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Jeep Cherokee Service Manual 2000 PDF
Jeep Cherokee Service Manual 2000 PDF
2000
JEEPT
CHEROKEE
The information contained in this service manual has been prepared for the professional automotive tech-
nician involved in daily repair operations. Information describing the operation and use of standard and
optional equipment is included in the Owner’s Manual provided with the vehicle.
Information in this manual is divided into groups. These groups contain general information, diagnosis,
testing, adjustments, removal, installation, disassembly, and assembly procedures for the systems and compo-
nents. To assist in locating a group title page, use the Group Tab Locator on the following page. The solid bar
after the group title is aligned to a solid tab on the first page of each group. The first page of the group has
a contents section that lists major topics within the group. If you are not sure which Group contains the infor-
mation you need, look up the Component/System in the alphabetical index located in the rear of this manual.
A Service Manual Comment form is included at the rear of this manual. Use the form to provide
DaimlerChrysler Corporation with your comments and suggestions.
Tightening torques are provided as a specific value throughout this manual. This value represents the
midpoint of the acceptable engineering torque range for a given fastener application. These torque values are
intended for use in service assembly and installation procedures using the correct OEM fasteners. When
replacing fasteners, always use the same type (part number) fastener as removed.
DaimlerChrysler Corporation reserves the right to change testing procedures, specifications, diagnosis,
repair methods, or vehicle wiring at any time without prior notice or incurring obligation.
GROUP TAB LOCATOR
Introduction
2 Suspension
5 Brakes
6 Clutch
7 Cooling System
8A Battery
8B Starting System
8C Charging System
8D Ignition System
8F Audio Systems
8G Horn Systems
8L Lamps
8W Wiring Diagrams
9 Engine
11 Exhaust System
14 Fuel System
19 Steering
23 Body
page page
LUBRICANTS
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
PARTS AND LUBRICANT RECOMMENDATIONS
RECOMMENDATIONS
When service is required, DaimlerChrysler Corpo-
ration recommends that only Mopart brand parts,
lubricants and chemicals be used. Mopar provides
the best engineered products for servicing Daimler-
Chrysler Corporation vehicles.
INTERNATIONAL SYMBOLS
DaimlerChrysler Corporation uses international
symbols to identify engine compartment lubricant
and fluid inspection and fill locations (Fig. 1).
Fig. 1 International Symbols
CLASSIFICATION OF LUBRICANTS
Only lubricants bearing designations defined by ENGINE OIL
the following organization should be used to service a
DaimlerChrysler Corporation vehicle. SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
• Society of Automotive Engineers (SAE) An SAE viscosity grade is used to specify the vis-
• American Petroleum Institute (API) (Fig. 2) cosity of engine oil. SAE 30 specifies a single viscos-
• National Lubricating Grease Institute (NLGI) ity engine oil. Engine oils also have multiple
(Fig. 3) viscosities. These are specified with a dual SAE vis-
cosity grade which indicates the cold-to-hot tempera-
ture viscosity range.
• SAE 30 = single grade engine oil.
• SAE 10W-30 = multiple grade engine oil.
DaimlerChrysler Corporation only recommends
multiple grade engine oils.
0-2 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
API QUALITY CLASSIFICATION LUBRICANTS AND GREASES
This symbol (Fig. 2) on the front of an oil container Lubricating grease is rated for quality and usage
means that the oil has been certified by the Ameri- by the NLGI. All approved products have the NLGI
can Petroleum Institute (API) to meet all the lubri- symbol (Fig. 3) on the label. At the bottom NLGI
cation requirements specified by DailmlerChrysler symbol is the usage and quality identification letters.
Corporation. Wheel bearing lubricant is identified by the letter
Refer to Group 9, Engine for gasoline engine oil “G”. Chassis lubricant is identified by the latter “L”.
specification. The letter following the usage letter indicates the
quality of the lubricant. The following symbols indi-
cate the highest quality.
MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page page
52,500 Miles (84 000 km) or at 42 months 97,500 Miles (156 000 km) or at 78 months
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Flush and replace engine coolant if not done at • Lubricate steering linkage (4x4 only).
36 months.
• Lubricate steering linkage (4x4 only). 105,000 Miles (168 000 km) or at 84 months
• Change engine oil.
60,000 Miles (96 000 km) or at 48 months • Replace engine oil filter.
• Change engine oil. • Lubricate steering linkage.
• Replace engine oil filter. • Flush and replace engine coolant if it has been
• Replace engine air cleaner element. 30,000 miles (48 000 km) or 24 months since last
• Replace ignition cables. change.
• Replace spark plugs. • Lubricate steering and suspension ball joints.
• Inspect drive belt, adjust tension as necessary.
• Lubricate steering linkage. 112,500 Miles (180 000 km) or at 90 months
• Drain and refill automatic transmission fluid. • Change engine oil.
• Drain and refill transfer case fluid. • Replace engine oil filter.
• Lubricate steering and suspension ball joints. • Inspect brake linings.
• Flush and replace engine coolant if it has been
67,500 Miles (108 000 km) or at 54 months 30,000 miles (48 000 km) or 24 months since last
• Change engine oil. change.
• Replace engine oil filter. • Lubricate steering linkage (4x4 only).
• Inspect brake linings. • Drain and refill manual transmission fluid.
• Lubricate steering linkage (4x4 only).
120,000 Miles (192 000 km) or at 96 months
75,000 Miles (120 000 km) or at 60 months • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Replace engine air cleaner element.
• Lubricate steering linkage. • Replace ignition cables.
• Replace spark plugs.
• Inspect drive belt, adjust tension as necessary.
0-6 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
• Lubricate steering linkage. • Lubricate steering and suspension ball joints.
• Drain and refill automatic transmission fluid. • Drain and refill manual transmission fluid.
• Drain and refill transfer case fluid.
• Lubricate steering and suspension ball joints. 21,000 Miles (34 000 km)
Important: Inspection and service should also be • Change engine oil.
performed any time a malfunction is observed or sus- • Replace engine oil filter.
pected. • Lubricate steering linkage.
9,000 Miles (14 000 km) 33,000 Miles (53 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Lubricate steering linkage. • Lubricate steering linkage.
12,000 Miles (19 000 km) 36,000 Miles (58 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Lubricate steering linkage. • Lubricate steering linkage.
• Drain and refill automatic transmission fluid. • Drain and refill automatic transmission fluid.
• Drain and refill front and rear axles.‡ • Drain and refill front and rear axles.‡
• Inspect brake linings. • Inspect brake linings.
• Lubricate steering and suspension ball joints. • Lubricate steering and suspension ball joints.
• Drain and refill manual transmission fluid.
15,000 Miles (24 000 km)
• Change engine oil. 39,000 Miles (62 000 km)
• Replace engine oil filter. • Change engine oil.
• Inspect engine air cleaner element, replace • Replace engine oil filter.
as necessary. • Lubricate steering linkage.
• Lubricate steering linkage.
42,000 Miles (67 000 km)
18,000 Miles (29 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage. • Lubricate steering and suspension ball joints.
XJ LUBRICATION AND MAINTENANCE 0-7
SERVICE PROCEDURES (Continued)
45,000 Miles (72 000 km) 66,000 Miles (106 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Inspect engine air cleaner element, replace • Lubricate steering linkage.
as necessary. • Lubricate steering and suspension ball joints.
• Lubricate steering linkage.
69,000 Miles (110 000 km)
48,000 Miles (77 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage.
• Drain and refill automatic transmission fluid. 72,000 Miles (115 000 km)
• Drain and refill front and rear axles.‡ • Change engine oil.
• Inspect brake linings. • Replace engine oil filter.
• Lubricate steering and suspension ball joints. • Lubricate steering linkage.
• Drain and refill automatic transmission fluid.
51,000 Miles (82 000 km) • Drain and refill front and rear axles.‡
• Change engine oil. • Inspect brake linings.
• Replace engine oil filter. • Lubricate steering and suspension ball joints.
• Flush and replace engine coolant. • Drain and refill manual transmission fluid.
• Lubricate steering linkage.
75,000 Miles (120 000 km)
54,000 Miles (86 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Inspect engine air cleaner element, replace
• Lubricate steering linkage. as necessary.
• Lubricate steering and suspension ball joints. • Lubricate steering linkage.
• Drain and refill manual transmission fluid.
78,000 Miles (125 000 km)
57,000 Miles (91 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage. • Lubricate steering and suspension ball joints.
60,000 Miles (96 000 km) 81,000 Miles (130 000 km)
• Change engine oil. • Change engine oil.
• Replace engine oil filter. • Replace engine oil filter.
• Replace engine air cleaner element. • Flush and replace engine coolant if it has been
• Replace ignition cables. 30,000 miles (48 000 km) since last change.
• Replace spark plugs. • Lubricate steering linkage.
• Inspect drive belt, adjust tension as necessary.
• Lubricate steering linkage. 84,000 Miles (134 000 km)
• Drain and refill automatic transmission fluid. • Change engine oil.
• Drain and refill transfer case fluid. • Replace engine oil filter.
• Drain and refill front and rear axles.‡ • Lubricate steering linkage.
• Inspect brake linings. • Drain and refill automatic transmission fluid.
• Lubricate steering and suspension ball joints. • Drain and refill front and rear axles.‡
• Inspect brake linings.
63,000 Miles (101 000 km) • Lubricate steering and suspension ball joints.
• Change engine oil.
• Replace engine oil filter.
• Lubricate steering linkage.
0-8 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
87,000 Miles (139 000 km) • Lubricate steering linkage.
• Change engine oil. • Drain and refill automatic transmission fluid.
• Replace engine oil filter. • Drain and refill front and rear axles.‡
• Lubricate steering linkage. • Inspect brake linings.
• Lubricate steering and suspension ball joints.
90,000 Miles (144 000 km) • Drain and refill manual transmission fluid.
• Change engine oil.
• Replace engine oil filter. 111,000 Miles (178 000 km)
• Replace engine air cleaner element. • Change engine oil.
• Replace spark plugs. • Replace engine oil filter.
• Inspect drive belt, adjust tension as necessary. • Flush and replace engine coolant if it has been
• Lubricate steering linkage. 30,000 miles (48 000 km) since last change.
• Drain and refill transfer case fluid. • Lubricate steering linkage.
• Lubricate steering and suspension ball joints.
• Drain and refill manual transmission fluid. 114,000 Miles (182 000 km)
• Change engine oil.
93,000 Miles (149 000 km) • Replace engine oil filter.
• Change engine oil. • Lubricate steering linkage.
• Replace engine oil filter. • Lubricate steering and suspension ball joints.
• Lubricate steering linkage.
117,000 Miles (187 000 km)
96,000 Miles (154 000 km) • Change engine oil.
• Change engine oil. • Replace engine oil filter.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage.
• Drain and refill automatic transmission fluid. 120,000 Miles (192 000 km)
• Drain and refill front and rear axles.‡ • Change engine oil.
• Inspect brake linings. • Replace engine oil filter.
• Lubricate steering and suspension ball joints. • Replace engine air cleaner element.
• Replace ignition cables.
99,000 Miles (158 000 km) • Replace spark plugs.
• Change engine oil. • Inspect drive belt, adjust tension as necessary.
• Replace engine oil filter. • Lubricate steering linkage.
• Lubricate steering linkage. • Drain and refill automatic transmission fluid.
• Drain and refill transfer case fluid.
102,000 Miles (163 000 km) • Drain and refill front and rear axles.‡
• Change engine oil. • Inspect brake linings.
• Replace engine oil filter. • Lubricate steering and suspension ball joints.
• Lubricate steering linkage. ‡Off-highway operation, trailer towing, taxi, limou-
• Lubricate steering and suspension ball joints. sine, bus, snow plowing, or other types of commercial
service or prolonged operation with heavy loading,
105,000 Miles (168 000 km) especially in hot weather, require front and rear axle
• Change engine oil. service indicated with a ‡ in Schedule “B”. Perform
• Replace engine oil filter. these services if the vehicle is usually operated under
• Inspect engine air cleaner element, replace these conditions.
as necessary. Important: Inspection and service should also be
• Lubricate steering linkage. performed any time a malfunction is observed or sus-
pected.
108,000 Miles (173 000 km)
• Change engine oil.
• Replace engine oil filter.
XJ LUBRICATION AND MAINTENANCE 0-9
TABLE OF CONTENTS
page page
CAUTION: Do not use steering column lock to WARNING: WHEN TOWING A DISABLED VEHICLE
secure steering wheel during towing operation. AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
2WD XJ vehicles can be towed with the front TRANSMISSION IS IN THE PARK POSITION (AUTO-
wheels on the surface for extended distances at MATIC TRANSMISSION) OR A FORWARD DRIVE
speeds not exceeding 48 km/h (30 mph). If the vehicle GEAR (MANUAL TRANSMISSION).
is equipped with a factory installed trailer tow pack-
age, use a SAE approved wheel lift device.
(1) Attach J-hooks around the axle shaft tube out- TOWING-REAR END LIFTED (SLING TYPE)
board of the shock absorber. (1) Raise front of vehicle off ground and install tow
(2) Place the sling crossbar under and forward of dollies under front wheels.
the bumper. (2) Attach J-hooks around rear axle shaft tube out-
(3) Attach safety chains around the frame rails. board of shock absorber.
(4) Turn the ignition switch to the OFF position to (3) Place sling crossbar under and forward of
unlock the steering wheel. bumper.
(5) Secure steering wheel in the straight ahead (4) Attach safety chains around frame rails.
position with a clamp device designed for towing. (5) Turn ignition switch to OFF position to unlock
(6) Verify that steering components are in good steering wheel.
condition. (6) Secure steering wheel in the straight ahead
(7) Shift the transmission to NEUTRAL. position with a clamp device designed for towing.
(7) Shift transfer case to neutral.
XJ LUBRICATION AND MAINTENANCE 0 - 11
SERVICE PROCEDURES (Continued)
TOWING-REAR END LIFTED (WHEEL LIFT) FLOOR JACK
(1) Raise front of vehicle off ground and install tow When properly positioned, a floor jack can be used
dollies under front wheels. to lift a Jeep vehicle (Fig. 2) and (Fig. 3). Support the
(2) Attach wheel lift to rear wheels. vehicle in the raised position with jack stands at the
(3) Place transmission in neutral. front and rear ends of the frame rails.
(4) Raise vehicle to towing height.
(5) Place transmission in park (automatic trans-
mission) or first gear (manual transmission).
HOISTING RECOMMENDATIONS
Refer to the Owner’s Manual for emergency vehicle
lifting procedures.
0 - 12 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
• An axle tube.
• A body side sill.
• A steering linkage component.
• A drive shaft.
• The engine or transmission oil pan.
• The fuel tank.
• A front suspension arm.
HOIST
A vehicle can be lifted with:
• A single-post, frame-contact hoist.
• A twin-post, chassis hoist.
• A ramp-type, drive-on hoist.
SUSPENSION
TABLE OF CONTENTS
page page
ALIGNMENT
TABLE OF CONTENTS
page page
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. 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.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/ 2. Inspect, tighten or replace components
suspension components. as necessary.
SERVICE PROCEDURES NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
PRE-ALIGNMENT angle has priority over caster. Refer to Group 3 Dif-
Before starting wheel alignment, the following ferential & Driveline for additional information.
inspection and necessary corrections must be com-
pleted. Refer to Suspension and Steering System
Diagnosis Chart for additional information.
(1) Inspect tires for size and tread wear.
(2) Set tire air pressure.
(3) Inspect front wheel bearings for wear.
(4) Inspect front wheels for excessive radial or lat-
eral runout and balance.
(5) Inspect ball studs, linkage pivot points and
steering gear for looseness, roughness or binding.
(6) Inspect suspension components for wear and
noise.
WHEEL ALIGNMENT
Before each alignment reading, the vehicle should
be jounced (rear first, then front). Grasp each
bumper at the center and jounce the vehicle up and
down several times. Always release the bumper in
the down position. Set the front end alignment to
specifications with the vehicle at its NORMAL RIDE Fig. 2 Caster Adjustment
HEIGHT. 1 – SHIM
2 – SUSPENSION ARM
CAMBER
The wheel camber angle is preset. This angle is not
adjustable and cannot be altered. TOE POSITION (LHD)
NOTE: The wheel toe position adjustment is the
CASTER
final adjustment. The engine must remain running
Before checking the caster of the front axle for cor-
during the entire toe position adjustment.
rect angle, be sure the axle is not bent or twisted.
Road test the vehicle, make left and right turns. If (1) Start the engine and turn wheels both ways
the steering wheel returns to the center position before straightening the wheels. Secure the steering
unassisted, the caster angle is correct. If steering wheel with the front wheels in the straight-ahead
wheel does not return toward the center position position.
unassisted, an incorrect caster angle is probable. (2) Loosen the adjustment sleeve clamp bolts (Fig.
Caster can be adjusted by installing the appropri- 3).
ate size shims (Fig. 2). (3) Adjust the right wheel toe position with the
drag link. Turn the sleeve until the right wheel is at
correct TOE-IN specifications. Position the clamp
XJ SUSPENSION 2-5
SERVICE PROCEDURES (Continued)
bolts as shown (Fig. 4) and tighten to 49 N·m (36 ft.
lbs.).
(4) Adjust the left wheel toe position with the tie
rod. Turn the sleeve until the left wheel is at specifi-
cations. Position the clamp bolts as shown (Fig. 4)
and tighten to 27 N·m (20 ft. lbs.).
(5) Verify the right toe setting and turn off engine.
(6) Road test the vehicle on a flat level road to ver-
ify the steering wheel is centered. Fig. 4 Drag Link and Tie Rod Clamp (LHD)
1 – TIE ROD CLAMP
NOTE: Once the toe setting is correct, the steering 2 – DRAG LINK CLAMPS
wheel can be re-centered by adjusting only the drag
link. wheel with the front wheels in the straight-ahead
position.
(2) Loosen the adjustment sleeve clamp bolts (Fig.
TOE POSITION (RHD)
5).
NOTE: The wheel toe position adjustment is the (3) Adjust the left wheel toe position with the drag
final adjustment. The engine must remain running link. Turn the sleeve until the left wheel is at the
during the entire toe position adjustment. correct TOE-IN specifications. Position the clamp
bolts to their original position and tighten to 49 N·m
(1) Start the engine and turn wheels both ways (36 ft. lbs.).
before straightening the wheels. Secure the steering
NOTE: Make sure the toe setting does not change (5) Verify the right toe setting and turn off engine.
during clamp tightening. (6) Road test the vehicle on a flat level road to ver-
ify the steering wheel is centered.
(4) Adjust the right wheel toe position with the tie
rod. Turn the sleeve until the right wheel is at cor- NOTE: Once the toe setting is correct, the steering
rect TOE-IN specifications. Position the clamp bolts wheel can be re-centered by adjusting only the drag
to their original position and tighten to 27 N·m (20 link.
ft. lbs.).
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
FRONT SUSPENSION
TABLE OF CONTENTS
page page
(8) Lower the axle until the spring is free from the STEERING KNUCKLE
upper mount. Remove the coil spring clip and remove For service procedures on the steering knuckle and
the spring. ball joints refer to Group 3 Differentials And Driv-
(9) Pull jounce bumper out of mount. eline.
REMOVAL
(1) Remove the upper suspension arm from axle.
2 - 12 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper, caliper adapter and
rotor, refer to Group 5 Brakes for procedure.
(4) Remove stud from hub with Remover C-4150A
Fig. 7 Track Bar (LHD) (Fig. 9).
1 – NUT
2 – SUPPORT BRACKET INSTALLATION
3 – LEFT FRAME RAIL (1) Install new stud into hub flange.
4 – STUD (2) Install three washers onto stud, then install
5 – SCREW lug nut with the flat side of the nut against the
6 – COTTER PIN washers.
7 – NUT (3) Tighten lug nut until the stud is pulled into
8 – FRAME BRACKET
the hub flange. Verify that the stud is properly
9 – NUT PLATE
seated into the flange.
10 – TRACK BAR
11 – BALL STUD END
(4) Remove lug nut and washers.
12 – NUT (5) Install the brake rotor, caliper adapter, and cal-
iper, refer to Group 5 Brakes for procedure.
(6) Install wheel and tire assembly, use new lug
(5) Remove the hub bearing mounting bolts from nut on stud or studs that were replaced.
the back of the steering knuckle. Remove hub bear- (7) Remove support and lower vehicle.
ing from the steering knuckle and off the axle shaft.
INSTALLATION
(1) Install the hub bearing and brake dust shield
to the knuckle.
2 - 14 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . 22 N·m (16 ft. lbs.)
Lower Nut . . . . . . . . . . . . . . . 23 N·m (17 ft. lbs.)
Suspension Arm Upper
Front Nut . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)
Rear Nut . . . . . . . . . . . . . . . . 89 N·m (66 ft. lbs.)
Suspension Arm Lower
Front Nut . . . . . . . . . . . . . . . 115 N·m (85 ft. lbs.)
Rear Nut . . . . . . . . . . . . . . . 115 N·m (85 ft. lbs.)
Stabilizer Bar
Clamp Bolt . . . . . . . . . . . . . . . 54 N·m (40 ft. lbs.)
Fig. 9 Wheel Stud Removal Link Upper Nut . . . . . . . . . . . 36 N·m (27 ft. lbs.)
1 – REMOVER Link Lower Nut . . . . . . . . . . . 95 N·m (70 ft. lbs.)
2 – WHEEL STUD Track Bar
Ball Stud Nut . . . . . . . . . . . . 81 N·m (60 ft. lbs.)
Axle Bracket Bolt . . . . . . . . . . 54 N·m (40 ft. lbs.)
XJ SUSPENSION 2 - 15
SPECIFICATIONS (Continued)
DESCRIPTION TORQUE
Track Bar Bracket
Bolts . . . . . . . . . . . . . . . . . . 125 N·m (92 ft. lbs.)
Nut . . . . . . . . . . . . . . . . . . . 100 N·m (74 ft. lbs.)
Support Bolts . . . . . . . . . . . . . 42 N·m (31 ft. lbs.)
Hub/Bearing
Bolts . . . . . . . . . . . . . . . . . . 102 N·m (75 ft. lbs.)
Axle Nut . . . . . . . . . . . . . . 237 N·m (175 ft. lbs.)
Nut, Long 7603
SPECIAL TOOLS
FRONT SUSPENSION
Remover C-4150A
2 - 16 SUSPENSION XJ
REAR SUSPENSION
TABLE OF CONTENTS
page page
DESCRIPTION DESCRIPTION
The top of the shock absorbers are bolted to the The front of the multi-leaf springs mount to frame
body crossmember. The bottom of the shocks are rail brackets. The rear of the spring mounts to shack-
bolted to the axle brackets. les which mount the frame. The springs and shackles
have bushing at the mounting points.
XJ SUSPENSION 2 - 17
DESCRIPTION AND OPERATION (Continued)
OPERATION tent. This condition is not repairable and the shock
The leaf springs control ride quality and maintain absorber must be replaced.
proper ride height. The shackles allow the springs to The shock absorbers are not refillable or adjust-
change their length as the vehicle moves over various able. If a malfunction occurs, the shock absorber
road conditions. The bushings are used to isolate must be replaced. To test a shock absorber, hold it in
axle/road noise. an upright position and force the piston in and out of
the cylinder four or five times. The action throughout
each stroke should be smooth and even.
DIAGNOSIS AND TESTING The spring eye and shock absorber bushings do not
require any type of lubrication. Do not attempt to
SPRING AND SHOCK stop spring bushing noise by lubricating them.
A knocking or rattling noise from a shock absorber Grease and mineral oil-base lubricants will deterio-
may be caused by movement between mounting rate the bushing rubber.
bushings and metal brackets or attaching compo- If the vehicle is used for severe, off-road operation,
nents. These noises can usually be stopped by tight- the springs should be examined periodically. Check
ening the attaching nuts. If the noise persists, for broken and shifted leafs, loose and missing clips,
inspect for damaged and worn bushings, and attach- and broken center bolts. Refer to Spring and Shock
ing components. Repair as necessary if any of these Absorber Diagnosis chart for additional information.
conditions exist.
A squeaking noise from the shock absorber may be
caused by the hydraulic valving and may be intermit-
LEAF SPRING (2) Position the rear eye in the shackle bracket.
Loosely install the attaching bolt and nut. Do not
REMOVAL tighten at this time.
(1) Raise vehicle at body rails. (3) Position the axle. Install the spring bracket,
(2) Remove the wheel and tire assemblies. U-bolts and nuts. Tighten the nuts to 70 N·m (52 ft.
(3) Support axle with hydraulic jack to relieve axle lbs.).
weight. (4) Connect the stabilizer bar link to the spring
(4) Disconnect the stabilizer bar link from the bracket.
spring bracket stud. (5) Remove the hydraulic jack.
(5) Remove nuts, U-bolts and spring bracket from (6) Lower the vehicle.
axle. (7) Tighten the spring front eye attaching bolts to
(6) Remove nut and bolt attaching spring front eye 156 N·m (115 ft. lbs.).
to shackle. (8) Tighten the spring rear eye attaching bolts to
(7) Remove nut and bolt from spring rear eye. 108 N·m (80 ft. lbs.).
(8) Remove spring from vehicle. (9) Tighten the stabilizer bar link to 74 N·m (55 ft.
lbs.).
INSTALLATION
(1) Position the spring front eye in the bracket. LEAF SPRING AND SHACKLE BUSHING
Loosely install the attaching bolt and nut. Do not For front bushings bend tabs DOWN before
tighten at this time. removal. Use an appropriate driver tool and force the
original bushing out of the spring eye.
XJ SUSPENSION 2 - 19
REMOVAL AND INSTALLATION (Continued)
page page
PROPELLER SHAFTS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION ment parts helps to ensure safe operation. All fasten-
ers must be torqued to the specified values for safe
PROPELLER SHAFT operation.
Also make alignment reference marks (Fig. 1) on
DESCRIPTION the propeller shaft yoke and axle, or transmission,
A propeller shaft (Fig. 2) is the shaft which con- yoke prior to servicing. This helps to eliminate possi-
nects the transmission/transfer case to the axle dif- ble vibration.
ferential. This is the link through which the engine
CAUTION: Do not allow the propeller shaft to drop
power is transmitted to the axle.
or hang from any propeller shaft joint during
The propeller shaft is designed and built with the
removal. Attach the propeller shaft to the vehicle
yoke lugs in line with each other which is called zero
underside with wire to prevent damage to the joints.
phasing. This design produces the smoothest running
condition, an out-of-phase shaft can cause a vibra-
OPERATION
tion.
The propeller shaft must operate through con-
Tubular propeller shafts are balanced by the man-
stantly changing relative angles between the trans-
ufacturer with weights spot welded to the tube.
mission and axle when going over various road
PRECAUTIONS surfaces. It must also be capable of changing length
while transmitting torque. The axle rides suspended
Use the exact replacement parts when installing
by springs in a floating motion.This is accomplished
the propeller shafts. The use of the correct replace-
through universal joints, which permit the propeller
3-2 PROPELLER SHAFTS XJ
DESCRIPTION AND OPERATION (Continued)
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
vibration.
OPERATION
This cancellation is done through the phasing of a
propeller shaft and ensuring that the proper propel-
ler shaft joint working angles are maintained.
A propeller shaft is properly phased when the yoke
ends are in the same plane, or in line. A twisted
shaft will make the yokes out of phase and cause a
noticeable vibration.
When taking propeller shaft joint angle measure-
ments, or checking the phasing, of two piece shafts,
consider each shaft separately.
Fig. 3 Single Cardan Universal Joint Ideally the driveline system should have;
1 – NEEDLE BEARING 6 – BEARING CAP
• Angles that are equal or opposite within 1
2 – BEARING CAP 7 – RETAINING CLIP
degree of each other.
3 – SEAL 8 – YOKE
4 – SPIDER 9 – SEAL
• Have a 3 degree maximum operating angle.
5 – NEEDLE BEARING • Have at least a 1/2 degree continuous operating
(propeller shaft) angle.
DRIVELINE VIBRATION
Propeller Shaft Noise 1) Undercoating or other foreign 1) Clean exterior of shaft and wash
material on shaft. with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or 3) Install new yoke.
excessive runout.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in 5) Loosen spring u-bolts and seat
seat. center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out 7) Installl new propeller shaft.
of balance.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced 9) Re-index propeller shaft, test,
condition. and evaluate.
10) Excessive drive pinion gear 10) Re-index propeller shaft and
shaft runout. evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.
XJ PROPELLER SHAFTS 3-5
DIAGNOSIS AND TESTING (Continued)
UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
vibrations.
RUNOUT
(10) Start the engine and re-check for vibration. If (1) Remove dirt, rust, paint, and undercoating
there is little or no change in vibration, move the from the propeller shaft surface where the dial indi-
clamp to one of the other three positions. Repeat the cator will contact the shaft.
vibration test. (2) The dial indicator must be installed perpendic-
(11) If there is no difference in vibration at the ular to the shaft surface.
other positions, the source of the vibration may not (3) Measure runout at the center and ends of the
be propeller shaft. shaft sufficiently far away from weld areas to ensure
(12) If the vibration decreased, install a second that the effects of the weld process will not enter into
clamp (Fig. 7) and repeat the test. the measurements.
3-6 PROPELLER SHAFTS XJ
DIAGNOSIS AND TESTING (Continued)
(4) Refer to Runout Specifications chart. (2) Rotate the shaft until transmission/transfer
(5) If the propeller shaft runout is out of specifica- case output yoke bearing is facing downward.
tion, remove the propeller shaft, index the shaft 180°, Always make measurements from front to
and re-install the propeller shaft. Measure shaft rear. Also, be sure to take all measurements
runout again. while working from the same side of the vehi-
(6) If the propeller shaft runout is now within cle.
specifications, mark the shaft and yokes for proper (3) Place Inclinometer on yoke bearing (A) parallel
orientation. to the shaft (Fig. 9). Center bubble in sight glass and
(7) If the propeller shaft runout is not within spec- record measurement.
ifications, verify that the runout of the transmission/ This measurement will give you the transmis-
transfer case and axle are within specifications. sion or Output Yoke Angle (A).
Correct as necessary and re-measure propeller shaft
runout.
(8) Replace the propeller shaft if the runout still
exceeds the limits.
RUNOUT SPECIFICATIONS
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION Fig. 9 Front (Output) Angle Measurement (A)
Before measuring universal joint angles, the fol- 1 – SLIP YOKE BEARING CAP
lowing must be done; 2 – SPECIAL TOOL 7663 (J-23498A)
• Inflate all tires to correct pressure.
• Check the angles in the same loaded or
(4) Rotate propeller shaft 90 degrees and place
unloaded condition as when the vibration occurred.
Inclinometer on yoke bearing parallel to the shaft
Propeller shaft angles change according to the
(Fig. 10). Center bubble in sight glass and record
amount of load in the vehicle.
measurement. This measurement can also be taken
• Check the condition of all suspension compo-
at the rear end of the shaft.
nents and verify all fasteners are torqued to specifi-
This measurement will give you the Propeller
cations.
Shaft Angle (C).
• Check the condition of the engine and transmis-
(5) Subtract smaller figure from larger (C minus
sion mounts and verify all fasteners are torqued to
A) to obtain Transmission Output Operating Angle.
specifications.
(6) Rotate propeller shaft 90 degrees and place
Inclinometer on pinion yoke bearing parallel to the
PROPELLER SHAFT ANGLE MEASUREMENT shaft (Fig. 11). Center bubble in sight glass and
To accurately check driveline alignment, raise and record measurement.
support the vehicle at the axles as level as possible.
Allow the wheels and propeller shaft to turn.
(1) Remove any external bearing snap rings, if
equipped, from universal joint so protractor base sits
flat.
XJ PROPELLER SHAFTS 3-7
SERVICE PROCEDURES (Continued)
INSTALLATION
(1) Slide the slip yoke on the transmission/transfer
case output shaft. Align the installation reference
marks at the axle yoke and install the propeller shaft
(Fig. 16).
(2) Tighten the U-joint strap/clamp bolts at the
axle yoke to 19 N·m (14 ft. lbs.) torque. Fig. 18 Remove Snap Ring
(3) Crimp clamp to hold dust boot to propeller 1 – SNAP RING
shaft yoke (Fig. 17).
3 - 10 PROPELLER SHAFTS XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Set the yoke in an arbor press or vise with a
socket whose inside diameter is large enough to
receive the bearing cap positioned beneath the yoke.
(5) Position the yoke with the grease fitting, if
equipped, pointing up.
(6) Place a socket with an outside diameter
smaller than the upper bearing cap on the upper
bearing cap and press the cap through the yoke to
release the lower bearing cap (Fig. 19).
(7) If the bearing cap will not pull out of the yoke
by hand after pressing, tap the yoke ear near the
bearing cap to dislodge the cap.
(8) To remove the opposite bearing cap, turn the
yoke over and straighten the cross in the open hole.
Then, carefully press the end of the cross until the
remaining bearing cap can be removed (Fig. 20).
ASSEMBLY
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 (3) Place a bearing cap over the trunnion and
or 2 grease to inside of yoke bores to aid in installa- align the cap with the yoke bore (Fig. 22). Keep the
tion. needle bearings upright in the bearing assembly. A
(2) Position the cross in the yoke with its lube fit- needle bearing lying at the bottom of the cap will
ting, if equipped, pointing up (Fig. 21). prevent proper assembly.
XJ PROPELLER SHAFTS 3 - 11
DISASSEMBLY AND ASSEMBLY (Continued)
ADJUSTMENTS
REAR AXLE PINION INPUT ANGLE
Adjust the rear axle pinion input angle on vehicles
equipped with leaf springs with tapered shims (Fig.
37). Install tapered shims between the springs and
axle pad to correct the angle. Refer to Group 2, Sus-
pension, for additional information.
SPECIAL TOOLS
Fig. 37 Pinion Angle Adjustment at Leaf Springs
1 – WEDGE PROPELLER SHAFT
Inclinometer—7663
SPECIFICATIONS
PROPELLER SHAFTS AND U–JOINTS
DESCRIPTION TORQUE
Bolts, Transfer Case Yoke . . . . . 27 N·m (20 ft. lbs.)
Bolts, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft. lbs.)
Bolts, Axle Yoke . . . . . . . . . . . . . 19 N·m (14 ft. lbs.)
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION For vehicles with ABS brakes, the ABS wheel
speed sensors are attached to the knuckle assem-
181 FBI AXLE blies. The tone rings for the ABS system are pressed
onto the axle shaft. Do not damage ABS tone
DESCRIPTION wheel or the sensor when removing axle shafts.
The 181 Front Beam-design Iron (FBI) axle con- The stamped steel cover provides a means for
sists of a cast iron differential housing with axle inspection and servicing the differential.
shaft tubes extending from either side. The tubes are The 181 FBI axle has the assembly part number
pressed into the differential housing and welded. and gear ratio listed on a tag. The tag is attached to
The integral type housing, hypoid gear design has the housing cover by a cover bolt. Build date identi-
the centerline of the pinion set above the centerline fication codes are stamped on the cover side of the
of the ring gear. axle shaft tube.
The axle has a fitting for a vent hose used to The differential case is a one–piece design. The dif-
relieve internal pressure caused by lubricant vapor- ferential pinion mate shaft is retained with a roll
ization and internal expansion. pin. Differential bearing preload and ring gear back-
The axles are equipped with semi–floating axle lash is adjusted by the use of shims (select thick-
shafts, meaning that loads are supported by the hub ness). The shims are located between the differential
bearings. The axle shafts are retained by nuts at the bearing cones and case. Pinion bearing preload is set
hub bearings. The hub bearings are bolted to the and maintained by the use of shims (select thick-
steering knuckle at the outboard end of the axle tube ness).
yoke. The hub bearings are serviced as an assembly.
XJ TUBE, 181, AND 186 FBI AXLE 3 - 17
DESCRIPTION AND OPERATION (Continued)
OPERATION The differential case is a one–piece design. The dif-
The axle receives power from the transfer case ferential pinion mate shaft is retained with a roll
through the front propeller shaft. The front propeller pin. Differential bearing preload and ring gear back-
shaft is connected to the pinion gear which rotates lash is adjusted by the use of shims (select thick-
the differential through the gear mesh with the ring ness). The shims are located between the differential
gear bolted to the differential case. The engine power bearing cones and case. Pinion bearing preload is set
is transmitted to the axle shafts through the pinion and maintained by the use of a collapsible spacer.
mate and side gears. The side gears are splined to
the axle shafts. OPERATION
The axle receives power from the transfer case
186 FBI AXLE through the front propeller shaft. The front propeller
shaft is connected to the pinion gear which rotates
DESCRIPTION the differential through the gear mesh with the ring
The 186 Front Beam-design Iron (FBI) axle con- gear bolted to the differential case. The engine power
sists of a cast iron differential housing with axle is transmitted to the axle shafts through the pinion
shaft tubes extending from either side. The tubes are mate and side gears. The side gears are splined to
pressed into the differential housing and welded. the axle shafts.
The integral type housing, hypoid gear design has
the centerline of the pinion set below the centerline LUBRICANT
of the ring gear.
The axle has a fitting for a vent hose used to DESCRIPTION
relieve internal pressure caused by lubricant vapor- A multi–purpose, hypoid gear lubricant which con-
ization and internal expansion. forms to the following specifications should be used.
The axles are equipped with semi–floating axle Mopart Hypoid Gear Lubricant conforms to all of
shafts, meaning that loads are supported by the hub these specifications.
bearings. The axle shafts are retained by nuts at the • The lubricant should have MIL–L–2105C and
hub bearings. The hub bearings are bolted to the API GL 5 quality specifications.
steering knuckle at the outboard end of the axle tube • Lubricant is a thermally stable SAE 80W–90
yoke. The hub bearings are serviced as an assembly. gear lubricant.
For vehicles with ABS brakes, the ABS wheel • Lubricant for axles intended for heavy-duty or
speed sensors are attached to the knuckle assem- trailer tow use is SAE 75W–140 SYNTHETIC gear
blies. The tone rings for the ABS system are pressed lubricant.
onto the axle shaft. Do not damage ABS tone The 181 FBI axle lubricant capacity is 1.2 L (2.5
wheel or the sensor when removing axle shafts. pts.). The 186 FBI axle lubricant capacity is 1.18 L
The stamped steel cover provides a means for (2.5 pts.).
inspection and servicing the differential.
The 186 FBI axle has the assembly part number CAUTION: If axle is submerged in water, lubricant
and gear ratio listed on a tag. The tag is attached to must be replaced immediately to avoid possible
the housing cover by a cover bolt. Build date identi- premature axle failure.
fication codes are stamped on the cover side of the
axle shaft tube.
3 - 18 TUBE, 181, AND 186 FBI AXLE XJ
DESCRIPTION AND OPERATION (Continued)
STANDARD DIFFERENTIAL
DESCRIPTION
The differential gear system divides the torque
between the axle shafts. It allows the axle shafts to
rotate at different speeds when turning corners.
Each differential side gear is splined to an axle
shaft. The pinion gears are mounted on a pinion
mate shaft and are free to rotate on the shaft. The
pinion gear is fitted in a bore in the differential case
and is positioned at a right angle to the axle shafts.
OPERATION
In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear Fig. 1 Differential Operation—Straight Ahead Driving
• The ring gear (bolted to the differential case) 1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
rotates the case 100% OF CASE SPEED
2 – PINION GEAR
• The differential pinion gears (mounted on the
3 – SIDE GEAR
pinion mate shaft in the case) rotate the side gears
4 – PINION GEARS ROTATE WITH CASE
• The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
pinion mate shaft but do not rotate around it (Fig. 1).
When turning corners, the outside wheel must
travel a greater distance than the inside wheel to
complete a turn. The difference must be compensated
for to prevent the tires from scuffing and skidding
through turns. To accomplish this, the differential
allows the axle shafts to turn at unequal speeds (Fig.
2). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster Fig. 2 Differential Operation—On Turns
speed. 1 – PINION GEARS ROTATE ON PINION SHAFT
XJ TUBE, 181, AND 186 FBI AXLE 3 - 19
DIAGNOSTIC CHART
Axle Shaft 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
Noise necessary.
Axle Shaft 1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube
Broke mis-alignment.
Differential 1. Improper adjustment of the 1. Replace case and inspect gears and bearings for
Cracked differential bearings. further damage. Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and bearings for
further damage. Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and bearings for
further damage. Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and bearings for
further damage. Avoid erratic use of clutch.
3 - 20 TUBE, 181, AND 186 FBI AXLE XJ
DIAGNOSIS AND TESTING (Continued)
Differential 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the
Gears Scored correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with the
correct fluid type and quantity.
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 1. Lubricant level too high. 1. Drain lubricant to the correct level.
Lubricant
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.
Gear Teeth 1. Overloading. 1. Replace gears. Examine other gears and bearings
Broke for possible damage.
2. Erratic clutch operation. 2. Replace gears and examine the remaining parts
for damage. Avoid erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining parts for
damage.
4. Improper adjustments. 4. Replace gears and examine remaining parts for
damage. Ensure ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and
quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion contact pattern.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear and
pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace components
as necessary.
8. Loose differential bearing cap bolts. 8. Inspect differential components and replace as
necessary. Ensure that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
XJ TUBE, 181, AND 186 FBI AXLE 3 - 21
DIAGNOSIS AND TESTING (Continued)
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
Fig. 3 Typical Housing Cover With Sealant
are not at their normal ride position, ride height and
1 – SEALING SURFACE
handling could be affected.
2 – CONTOUR OF BEAD
3 – BEAD THICKNESS 6.35mm (1/4”)
(1) Install the springs and retainer clips. Tighten
the retainer bolts to 21 N·m (16 ft. lbs.) torque.
Install the housing cover within 5 minutes (2) Support the axle on a suitable lifting device
after applying the sealant. and position axle under the vehicle.
(7) Install the cover and any identification tag. (3) Raise the axle and align it with the spring
Tighten the cover bolts in a criss–cross pattern to 41 pads.
N·m (30 ft. lbs.) torque. (4) Position the upper and lower suspension arms
(8) Refill the differential with Mopart Hypoid in the axle brackets. Loosely install bolts and nuts to
Gear Lubricant, or equivalent, to bottom of the fill hold suspension arms to the axle brackets.
plug hole. Refer to the Lubricant Specifications in (5) Connect the vent hose to the axle shaft tube.
this group for the quantity necessary. (6) Connect the track bar to the axle bracket.
(9) Install the fill hole plug and lower the vehicle. Loosely install the bolt to hold the track bar to the
Tighten fill plug to 34 N·m (25 ft. lbs.). axle bracket.
(7) Install the shock absorbers and tighten the
bolts to 23 N·m (17 ft. lbs.) torque.
REMOVAL AND INSTALLATION (8) Install the stabilizer bar links to the axle
brackets. Tighten the nut to 95 N·m (70 ft. lbs.)
DRIVE AXLE ASSEMBLY torque.
(9) Install the drag link and tie rod to the steering
REMOVAL knuckles. Refer to Group 2, Suspension, for proper
(1) Raise and support the vehicle. procedures.
(2) Position a suitable lifting device under the (10) Install the steering damper to the axle
axle. bracket and tighten the nut to 75 N·m (55 ft. lbs.)
(3) Secure axle to device. torque.
(4) Remove the wheels and tires. (11) Install the brake rotors and calipers. Refer to
(5) Remove the brake rotors and calipers from the Group 5, Brakes, for the proper procedures.
axle. Refer to Group 5, Brakes, for proper procedures. (12) Connect the wheel speed sensor wiring har-
(6) Disconnect the wheel sensor wiring harness ness to the vehicle wiring harness, if necessary.
from the vehicle wiring harness, if necessary.
XJ TUBE, 181, AND 186 FBI AXLE 3 - 23
REMOVAL AND INSTALLATION (Continued)
(13) Align the previously made marks on the pro- (4) Position the upper and lower suspension arms
peller shaft and the yoke. in the axle brackets. Loosely install bolts and nuts to
(14) Install the straps and bolts to hold the propel- hold suspension arms to the axle brackets.
ler shaft to the yoke. (5) Connect the track bar to the axle bracket.
(15) Check and fill axle lubricant. Refer to the Loosely install the bolt to hold the track bar to the
Lubricant Specifications in this group for the quan- axle bracket.
tity necessary. (6) Install the shock absorbers and tighten the
(16) Install the wheel and tire assemblies. bolts to 23 N·m (17 ft. lbs.) torque.
(17) Remove the lifting device from the axle and (7) Install the stabilizer bar links to the axle
lower the vehicle. brackets. Tighten the nut to 95 N·m (70 ft. lbs.)
(18) Tighten the upper suspension arm nuts to 75 torque.
N·m (55 ft. lbs.) torque. Tighten the lower suspension (8) Install the drag link and tie rod to the steering
arm nuts to 115 N·m (85 ft. lbs.) torque. knuckles. Refer to Group 2, Suspension, for proper
(19) Tighten the track bar bolt at the axle bracket procedures.
to 100 N·m (74 ft. lbs.) torque. (9) Install the steering damper to the axle bracket
(20) Check the front wheel alignment. and tighten the nut to 75 N·m (55 ft. lbs.) torque.
(10) Install the brake rotors and calipers. Refer to
TUBE AXLE ASSEMBLY Group 5, Brakes, for the proper procedures.
(11) Connect the wheel speed sensor wiring har-
REMOVAL ness to the vehicle wiring harness, if necessary.
(1) Raise and support the vehicle. (12) Install the wheel and tire assemblies.
(2) Position a suitable lifting device under the (13) Remove the lifting device from the axle and
axle. lower the vehicle.
(3) Secure axle to device. (14) Tighten the upper suspension arm nuts to 75
(4) Remove the wheels and tires. N·m (55 ft. lbs.) torque. Tighten the lower suspension
(5) Remove the brake rotors and calipers from the arm nuts to 115 N·m (85 ft. lbs.) torque.
axle. Refer to Group 5, Brakes, for proper procedures. (15) Tighten the track bar bolt at the axle bracket
(6) Disconnect the wheel sensor wiring harness to 100 N·m (74 ft. lbs.) torque.
from the vehicle wiring harness, if necessary. (16) Check the front wheel alignment.
(7) Disconnect stabilizer bar links at the axle.
(8) Disconnect shock absorbers from axle brackets. AXLE SHAFT—CARDAN U-JOINT
(9) Disconnect track bar. Single cardan U–joint components are not service-
(10) Disconnect the tie rod and drag link from the able. If defective, they must be replaced as a unit. If
steering knuckle. Refer to Group 2, Suspension, for the bearings, seals, spider, or bearing caps are dam-
proper procedures. aged or worn, replace the complete U–joint.
(11) Disconnect the steering damper from the axle
bracket. REMOVAL
(12) Disconnect the upper and lower suspension
arms from the axle brackets. CAUTION: Clamp only the narrow forged portion of
(13) Lower the lifting device enough to remove the the yoke in the vise. Also, to avoid distorting the
axle. The coil springs will drop with the axle. yoke, do not over tighten the vise jaws.
(14) Remove the coil springs from the axle.
(1) Remove axle shaft.
INSTALLATION (2) Remove the bearing cap retaining snap rings
(Fig. 4).
CAUTION: The weight of the vehicle must be sup- It can be helpful to saturate the bearing caps
ported by the springs before suspension arms and with penetrating oil prior to removal.
track bar fasteners can be tightened. If the springs (3) Locate a socket where the inside diameter is
are not at their normal ride position, ride height and larger in diameter than the bearing cap. Place the
handling could be affected. socket (receiver) against the yoke and around the
perimeter of the bearing cap to be removed.
(1) Install the springs and retainer clips. Tighten (4) Locate a socket where the outside diameter is
the retainer bolts to 21 N·m (16 ft. lbs.) torque. smaller in diameter than the bearing cap. Place the
(2) Support the axle on a suitable lifting device socket (driver) against the opposite bearing cap.
and position axle under the vehicle. (5) Position the yoke with the sockets in a vise
(3) Raise the axle and align it with the spring (Fig. 5).
pads.
3 - 24 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(6) Compress the vise jaws to force the bearing cap
into the larger socket (receiver).
(7) Release the vise jaws. Remove the sockets and
bearing cap that was partially forced out of the yoke.
(8) Repeat the above procedure for the remaining
bearing cap.
(9) Remove the remaining bearing cap, bearings,
seals and spider from the propeller shaft yoke.
INSTALLATION
(1) Pack the bearing caps 1/3 full of wheel bearing
lubricant. Apply extreme pressure (EP), lithium–base
lubricant to aid in installation.
(2) Position the spider in the yoke. Insert the seals
and bearings. Tap the bearing caps into the yoke
bores far enough to hold the spider in position.
(3) Place the socket (driver) against one bearing
cap. Position the yoke with the socket wrench in a
vise.
(4) Compress the vise to force the bearing caps
Fig. 4 Axle Shaft Outer U–Joint into the yoke. Force the caps enough to install the
1 – SHAFT YOKE retaining clips.
2 – BEARING CAP (5) Install the bearing cap retaining clips.
3 – SNAP RINGS
(6) Install axle shaft.
4 – BEARING CAP
5 – SPINDLE YOKE
6 – BEARING
181 FBI PINION SHAFT SEAL
7 – BEARING CAP
8 – SNAP RINGS REMOVAL
9 – BEARING CAP (1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pinion yoke (Fig. 6).
(10) Use a suitable pry tool or a slide hammer
mounted screw to remove the pinion shaft seal.
INSTALLATION
(1) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with Installer C-3972-A
Fig. 5 Yoke Bearing Cap Removal and Handle C-4171 (Fig. 7).
1 – LARGE-DIAMETER SOCKET WRENCH (2) Install yoke on the pinion gear with Installer
2 – VISE
W-162–D, Cup 8109, and Holder 6958 (Fig. 8).
3 – SMALL-DIAMETER SOCKET WRENCH
XJ TUBE, 181, AND 186 FBI AXLE 3 - 25
REMOVAL AND INSTALLATION (Continued)
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
(1) Raise and support the vehicle.
(2) Remove wheel and tire assemblies.
(3) Remove brake rotors and calipers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propeller shaft and pinion yoke for
installation reference.
(5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
(7) Measure the amount of torque necessary to
rotate the pinion gear with a (in. lbs.) dial-type
torque wrench. Record the torque reading for instal-
lation reference.
(8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
Fig. 13 Check Pinion Rotation Torque (9) Use Remover C-452 and Wrench C-3281 to
1 – PINION YOKE remove the pinion yoke (Fig. 15).
2 – INCH POUND TORQUE WRENCH (10) Use a suitable pry tool or a slide hammer
mounted screw, remove the pinion seal.
(11) Remove the front pinion bearing using a pair
of suitable pick tools to pull the bearing straight off
the pinion gear shaft. It may be necessary to lightly
tap the end of the pinion gear with a rawhide or rub-
ber mallet if the bearing becomes bound on the pin-
ion shaft.
(12) Remove the collapsible spacer.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the wheel and tire assembly.
(3) Remove the brake caliper and rotor. Refer to
Group 5, Brakes, for proper procedures. Fig. 23 Hub Bearing Bolts
(4) Remove ABS wheel speed sensor, if necessary. 1 – AXLE SHAFT
Refer to Group 5, Brakes, for proper procedures. 2 – AXLE
(5) Remove the cotter pin, nut retainer, and axle 3 – KNUCKLE
hub nut (Fig. 22), if necessary. 4 – HUB BEARING
(6) Remove the hub to knuckle bolts (Fig. 23).
(7) Remove the hub from the steering knuckle and (9) Remove the brake rotor shield from the hub
axle shaft, if necessary. bearing or knuckle (Fig. 22).
(8) Remove hub bearing and axle shaft assembly
(Fig. 24), or axle shaft from axle. Avoid damaging
the axle shaft oil seals in the axle housing.
XJ TUBE, 181, AND 186 FBI AXLE 3 - 31
REMOVAL AND INSTALLATION (Continued)
KNUCKLE REMOVAL
(1) Remove hub bearing and axle shaft.
(2) Disconnect the tie-rod or drag link from the
steering knuckle arm. Refer to Group 2, Suspension,
for proper procedures.
(3) Remove the cotter pins from the upper and
lower ball studs.
(4) Remove the upper and lower ball stud nuts.
(5) Strike the steering knuckle with a brass ham-
mer to loosen knuckle from the ball studs. Remove
Fig. 24 Hub Bearing and Axle Assembly knuckle from ball studs (Fig. 25).
1 – AXLE
2 – KNUCKLE
3 – HUB BEARING
4 – AXLE SHAFT
INSTALLATION
(1) Thoroughly clean the axle shaft (Fig. 22) and
apply a thin film of Mopart Wheel Bearing Grease,
or equivalent, to the shaft splines, seal contact sur-
face, and hub bore.
(2) Install the brake rotor shield to the knuckle.
(3) Install the hub bearing and axle shaft assem-
bly, or axle shaft, into the housing and differential
side gears. Avoid damaging the axle shaft oil seals in
the axle housing.
(4) Install the hub bearing, if necessary.
(5) Install the hub to knuckle bolts and tighten to
102 N·m (75 ft. lbs.) torque.
(6) Install the hub washer and nut, if necessary.
Tighten the hub nut to 237 N·m (175 ft. lbs.) torque.
Install the nut retainer and a new cotter pin (Fig.
22).
(7) Install ABS wheel speed sensor, if necessary. Fig. 25 Steering Knuckle Removal/Installation
1 – AXLE YOKE
Refer to Group 5, Brakes, for proper procedures.
2 – UPPER BALL STUD
(8) Install the brake rotor and caliper. Refer to
3 – LOWER BALL STUD
Group 5, Brakes, for proper procedures. 4 – STEERING KNUCKLE
(9) Install the wheel and tire assembly.
(10) Remove support and lower the vehicle.
3 - 32 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.
(3) Remove the differential housing cover and
allow fluid to drain.
(4) Remove hub bearings and axle shafts.
(5) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 28).
(6) Loosen the differential bearing cap bolts. Fig. 28 Bearing Cap Identification
(7) Position Spreader W–129–B, utilizing some 1 – INSTALLATION REFERENCE LETTERS
2 – INSTALLATION REFERENCE LETTERS
items from Adapter Kit 6987, with the tool dowel
pins seated in the locating holes (Fig. 29). Install the
holddown clamps and tighten the tool turnbuckle fin-
ger–tight.
3 - 34 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
NOTE: A pinion depth shim/oil baffle is placed
between the rear pinion bearing cone and pinion
gear. If the factory installed ring and pinion gears
are reused, the pinion depth shim/oil baffle should
not require replacement. Refer to Pinion Gear Depth
to select the proper thickness shim before installing
pinion gear.
(4) Install front pinion bearing, and oil slinger, if Fig. 46 Rear Pinion Bearing Installation
equipped. 1 – PRESS
(5) Apply a light coating of gear lubricant on the 2 – INSTALLATION TOOL
lip of pinion seal. Install seal with Installer C-3972-A 3 – PINION DEPTH SHIM/OIL BAFFLE
and Handle C–4171 (Fig. 45). 4 – DRIVE PINION
5 – DRIVE PINION SHAFT REAR BEARING
REMOVAL
(1) Remove differential assembly from axle hous- Fig. 51 Pinion Yoke Removal
ing. 1 – SPECIAL TOOL C-3281
(2) Mark pinion yoke and propeller shaft for 2 – YOKE
3 – SPECIAL TOOL C-452
installation alignment.
(3) Disconnect propeller shaft from pinion yoke.
Using suitable wire, tie propeller shaft to underbody.
3 - 42 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(6) Remove the pinion and collapsible spacer from (8) Remove the rear pinion bearing cup from axle
housing (Fig. 52). Catch the pinion with your hand to housing (Fig. 54). Use Remover D-149 and Handle
prevent it from falling and being damaged. C–4171.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If the factory installed ring gear and pinion
are reused, the pinion depth shim/oil slinger should Fig. 58 Pinion Outer Bearing Cup Installation
not require replacement. Refer to Pinion Gear Depth 1 – INSTALLER
to select the proper thickness shim/oil slinger 2 – HANDLE
before installing pinion.
(1) Apply Mopart Door Ease, or equivalent, stick (3) Install front pinion bearing, and oil slinger, if
lubricant to outside surface of rear pinion bearing equipped.
cup. Install the bearing cup with Installer D-146 and (4) Apply a light coating of gear lubricant on the
Driver Handle C–4171 (Fig. 57). Verify cup is cor- lip of pinion seal. Install seal with Installer C-3972-A
rectly seated. and Handle C–4171 (Fig. 59).
(2) Apply Mopart Door Ease, or equivalent, stick (5) Install the rear pinion bearing and the pinion
lubricant to outside surface of front pinion bearing depth shim/oil slinger onto the pinion with Installer
cup. Install the bearing cup with Installer D-130 and W-262 and a shop press (Fig. 60).
Handle C–4171 (Fig. 58).
3 - 44 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: Never loosen the pinion nut to decrease (9) Using Holder 6958 and torque wrench (set at
pinion bearing rotating torque and never exceed 352 N·m (260 ft. lbs.)), crush collapsible spacer until
XJ TUBE, 181, AND 186 FBI AXLE 3 - 45
REMOVAL AND INSTALLATION (Continued)
bearing end play is taken up (Fig. 63). If more than
353 N·m (260 ft. lbs.) is needed to begin to collapse
the spacer, the spacer is defective and must be
replaced.
(10) Slowly tighten the nut in 6.8 N·m (5 ft. lb.)
increments until the rotating torque is achieved.
Measure the rotating torque frequently to avoid over
crushing the collapsible spacer (Fig. 64).
RING GEAR
NOTE: The ring gear and pinion are serviced as a Fig. 65 Ring Gear Removal
1 – CASE
matched set. Do not replace the ring gear without
2 – RING GEAR
replacing the pinion.
3 – RAWHIDE HAMMER
REMOVAL INSTALLATION
(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with CAUTION: Do not reuse the bolts that held the ring
soft metal jaw protectors. (Fig. 65) gear to the differential case. The bolts can fracture
(3) Remove bolts holding ring gear to differential causing extensive damage.
case.
3 - 46 TUBE, 181, AND 186 FBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(1) Invert the differential case and start two ring
gear bolts. This will provide case-to-ring gear bolt
hole alignment.
(2) Invert the differential case in the vise.
(3) Install new ring gear bolts and alternately
tighten to 95–122 N·m (70–90 ft. lbs.) torque (Fig.
66).
(4) Install differential in axle housing and verify
gear mesh and contact pattern.
ASSEMBLY (2) Install the pinion mate gears and thrust wash-
(1) Install the differential side gears and thrust ers.
washers.
XJ TUBE, 181, AND 186 FBI AXLE 3 - 47
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Install the pinion gear mate shaft. Align the
roll pin holes in shaft and the differential case.
(4) Install the roll pin to hold the pinion mate
shaft in the differential case (Fig. 69).
ADJUSTMENTS
181 FBI PINION GEAR DEPTH
GENERAL INFORMATION
Ring and pinion gears are supplied as matched
sets only. The identifying numbers for the ring and
pinion gear are etched into the face of each gear (Fig.
71). A plus (+) number, minus (–) number or zero (0)
is etched into the face of the pinion gear. This num-
ber is the amount (in thousandths of an inch) the
depth varies from the standard depth setting of a
pinion etched with a (0). The standard setting from
the center line of the ring gear to the back face of the Fig. 72 Shim Locations
1 – PINION GEAR DEPTH SHIM/OIL BAFFLE
pinion is 92.08 mm (3.625 in.). The standard depth
2 – DIFFERENTIAL BEARING SHIM
provides the best gear tooth contact pattern. Refer to
Backlash and Contact Pattern Analysis paragraph in
this section for additional information. If a new gear set is being installed, note the depth
variance etched into both the original and replace-
ment pinion. Add or subtract this number from the
thickness of the original depth shim/oil slinger to
compensate for the difference in the depth variances.
Refer to the Depth Variance chart.
Note where Old and New Pinion Marking columns
intersect. Intersecting figure represents plus or
minus the amount needed.
Note the etched number on the face of the pinion
gear head (–1, –2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an inch deviation from the stan-
dard. If the number is negative, add that value to the
required thickness of the depth shims. If the number
is positive, subtract that value from the thickness of
the depth shim. If the number is 0 no change is nec-
essary.
Fig. 71 Pinion Gear ID Numbers
1 – PRODUCTION NUMBERS
2 – DRIVE PINION GEAR DEPTH VARIANCE
3 – GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
XJ TUBE, 181, AND 186 FBI AXLE 3 - 49
ADJUSTMENTS (Continued)
PINION GEAR DEPTH VARIANCE
Original Pinion Replacement Pinion Gear Depth Variance
Gear Depth
Variance −4 −3 −2 −1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 −0.001
+2 +0.006 +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
PINION DEPTH MEASUREMENT AND ADJUSTMENT (2) Insert assembled height gauge components,
Measurements are taken with pinion bearing cups rear bearing and screw into axle housing through
and pinion bearings installed in the axle housing. pinion bearing cups (Fig. 74).
Take measurements with Pinion Gauge Set and Dial (3) Install front pinion bearing and Cone-nut 6740
Indicator C-3339 (Fig. 73). hand tight (Fig. 73).
SHIM SELECTION
Fig. 85 Seat Pinion Gear Side Differential Dummy
NOTE: It is difficult to salvage the differential side Side Bearing
bearings during the removal procedure. Install 1 – MALLET
replacement bearings if necessary. 2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
(1) Remove differential side bearings from differ-
ential case. (8) Thread guide stud C-3288-B into rear cover
bolt hole below ring gear (Fig. 87).
3 - 54 TUBE, 181, AND 186 FBI AXLE XJ
ADJUSTMENTS (Continued)
Fig. 86 Seat Ring Gear Side Differential Dummy Fig. 88 Hold Differential Case and Zero Dial
Side Bearing Indicator
1 – AXLE HOUSING 1 – FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
2 – MALLET 2 – SPECIAL TOOL C-3288–B
3 – DIFFERENTIAL CASE 3 – SPECIAL TOOL C-3339
4 – ZERO DIAL INDICATOR FACE
SHIM SELECTION
Fig. 93 Backlash Shim Adjustment
NOTE: It is difficult to salvage the differential side
186 FBI DIFFERENTIAL BEARING PRELOAD
bearings during the removal procedure. Install
AND GEAR BACKLASH replacement bearings if necessary.
TORQUE
DESCRIPTION TORQUE
Fill Hole Plug . . . . . . . . . . . . . . 34 N·m (25 ft. lbs.)
Diff. Cover Bolt . . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bearing Cap Bolt . . . . . . . . . . . . 61 N·m (45 ft. lbs.)
Ring Gear Bolt . . . . . . . 95–122 N·m (70–90 ft. lbs.)
Axle Nut . . . . . . . . . . . . . . . . 237 N·m (175 ft. lbs.)
Hub Brg. Bolt . . . . . . . . . . . . . 102 N·m (75 ft. lbs.) Puller—C-452
Lower Ball Stud . . . . . . . . . . . 108 N·m (80 ft. lbs.)
Upper Ball Stud . . . . . . . . . . . 101 N·m (75 ft. lbs.)
Wrench—C-3281
3 - 62 TUBE, 181, AND 186 FBI AXLE XJ
SPECIAL TOOLS (Continued)
Dial Indicator—C-3339
Installer—W-162-D
Driver—C-3716-A
Cup—8109
Remover/Installer—6289
Handle—C-4171
Installer—6761
Installer—D-146
Remover—D-149 Installer—6752
XJ TUBE, 181, AND 186 FBI AXLE 3 - 63
SPECIAL TOOLS (Continued)
Turnbuckle—6797
Spreader—W-129-B
Adapter Kit—6987
Gauge Block—6733
Pilot Stud—C-3288-B
Spanner—6958
Remover—D-147
3 - 64 TUBE, 181, AND 186 FBI AXLE XJ
SPECIAL TOOLS (Continued)
Installer—D-144
Installer—W-262
XJ 194 RBI AXLE 3 - 65
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION The 194 RBI axle has the assembly part number
and gear ratio listed on a tag. The tag is attached to
194 RBI AXLE the differential housing by a cover bolt. Build date
identification codes are stamped on the cover side of
DESCRIPTION an axle shaft tube.
The 194 Rear Beam-design Iron (RBI) axle housing The differential case is a one-piece design. The dif-
has an iron center casting (differential housing) with ferential pinion mate shaft is retained with a
axle shaft tubes extending from either side. The threaded pin. Differential bearing preload and ring
tubes are pressed into and welded to the differential gear backlash is adjusted by the use of selective
housing to form a one-piece axle housing. spacer shims. Pinion bearing preload is set and
The integral type, hypoid gear design, housing has maintained by the use of a collapsible spacer (Fig. 1).
the centerline of the pinion set below the centerline Axles equipped with a Trac-Loky differential are
of the ring gear. optional. A Trac-Lok differential has a one-piece dif-
The axle has a vent hose to relieve internal pres- ferential case, and the same internal components as
sure caused by lubricant vaporization and internal a standard differential, plus two clutch disc packs.
expansion.
The axles are equipped with semi–floating axle OPERATION
shafts, meaning that loads are supported by the axle The axle receives power from the transmission/
shaft and bearings. The axle shafts are retained by transfer case through the rear propeller shaft. The
C–clips in the differential side gears. rear propeller shaft is connected to the pinion gear
The cover provides a means for servicing the differ- which rotates the differential through the gear mesh
ential without removing the axle. with the ring gear bolted to the differential case. The
For vehicles equipped with ABS brakes, the axles engine power is transmitted to the axle shafts
have a tone ring pressed onto the axle shaft. Use care through the pinion mate and side gears. The side
when removing axle shafts to ensure that the tone gears are splined to the axle shafts.
wheel or the wheel speed sensor are not damaged.
3 - 66 194 RBI AXLE XJ
DESCRIPTION AND OPERATION (Continued)
OPERATION
In operation, power flow occurs as follows:
• The pinion gear rotates the ring gear
• The ring gear (bolted to the differential case)
rotates the case
• The differential pinion gears (mounted on the
pinion mate shaft in the case) rotate the side gears
• The side gears (splined to the axle shafts) rotate
the shafts
During straight-ahead driving, the differential pin-
ion gears do not rotate on the pinion mate shaft. This
occurs because input torque applied to the gears is
divided and distributed equally between the two side
gears. As a result, the pinion gears revolve with the
Fig. 1 Shim Locations pinion mate shaft but do not rotate around it (Fig. 2).
1 – PINION GEAR DEPTH SHIM
2 – DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 – RING GEAR
4 – DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
5 – COLLAPSIBLE SPACER
LUBRICANT
DESCRIPTION
A multi-purpose, hypoid gear lubricant which con-
forms to the following specifications should be used.
Mopart Hypoid Gear Lubricant conforms to all of
these specifications.
• The lubricant should have MIL–L–2105C and
API GL 5 quality specifications. Fig. 2 Differential Operation—Straight Ahead Driving
• Lubricant is a thermally stable SAE 80W–90 1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
gear lubricant. 2 – PINION GEAR
• Lubricant for axles intended for heavy-duty or 3 – SIDE GEAR
trailer tow use is SAE 75W–140 SYNTHETIC gear 4 – PINION GEARS ROTATE WITH CASE
lubricant.
Trac-lok differentials require the addition of 3.5 oz.
When turning corners, the outside wheel must
of friction modifier to the axle lubricant. The 194 RBI
travel a greater distance than the inside wheel to
axle lubricant capacity is 1.66L (3.50 pts.) total,
complete a turn. The difference must be compensated
including the friction modifier if necessary.
for to prevent the tires from scuffing and skidding
CAUTION: If axle is submerged in water, lubricant through turns. To accomplish this, the differential
must be replaced immediately to avoid possible allows the axle shafts to turn at unequal speeds (Fig.
premature axle failure. 3). In this instance, the input torque applied to the
pinion gears is not divided equally. The pinion gears
now rotate around the pinion mate shaft in opposite
STANDARD DIFFERENTIAL directions. This allows the side gear and axle shaft
attached to the outside wheel to rotate at a faster
DESCRIPTION speed.
The differential gear system divides the torque
between the axle shafts. It allows the axle shafts to TRAC-LOKY DIFFERENTIAL
rotate at different speeds when turning corners.
Each differential side gear is splined to an axle DESCRIPTION
shaft. The pinion gears are mounted on a pinion In a standard differential, if one wheel spins, the
mate shaft and are free to rotate on the shaft. The opposite wheel will generate only as much torque as
pinion gear is fitted in a bore in the differential case the spinning wheel.
and is positioned at a right angle to the axle shafts.
XJ 194 RBI AXLE 3 - 67
DESCRIPTION AND OPERATION (Continued)
OPERATION
In operation, the Trac-loky clutches are engaged
by two concurrent forces. The first being the preload Fig. 4 Trac-lokY Limited Slip Differential Operation
force exerted through Belleville spring washers 1 – CASE
within the clutch packs. The second is the separating 2 – RING GEAR
forces generated by the side gears as torque is 3 – DRIVE PINION
applied through the ring gear (Fig. 4). 4 – PINION GEAR
The Trac-loky design provides the differential 5 – MATE SHAFT
action needed for turning corners and for driving 6 – CLUTCH PACK
straight ahead during periods of unequal traction. 7 – SIDE GEAR
When one wheel looses traction, the clutch packs 8 – CLUTCH PACK
transfer additional torque to the wheel having the
most traction. Trac-loky differentials resist wheel • Incorrect backlash.
spin on bumpy roads and provide more pulling power Axle gear problem conditions are usually the result
when one wheel looses traction. Pulling power is pro- of:
vided continuously until both wheels loose traction. If • Insufficient lubrication.
both wheels slip due to unequal traction, Trac-loky • Incorrect or contaminated lubricant.
operation is normal. In extreme cases of differences • Overloading (excessive engine torque) or exceed-
of traction, the wheel with the least traction may ing vehicle weight capacity.
spin. • Incorrect clearance or backlash adjustment.
Axle component breakage is most often the result
of:
DIAGNOSIS AND TESTING • Severe overloading.
• Insufficient lubricant.
GENERAL INFORMATION • Incorrect lubricant.
Axle bearing problem conditions are usually caused • Improperly tightened components.
by: • Differential housing bores not square to each
• Insufficient or incorrect lubricant. other.
• Foreign matter/water contamination.
• Incorrect bearing preload torque adjustment.
3 - 68 194 RBI AXLE XJ
DIAGNOSIS AND TESTING (Continued)
DIAGNOSTIC CHART
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting
tube mis-alignment.
Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears and
differential bearings. bearings for further damage. Set differential
bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid excessive
vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid erratic use
of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with
the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with
the correct fluid type and quantity.
3. Excessive spinning of one 3. Replace scored gears. Inspect all gears,
wheel/tire. pinion bores, and shaft for damage. Service
as necessary.
XJ 194 RBI AXLE 3 - 69
DIAGNOSIS AND TESTING (Continued)
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid type
and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and
bearings for possible damage.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type
and quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion contact pattern.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear
and pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap 8. Inspect differential components and replace
bolts. as necessary. Ensure that the bearing caps
are torqued tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
3 - 70 194 RBI AXLE XJ
DIAGNOSIS AND TESTING (Continued)
(6) If rotating torque is less than 22 N·m (30 ft. (10) Install the fill hole plug and lower the vehicle.
lbs.) or more than 271 N·m (200 ft. lbs.) on either (11) Trac–loky differential equipped vehicles
wheel the unit should be serviced. should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
SERVICE PROCEDURES ter noise complaint.
LUBRICANT CHANGE
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.
3 - 72 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (8) Connect the brake hose to the axle junction
block. Refer to Group 5, Brakes, for proper proce-
REAR AXLE dures.
(9) Install axle vent hose.
REMOVAL (10) Align propeller shaft and pinion yoke refer-
(1) Raise and support the vehicle. ence marks. Install U-joint straps and bolts. Tighten
(2) Position a suitable lifting device under the to 19 N·m (14 ft. lbs.) torque.
axle. (11) Install the wheels and tires.
(3) Secure axle to device. (12) Add gear lubricant, if necessary. Refer to
(4) Remove the wheels and tires. Lubricant Specifications in this section for lubricant
(5) Remove the brake drums from the axle. Refer requirements.
to Group 5, Brakes, for proper procedures. (13) Remove lifting device from axle and lower the
(6) Disconnect parking brake cables from brackets vehicle.
and lever.
(7) Remove wheel speed sensors, if necessary. PINION SHAFT SEAL
Refer to Group 5, Brakes, for proper procedures.
(8) Disconnect the brake hose at the axle junction REMOVAL
block. Do not disconnect the brake hydraulic lines at (1) Raise and support the vehicle.
the wheel cylinders. Refer to Group 5, Brakes, for (2) Remove wheel and tire assemblies.
proper procedures. (3) Remove the brake drums. Refer to Group 5,
(9) Disconnect the vent hose from the axle shaft Brakes, for proper procedures.
tube. (4) Mark the propeller shaft and pinion yoke for
(10) Mark the propeller shaft and yokes for instal- installation alignment reference.
lation alignment reference. (5) Remove the propeller shaft from the yoke.
(11) Remove propeller shaft. (6) Rotate the pinion gear three or four times.
(12) Disconnect stabilizer bar links. (7) Measure the amount of torque necessary to
(13) Disconnect shock absorbers from axle. rotate the pinion gear with a (in. lbs.) dial-type
(14) Remove the U-bolts which hold the axle to the torque wrench. Record the torque reading for instal-
spring brackets. lation reference.
(15) Separate the axle from the vehicle. (8) Using Holder 6958 to hold the pinion yoke,
remove the pinion nut and washer.
INSTALLATION (9) Use Remover C-452 and Wrench C-3281 to
remove the pinion yoke (Fig. 7).
NOTE: 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, vehicle ride
height and handling could be affected.
(1) Raise the axle with lifting device and align the
spring centering bolts with the mating holes in the
axle spring perch.
(2) Install the U-bolts which hold the axle to the
spring brackets. Tighten nuts to 70 N·m (52 ft. lbs.).
(3) Install shock absorbers and tighten nuts to 60
N·m (44 ft. lbs.) torque.
(4) Install stabilizer bar links and tighten nuts to
74 N·m (55 ft. lbs.) torque.
(5) Install the wheel speed sensors, if necessary.
Refer to Group 5, Brakes, for proper procedures.
(6) Connect parking brake cable to brackets and Fig. 7 Pinion Yoke Removal
1 – SPECIAL TOOL C-3281
lever.
2 – YOKE
(7) Install the brake drums. Refer to Group 5,
3 – SPECIAL TOOL C-452
Brakes, for proper procedures.
XJ 194 RBI AXLE 3 - 73
REMOVAL AND INSTALLATION (Continued)
(10) Use a suitable pry tool or slide hammer CAUTION: Never loosen pinion gear nut to
mounted screw to remove the pinion gear seal. decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
INSTALLATION torque or rotating torque is exceeded a new col-
(1) Apply a light coating of gear lubricant on the lapsible spacer must be installed. The torque
lip of pinion seal. Install seal with Installer C-3972-A sequence will then have to be repeated.
and Handle C-4171 (Fig. 8).
(5) Rotate the pinion shaft using a (in. lbs.) torque
wrench. Rotating torque should be equal to the read-
ing recorded during removal plus an additional 0.56
N·m (5 in. lbs.) (Fig. 10).
(11) Lower the vehicle. (4) Mark the propeller shaft and pinion yoke for
installation reference.
COLLAPSIBLE SPACER (5) Remove the propeller shaft from the yoke.
(6) Rotate the pinion gear three or four times.
REMOVAL W/PINION INSTALLED (7) Measure the amount of torque necessary to
(1) Raise and support the vehicle. rotate the pinion gear with a (in. lbs.) dial-type
(2) Remove wheel and tire assemblies. torque wrench. Record the torque reading for instal-
(3) Remove rear brake drums. Refer to Group 5, lation reference.
Brakes, for proper procedures. (8) Remove differential assembly from axle hous-
(4) Mark the propeller shaft and pinion yoke for ing.
installation reference. (9) Using Holder 6958 to hold yoke, remove the
(5) Remove the propeller shaft from the yoke. pinion yoke nut and washer.
(6) Rotate the pinion gear three or four times. (10) Using Remover C–452 and Wrench C–3281,
(7) Measure the amount of torque necessary to remove the pinion yoke from pinion shaft (Fig. 12).
rotate the pinion gear with a (in. lbs.) dial-type (11) Remove the pinion gear from housing (Fig.
torque wrench. Record the torque reading for instal- 13). Catch the pinion with your hand to prevent it
lation reference. from falling and being damaged.
(8) Using Holder 6958 to hold the pinion yoke, (12) Remove collapsible spacer from pinion shaft.
remove the pinion nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to INSTALLATION
remove the pinion yoke (Fig. 12). (1) Install a new collapsible preload spacer on pin-
(10) Use a suitable pry tool or a slide hammer ion shaft (Fig. 14).
mounted screw to remove the pinion shaft seal. (2) If pinion gear was removed, install pinion gear
(11) Remove the front pinion bearing using a pair of in housing.
suitable pick tools to pull the bearing straight off the (3) Install pinion front bearing, if necessary.
pinion gear shaft. It may be necessary to lightly tap the (4) Apply a light coating of gear lubricant on the
end of the pinion gear with a rawhide or rubber mallet lip of pinion seal. Install seal with Installer C-3972-A
if the bearing becomes bound on the pinion shaft. and Handle C–4171 (Fig. 15).
(12) Remove the collapsible spacer. (5) Install yoke with Screw 8112, Cup 8109, and
Holder 6958 (Fig. 16).
REMOVAL W/PINION REMOVED (6) If the original pinion bearings are being used,
(1) Raise and support the vehicle. install differential assembly and axle shafts, if neces-
(2) Remove wheel and tire assemblies. sary.
(3) Remove rear brake drums. Refer to Group 5,
Brakes, for proper procedures.
XJ 194 RBI AXLE 3 - 75
REMOVAL AND INSTALLATION (Continued)
AXLE SHAFT
REMOVAL
(1) Raise and support vehicle. Ensure that the Fig. 19 Mate Shaft Lock Screw
transmission is in neutral. 1 – LOCK SCREW
(2) Remove wheel and tire assembly. 2 – PINION GEAR MATE SHAFT
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure. (7) Push axle shaft inward and remove axle shaft
(4) Clean all foreign material from housing cover C–clip lock from the axle shaft (Fig. 20).
area. (8) Remove axle shaft. Use care to prevent damage
(5) Loosen housing cover bolts. Drain lubricant to axle shaft bearing and seal, which will remain in
from the housing and axle shaft tubes. Remove hous- axle shaft tube. Also, exercise care not to damage the
ing cover.
XJ 194 RBI AXLE 3 - 77
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Lubricate bearing bore and seal lip with gear
lubricant. Insert axle shaft through seal, bearing,
and engage it into side gear splines.
DIFFERENTIAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove the lubricant fill hole plug from the Fig. 24 Install Axle Housing Spreader
1 – AXLE HOUSING
differential housing cover.
2 – DOWEL
(3) Remove the differential housing cover and
3 – SAFETY HOLD DOWN
allow fluid to drain. 4 – SPECIAL TOOL W-129–B
(4) Remove axle shafts. 5 – TURNBUCKLE
(5) Note the installation reference letters stamped
on the bearing caps and housing machined sealing
surface (Fig. 23). (8) Install a Pilot Stud C-3288-B at the left side of
the differential housing. Attach Dial Indicator C-3339
to pilot stud. Load the indicator plunger against the
opposite side of the housing (Fig. 25) and zero the
indicator.
INSTALLATION
(1) Using tool C-3716-A with handle C-4171,
install differential side bearings (Fig. 31).
(2) Install differential in axle housing.
RING GEAR
Fig. 29 Differential Bearing Cap Reference Letters NOTE: The ring gear and pinion are serviced as a
1 – INSTALLATION REFERENCE LETTERS
matched set. Do not replace the ring gear without
2 – INSTALLATION REFERENCE LETTERS
replacing the pinion.
PINION GEAR
The ring and pinion gears are serviced in a
matched set. Do not replace the pinion gear without
replacing the ring gear.
REMOVAL
(1) Remove differential from the axle housing.
Fig. 32 Ring Gear Removal (2) Mark pinion yoke and propeller shaft for
1 – CASE installation alignment.
2 – RING GEAR
(3) Disconnect propeller shaft from pinion yoke.
3 – RAWHIDE HAMMER
Using suitable wire, tie propeller shaft to underbody.
(4) Using Holder 6958 to hold yoke, remove the
INSTALLATION pinion yoke nut and washer.
(5) Using Remover C–452 and Wrench C–3281,
CAUTION: Do not reuse the bolts that held the ring remove the pinion yoke from pinion shaft (Fig. 34).
gear to the differential case. The bolts can fracture (6) Remove the pinion gear from housing (Fig. 35).
causing extensive damage. Catch the pinion with your hand to prevent it from
falling and being damaged.
3 - 82 194 RBI AXLE XJ
REMOVAL AND INSTALLATION (Continued)
(7) Use a suitable pry tool or a slide hammer Fig. 37 Rear Bearing Cup Removal
mounted screw to remove the pinion shaft seal. 1 – DRIVER
(8) Remove oil slinger, if equipped, and front pin- 2 – HANDLE
ion bearing.
(9) Remove the front pinion bearing cup with
(12) Remove the rear bearing from the pinion with
Remover C-4345 and Handle C–4171 (Fig. 36).
Puller/Press C-293-PA and Adapters C-293-40 (Fig.
(10) Remove the rear bearing cup from housing
39).
(Fig. 37). Use Remover D-149 and Handle C–4171.
Place 4 adapter blocks so they do not damage
(11) Remove the collapsible preload spacer (Fig.
the bearing cage.
38).
XJ 194 RBI AXLE 3 - 83
REMOVAL AND INSTALLATION (Continued)
(13) Remove the depth shims from the pinion gear
shaft. Record the thickness of the depth shims.
INSTALLATION
(1) Apply Mopart Door Ease, or equivalent, stick
lubricant to outside surface of bearing cup.
(2) Install the pinion rear bearing cup with
Installer D-146 and Driver Handle C–4171 (Fig. 40).
Ensure cup is correctly seated.
ASSEMBLY
(1) Install the differential side gears and thrust Fig. 50 Pinion Mate Gear Removal
washers. 1 – THRUST WASHER
(2) Install the differential pinion gears and thrust 2 – SIDE GEAR
washers. 3 – PINION MATE GEAR
(3) Install the pinion mate shaft.
(4) Align the hole in the pinion mate shaft with
the hole in the differential case and install the pinion
mate shaft lock screw.
(5) Lubricate all differential components with
hypoid gear lubricant.
XJ 194 RBI AXLE 3 - 87
DISASSEMBLY AND ASSEMBLY (Continued)
TRAC-LOKY DIFFERENTIAL
The Trac–loky differential components are illus-
trated in (Fig. 51). Refer to this illustration during
repair service.
DISASSEMBLY
(1) Clamp Side Gear Holding Tool 6965 in a vise.
(2) Position the differential case on Side Gear
Holding Tool 6965 (Fig. 52).
(3) Remove ring gear, if necessary. Ring gear
removal is necessary only if the ring gear is to be
replaced. The Trac-loky differential can be serviced
with the ring gear installed.
(4) Remove the pinion gear mate shaft lock screw
(Fig. 53).
(5) Remove the pinion gear mate shaft. If neces-
sary, use a drift and hammer (Fig. 54).
(6) Install and lubricate Step Plate C-6960-3 (Fig.
55).
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
PINION DEPTH MEASUREMENT AND ADJUSTMENT (4) Place Arbor Disc 6732 on Arbor D-115-3 in posi-
Measurements are taken with pinion cups and pin- tion in axle housing side bearing cradles (Fig. 68).
ion bearings installed in housing. Take measure- Install differential bearing caps on Arbor Discs and
ments with a Pinion Gauge Set, Pinion Block 6735, tighten cap bolts. Refer to the Torque Specifications
Arbor Discs 6732, and Dial Indicator C-3339 (Fig. in this section.
66).
(1) Assemble Pinion Height Block 6739, Pinion NOTE: Arbor Discs 6732 have different step diame-
Block 6735, and rear pinion bearing onto Screw 6741 ters to fit other axle sizes. Pick correct size step for
(Fig. 66). axle being serviced.
(2) Insert assembled height gauge components,
(5) Assemble Dial Indicator C-3339 into Scooter
rear bearing and screw into axle housing through
Block D-115-2 and secure set screw.
pinion bearing cups (Fig. 67).
(3) Install front pinion bearing and Cone 6740
hand tight (Fig. 66).
XJ 194 RBI AXLE 3 - 93
ADJUSTMENTS (Continued)
Fig. 66 Pinion Gear Depth Gauge Tools—Typical (6) Place Scooter Block/Dial Indicator in position
1 – DIAL INDICATOR in axle housing so dial probe and scooter block are
2 – ARBOR flush against the surface of the pinion height block.
3 – PINION HEIGHT BLOCK Hold scooter block in place and zero the dial indica-
4 – CONE tor face to the pointer. Tighten dial indicator face
5 – SCREW lock screw.
6 – PINION BLOCK
(7) With scooter block still in position against the
7 – SCOOTER BLOCK
pinion height block, slowly slide the dial indicator
8 – ARBOR DISC
probe over the edge of the pinion height block.
Observe how many revolutions counterclockwise the
dial pointer travels (approximately 0.125 in.) to the
out-stop of the dial indicator.
(8) Slide the dial indicator probe across the gap
between the pinion height block and the arbor bar
with the scooter block against the pinion height block
(Fig. 69). When the dial probe contacts the arbor bar,
the dial pointer will turn clockwise. Bring dial
pointer back to zero against the arbor bar, do not
turn dial face. Continue moving the dial probe to the
crest of the arbor bar and record the highest reading.
If the dial indicator can not achieve the zero reading,
the rear bearing cup or the pinion depth gauge set is
not installed correctly.
(9) Select a shim equal to the dial indicator read-
ing plus the drive pinion gear depth variance number
etched in the face of the pinion gear (Fig. 64) using
Fig. 67 Pinion Height Block—Typical the opposite sign on the variance number. For exam-
1 – PINION BLOCK ple, if the depth variance is –2, add +0.002 in. to the
2 – PINION HEIGHT BLOCK dial indicator reading.
(10) Remove the pinion depth gauge components
from the axle housing
3 - 94 194 RBI AXLE XJ
ADJUSTMENTS (Continued)
DIFFERENTIAL BEARING PRELOAD AND GEAR (3) Install dummy side bearings D-348 on differen-
BACKLASH tial case.
Differential side bearing preload and gear backlash (4) Install differential case in axle housing.
is achieved by selective shims inserted between the (5) Insert Dummy Shims 8107 (0.118 in. (3.0 mm))
bearing cup and the axle housing. The proper shim starting point shims between the dummy bearing
thickness can be determined using slip-fit dummy and the axle housing (Fig. 71).
bearings D-348 in place of the differential side bear-
ings and a dial indicator C-3339. Before proceeding
with the differential bearing preload and gear back-
lash measurements, measure the pinion gear depth
and prepare the pinion gear for installation. Estab-
lishing proper pinion gear depth is essential to estab-
lishing gear backlash and tooth contact patterns.
After the overall shim thickness to take up differen-
tial side play is measured, the pinion gear is
installed, and the gear backlash shim thickness is
measured. The overall shim thickness is the total of
the dial indicator reading, starting point shim thick-
ness, and the preload specification added together.
The gear backlash measurement determines the
thickness of the shim used on the ring gear side of
the differential case. Subtract the gear backlash shim
thickness from the total overall shim thickness and
select that amount for the pinion gear side of the dif-
ferential (Fig. 70).
SHIM SELECTION
NOTE: It is difficult to salvage the differential side Fig. 71 Insert Starting Point Shims
bearings during the removal procedure. Install 1 – SPECIAL TOOL 8107
replacement bearings if necessary. 2 – AXLE HOUSING
3 – DIFFERENTIAL CASE
(1) Remove side bearings from differential case. 4 – SPECIAL TOOL D-348
(2) Install ring gear, if necessary, on differential
case and tighten bolts to specification.
XJ 194 RBI AXLE 3 - 95
ADJUSTMENTS (Continued)
(6) Install the marked bearing caps in their correct
positions. Install and snug the bolts.
(7) Using a dead-blow type mallet, seat the differ-
ential dummy bearings to each side of the axle hous-
ing (Fig. 72) and (Fig. 73).
SPECIFICATIONS
194 RBI AXLE
DESCRIPTION SPECIFICATION
Axle Type . . . . . . . . . . . . . . . Semi–Floating Hypoid
Lubricant . . . . . . . . SAE Thermally Stable 80W–90
Lubricant Trailer Tow . . . . . . . Synthetic 75W–140
Lube Capacity . . . . . . . . . . . . . . . 1.66 L (3.50 pts.) Adapter—C-293-40
Friction Modifier . . . . . . . . . . . . . 0.12 L (3.50 ozs.)
Axle Ratios . . . . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73
Differential Bearing Preload . . . 0.1 mm (0.008 in.)
Differential Side Gear Clearance . . . . . . 0–0.15 mm
(0–0.006 in.)
Ring Gear Diameter . . . . . . . . . 19.2 cm (7.562 in.)
Ring Gear Backlash . . 0–0.15 mm (0.005–0.008 in.)
Pinion Std. Depth . . . . . . . . . . 96.85 mm (3.813 in.)
Pinion Bearing Preload-Original
Bearings . . . . . . . . . . . . 1–2 N·m (10–20 in. lbs.)
Pinion Bearing Preload-New Bearings . . 1.5–4 N·m
(15–35 in. lbs.) Plug—SP-3289
194 RBI AXLE
DESCRIPTION TORQUE
Bolt, Diff. Cover . . . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bolt, Bearing Cap . . . . . . . . . . . 77 N·m (57 ft. lbs.)
Nut, Pinion . . . . . . . 271–474 N·m (200–350 ft. lbs.)
Screw, Pinion Mate Shaft Lock . . . . . . . . 16.25 N·m
(12 ft. lbs.)
Bolt, Ring Gear . . . . . . 95–122 N·m (70–90 ft. lbs.) Puller—C-452
Bolt, RWAL/ABS Sensor . . . . . . . 8 N·m (70 in. lbs.)
SPECIAL TOOLS
194 RBI AXLE
Wrench—C-3281
Puller—C-293-PA
Installer—C-3972-A
Adapter—C-293-39
3 - 100 194 RBI AXLE XJ
SPECIAL TOOLS (Continued)
Installer—D-130
Spanner—6958
Installer—D-146
Installer Screw—8112
Cup—8109 Remover—C-4345
Remover—D-149
Handle—C-4171
Installer—W-262
Driver—C-3716-A
XJ 194 RBI AXLE 3 - 101
SPECIAL TOOLS (Continued)
Installer—6436
Trac-lok Tool Set—6960
Holder—6965
Installer—6437
Puller—7794-A
Gauge Block—6735
Spreader—W-129-B
Guide Pin—C-3288-B
Hub Puller—6790
Dial Indicator—C-3339
XJ 8 1/4 REAR AXLE 3 - 103
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION threaded pin. Differential bearing preload and ring
gear backlash are set and maintained by threaded
8 1/4 AXLE adjusters at the outside of the differential housing.
Pinion bearing preload is set and maintained by the
DESCRIPTION use of a collapsible spacer.
The 8 1/4 inch axle housings consist of a cast iron Axles equipped with a Trac-Loky differential are
center section with axle tubes extending from either optional. A Trac-Lok differential has a one-piece dif-
side. The tubes are pressed into and welded to the ferential case, and the same internal components as
differential housing to form a one-piece axle housing a standard differential, plus two clutch disc packs.
(Fig. 1).
AXLE IDENTIFICATION
The axles have a vent hose to relieve internal pres-
sure caused by lubricant vaporization and internal The axle differential cover can be used for identifi-
expansion. cation of the axle (Fig. 2). A tag is also attached to
The axles are equipped with semi-floating axle the cover.
shafts, meaning vehicle loads are supported by the
axle shaft and bearings. The axle shafts are retained
OPERATION
by C-locks in the differential side gears. The axle receives power from the transmission/
The removable, stamped steel cover provides a transfer case through the rear propeller shaft. The
means for inspection and service without removing rear propeller shaft is connected to the pinion gear
the complete axle from the vehicle. which rotates the differential through the gear mesh
The 8 1/4 axle have a date tag and a gear ratio tag. with the ring gear bolted to the differential case. The
The tags are attached to the differential housing by a engine power is transmitted to the axle shafts
cover bolt. through the pinion mate and side gears. The side
The differential case is a one-piece design. The dif- gears are splined to the axle shafts.
ferential pinion mate shaft is retained with a
3 - 104 8 1/4 REAR AXLE XJ
DESCRIPTION AND OPERATION (Continued)
TRAC-LOKY DIFFERENTIAL
DESCRIPTION
In a standard differential, if one wheel spins, the
opposite wheel will generate only as much torque as
the spinning wheel.
In the Trac-loky differential, part of the ring gear
torque is transmitted through clutch packs which
contain multiple discs. The clutches will have radial
grooves on the plates, and concentric grooves on the
discs or bonded fiber material that is smooth in
Fig. 3 Differential Operation—Straight Ahead Driving appearance.
1 – IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED OPERATION
2 – PINION GEAR In operation, the Trac-loky clutches are engaged
3 – SIDE GEAR by two concurrent forces. The first being the preload
4 – PINION GEARS ROTATE WITH CASE
force exerted through Belleville spring washers
within the clutch packs. The second is the separating
forces generated by the side gears as torque is
applied through the ring gear (Fig. 5).
3 - 106 8 1/4 REAR AXLE XJ
DESCRIPTION AND OPERATION (Continued)
straight ahead during periods of unequal traction.
When one wheel looses traction, the clutch packs
transfer additional torque to the wheel having the
most traction. Trac-loky differentials resist wheel
spin on bumpy roads and provide more pulling power
when one wheel looses traction. Pulling power is pro-
vided continuously until both wheels loose traction. If
both wheels slip due to unequal traction, Trac-loky
operation is normal. In extreme cases of differences
of traction, the wheel with the least traction may
spin.
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting
tube mis-alignment.
Differential Cracked 1. Improper adjustment of the 1. Replace case and inspect gears and
differential bearings. bearings for further damage. Set differential
bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid excessive
vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid erratic use
of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with
the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with
the correct fluid type and quantity.
3. Excessive spinning of one 3. Replace scored gears. Inspect all gears,
wheel/tire. pinion bores, and shaft for damage. Service
as necessary.
3 - 108 8 1/4 REAR AXLE XJ
DIAGNOSIS AND TESTING (Continued)
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid type
and quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and
bearings for possible damage.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type
and quantity.
2. Improper ring gear and pinion 2. Check ring gear and pinion contact pattern.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear
and pinion.
4. Worn teeth on ring gear and/or 4. Replace ring gear and pinion.
pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap 8. Inspect differential components and replace
bolts. as necessary. Ensure that the bearing caps
are torqued tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
XJ 8 1/4 REAR AXLE 3 - 109
DIAGNOSIS AND TESTING (Continued)
(6) If rotating torque is less than 22 N·m (30 ft. (10) Install the fill hole plug and lower the vehicle.
lbs.) or more than 271 N·m (200 ft. lbs.) on either (11) Trac–loky differential equipped vehicles
wheel the unit should be serviced. should be road tested by making 10 to 12 slow figure-
eight turns. This maneuver will pump the lubricant
through the clutch discs to eliminate a possible chat-
SERVICE PROCEDURES ter noise complaint.
LUBRICANT CHANGE
(1) Raise and support the vehicle.
(2) Remove the lubricant fill hole plug from the
differential housing cover.
XJ 8 1/4 REAR AXLE 3 - 111
INSTALLATION
(1) Raise the axle with lifting device and align to
the leaf spring centering bolts.
(2) Install the spring clamps and spring brackets.
Refer to Group 2, Suspension, for proper procedures. Fig. 8 Pinion Mate Shaft Lock Screw
(3) Install shock absorbers and tighten nuts to 60 1 – LOCK SCREW
N·m (44 ft. lbs.) torque. 2 – PINION MATE SHAFT
(4) Install the stabilizer links. Tighten sway bar
links to 74 N·m (55 ft. lbs.). (7) Push axle shaft inward and remove axle shaft
(5) Connect the parking brake cables and cable C–lock from the axle shaft (Fig. 9).
brackets. (8) Remove axle shaft. Use care to prevent damage
(6) Install the brake drums. Refer to Group 5, to axle shaft bearing and seal, which will remain in
Brakes, for proper procedures. axle tube.
(7) Connect the brake hose to the axle junction (9) Inspect axle shaft seal for leakage or damage.
block. Refer to Group 5, Brakes, for proper proce- (10) Inspect roller bearing contact surface on axle
dures. shaft for signs of brinelling, galling and pitting. If
(8) Install axle vent hose. any of these conditions exist, the axle shaft and/or
(9) Align propeller shaft and pinion yoke reference bearing and seal must be replaced.
marks. Install universal joint straps and bolts.
Tighten to 19 N·m (14 ft. lbs.) torque. INSTALLATION
(10) Install the wheels and tires. (1) Lubricate bearing bore and seal lip with gear
(11) Add gear lubricant, if necessary. Refer to lubricant. Insert axle shaft through seal, bearing,
Lubricant Specifications in this section for lubricant and engage it into side gear splines.
requirements.
(12) Remove lifting device from axle and lower the NOTE: Use care to prevent shaft splines from dam-
vehicle. aging axle shaft seal lip.
3 - 112 8 1/4 REAR AXLE XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(2) Install the axle shaft bearing with Installer
NOTE: Do not install the original axle shaft seal. C-4198 and Handle C-4171 (Fig. 12). Ensure that the
Always install a new seal. bearing part number is against the installer. Verify
that the bearing in installed straight and the tool
(1) Wipe the axle tube bore clean. Remove any old fully contacts the axle tube when seating the bearing.
sealer or burrs from the tube.
XJ 8 1/4 REAR AXLE 3 - 113
REMOVAL AND INSTALLATION (Continued)
(3) Install a new axle seal with Installer C-4076-B
and Handle C-4735-1. When the tool contacts the
axle tube, the seal is installed to the correct depth.
(4) Coat the lip of the seal with axle lubricant for
protection prior to installing the axle shaft.
(5) Install the axle shaft.
RING GEAR
The ring gear and pinion are serviced in a matched
set. Do not replace the ring gear without replacing
the pinion.
REMOVAL
(1) Remove differential from axle housing.
(2) Place differential case in a suitable vise with
soft metal jaw protectors. (Fig. 22).
(3) Remove bolts holding ring gear to differential Fig. 22 Ring Gear Removal
case. 1 – CASE
(4) Using a soft hammer, drive ring gear from dif- 2 – RING GEAR
ferential case (Fig. 22). 3 – RAWHIDE HAMMER
INSTALLATION
(2) Position ring gear on the differential case and
CAUTION: Do not reuse the bolts that held the ring start two ring gear bolts. This will provide case-to-
gear to the differential case. The bolts can fracture ring gear bolt hole alignment.
causing extensive damage. (3) Invert the differential case in the vise.
(4) Install new ring gear bolts and alternately
(1) Invert the differential case. tighten to 102 N·m (75 ft. lbs.) torque (Fig. 23).
(5) Install differential in axle housing and verify
gear mesh and contact pattern.
XJ 8 1/4 REAR AXLE 3 - 117
REMOVAL AND INSTALLATION (Continued)
PINION GEAR
The ring gear and pinion are serviced in a matched
set. Do not replace the pinion without replacing the
ring gear.
REMOVAL
(1) Remove differential from the axle housing.
(2) Mark pinion yoke and propeller shaft for
installation alignment.
(3) Disconnect propeller shaft from pinion yoke.
Using suitable wire, tie propeller shaft to underbody.
(4) Using Yoke Holder 6719 to hold yoke and
Fig. 25 Remove Pinion Gear
remove the pinion yoke nut and washer.
1 – RAWHIDE HAMMER
(5) Using Remover C–452, remove the pinion yoke
from pinion shaft (Fig. 24).
(6) Partially install pinion nut onto pinion to pro- (12) Remove the collapsible preload spacer (Fig. 28).
tect the threads. (13) Remove the rear bearing from the pinion (Fig.
(7) Remove the pinion from housing (Fig. 25). 29) with Puller/Press C-293-PA and Adapters C-293-47.
Catch the pinion with your hand to prevent it from Place 4 adapter blocks so they do not damage
falling and being damaged. the bearing cage.
(8) Remove the pinion shaft seal with suitable pry (14) Remove the depth shims from the pinion
tool or slide-hammer mounted screw. shaft. Record the thickness of the depth shims.
(9) Remove oil slinger, if equipped, and front pin-
ion bearing. INSTALLATION
(10) Remove the front pinion bearing cup with (1) Apply Mopart Door Ease, or equivalent, stick
Remover C-4345 and Handle C–4171 (Fig. 26). lubricant to outside surface of bearing cup.
(11) Remove the rear bearing cup from housing (2) Install the pinion rear bearing cup (Fig. 30)
(Fig. 27). Use Remover C-4307 and Handle C–4171. with Installer C-4308 and Driver Handle C–4171.
3 - 118 8 1/4 REAR AXLE XJ
REMOVAL AND INSTALLATION (Continued)
TRAC-LOKY DIFFERENTIAL
The Trac–loky differential components are illus-
trated in (Fig. 38). Refer to this illustration during
repair service.
DISASSEMBLY
(1) Clamp Side Gear Holding Tool 8138 in a vise.
(2) Position the differential case on Side Gear
Holding Tool 8138 (Fig. 39).
Fig. 37 Pinion Mate Gear Removal (3) Remove ring gear, if necessary. Ring gear
1 – THRUST WASHER removal is necessary only if the ring gear is to be
2 – SIDE GEAR replaced. The Trac-loky differential can be serviced
3 – PINION MATE GEAR with the ring gear installed.
Fig. 40 Mate Shaft Lock Screw (8) Position a small screw driver in slot of
1 – LOCK SCREW
Threaded Adapter 8140-1 (Fig. 43) to prevent adapter
2 – PINION MATE SHAFT
from turning.
(9) Tighten forcing screw tool 122 N·m (90 ft. lbs.)
(5) Remove the pinion mate shaft. If necessary, use maximum to compress Belleville springs in clutch
a drift and hammer (Fig. 41). packs (Fig. 44).
(6) Install and lubricate Step Plate 8140–2 (Fig. (10) Using an appropriate size feeler gauge,
42). remove thrust washers from behind the differential
(7) Assemble Threaded Adapter 8140-1 into top pinions (Fig. 45).
side gear. Thread Forcing Screw 6960-4 into adapter (11) Insert Turning Bar 6960-2 in case (Fig. 46).
until it becomes centered in adapter plate.
XJ 8 1/4 REAR AXLE 3 - 123
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 47 Side Gear & Clutch Disc Removal Fig. 48 Clutch Disc Pack
1 – DIFFERENTIAL CASE 1 – CLUTCH PACK
2 – RETAINER 2 – RETAINER
3 – SIDE GEAR AND CLUTCH DISC PACK 3 – SIDE GEAR
4 – RETAINER
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
ADJUSTMENTS
8 1/4 AXLE PINION GEAR DEPTH
GENERAL INFORMATION
Ring gears and pinions are supplied as matched
sets only. The identifying numbers for the ring gear
and pinion are etched into the face of each gear (Fig.
51). A plus (+) number, minus (–) number or zero (0)
is etched into the face of the pinion. This number is
the amount (in thousandths of an inch) the depth
varies from the standard depth setting of a pinion
etched with a (0). The standard depth provides the
best gear tooth contact pattern. Refer to Backlash
and Contact Pattern Analysis paragraph in this sec-
tion for additional information. Fig. 52 Shim Locations
1 – AXLE HOUSING
2 – COLLAPSIBLE SPACER
3 – PINION BEARING
4 – PINION DEPTH SHIM
5 – PINION GEAR
6 – BEARING CUP
SPECIAL TOOLS
8 1/4 AXLES
Puller, Hub—6790
SPECIFICATIONS
8 1/4 INCH AXLE
Axle Type . . . . . . . . . . . . . . . Semi-floating, hypoid
Lubricant . . . . . . . . . . . . . . . . . . . . . . SAE 80W-90
Lube Capacity . . . . . . . . . . . . . . . . 2.08 L (4.4 pts.)
Trac-Lok Additive . . . . . . . . . . . . . . . 118 ml (4 oz.)
Axle Ratio . . . . . . . . . . . . . . . . . . . . 3.07, 3.55,.4.10
Differential
Case Clearance . . . . . . . . . . . . . 0.12 mm (0.005 in.) Installer—C-4198
Case Flange Runout . . . . . . . . 0.076 mm (0.003 in.)
Ring Gear
Diameter . . . . . . . . . . . . . . . . . . 20.95 cm (8.25 in.)
Backlash . . . . . . . . . 0.12-0.20 mm (0.005-0.008 in.)
Runout . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 in.)
Pinion Bearing
Preload-Used Bearings . . . . 1-2 N·m (10-20 in.lbs.)
Preload-New Bearings . . . . . 1-5 N·m (10-30 in.lbs.)
3 - 132 8 1/4 REAR AXLE XJ
SPECIAL TOOLS (Continued)
Puller—C-452
Handle—C-4171
Installer—C-3718
Installer—C-4076-B
Adjustment Rod—C-4164
Handle—C-4735-1
Puller/Press—C-293–PA
Holder—6719
Adapters—C-293-48
XJ 8 1/4 REAR AXLE 3 - 133
SPECIAL TOOLS (Continued)
Plug—SP-3289 Installer—C-4345
Adapters—C-293-47
Remover—C-4307
Installer—C-4308
Installer—C-4340
Installer—D-130
Holder—8138
Installer—6448
3 - 134 8 1/4 REAR AXLE XJ
SPECIAL TOOLS (Continued)
Trac-lokY Tools—8140
Pinion Gauge Block—8540
Trac-lokY Tools—6960
Arbor Discs—8541
BRAKES
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page page
FRONT DISC BRAKES pressure exerted against the caliper piston and
within the caliper bore will be equal (Fig. 2).
DESCRIPTION Fluid pressure applied to the piston is transmitted
The calipers are a single piston type. The calipers directly to the inboard brake shoe. This forces the
are free to slide laterally, this allows continuous com- shoe lining against the inner surface of the disc
pensation for lining wear. brake rotor. At the same time, fluid pressure within
the piston bore forces the caliper to slide inward on
OPERATION the mounting bolts. This action brings the outboard
When the brakes are applied fluid pressure is brake shoe lining into contact with the outer surface
exerted against the caliper piston. The fluid pressure of the disc brake rotor.
is exerted equally and in all directions. This means
XJ BRAKES 5-5
DESCRIPTION AND OPERATION (Continued)
BRAKE NOISES
Some brake noise is common with rear drum
brakes and on some disc brakes during the first few
stops after a vehicle has been parked overnight or
stored. This is primarily due to the formation of trace
corrosion (light rust) on metal surfaces. This light
corrosion is typically cleared from the metal surfaces
after a few brake applications causing the noise to
subside.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to linings that
are wet or contaminated with brake fluid, grease, or
oil. Glazed linings and rotors with hard spots can
also contribute to squeak. Dirt and foreign material Fig. 6 Brake Lamp Switch Terminal Identification
embedded in the brake lining will also cause squeak/ 1 – TERMINAL PINS
squeal. 2 – PLUNGER TEST POSITIONS
A very loud squeak or squeal is frequently a sign of
severely worn brake lining. If the lining has worn SWITCH CONTINUITY TEST
through to the brake shoes in spots, metal-to-metal
contact occurs. If the condition is allowed to continue, NOTE: Disconnect switch harness before testing
rotors and drums can become so scored that replace- switch continuity.
ment is necessary.
With the switch plunger retracted, attach test
BRAKE CHATTER leads to terminal pins 1 and 2. Replace switch if
Brake chatter is usually caused by loose or worn meter indicates no continuity.
components, or glazed/burnt lining. Rotors with hard With the switch plunger retracted, attach test
spots can also contribute to chatter. Additional causes leads to terminal pins 3 and 4. Replace switch if
of chatter are out-of-tolerance rotors, brake lining not meter indicates no continuity.
securely attached to the shoes, loose wheel bearings With the switch plunger extended, attach test
and contaminated brake lining. leads to terminal pins 5 and 6. Replace switch if
meter indicates no continuity.
THUMP/CLUNK NOISE
Thumping or clunk noises during braking are fre- RED BRAKE WARNING LAMP
quently not caused by brake components. In many The red brake warning lamp will illuminate under
cases, such noises are caused by loose or damaged the following conditions:
steering, suspension, or engine components. However, • Self test at start-up.
calipers that bind on the slide surfaces can generate • Parking brakes are applied.
a thump or clunk noise. In addition, worn out, • Leak in front/rear brake hydraulic circuit.
improperly adjusted, or improperly assembled rear If the red light remains on after start-up, first ver-
brake shoes can also produce a thump noise. ify that the parking brakes are fully released. Then
check pedal action and fluid level. If the lamp on and
the brake pedal is low this indicates the pressure dif-
5 - 10 BRAKES XJ
DIAGNOSIS AND TESTING (Continued)
ferential switch and valve have been actuated due to
a leak in the hydraulic system.
On models with ABS brakes, the amber warning
lamp only illuminates during the self test and when
an ABS malfunction has occurred. The ABS lamp
operates independently of the red warning lamp.
For additional information refer to Group 8W.
SERVICE PROCEDURES
Fig. 10 Measuring Rotor Thickness BRAKE FLUID LEVEL
1 – MICROMETER
Always clean the master cylinder reservoir and cap
2 – ROTOR
before adding fluid. This will prevent dirt from fall-
ing in the reservoir and contaminating the brake
the drum if machining causes the drum to exceed the fluid.
maximum allowable diameter. The reservoir has a ADD and a FULL mark on the
side (Fig. 11) fill to the FULL mark.
BRAKE LINE AND HOSES
Flexible rubber hose is used at both front brakes
and at the rear axle junction block. Inspect the hoses
whenever the brake system is serviced, at every
engine oil change, or whenever the vehicle is in for
service.
Inspect the hoses for surface cracking, scuffing, or
worn spots. Replace any brake hose immediately if
the fabric casing of the hose is exposed due to cracks
or abrasions.
Also check brake hose installation. Faulty installa-
tion can result in kinked, twisted hoses, or contact
with the wheels and tires or other chassis compo-
nents. All of these conditions can lead to scuffing,
cracking and eventual failure.
The steel brake lines should be inspected periodi-
cally for evidence of corrosion, twists, kinks, leaks, or Fig. 11 Master Cylinder Fluid Level
other damage. Heavily corroded lines will eventually 1 – FLUID LEVEL MARKS
rust through causing leaks. In any case, corroded or 2 – RESERVOIR
damaged brake lines should be replaced.
Factory replacement brake lines and hoses are rec-
ommended to ensure quality, correct length and supe- MASTER CYLINDER BLEEDING
rior fatigue life. Care should be taken to make sure A new master cylinder should be bled before instal-
that brake line and hose mating surfaces are clean lation on the vehicle. Required bleeding tools include
and free from nicks and burrs. Also remember that bleed tubes and a wood dowel to stroke the pistons.
right and left brake hoses are not interchangeable. Bleed tubes can be fabricated from brake line.
Use new copper seal washers at all caliper connec-
tions. Be sure brake line connections are properly BLEEDING PROCEDURE
made (not cross threaded) and tightened to recom- (1) Mount master cylinder in vise.
mended torque. (2) Attach bleed tubes to cylinder outlet ports.
Then position each tube end into reservoir (Fig. 12).
XJ BRAKES 5 - 13
SERVICE PROCEDURES (Continued)
(3) Fill reservoir with fresh brake fluid. (3) Attach one end of bleed hose to bleed screw
(4) Press cylinder pistons inward with wood dowel. and insert opposite end in glass container partially
Then release pistons and allow them to return under filled with brake fluid (Fig. 13). Be sure end of bleed
spring pressure. Continue bleeding operations until hose is immersed in fluid.
air bubbles are no longer visible in fluid.
INSTALLATION
(1) Pull switch plunger all the way out to fully
extended position.
(2) Connect harness wires to switch.
(3) Press and hold brake pedal in applied position.
(4) Install switch as follows: Align tab on switch
with notch in switch bracket. Then insert switch in
Fig. 16 ISO Flaring
bracket and turn it clockwise about 30° to lock it in
1 – ADAPTER
place.
2 – LUBRICATE HERE
3 – PILOT
(5) Release brake pedal. Then pull pedal lightly
4 – FLUSH WITH BAR rearward. Pedal will set plunger to correct position
5 – TUBING as pedal pushes plunger into switch body. Switch will
6 – BAR ASSEMBLY make ratcheting sound as it self adjusts.
COMBINATION VALVE
NOTE: The combination valve is not repairable. The
valve is serviced as an assembly only.
REMOVAL
(1) Remove air cleaner cover and hose for access to
valve.
Fig. 20 Combination Valve
(2) Unsnap connector lock tabs and disconnect dif-
1 – COMBINATION VALVE
ferential pressure switch wire at combination valve
2 – MASTER CYLINDER
(Fig. 19). Do not pull switch wire to disconnect.
(3) Disconnect brake lines at combination valve
(Fig. 20). (4) Connect wire to pressure differential switch.
(4) Remove mounting nut and remove valve. (5) Bleed base brakes.
INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
DISC BRAKE ROTOR (6) Remove hold-down springs, retainers and pins
with standard retaining spring tool.
REMOVAL (7) Install spring clamps on wheel cylinders to
(1) Remove wheel and tire assemble. hold pistons in place.
(2) Remove caliper. (8) Remove adjuster lever, adjuster screw and
(3) Remove retainers securing rotor to hub studs spring.
(Fig. 33). (9) Remove adjuster cable and cable guide.
(4) Remove rotor from hub. (10) Remove brake shoes and parking brake strut.
(5) If rotor shield requires service, remove front (11) Disconnect cable from parking brake lever and
hub and bearing assembly. remove lever.
INSTALLATION
(1) Clean support plate with brake cleaner.
(2) If new drums are being installed, remove pro-
tective coating with carburetor cleaner followed by
final rinse with brake cleaner.
(3) Clean and lubricate anchor pin with light coat
of Mopar multi-mileage grease.
(4) Apply Mopar multi-mileage grease to brake
shoe contact surfaces of support plate (Fig. 35).
(5) Lubricate adjuster screw threads and pivot
with spray lube.
(6) Attach parking brake lever to secondary brake
shoe. Use new washer and U-clip to secure lever.
(7) Remove wheel cylinder clamps.
(8) Attach parking brake cable to lever.
Fig. 33 Rotor & Hub (9) Install brake shoes on support plate. Secure
1 – ROTOR shoes with new hold-down springs, pins and retain-
2 – RETAINER ers.
3 – BEARING NUT
(10) Install parking brake strut and spring.
4 – NUT LOCK
(11) Install guide plate and adjuster cable on
5 – COTTER PIN
6 – WASHER
anchor pin.
(12) Install primary and secondary return springs.
(13) Install adjuster cable guide on secondary
INSTALLATION shoe.
(1) If new rotor is being installed, remove protec- (14) Lubricate and assemble adjuster screw.
tive coating from rotor surfaces with carburetor (15) Install adjuster screw, spring and lever and
cleaner. connect to adjuster cable.
(2) Install rotor on hub. (16) Adjust shoes to drum.
(3) Install caliper. (17) Install wheel/tire assemblies and lower vehi-
(4) Install wheel and tire assembly. cle.
(18) Verify firm brake pedal before moving vehicle.
DRUM BRAKE SHOES
WHEEL CYLINDER
REMOVAL
(1) Raise vehicle and remove rear wheels. REMOVAL
(2) Remove and discard spring nuts securing (1) Remove wheel and tire assembly.
drums to wheel studs. (2) Remove brake drum.
(3) Remove brake drums. If drums prove difficult (3) Disconnect wheel cylinder brake line.
to remove, retract brake shoes. Remove access plug (4) Remove brake shoe return springs and move
at the rear of backing plate and back off adjuster shoes out of engagement with cylinder push rods.
screw with brake tool and screwdriver. (5) Remove cylinder attaching bolts and remove
(4) Remove U-clip and washer securing adjuster cylinder from support plate.
cable to parking brake lever (Fig. 34).
(5) Remove primary and secondary return springs
from anchor pin with brake spring pliers.
5 - 22 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Apply bead of silicone sealer around cylinder
mounting surface of support plate.
(2) Install cylinder mounting bolts and tighten to
20 N·m (15 ft. lbs.).
(3) Connect brake line to cylinder.
(4) Install brake shoe return spring.
(5) Install brake drum.
(6) Install wheel and tire assembly.
(7) Bleed base brake system.
INSTALLATION
(1) Apply bead of silicone sealer around axle
mounting surface of support plate.
(2) Install support plate on axle flange. Tighten
attaching bolts to 115 N·m (85 ft. lbs.).
(3) Apply bead of silicone sealer around wheel cyl-
inder mounting surface and install wheel cylinder.
(4) Install brake line in wheel cylinder.
(5) Install parking brake cable in support plate.
(6) Install axle shaft, refer to Group 3 for proce-
Fig. 36 Parking Brake Cables
dure.
1 – REAR CABLES
(7) Connect parking brake cable to lever on sec- 2 – EQUALIZER
ondary shoe and install brake shoes on support plate. 3 – FRONT CABLE
(8) Adjust brake shoes to drum with brake gauge. 4 – TENSIONER ROD
(9) Install brake drum and wheel and tire assem-
bly.
(10) Bleed brake system.
INSTALLATION
(1) Install new cables in backing plates. Be sure
cable retainer is seated.
(2) Attach cable to lever on brake shoe and install
brake shoe on backing plate.
(3) Adjust brake shoes to drum with brake gauge.
Fig. 37 Cable Retainer
(4) Install brake drums and wheels.
1 – CABLE RETAINER
(5) Install cables into the cable bracket and insure
2 – REAR CABLE
retainers are seated in the bracket. 3 – WORM DRIVE HOSE CLAMP
(6) Engage the cable ends into the equalizer and
install equalizer nut.
(7) Adjust parking brakes. PARKING BRAKE LEVER
The center console must be removed to service the
parking brake lever. Refer to Group 23 Interior Com-
ponents for service procedures.
5 - 24 BRAKES XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Release parking brakes.
(2) Raise vehicle.
(3) Remove adjusting nut from tensioner rod at the
equalizer (Fig. 38).
Fig. 38 Parking Brake Equalizer (10) Verify correct parking brake operation.
1 – REAR CABLES
2 – EQUALIZER
3 – FRONT CABLE DISASSEMBLY AND ASSEMBLY
4 – TENSIONER ROD
MASTER CYLINDER RESERVOIR
(4) Lower vehicle.
REMOVAL
(5) Disengage front cable from the cable lever.
(1) Remove reservoir cap and empty fluid into
(6) Compress cable retainer with worm drive hose
drain container.
clamp and remove the cable from the parking brake
(2) Remove pins that retain reservoir to master
lever base.
cylinder. Use hammer and pin punch to remove pins
(7) Disconnect parking brake lamp switch wire
(Fig. 40).
(Fig. 39).
(8) Remove parking brake lever assembly mount-
ing bolts (Fig. 39).
(9) Remove lever assembly.
(10) Remove parking brake lamp switch.
INSTALLATION
(1) Install parking brake lamp switch.
(2) Position lever assembly on floorpan and install
lever mounting bolts.
(3) Tighten lever mounting bolts to 10 to 14 N·m
(7 to 10 ft. lbs.).
(4) Insert front cable through the parking brake
lever base. Insure the cable retainer is seated into
the base.
(5) Attach the front cable to the cable lever (Fig.
39).
(6) Connect parking brake lamp switch wire. Fig. 40 Reservoir Retaining Pins
(7) Raise vehicle. 1 – PIN PUNCH
(8) Install adjusting nut to the tensioner rod and 2 – RESERVOIR
adjust parking brakes. 3 – BODY
4 – ROLL PINS
(9) Lower vehicle.
XJ BRAKES 5 - 25
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Clamp cylinder body in vise with brass protec-
tive jaws.
(4) Loosen reservoir from grommets with pry tool
(Fig. 41).
(4) Remove caliper piston with short bursts of Fig. 46 Caliper Piston Removal
low pressure compressed air. Direct air through fluid 1 – AIR GUN
inlet port and ease piston out of bore (Fig. 46). 2 – CALIPER PISTON
3 – PADDING MATERIAL
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.
(1) Lubricate caliper piston bore, new piston seal (4) Install new piston seal into seal groove with
and piston with clean brake fluid. finger (Fig. 51).
(2) Lubricate caliper bushings and interior of (5) Install new dust boot on caliper piston and seat
bushing boots with silicone grease. boot in piston groove (Fig. 52).
(3) Install bushing boots in caliper, then insert (6) Press piston into caliper bore by hand, use a
bushing into boot and push bushing into place (Fig. turn and push motion to work piston into seal (Fig.
50). 53).
(7) Press caliper piston to bottom of bore.
XJ BRAKES 5 - 27
DISASSEMBLY AND ASSEMBLY (Continued)
ADJUSTMENT SPECIFICATIONS
(1) Raise vehicle.
(2) Back off tensioner adjusting nut to create slack BRAKE FLUID
in cables. The brake fluid used in this vehicle must conform
(3) Remove rear wheel/tire assemblies and remove to DOT 3 specifications and SAE J1703 standards.
brake drums. No other type of brake fluid is recommended or
approved for usage in the vehicle brake system. Use
5 - 32 BRAKES XJ
SPECIFICATIONS (Continued)
only Mopar brake fluid or an equivalent from a SPECIAL TOOLS
tightly sealed container.
BASE BRAKES
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.
ANTILOCK BRAKES
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION would in a vehicle without ABS. The HCU compo-
nents are not activated.
ANTILOCK BRAKE SYSTEM During antilock braking fluid pressure is modu-
lated according to wheel speed, degree of slip and
DESCRIPTION rate of deceleration. A sensor at each wheel converts
The purpose of the antilock system is to prevent wheel speed into electrical signals. These signals are
wheel lockup during periods of high wheel slip. Pre- transmitted to the CAB for processing and determi-
venting lockup helps maintain vehicle braking action nation of wheel slip and deceleration rate.
and steering control. The ABS system has three fluid pressure control
The antilock CAB activates the system whenever channels. The front brakes are controlled separately
sensor signals indicate periods of high wheel slip. and the rear brakes in tandem. A speed sensor input
High wheel slip can be described as the point where signal indicating a high slip condition activates the
wheel rotation begins approaching 20 to 30 percent of CAB antilock program. Two solenoid valves are used
actual vehicle speed during braking. Periods of high in each antilock control channel. The valves are all
wheel slip occur when brake stops involve high pedal located within the HCU valve body and work in pairs
pressure and rate of vehicle deceleration. to either increase, hold, or decrease apply pressure as
Battery voltage is supplied to the CAB ignition ter- needed in the individual control channels. The sole-
minal when the ignition switch is turned to Run posi- noid valves are not static during antilock braking.
tion. The CAB performs a system initialization They are cycled continuously to modulate pressure.
procedure at this point. Initialization consists of a Solenoid cycle time in antilock mode can be mea-
static and dynamic self check of system electrical sured in milliseconds.
components.
The static check occurs after the ignition switch is CONTROLLER ANTILOCK BRAKES
turned to Run position. The dynamic check occurs
when vehicle road speed reaches approximately 30 DESCRIPTION
kph (18 mph). During the dynamic check, the CAB The CAB is mounted to the HCU and operates the
briefly cycles the pump and solenoids to verify oper- ABS system (Fig. 1) separate from other vehicle elec-
ation. trical circuits.
If an ABS component exhibits a fault during ini-
tialization, the CAB illuminates the amber warning OPERATION
light and registers a fault code in the microprocessor The CAB voltage source is through the ignition
memory. switch in the RUN position. The CAB contains dual
OPERATION
During normal braking, the master cylinder, power
booster and wheel brake units all function as they
5 - 34 BRAKES XJ
DESCRIPTION AND OPERATION (Continued)
microprocessors. A logic block in each microprocessor power booster operate the same as a vehicle without
receives identical sensor signals. These signals are an ABS brake system.
processed and compared simultaneously. The CAB During antilock braking, solenoid valve pressure
contains a self check program that illuminates the modulation occurs in three stages, pressure increase,
ABS warning light when a system fault is detected. pressure hold, and pressure decrease. The valves are
Faults are stored in a diagnostic program memory all contained in the valve body portion of the HCU.
and are accessible with the DRB scan tool. ABS
faults remain in memory until cleared, or until after PRESSURE DECREASE
the vehicle is started approximately 50 times. Stored The outlet valve is opened and the inlet valve is
faults are not erased if the battery is disconnected. closed during the pressure decrease cycle.
A pressure decrease cycle is initiated when speed
sensor signals indicate high wheel slip at one or
more wheels. At this point, the CAB closes the inlet
then opens the outlet valve, which also opens the
return circuit to the accumulators. Fluid pressure is
allowed to bleed off (decrease) as needed to prevent
wheel lock.
Once the period of high wheel slip has ended, the
CAB closes the outlet valve and begins a pressure
increase or hold cycle as needed.
PRESSURE HOLD
Both solenoid valves are closed in the pressure
hold cycle. Fluid apply pressure in the control chan-
nel is maintained at a constant rate. The CAB main-
tains the hold cycle until sensor inputs indicate a
Fig. 1 Controller Antilock Brakes pressure change is necessary.
1 – HCU
2 – MOTOR PRESSURE INCREASE
3 – CAB The inlet valve is open and the outlet valve is
closed during the pressure increase cycle. The pres-
sure increase cycle is used to counteract unequal
HYDRAULIC CONTROL UNIT wheel speeds. This cycle controls re-application of
fluid apply pressure due to changing road surfaces or
DESCRIPTION wheel speed.
The HCU consists of a valve body, pump motor,
and wire harness (Fig. 1). WHEEL SPEED SENSORS AND TONE WHEEL
OPERATION DESCRIPTION
Accumulators in the valve body store extra fluid A speed sensor is used at each wheel. The front
released to the system for ABS mode operation. The sensors are mounted to the steering knuckles. The
pump provides the fluid volume needed and is oper- rear sensors at the outboard end of the axle.
ated by a DC type motor. The motor is controlled by
the CAB. OPERATION
The valves modulate brake pressure during The sensors convert wheel speed into a small AC
antilock braking and are controlled by the CAB. electrical signal. This signal is transmitted to the
The HCU provides three channel pressure control CAB. The CAB converts the AC signal into a digital
to the front and rear brakes. One channel controls signal for each wheel. This voltage is generated by
the rear wheel brakes in tandem. The two remaining magnetic induction when a tone wheel passes by the
channels control the front wheel brakes individually. stationary magnet of the wheel speed sensor.
During antilock braking, the solenoid valves are A gear type tone ring serves as the trigger mecha-
opened and closed as needed. The valves are not nism for each sensor. The tone rings are mounted at
static. They are cycled rapidly and continuously to the outboard ends of the front and rear axle shafts.
modulate pressure and control wheel slip and decel- Different sensors are used at the front and rear
eration. wheels (Fig. 2). The front/rear sensors have the same
During normal braking, the HCU solenoid valves electrical values but are not interchangeable. The
and pump are not activated. The master cylinder and
XJ BRAKES 5 - 35
DESCRIPTION AND OPERATION (Continued)
sensors have a resistance between 900 and 1300 OPERATION
ohms.
PRESSURE DIFFERENTIAL VALVE
The pressure differential switch is connected to the
brake warning light. The switch is actuated by move-
ment of the switch valve. The switch monitors fluid
pressure in the separate front/rear brake hydraulic
circuits.
A decrease or loss of fluid pressure in either
hydraulic circuit will cause the switch valve to shut-
tle to the low pressure side. Movement of the valve
pushes the switch plunger upward. This action closes
the switch internal contacts completing the electrical
circuit to the red warning light. The switch valve will
remain in an actuated position until repairs to the
brake system are made.
(7) Remove brake drum. Fig. 9 Setting Air Gap On Original Rear Sensor
(8) Remove clips securing sensor wires to brake 1 – WHEEL SPEED SENSOR
lines, rear axle and, brake hose. 2 – BRASS FEELER GAUGE
(9) Unseat sensor wire support plate grommet. 3 – TONE RING
(10) Remove bolt attaching sensor to bracket and
remove sensor (Fig. 8). Then tighten sensor bolt to 13 N·m (115 in. lbs.). Cor-
rect air gap will be established as tone ring rotates
INSTALLATION and peels spacer off sensor face.
(1) If original sensor is being installed, remove (7) Route sensor wires to rear seat area.
any remaining pieces of cardboard spacer from sen- (8) Feed sensor wires through floorpan access hole
sor pickup face. Use dry shop towel only to remove and seat sensor grommets in floorpan.
old spacer material. (9) Verify that rear sensor wires are secured to
(2) Insert sensor wire through support plate hole. rear brake hose and axle with clips. Verify that wire
Then seat sensor grommet in support plate. is clear of rotating components.
(3) Apply Mopar Lock N’ Seal or Loctite t 242 to (10) Install brake drum and wheel and tire assem-
original sensor bolt. Use new bolt if original is worn bly.
or damaged. (11) Lower vehicle.
(4) Install sensor bolt finger tight only at this (12) Connect sensor wire to harness connector.
time. Then reposition carpet and fold rear seat down.
(5) If original rear sensor was installed, adjust
sensor air gap to 0.92-1.275 mm (0.036-0.05 in.). Use G-SWITCH
feeler gauge to measure air gap (Fig. 9). Tighten sen-
sor bolt to 13 N·m (115 in. lbs.). REMOVAL
(6) If new sensor was installed, push cardboard (1) Raise and fold rear seat assembly forward for
spacer on sensor face against tone ring (Fig. 10). access to sensor.
XJ BRAKES 5 - 39
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
CAUTION: The mercury switch (inside the
G-switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig.
12).
CLUTCH
TABLE OF CONTENTS
page page
OPERATION
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate Fig. 1 Engine Powerflow
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage.
6-2 CLUTCH XJ
DESCRIPTION AND OPERATION (Continued)
The clutch master cylinder push rod is connected
to the clutch pedal. When the clutch pedal is
depressed, the slave cylinder is operated by the
clutch master cylinder mounted on the dash panel.
The release fork is actuated by the hydraulic slave
cylinder mounted on the transmission housing. The
release bearing is operated by a release fork pivoting
on a ball stud mounted in the transmission housing.
The release bearing then depresses the pressure
plate spring fingers, thereby releasing pressure on
the clutch disc and allowing the engine crankshaft to
spin independently of the transmission input shaft
(Fig. 2).
Fig. 3 Flywheel
1 – CRANKSHAFT
2 – RING GEAR
3 – FLYWHEEL
OPERATION
The flywheel serves to dampen the engine firing
pulses. The heavy weight of the flywheel relative to
the rotating mass of the engine components serves to
stabilize the flow of power to the remainder of the
drivetrain. The crankshaft has the tendency to
attempt to speed up and slow down in response to
the cylinder firing pulses. The flywheel dampens
these impulses by absorbing energy when the crank-
shaft speeds and releasing the energy back into the
system when the crankshaft slows down.
CLUTCH DISC
DESCRIPTION
Fig. 2 Clutch Operation The clutch disc friction material is riveted to the
1 – FLYWHEEL disc hub (Fig. 4). The hub bore is splined for installa-
2 – PRESSURE PLATE FINGERS tion on the transmission input shaft. The clutch disc
3 – PIVOT POINT has cushion springs in the disc hub to dampen disc
4 – RELEASE BEARING PUSHED IN vibrations during application and release of the clutch.
5 – CLUTCH DISC ENGAGED
6 – CLUTCH DISC ENGAGED
7 – RELEASE BEARING
OPERATION
The clutch disc is held onto the surface of the fly-
wheel by the force exerted by the pressure plate’s dia-
FLYWHEEL phragm spring. The friction material of the clutch disc
then transfers the engine torque from the flywheel and
DESCRIPTION pressure plate to the input shaft of the transmission.
The flywheel (Fig. 3) is a heavy plate bolted to the
rear of the crankshaft. The flywheel incorporates the CLUTCH PRESSURE PLATE
ring gear around the outer circumference to mesh
with the starter to permit engine cranking. The rear DESCRIPTION
face of the flywheel serves as the driving member to The clutch pressure plate assembly is a diaphragm
the clutch disc. type with a one-piece spring and multiple release fin-
gers (Fig. 5). The pressure plate release fingers are
preset during manufacture and are not adjustable.
The assembly also contains the cover, pressure plate,
and fulcrum components.
XJ CLUTCH 6-3
DESCRIPTION AND OPERATION (Continued)
OPERATION
The clutch pressure plate assembly clamps the
clutch disc against the flywheel. When the release
bearing is depressed by the shift fork, the pressure
exerted on the clutch disc by the pressure plate
spring is decreased. As additional force is applied,
the bearing presses the diaphragm spring fingers
inward on the fulcrums. This action moves the pres-
sure plate rearward relieving clamp force on the disc.
The clutch disc is disengaged and freewheeling at
this point.
OPERATION
The release bearing is operated by a release fork in
the clutch housing. Slave cylinder force causes the
release lever to move the release bearing into contact
with the diaphragm spring. As additional force is
applied, the bearing presses the diaphragm spring
Fig. 5 Clutch Pressure Plate-Typical fingers inward on the fulcrums. This action moves
1 – COVER the pressure plate rearward relieving clamp force on
2 – RELEASE FINGERS the disc. Releasing pedal pressure removes clutch
3 – PRESSURE PLATE hydraulic pressure. The release bearing then moves
away from the diaphragm spring which allows the
pressure plate to exert clamping force on the clutch
disc.
6-4 CLUTCH XJ
DESCRIPTION AND OPERATION (Continued)
CLUTCH CONTAMINATION of any clutch component will cause grab, chatter and
Fluid contamination is a frequent cause of clutch improper clutch release.
malfunctions. Oil, water, or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter, CLUTCH HOUSING MISALIGNMENT
slip and grab. Clutch housing alignment is important to proper
During inspection, note if any components are con- clutch operation. The housing maintains alignment
taminated with oil, hydraulic fluid, or water/road between the crankshaft and transmission input
splash. shaft. Misalignment can cause clutch noise, hard
Oil contamination indicates a leak at either the shifting, incomplete release and chatter. It can also
rear main seal or transmission input shaft. Oil leak- result in premature wear of the pilot bearing, cover
age produces a residue of oil on the housing interior release fingers and clutch disc. In severe cases, mis-
and on the clutch cover and flywheel. Heat buildup alignment can also cause premature wear of the
caused by slippage between the cover, disc and fly- transmission input shaft and front bearing.
wheel, can sometimes bake the oil residue onto the Housing misalignment is generally caused by
components. The glaze-like residue ranges in color incorrect seating on the engine or transmission, loose
from amber to black. housing bolts, missing alignment dowels, or housing
Road splash contamination means dirt/water is damage. Infrequently, misalignment may also be
entering the clutch housing due to loose bolts, hous- caused by housing mounting surfaces that are not
ing cracks, or through hydraulic line openings. Driv- completely parallel. Misalignment can be corrected
ing through deep water puddles can force water/road with shims.
splash into the housing through such openings.
Clutch fluid leaks are usually from damaged slave CLUTCH FLYWHEEL RUNOUT
cylinder push rod seals. This type of leak can only be Check flywheel runout whenever misalignment is
confirmed by visual inspection. suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
IMPROPER CLUTCH RELEASE OR the flywheel face with a dial indicator. Mount the
ENGAGEMENT indicator on a stud installed in place of one of the fly-
Clutch release or engagement problems are caused wheel bolts.
by wear, or damage to one or more clutch compo- Common causes of runout are:
nents. A visual inspection of the release components • heat warpage
will usually reveal the problem part. • improper machining
Release problems can result in hard shifting and • incorrect bolt tightening
noise. Items to look for are: leaks at the clutch cylin- • improper seating on crankshaft flange shoulder
ders and interconnecting line; loose slave cylinder • foreign material on crankshaft flange
bolts; worn/loose release fork and pivot stud; dam- Flywheel machining is not recommended. The fly-
aged release bearing; and a worn clutch disc, or pres- wheel clutch surface is machined to a unique contour
sure plate. and machining will negate this feature. However,
minor flywheel scoring can be cleaned up by hand
Normal condensation in vehicles that are stored or
out of service for long periods of time can generate with 180 grit emery, or with surface grinding equip-
enough corrosion to make the disc stick to the fly- ment. Remove only enough material to reduce scor-
wheel, or pressure plate. If this condition is experi- ing (approximately 0.001 - 0.003 in.). Heavy stock
enced, correction only requires that the disc be removal is not recommended. Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
loosened manually through the inspection plate open-
in.). Excessive stock removal can result in flywheel
ing.
Engagement problems usually result in slip, chat- cracking or warpage after installation; it can also
ter/shudder, and noisy operation. The primary causes weaken the flywheel and interfere with proper clutch
are clutch disc contamination; clutch disc wear; mis- release.
Clean the crankshaft flange before mounting the
alignment, or distortion; flywheel damage; or a com-
flywheel. Dirt and grease on the flange surface may
bination of the foregoing. A visual inspection is
cock the flywheel causing excessive runout. Use new
required to determine the part actually causing the
problem. bolts when remounting a flywheel and secure the
bolts with Mopart Lock And Seal. Tighten flywheel
bolts to specified torque only. Overtightening can dis-
CLUTCH MISALIGNMENT
tort the flywheel hub causing runout.
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage
XJ CLUTCH 6-7
DIAGNOSIS AND TESTING (Continued)
DIAGNOSIS CHART
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
Clutch disc facing contaminated with 1. Leak at rear main engine seal or 1. Replace appropriate seal.
oil, grease, or clutch fluid. transmission input shaft seal.
Clutch is running partially 1. Release bearing sticking or 1. Verify failure. Replace the release
disengaged. binding and does not return to the bearing and transmission front
normal running position. bearing retainer as necessary.
Clutch disc, cover and/or diaphragm 1. Rough handling. Impact bent 1. Replace disc or cover as
spring warped or distorted. cover, spring, or disc. necessary.
Facing on flywheel side of disc torn, 1. Flywheel surface scored or 2. Correct surface condition if
gouged, or worn. nicked. possible. Replace flywheel and disc
as necessary.
Clutch disc facing burnt. Flywheel 1. Frequent operation under high 1. Correct condition of flywheel and
and cover pressure plate surfaces loads or hard acceleration pressure plate surface. Replace
heavily glazed. conditions. clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub
splines. during installation. splines if possible. Replace disc if
necessary.
Clutch disc rusted to flywheel and/or 1. Clutch not used for and extended 1. Sand rusted surfaces with 180
pressure plate. period of time (e.g. long term grit sanding paper. Replace clutch
vehicle storage). cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers 1. Bearing cocked during 1. Install and lubricate a new
are worn. installation. bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
Clutch master or slave cylinder 1. Master or slave cylinder 1. Replace clutch hydraulic linkage
plunger dragging andør binding components worn or corroded. assembly.
Contact surface of release bearing 1. Clutch cover incorrect or release 1. Replace clutch cover and release
damaged. fingers bent or distorted. bearing.
Partial engagement of clutch disc. 1. Clutch pressure plate position 1. Replace clutch disc and cover.
One side of disc is worn and the incorrect.
other side is glazed and lightly 2. Clutch cover, spring, or release 2. Replace clutch disc and cover.
worn. fingers bent or distorted.
3. Clutch disc damaged or 2. Replace clutch disc.
distorted.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.
(c) Starting 180 degrees from the last pilot bolt, Fig. 12 Release Bearing Attachment
tighten 3 large hole bolts 3/4s of the way (any 1 – RETURN SPRING
sequence). 2 – PIVOT BALL STUD
(d) Tighten 3 pilot hole bolts all the way (any 3 – CLUTCH HOUSING
4 – RELEASE FORK
sequence).
5 – RELEASE BEARING
(e) Starting 180 degrees from last pilot bolt,
tighten 3 large bolts all the way (any sequence).
(11) Apply light coat of Mopart high temperature PILOT BEARING
bearing grease to clutch disc hub and splines of
transmission input shaft. Do not over lubricate REMOVAL
shaft splines. This will result in grease contam- (1) Remove transmission. Refer to Group 21,
ination of disc. Transmission and Transfer Case, for proper proce-
(12) Install transmission. dures.
(2) Remove clutch cover and disc.
RELEASE BEARING (3) Use a suitable blind hole puller to remove pilot
bearing.
REMOVAL
(1) Remove transmission. INSTALLATION
(2) Disconnect release bearing from release lever (1) Clean bearing bore with solvent and wipe dry
and remove bearing (Fig. 12). with shop towel.
(3) Inspect bearing slide surface of transmission (2) Lubricate new pilot bearing with Mopart high
front bearing retainer. Replace retainer if slide sur- temperature grease.
face is scored, worn, or cracked. (3) Position and start new bearing in bearing bore
(4) Inspect release fork and fork pivot. Be sure by hand. Note that pilot bearing has seal at one end.
pivot is secure and in good condition. Be sure fork is Install bearing so seal is facing outward toward
not distorted or worn. Replace release fork retainer transmission.
spring if bent or damaged. (4) Seat pilot bearing with clutch alignment tool
(Fig. 13). Keep bearing straight during installation.
INSTALLATION Do not allow bearing to become cocked. Tap bearing
(1) Lubricate crankshaft pilot bearing with Mopart into place until flush with edge of bearing bore. Do
high temperature bearing grease. Apply grease to not recess bearing.
end of long shank, small diameter flat blade screw- (5) Install transmission. Refer to Group 21, Trans-
driver. Then insert tool through clutch disc hub to mission and Transfer Case, for proper procedures.
reach bearing.
XJ CLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)
CLUTCH
TABLE OF CONTENTS
page page
OPERATION
Leverage, clamping force, and friction are what
make the clutch work. The disc serves as the friction
element and a diaphragm spring and pressure plate Fig. 1 Engine Powerflow
provide the clamping force. The clutch pedal, hydrau-
lic linkage, release lever and bearing provide the
leverage.
6-2 CLUTCH XJ
DESCRIPTION AND OPERATION (Continued)
The clutch master cylinder push rod is connected
to the clutch pedal. When the clutch pedal is
depressed, the slave cylinder is operated by the
clutch master cylinder mounted on the dash panel.
The release fork is actuated by the hydraulic slave
cylinder mounted on the transmission housing. The
release bearing is operated by a release fork pivoting
on a ball stud mounted in the transmission housing.
The release bearing then depresses the pressure
plate spring fingers, thereby releasing pressure on
the clutch disc and allowing the engine crankshaft to
spin independently of the transmission input shaft
(Fig. 2).
Fig. 3 Flywheel
1 – CRANKSHAFT
2 – RING GEAR
3 – FLYWHEEL
OPERATION
The flywheel serves to dampen the engine firing
pulses. The heavy weight of the flywheel relative to
the rotating mass of the engine components serves to
stabilize the flow of power to the remainder of the
drivetrain. The crankshaft has the tendency to
attempt to speed up and slow down in response to
the cylinder firing pulses. The flywheel dampens
these impulses by absorbing energy when the crank-
shaft speeds and releasing the energy back into the
system when the crankshaft slows down.
CLUTCH DISC
DESCRIPTION
Fig. 2 Clutch Operation The clutch disc friction material is riveted to the
1 – FLYWHEEL disc hub (Fig. 4). The hub bore is splined for installa-
2 – PRESSURE PLATE FINGERS tion on the transmission input shaft. The clutch disc
3 – PIVOT POINT has cushion springs in the disc hub to dampen disc
4 – RELEASE BEARING PUSHED IN vibrations during application and release of the clutch.
5 – CLUTCH DISC ENGAGED
6 – CLUTCH DISC ENGAGED
7 – RELEASE BEARING
OPERATION
The clutch disc is held onto the surface of the fly-
wheel by the force exerted by the pressure plate’s dia-
FLYWHEEL phragm spring. The friction material of the clutch disc
then transfers the engine torque from the flywheel and
DESCRIPTION pressure plate to the input shaft of the transmission.
The flywheel (Fig. 3) is a heavy plate bolted to the
rear of the crankshaft. The flywheel incorporates the CLUTCH PRESSURE PLATE
ring gear around the outer circumference to mesh
with the starter to permit engine cranking. The rear DESCRIPTION
face of the flywheel serves as the driving member to The clutch pressure plate assembly is a diaphragm
the clutch disc. type with a one-piece spring and multiple release fin-
gers (Fig. 5). The pressure plate release fingers are
preset during manufacture and are not adjustable.
The assembly also contains the cover, pressure plate,
and fulcrum components.
XJ CLUTCH 6-3
DESCRIPTION AND OPERATION (Continued)
OPERATION
The clutch pressure plate assembly clamps the
clutch disc against the flywheel. When the release
bearing is depressed by the shift fork, the pressure
exerted on the clutch disc by the pressure plate
spring is decreased. As additional force is applied,
the bearing presses the diaphragm spring fingers
inward on the fulcrums. This action moves the pres-
sure plate rearward relieving clamp force on the disc.
The clutch disc is disengaged and freewheeling at
this point.
OPERATION
The release bearing is operated by a release fork in
the clutch housing. Slave cylinder force causes the
release lever to move the release bearing into contact
with the diaphragm spring. As additional force is
applied, the bearing presses the diaphragm spring
Fig. 5 Clutch Pressure Plate-Typical fingers inward on the fulcrums. This action moves
1 – COVER the pressure plate rearward relieving clamp force on
2 – RELEASE FINGERS the disc. Releasing pedal pressure removes clutch
3 – PRESSURE PLATE hydraulic pressure. The release bearing then moves
away from the diaphragm spring which allows the
pressure plate to exert clamping force on the clutch
disc.
6-4 CLUTCH XJ
DESCRIPTION AND OPERATION (Continued)
CLUTCH CONTAMINATION of any clutch component will cause grab, chatter and
Fluid contamination is a frequent cause of clutch improper clutch release.
malfunctions. Oil, water, or clutch fluid on the clutch
disc and pressure plate surfaces will cause chatter, CLUTCH HOUSING MISALIGNMENT
slip and grab. Clutch housing alignment is important to proper
During inspection, note if any components are con- clutch operation. The housing maintains alignment
taminated with oil, hydraulic fluid, or water/road between the crankshaft and transmission input
splash. shaft. Misalignment can cause clutch noise, hard
Oil contamination indicates a leak at either the shifting, incomplete release and chatter. It can also
rear main seal or transmission input shaft. Oil leak- result in premature wear of the pilot bearing, cover
age produces a residue of oil on the housing interior release fingers and clutch disc. In severe cases, mis-
and on the clutch cover and flywheel. Heat buildup alignment can also cause premature wear of the
caused by slippage between the cover, disc and fly- transmission input shaft and front bearing.
wheel, can sometimes bake the oil residue onto the Housing misalignment is generally caused by
components. The glaze-like residue ranges in color incorrect seating on the engine or transmission, loose
from amber to black. housing bolts, missing alignment dowels, or housing
Road splash contamination means dirt/water is damage. Infrequently, misalignment may also be
entering the clutch housing due to loose bolts, hous- caused by housing mounting surfaces that are not
ing cracks, or through hydraulic line openings. Driv- completely parallel. Misalignment can be corrected
ing through deep water puddles can force water/road with shims.
splash into the housing through such openings.
Clutch fluid leaks are usually from damaged slave CLUTCH FLYWHEEL RUNOUT
cylinder push rod seals. This type of leak can only be Check flywheel runout whenever misalignment is
confirmed by visual inspection. suspected. Flywheel runout should not exceed 0.08
mm (0.003 in.). Measure runout at the outer edge of
IMPROPER CLUTCH RELEASE OR the flywheel face with a dial indicator. Mount the
ENGAGEMENT indicator on a stud installed in place of one of the fly-
Clutch release or engagement problems are caused wheel bolts.
by wear, or damage to one or more clutch compo- Common causes of runout are:
nents. A visual inspection of the release components • heat warpage
will usually reveal the problem part. • improper machining
Release problems can result in hard shifting and • incorrect bolt tightening
noise. Items to look for are: leaks at the clutch cylin- • improper seating on crankshaft flange shoulder
ders and interconnecting line; loose slave cylinder • foreign material on crankshaft flange
bolts; worn/loose release fork and pivot stud; dam- Flywheel machining is not recommended. The fly-
aged release bearing; and a worn clutch disc, or pres- wheel clutch surface is machined to a unique contour
sure plate. and machining will negate this feature. However,
minor flywheel scoring can be cleaned up by hand
Normal condensation in vehicles that are stored or
out of service for long periods of time can generate with 180 grit emery, or with surface grinding equip-
enough corrosion to make the disc stick to the fly- ment. Remove only enough material to reduce scor-
wheel, or pressure plate. If this condition is experi- ing (approximately 0.001 - 0.003 in.). Heavy stock
enced, correction only requires that the disc be removal is not recommended. Replace the flywheel
if scoring is severe and deeper than 0.076 mm (0.003
loosened manually through the inspection plate open-
in.). Excessive stock removal can result in flywheel
ing.
Engagement problems usually result in slip, chat- cracking or warpage after installation; it can also
ter/shudder, and noisy operation. The primary causes weaken the flywheel and interfere with proper clutch
are clutch disc contamination; clutch disc wear; mis- release.
Clean the crankshaft flange before mounting the
alignment, or distortion; flywheel damage; or a com-
flywheel. Dirt and grease on the flange surface may
bination of the foregoing. A visual inspection is
cock the flywheel causing excessive runout. Use new
required to determine the part actually causing the
problem. bolts when remounting a flywheel and secure the
bolts with Mopart Lock And Seal. Tighten flywheel
bolts to specified torque only. Overtightening can dis-
CLUTCH MISALIGNMENT
tort the flywheel hub causing runout.
Clutch components must be in proper alignment
with the crankshaft and transmission input shaft.
Misalignment caused by excessive runout or warpage
XJ CLUTCH 6-7
DIAGNOSIS AND TESTING (Continued)
DIAGNOSIS CHART
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
Clutch disc facing contaminated with 1. Leak at rear main engine seal or 1. Replace appropriate seal.
oil, grease, or clutch fluid. transmission input shaft seal.
Clutch is running partially 1. Release bearing sticking or 1. Verify failure. Replace the release
disengaged. binding and does not return to the bearing and transmission front
normal running position. bearing retainer as necessary.
Clutch disc, cover and/or diaphragm 1. Rough handling. Impact bent 1. Replace disc or cover as
spring warped or distorted. cover, spring, or disc. necessary.
Facing on flywheel side of disc torn, 1. Flywheel surface scored or 2. Correct surface condition if
gouged, or worn. nicked. possible. Replace flywheel and disc
as necessary.
Clutch disc facing burnt. Flywheel 1. Frequent operation under high 1. Correct condition of flywheel and
and cover pressure plate surfaces loads or hard acceleration pressure plate surface. Replace
heavily glazed. conditions. clutch cover and disc. Alert driver to
problem cause.
Clutch disc binds on input shaft 1. Clutch disc hub splines damaged 1. Clean, smooth, and lubricate hub
splines. during installation. splines if possible. Replace disc if
necessary.
Clutch disc rusted to flywheel and/or 1. Clutch not used for and extended 1. Sand rusted surfaces with 180
pressure plate. period of time (e.g. long term grit sanding paper. Replace clutch
vehicle storage). cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers 1. Bearing cocked during 1. Install and lubricate a new
are worn. installation. bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
Clutch master or slave cylinder 1. Master or slave cylinder 1. Replace clutch hydraulic linkage
plunger dragging andør binding components worn or corroded. assembly.
Contact surface of release bearing 1. Clutch cover incorrect or release 1. Replace clutch cover and release
damaged. fingers bent or distorted. bearing.
Partial engagement of clutch disc. 1. Clutch pressure plate position 1. Replace clutch disc and cover.
One side of disc is worn and the incorrect.
other side is glazed and lightly 2. Clutch cover, spring, or release 2. Replace clutch disc and cover.
worn. fingers bent or distorted.
3. Clutch disc damaged or 2. Replace clutch disc.
distorted.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andør
clutch housing. Correct as
necessary.
(c) Starting 180 degrees from the last pilot bolt, Fig. 12 Release Bearing Attachment
tighten 3 large hole bolts 3/4s of the way (any 1 – RETURN SPRING
sequence). 2 – PIVOT BALL STUD
(d) Tighten 3 pilot hole bolts all the way (any 3 – CLUTCH HOUSING
4 – RELEASE FORK
sequence).
5 – RELEASE BEARING
(e) Starting 180 degrees from last pilot bolt,
tighten 3 large bolts all the way (any sequence).
(11) Apply light coat of Mopart high temperature PILOT BEARING
bearing grease to clutch disc hub and splines of
transmission input shaft. Do not over lubricate REMOVAL
shaft splines. This will result in grease contam- (1) Remove transmission. Refer to Group 21,
ination of disc. Transmission and Transfer Case, for proper proce-
(12) Install transmission. dures.
(2) Remove clutch cover and disc.
RELEASE BEARING (3) Use a suitable blind hole puller to remove pilot
bearing.
REMOVAL
(1) Remove transmission. INSTALLATION
(2) Disconnect release bearing from release lever (1) Clean bearing bore with solvent and wipe dry
and remove bearing (Fig. 12). with shop towel.
(3) Inspect bearing slide surface of transmission (2) Lubricate new pilot bearing with Mopart high
front bearing retainer. Replace retainer if slide sur- temperature grease.
face is scored, worn, or cracked. (3) Position and start new bearing in bearing bore
(4) Inspect release fork and fork pivot. Be sure by hand. Note that pilot bearing has seal at one end.
pivot is secure and in good condition. Be sure fork is Install bearing so seal is facing outward toward
not distorted or worn. Replace release fork retainer transmission.
spring if bent or damaged. (4) Seat pilot bearing with clutch alignment tool
(Fig. 13). Keep bearing straight during installation.
INSTALLATION Do not allow bearing to become cocked. Tap bearing
(1) Lubricate crankshaft pilot bearing with Mopart into place until flush with edge of bearing bore. Do
high temperature bearing grease. Apply grease to not recess bearing.
end of long shank, small diameter flat blade screw- (5) Install transmission. Refer to Group 21, Trans-
driver. Then insert tool through clutch disc hub to mission and Transfer Case, for proper procedures.
reach bearing.
XJ CLUTCH 6 - 13
REMOVAL AND INSTALLATION (Continued)
COOLING SYSTEM
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION matic transmission fluid (if equipped). The cooling
system is pressurized and uses a centrifugal water
COOLING SYSTEM pump to circulate coolant throughout the system.
An optional factory installed heavy duty cooling
DESCRIPTION package is available on most models. The package
The cooling system regulates engine operating tem- consists of a radiator that has an increased number
perature. It allows the engine to reach normal oper- of cooling fins. Vehicles equipped with a 2.5L/4.0L
ating temperature as quickly as possible, maintains engine and heavy duty cooling and/or air condition-
normal operating temperature and prevents over- ing also have an auxiliary electric cooling fan.
heating. The cooling system consists of:
The cooling system also provides a means of heat- • A radiator
ing the passenger compartment and cooling the auto- • Cooling fan (mechanical and/or electrical)
• Thermal viscous fan drive
7-2 COOLING SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
• Fan shroud Transmission oil is cooled when it passes through
• Radiator pressure cap this separate cooler. In case of a leak in the internal
• Thermostat radiator mounted transmission oil cooler, engine cool-
• Coolant reserve/overflow system ant may become mixed with transmission fluid or
• Transmission oil cooler (if equipped with an transmission fluid may enter engine cooling system.
automatic transmission) Both cooling system and transmission should be
• Coolant drained and inspected if the internal radiator
• Water pump mounted transmission cooler is leaking.
• Hoses and hose clamps An auxiliary air-to-oil transmission oil cooler is
Cooling system circulation for 2.5L/4.0L models is available with most engine packages.
shown in (Fig. 1). The auxiliary air-to-oil transmission oil cooler is
located in front of the radiator or A/C condenser (if
equipped) and behind the grill. It is mounted to the
front frame crossmember.
The auxiliary oil coolers on all models operate in
conjunction with the internal radiator mounted main
oil cooler. The transmission oil is routed through the
main cooler first, then the auxiliary cooler, before
returning to the transmission.
OPERATION
As the engine cools, a vacuum is formed in the
cooling system of both the radiator and engine. Cool-
ant will then be drawn from the coolant tank and
returned to a proper level in the radiator.
OPERATION
Connecting the power cord to a grounded 110-120
volt AC electrical outlet with a grounded, three-wire Fig. 7 Thermostat and Housing
extension cord activates the block heater. 1 – LONG BOLT
2 – GASKET
3 – THERMOSTAT
4 – THERMOSTAT HOUSING
5 – SHORT BOLT
XJ COOLING SYSTEM 7-5
DESCRIPTION AND OPERATION (Continued)
OPERATION
The worm type hose clamp uses a specified torque
value to maintain proper tension on a hose connec-
tion.
The spring type hose clamp applies constant ten-
sion on a hose connection. To remove a spring type
hose clamp, use Special Tool 6094 or equivalent, con-
stant tension clamp pliers (Fig. 12) to compress the
Fig. 10 Reverse Rotating Water Pump—Typical hose clamp.
1 – R STAMPED INTO IMPELLER
XJ COOLING SYSTEM 7-7
DESCRIPTION AND OPERATION (Continued)
A thermostatic bimetallic spring coil is located on
the front face of the viscous fan drive unit. A typical
viscous unit is shown in (Fig. 13). This spring coil
reacts to the temperature of the radiator discharge
air. It engages the viscous fan drive for higher fan
speed if the air temperature from the radiator rises
above a certain point. Until additional engine cooling
is necessary, the fan will remain at a reduced rpm
regardless of engine speed.
Vehicles equipped with 2.5L engines have what is
know as an hybrid cooling fan system. This means
that not only do they have a viscous fan but they also
have an electric fan as well. The hybrid viscous fan
drive has a low speed characteristic. This causes the
mechanical fan speeds to be very low 200–400 rpm
range when not engaged allowing the engine to have
Fig. 12 Hose Clamp Tool
additional performance and horsepower gaines.
1 – HOSE CLAMP TOOL 6094
2 – HOSE CLAMP
RIB CHUNKING (One or more ribs 1. Foreign objects imbedded in 1. Remove foreign objects from
has separated from belt body) pulley grooves. pulley grooves. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt
groove
9GROOVE JUMPING” 1. Belt tension either too low or too 1. Adjust belt tension (2.5L)
(Belt does not maintain correct high
position on pulley)
2. Pulley(s) not within design 2. Replace pulley(s)
tolerance
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
TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to Group 25, Emission
LOW (DTC) been set indicating a stuck Systems for On-Board Diagnostics
open thermostat? and DTC information. Replace
thermostat if necessary.
TEMPERATURE GAUGE READS 1. Trailer is being towed, a steep 1. This may be a temporary
HIGH OR THE COOLANT hill is being climbed, vehicle is condition and repair is not
WARNING LAMP ILLUMINATES. operated in slow moving traffic, or necessary. Turn off the air
COOLANT MAY OR MAY NOT BE engine is being idled with very high conditioning and attempt to drive the
LOST OR LEAKING FROM THE ambient (outside) temperatures and vehicle without any of the previous
COOLING SYSTEM the air conditioning is on. Higher conditions. Observe the temperature
altitudes could aggravate these gauge. The gauge should return to
conditions. the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair. Refer to Possible
Causes (2-20).
TEMPERATURE GAUGE READS 6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
HIGH OR THE COOLANT cap seals. Refer to Radiator Cap.
WARNING LAMP ILLUMINATES. Replace cap if necessary.
COOLANT MAY OR MAY NOT BE (b) Check condition of radiator filler
LOST OR LEAKING FROM THE neck. If neck is bent or damaged,
COOLING SYSTEM (CONTINUED) replace radiator.
7. Coolant level low in radiator but 7. (a) Check condition of radiator
not in coolant reserve/overflow cap and cap seals. Refer to
tank. This means the radiator is not Radiator Cap in this Group. Replace
drawing coolant from the coolant cap if necessary.
reserve/overflow tank as the engine (b) Check condition of radiator filler
cools neck. If neck is bent or damaged,
replace radiator.
(c) Check 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 tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. Refer to Coolant
section in this Group for correct
coolant/water mixture ratio.
9. Coolant not flowing through 9. Check for coolant flow at radiator
system filler neck with some coolant
removed, engine warm and
thermostat open. Coolant should be
observed flowing through radiator. If
flow is not observed, determine area
of obstruction and repair as
necessary.
10. Radiator or A/C condenser fins 10. Remove insects and debris.
are dirty or clogged. Refer to Radiator Cleaning in this
Group.
11. Radiator core is corroded or 11. Have radiator re-cored or
plugged. replaced.
12. Aftermarket A/C installed 12. Install proper radiator.
without proper radiator.
13. Fuel or ignition system 13. Refer to Fuel and Ignition
problems. System Groups for diagnosis.
14. Dragging brakes. 14. Check and correct as
necessary. Refer to Group 5,
Brakes for correct procedures.
15. Bug screen or cardboard is 15. Remove bug screen or
being used, reducing airflow. cardboard.
16. Thermostat partially or 16. Check thermostat operation and
completely shut. replace as necessary. Refer to
Thermostats in this Group.
7 - 14 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
TEMPERATURE GAUGE READS 17. Viscous fan drive not operating 17. Check fan drive operation and
HIGH OR THE COOLANT properly. replace as necessary. Refer to
WARNING LAMP ILLUMINATES. Viscous Fan Drive in this Group.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM THE 18. Electric cooling fan not 18. Check electric fan operation and
COOLING SYSTEM (CONTINUED) operating properly (vehicles repair as necessary. Refer to
equipped with 2.5L/4.0L and air Electric Cooling Fan in this Group.
conditioning
19. Cylinder head gasket leaking. 19. Check for cylinder head gasket
leaks. Refer to Cooling System-
Testing 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 GAUGE READING 8. Water pump impeller loose on 8. Check water pump and replace
IS INCONSISTENT (FLUCTUATES, shaft. as necessary. Refer to water Pumps
CYCLES OR IS ERRATIC) in this group.
(CONTINUED)
9. Loose accessory drive belt. 9. Refer to Accessory Drive Belts in
(water pump slipping) this group. Check and correct as
necessary.
10. Air leak on the suction side of 10. Locate leak and repair as
the water pump allows air to build necessary.
up in cooling system causing
thermostat to open late.
PRESSURE CAP IS BLOWING 1. Pressure relief valve in radiator 1. Check condition of radiator cap
OFF STEAM AND/OR COOLANT cap is defective. and cap seals. Refer to Radiator
TO COOLANT TANK. Caps in this group. Replace cap as
TEMPERATURE GAUGE READING necessary.
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK
COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
GROUND WITHOUT PRESSURE system hoses, water pump or necessary. Refer to Cooling
CAP BLOWOFF. GAUGE READING engine. System-Testing For Leaks in this
HIGH OR HOT group.
HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. (a) Radiator cap relief valve
WHILE ENGINE IS RUNNING system on engine cool-down is not stuck. Refer to Radiator Cap in this
being relieved through coolant group. Replace if necessary
reserve/overflow system.
ELECTRIC RADIATOR FAN RUNS 1. Fan relay, powertrain control 1. Refer to Electric Cooling Fan
ALL OF THE TIME (2.5L/4.0L module (PCM) or coolant Diagnosis and Testing. Also refer to
MODELS EQUIPPED WITH A/C temperature sensor defective. Group 8W, Wiring Diagrams. Repair
AND 4.0L MODELS EQUIPPED as necessary.
WITH MAX COOLING)
7 - 16 COOLING SYSTEM XJ
DIAGNOSIS AND TESTING (Continued)
ELECTRIC RADIATOR FAN WILL 1. Blown Fuse in Power Distribution 1. Determine reason for blown fuse
NOT RUN AT ALL. GAUGE Center (PDC) and repair as necessary.
READING HIGH OR HOT
(2.5L/4.0L MODELS EQUIPPED 2. Fan relay, powertrain control 2. Refer to Electric Cooling Fan
WITH A/C AND 4.0L MODELS module (PCM) or coolant Diagnosis and Testing. Also refer to
EQUIPPED WITH MAX COOLING) temperature sensor defective. Group 8W, Wiring Diagrams. Repair
as necessary.
3. Fan Motor Defective 3. Refer to Electric Cooling Fan
Diagnosis and Testing. Also refer to
Group 8W, Wiring Diagrams. Repair
as necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly.
Refer to Cooling System Fans in
this Group
INADEQUATE HEATER 1. Has a Diagnostic trouble Code 1. Refer to Group 25, Emissions for
PERFORMANCE. THERMOSTAT (DTC) been set? correct procedures and replace
FAILED IN OPEN POSITION thermostat if necessary
2. Coolant level low 2. Refer to Cooling System-Testing
For Leaks in this group.
3. Obstructions in heater hose/ 3. Remove heater hoses at both
fittings ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping 5. Refer to Water Pump in this
water to/through the heater core. group. If a slipping belt is detected,
When the engine is fully warmed refer to Accessory Drive Belts in this
up, both heater hoses should be group. If heater core obstruction is
hot to the touch. If only one of the detected, refer to Group 24, Heating
hoses is hot, the water pump may and Air Conditioning.
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.
XJ COOLING SYSTEM 7 - 17
DIAGNOSIS AND TESTING (Continued)
STEAM IS COMING FROM THE 1. During wet weather, moisture 1. Occasional steam emitting from
FRONT OF VEHICLE NEAR THE (snow, ice or rain condensation) on this area is normal. No repair is
GRILL AREA WHEN WEATHER IS the radiator will evaporate when the necessary.
WET, ENGINE IS WARMED UP thermostat opens. This opening
AND RUNNING, AND VEHICLE IS allows heated water into the
STATIONARY. TEMPERATURE radiator. When the moisture
GAUGE IS IN NORMAL RANGE contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or
airflow to blow it away.
COOLANT COLOR 1. Coolant color is not necessarily 1. Refer to Coolant in this group for
an indication of adequate corrosion coolant concentration information.
or temperature protection. Do not Adjust coolant mixture as
rely on coolant color for determining necessary.
condition of coolant.
RADIATOR CAP-TO-FILLER NECK SEAL— There is no need to remove the radiator cap
except for the following purposes:
PRESSURE RELIEF CHECK
(1) To check and adjust antifreeze freeze point.
With radiator cap installed on filler neck, remove
(2) To refill system with new antifreeze.
coolant reserve/ overflow tank hose from nipple on
(3) For conducting service procedures.
filler neck. Connect a hand operated vacuum pump
(4) When checking for vacuum leaks.
to nipple. Operate pump until a reading of 47-to-61
kPa (14- to-18 in. Hg) appears on gauge. If the read- WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
ing stays steady, or drops slightly and then remains WAIT AT LEAST 15 MINUTES BEFORE REMOVING
steady, the pressure valve seal is good. Replace radi- RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
ator cap if reading does not hold. UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER THE CAP AND
WARNING: THE WARNING WORDS -DO NOT OPEN
WITHOUT PUSHING DOWN, ROTATE CAP
HOT- ON THE RADIATOR PRESSURE CAP (Fig. 19)
COUNTER-CLOCKWISE TO THE FIRST STOP.
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
ALLOW FLUID TO ESCAPE THROUGH OVERFLOW
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
HOSE INTO COOLANT RESERVE/OVERFLOW
VENT SCALDING OR INJURY, THE RADIATOR CAP
TANK. SQUEEZE RADIATOR UPPER HOSE TO
SHOULD NOT BE REMOVED WHILE THE SYSTEM
DETERMINE WHEN PRESSURE HAS BEEN
IS HOT AND/OR UNDER PRESSURE.
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
CHEMICAL CLEANING
If visual inspection indicates the formation of
sludge or scaly deposits, use a radiator cleaner
(Mopar Radiator Kleen or equivalent) before flushing.
This will soften scale and other deposits and aid the
flushing operation.
AIR-TO-OIL COOLER
REMOVAL
(1) Remove the grill mounting screws and remove
the grill. Refer to Group 23, Body for procedures.
(2) Place a drain pan below the transmission oil
cooler.
(3) Remove the two constant tension clamps at oil
cooler inlet and outlet tubes.
(4) Remove the two oil cooler mounting bolts (Fig.
22).
(5) Remove the oil cooler from vehicle.
INSTALLATION
(1) Position and secure oil cooler to vehicle.
Tighten mounting bolts to 8 N·m (72 in. lbs.) torque.
(2) Secure inlet and outlet tubes with constant
tension clamps.
Install the grill.
(3) Start engine and check transmission fluid level. Fig. 23 Reserve/Overflow Tank—Except Right Hand
Add fluid if necessary. Drive
1 – COOLANT RESERVE/OVERFLOW TANK
COOLANT RESERVE TANK 2 – CLAMP
3 – MOUNTING BOLTS
REMOVAL 4 – TUBE TO RADIATOR
(1) Remove the tube clamp at the tank and remove
tube.
7 - 24 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
THERMOSTAT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
INSTALLATION
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the
engine. All thermostats are marked on the outer
flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cyl-
inder head (Fig. 33). Fig. 33 Thermostat Recess
(b) Position thermostat into this groove with 1 – GROOVE
arrow and air bleed hole on outer flange pointing
up.
(2) Install replacement gasket and thermostat
housing.
XJ COOLING SYSTEM 7 - 29
REMOVAL AND INSTALLATION (Continued)
CAUTION: Tightening the thermostat housing (7) Disconnect electric cooling fan electrical con-
unevenly or with the thermostat out of its recess nector, if equipped.
may result in a cracked housing.
RADIATOR—2.5L
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR. Fig. 34 Radiator Petcock—Typical
1 – RADIATOR PETCOCK
DO NOT WASTE reusable coolant. If solution is
clean, drain coolant into a clean container for reuse.
(8) Disconnect CRS hose from radiator filler neck
WARNING: CONSTANT TENSION HOSE CLAMPS and remove from shroud retaining loops.
ARE USED ON MOST COOLING SYSTEM HOSES. (9) Remove the four (4) viscous fan/drive assembly
WHEN REMOVING OR INSTALLING, USE ONLY nuts from the water pump pulley and remove fan/
TOOLS DESIGNED FOR SERVICING THIS TYPE OF drive assy.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER (10) Remove the four (4) fan shroud to core sup-
6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER port mounting screws.
HPC-20) MAY BE USED FOR LARGER CLAMPS. (11) Remove the electric fan (if equipped) and
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- shroud assembly from the vehicle (Fig. 36).
ING CONSTANT TENSION CLAMPS. (12) Remove radiator upper crossmember (Fig. 36).
(13) If equipped with air conditioning, separate
radiator from condenser by removing condenser-to-ra-
CAUTION: A number or letter is stamped into the diator mounting brackets (Fig. 35).
tongue of constant tension clamps (Fig. 11). If (14) Disconnect upper and lower radiator hoses.
replacement is necessary, use only an original (15) If equipped, disconnect and plug automatic
equipment clamp with matching number or letter. transmission fluid cooler lines. Quick Connect Fitting
Release Tool 6935 may be needed. If equipped with
remote transmission cooler, remove line to cooler
REMOVAL from bracket at bottom of radiator.
(1) Disconnect battery negative cable. (16) Lift radiator straight up and out of engine
(2) Observe the previous WARNINGS. compartment taking care not to damage fins.
(3) Remove radiator pressure cap. (17) If radiator is to be replaced, be sure to remove
(4) For access to radiator draincock, remove radia- and transfer any components not included with
tor grill mounting screws and remove grill. Refer to replacement radiator.
Group 23, Body for procedures.
(5) Attach one end of a 24 inch long X 1/4 inch ID INSTALLATION
hose to the radiator petcock (Fig. 34). Put the other The radiator is supplied with two alignment dowels
end into a clean container. Open petcock and drain (Fig. 41). They are located on the bottom tank and fit
radiator. into rubber grommets in the radiator lower cross-
(6) Detach power steering fluid reservoir from fan member.
shroud and lay aside.
7 - 30 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(1) Lower radiator into engine compartment. Posi-
tion alignment dowels into rubber grommets in radi-
ator lower crossmember (Fig. 41).
(2) If equipped with air conditioning, attach con-
denser to radiator with mounting brackets (Fig. 35).
(3) Install radiator upper crossmember and four
mounting bolts.
(4) Install radiator upper crossmember-to-isolator
nuts. Tighten nuts to 10 N·m (86 in. lbs.) torque. If
isolator-to-radiator nuts had been removed, tighten
them to 5 N·m (47 in. lbs.) torque.
(5) Connect radiator upper and lower hoses.
(6) If equipped, connect automatic transmission
fluid cooler lines. If equipped with remote cooler,
attach cooler line to bracket at bottom of radiator.
(7) Install electric fan (if equipped) and shroud
assembly.. Insert alignment tabs at bottom of fan
shroud into slots in bracket at bottom of radiator.
Tighten mounting bolts to 3 N·m (31 in. lbs.) torque.
(8) Connect electric cooling fan electrical connector.
(9) Install power steering reservoir to fan shroud.
Fig. 35 Condenser-to-Radiator Mounting Brackets (10) Install grill.
1 – CONDENSER TO RADIATOR MOUNTING BRACKETS
(11) Connect battery negative cable.
REMOVAL
(1) Disconnect battery negative cable.
(2) Observe the previous WARNINGS.
(3) Remove radiator pressure cap.
(4) For access to radiator draincock, remove radia-
tor grill mounting screws and remove grill. Refer to
Group 23, Body for procedures.
(5) Attach one end of a 24 inch long X 1/4 inch ID
hose to the radiator petcock (Fig. 38). Put the other
end into a clean container. Open petcock and drain
radiator.
(6) Disconnect electric cooling fan electrical con-
nector, if equipped.
RADIATOR—4.0L
WARNING: DO NOT REMOVE THE CYLINDER Fig. 38 Radiator Petcock—Typical
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR 1 – RADIATOR PETCOCK
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
(7) If equipped, remove two electric cooling fan
CAN OCCUR.
mounting bolts. Lift cooling fan straight up until
DO NOT WASTE reusable coolant. If solution is alignment tabs at the bottom are clear of slots in
clean, drain coolant into a clean container for reuse. bracket at bottom of radiator (Fig. 39).
(8) Remove the two mechanical (non-electrical) fan
WARNING: CONSTANT TENSION HOSE CLAMPS shroud mounting bolts. Lift shroud straight up until
ARE USED ON MOST COOLING SYSTEM HOSES. alignment tabs at the bottom are clear of slots in
WHEN REMOVING OR INSTALLING, USE ONLY bracket at bottom of radiator (Fig. 39). Place shroud
TOOLS DESIGNED FOR SERVICING THIS TYPE OF over mechanical fan.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER (9) If equipped, disconnect and plug automatic
6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER transmission fluid cooler lines. Quick Connect Fitting
HPC-20) MAY BE USED FOR LARGER CLAMPS. Release Tool 6935 may be needed. If equipped with
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- remote transmission cooler, remove line to cooler
ING CONSTANT TENSION CLAMPS. from bracket at bottom of radiator.
7 - 32 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(10) Disconnect radiator upper and lower hoses (1) Lower radiator into engine compartment. Posi-
clamps. Disconnect radiator upper and lower hoses. tion alignment dowels into rubber grommets in radi-
(11) Mark the position of the hood latch striker on ator lower crossmember (Fig. 41)
the radiator crossmember and remove hood latch (2) If equipped with air conditioning, attach con-
striker. denser to radiator with mounting brackets (Fig. 40).
(12) Remove two radiator upper crossmember to (3) Install radiator upper crossmember and four
isolator nuts (Fig. 39). mounting bolts.
(13) Remove four radiator upper crossmember (4) Install radiator upper crossmember-to-isolator
bolts and remove upper crossmember. nuts. Tighten nuts to 10 N·m (86 in. lbs.) torque. If
(14) If equipped with air conditioning, separate isolator-to-radiator nuts had been removed, tighten
radiator from condenser by removing condenser-to-ra- them to 5 N·m (47 in. lbs.) torque.
diator mounting brackets (Fig. 40). (5) Install hood latch striker. Note previously
(15) Lift radiator straight up and out of engine marked position.
compartment taking care not to damage fins. (6) Connect radiator upper and lower hoses.
(7) If equipped, connect automatic transmission
INSTALLATION fluid cooler lines. Refer to Group 21, Transmissions
The radiator is supplied with two alignment dowels for procedures. If equipped with remote cooler, attach
(Fig. 41). They are located on the bottom tank and fit cooler line to bracket at bottom of radiator.
into rubber grommets in the radiator lower cross-
member.
XJ COOLING SYSTEM 7 - 33
REMOVAL AND INSTALLATION (Continued)
(8) Install electric cooling fan (if equipped). Insert
alignment tabs at bottom of fan shroud into slots in
bracket at bottom of radiator. Tighten mounting bolts
to 3 N·m (31 in. lbs.) torque.
(9) Connect electric cooling fan electrical connector.
(10) Install mechanical cooling fan shroud. Insert
alignment tabs at bottom of shroud into slots in
bracket at bottom of radiator. Tighten mounting bolts
to 3 N·m (31 in. lbs.) torque.
(11) Close radiator draincock.
(12) Install grill.
(13) Connect negative battery cable.
(14) Fill cooling system with correct coolant. Refer
to the Coolant section of this group.
(15) Install pressure cap.
(16) Check and adjust automatic transmission
fluid level (if equipped).
INSTALLATION
(1) Position fan module in shroud so that the har-
ness exits the motor at the 12 o’clock postion (Fig.
43).
(2) Install and tighten fan module to shroud
screws to 3 N·m (31 in. lbs.).
(3) Route fan harness through the shroud and
Fig. 41 Radiator Alignment Dowels—Typical attach to shroud at correct position.
1 – ALIGNMENT DOWEL (4) Lower fan and shroud assembly into place,
2 – RADIATOR making sure the shroud alignment tabs rest in their
3 – AIR CONDITIONING CONDENSER corresponding lower radiator slots.
4 – GROMMET (5) Install upper fan shroud screws and tighten to
3 N·m (31 in. lbs.).
7 - 34 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Align lower retaining tabs of fan shroud with
Fig. 43 Fan Module Orientation and Mounting slots in bracket at bottom of radiator. Push fan down
1 – FAN MOTOR HARNESS AT 12 O’CLOCK POSITION into position.
2 – MOUNTING SCREWS (4) (2) Tighten the mounting bolts to 4 N·m (31 in.
3 – FAN CONNECTOR
lbs.) torque.
XJ COOLING SYSTEM 7 - 35
REMOVAL AND INSTALLATION (Continued)
(2) Insert block heater assembly into core hole
with element loop pointing Up.
(3) Seat block heater flush against block face.
Tighten mounting screw to 3.6 N·m (32 in. lbs.)
torque.
(4) Fill cooling system with coolant. Pressurize
system and inspect for leaks.
(5) Plug power cord into block heater. Route cord
away from moving parts, linkages and exhaust sys-
tem components. Secure cord in place with tie-straps.
BELT SCHEMATICS
The belt routing schematics are published from the
latest information available at the time of publica-
tion. If anything differs between these schemat-
ics and the Belt Routing Label, use the
schematics on Belt Routing Label. This label is
located in the engine compartment.
Refer to (Fig. 47) (Fig. 48) (Fig. 49) (Fig. 50) for
proper belt routing on vehicles with conventional left
hand drive. Refer to (Fig. 51) (Fig. 52) for proper belt
routing on vehicles with right hand drive (RHD). Or,
refer to the Belt Routing Label located in the vehicle
engine compartment.
Fig. 48 Models with 2.5L Engine—Without A/C
Fig. 51 Models With 4.0L Engine—With A/C—With Fig. 53 Power Steering Pump Bracket and Idler
RHD Pulley
(2) Install new belt. 1 – ADJUSTING BOLT
(3) Using serpentine belt tension gauge, tighten 2 – IDLER PULLEY BOLT
adjusting bolt until belt reaches proper tension. Refer
to Belt Tension at the rear of this section for proper (3) Loosen upper alternator mounting nut.
belt tension. (4) Loosen adjusting bolt at upper alternator bracket
(4) After belt is tensioned correctly, tighten idler (Fig. 54) until belt can be removed from pulleys.
pulley bolt to 47 N·m (35 ft. lbs.) (5) Remove belt.
(5) After idler pulley has been tightened into posi-
tion, recheck belt tension. Adjust if necessary. INSTALLATION
(1) Check condition of all pulleys.
BELT REPLACEMENT OR ADJUSTMENT—RIGHT
HAND DRIVE (4.0L)
(1) Disconnect negative battery cable from battery.
(2) Loosen lower alternator mounting bolt and nut.
7 - 38 COOLING SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(2) Install new belt. drive should be removed from the vehicle as one
(3) Using serpentine belt tension gauge, tighten assembly.
adjusting bolt until belt reaches proper tension. Refer (4) Remove four fan hub mounting nuts (Fig. 55)
to Belt Tension at the rear of this section for proper (Fig. 56) and remove fan/viscous fan drive assembly
belt tension. from vehicle.
(4) Tighten alternator upper and lower mounting (5) After removing fan blade/viscous fan drive
bolts. assembly, do not place thermal viscous fan drive in
(5) After generator and adjust bracket have been horizontal position. If stored horizontally, silicone
tightened into position, recheck belt tension. Adjust if fluid in viscous fan drive could drain into its bearing
necessary. assembly and contaminate lubricant.
RADIATOR
CLEANING
Clean radiator fins With the engine cold, apply cold
water and compressed air to the back (engine side) of
the radiator to flush the radiator and/or A/C con-
denser of debris.
INSPECTION
The radiator cooling fins should be checked for
damage or deterioration. Inspect cooling fins to make
sure they are not bent or crushed, these areas result
in reduced heat exchange causing the cooling system
to operate at higher temperatures. Inspect the plastic
end tanks for cracks, damage or leaks.
Inspect the radiator neck for damage or distortion.
WATER PUMP
CLEANING
Clean the gasket mating surface. Use caution not
Fig. 56 Bracket Mounted Cooling Fan to damage the gasket sealing surface.
1 – WATER PUMP (2.5L ENGINE)
2 – HUB/BEARING (4.0L ENGINE) INSPECTION
3 – PULLEY NUTS
Inspect the water pump assembly for cracks in the
4 – PULLEY
housing, Water leaks from shaft seal, Loose or rough
5 – BRACKET
turning bearing or Impeller rubbing either the pump
body or timing chain case/cover.
(3) Install accessory drive belts. Tension belts to
specifications. Refer to the Specifications section at FAN BLADE
the end of this group.
CLEANING
VISCOUS FAN DRIVE REMOVAL/INSTALLATION Clean the fan blades using a mild soap and water.
Refer to Cooling System Fan for removal and Do not use an abrasive to clean the blades.
installation procedures of the viscous drive unit.
INSPECTION
Viscous Fan Drive Fluid Pump Out Requirement:
After installing a new viscous fan drive, bring the WARNING: DO NOT ATTEMPT TO BEND OR
engine speed up to approximately 2000 rpm and hold STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
for approximately two minutes. This will ensure SPECIFICATIONS.
proper fluid distribution within the drive.
CAUTION: If fan blade assembly is replaced
CLEANING AND INSPECTION because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
RADIATOR PRESSURE CAP components could have been damaged due to
excessive vibration.
CLEANING
Clean the radiator pressure cap using a mild soap (1) Remove fan blade assembly from viscous fan
and water only. drive unit (four bolts).
(2) Lay fan on a flat surface with leading edge fac-
INSPECTION ing down. With tip of blade touching flat surface,
Visually inspect the pressure valve gasket on the replace fan if clearance between opposite blade and
cap. Replace cap if the gasket is swollen, torn or surface is greater than 2.0 mm (.090 inch). Rocking
worn. Inspect the area around radiator filler neck for motion of opposite blades should not exceed 2.0 mm
white deposits that indicate a leaking cap. (.090 inch). Test all blades in this manner.
7 - 40 COOLING SYSTEM XJ
CLEANING AND INSPECTION (Continued)
(3) Inspect fan assembly for cracks, bends, loose
DESCRIPTION N·m Ft. In.
rivets or broken welds. Replace fan if any damage is
found. Lbs. Lbs.
Water Pump or Hub 27 20 —
COOLING SYSTEM HOSES Bearing—Nuts
SPECIFICATIONS
BELT TENSION
Belt tension must be adjusted. Refer to the follow-
ing Belt Tension chart for specifications.
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
CONTENTS
page page
INDEX
page page
DESCRIPTION AND OPERATION Components are shown two ways. A solid line
around a component indicates that the component is
INTRODUCTION complete. A dashed line around a component indi-
DaimlerChrysler wiring diagrams are designed to cates that the component being shown is not com-
provide information regarding the vehicles wiring plete. Incomplete components have a reference
content. In order to effectively use DaimlerChrysler number to indicate the page where the component is
wiring diagrams to diagnose and repair a Daimler- shown complete.
Chrysler vehicle, it is important to understand all of It is important to realize that no attempt is made
their features and characteristics. on the diagrams to represent components and wiring
Diagrams are arranged such that the power (B+) as they appear on the vehicle. For example, a short
side of the circuit is placed near the top of the page, piece of wire is treated the same as a long one. In
and the ground (B-) side of the circuit is placed near addition, switches and other components are shown
the bottom of the page. as simply as possible, with regard to function only.
All switches, components, and modules are shown
in the at rest position with the doors closed and the
key removed from the ignition.
8W - 01 - 2 8W - 01 GENERAL INFORMATION XJ
DESCRIPTION AND OPERATION (Continued)
The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 3
DESCRIPTION AND OPERATION (Continued)
The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
8W - 01 - 4 8W - 01 GENERAL INFORMATION XJ
DESCRIPTION AND OPERATION (Continued)
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)
Fig. 1 Wire Code Identification H OPEN
1 – COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER)
2 – GAUGE OF WIRE (18 GAUGE)
I NOT USED
3 – PART OF MAIN CIRCUIT (VARIES DEPENDING ON J OPEN
EQUIPMENT)
4 – MAIN CIRCUIT IDENTIFICATION K POWERTRAIN CONTROL MODULE
L EXTERIOR LIGHTING
WIRE COLOR CODE CHART M INTERIOR LIGHTING
N NOT USED
STANDARD O NOT USED
COLOR CODE COLOR TRACER P POWER OPTION (BATTERY FEED)
COLOR
Q POWER OPTIONS (IGNITION FEED)
BL BLUE WT
R PASSIVE RESTRAINT
BK BLACK WT
S SUSPENSION/STEERING
BR BROWN WT
T TRANSMISSION/TRANSAXLE/
DB DARK BLUE WT TRANSFER CASE
DG DARK GREEN WT U OPEN
GY GRAY BK V SPEED CONTROL, WIPER/WASHER
LB LIGHT BLUE BK W OPEN
LG LIGHT GREEN BK X AUDIO SYSTEMS
OR ORANGE BK Y OPEN
PK PINK BK or WT Z GROUNDS
RD RED WT
TN TAN WT
VT VIOLET WT
WT WHITE BK
YL YELLOW BK
* WITH TRACER
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)
LOCATIONS
WARNING: OPERATE THE ENGINE ONLY IN A
Section 8W-90 contains connector/ground location
WELL-VENTILATED AREA.
illustrations. The illustrations contain the connector
name (or number)/ground number and component
identification. Connector/ground location charts in WARNING: KEEP AWAY FROM MOVING PARTS
Section 8W-90 reference the illustration number for WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
components and connectors. FAN AND BELTS.
Section 8W-80 shows each connector and the cir-
cuits involved with that connector. The connectors
are identified using the name/number on the Dia- WARNING: TO PREVENT SERIOUS BURNS, AVOID
gram pages. CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
SPLICE LOCATIONS LYTIC CONVERTER, AND MUFFLER.
Splice Location charts in Section 8W-70 show the
entire splice, and provide references to other sections
WARNING: DO NOT ALLOW FLAME OR SPARKS
the splice serves.
NEAR THE BATTERY. GASES ARE ALWAYS
Section 8W-95 contains illustrations that show the
PRESENT IN AND AROUND THE BATTERY.
general location of the splices in each harness. The
illustrations show the splice by number, and provide
a written location. WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
NOTES, CAUTIONS, and WARNINGS ING.
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings. TAKE OUTS
NOTES are used to help describe how switches or The abbreviation T/O is used in the component
components operate to complete a particular circuit. location section to indicate a point in which the wir-
They are also used to indicate different conditions ing harness branches out to a component.
8W - 01 - 8 8W - 01 GENERAL INFORMATION XJ
DESCRIPTION AND OPERATION (Continued)
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE voltages in these circuits use a meter with a 10-me-
gohm or greater impedance rating.
DEVICES
All ESD sensitive components are solid state and a • Ohmmeter - Used to check the resistance
symbol (Fig. 2) is used to indicate this. When han- between two points of a circuit. Low or no resistance
dling any component with this symbol comply with in a circuit means good continuity.
the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad- CAUTION: - Most of the electrical components used
vertent discharge into the component. If it is not in today’s vehicle are Solid State. When checking
known whether the part is ESD sensitive, assume resistance in these circuits use a meter with a
that it is. 10-megohm or greater impedance rating. In addi-
(1) Always touch a known good ground before han- tion, make sure the power is disconnected from the
dling the part. This should be repeated while han- circuit. Circuits that are powered up by the vehicle
dling the part and more frequently after sliding electrical system can cause damage to the equip-
across a seat, sitting down from a standing position, ment and provide false readings.
or walking a distance.
(2) Avoid touching electrical terminals of the part, • Probing Tools - These tools are used for probing
unless instructed to do so by a written procedure. terminals in connectors (Fig. 3). Select the proper
(3) When using a voltmeter, be sure to connect the size tool from Special Tool Package 6807, and insert
ground lead first. it into the terminal being tested. Use the other end
(4) Do not remove the part from its protective of the tool to insert the meter probe.
packing until it is time to install the part.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical
system use the Wiring Diagrams and study the cir-
cuit. Also refer to the Troubleshooting Wiring Prob-
lems in this section.
CONNECTOR REPLACEMENT
(1) Disconnect battery. into the proper cavities. For additional connector pin-
(2) Disconnect the connector that is to be repaired out identification, refer to the wiring diagrams.
from its mating half/component (8) Insert the connector locking wedge into the
(3) Remove the connector locking wedge, if repaired connector, if required.
required (Fig. 15) (9) Connect connector to its mating half/compo-
(4) Position the connector locking finger away from nent.
the terminal using the proper pick from special tool (10) Connect battery and test all affected systems.
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 16) (Fig. 17). CONNECTOR AND TERMINAL REPLACEMENT
(5) Reset the terminal locking tang, if it has one. (1) Disconnect battery.
(6) Insert the removed wire in the same cavity on (2) Disconnect the connector (that is to be
the repair connector. repaired) from its mating half/component.
(7) Repeat steps four through six for each wire in (3) Cut off the existing wire connector directly
the connector, being sure that all wires are inserted behind the insulator. Remove six inches of tape from
the harness.
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)
DIODE REPLACEMENT
(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove
the protective covering.
(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).
SPECIAL TOOLS
Terminal Pick 6680
WIRING/TERMINAL
AUTOMATIC
RADIATOR 13 6 SHUT
FAN DOWN
RELAY D 14 12 10 8 5 2 RELAY
11 4
OXYGEN
ENGINE SENSOR
STARTER DOWNSTREAM
MOTOR 10 9 8 20 19 18 RELAY
RELAY
1 7 11 17
C OXYGEN
2 6 12 16
FUEL SENSOR
PUMP 3 4 5 13 14 15 UPSTREAM
RELAY RELAY
FOG CONTROLLER
LAMP 10 9 8 20 19 18
ANTI-LOCK
RELAY 1 7 11 17 BRAKE
NO. 1 B 2 12 RELAY
6 16
3 4 5 13 14 15
A/C FOG
COMPRESSOR LAMP
CLUTCH RELAY
RELAY F27 10A F24 F21 15A F18 15A NO. 2
1 2 7 8 13 14 19 20
A F26 20A F23 15A F20 15A F17 20A
3 4 9 10 15 16 21 22
F25 15A F22 15A F19 20A F16 15A
5 6 11 12 17 18 23 24
FUSES
8
7 14 21 15 28
30A
6 7 13 20 14 27
30A
5 6 12 19 13 26
40A 20A
4 5 11 18 12 25
40A 40A
3 4 10 17 11 24
50A 30A
2 3 9 16 10 23
40A 20A
1 2 8 15 9 22
40A 20A
M2 M1
GENERATOR BATTERY
J008W-7 XJD01002
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 3
FUSES
A3 14RD/WT
7 30A A0 6RD
A3 14RD/WT
A17 16RD/BK
9 20A A0 6RD
A17 16RD/BK
14 - - A0 6RD
15 - - A0 6RD
24 - - -
ABS
DRL
4.0L
XJD01003 J008W-7
8W - 10 - 4 8W-10 POWER DISTRIBUTION XJ
A999 16RD
D8 AUTOMATIC SHUT DOWN RELAY OUTPUT
A999 16RD
4.0L ABS EXCEPT DRL 2.5L, 4.0L M/T, RHD 4.0L A/T LHD 4.0 A/T
4.0L M/T LHD 4.0L M/T EXCEPT ABS EXCEPT DRL EXCEPT 4.0L M/T
4.0L A/T
J008W-7 XJD01004
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 5
B14 - -
C4 - -
C5 F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
EXCEPT DRL
DRL
XJD01005 J008W-7
8W - 10 - 6 8W-10 POWER DISTRIBUTION XJ
C19 - -
S118
A0 A0 A11
BATTERY 6 6 FUSIBLE 6
(8W-20-2) RD RD LINK BK/WT
A11
10
ENGINE DG
GENERATOR
STARTER (8W-20-2)
MOTOR
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
POWER
8 9 10 11 12
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE FUSE (8W-10-2)
2 3 4 5 6
40A 40A 50A 40A 40A
1 (8W-10-9) 2 (8W-10-9) 3 (8W-10-12) 4 (8W-10-13) 5 (8W-10-13)
A111
12
RD/LG
A1 A2 A7 F141 D5 C100
12 12 10 12
RD PK/BK RD/BK LG/RD LHD RHD
C2 C6 11 C201 7 C202
C100 TO TO
JUNCTION RADIATOR
TO TO BLOCK FAN 8 C209
IGNITION IGNITION RELAY
TO
SWITCH SWITCH (IN PDC)
BLOWER
MOTOR
RELAY
13 14 22 16 17
FUSE FUSE FUSE FUSE FUSE A
7 8 9 10 11
30A 30A 20A 20A 30A TO
(8W-10-14) (8W-10-15) (8W-10-14) (8W-10-16) (8W-10-16) FUSE 12
6 7 15 23 24
(PDC)
(8W-10-8)
A3 A16 A17 A4
14 14 16 12
RD/WT RD/LG RD/BK BK/PK
TO TO
TO AUTOMATIC A17 FUSE A41 TO
DAYTIME A3
SHUT DOWN 16 27 16 JUNCTION
RUNNING 14 RD/BK YL
RD/WT RELAY (IN PDC) BLOCK
LAMP (IN PDC)
MODULE
TO TO
D1 C100 A/C ENGINE
COMPRESSOR STARTER
TO CLUTCH MOTOR
HEADLAMP RELAY RELAY
SWITCH (IN PDC) (IN PDC)
XJD01007 J008W-7
8W - 10 - 8 8W-10 POWER DISTRIBUTION XJ
POWER
FROM
FUSE 11
DISTRIBUTION
(PDC) CENTER
(8W-10-7) (8W-10-2)
A
18 A23 A18
FUSE FUSE FUSE
12 16 19
40A 15A 20A
(ABS) (8W-10-17) (8W-10-18)
25 19 A24 A21 A17
(8W-10-16)
FUSE FUSE
13 17
20A 20A
26 (ABS) A22 (4.0L)
(8W-10-16) (8W-10-17)
F34
18
TN/BK
E6
C100
A18
TO TO TO TO TO TO
CONTROLLER CONTROLLER S135 OXYGEN HEADLAMP S218
ANTI-LOCK ANTI-LOCK SENSOR SWITCH
BRAKE BRAKE DOWNSTREAM
TO
RELAY DATA
(IN PDC)
CONNECTOR
A16 A11 A9 A6 A4
FUSE FUSE FUSE FUSE FUSE
20 22 23 25 26
15A 15A 15A 15A 20A
(8W-10-19) (8W-10-19) (8W-10-20) (8W-10-20) (8W-10-20)
A15 A12 A10 A5 A3
BATT A0 (8W-10-7)
POWER BRAKE
8 9
DISTRIBUTION WARNING
CENTER PRESSURE
FUSE FUSE (8W-10-2) SWITCH
2 3
1 (8W-40-7)
40A 40A
1 2 G9
20
GY/BK
A14
C100
E2
A1 A2
12 12 S211
RD PK/BK
G9
20
GY/BK
LHD RHD
C2 C6
C100 66 C201 13 C203
FROM
G9
S210 20
(8W-10-10) GY/BK
A1 A2 G9 G26 PARK
12 12 20 20 BRAKE
RD PK/BK GY/BK LB
SWITCH
(8W-40-7)
7 C1 3 C1 2 C1 1 C2
IGNITION
KEY-IN
SWITCH
SWITCH 1 START
1 4 1 4 1 4 1 4 1 4 2 RUN
2 3 2 3 2 3 2 3 2 3 0 OFF
0 0 0 0 0 3 LOCK
4 ACC
8 C1 9 C1 4 C1 10 C1 1 C1 2 C2
A31 A21 A22 A41 Z1 G16
12 12 12 14 20 20
BK/WT DB BK/OR YL BK BK/LB
RHD LHD
S207
(8W-15-9)
10 C201 RUN A22 TO
Z1 S200
(8W-10-11) 14 (8W-10-10)
BK
A31
12
ST-RUN A21 ST A41
BK/WT G108
(8W-10-10) (8W-10-11) (8W-15-9)
L1 C4
JUNCTION
86 BLOCK
CIGAR (8W-12-2)
FUSE FUSE CIRCUIT CIRCUIT LIGHTER
17 18 BREAKER BREAKER RELAY
15A 10A 28 30 (8W-41-2)
(8W-12-17) (8W-12-17) 25A 20A (8W-41-3)
(8W-12-18) (8W-12-18) (8W-12-23) (8W-12-25)
(8W-12-24) 85
RHD
LHD
XJD01009 J008W-7
8W - 10 - 10 8W-10 POWER DISTRIBUTION XJ
S200
LHD RHD
RUN-ACC A31 2
2 DRIVER
(8W-10-9) DRIVER DOOR
A21 DOOR JAMB
12 JAMB
DB SWITCH
SWITCH (8W-39-7)
(8W-39-6)
L2 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE FUSE
8 9 10 11 27
SPARE 10A 15A 20A 10A
(8W-12-11) (8W-12-11) (8W-12-12) (8W-12-13) (8W-12-23)
(8W-12-14) (8W-12-24)
J008W-7 XJD01010
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 11
BATT A2
(8W-10-9)
A2
12
PK/BK
3 C1
IGNITION
SWITCH
1 START
1 4 1 4 2 RUN
2 3 2 3 0 OFF
0 0 3 LOCK
4 ACC
(8W-10-9)
4 C1 10 C1
A22 A41
12 14
BK/OR YL
62 63 C201
A22 A41
12 14
BK/OR YL
M2 C4 M1 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
12 22 25 19
10A 20A 15A 10A
(8W-12-15) (8W-12-20) (8W-12-20) (8W-12-17)
(8W-12-16) (8W-12-21) (8W-12-21) (8W-12-18)
86
REAR FUSE FUSE
WINDOW 24 26
DEFOGGER SPARE 10A
RELAY (8W-12-20) (8W-12-23)
(8W-48-2) (8W-12-21) (8W-12-24)
(8W-48-3)
85
XJD01011 J008W-7
8W - 10 - 12 8W-10 POWER DISTRIBUTION XJ
BATT A0 (8W-10-7)
POWER
10
DISTRIBUTION
CENTER
FUSE (8W-10-2)
4
50A
3
A7
10
RD/BK
2 C2
JUNCTION
BLOCK
(8W-12-2)
30 86 30
CIGAR HORN
CIRCUIT LIGHTER RELAY
BREAKER RELAY (8W-41-2)
29 (8W-41-2) (8W-41-3)
25A (8W-41-3)
(8W-12-25)
87 85 87
M6 C4 4 C2
F30 X2
16 20
RD DG/RD
LHD RHD
50 C201 S131
F30 F30
16 16
RD RD X2 X2
20 20
DG/RD DG/RD
1
CIGAR LOW HIGH
LIGHTER NOTE NOTE
(8W-41-2) HORN HORN
(8W-41-3) (8W-41-2) (8W-41-2)
(8W-41-3) (8W-41-3)
J008W-7 XJD01012
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 13
BATT A0 (8W-10-7)
POWER
11 12
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-2)
5 6
40A 40A
4 5
F141 A111
12 12
LG/RD RD/LG
D10
RADIATOR D5 C100
FAN
RELAY A111
(IN PDC) 12
(8W-42-8) RD/LG
D14
11 C201 7 C202
8 C209
A111
12
RD/LG
1 4
RADIATOR BLOWER
FAN MOTOR
MOTOR RELAY
(8W-42-8) (8W-42-2)
(8W-42-3)
1 (8W-42-4)
(8W-42-5)
C1
12
DG
A
BLOWER
MOTOR
(8W-42-2)
(8W-42-3)
(8W-42-4)
XJD01013 (8W-42-5) J008W-7
8W - 10 - 14 8W-10 POWER DISTRIBUTION XJ
BATT A0 (8W-10-7)
POWER
13 22 A1
DISTRIBUTION
CENTER
FUSE FUSE FUSE (8W-10-2)
7 9 27
30A 20A 10A
6 15 A2
A3 A3 A17 A17 F1
14 14 16 16 20
RD/WT RD/WT RD/BK RD/BK DB/GY
B1
A/C
COMPRESSOR
CLUTCH
RELAY
B2 (IN PDC)
(8W-42-7)
C3
16
DB/BK
4.0L
RHD OTHER E10 C100
D1 C100 4 C108
C3 F1
16 20
DB/BK DB/GY
A/C
COMPRESSOR
CLUTCH
A3 (8W-42-7)
14
RD/WT
8 C1
HEADLAMP
SWITCH
(8W-50-2)
A3
14
RD/WT 6
SENTRY
6 2 KEY
DAYTIME HEADLAMP IMMOBILIZER
RUNNING DELAY MODULE
LAMP MODULE (8W-39-4)
(8W-39-5)
MODULE (8W-50-5)
(8W-50-11)
J008W-7 XJD01014
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 15
BATT A0 (8W-10-7)
POWER
14
DISTRIBUTION
A20 CENTER
FUSE FUSE (8W-10-2)
8 18
30A 15A
7 A19
A16 A142
14 18
RD/LG DG/OR
D2 1 C107
AUTOMATIC
A999 A142
SHUT 16 18
DOWN RD DG/OR
RELAY
D8 (IN PDC) S109
(8W-30-2)
A999
16 4.0L 2.5L
RD
F142
18
DG/WT S113
4.0L 2.5L A142 A142 A142 A142 A142 A142
18 18 18 18 18 18
DG/OR DG/OR DG/OR DG/OR DG/OR DG/OR
S168
1 1
FUEL FUEL
F142 F142 INJECTOR INJECTOR
18 18 NO. 3 NO. 6
DG/WT DG/WT (8W-30-6) (4.0L)
12 C3 7 C107 1 1 (8W-30-6)
POWERTRAIN FUEL FUEL
CONTROL F142
INJECTOR INJECTOR
MODULE 20
DG/WT NO. 2 NO. 5
(8W-30-2) (8W-30-6) (4.0L)
(8W-30-6)
S110 1 1
FUEL FUEL
F142 F142
20 20
INJECTOR INJECTOR
DG/WT DG/WT NO. 1 NO. 4
(8W-30-6) (8W-30-6)
1 1
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
(8W-30-8) (8W-30-8)
XJD01015 J008W-7
8W - 10 - 16 8W-10 POWER DISTRIBUTION XJ
BATT A0 (8W-10-7)
POWER
16 17 18 19
DISTRIBUTION
CENTER
FUSE FUSE FUSE FUSE (8W-10-2)
10 11 12 13
20A 30A 40A 20A
23 24 25 (ABS) 26 (ABS)
C6 25 9
ENGINE CONTROLLER
STARTER ANTI-LOCK
MOTOR BRAKE
RELAY (8W-35-2)
C7 (IN PDC) 1 C2
(8W-21-2)
(8W-21-3)
JUNCTION
(8W-21-4) BLOCK
30
(8W-21-5) (8W-12-2)
REAR
WINDOW
DEFOGGER
T40
RELAY
16
(8W-48-2)
BR
87 (8W-48-3)
FUSE FUSE
13 14
SPARE 10A
(8W-12-15) (8W-12-15)
1 C108 (8W-12-16) (8W-12-16)
1 C6
C15
12
BK/WT
T40
4 C326
16
C15
BR
12
BK/WT
2 C312
3 C310
C15
ENGINE 12
STARTER BK/WT
MOTOR
(8W-21-2) REAR
(8W-21-3)
(8W-21-4)
WINDOW
(8W-21-5) DEFOGGER
(8W-48-2)
(8W-48-3)
J008W-7 XJD01016
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 17
BATT A0 (8W-10-7)
POWER
A23 A21
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-2)
16 17
15A 20A
A24 A22 (4.0L)
M1
20 F99
PK 18
RD
S135
M1 M1 M1 C16
20 20 20 OXYGEN
PK PK PK SENSOR
12 C1 DOWNSTREAM
JUNCTION RELAY
BLOCK (IN PDC)
(8W-12-2) (8W-30-9)
1 F99
4 C7 S18 C4 3 C3 UNDERHOOD 18
LAMP/ RD
M1 M1 M1 MERCURY
20 20 20 SWITCH
PK PK PK
(8W-44-5)
5 C314 RHD LHD 25
TRANSMISSION C11
6 C201 C
CONTROL OXYGEN
TO MODULE SENSOR
S347 (4.0L) UPSTREAM
LHD RHD M1
20 S361 (8W-31-4) RELAY
PK (8W-10-18) (IN PDC)
(8W-30-9)
M1 M1
20 18 S214
PK PK
M1 M1 M1 M1
20 20 20 20
PK PK PK PK
A 7 C2
CARGO RADIO
LAMP/ A C208 A C207 (8W-47-2)
SWITCH (8W-47-3)
(8W-47-8)
(8W-44-6)
(8W-47-9)
(8W-44-7)
9 C1
INSTRUMENT
CLUSTER
(8W-40-2)
M1 M1
18 18
PK PK
1 1
LEFT RIGHT
SKIM
COURTESY COURTESY EXCEPT SKIM
LAMP LAMP
(8W-44-5) (8W-44-5)
XJD01017 J008W-7
8W - 10 - 18 8W-10 POWER DISTRIBUTION XJ
M1
20
F34
PK
18
TN/BK
LHD RHD
F34
18
F34
TN/BK
18
TN/BK
4 C1
HEADLAMP S218
SWITCH
(8W-50-2) F34 F34 F34
18 18 18
TN/BK TN/BK TN/BK
SKIM OTHERS
16 4 C1 16
DATA HEADLAMP DATA
S361 LINK SWITCH LINK
CONNECTOR (8W-50-2) CONNECTOR
(8W-30-19) (8W-30-19)
S347
FULL
M1 M1 OTHERS OPTIONS M1 M1
20 20 20 20
PK PK PK PK
MIDLINE BASE/POLICE M1
20
PK 2
OVERHEAD
2 MODULE
M1 M1 COMPASS (8W-49-2)
20 20 (8W-49-3)
(8W-49-2)
PK PK
A (8W-49-3)
RIGHT A
VISOR/ C 2 LEFT
VANITY DOME DOME VISOR/
LAMP LAMPS LAMP VANITY
(8W-44-4) SWITCH (8W-44-4) LAMP
(8W-44-4) (8W-44-4)
J008W-7 XJD01018
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 19
BATT A0 (8W-10-7)
POWER
A16 A11
DISTRIBUTION
CENTER
FUSE FUSE (8W-10-2)
20 22
15A 15A
A15 A12
A61
14
DG/BK
C1
FUEL
PUMP
RELAY
(IN PDC)
C2 (8W-30-3)
(8W-30-4)
L9 A141 A61
20 14 16
BK/PK DG/WT DG/BK
B11 D2
C100 14 C107
F5
A141
16
DG/WT
LHD RHD
13 C200 22 C204
L9 A141 A61
20 16 14
BK/PK DG/WT DG/BK
2 1 22 C1
COMBINATION FUEL POWERTRAIN
FLASHER PUMP CONTROL
(8W-52-2) MODULE MODULE
(8W-30-3) (8W-30-2)
(8W-30-4)
LHD
XJD01019 RHD J008W-7
8W - 10 - 20 8W-10 POWER DISTRIBUTION XJ
BATT A0 (8W-10-7)
POWER
A9 A6 A4 DISTRIBUTION
FUSE FUSE FUSE CENTER
23 25 26 (8W-10-2)
15A 15A 20A
A10 A5 A3
F32
20
PK/DB F61 F75
20 16
F8 C100 WT/OR VT
F32 B11
20
PK/DB
FOG
LAMP
6
RELAY
BRAKE
NO. 2
LAMP
B12 (IN PDC)
SWITCH (8W-50-9)
(8W-33-3) L39
(8W-50-10)
20
5 LB
L50 L50
C4 C100
20 8 C106
20
WT/TN WT/TN S106
S203 RHD LHD L39 L39
20 20 F75
LB LB 16
LHD RHD
B4 C100 E1 C100 VT
2
24 C200 LEFT
24 C204 L50 FOG
18 LAMP
WT/TN (8W-50-9)
12 (8W-50-10) LHD RHD
L50 CONTROLLER
20
WT/TN ANTI-LOCK 14 C200
BRAKE 21 C204
(8W-35-2)
F75 F75
14 16
S302 VT VT
L50
20
WT/TN 2
L50 L50 RIGHT
5 C326 20 20
FOG
WT/TN WT/TN
L50 LAMP
18 6 C322 6 C321 (8W-50-9)
WT/TN (8W-50-10) S301
1 C333 L50 L50
18 18 F75 F75
L50 WT/TN WT/TN 16 16
18 VT VT
DG/WT 3 3
LEFT RIGHT 1 C2 2 C2
2 POWER
CENTER TAIL/ TAIL/
STOP STOP AMPLIFIER
HIGH (8W-47-2)
MOUNTED LAMP LAMP (8W-47-3)
(8W-51-3) (8W-51-3)
STOP
LAMP
(8W-51-4)
J008W-7 XJD01020
XJ 8W - 12 JUNCTION BLOCK 8W - 12 - 1
C9
C3
28 29
25A 25A
30
1 25A
20A
C1
2 25A 25A 15
SPARE
3 10A 10A 16
RELAY
4 10A 15A 17
CIGAR
LIGHTER
C2 RELAY 5 10A 10A 18
6 5A 10A 19
7 10A 15A 20
C8
8 15A 21
11 20A 24
12 10A 15A 25
C4 REAR
WINDOW
DEFOGGER 13 10A 26
RELAY
14 10A 10A 27
C5
C7 C6
FRONT OF
JUNCTION BLOCK
J008W-7 XJD01202
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 3
FUSES
6 5A E2 20OR E1 20TN
8 - - A21 12DB
13 - - A4 12BK/PK
24 - - A22 12BK/OR
XJD01203 J008W-7
8W - 12 - 4 8W-12 JUNCTION BLOCK XJ
CIRCUIT BREAKERS
87A - -
87A - -
87A - -
J008W-7 XJD01204
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 5
BATT A7 (8W-10-12)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
1 2
25A 25A
30
CIGAR
LIGHTER
RELAY
(8W-41-2)
(8W-41-3)
87
M5 C4 M6 C4
F38 F30
16 16
RD/LB RD
65 C201 50 C201
F38 F30
16 16
RD/LB RD
1 1
POWER CIGAR
OUTLET LIGHTER
(8W-41-2) (8W-41-2)
(8W-41-3) (8W-41-3)
XJD01205 J008W-7
8W - 12 - 6 8W-12 JUNCTION BLOCK XJ
HEADLAMP
BEAM
SELECT
SWITCH
3 (8W-50-3)
(8W-50-4)
L3
16
RD/OR
S213
(8W-50-3)
(8W-50-4)
L3
16
RD/OR
LHD RHD
16 C201
L3
16
RD/OR
S7 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
3 16
10A 10A
9 C1 11 C1
L33 L34
20 20
RD RD/OR
2 6 C106
L33 L34
18 18
RD RD/OR
L33 A A
20 LEFT RIGHT
RD HEADLAMP HEADLAMP
12 C106 (8W-50-3) (8W-50-3)
(8W-50-4) (8W-50-4)
L33
20
RD/WT
B10
FOG
LAMP
RELAY
NO. 1
(IN PDC)
(EXCEPT DRL)
(8W-50-8)
J008W-7 XJD01206
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 7
HEADLAMP
BEAM
SELECT
SWITCH
1 (8W-50-3)
(8W-50-4)
L4
16
VT/WT
LHD RHD
L4
16
VT/WT
L4
22 C201 16
VT/WT
L4
16
VT/WT
L4
16
VT/WT
S3 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
4 5
10A 10A
10 C1 1 C1
L43 L44
20 20
VT VT/RD
S133
13
9 C106
OTHER DRL
L44 L44
20 18
VT/RD VT/RD
F6 C100
L43 L44 B12
18 18 10
VT VT/RD DAYTIME
RUNNING
LAMP
B B MODULE
LEFT RIGHT (8W-50-11)
HEADLAMP HEADLAMP
(8W-50-3) (8W-50-3)
(8W-50-4) (8W-50-4) RHD
LHD
XJD01207 J008W-7
8W - 12 - 8 8W-12 JUNCTION BLOCK XJ
LHD
HEADLAMP
SWITCH
(8W-50-2)
1 C1
E1
20
TN
42 C201
E1
20
TN
S1 C4
JUNCTION
BLOCK
FUSE (8W-12-2)
6
5A
S2 C4
E2
20
OR
S315
E2 E2
20 20
OR OR
1 C206
43 C201
E2 E2
20 20
OR OR
1 1
E2 PRNDL TRANSFER
20 ILLUMINATION CASE
OR
(A/T) SWITCH
(8W-44-2) ILLUMINATION
(8W-44-2)
S215
E2 E2 E2 E2 E2 E2
20 20 20 20 20 20
OR OR OR OR OR OR
A/C- POLICE
HEATER PACKAGE OTHERS
5 C2
RADIO 7 C1 CONTROL 4
(8W-47-2) (8W-42-4) EXTENDED
(8W-47-8) IDLE
HEATER
CONTROL SWITCH
(8W-42-2) (8W-30-17) 1
3 C1 3 4 FRONT
INSTRUMENT REAR REAR FOG
CLUSTER WIPER/ WINDOW LAMP
(8W-40-12) WASHER DEFOGGER SWITCH
SWITCH SWITCH (8W-44-2)
(8W-53-3) (8W-48-2) A/C
J008W-7 HEATER ONLY XJD01208
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 9
RHD
HEADLAMP
SWITCH
(8W-50-2)
1 C1
E1
20
TN
S1 C4
JUNCTION
BLOCK
FUSE (8W-12-2)
6
5A
S2 C4
E2
20
OR
S215
E2 E2 E2 E2 E2
20 20 20 20 20
OR OR OR OR OR
5 C2 4
12 C203 RADIO REAR
(8W-47-3) WINDOW
(8W-47-9) DEFOGGER
SWITCH
E2 (8W-48-3)
20
OR/BK 3 C1 1
INSTRUMENT FRONT
CLUSTER FOG
(8W-40-12) LAMP
SWITCH
(8W-44-3)
1 C206
E2 E2 E2 E2
20 20 20 20
OR OR OR OR
1 1
PRNDL TRANSFER 7 C1 A/C- 3
ILLUMINATION CASE HEATER REAR
(A/T) SWITCH CONTROL WIPER/
(8W-44-2) ILLUMINATION (8W-42-5) WASHER
(8W-44-3) SWITCH
HEATER (8W-53-4)
CONTROL
A/C (8W-42-3)
HEATER ONLY
XJD01209 J008W-7
8W - 12 - 10 8W-12 JUNCTION BLOCK XJ
HEADLAMP
SWITCH
(8W-50-2)
9 C1
L7
18
BK/YL
S206
LHD RHD
45 C201
M3 C4 L7
JUNCTION 18
BLOCK BK/YL
FUSE (8W-12-2)
7
10A
4 C2
RADIO
(8W-47-2)
(8W-47-3)
6 C2 2 C7 (8W-47-8)
L77
20 (8W-47-9)
L77
BR/YL 18
BR/YL
B6
L77 FOG
LAMP S311
20
TRAILER
BR/YL RELAY L77 L77
TOW
7 C106 NO. 1 18 18
BR/YL CONNECTOR BR/YL
B9 (IN PDC) (8W-54-2)
L77 (8W-50-8)
L139 2 C327 5
20 (8W-50-10) TRAILER
20
BR VT TOW OTHERS
L77 L77
S104 A5 C100 18 20
7 C323
BR/YL BR/YL
L77 L77 L77 3 L77
18 18 20 FRONT 4 C311 20
BR BR BR FOG 11 C310 BR/YL L77
1 LAMP L77 18
LEFT SWITCH 18 S340 BR/YL
SIDE (8W-50-9) BR/YL L77
ON (8W-50-10) 18
MARKER INDICATOR 1 C330 BR/YL
LAMP
(8W-50-6) 4 2 L78
2 L39 18
(8W-52-3)
LEFT 20 BK/YL 7 C322
FRONT LB 1 L77
PARK/ A4 C100 LICENSE 18
TURN L92 LAMP BR
20 (8W-51-4) 2
2 SIGNAL
LEFT LAMP PK LEFT
FRONT NO. 2 B15 TAIL/
PARK/ (8W-50-6) FOG STOP
TURN (8W-52-3) LAMP LAMP
RELAY (8W-51-3)
SIGNAL
LAMP NO. 2
NO. 1 B13 (IN PDC)
(8W-50-6) (8W-50-9)
(8W-52-3) (8W-50-10)
J008W-7 XJD01210
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 11
S13 C4
LHD RHD
F87 F87
20 20
WT/BK WT/BK
FULL
OPTIONS BASE
S225
F87 F87
20 20
WT/BK WT/BK
5 C201
F87 F87
20 20
WT/BK WT/BK
S216
F87 F87
20 20 F87 F87
WT/BK WT/BK 20 20
WT/BK WT/BK
LHD RHD
F87 4 8
20 SENTRY HEADLAMP
WT/BK KEY DELAY
IMMOBILIZER MODULE
6 C301
MODULE (8W-50-5)
(8W-39-4)
6 (8W-39-5) 8 C1
COMPASS INSTRUMENT
(8W-49-2) CLUSTER
(8W-49-3) (8W-40-2)
XJD01211 J008W-7
8W - 12 - 12 8W-12 JUNCTION BLOCK XJ
1 C201 B5
A/C
DUTY COMPRESSOR
CYCLE CLUTCH
F20 RELAY
18 EVAP/
F20 F20 (IN PDC)
WT 18 18 PURGE
(8W-42-7)
WT WT 2 SOLENOID
F20 (GAS)
E9
A9 C100 18 (8W-30-15)
RADIATOR
DIESEL OTHER WT
FAN
RELAY
S159 (IN PDC)
(4.0L M/T) D11 (8W-42-8)
(4.0L A/T DRL) (2.5L)
(4.0L A/T (4.0L A/T FOG F20
EXCEPT FOG) EXCEPT DRL) F20
18 18
WT WT
4.0L M/T 2.5L A/T 2.5L M/T
F26
18
F20 F20 PK/OR C18
18 18
F20 OXYGEN
WT WT F20 SENSOR
18 C18
WT 18 DOWNSTREAM
OXYGEN WT
11 C107 F26 SENSOR RELAY
1 C113 F20
18 DOWNSTREAM (IN PDC)
11 C107 PK/OR (8W-30-9)
18 RELAY
WT (IN PDC)
F20 F20
18 (8W-30-9) C13
18
WT WT
OXYGEN
TO F20 SENSOR
S161 18
(8W-51-6)
UPSTREAM
WT
RELAY
C13 (IN PDC)
F20 (8W-30-9)
18 OXYGEN
WT SENSOR B5
A UPSTREAM A/C
BACK-UP RELAY COMPRESSOR
LAMP (IN PDC) CLUTCH LHD
SWITCH (8W-30-9) RHD
RELAY
(8W-51-6) (IN PDC)
(8W-42-7)
J008W-7 XJD01212
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 13
2.5L
ST-RUN A21 (8W-10-10)
JUNCTION
BLOCK
(8W-12-2)
FUSE
11
20A
5 C2
F12
18
DB/WT
S130
C5
FUEL
PUMP
RELAY
(IN PDC)
C3 (8W-30-3)
(8W-30-4)
10 C107
D4
AUTOMATIC
F12
18
SHUT
DB/WT DOWN
RELAY
D6 (IN PDC)
(8W-30-2)
2 C1
POWERTRAIN
CONTROL
MODULE
(8W-30-2)
XJD01213 J008W-7
8W - 12 - 14 8W-12 JUNCTION BLOCK XJ
4.0L
ST-RUN A21 (8W-10-10)
JUNCTION
BLOCK
(8W-12-2)
FUSE
11
20A
5 C2
F12
18
DB/WT
S130
RHD LHD
26
TRANSMISSION
CONTROL
F12 F12 MODULE
18 18 (RHD)
DB/WT DB/WT
(8W-31-4)
D4 C5
S136 AUTOMATIC FUEL
SHUT PUMP
DOWN RELAY
F12 F12
18 18 RELAY (IN PDC)
DB/WT DB/WT D6 (IN PDC) C3 (8W-30-3)
(8W-30-2) (8W-30-4)
26
TRANSMISSION
CONTROL
MODULE
10 C107 (8W-31-4)
F12
18
DB/WT
2 C1
POWERTRAIN
CONTROL
MODULE
(8W-30-2)
J008W-7 XJD01214
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 15
LHD
RUN A22 (8W-10-11) BATT A4 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
86 30
REAR
WINDOW
DEFOGGER
RELAY
(8W-48-2)
85 87
FUSE FUSE
14 13
10A SPARE
3 C2
INSTRUMENT 2 C312
CLUSTER 3 C310
(8W-40-9)
37 C200
C16 C16
20 20
C15
LB/YL LB/YL
12
11 C305 BK/WT
3
FULL POWER
OPTIONS MIRRORS REAR
WINDOW
C16 C16 DEFOGGER
20 20 SWITCH
1
LB/YL BK/WT
COMBINATION (8W-48-2)
FLASHER
(8W-52-2) 5 REAR
DRIVER WINDOW
POWER DEFOGGER
MIRROR (8W-48-2)
(8W-48-2)
XJD01215 J008W-7
8W - 12 - 16 8W-12 JUNCTION BLOCK XJ
RHD
RUN A22 (8W-10-11) BATT A4 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
86 30
REAR
WINDOW
DEFOGGER
RELAY
(8W-48-3)
85 87
FUSE FUSE
14 13
10A SPARE
5
2 C204 DRIVER 4 C326
POWER
MIRROR
C16
(8W-48-3)
20
LB/YL
3
3 C2 REAR
C15
INSTRUMENT WINDOW 12
CLUSTER DEFOGGER BK/WT
(8W-40-10) SWITCH
(8W-48-3)
11 C305
FULL POWER
OPTIONS MIRRORS 2 C312
3 C310
C16 C16
20 20 C15
LB/YL BK/WT 12
BK/WT
1 5
COMBINATION PASSENGER REAR
FLASHER POWER WINDOW
(8W-52-2) MIRROR DEFOGGER
(8W-48-3) (8W-48-3)
J008W-7 XJD01216
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 17
LHD
BATT A7 (8W-10-12) RUN-ACC A31 (8W-10-9) ST A41 (8W-10-11)
JUNCTION
BLOCK
(8W-12-2)
9 C9 S9 C4 S4 C4 3 C1
X12 F83 2.5L A/T 4.0L A/T M/T
F35 16 18
16 RD/WT YL/DG
RD F45 F45 F45
54 44 20 20 20
C201 YL/RD YL/RD YL/RD
X12
16 2 2
RD/WT CLUTCH CLUTCH
C2 F45
6
18
INTERLOCK INTERLOCK
RADIO YL SWITCH SWITCH
(8W-47-2) JUMPER
(8W-47-8)
1 1
F83
18 T141
YL/DG 20 T141
YL 20
YL
39 C200 C8
ENGINE
HEATED STARTER
OTHER SEATS
MOTOR
RELAY
F83 C10 (IN PDC)
18 (8W-21-2)
F83
YL/DG (8W-21-3)
18
(8W-21-4)
YL/DG
S351 (8W-21-5)
1 C316
5 C2
PASSENGER S353
(8W-63-4)
POWER 3 C305 F83 F83
LOCK/ FULL OPTIONS POWER MIRRORS 18 18
WINDOW YL/DG YL/DG
SWITCH F83 F83 4
(FULL 18 18 LEFT
OPTIONS) YL/DG YL/DG HEATED
(8W-61-2) SEAT
3 C2 2 SWITCH
DRIVER POWER 4 (8W-63-4)
POWER MIRROR RIGHT
LOCK/ SWITCH HEATED
WINDOW (8W-62-6) SEAT
SWITCH SWITCH
(8W-62-2) (8W-63-4)
XJD01217 J008W-7
8W - 12 - 18 8W-12 JUNCTION BLOCK XJ
RHD
BATT A7 (8W-10-12) RUN-ACC A31 (8W-10-9) ST A41 (8W-10-11)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
15 17 18 19
25A 15A 10A 10A
7 C5 S9 C4 S4 C4 3 C1
16 C204 E7 C100
3 C300
6 C2
F35 RADIO F45
16 (8W-47-3) 20
RD (8W-47-9) YL/RD
F83
18
YL/DG
1 C306 POWER
MIRRORS FULL OPTIONS M/T A/T
S352
F35 F83 F45 F45
F83 20 20
16 18 18
RD YL/DG YL/RD YL/RD
YL/DG
1 C324 2 2
2 CLUTCH CLUTCH
POWER INTERLOCK F45
INTERLOCK
MIRROR 18
1 C316 SWITCH YL SWITCH
SWITCH JUMPER
(8W-62-7)
1 1
S353
(8W-63-4) F83 T141 T141
F83 18 20 20
18 F83 YL/DG YL YL
YL/DG 18
4 YL/DG
LEFT
HEATED 3 C2 E8 C100
SEAT DRIVER T141
SWITCH POWER 20
YL
5 C2 (8W-63-4) LOCK/
PASSENGER WINDOW C8
POWER SWITCH ENGINE
4
LOCK/ (8W-62-4) STARTER
RIGHT
WINDOW MOTOR
HEATED
SWITCH RELAY
SEAT
(FULL C10 (IN PDC)
SWITCH (8W-21-2)
OPTIONS) (8W-63-4) (8W-21-3)
(8W-61-3) (8W-21-4)
(8W-21-5)
J008W-7 XJD01218
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 19
BATT A7 (8W-10-12)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
20 21
15A 15A
86 30
HORN
RELAY
(8W-41-2)
(8W-41-3)
85 87
8 C7 S22 C4 1 C5 1 C5 S22 C4 4 C2
X3 X3
20 20
BK/RD BK/RD
A6 X3 X2
20 20 20
RD/OR BK/RD
26 C201 DG/RD
7 C301
3 C323 X3
20 S131
BK/RD
A6 X3 1 C1 X2 X2
20 20 20 20
RD/OR BK/RD DG/RD DG/RD
CLOCKSPRING
(8W-41-2)
(8W-41-3)
10
OVERHEAD HORN
MODULE SWITCH
(8W-49-4) (8W-41-2)
(8W-49-5) (8W-41-3)
LOW HIGH
NOTE NOTE
S338
HORN HORN
(8W-41-2) (8W-41-2)
(8W-41-3) (8W-41-3)
A6 A6 A6
20 20 20
RD/OR RD/OR RD/OR
3 3
4 TRAILER TRAILER
TOW TOW
TRAILER
LEFT RIGHT
TOW
TURN TURN
CONNECTOR
(8W-54-3)
RELAY RELAY
(8W-54-3) (8W-54-3)
XJD01219 J008W-7
8W - 12 - 20 8W-12 JUNCTION BLOCK XJ
LHD
RUN A22 (8W-10-11)
JUNCTION
BLOCK
(8W-12-2)
S11 C4 S8 C4 6 C1
V23 F15 F15
18 20 20
BR/PK DB/WT DB/WT
S219
39 C201
F15 F15
V23 20 20 S134
18 DB/WT DB/WT
BR/PK F15 F15
5 9 C209 18 20
5 DB/WT DB/WT
REAR 5
WIPER/ BLOWER
WASHER D2 MOTOR
SWITCH 20 RELAY B20
OR (8W-42-2) CONTROLLER
6 (8W-53-3)
(8W-42-4) ANTI-LOCK
10
BRAKE
V23
18 BLEND RELAY
BR/PK DOOR B18 (IN PDC)
(8W-35-3)
ACTUATOR
29 C200 (8W-42-7) 23
V23 F15 CONTROLLER
18 20 ANTI-LOCK
BR/PK DB/WT BRAKE
(8W-35-3)
4 C327 40 C201
V23 F15
18 20
BR/PK DB/WT
2 C313
7 C310
V23 S217
18
BR/PK F15 F15 F15
20 20 20
4 DB/WT DB/WT DB/WT
REAR
WIPER 2 3 4 C2
MOTOR SHIFT EXTENDED A/C-
(8W-53-3) LOCK IDLE HEATER
SOLENOID SWITCH CONTROL
(8W-31-3) (POLICE (8W-42-7)
(8W-31-7) PACKAGE)
(8W-30-17)
J008W-7 XJD01220
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 21
RHD
RUN A22 (8W-10-11)
JUNCTION
BLOCK
(8W-12-2)
S11 C4 S8 C4 6 C1
V23 F15 F15
18 20 20
BR/PK DB/WT DB/WT
6
REAR S134
WIPER/
F15
WASHER F15 20
SWITCH 18 DB/WT
(8W-53-4) DB/WT
5
B20
V23 CONTROLLER
18 ANTI-LOCK
BR/PK BRAKE
6 C203 RELAY
FULL B18 (IN PDC)
OPTIONS BASE (8W-35-3)
V23 23
18 S324 CONTROLLER
BR/PK ANTI-LOCK
V23
18 BRAKE
BR/PK (8W-35-3)
4 C327 1 C303 S219
NOT
USED F15 F15 F15
V23 20 20 20
18 DB/WT DB/WT DB/WT
BR/PK
4 C2
A/C- 1 C204
2 C313 HEATER S349
7 C310 CONTROL
(8W-42-7) F15 F15
20 20
DB/WT DB/WT
V23
9
18 5 C209
BR/PK
2 D2 5
4 SHIFT 20 BLOWER
LOCK OR MOTOR
REAR
SOLENOID 10 RELAY
WIPER
(8W-31-3) BLEND (8W-42-3)
MOTOR
(8W-53-4)
(8W-31-7) DOOR (8W-42-5)
ACTUATOR
(8W-42-7)
XJD01221 J008W-7
8W - 12 - 22 8W-12 JUNCTION BLOCK XJ
HEADLAMP
SWITCH
HEADLAMP
(8W-50-2)
SWITCH
OUTPUT
9 C1
L7
18
BK/YL
S206
(8W-12-10)
LHD RHD
45 C201
L7
18
BK/YL
M3 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE
23
10A
5 C1 6 C7
L78 L78
20 18
DG/YL DG/YL
7 C321
14 C106
L78 L78
20 18
DG/YL DG/YL
S101
L78 L78 L78
18 18 20
DG/YL DG/YL DG/YL
2 2 1
RIGHT RIGHT RIGHT
2
FRONT FRONT SIDE
RIGHT
PARK/ PARK/ MARKER
TAIL/
TURN TURN LAMP
STOP
SIGNAL SIGNAL (8W-50-7)
(8W-52-4) LAMP
LAMP LAMP (8W-51-3)
NO. 1 NO. 2
(8W-50-7) (8W-50-7)
(8W-52-4) (8W-52-4)
J008W-7 XJD01222
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 23
LHD
JUNCTION
BLOCK
(8W-12-2)
S21 C4 S23 C4 8 C5 1 C8
13 C201
F81
12
TN
33 C200
F81
12
TN
1 C307
F81
14
TN
20 17 9 C1 4 C2
AIRBAG DRIVER PASSENGER
CONTROL POWER POWER
MODULE LOCK/ LOCK/
(8W-43-2) WINDOW WINDOW
SWITCH SWITCH
(FULL OPTIONS) (FULL OPTIONS)
(8W-60-2) (8W-61-2)
(8W-60-4)
XJD01223 J008W-7
8W - 12 - 24 8W-12 JUNCTION BLOCK XJ
RHD
JUNCTION
BLOCK
(8W-12-2)
S21 C4 S23 C4 8 C5 1 C8
15 14 C204 3 C202
F81
12
TN
F14 F23
18 18 1 C307
LG/YL DB/YL
F81
14
TN
20 17 4 C2 9 C1
AIRBAG PASSENGER DRIVER
CONTROL POWER POWER
MODULE LOCK/ LOCK/
(8W-43-3) WINDOW WINDOW
SWITCH SWITCH
(FULL OPTIONS) (FULL OPTIONS)
(8W-61-3) (8W-60-3)
(8W-60-5)
J008W-7 XJD01224
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 25
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT CIRCUIT
BREAKER BREAKER
29 30
25A 20A
2 C6 M4 C4 8 C1
F37 V6
14 16
RD/LB DB
V6
LHD RHD 16
DB
8 C201
1
FRONT
V6 WIPER
16 MOTOR
DB (8W-53-2)
5
2 C316 WIPE/
WASH
F37 SWITCH
14 (8W-53-2)
RD/LB
S356
A 8 B
LEFT HEATED RIGHT
POWER SEAT POWER
SEAT RELAY SEAT
SWITCH (8W-63-6) SWITCH
(8W-63-2) (8W-63-3)
POWER SEATS
XJD01225 J008W-7
8W - 12 - 26 8W-12 JUNCTION BLOCK XJ
BATT A0 (8W-10-7)
POWER
A23
DISTRIBUTION
CENTER
FUSE (8W-10-2)
16
15A
A24 (8W-10-17)
M1
20
PK
S135
M1 M1 M1
20 20 20
PK PK PK
12 C1
JUNCTION 1
BLOCK UNDERHOOD
(8W-12-2) LAMP/
MERCURY
4 C7 S18 C4 3 C3 SWITCH
(8W-44-5)
M1 M1 M1
20 20 20
PK PK PK
5 C314 RHD LHD OTHERS SKIM 25
TRANSMISSION
6 C201 CONTROL
MODULE
TO TO (4.0L)
LHD RHD M1 S347 S361
20 (8W-31-4)
(8W-10-18) (8W-10-18)
PK
M1 M1
20 18 S214
PK PK
M1 M1 M1 M1
20 20 20 20
PK PK PK PK
A 7 C2
CARGO RADIO
LAMP/ A C208 A C207 (8W-47-2)
SWITCH (8W-47-3)
(8W-47-8)
(8W-44-6)
(8W-47-9)
(8W-44-7)
9 C1
INSTRUMENT
CLUSTER
(8W-40-2)
M1 M1
18 18
PK PK
1 1
LEFT RIGHT
COURTESY COURTESY
LAMP LAMP
(8W-44-5) (8W-44-5)
J008W-7 XJD01226
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 27
S201
LHD RHD
46 C201
M2
20
YL
S25 C4
JUNCTION
BLOCK
(8W-12-2)
7 C7 1 C3
M2
20
YL
M2
20 OVERHEAD MODULE BASE/POLICE
YL
M2
S345 20
YL
M2
20 FULL OPTIONS MIDLINE 3
YL DOME
1
M2 M2 LAMP
OVERHEAD (8W-44-4)
20 20
MODULE YL YL
(8W-49-4) 7 B
(8W-49-5)
COMPASS DOME
(8W-49-4) LAMPS
(8W-49-5) SWITCH
(8W-44-4)
S304
M2 M2 M2 M2 M2
20 20 20 20 20
YL YL YL YL YL
C317 C318
A
C318 A C320 A
C317 A C319 6 C314
M2 M2 M2 M2 M2
18 18 18 18 20
YL YL YL YL YL
1 3 1 3 B
DRIVER LEFT PASSENGER RIGHT CARGO
DOOR REAR DOOR REAR LAMP/
JAMB DOOR JAMB DOOR SWITCH
SWITCH JAMB SWITCH JAMB (8W-44-6)
(8W-39-6) SWITCH (8W-39-6) SWITCH (8W-44-7)
LHD
(8W-39-7) (8W-39-6) (8W-39-7) (8W-39-6)
XJD01227 RHD J008W-7
(8W-39-7) (8W-39-7)
8W - 12 - 28 8W-12 JUNCTION BLOCK XJ
LHD
PASSENGER PASSENGER
POWER DOOR
LOCK/ LOCK
WINDOW MOTOR
C1 SWITCH
(8W-61-4)
1 C1 5 2 1
(FULL OPTIONS)
(8W-61-4)
P34 P33 P33 P34
16 16 16 16
PK/BK OR/BK OR/BK PK/BK
S317
S316
P34 P33
16 16
PK/BK OR/BK
12 C9 1 C9
JUNCTION
BLOCK
(8W-12-2)
5 C7 1 C7
P34 P33
16 16
PK/BK OR/BK
S307
S306
2 1 C311
5 4 C310
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK
1 2 1 2 1 2 B A
DRIVER LEFT RIGHT LIFTGATE
DOOR REAR REAR LOCK
LOCK DOOR DOOR MOTOR
MOTOR LOCK LOCK (8W-61-4)
(8W-61-4) MOTOR MOTOR
(8W-61-4) (8W-61-4)
FULL OPTIONS
J008W-7 XJD01228
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 29
RHD
PASSENGER
POWER
LOCK/
WINDOW
1 C1 5 C1 SWITCH
(FULL OPTIONS)
(8W-61-5)
P34 P33
16 16
PK/BK OR/BK
S323
S322
P34 P33
P34 P33 16
16 16 16
PK/BK OR/BK
PK/BK OR/BK
1 2
PASSENGER
DOOR
5 4
C305 LOCK
MOTOR
(8W-61-5)
P34 P33
16 16
PK/BK OR/BK
S307
S306
5 C7 1 C7
5 4 C309 5 4 C304 2 1 C326 JUNCTION
P34 P33 BLOCK
16 16 (8W-12-2)
PK/BK OR/BK
2 1 C311 12 C9 1 C9
5 4 C310
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK
1 2 1 2 B A 1 2
LEFT RIGHT LIFTGATE DRIVER
REAR REAR LOCK DOOR
DOOR DOOR MOTOR LOCK
LOCK LOCK (8W-61-5) MOTOR
MOTOR MOTOR (8W-61-5)
(8W-61-5) (8W-61-5)
FULL OPTIONS
XJD01229 J008W-7
8W - 12 - 30 8W-12 JUNCTION BLOCK XJ
LHD EXCEPT FULL OPTIONS
1 3 4 7 8 5 6
2 5 1
DRIVER
POWER
M M MIRROR
(8W-62-6)
2 C9 6 C9
3 6 4
JUNCTION
BLOCK
(8W-12-2) P91 P76
20 20
WT/BK OR/YL
9 C5 10 C5
P74 P72 10 C9 7 C9
20 20 JUNCTION
DB YL/BK BLOCK
(8W-12-2)
24 20 C201
C200 2 C5 3 C5
35 34
P76 P91
P74 P72 20 20
20 20 OR/YL WT/BK
DB YL/BK
28 67 C201
9 8 C305
36 12 C200
P74 P72
20 20 P76 P91
DB YL/BK 20 20
2 5 1 OR/YL WT/BK
PASSENGER
POWER 10 13 C305
M M MIRROR
(8W-62-6) P76 P91
20 20
OR/YL WT/BK
3 6 4
J008W-7 XJD01230
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 31
LHD FULL OPTIONS
DRIVER DRIVER
POWER POWER
LOCK/ MIRROR
WINDOW (8W-62-2)
4 C2 7 C2 2 C2 SWITCH 2 4
(8W-62-3)
P76 P76 P76
20 20 20
OR/YL OR/YL OR/YL
P74 P72
20 20 S328
DB YL/BK
P76
20
OR/YL
9 8 10
C305
35 34 36
C200
24 20 28 C201
9 C5 10 C5 2 C5
JUNCTION
BLOCK
(8W-12-2)
2 C9 6 C9 10 C9
P74 P72 P76
20 20 20
DB YL/BK OR/YL
S318
P76 P76
20 20
OR/YL OR/YL
3 1 2 4
PASSENGER
POWER
MIRROR
(8W-62-3)
XJD01231 J008W-7
8W - 12 - 32 8W-12 JUNCTION BLOCK XJ
RHD EXCEPT FULL OPTIONS
RUN-ACC F83 (8W-12-18)
POWER
4 MIRROR
1
SWITCH
(8W-62-7)
1 RIGHT
2 UP
3 LEFT
4 DOWN
5 DRIVER MIRRIOR
2 3
6 PASSENGER
MIRROR
6 5 6 5
1 7 8 4 3 5 6
1 5 2
S319 DRIVER
(8W-15-7) P76 P91
POWER 20 20
M M MIRROR OR/YL WT/BK
Z1
16 (8W-62-7)
BK
4 6 3
11 C9 2 C9 6 C9
JUNCTION P76 P91
BLOCK 20 20
(8W-12-2) OR/YL WT/BK
S5 C4 9 C5 10 C5
Z1 P74 P72
14 20 20
BK DB YL/BK
10 C9 7 C9
9 8
C204 JUNCTION
BLOCK
P74 P72 (8W-12-2)
20 20
DB YL/BK
2 C5 3 C5 3 C7
P91
9 8 C305 20
S208 WT/BK
(8W-15-8) 10 C203
P76 P91 P91
P75 P71 20
20 20 20 20
OR/YL WT/BK WT/BK
DB/WT YL
10 C204 POWER
2 5 1 P76 BASE MIRRORS
Z1 PASSENGER 20
14 POWER OR/YL S359
BK M M MIRROR
(8W-62-7)
10 13 C305
3 6 4
P76 P91
20 20
G107 OR/YL WT/BK
(8W-15-8)
J008W-7 XJD01232
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 33
RHD FULL OPTIONS
PASSENGER
POWER
MIRROR
(8W-62-5)
3 1 2 4
S328
P76
20
OR/YL
9 8 10
C305
9 8 10 C204
9 C5 10 C5 2 C5
JUNCTION
BLOCK
(8W-12-2)
2 C9 6 C9 10 C9
S318
6 C2 1 C2 2 C2 2 4
DRIVER DRIVER
POWER POWER
LOCK/ MIRROR
WINDOW (8W-62-4)
SWITCH
(8W-62-5)
XJD01233 J008W-7
8W - 12 - 34 8W-12 JUNCTION BLOCK XJ
3 9
2 C3 S5 C4
Z1
RIGHT 14
VISOR/ BK
VANITY LHD RHD
LAMP
B (8W-44-4)
S314
(8W-15-7)
Z1 Z1 Z1 Z1
20 20 20 20 Z1 Z1
BK BK BK BK 14 14
BK BK
S342
(OVERHEAD 14 C201
Z1 CONSOLE)
20 Z1
(8W-15-7) 14
BK
BK
OTHER COMPASS
B
LEFT
VISOR/ Z1 Z1
VANITY 20 20 S208
BK BK (8W-15-8)
LAMP
(8W-44-4) Z1
A 1
14
DOME COMPASS BK
LAMPS (8W-49-2)
SWITCH (8W-49-3)
(8W-44-4)
G107
(8W-15-8)
J008W-7 XJD01234
XJ 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1
S107
POWERTRAIN
CONTROL DATA
MODULE LINK
CONTROLLER
(8W-30-2) CONNECTOR
ANTI-LOCK (8W-30-19)
31 C1 32 C1 BRAKE
TRANSMISSION 4 5
(8W-35-2)
CONTROL 8 24
Z1 Z12
MODULE 18 18
BK BK/TN
(4.0L)
24 (8W-31-4) A1 A7 C100
E7
BATTERY Z1 Z1
(8W-20-2) 12 12 Z1 Z12
BK BK 18 18
BK BK/TN
RHD
G100
G101
J008W-7 XJD01502
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 3
LHD 2.5L
REAR WINDSHIELD FOG FOG
WASHER WASHER LAMP LAMP
PUMP PUMP RELAY RELAY
(8W-53-3) (8W-53-2) NO. 2 NO. 1
2 B B13 (IN PDC) B8 (IN PDC)
(DRL) (DRL)
Z1 Z1 (8W-50-10) (8W-50-10)
18 20
BK BK
UNDERHOOD
LAMP/
MERCURY
SWITCH
2 (8W-44-5)
VEHICLE
SPEED
CONTROL
SERVO
4 (8W-33-3)
WASHER
FLUID
LEVEL
SWITCH
A (8W-40-5)
Z1 Z1
18 20 Z1 Z1 Z1
BK BK 20 18 20
BK BK BK
S132
Z1
16
BK
TO
G106
(8W-15-6)
XJD01503 J008W-7
8W - 15 - 4 8W-15 GROUND DISTRIBUTION XJ
LHD 4.0L
REAR WINDSHIELD
WASHER WASHER
PUMP PUMP
(8W-53-3) (8W-53-2)
2 B
WASHER FRONT TRANSMISSION
Z1 FLUID WIPER RANGE
18 LEVEL MOTOR SENSOR
BK
SWITCH (8W-53-2) (A/T)
A (8W-40-5) 4 8 (8W-31-6)
Z1 Z1 Z1 Z1
18 20 16 18
BK BK BK BK
S141
CONTROLLER ENGINE
ANTI-LOCK STARTER Z1 POWERTRAIN
BRAKE MOTOR 18
BK CONTROL
RELAY RELAY MODULE
B19 (IN PDC) C10 (IN PDC) (M/T)
(8W-35-3) (M/T) (8W-30-14)
(8W-21-5)
6 C1
T41
Z1 Z1 18
20 20 BK/WT
BK BK
5 C107
Z1 Z1 Z1 Z1
20 20 20 18
BK BK BK BK
S132
Z1
16
BK
TO
G106
(8W-15-6)
J008W-7 XJD01504
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 5
RHD
REAR WINDSHIELD FOG FOG
WASHER WASHER LAMP LAMP
PUMP PUMP RELAY RELAY
(8W-53-4) (8W-53-2) NO. 2 NO. 1
2 B B13 (IN PDC) B8 (IN PDC)
(8W-50-9) (8W-50-8)
Z1 Z1
(8W-50-10) (8W-50-10)
18 20
BK BK
UNDERHOOD
LAMP/
MERCURY
Z1
SWITCH 20
2 (8W-44-5) BK
Z1
20
BK
CONTROLLER
ANTI-LOCK
BRAKE ABS OTHER
RELAY
VEHICLE (IN PDC) Z1 Z1
B19 20 20
SPEED (8W-35-3)
BK BK
Z1 CONTROL
Z1
18 SERVO 20
BK (8W-33-3) BK
4
Z1
18
BK
S132
S141
Z1
16
BK
TO
G106
(8W-15-6)
XJD01505 J008W-7
8W - 15 - 6 8W-15 GROUND DISTRIBUTION XJ
S103
Z1
18
BK
S158
S102
RADIATOR FRONT
FAN WIPER
MOTOR MOTOR
(8W-42-8) (2.5L)
2 4 (8W-53-2)
Z1
18
BK FROM FROM
S132 S132
DAYTIME (8W-15-4) (8W-15-5)
RUNNING
B D
LAMP
C106 MODULE
11 4 (8W-50-11) FROM FROM FROM
8
S132 S141 S141
(8W-15-3) (8W-15-4) (8W-15-5)
A C E
Z1 Z1 Z1 Z12 Z1 Z1 Z1 Z1 Z1 Z1
20 20 12 16 16 16 16 16 16 16
BK/WT BK BK BK/TN BK BK BK BK BK BK
G106
J008W-7 XJD01506
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 7
S314
Z1 Z1
14 14
BK BK
14 C201
Z1
14
BK
I J
TO TO
S208 S208
(8W-15-8) (8W-15-8)
XJD01507 J008W-7
8W - 15 - 8 8W-15 GROUND DISTRIBUTION XJ
FROM
FROM JUNCTION EXTENDED FRONT
C201 BLOCK IDLE FOG
(8W-15-7) (8W-15-7) SWITCH LAMP
I J (8W-30-17) SWITCH
1 4 (8W-44-2)
(8W-44-3)
Z1 Z1
14 14
BK BK POLICE OTHERS
PACKAGE
LHD RHD
Z1 Z1 Z1 Z1 Z1
14 20 20 20 20
BK BK BK BK BK
S208
A/C- BLEND
HEATER DOOR
CONTROL ACTUATOR
(8W-42-7) (8W-42-7)
CIGAR
LIGHTER
2 C2 7
(8W-41-2) D1
(8W-41-3) 20
DB/WT
3 Z1
20
BK
1 C209
RHD LHD
POWER Z1 Z1
OUTLET 20 20
(8W-41-2) BK BK
Z1 (8W-41-3) Z1
16 17 C204 7 C201 14
BK 3 BK
Z1
16
Z1
BK
20
BK
G107
J008W-7 XJD01508
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 9
Z1
18
BK
S207
BLOWER
MOTOR
RELAY
SENTRY (8W-42-2)
KEY (8W-42-3)
IMMOBILIZER 2 (8W-42-4)
MODULE (8W-42-5)
Z1 COMPASS
5 3 (8W-39-4) 20
(8W-39-5) (8W-49-2)
BK
(8W-49-3)
Z2
20 10 C209
BK/LG 12
LHD RHD
INSTRUMENT Z2
20
CLUSTER BK/LG
(8W-40-2) Z8
20
BK/VT
5 C301
6 C1 9 C2 Z8
12 Z2
A/C- BK/VT 20
HEATER BK/LG
CONTROL LHD RHD
(8W-42-4)
(8W-42-5) 25 C201 58 C201
Z2
1 C1
HEATER
20
BK/LG CONTROL
POLICE/ (8W-42-2)
6 C202
OTHER POSTAL (8W-42-3)
Z2
Z8
1 C1 20
Z8 BK/LG
12
BK/VT 12 RADIO
S227 BK/VT (8W-47-2)
(8W-47-3)
(8W-47-8)
A/C OTHER (8W-47-9)
Z1 Z2 Z2 Z2 Z8 Z8 Z9
14 20 20 18 12 16 14
BK BK/LG BK/LG BK/LG BK/VT BK/VT BK
G108
XJD01509 J008W-7
8W - 15 - 10 8W-15 GROUND DISTRIBUTION XJ
LHD
LEFT
TAIL/ LEFT LEFT DRIVER
STOP TURN BACK-UP POWER
LAMP SIGNAL LAMP MIRROR
(8W-51-7) (8W-48-2)
1 (8W-51-3) LAMP
1 (8W-52-3) 1 6
Z1 Z1 Z1 DRIVER
18 POWER POWER
18 18
BK BK BK
LOCK/ MIRROR
WINDOW SWITCH
(8W-62-6)
5 C2 8 C1 SWITCH
(8W-60-2) 1
(8W-61-2)
S341 DRIVER
POWER
MIRROR
(8W-48-2)
TRAILER 6
Z1
TOW 18
Z1 Z1
Z1 Z1 Z1 18 14
CONNECTOR BK 14 14 16
(8W-54-2) BK BK
BK BK BK
8
FUEL S329 S329
PUMP Z1 TRAILER
2 C322
14 TOW OTHER
MODULE Z1 Z1
BK
(GAS) 12 16
(8W-30-3) Z1 BK BK
6 18
BK FULL POWER
LEFT OPTIONS MIRRORS
S337 Z1
REAR 14 DRIVER
DOOR BK DOOR
JAMB Z1
14 JAMB
2 SWITCH BK SWITCH
(8W-44-6) (8W-39-6)
Z1 3
18 2 C323 Z1
BK
18
B C320 BK
C C317 3 C307
Z1 Z1 Z1 Z1 Z1
16 20 14 20 12
BK BK BK BK BK
S309
AIRBAG POWER
CONTROL AMPLIFIER
MODULE (8W-47-2)
(8W-43-2)
(8W-43-3)
10 7 C2 8 C2
FULL
BASE OPTIONS Z1
12
Z6 Z6 BK
Z5 Z5
18 18 16 16
BK/YL BK/PK BK/LB BK/LB
G302
G301
J008W-7 G200 XJD01510
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 11
RHD
LEFT LEFT LEFT
TAIL/ TURN BACK-UP
STOP SIGNAL LAMP
LAMP LAMP (8W-51-7)
1 (8W-51-3) 1 (8W-52-3) 1
Z1 Z1 Z1
18 18 18
BK BK BK
S341
PRNDL TRAILER
ILLUMINATION TOW
(A/T) CONNECTOR
TRANSFER (8W-44-2)
(8W-54-2)
CASE 8
2 Z1
SWITCH PASSENGER 18
ILLUMINATION Z1 PASSENGER
20
POWER BK
2 (8W-44-3) POWER MIRROR
BK
Z1 LOCK/ (8W-48-3)
20 WINDOW 6
BK
6 C2 SWITCH Z1 TRAILER
2 C322
(8W-61-3) 16 TOW OTHER
Z1 BK
14 FULL POWER
2 C206 BK OPTIONS MIRRORS
SEAT Z1 Z1 Z1
BELT 14 18 14
S329 BK BK BK
SWITCH
Z1
(8W-40-6)
Z1 16 S337
B 12 BK
BK Z1
Z1 Z1 14
20 20 LEFT PASSENGER BK
BK BK REAR DOOR 2 C323
DOOR JAMB
S313
JAMB SWITCH
FUEL 2 SWITCH (8W-39-7)
3
PUMP (8W-44-7)
Z1 Z1
MODULE 18
(GAS) 18
BK BK
(8W-30-4)
6
B C320 3 C307 C C317
Z1 Z1 Z1 Z1 Z1 Z1
16 20 20 12 20 14
BK BK BK BK BK BK
S309
AIRBAG POWER
CONTROL AMPLIFIER
MODULE (8W-47-3)
(8W-43-2)
(8W-43-3) Z1
10 7 C2 8 C2 12
FULL
BASE OPTIONS BK
Z6 Z6 Z5 Z5
18 18 16 16
BK/YL BK/PK BK/LB BK/LB
Z1 Z1 Z1
18 18 18
BK BK BK
S348
RIGHT PASSENGER
REAR DOOR
DOOR JAMB
JAMB SWITCH
2 SWITCH 3 (8W-39-6)
(8W-39-6)
Z1 Z1 Z1
18 18 18
BK BK BK
Z1 Z1
20 20 Z1
BK BK 18
BK
S310
Z1
16
BK
G303
J008W-7 XJD01512
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 13
RHD
RIGHT RIGHT RIGHT
TAIL/ TURN BACK-UP
STOP SIGNAL LAMP
LAMP LAMP (8W-51-7)
1 (8W-51-3) 1 (8W-52-4) 1
Z1 Z1 Z1
18 18 18
BK BK BK
S348
S319
RIGHT Z1
REAR 14
BK
DOOR
JAMB
2 SWITCH
(8W-39-7)
Z1
18
BK
5 C303
S310
Z1
12
BK
G303
XJD01513 J008W-7
8W - 15 - 14 8W-15 GROUND DISTRIBUTION XJ
Z1
18
BK
2 C330
Z1 Z1 Z1
18 20 18
BK BK BK
S334
CENTER
HIGH
MOUNTED
STOP Z1
LAMP 18
(8W-51-4) BK
REAR
1 WINDOW
Z1 DEFOGGER 9 C310
18 (8W-48-2) 6 C311
BK (8W-48-3)
2 C333 Z1 Z1
12 18
Z1 BK BK
18
BK 2 C310
1 C312
Z1
12
BK
G304
J008W-7 XJD01514
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 15
Z1 Z1 Z1
18 18 18
BK BK BK
S354
LEFT RIGHT
Z1
18
HEATED HEATED
BK SEAT SEAT
SWITCH SWITCH
4 C332 12 C329 3 (8W-63-4) 3 (8W-63-4)
Z1 Z1 Z1 Z1
18 18 18 18
BK BK BK BK
S355
Z1 Z1 Z1 Z2
18 14 14 18
BK BK BK BK/LG
2 C362 2 C363 13 C329
Z1 Z1 Z2
14 14 18
BK BK BK/LG
G306
(HEATED SEATS)
XJD01515 J008W-7
XJ 8W - 20 CHARGING SYSTEM 8W - 20 - 1
POWER FUSIBLE
14 DISTRIBUTION LINK
CENTER A11
FUSE 10
8 (8W-10-2)
DG
30A
(8W-10-15)
7
A0 S118
6
A16
RD
14
A11
RD/LG
6
BK/WT
D2
AUTOMATIC
BATTERY SHUT
DOWN
GENERATOR
RELAY
D8 (IN PDC)
A0 (8W-30-2)
6
RD
A999 A999
16 16
RD RD
B(+) ENGINE
Z0 STARTER
8 MOTOR
BK (8W-21-2)
(8W-21-3) TO
(8W-21-4) 1 2
(8W-21-5) FUSE
18 (PDC)
(8W-10-15)
F142 C108
18 2 3
2.5L 4.0L DG/WT
2.5L 4.0L K72 K20
18 18
DG/OR DG
Z0 Z0
4 6 S168
BK BK (8W-10-15) S166
(8W-30-18) 2 C107
12 C3 25 C3 10 C2
G101 POWERTRAIN
FUSED GENERATOR GENERATOR
(8W-15-2)
AUTOMATIC SOURCE FIELD CONTROL
SHUT MODULE
DOWN (8W-30-2)
G100 RELAY (8W-30-18)
(8W-15-2) OUTPUT
J008W-7 XJD02002
XJ 8W-20 CHARGING SYSTEM 8W - 20 - 3
BATT A0 (8W-10-7)
POWER
A11 DISTRIBUTION
FUSE CENTER
22 (8W-10-2)
15A
(8W-10-19)
A12
S138
(8W-70-3)
A61 K167
14 20
DG/BK BR/YL
3 C107
C1
FUEL K167 K167
FUSED 20
B(+) PUMP 20
BR/YL BR/YL
RELAY
(IN PDC) S111
(8W-30-3) (8W-70-3)
(8W-30-4)
4.0L
CALIFORNIA OTHER
2
A61 BATTERY
16 TEMPERATURE
DG/BK SENSOR K167 K167
(8W-30-13) 20 18
BR/YL BR/YL
1
S123
(8W-70-2)
K167
14 C107 18
K118 BR/YL
18
PK/YL
A61
14
DG/BK
22 C1 15 C3 4 C1
FUSED BATTERY SENSOR POWERTRAIN
B(+) TEMPERATURE GROUND CONTROL
SENSOR MODULE
SIGNAL
(8W-30-3)
(8W-30-4)
(8W-30-13)
XJD02003 J008W-7
XJ 8W - 21 STARTING SYSTEM 8W - 21 - 1
E7 C100
F45
20 F45
YL/RD 20
YL/RD
2 2
CLUTCH CLUTCH A41 A0
F45 F45 16 6
18
INTERLOCK 18
INTERLOCK YL RD
YL SWITCH YL SWITCH
JUMPER JUMPER
1 1
T141
T141 20
20 YL
YL
E8 C100
C8 C6
ENGINE
STARTER
BATTERY
MOTOR (8W-20-2)
RELAY
C10 C7 (IN PDC)
T41 T40
20 16
BK/WT BR
5 C107
T41
18
BK/WT 1 C108
T40 A0
16 6
BR RD
S120
T41 T41
18 18 ENGINE
BK/WT BK/WT STARTER
2 6 C1 2 1 MOTOR
PARK/ POWERTRAIN 1 PULL-IN
PARK/
P/N 2 HOLD-IN
NEUTRAL NEUTRAL CONTROL
POSITION POSITION MODULE M
SWITCH
SWITCH SENSE
(8W-30-14)
(8W-31-2)
J008W-7 XJD02102
XJ 8W-21 STARTING SYSTEM 8W - 21 - 3
4.0L A/T
ST A41 (8W-10-11)
JUNCTION
BLOCK POWER
FUSE DISTRIBUTION
19 (8W-12-2) 16
10A
CENTER
FUSE (8W-10-2)
(8W-12-17) 10
(8W-12-18) 20A
3 C1 (8W-10-16)
23
F45
20
YL/RD
LHD RHD
E7 C100
F45 A0
20 6
A41
YL/RD RD
16
2 YL
CLUTCH
F45 F45 INTERLOCK
20 18 SWITCH
YL/RD YL
JUMPER
1
T141
20
YL
E8 C100
C8 C6
ENGINE
STARTER
MOTOR
BATTERY
RELAY (8W-20-2)
C10 C7 (IN PDC)
LHD RHD
E7 C100
A0
2 2 6
CLUTCH CLUTCH RD
INTERLOCK INTERLOCK
SWITCH SWITCH
1 1
BATTERY
(8W-20-2)
E8 C100
A41
T141 16
20 YL
YL
C8 C6
ENGINE
STARTER
MOTOR
RELAY
C10 C7 (IN PDC)
T41 T40
20 16
BK/WT BR
5 C107 1 C108
Z1
20 T40 A0
BK 16 6
BR RD
S107
(8W-15-2)
Z1 ENGINE
16 STARTER
BK
2 1 MOTOR
1 PULL-IN
G101 2 HOLD-IN
(8W-15-2)
M
J008W-7 XJD02104
XJ 8W-21 STARTING SYSTEM 8W - 21 - 5
4.0L M/T
ST A41 (8W-10-11)
JUNCTION POWER
BLOCK DISTRIBUTION
16
(8W-12-2) CENTER
FUSE FUSE (8W-10-2)
19 10
10A 20A
(8W-12-17) (8W-10-16)
23
(8W-12-18)
3 C1
F45
20
YL/RD
LHD RHD
E7 C100
A0
2 2 6
CLUTCH CLUTCH RD
INTERLOCK INTERLOCK
SWITCH SWITCH
1 1
BATTERY
(8W-20-2)
E8 C100
A41
T141 16
20 YL
YL
C8 C6
ENGINE
STARTER
MOTOR
RELAY
C10 C7 (IN PDC)
FOG
Z1 Z1 LAMP T40
20 20 RELAY 16
BK BK GROUND NO. 1 BR
B8 (IN PDC)
(EXCEPT ABS) 1 C108
S132 (EXCEPT DRL)
(8W-15-4) (8W-50-8) A0
T40
16 6
BR RD
Z1
16 ENGINE
BK STARTER
2 1 MOTOR
1 PULL-IN
2 HOLD-IN
M
G106
(8W-15-6)
XJD02105 J008W-7
XJ 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1
A16 A61
5 C2 14 14
F12 RD/LG DG/BK
18
DB/WT
C1
S130 FUSED FUEL
(8W-12-13) B(+) PUMP
F12 F12 (8W-12-14)
18 18 RELAY
DB/WT DB/WT (IN PDC)
(8W-30-3)
D4 D2
(8W-30-4)
AUTOMATIC
SHUT
DOWN
RELAY
D6 D8 (IN PDC)
A999
16
A61
4.0L RD
16
OTHER LHD A/T DG/BK
A14 POWER
FUSE
DISTRIBUTION
21 CENTER
15A (8W-10-2)
F12 F12
18 18 (8W-10-15)
A13
DB/WT DB/WT A999
F142 16
18 RD
S136 DG/WT
14 C107
(8W-12-14)
4.0L 2.5L
S168 TO
(8W-10-15) FUSE
10 C107 18 (PDC)
F12 K51 F142 (8W-10-15) A61
18 18 18 14
DB/WT DB/YL DG/WT DG/BK
2 C1 3 C3 12 C3 22 C1
FUSED AUTOMATIC FUSED FUSED POWERTRAIN
IGNITION SHUT AUTOMATIC B(+) CONTROL
SWITCH DOWN SHUT MODULE
OUTPUT RELAY DOWN
(ST-RUN) CONTROL RELAY
OUTPUT GROUND GROUND
32 C1 31 C1
Z12 Z12
14 14
BK/TN BK/TN
S117
(8W-15-2)
G101
(8W-15-2)
J008W-7 XJD03002
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3
LHD
ST-RUN A21 (8W-10-10) BATT A0 (8W-10-7)
JUNCTION POWER
BLOCK A11 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
11 22 (8W-10-2)
20A 15A
(8W-12-13) (8W-10-19)
A12
(8W-12-14)
5 C2 A61
F12 18DB/WT 14
S130 DG/BK
(8W-12-13)
(8W-12-14)
C5 C1
FUEL
PUMP
RELAY
(IN PDC)
C3 C2
A141 14DG/WT
D2 C100
A141
16
DG/WT
13 C200
3 1
FUEL
PUMP
M MODULE
4 6
K226 K167
20 20
DB/LG BR/YL
15 30
C200
F12 C100
S138 A61
(8W-70-3) 16
K226
20 3 C107 Z1 DG/BK
DB/LG K167 16
20 BK
F11 C100 BR/YL
S111
4.0L (8W-70-3)
CALIFORNIA OTHER
K167
20
K226 BR/YL K167 S309 14 C107
18 18 (8W-15-10)
K31
DB/LG
S123 BR/YL
Z1 A61
18 (8W-70-2) 12 14
K167
BR BK DG/BK
18
BR/YL
G302
19 C3 26 C3 4 C1 (8W-15-10) 22 C1
FUEL FUEL SENSOR FUSED POWERTRAIN
PUMP LEVEL GROUND B(+) CONTROL
RELAY SENSOR MODULE
CONTROL SIGNAL
XJD03003 J008W-7
8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM XJ
RHD
ST-RUN A21 (8W-10-10) BATT A0 (8W-10-7)
JUNCTION POWER
BLOCK A11 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
11 22 (8W-10-2)
20A 15A
(8W-12-13) (8W-10-19)
A12
(8W-12-14)
5 C2 A61
F12 18DB/WT 14
S130 DB/BK
(8W-12-13)
(8W-12-14)
C5 C1
FUEL
PUMP
RELAY
(IN PDC)
C3 C2
A141 14DG/WT
D2 C100
A141
16
DG/WT
4 C204
3 1
FUEL
PUMP
M MODULE
4 6
K226 K167
20 20
DB/LG BR/YL
6 7 C204
B3 C100
S138 A61
(8W-70-3) 16
K226
20 3 C107 Z1 DG/BK
DB/LG K167 16
20 BK
B2 C100 BR/YL
S111
4.0L (8W-70-3)
CALIFORNIA OTHER
K167
20
K226 BR/YL K167 S309 14 C107
18 18 (8W-15-11)
K31
DB/LG
S123 BR/YL
Z1 A61
18 (8W-70-2) 12 14
K167
BR BK DG/BK
18
BR/YL
G302
19 C3 26 C3 4 C1 (8W-15-11) 22 C1
FUEL FUEL SENSOR FUSED POWERTRAIN
PUMP LEVEL GROUND B(+) CONTROL
RELAY SENSOR MODULE
CONTROL SIGNAL
J008W-7 XJD03004
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5
D2 POWER
AUTOMATIC DISTRIBUTION
SHUT CENTER
DOWN (8W-10-2)
RELAY
(8W-30-2)
D8
A999 16RD
A999
16
RD
TO
A20 POWER FUSE
FUSE
DISTRIBUTION 21 (PDC)
18 CENTER (8W-10-15)
15A (8W-10-2)
(8W-10-15)
A19 S115
(8W-70-2)
K7 K7
20 18
A142 OR OR
18 3
DG/OR CRANKSHAFT
5V
SUPPLY POSITION
CRANKSHAFT SENSOR 3
POSITION
1 C107 SENSOR SENSOR 5V CAMSHAFT
SIGNAL GROUND SUPPLY POSITION
CAMSHAFT SENSOR
1 2 POSITION
SENSOR SENSOR
K167
GROUND SIGNAL
A142 20
18 BR/YL 2 1
DG/OR
K7 K24 S114
18 18
S109 OR GY/BK
(8W-70-3)
(8W-10-15)
K167 K167
A142 20 20
18 BR/YL BR/YL
DG/OR
S111
2 4.0L (8W-70-3)
1 CALIFORNIA OTHER
IGNITION
K167
COIL 20
BR/YL K167
RAIL 18
COIL S123 BR/YL
K44
2 3 1 (8W-70-2) 18
K167
1 TN/YL
18
K19 K17 K18 BR/YL
18 18 18
GY DB/TN RD/YL
7 C1 9 C2 1 C1 17 C1 8 C1 4 C1 18 C1
IGNITION IGNITION IGNITION 5V CRANKSHAFT SENSOR CAMSHAFT POWERTRAIN
COIL COIL COIL SUPPLY POSITION GROUND POSITION CONTROL
NO. 1 NO. 2 NO. 3 SENSOR SENSOR MODULE
DRIVER DRIVER DRIVER SIGNAL SIGNAL
4.0L
2.5L
XJD03005 J008W-7
8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM XJ
D2 POWER
AUTOMATIC A20 DISTRIBUTION
SHUT
FUSE CENTER
DOWN (8W-10-2)
18
RELAY
(8W-30-2) 15A
(8W-10-15)
D8 A19
A142
A999 A999 18
16 16 DG/OR
RD RD
1 C107
A142
18
DG/OR
TO
FUSE
21 (PDC) S109
(8W-10-15) (8W-10-15)
A142
18
DG/OR
S113
(8W-10-15)
1 1
FUEL 1 FUEL
INJECTOR FUEL INJECTOR
NO. 1 INJECTOR NO. 5
NO. 3 (4.0L)
2 2
2
1 1 1
FUEL FUEL FUEL
INJECTOR INJECTOR INJECTOR
NO. 2 NO. 4 NO. 6
(4.0L)
2 2 2
4 C2 15 C2 5 C2 16 C2 6 C2 12 C2
FUEL FUEL FUEL FUEL FUEL FUEL POWERTRAIN
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR CONTROL
NO. 1 NO. 2 NO. 3 NO. 4 NO. 5 NO. 6 MODULE
DRIVER DRIVER DRIVER DRIVER DRIVER DRIVER
J008W-7 XJD03006
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7
3
THROTTLE
POSITION
SENSOR
2 1
S114
S115 (8W-70-3)
(8W-70-2) K167 K167 K167
20 20 20
BR/YL BR/YL BR/YL
1 S111
(8W-70-3)
ENGINE
COOLANT
TEMPERATURE
SENSOR
2
1 4.0L
INTAKE CALIFORNIA OTHER
AIR K167
TEMPERATURE 20
SENSOR BR/YL K167
18
2 S123 BR/YL
(8W-70-2)
K7 K22 K21 K2 K167
18 18 18 18 18
OR OR/DB BK/RD TN/BK BR/YL
17 C1 23 C1 15 C1 16 C1 4 C1
5V THROTTLE INTAKE ENGINE SENSOR POWERTRAIN
SUPPLY POSITION AIR COOLANT GROUND CONTROL
SENSOR TEMPERATURE TEMPERATURE MODULE
SIGNAL SENSOR SENSOR
SIGNAL SIGNAL
XJD03007 J008W-7
8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM XJ
2.5L
BATT A16 (8W-10-15)
D2 POWER
AUTOMATIC A14 DISTRIBUTION
SHUT
FUSE CENTER
DOWN (8W-10-2)
21
RELAY
(8W-30-2) 15A
(8W-10-15)
D8 A13
F142
A999 18
16 DG/WT
RD
S168
(8W-10-15)
F142
18
DG/WT
7 C107
F142
20
DG/WT
S110
(8W-10-15)
F142 F142
20 20
DG/WT DG/WT
4 1 1 4
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
3 2 2 3
K167 Z1 Z1 K167
20 18 20 20
BR/YL BK BK BR/YL
S107
S114 (8W-15-2)
(8W-70-3)
Z1
16
BK
K167
20
BR/YL G101
(8W-15-2)
S111
(8W-70-3)
K41 K167 K141
18 18 18
BK/DG BR/YL TN/WT
24 C1 4 C1 25 C1
OXYGEN SENSOR OXYGEN POWERTRAIN
SENSOR GROUND SENSOR CONTROL
1/1 1/2 MODULE
SIGNAL SIGNAL
J008W-7 XJD03008
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9
4.0L
ST-RUN A21 (8W-10-10) BATT A0 (8W-10-7)
JUNCTION POWER
BLOCK A21 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
10 17 (8W-10-2)
15A 20A
(8W-12-12) A22 (8W-10-17)
S12 C4
F20
18
WT
LHD RHD
1 C201 A/T
C13 C11
FOG
EXCEPT OXYGEN
OTHER DRL SENSOR
E9
A9 C100
UPSTREAM
F26 F20 F99 F99 F20 RELAY
18 18 18 18 18
PK/OR WT RD RD WT C15 C12 (IN PDC)
F20
18
WT
S159
(8W-12-12) B5
A/T FOG FUSED A/C
OTHER EXCEPT DRL IGNITION COMPRESSOR
SWITCH CLUTCH
FUSED RADIATOR OUTPUT
IGNITION FAN (ST-RUN)
RELAY
F20
SWITCH RELAY (IN PDC)
F26 OUTPUT (A/T FOG)
18
(ST-RUN)
(IN PDC)
18 WT (8W-42-8) (EXCEPT DRL)
PK/OR D11 (8W-42-7)
TO
C107
(8W-30-10)
(8W-30-11)
9 C3 8 C3
OXYGEN OXYGEN POWERTRAIN
SENSOR SENSOR CONTROL
DOWNSTREAM UPSTREAM MODULE
RELAY RELAY
LHD CONTROL CONTROL
RHD
XJD03009 J008W-7
8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM XJ
4.0L
FROM TO
OXYGEN OXYGEN
SENSOR SENSOR
UPSTREAM DOWNSTREAM
RELAY RELAY
(8W-30-9) (8W-30-9)
B A
A42 A242
18 18
DG VT/OR
13
7 C107
4 1 1 4
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
3 2 2 3
K167 Z1 Z1 K167
20 20 20 20
BR/YL BK BK BR/YL
CALIFORNIA S107
OTHER
(8W-15-2)
S114 Z1
16
(8W-70-3)
BK
K167 G101
20 (8W-15-2)
BR/YL
S111
(8W-70-3)
K41 K167 K141
S123 18
18 18
(8W-70-2) TN/WT
BK/DG BR/YL
24 C1 4 C1 25 C1
OXYGEN SENSOR OXYGEN POWERTRAIN
SENSOR GROUND SENSOR CONTROL
1/1 1/2 MODULE
SIGNAL SIGNAL
CALIFORNIA
EXCEPT CALIFORNIA
J008W-7 XJD03010
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11
4.0L CALIFORNIA
FROM FROM
OXYGEN OXYGEN
SENSOR SENSOR
UPSTREAM DOWNSTREAM
RELAY RELAY
(8W-30-9) (8W-30-9)
B A
A42 A242
18 18
DG VT/OR
13
7 C107
4WD 2WD
A42 A242 A242
20 20 20
DG VT/OR DG/OR
S121 S122
A42 A42 A242 A242
20 20 20 20
DG DG VT/OR VT/OR
1 1
OXYGEN OXYGEN
SENSOR SENSOR
1/1 1/2
UPSTREAM DOWNSTREAM
(8W-30-10) (8W-30-10)
4 1 1 4
OXYGEN OXYGEN
SENSOR SENSOR
2/1 2/2
UPSTREAM DOWNSTREAM
3 2 2 3
K167 Z1 Z1 K167
20 20 20 20
BR/YL BK BK BR/YL
S107
(8W-15-2)
Z1
16
BK
G101
(8W-15-2)
S123
(8W-70-2)
K241 K167 K341
18 18 18
LG/RD BR/YL TN
26 C1 4 C1 29 C1
OXYGEN SENSOR OXYGEN POWERTRAIN
SENSOR GROUND SENSOR CONTROL
2/1 2/2 MODULE
SIGNAL SIGNAL
XJD03011 J008W-7
8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM XJ
3
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
2 1
K7 K167
20 20
OR BR/YL
S114
(8W-70-3)
K167
20
BR/YL
S115 S111
(8W-70-2) 4.0L (8W-70-3)
CALIFORNIA OTHER K167 K167
18 20
K167
BR/YL BR/YL
20
BR/YL K167 2
18
S123 BR/YL SENSOR VEHICLE
(8W-70-2) GROUND VEHICLE SPEED
K167
SPEED
18 5V SENSOR
SENSOR
BR/YL SUPPLY SIGNAL
1 3
3
ENGINE ENGINE G7
SENSOR 18
OIL GROUND OIL
PRESSURE WT/OR
SENSOR
5V PRESSURE
SIGNAL SUPPLY SENSOR S108
2 1
K6 K6 G7
18 18 20
VT/OR VT/OR WT/OR
DRL OTHER
S119 4 C107
NOT
USED
G7
20
WT/OR
K7 K1 K167 G60 K6 G7 7
18 18 18 18 18 18
OR DG/RD BR/YL GY/YL VT/OR WT/OR VEHICLE DAYTIME
SPEED RUNNING
SENSOR LAMP
SIGNAL
MODULE
(8W-50-11)
17 C1 27 C1 4 C1 23 C2 31 C2 27 C2
5V MANIFOLD SENSOR ENGINE 5V VEHICLE POWERTRAIN
SUPPLY ABSOLUTE GROUND OIL SUPPLY SPEED CONTROL
PRESSURE PRESSURE SENSOR MODULE
SENSOR SENSOR SIGNAL
SIGNAL SIGNAL
J008W-7 XJD03012
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13
LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 SET 1 RESUME/ACCEL
2 ON/OFF 2 CANCEL
(8W-33-2) 3 COAST
1 2 1 2 3 (8W-33-2)
2 1 2 1
V37 K167 V37 K167
20 20 20 20
RD/LG BR/YL RD/LG BR/YL
S221
S222
B C2 A C2
CLOCKSPRING
2 C1 3 C1
K4
V37 20
20 BK/RD
RD/LG
B5 B6
F18 C100
F17
K167
20
BR/YL
S138
(8W-70-3)
3 C107
K167
20
BR/YL
K167 S111
20 (8W-70-3)
BR/YL
4.0L
CALIFORNIA OTHER
2
BATTERY K167
TEMPERATURE 20
BR/YL K167
SENSOR
18
S123 BR/YL
1 (8W-70-2)
K167
18
V37 K118
BR/YL
18 18
RD/LG PK/YL
32 C3 15 C3 4 C1
SPEED BATTERY SENSOR POWERTRAIN
CONTROL TEMPERATURE GROUND CONTROL
SWITCH SENSOR MODULE
SIGNAL SIGNAL
RHD
LHD
XJD03013 J008W-7
8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM XJ
S141
F9 C100 G106 (8W-15-4)
F7 (8W-15-6) Z1 (8W-15-5)
16
V30 BK
20
DB/RD 4.0L 2.5L A/T 2.5L M/T G106
(8W-15-6)
S120
3 (8W-21-2)
VEHICLE T41 T41 T41 Z1
18 18 18 20
SPEED BK/WT BK/WT BK/WT BK
CONTROL
SERVO
(8W-33-3)
S107
1 2 (8W-15-2)
2
PARK/
P/N NEUTRAL
POSITION
SWITCH Z1
V32 V36 V35 (8W-31-2) 18
18 18 18 BK
YL/RD TN/RD LG/RD
J008W-7 XJD03014
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15
5 C2 S12 C4
F12 F20
18 18
DB/WT WT
S130 RHD LHD
(8W-12-13)
(8W-12-14)
1 C201
OTHER 4.0L LHD A/T A9 C100 F20
18
F12 WT
18
DB/WT E9 C100
S136
(8W-12-14)
F20
18
F12 WT
18
DB/WT S159
10 11 (8W-12-12)
C107
F20 F20
18 18
WT WT
S161
(8W-51-6) 2
F20 DUTY
18
WT CYCLE
A
EVAP/
TORQUE PURGE
CONVERTER 1 SOLENOID
CLUTCH
SOLENOID
B (2.5L A/T)
(8W-31-2)
F12 K54 K52
18 18 18
DB/WT OR/BK PK/BK
2 C1 11 C2 20 C3
FUSED TORQUE DUTY POWERTRAIN
IGNITION CONVERTER CYCLE CONTROL
SWITCH CLUTCH EVAP/ MODULE
OUTPUT SOLENOID PURGE
(ST-RUN) CONTROL SOLENOID
CONTROL
XJD03015 J008W-7
8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM XJ
POWERTRAIN
CONTROL
IDLE AIR IDLE AIR IDLE AIR IDLE AIR BRAKE MODULE
CONTROL CONTROL CONTROL CONTROL LAMP
NO. 3 NO. 2 NO. 1 NO. 4 SWITCH
DRIVER DRIVER DRIVER DRIVER SENSE
11 C1 10 C1 19 C1 20 C1 24 C3
K29
18
WT/PK
S140
(8W-31-7)
K29 K29
20 18
WT/PK WT/PK
LHD RHD
K29 K29
20 18
WT/PK WT/PK
S204
(8W-31-3)
(8W-31-7)
2 3 4 1 K29
18
IDLE AIR IDLE AIR IDLE AIR IDLE AIR IDLE WT/PK
CONTROL CONTROL CONTROL CONTROL AIR
NO. 3 NO. 2 NO. 1 NO. 4 CONTROL 1
DRIVER DRIVER DRIVER DRIVER BRAKE
MOTOR
LAMP
SWITCH
(8W-33-3)
2
Z1
18
BK
S207
(8W-15-9)
Z1
14
BK
G108
(8W-15-9)
RHD
LHD
J008W-7 XJD03016
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17
POWERTRAIN
PANEL HEADLAMP
LAMPS SWITCH POWER CONTROL
DIMMER (8W-50-2) STEERING MODULE
SWITCH PRESSURE
SIGNAL IDLE SWITCH
ACTUATOR SIGNAL
1 C1
12 C1 12 C1
42 C201 4.0L A/T 2.5L
S208
(8W-15-8)
Z1
14 G101
BK (8W-15-2)
G107
(8W-15-8)
XJD03017 J008W-7
8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM XJ
GENERATOR
ST-RUN F20 (8W-12-12) (8W-20-2)
POWER GENERATOR GENERATOR
DISTRIBUTION SOURCE FIELD
B5 D11
A/C RADIATOR CENTER 1 2
COMPRESSOR FAN (8W-10-2) K72 K20
CLUTCH RELAY 16 16
RELAY (8W-42-8) DG/OR DG
(8W-42-7) C108
2 3
B3 D13
K72
18
DG/OR
S166
K72 K20
18 18
DG/OR DG
2
EVAP
LEAK
DETECTION 2 C107
PUMP
3 4
C13 C27 K106 K105 K72 K20
18 18 18 18 18 18
DB/OR DB/PK WT/DG WT/OR DG/OR DG
1 C3 2 C3 10 C3 14 C3 25 C3 10 C2
A/C RADIATOR LEAK LEAK GENERATOR GENERATOR POWERTRAIN
COMPRESSOR FAN DETECTION DETECTION SOURCE FIELD CONTROL
CLUTCH RELAY PUMP PUMP MODULE
RELAY CONTROL SOLENOID SWITCH
CONTROL CONTROL SENSE
A/C
A/C A/C LED
SWITCH SELECT INDICATOR
SENSE INPUT SIGNAL
22 C3 23 C3 13 C3
C22 C90
18 18 C48
DB/WT LG 18
TN
S143
2.5L 4.0L 4.0L 2.5L
BATT A0 (8W-10-7)
POWER
A18 DISTRIBUTION
FUSE CENTER
19 (8W-10-2)
20A
(8W-10-18)
A17
F34
18
TN/BK
E6
A18 C100
LHD RHD
4 C1
FUSED HEADLAMP S218
B(+) SWITCH (8W-10-18)
(8W-50-2)
F34
18
TN/BK
16
DATA
LINK
5 4 6 7 CONNECTOR
Z12 Z1 D20 D21
18 18 20 20
BK/TN BK LG/BK PK
A7 A1 B7 B8 C100
E7 F1 F2
2.5L 4.0L
D21
20
PK
S139
D21 D21
18 20
Z12 Z1
PK PK
18 18
BK/TN BK 20
D20 SCI CONTROLLER
18 D21 TRANSMIT/ ANTI-LOCK
LG/BK 18 ISO 9141K BRAKE
PK (8W-35-2)
29 C3 27 C3 14
SCI SCI POWERTRAIN SCI TRANSMISSION
RECEIVE TRANSMIT/ CONTROL TRANSMIT/ CONTROL
ISO 9141K MODULE ISO 9141K MODULE
(8W-31-7)
G102 RHD
(8W-15-2) LHD
XJD03019 J008W-7
8W - 30 - 20 8W-30 FUEL/IGNITION SYSTEM XJ
LHD
3 11 DATA SENTRY
LINK CCD CCD KEY
D1 D2
18 TWISTED 18 CONNECTOR BUS BUS IMMOBILIZER
VT/BR PAIR WT/BK (+) (-) MODULE
1 2 (8W-39-8)
D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK
S238
S239
D1 TWISTED D2
TWISTED 20 PAIR 20
PAIR VT/BR WT/BK
D1 D2 D1 D2
20 20 20 20
VT/BR WT/BK VT/BR WT/BK
D1 D2 C201
20 20 51 52
VT/BR WT/BK D1 D2
2 C2 1 C2 18 18
INSTRUMENT VT/BR WT/BK
CCD CCD
BUS BUS CLUSTER 19 18
(+) (-) (8W-40-3) CCD CCD AIRBAG
BUS BUS CONTROL
(+) (-) MODULE
C201 (8W-43-2)
55 56
D1 D2 E11 E12 C100
4.0L
20 20 OTHER A/T
VT/BR WT/BK
4.0L A/T OTHER
D1
20 D2
1 2 C301 VT/BR 20
WT/BK
OTHER COMPASS COMPASS OTHER
S145 D2
D1 S144 18
18 WT/BK
S344 S346 D1 D2 D2
VT/BR TWISTED
20 20 18
D1 TWISTED D2 VT/BR PAIR WT/BK WT/BK
20 PAIR 20
7 6
VT/BR WT/BK
CCD CCD TRANSMISSION
BUS BUS CONTROL
5 11 (+) (-) MODULE
CCD CCD COMPASS D1
(8W-31-7)
D2
BUS BUS (8W-49-6) 18 18
(+) (-) VT/BR TWISTED WT/BK
PAIR
D1 D2 30 C3 28 C3
20 TWISTED 20 CCD CCD POWERTRAIN
VT/BR PAIR WT/BK BUS BUS CONTROL
(+) (-) MODULE
6 12
CCD CCD OVERHEAD
BUS BUS MODULE
(+) (-) (8W-49-6)
J008W-7 XJD03020
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 21
RHD
3 11 DATA SENTRY
LINK CCD CCD
KEY
D1 D2
18 TWISTED 18 CONNECTOR BUS BUS IMMOBILIZER
VT/BR PAIR WT/BK (+) (-) MODULE
1 2 (8W-39-9)
D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK
S238
S239
D1 TWISTED D2
TWISTED 20 PAIR 20
PAIR VT/BR WT/BK
D1 D2 D1 D2
20 20 20 20
VT/BR WT/BK VT/BR WT/BK
D1 D2
20 20 19 20 C204
VT/BR WT/BK D1 D2
2 C2 1 C2 18 18
INSTRUMENT VT/BR WT/BK
CCD CCD
BUS BUS CLUSTER 19 18
(+) (-) (8W-40-3) CCD CCD AIRBAG
BUS BUS CONTROL
(+) (-) MODULE
C301 (8W-43-3)
1 2
D1 D2 A11 4.0L A12 C100
20 20 OTHER A/T 4.0L A/T OTHER
VT/BR WT/BK
D1 D2
20 20
COMPASS OTHER VT/BR WT/BK
OTHER COMPASS D2
18
S145 S144 WT/BK
S344 S346 D1 D1 D2
18 20 D2 18
D1 TWISTED D2 VT/BR VT/BR
TWISTED 20 WT/BK
20 PAIR 20 PAIR WT/BK
VT/BR WT/BK 7 6
CCD CCD TRANSMISSION
5 11 BUS BUS CONTROL
(+) (-) MODULE
CCD CCD COMPASS D1 D2
BUS BUS (8W-49-6) (8W-31-7)
18 18
(+) (-) VT/BR TWISTED WT/BK
PAIR
D1 D2 30 C3 28 C3
20 TWISTED 20 POWERTRAIN
CCD CCD
VT/BR PAIR WT/BK BUS BUS CONTROL
(+) (-) MODULE
6 12
CCD CCD OVERHEAD
BUS BUS MODULE
(+) (-) (8W-49-6)
XJD03021 J008W-7
XJ 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
5 C2 S12 C4
F20 T41
18 20
WT BK/WT
LHD RHD
1 C201 F20
F12
18 F20 18
DB/WT 18 WT
WT
A9 C100 5 C107
E9 C100
S130 S159
(8W-12-13) (8W-12-12)
F20 T41
18 18
F12 BK/WT
WT
18
DB/WT 11 C107
S161 S120
(8W-51-6) (8W-21-2)
F20 F20 T41
18 18 18
WT WT BK/WT
1 2
PARK/
R P/N NEUTRAL
POSITION
10 C107 SWITCH
A
3
TORQUE
L10
CONVERTER 18
CLUTCH BR/LG
SOLENOID 12 C107
B
A15
C100
E3
LHD RHD
F12
18
DB/WT
16 C200 23 C204
T41
18
K54 BK/WT
18
OR/BK TO
S303
(8W-51-7)
2 C1 11 C2 6 C1
FUSED TORQUE PARK/NEUTRAL POWERTRAIN
IGNITION CONVERTER POSITION CONTROL
SWITCH CLUTCH SWITCH MODULE
OUTPUT SOLENOID SENSE (8W-30-2)
(ST-RUN) CONTROL (8W-30-14)
(8W-30-15)
RHD
J008W-7 LHD XJD03102
XJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3
2.5L
RUN A22 (8W-10-11)
JUNCTION
BLOCK
FUSE (8W-12-2)
25
15A
(8W-12-20)
(8W-12-21)
S8 C4
F15
20
DB/WT
S219
(8W-12-20)
(8W-12-21)
RHD LHD
40 C201
F15 F15
20 20
DB/WT DB/WT
S217
(8W-12-20)
2
SHIFT
LOCK
SOLENOID
1
RHD LHD
K29 K29
18 20
WT/PK WT/PK
S204
K29
18
RHD LHD
WT/PK
K29 K29 1
18 20 BRAKE
WT/PK WT/PK LAMP
SWITCH
(8W-33-3)
B1
C100 2
F10
Z1
18
K29
BK
18
WT/PK S207
24 C3 (8W-15-9)
POWERTRAIN Z1
BRAKE 14
LAMP CONTROL BK
SWITCH MODULE RHD
SENSE (8W-30-16) LHD
G108
(8W-15-9)
XJD03103 J008W-7
8W - 31 - 4 8W-31 TRANSMISSION CONTROL SYSTEM XJ
4.0L
ST-RUN A21 (8W-10-10) BATT A0 (8W-10-7)
JUNCTION POWER
BLOCK A23 DISTRIBUTION
FUSE
(8W-12-2)
FUSE CENTER
11 16 (8W-10-2)
20A 15A
(8W-12-14) (8W-10-17)
A24
5 C2 M1
F12 20
18 PK
DB/WT
S130
(8W-12-14)
LHD RHD
F12
18
DB/WT
S135
(8W-10-17)
S136
(8W-12-14)
F12 M1
18 20
DB/WT PK
26 25
FUSED FUSED TRANSMISSION
IGNITION B(+) CONTROL
SWITCH MODULE
OUTPUT
(ST-RUN)
SOLENOID A SOLENOID B SOLENOID C
GROUND CONTROL CONTROL CONTROL
24 12 13 11
Z12 T19 T60 T22
18 20 20 20
BK/TN WT OR/WT DB/WT
3 2 4
9 C107 TRANSMISSION
1-2 SOLENOID
AND 2-3 LOCK-UP
3-4 SOLENOID SOLENOID
SOLENOID
Z12
16
BK/TN
G101
(8W-15-2)
J008W-7 XJD03104
XJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5
4.0L
POWERTRAIN
CONTROL
5V SENSOR MODULE
SUPPLY GROUND (8W-30-7)
17 C1 4 C1
K7
18
OR 4.0L
CALIFORNIA OTHER
K167
18
BR/YL K167
18
S123 BR/YL
(8W-70-2)
K167
20
BR/YL
S111
(8W-70-3)
K167
20 K167
BR/YL 20
BR/YL
S115 S114
(8W-70-2) (8W-70-3)
K7 K167
3 C107
20 20
K22
OR BR/YL
20 K167
OR/DB 3 1 20
S112 THROTTLE BR/YL
(8W-30-7)
POSITION
K22 SENSOR
20 (8W-30-7) S138
OR/DB (8W-70-3)
2
6 C107
K22 K167
20 20
OR/DB BR/YL
17 16
THROTTLE SENSOR TRANSMISSION
POSITION GROUND CONTROL
INPUT SENSOR INPUT OUTPUT OUTPUT MODULE
SPEED SIGNAL SPEED SPEED SPEED
SENSOR SENSOR SENSOR SENSOR
SIGNAL GROUND SIGNAL GROUND
2 1 4 3
T52 T31 T14 T13
20 20 20 20
RD/BK VT/LG LG/WT DB/BK
1 5 7 6
TRANSMISSION
INPUT OUTPUT SOLENOID
SPEED SPEED
SENSOR SENSOR
XJD03105 J008W-7
8W - 31 - 6 8W-31 TRANSMISSION CONTROL SYSTEM XJ
4.0L
ST-RUN A21 (8W-10-10)
JUNCTION
BLOCK
FUSE (8W-12-2) FROM
10 ENGINE
15A
(8W-12-12)
STARTER
MOTOR
S12 C4 RELAY
(8W-21-3)
F20
18
WT
LHD RHD
1 C201 T41
F20
F20 18 20
18 WT BK/WT
WT
A9
E9 C100
F20
18
WT
S159
(8W-12-12)
F20
18
WT
3 7
TRANSMISSION
RANGE
R D D3 1-2 P/N SENSOR
6 4 2 1 8
L10 T1 T3 T42 Z1
18 18 18 18 18
BR/LG LG/BK VT VT/WT BK
S141
(8W-15-4)
(8W-15-5)
S142
(8W-51-6)
Z1
16
L10 BK
18
BR/LG
G106
(8W-15-6)
18 22 9 21
BACK-UP TRS TRS TRS TRANSMISSION
LAMP T1 T3 T42 CONTROL
FEED SENSE SENSE SENSE MODULE
LHD
RHD
J008W-7 XJD03106
XJ 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7
4.0L
RUN A22 (8W-10-11)
7 3 11 DATA
TWISTED LINK JUNCTION
PAIR CONNECTOR BLOCK
(8W-12-2)
(8W-30-20) FUSE
(8W-30-21) 25
15A
(8W-12-20)
(8W-12-21)
D1 D2 S8 C4
18 18 F15
VT/BR WT/BK 20
DB/WT
S219
(8W-12-20)
(8W-12-21)
S239 S238 LHD RHD
(8W-30-20) (8W-30-20) 40 C201
(8W-30-21) (8W-30-21)
F15 F15
20 20
DB/WT DB/WT
LHD RHD S217
(8W-12-20)
D21 D1 D2 K29 K29
20 20 20 20 18
F15
PK VT/BR WT/BK WT/PK WT/PK
20
DB/WT
2
SHIFT
B8 A11 A12 B1 C100 LOCK
F2 E11 E12 F10 SOLENOID
1
LHD RHD
D21 D1 D2 K29
20 20 20 20 K29 K29
PK VT/BR WT/BK WT/PK 20 18
WT/PK WT/PK
S204
S140 K29
18
S139 S145 S144 K29 WT/PK
(8W-30-19) (8W-30-20) (8W-30-20) 18
(8W-30-21) (8W-30-21) 1
WT/PK
BRAKE
LAMP
SWITCH
24 C3 (8W-33-3)
D21 D1 D2 K29 POWERTRAIN
20 BRAKE
20 20 TWISTED 20
LAMP CONTROL 2
PK VT/BR PAIR WT/BK WT/PK
SWITCH MODULE Z1
SENSE (8W-30-16) 18
BK
14 7 6 23
SCI CCD CCD BRAKE TRANSMISSION S207
TRANSMIT/ BUS BUS LAMP CONTROL (8W-15-9)
ISO9141K (+) (-) SWITCH MODULE Z1
SENSE 14
BK
RHD G108
LHD (8W-15-9)
XJD03107 J008W-7
XJ 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1
LEFT RIGHT
SPEED SPEED
CONTROL CONTROL
SWITCH SWITCH
1 SET 1 RESUME/ACCEL
2 ON/OFF 2 CANCEL
3 COAST
1 2 1 2 3
2 1 2 1
V37 K167 V37 K167
20 20 20 20
RD/LG BR/YL RD/LG BR/YL
S221
S222
B C2 A C2
CLOCKSPRING
2 C1 3 C1
K4
V37 20
20 BK/RD
RD/LG
B5 B6 C100
F17 F18
K167
20
BR/YL
S138
(8W-70-3)
3 C107
K167
20
BR/YL
S111
(8W-70-3)
4.0L
CALIFORNIA OTHER
K167
20
BR/YL K167
18
S123 BR/YL
(8W-70-2)
K167
18
V37
BR/YL
18
RD/LG
32 C3 4 C1
SPEED SENSOR POWERTRAIN
CONTROL GROUND CONTROL
SWITCH MODULE
SIGNAL (8W-30-13)
RHD
LHD
J008W-7 XJD03302
XJ 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3
BATT A0 (8W-10-7)
POWER
DISTRIBUTION
A9
LHD RHD CENTER
FUSE (8W-10-2)
23
15A
V32 V32 K29 (8W-10-20)
18 20 18 A10
YL/RD YL/RD WT/PK
F8 C100
F32
20
S204 PK/DB
(8W-31-3) 1 3 6
(8W-31-7) BRAKE
F9 C100
LAMP
SWITCH
LHD RHD 2 4 5
S207 F7 C100
(8W-15-9)
Z1 V30
14 20 TO
B1 BK DB/RD S203
F10 C100 (8W-10-20)
G108
(8W-15-9)
OTHER 4.0L A/T 3
VEHICLE
SPEED
K29
20 CONTROL
K29 SERVO
WT/PK
18
WT/PK
S140 1 2 4
(8W-31-7)
Z1
18
BK
S132
(8W-15-3)
Z1 (8W-15-4)
V32 K29 V36 V35 16 (8W-15-5)
18 18 18 18 BK
YL/RD WT/PK TN/RD LG/RD
G106
(8W-15-6)
11 C3 24 C3 4 C3 5 C3
SPEED BRAKE SPEED SPEED POWERTRAIN
CONTROL LAMP CONTROL CONTROL CONTROL
POWER SWITCH VACUUM VENT MODULE
SUPPLY SENSE SOLENOID SOLENOID (8W-30-14) RHD
CONTROL CONTROL (8W-30-16) LHD
XJD03303 J008W-7
XJ 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1
BATT A0 (8W-10-7)
POWER
18 19 A9 DISTRIBUTION
FUSE FUSE FUSE CENTER
12 13 23 (8W-10-2)
40A 20A 15A
(8W-10-16) (8W-10-16) (8W-10-20)
25 26 A10
DATA
F32
LINK 20
CONNECTOR PK/DB
(8W-30-19)
7 F8 C100
D21 F32
20 20
PK PK/DB
6
B8
F2 C100 BRAKE
LAMP
4.0L 2.5L SWITCH
(8W-33-3)
D21 D21 5
20 18 L50
PK PK
G
20
WT/TN SWITCH
S139
(8W-30-19) S203
(8W-10-20)
L50
20
WT/TN 3 2 1
RHD LHD B43 B41 B42
20 20 20
PK/OR YL/VT TN/WT
B4 C100 E1 C100 C109
C A B
25 9 20 12 13 6 7
FUSED FUSED SCI BRAKE G SWITCH G SWITCH G SWITCH CONTROLLER
B(+) B(+) TRANSMIT/ LAMP TEST NO. 1 NO. 2 ANTI-LOCK
ISO 9141K SWITCH SIGNAL SENSE SENSE BRAKE
OUTPUT
GROUND GROUND
8 24
Z1 Z1
12 12
BK BK
G102
RHD (8W-15-2)
LHD
J008W-7 XJD03502
XJ 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3
6 C1 S13 C4
F15 F87
20 20
DB/WT WT/BK
RHD LHD
FULL
BASE OPTIONS
S225
(8W-12-11)
5 C201
S216
(8W-12-11)
F87
20
WT/BK
8 C1
INSTRUMENT
S134 CLUSTER
(8W-12-20) ABS (8W-40-5)
(8W-12-21) INDICATOR
4 C1 FOG
F15 G19 LAMP
20 20 RELAY
DB/WT LG/OR GROUND NO. 1
F13 C100 B8 (IN PDC)
B20 B16 (4.0L ABS
CONTROLLER EXCEPT
Z1
ANTI-LOCK 20 DRL)
BRAKE BK (8W-50-8)
RELAY
B18 B19 (IN PDC)
F15 G83 Z1
18 18 20
DB/WT GY/BK BK
S132
23 16 (8W-15-4)
FUSED ABS CONTROLLER (8W-15-5)
Z1
IGNITION RELAY ANTI-LOCK 16
SWITCH CONTROL BRAKE BK
OUTPUT
(RUN)
G106
(8W-15-6)
XJD03503 J008W-7
8W - 35 - 4 8W-35 ANTI-LOCK BRAKES XJ
LEFT RIGHT
FRONT FRONT
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
2 1 2 1
LEFT RIGHT
REAR REAR
WHEEL WHEEL
SPEED SPEED
SENSOR SENSOR
B A B A
B4 B3 B2 B1
20 20 20 20
LG LG/DB YL YL/DB
G F C109 E D C109
B9 B8 B4 B3 B7 B6 B2 B1
18 18 18 18 18 18 18 18
RD RD/DB LG LG/DB WT WT/DB YL YL/DB
4 11 10 2 3 18 17 1
LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT CONTROLLER
FRONT FRONT REAR REAR FRONT FRONT REAR REAR ANTI-LOCK
WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL WHEEL BRAKE
SPEED SPEED SPEED SPEED SPEED SPEED SPEED SPEED
SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR SENSOR
(+) (-) (+) (-) (+) (-) (+) (-)
J008W-7 XJD03504
XJ 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
POWER
A23 DISTRIBUTION
FUSE CENTER
16 (8W-10-2)
15A
(8W-10-17)
A24
PASSENGER
DOOR POWER
DOOR UNLOCK
M1 LOCK RELAY
LOCK/
20 CONTROL CONTROL WINDOW
PK SWITCH
1 C2 2 C2
(8W-61-2)
P59 P55
S135 20 20
(8W-10-17) LB/RD DB/PK
12 C1
4 3
JUNCTION C300
BLOCK
(8W-12-2) P59 P55
20 20
3 C3 LB/RD DB/PK
OTHERS SKIM
S361 9 8 C301
(8W-10-18)
P59 P55
20 20
S347 LB/RD DB
(8W-10-18)
M1
20
PK
2 11 5
FUSED DOOR DOOR OVERHEAD
B(+) LOCK UNLOCK MODULE
CONTROL RELAY (8W-49-2)
GROUND GROUND CONTROL
3 9
Z1 Z1
20 20
BK BK
S342
2 C3 (8W-15-7)
JUNCTION
BLOCK
(8W-12-2)
S5 C4
S314
(8W-15-7)
Z1
14
BK
14 C201
S208
(8W-15-8)
Z1
14
BK
G107
(8W-15-8)
J008W-7 XJD03902
XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3
RHD
BATT A0 (8W-10-7)
POWER PASSENGER
DOOR
DISTRIBUTION DOOR UNLOCK
POWER
A23 LOCK/
CENTER LOCK RELAY
FUSE (8W-10-2) CONTROL CONTROL WINDOW
16 SWITCH
15A
1 C2 2 C2
(8W-61-3)
(8W-10-17)
A24
P59 P55
20 20
M1 LB/RD DB
20
PK 3 12
C305
P59 P55
S135 20 20
(8W-10-17) LB/RD DB/PK
12 C1
JUNCTION 2 1 C203
BLOCK
(8W-12-2) P59 P55
20 20
3 C3 LB/RD DB/PK
OTHERS SKIM
9 8 C301
S361
(8W-10-18)
P59 P55
20 20
LB/RD DB
S347
(8W-10-18)
M1
20
PK
2 11 5
OVERHEAD
FUSED DOOR DOOR
B(+) LOCK UNLOCK MODULE
CONTROL RELAY (8W-49-3)
CONTROL (8W-49-5)
GROUND GROUND
3 9
Z1 Z1
20 20
BK BK
S342
(8W-15-7)
2 C3
JUNCTION
BLOCK
(8W-12-2)
S5 C4
Z1
14
BK
S208
(8W-15-8)
Z1
14
BK
G107
(8W-15-8)
XJD03903 J008W-7
8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
LHD
BATT A17 (8W-10-14) ST-RUN A21 (8W-10-10)
POWER JUNCTION
DISTRIBUTION BLOCK
A1
CENTER (8W-12-2)
FUSE (8W-10-2) FUSE
27 9
10A 10A
(8W-10-14) (8W-12-11)
A2
S13 C4
F1 F87
20 20
DB/GY WT/BK
S225
(8W-12-11)
F87
20
WT/BK
E10 C100
5 C201
F87
20
WT/BK
S216
(8W-12-11)
F1 F87
20 20
DB/GY WT/BK
6 4
FUSED FUSED SENTRY
B(+) IGNITION KEY
SWITCH IMMOBILIZER
OUTPUT MODULE
(ST-RUN)
GROUND GROUND
5 3
Z2 Z2
20 20
BK/LG BK/LG
S227
(8W-15-9)
Z2
20
BK/LG
G108
(8W-15-9)
J008W-7 XJD03904
XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5
RHD
BATT A17 (8W-10-14) ST-RUN A21 (8W-10-10)
POWER JUNCTION
DISTRIBUTION BLOCK
A1
CENTER (8W-12-2)
FUSE (8W-10-2) FUSE
27 9
10A 10A
(8W-10-14) (8W-12-11)
A2
S13 C4
F1 F87
20 20
DB/GY WT/BK
E10 C100
S216
(8W-12-11)
F1 F87
20 20
DB/GY WT/BK
6 4
FUSED FUSED SENTRY
B(+) IGNITION KEY
SWITCH IMMOBILIZER
OUTPUT MODULE
(ST-RUN)
GROUND GROUND
5 3
Z2 Z2
20 20
BK/LG BK/LG
S227
(8W-15-9)
Z2
20
BK/LG
G108
(8W-15-9)
XJD03905 J008W-7
8W - 39 - 6 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
LHD
HEADLAMP OVERHEAD B A
DOOR SWITCH MODULE CARGO
JAMB (8W-50-2) COURTESY (8W-49-4) LAMP/
SWITCH LAMPS
SENSE SWITCH
DRIVER
(8W-44-6)
6 C1 1
IGNITION M2 M2
DRIVER SWITCH 20 20
DOOR (8W-10-9) YL YL
AJAR
SWITCH S345
SENSE (8W-12-27) 6 C314
2 C2 1 C3
G16 G16 JUNCTION C
20 20 BLOCK M4
BK/LB BK/LB (8W-12-2) 20
GY/BK
S200 7 C7 7 C314
(8W-10-10)
G16 M2 M2 M4
20 20 20 20
BK/LB YL YL GY/BK
3 C326
17 C200 S304
(8W-44-6) M4
20
G16 M2 M2 M2 M2
GY/BK
20 20 20 20 20
BK/LB YL YL YL YL 5 C311
NOT
A C320 USED
A C319 10 C310
M2 M2 M4
B A C317 A B C318 20
18 18
YL YL VT/YL
3 3 3
LEFT RIGHT LIFTGATE
REAR REAR SWITCH
G16 M2 M2 G16 (8W-44-6)
18 18 DOOR 18 18 DOOR
BK/LB YL JAMB YL BK/LB JAMB
2 SWITCH 2 SWITCH 1
2 1 1 2
DRIVER PASSENGER Z1
Z1 20
DOOR 18 DOOR Z1 BK
JAMB BK JAMB 18
BK
SWITCH SWITCH S334
(8W-15-14)
3 3
Z1
Z1 Z1 18
18 18 BK
BK BK 9 C310
6 C311
C C317 B C320 C C318 B C319 Z1
Z1 Z1 Z1 Z1 18
20 20 20 20 BK
BK BK BK BK
S309 S310
(8W-15-10) (8W-15-12)
Z1 Z1
12 16
BK BK
G304
G302 G303 (8W-15-14)
(8W-15-10) (8W-15-12)
J008W-7 XJD03906
XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 7
RHD
B OVERHEAD DOOR HEADLAMP
CARGO MODULE JAMB SWITCH
COURTESY (8W-49-5) SWITCH (8W-50-2)
LAMP/ LAMP SENSE
DOOR IGNITION
SWITCH CONTROL
(8W-44-7) JAMB SWITCH
1 SWITCH (8W-10-9) 6 C1
M2 SENSE
M2
20 20
YL YL 2 C2
G16 G16
S345 20 20
6 C314 (8W-12-27) BK/LB BK/LB
C S200
M4 1 C3 (8W-10-10)
20 JUNCTION
GY/BK BLOCK G16
(8W-12-2) 20
7 C314 BK/LB
M4
7 C7 4 C203
20 M2 M2
GY/BK 20 20 G16
YL YL 20
3 C326 BK/LB
M4 S304
20 M2 M2 (8W-44-7)
GY/BK 20 M2 20 M2
NOT YL 20 YL 20
5 C311 USED YL YL
10 C310 B C317 A C319
A
A C320 M2
A B C318
M4
20 M2 18 M2 G16
VT/YL 18 YL 18 18
YL YL BK/LB
3 1 3 1 2
LIFTGATE LEFT DRIVER
SWITCH G16 M2 REAR DOOR
(8W-44-7) 18 18 DOOR JAMB
BK/LB YL JAMB SWITCH
2 2 SWITCH
3
2 1 3
PASSENGER RIGHT
Z1 DOOR REAR
20 JAMB DOOR
BK
SWITCH JAMB
2 SWITCH
S334 3
(8W-15-14) Z1 Z1
Z1 18 18 Z1
Z1
18 BK BK 18
18
BK BK BK
9 C310 B C319 C C318
6 C311 C C317 B C320 Z1
Z1 Z1
Z1 Z1 20 20
18 20 20 BK
BK BK
BK BK
S310
S309 (8W-15-13)
(8W-15-11) Z1
Z1 12
12 BK
BK
G304 G303
(8W-15-14) G302 (8W-15-13)
(8W-15-11)
XJD03907 J008W-7
8W - 39 - 8 8W-39 VEHICLE THEFT SECURITY SYSTEM XJ
LHD
S238
(8W-30-20)
S239
(8W-30-20)
TWISTED
PAIR
TWISTED
BATT A7 (8W-10-12)
PAIR
D1 D2
20 20 JUNCTION
VT/BR WT/BK D2 D1 86 BLOCK
20 20 HORN (8W-12-2)
E11 E12 C100 WT/BK VT/BR RELAY
(8W-41-2)
4.0L
56 55 C201
OTHER A/T
D2 D1 85
20 20
D2 D2 WT/BK VT/BR
4.0L 18 20
OTHER A/T WT/BK WT/BK 2 1 C301
D1 1 C5
D1 D1 S144 20
(8W-30-20) VT/BR X3
18 20 20
VT/BR VT/BR D2
20 BK/RD
WT/BK OTHER COMPASS
OTHER COMPASS
S145 S344
(8W-30-20) (8W-30-20)
S346
(8W-30-20) 7 C301
TWISTED
PAIR TWISTED
PAIR
D1 D2 D2 D1 X3
18 18 20 20 20
VT/BR WT/BK WT/BK VT/BR BK/RD
12 6 10
CCD CCD HORN OVERHEAD
BUS BUS RELAY MODULE
(-) (+) CONTROL (8W-49-6)
30 C3 28 C3
CCD CCD POWERTRAIN
BUS BUS CONTROL
(+) (-) MODULE
(8W-30-20)
J008W-7 XJD03908
XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 9
RHD
S238
(8W-30-21)
S239
TWISTED TWISTED (8W-30-21)
PAIR PAIR
BATT A7 (8W-10-12)
D2 D1
D1 D2 20 20 JUNCTION
20 20 WT/BK VT/BR 86 BLOCK
VT/BR WT/BK HORN (8W-12-2)
RELAY
A11 A12 C100 (8W-41-3)
S346
S145 (8W-30-21)
(8W-30-21) 7 C301
TWISTED
PAIR
D2 D1 X3
20 20 20
WT/BK VT/BR BK/RD
TWISTED
12 6 10
PAIR
CCD CCD HORN OVERHEAD
BUS BUS RELAY MODULE
D1 D2 (-) (+) CONTROL (8W-49-6)
18 18
VT/BR WT/BK
30 C3 28 C3
CCD CCD POWERTRAIN
BUS BUS CONTROL
(+) (-) MODULE
(8W-30-21)
XJD03909 J008W-7
XJ 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1
S13 C4
F87
20
M1
WT/BK
20
PK
LHD RHD
S135
(8W-10-17)
FULL
OPTIONS BASE F87
12 C1
20
JUNCTION WT/BK
BLOCK S225
(8W-12-2) (8W-12-11)
S18 C4
M1
20 5 C201
PK
LHD RHD
F87
6 C201 20
WT/BK
S214 S216
(8W-10-17) (8W-12-11)
9 C1 8 C1
INSTRUMENT
CLUSTER
FUSED FUSED
B(+) IGNITION
SWITCH
OUTPUT
GROUND (ST-RUN)
9 C2 6 C1
Z2 Z2
18 20
BK/LG BK/LG
POLICE/
POSTAL OTHER
S227
(8W-15-9)
G108
(8W-15-9)
J008W-7 XJD04002
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3
INSTRUMENT
CLUSTER
LOW CHECK UPSHIFT
FUEL GAUGES INDICATOR
WARNING WARNING (M/T)
INDICATOR INDICATOR
30 C3 28 C3 26 C3 27 C2
CCD CCD FUEL VEHICLE POWERTRAIN
BUS BUS LEVEL SPEED CONTROL
(+) (-) SENSOR SENSOR MODULE
SIGNAL SIGNAL (8W-30-3)
(8W-30-4)
LHD (8W-30-12)
RHD (8W-30-20)
XJD04003 (8W-30-21) J008W-7
8W - 40 - 4 8W-40 INSTRUMENT CLUSTER XJ
INSTRUMENT
CLUSTER
CHECK
ENGINE
WARNING
INDICATOR
ENGINE OIL
COOLANT PRESSURE
TEMPERATURE GAUGE
GAUGE
2 C2 1 C2
D1 D2
20 20
VT/BR WT/BK
ENGINE
TWISTED ENGINE
COOLANT
PAIR COOLANT
TEMPERATURE TEMPERATURE
SENSOR SENSOR
SIGNAL (8W-30-7)
S239 S238
2
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
D1 D2
20 20
VT/BR WT/BK
A11
ENGINE ENGINE
E11 A12 C100 OIL OIL
4.0L
E12 4.0L PRESSURE
OTHER A/T
SENSOR
PRESSURE
OTHER A/T SENSOR
SIGNAL
2 (8W-30-12)
D1 D1 D2 D2
18 20 18 20
VT/BR VT/OR WT/BK WT/BK
S145 S144
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
TWISTED
PAIR
D1 D2 K2 G60
18 18 18 18
VT/BR WT/BK TN/BK GY/YL
30 C3 28 C3 16 C1 23 C2
CCD CCD ENGINE ENGINE POWERTRAIN
BUS BUS COOLANT OIL CONTROL
(+) (-) TEMPERATURE PRESSURE MODULE
SENSOR SENSOR (8W-30-7)
SIGNAL SIGNAL (8W-30-12)
(8W-30-20)
LHD (8W-30-21)
RHD
J008W-7 XJD04004
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5
LHD
ST-RUN F87 (8W-12-11)
INSTRUMENT
CLUSTER
AIRBAG SEAT LOW
ABS
WARNING BELT WASHER
INDICATOR
INDICATOR WARNING FLUID
INDICATOR INDICATOR
SEAT LOW
CCD CCD BELT WASHER
BUS BUS SWITCH FLUID
(+) (-) SENSE SENSE
2 C2 1 C2 10 C2 7 C1 4 C1
D1 D2 G10 G29 G19
20 20 20 20 20
VT/BR WT/BK LG/RD BK/LB LG/OR
S239 S238 A B
(8W-30-20) (8W-30-20) SEAT WASHER
BELT FLUID
SWITCH LEVEL
SWITCH
B A
Z1 Z1
D1 D2 20 20
20 20 B16
BK BK
VT/BR WT/BK CONTROLLER
ANTI-LOCK
TWISTED S314
(8W-15-7)
BRAKE
PAIR RELAY
Z1
14 4.0L A/T OTHER B19 (IN PDC)
BK (8W-35-3)
51 52 C201
TWISTED 14 C201 Z1
20
PAIR Z1 S141 S132 BK
14 (8W-15-4) (8W-15-3)
BK (8W-15-4)
D1 D2 S132
Z1 Z1 (8W-15-4)
18 18
VT/BR WT/BK
S208 16 16
(8W-15-8) BK BK
Z1
19 18 Z1 16
CCD CCD AIRBAG 14 BK
BUS BUS CONTROL BK
(+) (-) MODULE G106
(8W-43-2) G107 (8W-15-6)
(8W-15-8)
XJD04005 J008W-7
8W - 40 - 6 8W-40 INSTRUMENT CLUSTER XJ
RHD
ST-RUN F87 (8W-12-11)
INSTRUMENT
CLUSTER
AIRBAG SEAT LOW
ABS
WARNING BELT WASHER
INDICATOR
INDICATOR WARNING FLUID
INDICATOR INDICATOR
SEAT LOW
CCD CCD BELT WASHER
BUS BUS SWITCH FLUID
(+) (-) SENSE SENSE
2 C2 1 C2 10 C2 7 C1 4 C1
D1 D2 G10 G29 G19
20 20 20 20 20
VT/BR WT/BK LG/RD BK/LB LG/OR
TWISTED A8
PAIR 11 C203 F13 C100
G10 G29
20 20 G19
LG/RD BK/LB 20
LG/OR
S239 S238 A B16
(8W-30-21) (8W-30-21) SEAT CONTROLLER
BELT ANTI-LOCK
SWITCH BRAKE
RELAY
B B19 (IN PDC)
B (8W-35-3)
Z1 WASHER
20
D1 D2 BK FLUID
20 20 LEVEL
VT/BR WT/BK S313 SWITCH
(8W-15-11) A
TWISTED Z1 Z1
Z1 20
PAIR 20 20
BK BK
BK
19 20 S309
C204 (8W-15-11) S141 S132
(8W-15-5)
TWISTED (8W-15-5)
PAIR Z1
12 Z1
BK Z1 16
D1 D2 16 BK
18 18 BK
VT/BR WT/BK G302
(8W-15-11)
19 18
CCD CCD AIRBAG
BUS BUS CONTROL
(+) (-) MODULE G106
(8W-43-3) (8W-15-6)
J008W-7 XJD04006
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7
INSTRUMENT
CLUSTER
FULL PART RED
TIME TIME BRAKE
4WD 4WD WARNING
INDICATOR INDICATOR INDICATOR
7 C2 5 C2 2 C1
G106 G107 G99
20 20 20
BK/WT BK/RD GY/WT
A2 A3 A10 C100
G106 G107 E14
20 20 G99
BK/WT BK/RD 20
GY/WT
8
12 C107
G106 G107 2
20 20 BRAKE
BK/WT BK/RD WARNING
242 4WD 231 4WD PRESSURE
SWITCH
2 3 C112
1
G106 G107 4.0L A/T OTHER G9
20 20 20
BK/WT BK/RD 3 C112 GY/BK
A14
B D A C100
E2
TRANSFER TRANSFER S211
FULL PART CASE CASE (8W-10-9)
TIME TIME SWITCH SWITCH G9 G9
20 20
GY/BK GY/BK
A B
Z1
20 2 C1 LHD RHD
Z1 BK IGNITION
20 SWITCH 66 C201
4.0L A/T OTHER 1 START
BK
2 RUN 13 C203
1 C112 1 4 0 OFF
1 C112 2 3 3 LOCK
0 4 ACC
Z1 (8W-10-9)
20 Z1 1 C1
BK 20
BK Z1 G9
20 20
BK GY/BK
S107 S207
(8W-15-2) (8W-15-9)
Z1 Z1 PARK
16 14 BRAKE
BK BK
LHD SWITCH
RHD
G101 G108
(8W-15-2) (8W-15-9)
XJD04007 J008W-7
8W - 40 - 8 8W-40 INSTRUMENT CLUSTER XJ
BATT M1 (8W-10-17)
(8W-10-18)
INSTRUMENT
FUSED
CLUSTER
B(+)
CHIME
CONTROL
8 C2
G26
20
LB
S210
(8W-10-10)
1 C2 5
IGNITION HEADLAMP
KEY-IN
SWITCH SWITCH
SWITCH (8W-10-9) 0 OFF
1 PARK
0 1 2
2 HEAD
(8W-50-2)
2 C2 6
G16 G16
20 20
BK/LB BK/LB
S200
(8W-10-10)
LHD RHD
17 C200 4 C203
G16 G16
20 20
BK/LB BK/LB
B C317 B C318
G16 G16
18 18
BK/LB BK/LB
2 2
DRIVER DRIVER
DOOR DOOR
JAMB JAMB
SWITCH SWITCH
(8W-39-6) (8W-39-7)
3 3
Z1 Z1
18 18
BK BK
C C317 C C318
Z1 Z1
20 20
BK BK
S309 S310
(8W-15-10) (8W-15-13)
Z1 Z1
12 12
BK BK
G302 G303
(8W-15-10) (8W-15-13)
J008W-7 XJD04008
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9
LHD
RUN A22 OVERHEAD
(8W-10-11)
MODULE
CCD CCD
JUNCTION BUS BUS
(8W-49-6)
BLOCK (+) (-)
(8W-12-2)
FUSE 6 12 SENTRY
12 D1 TWISTED D2 KEY
20 20 CCD CCD
10A PAIR BUS BUS IMMOBILIZER
(8W-12-15) VT/BR WT/BK
(+) (-) MODULE
COMPASS OTHER COMPASS OTHER 1 2 (8W-39-8)
86
REAR S344 S346
WINDOW (8W-30-20) (8W-30-20) TWISTED
DEFOGGER PAIR
RELAY
1 2
(8W-48-2) C301
85 D1 D2
20 20
S26 C4 D1 D2
VT/BR WT/BK
20 20
55 56 VT/BR WT/BK
C201
C81
20 D1 TWISTED D2
LB/WT 20 PAIR 20
VT/BR WT/BK
17 C201
S239
(8W-30-20)
S238
C81 (8W-30-20)
20
D1 TWISTED D2
LB/WT PAIR
20 20
VT/BR WT/BK
3 C2 2 C2 1 C2
INSTRUMENT
REAR CCD CCD
CLUSTER
WINDOW REAR BUS BUS
DEFOGGER WINDOW (+) (-) VTSS
RELAY DEFOGGER INDICATOR
CONTROL SWITCH
SENSE
4 C2
C80
20
DB/WT
2
REAR
WINDOW
DEFOGGER
SWITCH
(8W-48-2)
1
Z1
20
BK
S208
(8W-15-8)
Z1
14
BK
G107
(8W-15-8)
XJD04009 J008W-7
8W - 40 - 10 8W-40 INSTRUMENT CLUSTER XJ
RHD
RUN A22 OVERHEAD
(8W-10-11)
MODULE
CCD CCD
JUNCTION BUS BUS
(8W-49-6)
BLOCK (+) (-)
(8W-12-2)
FUSE 6 12 SENTRY
12 D1 TWISTED D2 KEY
20 20 CCD CCD
10A PAIR BUS BUS IMMOBILIZER
(8W-12-16) VT/BR WT/BK
(+) (-) MODULE
COMPASS OTHER COMPASS OTHER 1 2 (EXCEPT
86 POLICE/
REAR S344 S346 POSTAL)
WINDOW (8W-30-21) (8W-30-21) TWISTED (8W-39-9)
DEFOGGER PAIR
RELAY
(8W-48-3) D1 D2
85 20 20
VT/BR WT/BK
S26 C4 D1 D2
1 2
C301 20 20
VT/BR WT/BK
C81
20
D1 TWISTED D2
LB/WT PAIR
20 20
VT/BR WT/BK
S239
(8W-30-21)
S238
(8W-30-21)
D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK
3 C2 2 C2 1 C2
INSTRUMENT
REAR CCD CCD
CLUSTER
WINDOW REAR BUS BUS
DEFOGGER WINDOW (+) (-) VTSS
RELAY DEFOGGER INDICATOR
CONTROL SWITCH
SENSE
4 C2
C80
20
DB/WT
2
REAR
WINDOW
DEFOGGER
SWITCH
(8W-48-3)
1
Z1
20
BK
S208
(8W-15-8)
Z1
14
BK
G107
(8W-15-8)
J008W-7 XJD04010
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 11
L3 S209 S212
16 (8W-52-3) (8W-52-4)
RD/OR
LHD RHD
D3 C100
L61 L60
G34 G34 L3 20 20
16 16 16 LG/WT TN
RD/GY RD/GY RD/OR
DRL OTHER
D4 C100
G34
16
RD/GY
5 C1 10 C1 6 C2
INSTRUMENT
CLUSTER
HIGH LEFT RIGHT
BEAM TURN TURN
INDICATOR SIGNAL SIGNAL
INDICATOR INDICATOR
9 C2 6 C1
POLICE/POSTAL OTHER
Z2
20
BK/LG
Z2
20 S227
Z2 (8W-15-9)
BK/LG
18
Z2
BK/LG
20
BK/LG
G108
(8W-15-9)
XJD04011 J008W-7
8W - 40 - 12 8W-40 INSTRUMENT CLUSTER XJ
4
HEADLAMP
SWITCH
0 OFF
1 PARK
3 4 0 1 2
2 HEAD
3 DIM
4 BRIGHT LIFTGATE
(8W-50-2) LIFTGATE SWITCH
AJAR
1 (8W-44-6)
SWITCH
(8W-44-7)
E1 SENSE
20 2
TN
LHD RHD
G78
42 C201 20
TN/BK
S1 C4
JUNCTION
BLOCK 6 C310
FUSE (8W-12-2) 3 C311
6
5A G78
(8W-12-8) 20
(8W-12-9) TN/BK
S2 C4 1 C327
E2
20 G78
OR 20
TN/BK
LHD RHD
LHD RHD
S315
(8W-12-8)
43 C201
40 C200 5 C204
S215
(8W-12-8)
(8W-12-9)
E2 G78
20 20
OR TN/BK
3 C1 1 C1
INSTRUMENT
CLUSTER CLUSTER
ILLUMINATION
LAMPS
TRIP LIFTGATE
RESET AJAR
SWITCH ODOMETER INDICATOR
SENSE CONTROL CONTROL
TRIP ODOMETER
RESET LIFTGATE
SWITCH AJAR
INDICATOR
J008W-7 XJD04012
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 13
INSTRUMENT
CLUSTER
CRUISE
ENGAGED
INDICATOR
FUSED CRUISE
IGNITION ENGAGED
SWITCH INDICATOR
OUTPUT CONTROL
(ST-RUN)
CCD CCD
BUS BUS
(+) (-)
2 C2 1 C2
D1 D2
20 20
VT/BR WT/BK
TWISTED
PAIR
S239 S238
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
D1 D2
20 20
VT/BR WT/BK
D1 D1 D2 D2
20 18 18 20
VT/BR VT/BR WT/BK WT/BK
S145 S144
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
TWISTED
PAIR
D1 D2
18 18
VT/BR WT/BK
30 C3 28 C3
CCD CCD POWERTRAIN
BUS BUS CONTROL
(+) (-) MODULE
(8W-30-20)
(8W-30-21)
RHD
LHD
XJD04013 J008W-7
XJ 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
JUNCTION
BLOCK
(8W-12-2)
86 30 86 30
CIGAR HORN
LIGHTER RELAY
RELAY
85 87 85 87
S5 C4 M6 C4 M5 C4 S22 C4 1 C5 4 C2
Z1 F30 F38 X3 X3 X2
14 16 16 20 20 20
BK RD RD/LB BK/RD BK/RD DG/RD
S314 S131
(8W-15-7) 7 C301 (8W-12-19)
X2 X2
Z1 20 20
14 DG/RD DG/RD
BK
14 50 65 26
C201 HIGH LOW
NOTE NOTE
Z1 F30 F38 X3 X3 HORN HORN
14 16 16 20 20
BK RD RD/LB BK/RD BK/RD
1 1 10
CIGAR POWER HORN OVERHEAD
LIGHTER OUTLET RELAY MODULE
CONTROL (8W-49-4)
3
1 C1
CLOCKSPRING
3
S208
(8W-15-8)
Z1 Z1 Z1
14 16 16 HORN
BK BK BK SWITCH
G107
(8W-15-8)
J008W-7 XJD04102
XJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3
RHD
RUN-ACC A31 (8W-10-9) BATT A7 (8W-10-12)
JUNCTION
BLOCK
(8W-12-2)
86 30 86 30
CIGAR HORN
LIGHTER RELAY
RELAY
85 87 85 87
S5 C4 M6 C4 M5 C4 1 C5 S22 C4 4 C2
Z1 F30 F38 X3 X3 X2
14 16 16 20 20 20
BK RD RD/LB BK/RD BK/RD DG/RD
7 C301
S131
S208 (8W-12-19)
(8W-15-8) X2 X2
20 20
DG/RD DG/RD
1 1
CIGAR POWER
LIGHTER OUTLET HIGH LOW
NOTE NOTE
X3
20 HORN HORN
BK/RD
3
10
HORN OVERHEAD
3
RELAY MODULE
CONTROL (8W-49-5)
1 C1
CLOCKSPRING
Z1 Z1 Z1
14 16 16
BK BK BK
HORN
G107 SWITCH
(8W-15-8)
XJD04103 J008W-7
XJ 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1
JUNCTION POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 12 CENTER
25 (8W-10-2)
FUSE
15A 6
(8W-12-20) 40A
(8W-10-13)
5 FROM
S215
S8 C4 (8W-12-8)
F15 A111
20 12
DB/WT RD/LG E2
20
D5 C100 OR
7 C1
S219 HEATER
(8W-12-20) CONTROL
0
1 HIGH
5 9
2 MEDIUM 2
A111 3 MEDIUM 1
FAN MODE
12 1 4 4 LOW
RD/LG 6 8
2 3 7 5 DEFROST
6 HEAT/DEFROST
7 HEAT
8 VENT
2 C1 3 C1 4 C1 5 C1 1 C1 9 BI-LEVEL
C201 0 OFF
11 12 61 60 59
A111 C7 C6 C5 C4 Z8
12 12 14 14 14 12
RD/LG BK/TN LB LG TN BK/VT
8 7 4 3 2
9 C209 G108
F15 A111 C7 C6 C5 C4 (8W-15-9)
20 12 12 14 14 14
DB/WT RD/LG BK/TN LB LG TN
5 4 S228
BLOWER 4 3 2 1
MOTOR BLOWER
C7
RELAY 12
MOTOR
BK/TN RESISTOR
2 1 B BLOCK
Z1 C1 BLOWER
20 12 MOTOR
BK DG M
10 C209
A
Z8
20
BK/VT
25 C201
Z8
16
BK/VT
G108
(8W-15-9)
J008W-7 XJD04202
XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3
RHD HEATER ONLY
RUN A22 (8W-10-11) BATT A0 (8W-10-7)
JUNCTION POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 12 CENTER
25 (8W-10-2)
FUSE
15A 6
(8W-12-21) 40A FROM
(8W-10-13) S215
5 (8W-12-9)
S8 C4
A111
12 E2
F15 RD/LG 20
20 OR
DB/WT D5 C100
7 C1
HEATER
S219 0 CONTROL
(8W-12-21) 1 HIGH
5 9
2 MEDIUM 2
F15 A111 3 MEDIUM 1
FAN MODE
20 12 1 4 4 LOW
DB/WT RD/LG 6 8
2 3 7 5 DEFROST
6 HEAT/DEFROST
1 C204 7 HEAT
F15 7 VENT
9 BI-LEVEL
20 2 C1 3 C1 4 C1 5 C1 1 C1 0 OFF
DB/WT C7 C6 C5 C4
12 14 14 14
BK/TN LB LG TN
S349
1 8 9 10
(8W-12-21) 7 C202
F15 A111 C7 C6 C5 C4 Z8
20 12 12 14 14 14 12
DB/WT RD/LG BK/TN LB LG TN BK/VT
8 7 4 3 2
9 C209
G108
C7 C6 C5 C4 (8W-15-9)
F15 A111 12 14 14 14
20 12 BK/TN LB LG TN
DB/WT RD/LG
5 4 S228
BLOWER 4 3 2 1
MOTOR BLOWER
C7
RELAY 12
MOTOR
BK/TN RESISTOR
2 1 B BLOCK
Z1 C1 BLOWER
20 12 MOTOR
BK DG M
10 C209
Z8 A
12
BK/VT
6 C202
Z8
16
BK/VT
G108
(8W-15-9)
XJD04203 J008W-7
8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER XJ
LHD
RUN A22 (8W-10-11) BATT A0 (8W-10-7)
JUNCTION POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 12 CENTER
25 (8W-10-2)
FUSE
15A 6
(8W-12-20) 40A
(8W-10-13)
5 FROM
S215
S8 C4 (8W-12-8)
F15 A111
20 12
DB/WT RD/LG E2
20
S219 OR
(8W-12-20) D5 C100
7 C1
A/C-
0 0
HEATER
5 11 5 CONTROL
11 1 HIGH
FAN 6 MODE 6
1 4 10 10 2 MEDIUM 2
7 9 7 9 3 MEDIUM 1
2 3 8 8 4 LOW
F15 A111 5 DEFROST
20 12 A/C
SELECT 6 HEAT/DEF(MIX)
DB/WT RD/LG 7 HEAT
2 C1 3 C1 4 C1 5 C1 6 C1 1 C1 8 VENT(PANEL)
9 BI-LEVEL
10 A/C
C201 11 MAX
11 12 61 60 59
0 OFF
A111 C7 C6 C5 C4 C90 Z8
12 12 14 14 14 20 12
RD/LG BK/TN LB LG TN LG BK/VT
8 7 4 3 2
9 C209
F15 A111
20 12
DB/WT RD/LG
5 4
BLOWER
MOTOR G108
A (8W-15-9)
RELAY C7 C6 C5 C4
12 14 14 14 TO
BK/TN LB LG TN C100
2 1 (8W-42-6)
Z1 C1 S228
20 12
4 3 2 1
BK DG
BLOWER
10 C209 C7
12
MOTOR
Z8 BK/TN RESISTOR
20 B BLOCK
BK/VT BLOWER
MOTOR
25 C201 M
Z8
16
A
BK/VT
G108
(8W-15-9)
J008W-7 XJD04204
XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5
RHD
RUN A22 (8W-10-11) BATT A0 (8W-10-7)
JUNCTION POWER
BLOCK DISTRIBUTION
FUSE
(8W-12-2) 12 CENTER
25 (8W-10-2)
FUSE
15A 6
(8W-12-21) 40A FROM
(8W-10-13)
5 S215
(8W-12-9)
S8 C4
F15 A111
20 12
E2
DB/WT RD/LG
20
OR
S219
(8W-12-21) D5 C100
F15 7 C1
20 A/C-
DB/WT HEATER
0 0
5 11 5 CONTROL
11 1 HIGH
1 C204 FAN 6 MODE 6
1 4 10 10 2 MEDIUM 2
F15 7 9 7 9 3 MEDIUM 1
2 3 8 8 4 LOW
20 A111
DB/WT A/C 5 DEFROST
12 6 HEAT/DEF(MIX)
RD/LG SELECT
7 HEAT
S349 2 C1 3 C1 4 C1 5 C1 6 C1 1 C1 8 VENT(PANEL)
(8W-12-21) 9 BI-LEVEL
1 8 9 10 10 A/C
7 C202 Z8 11 MAX
F15 12 0 OFF
20 BK/VT
A111 C7 C6 C5 C4 C90
DB/WT
12 12 14 14 14 20
RD/LG BK/TN LB LG TN LG
8 7 4 3 2 G108
9 C209 (8W-15-9)
F15 A111
20 12
DB/WT RD/LG
5 4
BLOWER
MOTOR A
RELAY C7 C6 C5 C4
12 14 14 14 TO
BK/TN LB LG TN C100
2 1 (8W-42-6)
Z1 C1 S228
20 12
4 3 2 1
BK DG
BLOWER
10 C209 C7
12
MOTOR
Z8 BK/TN RESISTOR
12 B BLOCK
BK/VT BLOWER
MOTOR
6 C202 M
Z8
16
A
BK/VT
G108
(8W-15-9)
XJD04205 J008W-7
8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER XJ
FROM
A/C-
HEATER
CONTROL
(8W-42-4)
(8W-42-5)
A
C90
20
LG
A6 C100
C90
20
LG
S143
C90 C90
20 20
LG LG
4.0L 2.5L
4 3 2
A/C A/C
HIGH LOW
PRESSURE PRESSURE
SWITCH SWITCH
2 1 1
C21 C21
20 20
DB/PK DB/PK
2 2
A/C A/C
LOW HIGH
PRESSURE PRESSURE
C90 C48
18 18 SWITCH SWITCH
LG TN 1 1
C22
18
DB/WT
23 C3 13 C3 22 C3
A/C RADIATOR A/C POWERTRAIN
SWITCH FAN SWITCH CONTROL
SENSE REQUEST SENSE MODULE
(8W-30-18)
J008W-7 XJD04206
XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7
3 C2 4 C2
BLEND FUSED A/C-
DOOR IGNITION HEATER
FEEDBACK SWITCH CONTROL
SIGNAL OUTPUT
(RUN)
GROUND
2 C2
RHD LHD
17 C204 7 C201
A/C
COMPRESSOR
CLUTCH
1 C3 Z1 Z1
A/C POWERTRAIN 20 20
COMPRESSOR CONTROL BK BK
CLUTCH MODULE
RELAY (8W-30-18)
CONTROL
G107
(8W-15-8)
XJD04207 J008W-7
8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER XJ
D13 D14
C27 C25
18 12
DB/PK LB
2 C3 1
RADIATOR POWERTRAIN RADIATOR
FAN CONTROL FAN
RELAY MODULE M MOTOR
CONTROL (8W-30-18)
2
Z1
12
BK
G106
(8W-15-6)
J008W-7 XJD04208
XJ 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
S21 C4 S23 C4
F14 F23
18 18
LG/YL DB/YL
20 17
FUSED FUSED AIRBAG
IGNITION IGNITION CONTROL
SWITCH SWITCH MODULE
OUTPUT OUTPUT
(RUN) CCD CCD (ST-RUN)
BUS BUS
(-) (+) GROUND
18 19 10
D2 D1
18 18
WT/BK VT/BR
TWISTED BASE FULL OPTIONS
PAIR
52 51 Z6 Z6
C201 18 18
BK/YL BK/PK
TWISTED
PAIR
D2 D1
20 20
WT/BK VT/BR
S238 S239
(8W-30-20) (8W-30-20)
D2 D1
18 18
WT/BK VT/BR
TWISTED
PAIR
11 3
DATA G200
LINK (8W-15-10)
CONNECTOR
(8W-30-20)
J008W-7 XJD04302
XJ 8W-43 AIRBAG SYSTEM 8W - 43 - 3
RHD
RUN A22 (8W-10-11) ST-RUN A21 (8W-10-10)
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
26 27
10A 10A
(8W-12-24) (8W-12-24)
S21 C4 S23 C4
F14 F23
18 18
LG/YL DB/YL
15 14
C204
F14 F23
18 18
LG/YL DB/YL
20 17
FUSED FUSED AIRBAG
IGNITION IGNITION CONTROL
SWITCH SWITCH MODULE
OUTPUT OUTPUT
(RUN) CCD CCD (ST-RUN)
BUS BUS
(-) (+) GROUND
18 19 10
D2 D1
18 18
WT/BK TWISTED VT/BR
PAIR
20 19 C204
D2 D1 Z6
20 20 18
WT/BK VT/BR BK/PK
TWISTED
PAIR
S238 S239
(8W-30-21) (8W-30-21)
D2 D1
18 18
WT/BK VT/BR
TWISTED
PAIR
11 3
DATA
LINK
CONNECTOR
(8W-30-21)
G300
(8W-15-11)
XJD04303 J008W-7
8W - 43 - 4 8W-43 AIRBAG SYSTEM XJ
AIRBAG
CONTROL
MODULE
DRIVER DRIVER PASSENGER PASSENGER
AIRBAG AIRBAG AIRBAG AIRBAG
LINE 1 LINE 2 LINE 2 LINE 1
1 2 5 6
TWISTED TWISTED
PAIR PAIR
4 3 1 2
C205
TWISTED TWISTED
PAIR PAIR
1 C3 2 C3
CLOCKSPRING
3 4
DRIVER DRIVER DRIVER PASSENGER PASSENGER PASSENGER
AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG AIRBAG
LINE 1 LINE 2 LINE 2 LINE 1
J008W-7 XJD04304
XJ 8W - 44 INTERIOR LIGHTING 8W - 44 - 1
HEADLAMP 1 C206
PANEL
LAMPS SWITCH
DIMMER (8W-50-2) 1
SWITCH PRNDL
S1 C4 SIGNAL ILLUMINATION
JUNCTION 1 (A/T) 1
BLOCK TRANSFER
FUSE (8W-12-2) E1
6 20 CASE
TN 2 SWITCH
5A
(8W-12-8)
42 C201 ILLUMINATION
E1 2
S2 C4 20
E2 E2 Z1 Z1
TN
20 20 20 20
OR OR BK BK
S315 2 C206
(8W-12-8)
Z1
43 C201 20
BK
E2 S314
20
(8W-15-7)
OR
Z1
14
S215 BK
(8W-12-8)
E2 E2 E2 E2 E2 E2 14 C201
20 20 20 20 20 20
OR OR OR OR OR OR Z1
POLICE
14
5 C2 PACKAGE OTHERS
BK
FUSED RADIO
PANEL (8W-47-2) S208
4
LAMPS (8W-47-8) 4 (8W-15-8)
DIMMER EXTENDED REAR Z1
SWITCH IDLE WINDOW 14
SIGNAL SWITCH DEFOGGER BK
(8W-30-17)
SWITCH G107
(8W-48-2)
1 (8W-15-8)
3 1
1
REAR FRONT 7 C1
WIPER/ FOG A/C-
WASHER LAMP HEATER
SWITCH SWITCH CONTROL
(8W-53-3) (8W-42-4)
1 4
Z1 Z1 Z1 Z1 1 C1
20 20 20 20
BK BK BK BK
S208
3 C1 (8W-15-8)
INSTRUMENT Z8
Z1
CLUSTER 14 12
(8W-40-12) BK BK/VT
G107 G108
(8W-15-8) (8W-15-9)
J008W-7 XJD04402
XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 3
RHD
HEADLAMP
PANEL
LAMPS SWITCH
1 C206
DIMMER (8W-50-2)
SWITCH
SIGNAL E2 E2
20 20
OR OR
E1 1 1
20 PRNDL TRANSFER
TN ILLUMINATION CASE
(A/T) SWITCH
S1 C4 E2
20 ILLUMINATION
JUNCTION OR/BK
BLOCK 2 2
FUSE (8W-12-2) Z1
Z1
6 20
20
5A BK
BK
(8W-12-9) 12 C203
2 C206
S2 C4
S313
E2 E2 (8W-15-11)
20 20 Z1
OR OR 20
BK
S215 S309
(8W-12-9) (8W-15-11)
E2 E2 E2 E2 E2 Z1
20 20 20 20 20 12
OR OR OR OR OR BK
G302
7 C1 5 C2 4 (8W-15-11)
A/C- FUSED RADIO REAR
HEATER PANEL (8W-47-3) WINDOW
CONTROL LAMPS (8W-47-9) DEFOGGER
DIMMER
(8W-42-5)
E2 SWITCH
SWITCH
20 SIGNAL (8W-48-3)
OR
1 C1 1
3 1
Z8 REAR FRONT
12
BK/VT WIPER/ FOG
WASHER LAMP
SWITCH SWITCH
(8W-53-4)
G108 1 4
(8W-15-9)
Z1 Z1 Z1
20 20 20
BK BK BK
3 C1 S208
(8W-15-8)
INSTRUMENT
CLUSTER Z1
(8W-40-12) 14
BK
G107
(8W-15-8)
XJD04403 J008W-7
8W - 44 - 4 8W-44 INTERIOR LIGHTING XJ
BATT M1 (8W-10-17)
(8W-10-18)
JUNCTION
BLOCK
(8W-12-2)
3 C3
M1 20PK
SKIM OTHERS
S361
(8W-10-18)
S347
(8W-10-18)
J008W-7 XJD04404
XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 5
BATT A0 (8W-10-7)
POWER
A23
DISTRIBUTION FROM
CENTER DOME
FUSE (8W-10-2) LAMPS
FROM
16
15A COMPASS SWITCH
A24 (8W-10-17) FULL (8W-44-4) MIDLINE
OPTIONS
A
M1
20
M2
PK
20
S135 YL
(8W-10-17)
12 C1 1 C3
M1 JUNCTION
20 BLOCK
PK (8W-12-2)
4 C7 S18 C4 7 C7 S25 C4
M1 LHD RHD M2
20 20 M2
PK 6 C201 YL 20
YL
5 C314 LHD RHD
S214
LHD RHD (8W-10-17)
M1 M1
M1 M1 20 20
20 18 D E
PK PK
PK PK
A C208 A C207 TO TO
B C S304 S304
M1 M1
18 18 (8W-44-6) (8W-44-7)
TO TO
PK PK
CARGO CARGO
1 1
LAMP/ LAMP/ RIGHT LHD RHD
LEFT
SWITCH SWITCH COURTESY
COURTESY
(8W-44-6) (8W-44-7) LAMP 46 C201
2 LAMP 2
1 M2 18BK/WT M2 18BK/WT
B C208 B C207
UNDERHOOD M2 M2 M2
LAMP/ 20 20 20
MERCURY YL YL YL
SWITCH S201
(8W-12-27)
3 C1
HEADLAMP HEADLAMP
DOME
2 DELAY LAMP SWITCH
MODULE SWITCH (8W-50-2)
Z1
20 GROUND (8W-50-5)
BK 4
Z1 Z1
S132 18 18
(8W-15-3) BK BK
Z1 (8W-15-4)
16 (8W-15-5) S207
BK (8W-15-9)
Z1
G106 14
(8W-15-6) BK
G108
XJD04405 (8W-15-9) J008W-7
8W - 44 - 6 8W-44 INTERIOR LIGHTING XJ
LHD
FROM
JUNCTION FROM
BLOCK C314
(8W-44-5) (8W-44-5)
D B
S304
M2 M2 M2 M2 M2
20 20 20 20 20
YL YL YL YL YL
6 C314
A C317 A C320 A C318 A C319 B A
CARGO
M2 M2 M2 M2 LAMP/
18 18 18 18 SWITCH
YL YL YL YL
3 3
C
LEFT RIGHT
M4
REAR REAR 20
DOOR DOOR GY/BK
JAMB JAMB
SWITCH SWITCH 7 C314
2 2
3 C326
M4
20
GY/BK
1 1 5 C311
DRIVER PASSENGER 10 C310
Z1 Z1 M4
DOOR 18
DOOR 18 20
JAMB BK JAMB BK VT/YL
SWITCH SWITCH 3 1
(8W-39-6) (8W-39-6) LIFTGATE
3 3 SWITCH
2
G78 Z1
Z1 Z1 20
18 18 20
TN/BK BK
BK BK
6 C310 S334
C C317 B C320 C C318 B C319 3 C311 (8W-15-14)
G78 Z1
Z1 Z1 Z1 Z1 18
20 20 20 20 20
TN/BK BK
BK BK BK BK
1 C327 9 C310
6 C311
S309 S310 G78
(8W-15-10) (8W-15-12) 20 Z1
TN/BK 18
BK
Z1 Z1 40 C200
12 16
1 C1 G304
BK BK (8W-15-14)
LIFTGATE INSTRUMENT
AJAR CLUSTER
G302 G303 SWITCH (8W-40-12)
(8W-15-10) (8W-15-12) SENSE
J008W-7 XJD04406
XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 7
RHD
FROM
JUNCTION FROM
BLOCK C314
(8W-44-5) (8W-44-5)
E C
S304
M2 M2 M2 M2 M2
20 20 20 20 20
YL YL YL YL YL
6 C314
3 3
C
LEFT RIGHT
M4
REAR REAR 20
DOOR DOOR GY/BK
JAMB JAMB
SWITCH SWITCH 7 C314
2 2
3 C326
Z1 Z1 M4
18 18 20
BK BK GY/BK
1 1
PASSENGER DRIVER 5 C311
DOOR DOOR
M4 C310
10
JAMB JAMB 20
SWITCH SWITCH VT/YL
(8W-39-7) (8W-39-7) 3 1
3 3 LIFTGATE
SWITCH
Z1 Z1
18 18
BK BK
2
C C317 B C320 C C318 B C319 Z1
G78
20 20
Z1 Z1 Z1 Z1
TN/BK BK
20 20 20 20
BK BK BK BK S334
6 C310 (8W-15-14)
S309 S310 3 C311 Z1
(8W-15-11) (8W-15-13) 18
1 C327 BK
9 C310
Z1
6 C311
12 5 C204
Z1
Z1 BK
18
12 1 C1 BK
BK LIFTGATE INSTRUMENT
AJAR CLUSTER
G302 SWITCH (8W-40-12) G304
(8W-15-11) G303 SENSE
(8W-15-13) (8W-15-14)
XJD04407 J008W-7
XJ 8W - 47 AUDIO SYSTEM 8W - 47 - 1
HEADLAMP POWER
SWITCH DISTRIBUTION
0 OFF A23
A4
CENTER
1 PARK FUSE (8W-10-2)
0 2 3 4 2 HEAD 16 FUSE
1
3 DIM 15A 26
4 BRIGHT (8W-10-17) 20A
(8W-50-2) A24
(8W-10-20)
A3
9 1
E1
20 M1 F75
TN 20 16
PK VT
42 C201
L7 E1
18 20 S135
BK/YL TN (8W-10-17)
M1
20
PK
RUN-ACC A31 (8W-10-9)
S1 C4 12 C1
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
6 17 C4 C100
5A 15A
(8W-12-8) (8W-12-17)
F75
16
S2 C4 S18 C4 S9 C4 VT
E2 M1 X12
20 20 16
OR PK RD/WT
14 C200
S315 F75
43 (8W-12-8) 6 54 14
C201 VT
S206 M1
(8W-12-10) 20 S301
S215 PK
(8W-12-8)
S214 F75 F75
16 16
ANTENNA (8W-10-17)
VT VT
L7 E2 M1 X12
18 20 20 16
BK/YL OR PK RD/WT
1 C2 2 C2
FUSED FUSED POWER
4 C2 5 C2 7 C2 6 C2 B(+) B(+) AMPLIFIER
HEADLAMP FUSED FUSED FUSED RADIO
SWITCH PANEL B(+) IGNITION
OUTPUT LAMPS SWITCH
DIMMER OUTPUT GROUND GROUND
SWITCH (RUN-ACC) 7 C2 8 C2
SIGNAL
GROUND
Z5 Z5
16 16
Z9 BK/LB BK/LB
14
BK G301
(8W-15-10)
G108
J008W-7 (8W-15-9) XJD04702
XJ 8W-47 AUDIO SYSTEM 8W - 47 - 3
RHD 6 SPEAKER SYSTEM
BATT F34 (8W-10-18) BATT A0 (8W-10-7)
HEADLAMP POWER
SWITCH DISTRIBUTION
0 OFF A23
A4
CENTER
1 PARK FUSE (8W-10-2)
0 2 3 4 2 HEAD 16 FUSE
1
3 DIM 15A 26
4 BRIGHT 20A
(8W-50-2) A24
(8W-10-20)
A3
9 1
L7 E1
18 20
BK/YL TN
M1 F75
20 16
PK VT
S135
(8W-10-17)
M1
20
PK RUN-ACC A31 (8W-10-9)
S1 C4 12 C1
JUNCTION
BLOCK C4 C100
(8W-12-2)
FUSE FUSE
6 17
5A 15A F75
(8W-12-9) (8W-12-18) 16
VT
S2 C4 S18 C4 S9 C4 21 C204
E2 M1 X12 F75
20 20 16 16
OR PK RD/WT VT
S215 S301
S206 (8W-12-9) S214
(8W-12-10) (8W-10-17) F75 F75
16 16
ANTENNA VT VT
L7 E2 M1
18 20 20
BK/YL OR PK
1 C2 2 C2
FUSED FUSED POWER
4 C2 5 C2 7 C2 6 C2 B(+) B(+) AMPLIFIER
HEADLAMP FUSED FUSED FUSED RADIO
SWITCH PANEL B(+) IGNITION
OUTPUT LAMPS SWITCH
DIMMER OUTPUT GROUND GROUND
SWITCH (RUN-ACC) 7 C2 8 C2
SIGNAL
GROUND
Z5 Z5
16 16
Z9 BK/LB BK/LB
14
BK G301
(8W-15-11)
G108
XJD04703 (8W-15-9) J008W-7
8W - 47 - 4 8W-47 AUDIO SYSTEM XJ
LHD 6 SPEAKER SYSTEM
RADIO
LEFT LEFT LEFT LEFT
REAR REAR FRONT FRONT RADIO
SPEAKER SPEAKER SPEAKER SPEAKER 12V
(+) (-) (+) (-) OUTPUT
2 C1 6 C1 4 C1 2 C2 1 C1
6 7 1 2 11 C200
X51 X57 X53 X55 X60
18 18 18 18 18
BR/YL BR/LB DG BR/RD DG/RD
7 C1 8 C1 5 C1 1 C1 4 C1
LEFT LEFT LEFT LEFT RADIO POWER
REAR REAR FRONT FRONT 12V AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT
(+) (-) (+) (-)
AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED LEFT LEFT
LEFT LEFT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (+) (-)
6 C2 14 C2 4 C2 12 C2
X93 X91 X87 X85
18 18 18 18
WT/RD WT/BK LG/VT BR/RD
4 3 C314 2 1 C305
S326
X85 X85
18 18
BK/RD LG/RD
A 1 1
LEFT LEFT LEFT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2
X87 X87
18 18
DG LG/BK
S327
J008W-7 XJD04704
XJ 8W-47 AUDIO SYSTEM 8W - 47 - 5
RHD 6 SPEAKER SYSTEM
RADIO
LEFT LEFT LEFT LEFT
REAR REAR FRONT FRONT RADIO
SPEAKER SPEAKER SPEAKER SPEAKER 12V
(+) (-) (+) (-) OUTPUT
2 C1 6 C1 4 C1 2 C2 1 C1
16 20 18 14
22 C203
X51 X57 X53 X55 X60
18 18 18 18 18
BR/YL BR/LB DG BR/RD DG/RD
7 C1 8 C1 5 C1 1 C1 4 C1
LEFT LEFT LEFT LEFT RADIO POWER
REAR REAR FRONT FRONT 12V AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT
(+) (-) (+) (-)
AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED LEFT LEFT
LEFT LEFT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(-) (+) (+) (-)
6 C2 14 C2 4 C2 12 C2
X93 X91 X87 X85
18 18 18 18
WT/RD WT/BK LG/VT BR/RD
4 3 C314 2 1 C305
S326
X85 X85
18 18
LG/RD LG/RD
A 1 1
LEFT LEFT LEFT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2
X87 X87
18 18
LG/BK LG/BK
S327
XJD04705 J008W-7
8W - 47 - 6 8W-47 AUDIO SYSTEM XJ
LHD 6 SPEAKER SYSTEM
RADIO
RIGHT RIGHT RIGHT RIGHT
REAR REAR FRONT FRONT
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
3 C1 7 C1 5 C1 3 C2
X52 X58 X54 X56
16 16 16 16
DB/WT DB/OR VT DB/RD
9 10 4 5 C200
9 C1 3 C1 6 C1 2 C1
RIGHT RIGHT RIGHT RIGHT POWER
REAR REAR FRONT FRONT AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED RIGHT RIGHT
RIGHT RIGHT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
5 C2 13 C2 11 C2 10 C2
2 1 C314 5 4
C303
S320
X80 X80
18 18
LB/BK LB/BK
A 1 1
RIGHT RIGHT RIGHT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2
X82 X82
18 18
LB/RD LB/RD
S321
J008W-7 XJD04706
XJ 8W-47 AUDIO SYSTEM 8W - 47 - 7
RHD 6 SPEAKER SYSTEM
RADIO
RIGHT RIGHT RIGHT RIGHT
REAR REAR FRONT FRONT
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
3 C1 7 C1 5 C1 3 C2
X52 X58 X54 X56
16 16 16 16
DB/WT DB/OR VT DB/RD
15 19 17
21 C203
9 C1 3 C1 6 C1 2 C1
RIGHT RIGHT RIGHT RIGHT POWER
REAR REAR FRONT FRONT AMPLIFIER
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED RIGHT RIGHT
RIGHT RIGHT FRONT FRONT
REAR REAR DOOR DOOR
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-)
5 C2 13 C2 11 C2 10 C2
2 1 C314 3 2
C324
S320
X80 X80
18 18
LB/BK LB/BK
A 1 1
RIGHT RIGHT RIGHT
SOUNDBAR FRONT FRONT
SPEAKER DOOR DOOR
SPEAKER TWEETER
B 2 2
X82 X82
18 18
LB/RD LB/RD
S321
XJD04707 J008W-7
8W - 47 - 8 8W-47 AUDIO SYSTEM XJ
LHD 4 SPEAKER SYSTEM
BATT F34 (8W-10-18)
E1
HEADLAMP 20
SWITCH TN
0 OFF
1 PARK 42 C201
0 2 3 4 2 HEAD
1 E1
3 DIM
20
4 BRIGHT
TN
(8W-50-2)
9 1
S18 C4 S9 C4 S2 C4
M1 X12 E2
S206 20 16 20
(8W-12-10) PK RD/WT OR
S315
(8W-12-8)
6 54 43
C201
L7 M1 E2
18 20 20
BK/YL PK OR
HEADLAMP
SWITCH
0 OFF
1 PARK
0 1 2 3 4 2 HEAD
3 DIM
4 BRIGHT
(8W-50-2)
9 1
L7
18
BK/YL
S206 E1
(8W-12-10) 20
TN
BATT M1 (8W-10-17) RUN-ACC A31 (8W-10-9)
(8W-10-18) S1 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE
17 6
15A 5A
(8W-12-18) (8W-12-9)
S18 C4 S9 C4 S2 C4
L7 M1 X12 E2
18 20 16 20
BK/YL PK RD/WT OR
S214 S215
(8W-10-17) (8W-12-9) ANTENNA
M1 E2
20 20
PK OR
4 C2 7 C2 6 C2 5 C2
HEADLAMP FUSED FUSED FUSED PANEL RADIO
SWITCH B(+) IGNITION LAMPS DIMMER
OUTPUT SWITCH SWITCH SIGNAL
OUTPUT
RIGHT RIGHT (RUN-ACC) LEFT LEFT
FRONT FRONT FRONT FRONT
SPEAKER SPEAKER SPEAKER SPEAKER
(+) (-) (+) (-) GROUND
5 C1 3 C2 4 C1 2 C2
X54 X56 X53 X55
16 16 16 16
Z9
VT DB/RD DG BR/RD
14
17 20 18
19 C203 BK
X54 X56 X53 X55
18 18 18 18
VT DB/RD DG BR/RD G108
(8W-15-9)
5 4 C303 2 1 C305
X80 X55
18 18
X82 LB/BK X53 LG/RD
18 1 18 1
LB/RD RIGHT LG/BK LEFT
FRONT FRONT
DOOR DOOR
SPEAKER SPEAKER
2 2
XJD04709 J008W-7
8W - 47 - 10 8W-47 AUDIO SYSTEM XJ
4 SPEAKER SYSTEM
RADIO
3 4 1 2 C314
A A
LEFT RIGHT
SOUNDBAR SOUNDBAR
SPEAKER SPEAKER
B B
J008W-7 XJD04710
XJ 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
(8W-12-15)
86 30
REAR
WINDOW FUSE
DEFOGGER 14
RELAY 10A
(8W-12-15)
85 87
S26 C4 S19 C4 3 C9 1 C6
C81 C16
20 2 C201 C15
20 12
LB/WT C16 BK/WT BK/WT
17 C201 20
5
LB/YL 4 C326
3 C2 PASSENGER
REAR WINDOW INSTRUMENT POWER 2 C312
DEFOGGER CLUSTER MIRROR 3 C310
RELAY CONTROL (8W-40-9) 37 C200 C15
REAR WINDOW 11 C305 6 12
DEFOGGER FULL POWER POWER FULL BK/WT
SWITCH SENSE OPTIONS MIRRORS MIRRORS OPTIONS
4 C2 C16 C16 Z1 REAR
20 20 18
FROM LB/YL BK/WT Z1 WINDOW
BK
S215 18 DEFOGGER
(8W-12-8) 5 BK S319
DRIVER (8W-15-7)
Z1
E2 C80 C16 POWER 16
20 20 20 MIRROR
OR DB/WT LB/YL BK
4 2 3 6 11 C9
REAR FULL POWER
JUNCTION
WINDOW OPTIONS MIRRORS
BLOCK
DEFOGGER (8W-12-2) Z1
Z1 Z1 12
SWITCH 16 18 S5 C4
DEFOGGER BK
SWITCH BK BK Z1
ON
ILLUM. INDICATOR
14 2 C310
S329 S329 BK 1 C312
(8W-15-10) (8W-15-10)
S314 Z1
Z1 Z1 (8W-15-7)
1 12 16 12
Z1 BK BK
14 C201 BK
20
BK
S208
(8W-15-8)
Z1 G304
S208 3 C307 (8W-15-14)
14
(8W-15-8)
Z1 S309 BK
14
(8W-15-10)
BK G107
G302 (8W-15-8)
G107 (8W-15-10)
(8W-15-8)
J008W-7 XJD04802
XJ 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 3
RHD
RUN A22 (8W-10-11) BATT A4 (8W-10-16)
JUNCTION
BLOCK
(8W-12-2)
FUSE
12
10A
(8W-12-16)
FUSE
86 30
14
REAR
10A
WINDOW
(8W-12-16)
DEFOGGER
RELAY
85 87
S26 C4 5 C5 S19 C4 3 C9 1 C6
C16 20BK/WT
2 C204
C81 C16 C15
20 C16 20 12
LB/WT 20 BK/WT BK/WT
LB/YL
11 C305 5 4 C326
3 C2 FULL POWER DRIVER 2 C312
REAR WINDOW INSTRUMENT OPTIONS MIRRORS POWER 3 C310
DEFOGGER CLUSTER MIRROR
TIMER (8W-40-10) C16 C16
20 20 REAR
REAR WINDOW LB/YL BK/WT
6
WINDOW
C16
DEFOGGER
20 DEFOGGER
SWITCH SENSE 5 Z1
LB/YL
4 C2 PASSENGER 18
POWER BK
POWER FULL
C80 MIRROR MIRRORS OPTIONS
20
DB/WT 6
Z1 S319 S319 Z1
16 (8W-15-13) (8W-15-13) 12
FROM FULL BK POWER Z1 Z1 BK
OPTIONS MIRRORS 16 14
S215 BK BK
(8W-12-9)
S329 Z1
(8W-15-11) 11 C9 2 C310
16
E2 Z1
BK
JUNCTION 1 C312
20 12 BLOCK 5 C303
OR BK (8W-12-2) Z1
2 4 3 14
REAR S5 C4 BK Z1
WINDOW 12
Z1
DEFOGGER S310 BK
SWITCH DEFOGGER 14
ON BK (8W-15-13)
ILLUM. INDICATOR SWITCH 3 C307 Z1
Z1 12
12 BK
BK G304
1
Z1 20BK
S208 G303 (8W-15-14)
S208 S309 (8W-15-8) (8W-15-13)
(8W-15-8) (8W-15-11) Z1
Z1 Z1
14 14
12 BK
BK BK
G107 G107
G302 (8W-15-8)
(8W-15-8) (8W-15-11)
XJD04803 J008W-7
XJ 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1
M1 F87
20 20
PK WT/BK
S135 S225
(8W-10-17) (8W-12-11)
12 C1 F87
JUNCTION 20
BLOCK WT/BK
(8W-12-2)
3 C3 6 C301
OTHERS SKIM
F87
20
S361 WT/BK
(8W-10-18) M1
20
PK
S347 2 6
(8W-10-18)
M1 FUSED FUSED COMPASS
20 B(+) IGNITION (FULL
PK SWITCH OPTIONS)
OUTPUT
2 (ST-RUN)
FUSED OVERHEAD GROUND GROUND
B(+) MODULE
1 12
Z1 Z2
20 20
GROUND GROUND BK BK/LG
9 3 S342
Z1 Z1 (8W-15-7) 5 C301
20 20
BK BK
2 C3
JUNCTION Z2
BLOCK 20
(8W-12-2) BK/LG
S5 C4
Z1 58 C201
14
BK
S314 Z2
20
(8W-15-7)
BK/LG
14 C201
S208
(8W-15-8) G108
(8W-15-9)
G107
(8W-15-8)
J008W-7 XJD04902
XJ 8W-49 OVERHEAD CONSOLE 8W - 49 - 3
RHD
BATT A0 (8W-10-7) ST-RUN A21 (8W-10-10)
POWER JUNCTION
A23 DISTRIBUTION BLOCK
FUSE CENTER (8W-12-2)
(8W-10-2) FUSE
16 9
15A 10A
(8W-10-17) (8W-12-11)
A24
S13 C4
M1 F87
20 20
PK WT/BK
S135 S216
(8W-10-17) (8W-12-11)
12 C1
JUNCTION F87
BLOCK 20
(8W-12-2) WT/BK
3 C3
OTHERS SKIM
S361
(8W-10-18) 6 C301
M1 F87
20 20
PK WT/BK
S347
(8W-10-18) 2 6
M1 FUSED FUSED COMPASS
20 B (+) IGNITION
PK SWITCH
OUTPUT
2 (ST-RUN)
FUSED OVERHEAD GROUND GROUND
B (+) MODULE
1 12
Z1
20
GROUND GROUND BK
Z2
9 3 S342 20
Z1 Z1 (8W-15-7) BK/LG
20 20
BK BK
2 C3
JUNCTION
BLOCK 5 C301
(8W-12-2)
S5 C4
Z1
14
BK
S208 Z2
(8W-15-8) 20
Z1 BK/LG
14
BK
G107
(8W-15-8) G108
(8W-15-9)
XJD04903 J008W-7
8W - 49 - 4 8W-49 OVERHEAD CONSOLE XJ
LHD
BATT A7 (8W-10-12)
JUNCTION AMBIENT
AMBIENT
BLOCK TEMPERATURE TEMPERATURE
86
HORN
(8W-12-2) SENSOR SENSOR SENSOR
RELAY SIGNAL GROUND
(8W-41-2) 1 2
G31 G32
85 20 20
VT/LG BK/LB
F14 F15
1 C5 C100
PASSENGER
DOOR G31 G32
X3 DOOR UNLOCK
POWER 20 20
20 LOCK RELAY LOCK/ VT/LG BK/LB
BK/RD CONTROL CONTROL WINDOW
1 C2 2 C2 SWITCH
(8W-61-2)
P59 P55 C201
20 20 32 35
LB/RD DB/PK
4 3 C300
P59 P55 G31 G32
20 20 20 20
LB/RD DB/PK VT/LG BK/LB
C301
7 9 8 C301 4 3
X3 P59 P55 G31 G32
20 20 20 20 20
BK/RD LB/RD DB VT/LG BK/LB
10 11 5 4 10
HORN DOOR DOOR OVERHEAD AMBIENT SENSOR COMPASS
RELAY LOCK UNLOCK MODULE TEMPERATURE GROUND
CONTROL CONTROL RELAY SENSOR
COURTESY CONTROL SIGNAL COURTESY
LAMPS LAMPS
DRIVER DRIVER
1 7
M2 M2
20 20
YL YL
S345
(8W-12-27)
1 C3
JUNCTION
BLOCK
(8W-12-2)
7 C7
M2
20
YL
S304
M2 20YL (8W-12-27)
A C317
M2
18
YL
1
COURTESY DRIVER
LAMPS DOOR
DRIVER JAMB
SWITCH
J008W-7 (8W-39-6) XJD04904
XJ 8W-49 OVERHEAD CONSOLE 8W - 49 - 5
RHD
BATT A7 (8W-10-12)
JUNCTION AMBIENT
AMBIENT
86 BLOCK TEMPERATURE TEMPERATURE
HORN (8W-12-2) SENSOR SENSOR SENSOR
RELAY SIGNAL GROUND
(8W-41-3)
1 2
G31 G32
85 20 20
VT/LG BK/LB
S22 C4
X3 PASSENGER F14 F15
20 DOOR C100
BK/RD DOOR UNLOCK
POWER
LOCK RELAY LOCK/
CONTROL CONTROL WINDOW G31 G32
1 C2 2 C2 SWITCH 20 20
(8W-61-3) VT/LG BK/LB
P59 P55
20 20
LB/RD DB
3 12
C305
P59 P55 4 3 C301
20 20
LB/RD DB/PK
2 1 C203
P59 P55 G31 G32
20 20 20 20
LB/RD DB/PK VT/LG BK/LB
7 9 8 C301
X3 P59 P55
20 20 20
BK/RD LB/RD DB
10 11 5 4 10
HORN DOOR DOOR OVERHEAD AMBIENT SENSOR COMPASS
RELAY LOCK UNLOCK MODULE TEMPERATURE GROUND
CONTROL CONTROL RELAY SENSOR
COURTESY CONTROL SIGNAL COURTESY
LAMPS LAMPS
DRIVER DRIVER
1 7
M2 M2
20 20
YL YL
S345
(8W-12-27)
M2
20
YL
1 C3 A C318
JUNCTION
M2
BLOCK 18
(8W-12-2) YL
7 C7 1
M2 M2 COURTESY DRIVER
20 20 LAMPS DOOR
YL YL DRIVER JAMB
S304 SWITCH
(8W-39-7)
(8W-12-27)
XJD04905 J008W-7
8W - 49 - 6 8W-49 OVERHEAD CONSOLE XJ
DATA LINK
CONNECTOR
(8W-30-20)
(8W-30-21)
3 11
D1 D2
18 18
VT/BR TWISTED WT/BK
PAIR
S239 S238
(8W-30-20) (8W-30-20)
(8W-30-21) (8W-30-21)
D1 D2
20 20
VT/BR WT/BK
LHD RHD LHD RHD
55 C201 56 C201
D1 TWISTED D2
20 PAIR 20
VT/BR WT/BK
1 2 C301
D1 D2
20 20
VT/BR WT/BK
S344 S346
(8W-30-20) (8W-30-20)
D1 (8W-30-21) D2 (8W-30-21)
20 20
VT/BR WT/BK
5 11
CCD CCD COMPASS
BUS BUS
(+) (-)
D1 D2
20 TWISTED 20
VT/BR PAIR WT/BK
6 12
CCD CCD OVERHEAD
BUS BUS MODULE
(+) (-)
J008W-7 XJD04906
XJ 8W - 50 FRONT LIGHTING 8W - 50 - 1
BATT A0 (8W-10-7)
POWER
A18 13 DISTRIBUTION A3
FUSE FUSE CENTER 14
19 7 (8W-10-2) RD/WT
20A 30A 6
HEADLAMP A17 (8W-10-18) 6 (8W-10-14) FUSED DAYTIME
DELAY B(+) RUNNING
MODULE LAMP
F34 A3
GROUND (8W-50-5) 18 14 MODULE
4 TN/BK RD/WT (8W-50-11)
RHD LHD
Z1
18
E6 D1
BK A18 C100
FROM S218 A3 FROM
S201 14 S210
(8W-10-18)
(8W-12-27) RD/WT (8W-10-10)
2
FUSED HEADLAMP
F34 A3 B(+) DELAY
M2 18 14 MODULE G26
20 TN/BK RD/WT (8W-50-5) 20
YL LB
3 4 8 5
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
3 DOME
0 3 4 5 0 1 2 0 1 2 0 1 2 4 DIM
5 BRIGHT
1 9 2 7 6
E1 L7 L2 G16
20 18 L2 14 L20 20
TN BK/YL 14 LG 14 BK/LB
LG LG/WT
6
LHD RHD
HEAD HEADLAMP
LAMP DELAY TO
Z1 42 C201 SWITCH MODULE
18 S200
OUTPUT (8W-50-5)
BK (8W-10-10)
A B
S207
(8W-15-9) TO TO
HEADLAMP HEADLAMP
TO TO
Z1 BEAM BEAM
FUSE S206
14 SELECT SELECT
BK 6 (JB) (8W-12-10)
(8W-12-8)
SWITCH SWITCH
(8W-12-9) (8W-50-3) (8W-50-3)
G108 (8W-50-4) (8W-50-4)
(8W-15-9)
J008W-7 XJD05002
XJ 8W-50 FRONT LIGHTING 8W - 50 - 3
LHD
FROM INSTRUMENT DAYTIME
DIMMER
HEADLAMP FROM HIGH CLUSTER SWITCH RUNNING
DELAY HEADLAMP BEAM (8W-40-11) HIGH LAMP
MODULE SWITCH INDICATOR BEAM MODULE
DRIVER OUTPUT
(8W-50-2) (8W-50-2) (8W-50-11)
A B
5 C1 1
G34
16
2 4
RD/GY L3
HEADLAMP D4 C100 16
BEAM RD
SELECT G34
SWITCH 16
1 2 3 1 2 3 RD/GY
1 FLASH
2 LOW
3 HIGH OTHER DRL
1 3
D3 C100
L4 L3 L3
16 16 16
VT/WT RD/OR RD/OR
S213
22 16 C201
L4 L3
16 16
VT/WT RD/OR
S3 C4 S7 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
4 3 5 16
10A 10A 10A 10A
(8W-12-7) (8W-12-6) (8W-12-7) (8W-12-6)
10 C1 9 C1 1 C1 11 C1
L43 L33 L44 L34
20 20 20 20
VT RD VT/RD RD/OR
9 2
C106 S133
L43 L33 (8W-12-7)
L44
18 18 20
VT RD VT/RD
13 6
C106
L33 20RD L44 L44 L34
B A 12 C106 18 18 18
VT/RD VT/RD RD/OR
LEFT L33 B A
HEADLAMP 20
C RD/WT 10 RIGHT
FUSED DAYTIME HEADLAMP
RIGHT RUNNING C
E
S103 LOW LAMP S102
(8W-15-6) TO BEAM (8W-15-6)
Z1 OUTPUT
MODULE Z1
FOG (8W-50-11)
18 18
BK LAMP BK
RELAY
11 C106 4 C106
NO. 1
Z1 (IN PDC) Z1
20 20
BK/WT (EXCEPT DRL) BK
(8W-50-8)
G106
(8W-15-6)
XJD05003 J008W-7
8W - 50 - 4 8W-50 FRONT LIGHTING XJ
RHD
FROM
HEADLAMP FROM
DELAY HEADLAMP
MODULE SWITCH
(8W-50-2) (8W-50-2)
A B
2 4
HEADLAMP
BEAM INSTRUMENT
DIMMER
SELECT SWITCH CLUSTER
HIGH (8W-40-11)
1 3 1 3
SWITCH
2 2 1 FLASH BEAM
2 LOW OUTPUT
1 3 3 HIGH 5 C1
L4 L3 L3
16 16 16
VT/WT RD/OR RD/OR
S213
L3
16
RD/OR
S3 C4 S7 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE FUSE FUSE FUSE
4 3 5 16
10A 10A 10A 10A
(8W-12-7) (8W-12-6) (8W-12-7) (8W-12-6)
10 C1 9 C1 1 C1 11 C1
L43 L33 L44 L34
20 20 20 20
VT RD VT/RD RD/OR
9 2
C106 S133
L43 L33 13 (8W-12-7) 6
C106
18 18
L44 L44 L34
VT RD
20 18 18
VT/RD VT/RD RD/OR
L33 20RD B12 C100 B A
NOT
B A 12 C106 USED
RIGHT
LEFT HEADLAMP
HEADLAMP C
L33
C 20 Z1
RD/WT 18
BK
S103 E S102
(8W-15-6) (8W-15-6)
Z1 TO Z1
18 18
BK
FOG BK
LAMP
11 C106 4 C106
RELAY
Z1
NO. 1 Z1
20 (IN PDC) 20
BK/WT (EXCEPT DRL) BK
(8W-50-8)
G106
(8W-15-6)
J008W-7 XJD05004
XJ 8W-50 FRONT LIGHTING 8W - 50 - 5
S13 C4
F87
A3 A3 20
14 14 WT/BK
RD/WT RD/WT
LHD RHD
D1 C100 6
FUSED DAYTIME BASE FULL OPTIONS
B(+) RUNNING
A3 LAMP
F87
14 MODULE 20 S225
RD/WT (8W-50-11) WT/BK (8W-12-11)
5 C201
F87
8 20
HEADLAMP WT/BK
FUSED
B(+) SWITCH
(8W-50-2) A3 S216
14 (8W-12-11)
HEADLAMP RD/WT
SWITCH
OUTPUT 2 8
2 HEADLAMP
DELAY
L2 MODULE
14 FUSED FUSED
LG B(+) IGNITION
SWITCH
OUTPUT
(ST-RUN)
HEADLAMP
TIMER GROUND
HEADLAMP
6 4
SWITCH
(8W-50-2)
L2 Z1
14 18 GROUND
LG BK
2 Z1
18
HEAD- HEADLAMP BK
LAMP BEAM
SWITCH SELECT
OUTPUT
S207
SWITCH (8W-15-9)
(8W-50-3) Z1
(8W-50-4) 14
BK
G108
(8W-15-9)
XJD05005 J008W-7
8W - 50 - 6 8W-50 FRONT LIGHTING XJ
L7 S105
18
L61
BK/YL
20
M3 C4 LG
JUNCTION 2
BLOCK LEFT
(8W-12-2) SIDE
FUSE MARKER
7 1 LAMP
10A L77 L61
(8W-12-10) 20 18
BR LG
6 C2 S104
(8W-12-10)
L77 L61 L77
L77 18 18
20 BR LG
LEFT 18
BR FRONT BR LEFT
2 1
PARK/ 2 1 FRONT
7 C106 TURN PARK/
L77 SIGNAL TURN
L77 20 3 SIGNAL
20
LAMP 3
BR/YL Z1 Z1 LAMP
BR/YL NO. 1
18 18 NO. 2
BK BK
B6 S158
(8W-15-6)
FOG
LAMP S103
RELAY (8W-15-6)
Z1
NO. 1 18
B9 (IN PDC) BK
(8W-50-8)
(8W-50-10)
11 C106
Z1
20
BK/WT
RHD G106
LHD (8W-15-6)
J008W-7 XJD05006
XJ 8W-50 FRONT LIGHTING 8W - 50 - 7
S101
L78 L60 L78 L60
18 18 18 18
DG/YL TN DG/YL TN
2 1 RIGHT 2 1 RIGHT
FRONT FRONT
PARK/ PARK/
TURN TURN
3 3
SIGNAL SIGNAL
Z1 Z1
LAMP LAMP
18 18
BK NO. 1 BK NO. 2
S102
Z1 18BK (8W-15-6)
4 C106
Z1
20
BK
LHD
G106
RHD
XJD05007 (8W-15-6) J008W-7
8W - 50 - 8 8W-50 FRONT LIGHTING XJ
EXCEPT DRL
BATT F34 (8W-10-18) S206
(8W-12-10)
HEADLAMP L7
SWITCH 18
1 PARK BK/YL
2 HEAD LHD RHD
0 2 0 OFF
1 45 C201
(8W-50-2)
FROM
9
C106 L7
L7 18
18 (8W-50-3)
(8W-50-4) BK/YL
BK/YL
M3 C4
E JUNCTION
BLOCK
(8W-12-2)
FUSE
FROM 7
FOG L33 10A
20 (8W-12-10)
LAMP
RD/WT
RELAY
NO. 2 6 C2
(IN PDC) L77
(8W-50-9) 20
F BR/YL
POWER
B10 B6
FOG
DISTRIBUTION
LAMP CENTER
Z1 RELAY (8W-10-2)
20 NO. 1
BK L77
20
B8 B9 BR/YL
Z1 L139
20 20
(2.5L) BK VT
(4.0L (4.0L A/T (4.0L LHD M/T
ABS) EXCEPT ABS) EXCEPT ABS)
A5 C100
L139
20
Z1 CONTROLLER Z1 ENGINE VT
7 C106
20 ANTI-LOCK 20 STARTER
BK BRAKE BK MOTOR
GROUND RELAY GROUND RELAY
B19 (IN PDC) C10 (IN PDC)
(8W-35-3) (8W-21-5) G
Z1 Z1 Z1 L77
20 20 20 TO 20
BK BK BK FRONT BR/YL
FOG
LAMP
Z1 SWITCH
20 (8W-50-9)
BK
S132
(8W-15-3)
Z1 (8W-15-4)
16 (8W-15-5)
BK TO
S104
G106 (8W-12-10)
(8W-15-6)
J008W-7 XJD05008
XJ 8W-50 FRONT LIGHTING 8W - 50 - 9
EXCEPT DRL
BATT F61 (8W-10-20)
FROM POWER
FOG LAMP DISTRIBUTION
RELAY NO. 1 CENTER
(IN PDC) B15 B11 (8W-10-2)
(8W-50-8) FOG
LAMP
G RELAY
NO. 2
B13 B12
1 3
FRONT
FOG A4 C100 8 C106
F
SWITCH ON LAMP
ILLUM. INDICATOR SWITCH TO L39
FOG LAMP 20
RELAY NO. 1 LB
(IN PDC)
4 2 (8W-50-8)
S106
Z1 L39 L39 L39
20 20 20 20
BK LB LB LB
2 2
LEFT RIGHT
FOG FOG
1 LAMP 1 LAMP
Z1 Z1
20 20
BK BK
S103 S102
S208 (8W-15-6) (8W-15-6)
(8W-15-8)
Z1 Z1 Z1
14 18 18
BK BK BK
11 4 C106
Z1 Z1
20 20
BK/WT BK
G107 G106
(8W-15-8) (8W-15-6)
XJD05009 J008W-7
8W - 50 - 10 8W-50 FRONT LIGHTING XJ
DRL
INSTRUMENT BATT F34
HIGH M3 C4 (8W-10-18)
CLUSTER
BEAM (8W-40-11) JUNCTION HEADLAMP
INDICATOR BLOCK
DRIVER SWITCH
(8W-12-2) 1 PARK
5 C1 FUSE L7 2 HEAD
DAYTIME 7 18
0 2 0 OFF
HIGH BK/YL 1
G34 RUNNING 10A (8W-50-2)
BEAM (8W-12-10)
16
INDICATOR
LAMP 45 C201
RD/GY MODULE 9
DRIVER L7 L7
4 (8W-50-11) 18 18
6 C2 BK/YL BK/YL
D4 C100
7 C106 L77
G34 G34 L77 L77 20 S206
16 16 20 20 BR (8W-12-10)
RD/GY RD/GY BR/YL BR/YL
TO
S104 BATT F61 (8W-10-20)
(8W-12-10)
POWER
DISTRIBUTION
B10 B6 CENTER
FOG B15 B11 (8W-10-2)
LAMP FOG
RELAY LAMP
NO. 1 RELAY
NO. 2
B8 B9
B13 B12
Z1 L139 L39
20 20 20
BK VT LB
Z1 20BK
A5 C100 L92 8 C106
20
L139 L39
PK
20 20
VT A4 C100 LB
1 3
FRONT S106
FOG
L39 L39
SWITCH ON LAMP 20 20
ILLUM. INDICATOR SWITCH LB LB
2 2
LEFT RIGHT
FOG FOG
4 2 LAMP LAMP
1 1
Z1 L39 Z1 Z1
20 20 20 20
BK LB BK BK
S103 S102
S132 S208 (8W-15-6) (8W-15-6)
(8W-15-3) (8W-15-8) Z1 Z1
Z1 (8W-15-4) Z1 18 18
16 14 BK BK
BK BK
11 4 C106
Z1 Z1
20 20
G106 G107 BK/WT BK
(8W-15-6) (8W-15-8)
G106
(8W-15-6)
J008W-7 XJD05010
XJ 8W-50 FRONT LIGHTING 8W - 50 - 11
DRL
BATT A0 (8W-10-7) ST-RUN A21 (8W-10-10)
POWER JUNCTION
DISTRIBUTION BLOCK
13 CENTER (8W-12-2)
FUSE (8W-10-2) FUSE
7 10 RIGHT
15A FUSED VEHICLE
RIGHT HEADLAMP
30A
(8W-10-14) (8W-12-12) VEHICLE SPEED
6 LOW (8W-50-3) SPEED
BEAM SENSOR
SENSOR
S12 C4 OUTPUT SIGNAL (8W-30-12)
B 3
F20
18 L44 G7
WT 18 18
VT/RD WT/OR
1 C201
13 C106 S108
F20 (8W-30-12)
18
WT
L44 G7
20 20
E9 C100 VT/RD WT/OR
16 C201 D4 C100
L3 G34
16 16
RD/OR RD/GY
S7 C4
JUNCTION 5 C1
BLOCK HIGH INSTRUMENT
(8W-12-2) BEAM CLUSTER
FUSE FUSE INDICATOR (8W-40-11)
3 16 DRIVER
10A 10A
(8W-12-6) (8W-12-6)
XJD05011 J008W-7
XJ 8W - 51 REAR LIGHTING 8W - 51 - 1
L7 F32
18 20
BK/YL PK/DB
S206 F8 C100
(8W-12-10)
F32
20
L7 PK/DB
18 6
BK/YL BRAKE
LHD RHD LAMP
SWITCH
(8W-33-3)
45 C201
5
L50
20
L7
WT/TN
18
BK/YL
S203
M3 C4 (8W-10-20)
JUNCTION L50
BLOCK 20
(8W-12-2) WT/TN
FUSE FUSE
7 23
10A 10A LHD RHD
(8W-12-10) (8W-12-22)
24 C200 24 C204
2 C7 6 C7
L77 L78
18 18
L50
BR/YL DG/YL
20
WT/TN
7 C321
L78
18
DG/YL
A B C
TO TO TO
S311 RIGHT S302
(8W-51-3) TAIL/ (8W-51-3)
(8W-51-4) (8W-51-4)
STOP
LAMP
(8W-51-3)
J008W-7 XJD05102
XJ 8W-51 REAR LIGHTING 8W - 51 - 3
FROM FROM
FUSE S203
(8W-51-2)
7 (JB)
(8W-51-2) C
A
L50
20
L77 WT/TN
18
BR/YL S302
(8W-10-20)
S311
(8W-12-10) FROM L50
L77 FUSE 20
TRAILER TOW OTHER WT/TN
18
BR/YL
23 (JB)
6 C323 (8W-51-2)
TRAILER TOW OTHERS 6 C321
S336 B
(8W-54-3)
7 C323
L78 L50
L77 L77 18 18
20 18 L50 DG/YL WT/TN
BR/YL BR/YL 20
WT/TN
S340 6 C322
(8W-12-10)
L50
L77 L77 L77 18
20 18 18 WT/TN
BR/YL BR/YL BR
2 3 LEFT 2 3 RIGHT
TAIL/ TAIL/
7 C322 STOP STOP
1 LAMP 1 LAMP
5 Z1 Z1
18 18
TRAILER BK BK
TOW
S341 S348
CONNECTOR (8W-15-10) (8W-15-12)
(8W-54-2)
(8W-15-11) Z1 (8W-15-13)
8 18
BK
Z1
18 2 C321
BK
Z1
18
2 C322 BK
TRAILER TOW OTHER
S310
Z1 Z1 (8W-15-12)
14 18 (8W-15-13)
BK BK Z1
14
S337 BK RHD LHD
(8W-15-10)
Z1 (8W-15-11) Z1 Z1
14 12 16
BK S309 BK BK
(8W-15-10)
2 C323 Z1 Z1
(8W-15-11)
14 12
BK BK
G302 G303
(8W-15-10) (8W-15-12)
(8W-15-11) (8W-15-13)
XJD05103 J008W-7
8W - 51 - 4 8W-51 REAR LIGHTING XJ
FROM
FUSE FROM
7 (JB) S203
(8W-51-2) (8W-51-2)
A C
L77 L50
18 20
BR/YL WT/TN
S311 S302
(8W-12-10) (8W-10-20)
L77 L50
18 20
BR/YL WT/TN
2 C327 5 C326
L77 L50
18 18
BR/YL WT/TN
4 C311
11 C310
L77
1 C333
18
BR/YL L50
18
1 C330 DG/WT
L78
18
BK/YL
2
CENTER
1 HIGH
LICENSE MOUNTED
LAMP STOP
2 LAMP
1
Z1
18
BK
2 C330 Z1
18
Z1 BK
18
BK
S334
(8W-15-14) 2 C333
Z1
18
BK
9 C310
6 C311
Z1 Z1
18 18
BK BK
G304
J008W-7 (8W-15-14) XJD05104
XJ 8W-51 REAR LIGHTING 8W - 51 - 5
TURN
SIGNAL/
LEFT RIGHT
TURN TURN
HAZARD
SIGNAL SIGNAL SWITCH
9 3 (8W-52-2)
L63 L62
20 20
DG/RD BR/RD
LHD RHD LHD RHD
L63
1 C321
20
DG/RD L62
18
1 C322 BR/RD
L63
18 2
DG/RD
RIGHT
2 TURN
LEFT
SIGNAL
TURN 1 LAMP
SIGNAL
1 LAMP Z1
Z1 18
18 BK
BK
S341 S348
(8W-15-10) (8W-15-12)
(8W-15-11) (8W-15-13)
TRAILER Z1 Z1
TOW 18 18
CONNECTOR BK BK
(8W-54-2)
8
2 C322 2 C321
TRAILER TOW OTHERS
Z1 Z1 Z1
14 18 18
BK BK Z1
BK
14
S337 BK
Z1
(8W-15-10) S310
(8W-15-11) (8W-15-12)
14
BK (8W-15-13)
2 C323 LHD RHD
Z1
14 Z1 Z1
BK 16 12
BK BK
S309
(8W-15-10)
Z1
(8W-15-11)
12
BK
G303
G302 (8W-15-12)
(8W-15-10) (8W-15-13)
XJD05105 (8W-15-11) J008W-7
8W - 51 - 6 8W-51 REAR LIGHTING XJ
S12 C4
F20
18
WT
LHD RHD
1 C201
F20
18
WT
A9
C100
E9
S159
(8W-12-12)
F20
18
WT
4.0L A/T 4.0L M/T 2.5L M/T 2.5L A/T
TO TO
S303 S303 RHD
(8W-51-7) (8W-51-7) LHD
J008W-7 XJD05106
XJ 8W-51 REAR LIGHTING 8W - 51 - 7
FROM FROM
C200 C204
(8W-51-6) (8W-51-6)
D E
LHD RHD
S303
L10 L10
18 18
BR/LG BR/LG
TRAILER
TOW OTHERS 5 C321
5 C323
S339
(8W-54-2)
L10
18
5 C322 BR/LG
L10
18
BR/LG
2 2
LEFT RIGHT
BACK-UP BACK-UP
1 LAMP LAMP
1
Z1 Z1
18 18
BK BK
S341
(8W-15-10) S348
(8W-15-11) (8W-15-12)
(8W-15-13)
Z1
18 Z1
TRAILER BK 18
TOW BK
CONNECTOR
(8W-54-2) TRAILER 2 C322
8 TOW OTHER
2 C321
Z1 Z1 Z1
14 18 18
BK BK BK
S337 Z1
(8W-15-10) 14 S310
Z1 (8W-15-12)
(8W-15-11) BK
14 (8W-15-13)
BK
2 C323 LHD RHD
Z1 14BK Z1 Z1
16 12
S309 BK BK
(8W-15-10)
Z1 (8W-15-11)
12
BK
G303
G302 (8W-15-12)
(8W-15-10) (8W-15-13)
XJD05107 (8W-15-11) J008W-7
XJ 8W - 52 TURN SIGNALS 8W - 52 - 1
S20 C4
L5 L9
20 20
BK BK/PK
LHD RHD
B11
3 C201 C100
F5
L9
20
L5
BK/PK
20
BK
1 2
FUSED FUSED COMBINATION
IGNITION B(+) FLASHER
SWITCH HAZARD
OUTPUT FLASHER
FLASHER (RUN) SELECT
OUTPUT SIGNAL GROUND
4 3 5
L6 Z1
20 L55 L12
20 20 20
RD/WT BK
RD/WT VT/TN
5 4 11 6
TURN S208
(8W-15-8)
SIGNAL/
HAZARD
SWITCH
(PART OF
MULTI-
FUNCTION
SWITCH)
L R L R L R L R
3 10 1 9
L62 L61 L60 L63
20 20 20 20
BR/RD LG/WT TN DG/RD
A B C D
TO TO TO TO Z1
14
C200 S209 S212 C200 BK
C204 (8W-52-3) (8W-52-4) C204
(8W-52-4) (8W-52-3)
G107
(8W-15-8)
LHD
RHD
J008W-7 XJD05202
XJ 8W-52 TURN SIGNALS 8W - 52 - 3
FROM FROM
TURN TURN
SIGNAL/ SIGNAL/
HAZARD HAZARD TRAILER
LHD RHD
SWITCH SWITCH TOW OTHER
(8W-52-2) (8W-52-2)
B D 1 C323
L63 L63
20 20
L61 L63
DG/RD DG/RD
S335
20 20 (8W-54-3)
LG/WT DG/RD
L61 Z1
20 18
LG BK
S341
S105 (8W-15-10)
(8W-50-6) (8W-15-11)
S104
(8W-12-10) Z1
L61 18
20 BK
LG
2 LEFT 2 C322
L77 L61 L77 L61
SIDE 18 18 18 18 TRAILER TOW OTHERS
MARKER BR LG BR LG
1 LAMP 2 1 LEFT 2 1 LEFT Z1
FRONT FRONT 18
L77 BK
20
PARK/ PARK/
BR TURN TURN S337
3 3
SIGNAL SIGNAL (8W-15-10) Z1
Z1 LAMP Z1 LAMP Z1 (8W-15-11) 14
18 NO. 1 18 NO. 2 14 BK
BK BK BK
S158 2 C323
(8W-15-6)
Z1
S103 14
(8W-15-6) BK
Z1
18
BK
S309
11 C106 (8W-15-10)
Z1 (8W-15-11)
Z1 12
20 BK
BK/WT
G302
G106 LHD
(8W-15-10)
(8W-15-6) RHD (8W-15-11)
XJD05203 J008W-7
8W - 52 - 4 8W-52 TURN SIGNALS XJ
FROM FROM
TURN TURN
SIGNAL/ SIGNAL/
HAZARD HAZARD
SWITCH SWITCH
(8W-52-2) (8W-52-2)
A C
L62 L60
20 20
BR/RD TN
LHD RHD S212
2 2 RIGHT
RIGHT
TURN SIDE
SIGNAL MARKER
1 LAMP 1 LAMP
Z1 L78
18 20
BK DG/YL
S348 S101
(8W-15-12) (8W-50-7)
Z1 (8W-15-13)
18 L78 L60 L78 L60
BK 18 18 18 18
DG/YL TN DG/YL TN
2 C321 2 1 RIGHT 2 1 RIGHT
Z1 FRONT FRONT
18 PARK/ PARK/
BK TURN TURN
3 3
SIGNAL SIGNAL
S310 Z1 LAMP Z1 LAMP
(8W-15-12) 18 18
(8W-15-13) NO. 1 NO. 2
BK BK
LHD RHD
S102
Z1 18BK (8W-15-6)
Z1 Z1
16 12 4 C106
BK BK
Z1
20
BK
LHD
G303
(8W-15-12)
RHD G106
(8W-15-13) (8W-15-6)
J008W-7 XJD05204
XJ 8W - 53 WIPERS 8W - 53 - 1
8W-53 WIPERS
Component Page Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . . . 8W-53-4 Headlamp Switch . . . . . . . . . . . . . . . . . . 8W-53-3, 4
Circuit Breaker 30 (JB) . . . . . . . . . . . . . . . 8W-53-2 Junction Block . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 4
Front Wiper Motor . . . . . . . . . . . . . . . . . . . 8W-53-2 Rear Washer Pump . . . . . . . . . . . . . . . 8W-53-2, 3, 4
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4 Rear Wiper Motor . . . . . . . . . . . . . . . . . . 8W-53-3, 4
Fuse 22 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4 Rear Wiper/Washer Switch . . . . . . . . . . . 8W-53-3, 4
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 4 Windshield Washer Pump . . . . . . . . . . 8W-53-2, 3, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4 Wipe/Wash Switch . . . . . . . . . . . . . . . . . . . 8W-53-2
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 Wiper Motor Relay . . . . . . . . . . . . . . . . . . . 8W-53-2
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4
8W - 53 - 2 8W-53 WIPERS XJ
M4 C4 8 C1
V6 V6
16 16
DB DB
LHD RHD
8 C201
5
WIPE/
WASH
SWITCH
3 3 3 0 OFF
0 0 0 1 DELAY
2 1 2 1 2 1 2 LOW
4 3 HIGH
INTERMITTENT WIPER 4 WASH
LOGIC 5 INTERMITTENT
WIPER
MOTOR
RELAY
5
MIN MAX
3 1 2 6 4
V10 V5 V4 V3
18 Z1 16 16 16
BR 16 DG/YL BR/VT BR/WT
E4 BK C5 C100
C3 C1
A16 C100 V5 V4 V3
A S207
16 16 16
(8W-15-9)
WINDSHIELD Z1 DG/YL BR/VT BR/WT
WASHER 14 2 6 5 1
M PUMP BK FRONT
REAR WIPER
G108 M
B WASHER (8W-15-9) PARK MOTOR
RUN
Z1 PUMP
18 GROUND (8W-53-3)
BK (8W-53-4) 4
2
S132 S141
(8W-15-3) (8W-15-4)
Z1 (8W-15-5) Z1
(8W-15-5)
Z1 16 16
16 BK BK
RHD
BK
LHD
G106
(8W-15-6)
J008W-7 XJD05302
XJ 8W-53 WIPERS 8W - 53 - 3
LHD
RUN A22 (8W-10-11) HEADLAMP S1 C4
PANEL SWITCH JUNCTION
JUNCTION LAMPS (8W-50-2) BLOCK
BLOCK DIMMER FUSE (8W-12-2)
(8W-12-2) SWITCH 6
FUSE SIGNAL 5A
22 1 (8W-12-8)
20A E1
(8W-12-20) E1 20
20 TN
S2 C4
TN
S11 C4 E2 20OR
V23
18 S315
BR/PK (8W-12-8)
43
39 C201 42 C201
V23 S215
18
(8W-12-8)
BR/PK
5 3
REAR
WIPER/
WASHER
SWITCH
1 2 0 1 0 0 OFF
2
1 WASH
2 WIPE
6 4 2 1
V23 V13 V20 Z1
18 18 18 20
BR/PK BR/LG BK/WT BK
29 27 C200 S205
V23 V13 28 C200 S208
18 18 V20 (8W-15-8)
BR/PK BR 18 Z1
BK/WT 14
4 3 5 C327 BK
E5 C100
V23 V13 V20 G107
18 18 18 (8W-15-8)
BR/PK BR/LG BK/WT V20
18
2 1 3 C313 BK/WT WINDSHIELD
7 C310 WASHER
8 1 1
4 3 2 PUMP
REAR (8W-53-2)
REAR WASHER GROUND
REAR WIPER MODULE WIPER M PUMP B
MOTOR Z1
1 PARK 18
2 RUN 2 BK
M 2.5L 4.0L
1 2
Z1 Z1
1 18 18
BK BK
S334
(8W-15-14) S132 S141
(8W-15-3)
9 C310 (8W-15-4)
6 C311 Z1 Z1
Z1 16
18 16
BK BK
BK
G106
(8W-15-6) G106
G304 (8W-15-6)
XJD05303 (8W-15-14) J008W-7
8W - 53 - 4 8W-53 WIPERS XJ
RHD
RUN A22 (8W-10-11) HEADLAMP S1 C4
PANEL SWITCH JUNCTION
JUNCTION LAMPS (8W-50-2) BLOCK
BLOCK DIMMER FUSE (8W-12-2)
(8W-12-2) SWITCH 6
FUSE SIGNAL 5A
22 1 (8W-12-9)
20A E1
(8W-12-21) E1 20
20 TN
S2 C4
TN
S11 C4 S215
(8W-12-9)
7 C1
V23
18 FUSED A/C- E2
BR/PK PANEL HEATER 20
LAMPS CONTROL OR
DIMMER (8W-42-5)
SWITCH
SIGNAL
6 3
REAR
WIPER/
WASHER
SWITCH
1 2 0 1 2 0 0 OFF
1 WASH
5 4 2 1 2 WIPE
V23 V13 V20 Z1
18 18 18 20
BR/PK BR/LG BK/WT BK
S208
6 7 5 C203 S205 (8W-15-8)
Z1
V23 V13 V20 14
18 18 18 BK
V20
BR/PK BR BK/WT
18
FULL G107
4 C327 BK/WT
BASE OPTIONS 3 5 (8W-15-8)
S324 V23 V13 V20 E5 C100
18 18 18
(8W-12-21)
BR/PK BR/LG BK/WT WINDSHIELD
2 1 3 C313 V20 WASHER
7 C310 18
8 1 PUMP
BK/WT (8W-53-2)
4 3 2 GROUND
REAR B
1
WIPER Z1
REAR WIPER MODULE REAR 18
MOTOR
1 PARK WASHER BK
2 RUN M PUMP
M 2
1 2
Z1
1 18
S334 BK
(8W-15-14)
S132
9 C310 (8W-15-5)
6 C311
Z1 Z1
18 16
BK BK
G304 G106
(8W-15-14) (8W-15-6)
J008W-7 XJD05304
XJ 8W - 54 TRAILER TOW 8W - 54 - 1
4
S206 HEADLAMP
LHD RHD
(8W-12-10) SWITCH
L7 1 PARK
18 2 HEAD
45 C201 BK/YL
0 1 2
0 OFF
(8W-50-2)
9
L7
18
BK/YL
M3 C4
JUNCTION
BLOCK
(8W-12-2)
FUSE
7
10A FROM
(8W-12-10) S303
(8W-51-7)
2 C7
L77
18 L10
BR/YL 18
BR/LG
S311 5 C323
(8W-12-10)
L77 L10
18 18
BR/YL BR/LG
7 C323
S339
L77
20
BR/YL L10 L10
18 18
S340 BR/LG BR/LG
(8W-12-10)
5 3 5 C322
7 8 TRAILER
B40 Z1 TOW L10
14 14 CONNECTOR 18
LB BK BR/LG
S337 2
TRAILER (8W-15-10) BACK-UP LEFT
(8W-15-11) LAMP BACK-UP
TOW
FEED LAMP
ELECTRIC 2 C323
(8W-51-7)
BRAKE Z1
PROVISION 14
BK
S309
(8W-15-10)
Z1
(8W-15-11)
12
BK
G302
(8W-15-10)
(8W-15-11)
J008W-7 XJD05402
XJ 8W-54 TRAILER TOW 8W - 54 - 3
BATT A7 (8W-10-12)
JUNCTION
BLOCK
(8W-12-2)
FUSE
20
15A
(8W-12-19)
8 C7
A6
20
RD/OR
3 C323
S338
TURN BRAKE TURN (8W-12-19)
SIGNAL/ BRAKE LAMP SIGNAL/
LEFT LAMP RIGHT
TURN HAZARD SWITCH
SWITCH TURN HAZARD
SIGNAL SWITCH OUTPUT (8W-33-3) SIGNAL SWITCH
9 (8W-52-2) 5 3 (8W-52-2)
L63 L50 L62
20 20 20
DG/RD WT/TN BR/RD
LHD RHD
S203
LHD RHD (8W-10-20) 25 C200 11 C204
26 C200 12 C204 LHD RHD
S312
24 C200 24 C204 (8W-70-2)
1 C323 L62
20
S335 BR/RD
S302 8 C323
L63 L63 A6 (8W-10-20)
20 20 20 L62 A6
DG/RD DG/RD RD/OR 20 20
L50
1 3 BK/RD RD/OR
20
TRAILER WT/TN 1 3
TOW TRAILER
LEFT 6 C323 TOW
TURN RIGHT
2 5 RELAY L50
TURN
L50 20 2 5 RELAY
20 WT/TN L50
WT/TN 20
WT/TN
1 C322 S336
L63
6 C322
L74 A6
18 20 20
L73 L50
DG/RD LG RD/OR
20 18
2 YL WT/TN
LEFT LEFT 3
TURN TURN BRAKE LEFT
SIGNAL SIGNAL LAMP TAIL/
LAMP SWITCH STOP
SIGNAL
(8W-52-3) LAMP
10 (8W-51-3) 2 4
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
28
25A
(8W-12-23)
8 C5
F81 12TN
13 C201
33 C200
F81
12
TN
1 C307
F81 14TN
9 C1
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3
5 C1 12 C1 3 C1 6 C1 8 C2 8 C1
Q16 Q26 Q1 Z1
14 14 14 14
BR/WT VT/WT YL BK
4
3 C306
S329
1 2 3 C303 (8W-15-10)
Q1 Z1
4 C1 3 C1 10 C1 14 12
PASSENGER YL BK
POWER 3
2 C307
LOCK/
Q11 Q21 WINDOW Q1 Z1
14 14 SWITCH 14 12
LB WT 1 UP YL BK
2 DOWN
3 LOCK S305 S309
4 UNLOCK (8W-15-10)
Q1 Q1 Z1
1 2 14 14 12
YL YL BK
3 C309 3 C304
9 C1 2 C1
Q12 Q22 Q1 Q1
14 14 14 14 G302
1 2 BR VT YL YL (8W-15-10)
DRIVER 1 2 6 6
POWER PASSENGER POWER LEFT POWER RIGHT
WINDOW POWER WINDOW REAR WINDOW REAR
MOTOR WINDOW SWITCH WINDOW SWITCH WINDOW
M FEED FEED
MOTOR SWITCH SWITCH
M (8W-60-4) (8W-60-4)
J008W-7 XJD06002
XJ 8W-60 POWER WINDOWS 8W - 60 - 3
RHD
RUN-ACC A31 (8W-10-9)
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
28
25A
(8W-12-24)
1 C8
F81
14
TN
9 C1
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3
3 C1 6 C1 5 C1 12 C1 8 C2 8 C1
Q1 Z1
Q11 Q21 Q16 Q26 14
14 14 14 14 14
YL BK
BR VT BR/WT VT/WT
7 8
C303 S319
(8W-15-13)
Q16 Q26
2 C307 4 5
C303
14 14
BR/WT VT/WT Q1 Q1 Q1
14 14 14
C306 YL YL YL
3 4
4 C1 3 C1 10 C1 S305
PASSENGER Z1
POWER 14
BK
LOCK/ Q1
Q1
WINDOW 14 14
S310
SWITCH YL YL
(8W-15-13)
1 UP Z1
2 DOWN 3 C309 3 C304 12
3 LOCK BK
4 UNLOCK Q1
1 2
14 G303
YL (8W-15-13)
6
9 C1 2 C1 POWER RIGHT
Q12 Q22 Q1 WINDOW REAR
14 14 14 SWITCH WINDOW
BR VT YL FEED
1 2 SWITCH
DRIVER 1 2 6 (8W-60-5)
POWER PASSENGER POWER LEFT
WINDOW POWER WINDOW REAR
MOTOR WINDOW SWITCH WINDOW
M FEED
MOTOR SWITCH
M (8W-60-5)
XJD06003 J008W-7
8W - 60 - 4 8W-60 POWER WINDOWS XJ
LHD
RUN-ACC F81 (8W-12-23)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3
4 C1 10 C1 2 C1 1 C1 8 C2 8 C1
Q1 Z1
14 14
YL BK
S309
Q17 Q27 Q18 Q28 Q1 (8W-15-10)
14 14 14 14 14 Z1
DB/WT RD/BK GY/BK DG/WT YL 12
BK
S305 G302
(8W-60-2) (8W-15-10)
Q1 Q1
14 14
YL YL
2 3 2 3
1 C309 1 C304
4 2 6 4 2 6
LEFT RIGHT
REAR REAR
WINDOW WINDOW
SWITCH SWITCH
1 UP 1 UP
2 DOWN 2 DOWN
1 2 1 2
1 5 1 5
Q13 Q23 Q14 Q24
14 14 14 14
DB RD/WT GY DG
1 2 1 2
LEFT RIGHT
REAR REAR
WINDOW WINDOW
MOTOR MOTOR
M M
J008W-7 XJD06004
XJ 8W-60 POWER WINDOWS 8W - 60 - 5
RHD
RUN-ACC F81 (8W-12-24)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 UP
1 2 1 2 1 2 1 2 2 DOWN
3 LOCK
4 4 UNLOCK
3
4 C1 10 C1 2 C1 1 C1 8 C2 8 C1
Q1 Z1
14 14
YL BK
S319
(8W-15-13)
Q17 Q27 Q18 Q28
14 14 14 14 Z1
DB/WT RD/BK GY/BK DG/WT 14
BK
6 1 2 4 5
3 C303
Q17 Q27 Q18 Q28 Q1
14 14 14 14 14
DB/WT RD/BK GY/BK DG/WT YL
S305
(8W-60-3)
Q1 Q1 Z1
14 14 14
YL YL BK
2 3 2 3
1 C309 1 C304
4 2 6 4 2 6
LEFT RIGHT
REAR REAR
WINDOW WINDOW
SWITCH SWITCH
1 UP 1 UP S310
2 DOWN 2 DOWN (8W-15-13)
1 2 1 2
1 5 1 5
Q13 Q23 Q14 Q24 Z1
14 14 14 14 12
DB RD/WT GY DG BK
1 2 1 2
LEFT RIGHT
REAR REAR
WINDOW WINDOW
MOTOR MOTOR G303
M M (8W-15-13)
XJD06005 J008W-7
XJ 8W - 61 POWER DOOR LOCKS 8W - 61 - 1
JUNCTION OVERHEAD
BLOCK DOOR MODULE
(8W-12-2) UNLOCK DOOR (8W-49-5)
FUSE CIRCUIT
RELAY LOCK
15 BREAKER
CONTROL CONTROL
25A 28
(8W-12-18) 25A 5 11
(8W-12-24) P55 P59
20 20
DB LB/RD
9
7 C5 8 C5 8 C301
F35 F81 P55 P59
16 12 20 20
RD TN DB/PK LB/RD
16 C204 3 C202 1 2
C203
F35 F81 P55 P59
16 12 20 20
RD TN DB/PK LB/RD
S317 S316
(8W-12-28) (8W-12-28)
P33 P33 P34 P34
16 16 16 16
OR/BK OR/BK PK/BK PK/BK
2 1
PASSENGER
DOOR
LOCK
MOTOR
M
1 C9 12 C9
JUNCTION
BLOCK
(8W-12-2)
1 C7 5 C7
P33 P34
16 16
OR/BK PK/BK
S307
(8W-12-28)
S306
(8W-12-28)
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK
2 1 C326
5 4 C305 5 4 C309 5 4 C304
2 1 C311
5 4 C310
P34 P33 P34 P33 P34 P33 P34 P33
16 16 16 16 16 16 16 16
PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK
1 2 1 2 1 2 B A
DRIVER LEFT RIGHT LIFTGATE
DOOR REAR REAR LOCK
LOCK DOOR DOOR MOTOR
MOTOR LOCK LOCK
M M M M
MOTOR MOTOR
J008W-7 XJD06104
XJ 8W-61 POWER DOOR LOCKS 8W - 61 - 5
RHD
PASSENGER
POWER
DOOR DOOR
LOCK UNLOCK LOCK/
DRIVER DRIVER WINDOW
5 C1 1 C1 SWITCH
P33 P34
16 16
OR/BK PK/BK
S323 S322
(8W-12-29) (8W-12-29)
P33 P33 P34 P34
16 16 16 16
OR/BK OR/BK PK/BK PK/BK
2 1
PASSENGER
DOOR
LOCK
MOTOR
M
5
4 C305
P33 P34
16 16
OR/BK PK/BK
S306
(8W-12-29)
S307
(8W-12-29)
P34 P33
16 16
PK/BK OR/BK
5 C7 1 C7
JUNCTION
P34 P33 BLOCK
16 16 (8W-12-2)
PK/BK OR/BK
2 1 C326 12 C9 1 C9
XJD06105 J008W-7
XJ 8W - 62 POWER MIRRORS 8W - 62 - 1
S4 C4
F83
18
YL/DG
44 C201
F83
18
YL/DG
39 C200
F83
18
YL/DG
3 C305
F83
18
YL/DG
3 C2
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 4 1 4 1 4 0 REST
2 0 3 2 0 3 2 0 3 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 6 5 6 5 DRIVER MIRROR
6 PASSENGER MIRROR
5 C2 2 C2 6 C2 1 C2
Z1
14 P76 P75 P71
BK 20 20 20
OR/YL DB/WT YL
S329
(8W-15-10)
Z1
12
3 5 1
BK
DRIVER
3 C307 POWER
Z1 M M
12 MIRROR
BK
S309 2 6 4
(8W-15-10)
Z1 P76 P76
12 20 20
BK OR/YL OR/YL
G302 S328
J008W-7 (8W-15-10) (8W-12-31) XJD06202
XJ 8W-62 POWER MIRRORS 8W - 62 - 3
LHD FULL OPTIONS
RUN-ACC F83 (8W-12-17)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
0 REST
1 4 1 4 1 4 1 LEFT
2 0 3 2 0 3 2 3 2 RIGHT
0 3 UP
4 DOWN
5 DRIVER MIRROR
5 6 5 6 6 PASSENGER MIRROR
5 C2 2 C2 4 C2 7 C2
Z1 P76 P74 P72
14 20 20 20
BK OR/YL DB YL/BK
S329 S328
(8W-15-10) (8W-12-31)
10 9 8
C305
3 C307 36 35 34
C200
Z1 P76 P74 P72
12 20 20 20
BK OR/YL DB YL/BK
S309 28 24 20 C201
(8W-15-10)
P76 P74 P72
Z1 20 20 20
12 OR/YL DB YL/BK
BK
2 C5 9 C5 10 C5
G302 JUNCTION
(8W-15-10) BLOCK
(8W-12-2)
10 C9 2 C9 6 C9
P76 P76 P74 P72
20 20 20 20
OR/YL OR/YL DB YL/BK
2 4 3 5 1
MIRROR MIRROR DRIVER PASSENGER
COMMON COMMON POWER POWER
DRIVER DRIVER M M
MIRROR MIRROR
(8W-62-2)
2 6 4
P76 P76 P76
20 20 20
OR/YL OR/YL OR/YL
S318
(8W-12-31)
XJD06203 J008W-7
8W - 62 - 4 8W-62 POWER MIRRORS XJ
RHD FULL OPTIONS
RUN-ACC A31 (8W-10-9)
JUNCTION
BLOCK
(8W-12-2)
FUSE
18
10A
(8W-12-18)
S4 C4
F83
18
YL/DG
3 C300
F83
18
YL/DG
S352
(8W-12-18)
F83
18
YL/DG
3 C2
DRIVER
POWER
LOCK/
WINDOW
SWITCH
1 4 1 4 1 4 0 REST
2 0 3 2 0 3 2 0 3 1 LEFT
2 RIGHT
3 UP
4 DOWN
5 6 5 6 5 DRIVER MIRROR
6 PASSENGER MIRROR
5 C2 2 C2 4 C2 7 C2
Z1
16 P76 P74 P72
BK 20 20 20
OR/YL DB YL/BK
S319
(8W-15-13)
Z1
14
BK
5 C303 3 5 1
DRIVER
Z1
14
POWER
M M MIRROR
BK
S310
2 6 4
(8W-15-13)
Z1 P76 P76
12 20 20
BK OR/YL OR/YL
G303 S318
(8W-15-13) (8W-12-33)
J008W-7 XJD06204
XJ 8W-62 POWER MIRRORS 8W - 62 - 5
RHD FULL OPTIONS
RUN-ACC F83 (8W-12-18)
DRIVER
POWER
LOCK/
WINDOW
SWITCH
0 REST
1 4 1 4 1 4 1 LEFT
2 0 3 2 0 3 2 3 2 RIGHT
0 3 UP
4 DOWN
5 DRIVER MIRROR
5 6 5 6 6 PASSENGER MIRROR
5 C2 2 C2 6 C2 1 C2
Z1 P76 P75 P71
16 20 20 20
BK OR/YL DB/WT YL/LB
S319
(8W-15-13) S318
(8W-12-33)
P76
20
Z1 OR/YL
14
BK
10 C9 2 C9 6 C9
JUNCTION
BLOCK
5 C303 (8W-12-2)
Z1
14 2 C5 9 C5 10 C5
BK
P76 P74 P72
20 20 20
S310 OR/YL DB YL/BK
(8W-15-13)
9 8
Z1 10 C204
12
BK P76 P74 P72
20 20 20
G303 OR/YL DB YL/BK
(8W-15-13)
10 9 8 C305
P76 P76 3 5 1
20 20 PASSENGER
OR/YL OR/YL POWER
2 4 M M MIRROR
MIRROR MIRROR DRIVER
COMMON COMMON POWER 2 6 4
DRIVER DRIVER MIRROR
(8W-62-4) P76 P76
20 20
OR/YL OR/YL
S328
(8W-12-33)
XJD06205 J008W-7
8W - 62 - 6 8W-62 POWER MIRRORS XJ
LHD EXCEPT FULL OPTIONS
2 3
1 3 4 7 8 5 6
S329 2 5 1
(8W-15-10) DRIVER
POWER
M M MIRROR
Z1
16 2 C9 6 C9
BK 3 6 4
JUNCTION
BLOCK
(8W-12-2) P91 P76
20 20
WT/BK OR/YL
9 C5 10 C5
P74 P72 10 C9 7 C9
3 C307 JUNCTION
20 20
DB YL/BK BLOCK
Z1 (8W-12-2)
12 24 20 C201
BK
C200 2 C5 3 C5
35 34
P76 P91
P74 P72 20 20
20 20 OR/YL WT/BK
DB YL/BK
S309
(8W-15-10) 28 67 C201
9 8 C305
Z1 36 12 C200
P74 P72
12 20 20 P76 P91
BK DB YL/BK 20 20
2 5 1 OR/YL WT/BK
PASSENGER
POWER 10 13 C305
M M MIRROR
P76 P91
20 20
OR/YL WT/BK
3 6 4
G302
(8W-15-10)
J008W-7 XJD06206
XJ 8W-62 POWER MIRRORS 8W - 62 - 7
RHD EXCEPT FULL OPTIONS
RUN-ACC F83 (8W-12-18)
POWER
4 MIRROR
1
SWITCH
1 RIGHT
2 UP
3 LEFT
4 DOWN
2 3
1 7 8 4 3 5 6
1 5 2
S319 DRIVER
(8W-15-13) P76 P91
POWER 20 20
M M MIRROR OR/YL WT/BK
Z1
16
BK
4 6 3
11 C9 2 C9 6 C9
JUNCTION P76 P91
20 20
BLOCK OR/YL WT/BK
(8W-12-2)
S5 C4 9 C5 10 C5
Z1 P74 P72
14 20 20
BK DB YL/BK
10 C9 7 C9
9 8
C204 JUNCTION
BLOCK
P74 P72 (8W-12-2)
20 20 2 C5
DB YL/BK
3 C5 3 C7
P76 P91
20 20
OR/YL WT/BK
9 8 C305
S208 10 C204
(8W-15-8)
P76
10 C203
20 P91 P91
P75 P71 OR/YL 20 20
20 20 WT/BK WT/BK
DB/WT YL
POWER
2 5 1 BASE MIRRORS
Z1 PASSENGER
14 POWER S359
BK M M (8W-12-32)
MIRROR
10 13 C305
3 6 4 P76 P91
20 20
G107 OR/YL WT/BK
(8W-15-8)
XJD06207 J008W-7
XJ 8W - 63 POWER SEAT 8W - 63 - 1
BATT A7 (8W-10-12)
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
29
25A
(8W-12-25)
2 C6
F37
14
RD/LB
2 C316
S356
(8W-12-25)
F37
14
RD/LB
1 C362
F37
14
RD
A
LEFT
POWER
SEAT
SWITCH
1 FRONT DOWN
2 FRONT UP
3 REAR DOWN
4 REAR UP
5 FORWARD
6 REARWARD
1 2 3 4 5 6
N M E J L K B
Z1
14
BK
P21 P19 P13 P11 P15 P17
14 14 14 14 14 14 2 C362
RD/LG YL/LG RD/WT YL/WT YL/LB RD/LB
Z1
14
BK
G306
(8W-15-15)
LEFT
FRONT REAR FORWARD/ POWER
M MOTOR M MOTOR M REARWARD SEAT
MOTOR MOTORS
J008W-7 XJD06302
XJ 8W-63 POWER SEAT 8W - 63 - 3
BATT A7 (8W-10-12)
JUNCTION
BLOCK
(8W-12-2)
CIRCUIT
BREAKER
29
25A
(8W-12-25)
2 C6
F37
14
RD/LB
2 C316
S356
(8W-12-25)
F37
F37 14
14 RD/LB
RD/LB
1 C362
F37
1 C363 14
RD
A
F37 FUSED LEFT
14 B(+) POWER
RD
SEAT
SWITCH
(8W-63-2)
B
RIGHT
POWER
SEAT
SWITCH
1 2 3 4 5 6 1 FRONT UP
2 FRONT DOWN
3 REAR UP
4 REAR DOWN
N M J E K L A 5 FORWARD
6 REARWARD
Z1
14
P20 P18 P12 P10 P14 P16 BK
14 14 14 14 14 14
RD/LG YL/LG RD/WT YL/WT YL/LB RD/LB
2 C363
Z1
14
BK
G306
(8W-15-15)
RIGHT
FRONT REAR FORWARD/ POWER
M MOTOR M MOTOR M REARWARD SEAT
MOTOR MOTORS
XJD06303 J008W-7
8W - 63 - 4 8W-63 POWER SEAT XJ
HEATED SEATS
RUN-ACC A31 (8W-10-9)
JUNCTION
BLOCK
(8W-12-2)
FUSE
18
10A
(8W-12-17)
(8W-12-18)
S4 C4
RHD LHD
F83 F83
18 18
YL/DG YL/DG
1 C316 11 C329
F83 F83
18 18
YL/DG YL/DG
S353
4 4
LEFT RIGHT
HEATED HEATED
2 1 SEAT 1 2 SEAT
SWITCH SWITCH
1 HIGH 1 HIGH
2 LOW 2 LOW
3 1 5 6 6 5 1 3
Z1 P137 P139 P133 P134 P140 P138 Z1
18 18 18 18 18 18 18 18
BK VT VT/WT TN/DG TN/RD VT/BK VT/LG BK
3 5 1 2 6 4
S355 C329 S355
(8W-15-15) P137 P139 P133 P134 P140 P138 (8W-15-15)
Z1 18 18 18 18 18 18
18 VT VT/WT TN/DG TN/RD VT/BK VT/LG
BK
G306
12 14 1 9 11 10 (8W-15-15)
LEFT LEFT LEFT RIGHT RIGHT RIGHT SEAT
G306 SEAT SEAT SEAT SEAT SEAT SEAT HEAT
(8W-15-15) LOW HIGH HEATER HEATER HIGH LOW INTERFACE
HEAT HEAT SWITCH SWITCH HEAT HEAT
LED LED MUX MUX LED LED
MODULE
DRIVER DRIVER DRIVER DRIVER
J008W-7 XJD06304
XJ 8W-63 POWER SEAT 8W - 63 - 5
HEATED SEATS
SEAT
HEAT
LEFT LEFT RIGHT RIGHT INTERFACE
HEATED HEAT HEAT HEATED MODULE
SEAT SENSE SENSOR SENSE SEAT
DRIVER INPUT FEED INPUT DRIVER GROUND
5 8 2 7 3 13
7 9 C329 13 C329
P87 P143 P141
18 18 18 Z2
BK/OR BK/DG TN/LB 18
BK/LG
3 2
C332
P87 P143
18 18 G306
BK/OR BK/DG (8W-15-15)
A D D A
LEFT RIGHT
HEATED HEATED
SEAT SEAT
CUSHION CUSHION
B C C B
1 C332
A P141 A
18
LEFT TN/LB
RIGHT
HEATED HEATED
SEAT SEAT
8 C329
BACK BACK
B P141 B
18
Z1 TN/LB Z1
18 18
BK BK
S357
4 C332 S354
(8W-15-15)
12 C329
Z1 Z1
18 18
BK BK
S355
(8W-15-15)
Z1
18
BK
G306
(8W-15-15)
XJD06305 J008W-7
8W - 63 - 6 8W-63 POWER SEAT XJ
HEATED SEATS
RUN-ACC A31 (8W-10-9) BATT A7 (8W-10-12)
JUNCTION
BLOCK
(8W-12-2)
FUSE CIRCUIT
18 BREAKER
10A 29
(8W-12-17) 25A
(8W-12-18) (8W-12-25)
S4 C4 2 C6
RHD LHD
1 2 C316
F83 F37
18 14
YL/DG RD/LB
S353 S356
(8W-63-4) (8W-12-25)
F83 F37 F37 F37
18 14 14 14
YL/DG RD/LB RD/LB RD/LB
10
11 C329 1 C363
F83 F37
1 C362
F37
18 14 F37 14
YL/DG RD/LB 14 RD
4 8 RD
HEATED B
SEAT A FUSED RIGHT
S354 FUSED LEFT B(+) POWER
RELAY
(8W-15-15) B(+) POWER SEAT
Z1 SEAT GROUND SWITCH
18 6 2 GROUND SWITCH (8W-63-3)
BK A
Z1 F235 F235 B (8W-63-2)
18 16 16
BK RD RD
2 C362 2 C363
12 C329 4 6 Z1 Z1
S355 HEATED HEATED SEAT 14 14
(8W-15-15) SEAT SEAT HEAT BK BK
RELAY RELAY INTERFACE
G306 OUTPUT OUTPUT G306
(8W-15-15) MODULE (8W-15-15)
J008W-7 XJD06306
XJ 8W - 70 SPLICE INFORMATION 8W - 70 - 1
K7 K7 K7 K7 K7
18 18 20 20 20
OR OR OR OR OR
S115
LHD RHD
K167 K167 K167 K167 K167
25 C200 11 C204 20 20 20 20 18
BR/YL BR/YL BR/YL BR/YL BR/YL
L62 L62
20 20
BR/RD BR/RD S123
(4.0L
CALIFORNIA)
S312
L62 L62
20 20
BR/RD BR/RD K167
20
1 C321 8 C323 BR/YL
L62 L62
18 20
A
BR/RD BK/RD
TO
2 1 S111
RIGHT TRAILER (8W-70-3)
TURN TOW
SIGNAL RIGHT
LAMP TURN
(8W-52-4) RELAY
(8W-54-3)
J008W-7 XJD07002
XJ 8W-70 SPLICE INFORMATION 8W - 70 - 3
FUEL CLOCKSPRING
PUMP (8W-33-2)
MODULE
(8W-30-3)
(8W-30-4)
4
K167
3 C1 BATTERY
20 TEMPERATURE
BR/YL K4 SENSOR
LHD RHD 20 (4.0L)
BK/RD (8W-30-13)
2
30 C200 7 C204
TRANSMISSION
CONTROL K167
MODULE B6
20
K167 (4.0L) F18 C100 BR/YL
20 (8W-31-5)
BR/YL 16
K167
B3 K167 20
C100 BR/YL
F12 20
BR/YL
S138
INTAKE MANIFOLD ENGINE
AIR ABSOLUTE COOLANT
TEMPERATURE PRESSURE TEMPERATURE
SENSOR SENSOR SENSOR
1 (8W-30-7) 1 (8W-30-12) 1 (8W-30-7)
S114
POWERTRAIN OXYGEN
CONTROL SENSOR
MODULE 1/2 ENGINE
(EXCEPT 4.0L DOWNSTREAM OIL
PRESSURE
4 C1 CALIFORNIA) (EXCEPT 4.0L K167
(8W-30-8) CALIFORNIA) SENSOR 20
(8W-30-10) 3 (8W-30-12) BR/YL
(8W-30-8) 3
(8W-30-12) (8W-30-10)
K167
18 FROM
BR/YL S123 3 C107
CAMSHAFT VEHICLE (8W-70-2) K167
POSITION SPEED 20
A K167
SENSOR SENSOR BR/YL
20
(8W-30-5) (8W-30-12) BR/YL
K167 RHD
2 2 20 LHD
K167
18 K167 K167 K167 BR/YL
BR/YL 20 20 20
BR/YL BR/YL BR/YL
S111
XJD07003 J008W-7
XJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1
1 2
CAV CIRCUIT FUNCTION
1 C22 18DB/WT A/C SWITCH SENSE
A/C HIGH
2 C21 20DB/PK A/C SWITCH SENSE
PRESSURE
SWITCH
(2.5L)
BLACK
BLACK
BACK-UP LAMP
SWITCH
BLACK
BLACK
CAV CIRCUIT FUNCTION
5 - -
10 5 6 - -
7 D1 20DB/WT GROUND
BLEND
8 D3 20YL BLEND DOOR FEEDBACK SIGNAL
DOOR
9 - -
ACTUATOR
10 D2 20OR FUSED IGNITION SWITCH OUTPUT (RUN)
J008W-7 XJD08006
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7
BLACK
CAV CIRCUIT FUNCTION
4
3 1 C1 12DG BLOWER MOTOR RELAY OUTPUT
2 5 2 Z1 20BK GROUND
3 - -
1
4 A111 12RD/LG FUSED B(+)
BLOWER
5 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
MOTOR
RELAY
BLACK
BLACK
1 2
LHD
RHD
XJD08007 J008W-7
8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS XJ
4.0L A/T
POWER AMPLIFIER
FOG LAMPS
DRL
EXCEPT DRL
J008W-7 XJD08008
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9
(CONTINUED)
2.5L ABS
SENTRY KEY IMMOBILIZER MODULE 4.0L A/T
4.0L A/T EXCEPT 4.0L A/T
EXCEPT 4.0L A/T SPEED CONTROL
EXCEPT 2.5L
XJD08009 J008W-7
8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS XJ
(CONTINUED)
ABS
SENTRY KEY IMMOBILIZER MODULE
XJD08011 J008W-7
8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS XJ
FOG LAMPS
DRL
A/T
M/T
J008W-7 XJD08012
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13
4.0L A/T
4WD
A/T
M/T
4WD A/T
DRL
2WD CALIFORNIA
4WD CALIFORNIA
EXTENDED IDLE
XJD08013 J008W-7
8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS XJ
BLACK BLACK
4 1
4 1 CAV CIRCUIT CAV CIRCUIT
1 T40 16BR 1 T40 16BR
2 K72 18DG/OR 2 K72 16DG/OR
3 K20 18DG 3 K20 16DG
4 C3 16DB/BK C108 4 C3 16DB/BK
C108
C113 C113
(M/T) (M/T)
XJD08015 J008W-7
8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS XJ
(CONTINUED)
J008W-7 XJD08016
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17
XJD08017 J008W-7
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS XJ
J008W-7 XJD08018
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19
YELLOW
YELLOW CAV CIRCUIT CAV CIRCUIT
1 R42 18BK/YL 1 R42 18BK/YL
2 R44 18DG/YL 2 R44 18DG/YL
1 4
3 R43 18BK/LB 3 R43 18BK/LB
4 1 4 R45 18DG/LB 4 R45 18DG/LB
C205 C205
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
1 E2 20OR E2 20OR
1 2 1 1
2 1 E2 20OR/BK E2 20OR
Z1 20BK
2 Z1 20BK 2
C206 Z1 20BK
C206
(A/T)
(A/T)
FULL OPTIONS
RHD
LHD
XJD08019 FULL OPTIONS W/POWER AMP J008W-7
8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS XJ
BLACK BLACK
1 2 1
2 CAV CIRCUIT CAV CIRCUIT
1 E2 20OR 1 E2 20OR
1 E2 20OR/BK 2 Z1 20BK
C206 2 Z1 20BK C206
(M/T) (M/T)
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M1 20PK B A A M1 18PK
A B
B M2 20YL B M2 18BK/WT
C207 C207
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M1 20PK B A A M1 18PK
A B
B M2 20YL B M2 18BK/WT
C208 C208
NATURAL
NATURAL
CAV CIRCUIT CAV CIRCUIT
1 P35 20OR/VT 1 P35 20OR/VT
1 3 2 P36 20PK/VT 3 1 2 P36 20PK/VT
3 P55 20DB/PK 3 P55 20DB/PK
4 6 6 4
4 P59 20LB/RD 4 P59 20LB/RD
5 G26 20LB 5 G26 20LB
C300 6 - C300 6 -
(LHD) (LHD)
RHD
LHD
J008W-7 XJD08020
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21
WHITE
WHITE
CAV CIRCUIT CAV CIRCUIT
1 P35 18OR/VT 1 P35 20OR/VT
1 3 2 P36 18PK/VT 3 1 2 P36 20PK/VT
3 F83 18YL/DG 3 F83 18YL/DG
4 6 - 6 4
4 4 -
5 - 5 -
C300 6 - C300 6 -
(RHD) (RHD)
FULL OPTIONS
OVERHEAD CONSOLE
FULL OPTIONS AND POWER MIRRORS 4 SPEAKER SYSTEM
XJD08021 BASE 6 SPEAKER SYSTEM J008W-7
8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS XJ
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
3 1 1 Q18 14GY/BK 1 Q18 14GY/BK
2 Q28 14DG/WT 1 3 2 Q28 14DG/WT
3 Q1 14YL 3 Q1 14YL
4 6
6 4 4 P33 16OR/BK 4 P33 16OR/BK
5 P34 16PK/BK 5 P34 16PK/BK
C304 6 - C304 6 -
(LHD) (LHD)
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
3 1 1 Q18 14GY/BK 1 Q18 14GY/BK
2 Q28 14DG/WT 1 3 2 Q28 14DG/WT
3 Q1 14YL 3 Q1 14YL
4 6
6 4 4 P33 16OR/BK 4 P33 16OR/BK
5 P34 16PK/BK 5 P34 16PK/BK
C304 6 - C304 6 -
(RHD) (RHD)
WHITE
CAV CIRCUIT WHITE CAV CIRCUIT
1 1 Q18 14GY/BK 1 Q18 14GY/BK
2
2 Q28 14DG/WT 2 Q28 14DG/WT
3 Q16 14BR/WT 2 1 3 Q16 14BR/WT
3 6 4 Q26 14VT/WT 6 3 4 Q26 14VT/WT
5 Q17 14DB/WT 5 Q17 14DB/WT
C306 6 Q27 14RD/BK C306 6 Q27 14RD/BK
(LHD) (LHD)
(POWER WINDOWS) (FULL OPTIONS)
WHITE
CAV CIRCUIT WHITE CAV CIRCUIT
1 2 1 F35 16RD 1 F35 16RD
2 G26 20LB 2 G26 20LB
3 Q16 14BR/WT 2 1 3 Q16 14BR/WT
3 6 4 Q26 14VT/WT 6 3 4 Q26 14VT/WT
5 - 5 -
C306 6 - C306 6 -
(RHD) (RHD)
(POWER WINDOWS) (FULL OPTIONS)
POWER MIRRORS
FULL OPTIONS
POWER MIRRORS W/O FULL OPTIONS
POWER LOCK/WINDOW SWITCHES
4 SPEAKERS
6 SPEAKERS
XJD08023 J008W-7
8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS XJ
WHITE WHITE
CAV CIRCUIT CAV CIRCUIT
1 F81 14TN 1 F81 12TN
2 Q1 14YL 1 3 2 Q1 14YL
3 1
3 Z1 12BK
3 Z1 12BK
3 Z1 16BK
C307 C307
BLACK BLACK
3 1 CAV CIRCUIT CAV CIRCUIT
1 Q17 14DB/WT 1 3 1 Q17 14DB/WT
2 Q27 14RD/BK 2 Q27 14RD/BK
4 6
6 4 3 Q1 14YL 3 Q1 14YL
4 P33 16OR/BK 4 P33 16OR/BK
C309 5 P34 16PK/BK
C309 5 P34 16PK/BK
(FULL OPTIONS) -
(FULL OPTIONS) -
6 6
CAV CIRCUIT
BLACK
1 P33 16OR/BK
2 P34 16PK/BK
3 4 3 G78 20TN/BK
4 L77 18BR/YL BLACK
1 6 5 M4 20GY/BK
6 Z1 18BK
C311
C313
POWER MIRRORS
FULL OPTIONS
J008W-7 XJD08024
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25
WHITE
WHITE
CAV CIRCUIT CAV CIRCUIT
1 2 1 X92 16TN/BK 2 1 1 X92 18TN/BK
3 6 1 X52 18DB/WT 6 3 1 X52 18DB/WT
7 8 8 7
2 X94 16TN/RD 2 X94 18TN/RD
2 X58 18DB/OR 2 X58 18DB/OR
C314 3 X91 16BR/DB C314 3 X91 18WT/BK
3 X51 18BR/YL 3 X51 18BR/YL
4 X93 16BR/YL 4 X93 18WT/RD
4 X57 18BR/LB 4 X57 18BR/LB
5 M1 18PK
5 M1 20PK
5 M1 20PK
6 M2 20YL 6 M2 20YL
7 M4 20GY/BK 7 M4 20GY/BK
8 - 8 -
BLACK
BLACK
2 1
1 2
CAV CIRCUIT CAV CIRCUIT
1 F83 18YL/DG 1 F83 18YL/DG
2 F37 14RD/LB 2 F37 14RD/LB
C316 C316
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
A C B G16 18BK/LB C A B G16 20BK/LB
C Z1 18BK C Z1 20BK
C317 C317
HEATED SEATS
6 SPEAKER
4 SPEAKER
LHD
XJD08025 RHD J008W-7
8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
B G16 18BK/LB C A B G16 20BK/LB
A C
C Z1 18BK C Z1 20BK
C318 C318
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
B A A B
B Z1 18BK B Z1 20BK
C319 C319
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
A M2 18YL A M2 20YL
B A A B
B Z1 18BK B Z1 20BK
C320 C320
RHD
J008W-7 XJD08026
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27
WHITE
WHITE
BLACK BLACK
CAV CIRCUIT CAV CIRCUIT
1 P33 16OR/BK 1 P33 16OR/BK
1 2 2 P34 16PK/BK 2 1 2 P34 16PK/BK
3 5 3 M4 20GY/BK 5 3 3 M4 20GY/BK
4 C15 12BK/WT 4 C15 12BK/WT
5 L50 18WT/TN 5 L50 20WT/TN
C326 C326
W/ POWER AMPLIFIER
FULL OPTIONS
XJD08027 J008W-7
8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
BLACK
C330 C330
NATURAL NATURAL
CAV CIRCUIT CAV CIRCUIT
1 P141 18TN/LB 1 P141 18TN/LB
2 P143 18BK/DG 1 4 2 P143 18BK/DG
4 1 3 P87 18BK/OR 3 P87 18BK/OR
4 Z1 18BK 4 Z1 18BK
C332 C332
BLACK BLACK
2 1
1 2 CAV CIRCUIT CAV CIRCUIT
1 L50 18WT/TN 1 L50 18DG/WT
2 Z1 18BK 2 Z1 18BK
C333 C333
J008W-7 XJD08028
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29
BLACK BLACK
C362 C362
BLACK BLACK
C363 C363
GRAY
BLACK
CAV CIRCUIT FUNCTION
A M1 18PK FUSED B(+)
A C A M1 20PK FUSED B(+)
B M2 20YL COURTESY LAMPS DRIVER
CARGO C M4 20GY/BK LIFTGATE COURTESY LAMP DRIVER
LAMP/SWITCH
RHD
LHD
XJD08029 J008W-7
8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
1
RED
CLOCKSPRING - C2
YELLOW
CAV CIRCUIT FUNCTION
2 1 1 R45 18DG/LB DRIVER AIRBAG LINE 1
2 R43 18BK/LB DRIVER AIRBAG LINE 2
CLOCKSPRING - C3
J008W-7 XJD08030
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31
GREEN
2 1
BLACK
BLACK
XJD08031 J008W-7
8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS XJ
J008W-7 XJD08032
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33
BLACK
XJD08033 J008W-7
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS XJ
1 BLACK
CAV CIRCUIT FUNCTION
1 M2 18YL COURTESY LAMPS DRIVER
2 3 2 G16 18BK/LB DRIVER DOOR AJAR SWITCH SENSE
3 Z1 18BK GROUND
DRIVER DOOR
JAMB SWITCH
2 1
J008W-7 XJD08034
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35
POWER MIRRORS
FULL OPTIONS
LHD
RHD
XJD08035 J008W-7
8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
BLACK
1 2
CAV CIRCUIT FUNCTION
1 Q11 14BR LEFT WINDOW DRIVER UP
2 Q21 14VT LEFT FRONT WINDOW DRIVER DOWN
DRIVER POWER
WINDOW MOTOR
(RHD)
BLACK
2 1
BLACK
1 2
CAV CIRCUIT FUNCTION
1 K167 20BR/YL SENSOR GROUND
ENGINE COOLANT 2 K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
TEMPERATURE
SENSOR
BLACK
3 1
CAV CIRCUIT FUNCTION
1 K6 18VT/OR 5V SUPPLY
ENGINE OIL 2 G60 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL
PRESSURE SENSOR 3 K167 18BR/YL SENSOR GROUND
J008W-7 XJD08036
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37
BLACK
WHITE
BLACK
XJD08037 J008W-7
8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
1 2
CAV CIRCUIT FUNCTION
1 A142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
FUEL INJECTOR 2 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
NO. 1
(2.5L)
BLACK
FUEL INJECTOR
NO. 2
(2.5L)
BLACK
BLACK
J008W-7 XJD08038
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39
BLACK
2 1
BLACK
2 1
BLACK
2 1
BLACK
2 1
BLACK
6 5 4
CAV CIRCUIT FUNCTION
1 A141 16DG/WT FUEL PUMP RELAY OUTPUT
2 - -
3 K226 20DB/LG FUEL LEVEL SENSOR SIGNAL
4 K167 20BR/YL SENSOR GROUND
3 2 1 5 - -
FUEL PUMP 6 Z1 16BK GROUND
MODULE
BLACK
G SWITCH
BLACK
GENERATOR
BLACK
CAV CIRCUIT FUNCTION
1 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
4 1
2 L2 14LG HEADLAMP SWITCH OUTPUT
3 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
HEADLAMP BEAM 4 L20 14LG/WT FUSED B (+)
SELECT SWITCH
J008W-7 XJD08040
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41
3 2 1 1 - -
F235 16RD B(+) TO HEATED SEAT MODULE
2
6 5 4 F235 16RD B(+) TO HEATED SEAT MODULE
3 - -
9 8 7 4 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
5 - -
6 Z1 18BK GROUND
HEATED SEAT 7 - -
RELAY 8 F37 14RD/LB FUSED B(+)
BLACK
1 4
CAV CIRCUIT FUNCTION
1 K59 18VT/BK IDLE AIR CONTROL NO. 4 DRIVER
2 K40 18BR/WT IDLE AIR CONTROL NO. 3 DRIVER
IDLE AIR 3 K60 18YL/BK IDLE AIR CONTROL NO. 2 DRIVER
CONTROL 4 K39 18GY/RD IDLE AIR CONTROL NO. 1 DRIVER
MOTOR
LHD
XJD08041 J008W-7
8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
IGNITION COIL
(2.5L)
GREEN
IGNITION
SWITCH - C2
J008W-7 XJD08042
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43
XJD08043 J008W-7
8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS XJ
GRAY
4.0L
J008W-7 XJD08044
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45
NATURAL
CAV CIRCUIT FUNCTION
1 3
1 M2 20YL COURTESY LAMPS DRIVER
2 Z1 20BK GROUND
3 M1 20PK FUSED B(+)
JUNCTION
BLOCK - C3
OVERHEAD CONSOLE
LHD
RHD
XJD08045 J008W-7
8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS XJ
2 1 NATURAL
JUNCTION
BLOCK - C6
FULL OPTIONS
RHD EXCEPT FULL OPTIONS
BASE
RHD
POWER SEATS
J008W-7 LHD XJD08046
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47
NATURAL
JUNCTION
BLOCK - C8
GRAY
1 2
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L10 18BR/LG BACK-UP LAMP FEED
LEFT BACK-UP
LAMP
POWER MIRROR
XJD08047 FULL OPTIONS J008W-7
8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
GRAY
LEFT FOG
LAMP
BLACK
CAV CIRCUIT FUNCTION
1 2 1 X85 18BK/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
1 X55 18LG/RD LEFT FRONT SPEAKER (-)
1 X85 18LG/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
LEFT FRONT
2 X87 18DG AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
DOOR SPEAKER
2 X53 18LG/BK LEFT FRONT SPEAKER (+)
2 X87 18LG/BK AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
BLACK
1
CAV CIRCUIT FUNCTION
2
1 X85 18LG/RD AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
2 X87 18LG/BK AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
LEFT FRONT
DOOR TWEETER
GRAY
6 SPEAKER LHD
6 SPEAKER RHD
4 SPEAKER
J008W-7 XJD08048
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49
GRAY
GRAY
FOG LAMPS
XJD08049 J008W-7
8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS XJ
RED
YELLOW
LEFT POWER
SEAT FRONT
VERTICAL MOTOR
YELLOW
LEFT POWER
SEAT HORIZONTAL
MOTOR
YELLOW
LEFT POWER
SEAT REAR
VERTICAL MOTOR
J008W-7 XJD08050
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51
BLACK
CAV CIRCUIT FUNCTION
A F37 14RD FUSED B(+)
M N Z1 14BK GROUND
B B
L C - -
K E P13 14RD/WT LEFT POWER SEAT REAR DOWN
F - -
A J
G - -
E F H - -
J P11 14YL/WT LEFT POWER SEAT REAR UP
C H G K P17 14RD/LB LEFT POWER SEAT HORIZONTAL REARWARD
L P15 14YL/LB LEFT POWER SEAT HORIZONTAL FORWARD
LEFT POWER M P19 14YL/LG LEFT POWER SEAT FRONT UP
SEAT SWITCH N P21 14RD/LG LEFT POWER SEAT FRONT DOWN
BLACK
1
BLACK
2 1
BLACK
LEFT REAR
WINDOW MOTOR
XJD08051 J008W-7
8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS XJ
NATURAL
LEFT SIDE
MARKER LAMP
1 2
CAV CIRCUIT FUNCTION
1 K167 20BR/YL SENSOR GROUND
LEFT SPEED 2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
CONTROL
SWITCH
BLACK
1 2 3
4 SPEAKER SYSTEM
6 SPEAKER SYSTEM
J008W-7 XJD08052
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53
BLACK
A B
CAV CIRCUIT FUNCTION
A M1 20PK FUSED B(+)
LEFT VISOR/ B Z1 20BK GROUND
VANITY
LAMP
LICENSE LAMP
BLACK
CAV CIRCUIT FUNCTION
A P33 16OR/BK DOOR LOCK DRIVER
B P34 16PK/BK DOOR UNLOCK DRIVER
A B
LIFTGATE
LOCK MOTOR
BLACK
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
3 1 2 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE
3 M4 20VT/YL LIFTGATE COURTESY LAMP DRIVER
LIFTGATE
SWITCH
XJD08053 J008W-7
8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
MANIFOLD
ABSOLUTE
PRESSURE
SENSOR
1 2 BLACK
CAV CIRCUIT FUNCTION
1 F142 20DG/WT FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2.5L
4.0L
J008W-7 XJD08054
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55
1 2 GRAY
1 2 BLACK
BLACK
PARK/NEUTRAL
POSITION SWITCH
(2.5L A/T)
BLACK
1
XJD08055 J008W-7
8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS XJ
2 1
BLUE
CAV CIRCUIT FUNCTION
1 P59 20LB/RD DOOR LOCK CONTROL
4 1 2 P55 20DB/PK DOOR UNLOCK RELAY CONTROL
2 P55 20DB DOOR UNLOCK RELAY CONTROL
3 P35 20OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
3 P36 18PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
8 5
4 F81 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
PASSENGER 5 F35 16RD FUSED B(+)
POWER LOCK/WINDOW 6 Z1 14BK GROUND
SWITCH - C2 7 P36 20PK/VT DOOR LOCK SWITCH OUTPUT (UNLOCK)
(FULL OPTIONS) 7 P35 18OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
8 G26 20LB KEY-IN IGNITION SWITCH SENSE
POWER MIRRORS
FULL OPTIONS
LHD
RHD
J008W-7 XJD08056
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57
BLACK
POWER MIRRORS
FULL OPTIONS
XJD08057 J008W-7
8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS XJ
RED
WHITE
POWER STEERING
PRESSURE SWITCH
(2.5L)
RHD
LHD
J008W-7 XJD08058
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59
4.0L CALIFORNIA
2.5L M/T
EXCEPT 2.5L M/T
4.0L
2.5L
2.5L A/T
4.0L A/T
XJD08059 J008W-7
8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS XJ
4.0L
2.5L A/T
J008W-7 XJD08060
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61
LEAK DETECT
4.0L
XJD08061 J008W-7
8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS XJ
PRNDL
ILLUMINATION
(A/T)
LT.GRAY
1 2
BLACK
J008W-7 XJD08062
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63
BLACK
GRAY
BLACK
CAV CIRCUIT FUNCTION
1 Z1 20BK GROUND
1 2 2 V20 18BK/WT REAR WASHER MOTOR CONTROLLER
3 6 3 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
4 V13 18BR/LG REAR WIPER MOTOR CONTROL
5 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
REAR WIPER/
6 V23 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN)
WASHER SWITCH
GRAY
RIGHT BACK-UP
LAMP
XJD08063 J008W-7
8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
RIGHT COURTESY
LAMP
GRAY
RIGHT
FOG LAMP
BLACK
BLACK
RIGHT FRONT
PARK/TURN
SIGNAL LAMP NO. 1
BLACK
CAV CIRCUIT FUNCTION
1 L60 18TN RIGHT TURN SIGNAL
2 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
3 Z1 18BK GROUND
3 1
RIGHT FRONT
PARK/TURN
SIGNAL LAMP NO. 2
J008W-7 XJD08064
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65
BLUE
YELLOW
RIGHT POWER
SEAT FRONT
VERTICAL MOTOR
XJD08065 J008W-7
8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS XJ
YELLOW
RIGHT POWER
SEAT HORIZONTAL
MOTOR
YELLOW
RIGHT POWER
SEAT REAR
VERTICAL MOTOR
BLACK
1
RED
BLACK
RIGHT REAR
WINDOW MOTOR
BLUE
NATURAL
CAV CIRCUIT FUNCTION
1 1 L78 20DG/YL FUSED HEADLAMP SWITCH OUTPUT
2
2 L60 20TN RIGHT TURN SIGNAL
RIGHT SIDE
MARKER LAMP
4 SPEAKER SYSTEM
XJD08067 6 SPEAKER SYSTEM J008W-7
8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS XJ
1 2
CAV CIRCUIT FUNCTION
1 K167 20BR/YL SENSOR GROUND
RIGHT SPEED 2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
CONTROL SWITCH
1 3
CAV CIRCUIT FUNCTION
1 Z1 18BK GROUND
2 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
3 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
RIGHT TAIL/
STOP LAMP
BLACK
BLACK
J008W-7 XJD08068
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69
BLACK
CAV CIRCUIT FUNCTION
1 D1 20VT/BR CCD BUS (+)
6 1
2 D2 20WT/BK CCD BUS (-)
3 Z2 20BK/LG GROUND
SENTRY KEY
IMMOBILIZER 4 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
MODULE 5 Z2 20BK/LG GROUND
6 F1 20DB/GY FUSED B(+)
WHITE
LHD
RHD
XJD08069 J008W-7
8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS XJ
WHITE
A B
CAV CIRCUIT FUNCTION
A F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
TORQUE CONVERTER B K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL
CLUTCH SOLENOID
(2.5L A/T)
BLACK
3 5 2 CAV CIRCUIT FUNCTION
1 L63 20DG/RD LEFT TURN SIGNAL
2 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
4 3 A6 20RD/OR FUSED B(+)
4 - -
1
5 L73 20YL BRAKE LAMP SWITCH OUTPUT
TRAILER TOW
LEFT TURN RELAY
BLACK
3 5 2 CAV CIRCUIT FUNCTION
1 L62 20BK/RD RIGHT TURN SIGNAL
2 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
4
3 A6 20RD/OR FUSED B(+)
4 - -
1
TRAILER TOW 5 L74 20LG BRAKE LAMP SWITCH OUTPUT
RIGHT TURN RELAY
4.0L A/T
EXCEPT 4.0L A/T
J008W-7 XJD08070
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71
BLACK
TRANSFER
CASE SWITCH
(231 4WD)
BLACK
BLACK
BLACK
1 4
CAV CIRCUIT FUNCTION
1 T52 20RD/BK INPUT SPEED SENSOR SIGNAL
2 T60 20OR/WT SOLENOID B CONTROL
3 T19 20WT SOLENOID A CONTROL
4 T22 20DB/WT SOLENOID C CONTROL
4 8 5 T31 20VT/LG INPUT SPEED SENSOR GROUND
6 T13 20DB/BK OUTPUT SPEED SENSOR GROUND
TRANSMISSION 7 T14 20LG/WT OUTPUT SPEED SENSOR SIGNAL
SOLENOID 8 - -
(4.0L)
XJD08071 J008W-7
8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS XJ
GRAY
CAV CIRCUIT FUNCTION
1 T42 18VT/WT TRS T42 SENSE
1 2 T3 18VT TRS T3 SENSE
2
3 3 F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
5 4
4 T1 18LG/BK TRS T1 SENSE
6
8 5 - -
7
6 L10 18BR/LG BACK-UP LAMP FEED
7 T41 20BK/WT PARK/ NEUTRAL POSITION SWITCH SENSE
TRANSMISSION 8 Z1 18BK GROUND
RANGE
SENSOR
(4.0L A/T)
J008W-7 XJD08072
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73
BLACK
UNDERHOOD
LAMP/
SWITCH
BLACK
BLACK
XJD08073 J008W-7
8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS XJ
BLACK
BLACK
NATURAL
CAV CIRCUIT FUNCTION
1 Z1 16BK GROUND
2 V5 16DG/YL WIPER PARK SWITCH SENSE
6 1 3 V10 18BR WASHER PUMP CONTROL
4 V3 16BR/WT WIPER LOW SPEED OUTPUT
WIPE/WASH 5 V6 16DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
SWITCH 6 V4 16BR/VT WIPER HIGH SPEED OUTPUT
J008W-7 XJD08074
XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 1
Fig. 30 Front and Rear Doors (Left Side Shown, Right Side Similar)
8W - 90 - 38 8W - 90 CONNECTOR LOCATIONS XJ
DESCRIPTION AND OPERATION (Continued)
Fig. 31 Liftgate
XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 39
DESCRIPTION AND OPERATION (Continued)
Fig. 34 Headliner
XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 41
DESCRIPTION AND OPERATION (Continued)
ENGINE
TABLE OF CONTENTS
page page
2.5L ENGINE
TABLE OF CONTENTS
page page
LUBRICATION SYSTEM
DESCRIPTION
A gear—type positive displacement pump is
mounted at the underside of the block opposite the
No. 4 main bearing.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
is driven between the drive and idler gears and
pump body, then forced through the outlet to the
block. An oil gallery in the block channels the oil to
Fig. 1 Engine Firing Order the inlet side of the full flow oil filter. After passing
The digits of the code identify: through the filter element, the oil passes from the
• 1st Digit—The year (8 = 1998). center outlet of the filter through an oil gallery that
• 2nd & 3rd Digits—The month (01 - 12). channels the oil up to the main gallery which
• 4th & 5th Digits—The engine type/fuel system/ extends the entire length of the block.
compression ratio (HX = A 2.5 liter (150 CID) 9.1:1 Galleries extend downward from the main oil gallery
compression ratio engine with a multi-point fuel to the upper shell of each main bearing. The crankshaft
injection system). is drilled internally to pass oil from the main bearing
• 6th & 7th Digits—The day of engine build (01 - 31). journals (except number 4 main bearing journal) to the
FOR EXAMPLE: Code * 801HX23 * identifies a connecting rod journals. Each connecting rod bearing
2.5 liter (150 CID) engine with a multi-point fuel cap has a small squirt hole, oil passes through the
injection system, 9.1:1 compression ratio and built on squirt hole and is thrown off as the rod rotates. This oil
January 23, 1998. throwoff lubricates the camshaft lobes, distributor drive
gear, cylinder walls, and piston pins.
The hydraulic valve tappets receive oil directly
from the main oil gallery. Oil is provided to the cam-
shaft bearing through galleries. The front camshaft
bearing journal passes oil through the camshaft
XJ 2.5L ENGINE 9-3
DESCRIPTION AND OPERATION (Continued)
sprocket to the timing chain. Oil drains back to the hole in the corresponding rocker arm. Oil from the
oil pan under the number one main bearing cap. rocker arm lubricates the valve train components,
The oil supply for the rocker arms and bridged then passes down through the push rod guide holes
pivot assemblies is provided by the hydraulic valve in the cylinder head past the valve tappet area, and
tappets which pass oil through hollow push rods to a returns to the oil pan.
9-4 2.5L ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
CYLINDER BLOCK
DESCRIPTION
The cylinder block is a cast iron inline four cylin-
der design. The cylinder block is drilled forming gal-
leries for both oil and coolant.
CYLINDER HEAD
DESCRIPTION
The cylinder head is made of cast iron containing
eight valves made of chrome plated heat resistant
steel, valve stem seals, springs, retainers and keep-
ers. The cylinder head, valve seats and guides can be
resurfaced for service purposes.
The cylinder head uses dual quench-type design
combustion chambers which cause turbulence in the
cylinders allowing faster burning of the air/fuel mix-
ture, resulting in better fuel economy.
The valve guides are integral to the cylinder head,
They are not replaceable. However, they are service-
able.
OPERATION
When the push rods are forced upward by the cam-
shaft lobes the push rod presses upward on the
rocker arms, the rocker arms pivot, forcing down-
ward pressure on the valves forcing the valves to
move downward and off from their seats.
VALVES
DESCRIPTION
Fig. 7 Camshaft—Typical The valves are made of heat resistant steel and
1 – CAMSHAFT have chrome plated stems to prevent scuffing. All
2 – LOBES
valves use three bead lock keepers to retain the valve
3 – BEARING JOURNAL
spring and promote valve rotation (Fig. 9).
XJ 2.5L ENGINE 9-7
DESCRIPTION AND OPERATION (Continued)
VALVE SPRING
DESCRIPTION
The valve springs are made of high strength
chrome silicon steel. The springs are common for
both intake and exhaust valves.
OIL PAN
Fig. 9 Valve and Keeper Configuration 2.5L Engine
1 – VALVE LOCKS (3–BEAD) DESCRIPTION
2 – RETAINER The oil pan is made of stamped steel. The oil pan
3 – VALVE STEM OIL SEAL
gasket is a one piece steel backbone silicone coated
4 – INTAKE VALVE
gasket.
5 – EXHAUST VALVE
6 – VALVE SPRING
HYDRAULIC TAPPET
DESCRIPTION
Valve lash is controlled by hydraulic tappets
located inside the cylinder block, in tappet bores
above the camshaft.
Fig. 11 Oil Pan
VALVE GUIDE 1 – OIL PAN
2 – OIL PAN DRAIN PLUG
DESCRIPTION
The valve guides are integral to the cylinder head,
They are not replaceable. However, they are service-
able.
9-8 2.5L ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
SERVICE DIAGNOSIS—PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to
Group 8A, Battery, for correct
procedures. Check charging system.
Refer to Group 8C, Charging
Systems, for correct procedures.
ENGINE CRANKS BUT WILL NOT 1. No spark 1. Check for spark. Refer to Group
START 8D, Ignition System, for correct
procedures.
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to group 8D, Ignition System
3. Worn or incorrect gapped spark 3. Clean plugs and set gap. (Refer
plugs to group 8D, Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust 10. Install new parts as necessary
system
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
9 - 10 2.5L ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to Group 14 for
correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap
plugs spark plugs (Refer to group 8D,
Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or 5. Check for correct firing order or
crossed replace spark plug cables. (Refer to
Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary
(Refer to group 8D, Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary (Refer to Group 11,
Exhaust System & Intake Manifold)
8. EGR valve leaking or stuck open 8. Test and replace, if necessary
(Refer to group 25, Emission
Control Systems)
ENGINE MISSES ON 1. Worn or incorrectly gapped spark 1. Replace spark plugs or clean and
ACCELERATION plugs set gap. (Refer to group 8D, Ignition
System)
2. Spark plug cables defective or 2. Check Idle Air Control circuit.
crossed (Refer to Group 14, Fuel 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
(refer to group 8D, Ignition System)
SERVICE DIAGNOSIS—MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil
Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
XJ 2.5L ENGINE 9 - 11
DIAGNOSIS AND TESTING (Continued)
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive connecting rod Measure bearings for correct
bearing clearance clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of 5. Replace crankshaft or grind
round journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive main bearing 4. Measure bearings for correct
clearance clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of 6. Grind journals or replace
round or worn crankshaft
7. Loose flywheel or torque 7. Inspect crankshaft, flexplate/
converter flywheel and bolts for damage.
Tighten to correct torque
9 - 12 2.5L ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
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
5. Thin or diluted oil 5. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose, 8. Inspect suction tube and clean or
broken, bent or clogged replace if necessary
9. Oil pump cover warped or 9. Install new oil pump
cracked
EXCESSIVE OIL CONSUMPTION 1. PCV System malfunction 1. Refer to group 25, Emission
OR SPARK PLUGS OIL FOULED Control System for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in 7. Remove rings and check ring end
grooves gap and side clearance. Replace if
necessary
XJ 2.5L ENGINE 9 - 13
DIAGNOSIS AND TESTING (Continued)
WARNING: USE EXTREME CAUTION WHEN THE CYLINDER-TO-WATER JACKET LEAKAGE TEST
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR WARNING: USE EXTREME CAUTION WHEN THE
HANDS NEAR THE PULLEYS, BELTS OR THE FAN. ENGINE IS OPERATING. DO NOT STAND IN A
DO NOT WEAR LOOSE CLOTHING. DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
(1) Start the engine. DO NOT WEAR LOOSE CLOTHING.
(2) Spray a small stream of water at the suspected
leak area. Remove the radiator cap.
(3) If a change in RPM is observed the area of the Start the engine and allow it to warm up until the
suspected leak has been found. engine thermostat opens.
(4) Repair as required. If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
CYLINDER COMPRESSION PRESSURE TEST If bubbles are not visible, install a radiator pres-
The results of a cylinder compression pressure test sure tester and pressurize the coolant system.
can be utilized to diagnose several engine malfunc- If a cylinder is leaking combustion pressure into
tions. the water jacket, the tester pointer will pulsate with
Ensure the battery is completely charged and the every combustion stroke of the cylinder.
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures may CYLINDER COMBUSTION PRESSURE LEAKAGE
not be valid for diagnosis purposes. TEST
(1) Clean the spark plug recesses with compressed air. The combustion pressure leakage test provides an
(2) Remove the spark plugs. accurate means for determining engine condition.
(3) Secure the throttle in the wide-open position. Combustion pressure leakage testing will detect:
(4) Disable the fuel system. (Refer to Group 14, • Exhaust and intake valve leaks (improper seating).
Fuel System for the correct procedure) • Leaks between adjacent cylinders or into water
(5) Disconnect the ignition coil. jacket.
(6) Insert a compression pressure gauge and rotate the • Any causes for combustion/compression pressure loss.
engine with the engine starter motor for three revolutions. (1) Check the coolant level and fill as required. DO
(7) Record the compression pressure on the 3rd revo- NOT install the radiator cap.
lution. Continue the test for the remaining cylinders. (2) Start and operate the engine until it attains nor-
Refer to Engine Specifications for the correct mal operating temperature, then turn the engine OFF.
engine compression pressures. (3) Remove the spark plugs.
(4) Remove the oil filler cap.
ENGINE CYLINDER HEAD GASKET FAILURE (5) Remove the air cleaner.
DIAGNOSIS (6) Calibrate the tester according to the manufactur-
A leaking engine cylinder head gasket usually results er’s instructions. The shop air source for testing should
in loss of power, loss of coolant and engine misfiring. maintain 483 kPa (70 psi) minimum, 1,379 kPa (200
An engine cylinder head gasket leak can be located psi) maximum and 552 kPa (80 psi) recommended.
between adjacent cylinders or between a cylinder and (7) Perform the test procedures on each cylinder
the adjacent water jacket. according to the tester manufacturer’s instructions.
• An engine cylinder head gasket leaking between While testing, listen for pressurized air escaping
adjacent cylinders is indicated by a loss of power through the throttle body, tailpipe and oil filler cap
and/or engine misfire. opening. Check for bubbles in the radiator coolant.
• An engine cylinder head gasket leaking between All gauge pressure indications should be equal,
a cylinder and an adjacent water jacket is indicated with no more than 25% leakage.
by coolant foaming or overheating and loss of coolant. FOR EXAMPLE: At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
CYLINDER-TO-CYLINDER LEAKAGE TEST tained in the cylinder.
To determine if an engine cylinder head gasket is Refer to the Cylinder Combustion Pressure Leak-
leaking between adjacent cylinders; follow the proce- age Test Diagnosis chart.
9 - 14 2.5L ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
ENGINE OIL LEAK INSPECTION (4) Gradually apply air pressure from 1 psi to 2.5
Begin with a thorough visual inspection of the psi maximum while applying soapy water at the sus-
engine, particularly at the area of the suspected leak. pected source. Adjust the regulator to the suitable
If an oil leak source is not readily identifiable, the test pressure that provide the best bubbles which
following steps should be followed: will pinpoint the leak source. If the oil leak is
(1) Do not clean or degrease the engine at this detected and identified, repair per service manual
time because some solvents may cause rubber to procedures.
swell, temporarily stopping the leak. (5) If the leakage occurs at the rear oil seal area,
(2) Add an oil soluble dye (use as recommended by refer to the section, Inspection for Rear Seal Area
manufacturer). Start the engine and let idle for Leak.
approximately 15 minutes. Check the oil dipstick to (6) If no leaks are detected, turn off the air supply
make sure the dye is thoroughly mixed as indicated and remove the air hose and all plugs and caps.
with a bright yellow color under a black light. Install the PCV valve and breather cap hose.
(3) Using a black light, inspect the entire engine (7) Clean the oil off the suspect oil leak area using
for fluorescent dye, particularly at the suspected area a suitable solvent. Drive the vehicle at various
of oil leak. If the oil leak is found and identified, speeds approximately 24 km (15 miles). Inspect the
repair per service manual instructions. engine for signs of an oil leak by using a black light.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and INSPECTION FOR REAR SEAL AREA LEAKS
repeat inspection. Since it is sometimes difficult to determine the
(4) If the oil leak source is not positively source of an oil leak in the rear seal area of the
identified at this time, proceed with the air leak engine, a more involved inspection is necessary. The
detection test method. following steps should be followed to help pinpoint
the source of the leak.
Air Leak Detection Test Method If the leakage occurs at the crankshaft rear oil seal
(1) Disconnect the breather cap to air cleaner hose area:
at the breather cap end. Cap or plug breather cap (1) Disconnect the battery.
nipple. (2) Raise the vehicle.
(2) Remove the PCV valve from the cylinder head (3) Remove torque converter or clutch housing
cover. Cap or plug the PCV valve grommet. cover and inspect rear of block for evidence of oil.
(3) Attach an air hose with pressure gauge and Use a black light to check for the oil leak:
regulator to the dipstick tube. (a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
CAUTION: Do not subject the engine assembly to (b) Where leakage tends to run straight down,
more than 20.6 kpa (3 PSI) of test pressure. possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
XJ 2.5L ENGINE 9 - 15
DIAGNOSIS AND TESTING (Continued)
filter runoff, and main bearing cap to cylinder pointer indicates 0.305 mm (0.012 inch) travel dis-
block mating surfaces. tance (lift).
(4) If no leaks are detected, pressurize the crank- • The timing notch index on the vibration damper
case as outlined in the, Inspection (Engine oil Leaks should be aligned with the TDC mark on the timing
in general) degree scale.
• If the timing notch is more than 13 mm (1/2
CAUTION: Do not exceed 20.6 kPa (3 psi). inch) away from the TDC mark in either direction,
the valve timing is incorrect.
(5) If the leak is not detected, very slowly turn the • If the valve timing is incorrect, the cause may be
crankshaft and watch for leakage. If a leak is a broken camshaft pin. It is not necessary to replace
detected between the crankshaft and seal while the camshaft because of pin failure. A spring pin is
slowly turning the crankshaft, it is possible the available for service replacement.
crankshaft seal surface is damaged. The seal area on
the crankshaft could have minor nicks or scratches VALVE, GUIDE AND SEAL
that can be polished out with emery cloth. Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
CAUTION: Use extreme caution when crankshaft
guides and head.
polishing is necessary to remove minor nicks and
Clean all grime and gasket material from the
scratches. The crankshaft seal flange is especially
engine cylinder head machined gasket surface.
machined to complement the function of the rear oil
Inspect for cracks in the combustion chambers and
seal.
valve ports.
(6) For bubbles that remain steady with shaft Inspect for cracks on the exhaust seat.
rotation, no further inspection can be done until dis- Inspect for cracks in the gasket surface at each
assembled. coolant passage.
Inspect valves for burned, cracked or warped
ENGINE OIL PRESSURE heads.
(1) Disconnect connector and remove oil pressure Inspect for scuffed or bent valve stems.
sending unit. Replace valves displaying any damage.
(2) Install Oil Pressure Line and Gauge Tool
C-3292 or equivalent. Start engine and record pres- VALVE REFACING
sure. Refer to Oil Pressure in Engine Specifications (1) Use a valve refacing machine to reface the
for the correct pressures. intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 0.787 mm
(0.031 inch) must remain (Fig. 13). If the margin is
SERVICE PROCEDURES less than 0.787 mm (0.031 inch), the valve must be
replaced.
VALVE TIMING
• Disconnect the spark plug wires and remove the VALVE SEAT REFACING
spark plugs. (1) Install a pilot of the correct size in the valve
• Remove the engine cylinder head cover. guide bore. Reface the valve seat to the specified
• Remove the capscrews, bridge and pivot assem- angle with a good dressing stone. Remove only
bly, and rocker arms from above the No.1 cylinder. enough metal to provide a smooth finish.
• Alternately loosen each capscrew, one turn at a (2) Use tapered stones to obtain the specified seat
time, to avoid damaging the bridge. width when required.
• Rotate the crankshaft until the No.4 piston is at (3) Control valve seat runout to a maximum of
top dead center (TDC) on the compression stroke. 0.0635 mm (0.0025 in.)— (Fig. 14).
• Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90°. VALVE STEM OIL SEAL REPLACEMENT
• Install a dial indicator on the end of the No.1 Valve stem oil seals are installed on each valve
cylinder intake valve push rod. Use rubber tubing to stem to prevent rocker arm lubricating oil from
secure the indicator stem on the push rod. entering the combustion chamber through the valve
• Set the dial indicator pointer at zero. guide bores. One seal is marked INT (intake valve)
• Set the dial indicator pointer at zero. and the other is marked EXH (exhaust valve).
• Rotate the crankshaft clockwise (viewed from Replace the oil seals whenever valve service is per-
the front of the engine) until the dial indicator formed or if the seals have deteriorated.
9 - 16 2.5L ENGINE XJ
SERVICE PROCEDURES (Continued)
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.
PREFERRED METHOD:
(1) Remove the valve from the head.
(2) Clean the valve stem guide bore with solvent
and a bristle brush.
(3) Insert a telescoping gauge into the valve stem
guide bore approximately 9.525 mm (.375 inch) from
the valve spring side of the head (Fig. 15).
VALVE GUIDES
(4) Remove and measure telescoping gauge with a
The valve guides are an integral part of the engine
micrometer.
cylinder head and are not replaceable.
(5) Repeat the measurement with contacts length-
When the valve stem guide clearance is excessive,
wise to engine cylinder head.
the valve guide bores must be reamed oversize. Ser-
(6) Compare the crosswise to lengthwise measure-
vice valves with oversize stems are available in 0.076
ments to determine out-of-roundness. If the measure-
mm (0.003 inch) and 0.381 mm (0.015 inch) incre-
ments differ by more than 0.0635 mm (0.0025 in.),
ments.
ream the guide bore to accommodate an oversize
Corresponding oversize valve stem seals are also
valve stem.
available and must be used with valves having 0.381
(7) Compare the measured valve guide bore diam-
mm (0.015 inch) oversize stems, 0.076mm (.003in.)
eter with specifications (7.95-7.97 mm or 0.313-0.314
oversize stems do not require oversize seals.
XJ 2.5L ENGINE 9 - 17
SERVICE PROCEDURES (Continued)
inch). If the measurement differs from specification
by more than 0.076 mm (0.003 inch), ream the guide
bore to accommodate an oversize valve stem.
ALTERNATIVE METHOD:
(1) Use a dial indicator to measure the lateral
movement of the valve stem (stem-to-guide clear-
ance). This must be done with the valve installed in
its guide and just off the valve seat (Fig. 16).
(2) Correct clearance is 0.025-0.0762 mm
(0.001-0.003 inch). If indicated movement exceeds the
specification ream the valve guide to accommodate
an oversize valve stem.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Raise the vehicle.
(3) Support the engine.
(4) Remove through bolt nut (Fig. 42). DO NOT
Fig. 40 Oil Filter—2.5L Engine remove the through bolt.
1 – OIL FILTER (5) Remove the retaining bolts and nuts from the
support cushions (Fig. 42).
(4) When filter separates from adapter nipple, tip (6) Remove the through bolt.
gasket end upward to minimize oil spill. Remove fil- (7) Remove the support cushions.
ter from vehicle.
(5) With a wiping cloth, clean the gasket sealing INSTALLATION
surface (Fig. 41) of oil and grime. (1) If the engine support bracket was removed,
position the LEFT bracket (Fig. 42) and the RIGHT
OIL FILTER INSTALLATION bracket (Fig. 43) onto the cylinder block. Install the
(1) Lightly lubricate oil filter gasket with engine bolts and stud nuts.
oil or chassis grease. (a) RIGHT SIDE (Fig. 43) —Tighten the bolts to
(2) Thread filter onto adapter nipple. When gasket 61 N·m (45 ft. lbs.) torque. Tighten the stud nuts to
makes contact with sealing surface, (Fig. 41) hand 46 N·m (34 ft. lbs.) torque.
tighten filter one full turn, do not over tighten. (b) LEFT SIDE (Fig. 42) —Tighten the bolts to
(3) Add oil, verify crankcase oil level and start 61 N·m (45 ft. lbs.) torque.
engine. Inspect for oil leaks. (2) If the support cushion brackets were removed,
position the brackets onto the lower front sill (Fig.
42) (Fig. 44). Install the bolts and stud nuts. Tighten
the bolts to 54 N·m (40 ft. lbs.) torque and the stud
nuts to 41 N·m (30 ft. lbs.) torque.
9 - 30 2.5L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
AUTOMATIC TRANSMISSION:
a. Remove the support cushion bolts and remove
the cushion and the transmission support bracket.
b. If necessary on 2WD vehicles, remove the bolts
holding the transmission support adaptor bracket to
the transmission (Fig. 46). Remove the adaptor
bracket.
CAUTION: Ensure that the accessory drive belt is Fig. 51 Intake/Exhaust Manifold Removal/
routed correctly. Failure to do so can cause the Installation—2.5L Engine
water pump to turn in the opposite direction result- (6) Install bolts 2 through 5 (Fig. 51). Tighten
ing in engine overheating. Refer to Group 7, Cool- these bolts to 31 N·m (23 ft. lbs.) torque.
ing System for the proper procedure. (7) Install new engine exhaust manifold spacers
over the engine exhaust manifold mounting studs in
(14) Connect the air inlet hose and resonator to
the cylinder head (Fig. 51).
the throttle body and the air cleaner.
(8) Tighten nuts 6 and 7 to 23 N·m (17 ft. lbs.)
(15) Connect the battery negative cable.
torque (Fig. 51).
(16) Start the engine and check for leaks.
(9) Install all components to the intake manifold.
(10) Raise the vehicle.
EXHAUST MANIFOLD (11) Connect the exhaust pipe to the engine
exhaust manifold. Tighten the bolts to 31 N·m (23 ft.
REMOVAL lbs.) torque.
(1) Disconnect the battery negative cable.
(12) Lower the vehicle.
(2) Raise the vehicle.
(13) Connect the battery negative cable.
(3) Disconnect the exhaust pipe from the engine
(14) Start the engine and check for leaks.
exhaust manifold.
(4) Lower the vehicle.
(5) Remove intake manifold (refer to procedure in
CYLINDER HEAD COVER
A cured gasket is part of the engine cylinder head
this section)
cover.
(6) Remove fasteners 2 through 5 and remove the
intake manifold (Fig. 51).
REMOVAL
(7) Remove fasteners 1, 6 and 7 and remove the
(1) Disconnect negative cable from battery.
engine exhaust manifold (Fig. 51).
(2) Disconnect the Crankcase Ventilation (CCV)
vacuum hose from engine cylinder head cover (Fig.
INSTALLATION
52).
(1) Clean the intake and engine exhaust manifolds
(3) Remove the air inlet hose and resonator from
and cylinder head mating surfaces. DO NOT allow
the air cleaner and throttle body.
foreign material to enter either the intake man-
(4) Remove the engine cylinder head cover mount-
ifold or the ports in the cylinder head.
ing bolts.
(2) Install a new intake manifold gasket over the
(5) Remove the engine cylinder head cover (Fig.
alignment dowels on the cylinder head.
52).
(3) Install the engine exhaust manifold assembly.
(6) Remove any original sealer from the cover seal-
Exhaust manifold must be centrally located
ing surface of the engine cylinder head and clean the
over the end studs and spacer (Fig. 51).
surface using a fabric cleaner.
(4) Tighten bolt No.1 to 41 N·m (30 ft. lbs.) torque
(7) Remove all residue from the sealing surface
(Fig. 51).
using a clean, dry cloth.
(5) Install the intake manifold on the cylinder
head dowels (Fig. 51).
9 - 36 2.5L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Remove the engine cylinder head cover. (Refer
to procedure in this section)
(2) Check for rocker arm bridges which are caus-
ing misalignment of the rocker arm to valve tip area.
(3) Remove the capscrews at each bridge and pivot
assembly (Fig. 53). Alternately loosen the capscrews
one turn at a time to avoid damaging the bridges.
(4) Remove the bridges, pivots and corresponding
pairs of rocker arms (Fig. 53). Place them on a bench
in the same order as removed.
(5) Remove the push rods and place them on a
bench in the same order as removed.
INSTALLATION
(1) Inspect the engine cylinder head cover for
cracks. Replace the cover, if cracked.
REMOVAL
Each valve spring is held in place by a retainer
and a set of conical valve locks. The locks can be
removed only by compressing the valve spring.
(1) Remove the engine cylinder head cover. Refer
to procedure in this section.
(2) Remove cap screws, bridge and pivot assem-
blies and rocker arms for access to each valve spring Fig. 54 Valve and Valve Components
to be removed. 1 – VALVE LOCKS (3–BEAD)
(3) Remove push rods. Retain the push rods, 2 – RETAINER
bridges, pivots and rocker arms in the same 3 – VALVE STEM OIL SEAL
order and position as removed. 4 – INTAKE VALVE
(4) Inspect the springs and retainer for cracks and 5 – EXHAUST VALVE
possible signs of weakening. 6 – VALVE SPRING
(5) Remove the spark plug(s) adjacent to the cylin-
der(s) below the valve springs to be removed. CAUTION: Install oil seals carefully to prevent dam-
(6) Install a 14 mm (1/2 inch) (thread size) air hose age from the sharp edges of the valve spring lock
adaptor in the spark plug hole. grove.
(7) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90 (1) Lightly push the valve seal over the valve stem
psi) of air pressure in the cylinder to hold the valves and valve guide boss. Be sure the seal is completely
against their seats. For vehicles equipped with an air seated on the valve guide boss.
conditioner, use a flexible air adaptor when servicing (2) Install valve spring and retainer.
the No.1 cylinder. (3) Compress the valve spring with Valve Spring
(8) Tap the retainer or tip with a rawhide hammer Compressor Tool MD-998772A and insert the valve
to loosen the lock from the retainer. Use Valve Spring locks. Release the spring tension and remove the
Compressor Tool MD-998772A to compress the spring tool. Tap the spring from side-to-side to ensure that
and remove the locks (Fig. 54). the spring is seated properly on the engine cylinder
(9) Remove valve spring and retainer (Fig. 54). head.
(10) Remove valve stem oil seals (Fig. 54). Note (4) Release air pressure and disconnect the air
the valve seals are different for intake and exhaust hose. Remove the adaptor from the spark plug hole
valves. The top of each seal is marked either INT and install the spark plug.
(intake/black in color) or EXH (exhaust/brown in (5) Repeat the procedures for each remaining valve
color). DO NOT mix the seals. spring to be removed.
(6) Install the push rods. Ensure the bottom end of
INSTALLATION each rod is centered in the plunger cap seat of the
Inspect the valve stems, especially the grooves. An hydraulic valve tappet.
Arkansas smooth stone should be used to remove (7) Install the rocker arms, pivots and bridge at
nicks and high spots. their original location.
(8) Tighten the bridge cap screws alternately, one
at a time, to avoid damaging the bridge. Tighten the
cap screws to 28 N·m (21 ft. lbs.) torque.
9 - 38 2.5L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
(9) Install the engine cylinder head cover.
CYLINDER HEAD
This procedure can be done with the engine in or
out of the vehicle.
REMOVAL
(1) Disconnect negative cable from battery.
Fig. 56 Engine Cylinder Head Assembly CAUTION: Engine cylinder head bolts should be
1 – BRIDGE reused only once. Replace the head bolts if they
2 – PIVOT ASM. were used before or if they have a paint dab on the
3 – ROCKER ARM top of the bolt.
4 – CYLINDER HEAD
5 – HEAD GASKET (6) Coat the threads of bolt No.7, only, with Loctite
6 – PUSH ROD
PST sealant or equivalent.
(7) Install all head bolts, except No.8 and No.10.
(1) Fabricate two engine cylinder head alignment (8) Remove the dowels.
dowels from used head bolts (Fig. 57). Use the long- (9) Install No.8 and No.10 head bolts.
est head bolt. Cut the head of the bolt off below the
hex head. Then cut a slot in the top of the dowel to CAUTION: During the final tightening sequence,
allow easier removal with a screwdriver. bolt No.7 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt No.7.
(10) Tighten the engine cylinder head bolts in
sequence according to the following procedure (Fig.
59) :
(a) Tighten all bolts in sequence (1 through 10)
to 30 N·m (22 ft. lbs.) torque.
(b) Tighten all bolts in sequence (1 through 10)
to 61 N·m (45 ft. lbs.) torque.
(c) Check all bolts to verify they are set to 61
N·m (45 ft. lbs.) torque.
(d) Tighten bolts (in sequence):
• Bolts 1 through 6 to 149 N·m (110 ft. lbs.)
torque.
• Bolt 7 to 136 N·m (100 ft. lbs.) torque.
• Bolts 8 through 10 to 149 N·m (110 ft. lbs.)
Fig. 57 Fabricate Alignment Dowels torque.
1 – USED CYLINDER HEAD BOLT (e) Check all bolts in sequence to verify the cor-
2 – SLOT rect torque.
(f) If not already done, clean and mark each bolt
(2) Install one dowel in bolt hole No.10 and the with a dab of paint after tightening. Should you
other dowel in bolt hole No.8 (Fig. 58). encounter bolts which were painted in an earlier
(3) Remove the shop towels from the cylinder service operation, replace them.
bores. Coat the bores with clean engine oil. (11) Connect the coolant temperature sending unit
(4) Place the engine cylinder head gasket (with the connector.
numbers facing up) over the dowels. (12) Install the spark plugs and tighten to 37 N·m
(5) Place the engine cylinder head over the dowels. (27 ft. lbs.) torque. Connect the ignition wires.
9 - 40 2.5L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
CYLINDER HEAD
DISASSEMBLY
(1) Use Valve Spring Compressor Tool
MD-998772A and compress each valve spring.
(2) Remove the valve locks, retainers, springs and
valve stem oil seals. Discard the oil seals.
(3) Use an Arkansas smooth stone or a jewelers
Fig. 59 Engine cylinder head Bolt Tightening
file to remove any burrs on the top of the valve stem,
Sequence
especially around the groove for the locks.
(13) Install the intake and exhaust manifolds (4) Remove the valves, and place them in a rack in
(refer to Group 11, Exhaust System and Intake Man- the same order as removed.
ifold for the proper procedures).
(14) Install the fuel supply line. Push until a ASSEMBLY
“click” is heard. Reinstall latch clip. (1) Thoroughly clean the valve stems and the valve
(15) If equipped, attach the power steering pump guide bores.
and bracket. (2) Lightly lubricate the stem.
(16) Install the push rods, rocker arms, pivots and (3) Install the valve in the original valve guide
bridges in the order they were removed. bore.
(17) Install the engine cylinder head cover. (4) Install the replacement valve stem oil seals on
(18) Attach the air conditioning compressor mount- the valve stems. If the 0.381 mm (0.015 inch) over-
ing bracket to the engine cylinder head and block. size valve stems are used, oversize oil seals are
Tighten the bolts to 40 N·m (30 ft. lbs.) torque. required.
(19) Attach the air conditioning compressor to the (5) Position the valve spring and retainer on the
bracket. Tighten the bolts to 27 N·m (20 ft. lbs.) engine cylinder head and compress the valve spring
torque. with Valve Spring Compressor Tool MD-998772A.
(6) Install the valve locks and release the tool.
CAUTION: The accessory drive belt must be routed (7) Tap the valve spring from side to side with a
correctly. Incorrect routing can cause the water hammer to ensure that the spring is properly seated
pump to turn in the opposite direction causing the at the engine cylinder head. Also tap the top of the
engine to overheat. retainer to seat the valve locks.
(20) Install the accessory drive belt and correctly
tension the belt (refer to Group 7, Cooling System for
HYDRAULIC TAPPETS
the proper procedure).
(21) Install the air cleaner assembly.
REMOVAL
(22) Connect the hoses to the thermostat housing Retain all the components in the same order as
and fill the cooling system to the specified level (refer removed.
to Group 7, Cooling Systems for the proper proce- (1) Remove the engine cylinder head cover (refer to
dure). procedure earlier in this section)
(23) Install the coolant temperature sending unit (2) Remove the bridge and pivot assemblies and
connector. rocker arms by removing the capscrews at each
(24) Connect negative cable to battery. bridge. Alternately loosen each capscrew, one turn at
(25) Connect the upper radiator hose and heater a time, to avoid damaging the bridges.
hose at the thermostat housing. (3) Remove the push rods.
(26) Fill the cooling system. Check for leaks. (4) Remove the tappets through the push rod open-
ings in the cylinder head with a Hydraulic Valve
WARNING: USE EXTREME CAUTION WHEN THE Tappet Removal/Installation Tool (Fig. 60).
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
XJ 2.5L ENGINE 9 - 41
REMOVAL AND INSTALLATION (Continued)
Fig. 60 Hydraulic Valve Tappet Removal/Installation With the key in position, align the keyway on the
Tool vibration damper hub with the crankshaft key and
1 – HYDRAULIC VALVE TAPPET REMOVAL/INSTALLATION TOOL
tap the damper onto the crankshaft.
(2) Install the vibration damper retaining bolt and
INSTALLATION washer.
It is not necessary to charge the tappets with (3) Tighten the damper retaining bolt to 108 N·m
engine oil. They will charge themselves within a very (80 ft. lbs.) torque.
short period of engine operation. (4) Install the serpentine drive belt and tighten to
(1) Dip each tappet in Mopar Engine Oil Supple- the specified tension (refer to Group 7, Cooling Sys-
ment, or equivalent. tems for the proper specifications and procedures).
(2) Use Hydraulic Valve Tappet Removal/Installa- (5) Connect negative cable to battery.
tion Tool to install each tappet in the same bore from
where it was originally removed. TIMING CASE COVER OIL SEAL
(3) Install the push rods in their original locations.
(4) Install the rocker arms and bridge and pivot REMOVAL
assemblies at their original locations. Loosely install This procedure is done with the timing case cover
the capscrews at each bridge. installed.
(5) Tighten the capscrews alternately, one turn at (1) Disconnect negative cable from battery.
a time, to avoid damaging the bridges. Tighten the (2) Remove the serpentine drive belt.
capscrews to 28 N·m (21 ft. lbs.) torque. (3) Remove the vibration damper.
(6) Install the engine cylinder head cover. (4) Remove the radiator shroud.
(5) Carefully remove the oil seal. Make sure seal
VIBRATION DAMPER bore is clean.
REMOVAL INSTALLATION
(1) Disconnect negative cable from battery. (1) Position the replacement oil seal on Timing
(2) Remove the serpentine drive belt and fan Case Cover Alignment and Seal Installation Tool
shroud. 6139 with seal open end facing inward. Apply a light
(3) Remove the vibration damper retaining bolt film of Perfect Seal, or equivalent, on the outside
and washer. diameter of the seal. Lightly coat the crankshaft with
(4) Use Vibration Damper Removal Tool 7697 to engine oil.
remove the damper from the crankshaft (Fig. 61). (2) Position the tool and seal over the end of the
crankshaft and insert a draw screw tool into Seal
INSTALLATION Installation Tool 6139 (Fig. 62). Tighten the nut
(1) Apply Mopar Silicone Rubber Adhesive Sealant against the tool until it contacts the cover.
to the keyway in the crankshaft and insert the key.
9 - 42 2.5L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the fan and shroud.
(3) Remove the serpentine drive belt. Fig. 66 Camshaft and Crankshaft Sprockets and
(4) Remove the crankshaft vibration damper. Chain
(5) Remove the timing case cover. 1 – CAMSHAFT SPROCKET
(6) Rotate crankshaft until the “0” timing mark is 2 – CRANKSHAFT SPROCKET
closest to and on the center line with camshaft 3 – CHAIN
sprocket timing mark (Fig. 65).
(7) Remove the oil slinger from the crankshaft.
crankshaft, camshaft sprockets and timing chain.
(8) Remove the camshaft retaining bolt and
Ensure the timing marks on the sprockets are prop-
remove the sprockets and chain as an assembly (Fig.
erly aligned (Fig. 65).
66).
(4) Install the camshaft sprocket retaining bolt
(9) To replace the timing chain tensioner, the oil
and washer. Tighten the bolt to 108 N·m (80 ft. lbs.)
pan must be removed.
torque.
INSTALLATION (5) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
(1) Turn the tensioner lever to the unlocked (down)
sprocket timing mark as shown in (Fig. 68). Count
position (Fig. 67).
the number of chain pins between the timing marks
(2) Pull the tensioner block toward the tensioner
of both sprockets. There must be 20 pins.
lever to compress the spring. Hold the block and turn
(6) Turn the chain tensioner lever to the unlocked
the tensioner lever to the lock position (Fig. 67).
(down) position (Fig. 67).
(3) Apply Mopar Silicone Rubber Adhesive Sealant
(7) Install the oil slinger.
to the keyway in the crankshaft and insert the key.
(8) Replace the oil seal in the timing case cover.
With the key in the crankshaft keyway, install the
(9) Install the timing case cover and gasket.
9 - 44 2.5L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
CAMSHAFT
REMOVAL
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
Fig. 69 Camshaft
(10) With the key inserted in the keyway in the
1 – CAMSHAFT
crankshaft, install the vibration damper, washer and 2 – CRANKSHAFT
bolt. Lubricate and tighten the bolt to 108 N·m (80 ft.
lbs.) torque.
(11) Install the fan and shroud. INSTALLATION
(12) Connect negative cable to battery. (1) Inspect the cam lobes for wear.
XJ 2.5L ENGINE 9 - 45
REMOVAL AND INSTALLATION (Continued)
(2) Inspect the bearing journals for uneven wear
pattern or finish.
(3) Inspect the bearings for wear.
(4) Inspect the distributor drive gear for wear.
(5) If the camshaft appears to have been rubbing
against the timing case cover, examine the oil pres-
sure relief holes in the rear cam journal. The oil
pressure relief holes must be free of debris.
(6) Lubricate the camshaft with Mopar Engine Oil
Supplement, or equivalent.
(7) Carefully install the camshaft to prevent dam-
age to the camshaft bearings (Fig. 69).
(8) Turn the tensioner lever to the unlocked (down)
position (Fig. 70).
(9) Pull the tensioner block toward the tensioner
lever to compress the spring. Hold the block and turn
the tensioner lever to the lock position (Fig. 70).
(10) Install the timing chain, crankshaft sprocket Fig. 71 Timing Case Cover
and camshaft sprocket with the timing marks 1 – TIMING CASE COVER
aligned. 2 – CAMSHAFT
(11) Install the camshaft sprocket retaining bolt 3 – CRANKSHAFT
and washer. Tighten the bolt to 108 N·m (80 ft. lbs.)
torque.
(19) Position the oil pump gear. Refer to Distribu-
(12) Release the timing chain tensioner by moving
tor in the Component Removal/Installation section of
the lever to the unlock position (Fig. 70).
Group 8D, Ignition Systems.
(13) Install the timing case cover with a replace-
(20) Install the distributor and ignition wires.
ment oil seal (Fig. 71). Refer to Timing Case Cover
Refer to Distributor in the Component Removal/In-
Installation.
stallation section of Group 8D, Ignition Systems.
(14) Install the vibration damper.
(21) Install the radiator or radiator and condenser,
if equipped with A/C.
(22) Fill the cooling system.
(23) Connect negative cable to battery.
INSTALLATION
(1) Clean the camshaft pin hole.
(2) Compress the center of the replacement spring
pin with vise grips.
(3) Carefully drive the pin into the camshaft pin
hole until it is seated.
(4) Install the camshaft sprocket, crankshaft
Fig. 72 Timing Chain Alignment sprocket and timing chain with the timing marks
1 – TIMING MARKS aligned (Fig. 72).
(5) To verify correct installation of the timing
chain, turn the crankshaft to position the camshaft
(11) Remove camshaft sprocket retaining bolt.
sprocket timing mark as shown in (Fig. 74). Count
(12) Remove the crankshaft oil slinger.
the number of chain pins between the timing marks
(13) Remove the sprockets and chain as an assem-
of both sprockets. There must be 20 pins.
bly (Fig. 73).
(6) Install the crankshaft oil slinger.
CAUTION: The following procedural step must be (7) Tighten the camshaft sprocket bolt to 108 N·m
accomplished to prevent the camshaft from damag- (80 ft. lbs.) torque.
ing the rear camshaft plug during pin installation. (8) Check the valve timing.
(9) Coat both sides of the replacement timing case
(14) Inspect the damaged camshaft pin. cover gasket with gasket sealer. Apply a 3 mm (1/8
(15) If the pin is a spring-type pin, remove the bro- inch) bead of Mopar Silicone Rubber Adhesive Seal-
ken pin by inserting a self-tapping screw into the pin ant, or equivalent to the joint formed at the timing
and carefully pulling the pin from the camshaft. case cover and cylinder block.
(16) If the pin is a dowel-type pin, center-punch it. (10) Position the timing case cover on the oil pan
Ensure the exact center is located when center- gasket and the cylinder block.
punching the pin. (11) Place Timing Case Cover Alignment and Seal
Installation Tool 6139 in the crankshaft opening of
CAUTION: Cover the opened oil pan area to pre- the cover (Fig. 75).
vent metal chips from entering the pan. (12) Install the timing case cover-to-cylinder block
bolts. Install the oil pan-to-timing case cover bolts.
(17) Drill into the pin center with a 4 mm (5/32 (13) Tighten the 1/4 inch cover-to-block bolts to 7
inch) drill bit. N·m (60 in. lbs.) torque. Tighten the 5/16 inch front
(18) Insert a self-tapping screw into the drilled pin cover-to-block bolts to 22 N·m (192 in. lbs.) torque.
and carefully pull the pin from the camshaft. Tighten the oil pan-to-cover 1/4 inch bolts to 14 N·m
XJ 2.5L ENGINE 9 - 47
REMOVAL AND INSTALLATION (Continued)
(17) If equipped with air conditioning:
(a) Install the A/C compressor serpentine drive
belt idler pulley.
(b) Install the generator.
(c) Install the A/C condenser and receiver/drier
assembly.
(18) Install the serpentine drive belt on the pulleys
and tighten (refer to Group 7, Cooling System for the
specifications and procedures).
(19) Install the radiator. Connect the radiator
hoses and automatic transmission fluid cooler pipes,
if equipped. Fill the cooling system.
(20) Install the fan and shroud.
(21) Connect negative cable to battery.
CAMSHAFT BEARINGS
The camshaft rotates within four steel-shelled,
babbitt-lined bearings that are pressed into the cyl-
inder block and then line reamed. The camshaft
bearing bores and bearing diameters are not the
same size. They are stepped down in 0.254 mm
(0.010 inch) increments from the front bearing (larg-
Fig. 74 Verify Crankshaft—Camshaft Installation est) to the rear bearing (smallest). This permits eas-
1 – CAMSHAFT SPROCKET
ier removal and installation of the camshaft. The
2 – 20 PINS
camshaft bearings are pressure lubricated.
3 – CRANKSHAFT SPROCKET
4 – TIMING MARKS
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available, such as recom-
mended tool 8544 Camshaft Bushing Remover
Installer.
Fig. 76 Removing Main Bearing Caps and Lower Fig. 77 Removing Upper Inserts
Inserts 1 – COTTER PIN
1 – CONNECTING ROD JOURNAL 2 – FABRICATED TOOL
2 – MAIN BEARING CAPS 3 – BEARING INSERT
4 – TONGUE DEPRESSOR
INSTALLATION
(1) Lubricate the bearing surface of each insert
with engine oil.
(2) Loosen all the main bearing caps. Install the
main bearing upper inserts.
(3) Install the lower bearing inserts into the main
bearing caps.
(4) Install the main bearing cap(s) and lower
insert(s).
(5) Clean the rear main bearing cap (No.5) mating
surfaces.
(6) Apply Mopart Gasket Maker, or equivalent on
the rear bearing cap (Fig. 78). The bead should be 3
mm (0.125 in) thick. DO NOT apply Mopart Gasket
Maker, or equivalent to the lip of the seal.
(7) Install the rear main bearing cap. DO NOT Fig. 78 Location of MoparT Gasket Maker
strike the cap more than twice for proper engage- 1 – MOPART GASKET MAKER (OR EQUIVALENT)
ment. 2 – 19 mm (.75 IN)
(8) Tighten the bolts of caps 1, 3, 4 and 5 to 54 3 – 6 mm (0.025 IN)
N·m (40 ft. lbs.) torque. Now tighten these bolts to 95
N·m (70 ft. lbs.) torque. Finally, tighten these bolts to
108 N·m (80 ft. lbs.) torque.
XJ 2.5L ENGINE 9 - 49
REMOVAL AND INSTALLATION (Continued)
(9) Push the crankshaft forward and backward. (14) Install the drain plug. Tighten the plug to 34
Load the crankshaft front or rear and tighten cap N·m (25 ft. lbs.) torque.
bolt No.2 to 54 N·m (40 ft. lbs.) torque. Then tighten (15) Install new rearmain seal. Refer to Rear Main
to 95 N·m (70 ft. lbs.) torque and finally tighten to Seal in this section.
108 N·m (80 ft. lbs.) torque. (16) Lower the vehicle.
(10) Rotate the crankshaft after tightening each (17) Install the spark plugs. Tighten the plugs to
main bearing cap to ensure the crankshaft rotates 37 N·m (27 ft. lbs.) torque.
freely. (18) Fill the oil pan with engine oil to the safe
(11) Check crankshaft end play. Crankshaft end mark on the dipstick level.
play is controlled by the thrust bearing which is (19) Connect negative cable to battery.
flange and installed at the No.2 main bearing posi-
tion. OIL PAN
(a) Attach a magnetic base dial indicator to the
cylinder block at either the front or rear of the REMOVAL
engine. (1) Disconnect negative cable from battery.
(b) Position the dial indicator rod so that it is (2) Raise the vehicle.
parallel to the center line of the crankshaft. (3) Remove the oil pan drain plug and drain the
(c) Pry the crankshaft forward, position the dial engine oil.
indicator to zero. (4) Disconnect the exhaust pipe at the engine
(d) Pry the crankshaft forward and backward. exhaust manifold.
Note the dial indicator readings. End play is the (5) Disconnect the exhaust hanger at the catalytic
difference between the high and low measurements converter and lower the pipe.
(Fig. 79). Correct end play is 0.038-0.165 mm (6) Remove the engine starter motor.
(0.0015-0.0065 inch). The desired specifications are (7) Remove the flywheel/torque converter housing
0.051-0.064 mm (0.002-0.0025 inch). access cover.
(e) If end play is not within specification, inspect (8) Position a jack stand directly under the engine
crankshaft thrust faces for wear. If no wear is vibration damper.
apparent, replace the thrust bearing and measure (9) Place a piece of wood (2 x 2) between the jack
end play. If end play is still not within specifica- stand and the engine vibration damper.
tion, replace the crankshaft. (10) Remove the engine mount through bolts.
(11) Using the jack stand, raise the engine until
adequate clearance is obtained to remove the oil pan.
(12) If equipped, disconnect the transmission
cooler lines and oxygen sensor harness from oil pan
mounting studs.
(13) Remove the oil pan bolts and studs. Carefully
remove the oil pan and gasket.
INSTALLATION
(1) Clean the block and pan gasket surfaces.
(2) Fabricate 4 alignment dowels from 1/4 x 1 1/2
inch bolts. Cut the head off the bolts and cut a slot
into the top of the dowel. This will allow easier
installation and removal with a screwdriver (Fig. 80).
(3) Install two dowels in the timing case cover.
Install the other two dowels in the cylinder block
(Fig. 81).
Fig. 79 Crankshaft End Play Measurement (4) Apply Mopart Silicone Adhesive Sealant onto
1 – DIAL INDICATOR the cylinder block in four location as shown (Fig. 82)
2 – CRANKSHAFT (5) Slide the one-piece gasket over the dowels and
onto the block and timing case cover.
(12) If the crankshaft was removed, install the (6) Position the oil pan over the dowels and onto
crankshaft into the cylinder block (refer to Cylinder the gasket.
Block - Assemble). (7) Install the 1/4 inch oil pan bolts. Tighten these
(13) Install the oil pan. bolts to 9.5 N·m (84 in. lbs.) torque. Install the 5/16
9 - 50 2.5L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
ASSEMBLY
(1) Install the crankshaft.
(2) Install the connecting rods and the pistons
through the top of the cylinder bores.
Fig. 88 Replacement of Rear Crankshaft Oil Seal (3) Install the front and rear oil galley plugs.
1 – CRANKSHAFT
(4) Install the timing chain tensioner.
2 – CRANKSHAFT OIL SEAL (5) Install the camshaft.
(6) Install the sprockets and chain as an assembly.
(7) Install the oil slinger to the crankshaft.
INSTALLATION (8) Install the timing chain bumper.
(1) Wipe the seal surface area of the crankshaft (9) Install the timing case cover seal.
until it is clean. (10) Install the timing case cover.
(2) Coat the outer lip of the replacement rear main (11) Install the oil pan gasket and oil pan.
bearing seal with engine oil. (12) Install the vibration damper.
(3) Carefully position the seal into place. Use rear (13) Install the water pump. Tighten the mounting
main Seal Installer Tool 6271A to install the seal bolts to 31 N·m (270 in. lbs.) torque.
flush with the cylinder block. (14) Remove the distributor from the cylinder
block.
CAUTION: The felt lip must be located inside the (15) Lubricate the oil filter seal with clean engine
flywheel mounting surface. If the lip is not posi- oil. Tighten oil filter to 18 N·m (13 ft. lbs.) torque.
tioned correctly the flywheel could tear the seal. (16) Install the engine into the vehicle.
(17) Fill the engine with clean lubrication oil.
(4) Install the flywheel or converter drive plate.
(18) Fill the cooling system.
New bolts MUST be used when installing the fly-
wheel or converter plate. Tighten the new bolts to 68
N·m (50 ft. lbs.) torque. Turn the bolts an additional CLEANING AND INSPECTION
60°.
ROCKER ARMS AND PUSH RODS
DISASSEMBLY AND ASSEMBLY CLEANING
Clean all the components with cleaning solvent.
CYLINDER BLOCK Use compressed air to blow out the oil passages in
the rocker arms and push rods.
DISASSEMBLY
(1) Drain the engine oil. Remove and discard the INSPECTION
oil filter.
Inspect the pivot surface area of each rocker arm.
(2) Remove the water pump from the cylinder
Replace any that are scuffed, pitted, cracked or
block.
excessively worn.
(3) Remove the distributor from the cylinder block.
9 - 54 2.5L ENGINE XJ
CLEANING AND INSPECTION (Continued)
Inspect the valve stem tip contact surface of each rocker
arm and replace any rocker arm that is deeply pitted.
Inspect each push rod end for excessive wear and
replace as required. If any push rod is excessively
worn because of lack of oil, replace it and inspect the
corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
them on a flat surface or by shining a light between
the push rod and the flat surface.
A wear pattern along the length of the push rod is
not normal. Inspect the engine cylinder head for
obstruction if this condition exists.
INSPECTION
Use a straightedge and feeler gauge to check the
flatness of the engine cylinder head and block mating
surfaces.
CYLINDER BLOCK
CLEANING
Thoroughly clean the oil pan and engine block gas-
ket surfaces.
Fig. 90 Front Oil Galley Hole
Use compressed air to clean out:
1 – FRONT OIL GALLEY HOLE
• The galley at the oil filter adaptor hole, the filter
bypass hole (Fig. 89).
• The front and rear oil galley holes (Fig. 90) (Fig.
91).
• The feed holes for the crankshaft main bearings.
Once the block has been completely cleaned, apply
Mopart Thread Sealant with Teflon to the threads of
the front and rear oil galley plugs. Tighten the plugs
to 41 N·m (30 ft. lbs.) torque.
INSPECTION
Inspect the cylinder bores for signs of scorring, pit-
ting or cracks. If the cylinder bores are scorred or
pitted the cylinder bores will require boreing or hon-
ing to clean them up. Refer to Honing Cylinder Bores
in this Section. If the cylinder bore(s) are cracked the
cylinder block must be replaced.
Fig. 91 Rear Oil Galley Hole
Inspect the cylinder block to cylinder head mating
1 – REAR OIL GALLEY HOLE
surface for flatness and/or pitting.
XJ 2.5L ENGINE 9 - 55
Inside Diameter (Top) 21.0 mm to 21.51 mm Deck Height 236.73 mm (9.320 in.)
(0.827 to 0.847 in.)
Deck Clearance 0.000 mm (0.000 in.)
Installed Height 41.656 mm (1.640 in.)
Cylinder Bore Diameter—
CRANKSHAFT Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
End Play 0.038 to 0.165 mm
(0.0015 to 0.0065 in.) Cylinder Bore Diameter—
Taper (Max) 0.025 mm
Main Bearing Journal 63.489 to 63.502 mm
Diameter (0.001 in.)
(2.4996 to 2.5001 in.) Out of Round (Max) 0.025 mm
(0.001 in.)
Flatness Max 0.20 mm for total length Valve Seat Runout 0.064 mm
(0.008 in. for total length) (0.0025 in.)
Piston Pin Bore Diameter 23.59 to 23.62 mm Push Rod Length (Blue) 241.300 to 241.808 mm
(0.9288 to 0.9298 in.) (9.500 to 9.520 in.)
Bore (Less Bearings) 56.08 to 56.09 mm Push Rod Diameter 7.92 to 8.00 mm
(2.2080 to 2.2085 in.) (0.312 to 0.315 in.)
Oil Control Ring 89.66 to 89.92 mm OIL PUMP AND OIL PRESSURE
(3.53 to 3.54 in.)
Gear to Body Clearance
Piston Pin Bore Diameter 23.650 to 23.658 mm (Radial) 0.051 to 0.102 mm
(0.9312 to 0.9315 in.) (0.002 to 0.004 in.)
Piston Pin Diameter 23.637 to 23.640 mm (Radial Preferred) 0.051 mm
(0.9306 to 0.9307 in.) (0.002 in.)
SPECIAL TOOLS
2.5L ENGINE SPECIAL TOOLS
4.0L ENGINE
TABLE OF CONTENTS
page page
LUBRICATION SYSTEM
DESCRIPTION
A gear—type positive displacement pump is
mounted at the underside of the block opposite the
No. 4 main bearing.
OPERATION
The pump draws oil through the screen and inlet
tube from the sump at the rear of the oil pan. The oil
Fig. 1 Engine Firing Order is driven between the drive and idler gears and
The crankshaft rotation is clockwise, when viewed pump body, then forced through the outlet to the
from the front of the engine. The crankshaft rotates block. An oil gallery in the block channels the oil to
within seven main bearings. The camshaft rotates the inlet side of the full flow oil filter. After passing
within four bearings. through the filter element, the oil passes from the
BUILD DATE CODE center outlet of the filter through an oil gallery that
The engine Build Date Code is located on a channels the oil up to the main gallery which
machined surface on the right side of the cylinder extends the entire length of the block.
block between the No.2 and No.3 cylinders (Fig. 2). Galleries extend downward from the main oil gal-
The digits of the code identify: lery to the upper shell of each main bearing. The
• 1st Digit—The year (8 = 1998). crankshaft is drilled internally to pass oil from the
• 2nd & 3rd Digits—The month (01 - 12). main bearing journals (except number 4 main bear-
• 4th & 5th Digits—The engine type/fuel system/ ing journal) to the connecting rod journals. Each con-
compression ratio (MX = A 4.0 Liter (242 CID) 8.7:1 necting rod bearing cap has a small squirt hole, oil
compression ratio engine with a multi-point fuel passes through the squirt hole and is thrown off as
injection system). the rod rotates. This oil throwoff lubricates the cam-
• 6th & 7th Digits—The day of engine build (01 - shaft lobes, distributor drive gear, cylinder walls, and
31). piston pins.
(1) FOR EXAMPLE: Code * 801MX12 * identi- The hydraulic valve tappets receive oil directly
fies a 4.0 Liter (242 CID) engine with a multi-point from the main oil gallery. Oil is provided to the cam-
fuel injection system, 8.7:1 compression ratio and shaft bearing through galleries. The front camshaft
built on January 12, 1998. bearing journal passes oil through the camshaft
XJ 4.0L ENGINE 9 - 63
DESCRIPTION AND OPERATION (Continued)
sprocket to the timing chain. Oil drains back to the hole in the corresponding rocker arm. Oil from the
oil pan under the number one main bearing cap. rocker arm lubricates the valve train components,
The oil supply for the rocker arms and bridged then passes down through the push rod guide holes
pivot assemblies is provided by the hydraulic valve in the cylinder head past the valve tappet area, and
tappets which pass oil through hollow push rods to a returns to the oil pan.
9 - 64 4.0L ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
CYLINDER BLOCK
DESCRIPTION
The cylinder block is a cast iron inline six cylinder
design. The cylinder block is drilled forming galleries
for both oil and coolant (Fig. 3).
CRANKSHAFT
DESCRIPTION
The crankshaft is constructed of nodular cast iron.
The crankshaft is a crosshaped four throw design
Fig. 3 4.0L Cylinder Block with Main Bearing Caps with eight counterweights for balancing purposes.
and Cap Brace The crankshaft is supported by seven select main
1 – BLOCK bearings with the number three serving as the thrust
2 – MAIN BEARING CAP BRACE washer location. The main journals of the crankshaft
are cross drilled to improve rod bearing lubrication.
The select fit main bearing markings are located on
CYLINDER HEAD the crankshaft counter weights. The crankshaft rear
oil seal is a two piece design. The front oil seal is a
DESCRIPTION one piece design retained in the timing chain cover
The cylinder head is made of cast iron containing (Fig. 5).
twelve valves made of chrome plated heat resistant
steel, valve stem seals, springs, retainers and keep-
ers. The cylinder head and valve seats can be resur-
faced for service purposes.
The valve guides are integral to the cylinder head,
They are not replaceable. However, they are service-
able.
The cylinder head uses dual quench-type design
combustion chambers which cause turbulence in the
cylinders allowing faster burning of the air/fuel mix-
ture, resulting in better fuel economy (Fig. 4).
Fig. 7 Camshaft—Typical
1 – CAMSHAFT
2 – LOBES
3 – BEARING JOURNAL
ROCKER ARM
DESCRIPTION
The rocker arms are made of stamped steel and
have a operational ratio of 1.6:1. When the push rods
are forced upward by the camshaft lobes the push
rod presses upward on the rocker arms, the rocker
arms pivot, forcing downward pressure on the valves
forcing the valves to move downward and off from
their seats (Fig. 8). Fig. 8 Rocker Arms 4.0L Engine
1 – CAPSCREWS
2 – BRIDGE
3 – PIVOT ASSEMBLY
4 – PUSH RODS
5 – ROCKER ARMS
XJ 4.0L ENGINE 9 - 67
DESCRIPTION AND OPERATION (Continued)
VALVES
DESCRIPTION
The valves are made of heat resistant steel and
have chrome plated stems to prevent scuffing. All
valves use three bead locks to promote valve rotation
(Fig. 9).
VALVE GUIDE
DESCRIPTION
The valve guides are integral to the cylinder head,
They are not replaceable. However, they are service-
Fig. 9 Valve and Keeper Configuration 4.0L Engine able.
1 – VALVE LOCKS (3–BEAD)
2 – RETAINER OIL PAN
3 – VALVE STEM OIL SEAL
4 – INTAKE VALVE
5 – EXHAUST VALVE
DESCRIPTION
6 – VALVE SPRING The oil pan is made of stamped steel. The oil pan
gasket is a one piece steel backbone silicone coated
gasket.
VALVE SPRING
VALVE STEM SEAL
DESCRIPTION
The valve springs are made of high strength silicon DESCRIPTION
chrome spring steel. The springs are common for The valve stem seals are made of rubber and incor-
both intake and exhaust valves. (Fig. 9). porate a garter spring to maintain consistent lubrica-
tion control (Fig. 9).
CYLINDER HEAD COVER
INTAKE MANIFOLD
DESCRIPTION
The cylinder head cover (Fig. 10) is made of DESCRIPTION
stamped steel and incorporates the Crankcase Venti- The intake manifold is made of cast aluminum and
lation (CCV) Hoses and the oil fill opening. uses eleven bolts to mount to the cylinder head. This
mounting style improves sealing and reduces the
chance of leaks.
9 - 68 4.0L ENGINE XJ
DESCRIPTION AND OPERATION (Continued)
exhaust manifolds share a common gasket with the
intake manifold. The exhaust manifolds also incorpo-
rate ball flange outlets for improved sealing and
strain free connections.
SERVICE DIAGNOSIS—PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to
Group 8A, Battery, for correct
procedures. Check charging system.
Refer to Group 8C, Charging
Systems, for correct procedures.
ENGINE CRANKS BUT WILL NOT 1. No spark 1. Check for spark. Refer to Group
START 8D, Ignition System, for correct
procedures.
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to group 8D, Ignition System
3. Worn or incorrect gapped spark 3. Clean plugs and set gap. (Refer
plugs to group 8D, Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust 10. Install new parts as necessary
system
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
9 - 70 4.0L ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to Group 14 for
correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap
plugs spark plugs (Refer to group 8D,
Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or 5. Check for correct firing order or
crossed replace spark plug cables. (Refer to
Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary
(Refer to group 8D, Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary (Refer to Group 11,
Exhaust System & Intake Manifold)
8. EGR valve leaking or stuck open 8. Test and replace, if necessary
(Refer to group 25, Emission
Control Systems)
ENGINE MISSES ON 1. Worn or incorrectly gapped spark 1. Replace spark plugs or clean and
ACCELERATION plugs set gap. (Refer to group 8D, Ignition
System)
2. Spark plug cables defective or 2. Check Idle Air Control circuit.
crossed (Refer to Group 14, Fuel 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
(refer to group 8D, Ignition System)
SERVICE DIAGNOSIS—MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil
Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
XJ 4.0L ENGINE 9 - 71
DIAGNOSIS AND TESTING (Continued)
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive connecting rod Measure bearings for correct
bearing clearance clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of 5. Replace crankshaft or grind
round journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
2. Low oil pressure 2. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive main bearing 4. Measure bearings for correct
clearance clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of 6. Grind journals or replace
round or worn crankshaft
7. Loose flywheel or torque 7. Inspect crankshaft, flexplate/
converter flywheel and bolts for damage.
Tighten to correct torque
9 - 72 4.0L ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
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
5. Thin or diluted oil 5. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose, 8. Inspect suction tube and clean or
broken, bent or clogged replace if necessary
9. Oil pump cover warped or 9. Install new oil pump
cracked
EXCESSIVE OIL CONSUMPTION 1. PCV System malfunction 1. Refer to group 25, Emission
OR SPARK PLUGS OIL FOULED Control System for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in 7. Remove rings and check ring end
grooves gap and side clearance. Replace if
necessary
INTAKE MANIFOLD LEAKAGE DIAGNOSIS WARNING: USE EXTREME CAUTION WHEN THE
An intake manifold air leak is characterized by ENGINE IS OPERATING. DO NOT STAND IN A
lower than normal manifold vacuum. Also, one or DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
more cylinders may not be functioning. HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
XJ 4.0L ENGINE 9 - 73
DIAGNOSIS AND TESTING (Continued)
(1) Start the engine. CYLINDER-TO-WATER JACKET LEAKAGE TEST
(2) Spray a small stream of water at the suspected
leak area. WARNING: USE EXTREME CAUTION WHEN THE
(3) If a change in RPM is observed the area of the ENGINE IS OPERATING. DO NOT STAND IN A
suspected leak has been found. DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
(4) Repair as required. HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
CYLINDER COMPRESSION PRESSURE TEST
The results of a cylinder compression pressure test Remove the radiator cap.
can be utilized to diagnose several engine malfunc- Start the engine and allow it to warm up until the
tions. engine thermostat opens.
Ensure the battery is completely charged and the If a large combustion/compression pressure leak
engine starter motor is in good operating condition. exists, bubbles will be visible in the coolant.
Otherwise the indicated compression pressures may If bubbles are not visible, install a radiator pres-
not be valid for diagnosis purposes. sure tester and pressurize the coolant system.
(1) Clean the spark plug recesses with compressed If a cylinder is leaking combustion pressure into
air. the water jacket, the tester pointer will pulsate with
(2) Remove the spark plugs. every combustion stroke of the cylinder.
(3) Secure the throttle in the wide-open position.
(4) Disable the fuel system. (Refer to Group 14, CYLINDER COMBUSTION PRESSURE LEAKAGE
Fuel System for the correct procedure) TEST
(5) Disconnect the ignition coil. The combustion pressure leakage test provides an
(6) Insert a compression pressure gauge and rotate accurate means for determining engine condition.
the engine with the engine starter motor for three Combustion pressure leakage testing will detect:
revolutions. • Exhaust and intake valve leaks (improper seat-
(7) Record the compression pressure on the 3rd ing).
revolution. Continue the test for the remaining cylin- • Leaks between adjacent cylinders or into water
ders. jacket.
Refer to Engine Specifications for the correct • Any causes for combustion/compression pressure
engine compression pressures. loss.
(1) Check the coolant level and fill as required. DO
ENGINE CYLINDER HEAD GASKET FAILURE NOT install the radiator cap.
DIAGNOSIS (2) Start and operate the engine until it attains
A leaking engine cylinder head gasket usually normal operating temperature, then turn the engine
results in loss of power, loss of coolant and engine OFF.
misfiring. (3) Remove the spark plugs.
An engine cylinder head gasket leak can be located (4) Remove the oil filler cap.
between adjacent cylinders or between a cylinder and (5) Remove the air cleaner.
the adjacent water jacket. (6) Calibrate the tester according to the manufac-
• An engine cylinder head gasket leaking between turer’s instructions. The shop air source for testing
adjacent cylinders is indicated by a loss of power should maintain 483 kPa (70 psi) minimum, 1,379
and/or engine misfire. kPa (200 psi) maximum and 552 kPa (80 psi) recom-
• An engine cylinder head gasket leaking between mended.
a cylinder and an adjacent water jacket is indicated (7) Perform the test procedures on each cylinder
by coolant foaming or overheating and loss of coolant. according to the tester manufacturer’s instructions.
While testing, listen for pressurized air escaping
CYLINDER-TO-CYLINDER LEAKAGE TEST through the throttle body, tailpipe and oil filler cap
To determine if an engine cylinder head gasket is opening. Check for bubbles in the radiator coolant.
leaking between adjacent cylinders; follow the proce- All gauge pressure indications should be equal,
dures outlined in Cylinder Compression Pressure with no more than 25% leakage.
Test. An engine cylinder head gasket leaking between FOR EXAMPLE: At 552 kPa (80 psi) input pres-
adjacent cylinders will result in approximately a sure, a minimum of 414 kPa (60 psi) should be main-
50-70% reduction in compression pressure. tained in the cylinder.
Refer to the Cylinder Combustion Pressure Leak-
age Test Diagnosis chart.
9 - 74 4.0L ENGINE XJ
DIAGNOSIS AND TESTING (Continued)
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
ENGINE OIL LEAK INSPECTION (4) Gradually apply air pressure from 1 psi to 2.5
Begin with a thorough visual inspection of the psi maximum while applying soapy water at the sus-
engine, particularly at the area of the suspected leak. pected source. Adjust the regulator to the suitable
If an oil leak source is not readily identifiable, the test pressure that provide the best bubbles which
following steps should be followed: will pinpoint the leak source. If the oil leak is
(1) Do not clean or degrease the engine at this detected and identified, repair per service manual
time because some solvents may cause rubber to procedures.
swell, temporarily stopping the leak. (5) If the leakage occurs at the rear oil seal area,
(2) Add an oil soluble dye (use as recommended by refer to the section, Inspection for Rear Seal Area
manufacturer). Start the engine and let idle for Leak.
approximately 15 minutes. Check the oil dipstick to (6) If no leaks are detected, turn off the air supply
make sure the dye is thoroughly mixed as indicated and remove the air hose and all plugs and caps.
with a bright yellow color under a black light. Install the PCV valve and breather cap hose.
(3) Using a black light, inspect the entire engine (7) Clean the oil off the suspect oil leak area using
for fluorescent dye, particularly at the suspected area a suitable solvent. Drive the vehicle at various
of oil leak. If the oil leak is found and identified, speeds approximately 24 km (15 miles). Inspect the
repair per service manual instructions. engine for signs of an oil leak by using a black light.
(4) If dye is not observed, drive the vehicle at var-
ious speeds for approximately 24km (15 miles), and INSPECTION FOR REAR SEAL AREA LEAKS
repeat inspection. Since it is sometimes difficult to determine the
(4) If the oil leak source is not positively source of an oil leak in the rear seal area of the
identified at this time, proceed with the air leak engine, a more involved inspection is necessary. The
detection test method. following steps should be followed to help pinpoint
the source of the leak.
Air Leak Detection Test Method If the leakage occurs at the crankshaft rear oil seal
(1) Disconnect the breather cap to air cleaner hose area:
at the breather cap end. Cap or plug breather cap (1) Disconnect the battery.
nipple. (2) Raise the vehicle.
(2) Remove the PCV valve from the cylinder head (3) Remove torque converter or clutch housing
cover. Cap or plug the PCV valve grommet. cover and inspect rear of block for evidence of oil.
(3) Attach an air hose with pressure gauge and Use a black light to check for the oil leak:
regulator to the dipstick tube. (a) Circular spray pattern generally indicates
seal leakage or crankshaft damage.
CAUTION: Do not subject the engine assembly to (b) Where leakage tends to run straight down,
more than 20.6 kpa (3 PSI) of test pressure. possible causes are a porous block, distributor seal,
camshaft bore cup plugs oil galley pipe plugs, oil
XJ 4.0L ENGINE 9 - 75
DIAGNOSIS AND TESTING (Continued)
filter runoff, and main bearing cap to cylinder The timing notch index on the vibration damper
block mating surfaces. should be aligned with the TDC mark on the timing
(4) If no leaks are detected, pressurize the crank- degree scale.
case as outlined in the, Inspection (Engine oil Leaks If the timing notch is more than 13 mm (1/2 inch)
in general) away from the TDC mark in either direction, the
valve timing is incorrect.
CAUTION: Do not exceed 20.6 kPa (3 psi). If the valve timing is incorrect, the cause may be a
broken camshaft pin. It is not necessary to replace
(5) If the leak is not detected, very slowly turn the the camshaft because of pin failure. A spring pin is
crankshaft and watch for leakage. If a leak is available for service replacement.
detected between the crankshaft and seal while
slowly turning the crankshaft, it is possible the VALVE SERVICE
crankshaft seal surface is damaged. The seal area on
Clean all carbon deposits from the combustion
the crankshaft could have minor nicks or scratches
chambers, valve ports, valve stems, valve stem
that can be polished out with emery cloth. guides and head.
Clean all grime and gasket material from the
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and engine cylinder head machined gasket surface.
scratches. The crankshaft seal flange is especially Inspect for cracks in the combustion chambers and
valve ports.
machined to complement the function of the rear oil
seal. Inspect for cracks on the exhaust seat.
Inspect for cracks in the gasket surface at each
(6) For bubbles that remain steady with shaft coolant passage.
rotation, no further inspection can be done until dis- Inspect valves for burned, cracked or warped
assembled. heads.
Inspect for scuffed or bent valve stems.
ENGINE OIL PRESSURE Replace valves displaying any damage.
(1) Disconnect connector and remove oil pressure
sending unit. VALVE REFACING
(2) Install Oil Pressure Line and Gauge Tool (1) Use a valve refacing machine to reface the
C-3292 or equivalent. Start engine and record pres- intake and exhaust valves to the specified angle.
sure. Refer to Oil Pressure in Engine Specifications (2) After refacing, a margin of at least 0.787 mm
for the correct pressures. (0.031 inch) must remain (Fig. 14). If the margin is
less than 0.787 mm (0.031 inch), the valve must be
replaced.
SERVICE PROCEDURES
VALVE TIMING
Disconnect the spark plug wires and remove the
spark plugs.
Remove the engine cylinder head cover.
Remove the capscrews, bridge and pivot assembly,
and rocker arms from above the No.1 cylinder.
Alternately loosen each capscrew, one turn at a
time, to avoid damaging the bridge.
Rotate the crankshaft until the No.6 piston is at
top dead center (TDC) on the compression stroke.
Rotate the crankshaft counterclockwise (viewed
from the front of the engine) 90°.
Install a dial indicator on the end of the No.1 cyl-
inder intake valve push rod. Use rubber tubing to
secure the indicator stem on the push rod.
Set the dial indicator pointer at zero. Fig. 14 Valve Facing Margin
Rotate the crankshaft clockwise (viewed from the 1 – VALVE MARGIN
front of the engine) until the dial indicator pointer 2 – NO MARGIN
indicates 0.305 mm (0.012 inch) travel distance (lift).
9 - 76 4.0L ENGINE XJ
SERVICE PROCEDURES (Continued)
VALVE SEAT REFACING VALVE STEM-TO-GUIDE CLEARANCE
(1) Install a pilot of the correct size in the valve MEASUREMENT
guide bore. Reface the valve seat to the specified Valve stem-to-guide clearance may be measured by
angle with a good dressing stone. Remove only either of the following two methods.
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat PREFERRED METHOD
width when required. (1) Remove the valve from the head.
(3) Control valve seat runout to a maximum of (2) Clean the valve stem guide bore with solvent
0.0635 mm (0.0025 in.) (Fig. 15). and a bristle brush.
(3) Insert a telescoping gauge into the valve stem
guide bore approximately 9.525 mm (.375 inch) from
the valve spring side of the head (Fig. 16).
CONNECTING RODS
Misaligned or bent connecting rods can cause
abnormal wear on pistons, piston rings, cylinder
walls, connecting rod bearings and crankshaft con-
Fig. 27 Compression Ring Installation
necting rod journals. If wear patterns or damage to
1 – COMPRESSION RING
2 – RING EXPANDER RECOMMENDED
any of these components indicate the probability of a
misaligned connecting rod, inspect it for correct rod
XJ 4.0L ENGINE 9 - 81
SERVICE PROCEDURES (Continued)
alignment. Replace misaligned, bent or twisted con-
necting rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wipe the oil from the connecting rod journal.
(2) Use short rubber hose sections over rod bolts
during installation.
(3) Lubricate the upper bearing insert and install
in connecting rod.
(4) Use piston ring compressor to install the rod
and piston assemblies. The oil squirt holes in the
rods must face the camshaft. The arrow on the piston
crown should point to the front of the engine (Fig.
32). 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) FOR EXAMPLE: If the initial clearance was (13) Once you have selected the proper insert,
0.0762 mm (0.003 inch), 0.025 mm (0.001 inch) install the insert and cap. Tighten the connecting rod
undersize inserts would reduce the clearance by bolts to 45 N·m (33 ft. lbs.) torque.
0.025 mm (0.001 inch). The clearance would be 0.002
inch and within specification. A 0.051 mm (0.002 SIDE CLEARANCE MEASUREMENT
inch) undersize insert would reduce the initial clear- Slide snug-fitting feeler gauge between the con-
ance an additional 0.013 mm (0.0005 inch). The necting rod and crankshaft journal flange (Fig. 34).
clearance would then be 0.038 mm (0.0015 inch). Refer to Engine Specifications for the proper clear-
(12) Repeat the Plastigage measurement to verify ance. Replace the connecting rod if the side clearance
your bearing selection prior to final assembly. is not within specification.
XJ 4.0L ENGINE 9 - 83
SERVICE PROCEDURES (Continued)
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The main bearing caps, numbered (front to rear)
from 1 through 7 have an arrow to indicate the for-
ward position. The upper main bearing inserts are
grooved to provide oil channels while the lower
inserts are smooth.
Each bearing insert pair is selectively fitted to its
respective journal to obtain the specified operating
clearance. In production, the select fit is obtained by
using various-sized color-coded bearing insert pairs
as listed in the Main Bearing Fitting Chart. The
bearing color code appears on the edge of the insert.
The size is not stamped on bearing inserts used
for engine production.
The main bearing journal size (diameter) is identi-
fied by a color-coded paint mark (Fig. 36) on the
Fig. 34 Checking Connecting Rod Side Clearance— adjacent cheek or counterweight towards the rear of
Typical the crankshaft (flange end). The rear main journal, is
FITTING CRANKSHAFT MAIN BEARINGS identified by a color-coded paint mark on the crank-
shaft rear flange.
When required, upper and lower bearing inserts of
INSPECTION
different sizes may be used as a pair. A standard size
Wipe the inserts clean and inspect for abnormal
insert is sometimes used in combination with a 0.025
wear patterns and for metal or other foreign material
mm (0.001 inch) undersize insert to reduce the clear-
imbedded in the lining. Normal main bearing insert
ance by 0.013 mm (0.0005 inch). Never use a pair
wear patterns are illustrated (Fig. 35). In general the
of bearing inserts with greater than a 0.025 mm
lower bearing half will have a heaver wear pattern.
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.
BEARING INSERT PAIRS CHART Plastigage should indicate the same clearance
across the entire width of the insert. If clearance var-
INSERT CORRECT INCORRECT ies, it may indicate a tapered journal or foreign
material trapped behind the insert.
UPPER STANDARD STANDARD If the specified clearance is indicated and there are
LOWER 0.025 mm 0.051 mm no abnormal wear patterns, replacement of the bear-
(0.001 in.) (0.002 in.) ing inserts is not necessary. Remove the Plastigage
UNDERSIZE UNDERSIZE from the crankshaft journal and bearing insert. Pro-
ceed to Crankshaft Main Bearing—Installation.
(Fig. 37). Refer to Engine Specifications for the If the clearance exceeds specification, install a pair
proper clearance. of 0.025 mm (0.001 inch) undersize bearing inserts
and measure the clearance as described in the previ-
ous steps.
The clearance indicate with the 0.025 mm (0.001
inch) undersize insert pair installed will determine if
this insert size or some other combination will pro-
vide the specified clearance. FOR EXAMPLE: If the
clearance was 0.0762 mm (0.003 inch) originally, a
pair of 0.0254 mm (0.001 inch) undersize inserts
would reduce the clearance by 0.0254 mm (0.001
inch). The clearance would then be 0.0508 mm (0.002
inch) and within the specification. A 0.051 mm (0.002
inch) undersize bearing insert and a 0.0254 mm
(0.001 inch) undersize insert would reduce the origi-
nal clearance an additional 0.0127 mm (0.0005 inch).
The clearance would then be 0.0381 mm (0.0015
inch).
Fig. 37 Measuring Bearing Clearance with CAUTION: Never use a pair of inserts that differ
Plastigage more than one bearing size as a pair.
1 – PLASTIGAGE SCALE
2 – COMPRESSED PLASTIGAGE FOR EXAMPLE: DO NOT use a standard size
upper insert and a 0.051 mm (0.002 inch) undersize
lower insert.
XJ 4.0L ENGINE 9 - 85
SERVICE PROCEDURES (Continued)
If the clearance exceeds specification using a pair MAIN BEARING JOURNAL DIAMETER
of 0.051 mm (0.002 inch) undersize bearing inserts, (CRANKSHAFT REMOVED)
measure crankshaft journal diameter with a Remove the crankshaft from the cylinder block
micrometer. If the journal diameter is correct, the (refer to Cylinder Block - Disassemble).
crankshaft bore in the cylinder block may be mis- Clean the oil off the main bearing journal.
aligned, which requires cylinder block replacement or Determine the maximum diameter of the journal
machining to true bore. with a micrometer. Measure at two locations 90°
Replace the crankshaft or grind to accept the apart at each end of the journal.
appropriate undersize bearing inserts if: The maximum allowable taper and out of round is
• Journal diameters 1 through 6 are less than 0.013 mm (0.0005 inch). Compare the measured
63.4517 mm (2.4981 inches) diameter with the journal diameter specification
• Journal 7 diameter is less than 63.4365 mm (Main Bearing Fitting Chart). Select inserts required
(2.4975 inches). to obtain the specified bearing-to-journal clearance.
Once the proper clearances have been obtained, Install the crankshaft into the cylinder block (refer
proceed to Crankshaft Main Bearing—Installation. to Cylinder Block - Assemble and Crankshaft Main
Bearings - Installation).
REPAIR DAMAGED OR WORN THREADS (9) Squirt engine oil into the cylinders to lubricate
the walls. This will prevent damage on restart.
CAUTION: Be sure that the tapped holes maintain (10) Install new spark plugs. Tighten the spark
the original center line. plugs to 37 N·m (27 ft. lbs.) torque.
(11) Drain engine oil. Remove and discard the oil
Damaged or worn threads can be repaired. Essen- filter.
tially, this repair consists of: (12) Install the drain plug. Tighten the plug to 34
• Drilling out worn or damaged threads. N·m (25 ft. lbs.) torque.
• Tapping the hole with a special Heli-Coil Tap, or (13) Install a new oil filter.
equivalent. (14) Fill engine crankcase with the specified
• Installing an insert into the tapped hole to bring amount and grade of oil (refer to Group 0, Lubrica-
the hole back to its original thread size. tion and Maintenance).
(15) Connect the negative cable to the battery.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK) (16) Start the engine and check for any leaks.
A service replacement engine assembly (short
block) may be installed whenever the original cylin- ENGINE OIL SERVICE
der block is defective or damaged beyond repair. It
consists of the cylinder block, crankshaft, piston and WARNING: NEW OR USED ENGINE OIL CAN BE
rod assemblies. If needed, the camshaft must be pro- IRRITATING TO THE SKIN. AVOID PROLONGED OR
cured separately and installed before the engine is REPEATED SKIN CONTACT WITH ENGINE OIL.
installed in the vehicle. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
A short block is identified with the letter “S” INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
stamped on the same machined surface where the YOUR HEALTH. THOROUGHLY WASH EXPOSED
build date code is stamped for complete engine SKIN WITH SOAP AND WATER. DO NOT WASH
assemblies. SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
Installation includes the transfer of components SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
from the defective or damaged original engine. Fol- NOT POLLUTE, DISPOSE OF USED ENGINE OIL
low the appropriate procedures for cleaning, inspec- PROPERLY.
tion and torque tightening.
REMOVAL
Fig. 42 Oil Filter—4.0L Engine (1) Disconnect negative cable from battery.
1 – CYLINDER BLOCK (2) Raise the vehicle.
2 – ADAPTER (3) Support the engine.
3 – OIL FILTER (4) Remove the nut from the through bolt (Fig. 44).
DO NOT remove the through bolt.
(5) Remove the retaining bolts and nuts from the
(4) When filter separates from adapter nipple, tip
support cushions (Fig. 44).
gasket end upward to minimize oil spill. Remove fil-
(6) Remove the through bolt.
ter from vehicle.
(7) Remove the support cushions.
(5) Make sure old gasket comes off with oil filter.
With a wiping cloth, clean the gasket sealing surface
INSTALLATION
(Fig. 43) of oil and grime.
(1) If the engine support bracket was removed,
OIL FILTER INSTALLATION position the bracket onto the block and install the
attaching bolts (Fig. 44). Tighten the engine support
(1) Lightly lubricate oil filter gasket with engine
bracket bolts to 61 N·m (45 ft. lbs.) torque.
oil or chassis grease.
(2) If the support cushion bracket was removed,
(2) Thread filter onto adapter nipple. When gasket
position the bracket onto the lower front sill (Fig.
makes contact with sealing surface, (Fig. 43) hand
45). Install support cushion bracket bolts and nuts.
tighten filter one full turn, do not over tighten.
Tighten the bolts to 54 N·m (40 ft. lbs.) torque.
(3) Add oil, verify crankcase oil level and start
Tighten the nuts to 41 N·m (30 ft. lbs.) torque.
engine. Inspect for oil leaks.
(3) Place the support cushion into position on the
USED ENGINE OIL DISPOSAL support cushion bracket (Fig. 44). Install and tighten
Care should be exercised when disposing used the bolts and nuts to 41 N·m (30 ft. lbs.) torque.
engine oil after it has been drained from a vehicle (4) Install the through bolt and the retaining nut
engine. Refer to the WARNING at beginning of this (Fig. 44). Tighten the through bolt nut to 65 N·m (48
section. ft. lbs.) torque.
XJ 4.0L ENGINE 9 - 91
REMOVAL AND INSTALLATION (Continued)
REMOVAL INSTALLATION
(1) Disconnect negative cable from battery. MANUAL TRANSMISSION:
(2) Raise the vehicle and support the transmission.
a. Install the transmission support bracket to the
(3) Remove the nuts holding the support cushion
transmission. Install the bolts and tighten to 46 N·m
to the crossmember (Fig. 46) (Fig. 47). Remove the
(34 ft. lbs.) torque.
crossmember.
9 - 92 4.0L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
INTAKE AND EXHAUST MANIFOLD (3) Install intake manifold on the cylinder head
dowels.
REMOVAL (4) Install washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fig. 50).
NOTE: THE ENGINE INTAKE AND EXHAUST MANI- (5) Install washer and fastener Numbers 6 and 7
FOLD MUST BE REMOVED AND INSTALLED (Fig. 50).
TOGETHER. THE MANIFOLDS USE A COMMON (6) Tighten the fasteners in sequence and to the
GASKET AT THE CYLINDER HEAD. specified torque (Fig. 50).
• Fastener Numbers 1 through 5—Tighten to 33
(1) Disconnect the battery negative cable. N·m (24 ft. lbs.) torque.
(2) Remove air cleaner inlet hose from the resona- • Fastener Numbers 6 and 7—Tighten to 31 N·m
tor assembly. (23 ft. lbs.) torque.
(3) Remove the air cleaner assembly. • Fastener Numbers 8 through 11—Tighten to 33
(4) Remove the throttle cable, vehicle speed control N·m (24 ft. lbs.) torque.
cable (if equipped) and the transmission line pres-
sure cable.
(5) Disconnect the following electrical connections
and secure their harness out of the way:
• Throttle Position Sensor
• Idle Air Control Motor
• Coolant Temperature Sensor (at thermostat
housing)
• Intake Air Temperature Sensor
• Oxygen Sensor
• Crank Position Sensor
• Six (6) Fuel Injector Connectors
• Manifold Absolute Pressure (MAP) Sensor.
(6) Disconnect HVAC, and Brake Booster vacuum
supply hoses at the intake manifold.
(7) Perform the fuel pressure release procedure.
(Refer to Group 14, Fuel Systems for correct proce-
Fig. 50 Intake and Exhaust Manifolds—4.0L
dure)
(8) Disconnect and remove the fuel system supply (7) Install the power steering pump to the intake
line from the fuel rail assembly. (Refer to Group 14, manifold.
Quick Connect Fittings for correct procedures) (8) Install the accessory drive belt. (Refer to Group
(9) Remove the accessory drive belt (refer to Group 7, Cooling System for the correct procedures)
7, Cooling System). Loosen the tensioner. (9) Install the fuel system supply line to the fuel
(10) Remove the power steering pump from the rail assembly. Before connecting the fuel supply
intake manifold and set aside. line to the fuel rail inspect the O-rings and
(11) Raise the vehicle. replace if necessary. Refer to Group 14, Fuel
(12) Disconnect the exhaust pipes from the engine System for the correct procedure.
exhaust manifolds. (10) Connect all electrical connections on the
(13) Lower the vehicle. intake manifold.
(14) Remove the intake manifold and engine (11) Connect the vacuum hoses previously
exhaust manifolds. removed.
(12) Install throttle cable, vehicle speed control
INSTALLATION cable (if equipped).
If the manifold is being replaced, ensure all the fit- (13) Install the transmission line pressure cable (if
ting, etc. are transferred to the replacement mani- equipped). Refer to Group 21, Transmission for the
fold. adjustment procedures.
(1) Install a new engine exhaust/intake manifold (14) Install air cleaner assembly.
gasket over the alignment dowels on the cylinder (15) Connect air inlet hose to the resonator assem-
head. bly.
(2) Position the engine exhaust manifolds to the (16) Raise the vehicle.
cylinder head. Install fastener Number 3 and finger (17) Connect the exhaust pipes to the engine
tighten at this time (Fig. 50). exhaust manifolds. Tighten the bolts to 31 N·m (23
ft. lbs.)
9 - 96 4.0L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
(18) Lower the vehicle.
(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect the Crankcase Ventilation (CCV)
vacuum hose from engine cylinder head cover.
(3) Disconnect the fresh air inlet hose from the
engine cylinder head cover.
(4) Disconnect the accelerator, transmission, and
speed (if equipped) control cables from the throttle
body (Fig. 51).
(5) Remove the three bolts that fasten the control
cable bracket to the intake manifold.
(6) Remove control cables from cylinder head cover Fig. 52 Cylinder Head Cover Gasket Locator Pins at
clip. #8 & #9
(7) Position control cables and bracket away from ROCKER ARMS AND PUSH RODS
cylinder head cover secure with tie straps. This procedure can be done with the engine in or
(8) Remove the engine cylinder head cover mount- out of the vehicle.
ing bolts.
(9) Remove the engine cylinder head cover and REMOVAL
gasket. (1) Remove the engine cylinder head cover.
(2) Check for rocker arm bridges which are caus-
INSTALLATION ing misalignment of the rocker arm to valve tip area.
(1) If a replacement cover is installed, transfer the (3) Remove the capscrews at each bridge and pivot
CCV valve grommet and oil filler cap from the origi- assembly (Fig. 53). Alternately loosen the capscrews
nal cover to the replacement cover. one turn at a time to avoid damaging the bridges.
(2) Install cylinder head cover and gasket. Tighten (4) Remove the bridges, pivots and corresponding
the mounting bolts to 10 N·m (85 in. lbs.) torque. pairs of rocker arms (Fig. 53). Place them on a bench
(3) Connect the CCV hoses. in the same order as removed.
(4) Install control cables and bracket on intake (5) Remove the push rods and place them on a
manifold and tighten bolts to 8.7 N·m (77 in. lbs.) bench in the same order as removed.
torque.
(5) Connect control cables to throttle body linkage. INSTALLATION
(6) Snap control cables into cylinder head cover (1) Lubricate the ball ends of the push rods with
clip. Mopar Engine Oil Supplement, or equivalent and
(7) Connect negative cable to battery. install push rods in their original locations. Ensure
XJ 4.0L ENGINE 9 - 97
REMOVAL AND INSTALLATION (Continued)
(2) Remove cap screws, bridge and pivot assem-
blies and rocker arms for access to each valve spring
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) Inspect the springs and retainer for cracks and
possible signs of weakening.
(5) Remove the spark plug(s) adjacent to the cylin-
der(s) below the valve springs to be removed.
(6) Connect an air hose to the adapter and apply
air pressure slowly. Maintain at least 621 kPa (90
psi) of air pressure in the cylinder to hold the valves
against their seats. For vehicles equipped with an air
conditioner, use a flexible air adaptor when servicing
the No.1 cylinder.
(7) Tap the retainer or tip with a rawhide hammer
to loosen the lock from the retainer. Use Valve Spring
Compressor Tool MD-998772A to compress the spring
and remove the locks (Fig. 54).
(8) Remove valve spring and retainer (Fig. 54).
(9) Remove valve stem oil seals (Fig. 54). Note the
valve seals are different for intake and exhaust
Fig. 53 Rocker Arm Assembly valves. The top of each seal is marked either INT
1 – CAPSCREWS (intake/black in color) or EXH (exhaust/brown in
2 – BRIDGE color). DO NOT mix the seals.
3 – PIVOT ASSEMBLY
4 – PUSH RODS
5 – ROCKER ARMS
POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
8,9 1/2 in.-13 BOLT WITH DOWEL
POINT
2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD
END
All bolts are 12 point drives for rocker cover clearance
(3) With bolt No.14 held in place (tape around Fig. 56 Engine Cylinder Head Bolt Tightening
bolt), install the engine cylinder head over the same Sequence
dowels used to locate the gasket. Remove the tape (6) Install the spark plugs and tighten to 37 N·m
from bolt No.14. (27 ft. lbs.) torque.
(4) Coat the threads of stud bolt No.11 with Loc- (7) Connect the temperature sending unit wire
tite 592 sealant, or equivalent. connector.
(5) Tighten the engine cylinder head bolts in (8) Install the ignition coil rail and coil rail electri-
sequence according to the following procedure (Fig. cal connectors.
56). (9) Install the intake and engine exhaust mani-
folds (refer to procedures in this section).
CAUTION: During the final tightening sequence, (10) Install the fuel line and the vacuum advance
bolt No.11 will be tightened to a lower torque than hose.
the rest of the bolts. DO NOT overtighten bolt (11) Attach the power steering pump and bracket.
No.11. (12) Install the push rods, rocker arms, pivots and
bridges in the order they were removed (refer to
(a) Tighten all bolts in sequence (1 through 14)
Rocker Arms and Push Rods in this section).
to 30 N·m (22 ft. lbs.) torque.
(13) Install the engine cylinder head cover.
(b) Tighten all bolts in sequence (1 through 14)
(14) Attach the air conditioner compressor mount-
to 61 N·m (45 ft. lbs.) torque.
ing bracket to the engine cylinder head and block.
(c) Check all bolts to verify they are set to 61
Tighten the bolts to 40 N·m (30 ft. lbs.) torque.
N·m (45 ft. lbs.) torque.
(15) Attach the air conditioning compressor to the
(d) Tighten bolts in sequence:
bracket. Tighten the bolts to 27 N·m (20 ft. lbs.)
• Bolts 1 through 10 to 149 N·m (110 ft. lbs.)
torque.
torque.
• Bolt 11 to 135 N·m (100 ft. lbs.) torque.
9 - 100 4.0L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
CAUTION: The serpentine drive belt must be routed (4) Install the replacement valve stem oil seals on
correctly. Incorrect routing can cause the water the valve stems. If the 0.381 mm (0.015 inch) over-
pump to turn in the opposite direction causing the size valve stems are used, oversize oil seals are
engine to overheat. required.
(5) Position the valve spring and retainer on the
(16) Install the serpentine drive belt. (refer to engine cylinder head and compress the valve spring
Group 7, Cooling System for the proper procedure). with Valve Spring Compressor Tool MD-998772A.
(17) Install the air cleaner and ducting. (6) Install the valve locks and release the tool.
(18) Connect the hoses to the engine thermostat (7) Tap the valve spring from side to side with a
housing and fill the cooling system to the specified hammer to ensure that the spring is properly seated
level (refer to Group 7, Cooling Systems for the at the engine cylinder head. Also tap the top of the
proper procedure). retainer to seat the valve locks.
(19) The automatic transmission throttle linkage (8) Install the engine cylinder head.
and cable must be adjusted after completing the
engine cylinder head installation (refer to Group 21, HYDRAULIC TAPPETS
Transmissions for the proper procedures). Retain all the components in the same order as
(20) Install the temperature sending unit and con- removed.
nect the wire connector.
(21) If equipped with air conditioning, install A/C REMOVAL
compressor and charge A/C system (refer to Group 24 (1) Remove the engine cylinder head (Refer to cyl-
Heating and Air Conditioning). inder head r&i in this section).
(22) Connect negative cable to battery. (2) Remove the push rods.
(3) Remove the tappets through the push rod open-
WARNING: USE EXTREME CAUTION WHEN THE ings in the cylinder block with a Hydraulic Valve
ENGINE IS OPERATING. DO NOT STAND IN DIRECT Tappet Removal/Installation Tool (Fig. 57).
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
INSTALLATION INSTALLATION
(1) Apply Mopar Silicone Rubber Adhesive Sealant Clean the timing case cover, oil pan and cylinder
to the keyway in the crankshaft and insert the key. block gasket surfaces.
With the key in position, align the keyway on the (1) Install a new crankshaft oil seal in the timing
vibration damper hub with the crankshaft key and case cover. The open end of the seal should be toward
tap the damper onto the crankshaft. the inside of the cover. Support the cover at the seal
(2) Install the vibration damper retaining bolt and area while installing the seal. Force it into position
washer. with Seal Installation Tool 6139.
(2) Position the gasket on the cylinder block.
9 - 102 4.0L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
(3) Position the timing case cover on the oil pan (6) Rotate crankshaft until the “0” timing mark is
gasket and the cylinder block. closest to and on the center line with camshaft
(4) Insert Timing Case Cover Alignment and Seal sprocket timing mark (Fig. 61).
Installation Tool 6139 in the crankshaft opening in
the cover (Fig. 60).
TIMING CHAIN AND SPROCKETS Fig. 62 Camshaft Sprocket and Thrust Plate
1 – CAMSHAFT
REMOVAL 2 – CAMSHAFT SPROCKET W/INTEGRAL KEY
(1) Disconnect negative cable from battery. 3 – BOLT & CUP WASHER
4 – THRUST PLATE
(2) Remove the fan and shroud.
(3) Remove the serpentine drive belt.
(4) Remove the crankshaft vibration damper. (9) Remove the crankshaft sprocket, camshaft
(5) Remove the timing case cover. sprocket and timing chain as an assembly.
XJ 4.0L ENGINE 9 - 103
REMOVAL AND INSTALLATION (Continued)
(10) Installation of the timing chain with the tim- (9) Remove the vibration damper.
ing marks on the crankshaft and camshaft sprockets (10) Remove the timing case cover.
properly aligned ensures correct valve timing. A worn (11) Rotate the crankshaft until the crankshaft
or stretched timing chain will adversely affect valve sprocket timing mark is aligned on centerline with
timing. If the timing chain deflects more than 12.7 the camshaft sprocket timing mark (Fig. 64).
mm (1/2 inch) replace it. (12) Remove the timing chain and sprockets.
(13) Remove the front bumper and/or grille, as
INSTALLATION required.
Assemble the timing chain, crankshaft sprocket (14) Remove the two thrust plate retaining screws,
and camshaft sprocket with the timing marks thrust plate and camshaft (Fig. 63).
aligned (Fig. 61).
(1) Apply Mopar Silicone Rubber Adhesive Sealant
to the keyway in the crankshaft and insert the key.
With the key in the keyway on the crankshaft, install
the assembly on the crankshaft and camshaft.
(2) Install the camshaft sprocket bolt and washer
(Fig. 62). Tighten the bolt to 68 N·m (50 ft. lbs.)
torque.
(3) To verify correct installation of the timing
chain, rotate the crankshaft 2 revolutions. The cam-
shaft and crankshaft sprocket timing mark should
align (Fig. 61).
(4) Install the crankshaft oil slinger.
(5) Replace the oil seal in the timing case cover.
(6) Install the timing case cover and gasket.
(7) With the key installed in the crankshaft key-
way, install the vibration damper, washer and bolt.
Lubricate and tighten the bolt to 108 N·m (80 ft. lbs.)
torque.
(8) Install the serpentine drive belt. (refer to
Group 7, Cooling System for the proper procedure).
(9) Install the fan and hub assembly. Install the Fig. 63 Camshaft
shroud. 1 – CAMSHAFT
(10) Connect negative cable to battery. 2 – CRANKSHAFT
CAMSHAFT
INSTALLATION
(1) Inspect the cam lobes for wear.
REMOVAL
(2) Inspect the bearing journals for uneven wear
WARNING: THE COOLANT IN A RECENTLY OPER- pattern or finish.
ATED ENGINE IS HOT AND PRESSURIZED. (3) Inspect the bearings for wear.
RELEASE THE PRESSURE BEFORE REMOVING (4) Inspect the distributor drive gear for wear.
THE DRAIN COCK, CAP AND DRAIN PLUGS. (5) If the camshaft appears to have been rubbing
against the thrust washer, examine the oil pressure
(1) Disconnect negative cable from battery. relief holes in the rear cam journal. The oil pressure
(2) Drain the cooling system. DO NOT waste reus- relief holes must be free of debris.
able coolant. If the solution is clean, drain it into a (6) Lubricate the camshaft with Mopar Engine Oil
clean container for reuse. Supplement, or equivalent.
(3) Remove the radiator or radiator and condenser, (7) Carefully install the camshaft to prevent dam-
if equipped with A/C (refer to Group 7, Cooling Sys- age to the camshaft bearings (Fig. 63).
tem for the proper procedure). (8) Position thrust plate and install retaining
(4) Remove the engine cylinder head cover. screws. Tighten screws to 24 N·m (18 ft. lbs.).
(5) Remove the rocker arms, bridges and pivots. (9) Install the timing chain, crankshaft sprocket
(6) Remove the push rods. and camshaft sprocket with the timing marks
(7) Remove the engine cylinder head and gasket. aligned.
(8) Remove the hydraulic valve tappets from the (10) Install the camshaft sprocket bolt/cup washer.
engine cylinder block. Tighten the bolt to 68 N·m (50 ft. lbs.).
9 - 104 4.0L ENGINE XJ
REMOVAL AND INSTALLATION (Continued)
(15) Install the cylinder head and head bolts
(Refer to cylinder head R&I in this section for torque
values and tightening sequence).
(16) Install the push rods.
(17) Install the rocker arms and pivot and bridge
assemblies. Tighten each of the capscrews for each
bridge alternately, one turn at a time, to avoid dam-
aging the bridge (Refer to Rocker Arms and Push
Rods in this section).
(18) Install the engine cylinder head cover.
(19) Install the serpentine drive belt. (refer to
Group 7, Cooling System for the proper procedure).
INSTALLATION
(1) Clean the block and pan gasket surfaces.
(2) Fabricate 4 alignment dowels from 1 1/2 x 1/4
inch bolts. Cut the head off the bolts and cut a slot
Fig. 71 Crankshaft End Play Measurement into the top of the dowel. This will allow easier
1 – DIAL INDICATOR installation and removal with a screwdriver (Fig. 72).
2 – CRANKSHAFT
INSTALLATION
(1) Clean the cylinder bores thoroughly. Apply a
light film of clean engine oil to the bores with a clean
lint-free cloth.
(2) Install the piston rings on the pistons if
removed.
(3) Lubricate the piston and rings with clean
engine oil.
REMOVAL
(1) Remove transmission inspection cover.
(2) Remove oil pan. Refer to procedure in this sec-
tion
Fig. 79 Rod and Piston Assembly Installation (3) Remove main bearing cap brace.
(6) Raise the vehicle. (4) Remove rear main bearing cap (No.7).
(7) Each bearing insert is fitted to its respective (5) Push upper seal out of the groove. Ensure that
journal to obtain the specified clearance between the the crankshaft and seal groove are not damaged.
bearing and the journal. In production, the select fit (6) Remove lower half of the seal from the bearing
is obtained by using various-sized, color-coded bear- cap.
ing inserts as listed in the Connecting Rod Bearing
Fitting Chart. The color code appears on the edge of INSTALLATION
the bearing insert. The size is not stamped on inserts (1) Wipe the seal surface area of the crankshaft
used for production of engines. until it is clean.
(8) The rod journal is identified during the engine (2) Apply a thin coat of engine oil.
production by a color-coded paint mark on the adja- (3) Coat lip of the seal with engine oil.
cent cheek or counterweight toward the flange (rear) (4) Carefully position the upper seal into the
end of the crankshaft. The color codes used to indi- groove in the cylinder block. The lip of the seal faces
cate journal sizes are listed in the Connecting Rod toward the front of the engine.
Bearing Fitting Chart. (5) Apply Mopart Gasket Maker sealer on both
(9) When required, upper and lower bearing sides of cylinder block as shown in (Fig. 80). The dab
inserts of different sizes may be used as a pair (refer of sealer should be 3 mm (0.125 in.) in diameter.
to Connecting Rod Bearing Fitting Chart). A stan- (6) Apply Mopart Gasket Maker on the rear bear-
dard size insert is sometimes used in combination ing cap (Fig. 80). The bead should be 2.3 mm (0.09
with a 0.025 mm (0.001 inch) undersize insert to in.) in diameter. DO NOT apply sealer to the lip of
reduce clearance 0.013 mm (0.0005 inch). the seal.
(7) Position the lower seal into the bearing cap
CAUTION: DO NOT intermix bearing caps. Each recess and seat it firmly. Be sure the seal is flush
connecting rod and bearing cap are stamped with with the cylinder block pan rail.
the cylinder number. The stamp is located on a (8) Coat the outer curved surface of the lower seal
machined surface adjacent to the oil squirt hole with soap and the lip of the seal with engine oil.
that faces the camshaft side of the cylinder block. (9) Install the rear main bearing cap. DO NOT
strike the cap more than twice for proper engage-
(10) Install the connecting rod bearing caps and ment.
inserts in the same positions as removed. (10) Tighten all main bearing bolts to 108 N·m (80
ft. lbs.) torque.
CAUTION: Verify that the oil squirt holes in the (11) Install the main bearing cap brace. Tighten
rods face the camshaft and that the arrows on the nuts to 47 N·m (35 ft. lbs.).
pistons face the front of the engine. (12) Install the oil pan gasket and oil pan. Tighten
1/4 – 20 screws to 14 N·m (120 in. lbs.). Tighten 5/16
(11) Install main bearing cap brace (Fig. 76). – 18 screws to 18 N·m (156 in. lbs.)
Tighten nuts to 47 N·m (35 ft. lbs.).
XJ 4.0L ENGINE 9 - 111
REMOVAL AND INSTALLATION (Continued)
The pump incorporates a nonadjustable pressure
relief valve to limit maximum pressure to 517 kPa
(75 psi). In the relief position, the valve permits oil to
bypass through a passage in the pump body to the
inlet side of the pump.
Oil pump removal or replacement will not affect
the distributor timing because the distributor drive
gear remains in mesh with the camshaft gear.
REMOVAL
(1) Drain the engine oil.
(2) Remove the oil pan.
(3) Remove the pump-to-cylinder block attaching
bolts. Remove the pump assembly with gasket (Fig.
82).
ASSEMBLY
Refer to the applicable sections for detailed
instructions.
(1) Install the crankshaft.
(2) Install the connecting rods and the pistons
through the top of the cylinder bores.
(3) Install the oil pump.
Fig. 83 Timing Case Cover Oil Seal Installation (4) Install the oil pan and gasket.
1 – SEAL INSTALLATION TOOL (5) Install the camshaft.
2 – DRAW SCREW TOOL (6) Install the sprockets and chain as an assembly.
(7) Install the oil slinger from the crankshaft.
(3) Remove the tools. Apply a light film of engine (8) Install the timing case cover seal.
oil on the vibration damper hub contact surface of (9) Install the timing case cover.
the seal. (10) Install the vibration damper.
(11) Install the water pump. Tighten the mounting
bolts to 31 N·m (23 ft. lbs.) torque.
XJ 4.0L ENGINE 9 - 113
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Lubricate the oil filter seal with clean engine INSPECTION
oil. Tighten oil filter to 18 N·m (156 in. lbs.) torque. Inspect the pivot surface area of each rocker arm.
(13) Install the engine into the vehicle. Replace any that are scuffed, pitted, cracked or
(14) Fill the engine with clean lubrication oil (refer excessively worn.
to Group 0, Lubrication and Maintenance). Inspect the valve stem tip contact surface of each
(15) Fill the cooling system. rocker arm and replace any rocker arm that is deeply
pitted.
Inspect each push rod end for excessive wear and
CLEANING AND INSPECTION replace as required. If any push rod is excessively
worn because of lack of oil, replace it and inspect the
CYLINDER HEAD corresponding hydraulic tappet for excessive wear.
Inspect the push rods for straightness by rolling
CLEANING them on a flat surface or by shining a light between
Thoroughly clean the engine cylinder head and cyl- the push rod and the flat surface.
inder block mating surfaces. Clean the intake and A wear pattern along the length of the push rod is
engine exhaust manifold and engine cylinder head not normal. Inspect the engine cylinder head for
mating surfaces. Remove all gasket material and car- obstruction if this condition exists.
bon.
Check to ensure that no coolant or foreign material HYDRAULIC TAPPETS
has fallen into the tappet bore area.
Remove the carbon deposits from the combustion CLEANING
chambers and top of the pistons. Clean each tappet assembly in cleaning solvent to
remove all varnish, gum and sludge deposits.
INSPECTION
Use a straightedge and feeler gauge to check the INSPECTION
flatness of the engine cylinder head and block mating Inspect for indications of scuffing on the side and
surfaces. base of each tappet body.
Inspect each tappet base for concave wear with a
CYLINDER HEAD COVER straightedge positioned across the base. If the base is
concave, the corresponding lobe on the camshaft is
CLEANING also worn. Replace the camshaft and defective tap-
Remove any original sealer from the cover sealing pets.
surface of the engine cylinder head and clean the After cleaning and inspection, test each tappet for
surface using a fabric cleaner. specified leak-down rate tolerance to ensure zero-lash
Remove all residue from the sealing surface using operation (Fig. 84).
a clean, dry cloth. Swing the weighted arm of the hydraulic valve tap-
pet tester away from the ram of the Leak-Down
INSPECTION Tester.
Inspect the engine cylinder head cover for cracks. (1) Place a 7.925-7.950 mm (0.312-0.313 inch)
Replace the cover, if cracked. diameter ball bearing on the plunger cap of the tap-
The original dark grey gasket material should pet.
NOT be removed. If sections of the gasket material (2) Lift the ram and position the tappet (with the
are missing or are compressed, replace the engine ball bearing) inside the tester cup.
cylinder head cover. However, sections with minor (3) Lower the ram, then adjust the nose of the ram
damage such as small cracks, cuts or chips may be until it contacts the ball bearing. DO NOT tighten
repaired with a hand held applicator. The new mate- the hex nut on the ram.
rial must be smoothed over to maintain gasket (4) Fill the tester cup with hydraulic valve tappet
height. Allow the gasket material to cure prior to test oil until the tappet is completely submerged.
engine cylinder head cover installation. (5) Swing the weighted arm onto the push rod and
pump the tappet plunger up and down to remove air.
ROCKER ARMS AND PUSH RODS When the air bubbles cease, swing the weighted arm
away and allow the plunger to rise to the normal
CLEANING position.
Clean all the components with cleaning solvent. (6) Adjust the nose of the ram to align the pointer
Use compressed air to blow out the oil passages in with the SET mark on the scale of the tester and
the rocker arms and push rods. tighten the hex nut.
9 - 114 4.0L ENGINE XJ
CLEANING AND INSPECTION (Continued)
(7) Slowly swing the weighted arm onto the push INSPECTION
rod. (1) It is mandatory to use a dial bore gauge to
(8) Rotate the cup by turning the handle at the measure each cylinder bore diameter (Fig. 85). To
base of the tester clockwise one revolution every 2 correctly select the proper size piston, a cylinder bore
seconds. gauge, capable of reading in 0.003 mm (.0001 in.)
(9) Observe the leak-down time interval from the INCREMENTS is required. If a bore gauge is not
instant the pointer aligns with the START mark on available, do not use an inside micrometer.
the scale until the pointer aligns with the 0.125
mark. A normally functioning tappet will require
20-110 seconds to leak-down. Discard tappets with
leak-down time interval not within this specification.
Flatness Max. 0.20 mm max. for total Valve Stem-to-Guide 0.025 to 0.076 mm
length Clearance (0.001 to 0.003 in.)
(0.008 in. max. for total
length) Valve Seat Angle
Intake 44.5°
Main Bearing Bore 68.3514 to 68.3768 mm
Exhaust 44.5°
Diameter
(2.691 to 2.692 in.)
Valve Seat Width 1.02 to 1.52 mm
CONNECTING ROD (0.040 to 0.060 in.)
Total Weight (Less 663 to 671 grams Valve Seat Runout 0.064 mm (0.0025 in.)
Bearing)
(23.39 to 23.67 oz.) Flatness 0.03 mm per 25 mm
Length (Center-to-Center) 155.52 to 155.62 mm (0.001 in. per 1 in.)
(6.123 to 6.127 in.) 0.05 mm per 152 mm
(0.002 in. per 6 in.)
Piston Pin Bore Diameter 23.59 to 23.62 mm
(0.9288 to 0.9298 in.)
XJ 4.0L ENGINE 9 - 117
SPECIFICATIONS (Continued)
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
CATALYTIC CONVERTERS sive heat will not be the fault of the converter. If
unburned fuel enters the converter, overheating may
DESCRIPTION occur. If a converter is heat-damaged, correct the
California emissions vehicles incorporate two mini cause of the damage at the same time the converter
catalytic converters into the exhaust system. These is replaced. Also, inspect all other components of the
catalytic converters are made of stainless steel exhaust system for heat damage.
designed to operate at extremely high temperatures. Unleaded gasoline must be used to avoid con-
The stainless steel catalytic converter body is taminating the catalyst core.
designed to last the life of the vehicle. Excessive heat
can result in bulging or other distortion, but exces-
XJ EXHAUST SYSTEM 11 - 3
DESCRIPTION AND OPERATION (Continued)
MUFFLER
DESCRIPTION
Both the 2.5L and 4.0L engines use a galvanized
steel muffler to control exhaust noise levels and
exhaust back pressure.
Fig. 5 Muffler—Typical
1 – MUFFLER
11 - 4 EXHAUST SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
TAILPIPE
DESCRIPTION
The tail pipe is also made of galvanized steel.
OPERATION
The tailpipe channels the exhaust out of the muf-
fler and out from under the vehicle to control noise
and prevent exhaust gas fumes from entering the
passenger compartment.
Fig. 6 Tailpipe—Typical
1 – TAILPIPE
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
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.
XJ EXHAUST SYSTEM 11 - 5
REMOVAL
(1) Raise and support the vehicle.
(2) Saturate the bolts and nuts with Mopart Rust
Penetrant (Fig. 7) (Fig. 8). Allow 5 minutes for pene- Fig. 8 Exhaust Pipe Removal—4.0L
tration. 1 – NUT
2 – EXHAUST MANIFOLD
3 – TRANSMISSION SUPPORT
4 – EXHAUST PIPE
5 – MINI CATALYTIC CONVERTER
6 – BOLT
INSTALLATION
(1) Assemble exhaust pipe to manifold and cata-
lytic converter loosely to permit proper alignment of
all parts.
(2) Use a new clamp and tighten the nuts to 61
N·m (45 ft. lbs.) torque.
(3) Connect the exhaust pipe to the engine exhaust
manifold (Fig. 7) (Fig. 8). Install a new seal between
the exhaust manifold and the exhaust pipe (4.0L
engine only). Tighten the nuts to 31 N·m (23 ft. lbs.)
Fig. 7 Exhaust Pipe Removal—2.5L torque.
1 – NUT (4) Install the rear crossmember. Install and
2 – TRANSMISSION SUPPORT tighten the four (4) crossmember to rear mount nuts
3 – MINI CATALYTIC CONVERTER to 22 N·m (16 ft. lbs.) Install and tighten the cross-
4 – EXHAUST PIPE member to sill bolts to 42 N·m (31 ft. lbs.) torque.
5 – EXHAUST MANIFOLD Remove the support from the transmission.
(5) Carefully coat the threads on the oxygen sen-
(3) Disconnect the oxygen sensor connector(s). sor(s) with anti-seize compound. Install the sensor
(4) Disconnect the exhaust pipe from the engine and tighten the nut to 27 N·m (20 ft. lbs.) torque.
exhaust manifold. Discard the seal (4.0L engine, (6) Lower the vehicle.
only). (7) Start the engine and inspect for exhaust leaks
(5) Support the transmission and remove the rear and exhaust system contact with the body panels.
crossmember. Adjust the alignment, if needed.
(6) Remove the clamp nuts and clamp. To remove
the exhaust pipe from the catalytic converter, apply
heat until the metal becomes cherry red. Disconnect
11 - 6 EXHAUST SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
CATALYTIC CONVERTER
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the clamps from the catalytic converter
and muffler connection (Fig. 9).
(3) Disconnect and remove the oxygen sensor from
the catalytic converter.
(4) Heat the catalytic converter and muffler con-
nection with an oxyacetylene torch until the metal Fig. 9 Catalytic Converter to Muffler and Exhaust
becomes cherry red. Pipe Connection
(5) While the metal is still cherry red, twist the 1 – EXHAUST CLAMP ASSEMBLY
muffler assembly back and forth to separate it from 2 – OXYGEN SENSOR
the catalytic converter. 3 – MUFFLER
(6) Disconnect the exhaust pipe from the catalytic 4 – CATALYTIC CONVERTER
converter (Fig. 9). If needed, heat up the pipes to sep- 5 – EXHAUST PIPE
arate.
WARNING: IF TORCHES ARE USED WHEN WORK-
INSTALLATION ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
(1) Connect the catalytic converter to the exhaust THE FLAME NEAR THE FUEL LINE.
pipe and the muffler/tailpipe assy. (Fig. 9). Use a new
clamp and tighten the nuts to 61 N·m (45 ft. lbs.)
torque. CAUTION: When servicing exhaust system compo-
(2) Install the muffler onto the catalytic converter nents, disconnect the oxygen sensor connector.
until the alignment tab is inserted into the align- Allowing the exhaust system to hang by the oxygen
ment slot. sensor harness will damage the wiring and/or sen-
(3) Install a new clamp at the muffler and cata- sor.
lytic converter connection (Fig. 9). Tighten the clamp
nut to 61 N·m (45 ft. lbs.) torque.
(4) Coat the oxygen sensor with anti-seize com- REMOVAL
pound. Install the sensor and tighten the nut to 27 (1) Raise and support the vehicle.
N·m (20 ft. lbs.) torque. (2) Disconnect front tailpipe hanger from the insu-
(5) Lower the vehicle. lator (Fig. 10).
(6) Start the engine and inspect for exhaust leaks (3) Remove the front exhaust clamp from the cat-
and exhaust system contact with the body panels. alytic converter and muffler connection (Fig. 11).
Adjust the alignment, if needed. (4) Heat the catalytic converter-to-muffler connec-
tion with an oxyacetylene torch until the metal
MUFFLER AND TAILPIPE becomes cherry red.
All original equipment exhaust systems are manu- (5) While the metal is still cherry red, remove the
factured with the exhaust tailpipe welded to the muf- exhaust muffler/tailpipe assembly from the catalytic
fler. Service replacement mufflers and exhaust converter.
tailpipes are either clamped together or welded (6) Slide the muffler/tailpipe assy. rearward and
together. out of the rear exhaust tailpipe mounting bracket
(Fig. 11).
XJ EXHAUST SYSTEM 11 - 7
REMOVAL AND INSTALLATION (Continued)
• To remove an original equipment exhaust muf-
fler/tailpipe combination, cut the exhaust tailpipe
close to the muffler. Collapse the part remaining in
the muffler and remove.
• To remove a service exhaust tailpipe/muffler
combination, apply heat until the metal becomes
cherry red. Remove the exhaust tailpipe/muffler
clamp and twist the exhaust tailpipe out of the muf-
fler.
INSTALLATION
(1) Install the muffler onto the catalytic converter.
Install the clamp and tighten the nut finger tight.
(2) Install the exhaust tailpipe into the rear of the
muffler.
(3) Install the exhaust tailpipe/muffler assembly
on the rear exhaust tailpipe mounting bracket. Make
sure that the exhaust tailpipe has sufficient clear-
ance from the floor pan.
(4) Install front tailpipe hanger into the insulator
(Fig. 10).
(5) Align the muffler and tighten the nuts on the
Fig. 10 Front Exhaust Tailpipe Hanger muffler-to-catalytic converter clamp to 61 N·m (45 ft.
1 – MUFFLER lbs.) torque (Fig. 11).
2 – INSULATOR (6) Align the tailpipe and install a new clamp at
3 – TAILPIPE the muffler to tailpipe connection.
4 – FRONT TAILPIPE HANGER
(7) Tighten the muffler to tailpipe clamp to 61 N·m
(45 ft. lbs.)
(7) Remove the muffler from the exhaust tailpipe: (8) Lower the vehicle.
Crossmember to Sill—Bolts 42 31 —
Crossmember to Transmission
Mount—Nuts 22 16 —
Muffler to Catalytic
(3) When removing muffler heat shield, the muf- Converter—
fler front support bracket must be removed first.
(4) Slide the shields out around the exhaust sys- Exhaust Clamp Nut 61 45 —
tem. Oxygen Sensors 27 20 —
INSTALLATION Rear Tail Pipe Hanger—Nuts 54 40 —
(1) Position the heat shields to the floor pan or the
frame and install the screws and/or nuts.
(2) Tighten the nuts and/or screws to 45 N·m (33
ft. lbs.) (Fig. 12).
(3) Lower the vehicle.
XJ FRAME AND BUMPERS 13 - 1
page page
TABLE OF CONTENTS
page
BUMPERS
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION (4) Lifting the end cap from the bottom, tilt
slightly upward and slide it outward to disengage the
FRONT BUMPER END CAP retainer tab from the bumper (Fig. 2).
(5) Separate the end cap from the bumper.
REMOVAL
(1) Remove the rivet attaching the end cap to the INSTALLATION
air deflector. (1) Position the end cap on the bumper and engage
(2) Remove the bolts and nuts attaching the end the retaining tab.
cap to the bumper (Fig. 1). (2) Install the screws attaching the end cap to the
(3) Pull back the wheelhouse liner and remove the front fender.
screws attaching the end cap to the front fender. (3) Install the bolts attaching the end cap to the
bumper. Tighten the nut to 9 N·m (7 ft. lbs.) torque.
INSTALLATION
(1) If removed, install bolts attaching bumper
mounting brackets to frame. Tighten bolts to 55 N·m
(41 ft. lbs.) torque.
(2) Position bumper on front of vehicle.
(3) Install Torx-head bolts that attach bumper to Fig. 4 Front Tow Hook
1 – MOUNTING BRACKET
mounting brackets. Tighten bolts to 55 N·m (41 ft.
2 – TOW HOOK
lbs.) torque. 3 – TOW HOOK REINFORCEMENT
(4) Connect vacuum line to reservoir.
(5) If equipped, engage fog lamp wire harness con-
nectors. INSTALLATION
(6) Install bumper end caps. (1) If removed, install bolt attaching tow hook
reinforcement to frame. Tighten bolt to 30 N·m (22 ft.
FRONT TOW HOOK lbs.) torque.
(2) Position tow hook on reinforcement.
REMOVAL (3) Install bolts attaching tow hook to tow hook
(1) Remove bolts attaching tow hook to tow hook reinforcement. Tighten bolts to 100 N·m (74 ft. lbs.)
reinforcement (Fig. 4). torque.
(2) Separate tow hook from reinforcement.
13 - 4 FRAME AND BUMPERS XJ
REMOVAL AND INSTALLATION (Continued)
REAR BUMPER END CAP refer to removal procedure within Group 13, Frame
and Bumpers.
REMOVAL (2) Remove bumper end caps.
(1) Remove the screws attaching the bumper end (3) Remove upper nuts that attach bumper to
cap to the quarter panel and the bumper (Fig. 5). bumper support brackets (Fig. 5).
(2) Lift the end cap slightly upward and slide it (4) Remove lower bolts that attach bumper to
rearward to release it from the retainer. bumper support brackets.
(3) Separate the end cap from the vehicle. (5) Remove bumper from vehicle.
(6) If necessary, remove bumper support brackets
INSTALLATION from the rear sill.
(1) Position the end cap on the rear of the retainer
and the outer edge of the bumper. INSTALLATION
(2) Slide the end cap forward onto the retainer. (1) If removed, install bumper support brackets on
Ensure the end cap overlaps the lip of the rear the rear sill. Tighten bolts to 55 N·m (41 ft. lbs.)
wheelhouse liner. torque.
(3) Install the screw attaching the front of the end (2) Position bumper on support brackets.
cap to the underside of the quarter panel and (3) Install bolts that attach bumper to bumper
bumper. support brackets. Tighten nuts to 55 N·m (41 ft. lbs.)
torque.
REAR BUMPER (4) Install bumper end caps.
(5) If removed, install trailer hitch.
REMOVAL
(1) For vehicles equipped with a trailer hitch,
remove hitch before removing bumper. If necessary,
INSTALLATION
(1) Position bracket and tow hook on frame rail.
(2) Install bolts that attach tow hook bracket and
tow hook to frame rail. Tighten bolts to 94 N·m (70
ft. lbs.) torque.
FRAME
TABLE OF CONTENTS
page page
INSTALLATION
(1) Position and support skid plate under fuel tank.
(2) Install bolts to attach skid plate to underbody
rails. Tighten bolts to 74 N·m (55 ft. lbs.) torque.
(3) Remove support from under skid plate.
Fig. 5 Trailer Hitch
TRAILER HITCH 1 – TRAILER HITCH
2 – BLIND RIVET
REMOVAL 3 – RIVET HOLES
4 – REINFORCEMENT
(1) If necessary, remove the trailer tow wire har-
ness connector from the hitch (Fig. 4).
(2) Support the hitch. (4) Loosely install the bolts to attach the trailer
(3) Remove the bolts that attach the trailer hitch hitch (and the skid plate) to frame sills and reinforce-
to the frame sills and reinforcement brackets (Fig. 5). ment brackets.
(4) If equipped, remove the fuel tank skid plate. (5) Tighten all bolts/nuts to 74 N·m (55 ft. lbs.)
torque.
NOTE: The reinforcement brackets are held on the
(6) Remove the lift/support.
frame sills with two blind rivets.
(7) If removed, attach the trailer wire harness con-
nector to the hitch.
INSTALLATION
(1) Install frame reinforcement brackets, if removed.
Slide the brackets through the vehicle rear sill open- SPECIFICATIONS
ings and attach to the frame sills with blind rivets.
(2) Using an adequate lifting device, position hitch FRAME DIMENSIONS
at the proper location for installation on vehicle and Frame dimensions are listed in millimeter scale.
support it. All dimensions are from center to center of Principal
(3) If equipped, position fuel tank skid plate on Locating Point (PLP), or from center to center of PLP
vehicle frame sills. and fastener location (Fig. 6).
13 - 8 FRAME AND BUMPERS XJ
SPECIFICATIONS (Continued)
FUEL SYSTEM
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page page
OPERATION
Fuel is returned through the fuel pump module
and back into the fuel tank through the fuel filter/
fuel pressure regulator. A separate fuel return line
from the engine to the tank is not used.
The fuel tank assembly consists of: the fuel tank,
fuel pump module assembly, fuel pump module lock-
nut/gasket, and rollover valve (refer to Group 25,
Emission Control System for rollover valve informa-
tion). Fig. 1 Fuel Tank/Fuel Pump Module (Top View)
A fuel filler/vent tube assembly using a pressure/ 1 – ROLLOVER VALVE
vacuum, 1/4 turn fuel filler cap is used. The fuel 2 – RETAINER CLAMP
filler tube contains a flap door located below the fuel 3 – LOCKNUT
fill cap. 4 – FUEL PUMP MODULE
5 – FUEL FILTER/FUEL PRESSURE REGULATOR
Also to be considered part of the fuel system is the
6 – ALIGNMENT ARROW
evaporation control system. This is designed to
7 – PIGTAIL HARNESS
reduce the emission of fuel vapors into the atmo- 8 – FUEL SUPPLY TUBE
sphere. The description and function of the Evapora- 9 – EVAP CANISTER VENT LINE
tive Control System is found in Group 25, Emission
Control Systems.
Both fuel filters (at bottom of fuel pump module
and within fuel pressure regulator) are designed for
extended service. They do not require normal sched-
uled maintenance. Filters should only be replaced if
a diagnostic procedure indicates to do so.
DESCRIPTION DESCRIPTION
The fuel gauge sending unit (fuel level sensor) is The combination fuel filter and fuel pressure regu-
attached to the side of the fuel pump module. The lator is located on the top of fuel pump module (Fig.
sending unit consists of a float, an arm, and a vari- 1).
able resistor track (card).
OPERATION
OPERATION A combination fuel filter and fuel pressure regula-
The fuel pump module has 4 different circuits tor is used on all engines. A separate frame mounted
(wires). Two of these circuits are used for the fuel fuel filter is not used with any engine.
gauge sending unit for fuel gauge operation, and for Fuel Pressure Regulator Operation: The pres-
certain OBD II emission requirements. The other 2 sure regulator is a mechanical device that is not con-
wires are used for electric fuel pump operation. trolled by engine vacuum or the Powertrain Control
For Fuel Gauge Operation: A constant input Module (PCM).
voltage source of about 12 volts (battery voltage) is The regulator is calibrated to maintain fuel system
supplied to the resistor track on the fuel gauge send- operating pressure of approximately 339 kPa 6 34
ing unit. This is fed directly from the Powertrain kPa (49.2 psi 6 5 psi) at the fuel injectors. It con-
Control Module (PCM). NOTE: For diagnostic pur- tains a diaphragm, calibrated springs and a fuel
poses, this 12V power source can only be veri- return valve. The internal fuel filter is also part of
fied with the circuit opened (fuel pump module the assembly.
electrical connector unplugged). With the con- Fuel is supplied to the filter/regulator by the elec-
nectors plugged, output voltages will vary from tric fuel pump through an opening tube at the bot-
about.6 volts at FULL, to about 8.6 volts at tom of filter/regulator (Fig. 3).
EMPTY (about 8.6 volts at EMPTY for Jeep The regulator acts as a check valve to maintain
models, and about 7.0 volts at EMPTY for some fuel pressure when the engine is not operating.
Dodge Truck models). The resistor track is used to This will help to start the engine. A second check
vary the voltage (resistance) depending on fuel tank valve is located at the outlet end of the electric fuel
float level. As fuel level increases, the float and arm pump. Refer to Fuel Pump—Description and
14 - 4 FUEL SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
into the intake manifold. Certain models are also
equipped with a self-diagnosing system using a Leak
Detection Pump (LDP). Refer to Emission Control
System for additional information.
FUEL INJECTORS
DESCRIPTION
An individual fuel injector (Fig. 4) is used for each
individual cylinder.
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
TERMINAL LEGEND PROCEDURE
NUMBER IDENTIFICATION Use following procedure if the fuel injector
30 COMMON FEED rail is, or is not equipped with a fuel pressure
85 COIL GROUND test port.
86 COIL BATTERY (1) Remove fuel fill cap.
87 NORMALLY OPEN (2) Remove fuel pump relay from Power Distribu-
87A NORMALLY CLOSED tion Center (PDC). For location of relay, refer to label
on underside of PDC cover.
(3) Start and run engine until it stalls.
Fig. 11 Type–2 Relay
(4) Attempt restarting engine until it will no
longer run.
(5) Turn ignition key to OFF position.
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
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.
CONNECTING
(1) Inspect quick-connect fitting body and fuel sys-
tem component for damage. Replace as necessary.
(2) Prior to connecting quick-connect fitting to
component being serviced, check condition of fitting
and component. Clean parts with a lint-free cloth.
Lubricate with clean engine oil.
(3) Insert quick-connect fitting into fuel tube or
fuel system component until built-on stop on fuel
tube or component rests against back of fitting.
(4) Continue pushing until a click is felt.
(5) Single-tab type fitting: Push new tab down
until it locks into place in quick-connect fitting.
(6) Verify a locked condition by firmly pulling on
fuel tube and fitting (15-30 lbs.).
(7) Latch Clip Equipped: Install latch clip (snaps
into position). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
Fig. 19 Latch Clip—Type 2 rail (or other fuel line). Recheck fuel line con-
1 – LATCH CLIP nection.
(8) Connect negative cable to battery.
(9) Start engine and check for leaks.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal/
Installation.
(2) Clean area around filter/regulator.
Fig. 20 Fuel Line Disconnection Using Special Tool (3) Disconnect fuel line at filter/regulator. Refer to
1 – SPECIAL FUEL LINE TOOL Quick-Connect Fittings in this group for procedures.
2 – FUEL LINE (4) Remove retainer clamp from top of filter/regu-
3 – FUEL RAIL
lator (Fig. 21). Clamp snaps to tabs on pump module.
Discard old clamp.
(d) Insert special fuel line removal tool (Snap-On (5) Pry filter/regulator from top of pump module
number FIH 9055-1 or equivalent) into fuel line with 2 screwdrivers. Unit is snapped into module.
(Fig. 20). Use tool to release locking fingers in end (6) Discard gasket below filter/regulator (Fig. 22).
of line. (7) Before discarding filter/regulator assembly,
(e) With special tool still inserted, pull fuel line inspect assembly to verify that o-rings (Fig. 23) are
from fuel rail. intact. If the smallest of the two o-rings can not be
(f) After disconnection, locking fingers will found on bottom of filter/regulator, it may be neces-
remain within quick-connect fitting at end of fuel sary to remove it from the fuel inlet passage in fuel
line. pump module.
14 - 14 FUEL SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 21 Fuel Filter/Fuel Pressure Regulator Fig. 23 Fuel Filter/Fuel Pressure Regulator O-Rings
1 – RETAINER CLAMP 1 – FUEL FILTER/FUEL PRESSURE REGULATOR
2 – FUEL FILTER/FUEL PRESSURE REGULATOR 2 – TO FUEL INJECTORS
3 – FUEL SUPPLY TUBE 3 – FUEL SUPPLY TUBE
4 – ALIGNMENT ARROW 4 – O-RINGS
5 – FUEL INLET FROM PUMP
6 – FUEL RETURN TO TANK
Fig. 26 Fuel Pump Inlet Filter Fig. 28 Fuel Gauge Sending Unit Release Tab
1 – FUEL PUMP MODULE 1 – ELECTRICAL CONNECTOR
2 – FUEL PUMP INLET FILTER 2 – FUEL GAUGE SENDING UNIT
3 – RELEASE TAB
4 – FUEL PUMP MODULE
FUEL GAUGE SENDING UNIT
The fuel gauge sending unit (fuel level sensor) and
float assembly is located on the side of fuel pump (2) Remove fuel pump module. Refer to Fuel Pump
module (Fig. 27). The fuel pump module is located Module Removal/Installation.
within the fuel tank. (3) Remove electrical wire connector at sending
unit terminals.
(4) Press on release tab (Fig. 28) to remove send-
ing unit from pump module.
INSTALLATION
(1) Position sending unit to pump module and
snap into place.
(2) Connect electrical connector to terminals.
(3) Install fuel pump module. Refer to Fuel Pump
Module Removal/Installation.
(4) Install fuel tank. Refer to Fuel Tank Removal/
Installation.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Release fuel system pressure. Refer to the Fuel
System Pressure Release Procedure in this group.
(3) Raise and support vehicle.
(4) If Equipped: Remove fuel tank skid plate. Refer
to Group 23, Body for procedures.
(5) Remove 4 fuel hose shield mounting bolts and
remove fuel hose shield (Fig. 33) from body.
(6) Remove fuel tank fill hose and vent hose
clamps at fuel tank filler tube (Fig. 34). Remove both
Fig. 32 Fuel Injector Mounting hoses at fuel filler tube (Fig. 34).
1 – INLET FITTING (7) Remove exhaust tailpipe heat shield mounting
2 – FUEL INJECTOR RAIL bolts and remove shield.
3 – CLIP
4 – FUEL INJECTOR CAUTION: To protect fuel tank from exhaust heat,
this shield must reinstalled after tank installation.
INSTALLATION (8) Place a hydraulic jack to bottom of fuel tank.
(1) Install fuel injector(s) into fuel rail assembly
and install retaining clip(s). WARNING: PLACE A SHOP TOWEL AROUND FUEL
(2) If same injector(s) is being reinstalled, install LINES TO CATCH ANY EXCESS FUEL.
new o-ring(s).
(3) Apply a small amount of clean engine oil to (9) Disconnect fuel supply line from fuel extension
each injector o-ring. This will aid in installation. line near front of fuel tank (Fig. 35). Refer to Fuel
(4) Install fuel rail. Refer to Fuel Rail Installation. Tubes/Lines/Hoses and Clamps in this group. Also
(5) Start engine and check for fuel leaks. refer to Quick-Connect Fittings for procedures.
(10) Disconnect EVAP canister vent line near front
of tank (Fig. 35).
14 - 20 FUEL SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 33 Fuel Hose Shield Fig. 35 Fuel Tank Connections at Front of Fuel Tank
1 – FUEL HOSE SHIELD 1 – FUEL PUMP MODULE CONNECTOR
2 – MOUNTING BOLTS (4) 2 – LEFT-REAR SHOCK ABSORBER
3 – EVAP CANISTER VENT LINE CONNECTION
4 – FRONT OF FUEL TANK
5 – FUEL SUPPLY LINE CONNECTION
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend unleaded gasoline with MATERIALS ADDED TO FUEL
oxygenates such as 10% ethanol, MTBE, and ETBE. All gasoline sold in the United States and Canada
Oxygenates are required in some areas of the country are required to contain effective detergent additives.
14 - 24 FUEL SYSTEM XJ
SPECIFICATIONS (Continued)
Use of additional detergents or other additives is not of these products contain high concentrations of
needed under normal conditions. methanol. Fuel system damage or vehicle perfor-
mance problems resulting from the use of such fuels
FUEL SYSTEM CAUTIONS or additives is not the responsibility of Daimler-
Chrysler Corporation and may not be covered under
CAUTION: Follow these guidelines to maintain your the new vehicle warranty.
vehicle’s performance:
NOTE: Intentional tampering with emissions control
• The use of leaded gas is prohibited by Federal systems can result in civil penalties being assessed
law. Using leaded gasoline can impair engine perfor- against you.
mance, damage the emission control system, and
could result in loss of warranty coverage.
• An out-of-tune engine, or certain fuel or ignition TORQUE CHART
malfunctions, can cause the catalytic converter to
overheat. If you notice a pungent burning odor or DESCRIPTION TORQUE
some light smoke, your engine may be out of tune or Accelerator Pedal Bracket Mounting Nuts . . 5 N·m
malfunctioning and may require immediate service. (36 in. lbs.)
Contact your dealer for service assistance. Fuel Hose Clamps . . . . . . . . . . . 3 N·m (25 in. lbs.)
• When pulling a heavy load or driving a fully Fuel Rail Mounting Bolts . . . . 11 N·m (100 in. lbs.)
loaded vehicle when the humidity is low and the tem- Fuel Tank Mounting Strap Nuts . . . . . . . . . 10 N·m
perature is high, use a premium unleaded fuel to (90 in. lbs.)
help prevent spark knock. If spark knock persists, Fuel Pump Module Locknut . . . 74 N·m (55 ft. lbs.)
lighten the load, or engine piston damage may result.
• The use of fuel additives which are now being
sold as octane enhancers is not recommended. Most
XJ FUEL SYSTEM 14 - 25
TABLE OF CONTENTS
page page
INTAKE MANIFOLD AIR TEMPERATURE The MAP sensor input is the number one contrib-
utor to fuel injector pulse width. The most important
SENSOR—PCM INPUT
function of the MAP sensor is to determine baromet-
ric pressure. The PCM needs to know if the vehicle is
DESCRIPTION
at sea level or at a higher altitude, because the air
The 2–wire Intake Manifold Air Temperature (IAT)
density changes with altitude. It will also help to cor-
sensor is installed in the intake manifold with the
rect for varying barometric pressure. Barometric
sensor element extending into the air stream.
pressure and altitude have a direct inverse correla-
The IAT sensor is a two-wire Negative Thermal
tion; as altitude goes up, barometric goes down. At
Coefficient (NTC) sensor. Meaning, as intake mani-
key-on, the PCM powers up and looks at MAP volt-
fold temperature increases, resistance (voltage) in the
age, and based upon the voltage it sees, it knows the
sensor decreases. As temperature decreases, resis-
current barometric pressure (relative to altitude).
tance (voltage) in the sensor increases.
Once the engine starts, the PCM looks at the voltage
again, continuously every 12 milliseconds, and com-
OPERATION
pares the current voltage to what it was at key-on.
The IAT sensor provides an input voltage to the
The difference between current voltage and what it
Powertrain Control Module (PCM) indicating the
was at key-on, is manifold vacuum.
density of the air entering the intake manifold based
During key-on (engine not running) the sensor
upon intake manifold temperature. At key-on, a
reads (updates) barometric pressure. A normal range
5–volt power circuit is supplied to the sensor from
can be obtained by monitoring a known good sensor.
the PCM. The sensor is grounded at the PCM
As the altitude increases, the air becomes thinner
through a low-noise, sensor-return circuit.
(less oxygen). If a vehicle is started and driven to a
The PCM uses this input to calculate the following:
very different altitude than where it was at key-on,
• Injector pulse-width
the barometric pressure needs to be updated. Any
• Adjustment of spark timing (to help prevent
time the PCM sees Wide Open Throttle (WOT), based
spark knock with high intake manifold air-charge
upon Throttle Position Sensor (TPS) angle and RPM,
temperatures)
it will update barometric pressure in the MAP mem-
The resistance values of the IAT sensor is the same
ory cell. With periodic updates, the PCM can make
as for the Engine Coolant Temperature (ECT) sensor.
its calculations more effectively.
The PCM uses the MAP sensor input to aid in cal-
MANIFOLD ABSOLUTE PRESSURE (MAP) culating the following:
SENSOR—PCM INPUT • Manifold pressure
• Barometric pressure
DESCRIPTION • Engine load
The Manifold Absolute Pressure (MAP) sensor is • Injector pulse-width
attached to the side of the engine throttle body with • Spark-advance programs
2 screws. The sensor is connected to the throttle body • Shift-point strategies (certain automatic trans-
with a rubber L-shaped fitting. missions only)
• Idle speed
OPERATION • Decel fuel shutoff
The MAP sensor is used as an input to the Power- The MAP sensor signal is provided from a single
train Control Module (PCM). It contains a silicon piezoresistive element located in the center of a dia-
based sensing unit to provide data on the manifold phragm. The element and diaphragm are both made
vacuum that draws the air/fuel mixture into the com- of silicone. As manifold pressure changes, the dia-
bustion chamber. The PCM requires this information phragm moves causing the element to deflect, which
to determine injector pulse width and spark advance. stresses the silicone. When silicone is exposed to
When manifold absolute pressure (MAP) equals stress, its resistance changes. As manifold vacuum
Barometric pressure, the pulse width will be at max- increases, the MAP sensor input voltage decreases
imum. proportionally. The sensor also contains electronics
A 5 volt reference is supplied from the PCM and that condition the signal and provide temperature
returns a voltage signal to the PCM that reflects compensation.
manifold pressure. The zero pressure reading is 0.5V The PCM recognizes a decrease in manifold pres-
and full scale is 4.5V. For a pressure swing of 0–15 sure by monitoring a decrease in voltage from the
psi, the voltage changes 4.0V. To operate the sensor, reading stored in the barometric pressure memory
it is supplied a regulated 4.8 to 5.1 volts. Ground is cell. The MAP sensor is a linear sensor; meaning as
provided through the low-noise, sensor return circuit pressure changes, voltage changes proportionately.
at the PCM.
XJ FUEL SYSTEM 14 - 33
DESCRIPTION AND OPERATION (Continued)
The range of voltage output from the sensor is usu- • Generator field winding
ally between 4.6 volts at sea level to as low as 0.3 • Fuel injectors
volts at 26 in. of Hg. Barometric pressure is the pres- • Ignition coil(s)
sure exerted by the atmosphere upon an object. At • Certain relays/solenoids
sea level on a standard day, no storm, barometric • Certain sensors
pressure is approximately 29.92 in Hg. For every 100
feet of altitude, barometric pressure drops.10 in. Hg. POWER STEERING PRESSURE SWITCH—PCM
If a storm goes through it can change barometric INPUT
pressure from what should be present for that alti-
tude. You should know what the average pressure DESCRIPTION
and corresponding barometric pressure is for your A pressure sensing switch (Fig. 2) is included in
area. the power steering system (mounted on the high-
pressure line). This switch will be used only on vehi-
OIL PRESSURE SENSOR—PCM INPUT cles equipped with a 2.5L engine and power steering.
DESCRIPTION
The 3–wire, solid-state engine oil pressure sensor
(sending unit) is located in an engine oil pressure
gallery.
OPERATION
The oil pressure sensor uses three circuits. They
are:
• A 5–volt power supply from the Powertrain Con-
trol Module (PCM)
• A sensor ground through the PCM’s sensor
return
• A signal to the PCM relating to engine oil pres-
sure
The oil pressure sensor has a 3–wire electrical
function very much like the Manifold Absolute Pres-
sure (MAP) sensor. Meaning different pressures
relate to different output voltages.
A 5–volt supply is sent to the sensor from the PCM
Fig. 2 Power Steering Pump Pressure Switch—2.5L
to power up the sensor. The sensor returns a voltage
Engine
signal back to the PCM relating to engine oil pres-
1 – POWER STEERING PRESSURE SWITCH
sure. This signal is then transferred (bussed) to the
2 – ELECTRICAL CONNECTOR
instrument panel on either a CCD or PCI bus circuit 3 – POWER STEERING PUMP
(depending on vehicle line) to operate the oil pressure
gauge and the check gauges lamp. Ground for the
sensor is provided by the PCM through a low-noise OPERATION
sensor return. The power steering pressure switch provides an
input to the Powertrain Control Module (PCM). This
POWER GROUNDS input is provided during periods of high pump load
and low engine rpm; such as during parking maneu-
OPERATION vers. The PCM will then increase the idle speed
The Powertrain Control Module (PCM) has 2 main through the Idle Air Control (IAC) motor. This is
grounds. Both of these grounds are referred to as done to prevent the engine from stalling under the
power grounds. All of the high-current, noisy, electri- increased load.
cal devices are connected to these grounds as well as When steering pump pressure exceeds 3275 kPa 6
all of the sensor returns. The sensor return comes 690 kPa (475 psi 6 100 psi), the normally closed
into the sensor return circuit, passes through noise switch will open and the PCM will increase the
suppression, and is then connected to the power engine idle speed. This will prevent the engine from
ground. stalling.
The power ground is used to control ground cir-
cuits for the following PCM loads:
14 - 34 FUEL SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
When pump pressure drops to approximately 1379 VEHICLE SPEED AND DISTANCE SENSOR—
kPa (200 psi), the switch circuit will re-close and
PCM INPUT
engine idle speed will return to its previous setting.
DESCRIPTION
SENSOR RETURN—PCM INPUT The 3–wire Vehicle Speed Sensor (VSS) is located
on the speedometer pinion gear adapter. If equipped
OPERATION with 4WD, this adapter is located on the extension
The Sensor Return circuits are internal to the Pow- housing of the transfer case (drivers side). If
ertrain Control Module (PCM). equipped with 2WD, this adapter is located on the
Sensor Return provides a low–noise ground refer- left side of the transmission extension housing.
ence for all engine control system sensors. Refer to
Power Grounds for more information. OPERATION
The VSS is a 3–circuit (3–wire), magnetic, hall-ef-
THROTTLE POSITION SENSOR (TPS)—PCM fect sensor.
INPUT The 3 circuits are:
• A 5–volt power supply from the Powertrain Con-
DESCRIPTION trol Module (PCM).
The 3–wire Throttle Position Sensor (TPS) is • A ground is provided for the sensor though a
mounted on the throttle body and is connected to the low-noise sensor return circuit in the PCM.
throttle blade. • An input to the PCM is used to determine vehi-
cle speed and distance traveled.
OPERATION The speed sensor generates 8 pulses per sensor
The TPS is a 3–wire variable resistor that provides revolution. These signals, in conjunction with a
the Powertrain Control Module (PCM) with an input closed throttle signal from the throttle position sen-
signal (voltage) that represents the throttle blade sor, indicate a closed throttle deceleration to the
position of the throttle body. The sensor is connected PCM. When the vehicle is stopped at idle, a closed
to the throttle blade shaft. As the position of the throttle signal is received by the PCM (but a speed
throttle blade changes, the resistance (output volt- sensor signal is not received).
age) of the TPS changes. Under deceleration conditions, the PCM adjusts
The PCM supplies approximately 5 volts to the the Idle Air Control (IAC) motor to maintain a
TPS. The TPS output voltage (input signal to the desired MAP value. Under idle conditions, the PCM
PCM) represents the throttle blade position. The adjusts the IAC motor to maintain a desired engine
PCM receives an input signal voltage from the TPS. speed.
This will vary in an approximate range of from.26
volts at minimum throttle opening (idle), to 4.49 volts AUTO SHUTDOWN (ASD) RELAY—PCM
at wide open throttle. Along with inputs from other OUTPUT
sensors, the PCM uses the TPS input to determine
current engine operating conditions. In response to DESCRIPTION
engine operating conditions, the PCM will adjust fuel The 5–pin, 12–volt, Automatic Shutdown (ASD)
injector pulse width and ignition timing. relay is located in the Power Distribution Center
The PCM needs to identify the actions and position (PDC). Refer to label on PDC cover for relay location.
of the throttle blade at all times. This information is
needed to assist in performing the following calcula- OPERATION
tions: The ASD relay supplies battery voltage (12+ volts)
• Ignition timing advance to the fuel injectors and ignition coil(s). With certain
• Fuel injection pulse-width emissions packages it also supplies 12–volts to the
• Idle (learned value or minimum TPS) oxygen sensor heating elements.
• Off-idle (0.06 volt) The ground circuit for the coil within the ASD
• Wide Open Throttle (WOT) open loop (2.608 relay is controlled by the Powertrain Control Module
volts above learned idle voltage) (PCM). The PCM operates the ASD relay by switch-
• Deceleration fuel lean out ing its ground circuit on and off.
• Fuel cutoff during cranking at WOT (2.608 volts The ASD relay will be shut–down, meaning the
above learned idle voltage) 12–volt power supply to the ASD relay will be de-ac-
• A/C WOT cutoff (certain automatic transmis- tivated by the PCM if:
sions only)
XJ FUEL SYSTEM 14 - 35
DESCRIPTION AND OPERATION (Continued)
• the ignition key is left in the ON position. This injector pulse width based on various inputs it
is if the engine has not been running for approxi- receives.
mately 1.8 seconds. Battery voltage (12 volts +) is supplied to the injec-
• there is a crankshaft position sensor signal to tors through the ASD relay. The ASD relay will shut-
the PCM that is lower than pre-determined values. down the 12 volt power source to the fuel injectors if
The PCM will sense if or when the ASD relay has the PCM senses the ignition is on, but the engine is
been activated through a “sense circuit”. Refer to not running. This occurs after the engine has not
Automatic Shut-Down (ASD) Relay Sense-PCM Input been running for approximately 1.8 seconds.
for additional information. The PCM determines injector on-time (pulse width)
based on various inputs.
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS
FUEL PUMP RELAY-PCM OUTPUT
OPERATION
The Powertrain Control Module (PCM) sends cer- DESCRIPTION
tain output signals through the CCD bus circuits. The 5–pin, 12–volt, fuel pump relay is located in
These signals are used to control certain instrument the Power Distribution Center (PDC). Refer to the
panel located items and to determine certain identi- label on the PDC cover for relay location.
fication numbers.
Refer to Group 8E, Instrument Panel and Gauges OPERATION
for additional information. The Powertrain Control Module (PCM) energizes
the electric fuel pump through the fuel pump relay.
DATA LINK CONNECTOR—PCM INPUT AND The fuel pump relay is energized by first applying
OUTPUT battery voltage to it when the ignition key is turned
ON, and then applying a ground signal to the relay
DESCRIPTION from the PCM.
The data link connector is located at the lower Whenever the ignition key is turned ON, the elec-
edge of the instrument panel near the steering col- tric fuel pump will operate. But, the PCM will shut-
umn. down the ground circuit to the fuel pump relay in
approximately 1–3 seconds unless the engine is oper-
OPERATION ating or the starter motor is engaged.
The 16–way data link connector (diagnostic scan
tool connector) links the Diagnostic Readout Box IDLE AIR CONTROL (IAC) MOTOR—PCM
(DRB) scan tool or the Mopar Diagnostic System OUTPUT
(MDS) with the Powertrain Control Module (PCM).
DESCRIPTION
FUEL INJECTORS—PCM OUTPUT The IAC stepper motor is mounted to the throttle
body, and regulates the amount of air bypassing the
DESCRIPTION control of the throttle plate. As engine loads and
The fuel injectors are connected to the engine with ambient temperatures change, engine rpm changes. A
the fuel injector rail. pintle on the IAC stepper motor protrudes into a pas-
sage in the throttle body, controlling air flow through
OPERATION the passage. The IAC is controlled by the Powertrain
The nozzle ends of the injectors are positioned into Control Module (PCM) to maintain the target engine
openings in the intake manifold just above the intake idle speed.
valve ports of the cylinder head. The engine wiring
harness connector for each fuel injector is equipped OPERATION
with an attached numerical tag (INJ 1, INJ 2 etc.). At idle, engine speed can be increased by retract-
This is used to identify each fuel injector with its ing the IAC motor pintle and allowing more air to
respective cylinder number. pass through the port, or it can be decreased by
The injectors are energized individually in a restricting the passage with the pintle and diminish-
sequential order by the Powertrain Control Module ing the amount of air bypassing the throttle plate.
(PCM). The PCM will adjust injector pulse width by The IAC is called a stepper motor because it is
switching the ground path to each individual injector moved (rotated) in steps, or increments. Opening the
on and off. Injector pulse width is the period of time IAC opens an air passage around the throttle blade
that the injector is energized. The PCM will adjust which increases RPM.
14 - 36 FUEL SYSTEM XJ
DESCRIPTION AND OPERATION (Continued)
The PCM uses the IAC motor to control idle speed can anticipate A/C compressor loads. This is accom-
(along with timing) and to reach a desired MAP dur- plished by delaying compressor operation for approx-
ing decel (keep engine from stalling). imately 0.5 seconds until the PCM moves the IAC
The IAC motor has 4 wires with 4 circuits. Two of stepper motor to the recorded steps that were loaded
the wires are for 12 volts and ground to supply elec- into the memory cell. Using this program helps elim-
trical current to the motor windings to operate the inate idle-quality changes as loads change. Finally,
stepper motor in one direction. The other 2 wires are the PCM incorporates a “No-Load9 engine speed lim-
also for 12 volts and ground to supply electrical cur- iter of approximately 1800 - 2000 rpm, when it rec-
rent to operate the stepper motor in the opposite ognizes that the TPS is indicating an idle signal and
direction. IAC motor cannot maintain engine idle.
To make the IAC go in the opposite direction, the A (factory adjusted) set screw is used to mechani-
PCM just reverses polarity on both windings. If only cally limit the position of the throttle body throttle
1 wire is open, the IAC can only be moved 1 step plate. Never attempt to adjust the engine idle
(increment) in either direction. To keep the IAC speed using this screw. All idle speed functions are
motor in position when no movement is needed, the controlled by the IAC motor through the PCM.
PCM will energize both windings at the same time.
This locks the IAC motor in place. RADIATOR FAN RELAY—PCM OUTPUT
In the IAC motor system, the PCM will count
every step that the motor is moved. This allows the DESCRIPTION
PCM to determine the motor pintle position. If the The electric radiator cooling fan relay is located in
memory is cleared, the PCM no longer knows the the Power Distribution Center (PDC).
position of the pintle. So at the first key ON, the
PCM drives the IAC motor closed, regardless of OPERATION
where it was before. This zeros the counter. From An electric radiator cooling fan is used with certain
this point the PCM will back out the IAC motor and models/engines. It is controlled by the Powertrain
keep track of its position again. Control Module (PCM) through the radiator fan
When engine rpm is above idle speed, the IAC is relay. Not Equipped With A/C: The relay is ener-
used for the following: gized when coolant temperature is above 103°C
• Off-idle dashpot (throttle blade will close quickly (217°F). It will then de-energize when coolant tem-
but idle speed will not stop quickly) perature drops to 98°C (208°F). Refer to Cooling Sys-
• Deceleration air flow control tems for additional information. Equipped With
• A/C compressor load control (also opens the pas- A/C: In addition to using coolant temperatures to
sage slightly before the compressor is engaged so control cooling fan operation, a two-gang A/C high-
that the engine rpm does not dip down when the pressure switch is also used to control cooling fan
compressor engages) operation. When equipped with this high-pressure
• Power steering load control switch, the cooling fan will not operate each time
The PCM can control polarity of the circuit to con- the A/C clutch is engaged. Refer to Heating and Air
trol direction of the stepper motor. Conditioning for additional information.
IAC Stepper Motor Program: The PCM is also
equipped with a memory program that records the THROTTLE BODY
number of steps the IAC stepper motor most recently
advanced to during a certain set of parameters. For DESCRIPTION
example: The PCM was attempting to maintain a The throttle body is located on the intake manifold.
1000 rpm target during a cold start-up cycle. The last Fuel does not enter the intake manifold through the
recorded number of steps for that may have been throttle body. Fuel is sprayed into the manifold by
125. That value would be recorded in the memory the fuel injectors.
cell so that the next time the PCM recognizes the
identical conditions, the PCM recalls that 125 steps OPERATION
were required to maintain the target. This program Filtered air from the air cleaner enters the intake
allows for greater customer satisfaction due to manifold through the throttle body. The throttle body
greater control of engine idle. contains an air control passage controlled by an Idle
Another function of the memory program, which Air Control (IAC) motor. The air control passage is
occurs when the power steering switch (if equipped), used to supply air for idle conditions. A throttle valve
or the A/C request circuit, requires that the IAC step- (plate) is used to supply air for above idle conditions.
per motor control engine rpm, is the recording of the Certain sensors are attached to the throttle body.
last targeted steps into the memory cell. The PCM The accelerator pedal cable, speed control cable and
XJ FUEL SYSTEM 14 - 37
DESCRIPTION AND OPERATION (Continued)
transmission control cable (when equipped) are con-
nected to the throttle body linkage arm.
A (factory adjusted) set screw is used to mechani-
cally limit the position of the throttle body throttle
plate. Never attempt to adjust the engine idle
speed using this screw. All idle speed functions are
controlled by the PCM.
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
TESTING
The following procedure applies to the ASD and
fuel pump relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be between 75
65 ohms. Fig. 20 6714 Fixed Orifice Tool
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
XJ FUEL SYSTEM 14 - 43
DIAGNOSIS AND TESTING (Continued)
(1) Start the engine and bring to operating tem-
perature. Be sure all accessories are off before per-
forming this test.
(2) Shut off engine and remove air duct at throttle
body.
(3) 2.5L 4–Cylinder Engine: Near front/top of
valve cover, disconnect CCV tube at fixed orifice fit-
ting (Fig. 21). Insert Special Tool 6714 into end of
disconnected CCV tube (insert either end of tool into
tube). Let tool and tube hang disconnected at side of
engine.
(4) 4.0L 6–Cylinder Engine: Disconnect CCV
tube (Fig. 22) at intake manifold fitting. Attach a
short piece of rubber hose to special tool 6714 (insert
rubber hose to either end of tool). Install rubber hose/
tool to intake manifold fitting. Let CCV tube hang
disconnected at side of engine.
Fig. 23 Power Distribution Center (PDC) Fig. 24 Throttle Body and Sensor Locations—4.0L
1 – POWER DISTRIBUTION CENTER (PDC) Engine
1 – MOUNTING BOLTS (4)
2 – THROTTLE BODY
FUEL PUMP RELAY 3 – IAC MOTOR
The fuel pump relay is located in the Power Distri- 4 – ELEC. CONN.
bution Center (PDC) (Fig. 23). Refer to label on PDC 5 – TPS
cover for relay location. 6 – MAP SENSOR
7 – ELEC. CONN.
REMOVAL 8 – IAT SENSOR
(1) Remove PDC cover. 9 – ELEC. CONN.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC (3) Remove all control cables from throttle body
connector terminals for damage or corrosion. Repair (lever) arm. Refer to the Accelerator Pedal and Throt-
if necessary before installing relay. tle Cable section of this group for additional informa-
(4) Check for pin height (pin height should be the tion.
same for all terminals within the PDC connector). (4) Remove four throttle body mounting bolts.
Repair if necessary before installing relay. (5) Remove throttle body from intake manifold.
(6) Discard old throttle body-to-intake manifold
INSTALLATION gasket.
(1) Install relay to PDC.
(2) Install cover to PDC. INSTALLATION
(1) Clean mating surfaces of throttle body and
THROTTLE BODY intake manifold.
A (factory adjusted) set screw is used to mechani- (2) Install new throttle body-to-intake manifold
cally limit the position of the throttle body throttle gasket.
plate. Never attempt to adjust the engine idle (3) Install throttle body to intake manifold.
speed using this screw. All idle speed functions are (4) Install four mounting bolts. Tighten bolts to 11
controlled by the Powertrain Control Module (PCM). N·m (100 in. lbs.) torque.
(5) Install control cables.
REMOVAL (6) Install electrical connectors.
(1) Remove air cleaner tube at throttle body. (7) Install air cleaner at throttle body.
(2) Disconnect throttle body electrical connectors
at MAP sensor, IAC motor and TPS (Fig. 24) or (Fig.
25).
XJ FUEL SYSTEM 14 - 45
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Remove air cleaner tube at throttle body.
(2) Disconnect TPS electrical connector.
(3) Remove TPS mounting screws (Fig. 26).
Fig. 27 Throttle Position Sensor—Installation
(4) Remove TPS.
1 – TANGS
2 – THROTTLE SHAFT
INSTALLATION 3 – THROTTLE BODY
The throttle shaft end of the throttle body slides 4 – TPS
into a socket in the TPS (Fig. 27). The TPS must be
installed so that it can be rotated a few degrees. (If
the sensor will not rotate, install the sensor with the REMOVAL
throttle shaft on the other side of the socket tangs). (1) Remove air cleaner tube at throttle body.
The TPS will be under slight tension when rotated. (2) Disconnect electrical connector from IAC motor.
(1) Install TPS and retaining screws. (3) Remove two mounting bolts (screws) (Fig. 28).
(2) Tighten screws to 7 N·m (60 in. lbs.) torque. (4) Remove IAC motor from throttle body.
(3) Connect TPS electrical connector to TPS.
(4) Manually operate throttle (by hand) to check INSTALLATION
for any TPS binding before starting engine. (1) Install IAC motor to throttle body.
(5) Install air cleaner tube to throttle body. (2) Install and tighten two mounting bolts (screws)
to 7 N·m (60 in. lbs.) torque.
IDLE AIR CONTROL (IAC) MOTOR (3) Install electrical connector.
The IAC motor is located on the side of the throttle (4) Install air cleaner tube to throttle body.
body (Fig. 24) or (Fig. 25).
14 - 46 FUEL SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
(3) While removing MAP sensor, slide the rubber
L-shaped fitting (Fig. 29) from throttle body.
(4) Remove rubber L-shaped fitting from MAP sen-
sor.
INSTALLATION
(1) Install rubber L-shaped fitting to MAP sensor.
(2) Position sensor to throttle body while guiding
rubber fitting over throttle body vacuum nipple.
(3) Install MAP sensor mounting bolts (screws).
Tighten screws to 3 N·m (25 in. lbs.) torque.
(4) Install air cleaner intake tube.
REMOVAL
To avoid possible voltage spike damage to the
PCM, ignition key must be off, and negative battery
cable must be disconnected before unplugging PCM
connectors.
(1) Disconnect negative battery cable at battery.
(2) Remove cover over electrical connectors. Cover
snaps onto PCM.
Fig. 29 MAP Sensor Mounting
(3) Carefully unplug the three 32–way connectors
1 – THROTTLE BODY
2 – MAP SENSOR
(Fig. 31) from PCM.
3 – RUBBER FITTING (4) Remove three PCM mounting bolts and remove
4 – MOUNTING SCREWS (2) PCM from vehicle.
INSTALLATION
REMOVAL (1) Install PCM and mounting bolts to vehicle.
(1) Remove air cleaner intake tube at throttle (2) Tighten bolts to 4 N·m (35 in. lbs.).
body. (3) Check pin connectors in the PCM and the three
(2) Remove two MAP sensor mounting bolts 32–way connectors for corrosion or damage. Also, the
(screws) (Fig. 29). pin heights in connectors should all be same. Repair
as necessary before installing connectors.
XJ FUEL SYSTEM 14 - 47
REMOVAL AND INSTALLATION (Continued)
Fig. 37 Air Cleaner Housing and Element (Filter) Fig. 39 Clamp Installation
1 – COVER 1 – CLAMP
2 – AIR TUBE 2 – ADJUSTABLE PLIERS
3 – CLAMPS (2)
4 – HOUSING
5 – CLIPS (3) ENGINE COOLANT TEMPERATURE SENSOR
6 – ELEMENT (FILTER)
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
INSTALLATION MUST BE PARTIALLY DRAINED BEFORE REMOV-
(1) Install air cleaner element into housing. ING THE COOLANT TEMPERATURE SENSOR.
(2) Install air cleaner cover to housing (three REFER TO GROUP 7, COOLING.
clips). Be sure cover is properly seated to air cleaner
housing. The coolant temperature sensor is installed in the
(3) Install air tube and clamp to cover. Compress thermostat housing (Fig. 40).
clamp snugly with adjustable pliers as shown in (Fig.
39). REMOVAL
(1) Partially drain cooling system until coolant
level is below cylinder head. Observe the WARN-
INGS in Group 7, Cooling.
14 - 50 FUEL SYSTEM XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL
(1) Disconnect electrical connector from IAT sen-
sor.
(2) Remove sensor from intake manifold.
INSTALLATION
(1) Install IAT sensor into intake manifold.
Tighten sensor to 28 N·m (20 ft. lbs.) torque. Fig. 42 IAT Sensor Location—2.5L Engine
(2) Connect electrical connector to sensor. 1 – ELECTRICAL CONNECTOR
2 – INTAKE MANIFOLD TEMPERATURE SENSOR
3 – FUEL INJECTOR
XJ FUEL SYSTEM 14 - 51
REMOVAL AND INSTALLATION (Continued)
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench—6856
STEERING
TABLE OF CONTENTS
page page
POWER STEERING
TABLE OF CONTENTS
page page
OPERATION
The steering gear acts as a rolling thread between the rack piston. The rack piston movement turns the
the worm shaft and the rack piston. Power assist is pitman shaft which is connected to the steering link-
provided by the hydraulic pump. When the steering age by the pitman arm.
wheel is turned the worm shaft turns which moves
19 - 2 STEERING XJ
There is some noise in all power steering systems. One of the most common is a hissing sound evident at a
standstill parking. Or when the steering wheel is at the end of it’s travel. Hiss is a high frequency noise similar
to that of a water tap being closed slowly. The noise is present in all valves that have a high velocity fluid passing
through an orifice. There is no relationship between this noise and steering performance.
OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash panel 1. Check and repair seal at dash
WHISTLE seal. panel.
TABLE OF CONTENTS
page page
OPERATION
The power steering pump is a constant flow rate
and displacement, vane-type pump. The pump inter-
nal parts operate submerged in fluid. The flow con-
trol orifice is part of the high pressure line fitting.
The pressure relief valve inside the flow control valve
Fig. 1 Pump With Integral Reservoir
limits the pump pressure.
1 – CAP
2 – FLUID RESERVOIR (TYPICAL)
NOTE: Power steering pumps have different pres-
3 – HIGH-PRESSURE FITTING
sure rates and are not interchangeable with other
4 – DRIVE PULLEY
pumps. 5 – PUMP BODY
6 – RESERVOIR CLIP
POWER STEERING RETURN LINE (4) Disconnect high pressure hose at the pump.
Use a container for dripping fluid.
DESCRIPTION (5) Connect Tube 6865 to the pump hose fitting.
Power steering return line is a hose which is (6) Connect the power steering hose from the
clamped at the pump and the gear. steering gear to Adapter 6826.
(7) Open the test valve completely.
OPERATION (8) Start engine and let idle long enough to circu-
Power steering return line, is used to transfer low late power steering fluid through flow/pressure test
pressure power steering fluid, from the power steer- gauge and to get air out of the fluid. Then shut off
ing gear to the power steering pump. engine.
(9) Check fluid level, add fluid as necessary. Start
engine again and let idle.
DIAGNOSIS AND TESTING (10) Gauge should read below 862 kPa (125 psi), if
above, inspect the hoses for restrictions and repair as
POWER FLOW AND PRESSURE necessary. The initial pressure reading should be in
The following procedure is used to test the opera- the range of 345-552 kPa (50-80 psi).
tion of the power steering system on the vehicle. This (11) Increase the engine speed to 1500 RPM and
test will provide the gallons per minute (GPM) or read the flow meter. The reading should be 2.4 - 2.8
flow rate of the power steering pump along with the GPM, if the reading is below this specification the
maximum relief pressure. Perform test any time a pump should be replaced.
power steering system problem is present. This test
will determine if the power steering pump or power CAUTION: The next step involves testing maximum
steering gear is not functioning properly. The follow- pump pressure output and flow control valve oper-
ing pressure and flow test is performed using Power ation. Do not leave valve closed for more than three
Steering Analyzer Tool Kit 6815 (Fig. 2) and Adapter seconds as the pump could be damaged.
Kit 6893.
(12) Close valve fully three times and record high-
est pressure indicated each time. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
• Pressures above specifications but not within
345 kPa (50 psi) of each other, replace pump.
• Pressures within 345 kPa (50 psi) of each other
but below specifications, replace pump.
(13) Open the test valve, turn steering wheel
extreme left and right positions against the stops.
Record the highest indicated pressure at each posi-
tion. Compare readings to specifications. If highest
output pressures are not the same against either
stop, the gear is leaking internally and must be
repaired.
PUMP LEAKAGE DIAGNOSIS (8) Stop the engine and check the fluid level and
refill as required.
(9) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
REMOVAL
(1) Remove serpentine drive belt, refer to Group 7
Cooling.
(2) Remove pressure and return hoses from pump,
and drain pump.
(3) Remove 3 pump mounting bolts through pulley
access holes.
(4) Loosen the 3 pump bracket bolts (Fig. 3) and
SERVICE PROCEDURES (Fig. 4).
(5) Tilt pump downward and remove from engine.
POWER STEERING PUMP - INITIAL (6) Remove pulley from pump.
OPERATION
INSTALLATION
WARNING: THE FLUID LEVEL SHOULD BE (1) Install pulley on pump.
CHECKED WITH ENGINE OFF TO PREVENT INJURY (2) Install pump on engine.
FROM MOVING COMPONENTS. (3) Tighten pump bracket bolts to 47 N·m (35 ft.
lbs.).
(4) Install 3 pump mounting bolts and tighten to
CAUTION: Use MOPAR Power Steering Fluid or
27 N·m (20 ft. lbs.).
equivalent. Do not use automatic transmission fluid
(5) Install the pressure and return hoses to pump.
and do not overfill.
(6) Install drive belt, refer to Group 7 Cooling.
Wipe filler cap clean, then check the fluid level. (7) Add power steering fluid and perform Power
The dipstick should indicate COLD when the fluid is Steering Pump Initial Operation.
at normal ambient temperature.
(1) Fill the pump fluid reservoir to the proper level PUMP RESERVOIR-2.5L
and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds REMOVAL
then turn engine off. (1) Remove the hoses from the bottom of the res-
(3) Add fluid if necessary. Repeat the above proce- ervoir and drain the reservoir.
dure until the fluid level remains constant after run- (2) Remove the push-in fastener from the top of
ning the engine. the fan shroud.
(4) Raise the front wheels off the ground. (3) Slide reservoir up off the fan shroud.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times. INSTALLATION
(6) Check the fluid level add if necessary. (1) Slide reservoir down onto fan shroud.
(7) Lower the vehicle, start the engine and turn (2) Install the push-in fastener in the top of fan
the steering wheel slowly from lock to lock. shroud.
19 - 8 STEERING XJ
REMOVAL AND INSTALLATION (Continued)
(3) Install the pump hoses. (4) With Serpentine Belt, run engine until warm (5
(4) Fill reservoir to proper level. Refer to Power min.) and note any belt chirp. If chirp exists, move
Steering Pump Initial Operation. pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.). Be
careful that pulley does not contact mounting
DISASSEMBLY AND ASSEMBLY bolts.
(2) Install O-ring seal in housing. (5) Install power steering pump.
(3) Install reservoir onto housing. (6) Add power steering fluid, refer to Pump Initial
(4) Slide and tap in new reservoir retainer clips Operation.
until tab locks to housing.
19 - 10 STEERING XJ
DISASSEMBLY AND ASSEMBLY (Continued)
SPECIAL TOOLS
POWER STEERING PUMP
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Pump
Bracket to Pump . . . . . . . . . . 28 N·m (21 ft. lbs.)
Bracket to Engine . . . . . . . . . 47 N·m (35 ft. lbs.)
Flow Control Valve . . . . . . . . 75 N·m (55 ft. lbs.)
Pressure Line . . . . . . . . . . . . . 28 N·m (21 ft. lbs.)
Puller C-4333
TABLE OF CONTENTS
page page
OPERATION
The gear acts as a rolling thread between the
worm shaft and rack piston. The worm shaft is sup-
ported by a thrust bearing at the lower end and a
bearing assembly at the upper end. When the worm
shaft is turned the rack piston moves. The rack pis-
ton teeth mesh with the pitman shaft. Turning the
worm shaft turns the pitman shaft, which turns the
steering linkage.
SPOOL VALVE
DISASSEMBLY
(1) Remove lock nut (Fig. 8).
Fig. 6 Pitman Shaft Seals & Bearing (2) Remove adjuster nut with Spanner Wrench
1 – BEARING C-4381.
2 – WASHER
(3) Remove thrust support assembly out of the
3 – DUST SEAL
housing (Fig. 9).
4 – RETAINER
5 – OIL SEAL
(4) Pull stub shaft and valve assembly from the
housing (Fig. 10).
ASSEMBLY
(12) Remove the adjuster lock nut and adjuster
nut from the stub shaft. NOTE: Clean and dry all components and lubricate
(13) Pull the stub shaft with the spool valve and with power steering fluid.
thrust support assembly out of the housing.
(14) Remove the worm shaft from the housing (1) Check for scores, nicks or burrs on the rack
(Fig. 20). piston finished surface. Slight wear is normal on the
worm gear surfaces.
19 - 18 STEERING XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Install remaining balls in guide using grease to
hold the balls in place (Fig. 22).
ADJUSTMENTS
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.
DESCRIPTION TORQUE
Power Steering Gear
Adjustment Cap Locknut . . . 108 N·m (80 ft. lbs.)
Remover/Installer Steering Rack Piston C-4175
Adjustment Screw Locknut . . 49 N·m (36 ft. lbs.)
Gear to Frame Bolts . . . . . . . 95 N·m (70 ft. lbs.)
Pitman Shaft Nut . . . . . . . 251 N·m (185 ft. lbs.)
Rack Piston Plug . . . . . . . . . 102 N·m (75 ft. lbs.)
Side Cover Bolts . . . . . . . . . . 60 N·m (44 ft. lbs.)
Pressure Line . . . . . . . . . . . . . 28 N·m (21 ft. lbs.)
Return Line . . . . . . . . . . . . . . 28 N·m (21 ft. lbs.)
Return Guide Clamp Bolt . . . 58 N·m (43 ft. lbs.)
19 - 22 STEERING XJ
STEERING LINKAGE
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION specifications are the same for LHD and RHD vehi-
cles.
STEERING LINKAGE
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
DESCRIPTION
the slot in the nut does not line up with the cotter
The steering linkage consist of a pitman arm, drag
pin hole, tighten nut until it is aligned. Never loosen
link, tie rod, tie rod ends and a steering damper (Fig.
the nut to align the cotter pin hole.
1) and (Fig. 2). The service procedures and torque
INSTALLATION
(1) Align and install the pitman arm on steering
gear shaft.
(2) Install the washer and nut on the shaft and
tighten nut to 251 N·m (185 ft. lbs.).
(3) Install drag link ball stud to pitman arm
install nut and tighten to 74 N·m (55 ft. lbs.). Install
a new cotter pin.
DRAG LINK
REMOVAL
(1) Remove cotter pins and nuts from drag link
Fig. 4 Tie Rod/Drag Link Clamps (2) Remove the steering damper ball stud from the
1 – TIE ROD CLAMP
drag link.
2 – DRAG LINK CLAMPS (3) Remove tie rod from drag link
(4) Remove drag link from the steering knuckle
and pitman arm.
PITMAN ARM
INSTALLATION
REMOVAL (1) Install the drag link onto steering knuckle and
(1) Remove the cotter pin and nut from the drag pitman arm.
link at the pitman arm. (2) Install nut at steering knuckle and tighten to
(2) Remove the drag link ball stud from the pit- 47 N·m (35 ft. lbs.). Install new cotter pins.
man arm with a puller. (3) Install nut at pitman arm and tighten to 74
(3) Remove the nut and washer from the steering N·m (55 ft. lbs.). Install new cotter pins.
gear shaft. Mark the pitman shaft and pitman arm (4) Install tie rod onto drag link and install nut.
for installation reference. Remove the pitman arm Tighten nut to 74 N·m (55 ft. lbs.) and install new
from steering gear with Puller C-4150-A (Fig. 5). cotter pins.
XJ STEERING 19 - 25
REMOVAL AND INSTALLATION (Continued)
(5) Install steering damper onto drag link and SPECIAL TOOLS
install nut. Tighten nut to 74 N·m (55 ft. lbs.) and
install a new cotter pin. STEERING LINKAGE
STEERING DAMPER
REMOVAL
(1) Remove the steering damper retaining bolt
from the axle bracket.
(2) Remove the cotter pin and nut from the ball
stud at the drag link.
(3) Remove the steering damper ball stud from the
drag link with Puller C-3894-A.
Puller C-3894–A
INSTALLATION
(1) Install steering damper onto the axle bracket
and drag link.
(2) Install steering damper bolt in axle bracket
and tighten nut to 75 N·m (55 ft. lbs.).
(3) Install ball stud nut at the drag link and
tighten nut to 75 N·m (55 ft. lbs.). Install a new cot-
ter pin.
DESCRIPTION TORQUE
Pitman Arm
Shaft . . . . . . . . . . . . . . . . . 251 N·m (185 ft. lbs.)
Drag Link
Ball Studs . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)
Clamp . . . . . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.)
Tie Rod Ends
Ball Studs . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)
Clamp . . . . . . . . . . . . . . . . . . 27 N·m (20 ft. lbs.)
Tie Rod
Ball Stud . . . . . . . . . . . . . . . . 47 N·m (35 ft. lbs.)
Steering Damper
Frame . . . . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)
Drag Link . . . . . . . . . . . . . . . 74 N·m (55 ft. lbs.)
19 - 26 STEERING XJ
STEERING COLUMN
TABLE OF CONTENTS
page page
(6) Remove knee blocker cover and knee blocker, (11) Remove column.
Refer to Group 8E Instrument Panel Systems. (12) Remove nut and bolt from the upper column
(7) Remove screws from the lower column shroud mounting bracket on non-tilt column (Fig. 6). Remove
(Fig. 3) and remove lower shroud. the bracket from the column and note the mount-
(8) Remove the steering coupler bolt and column ing location and orientation of the bracket..
mounting nuts (Fig. 4) then lower column off the (13) Remove clock spring, switches, (SKIM if
mounting stud. equipped) and ignition key cylinder, refer to Group 8
(9) Remove upper column shroud (Fig. 3). Electrical for service procedures.
(10) Disconnect and remove the wiring harness
from the column (Fig. 5). INSTALLATION
(1) Install upper column mounting bracket on non-
NOTE: If vehicle is equipped with automatic trans-
tilt column. Install the mounting bolt and tighten the
mission, remove shifter interlock cable. Refer to
nut to 17 N·m (150 in. lbs.).
Group 21 Transmission and Transfer Case for pro-
(2) Install switches, refer to Group 8 Electrical for
cedure.
service procedures.
19 - 28 STEERING XJ
REMOVAL AND INSTALLATION (Continued)
(4) Install column harness and connect harness to
switches.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Tilt Steering Column
Steering Wheel Nut . . . . . . . . 54 N·m (40 ft. lbs.)
Mounting Nuts . . . . . . . . . . . 23 N·m (17 ft. lbs.)
Coupler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.)
Fig. 6 Non-Tilt Column Non-Tilt Steering Column
1 – NON-TILT COLUMN Steering Wheel Nut . . . . . . . . 54 N·m (40 ft. lbs.)
2 – UPPER BRACKET Mounting Nuts . . . . . . . . . . . 23 N·m (17 ft. lbs.)
Coupler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft. lbs.)
(3) Align and install column into the steering cou- Upper Bracket Nut . . . . . . . 17 N·m (150 in. lbs.)
pler.
XJ TRANSMISSION AND TRANSFER CASE 21 - 1
page page
TABLE OF CONTENTS
page page
LUBRICANT
Fig. 2 Transmission Identification
DESCRIPTION
1 – I. D. CODE ON CASE NEAR DRAIN PLUG
Recommended lubricant for AX5 transmissions is
Mopart 75W–90, API Grade GL–3 gear lubricant, or
engaged. The input shaft is connected to the trans- equivalent.
mission countershaft through the mesh of fourth Correct lubricant level is from the bottom edge, to
speed gear on the input shaft and the fourth counter- no more than 6 mm (1/4 in.) below the bottom edge of
shaft gear. At this point, all the transmission gears the fill plug hole.
are spinning. The fill plug is on the passenger side of the
The driver selects a particular gear by moving the adapter housing (Fig. 3). The drain plug is on the
shift lever to the desired gear position. This move- bottom of the case.
ment moves the internal transmission shift compo-
XJ AX5 MANUAL TRANSMISSION 21 - 3
DESCRIPTION AND OPERATION (Continued)
Approximate dry fill lubricant capacity is: HARD SHIFTING
• 3.3 liters (3.49 quarts) for 4–wheel drive applica- Hard shifting is usually caused by a low lubricant
tions. level, improper, or contaminated lubricants. The con-
• 3.5 liters (3.70 quarts) for 2–wheel drive applica- sequence of using non–recommended lubricants is
tions. noise, excessive wear, internal bind, and hard shift-
ing. Substantial lubricant leaks can result in gear,
shift rail, synchro, and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of component damage are usually hard shift-
ing and noise.
Component damage, incorrect clutch adjustment,
or a damaged clutch pressure plate or disc are addi-
tional probable causes of increased shift effort. Incor-
rect adjustment or a worn/damaged pressure plate or
disc can cause incorrect release. If the clutch problem
is advanced, gear clash during shifts can result.
Worn or damaged synchro rings can cause gear clash
when shifting into any forward gear. In some new or
rebuilt transmissions, new synchro rings may tend to
stick slightly causing hard or noisy shifts. In most
cases, this condition will decline as the rings wear–
in.
INSTALLATION
(1) Clean seal bore of extension housing of any
residual sealer material from original seal.
(2) Using Tool Handle C-4171 and Seal Installer
8212, install new extension housing seal so that the
seal is located 0 6 0.5 mm (0 6 0.02 in.) to the face
of the extension housing (Fig. 12).
(3) Install propeller shaft. Refer to Group 3, Differ-
ential and Driveline, for proper procedures. Fig. 13 Remove Adapter Housing Seal
1 – ADAPTER HOUSING OIL SEAL
(4) Check and add fluid to transmission as neces-
sary. Refer to the Recommended Lubricant section for
proper fluid requirements. INSTALLATION
(5) Lower vehicle. (1) Clean seal bore of adapter housing of any
residual sealer material from original seal.
ADAPTER HOUSING SEAL (2) Using Tool Handle C-4171 and Seal Installer
8208, install new seal so that the seal is located 0 6
REMOVAL 0.2 mm (0 6 0.008 in.) to the seal bore face of
(1) Hoist and support vehicle. adapter housing (Fig. 14).
(2) Remove transfer case. (3) Install transfer case.
(3) Using a suitable pry tool, or a slide hammer (4) Check and add fluid to transmission as neces-
mounted screw, remove the adapter housing seal sary. Refer to the Recommended Lubricant section for
(Fig. 13). proper fluid requirements.
(5) Lower vehicle.
21 - 8 AX5 MANUAL TRANSMISSION XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 29 Remove Input Shaft Bearing Snap-ring Fig. 31 Remove Intermediate Plate from
1 – SNAP RING PLIERS Transmission Case
2 – INPUT SHAFT 1 – GEAR CASE
3 – INPUT SHAFT BEARING SNAP RING 2 – INTERMEDIATE PLATE
Fig. 36 Speedometer Drive Gear Assembly Fig. 38 Position Shift Arm in Adapter or Extension
1 – SNAP RING
Housing
2 – LOCK BALL
1 – SHIFT ARM
3 – SNAP RING
4 – OUTPUT SHAFT GROOVES
5 – SPEEDOMETER GEAR (12) Rotate the shifter arm shaft until the hole in
the shift arm is aligned with the hole in the shaft.
(13) Install the shift arm retainer bolt and tighten
to 38 N·m (28 ft. lbs.) (Fig. 40).
(14) Install and tighten shifter arm shaft plug to
18 N·m (13 ft. lbs.) torque (Fig. 41).
Fig. 45 Install Detent Ball Plug Fig. 47 Install Backup Lamp Switch
1 – SHIFT TOWER
1 – TORX BIT
2 – BACKUP LAMP SWITCH
2 – DETENT BALL PLUG
(19) Install shift tower gasket onto shift tower. (25) Install new seal in adapter/extension housing.
(20) Install the shift tower oil deflector and gasket (26) Install vehicle speed sensor, if necessary.
onto the adapter or extension housing. (27) Install clutch housing, release bearing, release
(21) Install shift tower onto transmission case fork and retainer clip.
(Fig. 46).
(22) Install bolts to hold shift tower to transmis-
sion case. Tighten tower bolts to 18 N·m (13 ft. lbs.)
torque.
XJ AX5 MANUAL TRANSMISSION 21 - 17
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 52 Remove Fifth Gear Synchro Ring Fig. 54 Remove Fifth Gear Thrust Ring
1 – FIFTH GEAR SYNCHRO RING
1 – LOCK BALL NOTCH
2 – FIFTH GEAR THRUST RING
XJ AX5 MANUAL TRANSMISSION 21 - 19
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 59 Remove Reverse Shift Arm Bracket Bolts Fig. 61 Remove Countershaft and Countershaft
1 – REVERSE SHIFT ARM BOLTS Rear Bearing
1 – INPUT SHAFT
(14) Remove snap-ring holding output shaft rear 2 – INTERMEDIATE PLATE
3 – OUTPUT SHAFT
bearing into the intermediate plate (Fig. 60).
4 – COUNTERSHAFT
(15) Remove countershaft rear bearing snap-ring.
5 – COUNTERSHAFT REAR BEARING
(16) With aid of an assistant, support the main- (18) Remove the 3–4 shift fork from the 3–4 shift
shaft and countershaft. Tap on the rear of the main- rail (Fig. 63).
shaft and countershaft with a suitable plastic mallet. (19) Remove the snap-ring from near the end of
This will release the countershaft from the counter- the 1–2 shift rail to allow the removal of the 1–2
shaft rear bearing and the mainshaft rear bearing shift fork.
XJ AX5 MANUAL TRANSMISSION 21 - 21
DISASSEMBLY AND ASSEMBLY (Continued)
(20) Remove the 1–2 shift fork from the 1–2 and (21) Remove threaded plugs from intermediate
the 3–4 shift rails (Fig. 64). plate. Then remove lock ball and spring from plug
holes with pencil magnet (Fig. 65). Note that the bot-
tom spring is shorter in length than the other two
springs.
ASSEMBLY
Refer to (Fig. 74) while assembling and installing
the shift rail components. Also, verify that all shift
rail components are in their neutral position when
installing the check balls and interlock pins.
(1) Install the 3–4 shift rail into the intermediate
plate.
(2) Install the 1–2 elongated check ball into the
intermediate plate (Fig. 75).
(3) Install the interlock pin into the 1–2 shift rail
(Fig. 76).
(4) Install the 1–2 shift rail into the intermediate
plate.
Fig. 80 Install Reverse Shift Rail Fig. 82 Install Fifth Gear Check Ball
1 – FIFTH GEAR CHECK BALL
1 – REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY
(10) Install snap-ring onto reverse shift rail (Fig. (13) Install fifth gear shift rail (Fig. 83).
81).
Fig. 88 Install Compression Spring And Pin Fig. 90 Align Idler Shaft Pin
1 – REVERSE IDLER GEAR SHAFT 1 – REVERSE IDLER GEAR ASSEMBLY
2 – PIN 2 – ALIGNMENT NOTCH
3 – COMPRESSION SPRING
(36) Install the reverse idler gear shaft the
remainder of the way through the reverse idler gear
assembly.
XJ AX5 MANUAL TRANSMISSION 21 - 29
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 91 Depress Pin In Reverse Idler Gear Shaft Fig. 93 Install Fifth Gear Thrust Ring
1 – DEPRESS PIN 1 – LOCK BALL NOTCH
2 – FIFTH GEAR THRUST RING
COUNTERSHAFT
DISASSEMBLY
(1) Remove select fit snap-ring holding the coun-
tershaft front bearing onto the countershaft (Fig. 95).
(2) Using Bearing Splitter P-334, a suitable spacer
on center of countershaft, and a shop press, remove
the countershaft front bearing from the countershaft.
DISASSEMBLY ASSEMBLY
(1) Verify that the 3–4 synchronizer is in the neu- (1) Position input shaft bearing onto input shaft.
tral position. (2) Using Driver L-4507, drive bearing onto input
(2) Separate input shaft from output shaft (Fig. shaft.
96). Note that the output shaft pilot bearing is an (3) Select the thickest snap-ring that will fit into
uncaged roller type bearing. the snap-ring groove of the input shaft (Fig. 98).
(3) Remove the output shaft pilot bearing rollers (4) Lubricate output shaft pilot bearing bore of
from the input shaft and the output shaft. input shaft with petroleum jelly.
XJ AX5 MANUAL TRANSMISSION 21 - 31
DISASSEMBLY AND ASSEMBLY (Continued)
OUTPUT SHAFT
DISASSEMBLY
(1) Remove input shaft and output shaft pilot
bearing rollers from output shaft.
(2) Measure and note thrust clearance of output
shaft gears (Fig. 100). Clearance should be 0.10 –
0.25 mm (0.004 – 0.010 in.).
(19) Install first gear onto output shaft and over Fig. 113 Check First–Second Gear Thrust Clearance
bearing.
(25) Position fifth gear onto output shaft with the
(20) Install first gear bearing inner race onto out-
gear’s short shoulder toward the rear of shaft.
put shaft and inside first gear bearing. Rotate bear-
Ensure that the gear and output shaft splines are
ing race until race installs over lock ball.
aligned.
(21) Position output shaft rear bearing onto output
(26) Using Adapter 6747-1A, Driver L-4507, and a
shaft. Ensure that the snap ring groove in bearing
shop press, press fifth gear onto output shaft.
outer race is toward rear of output shaft.
(27) Select the thickest snap-ring that will fit into
(22) Using Driver L-4507 and suitable mallet,
the snap-ring groove of the output shaft (Fig. 114).
drive bearing onto output shaft.
21 - 36 AX5 MANUAL TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(28) Install snap-ring to hold fifth gear onto output
shaft.
OUTPUT SHAFT
Check thickness of the output shaft and inner
bearing race flanges with a micrometer or vernier
calipers (Fig. 119).
• Minimum thickness for shaft flange is 4.80 mm
(0.189 in.)
Fig. 118 Remove Reverse Idler Gear Synchronizer • Minimum thickness for first gear bearing inner
Ring race flange is 3.99 mm (0.157 in.)
1 – REVERSE SYNCHRONIZER RING Measure diameter of the output shaft journal sur-
2 – REVERSE IDLER GEAR HUB faces with a micrometer. Replace the shaft if either of
these surfaces are worn beyond specified limits.
• Second gear surface minimum diameter is
ASSEMBLY 37.964 mm (1.495 in.)
(1) Install the reverse idler gear synchronizer ring • Third gear surface minimum diameter is 34.984
onto the reverse idler gear hub/race. Apply a film of mm (1.377 in.)
75W-90 GL-3 transmission oil to the contact surface Measure diameter of the first gear bearing inner
of the synchronizer ring prior to assembly. race. Minimum diameter is 38.985 mm (1.535 in.).
(2) Install the reverse idler gear onto the reverse Measure output shaft runout with a dial indicator
idler gear hub/race. Apply a film of 75W-90 GL-3 (Fig. 120). Runout should not exceed 0.05 mm (0.002
transmission oil to the reverse idler gear bushing in.).
prior to assembly. Verify that the teeth on the syn- Replace output shaft or first gear inner bearing
chronizer ring are properly engaged into the recesses race if measurement of any surface is out of specifi-
of the reverse idler gear. cation. Do not attempt to repair out of specification
(3) Install the plate washer over the reverse idler components.
gear hub/race and onto the reverse idler gear.
(4) Install the snap-ring to hold the reerse idler
gear onto the reverse idler hub/race.
21 - 38 AX5 MANUAL TRANSMISSION XJ
CLEANING AND INSPECTION (Continued)
COUNTERSHAFT
Inspect the countershaft gear teeth. Replace the
countershaft if any teeth are worn or damaged.
Inspect the bearing surfaces and replace shaft if any
surface shows damage or wear.
Check condition of the countershaft front bearing.
Replace the bearing if worn, noisy, or damaged.
Fig. 122 Check Gear–To–Shaft Oil Clearance Fig. 124 Check Fork–To–Hub Clearance
1 – GEAR BEING CHECKED 1 – SHIFT FORK
2 – OUTPUT SHAFT 2 – FEELER GAUGE
3 – SYNCHRONIZER SLEEVE
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Plugs, Access . . . . . . . . . . . . . . . 19 N·m (14 ft.lbs.)
Bolts, Adapter Housing . . . . . . . 34 N·m (25 ft.lbs.)
Switch, Back-up Light . . . . . . . 44 N·m (32.5 ft.lbs.)
Plugs, Drain and Fill . . . . . . . . 44 N·m (32.5 ft.lbs.)
Bolts, Front Bearing Retainer . . 17 N·m (12 ft.lbs.)
Plugs, Interlock and Detent . . . . 19 N·m (14 ft.lbs.)
Screws, Propeller Shaft Clamp . . . . . . . 16–23 N·m
(140–200 in.lbs.)
Bolts, Rear Mount to Transmission . . . . 33–60 N·m
(24–44 ft.lbs.)
Nut, Rear Mount Clevis . . 54–75 N·m (40–55 ft.lbs.)
Nuts, Rear Mount to Crossmember . . . . 41–68 N·m
(30–50 ft.lbs.)
Pins, Restrictor . . . . . . . . . . . . 27.4 N·m (20 ft.lbs.)
Fig. 123 Check Synchronizer Ring Wear Bolts, Reverse Shift Arm Bracket . . . . . . . . 18 N·m
1 – FEELER GAUGE (13 ft.lbs.)
2 – SYNCHRONIZER RING Screw, Shift Arm Set . . . . . . . . . 38 N·m (28 ft.lbs.)
Screws, Shift Fork Set . . . . . . . . 20 N·m (15 ft.lbs.)
Nut, Shift Knob . . . . . . . . 20–34 N·m (15–25 ft.lbs.)
Screws, Shifter Floor Cover . . . . . . . . . . . . 2–3 N·m
(17–30 in.lbs.)
Bolts, Shift Tower . . . . . . . . . . . . 18 N·m (13 ft.lbs.)
Nuts, Transfer Case Mounting . . . . . . . 30–41 N·m
(22–30 ft.lbs.)
21 - 40 AX5 MANUAL TRANSMISSION XJ
SPECIAL TOOLS
AX5
TABLE OF CONTENTS
page page
LUBRICANT
DESCRIPTION
Required lubricant for the NV3550 is Mopart Man-
ual Transmission Lubricant, P/N 4761526. This is the
only lubricant to be used in NV3550 transmissions.
No other lubricants are acceptable, or recommended.
The correct transmission lubricant level is to the
bottom edge of the fill plug hole (Fig. 3).
The transmission must be level to obtain an accu-
rate lubricant level check. A drive–on type of hoist is
recommended for this purpose.
Lubricant capacity of the NV3500 is approximately
2.28 liters (4.8 pints). This represents the approxi-
mate quantity needed to refill the transmission after
a lubricant change or overhaul.
Fig. 2 NV3550 Identification
DRAIN AND FILL PLUG LOCATIONS
1 – PART NUMBER TAG
2 – IDENTIFICATION TAG The NV3550 fill plug is located in the front hous-
3 – FRONT OF REAR HOUSING ing. The drain plug is at the bottom rear of the hous-
ing (Fig. 3).
21 - 44 NV3550 MANUAL TRANSMISSION XJ
GENERAL INFORMATION (Continued)
A correct lubricant level check can only be made
when the vehicle is level; use a drive–on hoist to
ensure this. Also allow the lubricant to settle for a
minute or so before checking. These recommenda-
tions will ensure an accurate check and avoid an
under-or-overfill condition.
HARD SHIFTING
Hard shifting is usually caused by a low lubricant
level, improper or contaminated lubricants, transmis-
sion component damage, clutch linkage malfunction,
or by a damaged clutch pressure plate or disc.
Substantial lubricant leaks can result in gear, shift
component, synchro and bearing damage. If a leak
goes undetected for an extended period, the first indi-
cations of a problem are usually hard shifting and
noise.
Incorrect or contaminated lubricants can also con-
tribute to hard shifting. The consequence of using
non–recommended lubricants is noise, excessive
wear, internal bind and hard shifting.
Improper clutch release is a frequent cause of hard
shifting. Incorrect adjustment or a worn, damaged
pressure plate or disc can cause incorrect release. If
the clutch problem is advanced, gear clash during
shifts can result.
Worn or damaged synchro rings can cause gear
clash when shifting into any forward gear. In some
Fig. 3 Drain and Fill Plug Locations new or rebuilt transmissions, new synchro rings may
1 – DRAIN PLUG tend to stick slightly causing stiff and/or noisy shifts.
2 – FILL PLUG
In most cases, this condition will decline as the rings
wear in.
DIAGNOSIS AND TESTING
TRANSMISSION NOISE
LOW LUBRICANT LEVEL Most manual transmissions make some noise dur-
A low transmission lubricant level is generally the ing normal operation. Rotating gears can generate a
result of a leak, inadequate lubricant fill, or an incor- mild whine that may only be audible at extreme
rect lubricant level check. speeds.
Leaks can occur at the mating surfaces of the Severe, obviously audible transmission noise is
housings, or from the front/rear seals. A suspected generally the result of a lubricant problem. Insuffi-
leak could also be the result of an overfill condition. cient, improper, or contaminated lubricant can pro-
Leaks at component mating surfaces will probably mote rapid wear of gears, synchros, shift rails, forks
be the result of inadequate sealer, gaps in the sealer, and bearings. The overheating caused by a lubricant
incorrect bolt tightening, or use of a non–recom- problem, can also lead to gear breakage.
mended sealer.
A leak at the front of the transmission will be from REMOVAL AND INSTALLATION
either a loose or damaged, front bearing retainer or
retainer seal. Lubricant may also drip from the
transmission clutch housing after extended opera-
TRANSMISSION
tion. If the leak is severe, it will contaminate the
REMOVAL
clutch disc causing slip, grab and chatter.
(1) Shift transmission into first or third gear.
Transmissions filled from air or electrically pow-
(2) Remove the floor console and shift boot as nec-
ered lubricant containers can be under filled. Always
essary to access the bottom of the shift lever at the
check the lubricant level after filling to avoid an
shift tower attachment.
under fill condition.
XJ NV3550 MANUAL TRANSMISSION 21 - 45
REMOVAL AND INSTALLATION (Continued)
(3) Install nuts on two M6X1.0 bolts and thread
the bolts into the threaded holes at the base of the
shift lever.
(4) Tighten the nuts equally until the shift lever
loosens on the shift tower stub shaft.
(5) Remove the shift lever from the shift tower.
(6) Raise and support vehicle on suitable safety
stands.
(7) Support engine with adjustable jack stand.
Position wood block between jack and oil pan to
avoid damaging pan.
(8) Remove crossmember/skid plate.
(9) Disconnect necessary exhaust system compo-
nents.
(10) Remove skid plate, if equipped.
(11) Remove slave cylinder (Fig. 4) from clutch
housing. Fig. 5 Marking Propeller Shaft And Axle Yokes
1 – REFERENCE MARKS
Fig. 8 Align Propeller Shaft And Rear Axle Yokes Fig. 9 Remove Shift Tower
1 – SHIFT TOWER AND LEVER ASSEMBLY
Alignment Marks
2 – SHIFT SOCKET
1 – REFERENCE MARKS
3 – SEAL
Fig. 15 Shift Tower Removal Fig. 17 Detent Plunger And Spring Removal
1 – SHIFT TOWER AND LEVER ASSEMBLY 1 – FRONT HOUSING
2 – SHIFT SOCKET 2 – PLUG
3 – SEAL 3 – SPRING
4 – PLUNGER
Fig. 35 Removing/Installing Output Shaft Bearing Fig. 36 Unseating Rear Housing From Output Shaft
Retainer Bolts—2WD Bearing—2WD
1 – OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT 1 – REAR HOUSING
IS AT OPPOSITE SIDE OF CASE) 2 – PLASTIC OR RAWHIDE MALLET
3 – FIXTURE TOOL
(2) Unseat output shaft bearing from bearing bore
in rear housing. Use plastic or rawhide mallet to tap REAR ADAPTER HOUSING REMOVAL—4WD
rear housing upward and off output shaft bearing as (1) Locate dimples in face of rear seal (Fig. 39).
shown (Fig. 36). Use a suitable slide hammer mounted screw to
(3) Lift rear housing up and off geartrain (Fig. 37). remove seal by inserting screw into seal at dimple
(4) Remove countershaft rear bearing from coun- locations (Fig. 40).
tershaft (Fig. 38).
(5) Examine condition of bearing bore and idler
shaft notch in rear housing. Replace housing if any of
these components are damaged.
XJ NV3550 MANUAL TRANSMISSION 21 - 55
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 72 Installing 1-2 Synchro Hub Snap Ring Fig. 74 Second Gear Bearing Installation
1 – 1–2 SYNCHRO
1 – SECOND GEAR BEARING
2 – SPECIAL TOOL
6310–1 2 – SPECIAL TOOL
6310–1
3 – SYNCHRO SNAP RING
(8) Install front thrust washer on shaft and slide (9) Install wave washer, flat washer and remain-
washer up against gear and over lock ball (Fig. 89). ing snap ring on idler shaft (Fig. 89). Be sure snap
ring is fully seated.
21 - 70 NV3550 MANUAL TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(c) Attach a slide hammer or suitable puller to
the bolt and remove the bearing.
(d) Use the short end of Installer 8119 to install
the new bearing.
(e) The bearing is correctly installed if the bear-
ing is flush with the transmission case.
(4) Inspect detent plunger bushings for damage.
REAR HOUSING—2WD
(1) Drive adapter housing alignment dowels back
into housing until dowels are flush with mounting
surface (Fig. 100).
Fig. 103 Rear Housing Installation—2WD Fig. 105 Removing Pilot Stud Tool And Installing
1 – REAR HOUSING Retainer Bolts—2WD
2 – SHIFT FORKS AND GEARTRAIN 1 – BEARING RETAINER BOLT
2 – SPECIAL TOOL 8120
(8) Seat rear housing on output shaft rear bearing
and countershaft. Use plastic or rawhide mallet to
tap housing into place.
21 - 76 NV3550 MANUAL TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
ADAPTER HOUSING—4WD (9) Install rear bearing snap ring on output shaft
(1) Install rear bearing in adapter housing. Use (Fig. 107).
wood hammer handle or wood dowel to tap bearing
into place.
(2) Position rear bearing retainer in adapter hous-
ing (Fig. 106).
Fig. 124 Installing Shift Shaft Bushing Lock Bolt (17) Install input shaft snap ring (Fig. 127).
1 – SHIFT SHAFT LOCK BOLT
2 – SHAFT SOCKET
Fig. 128 Installing Oil Seal In Front Bearing Retainer Fig. 130 Installing Input Shaft Bearing Retainer—
1 – SPECIAL TOOL
6448 Typical
2 – FRONT BEARING RETAINER 1 – INPUT SHAFT
2 – OIL FEED
3 – BEARING RETAINER
NOTE: The front housing contains the countershaft ing race becomes damaged, it will be necessary to
front bearing race. The rear housing contains the replace the front or rear housing as necessary. A
countershaft rear bearing race. Be advised that new countershaft bearing will be supplied with each
these components are NOT serviceable items. The new housing for service use.
front housing will have to be replaced if the coun-
tershaft bearing race is loose, worn, or damaged. The countershaft bearings can be installed back-
The rear housing will have to be replaced if the wards if care is not exercised. The bearing roller cage
countershaft rear bearing race is loose, worn, or is a different diameter on each side. Be sure the
damaged. bearing is installed so the large diameter side of the
cage is facing the countershaft gear (Fig. 135). The
Inspect the input shaft bearing retainer. Be sure small diameter side goes in the bearing race.
the release bearing slide surface of the retainer is in
good condition. Minor nicks on the surface can be REVERSE IDLER COMPONENTS
smoothed off with 320/420 grit emery cloth and final Inspect the idler gear, bearing, shaft, thrust
polished with oil coated crocus cloth. Replace the washer, wave washer and thrust plate. Replace the
retainer seal if necessary. bearing if any of the needle bearing rollers are worn,
Inspect the output shaft bearing retainer. Be sure chipped, cracked, flat-spotted, or brinnelled. Also
the U-shaped retainer is flat and free of distortion. replace the bearing if the plastic bearing cage is
Replace the retainer if the threads are damaged, or if damaged or distorted.
the retainer is bent, or cracked. Replace the thrust washer, wave washer, or thrust
plate if cracked, chipped, or worn. Replace the idler
COUNTERSHAFT BEARINGS AND RACES gear if the teeth are chipped, cracked or worn thin.
The countershaft bearings and races are machine Replace the shaft if worn, scored, or the bolt threads
lapped during manufacture to form matched sets. are damaged beyond repair. Replace the support seg-
The bearings and races should not be interchanged. ment if cracked, or chipped and replace the idler
attaching bolts if the threads are damaged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
XJ NV3550 MANUAL TRANSMISSION 21 - 85
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
TORQUE
Description Torque
Clutch Housing Bolts . . . 54–61 N·m (40–45 ft. lbs.)
Crossmember-To-Frame Bolts . . . . . . . . 61–75 N·m
(44–55 ft. lbs.)
Crossmember-To-Insulator Nuts . . . . . . 54–61 N·m
(40–45 ft. lbs.)
Drain/Fill Plug . . . . . . . . . 9–27 N·m (14–20 ft. lbs.)
Front-To-Rear Housing Bolts . . . . . . . . . 30–35 N·m
(22–26 ft. lbs.)
Front Bearing Retainer Bolts . . . . . . . . . 7–10 N·m
(5–7 ft. lbs.)
Idler Shaft Bolts . . . . . . 19–25 N·m (14–18 ft. lbs.)
Rear Bearing Retainer Bolts . . . . . . . . . 30–35 N·m
(22–26 ft. lbs.)
Shift Tower Bolts . . . . . . . . . 7–10 N·m (5–7 ft. lbs.)
Slave Cylinder Attaching Nuts . . . . . . . . . . 23 N·m
(200 in. lbs.)
Fig. 135 Correct Countershaft Bearing Installation Transfer Case Attaching Nuts . . 47 N·m (35 ft. lbs.)
1 – COUNTERSHAFT U-Joint Clamp Bolts . . . . . . . . 19 N·m (170 in. lbs.)
2 – BEARING CAGE
SPECIAL TOOLS
Shift Socket
Inspect the shift socket for wear or damage. NV3550 MANUAL TRANSMISSION
replace the socket if the roll pin, or shift shaft bores
are damaged. Minor nicks in the shift lever ball seat
in the socket can be smoothed down with 400 grit
emery or wet/dry paper. Replace the socket if the ball
seat is worn, or cracked. Do not reuse the original
shift socket roll pin. Install a new pin during reas-
sembly. The socket roll pin is approximately is
approximately 33 mm (1-1/4 in.) long.
Installer, Bushing—6951
Fixture, NV3550—6747
Adapter, Fixture—6747-1A
Handle—C-4171
Adapter, Fixture—6747-2A
Remover—8117
Cup, Fixture—8115
XJ NV3550 MANUAL TRANSMISSION 21 - 87
SPECIAL TOOLS (Continued)
Tube—6310-1
Installer, Seal—C-3860-A
Installer—8118
Installer—8123
Remover/Installer—8119
AUTOMATIC TRANSMISSION—30RH
TABLE OF CONTENTS
page page
OPERATION
The automatic transmission fluid is selected based
upon several qualities. The fluid must provide a high
level of protection for the internal components by
providing a lubricating film between adjacent metal
components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
a large temperature range. If the viscosity stays con-
stant through the temperature range of operation,
transmission operation and shift feel will remain con-
sistent. Transmission fluid must also be a good con-
ductor of heat. The fluid must absorb heat from the
internal transmission components and transfer that
heat to the transmission case.
Fig. 10 Impeller
1 – ENGINE FLEXPLATE 4 – ENGINE ROTATION
2 – OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 – ENGINE ROTATION
SECTION
3 – IMPELLER VANES AND COVER ARE INTEGRAL
XJ AUTOMATIC TRANSMISSION—30RH 21 - 99
DESCRIPTION AND OPERATION (Continued)
Fig. 11 Turbine
1 – TURBINE VANE 4 – PORTION OF TORQUE CONVERTER COVER
2 – ENGINE ROTATION 5 – ENGINE ROTATION
3 – INPUT SHAFT 6 – OIL FLOW WITHIN TURBINE SECTION
STATOR
The stator assembly (Fig. 12) is mounted on a sta-
tionary shaft which is an integral part of the oil
pump. The stator is located between the impeller and
turbine within the torque converter case (Fig. 13).
The stator contains an over-running clutch, which
allows the stator to rotate only in a clockwise direc-
tion. When the stator is locked against the over-run-
ning clutch, the torque multiplication feature of the
torque converter is operational.
OIL PUMP
Fig. 16 Stator Operation
1 – DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES DESCRIPTION
2 – FRONT OF ENGINE The oil pump (Fig. 17) is located in the pump hous-
3 – INCREASED ANGLE AS OIL STRIKES VANES ing inside the bell housing of the transmission case.
4 – DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING The oil pump consists of an inner and outer gear, a
AGAINST STATOR VANES
housing, and a cover that also serves as the reaction
shaft support.
stator is freewheeling, providing no torque multipli-
cation. By applying the turbine’s piston to the front
cover’s friction material, a total converter engage-
ment can be obtained. The result of this engagement
21 - 102 AUTOMATIC TRANSMISSION—30RH XJ
DESCRIPTION AND OPERATION (Continued)
VALVE BODY
DESCRIPTION
The valve body consists of a cast aluminum valve
body, a separator plate, and transfer plate. The valve
body contains valves and check balls that control
fluid delivery to the torque converter clutch, bands,
and frictional clutches. The valve body contains the
following components (Fig. 18) and (Fig. 19):
• Regulator valve
• Regulator valve throttle pressure plug
• Line pressure plug and sleeve
• Kickdown valve
• Kickdown limit valve
• 1–2 shift valve
• 1–2 control valve
Fig. 17 Oil Pump Assembly • 2–3 shift valve
1 – OIL SEAL
• 2–3 governor plug
2 – OIL PUMP BODY
• Throttle valve
3 – VENT
4 – REACTION SHAFT SUPPORT
• Throttle pressure plug
5 – INNER ROTOR • Switch valve
6 – OUTER ROTOR • Manual valve
7 – “O” RING • Converter clutch control valve
• Fail-safe valve
• Shuttle valve
OPERATION • Shuttle valve throttle plug
As the torque converter rotates, the converter hub • 9 check balls
rotates the inner and outer gears. As the gears By adjusting the spring pressure acting on the reg-
rotate, the clearance between the gear teeth ulator valve, transmission line pressure can be
increases in the crescent area, and creates a suction adjusted.
at the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the OPERATION
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump NOTE: Refer to the Hydraulic Schematics for a
outlet and to the valve body. visual aid in determining valve location, operation
and design.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 103
DESCRIPTION AND OPERATION (Continued)
REGULATOR VALVE the oil at specific pressures. With the engine run-
The pressure regulator valve is needed to control ning, fluid flows from the pump to the pressure reg-
the hydraulic pressure within the system and reduce ulator valve, manual valve, and the interconnected
the amount of heat produced in the fluid. The pres- circuits. As fluid is sent through passages to the reg-
sure regulator valve is located in the valve body near ulator valve, the pressure pushes the valve to the
the manual valve. The pressure regulator valve train right against the large spring. It is also sent to the
controls the maximum pressure in the lines by reaction areas on the left side of the throttle pressure
metering the dumping of fluid back into the sump. plug and the line pressure plug. With the gear selec-
Regulated pressure is referred to as “line pressure.” tor in the park position, fluid recirculates through
The regulator valve (Fig. 20) has a spring on one the regulator and manual valves back to the sump.
end that pushes the valve to the left. This closes a
dump (vent) that is used to lower pressure. The clos-
ing of the dump will cause the oil pressure to
increase. Oil pressure on the opposite end of the
valve pushes the valve to the right, opening the
dump and lowering oil pressure. The result is spring
pressure working against oil pressure to maintain
21 - 104 AUTOMATIC TRANSMISSION—30RH XJ
DESCRIPTION AND OPERATION (Continued)
Meanwhile, the torque converter is filled slowly. In
all other gear positions (Fig. 21), fluid flows between
two right side lands to the switch valve and torque
converter. At low pump speeds, the flow is controlled
by the pressure valve groove to reduce pressure to
the torque converter. After the torque converter and
switch valve fill with fluid, the switch valve becomes
the controlling metering device for torque converter
pressure. The regulator valve then begins to control
the line pressure for the other transmission circuits.
The balance of the fluid pressure pushing the valve
to the right and the spring pressure pushing to the
left determines the size of the metering passage at
land #2 (land #1 being at the far right of the valve in
the diagram). As fluid leaks past the land, it moves
into a groove connected to the filter or sump. As the
Fig. 19 Valve Body Assembly land meters the fluid to the sump, it causes the pres-
1 – ADJUSTER BRACKET sure to reduce and the spring decreases the size of
2 – LINE PRESSURE ADJUSTER the metering passage. When the size of the metering
3 – PRESSURE REGULATOR VALVE passage is reduced, the pressure rises again and the
4 – SWITCH VALVE
size of the land is increased again. Pressure is regu-
5 – VALVE BODY
6 – TRANSFER PLATE
lated by this constant balance of hydraulic and
7 – THROTTLE VALVE spring pressure.
8 – SLEEVE
9 – KICKDOWN VALVE
10 – THROTTLE PRESSURE ADJUSTER
When governor pressure builds to a point where it plate overcoming governor pressure. With the combi-
can overcome the combined force of the spring and nation of the line pressure and spring pressure, the
throttle pressure on the other side of the valve, the valve cannot move, preventing any upshift.
valve will begin to move over to the right. As the
valve moves to the right, the middle land of the valve 1–2 SHIFT CONTROL VALVE
will close off the circuit supplying the throttle pres- It contains a valve with four lands and a spring. It
sure to the right side of the valve. When the throttle is used as both a “relay” and “balanced” valve.
pressure is closed off, the valve will move even far- The valve has two specific operations (Fig. 29):
ther to the right, allowing line pressure to enter • Aid in quality of the 1–2 upshift.
another circuit and energize the front servo, applying • Aid in the quality and timing of the 3–2 kick-
the front band (Fig. 28). down ranges.
The governor plug serves a dual purpose: [0001] When the manual valve is set to the Drive position
• It allows the shift valves to move either left or and the transmission is in the first or second gear
right, allowing both upshifts and downshifts. range, 1–2 shift control or “modulated throttle pres-
• When in a manual selection position, it will be sure” is supplied to the middle of the accumulator
hydraulically “blocked” into position so no upshift can piston by the 1–2 shift control valve. During the 1–2
occur. upshift, this pressure is used to control the kickdown
The physical blocking of the upshift while in the servo apply pressure that is needed to apply the kick-
manual “1” position is accomplished by the directing down and accumulator pistons. Thus, the 1–2 shift
of line pressure between both lands of the governor point is “cushioned” and the quality is improved.
plug. The line pressure reacts against the larger land During a WOT kickdown, kickdown pressure is
of the plug, pushing the plug back against the end applied between the kickdown valve and the 1–2
XJ AUTOMATIC TRANSMISSION—30RH 21 - 111
DESCRIPTION AND OPERATION (Continued)
shift control valve. This additional pressure is fluid discharge from the front clutch and servo
directed to the 1–2 shift control’s spring cavity, add- release circuits. During a 3–2 kickdown, fluid dis-
ing to the spring load on the valve. The result of this charges through the shuttle by–pass circuit. When
increased “modulated” throttle pressure is a firmer the shuttle valve closes the by–pass circuit, fluid dis-
WOT upshift. charge is restricted and controlled for the application
of the front band. During a 2–3 “lift foot” upshift, the
SHUTTLE VALVE shuttle valve by–passes the restriction to allow full
The assembly is contained in a bore in the valve fluid flow through the by–pass groove for a faster
body above the shift valves. When the manual valve release of the band.
is positioned in the Drive range, throttle pressure
acts on the throttle plug of the shuttle valve (Fig. 29) 2–3 SHIFT VALVE
to move it against a spring, increasing the spring The 2–3 shift valve mechanism (Fig. 30) consists of
force on the shuttle valve. During a part or full throt- the 2–3 shift valve, governor plug and spring, and a
tle 1–2 upshift, the throttle plug is bottomed by throttle plug. After the 1–2 shift valve has completed
throttle pressure, holding the shuttle valve to the its operation and applied the front band, line pres-
right against governor pressure, and opening a sure is directed to the 2–3 shift valve through the
by–pass circuit. The shuttle valve controls the qual- connecting passages from the 1–2 shift valve. The
ity of the kickdown shift by restricting the rate of line pressure will then dead–end at land #2 until the
OPERATION
The principal which makes this operation possible is
known as Pascal’s Law. Pascal’s Law can be stated as:
“Pressure on a confined fluid is transmitted equally in
all directions and acts with equal force on equal areas.”
PRESSURE
Pressure (Fig. 39) is nothing more than force (lbs.)
divided by area (in or ft.), or force per unit area.
Given a 100 lb. block and an area of 100 sq. in. on
the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.
OVERRUNNING CLUTCH
DESCRIPTION
The overrunning clutch (Fig. 45) consists of an
inner race, an outer race (or cam), rollers and
springs, and the spring retainer. The number of roll-
ers and springs depends on what transmission and
which overrunning clutch is being dealt with.
OPERATION OPERATION
As the inner race is rotated in a clockwise direction With any given planetary gearset, several condi-
(as viewed from the front of the transmission), the tions must be met for power to be able to flow:
race causes the rollers to roll toward the springs, • One member must be held.
causing them to compress against their retainer. The • Another member must be driven or used as an
compression of the springs increases the clearance input.
between the rollers and cam. This increased clear- • The third member may be used as an output for
ance between the rollers and cam results in a free- power flow.
wheeling condition. When the inner race attempts to • For direct drive to occur, two gear members in
rotate counterclockwise, the action causes the rollers the front planetary gearset must be driven.
to roll in the same direction as the race, aided by the
pushing of the springs. As the rollers try to move in NOTE: Gear ratios are dependent on the number of
the same direction as the inner race, they are teeth on the annulus and sun gears.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 123
DESCRIPTION AND OPERATION (Continued)
BANDS
DESCRIPTION
KICKDOWN (FRONT) BAND
The kickdown, or “front”, band (Fig. 47) holds the
common sun gear of the planetary gear sets. The
front (kickdown) band is made of steel, and faced on
its inner circumference with a friction–type lining.
One end of the band is anchored to the transmission
case, and the other is acted on with a pushing force
by a servo piston. The front band is a single–wrap
design (the band does not completely encompass/
wrap the drum that it holds).
SERVOS
Fig. 50 Governor
1 – SEAL RING (PLAIN END) 9 – SNAP RING (THIN)
2 – SEAL RING (HOOK END) 10 – SNAP RING (THICK)
3 – PARK GEAR 11 – SNAP RING
4 – GOVERNOR BODY 12 – RETAINER WASHER
5 – GOVERNOR VALVE 13 – GOVERNOR WEIGHT ASSEMBLY
6 – VALVE SHAFT 14 – GOVERNOR BODY BOLTS (4)
7 – E-CLIPS (2) 15 – WASHER
8 – FILTER
Drive range provides first, second, and third gear BRAKE TRANSMISSION SHIFT INTERLOCK
ranges.
MECHANISM
CONVERTER DRAINBACK VALVE DESCRIPTION
The Brake Transmission Shifter/Ignition Interlock
DESCRIPTION (BTSI), is a cable and solenoid operated system. It
The drainback valve is located in the transmission
interconnects the automatic transmission floor
cooler outlet (pressure) line.
mounted shifter to the steering column ignition
switch (Fig. 54).
OPERATION
The valve prevents fluid from draining from the OPERATION
converter into the cooler and lines when the vehicle The system locks the shifter into the PARK posi-
is shut down for lengthy periods. Production valves tion. The Interlock system is engaged whenever the
have a hose nipple at one end, while the opposite end ignition switch is in the LOCK or ACCESSORY posi-
is threaded for a flare fitting. All valves have an tion. An additional electrically activated feature will
arrow (or similar mark) to indicate direction of flow prevent shifting out of the PARK position unless the
through the valve. brake pedal is depressed at least one-half an inch. A
magnetic holding device in line with the park/brake
interlock cable is energized when the ignition is in
21 - 126 AUTOMATIC TRANSMISSION—30RH XJ
DESCRIPTION AND OPERATION (Continued)
FLUID CONTAMINATION
Transmission fluid contamination is generally a
result of:
• adding incorrect fluid
• failure to clean dipstick and fill tube when
checking level
• engine coolant entering the fluid
• internal failure that generates debris
• overheat that generates sludge (fluid break-
down)
• failure to reverse flush cooler and lines after
Fig. 55 Ignition Key Cylinder Actuation repair
1 – SLIDER LOCKED
2 – CAM RETURN SPRING
3 – INTERLOCK CABLE
4 – CAM
5 – SLIDER
21 - 128 AUTOMATIC TRANSMISSION—30RH XJ
DIAGNOSIS AND TESTING (Continued)
• failure to replace contaminated converter after VEHICLE IS DISABLED
repair (1) Check fluid level and condition.
The use of non recommended fluids can result in (2) Check for broken or disconnected gearshift or
transmission failure. The usual results are erratic throttle linkage.
shifts, slippage, abnormal wear and eventual failure (3) Check for cracked, leaking cooler lines, or loose
due to fluid breakdown and sludge formation. Avoid or missing pressure-port plugs.
this condition by using recommended fluids only. (4) Raise and support vehicle on safety stands,
The dipstick cap and fill tube should be wiped start engine, shift transmission into gear, and note
clean before checking fluid level. Dirt, grease and following:
other foreign material on the cap and tube could fall (a) If propeller shaft turns but wheels do not,
into the tube if not removed beforehand. Take the problem is with differential or axle shafts.
time to wipe the cap and tube clean before withdraw- (b) If propeller shaft does not turn and transmis-
ing the dipstick. sion is noisy, stop engine. Remove oil pan, and
Engine coolant in the transmission fluid is gener- check for debris. If pan is clear, remove transmis-
ally caused by a cooler malfunction. The only remedy sion and check for damaged drive plate, converter,
is to replace the radiator as the cooler in the radiator oil pump, or input shaft.
is not a serviceable part. If coolant has circulated (c) If propeller shaft does not turn and transmis-
through the transmission for some time, an overhaul sion is not noisy, perform hydraulic-pressure test to
may also be necessary; especially if shift problems determine if problem is hydraulic or mechanical.
had developed.
The transmission cooler and lines should be PARK/NEUTRAL POSITION SWITCH
reverse flushed whenever a malfunction generates The center terminal of the park/neutral position
sludge and/or debris. The torque converter should switch is the starter-circuit terminal. It provides the
also be replaced at the same time. ground for the starter solenoid circuit through the
Failure to flush the cooler and lines will result in selector lever in PARK and NEUTRAL positions only.
recontamination. Flushing applies to auxiliary cool- The outer terminals on the switch are for the backup
ers as well. The torque converter should also be lamp circuit.
replaced whenever a failure generates sludge and
debris. This is necessary because normal converter SWITCH TEST
flushing procedures will not remove all contami- To test the switch, remove the wiring connector.
nants. Test for continuity between the center terminal and
the transmission case. Continuity should exist only
PRELIMINARY DIAGNOSIS when the transmission is in PARK or NEUTRAL.
Two basic procedures are required. One procedure Shift the transmission into REVERSE and test
for vehicles that are drivable and an alternate proce- continuity at the switch outer terminals. Continuity
dure for disabled vehicles (will not back up or move should exist only when the transmission is in
forward). REVERSE. Continuity should not exist between the
outer terminals and the case.
VEHICLE IS DRIVEABLE Check gearshift linkage adjustment before replac-
(1) Check for transmission fault codes using DRB ing a switch that tests faulty.
scan tool.
(2) Check fluid level and condition. GEARSHIFT CABLE
(3) Adjust throttle and gearshift linkage if com- (1) The floor shifter lever and gate positions
plaint was based on delayed, erratic, or harsh shifts. should be in alignment with all transmission PARK,
(4) Road test and note how transmission upshifts, NEUTRAL, and gear detent positions.
downshifts, and engages. (2) Engine starts must be possible with floor shift
(5) Perform stall test if complaint is based on slug- lever in PARK or NEUTRAL gate positions only.
gish acceleration. Or, if abnormal throttle opening is Engine starts must not be possible in any other gear
needed to maintain normal speeds with a properly position.
tuned engine. (3) With floor shift lever handle push-button not
(6) Perform hydraulic pressure test if shift prob- depressed and lever in:
lems were noted during road test. (a) PARK position—Apply forward force on cen-
(7) Perform air-pressure test to check clutch-band ter of handle and remove pressure. Engine starts
operation. must be possible.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 129
DIAGNOSIS AND TESTING (Continued)
(b) PARK position—Apply rearward force on cen-
ter of handle and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position—Normal position. Engine
starts must be possible.
(d) NEUTRAL position—Engine running and
brakes applied, apply forward force on center of
shift handle. Transmission shall not be able to shift
from neutral to reverse.
SERVICE PROCEDURES intervals. The service fluid fill after a filter change is
approximately 3.8 liters (4.0 quarts).
FLUID LEVEL CHECK
Transmission fluid level should be checked monthly REMOVAL
under normal operation. If the vehicle is used for (1) Hoist and support vehicle on safety stands.
trailer towing or similar heavy load hauling, check (2) Remove the transmission/skip plate as neces-
fluid level and condition weekly. Fluid level is sary to access the transmission oil pan.
checked with the engine running at curb idle speed, (3) Place a large diameter shallow drain pan
the transmission in NEUTRAL and the transmission beneath the transmission pan.
fluid at normal operating temperature. (4) Remove bolts holding front and sides of pan to
transmission (Fig. 65).
FLUID LEVEL CHECK PROCEDURE (5) Loosen bolts holding rear of pan to transmis-
(1) Transmission fluid must be at normal operat- sion.
ing temperature for accurate fluid level check. Drive (6) Slowly separate front of pan away from trans-
vehicle if necessary to bring fluid temperature up to mission allowing the fluid to drain into drain pan.
normal hot operating temperature of 82°C (180°F). (7) Hold up pan and remove remaining bolts hold-
(2) Position vehicle on level surface. ing pan to transmission.
(3) Start and run engine at curb idle speed. (8) While holding pan level, lower pan away from
(4) Apply parking brakes. transmission.
(5) Shift transmission momentarily into all gear (9) Pour remaining fluid in pan into drain pan.
ranges. Then shift transmission back to Neutral. (10) Remove screws holding filter to valve body
(6) Clean top of filler tube and dipstick to keep (Fig. 66).
dirt from entering tube. (11) Separate filter from valve body and pour fluid
(7) Remove dipstick (Fig. 64) and check fluid level in filter into drain pan.
as follows: (12) Dispose used trans fluid and filter properly.
(a) Correct acceptable level is in crosshatch area.
(b) Correct maximum level is to MAX arrow
mark.
(c) Incorrect level is at or below MIN line.
(d) If fluid is low, add only enough Mopart ATF
Plus 3 to restore correct level. Do not overfill.
INSPECTION
Inspect bottom of pan and magnet for excessive
Fig. 64 Dipstick Fluid Level Marks—Typical amounts of metal or fiber contamination. A light
1 – DIPSTICK coating of clutch or band material on the bottom of
2 – MAXIMUM CORRECT FLUID LEVEL the pan does not indicate a problem unless accompa-
3 – ACCEPTABLE FLUID LEVEL nied by slipping condition or shift lag. If fluid and
pan are contaminated with excessive amounts or
debris, refer to the diagnosis section of this group.
FLUID AND FILTER REPLACEMENT Check the adjustment of the front and rear bands,
Refer to the Maintenance Schedules in Group 0, adjust if necessary. Refer to Adjustment section of
Lubrication and Maintenance, for proper service this group for proper procedure.
21 - 142 AUTOMATIC TRANSMISSION—30RH XJ
SERVICE PROCEDURES (Continued)
(5) Apply service brakes, shift transmission through
all gear ranges then back to NEUTRAL, set parking
brake, and leave engine running at curb idle speed.
(6) Remove funnel, insert dipstick and check fluid
level. If level is low, add fluid to bring level to
MIN mark on dipstick. Check to see if the oil level
is equal on both sides of the dipstick. If one side is
noticably higher than the other, the dipstick has
picked up some oil from the dipstick tube. Allow the
oil to drain down the dipstick tube and re-check.
(7) Drive vehicle until transmission fluid is at nor-
mal operating temperature.
(8) With the engine running at curb idle speed, the
gear selector in NEUTRAL, and the parking brake
applied, check the transmission fluid level.
INSTALLATION
(1) Check torque converter hub and hub drive (12) Carefully work transmission forward and over
notches for sharp edges burrs, scratches, or nicks. engine block dowels until converter hub is seated in
Polish the hub and notches with 320/400 grit paper crankshaft.
and crocus cloth if necessary. The hub must be (13) Install and tighten bolts that attach transmis-
smooth to avoid damaging pump seal at installation. sion converter housing to engine block (Fig. 69).
(2) Lubricate converter drive hub and oil pump
CAUTION: Be sure the converter housing is fully
seal lip with transmission fluid.
seated on the engine block dowels before tighten-
(3) Align converter and oil pump.
ing any bolts.
(4) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in (14) Install torque converter attaching bolts.
pump gears. Tighten bolts to following torque.
(5) Check converter seating with steel scale and • 54 N·m (40 ft. lbs.) with 9.5 in. 3-lug converter
straightedge (Fig. 68). Surface of converter lugs • 74 N·m (55 ft. lbs.) with 9.5 in. 4-lug converter
should be 1/2 in. to rear of straightedge when con- • 74 N·m (55 ft. lbs.) with 10.0 in. 4-lug converter
verter is fully seated. • 31 N·m (270 in. lbs.) with 10.75 in. 4-lug con-
(6) Temporarily secure converter with C-clamp. verter
(7) Lubricate the pocket in the rear of the crank- (15) Install crankshaft position sensor.
shaft, in which the converter pilot hub rides, with a (16) Install transmission fill tube and seal. Install
light coating of Mopart High-Temp Grease. new fill tube seal in transmission before installation.
(8) Position transmission on jack and secure it (17) Connect transmission cooler lines to transmis-
with safety chains. sion.
(9) Check condition of converter driveplate. (18) Install transfer case onto transmission.
Replace the plate if cracked, distorted or damaged. (19) Install rear crossmember and attach trans-
Also be sure transmission dowel pins are seated mission rear support to crossmember.
in engine block and protrude far enough to (20) Remove engine support fixture.
hold transmission in alignment. (21) Remove transmission jack.
(10) Raise transmission and align converter with (22) Connect vehicle speed sensor wires.
drive plate and converter housing with engine block. (23) Connect wires to park/neutral position switch.
(11) Move transmission forward. Then raise, lower (24) Install crankshaft position sensor.
or tilt transmission to align converter housing with (25) Install converter housing access cover.
engine block dowels. (26) Install exhaust pipes and support brackets, if
removed.
21 - 146 AUTOMATIC TRANSMISSION—30RH XJ
REMOVAL AND INSTALLATION (Continued)
REMOVAL INSTALLATION
(1) Align bushing oil hole with oil slot in extension
(1) Raise vehicle.
housing.
(2) Mark propeller shaft and axle yoke for align-
(2) Tap bushing into place with Installer 6951 and
ment reference.
Handle C-4171.
(3) Disconnect and remove propeller shaft.
(3) Install new oil seal in housing using Seal
(4) Remove old seal with Seal Remover C-3985-B
Installer C-3995–A (Fig. 74).
(Fig. 71) from extension housing.
ITEM TORQUE
A 2-3 N·m (15-27 in. lbs.)
B 10-12 N·m (90-110 in. lbs.)
GEARSHIFT CABLE
REMOVAL
(1) Shift transmission into Park.
(2) Remove shift lever bezel and necessary console
parts for access to shift lever assembly.
(3) Disconnect cable at shift lever and feed cable
through dash panel opening to underside of vehicle.
(4) Raise vehicle.
(5) Disengage cable eyelet at transmission shift
lever and pull cable adjuster out of mounting
bracket. Then remove old cable from vehicle.
INSTALLATION
(1) Route cable through hole in dash panel. Fully Fig. 79 Brake/Park Interlock Cable
seat cable grommet into dash panel. 1 – IGNITION LOCK
2 – LOCK TAB
(2) Place the auto transmission manual shift con-
3 – CABLE END
trol lever in “Park” detent (rearmost) position and
rotate prop shaft to ensure transmission is in park.
(3) Connect shift cable to shifter mechanism by (9) Disconnect and remove the cable from the shift
snapping cable retaining ears into shifter bracket bracket.
and press cable end fitting onto lever ball stud.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 151
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Install bearing on output shaft. Be sure retain-
ing ring groove in outer circumference of bearing is
toward the governor. Fig. 85 Governor Valve
(2) Install rear bearing retaining snap ring (Fig. 1 – E-CLIP
84). 2 – PARK GEAR
(3) Install extension housing. 3 – CURVER BOSS
4 – GOVERNOR VALVE
5 – GOVERNOR
PARK LOCK
REMOVAL
(1) Raise vehicle and remove propeller shaft.
(2) Remove extension housing.
(3) Slide sprag shaft out of extension housing and
remove sprag and spring (Fig. 88).
(4) Remove snap ring and slide reaction plug and
pin assembly out of housing.
(5) If park rod requires service, it will be necessary
to remove valve body.
INSTALLATION
(1) Inspect sprag shaft for scores and free move-
ment in housing and sprag. Inspect sprag and control
rod springs for distortion and loss of tension. replace
Fig. 87 Governor Body worn, damaged parts as necessary.
1 – GOVERNOR/PARK ASSEMBLY
(2) Inspect square lug on sprag for broken edges.
2 – GOVERNOR VALVE SHAFT BORE Check lugs on park gear for damage. Inspect knob on
3 – REAR SUPPORT end of control rod for wear grooves, or being seized
4 – OUTPUT SHAFT SPLINES on rod. Replace rod if bent, if knob is worn/grooved,
5 – SEAL RINGS or it has seized on rod. Replace park gear if lugs are
damaged. Replace the park lock rod if it is suspected
that the rod is not the correct length.
INSTALLATION (3) Install reaction plug and pin assembly in hous-
(1) Install park gear into rear support so crown on
ing and secure with new snap ring (Fig. 88).
curved boss is in line with hole through output shaft.
(4) Position sprag and spring in housing and insert
(2) Install governor filter in park gear.
sprag shaft. Be sure square lug on sprag is toward
(3) Slip governor body over output shaft and align
park gear. Also be sure spring is positioned so it
port to filter.
moves sprag away from gear.
(4) Install bolts to hold governor body to park gear.
(5) Install extension housing.
Tighten bolts to 11 N·m (95 in. lbs.) torque (Fig. 87).
(6) Install propeller shaft and lower vehicle.
(5) Install governor body-park gear snap rings and
(7) Check transmission fluid level. Add fluid if nec-
washer on output shaft as follows:
essary.
(a) Install thin snap ring first. Then install
thrust washer second, and thick snap ring last
(Fig. 86). DISASSEMBLY AND ASSEMBLY
(b) Verify correct position of snap rings. Be sure
flat side of each snap ring is toward governor GOVERNOR AND PARK GEAR
body.
(6) Insert governor valve and shaft through gover- DISASSEMBLY
nor and install E-clip (Fig. 85).
(1) Remove governor body from transmission.
(7) Install extension housing and gasket on trans-
(2) Clean and inspect governor filter (Fig. 89).
mission. Tighten housing bolts to 32 N·m (24 ft. lbs.).
(3) Remove snap ring and washer that secure gov-
(8) Install rear transmission mount and skid plate.
ernor weight assembly in body (Fig. 90).
(9) Install speed sensor and speedometer compo-
(4) Remove governor weight assembly from gover-
nents and connect speed sensor wires.
nor body bore.
(10) Connect exhaust components and brake cable,
(5) Slide intermediate and inner weight from outer
if removed.
weight.
(11) Install propeller shaft.
(6) Position intermediate weight on suitable size
(12) Remove supports and lower vehicle.
socket (Fig. 91).
(13) Check transmission fluid level. Add fluid if
(7) Push inner weight downward with nut driver.
necessary.
Then remove inner weight snap ring with Miller
Plier Tool 6823 (Fig. 91).
(8) Remove inner weight and spring from interme-
diate weight.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 155
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
CAUTION: Exercise care when installing the rings. Fig. 91 Inner Weight Snap Ring
They are easily broken if overspread or twisted dur- 1 – NUT DRIVER
2 – SUITABLE SIZE SOCKET
ing installation.
3 – INTERMEDIATE WEIGHT
4 – INNER WEIGHT SNAP RING
If it was necessary to remove the park gear,
5 – SPECIAL TOOL 6823
inspect the seal rings and bore in rear support.
21 - 156 AUTOMATIC TRANSMISSION—30RH XJ
DISASSEMBLY AND ASSEMBLY (Continued)
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.
Fig. 94 Adjusting Screw Bracket, Springs, Valve Fig. 96 Manual And Throttle Levers
Removal 1 – PARK ROD
1 – ADJUSTER BRACKET 2 – E-RING
2 – LINE PRESSURE ADJUSTER 3 – WASHER
3 – PRESSURE REGULATOR VALVE 4 – MANUAL LEVER
4 – SWITCH VALVE 5 – MANUAL VALVE
5 – VALVE BODY 6 – SPRING
6 – TRANSFER PLATE 7 – DETENT BALL
7 – THROTTLE VALVE 8 – VALVE BODY
8 – SLEEVE
9 – KICKDOWN VALVE
10 – THROTTLE PRESSURE ADJUSTER
Fig. 103 Transfer And Separator Plates Fig. 105 Shuttle Valve End Plate
1 – SEPARATOR PLATE 1 – VALVE BODY
2 – FILTER 2 – SHUTTLE VALVE END PLATE
3 – TRANSFER PLATE
CAUTION: Do not force valves or plugs into place (3) Install regulator valve end plate on valve body
during reassembly. If the valve body bores, valves, (Fig. 107).
and plugs are free of distortion or burrs, the valve (4) Install kickdown limit valve and spring in kick-
body components should all slide into place easily. down limit valve body (Fig. 107). Verify valve compo-
In addition, do not overtighten the transfer plate nents slide freely.
and valve body screws during reassembly. Over- (5) Compress spring into kickdown limit valve
tightening can distort the valve body resulting in body.
valve sticking, cross leakage and unsatisfactory (6) Install retainer in grooves at end of kickdown
operation. Tighten valve body screws to recom- limit valve body (Fig. 107).
mended torque only. (7) Install throttle pressure plug in kickdown limit
valve body (Fig. 107).
(1) Lubricate valve body bores, valves and plugs (8) Install 1-2 shift valve and spring into valve
with Mopart ATF Plus 3, Type 7176, transmission body (Fig. 107).
fluid. (9) Install 2-3 shift valve and spring into valve
(2) Install regulator valve line pressure plug, pres- body (Fig. 107).
sure plug sleeve, regulator valve throttle pressure (10) Install 1-2 shift control valve and spring into
plug, and spring into valve body (Fig. 107). Verify valve body (Fig. 107).
valve components slide freely. (11) Verify valve components slide freely.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 161
DISASSEMBLY AND ASSEMBLY (Continued)
(12) Place kickdown limit valve body and end plate
in position on valve body and compress springs (Fig.
107).
(13) Install screws to attach kickdown limit valve
body to valve body (Fig. 107).
(14) Install shuttle valve throttle plug, primary
spring and shuttle valve into valve body (Fig. 107).
Verify valve components slide freely.
(15) Install 1-2 and 2-3 shift valve governor plugs
into valve body (Fig. 107). Verify valve components
slide freely.
(16) Place governor plug end plate in position on
valve body and compress spring.
(17) Install screws to attach governor plug end
plate to valve body (Fig. 107).
(18) Assemble shuttle valve spring and guides Fig. 109 Shuttle Valve End Plate
(Fig. 107). Place spring and guides in position on 1 – VALVE BODY
shuttle valve stem. 2 – SHUTTLE VALVE END PLATE
(19) Compress spring and install E-clip in groove
on shuttle valve stem (Fig. 108).
(20) Place shuttle valve end plate in position on
valve body (Fig. 109).
(21) Install screws to attach shuttle valve end
plate to valve body (Fig. 109).
TRANSMISSION
DISASSEMBLY
(1) Remove transmission from vehicle.
Fig. 119 Manual Valve Fig. 121 Manual Valve And Throttle Lever Alignment
1 – MANUAL VALVE 1 – THROTTLE LEVER
2 – VALVE BODY 2 – MANUAL LEVER VALVE ARM
3 – MANUAL VALVE
4 – KICKDOWN VALVE
Fig. 132 Front Band Fig. 134 Rear Band Adjuster Location
1 – FRONT BAND 1 – PLANETARY GEARTRAIN
2 – TRANSMISSION HOUSING 2 – REAR BAND
3 – LEVER
4 – SERVO
5 – ADJUSTER
ASSEMBLY
(1) Install rear servo piston, spring and spring
retainer. Compress rear servo spring and retainer
with Compressor Tool C-3422-B (Fig. 145) or a large
C-clamp.
(2) Install front servo piston, spring, and rod
guide. Compress front servo rod guide with Valve
Spring Compressor C-3422-B and install servo snap
ring (Fig. 144).
(3) Assemble link bar to band. Notched side of link
toward band (Fig. 143).
(4) Insert rear band through pan opening in trans-
Fig. 143 Rear Band Servo Lever Pin mission case.
1 – PARALLEL JAW SNAP RING PLIERS
(5) Insert hook on band onto adjuster lever.
2 – REAR BAND LEVER PIVOT PIN
(6) Align holes in link bar with hole in transmis-
sion case outboard of rear support opening (Fig. 142).
(7) Insert anchor pin into case through link bar.
21 - 170 AUTOMATIC TRANSMISSION—30RH XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(16) Push low-reverse drum rearward to close gap
between cam and case.
(17) Install overrunning clutch cam bolts. Clutch
cam bolts are shorter than rear support bolts.
Tighten cam bolts to 17 N·m (150 in. lbs. or 13 ft.
lbs.) torque.
ASSEMBLY
(1) Assemble clutch rollers and springs in retainer
if necessary (Fig. 165).
(2) Install overrunning clutch roller, spring and
retainer assembly in clutch cam (Fig. 166).
(3) Temporarily assemble and check overrunning
clutch operation as follows:
(a) Assemble cam and clutch.
REAR SERVO PISTON (2) Mark pump housing and support assembly for
alignment reference.
DISASSEMBLY (3) Remove bolts attaching pump body to support
(1) Remove small snap ring and remove plug and (Fig. 172).
spring from servo piston (Fig. 170).
(2) Remove and discard servo piston seal ring.
ASSEMBLY
(1) Lubricate piston and guide seals with petro-
leum jelly. Lubricate other servo parts with Mopart
ATF Plus 3, Type 7176, transmission fluid.
(2) Install new seal ring on servo piston.
(3) Assemble piston, plug, spring and new snap
ring.
(4) Lubricate piston seal lip with petroleum jelly.
Fig. 181 Hub Seal Ring Position Fig. 183 Pump Oil Seal Installation
1 – SEAL RINGS 1 – PUMP BODY
2 – SUPPORT HUB 2 – PUMP SEAL
3 – SPECIAL TOOL C-4193
FRONT CLUTCH
DISASSEMBLY
(1) Remove waved snap ring and remove pressure
plate, clutch plates and clutch discs (Fig. 184).
(2) Compress clutch piston spring with Compressor
Tool C-3575-A (Fig. 185). Be sure legs of tool are
seated squarely on spring retainer before compress-
ing spring.
(3) Remove retainer snap ring and remove com-
Fig. 182 Assembling Reaction Shaft Support And pressor tool.
Pump Housing (4) Remove spring retainer and clutch spring. Note
1 – PUMP HOUSING
position of retainer on spring for assembly reference.
2 – REACTION SHAFT SUPPORT (5) Remove clutch piston from clutch retainer.
Remove piston by rotating it up and out of retainer.
(6) Remove seals from clutch piston and clutch
(10) Install all bolts that attach support to pump retainer hub. Discard both seals as they are not reus-
housing. Then tighten bolts finger tight. able.
(11) Tighten support-to-pump bolts to required
torque as follows: ASSEMBLY
(a) Reverse pump assembly and install it in (1) Soak clutch discs in transmission fluid while
transmission case. Position pump so bolts are fac- assembling other clutch parts.
ing out and are accessible. (2) Install new seals on piston and in hub of
(b) Secure pump assembly in case with 2 or 3 retainer. Be sure lip of each seal faces interior of
bolts, or with pilot studs. clutch retainer.
(c) Tighten support-to-pump bolts to 20 N·m (15 (3) Lubricate lips of piston and retainer seals with
ft. lbs.). liberal quantity of Mopart Door Ease, or Ru-Glyde.
(d) Remove pump assembly from transmission Then lubricate retainer hub, bore and piston with
case. light coat of transmission fluid.
(12) Install new oil seal in pump with Special Tool (4) Install clutch piston in retainer (Fig. 186). Use
C-4193 and Tool Handle C-4171 (Fig. 183). Be sure twisting motion to seat piston in bottom of retainer. A
seal lip faces inward. thin strip of plastic (about 0.020” thick), can be used
(13) Install new seal ring around pump housing. to guide seals into place if necessary.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal and O-ring seal CAUTION: Never push the clutch piston straight in.
with transmission fluid. 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.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 181
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Position spring in clutch piston (Fig. 187). will assure that the snap-ring is at the top of the
(6) Position spring retainer on top of piston spring groove.
(Fig. 188). Make sure retainer is properly (c) Release the pressure plate and zero the dial
installed. Small raised tabs should be facing indicator.
upward. Semicircular lugs on underside of (d) Lift the pressure plate until it contacts the
retainer are for positioning retainer in spring. waved snap-ring and record the dial indicator read-
(7) Compress piston spring and retainer with Com- ing.
pressor Tool C-3575-A (Fig. 185). Then install new Clearance should be 1.70 to 3.40 mm (0.067 to
snap ring to secure spring retainer and spring. 0.134 in.). If clearance is incorrect, clutch discs,
(8) Install clutch plates and discs (Fig. 184). plates pressure plates and snap ring may have to be
Install steel plate then disc until all plates and discs changed.
are installed. The front clutch uses 4 clutch discs.
(9) Install pressure plate and waved snap ring REAR CLUTCH
(Fig. 184).
(10) Using a suitable gauge bar and dial indicator, DISASSEMBLY
measure clutch plate clearance (Fig. 189). (1) Remove thrust washer from forward side of
(a) Position gauge bar across the clutch drum clutch retainer.
with the dial indicator pointer on the pressure (2) Remove input shaft front/rear seal rings.
plate (Fig. 189). (3) Remove selective clutch pack snap ring (Fig.
(b) Using two small screw drivers, lift the pres- 190).
sure plate and compress the waved snap-ring. This
21 - 182 AUTOMATIC TRANSMISSION—30RH XJ
DISASSEMBLY AND ASSEMBLY (Continued)
CLEANING AND INSPECTION Examine the park lock components in the housing.
If replacement is necessary, remove the shaft with
GOVERNOR AND PARK GEAR parallel jaw snap ring pliers (Fig. 220) and remove
Thoroughly clean all the governor parts in a suit- the sprag and spring. Then remove the spring clip
able cleaning solution but do not use any type of and reaction plug (Fig. 221). Compress the reac-
caustic cleaning agents. tion plug spring clip only enough to remove
The governor weight components (Fig. 218) and the and install it. Do not distort the clip during
governor valve (Fig. 219), must slide freely in their removal or installation.
bores when clean and dry. Minor surface scratches Be sure a replacement sprag is installed so the
and burrs can be smoothed with crocus cloth. sprag locking lug will face the park gear (Fig. 222).
The aluminum governor valve and outer weight Also be sure the spring is correctly positioned as
have a hard coating on them. Check condition of this shown (Fig. 222). The sprag may not retract if the
coating carefully. Do not reuse either part if the coat- spring is improperly installed.
ing is damaged.
Inspect the governor weight spring for distortion. VALVE BODY
Replace the spring, if distorted, collapsed, or broken. Serviceable valve body components are:
Clean the filter in solvent and dry it with compressed • park lock rod and E-clip
air. Replace the filter, if damaged. Inspect the park • switch valve and spring
gear for chipped or worn gear teeth or damaged ring • pressure adjusting screw bracket
grooves. Replace the gear, if damaged. • throttle valve lever
Check the teeth on the park gear for wear or dam- • manual lever
age. Replace the gear if necessary. Inspect the metal • manual lever shaft seal, washer, E-clip and
seal rings on the park gear hub. Replace the rings detent ball
only if severely worn, or broken. • fluid filter
• converter clutch solenoid
EXTENSION HOUSING AND PARK LOCK The remaining valve body components are serviced
Clean the housing and park lock components in only as part of a complete valve body assembly.
solvent and dry them with compressed air.
Clean the valve body components in a parts clean- be removed with crocus cloth using only very light
ing solution only. Do not use gasoline, kerosene, or pressure.
any type of caustic solution. Dry the parts with com- Minor distortion of a valve body mating surface
pressed air. Make sure all passages are clean and may be corrected by smoothing the surface with cro-
free from obstructions. cus cloth. The cloth should be in sheet form and be
positioned on a surface plate, sheet of plate glass, or
NOTE: Do not use rags or shop towels to wipe off equally flat surface. However, if distortion is severe
valve body components. Lint from these materials or any surfaces are heavily scored, the valve body
will adhere to the valve body components. Lint will will have to be replaced.
interfere with valve operation and may clog filters
and fluid passages. CAUTION: Many of the valve body valves and plugs
are made of coated aluminum. Aluminum compo-
Inspect the throttle and manual valve levers and nents can be identified by the dark color of the spe-
shafts. Do not attempt to straighten a bent shaft or cial coating applied to the surface (or by testing
correct a loose lever. Replace these components if with a magnet). DO NOT polish or sand aluminum
worn, bent, loose or damaged in any way. valves or plugs with any type of material, or under
Inspect all of the valve body mating surfaces for any circumstances. This practice might damage the
scratches, nicks, burrs, or distortion. Use a straight- special coating and cause the valves and plugs to
edge to check surface flatness. Minor scratches may stick and bind.
XJ AUTOMATIC TRANSMISSION—30RH 21 - 193
CLEANING AND INSPECTION (Continued)
Fig. 220 Park Sprag, Shaft And Spring Fig. 222 Correct Position Of Sprag And Spring
1 – SPRAG SHAFT 1 – SPRAG SHAFT
2 – PARALLEL JAW SNAP RING PLIERS 2 – SPRAG LOCKING LUG
3 – SPRAG 3 – SPRING
4 – SPRING
SPECIFICATIONS
30RH AUTOMATIC TRANSMISSION
GENERAL
PRESSURE TEST—ALL
TORQUE
DESCRIPTION TORQUE
Bolt/nut, crossmember . . . . . . . . 68 N·m (50 ft. lbs.)
Bolt, driveplate to crankshaft . . 75 N·m (55 ft. lbs.)
Plug, front band reaction . . . . . 17 N·m (13 ft. lbs.)
Locknut, front band adj. . . . . . . 34 N·m (25 ft. lbs.)
Switch, park/neutral . . . . . . . . . 34 N·m (25 ft. lbs.)
Bolt, fluid pan . . . . . . . . . . . . . . 17 N·m (13 ft. lbs.)
Bolt, oil pump . . . . . . . . . . . . . . 20 N·m (15 ft. lbs.)
Bolt, overrunning clutch cam . . 17 N·m (13 ft. lbs.) Retainer, Detent Ball and Spring—6583
Plug, pressure test port . . . . . . . 14 N·m (10 ft. lbs.)
Bolt, reaction shaft support . . . . 20 N·m (15 ft. lbs.)
Locknut, rear band . . . . . . . . . . 41 N·m (30 ft. lbs.)
Bolt. speedometer adapter . . . . . . 11 N·m (8 ft. lbs.)
Screw, fluid filter . . . . . . . . . . . . 4 N·m (35 in. lbs.)
Bolt, valve body to case . . . . . 12 N·m (100 in. lbs.)
SPECIAL TOOLS
30RH TRANSMISSIONS
Snap-ring Plier—6823
Installer—6951
Pressure Gauge—C-3292
21 - 214 AUTOMATIC TRANSMISSION—30RH XJ
SPECIAL TOOLS (Continued)
Pressure Gauge—C-3293SP
Spring Compressor—C-3863-A
Spring Compressor—C-3575-A
Installer, Bushing—SP-5302
Seal Installer—C-3860-A
Remover, Bushing—SP-3550
Bushing Remover/Installer—C-3887-J
Remover, Bushing—SP-3629
Cup, Remover—SP-3633
Installer, Bushing—SP-5511
Remover, Bushing—SP-5301
Snap-ring Plier—C-3915
Installer, Bushing—SP-5118
21 - 216 AUTOMATIC TRANSMISSION—30RH XJ
SPECIAL TOOLS (Continued)
Installer—C-3995-A
Seal Remover—C-3985-B
Bushing, Remover—6957
Universal Handle—C-4171
Remover/Installer—C-4470
TABLE OF CONTENTS
page page
FOURTH GEAR OVERDRIVE COMPONENTS NOTE: Refer to Service Procedures in this group
for fluid level checking procedures.
The overdrive system consists of the input shaft,
one–way clutch, planetary sun gear, ring gear, plan-
etary carrier, overdrive clutch and overdrive brake DESCRIPTION
(Fig. 4). The overdrive elements are controlled and Mopart Dexron IIE/Mercon is the recommended
fluid for the AW-4 automatic transmissions.
Dexron II fluid IS NOT recommended. Clutch clutch operation and inhibit overheating, oxidation,
chatter can result from the use of improper varnish, and sludge. These claims have not been sup-
fluid. ported to the satisfaction of DaimlerChrysler and
Mopart Dexron IIE/Mercon automatic transmission these additives must not be used. The use of trans-
fluid when new is red in color. The ATF is dyed red mission “sealers” should also be avoided, since they
so it can be identified from other fluids used in the may adversely affect the integrity of transmission
vehicle such as engine oil or antifreeze. The red color seals.
is not permanent and is not an indicator of fluid con-
dition. As the vehicle is driven, the ATF will begin to OPERATION
look darker in color and may eventually become The automatic transmission fluid is selected based
brown. This is normal. A dark brown/black fluid upon several qualities. The fluid must provide a high
accompanied with a burnt odor and/or deterioration level of protection for the internal components by
in shift quality may indicate fluid deterioration or providing a lubricating film between adjacent metal
transmission component failure. components. The fluid must also be thermally stable
so that it can maintain a consistent viscosity through
FLUID ADDITIVES a large temperature range. If the viscosity stays con-
DaimlerChrysler strongly recommends against the stant through the temperature range of operation,
addition of any fluids to the transmission, other than transmission operation and shift feel will remain con-
those automatic transmission fluids listed above. sistent. Transmission fluid must also be a good con-
Exceptions to this policy are the use of special dyes ductor of heat. The fluid must absorb heat from the
to aid in detecting fluid leaks. internal transmission components and transfer that
Various “special” additives and supplements exist heat to the transmission case.
that claim to improve shift feel and/or quality. These
additives and others also claim to improve converter
21 - 222 AW–4 AUTOMATIC TRANSMISSION XJ
DESCRIPTION AND OPERATION (Continued)
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fig. 5) is a hydraulic device
that couples the engine crankshaft to the transmis-
sion. The torque converter consists of an outer shell
with an internal turbine, a stator, an overrunning
clutch, an impeller and an electronically applied con-
verter clutch. The converter clutch provides reduced
engine speed and greater fuel economy when
engaged. Clutch engagement also provides reduced
transmission fluid temperatures. Torque converter
clutch engagement occurs in second gear in 1–2 posi-
tion; third gear in 3 position and third and fourth
gear in D position. The torque converter hub drives
the transmission oil (fluid) pump.
The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.
Fig. 6 Impeller
1 – ENGINE FLEXPLATE 4 – ENGINE ROTATION
2 – OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 – ENGINE ROTATION
SECTION
3 – IMPELLER VANES AND COVER ARE INTEGRAL
21 - 224 AW–4 AUTOMATIC TRANSMISSION XJ
DESCRIPTION AND OPERATION (Continued)
TURBINE
The turbine (Fig. 7) is the output, or driven, mem-
ber of the converter. The turbine is mounted within
the housing opposite the impeller, but is not mounted
to the housing. The input shaft is inserted through
the center of the impeller and splined into the tur-
bine. The design of the turbine is similar to the
impeller, except the blades of the turbine are curved
in the opposite direction.
Fig. 7 Turbine
1 – TURBINE VANE 4 – PORTION OF TORQUE CONVERTER COVER
2 – ENGINE ROTATION 5 – ENGINE ROTATION
3 – INPUT SHAFT 6 – OIL FLOW WITHIN TURBINE SECTION
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 225
DESCRIPTION AND OPERATION (Continued)
STATOR
The stator assembly (Fig. 8) is mounted on a sta-
tionary shaft which is an integral part of the oil
pump. The stator also contains an over–running
clutch. The stator is located between the impeller
and turbine within the torque converter case (Fig. 9).
The over–running clutch of the stator allows the sta-
tor to rotate only in a clockwise direction.
OPERATION
The converter impeller (Fig. 11) (driving member),
which is integral to the converter housing and bolted
to the engine drive plate, rotates at engine speed.
The converter turbine (driven member), which reacts
from fluid pressure generated by the impeller, rotates
and turns the transmission input shaft. Fig. 10 Torque Converter Clutch (TCC)
1 – IMPELLER FRONT COVER
TURBINE 2 – THRUST WASHER ASSEMBLY
3 – IMPELLER
As the fluid that was put into motion by the impel- 4 – STATOR
ler blades strikes the blades of the turbine, some of 5 – TURBINE
the energy and rotational force is transferred into the 6 – FRICTION DISC
turbine and the input shaft. This causes both of them
21 - 226 AW–4 AUTOMATIC TRANSMISSION XJ
DESCRIPTION AND OPERATION (Continued)
STATOR
Torque multiplication is achieved by locking the
clutch to its shaft (Fig. 12). Under stall conditions
(the turbine is stationary), the oil leaving the turbine
vanes strikes the face of the stator vanes and tries to
rotate them in a counterclockwise direction. When
this happens the over–running clutch of the stator
locks and holds the stator from rotating. With the
stator locked, the oil strikes the stator vanes and is Fig. 12 Stator Operation
1 – DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
redirected into a “helping” direction before it enters PUSHING ON BACKSIDE OF VANES
the impeller. This circulation of oil from impeller to 2 – FRONT OF ENGINE
turbine, turbine to stator, and stator to impeller, can 3 – INCREASED ANGLE AS OIL STRIKES VANES
produce a maximum torque multiplication of about 4 – DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
2.2:1. As the turbine begins to match the speed of the AGAINST STATOR VANES
impeller, the fluid that was hitting the stator in such
as way as to cause it to lock–up is no longer doing so.
In this condition of operation, the stator begins to
free wheel and the converter acts as a fluid coupling.
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 227
DESCRIPTION AND OPERATION (Continued)
TORQUE CONVERTER CLUTCH (TCC) OIL PUMP
In a standard torque converter, the impeller and
turbine are rotating at about the same speed and the DESCRIPTION
stator is freewheeling, providing no torque multipli- The oil pump (Fig. 13) is located in the pump hous-
cation. By applying the turbine’s piston to the impel- ing inside the bell housing of the transmission case.
ler’s friction material, a total converter engagement The oil pump consists of an inner and outer gear, a
can be obtained. The result of this engagement is a housing, and a cover that also serves as the reaction
direct 1:1 mechanical link between the engine and shaft support.
the transmission.
The engagement and disengagement of the TCC OPERATION
are automatic and controlled by the Transmission As the torque converter rotates, the converter hub
Control Module (TCM). Inputs that determine clutch rotates the inner and outer gears. As the gears
engagement are: coolant temperature, vehicle speed rotate, the clearance between the gear teeth
and throttle position. Clutch engagement is con- increases in the crescent area, and creates a suction
trolled by transmission valve body solenoid number at the inlet side of the pump. This suction draws
three and by the converter clutch relay valve. The fluid through the pump inlet from the oil pan. As the
solenoid channels line pressure to the clutch through clearance between the gear teeth in the crescent area
the relay valve at clutch engagement speeds. decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
OPERATION
MANUAL VALVE
The manual valve is operated by the gearshift link-
age. The valve diverts fluid to the apply circuits
according to shift lever position (Fig. 17).
PRESSURE
Pressure (Fig. 31) is nothing more than force (lbs.)
divided by area (in or ft.), or force per unit area.
Given a 100 lb. block and an area of 100 sq. in. on
the floor, the pressure exerted by the block is: 100
lbs. 100 in or 1 pound per square inch, or PSI as it is
commonly referred to.
Fig. 29 Accumulators
1 – OVERDRIVE CLUTCH
2 – SECOND BRAKE
3 – DIRECT CLUTCH
4 – OVERDRIVE BRAKE
HYDRAULIC SYSTEM
DESCRIPTION
The hydraulic system consists of the pump, valve
body and solenoids, and four hydraulic accumulators.
Fig. 35 AW–4 Shift Lever Positions And The oil pump provides lubrication and operating
Transmission Ranges pressure.
The valve body controls application of the clutches,
TRANSMISSION CONTROL MODULE (TCM) brakes, second coast band, and the converter clutch.
The valve body solenoids control sequencing of the
DESCRIPTION 1–2, 2–3 and 3–4 shift valves. The solenoids are acti-
The module determines shift and converter clutch vated by signals from the transmission control mod-
engagement timing based on signals from sensors. ule.
The valve body solenoids are activated, or deacti- The accumulators are used in the clutch and brake
vated accordingly. feed circuits to control initial apply pressure. Spring
The TCM has a self diagnostic program. Compo- loaded accumulator pistons modulate the initial
nent and circuitry malfunctions can be diagnosed surge of apply pressure for smooth engagement.
with the DRB scan tool. Once a malfunction is noted
and stored in control module memory, it is retained TRANSMISSION COOLER
even after the problem has been corrected. To cancel
a stored malfunction, disconnect and reconnect the DESCRIPTION
“Trans.” fuse in the module harness.
MAIN COOLER
SENSORS The transmission main cooler is located in the
Sensors include: radiator. The main cooler can be flushed when neces-
• throttle position sensor (TPS) sary, however, the cooler is not a repairable compo-
• transmission speed sensor nent. If the cooler is damaged, plugged, or leaking,
• vehicle speed sensor the radiator will have to be replaced.
• park/neutral position switch
• brake switch AUXILIARY COOLER
The auxiliary cooler is mounted in front of the
OPERATION radiator at the driver side of the vehicle (Fig. 36).
The throttle position sensor is mounted on the The cooler can be flushed when necessary, while
throttle body. It electronically determines throttle mounted in the vehicle. The cooler can also be
position and relays this information to the transmis- removed for access, repair, or replacement as needed.
sion control module to determine shift points and The main and auxiliary coolers should both be
converter clutch engagement. flushed whenever a transmission or converter clutch
21 - 238 AW–4 AUTOMATIC TRANSMISSION XJ
DESCRIPTION AND OPERATION (Continued)
CAUTION: Do not hold wide open throttle for more TEST PROCEDURE
than 3–4 seconds at a time. (1) Check and adjust transmission fluid level if
necessary.
(8) Shift transmission into Reverse and note line
(2) Bring transmission to normal operating tem-
pressure with engine at curb idle speed. Pressure
perature.
should be 75–to–90 psi (519–to–618 kPa).
(3) Apply parking brakes and turn off air condi-
(9) Press accelerator to wide open throttle position
tioning unit.
and note line pressure in Reverse. Pressure should
(4) Shift transfer case into 2H range.
be 213–to–263 psi (1471–to–1814 kPa).
(5) Start engine and check curb idle speed. Adjust
CAUTION: Do not hold wide open throttle for more speed if necessary. Curb idle must be correct to
than 4 seconds. ensure accurate test results.
(6) Shift transmission into Neutral and set stop
(10) If line pressure is not within specifications, watch.
adjust transmission throttle cable and repeat pres- (7) During following test steps, start stop watch as
sure test. soon as shift lever reaches D and Reverse ranges.
(8) Shift transmission into D range and record
PRESSURE TEST ANALYSIS time it takes for engagement. Repeat test two more
If pressures in D and Reverse are higher than times.
specified in test, check for the following: (9) Reset stop watch and shift transmission back
• throttle cable loose, worn, binding or out of to Neutral.
adjustment (10) Shift transmission into Reverse and record
• throttle valve, downshift plug, throttle cam, or time it takes for engagement. Repeat test two more
primary regulator valve are sticking, worn or dam- times.
aged
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 243
DIAGNOSIS AND TESTING (Continued)
(11) Engagement time in D range should be a • forward clutch worn
maximum of 1.2 seconds. Engagement time for • overdrive clutch worn or damaged
Reverse should be a maximum of 1.5 seconds. If engagement time is longer than specified for
Reverse, check for the following:
TIME LAG TEST ANALYSIS • shift cable misadjusted
If engagement time is longer than specified for D • line pressure low
range, check for the following: • direct clutch worn
• shift cable misadjusted • first/reverse brake worn
• line pressure low • overdrive clutch worn or damaged
SERVICE DIAGNOSIS
DIAGNOSIS TABLE
VEHICLE WILL NOT BACK UP OR Shift cable out of adjustment or Adjust cable or replace cable
MOVE FORWARD damaged
Valve body or primary regulator Inspect/repair valve body
faulty
Park lock pawl faulty Repair park pawl
Torque converter faulty Replace torque converter
Converter drive plate broken Replace drive plate
Oil pump intake screen blocked Clean screen
Transmission faulty Disassemble and repair
transmission
SHIFT LEVER POSITION Shift cable out of adjustment Adjust cable
INCORRECT Manual valve and lever faulty Repair valve body
HARSH ENGAGEMENT Throttle cable out of adjustment Adjust throttle cable
Valve body or primary regulator Repair valve body
faulty
Accumulator pistons faulty Repair pistons
Transmission faulty Disassemble and repair
transmission
DELAYED 1-2, 2-3 OR 3-4 Electronic control problem Locate problem with DRB Tester
UP-SHIFT, OR DOWN-SHIFTS
Valve body faulty Repair valve body
FROM 4-3 OR 3-2 AND SHIFTS
BACK TO 4 OR 3 Solenoid faulty Repair solenoid
SLIPS ON 1-2, 2-3 OR 3-4 Shift cable out of adjustment Adjust cable
UP-SHIFT, OR SLIPS OR Throttle cable out of adjustment Adjust cable
SHUDDERS DURING
Valve body faulty Repair valve body
ACCELERATION
Solenoid faulty Replace solenoid
Transmission faulty Disassemble and repair
transmission
21 - 244 AW–4 AUTOMATIC TRANSMISSION XJ
DIAGNOSIS AND TESTING (Continued)
DRAG OR BIND ON 1-2, 2-3 OR Shift cable out of adjustment Adjust cable
3-4 UP-SHIFT Valve body faulty Repair valve body
Transimssion faulty Disassemble and repair
transmission
CONVERTER CLUTCH DOES NOT Electronic control problem Check with DRB Tester
ENGAGE IN 2ND, 3RD OR 4TH Valve body faulty Repair valve body
Solenoid faulty Replace solenoid
Transmission faulty Disassemble and repair
transmission
HARSH DOWN-SHIFT Throttle cable out of adjustment Adjust cable
Throttle cable and cam faulty Replace cable and cam
Accumulator pistons faulty Repair pistons
Valve body faulty Repair valve body
Transmission faulty Disassemble and repair
transmission
NO DOWN-SHIFT WHEN Valve body faulty Repair valve body
COASTING Solenoid faulty Replace solenoid
Electronic control problem Locate problem with DRB Tester
DOWN-SHIFT LATE OR EARLY Throttle cable faulty Replace cable
DURING COAST Valve body faulty Repair valve body
Transmission faulty Disassembly and repair
transmission
Solenoid faulty Replace solenoid
Electronic control problem Locate problem with DRB Tester
NO 4-3, 3-2 OR 2-1 KICKDOWN Solenoid faulty Replace solenoid
Electronic control problem Locate problem with DRB Tester
Valve body faulty Repair valve body
NO ENGINE BRAKING IN 1-2 Solenoid faulty Replace solenoid
POSITION Electronic control problem Locate problem with DRB Tester
Valve body faulty Repair valve body
Transmission faulty Disassemble and repair
transmission
VEHICLE DOES NOT HOLD IN Shift cable out of adjustment Adjust cable
PARK Parking lock pawl cam and spring Replace cam and spring
faulty
OVERHEAT DURING NORMAL Low fluid level Add fluid and check for leaks
OPERATION (FLUID Fluid cooler, lines blocked, or cooler Flush cooler and lines and replace
DISCOLORED, SMELLS BURNED) cracked (oil in engine coolant) radiator if transmission fluid has
entered coolant
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 245
DIAGNOSIS AND TESTING (Continued)
OVERHEAT DURING Vehicle not properly equipped for Be sure vehicle is equipped with
COMMERCIAL OPERATION OR trailer towing or commercial use recommended optional components
WHILE TRAILE TOWING (FLUID (i.e. HD springs, transmission, axle,
DARK AND BURNED WITH SOME larger CID engine, auxiliary cooler,
SLUDGE FORMATION) correct axle ratio, etc.). If vehicle is
not so equipped, it should not be
used for severe service operation
Vehicle not equipped with auxiliary Drain fluid, change filter, and install
fluid cooler auxiliary cooler
Extensive idling time or operation in Cut down on idling time; shift into
heavy traffic in hot weather neutral every so often and run
engine at 1000 rpm to help circulate
fluid through cooler
Tow vehicle overloaded (exceeding Be sure vehicle is properly equipped
vehicle tow capacity to handle load; do not tow Class
III-type loads with a vehicle that is
only rated for Class I or II operation
Air flow to auxiliary cooler blocked Remove or reposition item causing
by snow plow, front mounted spare air flow blockage
tire, bug screen, or similar item
OIL COMES OUT FILLER TUBE Transmission overfilled Drain fluid to correct level; remove
neutral switch and drain through
switch hole with suction gun
Breather vent in oil pump blocked Inspect and clear blockage
Fluid cooler or cooler lines plugged Flush cooler and lines
SERVICE PROCEDURES
CHECKING FLUID LEVEL
(1) Be sure transmission fluid is at normal operat-
ing temperature. Normal operating temperature is
reached after approximately 15 miles (25 km) of
operation.
(2) Position vehicle on level surface. This is impor-
tant for an accurate fluid level check.
(3) Shift transmission through all gear ranges and
back to Park.
(4) Apply parking brakes.
(5) Verify that transmission is in Park.
(6) Wipe off dipstick handle to prevent dirt from
entering fill tube. Then remove dipstick and check
fluid level and condition.
(7) Correct fluid level is to FULL mark on dip-
stick when fluid is at normal operating temper-
ature (Fig. 44).
(8) If fluid level is low, top off level with Mopar
Dexron IIE/Mercon. Mopar Dexron II can be used but
only if Mercon is not available. Do not overfill
transmission. Add only enough fluid to bring
level to Full mark. Fig. 43 Checking Operation Of Torque Converter
(9) If too much fluid was added, excess amount can Stator One–Way Clutch
be removed with suction gun and appropriate diame-
21 - 248 AW–4 AUTOMATIC TRANSMISSION XJ
SERVICE PROCEDURES (Continued)
Do not overfill. 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 fluid level is correct, shut engine off,
release park brake, remove funnel, and reseat dip-
stick in fill tube.
TORQUE CONVERTER
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
ITEM TORQUE
INSTALLATION (6) Install valve body oil tubes. Be sure tube ends
(1) Connect cable to throttle cam (Fig. 64). (L) and (M) are installed as shown in (Fig. 69).
(2) Install check ball and spring (Fig. 67). (7) Remove old sealer material from oil pan and
(3) Position accumulator springs and spacers on transmission case.
valve body. (8) Clean oil screen and oil pan with solvent (if not
(4) Align valve body manual valve with shift sector done previously). Dry both components with com-
(Fig. 68) and carefully position valve body on case. pressed air only. Do not use shop towels.
(5) Install valve body bolts (Fig. 65). Tighten bolts (9) Install new gaskets on oil screen and install
evenly to 10 N·m (7 ft. lbs.) torque. screen on case. Tighten screen attaching bolts to 10
N·m (7 ft. lbs.) torque.
21 - 260 AW–4 AUTOMATIC TRANSMISSION XJ
REMOVAL AND INSTALLATION (Continued)
Fig. 65 Transmission Valve Body Bolt Locations Fig. 67 Removing/Installing Check Ball And Spring
1 – CHECK BALL AND SPRING
INSTALLATION
(1) Lubricate new O–ring and install it on adapter.
(2) Install solenoid wire harness and adapter in
case.
(3) Install adapter bracket and bracket bolt.
(4) Connect wires to solenoids.
(5) Install oil screen.
(6) Apply bead of Threeebondt Liquid Gasket
TB1281, P/N 83504038, to oil pan seal surface.
Sealer bead should be at least 3 mm (1/8 in.) wide.
(7) Install oil pan on transmission. Tighten pan
bolts to 7 N·m (65 in. lbs.) torque.
(8) Install and tighten oil pan drain plug to 20
N·m (15 ft. lbs.) torque.
(9) Fill transmission with Mopar Dexron IIE/Mer-
con.
(1) Remove park/neutral position switch and dis- (5) Cut spacer sleeve with chisel and remove it
connect transmission shift lever (Fig. 74). from manual valve shaft (Fig. 77).
(2) Remove oil pan and valve body. (6) Remove pin from shaft and sector with pin
(3) Remove bolts attaching park rod bracket to punch.
case (Fig. 75). (7) Remove shaft and sector from case.
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 263
REMOVAL AND INSTALLATION (Continued)
(2) Coat replacement shaft seals with petroleum
jelly and seat them in the case using an appropri-
ately sized driver/socket (Fig. 79).
(3) Remove and discard piston O–ring seals. Then Fig. 83 Small Cushion Spring Retention
clean pistons and springs with solvent. 1 – ACCUMULATOR PISTON (TYPICAL)
2 – SMALL CUSHION SPRING
INSTALLATION 3 – RETAINER CLIP
(1) Inspect pistons, springs and piston bores.
Replace worn damaged pistons. Replace broken, col-
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 265
REMOVAL AND INSTALLATION (Continued)
(3) Install new O–ring seals on pistons. Lubricate
seals and pistons and piston bores with transmission
fluid.
(4) Install pistons and springs (Fig. 84).
INSTALLATION
(1) Install new seals on cover and piston.
(2) Lubricate servo components with transmission
fluid.
(3) Assemble and install servo components in case.
Be sure servo piston rod is properly engaged in the
second coast brake band.
(4) Compress cover and piston and install cover
snap ring.
(5) Install valve body, oil screen and oil pan. Fig. 89 Removing/Installing Park Rod
1 – SHIFT SECTOR
2 – MANUAL VALVE SHAFT
PARK ROD AND PAWL 3 – PARK ROD
REMOVAL
(1) Remove valve body as outlined in this section.
(2) Remove bolts attaching park rod bracket to
case (Fig. 88).
(3) Remove park rod from manual valve shaft sec-
tor (Fig. 89).
(4) Remove park rod.
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 267
REMOVAL AND INSTALLATION (Continued)
(5) Remove park pawl, pin and spring (Fig. 90).
INSTALLATION
(1) Examine park rod, pawl, pin and spring.
Replace any component that is worn or damaged.
(2) Install pawl in case. Insert pin and install spring.
Be sure spring is positioned as shown in Figure 35.
(3) Install park rod and bracket (Fig. 88). Tighten
bracket bolts to 10 N·m (7 ft. lbs.) torque.
(4) Install valve body, oil screen and oil pan.
(a) Mount dial indicator on case using Miller (29) Remove overdrive brake pack discs and
Tool C-3339 and a suitable bolt threaded into the plates. Inspect and replace as necessary.
transmission case. (30) Remove overdrive support lower race and
(b) Verify that the dial indicator is mounted sol- upper bearing and race assembly (Fig. 111).
idly and square to the direction of the piston
travel.
(c) Apply 57–114 psi air pressure through piston
apply port and note piston stroke on dial indicator.
Stroke length should be: 1.40 – 1.70 mm (0.055 –
0.0699 in.).
(d) Record the reading for use during re-assem-
bly.
(e) Remove the dial indicator set-up from the
transmission.
(25) Measure stroke length of second coast brake
piston rod as follows:
(a) Install a small wire tie strap around the sec-
ond coast brake piston rod tight against the trans-
mission case.
(b) Apply 57–114 psi air pressure through piston
feed hole and check stroke length with Gauge Tool
7552.
(c) Stroke length should be 1.5 – 3.0 mm (0.059
– 0.118 in.).
(d) Record the reading for use during re-assem-
bly. Fig. 111 Overdrive Support Bearing/Race Removal
(26) Remove the bolt holding the input speed sen- 1 – UPPER BEARING AND RACE
2 – LOWER RACE
sor to the transmission case.
(27) Remove the input speed sensor from the
transmission case.
21 - 274 AW–4 AUTOMATIC TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(31) Remove overdrive support snap ring with
Snap Ring Plier Tool 7540 (Fig. 112).
Fig. 130 Removing Second Brake Piston Sleeve Fig. 132 Removing/Installing Bearing And Race
1 – REMOVER TOOL
Assembly
2 – PISTON SLEEVE 1 – BEARING AND RACE ASSEMBLY
(22) Install park lock pawl, spring and pin (Fig. Fig. 146 Park Lock Rod Installation
145). 1 – SHIFT SECTOR
(23) Install the manual valve shift assembly. 2 – PARK LOCK ROD
(24) Connect park lock rod to manual valve shift
sector (Fig. 146).
21 - 284 AW–4 AUTOMATIC TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(25) Position park lock rod bracket on case and
tighten bracket attaching bolts to 10 N·m (7 ft. lbs.)
torque (Fig. 147).
Fig. 187 Aligning Manual Valve, Shift Sector And Fig. 189 Connecting Valve Body Solenoid Wires
Detent Spring 1 – SOLENOID WIRE CONNECTORS
1 – DETENT SPRING
2 – SHIFT SECTOR
3 – VALVE BODY
4 – MANUAL VALVE
(95) Install adapter housing on transmission. (98) Install transmission shift lever on manual
Tighten adapter bolts to 34 N·m (25 ft. lbs.) torque. valve shaft. Do not install lever attaching nut at this
(96) Install transmission speed sensor (Fig. 194). time.
Tighten sensor bolt to 7.4 N·m (65 in. lbs.) torque (99) Move transmission shift lever fully rearward.
and connect sensor wire harness connector. Then move lever two detent positions forward.
(97) Install converter housing (Fig. 195). Tighten (100) Mount park/neutral position switch on man-
12 mm diameter housing bolts to 57 N·m (42 ft. lbs.) ual valve shaft and tighten switch adjusting bolt just
torque. Tighten 10 mm diameter housing bolts to 34 enough to keep switch from moving (Fig. 196).
N·m (25 ft. lbs.) torque. (101) Install park/neutral position switch tabbed
washer and retaining nut (Fig. 196). Tighten nut to
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 297
DISASSEMBLY AND ASSEMBLY (Continued)
6.9 N·m (61 in. lbs.) torque, but do not bend any of
the washer tabs against the nut at this time.
(102) Align park/neutral position switch standard
line with groove or flat on manual shaft (Fig. 196).
(103) Tighten park/neutral position switch adjust-
ing bolt to 13 N·m (9 ft. lbs.) torque.
(104) Install transmission shift lever on manual
valve shaft. Tighten lever attaching nut to 16 N·m
(12 ft. lbs.) torque.
(105) Install retaining clamp for wire harness and
throttle cable (Fig. 197).
(106) Install torque converter.
(107) Verify that converter is seated by measuring
distance between converter housing flange and one of
the converter mounting pads (Fig. 198). Use straight-
edge and vernier calipers to measure distance. On
6–cyl. transmissions, distance should be 16.5 mm
(0.650 in.).
(108) Secure converter in transmission with
C–clamp or metal strapping. Do this before mounting
transmission on jack or moving transmission under
vehicle. Fig. 197 Installing Cable/Harness Clamps
(109) Install lower half of transmission fill tube 1 – TRANSMISSION HARNESS
(install upper half after transmission is in vehicle). 2 – THROTTLE CABLE
3 – RETAINING CLAMPS
CAUTION: The transmission cooler and lines must
be reverse flushed if overhaul corrected a malfunc-
tion that generated sludge, metal particles, or function. Debris and residue not flushed from the
clutch friction material. The torque converter should cooler and lines will flow back into the transmission
also be replaced if contaminated by the same mal- and converter. The result will be a repeat failure and
shop comeback.
21 - 298 AW–4 AUTOMATIC TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
OIL PUMP
DISASSEMBLY
(1) Remove pump body O–ring (Fig. 199).
(2) Remove pump seal.
(3) Remove pump seal rings (Fig. 199).
(4) Remove bolts attaching stator shaft to pump
body and separate components.
(5) Remove drive gear and driven gear from pump
body (Fig. 199).
OVERDRIVE PLANETARY GEAR AND CLUTCH (1) Check operation of one–way clutch in clutch
drum (Fig. 204). Hold drum and turn planetary shaft
DISASSEMBLY clockwise and counterclockwise. Shaft should turn
Fig. 204 Checking One–Way Clutch Fig. 206 Assembling Converter, Pump And Clutch
1 – CLUTCH DRUM
For Test
2 – PLANETARY SHAFT 1 – OVERDRIVE CLUTCH
2 – OIL PUMP
3 – TORQUE CONVERTER
(2) Remove overdrive clutch from planetary gear
(Fig. 205).
(b) Install a suitable threaded bolt/rod into oil
pump for use in mounting Miller Tool C-3339 dial
indicator components securely.
(c) Mount dial indicator on the bolt/rod and posi-
tion the dial indicator squarely on the clutch pis-
ton.
(d) Apply compressed air through clutch feed
hole in oil pump and note piston stroke length.
Stroke length should be 1.85 – 2.15 mm (0.0728 –
0.0846 in.).
(4) Remove thrust bearing and race assembly from
clutch drum (Fig. 207).
(5) Remove clutch pack snap ring and remove the
clutch pack (Fig. 208).
(6) Measure overdrive clutch disc thickness. Mini-
mum allowable thickness is 1.84 mm (0.0724 in.).
(7) If the clutch pack stroke length is out of speci-
fication or any clutch disc fails to meet the minimum
thickness, new discs will need to be installed during
assembly.
Fig. 205 Removing Overdrive Clutch From Gear (8) Compress piston return spring with Tool 7538
1 – OVERDRIVE CLUTCH (Fig. 209). Remove snap ring and remove compressor
2 – PLANETARY GEAR tool.
(9) Remove the piston return springs.
(10) Mount oil pump on converter. Then mount
(3) Measure stroke length of overdrive clutch pis-
clutch on oil pump (Fig. 210).
ton as follows:
(11) Hold clutch piston by hand and apply com-
pressed air through oil pump feed hole to ease piston
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 303
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 207 Removing Clutch Drum Bearing And Race Fig. 209 Removing Clutch Piston Snap Ring
1 – CLUTCH DRUM 1 – COMPRESSOR TOOL
2 – THRUST BEARING AND RACE 2 – CLUTCH PISTON SNAP RING
Fig. 211 Checking Piston Return Spring Length Fig. 213 Checking Clutch Drum Bushings
1 – CLUTCH DRUM
1 – PISTON RETURN SPRINGS
2 – SPRING RETAINER
OVERDRIVE SUPPORT
DISASSEMBLY
(1) Check brake piston operation. Mount support
on clutch (Fig. 229).
(2) Apply compressed air through support feed
hole and observe brake piston movement (Fig. 229).
Piston should move smoothly and not bind or stick. If
operation is incorrect, replace piston and support.
(3) Remove thrust bearing front race, thrust bear- Fig. 230 Removing Support Thrust Bearing And
ing and rear race (Fig. 230). Races
(4) Turn overdrive support over and remove bear- 1 – THRUST BEARING
ing race and clutch drum thrust washer (Fig. 231). 2 – FRONT RACE
(5) Compress piston return spring with Spring 3 – REAR RACE
Compressor 7537 and remove piston snap ring (Fig.
232).
21 - 310 AW–4 AUTOMATIC TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Mount support in direct clutch and remove
brake piston with compressed air. Apply air to same
feed hole used when checking piston operation.
(7) Remove and discard support O–rings (Fig. 233).
(8) Remove support seal rings (Fig. 234).
(9) Measure free length of piston return springs
with springs mounted in retainer (Fig. 235). Length
should be 17.23 mm (0.678 in.).
(10) Clean support components and dry them with
compressed air.
(11) Inspect overdrive support and brake piston.
Replace support and piston if either part is worn or
damaged.
ASSEMBLY
(1) Lubricate new support seal rings. Then com-
press rings and install them on support (Fig. 236).
(2) Lubricate and install new O–rings on brake
piston. Then carefully seat piston in support.
(3) Install return springs on brake piston.
(4) Compress return springs with Spring Compres-
sor 7537 (Fig. 232) and install piston snap ring.
(5) Install support bearing race and clutch drum
thrust washer (Fig. 231).
(6) Install thrust bearing and front and rear bear-
ing races. Thrust bearing rollers should face upward
as shown (Fig. 236).
(7) Verify thrust bearing/race sizes (Fig. 237).
Fig. 231 Removing Clutch Drum Thrust Washer And • Front race outer diameter is 47.8 mm (1.882 in.)
Race and inside diameter is 30.7 mm (1.209 in.).
1 – BEARING RACE
• Rear race outer diameter is 47.8 mm (1.882 in.)
2 – OVERDRIVE SUPPORT
and inside diameter is 34.3 mm (1.350 in.).
3 – THRUST WASHER
• Bearing outer diameter is 47.7 mm (1.878 in.)
and inside diameter is 32.7 mm (1.287 in.).
(8) Verify brake piston operation. Use same proce-
dure described at beginning of disassembly. Piston
should operate smoothly and not bind or stick.
DIRECT CLUTCH
DISASSEMBLY
(1) Remove direct clutch from forward clutch (Fig.
238).
FORWARD CLUTCH
DISASSEMBLY
(1) Check clutch piston stroke as outlined in fol- (4) Install a suitable threaded bolt/rod into the
lowing steps. side of the overdrive support.
(2) Position overdrive support on wood blocks and (5) Mount Miller Tool C-3339 dial indicator compo-
mount forward clutch drum on support (Fig. 253). nents onto the threaded rod as necessary.
(3) Remove bearing and race from forward clutch (6) Position dial indicator plunger squarely against
drum (Fig. 253). clutch piston.
21 - 318 AW–4 AUTOMATIC TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Lubricate bearing and race assembly with Fig. 262 Testing Piston Check Ball
petroleum jelly and install it in clutch drum (Fig. 1 – PISTON CHECK BALL
263). Race side of assembly faces downward and 2 – USE LOW AIR PRESSURE FOR TEST
toward drum. Bearing rollers face up (Fig. 263)
(2) Coat new clutch drum shaft seal rings with
petroleum jelly. Before installing drum shaft seal (3) Install seal rings on shaft. Keep rings closed as
rings, squeeze each ring so ring ends overlap (Fig. tightly as possible during installation. Avoid over-
264). This tightens ring making clutch installation spreading them.
easier. (4) Mount clutch drum on overdrive support.
(5) Lubricate and install new O–ring on clutch
drum hub (Fig. 257).
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 321
DISASSEMBLY AND ASSEMBLY (Continued)
(7) Install piston return springs.
(8) Compress piston return springs with Tool 7538
and shop press and install piston snap ring. Be sure
snap ring end gap is not aligned with any notches in
drum.
(9) Install cushion plate in drum. Concave side of
plate faces downward (Fig. 255).
(10) Install clutch discs, plates and retainer (Fig.
265). Install tabbed plate followed by disc until
required number of plates and discs are installed.
Use six plates and discs.
ASSEMBLY
(1) Lubricate planetary and ring gear bearings and
races with petroleum jelly.
(2) Identify planetary bearings and races before
installation. (Fig. 268). Bearings and races can be
identified by following dimensions:
• Outer diameter of rear bearing is 47.7 mm
(1.878 in.). Inner diameter is 35.5 mm (1.398 in.).
• Outer diameter of rear race 47.6 mm (1.874 in.).
Inner diameter is 33.7 mm (1.327 in.).
• Outer diameter of front race is 53.6 mm (2.110
in.). Inner diameter is 30.5 mm (1.201 in.).
• Outer diameter of front bearing is 47.7 mm Fig. 270 Front Planetary Thrust Race Installation
(1.878 in.). Inner diameter is 32.6 (1.283 in.). 1 – TABBED THRUST RACE
• Outer diameter of forward race is 47.0 mm 2 – PLANETARY GEAR
(1.850 in.). Inner diameter is 26.5 mm 1.043 in.).
(3) Install rear race and bearing in gear (Fig. 269).
(4) Turn planetary over and install thrust race
(Fig. 270).
(5) Install front race and bearing and forward race
in ring gear (Fig. 271).
Fig. 269 Front Planetary Rear Bearing and Race Fig. 271 Front Planetary Front Bearing And Races
Installation Installation
1 – REAR BEARING AND RACE
1 – FRONT BEARING AND RACE
2 – PLANETARY GEAR
2 – FORWARD RACE
21 - 324 AW–4 AUTOMATIC TRANSMISSION XJ
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Install first snap ring on sun gear.
Fig. 279 Installing Clutch And Hub Assembly On
(2) Install sun gear in drum and install remaining
Sun Gear
1 – CLUTCH AND HUB ASSEMBLY
snap ring.
(3) Coat replacement seal rings with petroleum
jelly and install them on sun gear. Be sure seal (5) Install one–way clutch/second brake hub
ring ends are interlocked. assembly on sun gear. Deep side of hub flange faces
(4) Install thrust washer. Be sure washer tabs are upward (Fig. 279).
seated in drum slots.
SECOND BRAKE
DISASSEMBLY
(1) Remove second brake drum from output shaft
(Fig. 280).
ASSEMBLY
(1) Lubricate and install new O–rings on brake
piston. Then install brake piston in drum.
(2) Install return springs and retainer on brake
piston.
(3) Compress return springs with shop press and Fig. 286 Installing Second Brake Thrust Washer
Compressor Tool 7538. Install piston snap ring and 1 – THRUST WASHER NOTCHES
2 – SPRING RETAINER TABS
remove brake assembly from press.
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 329
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
(1) Measure thickness of each brake pack disc.
Minimum thickness is 1.51 mm (0.0594 in.). Replace
all discs if any disc is thinner than specified.
(2) Install hub and snap ring in ring gear (Fig.
296)
(3) Identify ring gear thrust bearing and races by
following dimensions (Fig. 295) :
• Outer diameter of bottom race is 44.8 mm (1.764
in.) and inner diameter is 27.6 mm (1.087 in.).
• Outer diameter of bearing is 44.7 mm (1.760 in.)
and inner diameter is 30.1 mm (1.185 in.).
Fig. 295 Removing/Installing Ring Gear Thrust • Outer diameter of upper race is 44.8 mm (1.764
Bearing And Races in.) and inner diameter is 28.8 mm (1.134 in.).
1 – THRUST BEARING AND RACES (4) Lubricate ring gear thrust bearing and races
2 – RING GEAR with petroleum jelly and install them in ring gear
(Fig. 295).
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 333
DISASSEMBLY AND ASSEMBLY (Continued)
(5) Coat planetary thrust washers with petroleum (9) Install clutch retaining snap ring and install
jelly and install them in gear (Fig. 294). clutch inner race (Fig. 292). Turn race counterclock-
(6) Install No. 2 one–way clutch bottom end cap wise to ease installation.
into the planetary gear. (10) Verify one–way clutch operation. Hold gear
(7) Install No. 2 one–way clutch in planetary gear. and turn inner race in both directions. Race should
Be sure flanged side of clutch faces upward (Fig. turn freely counterclockwise, but lock when turned
297). clockwise.
(8) Install No. 2 one–way clutch top end cap into (11) Install planetary gear in ring gear.
the planetary gear. (12) Install thrust bearing and washers onto the
ring gear (Fig. 295).
(13) Assemble clutch discs and clutch plates (Fig.
289). Sequence is disc first, then a plate. Use seven
discs and plates.
(14) Install brake pack on planetary gear (Fig.
289).
(15) Install new seal ring on output shaft (Fig.
288). Be sure ring ends are interlocked as shown.
CLEANING AND INSPECTION (10) Lock shift cable by pressing cable adjuster
clamp down until it snaps into place.
TRANSMISSION PARTS CLEANING AND (11) Lower vehicle and check engine starting.
Engine should start only in Park and Neutral.
INSPECTION
Clean the transmission components with solvent
and dry them with compressed air only. Do not use
shop towels or rags.
Blow compressed air through all oil feed passages
and channels to be sure they are clear. Inspect the
transmission components for wear and damage.
Replace components that are damaged or worn
beyond the limits specified in the individual overhaul
procedures.
Replace all O–rings, gaskets and seals. These com-
ponents are not reusable. Also replace any snap ring
that is distorted or damaged.
During overhaul assembly operations, lubricate the
transmission components with Mopar Mercony auto-
matic transmission fluid or petroleum jelly as indi-
cated. Petroleum jelly should be used to prelubricate
thrust bearings, washers and races. It can also be
used to hold parts in position during assembly.
Soak replacement clutch and brake pack
components in transmission fluid for at least 30
minutes before installation.
Fig. 300 Shift Cable Attachment At
ADJUSTMENTS Transmission–Typical
1 – THROTTLE VALVE CABLE
2 – TRANSMISSION SHIFT LEVER
GEARSHIFT CABLE 3 – SHIFT CABLE
Check adjustment by starting the engine in Park 4 – SHIFT CABLE BRACKET
and Neutral. Adjustment is OK if the engine starts
only in these positions. Adjustment is incorrect if the
engine starts in one but not both positions. If the BRAKE TRANSMISSION SHIFT INTERLOCK
engine starts in any position other than Park or Neu- CABLE ADJUSTMENT
tral, or if the engine will not start at all, the park/ (1) Shift transmission into PARK.
neutral position switch may be faulty. (2) Remove shift lever bezel and console screws.
Raise bezel and console for access to cable.
Gearshift Adjustment Procedure (3) Pull cable lock button up to release cable (Fig.
(1) Shift transmission into Park. 301).
(2) Raise vehicle. (4) Turn ignition switch to LOCK position.
(3) Release cable adjuster clamp (at transmission (5) Use a spacer to create a one millimeter gap
end of cable) to unlock cable. between the shifter pawl and top of the shift gate.
(4) Unsnap cable from cable mounting bracket on (6) Pull cable forward. Then release cable and
transmission (Fig. 300). press cable lock button down until it snaps in place.
(5) Slide cable eyelet off transmission shift lever. (7) Check adjustment as follows:
(6) Verify transmission shift lever is in Park (a) Check movement of release shift handle but-
detent by moving lever fully rearward. Last rearward ton (floor shift) or release lever (column shift). You
detent is Park position. should not be able to press button inward or move
(7) Verify positive engagement of transmission column lever.
park lock by attempting to rotate propeller shaft. (b) Turn ignition switch to RUN position.
Shaft will not rotate when park lock is engaged. (c) Shifting out of park should not be possible.
(8) Slide cable eyelt onto transmission shift lever. (d) Apply the brake and attempt to shift out of
(9) Snap shift cable adjuster into mounting PARK. Shifting should be possible.
bracket on transmission. (e) While the transmission is shifted out of
PARK, release the brake and attempt to shift
XJ AW–4 AUTOMATIC TRANSMISSION 21 - 337
ADJUSTMENTS (Continued)
SPECIAL TOOLS
AW-4
C-3293-SP Gauge
TABLE OF CONTENTS
page page
OPERATING RANGES
Transfer case operating ranges are:
• 2WD (2-wheel drive)
• 4x4 (4-wheel drive)
• 4 Lo (4-wheel drive low range
The 2WD range is for use on any road surface at
any time.
The 4x4 and 4 Lo ranges are for off road use only.
They are not for use on hard surface roads. The only Fig. 1 Fill/Drain Plug And I. D. Tag Locations
exception being when the road surface is wet or slip- 1 – I. D. TAG
pery or covered by ice and snow. 2 – FILL PLUG
The low range reduction gear system is operative 3 – DRAIN PLUG
in 4 Lo range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
OPERATION
The input gear is splined to the transmission out-
SHIFT MECHANISM put shaft. The input gear drives the mainshaft
Operating ranges are selected with a floor mounted through the planetary assembly and range hub. The
shift lever. The shift lever is connected to the trans- front output shaft is operated by a drive chain that
fer case range lever by an adjustable linkage rod. A connects the shaft to a drive sprocket on the main-
straight line shift pattern is used. Range positions shaft. The drive sprocket is engaged/disengaged by
are marked on the shifter bezel cover plate. the mode fork, which operates the mode sleeve and
XJ NV231 TRANSFER CASE 21 - 347
DESCRIPTION AND OPERATION (Continued)
hub. The sleeve and hub are not equipped with a
synchronizer mechanism for shifting.
NV231 DIAGNOSIS
DIAGNOSIS CHART
TORQUE
A 3-4 N•m (27-35 in. lbs.)
B 11-14 N•m (97-123 in. lbs.)
C 8-14 N•m (72-120 in. lbs.)
ITEM TORQUE
A 2-3 N·m (15-27 in. lbs.)
B 10-12 N·m (90-110 in. lbs.)
Fig. 9 Rear Slinger Removal Fig. 11 Output Shaft Rear Bearing Retaining Ring
1 – TRANSFER CASE 1 – REAR RETAINER
2 – SPECIAL TOOL MD998056–A 2 – OUTPUT SHAFT SEAL
3 – SLINGER
Fig. 27 Sector Bushing And O-Ring Removal Fig. 29 Mode Hub Removal
1 – SEAL RETAINER 1 – MAINSHAFT
2 – SECTOR SHAFT BORE 2 – MODE HUB
3 – O-RING SEAL
MAINSHAFT DISASSEMBLY
(1) Remove mode hub retaining ring with heavy
duty snap-ring pliers (Fig. 28).
(2) Slide mode hub off mainshaft (Fig. 29).
(3) Slide drive sprocket off mainshaft (Fig. 30).
XJ NV231 TRANSFER CASE 21 - 357
DISASSEMBLY AND ASSEMBLY (Continued)
ASSEMBLY
Lubricate transfer case components with Mopart
Dexron II automatic transmission fluid or petroleum
jelly (where indicated) during assembly. Fig. 41 Front Output Shaft Bearing Retaining Ring
Removal
BEARING AND SEAL INSTALLATION 1 – SCREWDRIVERS
2 – SNAP RING
CAUTION: The bearing bores in various transfer 3 – FRONT OUTPUT SHAFT BEARING
case components contain oil feed holes. Make sure 4 – FRONT CASE
replacement bearings do not block the holes.
21 - 360 NV231 TRANSFER CASE XJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 42 Front Output Shaft Bearing Removal (6) Install new front output seal in front case with
1 – FRONT CASE Installer Tool 8143 as follows:
2 – SPECIAL TOOL C-4171 (a) Place new seal on tool. Garter spring on
3 – SPECIAL TOOL 5065 seal goes toward interior of case.
(b) Start seal in bore with light taps from ham-
(4) Install front output shaft front bearing in case mer (Fig. 45). Once seal is started, continue tap-
with Tool Handle C-4171 and Installer 5064 (Fig. 43). ping seal into bore until installer tool bottoms
against case.
Fig. 57 Input/Low Range Gear Installation Fig. 59 Install Front Bearing Retainer
1 – ANNULUS GEAR 1 – FRONT BEARING RETAINER
2 – INPUT/LOW RANGE GEAR
Fig. 61 Shift Sector Installation (8) Insert mode sleeve in mode fork mode fork. Be
1 – SHIFT SECTOR sure long side of sleeve is toward long end of shift
rail (Fig. 65).
Fig. 76 Yoke Seal Washer Installation (7) Install rear slinger with Installer 8408.
1 – YOKE SEAL WASHER (8) Install boot on output shaft slinger and crimp
retaining clamp with tool C-4975-A (Fig. 79).
XJ NV231 TRANSFER CASE 21 - 369
CLEANING AND INSPECTION (Continued)
The oil pickup screen can be cleaned with solvent.
Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the
teeth on the sprocket (Fig. 80). Minor nicks and
scratches can be smoothed with an oilstone. However,
replace any part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320–400 grit emery cloth but do
not try to salvage the shaft if nicks or wear is severe.
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig.
87).
(4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully
engaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
Fig. 85 Seal Contact Surface Of Yoke Slinger (7) Lower vehicle.
1 – FRONT SLINGER (PART OF YOKE)
2 – SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Plug, Detent . . . . . . . . . . 16–24 N·m (12–18 ft. lbs.)
Plug, Drain/Fill . . . . . . . 20–34 N·m (15–25 ft. lbs.)
Bolt, Front Brg. Retainer . . . . . 21 N·m (16 ft. lbs.)
Bolt, Front Brg. Retainer . . . . . 21 N·m (16 ft. lbs.)
Bolt, Case Half . . . . . . . . 27–34 N·m (20–25 ft. lbs.) Seal Protector—6992
Nut, Front Yoke . . . . 122–176 N·m (90–130 ft. lbs.)
Nut, Range Lever . . . . . . 27–34 N·m (20–25 ft. lbs.)
Bolt, Rear Retainer . . . . 35–46 N·m (26–34 ft. lbs.)
Nuts, Mounting . . . . . . . 35–47 N·m (26–35 ft. lbs.)
Switch, Indicator . . . . . . 20–34 N·m (15–25 ft. lbs.)
SPECIAL TOOLS
NV231
Installer—C-4076-B
Installer, Seal—8143
Puller, Slinger—MD-998056–A
Handle, Universal—C-4171
Installer—MD-998323
21 - 374 NV231 TRANSFER CASE XJ
SPECIAL TOOLS (Continued)
Installer, Bearing—5064
Remover—L-4454
Installer, Bearing—5065
Cup—8148
Installer, Bushing—5066
Installer, Seal—7884
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION drive sprocket on the mainshaft. The drive sprocket
is engaged/disengaged by the mode fork, which oper-
NV242 TRANSFER CASE ates the mode sleeve and hub. The sleeve and hub
are not equipped with a synchro mechanism for shift-
DESCRIPTION ing.
The NV242 is a full-time transfer case (Fig. 1). It The geartrain is mounted in two aluminum case
provides full time 2-wheel, or 4-wheel drive opera- halves attached with bolts. The mainshaft front and
tion. rear bearings are mounted in aluminum retainer
A differential in the transfer case is used to control housings bolted to the case halves.
torque transfer to the front and rear axles. A low
TRANSFER CASE IDENTIFICATION
range gear provides increased low speed torque capa-
bility for off road operation. The low range provides a A circular ID tag is attached to the rear case of
2.72:1 reduction ratio. each transfer case (Fig. 2). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
SHIFT MECHANISM
Operating ranges are selected with a floor mounted
shift lever. The shift lever is connected to the trans-
fer case range lever by an adjustable linkage rod. A
straight line shift pattern is used. Range positions
are marked on the shifter bezel cover plate, or on the
shift knob.
TORQUE
A 3-4 N•m (27-35 in. lbs.)
B 11-14 N•m (97-123 in. lbs.)
C 8-14 N•m (72-120 in. lbs.)
ITEM TORQUE
A 2-3 N·m (15-27 in. lbs.)
B 10-12 N·m (90-110 in. lbs.)
INSTALLATION AND INDEXING (12) Lower vehicle and top off transmission fluid
(1) Thoroughly clean adapter flange and adapter level if necessary.
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-
ation.
(2) Install new O-rings on speed sensor and speed-
ometer adapter (Fig. 6), if necessary.
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 N·m
(15-27 in. lbs.) torque.
(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 7).
These numbers will correspond to number of teeth on Fig. 7 Location Of Index Numbers On Speedometer
pinion. Adapter
(8) Install speedometer assembly in housing. 1 – SPEEDOMETER ADAPTER
(9) Rotate adapter until required range numbers 2 – INDEX NUMBER LOCATION
are at 6 o-clock position. Be sure range index num-
bers correspond to number of teeth on pinion gear.
(10) Install speedometer adapter clamp and retain- FRONT OUTPUT SHAFT SEAL
ing screw. Tighten clamp screw to 10-12 N·m (90-110
in. lbs.) torque. REMOVAL
(11) Connect wires to vehicle speed sensor. (1) Raise vehicle.
(2) Remove front propeller shaft. Refer to Group 3,
Differential and Driveline, for proper procedure.
21 - 380 NV242 TRANSFER CASE XJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove front output shaft yoke. DISASSEMBLY AND ASSEMBLY
(4) Remove seal from front case with pry tool (Fig.
8). NV242 TRANSFER CASE
DISASSEMBLY
REAR RETAINER REMOVAL
(1) Remove output shaft boot. Spread band clamp
that secures boot on slinger with a suitable awl.
Then slide boot off shaft (Fig. 10).
INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 6952-A as follows:
(a) Place new seal on tool. Garter spring on seal Fig. 10 Output Boot—Typical
goes toward interior of case. 1 – SLINGER
(b) Start seal in bore with light taps from ham- 2 – BOOT
mer (Fig. 9). Once seal is started, continue tapping 3 – AWL
4 – TRANSFER CASE
seal into bore until installer tool seats against case.
SHIFT FORKS AND MAINSHAFT REMOVAL AND Fig. 24 Drive Sprocket And Chain Removal
DISASSEMBLY
1 – DRIVE SPROCKET
(1) Remove shift detent plug, spring and pin (Fig. 2 – DRIVE CHAIN
26).
(2) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range (a) Insert easy-out tool through access hole in
fork lockpin with access hole. side of transfer case and into lock-pin.
(3) Remove range fork lockpin with size number (b) Tap easy-out tool into lock-pin with hammer
one easy-out tool as follows: until tool is securely engaged into the lock-pin.
21 - 384 NV242 TRANSFER CASE XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(6) Remove mode shift sleeve and mode fork
assembly from mainshaft (Fig. 29). Note position of
mode sleeve in fork and remove sleeve.
(13) Slide low range fork pin out of shift sector slot
(Fig. 35).
(14) Remove low range fork and hub (Fig. 36).
XJ NV242 TRANSFER CASE 21 - 387
DISASSEMBLY AND ASSEMBLY (Continued)
DIFFERENTIAL DISASSEMBLY
(1) Mark differential case halves for reference.
(2) Remove differential case bolts.
(3) Invert differential on workbench.
(4) Separate top case from bottom case. Use slots
Fig. 46 Planet Gears And Thrust Washer Removal
in case halves to pry them apart (Fig. 45).
1 – BOTTOM CASE
2 – THRUST WASHERS (12)
3 – PLANET GEARS (6)
ASSEMBLY
Lubricate transfer case components with automatic
transmission fluid or petroleum jelly (where indi-
cated) during assembly.
(6) Remove input gear bearing with Tool Handle Fig. 53 Seating Input Gear Bearing
C-4171 and Remover C-4210 (Fig. 52). 1 – SNAP RING
2 – INPUT SHAFT BEARING
(7) Install snap-ring on new input gear bearing.
(8) Install new input gear bearing with Tool Han-
dle C-4171 and Remover C-4210. Install bearing far
enough to seat snap-ring against case (Fig. 53).
Fig. 55 Install Input Gear Pilot Bearing Fig. 57 Remove Front Output Shaft Rear Bearing
1 – HANDLE C-4171 1 – REAR CASE
2 – INSTALLER 8128 2 – SPECIAL TOOL L-4454–1 AND L-4454–3
3 – INPUT GEAR 3 – SPECIAL TOOL 8148
Fig. 56 Front Bearing Retainer Seal Installation Fig. 58 Install Front Output Shaft Rear Bearing
1 – FRONT BEARING RETAINER 1 – HANDLE C-4171
2 – SPECIAL TOOL 7884 2 – OUTPUT SHAFT INNER BEARING
3 – INSTALLER 5066
(13) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 58). Lubricate bearing after (14) Install new seal in oil pump feed housing with
installation. Special Tool 7888 (Fig. 59).
XJ NV242 TRANSFER CASE 21 - 393
DISASSEMBLY AND ASSEMBLY (Continued)
DIFFERENTIAL ASSEMBLY
(1) Lubricate differential components with auto-
matic transmission fluid.
(2) Install sprocket gear in differential bottom case
(Fig. 61).
(3) Install differential planet gears and new thrust
washers (Fig. 62). Be sure thrust washers are
installed at top and bottom of each planet gear.
21 - 394 NV242 TRANSFER CASE XJ
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 73 Installing Differential Snap-Ring Fig. 75 Installing Clutch Shaft Thrust Washer
1 – DIFFERENTIAL SNAP RING 1 – CLUTCH SHAFT THRUST RING
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 93). Minor nicks on the shift rail can
be smoothed with 320–400 grit emery cloth.
Inspect the shift fork wear pads. The mode fork
pads are serviceable and can be replaced if necessary.
The range fork pads are also serviceable.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
Fig. 95 Seal Contact Surface Of Yoke Slinger Fig. 96 Low Range Annulus Gear
1 – FRONT SLINGER (PART OF YOKE)
1 – FRONT CASE
2 – SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
2 – LOW RANGE ANNULUS GEAR
XJ NV242 TRANSFER CASE 21 - 405
CLEANING AND INSPECTION (Continued)
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig.
97).
(4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully
engaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
SPECIFICATIONS
TORQUE Fig. 97 Shift Linkage
1 – TRANSFER CASE SHIFT LEVER SHAFT
DESCRIPTION TORQUE 2 – SEAL
Plug, Detent . . . . . . . . . . 16–24 N·m (12–18 ft. lbs.) 3 – TRANSFER CASE SHIFT LEVER ASSEMBLY
Bolt, Diff. Case . . . . . . . . 17–27 N·m (15–24 ft. lbs.) 4 – FLOORPAN
Plug, Drain/Fill . . . . . . . 20–25 N·m (15–25 ft. lbs.) 5 – TRUNNION LOCK BOLT
Bolt, Front Brg. Retainer . . . . . . . . . . . . 16–27 N·m 6 – SHIFT ROD
7 – ADJUSTING TRUNNION
(12–20 ft. lbs.)
8 – TORQUE SHAFT BRACKET
Bolt, Case Half . . . . . . . . 35–46 N·m (26–34 ft. lbs.) 9 – RANGE LEVER
Nut, Front Yoke . . . . 122–176 N·m (90–130 ft. lbs.) 10 – TORQUE SHAFT ROD
Screw, Oil Pump . . . . . 1.2–1.8 N·m (12–15 in. lbs.) 11 – TORQUE SHAFT
Nut, Range Lever . . . . . . 27–34 N·m (20–25 ft. lbs.) 12 – LINKAGE BRACKET
Bolt, Rear Retainer . . . . 35–46 N·m (26–34 ft. lbs.)
Nuts, Mounting . . . . . . . . . . . . . 35 N·m (26 ft. lbs.)
Bolts, U-Joint . . . . . . . . . . . . . . 19 N·m (17 ft. lbs.)
21 - 406 NV242 TRANSFER CASE XJ
SPECIAL TOOLS
NV242
Installer—MD-998323
Installer—C-4076-B
Installer, Bearing—5064
Installer—8128
Handle, Universal—C-4171
Installer—5066
Remover—C-4210
Installer—6952-A
Puller, Slinger—MD-998056–A
XJ NV242 TRANSFER CASE 21 - 407
SPECIAL TOOLS (Continued)
Cup—8148
Installer, Pump Housing Seal—7888
Seal Protector—6992
Installer, Bearing—8033-A
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRES
TABLE OF CONTENTS
page page
SPARE TIRE–TEMPORARY
DESCRIPTION
The temporary spare tire is designed for emer-
gency use only. The original tire should be repaired
or replaced at the first opportunity, then reinstalled.
Do not exceed speeds of 50 M. P. H. when using the
temporary spare tire. Refer to Owner’s Manual for
complete details.
RADIAL-PLY TIRES Over inflation will cause rapid center wear and
loss of the tire’s ability to cushion shocks (Fig. 3).
DESCRIPTION
Radial-ply tires improve handling, tread life and
ride quality, and decrease rolling resistance.
Radial-ply tires must always be used in sets of
four. Under no circumstances should they be used on
the front only. They may be mixed with temporary
spare tires when necessary. A maximum speed of 50
MPH is recommended while a temporary spare is in
use.
Radial-ply tires have the same load-carrying capac-
ity as other types of tires of the same size. They also
use the same recommended inflation pressures.
The use of oversized tires, either in the front or
rear of the vehicle, can cause vehicle drive train fail-
ure. This could also cause inaccurate wheel speed
signals when the vehicle is equipped with Anti-Lock
Brakes. Fig. 3 Over Inflation Wear
The use of tires from different manufactures on the 1 – THIN TIRE THREAD AREA
same vehicle is NOT recommended. The proper tire
pressure should be maintained on all four tires. Improper inflation can cause:
• Uneven wear patterns
XJ TIRES AND WHEELS 22 - 3
DESCRIPTION AND OPERATION (Continued)
• Reduced tread life • Handling
• Reduced fuel economy • Durability
• Unsatisfactory ride • Tread life
• Vehicle drift • Traction
For proper tire pressure specification refer to the • Rolling resistance
Tire Inflation Pressure Chart provided with the vehi- • Speed capability
cle. It is recommended that tires equivalent to the orig-
Tire pressures have been chosen to provide safe inal equipment tires be used when replacement is
operation, vehicle stability, and a smooth ride. Tire needed.
pressure should be checked cold once a month. The Failure to use equivalent replacement tires may
spare tire pressure should be check at least twice adversely affect the safety and handling of the vehi-
annually. Tire pressure decreases as the ambient cle.
temperature drops. Check tire pressure frequently The use of oversize tires may cause interference
when ambient temperature varies widely. with vehicle components. Under extremes of suspen-
Inflation pressures specified on the placards are sion and steering travel, interference with vehicle
cold inflation pressure. The vehicle must sit for at components may cause tire damage.
least 3 hours to obtain the correct cold inflation pres-
sure reading. Or driven less than one mile after sit- WARNING: FAILURE TO EQUIP THE VEHICLE WITH
ting for 3 hours. Tire inflation pressures may TIRES HAVING ADEQUATE SPEED CAPABILITY
increase from 2 to 6 pounds per square inch (psi) CAN RESULT IN SUDDEN TIRE FAILURE.
during operation, due to increased tire temperature.
REPAIRING LEAKS
Fig. 8 First Measurement On Tire For proper repairing, a radial tire must be removed
1 – REFERENCE MARK from the wheel. Repairs should only be made if the
2 – 1ST MEASUREMENT defect, or puncture, is in the tread area (Fig. 11). The
HIGH SPOT MARK TIRE AND RIM tire should be replaced if the puncture is located in
3 – WHEEL
the sidewall.
4 – VALVE STEM
22 - 6 TIRES AND WHEELS XJ
SERVICE PROCEDURES (Continued)
WHEELS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION sure, the raised sections help hold the tire on the
wheel.
WHEEL The wheel studs and nuts are designed for specific
applications. All aluminum and some steel wheels
DESCRIPTION have wheel stud nuts with an enlarged nose. This
The rim size is on the vehicle safety certification enlarged nose is necessary to ensure proper retention
label located on the drivers door shut face. The size of the wheels. Do not use replacement studs or nuts
of the rim is determined by the drivetrain package. with a different design or lesser quality.
Original equipment wheels/rims are designed for
operation up to the specified maximum vehicle capac- DIAGNOSIS AND TESTING
ity.
All models use stamped steel, cast aluminum or
WHEEL INSPECTION
forged aluminum wheels. Every wheel has raised sec-
Inspect wheels for:
tions between the rim flanges and rim drop well
• Excessive run out
called safety humps (Fig. 1).
• Dents or cracks
• Damaged wheel lug nut holes
• Air Leaks from any area or surface of the rim
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Lug Nut
1/2 X 20 with 60° Cone . . . . . . . . . . 115-150 N·m
(85-115 ft. lbs.)
XJ BODY 23 - 1
BODY
TABLE OF CONTENTS
page page
TABLE OF CONTENTS
page
DESCRIPTION AND OPERATION elements. Windshields are also used to retain some
airbags in position during deployment. Urethane
BODY COMPONENTS bonded glass is difficult to salvage during removal.
The urethane bonding is difficult to cut or clean from
PAINT any surface. Before removing the glass, check the
availability of replacement components.
DESCRIPTION
The original equipment finish is a multi-step pro- SEATS
cess that involves cleaning, electrodeposition (e-coat),
DESCRIPTION
base coat, and clear coat steps. Additionally, selected
areas of the vehicle may be coated with an anti-chip Seat modules are made up of a seat frame, seat
finish. cushion, seat back cushion, a covering material, and
the electrical components used for power operation, if
OPERATION equipped. Some seat systems also contain seat belt
On most vehicles a two-stage paint application components and supplemental restraint systems.
(base coat/clear coat) is used. Color that is applied to
OPERATION
primer is called base coat. The clear coat protects the
base coat from ultraviolet light and provides a dura- Seat assemblies transport the occupants in comfort
ble high-gloss finish. and safety. Seat assemblies also help position occu-
pants correctly in the event of airbag deployment.
STATIONARY GLASS Seat cushions, coverings, and electrical components
are serviceable. Refer to the appropriate group in
DESCRIPTION this manual.
Windshields and selected stationary glass are
structural members of the vehicle. The windshield EXTERIOR COMPONENTS
glass is bonded to the windshield frame with ure-
DESCRIPTION
thane adhesive.
Exterior sheet metal components make up the
OPERATION exterior of the vehicle. Some exterior metal systems
Windshields are made of two pieces of glass with a are welded assemblies, such as doors and hoods.
plastic inner layer. Windshields and other stationary Some exterior trim items are made of composite.
glass protect the occupants from the effects of the
23 - 2 BODY XJ
DESCRIPTION AND OPERATION (Continued)
OPERATION component systems are adjustable as a system. Trim
The exterior is finished in various metal stampings components made of composite are stamped with the
and composite moldings. These assemblies give the type of material used. DaimlerChrysler uses various
vehicle a finished appearance and protect the occu- fasteners to retain trim items. At times, it is not pos-
pants from the elements. Some components are part sible to remove trim items without damaging the fas-
of the energy absorbing system used to protect the tener. If it is not possible to remove an item without
occupants in collisions. The exterior sheet metal is damaging a component, cut or break the fasteners
repairable and adjustable for fit and finish. Welded and use new ones when installing the component.
XJ BODY 23 - 3
SAFETY PRECAUTIONS
TABLE OF CONTENTS
page
SERVICE PROCEDURES
SAFETY PRECAUTIONS AND WARNINGS . . . . . . 3
PAINT
TABLE OF CONTENTS
page page
SPECIFICATIONS
DAIMLER AKZO
EXTERIOR S-W** SPIES
CHRYSLER PPG DuPONT NOBEL ICI**
COLOR M-S** HECKER
CODE SIKKENS
Flame Red 30116 2NN6B
PR4 4679 B9326 46916 CHA93:PR4
Clear Coat
Chili Pepper 33688 HMT3B
VEA 5361 B9823 54470 CHA98:VEA
Red
Medium Fern 61088
RJP 4969 B9524 50270 CHA99:RJP 7CD6B
Pearl Coat
Forest Green 61633
SG8 5065 B9609 51062 CHA95:SG8 7MR8B
Pearl Coat
Intense Blue 55321
VB3 5357 B9822 54468 CHA98:VB3 HMR9B
Pearl Coat
Desert Sand WTD 5474 B9884 56153 CHA99:WTD 81764 KGC7B
Deep 54755 FNE4B
Amethyst TCN 5246 B9736 52026 CHA97:TCN
Pearl Coat
Black Clear 73328 TC60B
DX8 9700 99 34858 CHA85:DX8
Coat
Gunmetal 73320 ERA9B
TQ7 5248 B9735 52952 CHA97:TQ7
Pearl Coat
Stone White 15069 8KY5B
SW1 83542 B9622 51539 CHA96:SW1
Clear Coat
INTERIOR COLOR
DIAMLER AKZO
INTERIOR S-W** SPIES
CHRYSLER PPG DuPONT NOBEL ICI**
COLOR M-S** HECKER
CODE* SIKKENS
9856 / CHALAZI 75016 7WC8
Agate AZ C9208 45994
2-1461
Camel / Dark N/A NA K5/G8
KG N/A N/A N/A
Green
NOTE: *Herberts Standox and BASF use the S-W = Sherwin-Williams, M-S = Martin Senour, ICI =
Chrysler paint code as listed on the Body Code ICI Autocolor.
Plate and the Vehicle Safety Certification label. **
23 - 6 BODY XJ
STATIONARY GLASS
TABLE OF CONTENTS
page page
DESCRIPTION OPERATION
WARNING: DO NOT OPERATE THE VEHICLE The windshield is attached to the window frame
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. with urethane adhesive. The urethane adhesive is
IT TAKES AT LEAST 24 HOURS FOR URETHANE applied cold and seals the surface area between the
ADHESIVE TO CURE. IF IT IS NOT CURED, THE window opening and the glass. The primer adheres
WINDSHIELD MAY NOT PERFORM PROPERLY IN the urethane adhesive to the windshield.
AN ACCIDENT. It is difficult to salvage a windshield during the
URETHANE ADHESIVES ARE APPLIED AS A SYS- removal operation. The windshield is part of the
TEM. USE GLASS CLEANER, GLASS PREP SOL- structural support for the roof. The urethane bonding
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND used to secure the windshield to the fence is difficult
PINCH WELD (FENCE) PRIMER PROVIDED BY THE to cut or clean from any surface. If the moldings are
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL set in urethane, it would also be unlikely they could
INTEGRITY COULD BE COMPROMISED. be salvaged. Before removing the windshield, check
DAIMLERCHRYSLER DOES NOT RECOMMEND the availability of the windshield and moldings from
GLASS ADHESIVE BY BRAND. TECHNICIANS the parts supplier.
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES REMOVAL AND INSTALLATION
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF WINDSHIELD
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
The windshield is positioned in the reveal molding
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
and is bonded to the windshield frame with urethane
WITH THE PARTICULAR ADHESIVE USED.
adhesive.
BE SURE TO REFER TO THE URETHANE MANU-
Depending on the circumstances, either one of two
FACTURER’S DIRECTIONS FOR CURING TIME
windshield glass installation methods can be used:
SPECIFICATIONS, AND DO NOT USE ADHESIVE
• The short method.
AFTER ITS EXPIRATION DATE.
• The extended method.
VAPORS THAT ARE EMITTED FROM THE URE-
The short method is used when the windshield
THANE ADHESIVE OR PRIMER COULD CAUSE
glass is removed intact, and the body opening and
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
the pinchweld flanges do not require repair.
LATED AREA.
The extended method must be used when the body
SKIN CONTACT WITH URETHANE ADHESIVE
opening or a flange is damaged. The extended
SHOULD BE AVOIDED. PERSONAL INJURY MAY
method must also be used when urethane no longer
RESULT.
adheres to either the windshield glass or the pinch-
ALWAYS WEAR EYE AND HAND PROTECTION
weld flanges.
WHEN WORKING WITH GLASS.
REMOVAL
CAUTION: Protect all painted and trimmed surfaces (1) Cover the interior and exterior body surface
from coming in contact with urethane or primers. areas with a protective covering.
XJ BODY 23 - 7
REMOVAL AND INSTALLATION (Continued)
(2) Remove the windshield wiper arms and the (4) Apply the molding to the windshield:
rearview mirror. • With the molding at room temperature, press
(3) Using a razor knife, slide the blade between the molding onto the windshield corners.
the windshield glass and the inboard edge of the • From corner to corner, work the molding to the
reveal molding. center of each side. (Some stretching of the molding
(4) Cut around the interior perimeter of the reveal may be required during this procedure.)
molding and sever the cap of the reveal molding. (5) Place the glass on the pinchweld flanges and
(5) Using a cold knife, cut the urethane around the inspect for gaps in the urethane. Gaps in excess of 3
perimeter of the windshield (Fig. 1). mm (1/8 inch) must be filled with urethane.
(6) Remove the windshield glass from the frame. (6) Adjust windshield glass position until it is
aligned with the flanges and adhesive.
(7) Using a grease pencil or equivalent, make
alignment marks on the glass and body.
(8) Remove replacement windshield from wind-
shield opening.
(9) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 2).
(2) Clean inside of windshield with ammonia based CAUTION: Be prepared to install the glass immedi-
glass cleaner and lint-free cloth. ately after applying the adhesive, as the adhesive
(3) Prime outer perimeter of interior side of glass will begin to cure in less than 10 minutes.
16 mm (5/8 inch) from edge. Use a wipe-off type ure-
thane primer and wipe glass dry after primer appli- (13) Apply a continuous, 6-mm (1/4-in) diameter
cation. bead of urethane adhesive to the surface area.
(14) Align the glass with the reference marks and
NOTE: The reveal molding has an adhesive applied position the glass on the pinchweld flanges. Ensure
to the windshield contact surface to help secure the that the windshield glass is correctly seated on the
molding to the windshield during the installation support spacers.
procedure.
23 - 8 BODY XJ
REMOVAL AND INSTALLATION (Continued)
(15) Force the windshield glass inward just enough
to wet-out and set the urethane. Use care to avoid
excessive squeeze-out of adhesive.
(16) Water test the windshield with a water spray
after installation. Do not direct high pressure
streams of water directly at urethane. If any leaks
are detected, apply urethane as necessary.
(17) If used, remove the masking tape from the
inner surface of the glass.
(18) Install all components and clean the vehicle.
(19) Open the vehicle windows to prevent interior
pressure while the urethane is curing. If not
vented, pressure in the interior of the vehicle
may interfere with proper glass bonding.
(20) Install the rearview mirror.
Fig. 3 Masking Tape Location For Blackout Primer Fig. 5 Windshield Bottom Support Spacers
1 – POSITION TAPE 5/8 INCH FROM EDGE OF GLASS 1 – SUPPORT SPACERS
2 – 1-INCH WIDE MASKING TAPE 2 – WINDSHIELD
3 – SUPPORT SPACER
4 – COWL
INSTALLATION—EXTENDED METHOD 5 – MOLDING
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.
Fig. 10 Quarter Window With Vent
(1) Trim the urethane from the liftgate glass open-
1 – QUARTER WINDOW W/VENT
2 – WEATHERSTRIP SEAL
ing flanges. Leave a 3 mm (0.1 in.) level base of ure-
3 – INSTALLATION CORD thane on the flanges.
(2) Starting in the corners, press reveal molding
onto glass.
LIFTGATE GLASS (3) Place replacement glass into liftgate opening
and position glass in the center of the opening
REMOVAL against flange.
(1) Open liftgate. (4) Verify the glass lays evenly against the fence at
(2) Remove liftgate trim panel. the sides, top and bottom. If not, the flange must be
(3) Disconnect heated backlite (HBL) connector. formed to the shape of the new glass.
(4) Remove wiper arm. (5) Using a grease pencil or equivalent, make ref-
(5) Remove CHMSL lens. erences marks on the glass and body.
(6) Using a razor knife, slide the blade between (6) Remove replacement glass from liftgate open-
the liftgate glass and the inboard edge of the reveal ing.
molding. (7) Position the glass inside up on a suitable work
(7) Cut around the interior perimeter of the reveal surface.
molding and severe the cap of the reveal molding.
23 - 12 BODY XJ
REMOVAL AND INSTALLATION (Continued)
WARNING: DO NOT USE SOLVENT BASED GLASS (13) Push the glass inward until the reveal mold-
CLEANER TO CLEAN WINDSHIELD BEFORE ing is seated onto the liftgate frame. Use care to
APPLYING GLASS PREP AND PRIMER. POOR avoid excessive squeeze-out of adhesive.
ADHESION CAN RESULT. (14) Open windows to prevent pressure build-up
while the urethane is curing.
(8) Clean inside of glass with Mopar Glass Cleaner (15) Apply 150 mm (6 in.) lengths of 50 mm (2 in.)
and lint-free cloth. masking tape spaced 250 mm (10 in.) apart to hold
(9) Apply PVC (vinyl) primer 25 mm (1 in.) wide glass in place until urethane cures.
around edge of glass. Wipe with clean/dry lint-free (16) Install the wiper arm.
cloth. (17) Install CHMSL lens.
(10) If necessary, apply fence primer around edge (18) Connect heated backlite (HBL) connector.
of fence. Allow at least eighteen minutes drying time. (19) After urethane has cured, remove tape strips
(11) Apply a 10 mm (0.4 in.) bead of urethane and water test to verify repair.
around glass border. (20) Install liftgate trim panel.
(12) Position glass into liftgate opening and refer-
ence marks.
XJ BODY 23 - 13
SEATS
TABLE OF CONTENTS
page page
REMOVAL AND INSTALLATION (7) Remove extractor tool from sleeve and remove
sleeve from seat back.
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.
BUCKET SEAT
Fig. 7 Bucket Seat—Power Seat
REMOVAL 1 – NUT
(1) Remove bolts attaching seat to floor pan (Fig. 2 – DRIVER SIDE FRONT SEAT
7). 3 – SCREW
(2) Remove nut attaching seat to floor pan. 4 – STUD
(3) For power seat, disconnect wire harness con- 5 – SCREW
nector. If equipped, disconnect wire harness for
heated seat.
(3) If equipped, disengage the power seat connec-
(4) Disconnect seat belt buckle warning wire har-
tor from the power seat switch.
ness connector.
(4) Remove the nuts attaching the seat track to
(5) Separate seat from floor panel.
the bucket seat platform.
(5) When separating the seat track from the plat-
INSTALLATION
form, route the power seat switch connector through
(1) Position seat on floor pan.
the access hole in the seat cushion frame, if
(2) Connect seat belt buckle warning wire harness
equipped.
connector.
(3) For power seats, connect wire harness connec-
INSTALLATION
tor. If equipped, connect harness for heated seat.
(1) While positioning the seat track on the bucket
(4) Install front fasteners attaching seat to floor
seat platform, route the power seat switch connector
pan. Tighten to 27 N·m (20 ft. lbs.) torque.
through the access hole in the seat cushion frame, if
(5) Install rear fasteners attaching seat to floor
equipped.
pan. Tighten to 27 N·m (20 ft. lbs.) torque.
(2) Install the nuts attaching the seat track to the
(6) Install nut attaching seat to floor pan. Tighten
bucket seat platform.
to 40 N·m (30 ft. lbs.) torque.
(3) If equipped, engage the power seat connector to
the power seat switch.
BUCKET SEAT TRACK (4) Install screws attaching the side shield trim
cover to the seat.
REMOVAL (5) Install bucket seat.
NOTE: If the vehicle is equipped with manually
adjusted bucket seats, the inboard or outboard seat BUCKET SEAT PLATFORM
track may be serviced separately. Bucket seat platforms are not repairable. If the
seat platform is damaged, replace platform as a unit.
(1) Remove bucket seat from vehicle.
(2) Remove screws attaching the side shield trim
cover from the seat.
23 - 16 BODY XJ
REMOVAL AND INSTALLATION (Continued)
REAR SEATBACK
REMOVAL
(1) Disengage the seat cushion at the rear by pull-
ing upward on the release strap.
(2) Tilt the seat cushion forward.
(3) Remove the shoulder/lap belt buckles from the
elastic straps.
(4) Release the seatback latch from the striker.
(5) Remove the pivot bolts and the washers from
the wheelhouse panel anchors (Fig. 15).
(6) Tilt the seatback forward, lift it upward and
remove it from the vehicle.
INSTALLATION
(1) Position shims and latch striker bracket on
trim panel.
(2) Install screws attaching latch striker bracket
Fig. 17 Seat Cushion Cover Retaining Clip Removal
and shims to trim panel. Tighten screws to 6 N·m (50
1 – CLIP REMOVER TOOL
in. lbs.) torque.
2 – SEAT COVER CLIPS
(3) Engage seatback latch with striker.
23 - 20 BODY XJ
REMOVAL AND INSTALLATION (Continued)
(4) Pivot seat cushion to horizontal position and
lock it in-place by pressing firmly on center of the
cushion until latch engages.
INSTALLATION
(1) Install the cover on the seatback.
(2) Attach the cover J-strap to the seatback frame.
(3) Engage the cover zippers.
(4) Install the seat latch release bezel and handle. Fig. 19 Seatback Cover Removal
(5) Install the seatback in the vehicle. 1 – SEAT BACK
2 – COVER ZIPPER
SPECIAL TOOLS
SPECIAL TOOLS—SEATS
TABLE OF CONTENTS
page page
HOOD HINGE
REMOVAL
(1) Raise and support hood.
(2) Using a grease pencil or equivalent, mark posi-
tion of hood.
(3) Remove seal from hinge base (Fig. 4).
(4) Remove hinge retaining nuts from studs.
INSTALLATION
(1) Connect the latch to the latch connecting rod
and
XJ BODY 23 - 27
REMOVAL AND INSTALLATION (Continued)
HOOD RELEASE CABLE (2) Remove the nuts attaching the safety latch to
the inner hood panel (Fig. 7).
REMOVAL (3) Separate the safety latch from the hood.
(1) Drill out bellcrank to hood rivet heads and
remove rivets (Fig. 6).
(2) Disconnect bellcrank from latch rod and hood
release cable. Remove bellcrank from hood.
(3) Disconnect hood release cable from clips on
hood.
(4) Remove left cowl side trim panel.
(5) Remove cable bracket screws from cowl side
panel.
(6) Route cable through dash panel and remove it
from under instrument panel.
INSTALLATION
(1) Position the safety latch on the hood.
(2) Install the nuts attaching the safety latch to
the inner hood panel.
(3) Close hood.
Fig. 6 Hood Release Cable Bellcrank
1 – HOOD INNER PANEL
SAFETY LATCH STRIKER
2 – RIVET
3 – BELLCRANK
4 – LATCH RELEASE CABLE
REMOVAL
5 – LATCH CONNECTING ROD (1) Remove striker screws from radiator support
crossmember (Fig. 8).
(2) Remove striker from crossmember.
INSTALLATION
(1) Insert replacement cable end through hole in INSTALLATION
dash panel into engine compartment. (1) Position striker on radiator support crossmem-
(2) Route cable forward and seat grommet in dash ber and install screws.
panel. (2) Test safety latch operation.
(3) Position cable bracket on cowl side panel and
install screws. HOOD SILENCER PAD
(4) Install left cowl side trim panel.
(5) Connect cable and latch rod to bellcrank. REMOVAL
(6) Position bellcrank on hood and install rivets. (1) Open and support hood.
(7) Attach cable to clips. (2) Remove the hood latch release bellcrank.
(8) Test release cable for proper operation. (3) Remove the clips attaching the latch connect-
ing rod to the hood inner panel.
HOOD SAFETY LATCH (4) Remove the retainers attaching the hood
silencer pad to the inner hood panel (Fig. 9).
REMOVAL (5) Separate the hood silencer pad from the hood.
(1) Open and support hood.
23 - 28 BODY XJ
REMOVAL AND INSTALLATION (Continued)
COWL WEATHERSTRIP
REMOVAL
The cowl weatherstrip is attached to the cowl with
adhesive tape.
(1) Peel weatherstrip from cowl (Fig. 10).
INSTALLATION
(1) Clean contact surface with Mopar Super Kleen
or equivalent.
(2) Position weatherstrip on cowl.
(3) Press weatherstrip into place.
COWL GRILLE
REMOVAL
(1) Remove the windshield wiper arms from the
pivots.
Fig. 9 Hood Silencer Pad (2) Remove the screws that attach the grille to the
1 – HOOD cowl.
2 – SILENCER PAD
(3) Remove the windshield washer tubes from the
3 – RETAINER
nozzles.
(4) Remove the cowl grille and screen from the
INSTALLATION cowl (Fig. 11).
(1) Position the hood silencer pad on the hood
inner panel. INSTALLATION
(2) Install the retainers attaching the hood
silencer pad to the inner hood panel. CAUTION: The washer fluid tubes must be routed
(3) Install the clips attaching the latch connecting and installed so that they are not pinched.
rod to the hood inner panel.
(1) Position the cowl grille and screen on the cowl.
(4) Install the hood latch release bellcrank.
(2) Install the windshield washer tubes on the noz-
(5) Close hood.
zles.
(3) Install the cowl screen and grille screws with
new sealer. Tighten in sequence (Fig. 12).
XJ BODY 23 - 29
REMOVAL AND INSTALLATION (Continued)
Decal replacement requires that the metal repair
and paint refinish be completed first.
The work area temperature should be between
21°C (70°F) and 32°C (90°F). A decal should not be
replaced if the work area temperature is less
than 21°C (70°F).
The following equipment and material are neces-
sary for removal and installation:
• Liquid dish detergent (for the wetting solution).
• Mixture of wetting solution.
• Commercial wax and silicone removal solution.
• Isopropyl (rubbing) alcohol.
• Small squeegee (plastic or hard rubber).
• Water bucket and sponge.
• Clean wiping rags or paper towels.
• Heat gun (or infra-red heat bulb).
• Wax pencil.
Fig. 11 Cowl Grille, Screen & Washer Nozzles
• Sharp knife, single edge razor blade or X-acto
1 – PLASTIC PUSH-RIVET
2 – SCREEN
knife.
3 – SCREEN • Pair of scissors.
4 – RIVET • Needle or pin.
5 – NOZZLE
6 – GRILLE WARNING: USE DECAL REMOVAL SOLUTION IN A
7 – PLASTIC PUSH-RIVET WELL-VENTILATED AREA ONLY.
8 – GRILLE
9 – NOZZLE A decal removal solution can be used for removal
at areas where a heat gun is ineffective. Follow the
manufacturers instructions whenever this type of
NOTE: Force the cowl grille rearward while tighten-
product is used.
ing the screws.
INSTALLATION
(1) The area that will be covered by the decal must
be cleaned with cleaning solution.
(2) Freshly painted surfaces must be thoroughly
dry.
(3) Clean the painted surface with a commercial
wax and silicone removal solution. Wipe the surface
with a clean cloth and allow it to dry.
(4) Prepare a wetting solution by mixing two or
three teaspoons of dish detergent with 1 gallon of
water. Do not use soap.
Fig. 12 Cowl Grille Screw Tightening Sequence NOTE: Too much detergent will reduce the effec-
BODY DECALS tiveness of the mixture.
Small nicks, scratches and other surface marks in
a decal can be touched-up with paint. (5) Use a clean sponge and apply the wetting solu-
To eliminate blisters and air bubbles in a decal, tion to the adhesive side of the decal and to the
pierce them with a needle or pin. painted panel surface. The wetting solution will per-
A heat gun can also be used to remove small wrin- mit ease of decal movement when positioning it.
kles in a decal.
23 - 30 BODY XJ
REMOVAL AND INSTALLATION (Continued)
(6) Align a straight edge with the existing decal
ends (Fig. 13).
INSTALLATION
(1) Remove protective cover from adhesive tape on
back of emblem.
(2) Position emblem properly on body (Fig. 15).
(3) Press emblem firmly to body with palm of
hand.
(4) If temperature is below 21°C (70°F) warm
emblem with a heat lamp or gun to assure adhesion.
Do not exceed 52°C (120°F) when heating emblem.
INSTALLATION
(1) Position the fender flare and retainer on the
fender.
Fig. 16 Side View Mirror (2) Install the nuts attaching the fender flare and
1 – SIDE VIEW MIRROR retainer to the wheelhouse fender.
2 – WIRE HARNESS (3) Install the screw attaching the lower part of
3 – SEAL flare to the bottom of the fender.
4 – GROMMET
5 – DOOR
23 - 32 BODY XJ
REMOVAL AND INSTALLATION (Continued)
FRONT WHEELHOUSE LINER (13) Remove the fender top, front and the rear
screws.
REMOVAL (14) Remove the screws attaching the fender to the
(1) Hoist vehicle. inner support bracket (Fig. 20).
(2) Remove tire. (15) Separate the fender from the inner fender
(3) Remove the push-in fasteners attaching the panel.
wheelhouse liner to the inner fender.
(4) Separate the wheelhouse liner from the fender INSTALLATION
(Fig. 18). (1) Position the fender on the inner fender panel.
(2) Install all fender screws finger-tight.
(3) Align the fender with the body panels and
tighten the screws attaching the fender to the body
panels.
(4) Install the air deflector.
(5) Install the fender flare and retainers.
(6) Install the wheelhouse liner.
(7) Install the front bumper end cap.
(8) Install the wheel, remove the support and
lower the vehicle.
(9) Install the grille opening panel (GOP).
(10) Install the radio antenna.
INSTALLATION
(1) Replace any broken or damaged push-in fasten-
ers.
Fig. 20 Inner Support Bracket (2) Connect the power door locks/windows/mirrors
1 – U-NUT wire harness connectors, if equipped.
2 – FRONT FENDER (3) Move the door trim panel outward and connect
3 – SUPPORT BRACKET the handle-to-latch rods.
(4) Position the trim panel on the inner belt seal
and push down to seat.
FRONT DOOR TRIM PANEL (5) Align the locating pins and push- (Fig. 25) in
fasteners. Press inward to secure.
REMOVAL (6) Install the screws attaching the trim panel to
(1) Roll window down. the door inner panel.
(2) Remove window crank, if equipped (Fig. 21). (7) Install the window crank, if equipped.
23 - 34 BODY XJ
REMOVAL AND INSTALLATION (Continued)
INSTALLATION REMOVAL
(1) Position hinge plates and shims on door face. (1) Remove the door trim panel and waterdam.
23 - 36 BODY XJ
REMOVAL AND INSTALLATION (Continued)
(2) Install the forward nut attaching the handle to
the door.
(3) Connect the latch to handle rod, to the handle
latch release lever arm.
(4) Install the rearward nut attaching the door
handle to the door.
(5) Install the access hole cover.
(6) Install the door waterdam and trim panel.
INSTALLATION
(1) Position the lock cylinder and in the door open-
Fig. 28 Front Door Outside Handle ing.
1 – OUTSIDE DOOR HANDLE
(2) Install the retainer clip.
2 – OUTSIDE HANDLE TO LATCH ROD
3 – DOOR LATCH
(3) Connect the door latch-to-lock cylinder rod to
4 – OUTSIDE HANDLE TO LATCH ROD the door latch.
(4) Press the waterdam into position.
(5) Install the door trim panel.
INSTALLATION
(1) Position the handle in the door.
XJ BODY 23 - 37
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Position and align striker on B-pillar.
(2) Install screws attaching striker to B-pillar.
Tighten screws to 28 N·m (20 ft. lbs.) torque.
INSTALLATION INSTALLATION
(1) Position latch on door face. (1) Position the inside handle in the trim panel.
(2) Connect power lock motor wire connector, if (2) Heat stake the inside handle to the trim panel.
equipped. (3) Install the door trim panel.
(3) Connect all rods to latch.
(4) Install screws attaching latch to door. Tighten FRONT DOOR INNER BELT WEATHERSTRIP
screws to 11 N·m (8 ft. lbs.) torque.
(5) Install waterdam and door trim panel. REMOVAL
(1) Roll window down.
FRONT DOOR LATCH STRIKER (2) Remove door trim panel.
(3) Pull up on the rear corner of the weatherstrip
REMOVAL and lift from the door (Fig. 32).
(1) Using a grease pencil or equivalent, mark posi-
tion of striker.
23 - 38 BODY XJ
REMOVAL AND INSTALLATION (Continued)
• Continue working/pressing the weatherstrip into
the channel along the upper window frame.
• Press weatherstrip into lower rear corner.
• Work/press the weatherstrip upward and to the
upper rear corner, seat the weatherstrip into the
channel.
• Press the weatherstrip to seat into the front
lower glass run channel.
(2) As applicable, move upward and forward
evenly until the weatherstrip seal is fully seated in
the channel.
(3) Install waterdam.
(4) Install door trim panel.
INSTALLATION
(1) Position the weatherstrip on the door.
(2) Push weatherstrip down to seat onto door.
Fig. 36 Power Window Regulator (1) Position the regulator in the door and align
1 – FRONT DOOR
with key hole slots.
2 – LOOSEN BOLTS (2) Attach the regulator to door inner panel with
3 – LOOSEN NUTS bolts (Fig. 38).
(3) Install the window glass
(4) Install the waterdam.
(5) Install the trim panel.
INSTALLATION
(1) As applicable, position the spacer block on the
door window frame or door face.
Fig. 41 Front Door Glass
(2) Upper spacer block: Install the replacement
1 – NUT
rivets in the spacer block and reinforcement plate. 2 – RETAINER
(3) Lower spacer block: install the screws in the 3 – WINDOW GLASS
door face. Tighten the screws to 1 N·m (11 in-lbs) 4 – REGULATOR
torque.
INSTALLATION
(1) Position door in body opening.
(2) Align door hinges, plates and shims and install
bolts. Tighten bolts to 3 N·m (2 ft. lbs.) torque.
(3) Install door restraint (check).
(4) If applicable, route and connect wire harness
connectors.
(5) If necessary, install door waterdam and trim
panel.
INSTALLATION
(1) Position hinge plates and shims on door face.
(2) Align door hinges and shims with bolt holes
and install hinges. Tighten bolts to 3 N·m (2 ft. lbs.).
(3) Adjust/align latch striker and latch as neces-
sary.
(4) Install door restrain (check) retaining pin.
INSTALLATION
Fig. 60 Body Side Molding—4-Door (1) Position the replacement applique the on panel
(3) Remove the backing from the tape, align the and install the nuts.
molding and position it on the body panel. (2) Install the liftgate pillar trim.
(4) Press the molding onto the body panel with a
roller or hand pressure.
INSTALLATION REMOVAL
(1) Position the fender flare and retainer on the (1) Pry the clips from the roof flange.
fender. (2) Remove the clips and molding from the roof
flange (Fig. 62).
23 - 50 BODY XJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove the remaining sealant and clean the (3) Verify that each skid strip is properly aligned.
roof flange. (4) Press each skid strip onto roof panel with a
roller (or use hand pressure).
INSTALLATION
(1) Position the drip rail molding with clips at the NOTE: To prevent water leaks, apply 3M Drip-Chek
roof flange and force the clips onto the roof flange. Sealant, or equivalent.
(2) Apply sealant to the inner side of the molding
to seal the roof flange. (5) Position luggage rack on roof with screw holes
aligned.
LUGGAGE RACK (6) Install and tighten slide rail screws.
INSTALLATION
Steel clips are used for manufacturing purposes
and are not required for service.
(1) Position trim on roof panel.
(2) Install the screws attaching the liftgate open-
ing upper trim to the roof panel.
REMOVAL
(1) Slide the front seats all the way forward for
access to the belt anchor bolt.
(2) Disconnect the belt wire harness connector.
(3) Remove the anchor bolt cover.
(4) Remove the anchor bolt attaching the buckle to
the seat.
(5) Remove the turning loop cover concealing the
shoulder belt upper anchor bolt.
(6) Use a Torx bit to remove the upper anchor bolt
(Fig. 73). Remove the support/guide washer.
(7) Remove the inner scuff plate/trim panel from
the door sill and remove the shoulder belt lower
anchor bolt(s) with a Torx bit (Fig. 74) and (Fig. 75).
(8) Remove the shoulder belt and the retractor.
INSTALLATION
(1) Position the shoulder belt retractor in the
shield and install the lower anchor bolt with a Torx
bit. Tighten bolt to 43 N·m (32 ft. lbs.) torque. Fig. 74 Front Shoulder Belt—2-Door Vehicles
(2) Position the support/guide washer and shoulder 1 – ADJUSTER
2 – TRIM PANEL
belt upper anchor plate on the trim panel. Install the
3 – TURNING LOOP
upper anchor bolt with a Torx bit.
4 – RETRACTOR
(3) Route belt through trim panel. 5 – TRIM PANEL
(4) Tighten the upper and lower anchor bolts to 43
N·m (32 ft. lbs.) torque.
(5) Install the door sill inner scuff plate/trim panel
and install the cap over the upper anchor bolt.
(6) Install the shoulder belt buckle and anchor
bolt. Connect the wire harness connectors. Tighten
the buckle anchor bolt to 43 N·m (32 ft. lbs.) torque.
XJ BODY 23 - 57
REMOVAL AND INSTALLATION (Continued)
Fig. 75 Front Shoulder Belt—4-Door Vehicles Fig. 76 Rear Seat Shoulder/Lap Belts and Buckles
1 – TRIM PANEL 1 – TURNING LOOP
2 – TURNING LOOP 2 – RETRACTOR
3 – RETRACTOR 3 – LAP BELT AND BUCKLE
4 – TRIM PANEL
5 – ADJUSTER
(3) Install retractor support on rear quarter rail.
Tighten screw.
REAR SHOULDER/LAP BELT/BUCKLE (4) Route shoulder belt through quarter trim panel
slot.
WARNING: Inspect rear shoulder/lap belts and (5) Position shoulder belt at roof rail and install
buckles. Replace any belt that is either cut, frayed, upper anchor bolt. Tighten bolt to 43 N·m (32 ft. lbs.)
torn or damaged in any way. Replace shoulder belt torque.
if retractor is damaged or inoperative. (6) Install quarter trim panel.
(7) Install shoulder belt lower anchor bolt. Tighten
bolt to 43 N·m (32 ft. lbs.) torque.
REMOVAL (8) Return rear seat cushion to normal position
(1) Pull rear seat release strap and tilt seat cush- and engage latch.
ion forward.
(2) Remove shoulder belt buckle and lap belt/
FULL FLOOR CONSOLE
buckle anchor plate bolts from floor pan (Fig. 76).
(3) Remove shoulder belt lower outer anchor bolt.
REMOVAL
(4) Remove quarter trim panel. If necessary, refer
(1) Remove the transmission shift lever handle/
to removal procedure.
knob:
(5) Remove shoulder belt upper anchor bolt.
• Automatic transmissions, pull the handle
(6) Remove bolt attaching retractor to rear quarter
straight upward to remove it.
rail.
• Insert a thin-blade tool under the edge of the
(7) Separate retractor and shoulder belt from trim
transmission shift indicator bezel and pry up to
panel.
remove.
• Manual transmissions, loosen the locknut and
INSTALLATION
un-thread the shift knob from the shaft.
(1) Position shoulder belt buckle and lap belt/
• Pull the shift boot up to remove.
buckle anchor plates on floor panel.
(2) Insert a thin-blade tool under the edge of the
(2) Install anchor bolts. Tighten bolts to 43 N·m
transfer case shift indicator bezel or cover plate and
(32 ft. lbs.) torque.
pry up to remove.
23 - 58 BODY XJ
REMOVAL AND INSTALLATION (Continued)
(3) Open the console lid.
(4) Remove the screws attaching the console to the
floor and mounting bracket (Fig. 77).
(5) Disconnect the wire harness connector.
(6) Separate the console from the floor.
INSTALLATION REMOVAL
(1) Remove the liftgate latch striker and scuff
(1) Position the console on the floor.
plate.
(2) Attach the air duct to the air outlet duct.
(2) Drill-out the retaining rivet heads and remove
(3) Connect the wire harness connectors.
the cargo tie-down footman loops from the carpet.
(4) Install the screws attaching the console to the
(3) As necessary, remove the trim panels and
mounting bracket.
moldings.
(5) Install the shift indicator bezels (or cover
(4) Remove the all other interfering components.
plate).
(5) Remove the carpet and mat from the floor
(6) Install the shift lever handle/knob.
panel.
(6) If necessary, remove the insulation from the
FRONT CARPET/MAT wheelhouse (Fig. 79).
REMOVAL INSTALLATION
(1) Remove the door sill inner scuff plates.
(1) If removed, install the insulation on the wheel-
(2) Remove the front and rear seats (as applica-
houses.
ble).
(2) Position the mat on the floor panel.
(3) Remove floor console.
(3) Position the carpet on the mat.
(4) As necessary, remove the trim panels and
(4) Install all the components that were removed
moldings.
to facilitate carpet and mat removal.
(5) Remove all other interfering components.
(5) Install the trim panels and moldings.
(6) Remove the carpet and mat from the floor
(6) Install the cargo tie-down footman loops on the
panel (Fig. 78).
carpet with replacement rivets.
(7) Install the liftgate scuff plate and latch striker.
INSTALLATION
(1) Position the carpet and mat on the floor panel.
XJ BODY 23 - 59
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Position the mirror base at the bracket and
slide it downward onto the support bracket.
(2) Tighten setscrew to1 N·m (9 in. lbs.) torque.
SUNVISORS
REMOVAL
(1) Remove the screws that attach the sunvisor
arm support bracket to the headliner and the roof
panel (Fig. 81) and (Fig. 82).
(2) Disconnect vanity lamp connector, if equipped.
(3) Detach the sunvisor from the support clip.
(4) Remove the sunvisor from the vehicle.
(5) Remove the retaining screw and support clip.
On vehicles equipped with an overhead console, the
support clip is integral with the overhead console.
Fig. 81 Sunvisor
1 – HEADLINER
2 – VEHICLE ROOF
3 – HEADLINER
4 – SUPPORT CLIP
5 – SCREW
6 – SUN VISOR
7 – SCREW
8 – SUN VISOR ARM SUPPORT BRACKET Fig. 83 Headliner Trim Moldings
1 – ROOF RAIL
2 – HEADLINER MOULDING
INSTALLATION 3 – SCREW
(1) Install the support bracket and the retaining 4 – SPACER
screw. 5 – LIFTGATE PILLAR TRIM COVER
(2) Connect vanity lamp connector, if equipped. 6 – ASSIST HANDLE
(3) Position the sunvisor in the support clip and 7 – SCREW
align the arm support bracket holes with the head- 8 – ASSIST HANDLE
9 – WINDSHIELD SIDE MOULDING
liner holes.
10 – COVER PLUG
(4) Install the screws that attach the sunvisor arm 11 – SCREW
support bracket to the headliner and the roof panel.
REMOVAL
CAUTION: The headliner is a one-piece, molded
component (Fig. 84). It has limited flexibility and
must not be bent during removal/installation.
Fig. 84 Headliner
1 – TAB
2 – SPEAKER
3 – GRILLE
4 – CARGO LAMP
5 – HEADLINER
INSTALLATION
(1) Engage tabs attaching headliner/speaker struc-
ture to roof rail, if equipped. (Fig. 84)
(2) On vehicles without headliner speakers, ensure Fig. 86 Headliner Retainer Clip and Retainer Rail
that the retainer clips on upper liftgate opening trim 1 – CLIP
2 – RETAINER REAR
and rails are installed. (Fig. 86)
(3) Engage rear speaker harness connector.
(4) Install the upper trim moldings around the LIFTGATE TRIM PANEL
perimeter of the headliner. Tighten the retaining
screws to 1 N·m (11 in. lbs.) torque. REMOVAL
(5) As applicable, install: (1) Using a small flat blade, pry out the trim plugs
• Assist handles. from the liftgate assist handle.
• Sunvisors. (2) Remove the screws attaching the assist handle
• Dome/cargo lamps. to the liftgate (Fig. 87).
• Overhead console.
23 - 62 BODY XJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove the screws that attach the liftgate trim (1) Remove center high mounted stop lamp
panel to the liftgate. (CHMSL).
(4) Using a trim panel removal tool, detach the (2) Open and support liftgate.
push-in fasteners from the liftgate. (3) Remove liftgate trim panel.
(5) Remove the trim panel from the liftgate. (4) Disconnect and plug backlite washer fluid sup-
ply line.
(5) Remove screws that attach rear wiper and lift-
gate power lock wire harness connectors to liftgate
and disconnect connectors.
(6) Using access hole created by removal of
CHMSL, route backlite washer fluid supply line and
rear wiper and liftgate power lock wire harness/
grommets through access hole and separate from lift-
gate.
(7) Remove retainer clips that secure support rods
to ball studs.
(8) Remove support rods from ball studs.
(9) Remove bolts attaching hinges to liftgate.
(10) Remove liftgate from vehicle.
INSTALLATION
(1) Position and support liftgate at opening in body
Fig. 87 Liftgate Trim Panel and install bolts attaching hinges to liftgate. Tighten
1 – TRIM PANEL bolts to 26 N·m (19 ft. lbs.) torque.
2 – PUSH NUT (2) Connect liftgate support rods to ball studs and
3 – LIFTGATE install retainer clips.
4 – ASSIST HANDLE (3) Route backlite washer fluid supply line and
5 – PLUG
rear wiper and liftgate power lock wire harnesses/
grommets through access hole.
INSTALLATION (4) Connect connectors and install screws that
(1) Position the trim panel on liftgate. attach rear wiper and liftgate power lock wire har-
(2) Using new push-in fasteners, align the push-in ness connectors to liftgate
fasteners with the holes in the liftgate inner panel (5) Unplug and connect backlite washer fluid sup-
and press the trim panel into place. ply line.
(3) Install the screws to attach the liftgate trim (6) Install liftgate trim panel.
panel to the liftgate. (7) Remove supports and close liftgate.
(4) Install the screws attaching the assist handle (8) Install (CHMSL).
to the liftgate.
(5) Press the trim plugs into the liftgate assist LIFTGATE HINGE
handle.
REMOVAL
LIFTGATE It is not necessary to remove the liftgate to replace
one or both hinges.
REMOVAL (1) Open and support the liftgate.
(2) Remove the liftgate opening upper trim.
WARNING: DO NOT DISCONNECT SUPPORT ROD (3) Remove the bolts attaching the hinge to the
CYLINDERS WITH LIFTGATE CLOSED. SUPPORT header panel (Fig. 88).
ROD PISTONS ARE OPERATED BY HIGH PRES- (4) Remove the bolts attaching the hinge to the
SURE GAS. THIS COULD CAUSE DAMAGE AND/OR liftgate.
PERSONAL INJURY IF THEY ARE REMOVED WHILE
PISTONS ARE COMPRESSED.
XJ BODY 23 - 63
REMOVAL AND INSTALLATION (Continued)
LIFTGATE LATCH
REMOVAL
(1) Raise liftgate.
(2) Remove liftgate trim panel.
(3) Remove screws attaching latch to liftgate (Fig.
92).
(4) Disconnect rod from latch.
(5) Disconnect power lock connector from handle, if
equipped.
(6) Remove latch from liftgate.
INSTALLATION
(1) Position latch in liftgate.
(2) Connect power lock connector to handle, if
equipped.
Fig. 91 Liftgate Lock Cylinder (3) Connect latch rod.
1 – CLIP (4) Install screws attaching latch to liftgate.
2 – OUTSIDE HANDLE Tighten screws to 13 N·m (9 ft. lbs.) torque.
3 – LOCK CYLINDER (5) Install liftgate trim panel.
INSTALLATION HOOD
(1) Position weatherstrip seal in the opening with The hood bolt holes are elongated for fore and aft
the left end of the seal at the opening centerline. and side-to-side adjustment.
Install the seal in a clockwise direction. (1) If hood is low to the cowl panel, insert shims
(2) Move to the left and mate the seal with the between the hinge and hood at the rear hinge bolts.
bottom-left flange (Fig. 94). (2) Adjust the hood bumper (Fig. 95) in or out to
(3) Move upward and mate the seal with the left- provide proper hood-to-fender height alignment.
side flange. (3) Adjust the hood strikers (Fig. 96) with shims
(4) Move to the right and mate the seal with the as necessary. Tighten the screws to 22 N·m (16 ft-lbs)
top-left roof flange. torque after adjustment.
(5) Seat the installed part of the seal with a roller. (4) Align each latch and striker so that the striker
Move the roller from the left-bottom end of seal to enters latch squarely.
the top-left half of the seal.
(6) Move to the right and mate the seal with the DOOR
top-right roof flange.
(7) Move downward and mate the seal with the IN AND OUT—MINOR ADJUSTMENT
right-side flange. (1) Loosen the latch striker.
(8) Move to the left and mate the seal with the (2) Tap the latch striker inward if the door charac-
bottom-right flange. ter line is outboard of the body character line or tap
(9) Center and butt seal the ends together at the the latch striker outward if the door character line is
centerline. inboard of the body character line.
(10) Seat the remaining part of the seal with a (3) Inspect alignment. If correct, tighten striker
roller. Move the roller the from top-left half of the with 28 N·m (20 ft. lbs.) torque.
seal to the right-bottom end of the seal.
23 - 66 BODY XJ
ADJUSTMENTS (Continued)
ALIGNMENT MAJOR—ADJUSTMENT
Adjustment for alignment of the door is made by
installing shims between hinge and door face (Fig.
97).
LIFTGATE
The position of liftgate can be adjusted upward or
downward by use of slots in the hinge. An inward or
outward adjustment is achieved by use of slots in the
body. If an inward or outward adjustment is needed,
use 3My Fast and Firm or equivalent on the hinge
to body mating surface as a sealant.
REAR SEATBACK
(1) Unlatch and position seatback in cargo posi-
tion.
(2) Loosen the screws attaching the strikers to the
rear wheelhouse.
(3) Position the seat back in the full upright posi-
tion and secure the latch into the strikers.
(4) From the cargo area of the vehicle, push the
Fig. 98 Door Latch Adjustment rear of the seatback forward.
1 – ACCESS HOLE (5) Unlatch and position seatback in cargo posi-
2 – DOOR tion.
3 – LATCH MOUNTING BOLTS (6) Tighten the screws attaching the strikers to
4 – LATCH
the rear wheelhouse.
(7) Position the seat back in the full upright posi-
tion and secure the latch into the strikers.
(8) Verify latch operation.
SPECIFICATIONS
BODY LUBRICANTS
WELD LOCATIONS
UPPER COWL
XJ BODY 23 - 69
SPECIFICATIONS (Continued)
UPPER COWL
23 - 70 BODY XJ
SPECIFICATIONS (Continued)
COWL
XJ BODY 23 - 71
SPECIFICATIONS (Continued)
A—PILLAR
23 - 72 BODY XJ
SPECIFICATIONS (Continued)
A—PILLAR
XJ BODY 23 - 73
SPECIFICATIONS (Continued)
A—PILLAR
23 - 74 BODY XJ
SPECIFICATIONS (Continued)
A—PILLAR
XJ BODY 23 - 75
SPECIFICATIONS (Continued)
B—PILLAR
23 - 76 BODY XJ
SPECIFICATIONS (Continued)
D—PILLAR
XJ BODY 23 - 77
SPECIFICATIONS (Continued)
FUEL FILLER OPENING
23 - 78 BODY XJ
SPECIFICATIONS (Continued)
CARGO AREA FLOOR PAN
XJ BODY 23 - 79
SPECIFICATIONS (Continued)
ROOF AND D—PILLAR
23 - 80 BODY XJ
SPECIFICATIONS (Continued)
LIFTGATE OPENING
XJ BODY 23 - 81
SPECIFICATIONS (Continued)
ROOF
23 - 82 BODY XJ
SPECIFICATIONS (Continued)
ROOF
XJ BODY 23 - 83
SPECIFICATIONS (Continued)
FRAME RAIL
23 - 84 BODY XJ
SPECIFICATIONS (Continued)
FRAME RAIL
XJ BODY 23 - 85
SPECIFICATIONS (Continued)
FRAME RAIL
23 - 86 BODY XJ
SPECIFICATIONS (Continued)
FRAME RAIL
XJ BODY 23 - 87
SPECIFICATIONS (Continued)
REINFORCEMENT
23 - 88 BODY XJ
SPECIFICATIONS (Continued)
FRONT INNER FENDER
XJ BODY 23 - 89
SPECIFICATIONS (Continued)
FRONT INNER FENDER AND RADIATOR CLOSURE
PANEL
23 - 90 BODY XJ
SPECIFICATIONS (Continued)
REINFORCEMENT
XJ BODY 23 - 91
SPECIFICATIONS (Continued)
FRONT FENDER
23 - 92 BODY XJ
SPECIFICATIONS (Continued)
BODY SIDE
XJ BODY 23 - 93
SPECIFICATIONS (Continued)
REAR WHEELHOUSE
23 - 94 BODY XJ
SPECIFICATIONS (Continued)
REAR INNER WHEELHOUSE
XJ BODY 23 - 95
SPECIFICATIONS (Continued)
BODY SIDE
23 - 96 BODY XJ
SPECIFICATIONS (Continued)
BODY SIDE
XJ BODY 23 - 97
SPECIFICATIONS (Continued)
BODY SIDE
23 - 98 BODY XJ
SPECIFICATIONS (Continued)
BODY SIDE
XJ BODY 23 - 99
SPECIFICATIONS (Continued)
BODY SIDE
23 - 100 BODY XJ
SPECIFICATIONS (Continued)
BODY SIDE
XJ BODY 23 - 101
SPECIFICATIONS (Continued)
UNDERBODY
23 - 102 BODY XJ
SPECIFICATIONS (Continued)
UNDERBODY
XJ BODY 23 - 103
SPECIFICATIONS (Continued)
UNDERBODY
23 - 104 BODY XJ
SPECIFICATIONS (Continued)
UNDERBODY
XJ BODY 23 - 105
SPECIFICATIONS (Continued)
UNDERBODY
23 - 106 BODY XJ
SPECIFICATIONS (Continued)
UNDERBODY
XJ BODY 23 - 107
SPECIFICATIONS (Continued)
UNDERBODY
23 - 108 BODY XJ
SPECIFICATIONS (Continued)
UNDERBODY
XJ BODY 23 - 109
SPECIFICATIONS (Continued)
UNDERBODY
23 - 110 BODY XJ
SPECIFICATIONS (Continued)
UNDERBODY
XJ BODY 23 - 111
SPECIFICATIONS (Continued)
UNDERBODY
23 - 112 BODY XJ
SPECIFICATIONS (Continued)
• A. Center of front door lower rear radius to cen- • C. Center of radius at bottom front to center of
ter of A-pillar radius radius at top rear
• B. Center of radius at bottom rear to center of
radius at lower A-pillar
23 - 130 BODY XJ
SPECIFICATIONS (Continued)
FRONT DOOR OPENING 4–DOOR
• C. Center of front door lower rear radius to cen- • F. Center of radius at bottom front to center of
ter of A-pillar radius radius at top rear
• E. Center of radius at bottom rear to center of
radius at lower A-pillar
XJ BODY 23 - 131
SPECIFICATIONS (Continued)
REAR DOOR OPENING
• A. Quarter panel to front outer body side upper • C. Center of front lower door radius to center of
and lower seam rear upper door radius
• B. Center of front upper door radius to center of • D. Flange to rear door striker mount
rear lower door radius
23 - 132 BODY XJ
SPECIFICATIONS (Continued)
QUARTER WINDOW OPENING 2–DOOR
• A. Center of upper and lower rear quarter win- • C. Center of radius front upper corner to center
dow opening of radius rear lower corner
• B. Center of radius front lower corner to center
of radius rear upper corner
XJ BODY 23 - 133
SPECIFICATIONS (Continued)
QUARTER WINDOW OPENING 4–DOOR
• A. Center of upper and lower rear quarter win- • C. Center of radius front upper corner to center
dow opening of radius rear lower corner
• B. Center of radius front lower corner to center
of radius rear upper corner
23 - 134 BODY XJ
SPECIFICATIONS (Continued)
ENGINE COMPARTMENT
page page
OPERATION
The blower motor relay is installed in a wire har-
Fig. 1 Accumulator - Typical ness connector that is secured to the passenger side
1 – LOW PRESSURE CYCLING CLUTCH SWITCH outboard end of the heater-A/C housing in the pas-
2 – PRESSURE SWITCH FITTING senger compartment, next to the heater-A/C wire
3 – OUTLET TO COMPRESSOR
harness connector.
4 – ANTI-SIPHON HOLE
The blower motor relay cannot be repaired and, if
5 – DESICCANT BAG
6 – OIL RETURN ORIFICE FILTER
faulty or damaged, it must be replaced.
7 – VAPOR RETURN TUBE
8 – ACCUMULATOR DOME
9 – O-RING SEAL
10 – INLET FROM EVAPORATOR
XJ HEATING AND AIR CONDITIONING 24 - 3
DESCRIPTION AND OPERATION (Continued)
OPERATION
The blower motor switch directs the blower motor
ground path through the mode control switch to the
blower motor resistor, or directly to ground, as
required to achieve the selected blower motor speed.
The blower motor switch cannot be repaired and, if
faulty or damaged, the entire heater-only or heater-
A/C control unit must be replaced.
COMPRESSOR
Fig. 2 Compressor Clutch - Typical
DESCRIPTION 1 – CLUTCH PLATE
The air conditioning system uses a Sanden 2 – SHAFT KEY
3 – PULLEY
SD7H15 seven cylinder, reciprocating wobble plate-
4 – COIL
type compressor on all models. This compressor has a
5 – CLUTCH SHIMS
fixed displacement of 150 cubic centimeters (9.375 6 – SNAP RING
cubic inches), and has both the suction and discharge 7 – SNAP RING
ports located on the cylinder head. A label identifying
the use of R-134a refrigerant is located on the com-
pressor. OPERATION
When the clutch coil is energized, it magnetically
OPERATION draws the clutch into contact with the pulley and
The compressor is driven by the engine through an drives the compressor shaft. When the coil is not
electric clutch, drive pulley and belt arrangement. energized, the pulley freewheels on the clutch hub
24 - 4 HEATING AND AIR CONDITIONING XJ
DESCRIPTION AND OPERATION (Continued)
bearing, which is part of the pulley. The compressor there are no objects placed in front of the radiator
clutch and coil are the only serviced parts on the grille openings in the front of the vehicle or foreign
compressor. material on the condenser fins that might obstruct
The compressor clutch engagement is controlled by proper air flow. Also, any factory-installed air seals or
several components: the heater-A/C mode control shrouds must be properly reinstalled following radia-
switch, the low pressure cycling clutch switch, the tor or condenser service.
high pressure cut-off switch, the compressor clutch The condenser cannot be repaired and, if faulty or
relay, and the Powertrain Control Module (PCM). damaged, it must be replaced.
The PCM may delay compressor clutch engagement
for up to thirty seconds. Refer to Group 14 - Fuel DUAL FUNCTION HIGH PRESSURE SWITCH
System for more information on the PCM controls. (4.0 L)
COMPRESSOR CLUTCH RELAY DESCRIPTION
The Dual Function High Pressure Switch controls
DESCRIPTION
both A/C clutch engagement/disengagement, and elec-
The compressor clutch relay is a International tric cooling fan operations. The switch is located on
Standards Organization (ISO) micro-relay. The termi- the discharge line near the compressor. The switch is
nal designations and functions are the same as a con- screwed onto a fitting that contains a Schrader-type
ventional ISO relay. However, the micro-relay valve, which allows the switch to be serviced without
terminal orientation (footprint) is different, the cur- discharging the refrigerant system. The discharge
rent capacity is lower, and the relay case dimensions line fitting is equipped with an O-ring to seal the
are smaller than those of the conventional ISO relay. switch connection.
The compressor clutch relay is located in the Power
Distribution Center (PDC) in the engine compart- OPERATION
ment. Refer to the PDC label for relay identification The dual function switch is connected in series
and location. electrically with the low pressure cycling clutch
switch between ground and the Powertrain Control
OPERATION
Module (PCM). The switch contacts open and close
The compressor clutch relay is a electromechanical causing the PCM to turn the compressor clutch on
device that switches battery current to the compres- and off. This prevents compressor operation when the
sor clutch coil when the Powertrain Control Module discharge line pressure approaches high levels, and
(PCM) grounds the coil side of the relay. The PCM also reduces electrical surging from compressor
responds to inputs from the heater-A/C mode control clutch engagement.
switch, the low pressure cycling clutch switch, and The dual function switch controls the electric cool-
the high pressure cut-off switch. See Compressor ing fan operation by monitoring refrigerant line pres-
Clutch Relay in the Diagnosis and Testing section of sures. When the discharge line pressure rises above
this group for more information. 1900 to 2200 kPa (280 to 320 psi) the fan will turn
The compressor clutch relay cannot be repaired on. The cooling fan will turn off when the discharge
and, if faulty or damaged, it must be replaced. line pressure drops to 1600 kPa (235 psi).
The dual function switch controls the A/C clutch
CONDENSER operation by disengaging the clutch when the dis-
charge line pressure rises above 3100 to 3375 kPa
DESCRIPTION (450 to 490 psi). The switch contacts will close and
The condenser is located in the air flow in front of allow A/C clutch engagement when the discharge line
the engine cooling radiator. The condenser is a heat pressure drops to 1860 to 2275 kPa (270 to 330 psi).
exchanger that allows the high-pressure refrigerant The Dual Function High Pressure Switch is a fac-
gas being discharged by the compressor to give up its tory-calibrated unit. The switch cannot be adjusted
heat to the air passing over the condenser fins. or repaired and, if faulty or damaged, it must be
replaced.
OPERATION
When the refrigerant gas gives up its heat, it con- EVAPORATOR COIL
denses. When the refrigerant leaves the condenser, it
has become a high-pressure liquid refrigerant. The DESCRIPTION
volume of air flowing over the condenser fins is crit- The evaporator coil is located in the heater-A/C
ical to the proper cooling performance of the air con- housing, under the instrument panel. The evaporator
ditioning system. Therefore, it is important that coil is positioned in the heater-A/C housing so that
XJ HEATING AND AIR CONDITIONING 24 - 5
DESCRIPTION AND OPERATION (Continued)
all air that enters the housing must pass over the pressure liquid refrigerant from the condenser
fins of the evaporator before it is distributed through expands into a low-pressure liquid as it passes
the system ducts and outlets. However, air passing through the metering orifice and diffuser screen of
over the evaporator coil fins will only be conditioned the fixed orifice tube.
when the compressor is engaged and circulating The fixed orifice tube cannot be repaired and, if
refrigerant through the evaporator coil tubes. faulty or plugged, the liquid line and fixed orifice
tube unit or liquid line jumper and fixed orifice tube
OPERATION unit must be replaced.
Refrigerant enters the evaporator from the fixed
orifice tube as a low-temperature, low-pressure liq- HEATER AND AIR CONDITIONER
uid. As air flows over the fins of the evaporator, the
humidity in the air condenses on the fins, and the DESCRIPTION
heat from the air is absorbed by the refrigerant. Heat All vehicles are equipped with a common heater-
absorption causes the refrigerant to boil and vapor- A/C housing assembly (Fig. 4). The system combines
ize. The refrigerant becomes a low-pressure gas when air conditioning, heating, and ventilating capabilities
it leaves the evaporator. in a single unit housing mounted under the instru-
The evaporator coil cannot be repaired and, if ment panel. On heater-only systems, the evaporator
faulty or damaged, it must be replaced. coil and recirculating air door are omitted from the
housing.
FIXED ORIFICE TUBE
DESCRIPTION
The fixed orifice tube is installed in the liquid line
(left-hand drive) or liquid line jumper (right-hand
drive) between the outlet of the condenser and the
inlet of the evaporator. The fixed orifice tube is
located in the end of the liquid line or liquid line
jumper that is closest to the condenser outlet tube.
The inlet end of the fixed orifice tube has a nylon
mesh filter screen, which filters the refrigerant and
helps to reduce the potential for blockage of the Fig. 4 Common Blend-Air Heater-Air Conditioner
metering orifice by refrigerant system contaminants System - Typical
(Fig. 3). The outlet end of the tube has a nylon mesh 1 – HEATER CORE
diffuser screen. The O-rings on the plastic body of 2 – BLEND-AIR DOOR
the fixed orifice tube seal the tube to the inside of 3 – EVAPORATOR A/C ONLY
the liquid line and prevent the refrigerant from 4 – RECIRCULATING AIR DOOR A/C ONLY
bypassing the fixed metering orifice. 5 – FLOOR/PANEL DOOR
6 – FLOOR/DEFROST DOOR
Pressure Diagnosis
Condition Possible Causes Correction
Rapid compressor clutch 1. Low refrigerant system 1. See Refrigerant System Leaks in this group.
cycling (ten or more cycles charge. Test the refrigerant system for leaks. Repair,
per minute). evacuate and charge the refrigerant system, if
required.
Equal pressures, but the 1. No refrigerant in the 1. See Refrigerant System Leaks in this group.
compressor clutch does not refrigerant system. Test the refrigerant system for leaks. Repair,
engage. 2. Faulty fuse. evacuate and charge the refrigerant system, if
3. Faulty compressor clutch required.
coil. 2. Check the fuses in the Power Distribution
4. Faulty compressor clutch Center and the junction block. Repair the shorted
relay. circuit or component and replace the fuses, if
5. Improperly installed or required.
faulty low pressure cycling 3. See Compressor Clutch Coil in this group. Test
clutch switch. the compressor clutch coil and replace, if
6. Faulty high pressure required.
cut-off switch. 4. See Compressor Clutch Relay in this group.
7. Faulty Powertrain Control Test the compressor clutch relay and relay
Module (PCM). 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 1. Excessive refrigerant oil in 1. See Refrigerant Oil Level in this group.
Performance Test air system. Recover the refrigerant from the refrigerant
temperatures at center panel 2. Blend-Air door inoperative system and inspect the refrigerant oil content.
outlet are too high. or sealing improperly. Restore the refrigerant oil to the proper level, if
3. Blend-Air door motor faulty required.
or inoperative. 2. 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.
3. Perform Blend-Air door motor diagnosis,
replace if faulty.
The low side pressure is 1. Low refrigerant system 1. See Refrigerant System Leaks in this group.
normal or slightly low, and charge. Test the refrigerant system for leaks. Repair,
the high side pressure is too 2. Refrigerant flow through evacuate and charge the refrigerant system, if
low. the accumulator is restricted. required.
3. Refrigerant flow through 2. See Accumulator in this group. Replace the
the evaporator coil is restricted accumulator, if required.
restricted. 3. See Evaporator Coil in this group. Replace the
4. Faulty compressor. restricted evaporator coil, if required.
4. See Compressor in this group. Replace the
compressor, if required.
24 - 12 HEATING AND AIR CONDITIONING XJ
DIAGNOSIS AND TESTING (Continued)
Pressure Diagnosis
Condition Possible Causes Correction
The low side pressure is 1. Condenser air flow 1. Check the condenser for damaged fins, foreign
normal or slightly high, and restricted. objects obstructing air flow through the condenser
the high side pressure is too 2. Inoperative cooling fan. fins, and missing or improperly installed air seals.
high. 3. Refrigerant system Refer to Group 7 - Cooling System for more
overcharged. information on air seals. Clean, repair, or replace
4. Air in the refrigerant components as required.
system. 2. Refer to Group 7 - Cooling System for more
5. Engine overheating. 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.
4. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
5. Refer to Group 7 - Cooling System for more
information. Test the cooling system and repair, if
required.
The low side pressure is too 1. Accessory drive belt 1. Refer to Group 7 - Cooling System for more
high, and the high side slipping. information. Inspect the accessory drive belt
pressure is too low. 2. Fixed orifice tube not condition and tension. Tighten or replace the
installed. accessory drive belt, if required.
3. Faulty compressor. 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.
The low side pressure is too 1. Restricted refrigerant flow 1. See Liquid Line and Suction and Discharge
low, and the high side through the refrigerant lines. Line in this group. Inspect the refrigerant lines for
pressure is too high. 2. Restricted refrigerant flow kinks, tight bends or improper routing. Correct the
through the fixed orifice tube. routing or replace the refrigerant line, if required.
3. Restricted refrigerant flow 2. See Fixed Orifice Tube in this group. Replace
through the condenser. the restricted fixed orifice tube, if required.
3. See Condenser in this group. Replace the
restricted condenser, if required.
NOISE
To verify that the blower is the source of the noise,
unplug the blower motor wire harness connector and
operate the heater-A/C system. If the noise goes
away, possible causes include: TERMINAL LEGEND
• Foreign material in the heater-A/C housing
NUMBER IDENTIFICATION
• Improper blower motor mounting
• Improper blower wheel mounting 30 COMMON FEED
• Blower motor faulty. 85 COIL GROUND
86 COIL BATTERY
BLOWER MOTOR RELAY
87 NORMALLY OPEN
WARNING: ON VEHICLES EQUIPPED WITH AIR- 87A NORMALLY CLOSED
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR Fig. 7 Blower Motor Relay
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (1) The relay common feed terminal cavity (30) is
SERVICE. FAILURE TO TAKE THE PROPER PRE- connected to fused battery feed directly from a fuse
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- in the Power Distribution Center (PDC), and should
BAG DEPLOYMENT AND POSSIBLE PERSONAL be hot at all times. Check for battery voltage at the
INJURY. connector cavity for relay terminal 30. If OK, go to
Step 2. If not OK, repair the open circuit to the PDC
fuse as required.
RELAY TEST (2) The relay normally closed terminal cavity (87A)
The blower motor relay (Fig. 7) is located in a wire is not used for this application. Go to Step 3.
harness connector that is secured to the heater-A/C (3) The relay normally open terminal cavity (87) is
housing behind the glove box on the passenger side connected to the blower motor. When the relay is
of the vehicle, next to the heater-A/C wire harness energized, terminal 87 is connected to terminal 30
connector in the passenger compartment. Remove the and provides full battery current to the blower motor
relay from its connector to perform the following feed circuit. There should be continuity between the
tests: connector cavity for terminal 87 and the blower
(1) A relay in the de-energized position should motor relay output circuit cavity of the blower motor
have continuity between terminals 87A and 30, and wire harness connector at all times. If OK, go to Step
no continuity between terminals 87 and 30. If OK, go 4. If not OK, repair the open circuit to the blower
to Step 2. If not OK, replace the faulty relay. motor as required.
(2) Resistance between terminals 85 and 86 (elec- (4) The coil battery terminal cavity (86) is con-
tromagnet) should be 75 6 5 ohms. If OK, go to Step nected to the ignition switch. When the ignition
3. If not OK, replace the faulty relay. switch is placed in the On position, fused ignition
(3) Connect a battery to terminals 85 and 86. switch output is directed from a fuse in the junction
There should now be continuity between terminals block to the relay electromagnetic coil to energize the
30 and 87, and no continuity between terminals 87A relay. There should be battery voltage at the connec-
and 30. If OK, see the Relay Circuit Test procedure tor cavity for relay terminal 86 with the ignition
in this group. If not OK, replace the faulty relay. switch in the On position. If OK, go to Step 5. If not
OK, repair the open circuit to the junction block fuse
RELAY CIRCUIT TEST as required.
For circuit descriptions and diagrams, refer to (5) The coil ground terminal cavity (85) is con-
8W-42 - Air Conditioning/Heater in Group 8W - Wir- nected to ground. This terminal supplies the ground
ing Diagrams. for the relay electromagnet coil. There should be con-
tinuity between the connector cavity for relay termi-
24 - 14 HEATING AND AIR CONDITIONING XJ
DIAGNOSIS AND TESTING (Continued)
nal 85 and a good ground at all times. If not OK, nuity. If OK, go to Step 3. If not OK, repair the open
repair the open circuit as required. circuit to ground as required.
(3) With the heater-A/C control wire harness con-
BLOWER MOTOR RESISTOR nector unplugged, place the heater-A/C mode control
For circuit descriptions and diagrams, refer to switch knob in any position except the Off position.
8W-42 - Air Conditioning/Heater in Group 8W - Wir- Check for continuity between the ground circuit ter-
ing Diagrams. minal and each of the blower motor driver circuit ter-
minals of the heater-A/C control as you move the
WARNING: ON VEHICLES EQUIPPED WITH AIR- blower motor switch knob to each of the four speed
BAGS, REFER TO GROUP 8M - PASSIVE positions. There should be continuity at each driver
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY circuit terminal in only one blower motor switch
STEERING WHEEL, STEERING COLUMN, OR speed position. If OK, test and repair the blower
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR driver circuits between the heater-A/C control con-
SERVICE. FAILURE TO TAKE THE PROPER PRE- nector and the blower motor resistor as required. If
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- not OK, replace the faulty heater-A/C control unit.
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. COMPRESSOR
When investigating an air conditioning related
(1) Disconnect and isolate the battery negative noise, you must first know the conditions under
cable. which the noise occurs. These conditions include:
(2) Remove the kick cover from the heater-A/C weather, vehicle speed, transmission in gear or neu-
housing and unplug the wire harness connector from tral, engine speed, engine temperature, and any
the blower motor resistor. other special conditions. Noises that develop during
(3) Check for continuity between each of the air conditioning operation can often be misleading.
blower motor switch input terminals of the resistor For example: What sounds like a failed front bearing
and the resistor output terminal. In each case there or connecting rod, may be caused by loose bolts, nuts,
should be continuity. If OK, repair the wire harness mounting brackets, or a loose compressor clutch
circuits between the blower motor switch and the assembly.
blower motor resistor or blower motor relay as Drive belts are speed sensitive. At different engine
required. If not OK, replace the faulty blower motor speeds and depending upon belt tension, belts can
resistor. develop noises that are mistaken for a compressor
noise. Improper belt tension can cause a misleading
BLOWER MOTOR SWITCH noise when the compressor clutch is engaged, which
For circuit descriptions and diagrams, refer to may not occur when the compressor clutch is disen-
8W-42 - Air Conditioning/Heater in Group 8W - Wir- gaged. Check the serpentine drive belt condition and
ing Diagrams. tension as described in Group 7 - Cooling System
before beginning this procedure.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
(1) Select a quiet area for testing. Duplicate the
BAGS, REFER TO GROUP 8M - PASSIVE
complaint conditions as much as possible. Switch the
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
compressor on and off several times to clearly iden-
STEERING WHEEL, STEERING COLUMN, OR
tify the compressor noise. Listen to the compressor
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
while the clutch is engaged and disengaged. Probe
SERVICE. FAILURE TO TAKE THE PROPER PRE-
the compressor with an engine stethoscope or a long
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
screwdriver with the handle held to your ear to bet-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
ter localize the source of the noise.
INJURY.
(2) Loosen all of the compressor mounting hard-
(1) Check for battery voltage at the fuse in the ware and retighten. Tighten the compressor clutch
Power Distribution Center (PDC). If OK, go to Step mounting nut. Be certain that the clutch coil is
2. If not OK, repair the shorted circuit or component mounted securely to the compressor, and that the
as required and replace the faulty fuse. clutch plate and pulley are properly aligned and have
(2) Turn the ignition switch to the Off position. the correct air gap. See Compressor and Compressor
Disconnect and isolate the battery negative cable. Clutch in the Removal and Installation section of this
Remove the heater-A/C control from the instrument group for the procedures.
panel. Check for continuity between the ground cir- (3) To duplicate a high-ambient temperature condi-
cuit cavity of the heater-A/C control wire harness tion (high head pressure), restrict the air flow
connector and a good ground. There should be conti- through the condenser. Install a manifold gauge set
XJ HEATING AND AIR CONDITIONING 24 - 15
DIAGNOSIS AND TESTING (Continued)
to be certain that the discharge pressure does not • Heater-A/C mode control switch
exceed 2760 kPa (400 psi). • Compressor clutch relay
(4) Check the refrigerant system plumbing for • High pressure cut-off switch
incorrect routing, rubbing or interference, which can • Low pressure cycling clutch switch
cause unusual noises. Also check the refrigerant lines • Powertrain Control Module (PCM).
for kinks or sharp bends that will restrict refrigerant (4) The compressor clutch coil is acceptable if the
flow, which can cause noises. See Suction and Dis- current draw measured at the clutch coil is 2.0 to 3.9
charge Line in the Removal and Installation section amperes with the electrical system voltage at 11.5 to
of this group for more information. 12.5 volts. This should only be checked with the work
(5) If the noise is from opening and closing of the area temperature at 21° C (70° F). If system voltage
high pressure relief valve, evacuate and recharge the is more than 12.5 volts, add electrical loads by turn-
refrigerant system. See Refrigerant System Evacuate ing on electrical accessories until the system voltage
and Refrigerant System Charge in the Service Proce- drops below 12.5 volts.
dures section of this group. If the high pressure relief (a) If the clutch coil current reading is four
valve still does not seat properly, replace the com- amperes or more, the coil is shorted and should be
pressor. replaced.
(6) If the noise is from liquid slugging on the suc- (b) If the clutch coil current reading is zero, the
tion line, replace the accumulator. See Accumulator coil is open and should be replaced.
in the Removal and Installation section of this group
for the procedures. Check the refrigerant oil level COMPRESSOR CLUTCH RELAY
and the refrigerant system charge. See Refrigerant
Oil Level and Refrigerant System Charge in the Ser- RELAY TEST
vice Procedures section of this group. If the liquid The compressor clutch relay (Fig. 8) is located in
slugging condition continues following accumulator the Power Distribution Center (PDC). Refer to the
replacement, replace the compressor. PDC label for relay identification and location.
(7) If the noise continues, replace the compressor Remove the relay from the PDC to perform the fol-
and repeat Step 1. lowing tests:
(1) A relay in the de-energized position should
COMPRESSOR CLUTCH COIL have continuity between terminals 87A and 30, and
For circuit descriptions and diagrams, refer to no continuity between terminals 87 and 30. If OK, go
8W-42 - Air Conditioning/Heater in Group 8W - Wir- to Step 2. If not OK, replace the faulty relay.
ing Diagrams. The battery must be fully-charged (2) Resistance between terminals 85 and 86 (elec-
before performing the following tests. Refer to Group tromagnet) should be 75 6 5 ohms. If OK, go to Step
8A - Battery for more information. 3. If not OK, replace the faulty relay.
(1) Connect an ammeter (0 to 10 ampere scale) in (3) Connect a battery to terminals 85 and 86.
series with the clutch coil terminal. Use a voltmeter There should now be continuity between terminals
(0 to 20 volt scale) with clip-type leads for measuring 30 and 87, and no continuity between terminals 87A
the voltage across the battery and the compressor and 30. If OK, see Relay Circuit Test in the Diagno-
clutch coil. sis and Testing section of this group. If not OK,
(2) With the heater-A/C mode control switch in any replace the faulty relay.
A/C mode, and the blower motor switch in the lowest
speed position, start the engine and run it at normal RELAY CIRCUIT TEST
idle. For circuit descriptions and diagrams, refer to
(3) The compressor clutch coil voltage should read 8W-42 - Air Conditioning/Heater in Group 8W - Wir-
within two volts of the battery voltage. If there is ing Diagrams.
voltage at the clutch coil, but the reading is not (1) The relay common feed terminal cavity (30) is
within two volts of the battery voltage, test the connected to fused battery feed. There should be bat-
clutch coil feed circuit for excessive voltage drop and tery voltage at the cavity for relay terminal 30 at all
repair as required. If there is no voltage reading at times. If OK, go to Step 2. If not OK, repair the open
the clutch coil, use a DRB scan tool and the proper circuit to the fuse in the PDC as required.
Diagnostic Procedures manual for testing of the com- (2) The relay normally closed terminal (87A) is not
pressor clutch circuit. The following components used in this application. Go to Step 3.
must be checked and repaired as required before you (3) The relay normally open terminal cavity (87) is
can complete testing of the clutch coil: connected to the compressor clutch coil. There should
• Fuses in the junction block and the Power Dis- be continuity between this cavity and the A/C com-
tribution Center (PDC) pressor clutch relay output circuit cavity of the com-
24 - 16 HEATING AND AIR CONDITIONING XJ
DIAGNOSIS AND TESTING (Continued)
Temperature Reference
15.5° C 21.1° C 26.6° C 32.2° C
Ambient Air Temperature
(60° F) (70° F) (80° F) (90° F)
Minimum Air Temperature at 62.2° C 63.8° C 65.5° C 67.2° C
Floor Outlet (144° F) (147° F) (150° F) (153° F)
XJ HEATING AND AIR CONDITIONING 24 - 17
DIAGNOSIS AND TESTING (Continued)
If the floor outlet air temperature is too low, refer (2) Unplug the low pressure cycling clutch switch
to Group 7 - Cooling System to check the engine cool- wire harness connector from the switch on the accu-
ant temperature specifications. Both of the heater mulator fitting.
hoses should be hot to the touch. The coolant return (3) Install a jumper wire between the two cavities
heater hose should be slightly cooler than the coolant of the low pressure cycling clutch switch wire har-
supply heater hose. If the return hose is much cooler ness connector.
than the supply hose, locate and repair the engine (4) Connect a manifold gauge set to the refrigerant
coolant flow obstruction in the cooling system. Refer system service ports. See Refrigerant System Service
to Group 7 - Cooling System for the procedures. Equipment and Refrigerant System Service Ports in
OBSTRUCTED COOLANT FLOW Possible loca- the Description and Operation section of this group
tions or causes of obstructed coolant flow: for more information.
• Pinched or kinked heater hoses. (5) Connect the battery negative cable.
• Improper heater hose routing. (6) Place the heater-A/C mode control switch knob
• Plugged heater hoses or supply and return ports in any A/C position and start the engine.
at the cooling system connections. (7) Check for continuity between the two terminals
• A plugged heater core. of the low pressure cycling clutch switch. There
If proper coolant flow through the cooling system is should be continuity with a suction pressure reading
verified, and heater outlet air temperature is still of 262 kPa (38 psi) or above, and no continuity with a
low, a mechanical problem may exist. suction pressure reading of 141 kPa (20.5 psi) or
MECHANICAL PROBLEMS Possible locations or below. If OK, test and repair the A/C switch sense
causes of insufficient heat: circuit as required. If not OK, replace the faulty
• An obstructed cowl air intake. switch.
• Obstructed heater system outlets.
• A blend-air door not functioning properly. REFRIGERANT SYSTEM LEAKS
TEMPERATURE CONTROL WARNING: REVIEW THE WARNINGS AND CAU-
If the heater outlet air temperature cannot be TIONS IN THE FRONT OF THIS GROUP BEFORE
adjusted with the temperature control knob on the LEAK TESTING THE SYSTEM.
heater-A/C control panel, the following could require
service: If the air conditioning system is not cooling prop-
• The heater-A/C control. erly, determine if the refrigerant system is fully-
• The temperature control motor. charged. See A/C Performance in this group for the
• The blend-air door. procedures. If the refrigerant system is low or empty;
• Improper engine coolant temperature. a leak at a refrigerant line, connector fitting, compo-
nent, or component seal is likely.
LOW PRESSURE CYCLING CLUTCH SWITCH An electronic leak detector designed for R-134a
Before performing diagnosis of the low pressure refrigerant, or a fluorescent R-134a leak detection
cycling clutch switch, be certain that the switch is dye and a black light are recommended for locating
properly installed on the accumulator fitting. If the and confirming refrigerant system leaks. Refer to the
switch is too loose it may not open the Schrader-type operating instructions supplied by the equipment
valve in the accumulator fitting, which will prevent manufacturer for proper care and use of this equip-
the switch from correctly monitoring the refrigerant ment.
system pressure. Remember that lower ambient tem- An oily residue on or near refrigerant system lines,
peratures, below about -1° C (30° F), during cold connector fittings, components, or component seals
weather will open the switch contacts and prevent can indicate the general location of a possible refrig-
compressor operation due to the pressure/tempera- erant leak. However, the exact leak location should
ture relationship of the refrigerant. be confirmed with an electronic leak detector prior to
Also verify that the refrigerant system has the cor- component repair or replacement.
rect refrigerant charge. See Refrigerant System To detect a leak in the refrigerant system with an
Charge in the Service Procedures section of this electronic leak detector, perform one of the following
group for more information. procedures:
For circuit descriptions and diagrams, refer to
8W-42 - Air Conditioning/Heater in Group 8W - Wir- SYSTEM EMPTY
ing Diagrams. (1) Evacuate the refrigerant system. See Refriger-
(1) Disconnect and isolate the battery negative ant System Evacuate in this group for the proce-
cable. dures.
24 - 18 HEATING AND AIR CONDITIONING XJ
DIAGNOSIS AND TESTING (Continued)
(2) Connect and dispense 0.283 kilograms (0.625 Use an adjustable vacuum test set (Special Tool
pounds or 10 ounces) of R-134a refrigerant into the C-3707-B) and a suitable vacuum pump to test the
evacuated refrigerant system. See Refrigerant Sys- heater-A/C vacuum control system. With a finger
tem Charge in this group for the procedures. placed over the end of the vacuum test hose probe
(3) Position the vehicle in a wind-free work area. (Fig. 9), adjust the bleed valve on the test set gauge
This will aid in detecting small leaks. to obtain a vacuum of exactly 27 kPa (8 in. Hg.).
(4) With the engine not running, use a electronic Release and block the end of the probe several times
R-134a leak detector and search for leaks. Because to verify that the vacuum reading returns to the
R-134a refrigerant is heavier than air, the leak detec- exact 27 kPa (8 in. Hg.) setting. Otherwise, a false
tor probe should be moved slowly along the bottom reading will be obtained during testing.
side of all refrigerant lines, connector fittings and
components.
(5) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet. Set the blower motor switch
to the lowest speed position, and the mode control
switch in the recirculation mode.
SYSTEM LOW
(1) Position the vehicle in a wind-free work area.
This will aid in detecting small leaks.
(2) Bring the refrigerant system up to operating
temperature and pressure. This is done by allowing
the engine to run with the air conditioning system
turned on for five minutes.
(3) With the engine not running, use a electronic
R-134a leak detector and search for leaks. Because
R-134a refrigerant is heavier than air, the leak detec- Fig. 9 Adjust Vacuum Test Bleed Valve
1 – VACUUM PUMP TOOL C-4289
tor probe should be moved slowly along the bottom
2 – VACUUM TEST SET C-3707
side of all refrigerant lines, connector fittings and
3 – BLEED VALVE
components. 4 – PROBE
(4) To inspect the evaporator coil for leaks, insert
the electronic leak detector probe into the center
instrument panel outlet. Set the blower motor switch VACUUM CHECK VALVE
to the lowest speed position, and the mode control (1) Remove the vacuum check valve. The valve is
switch in the recirculation mode. located in the vacuum supply tube (black) at the
heater-A/C system vacuum tee.
VACUUM SYSTEM (2) Connect the test set vacuum supply hose to the
Vacuum control is used to operate the mode doors heater-A/C control side of the valve. When connected
in the heater-only and heater-A/C housings. Testing to this side of the check valve, no vacuum should
of the heater-only and heater-A/C mode control pass and the test set gauge should return to the 27
switch operation will determine if the vacuum, elec- kPa (8 in. Hg.) setting. If OK, go to Step 3. If not OK,
trical, and mechanical controls are functioning. How- replace the faulty valve.
ever, it is possible that a vacuum control system that (3) Connect the test set vacuum supply hose to the
operates perfectly at engine idle (high engine vac- engine vacuum side of the valve. When connected to
uum) may not function properly at high engine this side of the check valve, vacuum should flow
speeds or loads (low engine vacuum). This can be through the valve without restriction. If not OK,
caused by leaks in the vacuum system, or a faulty replace the faulty valve.
vacuum check valve.
A vacuum system test will help to identify the HEATER-A/C CONTROLS
source of poor vacuum system performance or vac- (1) Connect the test set vacuum probe to the heat-
uum system leaks. Before starting this test, stop the er-A/C vacuum supply (black) tube at the tee in the
engine and make certain that the problem is not a engine compartment. Position the test set gauge so
disconnected vacuum supply tube at the engine that it can be viewed from the passenger compart-
intake manifold vacuum tap or at the vacuum reser- ment.
voir.
XJ HEATING AND AIR CONDITIONING 24 - 19
DIAGNOSIS AND TESTING (Continued)
(2) Place the heater-A/C mode control switch knob
in each mode position, one position at a time, and
pause after each selection. The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after
each selection is made. If not OK, a component or
vacuum line in the vacuum circuit of the selected
mode has a leak. See the procedure in Locating Vac-
uum Leaks.
COMPRESSOR CLUTCH
The refrigerant system can remain fully-charged
during compressor clutch, pulley, or coil replacement.
The compressor clutch can be serviced in the vehicle.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the serpentine drive belt. Refer to
Group 7 - Cooling System for the procedures.
(3) Unplug the compressor clutch coil wire harness
connector.
(4) Remove the four bolts that secure the compres-
sor to the mounting bracket.
(5) Remove the compressor from the mounting
bracket. Support the compressor in the engine com-
partment while servicing the clutch.
Fig. 21 Clutch Plate Remove
1 – CLUTCH PLATE PULLER
(6) Insert the two pins of the spanner wrench
2 – CLUTCH PLATE
(Special Tool C-4489) into the holes of the clutch
plate. Hold the clutch plate stationary and remove
the hex nut (Fig. 20).
Fig. 23 Shaft Protector and Puller Fig. 25 Clutch Coil Lead Wire Harness
1 – PULLER JAW 1 – COIL
2 – SHAFT PROTECTOR 2 – COIL WIRE
3 – RETAINER SCREW
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the heater-A/C control to the
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
Fig. 28 Clutch Plate Driver
1 – CLUTCH PLATE
2 – DRIVER
COMPRESSOR CLUTCH RELAY
(1) Disconnect and isolate the battery negative
cable.
(8) Check the clutch air gap with a feeler gauge (2) Remove the cover from the Power Distribution
(Fig. 29). If the air gap does not meet the specifica- Center (PDC) (Fig. 30).
tion, add or subtract shims as required. The air gap (3) Refer to the label on the PDC for compressor
specification is 0.41 to 0.79 millimeter (0.016 to 0.031 clutch relay identification and location.
inch). If the air gap is not consistent around the cir- (4) Unplug the compressor clutch relay from the
cumference of the clutch, lightly pry up at the mini- PDC.
mum variations. Lightly tap down at the points of (5) Install the compressor clutch relay by aligning
maximum variation. the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
NOTE: The air gap is determined by the spacer (6) Install the PDC cover.
shims. When installing an original, or a new clutch (7) Connect the battery negative cable.
assembly, try the original shims first. When install- (8) Test the relay operation.
ing a new clutch onto a compressor that previously
24 - 32 HEATING AND AIR CONDITIONING XJ
REMOVAL AND INSTALLATION (Continued)
line fitting at the condenser outlet. See Refrigerant
Line Coupler in this group for the procedures. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(5) Remove the radiator and the condenser from
the vehicle as a unit. Refer to Group 7 - Cooling Sys-
tem for the procedures.
(6) Remove the two nuts that secure the condenser
studs to the upper brackets of the radiator (Fig. 31).
INSTALLATION
REMOVAL
(1) Install the holes of the condenser lower brack-
(1) Disconnect and isolate the battery negative
ets over the dowel pins on the bottom of the radiator.
cable.
(2) Slide the condenser upwards until both of the
(2) Recover the refrigerant from the refrigerant
condenser studs are installed through the holes in
system. See Refrigerant Recovery in this group for
the radiator upper brackets. Tighten the mounting
the procedures.
nuts to 5.3 N·m (47 in. lbs.).
(3) Disconnect the discharge line refrigerant line
(3) Renstall the radiator and condenser unit in the
fitting at the condenser inlet. See Refrigerant Line
vehicle. Refer to Group 7 - Cooling System for the
Coupler in this group for the procedures. Install
procedures.
plugs in, or tape over all of the opened refrigerant
(4) Remove the tape or plugs from the refrigerant
line fittings.
line fittings on the condenser outlet and the liquid
(4) Disconnect the liquid line (Left-Hand Drive) or
line (Left-Hand Drive) or the liquid line jumper
liquid line jumper (Right-Hand Drive) refrigerant
(Right-Hand Drive). Install the liquid line or the liq-
XJ HEATING AND AIR CONDITIONING 24 - 33
REMOVAL AND INSTALLATION (Continued)
uid line jumper to the condenser outlet. See Refriger- STEERING WHEEL, STEERING COLUMN, OR
ant Line Coupler in this group for the procedures. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
(5) Remove the tape or plugs from the refrigerant SERVICE. FAILURE TO TAKE THE PROPER PRE-
line fittings on the condenser inlet and the discharge CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
line. Connect the discharge line to the condenser BAG DEPLOYMENT AND POSSIBLE PERSONAL
inlet. See Refrigerant Line Coupler in this group for INJURY.
the procedures.
(6) Connect the battery negative cable.
(7) Evacuate the refrigerant system. See Refriger- PANEL OUTLET DUCTS
ant System Evacuate in this group for the proce- The panel outlet ducts are integral to the instru-
dures. ment panel assembly. Refer to Instrument Panel
(8) Charge the refrigerant system. See Refrigerant Assembly in Group 8E - Instrument Panel Systems
System Charge in this group for the procedures. for the procedures.
INSTALLATION
(1) Lubricate a new O-ring seal with clean refrig- (2) To install, position the barrel in the panel out-
erant oil and install it on the discharge line fitting. let housing and press firmly until the barrel snaps
Use only the specified O-rings as they are made of a into place.
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the com- DEMISTER OUTLETS
pressor in the vehicle. The side window demister outlets are integral to
(2) Install and tighten the high pressure switch on the instrument panel end caps. Refer to Instrument
the discharge line fitting. Panel End Cap in Group 8E - Instrument Panel Sys-
(3) Plug the wire harness connector into the high tems for the procedures.
pressure cut-off switch.
(4) Connect the battery negative cable. DEFROST DUCT/DEMISTER ADAPTER
(1) Remove the instrument panel assembly from
DUCTS AND OUTLETS the vehicle. Refer to Instrument Panel Assembly in
Group 8E - Instrument Panel Systems for the proce-
WARNING: ON VEHICLES EQUIPPED WITH AIR- dures.
BAGS, REFER TO GROUP 8M - PASSIVE (2) Disconnect the demister hoses from the defrost
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY duct/demister adapter (Fig. 33).
24 - 34 HEATING AND AIR CONDITIONING XJ
REMOVAL AND INSTALLATION (Continued)
EVAPORATOR COIL
Hand Drive) near the condenser. The orifice has filter
WARNING: ON VEHICLES EQUIPPED WITH AIR- screens on the inlet and outlet ends of the tube body.
BAGS, REFER TO GROUP 8M - PASSIVE If the fixed orifice tube is faulty or plugged, the liq-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY uid line unit or liquid line jumper unit must be
STEERING WHEEL, STEERING COLUMN, OR replaced. See Liquid Line in this group for the ser-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR vice procedures.
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- HEATER-A/C CONTROL
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
(1) Remove and disassemble the heater-A/C hous- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ing. See Heater-A/C Housing in this group for the STEERING WHEEL, STEERING COLUMN, OR
procedures. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
(2) Lift the evaporator coil unit out of the lower SERVICE. FAILURE TO TAKE THE PROPER PRE-
half of the heater-A/C housing (Fig. 36). CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(3) Reverse the removal procedures to install. Be BAG DEPLOYMENT AND POSSIBLE PERSONAL
certain that the evaporator foam insulator wrap and INJURY.
rubber tube seal are reinstalled.
DISASSEMBLY
(1) Remove the heater-A/C housing from the vehi-
cle and place it on a work bench.
(2) Unplug the vacuum harness connectors from
the floor door actuator and, if the unit is so equipped,
the recirculation air door actuator.
(3) Disengage the vacuum harness from any rout-
ing clips located on the lower half of the heater-A/C
housing.
(4) Disengage the heater-A/C wire harness connec-
tor and the blower motor relay wire harness connec-
tor push-in retainers from their mounting holes on
the heater-A/C housing.
(5) Remove the blower motor and blower wheel
unit from the heater-A/C housing. See Blower Motor
Fig. 39 Heater-A/C Unit Connector in this group for the procedures.
1 – BLOWER MOTOR RELAY (6) Carefully remove the foam seal from the flange
2 – VACUUM HARNESS
around the blower motor opening in the heater-A/C
3 – HEATER-A/C WIRE HARNESS CONNECTOR
4 – HEATER-A/C HOUSING
housing. If the seal is deformed or damaged, it must
be replaced.
(7) Pull the vacuum supply line and connector
(10) Remove the five nuts from the heater-A/C through the foam seal on the heater core and evapo-
housing mounting studs on the engine compartment rator coil tube mounting flange of the heater-A/C
side of the dash panel (Fig. 40). Remove or reposition housing (Fig. 41).
the evaporation canister for additional access, if (8) If the unit is equipped with air conditioning,
required. remove the screw that secures the clamp to the evap-
orator coil tubes and remove the clamp.
24 - 38 HEATING AND AIR CONDITIONING XJ
REMOVAL AND INSTALLATION (Continued)
BLEND-AIR DOOR
(1) Remove and disassemble the heater-A/C hous-
ing. See Heater-A/C Housing in this group for the
procedures.
(2) Lift the blend-air door pivot shaft out of the Fig. 44 Mode Door Lever Remove/Install - Typical
pivot hole in the bottom of the lower half of the heat- 1 – DOOR PIVOT SHAFT
er-A/C housing (Fig. 43). 2 – LATCH HOLE
(3) Reverse the removal procedures to install. 3 – CRANK ARM LATCH
4 – FLAT BLADE PRY TOOL
PANEL/DEMIST DOOR AND LEVER
(1) Remove and disassemble the heater-A/C hous-
(4) Reach inside the upper half of the heater-A/C
ing. See Heater-A/C Housing in this group for the
housing and carefully flex the panel/defrost door (Fig.
procedures.
45) enough so that the door pivot clears the pivot
(2) Remove the defrost and panel/demist door vac-
hole in the housing.
uum actuators from the heater-A/C housing. See
(5) Remove the panel/demist door from the heater-
Mode Door Vacuum Actuator in this group for the
A/C housing.
procedures.
(6) Reverse the removal procedures to install.
24 - 40 HEATING AND AIR CONDITIONING XJ
REMOVAL AND INSTALLATION (Continued)
enough so that the door pivot clears the pivot hole in
the housing.
HEATER CORE
that each of the refrigerant system connections is
WARNING: ON VEHICLES EQUIPPED WITH AIR- pressure-tight and leak free. It is a good practice to
BAGS, REFER TO GROUP 8M - PASSIVE inspect all flexible hose refrigerant lines at least once
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY a year to make sure they are in good condition and
STEERING WHEEL, STEERING COLUMN, OR properly routed.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- WARNING: REVIEW THE WARNINGS AND CAU-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- TIONS IN THE FRONT OF THIS GROUP BEFORE
BAG DEPLOYMENT AND POSSIBLE PERSONAL PERFORMING THE FOLLOWING OPERATION.
INJURY.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. See Refrigerant Recovery in this group for
the procedures.
(3) Unplug the wire harness connector from the
high pressure cut-off switch.
(4) Disconnect the discharge line refrigerant line Fig. 56 Suction and Discharge Line
fitting from the condenser inlet tube (Fig. 56). See 1 – SUCTION AND DISCHARGE LINE
Refrigerant Line Coupler in this group for the proce- 2 – SCREW
dures. Install plugs in, or tape over all of the opened 3 – COMPRESSOR
refrigerant line fittings. 4 – CONDENSER
(5) Remove the nut that secures the suction line 5 – INLET
block fitting to the accumulator outlet. Install plugs 6 – CLIP
in, or tape over all of the opened refrigerant line fit- 7 – HEX NUT
tings. 8 – ACCUMULATOR
(6) Remove the screw that secures the suction and
discharge line manifold to the compressor. Install (4) Plug in the wire harness connector to the high
plugs in, or tape over all of the opened refrigerant pressure cut-off switch.
line fittings. (5) Connect the battery negative cable.
(7) Remove the suction and discharge line assem- (6) Evacuate the refrigerant system. See Refriger-
bly from the vehicle. ant System Evacuate in this group for the proce-
dures.
INSTALLATION (7) Charge the refrigerant system. See Refrigerant
(1) Remove the tape or plugs from the suction and System Charge in this group for the procedures.
discharge line manifold and the compressor. Install
the suction and discharge line manifold to the com- VACUUM CHECK VALVE
pressor. Tighten the mounting screw to 28 N·m (250 (1) Unplug the heater-A/C vacuum supply line con-
in. lbs.). nector at the vacuum check valve (Fig. 57).
(2) Remove the tape or plugs from the suction line (2) Note the orientation of the check valve in the
and the accumulator outlet block fittings. Install the vacuum supply line for correct reinstallation.
suction line to the accumulator outlet and tighten the (3) Unplug the vacuum check valve from the vac-
mounting nut to 9 N·m (80 in. lbs.). uum supply line fittings.
(3) Remove the tape or plugs from the refrigerant (4) Reverse the removal procedures to install.
line fittings on the discharge line and the condenser
inlet tube. Connect the discharge line refrigerant line
coupler to the condenser inlet tube. See Refrigerant
Line Coupler in this group for the procedures.
XJ HEATING AND AIR CONDITIONING 24 - 47
REMOVAL AND INSTALLATION (Continued)
(3) Remove the two screws that secure the vacuum
reservoir to the front bumper.
(4) Remove the vacuum reservoir from behind the
front bumper.
(5) Reverse the removal procedures to install.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).
SPECIFICATIONS
A/C APPLICATION TABLE
Item Description Notes
Vehicle XJ Cherokee/
Laredo
Fig. 57 Vacuum Supply System R134a w/orifice
1 – VACUUM CHECK VALVE tube
2 – TO ENGINE INTAKE MANIFOLD
Compressor Sanden SP-20 PAG oil
3 – TO HEATER-A/C CONTROLS
SD7H15
4 – TO VACUUM RESERVOIR
5 – TO SPEED CONTROL SERVO Freeze–up Low Pressure accumulator
6 – VACUUM SUPPLY LINE Control cycling cutout mounted
switch
VACUUM RESERVOIR Low psi Control opens < 25 psi
(1) Remove the passenger side bumper end cap - resets > 43
from the front bumper. Refer to Group 23 - Body for psi
the procedures. High psi Control switch - opens discharge line
(2) Unplug the vacuum supply line connector from > 450-490 psi -
the vacuum reservoir (Fig. 58). resets <
270-330 psi
Control Head manual type
Mode Door vacuum
Blend-Air Door electric
Fresh/Recirc vacuum
door
Blower Motor hardwired to resistor block
control head
Cooling Fan viscous for
cooling, single
speed electric
for A/C
Clutch
Control relay PCM
Draw 2 - 3.7 amps @ 6 0.5V @ 70° F
12V
Gap 0.016” - 0.0319
Fig. 58 Vacuum Reservoir Remove/Install
1 – VACUUM LINE DRB IIIT
2 – RESERVOIR SCREWS Reads TPS, RPM, A/C
3 – VACUUM RESERVOIR switch test
Actuators clutch and fan
relay
XJ INDEX 1
Description Group-Page Description Group-Page Description Group-Page
ABS BRAKE SYSTEM, BLEEDING . . . . . . . . . 5-36 AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-7 AXLE ASSEMBLY, DRIVE . . . . . . . . . . . . . . . . 3-22
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . 5-35 ANALYSIS, GEAR CONTACT PATTERN . . . . 3-129, AXLE ASSEMBLY, TUBE . . . . . . . . . . . . . . . . . 3-23
ABSOLUTE PRESSURE (MAP) SENSOR, 3-59,3-97 AXLE BUSHING, FRONT . . . . . . . . . . . . . . . . 2-11
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46 ANALYSIS, PRESSURE TEST . . . . . . . . . . . 21-242 AXLE BUSHING REPLACEMENT . . . . . . . . . . 3-33
ABSOLUTE PRESSURE (MAP) ANALYSIS, TIME LAG TEST . . . . . . . . . . . . 21-243 AXLE COMPONENTS . . . . . . . . . . . . . . . 3-47,3-91
SENSOR—PCM INPUT, MANIFOLD . . . . . . . 14-32 ANALYZING ROAD TEST . . . . . . . . . . . . . . 21-129 AXLE PINION GEAR DEPTH, 8 1/4 . . . . . . . 3-126
ABSORBER, SHOCK . . . . . . . . . . . . . . . . 2-17,2-9 ANGLE, FRONT AXLE PINION INPUT . . . . . . 3-15 AXLE PINION INPUT ANGLE, FRONT . . . . . . 3-15
ABSORBERS, SHOCK . . . . . . . . . . . . . . . 2-16,2-7 ANGLE MEASUREMENT PREPARATION, AXLE PINION INPUT ANGLE, REAR . . . . . . . 3-15
A/C APPLICATION TABLE . . . . . . . . . . . . . . . 24-47 DRIVELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 AXLE, REAR . . . . . . . . . . . . . . . . . . . . 3-111,3-72
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . 24-9 ANGLE MEASUREMENT, PROPELLER AXLE SEAL AND BEARING . . . . . . . . . . . . . 3-112
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . 14-21 SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 AXLE SHAFT . . . . . . . . . . . . . . . . . . . . 3-111,3-76
ACCESSORY DRIVE BELT DIAGNOSIS . . . . . . 7-9 ANGLE, PROPELLER SHAFT JOINT . . . . . . . . . 3-3 AXLE SHAFT, HUB BEARING . . . . . . . . . . . . . 3-30
ACCESSORY DRIVE BELTS, ENGINE . . . . . . . 7-35 ANGLE, REAR AXLE PINION INPUT . . . . . . . 3-15 AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . 3-36
ACCESSORY SWITCH BEZEL, ANTENNA . . . . . . . . . . . . . . . . . . . 8F-10,8F-2,8F-5 AXLE SHAFT SEAL AND BEARING . . . . . . . . 3-77
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-15 ANTILOCK BRAKE, HYDRAULIC AXLE SHAFT—CARDAN U-JOINT . . . . . . . . . 3-23
ACCUMULATOR; HEATING AND AIR CONTROL UNIT/CONTROLLER . . . . . . . . . . . 5-39 AXLE, TUBE, 181, AND 186 FBI . . . . . . . . . . 3-16
CONDITIONING . . . . . . . . . . . . . . . . . . 24-2,24-25 ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 5-33 AXLES, 8 1/4 . . . . . . . . . . . . . . . . . . . . . . . . 3-131
ACCUMULATOR; TRANSMISSION AND ANTILOCK BRAKES . . . . . . . . . . . . . . . . 5-33,5-36 BACKLASH, 181 FBI DIFFERENTIAL
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-117 ANTI-LOCK BRAKES, 8W-35 . . . . . . . . . . . . 8W-1 BEARING PRELOAD AND GEAR . . . . . . . . . . 3-52
ACCUMULATOR PISTONS AND SPRINGS . 21-264 ANTILOCK BRAKES, CONTROLLER . . . . . . . . 5-33 BACKLASH, 186 FBI DIFFERENTIAL
ACTUATION TEST MODE, CIRCUIT . . . . . . . . 25-2 ANTILOCK BRAKES, HYDRAULIC BEARING PRELOAD AND GEAR . . . . . . . . . . 3-56
ACTUATOR, FRONT DOOR INSIDE CONTROL UNIT/CONTROLLER . . . . . . . . . . . 5-36 BACKLASH, DIFFERENTIAL BEARING
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37 A-PILLAR COWL TRIM, LOWER . . . . . . . . . 23-51 PRELOAD AND GEAR . . . . . . . . . . . . . 3-127,3-94
ACTUATOR, MODE DOOR VACUUM . . . . . . 24-43 A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-51 BACK-UP/BRAKE/REAR TURN SIGNAL/
ACTUATOR, REAR DOOR INSIDE APPLICATION, BULB . . . . . . . . . . . . . . . . . . 8L-20 TAIL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45 APPLICATION TABLE, A/C . . . . . . . . . . . . . . 24-47 BACK-UP/BRAKE/REAR TURN SIGNAL/
ADAPTER HOUSING . . . . . . . . . . . . . . . . . 21-147 APPLIQUE, QUARTER WINDOW . . . . . . . . . 23-49 TAIL LAMP BULB . . . . . . . . . . . . . . . . . . . . 8L-11
ADAPTER HOUSING SEAL . . . . . . . . . 21-252,21-7 ARM AND BLADE, WIPER . . . . . . . . . . . . . . . . 8K-2 BALANCE, TIRE AND WHEEL . . . . . . . . . . . . . . 22-9
ADAPTER SEAL, SOLENOID HARNESS . . . . 21-261 ARM, LOWER SUSPENSION . . . . . . . . . . . . . 2-10 BALL STUD, LIFTGATE SUPPORT ROD . . . . 23-63
ADAPTER, SPEEDOMETER . . . . . . 21-148,21-253 ARM, PITMAN . . . . . . . . . . . . . . . . . . . . . . . 19-24 BALL STUDS, STEERING KNUCKLE . . . . . . . 3-31
ADAPTER/EXTENSION HOUSING AND ARM, ROCKER . . . . . . . . . . . . . . . . . . . . 9-6,9-66 BAND ADJUSTMENT, FRONT . . . . . . . . . . . 21-199
FRONT BEARING RETAINER . . . . . . . . . . . . . 21-8 ARM, UPPER SUSPENSION . . . . . . . . . . . . . 2-11 BAND ADJUSTMENT, REAR . . . . . . . . . . . . 21-200
ADDITIONAL, COOLANT—ADDING . . . . . . . . 7-21 ARM, WIPER . . . . . . . . . . . . . . . . . . . . . . . . . 8K-8 BAND OPERATION, AIR TESTING
ADHESIVE LOCATIONS, STRUCTURAL . . . 23-124 ARMS AND BUSHINGS, LOWER TRANSMISSION CLUTCH . . . . . . . . . . . . . 21-131
ADJUSTER AND MOTORS, POWER SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-123
SEAT . . . . . . . . . . . . . . . . . . . . . . 8R-1,8R-2,8R-3 ARMS AND BUSHINGS, UPPER BAR, STABILIZER . . . . . . . . . . 2-12,2-16,2-17,2-9
ADJUSTMENT, BRAKE TRANSMISSION SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 BAR, TRACK . . . . . . . . . . . . . . . . . . . . . . 2-12,2-9
SHIFT INTERLOCK CABLE . . . . . . . 21-198,21-336 ARMS AND PUSH RODS, ROCKER . . 9-113,9-36, BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . 5-13
ADJUSTMENT, COMPASS VARIATION . . . . . . 8V-4 9-53,9-96 BASE BRAKE SYSTEM . . . . . . . . . . . . . . . 5-1,5-7
ADJUSTMENT, DOOR LATCH . . . . . . . . . . . . 23-66 ASD AND FUEL PUMP RELAYS . . . . . . . . . . 14-41 BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5-32
ADJUSTMENT, FOG LAMP . . . . . . . . . . . . . . . 8L-8 ASSEMBLY, DRIVE AXLE . . . . . . . . . . . . . . . . 3-22 BASE COAT/CLEAR COAT FINISH . . . . . . . . . 23-4
ADJUSTMENT, FRONT BAND . . . . . . . . . . . 21-199 ASSEMBLY, ENGINE . . . . . . . . . . . . . . . . . . . . 9-92 BATTERY . . . . . . . . 8A-1,8A-21,8A-23,8A-24,8A-5
ADJUSTMENT, HEADLAMP . . . . . . . . . . . . . . 8L-6 ASSEMBLY, FINAL . . . . . . . . . . . . . . . . . 3-47,3-85 BATTERY CABLES . . . . . . . . . . . 8A-14,8A-18,8A-3
ADJUSTMENT, PRELIMINARY ASSEMBLY, INSTRUMENT PANEL . . . . . . . . 8E-26 BATTERY CHARGING . . . . . . . . . . . . . . . . . . 8A-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-241 ASSEMBLY (SHORT BLOCK), SERVICE BATTERY HOLD DOWNS . . . . . . . . . . . 8A-20,8A-4
ADJUSTMENT, REAR BAND . . . . . . . . . . . . 21-200 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 9-27,9-88 BATTERY REPLACEMENT, REMOTE
ADJUSTMENT, SHIFT LINKAGE . . . 21-372,21-405 ASSEMBLY, TUBE AXLE . . . . . . . . . . . . . . . . . 3-23 KEYLESS ENTRY TRANSMITTER . . . . . . . . . 8P-6
ADJUSTMENT, TRANSMISSION ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . 23-52 BATTERY TEMPERATURE SENSOR . . . . 8C-2,8C-5
THROTTLE VALVE CABLE . . . . . . . 21-198,21-337 AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . 8F-1,8F-2 BATTERY THERMOGUARD . . . . . . . . . 8A-22,8A-5
AERATION, COOLANT—LOW LEVEL . . . . . . . 7-21 AUDIO SYSTEM, 8W-47 . . . . . . . . . . . . . . . . 8W-1 BATTERY TRAY . . . . . . . . . . . . . . . . . . 8A-22,8A-5
AFTER OVERHAUL OR FLUID/FILTER AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . 8F-12 BATTERY VOLTAGE—PCM INPUT . . . . . . . . 14-29
CHANGE, REFILLING . . . . . . . . . . . . . . . . . 21-248 AUGAT CONNECTORS, TERMINAL/ BEARING AND AXLE SHAFT, HUB . . . . . . . . . 3-30
AFTERMARKET PAINT REPAIR CONNECTOR REPAIR- . . . . . . . . . . . . . . . . 8W-11 BEARING, AXLE SEAL . . . . . . . . . . . . . . . . . 3-112
PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5 AUTO SHUTDOWN (ASD) RELAY—PCM BEARING, AXLE SHAFT SEAL . . . . . . . . . . . . 3-77
AIR CLEANER ELEMENT (FILTER) . . . . . . . . 14-49 OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34 BEARING, CLUTCH RELEASE . . . . . . . . . . . . . 6-3
AIR CONDITIONER CONTROL, HEATER . . . . . 24-6 AUTOMATIC SHUTDOWN (ASD) RELAY . . . 14-43 BEARING, HUB . . . . . . . . . . . . . . . . . . . . . . . 2-12
AIR CONDITIONER, HEATER . . . . . . . . . . . . . 24-5 AUTOMATIC SHUTDOWN (ASD) RELAY BEARING NOISE . . . . . . . . . . . . . 3-109,3-21,3-70
AIR CONDITIONING-HEATER, 8W-42 . . . . . . 8W-1 SENSE—PCM INPUT . . . . . . . . . . . . . . . . . . 14-29 BEARING, OUTPUT SHAFT REAR . . . . . . . 21-153
AIR CONTROL (IAC) MOTOR, IDLE . . . . . . . 14-45 AUTOMATIC TRANSMISSION, 30RH . . . . 21-212, BEARING, PILOT . . . . . . . . . . . . . . . . . . . . . . 6-12
AIR CONTROL (IAC) MOTOR—PCM 21-89 BEARING PRELOAD AND GEAR
OUTPUT, IDLE . . . . . . . . . . . . . . . . . . . . . . . 14-35 AUTOMATIC TRANSMISSION, AW-4 . . . . . 21-338 BACKLASH, 181 FBI DIFFERENTIAL . . . . . . . 3-52
AIR EXHAUST GRILLE . . . . . . . . . . . . . . . . . 23-50 AUTOMATIC TRANSMISSION, AW–4 . . . . . 21-218 BEARING PRELOAD AND GEAR
AIR FLOW CHECK PROCEDURE, AUTOMATIC TRANSMISSION, AW–4 BACKLASH, 186 FBI DIFFERENTIAL . . . . . . . 3-56
THROTTLE BODY MINIMUM . . . . . . . . . . . . 14-42 AUTOMATIC TRANSMISSIONAW–4 . . . . . . 21-217 BEARING PRELOAD AND GEAR
AIR TEMPERATURE SENSOR, INTAKE AUTOMATIC TRANSMISSION DIAGNOSIS . 21-126 BACKLASH, DIFFERENTIAL . . . . . . . . . 3-127,3-94
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50 AUTOMATIC TRANSMISSION OIL BEARING, RELEASE . . . . . . . . . . . . . . . . . . . . 6-12
AIR TEMPERATURE SENSOR—PCM COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 BEARING RETAINER, ADAPTER/
INPUT, INTAKE MANIFOLD . . . . . . . . . . . . . 14-32 AUTOMATIC TRANSMISSIONAW–4 EXTENSION HOUSING AND FRONT . . . . . . . . 21-8
AIR TESTING TRANSMISSION CLUTCH AUTOMATIC TRANSMISSION, AW–4 . . . . . 21-217 BEARING RETAINER SEAL, FRONT . . . . . . . . 21-6
AND BAND OPERATION . . . . . . . . . . . . . . . 21-131 AUTOMATIC TRANSMISSION— BEARINGS, CAMSHAFT . . . . . . . . . . . . 9-104,9-47
AIRBAG CONTROL MODULE . . . . . . . 8M-12,8M-3 30RHAUTOMATIC TRANSMISSION— BEARINGS, CRANKSHAFT MAIN . . . . . 9-105,9-47
AIRBAG DOOR, PASSENGER SIDE . . . . . . . 8M-11 30RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-88 BEARINGS, DIFFERENTIAL SIDE . 3-115,3-36,3-80
AIRBAG MODULE, DRIVER SIDE . . . . 8M-2,8M-6 AW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-344 BEARINGS, FITTING CONNECTING ROD . . . . 9-80
AIRBAG MODULE, PASSENGER SIDE . 8M-3,8M-9 AW-4 AUTOMATIC TRANSMISSION . . . . . . 21-338 BEARINGS, FITTING CRANKSHAFT MAIN . . 9-23,
AIRBAG MODULE TRIM COVER, DRIVER AW–4 AUTOMATIC TRANSMISSION . . . . . 21-218 9-83
SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7 AW–4 AUTOMATIC TRANSMISSIONAW–4 BEARINGS—FITTING, CONNECTING ROD . . . 9-21
AIRBAG SYSTEM . . . . . . . . . . . . 8M-1,8M-4,8M-5 AUTOMATIC TRANSMISSION . . . . . . . . . . 21-217 BELT DIAGNOSIS, ACCESSORY DRIVE . . . . . . 7-9
AIRBAG SYSTEM, 8W-43 . . . . . . . . . . . . . . . 8W-1 AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-40 BELT SWITCH, DRIVER SEAT . . . . . . . . . . . . 8U-2
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 2-1,2-6 AX5 MANUAL TRANSMISSION . . . . . . . . . . . 21-1 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . 7-40
ALIGNMENT, HEADLAMP . . . . . . . . . . . 8L-6,8L-9 AX5 MANUAL TRANSMISSION BELT WEATHERSTRIP, FRONT DOOR
ALIGNMENT SCREEN PREPARATION, COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 21-37 INNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-6 AXLE, 181 AND 186 FBI . . . . . . . . . . . . . . . . 3-61 BELT WEATHERSTRIP, FRONT DOOR
ALIGNMENT, VEHICLE PREPARATION AXLE, 181 FBI . . . . . . . . . . . . . . . . . . . . 3-16,3-61 OUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
FOR HEADLAMP . . . . . . . . . . . . . . . . . . . . . . 8L-6 AXLE, 186 FBI . . . . . . . . . . . . . . . . . . . . 3-17,3-61 BELT WEATHERSTRIP, REAR DOOR
ALIGNMENT, WHEEL . . . . . . . . . . . . . . . . . 2-1,2-4 AXLE, 194 RBI . . . . . . . . . . . . . . . . . . . 3-65,3-99 INNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
ALUMINUM THREAD REPAIR . . . . 21-144,21-249 AXLE, 8 1/4 . . . . . . . . . . . . . . . . . . . . 3-103,3-125 BELT WEATHERSTRIP, REAR DOOR
AMBIENT TEMPERATURE SENSOR . . . . . . . . 8V-8 AXLE, 8 1/4 INCH . . . . . . . . . . . . . . . . . . . . 3-131 OUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
AMPERAGE TEST, FUEL PUMP . . . . . . . . . . . 14-8 AXLE, 8 1/4 REAR . . . . . . . . . . . . . . . . . . . . 3-103 BELT/BUCKLE, FRONT SHOULDER . . . . . . . 23-55
2 INDEX XJ
Description Group-Page Description Group-Page Description Group-Page
BELT/BUCKLE, REAR SHOULDER/LAP . . . . . 23-57 BRAKE SHOES, DRUM . . . . . . . . . . . . . . . . . 5-21 CABLE, TRANSMISSION THROTTLE . . . . . 21-267
BELTS, ENGINE ACCESSORY DRIVE . . . . . . . 7-35 BRAKE SHOES, FRONT DISC . . . . . . . . . . . . . 5-20 CABLES, BATTERY . . . . . . . . . . 8A-14,8A-18,8A-3
BETTS CONNECTORS, TERMINAL/ BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . 5-22 CABLES, REAR PARKING BRAKE . . . . . . . . . 5-23
CONNECTOR REPAIR—THOMAS . . . . . . . . 8W-10 BRAKE SWITCH—PCM INPUT . . . . . . . . . . 14-29 CABLES, SPARK PLUG . . . . . . . . . . . . 8D-10,8D-7
BEZEL, CLUSTER . . . . . . . . . . . . . . . . . . . . . 8E-16 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 5-2 CABLES-2.5L ENGINE, SPARK PLUG . . . . . . 8D-2
BEZEL, INSTRUMENT PANEL BRAKE SYSTEM, ANTILOCK . . . . . . . . . . . . . 5-33 CALIBRATION, COMPASS . . . . . . . . . . . . . . . 8V-5
ACCESSORY SWITCH . . . . . . . . . . . . . . . . . 8E-15 BRAKE SYSTEM, BASE . . . . . . . . . . . . . . . 5-1,5-7 CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
BEZEL, INSTRUMENT PANEL CENTER . . . . 8E-14 BRAKE SYSTEM, BLEEDING ABS . . . . . . . . . 5-36 CALIPER, DISC BRAKE . . . . . . . . . . . . . . . . . 5-25
BIN DOOR, GARAGE DOOR OPENER BRAKE TRANSMISSION SHIFT CALIPER, FRONT DISC BRAKE . . . . . . . . . . . 5-18
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8 INTERLOCK . . . . . . . . . . . . . . . . . . 21-150,21-256 CAM, TURN SIGNAL CANCELLING . . . . . . . . 8J-3
BIN, GARAGE DOOR OPENER STORAGE . . . 8V-3 BRAKE TRANSMISSION SHIFT CAMSHAFT . . . . . . . . . . . . . . 9-103,9-44,9-6,9-66
BIN, SUNGLASSES STORAGE . . . . . . . . 8V-3,8V-8 INTERLOCK CABLE ADJUSTMENT . . . . . . 21-198, CAMSHAFT BEARINGS . . . . . . . . . . . . 9-104,9-47
BLADE, FAN . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 21-336 CAMSHAFT PIN REPLACEMENT . . . . . . . . . . 9-45
BLADE, WIPER . . . . . . . . . . . . . . . . . . . . . . . 8K-8 BRAKE TRANSMISSION SHIFT CAMSHAFT POSITION SENSOR-2.5L
BLADE, WIPER ARM . . . . . . . . . . . . . . . . . . . 8K-2 INTERLOCK MECHANISM . . . . . . . 21-125,21-238 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-4
BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . 5-36 BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . 5-14 CAMSHAFT POSITION SENSOR—2.5L
BLEEDING, BASE BRAKE . . . . . . . . . . . . . . . . 5-13 BRAKE WARNING LAMP, RED . . . . . . . . . 5-3,5-9 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-14
BLEEDING, MASTER CYLINDER . . . . . . . . . . 5-12 BRAKES, 8W-35 ANTI-LOCK . . . . . . . . . . . . 8W-1 CAMSHAFT POSITION SENSOR—4.0L
BLEND-AIR DOOR MOTOR . . . . . . . . . . . . . 24-26 BRAKES, ANTILOCK . . . . . . . . . . . . . . . 5-33,5-36 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 8D-15,8D-5
BLOCK, 8W-12 JUNCTION . . . . . . . . . . . . . . 8W-1 BRAKES, BASE . . . . . . . . . . . . . . . . . . . . . . . 5-32 CANCELLING CAM, TURN SIGNAL . . . . . . . . 8J-3
BLOCK, CYLINDER . . . 9-112,9-114,9-5,9-53,9-54, BRAKES, CONTROLLER ANTILOCK . . . . . . . . 5-33 CANISTER, EVAP . . . . . . . . . . . . . . . . 25-24,25-27
9-65 BRAKES, FRONT DISC . . . . . . . . . . . . . . . . . . . 5-4 CANISTER PURGE SOLENOID, DUTY
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . 7-35,7-4 BRAKES, HYDRAULIC CONTROL CYCLE EVAP . . . . . . . . . . . . . . . . . . . 25-24,25-27
BLOCK, JUNCTION . . . . . . . . . . . . . . . . 8O-3,8O-6 UNIT/CONTROLLER ANTILOCK . . . . . . . . . . . 5-36 CAP, FRONT BUMPER END . . . . . . . . . . . . . . 13-2
BLOCKER, KNEE . . . . . . . . . . . . . . . . . . . . . 8E-14 BREAKER, CIRCUIT; POWER SEAT CAP, FUEL TANK FILLER TUBE . . . . . . 14-21,14-6
BLOCKS—TWO-DOOR VEHICLES, FRONT SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-2 CAP, INSTRUMENT PANEL END . . . . . . . . . 8E-25
DOOR SPACER . . . . . . . . . . . . . . . . . . . . . . 23-41 BREAKER, CIRCUIT; POWER WINDOW CAP, RADIATOR PRESSURE . . . . . . . . . . 7-39,7-5
BLOWER MOTOR . . . . . . . . . . . . . 24-12,24-2,24-26 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 8S-2,8S-3 CAP, REAR BUMPER END . . . . . . . . . . . . . . . 13-4
BLOWER MOTOR RELAY . . . . . . 24-13,24-2,24-27 BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 23-15 CAP-2.5L ENGINE, DISTRIBUTOR . . . . . . . . . 8D-6
BLOWER MOTOR RESISTOR . . 24-14,24-27,24-3 BUCKET SEAT CUSHION COVER . . . . . . . . . 23-17 CAPACITIES, FLUID . . . . . . . . . . . . . . . . . . . . . 0-3
BLOWER MOTOR SWITCH . . . . . . . . . 24-14,24-3 BUCKET SEAT PLATFORM . . . . . . . . . . . . . . 23-15 CAPACITY, FUEL TANK . . . . . . . . . . . . . . . . 14-23
BODY COMPONENT SERVICE . . . . . . . . . . . 23-21 BUCKET SEAT RECLINER . . . . . . . . . . . . . . 23-17 CAPACITY TEST, FUEL PUMP . . . . . . . . . . . . 14-7
BODY COMPONENTS . . . . . . . . . . . . . . . . . . . 23-1 BUCKET SEAT TRACK . . . . . . . . . . . . . . . . . 23-15 CAP—PRESSURE TESTING, RADIATOR . . . . 7-20
BODY COMPONENTS, TRANSMISSION BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . 23-16 CAP-TO-FILLER NECK SEAL—PRESSURE
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-228 BUCKET SEATBACK COVER . . . . . . . . . . . . . 23-16 RELIEF CHECK, RADIATOR . . . . . . . . . . . . . . 7-20
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . 23-29 BUFFING, AND POLISHING, FINESSE CARDAN JOINT, DOUBLE . . . . . . . . . . . . . . . 3-11
BODY GAP AND FLUSH SANDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4 CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . 3-47
MEASUREMENTS . . . . . . . . . . . . . . . . . . . 23-127 BULB APPLICATION . . . . . . . . . . . . . . . . . . . 8L-20 CARDAN UNIVERSAL JOINT, SINGLE . . . . . . . 3-9
BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . 23-67 BULB, BACK-UP/BRAKE/REAR TURN CARGO LAMP . . . . . . . . . . . . . . . . . . . . . . . 8L-17
BODY LUBRICATION . . . . . . . . . . . . . . . . . . 23-23 SIGNAL/TAIL LAMP . . . . . . . . . . . . . . . . . . . 8L-11 CARGO LAMP BULB . . . . . . . . . . . . . . . . . . 8L-13
BODY MINIMUM AIR FLOW CHECK BULB, CARGO LAMP . . . . . . . . . . . . . . . . . . 8L-13 CARPET/MAT, FRONT . . . . . . . . . . . . . . . . . 23-58
PROCEDURE, THROTTLE . . . . . . . . . . . . . . . 14-42 BULB, CENTER HIGH MOUNTED STOP CARPET/MAT, REAR . . . . . . . . . . . . . . . . . . 23-58
BODY OPENING DIMENSIONS . . . . . . . . . . 23-128 LAMP (CHMSL) . . . . . . . . . . . . . . . . . . . . . . 8L-12 CASE COVER OIL SEAL, TIMING . . . . . 9-112,9-41
BODY SEALING LOCATIONS . . . . . . . . . . . 23-112 BULB, FOG LAMP . . . . . . . . . . . . . . . . . . . . 8L-10 CASE COVER, TIMING . . . . . . . . . . . . . 9-101,9-42
BODY SIDE MOLDING . . . . . . . . . . . . . . . . . 23-48 BULB, FRONT PARK/TURN SIGNAL CASE, NV231 TRANSFER . 21-346,21-351,21-369
BODY SOLENOIDS, TRANSMISSION LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11 CASE, NV231 TRANSFER CASENV231
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-258 BULB, HEADLAMP . . . . . . . . . . . . . . . . . . . . 8L-10 TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-346
BODY, THROTTLE . . . . . . . . . . . . . . . 14-36,14-44 BULB, LICENSE PLATE LAMP . . . . . . . . . . . 8L-12 CASE, NV242 TRANSFER . 21-375,21-380,21-402
BODY, TRANSMISSION VALVE . . . 21-259,21-333 BULB, MAP READING LAMP . . . . . . . . . . . . 8L-13 CASE, NV242 TRANSFER CASENV242
BODY, VALVE . . . . 21-102,21-151,21-156,21-191, BULB, READING AND COURTESY LAMP . . . 8V-8 TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-375
21-200 BULB SERVICE, LAMP . . . . . . . . . . . . . . . . . 8L-10 CASE SKID PLATE, TRANSFER . . . . . . . . . . . 13-6
BOOSTER, MASTER CYLINDER/POWER . . . . 5-10 BULB, SIDE MARKER LAMP . . . . . . . . . . . . 8L-11 CASE, TRANSFER . . . . . . . . . . . . . 21-348,21-377
BOOSTER, POWER BRAKE . . . . . . . . . . . 5-17,5-3 BULB, UNDERHOOD LAMP . . . . . . . . . . . . . 8L-12 CASENV231 TRANSFER CASE, NV231
BORES, HONING CYLINDER . . . . . . . . . 9-26,9-87 BULB, VISOR VANITY LAMP . . . . . . . . . . . . 8L-13 TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-346
BOX COMPONENTS, GLOVE . . . . . . . . . . . . 8E-23 BUMPER, COIL SPRING/JOUNCE . . . . . . . . . . 2-9 CASENV242 TRANSFER CASE, NV242
BOX, GLOVE . . . . . . . . . . . . . . . . . . . . . . . . 8E-22 BUMPER END CAP, FRONT . . . . . . . . . . . . . . 13-2 TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-375
BOX LATCH STRIKER, GLOVE . . . . . . . . . . . 8E-24 BUMPER END CAP, REAR . . . . . . . . . . . . . . . 13-4 CATALYTIC CONVERTER . . . . . . . . . . . . . . . . 11-6
B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-52 BUMPER, FRONT . . . . . . . . . . . . . . . . . . . . . . 13-3 CATALYTIC CONVERTERS . . . . . . . . . . . . . . . 11-2
BRACKET, INSTRUMENT PANEL CENTER BUMPER, JOUNCE . . . . . . . . . . . . . . . . . . . . . 2-7 CAUSES OF BURNT FLUID . . . . . . 21-126,21-240
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-26 BUMPER, REAR . . . . . . . . . . . . . . . . . . . . . . . 13-4 CAUTIONS, AND WARNINGS, NOTES . . . . . 8W-7
BRACKET, REARVIEW MIRROR SUPPORT . 23-59 BUMPER, REAR SEATBACK LATCH CAUTIONS, SERVICE WARNINGS & . . . . . . . . 5-2
BRAKE BLEEDING, BASE . . . . . . . . . . . . . . . . 5-13 STRIKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-19 CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . 14-35
BRAKE BOOSTER, POWER . . . . . . . . . . . 5-17,5-3 BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 CENTER BEZEL, INSTRUMENT PANEL . . . . 8E-14
BRAKE CABLE TENSIONER, PARKING . . . . . . 5-31 BUMPERS, FRAME . . . . . . . . . . . . . . . . . . . . 13-1 CENTER HIGH MOUNTED STOP LAMP
BRAKE CABLES, REAR PARKING . . . . . . . . . 5-23 BUMPERS, JOUNCE . . . . . . . . . . . . . . . . . . . 2-16 (CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
BRAKE CALIPER, DISC . . . . . . . . . . . . . . . . . 5-25 BURNT FLUID, CAUSES OF . . . . . . 21-126,21-240 CENTER HIGH MOUNTED STOP LAMP
BRAKE CALIPER, FRONT DISC . . . . . . . . . . . 5-18 BUS (+/-) CIRCUITS-PCM OUTPUTS, CCD . 14-35 (CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . 8L-12
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 5-32 BUSHING, EXTENSION HOUSING . . . . . . . 21-147 CENTER, POWER DISTRIBUTION . . . . 8O-2,8O-4,
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . 5-11 BUSHING, FRONT AXLE . . . . . . . . . . . . . . . . 2-11 8O-7
BRAKE DRUM MACHINING . . . . . . . . . . . . . . 5-14 BUSHING, LEAF SPRING AND SHACKLE . . . . 2-18 CENTER SUPPORT BRACKET,
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 5-31 BUSHING, REAR HOUSING YOKE . . . . . . . . 21-48 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-26
BRAKE FLUID CONTAMINATION . . . . . . . . . . 5-12 BUSHING REPLACEMENT, AXLE . . . . . . . . . . 3-33 CENTERING, CLOCKSPRING . . . . . . . . . . . . 8M-15
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . 5-12 BUSHINGS, LOWER SUSPENSION ARMS . . . . 2-8 CERTIFICATION LABEL, VEHICLE SAFETY . Intro.-2
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . 5-7 BUSHINGS, UPPER SUSPENSION ARMS . . . . 2-8 CHAIN AND SPROCKETS, TIMING . . . 9-102,9-43
BRAKE, HYDRAULIC CONTROL BUTTON MODULE, PUSH . . . . . . . . . . . . . . . 8V-7 CHANGE, LUBRICANT . . . . . . . . . 3-110,3-21,3-71
UNIT/CONTROLLER ANTILOCK . . . . . . . . . . . 5-39 CABLE ADJUSTMENT, BRAKE CHANGE, REFILLING AFTER OVERHAUL
BRAKE LAMP SWITCH; BRAKES . . 5-15,5-2,5-30, TRANSMISSION SHIFT INTERLOCK . . . . . 21-198, OR FLUID/FILTER . . . . . . . . . . . . . . . . . . . . 21-248
5-9 21-336 CHANNEL WEATHERSTRIP, FRONT DOOR
BRAKE LAMP SWITCH; SPEED CONTROL CABLE ADJUSTMENT, TRANSMISSION GLASS RUN . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3 THROTTLE VALVE . . . . . . . . . . . . . 21-198,21-337 CHANNEL WEATHERSTRIP, REAR DOOR
BRAKE LEVER, PARKING . . . . . . . . . . . . . . . 5-23 CABLE, GEARSHIFT . . . . . 21-128,21-150,21-197, GLASS RUN . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . 5-12 21-246,21-256,21-336 CHARGE, REFRIGERANT SYSTEM . . . . . . . . 24-22
BRAKE, PARKING . . . . . . . . . . . . . . . . . . . . . . 5-5 CABLE, HOOD RELEASE . . . . . . . . . . . . . . . 23-27 CHARGING, BATTERY . . . . . . . . . . . . . . . . . 8A-16
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . 5-15,5-2 CABLE RESISTANCE, SPARK PLUG . . . . . . 8D-23 CHARGING SYSTEM . . . . . . . . . . . . . . . 8C-1,8C-2
BRAKE, REAR DRUM . . . . . . . . . . . 5-29,5-30,5-5 CABLE, SERVO . . . . . . . . . . . . . . . . . . . 8H-3,8H-6 CHARGING SYSTEM, 8W-20 . . . . . . . . . . . . 8W-1
BRAKE ROTOR, DISC . . . . . . . . . . . . . . 5-11,5-21 CABLE TENSIONER, PARKING BRAKE . . . . . . 5-31 CHARGING SYSTEM, ON-BOARD
BRAKE, SECOND . . . . . . . . . . . . . . . . . . . . 21-327 CABLE, THROTTLE . . . . . . . . . . . . . . . . . . . 14-22 DIAGNOSTIC TEST . . . . . . . . . . . . . . . . . . . . 8C-3
BRAKE SERVO, SECOND COAST . . . . . . . . 21-265 CABLE, THROTTLE VALVE . . . . . . . 21-129,21-246 CHART, T0RQUE . . . . . . . . . . . . . . . . . . . . . . 5-40
XJ INDEX 3
Description Group-Page Description Group-Page Description Group-Page
CHART, TORQUE; BRAKES . . . . . . . . . . . . . . 5-32 CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . 6-9 CONNECTORS, TERMINAL/CONNECTOR
CHART, TORQUE; CHARGING SYSTEM . . . . . 8C-5 CLUTCH LINKAGE, HYDRAULIC . . . . . . . . . . . 6-4 REPAIR—THOMAS AND BETTS . . . . . . . . . 8W-10
CHART, TORQUE; EMISSION CONTROL CLUTCH MISALIGNMENT . . . . . . . . . . . . . . . . 6-6 CONSOLE, 8W-49 OVERHEAD . . . . . . . . . . . 8W-1
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-28 CLUTCH, OVERDRIVE PLANETARY GEAR . 21-301 CONSOLE, FULL FLOOR . . . . . . . . . . . . . . . 23-57
CHART, TORQUE; FUEL SYSTEM . . . . 14-24,14-51 CLUTCH, OVERRUNNING . . . . . . . . . . . . . 21-122 CONSOLE, OVERHEAD . . . . . . . . . . . . . 8V-1,8V-6
CHART, TORQUE; IGNITION SYSTEM . . . . . 8D-24 CLUTCH PRESSURE PLATE . . . . . . . . . . . . . . . 6-2 CONTACT PATTERN ANALYSIS, GEAR . . . . 3-129,
CHART, TORQUE; SPEED CONTROL CLUTCH, REAR . . . . . . . . . 21-121,21-181,21-196 3-59,3-97
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-7 CLUTCH RELAY, COMPRESSOR . . . . 24-15,24-31, CONTAMINATION, BRAKE FLUID . . . . . . . . . . 5-12
CHART, TORQUE; STEERING . 19-10,19-21,19-25, 24-4 CONTAMINATION, CLUTCH . . . . . . . . . . . . . . . 6-6
19-28 CLUTCH RELEASE BEARING . . . . . . . . . . . . . . 6-3 CONTAMINATION, FLUID . . . . . . . . 21-127,21-240
CHART, TORQUE; SUSPENSION . . . . . . 2-14,2-19 CLUTCH RELEASE OR ENGAGEMENT, CONTROL, 8W-33 VEHICLE SPEED . . . . . . . 8W-1
CHART, TORQUE; TIRES AND WHEELS . . . . 22-11 IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 CONTROL, HEATER AND AIR
CHARTS, CLUTCH DIAGNOSIS . . . . . . . . . . . . 6-7 CLUTCH, SUN GEAR AND NO. 1 CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 24-6
CHARTS, DIAGNOSIS . . . . . . . . . . . . . . . . 21-133 ONE–WAY . . . . . . . . . . . . . . . . . . . . . . . . . 21-324 CONTROL, HEATER-A/C . . . . . . . . . . . . . . . . 24-35
CHARTS, POWER STEERING SYSTEM CLUTCH SWITCH, LOW PRESSURE CONTROL (IAC) MOTOR, IDLE AIR . . . . . . . 14-45
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 CYCLING . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7 CONTROL (IAC) MOTOR—PCM OUTPUT,
CHECK, COOLANT—LEVEL . . . . . . . . . . . . . . 7-21 CLUTCH/LOW-REVERSE DRUM, IDLE AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
CHECK, COOLANT—ROUTINE LEVEL . . . . . . 7-21 OVERRUNNING . . . . . . . . . . . . . . . . . . . . . 21-175 CONTROL INFORMATION (VECI) LABEL,
CHECK, FLUID LEVEL . . . . . . . . . . . . . . . . 21-141 CLUTCH/LOW-REVERSE DRUM/ VEHICLE EMISSION . . . . . . . . . . . . . . . . . . . 25-26
CHECK, OIL PUMP VOLUME . . . . . 21-142,21-248 OVERDRIVE PISTON RETAINER, CONTROL MODULE, AIRBAG . . . . . . 8M-12,8M-3
CHECK PROCEDURE, THROTTLE BODY OVERRUNNING . . . . . . . . . . . . . . . . . . . . . 21-195 CONTROL MODULE (PCM),
MINIMUM AIR FLOW . . . . . . . . . . . . . . . . . 14-42 COAST BRAKE SERVO, SECOND . . . . . . . . 21-265 POWERTRAIN . . . . . . . . . . . . . . . . . . 14-25,14-46
CHECK, RADIATOR CAP-TO-FILLER NECK COAT FINISH, BASE COAT/CLEAR . . . . . . . . . 23-4 CONTROL MODULE (TCM) SERVICE,
SEAL—PRESSURE RELIEF . . . . . . . . . . . . . . 7-20 COAT/CLEAR COAT FINISH, BASE . . . . . . . . . 23-4 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-248
CHECK, RADIATOR COOLANT FLOW . . . . . . . 7-17 CODE DESCRIPTIONS, DIAGNOSTIC CONTROL MODULE (TCM),
CHECK VALVE SERVICE, CONVERTER TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-237
DRAINBACK . . . . . . . . . . . . . . . . . . . . . . . . 21-142 CODE, PAINT . . . . . . . . . . . . . . . . . . . . . . . . . 23-4 CONTROL MODULE, TRANSMISSION . . . . 21-260
CHECK VALVE, VACUUM . . . . . . . . . . . 24-46,24-9 CODES, DIAGNOSTIC TROUBLE . . . . . . . . . . 25-2 CONTROL SERVO, SPEED . . . . . . . . . . 8H-2,8H-5
CHECKING FLUID CONDITION . . . . . . . . . . . 21-248 COIL, COMPRESSOR CLUTCH . . . . . . . . . . . 24-15 CONTROL SOLENOID CIRCUITS, SPEED . . . 8H-2
CHECKING FLUID LEVEL . . . . . . . . . . . . . . 21-247 COIL, EVAPORATOR . . . . . . . . . . . . . . 24-35,24-4 CONTROL SWITCH, SPEED . . . . . . . . . . . . . . 8H-5
CHECKS, PRELIMINARY . . . . . . . . . . . . . . . . 7-11 COIL RESISTANCE—2.5L ENGINE, CONTROL SWITCHES, SPEED . . . . . . . . . . . . 8H-2
CHIME WARNING SYSTEM . . . . . . . . . . . . . . 8U-1 IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 CONTROL SYSTEM, 8W-31
CHIME WARNING SYSTEM SWITCHES . . . . 8U-4 COIL RESISTANCE—4.0L ENGINE, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 8W-1
CIGAR LIGHTER, INSTRUMENT PANEL . . . 8E-11, IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 CONTROL SYSTEM, EVAPORATION . . . . . . . 25-23
8E-3 COIL SPRING/JOUNCE BUMPER . . . . . . . . . . . 2-9 CONTROL SYSTEM, SPEED . . . . . . . . . . . . . 8H-1
CIGAR LIGHTER RELAY . . . . . . 8E-12,8E-16,8E-4 COIL SPRINGS AND ISOLATORS . . . . . . 2-16,2-8 CONTROL UNIT, HYDRAULIC . . . . . . . . . . . . 5-34
CIRCUIT ACTUATION TEST MODE . . . . . . . . . 25-2 COIL-2.5L ENGINE, IGNITION . . . . . . . . . . . . 8D-3 CONTROL UNIT/CONTROLLER ANTILOCK
CIRCUIT BREAKER; POWER SEAT COIL—2.5L ENGINE, IGNITION . . . . . . . . . . 8D-12 BRAKE, HYDRAULIC . . . . . . . . . . . . . . . . . . . 5-39
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-2 COIL—4.0L ENGINE, IGNITION . . . . . 8D-12,8D-3 CONTROL UNIT/CONTROLLER ANTILOCK
CIRCUIT BREAKER; POWER WINDOW COLLAPSIBLE SPACER . . . . . . . . . . . . . 3-27,3-74 BRAKES, HYDRAULIC . . . . . . . . . . . . . . . . . . 5-36
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 8S-2,8S-3 COLUMN OPENING COVER, STEERING . . . . 8E-13 CONTROLLER ANTILOCK BRAKES . . . . . . . . 5-33
CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . . . 8W-4 COLUMN, STEERING . . . . . . . . . . . . . . . . . . 19-26 CONTROLS, EVAPORATIVE EMISSION . . . . 25-23
CIRCUIT INFORMATION . . . . . . . . . . . . . . . . 8W-4 COMBINATION FLASHER . . . . . . . . . . . . 8J-3,8J-5 CONVERTER, CATALYTIC . . . . . . . . . . . . . . . . 11-6
CIRCUIT SENSE—PCM INPUT, IGNITION . . 14-31 COMBINATION VALVE . . . . . . . 5-11,5-16,5-3,5-35 CONVERTER DRAINBACK CHECK VALVE
CIRCUITS, NON-MONITORED . . . . . . . . . . . 25-22 COMBUSTION PRESSURE LEAKAGE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-142
CIRCUITS, SPEED CONTROL SOLENOID . . . 8H-2 TEST, CYLINDER . . . . . . . . . . . . . . . . . . 9-13,9-73 CONVERTER DRAINBACK VALVE . . . . . . . . 21-125
CIRCUITS-PCM OUTPUTS, CCD BUS (+/-) . 14-35 COMPASS . . . . . . . . . . . . . . . . . . . . . . . 8V-2,8V-9 CONVERTER HOUSING FLUID LEAK
CLAMPS, FUEL TUBES/LINES/HOSES . . . . . . 14-6 COMPASS, AND THERMOMETER DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 21-132
CLAMPS, HOSE . . . . . . . . . . . . . . . . . . . . . . . . 7-6 DISPLAY MODULE, TRIP COMPUTER . . 8V-3,8V-7 CONVERTER STATOR CLUTCH
CLASSIFICATION OF LUBRICANTS . . . . . . . . . 0-1 COMPASS CALIBRATION . . . . . . . . . . . . . . . . 8V-5 INSPECTION, TORQUE . . . . . . . . . . . . . . . . 21-247
CLEANER ELEMENT (FILTER), AIR . . . . . . . 14-49 COMPASS DEMAGNETIZING . . . . . . . . . . . . . 8V-6 CONVERTER, TORQUE . . . 21-146,21-222,21-252,
CLEANING AND INSPECTION, COMPASS VARIATION ADJUSTMENT . . . . . . 8V-4 21-97
TRANSMISSION PARTS . . . . . . . . . . . . . . . 21-336 COMPRESSION PRESSURE TEST, CONVERTER, TRANSMISSION AND
CLEANING TIRES . . . . . . . . . . . . . . . . . . . . . . 22-6 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-250
CLEARANCE, SIDE GEAR . . . . . . . . . . . . . . . 3-129 COMPRESSOR . . . . . . . . . . . . . . 24-14,24-28,24-3 CONVERTERS, CATALYTIC . . . . . . . . . . . . . . . 11-2
CLOCKSPRING . . . . . . . . . . . . . . . . . 8M-13,8M-4 COMPRESSOR CLUTCH . . . . . . . . . . . 24-29,24-3 COOLANT FLOW CHECK, RADIATOR . . . . . . . 7-17
CLOCKSPRING CENTERING . . . . . . . . . . . . 8M-15 COMPRESSOR CLUTCH COIL . . . . . . . . . . . 24-15 COOLANT RESERVE TANK . . . . . . . . . . . . . . . 7-23
CLUSTER, 8W-40 INSTRUMENT . . . . . . . . . 8W-1 COMPRESSOR CLUTCH RELAY . 24-15,24-31,24-4 COOLANT RESERVE/OVERFLOW SYSTEM . . . 7-2
CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . 8E-16 COMPUTER, COMPASS, AND COOLANT TEMPERATURE SENSOR,
CLUSTER COMPONENTS, INSTRUMENT . . . 8E-19 THERMOMETER DISPLAY MODULE, ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
CLUSTER, INSTRUMENT; CHIME/BUZZER TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-3,8V-7 COOLANT TEMPERATURE SENSOR—
WARNING SYSTEMS . . . . . . . . . . . . . . 8U-1,8U-3 COMPUTER, TRIP . . . . . . . . . . . . . . . . . . . . . 8V-1 PCM INPUT, ENGINE . . . . . . . . . . . . . . . . . . 14-30
CLUSTER, INSTRUMENT; ELECTRICALLY CONDENSER . . . . . . . . . . . . . . . . . . . . 24-32,24-4 COOLANT—ADDING ADDITIONAL . . . . . . . . . 7-21
HEATED SYSTEMS . . . . . . . . . . . . . . . . 8N-2,8N-5 CONDITION, CHECKING FLUID . . . . . . . . . 21-248 COOLANT—LEVEL CHECK . . . . . . . . . . . . . . . 7-21
CLUSTER, INSTRUMENT; INSTRUMENT CONDITIONER CONTROL, HEATER AND COOLANT—LOW LEVEL AERATION . . . . . . . 7-21
PANEL SYSTEMS . . . . . . . . . . . . 8E-18,8E-2,8E-5 AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-6 COOLANT—ROUTINE LEVEL CHECK . . . . . . . 7-21
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CONDITIONER, HEATER AND AIR . . . . . . . . . 24-5 COOLER, AUTOMATIC TRANSMISSION
CLUTCH AND BAND OPERATION, AIR CONDITIONING-HEATER, 8W-42 AIR . . . . . . 8W-1 OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
TESTING TRANSMISSION . . . . . . . . . . . . . 21-131 CONDITIONS, SPARK PLUG . . . . . . . . . . . . . 8D-8 COOLER, FLOW TESTING
CLUTCH COIL, COMPRESSOR . . . . . . . . . . . 24-15 CONNECTING ROD BEARINGS, FITTING . . . . 9-80 TRANSMISSION MAIN . . . . . . . . . . . . . . . . 21-246
CLUTCH COMPONENT LUBRICATION . . . . . . . 6-9 CONNECTING ROD BEARINGS—FITTING . . . 9-21 COOLER, TRANSMISSION . . . . . . . . . . . . . 21-237
CLUTCH, COMPRESSOR . . . . . . . . . . . 24-29,24-3 CONNECTING ROD, PISTON . . . . . . 9-51,9-6,9-66 COOLERS AND TUBES, FLUSHING . . . . . . 21-143,
CLUTCH CONTAMINATION . . . . . . . . . . . . . . . 6-6 CONNECTING RODS, PISTONS . . . . . . . . . . 9-108 21-248
CLUTCH COVER AND DISC . . . . . . . . . . . . . . 6-11 CONNECTIONS, INTERMITTENT AND COOLERS, TRANSMISSION OIL . . . . . . . . . . 7-23
CLUTCH COVER AND DISC RUNOUT . . . . . . . 6-7 POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-8 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
CLUTCH DIAGNOSIS CHARTS . . . . . . . . . . . . . 6-7 CONNECTOR AND TERMINAL COOLING FAN, ELECTRIC . . . . . . . . . . . . 7-19,7-8
CLUTCH DIAGNOSTIC INFORMATION . . . . . . . 6-4 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 8W-12 COOLING FAN—2.5L, ELECTRIC . . . . . . . . . . 7-33
CLUTCH, DIRECT . . . . . . . . . . . . . . . . . . . . 21-312 CONNECTOR INFORMATION . . . . . . . . . . . . 8W-7 COOLING FAN—4.0L, ELECTRIC . . . . . . . . . . 7-34
CLUTCH DISC . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 CONNECTOR LOCATIONS, 8W-90 . . . . . . . . 8W-1 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-1
CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . 6-10 CONNECTOR PIN-OUTS, 8W-80 . . . . . . . . . . 8W-1 COOLING SYSTEM FANS . . . . . . . . . . . . . 7-3,7-38
CLUTCH FLYWHEEL RUNOUT . . . . . . . . . . . . . 6-6 CONNECTOR REPLACEMENT . . . . . . . . . . . 8W-12 COOLING SYSTEM HOSES . . . . . . . . . . . . . . 7-40
CLUTCH, FORWARD . . . . . . . . . . . . . . . . . 21-317 CONNECTOR/GROUND LOCATIONS . . . . . . . 8W-1 COOLING SYSTEM—DRAINING AND
CLUTCH, FRONT . . . . . . . . 21-120,21-180,21-196 CONNECTOR—PCM INPUT AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . 6-13 OUTPUT, DATA LINK . . . . . . . . . . . . . . . . . . 14-35 COOLING SYSTEM—REVERSE
CLUTCH HOUSING MISALIGNMENT . . . . . . . . 6-6 CONNECTORS, TERMINAL/CONNECTOR FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . 6-13 REPAIR- AUGAT . . . . . . . . . . . . . . . . . . . . . 8W-11 COOLING SYSTEM—TESTING FOR
CLUTCH INSPECTION, TORQUE CONNECTORS, TERMINAL/CONNECTOR LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
CONVERTER STATOR . . . . . . . . . . . . . . . . 21-247 REPAIR-MOLEX . . . . . . . . . . . . . . . . . . . . . 8W-10 CORE, HEATER . . . . . . . . . . . . . . . . . . 24-41,24-6
4 INDEX XJ
Description Group-Page Description Group-Page Description Group-Page
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . 21-30 DEFOGGER RELAY . . . . . . . . . . . . 8N-3,8N-4,8N-7 DISTANCE SENSOR—PCM INPUT,
COUPLER, REFRIGERANT LINE . . . . . . . . . . 24-45 DEFOGGER SWITCH . . . . . . . . . . . 8N-2,8N-4,8N-6 VEHICLE SPEED . . . . . . . . . . . . . . . . . . . . . 14-34
COUPLERS, REFRIGERANT LINE . . . . . . . . . . 24-8 DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . 8N-3 DISTRIBUTION, 8W-10 POWER . . . . . . . . . . 8W-1
COURTESY LAMP BULB, READING . . . . . . . . 8V-8 DEFOGGER SYSTEM, REAR WINDOW . . . . . 8N-1 DISTRIBUTION, 8W-15 GROUND . . . . . . . . . 8W-1
COURTESY LAMP, READING . . . . . . . . . . . . . 8V-2 DELAY MODULE, SENTINEL HEADLAMP . . . 8L-19 DISTRIBUTION CENTER, POWER . . . . 8O-2,8O-4,
COVER AND DISC, CLUTCH . . . . . . . . . . . . . 6-11 DELIVERY SYSTEM, FUEL . . . . . . . . . . . . . . . 14-1 8O-7
COVER AND DISC RUNOUT, CLUTCH . . . . . . . 6-7 DEMAGNETIZING, COMPASS . . . . . . . . . . . . 8V-6 DISTRIBUTION SYSTEM, POWER . . . . . . . . . 8O-1
COVER, BUCKET SEAT CUSHION . . . . . . . . 23-17 DEPTH, 181 FBI PINION GEAR . . . . . . . . . . . 3-48 DISTRIBUTION SYSTEMS, POWER . . . . . . . 8O-10
COVER, BUCKET SEATBACK . . . . . . . . . . . . 23-16 DEPTH, 186 FBI PINION GEAR . . . . . . . . . . . 3-50 DISTRIBUTOR CAP-2.5L ENGINE . . . . . . . . . 8D-6
COVER, CYLINDER HEAD . . . 9-113,9-35,9-67,9-7, DEPTH, 8 1/4 AXLE PINION GEAR . . . . . . . 3-126 DISTRIBUTOR ROTOR-2.5L ENGINE . . . . . . . 8D-6
9-96 DEPTH, PINION GEAR . . . . . . . . . . . . . . . . . . 3-91 DISTRIBUTOR-2.5L ENGINE . . . . . . . . . . . . . 8D-2
COVER, DRIVER SIDE AIRBAG MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 DISTRIBUTOR—2.5L ENGINE . . . . . . . . . . . 8D-17
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7 DESCRIPTION AND OPERATION; BODY . . . . 23-1 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-65
COVER, HEAD RESTRAINT . . . . . . . . . . . . . 23-14 DESCRIPTION AND OPERATION; FRAME DOOR, FRONT . . . . . . . . . . . . . . . . . . . . . . . 23-35
COVER, INSTRUMENT PANEL TOP . . . . . . . 8E-21 AND BUMPERS . . . . . . . . . . . . . . . . . . . . . . . 13-1 DOOR, GARAGE DOOR OPENER
COVER, KICK . . . . . . . . . . . . . . . . . . . . . . . . 24-42 DESCRIPTIONS, DIAGNOSTIC TROUBLE STORAGE BIN . . . . . . . . . . . . . . . . . . . . . . . . 8V-8
COVER OIL SEAL, TIMING CASE . . . . . 9-112,9-41 CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3 DOOR GLASS EXTERIOR MOLDING,
COVER, QUARTER PANEL TRIM AND DETECTION PUMP (LDP), LEAK . . . . 25-24,25-27, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . . 23-54 25-28 DOOR GLASS EXTERIOR MOLDING,
COVER, REAR SEAT CUSHION . . . . . . . . . . 23-19 DEVICES, ELECTROSTATIC DISCHARGE REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
COVER, REAR SEATBACK . . . . . . . . . . . . . . 23-20 (ESD) SENSITIVE . . . . . . . . . . . . . . . . . . . . . 8W-8 DOOR GLASS, FRONT . . . . . . . . . . . . . . . . . 23-41
COVER, STEERING COLUMN OPENING . . . . 8E-13 DIAGNOSIS, ACCESSORY DRIVE BELT . . . . . . 7-9 DOOR GLASS RUN CHANNEL
COVER, TIMING CASE . . . . . . . . . . . . . 9-101,9-42 DIAGNOSIS, AUTOMATIC WEATHERSTRIP, FRONT . . . . . . . . . . . . . . . 23-38
COWL GRILLE . . . . . . . . . . . . . . . . . . . . . . . 23-28 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-126 DOOR GLASS RUN CHANNEL
COWL TRIM, LOWER A-PILLAR . . . . . . . . . 23-51 DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . 21-133 WEATHERSTRIP, REAR . . . . . . . . . . . . . . . . 23-46
COWL WEATHERSTRIP . . . . . . . . . . . . . . . . 23-28 DIAGNOSIS CHARTS, CLUTCH . . . . . . . . . . . . 6-7 DOOR, HEATER-A/C HOUSING . . . . . . . . . . 24-39
C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . 23-53 DIAGNOSIS CHARTS, POWER STEERING DOOR HINGE, FRONT . . . . . . . . . . . . . . . . . 23-35
CRANKCASE VENTILATION SYSTEM . 25-25,25-27 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 DOOR HINGE, REAR . . . . . . . . . . . . . . . . . . 23-43
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . 9-5,9-65 DIAGNOSIS, CONVERTER HOUSING DOOR INNER BELT WEATHERSTRIP,
CRANKSHAFT MAIN BEARINGS . . . . . 9-105,9-47 FLUID LEAK . . . . . . . . . . . . . . . . . . . . . . . . 21-132 FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
CRANKSHAFT MAIN BEARINGS, FITTING . . 9-23, DIAGNOSIS, ENGINE CYLINDER HEAD DOOR INNER BELT WEATHERSTRIP,
9-83 GASKET FAILURE . . . . . . . . . . . . . . . . . 9-13,9-73 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
CRANKSHAFT OIL SEALS—REAR . . . . . . . . 9-110 DIAGNOSIS INFORMATION, GENERAL . . . 21-239 DOOR INSIDE HANDLE ACTUATOR,
CRANKSHAFT POSITION (CKP) SENSOR . . 8D-13 DIAGNOSIS, INTAKE MANIFOLD FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
CRANKSHAFT POSITION SENSOR . . . . . . . . 8D-4 LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-72 DOOR INSIDE HANDLE ACTUATOR,
CUSHION COVER, BUCKET SEAT . . . . . . . . 23-17 DIAGNOSIS, LAMP . . . . . . . . . . . . . . . . . . . . 8L-3 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
CUSHION COVER, REAR SEAT . . . . . . . . . . 23-19 DIAGNOSIS, NV231 . . . . . . . . . . . . . . . . . . 21-347 DOOR JAMB SWITCH, DRIVER . . . . . . . . . . . 8U-2
CUSHION, REAR SEAT . . . . . . . . . . . . . . . . . 23-17 DIAGNOSIS, NV242 . . . . . . . . . . . . . . . . . . 21-376 DOOR LATCH ADJUSTMENT . . . . . . . . . . . . 23-66
CUT-OFF SWITCH, DUAL FUNCTION DIAGNOSIS, PRELIMINARY . . . . . . . . . . . . 21-128 DOOR LATCH, FRONT . . . . . . . . . . . . . . . . . 23-37
HIGH PRESSURE SWITCH/HIGH DIAGNOSIS, PUMP LEAKAGE . . . . . . . . . . . . 19-7 DOOR LATCH, REAR . . . . . . . . . . . . . . . . . . 23-44
PRESSURE . . . . . . . . . . . . . . . . . . . . 24-16,24-33 DIAGNOSIS, SERVICE . . . . . . . . . . . . . . . . 21-243 DOOR LATCH STRIKER, FRONT . . . . . . . . . 23-37
CUT-OFF SWITCH, HIGH PRESSURE . . . . . . . 24-6 DIAGNOSIS, SHOCK . . . . . . . . . . . . . . . . . . . . 2-9 DOOR LATCH STRIKER, REAR . . . . . . . . . . 23-45
CYCLE EVAP CANISTER PURGE DIAGNOSIS, SYSTEM . . . . . . . . . . . . . . . . . . 8L-3 DOOR LOCK CYLINDER, FRONT . . . . . . . . . 23-36
SOLENOID, DUTY . . . . . . . . . . . . . . . 25-24,25-27 DIAGNOSIS—INTRODUCTION, ENGINE . 9-68,9-8 DOOR LOCKS, 8W-61 POWER . . . . . . . . . . . 8W-1
CYCLING CLUTCH SWITCH, LOW DIAGNOSIS—MECHANICAL, SERVICE . 9-10,9-70 DOOR MODULE; POWER LOCK
PRESSURE . . . . . . . . . . . . . . . . 24-17,24-42,24-7 DIAGNOSIS—PERFORMANCE, SERVICE . 9-69,9-9 SYSTEMS . . . . . . . . . . . . . . . . . . . 8P-2,8P-3,8P-7
CYLINDER BLEEDING, MASTER . . . . . . . . . . 5-12 DIAGNOSTIC INFORMATION, CLUTCH . . . . . . 6-4 DOOR MODULE; POWER MIRROR
CYLINDER BLOCK . . . 9-112,9-114,9-5,9-53,9-54, DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . 8L-3 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 8T-2,8T-3
9-65 DIAGNOSTIC TEST FOR CHARGING DOOR MODULE; POWER WINDOW
CYLINDER BORES, HONING . . . . . . . . . 9-26,9-87 SYSTEM, ON-BOARD . . . . . . . . . . . . . . . . . . 8C-3 SYSTEMS . . . . . . . . . . . . . . . . . . . 8S-2,8S-3,8S-4
CYLINDER COMBUSTION PRESSURE DIAGNOSTIC TROUBLE CODE DOOR MOTOR, BLEND-AIR . . . . . . . . . . . . . 24-26
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . 9-13,9-73 DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . 25-3 DOOR OPENER STORAGE BIN DOOR,
CYLINDER COMPRESSION PRESSURE DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . 25-2 GARAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73 DIAGNOSTICS (OBD), ON-BOARD . . . . . . . . . . 7-9 DOOR OPENER STORAGE BIN, GARAGE . . . 8V-3
CYLINDER, FRONT DOOR LOCK . . . . . . . . . 23-36 DIAGNOSTICS, ON-BOARD . . . . . . . . . . . . . . 25-1 DOOR OPENING SECONDARY
CYLINDER HEAD . . 9-113,9-38,9-40,9-5,9-65,9-98 DIFFERENTIAL . . . . . . . . . . . . . . . 3-114,3-33,3-78 WEATHERSTRIP, FRONT . . . . . . . . . . . . . . . 23-39
CYLINDER HEAD COVER . . . 9-113,9-35,9-67,9-7, DIFFERENTIAL BEARING PRELOAD AND DOOR OPENING WEATHERSTRIP, FRONT . . 23-38
9-96 GEAR BACKLASH . . . . . . . . . . . . . . . . 3-127,3-94 DOOR OUTER BELT WEATHERSTRIP,
CYLINDER HEAD, ENGINE . . . . . . . . . . . . . . . 9-54 DIFFERENTIAL BEARING PRELOAD AND FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
CYLINDER HEAD GASKET FAILURE GEAR BACKLASH, 181 FBI . . . . . . . . . . . . . . 3-52 DOOR OUTER BELT WEATHERSTRIP,
DIAGNOSIS, ENGINE . . . . . . . . . . . . . . . 9-13,9-73 DIFFERENTIAL BEARING PRELOAD AND REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
CYLINDER, IGNITION SWITCH AND KEY . . 8D-20 GEAR BACKLASH, 186 FBI . . . . . . . . . . . . . . 3-56 DOOR OUTSIDE HANDLE, FRONT . . . . . . . . 23-35
CYLINDER, IGNITION SWITCH AND KEY DIFFERENTIAL NOISE, TRAC–LOKY . . 3-109,3-70 DOOR OUTSIDE HANDLE, REAR . . . . . . . . . 23-44
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9 DIFFERENTIAL SIDE BEARINGS . 3-115,3-36,3-80 DOOR, PASSENGER SIDE AIRBAG . . . . . . . 8M-11
CYLINDER, LIFTGATE LOCK . . . . . . . . . . . . 23-64 DIFFERENTIAL, STANDARD . . . 3-105,3-120,3-18, DOOR, REAR . . . . . . . . . . . . . . . . . . . . . . . . 23-43
CYLINDER, LIFTGATE SUPPORT ROD . . . . . 23-63 3-46,3-66,3-86 DOOR RESTRAINT, FRONT . . . . . . . . . . . . . 23-35
CYLINDER, MASTER . . . . . . . . . . . . . . . . 5-16,5-3 DIFFERENTIAL, TRAC-LOKY . . 3-105,3-121,3-66, DOOR RESTRAINT, REAR . . . . . . . . . . . . . . 23-43
CYLINDER RESERVOIR, MASTER . . . . . . . . . 5-24 3-87 DOOR SILL SCUFF PLATE . . . . . . . . . . . . . . 23-52
CYLINDER, WHEEL . . . . . . . . . . . . 5-21,5-28,5-29 DIMENSIONS, BODY OPENING . . . . . . . . . 23-128 DOOR SPACER BLOCKS—TWO-DOOR
CYLINDER/POWER BOOSTER, MASTER . . . . 5-10 DIMENSIONS, FRAME . . . . . . . . . . . . . . . . . . 13-7 VEHICLES, FRONT . . . . . . . . . . . . . . . . . . . . 23-41
CYLINDERS, LOCK . . . . . . . . . . . . . . . . . . . 23-37 DIODE REPLACEMENT . . . . . . . . . . . . . . . . 8W-14 DOOR STATIONARY WINDOW GLASS,
DAMAGED OR WORN THREADS, REPAIR . . 9-27, DIRECT CLUTCH . . . . . . . . . . . . . . . . . . . . 21-312 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9
9-88 DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 5-25 DOOR TRIM PANEL, FRONT . . . . . . . . . . . . 23-33
DAMPER, STEERING . . . . . . . . . . . . . . . . . . 19-25 DISC BRAKE CALIPER, FRONT . . . . . . . . . . . 5-18 DOOR TRIM PANEL, REAR . . . . . . . . . . . . . 23-42
DAMPER, VIBRATION . . . . . . . . . . . . . 9-101,9-41 DISC BRAKE ROTOR . . . . . . . . . . . . . . . 5-11,5-21 DOOR VACUUM ACTUATOR, MODE . . . . . . 24-43
DAMPER—2.5L ENGINE, FUEL INJECTOR DISC BRAKE SHOES, FRONT . . . . . . . . . . . . . 5-20 DOOR WATERDAM, FRONT . . . . . . . . . . . . . 23-34
RAIL/FUEL . . . . . . . . . . . . . . . . . . . . . . 14-16,14-5 DOOR WATERDAM, REAR . . . . . . . . . . . . . . 23-42
DAMPER—4.0L ENGINE, FUEL INJECTOR DISC BRAKES, FRONT . . . . . . . . . . . . . . . . . . . 5-4
RAIL/FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17 DISC, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 DOOR WEATHERSTRIP, REAR . . . . . . . . . . . 23-46
DAMPER—4.0L ENGINE, FUEL DISC, CLUTCH COVER . . . . . . . . . . . . . . . . . 6-11 DOOR WINDOW GLASS, REAR . . . . . . . . . . 23-47
RAIL/FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 DISC ROTOR MACHINING . . . . . . . . . . . . . . . 5-13 DOOR WINDOW REGULATOR, FRONT . . . . 23-39
DATA LINK CONNECTOR—PCM INPUT DISC RUNOUT, CLUTCH COVER . . . . . . . . . . . 6-7 DOOR WINDOW REGULATOR, REAR . . . . . 23-47
AND OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . 14-35 DISCHARGE (ESD) SENSITIVE DEVICES, DOUBLE CARDAN JOINT . . . . . . . . . . . . . . . . 3-11
DAYTIME RUNNING LAMP MODULE . . . . . . 8L-19 ELECTROSTATIC . . . . . . . . . . . . . . . . . . . . . . 8W-8 DOWNS, BATTERY HOLD . . . . . . . . . . 8A-20,8A-4
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 DISCHARGE LINE, SUCTION . . . . . . . . . . . . 24-45 DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . 19-24
DECALS, BODY . . . . . . . . . . . . . . . . . . . . . . 23-29 DISPLAY MODULE, TRIP COMPUTER, DRAINBACK CHECK VALVE SERVICE,
DEFINITION, TRIP . . . . . . . . . . . . . . . . . . . . 25-21 COMPASS, AND THERMOMETER . . . . . 8V-3,8V-7 CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-142
DEFOGGER, 8W-48 REAR WINDOW . . . . . . 8W-1 DISPLAY TEST MODE, STATE . . . . . . . . . . . . 25-2 DRAINBACK VALVE, CONVERTER . . . . . . . 21-125
XJ INDEX 5
Description Group-Page Description Group-Page Description Group-Page
DRAW FUSE, IGNITION-OFF; AUDIO ENGINE, ENGINE FIRING ORDER—4.0L FBI DIFFERENTIAL BEARING PRELOAD
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1 6-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 AND GEAR BACKLASH, 181 . . . . . . . . . . . . . 3-52
DRAW FUSE, IGNITION-OFF; POWER ENGINE, EXHAUST MANIFOLD—4.0L . . . . . . 9-96 FBI DIFFERENTIAL BEARING PRELOAD
DISTRIBUTION SYSTEMS . . . . . . . . . . . 8O-2,8O-5 ENGINE FIRING ORDER—2.5L AND GEAR BACKLASH, 186 . . . . . . . . . . . . . 3-56
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . 7-9 4-CYLINDER ENGINE . . . . . . . . . . . . . . . . . 8D-23 FBI PINION, 181 . . . . . . . . . . . . . . . . . . . . . . 3-36
DRIP RAIL MOLDING . . . . . . . . . . . . . . . . . 23-49 ENGINE FIRING ORDER—4.0L FBI PINION, 186 . . . . . . . . . . . . . . . . . . . . . . 3-41
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . 3-22 6-CYLINDER ENGINE . . . . . . . . . . . . . . . . . 8D-23 FBI PINION GEAR DEPTH, 181 . . . . . . . . . . . 3-48
DRIVE BELT DIAGNOSIS, ACCESSORY . . . . . . 7-9 ENGINE, FUEL INJECTOR RAIL/FUEL FBI PINION GEAR DEPTH, 186 . . . . . . . . . . . 3-50
DRIVE BELTS, ENGINE ACCESSORY . . . . . . . 7-35 DAMPER—2.5L . . . . . . . . . . . . . . . . . . 14-16,14-5 FBI PINION SHAFT SEAL, 181 . . . . . . . . . . . . 3-24
DRIVE GEAR, SPEED SENSOR ENGINE, FUEL INJECTOR RAIL/FUEL FBI PINION SHAFT SEAL, 186 . . . . . . . . . . . . 3-26
ROTOR-SPEEDOMETER . . . . . . . . . . . . . . . 21-254 DAMPER—4.0L . . . . . . . . . . . . . . . . . . . . . . 14-17 FENDER FLARE, FRONT . . . . . . . . . . . . . . . . 23-31
DRIVE REMOVAL/INSTALLATION, ENGINE, FUEL RAIL/FUEL DAMPER— FENDER FLARE, REAR . . . . . . . . . . . . . . . . . 23-49
VISCOUS FAN . . . . . . . . . . . . . . . . . . . . . . . . 7-39 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 FENDER, LEFT FRONT . . . . . . . . . . . . . . . . . 23-32
DRIVE, VISCOUS FAN . . . . . . . . . . . . . . . 7-19,7-7 ENGINE, IGNITION COIL RESISTANCE— FENDER, RIGHT FRONT . . . . . . . . . . . . . . . . 23-32
DRIVELINE ANGLE MEASUREMENT 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 FILL LEVEL, LUBRICANT . . . . . . . . 21-347,21-376
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 ENGINE, IGNITION COIL RESISTANCE— FILL PROCEDURE, TRANSMISSION . . . . . 21-142
DRIVELINE SNAP . . . . . . . . . . . . 3-109,3-21,3-70 4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 FILLER TUBE CAP, FUEL TANK . . . . . . 14-21,14-6
DRIVER DOOR JAMB SWITCH . . . . . . . . . . . 8U-2 ENGINE, IGNITION COIL-2.5L . . . . . . . . . . . . 8D-3 FILLING, COOLING SYSTEM—DRAINING . . . 7-21
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . 8U-2 ENGINE, IGNITION COIL—2.5L . . . . . . . . . . 8D-12 FILTER, FUEL PUMP INLET . . . . . . . . . . . . . 14-15
DRIVER SIDE AIRBAG MODULE . . . . . 8M-2,8M-6 ENGINE, IGNITION COIL—4.0L . . . . . 8D-12,8D-3 FILTER REPLACEMENT, FLUID . . . . . . . . . 21-141
DRIVER SIDE AIRBAG MODULE TRIM ENGINE MOUNT—REAR . . . . . . . . . . . . 9-30,9-91 FILTER/FUEL PRESSURE REGULATOR,
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7 ENGINE MOUNTS—FRONT . . . . . . . . . . 9-29,9-90 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13,14-3
DRUM, BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 5-11 ENGINE OIL LEAK INSPECTION . . . . . . 9-14,9-74 FINAL ASSEMBLY . . . . . . . . . . . . . . . . . 3-47,3-85
DRUM BRAKE, REAR . . . . . . . . . . . 5-29,5-30,5-5 ENGINE OIL PRESSURE . . . . . . . . . . . . 9-15,9-75 FINESSE SANDING, BUFFING, AND
DRUM BRAKE SHOES . . . . . . . . . . . . . . . . . . 5-21 ENGINE OIL SERVICE . . . . . . . . . . . . . . 9-27,9-88 POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
DRUM MACHINING, BRAKE . . . . . . . . . . . . . 5-14 ENGINE PERFORMANCE . . . . . . . . . . . . 9-26,9-87 FINISH, BASE COAT/CLEAR COAT . . . . . . . . . 23-4
DRUM, OVERRUNNING CLUTCH/LOW- ENGINE, POWER STEERING PRESSURE FIRING ORDER—2.5L 4-CYLINDER
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-175 SWITCH—2.5L . . . . . . . . . . . . . . . . . . . . . . 14-47 ENGINE, ENGINE. . . . . . . . . . . . . . . . . . . . . . 8D-23
DRUM/OVERDRIVE PISTON RETAINER, ENGINE, SPARK PLUG CABLES-2.5L . . . . . . 8D-2 FIRING ORDER—4.0L 6-CYLINDER
OVERRUNNING CLUTCH/LOW- ENGINE SPECIAL TOOLS, 2.5L . . . . . . . . . . . . . 9-60 ENGINE, ENGINE . . . . . . . . . . . . . . . . . . . . . 8D-23
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-195 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . 9-55 FITTING CONNECTING ROD BEARINGS . . . . 9-80
DUAL FUNCTION HIGH PRESSURE ENGINE, STARTER MOTOR NOISE - 2.5L . . . 8B-8 FITTING CRANKSHAFT MAIN BEARINGS . . . 9-23,
SWITCH (4.0 L) . . . . . . . . . . . . . . . . . . . . . . . 24-4 ENTRY RECEIVER PROGRAMMING, 9-83
DUAL FUNCTION HIGH PRESSURE REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8P-6 FITTING, PISTON . . . . . . . . . . . . . . . . . . . . . . 9-77
SWITCH/HIGH PRESSURE CUT-OFF ENTRY RECEIVER, REMOTE KEYLESS . 8P-2,8P-5, FITTINGS, QUICK-CONNECT . . . . . . . . 14-10,14-6
SWITCH . . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33 8P-8 FIVE VOLT SENSOR SUPPLIES—
DUCTS AND OUTLETS . . . . . . . . . . . . . . . . . 24-33 ENTRY SYSTEM, POWER LOCK SYSTEM PRIMARY AND SECONDARY . . . . . . . . . . . . 14-29
DUTY CYCLE EVAP CANISTER PURGE AND REMOTE KEYLESS . . . . . . . . . . . . . . . . 8P-3 FIXED ORIFICE TUBE . . . . . . . . . . . . . . 24-35,24-5
SOLENOID . . . . . . . . . . . . . . . . . . . . . 25-24,25-27 ENTRY SYSTEM, REMOTE KEYLESS . . . . . . 8P-1 FLARE, FRONT FENDER . . . . . . . . . . . . . . . . 23-31
EFFECTS OF INCORRECT FLUID LEVEL . . 21-126, ENTRY TRANSMITTER BATTERY FLARE, REAR FENDER . . . . . . . . . . . . . . . . . 23-49
21-239 REPLACEMENT, REMOTE KEYLESS . . . . . . . 8P-6 FLARING, BRAKE TUBE . . . . . . . . . . . . . . . . . 5-14
ELECTRIC COOLING FAN . . . . . . . . . . . . . 7-19,7-8 ENTRY TRANSMITTER PROGRAMMING, FLASHER, COMBINATION . . . . . . . . . . . 8J-3,8J-5
ELECTRIC COOLING FAN—2.5L . . . . . . . . . . 7-33 REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8P-6 FLOOR CONSOLE, FULL . . . . . . . . . . . . . . . 23-57
ELECTRIC COOLING FAN—4.0L . . . . . . . . . . 7-34 ENTRY TRANSMITTER, REMOTE FLOW AND PRESSURE, POWER . . . . . . . . . . 19-6
ELECTRONIC VOLTAGE REGULATOR . . . . . . . 8C-2 KEYLESS . . . . . . . . . . . . . . . . . . . . . . . . 8P-2,8P-5 FLOW CHECK PROCEDURE, THROTTLE
ELECTROSTATIC DISCHARGE (ESD) EQUIPMENT, REFRIGERANT SYSTEM BODY MINIMUM AIR . . . . . . . . . . . . . . . . . . 14-42
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . 8W-8 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-22 FLOW CHECK, RADIATOR COOLANT . . . . . . . 7-17
ELEMENT AND SENSOR, HEATED SEAT . . 8N-11, EVACUATE, REFRIGERANT SYSTEM . . . . . . 24-22 FLOW TESTING TRANSMISSION MAIN
8N-9 EVAP CANISTER . . . . . . . . . . . . . . . . 25-24,25-27 COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-246
ELEMENT (FILTER), AIR CLEANER . . . . . . . 14-49 EVAP CANISTER PURGE SOLENOID, FLUID . . . . . . . . . . . . . . . . . . . . . . . 21-220,21-96
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . 0-11 DUTY CYCLE . . . . . . . . . . . . . . . . . . . 25-24,25-27 FLUID AND FILTER REPLACEMENT . . . . . . 21-141
EMISSION CONTROL INFORMATION EVAPORATION CONTROL SYSTEM . . . . . . . 25-23 FLUID, BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 5-31
(VECI) LABEL, VEHICLE . . . . . . . . . . . . . . . . 25-26 EVAPORATIVE EMISSION CONTROLS . . . . . 25-23 FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . 0-3
EMISSION CONTROLS, EVAPORATIVE . . . . 25-23 EVAPORATOR COIL . . . . . . . . . . . . . . . 24-35,24-4 FLUID, CAUSES OF BURNT . . . . . . 21-126,21-240
EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . 25-1 EXHAUST GRILLE, AIR . . . . . . . . . . . . . . . . 23-50 FLUID, CLUTCH LINKAGE . . . . . . . . . . . . . . . . 6-9
END CAP, FRONT BUMPER . . . . . . . . . . . . . . 13-2 EXHAUST MANIFOLD . . . . . . . . . . . 9-35,9-68,9-8 FLUID CONDITION, CHECKING . . . . . . . . . 21-248
END CAP, INSTRUMENT PANEL . . . . . . . . . 8E-25 EXHAUST MANIFOLD, INTAKE . . . . . . . . . . . . 9-95 FLUID CONTAMINATION . . . . . . . . 21-127,21-240
END CAP, REAR BUMPER . . . . . . . . . . . . . . . 13-4 EXHAUST MANIFOLD—4.0L ENGINE . . . . . . 9-96 FLUID CONTAMINATION, BRAKE . . . . . . . . . . 5-12
END PLUG, HOUSING . . . . . . . . . . . . . . . . . 19-12 EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . 11-5 FLUID LEAK DIAGNOSIS, CONVERTER
ENGAGEMENT, IMPROPER CLUTCH EXHAUST SYSTEM . . . . . . . . . . . . . . . . 11-1,11-4 HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-132
RELEASE OR . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 EXTENDED IDLE SWITCH—PCM INPUT . . . 14-30 FLUID LEVEL, BRAKE . . . . . . . . . . . . . . . . . . 5-12
ENGINE . . . . . . . . . . . . . . . . . . . . . . 9-2,9-31,9-62 EXTENSION HOUSING AND PARK LOCK . . 21-191 FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . 21-141
ENGINE, 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 EXTENSION HOUSING BUSHING . . . . . . . . 21-147 FLUID LEVEL, CHECKING . . . . . . . . . . . . . 21-247
ENGINE, 4.0L . . . . . . . . . . . . . . . . . . . . 9-119,9-61 EXTENSION HOUSING SEAL . . . . . . . . . . . . . 21-7 FLUID LEVEL, CLUTCH . . . . . . . . . . . . . . . . . 6-10
ENGINE ACCESSORY DRIVE BELTS . . . . . . . 7-35 EXTENSION, QUARTER PANEL TRIM . . . . . 23-54 FLUID LEVEL, EFFECTS OF INCORRECT . . 21-126,
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 9-92 EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . 8L-20 21-239
ENGINE ASSEMBLY (SHORT BLOCK), EXTERIOR MOLDING, FRONT DOOR FLUID LEVEL SENSOR, WASHER . . . . . . . . . 8K-4
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 9-27,9-88 GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39 FLUID/FILTER CHANGE, REFILLING
ENGINE, CAMSHAFT POSITION EXTERIOR MOLDING, REAR DOOR AFTER OVERHAUL OR . . . . . . . . . . . . . . . . 21-248
SENSOR-2.5L . . . . . . . . . . . . . . . . . . . . . . . . 8D-4 GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46 FLUSH MEASUREMENTS, BODY GAP . . . . 23-127
ENGINE, CAMSHAFT POSITION EXTERIOR NAMEPLATES . . . . . . . . . . . . . . . 23-30 FLUSHING COOLERS AND TUBES . 21-143,21-248
SENSOR—2.5L . . . . . . . . . . . . . . . . . . . . . . 8D-14 FAILURE DIAGNOSIS, ENGINE CYLINDER FLUSHING, COOLING SYSTEM—
ENGINE, CAMSHAFT POSITION HEAD GASKET . . . . . . . . . . . . . . . . . . . . 9-13,9-73 REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
SENSOR—4.0L . . . . . . . . . . . . . . . . . . 8D-15,8D-5 FAN BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . 6-10,6-2
ENGINE COOLANT TEMPERATURE FAN DRIVE REMOVAL/INSTALLATION, FLYWHEEL RUNOUT, CLUTCH . . . . . . . . . . . . . 6-6
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49 VISCOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15
ENGINE COOLANT TEMPERATURE FAN DRIVE, VISCOUS . . . . . . . . . . . . . . . 7-19,7-7 FOG LAMP ADJUSTMENT . . . . . . . . . . . . . . . 8L-8
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . 14-30 FAN, ELECTRIC COOLING . . . . . . . . . . . . 7-19,7-8 FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . 8L-10
ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . 9-54 FAN RELAY—PCM OUTPUT, RADIATOR . . . 14-36 FORM-IN-PLACE GASKETS . . . . . . . . . . 9-25,9-86
ENGINE CYLINDER HEAD GASKET FAN—2.5L, ELECTRIC COOLING . . . . . . . . . . 7-33 FORWARD CLUTCH . . . . . . . . . . . . . . . . . . 21-317
FAILURE DIAGNOSIS . . . . . . . . . . . . . . . 9-13,9-73 FAN—4.0L, ELECTRIC COOLING . . . . . . . . . . 7-34 FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . 0-10
ENGINE DIAGNOSIS—INTRODUCTION . . 9-68,9-8 FANS, COOLING SYSTEM . . . . . . . . . . . . 7-3,7-38 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
ENGINE, DISTRIBUTOR CAP-2.5L . . . . . . . . . 8D-6 FASTENER IDENTIFICATION . . . . . . . . . . . Intro.-3 FRAME AND BUMPERS . . . . . . . . . . . . . . . . . 13-1
ENGINE, DISTRIBUTOR ROTOR-2.5L . . . . . . 8D-6 FASTENER USAGE . . . . . . . . . . . . . . . . . . . Intro.-3 FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . 13-7
ENGINE, DISTRIBUTOR-2.5L . . . . . . . . . . . . . 8D-2 FBI AXLE, 181 . . . . . . . . . . . . . . . . . . . . 3-16,3-61 FRAME TORQUE SPECIFICATIONS . . . . . . . . 13-9
ENGINE, DISTRIBUTOR—2.5L . . . . . . . . . . 8D-17 FBI AXLE, 181 AND 186 . . . . . . . . . . . . . . . . 3-61 FREQUENCY INTERFERENCE, RADIO . . . . . . 8F-6
ENGINE, ENGINE FIRING ORDER—2.5L FBI AXLE, 186 . . . . . . . . . . . . . . . . . . . . 3-17,3-61 FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . 2-11
4-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 FBI AXLE, TUBE, 181, AND 186 . . . . . . . . . . 3-16 FRONT AXLE PINION INPUT ANGLE . . . . . . . 3-15
6 INDEX XJ
Description Group-Page Description Group-Page Description Group-Page
FRONT BAND ADJUSTMENT . . . . . . . . . . . 21-199 FUEL TUBES/LINES/HOSES AND CLAMPS . . 14-6 GRID, OUTSIDE MIRROR HEATING . . . . . . . 8N-2
FRONT BEARING RETAINER, ADAPTER/ FUEL/IGNITION SYSTEM, 8W-30 . . . . . . . . . 8W-1 GRID, REAR GLASS HEATING . . . . . . . 8N-2,8N-4
EXTENSION HOUSING . . . . . . . . . . . . . . . . . . 21-8 FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . 23-57 GRID REPAIR, REAR GLASS HEATING . . . . . 8N-6
FRONT BEARING RETAINER SEAL . . . . . . . . 21-6 FUNCTION HIGH PRESSURE SWITCH GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-24
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . 13-3 (4.0 L), DUAL . . . . . . . . . . . . . . . . . . . . . . . . 24-4 GRILLE, AIR EXHAUST . . . . . . . . . . . . . . . . 23-50
FRONT BUMPER END CAP . . . . . . . . . . . . . . 13-2 FUNCTION HIGH PRESSURE SWITCH/ GRILLE, COWL . . . . . . . . . . . . . . . . . . . . . . 23-28
FRONT CARPET/MAT . . . . . . . . . . . . . . . . . . 23-58 HIGH PRESSURE CUT-OFF SWITCH, GRILLE OPENING PANEL (GOP) . . . . . . . . . 23-24
FRONT CLUTCH . . . . . . . . . 21-120,21-180,21-196 DUAL . . . . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33 GROUND DISTRIBUTION, 8W-15 . . . . . . . . . 8W-1
FRONT DISC BRAKE CALIPER . . . . . . . . . . . . 5-18 FUNCTIONS, CIRCUIT . . . . . . . . . . . . . . . . . . 8W-4 GROUNDS, POWER . . . . . . . . . . . . . . . . . . . 14-33
FRONT DISC BRAKE SHOES . . . . . . . . . . . . . 5-20 FUSE, IGNITION-OFF DRAW; AUDIO G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . 5-35,5-38
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . 5-4 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1 GUIDE AND SEAL, VALVE . . . . . . . . . . . . . . . 9-15
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-35 FUSE, IGNITION-OFF DRAW; POWER GUIDE, VALVE . . . . . . . . . . . . . . . . . . . . . 9-67,9-7
FRONT DOOR GLASS . . . . . . . . . . . . . . . . . 23-41 DISTRIBUTION SYSTEMS . . . . . . . . . . . 8O-2,8O-5 HANDLE ACTUATOR, FRONT DOOR
FRONT DOOR GLASS EXTERIOR GAP AND FLUSH MEASUREMENTS, INSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39 BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-127 HANDLE ACTUATOR, REAR DOOR
FRONT DOOR GLASS RUN CHANNEL GARAGE DOOR OPENER STORAGE BIN . . . . 8V-3 INSIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-38 GARAGE DOOR OPENER STORAGE BIN HANDLE, ASSIST . . . . . . . . . . . . . . . . . . . . . 23-52
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . 23-35 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8 HANDLE, FRONT DOOR OUTSIDE . . . . . . . . 23-35
FRONT DOOR INNER BELT GASKET FAILURE DIAGNOSIS, ENGINE HANDLE, LIFTGATE OUTSIDE . . . . . . . . . . . 23-63
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-37 CYLINDER HEAD . . . . . . . . . . . . . . . . . . 9-13,9-73 HANDLE, REAR DOOR OUTSIDE . . . . . . . . . 23-44
FRONT DOOR INSIDE HANDLE GASKETS, FORM-IN-PLACE . . . . . . . . . . 9-25,9-86 HARD SHIFTING . . . . . . . . . . . . . . . . . 21-3,21-44
ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37 GAUGE SENDING UNIT, FUEL . . 14-10,14-16,14-3 HARNESS ADAPTER SEAL, SOLENOID . . . 21-261
FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . 23-37 GAUGES, PRESSURE . . . . . . . . . . . . . . . . . . . 22-3 HAZARD WARNING SWITCH, TURN
FRONT DOOR LATCH STRIKER . . . . . . . . . . 23-37 GEAR AND CLUTCH, OVERDRIVE SIGNAL SWITCH . . . . . . . . . . . . . . 8J-2,8J-5,8J-6
FRONT DOOR LOCK CYLINDER . . . . . . . . . . 23-36 PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-301 HAZARD WARNING SYSTEM . . . . . . . . . . . . . 8J-1
FRONT DOOR OPENING SECONDARY GEAR AND NO. 1 ONE–WAY CLUTCH, HAZARD WARNING SYSTEMS, TURN
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-39 SUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-324 SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-4
FRONT DOOR OPENING WEATHERSTRIP . . 23-38 GEAR BACKLASH, 181 FBI DIFFERENTIAL HEAD COVER, CYLINDER . . . 9-113,9-35,9-67,9-7,
FRONT DOOR OUTER BELT BEARING PRELOAD . . . . . . . . . . . . . . . . . . . . 3-52 9-96
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-38 GEAR BACKLASH, 186 FBI DIFFERENTIAL HEAD, CYLINDER . 9-113,9-38,9-40,9-5,9-65,9-98
FRONT DOOR OUTSIDE HANDLE . . . . . . . . 23-35 BEARING PRELOAD . . . . . . . . . . . . . . . . . . . . 3-56 HEAD, ENGINE CYLINDER . . . . . . . . . . . . . . . 9-54
FRONT DOOR RESTRAINT . . . . . . . . . . . . . . 23-35 GEAR BACKLASH, DIFFERENTIAL HEAD GASKET FAILURE DIAGNOSIS,
FRONT DOOR SPACER BLOCKS—TWO- BEARING PRELOAD . . . . . . . . . . . . . . . 3-127,3-94 ENGINE CYLINDER . . . . . . . . . . . . . . . . 9-13,9-73
DOOR VEHICLES . . . . . . . . . . . . . . . . . . . . . 23-41 GEAR CLEARANCE, SIDE . . . . . . . . . . . . . . . 3-129 HEAD RESTRAINT COVER . . . . . . . . . . . . . . 23-14
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . 23-33 GEAR CONTACT PATTERN ANALYSIS . 3-129,3-59, HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . 23-13
FRONT DOOR WATERDAM . . . . . . . . . . . . . 23-34 3-97 HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-14
FRONT DOOR WINDOW REGULATOR . . . . . 23-39 GEAR DEPTH, 181 FBI PINION . . . . . . . . . . . 3-48 HEADLAMP ADJUSTMENT . . . . . . . . . . . . . . 8L-6
FRONT FENDER FLARE . . . . . . . . . . . . . . . . 23-31 GEAR DEPTH, 186 FBI PINION . . . . . . . . . . . 3-50 HEADLAMP ALIGNMENT . . . . . . . . . . . . 8L-6,8L-9
FRONT FENDER, LEFT . . . . . . . . . . . . . . . . . 23-32 GEAR DEPTH, 8 1/4 AXLE PINION . . . . . . . 3-126 HEADLAMP ALIGNMENT, VEHICLE
FRONT FENDER, RIGHT . . . . . . . . . . . . . . . . 23-32 GEAR DEPTH, PINION . . . . . . . . . . . . . . . . . . 3-91 PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 8L-6
FRONT INNER SCUFF PLATE . . . . . . . . . . . . 23-52 GEAR, FRONT PLANETARY . . . . . . . . . . . . 21-322 HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . 8L-10
FRONT LIGHTING, 8W-50 . . . . . . . . . . . . . . 8W-1 GEAR, GOVERNOR AND PARK . . . 21-153,21-154, HEADLAMP DELAY MODULE, SENTINEL . . . 8L-19
FRONT OUTPUT SHAFT SEAL . . . . 21-350,21-379 21-191 HEADLAMP SWITCH; CHIME/BUZZER
FRONT PARK/TURN SIGNAL LAMP . . . . . . . 8L-15 GEAR LEAKAGE, POWER STEERING . . . . . . 19-11 WARNING SYSTEMS . . . . . . . . . . . . . . 8U-2,8U-3
FRONT PARK/TURN SIGNAL LAMP BULB . . 8L-11 GEAR NOISE . . . . . . . . . . . . . . . . 3-109,3-21,3-70 HEADLAMP SWITCH; INSTRUMENT
FRONT PLANETARY GEAR . . . . . . . . . . . . . 21-322 GEAR, PINION . . . . . . . . . . . . . . . . . . . 3-117,3-81 PANEL SYSTEMS . . . . . . . . . . . . . . . . . . . . . 8E-17
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . 3-8 GEAR, POWER STEERING . . . . . . . . . 19-11,19-21 HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-60
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . 21-195 GEAR, RING . . . . . . . . . . . . . . . . 3-116,3-45,3-80 HEAT INTERFACE MODULE, SEAT . . . 8N-12,8N-9
FRONT SERVO PISTON . . . . . . . . . . . . . . . 21-176 GEAR, SEMI-SYNCHRONIZED REVERSE HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . 11-8
FRONT SHOULDER BELT/BUCKLE . . . . . . . . 23-55 IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-36 HEATED SEAT ELEMENT AND SENSOR . . . 8N-11,
FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . 13-6 GEAR, SPEED SENSOR ROTOR- 8N-9
FRONT SUSPENSION . . . . . . . . . . . . . . . 2-15,2-7 SPEEDOMETER DRIVE . . . . . . . . . . . . . . . 21-254 HEATED SEAT RELAY . . . . . . . . 8N-11,8N-12,8N-9
FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . 13-3 GEAR, STEERING . . . . . . . . . . . . . . . 19-12,19-19 HEATED SEAT SWITCH . . . . . . 8N-10,8N-12,8N-8
FRONT WHEEL SPEED SENSOR . . . . . . . . . . 5-37 GEARSET, PLANETARY . . . . . . . . . . . . . . . 21-122 HEATED SEAT SYSTEM . . . . . . . . . . . . 8N-8,8N-9
FRONT WHEELHOUSE LINER . . . . . . . . . . . 23-32 GEARSHIFT CABLE . . . . . . 21-128,21-150,21-197, HEATER AND AIR CONDITIONER . . . . . . . . . 24-5
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . 14-1 21-246,21-256,21-336 HEATER AND AIR CONDITIONER
FUEL FILTER/FUEL PRESSURE GEARSHIFT MECHANISM . . . . . . . . . . . . . 21-124 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-6
REGULATOR . . . . . . . . . . . . . . . . . . . . 14-13,14-3 GEARTRAIN, SHIFT MECHANISM . . . . . . . . 21-17 HEATER, BLOCK . . . . . . . . . . . . . . . . . . . 7-35,7-4
FUEL GAUGE SENDING UNIT . . 14-10,14-16,14-3 GEARTRAIN/OUTPUT SHAFT, HEATER CORE . . . . . . . . . . . . . . . . . . . 24-41,24-6
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . 14-25 PLANETARY . . . . . . . . . . . . . . . . . . 21-185,21-197 HEATER PERFORMANCE . . . . . . . . . . . . . . . 24-16
FUEL INJECTOR RAIL/FUEL DAMPER— GENERAL DIAGNOSIS INFORMATION . . . . 21-239 HEATER-A/C CONTROL . . . . . . . . . . . . . . . . 24-35
2.5L ENGINE . . . . . . . . . . . . . . . . . . . . 14-16,14-5 GENERAL INFORMATION . . . . . . 3-106,3-19,3-67 HEATER-A/C HOUSING . . . . . . . . . . . . . . . . 24-36
FUEL INJECTOR RAIL/FUEL DAMPER— GENERAL INFORMATION, 8W-01 . . . . . . . . . 8W-1 HEATER-A/C HOUSING DOOR . . . . . . . . . . . 24-39
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 14-17 GENERATOR . . . . . . . . . . . . . . . . . . . . . 8C-1,8C-3 HEATING GRID, OUTSIDE MIRROR . . . . . . . 8N-2
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . 14-10 GENERATOR RATINGS . . . . . . . . . . . . . . . . . 8C-5 HEATING GRID, REAR GLASS . . . . . . . 8N-2,8N-4
FUEL INJECTORS . . . . . . . . . . . . . . . . 14-19,14-4 GLASS EXTERIOR MOLDING, FRONT HEATING GRID REPAIR, REAR GLASS . . . . . 8N-6
FUEL INJECTORS—PCM OUTPUT . . . . . . . . 14-35 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39 HIGH AND LOW LIMITS . . . . . . . . . . . . . . . 25-22
FUEL LEVEL SENSOR—PCM INPUT . . . . . . 14-30 GLASS EXTERIOR MOLDING, REAR HIGH MOUNTED STOP LAMP (CHMSL)
FUEL PRESSURE LEAK DOWN TEST . . . . . . 14-7 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46 BULB, CENTER . . . . . . . . . . . . . . . . . . . . . . 8L-12
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 GLASS, FRONT DOOR . . . . . . . . . . . . . . . . . 23-41 HIGH MOUNTED STOP LAMP (CHMSL),
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . 14-8 GLASS HEATING GRID, REAR . . . . . . . 8N-2,8N-4 CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . 14-7 GLASS HEATING GRID REPAIR, REAR . . . . . 8N-6 HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 24-6
FUEL PUMP INLET FILTER . . . . . . . . . . . . . 14-15 GLASS, LIFTGATE . . . . . . . . . . . . . . . . . . . . 23-11 HIGH PRESSURE RELIEF VALVE . . . . . . . . . . 24-7
FUEL PUMP MODULE . . . . . . . . . . . . . 14-14,14-2 GLASS, REAR DOOR STATIONARY HIGH PRESSURE SWITCH (4.0 L), DUAL
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . 14-6 WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9 FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-4
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . 14-44 GLASS, REAR DOOR WINDOW . . . . . . . . . . 23-47 HIGH PRESSURE SWITCH/HIGH
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . 14-35 GLASS, REAR QUARTER WINDOW . . . . . . . 23-10 PRESSURE CUT-OFF SWITCH, DUAL
FUEL PUMP RELAYS, ASD . . . . . . . . . . . . . 14-41 GLASS RUN CHANNEL WEATHERSTRIP, FUNCTION . . . . . . . . . . . . . . . . . . . . . 24-16,24-33
FUEL RAIL/FUEL DAMPER—4.0L ENGINE . . 14-5 FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-38 HIGH SPEED, TIRE PRESSURE . . . . . . . . . . . 22-3
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . 14-23 GLASS RUN CHANNEL WEATHERSTRIP, HINGE, FRONT DOOR . . . . . . . . . . . . . . . . . 23-35
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-52 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . 23-46 HINGE, HOOD . . . . . . . . . . . . . . . . . . . . . . . 23-26
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . 14-23 GLASS, STATIONARY . . . . . . . . . . . . . . . . . . 23-6 HINGE, LIFTGATE . . . . . . . . . . . . . . . . . . . . . 23-62
FUEL SYSTEM PRESSURE RELEASE GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . 8E-22 HINGE, REAR DOOR . . . . . . . . . . . . . . . . . . 23-43
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 14-10 GLOVE BOX COMPONENTS . . . . . . . . . . . . . 8E-23 HITCH, TRAILER . . . . . . . . . . . . . . . . . . . . . . 13-7
FUEL TANK . . . . . . . . . . . . . . . . . . . . . 14-19,14-4 GLOVE BOX LATCH STRIKER . . . . . . . . . . . 8E-24 HOISTING, JUMP STARTING, TOWING . . . . . . 0-9
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . 14-23 GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . 21-124 HOISTING RECOMMENDATIONS . . . . . . . . . . 0-11
FUEL TANK FILLER TUBE CAP . . . . . . 14-21,14-6 GOVERNOR AND PARK GEAR . . . 21-153,21-154, HOLD DOWNS, BATTERY . . . . . . . . . . 8A-20,8A-4
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . 13-7 21-191 HOLE REPAIR, THREADED . . . . . . . . . . . . Intro.-3
XJ INDEX 7
Description Group-Page Description Group-Page Description Group-Page
HONING CYLINDER BORES . . . . . . . . . . 9-26,9-87 IMPROPER CLUTCH RELEASE OR INSTRUMENT PANEL END CAP . . . . . . . . . . 8E-25
HOOD . . . . . . . . . . . . . . . . . . . . . . . . 23-24,23-65 ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 INSTRUMENT PANEL POWER OUTLET . . . 8E-12,
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . 23-26 INCH AXLE, 8 1/4 . . . . . . . . . . . . . . . . . . . . 3-131 8E-4
HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . 23-26 INCORRECT FLUID LEVEL, EFFECTS OF . . 21-126, INSTRUMENT PANEL SYSTEM . . . . . . . . . . . 8E-1
HOOD LATCH STRIKER . . . . . . . . . . . . . . . . 23-26 21-239 INSTRUMENT PANEL TOP COVER . . . . . . . 8E-21
HOOD RELEASE CABLE . . . . . . . . . . . . . . . . 23-27 INDEX, 8W-02 COMPONENT . . . . . . . . . . . . 8W-1 INTAKE AND EXHAUST MANIFOLD . . . . . . . . 9-95
HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . 23-27 INDICATOR LAMP (MIL), MALFUNCTION . . . 25-2 INTAKE MANIFOLD . . . . . . . . . . . . . 9-33,9-67,9-8
HOOD SILENCER PAD . . . . . . . . . . . . . . . . . 23-27 INDICATOR LAMP, SENTRY KEY INTAKE MANIFOLD AIR TEMPERATURE
HOOK, FRONT TOW . . . . . . . . . . . . . . . . . . . . 13-3 IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . 8Q-3 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50
HOOK, REAR TOW . . . . . . . . . . . . . . . . . . . . . 13-5 INDICATORS, TREAD WEAR . . . . . . . . . . . . . 22-3 INTAKE MANIFOLD AIR TEMPERATURE
HOOKS, EMERGENCY TOW . . . . . . . . . . . . . . 0-11 INFLATION PRESSURES, TIRE . . . . . . . . . . . 22-2 SENSOR—PCM INPUT . . . . . . . . . . . . . . . . 14-32
HORN . . . . . . . . . . . . . . . . . . . . . . 8G-1,8G-4,8G-5 INITIAL OPERATION, POWER STEERING INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . 9-13,
HORN RELAY . . . . . . . . . . . . . . . . 8G-2,8G-3,8G-4 PUMP - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7 9-72
HORN SWITCH . . . . . . . . . . . . . . . . . . . 8G-2,8G-4 INJECTION SYSTEM, FUEL . . . . . . . . . . . . . 14-25 INTERFACE MODULE, SEAT HEAT . . . 8N-12,8N-9
HORN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 8G-1 INJECTOR RAIL/FUEL DAMPER—2.5L INTERFERENCE, RADIO FREQUENCY . . . . . . 8F-6
HORN/CIGAR LIGHTER/POWER OUTLET, ENGINE, FUEL . . . . . . . . . . . . . . . . . . . 14-16,14-5 INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . 8L-20
8W-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 INJECTOR RAIL/FUEL DAMPER—4.0L INTERIOR LIGHTING, 8W-44 . . . . . . . . . . . . 8W-1
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . 7-6 ENGINE, FUEL . . . . . . . . . . . . . . . . . . . . . . . 14-17 INTERLOCK, BRAKE TRANSMISSION
HOSES AND LINES, BRAKE . . . . . . . . . . . . . . . 5-7 INJECTOR TEST, FUEL . . . . . . . . . . . . . . . . . 14-10 SHIFT . . . . . . . . . . . . . . . . . . . . . . . 21-150,21-256
HOSES, BRAKE LINE . . . . . . . . . . . . . . . . . . . 5-12 INJECTORS, FUEL . . . . . . . . . . . . . . . . 14-19,14-4 INTERLOCK CABLE ADJUSTMENT,
HOSES, COOLING SYSTEM . . . . . . . . . . . . . . 7-40 INJECTORS—PCM OUTPUT, FUEL . . . . . . . 14-35 BRAKE TRANSMISSION SHIFT . . . 21-198,21-336
HOUSING, ADAPTER . . . . . . . . . . . . . . . . . 21-147 INLET FILTER, FUEL PUMP . . . . . . . . . . . . . 14-15 INTERLOCK MECHANISM, BRAKE
HOUSING AND FRONT BEARING INNER BELT WEATHERSTRIP, FRONT TRANSMISSION SHIFT . . . . . . . . . 21-125,21-238
RETAINER, ADAPTER/EXTENSION . . . . . . . . . 21-8 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37 INTERLOCK, SHIFTER/IGNITION . . . . . . . . . 8D-22
HOUSING AND PARK LOCK, EXTENSION . 21-191 INNER BELT WEATHERSTRIP, REAR INTERMITTENT AND POOR
HOUSING BUSHING, EXTENSION . . . . . . . 21-147 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45 CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 8W-8
HOUSING, CLUTCH . . . . . . . . . . . . . . . . . . . . 6-13 INNER SCUFF PLATE, FRONT . . . . . . . . . . . 23-52 INTERNATIONAL SYMBOLS;
HOUSING DOOR, HEATER-A/C . . . . . . . . . . 24-39 INPUT AND OUTPUT, DATA LINK INTRODUCTION . . . . . . . . . . . . . . . . . . . . . Intro.-2
HOUSING END PLUG . . . . . . . . . . . . . . . . . . 19-12 CONNECTOR—PCM . . . . . . . . . . . . . . . . . . . 14-35 INTERNATIONAL SYMBOLS;
HOUSING FLUID LEAK DIAGNOSIS, INPUT ANGLE, FRONT AXLE PINION . . . . . . . . 3-15 LUBRICATION AND MAINTENANCE . . . . . . . . . 0-1
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-132 INPUT ANGLE, REAR AXLE PINION . . . . . . . 3-15 INTRODUCTION; AUDIO SYSTEMS . . . . . . . . 8F-1
HOUSING, HEATER-A/C . . . . . . . . . . . . . . . . 24-36 INPUT, AUTOMATIC SHUTDOWN (ASD) INTRODUCTION; CHIME/BUZZER
HOUSING MISALIGNMENT, CLUTCH . . . . . . . . 6-6 RELAY SENSE—PCM . . . . . . . . . . . . . . . . . 14-29 WARNING SYSTEMS . . . . . . . . . . . . . . . . . . . 8U-1
HOUSING SEAL, ADAPTER . . . . . . . . 21-252,21-7 INPUT, BATTERY VOLTAGE—PCM . . . . . . . . 14-29 INTRODUCTION; ELECTRICALLY HEATED
HOUSING SEAL, EXTENSION . . . . . . . . . . . . . 21-7 INPUT, BRAKE SWITCH—PCM . . . . . . . . . . 14-29 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 8N-1,8N-8
HOUSING YOKE BUSHING, REAR . . . . . . . . 21-48 INPUT, ENGINE COOLANT INTRODUCTION; OVERHEAD CONSOLE
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . 2-12 TEMPERATURE SENSOR—PCM . . . . . . . . . 14-30 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-1
HUB BEARING AND AXLE SHAFT . . . . . . . . . 3-30 INPUT, EXTENDED IDLE SWITCH—PCM . . . 14-30 INTRODUCTION; POWER LOCK
HUB/BEARING . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 INPUT, FUEL LEVEL SENSOR—PCM . . . . . . 14-30 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-1
HYDRAULIC CLUTCH LINKAGE . . . . . . . . . . . . 6-4 INPUT, IGNITION CIRCUIT SENSE—PCM . . 14-31 INTRODUCTION; POWER MIRROR
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . 5-34 INPUT, INTAKE MANIFOLD AIR SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-1
HYDRAULIC CONTROL UNIT/ TEMPERATURE SENSOR—PCM . . . . . . . . . 14-32 INTRODUCTION; POWER SEAT SYSTEMS . . 8R-1
CONTROLLER ANTILOCK BRAKE . . . . . . . . . 5-39 INPUT, MANIFOLD ABSOLUTE INTRODUCTION; POWER WINDOW
HYDRAULIC CONTROL UNIT/ PRESSURE (MAP) SENSOR—PCM . . . . . . . 14-32 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-1
CONTROLLER ANTILOCK BRAKES . . . . . . . . 5-36 INPUT, OIL PRESSURE SENSOR—PCM . . . 14-33 INTRODUCTION; VEHICLE THEFT/
HYDRAULIC LINKAGE, CLUTCH . . . . . . . . . . 6-13 INPUT, OXYGEN SENSOR—PCM . . . . . . . . . 14-30 SECURITY SYSTEMS . . . . . . . . . . . . . . . . . . 8Q-1
HYDRAULIC PRESSURE TEST . . . . 21-129,21-241 INPUT, POWER STEERING PRESSURE INTRODUCTION; WIPER AND WASHER
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . 21-201 SWITCH—PCM . . . . . . . . . . . . . . . . . . . . . . 14-33 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . 21-237 INPUT, SENSOR RETURN—PCM . . . . . . . . . 14-34 INTRODUCTION; WIRING DIAGRAMS . . . . . 8W-1
HYDRAULIC TAPPET . . . . . . . . . . . . . . . . 9-67,9-7 INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . 21-30 ISOLATORS, COIL SPRINGS . . . . . . . . . . 2-16,2-8
HYDRAULIC TAPPETS . . . . . . . . 9-100,9-113,9-40 INPUT, THROTTLE POSITION SENSOR JAMB SWITCH, DRIVER DOOR . . . . . . . . . . . 8U-2
HYDROSTATIC LOCK . . . . . . . . . . . . . . . 9-27,9-88 (TPS)—PCM . . . . . . . . . . . . . . . . . . . . . . . . 14-34 JOINT ANGLE, PROPELLER SHAFT . . . . . . . . . 3-3
IDENTIFICATION, FASTENER . . . . . . . . . . . Intro.-3 INPUT, VEHICLE SPEED AND DISTANCE JOINT, DOUBLE CARDAN . . . . . . . . . . . . . . . 3-11
IDENTIFICATION NUMBER, VEHICLE . . . . Intro.-1 SENSOR—PCM . . . . . . . . . . . . . . . . . . . . . . 14-34 JOINT, SINGLE CARDAN UNIVERSAL . . . . . . . 3-9
IDENTIFICATION, SECTION . . . . . . . . . . . . . . 8W-5 INSIDE HANDLE ACTUATOR, FRONT JOINTS, PROPELLER SHAFT . . . . . . . . . . . . . . 3-2
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . 14-45 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37 JOUNCE BUMPER . . . . . . . . . . . . . . . . . . . . . . 2-7
IDLE AIR CONTROL (IAC) MOTOR—PCM INSIDE HANDLE ACTUATOR, REAR JOUNCE BUMPERS . . . . . . . . . . . . . . . . . . . . 2-16
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45 JUMP STARTING PROCEDURE . . . . . . . . . . . . 0-9
IDLE SWITCH—PCM INPUT, EXTENDED . . . 14-30 INSPECTION AND ADJUSTMENT, JUMP STARTING, TOWING AND
IDLER GEAR, SEMI-SYNCHRONIZED PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . 21-241 HOISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-36 INSPECTION, ENGINE OIL LEAK . . . . . . 9-14,9-74 JUNCTION BLOCK . . . . . . . . . . . . . . . . 8O-3,8O-6
IGNITION CIRCUIT SENSE—PCM INPUT . . 14-31 INSPECTION, TORQUE CONVERTER JUNCTION BLOCK, 8W-12 . . . . . . . . . . . . . . 8W-1
IGNITION COIL RESISTANCE—2.5L STATOR CLUTCH . . . . . . . . . . . . . . . . . . . . 21-247 KEY CYLINDER, IGNITION SWITCH . . . . . . 8D-20
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 INSPECTION, TRANSMISSION PARTS KEY IMMOBILIZER MODULE, SENTRY . 8Q-1,8Q-4
IGNITION COIL RESISTANCE—4.0L CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 21-336 KEY IMMOBILIZER SYSTEM INDICATOR
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 INSPECTION, UNSCHEDULED . . . . . . . . . . . . . 0-4 LAMP, SENTRY . . . . . . . . . . . . . . . . . . . . . . . 8Q-3
IGNITION COIL-2.5L ENGINE . . . . . . . . . . . . 8D-3 INSPECTION, VISUAL . . . . . . . . . . . . . . . . . 14-37 KEY IMMOBILIZER SYSTEM, SENTRY . 8Q-1,8Q-3
IGNITION COIL—2.5L ENGINE . . . . . . . . . . 8D-12 INSPECTION, WHEEL . . . . . . . . . . . . . . . . . . 22-7 KEY IMMOBILIZER SYSTEM
IGNITION COIL—4.0L ENGINE . . . . . . 8D-12,8D-3 INSTALLATION METHODS AND PARTS TRANSPONDER PROGRAMMING,
IGNITION SWITCH AND KEY CYLINDER . . . 8D-20 USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 SENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-4
IGNITION SWITCH AND KEY LOCK INSTALLATION, WHEEL . . . . . . . . . . . . . . . . . 22-8 KEY IMMOBILIZER TRANSPONDER,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9 INSTRUMENT CLUSTER; CHIME/BUZZER SENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-2
IGNITION SWITCH, KEY-IN . . . . . . . . . . 8U-2,8U-3 WARNING SYSTEMS . . . . . . . . . . . . . . 8U-1,8U-3 KEY LOCK CYLINDER, IGNITION SWITCH . . 8D-5,
INSTRUMENT CLUSTER; ELECTRICALLY 8D-9
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . 8D-1 HEATED SYSTEMS . . . . . . . . . . . . . . . . 8N-2,8N-5 KEY-IN IGNITION SWITCH . . . . . . . . . . 8U-2,8U-3
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . 8D-23 INSTRUMENT CLUSTER; INSTRUMENT KEYLESS ENTRY RECEIVER
IGNITION-OFF DRAW FUSE; AUDIO PANEL SYSTEMS . . . . . . . . . . . . 8E-18,8E-2,8E-5 PROGRAMMING, REMOTE . . . . . . . . . . . . . . 8P-6
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1 INSTRUMENT CLUSTER, 8W-40 . . . . . . . . . 8W-1 KEYLESS ENTRY RECEIVER, REMOTE . 8P-2,8P-5,
IGNITION-OFF DRAW FUSE; POWER INSTRUMENT CLUSTER COMPONENTS . . . 8E-19 8P-8
DISTRIBUTION SYSTEMS . . . . . . . . . . . 8O-2,8O-5 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-1 KEYLESS ENTRY SYSTEM, POWER LOCK
IMMOBILIZER MODULE, SENTRY KEY . 8Q-1,8Q-4 INSTRUMENT PANEL ACCESSORY SYSTEM AND REMOTE . . . . . . . . . . . . . . . . . 8P-3
IMMOBILIZER SYSTEM INDICATOR SWITCH BEZEL . . . . . . . . . . . . . . . . . . . . . . 8E-15 KEYLESS ENTRY SYSTEM, REMOTE . . . . . . 8P-1
LAMP, SENTRY KEY . . . . . . . . . . . . . . . . . . . 8Q-3 INSTRUMENT PANEL ASSEMBLY . . . . . . . . 8E-26 KEYLESS ENTRY TRANSMITTER
IMMOBILIZER SYSTEM, SENTRY KEY . 8Q-1,8Q-3 INSTRUMENT PANEL CENTER BEZEL . . . . . 8E-14 BATTERY REPLACEMENT, REMOTE . . . . . . . 8P-6
IMMOBILIZER SYSTEM TRANSPONDER INSTRUMENT PANEL CENTER SUPPORT KEYLESS ENTRY TRANSMITTER
PROGRAMMING, SENTRY KEY . . . . . . . . . . . 8Q-4 BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-26 PROGRAMMING, REMOTE . . . . . . . . . . . . . . 8P-6
IMMOBILIZER TRANSPONDER, SENTRY INSTRUMENT PANEL CIGAR LIGHTER . . . . 8E-11, KEYLESS ENTRY TRANSMITTER,
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-2 8E-3 REMOTE . . . . . . . . . . . . . . . . . . . . . . . . 8P-2,8P-5
8 INDEX XJ
Description Group-Page Description Group-Page Description Group-Page
KICK COVER . . . . . . . . . . . . . . . . . . . . . . . . 24-42 LEFT FRONT FENDER . . . . . . . . . . . . . . . . . 23-32 LOW PRESSURE CYCLING CLUTCH
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . 8E-14 LEVEL AERATION, COOLANT—LOW . . . . . . . 7-21 SWITCH . . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7
KNOCK, LOW SPEED . . . . . . . . . . 3-109,3-21,3-70 LEVEL, BRAKE FLUID . . . . . . . . . . . . . . . . . . 5-12 LOW SPEED KNOCK . . . . . . . . . . 3-109,3-21,3-70
KNUCKLE AND BALL STUDS, STEERING . . . 3-31 LEVEL CHECK, COOLANT—ROUTINE . . . . . . 7-21 LOWER A-PILLAR COWL TRIM . . . . . . . . . . 23-51
KNUCKLE, STEERING . . . . . . . . . . . . . . . . . . 2-10 LEVEL CHECK, FLUID . . . . . . . . . . . . . . . . 21-141 LOWER SUSPENSION ARM . . . . . . . . . . . . . . 2-10
LABEL, VEHICLE EMISSION CONTROL LEVEL, CHECKING FLUID . . . . . . . . . . . . . 21-247 LOWER SUSPENSION ARMS AND
INFORMATION (VECI) . . . . . . . . . . . . . . . . . 25-26 LEVEL, CLUTCH FLUID . . . . . . . . . . . . . . . . . 6-10 BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
LABEL, VEHICLE SAFETY CERTIFICATION . Intro.-2 LEVEL, EFFECTS OF INCORRECT FLUID . . 21-126, LUBRICANT; DIFFERENTIAL AND
LAG TEST ANALYSIS, TIME . . . . . . . . . . . . 21-243 21-239 DRIVELINE . . . . . . . . . . . . . . . . . 3-104,3-17,3-66
LAG TEST, TIME . . . . . . . . . . . . . . . . . . . . 21-242 LEVEL, LOW LUBRICANT . . . . . . . . . . 21-3,21-44 LUBRICANT; TRANSMISSION AND
LAMP, ABS WARNING . . . . . . . . . . . . . . . . . . 5-35 LEVEL, LUBRICANT AND FILL . . . . 21-347,21-376 TRANSFER CASE . . . . . . . . . . . . . . . . . 21-2,21-43
LAMP ADJUSTMENT, FOG . . . . . . . . . . . . . . . 8L-8 LEVEL, REFRIGERANT OIL . . . . . . . . . . . . . 24-19 LUBRICANT AND FILL LEVEL . . . . 21-347,21-376
LAMP ALIGNMENT SCREEN LEVEL SENSOR, WASHER FLUID . . . . . . . . . 8K-4 LUBRICANT CHANGE . . . . . . . . . 3-110,3-21,3-71
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 8L-6 LEVEL SENSOR—PCM INPUT, FUEL . . . . . . 14-30 LUBRICANT LEVEL, LOW . . . . . . . . . . 21-3,21-44
LAMP, BACK-UP/BRAKE/REAR TURN LEVER, PARKING BRAKE . . . . . . . . . . . . . . . 5-23 LUBRICANT RECOMMENDATIONS,
SIGNAL/TAIL . . . . . . . . . . . . . . . . . . . . . . . . 8L-16 LEVER POSITIONS, TRANSMISSION PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
LAMP BULB, BACK-UP/BRAKE/REAR RANGES AND SHIFT . . . . . . . . . . . . . . . . . 21-236 LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
TURN SIGNAL/TAIL . . . . . . . . . . . . . . . . . . . 8L-11 LEVER, SHIFT . . . . . . . . . . . . . . . . 21-349,21-377 LUBRICANTS, BODY . . . . . . . . . . . . . . . . . . 23-67
LAMP BULB, CARGO . . . . . . . . . . . . . . . . . . 8L-13 LICENSE PLATE LAMP . . . . . . . . . . . . . . . . 8L-16 LUBRICANTS, CLASSIFICATION OF . . . . . . . . . 0-1
LAMP BULB, FOG . . . . . . . . . . . . . . . . . . . . 8L-10 LICENSE PLATE LAMP BULB . . . . . . . . . . . 8L-12 LUBRICATION, BODY . . . . . . . . . . . . . . . . . . 23-23
LAMP BULB, FRONT PARK/TURN LIFTGATE . . . . . . . . . . . . . . . . . . . . . . 23-62,23-67 LUBRICATION, CLUTCH COMPONENT . . . . . . . 6-9
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11 LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . 23-11 LUBRICATION SYSTEM . . . . . . . . . . . . . . 9-2,9-62
LAMP BULB, LICENSE PLATE . . . . . . . . . . . 8L-12 LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . 23-62 LUGGAGE RACK . . . . . . . . . . . . . . . . . . . . . 23-50
LAMP BULB, MAP READING . . . . . . . . . . . . 8L-13 LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . 23-64 MACHINING, BRAKE DRUM . . . . . . . . . . . . . 5-14
LAMP BULB, READING AND COURTESY . . . 8V-8 LIFTGATE LATCH STRIKER . . . . . . . . . . . . . 23-64 MACHINING, DISC ROTOR . . . . . . . . . . . . . . 5-13
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . 8L-10 LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . 23-64 MAIN BEARINGS, CRANKSHAFT . . . . . 9-105,9-47
LAMP BULB, SIDE MARKER . . . . . . . . . . . . 8L-11 LIFTGATE OPENING UPPER TRIM . . . . . . . . 23-55 MAIN BEARINGS, FITTING CRANKSHAFT . . 9-23,
LAMP BULB, UNDERHOOD . . . . . . . . . . . . . . 8L-12 LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . 23-63 9-83
LAMP BULB, VISOR VANITY . . . . . . . . . . . . 8L-13 LIFTGATE PILLAR TRIM . . . . . . . . . . . . . . . 23-55 MAIN COOLER, FLOW TESTING
LAMP, CARGO . . . . . . . . . . . . . . . . . . . . . . . 8L-17 LIFTGATE SCUFF PLATE . . . . . . . . . . . . . . . 23-55 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-246
LAMP (CHMSL) BULB, CENTER HIGH LIFTGATE SUPPORT ROD BALL STUD . . . . 23-63 MAIN OIL SEAL, REAR . . . . . . . . . . . . . . . . . 9-52
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-12 LIFTGATE SUPPORT ROD CYLINDER . . . . . 23-63 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . 0-4
LAMP (CHMSL), CENTER HIGH LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . 23-61 MALFUNCTION INDICATOR LAMP (MIL) . . . . 25-2
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-16 LIFTGATE WEATHERSTRIP . . . . . . . . . . . . . 23-65 MANAGER, TASK . . . . . . . . . . . . . . . . . . . . . 25-16
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 8L-3 LIGHTER, INSTRUMENT PANEL CIGAR . . . 8E-11, MANIFOLD ABSOLUTE PRESSURE (MAP)
LAMP, FOG . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15 8E-3 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
LAMP, FRONT PARK/TURN SIGNAL . . . . . . 8L-15 LIGHTER RELAY, CIGAR . . . . . . 8E-12,8E-16,8E-4 MANIFOLD ABSOLUTE PRESSURE (MAP)
LAMP, LICENSE PLATE . . . . . . . . . . . . . . . . 8L-16 LIGHTER/POWER OUTLET, 8W-41 SENSOR—PCM INPUT . . . . . . . . . . . . . . . . 14-32
LAMP, MAP/READING . . . . . . . . . . . . . . . . . 8L-17 HORN/CIGAR . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 MANIFOLD AIR TEMPERATURE SENSOR,
LAMP (MIL), MALFUNCTION INDICATOR . . . 25-2 LIGHTING, 8W-44 INTERIOR . . . . . . . . . . . . 8W-1 INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50
LAMP MODULE, DAYTIME RUNNING . . . . . 8L-19 LIGHTING, 8W-50 FRONT . . . . . . . . . . . . . . 8W-1 MANIFOLD AIR TEMPERATURE
LAMP, READING AND COURTESY . . . . . . . . . 8V-2 LIGHTING, 8W-51 REAR . . . . . . . . . . . . . . . 8W-1 SENSOR—PCM INPUT, INTAKE . . . . . . . . . . 14-32
LAMP, RED BRAKE WARNING . . . . . . . . . 5-3,5-9 LIMITS, HIGH AND LOW . . . . . . . . . . . . . . . 25-22 MANIFOLD, EXHAUST . . . . . . . . . . . 9-35,9-68,9-8
LAMP, SENTRY KEY IMMOBILIZER LINE AND HOSES, BRAKE . . . . . . . . . . . . . . . 5-12 MANIFOLD, INTAKE . . . . . . . . . . . . . 9-33,9-67,9-8
SYSTEM INDICATOR . . . . . . . . . . . . . . . . . . . 8Q-3 LINE COUPLER, REFRIGERANT . . . . . . . . . . 24-45 MANIFOLD, INTAKE AND EXHAUST . . . . . . . 9-95
LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . 8L-14 LINE COUPLERS, REFRIGERANT . . . . . . . . . . 24-8 MANIFOLD LEAKAGE DIAGNOSIS,
LAMP, SIDE MARKER . . . . . . . . . . . . . . . . . 8L-15 LINE, LIQUID . . . . . . . . . . . . . . . . . . . . . . . . 24-41 INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-72
LAMP SWITCH, BRAKE; BRAKES . . 5-15,5-2,5-30, LINE, POWER STEERING PRESSURE . . . . . . 19-5 MANIFOLD—4.0L ENGINE, EXHAUST . . . . . . 9-96
5-9 LINE, POWER STEERING RETURN . . . . . . . . 19-6 MANUAL SHIFTING TEST . . . . . . . . . . . . . 21-241
LAMP SWITCH, BRAKE; SPEED LINE, SUCTION AND DISCHARGE . . . . . . . . 24-45 MANUAL TRANSMISSION, AX5 . . . . . . . . . . . 21-1
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-3 LINER, FRONT WHEELHOUSE . . . . . . . . . . . 23-32 MANUAL TRANSMISSION COMPONENTS,
LAMP SYSTEMS . . . . . . . . . . . . . . . . . 8L-1,8L-19 LINES, BRAKE HOSES . . . . . . . . . . . . . . . . . . . 5-7 AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37
LAMP, UNDERHOOD . . . . . . . . . . . . . . . . . . 8L-16 LINES, REFRIGERANT . . . . . . . . . . . . . . . . . . 24-7 MANUAL TRANSMISSION, NV3550 . . 21-42,21-85
LAMP, VISOR VANITY . . . . . . . . . . . . . . . . . 8L-18 LINK CONNECTOR—PCM INPUT AND MANUAL TRANSMISSION, NV3550
LAMPS, EXTERIOR . . . . . . . . . . . . . . . . . . . 8L-20 OUTPUT, DATA . . . . . . . . . . . . . . . . . . . . . . . 14-35 MANUAL TRANSMISSIONNV3550 . . . . . . . . 21-42
LAMPS, INTERIOR . . . . . . . . . . . . . . . . . . . . 8L-20 LINK, DRAG . . . . . . . . . . . . . . . . . . . . . . . . . 19-24 MANUAL TRANSMISSIONNV3550
LATCH ADJUSTMENT, DOOR . . . . . . . . . . . . 23-66 LINKAGE ADJUSTMENT, SHIFT . . . 21-372,21-405 MANUAL TRANSMISSION, NV3550 . . . . . . . 21-42
LATCH, FRONT DOOR . . . . . . . . . . . . . . . . . 23-37 LINKAGE AND PIVOT, WIPER . . . . . . . . 8K-2,8K-9 MANUAL VALVE SHAFT SEAL . . . . . . . . . . 21-262
LATCH, HOOD . . . . . . . . . . . . . . . . . . . . . . . 23-26 LINKAGE, CLUTCH HYDRAULIC . . . . . . . . . . 6-13 MAP READING LAMP BULB . . . . . . . . . . . . 8L-13
LATCH, HOOD SAFETY . . . . . . . . . . . . . . . . 23-27 LINKAGE FLUID, CLUTCH . . . . . . . . . . . . . . . . 6-9 MAP/READING LAMP . . . . . . . . . . . . . . . . . 8L-17
LATCH, LIFTGATE . . . . . . . . . . . . . . . . . . . . 23-64 LINKAGE, HYDRAULIC CLUTCH . . . . . . . . . . . 6-4 MARKER LAMP BULB, SIDE . . . . . . . . . . . . 8L-11
LATCH, REAR DOOR . . . . . . . . . . . . . . . . . . 23-44 LINKAGE, STEERING . . . . . . . . 19-22,19-23,19-25 MARKER LAMP, SIDE . . . . . . . . . . . . . . . . . 8L-15
LATCH STRIKER AND BUMPER, REAR LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . 24-41 MASTER CYLINDER . . . . . . . . . . . . . . . . 5-16,5-3
SEATBACK . . . . . . . . . . . . . . . . . . . . . . . . . . 23-19 LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . 25-22 MASTER CYLINDER BLEEDING . . . . . . . . . . . 5-12
LATCH STRIKER, FRONT DOOR . . . . . . . . . 23-37 LOCATIONS, 8W-90 CONNECTOR . . . . . . . . 8W-1 MASTER CYLINDER RESERVOIR . . . . . . . . . 5-24
LATCH STRIKER, GLOVE BOX . . . . . . . . . . . 8E-24 LOCATIONS, 8W-95 SPLICE . . . . . . . . . . . . . 8W-1 MASTER CYLINDER/POWER BOOSTER . . . . . 5-10
LATCH STRIKER, HOOD . . . . . . . . . . . . . . . 23-26 LOCATIONS, BODY SEALING . . . . . . . . . . . 23-112 MATCH MOUNTING . . . . . . . . . . . . . . . . . . . . 22-4
LATCH STRIKER, LIFTGATE . . . . . . . . . . . . . 23-64 LOCATIONS, CONNECTOR/GROUND . . . . . . 8W-1 MEASUREMENT PREPARATION,
LATCH STRIKER, REAR DOOR . . . . . . . . . . 23-45 LOCATIONS, SPLICE . . . . . . . . . . . . . . 8W-1,8W-7 DRIVELINE ANGLE . . . . . . . . . . . . . . . . . . . . . 3-6
LATCH STRIKER, SAFETY . . . . . . . . . . . . . . 23-27 LOCATIONS, STRUCTURAL ADHESIVE . . . 23-124 MEASUREMENT, PROPELLER SHAFT
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . 2-18 LOCATIONS, WELD . . . . . . . . . . . . . . . . . . . 23-68 ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
LEAF SPRING AND SHACKLE BUSHING . . . . 2-18 LOCK CYLINDER, FRONT DOOR . . . . . . . . . 23-36 MEASUREMENTS, BODY GAP AND
LEAK DETECTION PUMP (LDP) . . . . 25-24,25-27, LOCK CYLINDER, IGNITION SWITCH AND FLUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-127
25-28 KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9 MECHANISM AND GEARTRAIN, SHIFT . . . . 21-17
LEAK DIAGNOSIS, CONVERTER LOCK CYLINDER, LIFTGATE . . . . . . . . . . . . 23-64 MECHANISM, BRAKE TRANSMISSION
HOUSING FLUID . . . . . . . . . . . . . . . . . . . . 21-132 LOCK CYLINDERS . . . . . . . . . . . . . . . . . . . . 23-37 SHIFT INTERLOCK . . . . . . . . . . . . . 21-125,21-238
LEAK DOWN TEST, FUEL PRESSURE . . . . . . 14-7 LOCK, EXTENSION HOUSING AND PARK . 21-191 MECHANISM, GEARSHIFT . . . . . . . . . . . . . 21-124
LEAK INSPECTION, ENGINE OIL . . . . . . 9-14,9-74 METHODS AND PARTS USAGE,
LEAKAGE DIAGNOSIS, INTAKE LOCK, HYDROSTATIC . . . . . . . . . . . . . . 9-27,9-88 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-72 LOCK MOTOR, POWER . . . . . . . . 8P-2,8P-4,8P-7 METRIC SYSTEM . . . . . . . . . . . . . . . . . . . Intro.-6
LEAKAGE DIAGNOSIS, PUMP . . . . . . . . . . . . 19-7 LOCK, PARK . . . . . . . . . . . . . . . . . . . . . . . 21-154 MINIMUM AIR FLOW CHECK
LEAKAGE, POWER STEERING GEAR . . . . . . 19-11 LOCK SWITCH, POWER . . . . . . . . . . . . . . . . 8P-2 PROCEDURE, THROTTLE BODY . . . . . . . . . 14-42
LEAKAGE TEST, CYLINDER COMBUSTION LOCK SYSTEM AND REMOTE KEYLESS MIRROR HEATING GRID, OUTSIDE . . . . . . . 8N-2
PRESSURE . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73 ENTRY SYSTEM, POWER . . . . . . . . . . . . . . . 8P-3 MIRROR, POWER . . . . . . . . . . . . . . . . . 8T-1,8T-4
LEAKS, COOLING SYSTEM—TESTING . . . . . 7-17 LOCK SYSTEM, POWER . . . . . . . . . . . . . . . . 8P-1 MIRROR, REARVIEW . . . . . . . . . . . . . . . . . . 23-59
LEAKS, REFRIGERANT SYSTEM . . . . . . . . . 24-17 LOCKS, 8W-61 POWER DOOR . . . . . . . . . . . 8W-1 MIRROR, SIDE VIEW . . . . . . . . . . . . . . . . . . 23-31
LEAKS, REPAIRING . . . . . . . . . . . . . . . . . . . . 22-5 LOW LIMITS, HIGH . . . . . . . . . . . . . . . . . . . 25-22 MIRROR SUPPORT BRACKET, REARVIEW . 23-59
LEAKS, WATER . . . . . . . . . . . . . . . . . . . . . . 23-22 LOW LUBRICANT LEVEL . . . . . . . . . . . 21-3,21-44 MIRROR SWITCH, POWER . . . . . . . . . . 8T-1,8T-3
XJ INDEX 9
Description Group-Page Description Group-Page Description Group-Page
MIRROR SYSTEM, POWER . . . . . . . . . . 8T-1,8T-2 NV231 TRANSFER CASENV231 OVERHAUL OR FLUID/FILTER CHANGE,
MIRRORS, 8W-62 POWER . . . . . . . . . . . . . . 8W-1 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-346 REFILLING AFTER . . . . . . . . . . . . . . . . . . . 21-248
MISALIGNMENT, CLUTCH . . . . . . . . . . . . . . . . 6-6 NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-406 OVERHEAD CONSOLE . . . . . . . . . . . . . . 8V-1,8V-6
MISALIGNMENT, CLUTCH HOUSING . . . . . . . . 6-6 NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . 21-376 OVERHEAD CONSOLE, 8W-49 . . . . . . . . . . . 8W-1
MODE, CIRCUIT ACTUATION TEST . . . . . . . . 25-2 NV242 TRANSFER CASE . . 21-375,21-380,21-402 OVERRUNNING CLUTCH . . . . . . . . . . . . . . 21-122
MODE DOOR VACUUM ACTUATOR . . . . . . . 24-43 NV242 TRANSFER CASENV242 OVERRUNNING CLUTCH/LOW-REVERSE
MODE, STATE DISPLAY TEST . . . . . . . . . . . . 25-2 TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-375 DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-175
MODES OF OPERATION . . . . . . . . . . . . . . . . 14-26 NV3550 MANUAL TRANSMISSION . . 21-42,21-85 OVERRUNNING CLUTCH/LOW-REVERSE
MODULE, AIRBAG CONTROL . . . . . . 8M-12,8M-3 NV3550 MANUAL DRUM/OVERDRIVE PISTON RETAINER . . . 21-195
MODULE, DAYTIME RUNNING LAMP . . . . . 8L-19 TRANSMISSIONNV3550 MANUAL OXYGEN SENSOR . . . . . . . . . . . . . . . . . . . . 14-47
MODULE, DOOR; POWER LOCK TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-42 OXYGEN SENSOR—PCM INPUT . . . . . . . . . 14-30
SYSTEMS . . . . . . . . . . . . . . . . . . . 8P-2,8P-3,8P-7 OIL COOLER, AUTOMATIC PACK/OUTPUT SHAFT, PLANETARY/
MODULE, DOOR; POWER MIRROR TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 7-2 BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-329
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 8T-2,8T-3 OIL COOLERS, TRANSMISSION . . . . . . . . . . 7-23 PAD, HOOD SILENCER . . . . . . . . . . . . . . . . 23-27
MODULE, DOOR; POWER WINDOW OIL LEAK INSPECTION, ENGINE . . . . . . 9-14,9-74 PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
SYSTEMS . . . . . . . . . . . . . . . . . . . 8S-2,8S-3,8S-4 OIL LEVEL, REFRIGERANT . . . . . . . . . . . . . 24-19 PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
MODULE, DRIVER SIDE AIRBAG . . . . 8M-2,8M-6 OIL PAN . . . . . . . . . . . . . . . . 9-107,9-49,9-67,9-7 PAINT REPAIR PRODUCTS,
MODULE, FUEL PUMP . . . . . . . . . . . . 14-14,14-2 OIL PRESSURE, ENGINE . . . . . . . . . . . . 9-15,9-75 AFTERMARKET . . . . . . . . . . . . . . . . . . . . . . . 23-5
MODULE, PASSENGER SIDE AIRBAG . 8M-3,8M-9 OIL PRESSURE SENSOR—PCM INPUT . . . 14-33 PAINTED SURFACE TOUCH-UP . . . . . . . . . . . 23-4
MODULE (PCM), POWERTRAIN OIL PUMP; ENGINE . . . . . . . . . . . . . . . 9-111,9-50 PAN, OIL . . . . . . . . . . . . . . . . 9-107,9-49,9-67,9-7
CONTROL . . . . . . . . . . . . . . . . . . . . . 14-25,14-46 OIL PUMP; TRANSMISSION AND PANEL ACCESSORY SWITCH BEZEL,
MODULE, PUSH BUTTON . . . . . . . . . . . . . . . 8V-7 TRANSFER CASE . . . . . . . . 21-101,21-227,21-298 INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 8E-15
MODULE, SEAT HEAT INTERFACE . . . 8N-12,8N-9 OIL PUMP AND REACTION SHAFT PANEL ASSEMBLY, INSTRUMENT . . . . . . . . 8E-26
MODULE, SENTINEL HEADLAMP DELAY . . . 8L-19 SUPPORT . . . . . . . . . . . . . . . . . . . 21-177,21-195 PANEL CENTER BEZEL, INSTRUMENT . . . . 8E-14
MODULE, SENTRY KEY IMMOBILIZER . 8Q-1,8Q-4 OIL PUMP SEAL . . . . . . . . . . . . . . . . . . . . 21-268 PANEL CENTER SUPPORT BRACKET,
MODULE (TCM) SERVICE, OIL PUMP VOLUME CHECK . . . . . 21-142,21-248 INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 8E-26
TRANSMISSION CONTROL . . . . . . . . . . . . 21-248 OIL, REFRIGERANT . . . . . . . . . . . . . . . . . . . . 24-8 PANEL CIGAR LIGHTER, INSTRUMENT . . . 8E-11,
MODULE (TCM), TRANSMISSION OIL SEAL, AXLE SHAFT . . . . . . . . . . . . . . . . . 3-36 8E-3
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 21-237 OIL SEAL, REAR MAIN . . . . . . . . . . . . . . . . . . . 9-52 PANEL END CAP, INSTRUMENT . . . . . . . . . 8E-25
MODULE, TRANSMISSION CONTROL . . . . 21-260 OIL SEAL, TIMING CASE COVER . . . . . 9-112,9-41 PANEL, FRONT DOOR TRIM . . . . . . . . . . . . 23-33
MODULE TRIM COVER, DRIVER SIDE OIL SEALS, VALVE SPRINGS . . . . . . . . . . . . . 9-97 PANEL (GOP), GRILLE OPENING . . . . . . . . . 23-24
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7 OIL SEALS—REAR, CRANKSHAFT . . . . . . . 9-110 PANEL, INSTRUMENT . . . . . . . . . . . . . . . . . . 8E-1
MODULE, TRIP COMPUTER, COMPASS, OIL SERVICE, ENGINE . . . . . . . . . . . . . . 9-27,9-88 PANEL, LIFTGATE TRIM . . . . . . . . . . . . . . . . 23-61
AND THERMOMETER DISPLAY . . . . . . . 8V-3,8V-7 ON-BOARD DIAGNOSTIC TEST FOR PANEL POWER OUTLET, INSTRUMENT . . . 8E-12,
MOLDING, BODY SIDE . . . . . . . . . . . . . . . . 23-48 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . 8C-3 8E-4
MOLDING, DRIP RAIL . . . . . . . . . . . . . . . . . 23-49 ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . 25-1 PANEL, REAR DOOR TRIM . . . . . . . . . . . . . 23-42
MOLDING, FRONT DOOR GLASS ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . 7-9 PANEL SYSTEM, INSTRUMENT . . . . . . . . . . . 8E-1
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39 ONE–WAY CLUTCH, SUN GEAR AND PANEL TOP COVER, INSTRUMENT . . . . . . . 8E-21
MOLDING, REAR DOOR GLASS NO. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-324 PANEL TRIM AND WHEELHOUSE COVER,
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46 OPENER STORAGE BIN DOOR, GARAGE QUARTER . . . . . . . . . . . . . . . . . . . . . . . . . . 23-54
MONITORED SYSTEMS . . . . . . . . . . . . . . . . 25-19 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8 PANEL TRIM EXTENSION, QUARTER . . . . . 23-54
MONITORS, COMPONENT . . . . . . . . . . . . . . 25-21 OPENER STORAGE BIN, GARAGE DOOR . . . 8V-3 PARK GEAR, GOVERNOR . 21-153,21-154,21-191
MOTOR, BLEND-AIR DOOR . . . . . . . . . . . . . 24-26 OPENING COVER, STEERING COLUMN . . . . 8E-13 PARK LOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-154
MOTOR, BLOWER . . . . . . . . . . . 24-12,24-2,24-26 OPENING DIMENSIONS, BODY . . . . . . . . . 23-128 PARK LOCK, EXTENSION HOUSING . . . . . 21-191
MOTOR, IDLE AIR CONTROL (IAC) . . . . . . . 14-45 OPENING PANEL (GOP), GRILLE . . . . . . . . . 23-24 PARK ROD AND PAWL . . . . . . . . . . . . . . . 21-266
MOTOR NOISE - 2.5L ENGINE, STARTER . . . 8B-8 OPENING SECONDARY WEATHERSTRIP, PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . 5-5
MOTOR, POWER LOCK . . . . . . . . 8P-2,8P-4,8P-7 FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-39 PARKING BRAKE CABLE TENSIONER . . . . . . 5-31
MOTOR, POWER WINDOW . . . . . 8S-2,8S-4,8S-6 OPENING UPPER TRIM, LIFTGATE . . . . . . . 23-55 PARKING BRAKE CABLES, REAR . . . . . . . . . 5-23
MOTOR RELAY, BLOWER . . . . . 24-13,24-2,24-27 OPENING WEATHERSTRIP, FRONT DOOR . . 23-38 PARKING BRAKE LEVER . . . . . . . . . . . . . . . . 5-23
MOTOR RESISTOR, BLOWER . . 24-14,24-27,24-3 OPERATION, AIR TESTING PARK/NEUTRAL POSITION SWITCH . . . . . 21-128,
MOTOR, STARTER . . . . . . . . . . . 8B-11,8B-2,8B-9 TRANSMISSION CLUTCH AND BAND . . . . 21-131 21-149,21-245,21-255
MOTOR SWITCH, BLOWER . . . . . . . . . 24-14,24-3 OPERATION, DESCRIPTION; BODY . . . . . . . . 23-1 PARK/TURN SIGNAL LAMP BULB,
MOTOR, WIPER . . . . . . . . . . . . . . . . . . 8K-2,8K-9 OPERATION, DESCRIPTION; FRAME AND FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11
MOTOR—PCM OUTPUT, IDLE AIR BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 PARK/TURN SIGNAL LAMP, FRONT . . . . . . 8L-15
CONTROL (IAC) . . . . . . . . . . . . . . . . . . . . . . 14-35 OPERATION, MODES OF . . . . . . . . . . . . . . . 14-26 PARTS AND LUBRICANT
MOTORS, POWER SEAT ADJUSTER . . 8R-1,8R-2, OPERATION, POWER STEERING PUMP - RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 0-1
8R-3 INITIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7 PARTS CLEANING AND INSPECTION,
MOUNTED STOP LAMP (CHMSL) BULB, ORIFICE TUBE, FIXED . . . . . . . . . . . . . 24-35,24-5 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-336
CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-12 OUTER BELT WEATHERSTRIP, FRONT PARTS USAGE, INSTALLATION METHODS . . . 6-4
MOUNTED STOP LAMP (CHMSL), DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38 PASSENGER SIDE AIRBAG DOOR . . . . . . . 8M-11
CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-16 OUTER BELT WEATHERSTRIP, REAR PASSENGER SIDE AIRBAG MODULE . 8M-3,8M-9
MOUNTING, MATCH . . . . . . . . . . . . . . . . . . . 22-4 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45 PASSIVE RESTRAINT SYSTEMS . . . . . . . . . 8M-16
MOUNTING STUDS, WHEEL . . . . . . . . . . . . . 2-13 OUTLET, 8W-41 HORN/CIGAR PATTERN ANALYSIS, GEAR CONTACT . . . . 3-129,
MOUNT—REAR, ENGINE . . . . . . . . . . . 9-30,9-91 LIGHTER/POWER . . . . . . . . . . . . . . . . . . . . . 8W-1 3-59,3-97
MOUNTS—FRONT, ENGINE . . . . . . . . . . 9-29,9-90 OUTLET, INSTRUMENT PANEL POWER . . . 8E-12, PATTERNS, TIRE WEAR . . . . . . . . . . . . . . . . 22-3
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3 8E-4 PAWL, PARK ROD . . . . . . . . . . . . . . . . . . . 21-266
MUFFLER AND TAILPIPE . . . . . . . . . . . . . . . . 11-6 OUTLETS, DUCTS . . . . . . . . . . . . . . . . . . . . 24-33 PCM VIN REPROGRAMMING . . . . . . . . . . . . 14-1
NAMEPLATES, EXTERIOR . . . . . . . . . . . . . . 23-30 OUTPUT, AUTO SHUTDOWN (ASD) PEDAL, ACCELERATOR . . . . . . . . . . . . . . . . 14-21
NECK SEAL—PRESSURE RELIEF CHECK, RELAY—PCM . . . . . . . . . . . . . . . . . . . . . . . 14-34 PEDAL, BRAKE . . . . . . . . . . . . . . . . . . . . 5-15,5-2
RADIATOR CAP-TO-FILLER . . . . . . . . . . . . . . 7-20 OUTPUT, DATA LINK CONNECTOR—PCM PERFORMANCE, A/C . . . . . . . . . . . . . . . . . . . 24-9
NOISE - 2.5L ENGINE, STARTER MOTOR . . . 8B-8 INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35 PERFORMANCE, ENGINE . . . . . . . . . . . . 9-26,9-87
NOISE, BEARING . . . . . . . . . . . . . 3-109,3-21,3-70 OUTPUT, FUEL INJECTORS—PCM . . . . . . . 14-35 PERFORMANCE, HEATER . . . . . . . . . . . . . . 24-16
NOISE, GEAR . . . . . . . . . . . . . . . . 3-109,3-21,3-70 OUTPUT, FUEL PUMP RELAY-PCM . . . . . . . 14-35 PILLAR TRIM, LIFTGATE . . . . . . . . . . . . . . . 23-55
NOISE OR VIBRATION, TIRE . . . . . . . . . . . . . 22-3 OUTPUT, IDLE AIR CONTROL (IAC) PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . 6-12
NOISE SUPPRESSION COMPONENTS, MOTOR—PCM . . . . . . . . . . . . . . . . . . . . . . . 14-35 PIN REPLACEMENT, CAMSHAFT . . . . . . . . . . 9-45
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-11 OUTPUT, RADIATOR FAN RELAY—PCM . . . 14-36 PINION, 181 FBI . . . . . . . . . . . . . . . . . . . . . . 3-36
NOISE SUPPRESSION, RADIO . . . . . . . . . . . . 8F-2 OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-31 PINION, 186 FBI . . . . . . . . . . . . . . . . . . . . . . 3-41
NOISE, TRAC–LOKY DIFFERENTIAL . . 3-109,3-70 PINION GEAR . . . . . . . . . . . . . . . . . . . 3-117,3-81
OUTPUT SHAFT REAR BEARING . . . . . . . . 21-153 PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . 3-91
NOISE, TRANSMISSION . . . . . . . . . . . 21-3,21-44 OUTPUT SHAFT SEAL, FRONT . . . 21-350,21-379 PINION GEAR DEPTH, 181 FBI . . . . . . . . . . . 3-48
NOISE, WIND . . . . . . . . . . . . . . . . . . . . . . . . 23-23 OUTPUTS, CCD BUS (+/-) CIRCUITS-PCM . 14-35 PINION GEAR DEPTH, 186 FBI . . . . . . . . . . . 3-50
NON-MONITORED CIRCUITS . . . . . . . . . . . . 25-22 OUTSIDE HANDLE, FRONT DOOR . . . . . . . . 23-35 PINION GEAR DEPTH, 8 1/4 AXLE . . . . . . . 3-126
NOTES, CAUTIONS, AND WARNINGS . . . . . 8W-7 OUTSIDE HANDLE, LIFTGATE . . . . . . . . . . . 23-63 PINION INPUT ANGLE, FRONT AXLE . . . . . . 3-15
NOZZLE AND PLUMBING, WASHER . . . . . . . 8K-4 OUTSIDE HANDLE, REAR DOOR . . . . . . . . . 23-44 PINION INPUT ANGLE, REAR AXLE . . . . . . . 3-15
NUMBER, VEHICLE IDENTIFICATION . . . . Intro.-1 OUTSIDE MIRROR HEATING GRID . . . . . . . . 8N-2 PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . 3-113
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-373 OVERDRIVE PLANETARY GEAR AND PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . 3-72
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . 21-347 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-301 PINION SHAFT SEAL, 181 FBI . . . . . . . . . . . . 3-24
NV231 TRANSFER CASE . . 21-346,21-351,21-369 OVERDRIVE SUPPORT . . . . . . . . . . . . . . . 21-309 PINION SHAFT SEAL, 186 FBI . . . . . . . . . . . . 3-26
10 INDEX XJ
Description Group-Page Description Group-Page Description Group-Page
PIN-OUTS, 8W-80 CONNECTOR . . . . . . . . . . 8W-1 POWER STEERING GEAR . . . . . . . . . 19-11,19-21 PROGRAMMING, REMOTE KEYLESS
PIPE, EXHAUST . . . . . . . . . . . . . . . . . . . . . . . 11-5 POWER STEERING GEAR LEAKAGE . . . . . . 19-11 ENTRY RECEIVER . . . . . . . . . . . . . . . . . . . . . 8P-6
PISTON AND CONNECTING ROD . . 9-51,9-6,9-66 POWER STEERING PRESSURE LINE . . . . . . . 19-5 PROGRAMMING, REMOTE KEYLESS
PISTON AND WORM SHAFT, RACK . . . . . . . 19-16 POWER STEERING PRESSURE ENTRY TRANSMITTER . . . . . . . . . . . . . . . . . 8P-6
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 9-77 SWITCH—2.5L ENGINE . . . . . . . . . . . . . . . . 14-47 PROGRAMMING, SENTRY KEY
PISTON, FRONT SERVO . . . . . . . . . . . . . . 21-176 POWER STEERING PRESSURE IMMOBILIZER SYSTEM TRANSPONDER . . . . 8Q-4
PISTON, REAR SERVO . . . . . . . . . . . . . . . 21-177 SWITCH—PCM INPUT . . . . . . . . . . . . . . . . 14-33 PROPELLER SHAFT . . . . . . . . . . . . . 3-1,3-14,3-15
PISTON RETAINER, OVERRUNNING POWER STEERING PUMP . . . . . . 19-10,19-5,19-7 PROPELLER SHAFT ANGLE
CLUTCH/LOW-REVERSE DRUM/ POWER STEERING PUMP - INITIAL MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 3-6
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-195 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7 PROPELLER SHAFT, FRONT . . . . . . . . . . . . . . 3-8
PISTON RING—FITTING . . . . . . . . . . . . 9-18,9-77 POWER STEERING RETURN LINE . . . . . . . . . 19-6 PROPELLER SHAFT JOINT ANGLE . . . . . . . . . 3-3
PISTON—FITTING . . . . . . . . . . . . . . . . . . . . . 9-17 POWER STEERING SYSTEM DIAGNOSIS PROPELLER SHAFT JOINTS . . . . . . . . . . . . . . 3-2
PISTONS . . . . . . . . . . . . . . . . . . . . 21-118,21-234 CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 PROPELLER SHAFT, REAR . . . . . . . . . . . . . . . 3-8
PISTONS AND CONNECTING RODS . . . . . . 9-108 POWER WINDOW MOTOR . . . . . . 8S-2,8S-4,8S-6 PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . 3-1
PISTONS AND SPRINGS, ACCUMULATOR . 21-264 POWER WINDOW SWITCH . . . . . . 8S-1,8S-4,8S-5 PROPELLER SHAFTS AND U–JOINTS . . . . . . 3-15
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . 19-24 POWER WINDOW SYSTEM . . . . . . . . . 8S-1,8S-2 PULLEY, PUMP . . . . . . . . . . . . . . . . . . . . . . . 19-8
PITMAN SHAFT/SEALS/BEARING . . . . . . . . 19-12 POWER WINDOWS, 8W-60 . . . . . . . . . . . . . 8W-1 PUMP - INITIAL OPERATION, POWER
PIVOT, WIPER LINKAGE . . . . . . . . . . . . 8K-2,8K-9 POWERTRAIN CONTROL MODULE (PCM) . 14-25, STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7
PLANETARY GEAR AND CLUTCH, 14-46 PUMP AMPERAGE TEST, FUEL . . . . . . . . . . . 14-8
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-301 PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 2-4 PUMP AND REACTION SHAFT SUPPORT,
PLANETARY GEAR, FRONT . . . . . . . . . . . . 21-322 PRECAUTIONS AND WARNINGS, SAFETY . . . 23-3 OIL . . . . . . . . . . . . . . . . . . . . . . . . . 21-177,21-195
PLANETARY GEARSET . . . . . . . . . . . . . . . . 21-122 PRECAUTIONS, SAFETY; BODY . . . . . . . . . . . 23-3 PUMP CAPACITY TEST, FUEL . . . . . . . . . . . . 14-7
PLANETARY GEARTRAIN/OUTPUT PRECAUTIONS, SAFETY; CLUTCH . . . . . . . . . . 6-4 PUMP, FUEL . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-185,21-197 PRECAUTIONS, SAFETY; LAMPS . . . . . . . . . . 8L-2 PUMP INLET FILTER, FUEL . . . . . . . . . . . . . 14-15
PLANETARY/BRAKE PACK/OUTPUT PRECAUTIONS, SERVICE WARNINGS . . . . . 24-23 PUMP (LDP), LEAK DETECTION . . . . 25-24,25-27,
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-329 PRECAUTIONS, WINDSHIELD SAFETY . . . . . 23-6 25-28
PLATE, BRAKE SUPPORT . . . . . . . . . . . . . . . 5-22 PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . 7-11 PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . 19-7
PLATE, CLUTCH PRESSURE . . . . . . . . . . . . . . . . 6-2 PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . 21-128 PUMP MODULE, FUEL . . . . . . . . . . . . 14-14,14-2
PLATE, DOOR SILL SCUFF . . . . . . . . . . . . . 23-52 PRELIMINARY INSPECTION AND PUMP, OIL; ENGINE . . . . . . . . . . . . . . . . 9-111,9-50
PLATE, FRONT INNER SCUFF . . . . . . . . . . . 23-52 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21-241 PUMP, OIL; TRANSMISSION AND
PLATE, FRONT SKID . . . . . . . . . . . . . . . . . . . 13-6 PRELOAD AND GEAR BACKLASH, 181 TRANSFER CASE . . . . . . . . 21-101,21-227,21-298
PLATE, FUEL TANK SKID . . . . . . . . . . . . . . . . 13-7 FBI DIFFERENTIAL BEARING . . . . . . . . . . . . . 3-52 PUMP, POWER STEERING . . . . . 19-10,19-5,19-7
PLATE LAMP BULB, LICENSE . . . . . . . . . . . 8L-12 PRELOAD AND GEAR BACKLASH, 186 PUMP PRESSURE TEST, FUEL . . . . . . . . . . . 14-6
PLATE LAMP, LICENSE . . . . . . . . . . . . . . . . 8L-16 FBI DIFFERENTIAL BEARING . . . . . . . . . . . . . 3-56 PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . 19-8
PLATE, LIFTGATE SCUFF . . . . . . . . . . . . . . . 23-55 PRELOAD AND GEAR BACKLASH, PUMP RELAY, FUEL . . . . . . . . . . . . . . . . . . . 14-44
PLATE, TRANSFER CASE SKID . . . . . . . . . . . 13-6 DIFFERENTIAL BEARING . . . . . . . . . . . 3-127,3-94 PUMP RELAY-PCM OUTPUT, FUEL . . . . . . . 14-35
PLATFORM, BUCKET SEAT . . . . . . . . . . . . . 23-15 PREPARATION, DRIVELINE ANGLE PUMP RELAYS, ASD AND FUEL . . . . . . . . . 14-41
PLUG CABLE RESISTANCE, SPARK . . . . . . 8D-23 MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 3-6 PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . 19-8
PLUG CABLES, SPARK . . . . . . . . . . . . 8D-10,8D-7 PREPARATION FOR HEADLAMP PUMP RESERVOIR-2.5L . . . . . . . . . . . . . . . . 19-7
PLUG CABLES-2.5L ENGINE, SPARK . . . . . . 8D-2 ALIGNMENT, VEHICLE . . . . . . . . . . . . . . . . . . 8L-6 PUMP SEAL, OIL . . . . . . . . . . . . . . . . . . . . 21-268
PLUG CONDITIONS, SPARK . . . . . . . . . . . . . 8D-8 PREPARATION, LAMP ALIGNMENT PUMP VOLUME CHECK, OIL . . . . . 21-142,21-248
PLUG, HOUSING END . . . . . . . . . . . . . . . . . 19-12 SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-6 PUMP, WASHER . . . . . . . . . . . . . . . . . . . . . . 8K-4
PLUGS, SPARK . . . . . . . . . . . . 8D-10,8D-2,8D-23 PRESSURE CAP, RADIATOR . . . . . . . . . . 7-39,7-5 PUMP, WATER . . . . . . . . . . . . . . . . . 7-24,7-39,7-6
PLUMBING, WASHER NOZZLE . . . . . . . . . . . 8K-4 PRESSURE CUT-OFF SWITCH, DUAL PURGE SOLENOID, DUTY CYCLE EVAP
POLISHING, FINESSE SANDING, FUNCTION HIGH PRESSURE CANISTER . . . . . . . . . . . . . . . . . . . . . 25-24,25-27
BUFFING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4 SWITCH/HIGH . . . . . . . . . . . . . . . . . . 24-16,24-33 PUSH BUTTON MODULE . . . . . . . . . . . . . . . . 8V-7
POOR CONNECTIONS, INTERMITTENT . . . . 8W-8 PRESSURE CUT-OFF SWITCH, HIGH . . . . . . . 24-6 PUSH RODS, ROCKER ARMS . . 9-113,9-36,9-53,
PORT, REFRIGERANT SYSTEM SERVICE . . . . 24-9 PRESSURE CYCLING CLUTCH SWITCH, 9-96
POSITION (CKP) SENSOR, CRANKSHAFT . . 8D-13 LOW . . . . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7 QUARTER PANEL TRIM AND
POSITION SENSOR, CRANKSHAFT . . . . . . . . 8D-4 PRESSURE, ENGINE OIL . . . . . . . . . . . . 9-15,9-75 WHEELHOUSE COVER . . . . . . . . . . . . . . . . . 23-54
POSITION SENSOR (TPS), THROTTLE . . . . 14-45 PRESSURE FOR HIGH SPEED, TIRE . . . . . . . 22-3 QUARTER PANEL TRIM EXTENSION . . . . . . 23-54
POSITION SENSOR (TPS)—PCM INPUT, PRESSURE, FUEL SYSTEM . . . . . . . . . . . . . 14-23 QUARTER WINDOW APPLIQUE . . . . . . . . . . 23-49
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34 PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . 22-3 QUARTER WINDOW GLASS, REAR . . . . . . . 23-10
POSITION SENSOR-2.5L ENGINE, PRESSURE LEAK DOWN TEST, FUEL . . . . . . 14-7 QUICK-CONNECT FITTINGS . . . . . . . . . 14-10,14-6
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-4 PRESSURE LEAKAGE TEST, CYLINDER RACK, LUGGAGE . . . . . . . . . . . . . . . . . . . . . 23-50
POSITION SENSOR—2.5L ENGINE, COMBUSTION . . . . . . . . . . . . . . . . . . . . 9-13,9-73 RACK PISTON AND WORM SHAFT . . . . . . . 19-16
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 8D-14 PRESSURE LINE, POWER STEERING . . . . . . 19-5 RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . 22-2
POSITION SENSOR—4.0L ENGINE, PRESSURE (MAP) SENSOR, MANIFOLD RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . 7-39,7-5
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . 8D-15,8D-5 ABSOLUTE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46 RADIATOR CAP—PRESSURE TESTING . . . . . 7-20
POSITION SWITCH, PARK/NEUTRAL . . . . 21-128, PRESSURE (MAP) SENSOR—PCM RADIATOR CAP-TO-FILLER NECK
21-149,21-245,21-255 INPUT, MANIFOLD ABSOLUTE . . . . . . . . . . . 14-32 SEAL—PRESSURE RELIEF CHECK . . . . . . . . 7-20
POSITIONS, TRANSMISSION RANGES PRESSURE PLATE, CLUTCH . . . . . . . . . . . . . . 6-2 RADIATOR COOLANT FLOW CHECK . . . . . . . 7-17
AND SHIFT LEVER . . . . . . . . . . . . . . . . . . . 21-236 PRESSURE, POWER FLOW . . . . . . . . . . . . . . 19-6 RADIATOR FAN RELAY—PCM OUTPUT . . . 14-36
POWER BRAKE BOOSTER . . . . . . . . . . . . 5-17,5-3 PRESSURE REGULATOR, FUEL RADIATOR PRESSURE CAP . . . . . . . . . . 7-39,7-5
POWER DISTRIBUTION, 8W-10 . . . . . . . . . . 8W-1 FILTER/FUEL . . . . . . . . . . . . . . . . . . . . 14-13,14-3 RADIATOR—2.5L . . . . . . . . . . . . . . . . . . . . . 7-29
POWER DISTRIBUTION CENTER . 8O-2,8O-4,8O-7 PRESSURE RELEASE PROCEDURE, FUEL RADIATOR—4.0L . . . . . . . . . . . . . . . . . . . . . 7-31
POWER DISTRIBUTION SYSTEM . . . . . . . . . 8O-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10 RADIO . . . . . . . . . . . . . . . . . . . . . . 8F-1,8F-4,8F-7
POWER DISTRIBUTION SYSTEMS . . . . . . . 8O-10 PRESSURE RELIEF VALVE, HIGH . . . . . . . . . 24-7 RADIO FREQUENCY INTERFERENCE . . . . . . . 8F-6
POWER DOOR LOCKS, 8W-61 . . . . . . . . . . . 8W-1 PRESSURE SENSOR—PCM INPUT, OIL . . . 14-33 RADIO NOISE SUPPRESSION . . . . . . . . . . . . 8F-2
POWER FLOW AND PRESSURE . . . . . . . . . . 19-6 PRESSURE SWITCH (4.0 L), DUAL RADIO NOISE SUPPRESSION
POWER GROUNDS . . . . . . . . . . . . . . . . . . . 14-33 FUNCTION HIGH . . . . . . . . . . . . . . . . . . . . . . 24-4 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 8F-11
POWER LOCK MOTOR . . . . . . . . . 8P-2,8P-4,8P-7 PRESSURE SWITCH/HIGH PRESSURE RAIL MOLDING, DRIP . . . . . . . . . . . . . . . . . 23-49
POWER LOCK SWITCH . . . . . . . . . . . . . . . . . 8P-2 CUT-OFF SWITCH, DUAL FUNCTION RAIL/FUEL DAMPER—2.5L ENGINE,
POWER LOCK SYSTEM . . . . . . . . . . . . . . . . . 8P-1 HIGH . . . . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33 FUEL INJECTOR . . . . . . . . . . . . . . . . . 14-16,14-5
POWER LOCK SYSTEM AND REMOTE PRESSURE SWITCH—2.5L ENGINE, RAIL/FUEL DAMPER—4.0L ENGINE,
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . . 8P-3 POWER STEERING . . . . . . . . . . . . . . . . . . . 14-47 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
POWER MIRROR . . . . . . . . . . . . . . . . . . 8T-1,8T-4 PRESSURE SWITCH—PCM INPUT, RAIL/FUEL DAMPER—4.0L ENGINE,
POWER MIRROR SWITCH . . . . . . . . . . . 8T-1,8T-3 POWER STEERING . . . . . . . . . . . . . . . . . . . 14-33 FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . 14-17
POWER MIRROR SYSTEM . . . . . . . . . . 8T-1,8T-2 PRESSURE TEST ANALYSIS . . . . . . . . . . . 21-242 RANGES AND SHIFT LEVER POSITIONS,
POWER MIRRORS, 8W-62 . . . . . . . . . . . . . . 8W-1 PRESSURE TEST, CYLINDER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-236
POWER OUTLET, INSTRUMENT PANEL . . . 8E-12, COMPRESSION . . . . . . . . . . . . . . . . . . . 9-13,9-73 RATINGS, GENERATOR . . . . . . . . . . . . . . . . . 8C-5
8E-4 PRESSURE TEST, FUEL PUMP . . . . . . . . . . . 14-6 RBI AXLE, 194 . . . . . . . . . . . . . . . . . . . 3-65,3-99
POWER SEAT, 8W-63 . . . . . . . . . . . . . . . . . . 8W-1 PRESSURE TEST, HYDRAULIC . . . 21-129,21-241 REACTION SHAFT SUPPORT, OIL PUMP . 21-177,
POWER SEAT ADJUSTER AND MOTORS . . . 8R-1, PRESSURES, TIRE INFLATION . . . . . . . . . . . 22-2 21-195
8R-2,8R-3 PROBLEMS, TROUBLESHOOTING READING AND COURTESY LAMP . . . . . . . . . 8V-2
POWER SEAT SWITCH . . . . . . . . . 8R-1,8R-2,8R-3 WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-9 READING AND COURTESY LAMP BULB . . . . 8V-8
POWER SEAT SYSTEM . . . . . . . . . . . . . 8R-1,8R-2 PRODUCTS, AFTERMARKET PAINT READING LAMP BULB, MAP . . . . . . . . . . . . 8L-13
POWER STEERING . . . . . . . . . . . . . . . . . . . . 19-1 REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5 REAR AXLE . . . . . . . . . . . . . . . . . . . . . 3-111,3-72
XJ INDEX 11
Description Group-Page Description Group-Page Description Group-Page
REAR AXLE, 8 1/4 . . . . . . . . . . . . . . . . . . . . 3-103 RELAY, AUTOMATIC SHUTDOWN (ASD) . . . 14-43 RETURN LINE, POWER STEERING . . . . . . . . 19-6
REAR AXLE PINION INPUT ANGLE . . . . . . . . 3-15 RELAY, BLOWER MOTOR . . . . . 24-13,24-2,24-27 RETURN—PCM INPUT, SENSOR . . . . . . . . . 14-34
REAR BAND ADJUSTMENT . . . . . . . . . . . . 21-200 RELAY, CIGAR LIGHTER . . . . . . 8E-12,8E-16,8E-4 REVERSE IDLER GEAR, SEMI-
REAR BEARING, OUTPUT SHAFT . . . . . . . 21-153 RELAY, COMPRESSOR CLUTCH . . . . 24-15,24-31, SYNCHRONIZED . . . . . . . . . . . . . . . . . . . . . 21-36
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . 13-4 24-4 RIGHT FRONT FENDER . . . . . . . . . . . . . . . . 23-32
REAR BUMPER END CAP . . . . . . . . . . . . . . . 13-4 RELAY, DEFOGGER . . . . . . . . . . . . 8N-3,8N-4,8N-7 RING GEAR . . . . . . . . . . . . . . . . . 3-116,3-45,3-80
REAR CARPET/MAT . . . . . . . . . . . . . . . . . . . 23-58 RELAY, FUEL PUMP . . . . . . . . . . . . . . . . . . . 14-44 RING—FITTING, PISTON . . . . . . . . . . . . 9-18,9-77
REAR CLUTCH . . . . . . . . . . 21-121,21-181,21-196 RELAY, HEATED SEAT . . . . . . . 8N-11,8N-12,8N-9 ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-4
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . 23-43 RELAY, HORN . . . . . . . . . . . . . . . . 8G-2,8G-3,8G-4 ROAD TEST, ANALYZING . . . . . . . . . . . . . . 21-129
REAR DOOR GLASS EXTERIOR RELAY SENSE—PCM INPUT, AUTOMATIC ROAD TESTING . . . . . . . . . . . . . . . . . . . . . 21-129
MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46 SHUTDOWN (ASD) . . . . . . . . . . . . . . . . . . . 14-29 ROCKER ARM . . . . . . . . . . . . . . . . . . . . . 9-6,9-66
REAR DOOR GLASS RUN CHANNEL RELAY, STARTER . . . . . . . . . . . 8B-10,8B-13,8B-3 ROCKER ARMS AND PUSH RODS . . . 9-113,9-36,
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-46 RELAY—PCM OUTPUT, AUTO 9-53,9-96
REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . 23-43 SHUTDOWN (ASD) . . . . . . . . . . . . . . . . . . . 14-34 ROD AND PAWL, PARK . . . . . . . . . . . . . . . 21-266
REAR DOOR INNER BELT RELAY—PCM OUTPUT, RADIATOR FAN . . . 14-36 ROD BALL STUD, LIFTGATE SUPPORT . . . . 23-63
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-45 RELAY-PCM OUTPUT, FUEL PUMP . . . . . . . 14-35 ROD BEARINGS, FITTING CONNECTING . . . . 9-80
REAR DOOR INSIDE HANDLE ACTUATOR . . 23-45 RELAYS, ASD AND FUEL PUMP . . . . . . . . . 14-41 ROD BEARINGS—FITTING, CONNECTING . . . 9-21
REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . 23-44 RELEASE BEARING . . . . . . . . . . . . . . . . . . . . 6-12 ROD CYLINDER, LIFTGATE SUPPORT . . . . . 23-63
REAR DOOR LATCH STRIKER . . . . . . . . . . . 23-45 RELEASE BEARING, CLUTCH . . . . . . . . . . . . . 6-3 ROD, PISTON AND CONNECTING . . 9-51,9-6,9-66
REAR DOOR OUTER BELT RELEASE CABLE, HOOD . . . . . . . . . . . . . . . 23-27 ROD, TIE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-23
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-45 RELEASE OR ENGAGEMENT, IMPROPER RODS, PISTONS AND CONNECTING . . . . . . 9-108
REAR DOOR OUTSIDE HANDLE . . . . . . . . . 23-44 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 RODS, ROCKER ARMS AND PUSH . . 9-113,9-36,
REAR DOOR RESTRAINT . . . . . . . . . . . . . . . 23-43 RELEASE PROCEDURE, FUEL SYSTEM 9-53,9-96
REAR DOOR STATIONARY WINDOW PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-10 ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . 25-23
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9 RELIEF CHECK, RADIATOR CAP-TO- ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . 25-27
REAR DOOR TRIM PANEL . . . . . . . . . . . . . . 23-42 FILLER NECK SEAL—PRESSURE . . . . . . . . . 7-20 ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
REAR DOOR WATERDAM . . . . . . . . . . . . . . 23-42 RELIEF VALVE, HIGH PRESSURE . . . . . . . . . 24-7 ROTOR, DISC BRAKE . . . . . . . . . . . . . . . . 5-11,5-21
REAR DOOR WEATHERSTRIP . . . . . . . . . . . . 23-46 REMOTE KEYLESS ENTRY RECEIVER . 8P-2,8P-5, ROTOR MACHINING, DISC . . . . . . . . . . . . . . 5-13
REAR DOOR WINDOW GLASS . . . . . . . . . . 23-47 8P-8 ROTOR-2.5L ENGINE, DISTRIBUTOR . . . . . . 8D-6
REAR DOOR WINDOW REGULATOR . . . . . . 23-47 REMOTE KEYLESS ENTRY RECEIVER ROTOR-SPEEDOMETER DRIVE GEAR,
REAR DRUM BRAKE . . . . . . . . . . . . 5-29,5-30,5-5 PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 8P-6 SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . 21-254
REAR FENDER FLARE . . . . . . . . . . . . . . . . . 23-49 REMOTE KEYLESS ENTRY SYSTEM . . . . . . . 8P-1 RUN CHANNEL WEATHERSTRIP, FRONT
REAR GLASS HEATING GRID . . . . . . . . 8N-2,8N-4 REMOTE KEYLESS ENTRY SYSTEM, DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . 23-38
REAR GLASS HEATING GRID REPAIR . . . . . 8N-6 POWER LOCK SYSTEM . . . . . . . . . . . . . . . . . 8P-3 RUN CHANNEL WEATHERSTRIP, REAR
REAR HOUSING YOKE BUSHING . . . . . . . . 21-48 REMOTE KEYLESS ENTRY DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . 23-46
REAR LIGHTING, 8W-51 . . . . . . . . . . . . . . . 8W-1 TRANSMITTER . . . . . . . . . . . . . . . . . . . 8P-2,8P-5 RUNNING LAMP MODULE, DAYTIME . . . . . 8L-19
REAR MAIN OIL SEAL . . . . . . . . . . . . . . . . . . 9-52 REMOTE KEYLESS ENTRY RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
REAR PARKING BRAKE CABLES . . . . . . . . . . 5-23 TRANSMITTER BATTERY RUNOUT, CLUTCH COVER AND DISC . . . . . . . 6-7
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . 3-8 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 8P-6 RUNOUT, CLUTCH FLYWHEEL . . . . . . . . . . . . . 6-6
REAR QUARTER WINDOW GLASS . . . . . . . 23-10 REMOTE KEYLESS ENTRY RUNOUT, TIRE AND WHEEL . . . . . . . . . . . . . 22-7
REAR SEAT CUSHION . . . . . . . . . . . . . . . . . 23-17 TRANSMITTER PROGRAMMING . . . . . . . . . . 8P-6 SAFETY CERTIFICATION LABEL, VEHICLE . Intro.-2
REAR SEAT CUSHION COVER . . . . . . . . . . . 23-19 REMOVAL/INSTALLATION, VISCOUS FAN SAFETY LATCH, HOOD . . . . . . . . . . . . . . . . 23-27
REAR SEATBACK . . . . . . . . . . . . . . . . 23-18,23-67 DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 SAFETY LATCH STRIKER . . . . . . . . . . . . . . . 23-27
REAR SEATBACK COVER . . . . . . . . . . . . . . . 23-20 REPAIR, ALUMINUM THREAD . . . . 21-144,21-249 SAFETY PRECAUTIONS; BODY . . . . . . . . . . . 23-3
REAR SEATBACK LATCH STRIKER AND REPAIR- AUGAT CONNECTORS, SAFETY PRECAUTIONS; CLUTCH . . . . . . . . . . 6-4
BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-19 TERMINAL/CONNECTOR . . . . . . . . . . . . . . . 8W-11 SAFETY PRECAUTIONS; LAMPS . . . . . . . . . . 8L-2
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . 21-195 REPAIR DAMAGED OR WORN THREADS . . . 9-27, SAFETY PRECAUTIONS AND WARNINGS . . . 23-3
REAR SERVO PISTON . . . . . . . . . . . . . . . . 21-177 9-88 SAFETY PRECAUTIONS, WINDSHIELD . . . . . 23-6
REAR SHOULDER/LAP BELT/BUCKLE . . . . . 23-57 REPAIR PRODUCTS, AFTERMARKET SANDING, BUFFING, AND POLISHING,
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . 2-16 PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5 FINESSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . . 13-5 REPAIR, REAR GLASS HEATING GRID . . . . . 8N-6 SCAN TOOL, DRB . . . . . . . . . . . . . . . . . . . . . . 7-9
REAR WHEEL SPEED SENSOR . . . . . . . . . . . 5-37 REPAIR, THREADED HOLE . . . . . . . . . . . . Intro.-3 SCHEDULES, MAINTENANCE . . . . . . . . . . . . . 0-4
REAR WINDOW DEFOGGER, 8W-48 . . . . . . 8W-1 REPAIR, WIRING . . . . . . . . . . . . . . . . . . . . 8W-10 SCHEMATICS, HYDRAULIC . . . . . . . . . . . . 21-201
REAR WINDOW DEFOGGER SYSTEM . . . . . . 8N-1 REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . 22-5 SCHEMATICS, VACUUM . . . . . . . . . . . . . . . 25-26
REAR WIPER AND WASHER SYSTEM . . . . . 8K-2 REPAIR-MOLEX CONNECTORS, SCREEN PREPARATION, LAMP
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . 23-59 TERMINAL/CONNECTOR . . . . . . . . . . . . . . . 8W-10 ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-6
REARVIEW MIRROR SUPPORT BRACKET . . 23-59 REPAIR—THOMAS AND BETTS SCUFF PLATE, DOOR SILL . . . . . . . . . . . . . 23-52
RECEIVER PROGRAMMING, REMOTE CONNECTORS, TERMINAL/CONNECTOR . . 8W-10 SCUFF PLATE, FRONT INNER . . . . . . . . . . . 23-52
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8P-6 REPROGRAMMING, PCM VIN . . . . . . . . . . . . 14-1 SCUFF PLATE, LIFTGATE . . . . . . . . . . . . . . . 23-55
RECEIVER, REMOTE KEYLESS ENTRY . 8P-2,8P-5, REQUIREMENTS, FUEL . . . . . . . . . . . . . . . . 14-23 SEAL, 181 FBI PINION SHAFT . . . . . . . . . . . . 3-24
8P-8 RESERVE TANK, COOLANT . . . . . . . . . . . . . . 7-23 SEAL, 186 FBI PINION SHAFT . . . . . . . . . . . . 3-26
RECLINER, BUCKET SEAT . . . . . . . . . . . . . . 23-17 RESERVE/OVERFLOW SYSTEM, SEAL, ADAPTER HOUSING . . . . . . . . 21-252,21-7
RECOMMENDATIONS, HOISTING . . . . . . . . . 0-11 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 SEAL AND BEARING, AXLE . . . . . . . . . . . . . 3-112
RECOMMENDATIONS, PARTS AND RESERVOIR, MASTER CYLINDER . . . . . . . . . 5-24 SEAL AND BEARING, AXLE SHAFT . . . . . . . . 3-77
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1 RESERVOIR, PUMP . . . . . . . . . . . . . . . . . . . . 19-8 SEAL, AXLE SHAFT OIL . . . . . . . . . . . . . . . . . 3-36
RECOVERY, REFRIGERANT . . . . . . . . . . . . . 24-22 RESERVOIR, VACUUM; HEATING AND SEAL, EXTENSION HOUSING . . . . . . . . . . . . . 21-7
RED BRAKE WARNING LAMP . . . . . . . . . . 5-3,5-9 AIR CONDITIONING . . . . . . . . . . . . . . . 24-47,24-9 SEAL, FRONT BEARING RETAINER . . . . . . . . 21-6
REFERENCES, TORQUE . . . . . . . . . . . . . . . Intro.-6 RESERVOIR, VACUUM; SPEED CONTROL SEAL, FRONT OUTPUT SHAFT . . . 21-350,21-379
REFILLING AFTER OVERHAUL OR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 8H-3,8H-6 SEAL, MANUAL VALVE SHAFT . . . . . . . . . 21-262
FLUID/FILTER CHANGE . . . . . . . . . . . . . . . 21-248 RESERVOIR, WASHER . . . . . . . . . . . . . . . . . 8K-3 SEAL, OIL PUMP . . . . . . . . . . . . . . . . . . . . 21-268
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . 24-7 RESERVOIR-2.5L, PUMP . . . . . . . . . . . . . . . . 19-7 SEAL, PINION . . . . . . . . . . . . . . . . . . . . . . . 3-113
REFRIGERANT LINE COUPLER . . . . . . . . . . 24-45 RESISTANCE, SPARK PLUG CABLE . . . . . . 8D-23 SEAL, PINION SHAFT . . . . . . . . . . . . . . . . . . 3-72
REFRIGERANT LINE COUPLERS . . . . . . . . . . 24-8 RESISTANCE—2.5L ENGINE, IGNITION SEAL, REAR MAIN OIL . . . . . . . . . . . . . . . . . 9-52
REFRIGERANT LINES . . . . . . . . . . . . . . . . . . 24-7 COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 SEAL REPLACEMENT, YOKE . . . . . . . . . . . 21-147
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . 24-8 RESISTANCE—4.0L ENGINE, IGNITION SEAL, SOLENOID HARNESS ADAPTER . . . 21-261
REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . 24-19 COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23 SEAL, TIMING CASE COVER OIL . . . . . 9-112,9-41
REFRIGERANT RECOVERY . . . . . . . . . . . . . 24-22 RESISTOR, BLOWER MOTOR . . 24-14,24-27,24-3 SEAL, VALVE, GUIDE . . . . . . . . . . . . . . . . . . . 9-15
REFRIGERANT SYSTEM CHARGE . . . . . . . . 24-22 RESTRAINT COVER, HEAD . . . . . . . . . . . . . 23-14 SEAL, VALVE SPRING . . . . . . . . . . . . . . . . . . 9-37
REFRIGERANT SYSTEM EVACUATE . . . . . . . 24-22 RESTRAINT, FRONT DOOR . . . . . . . . . . . . . 23-35 SEAL, VALVE STEM . . . . . . . . . . . . . . . . . 9-67,9-8
REFRIGERANT SYSTEM LEAKS . . . . . . . . . . 24-17 RESTRAINT, REAR DOOR . . . . . . . . . . . . . . 23-43 SEALING LOCATIONS, BODY . . . . . . . . . . . 23-112
REFRIGERANT SYSTEM SERVICE RESTRAINT SLEEVE, HEAD . . . . . . . . . . . . . 23-13 SEAL—2WD, YOKE . . . . . . . . . . . . . . . . . . . 21-47
EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . 24-22 RESTRAINT SYSTEMS, PASSIVE . . . . . . . . 8M-16 SEAL—PRESSURE RELIEF CHECK,
REFRIGERANT SYSTEM SERVICE PORT . . . . 24-9 RETAINER, ADAPTER/EXTENSION RADIATOR CAP-TO-FILLER NECK . . . . . . . . . 7-20
REGULATOR, ELECTRONIC VOLTAGE . . . . . . 8C-2 HOUSING AND FRONT BEARING . . . . . . . . . . 21-8 SEALS, VALVE SPRINGS AND OIL . . . . . . . . 9-97
REGULATOR, FRONT DOOR WINDOW . . . . 23-39 RETAINER, OVERRUNNING CLUTCH/ SEALS—REAR, CRANKSHAFT OIL . . . . . . . 9-110
REGULATOR, FUEL FILTER/FUEL LOW-REVERSE DRUM/OVERDRIVE SEAT, 8W-63 POWER . . . . . . . . . . . . . . . . . . 8W-1
PRESSURE . . . . . . . . . . . . . . . . . . . . . 14-13,14-3 PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-195 SEAT ADJUSTER AND MOTORS, POWER . . 8R-1,
REGULATOR, REAR DOOR WINDOW . . . . . 23-47 RETAINER SEAL, FRONT BEARING . . . . . . . . 21-6 8R-2,8R-3
12 INDEX XJ
Description Group-Page Description Group-Page Description Group-Page
SEAT BELT SWITCH, DRIVER . . . . . . . . . . . . 8U-2 SENTRY KEY IMMOBILIZER MODULE . 8Q-1,8Q-4 SIGNAL AND HAZARD WARNING
SEAT, BUCKET . . . . . . . . . . . . . . . . . . . . . . . 23-15 SENTRY KEY IMMOBILIZER SYSTEM . 8Q-1,8Q-3 SYSTEMS, TURN . . . . . . . . . . . . . . . . . . . . . . 8J-4
SEAT CUSHION COVER, BUCKET . . . . . . . . 23-17 SENTRY KEY IMMOBILIZER SYSTEM SIGNAL CANCELLING CAM, TURN . . . . . . . . 8J-3
SEAT CUSHION COVER, REAR . . . . . . . . . . 23-19 INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . 8Q-3 SIGNAL LAMP BULB, FRONT PARK/
SEAT CUSHION, REAR . . . . . . . . . . . . . . . . . 23-17 SENTRY KEY IMMOBILIZER SYSTEM TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11
SEAT ELEMENT AND SENSOR, HEATED . . 8N-11, TRANSPONDER PROGRAMMING . . . . . . . . . 8Q-4 SIGNAL LAMP, FRONT PARK/TURN . . . . . . 8L-15
8N-9 SENTRY KEY IMMOBILIZER SIGNAL SWITCH AND HAZARD
SEAT HEAT INTERFACE MODULE . . . . 8N-12,8N-9 TRANSPONDER . . . . . . . . . . . . . . . . . . . . . . . 8Q-2 WARNING SWITCH, TURN . . . . . . . 8J-2,8J-5,8J-6
SEAT PLATFORM, BUCKET . . . . . . . . . . . . . 23-15 SERVO CABLE . . . . . . . . . . . . . . . . . . . 8H-3,8H-6 SIGNAL SYSTEM, TURN . . . . . . . . . . . . . . . . 8J-1
SEAT RECLINER, BUCKET . . . . . . . . . . . . . . 23-17 SERVO, FRONT . . . . . . . . . . . . . . . . . . . . . 21-195 SIGNALS, 8W-52 TURN . . . . . . . . . . . . . . . . 8W-1
SEAT RELAY, HEATED . . . . . . . 8N-11,8N-12,8N-9 SERVO PISTON, FRONT . . . . . . . . . . . . . . 21-176 SIGNAL/TAIL LAMP, BACK-UP/BRAKE/
SEAT SWITCH, HEATED . . . . . . 8N-10,8N-12,8N-8 SERVO PISTON, REAR . . . . . . . . . . . . . . . 21-177 REAR TURN . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
SEAT SWITCH, POWER . . . . . . . . 8R-1,8R-2,8R-3 SERVO, REAR . . . . . . . . . . . . . . . . . . . . . . 21-195 SIGNAL/TAIL LAMP BULB, BACK-UP/
SEAT SYSTEM, HEATED . . . . . . . . . . . . 8N-8,8N-9 SERVO, SECOND COAST BRAKE . . . . . . . . 21-265 BRAKE/REAR TURN . . . . . . . . . . . . . . . . . . . 8L-11
SEAT SYSTEM, POWER . . . . . . . . . . . . 8R-1,8R-2 SERVO, SPEED CONTROL . . . . . . . . . . 8H-2,8H-5 SILENCER PAD, HOOD . . . . . . . . . . . . . . . . 23-27
SEAT TRACK, BUCKET . . . . . . . . . . . . . . . . . 23-15 SERVOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-123 SILL SCUFF PLATE, DOOR . . . . . . . . . . . . . 23-52
SEATBACK, BUCKET . . . . . . . . . . . . . . . . . . 23-16 SHACKLE BUSHING, LEAF SPRING . . . . . . . . 2-18 SINGLE CARDAN UNIVERSAL JOINT . . . . . . . 3-9
SEATBACK COVER, BUCKET . . . . . . . . . . . . 23-16 SHAFT ANGLE MEASUREMENT, SIZE, TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
SEATBACK COVER, REAR . . . . . . . . . . . . . . 23-20 PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 SKID PLATE, FRONT . . . . . . . . . . . . . . . . . . . 13-6
SEATBACK LATCH STRIKER AND SHAFT, AXLE . . . . . . . . . . . . . . . . . . . . 3-111,3-76 SKID PLATE, FUEL TANK . . . . . . . . . . . . . . . . 13-7
BUMPER, REAR . . . . . . . . . . . . . . . . . . . . . . 23-19 SHAFT, FRONT PROPELLER . . . . . . . . . . . . . . 3-8 SKID PLATE, TRANSFER CASE . . . . . . . . . . . 13-6
SEATBACK, REAR . . . . . . . . . . . . . . . 23-18,23-67 SHAFT, HUB BEARING AND AXLE . . . . . . . . . 3-30 SLEEVE, HEAD RESTRAINT . . . . . . . . . . . . . 23-13
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-13 SHAFT, INPUT . . . . . . . . . . . . . . . . . . . . . . . 21-30 SNAP, DRIVELINE . . . . . . . . . . . . 3-109,3-21,3-70
SECOND BRAKE . . . . . . . . . . . . . . . . . . . . 21-327 SHAFT JOINT ANGLE, PROPELLER . . . . . . . . . 3-3 SOLENOID CIRCUITS, SPEED CONTROL . . . 8H-2
SECOND COAST BRAKE SERVO . . . . . . . . 21-265 SHAFT JOINTS, PROPELLER . . . . . . . . . . . . . . 3-2 SOLENOID, DUTY CYCLE EVAP
SECONDARY, FIVE VOLT SENSOR SHAFT OIL SEAL, AXLE . . . . . . . . . . . . . . . . . 3-36 CANISTER PURGE . . . . . . . . . . . . . . . 25-24,25-27
SUPPLIES—PRIMARY. . . . . . . . . . . . . . . . . . 14-29 SHAFT, OUTPUT . . . . . . . . . . . . . . . . . . . . . 21-31 SOLENOID HARNESS ADAPTER SEAL . . . 21-261
SECONDARY WEATHERSTRIP, FRONT SHAFT, PLANETARY GEARTRAIN/ SOLENOID TESTING, TRANSMISSION . . . . 21-245
DOOR OPENING . . . . . . . . . . . . . . . . . . . . . 23-39 OUTPUT . . . . . . . . . . . . . . . . . . . . . 21-185,21-197 SOLENOIDS, TRANSMISSION VALVE
SECTION IDENTIFICATION . . . . . . . . . . . . . . 8W-5 SHAFT, PLANETARY/BRAKE PACK/ BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-258
SECURITY SYSTEM, 8W-39 VEHICLE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-329 SPACER BLOCKS—TWO-DOOR
THEFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 SHAFT, PROPELLER . . . . . . . . . . . . 3-1,3-14,3-15 VEHICLES, FRONT DOOR . . . . . . . . . . . . . . 23-41
SEMI-SYNCHRONIZED REVERSE IDLER SHAFT, RACK PISTON AND WORM . . . . . . . 19-16 SPACER, COLLAPSIBLE . . . . . . . . . . . . . 3-27,3-74
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-36 SHAFT REAR BEARING, OUTPUT . . . . . . . 21-153 SPARE TIRE–TEMPORARY . . . . . . . . . . . . . . 22-2
SENDING UNIT, FUEL GAUGE . . 14-10,14-16,14-3 SHAFT, REAR PROPELLER . . . . . . . . . . . . . . . 3-8 SPARK PLUG CABLE RESISTANCE . . . . . . . 8D-23
SENSE—PCM INPUT, AUTOMATIC SHAFT SEAL, 181 FBI PINION . . . . . . . . . . . . 3-24 SPARK PLUG CABLES . . . . . . . . . . . . 8D-10,8D-7
SHUTDOWN (ASD) RELAY . . . . . . . . . . . . . 14-29 SHAFT SEAL, 186 FBI PINION . . . . . . . . . . . . 3-26 SPARK PLUG CABLES-2.5L ENGINE . . . . . . . 8D-2
SENSE—PCM INPUT, IGNITION CIRCUIT . . 14-31 SHAFT SEAL AND BEARING, AXLE . . . . . . . . 3-77 SPARK PLUG CONDITIONS . . . . . . . . . . . . . . 8D-8
SENSITIVE DEVICES, ELECTROSTATIC SHAFT SEAL, FRONT OUTPUT . . . 21-350,21-379 SPARK PLUGS . . . . . . . . . . . . . 8D-10,8D-2,8D-23
DISCHARGE (ESD) . . . . . . . . . . . . . . . . . . . . 8W-8 SHAFT SEAL, MANUAL VALVE . . . . . . . . . 21-262 SPEAKER . . . . . . . . . . . . . . . . . . . . 8F-2,8F-4,8F-8
SENSOR, AMBIENT TEMPERATURE . . . . . . . 8V-8 SHAFT SEAL, PINION . . . . . . . . . . . . . . . . . . 3-72 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9-115
SENSOR, BATTERY TEMPERATURE . . . 8C-2,8C-5 SHAFT SUPPORT, OIL PUMP AND SPECIFICATIONS, ENGINE . . . . . . . . . . . . . . . 9-55
SENSOR, CRANKSHAFT POSITION . . . . . . . . 8D-4 REACTION . . . . . . . . . . . . . . . . . . . 21-177,21-195 SPECIFICATIONS, FRAME TORQUE . . . . . . . . 13-9
SENSOR, CRANKSHAFT POSITION (CKP) . . 8D-13 SHAFT—CARDAN U-JOINT, AXLE . . . . . . . . . 3-23 SPECIFICATIONS, TORQUE; BODY . . . . . . 23-135
SENSOR, ENGINE COOLANT SHAFTS AND U–JOINTS, PROPELLER . . . . . 3-15 SPECIFICATIONS, TORQUE; COOLING
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-49 SHAFTS, PROPELLER . . . . . . . . . . . . . . . . . . . 3-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
SENSOR, FRONT WHEEL SPEED . . . . . . . . . . 5-37 SHAFT/SEALS/BEARING, PITMAN . . . . . . . . 19-12 SPECIFICATIONS, TORQUE; ENGINE . . . . . . 9-118
SENSOR, HEATED SEAT ELEMENT . . . 8N-11,8N-9 SHIELDS, HEAT . . . . . . . . . . . . . . . . . . . . . . . 11-8 SPECIFICATIONS, TORQUE; EXHAUST
SENSOR, INTAKE MANIFOLD AIR SHIFT INTERLOCK, BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-50 TRANSMISSION . . . . . . . . . . . . . . . 21-150,21-256 SPECIFICATIONS—TORQUE . . . . . . . . . . . . . 9-59
SENSOR, MANIFOLD ABSOLUTE SHIFT INTERLOCK CABLE ADJUSTMENT, SPEED AND DISTANCE SENSOR—PCM
PRESSURE (MAP) . . . . . . . . . . . . . . . . . . . . 14-46 BRAKE TRANSMISSION . . . . . . . . 21-198,21-336 INPUT, VEHICLE . . . . . . . . . . . . . . . . . . . . . 14-34
SENSOR, OXYGEN . . . . . . . . . . . . . . . . . . . . 14-47 SHIFT INTERLOCK MECHANISM, BRAKE SPEED CONTROL, 8W-33 VEHICLE . . . . . . . 8W-1
SENSOR, REAR WHEEL SPEED . . . . . . . . . . . 5-37 TRANSMISSION . . . . . . . . . . . . . . . 21-125,21-238 SPEED CONTROL SERVO . . . . . . . . . . . 8H-2,8H-5
SENSOR RETURN—PCM INPUT . . . . . . . . . 14-34 SHIFT LEVER . . . . . . . . . . . . . . . . . 21-349,21-377 SPEED CONTROL SOLENOID CIRCUITS . . . . 8H-2
SENSOR ROTOR-SPEEDOMETER DRIVE SHIFT LEVER POSITIONS, SPEED CONTROL SWITCH . . . . . . . . . . . . . . 8H-5
GEAR, SPEED . . . . . . . . . . . . . . . . . . . . . . 21-254 TRANSMISSION RANGES . . . . . . . . . . . . . 21-236 SPEED CONTROL SWITCHES . . . . . . . . . . . . 8H-2
SENSOR, SPEED . . . . . . . . . . . . . . . . . . . . 21-252 SHIFT LINKAGE ADJUSTMENT . . . 21-372,21-405 SPEED CONTROL SYSTEM . . . . . . . . . . . . . . 8H-1
SENSOR (SPEED CONTROL OPERATION), SHIFT MECHANISM AND GEARTRAIN . . . . . 21-17 SPEED KNOCK, LOW . . . . . . . . . . 3-109,3-21,3-70
VEHICLE SPEED . . . . . . . . . . . . . . . . . . . . . . 8H-4 SHIFT TOWER . . . . . . . . . . . . . . . . . . . . . . . 21-47 SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . 21-252
SENSOR SUPPLIES—PRIMARY AND SHIFTER/IGNITION INTERLOCK . . . . . . . . . 8D-22 SPEED SENSOR, FRONT WHEEL . . . . . . . . . . 5-37
SECONDARY, FIVE VOLT . . . . . . . . . . . . . . . 14-29 SHIFTING, HARD . . . . . . . . . . . . . . . . . 21-3,21-44 SPEED SENSOR, REAR WHEEL . . . . . . . . . . . 5-37
SENSOR TESTING, SPEED . . . . . . . . . . . . . 21-246 SHIFTING TEST, MANUAL . . . . . . . . . . . . . 21-241 SPEED SENSOR ROTOR-SPEEDOMETER
SENSOR (TPS), THROTTLE POSITION . . . . 14-45 SHOCK ABSORBER . . . . . . . . . . . . . . . . . 2-17,2-9 DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . 21-254
SENSOR (TPS)—PCM INPUT, THROTTLE SHOCK ABSORBERS . . . . . . . . . . . . . . . . 2-16,2-7 SPEED SENSOR (SPEED CONTROL
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34 SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 2-9 OPERATION), VEHICLE . . . . . . . . . . . . . . . . . 8H-4
SENSOR, VEHICLE SPEED . . . . . . . . . . . . . . 14-51 SHOCK, SPRING . . . . . . . . . . . . . . . . . . . . . . 2-17 SPEED SENSOR TESTING . . . . . . . . . . . . . 21-246
SENSOR, WASHER FLUID LEVEL . . . . . . . . . 8K-4 SHOES, DRUM BRAKE . . . . . . . . . . . . . . . . . 5-21 SPEED SENSOR, VEHICLE . . . . . . . . . . . . . . 14-51
SENSOR-2.5L ENGINE, CAMSHAFT SHOES, FRONT DISC BRAKE . . . . . . . . . . . . . 5-20 SPEED SENSORS AND TONE WHEEL,
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-4 SHOULDER BELT/BUCKLE, FRONT . . . . . . . 23-55 WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SENSOR—2.5L ENGINE, CAMSHAFT SHOULDER/LAP BELT/BUCKLE, REAR . . . . . 23-57 SPEED, TIRE PRESSURE FOR HIGH . . . . . . . 22-3
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-14 SHUTDOWN (ASD) RELAY, AUTOMATIC . . . 14-43 SPEEDOMETER . . . . . . . . . . . . . . . 21-350,21-378
SENSOR—4.0L ENGINE, CAMSHAFT SHUTDOWN (ASD) RELAY SENSE—PCM SPEEDOMETER ADAPTER . . . . . . . 21-148,21-253
POSITION . . . . . . . . . . . . . . . . . . . . . . 8D-15,8D-5 INPUT, AUTOMATIC . . . . . . . . . . . . . . . . . . . 14-29 SPLICE INFORMATION, 8W-70 . . . . . . . . . . . 8W-1
SENSOR—PCM INPUT, ENGINE SHUTDOWN (ASD) RELAY—PCM SPLICE LOCATIONS . . . . . . . . . . . . . . 8W-1,8W-7
COOLANT TEMPERATURE . . . . . . . . . . . . . . 14-30 OUTPUT, AUTO . . . . . . . . . . . . . . . . . . . . . . 14-34 SPLICE LOCATIONS, 8W-95 . . . . . . . . . . . . . 8W-1
SENSOR—PCM INPUT, FUEL LEVEL . . . . . . 14-30 SIDE AIRBAG DOOR, PASSENGER . . . . . . . 8M-11 SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . 19-14
SENSOR—PCM INPUT, INTAKE SPRING AND SEAL, VALVE . . . . . . . . . . . . . . 9-37
MANIFOLD AIR TEMPERATURE . . . . . . . . . . 14-32 SIDE AIRBAG MODULE, DRIVER . . . . 8M-2,8M-6 SPRING AND SHACKLE BUSHING, LEAF . . . . 2-18
SENSOR—PCM INPUT, MANIFOLD SIDE AIRBAG MODULE, PASSENGER . 8M-3,8M-9 SPRING AND SHOCK . . . . . . . . . . . . . . . . . . . 2-17
ABSOLUTE PRESSURE (MAP) . . . . . . . . . . . 14-32 SIDE AIRBAG MODULE TRIM COVER, SPRING, LEAF . . . . . . . . . . . . . . . . . . . . . . . . 2-18
SENSOR—PCM INPUT, OIL PRESSURE . . . 14-33 DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7 SPRING, VALVE . . . . . . . . . . . . . . . . . . . . 9-67,9-7
SENSOR—PCM INPUT, OXYGEN . . . . . . . . . 14-30 SIDE BEARINGS, DIFFERENTIAL . 3-115,3-36,3-80 SPRING/JOUNCE BUMPER, COIL . . . . . . . . . . 2-9
SENSOR—PCM INPUT, VEHICLE SPEED SIDE GEAR CLEARANCE . . . . . . . . . . . . . . . 3-129 SPRINGS, ACCUMULATOR PISTONS . . . . 21-264
AND DISTANCE . . . . . . . . . . . . . . . . . . . . . . 14-34 SIDE MARKER LAMP . . . . . . . . . . . . . . . . . 8L-15 SPRINGS AND ISOLATORS, COIL . . . . . . 2-16,2-8
SENSORS AND TONE WHEEL, WHEEL SIDE MARKER LAMP BULB . . . . . . . . . . . . 8L-11 SPRINGS AND OIL SEALS, VALVE . . . . . . . . 9-97
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 SIDE MOLDING, BODY . . . . . . . . . . . . . . . . 23-48 SPRINGS, VALVES AND VALVE . . . . . . . . . . 9-100
SPROCKETS, TIMING CHAIN . . . . . . . . 9-102,9-43
SENTINEL HEADLAMP DELAY MODULE . . . 8L-19 SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . 23-31 STABILIZER BAR . . . . . . . . . . . 2-12,2-16,2-17,2-9
XJ INDEX 13
Description Group-Page Description Group-Page Description Group-Page
STANDARD DIFFERENTIAL . . . . 3-105,3-120,3-18, SUSPENSION COMPONENT . . . . . . . . . . . . . . 2-16 SYSTEM, DEFOGGER . . . . . . . . . . . . . . . . . . 8N-3
3-46,3-66,3-86 SUSPENSION COMPONENTS . . . . . . . . . . . . . 2-7 SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . 8L-3
STARTER MOTOR . . . . . . . . . . . . 8B-11,8B-2,8B-9 SUSPENSION, FRONT . . . . . . . . . . . . . . . 2-15,2-7 SYSTEM DIAGNOSIS CHARTS, POWER
STARTER MOTOR NOISE - 2.5L ENGINE . . . 8B-8 SUSPENSION, REAR . . . . . . . . . . . . . . . . . . . 2-16 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
STARTER RELAY . . . . . . . . . . . . 8B-10,8B-13,8B-3 SWITCH (4.0 L), DUAL FUNCTION HIGH SYSTEM, EMISSION . . . . . . . . . . . . . . . . . . . 25-1
STARTING PROCEDURE, JUMP . . . . . . . . . . . . 0-9 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 24-4 SYSTEM EVACUATE, REFRIGERANT . . . . . . 24-22
STARTING SYSTEM . . . . . 8B-1,8B-14,8B-15,8B-4 SWITCH AND HAZARD WARNING SYSTEM, EVAPORATION CONTROL . . . . . . . 25-23
STARTING SYSTEM, 8W-21 . . . . . . . . . . . . . 8W-1 SWITCH, TURN SIGNAL . . . . . . . . . 8J-2,8J-5,8J-6 SYSTEM, EXHAUST . . . . . . . . . . . . . . . . 11-1,11-4
STARTING, TOWING AND HOISTING, SWITCH AND KEY CYLINDER, IGNITION . . 8D-20 SYSTEM FANS, COOLING . . . . . . . . . . . . 7-3,7-38
JUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 SWITCH AND KEY LOCK CYLINDER, SYSTEM, FUEL . . . . . . . . . . . . . . . . . . . . . . 14-52
STATE DISPLAY TEST MODE . . . . . . . . . . . . . 25-2 IGNITION . . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9 SYSTEM, FUEL DELIVERY . . . . . . . . . . . . . . . 14-1
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . 23-6 SWITCH AND WASHER SWITCH, WIPER . . 8K-11, SYSTEM, FUEL INJECTION . . . . . . . . . . . . . 14-25
STATIONARY WINDOW GLASS, REAR 8K-3,8K-7 SYSTEM, HAZARD WARNING . . . . . . . . . . . . 8J-1
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9 SWITCH BEZEL, INSTRUMENT PANEL SYSTEM, HEATED SEAT . . . . . . . . . . . . 8N-8,8N-9
STATOR CLUTCH INSPECTION, TORQUE ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . 8E-15 SYSTEM, HORN . . . . . . . . . . . . . . . . . . . . . . 8G-1
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-247 SWITCH, BLOWER MOTOR . . . . . . . . . 24-14,24-3 SYSTEM HOSES, COOLING . . . . . . . . . . . . . . 7-40
STEERING COLUMN . . . . . . . . . . . . . . . . . . 19-26 SWITCH, BRAKE LAMP; BRAKES . . 5-15,5-2,5-30, SYSTEM, HYDRAULIC . . . . . . . . . . . . . . . . 21-237
STEERING COLUMN OPENING COVER . . . . 8E-13 5-9 SYSTEM, IGNITION . . . . . . . . . . . . . . . . . . . . 8D-1
STEERING DAMPER . . . . . . . . . . . . . . . . . . 19-25 SWITCH, BRAKE LAMP; SPEED SYSTEM INDICATOR LAMP, SENTRY KEY
STEERING GEAR . . . . . . . . . . . . . . . . 19-12,19-19 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-3 IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . 8Q-3
STEERING GEAR LEAKAGE, POWER . . . . . . 19-11 SWITCH, DEFOGGER . . . . . . . . . . 8N-2,8N-4,8N-6 SYSTEM, INSTRUMENT PANEL . . . . . . . . . . . 8E-1
STEERING GEAR, POWER . . . . . . . . . 19-11,19-21 SWITCH, DRIVER DOOR JAMB . . . . . . . . . . . 8U-2 SYSTEM LEAKS, REFRIGERANT . . . . . . . . . 24-17
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . 2-10 SWITCH, DRIVER SEAT BELT . . . . . . . . . . . . 8U-2 SYSTEM, LUBRICATION . . . . . . . . . . . . . 9-2,9-62
STEERING KNUCKLE AND BALL STUDS . . . . 3-31 SWITCH, DUAL FUNCTION HIGH SYSTEM, METRIC . . . . . . . . . . . . . . . . . . . Intro.-6
STEERING LINKAGE . . . . . . . . 19-22,19-23,19-25 PRESSURE SWITCH/HIGH PRESSURE SYSTEM, ON-BOARD DIAGNOSTIC TEST
STEERING, POWER . . . . . . . . . . . . . . . . . . . . 19-1 CUT-OFF . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33 FOR CHARGING . . . . . . . . . . . . . . . . . . . . . . . 8C-3
STEERING PRESSURE LINE, POWER . . . . . . 19-5 SWITCH, HEADLAMP; CHIME/BUZZER SYSTEM, POWER DISTRIBUTION . . . . . . . . . . 8O-1
STEERING PRESSURE SWITCH—2.5L WARNING SYSTEMS . . . . . . . . . . . . . . 8U-2,8U-3 SYSTEM, POWER LOCK . . . . . . . . . . . . . . . . 8P-1
ENGINE, POWER . . . . . . . . . . . . . . . . . . . . . 14-47 SWITCH, HEADLAMP; INSTRUMENT SYSTEM, POWER LOCK SYSTEM AND
STEERING PRESSURE SWITCH—PCM PANEL SYSTEMS . . . . . . . . . . . . . . . . . . . . . 8E-17 REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . 8P-3
INPUT, POWER . . . . . . . . . . . . . . . . . . . . . . 14-33 SWITCH, HEATED SEAT . . . . . . . 8N-10,8N-12,8N-8 SYSTEM, POWER MIRROR . . . . . . . . . . 8T-1,8T-2
STEERING PUMP - INITIAL OPERATION, SWITCH, HIGH PRESSURE CUT-OFF . . . . . . . 24-6 SYSTEM, POWER SEAT . . . . . . . . . . . . 8R-1,8R-2
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7 SWITCH, HORN . . . . . . . . . . . . . . . . . . 8G-2,8G-4 SYSTEM, POWER WINDOW . . . . . . . . . 8S-1,8S-2
STEERING PUMP, POWER . . . . . 19-10,19-5,19-7 SWITCH, KEY-IN IGNITION . . . . . . . . . . 8U-2,8U-3 SYSTEM PRESSURE, FUEL . . . . . . . . . . . . . 14-23
STEERING RETURN LINE, POWER . . . . . . . . 19-6 SWITCH, LOW PRESSURE CYCLING SYSTEM PRESSURE RELEASE
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 19-1 CLUTCH . . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7 PROCEDURE, FUEL . . . . . . . . . . . . . . . . . . . 14-10
STEERING SYSTEM DIAGNOSIS CHARTS, SWITCH, PARK/NEUTRAL POSITION . . . . 21-128, SYSTEM, REAR WINDOW DEFOGGER . . . . . 8N-1
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2 21-149,21-245,21-255 SYSTEM, REAR WIPER AND WASHER . . . . . 8K-2
STEERING SYSTEM, SUSPENSION . . . . . . . . . 2-3 SWITCH, POWER LOCK . . . . . . . . . . . . . . . . 8P-2 SYSTEM, REMOTE KEYLESS ENTRY . . . . . . 8P-1
STEM SEAL, VALVE . . . . . . . . . . . . . . . . . 9-67,9-8 SWITCH, POWER MIRROR . . . . . . . . . . 8T-1,8T-3 SYSTEM, SENTRY KEY IMMOBILIZER . 8Q-1,8Q-3
STOP LAMP (CHMSL) BULB, CENTER SWITCH, POWER SEAT . . . . . . . . 8R-1,8R-2,8R-3 SYSTEM SERVICE EQUIPMENT,
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-12 SWITCH, POWER WINDOW . . . . . 8S-1,8S-4,8S-5 REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-22
STOP LAMP (CHMSL), CENTER HIGH SWITCH, SPEED CONTROL . . . . . . . . . . . . . . 8H-5 SYSTEM SERVICE PORT, REFRIGERANT . . . . 24-9
MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16 SWITCH, TURN SIGNAL SWITCH AND SYSTEM, SPEED CONTROL . . . . . . . . . . . . . 8H-1
STORAGE BIN DOOR, GARAGE DOOR HAZARD WARNING . . . . . . . . . . . . 8J-2,8J-5,8J-6 SYSTEM, STARTING . . . . . 8B-1,8B-14,8B-15,8B-4
OPENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8 SWITCH, WIPER SWITCH AND WASHER . . 8K-11, SYSTEM, STEERING . . . . . . . . . . . . . . . . . . . 19-1
STORAGE BIN, GARAGE DOOR OPENER . . . 8V-3 8K-3,8K-7 SYSTEM, SUSPENSION AND STEERING . . . . . 2-3
STORAGE BIN, SUNGLASSES . . . . . . . . 8V-3,8V-8 SWITCHES, CHIME WARNING SYSTEM . . . . 8U-4 SYSTEM SWITCHES, CHIME WARNING . . . . 8U-4
STRIKER AND BUMPER, REAR SWITCHES, SPEED CONTROL . . . . . . . . . . . . 8H-2 SYSTEM TRANSPONDER
SEATBACK LATCH . . . . . . . . . . . . . . . . . . . . 23-19 SWITCH/HIGH PRESSURE CUT-OFF PROGRAMMING, SENTRY KEY
STRIKER, FRONT DOOR LATCH . . . . . . . . . 23-37 SWITCH, DUAL FUNCTION HIGH IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . 8Q-4
STRIKER, GLOVE BOX LATCH . . . . . . . . . . . 8E-24 PRESSURE . . . . . . . . . . . . . . . . . . . . 24-16,24-33 SYSTEM, TURN SIGNAL . . . . . . . . . . . . . . . . 8J-1
STRIKER, HOOD LATCH . . . . . . . . . . . . . . . 23-26 SWITCH—2.5L ENGINE, POWER SYSTEM, VACUUM . . . . . . . . . . . . . . . . . . . 24-18
STRIKER, LIFTGATE LATCH . . . . . . . . . . . . . 23-64 STEERING PRESSURE . . . . . . . . . . . . . . . . . 14-47 SYSTEM, WASHER . . . . . . . . . . . . . . . 8K-13,8K-6
STRIKER, REAR DOOR LATCH . . . . . . . . . . 23-45 SWITCH—PCM INPUT, BRAKE . . . . . . . . . . 14-29 SYSTEM, WINDSHIELD WASHER . . . . . . . . . 8K-1
STRIKER, SAFETY LATCH . . . . . . . . . . . . . . 23-27 SWITCH—PCM INPUT, EXTENDED IDLE . . . 14-30 SYSTEM, WINDSHIELD WIPER . . . . . . . . . . . 8K-1
STRUCTURAL ADHESIVE LOCATIONS . . . . 23-124 SWITCH—PCM INPUT, POWER SYSTEM, WIPER . . . . . . . . . . . . . . . . . . . . . . 8K-4
STUD, LIFTGATE SUPPORT ROD BALL . . . . 23-63 STEERING PRESSURE . . . . . . . . . . . . . . . . . 14-33 SYSTEM—DRAINING AND FILLING,
STUDS, STEERING KNUCKLE AND BALL . . . 3-31 SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-5 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
STUDS, WHEEL MOUNTING . . . . . . . . . . . . . 2-13 SYMBOLS, INTERNATIONAL; SYSTEM—REVERSE FLUSHING,
SUCTION AND DISCHARGE LINE . . . . . . . . 24-45 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . Intro.-2 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
SUN GEAR AND NO. 1 ONE–WAY SYMBOLS, INTERNATIONAL; SYSTEM—TESTING FOR LEAKS,
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-324 LUBRICATION AND MAINTENANCE . . . . . . . . . 0-1 COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
SUNGLASSES STORAGE BIN . . . . . . . . 8V-3,8V-8 SYSTEM, 8W-20 CHARGING . . . . . . . . . . . . 8W-1 SYSTEMS, AUDIO . . . . . . . . . . . . . . . . . . . . 8F-12
SUNVISORS . . . . . . . . . . . . . . . . . . . . . . . . . 23-60 SYSTEM, 8W-21 STARTING . . . . . . . . . . . . . 8W-1 SYSTEMS, LAMP . . . . . . . . . . . . . . . . . 8L-1,8L-19
SUPPLIES—PRIMARY AND SECONDARY, SYSTEM, 8W-30 FUEL/IGNITION . . . . . . . . . 8W-1 SYSTEMS, MONITORED . . . . . . . . . . . . . . . 25-19
FIVE VOLT SENSOR . . . . . . . . . . . . . . . . . . . 14-29 SYSTEM, 8W-31 TRANSMISSION SYSTEMS, PASSIVE RESTRAINT . . . . . . . . 8M-16
SUPPLY TEST, VACUUM . . . . . . . . . . . . . . . . 8H-4 CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 SYSTEMS, POWER DISTRIBUTION . . . . . . . 8O-10
SUPPORT BRACKET, INSTRUMENT SYSTEM, 8W-39 VEHICLE THEFT SYSTEMS, TURN SIGNAL AND HAZARD
PANEL CENTER . . . . . . . . . . . . . . . . . . . . . . 8E-26 SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-4
SUPPORT BRACKET, REARVIEW MIRROR . 23-59 SYSTEM, 8W-43 AIRBAG . . . . . . . . . . . . . . . 8W-1 T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 5-40
SUPPORT, OIL PUMP AND REACTION SYSTEM, 8W-47 AUDIO . . . . . . . . . . . . . . . . 8W-1 TABLE, A/C APPLICATION . . . . . . . . . . . . . . 24-47
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-177,21-195 SYSTEM, AIRBAG . . . . . . . . . . . 8M-1,8M-4,8M-5 TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
SUPPORT, OVERDRIVE . . . . . . . . . . . . . . . 21-309 SYSTEM AND REMOTE KEYLESS ENTRY TAILPIPE, MUFFLER . . . . . . . . . . . . . . . . . . . 11-6
SUPPORT PLATE, BRAKE . . . . . . . . . . . . . . . 5-22 SYSTEM, POWER LOCK . . . . . . . . . . . . . . . . 8P-3 TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . 8W-7
SUPPORT ROD BALL STUD, LIFTGATE . . . . 23-63 SYSTEM, ANTILOCK BRAKE . . . . . . . . . . . . . 5-33 TANK CAPACITY, FUEL . . . . . . . . . . . . . . . . 14-23
SUPPORT ROD CYLINDER, LIFTGATE . . . . . 23-63 SYSTEM, AUDIO . . . . . . . . . . . . . . . . . . 8F-1,8F-2 TANK, COOLANT RESERVE . . . . . . . . . . . . . . 7-23
SUPPRESSION COMPONENTS, RADIO SYSTEM, BASE BRAKE . . . . . . . . . . . . . . . 5-1,5-7
NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-11 SYSTEM, BLEEDING ABS BRAKE . . . . . . . . . 5-36 TANK FILLER TUBE CAP, FUEL . . . . . . 14-21,14-6
SUPPRESSION, RADIO NOISE . . . . . . . . . . . . 8F-2 SYSTEM, BRAKE . . . . . . . . . . . . . . . . . . . . . . . 5-2 TANK, FUEL . . . . . . . . . . . . . . . . . . . . . 14-19,14-4
SURFACE TOUCH-UP, PAINTED . . . . . . . . . . . 23-4 SYSTEM CHARGE, REFRIGERANT . . . . . . . . 24-22 TANK SKID PLATE, FUEL . . . . . . . . . . . . . . . . 13-7
SUSPENSION AND STEERING SYSTEM . . . . . 2-3 SYSTEM, CHARGING . . . . . . . . . . . . . . 8C-1,8C-2 TAPPET, HYDRAULIC . . . . . . . . . . . . . . . . 9-67,9-7
SUSPENSION ARM, LOWER . . . . . . . . . . . . . 2-10 SYSTEM, CHIME WARNING . . . . . . . . . . . . . 8U-1 TAPPETS, HYDRAULIC . . . . . . . 9-100,9-113,9-40
SUSPENSION ARM, UPPER . . . . . . . . . . . . . 2-11 SYSTEM, COOLANT RESERVE/ TASK MANAGER . . . . . . . . . . . . . . . . . . . . . 25-16
SUSPENSION ARMS AND BUSHINGS, OVERFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 TEMPERATURE SENSOR, AMBIENT . . . . . . . 8V-8
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 SYSTEM, COOLING . . . . . . . . . . . . . . . . . . . . . 7-1 TEMPERATURE SENSOR, BATTERY . . . 8C-2,8C-5
SUSPENSION ARMS AND BUSHINGS, SYSTEM, CRANKCASE VENTILATION . . . . . 25-25, TEMPERATURE SENSOR, ENGINE
UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 25-27 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
14 INDEX XJ
Description Group-Page Description Group-Page Description Group-Page
TEMPERATURE SENSOR, INTAKE TIRES, RADIAL-PLY . . . . . . . . . . . . . . . . . . . . 22-2 TRANSMISSION CONTROL MODULE . . . . 21-260
MANIFOLD AIR . . . . . . . . . . . . . . . . . . . . . . 14-50 TIRES, REPLACEMENT . . . . . . . . . . . . . . . . . 22-3 TRANSMISSION CONTROL MODULE
TEMPERATURE SENSOR—PCM INPUT, TONE WHEEL, WHEEL SPEED SENSORS . . . 5-34 (TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-237
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . 14-30 TOOL, DRB SCAN . . . . . . . . . . . . . . . . . . . . . . 7-9 TRANSMISSION CONTROL MODULE
TEMPERATURE SENSOR—PCM INPUT, TOOLS, 2.5L ENGINE SPECIAL . . . . . . . . . . . 9-60 (TCM) SERVICE . . . . . . . . . . . . . . . . . . . . . 21-248
INTAKE MANIFOLD AIR . . . . . . . . . . . . . . . . 14-32 TOOLS, TROUBLESHOOTING . . . . . . . . . . . . 8W-8 TRANSMISSION CONTROL SYSTEM,
TENSION, BELT . . . . . . . . . . . . . . . . . . . . . . . 7-40 TOOLS—BODY, SPECIAL . . . . . . . . . . . . . . 23-135 8W-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
TENSIONER, PARKING BRAKE CABLE . . . . . . 5-31 TOOLS—SEATS, SPECIAL . . . . . . . . . . . . . . 23-20 TRANSMISSION COOLER . . . . . . . . . . . . . 21-237
TERMINAL REPLACEMENT . . . . . . . . . . . . 8W-13 TOP COVER, INSTRUMENT PANEL . . . . . . . 8E-21 TRANSMISSION DIAGNOSIS,
TERMINAL REPLACEMENT, CONNECTOR . 8W-12 TORQUE; CLUTCH . . . . . . . . . . . . . . . . . . . . . 6-15 AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . 21-126
TERMINAL/CONNECTOR REPAIR- AUGAT TORQUE; DIFFERENTIAL AND DRIVELINE . . . 3-61 TRANSMISSION FILL PROCEDURE . . . . . . 21-142
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . 8W-11 TORQUE; TRANSMISSION AND TRANSMISSION MAIN COOLER, FLOW
TERMINAL/CONNECTOR REPAIR-MOLEX TRANSFER CASE . . 21-213,21-373,21-39,21-405, TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-246
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . 8W-10 21-85 TRANSMISSION NOISE . . . . . . . . . . . . 21-3,21-44
TERMINAL/CONNECTOR REPAIR— TORQUE CHART; BRAKES . . . . . . . . . . . . . . . 5-32 TRANSMISSION, NV3550 MANUAL . . 21-42,21-85
THOMAS AND BETTS CONNECTORS . . . . . 8W-10 TORQUE CHART; CHARGING SYSTEM . . . . . 8C-5 TRANSMISSION, NV3550 MANUAL
TEST ANALYSIS, PRESSURE . . . . . . . . . . . 21-242 TORQUE CHART; EMISSION CONTROL TRANSMISSIONNV3550 MANUAL . . . . . . . . 21-42
TEST ANALYSIS, TIME LAG . . . . . . . . . . . . 21-243 SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-28 TRANSMISSION OIL COOLER,
TEST, ANALYZING ROAD . . . . . . . . . . . . . . 21-129 TORQUE CHART; FUEL SYSTEM . . . . 14-24,14-51 AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
TEST, CYLINDER COMBUSTION TORQUE CHART; IGNITION SYSTEM . . . . . 8D-24 TRANSMISSION OIL COOLERS . . . . . . . . . . . 7-23
PRESSURE LEAKAGE . . . . . . . . . . . . . . 9-13,9-73 TORQUE CHART; SPEED CONTROL TRANSMISSION PARTS CLEANING AND
TEST, CYLINDER COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-7 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-336
PRESSURE . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73 TORQUE CHART; STEERING . . 19-10,19-21,19-25, TRANSMISSION RANGES AND SHIFT
TEST FOR CHARGING SYSTEM, 19-28 LEVER POSITIONS . . . . . . . . . . . . . . . . . . . 21-236
ON-BOARD DIAGNOSTIC . . . . . . . . . . . . . . . . 8C-3 TORQUE CHART; SUSPENSION . . . . . . . 2-14,2-19 TRANSMISSION SHIFT INTERLOCK,
TEST, FUEL INJECTOR . . . . . . . . . . . . . . . . . 14-10 TORQUE CHART; TIRES AND WHEELS . . . . 22-11 BRAKE . . . . . . . . . . . . . . . . . . . . . . 21-150,21-256
TEST, FUEL PRESSURE LEAK DOWN . . . . . . 14-7 TORQUE CONVERTER . . . . 21-146,21-222,21-252, TRANSMISSION SHIFT INTERLOCK
TEST, FUEL PUMP AMPERAGE . . . . . . . . . . . 14-8 21-97 CABLE ADJUSTMENT, BRAKE . . . . 21-198,21-336
TEST, FUEL PUMP CAPACITY . . . . . . . . . . . . 14-7 TORQUE CONVERTER STATOR CLUTCH TRANSMISSION SHIFT INTERLOCK
TEST, FUEL PUMP PRESSURE . . . . . . . . . . . . . 14-6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-247 MECHANISM, BRAKE . . . . . . . . . . 21-125,21-238
TEST, HYDRAULIC PRESSURE . . . 21-129,21-241 TORQUE CONVERTER, TRANSMISSION . . 21-250 TRANSMISSION SOLENOID TESTING . . . . 21-245
TEST, MANUAL SHIFTING . . . . . . . . . . . . . 21-241 TORQUE REFERENCES . . . . . . . . . . . . . . . Intro.-6 TRANSMISSION THROTTLE CABLE . . . . . . 21-267
TEST MODE, CIRCUIT ACTUATION . . . . . . . . 25-2 TORQUE SPECIFICATIONS; BODY . . . . . . . 23-135 TRANSMISSION THROTTLE VALVE
TEST MODE, STATE DISPLAY . . . . . . . . . . . . 25-2 TORQUE SPECIFICATIONS; COOLING CABLE ADJUSTMENT . . . . . . . . . . 21-198,21-337
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . 21-242 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40 TRANSM