITCH (LHD)
BLACK
4 1
1
BLACK
2
BLACK
5 1
10 6
1 Z1 20BK GROUND
2 G9 20GY/BK BRAKE INDICATOR LAMP
3 A2 12PK/BK FUSED B(+)
4 A22 12BK/OR IGNITION OUTPUT (RUN)
5
6
7 A1 12RD FUSED B(+)
8 A31 12BK/WT IGNITION OUTPUT (RUN/START)
9 A21 12DB IGNITION OUTPUT (START/RUN)
10 A41 14YL IGNITION OUTPUT (START)
IGNITION
SWITCH (RHD)
BLACK
5 1
10 6
J978W-7
XJI08054
1 A142 18DG/OR AUTOMATIC SHUT DOWN FEED FROM RELAY
2 K11 18WT/DB INJECTOR NO. 1 DRIVER
INJECTOR NO. 1
2
BLACK
1
2 K12 18TN INJECTOR NO. 2 DRIVER
INJECTOR NO. 2
2 K13 18YL/WT INJECTOR NO. 3 DRIVER
INJECTOR NO. 3
2 K14 18LB/BR INJECTOR NO. 4 DRIVER
INJECTOR NO. 4
2 K15 18PK/BK INJECTOR NO. 5 DRIVER
INJECTOR NO. 5
2 K16 18LG/BK INJECTOR NO. 6 DRIVER
INJECTOR NO. 6
2
BLACK
1
2
BLACK
1
2
BLACK
1
2
BLACK
1
2
BLACK
1
J978W-7
XJI08055
1 Z2 18BK/LG GROUND
2 G99 20GY/WT BRAKE INDICATOR LAMP
3 E2 20OR CLUSTER ILLUMINATION
4 G19 20LG/OR ABS INDICATOR LAMP
5 G34 16RD/GY HIGH BEAM INDICATOR LAMP
6 Z2 18BK/LG GROUND
7 G38 20GY SECURITY INDICATOR LAMP
9 M1 20PK FUSED B(+)
10 L61 20LG/WT LEFT TURN SIGNAL INDICATOR
INSTRUMENT
CLUSTER C1
(RHD)
1 D2 20WT/BK CCD ()
2 D1 20VT/BR CCD (+)
3 C81 20LB/WT HEATED MIRRORS/REAR WINDOW DEFOGGER TIMER
4 C80 20DB/WT HEATED MIRRORS/REAR WINDOW DEFOGGER ON
5 G107 20BK/RD FULL TIME 4WD INDICATOR LAMP
6 L60 20TN RIGHT TURN SIGNAL INDICATOR LAMP
7 G106 20BK/WT PART TIME 4WD INDICATOR LAMP
8 G26 20LB IGNITION KEY-IN TO CLUSTER
9 G29 20BK/TN WASHER FLUID SWITCH SENSE
10 G10 20LG/RD SEAT BELT SWITCH SENSE
INSTRUMENT
CLUSTER C2
2 K21 18BK/RD INTAKE AIR TEMPERATURE SENSOR
INTAKE AIR
TEMPERATURE SENSOR
BLACK
5 1
10 6
BLACK
5 1
10 6
GRAY
B A
1 Z2 18BK/LG GROUND
2 G99 20GY/WT BRAKE INDICATOR LAMP
3 E2 20OR CLUSTER ILLUMINATION
4 G19 20LG/OR ABS INDICATOR LAMP
5 G34 16RD/GY HIGH BEAM INDICATOR LAMP
6 Z2 18BK/LG GROUND
7 G38 20GY SECURITY INDICATOR LAMP
10 L61 20LG/WT LEFT TURN SIGNAL INDICATOR
INSTRUMENT
CLUSTER C1
(LHD)
BLACK
5 1
10 6
1 2
J978W-7
XJI08056
1 L44 20VT/RD FUSED DIMMER SWITCH LOW BEAM OUTPUT
2
3 F45 20YL/RD FUSED IGNITION (START)
4
5 L78 20DG/YL FUSED DIMMER SWITCH RGHT PARK LAMP OUTPUT
6 F15 20DB/WT FUSED IGNITION (RUN)
7
8 V6 16DB FUSED IGNITION (RUN/ALL)
9 L33 20RD FUSED DIMMER SWITCH LEFT HIGH BEAM OUTPUT
10 L43 20VT FUSED DIMMER SWITCH LEFT LOW BEAM OUTPUT
11
L34 20DG/OR
*
FUSED DIMMER SWITCH RIGHT HIGH BEAM OUTPUT
L34 20DG/OR
**
FUSED DIMMER SWITCH RIGHT HIGH BEAM OUTPUT
JUNCTION
BLOCK C1
1 A4 12BK/PK FUSED B(+)
2 A7 10RD/BK FUSED B(+)
3
4 X2 20DG/RD HORN RELAY OUTPUT
5 F12 18DB/WT FUSED IGNITION (RUN/START)
6 L77 20BR/YL FUSED DIMMER SWITCH LEFT PARK LAMP OUTPUT
JUNCTION
BLOCK C2
2 Z1 20BK GROUND
JUNCTION
BLOCK C3
L1 A31 12BK/WT IGNITION SWITCH OUTPUT (RUN/ACC)
L2 A21 12DB IGNITION SWITCH OUTPUT (START/RUN)
M1 A41 12YL IGNITION SWITCH OUTPUT (START)
M1 A41 14YL
*
IGNITION SWITCH OUTPUT (START)
M2 A22 12BK/OR IGNITION SWITCH OUTPUT (RUN)
M3 L7 18BK/YL PARK LAMP FEED
M4 V6 18DB FUSED IGNITION (RUN/ACC)
M4 Y6 16DB
**
FUSED IGNITION (RUN/ACC)
M5 F38 16RD/LB FUSED B(+)
M6 F30 16RD CIGAR LIGHTER RELAY OUTPUT
S1 E1 20TN PANEL LAMPS FUSE FEED
S2 E2 20OR FUSED DIMMER SWITCH OUTPUT
S3 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
S4
S5 Z1 14BK GROUND
S6
JUNCTION
BLOCK C4
BLACK
2
1
6
3
7
2
12
3
1
8
NATURAL
NATURAL
1 3
S1
S2
S3
S24
S25
S26
M1
M2
M3
M4
M5
M6
S7 L1 S14
S13 L2 S20
NATURAL
WHITE
*
RHD, 4.0L AUTOMATIC TRANSMISSION
**
ALL OTHERS
J978W-7
XJI08057
S7 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
S8 F15 20DB/WT FUSED IGNITION (RUN)
S9 X12 16RD/WT FUSED IGNITION (RUN/ACC)
S10
S11 V23 18BR/PK FUSED IGNITION (RUN)
S12
S13 F87 20WT/BK FUSED IGNITION (START/RUN)
S14
S15
S16
S17
S18 M1 20PK FUSED B(+)
S19
C16 20LB/YL
*
C16 20BK/WT
**
S20 L5 20BK FUSED IGNITION (RUN)
S21 F14 18LG/YL FUSED IGNITION (RUN)
S22 X3 20BK/RD HORN RELAY CONTROL
S23 F23 18DB/YL FUSED IGNITION (START/RUN)
S24
S25 M2 20YL COURTESY LAMP SWITCH OUTPUT
S26 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL
(CONTINUED)
1 X3 20BK/RD HORN RELAY CONTROL
2 P76 20OR/YL POWER MIRROR CONTROL
3
4
5 C16 20LB/YL REAR WINDOW DEFOGGER RELAY OUTPUT
6 F35 16RD FUSED B(+)
7
8 F81 12TN FUSED IGNITION (RUN/ACC)
9 P74 20DB RIGHT POWER MIRROR HORIZONTAL MOTOR
10 P72 20YL/BK RIGHT POWER MIRROR VERTICAL MOTOR
JUNCTION
BLOCK C5
1 C15 12BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT
2 F37 14RD/LB FUSED B(+)
JUNCTION
BLOCK C6
1 P33 16OR/BK DOOR LOCK RELAY OUTPUT
2 L77 18BR LEFT PARK LAMP
3 Q1 14YL MASTER SWITCH LOCKOUT
4 M1 20PK POWER MIRROR LOCK SWITCH POWER
5 P34 16PK/BK DOOR UNLOCK RELAY OUTPUT
6 L78 18DG/YL RIGHT PARK LAMP
7 M2 20YL DOOR AND LIFT GROUND SWITCHES
8 A6 20RD/OR FUSED B(+)
JUNCTION
BLOCK C7
1 4
5 7 8 10
NATURAL
NATURAL
2 1
NATURAL
1
4
3
8
*
LHD, BASE MODEL
**
ALL OTHERS
J978W-7
XJI08058
1 F81 12TN FUSED IGNITION (RUN/ACC)
2
JUNCTION
BLOCK C8
1 P33 16OR/BK RIGHT FRONT DOOR LOCK SWITCH TO ACTUATOR
2 P74 20DB RIGHT POWER MIRROR
3 C16 20BK/WT RIGHT POWER MIRROR HEATER
4
5
6 P72 20YL/BK RIGHT POWER MIRROR
8
9 F35 16RD FUSED B(+)
10 P76 20OR/YL RIGHT POWER MIRROR
11 Z1 16BK GROUND
12 P34 16PK/BK RIGHT FRONT DOOR SWITCH TO ACTUATOR
JUNCTION
BLOCK C9
KEY-IN SWITCH
A L10 18BR/LG BACK-UP LAMP SWITCH OUTPUT
G Z1 18BK GROUND
LEFT BACK-UP
LAMP
1 M1 18PK COURTESY LAMP FEED
2 M2 18BK/WT SWITCHED GROUND
LEFT
COURTESY LAMP
1 G26 20LB KEY-IN IGNITION SWITCH SENSE
2 G16 20BK/LB KEY-IN IGNITION SWITCH SIGNAL
BLACK
A
G
BLACK
NATURAL
2 1
NATURAL
12
5
6
1
YELLOW
2 1
GREEN
J978W-7
XJI08059
1 M2 18YL COURTESY LAMPS DRIVER
2 G16 18BK/LB DOOR AJAR SWITCH SENSE
3 Z1 18BK GROUND
LEFT FRONT
DOOR JAMB SWITCH
1 X80 16LB/BR LEFT FRONT DOOR TWEETER ()
2 X80 16LB/RD LEFT FRONT DOOR TWEETER (+)
LEFT FRONT
DOOR TWEETER
(RHD)
1 X85 16BK/RD LEFT FRONT DOOR SPEAKER ()
2 X87 16DG LEFT FRONT DOOR SPEAKER (+)
LEFT FRONT
DOOR SPEAKER (LHD)
1 X85 16LG/RD LEFT DOOR TWEETER ()
2 X87 16LG/BK LEFT DOOR TWEETER (+)
LEFT FRONT
DOOR TWEETER (LHD)
1 X80 16LB/BR LEFT FRONT DOOR SPEAKER ()
2 X82 16LB/RD LEFT FRONT DOOR SPEAKER (+)
LEFT FRONT
DOOR SPEAKER (RHD)
BLACK
1 2
BLACK
1 2
2 3
1
BLACK
BLACK
1
2
BLACK
1
2
1 Z1 20BK GROUND
2 L39 20LB LEFT FOG LAMP
LEFT
FOG LAMP
BLACK
2 1
J978W-7
XJI08060
1 P34 16PK/BK POWER DOOR UNLOCK RELAY
2 P33 16OR/BK POWER DOOR LOCK RELAY
LEFT FRONT POWER
DOOR LOCK MOTOR (LHD)
1 Q28 14DG/WT MASTER SWITCH TO RIGHT REAR MOTOR (DOWN)
2 Q18 14GY/BK MASTER SWITCHTO RIGHT REAR MOTOR (UP)
3 Q16 14BR/WT MASTER SWITCH TO RIGHT FRONT MOTOR (UP)
4 Q17 14DB/WT MASTER SWITCH TO LEFT REAR MOTOR (UP)
5 Q11 16LB MASTER SWITCH TO LEFT FRONT MOTOR (UP)
6 Q26 14VT/WT MASTER SWITCH TO RIGHT FRONT MOTOR (DOWN)
7 P35 18OR/VT MASTER SWITCH TO POWER DOOR LOCK RELAY
8 Z1 12BK GROUND
9 F81 12TN MASTER SWITCH POWER FEED (RUN)
10 Q27 14RD/BK MASTER SWTICH TO LEFT REAR MOTOR (DOWN)
11 P36 18PK/VT MASTER SWITCH TO POWER DOOR UNLOCK RELAY
12 Q21 16WT MASTER SWITCH TO LEFT FRONT MOTOR (DOWN)
LEFT FRONT
POWER LOCK/ WINDOW
SWITCH C1 (LHD)
1 P71 20YL LEFT POWER MIRROR (UP)
2 P76 20OR/YL LEFT POWER MIRROR (DOWN/RIGHT)
3 M1 18PK FUSED IGNITION B(+)
4 P74 20DB RIGHT POWER MIRROR (RIGHT)
5 Z1 12BK GROUND
6 P75 20DB/WT LEFT POWER MIRROR (RIGHT)
7 P72 20YL/BK RIGHT POWER MIRROR (UP)
LEFT FRONT
POWER LOCK/WINDOW
SWITCH C2 (LHD)
1 Q11 16LB POWER WINDOW MOTOR (UP)
2 Q21 16WT POWER WINDOW MOTOR (DOWN)
LEFT FRONT
POWER WINDOW
MOTOR (LHD)
2 L61 20LG LEFT TURN SIGNAL
LEFT FRONT
SIDE MARKER LAMP
BLACK
2 1
YELLOW
1 2
BLUE
1
6
5
12
BLACK
2 1
8 5
4 1
WHITE
J978W-7
XJI08061
1 B8 20RD/DB LEFT FRONT WHEEL SPEED SENSOR ()
2 B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT
WHEEL SPEED
SENSOR (LHD)
1 B8 20RD/DB LEFT FRONT WHEEL SPEED SENSOR ()
2 B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT
WHEEL SPEED
SENSOR (RHD)
A
L33 20RD LEFT HIGH BEAM
L33 20RD
*
LEFT HIGH BEAM
B L43 VT LEFT LOW BEAM
C Z1 18BK GROUND
LEFT
HEADLAMP
BLACK
2 1
BLACK
2 1
A C
B
BLACK
2 Z1 20BK GROUND
LEFT PARK
LAMP
1 P71 20YL LEFT POWER MIRROR (UP)
3
P75 20DB/WT
**
LEFT POWER MIRROR (RIGHT)
P75 20DB/RD
***
LEFT POWER MIRROR (RIGHT)
5 C16 20LB/YL HEATED MIRROR FEED
6 Z1 16BK GROUND
LEFT POWER
MIRROR
RED
3
4
1
6
*
WITH FOG LAMPS
**
LHD
***
RHD
1
2
J978W-7
XJI08062
1 P34 16PK/BK DOOR LOCK MOTOR UNLOCK
2 P33 16OR/BK DOOR LOCK MOTOR LOCK
LEFT REAR POWER
DOOR LOCK MOTOR
BLACK
1 2
1 F37 14RD/LB POWER SEAT FEED
2 Z1 14BK BODY GROUND
LEFT
POWER SEAT
BLACK
2 1
A M2 18YL COURTESY LAMPS DRIVER
B Z1 18BK GROUND
C
LEFT REAR
DOOR JAMB SWITCH
1 Q13 16DB REAR SWITCH TO MOTOR UP
2 Q23 16RD/WT REAR SWITCH TO MOTOR DOWN
LEFT REAR POWER
WINDOW MOTOR
1 Q13 16DB REAR SWITCH TO MOTOR UP
2 Q28 14DG/WT REAR SWITCH TO MASTER DOWN
3
4 Q18 14GY/BK REAR SWITCH TO MASTER UP
5 Q23 16RD/WT REAR SWITCH TO MOTOR DOWN
LEFT REAR POWER
WINDOW SWITCH
3
6
1
4
BLUE
BLACK
2 1
B C
A
BLACK
J978W-7
XJI080563
A L90 18DB/RD PARK LAMP SWITCH OUTPUT
B Z1 18BK GROUND
LEFT REAR SIDE
MARKER LAMP
YELLOW
A B
A L60 18TN LEFT TURN SIGNAL
G Z1 18BK GROUND
LEFT REAR TURN
SIGNAL LAMP
A B3 20LG/DB LEFT REAR WHEEL SENSOR ()
B B4 20LG LEFT REAR WHEEL SENSOR (+)
LEFT REAR WHEEL
SPEED SENSOR (LHD)
A B3 18LG/DB LEFT REAR WHEEL SENSOR ()
B B4 18LG LEFT REAR WHEEL SENSOR (+)
LEFT REAR WHEEL
SPEED SENSOR (RHD)
A
G
BLACK
B A
BLACK
B A
BLACK
A X91 16WT/BK LEFT SOUND BAR SPEAKER ()
B X93 16WT/RD LEFT SOUND BAR SPEAKER (+)
LEFT SOUND
BAR SPEAKER
1 X91 16WT/BK SOUND BAR ()
2 X93 16WT/RD SOUND BAR (+)
LEFT SPEAKER
(WITH SOUND BAR)
BLACK
A B A B
BLACK
2 1
J978W-7
XJI08064
A L50 18WT/TN STOP LAMP SWITCH OUTPUT
B L90 18DB/RD PARK LAMP SWITCH OUTPUT
G Z1 18BK GROUND
LEFT TAIL/
STOP LAMP
BLACK
A
B
G
2 Z1 18BK GROUND
LEFT TURN
JUMPER
1 Z1 18BK GROUND
2
LEFT TURN
SIGNAL
1 L77 18BR PARK LAMP SWITCH OUTPUT
2 Z1 18BK GROUND
LICENSE
LAMP
1 Z1 20BK GROUND
2
3 M4 20VT/YL COURTESY LAMPS DRIVER
LIFTGATE JAMB
SWITCH
YELLOW
1 2
BLACK
3 1
BLACK
3 1
BLACK
2 1
J978W-7
XJI08065
A P33 16OR/BK DOOR LOCK RELAY OUTPUT
B P34 16PK/BK DOOR UNLOCK RELAY OUTPUT
LIFTGATE LOCK
MOTOR
BLACK
A B
1 G18 20PK/BK COOLANT LEVEL SENSOR
2 K167 20BR/YL SIGNAL GROUND LOW COOLANT
LOW COOLANT
SENSOR (DIESEL)
A Z1 20BK GROUND
B G29 20BK/LB
*
WASHER FLUID SWITCH SENSE
B G29 20BK/TN
**
WASHER FLUID SWITCH SENSE LOW WASHER
FLUID LEVEL SWITCH
BLACK
A B
2 K1 18DG/RD MAP SENSOR
MANIFOLD ABSOLUTE
PRESSURE SENSOR
BLACK
1 Z2 18BK/LG GROUND
2 K4 20BK/LB SENSOR GROUND
3 F142 18DG/OR FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT
4 K155 20DB MASS AIR FLOW SENSOR SIGNAL
MASS AIR FLOW
SENSOR (DIESEL)
*
GAS
**
DIESEL
BLACK
1 2
4 1
J978W-7
XJI08066
1 Z12 14BK/GL POWER GROUND
2 G21 20GY/LB TACHOMETER SIGNAL
3 K185 20OR/LB WAIT TO START LAMP
4 K140 16TN/WT FUEL QUANTITY ACTUATOR GROUND
5 K140 16TN/WT FUEL QUANTITY ACTUATOR GROUOND
6
7 K57 20LG/OR CONT SLEEVE POSITION SENSOR
8 K24 20GY/BK CRANK POSITION SENSOR SIGNAL
9
10
11 K68 18LG/YL NEEDLE MOVEMENT SENSOR ()
12 K67 18BR/BK NEEDLE MOVEMENT SENSOR (+)
13 K155 20DB AIR FLOW METER SIGNAL
14 K2 20TN/BK ENGINE COOLANT TEMEPRATURE SENSOR SIGNAL
15 K22 20OR/DB THROTTLE POSITION SENSOR SIGNAL
16
17
18
19
20 K29 20WT/PK BRAKE SWITCH SENSE
21 K3 20LG/BK SENSOR GROUND
22
23 A142 16DG/OR AUTO SHUTDOWN RELAY OUTPUT
24 Z12 16BK/LG POWER GROUND
25 K35 18GY/YL EGR SOLENOID CONTROL
26 K48 20OR/RD FLT SIGNAL
27 V66 20RD/LG WIPER PARK SWITCH SENSE
28 C22 20DB/WT PRESSURE SWITCH OUTPUT
29 K134 20LB/BK SLEEVE POSITION SENSOR ()
30
31
32
33 K4 20BK/LB SENSOR GROUND
34
35
36 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
37 C103 20DG A/C SWITCH SIGNAL
38 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT
39
40
41
42 K51 20DB/YL AUTO SHUTDOWN RELAY CONTROL
45 A142 16DG/OR AUTO DHUTDOWN RELAY OUTPUT
46 Z12 16BK/LG POWER GROUOND
47
48
49 K140 16TN/WT FUEL QUANTITY ACTUATOR GROUND
50 K152 18WT GLOW PLUG RELAY CONTROL SENSE
51 K126 16LG SOLENOID CONTROL
52 K135 20WT/BK SLEEVE POSITION SENSOR (+)
MSA CONTROLLER
(DIESEL)
1
2
22
23
68
48
J978W-7
XJI08067
1 K67 18BR/BK NEEDLE MOVEMENT SENSOR B(+)
2 K68 18LG/YL NEEDLE MOVEMENT SENSOR B()
NEEDLE
MOVEMENT SENSOR
(DIESEL)
BLACK
2 1
1 K167 20BR/YL SIGNAL GROUND OIL PRESSURE SWITCH
2 G60 20GY/YL OIL PRESSURE GAUGE SENDING UNIT
OIL PRESSURE
SWITCH (DIESEL)
(CONTINUED)
53 K153 16OR SHUTOFF FEED
54
55 K255 20WT/DG PEDAL POSITION SENSOR
56
57 K6 20VT/WT 5 VOLT SUPPLY
58
59 G55 20OR/BK ENGINE DISABLE SIGNAL
60
62
63 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL
64
65 K151 20WT LOW IDLE POSITION SWITCH
66
67
1 M2 20YL DOOR AJAR
2 M1 20PK COURTESY LAMPS
3 Z1 20BK POWER GROUND
4 G38 20GY IMMOBILIZER TELLTALE
5 P55 20DB UNLOCK CONTROL
7
8 F1 20DB/GY FUSED BATTERY SIGNAL
9 Z2 20BK/LG LOGIC GROUND
10 X3 20BK/RD HORN RELAY
11 P59 20LB/RD LOCK CONTROL
OVERHEAD MODULE
(WITH IMMOBILIZER)
12 11 10 9 8 7
6 5 4 3 2 1
1
2
J978W-7
XJI08068
1 G9 18GY/BK BRAKE SWITCH SENSE
2
PARK BRAKE
SWITCH (LHD)
1 G9 20GY/BK BRAKE SWITCH SENSE
2
PARK BRAKE
SWITCH (RHD)
BLACK
BLACK
1 R51 20WT/YL PRESSURE SENSE ()
2 R50 20BR/YL PRESSURE SENSE (+)
3 R42 18BK/YL AIRBAG SQUIB ()
4 R44 18DG/YL AIRBAG SQUIB (+)
PASSENGER
AIRBAG
YELLOW
1 4
1
2
3 K4 20BK/LB SIGNAL GROUND PEDAL POSITION SENSOR
4
5 K151 20WT PEDAL POSITION SENSOR LOW IDLE SIGNAL
6
7 K22 20OR/DB THROTTLE POSITION SIGNAL
8 K255 20WT/DG PEDAL POSITION SENSOR GROUND
9
10 K6 20VT/WT 5 VOLT OUTPUT FOR M.A.P.P. & T.P.P.
PEDAL POSITION
SENSOR (DIESEL)
5
10
1
6
BLACK
1 X55 16BR/RD LEFT DOOR SPEAKER ()
2 X56 16DB/RD RIGHT DOOR SPEAKER ()
3 X58 16DB/OR RIGHT SOUND BAR SPEAKER ()
4 X60 16DG/RD POWER AMP RELAY FEED
5 X53 16DG LEFT DOOR SPEAKER (+)
6 X54 16VT RIGHT DOOR SPEAKER (+)
7 X51 16BR/YL LEFT SOUND BAR SPEAKER (+)
8 X57 16BR/LB LEFT SOUND BAR SPEAKER ()
9 X52 16DB/WT RIGHT SOUND BAR SPEAKER (+)
10
POWER
AMPLIFIER C1
4
NATURAL
10
1
5
J978W-7
XJI08069
1 F75 16VT POWER AMP FEED
3
5 X94 16TN/RD RIGHT SOUND BAR SPEAKER (+)
6 X93 16WT/TN LEFT SOUND BAR SPEAKER ()
7 Z5 16BK POWER AMP GROUND
9
10 X80 16LB/BK RIGHT DOOR SPEAKER ()
11 X82 16LB/RD RIGHT DOOR SPEAKER (+)
13 X92 16TN/BK RIGHT SOUND BAR SPEAKER ()
14 X91 16WT/BK LEFT SOUND BAR SPEKAER ()
POWER
AMPLIFIER C2 (LHD)
NATURAL
1
7
6
14
3
5 X94 16TN/RD RIGHT SOUND BAR SPEAKER (+)
6 X93 16WT/TN LEFT SOUND BAR SPEAKER (+)
9
10 X80 16LB/BK RIGHT DOOR SPEAKER ()
11 X82 16LB/RD RIGHT DOOR SPEAKER (+)
13 X92 16TN/BK RIGHT SOUND BAR SPEAKER ()
14 X91 16WT/BK LEFT SOUND BAR SPEKAER ()
POWER
AMPLIFIER C2 (RHD)
1 Z1 16BK GROUND
2 F38 16RD/LB POWER OUTLET FEED
POWER OUTLET
BLACK
1
2
NATURAL
1
7
6
14
1 Z1 20BK GROUND
2 K10 18DB/BR POWER STEERING PRESSURE SWITCH SENSE
POWER STEERING
PRESSURE SWITCH (2.5L)
WHITE
2 1
J978W-7
XJI08070
A1
A2 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN/START)
A3
A4 K167 18BR/YL SENSOR RETURN
A5
T41 18BK/WT PARK/NEUTRAL SWITCH
*

A6
T41 18BK/WT PARK NEUTRAL SWITCH
*
Z1 18BK GROUND
**
A7 K19 18GY IGNITION COILS NO. 1 NO. 6 DRIVER
A8 K24 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL
A9
A10 K60 18YL/BK AIS MOTOR CLOSE SIGNAL
A11 K40 18BR/WT AIS MOTOR CLOSE SIGNAL
A12 K10 18DB/BK POWER STEERING PRESSURE SWITCH
***
A12 K78 18GY EXTENDED IDLE SWITCH (POLICE)
****
A13
A14
A15 K21 18BK/RD CHARGE AIR TEMP SENSOR
A16 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR
A17 K7 18OR 5 VOLT SUPPLY
A18 K44 18TN/YL CAMSHAFT POSITION SENSOR SIGNAL
A19 K39 18GY/RD AIS MOTOR OPEN SIGNAL
A20 K59 18VT/BK AIS MOTOR CLOSE SIGNAL
A21
A22 A61 16DG/BK FUSED B(+)
A23 K22 18OR/DB THROTTLE POSITION SENSOR
A24 K41 18BK/DG UPSTREAM HEATED OXYGEN SENSOR
A25 K141 18TN/BK DOWNSTREAM HEATED OXYGEN SENSOR
A26
A27 K1 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR
A28
A29
A30
A31 Z12 14BK/TN GROUND
A32 Z12 14BK/TN GROUND
POWERTRAIN
CONTROL MODULE C1
*
WITH AUTOMATIC TRANSMISSION
**
WITH MANUAL TRANSMISSION
***
WITH 2.5L ENGINE
****
WITH 4.0L ENGINE, AUTOMATIC TRANSMISSSION
1 11
22
12 21
32
BLACK
2
3 F16 16RD/LG FUSED B(+)
5
7
8 G18 20PK/BK COOLANT LEVEL SWITCH SENSE
9 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT
10
13
14
15 G55 20OR/BK ENGINE DISABLE SIGNAL
16
17
18
19
20 K20 18DG GENERATOR FIELD DRIVER
21 K222 20TN/RD SECONDARY ENGINE COOLANT TEMP SENSOR
22 K48 20OR/RD FLT SIGNAL
23 G123 20DG/WT WATER IN FUEL SENSE
24 G21 20GY/LB TACHOMETER SIGNAL
27
29
30
31 G86 20TN/OR WATER IN FUEL WARNING LAMP DRIVER
32
33
34
35
36
37
38 -
39
40
41 V66 20RD/LG WIPER PARK SWITCH SENSE
42 G60 20GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
43
44
45 D20 20LG/BK SCI RECEIVE
46 D2 20WT/BK CCD BUS ()
48
49
50
51
52
53
POWERTRAIN
CONTROL MODULE
(DIESEL) C1
BLACK
41 21 1
60 40 20
J978W-7
XJI08072
54 G154 20VT/LG LOW COOLANT WARNING LAMP DRIVER
55
56
58
59 C103 20DG A/C SWITCH SIGNAL
60
(CONTINUED
*
WITH 4.0L ENGINE
B1
B2
B3
B4 K11 18WT/DB INJECTOR NO. 1 DRIVER
B5 K13 18YL/WT INJECTOR NO. 3 DRIVER
B6 K15 18PK/BK INJECTOR NO. 5 DRIVER
*
B7
B8
B9
B10 K20 18DG GENERATOR FIELD DRIVER
B11
B12 K16 18LG/BK INJECTOR NO. 6 DRIVER
*
B13
B14
B15 K12 18TN INJECTOR NO. 2 DRIVER
B16 K14 18LB/BR INJECTOR NO. 4 DRIVER
B17
B18
B19
B20
B21
B22
B23 G60 18GY/YL OIL PRESSURE SENSOR
B24
B25
B26
B27 G7 18WT/OR VEHICLE SPEED SENSOR
B28
B29
B30
B31 K6 18VT/OR 5 VOLT SUPPLY
B32
POWERTRAIN
CONTROL MODULE C2
1 11
22
12 21
32
WHITE
J978W-7
XJI08073
C1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
C2 C27 18DB/PK RADIATOR FAN RELAY CONTROL
C3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
C4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
C5 V35 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL
C6
C7
C8
C9
C10
C11 V32 18YL/RD STOP SWITCH SPEED CONTROL SOURCE
C12 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
C13
C14
C15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
C16
C17
C18
C19 K31 18BR FUEL PUMP RELAY CONTROL
C20 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
C21
C22 C22 18DB/WT A/C SWITCH SENSE
C23 C90 18LG/RD A/C SELECT SIGNAL
C24 K29 18WT/PK STOP LAMP SWITCH SENSE
C25 K72 18DG/OR GENERATOR SOURCE
C26 K226 18DB/LG FUEL LEVEL SENSE
C27 D21 18PK SCI TRANSMIT
C28 D2 18WT/BK CCD BUS()
C29 D20 18LG/BK SCI RECEIVE
C30 D1 18VT/BR CCD BUS (+)
C31
C32 V37 18RD/LG SPEED CONTROL SWITCH SENSE
POWERTRAIN
CONTROL MODULE C3
(2.5L, RHD, MANUAL TRANSMISSION)
32 22
11
21 12
1
GRAY
J978W-7
XJI08074
C1 C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
C2 C27 18DB/PK RADIATOR FAN RELAY CONTROL
C3 K51 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL
C4 V36 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL
C5 V35 18LG/RD SPPED CONTROL VENT SOLENOID CONTROL
C6
C7
C8
C9
C10
C11 V32 18YL/RD STOP SWITCH SPEED CONTROL SOURCE
C12 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
C13
C14
C15 K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL
C16
C17
C18
C19 K31 18BR FUEL PUMP RELAY CONTROL
C20 K52 18PK/BK EVAP/PURGE SOLENOID CONTROL
C21
C22 C22 18DB/WT A/C SWITCH SENSE
C23 C90 18LG A/C SELECT SIGNAL
C24 K29 18WT/PK STOP LAMP SWITCH SENSE
C25 K72 18DG/OR GENERATOR SOURCE
C26 K226 18DB/LG FUEL LEVEL SENSE
C27 D21 18PK SCI TRANSMIT
C28 D2 18WT/BK CCD BUS ()
C29 D20 18LG/BK SCI RECEIVE
C30 D1 18VT/BR CCD BUS (+)
C31
C32 V37 18RD/LG SPEED CONTROL SWITCH SENSE
POWERTRAIN
CONTROL MODULE C3
(ALL OTHERS )
32 22
11
21 12
1
GRAY
J978W-7
XJI08075
PRNDL LAMP
1 C25 12LB RADIATOR FAN
2 Z1 12BK GROUND
RADIATOR
FAN MOTOR
LT.GRAY
2 1
BLACK
1 2
1 X60 16DG/RD POWER AMP RELAY FEED
2 X51 16BR/YL LEFT REAR SPEAKER (+)
3 X52 16DB/WT RIGHT REAR SPEAKER (+)
4 X53 16DG LEFT FRONT DOOR SPEAKER (+)
5 X54 16VT RIGHT FRONT DOOR SPEAKER (+)
6 X57 16BR/LB LEFT REAR SPEAKER ()
7 X58 16DB/OR RIGHT REAR SPEAKER ()
RADIO C1
1
2 X55 16BR/RD LEFT FRONT DOOR SPEAKER ()
3 X56 16DB/RD RIGHT FRONT DOOR SPEAKER ()
4 L7 18BK/YL MASTER RADIO ILLUMINATION
5 E2 20OR RADIO ILLUMINATION
6 X12 16RD/WT RADIO POWER FEED
7 M1 20PK
RADIO C2
1 7
BLACK
1 Z9 14BK GROUND
2
RADIO C3
BLACK
1 7
BLACK
J978W-7
XJI08076
1 M2 18YL COURTESY LAMP FEED
2 G16 18BK/LB SWITCHED GROUND
3 Z1 18BK GROUND
REAR DOOR
JAMB SWITCH (LHD)
1
2 Z1 18BK REAR DOOR SWITCH TO COURTESY LAMP
3 M2 18YL REAR DOOR SWITCH TO COURTESY LAMP
REAR DOOR
JAMB SWITCH (RHD)
2 3
1
BLACK
2 3
1
BLACK
2 L36 18LG/BK REAR FOG LAMPS ON RELAY
3 Z1 16BK GROUND
4 L38 18BR/WT REAR FOG LAMP RELAY FEED
5 L2 16LG BATTERY FEED TO REAR FOG LAMP RELAY
5 L2 16LG BATTERY FEED TO DIMMER FLASHER
REAR FOG
LAMP RELAY
BLACK
2 5
4
3
1
1 Z15 18BK GROUND
2 L36 18LG/BK REAR FOG LAMPS ON RELAY
3 L38 18BR/WT REAR FOG LAMP SWITCHES FEED
4 E2 20OR REAR FOG LAMP ILLUMINATION
REAR FOG
LAMP SWITCH
BLACK
1 4
1 V20 18VT/OR REAR WASHER PUMP MOTOR CONTROL
2 Z1 18BK GROUND
REAR WASHER
PUMP MOTOR
(WITH 2.5L ENGINE, DIESEL)
BLACK
1
2
J978W-7
XJI08077
1 V20 18BK/WT REAR WASHER PUMP MOTOR CONTROL
2
Z1 18BK GROUND
Z1 18BK GROUND
REAR WASHER
PUMP MOTOR
(ALL OTHERS)
BLACK
2
1
1 C15 12BK/WT REAR WINDOW DEFOGGER POWER
2
REAR WINDOW
DEFOGGER C1
BLACK
1 Z1 12BK REAR WINDOW DEFOGGER GROUND
2
REAR WINDOW
DEFOGGER C2
BLACK
1 Z1 18BK GROUND
2 C80 20DB/WT REAR WINDOW DEFOGGER RELAY CONTROL
3 C116 20LB/YL HEATED MIRROR
4 E2 20OR REAR WINDOW DEFOGGER SWITCH ILLUMINATION
REAR WINDOW
DEFOGGER SWITCH
1 Z1 18BK GROUND
2 V20 18BK/WT REAR WASHER MOTOR CONTROL
3 V13 18BR/LG REAR WIPER MOTOR CONTROL
4 V23 18BK/PK FUSED IGNITION SWITCH OUTPUT (RUN) REAR WIPER
MOTOR
BLACK
4 1
1 4
J978W-7
XJI08078
1 Z1 18BK GROUND
2 V20 18BK/WT REAR WASHER SIGNAL TO MODULE
3 E2 20OR REAR WIPER SWITCH ILLUMINATION
4 V13 18BR/LG REAR WIPER FEED
5 V23 18BR/PK FUSED B(+)
6 V23 18BR/PK FUSED B(+)
REAR WIPER
SWITCH
BLACK
2
6
1
3
A L10 18BR/LG BACK-UP LAMP SWITCH OUTPUT
G Z1 18BK GROUND
RIGHT BACK-UP
LAMP
1 M1 18PK COURTESY LAMP FEED
2 M2 18BK/WT SWITCHED GROUND
RIGHT COURTESY
LAMP
BLACK
A
G
BLACK
1 Z1 20BK GROUND
2 L39 20LB RIGHT FOG LAMP
RIGHT
FOG LAMP
BLACK
2 1
J978W-7
XJI08079
1 M2 18YL COURTESY LAMPS DRIVER
2 G16 18BK/LB DOOR AJAR SWITCH SENSE
3 Z1 18BK GROUND
RIGHT FRONT
DOOR JAMB SWITCH
2 3
1
BLACK
1 X80 16LB/BR RIGHT FRONT DOOR SPEAKER (+)
2 X82 16LB/RD RIGHT FRONT DOOR SPEAKER () RIGHT FRONT
DOOR SPEAKER
(LHD)
BLACK
1 2
1 X85 16LG/RD RIGHT FRONT DOOR SPEAKER ()
2 X87 16LG/BK RIGHT FRONT DOOR SPEAKER (+)
RIGHT FRONT
DOOR SPEAKER
(RHD)
1 X80 16LB/BR RIGHT FRONT DOOR TWEETER ()
2 X82 16LB/RD RIGHT FRONT DOOR TWEETER (+)
RIGHT FRONT
DOOR TWEETER
(LHD)
BLACK
1 2
BLACK
1
2
1 X85 16LG/RD RIGHT FRONT DOOR TWEETER ()
2 X87 16LG/BK RIGHT FRONT DOOR TWEETER (+)
RIGHT FRONT
DOOR TWEETER
(RHD)
BLACK
1
2
J978W-7
XJI08080
1 P34 16PK/BR POWER DOOR UNLOCK RELAY
2 P33 16OR/BK POWER DOOR LOCK RELAY
RIGHT FRONT
POWER DOOR
LOCK MOTOR (LHD)
1 P34 16PK/BK POWER DOOR LOCK MOTOR (UNLOCK)
2 Q22 16VT RIGHT FRONT POWER WINDOW MOTOR (DOWN)
3 Q26 14VT/WT MASTER SWITCH RIGHT FRONT WINDOW MOTOR (DOWN)
4 Q16 14BR/WT MASTER SWITCH RIGHT FRONT WINDOW MOTOR (UP)
5 P33 18OR/BK POWER DOOR LOCK MOTOR (LOCK)
6
7
8
9 Q12 16BR RIGHT FRONT POWER WINDOW MOTOR (UP)
10 Q1 14YL MASTER SWITCH LOCK OUT
11
12
RIGHT FRONT
POWER LOCK/WINDOW
SWITCH C1 (LHD)
BLACK
2 1
BLUE
1
6
5
12
1 P34 16PK/BK POWER DOOR LOCK MOTOR (UNLOCK)
2 Q22 16VT POWER WINDOW MOTOR (DOWN)
3 Q26 14VT/WT POWER WINDOW MASTER SWITCH (DOWN)
4 Q16 14BR/WT POWER WINDOW MASTER SWITCH (UP)
5 P33 18OR/BK POWER DOOR LOCK SWITCH (LOCK)
6
7
8
9 Q12 16BR POWER WINDOW MOTOR (UP)
10 Q1 14YL MASTER SWITCH LOCK OUT
11
12
RIGHT FRONT
POWER LOCK/WINDOW
SWITCH C1 (RHD)
BLUE
1
6
5
12
1 P59 20LB/RD RKE LOCK CONTROL
2 P55 20DB RKE UNLOCK CONTROL
3 P35 20OR/VT POWER DOOR LOCK RELAY
4 F81 12TN POWER WINDOW SWITCH FEED (RUN)
5 F35 16RD POWER DOOR LOCK RELAY FEED
6 Z1 16BK GROUND
7 P36 20PK/VT POWER DOOR UNLOCK RELAY
8 G26 20LB DOOR AJAR KEY-IN
RIGHT FRONT
POWER LOCK/WINDOW
SWITCH C2 (LHD)
WHITE
1
5
4
8
J978W-7
XJI08081
1 P59 20LB/RD RKE LOCK CONTROL
2 P55 20DB RKE UNLOCK CONTROL
3 P35 20OR/VT POWER DOOR LOCK RELAY
4 F81 12TN POWER WINDOW SWITCH FEED (RUN)
5 F35 16RD POWER DOOR LOCK RELAY FEED
6 Z1 12BK GROUND
7 P36 18PK/VT POWER DOOR UNLOCK RELAY
8 G26 20LB DOOR AJAR KEY-IN
RIGHT FRONT
POWER LOCK/WINDOW
SWITCH C2 (RHD)
1 Q12 16BR POWER WINDOW MOTOR UP
2 Q22 16VT POWER WINDOW MOTOR DOWN
RIGHT FRONT
POWER WINDOW MOTOR
BLACK
2 1
WHITE
1
5
4
8
2 L60 20TN RIGHT TURN SIGNAL
RIGHT FRONT SIDE
MARKER LAMP
1 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR ()
2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+)
RIGHT FRONT WHEEL
SPEED SENSOR (LHD)
1 B6 20WT/DB RIGHT FRONT WHEEL SPEED SENSOR ()
2 B7 20WT RIGHT FRONT WHEEL SPEED SENSOR (+) RIGHT FRONT WHEEL
SPEED SENSOR (RHD)
1
BLACK
2
1
BLACK
2
YELLOW
1 2
J978W-7
RIGHT
HEADLAMP
A C
B
BLACK
XJI08082
A L34 18RD/OR RIGHT HIGH BEAM
B L44 18VT/RD RIGHT LOW BEAM
C Z1 18BK GROUND
2 Z1 20BK GROUND
RIGHT PARK
LAMP
1 P72 20YL/BK RIGHT POWER MIRROR (UP)
2 P76 20OR/YL RIGHT POWER MIRROR (DOWN/RIGHT)
3 P74 20DB RIGHT POWER MIRROR (LEFT)
5 C16 20BK/WT HEATED MIRROR FEED
6 Z1 18BK GROUND
RIGHT POWER
MIRROR (LHD)
1 P71 20YL RIGHT POWER MIRROR (UP)
3 P75 20DB/RD RIGHT POWER MIRROR (RIGHT)
5 C16 20BK/WT HEATED MIRROR FEED
6 Z1 16BK GROUND
RIGHT POWER
MIRROR (RHD)
6 5 4
1 2 3
RED
6 5 4 RED
1 F37 14RD/LB RIGHT SEAT
RIGHT POWER
SEAT (WITH ECE)
BLACK
2 1
1
2
J978W-7
XJI08083
A M2 18YL COURTESY LAMPS DRIVER
B Z1 18BK GROUND
RIGHT REAR
DOOR JAMB SWITCH
1 P34 16PK/BK DOOR LOCK MOTOR UNLOCK
2 P33 16OR/BK DOOR LOCK MOTOR LOCK
RIGHT REAR
POWER DOOR
LOCK MOTOR
1 Q14 16GY REAR SWITCH TO MOTOR (UP)
2 Q24 16DG REAR SWITCH TO MOTOR (DOWN)
RIGHT REAR
POWER WINDOW
MOTOR
2 3
1
BLACK
BLACK
1 2
2
BLACK
1
1 Q14 16GY REAR SWITCH TO MOTOR (UP)
2 Q28 14DG/WT REAR SWITCH TO MASTER (DOWN)
3
4 Q18 14GY/BK REAR SWITCH TO MASTER (UP)
5 Q24 16DG REAR SWITCH TO MOTOR (DOWN)
RIGHT REAR
POWER WINDOW
SWITCH
A L90 18DB/RD PARK LAMP SWITCH OUTPUT
B Z1 18BK GROUND
RIGHT REAR SIDE
MARKER LAMP
3
6
1
4
BLUE
YELLOW
A B
J978W-7
XJI08084
A L60 18TN RIGHT TURN SIGNAL
G Z1 18BK GROUND
RIGHT REAR
TURN SIGNAL LAMP
A B2 20YL RIGHT REAR WHEEL SENSOR (+)
B B1 20YL/DB RIGHT REAR WHEEL SENSOR ()
RIGHT REAR
WHEEL SPEED SENSOR
(LHD)
A B2 18YL RIGHT REAR WHEEL SENSOR (+)
B B1 18YL/DB RIGHT REAR WHEEL SENSOR ()
RIGHT REAR
WHEEL SPEED SENSOR
(RHD)
A X92 16TN/BK RIGHT SOUND BAR SPEAKER ()
B X94 16TN/RD RIGHT SOUND BAR SPEAKER (+) RIGHT SOUND
BAR SPEAKER
BLACK
A
G
A B
RED
A B
RED
A X92 16TN/BK RIGHT SOUND BAR ()
B X94 16TN/RD RIGHT SOUND BAR (+)
RIGHT SPEAKER
(WITH SOUND BAR)
BLACK
2 1
BLACK
A B A B
J978W-7
XJI08085
A L50 18WT/TN STOP LAMP SWITCH OUTPUT
B L90 18DB/RD PARK LAMP SWITCH OUTPUT
G Z1 18BK GROUND
RIGHT TAIL/
STOP LAMP
BLACK
B
A
G
2 Z1 18BK GROUND
RIGHT TURN
JUMPER
1 Z1 18BK GROUND
2
RIGHT TURN
SIGNAL
A G10 20LG/RD SEAT BELT SWITCH SENSE
B Z1 20BK GROUND
SEAT BELT
SWITCH
1
BLACK
2
1 A0 06RD BATTERY TO STARTER (+)
2 T40 14LG/BK STARTER RELAY CONTACT TO SOLENOID
STARTER
BLACK
2 1
BLACK
3 1
1
2
BLACK
J978W-7
XJI08086
2 Z1 18BK GROUND
3 V32 20YL/RD VEHICLE SPEED CONTROL ON/OFF SENSE
4 V30 20DB/RD VEHICLE SPEED CONTROL BRAKE SWITCH OUTPUT
6 F32 20PK/DB FUSED B(+)
STOP LAMP
SWITCH (LHD)
2 Z1 18BK GROUND
3 V32 20YL/RD VEHICLE SPEED CONTROL ON/OFF SENSE
4 V30 20DG/RD VEHICLE SPEED CONTROL BRAKE SWITCH OUTPUT
6 F32 20PK/DB FUSED B(+)
STOP LAMP
SWITCH (RHD)
GRAY
6 5 4 3 2 1
GRAY
6 5 4 3 2 1
1 F87 20WT/BK IGNITION (START/RUN)
2
3
4 K185 20OR/LB WAIT TO START WARNING SIGNAL
5
6
7 G86 20TN/OR WATER IN FUEL WARNING SIGNAL
8 G154 20VT/LG LOW COOLANT WARNING SIGNAL
TELL TALE
MODULE (DIESEL)
THROTTLE POSITION
SENSOR (4.0L 2WD)
BLACK
3 2 1
4
6
1
5
BLACK
J978W-7
XJI08087
TRACTION
CONTROL SWITCH
1 B40 14LB ELECTRIC BRAKE
2
TRAILER TOW
ELECTRIC BRAKE
1 L63 20DG/RD LEFT REAR STOP/TURN LAMP
3 A6 20RD/OR TRAILER TOW FEED
4
5 L73 20YL LEFT TURN TRAILER TOW
LEFT TURN RELAY
BLACK
3 5
2
4
1
BLACK
1 2
BLACK
1 2
1 L62 20BK/RD RIGHT REAR STOP/TURN LAMP
3 A6 20RD/OR TRAILER TOW FEED
4
5 L74 20LG RIGHT TURN TRAILER TOW
RIGHT TURN RELAY
BLACK
3 5
2
4
1
THROTTLE POSITION
SENSOR
(ALL OTHERS)
BLACK
3 2 1
BLACK
1 2
J978W-7
XJI08088
1
2
3
4 T14 20LG/WT OUTPUT SHAFT SPEED SIGNAL
5
6 D2B 20WT/BK CCD BUS ()
7 D1B 20VT/BR CCD BUS (+)
8
9 T3 18VT RANGE SENSOR D3
10
11 T22 20DB/WT TRANS SOLENOID (LOCK UP)
12 T19 20WT TRANS SOLENOID A
13 T60 20OR/WT TRANS SOLENOID B
14 D21C 20PK DATA LINK TRANSMIT
15
16 K167E 20BR/YL SENSOR RETURN
17 K22 20OR/DB TPS TO TCU
18 L10A 18BR/LG BACKUP LAMPS
19
20
21 T42 18VT/WT RANGE SENSOR L
22 T1 18LG/BK RANGE SENSOR D
23 K29A 20WT/PK STOP SWITCH-NORMALLY CLOSED
24 Z12A 18BK/TN GROUND
25 M1D 20PK UNDERHOOD LAMP & IGNITION OFF DRAW
26 F12A 18DB/WT IGNITION (RUN/START)
TRANSMISSION
CONTROL MODULE
BLACK
13
26
1
14
1 Z1 18BK GROUND
2
3 T19 20WT TRANS SOLENOID A
4 T14 20LG/WT OUTPUT SHAFT SPEED SIGNAL
5 T22 20DB/WT TRANS SOLENOID C (LOCK-UP)
6 T60 20OR/WT TRANS SOLENOID B TRANSMISSION
CONTROL SOLENOIDS
BLACK
1 3
4 6
1 T42 18VT/WT RANGE SENSOR L
2 T3 18VT RANGE SENSOR D3
3 F12 18DB/WT IGNITION (RUN/START)
4 T1 18LG/BK RANGE SENSOR D
5
6 L10 18BR/LG BACK-UP LAMPS
7 T41 20BK/WT STARTER RELAY
8 Z1 18BK GROUND
TRANSMISSION
RANGE SENSORS
1
4
7
2
5
8
BLACK
6
3
J978W-7
XJI08089
1 L60 20TN RIGHT FRONT TURN SIGNAL
2
3 L62 20BR/RD RIGHT REAR TURN SIGNAL
4 L55 20BK/YL HAZARD AND TURN SIGNAL OUT TO LAMPS
5 L6 20RD/WT TURN SIGNALS TO COMBINATION FLASHER
6 L12 20VT/TN HAZARD FLASHER INPUT TO COMBO FLASHER
7
8
9 L63 20DG/RD LEFT REAR TURN SIGNAL
10 L61 20LG/WT LEFT FRONT TURN SIGNAL
11 L55 20BK/YL HAZARD AND TURN SIGNAL OUT TO LAMPS
TURN SIGNAL
HAZARD SWTICH
1 Z1 20BK GROUND
UNDERHOOD
LAMP
1 F142 20DG/WT AUTOMATIC SHUTDOWN RELAY OUTPUT
2 Z1 18BK GROUND
4 K41 18BK/DG UPSTREAM HEATED OXYGEN SENSOR SIGNAL UPSTREAM HEATED
OXYGEN SENSOR
BLACK
6 1
11 7
BLACK
1 2
GRAY
2
4
1
3
1 V36 18TN/RD SPEED CONTROL VACUUM
2 V35 18LG/RD SPEED CONTROL VENT
3 V30 20DB/RD STOP SWITCH-SPEED CONTROL
4 Z1E 18BK GROUND
VEHICLE SPEED
CONTROL SERVO (LHD)
1 V36 18TN/RD SPEED CONTROL VACUUM
2 V35 18LG/RD SPEED CONTROL VENT
3 V30 20DB/RD STOP SWITCH-SPEED CONTROL
4 Z1E 18BK GROUND
VEHICLE SPEED
CONTROL SERVO (RHD)
BLACK
1 4
BLACK
1 4
J978W-7
XJI08090
1 K6 18VT/OR 5 VOLT SUPPLY
3 G7 18WT/OR VEHICLE SPEED SENSOR
VEHICLE SPEED
SENSOR (LHD)
1 K6 18VT/OR 5 VOLT SUPPLY
3 G7 18WT/OR VEHICLE SPEED SENSOR
VEHICLE SPEED
SENSOR (RHD)
BLACK
1 3
BLACK
1 3
1 G123 20DG/WT WATER IN FUEL SENSOR
2 K167 20BR/YL SIGNAL GROUND WATER IN FUEL SENSOR
WATER IN FUEL
SENSOR (DIESEL)
2 1
BLACK
1 Z1 18BK GROUND
2 V5 16DG/YL PARK SENSE
3 V10 18BR WASHER SIGNAL
4 V3 16BR/WT LOW
5 V6 18DB WIPER FEED
6 V4 16BR/VT HIGH
WIPER/WASHER
SWITCH (LHD)
1 Z1 18BK GROUND
2 V5 16DG/YL PARK SENSE
3 V10 18BR WASHER SIGNAL
4 V3 16BR/WT LOW
5 V6 16DB WIPER FEED
6 V4 16BR/VT HIGH
WIPER/WASHER
SWITCH (RHD)
GRAY
6 1
GRAY
6 1
8W-90 CONNECTOR LOCATIONS
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng com-
ponent and connector l ocati ons i n the vehi cl e. A con-
nector i ndex i s provi ded. Use the wi ri ng di agrams i n
each secti on for connector number i denti fi cati on.
Refer to the i ndex for the proper fi gure number.
CONNECTOR/GROUND LOCATIONS
For i tems that are not shown i n thi s secti on N/S i s
pl aced i n the Fi g. col umn.
Connector
Name/Number
Color Location Fig.
4WD Switch
(231)
BK On Transfer
Case
31
4WD Switch
(242)
BK On Transfer
Case
31
A/C Compressor
Clutch
BK Top of
Compressor
37
A/C Heater
Control (LHD)
BK At Control Unit 19
A/C Heater
Control (RHD)
BK At Control Unit 20
A/C High
Pressure Switch
BK At Drier Bottle 6
A/C Low
Pressure Switch
(Diesel)
BK Top of Drier
Bottle
33
A/C Low
Pressure Switch
BK At Switch N/S
A/C Low
Pressure Switch
(2.5L M/T RHD)
BK At Drier Bottle 3
A/C Low
Pressure Switch
(RHD All Others)
BK At Switch N/S
Air Bag Control
Module (LHD)
BK Under Left Seat 21
Air Bag Control
Module (RHD)
BK Under Left Seat 22
Ambient
Temperature
Sensor
BK Lower Radiator
Support
5, 10
Back-Up Lamp
Switch (M/T)
BK On Transmission 31
Battery
Temperature
Sensor
BK At Battery 16
Beam Select
Switch (LHD)
BK On Steering
Column
24
Connector
Name/Number
Color Location Fig.
Beam Select
Switch (RHD)
BK On Steering
Column
24
Brake Pressure
Switch
BK At Master
Cylinder
2, 5
Brake Shift
Interlock
Solenoid (LHD)
BK Lower Steering
Column
N/S
Brake Shift
Interlock
Solenoid (RHD)
BK Lower Steering
Column
N/S
C100 (LHD) BK To Headlamp
and Dash
17, 23
C100 (RHD) BK To Headlamp
and Dash
18
C102 (RHD) GY Right Hand
Drive Jumper
N/S
C103 (RHD) BL Right Hand
Drive Jumper
N/S
C104 (RHD) WT Right Hand
Drive Jumper
N/S
C106 (Diesel) BK Near Left Front
Headlamp
32
C106 (4.0L DRL) BK Front End
Lighting
N/S
C106 (4.0L DRL,
W/FOG)
BK Front End
Lighting
N/S
C106 (All Others
W/Fog Lamps)
BK Front End
Lighting
N/S
C106 (All
Others)
BK Front End
Lighting
N/S
C107 (Diesel) BK Rear of Engine
Compartment
N/S
C107 2.5L M/T
231, 2WD
BK Rear of Engine
Compartment
13, 14
XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 1
Connector
Name/Number
Color Location Fig.
C107 2.5L M/T
231, 2WD
W/DRL
BK Rear of Engine
Compartment
13, 14
C107 4.0L A/T
231, 242
BK Rear of Engine
Compartment
11
C107 4.0L A/T
231, 242, DRL
BK Rear of Engine
Compartment
11
C107 4.0L A/T
2WD
BK Rear of Engine
Compartment
11
C107 4.0L A/T
2WD DRL
BK Rear of Engine
Compartment
11
C107 4.0L M/T
231, 242
BK Rear of Engine
Compartment
11
C107 4.0L M/T
2WD
BK Rear of Engine
Compartment
11
C108 GY Near Battery N/S
C109 (LHD) BK ABS Connector N/S
C109 (RHD) BK ABS Connector N/S
C110 (Diesel) GY Near Battery NS
C200 (LHD Full
Options)
GY To Left Body
Harness
17, 23
C200 (RHD) GY To Left Body
Harness
18
C201 (LHD)
Base
WT Lower
Instrument
Panel
17, 23
C201 (LHD) Full
Options
WT Lower
Instrument
Panel
17
C202 (RHD) BK Lower
Instrument
Panel
18
C203 (RHD) BK Lower
Instrument
Panel
18
C204 (RHD) BK Lower
Instrument
Panel
18
C205 YL Lower
Instrument
Panel
17, 18,
23
C206 (A/T) GY At Center
Console
17, 21,
22
C206 (M/T) GY At Center
Console
21, 22
C207 BK Courtesy Lamp N/S
Connector
Name/Number
Color Location Fig.
C208 BK Left Courtesy
Lamp
N/S
C300 (LHD) NAT At Right Kick
Panel
21
C301 BK At Overhead
Console
21
C301 (W/
Immobilizer
BK At Overhead
Console
N/S
C302 (W/
Immobilizer
BK At Overhead
Console
18
C303 (LHD) BK Right Door N/S
C304 BK Right Rear Door N/S
C305 (LHD) WT Left Door N/S
C305 (RHD) WT Left Door N/S
C308 (LHD) BK At Liftgate 27
C308 (RHD) BK At Liftgate 27
C309 BK Left Rear Door N/S
C310 BK Top of Liftgate 30
C311 BK Top of Liftgate 30
C312 GY Top of Liftgate 30
C313 GN Top of Liftgate 30
C314 WT At Soundbar N/S
C315 BK Near Liftgate 27
C316 (LHD) BK At Power Seat N/S
C316 (RHD) BK At Power Seat N/S
C317 (LHD) GY Left Front Jamb
Switch
25
C317 (RHD) GY Left Front Jamb
Switch
25
C318 (LHD) GY Right Front
Jamb Switch
N/S
C318 (RHD) GY Right Front
Jamb Switch
N/S
C319 BK Rear Jamb
Switch
N/S
C320 BK Left Rear Jamb
Switch
25
C321 NAT At Right Tail
Lamp
N/S
8W - 90 - 2 8W - 90 CONNECTOR LOCATIONS XJ
Connector
Name/Number
Color Location Fig.
C322 NAT Trailer Tow
Harness
N/S
Camshaft
Position Sensor
BK Near Distributor 13, 14,
15
Cargo Lamp (All
Except With
Sound Bar
BK At Lamp N/S
Cargo Lamp
(With Sound Bar)
BK At Lamp N/S
Center High
Mounted Stop
Lamp
BK Liftgate N/S
Cigar Lighter BK Instrument
Panel
19, 20
Clock Spring
(LHD)
NAT Steering Column 24
Clock Spring
(RHD)
NAT Steering Column 24
Clutch Interlock
Switch (RHD
M/T)
GN Lower Steering
Column
12, 18,
24
Clutch Interlock
Switch (M/T)
GN Lower Steering
Column
12, 18,
24
Clutch Interlock
Switch Jumper
(RHD A/T)
GN Lower Steering
Column
12, 18,
24
Combination
Flasher
BK Near Headlamp
Switch
17, 18
Compass BK Overhead
Console
29
Console
Illumination
BK Overhead
Console
29
Controller
Anti-Lock Brake
(LHD)
BK At Controller
Anti-Lock Brake
8
Controller
Anti-Lock Brake
(RHD)
BK At Controller
Anti-Lock Brake
9
Coolant
Temperature
Sensor (Diesel)
BK Above Injection
Pump Assembly
36, 37
Crankshaft
Position Sensor
BK Near Fuel Rail 16
Data Link
Connector
BK Lower
Instrument
Panel
17, 18
Daytime Running
Lamp Module
BK Front End
Lighting
6
Connector
Name/Number
Color Location Fig.
Diagnostics
Splice Block
GY Near Data Link
Connector
N/S
Dome Lamp
(With Vanity
Lamps,
Immobilizer)
BK Overhead
Console
29
Downstream
Heated Oxygen
Sensor
BK Exhaust N/S
Driver Air Bag YL Steering Column 24
EGR Solenoid
(Diesel)
BK Right Side of
Engine
N/S
Engine Coolant
Temperature
Sensor
BK Front of Engine 13, 14
Engine Oil
Pressure Sensor
BK Near Generator 13
EVAP/Purge
Solenoid
BK Rear of Engine
Compartment
3,4,9,
10
Fog Lamp
Switch
BK Instrument
Panel
19, 20
Front Washer
Pump Motor
BK At Washer
Reservoir
6, 7
Front Wiper
Motor
BK At Wiper Motor 7
Fuel Heater
(Diesel)
BK Left Rear
Engine
Compartment
32, 33
Fuel Pump
Module (Diesel)
BK Left Side of
Engine
36, 37
Fuel Pump
Module (LHD)
BK At Fuel Pump
Module
N/S
Fuel Pump
Module (RHD)
BK At Fuel Pump
Module
N/S
G100 Near Battery 16
G101 Near Starter 13, 14,
15, 16
G102 Near Engine
Connector C107
N/S
G103 Near Generator 16
G104 Body Ground
(VM Diesel)
from Negative
Battery Cable
N/S
Connector
Name/Number
Color Location Fig.
G105 Engine Ground
(VM Diesel)
from Negative
Battery Cable
N/S
G106 Near Powertrain
Control Module
2, 3, 8,
9
G107 Near Glove Box
Lamp Switch
17, 18
G108 Near Headlamp
Switch
17, 18
G200 Near Air Bag
Control Module
21
G300 Near Air Bag
Control Module
N/S
G301 Near Power
Amplifier
25
G302 Near Left Tail
Lamp
27
G303 Between Right
Tail Lamp and
Power Amplifier
27
G304 Near Rear
Window
Defogger Grid
N/S
G Switch (LHD) BK Under Rear
Seat
26
Generator BK At Generator 36, 37
Glove Box Lamp
Switch
BK At Glove Box 17, 18,
19
Glow Plug Relay
(Diesel)
BK Left Rear
Engine
Compartment
32, 33
HeadLamp Delay
Module (LHD)
BK Near Headlamp
Switch
17
HeadLamp Delay
Module (RHD)
BK Near Headlamp
Switch
18
Headlamp
Switch C1 (RHD)
BK At Headlamp
Switch
18
Headlamp
Switch C2
BK At Headlamp
Switch
17, 18
Headlamp
Switch C1 (LHD)
BK At Headlamp
Switch
17
HVAC Unit
(LHD)
BK On HVAC Tub 21
HVAC Unit
(RHD)
BK On HVAC Tub N/S
Connector
Name/Number
Color Location Fig.
Idle Air Control
Motor
BK At Throttle Body 14
Ignition Coil BK Front of Engine 13, 14
Ignition Switch
(LHD)
BK Steering Column 24
Ignition Switch
(RHD)
Injector No. 1 BK At Injector 14, 15
Injector No. 5 BK At Injector 15
Injector No. 6 BK At Injector 15
Instrument
Cluster C1 (LHD)
BK At Instrument
Cluster
17
Instrument
Cluster C1
(RHD)
BK At Instrument
Cluster
18
Instrument
Cluster C2
BK At Instrument
Cluster
17, 18
Intake Air
Temperature
Sensor
GY At Intake
Manifold
13, 15
Junction Block
C1
NAT At Junction
Block
29
Junction Block
C2
WT At Junction
Block
29
Junction Block
C3
NAT At Junction
Block
29
Junction Block
C4
NAT At Junction
Block
29
Junction Block
C5
NAT At Junction
Block
29
Junction Block
C6
NAT At Junction
Block
29
Junction Block
C7
NAT At Junction
Block
29
Junction Block
C8
NAT At Junction
Block
29
Junction Block
C9
NAT At Junction
Block
29
Key-In Switch GN Steering Column 24
Left Back-Up
Lamp
BK At Back-Up
Lamp
N/S
Left Courtesy
Lamp
BK At Courtesy
Lamp
N/S
Connector
Name/Number
Color Location Fig.
Left Fog Lamp BK At Fog Lamp N/S
Left Front Door
Jamb Switch
BK At Switch N/S
Left Front Door
Speaker (LHD)
BK At Speaker N/S
Left Front Door
Speaker (RHD)
BK At Speaker N/S
Left Front Door
Tweeter (LHD)
BK Left Front Door N/S
Left Front Door
Tweeter (RHD)
BK Left Front Door N/S
Left Front
Park/Turn Signal
Lamp
BK At Lamp N/S
Left Front Power
Door Lock Motor
BK In Respective
Door
28
Left Front Power
Lock/Window
Switch C1 (LHD)
BL In Respective
Door
28
Left Front Power
Lock/Window
Switch C2 (LHD)
WT In Respective
Door
28
Left Front Power
Window Motor
(LHD)
BK In Respective
Door
28
Left Front Side
Marker Lamp
YL At Lamp 1
Left Front Wheel
Speed Sensor
(LHD)
BK Left Engine
Compartment
8
Left Front Wheel
Speed Sensor
(RHD)
BK Left Engine
Compartment
9
Left Headlamp BK At Headlamp 1
Left Park Lamp BK At Lamp N/S
Left Power Mirror RD At Mirror N/S
Left Rear Power
Door Lock Motor
BK In Respective
Door
28
Left Rear Power
Window Motor
BK In Respective
Door
28
Left Rear Power
Window Switch
BL In Respective
Door
28
Left Rear Side
Marker Lamp
YL At Lamp 1
Left Rear Turn
Signal Lamp
BK At Lamp 1
Connector
Name/Number
Color Location Fig.
Left Rear Wheel
Speed Sensor
(LHD)
BK Under Rear
Seat
26
Left Rear Wheel
Speed Sensor
(RHD)
BK Under Rear
Seat
26
Left Sound Bar
Speaker
BK At Soundbar N/S
Left Speaker
(With Sound Bar)
BK At Soundbar N/S
Left Tail/Stop
Lamp
BK At Lamp N/S
Left Turn Jumper BK At Lamp N/S
Left Turn Signal BK At Lamp N/S
License Lamp YL At Lamp N/S
Liftgate Jamb
Switch
BK Lailgate 30
Liftgate Lock
Motor
BK Liftgate 30
Low Coolant
Sensor (Diesel)
BK Right Rear
Engine
Compartment
34, 35
Low Washer
Fluid Level
Switch
BK At Washer
Reservoir
6, 7
Manifold
Absolute
Pressure Sensor
BK At Throttle Body 13, 14,
15
Mass Air Flow
Sensor (Diesel)
BK At Air Intake N/S
MSA Controller
(Diesel)
BK Fender Side
Shield
34, 35
Needle
Movement
Sensor (Diesel)
BK Left Front of
Engine
36
Oil Pressure
Switch (Diesel)
BK Right Rear of
Engine
38
Overhead
Module (With
Immobilizer)
BK Overhead
Module
N/S
Park Brake
Switch (LHD)
BK At Park Brake
Lever
21
Park Brake
Switch (RHD)
BK At Park Brake
Lever
22
Passenger Air
Bag
YL Behind
Instrument
Panel
17, 18,
19, 20
Connector
Name/Number
Color Location Fig.
Pedal Position
Sensor (Diesel)
BK At Accelerator
Pedal
N/S
Power Amplifier
C2 (LHD)
NAT At Power
Amplifier
25
Power Amplifier
C1
NAT At Power
Amplifier
25
Power Amplifier
C2 (RHD)
NAT At Power
Amplifier
25
Power
Distribution
Center (4.0L,
ABS, DRL)
BK Fender Side
Shield
5, 10,
11, 16
Power
Distribution
Center (RHD
2.5L M/T)
BK Fender Side
Shield
5, 10,
11, 16
Power Outlet BK Instrument
Panel
19, 20
Power Seat BK At Power Seat N/S
Power Steering
Pressure Switch
WT Front of Engine 13, 14
Powertrain
Control Module
C1
BK Fender Side
Shield
2, 6, 7
Powertrain
Control Module
C1 (Diesel)
BK Under
Instrument
Panel
N/S
Powertrain
Control Module
C2
WT Fender Side
Shield
2, 6, 7
Powertrain
Control Module
2.5L M/T (RHD)
C3
GY Fender Side
Shield
2, 6, 7
Powertrain
Control Module
All Others C3
GY Fender Side
Shield
2, 6, 7
PRNDL Lamp BK Steering Co;umn N/S
Radiator Fan
Motor
LT GY At Radiator 8, 9
Radio C1 BK Behind Radio 19, 20
Radio C2 GY Behind Radio 19, 20
Radio C3 BK Behind Radio 19, 20
Rear Door Jamb
Switch (LHD)
BK At Respective
Door
N/S
Rear Door Jamb
Switch (RHD)
BK At Respective
Door
N/S
Connector
Name/Number
Color Location Fig.
Rear Washer
Pump Motor
(2.5L)
BK At Washer
Reservoir
6, 7
Rear Fog Lamp
Relay
BK Instrument
Panel
N/S
Rear Fog Lamp
Switch
BK Instrument
Panel
N/S
Rear Washer
Pump Motor
(Diesel)
BK At Washer
Reservoir
32, 33
Rear Washer
Pump Motor (All
Others)
BK At Washer
Reservoir
6, 7
Rear Window
Defogger Switch
BK Instrument
Panel
19, 20
Rear Wiper
Motor
BK Liftgate 30
Rear Wiper
Switch
BK Instrument
Panel
19, 20
Right Back-Up
Lamp
BK At Lamp N/S
Right Courtesy
Lamp
BK At Lamp N/S
Right Fog Lamp BK At Lamp 1
Right Front Door
Jamb Switch
BK At Respective
Door
N/S
Right Front Door
Speaker (LHD)
BK At Respective
Door
28
Right Front Door
Speaker (RHD)
BK At Respective
Door
28
Right Front Door
Tweeter (LHD)
BK At Respective
Door
28
Right Front Door
Tweeter (RHD)
BK At Respective
Door
28
Right Front
Park/Turn Signal
Lamp
BK At:Lamp 1
Right Front
Power Door Lock
Motor
BK At Respective
Door
28
Right Front
Power Lock/
Window Switch
C1 (LHD)
BL At Respective
Door
28
Right Front
Power Lock/
Window Switch
C1 (RHD)
BL At Respective
Door
28
Connector
Name/Number
Color Location Fig.
Right Front
Power Lock/
Window Switch
C2 (LHD)
WT At Respective
Door
28
Right Front
Power Lock/
Window Switch
C2 (RHD)
WT At Respective
Door
28
Right Front
Power Window
Motor
BK At Respective
Door
28
Right Front Side
Marker Lamp
YL At Lamp 1
Right Front
Wheel Speed
Sensor (LHD)
BK Left Engine
Compartment
N/S
Right Front
Wheel Speed
Sensor (RHD)
BK Left Engine
Compartment
N/S
Right Headlamp BK At Headlamp 1
Right Park Lamp BK At Lamp N/S
Right Power
Mirror (LHD)
RD In Respective
Door
N/S
Right Power
Mirror (RHD)
RD In Respective
Door
N/S
Right Rear Door
Jamb Switch
BK At Respective
Door
N/S
Right Rear
Power Door Lock
Motor
BK At Respective
Door
N/S
Right Rear
Power Window
Motor
BK At Respective
Door
N/S
Right Rear
Power Window
Switch
BL At Respective
Door
N/S
Right Rear Side
Marker Lamp
YL At Lamp 1
Right Rear Turn
Signal Lamp
BK At Lamp N/S
Right Rear
Wheel Speed
Sensor (LHD)
RD Under Rear
Seat
26
Right Rear
Wheel Speed
Sensor (RHD)
RD Under Rear
Seat
26
Right Sound Bar
Speaker
BK At Soundbar N/S
Connector
Name/Number
Color Location Fig.
Right Speaker
(With Sound Bar)
BK At Soundbar N/S
Right Tail/Stop
Lamp
BK At Lamp N/S
Right Turn
Jumper
BK At Lamp N/S
Seat Belt Switch BK Near Center
Console
21, 22
Starter (Diesel) BK At Starter 38
Stop Lamp
Switch (LHD)
GY Near Brake
Pedal
12
Stop Lamp
Switch (RHD)
GY Near Brake
Pedal
12
Tell Tale Module
(Diesel)
BK Overhead
Console
N/S
Throttle Position
Sensor (4.0L
2WD)
BK On Throttle
Body
13, 14,
15, 16
Throttle Position
Sensor (All
Others)
BK On Throttle
Body
13, 14,
15, 16
Traction Control
Switch
BK Console N/S
Trailer Tow
Electric Brake
BK Trailer Tow
Wiring Harness
N/S
Trailer Tow Left
Turn Relay
BK Trailer Tow
Wiring Harness
N/S
Trailer Tow Right
Turn Relay
BK Trailer Tow
Wiring Harness
N/S
Transmission
Control Module
BK Under Center
Instrument
Panel
N/S
Transmission
Control
Solenoids
BK On Transmission N/S
Transmission
Range Sensor
BK On Transmission N/S
Turn Signal
Hazard Switch
Underhood Lamp BK At Lamp 4, 5
Upstream
Heated Oxygen
Sensor
GY Exhaust 13, 14,
15
Vehicle Speed
Control Servo
(LHD)
BK At Speed
Control Servo
4
Connector
Name/Number
Color Location Fig.
Vehicle Speed
Control Servo
(RHD)
BK At Speed
Control Servo
7
Vehicle Speed
Sensor (LHD)
Vehicle Speed
Sensor (RHD)
Connector
Name/Number
Color Location Fig.
Water In Fuel
Sensor
BK At Fuel Heater 32, 33
Wiper/Washer
Switch (LHD)
GY Steering Column 24
Wiper/Washer
Switch (RHD)
GY Steering Column 24
F
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1
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2
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Fig. 26 ABS G-Sensor
F
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2
7
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2
8
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Fig. 30 Liftgate
F
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3
1
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8W-95 SPLICE LOCATIONS
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of the spl i ces i n thi s vehi cl e. A spl i ce
i ndex i s provi ded. Use the wi ri ng di agrams i n each
secti on for spl i ce number i denti fi cati on. Refer to the
i ndex for proper spl i ce number.
SPLICE LOCATIONS
For spl i ces that are not shown i n the fi gures i n
thi s secti on a N/S i s pl aced i n the Fi g. col umn.
Splice
Number
Location Fig.
S100 Near Right Headlamp 9
S101 Near Right Headlamp 9
S102 Between Headlamps 9
S103 Near Left Headlamp 9
S107 Rear of Engine 10, 11, 12
S108 Rear of Engine 10, 11, 12
S109 Near Fuel Injector Harness 10, 11, 12
S112 Near Fuel Injector Harness 10
S115 Near MAP Sensor 11, 12
S116 Near Back-Up Switch 11, 12
S118 Near Generator 10
S119 Near Battery N/S
S130 Near Power Distribution Center 3, 4, 7, 8,
17, 18
S131 Near Purge Solenoid 3, 4, 7, 8,
18, 19, 20
S132 Near Purge Solenoid 3, 4, 7, 8, 18
S133 Left Rear of Engine
Compartment
1, 2, 6, 7,
17, 20
Compartment
2, 3
S135 Rear of Engine Compartment 3, 4, 7, 8
S136 Rear of Engine Compartment 2, 3, 6, 7
S137 Rear of Engine Compartment 1, 2, 5, 6, 7,
17, 18
Splice
Number
Location Fig.
S138 Rear of Engine Compartment 1, 2, 5, 6, 7,
17, 18
Compartment
1, 2, 6, 17,
18
Compartment
1, 2, 6
Compartment
1, 2, 17
Compartment
1, 4
Compartment
1, 4, 5, 8
Compartment
1, 2, 6
Compartment
1, 2, 6
S146 Near MSA Controller (Diesel) 19, 20
Compartment
17, 18
Compartment
17, 18
Compartment
17, 18
Compartment
17, 18
S151 Left Fender Side Shield 17, 18
S152 Left Fender Side Shield 18
S156 Rear of Engine Compartment 17
Compartment
17
S200 Near Headlamp Switch 13, 14
S201 Near Data Link Connector 13, 14
S202 Lower Left Instrument Panel 13
S203 Near Brake switchl 13
S204 Near Brake Switch 13, 14
XJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 1
Splice
Number
Location Fig.
S205 Lower Instrument Panel 13, 14
S206 In Lower Instrument Panel
Trough
13, 14
Trough
13, 14
Trough
13, 14
Trough
13, 14
Trough
13, 14
Trough
13, 14
S212 Near Brake Shift Interlock 13, 14
S213 Near Brake Shift Interlock 13, 14
S214 Between Glove Box Lamp and
Troughl
13, 14
S215 Near Center Console 13, 14
S216 Near Instrument Cluster 13, 14
S217 Lower Instrument Panel 13
S221 Near Clock Spring N/S
S222 Near Clock Spring N/S
S300 Left Side Body Harness 16
S301 Near Power Amplifier 16
S304 Near Right Front Door Jamp
Switch
N/S
S305 Between Right Tail Lamp and
Power Seat
N/S
Power Seat
N/S
Power Seat
N/S
S308 Between Left Tail Lamp and
Left Rear Door
N/S
S309 Between Left Tail Lamp and
Left Rear Door
N/S
S310 Near Right Rear Door Jamb
Switch
N/S
S311 Near Left Tail Lamp N/S
Splice
Number
Location Fig.
S312 Near Power Seat N/S
S313 Near Console Illumination N/S
S314 Instrument Panel to Body
Harness
15
S315 Instrument Panel to Body
Harness
15
S316 Near Right Power Window N/S
S317 Near Right Power Window N/S
S318 Right Front Door N/S
S322 Near Left Power Mirror N/S
S323 Near Left Door Tweeter N/S
S326 Near Left Door Speaker N/S
S327 Near Left Door Speaker N/S
S330 Near Left Front Door Speaker N/S
S331 Near Left Front Door Speaker N/S
S333 Liftgate N/S
S334 Liftgate N/S
S335 Trailer Tow Harness N/S
S342 Overhead Console N/S
S347 Dome and Vanity Harness N/S
8W - 95 - 2 8W - 95 SPLICE LOCATIONS XJ
F
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.
1
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1
4
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ENGINE
CONTENTS
page page
2. 5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. 0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 8
STANDARD SERVICE INFORMATION . . . . . . . . . . 1
STANDARD SERVICE INFORMATION
INDEX
page page
GENERAL INFORMATION
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 2
FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . . . . 1
HONING CYLINDER BORES . . . . . . . . . . . . . . . . 2
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 4
MEASURING WITH PLASTIGAGE . . . . . . . . . . . . 3
REPAIR DAMAGED OR WORN THREADS . . . . . . 4
SERVICE ENGINE ASSEMBLY
(SHORT BLOCK) . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
FORM-IN-PLACE GASKETS
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when appl yi ng form-i n-pl ace gaskets.
Bead si ze, conti nui ty and l ocati on are of great i mpor-
tance. Too thi n a bead can resul t i n l eakage whi l e too
much can resul t i n spi l l -over. A conti nuous bead of
the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar Si l i cone Rubber
Adhesi ve Seal ant and Mopar Gasket Maker). Each
have di fferent properti es and cannot be used i nter-
changeabl y.
MOPAR SILICONE RUBBER ADHESIVE
SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant, normal l y
bl ack i n col or, i s avai l abl e i n 3 ounce tubes. Moi sture
i n the ai r causes the seal ant materi al to cure. Thi s
materi al i s normal l y used on fl exi bl e metal fl anges.
I t has a shel f l i fe of a year and wi l l not properl y cure
i f over aged. Al ways i nspect the package for the expi -
rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normal l y red i n col or, i s
avai l abl e i n 6 cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et or other sui tabl e tool to break the seal
between the mati ng surfaces. A fl at gasket scraper
may al so be l i ghtl y tapped i nto the joi nt but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
gasket rai l s are fl at. Fl atten rai l s wi th a hammer on
a fl at pl ate, i f requi red. Gasket surfaces must be free
of oi l and di rt. Make sure the ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar Si l i cone Rubber Adhesi ve Seal ant shoul d be
appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
XJ ENGINE 9 - 1
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n 10
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can easi l y be wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
ENGINE PERFORMANCE
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and the l owest emi ssi on l evel s. I f vehi cl e i s not oper-
ati ng to these standards, refer to Engi ne Di agnosi s
outl i ned i n thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. Refer to El ectri -
cal Group 8B, Col d Cranki ng Test.
(2) Check i ntake mani fol d bol t torque; Refer to
Group 11, Exhaust System and I ntake Mani fol d.
(3) Perform cyl i nder compressi on test. Refer to
Cyl i nder Compressi on Pressure Test i n the Engi ne
Di agnosi s area of thi s secti on.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n El ectri cal Group 8D.
Ti ghten to speci fi cati ons.
(5) Test resi stance of spark pl ug cabl es. Refer to
El ectri cal Group 8D, Spark Pl ug Cabl es.
(6) I nspect the pri mary wi res. Test coi l output vol t-
age and pri mary resi stance. Repl ace parts as neces-
sary. Refer to El ectri cal Group 8D, for speci fi cati ons.
(7) Test fuel pump for pressure. Refer to Group 14,
Fuel System Speci fi cati ons.
(8) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Lubri cati on and Mai ntenance, Group 0.
(9) I nspect crankcase venti l ati on system as out
l i ned i n Group 0, Lubri cati on and Mai ntenance. For
emi ssi on control s see Group 25, Emi ssi on Control s
for servi ce procedures.
(10) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). 20-60 strokes,
dependi ng on the bore condi ti on, wi l l be suffi ci ent to
provi de a sati sfactory surface. Usi ng honi ng oi l
C-3501-3880 or a l i ght honi ng oi l avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 1).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
Fig. 1 Cylinder Bore Crosshatch Pattern
9 - 2 ENGINE XJ
MEASURING WITH PLASTIGAGE
CRANKSHAFT MAIN BEARING CLEARANCE
Engi ne crankshaft beari ng cl earances can be deter-
mi ned by use of Pl asti gage, or equi val ent. The fol l ow-
i ng i s the recommended procedures for the use of
Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) The total cl earance of the mai n beari ngs can
onl y be determi ned by removi ng the wei ght of the
crankshaft. Thi s can be accompl i shed by ei ther of two
methods:
METHOD - 1 (PREFERRED)
Shi m the beari ngs adjacent to the beari ng to be
checked. Thi s wi l l remove the cl earance between
upper beari ng shel l and the crankshaft. Pl ace a mi n-
i mum of 0.254 mm (0.010 i nch) shi m between the
beari ng shel l and the adjacent beari ng cap. Ti ghten
the bol ts to 18 Nm (13 ft. l bs.) torque.
ALL ENGINESWhen checki ng No.1 mai n
beari ng; shi m No.2 mai n beari ng.
beari ng; shi m No.1 and No.3 mai n beari ng.
2.5L ENGINEWhen checki ng No.5 mai n bear-
i ng; shi m No.4 mai n beari ng.
i ng; shi m No.4 and No.6 mai n beari ng.
i ng; shi m No.5 and No.7 mai n beari ng.
i ng; shi m No.6 mai n beari ng.
NOTE: Remove all shims before assembling
engine.
METHOD - 2 (ALTERNATIVE)
The wei ght of the crankshaft i s supported by a jack
under the counterwei ght adjacent to the beari ng
bei ng checked.
(1) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 2). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n
that area. Ti ghten the beari ng cap bol ts of the bear-
i ng bei ng checked to 108 Nm (80 ft. l bs.) torque. DO
NOT rotate the crankshaft or the Plastigage
may be smeared, giving inaccurate results.
(2) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 3). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(3) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
CONNECTING ROD BEARING CLEARANCE
Engi ne connecti ng rod beari ng cl earances can be
determi ned by use of Pl asti gage, or equi val ent. The
fol l owi ng i s the recommended procedures for the use
of Pl asti gage:
(1) Remove oi l fi l m from surface to be checked.
Pl asti gage i s sol ubl e i n oi l .
(2) Pl ace a pi ece of Pl asti gage across the enti re
wi dth of the beari ng cap shel l (Fi g. 2). Posi ti on the
Pl asti gage approxi matel y 6.35 mm (1/4 i nch) off cen-
ter and away from the oi l hol es. I n addi ti on, suspect
areas can be checked by pl aci ng the Pl asti gage i n the
suspect area.
(3) The crankshaft must be turned unti l the con-
necti ng rod to be checked starts movi ng toward the
top of the engi ne. Onl y then shoul d the rod cap wi th
Pl asti gage i n pl ace be assembl ed. Ti ghten the rod cap
nut to 45 Nm (33 ft. l bs.) torque. DO NOT rotate
Fig. 2 Placement of Plastigage in Bearing Shell
Fig. 3 Clearance Measurement
XJ ENGINE 9 - 3
the crankshaft or the Plastigage may be
smeared, giving inaccurate results.
(4) Remove the beari ng cap and compare the wi dth
of the fl attened Pl asti gage wi th the scal e provi ded on
the package (Fi g. 3). Pl asti gage general l y comes i n 2
scal es (one scal e i s i n i nches and the other i s a met-
ri c scal e). Locate the band cl osest to the same wi dth.
Thi s band shows the amount of cl earance. Di ffer-
ences i n readi ngs between the ends i ndi cate the
amount of taper present. Record al l readi ngs taken
(refer to Engi ne Speci fi cati ons).
(5) Pl asti gage i s avai l abl e i n a vari ety of cl earance
ranges. The 0.025-0.076 mm (0.001-0.003 i nch) range
i s usual l y the most appropri ate for checki ng engi ne
beari ng cl earances.
REPAIR DAMAGED OR WORN THREADS
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
CAUTION: Be sure that the tapped holes maintain
the original center line.
Hel i -Coi l tool s and i nserts are readi l y avai l abl e
from automoti ve parts jobbers.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter S
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
HYDROSTATIC LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(refer to Group 14, Fuel System).
(2) Di sconnect the negati ve cabl e from the battery.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 37 Nm (27 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l (refer to Group 0, Lubri ca-
ti on and Mai ntenance).
(15) Connect the negati ve cabl e to the battery.
(16) Start the engi ne and check for any l eaks.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
9 - 4 ENGINE XJ
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed or an oi l that conforms to the API Servi ce Grade
SH or SH/CD. MOPAR provi des engi ne oi l s that con-
form to al l of these servi ce grades.
SAE VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 4).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. They are desi gnated as ei ther
ENERGY CONSERVI NG or ENERGY CONSERV-
I NG I I .
CONTAINER IDENTIFICATION
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 5).
ENGINE OIL ADDITIVES
I n some i nstances, such as i nfrequent operati on,
short tri p dri vi ng, and duri ng break-i n after a major
overhaul , addi ti on of speci al materi al s contai ni ng
anti -rust and anti -scuff addi ti ves are benefi ci al . A
sui tabl e product for thi s purpose i s MOPAR Engi ne
Oi l Suppl ement.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine
oil, oil foaming and oil pressure loss can result.
The engi ne oi l l evel i ndi cator (Di psti ck) i s l ocated
at the ri ght rear of both 2.5L engi nes and 4.0L
engi nes. I nspect engi ne oi l l evel approxi matel y every
800 ki l ometers (500 mi l es). Unl ess the engi ne has
exhi bi ted l oss of oi l pressure, run the engi ne for
about fi ve mi nutes before checki ng oi l l evel . Checki ng
engi ne oi l l evel on a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 6)
(Fi g. 7).
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng (Fi g. 6) (Fi g. 7).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
Fig. 4 Temperature/Engine Oil Viscosity
Fig. 5 Engine Oil Container Standard Notations
Fig. 6 Engine Oil Dipstick2.5L Engine
XJ ENGINE 9 - 5
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Chrysl er Corpo-
rati on recommends a Mopar or equi val ent oi l fi l ter be
used.
OIL FILTER REMOVAL
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss or fi l ter
adapter housi ng (Fi g. 8) (Fi g. 9).
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Make sure ol d gasket comes off wi th oi l fi l ter.
Wi th a wi pi ng cl oth, cl ean the gasket seal i ng surface
(Fi g. 10) of oi l and gri me.
Fig. 7 Engine Oil Dipstick4.0L Engine
Fig. 8 Oil Filter2.5L Engine
Fig. 9 Oil Filter4.0L Engine
9 - 6 ENGINE XJ
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 10) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
Fig. 10 Oil Filter Sealing SurfaceTypical
XJ ENGINE 9 - 7
ENGINE DIAGNOSIS
INDEX
page page
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 9
CYLINDER COMPRESSION PRESSURE TEST . . 8
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 8
INSPECTION (ENGINE OIL LEAKS IN
GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 8
SERVICE DIAGNOSISMECHANICAL . . . . . . . . 13
SERVICE DIAGNOSISPERFORMANCE . . . . . . 11
GENERAL INFORMATION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne tune-ups.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
Refer to the Servi ce Di agnosi sPerformance chart
and the Servi ce Di agnosi sMechani cal chart for pos-
si bl e causes and correcti ons of mal functi ons. Refer to
Group 14, Fuel System for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test.
Cyl i nder Combusti on Pressure Leakage Test.
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s.
I ntake Mani fol d Leakage Di agnosi s.
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sconnect the i gni ti on coi l .
(5) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(6) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
Refer to Engi ne Speci fi cati ons for the correct
engi ne compressi on pressures.
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS
A l eaki ng engi ne cyl i nder head gasket usual l y
resul ts i n l oss of power, l oss of cool ant and engi ne
mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
An engi ne cyl i nder head gasket l eaki ng between
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
dures outl i ned i n Cyl i nder Compressi on Pressure
9 - 8 ENGINE XJ
Test. An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders wi l l resul t i n approxi matel y a
50-70% reducti on i n compressi on pressure.
CYLINDER-TO-WATER J ACKET LEAKAGE
TEST
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1 379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to the Cyl i nder Combusti on Pressure Leak-
age Test Di agnosi s chart.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begi n wi th a through vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve. Reface or replace, as
necessary
AIR ESCAPES THROUGH TAILPIPE Exhaust valve bent, burnt, or not
seated properly
Inspect valve. Reface or replace, as
necessary
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE FROM
ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Remove cylinder head and inspect.
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings; cracked
piston; worn rings and/or cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
XJ ENGINE 9 - 9
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(5) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method.
Air Leak Detec tion Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(1) Di sconnect the battery.
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
ENGINE OIL PRESSURE
(1) Remove oi l pressure sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292. Start engi ne and record pressure. Refer to
Oi l Pressure i n Engi ne Speci fi cati ons for the proper
pressures.
9 - 10 ENGINE XJ
SERVICE DIAGNOSIS PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
ENGINE LOSS OF POWER 1. Incorrect ignition timing 1. Refer to group 8D, Ignition System
2. Worn or burned distributor rotor 2. Install new distributor rotor
3. Worn distributor shaft 3. Remove and repair distributor
(Refer to group 8D, Ignition System
4. Dirty or incorrect gapped spark
plugs
4. Clean plugs and set gap (Refer to
group 8D, Ignition System
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 cylinder compression
10. Burned, warped, or pitted valves 10. Install/Reface valves as
necessary
11. Plugged or restricted exhaust
system
11. Install new parts as necessary
12. Faulty ignition cables 12. Replace any cracked or shorted
cables
13. Faulty ignition coil 13. Test and replace, as necessary
(Refer to Group 8D, ignition system)
14. Faulty crank or cam sensor 14. Replace sensor
ENGINE STALLS OR ROUGH IDLE 1. Idle speed set too low 1. Refer to group 14, Fuel System
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 11, Exhaust System
& Intake Manifold
4. Worn 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 8D, Ignition System)
7. EGR valve leaking or stuck open 7. Test and replace, if necessary
(refer to group 25, Emission Control
Systems)
ENGINE LOSS OF POWER 1. Incorrect ignition timing 1. Refer to Group 8D, Ignition
System
4. Dirty or incorrectly gapped spark
plugs
4. Clean plugs and set gap (refer to
group 8D, Ignition System)
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 cylinder compression
10. Burned, warped or pitted valves 10. Reface/replace valves
XJ ENGINE 9 - 11
ENGINE LOSS OF POWER
(CONTD)
11. Plugged or restricted exhaust
system
11. Install new parts as necessary
12. Faulty ignition cables 12. Replace any cracked or shorted
cables
13. Faulty coil 13. Test and replace, as necessary
14. Faulty crankshaft or camshaft
sensor
14. Replace sensor
ENGINE MISSES ON
ACCELERATION
1. Dirty or gap set too wide in spark
plug
1. Clean spark plugs and set gap
2. Incorrect ignition timing 2. Refer to group 8D, Ignition 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 as necessary
ENGINE MISSES AT HIGH SPEED 1. Dirty or gap set too wide in spark
plug
1. Clean spark plugs and set gap
4. Faulty coil 4. Test and replace, as necessary
5. Incorrect ignition timing 5. Refer to group 8D, Ignition System
6. Dirty injector in throttle body 6. Clean injector
filter
9 - 12 ENGINE XJ
SERVICE DIAGNOSIS MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES 1. High or low oil level in crankcase 1. Check for correct oil level (refer to
group 0, Lubrication and
Maintenance)
2. Thin 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/lash adjusters 4. Clean hydraulic tappets/lash
adjusters
5. Bent push rods 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Ream and install new valves with
oversize stems
9. Excessive runout of valve seats or
valve faces
9. Grind valve seats and valves
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level (refer to
Maintenance)
2. Low oil pressure 2. Check engine oil level. Perform
manual oil pressure test
3. Thin or diluted oil 3. Change oil to correct viscosity
4. Excessive bearing clearance Measure bearings for correct
clearance. Repair as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level (refer to
Maintenance)
2. Low oil pressure 2. Check engine oil level. Perform
manual oil pressure test if necessary
4. Excessive bearing clearance 4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque converter 7. Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace worn gears or oil pump
assy
LOW OIL PRESSURE (CONTD) 6. Excessive bearing clearance 6. Measure bearings for correct
clearance
XJ ENGINE 9 - 13
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or cracked 9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated gaskets 1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup plug 4. Remove and reseal threaded plug.
Replace cup style plug
OIL CONSUMPTION OR SPARK
PLUGS OIL FOULED
1. PCV System malfunction 1. Refer to group 25, Emission
Control System for proper operation
2. Defective valve stem seal 2. Repair or replace seal
3. Worn, scuffed or broken piston
rings
3. Hone cylinder bores. Install new
rings
4. Carbon in oil control ring groove 4. Remove rings and de-carbon
piston
5. Worn valve guides 5. Ream guides and replace valves
with oversize valves and seals
6. Piston rings fitted too tightly in
grooves
6. Remove rings and check ring end
gap and side clearance. Replace if
necessary
9 - 14 ENGINE XJ
2.5L ENGINE
INDEX
page page
ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . 15
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 16
OIL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . 18
OVERSIZE AND UNDERSIZE COMPONENT
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES
FITTING CONNECTING ROD BEARINGS . . . . . . 21
FITTING CRANKSHAFT MAIN BEARINGS . . . . . 23
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . . 18
PISTON RING FITTING . . . . . . . . . . . . . . . . . . . 19
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 41
CAMSHAFT PIN REPLACEMENT . . . . . . . . . . . . 39
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 41
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 30
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 28
ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . . . 32
ENGINE MOUNTSFRONT . . . . . . . . . . . . . . . . 27
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . . 28
HYDRAULIC TAPPETS . . . . . . . . . . . . . . . . . . . . 35
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
PISTONS AND CONNECTING RODS . . . . . . . . . 44
REAR MAIN OIL SEALS . . . . . . . . . . . . . . . . . . . 46
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 31
TIMING CASE COVER OIL SEAL . . . . . . . . . . . 36
TIMING CASE COVER . . . . . . . . . . . . . . . . . . . . 36
TIMING CHAIN AND SPROCKETS . . . . . . . . . . . 37
VALVE SPRINGS AND OIL SEALS . . . . . . . . . . . 31
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 34
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 35
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 48
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 46
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 49
SPECIFICATIONS
2.5L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 50
2.5L TORQUE SPECIFICATIONS . . . . . . . . . . . . 52
SPECIAL TOOLS
2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINE DESCRIPTION
The 2.5 l i ter (150 CI D) four-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Engine Description
Engi ne Type . . . . . . . . . . . . . . . . . .I n-l i ne 4 Cyl i nder
Bore and Stroke. . . . .98.4 x 81.0mm (3.88 x 3.19 i n.)
Di spl acement . . . . . . . . . . . . . . . . . . .2.5 (150 cu. i n.)
Compressi on Rati o . . . . . . . . . . . . . . . . . . . . . . .9.1:1
Torque . . . . . . . . . .202 Nm (149 ft. l bs.) @ 3250 rpm
Fi ri ng Order . . . . . . . . . . . . . . . . . . . . . . . . .1342
Lubri cati on . . . . .Pressure FeedFul l Fl ow Fi l trati on
Engi ne Oi l Capaci ty . . . . . . . . . . . . .3.8 L (4 Quarts)
Cool i ng System . . .Li qui d Cool edForced Ci rcul ati on
Cool i ng System Capaci ty . . . . . . . . .9.5L (10 Quarts)
Cyl i nder Bl ock . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Crankshaft . . . . . . . . . . . . . . . . . .Cast Nodul ar I ron
Cyl i nder Head . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Pi stons. . . . . . . . . . . . .Al umi num Al l oy (wi th Struts)
Cyl i nder Combusti on Cavi ty . . . . . . .Doubl e Quench
Connecti ng Rods . . . . . . . . . . . . .Cast Mal l eabl e I ron
Thi s engi ne i s desi gned for unl eaded fuel .
The engi ne cyl i nder head has dual quench-type
combusti on chambers that create turbul ence and fast
burni ng of the ai r/fuel mi xture. Thi s resul ts i n good
fuel economy.
The cyl i nders are numbered 1 through 4 from front
to rear. The fi ri ng order i s 1-3-4-2 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n fi ve mai n beari ngs and the camshaft rotates
wi thi n four beari ngs.
BUILD DATE CODE
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.3 and No.4 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (7 = 1997).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (HX = A 2.5 l i ter (150 CI D) 9.1:1
XJ 2. 5L ENGINE 9 - 15
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
6th & 7th Di gi tsThe day of engi ne bui l d (01 -
31).
FOR EXAMPLE: Code * 701HX23 * i denti fi es a
2.5 l i ter (150 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, 9.1:1 compressi on rati o and bui l t on
January 23, 1997.
LUBRICATION SYSTEM
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng. The pump draws oi l through the
screen and i nl et tube from the sump at the rear of
the oi l pan. The oi l i s dri ven between the dri ve and
i dl er gears and pump body, then forced through the
outl et to the bl ock. An oi l gal l ery i n the bl ock chan-
nel s the oi l to the i nl et si de of the ful l fl ow oi l fi l ter.
After passi ng through the fi l ter el ement, the oi l
passes from the center outl et of the fi l ter through an
oi l gal l ery that channel s the oi l up to the mai n gal -
l ery whi ch extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
9 - 16 2. 5L ENGINE XJ
Oil Lubrication System
OIL PUMP PRESSURE
The MI NI MUM oi l pump pressure i s 89.6 kPa (13
psi ) at 600 rpm. The NORMAL oi l pump pressure i s
255-517 kPa (37-75 psi ) at 1600 rpm or more.
OVERSIZE AND UNDERSIZE COMPONENT CODES
Some engi nes may be bui l t wi th oversi ze or under-
si ze components such as:
Oversi ze cyl i nder bores.
Oversi ze camshaft beari ng bores.
Undersi ze crankshaft mai n beari ng journal s.
Undersi ze connecti ng rod journal s.
These engi nes are i denti fi ed by a l etter code (Fi g.
3) stamped on the oi l fi l ter boss near the di stri butor
(Fi g. 4).
SERVICE PROCEDURES
VALVE TIMING
Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assembl y,
and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.4 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90.
I nstal l a di al i ndi cator on the end of the No.1 cyl -
i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
Set the di al i ndi cator poi nter at zero.
Rotate the crankshaft cl ockwi se (vi ewed from the
front of the engi ne) unti l the di al i ndi cator poi nter
i ndi cates 0.305 mm (0.012 i nch) travel di stance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2 i nch)
away from the TDC mark i n ei ther di recti on, the
val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be a
broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
PISTON FITTING
BORE GAUGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm (
.0001 i n.) I NCREMENTS i s requi red. I f a bore gauge
i s not avai l abl e, do not use an i nsi de mi crometer.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 6).
Fig. 3 Oversize and Undersize Component Codes
Fig. 4 Oversize and Undersize Component Code
Location
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 5). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON SIZE CHART
CYLINDER PISTON
BORE LETTER
SIZE SIZE
98.438 to 98.448 mm (3.8755 to 3.8759 i n.) . . . . . . .A
98.448 to 98.458 mm (3.8759 to 3.8763 i n.) . . . . . . .B
98.458 to 98.468 mm (3.8763 to 3.8767 i n.) . . . . . . .C
98.468 to 98.478 mm (3.8767 to 3.8771 i n.) . . . . . . .D
98.478 to 98.488 mm (3.8771 to 3.8775 i n.) . . . . . . .E
98.488 to 98.498 mm (3.8775 to 3.8779 i n.) . . . . . . .F
PISTON RING FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 7) (Fi g. 8). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
Fig. 5 Moly Coated Piston
Fig. 6 Bore Gauge
Fig. 7 Piston Dimensions
Ring Side Clearance Measurement
Top Compressi on Ri ng. . . . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Second Compressi on Ri ng . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Oi l Control Ri ng . . . . . . . . . . . . . . . .0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 9).
Ring Gap Measurement
Top Compressi on Ri ng . . . . . . . . . 0.229 to 0.610 mm
(0.0090 to 0.0240 i nch)
(0.0190 to 0.0380 i nch)
Oi l Control Ri ng . . . . . . . . . . . . . .0.254 to 1.500 mm
(0.010 to 0.060 i nch)
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 10).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 11).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 11) (Fi g.
13).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Fig. 8 Ring Side Clearance Measurement
Fig. 9 Gap Measurement
Fig. 10 Top Compression ring identification
Fig. 11 Second Compression Ring Identification
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g.
14).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
FITTING CONNECTING ROD BEARINGS
INSPECTION
BEARINGS
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 15) (Fi g. 16). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 17). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
CONNECTING RODS
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
Fig. 12 Compression Ring Chamfer Location
Fig. 13 Compression Ring Installation
Fig. 14 Ring Gap Orientation
Fig. 15 Connecting Rod Bearing Inspection
BEARING-TO-J OURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
18). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 19). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage 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) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
Fig. 16 Locking Tab Inspection
Fig. 17 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
Fig. 18 Rod and Piston Assembly Installation
Fig. 19 Measuring Bearing Clearance with
Plastigage
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 20).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 21).
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT
INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 5 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
CONNECTING ROD BEARING FITTING CHART
Fig. 20 Checking Connecting Rod Side Clearace
Typical
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark on the adjacent
cheek. The rear mai n journal , i s i denti fi ed by a col or-
coded pai nt mark on the crankshaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size (Fig. 22).
NOTE: 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 beari ngs have been properl y fi tted, pro-
ceed to Crankshaft Mai n Beari ngI nstal l ati on.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 23). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cated wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
Fig. 21 Main Bearing Wear Patterns
Fig. 22 Bearing Insert Pairs
Plastigage
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
I f journal s 1 through 5 di ameters are l ess than
63.4517 mm (2.4981 i nches), repl ace crankshaft or
gri nd crankshaft down to accept the appropri ate
undersi ze beari ng i nserts.
Once the proper cl earances have been obtai ned,
proceed to Crankshaft Mai n Beari ngI nstal l ati on.
MAIN BEARING J OURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
MAIN BEARING FITTING CHART
CRANKSHAFT JOURNALS #1 - #4 CORRESPONDING CRANKSHAFT BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow 63.5025 - 63.4898 mm Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
Orange 63.4898 - 63.4771mm Yellow - Undersize
0.025 mm (0.001 in.)
Blue - Standard
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue 63.4771 - 63.4644 mm Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green 63.4644 - 63.4517 mm Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
Red 63.2485 - 63.2358 mm Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
CRANKSHAFT JOURNAL #5 ONLY CORRESPONDING CRANKSHAFT BEARING INSERT
(2.4995 - 2.4990 in.)
Orange 63.4746 - 63.4619 mm Yellow - Undersize
0.025 mm (0.001 in.)
Blue - Standard
(2.4990 - 2.4985 in.)
0.0127 mm (0.0005 in.
Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4985 - 2.4980 in.)
0.0254 mm (0.001 in.)
Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4980- 2.4975 in.)
0.0381 mm (0.0015 in.)
Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4895 - 2.4890 in.)
0.254 mm (0.010 in.)
Undersize
ENGINE MOUNTS FRONT
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
REMOVAL
(3) Support the engi ne.
(4) Remove through bol t nut (Fi g. 24). DO NOT
remove the through bol t.
(5) Remove the retai ni ng bol ts and nuts from the
support cushi ons (Fi g. 24).
(6) Remove the through bol t.
(7) Remove the support cushi ons.
INSTALLATION
(1) I f the engi ne support bracket was removed,
posi ti on the LEFT bracket (Fi g. 24) and the RI GHT
bracket (Fi g. 25) onto the cyl i nder bl ock. I nstal l the
bol ts and stud nuts.
(a) RI GHT SI DE (Fi g. 25) Ti ghten the bol ts to
61 Nm (45 ft. l bs.) torque. Ti ghten the stud nuts to
(b) LEFT SI DE (Fi g. 24) Ti ghten the bol ts to
(2) I f the support cushi on brackets were removed,
posi ti on the brackets onto the l ower front si l l (Fi g.
24) (Fi g. 26). I nstal l the bol ts and stud nuts. Ti ghten
the bol ts to 54 Nm (40 ft. l bs.) torque and the stud
nuts to 41 Nm (30 ft. l bs.) torque.
(3) Pl ace the support cushi ons onto the support
cushi on brackets (Fi g. 24). Ti ghten the ri ght support
cushi on nuts to 65 Nm (48 ft. l bs.) torque. Ti ghten
the l eft support cushi on bol t and nut to 41 Nm (30
ft. l bs.) torque.
(4) I nstal l the through bol t and the retai ni ng nut
(Fi g. 24). Ti ghten the through bol t nut to 65 Nm (48
ft. l bs.) torque.
(5) Remove the engi ne support.
Fig. 24 Front Mounts
Fig. 25 Engine Support BracketRight Side
Fig. 26 Support Cushion BracketLeft Side
ENGINE MOUNT REAR
A resi l i ent rubber cushi on supports the transmi s-
si on at the rear between the transmi ssi on extensi on
housi ng and the rear support crossmember or ski d
pl ate.
REMOVAL
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the crossmember (Fi g. 27) (Fi g. 28). Remove the
crossmember.
MANUAL TRANSMISSION:
a. Remove the support cushi on nuts and remove
the cushi on.
b. I f necessary, remove the bol ts hol di ng the trans-
mi ssi on support bracket to the transmi ssi on (Fi g. 27).
Remove the bracket.
AUTOMATIC TRANSMISSION:
a. Remove the support cushi on bol ts and remove
the cushi on and the transmi ssi on support bracket.
b. I f necessary on 2WD vehi cl es, remove the bol ts
hol di ng the transmi ssi on support adaptor bracket to
the transmi ssi on (Fi g. 28). Remove the adaptor
bracket.
INSTALLATION
a. I f removed, posi ti on the transmi ssi on support
bracket to the transmi ssi on and i nstal l the bol ts.
Ti ghten the bol ts to 43 Nm (32 ft. l bs.) torque.
b. Posi ti on the support cushi on onto the transmi s-
si on support bracket. I nstal l and ti ghten the nuts to
a. I f removed, posi ti on the transmi ssi on support
adaptor bracket (2WD vehi cl es) to the transmi ssi on
and i nstal l the bol ts. Ti ghten the bol ts to 75 Nm (55
ft. l bs.) torque.
b. Posi ti on the transmi ssi on support bracket and
support cushi on to the transmi ssi on and i nstal l the
bol ts. Ti ghten the bol ts to 75 Nm (55 ft. l bs.) torque.
(1) Posi ti on the crossmember onto the support
cushi on studs and i nstal l the nuts. Ti ghten the nuts
(2) I nstal l the crossmember to si l l bol ts and
ti ghten to 41 Nm (30 ft. l bs.) torque.
(3) Remove the transmi ssi on support.
ENGINE ASSEMBLY
REMOVAL
(1) Di sconnect the battery cabl es. Remove the bat-
tery.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
Fig. 27 Rear Mount (Manual Transmission)
Fig. 28 Rear Mount (Automatic Transmission)
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(3) Loosen the radi ator drai n cock and radi ator cap
to drai n the cool ant. DO NOT waste usabl e cool ant.
I f the sol uti on i s cl ean, drai n the cool ant i nto a cl ean
contai ner for reuse.
(4) Remove the ai r cl eaner assembl y.
(5) Remove the l ower radi ator hose.
(6) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 29).
(7) Remove the fan shroud (Fi g. 29).
(8) Remove the radi ator/condenser (i f equi pped
wi th ai r condi ti oni ng).
(9) Remove fan assembl y and i nstal l a 5/16 x 1/2-
i nch SAE capscrew through fan pul l ey i nto water
pump fl ange. Thi s wi l l mai ntai n the pul l ey and
water pump i n al i gnment when crankshaft i s rotated.
(10) Di sconnect the heater hoses.
(11) Di sconnect the throttl e cabl e, speed control
cabl e (i f equi pped) and transmi ssi on cabl e (i f
equi pped).
(12) Di sconnect the body ground at the fi rewal l .
(13) Di sconnect the wi res from the starter motor
sol enoi d.
(14) Di sconnect al l fuel i njecti on harness connec-
ti ons.
STANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE DISCONNECTING FUEL
LINES, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(15) Perform fuel pressure rel ease procedure.
(refer to Group 14, Fuel System for the proper proce-
dure).
(16) Remove l atch cl i p and di sconnect the qui ck-
connect fuel l i ne at the fuel rai l
(17) Recover refri gerant (i f equi pped wi th A/C).
(Refer to group 24, Heati ng and Ai r Condi ti oni ng for
proper procedures.)
(18) Di sconnect sucti on/di scharge hose from A/C
compressor and cap off ports to prevent i ntrusi on of
forei gn materi al or refri gerant oi l l oss.
(19) Remove the power brake vacuum check val ve
from the booster, i f equi pped.
(20) I f equi pped wi th power steeri ng:
(a) Di sconnect the power steeri ng hoses from the
fi tti ngs at the steeri ng gear.
(b) Drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn materi al from enteri ng the
system.
(21) I denti fy, tag and di sconnect al l necessary wi re
connectors and vacuum hoses.
(23) Remove the oi l fi l ter.
(24) Remove the starter motor.
(25) Di sconnect the exhaust pi pe from the exhaust
mani fol d.
(26) Remove the fl ywheel housi ng access cover.
(27) Remove the upper fl ywheel and converter
housi ng bol ts and l oosen the bottom bol ts.
(28) Remove the engi ne support cushi on-to-engi ne
compartment bracket bol ts.
(29) Remove the engi ne shock damper bracket
from the si l l .
(31) Attach a l i fti ng devi ce to the engi ne.
(32) Rai se the engi ne sl i ghtl y off the front sup-
ports.
(33) Pl ace a support stand under the converter or
fl ywheel housi ng.
(34) Li ft the engi ne out of the engi ne compartment
and i nstal l on an engi ne stand.
(35) I nstal l the oi l fi l ter to keep forei gn materi al
out of the engi ne.
INSTALLATION
(1) Remove the oi l fi l ter.
(2) Li ft the engi ne off the stand and l ower i t i nto
the engi ne compartment. For easi er i nstal l ati on, i t
may be useful to remove the engi ne support cushi ons
from the engi ne support brackets as an ai de for
al i gnment of the engi ne-to-transmi ssi on.
(3) I nsert the transmi ssi on shaft i nto the cl utch
spl i ne. (M/T model s)
(4) Al i gn the fl ywheel housi ng wi th the engi ne.
(5) I nstal l and ti ghten the fl ywheel housi ng l ower
bol ts.
Fig. 29 Upper Radiator Hose, Coolant Recovery
Hose & Fan Shroud
(6) I nstal l the engi ne support cushi ons (i f
removed).
(7) Lower the engi ne and engi ne support cushi ons
onto the engi ne compartment brackets.
(8) Remove the engi ne l i fti ng devi ce.
(10) I nstal l the converter-housi ng access cover.
(11) I nstal l the exhaust pi pe support.
(12) I nstal l the starter motor and connect the
cabl e. Ti ghten the bol ts to 45 Nm (33 ft. l bs.) torque.
(13) Ti ghten the engi ne support cushi on through-
bol t nuts.
(14) Connect the exhaust pi pe to the mani fol d.
(15) I nstal l the oi l fi l ter.
(17) Connect the cool ant hoses and ti ghten the
cl amps.
(a) Remove the protecti ve caps
(b) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(c) Fi l l the pump reservoi r wi th fl ui d.
(19) Remove the pul l ey-to-water pump fl ange
al i gnment capscrew and i nstal l the fan assembl y.
(20) I nstal l the fan shroud and radi ator and con-
denser (i f equi pped wi th ai r condi ti oni ng).
(21) Connect the radi ator hoses.
(22) Connect the oxygen sensor wi re connector.
(23) Connect the throttl e cabl e and i nstal l the rod.
Connect the transmi ssi on and speed control cabl es (i f
equi pped)
(24) Connect the fuel suppl y l i ne to the i njector
rai l . push unti l a cl i ck i s heard. Re-i nstal l l atch
cl i p.
(25) Connect al l the vacuum hoses and wi re con-
nectors.
(26) Connect sucti on/di scharge hose to compressor.
(i f equi pped)
(27) Fi l l the power steeri ng reservoi r.
(28) Connect the battery cabl es.
(29) I nstal l the ai r cl eaner.
(30) I nstal l the hood.
(31) Add engi ne oi l and cool ant.
(32) Start the engi ne and i nspect for l eaks.
(33) Stop the engi ne and check the fl ui d l evel s.
Add fl ui d, as requi red.
(34) Recharge ai r condi ti oni ng (Refer to group 24,
Heati ng and Ai r Condi ti oni ng for proper procedures).
CYLINDER HEAD COVER
A cured gasket i s part of the engi ne cyl i nder head
cover.
REMOVAL
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover (Fi g.
30).
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover (Fi g. 30).
(4) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(5) Remove the engi ne cyl i nder head cover.
(6) Remove any ori gi nal seal er from the cover seal -
i ng surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
(7) Remove al l resi due from the seal i ng surface
usi ng a cl ean, dry cl oth.
INSTALLATION
(1) I nspect the engi ne cyl i nder head cover for
cracks. Repl ace the cover, i f cracked.
NOTE: The original dark grey gasket material
should NOT be removed. If sections of the gasket
material are missing 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.
(2) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet the oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(3) I nstal l engi ne cyl i nder head cover. Ti ghten the
mounti ng bol ts to 13 Nm (115 i n. l bs.) torque.
Fig. 30 Engine Cylinder Head Cover
(4) Connect the CCV hoses (Fi g. 30).
ROCKER ARMS AND PUSH RODS
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Remove the engi ne cyl i nder head cover. (Refer
to procedure i n thi s secti on)
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 31). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 31). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
(6) Cl ean al l the components wi th cl eani ng sol -
vent.
(7) Use compressed ai r to bl ow out the oi l passages
i n the rocker arms and push rods.
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover.
VALVE SPRINGS AND OIL SEALS
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(2) Remove capscrews, bri dge and pi vot assembl i es
and rocker arms for access to each val ve spri ng to be
removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) I nstal l a 14 mm (1/2 i nch) (thread si ze) ai r hose
adaptor i n the spark pl ug hol e.
(7) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(8) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 32).
(9) Remove val ve spri ng and retai ner (Fi g. 32).
(10) Remove val ve stem oi l seal s (Fi g. 32). Note
the val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(I ntake) or EXH (Exhaust). DO NOT mi x the seal s.
INSTALLATION
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
CAUTION: Install oil seals carefully to prevent
damage from the sharp edges of the valve spring
lock grove.
Fig. 31 Rocker Arm Assembly
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge capscrews al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
ENGINE CYLINDER HEAD
REMOVAL
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean and i s bei ng
drai ned onl y to servi ce the engi ne or cool i ng system,
drai n the cool ant i nto a cl ean contai ner for reuse.
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms (Fi g. 33).
(6) Remove the push rods (Fi g. 33). Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the serpenti ne dri ve bel t at the power
steeri ng pump bracket, i f equi pped or at the i dl er
pul l ey bracket (refer to Group 7, Cool i ng System for
the proper procedure).
(8) I f equi pped wi th ai r condi ti oni ng, perform the
fol l owi ng:
(a) Remove the bol ts from the A/C compressor
mounti ng bracket and set the compressor asi de.
(b) Remove the ai r condi ti oner compressor
bracket bol ts from the engi ne cyl i nder head.
(c) Loosen the through bol t at the bottom of the
bracket.
(9) I f equi pped, di sconnect the power steeri ng
pump bracket. Set the pump and bracket asi de. DO
NOT di sconnect the hoses.
Fig. 32 Valve and Valve Components
(10) Perform fuel pressure rel ease procedure
(Refer to Group 14, fuel systems for proper proce-
dures).
(11) Remove the l atch cl i p and di sconnect the fuel
suppl y hose.
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head (refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures).
(13) Number and di sconnect the i gni ti on wi res and
remove the spark pl ugs.
(14) Di sconnect the cool ant temperature sendi ng
uni t connector.
(15) Remove the engi ne cyl i nder head bol ts.
(16) Remove the engi ne cyl i nder head and gasket
(Fi g. 34).
(17) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(18) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If valves, springs, or seals are to be inspect-
ed/replaced at this time, refer to Valves and Valve
Springs later in this section for proper procedures.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Fabri cate two engi ne cyl i nder head al i gnment
dowel s from used head bol ts (Fi g. 35). Use the l ong-
est head bol t. Cut the head of the bol t off bel ow the
hex head. Then cut a sl ot i n the top of the dowel to
al l ow easi er removal wi th a screwdri ver.
(2) I nstal l one dowel i n bol t hol e No.10 and the
other dowel i n bol t hol e No.8 (Fi g. 36).
(3) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(4) Pl ace the engi ne cyl i nder head gasket (wi th the
numbers faci ng up) over the dowel s.
(5) Pl ace the engi ne cyl i nder head over the dowel s.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(6) Coat the threads of bol t No.7, onl y, wi th Locti te
PST seal ant or equi val ent.
(7) I nstal l al l head bol ts, except No.8 and No.10.
(8) Remove the dowel s.
(9) I nstal l No.8 and No.10 head bol ts.
Fig. 34 Engine Cylinder Head Assembly
Fig. 35 Fabricate Alignment Dowels
Fig. 36 Alignment Dowel Locations
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.
(10) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
37):
(a) Ti ghten al l bol ts i n sequence (1 through 10)
(b) Ti ghten al l bol ts i n sequence (1 through 10)
(c) Check al l bol ts to veri fy they are set to 61
(d) Ti ghten bol ts (i n sequence):
Bol ts 1 through 6 to 149 Nm (110 ft. l bs.)
torque.
Bol t 7 to 136 Nm (100 ft. l bs.) torque.
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(11) Connect the cool ant temperature sendi ng uni t
connector.
(12) I nstal l the spark pl ugs and ti ghten to 37 Nm
(27 ft. l bs.) torque. Connect the i gni ti on wi res.
(13) I nstal l the i ntake and exhaust mani fol ds
(refer to Group 11, Exhaust System and I ntake Man-
i fol d for the proper procedures).
(14) I nstal l the fuel suppl y l i ne. Push unti l a
cl i ck i s heard. Rei nstal l l atch cl i p.
(15) I f equi pped, attach the power steeri ng pump
and bracket.
(16) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed.
(18) Attach the ai r condi ti oni ng compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
(19) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
CAUTION: The serpentine drive belt must be
routed correctly. Incorrect routing can cause the
water pump to turn in the opposite direction caus-
ing the engine to overheat.
(20) I nstal l the serpenti ne dri ve bel t and correctl y
tensi on the bel t (refer to Group 7, Cool i ng System for
(21) I nstal l the ai r cl eaner and ducti ng.
(22) Connect the hoses to the thermostat housi ng
and fi l l the cool i ng system to the speci fi ed l evel (refer
to Group 7, Cool i ng Systems for the proper proce-
dure).
(23) I nstal l the cool ant temperature sendi ng uni t
connector.
(25) Connect the upper radi ator hose and heater
hose at the thermostat housi ng.
(26) Fi l l the cool i ng system. Check for l eaks.
ENGINE IS 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.
(27) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
VALVES AND VALVE SPRINGS
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
REMOVAL
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock (Refer to procedure earl i er i n thi s secti on)
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
(4) Use an Arkansas smooth stone or a jewel ers
fi l e to remove any burrs on the top of the val ve stem,
especi al l y around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
INSTALLATION
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
Fig. 37 Engine cylinder head Bolt Tightening
Sequence
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head.
HYDRAULIC TAPPETS
REMOVAL
Retai n al l the components i n the same order as
removed.
(1) Remove the engi ne cyl i nder head cover (refer to
procedure earl i er i n thi s secti on)
(2) Remove the bri dge and pi vot assembl i es and
rocker arms by removi ng the capscrews at each
bri dge. Al ternatel y l oosen each capscrew, one turn at
a ti me, to avoi d damagi ng the bri dges.
(3) Remove the push rods.
(4) Remove the tappets through the push rod open-
i ngs i n the cyl i nder head wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 38).
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(4) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(5) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
(6) Pour the remai ni ng Mopar Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar Engi ne Oi l Suppl ement, or
equi val ent must remai n wi th the engi ne oi l for at
l east 1 600 km (1,000 mi l es). The oi l suppl ement
need not be drai ned unti l the next schedul ed oi l
change.
VIBRATION DAMPER
REMOVAL
(2) Remove the serpenti ne dri ve bel t and fan
shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 39).
INSTALLATION
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n posi ti on, al i gn the keyway on the
Fig. 38 Hydraulic Valve Tappet Removal/Installation
Tool
Fig. 39 Vibration Damper Removal Tool 7697
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
(4) I nstal l the serpenti ne dri ve bel t and ti ghten to
the speci fi ed tensi on (refer to Group 7, Cool i ng Sys-
tems for the proper speci fi cati ons and procedures).
TIMING CASE COVER OIL SEAL
REMOVAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
(2) Remove the serpenti ne dri ve bel t.
(3) Remove the vi brati on damper.
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 40). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
TIMING CASE COVER
REMOVAL
(2) Remove accessory dri ve bel t (Refer to Group
07, Cool i ng System for proper procedure)
(3) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(4) Remove the fan and hub assembl y and remove
the fan shroud.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the vi brati on damper (Fi g. 41).
(7) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(8) Remove the ti mi ng case cover and gasket from
the engi ne.
(9) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 41).
INSTALLATION
(1) Cl ean the ti mi ng case cover, oi l pan and cyl i n-
der bl ock gasket surfaces.
(2) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
Fig. 40 Timing Case Cover Oil Seal Installation
Fig. 41 Timing Case Cover Components
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(3) Posi ti on the gasket on the cyl i nder bl ock.
(4) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(5) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 42).
(6) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(7) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover bol ts to 9.5 Nm (84 i n.
l bs.) torque.
(8) Remove the cover al i gnment tool .
(9) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
(10) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper, washer and
bol t. Lubri cate and ti ghten the bol t to 108 Nm (80 ft.
l bs.) torque.
(11) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(12) I nstal l the engi ne fan and hub assembl y and
shroud.
(13) I nstal l the serpenti ne dri ve bel t and ti ghten
to obtai n the speci fi ed tensi on.
TIMING CHAIN AND SPROCKETS
The ti mi ng chai n tensi oner reduces noi se and pro-
l ongs ti mi ng chai n l i fe. I n addi ti on, i t compensates
for sl ack i n a worn or stretched chai n and mai ntai ns
the correct val ve ti mi ng.
REMOVAL
(2) Remove the fan and shroud.
(4) Remove the crankshaft vi brati on damper.
(5) Remove the ti mi ng case cover.
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 43).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y (Fi g.
44).
(9) To repl ace the ti mi ng chai n tensi oner, the oi l
pan must be removed.
INSTALLATION
(1) Turn the tensi oner l ever to the unl ocked (down)
posi ti on (Fi g. 45).
Fig. 42 Timing Case Cover Alignment and Seal
Installation Tool 6139
Fig. 43 CrankshaftCamshaft Alignment
Fig. 44 Camshaft and Crankshaft Sprockets and
Chain
(2) Pul l the tensi oner bl ock toward the tensi oner
l ever to compress the spri ng. Hol d the bl ock and turn
the tensi oner l ever to the l ock posi ti on (Fi g. 45).
Wi th the key i n the crankshaft keyway, i nstal l the
crankshaft, camshaft sprockets and ti mi ng chai n.
Ensure the ti mi ng marks on the sprockets are prop-
erl y al i gned (Fi g. 43).
(4) I nstal l the camshaft sprocket retai ni ng bol t
and washer. Ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(5) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 46). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 20 pi ns.
(6) Turn the chai n tensi oner l ever to the unl ocked
(down) posi ti on (Fi g. 45).
(7) I nstal l the oi l sl i nger.
(8) Repl ace the oi l seal i n the ti mi ng case cover.
(9) I nstal l the ti mi ng case cover and gasket.
(10) Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper, washer and
bol t. Lubri cate and ti ghten the bol t to 108 Nm (80 ft.
l bs.) torque.
(11) I nstal l the fan and shroud.
CAMSHAFT
REMOVAL
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
cl ean contai ner for reuse.
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C.
(4) Scri be a mark on the di stri butor housi ng i n
l i ne wi th the l i p of the rotor.
(5) Scri be a mark on the di stri butor housi ng near
the cl amp and conti nue the scri be mark on the cyl i n-
der bl ock i n l i ne wi th the di stri butor mark.
(6) For ease of i nstal l ati on, note the posi ti on of the
rotor and di stri butor housi ng i n rel ati on to adjacent
engi ne components.
(7) Remove the di stri butor and i gni ti on wi res.
(9) Remove the rocker arms, bri dges and pi vots.
(11) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder head.
(14) Remove the ti mi ng chai n and sprockets.
(15) Remove the camshaft (Fi g. 47).
INSTALLATION
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the ti mi ng case cover, exami ne the oi l pres-
Fig. 45 Loading Timing Chain Tensioner
Fig. 46 Verify SprocketChain Installation
sure rel i ef hol es i n the rear cam journal . The oi l
pressure rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 47).
(8) Turn the tensi oner l ever to the unl ocked (down)
posi ti on (Fi g. 48).
NOTE: Pull the tensioner block toward the ten-
sioner lever to compress the spring. Hold the block
and turn the tensioner lever to the lock position
(Fig. 48).
(9) I nstal l the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned.
(10) I nstal l the camshaft sprocket retai ni ng bol t
and washer. Ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(11) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 49). Refer to Ti mi ng Case Cover
I nstal l ati on.
(12) I nstal l the vi brati on damper.
(13) I nstal l the hydraul i c val ve tappets.
(14) I nstal l the push rods.
(15) I nstal l the rocker arms, bri dges and pi vots.
(17) Posi ti on the oi l pump gear. Refer to Di stri bu-
tor i n the Component Removal /I nstal l ati on secti on of
Group 8D, I gni ti on Systems.
(18) I nstal l the di stri butor and i gni ti on wi res.
Refer to Di stri butor i n the Component Removal /I n-
stal l ati on secti on of Group 8D, I gni ti on Systems.
(19) I nstal l the radi ator or radi ator and condenser,
i f equi pped wi th A/C.
(20) Fi l l the cool i ng system.
CAMSHAFT PIN REPLACEMENT
REMOVAL
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(2) Drai n the radi ator. DO NOT waste reusabl e
cool ant. Drai n the cool ant i nto a cl ean contai ner.
(4) Di sconnect the radi ator overfl ow tube, radi ator
hoses, automati c transmi ssi on fl ui d cool er pi pes (i f
equi pped).
(5) Remove the radi ator.
(6) I f equi pped wi th ai r condi ti oni ng:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
Fig. 47 Camshaft Fig. 48 Loading Timing Chain Tensioner
Fig. 49 Timing Case Cover
(a) Remove the A/C compressor serpenti ne dri ve
bel t i dl er pul l ey.
(b) Di sconnect and remove the generator.
(c) Remove the A/C condenser attachi ng bol ts
and move the condenser and recei ver/dri er assem-
bl y up and out of the way.
(9) Remove the ti mi ng case cover. Cl ean the gasket
materi al from the cover.
(10) Rotate crankshaft unti l the crankshaft
sprocket ti mi ng mark i s cl osest to and on the center
l i ne wi th the camshaft sprocket ti mi ng mark (Fi g.
50).
(11) Remove camshaft sprocket retai ni ng bol t.
(12) Remove the crankshaft oi l sl i nger.
(13) Remove the sprockets and chai n as an assem-
bl y (Fi g. 51).
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(14) I nspect the damaged camshaft pi n.
(15) I f the pi n i s a spri ng-type pi n, remove the bro-
ken pi n by i nserti ng a sel f-tappi ng screw i nto the pi n
and careful l y pul l i ng the pi n from the camshaft.
(16) I f the pi n i s a dowel -type pi n, center-punch i t.
Ensure the exact center i s l ocated when center-
punchi ng the pi n.
CAUTION: Cover the opened oil pan area to pre-
vent metal chips from entering the pan.
(17) Dri l l i nto the pi n center wi th a 4 mm (5/32
i nch) dri l l bi t.
(18) I nsert a sel f-tappi ng screw i nto the dri l l ed pi n
and careful l y pul l the pi n from the camshaft.
INSTALLATION
(1) Cl ean the camshaft pi n hol e.
(2) Compress the center of the repl acement spri ng
pi n wi th vi se gri ps.
(3) Careful l y dri ve the pi n i nto the camshaft pi n
hol e unti l i t i s seated.
(4) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
al i gned (Fi g. 50).
(6) I nstal l the crankshaft oi l sl i nger.
(7) Ti ghten the camshaft sprocket bol t to 108 Nm
Fig. 50 Timing Chain Alignment
Fig. 51 Camshaft and Crankshaft Sprocket and Chain
Fig. 52 Verify CrankshaftCamshaft Installation
(8) Check the val ve ti mi ng.
(9) Coat both si des of the repl acement ti mi ng case
cover gasket wi th gasket seal er. Appl y a 3 mm (1/8
i nch) bead of Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent to the joi nt formed at the ti mi ng
case cover and cyl i nder bl ock.
(11) Pl ace Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng of
bol ts. I nstal l the oi l pan-to-ti mi ng case cover bol ts.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 14 Nm
(120 i n. l bs.) torque. Ti ghten the oi l pan-to-cover 5/16
i nch bol ts to 18 Nm (156 i n. l bs.) torque.
(14) Remove the cover al i gnment tool and i nstal l a
repl acement oi l seal i nto the cover.
(15) I nstal l the vi brati on damper on the crankshaft.
(16) Lubri cate and ti ghten the damper bol t to 108
(a) I nstal l the A/C compressor serpenti ne dri ve
(b) I nstal l the generator.
(c) I nstal l the A/C condenser and recei ver/dri er
assembl y.
(18) I nstal l the serpenti ne dri ve bel t on the pul l eys
and ti ghten (refer to Group 7, Cool i ng System for the
speci fi cati ons and procedures).
(19) I nstal l the radi ator. Connect the radi ator
hoses and automati c transmi ssi on fl ui d cool er pi pes,
i f equi pped. Fi l l the cool i ng system.
CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available.
Camshaft end pl ay i s mai ntai ned by the l oad pl aced
on the camshaft by the oi l pump and di stri butor dri ve
gear. The hel i cal cut of the gear hol ds the camshaft
sprocket thrust face agai nst the cyl i nder bl ock face.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(4) Remove the oi l pan and oi l pump.
(5) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 54).
(6) Remove the l ower i nsert from the beari ng cap.
(7) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
Fig. 54 Removing Main Bearing Caps and Lower Inserts
ri cate the tool (Fi g. 55). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 55). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(8) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(5) Cl ean the rear mai n beari ng cap (No.5) mati ng
surfaces.
(6) Appl y Locti te 518, or equi val ent on the rear
beari ng cap (Fi g. 56). The bead shoul d be 3 mm
(0.125 i n) thi ck. DO NOT appl y Locti te 518, or equi v-
al ent to the l i p of the seal .
(7) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(8) Ti ghten the bol ts of caps 1, 3, 4 and 5 to 54
Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to 95
Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these bol ts to
(9) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.2 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
(10) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(11) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 57). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(12) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
Fig. 55 Removing Upper Inserts
Fig. 56 Location of Loctite 518 (or equivalent)
(13) I nstal l the oi l pan.
(16) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(17) Fi l l the oi l pan wi th engi ne oi l to the safe
mark on the di psti ck l evel .
OIL PAN
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the engi ne
exhaust mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the engi ne starter motor.
(7) Remove the fl ywheel /torque converter housi ng
access cover.
(8) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(9) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(10) Remove the engi ne mount through bol ts.
(11) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(12) Remove the oi l pan bol ts. Careful l y remove
the oi l pan and gasket.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1/4 x 1 1/2
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 58).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 59).
(4) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(5) Posi ti on the oi l pan over the dowel s and onto
the gasket.
(6) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 60). Ti ghten these bol ts to 15
(7) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
(8) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(9) I nstal l the through bol ts and ti ghten the nuts.
(10) Lower the jack stand and remove the pi ece of
wood.
(11) I nstal l the fl ywheel and torque converter
housi ng access cover.
(12) I nstal l the engi ne starter motor.
Fig. 57 Crankshaft End Play Measurement
Fig. 58 Fabrication of Alignment Dowels
Fig. 59 Position of Dowels in Cylinder Block
(13) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(14) I nstal l the oi l pan drai n pl ug (Fi g. 60).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(17) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
OIL PUMP
The posi ti ve-di spl acement gear-type oi l pump i s
dri ven by the di stri butor shaft, whi ch i s dri ven by a
gear on the camshaft. Oi l i s si phoned i nto the pump
through an i nl et tube and strai ner assembl y that i s
pressed i nto the pump body.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(1) Drai n the engi ne oi l .
(2) Remove the oi l pan.
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
61).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(2) I nstal l the oi l pan and gasket.
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
PISTONS AND CONNECTING RODS
REMOVAL
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(8) Remove the oi l pan and gasket.
(9) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 62).
(10) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
Fig. 60 Position of 5/16 inch Oil Pan Bolts
Fig. 61 Oil Pump Assembly
CAUTION: Ensure that the connecting rod bolts
DO NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 63).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts do not
scratch the crankshaft journals or cylinder walls.
Short pieces of rubber hose slipped over the con-
necting rod bolts will provide protection during
installation.
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 64).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 64).
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
Fig. 62 Stamped Connecting Rods and Caps
Fig. 63 Removal of Connecting Rod and Piston
Assembly
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(11) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(13) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(14) Fi l l the crankcase wi th engi ne oi l .
REAR MAIN OIL SEALS
REMOVAL
(1) Remove the fl ywheel or converter dri ve pl ate.
Di scard the ol d bol ts.
(2) Pry out the seal from around the crankshaft
fl ange (Fi g. 65).
INSTALLATION
(1) Coat the outer l i p of the repl acement rear mai n
beari ng seal wi th engi ne oi l .
(2) Careful l y posi ti on the seal i nto pl ace. Use rear
mai n Seal I nstal l er Tool 6271A to i nstal l the seal
fl ush wi th the cyl i nder bl ock.
CAUTION: The felt lip must be located inside the
flywheel mounting surface. If the lip is not posi-
tioned correctly the flywheel could tear the seal.
(3) I nstal l the fl ywheel or converter dri ve pl ate.
New bol ts MUST be used when i nstal l i ng the fl y-
wheel or converter pl ate. Ti ghten the new bol ts to 68
Nm (50 ft. l bs.) torque. Turn the bol ts an addi ti onal
60.
VALVE SERVICE
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 66). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
Fig. 65 Replacement of Rear Crankshaft Oil Seal
Fig. 66 Valve Facing Margin
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 67).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems, 0.076mm (.003i n.)
oversi ze stems do not requi re oversi ze seal s.
NOTE: 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
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD:
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 68).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD:
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 69).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
Fig. 67 Measurement of Valve Seat Runout
Fig. 68 Measurement of Valve Guide Bore Diameter
VALVE SPRING TENSION TEST
Use a Uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 70).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
CYLINDER BLOCK
Remove the Engi ne Assembl y from the vehi cl e.
DISASSEMBLY
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
(2) Remove the water pump from the cyl i nder
bl ock.
(3) Remove the di stri butor from the cyl i nder bl ock.
(5) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(6) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(7) Remove the ti mi ng chai n bumper.
(8) Remove the oi l sl i nger from crankshaft.
remove the sprockets and chai n as an assembl y.
(10) Remove the camshaft.
(12) Remove the ti mi ng chai n tensi oner.
(13) Remove the front and rear oi l gal l ey pl ugs.
(14) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
through the top of the cyl i nder bores.
(15) Remove the crankshaft.
ASSEMBLY
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
(3) I nstal l the front and rear oi l gal l ey pl ugs.
(4) I nstal l the ti mi ng chai n tensi oner.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger to the crankshaft.
(8) I nstal l the ti mi ng chai n bumper.
(9) I nstal l the ti mi ng case cover seal .
(10) I nstal l the ti mi ng case cover.
(11) I nstal l the oi l pan gasket and oi l pan.
(13) I nstal l the water pump. Ti ghten the mounti ng
(14) Remove the di stri butor from the cyl i nder
bl ock.
(15) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 Nm (13 ft. l bs.) torque.
(16) I nstal l the engi ne i nto the vehi cl e.
(17) Fi l l the engi ne wi th cl ean l ubri cati on oi l .
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
Fig. 69 Measurement of Lateral Movement Of Valve
Stem
Fig. 70 Valve Spring Tester
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
exhaust mani fol d and engi ne cyl i nder head mati ng
surfaces. Remove al l gasket materi al and carbon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e, the fi l ter
bypass hol e (Fi g. 71).
The front and rear oi l gal l ey hol es (Fi g. 72) (Fi g.
73).
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 41 Nm (30 ft. l bs.) torque.
INSPECTIONCYLINDER BORE
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 74). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
Fig. 71 Oil Filter Adaptor Hole
Fig. 72 Front Oil Galley Hole
Fig. 73 Rear Oil Galley Hole
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
HONINGCYLINDER BORE
The honi ng operati on shoul d be cl osel y coordi nated
wi th the fi tti ng of pi stons and ri ngs. Thi s wi l l ensure
speci fi ed cl earances are mai ntai ned.
SPECIFICATIONS
2. 5L ENGINE SPECIFICATIONS
Camshaft
Hydraul i c Tappet Cl earance . . . . . . . . . .Zero Lash
Beari ng Cl earance . . . . . . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Bearing J ournal Diameter
No. 1 . . . . . .51.54 to 51.56 mm (2.029 to 2.030 i n.)
No. 2 . . . . . .51.28 to 51.31 mm (2.019 to 2.020 i n.)
No. 3 . . . . . .51.03 to 51.05 mm (2.009 to 2.010 i n.)
No. 4 . . . . . .50.78 to 50.80 mm (1.999 to 2.000 i n.)
Base Ci rcl e Runout. . . . . . . . . . . . .0.03 mm - max.
(0.001 i n. - max.)
Camshaft Lobe Lift
Exhaust . . . . . . . . . . . . . . . . .6.579 mm (0.259 i n.)
I ntake . . . . . . . . . . . . . . . . . . .6.477 mm (0.255 i n.)
Valve Lift
Exhaust . . . . . . . . . . . . . . .10.528 mm (0.4145 i n.)
I ntake . . . . . . . . . . . . . . . . .10.350 mm (0.4075 i n.)
Intake Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . .15.4 BTDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . . .58 ABDC
Exhaust Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . .52.8 BBDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . .26.2 ATDC
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . .41.6
I ntake Durati on . . . . . . . . . . . . . . . . . . . . . .253.3
Exhaust Durati on . . . . . . . . . . . . . . . . . . . . . .259
Crankshaft
End Pl ay . . . . . . . . . . . . . . . . . .0.038 to 0.165 mm
(0.0015 to 0.0065 i n.)
Mai n Beari ng Journal
Di ameter . . . . . . . . . . . . . .63.489 to 63.502 mm
(2.4996 to 2.5001 i n.)
Wi dth No. 1. . . . . . . . . . . . . . . .27.58 to 27.89 mm
(1.086 to 1.098 i n.)
Wi dth No. 2 . . . . . . . . . . . . .32.28 to 32.33 mm
(1.271 to 1.273 i n.)
Wi dth No. 3-4-5 . . . . . . . . . . .30.02 to 30.18 mm
(1.182 to 1.188 i n.)
Mai n Beari ng Cl earance . . . . . . . .0.03 to 0.06 mm
(0.001 to 0.0025 i n.)
Mai n Beari ng Cl earance (Preferred) . . . .0.051 mm
(0.002 i n.)
Connecti ng Rod Journal
Di ameter . . . . . . . . . . . . . . . .53.17 to 53.23 mm
(2.0934 to 2.0955 i n.)
Wi dth . . . . . . . . . . . . . . . . . . .27.18 to 27.33 mm
(1.070 to 1.076 i n.)
Out-of-Round (Max. Al l Journal s).0.013 mm (0.0005
i n.)
Taper (Max. Al l Journal s). . . . . . . . . . .0.013 mm
(0.0005 i n.)
Cylinder Block
Deck Hei ght . . . . . . . . . . . . .236.73 mm (9.320 i n.)
Deck Cl earance. . . . . . . . . . . .0.000 mm (0.000 i n.)
Cyl i nder Bore Di ameter
Standard . . . . . . . . . . . . . . . .98.45 to 98.48 mm
(3.8759 to 3.8775 i n.)
Taper (Max.). . . . . . . . . . . .0.025 mm (0.001 i n.)
Out-of-Round (Max.) . . . . . 0.025 mm (0.001 i n.)
Fig. 74 Cylinder Bore Measurement
Tappet Bore Di ameter.23.000 to 23.025 mm (0.9055
to 0.9065 i n.)
Fl atness . . . . . . . . . . . . . . . . .0.03 mm per 25 mm
(0.001 i n. per 1 i n.)
Fl atness. . . . . . . . . . . . . . . . .0.05 mm per 152 mm
(0.002 i n. per 6 i n.)
Fl atness Max. . . . . . . . . . .0.20 mm for total l ength
(0.008 i n. for total l ength)
Mai n Beari ng Bore
Di ameter . . . . . . . . . . . .68.3514 to 68.3768 mm
(2.691 to 2.692 i n.)
Connecting Rods
Total Wei ght (Less Beari ng).657 to 665 grams (23.17
to 23.45 oz.)
Length (Center-to-Center) . . .155.52 to 155.62 mm
(6.123 to 6.127 i n.)
Pi ston Pi n Bore Di ameter.23.59 to 23.62 mm (0.9288
to 0.9298 i n.)
Bore (Less Beari ngs) . . . . . . . . .56.08 to 56.09 mm
(2.2080 to 2.2085 i n.)
(0.001 to 0.003 i n.)
Beari ng Cl earance (Preferred) . .0.044 to 0.050 mm
(0.0015 to 0.0020 i n.)
Si de Cl earance. . . . . . . . . . . . . . . .0.25 to 0.48 mm
(0.010 to 0.019 i n.)
Twi st (Max.).0.001 mm per mm (0.001 i n. per i nch)
Bend Max.). . . . . . . . . . . . . . . . .0.001 mm per mm
(0.001 i n. per i nch.)
Cylinder Compression Pressure
Rati o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1:1
Pressure Range. . . . . . . . . . . . . . .827 to 1,034 kPa
(120 to 150 psi )
Max. Vari ati on Between
Cyl i nders . . . . . . . . . . . . . . . . . .206 kPa (30 psi )
Cylinder Head
Combusti on Chamber . . . . . . . . . . . .49.9 to 52.9 cc
(3.04 to 3.23 cu. i n.)
Val ve Gui de I .D. (I ntegral ) . . . . . .7.95 to 7.97 mm
(0.313 to 0.314 i n.)
Val ve Stem-to-Gui de
Cl earance . . . . . . . . . . . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
I ntake Val ve Seat Angl e . . . . . . . . . . . . . . . . .44.5
Exhaust Val ve Seat Angl e . . . . . . . . . . . . . . . .44.5
Val ve Seat Wi dth . . . . . . . . . . . . . .1.01 to 1.52 mm
(0.040 to 0.060 i n.)
Val ve Seat Runout . . . . . . . .0.064 mm (0.0025 i n.)
(0.001 i n. per 1 i n.)
(0.002 i n. per 6 i n.)
Fl atness Max. . . . . . . . . . .0.20 mm for total l ength
(0.008 i n. for total l ength)
Rocker Arms, Push Rods & Tappets
Rocker Arm Rati o . . . . . . . . . . . . . . . . . . . . . .1.6:1
Push Rod Length . . . . . . . .241.300 to 241.808 mm
(9.500 to 9.520i n.)
Push Rod Di ameter . . . . . . . . . . . .7.92 to 8.00 mm
(0.312 to 0.315 i n.)
Hydraul i c Tappet Di ameter . .22.962 to 22.974 mm
(0.904 to 0.9045 i n.)
Tappet-to-Bore Cl earance.0.025 to 0.063 mm (0.001
to 0.0025 i n.)
Valves
Length (Ti p-to-Gauge Di mensi on Li ne)
I ntake. . . . . . . . . . . . . . 124.435 to 125.070 mm
(4.899 to 4.924 i n.)
Exhaust . . . . . . . . . . . . . . .125.120 to 125.755 mm
(4.927 to 4.952 i n.)
Val ve Stem Di ameter . . . . . . . . .7.899 to 7.925 mm
(0.311 to 0.312 i n.)
Stem-to-Gui de Cl earance . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
Val ve Head Di ameter
I ntake .48.387 to 48.641 mm (1.905 to 1.915 i n.)
Exhaust . . . . . . . . . . . . . . .37.973 to 38.227 mm
(1.495 to 1.505 i n.)
Val ve Face Angl eI ntake . . . . . . . . . . . . . . . . .45
Val ve Face Angl eExhaust . . . . . . . . . . . . . . . .45
Ti p Refi ni shi ng (Max. Al l owabl e). . . . . . . .0.25 mm
(0.010 i n.)
Valve Springs
Free Length (Approx.) . . . . . .47.65 mm (1.876 i n.)
Spri ng Tensi onVal ve
Cl osed . . . . . . . . . . . .271 to 307 N @ 41.656 mm
(61 to 69 l bf. @ 1.64 i n.)
Spri ng Tensi onVal ve
pen . . . . . . . . . . . .818.5 to 871.9 N @ 30.89 mm
(184 to 196 l bf @ 1.216 i n.)
I nsi de Di ameter . . . . . . . . . .21.0 mm to 21.51 mm
(0.827 to 0.847 i n.)
I nstal l ed Hei ght . . . . . . . . . .41.656 mm (1.640 i n.)
Pistons
Wei ght (Less Pi n). . . . . . . . . . . . .563 to 567 grams
(19.86 to 20.00 oz.)
Pi ston Pi n Bore (Centerl i ne to
Pi ston Top). . . . . . . . . . . . . . .40.61 to 40.72 mm
(1.599 to 1.603 i n.)
Pi ston-to-Bore Cl earance.0.033 to 0.053 mm (0.0013
to 0.0021 i n.)
Pi ston-to-Bore Cl earance
(Preferred) . . . . . . . . . . . . . . .0.033 to 0.038 mm
(0.0013 to 0.0015 i n.)
Ri ng Gap Cl earanceTop
Compressi on Ri ng . . . . . . . . .0.229 to 0.610 mm
(0.0090 to 0.0240 i n.)
Ri ng Gap Cl earance2nd
Compressi on Ri ng . . . . . . . . .0.483 to 0.965 mm
(0.0190 to 0.0380 i n.)
Ri ng Gap Cl earanceOi l Control
Steel Rai l s . . . . . . . . . . . . . . .0.254 to 1.500 mm
(0.010 to 0.060 i n.)
Ri ng Si de Cl earanceCompressi on
Ri ngs . . . . . . . . . . . . . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Ri ng Si de Cl earanceOi l Control
Ri ng. . . . . . . . . . . . . . . . . . . . . .0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
Pi ston Ri ng Groove Hei ght
Compressi on Ri ngs . . . . . . . . 1.530 to 1.555mm
(0.0602 to 0.0612 i n.)
Oi l Control Ri ng. . . . . . . . . . .4.035 to 4.060 mm
(0.1589 to 0.1598 i n.)
Pi ston Ri ng Groove Di ameter
Compressi on Ri ngs . . . . . . . . 87.78 to 87.90 mm
(3.456 to 3.461 i n.)
Pi ston Ri ng Groove Di ameterOi l Control
Ri ng . . . . . . . . . . . . . . . . . . . 87.50 to 87.75 mm
(3.445 to 3.455 i n.)
Pi ston Pi n Bore Di ameter . . .23.647 to 23.655 mm
(0.9310 to 0.9313 i n.)
Pi ston Pi n Di ameter . . . . . . . .23.637 to 23.640 mm
(0.9306 to 0.9307 i n.)
Pi ston-to-Pi n Cl earance . . . . .0.0076 to 0.0178 mm
(0.0003 to 0.0007 i n.)
Pi ston-to-Pi n Cl earance
(Preferred). . . . . . . . . . . . . . . .0.015 mmLoose
(0.0006 i n.Loose)
Pi ston-to-Pi n Connecti ng Rod
(Press Fi t) . . . . . . . . . . . . . . . .8.9 kN (2000 l bf.)
Oil Pump
Gear-to-Body Cl earance
(Radi al ) . . . . . . . . . . . . . . . . .0.051 to 0.102 mm
(0.002 to 0.004 i n.)
Gear-to-Body Cl earance (Radi al )
(Preferred) . . . . . . . . . . . . .0.051 mm (0.002 i n.)
Gear End Cl earance
Pl asti gage . . . . . . . . . . . . . . .0.051 to 0.152 mm
(0.002 to 0.006 i n.)
Gear End Cl earancePl asti gage
(Preferred). . . . . . . . . . . . .0.051 mm (0.002 i n.)
Gear End Cl earanceFeel er
Gauge. . . . . . . . . . . . . . . . .0.1016 to 0.2032 mm
(0.004 to 0.008 i n.)
Gear End Cl earanceFeel er Gauge
(Preferred) . . . . . . . . . . . . 0.1778 mm (0.007 i n.)
Oil Pressure
Mi n. Pressure (600 rpm). . . . . . . .89.6 kPa (13 psi )
At I dl e Speed (800 rpm) . . . . . . . . .172 to 241 kPa
(25 to 35 psi )
At 1600 rpm & Hi gher . . . . . . . . . .255 to 517 kPa
(37 to 75 psi )
Oi l Pressure Rel i ef . . . . . . . . . . . .517 kPa (75 psi )
2. 5L TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
A/C Compressor Bracket-to-Engine
Bol ts . . . . . . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
A/C Compressor
Mounti ng Bol ts . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Block Heater
Nut . . . . . . . . . . . . . . . . . . . . .1.8 Nm (16 i n. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Connecting Rod
Nuts . . . . . . . . . . . . . . . . . . . . .45 Nm (33 ft. l bs.)
Clutch Cover to Flywheel
Bol ts . . . . . . . . . . . . . . . . . . . . .31 Nm (23 ft. l bs.)
Cylinder Block
Drai n Pl ugs . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Cylinder Head
Bol ts #110 & #1214 . . . . . .149 Nm (110 ft. l bs.)
Bol t #11 . . . . . . . . . . . . . . . . .135 Nm (100 ft. l bs.)
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . .13 Nm (115 i n. l bs.)
Dipstick Tube Bracket to Cylinder Block
Bol t . . . . . . . . . . . . . . . . . . . . .19 Nm (168 i n. l bs.)
Distributor Hold-Down Clamp
Bol t . . . . . . . . . . . . . . . . . . . . .23 Nm (204 i n. l bs.)
Engine Shock Damper
Stud Nuts . . . . . . . . . . . . . . . . .23 Nm (17 ft. l bs.)
Engine MountsFront
I nsul ator Bracket Bol ts . . . . . . .81 Nm (60 ft. l bs.)
I nsul ator Bracket Nuts . . . . . . .47 Nm (35 ft. l bs.)
I nsul ator Thru-Bol t . . . . . . . . . .81 Nm (60 ft. l bs.)
Engine MountsRear
Support Cushi on/Crossmember Nuts. . . . . .22 Nm
(192 i n. l bs.)
Support Cushi on/Bracket Nuts . . . . . . . . . .46 Nm
(34 ft. l bs.)
Transmi ssi on Support Bracket Bol ts . . . . . .43 Nm
(32 ft. l bs.)
Transmi ssi on Support Bracket/
Cushi on Bol t . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Transmi ssi on Support Adaptor
Bracket Bol ts. . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Exhaust Manifold/Pipe
Nuts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Flywheel/Converter Housing
Bol ts . . . . . . . . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Flywheel to Crankshaft
Bol ts . . . . . . . . . . . . . . . . . . .143 Nm (105 ft. l bs.)
Front Cover to Block
Bol ts 1/420 . . . . . . . . . . . . . . . .7 Nm (60 i n. l bs.)
Bol ts 5/1618 . . . . . . . . . . . . .22 Nm (192 i n. l bs.)
Generator
Adjusti ng Bol t . . . . . . . . . . . . . .24 Nm (18 ft. l bs.)
Pi vot Bol t/Nut . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
DESCRIPTION TORQUE
Mounti ng Bracket-toEngi ne
Bol ts . . . . . . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Mounti ng/Head Bol ts. . . . . . . . .45 Nm (33 ft. l bs.)
Main Bearing
Bol ts . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Oil Filter
Adaptor Bol t . . . . . . . . . . . . . .102 Nm (75 ft. l bs.)
Connector . . . . . . . . . . . . . . . . .68 Nm (50 ft. l bs.)
Fi l ter . . . . . . . . . . . . . . . . . . . . .18 Nm (13 ft. l bs.)
Oil Galley
Pl ug. . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Oil Pan
1/420 Bol ts . . . . . . . . . . . . . . .9.5 Nm (84 i n. l bs.)
5/1618 Bol ts . . . . . . . . . . . . .15 Nm (132 i n. l bs.)
Drai n Pl ug. . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Oil Pressure Sending Unit
Sendi ng Uni t. . . . . . . . . . . . . .15 Nm (130 i n. l bs.)
Oil Pump
Short Attachi ng Bol ts . . . . . . .23 Nm (204 i n. l bs.)
Long Attachi ng Bol ts . . . . . . .23 Nm (204 i n. l bs.)
Cover Bol ts . . . . . . . . . . . . . . . . .8 Nm (70 i n. l bs.)
Power Steering Pump Pressure Hose
Nut . . . . . . . . . . . . . . . . . . . . . .52 Nm (38 ft. l bs.)
Rocker ArmAssembly to Cylinder Head
Capscrews . . . . . . . . . . . . . . . . .28 Nm (21 ft. l bs.)
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . .37 Nm (27 ft. l bs.)
Starter Motor
Tensioner Bracket ot Cylinder Block
Bol ts . . . . . . . . . . . . . . . . . . . .19 Nm (168 i n. l bs.)
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . .18 Nm (156 i n. l bs.)
Throttle Body
Bol ts . . . . . . . . . . . . . . . . . . . . .10 Nm (90 i n. l bs.)
Vibration Damper
Bol t . . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Water Pump to Block
Bol ts . . . . . . . . . . . . . . . . . . . . .31 Nm (23 ft. l bs.)
SPECIAL TOOLS
2. 5L ENGINE
Valve Spring Compressor Tool MD-998772A
Hydraulic Valve Tappet Removal/Installation Tool
C-4129-A
Timing Case Cover Alignment and Seal Installation
Tool 6139
Vibration Damper Removal Tool 7697
Rear Main Seal Installer Tool 6271A
4.0L ENGINE
INDEX
page page
ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . 54
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . 55
OIL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . 57
OVERSIZE AND UNDERSIZE COMPONENT
CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SERVICE PROCEDURES
FITTING CONNECTING ROD BEARINGS . . . . . . 60
FITTING CRANKSHAFT MAIN BEARINGS . . . . . 62
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . . 57
PISTON RING FITTING . . . . . . . . . . . . . . . . . . . 58
VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CAMSHAFT PIN REPLACEMENT . . . . . . . . . . . . 78
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 80
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 67
ENGINE CYLINDER HEAD COVER . . . . . . . . . . 69
ENGINE MOUNTSFRONT . . . . . . . . . . . . . . . . 66
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . . 66
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
PISTONS AND CONNECTING RODS . . . . . . . . . 82
REAR MAIN OIL SEAL . . . . . . . . . . . . . . . . . . . . 83
TIMING CASE COVER OIL SEAL . . . . . . . . . . . . 84
TIMING CASE COVER . . . . . . . . . . . . . . . . . . . . 75
TIMING CHAIN AND SPROCKETS . . . . . . . . . . . 75
VALVE STEM SEAL AND SPRING . . . . . . . . . . . 71
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 73
VIBRATION DAMPER . . . . . . . . . . . . . . . . . . . . . 74
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 87
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 85
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . 88
ENGINE CYLINDER HEAD COVER . . . . . . . . . . 88
SPECIFICATIONS
4.0L ENGINE SPECIFICATIONS . . . . . . . . . . . . . 90
4.0L TORQUE SPECIFICATIONS . . . . . . . . . . . . 92
SPECIAL TOOLS
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
ENGINE DESCRIPTION
The 4.0 Li ter (242 CI D) si x-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Bore and Stroke . .98.4 x 86.69 mm (3.88 x 3.413 i n.)
Di spl acement . . . . . . . . . . . . . . . . . . .4.0 (242 cu. i n.)
Compressi on Rati o . . . . . . . . . . . . . . . . . . . . . . .8.7:1
Torque . . . . . . . . . .305 Nm (225 ft. l bs.) @ 4000 rpm
Fi ri ng Order . . . . . . . . . . . . . . . . . . . . .153624
Lubri cati on . . . . .Pressure FeedFul l Fl ow Fi l trati on
Engi ne Oi l Capaci ty . . . . . . . . . . . . .5.7 L (6 Quarts)
Cool i ng System . . .Li qui d Cool edForced Ci rcul ati on
Cool i ng System Capaci ty . . . . . . . .11.4 L (12 Quarts)
Cyl i nder Bl ock . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Crankshaft . . . . . . . . . . . . . . . . . .Cast Nodul ar I ron
Cyl i nder Head . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . .Cast I ron
Pi stons. . . . . . . . . . . . .Al umi num Al l oy (wi th Struts)
Pi stons Combusti on Cavi ty . . . . . . . .Doubl e Quench
Connecti ng Rods . . . . . . . . . . . . .Cast Mal l eabl e I ron
Thi s engi ne i s desi gned for unl eaded fuel .
The engi ne cyl i nder head has dual quench-type
combusti on chambers that create turbul ence and fast
burni ng of the ai r/fuel mi xture. Thi s resul ts i n good
fuel economy.
The cyl i nders are numbered 1 through 6 from front
to rear. The fi ri ng order i s 1-5-3-6-2-4 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n seven mai n beari ngs. The camshaft rotates
wi thi n four beari ngs.
BUI LD DATE CODE
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.2 and No.3 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (7 = 1997).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (MX = A 4.0 Li ter (242 CI D) 8.7:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
6th & 7th Di gi tsThe day of engi ne bui l d (01 -
31).
(1) FOR EXAMPLE: Code * 701MX12 * i denti fi es
a 4.0 Li ter (242 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, 8.7:1 compressi on rati o and bui l t on
January 12, 1997.
LUBRICATION SYSTEM
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng. The pump draws oi l through the
screen and i nl et tube from the sump at the rear of
the oi l pan. The oi l i s dri ven between the dri ve and
i dl er gears and pump body, then forced through the
outl et to the bl ock. An oi l gal l ery i n the bl ock chan-
nel s the oi l to the i nl et si de of the ful l fl ow oi l fi l ter.
After passi ng through the fi l ter el ement, the oi l
passes from the center outl et of the fi l ter through an
oi l gal l ery that channel s the oi l up to the mai n gal -
l ery whi ch extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
Oil Lubrication System
OIL PUMP PRESSURE
The MI NI MUM oi l pump pressure i s 89.6 kPa (13
psi ) at 600 rpm. The NORMAL oi l pump pressure i s
517 kPa (75 psi ) at 1600 rpm or more.
OVERSIZE AND UNDERSIZE COMPONENT CODES
Some engi nes may be bui l t wi th oversi ze or under-
si ze components such as:
Oversi ze cyl i nder bores.
Oversi ze camshaft beari ng bores.
Undersi ze crankshaft mai n beari ng journal s.
Undersi ze connecti ng rod journal s.
These engi nes are i denti fi ed by a l etter code (Fi g.
3) stamped on a boss between the i gni ti on coi l and
the di stri butor (Fi g. 4).
SERVICE PROCEDURES
VALVE TIMING
Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assembl y,
and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.6 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90.
I nstal l a di al i ndi cator on the end of the No.1 cyl -
i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
Set the di al i ndi cator poi nter at zero.
Rotate the crankshaft cl ockwi se (vi ewed from the
front of the engi ne) unti l the di al i ndi cator poi nter
i ndi cates 0.305 mm (0.012 i nch) travel di stance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2 i nch)
away from the TDC mark i n ei ther di recti on, the
val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be a
broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
PISTON FITTING
BORE GAGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm
(.0001 i n.) I NCREMENTS i s requi red. I f a bore
gauge i s not avai l abl e, do not use an i nsi de mi crome-
ter.
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
Fig. 3 Oversize and Undersize Component Codes
Fig. 4 Oversize and Undersize Component Code
Location
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 6).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 5). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON SIZE CHART
CYLINDER PISTON
BORE LETTER
SIZE SIZE
98.438 to 98.448 mm (3.8755 to 3.8759 i n.) . . . . . . .A
98.448 to 98.458 mm (3.8759 to 3.8763 i n.) . . . . . . .B
98.458 to 98.468 mm (3.8763 to 3.8767 i n.) . . . . . . .C
98.468 to 98.478 mm (3.8767 to 3.8771 i n.) . . . . . . .D
98.478 to 98.488 mm (3.8771 to 3.8775 i n.) . . . . . . .E
98.488 to 98.498 mm (3.8775 to 3.8779 i n.) . . . . . . .F
PISTON RING FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 7) (Fi g. 8). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
Ring Side Clearance Measurement
Top Compressi on Ri ng. . . . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
(0.0017 to 0.0033 i n.)
Oi l Control Ri ng . . . . . . . . . . . . . . . .0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 9).
Fig. 5 Moly Coated Piston
Fig. 6 Bore Gauge
Ring Gap Measurement
Top Compressi on Ri ng . . . . . . . . . 0.229 to 0.610 mm
(0.0090 to 0.0240 i nch)
(0.0190 to 0.0380 i nch)
Oi l Control Ri ng . . . . . . . . . . . . . .0.254 to 1.500 mm
(0.010 to 0.060 i nch)
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 10).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 11).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 11) (Fi g.
13).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g.
14).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
Fig. 8 Ring Side Clearance Measurement
Fig. 7 Piston Dimensions
Fig. 9 Gap Measurement
Fig. 10 Top Compression ring identification
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
FITTING CONNECTING ROD BEARINGS
INSPECTION
BEARINGS
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 15) (Fi g. 16). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 17). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
CONNECTING RODS
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
Fig. 11 Second Compression Ring Identification
Fig. 12 Compression Ring Chamfer Location
Fig. 13 Compression Ring Installation
Fig. 14 Ring Gap Orientation
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
18). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 19). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage 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) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
Fig. 15 Connecting Rod Bearing Inspection
Fig. 16 Locking Tab Inspection
Fig. 17 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
Plastigage
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 20).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 21).
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT
INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 7 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
CONNECTING ROD BEARING FITTING CHART
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark (Fi g. 22) on the
adjacent cheek or counterwei ght towards the rear of
the crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size (Fig. 23).
NOTE: 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 beari ngs have been properl y fi tted, pro-
Fig. 22 Crankshaft Journal Size Paint I.D. Location
Fig. 20 Checking Connecting Rod Side Clearance
Typical
Fig. 21 Main Bearing Wear Patterns
Fig. 23 Bearing Insert Pairs
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 24). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cate wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
Repl ace the crankshaft or gri nd to accept the
appropri ate undersi ze beari ng i nserts i f:
Journal di ameters 1 through 6 are l ess than
63.4517 mm (2.4981 i nches)
Journal 7 di ameter i s l ess than 63.4365 mm
(2.4975 i nches).
MAIN BEARING J OURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock (refer
to Cyl i nder Bl ock - Assembl e and Crankshaft Mai n
Beari ngs - I nstal l ati on).
Plastigage
MAIN BEARING FITTING CHART
Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert
Yellow 63.5025 -63.4898 mm Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
Orange 63.4898 - 63.4771 mm Yellow - Standard Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0015 in.)
Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
Crankshaft Journal #7 Only Corresponding Bearing Insert
(2.4995 - 2.4990 in.)
Orange 63.4746 - 63.4619 mm Yellow - Standard Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4985 - 2.4980 in.)
0.0254 mm (0.001 in.)
Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4980 - 2.4975 in.)
0.0381 mm (0.0015 in.)
Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4895 - 2.4890 in.)
0.254 mm (0.010 in.)
Undersize
ENGINE MOUNTS FRONT
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
REMOVAL
(3) Support the engi ne.
(4) Remove the nut from the through bol t (Fi g. 25).
DO NOT remove the through bol t.
(5) Remove the retai ni ng bol ts and nuts from the
support cushi ons (Fi g. 25).
(6) Remove the through bol t.
(7) Remove the support cushi ons.
INSTALLATION
(1) I f the engi ne support bracket was removed,
posi ti on the bracket onto the bl ock and i nstal l the
attachi ng bol ts (Fi g. 25). Ti ghten the engi ne support
(2) I f the support cushi on bracket was removed,
posi ti on the bracket onto the l ower front si l l (Fi g.
26). I nstal l support cushi on bracket bol ts and nuts.
Ti ghten the nuts to 41 Nm (30 ft. l bs.) torque.
(3) Pl ace the support cushi on i nto posi ti on on the
support cushi on bracket (Fi g. 25). I nstal l and ti ghten
the bol ts and nuts to 41 Nm (30 ft. l bs.) torque.
(4) I nstal l the through bol t and the retai ni ng nut
(Fi g. 25). Ti ghten the through bol t nut to 65 Nm (48
ft. l bs.) torque.
(5) Remove the engi ne support.
ENGINE MOUNT REAR
A resi l i ent rubber cushi on supports the transmi s-
si on at the rear between the transmi ssi on extensi on
housi ng and the rear support crossmember or ski d
pl ate.
REMOVAL
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the crossmember (Fi g. 27) (Fi g. 28). Remove the
crossmember.
MANUAL TRANSMISSION
(Fi g. 27)
a. Remove the support cushi on nuts and remove
the cushi on.
Fig. 25 Front Mounts
Fig. 26 Support Cushion Bracket
b. Remove the transmi ssi on support bracket bol ts
and remove the bracket from the transmi ssi on.
AUTOMATIC TRANSMISSION
a. Remove the support cushi on bol ts and remove
the cushi on and the support bracket from the trans-
mi ssi on (4WD) or from the adaptor bracket (2WD).
b. On 2WD vehi cl es, remove the bol ts hol di ng the
transmi ssi on support adaptor bracket to the trans-
mi ssi on (Fi g. 28). Remove the adaptor bracket.
INSTALLATION
a. I nstal l the transmi ssi on support bracket to the
transmi ssi on. I nstal l the bol ts and ti ghten to 46 Nm
b. I nstal l the support cushi on to the support
bracket. I nstal l the nuts and ti ghten to 75 Nm (55
ft. l bs.) torque.
a. On 2WD vehi cl es, posi ti on the transmi ssi on
support adaptor bracket to the transmi ssi on. I nstal l
the bol ts and ti ghten to 75 Nm (55 ft. l bs.) torque.
b. Posi ti on the transmi ssi on support bracket and
support cushi on to the adaptor bracket (2WD) or the
transmi ssi on (4WD). I nstal l the bol ts and ti ghten to
(1) Posi ti on the crossmember onto the support
cushi on studs. I nstal l the stud nuts and ti ghten to 22
Nm (192 i n. l bs) torque.
(2) I nstal l crossmember-to-si l l bol ts and ti ghten to
(3) Remove the transmi ssi on support.
ENGINE ASSEMBLY
REMOVAL
(1) Di sconnect the battery cabl es. Remove the bat-
tery.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(4) Loosen the radi ator drai n cock and radi ator cap
to drai n the cool ant. DO NOT waste usabl e cool ant.
I f the sol uti on i s cl ean, drai n the cool ant i nto a cl ean
contai ner for reuse.
(5) Remove the l ower radi ator hose.
Fig. 27 Rear Mount(Manual Transmission)
Fig. 28 Rear Mount(Automatic Transmission)
(6) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 29).
(7) Remove upper radi ator support retai ni ng bol ts
and remove radi ator support.
(8) Remove the fan shroud (Fi g. 29) and el ectri c
cool i ng fan.
(9) Di sconnect the transmi ssi on fl ui d cool er tubi ng
(automati c transmi ssi on).
(10) Di sconnect radi ator fan swi tch wi re connector.
(11) Vehicles with Air Conditioning:
(a) Di scharge A/C system (refer to group 24,
Heati ng and Ai r Condi ti oni ng for proper proce-
dures)
(b) Di sconnect the sucti on/di scharge hose and
cap off compressor ports to prevent forei gn mate-
ri al and refri gerant oi l l oss.
(12) Remove the radi ator or radi ator and con-
denser (i f equi pped wi th A/C).
(13) Remove the fan assembl y from the i dl er pul -
l ey.
(14) Di sconnect the heater hoses at the engi ne
thermostat housi ng and water pump (Fi g. 29) (Fi g.
30).
(15) Di sconnect the throttl e cabl e.
(16) Di sconnect the speed control cabl e (i f
equi pped).
(17) Di sconnect the l i ne pressure cabl e (i f equi pped
wi th automati c transmi ssi on).
(18) Di sconnect the fuel i njector harness at the
i njectors.
(19) Di sconnect the di stri butor el ectri cal connec-
ti on and the oi l pressure swi tch connector.
STANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE DISCONNECTING FUEL
LINES, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(20) Perform the Fuel System Pressure Rel ease
procedure (refer to Group 14, Fuel System).
(21) Remove the l atch cl i p and di sconnect fuel sup-
pl y l i ne.
(22) Remove the power brake vacuum check val ve
from the booster, i f equi pped.
(a) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(b) Drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the
system.
(24) I denti fy, tag and di sconnect al l necessary wi re
connectors and vacuum hoses.
(26) Di sconnect the wi res from the starter motor
sol enoi d.
(28) Di sconnect the exhaust pi pe from the mani -
fol d.
(29) Di sconnect the engi ne speed sensor wi re con-
necti on.
(30) Remove the exhaust pi pe support.
(31) Remove the fl ywheel and converter housi ng
access cover.
(32) Vehicles with Automatic Transmission:
(a) Mark the converter and dri ve pl ate l ocati on.
(b) Remove the converter-to-dri ve pl ate bol ts.
(33) Remove the upper fl ywheel and converter
housi ng bol ts and l oosen the bottom bol ts.
(34) Remove the engi ne mount cushi on-to-engi ne
compartment bracket bol ts.
(36) Attach a l i fti ng devi ce to the engi ne.
(37) Rai se the engi ne off the front supports.
(38) Pl ace a support or fl oor jack under the con-
verter (or fl ywheel ) housi ng.
Fig. 29 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Heater hoses
Fig. 30 Heater Hoses (RH Drive Vehicle)
(39) Remove the remai ni ng converter (or fl ywheel )
housi ng bol ts.
(40) Li ft the engi ne out of the engi ne compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehi-
cle equipped with an automatic transmission, be
careful not to damage the trigger wheel on the fly-
wheel.
(1) Attach a l i fti ng devi ce to the engi ne and l ower
the engi ne i nto the engi ne compartment. For easi er
i nstal l ati on, i t may be necessary to remove the
engi ne mount cushi ons from the engi ne mount
bracket as an ai de i n al i gnment of the engi ne to the
transmi ssi on.
(2) Vehicles with Manual Transmission:
(a) I nsert the transmi ssi on shaft i nto the cl utch
spl i ne.
(b) Al i gn the fl ywheel housi ng wi th the engi ne.
(c) I nstal l and ti ghten the fl ywheel housi ng
l ower bol ts fi nger ti ght.
(a) Al i gn the transmi ssi on torque converter
housi ng wi th the engi ne.
(b) Loosel y i nstal l the converter housi ng l ower
bol ts and i nstal l the next hi gher bol t and nut on
each si de.
(c) Ti ghten al l 4 bol ts fi nger ti ght.
(4) I nstal l the engi ne mount cushi ons (i f removed).
(5) Lower the engi ne and engi ne mount cushi ons
onto the engi ne compartment brackets. I nstal l the
bol ts and fi nger ti ghten the nuts.
(6) Remove the engi ne l i fti ng devi ce.
(8) I nstal l the remai ni ng fl ywheel and converter
housi ng bol ts. Ti ghten al l bol ts to 38 Nm (28 ft. l bs.)
torque.
(a) I nstal l the converter-to-dri ve pl ate bol ts.
(b) Ensure the i nstal l ati on reference marks are
al i gned.
(10) I nstal l the fl ywheel and converter housi ng
access cover.
(11) I nstal l the exhaust pi pe support and ti ghten
the screw.
(12) Ti ghten the engi ne mount-to-bracket bol ts.
(13) Connect the engi ne speed sensor wi re connec-
ti ons and ti ghten the screws.
(14) Connect the exhaust pi pe to the mani fol d.
(15) I nstal l the starter motor and connect the
cabl e.
(16) Connect the wi res to the starter motor sol e-
noi d.
(18) Connect al l the vacuum hoses and wi re con-
nectors i denti fi ed duri ng engi ne removal .
(19) Vehicles with Power Steering:
(a) Remove the protecti ve caps
(b) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(c) Fi l l the pump reservoi r wi th fl ui d.
(20) I nstal l the power brake vacuum check val ve
to the booster, i f equi pped.
(21) Connect the fuel suppl y hose the fuel rai l .
Push unti l a cl i ck i s heard. I nstal l l atch cl i p
(22) Connect the fuel i njector harness to the i njec-
tors.
(23) Connect the di stri butor el ectri cal connector
and oi l pressure swi tch connector.
(24) Connect the l i ne pressure cabl e (i f equi pped
wi th automati c transmi ssi on).
(25) Connect the speed control cabl e, i f equi pped.
(26) Connect the throttl e cabl e.
(27) Connect the heater hoses at the engi ne ther-
mostat housi ng and water pump.
(28) I nstal l the fan assembl y to the i dl er pul l ey.
(29) Connect the sucti on/di scharge hose to the
compressor.
(30) Connect automati c transmi ssi on fl ui d cool er
l i nes, i f equi pped.
(31) I nstal l the fan shroud, el ectri c cool i ng fan and
radi ator and condenser (i f equi pped wi th A/C).
(32) Connect the el ectri c fan connector.
(33) I nstal l upper radi ator support.
(34) Connect the upper radi ator hose.
(35) Connect the l ower radi ator hose.
(36) Al i gn the hood to the scri be marks. I nstal l the
hood.
(37) I nstal l the ai r cl eaner assembl y.
(38) I nstal l the battery and connect the battery
cabl e.
(39) Add the proper amount of engi ne oi l and cool -
ant.
(40) Start the engi ne, i nspect for l eaks and correct
the fl ui d l evel s, as necessary.
(41) Charge the ai r condi ti oni ng system (refer to
Group 24, Heati ng and Ai r Condi ti oni ng for proper
procedures).
ENGINE CYLINDER HEAD COVER
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
There are two cyl i nder head bol ts that have a pi n
to l ocate the cyl i nder head cover gasket, they are
l ocated at posi ti on 8 and 9 (Fi g. 32)
REMOVAL
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover.
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover.
(4) Di sconnect the accel erator, transmi ssi on, and
speed (i f equi pped) control cabl es from the throttl e
body (Fi g. 31).
(5) Remove the three bol ts that fasten the control
cabl e bracket to the i ntake mani fol d.
(6) Remove control cabl es from cyl i nder head cover
cl i p.
(7) Posi ti on control cabl es and bracket away from
cyl i nder head cover secure wi th ti e straps.
(8) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(9) Remove the engi ne cyl i nder head cover and
gasket.
INSTALLATION
(1) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet and oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(2) I nstal l cyl i nder head cover and gasket. Ti ghten
the mounti ng bol ts to 10 Nm (85 i n. l bs.) torque.
(3) Connect the CCV hoses.
(4) I nstal l control cabl es and bracket on i ntake
mani fol d and ti ghten bol ts to 8.7 Nm (77 i n. l bs.)
torque.
(5) Connect control cabl es to throttl e body l i nkage.
(6) Snap control cabl es i nto cyl i nder head cover
cl i p.
REMOVAL
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 33). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 33). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
Fig. 31 Engine Cylinder Head Cover
Fig. 32 Cylinder Head Cover Gasket Locator Pins at
#8 & #9
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal l y posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
VALVE STEM SEAL AND SPRING
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(2) Remove capscrews, bri dge and pi vot assembl i es
and rocker arms for access to each val ve spri ng to be
removed.
(3) Remove push rods. Retain the push rods,
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 34).
(8) Remove val ve spri ng and retai ner (Fi g. 34).
(9) Remove val ve stem oi l seal s (Fi g. 34). Note the
val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(I ntake) or EXH (Exhaust). DO NOT mi x the seal s.
INSTALLATION
CAUTION: Install oil seals carefully to prevent
damage from the sharp edges of the valve spring
lock grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge capscrews al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
Fig. 34 Valve and Valve Components
REMOVAL
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean and i s bei ng
drai ned onl y to servi ce the engi ne or cool i ng system,
drai n the cool ant i nto a cl ean contai ner for reuse.
(4) Remove the engi ne cyl i nder head cover and
gasket.
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms.
(6) Remove the push rod. Retain the push rods,
order as removed.
(7) Loosen the serpenti ne dri ve bel t at the power
steeri ng pump, i f equi pped or at the i dl er pul l ey
(refer to Group 7, Cool i ng System for the proper pro-
cedure).
(8) I f equi pped wi th ai r condi ti oni ng, perform the
fol l owi ng:
(a) Remove the bol ts from the A/C compressor
mounti ng bracket and set the compressor asi de.
(b) Remove the ai r condi ti oner compressor
bracket bol ts from the engi ne cyl i nder head.
(c) Loosen the through bol t at the bottom of the
bracket.
(9) I f equi pped, di sconnect the power steeri ng
pump bracket. Set the pump and bracket asi de. DO
NOT di sconnect the hoses.
(10) Perform the Fuel System Pressure Rel ease
procedure (refer to Group 14, Fuel System).
(11) Remove the fuel l i nes and vacuum advance
hose.
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head (refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures).
(13) Di sconnect the i gni ti on wi res and remove the
spark pl ugs.
(14) Remove the i gni ti on coi l and bracket assem-
bl y.
(15) Remove the engi ne cyl i nder head bol ts. Bol t
No.14 cannot be removed unti l the head i s moved for-
ward (Fi g. 35). Pul l bol t No.14 out as far as i t wi l l go
and then suspend the bol t i n thi s posi ti on (tape
around the bol t).
(16) Remove the engi ne cyl i nder head and gasket
(Fi g. 35).
(17) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(18) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) Posi ti on the engi ne cyl i nder head gasket (wi th
the numbers faci ng up) onto the cyl i nder bl ock.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) Wi th bol t No.14 hel d i n pl ace (tape around
bol t), i nstal l the engi ne cyl i nder head. Remove the
tape from bol t No.14.
(4) Coat the threads of stud bol t No.11 wi th Loc-
ti te 592 seal ant, or equi val ent.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
36).
Fig. 35 Engine Cylinder Head Assembly
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
(a) Ti ghten al l bol ts i n sequence (1 through 14)
(b) Ti ghten al l bol ts i n sequence (1 through 14)
(c) Check al l bol ts to veri fy they are set to 61
(d) Ti ghten bol ts (i n sequence):
torque.
Bol t 11 to 13 Nm (100 ft. l bs.) torque.
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(6) I nstal l the i gni ti on coi l and bracket assembl y.
(7) Connect the temperature sendi ng uni t wi re
connector.
(8) I nstal l the spark pl ugs and ti ghten to 37 Nm
(27 ft. l bs.) torque. Connect the i gni ti on wi res.
(9) I nstal l the i ntake and engi ne exhaust mani -
fol ds (refer to Group 11, Exhaust System and I ntake
Mani fol d for the proper procedures).
(10) I nstal l the fuel l i nes and the vacuum advance
hose.
(11) I f equi pped, attach the power steeri ng pump
and bracket.
(12) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed (refer to
Rocker Arms and Push Rods i n thi s secti on).
(13) I nstal l the engi ne cyl i nder head cover and
gasket.
(14) Attach the ai r condi ti oner compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
(15) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
CAUTION: The serpentine drive belt must be
routed correctly. Incorrect routing can cause the
water pump to turn in the opposite direction caus-
ing the engine to overheat.
(16) I nstal l the serpenti ne dri ve bel t and correctl y
tensi on the bel t (refer to Group 7, Cool i ng System for
(17) I nstal l the ai r cl eaner and ducti ng.
(19) Connect the hoses to the engi ne thermostat
housi ng and fi l l the cool i ng system to the speci fi ed
l evel (refer to Group 7, Cool i ng Systems for the
proper procedure).
(20) The automati c transmi ssi on throttl e l i nkage
and cabl e must be adjusted after compl eti ng the
engi ne cyl i nder head i nstal l ati on (refer to Group 21,
Transmi ssi ons for the proper procedures).
(21) Connect the fuel l i ne.
(23) Connect the upper radi ator hose and heater
hose at the engi ne thermostat housi ng.
(24) Fi l l the cool i ng system. Check for l eaks.
ENGINE IS 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.
(25) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the engi ne thermostat opens. Add cool ant, i f
requi red.
VALVES AND VALVE SPRINGS
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
REMOVAL
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock.
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
(4) Use a smooth stone or a jewel ers fi l e to remove
any burrs on the top of the val ve stem, especi al l y
around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
Fig. 36 Engine Cylinder Head Bolt Tightening
Sequence
INSTALLATION
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head.
HYDRAULIC TAPPETS
Retai n al l the components i n the same order as
removed.
REMOVAL
(1) Remove the engi ne cyl i nder head (Refer to cyl -
i nder head r&i i n thi s secti on).
(3) Remove the tappets through the push rod open-
i ngs i n the cyl i nder bl ock wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 37).
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the cyl i nder head assy (Refer to cyl i nder
head r&i i n thi s secti on).
(4) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(5) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(6) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
(7) Pour the remai ni ng Mopar Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar Engi ne Oi l Suppl ement, or
equi val ent must remai n wi th the engi ne oi l for at
l east 1 609 km (1,000 mi l es). The oi l suppl ement
need not be drai ned unti l the next schedul ed oi l
change.
VIBRATION DAMPER
REMOVAL
(2) Remove the serpenti ne dri ve bel t and fan
shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 38).
INSTALLATION
Wi th the key i n posi ti on, al i gn the keyway on the
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
Fig. 37 Hydraulic Valve Tappet Removal
Installation Tool
Fig. 38 Vibration Damper Removal Tool 7697
tems for the proper speci fi cati ons and procedures).
TIMING CASE COVER
REMOVAL
(3) Remove the fan and hub assembl y and remove
the fan shroud.
(4) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(7) Remove the ti mi ng case cover and gasket from
the engi ne. Make sure the tensi on spri ng and thrust
pi n do not fal l out of the prel oad bol t.
(8) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 39).
INSTALLATION
Cl ean the ti mi ng case cover, oi l pan and cyl i nder
bl ock gasket surfaces.
(1) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(2) Posi ti on the gasket on the cyl i nder bl ock.
gasket and the cyl i nder bl ock. Make sure the tensi on
spri ng and thrust pi n are i n pl ace i n the camshaft
prel oad bol t.
(4) I nsert Ti mi ng Case Cover Al i gnment and Seal
and the oi l pan-to-ti mi ng case cover bol ts.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 9.5 Nm
(7) Remove the cover al i gnment tool .
(8) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
torque.
(10) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(11) I nstal l the engi ne fan and hub assembl y and
shroud.
to obtai n the speci fi ed tensi on.
TIMING CHAIN AND SPROCKETS
REMOVAL
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 41).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the tensi on spri ng and thrust pi n from
the prel oad bol t (Fi g. 42). Remove the camshaft
sprocket retai ni ng prel oad bol t and washer.
(9) Remove the crankshaft sprocket, camshaft
sprocket and ti mi ng chai n as an assembl y.
(10) I nstal l ati on of the ti mi ng chai n wi th the ti m-
i ng marks on the crankshaft and camshaft sprockets
properl y al i gned ensures correct val ve ti mi ng. A worn
or stretched ti mi ng chai n wi l l adversel y affect val ve
ti mi ng. I f the ti mi ng chai n defl ects more than 12.7
mm (1/2 i nch) repl ace i t. The correct ti mi ng chai n
has 48 pi ns. A chai n wi th more than 48 pi ns wi l l
cause excessi ve sl ack.
INSTALLATION
Assembl e the ti mi ng chai n, crankshaft sprocket
Wi th the key i n the keyway on the crankshaft, i nstal l
the assembl y on the crankshaft and camshaft.
(2) I nstal l the camshaft sprocket retai ni ng prel oad
bol t and washer (Fi g. 42). Ti ghten the prel oad bol t to
(5) Repl ace the oi l seal i n the ti mi ng case cover.
(6) Lubri cate the tensi on spri ng, thrust pi n and
pi n bore i n the prel oad bol t wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent. I nstal l the spri ng and
thrust pi n i n the prel oad bol t head (Fi g. 42).
(7) I nstal l the ti mi ng case cover and gasket.
(8) Wi th the key i nstal l ed i n the crankshaft key-
way, i nstal l the vi brati on damper, washer and bol t.
torque.
tem for the proper procedure).
(10) I nstal l the fan and hub assembl y. I nstal l the
shroud.
Fig. 41 CrankshaftCamshaft AlignmentTypical
Fig. 42 Camshaft Sprocket Preload Bolt
Fig. 43 Verify SprocketChain InstallationTypical
CAMSHAFT
REMOVAL
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
cl ean contai ner for reuse.
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C (refer to Group 7, Cool i ng Sys-
tem for the proper procedure).
(4) Remove the ai r condi ti oner condenser and
recei ver/dri er assembl y as a charged uni t, i f equi pped
(refer to Group 24, Heati ng and Ai r Condi ti oni ng).
(5) Remove the di stri butor cap and mark the posi -
ti on of the rotor.
(6) Remove the di stri butor and i gni ti on wi res.
(10) Remove the engi ne cyl i nder head and gasket.
(11) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder bl ock.
(14) Remove the ti mi ng chai n and sprockets.
(15) Remove the front bumper and/or gri l l e, as
requi red.
(16) Remove the camshaft (Fi g. 44).
INSTALLATION
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the ti mi ng case cover, exami ne the oi l pres-
sure rel i ef hol es i n the rear cam journal . The oi l
pressure rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 44).
(8) I nstal l the ti mi ng chai n, crankshaft sprocket
al i gned.
(9) I nstal l the camshaft sprocket retai ni ng prel oad
bol t. Ti ghten the bol t to 108 Nm (80 ft. l bs.) torque.
(10) Lubri cate the tensi on spri ng, the thrust pi n
and the pi n bore i n the prel oad bol t wi th Mopar
Engi ne Oi l Suppl ement, or equi val ent. I nstal l the
spri ng and thrust pi n i n the prel oad bol t head.
(11) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 45). Refer to Ti mi ng Case Cover
I nstal l ati on.
(12) I nstal l the vi brati on damper (Fi g. 45).
(13) I nstal l the hydraul i c val ve tappets.
(14) I nstal l the cyl i nder head gasket wi th the
numbers faci ng up.
(15) I nstal l the cyl i nder head and head bol ts
(Refer to cyl i nder head R&I i n thi s secti on for torque
val ues and ti ghteni ng sequence).
(16) I nstal l the push rods.
(17) I nstal l the rocker arms and pi vot and bri dge
assembl i es. Ti ghten each of the capscrews for each
bri dge al ternatel y, one turn at a ti me, to avoi d dam-
agi ng the bri dge (Refer to Rocker Arms and Push
Rods i n thi s secti on).
(19) Posi ti on the oi l pump gear. Refer to Di stri bu-
tor i n the Component Removal /I nstal l ati on secti on of
Group 8D, I gni ti on Systems.
Fig. 44 Camshaft
(20) I nstal l the di stri butor and i gni ti on wi res.
Refer to Di stri butor i n the Component Removal /I n-
stal l ati on secti on of Group 8D, I gni ti on Systems.
to the speci fi ed tensi on (refer to Group 7, Cool i ng
System for the proper procedure).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with Mopar
Engine Oil Supplement, or equivalent. The Mopar
Engine Oil Supplement, or equivalent must remain
with the engine oil for at least 1609 km (1,000
miles). The oil supplement need not be drained until
the next scheduled oil change.
(22) I nstal l the A/C condenser and recei ver/dri er
assembl y, i f equi pped (refer to Group 24, Heati ng and
Ai r Condi ti oni ng).
CAUTION: Both service valves must be opened
before the air conditioning system is operated.
(23) I nstal l the radi ator, connect the hoses and fi l l
the cool i ng system to the speci fi ed l evel (refer to
Group 7, Cool i ng System for the proper procedure).
(24) Check the i gni ti on ti mi ng and adjust as nec-
essary.
(25) I nstal l the gri l l e and bumper, i f removed.
CAMSHAFT PIN REPLACEMENT
REMOVAL
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(2) Drai n the radi ator. DO NOT waste reusabl e
cool ant. Drai n the cool ant i nto a cl ean contai ner.
(4) Di sconnect the radi ator overfl ow tube, radi ator
hoses, automati c transmi ssi on fl ui d cool er pi pes (i f
equi pped).
(5) Remove the radi ator.
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
(a) Remove the A/C compressor serpenti ne dri ve
(b) Di sconnect and remove the generator.
(c) Remove the A/C condenser attachi ng bol ts
and move the condenser and recei ver/dri er assem-
bl y up and out of the way.
(9) Remove the ti mi ng case cover. Cl ean the gasket
materi al from the cover.
(10) Remove the thrust pi n and tensi on spri ng
from the prel oad bol t head.
(11) Rotate crankshaft unti l the crankshaft
sprocket ti mi ng mark i s cl osest to and on the center
l i ne wi th the camshaft sprocket ti mi ng mark (Fi g.
46).
(12) Remove the camshaft sprocket prel oad retai n-
i ng bol t and washer.
(13) Remove the crankshaft oi l sl i nger.
(14) Remove the sprockets and chai n as an assem-
bl y.
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(15) I nspect the damaged camshaft pi n.
(16) I f the pi n i s a spri ng-type pi n, remove the bro-
ken pi n by i nserti ng a sel f-tappi ng screw i nto the pi n
and careful l y pul l i ng the pi n from the camshaft.
(17) I f the pi n i s a dowel -type pi n, center-punch i t.
Ensure the exact center i s l ocated when center-
punchi ng the pi n.
CAUTION: Cover the opened oil pan area to pre-
vent metal chips from entering the pan.
(18) Dri l l i nto the pi n center wi th a 4 mm (5/32
i nch) dri l l bi t.
(19) I nsert a sel f-tappi ng screw i nto the dri l l ed pi n
and careful l y pul l the pi n from the camshaft.
Fig. 46 Timing Chain AlignmentTypical
CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available.
Camshaft end pl ay i s mai ntai ned by the l oad
pl aced on the camshaft by the sprocket prel oad bol t
tensi on spri ng and thrust pi n.
INSTALLATION
(1) Cl ean the camshaft pi n hol e.
(2) Compress the center of the repl acement spri ng
pi n wi th vi se gri ps.
(3) Careful l y dri ve the pi n i nto the camshaft pi n
hol e unti l i t i s seated.
(4) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
(7) Ti ghten the camshaft sprocket prel oad bol t to
(8) Check the val ve ti mi ng.
(9) Lubri cate the tensi on spri ng, the thrust pi n
and the pi n bore i n the prel oad bol t wi th Mopar
Engi ne Oi l Suppl ement, or equi val ent. I nstal l the
spri ng and thrust pi n i n the prel oad bol t head.
(10) Coat both si des of the repl acement ti mi ng
case cover gasket wi th gasket seal er. Appl y a 3 mm
(1/8 i nch) bead of Mopar Si l i cone Rubber Adhesi ve
Seal ant, or equi val ent to the joi nt formed at the oi l
pan and cyl i nder bl ock.
(12) Pl ace Ti mi ng Case Cover Al i gnment and Seal
bol ts. I nstal l the oi l pan-to-ti mi ng case cover bol ts.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 14 Nm
(120 i n. l bs.) torque. Ti ghten the oi l pan-to-cover 5/16
i nch bol ts to 18 Nm (156 i n. l bs.) torque.
(15) Remove the cover al i gnment tool and i nstal l a
repl acement oi l seal i nto the cover.
(16) I nstal l the vi brati on damper on the crank-
shaft.
(17) Lubri cate and ti ghten the damper bol t to 108
(a) I nstal l the A/C compressor serpenti ne dri ve
(b) I nstal l the generator.
(c) I nstal l the A/C condenser and recei ver/dri er
assembl y.
Fig. 47 Verify CrankshaftCamshaft Installation
Typical
(19) I nstal l the serpenti ne dri ve bel t on the pul l eys
and ti ghten (refer to Group 7, Cool i ng System for the
speci fi cati ons and procedures).
(20) I nstal l the radi ator. Connect the radi ator
hoses and automati c transmi ssi on fl ui d cool er pi pes,
i f equi pped. Fi l l the cool i ng system.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(4) Remove the oi l pan and oi l pump.
(5) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 49).
(6) Remove the l ower i nsert from the beari ng cap.
(7) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 50). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 50). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(8) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(5) Ti ghten the bol ts of caps 1, 2, 4, 5, 6, and 7 to
54 Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to
95 Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these
(6) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.3 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
(7) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(8) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
Fig. 49 Removing Main Bearing Caps and Lower
Inserts
Fig. 50 Removing Upper Inserts
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 51). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(9) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
(13) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(14) Fi l l the oi l pan wi th engi ne oi l to the ful l
mark on the di psti ck l evel .
OIL PAN
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the exhaust
mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(7) Remove the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(8) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(9) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(10) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(11) Remove the engi ne mount through bol ts.
(12) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(13) Remove the oi l pan bol ts. Careful l y sl i de the
oi l pan and gasket to the rear. I f equi pped wi th an oi l
l evel sensor, take care not to damage the sensor.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1 1/2 x 1/4
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 52).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 53).
Fig. 51 Crankshaft End Play Measurement
Fig. 52 Fabrication of Alignment Dowels
Fig. 53 Position of Dowels in Cylinder Block
(4) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(5) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(6) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 54). Ti ghten these bol ts to 15
(7) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
(8) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(9) I nstal l the through bol ts and ti ghten the nuts.
(10) Lower the jack stand and remove the pi ece of
wood.
(11) I nstal l the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(12) I nstal l the engi ne starter motor.
(13) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(14) I nstal l the oi l pan drai n pl ug (Fi g. 54).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(17) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
PISTONS AND CONNECTING RODS
REMOVAL
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(9) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 55).
(10) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
CAUTION: Ensure that the connecting rod bolts
DO NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 56).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
Fig. 54 Position of 5/16 inch Oil Pan Bolts
Fig. 55 Stamped Connecting Rods and Caps
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 57).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 57).
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(11) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(13) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(14) Fi l l the crankcase wi th engi ne oi l .
REAR MAIN OIL SEAL
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
REMOVAL
(1) Remove the transmi ssi on i nspecti on cover.
(3) Remove the mai n beari ng cap brace.
(4) Remove the rear mai n beari ng cap (No.7).
(5) Push the upper seal out of the groove. Ensure
that the crankshaft and seal groove are not damaged.
(6) Remove the l ower hal f of the seal from the
beari ng cap.
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Appl y a thi n coat of engi ne oi l .
(3) Coat the l i p of the seal wi th engi ne oi l .
(4) Careful l y posi ti on the upper seal i nto the
groove i n the cyl i nder bl ock. The l i p of the seal faces
toward the front of the engi ne.
Fig. 56 Removal of Connecting Rod and Piston
Assembly
(5) Pl ace the l ower hal f of the seal i nto beari ng cap
No.7 (Fi g. 58).
(6) Coat the outer curved surface of the l ower seal
wi th soap and the l i p of the seal wi th engi ne oi l (Fi g.
58).
(7) Posi ti on the l ower seal i nto the beari ng cap
recess and seat i t fi rml y. Be sure the seal i s fl ush
wi th the cyl i nder bl ock pan rai l .
(8) Appl y Locti te 518, or equi val ent on the rear
beari ng cap (Fi g. 59). The bead shoul d be 3 mm
(0.125 i n) thi ck. DO NOT appl y Locti te 518, or equi v-
al ent to the l i p of the seal .
(9) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(10) Ti ghten al l mai n beari ng bol ts to 108 Nm (80
ft. l bs.) torque.
(11) I nstal l the mai n beari ng cap brace. Ti ghten
nuts to 47 Nm (35 ft. l bs.).
(12) I nstal l the oi l pan gasket and oi l pan. Ti ghten
1/4 20 screws to 14 Nm (120 i n. l bs.). Ti ghten 5/16
18 screws to 18 Nm (156 i n. l bs.)
(13) I nstal l the engi ne fl ywheel or converter dri ve
pl ate. Ti ghten bol ts to 142 Nm (105 ft. l bs.)
OIL PUMP
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
60).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
TIMING CASE COVER OIL SEAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
REMOVAL
Fig. 58 Rear Main Bearing Oil Seal
Fig. 59 Location of Loctite 518 (or equivalent)
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 61). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
VALVE SERVICE
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 62). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 63).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
Fig. 60 Oil Pump Assembly
Fig. 61 Timing Case Cover Oil Seal Installation
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems.
NOTE: 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
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 64).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 65).
Fig. 62 Valve Facing Margin
Fig. 63 Measurement of Valve Seat Runout
Fig. 64 Measurement of Valve Guide Bore Diameter
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 66).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
CYLINDER BLOCK
DISASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
(2) Remove the water pump from the cyl i nder
bl ock.
(4) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(5) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(6) Remove the oi l sl i nger from crankshaft.
remove the sprockets and chai n as an assembl y.
(8) Remove the camshaft.
(10) Remove the front and rear oi l gal l ey pl ugs.
(11) Remove the oi l pump.
(12) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
(13) Remove the crankshaft.
ASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
(3) I nstal l the oi l pump.
(4) I nstal l the oi l pan and gasket.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger from the crankshaft.
(8) I nstal l the ti mi ng case cover seal .
(9) I nstal l the ti mi ng case cover.
(11) I nstal l the water pump. Ti ghten the mounti ng
(12) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 Nm (156 i n. l bs.) torque.
(13) I nstal l the engi ne i nto the vehi cl e.
(14) Fi l l the engi ne wi th cl ean l ubri cati on oi l (refer
to Group 0, Lubri cati on and Mai ntenance).
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
engi ne exhaust mani fol d and engi ne cyl i nder head
mati ng surfaces. Remove al l gasket materi al and car-
bon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Fig. 65 Measurement of Lateral Movement of Valve
Stem
Fig. 66 Valve Spring Tester
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
ENGINE CYLINDER HEAD COVER
CLEANING
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
INSPECTION
I nspect the engi ne cyl i nder head cover for cracks.
Repl ace the cover, i f cracked.
The ori gi nal dark grey gasket materi al shoul d
NOT be removed. I f secti ons of the gasket materi al
are mi ssi ng or are compressed, repl ace the engi ne
cyl i nder head cover. However, secti ons wi th mi nor
damage such as smal l cracks, cuts or chi ps may be
repai red wi th a hand hel d appl i cator. The new mate-
ri al must be smoothed over to mai ntai n gasket
hei ght. Al l ow the gasket materi al to cure pri or to
engi ne cyl i nder head cover i nstal l ati on.
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
HYDRAULIC TAPPETS
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and defecti ve tap-
pets.
LEAK-DOWN TEST
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 67).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTIONCYLINDER BORE
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 68). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001 i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
HONINGCYLINDER BORE
The honi ng operati on shoul d be cl osel y coordi nated
wi th the fi tti ng of pi stons and ri ngs. Thi s wi l l ensure
speci fi ed cl earances are mai ntai ned.
Refer to Standard Servi ce Procedures i n the begi n-
ni ng of thi s Group for the proper honi ng of cyl i nder
bores.
Fig. 67 Leak-Down Tester
Fig. 68 Cylinder Bore Measurement
SPECIFICATIONS
4. 0L ENGINE SPECIFICATIONS
Camshaft
Hydraul i c Tappet Cl earance . . . . . . . . . .Zero Lash
(0.001 to 0.003 i n.)
Bearing J ournal Diameter
No. 1 . . . . . .51.54 to 51.56 mm (2.029 to 2.030 i n.)
No. 2 . . . . . .51.28 to 51.31 mm (2.019 to 2.020 i n.)
No. 3 . . . . . .51.03 to 51.05 mm (2.009 to 2.010 i n.)
No. 4 . . . . . .50.78 to 50.80 mm (1.999 to 2.000 i n.)
Base Ci rcl e Runout. . . . . . . . . . . . .0.03 mm - max.
(0.001 i n. - max.)
Val ve Li ft . . . . . . . . . . . . . . . .10.29 mm (0.405 i n.)
Intake Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . .12.4 BTDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . .60.9 ABDC
Exhaust Valve Timing
Opens . . . . . . . . . . . . . . . . . . . . . . . . . .49.8 BBDC
Cl oses . . . . . . . . . . . . . . . . . . . . . . . . . .29.2 ATDC
Val ve Overl ap . . . . . . . . . . . . . . . . . . . . . . . . .42.6
I ntake Durati on . . . . . . . . . . . . . . . . . . . . . .253.3
Exhaust Durati on . . . . . . . . . . . . . . . . . . . . . .259.
Crankshaft
End Pl ay . . . . . . . . . . . . . . . . . .0.038 to 0.165 mm
(0.0015 to 0.0065 i n.)
Di ameter No. 1-6 . . . . . . . .63.489 to 63.502 mm
(2.4996 to 2.5001 i n.)
Mai n Beari ng Journal Di ameter
No. 7 . . . . . . . . . . . . . . . . .63.449 to 63.487 mm
(2.4980 to 2.4995 i n.)
Wi dth No. 1 . . . . . . . . . . . . . .27.58 to 27.89 mm
(1.086 to 1.098 i n.)
Wi dth No. 3 . . . . . . . . . . . . . .32.28 to 32.33 mm
(1.271 to 1.273 i n.)
Wi dth No. 2-4-5-6-7 . . . . . . . .30.02 to 30.18 mm
(1.182 to 1.188 i n.)
Mai n Beari ng Cl earance . . . . . . . .0.03 to 0.06 mm
(0.001 to 0.0025 i n.)
Mai n Beari ng Cl earance
(Preferred) . . . . . . . . . . . . .0.051 mm (0.002 i n.)
Di ameter . . . . . . . . . . . . . . . .53.17 to 53.23 mm
(2.0934 to 2.0955 i n.)
Wi dth. . . .27.18 to 27.33 mm (1.070 to 1.076 i n.)
Out-of-Round (Max. Al l Journal s).0.013 mm (0.0005
i n.)
Taper (Max. Al l Journal s). . . . . . . . . . .0.013 mm
(0.0005 i n.)
Cylinder Block
Deck Hei ght . . . . . . . . . . . . . .240.03 to 240.18 mm
(9.450 to 9.456 i n.)
Deck Cl earance (Bel ow Bl ock). . . . . . . . .0.546 mm
(0.0215 i n.)
Standard . . . . . . . . . . . . . . . .98.45 to 98.48 mm
(3.8759 to 3.8775 i n.)
Cyl i nder Bore Di ameter Taper
(Max.). . . . . . . . . . . . . . . . .0.025 mm (0.001 i n.)
Out-of-Round . . . . . . . . . . .0.025 mm (0.001 i n.)
Tappet Bore Di ameter.23.000 to 23.025 mm (0.9055
to 0.9065 i n.)
(0.001 i n. per 1 i n.)
(0.002 i n. per 6 i n.)
Fl atness Max..0.20 mm max. for total l ength (0.008
i n. max. for total l ength)
Mai n Beari ng Bore
Di ameter . . . . . . . . . . . .68.3514 to 68.3768 mm
(2.691 to 2.692 i n.)
Connecting Rods
Total Wei ght (Less Beari ng).657 to 665 grams (23.17
to 23.45 oz.)
Length (Center-to-Center) . . .155.52 to 155.62 mm
(6.123 to 6.127 i n.)
Pi ston Pi n Bore Di ameter.23.59 to 23.62 mm (0.9288
to 0.9298 i n.)
Bore (Less Beari ngs) . . . . . . . . .56.08 to 56.09 mm
(2.2080 to 2.2085 i n.)
(0.001 to 0.003 i n.)
Beari ng Cl earance
(Preferred) . . . . . . . . . . . . . . .0.044 to 0.050 mm
(0.0015 to 0.0020 i n.)
Si de Cl earance. . . . . . . . . . . . . . . .0.25 to 0.48 mm
(0.010 to 0.019 i n.)
Twi st (Max.) . . . . . . . . . . . . . . .0.001 mm per mm(
0.001 i n. per i nch)
Bend (Max.) . . . . . . . . . . . . . . .0.001 mm per mm(
0.001 i n. per i nch.)
Cylinder Compression Pressure
Rati o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.7:1
Pressure Range. . . . . . . . . . . . . . .827 to 1,034 kPa
(120 to 150 psi )
Max. Vari ati on Between
Cyl i nders . . . . . . . . . . . . . . . . . .206 kPa (30 psi )
Cylinder Head
Combusti on Chamber . . . . . . . . . .52.22 to 58.22 cc
(3.37 to 3.55 cu. i n.)
Val ve Gui de I .D. (I ntegral ) . . . . .7.9 mm (0.312 i n.)
Val ve Stem-to-Gui de
Cl earance . . . . . . . . . . . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
I ntake Val ve Seat Angl e . . . . . . . . . . . . . . . . .44.5
Exhaust Val ve Seat Angl e . . . . . . . . . . . . . . . .44.5
Val ve Seat Wi dth . . . . . . . . . . . . . .1.02 to 1.52 mm
(0.040 to 0.060 i n.)
Val ve Seat Runout . . . . . . . .0.064 mm (0.0025 i n.)
(0.001 i n. per 1 i n.)
(0.002 i n. per 6 i n.)
Fl atness Max..0.20 mm - max. for total l ength (0.008
i n. max. for total l ength)
Rocker Arms, Push Rods & Tappets
Rocker Arm Rati o . . . . . . . . . . . . . . . . . . . . . .1.6:1
Push Rod Length . . . . . . . .244.856 to 245.364 mm
(9.640 to 9.660 i n.)
Push Rod Di ameter . . . . . . . . . . . .7.92 to 8.00 mm
(0.312 to 0.315 i n.)
Hydraul i c Tappet Di ameter . .22.962 to 22.974 mm
(0.904 to 0.9045 i n.)
Tappet-to-Bore Cl earance.0.025 to 0.063 mm (0.001
to 0.0025 i n.)
Valves
Length (Ti p-to-Gauge Di mensi on
Li ne) I ntake . . . . . . . . . 122.479 to 122.860 mm
(4.822 to 4.837 i n.)
Exhaust . . . . . . . . . . . . .122.860 to 123.241 mm
(4.837 to 4.852 i n.)
Val ve Stem Di ameter . . . . . . . . .7.899 to 7.925 mm
(0.311 to 0.312 i n.)
Stem-to-Gui de Cl earance . . . . . .0.025 to 0.076 mm
(0.001 to 0.003 i n.)
I ntake . . . . . . . . . . . . . . . .48.387 to 48.641 mm
(1.905 to 1.915 i n.)
Exhaust . . . . . . . . . . . . . . .37.973 to 38.227 mm
(1.495 to 1.505 i n.)
Val ve Face Angl eI ntake . . . . . . . . . . . . . . . . .45
Val ve Face Angl eExhaust . . . . . . . . . . . . . . . .45
Ti p Refi ni shi ng (Max. Al l owabl e). . . . . . . .0.25 mm
(0.010 i n.)
Valve Springs
Free Length (Approx.) . . . . . .47.65 mm (1.876 i n.)
Spri ng Tensi onVal ve Cl osed.271 to 307 N @ 41.656
mm
(61 to 69 l bf. @ 1.64 i n.)
Spri ng Tensi onVal ve Open . . .818.5 to 871.9 N @
30.89 mm
(184 to 196 l bf @ 1.216 i n.)
I nsi de Di ameter . . . . . . . . . .21.0 mm to 21.51 mm
(0.827 to 0.847 i n.)
Pistons
Wei ght (Less Pi n). . . . . . . . . . . . .563 to 567 grams
(19.86 to 20.00 oz.)
Pi ston Pi n Bore (Centerl i ne to
Pi ston Top). . . . . . . . . . . . . . .40.61 to 40.72 mm
(1.599 to 1.603 i n.)
Pi ston-to-Bore Cl earance.0.033 to 0.053 mm (0.0013
to 0.0021 i n.)
Pi ston-to-Bore Cl earance
(Preferred) . . . . . . . . . . . . . . .0.033 to 0.038 mm
(0.0013 to 0.0015 i n.)
Ri ng Gap Cl earance Top Compressi on
Ri ng . . . . . . . . . . . . . . . . . . . .0.229 to 0.610mm
(0.0090 to 0.0240 i n.)
Ri ng Gap Cl earance 2nd Compressi on
Ri ng . . . . . . . . . . . . . . . . . . . .0.483 to 0.965 mm
(0.0190 to 0.0380 i n.)
Ri ng Gap Cl earanceOi l Control
Steel Rai l s . . . . . . . . . . . . . . .0.254 to 1.500 mm
(0.010 to 0.060 i n.)
Ri ng Si de Cl earanceCompressi on
Ri ngs . . . . . . . . . . . . . . . . . . .0.042 to 0.084 mm
(0.0017 to 0.0033 i n.)
Ri ng Si de Cl earanceOi l Control
Ri ngs . . . . . . . . . . . . . . . . . . . . .0.06 to 0.21 mm
(0.0024 to 0.0083 i n.)
Compressi on Ri ngs . . . . . . . . 1.530 to 1.555 mm
(0.0602 to 0.0612 i n.)
Oi l Control Ri ng. . . . . . . . . . .4.035 to 4.060 mm
(0.1589 to 0.1598 i n.)
Compressi on Ri ngs . . . . . . . . . 88.3 to 88.55 mm
(3.476 to 3.486 i n.)
Oi l Control Ri ng . . . . . . . . . . 90.35 to 90.60 mm
(3.557 to 3.566 i n.)
Pi ston Pi n Bore Di ameter . . .23.647 to 23.655 mm
(0.9310 to 0.9313 i n.)
Pi ston Pi n Di ameter . . . . . . . .23.637 to 23.640 mm
(0.9306 to 0.9307 i n.)
Pi ston-to-Pi n
Cl earance . . . . . . . .0.0076 to 0.0178 mmLoose
(0.0003 to 0.0007 i n. Loose)
Pi ston-to-Pi n Cl earance
(Preferred) . . . . . . . . . . . .0.013 mm (0.0005 i n.)
Pi ston-to-Pi n Connecti ng Rod
(Press Fi t) . . . . . . . . . . . . . . . .8.9 kN (2000 l bf.)
Oil Pump
Gear-to-Body Cl earance
(Radi al ) . . . . . . . . . . . . . . . . .0.051 to 0.102 mm
(0.002 to 0.004 i n.)
Gear-to-Body Cl earance (Radi al )
(Preferred) . . . . . . . . . . . . .0.051 mm (0.002 i n.)
Gear End Cl earance
Pl asti gage . . . . . . . . . . . . . . .0.051 to 0.152 mm
(0.002 to 0.006 i n.)
Gear End Cl earancePl asti gage
(Preferred) . . . . . . . . . . . . .0.051 mm (0.002 i n.)
Gear End Cl earance
Feel er Gauge . . . . . . . . . . .0.1016 to 0.2032 mm
(0.004 to 0.008 i n.)
Gear End Cl earanceFeel er
Gauge (Preferred) . . . . . .0.1778 mm (0.007 i n.)
Oil Pressure
At I dl e Speed (600 rpm) . . . . . . . .89.6 kPa (13 psi )
At 1600 rpm & Hi gher . . . . . . . . . .255 to 517 kPa
(37 to 75 psi )
Oi l Pressure Rel i ef . . . . . . . . . . . .517 kPa (75 psi )
4. 0L TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
A/C Compressor Bracket-to-Engine
Bol ts . . . . . . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
A/C Compressor
A/C Low Pressure Service Valve
Nut . . . . . . . . . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Block Heater
Nut . . . . . . . . . . . . . . . . . . . . . . .2 Nm (16 i n. l bs.)
Camshaft Sprocket
Bol t . . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Clutch Cover to Flywheel
Bol ts . . . . . . . . . . . . . . . . . . . . .54 Nm (40 ft. l bs.)
Coil Bracket to Block
Bol ts . . . . . . . . . . . . . . . . . . . .22 Nm (192 i n. l bs.)
Connecting Rod
Nuts . . . . . . . . . . . . . . . . . . . . .45 Nm (33 ft. l bs.)
Cylinder Block
Drai n Pl ugs . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Cylinder Head
Bol ts . . . . . . . . . . . . . . . . . . .135 Nm (100 ft. l bs.)
Cylinder Head Cover
Bol ts . . . . . . . . . . . . . . . . . . . . .10 Nm (85 i n. l bs.)
Distributor Clamp
Bol t . . . . . . . . . . . . . . . . . . . . .23 Nm (204 i n. l bs.)
Engine MountsFront
Support Bracket Bol ts . . . . . . . .61 Nm (45 ft. l bs.)
Support Cushi on Bol ts/Nuts . . . . . . . . . . . .41 Nm
(30 ft. l bs.)
Support Cushi on Bracket Bol ts . . . . . . . . . .54 Nm
(40 ft. l bs.)
Support Cushi on Bracket Stud Nuts . . . . . .41 Nm
(30 ft. l bs.)
Support Cushi on Thru-Bol t . . . .65 Nm (48 ft. l bs.)
DESCRIPTION TORQUE
Engine MountsRear
Crossmember-to-Si l l Bol ts
(Automati c) . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
I nsul ator Stud Assembl y
Nut . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Support Cushi on/Crossmember
Nuts . . . . . . . . . . . . . . . . . .22 Nm (192 i n. l bs.)
Support Cushi on/Bracket Nuts
(Manual ) . . . . . . . . . . . . . . . .75 Nm (55 ft. l bs.)
Transmi ssi on Support Bracket Bol t
(Manual ) . . . . . . . . . . . . . . . .46 Nm (34 ft. l bs.)
Transmi ssi on Support Bracket/Cushi on
Bol t (4WD Auto). . . . . . . . . . 75 Nm (55 ft. l bs.)
Transmi ssi on Support Adaptor Bracket
Bol ts (2WD Auto) . . . . . . . . . 75 Nm (55 ft. l bs.)
Exhaust Manifold/Pipe
Nuts . . . . . . . . . . . . . . . . . . . . .27 Nm (20 ft. l bs.)
Flywheel to Converter Housing
Bol ts . . . . . . . . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Flywheel to Crankshaft
Bol ts . . . . . . . . . . . . . . . . . . .143 Nm (105 ft. l bs.)
Front Cover-to-Block
Bol ts 1/420 . . . . . . . . . . . . . . . .7 Nm (60 i n. l bs.)
Bol ts 5/1618 . . . . . . . . . . . . .22 Nm (192 i n. l bs.)
Fuel Rail
Bol ts/Stud . . . . . . . . . . . . . . . .12 Nm (108 i n. l bs.)
Generator
Fi xed Bol t . . . . . . . . . . . . . . . . .24 Nm (18 ft. l bs.)
Thru Bol t/Nut . . . . . . . . . . . . . .38 Nm (28 ft. l bs.)
Main Bearing Cap
Bol ts . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Main Bearing Brace
Nuts . . . . . . . . . . . . . . . . . . . . .47 Nm (35 ft. l bs.)
Oil Filter
Fi l ter . . . . . . . . . . . . . . . . . . . .18 Nm (156 i n. l bs.)
Connector (to adaptor). . . . . . . .47 Nm (35 ft. l bs.)
Connector (to bl ock). . . . . . . . . .68 Nm (50 ft. l bs.)
Adaptor Bol ts . . . . . . . . . . . . .102 Nm (50 ft. l bs.)
Oil Galley
Pl ug. . . . . . . . . . . . . . . . . . . . . .41 Nm (30 ft. l bs.)
Oil Pan
1/420 Bol ts . . . . . . . . . . . . . . .9.5 Nm (84 i n. l bs.)
5/1618 Bol ts . . . . . . . . . . . . .15 Nm (132 i n. l bs.)
Drai n Pl ug. . . . . . . . . . . . . . . . .34 Nm (25 ft. l bs.)
Oil Pump
Short Attachi ng Bol ts . . . . . . .23 Nm (204 i n. l bs.)
Long Attachi ng Bol ts . . . . . . .23 Nm (204 i n. l bs.)
Cover Bol ts . . . . . . . . . . . . . . . . .8 Nm (70 i n. l bs.)
Power Steering Pump Pressure Hose
Nut . . . . . . . . . . . . . . . . . . . . . .52 Nm (38 ft. l bs.)
Rocker ArmAssembly-to-Cylinder Head
Capscrews. . . . . . . . . . . . . . . . . .28 Nm (21ft. l bs.)
Spark Plugs
Pl ugs . . . . . . . . . . . . . . . . . . . . .37 Nm (27 ft. l bs.)
DESCRIPTION TORQUE
Starter Motor
Thermostat Housing
Bol ts . . . . . . . . . . . . . . . . . . . .18 Nm (156 i n. l bs.)
Throttle Body
Bol ts . . . . . . . . . . . . . . . . . . . . .10 Nm (90 i n.l bs.)
Vibration Damper
Bol ts . . . . . . . . . . . . . . . . . . . .108 Nm (80 ft. l bs.)
Water Pump/Block
Bol ts . . . . . . . . . . . . . . . . . . . . .31 Nm (23 ft. l bs.)
SPECIAL TOOLS
4. 0L ENGINE
Valve Spring Compressor Tool MD-998772A
Timing Case Cover Alignment and Seal installation
Tool 6139
Vibration Damper Removal Tool 7697
Rear Main Seal Installer Tool 6271A
Hydraulic Valve Tappet Removal Tool C-4129-A
INTRODUCTION
CONTENTS
page page
GENERAL INFORMATION
BODY CODE PLATE . . . . . . . . . . . . . . . . . . . . . 2
FASTENER IDENTIFICATION . . . . . . . . . . . . . . . 4
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . . . . 4
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 7
TORQUE REFERENCES . . . . . . . . . . . . . . . . . . 7
VEHICLE DIMENSIONS . . . . . . . . . . . . . . . . . . . 3
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . 1
VEHICLE SAFETY CERTIFICATION LABEL . . . . 2
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
VEHICLE IDENTIFICATION NUMBER
The Vehi cl e I denti fi cati on Number (VI N) pl ate i s
l ocated on the l ower wi ndshi el d fence near the l eft
A-pi l l ar. The VI N contai ns 17 characters that provi de
data concerni ng the vehi cl e. Refer to the VI N decod-
i ng chart to determi ne the i denti fi cati on of a vehi cl e.
The Vehi cl e I denti fi cati on Number i s al so
i mpri nted on the:
Body Code Pl ate.
Vehi cl e Safety Certi fi cati on Label .
Frame rai l .
Engi ne-Last 8 of VI N (Requi res Stampi ng).
Transmi ssi on-Last 8 of VI N (Requi res Stamp-
i ng).
Ri ght front fender.
Left front fender.
Hood.
Ri ght front door.
Left front door.
Ri ght rear quarter panel .
Left rear quarter panel .
Li ftgate.
To protect the consumer from theft and possi bl e
fraud the manufacturer i s requi red to i ncl ude a
Check Di gi t at the ni nth posi ti on of the Vehi cl e I den-
ti fi cati on Number. The check di gi t i s used by the
manufacturer and government agenci es to veri fy the
authenti ci ty of the vehi cl e and offi ci al documenta-
VEHICLE IDENTIFICATION NUMBER DECODING CHART
POSITION INTERPRETATION CODE = DESCRIPTION
1 Country of Origin 1 = United States
2 Make J = Jeep
3 Vehicle Type 4 = MPV
4 Gross Vehicle Weight Rating F = 4001-5000 lbs.
5 Vehicle Line J = Cherokee 4X4 (LHD)
N = Cherokee 4X4 (RHD)
B = Cherokee 4X2 (RHD)
T = Cherokee 4X2 (LHD)
6 Series 2 = SE
6 = Sport
7 = Country
7 Body Style 7 = 2dr Sport Utility
8 = 4dr Sport Utility
8 Engine P = 2.5L Gasoline
S = 4.0L Gasoline
9 Check Digit
10 Model Year V = 1997
11 Assembly Plant L = Toledo #1
12 thru 17 Vehicle Build Sequence
XJ INTRODUCTION 1
ti on. The formul a to use the check di gi t i s not
rel eased to the general publ i c.
VEHICLE SAFETY CERTIFICATION LABEL
A vehi cl e safety certi fi cati on l abel (Fi g. 1) i s
attached to every Chrysl er Corporati on vehi cl e. The
l abel certi fi es that the vehi cl e conforms to al l appl i -
cabl e Federal Motor Vehi cl e Safety Standards. The
l abel al so l i sts:
Month and year of vehi cl e manufacture.
Gross Vehi cl e Wei ght Rati ng (GVWR). The gross
front and rear axl e wei ght rati ngs (GAWRs) are
based on a mi ni mum ri m si ze and maxi mum col d ti re
i nfl ati on pressure.
Vehi cl e I denti fi cati on Number (VI N).
Type of vehi cl e.
Type of rear wheel s.
Bar code.
Month, Day and Hour (MDH) of fi nal assembl y.
Pai nt and Tri m codes.
Country of ori gi n.
The l abel i s l ocated on the dri ver-si de door shut-
face.
BODY CODE PLATE
LOCATION AND DECODING
A metal body code pl ate i s attached to the l eft
(dri vers si de of the dash panel i n the engi ne com-
partment. There are seven l i nes of i nformati on on
the body code pl ate. Li nes 4, 5, 6, and 7 are not used
to defi ne servi ce i nformati on. I nformati on reads from
l eft to ri ght, starti ng wi th l i ne 3 i n the center of the
pl ate to l i ne 1 at the bottom of the pl ate (Fi g. 2).
The l ast code i mpri nted on a vehi cl e code pl ate wi l l
be fol l owed by the i mpri nted word END. When two
vehi cl e code pl ates are requi red, the l ast avai l abl e
spaces on the fi rst pl ate wi l l be i mpri nted wi th the
l etters CTD (for conti nued).
When a second vehi cl e code pl ate i s necessary, the
fi rst four spaces on each row wi l l not be used because
of the pl ate overl ap.
BODY CODE PLATELINE 3
DIGITS 1 THROUGH 12
Vehi cl e Order Number
DIGITS 13, 14, AND 15
Open Space
Car Li ne Shel l
XJT = Cherokee 2WD (LHD)
XJJ = Cherokee 4WD (LHD)
XJB = Cherokee 2WD (RHD)
XJU = Cherokee 4WD (RHD)
DIGIT 19
Pri ce Cl ass
L = Cherokee (Al l )
DIGITS 20 AND 21
Body Type
72 = 2Door
74 = 4Door
BODY CODE PLATELINE 2
DIGITS 1, 2, AND 3
Pai nt Procedure
DIGIT 4
Open Space
DIGITS 5 THROUGH 8
Pri mary Pai nt
Refer to Group 23, Body for col or codes.
Fig. 1 Vehicle Safety Certification LabelTypical
Fig. 2 Body Code Plate Decoding
PRIMARY PAINT SECONDARY PAINT VINYL ROOF VEHICLE ORDER NUMBER CAR LINE SHELL PAINT PRO- CEDURE ENGINE TRIM TRANSMISSION MARKET VIN
2 INTRODUCTION XJ
DIGIT 9
Open Space
DIGITS 10 THROUGH 13
Secondary Pai nt
DIGIT 14
Open Space
DIGITS 15 THROUGH 18
I nteri or Tri m Code
DIGIT 19
Open Space
Engi ne Code
EPE = 2.5 L 4 cyl . MPI Gasol i ne
ERH = 4.0L 6 cyl . MPI Gasol i ne
BODY CODE PLATE LINE 1
DIGITS 1, 2, AND 3
Transmi ssi on Codes
DDQ = AX5 5speed Manual
DGD = 30RH 3speed Automati c
DGS = AW4 4speed Automati c
DIGIT 4
Open Space
DIGIT 5
Market Code
B = I nternati onal
C = Canada
M = Mexi co
U = Uni ted States
DIGIT 6
Open Space
DIGITS 7 THROUGH 23
Vehi cl e I denti fi cati on Number (VI N)
Refer to Vehi cl e I denti fi cati on Number (VI N) para-
graph for proper breakdown of VI N code.
VEHICLE DIMENSIONS
The vehi cl e di mensi on data charts l i st the exteri or
and i nteri or di mensi ons. Al l di mensi ons are l i sted i n
centi meters and i nches.
VEHICLE EXTERIOR DIMENSIONS
MODEL NAME
WHEEL
BASE
TRACK FRONT TRACK REAR LENGTH
OVERALL
WIDTH
HEIGHT
Cherokee
2WD/4WD
257.6 101.4 147.3 58.0 147.3 58.0 424.4 167.5 172.5 67.9 162.3 63.9
VEHICLE INTERIOR DIMENSIONS
MODEL NAME
HEAD
FRONT/ REAR
LEG
FRONT / REAR
SHOULDER
FRONT / REAR
HIP
FRONT / REAR
Cherokee
2WD / 4WD
96.0 / 96.5
37.8 / 38.0
105.2 / 88.9
41.4 / 35.0
140.2 / 140.2
55.2 / 55.2
140.2 / 113.3
55.2 / 44.6
XJ INTRODUCTION 3
INTERNATIONAL VEHICLE CONTROL AND DISPLAY
SYMBOLS
INTERNATIONAL VEHICLE CONTROL AND
DISPLAY SYMBOLS
The graphi c symbol s i l l ustrated i n the fol l owi ng
chart (Fi g. 3) are used to i denti fy vari ous i nstrument
control s. The symbol s correspond to the control s and
di spl ays that are l ocated on the i nstrument panel .
FASTENER IDENTIFICATION
THREAD IDENTIFICATION
SAE and metri c bol t/nut threads are not the same.
The di fference i s descri bed i n the Thread Notati on
chart (Fi g. 4).
GRADE/CLASS IDENTIFICATION
The SAE bol t strength grades range from grade 2
to grade 8. The hi gher the grade number, the greater
the bol t strength. I denti fi cati on i s determi ned by the
l i ne marks on the top of each bol t head. The actual
bol t strength grade corresponds to the number of l i ne
marks pl us 2. The most commonl y used metri c bol t
strength cl asses are 9.8 and 12.9. The metri c
strength cl ass i denti fi cati on number i s i mpri nted on
the head of the bol t. The hi gher the cl ass number,
the greater the bol t strength. Some metri c nuts are
i mpri nted wi th a si ngl e-di gi t strength cl ass on the
nut face. Refer to the Fastener I denti fi cati on and
Fastener Strength Charts.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
HIGH BEAM FOG LIGHTS HEADLIGHTS, PARKING LIGHTS, PANEL LIGHTS TURN SIGNAL HAZARD WARNING WINDSHIELD WASHER WINDSHIELD WIPERWINDSHIELD WIPER AND WASHER WINDSCREEN DEMISTING AND DEFROSTING VENTILATING FAN REAR WINDOW DEFOGGER REAR WINDOW WIPER REAR WINDOW WASHER FUEL ENGINE COOLANT TEMPER- ATURE BATTERY CHARGING CON- DITION ENGINE OIL SEAT BELT BRAKE FAILURE PARKING BRAKE FRONT HOOD REAR HOOD (TRUNK) HORN LIGHTER
Fig. 3
Fig. 4 Thread NotationSAE and Metric
4 INTRODUCTION XJ
XJ INTRODUCTION 5
FASTENER STRENGTH
HOW TO DETERMINE BOLT STRENGTH Mark Class Mark Class Hexagon head bolt Bolt head No. Stud bolt No mark No mark Hexagon flange bolt w/washer hexagon bolt No mark Grooved Hexagon head bolt Two protruding lines Hexagon flange bolt w/washer hexagon bolt Two protruding lines Welded bolt Hexagon head bolt Three protruding lines Hexagon head bolt Four protruding lines
6 INTRODUCTION XJ
METRIC SYSTEM
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Fi gure art, speci fi cati ons and torque references i n
thi s Servi ce Manual are i denti fi ed i n metri c and SAE
format.
Duri ng any mai ntenance or repai r procedures, i t i s
i mportant to sal vage metri c fasteners (nuts, bol ts,
etc.) for reassembl y. I f the fastener i s not sal vage-
abl e, a fastener of equi val ent speci fi cati on shoul d be
used.
The metri c system i s based on quanti ti es of one,
ten, one hundred, one thousand and one mi l l i on (Fi g.
5).
The fol l owi ng chart wi l l assi st i n converti ng metri c
uni ts to equi val ent Engl i sh and SAE uni ts, or vi se
versa.
Refer to the Conversi on Chart to convert torque
val ues l i sted i n metri c Newton- meters (Nm). Al so,
use the chart to convert between mi l l i meters (mm)
and i nches (i n.)
TORQUE REFERENCES
I ndi vi dual Torque Charts appear at the end of
many Groups. Refer to the Standard Torque Speci fi -
cati ons Chart for torque references not l i sted i n the
i ndi vi dual torque charts.
CONVERSION FORMULAS AND EQUIVALENT VALUES
Multiply By To Get Multiply By To Get
in-lbs x 0.11298 = Newton-Meters (Nm) Nm x 8.851 = in-lbs
ft-lbs x 1.3558 = Newton-Meters (Nm) Nm x 0.7376 = ft-lbs
Inches Hg
(60F)
x 3.377 = Kilopascals (kPa) kPa x 0.2961 = Inches Hg
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
Fig. 5 Metric Prefixes
XJ INTRODUCTION 7
METRIC CONVERSION
in-lbs to Nm Nm to in-lbs
in-
lb
Nm in-lb Nm in-lb Nm in-lb Nm in-lb Nm Nm in-lb Nm in-lb Nm in-lb Nm in-lb Nm in-lb
2 .2260 42 4.7453 82 9.2646 122 13.7839 162 18.3032 .2 1.7702 4.2 37.1747 8.2 72.5792 12.2 107.9837 16.2 143.3882
4 .4519 44 4.9713 84 9.4906 124 14.0099 164 18.5292 .4 3.5404 4.4 38.9449 8.4 74.3494 12.4 109.7539 16.4 145.1584
6 .6779 46 5.1972 86 9.7165 126 14.2359 166 18.7552 .6 5.3107 4.6 40.7152 8.6 76.1197 12.6 111.5242 16.6 146.9287
8 .9039 48 5.4232 88 9.9425 128 14.4618 168 18.9811 .8 7.0809 4.8 42.4854 8.8 77.8899 12.8 113.2944 16.8 148.6989
10 1.1298 50 5.6492 90 10.1685 130 14.6878 170 19.2071 1 8.8511 5 44.2556 9 79.6601 13 115.0646 17 150.4691
12 1.3558 52 5.8751 92 10.3944 132 14.9138 172 19.4331 1.2 10.6213 5.2 46.0258 9.2 81.4303 13.2 116.8348 17.2 152.2393
14 1.5818 54 6.1011 94 10.6204 134 15.1397 174 19.6590 1.4 12.3916 5.4 47.7961 9.4 83.2006 13.4 118.6051 17.4 154.0096
16 1.8077 56 6.3270 96 10.8464 136 15.3657 176 19.8850 1.6 14.1618 5.6 49.5663 9.6 84.9708 13.6 120.3753 17.6 155.7798
18 2.0337 58 6.5530 98 11.0723 138 15.5917 178 20.1110 1.8 15.9320 5.8 51.3365 9.8 86.7410 13.8 122.1455 17.8 157.5500
20 2.2597 60 6.7790 100 11.2983 140 15.8176 180 20.3369 2 17.7022 6 53.1067 10 88.5112 14 123.9157 18 159.3202
22 2.4856 62 7.0049 102 11.5243 142 16.0436 182 20.5629 2.2 19.4725 6.2 54.8770 10.2 90.2815 14.2 125.6860 18.5 163.7458
24 2.7116 64 7.2309 104 11.7502 144 16.2696 184 20.7889 2.4 21.2427 6.4 56.6472 10.4 92.0517 14.4 127.4562 19 168.1714
26 2.9376 66 7.4569 106 11.9762 146 16.4955 186 21.0148 2.6 23.0129 6.6 58.4174 10.6 93.8219 14.6 129.2264 19.5 172.5970
28 3.1635 68 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 20 177.0225
30 3.3895 70 7.9088 110 12.4281 150 16.9475 190 21.4668 3 26.5534 7 61.9579 11 97.3624 15 132.7669 20.5 181.4480
32 3.6155 72 8.1348 112 12.6541 152 17.1734 192 21.6927 3.2 28.3236 7.2 63.7281 11.2 99.1326 15.2 134.5371 21 185.8736
34 3.8414 74 8.3607 114 12.8801 154 17.3994 194 21.9187 3.4 30.0938 7.4 65.4983 11.4 100.9028 15.4 136.3073 22 194.7247
36 4.0674 76 8.5867 116 13.1060 156 17.6253 196 22.1447 3.6 31.8640 7.6 67.2685 11.6 102.6730 15.6 138.0775 23 203.5759
38 4.2934 78 8.8127 118 13.3320 158 17.8513 198 22.3706 3.8 33.6342 7.8 69.0388 11.8 104.4433 15.8 139.8478 24 212.4270
40 4.5193 80 9.0386 120 13.5580 160 18.0773 200 22.5966 4 35.4045 8 70.8090 12 106.2135 16 141.6180 25 221.2781
ft-lbs to Nm Nm to ft-lbs
ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm Nm ft-lb Nm ft-lb Nm ft-lb Nm ft-lb Nm 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 60.4801
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 89.4840 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 42.0304 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 97.6189 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 .00039 .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 .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 .03307
.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 .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 .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 .03071 .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
8 INTRODUCTION XJ
SPECIFIED TORQUE FOR STANDARD BOLTS
Class Diameter
mm
Pitch
mm
Specified torque
Hexagon head bolt Hexagon flange bolt
Nm kgf-cm ft-lbf Nm kgf-cm ft-lbf
6 1 5 55 48 in.-lbf 6 60 52 in.-lbf
8 1.25 12.5 130 9 14 145 10
4T 10 1.25 26 260 19 29 290 21
12 1.25 47 480 35 53 540 39
14 1.5 74 760 55 84 850 61
16 1.5 115 1,150 83
6 1 6.5 65 56 in.-lbf 7.5 75 65 in.-lbf
8 1.25 15.5 160 12 17.5 175 13
5T 10 1.25 32 330 24 36 360 26
12 1.25 59 600 43 65 670 48
14 1.5 91 930 67 100 1,050 76
16 1.5 140 1,400 101
6 1 8 80 69 in.-lbf 9 90 78 in.-lbf
8 1.25 19 195 14 21 210 15
6T 10 1.25 39 400 29 44 440 32
12 1.25 71 730 53 80 810 59
14 1.5 110 1,100 80 125 1,250 90
16 1.5 170 1,750 127
6 1 10.5 110 8 12 120 9
8 1.25 25 260 19 28 290 21
7T 10 1.25 52 530 38 58 590 43
12 1.25 95 970 70 105 1,050 76
14 1.5 145 1,500 108 165 1,700 123
16 1.5 230 2,300 166
8 1.25 29 300 22 33 330 24
8T 10 1.25 61 620 45 68 690 50
12 1.25 110 1,100 80 120 1,250 90
8 1.25 34 340 25 37 380 27
9T 10 1.25 70 710 51 78 790 57
12 1.25 125 1,300 94 140 1,450 105
8 1.25 38 390 28 42 430 31
10T 10 1.25 78 800 58 88 890 64
12 1.25 140 1,450 105 155 1,600 116
8 1.25 42 430 31 47 480 35
11T 10 1.25 87 890 64 97 990 72
12 1.25 155 1,600 116 175 1,800 130
XJ INTRODUCTION 9

1997 XJ Service Book

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LUBRICATION AND MAINTENANCE

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