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Jeep 200 Cherokee, Service Manual

Get ready to explore the vast capabilities of the Jeep 200 Cherokee with the comprehensive Service Manual! This invaluable manual equips you with step-by-step instructions and expert guidance for all your maintenance and repair needs. Download it for free from manualshive.com and unlock the true potential of your Jeep 200 Cherokee.

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RED BRAKE WARNING LAMP

DESCRIPTION

A red warning lamp is used for the service brake

portion of the hydraulic system. The lamp is located
in the instrument cluster.

OPERATION

The red warning light alerts the driver if a pres-

sure differential exists between the front and rear
hydraulic systems or the parking brakes are applied.
The lamp is turned on momentarily when the igni-
tion switch is turn to the on position. This is a self
test to verify the lamp is operational.

POWER BRAKE BOOSTER

DESCRIPTION

The booster assembly consists of a housing divided

into separate chambers by two internal diaphragms.
The outer edge of each diaphragm is attached to the
booster housing. The diaphragms are connected to
the booster primary push rod.

Two push rods are used in the booster. The pri-

mary push rod connects the booster to the brake
pedal. The secondary push rod connects the booster
to the master cylinder to stroke the cylinder pistons.

OPERATION

The atmospheric inlet valve is opened and closed

by the primary push rod. Booster vacuum supply is
through a hose attached to an intake manifold fitting
at one end and to the booster check valve at the
other. The vacuum check valve in the booster housing
is a one-way device that prevents vacuum leak back.

Power assist is generated by utilizing the pressure

differential between normal atmospheric pressure
and a vacuum. The vacuum needed for booster oper-
ation is taken directly from the engine intake mani-
fold. The entry point for atmospheric pressure is
through a filter and inlet valve at the rear of the
housing (Fig. 1).

The chamber areas forward of the booster dia-

phragms are exposed to vacuum from the intake
manifold. The chamber areas to the rear of the dia-
phragms, are exposed to normal atmospheric pres-
sure of 101.3 kilopascals (14.7 pounds/square in.).

Brake pedal application causes the primary push

rod to open the atmospheric inlet valve. This exposes
the area behind the diaphragms to atmospheric pres-
sure. The resulting pressure differential provides the
extra apply force for power assist.

The booster check valve, check valve grommet and

booster seals are serviceable.

MASTER CYLINDER

DESCRIPTION

The master cylinder has a removable nylon reser-

voir. The cylinder body is made of aluminum and
contains a primary and secondary piston assembly.
The cylinder body including the piston assemblies
are not serviceable. If diagnosis indicates an internal
problem with the cylinder body, it must be replaced
as an assembly. The reservoir and grommets are the
only replaceable parts on the master cylinder.

OPERATION

The master cylinder bore contains a primary and

secondary

piston.

The

primary

piston

supplies

hydraulic pressure to the front brakes. The secondary
piston supplies hydraulic pressure to the rear brakes.
The master cylinder reservoir stores reserve brake
fluid for the hydraulic brake circuits.

COMBINATION VALVE

DESCRIPTION

The combination valve contains a pressure differ-

ential valve and switch and a rear brake proportion-
ing valve. The valve is not repairable and must be
replaced as an assembly if diagnosis indicates this is
necessary.

OPERATION

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.

PROPORTIONING VALVE

The proportioning valve is used to balance front-

rear brake action at high decelerations. The valve
allows normal fluid flow during moderate braking.
The valve only controls fluid flow during high decel-
erations brake stops.

XJ

BRAKES

5 - 3

DESCRIPTION AND OPERATION (Continued)

Summary of Contents for 200 Cherokee

Page 1: ...ssive Restraint Systems 8N Electrically Heated Systems 8O Power Distribution Systems 8P Power Lock Systems 8Q Vehicle Theft Security Systems 8Qa Vehicle Theft Security Systems 8R Power Seats Systems 8S Power Window Systems 8T Power Mirror Systems 8U Chime Buzzer Warning Systems 8V Overhead Console Systems 8W Wiring Diagrams 9 Engine 9a Engine 11 Exhaust System and Intake Manifold 11a Exhaust Syste...

Page 2: ...he consumer from theft and possible fraud the manufacturer is required to include a Check Digit at the ninth position of the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta tion The formula to use the check digit is not released to the general public VEHICLE IDENTIFICATION NUMBER DEC...

Page 3: ...imum cold tire inflation pressure Vehicle Identification Number VIN Type of vehicle Type of rear wheels Bar code Month Day and Hour MDH of final assembly Paint and Trim codes Country of origin The label is located on the driver side door shut face INTERNATIONAL SYMBOLS DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are used to identify ...

Page 4: ...Figure art specifications and torque references in this Service Manual are identified in metric and SAE format During any maintenance or repair procedures it is important to salvage all fasteners nuts bolts etc for reassembly If the fastener is not salvageable a fastener of equivalent specification must be used THREADED HOLE REPAIR Most stripped threaded holes can be repaired using a Helicoilt Fol...

Page 5: ...FASTENER IDENTIFICATION 4 INTRODUCTION XJ DESCRIPTION AND OPERATION Continued ...

Page 6: ...FASTENER STRENGTH XJ INTRODUCTION 5 DESCRIPTION AND OPERATION Continued ...

Page 7: ...rds mph x 1 6093 Kilometers Hr Km h Km h x 0 6214 mph Feet Sec x 0 3048 Meters Sec M S M S x 3 281 Feet Sec mph x 0 4470 Meters Sec M S M S x 2 237 mph Kilometers Hr Km h x 0 27778 Meters Sec M S M S x 3 600 Kilometers Hr Km h COMMON METRIC EQUIVALENTS 1 inch 25 Millimeters 1 Cubic Inch 16 Cubic Centimeters 1 Foot 0 3 Meter 1 Cubic Foot 0 03 Cubic Meter 1 Yard 0 9 Meter 1 Cubic Yard 0 8 Cubic Mete...

Page 8: ...METRIC CONVERSION CHART XJ INTRODUCTION 7 DESCRIPTION AND OPERATION Continued ...

Page 9: ...TORQUE SPECIFICATIONS 8 INTRODUCTION XJ DESCRIPTION AND OPERATION Continued ...

Page 10: ...f the Vehicle Iden tification Number The check digit is used by the manufacturer and government agencies to verify the authenticity of the vehicle and official documenta tion The formula to use the check digit is not released to the general public VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE DESCRIPTION 1 Country of Origin 1 United States 2 Make J Jeep 3 Vehicle Type 4...

Page 11: ...E DESCRIPTION The Manufacturer Plate Fig 2 is located in the engine compartment on the radiator closure panel crossmember adjacent to the Body Code Plate The plate contains five lines of information 1 Vehicle Identification Number VIN 2 Gross Vehicle Mass GVM 3 Gross Train Mass GTM 4 Gross Front Axle Rating GFAR 5 Gross Rear Axle Rating GRAR Fig 1 E Mark Label 1 Country Code 2 Regulation Number 3 ...

Page 12: ...ne compartment lubricant and fluid inspection and fill locations Fig 1 CLASSIFICATION OF LUBRICANTS Only lubricants bearing designations defined by the following organization should be used to service a DaimlerChrysler Corporation vehicle Society of Automotive Engineers SAE American Petroleum Institute API Fig 2 National Lubricating Grease Institute NLGI Fig 3 ENGINE OIL SAE VISCOSITY RATING INDIC...

Page 13: ...nts usage LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI All approved products have the NLGI symbol Fig 3 on the label At the bottom NLGI symbol is the usage and quality identification letters Wheel bearing lubricant is identified by the letter G Chassis lubricant is identified by the latter L The letter following the usage letter indicates the quality of the ...

Page 14: ...5 L 3 7 qts AX5 4X4 3 3 L 3 5 qts AX15 4X2 3 15 L 3 3 qts AX15 4X4 3 15 L 3 3 qts TRANSFER CASE SELEC TRAC 242 1 3 L 2 85 pts COMMAND TRAC 231 1 0 L 2 2 pts FRONT AXLE 181 FBI 1 48 L 3 13 pts 186 FBI 1 18L 2 5pts REAR AXLE 194 RBI 1 66 L 3 5 pts 8 1 4 2 08 L 4 4 pts When equipped with TRAC LOK include 3 5 ounces of Friction Modifier Additive When equipped with TRAC LOK include 4 ounces of Friction...

Page 15: ...d Check all lights and all other electrical items for correct operation At Each Oil Change Inspect exhaust system Inspect brake hoses Rotate the tires at each oil change interval shown on Schedule A 7 500 miles or every other interval shown on Schedule B 6 000 miles Check coolant level hoses and clamps After completion of off road operation the underside of the vehicle should be thoroughly inspect...

Page 16: ...g linkage Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change Lubricate steering and suspension ball joints Drain and refill manual transmission fluid 82 500 Miles 133 000 km or at 66 months Change engine oil Replace engine oil filter Flush and replace engine coolant if it has been 30 000 miles 48 000 km or 24 months since last change Lubricate ste...

Page 17: ...9 000 km Change engine oil Replace engine oil filter Lubricate steering linkage Lubricate steering and suspension ball joints Drain and refill manual transmission fluid 21 000 Miles 34 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 24 000 Miles 38 000 km Change engine oil Replace engine oil filter Lubricate steering linkage Drain and refill automatic transmission flu...

Page 18: ...s 63 000 Miles 101 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 66 000 Miles 106 000 km Change engine oil Replace engine oil filter Lubricate steering linkage Lubricate steering and suspension ball joints 69 000 Miles 110 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 72 000 Miles 115 000 km Change engine oil Replace engine oil filter...

Page 19: ...n fluid Drain and refill front and rear axles Inspect brake linings Lubricate steering and suspension ball joints Drain and refill manual transmission fluid 111 000 Miles 178 000 km Change engine oil Replace engine oil filter Flush and replace engine coolant if it has been 30 000 miles 48 000 km since last change Lubricate steering linkage 114 000 Miles 182 000 km Change engine oil Replace engine ...

Page 20: ...er vehicle TO JUMP START A DISABLED VEHICLE 1 Raise hood on disabled vehicle and visually inspect engine compartment for Battery cable clamp condition clean if necessary Frozen battery Yellow or bright color test indicator if equipped Low battery fluid level Generator drive belt condition and tension Fuel fumes or leakage correct if necessary CAUTION If the cause of starting problem on dis abled v...

Page 21: ...d condition 7 Shift the transmission to NEUTRAL TOWING REAR END LIFTED WHEEL LIFT 1 Raise front of vehicle off ground and install tow dollies under front wheels 2 Attach wheel lift to rear wheels 3 Place transmission in neutral 4 Raise vehicle to towing height 5 Place transmission in park automatic trans mission or fist gear manual transmission TOWING FRONT END LIFTED To prevent damage to front fa...

Page 22: ...mission in park automatic trans mission or first gear manual transmission EMERGENCY TOW HOOKS WARNING REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS THE TOW STRAPS CHAINS COULD BREAK AND CAUSE SERIOUS INJURY Some Jeep vehicles are equipped with front and rear emergency tow hooks The tow hooks should be used for EMERGENCY purposes only CAUTION DO NOT use emergency to...

Page 23: ...oist A ramp type drive on hoist NOTE When a frame contact type hoist is used verify that the lifting pads are positioned properly WARNING THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHI CLE WHEN A CHASSIS OR DRIVETRAIN COMPO NENT IS REMOVED FROM A VEHICLE THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING D...

Page 24: ...um temperatures consistently fall below 12 C FLUID CAPACITIES FUEL TANK Diesel Engine Equipped Vehicles 76 4 L ENGINE OIL 2 5L Diesel Engine includes filter 6 8 L Oil Filter Replacement Only 0 4 L COOLING SYSTEM 2 5L Diesel 8 0 L MANUAL TRANSMISSION Recommended lubricant for AX15 transmissions is Mopart 75W 90 API Grade GL 3 gear lubricant or equivalent Correct lubricant level is from the bottom e...

Page 25: ...bove 32 C 90 F Taxi police or delivery service Trailer towing AT EACH STOP FOR FUEL OR SCHEDULED SERVICE STOP Check engine oil level Check engine coolant level Inspect drive belt Visually inspect intercooler for obstruction Clean as necessary Visually inspect radiator for obstruction Clean as necessary Inspect for fuel oil or coolant leaks Inspect battery cable connection and excessive corrosion I...

Page 26: ...torque intake manifold mounting nuts Check correct torque exhaust manifold mount ing nuts Check correct torque turbocharger mounting nuts Check correct torque water manifold bolts 1 000 KM Change engine oil Change engine oil filter Check all fluid levels 5 000 KM Change engine oil Change engine oil filter 10 000 KM Change engine oil Change engine oil filter Replace air filter element Drive belt vi...

Page 27: ... 000 KM Change engine oil Change engine oil filter 90 000 KM Change engine oil Change engine oil filter Replace air filter element Drive belt visual inspection 95 000 KM Change engine oil Change engine oil filter 100 000 KM Change engine oil Change engine oil filter Replace air filter element Drive belt visual inspection Check glow plug operation Replace fuel filter water separator element EVERY 5...

Page 28: ...ntenance for the rec ommended maintenance schedule OPERATION CASTER is the forward or rearward tilt of the steering knuckle from vertical Tilting the top of the knuckle rearward provides positive caster Tilting the top of the knuckle forward provides negative caster Caster is a directional stability angle This angle enables the front wheels to return to a straight ahead position after turns CAMBER...

Page 29: ...and exces sive tire wear This angle is not adjustable damaged component s must be replaced to correct the thrust angle Fig 1 Wheel Alignment Measurements 1 WHEEL CENTERLINE 2 NEGATIVE CAMBER ANGLE 3 PIVOT CENTERLINE 4 SCRUB RADIUS 5 TRUE VERTICAL 6 KING PIN 7 VERTICAL 8 POSITIVE CASTER 2 2 SUSPENSION XJ DESCRIPTION AND OPERATION Continued ...

Page 30: ... wheel bearings 1 Adjust or replace wheel bearings 2 Loose or worn steering or suspension components 2 Tighten or replace components as necessary 3 Tire pressure 3 Adjust tire pressure 4 Alignment 4 Align vehicle to specifications EXCESSIVE STEERING EFFORT 1 Loose or worn steering gear 1 Adjust or replace steering gear 2 Power steering fluid low 2 Add fluid and repair leak 3 Column coupler binding...

Page 31: ...on Set the front end alignment to specifications with the vehicle at its NORMAL RIDE HEIGHT CAMBER The wheel camber angle is preset This angle is not adjustable and cannot be altered CASTER Before checking the caster of the front axle for cor rect angle be sure the axle is not bent or twisted Road test the vehicle make left and right turns If the steering wheel returns to the center position unass...

Page 32: ... the drag link TOE POSITION RHD NOTE The wheel toe position adjustment is the final adjustment The engine must remain running during the entire toe position adjustment 1 Start the engine and turn wheels both ways before straightening the wheels Secure the steering wheel with the front wheels in the straight ahead position 2 Loosen the adjustment sleeve clamp bolts Fig 5 3 Adjust the left wheel toe...

Page 33: ...urn off engine 6 Road test the vehicle on a flat level road to ver ify the steering wheel is centered NOTE Once the toe setting is correct the steering wheel can be re centered by adjusting only the drag link SPECIFICATIONS ALIGNMENT NOTE All alignment specifications are in degrees ANGLE PREFERRED RANGE MAX RT LT DIFFERENCE CASTER 7 0 5 25 to 8 5 1 25 CAMBER fixed angle 0 25 0 75 to 0 5 1 0 TOTAL ...

Page 34: ...cation Then if the slot in the nut does not line up with the cotter pin hole tighten nut until it is aligned Never loosen the nut to align the cotter pin hole CAUTION Suspension components with rubber urethane bushings except stabilizer bar should be tightened with the vehicle at normal ride height It is important to have the springs supporting the weight of the vehicle when the fasteners are torq...

Page 35: ...OPERATION The arm and bushings provide location and react to loads from the axle The bushings provide isolation from the axle The lower suspension arms can be used to adjust caster and pinion angle through the use of shims at the frame rail bracket UPPER SUSPENSION ARMS AND BUSHINGS DESCRIPTION The upper suspension arms are steel and use rub ber bushings at each end of the arm The arms mount to th...

Page 36: ...damaged and worn bushings and attach ing components Repair as necessary if any of these conditions exist A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermit tent This condition is not repairable and the shock absorber must be replaced The shock absorbers are not refillable or adjust able If a malfunction occurs the shock absorber must be replaced To...

Page 37: ... lower the vehicle 10 Tighten lower suspension arms nuts to 115 N m 85 ft lbs STEERING KNUCKLE For service procedures on the steering knuckle and ball joints refer to Group 3 Differentials And Driv eline LOWER SUSPENSION ARM REMOVAL 1 Raise and support the vehicle 2 Remove the lower suspension arm nut and bolt from the axle bracket 3 Remove the nut and bolt from the rear bracket and remove the low...

Page 38: ...ainst other side of the bushing 5 Install bolt 7604 through remover bushing and receiver 6 Install Long Nut 7603 and tighten nut too pull bushing out of the axle bracket 7 Remove nut bolt receiver remover and bush ing NOTE On 4x2 vehicle and right side of 4x4 vehicle leave Spacer 7932 3 in position for bushing instal lation INSTALLATION 1 Place Receiver 7932 1 on the other side of the axle bracket...

Page 39: ...il bracket 3 Use a universal puller tool to separate the ball stud from the frame rail bracket 4 Remove the bolt and flag nut from the axle shaft tube bracket Fig 7 5 Remove the track bar INSTALLATION 1 Install the track bar at axle tube bracket Loosely install the retaining bolt and flag nut 2 It may be necessary to pry the axle assembly over to install the track bar at the body rail Install trac...

Page 40: ...move 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 9 INSTALLATION 1 Install new stud into hub flange 2 Install three washers onto stud then install lug nut with the flat side of the nut against the washers 3 Tighten lug nut until the stud is pulled into the hub flange Verify that the st...

Page 41: ...15 N m 85 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40 ft lbs Link Upper Nut 36 N m 27 ft lbs Link Lower Nut 95 N m 70 ft lbs Track Bar Ball Stud Nut 81 N m 60 ft lbs Axle Bracket Bolt 54 N m 40 ft lbs Fig 8 Hub Bearing Knuckle 1 BRAKE SHIELD 2 WASHER 3 RETAINER 4 COTTER PIN 5 NUT 6 HUB AND BEARING ASSEMBLY 7 STEERING KNUCKLE 8 BOLT 9 TONE WHEEL ABS Fig 9 Wheel Stud Removal 1 REMOVER 2 WHEEL STUD 2 ...

Page 42: ... 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 SPECIAL TOOLS FRONT SUSPENSION Remover Installer Suspension Bushing 7932 Nut Long 7603 Bolt Special 7604 Remover C 4150A XJ SUSPENSION 2 15 SPECIFICATIONS Continued ...

Page 43: ...g the weight of the vehicle when the fasteners are torqued If springs are not at their normal ride position vehicle ride comfort could be affected and premature bush ing wear may occur SHOCK ABSORBERS DESCRIPTION The top of the shock absorbers are bolted to the body crossmember The bottom of the shocks are bolted to the axle brackets OPERATION The shock absorbers dampen jounce and rebound motion o...

Page 44: ...amined periodically Check for broken and shifted leafs loose and missing clips and broken center bolts Refer to Spring and Shock Absorber Diagnosis chart for additional information SPRING AND SHOCK ABSORBER CONDITION POSSIBLE CAUSES CORRECTION SPRING SAGS 1 Broken leaf 1 Replace spring 2 Spring fatigue 2 Replace spring SPRING NOISE 1 Loose spring clamp bolts 1 Tighten to specification 2 Worn bushi...

Page 45: ...o not tighten at this time 3 Position the axle Install the spring bracket U bolts and nuts Tighten the nuts to 70 N m 52 ft lbs 4 Connect the stabilizer bar link to the spring bracket 5 Remove the hydraulic jack 6 Lower the vehicle 7 Tighten the spring front eye attaching bolts to 156 N m 115 ft lbs 8 Tighten the spring rear eye attaching bolts to 108 N m 80 ft lbs 9 Tighten the stabilizer bar lin...

Page 46: ...hings bend tabs up after installa tion SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber Upper Bolt 23 N m 17 ft lbs Lower Nut 62 N m 46 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40 ft lbs Link Upper Bolt 12 N m 9 ft lbs Link Lower Nut 74 N m 55 ft lbs Spring U Bolt Nut 70 N m 52 ft lbs Front Pivot Bolt 156 N m 115 ft lbs Upper Shackle Bolt 156 N m 115 ft lbs Lower Shackle Bolt 108 N m 8...

Page 47: ......

Page 48: ...d and built with the yoke lugs in line with each other which is called zero phasing This design produces the smoothest running condition an out of phase shaft can cause a vibra tion Tubular propeller shafts are balanced by the man ufacturer with weights spot welded to the tube PRECAUTIONS Use the exact replacement parts when installing the propeller shafts The use of the correct replace ment parts...

Page 49: ...plied when tightening the fasteners PROPELLER SHAFT JOINTS DESCRIPTION Two different types of propeller shaft joints are used Single cardan universal joint Fig 3 Double cardan CV universal joint Fig 4 None of the universal joints are serviceable If one becomes worn or damaged the complete universal joint assembly must be replaced Fig 2 Propeller Shafts 1 FRONT AXLE 2 FRONT PROPELLER SHAFT 3 TRANSF...

Page 50: ...hased 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 Ideally the driveline system should have Angles that are equal or opposite within 1 degree of each other Have a 3 degree maximum op...

Page 51: ... 1 Clean exterior of shaft and wash 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 excessive runout 3 Install new yoke 4 Incorrect driveline angularity 4 Measure and correct driveline angles 5 Rear spring center bolt not in seat 5 Loosen spring u bolts and seat center bolt 6 Worn U joint bearings 6 Install new ...

Page 52: ...e other three positions Repeat the vibration test 11 If there is no difference in vibration at the other positions the source of the vibration may not be propeller shaft 12 If the vibration decreased install a second clamp Fig 7 and repeat the test 13 If the additional clamp causes an additional vibration separate the clamps 1 4 inch above and below the mark Repeat the vibration test Fig 8 14 Incr...

Page 53: ...ernal bearing snap rings if equipped from universal joint so protractor base sits flat 2 Rotate the shaft until transmission transfer case output yoke bearing is facing downward Always make measurements from front to rear Also be sure to take all measurements while working from the same side of the vehi cle 3 Place Inclinometer on yoke bearing A parallel to the shaft Fig 9 Center bubble in sight g...

Page 54: ...xample in Fig 12 for additional information Fig 11 Rear Input Angle Measurement B 1 PINION YOKE BEARING CAP 2 SPECIAL TOOL 7663 J 23498A Fig 12 Universal Joint Angle Example 1 4 9 Angle C 2 3 2 Angle B 3 Input Yoke 4 3 0 Angle A 5 Output Yoke Fig 10 Propeller Shaft Angle Measurement C 1 SHAFT YOKE BEARING CAP 2 SPECIAL TOOL 7663 J23498 A XJ PROPELLER SHAFTS 3 7 SERVICE PROCEDURES Continued ...

Page 55: ...propeller shaft under vehicle with rear universal joint over the transfer case yoke 2 Place front universal joint into the axle pinion yoke 3 Align mark on the rear link yoke and universal joint to the mark on the transfer case yoke Fig 13 4 Loosely install bolts to hold universal joint to transfer case yoke 5 Align mark on front universal joint to the mark on the axle pinion yoke 6 Tighten the U ...

Page 56: ...l components of cardan universal joints are not serviceable If worn or leaking they must be replaced as an assembly 1 Remove the propeller shaft 2 Using a soft drift tap the outside of the bear ing cap assembly to loosen snap ring 3 Remove snap rings from both sides of yoke Fig 18 Fig 15 Dust Boot Clamp 1 SLINGER 2 BOOT 3 AWL 4 TRANSFER CASE Fig 16 Rear Propeller Shaft 1 CLAMP 2 YOKE 3 PROPELLER S...

Page 57: ...s the end of the cross until the remaining bearing cap can be removed Fig 20 CAUTION If the cross or bearing cap are not straight during installation the bearing cap will score the walls of the yoke bore and damage can occur ASSEMBLY 1 Apply extreme pressure EP N L G I Grade 1 or 2 grease to inside of yoke bores to aid in installa tion 2 Position the cross in the yoke with its lube fit ting if equ...

Page 58: ...receive the bearing cap positioned beneath the link yoke 5 Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from the outboard side of the link yoke enough to grasp the bearing cap with vise jaws Fig 24 Be sure to remove grease fittings that interfere with removal 6 Grasp the protruding bearing by vise jaws Tap t...

Page 59: ...ing cap over the trunnion and align the cap with the yoke bore Fig 28 Keep the needle bearings upright in the bearing assembly A needle bearing lying at the bottom of the cap will prevent proper assembly 4 Press the bearing cap into the yoke bore enough to install a snap ring Fig 29 5 Install a snap ring Fig 25 Remove Bearing From Yoke Fig 26 Remove Centering Kit Fig 27 Install Cross In Yoke Fig 2...

Page 60: ...run nions and press both bearing caps into place Fig 31 8 Install snap rings 9 Install the centering kit assembly inside the link yoke making sure the spring is properly posi tioned Fig 32 Fig 29 Press In Bearing Cap Fig 30 Press In Bearing Cap Fig 31 Install Link Yoke Fig 32 Install Centering Kit XJ PROPELLER SHAFTS 3 13 DISASSEMBLY AND ASSEMBLY Continued ...

Page 61: ...13 Check for proper assembly Flex the joint beyond center it should snap over center in both directions when correctly assembled Fig 36 14 Install the propeller shaft CLEANING AND INSPECTION PROPELLER SHAFT 1 Clean all universal joint bores with cleaning solvent and a wire brush 2 Inspect the yokes for distortion cracks and worn bearing cap bores Fig 33 Install Remaining Cross Fig 34 Press In Bear...

Page 62: ...38 Adding shims will decrease the pinion shaft angle but will also increase the caster angle The pinion shaft angle has priority over the caster angle Refer to Group 2 Suspension for additional information 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 SPECIAL TOOLS PROPELLE...

Page 63: ...s are pressed into the differential housing and welded The integral type housing hypoid gear design has the centerline of the pinion set above the centerline of the ring gear The axle has a fitting for a vent hose used to relieve internal pressure caused by lubricant vapor ization and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the h...

Page 64: ... 186 FBI axle has the assembly part number and gear ratio listed on a tag The tag is attached to the housing cover by a cover bolt Build date identi fication codes are stamped on the cover side of the axle shaft tube The differential case is a one piece design The dif ferential pinion mate shaft is retained with a roll pin Differential bearing preload and ring gear back lash is adjusted by the use...

Page 65: ... 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...

Page 66: ...ar backlash between the ring gear and pinion 4 Check adjustment of the ring gear and pinion backlash Correct as necessary 5 Improper adjustment of pinion gear bearings 5 Adjust the pinion bearings pre load 6 Loose pinion yoke nut 6 Tighten the pinion yoke nut 7 Scuffed gear tooth contact surfaces 7 Inspect and replace as necessary Axle Shaft Broke 1 Misaligned axle tube 1 Replace the broken shaft ...

Page 67: ...Broke 1 Overloading 1 Replace gears Examine other gears and bearings 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 A...

Page 68: ...he right This will load the bearings and change the noise level Where axle bearing damage is slight the noise is usually not noticeable at speeds above 30 mph LOW SPEED KNOCK Low speed knock is generally caused by a worn U joint or by worn side gear thrust washers A worn pinion shaft bore will also cause low speed knock VIBRATION Vibration at the rear of the vehicle is usually caused by a Damaged ...

Page 69: ...kets 16 Lower the lifting device enough to remove the axle The coil springs will drop with the axle 17 Remove the coil springs from the axle INSTALLATION CAUTION The weight of the vehicle must be sup ported by the springs before suspension arms and track bar fasteners can be tightened If the springs are not at their normal ride position ride height and handling could be affected 1 Install the spri...

Page 70: ...n the upper and lower suspension arms in the axle brackets Loosely install bolts and nuts to hold suspension arms to the axle brackets 5 Connect the track bar to the axle bracket Loosely install the bolt to hold the track bar to the axle bracket 6 Install the shock absorbers and tighten the bolts to 23 N m 17 ft lbs torque 7 Install the stabilizer bar links to the axle brackets Tighten the nut to ...

Page 71: ...ssemblies 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 re...

Page 72: ...ut in 6 8 N m 5 ft lbs increments until proper rotating torque is achieved 7 Align the installation reference marks on the propeller shaft and yoke and install the propeller shaft 8 Check and fill the gear lubricant Refer to the Lubricant Specifications for gear lubricant require ments 9 Install the brake rotors and calipers Refer to Group 5 Brakes for proper procedures 10 Install wheel and tire a...

Page 73: ...ed the minimum tightening torque when installing the pinion yoke retaining nut at this point Damage to collapsible spacer or bear ings may result 3 Install the pinion washer and a new nut on the pinion gear Tighten the nut only enough to remove the shaft end play 4 Rotate the pinion shaft using a in lbs torque wrench Rotating torque should be equal to the read ing recorded during removal plus an a...

Page 74: ... 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 15 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 ...

Page 75: ...Fig 16 Catch the pinion with your hand to prevent it from falling and being damaged 12 Remove collapsible spacer from pinion shaft INSTALLATION 1 Install a new collapsible preload spacer on pin ion shaft Fig 17 2 If pinion gear was removed install pinion gear in housing 3 Install pinion front bearing if necessary 4 Apply a light coating of gear lubricant on the lip of pinion seal Install seal with...

Page 76: ...acer is defective and must be replaced 9 Slowly tighten the nut in 6 8 N m 5 ft lbs increments until the rotating torque is achieved Measure the rotating torque frequently to avoid over crushing the collapsible spacer Fig 21 10 Check rotating torque with an inch pound torque wrench Fig 21 The torque necessary to rotate the pinion gear should be Original Bearings The reading recorded dur ing remova...

Page 77: ...ecessary Refer to Group 5 Brakes for proper procedures 5 Remove the cotter pin nut retainer and axle hub nut Fig 22 if necessary 6 Remove the hub to knuckle bolts Fig 23 7 Remove the hub from the steering knuckle and axle shaft if necessary 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 9 Remove the brake roto...

Page 78: ...fer to Group 5 Brakes for proper procedures 9 Install the wheel and tire assembly 10 Remove support and lower the vehicle STEERING KNUCKLE AND BALL STUDS Ball stud service procedures below require removal of the hub bearing and axle shaft Removal and installation of upper and lower ball studs require the use of Tool Kit 6289 KNUCKLE REMOVAL 1 Remove hub bearing and axle shaft 2 Disconnect the tie ...

Page 79: ... 2 Install and tighten the bottom retaining nut to 109 N m 80 ft lbs torque Install new cotter pin 3 Install and tighten the top retaining nut to 101 N m 75 ft lbs torque Install new cotter pin 4 Install the hub bearing and axle shaft 5 Connect the tie rod or drag link end to the steering knuckle arm Refer to Group 2 Suspension for proper procedures Fig 26 Upper Ball Stud Remove Install 3 32 TUBE ...

Page 80: ...sealing surface Fig 28 6 Loosen the differential bearing cap bolts 7 Position Spreader W 129 B utilizing some 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 Fig 27 Lower Ball Stud Remove Install 1 SPECIAL TOOL 6289 12 2 SPECIAL TOOL 6289 4 3 SPECIAL TOOL 4212F 4 SPECIAL TOOL 4212F 5 ...

Page 81: ...12 Remove the differential and the differential preload shims for the 181FBI axles from the hous ing Ensure that the differential bearing cups remain in position on the differential bearings Fig 32 13 Mark or tag the differential bearing cups and the differential preload shims for the 181FBI axles to indicate which side of the differential they were removed from 14 Remove spreader from housing Fig...

Page 82: ...ough to install the case in the housing Measure the distance with the dial indicator Fig 31 4 Remove the dial indicator 5 Install differential case and the differential preload shims for the 181FBI axles in the housing Ensure that the differential bearing cups remain in position on the differential bearings Tap the differ ential case to ensure the bearings cups are fully seated in the housing 6 In...

Page 83: ...ial assembly 3 Remove the inner axle shaft seals with a pry bay INSTALLATION 1 Remove any sealer remaining from original seals 2 Remove sealer from axle tube to housing junc tion if necessary 3 Install oil seals with Discs 8110 and Turn buckle 6797 Fig 37 Tighten tool until disc bottoms in housing 4 Install differential assembly 181 FBI PINION The ring gear and pinion are serviced as a matched set...

Page 84: ...t from falling and being damaged 7 Remove the front pinion bearing cup bearing oil slinger if equipped and pinion seal with Remover D 147 and Handle C 4171 Fig 40 Fig 37 Axle Seal Installation 1 TURNBUCKLE 6797 2 DISCS 8110 Fig 38 Pinion Yoke Removal 1 SPECIAL TOOL C 3281 2 YOKE 3 SPECIAL TOOL C 452 Fig 39 Remove Pinion Gear 1 RAWHIDE HAMMER Fig 40 Front Bearing Cup Removal 1 REMOVER 2 HANDLE XJ T...

Page 85: ...lled 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 1 Install a new oil slinger of the same thickness as the original into the rear pinion bearing bore of the axle housing 2 Apply Mopart Door Ease or equivalent stick lubricant to outside surface of rear pin...

Page 86: ... shim oil baffle onto the pinion gear with Installer W 262 and a shop press Fig 46 7 Install pinion bearing preload shims onto the pinion gear Fig 47 8 Install pinion gear in housing 9 Install yoke with Installer W 162 B Cup 8109 and Holder 6958 Fig 48 Fig 44 Pinion Outer Bearing Cup Installation 1 INSTALLER 2 HANDLE Fig 45 Pinion Seal Installation 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL C 3972 A Fig...

Page 87: ... above the desired amount remove the pinion yoke and increase the preload shim pack thickness Increasing the shim pack thickness 0 025 mm 0 001 in will decrease the rotating torque approximately 0 9 N m 8 in lbs 13 Tighten pinion shaft nut in 6 8 N m 5 ft lbs increments until the maximum tightening or desired rotating torque is reached Maximum tightening torque is 271 N m 200 ft lbs Fig 47 Pinion ...

Page 88: ...assembly from axle hous ing 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 Holder 6958 to the hold yoke remove the pinion nut and washer Fig 50 5 Using Remover C 452 and Holder C 3281 remove the pinion yoke from pinion shaft Fig 51 Fig 49 Check Pinion Gear Rotating Torque 1...

Page 89: ... 8 Remove the rear pinion bearing cup from axle housing Fig 54 Use Remover D 149 and Handle C 4171 9 Remove the collapsible preload spacer from pinion gear Fig 55 Fig 52 Remove Pinion 1 RAWHIDE HAMMER Fig 53 Front Bearing Cup Removal 1 REMOVER 2 HANDLE Fig 54 Rear Bearing Cup Removal 1 DRIVER 2 HANDLE Fig 55 Collapsible Spacer 1 COLLAPSIBLE SPACER 2 SHOULDER 3 PINION 4 PINION DEPTH SHIM 5 REAR BEA...

Page 90: ...urface of rear pinion bearing cup Install the bearing cup with Installer D 146 and Driver Handle C 4171 Fig 57 Verify cup is cor rectly seated 2 Apply Mopart Door Ease or equivalent stick lubricant to outside surface of front pinion bearing cup Install the bearing cup with Installer D 130 and Handle C 4171 Fig 58 3 Install front pinion bearing and oil slinger if equipped 4 Apply a light coating of...

Page 91: ...ue is exceeded a new collapsible spacer must be installed The torque sequence will then have to be repeated 9 Using Holder 6958 and torque wrench set at 352 N m 260 ft lbs crush collapsible spacer until Fig 59 Pinion Seal Installation 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL C 3972 A Fig 60 Rear Pinion Bearing Installation 1 PRESS 2 INSTALLATION TOOL 3 PINION DEPTH SHIM OIL BAFFLE 4 DRIVE PINION 5 DRI...

Page 92: ...R NOTE The ring gear and pinion are serviced as 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 65 3 Remove bolts holding ring gear to differential case 4 Using a soft hammer drive ring gear from dif ferential case Fig 65 INSTALLATION CAUTION Do no...

Page 93: ...ate shaft in the differ ential case Fig 67 3 Remove the pinion gear mate shaft from the differential case and the pinion mate gears 4 Rotate differential side gears and remove the pinion mate gears and thrust washers Fig 68 5 Remove the differential side gears and thrust washers ASSEMBLY 1 Install the differential side gears and thrust washers 2 Install the pinion mate gears and thrust wash ers Fi...

Page 94: ... U JOINT Clean all the U joint yoke bores with cleaning sol vent and a wire brush Ensure that all the rust and foreign matter are removed from the bores Inspect the yokes for distortion cracks and worn bearing cap bores Replace the complete U joint if any of the compo nents are defective AXLE COMPONENTS Wash differential components with cleaning solvent and dry with compressed air Do not steam cle...

Page 95: ...agraph in this section for additional information Compensation for pinion depth variance is achieved with a select shim oil baffle The shims are placed between the rear pinion bearing and the pin ion gear head Fig 72 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...

Page 96: ...lock D 115 2 and secure set screw 6 Place Scooter Block Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pinion PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear Depth Variance 4 3 2 1 0 1 2 3 4 4 0 008 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 3 0 007 0 006 0 005 0 004 0 003 0 002 0 001 ...

Page 97: ...s for the ring gear and pinion are etched into the face of each gear Fig 77 A plus number minus number or zero 0 is etched into the face of the pinion gear head 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 setting from the center line of the ring gear to the back face of the pinion is 92 08 mm 3 625 in...

Page 98: ...r C 3339 Fig 79 PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear Depth Variance 4 3 2 1 0 1 2 3 4 4 0 008 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 3 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 2 0 006 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 1 0 005 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 0 004 0 003 0 002 0 001 0 0 001 0 002 0 003 0 004 1 0 ...

Page 99: ...of the pinion height block 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 82 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 ...

Page 100: ...ial Fig 83 Differential shim measurements are performed with axle spreader W 129 B removed SHIM SELECTION NOTE It is difficult to salvage the differential side bearings during the removal procedure Install replacement bearings if necessary 1 Remove differential side bearings from differ ential case 2 Remove factory installed shims from differen tial case 3 Install ring gear on differential case an...

Page 101: ...ifferential is installed 15 Rotate dial indicator out of the way on the guide stud 16 Remove differential case and dummy bearings from axle housing Fig 86 Seat Ring Gear Side Differential Dummy Side Bearing 1 AXLE HOUSING 2 MALLET 3 DIFFERENTIAL CASE Fig 87 Differential Side play Measurement 1 DIFFERENTIAL CASE 2 AXLE HOUSING 3 SPECIAL TOOL C 3288 B 4 SPECIAL TOOL C 3339 Fig 88 Hold Differential C...

Page 102: ...on axle housing and spread axle opening enough to receive differential case 32 Install differential case into the axle housing 33 Remove spreader from axle housing 34 Rotate the differential case several times to seat the side bearings 35 Position the indicator plunger against a ring gear tooth Fig 92 36 Push and hold ring gear upward while not allowing the pinion gear to rotate 37 Zero dial indic...

Page 103: ...ification 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 94 Differential shim measurements are performed with axle spreader W 129 B removed SHIM SELECTION NOTE ...

Page 104: ...l indicator face to pointer Fig 99 12 Push and hold differential case to ring gear side of the axle housing Fig 100 13 Record dial indicator reading Fig 100 14 Add 0 008 in 0 2 mm to the zero end play total This new total represents the thickness of Fig 95 Tighten Bolts Holding Bearing Caps 1 BEARING CAP 2 AXLE HOUSING 3 DIFFERENTIAL CASE Fig 96 Seat Pinion Gear Side Differential Dummy Side Bearin...

Page 105: ...ndicator face to pointer Fig 101 23 Push and hold differential case to ring gear side of the axle housing Fig 102 24 Record dial indicator reading Fig 102 Fig 99 Hold Differential Case and Zero Dial Indicator 1 FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE 2 SPECIAL TOOL C 3288 B 3 SPECIAL TOOL C 3339 4 ZERO DIAL INDICATOR FACE Fig 100 Hold Differential Case and Read Dial Indicator 1 READ DIAL INDIC...

Page 106: ... Fig 104 39 Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear Readings should not vary more than 0 05 mm 0 002 in If readings vary more than specified the ring gear or the differential case is defective After the proper backlash is achieved perform Gear Contact Pattern Analysis procedure GEAR CONTACT PATTERN ANALYSIS The...

Page 107: ...Fig 105 Gear Tooth Contact Patterns 3 60 TUBE 181 AND 186 FBI AXLE XJ ADJUSTMENTS Continued ...

Page 108: ...nthetic Lube Capacity 1 18 L 2 5 pts Axle Ratio 3 07 3 55 3 73 4 10 Differential Side Gear Clearance 0 12 0 20 mm 0 005 0 008 in Ring Gear Diameter 18 59 cm 7 33 in Backlash 0 0 15 mm 0 005 0 008 in Pinion Std Depth 92 1 mm 3 625 in Pinion Bearing Rotating Torque Original Bearings 1 2 N m 10 20 in lbs New Bearings 1 5 4 N m 15 35 in lbs TORQUE DESCRIPTION TORQUE Fill Hole Plug 34 N m 25 ft lbs Dif...

Page 109: ...cator C 3339 Driver C 3716 A Handle C 4171 Installer D 146 Remover D 149 Installer W 162 D Cup 8109 Remover Installer 6289 Installer 6761 Installer 6752 3 62 TUBE 181 AND 186 FBI AXLE XJ SPECIAL TOOLS Continued ...

Page 110: ...10 Turnbuckle 6797 Tool Set Pinion Depth 6774 Gauge Block 6733 Spanner 6958 Installer C 3972 A Spreader W 129 B Adapter Kit 6987 Pilot Stud C 3288 B Remover D 147 XJ TUBE 181 AND 186 FBI AXLE 3 63 SPECIAL TOOLS Continued ...

Page 111: ...Installer D 144 Installer W 262 3 64 TUBE 181 AND 186 FBI AXLE XJ SPECIAL TOOLS Continued ...

Page 112: ...sion The axles are equipped with semi floating axle shafts meaning that loads are supported by the axle shaft and bearings The axle shafts are retained by C clips in the differential side gears The cover provides a means for servicing the differ ential without removing the axle For vehicles equipped with ABS brakes the axles have a tone ring pressed onto the axle shaft Use care when removing axle ...

Page 113: ...ars 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 pinion ...

Page 114: ...o 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 DIAGNOSIS AND TESTING GENERAL INFORMATION Axle bearing problem conditions are usually caused by Insufficient or incorrect lubricant Foreign matter water contamination Incorrect bearing ...

Page 115: ...tch operation 3 Replace broken shaft and avoid or correct erratic clutch operation 4 Grabbing clutch 4 Replace broken shaft and inspect and repair clutch as necessary Differential Cracked 1 Improper adjustment of the differential bearings 1 Replace case and inspect gears and bearings for further damage Set differential bearing pre load properly 2 Excessive ring gear backlash 2 Replace case and ins...

Page 116: ...atic 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 adjustment 2 Check ring gear and pinion contact pattern ...

Page 117: ...le bearing damage is slight the noise is usually not noticeable at speeds above 30 mph LOW SPEED KNOCK Low speed knock is generally caused by a worn U joint or by worn side gear thrust washers A worn pinion shaft bore will also cause low speed knock VIBRATION Vibration at the rear of the vehicle is usually caused by a Damaged drive shaft Missing drive shaft balance weight s Worn or out of balance ...

Page 118: ...lint free cloth Do not use water steam kerosene or gasoline for cleaning 5 Remove the original sealant from the housing and cover surfaces 6 Apply a bead of Mopart Silicone Rubber Seal ant or equivalent to the housing cover Fig 6 Install the housing cover within 5 minutes after applying the sealant 7 Install the cover and any identification tag Tighten the cover bolts to 41 N m 30 ft lbs torque 8 ...

Page 119: ...0 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 lever 7 Install the brake drums Refer to Group 5 Brakes for proper procedures 8 Connect the brake ho...

Page 120: ... 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 6 If the rotating torque is low use Holder 6958 to hold the pinion yoke Fig 11 and tighten the pinion shaft nut in 6 8 N m 5 ft lbs increments until the proper rotating torque is achieved CAUTION If the maximum tightening torque is reached prior to reach...

Page 121: ...edures 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 Remove differential assembly from axle hous ing 9 Using Holder 6958 to hol...

Page 122: ...apsible spacer must be installed The torque sequence will then have to be repeated 9 Using yoke holder 6958 and a torque wrench set at 474 N m 350 ft lbs crush collapsible spacer until bearing end play is taken up Fig 17 NOTE If more than 474 N m 350 ft lbs of torque is necessary to remove the bearing end play the collapsible spacer is defective and must be replaced Fig 13 Remove Pinion Gear 1 RAW...

Page 123: ...HAFT REMOVAL 1 Raise and support vehicle Ensure that the transmission is in neutral 2 Remove wheel and tire assembly 3 Remove brake drum Refer to Group 5 Brakes for proper procedure 4 Clean all foreign material from housing cover area 5 Loosen housing cover bolts Drain lubricant from the housing and axle shaft tubes Remove hous ing cover 6 Rotate differential case so that pinion mate gear shaft lo...

Page 124: ...Lubricant Change procedure in this section for procedure and lubricant requirements 6 Install brake drum Refer to Group 5 Brakes for proper procedures 7 Install wheel and tire 8 Lower vehicle AXLE SHAFT SEAL AND BEARING REMOVAL 1 Remove the axle shaft 2 Remove the axle shaft seal from the end of the axle shaft tube with a small pry bar NOTE The seal and bearing can be removed at the same time with...

Page 125: ...e indicator CAUTION Do not spread over 0 38 mm 0 015 in If the housing is over spread it could be distorted or damaged 9 Spread the housing enough to remove the dif ferential case from the housing Measure the dis tance with the dial indicator Fig 26 10 Remove the dial indicator 11 While holding the differential case in position remove the differential bearing cap bolts and caps 12 Remove the diffe...

Page 126: ...Fig 25 and zero the indicator CAUTION Do not spread over 0 38 mm 0 015 in If the housing is over spread it could be distorted or damaged 3 Spread the housing enough to install the case in the housing Measure the distance with the dial indicator Fig 26 4 Remove the dial indicator 5 Install differential case in the housing Ensure that the differential bearing cups remain in position on the different...

Page 127: ... 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 32 3 Remove bolts holding ring gear to differential case 4 Using a soft hammer drive ring gear from dif ferential case Fig 32 Fig 28 Install Axle Housing Spreader 1 AXLE HOUSING 2 DOWEL 3 SAFETY HOLD DOWN 4 SPECIAL TOOL W 129 B 5 TURNBUC...

Page 128: ...ear 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 Holder 6958 to hold yoke remove the pinion yoke nut and washer 5 Using Remover C 452 and Wrench C 3281 remove the pinion yoke from pinion shaft Fig 34 6 Remove the pinion ...

Page 129: ...and Handle C 4171 11 Remove the collapsible preload spacer Fig 38 12 Remove the rear bearing from the pinion with Puller Press C 293 PA and Adapters C 293 40 Fig 39 Place 4 adapter blocks so they do not damage the bearing cage Fig 34 Pinion Yoke Removal 1 SPECIAL TOOL C 3281 2 YOKE 3 SPECIAL TOOL C 452 Fig 35 Remove Pinion Gear 1 RAWHIDE HAMMER Fig 36 Front Bearing Cup Removal 1 REMOVER 2 HANDLE F...

Page 130: ... pinion seal Install seal with Installer C 3972 A and Handle C 4171 Fig 42 NOTE Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear mesh If the factory installed ring and pinion gears are reused the pin ion depth shim should not require replacement If required refer to Pinion Gear Depth to select the proper thickness shim before...

Page 131: ...loosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque If preload torque or rotating torque is exceeded a new col lapsible spacer must be installed The torque sequence will then have to be repeated Fig 41 Pinion Front Bearing Cup Installation 1 INSTALLER 2 HANDLE Fig 42 Pinion Seal Installation 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL C 3972 A ...

Page 132: ...om the housing and cover mating surfaces Clean the mating surfaces with mineral spirits Apply a bead of Mopart Silicone Rubber Sealant or equivalent on the housing cover Fig 48 Install the housing cover within 5 minutes after applying the sealant 2 Install the cover on the differential with the attaching bolts Install the identification tag Tighten the cover bolts to 41 N m 30 ft lbs torque CAUTIO...

Page 133: ...ferential pinion gears and thrust washers 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 Fig 48 Typical Housing Cover With Sealant 1 SEALING SURFACE 2 CONTOUR OF BEAD 3 BEAD THICKNESS 6 35mm 1 4 Fig 49 Pinion Mate Shaft Lo...

Page 134: ...he 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 Fig 51 Trac lokY Differential Components 1 THRUST WASHER 2 PINION 3 SHAFT LOCK SCREW 4 PINION MATE SHAFT 5 SIDE GEAR 6 RETAINER 7 DISC 8 CLUTCH ...

Page 135: ...o compress Belleville springs in clutch packs Fig 57 Fig 53 Mate Shaft Lock Screw 1 LOCK SCREW 2 PINION GEAR MATE SHAFT Fig 54 Mate Shaft Removal 1 PINION MATE SHAFT 2 SIDE GEAR 3 DRIFT 4 PINION MATE GEAR Fig 55 Step Plate Tool Installation 1 LOWER SIDE GEAR 2 DIFFERENTIAL CASE 3 SPECIAL TOOL C 6960 3 Fig 56 Threaded Adapter Installation 1 SOCKET 2 SLOT IN ADAPTER 3 SCREWDRIVER 4 DISC C 6960 3 5 T...

Page 136: ...ars from differential case 15 Remove Forcing Screw C 6960 4 Step Plate C 6960 3 and Threaded Adapter C 6960 1 16 Remove top side gear clutch pack retainer and clutch pack Keep plates in correct order during removal Fig 60 Fig 57 Tighten Belleville Spring Compressor Tool 1 TORQUE WRENCH 2 TOOL ASSEMBLED 3 DIFFERENTIAL CASE Fig 58 Remove Pinion Gear Thrust Washer 1 THRUST WASHER 2 FEELER GAUGE Fig 5...

Page 137: ...ated in the case pockets 4 Position the differential case on Side Gear Holding Tool 6965 5 Install lubricated Step Plate C 6960 3 in lower side gear Fig 63 6 Install the upper side gear and clutch disc pack Fig 63 7 Hold assembly in position Insert Threaded Adapter C 6960 1 into top side gear 8 Insert Forcing Screw C 6960 4 9 Tighten forcing screw tool to slightly compress clutch discs 10 Place pi...

Page 138: ...r and damage to pinion gear mate shaft pinion gears side gears and thrust washers Replace as a matched set only Ring and pinion gear for worn and chipped teeth Ring gear for damaged bolt threads Replaced as a matched set only Pinion yoke for cracks worn splines pitted areas and a rough corroded seal contact surface Repair or replace as necessary Preload shims for damage and distortion Install new ...

Page 139: ...aring onto Screw 6741 Fig 66 2 Insert assembled height gauge components rear bearing and screw into axle housing through pinion bearing cups Fig 67 3 Install front pinion bearing and Cone 6740 hand tight Fig 66 4 Place Arbor Disc 6732 on Arbor D 115 3 in posi tion in axle housing side bearing cradles Fig 68 Install differential bearing caps on Arbor Discs and tighten cap bolts Refer to the Torque ...

Page 140: ... 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 et...

Page 141: ...e 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 bearings during the removal procedure Install replacement bearings if necessary 1 Remove side beari...

Page 142: ...xle housing Fig 75 11 Zero dial indicator face to pointer 12 Push firmly and hold differential case to ring gear side of the axle housing Fig 76 13 Record dial indicator reading Fig 72 Seat Pinion Gear Dummy Side Bearing 1 MALLET 2 AXLE HOUSING 3 DIFFERENTIAL CASE Fig 73 Seat Ring Gear Side Dummy Bearing 1 AXLE HOUSING 2 MALLET 3 DIFFERENTIAL CASE Fig 74 Differential Side play Measurement 1 DIFFER...

Page 143: ...lash 26 Subtract the backlash shim thickness from the total preload shim thickness The remainder is the shim thickness required on the pinion side of the axle housing 27 Rotate dial indicator out of the way on guide stud 28 Remove differential case and dummy bearings from axle housing 29 Install new side bearing cones and cups on differential case 30 Install spreader W 129 B utilizing some com pon...

Page 144: ...ly a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth 2 Wrap twist and hold a shop towel around the pinion yoke to increase the turning resistance of the pinion This will provide a more distinct contact pat tern 3 Using a boxed end wrench on a ring gear bolt Rotate the differential case one complete revolution in both directions while a load is be...

Page 145: ...Fig 79 Gear Tooth Contact Patterns 3 98 194 RBI AXLE XJ ADJUSTMENTS Continued ...

Page 146: ...lash 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 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...

Page 147: ...Spanner 6958 Installer Screw 8112 Cup 8109 Handle C 4171 Driver C 3716 A Installer D 130 Installer D 146 Remover C 4345 Remover D 149 Installer W 262 3 100 194 RBI AXLE XJ SPECIAL TOOLS Continued ...

Page 148: ...Installer 6437 Disc Axle Arbor 6732 Gauge Block 6735 Tool Set Pinion Depth 6774 Trac lok Tool Set 6960 Holder 6965 Puller 7794 A Starting Point Shim 8107 Spreader W 129 B XJ 194 RBI AXLE 3 101 SPECIAL TOOLS Continued ...

Page 149: ...Adapter Kit 6987 Guide Pin C 3288 B Bearing Remover Tool Set 6310 Hub Puller 6790 Dial Indicator C 3339 3 102 194 RBI AXLE XJ SPECIAL TOOLS Continued ...

Page 150: ...pped with semi floating axle shafts meaning vehicle loads are supported by the axle shaft and bearings The axle shafts are retained by C locks in the differential side gears The removable stamped steel cover provides a means for inspection and service without removing the complete axle from the vehicle The 8 1 4 axle have a date tag and a gear ratio tag The tags are attached to the differential ho...

Page 151: ...r service The 8 1 4 axle lubricant capacity is 2 08 L 4 4 pts total including the friction modifier if necessary CAUTION If the rear axle is submerged in water the lubricant must be replaced immediately Avoid the possibility of premature axle failure resulting from water contamination of the lubricant Fig 1 8 1 4 Axle Fig 2 Differential Cover 8 1 4 Inch Axle 1 DIFFERENTIAL COVER 2 IDENTIFICATION T...

Page 152: ...ires from scuffing and skidding through turns To accomplish this the differential allows the axle shafts to turn at unequal speeds Fig 4 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 speed...

Page 153: ...INFORMATION Axle bearing problem conditions are usually caused by Insufficient or incorrect lubricant Foreign matter water contamination Incorrect bearing preload torque adjustment Incorrect backlash Axle gear problem conditions are usually the result of Insufficient lubrication Incorrect or contaminated lubricant Overloading excessive engine torque or exceed ing vehicle weight capacity Incorrect ...

Page 154: ...h operation 3 Replace broken shaft and avoid or correct erratic clutch operation 4 Grabbing clutch 4 Replace broken shaft and inspect and repair clutch as necessary Differential Cracked 1 Improper adjustment of the differential bearings 1 Replace case and inspect gears and bearings for further damage Set differential bearing pre load properly 2 Excessive ring gear backlash 2 Replace case and inspe...

Page 155: ...ic 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 adjustment 2 Check ring gear and pinion contact pattern 3 ...

Page 156: ... bearing damage is slight the noise is usually not noticeable at speeds above 30 mph LOW SPEED KNOCK Low speed knock is generally caused by a worn U joint or by worn side gear thrust washers A worn pinion shaft bore will also cause low speed knock VIBRATION Vibration at the rear of the vehicle is usually caused by a Damaged drive shaft Missing drive shaft balance weight s Worn or out of balance wh...

Page 157: ...nt free cloth Do not use water steam kerosene or gasoline for cleaning 5 Remove the original sealant from the housing and cover surfaces 6 Apply a bead of Mopart Silicone Rubber Seal ant or equivalent to the housing cover Fig 7 Install the housing cover within 5 minutes after applying the sealant 7 Install the cover and any identification tag Tighten the cover bolts to 41 N m 30 ft lbs torque 8 Fo...

Page 158: ...axle vent hose 9 Align propeller shaft and pinion yoke reference marks Install universal joint straps and bolts Tighten to 19 N m 14 ft lbs torque 10 Install the wheels and tires 11 Add gear lubricant if necessary Refer to Lubricant Specifications in this section for lubricant requirements 12 Remove lifting device from axle and lower the vehicle AXLE SHAFT REMOVAL 1 Raise and support vehicle Ensur...

Page 159: ...E The seal and bearing can be removed at the same time with the bearing removal tool 3 Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310 using Adapter Foot 6310 9 Fig 11 INSTALLATION NOTE Do not install the original axle shaft seal Always install a new seal 1 Wipe the axle tube bore clean Remove any old sealer or burrs from the tube 2 Install the axle shaft bearin...

Page 160: ... with Wrench 6719 Remove the pinion nut and washer 9 Remove the yoke with Remover C 452 Fig 13 10 Remove the pinion seal with suitable pry tool or slide hammer mounted screw INSTALLATION 1 Clean the seal contact surface in the housing bore 2 Examine the splines on the pinion shaft for burrs or wear Remove any burrs and clean the shaft 3 Inspect pinion yoke for cracks worn splines and worn seal con...

Page 161: ... torque sequence will then have to be repeated 11 If the rotating torque is low use Yoke Holder 6719 to hold the pinion yoke Fig 15 and tighten the pinion nut in 6 8 N m 5 ft lbs increments until proper rotating torque is achieved NOTE The bearing rotating torque should be con stant during a complete revolution of the pinion If the rotating torque varies this indicates a binding condition 12 The s...

Page 162: ... the upper bolts to 14 N m 10 ft lbs Tighten the lower bolts finger tight until the bolt head is seated 4 Perform the differential bearing preload and adjustment procedure NOTE Be sure that all bearing cap bolts are tight ened to the final torque of 95 N m 70 ft lbs before proceeding 5 Install axle shafts and differential housing cover DIFFERENTIAL SIDE BEARINGS REMOVAL 1 Remove differential case ...

Page 163: ...Invert the differential case 2 Position ring gear on the differential case and start two ring gear bolts This will provide case to ring gear bolt hole alignment 3 Invert the differential case in the vise 4 Install new ring gear bolts and alternately tighten to 102 N m 75 ft lbs torque Fig 23 5 Install differential in axle housing and verify gear mesh and contact pattern Fig 20 Differential Bearing...

Page 164: ... Remove oil slinger if equipped and front pin ion bearing 10 Remove the front pinion bearing cup with Remover C 4345 and Handle C 4171 Fig 26 11 Remove the rear bearing cup from housing Fig 27 Use Remover C 4307 and Handle C 4171 12 Remove the collapsible preload spacer Fig 28 13 Remove the rear bearing from the pinion Fig 29 with Puller Press C 293 PA and Adapters C 293 47 Place 4 adapter blocks ...

Page 165: ...ight coating of gear lubricant on the lip of pinion seal Install seal with Installer C 4076 B and Handle C 4735 1 Fig 32 Fig 26 Front Bearing Cup Removal 1 REMOVER 2 HANDLE Fig 27 Rear Bearing Cup Removal 1 DRIVER 2 HANDLE Fig 28 Collapsible Spacer 1 COLLAPSIBLE SPACER 2 SHOULDER 3 PINION 4 PINION DEPTH SHIM 5 REAR BEARING Fig 29 Rear Bearing Removal 1 SPECIAL TOOL C 293 PA 2 VISE 3 ADAPTERS 4 DRI...

Page 166: ...6448 9 Install a new collapsible preload spacer on pin ion shaft and install pinion in housing Fig 34 10 Install pinion in housing 11 Install yoke with Installer C 3718 and Yoke Holder 6719 12 Install the yoke washer and a new nut on the pinion and tighten the pinion nut until there is zero Fig 30 Pinion Rear Bearing Cup Installation 1 INSTALLER 2 HANDLE Fig 31 Pinion Front Bearing Cup Installatio...

Page 167: ...e spacer Fig 35 16 Check bearing rotating torque with an inch pound torque wrench Fig 35 The torque necessary to rotate the pinion gear should be Original Bearings 1 to 2 N m 10 to 20 in lbs New Bearings 1 to 5 N m 10 to 30 in lbs 17 Install propeller shaft 18 Install differential in housing DISASSEMBLY AND ASSEMBLY STANDARD DIFFERENTIAL DISASSEMBLY 1 Remove pinion mate shaft lock screw Fig 36 2 R...

Page 168: ...lustration 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 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 Fig 37 Pinion Mate Gear Removal 1 THRUST WASHER 2 SIDE GEAR 3 P...

Page 169: ...ng screw tool 122 N m 90 ft lbs maximum to compress Belleville springs in clutch packs Fig 44 10 Using an appropriate size feeler gauge remove thrust washers from behind the differential pinions Fig 45 11 Insert Turning Bar 6960 2 in case Fig 46 Fig 39 Differential Case Holding Tool 1 SIDE GEAR HOLDING TOOL 2 VISE 3 DIFFERENTIAL Fig 40 Mate Shaft Lock Screw 1 LOCK SCREW 2 PINION MATE SHAFT Fig 41 ...

Page 170: ...ainer and clutch pack Keep plates in correct order during removal Fig 47 17 Remove differential case from Side Gear Hold ing Tool 8138 Remove side gear clutch pack retainer Fig 43 Threaded Adapter Installation 1 SOCKET 2 SLOT IN ADAPTER 3 SCREWDRIVER 4 DISC 8140 2 5 THREADED ROD C 6960 4 6 THREADED ADAPTER DISC 8140 1 Fig 44 Tighten Belleville Spring Compressor Tool 1 TORQUE WRENCH 2 TOOL ASSEMBLE...

Page 171: ...ep Plate 8140 2 in lower side gear Fig 50 6 Install the upper side gear and clutch disc pack Fig 50 7 Hold assembly in position Insert Threaded Adapter 8140 1 into top side gear 8 Insert Forcing Screw 6960 4 9 Tighten forcing screw tool to slightly compress clutch discs 10 Place differential pinions in position in side gears and verify that the pinion mate shaft holes are aligned 11 Rotate case wi...

Page 172: ...tched set only Ring gear and pinion for worn and chipped teeth Ring gear for damaged bolt threads Replaced as a matched set only Pinion yoke for cracks worn splines pitted areas and a rough corroded seal contact surface Repair or replace as necessary Pinion depth shims for damage and distortion Install new shims if necessary The differential case Replace the case if cracked or damaged The axle sha...

Page 173: ...ve subtract that value from the thickness of the depth shim If the number is 0 no change is nec essary PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion bearing cups and pinion bearings installed in the axle housing Take measurements with Pinion Gauge Set and Dial Indicator C 3339 Fig 53 1 Assemble Pinion Height Block 6739 Pinion Block 8540 and rear pinion bearing onto Scr...

Page 174: ... in to the dial indicator reading DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH The following must be considered when adjusting bearing preload and gear backlash The maximum ring gear backlash variation is 0 003 inch 0 076 mm PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear Depth Variance 4 3 2 1 0 1 2 3 4 4 0 008 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 3...

Page 175: ...Allow some ring gear backlash approximately 0 01 inch 0 25 mm between the ring and pinion gear Seat the bearing cups with the procedure described above 2 Install dial indicator and position the plunger against the drive side of a ring gear tooth Fig 58 Measure the backlash at 4 positions 90 degrees apart around the ring gear Locate and mark the area of minimum backlash 3 Rotate the ring gear to th...

Page 176: ...ear teeth to Gear Tooth Contact Patterns chart Fig 59 and adjust pinion depth and gear backlash as necessary SIDE GEAR CLEARANCE When measuring side gear clearance check each gear independently If it necessary to replace a side gear replace both gears as a matched set 1 Install the axle shafts and C locks and pinion mate shaft 2 Measure each side gear clearance Insert a matched pair of feeler gaug...

Page 177: ...Fig 59 Gear Tooth Contact Patterns 3 130 8 1 4 REAR AXLE XJ ADJUSTMENTS Continued ...

Page 178: ...n 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 8 1 4 INCH AXLE DESCRIPTION TORQUE Diff Cover Bolt 41 N m 30 ft lbs Bearing Cap Bolt 136 N m 100 ft lbs Pinion Nut Minimum 285 N m 210 ft lbs Ring Gear Bolt 95 N m 70 ft lbs Backing Plate Bolt 614 N m...

Page 179: ...Handle C 4171 Installer C 4076 B Handle C 4735 1 Holder 6719 Puller C 452 Installer C 3718 Adjustment Rod C 4164 Puller Press C 293 PA Adapters C 293 48 3 132 8 1 4 REAR AXLE XJ SPECIAL TOOLS Continued ...

Page 180: ...Plug SP 3289 Adapters C 293 47 Installer C 4340 Holder 8138 Installer C 4345 Remover C 4307 Installer C 4308 Installer D 130 Installer 6448 XJ 8 1 4 REAR AXLE 3 133 SPECIAL TOOLS Continued ...

Page 181: ...Trac lokY Tools 8140 Trac lokY Tools 6960 Pinion Gauge Block 8540 Arbor Discs 8541 Pinion Gauge Set 3 134 8 1 4 REAR AXLE XJ SPECIAL TOOLS Continued ...

Page 182: ...PROCEDURES BRAKE FLUID LEVEL 12 MASTER CYLINDER BLEEDING 12 BASE BRAKE BLEEDING 13 DISC ROTOR MACHINING 13 BRAKE DRUM MACHINING 14 BRAKE TUBE FLARING 14 REMOVAL AND INSTALLATION BRAKE LAMP SWITCH 15 BRAKE PEDAL 15 COMBINATION VALVE 16 MASTER CYLINDER 16 POWER BRAKE BOOSTER 17 FRONT DISC BRAKE CALIPER 18 FRONT DISC BRAKE SHOES 20 DISC BRAKE ROTOR 21 DRUM BRAKE SHOES 21 WHEEL CYLINDER 21 BRAKE SUPPO...

Page 183: ...TECTION AGENCY FOR THE HANDLING PROCESSING AND DISPOSITION OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS CAUTION Never use gasoline kerosene alcohol motor oil transmission fluid or any fluid containing mineral oil to clean the system components These fluids damage rubber cups and seals Use only fresh brake fluid or Mopar brake cleaner to clean or flush brake system components These are the on...

Page 184: ...nd the diaphragms to atmospheric pres sure The resulting pressure differential provides the extra apply force for power assist The booster check valve check valve grommet and booster seals are serviceable MASTER CYLINDER DESCRIPTION The master cylinder has a removable nylon reser voir The cylinder body is made of aluminum and contains a primary and secondary piston assembly The cylinder body inclu...

Page 185: ... to the inboard brake shoe This forces the shoe lining against the inner surface of the disc brake rotor At the same time fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts This action brings the outboard brake shoe lining into contact with the outer surface of the disc brake rotor Fig 1 Power Brake Booster Typical 1 VACUUM CHECK VALVE 2 FRONT DIAPHRAGM ...

Page 186: ...secondary design Fig 4 OPERATION When the brake pedal is depressed hydraulic pres sure pushes the rear brake wheel cylinder pistons outward The wheel cylinder push rods then push the brake shoes outward against the brake drum When the brake pedal is released return springs attached to the brake shoes pull the shoes back to there orig inal position PARKING BRAKE DESCRIPTION The parking bake is a ha...

Page 187: ...ever The switch which is in circuit with the red warning light in the dash will illuminate the warn ing light whenever the parking brakes are applied Parking brake adjustment is controlled by a cable tensioner mechanism The cable tensioner once adjusted at the factory should not need further adjustment under normal circumstances Adjustment Fig 4 Brake Components 1 ADJUSTER LEVER 2 ADJUSTER CABLE 3...

Page 188: ...arking brake partially applied 5 Check brake pedal operation Verify that pedal does not bind and has adequate free play If pedal lacks free play check pedal and power booster for being loose or for bind condition Do not road test until condition is corrected 6 Check booster vacuum check valve and hose 7 If components checked appear OK road test the vehicle ROAD TESTING 1 If complaint involved low ...

Page 189: ...ads Refer to the Brake Drag information in this section for causes BRAKE PULL Front brake pull condition could result from Contaminated lining in one caliper Seized caliper piston Binding caliper Loose caliper Rusty caliper slide surfaces Improper brake shoes Damaged rotor A worn damaged wheel bearing or suspension component are further causes of pull A damaged front tire bruised ply separation ca...

Page 190: ...ter are out of tolerance rotors brake lining not securely attached to the shoes loose wheel bearings and contaminated brake lining THUMP CLUNK NOISE Thumping or clunk noises during braking are fre quently not caused by brake components In many cases such noises are caused by loose or damaged steering suspension or engine components However calipers that bind on the slide surfaces can generate a th...

Page 191: ...hrottle and immediately turn off igni tion to stop engine 7 Wait a minimum of 90 seconds and try brake action again Booster should provide two or more vac uum assisted pedal applications If vacuum assist is not provided booster is faulty POWER BOOSTER VACUUM TEST 1 Connect vacuum gauge to booster check valve with short length of hose and T fitting Fig 7 2 Start and run engine at curb idle speed fo...

Page 192: ...ness or if machining would reduce thickness below the allowable minimum Rotor minimum thickness is usually specified on the rotor hub The specification is either stamped or cast into the hub surface ROTOR RUNOUT Check rotor lateral runout with dial indicator C 3339 Fig 9 Excessive lateral runout will cause brake pedal pulsation and rapid uneven wear of the brake shoes Position the dial indicator p...

Page 193: ...onnec tions Be sure brake line connections are properly made not cross threaded and tightened to recom mended torque BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts Swollen rubber parts indicate the presence of petroleum in the brake fluid To test for contamination put a small amount of drained brake fluid in clear glass jar If fluid sepa rates...

Page 194: ...er cylinder reservoir once more before proceeding 3 Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid Fig 13 Be sure end of bleed hose is immersed in fluid 4 Open up bleeder then have a helper press down the brake pedal Once the pedal is down close the bleeder Repeat bleeding until fluid stream is clear and free of bubbles Then...

Page 195: ...ergency repair when factory replacement parts are not readily available Special bending tools are needed to avoid kinking or twisting of metal brake tubes Special flaring tools are needed to make a double inverted flare or ISO flare Fig 14 DOUBLE INVERTED FLARING 1 Cut off damaged tube with Tubing Cutter 2 Ream cut edges of tubing to ensure proper flare 3 Install replacement tube nut on the tube 4...

Page 196: ...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 bracket and turn it clockwise about 30 to lock it in place 5 Release brake pedal Then pull pedal lightly rearward Pedal will set plunger to correct position as pedal pushes plunger into switch body Switch will make rat...

Page 197: ... Do not pull switch wire to disconnect 3 Disconnect brake lines at combination valve Fig 20 4 Remove mounting nut and remove valve INSTALLATION 1 Install valve and tighten mounting nut to 17 N m 155 in lbs 2 Connect brake lines to replacement valve Start line fittings by hand to avoid cross threading 3 Tighten brake line fittings to 14 N m 124 in lbs 4 Connect wire to pressure differential switch ...

Page 198: ...cles remove the coolant reserve overflow tank Refer to Group 7 Cooling System 2 Disconnect brake lines at master cylinder 3 Disconnect wire at combination valve differen tial pressure switch 4 Remove nut mounting combination valve bracket to booster studs and remove valve 5 Remove nuts mounting master cylinder to booster studs and remove cylinder 6 Disconnect vacuum hose from booster check valve 7...

Page 199: ...ighten bracket mounting nuts to 17 5 N m 155 in lbs 13 Connect wire to combination valve switch 14 On RHD vehicles install the coolant reserve overflow tank Refer to Group 7 Cooling System 15 Fill and bleed base brake system 16 Verify proper brake operation before moving vehicle FRONT DISC BRAKE CALIPER REMOVAL 1 Raise and support vehicle 2 Remove front wheel and tire assembly 3 Drain small amount...

Page 200: ...N m 11 ft lbs CAUTION If new caliper bolts are being installed or if the original reason for repair was a drag pull condition check caliper bolt length before proceed ing Bolts must not have a shank length greater than 67 6 mm 2 66 in Fig 30 4 Install brake hose to caliper with new seal washers and tighten fitting bolt to 31 N m 23 ft lbs Fig 26 Caliper Mounting Bolts 1 CALIPER MOUNTING BOLT 2 2 C...

Page 201: ...by suspension part with wire Do not allow brake hose to support caliper weight 7 Wipe caliper off with shop rags or towels CAUTION Do not use compressed air this can unseat dust boot and force dirt into piston bore INSTALLATION 1 Install inboard shoe in caliper and verify shoe retaining is fully seated into the piston 2 Starting one end of outboard shoe in caliper and rotating shoe downward into p...

Page 202: ...h 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 le...

Page 203: ...press parking brake cable retainer tabs Then push retainer and cable through and out of support plate Fig 34 Drum Brake Components Typical 1 ADJUSTER LEVER 2 ADJUSTER CABLE 3 HOLDDOWN SPRING AND RETAINERS 4 ADJUSTER LEVER SPRING 5 TRAILING SHOE 6 CYLINDER TO SUPPORT SEAL 7 HOLDDOWN PINS 8 ACCESS PLUGS 9 SUPPORT PLATE 10 CABLE HOLE PLUG 11 PARK BRAKE STRUT AND SPRING 12 ADJUSTER SCREW ASSEMBLY 13 H...

Page 204: ... slack 2 Disengage cables from equalizer and compress cable retainers with a worm drive hose clamp 3 Remove cables from the cable bracket Fig 36 4 Remove rear wheel and brake drums 5 Remove secondary brake shoe and disconnect cable from lever on brake shoe 6 Compress cables retainer with worm drive hose clamp Fig 37 and remove cables from backing plates INSTALLATION 1 Install new cables in backing...

Page 205: ... 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 7 Raise vehicle 8 Install adjusting nut to the tensioner rod and adjust parking brakes 9 Lower vehicle 10 Verify correct parking brake operation DISASSEMBLY AND ASSEMBLY MASTER CYLINDER RESERVOIR REMOVAL 1 Remove reservoir cap a...

Page 206: ...oir in grommets Then rock reser voir back and forth while pressing downward to seat it in grommets 3 Install pins that retain reservoir to cylinder body 4 Fill and bleed master cylinder on bench before installation in vehicle DISC BRAKE CALIPER DISASSEMBLY 1 Remove brake shoes from caliper 2 Drain brake fluid out of caliper 3 Take a piece of wood and pad it with one inch thickness of shop towels P...

Page 207: ...TION Dirt oil and solvents can damage cali per seals Insure assembly area is clean and dry 1 Lubricate caliper piston bore new piston seal and piston with clean brake fluid 2 Lubricate caliper bushings and interior of bushing boots with silicone grease 3 Install bushing boots in caliper then insert bushing into boot and push bushing into place Fig 50 4 Install new piston seal into seal groove with...

Page 208: ...ushing And Boot 1 CALIPER SLIDE BUSHING 2 BOOT Fig 50 Bushings And Boots Installation 1 BUSHING 2 BOOT Fig 51 Piston Seal Installation 1 SEAL GROOVE 2 PISTON SEAL Fig 52 Dust Boot On Piston 1 PISTON 2 DUST BOOT Fig 53 Caliper Piston Installation 1 PISTON 2 BOOT XJ BRAKES 5 27 DISASSEMBLY AND ASSEMBLY Continued ...

Page 209: ...ressure com pressed air CAUTION Do not use gasoline kerosene thinner or similar solvents These products may leave a residue that could damage the piston and seal INSPECTION The piston is made from a phenolic resin plastic material and should be smooth and clean The piston must be replaced if cracked or scored Do not attempt to restore a scored piston surface by sanding or polishing CAUTION If the ...

Page 210: ...te replace the support plate if any of the pads are worn or rusted through Also replace the plate if it is bent or distorted Fig 57 WHEEL CYLINDER CLEANING Clean the cylinder and pistons with clean brake fluid or brake cleaner only Do not use any other cleaning agents Dry the cylinder and pistons with compressed air Do not use rags or shop towels to dry the cylinder components Lint from cloth mate...

Page 211: ...in position Fig 58 5 Reverse gauge and install it on brake shoes Position gauge legs at shoe centers as shown Fig 59 If gauge does not fit too loose too tight adjust shoes 6 Pull shoe adjuster lever away from adjuster screw star wheel 7 Turn adjuster screw star wheel by hand to expand or retract brake shoes Continue adjustment until gauge outside legs are light drag fit on shoes 8 Install brake dr...

Page 212: ...y that parking brake cables operate freely and are not binding or seized Replace faulty cables before proceeding 6 Reinstall brake drums and wheel tire assem blies after brake shoe adjustment is complete 7 Lower vehicle enough for access to parking brake lever Then fully apply parking brakes Leave brakes applied until adjustment is complete 8 Raise vehicle and mark tensioner rod 6 5 mm 1 4 in from...

Page 213: ... 12 mm 0 005 in Max Thickness Variation 0 013 mm 0 0005 in Min Thickness 22 7 mm 0 8937 in Brake Drum Size 9 in or 10 in Brake Booster Type Dual Diaphragm TORQUE CHART DESCRIPTION TORQUE Brake Pedal Pivot Bolt Nut 35 N m 26 ft lbs Brake Booster Mounting Nuts 39 N m 29 ft lbs Master Cylinder Mounting Nuts 17 5 N m 155 in lbs Brake Lines 14 N m 124 in lbs Combination Valve Mounting Nuts 17 5 N m 155...

Page 214: ... dynamic check occurs when vehicle road speed reaches approximately 30 kph 18 mph During the dynamic check the CAB briefly cycles the pump and solenoids to verify oper ation If an ABS component exhibits a fault during ini tialization the CAB illuminates the amber warning light and registers a fault code in the microprocessor memory OPERATION During normal braking the master cylinder power booster ...

Page 215: ...nd the inlet valve is 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 hi...

Page 216: ...ssure 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 PROPORTIONING VALVE The proportioning valve...

Page 217: ... brake section for procedure 2 Connect scan tool to the Data Link Connector 3 Select ANTILOCK BRAKES followed by MIS CELLANEOUS then ABS BRAKES Follow the instructions displayed When scan tool displays TEST COMPLETE disconnect scan tool and proceed 4 Perform base brake bleeding a second time Refer to base brake section for procedure 5 Top off master cylinder fluid level and verify proper brake ope...

Page 218: ...5 mm 0 014 to 0 059 in If gap is incorrect sensor is either loose or damaged 6 Secure sensor wire to steering knuckle and body brackets 7 Route sensor wire forward and behind shock absorber Then attach sensor wire to spring seat bracket with grommets on sensor wire 8 Route sensor wire to outer sill bracket Remove all twists or kinks from wire 9 Attach sensor wire to sill bracket with grom met Be s...

Page 219: ...or face against tone ring Fig 10 Then tighten sensor bolt to 13 N m 115 in lbs Cor rect air gap will be established as tone ring rotates and peels spacer off sensor face 7 Route sensor wires to rear seat area 8 Feed sensor wires through floorpan access hole and seat sensor grommets in floorpan 9 Verify that rear sensor wires are secured to rear brake hose and axle with clips Verify that wire is cl...

Page 220: ...h Be sure harness connector is firmly seated 4 Move seat back to normal position DISASSEMBLY AND ASSEMBLY HYDRAULIC CONTROL UNIT CONTROLLER ANTILOCK BRAKE DISASSEMBLY 1 Remove pump motor connector from the CAB 2 Remove CAB mounting screws from the HCU Fig 13 3 Remove CAB from the HCU Fig 10 New Rear Sensor 1 REAR SENSOR 2 AIR GAP SPACER ATTACHED TO SENSOR FACE Fig 11 G Switch Mounting 1 ACCELERATI...

Page 221: ...QUE G Sensor Sensor Bolt 3 N m 27 5 in lbs Bracket Bolt 2 7 N m 24 in lbs Hydraulic Control Unit Controller Antilock Brakes Mounting Nuts 11 5 N m 102 in lbs Brake Lines 19 N m 170 in lbs Controller Antilock Brakes Mounting Screws 1 8 N m 16 in lbs Wheel Speed Sensors Front Mounting Bolt 4 7 N m 42 in lbs Rear Mounting Bolt 13 N m 115 in lbs 5 40 BRAKES XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 222: ... and remove the valve and bracket assembly from the vehicle 5 Remove the master cylinder retaining nuts Fig 8 and remove the master cylinder from the brake booster by sliding straight off mounting studs 6 Disconnect the vacuum supply hose from the brake booster 7 Disconnect the coolant level switch electrical connector Located on the side of the coolant reser voir NOTE It is not necessary to drain...

Page 223: ... 3 Slide booster push rod onto the brake pedal pin Then secure push rod to pedal pin with retaining clip 4 Torque booster mounting nuts to 39 N m 29 ft lbs 5 Install the steel and plastic knee blocker in the vehicle Refer to Group 23 Body for the procedure 6 Install the hood release cable handle 7 Install the coolant reservoir bottle retaining screws and connect the coolant level switch 8 Connect ...

Page 224: ...remove the valve and bracket assembly from the vehicle 5 Remove the master cylinder retaining nuts Fig 8 and remove the master cylinder from the brake booster by sliding straight off mounting studs INSTALLATION NOTE Be certain rubber o ring vacuum seal is installed in the master cylinder mounting flange prior to installation NOTE If a new master cylinder is being installed cylinder must be bench b...

Page 225: ...ect the negative battery cable 9 Adjust the brake lamp switch Refer to the pro cedure in this group WARNING Be certain a firm brake pedal is achieved prior to attempting to operate the vehicle SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION TORQUE Brake Booster to Cowl Panel Nuts 39 N m 29 ft lbs Brake Lines at Master Cylinder and Combination Valve Tube Nuts 19 N m 170 in lbs Master Cylinder to V...

Page 226: ...N The clutch mechanism consists of a flywheel a sin gle dry type disc and a diaphragm style clutch cover Fig 1 A hydraulic linkage is used to operate the clutch release bearing and fork The flywheel is bolted to the rear flange of the crankshaft The clutch pressure plate is bolted to the flywheel with the clutch disc located between these two compo nents The clutch system provides the mechanical b...

Page 227: ...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 The clutch disc friction material is riveted to the disc hub Fig 4 The hub bore is splined for installa tion on the transmission input shaft The cl...

Page 228: ...e release fork which moves the bear ing into contact with the clutch cover diaphragm spring 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 fingers inward on the fulcrums This actio...

Page 229: ...D BAGS OR CONTAINERS THIS WILL HELP MINIMIZE EXPOSURE TO YOURSELF AND TO OTHERS FOLLOW ALL REC OMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMIN ISTRATION OSHA AND THE ENVIRONMENTAL SAFETY AGENCY EPA FOR THE HANDLING AND DISPOSAL OF PRODUCTS CONTAINING ASBESTOS INSTALLATION METHODS AND PARTS USAGE Distortion of clutch components during installation and the use of non...

Page 230: ...Fig 8 Clutch Components And Inspection XJ CLUTCH 6 5 DIAGNOSIS AND TESTING Continued ...

Page 231: ... in proper alignment with the crankshaft and transmission input shaft Misalignment caused by excessive runout or warpage of any clutch component will cause grab chatter and improper clutch release CLUTCH HOUSING MISALIGNMENT Clutch housing alignment is important to proper clutch operation The housing maintains alignment between the crankshaft and transmission input shaft Misalignment can cause clu...

Page 232: ...a convenient reference when diagnosing faulty clutch operation DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Disc facing worn out 1 Normal wear 1 Replace cover and disc 2 Driver frequently rides slips the clutch Results in rapid overheating and wear 2 Replace cover and disc 3 Insufficient clutch cover diaphragm spring tension 3 Replace cover and disc Clutch disc facing contaminated with oil...

Page 233: ...lean smooth and lubricate shaft splines if possible Replace input shaft if necessary Clutch disc rusted to flywheel and or pressure plate 1 Clutch not used for and extended period of time e g long term vehicle storage 1 Sand rusted surfaces with 180 grit sanding paper Replace clutch cover and flywheel if necessary Pilot bearing seized loose or rollers are worn 1 Bearing cocked during installation ...

Page 234: ...ers bent or distorted 2 Replace clutch disc and cover 3 Clutch disc damaged or distorted 2 Replace clutch disc 4 Clutch misalignment 4 Check alignment and runout of flywheel disc pressure plate andør clutch housing Correct as necessary SERVICE PROCEDURES CLUTCH COMPONENT LUBRICATION Proper clutch component lubrication is important to satisfactory operation Using the correct lubricant and not over ...

Page 235: ...3 in Measure runout at the outer edge of the fly wheel face with a dial indicator Mount the dial indi cator on a stud installed in place of one of the clutch housing attaching bolts Clean the crankshaft flange before mounting the flywheel Dirt and grease on the flange surface may cock the flywheel causing excessive runout Check condition of the flywheel hub and attaching bolts Replace the flywheel...

Page 236: ... Fig 10 INSTALLATION 1 Lightly scuff sand flywheel face with 180 grit emery cloth Then clean surface with a wax and grease remover 2 Lubricate pilot bearing with Mopar high tem perature bearing grease 3 Check runout and free operation of new clutch disc as follows a Slide disc onto transmission input shaft splines Disc should slide freely on splines b Leave disc on shaft and check face runout with...

Page 237: ...ricate input shaft splines bearing retainer slide surface fork pivot and release fork pivot surface with Mopart high temperature grease 3 Install new release bearing Be sure bearing is properly secured to release fork 4 Install transmission PILOT BEARING REMOVAL 1 Remove transmission Refer to Group 21 Transmission and Transfer Case for proper proce dures 2 Remove clutch cover and disc 3 Use a suit...

Page 238: ...ote that removal installation pro cedures for right and left hand drive models are basi cally the same Only master cylinder location is different REMOVAL 1 Raise vehicle 2 Remove fasteners attaching slave cylinder to clutch housing 3 Remove slave cylinder from clutch housing Fig 15 4 Disengage clutch fluid line from body clips if applicable 5 Lower vehicle 6 Verify that cap on clutch master cylind...

Page 239: ...nder attaching nuts to 38 N m 28 ft lbs torque 6 Raise vehicle 7 Insert slave cylinder push rod through clutch housing opening and into release lever Be sure cap on end of rod is securely engaged in lever Check this before installing cylinder attaching nuts 8 Install and tighten slave cylinder attaching nuts to 23 N m 17 ft lbs torque Fig 15 Slave Cylinder 1 CLUTCH SLAVE CYLINDER Fig 16 Left Hand ...

Page 240: ...housing M12 75 N m 55 ft lbs Bolt clutch housing 3 8 37 N m 27 ft lbs Bolt clutch housing 7 16 58 N m 43 ft lbs Bolt clutch housing trans 46 N m 34 ft lbs Bolt dust shield M8 8 N m 72 in lbs Bolt dust shield lower 50 N m 37 ft lbs Bolt X member frame 41 N m 30 ft lbs Bolt X member rear support 45 N m 33 ft lbs Bolts flywheel 4 0 L 142 N m 105 ft lbs Bolts flywheel 2 5 L 95 N m 70 ft lbs Bolt start...

Page 241: ......

Page 242: ... indicates additional fluid is needed add fluid from a sealed container only Use Mopart brake fluid or an equivalent meeting standards SAE J1703 and DOT 3 Do not use any other type of fluid REMOVAL AND INSTALLATION CLUTCH COVER AND DISC REMOVAL 1 Remove the transmission Refer to Group 21 Transmission and Transfer Case for procedure 2 If the original clutch cover will be reinstalled mark position o...

Page 243: ...d on the flywheel Fig 5 7 Install the clutch cover bolts finger tight Fig 5 8 Starting with the bolts marked P on the cover first tighten clutch cover bolts in a star pattern to 50 N m torque 37 ft lbs 9 Apply light coat of Mopart high temperature bearing grease to pilot bearing and splines of trans mission input shaft CAUTION Do not over lubricate as this will result in grease contamination of th...

Page 244: ...aring retainer on two wood blocks 6 Remove the pilot bearing with a suitable sized socket and extension Fig 8 Use mallet to tap bear ing out of retainer Fig 4 Clutch Disc Alignment Typical 1 FLYWHEEL 2 CLUTCH COVER AND DISC 3 CLUTCH DISC ALIGNMENT TOOL Fig 5 Clutch Cover Pressure Plate View 1 VEHICLE UNDERBODY 2 ENGINE SPEED SENSOR 3 PRESSURE PLATE RETAINING BOLTS 4 CLUTCH COVER PRESSURE PLATE 5 E...

Page 245: ...th lower edge of chamfer in retainer bore Fig 10 Reposition the bearing if necessary 3 Install the bearing retainer Torque bolts to 28 N m 20 ft lbs 4 Lubricate the pilot bearing with Mopart high temperature wheel bearing grease Fig 7 Pilot Bearing Retainer Bolt Removal Installation 1 RETAINER 2 PILOT BEARING 3 FLYWHEEL Fig 8 Pilot Bearing Removal 1 HOUSING 2 SUITABLE SIZE SOCKET 3 EXTENSION Fig 9...

Page 246: ...aged Resurface the flywheel if the clutch contact surface is scored or rough refer to flywheel finishing and ring gear replacement information in this section Check flywheel runout if misalignment is sus pected Runout should not exceed 0 08 mm Measure flywheel face runout with a dial indicator Fig 13 Mount the indicator on a stud installed in the engine block or in one of the flywheel attaching bo...

Page 247: ...ighten ing method until completion 5 Install the clutch cover and disc Fig 16 Refer to clutch cover and disc removal and installation pro cedure in this section 6 Install the transmission and transfer case Refer to Group 21 Transmission and Transfer Case for removal and installation procedure Fig 13 Checking Flywheel Runout 1 DIAL INDICATOR 2 FLYWHEEL FACE Fig 14 Flywheel Mounting VM Diesel 1 O RI...

Page 248: ...erature of the torch flame can cause localized heating that will damage the fly wheel In addition using the torch to heat a replace ment gear will cause uneven heating and expansion The torch flame can also anneal the gear teeth resulting in rapid wear and damage after installation INSTALLATION 1 Position and install the heated ring gear on the flywheel a Wear heat resistant gloves to handle the h...

Page 249: ...eel Crankshaft Bolts 28 N m 20 ft lbs Clutch Housing to Engine Top 2 Bolts 37 N m 27 ft lbs Middle 2 Bolts 58 N m 43 ft lbs Bottom 2 Bolts 75 N m 55 ft lbs SPECIAL TOOLS SPECIAL TOOLS Fig 18 Clutch Cover Pressure Plate View 1 VEHICLE UNDERBODY 2 ENGINE SPEED SENSOR 3 PRESSURE PLATE RETAINING BOLTS 4 CLUTCH COVER PRESSURE PLATE 5 ENGINE OIL PAN 6 PRESSURE PLATE RETAINING BOLTS Universal Handle C 41...

Page 250: ...L 34 BLOCK HEATER 35 ENGINE ACCESSORY DRIVE BELTS 35 COOLING SYSTEM FANS 38 VISCOUS FAN DRIVE REMOVAL INSTALLATION 39 CLEANING AND INSPECTION RADIATOR PRESSURE CAP 39 RADIATOR 39 WATER PUMP 39 FAN BLADE 39 COOLING SYSTEM HOSES 40 SPECIFICATIONS BELT TENSION 40 TORQUE SPECIFICATIONS 40 SPECIAL TOOLS COOLING 40 DESCRIPTION AND OPERATION COOLING SYSTEM DESCRIPTION The cooling system regulates engine ...

Page 251: ...gine packages 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 befor...

Page 252: ...ermal viscous fan drive is a torque and tempera ture sensitive clutch unit It automatically increases or decreases fan speed to provide proper engine cool ing Vehicles with a 2 5L 4 0L engine with air condi tioning or 4 0L with max cooling also have an auxiliary electrical cooling fan Fig 3 Reserve Overflow Tank Except Right Hand Drive 1 COOLANT RESERVE OVERFLOW TANK 2 CLAMP 3 MOUNTING BOLTS 4 TUB...

Page 253: ...ermostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator On all engines the thermostat is closed below 195 F 90 C Above this temperature coolant is allowed to flow to the radia tor This provides quick engine warm up and overall temperature control An arrow plus the word UP is stamped on the front flange next to the air bleed The words TO R...

Page 254: ...re reaches release range of 83 110 kPa 12 16 psi A rubber gasket seals radiator filler neck This is done to maintain vacuum during coolant cool down and to prevent leakage when system is under pres sure OPERATION A vent valve in the center of cap allows a small coolant flow through cap when coolant is below boil ing temperature The valve is completely closed when boiling point is reached As the co...

Page 255: ...e coolant mixture No addi tional lubrication is necessary HOSE CLAMPS DESCRIPTION The cooling system utilizes both worm drive and spring type hose clamps If a spring type clamp replacement is necessary replace with the original Mopart equipment spring type clamp CAUTION A number or letter is stamped into the tongue of constant tension clamps If replacement is necessary use only a original equipmen...

Page 256: ...arge 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...

Page 257: ...less the coolant temperature is at least 103 C 218 F at which time the fan will come on and remain on until the coolant temperature drops to 99 C 210 F or below When air conditioning is requested including defroster operation the fan will cycle on and off in conjunction with the A C compres sor unless the coolant temperature is at least 97 C 207 F at which time the fan will come on and remain on u...

Page 258: ...ice technician Refer to Group 25 Emission Control Systems for proper procedures ACCESSING DIAGNOSTIC TROUBLE CODES To read DTC s and to obtain cooling system data refer to Group 25 Emission Control Systems for proper procedures DRB SCAN TOOL For operation of the DRB scan tool refer to the appropriate Powertrain Diagnostic Procedures ser vice manual ACCESSORY DRIVE BELT DIAGNOSIS VISUAL DIAGNOSIS W...

Page 259: ...seizure 3 Replace faulty component or bearing 4 Belt glazed or hardened from heat and excessive slippage 4 Replace belt LONGITUDAL BELT CRACKING 1 Belt has mistracked from pulley groove 1 Replace belt 2 Pulley groove tip has worn away rubber to tensile member 2 Replace belt 9GROOVE JUMPING Belt does not maintain correct position on pulley 1 Belt tension either too low or too high 1 Adjust belt ten...

Page 260: ...ads on the cooling system such as the following may be the cause PROLONGED IDLE VERY HIGH AMBIENT TEMPERATURE SLIGHT TAIL WIND AT IDLE SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED OR STEEP GRADES Driving techniques that avoid overheating are Idle with A C off when temperature gauge is at end of normal range Increasing engine speed for more air flow is rec ommended TRAILER TOWING Consult Trailer Towing sec...

Page 261: ...AMP ILLUMINATES COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM THE COOLING SYSTEM 1 Trailer is being towed a steep hill is being climbed vehicle is operated in slow moving traffic or engine is being idled with very high ambient outside temperatures and the air conditioning is on Higher altitudes could aggravate these conditions 1 This may be a temporary condition and repair is not necessary Turn o...

Page 262: ...age 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 system 9 Check for coolant flow at radiator filler neck with some coolant removed engine warm and thermostat open Coolant should be observed flowing through radiator If flow is not observed determine area of obstructi...

Page 263: ...d Testing in this group 2 During cold weather operation with the heater blower in the high position the gauge reading may drop slightly 2 A normal condition No correction is necessary 3 Temperature gauge or engine mounted gauge sensor defective or shorted Also corroded or loose wiring in this circuit 3 Check operation of gauge and repair if necessary Refer to Group 8E Instrument Panel and Gauges 4...

Page 264: ... System Testing For Leaks in this group DETONATION OR PRE IGNITION NOT CAUSED BY IGNITION SYSTEM GAUGE MAY OR MAY NOT BE READING HIGH 1 engine overheating 1 Check reason for overheating and repair as necessary 2 Freeze point of coolant not correct Mixture is too rich or too lean 2 Check coolant concentration Refer to the Coolant section of this group and adjust ratio as required HOSE OR HOSES COLL...

Page 265: ...le Refer to Viscous Fan Drive in this group 5 A certain amount of fan noise may be evident on models equipped with a thermal viscous fan drive Some of this noise is normal 5 Refer to Viscous Fan Drive in this group for an explanation of normal fan noise INADEQUATE HEATER PERFORMANCE THERMOSTAT FAILED IN OPEN POSITION 1 Has a Diagnostic trouble Code DTC been set 1 Refer to Group 25 Emissions for co...

Page 266: ...e level should return to within that range after operation at elevated temperatures 1 A normal condition No repair is necessary RADIATOR COOLANT FLOW CHECK The following procedure will determine if coolant is flowing through the cooling system If engine is cold idle engine until normal operating temperature is reached Then feel the upper radiator hose If hose is hot the thermostat is open and wate...

Page 267: ...and reinspect the system with pressure applied Drops Quickly Shows that a serious leakage is occurring Examine the system for serious external leakage If no leaks are visible inspect for internal leakage Large radiator leak holes should be repaired by a reputable radiator repair shop INTERNAL LEAKAGE INSPECTION Remove the engine oil pan drain plug and drain a small amount of engine oil Coolant bei...

Page 268: ... Insert thermometer through the hole in the shroud Be sure that there is adequate clearance from the fan blades 3 Connect a tachometer and an engine ignition timing light timing light is to be used as a strobe light 4 Block the air flow through the radiator Secure a sheet of plastic in front of the radiator or air con ditioner condenser Use tape at the top to secure the plastic and be sure that th...

Page 269: ... 3 For conducting service procedures 4 When checking for vacuum leaks WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP WITH A RAG SQUEEZE RADIATOR UPPER HOSE TO CHECK IF SYSTEM IS UNDER PRESSURE PLACE A RAG OVER THE CAP AND WITHOUT PUSHING DOWN ROTATE CAP COUNTER CLOCKWISE TO THE FIRST STOP ALLOW FLUID TO ESCAPE THROUGH OVERFLOW HOSE INTO COOLANT RESER...

Page 270: ...olant level inspections The coolant level can be checked at coolant reserve overflow tank The coolant reserve overflow system provides a quick visual method for determining coolant level without removing radiator pressure cap With engine cold and not running observe coolant level in reserve overflow tank The coolant level should be between ADD and FULL marks COOLANT ADDING ADDITIONAL Do not remove...

Page 271: ...e flushing This will soften scale and other deposits and aid the flushing operation CAUTION Be sure instructions on the container are followed REVERSE FLUSHING RADIATOR Disconnect the radiator hoses from the radiator fit tings Attach a section of radiator hose to the radia tor bottom outlet fitting and insert the flushing gun Connect a water supply hose and air supply hose to the flushing gun CAUT...

Page 272: ...nd torque convertor may not require reconditioning Refer to Group 21 for automatic transmission servicing 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...

Page 273: ...mplete assembly WARNING DO NOT REMOVE THE BLOCK DRAIN PLUG S OR LOOSEN RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR DO NOT WASTE reusable coolant If the solution is clean drain coolant into a clean container for reuse REMOVAL 2 5L ENGINE LHD RHD 1 Disconnect battery negative cable 2 Drain cooling system Refer to Cooling System Draining and Filling ...

Page 274: ...efore removal INSTALLATION 2 5L ENGINE LHD RHD 1 If pump is being replaced install the heater hose pipe to the pump Use a sealant on the fitting such as Mopart Thread Sealant With Teflon Refer to the directions on the package 2 Clean the gasket mating surfaces If the origi nal pump is used remove any deposits or other for eign material Inspect the cylinder block and water Fig 26 Fan Mounting Nuts ...

Page 275: ...s 2 6 Loosen but do not remove at this time the four water pump pulley to water pump hub mounting bolts Fig 29 and the four viscous fan to idler pulley nuts NOTE The accessory drive belt must be removed prior to removing the fan if installed at pump or fan pulley 7 Remove accessory drive belt refer to Accessory Drive Belt Removal and Installation in this group 8 Remove the four viscous fan to idle...

Page 276: ...ne may overheat due to the water pump rotating in the wrong direction Refer to the Belt Removal and Installation in this group for appropriate belt rout ing You may also refer to the Belt Routing Label in the vehicle engine compartment 9 Install and tighten viscous fan shroud bolts to 4 N m 31 in lbs 10 Install and tension the accessory drive belt refer to Accessory Drive Belt removal and installa...

Page 277: ...r or letter is stamped into the tongue of constant tension clamps Fig 11 If replacement is necessary use only an original equipment clamp with matching number or letter 2 Remove radiator upper hose and heater hose at thermostat housing 3 Disconnect wiring connector at engine coolant temperature sensor 4 Remove thermostat housing mounting bolts thermostat housing gasket and thermostat Fig 32 Discar...

Page 278: ...a 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 34 Put the other end into a clean container Open petcock and drain radiator 6 Detach power steering fluid reservoir from fan shroud and lay aside 7 Disconnect electric cooling fan electrical con nector if equipped 8 Disconnect CRS hose...

Page 279: ...on 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 ...

Page 280: ...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 nec...

Page 281: ... 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 40 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 tigh...

Page 282: ...and lay aside 4 Remove the four viscous fan drive assembly mounting nuts from the water pump studs and remove viscous fan assembly 5 Disconnect cooling fan electrical connector 6 Remove the four upper fan shroud to radiator crossmember mounting screws Fig 42 7 Lift fan and shroud assy from vehicle 8 Detach fan harness from shroud 9 Remove four fan module to shroud phillips head screws Fig 43 and r...

Page 283: ...ber Fig 44 2 Disconnect the electric fan connector 3 Lift fan straight up and out of vehicle INSTALLATION 1 Align lower retaining tabs of fan shroud with slots in bracket at bottom of radiator Push fan down into position 2 Tighten the mounting bolts to 4 N m 31 in lbs torque Fig 42 Fan Shroud Removal Installation 1 ELECTRIC FAN SHROUD ASSEMBLY 2 UPPER CROSSMEMBER 3 ISOLATOR 4 RADIATOR 5 LOWER CROS...

Page 284: ...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 ENGINE ACCESSORY DRIVE BELTS Correct drive belt tension is required to ensure opti...

Page 285: ...d drive RHD Or refer to the Belt Routing Label located in the vehicle engine compartment BELT REPLACEMENT OR ADJUSTMENT LEFT HAND DRIVE Belt tension is adjusted at the power steering pump bracket and idler pulley assembly 1 Disconnect negative battery cable from battery 2 Loosen idler pulley bolt at the power steering bracket Fig 53 3 Loosen adjusting bolt until belt can be removed from pulleys 4 ...

Page 286: ...AND DRIVE 4 0L 1 Disconnect negative battery cable from battery 2 Loosen lower alternator mounting bolt and nut 3 Loosen upper alternator mounting nut 4 Loosen adjusting bolt at upper alternator bracket Fig 54 until belt can be removed from pulleys 5 Remove belt INSTALLATION 1 Check condition of all pulleys Fig 50 Models With 4 0L Engine With A C Except RHD Fig 51 Models With 4 0L Engine With A C ...

Page 287: ... blade viscous fan drive should be removed from the vehicle as one assembly 4 Remove four fan hub mounting nuts Fig 55 Fig 56 and remove fan viscous fan drive assembly from vehicle 5 After removing fan blade viscous fan drive assembly do not place thermal viscous fan drive in horizontal position If stored horizontally silicone fluid in viscous fan drive could drain into its bearing assembly and co...

Page 288: ...ng 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 to damage the gasket sealing surface INSPECTION Inspect the water pump assembly for cracks in the housing Water leaks from shaft seal Loose or rough turning bearing or ...

Page 289: ...ine Belt 800 900 180 200 Used Serpentine Belt 623 712 140 160 Belt is considered new if it has been used 15 minetes or less TORQUE SPECIFICATIONS DESCRIPTION N m Ft In Lbs Lbs Trans Auxiliary Oil Cooler Screws 2 18 Block Heater Screw 4 20 Condenser to Radiator Bolts 6 55 Electric Cooling Fan Bolts 3 31 Fan Blade Assy to Viscous Fan Drive Bolts 24 18 Fan Shroud Bolts 3 31 Isolator to Crossmember Nu...

Page 290: ...IFICATIONS COOLING SYSTEM CAPACITY 28 THERMOSTAT 28 TORQUE SPECIFICATIONS 28 DESCRIPTION AND OPERATION COOLING SYSTEM DESCRIPTION The cooling system regulates engine operating tem perature It allows the engine to reach normal oper ating temperature as quickly as possible maintains normal operating temperature and prevents over heating The cooling system also provides a means of heat ing the passen...

Page 291: ...HOSES 5 HEATER CORE 6 WATER MANIFOLD FITTING 7 WATER MANIFOLD TOP OF CYLINDER HEAD 8 ENGINE TOP VIEW 9 UPPER RADIATOR HOSE 10 RADIATOR 11 THERMOSTAT 12 FILL VENT CAP 13 WATER PUMP 14 LOWER RADIATOR HOSE 15 VENT HOSE 16 LARGER FITTING TO COOLANT TANK 17 HOSES 18 HOSE 19 ENGINE OIL COOLER 20 LOW COOLANT LEVEL SENSOR 7 2 COOLING SYSTEM XJ DESCRIPTION AND OPERATION Continued ...

Page 292: ...ven from the engine crankshaft by a drive belt The water pump is bolted to the water pump adapter Fig 3 The water pump adapter is bolted to the engine The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing The bottom of the housing is equipped with a small vent tube Fig 3 to allow seepage to escape A drain hose is attached to this tube The wat...

Page 293: ...RESSURE VENT CAP DESCRIPTION The pressure vent cap is threaded on to the coolant tank This cap releases excess pressure at some point within a range of 90 117 kPa 13 17 psi The actual pressure relief point in pounds is labeled on top of the cap Fig 5 OPERATION The cooling system will operate at pressures up to 103 kPa 15 psi This results in a higher coolant boiling point allowing increased radiato...

Page 294: ...ed temperature can result in engine detona tion In addition 100 percent ethylene glycol freezes at 22 deg C 8 deg F Propylene glycol Formulations Should Not Be Used in DaimlerChrysler Corporation Vehicles Propylene glycol formulations do not meet Chrysler coolant specifications It s overall effec tive temperature range is smaller than that of ethyl ene glycol The freeze point of 50 50 propylene gl...

Page 295: ...t loss and engine over heating Ordinary worm gear type hose clamps when equipped can be removed with a straight screw driver or a hex socket To prevent damage to hoses or clamps the hose clamps should be tightened to 4 N m 34 in lbs torque Do not over tighten hose clamps When performing a hose inspection inspect the radiator lower hose for proper position and condition of the internal spring VISCO...

Page 296: ...uch as when towing a trailer Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged warm position This can occur during the first 15 seconds to one minute after engine start up on a cold engine LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing If leakage appears excessive replace the fan drive unit BELT TENSION ...

Page 297: ...iagnosis charts These charts are to be used as a quick reference only Refer to the group text for information COOLING SYSTEM DIAGNOSIS DIESEL ENGINE CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS LOW 1 Diesel engines due to their inherent efficiency are slower to warm up than gasoline powered engines and will operate at lower temperatures when the vehicle is unloaded 1 The low gauge ...

Page 298: ...the cause for overheating and repair Refer to POSSIBLE CAUSES numbers 2 through 16 2 Is temperature gauge reading correctly 2 Check gauge Refer to Group 8E Repair as necessary 3 Coolant low in coolant tank and radiator 3 Check for coolant leaks and repair as necessary Refer to Testing Cooling System For Leaks in this group 4 Pressure cap not installed tightly If cap is loose boiling point of coola...

Page 299: ...11 Dragging brakes 11 Check and correct as necessary Refer to Group 5 Brakes in the manual text 12 Non factory bug screen is being used reducing airflow 12 Only a factory approved screen may be used 13 Thermostat partially or completely shut This is more prevalent on high mileage vehicles 13 Check thermostat operation and replace as necessary Refer to Thermostats in this group 14 Thermal viscous f...

Page 300: ... Check and correct coolant leaks Refer to Testing Cooling System For Leaks in this group 6 Cylinder head gasket leaking allowing exhaust gas to enter cooling system causing thermostat to open late 6 a Check for cylinder head gasket leaks with a commercially available Block Leak Tester Repair as necessary b Check for coolant in the engine oil Inspect for white steam emitting from exhaust system Rep...

Page 301: ...eable Refer to Viscous Fan Drive in this group 5 A certain amount of fan noise roaring may be evident on models equipped with a thermal viscous fan drive Some of this noise is normal 5 Refer to Viscous Fan Drive in this group for an explanation of normal fan noise INADEQUATE AIR CONDITIONER PERFORMANCE COOLING SYSTEM SUSPECTED 1 Radiator and or A C condenser is restricted obstructed or dirty insec...

Page 302: ... are used at certain drive line components One or more of these shields may be missing 1 Locate missing shields and replace or repair as necessary 2 Is temperature gauge reading above the normal range 2 Refer to the previous Temperature Gauge Reads High in these Diagnosis Charts Repair as necessary 3 Is cooling fan operating correctly 3 Refer to Cooling System Fan in this group for diagnosis Repai...

Page 303: ...thermostat should be fully open valve will stop moving at approximately 89 C 192 F If the valve is still moving after the water temperature reaches this temperature it is opening too late Replace thermostat 8 If the valve refuses to move at any time replace thermostat VISCOUS FAN DRIVE TESTING If the fan assembly free wheels without drag the fan blades will revolve more than five turns when spun b...

Page 304: ...ESSURE TESTER METHOD WARNING HOT PRESSURIZED COOLANT CAN CAUSE SERIOUS INJURY BY SCALDING NEVER REMOVE THE PRESSURE VENT CAP OR PRES SURE TESTER WHEN THE COOLING SYSTEM IS HOT OR UNDER PRESSURE Allow the engine to cool sufficiently so that the system is not under pressure and carefully remove the pressure vent cap from the filler neck Warm the engine with the pressure vent cap off to normal oper a...

Page 305: ...ase pump the pressure tester until the indicated pressure is within the system range Vibration of the gauge pointer indicates compression or combustion leakage into the cooling system PRESSURE VENT CAP PRESSURE TESTING Remove the cap from the coolant tank Be sure that sealing surfaces are clean Moisten rubber gas ket with water A two piece threaded adapter set Fig 11 must be used to adapt a standa...

Page 306: ...IBS HAS SEPARATED FROM BELT BODY 1 Foreign objects imbedded in pulley grooves 1 Remove foreign objects from pulley grooves Replace belt 2 Installation damage 2 Replace belt RIB OR BELT WEAR 1 Pulley s misaligned 1 Align pulley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust from pulley s 4 Sharp or jagged pulley groove tips 4 Replace pulley 5 Rubb...

Page 307: ...Check and replace 5 Bracket pulley or bearing failure 5 Replace defective component and belt NOISE OBJECTIONAL SQUEAL SQUEAK OR RUMBLE IS HEARD OR FELT WHILE DRIVE BELT IS IN OPERATION 1 Belt slippage 1 Replace belt or automatic belt tensioner 2 Bearing noise 2 Locate and repair 3 Belt misalignment 3 Replace belt 4 Belt to pulley mismatch 4 Install correct belt SERPENTINE DRIVE BELT DIAGNOSIS SERV...

Page 308: ...lug This hex headed plug is located on the right rear side of the engine above the starter motor REFILLING COOLING SYSTEM The cooling system is equipped with a pressurized coolant tank using a pressure vent cap Refilling of the system is done through this tank NOTE The radiator draincock is equipped with a rubber o ring Do not over tighten draincock 1 Tighten the radiator draincock and if removed ...

Page 309: ...ry cable at battery 2 Observe the previous WARNINGS 3 Drain cooling system Refer to Draining Cool ing System in this group 4 Remove the upper fan shroud to upper cross member mounting bolts One of the bolts is mounted vertically at the bottom of the fan shroud 5 Lift the fan shroud up until alignment tabs at the bottom are clear of slots in bracket at bottom of radiator Slip the fan shroud rearwar...

Page 310: ...attached threaded to the fan pulley shaft Fig 18 Remove fan blade viscous fan drive assem bly from fan pulley by turning mounting nut counter clockwise as viewed from front Threads on viscous fan drive are RIGHT HAND Snap Ont 36 MM Fan Wrenches number SP346 can be used to turn the mounting nut and to hold the fan pulley from rotat ing 3 Do not attempt to remove fan viscous fan drive assembly from ...

Page 311: ... increases fan speed to provide the necessary additional engine cooling Once the engine has cooled the radiator discharge temperature will drop The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed NOISE NOTE It is normal for fan noise to be louder roar ing when The underhood temperature is above the engage ment point for the viscous drive coupling This may...

Page 312: ...to the correct level with the required coolant mixture Refer to Refilling Cooling System in this group for procedures 7 Start and warm the engine Check thermostat and hose for leaks DRIVE BELT CAUTION The drive belt on the 2 5L diesel engine is equipped with a spring loaded automatic belt ten sioner After belt installation do not attempt to check belt tension with a belt tension gauge AUTOMATIC BE...

Page 313: ...the 3 water pump pulley bolts Fig 22 8 Remove the drive belt by relieving the tension on the belt tensioner For procedures refer to Belt Removal Installation in the Engine Accessory Drive Belt section of this group WARNING CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES WHEN REMOVING OR INSTALLING USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP Fig 24 ALWAYS WEAR SAFETY...

Page 314: ... pulley bolts Fig 22 Fig 23 Thermal Viscous Fan Drive and Blade Assembly 1 FAN PULLEY 2 FAN DRIVE TO FAN BLADE BOLTS 4 3 MOUNTING NUT 4 THERMAL VISCOUS FAN DRIVE 5 FAN BLADES 6 FAN PULLEY SHAFT 7 WATER PUMP Fig 24 Hose Clamp Tool 1 HOSE CLAMP TOOL 6094 2 HOSE CLAMP Fig 25 Clamp Number Letter Location 1 TYPICAL CONSTANT TENSION HOSE CLAMP 2 CLAMP NUMBER LETTER LOCATION 3 TYPICAL HOSE Fig 26 Coolant...

Page 315: ... the water pump assembly if it has any of the following conditions The body is cracked or damaged Water leaks from the shaft seal This is evident by traces of coolant below the vent tube drain hose Loose or rough turning bearing Impeller rubs either the water pump body or water pump adapter RADIATOR CLEANING The radiator and air conditioning fins should be cleaned when an accumulation of bugs leav...

Page 316: ...o 117 kPa 13 to 17 psi pressure Exceeding this pressure may damage the radiator or hoses Allow the coolant tank and radiator to fill with water When radiator is filled apply air in short blasts allowing radiator to refill between blasts Con tinue this reverse flushing until clean water flows out through rear of radiator cooling tube passages For more information refer to operating instructions sup...

Page 317: ...CAUTION Be sure instructions on the container are followed SPECIFICATIONS COOLING SYSTEM CAPACITY 2 5L Diesel Engine 9 8 Liters 10 4 qts THERMOSTAT Starts to open at 80 C 176 F TORQUE SPECIFICATIONS DESCRIPTION TORQUE Automatic Belt Tensioner to Mounting Bracket Bolt 1 75 N m Automatic Belt Tensioner to Block Bolts 2 120 N m Coolant Tank Cap 5 N m Fan Shroud to Radiator Mounting Bolts 3 N m Fan Bl...

Page 318: ...manual for the location of more information on the battery cables that connect the battery to the vehicle electri cal system This battery is designed to provide a safe efficient and reliable means of storing electrical energy in a chemical form This means of energy storage allows the battery to produce the electrical energy required to operate the engine starting system as well as to operate many ...

Page 319: ...res outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required BATTERY SIZE AND RATINGS The battery Group Size number the Cold Cranking Amperage CCA rating and the Reserve Capacity RC rating or Ampere Hours AH rating can be found on the original equipment battery label Be certain that a r...

Page 320: ... ity and reliability with high electrical current carry ing capacity Refer to Wiring Diagrams in the index of this service manual for the location of the proper battery cable wire gauge information A clamping type female battery terminal made of soft lead is die cast onto one end of the battery cable wire A square headed pinch bolt and hex nut are installed at the open end of the female battery te...

Page 321: ...x of this service manual for the location of the proper battery hold down installation procedures including the proper hold down fastener tightness specifications OPERATION The battery hold down hardware secures the bat tery to the battery tray in the engine compartment The hold down support strap provides an additional anchor point for the upper end of the battery and hold down hardware at the up...

Page 322: ...coned washers to three weld studs located on the front extension of the right front wheelhouse inner panel forward of the right front wheel A hole in the bottom of the battery tray is fitted with a battery temperature sensor Refer to Battery Temperature Sensor in the index of this service manual for the location of more information on the battery temperature sensor Refer to Battery Hold Downs in t...

Page 323: ...LT THE BATTERY CONTAINS SULFURIC ACID WHICH IS POISONOUS AND CAUSTIC AVOID CON TACT WITH THE SKIN EYES OR CLOTHING IN THE EVENT OF CONTACT FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY KEEP OUT OF THE REACH OF CHILDREN IF THE BATTERY IS EQUIPPED WITH REMOV ABLE CELL CAPS BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE PER SONAL INJURY AND O...

Page 324: ...e battery terminal connections as required 4 Determine the battery state of charge Refer to Built In Test Indicator Hydrometer Test or Open Circuit Voltage Test in this section for the proper test procedures Charge the faulty battery as required 5 Refer to Ignition Off Draw Test in this section for the proper test procedures Repair the faulty electrical system as required 6 Determine the battery c...

Page 325: ...g system is performing to specifications Refer to Starting System in the index of this service manual for the location of the proper starting system diagnosis and testing procedures Repair the faulty starting system as required 7 Determine if the charging system is performing to specifications Refer to Charging System in the index of this service manual for the location of the proper charging syst...

Page 326: ...n test indi cator it is important that the battery be level and have a clean sight glass Additional light may be required to view the indicator Do not use open flame as a source of additional light To read the built in test indicator look into the sight glass and note the color of the indicator Fig 7 The battery condition that each color indicates is described in the following list Green Indicates...

Page 327: ...HING IN THE EVENT OF CONTACT FLUSH WITH WATER AND CALL A PHYSICIAN IMMEDIATELY KEEP OUT OF THE REACH OF CHILDREN IF THE BATTERY IS EQUIPPED WITH REMOV ABLE CELL CAPS BE CERTAIN THAT EACH OF THE CELL CAPS IS IN PLACE AND TIGHT BEFORE THE BATTERY IS RETURNED TO SERVICE PER SONAL INJURY AND OR VEHICLE DAMAGE MAY RESULT FROM LOOSE OR MISSING CELL CAPS Before testing visually inspect the battery for an...

Page 328: ... battery This test can be used in place of the hydrometer test when a hydrom eter is not available or for maintenance free batter ies with non removable cell caps WARNING IF THE BATTERY SHOWS SIGNS OF FREEZ ING LEAKING LOOSE POSTS OR LOW ELECTRO LYTE LEVEL DO NOT TEST ASSIST BOOST OR CHARGE THE BATTERY MAY ARC INTERNALLY AND EXPLODE PERSONAL INJURY AND OR VEHI CLE DAMAGE MAY RESULT EXPLOSIVE HYDRO...

Page 329: ... and isolate both battery cables neg ative cable first The battery top and posts should be clean 2 Connect a suitable volt ammeter load tester Fig 10 to the battery posts Fig 11 See the instructions provided by the manufacturer of the tester you are using Check the open circuit voltage no load of the battery Refer to Open Circuit Volt age Test in this section for the proper battery open circuit vo...

Page 330: ...more stored remove the IOD fuse from the Power Distribution Center PDC This will reduce battery discharging Excessive IOD can be caused by Electrical items left on Faulty or improperly adjusted switches Faulty or shorted electronic modules and compo nents An internally shorted generator Intermittent shorts in the wiring If the IOD is over twenty five milliamperes the problem must be found and corr...

Page 331: ...e manual for the location of complete PDC and JB fuse and circuit breaker identification contained in the wiring dia grams until the amperage reading becomes very low or nonexistent This will isolate each circuit and identify the circuit that is the source of the high am perage IOD If the amperage reading remains high after removing and replacing each fuse and circuit breaker disconnect the wire h...

Page 332: ...tery Charging in the index of this ser vice manual for the location of the proper battery charging procedures Refer to Battery in the index of this service manual for the location of the battery diagnosis and testing procedures including the proper battery load test procedures Fully engage the parking brake If the vehicle is equipped with an automatic transmission place the gearshift selector leve...

Page 333: ...e faulty battery negative cable SERVICE PROCEDURES BATTERY CHARGING Battery charging is the means by which the bat tery can be restored to its full voltage potential A battery is fully charged when All of the battery cells are gassing freely during battery charging A green color is visible in the sight glass of the battery built in test indicator Three hydrometer tests taken at one hour inter vals...

Page 334: ...battery will not accept charging current See the instructions provided by the manufacturer of the battery charger for details on how to bypass the polarity sensing circuitry After the battery has been charged to 12 4 volts or greater perform a load test to determine the battery cranking capacity Refer to Battery in the index of this service manual for the location of the battery diagnosis and test...

Page 335: ...D INSTALLATION BATTERY CABLES Both the battery negative cable and the battery positive cable are serviced in the battery wire har ness If either battery cable is damaged or faulty the battery wire harness unit must be replaced REMOVAL 1 Turn the ignition switch to the Off position Be certain that all electrical accessories are turned off 2 Loosen the battery negative cable terminal clamp pinch bol...

Page 336: ...ghten the nut that secures the battery positive cable eyelet terminal to the B ter minal stud on the starter solenoid Tighten the nut to 10 N m 90 in lbs 6 On models with a 2 5L engine install and tighten the nut that secures the battery wire harness locator clip to the stud on the right side engine block oil pan rail below and forward of the engine oil filter adapter Tighten the nut to 8 4 N m 75...

Page 337: ...he end of the battery support strap with a slotted hole to the top of the upper radiator crossmember 6 Remove the battery support strap from the threaded end of the T bolt nearest to the front of the vehicle 7 Remove the battery hold down bracket from the threaded ends of the two T bolts and the top of the battery case INSTALLATION 1 Clean and inspect the battery hold down hard ware Refer to Batte...

Page 338: ...eaning and inspection procedures 2 Reinstall the battery thermoguard onto the battery case Refer to Battery Thermoguard in the index of this service manual for the location of the proper battery thermoguard installation procedures 3 Position the battery and the battery thermo guard onto the battery tray as a unit Ensure that the battery positive and negative terminal posts are correctly positioned...

Page 339: ... dures 2 Remove the battery temperature sensor from the battery tray Refer to Battery Temperature Sensor in the index of this service manual for the location of the proper battery temperature sensor removal procedures 3 Remove the three nuts with washers that secure the battery tray to the weld studs on the front extension of the right front wheelhouse inner panel Fig 23 4 Remove the battery tray ...

Page 340: ...ng a wire brush or a post and terminal cleaning tool and a sodium bicarbonate baking soda and warm water cleaning solution Fig 24 2 Clean the battery tray and battery hold down hardware of all corrosion Remove any corrosion using a wire brush and a sodium bicarbonate baking soda and warm water cleaning solution Paint any exposed bare metal 3 If the removed battery is to be reinstalled clean the ou...

Page 341: ...or another suitable wide flat bladed tool to pry the cell caps off Fig 27 Do not use a screw driver Add distilled water to each cell until the liq uid reaches the bottom of the vent well DO NOT OVERFILL 6 Inspect the battery built in test indicator sight glass for an indication of the battery condition If the battery is discharged charge as required Refer to Battery in the index of this service ma...

Page 342: ...rrent needed to operate the starting system Refer to Battery in the index of this service manual for the location of more information on the battery The battery cables connect the battery to the electrical system of the vehicle and to the starting system Refer to Battery Cables in the index of this service manual for the location of more information on the battery cables The starting system low am...

Page 343: ...etween the starter relay coil ground terminal and ground This normally open switch prevents the starter relay from being energized and the starter motor from operating unless the automatic transmission gear selector is in the Neutral or Park positions When the starter relay coil windings are energized the relay directs battery current to the starter sole noid coil windings When the starter solenoi...

Page 344: ...rgizing the starter and cranking the engine Once the engine starts the overrunning clutch pro tects the starter motor from damage by allowing the starter pinion gear to spin faster than the pinion shaft When the solenoid plunger hold in coil is de energized the solenoid plunger return spring returns the plunger to its relaxed position This causes the solenoid contact disc to open the starter feed ...

Page 345: ...pedal position switch faulty 6 Park Neutral position switch faulty or misadjusted 7 Starter solenoid faulty 8 Starter motor faulty 1 Refer to Battery in the index of this service manual for the location of the proper battery diagnosis and testing procedures Replace the faulty battery as required 2 Refer to Starting System in the index of this service manual for the location of complete starting sy...

Page 346: ...faulty 3 Ignition switch faulty 4 Starter motor faulty 1 Refer to Starter Motor in the index of this service manual for the location of the proper starter motor installation procedures Tighten the starter motor mounting hardware to the correct tightness specifications as required 2 Refer to Starter Relay in the index of this service manual for the location of the proper starter relay diagnosis and...

Page 347: ...g and reduce the bat tery voltage reading FEED CIRCUIT TEST The starter feed circuit test voltage drop method will determine if there is excessive resistance in the high amperage starter feed circuit Refer to Starting System in the index of this service manual for the location of complete starting system wiring diagrams When performing the voltage drop test it is impor tant to remember that the vo...

Page 348: ...p and the battery positive terminal post 3 Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B terminal stud Fig 6 Rotate and hold the ignition switch in the Start position Observe the voltmeter If the reading is above 0 2 volt clean and tighten the battery positive cable eyelet terminal con nection at the starter solenoid B terminal stud R...

Page 349: ...gnition Switch Refer to Ignition Switch and Key Lock Cylinder in the index of this service manual for the location of the proper ignition switch diagnosis and testing procedures Clutch Pedal Position Switch If the vehicle is equipped with a manual transmission refer to Clutch Pedal Position Switch in the index of this service manual for the location of the proper clutch pedal position switch diagn...

Page 350: ... installation procedures NOTE The shim thickness is 0 381 mm 0 015 in These shims may be stacked if additional thickness is required 2 If the complaint is similar to Condition 2 the starter motor must be moved away from the starter ring gear This is done by installing shim s across both starter mounting pads on the engine block More than one shim may be required Refer to Starter Motor in the index...

Page 351: ...on procedures 2 Disconnect the wire from the solenoid field coil terminal 3 Check for continuity between the solenoid ter minal and the solenoid field coil terminal with a con tinuity tester Fig 11 There should be continuity If OK go to Step 4 If not OK replace the faulty starter motor 4 Check for continuity between the solenoid ter minal and the solenoid case Fig 12 There should be continuity If ...

Page 352: ...gnition Switch and Key Lock Cylinder in the index of this service manual for the location of the proper ignition switch diagnosis and testing procedures 5 The coil ground terminal 85 is connected to the electromagnet in the relay On vehicles with a manual transmission it is grounded at all times On vehicles with an automatic transmission it is grounded through the park neutral position switch only...

Page 353: ...ual transmission clutch housing or automatic transmission torque converter housing far enough to access and remove the nut that secures the battery positive cable eyelet terminal to the starter solenoid B terminal stud Fig 15 Always support the starter motor during this process Do not let the starter motor hang from the wire harness 6 Remove the battery positive cable eyelet termi nal from the sol...

Page 354: ...process Do not let the starter motor hang from the wire harness 3 Install the battery positive cable eyelet termi nal onto the starter solenoid B terminal stud Always support the starter motor during this process Do not let the starter motor hang from the wire har ness 4 Install and tighten the nut that secures the battery positive cable eyelet terminal to the starter solenoid B terminal stud Tigh...

Page 355: ...ocation of the proper wir ing repair or connector and terminal service proce dures Refer to Clutch Hydraulic Linkage in the index of this service manual for the location of the proper clutch pedal position switch service proce dures Park Neutral Position Switch If the vehicle is equipped with an automatic transmission visually inspect the park neutral position switch for indica tions of physical d...

Page 356: ...nual for the location of complete starting system wiring diagrams Refer to Wiring Diagrams in the index of this service manual for the location of the proper wir ing repair or connector and terminal service proce dures SPECIFICATIONS STARTING SYSTEM Starter Motor and Solenoid Manufacturer Mitsubishi Engine Application 2 5L 4 0L Power Rating 2 5L 1 2 Kilowatt 1 6 Horsepower 4 0L 1 4 Kilowatt 1 9 Ho...

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Page 358: ... Fig 2 Do not remove the bolt at this time 7 Position a jack stand and raise the weight off the right engine mount 8 Remove the 2 right engine mount lower sill plate bolts 9 Remove the 4 right engine mount bracket to engine block retaining bolts 10 Remove the engine mount throughbolt 11 Remove the engine mount and the engine mount bracket from the vehicle Fig 1 LHD Engine Compartment Diesel 1 INTA...

Page 359: ... on turbo charger 16 Connect the negative battery cable STARTER RHD DIESEL REMOVAL 1 Disconnect the negative battery cable 2 Make sure steering wheel is in the unlocked position 3 Raise the vehicle on a hoist 4 Rotate the front wheels to access and remove the steering shaft pinch bolt slide shaft straight off gearbox input shaft and position steering shaft aside 5 Remove the turbocharger oil retur...

Page 360: ...ue the lower engine mount retaining bolts to 54 N m 40 ft lbs 12 Torque the larger track bar support bracket bolts to 125 N m 92 ft lbs 13 Torque the engine mount throughbolt nut to 65 N m 48 ft lbs 14 Install the oil return line on the engine block nipple 15 Install steering shaft pinch bolt Torque to 49 N m 36 ft lbs 16 Lower the vehicle from the hoist 17 Connect the negative battery cable START...

Page 361: ... test 350 Amperes Test at operating temperature Cold engine tight new engine or heavy oil will increase starter amperage draw TORQUE SPECIFICATIONS DESCRIPTION TORQUE Engine Mount Throughbolt 65 N m 48 ft lbs Engine Mount Upper Sill Plate Nuts 41 N m 30 ft lbs Engine Mount to Engine Mounting Bolts 61 N m 45 ft lbs Lower Engine Mount Bolts 54 N m 40 ft lbs Stater Motor B Terminal 27 N m 20 ft lbs S...

Page 362: ... second rotor field terminal and ground A battery temperature sensor located in the bat tery tray housing is used to sense battery tempera ture This temperature data along with data from monitored line voltage is used by the PCM to vary the battery charging rate This is done by cycling the ground path to control the strength of the rotor mag netic field The PCM then compensates and regulates gener...

Page 363: ...train Control Module PCM The EVR is not serviced separately If replacement is necessary the PCM must be replaced OPERATION The amount of DC current produced by the gener ator is controlled by EVR circuitry contained within the PCM This circuitry is connected in series with the generators second rotor field terminal and its ground Voltage is regulated by cycling the ground path to control the stren...

Page 364: ...e checked continu ously and some are checked only under certain con ditions For DTC information refer to Diagnostic Trouble Codes in Group 25 Emission Control System This will include a complete list of DTC s including DTC s for the charging system REMOVAL AND INSTALLATION GENERATOR REMOVAL WARNING DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE B WIRE FROM GENERATOR FAI...

Page 365: ...verheat Refer to belt routing label in engine compartment or refer to Belt Schematics in Group 7 Cooling System 5 LHD Vehicles Install generator drive belt Refer to Group 7 Cooling System for procedures 6 RHD Vehicles Install upper nut generator adjustment nut and both belt adjustment bolts Install generator lower nut bolt 7 RHD Vehicles On vehicles equipped with RHD the generator is used to adjus...

Page 366: ...INGS TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS DENSO 56041685AA 117 4 0L 88 DENSO 56041565AA 81 4 0L 57 DENSO 56005684AB 81 2 5L 57 DENSO 56005685AC 117 2 5L 88 DENSO 56041822AA 124 2 5L 4 0L 90 TORQUE CHART Right Hand Drive RHD Left Hand Drive LHD Description Torque Generator Mounting Bolt LHD 2 5L 4 0L Engine 55 N m 41 ft lbs Generator Pivot Bolt Nut LHD 2 5L 4 0L Engine 55 N m 4...

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Page 368: ...outing label in engine compartment or refer to Belt Schematics in Group 7 Cooling System 1 Disconnect negative battery cable 2 Remove generator drive belt Refer to Group 7 Cooling System for procedure 3 Remove the nut securing battery output cable to B terminal at rear of generator Fig 1 4 Unplug field terminal connector at rear of gen erator Fig 1 5 Remove upper generator mounting bolt Fig 2 6 Re...

Page 369: ...Nut 8 5 N m Lower Generator Mounting Bolt 47 N m Upper Generator Mounting Bolt 27 5 N m Vacuum Pump Oil Feed Hose Banjo Bolt 15 N m Fig 2 Generator Mounting Bolts 1 GENERATOR MOUNTING BOLTS 8C 2 CHARGING SYSTEM XJ REMOVAL AND INSTALLATION Continued ...

Page 370: ...ed One type is used for the 2 5L 4 cylinder engine The other is used for the 4 0L 6 cylinder engine OPERATION 2 5L 4 Cylinder Engine The ignition system is controlled by the Powertrain Control Module PCM The ignition system consists of Spark Plugs Ignition Coil Secondary Ignition Cables Distributor contains rotor and camshaft position sensor Powertrain Control Module PCM Crankshaft Position Camsha...

Page 371: ...rate readings will result OPERATION To prevent possible pre ignition and or mechanical engine damage the correct type heat range number spark plug must be used Always use the recommended torque when tighten ing spark plugs Incorrect torque can distort the spark plug and change plug gap It can also pull the plug threads and do possible damage to both the spark plug and the cylinder head Remove the ...

Page 372: ... spark plugs to the coil Inside each rubber boot is a spring The spring is used for a mechanical contact between the coil and the top of the spark plug These rubber boots and springs are a permanent part of the coil and are not serviced separately 1 The coil is bolted directly to the cylinder head Fig 3 One electrical connector located at rear of coil is used for all three coils OPERATION Although...

Page 373: ...hes Fig 5 The notches cause a pulse to be generated when they pass under the sensor The pulses are the input to the PCM For each engine revolution there are two groups of four pulses generated on 2 5L 4 cylinder engines There are 3 groups of four pulses generated on 4 0L 6 cylinder engines The trailing edge of the fourth notch which causes the pulse is four degrees before top dead center TDC of th...

Page 374: ...on sensor to differenti ate between fuel injection and spark events It is also used to synchronize the fuel injectors with their respective cylinders When the leading edge of the pulse ring shutter enters the sync signal generator the following occurs The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approxi mately 5 volts When the trailing edge of ...

Page 375: ... ACCESSORY posi tion If it is difficult to rotate the key to the LOCK or ACCESSORY position the lever mechanism may be defective This mechanism is not serviceable If repair is necessary the steering column assembly must be replaced Refer to Group 19 Steering for procedures On other models the ignition key cylinder must be depressed to allow it to be rotated into the LOCK or ACCESSORY position If i...

Page 376: ...e along the entire length of all spark plug cables If cables are cracked or punctured there will be a noticeable spark jump from the damaged area to the test probe The cable running from the ignition coil to the distributor cap can be checked in the same manner Cracked dam aged or faulty cables should be replaced with resis tance type cable This can be identified by the words ELECTRONIC SUPPRESSIO...

Page 377: ... fouling The deposits that cause cold fouling are basi cally carbon Fig 11 A dry black deposit on one or two plugs in a set may be caused by sticking valves or defective spark plug cables Cold carbon fouling of the entire set of spark plugs may be caused by a clogged air cleaner element or repeated short operat ing times short trips WET FOULING OR GAS FOULING A spark plug coated with excessive wet...

Page 378: ... has the correct heat range rating for the engine Determine if ignition timing is over advanced or if other operating conditions are causing engine over heating The heat range rating refers to the operat ing temperature of a particular type spark plug Spark plugs are designed to operate within specific temperature ranges This depends upon the thick ness and length of the center electrodes porcelai...

Page 379: ...to Group 19 Steering for procedures Vehicles equipped with a manual transmis sion and a floor mounted shifter on certain mod els a lever is located on the steering column behind the ignition key lock cylinder The lever must be manually operated to allow rotation of the ignition key lock cylinder to the LOCK or ACCESSORY posi tion If it is difficult to rotate the key to the LOCK or ACCESSORY positi...

Page 380: ...gap gauge tool If the gap is not correct adjust it by bending the ground electrode Fig 19 Never attempt to adjust the gap by bending the center electrode SPARK PLUG GAP 2 5L 4 Cylinder Engine Spark Plug Gap 89 mm 035 in 4 0L 6 Cylinder Engine Spark Plug Gap 89 mm 035 in PLUG INSTALLATION Always tighten spark plugs to the specified torque Over tightening can cause distortion This may result in a ch...

Page 381: ... a spring The spring is used for an electrical contact between the coil and the top of the spark plug These rubber boots and springs are a permanent part of the coil and are not serviced separately 1 Disconnect negative battery cable at battery 2 The coil is bolted directly to the cylinder head Remove 4 coil mounting bolts Fig 22 3 Carefully pry up coil assembly from spark plugs Do this by prying ...

Page 382: ...sor is mounted to the transmission bellhousing at the left rear side of the engine block The sensor may be mounted to the transmission with one of the following three different configura tions with one bolt Fig 24 If sensor is equipped with one mounting bolt it is adjustable with two nuts Fig 25 with two bolts Fig 26 Fig 22 Ignition Coil Rail Location 4 0L 6 Cylinder Engine 1 COIL RAIL 2 COIL MOUN...

Page 383: ...e broken the first time engine is started 4 New Sensors Be sure paper spacer is installed to bottom of sensor If not obtain spacer PN05252229 5 Used Sensors Clean bottom of sensor and install spacer PN05252229 6 Install sensor into transmission bellhousing hole 7 Push sensor against flywheel drive plate With sensor pushed against flywheel drive plate tighten mounting bolt to 7 N m 60 in lbs torque...

Page 384: ...procedure is to be used if the engine has been disassembled An internal oil seal is used in the drive shaft hous ing that prevents engine oil at the bottom of the sen sor The seal is not serviceable REMOVAL SENSOR ONLY 1 Disconnect electrical connector at CMP sensor Fig 29 2 Remove 2 sensor mounting bolts Fig 28 or Fig 29 3 Remove sensor from oil pump drive INSTALLATION SENSOR ONLY 1 Install senso...

Page 385: ...pump drive housing Align toothpick into mating hole on pulse ring Fig 30 4 Install oil pump drive into engine while align ing into slot on oil pump Rotate oil pump drive back to its original position and install hold down clamp and bolt Finger tighten bolt Do not do a final tight ening of bolt at this time 5 If engine crankshaft or camshaft has been rotated such as during engine tear down CMP sen ...

Page 386: ...ive 14 If a plus or a minus is displayed next to degree number and or the degree displayed is not zero loosen but do not remove hold down clamp bolt Rotate oil pump drive until IN RANGE appears on screen Continue to rotate oil pump drive until achieving as close to 0 as possible The degree scale on SET SYNC screen of DRB is referring to fuel synchronization only It is not referring to ignition tim...

Page 387: ...engine crank shaft with a socket and ratchet using vibration damper bolt 10 Remove distributor holddown bolt and clamp 11 Remove distributor from engine by slowly lift ing straight up 12 Note that rotor will rotate slightly in a coun terclockwise direction while lifting up distributor The oil pump gear will also rotate slightly in a coun terclockwise direction while lifting up distributor This is ...

Page 388: ...all pin punch tool through proper alignment hole in plastic ring Fig 36 and into mating access hole in distributor housing This will prevent distributor shaft and rotor from rotating 8 Clean distributor mounting hole area of engine block 9 Install new distributor to engine block gasket Fig 33 10 Install rotor to distributor shaft 11 Pre position distributor into engine while holding centerline of ...

Page 389: ...rted 16 Install distributor cap Tighten distributor cap holddown screws to 3 N m 26 in lbs torque 17 If removed install spark plug cables to dis tributor cap For proper firing order refer to Engine Firing Order 18 Connect distributor wiring harness to main engine harness 19 Connect battery cable to battery IGNITION SWITCH AND KEY CYLINDER The ignition key must be in the key cylinder for cylinder r...

Page 390: ...on locking tab Fig 41 and remove switch from steering column 5 Disconnect two electrical connectors at rear of ignition switch Fig 43 Fig 39 Key Cylinder Release Tang 1 KEY CYLINDER 2 RELEASE TANG Fig 40 Key Cylinder and Cover Removal 1 LOWER COVER 2 ACCESS HOLE 3 PIN PUNCH 4 COVER SCREWS 3 Fig 41 Ignition Switch Lock Tab 1 LOCK TAB 2 IGNITION SWITCH 3 SCREWDRIVER Fig 42 Switch In ON Position 1 IG...

Page 391: ...o Group 21 Transmission for procedures Manual Transmission Be sure key cannot be removed until release lever is operated If key can be removed release lever mechanism may be defective Release lever mechanism is not serviced separately If repair is necessary the steering column must be replaced Refer to Group 19 Steering for procedures 5 Connect negative cable to battery 6 Check electrical operatio...

Page 392: ...mm 0 035 in SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12 000 Ohms Per Foot IGNITION COIL RESISTANCE 2 5L ENGINE COIL MANUFACTURER PRIMARY RESISTANCE 21 27 C 70 80 F SECONDARY RESISTANCE 21 27 C 70 80 F Diamond 0 97 1 18 Ohms 11 300 15 300 Ohms Toyodenso 0 95 1 20 Ohms 11 300 13 300 Ohms IGNITION COIL RESISTANCE 4 0L ENGINE PRIMARY RESISTANC...

Page 393: ...olt sensor mounted with 1 bolt 7 N m 60 in lbs Distributor Hold Down Bolt 2 5L 23 N m 17 ft lbs Distributor Cap Screws 2 5L 3 N m 26 in lbs Ignition Coil Mounting if tapped bolts are used 2 5L 5 N m 50 in lbs Ignition Coil Mounting if nuts bolts are used 2 5L 11 N m 100 in lbs Ignition Coil Rail Mounting Bolts 4 0L 29 N m 250 in lbs Oil Pump Drive Hold down Bolt 4 0L 23 N m 17 ft lbs Spark Plugs a...

Page 394: ...on the fea tures use and operation of all of the instrument panel components and systems This group is responsible for covering service infor mation for the vehicle instrument panel systems However complete service information coverage for all of the systems and components housed in the instrument panel in a single section of the service manual would not be practical Therefore the service informat...

Page 395: ...CD data bus network for control of all gauges and many of the indicator lamps These clus ters also incorporate a digital Vacuum Fluorescent Display VFD for the odometer trip odometer display functions Some variations of each cluster exist due to optional equipment and regulatory requirements The low line cluster includes the following analog gauges Fuel gauge Speedometer This cluster also includes...

Page 396: ...er fluid warning lamp and turn signal indicator lamps are hard wired The seat belt reminder lamp is controlled by the instrument cluster programming The Malfunction Indicator Lamp MIL is normally controlled by CCD data bus messages from the Powertrain Control Mod ule PCM however if the instrument cluster detects a loss of CCD data bus communication the cluster will automatically turn the MIL on an...

Page 397: ...battery current to the cigar lighter when the ignition switch is turned to the Accessory or On positions The cigar lighter relay is located in the junction block on the right cowl side panel below the instrument panel in the passenger compartment The cigar lighter relay is a International Standards Organization ISO relay Relays conforming to the ISO specifications have common physical dimensions c...

Page 398: ...gnition switch output run start fuse in the junction block If OK go to Step 7 If not OK repair the open fused ignition switch output run start circuit to the ignition switch as required 7 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable Install the instrument cluster Connect the battery negative cable Turn the ignition switch to the On position Set the...

Page 399: ...EEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY ANTI LOCK BRAKE SYSTEM LAMP The diagnosis found here addresses an inoperative Anti lock Brake System ABS lamp condition If the ABS lamp stays on with the ignition switch in the On position or comes on and stays on ...

Page 400: ...Fig 1 Low Line Instrument Cluster Actuator Test XJ INSTRUMENT PANEL SYSTEMS 8E 7 DIAGNOSIS AND TESTING Continued ...

Page 401: ...Fig 2 High Line Instrument Cluster Actuator Test 8E 8 INSTRUMENT PANEL SYSTEMS XJ DIAGNOSIS AND TESTING Continued ...

Page 402: ...ake switch wire harness connector and a good ground There should be continuity If OK go to Step 8 If not OK repair the open red brake warning indi cator driver circuit to the ignition switch as required 8 Turn the ignition switch to the Off position Remove the instrument cluster Check for continuity between the red brake warning indicator driver cir cuit cavity of the instrument cluster wire harne...

Page 403: ...cable Turn the ignition switch to the On position Install a jumper wire between the part time four wheel drive indicator lamp driver circuit cavity of the transfer case switch wire harness connector and a good ground The part time four wheel drive indicator lamp should light If OK replace the faulty transfer case switch If not OK go to Step 5 5 Turn the ignition switch to the Off position Disconne...

Page 404: ...urn signal problem refer to Turn Signal and Haz ard Warning Systems in the Diagnosis and Testing section of Group 8J Turn Signal and Hazard Warn ing Systems for further diagnosis If no turn signal or hazard warning system problem is found the follow ing procedure will help locate a short or open in the indicator lamp circuit For complete circuit diagrams refer to Instrument Cluster in the Contents...

Page 405: ...at the fused B circuit cavity of the accessory relay wire harness connector If OK go to Step 2 If not OK repair the fused B circuit to the fuse in the junction block as required 2 The relay normally closed terminal 87A is connected to terminal 30 in the de energized position but is not used for this application Go to Step 3 3 The relay normally open terminal 87 is con nected to the common feed ter...

Page 406: ...unction block fuse as required REMOVAL AND INSTALLATION STEERING COLUMN OPENING COVER WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY REMOVAL ...

Page 407: ...that is closest to the driver side front door of the vehicle Fig 6 3 Install the steering column opening cover onto the instrument panel Refer to Steering Column Opening Cover in the Removal and Installation sec tion of this group for the procedures 4 Reconnect the battery negative cable INSTRUMENT PANEL CENTER BEZEL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SY...

Page 408: ...rs 5 Disconnect the instrument panel wire harness connectors from the connector receptacles the acces sory switches the cigar lighter and the accessory power outlet on the back of the accessory switch bezel 6 Remove the accessory switch bezel from the instrument panel INSTALLATION 1 Position the accessory switch bezel to the instrument panel 2 Reconnect the instrument panel wire harness connectors...

Page 409: ...ign the terminals of the cigar lighter relay with the cavities in the junction block receptacle 4 Push on the cigar lighter relay case firmly and evenly until all of the relay terminals are fully seated within the cavities of the junction block receptacle 5 Position the right cowl side trim to the right door sill trim 6 Install and tighten the screw that secures the right cowl side trim to the rig...

Page 410: ...p switch Refer to Headlamp Switch in the Removal and Installation section of this group for the procedures 6 Install and tighten the four screws that secure the cluster bezel to the instrument panel beneath the instrument panel center bezel Tighten the screws to 2 2 N m 20 in lbs 7 Install the center bezel onto the instrument panel Refer to Instrument Panel Center Bezel in the Removal and Installa...

Page 411: ...in the span ner nut and into the headlamp switch 6 Push the headlamp switch control knob and shaft unit all the way into the headlamp switch body 7 Install the knee blocker onto the instrument panel Refer to Knee Blocker in the Removal and Installation section of this group for the procedures 8 Reconnect the battery negative cable INSTRUMENT CLUSTER WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER...

Page 412: ...to each of the incandescent cluster illumination lamp or indicator lamp bulb and bulb holder units However the illumination lamps and the indicator lamps use different bulb and bulb holder unit sizes They must never be interchanged Be certain that any bulb and bulb holder unit removed from the cluster electronic circuit board is reinstalled in the correct position Always use the correct bulb size ...

Page 413: ...nd Installation section of this group for the procedures 3 Work around the perimeter of the cluster hous ing to disengage each of the latches that secure the rear cover to the cluster housing Fig 14 4 Gently pull the rear cover away from the back of the cluster housing INSTALLATION CLUSTER BULB This procedure applies to each of the incandescent cluster illumination lamp or indicator lamp bulb and ...

Page 414: ...er hous ing Refer to Instrument Cluster Components Cluster Lens in the Removal and Installation sec tion of this group for the procedures 5 Install the instrument cluster onto the instru ment panel Refer to Instrument Cluster in the Removal and Installation section of this group for the procedures 6 Reconnect the battery negative cable CLUSTER HOUSING REAR COVER 1 Position the rear cover to the ba...

Page 415: ...the instrument panel upper glove box opening reinforce ment 5 Roll the glove box downward so that the stops molded into the glove box bin pass through the stop bumper slots in the instrument panel upper glove box opening reinforcement 6 Reverse the roll down procedure to roll the glove box back up into the instrument panel REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the th...

Page 416: ...m the instrument panel Refer to Glove Box Removal in the Removal and Installation section of this group for the procedures 3 Remove the seven screws that secure the inner glove box door to the outer glove box door Fig 18 4 Remove the outer glove box door from the inner glove box door unit GLOVE BOX LOCK CYLINDER 1 Insert the key into the glove box lock cylinder and turn the lock cylinder to the un...

Page 417: ...TEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY REMOVAL 1 Disconnect and isolate the battery negative cable 2 Open the glove box 3 Remove the passenger side airbag module from the instrument panel Refer to Passenger Side Air bag Module in...

Page 418: ...Systems for the pro cedures 5 Remove the six screws that secure the end cap to the instrument panel Fig 21 6 Remove the end cap from the instrument panel INSTALLATION DRIVER SIDE 1 Position the end cap to the instrument panel 2 Install and tighten the five screws that secure the end cap to the instrument panel Tighten the screws to 2 2 N m 20 in lbs 3 Install the top cover onto the instrument pane...

Page 419: ...Install and tighten the two nuts that secure the center support bracket to the studs on the instru ment panel Tighten the nuts to 28 N m 250 in lbs 4 Position the floor carpet back onto the front of the floor panel transmission tunnel 5 Install the floor console onto the floor panel transmission tunnel Refer to Floor Console in the Removal and Installation section of Group 23 Body for the procedur...

Page 420: ...ss connector at the floor panel transmission tunnel under the instrument panel 10 Roll down the glove box from the instrument panel Refer to Glove Box Roll Down in the Removal and Installation section of this group for the procedures 11 Reach through the inboard side of the instru ment panel glove box opening to disconnect the two halves of the heater A C system vacuum harness con nector 12 Reach ...

Page 421: ...trument panel to floor wire har ness connector at the floor panel transmission tunnel under the instrument panel 8 Reconnect the instrument panel to floor wire harness connector near the floor panel transmission tunnel under the instrument panel and tighten the connector screw Tighten the screw to 4 N m 35 in lbs 9 Reconnect the instrument panel to body and the instrument panel to headlamp and das...

Page 422: ...REAR FOG LAMP SWITCH WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Using a trim stick ...

Page 423: ...ap retainers in the receptacle on the back of the accessory switch bezel are fully engaged Tighten the mounting screws to 2 2 N m 20 in lbs Fig 2 Accessory Switch Bezel Remove Install 1 ACCESSORY SWITCH BEZEL 2 SCREW 8E 2 INSTRUMENT PANEL SYSTEMS XJ REMOVAL AND INSTALLATION Continued ...

Page 424: ...re general descriptions of the major components in the standard and optional factory in stalled audio systems Refer to the owner s manual in the vehicle glove box for more information on the fea tures use and operation of each of the available audio systems DESCRIPTION AND OPERATION RADIO Available factory installed radio receivers for this model include an AM FM RAL sales code an AM FM cassette R...

Page 425: ...To eliminate static the antenna base must have a good ground The coaxial antenna cable shield the outer wire mesh of the cable is grounded to the antenna base and the radio chassis The antenna coaxial cable has an additional dis connect located near the right cowl side inner panel behind the instrument panel This additional discon nect allows the instrument panel assembly to be removed and install...

Page 426: ...IME 1 Fuse faulty 2 Radio connector faulty 3 Wiring faulty 4 Ground faulty 5 Radio faulty 1 Check ignition off draw fuse Replace fuse if required 2 Check for loose or corroded radio connector Repair if required 3 Check for battery voltage at radio connector Repair wiring if required 4 Check for continuity between radio chassis and a known good ground There should be continuity Repair ground if req...

Page 427: ...RE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY CAUTION The speaker output of the radio is a floating ground system Do not allow any speaker lead to short to ground as damage to the radio may result 1 Turn the ignition switch to the ...

Page 428: ...vities of the amplifier wire harness connectors for continuity to ground In each case there should be no continuity If OK go to Step 13 If not OK repair the short circuit as required 13 For each inoperative speaker location check the resistance between the amplified feed circuit and the amplified return circuit cavities of the amplifier wire harness connectors The meter should read between 2 and 1...

Page 429: ...n the antenna base to fender mounting hardware RADIO FREQUENCY INTERFERENCE WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY For complete circu...

Page 430: ...l from the instrument panel 4 Remove the two screws that secure the radio to the instrument panel Fig 3 5 Pull the radio out from the instrument panel far enough to access the wire harness connectors and the antenna coaxial cable connector Fig 4 6 Unplug the wire harness connectors and the antenna coaxial cable connector from the rear of the radio 7 Remove the radio from the instrument panel 8 Rev...

Page 431: ...etainers NOTE To aid in the removal of the trim panel start at the bottom of the panel 5 Lift the front door trim panel upwards and away from the inner door panel far enough to disen Fig 4 Radio Connections Typical 1 ANTENNA CABLE 2 RADIO 3 INSTRUMENT PANEL WIRING 4 GROUND WIRE Fig 5 Amplifier Remove Install 1 AMPLIFIER 2 WIRE HARNESS CONNECTORS 3 REAR FLOOR PAN 4 SCREW Fig 6 Window Regulator Cran...

Page 432: ...install Tighten the speaker mounting screws to 1 1 N m 10 in lbs Tighten the trim panel mounting screws to 2 2 N m 20 in lbs UPPER 1 Remove the front door trim panel from the front door See Speaker Front Door Lower in this group for the procedures 2 Remove the one screw that secures the front door flag trim to the inner door panel Fig 10 3 Using a trim stick or another suitable wide flat bladed to...

Page 433: ...from the headliner 7 Reverse the removal procedures to install Tighten the mounting screws to 2 2 N m 20 in lbs ANTENNA WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND...

Page 434: ...ghten the antenna mast to 3 3 N m 30 in lbs RADIO NOISE SUPPRESSION COMPONENTS WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY REMOVAL ENGINE ...

Page 435: ... to body ground strap eyelet over the stud on the left upper rear corner of the engine cylinder head 3 Install and tighten the nut that secures the engine to body ground strap eyelet to the stud on the left upper rear corner of the engine cylinder head Tighten the nut to 27 N m 20 ft lbs 4 Install and tighten the screw that secures the engine to body ground strap eyelet to the dash panel Tighten t...

Page 436: ...odule trim cover closes the horn switch Closing the horn switch acti vates the horn relay The activated horn relay then switches the battery current needed to energize the horns Refer to the owner s manual in the vehicle glove box for more information on the features use and operation of the horn system REMOTE KEYLESS ENTRY RECEIVER The Remote Keyless Entry RKE receiver can also operate the horn s...

Page 437: ...elay cannot be repaired or adjusted and if faulty or damaged it must be replaced OPERATION The ISO relay consists of an electromagnetic coil a resistor or diode and three two fixed and one mov able electrical contacts The movable common feed relay contact is held against one of the fixed contacts normally closed by spring pressure When the elec tromagnetic coil is energized it draws the movable co...

Page 438: ...t a battery to terminals 85 and 86 There should now be continuity between terminals 30 and 87 and no continuity between terminals 87A and 30 If OK perform the Relay Circuit Test that follows If not OK replace the faulty relay RELAY CIRCUIT TEST 1 The relay common feed terminal cavity 30 is connected to battery voltage and should be hot at all times If OK go to Step 2 If not OK repair the open circ...

Page 439: ... feed wire and the horn switch ground wire on the driver side airbag module There should now be continuity If not OK replace the faulty horn switch HORN For complete circuit diagrams refer to Horn Ci gar Lighter in the Contents of Group 8W Wiring Diagrams 1 Measure the resistance between the horn s mounting bracket s and a good ground There should be no measurable resistance If OK go to Step 2 If ...

Page 440: ... cowl side inner trim panel 10 Reconnect the battery negative cable HORN REMOVAL 1 Disconnect and isolate the battery negative cable 2 Raise and support the vehicle 3 Remove the front underbody splash shield NOTE Remove the horn and its mounting bracket from the vehicle as a unit Do not remove the horn from its mounting bracket 4 Remove the screw that secures the horn and mounting bracket unit to ...

Page 441: ...and mounting bracket unit to the radiator closure panel brace 4 Install and tighten the screw that secures the horn and mounting bracket unit to the radiator clo sure panel brace Tighten the screw to 28 5 N m 21 ft lbs 5 Install the front underbody splash shield 6 Lower the vehicle 7 Reconnect the battery negative cable 8G 6 HORN SYSTEMS XJ REMOVAL AND INSTALLATION Continued ...

Page 442: ...er for the speed control to engage the brakes cannot be applied nor can the gear selector be indicating the transmission is in Park or Neutral The speed control can be disengaged manually by Stepping on the brake pedal Depressing the OFF switch Depressing the CANCEL switch Depressing the clutch pedal if equipped NOTE Depressing the OFF switch or turning off the ignition switch will erase the set s...

Page 443: ...circuits is restored SPEED CONTROL SOLENOID CIRCUITS OPERATION When all of the speed control parameters are met and the SET button is pressed the PCM actuates the vent solenoid and duty cycles the vacuum solenoid to open the throttle and bring the vehicle up to tar get speed When the vehicle is at target speed it will actuate the vent solenoid with the vacuum solenoid de activated to maintain the ...

Page 444: ...h the speed control option use a dual function brake lamp switch The PCM moni tors the state of the dual function brake lamp switch Refer to the Brake section for more information on brake lamp switch service and adjustment proce dures The brake switch is equipped with three sets of contacts one normally open and the other two nor mally closed brakes disengaged The PCM sends a 12 volt signal to on...

Page 445: ...air valve Failed speed control servo Do the servo vacuum test CAUTION When test probing for voltage or conti nuity at electrical connectors care must be taken not to damage connector terminals or seals If these components are damaged intermittent or complete system failure may occur VACUUM SUPPLY TEST 1 Disconnect vacuum hose at speed control servo and install a vacuum gauge into the disconnected ...

Page 446: ...tuds through holes in servo mounting bracket 4 Install servo mounting nuts and tighten to 8 5 N m 75 in lbs 5 Connect vacuum line at servo 6 Connect electrical connector at servo 7 Connect servo cable to throttle body Refer to Servo Cable Removal Installation 8 Connect negative battery cable to battery 9 Before starting engine operate accelerator pedal to check for any binding SPEED CONTROL SWITCH...

Page 447: ...racket 4 Unclip cable from cable guide at valve cover 5 Disconnect servo cable at servo Refer to Speed Control Servo Removal Installation INSTALLATION 1 Attach end of cable to speed control servo Refer to Speed Control Servo Removal Installation 2 Install cable into cable bracket snaps in 3 Install cable connector at throttle body bellcrank pin snaps on 4 Clip cable to cable guide at valve cover 5...

Page 448: ...nstallation SPECIFICATIONS TORQUE CHART Description Torque Servo Mounting Bracket to Servo Nuts 8 5 N m 75 in lbs Servo Mounting Bracket to Body Bolts 2 N m 20 in lbs Speed Control Switch Mounting Screws 1 5 N m 14 in lbs Vacuum Reservoir Mounting Bolts 8 N m 72 in lbs Fig 5 Vacuum Reservoir Location 1 BUMPER END CAP 2 VACUUM RESERVOIR Fig 6 Vacuum Reservoir Removal Installation 1 VACUUM LINE 2 RE...

Page 449: ......

Page 450: ...heel to the left and right side of the driver s airbag module Switch features are Within the two switch modules five momen tary contact switches supporting seven different speed control functions are used The outputs from these switches are filtered into one input The MSA determines which output has been applied through resistive multiplexing The input circuit voltage is measured by the MSA to det...

Page 451: ......

Page 452: ...ved up right turn or down left turn the turn signal system is activated When the turn signal system is activated the circuitry of the turn signal switch and the combination flasher will cause the selected right or left turn signal indicator lamp front park turn signal lamp front side marker lamp and rear tail stop turn signal lamp to flash on and off If the exterior lamps are turned off the front ...

Page 453: ... warning functions For information relative to the other systems that are controlled by and circuits that are integral to the multi function switch see the group in this service manual that covers that system However the turn signal and hazard warning switches cannot be repaired If these switches or any other circuit or component of the multi function switch unit is faulty or damaged the entire mu...

Page 454: ...never be substituted for an ISO relay or replaced with an ISO relay or else component and vehicle damage may occur Because of the active electronic elements within the combination flasher it cannot be tested with con ventional automotive electrical test equipment If the combination flasher is believed to be faulty test the turn signal system and hazard warning system cir cuits as described in this...

Page 455: ...ES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Turn the ignition switch to the On position Actuate the turn signal switch or the hazard warning switch Obser...

Page 456: ...ring Diagrams WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Disconnect the instrument pan...

Page 457: ...RD WARNING SWITCH WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY MENT AND POSSIBLE PERSONAL INJURY REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the knee...

Page 458: ... water shield onto the switch by pulling it over the hazard warning switch button and the multi function switch control stalk 2 Position the multi function switch and water shield near its mounts on the steering column as a unit 3 Reconnect the two instrument panel wire har ness connectors to the multi function switch connec tor receptacles 4 Position the multi function switch onto its mounts on t...

Page 459: ...teering column upper mounting bracket to the dash panel steering column support bracket studs Tighten the nuts to 22 N m 200 in lbs 11 Install the knee blocker onto the instrument panel Refer to Knee Blocker in the Removal and Installation section of Group 8E Instrument Panel Systems for the procedures 12 Reconnect the battery negative cable 8J 8 TURN SIGNAL AND HAZARD WARNING SYSTEMS XJ REMOVAL A...

Page 460: ...cedure is required WINDSHIELD WIPER SYSTEM An intermittent windshield wiper system is stan dard equipment on this model The intermittent wiper system lets the driver select from either of two wiper speeds low or high or the intermittent wipe delay mode The intermittent wipe mode delay times are driver adjustable from about one second to about fifteen sec onds The intermittent wipe mode is provided...

Page 461: ...ue to streak or smear the wiper blades should be replaced The blades are mounted to spring loaded wiper arms The spring tension of the wiper arms controls the pressure applied to the blades on the glass The windshield wiper arms are secured by an integral latch to the two wiper pivots on the cowl plenum cov er grille panel at the base of the windshield The rear wiper arm is secured by a nut direct...

Page 462: ...of the switch is faulty or if the switch is damaged the entire switch unit must be replaced REAR The single two function rear wiper and washer switch is installed in the instrument panel accessory switch bezel which is located near the bottom of the instrument panel center bezel area below the heater and air conditioner controls The rear wiper and washer switch controls the rear wiper and washer f...

Page 463: ...gh a single hose attached to a barbed nipple on the rear washer pump The hose is routed from the front of the vehi cle to the liftgate with the body wire harness Located at the highest point of the supply hose routing beneath the liftgate opening upper header garnish moulding the hose connects to a check valve The check valve prevents washer fluid drain back or siphoning from occurring From the ch...

Page 464: ...T SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Check the fuse in the junction block If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace the faulty fuse 2 Disconnect and isolat...

Page 465: ... harness connector and the wiper washer switch wire harness connector There should be con tinuity If OK replace the faulty switch If not OK repair the open circuit as required REAR The diagnosis found here addresses an inoperative rear washer pump If the washer pump operates but no washer fluid is emitted from the washer nozzle be certain to check the fluid level in the reservoir Check for ice or ...

Page 466: ...ear wiper system and or washer system as described in this group before testing the rear wiper and washer switch For circuit descriptions and diagrams see 8W 53 Wip ers in Group 8W Wiring Diagrams WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO T...

Page 467: ...p towards the rear wiper motor output shaft end of the arm Fig 4 3 To install the wiper blade on the wiper arm slide the blade retainer into the U shaped formation on the tip of the wiper arm until the release tab snaps into its locked position Be certain that the notched retainer for the wiper element is oriented towards the end of the wiper blade that is nearest to the rear wiper motor output sh...

Page 468: ...he wiper arm retaining nut 5 Operate the rear wiper with the liftgate glass wet then turn the rear wiper switch to the Off posi tion so that the blade moves to the Park position 6 The measurement from the tip of the blade should now be from 27 to 35 mm 1 06 to 1 38 inch above the upper edge of the lower liftgate glass seal Fig 8 Check for the correct wiper arm positioning and readjust if required ...

Page 469: ...d reinforce ment nuts 6 N m 50 in lbs REAR 1 Disconnect and isolate the battery negative cable 2 From the outside of the liftgate glass remove the rear wiper arm from the rear wiper motor output shaft See Wiper Arm in this group for the proce dures 3 From the outside of the liftgate remove the rear wiper motor output shaft nut Fig 11 4 Pull the rear wiper motor output shaft bezel and rubber gasket...

Page 470: ...n to the fully lowered position 5 Remove both the upper and lower shrouds from the steering column 6 Remove the two screws that secure the switch water shield and bracket to the top of the steering column Fig 13 7 Remove the one screw located below the multi function switch lever that secures the switch water shield and bracket to the steering column Fig 14 8 Gently pull the lower mounting tab of ...

Page 471: ...OYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove the center bezel from the instrument panel See Instrument Panel Center Bezel in Group 8E Instrument Panel Systems for the procedures 3 Remove the three screws that secure the acces sory switch bezel to the instrument panel Fig 15 4 Pull the accessory switch bezel out from the instrument panel far enoug...

Page 472: ...or 9 Slide the reservoir slightly towards the rear of the vehicle to release the two hooks from the inner fender ledge slots 10 Lower the front of the washer reservoir and slide the unit forward to remove it from the vehicle 11 Reverse the removal procedures to install Tighten the reservoir mounting screws to 3 N m 26 in lbs WASHER PUMP 1 Disconnect and isolate the battery negative cable 2 Raise a...

Page 473: ...ille panel and screen to the cowl top panel Fig 18 3 Carefully lift the cowl plenum cover grille panel and screen from the vehicle far enough to access the windshield washer plumbing Use care so as not to damage the paint around the pivot openings of the panel 4 Disconnect the windshield washer supply hose and the passenger side washer nozzle hose from the washer nozzle supply hose tee fitting 5 R...

Page 474: ...ove the garnish moulding from the upper liftgate opening 4 Disconnect the liftgate half of the washer sup ply hose from the barbed nipple of the rear washer system check valve 5 Disconnect the body half of the washer supply hose from the other barbed nipple of the rear washer system check valve 6 Remove the check valve from the vehicle 7 When reinstalling the check valve be certain the valve is pr...

Page 475: ......

Page 476: ...ally HEADLAMP SWITCH DESCRIPTION The headlamp switch is located on the instrument panel The headlamp switch controls the parking lamps the headlamps the interior lamps and instrument cluster illumination The headlamp switch also contains a rheostat for controlling the illumination level of the instrument cluster lamps OPERATION The headlamp switch has an off position a parking lamp position and a ...

Page 477: ...Daytime Running Lights Headlamps System is installed on vehicles manufactured for sale in Can ada only A separate module mounted on the cowl controls the DRL OPERATION The headlamps are illuminated when the ignition switch is turned to the ON position The DRL module receives a vehicle moving signal from the vehicle speed sensor This provides a constant head lamps on condition as long as the vehicl...

Page 478: ...Loose or worn generator drive belt 2 Adjust or replace generator drive belt 3 Charging system output too low 3 Test and repair charging system refer to Group 8A 4 Battery has insufficient charge 4 Test battery state of charge refer to Group 8A 5 Battery is sulfated or shorted 5 Load test battery refer to Group 8A 6 Poor lighting circuit Z1 ground 6 Test for voltage drop across Z1 ground locations ...

Page 479: ... FOG LAMPS ARE DIM WITH ENGINE IDLING OR IGNITION TURNED OFF 1 Loose or corroded battery cables 1 Clean and secure battery cable clamps and posts 2 Loose or worn generator drive belt 2 Adjust or replace generator drive belt 3 Charging system output too low 3 Test and repair charging system Refer to Group 8A 4 Battery has insufficient charge 4 Test battery state of charge Refer to Group 8A 5 Batter...

Page 480: ...nd test the HDLP delay 10 amp fuse in junction box Replace if defective 3 With the key off and the connector discon nected measure the resistance from the delay mod ule connector terminal 4 to vehicle body ground The ohmmeter should indicate zero ohms If not repair the open circuit in the wire harness to vehicle body ground 4 With the key on measure the voltage between the delay module connector t...

Page 481: ... headlamp dimmer switch and high beam indicator operation 2 Correct defective components that could hinder proper headlamp alignment 3 Verify proper tire inflation 4 Clean headlamp lenses 5 Verify that luggage area is not heavily loaded 6 Fuel tank should be FULL Add 2 94 kg 6 5 lbs of weight over the fuel tank for each estimated gallon of missing fuel HEADLAMP ADJUSTMENT Headlamps can be aligned ...

Page 482: ...en Typical 1 CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS 2 FLOOR TO CENTER OF HEADLAMP LENS 3 7 62 METERS 25 FEET 4 FRONT OF HEADLAMP 5 VEHICLE CENTERLINE Fig 2 Headlamp Alignment Screen Target 1 LOW BEAM INTENSITY PATTERN ISO CANDELA CURVE Fig 3 Headlamp Beam Adjustment Screws 1 LEFT RIGHT ADJUSTMENT SCREW 2 UP DOWN ADJUSTMENT SCREW 3 HEADLAMP XJ LAMPS 8L 7 SERVICE PROCEDURES Continued ...

Page 483: ...4 Rotate the adjustment screw to adjust beam height Fig 5 Fig 4 Fog Lamp Alignment Typical 1 VEHICLE CENTERLINE 2 CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS 3 HIGH INTENSITY AREA 4 FLOOR TO CENTER OF FOG LAMP LENS 5 100 mm 4 in 6 7 62 METERS 25 FEET 7 FRONT OF FOG LAMP Fig 5 Fog Lamp Adjustment 1 ADJUSTMENT SCREW 2 MOUNTING BRACKET 3 FOG LAMP 8L 8 LAMPS XJ SERVICE PROCEDURES Continued ...

Page 484: ...SPECIAL TOOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C 4466 A XJ LAMPS 8L 9 ...

Page 485: ...ulb wire harness connector 4 Separate the sealed beam from the vehicle INSTALLATION 1 Connect wire harness connector 2 Position bulb in canister 3 Position retaining ring on sealed beam and install screws 4 Install headlamp bezel FOG LAMP BULB REMOVAL 1 Remove the screws attaching the access cover to the bottom of the fog lamp Fig 2 2 Remove spring clip securing bulb to fog lamp 3 Disconnect bulb ...

Page 486: ...bulb socket counter clockwise and pull from back side of lamp housing Fig 4 3 Pull bulb from socket INSTALLATION 1 Install bulb in socket 2 Install bulb and socket in back of side marker lamp housing 3 Install side marker lamp housing BACK UP BRAKE REAR TURN SIGNAL TAIL LAMP BULB REMOVAL 1 Remove tail lamp housing 2 Rotate bulb socket one third turn counter clock wise and remove bulb socket from l...

Page 487: ... from socket INSTALLATION 1 Push bulb into socket 2 Position socket in lamp and rotate 1 4 turn clockwise 3 Install screws attaching lamp housing to the liftgate UNDERHOOD LAMP BULB REMOVAL 1 Insert a small flat blade in the access slot between the lamp base and lamp lens 2 Pry the lamp lens upward and remove the lamp lens Fig 7 3 Depress the bulb terminal inward Fig 8 to release the bulb INSTALLA...

Page 488: ...n slot at front of lens Fig 10 2 Rotate the screwdriver until lens snaps out of the housing 3 Remove lens from housing 4 Remove bulb from terminals INSTALLATION 1 Insert bulb into reading lamp terminals 2 Replace lens by holding lens level and pushing rearward into housing 3 Push lens up to snap into housing VISOR VANITY LAMP BULB REMOVAL 1 Using a small flat blade carefully pry each cor ner of le...

Page 489: ...he vehicle 5 Remove the spring attaching the headlamp bucket to the grille opening panel Fig 2 6 Slide the headlamp bucket downward to disen gage it from the headlamp adjusting screws INSTALLATION 1 Position the headlamp bucket in the grille opening panel and slide the headlamp bucket upward to engage it with the headlamp adjusting screws 2 Install the spring attaching the headlamp bucket to the g...

Page 490: ...te from the vehicle INSTALLATION 1 Install bulbs and sockets in the lamp housing 2 Position the park turn signal lamp housing on the grille opening panel and install the screws 3 Install the headlamp bezel SIDE MARKER LAMP REMOVAL 1 Remove screws attaching side marker lamp lens to grille opening panel Fig 5 2 Remove bulb and socket from back side of lamp INSTALLATION 1 Install bulb and socket in b...

Page 491: ...ATION 1 Connect the wire harness connector 2 Position the CHMSL on the liftgate 3 Install the screws attaching the CHMSL to the liftgate LICENSE PLATE LAMP REMOVAL 1 Remove screws attaching the license plate lamp to the liftgate 2 Remove the bulb from the lamp socket INSTALLATION 1 Install bulb in the lamp socket 2 Position the license plate lamp on the liftgate and install screws UNDERHOOD LAMP T...

Page 492: ... from the headliner cavity 6 Disconnect the wire harness connector INSTALLATION 1 Position the dome lamp housing at the head liner cavity 2 Connect the wire harness connector 3 Install the fasteners attaching the lamp to the roof 4 Position the lens at the lamp housing and force it upward into the housing until the mounting tabs are seated on the lamp mounting pins MAP READING LAMP The map reading...

Page 493: ...t to left use a small flat blade carefully pry lamp from visor 3 Disconnect visor lamp wire connector and remove from vehicle INSTALLATION 1 Position visor lamp at visor and connect visor lamp wire connector 2 Position visor lamp in visor and press into place 8L 18 LAMPS XJ REMOVAL AND INSTALLATION Continued ...

Page 494: ...attaches the module to the inside of the instrument panel 3 Install the knee blocker DAYTIME RUNNING LAMP MODULE REMOVAL The Daytime Running Lights DRL module is located on the right fender inner panel adjacent to the dash panel Fig 2 1 Disconnect the wire harness connector from the module 2 Remove the screws that attach the module to the fender inner panel 3 Remove the module from the fender inne...

Page 495: ...le Damage to lamp can result Service procedures for most of the lamps in the instrument panel Instrument cluster and switches are located in Group 8E Instrument Panel and Gauges Some components have lamps that can only be serviced by an Authorized Service Center ASC after the component is removed from the vehicle The following Bulb Application Tables lists the lamp title on the left side of the co...

Page 496: ...ccessed from underneath the vehicle OPERATION This system allows the driver to adjust the vertical headlamp aim from the interior of the vehicle to com pensate for passenger or cargo load A headlamp lev eling switch is located in the instrument panel and controls the headlamp leveling motor function DIAGNOSIS AND TESTING DIAGNOSTIC PROCEDURES When a vehicle experiences problems with the headlamp s...

Page 497: ...Refer to Group 8W Wiring 3 Defective motor 3 Replace motor BOTH MOTORS DO NOT OPERATE 1 No voltage at headlamp leveling switch 1 Repair circuit or replace fuse Refer to Group 8W Wiring 2 No voltage at both motors 2 Repair circuit or replace fuse Refer to Group 8W Wiring 3 Poor connection at motors 3 Secure connectors on motors 4 Both motors defective 4 Replace motors 8L 2 LAMPS XJ DIAGNOSIS AND TE...

Page 498: ...of vehi cle forward to verify accuracy of the line placement 5 Rock vehicle side to side three times and allow suspension to stabilize 6 Jounce front suspension three times by pushing downward on front bumper and releasing 7 Measure the distance from the center of head lamp lens to the floor Transfer measurement to the alignment screen with tape Use this line for up down adjustment reference 8 Pla...

Page 499: ...rn on the alignment screen disable the headlamps by disengaging the wire connectors from the headlamp bulbs To adjust fog lamp alignment rotate alignment screws Fig 4 to achieve the specified pattern Fig 2 Headlamp Beam Adustment Screws 1 LEFT RIGHT ADJUSTMENT SCREW 2 UP DOWN ADJUSTMENT SCREW 3 HEADLAMP Fig 1 Headlamp Alignment Screen Typical 1 CENTER OF VEHICLE 2 CENTER OF HEADLAMPS 3 15 CUT OFF ...

Page 500: ...2 CENTER OF VEHICLE 3 VERTICAL CENTER OF FOG LAMP 4 HORIZONTAL CENTER OF FOG LAMP 5 200mm 8 in 6 FRONT OF FOG LAMP 7 10 METERS 32 8 ft Fig 4 Fog Lamp Beam Adjustment Screws 1 ADJUSTMENT SCREW 2 MOUNTING BRACKET 3 FOG LAMP XJ LAMPS 8L 5 ADJUSTMENTS Continued ...

Page 501: ...et INSTALLATION 1 Install the front position lamp bulb in lamp socket 2 Verify lamp operation 3 Install front position lamp in headlamp 4 Connect headlamp electrical connector 5 Position the headlamp headlamp retaining ring and install the retaining screws 6 Position the headlamp bezel and install retain ing screws SIDE REPEATER LAMP BULB REMOVAL 1 Grip the side repeater lamp assembly and pull str...

Page 502: ... its socket 2 Verify lamp operation 3 Install the remaining three lamp sockets in the taillamp assembly 4 Position the taillamp assembly and install the retaining screws LICENSE PLATE LAMP BULB REMOVAL 1 Remove the appropriate license plate lamp retaining screws 2 Pull lamp housing from rear liftgate Lamp must be positioned properly to allow removal without removing license plate 3 Rotate the lamp...

Page 503: ...f 5 Remove the headlamp from the vehicle INSTALLATION 1 Install front position lamp in headlamp 2 Connect headlamp electrical connector 3 Position the headlamp headlamp retaining ring and install the retaining screws 4 Position the headlamp bezel and install retain ing screws HEADLAMP LEVELING MOTOR REMOVAL 1 Open the hood and disconnect the negative bat tery cable 2 Raise the vehicle on a hoist o...

Page 504: ...ocket into the housing 2 Verify lamp operation 3 Press the lamp assembly into the fender mounting hole FRONT FOG LAMP REMOVAL 1 Remove the 2 screws from the bottom cover of the lamp body 2 Disconnect the 2 wires from the lamp element 3 Remove the lamp element from the housing INSTALLATION 1 Install the new lamp element in the housing and reinstall the lower housing REAR TURN SIGNAL BACKUP TAILLAMP...

Page 505: ...NSTALLATION 1 Install lamp socket in lamp housing 2 Verify lamp operation 3 Install license plate lamp assembly in liftgate and install retaining screws 8L 10 LAMPS XJ REMOVAL AND INSTALLATION Continued ...

Page 506: ... Lamp W5W Underhood Retractable Lamp 105 Front Fog H3 CHMSL W16W Interior Lamps Bulb Type Ashtray Lamp 1891 Cigarette Lighter Lamp 53 Auto Trans Floor Shift Lamp 658 Cargo Lamp 561 Climate Control Lamp 2 74 Dome Lamp 561 Dome Reading Lamp 1 561 and 2 906 Glove Box Lamp 194 Lighted Vanity Mirror 2 74 Map Reading Light in Overhead Console 4 912 Rocker Switch 37 Transfer Case Lamp 658 Underpanel Cour...

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Page 508: ...lustrations used in this group represent only the LHD version the diagnostic and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required The dual front airbag system consists of the follow ing components Airbag Control Module ACM Airbag indicator lamp Clockspring Dri...

Page 509: ...RE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY THE DRIVER SIDE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTAS SIUM NITRATE THESE MATERIALS ARE POISON OUS AND EXTREMELY FLAMMABLE CONTACT WITH ACID WATER OR HEAVY METALS MAY PRO DUCE HARMFUL AND IRRITATING GASES SODIUM HYDROXIDE IS FORMED IN THE PRESEN...

Page 510: ...ompressed argon gas The inflator seals the hole in the airbag cushion so it can dis charge the gas it produces directly into the cushion when supplied with the proper electrical signal Fol lowing an airbag deployment the airbag cushion quickly deflates by venting this gas through the porous fabric material used on each end panel of the airbag cushion The molded plastic passenger side airbag door i...

Page 511: ...consists of a plastic case which contains a flat ribbon like electrically conduc tive tape that winds and unwinds like a clockspring with the steering wheel rotation The electrically con ductive tape consists of several fine gauge copper wire leads sandwiched between two narrow strips of plastic film Like the clockspring in a timepiece the clockspring tape has travel limits and can be damaged by b...

Page 512: ...column components DISPOSAL OF NON DEPLOYED AIRBAG MODULES All damaged or faulty and non deployed driver side or passenger side airbag modules which are replaced on vehicles are to be returned If an airbag module assembly is faulty or damaged and non deployed refer to the parts return list in the current Chrysler Corporation Warranty Policies and Procedures man ual for the proper handling and dispo...

Page 513: ...OYMENT AND POSSIBLE PERSONAL INJURY WHEN REMOVING A DEPLOYED AIRBAG MOD ULE RUBBER GLOVES EYE PROTECTION AND A LONG SLEEVED SHIRT SHOULD BE WORN THERE MAY BE DEPOSITS ON THE AIRBAG MODULE AND OTHER INTERIOR SURFACES IN LARGE DOSES THESE DEPOSITS MAY CAUSE IRRITATION TO THE SKIN AND EYES REMOVAL 1 Disconnect and isolate the battery negative cable If either of the airbags has not been deployed wait ...

Page 514: ...he screws to 10 2 N m 90 in lbs 5 Do not reconnect the battery negative cable at this time Refer to Airbag System in the Diagnosis and Testing section of this group for the proper pro cedures DRIVER SIDE AIRBAG MODULE TRIM COVER The horn switch is integral to the driver side air bag module trim cover If either component is faulty or damaged the entire driver side airbag module trim cover and horn ...

Page 515: ...LE OR BECOMING ENTRAPPED BETWEEN THE AIRBAG CUSHION AND THE DRIVER SIDE AIRBAG TRIM COVER FAILURE TO OBSERVE THIS WARNING COULD RESULT IN OCCUPANT INJURIES UPON AIRBAG DEPLOYMENT THE DRIVER SIDE AIRBAG MODULE TRIM COVER MUST NEVER BE PAINTED REPLACEMENT TRIM COVERS ARE SERVICED IN THE ORIGINAL COLORS PAINT MAY CHANGE THE WAY IN WHICH THE MATERIAL OF THE TRIM COVER RESPONDS TO AN AIRBAG DEPLOYMENT ...

Page 516: ...EGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYS TEM CAPACITOR TO DISCHARGE BEFORE FUR THER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY WHEN REMOVING A DEPLOYED AIRBAG MOD ULE RUBBER GLOVES EYE PROTECTION AND A LONG SLEEVED SHIRT SHOULD BE WORN THERE MAY BE DEPOSITS ON THE ...

Page 517: ...side airbag module lower mounting brackets to the instrument panel structural support Tighten the screws to 11 8 N m 105 in lbs 4 Install and tighten the four screws that secure the lower flange of the passenger side airbag door to the instrument panel upper glove box opening rein forcement Tighten the screws to 2 2 N m 20 in lbs 5 Install the glove box into the instrument panel Refer to Glove Box...

Page 518: ...oor mounting flanges clear the three tabs on the top and the bottom of the airbag module housing Fig 11 4 Disengage the keyed holes in the returns of the upper and lower airbag door mounting flange returns from the three tabs on the top and the bottom of the passenger side airbag module housing 5 Remove the passenger side airbag door from the airbag module INSTALLATION WARNING USE EXTREME CARE TO ...

Page 519: ...s 4 Remove the three screws that secure the center floor console rear mounting bracket to the floor panel transmission tunnel 5 Remove the center floor console rear mounting bracket from the floor panel transmission tunnel 6 Disconnect the instrument panel wire harness connector from the Airbag Control Module ACM Fig 12 To disconnect the instrument panel wire harness connector from the ACM a Squee...

Page 520: ...rbag Mod ule in the Removal and Installation section of this group for the procedures 3 If the vehicle is so equipped disconnect the upper clockspring wire harness connector from the steering wheel wire harness for the vehicle speed control switches located within the hub cavity of the steering wheel 4 Remove the nut that secures the steering wheel armature to the steering column upper shaft which...

Page 521: ...locking pin is removed before the clockspring is installed on a steering column the clockspring cen tering procedure must be performed NOTE Before starting this procedure be certain that the front wheels are still in the straight ahead position 1 If the removed clockspring is being reused remove the wire from the index hole that is locking the clockspring rotor to the clockspring case to main tain...

Page 522: ...st then be re centered following com pletion of the service or the clockspring tape may be damaged Service replacement clocksprings are shipped pre centered and with a locking pin installed This lock ing pin should not be removed until the clockspring has been installed on the steering column If the locking pin is removed before the clockspring is installed on a steering column the clockspring cen...

Page 523: ...s can be done by inserting a stiff wire through the small index hole located at about the 11 o clock position in the centered clockspring rotor and case Bend the wire over after it has been inserted through the index hole to prevent it from falling out 7 The front wheels should still be in the straight ahead position Install the clockspring onto the steer ing column Refer to Clockspring in the Rem...

Page 524: ...and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required REAR WINDOW DEFOGGER SYSTEM The rear window defogger system will only operate when the ignition switch is in the On position When the defogger switch is in the On position an electric heater grid on the rear...

Page 525: ... inoperative but the rear window heating grid is operating as designed refer to Power Mirror in the Diagnosis and Testing section of Group 8T Power Mirror Systems for diagnosis of the mirror heating grids The heating grid behind each outside mirror glass cannot be repaired and if faulty or damaged the entire power mirror unit must be replaced Refer to Power Mirror in the Removal and Installation s...

Page 526: ...ration can be checked by feeling the rear window or outside rear view mirror glass A dis tinct difference in temperature between the grid lines and the adjacent clear glass or the mirror glass can be detected within three to four minutes of operation 3 Using a 12 volt DC voltmeter contact the rear glass heating grid terminal A right side with the negative lead and terminal B left side with the pos...

Page 527: ...AKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Remove the accessory switch bezel from the instrument panel and unplug the defogger switch wire harness connector 2 Check for continuity between the ground cir cuit cavity of the defogger switch wire harness con nector and a good ground There sh...

Page 528: ... and should be hot when the ignition switch is in the On position Check for battery voltage at the cavity for relay ter minal 86 with the ignition switch in the On position If OK see the diagnosis for Instrument Cluster in this group If not OK repair the open circuit to the fuse in the junction block as required INSTRUMENT CLUSTER Before performing this test complete the Defogger Switch and the De...

Page 529: ...th masking tape or a template 5 Apply the epoxy through the slit in the mask ing tape or template Overlap both ends of the break by at least 19 millimeters 0 75 inch 6 For a terminal or pigtail wire replacement mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar Apply a thin layer of epoxy to the area where the terminal or pigtail wire was fasten...

Page 530: ...ENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove the fuse access panel by unsnapping it from the right cowl side trim panel 3 Remove the stamped nut that secures the right cowl side trim to the junction block stud Fig 6 4 Remove the screw located abo...

Page 531: ...he run position the heated seat system shall remain deactivated until a momentary switch is depressed When a seat heater is turned on a sensor located near the seat cushion electric heater element provides the SHIM with input indicating the surface temperature of the seat cushion If the surface tem perature input is below the temperature set point of the SHIM for the selected temperature setting a...

Page 532: ...ushion heating element The heating elements are sewn into the seat cush ion cover and seat back cover assemblies which are serviced individually The heating elements and tem perature sensor cannot be repaired and if faulty or damaged the affected seat cover assembly must be replaced Refer to Group 23 Body for the seat cush ion cover and seat back cover Removal and Installa tion DIAGNOSIS AND TESTI...

Page 533: ...e center console Remove the connector from the suspect switch Check for continuity between the ground circuit cavity of the 6 way heated seat switch wire harness connector and a good ground There should be continuity If OK go to Step 3 If not OK repair the open circuit as required 3 Connect the battery negative cable Turn the ignition switch to the ON position Check for battery voltage at the fuse...

Page 534: ... isolate the battery negative cable Unplug the 4 way heated seat cushion wire harness connector 2 Using an ohmmeter check the resistance between the heated seat sensor input circuit cavity and the heated seat sensor feed circuit cavity of the seat cushion cover half of the heated seat cushion wire harness connector The sensor resistance should be between 1 Kohm and 200 Kohms If OK see Heated Seat ...

Page 535: ...the wire harness connectors 4 Remove the heated seat switch assembly from the console 5 Remove the heated seat switch es from the heated seat switch assembly 6 Reverse the removal procedures to install SEAT HEAT INTERFACE MODULE 1 Move the right power seat adjuster to its full up and full rear stop positions 2 Disconnect and isolate the battery negative cable 3 Unhook the seat cushion cover retain...

Page 536: ...w Christmas tree fastener must be used to mount the relay Be certain that the relay terminals are aligned with the cavities in the wire harness connec tor before pushing the relay firmly into place Fig 3 Heated Seat Relay Remove Install 1 HEATED SEAT RELAY 2 SEAT CUSHION FRAME 3 WIRE HARNESS CONNECTOR 4 POWER SEAT TRACK FRONT BRACKET XJ ELECTRICALLY HEATED SYSTEMS 8N 13 REMOVAL AND INSTALLATION Co...

Page 537: ......

Page 538: ...and service procedures outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required REAR WINDOW DEFOGGER SYSTEM The rear window defogger system will only operate when the ignition switch is in the On position When the defogger switch is in the On position an electric heater grid on the rear...

Page 539: ... inoperative but the rear window heating grid is operating as designed refer to Power Mirror in the Diagnosis and Testing section of Group 8T Power Mirror Systems for diagnosis of the mirror heating grids The heating grid behind each outside mirror glass cannot be repaired and if faulty or damaged the entire power mirror unit must be replaced Refer to Power Mirror in the Removal and Installation s...

Page 540: ...ration can be checked by feeling the rear window or outside rear view mirror glass A dis tinct difference in temperature between the grid lines and the adjacent clear glass or the mirror glass can be detected within three to four minutes of operation 3 Using a 12 volt DC voltmeter contact the rear glass heating grid terminal A right side with the negative lead and terminal B left side with the pos...

Page 541: ...AKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable Remove the accessory switch bezel from the instrument panel and unplug the defogger switch wire harness connector 2 Check for continuity between the ground cir cuit cavity of the defogger switch wire harness con nector and a good ground There sh...

Page 542: ... and should be hot when the ignition switch is in the On position Check for battery voltage at the cavity for relay ter minal 86 with the ignition switch in the On position If OK see the diagnosis for Instrument Cluster in this group If not OK repair the open circuit to the fuse in the junction block as required INSTRUMENT CLUSTER Before performing this test complete the Defogger Switch and the De...

Page 543: ...th masking tape or a template 5 Apply the epoxy through the slit in the mask ing tape or template Overlap both ends of the break by at least 19 millimeters 0 75 inch 6 For a terminal or pigtail wire replacement mask the adjacent areas so the epoxy can be extended onto the adjacent grid line as well as the bus bar Apply a thin layer of epoxy to the area where the terminal or pigtail wire was fasten...

Page 544: ...ENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and isolate the battery negative cable 2 Remove the fuse access panel by unsnapping it from the right cowl side trim panel 3 Remove the stamped nut that secures the right cowl side trim to the junction block stud Fig 6 4 Remove the screw located abo...

Page 545: ...he run position the heated seat system shall remain deactivated until a momentary switch is depressed When a seat heater is turned on a sensor located near the seat cushion electric heater element provides the SHIM with input indicating the surface temperature of the seat cushion If the surface tem perature input is below the temperature set point of the SHIM for the selected temperature setting a...

Page 546: ...ushion heating element The heating elements are sewn into the seat cush ion cover and seat back cover assemblies which are serviced individually The heating elements and tem perature sensor cannot be repaired and if faulty or damaged the affected seat cover assembly must be replaced Refer to Group 23 Body for the seat cush ion cover and seat back cover Removal and Installa tion DIAGNOSIS AND TESTI...

Page 547: ...e center console Remove the connector from the suspect switch Check for continuity between the ground circuit cavity of the 6 way heated seat switch wire harness connector and a good ground There should be continuity If OK go to Step 3 If not OK repair the open circuit as required 3 Connect the battery negative cable Turn the ignition switch to the ON position Check for battery voltage at the fuse...

Page 548: ... isolate the battery negative cable Unplug the 4 way heated seat cushion wire harness connector 2 Using an ohmmeter check the resistance between the heated seat sensor input circuit cavity and the heated seat sensor feed circuit cavity of the seat cushion cover half of the heated seat cushion wire harness connector The sensor resistance should be between 1 Kohm and 200 Kohms If OK see Heated Seat ...

Page 549: ...the wire harness connectors 4 Remove the heated seat switch assembly from the console 5 Remove the heated seat switch es from the heated seat switch assembly 6 Reverse the removal procedures to install SEAT HEAT INTERFACE MODULE 1 Move the right power seat adjuster to its full up and full rear stop positions 2 Disconnect and isolate the battery negative cable 3 Unhook the seat cushion cover retain...

Page 550: ...w Christmas tree fastener must be used to mount the relay Be certain that the relay terminals are aligned with the cavities in the wire harness connec tor before pushing the relay firmly into place Fig 3 Heated Seat Relay Remove Install 1 HEATED SEAT RELAY 2 SEAT CUSHION FRAME 3 WIRE HARNESS CONNECTOR 4 POWER SEAT TRACK FRONT BRACKET XJ ELECTRICALLY HEATED SYSTEMS 8N 13 REMOVAL AND INSTALLATION Co...

Page 551: ......

Page 552: ...rious power distribu tion system components NOTE This group covers both Left Hand Drive LHD and Right Hand Drive RHD versions of this model Whenever required and feasible the RHD versions of affected vehicle components have been constructed as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures out...

Page 553: ...al stud cover the PDC relay wedges and the PDC relay cassettes are available for service replacement The PDC main housing unit the fuse wedges the fuse cassette and the bus bars cannot be repaired and are only serviced as a unit with the headlamp and dash wire harness If the PDC main housing unit fuse wedges fuse cassette or the bus bars are faulty or damaged the headlamp and dash wire harness uni...

Page 554: ...t of any other standard circuit protection device The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days However it must be remembered that removing the IOD fuse will not eliminate IOD but only reduce this normal condition If a vehicle will be stored for more than about thirty days...

Page 555: ...vice manual for the location of more information on the ground eyelet locations 4 Disengage each of the retainers that secure the headlamp and dash wire harness to the vehicle body and chassis components Refer to Connector Loca tions in the index of this service manual for the loca tion of more information on the headlamp and dash wire harness retainer locations 5 Unlatch and remove the B terminal...

Page 556: ...ectors Refer to Connector Loca tions in the index of this service manual for the loca tion of more information on the headlamp and dash wire harness connector locations 11 Reconnect the battery negative cable IGNITION OFF DRAW FUSE The Ignition Off Draw IOD fuse is removed from Power Distribution Center PDC fuse cavity 16 Fig 7 when the vehicle is shipped from the assembly plant Dealer personnel m...

Page 557: ...IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY REMOVAL 1 Disconnect and isolate the battery negative cable 2 Remove the fuse access panel by unsnapping it from the right cowl side inner trim panel Fig 8 3 Remove the push nut that secures the right cowl side inner trim panel to the mounting stud on the Junction Block JB 4 Remove the screw located above the fuse access opening that se...

Page 558: ...ing it onto the right cowl side inner trim panel 10 Reconnect the battery negative cable DISASSEMBLY AND ASSEMBLY POWER DISTRIBUTION CENTER The Power Distribution Center PDC cover the PDC housing lower cover the PDC relay wedges the PDC relay cassettes and the PDC B terminal stud cover are available for service replacement Fig 10 The PDC cover and B terminal stud cover can be simply unlatched and ...

Page 559: ...ary to remove each of the interfering relay wedges and relay cassettes from the PDC housing 2 From the top of the PDC housing use a small screwdriver or a terminal pick tool Special Tool Kit 6680 to release the two latches that secure the relay cassette in the PDC Fig 13 3 Gently and evenly press the relay cassette down through the PDC housing Fig 10 Power Distribution Center Components 1 LATCH 2 ...

Page 560: ...olutely certain into which cavity a terminal should be installed refer to Power Distribution in the index of this service manual for the location of complete circuit diagrams covering the PDC 4 While pulling gently on the wire from the bot tom of the faulty PDC relay cassette use a terminal pick tool Special Tool Kit 6680 from the top of the relay cassette to release the latch that secures the ter...

Page 561: ...ots on the PDC housing with the stanchions of the PDC mounting bracket and push the unit downward until the mounting bracket latches fully engage the mounting tabs on the PDC housing 4 Install the battery wire harness PDC take out eyelets over the PDC B terminal stud 5 Install and tighten the nut that secures the eyelets of the battery wire harness PDC take outs to the B terminal stud Tighten the ...

Page 562: ...ion Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required POWER LOCK SYSTEM The power lock system allows all of the doors and the liftgate to be locked or unlocked electrically by operating the switch on either front door trim panel This system operates with battery power supplied through a fuse in the junction block independent of th...

Page 563: ...M houses individual switches for each passenger door power window a power win dow lockout switch and the power mirror switch The PDM contains the control circuitry and the power lock and unlock relays for the entire power lock sys tem In its role as the power lock control module the PDM receives inputs from the battery the ignition switch the DDM the driver door ajar switch the key in ignition swi...

Page 564: ...lock switches and or the RKE transmitter see the Power Lock Motor diagnosis in this group If the RKE and power lock systems are function ing but the illuminated entry system fails to operate see the Remote Keyless Entry Receiver diagnosis in this group DOOR MODULE If the power lock system is inoperative with either front door power lock switch test the Passenger Door Module PDM If the power lock s...

Page 565: ...e Accessory or On positions check for battery voltage at the fused ignition switch output circuit cavity of the 8 way PDM wire harness connector If OK replace the faulty PDM If not OK repair the open circuit to the junction block as required 5 If the problem being diagnosed is an inopera tive door lock inhibit feature or a power lock system that responds to an Unlock command but not a Lock command...

Page 566: ... transmitter Use a DRB scan tool as described in the proper Diagnostic Pro cedures manual 3 Test the RKE system operation with both transmitters If both transmitters fail to operate the power lock system see the diagnosis for the Remote Keyless Entry Receiver in this group If the known good transmitter operates the power locks and the suspect transmitter does not replace the faulty transmitter NOT...

Page 567: ...ontinuity until the driver door is opened If OK replace the faulty RKE receiver If not OK repair the circuit or replace the faulty driver door ajar switch as required 10 Unplug the horn relay from the junction block Check for continuity between the horn relay output circuit cavity of the RKE receiver wire har ness connector and a good ground There should be no continuity If OK go to Step 11 If not...

Page 568: ...ck linkage rods near the back of the inside door remote controls 6 Unsnap the plastic retainer clips from the inside door remote control ends of the latch release and lock linkage rods and remove the rod ends from the inside door remote controls 7 Unplug the wire harness connectors from the door module 8 Remove the trim panel from the front door 9 Remove the three screws that secure the door modul...

Page 569: ...ndling and service procedures Electrically con ductive wrist or heel straps are recommended or static dissipating shoes are also acceptable Work and storage areas should be free of static genera tive materials such as dry air glass nylon wool fur silk rayon acrylic polystyrene foam polyester saran polyethylene polypropylene PVC and teflon MINI DOME MOUNTED TYPE 1 Disconnect and isolate the battery...

Page 570: ...d console bezel far enough to clear the tabs on the rear console housing and remove the housing from the bezel 5 Remove the two screws that secure the RKE receiver circuit board to the rear overhead console housing 6 Remove the RKE circuit board from the rear overhead console housing 7 Reverse the removal procedures to install Tighten the mounting screws to 2 2 N m 20 in lbs Fig 7 RKE Receiver Rem...

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Page 572: ...ing the Customer Learn programming procedure or a DRBIIIt scan tool The SKIS will recognize no more than eight valid Sentry Key transponders at any one time The SKIS performs a self test each time the igni tion switch is turned to the On position and will store Diagnostic Trouble Codes DTCs if a system malfunction is detected The SKIS can be diagnosed and any stored DTC can be retrieved using a DR...

Page 573: ... and stays on after the bulb test it indi cates that the SKIM has detected a system malfunction and or that the SKIS has become inoperative If the SKIM detects an invalid key when the ignition switch is turned to the On position it sends messages to the instrument cluster to flash the SKIS indicator lamp The SKIM can also send messages to the instrument cluster to flash the lamp and to generate a ...

Page 574: ...s and service of a faulty SKIS indicator lamp If the SKIS indicator lamp comes on and stays on after the bulb test func tion diagnosis of the SKIS should be performed with a DRB scan tool and the proper Diagnostic Proce dures manual DIAGNOSIS AND TESTING SENTRY KEY IMMOBILIZER SYSTEM WARNING ON VEHICLES EQUIPPED WITH AIRBAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYS TEMS BEFORE ATTEMPTING ANY STEERI...

Page 575: ...ff position replace the valid Sentry Key with a blank Sentry Key transponder and turn the ignition switch back to the On position 6 About ten seconds after the completion of Step 5 a single audible chime tone will sound and the SKIS indicator lamp will stop flashing and stay on solid for about three seconds to indicate that the blank Sentry Key transponder has been successfully programmed The SKIS...

Page 576: ...his clip from the steering column jacket 9 Rotate the SKIM and its mounting bracket downwards and then to the side away from the steer ing column to slide the SKIM antenna ring from around the ignition switch lock cylinder housing 10 Remove the SKIM from the vehicle 11 Reverse the removal procedures to install Tighten the non tilt steering column mounting nuts to 22 N m 200 in lbs and the steering...

Page 577: ......

Page 578: ...transceiver and a cen tral processing unit which includes the Sentry Key Immobilizer System SKIS program logic The SKIS programming enables the SKIM to program and retain in memory the codes of at least two but no more than eight electronically coded Sentry Key transponders The SKIS programming also enables the SKIM to communicate over the Chrysler Collision Detection CCD data bus network with the...

Page 579: ... the factory The transponder chip is insulated within a nylon mount inserted in the head of the key and invisible beneath a molded rubber cap Fig 1 Each Sentry Key transponder has a unique tran sponder identification code programmed into it by the manufacturer The Sentry Key Immobilizer Module SKIM has a unique Secret Key code programmed into it by the manufacturer When a Sentry Key transponder is...

Page 580: ...ion Detection CCD data bus net work should be diagnosed using a DRB scan tool The DRB will allow confirmation that the CCD data bus is functional that the Sentry Key Immobilizer Module SKIM is placing the proper messages on the CCD data bus and that the Powertrain Control Mod ule PCM and the instrument cluster are receiving the CCD data bus messages Refer to the proper Diagnostic Procedures manual...

Page 581: ...If the vehicle is so equipped move the tilt steering column to the fully lowered position 8 If the vehicle is so equipped loosen the two nuts that secure the non tilt steering column upper mounting bracket to the dash panel steering column support bracket studs Lower the column far enough to remove the upper steering column shroud 9 Remove both the upper and lower shrouds from the steering column ...

Page 582: ... with a new unit a DRB scan tool and the proper Diagnostic Procedures manual MUST be used to initialize the new SKIM and to program at least two Sentry Key transponders Fig 3 Sentry Key Immobilizer Module Remove Install 1 UPPER SHROUD 2 STEERING COLUMN 3 WIRE HARNESS CONNECTOR 4 SENTRY KEY IMMOBILIZER MODULE 5 IGNITION LOCK CYLINDER 6 SCREW 7 LOWER SHROUD 8 STEERING WHEEL XJ VEHICLE THEFT SECURITY...

Page 583: ......

Page 584: ...unction block regardless of the ignition switch position The power seat system includes the power seat adjuster and motors unit the power seat switch and the circuit breaker Following are general descrip tions of the major components in the power seat sys tem Refer to the owner s manual in the vehicle glove box for more information on the features use and operation of the power seat system DESCRIP...

Page 585: ...aulty and must be replaced If neither ter minal has battery voltage repair the open circuit from the Power Distribution Center PDC as required POWER SEAT ADJUSTER AND MOTORS For circuit descriptions and diagrams refer to 8W 63 Power Seat in Group 8W Wiring Diagrams Operate the power seat switch to move all three seat motors in each direction The seat should move in each of the selected directions ...

Page 586: ... the battery negative cable 3 For the driver side power seaat only unplug the seat belt switch wire harness connector from the driver side seat belt buckle half on the inboard side of the seat Fig 3 4 Unplug the power seat wire harness connector from the body wire harness connector Fig 1 Power Seat Switch Continuity POWER SEAT SWITCH LEFT SEAT SWITCH SWITCH POSITION CONTINUITY BETWEEN Off B E B J ...

Page 587: ...he proper power seat switch removal and installa tion procedures 11 Disengage the power seat switch wire harness and connector from the seat cushion frame 12 Remove the power seat adjuster and motors assembly from the seat cushion frame 13 Reverse the removal procedures to install Tighten the seat mounting hardware as follows Seat adjuster to seat cushion frame nuts 25 N m 18 ft lbs Seat adjuster ...

Page 588: ...passenger door windows A power window lockout switch on the driver side front door trim panel can prevent the pas senger door windows from being operated except from the master switches The power window system receives battery current through a circuit breaker in the junction block only when the ignition switch is in the On or Accessory positions The power window system includes the power win dow ...

Page 589: ...ve battery connection to the two motor terminals will cause the motor to rotate in one direction Reversing the current through these same two connections will cause the motor to rotate in the opposite direction In addition each power window motor is equipped with an integral self resetting circuit breaker to pro tect the motor from overloads The power window motor and gearbox assembly cannot be re...

Page 590: ...circuit breaker checks OK but no power windows operate see Power Window System in the Diagnosis and Testing section of this group DOOR MODULE The Driver Door Module DDM contains the mas ter switches and the lockout switch in the power win dow system The DDM also contains an integrated circuit to support the one touch down feature of the driver side front door power window Remember that the passeng...

Page 591: ...dule or the power window switch as required If not OK replace the faulty motor 3 If the motor operates in both directions check the operation of the window glass and lift mechanism through its complete up and down travel There should be no binding or sticking of the window glass or lift mechanism through the entire travel range If not OK refer to Group 23 Body to check the win dow glass tracks and...

Page 592: ...cess the inside door latch release and lock linkage rods near the back of the inside door remote controls 6 Unsnap the plastic retainer clips from the inside door remote control ends of the latch release and lock linkage rods and remove the rod ends from the inside door remote controls 7 Unplug the wire harness connector from the rear door power window switch 8 Remove the trim panel from the rear ...

Page 593: ...ator service procedures REAR DOOR The rear door power window motor and mechanism is integral to the rear door power window regulator unit If the rear door power window motor or mech anism is faulty or damaged the entire power window regulator unit must be replaced Refer to Group 23 Body for the rear door window regulator service procedures Fig 7 Rear Door Power Window Switch Remove Install 1 REAR ...

Page 594: ...he heating grid receives fused battery current through the rear window defogger relay only when the rear window defogger system is turned on Refer to Group 8N Electrically Heated Systems for more information on the rear window defogger system Following are general descriptions of the major components in the power mirror system Refer to the owner s manual in the vehicle glove box for more informati...

Page 595: ...ver side front door trim panel and unplug the DDM wire harness connectors Connect the battery negative cable Turn the ignition switch to the On position Check for battery voltage at the fused ignition switch output circuit cavity of the 12 way DDM wire harness connector If OK replace the faulty DDM If not OK repair the open circuit to the power window circuit breaker in the junction block as requi...

Page 596: ...olate the battery negative cable 2 Using a trim stick or another suitable wide flat bladed tool gently pry around the perimeter edge of the switch to release the snap clips that secure the switch to the trim panel Fig 4 3 Pull the power mirror switch away from the trim panel far enough to access the wire harness con nector 4 Unplug the power mirror switch from the wire harness connector 5 Reverse ...

Page 597: ...l 11 Reverse the removal procedures to install Tighten the mounting screws to 2 2 N m 20 in lbs POWER MIRROR 1 Disconnect and isolate the battery negative cable 2 If the vehicle is so equipped remove the man ual window regulator crank handle with a removal tool Fig 7 3 Remove the screws that secure the front door trim panel to the inner door panel Fig 8 or Fig 9 4 Using a trim stick or another sui...

Page 598: ...h module or on the driver side only the stand alone power mirror switch 9 Set the front door trim panel aside 10 Remove the one screw that secures the front door flag trim to the inner door panel Fig 10 11 Using a trim stick or another suitable wide flat bladed tool gently pry the door flag trim away Fig 6 Door Module Remove Install 1 INSIDE DOOR LATCH AND LOCK REMOTE CONTROLS 2 CONNECTOR 1 RECEPT...

Page 599: ...the door while feeding the wire harness grommet and connector out through the hole from the inside of the door 16 Reverse the removal procedures to install Tighten the mirror mounting screws to 4 3 N m 38 in lbs Tighten the door trim mounting screws to 2 2 N m 20 in lbs Fig 10 Front Door Flag Trim Panel Remove Install 1 FRONT DOOR 2 DOOR FLAG TRIM PANEL 3 RETAINER 4 SCREW 5 UPPER SPEAKER WIRE HARN...

Page 600: ...ngine coolant temperature is high Head or park lamps are turned on with the igni tion switch Off and the driver side front door open Key is in the ignition switch with the ignition switch Off and the driver side front door open Low fuel warning lamp illumination less than about one eighth tank of fuel remaining Overhead console trip computer is reset The optional Sentry Key Immobilizer System SKIS...

Page 601: ...or the service procedures HEADLAMP SWITCH The headlamp switch is located in the instrument panel outboard of the steering column It closes a path to ground for the instrument cluster chime warning circuitry when the park or head lamps are on and the driver door jamb switch is closed driver door is open The headlamp switch opens the ground path when the headlamp switch is turned off The headlamp sw...

Page 602: ... with the key removed from the ignition lock cylinder If OK go to Step 3 If not OK replace the faulty ignition switch assembly 3 Check for continuity between the left front door jamb switch sense circuit cavity of the key in ignition switch wire harness connector and a good ground There should be continuity with the driver door open and no continuity with the driver door closed If OK see the diagn...

Page 603: ...ontinuity If OK go to Step 4 If not OK repair the open circuit as required 4 Unplug the driver seat belt switch wire har ness connector Check for continuity between the seat belt switch sense circuit cavity of the right instru ment cluster wire harness connector connector B and a good ground There should be no continuity If OK go to Step 5 If not OK repair the short circuit as required 5 Check for...

Page 604: ... outlined can generally be applied to either version Exceptions to this rule have been clearly identified as LHD or RHD if a special illustration or procedure is required OVERHEAD CONSOLE The overhead console for this model includes a mini trip computer an electronic compass and an outside ambient temperature thermometer The over head console also houses two front mounted and two rear mounted read...

Page 605: ...he compensating ability of the compass unit if placed on the roof panel Mag netic bit drivers used on the fasteners that hold the assembly to the roof header can also affect compass operation If the vehicle roof should become magne tized demagnetizing and calibration may be required to restore proper compass operation See Compass Calibration or Compass Demagnetizing in the Service Procedures secti...

Page 606: ...nt cluster over the Chrysler Collision Detection CCD data bus If the problem is a no display condition use the following procedures For circuit descriptions and diagrams refer to 8W 49 Overhead Console in Group 8W Wiring Diagrams 1 Check the fuses in the junction block and the Power Distribution Center PDC If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace...

Page 607: ...see the Trip Com puter Compass and Thermometer Display Module diagnosis in this group For circuit descriptions and diagrams refer to 8W 49 Overhead Console in Group 8W Wiring Diagrams SENSOR TEST 1 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable Unplug the temperature sensor wire harness connec tor 2 Measure the resistance of the temperature sen sor A...

Page 608: ...automatically updates the compass calibration while the vehicle is being driven This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use Do not attempt to calibrate the compass near large metal objects such as other vehicles large buildings or bridges NOTE Whenever the compass is calibrated manu ally the variation number ...

Page 609: ...d on the vehicle lengthwise from front to rear on the center line of the roof at the windshield header Fig 2 The pur pose of the paper is to protect the roof panel from scratches and to define the area to be demagnetized 7 Plug in the degaussing tool while keeping the tool at least 61 centimeters 2 feet away from the compass unit 8 Slowly approach the center line of the roof panel at the windshiel...

Page 610: ... harness connectors 5 Unplug the overhead console and push button module wire harness connectors from the trip com puter compass and thermometer display module 6 Remove the trip computer compass and ther mometer display module from the overhead console housing 7 Reverse the removal procedures to install Tighten the mounting screws to 2 2 N m 20 in lbs PUSH BUTTON MODULE 1 Remove the overhead conso...

Page 611: ...e door opener storage bin opening of the overhead con sole housing and push the door into the opening Guide the door into the opening so that the second pivot pin snaps into its pivot hole SUNGLASSES STORAGE BIN The sunglasses storage bin door and bin housing damper spring and latch are serviced only as a unit Remove the sunglasses storage bin module from the overhead console as follows 1 Remove t...

Page 612: ...sensor mounting screw to 3 4 N m 30 in lbs SPECIAL TOOLS COMPASS Fig 7 Ambient Temperature Sensor Remove Install 1 WIRE HARNESS 2 SCREW 3 SENSOR 4 RADIATOR SUPPORT CROSSMEMBER 5 CLIPS 6 HORN Degaussing Tool 6029 XJ OVERHEAD CONSOLE SYSTEMS 8V 9 REMOVAL AND INSTALLATION Continued ...

Page 613: ......

Page 614: ...R LIGHTER POWER OUTLET 8W 41 1 INSTRUMENT CLUSTER 8W 40 1 INTERIOR LIGHTING 8W 44 1 JUNCTION BLOCK 8W 12 1 OVERHEAD CONSOLE 8W 49 1 POWER DISTRIBUTION 8W 10 1 POWER DOOR LOCKS 8W 61 1 POWER MIRRORS 8W 62 1 POWER SEAT 8W 63 1 POWER WINDOWS 8W 60 1 REAR LIGHTING 8W 51 1 REAR WINDOW DEFOGGER 8W 48 1 SPLICE INFORMATION 8W 70 1 SPLICE LOCATIONS 8W 95 1 STARTING SYSTEM 8W 21 1 TRAILER TOW 8W 54 1 TRANSM...

Page 615: ......

Page 616: ... In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle it is impor tant to understand all of their features and charac teristics Diagrams are arranged such that the power B side of the circuit is placed near the top of the page and the ground B side of the circuit is placed near the bottom of the page All switches components and modules are shown in the at ...

Page 617: ...The System shown here is an EXAMPLE ONLY It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION 8W 01 2 8W 01 GENERAL INFORMATION XJ DESCRIPTION AND OPERATION Continued ...

Page 618: ...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 ...

Page 619: ...R CODE CHART COLOR CODE COLOR STANDARD TRACER COLOR BL BLUE WT BK BLACK WT BR BROWN WT DB DARK BLUE WT DG DARK GREEN WT GY GRAY BK LB LIGHT BLUE BK LG LIGHT GREEN BK OR ORANGE BK PK PINK BK or WT RD RED WT TN TAN WT VT VIOLET WT WT WHITE BK YL YELLOW BK WITH TRACER CIRCUIT IDENTIFICATION CODE CHART CIRCUIT FUNCTION A BATTERY FEED B BRAKE CONTROLS C CLIMATE CONTROLS D DIAGNOSTIC CIRCUITS E DIMMING ...

Page 620: ... throughout the wir ing diagrams These symbols are consistent with those being used around the world GROUP TOPIC 8W 01 thru 8W 09 General Information and Diagram Overview 8W 10 thru 8W 19 Main Sources of Power and Vehicle Grounding 8W 20 thru 8W 29 Starting and Charging 8W 30 thru 8W 39 Powertrain Drivetrain Systems 8W 40 thru 8W 49 Body Electrical items and A C 8W 50 thru 8W 59 Exterior Lighting ...

Page 621: ...Wiring Diagram Symbols 8W 01 6 8W 01 GENERAL INFORMATION XJ DESCRIPTION AND OPERATION Continued ...

Page 622: ...ation charts in Section 8W 90 reference the illustration number for components and connectors 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 gram pages SPLICE LOCATIONS Splice Location charts in Section 8W 70 show the entire splice and provide references to other sections the splice serves Section 8W ...

Page 623: ...the vehicle DIAGNOSIS AND TESTING TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary These tools are listed and explained below Jumper Wire This is a test wire used to con nect two points of a circuit It can be used to bypass an open in a circuit WARNING NEVER USE A JUMPER WIRE ACROSS A LOAD SUCH AS A MOTOR CONNECTED BETWEEN A BATTERY ...

Page 624: ...e other lead of the voltmeter to the selected test point The vehicle ignition may need to be turned ON to check voltage Refer to the appropri ate test procedure TESTING FOR CONTINUITY 1 Remove the fuse for the circuit being checked or disconnect the battery 2 Connect one lead of the ohmmeter to one side of the circuit being tested Fig 5 3 Connect the other lead to the other end of the circuit bein...

Page 625: ...m 6 Verify proper operation For this step check for proper operation of all items on the repaired circuit Refer to the wiring diagrams SERVICE PROCEDURES WIRING REPAIR When replacing or repairing a wire it is important that the correct gage be used as shown in the wiring diagrams The wires must also be held securely in place to prevent damage to the insulation 1 Disconnect battery negative cable 2...

Page 626: ... BETTS CONNECTORS 1 Disconnect battery 2 Disconnect the connector from its mating half component 3 Push in the two lock tabs on the side of the connector Fig 10 4 Insert the probe end of special tool 6934 into the back of the connector cavity Fig 11 5 Grasp the wire and tool 6934 and slowly remove the wire and terminal from the connector Fig 8 Molex Connector Repair 1 CONNECTOR 2 SPECIAL TOOL 6742...

Page 627: ...al as necessary 6 When re assembling the connector the locking wedge must be placed in the locked position to pre vent terminal push out CONNECTOR REPLACEMENT 1 Disconnect battery 2 Disconnect the connector that is to be repaired from its mating half component 3 Remove the connector locking wedge if required Fig 15 4 Position the connector locking finger away from the terminal using the proper pic...

Page 628: ...rder as was done on the harness side of the repair Allow extra length for soldered connections Check that the overall length is the same as the original Fig 18 7 Remove 1 inch of insulation from each wire 8 Place a piece of heat shrink tubing over one side of the wire Be sure the tubing will be long enough to cover and seal the entire repair area 9 Spread the strands of the wire apart on each part...

Page 629: ...es 11 Push the two ends of wire together until the strands of wire are close to the insulation 12 Twist the wires together 13 Solder the connection together using rosin core type solder only Do not use acid core solder 14 Center the heat shrink tubing over the joint and heat using a heat gun Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing 15 Inser...

Page 630: ...r only Do not use acid core solder 7 Tape the diode to the harness using electrical tape making sure the diode is completely sealed from the elements 8 Re connect the battery and test affected sys tems SPECIAL TOOLS WIRING TERMINAL Fig 22 Diode Identification 1 CURRENT FLOW 2 BAND AROUND DIODE INDICATES CURRENT FLOW 3 DIODE AS SHOWN IN THE DIAGRAMS Probing Tool Package 6807 Terminal Pick 6680 Term...

Page 631: ......

Page 632: ...rs 8W 61 Duty Cycle Evap Purge Solenoid 8W 30 Engine Control Module 8W 30 Engine Coolant Temperature Gauge 8W 40 Engine Coolant Temperature Sensors 8W 30 Engine Oil Pressure Sensor 8W 30 Engine Speed Sensor 8W 30 Component Page Engine Starter Motor Relay 8W 21 Engine Starter Motor 8W 21 Evap Leak Detection Pump 8W 30 Extended Idle Switch 8W 30 Fog Lamp Relays 8W 50 Fog Lamps 8W 50 51 Forward Rearw...

Page 633: ...elay 8W 48 Rear Window Defogger Switch 8W 48 Rear Window Defogger 8W 48 Component Page Rear Wiper Motor 8W 53 Rear Wiper Washer Switch 8W 53 Repeater Lamps 8W 50 52 Seat Belt Switch 8W 40 Seat Heat Interface Module 8W 63 Sentry Key Immobilizer Module 8W 39 Shift Lock Solenoid 8W 31 Side Marker Lamps 8W 50 52 Speakers 8W 47 Speed Control Switches 8W 33 Speedometer 8W 40 Splice Information 8W 70 Tac...

Page 634: ...se 15 JB 8W 10 20 26 Fuse 15 PDC 8W 10 14 24 Fuse 16 PDC 8W 10 12 14 27 30 Component Page Fuse 17 JB 8W 10 15 16 Fuse 17 PDC 8W 10 12 27 Fuse 18 JB 8W 10 15 16 Fuse 18 PDC 8W 10 23 Fuse 19 JB 8W 10 18 Fuse 19 PDC 8W 10 12 14 28 29 32 Fuse 20 JB 8W 10 20 26 Fuse 20 PDC 8W 10 12 14 31 32 Fuse 21 JB 8W 10 20 26 Fuse 21 PDC 8W 10 19 23 34 Fuse 22 JB 8W 10 18 Fuse 22 PDC 8W 10 12 14 31 34 Fuse 23 PDC 8...

Page 635: ... 5 6 40A 12 4 5 40A 11 3 4 50A 10 2 3 40A 9 1 2 40A 8 21 15 16 17 18 19 20 22 23 24 25 26 27 28 15 14 13 20A 12 40A 11 10 20A 9 20A F21 15A F27 10A 1 2 F24 F23 15A 4 3 F26 20A F20 15A F17 20A F16 15A F19 20A F25 15A 5 6 F22 15A 8 7 9 10 12 11 14 13 15 16 18 17 20 19 21 22 24 23 GENERATOR BATTERY M1 M2 30A 6 9 8 10 7 1 3 5 4 2 12 14 15 13 11 17 20 18 19 16 FAN RADIATOR RELAY RELAY OXYGEN SENSOR DOW...

Page 636: ...16 17 20A 20A 18 19 15A A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A17 16RD BK A3 14RD WT A17 16RD BK 26 10A F1 20DB GY A17 16RD BK 20 15A F142 18DG WT A999 16RD 21 15A A61 14DG BK A0 6RD 22 15A F32 20PK DB A0 6RD 23 24 15A F61 20WT OR A0 6RD 25 20A F75 16VT A0 6RD A41 16YL A0 6RD ABS 27 DRL 30A A16 14RD LG A0 6RD 15A A142 18DG O...

Page 637: ...20 B16 B19 FUNCTION CAVITY CIRCUIT G19 20LG OR ABS WARNING INDICATOR DRIVER T141 20YL IGNITION SWITCH OUTPUT START C8 PARK NEUTRAL POSITION SWITCH SENSE T41 20BK WT C10 ENGINE STARTER MOTOR RELAY OUTPUT T40 16BR PARK NEUTRAL POSITION SWITCH SENSE FUSED B ENGINE STARTER MOTOR RELAY F45 20YL RD C9 C7 C6 C8 FUNCTION CAVITY CIRCUIT A41 16YL FUSED B RELAY BRAKE ANTI LOCK CONTROLLER RELAY AUTOMATIC SHUT...

Page 638: ...4 16RD GY FOG LAMP RELAY OUTPUT NO 1 L139 20VT B9 FUSED HEADLAMP SWITCH OUTPUT L77 20BR YL B6 B8 B10 B7 B10 FUSED HEADLAMP SWITCH OUTPUT L77 20BR YL Z1 20BK GROUND L33 20RD WT FUSED B G34 16RD GY HIGH BEAM INDICATOR DRIVER FUSED B F61 20WT OR GROUND Z1 20BK L92 20PK FOG LAMP SWITCH OUTPUT B12 B14 B11 B13 B15 FUNCTION CAVITY CIRCUIT FUNCTION CAVITY CIRCUIT RELAY PUMP FUEL DRL L39 20LB FOG LAMP RELA...

Page 639: ...ATOR FAN RELAY CIRCUIT CAVITY FUNCTION FUSED B F99 18RD FUSED B F99 18RD C17 C20 C16 C18 K74 18BR VT OXYGEN SENSOR DOWNSTREAM RELAY CONTROL A242 18VT OR OXYGEN SENSOR 1 2 DOWNSTREAM F26 18PK OR FUSED IGNITION SWITCH OUTPUT ST RUN C19 F26 18PK OR FUSED IGNITION SWITCH OUTPUT ST RUN DOWNSTREAM SENSOR OXYGEN RELAY GAS C13 2 5L 4 0L A T FOG EXCEPT DRL 4 0L A T DRL A T EXCEPT FOG M T FUSED IGNITION SWI...

Page 640: ...OR RELAY CONTROLLER ANTI LOCK BRAKE A FUSES 14 7 6 7 20A 13 5 6 30A 12 4 5 40A 11 3 4 30A 10 2 3 50A 9 1 2 50A 8 21 15 16 17 18 19 20 22 23 24 25 26 27 28 15 13 40A 12 40A 10 40A 9 50A F21 20A F27 10A 1 2 F24 10A F23 15A 4 3 F26 20A F20 20A F16 15A F19 15A F25 15A 5 6 F22 20A 8 7 9 10 12 11 14 13 15 16 18 17 20 19 21 22 24 23 GENERATOR BATTERY M1 M2 30A 8 20A 14 40A 11 F17 F18 30A FOG LAMP RELAY X...

Page 641: ...30A A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A7 10RD BK 30A A3 14RD WT A0 6RD 26 20A F34 18TN BK A0 6RD 20 20A A17 18RD BK A0 6RD 21 20A F142 16DG OR A142 16DG OR 22 20A F75 16VT A0 6RD 23 15A L9 20BK PK A0 6RD 24 10A F16 16RD LG A16 12RD LG 25 15A F61 20WT OR A0 6RD 27 10A F1 20DB GY A17 18RD BK M1 20PK A17 16RD BK 40A F141 12LG RD A...

Page 642: ...RESSOR CLUTCH RELAY OUTPUT C3 16DB BK FUNCTION CAVITY CIRCUIT B17 F15 18DB WT FUSED IGNITION SWITCH OUTPUT RUN ABS RELAY CONTROL C5 C2 C6 C4 AUTOMATIC SHUT DOWN RELAY OUTPUT A142 18DG OR A16 12RD LG FUSED B K51 20DB YL AUTOMATIC SHUT DOWN RELAY CONTROL FUNCTION CAVITY CIRCUIT A16 12RD LG FUSED B CLUTCH COMPRESSOR A C RELAY RELAY AUTOMATIC SHUT DOWN RELAY CONTROLLER ANTI LOCK BRAKE A142 16DG OR AUT...

Page 643: ...20BK YL B13 B15 B11 B14 B12 Z1 20BK GROUND F61 20WT OR FUSED B L39 20LB FOG LAMP RELAY OUTPUT FUNCTION CAVITY CIRCUIT RADIATOR FAN RELAY C14 C12 C10 C13 C11 RADIATOR FAN RELAY OUTPUT C25 12LB F141 12LG RD FUSED B C27 20DB PK RADIATOR FAN RELAY CONTROL FUNCTION CAVITY CIRCUIT A142 18DG OR AUTOMATIC SHUT DOWN RELAY OUTPUT RELAY HEATER FUEL RELAY LAMP FOG MOTOR STARTER ENGINE RELAY ENGINE STARTER MOT...

Page 644: ...T 14 A3 23 16 20A FUSE 10 A4 12 BK PK F141 12 LG RD FAN RADIATOR TO RELAY TO A C COMPRESSOR RD BK 16 A17 CLUTCH RELAY IN PDC A17 16 RD BK 27 FUSE TO TO ENGINE STARTER YL 16 A41 MOTOR RELAY TO BLOCK JUNCTION IN PDC IN PDC 11 FUSE 30A 17 24 C6 C100 C2 IN PDC MODULE LAMP RUNNING DAYTIME D1 C100 7 14 30A FUSE 8 TO RD LG 14 A16 IN PDC RELAY AUTOMATIC SHUT DOWN D5 C100 C201 11 7 C202 8 C209 MOTOR RELAY ...

Page 645: ... 20A FUSE 26 A4 A3 A10 A9 23 FUSE 15A SWITCH F32 20 PK DB TO BRAKE LAMP S301 TO VT 16 F75 S218 TO F34 18 TN BK RELAY F61 20 WT OR TO FOG LAMP NO 2 IN PDC IN PDC F8 C100 ABS ABS RELAY OXYGEN SENSOR DOWNSTREAM E6 C100 A18 LHD RHD B11 C100 F5 FLASHER C4 C100 C200 14 21 C204 LHD RHD TO HEADLAMP SWITCH LHD EXCEPT BUILT UP EXPORT OTHER 4 0L F75 16 VT F75 14 VT IN PDC DATA TO CONNECTOR C107 14 MODULE TO ...

Page 646: ...LG 12 A16 A1 12 RD SWITCH IGNITION TO TO S151 A7 10 RD BK BLOCK JUNCTION TO A2 12 PK BK SWITCH IGNITION TO TO BLOWER RD LG 12 A111 24 17 40A FUSE 11 12 FUSE 40A 18 25 A10 12 RD DG TO BRAKE ANTI LOCK CONTROLLER A61 14 LG RD FUEL HEATER RELAY TO TO MOTOR STARTER ENGINE RELAY IN PDC C2 C100 IN PDC C6 C100 D1 C100 ABS D5 C100 7 C202 C201 11 8 C209 MOTOR RELAY LHD RHD DELAY TO HEADLAMP MODULE 8W 20 4 8...

Page 647: ...0 12 RD DB FROM FUSE 12 PDC 20 27 A23 A24 A18 A17 BLOCK 26 19 13 FUSE 40A LG RD 12 F141 TO RADIATOR FAN RELAY IN PDC FUSE 27 TO RD BK 18 A17 A17 16 RD BK CLUTCH RELAY F61 20 WT OR TO FOG LAMP RELAY IN PDC IN PDC IN PDC 30A 21 28 A4 12 BK PK TO JUNCTION BLOCK FUSE 15 SWITCH MERCURY F8 C100 COMBINATION ABS E6 C100 A18 C100 B11 F5 FLASHER C4 C100 21 C204 C200 14 F75 14 VT F75 16 VT LHD RHD LHD RHD 8W...

Page 648: ... 20 GY BK C100 G9 20 GY BK 66 C201 S211 S210 FROM TO S200 15A FUSE 17 BLOCK JUNCTION L1 C4 18 FUSE 10A 25A 28 BREAKER CIRCUIT CIRCUIT BREAKER 30 20A RUN A22 G108 G9 20 GY BK A31 12 BK WT 4 ACC 3 LOCK 0 OFF 2 RUN 1 START SWITCH IGNITION S207 Z1 14 BK 86 ST A41 CIGAR LIGHTER RELAY C203 13 LHD RHD RHD LHD C201 10 85 E2 A14 RHD LHD WARNING 8W 10 2 8W 10 11 8W 10 17 8W 40 9 8W 40 9 8W 10 17 8W 10 17 8W...

Page 649: ... 20 GY BK A14 C100 G9 20 GY BK 66 C201 S211 S210 FROM TO S200 15A FUSE 17 BLOCK JUNCTION L1 C4 18 FUSE 10A 25A 28 BREAKER CIRCUIT CIRCUIT BREAKER 30 20A RUN A22 G108 G9 20 GY BK 10 C201 A31 12 BK WT 4 ACC 3 LOCK 0 OFF 2 RUN 1 START SWITCH IGNITION S207 Z1 14 BK 86 ST A41 CIGAR LIGHTER RELAY RHD LHD C203 13 LHD RHD E2 RHD 85 LHD WARNING 8W 10 7 8W 10 13 8W 10 17 8W 40 10 8W 40 10 8W 10 17 8W 10 17 ...

Page 650: ... IGNITION C1 9 3 0 2 1 4 A21 12 DB BK LB 20 G16 RHD LHD C306 2 C203 3 LHD RHD 4 C203 B C318 G16 18 BK LB 2 LHD RHD BK LB 20 G16 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD C1 6 0 1 2 8 C2 C2 8 SWITCH WINDOW LOCK POWER PASSENGER LB 20 G26 LB 20 G26 G26 20 LB BK LB 20 G16 G16 20 BK LB SWITCH JAMB DOOR DRIVER SWITCH JAMB DOOR DRIVER OPTIONS FULL OPTIONS FULL 8W 10 15 8W 10 16 8W 12 25 8W 12 26 8W 12 15 8W 12...

Page 651: ... OR 12 A22 A41 14 YL 4 1 2 0 3 10 C1 3 0 2 1 4 C1 3 C1 4 PK BK 12 A2 BATT A2 C201 63 10A FUSE 19 M1 C4 LHD RHD RHD LHD YL 14 A41 SPARE FUSE 24 85 8W 48 2 8W 48 3 8W 12 22 8W 12 23 8W 12 17 8W 12 18 8W 12 2 8W 12 22 8W 12 23 8W 12 25 8W 12 26 8W 10 15 8W 10 16 8W 10 15 8W 10 16 8W 12 19 8W 12 20 8W 12 22 8W 12 23 8W 10 18 8W 10 POWER DISTRIBUTION XJ J008W 7 XJI01018 ...

Page 652: ...CONTROL MODULE F16 16 RD LG A142 16 DG OR S137 A142 DG OR 16 A142 DG OR A142 16 16 A142 DG OR 9 PUMP INJECTION FUEL 16 DG OR ASSEMBLY A14 A13 21 FUSE 20A A142 16 DG OR DOWN C6 22 C1 2 C1 12 C3 A142 16 DG OR ENGINE CONTROL MODULE 2 C1 28 C1 A142 18 DG OR A142 18 DG OR C11 C13 B5 B3 RELAY CLUTCH COMPRESSOR A C RADIATOR FAN RELAY IN PDC IN PDC 8W 10 7 8W 10 13 8W 30 25 8W 30 22 8W 10 7 8W 30 23 8W 30...

Page 653: ...ENTER 30 87 87 30 86 M6 C4 1 LIGHTER CIGAR 50 C201 F30 16 RD DG RD 20 X2 C2 4 S131 LHD RHD X2 20 DG RD X2 20 DG RD RD 16 F30 LOW NOTE HORN HIGH NOTE HORN 85 F30 16 RD 8W 12 2 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 12 27 8W 12 21 8W 12 21 8W 12 5 8W 12 5 8W 12 19 8W 12 20 8W 10 11 8W 10 2 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 10 20 8W 10 POWER DISTRIBUTION GAS XJ J008W 7 XJI01020 ...

Page 654: ...LHD C202 7 LG RD 12 F141 IN PDC FAN RADIATOR RELAY LB 12 C25 RD LG 12 A111 RADIATOR FAN MOTOR A111 12 RD LG 8 C209 RELAY MOTOR BLOWER 1 C1 12 DG A MOTOR BLOWER 8W 10 11 8W 10 2 8W 42 9 8W 42 9 8W 42 2 8W 42 3 8W 42 4 8W 42 5 8W 42 2 8W 42 3 8W 42 4 8W 42 5 XJ 8W 10 POWER DISTRIBUTION GAS 8W 10 21 XJI01021 J008W 7 ...

Page 655: ... C1 RD WT A3 DAYTIME RUNNING LAMP MODULE 6 D1 C100 A3 RD WT CENTER DISTRIBUTION POWER BATT A0 30A FUSE 7 6 RD WT 14 A3 RHD OTHER 4 0L A17 16 RD BK 14 14 14 A C COMPRESSOR CLUTCH RELAY IN PDC 6 F1 20 DB GY MODULE IMMOBILIZER KEY SENTRY 8W 42 7 8W 50 8 8W 50 9 8W 50 2 8W 50 3 8W 50 18 8W 10 2 8W 10 11 8W 42 7 8W 39 4 8W 39 5 8W 10 22 8W 10 POWER DISTRIBUTION GAS XJ J008W 7 XJI01022 ...

Page 656: ...REAM 15A FUSE 18 A19 A20 A999 16 RD 1 C107 A142 18 DG OR A142 18 DG OR S109 1 COIL IGNITION A142 18 DG OR A142 DG OR 18 18 DG OR A142 FUEL INJECTOR NO 6 NO 5 INJECTOR FUEL 1 1 FUEL INJECTOR NO 3 NO 4 INJECTOR FUEL FUEL INJECTOR NO 2 NO 1 INJECTOR FUEL 1 18 DG OR A142 DG OR 18 A142 S113 4 0L 4 0L A142 18 DG OR 1 1 DG OR 18 A142 A142 18 DG OR 1 2 5L 4 0L DG OR 18 A142 RAIL COIL 2 8W 30 2 8W 10 2 8W ...

Page 657: ...AR 4 C326 3 C312 C310 C15 12 BK WT 7 8 FUSE 30A 14 A3 RD WT D1 C100 A3 RD WT C1 8 SWITCH HEADLAMP A3 14 RD WT 2 HEADLAMP DELAY MODULE C111 2 FUEL HEATER RELAY IN PDC LG RD 14 A61 A41 16 YL ENGINE STARTER MOTOR RELAY IN PDC BK WT 12 C15 BR 14 T40 14 14 13 20A FUSE 7 6 8W 30 24 8W 10 7 8W 10 13 8W 21 6 8W 12 2 8W 48 2 8W 48 3 8W 48 2 8W 48 3 8W 50 3 8W 50 9 8W 12 17 8W 12 18 8W 12 17 8W 12 18 8W 30 ...

Page 658: ...ELAY BK PK 12 A4 C2 1 BLOCK JUNCTION BATT A0 20A FUSE 10 23 16 C6 C7 POWER DISTRIBUTION CENTER 30 87 BRAKE ANTI LOCK CONTROLLER 2 ENGINE STARTER MOTOR RELAY A41 16 YL IN PDC C15 12 BK WT 17 24 11 FUSE 30A ABS ABS 8W 21 2 8W 21 3 8W 21 4 8W 21 5 8W 48 2 8W 48 3 8W 48 2 8W 48 3 8W 12 2 8W 10 11 8W 10 2 8W 35 2 8W 12 17 8W 12 18 8W 12 17 8W 12 18 8W 21 2 8W 21 3 8W 21 4 8W 21 5 XJ 8W 10 POWER DISTRIB...

Page 659: ...ORN BLOCK JUNCTION A111 12 RD LG D5 C100 C201 11 4 22 RHD LHD 7 C202 X2 20 DG RD X2 20 DG RD LHD 50 C201 RHD 40A FUSE 13 26 19 LG RD 12 F141 C10 C14 RELAY FAN RADIATOR IN PDC 1 C25 12 LB RADIATOR FAN MOTOR LOW NOTE HORN HIGH NOTE HORN ABS ABS RELAY MOTOR BLOWER C209 8 85 8W 35 3 8W 41 2 8W 41 3 8W 10 7 8W 10 13 8W 12 19 8W 12 20 8W 12 5 8W 12 5 8W 12 21 8W 12 21 8W 12 27 8W 41 2 8W 41 3 8W 41 2 8W...

Page 660: ...0 M1 A C207 M1 18 PK C208 A PK 18 M1 M1 20 PK A LAMP CARGO C3 3 PK 20 M1 C 8W 10 28 TO S347 4 0L PK 18 M1 C314 5 LHD RHD RHD LHD SWITCH SWITCH MERCURY LAMP UNDERHOOD S361 SKIM EXCEPT SKIM 20A FUSE 17 A22 A21 RD 18 F99 C16 IN PDC RELAY DOWNSTREAM SENSOR OXYGEN F99 18 RD C11 OXYGEN SENSOR RELAY IN PDC UPSTREAM 4 0L 8W 47 2 8W 47 3 8W 47 9 8W 47 10 8W 12 2 8W 31 4 8W 10 2 8W 10 11 8W 40 2 8W 44 6 8W ...

Page 661: ... DATA LINK CONNECTOR 16 HEADLAMP SWITCH 4 C1 LHD RHD S218 F34 18 TN BK SWITCH M1 20 PK LAMP VANITY VISOR LEFT 18 TN BK A18 C100 E6 C100 18 TN BK F34 F34 OTHERS OPTIONS FULL RIGHT VISOR VANITY LAMP M1 20 PK S361 OTHERS SKIM MIDLINE BASE POLICE LAMP DOME 2 M1 20 PK A A 8W 49 2 8W 49 3 8W 44 5 8W 49 2 8W 49 3 8W 10 11 8W 10 2 8W 50 2 8W 30 19 8W 30 19 8W 50 2 8W 44 5 8W 44 5 8W 44 5 8W 10 28 8W 10 PO...

Page 662: ... RELAY OPTIONS LAMP VANITY VISOR RIGHT LAMP VANITY VISOR LEFT A18 C100 E6 C100 F34 18 TN BK LHD RHD FULL S361 SKIM OTHERS M1 20 PK OTHERS M1 20 PK LAMP DOME 2 MIDLINE BASE POLICE BATT A0 CENTER DISTRIBUTION POWER 20A FUSE 19 A17 A18 A4 A3 DIESEL GAS 20A FUSE 26 A A 8W 49 2 8W 49 3 8W 44 5 8W 49 2 8W 49 3 8W 30 19 8W 30 34 8W 50 3 8W 47 4 8W 44 5 8W 44 5 8W 44 5 8W 10 11 8W 10 13 8W 10 2 XJ 8W 10 P...

Page 663: ...C DOME LAMPS OVERHEAD MODULE 2 S347 M1 20 PK M1 20 PK RHD LHD LHD RHD PK 18 M1 C314 5 SWITCH SWITCH M1 20 PK M1 20 PK FULL OPTIONS LAMP VANITY VISOR LEFT LAMP VANITY VISOR RIGHT SWITCH MERCURY LAMP UNDERHOOD S214 RADIO 7 C2 PK 20 M1 M1 20 PK PK 20 M1 LAMP DOME 2 OTHERS MIDLINE BASE POLICE A A 8W 12 2 8W 10 7 8W 10 13 8W 40 2 8W 44 7 8W 44 7 8W 49 2 8W 49 3 8W 49 2 8W 49 3 8W 44 8 8W 44 9 8W 44 5 8...

Page 664: ...11 A12 22 FUSE 15A C1 C2 2 COMBINATION FLASHER BATT A0 CENTER DISTRIBUTION POWER 15A FUSE 20 A15 A16 BK PK 20 L9 F5 L9 20 BK PK LHD RHD 22 C204 FUEL PUMP RELAY IN PDC A61 14 DG BK C200 13 B11 RHD LHD 8W 30 3 8W 30 4 8W 30 3 8W 30 4 8W 52 2 8W 52 3 8W 10 7 8W 10 2 8W 30 3 8W 30 4 XJ 8W 10 POWER DISTRIBUTION GAS 8W 10 31 XJI01031 J008W 7 ...

Page 665: ...OMPRESSOR CLUTCH LHD RHD 24 C204 L50 20 WT TN 2 WT TN 20 L50 RD BK 16 A17 A17 18 RD BK DB GY 20 F1 6 F1 20 DB GY CLUTCH RELAY COMPRESSOR A C IN PDC PK DB 20 F32 E10 C100 L50 20 WT TN ENGINE CONTROL MODULE 20 C1 ABS OTHER SENTRY KEY IMMOBILIZER MODULE 1 C333 A6 A5 25 FUSE 15A FOG LAMP IN PDC RELAY B12 B11 F61 20 WT OR L39 20 LB 2 8 C106 L39 20 LB L50 18 WT TN 2 RIGHT FOG LAMP L39 20 LB S106 RHD LHD...

Page 666: ...T 16 F75 F75 16 VT VT 16 F75 VT 16 F75 S301 AMPLIFIER POWER 1 C2 C2 2 RHD LHD 24 C204 C204 21 LHD RHD 14 C200 F61 20 WT OR NO 2 FOG LAMP RELAY IN PDC PK DB 20 F32 WT TN 20 L50 F8 C100 C4 C100 E1 C100 B4 C100 RHD LHD 3 L50 18 WT TN 1 C333 L50 18 DG WT L50 20 WT TN L50 18 WT TN L39 20 LB 8 C106 2 LEFT FOG LAMP LAMP FOG RIGHT 2 L39 20 LB L39 20 LB S106 F75 14 VT F75 16 VT 8W 10 2 8W 10 11 8W 33 4 8W ...

Page 667: ...LAY AMPLIFIER POWER S156 S301 S137 C200 14 21 C204 C4 C100 A142 16 DG OR A142 16 DG OR F142 16 DG OR F142 16 DG OR F142 18 DG OR F142 18 DG OR F75 16 VT F75 16 VT F75 16 VT F75 14 VT F75 16 VT F75 16 VT AUTOMATIC SHUT RELAY DOWN LHD RHD 3 8W 10 19 8W 10 7 8W 10 7 8W 10 13 8W 30 24 8W 30 26 8W 30 25 8W 47 2 8W 47 3 8W 10 19 8W 30 22 8W 10 34 8W 10 POWER DISTRIBUTION DIESEL XJ J008W 7 XJI01034 ...

Page 668: ...TER BATT A0 A9 A10 23 FUSE 15A BK PK 20 L9 L9 20 BK PK 2 COMBINATION FLASHER RELAY LAMP FOG IN PDC WT OR 20 F61 B11 C100 F5 C100 LHD RHD LEFT FOG LAMP RIGHT FOG LAMP 2 2 L39 20 LB 8W 10 7 8W 10 13 8W 52 4 8W 50 17 8W 50 17 8W 50 17 XJ 8W 10 POWER DISTRIBUTION DIESEL 8W 10 35 XJI01035 J008W 7 ...

Page 669: ......

Page 670: ... 12 21 Instrument Cluster 8W 12 8 9 13 17 18 28 29 Junction Block 8W 12 2 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Left City Lamp 8W 12 11 12 Left Courtesy Lamp 8W 12 28 29 30 Left Front Park Turn Signal Lamp No 1 8W 12 10 Left Front Park Turn Signal Lamp No 2 8W 12 10 Left Headlamp 8W 12 6 7 Left Headlamp Leveling Motor 8W 12 7 Left Heated Seat Sw...

Page 671: ...A 22 20A 8 21 15A 10A 16 10A 3 5 10A 18 4 10A 17 15A 10A 19 5A 6 15A 20 10A 7 C1 C2 C8 C4 C5 C7 C6 C9 C3 1 25A 25A 2 25A 15 SPARE RELAY 30 28 29 10A 10A 25A 25A 20A CIGAR LIGHTER RELAY HORN WINDOW REAR RELAY RELAY DEFOGGER 10A 15A 8W 12 2 8W 12 JUNCTION BLOCK XJ J008W 7 XJI01202 ...

Page 672: ... 21 22 23 24 25 26 27 L4 16VT WT 10A L44 20VT RD L4 16VT WT A22 12BK OR A22 12BK OR A22 12BK OR A41 14YL A7 10RD BK A7 10RD BK A7 10RD BK A4 12BK PK INTERNAL A31 12BK WT A31 12BK WT A21 12DB L3 16RD OR L7 18BK YL INTERNAL 10A 25A F35 16RD 15A X12 16RD WT 10A F45 20YL RD 15A A6 20RD OR 15A 20A V23 18BR PK 15A F15 20DB WT 10A F14 18LG YL 10A F23 18DB YL 10A L34 20RD OR 10A 10A F83 18YL DG A22 12BK O...

Page 673: ...EFOGGER RELAY CONTROL FUSED B HORN RELAY OUTPUT 87A GROUND CIGAR LIGHTER RELAY OUTPUT FUSED IGNITION SWITCH OUTPUT RUN ACC FUSED B F30 16RD A31 12BK WT INTERNAL 87 86 85 30 FUNCTION CAVITY CIRCUIT 87A INTERNAL INTERNAL CIRCUIT BREAKERS FEED CIRCUIT FUSED CIRCUIT AMPS CB NO V6 16DB 20A F37 14RD LB 25A INTERNAL 25A A7 10RD BK A31 12BK WT A31 12BK WT 30 29 28 RELAY LIGHTER CIGAR HORN RELAY DEFOGGER W...

Page 674: ...UTLET M5 C4 RD LB 16 F38 87 30 25A FUSE 2 M6 C4 RD 16 F30 F30 16 RD LIGHTER CIGAR 1 CIGAR LIGHTER RELAY 65 C201 C201 50 LHD RHD LHD RHD 8W 12 2 8W 10 20 8W 10 26 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 41 2 8W 41 3 XJ 8W 12 JUNCTION BLOCK 8W 12 5 XJI01205 J008W 7 ...

Page 675: ...3 C201 16 L3 16 RD OR S213 RD OR 16 L3 LHD RHD RD OR 20 L34 GAS EXCEPT DRL IN PDC NO 1 RELAY LAMP FOG 12 L33 20 RD WT L33 20 RD BEAM B10 C106 EXCEPT BUILT UP EXPORT 8W 12 2 8W 50 4 8W 50 5 8W 50 6 8W 50 7 8W 50 4 8W 50 5 8W 50 6 8W 50 7 8W 50 4 8W 50 5 8W 50 6 8W 50 7 8W 50 4 8W 50 5 8W 50 6 8W 50 7 8W 50 14 8W 50 15 8W 12 6 8W 12 JUNCTION BLOCK XJ J008W 7 XJI01206 ...

Page 676: ...1 S162 S163 L43 18 VT L44 18 VT RD L43 18 VT VT RD 18 L44 BUILT UP EXPORT EXPORT BUILT UP EXCEPT UP EXPORT BUILT EXPORT BUILT UP EXCEPT F6 RHD LHD L44 20 VT RD C100 EXPORT BUILT UP EXCEPT UP EXPORT BUILT DRL OTHER VT RD 18 L44 10 MODULE LAMP RUNNING DAYTIME HEADLAMP L43 18 VT F6 B12 L43 18 VT L44 18 VT RD L44 18 VT RD L44 20 VT RD 8W 12 2 8W 50 4 8W 50 5 8W 50 6 8W 50 7 8W 50 4 8W 50 5 8W 50 6 8W ...

Page 677: ...W REAR 4 DEFOGGER 3 C1 INSTRUMENT CLUSTER HEATER A C 7 CONTROL SWITCH 3 REAR WASHER TN 20 E1 C1 4 IDLE EXTENDED SWITCH POLICE PACKAGE OTHERS WIPER ILLUMINATION SWITCH CASE TRANSFER S215 OR 20 E2 4 EXPORT SWITCH LAMP FOG REAR BUILT UP CONTROL HEATER A C HEATER ONLY C1 8W 12 2 8W 50 2 8W 50 3 8W 47 2 8W 47 9 8W 44 2 8W 44 3 8W 48 2 8W 40 15 8W 42 4 8W 53 4 8W 53 5 8W 30 17 8W 44 2 8W 44 3 8W 44 2 8W...

Page 678: ...CLUSTER HEATER A C 7 CONTROL SWITCH 3 REAR WASHER JUNCTION BLOCK 6 FUSE 5A S2 C4 E2 20 OR S1 C4 E1 20 TN HEADLAMP SWITCH 1 C1 WIPER SWITCH FOG REAR 4 LAMP OR 20 E2 BUILT UP EXPORT ILLUMINATION SWITCH CASE TRANSFER CONTROL HEATER A C HEATER ONLY C1 8W 44 4 8W 47 3 8W 47 10 8W 44 4 8W 48 3 8W 40 15 8W 42 5 8W 53 6 8W 53 7 8W 12 2 8W 50 2 8W 50 3 8W 51 12 8W 44 4 8W 42 3 XJ 8W 12 JUNCTION BLOCK RHD 8...

Page 679: ...NECTOR S340 LAMP STOP TAIL LEFT 2 OTHERS TOW TRAILER L77 18 BR YL L77 20 S206 C1 LAMP BR YL BR YL BR YL BR YL BR YL L77 18 BR YL FRONT FRONT LAMP LAMP C323 7 7 C322 L77 18 BR C2 4 RADIO L7 18 BK YL 1 C330 L78 18 BK YL L77 18 BR YL B9 4 3 A5 C100 B15 B13 SWITCH LAMP FOG FRONT A4 C100 2 IN PDC NO 2 RELAY LAMP FOG L92 20 PK L39 20 LB L139 20 VT ON INDICATOR 8W 12 2 8W 50 2 8W 50 14 8W 51 4 8W 50 10 8...

Page 680: ... BR YL C323 7 L77 18 BR C322 7 C2 4 RADIO L7 18 BK YL L77 20 BR YL 1 C330 L78 18 BK YL L77 18 BR YL A 8W 12 12 TO S169 L77 18 BR YL LEFT RIGHT LAMP LICENSE 1 L78 18 BK YL L78 18 BK YL S333 B6 NO 1 RELAY LAMP FOG IN PDC B9 4 3 A5 C100 B15 B13 SWITCH LAMP FOG FRONT 2 IN PDC NO 2 RELAY LAMP FOG L92 20 PK L39 20 LB L139 20 VT 3 MODULE DIODE S230 ON INDICATOR A4 C100 8W 12 2 8W 50 3 8W 51 4 8W 50 11 8W...

Page 681: ... C100 A4 7 C106 A5 C100 A 8W 12 11 FUSE 7 JB FROM SWITCH LAMP FOG FRONT S230 L77 20 BR YL L77 20 BR YL L77 20 BR L139 20 VT L39 20 LB L39 20 LB L39 18 LB L92 20 PK S169 L77 18 BR YL IN PDC 8W 50 17 8W 51 9 8W 51 10 8W 50 11 8W 50 17 8W 12 12 8W 12 JUNCTION BLOCK DIESEL XJ J008W 7 XJI01212 ...

Page 682: ...87 20 WT BK WT BK 20 F87 S216 OPTIONS FULL BASE WT BK 20 F87 F87 20 WT BK S225 WT BK 20 F87 1 MESSAGE CENTER 4 F87 20 WT BK DIESEL SENTRY KEY IMMOBILIZER MODULE C301 6 LHD RHD RHD LHD F87 20 WT BK F87 20 WT BK F87 20 WT BK F87 20 WT BK 8W 12 2 8W 10 17 8W 49 2 8W 50 8 8W 50 9 8W 40 2 8W 30 33 8W 39 4 XJ 8W 12 JUNCTION BLOCK 8W 12 13 XJI01213 J008W 7 ...

Page 683: ... 18 WT F20 18 WT F20 18 WT GAS DIESEL LHD RHD E9 PK OR 18 F26 IN PDC RELAY SENSOR OXYGEN UPSTREAM C13 WT 18 F20 2 B5 IN PDC RELAY CLUTCH COMPRESSOR A C DOWNSTREAM OXYGEN SENSOR RELAY IN PDC 4 0L A T 4 0L A T DRL 4 0L M T 2 5L 4 0L A T FOG IN PDC D11 RELAY FAN RADIATOR WT 18 F20 F20 18 WT PK OR 18 F26 EXCEPT FOG 4 0L A T 4 0L A T DRL 4 0L M T IN PDC RELAY FAN RADIATOR C18 1 C113 11 C107 2 5L A T F2...

Page 684: ...DC C5 RELAY FUEL PUMP IN PDC F12 18 DB WT F12 18 DB WT F12 18 DB WT DB WT 18 F12 10 C107 F12 18 DB WT IN PDC RELAY HEATER FUEL D4 GAS GAS DB WT 18 F12 C1 47 DIESEL MODULE CONTROL ENGINE GAS DIESEL D6 D6 C3 8W 12 2 8W 10 17 8W 30 24 8W 30 2 8W 30 3 8W 30 4 8W 30 22 8W 30 2 XJ 8W 12 JUNCTION BLOCK 2 5L 8W 12 15 XJI01215 J008W 7 ...

Page 685: ... PUMP IN PDC F12 18 DB WT F12 18 DB WT DB WT 18 F12 10 C107 F12 18 DB WT DB WT 18 F12 26 RHD MODULE CONTROL TRANSMISSION F12 18 DB WT F12 18 DB WT MODULE CONTROL TRANSMISSION 26 F12 18 DB WT F12 18 DB WT S136 RHD LHD C3 D6 8W 12 2 8W 10 17 8W 30 2 8W 30 2 8W 30 3 8W 30 4 8W 31 4 8W 31 4 8W 12 16 8W 12 JUNCTION BLOCK 4 0L XJ J008W 7 XJI01216 ...

Page 686: ...AR 3 DEFOGGER SWITCH 37 C200 11 C305 MIRROR 5 DRIVER POWER CLUSTER INSTRUMENT 3 C16 20 LB YL POWER PASSENGER 5 MIRROR DEFOGGER REAR WINDOW 4 C326 C312 2 C310 C15 12 BK WT BK WT 12 C15 C2 17 LB WT 20 C81 LB YL 20 C16 2 C201 3 LB YL 20 C16 BK WT 20 C16 OPTIONS FULL MIRRORS POWER C16 20 LB YL 8W 12 2 8W 10 18 8W 10 24 8W 52 2 8W 52 3 8W 52 4 8W 48 2 8W 48 2 8W 40 12 8W 48 2 8W 48 2 8W 48 2 XJ 8W 12 J...

Page 687: ...R C16 20 LB YL WINDOW REAR 3 DEFOGGER SWITCH 2 C204 11 C305 MIRROR 5 PASSENGER POWER CLUSTER INSTRUMENT 3 C16 20 LB YL DEFOGGER REAR WINDOW 4 C326 C312 2 C310 C15 12 BK WT BK WT 12 C15 C2 3 C9 BK WT 20 C16 POWER DRIVER 5 MIRROR 3 BK WT 20 C16 MIRRORS POWER FULL OPTIONS 8W 12 2 8W 10 18 8W 10 24 8W 52 2 8W 52 3 8W 52 4 8W 48 3 8W 48 3 8W 40 13 8W 48 3 8W 48 3 8W 48 3 8W 12 18 8W 12 JUNCTION BLOCK R...

Page 688: ... 3 4 0L A T T141 20 YL YL RD 20 F45 CLUTCH INTERLOCK SWITCH 2 1 JUMPER C200 39 1 F83 18 YL DG OTHER RELAY LAMP FOG REAR UP EXPORT BUILT F45 18 YL 2 POWER SWITCH MIRROR F83 18 YL DG FULL OPTIONS POWER MIRRORS OTHER HEATED SEATS F83 18 YL DG F83 18 YL DG S351 C316 1 F83 18 YL DG F83 18 YL DG 4 SWITCH SEAT HEATED RIGHT LEFT HEATED SEAT SWITCH 4 S353 OPTIONS FULL 2 1 DIESEL GAS D11 C10 D13 8W 12 2 8W ...

Page 689: ...OW C100 E8 YL DG 18 F83 C4 S4 3 C300 F83 18 YL DG F45 18 YL 1 S232 RELAY LAMP FOG REAR BUILT UP EXPORT OTHER F83 18 YL DG POWER C2 DRIVER 3 SWITCH LOCK WINDOW 2 POWER MIRROR SWITCH F83 18 YL DG S352 MIRRORS POWER FULL OPTIONS F83 18 YL DG F83 18 YL DG 1 C324 C316 1 4 SWITCH SEAT HEATED LEFT RIGHT HEATED SEAT SWITCH 4 F83 18 YL DG F83 18 YL DG S353 OPTIONS FULL GAS DIESEL D11 D13 C10 8W 12 2 8W 10 ...

Page 690: ...ILER TOW CONNECTOR 10 OVERHEAD MODULE HORN LOW HIGH HORN SWITCH HORN CLOCKSPRING 1 1 C5 RHD LHD LHD RHD S22 C4 BK RD 20 X3 3 3 A6 20 RD OR S338 RD OR 20 A6 RD OR 20 A6 RELAY TURN LEFT TOW TRAILER TRAILER TOW RIGHT TURN RELAY NOTE NOTE C1 8W 12 2 8W 10 20 8W 10 26 8W 54 3 8W 49 4 8W 49 5 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 54 3 8W 54 3 8W 41 2 8W 41 3 XJ 8W 12 JUNCTIO...

Page 691: ... PACKAGE 5 S219 HEATER A C 4 CONTROL F15 20 DB WT DIESEL 4 0L DB WT 18 F15 BRAKE CONTROLLER ANTI LOCK 23 RELAY BRAKE CONTROLLER ANTI LOCK B18 F15 20 DB WT IN PDC IN PDC DB WT 20 F15 S134 DB WT 20 F15 B20 ANTI LOCK CONTROLLER BRAKE RELAY ANTI LOCK CONTROLLER BRAKE C1 6 F15 18 DB WT 23 F15 20 DB WT F15 20 DB WT MOTOR BLOWER RELAY ACTUATOR BLEND DOOR C209 9 5 OR 20 D2 C2 B20 B18 8W 12 2 8W 10 18 8W 3...

Page 692: ... IN PDC DB WT 20 F15 F15 20 DB WT S219 DB WT 20 F15 1 C204 WASHER S349 DB WT 20 F15 4 A C HEATER CONTROL IN PDC DB WT 20 F15 B18 ANTI LOCK CONTROLLER BRAKE RELAY 23 ANTI LOCK CONTROLLER BRAKE F15 18 DB WT 4 0L DIESEL F15 20 DB WT F15 20 DB WT 1 C303 NOT USED V23 18 BR PK S324 FULL OPTIONS BASE RELAY MOTOR BLOWER DOOR BLEND 10 ACTUATOR D2 20 OR 5 C2 C209 9 B18 B20 8W 12 2 8W 10 18 8W 31 3 8W 31 7 8...

Page 693: ...D LHD L7 18 BK YL HEADLAMP SWITCH 9 2 RIGHT TAIL STOP LAMP S206 LAMP C1 HEADLAMP SWITCH OUTPUT DG YL 18 L78 L78 20 DG YL 1 RIGHT CITY LAMP GAS DIESEL BUILT UP EXPORT NO 1 LAMP SIGNAL TURN PARK FRONT RIGHT RIGHT FRONT PARK TURN SIGNAL LAMP NO 2 EXCEPT BUILT UP EXPORT 8W 12 2 8W 50 2 8W 50 3 8W 51 3 8W 12 10 8W 12 11 8W 50 12 8W 50 13 8W 50 12 8W 50 12 8W 12 24 8W 12 JUNCTION BLOCK XJ J008W 7 XJI012...

Page 694: ...1 8 C5 C8 1 F81 14 TN 4 PASSENGER POWER C2 LOCK WINDOW SWITCH SWITCH WINDOW LOCK C1 POWER DRIVER 9 1 C307 TN 12 F81 TN 14 F81 LG YL 18 F14 F23 18 DB YL 13 C201 F81 12 TN 33 C200 TN 12 F81 FULL OPTIONS FULL OPTIONS 8W 10 18 8W 43 2 8W 12 2 8W 10 17 8W 10 15 8W 10 16 8W 60 2 8W 61 2 XJ 8W 12 JUNCTION BLOCK LHD 8W 12 25 XJI01225 J008W 7 ...

Page 695: ... BREAKER CIRCUIT RUN ACC A31 8 C5 C8 1 F81 14 TN TN 12 F81 15 C204 14 LG YL 18 F14 F23 18 DB YL C202 3 SWITCH WINDOW LOCK C2 POWER PASSENGER 4 F81 14 TN C307 1 SWITCH WINDOW LOCK C1 POWER DRIVER 9 FULL OPTIONS FULL OPTIONS 8W 10 18 8W 43 3 8W 12 2 8W 10 17 8W 10 15 8W 10 16 8W 60 5 8W 61 3 8W 12 26 8W 12 JUNCTION BLOCK RHD XJ J008W 7 XJI01226 ...

Page 696: ...01 8 DB 16 V6 WIPE WASH SWITCH SWITCH SEAT POWER LEFT 8 HEATED SEAT RELAY 10 C329 RIGHT POWER SEAT SWITCH B S356 F37 14 RD F37 14 RD LB F37 14 RD LB F37 14 RD C362 1 C363 1 F37 14 RD LB F37 14 RD LB C316 2 F37 14 RD LB POWER SEATS 8W 53 2 8W 10 20 8W 10 26 8W 12 2 8W 10 15 8W 10 16 8W 53 2 8W 63 2 8W 63 6 8W 63 3 XJ 8W 12 JUNCTION BLOCK 8W 12 27 XJI01227 J008W 7 ...

Page 697: ...1 20 PK M1 20 PK 6 C201 M1 20 PK S18 C4 M1 20 PK M1 20 PK PK 20 M1 A C207 M1 18 PK C208 A PK 18 M1 M1 20 PK A LAMP CARGO C3 3 PK 20 M1 TO S347 4 0L PK 18 M1 C314 5 LHD RHD RHD LHD SWITCH SWITCH MERCURY LAMP UNDERHOOD S361 TO OTHERS SKIM 8W 47 2 8W 47 3 8W 47 9 8W 47 10 8W 12 2 8W 31 4 8W 10 2 8W 10 11 8W 40 2 8W 44 6 8W 44 6 8W 44 8 8W 44 9 8W 10 28 8W 10 29 8W 10 27 8W 44 6 8W 10 28 8W 10 29 8W 1...

Page 698: ...1 1 M1 20 PK M1 20 PK 6 C201 M1 20 PK S18 C4 M1 20 PK PK 20 M1 A C207 M1 18 PK C208 A PK 18 M1 M1 20 PK A LAMP CARGO C3 3 PK 20 M1 TO S347 PK 18 M1 C314 5 LHD RHD RHD LHD SWITCH S214 SWITCH MERCURY LAMP UNDERHOOD 8W 47 2 8W 47 3 8W 47 9 8W 47 10 8W 12 2 8W 10 7 8W 10 13 8W 40 2 8W 44 7 8W 44 7 8W 44 8 8W 44 9 8W 10 30 8W 10 30 8W 44 7 XJ 8W 12 JUNCTION BLOCK DIESEL 8W 12 29 XJI01229 J008W 7 ...

Page 699: ... SWITCH YL 18 M2 SWITCH JAMB DOOR LEFT REAR M2 18 YL M2 20 YL A C317 A C320 C319 A C318 A YL 20 M2 YL 18 M2 REAR DOOR JAMB SWITCH M2 18 YL SWITCH JAMB DOOR 3 1 PASSENGER S304 M2 20 YL RIGHT CARGO B SWITCH LAMP M2 20 YL M2 20 YL 6 C314 SWITCH YL 20 M2 LAMPS DOME B FULL OPTIONS MIDLINE DOME LAMP LHD RHD C317 C318 8W 12 2 8W 50 2 8W 50 3 8W 44 6 8W 44 7 8W 44 6 8W 44 7 8W 49 4 8W 49 4 8W 39 6 8W 39 7...

Page 700: ...1 4 OR BK 16 P33 LOCK DRIVER DOOR MOTOR 2 2 MOTOR DOOR LEFT REAR LOCK LOCK REAR RIGHT DOOR MOTOR 2 A LIFTGATE LOCK MOTOR 1 PK BK 16 P34 1 C1 P34 16 PK BK S316 PK BK 16 P34 C9 12 C7 5 PK BK 16 P34 1 1 P34 16 PK BK 1 P34 16 PK BK B P34 16 PK BK 5 5 5 P34 16 PK BK PK BK 16 P34 PK BK 16 P34 PK BK 16 P34 5 2 2 S307 PK BK 16 P34 PK BK 16 P34 P33 16 OR BK FULL OPTIONS FULL OPTIONS 8W 12 2 8W 61 4 8W 61 4...

Page 701: ...T REAR LOCK LOCK REAR RIGHT DOOR MOTOR 2 A LIFTGATE LOCK MOTOR 1 C1 P34 16 PK BK S322 PK BK 16 P34 1 1 P34 16 PK BK 1 P34 16 PK BK B P34 16 PK BK 5 5 5 P34 16 PK BK PK BK 16 P34 PK BK 16 P34 PK BK 16 P34 5 2 2 S307 P34 16 PK BK OR BK 16 P33 SWITCH PK BK 16 P34 1 2 P33 16 OR BK 12 C9 C9 1 5 C7 1 C7 P34 16 PK BK P33 16 OR BK PK BK 16 P34 P33 16 OR BK FULL OPTIONS FULL OPTIONS 8W 12 2 8W 61 5 8W 61 5...

Page 702: ...6 20 OR YL 12 C200 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 8 7 P71 20 YL P75 20 DB WT P91 20 WT BK P76 20 OR YL 1 2 3 4 4 DOWN 3 LEFT 1 RIGHT 2 UP P91 20 WT BK P76 20 OR YL C305 28 C201 67 20 24 C201 BLOCK JUNCTION RUN ACC F83 P74 20 DB P72 20 YL BK P72 20 YL BK P74 20 DB 6 PASSENGER 5 DRIVER MIRROR MIRROR 6 5 6 5 8W 12 2 8W 12 2 8W 12 19 8W 62 7 8W 62 7 8W 62 7 XJ 8W 12 JUNCTION BLO...

Page 703: ...34 8 P72 20 YL BK 7 C2 YL BK 20 P72 YL BK 20 P72 YL BK 20 P72 POWER DRIVER MIRROR C2 2 OR YL 20 P76 P76 20 OR YL 2 4 OR YL 20 P76 S328 P76 20 OR YL 10 C305 36 C200 OR YL 20 P76 28 C201 P76 20 OR YL OR YL 20 P76 2 C5 10 C9 2 OR YL 20 P76 S318 P76 20 OR YL OR YL 20 P76 4 8W 12 2 8W 62 4 8W 62 4 8W 62 2 8W 62 3 8W 12 34 8W 12 JUNCTION BLOCK LHD FULL OPTIONS XJ J008W 7 XJI01234 ...

Page 704: ...05 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 3 4 P74 20 DB P72 20 YL BK S319 S5 C4 G107 P91 20 WT BK P76 20 OR YL Z1 14 BK S208 Z1 14 BK 1 2 3 4 4 DOWN 3 LEFT 1 RIGHT 2 UP P91 20 WT BK P76 20 OR YL BLOCK JUNCTION RUN ACC F83 P74 20 DB P72 20 YL BK C305 Z1 16 BK 3 C7 S359 P91 20 WT BK POWER MIRRORS BASE 6 5 6 5 5 DRIVER MIRRIOR 6 PASSENGER MIRROR 8W 12 2 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 1...

Page 705: ... 8 8 P71 20 YL 1 YL BK 20 P72 POWER PASSENGER MIRROR P76 20 OR YL 2 4 OR YL 20 P76 S328 P76 20 OR YL 10 C305 10 C204 OR YL 20 P76 P76 20 OR YL 2 C5 10 C9 2 OR YL 20 P76 S318 P76 20 OR YL OR YL 20 P76 4 YL BK 20 P72 P74 20 DB OR YL 20 P76 2 C2 C2 C2 8W 12 2 8W 62 6 8W 62 5 8W 62 6 8W 12 36 8W 12 JUNCTION BLOCK RHD FULL OPTIONS XJ J008W 7 XJI01236 ...

Page 706: ... 9 BK 20 Z1 LHD 1 SWITCH MIRROR POWER Z1 20 BK DOME A Z1 20 BK LAMPS SWITCH OTHER COMPASS 6 Z1 18 BK MIRROR POWER PASSENGER S319 FULL OPTIONS S342 Z1 16 BK POWER MIRRORS RHD LHD MIRRORS POWER OVERHEAD CONSOLE BK 20 Z1 B Z1 20 BK B LAMP VANITY VISOR RIGHT LEFT VISOR VANITY LAMP 8W 12 2 8W 15 13 8W 15 14 8W 15 15 8W 41 2 8W 41 3 8W 61 2 8W 48 2 8W 48 3 8W 49 2 8W 49 3 8W 49 2 8W 49 3 8W 15 14 8W 15 ...

Page 707: ......

Page 708: ...ar Door Jamb Switch 8W 15 17 18 Left Rear Fog Lamp 8W 15 17 18 Left Repeater Lamp 8W 15 10 12 Left Tail Stop Lamp 8W 15 17 18 Left Turn Signal Lamp 8W 15 17 18 Left Visor Vanity Lamp 8W 15 13 License Lamp 8W 15 21 Liftgate Switch 8W 15 21 Overhead Module 8W 15 13 Oxygen Sensor 1 1 Upstream 8W 15 2 Oxygen Sensor 1 2 Downstream 8W 15 2 Oxygen Sensor 2 1 Upstream 8W 15 2 Oxygen Sensor 2 2 Downstream ...

Page 709: ... BK 12 Z1 G102 Z1 12 BK BK 18 Z1 Z12 18 BK TN A1 C100 A7 BK TN 18 Z12 Z1 18 BK 4 5 LINK DATA CONNECTOR C1 C10 IN PDC 2 5L M T RELAY MOTOR STARTER ENGINE T41 20 BK WT PRESSURE TRANSFER CASE SWITCH Z1 20 BK Z1 20 BK E7 LHD RHD C1 C1 Z1 20 BK 4 0L 2 5L BK 20 Z1 2 2 OXYGEN SENSOR DOWNSTREAM Z1 20 BK 4 0L CALIFORNIA EUROPEAN III EUROPEAN III CALIFORNIA 4 0L UPSTREAM SENSOR OXYGEN 2 1 S117 Z12 14 BK TN ...

Page 710: ...K 24 BK 12 Z1 Z1 12 BK BK 18 Z1 A1 Z1 18 BK 4 LINK DATA CONNECTOR BATTERY BK 6 Z0 G104 G105 Z0 2 0 BK ENGINE CONTROL MODULE 1 C1 27 C1 32 C1 31 C1 E7 C100 A7 C100 LHD RHD C100 Z12 18 BK TN Z12 20 BK TN Z12 18 BK TN Z12 18 BK TN 8W 30 23 8W 35 3 8W 30 34 8W 20 4 8W 30 22 XJ 8W 15 GROUND DISTRIBUTION DIESEL 8W 15 3 XJI01503 J008W 7 ...

Page 711: ... 20 Z1 Z1 16 BK S132 2 4 CONTROL VEHICLE SPEED SERVO IN PDC B8 RELAY FOG LAMP NO 1 NO 2 LAMP FOG RELAY B13 IN PDC Z1 20 BK BK 18 Z1 A 8W 15 7 TO G106 DRL DRL SWITCH MERCURY LAMP UNDERHOOD 8W 53 4 8W 53 2 8W 40 6 8W 33 4 8W 50 15 8W 50 15 8W 44 6 8W 15 4 8W 15 GROUND DISTRIBUTION LHD 2 5L GAS XJ J008W 7 XJI01504 ...

Page 712: ...6 C 8W 15 7 TO G106 REAR WASHER PUMP SWITCH MERCURY C10 Z1 20 BK C107 5 T41 18 BK WT 6 C1 MODULE CONTROL POWERTRAIN IN PDC RELAY MOTOR STARTER ENGINE ABS EXCEPT DRL IN PDC RELAY BRAKE ANTI LOCK CONTROLLER B13 Z1 20 BK Z1 20 BK M T BK 20 Z1 EXCEPT DRL EXCEPT ABS M T DRL EXCEPT ABS A T M T LEVEL SWITCH FLUID WASHER 8W 53 2 8W 31 6 8W 44 6 8W 33 4 8W 50 14 8W 50 15 8W 50 14 8W 50 15 8W 53 2 8W 53 4 8...

Page 713: ... 15 10 TO G106 E 8W 15 10 TO G106 WINDSHIELD WASHER PUMP REAR WASHER PUMP SWITCH LEVEL FLUID WASHER SWITCH MERCURY LAMP UNDERHOOD B8 B13 IN PDC NO 1 RELAY LAMP FOG IN PDC NO 2 RELAY LAMP FOG Z1 20 BK Z1 20 BK Z1 20 BK ABS OTHER Z1 20 BK MOTOR 4 0L WIPER FRONT 8W 31 6 8W 33 4 8W 35 4 8W 53 2 8W 53 6 8W 40 8 8W 44 6 8W 50 14 8W 50 14 8W 53 3 8W 53 2 8W 15 7 8W 15 7 8W 15 6 8W 15 GROUND DISTRIBUTION ...

Page 714: ...HT NO 2 LAMP SIGNAL TURN PARK FRONT RIGHT LEFT FRONT PARK TURN SIGNAL LAMP NO 1 LEFT FRONT PARK TURN SIGNAL LAMP NO 2 S158 RADIATOR FAN MOTOR C106 BK 16 Z1 C 8W 15 5 S141 FROM BK 16 Z1 B 8W 15 5 S132 FROM Z1 18 BK 4 2 5L MOTOR WIPER FRONT FROM S132 D 8W 15 6 Z1 16 BK FROM S141 E 8W 15 6 Z1 16 BK 8W 50 18 8W 50 4 8W 50 5 8W 50 14 8W 50 15 8W 50 14 8W 50 15 8W 50 4 8W 50 5 8W 50 12 8W 52 7 8W 50 12 ...

Page 715: ...8 Z1 F 8W 15 10 TO G106 G 8W 15 10 TO G106 SWITCH LEVEL FLUID WASHER SWITCH MERCURY LAMP UNDERHOOD OTHER ABS BK 20 Z1 BK 20 Z1 BK 20 Z1 FOG LAMP RELAY NO 2 IN PDC FOG LAMP RELAY NO 1 IN PDC B13 B8 IN PDC B19 BRAKE CONTROLLER ANTI LOCK RELAY Z1 20 BK 8W 53 4 8W 53 2 8W 53 2 8W 31 6 8W 33 4 8W 40 6 8W 44 6 8W 50 14 8W 50 14 8W 35 4 8W 15 8 8W 15 GROUND DISTRIBUTION BUILT UP EXPORT LHD 4 0L A T XJ J0...

Page 716: ...CONTROL POWERTRAIN 6 C1 C107 5 T41 18 BK WT EXCEPT ABS Z1 20 BK BK 20 Z1 BK 20 Z1 B13 CONTROLLER ANTI LOCK BRAKE RELAY IN PDC ABS ENGINE STARTER MOTOR RELAY IN PDC BK 20 Z1 C10 DRL DRL BK 20 Z1 B19 BK 20 Z1 IN PDC B8 RELAY FOG LAMP NO 1 NO 2 LAMP FOG RELAY IN PDC 8W 53 4 8W 53 2 8W 33 4 8W 44 6 8W 40 6 8W 30 14 8W 35 4 8W 21 5 8W 50 14 8W 50 14 XJ 8W 15 GROUND DISTRIBUTION BUILT UP EXPORT LHD 4 0L...

Page 717: ...GHT 3 HEADLAMP Z15 18 BK GY BK GY 18 Z15 HEADLAMP 3 LEFT LEVELING MOTOR 5 C106 Z15 16 BK GY 2 C114 BK GY 18 Z15 S165 C106 2 C115 Z1 18 BK Z1 18 BK S158 NO 2 LAMP SIGNAL TURN FRONT LEFT NO 1 LAMP SIGNAL TURN FRONT LEFT FAN RADIATOR NO 2 LAMP SIGNAL TURN FRONT RIGHT NO 1 LAMP SIGNAL TURN FRONT RIGHT MOTOR Z1 16 BK Z1 18 BK NO 1 4 D 8W 15 6 Z1 16 BK S132 FROM E 8W 15 6 Z1 16 BK S141 FROM 2 5L MOTOR F...

Page 718: ...18 Z1 H 8W 15 12 TO G106 BK 16 Z1 2 CLUTCH COMPRESSOR A C 11 C120 Z1 16 BK 1 SWITCH PRESSURE LOW A C Z1 20 BK MERCURY SWITCH BK 18 Z1 B Z1 20 BK 4 C111 231 4WD SWITCH CASE TRANSFER B13 IN PDC RELAY LAMP FOG Z1 20 BK YL 3 SWITCH PRESSURE HIGH A C S170 Z1 18 BK Z1 16 BK B19 IN PDC RELAY BRAKE ANTI LOCK CONTROLLER Z1 20 BK 8W 53 3 8W 53 5 8W 53 7 8W 40 7 8W 40 8 8W 30 24 8W 21 6 8W 44 7 8W 53 3 8W 30...

Page 719: ...ATER LEFT 2 BK 20 Z1 Z1 18 BK 2 RIGHT Z1 20 BK RIGHT 2 BK 18 Z1 12 C106 BK 20 Z1 REPEATER LAMP LAMP CITY BK 12 Z1 MOTOR LEVELING RIGHT 3 HEADLAMP Z15 18 BK GY BK GY 18 Z15 HEADLAMP 3 LEFT LEVELING MOTOR 5 C106 Z15 16 BK GY 2 C114 BK 18 Z1 Z15 18 BK GY C106 2 C115 Z1 18 BK S165 NO 1 NO 2 S158 NO 1 NO 2 FAN RADIATOR MOTOR Z1 14 BK 2 HEATER FUEL NOT USED Z1 18 BK 8W 50 13 8W 50 13 8W 50 6 8W 50 7 8W ...

Page 720: ... S319 PASSENGER POWER MIRROR BK 18 Z1 6 BK 20 Z1 POWER MIRROR SWITCH 1 LHD 6 Z1 18 BK MIRROR DRIVER POWER LHD POWER PASSENGER MIRROR 6 SWITCH WINDOW 6 C2 POWER PASSENGER LOCK BK 18 Z1 Z1 14 BK S319 BK 16 Z1 C9 11 S208 TO J 8W 15 14 OVERHEAD CONSOLE FULL OPTIONS Z1 20 BK BK 20 Z1 B B LAMP VANITY VISOR LEFT LAMP VANITY VISOR RIGHT Z1 20 BK S314 8W 12 2 8W 41 2 8W 41 3 8W 49 2 8W 49 3 8W 40 6 8W 40 7...

Page 721: ...WITCH 1 OTHERS POLICE PACKAGE I 8W 15 13 C201 FROM BK 14 Z1 2 A C HEATER CONTROL Z1 20 BK LHD RHD 7 17 C204 Z1 20 BK Z1 20 BK C201 7 J 8W 15 13 JUNCTION BLOCK FROM LHD RHD Z1 14 BK Z1 14 BK Z1 20 BK DB WT 20 D1 C209 1 ACTUATOR DOOR BLEND C2 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 48 2 8W 48 3 8W 53 4 8W 52 2 8W 44 2 8W 44 4 8W 30 17 8W 42 7 8W 42 7 8W 15 14 8W 15 GROUND DISTRIBUTION EXCEPT BUILT UP EXP...

Page 722: ...BK GY LEVELING HEADLAMP 5 RHD LHD Z15 20 BK GY Z15 18 BK GY 7 D1 20 DB WT 7 C201 Z1 20 BK 3 OUTLET POWER RHD LHD C204 17 J 8W 15 13 JUNCTION BLOCK FROM RHD LHD Z1 14 BK Z1 14 BK Z1 16 BK LIGHTER CIGAR S237 A C HEATER CONTROL C2 ACTUATOR DOOR BLEND 1 C209 Z1 20 BK Z1 20 BK LHD RHD LHD RHD BK 20 Z1 8W 51 11 8W 51 12 8W 48 2 8W 48 3 8W 53 4 8W 53 5 8W 53 6 8W 53 7 8W 52 3 8W 52 4 8W 44 3 8W 44 4 8W 4...

Page 723: ...MPASS 12 C301 5 Z2 20 BK LG C201 58 LHD RHD BK LG 20 Z2 3 SENTRY KEY 5 Z2 20 BK LG BK LG 20 Z2 MODULE IMMOBILIZER S227 BK LG 20 Z2 1 CONTROL HEATER OTHER A C Z8 12 BK VT Z8 20 BK VT POSTAL OTHER POLICE Z8 12 BK VT BK 20 Z1 10 C209 BLOWER MOTOR RELAY C1 C1 8W 42 4 8W 42 5 8W 40 2 8W 50 8 8W 50 9 8W 50 2 8W 50 3 8W 53 2 8W 53 3 8W 10 15 8W 10 16 8W 47 2 8W 47 3 8W 47 9 8W 47 10 8W 33 4 8W 33 5 8W 49...

Page 724: ...H Z1 14 BK BK 18 Z1 8 TRAILER TOW CONNECTOR S337 LAMP STOP TAIL LEFT 1 1 LEFT TURN SIGNAL LAMP LAMP BACK UP LEFT 1 Z1 18 BK BK 18 Z1 BK 18 Z1 S341 TRAILER TOW OTHER DRIVER 1 LAMP FOG REAR LEFT BUILT UP Z1 18 BK 2 C323 EXPORT BUILT UP EXPORT UP EXPORT EXCEPT BUILT Z1 16 BK Z1 18 BK GAS DRIVER 6 POWER MIRROR SWITCH MIRROR 1 POWER S329 Z1 18 BK Z1 14 BK FULL OPTIONS MIRRORS POWER Z1 12 BK Z1 16 BK 2 ...

Page 725: ...00 Z6 18 BK YL 10 AIRBAG CONTROL MODULE Z1 14 BK Z1 14 BK BK 18 Z1 8 TRAILER TOW CONNECTOR S337 LAMP STOP TAIL LEFT 1 1 LEFT TURN SIGNAL LAMP LAMP BACK UP LEFT 1 Z1 18 BK BK 18 Z1 BK 18 Z1 S341 BK 14 Z1 EXPORT Z1 18 BK LAMP FOG REAR LEFT 1 ILLUMINATION SWITCH CASE TRANSFER BUILT UP 2 C323 FULL OPTIONS POWER MIRRORS Z1 12 BK Z1 16 BK GAS EXPORT 2 C322 Z1 18 BK Z1 16 BK EXCEPT BUILT UP EXPORT BUILT ...

Page 726: ...ITCH SWITCH JAMB DOOR PASSENGER 3 Z1 18 BK C318 C LAMP STOP TAIL RIGHT 1 1 RIGHT TURN SIGNAL LAMP LAMP BACK UP RIGHT 1 Z1 18 BK BK 18 Z1 BK 18 Z1 S348 BK 18 Z1 1 RIGHT REAR FOG LAMP BUILT UP EXPORT 8W 39 6 8W 39 6 8W 51 3 8W 51 5 8W 51 8 8W 51 11 XJ 8W 15 GROUND DISTRIBUTION LHD 8W 15 19 XJI01519 J008W 7 ...

Page 727: ...18 BK BK 18 Z1 BK 18 Z1 S348 SWITCH JAMB DOOR DRIVER 3 Z1 18 BK S319 Z1 18 BK Z1 16 BK BK 14 Z1 BK 14 Z1 6 POWER MIRROR LOCK POWER DRIVER 8 C1 WINDOW SWITCH 5 C2 BK 18 Z1 1 RIGHT REAR FOG LAMP DRIVER BUILT UP 5 C303 Z1 14 BK EXPORT FULL OPTIONS OPTIONS FULL 8W 39 7 8W 51 3 8W 51 5 8W 51 8 8W 39 7 8W 48 3 8W 60 5 8W 61 3 8W 51 12 8W 15 20 8W 15 GROUND DISTRIBUTION RHD XJ J008W 7 XJI01520 ...

Page 728: ...ATE 1 MOTOR 1 REAR WIPER LAMP MOUNTED HIGH CENTER STOP 1 C333 2 Z1 18 BK C330 2 Z1 18 BK LAMP LICENSE 2 LEFT RIGHT 2 LICENSE LAMP S332 Z1 18 BK Z1 18 BK Z1 18 BK EXCEPT BUILT UP EXPORT UP EXPORT BUILT Z1 18 BK 8W 48 2 8W 48 3 8W 51 4 8W 53 4 8W 53 5 8W 53 6 8W 53 7 8W 44 8 8W 44 9 8W 51 4 8W 51 4 8W 51 4 XJ 8W 15 GROUND DISTRIBUTION 8W 15 21 XJI01521 J008W 7 ...

Page 729: ...1 18 BK SWITCH SWITCH BK 18 Z1 3 RIGHT HEATED SEAT S355 Z1 18 BK SEAT POWER RIGHT A Z1 14 BK SWITCH SWITCH BK 14 Z1 B LEFT POWER SEAT INTERFACE BK LG 18 Z2 13 SEAT HEAT MODULE Z2 18 BK LG C329 13 G306 HEATED SEATS C362 2 2 C363 Z1 14 BK Z1 14 BK 8W 63 5 8W 63 5 8W 63 6 8W 63 4 8W 63 4 8W 63 3 8W 63 2 8W 63 5 8W 15 22 8W 15 GROUND DISTRIBUTION XJ J008W 7 XJI01522 ...

Page 730: ...or 8W 20 2 4 Fuel Pump Relay 8W 20 3 Fuse 4 PDC 8W 20 4 Fuse 8 PDC 8W 20 2 Fuse 18 PDC 8W 20 2 Fuse 21 PDC 8W 20 2 Component Page Fuse 22 PDC 8W 20 3 Fuse 24 PDC 8W 20 5 Fusible Link 8W 20 2 4 G100 8W 20 2 G101 8W 20 2 G104 8W 20 4 G105 8W 20 4 Generator 8W 20 2 4 Power Distribution Center 8W 20 2 3 4 5 Powertrain Control Module 8W 20 2 3 4 5 XJ 8W 20 CHARGING SYSTEM 8W 20 1 ...

Page 731: ... A14 A13 POWER DISTRIBUTION CENTER DG WT F142 18 15A FUSE 21 1 S168 18 F142 DG WT 3 C108 C107 2 K20 18 DG DG 18 K20 2 K72 16 DG OR DG OR 18 K72 25 C3 DRIVER GENERATOR DG 10 A11 FUSIBLE LINK S118 ENGINE STARTER MOTOR RD 6 A0 Z0 G101 IN PDC B 4 0L 2 5L Z0 BK 6 2 5L 4 0L S166 K72 18 DG OR FUSED 8W 30 2 8W 30 18 8W 10 23 8W 10 2 8W 30 2 8W 10 23 8W 10 2 8W 10 23 8W 10 23 8W 21 2 8W 21 3 8W 21 4 8W 21 ...

Page 732: ...OTHER BR YL 18 K167 BUILT UP CALIFORNIA 4 0L BR YL 18 K167 BR YL 20 K167 S123 EXPORT BATT A0 CENTER DISTRIBUTION POWER A11 A12 A61 14 DG BK 15A FUSE 22 C1 FUEL PUMP RELAY 14 C107 A61 16 DG BK DG BK 14 A61 22 C1 B FUSED IN PDC FUSED B K167 20 BR YL 8W 70 3 8W 70 3 8W 70 2 8W 10 11 8W 10 2 8W 10 31 8W 30 3 8W 30 4 8W 30 13 XJ 8W 20 CHARGING SYSTEM GAS 8W 20 3 XJI02003 J008W 7 ...

Page 733: ... 1 S137 16 A142 DG OR 5 C120 K20 18 DG 7 DG 10 A11 FUSIBLE LINK S118 ENGINE STARTER MOTOR RD 2 0 A0 G105 Z0 2 0 BK S151 DG OR A142 16 RD LG A16 12 18 K72 DG OR 18 K72 DG OR RELAY OUTPUT RELAY IN PDC AUTOMATIC DOWN ENGINE CONTROL MODULE 28 C1 2 C1 25 C3 GENERATOR SOURCE 10 C2 SHUT SHUT 8W 30 23 8W 10 19 8W 10 7 8W 10 19 8W 21 6 8W 10 19 8W 30 22 8W 30 22 8W 15 3 8W 15 3 8W 20 4 8W 20 CHARGING SYSTE...

Page 734: ...5 C3 PK YL 18 K118 BR YL 20 K167 2 1 C1 4 S138 GROUND SENSOR K167 18 BR YL F16 16 RD LG C1 22 B FUSED BATT A16 POWERTRAIN CONTROL MODULE BATTERY TEMPERATURE SENSOR 8W 10 19 8W 10 7 8W 70 4 8W 10 19 8W 30 23 8W 30 31 8W 30 31 XJ 8W 20 CHARGING SYSTEM DIESEL 8W 20 5 XJI02005 J008W 7 ...

Page 735: ......

Page 736: ...lay 8W 21 2 3 4 5 6 Fog Lamp Relay 8W 21 6 Fog Lamp Relay No 1 8W 21 5 Fuse 7 PDC 8W 21 6 Fuse 10 PDC 8W 21 2 3 4 5 Component Page Fuse 19 JB 8W 21 2 3 4 5 6 G101 8W 21 4 G106 8W 21 3 5 6 Junction Block 8W 21 2 3 4 5 6 Park Neutral Position Switch 8W 21 2 Power Distribution Center 8W 21 2 3 4 5 6 Powertrain Control Module 8W 21 2 3 Transmission Range Sensor 8W 21 3 XJ 8W 21 STARTING SYSTEM 8W 21 1...

Page 737: ... FUSE 10A ST A41 3 C1 JUNCTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC 1 C108 BR 16 T40 16 E7 C100 1 2 JUMPER SWITCH INTERLOCK CLUTCH E8 C100 LHD RHD 1 PULL IN 2 HOLD IN BK WT 20 T41 C107 5 T41 18 BK WT SWITCH S120 CLUTCH INTERLOCK SWITCH JUMPER 2 1 F45 18 YL F45 18 YL F45 20 YL RD T141 20 YL YL 20 T141 F45 20 YL RD M 8W 10 25 8W 10 2 8W 20 2 8W 30 14 8W 12 19 8W 12 20 8W 10 18 8W 12 2 8W 31 2 8W ...

Page 738: ...19 FUSE 10A ST A41 3 C1 JUNCTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC 8 Z1 18 BK S141 5 C107 T41 20 BK WT 1 C108 BR 16 T40 16 E7 C100 1 2 JUMPER SWITCH INTERLOCK CLUTCH E8 C100 LHD RHD 1 PULL IN 2 HOLD IN F45 18 YL T141 20 YL G106 Z1 16 BK F45 20 YL RD F45 20 YL RD SWITCH M 8W 10 25 8W 10 2 8W 20 2 8W 31 6 8W 30 14 8W 12 19 8W 12 20 8W 10 18 8W 12 2 8W 15 5 8W 15 6 8W 15 8 8W 15 7 8W 15 10 XJ 8...

Page 739: ...CTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC 1 C108 BR 16 T40 16 CLUTCH INTERLOCK SWITCH G101 S107 Z1 16 BK BK WT 20 T41 5 C107 Z1 20 BK RHD LHD YL 20 T141 C100 E8 2 1 C100 E7 1 PULL IN 2 HOLD IN 1 SWITCH INTERLOCK CLUTCH 2 M 8W 10 25 8W 10 2 8W 20 2 8W 12 19 8W 12 20 8W 10 18 8W 12 2 8W 15 2 8W 15 2 8W 21 4 8W 21 STARTING SYSTEM 2 5L GAS M T XJ J008W 7 XJI02104 ...

Page 740: ...LAY IN PDC Z1 20 BK BK 16 Z1 S132 G106 1 C108 16 CLUTCH INTERLOCK SWITCH RHD LHD YL 20 T141 C100 E8 2 1 C100 E7 T40 16 BR 1 PULL IN 2 HOLD IN 1 SWITCH INTERLOCK CLUTCH 2 B8 Z1 20 BK EXCEPT DRL EXCEPT ABS IN PDC NO 1 RELAY LAMP FOG GROUND M 8W 10 25 8W 10 2 8W 20 2 8W 12 19 8W 12 20 8W 10 18 8W 12 2 8W 15 5 8W 15 9 8W 15 7 8W 15 10 8W 50 14 XJ 8W 21 STARTING SYSTEM 4 0L M T 8W 21 5 XJI02105 J008W 7...

Page 741: ...LAY IN PDC Z1 20 BK BK 12 Z1 S141 G106 10 C111 BR 14 T40 13 S132 Z1 12 BK 1 PULL IN 2 HOLD IN YL RD 20 F45 CLUTCH INTERLOCK SWITCH RHD LHD RHD LHD YL 20 T141 C100 E8 C100 E7 2 1 2 1 LHD RHD B13 IN PDC RELAY LAMP FOG Z1 20 BK YL GROUND M 8W 10 24 8W 10 7 8W 20 4 8W 12 19 8W 12 20 8W 10 18 8W 12 2 8W 15 11 8W 15 12 8W 15 11 8W 50 17 8W 21 6 8W 21 STARTING SYSTEM DIESEL XJ J008W 7 XJI02106 ...

Page 742: ...17 Fuse 26 PDC 8W 30 34 G101 8W 30 2 8 10 11 14 17 Component Page G102 8W 30 19 22 23 34 G106 8W 30 14 G107 8W 30 17 G108 8W 30 16 32 G123 8W 30 31 G154 8W 30 33 G302 8W 30 3 4 Generator 8W 30 18 23 Glow Plug Assembly 8W 30 25 Glow Plug No 1 8W 30 25 Glow Plug No 2 8W 30 25 Glow Plug No 3 8W 30 25 Glow Plug No 4 8W 30 25 Glow Plug Relay 8W 30 25 Headlamp Switch 8W 30 17 19 34 Idle Air Control Moto...

Page 743: ...13 POWER DISTRIBUTION CENTER 15A FUSE 21 F142 18 DG WT A11 A12 A61 14 DG BK 15A FUSE 22 C1 FUEL PUMP RELAY 14 C107 A61 16 DG BK DG BK 14 A61 22 C1 B FUSED 31 Z12 14 14 Z12 32 G101 GROUND C1 C1 GROUND BK TN BK TN A999 16 RD TO 18 PDC FUSE S168 DB WT 18 F12 IN PDC FUSED B OUTPUT S136 F12 18 DB WT F12 18 DB WT OTHER LHD A T 4 0L ST RUN 4 0L 2 5L S117 FUSED 8W 12 15 8W 12 16 8W 10 23 8W 12 15 8W 12 16...

Page 744: ... C200 S138 F12 C100 K167 20 BR YL FUSED B C1 A61 14 DG BK 22 14 C107 DG BK 16 A61 3 26 C3 FUEL LEVEL SENSOR F11 C100 15 DB LG 20 K226 S111 BR YL 20 K167 BK 12 Z1 SIGNAL K226 20 DB LG OTHER EUROPEAN III CALIFORNIA 4 0L BR YL 18 K167 BR YL 18 K167 BR YL 20 K167 S123 F12 18DB WT C200 13 D2 C100 A141 14DG WT A141 16 DG WT 8W 12 15 8W 12 16 8W 12 15 8W 12 16 8W 10 2 8W 10 17 8W 12 2 8W 10 11 8W 10 31 8...

Page 745: ... 7 C204 S138 B3 C100 K167 20 BR YL FUSED B C1 A61 14 DG BK 22 14 C107 DG BK 16 A61 3 26 C3 FUEL LEVEL SENSOR B2 C100 6 DB LG 20 K226 S111 BR YL 20 K167 BK 12 Z1 SIGNAL K226 20 DB LG OTHER EUROPEAN III CALIFORNIA 4 0L BR YL 18 K167 BR YL 18 K167 BR YL 20 K167 S123 F12 18DB WT D2 C100 A141 14DG WT A141 16 DG WT 4 C204 8W 12 15 8W 12 16 8W 12 15 8W 12 16 8W 10 2 8W 10 17 8W 12 2 8W 10 11 8W 10 31 8W ...

Page 746: ... 20 BR YL SUPPLY 5V 5V SUPPLY S109 1 C107 18 FUSE 15A A20 A19 POWER DISTRIBUTION CENTER A999 16 RD TO 21 PDC FUSE BR YL 20 K167 K167 20 BR YL A142 18 DG OR A142 18 DG OR OR 18 K7 OR 18 K7 2 SIGNAL SENSOR POSITION CAMSHAFT CRANKSHAFT POSITION SENSOR SIGNAL 2 1 4 0L 2 5L A999 16RD OTHER BR YL 18 K167 EUROPEAN III CALIFORNIA 4 0L BR YL 18 K167 BR YL 20 K167 S123 COIL RAIL 3 K17 18 DB TN C2 9 NO 1 1 C...

Page 747: ...8 A142 DG OR 18 A142 DG OR 18 A142 C2 C2 C2 C2 C2 D8 BATT A16 POWER DISTRIBUTION CENTER AUTOMATIC SHUT DOWN RELAY D2 S109 DG OR 18 A142 1 C107 18 FUSE 15A A20 A19 TO 21 PDC FUSE A142 18 DG OR RD 16 A999 A999 16 RD 4 0L 4 0L FUEL INJECTOR NO 1 DRIVER DRIVER NO 2 INJECTOR FUEL DRIVER NO 3 INJECTOR FUEL DRIVER NO 4 INJECTOR FUEL DRIVER NO 5 INJECTOR FUEL DRIVER NO 6 INJECTOR FUEL A142 18 DG OR 8W 10 ...

Page 748: ...PERATURE AIR INTAKE ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 20 BR YL K167 S111 BR YL 20 K167 SIGNAL SENSOR POSITION THROTTLE S112 OR DB 20 K22 17 TRANSMISSION CONTROL MODULE 6 C107 K22 20 OR DB OR 18 K7 OR DB 20 K22 K167 BR YL 20 OTHER 4 0L A T THROTTLE POSITION SENSOR SIGNAL K22 18 OR DB OTHER BR YL 18 K167 EUROPEAN III CALIFORNIA 4 0L BR YL 18 K167 BR YL 20 K167 S123 8W 70 2 8W 70 3 8W 70 3 8W ...

Page 749: ...1 SIGNAL 1 1 SENSOR OXYGEN BK 16 Z1 S107 S114 BR YL 20 K167 K167 20 BR YL K167 20 BR YL D8 BATT A16 POWER DISTRIBUTION CENTER AUTOMATIC SHUT DOWN RELAY D2 DG WT 18 F142 7 C107 21 FUSE 15A A14 A13 A999 16 RD F142 20 DG WT DG WT 20 F142 F142 20 DG WT 1 4 2 3 S168 F142 18 DG WT 8W 70 3 8W 15 2 8W 15 2 8W 70 3 8W 10 23 8W 10 2 8W 30 2 8W 10 23 8W 10 23 8W 10 23 8W 30 8 8W 30 FUEL IGNITION SYSTEM 2 5L ...

Page 750: ...F20 18 WT F99 18 RD F99 18 RD A42 18 DG A242 18 VT OR K73 18 BR OR K74 18 BR VT A21 A22 EXCEPT DRL OTHER PK OR 18 F26 DRL OTHER WT 18 F20 F26 18 PK OR EXCEPT FOG A T A T FOG C4 A9 LHD RHD OXYGEN SENSOR DOWNSTREAM RELAY CONTROL CONTROL RELAY UPSTREAM SENSOR OXYGEN FUSED IGNITION SWITCH OUTPUT ST RUN B5 EXCEPT DRL A T FOG IN PDC RELAY CLUTCH COMPRESSOR A C WT 18 F20 ST RUN OUTPUT SWITCH IGNITION FUS...

Page 751: ...1 4 2 3 S121 S122 B 8W 30 9 A 8W 30 9 7 13 C107 OTHER OTHER CALIFORNIA EUROPEAN III OXYGEN SENSOR UPSTREAM RELAY FROM OXYGEN SENSOR DOWNSTREAM RELAY TO A42 18 DG A42 20 DG A42 20 DG A42 20 DG A242 20 VT OR A242 20 DG OR A242 20 VT OR A242 18 VT OR CALIFORNIA EUROPEAN III OTHER S123 CALIFORNIA EUROPEAN III EXCEPT CALIFORNIA EUROPEAN III VT OR 20 A242 4WD 2WD EUROPEAN III CALIFORNIA 8W 70 3 8W 15 2 ...

Page 752: ...7 BR YL 20 K167 K167 20 BR YL 1 4 2 3 B 8W 30 9 A 8W 30 9 OXYGEN SENSOR UPSTREAM RELAY FROM OXYGEN SENSOR DOWNSTREAM RELAY FROM 7 13 C107 S121 S122 A42 18 DG A42 20 DG A42 20 DG A42 20 DG A242 18 VT OR A242 20 VT OR A242 20 DG OR A242 20 VT OR A242 20 VT OR 1 1 UPSTREAM 1 1 SENSOR OXYGEN DOWNSTREAM 1 2 SENSOR OXYGEN 4WD 2WD 8W 70 2 8W 15 2 8W 15 2 8W 30 10 8W 30 10 XJ 8W 30 FUEL IGNITION SYSTEM 4 ...

Page 753: ...BR YL WT OR 20 G7 G7 20 WT OR 7 MODULE LAMP RUNNING DAYTIME 4 C107 OTHER DRL SUPPLY 5V VEHICLE SPEED SENSOR SIGNAL SENSOR GROUND VEHICLE SPEED SENSOR SIGNAL NOT USED ENGINE GROUND SENSOR OIL PRESSURE SENSOR SIGNAL 5V SUPPLY 2 ENGINE OIL PRESSURE SENSOR 1 3 C2 23 K167 18 BR YL S119 K6 18 VT OR K6 18 VT OR G60 18 GY YL SIGNAL SENSOR PRESSURE OIL ENGINE OTHER BR YL 18 K167 EUROPEAN III CALIFORNIA 4 0...

Page 754: ... BR YL K4 20 BK RD SWITCH CONTROL SPEED LEFT 2 1 1 2 RIGHT SPEED CONTROL SWITCH 3 3 COAST 2 CANCEL 1 RESUME ACCEL 2 ON OFF 1 SET 1 2 2 1 B A S222 S221 V37 20 RD LG K167 20 BR YL RD LG 20 V37 BR YL 20 K167 C2 C2 C1 C1 RHD F17 F18 LHD K167 20 BR YL K167 20 BR YL OTHER BR YL 18 K167 EUROPEAN III CALIFORNIA 4 0L BR YL 18 K167 BR YL 20 K167 S123 8W 70 3 8W 70 3 8W 33 2 8W 33 2 8W 70 2 XJ 8W 30 FUEL IGN...

Page 755: ...OWER C3 F9 F7 Z1 18 BK BRAKE LAMP SWITCH SWITCH PARK NEUTRAL POSITION P N BK WT 18 T41 T41 18 BK WT 2 S120 ST T141 SUPPLY 2 5L A T OTHER 4 0L A T V32 18 YL RD RHD LHD YL RD 18 V32 PARK NEUTRAL POSITION SWITCH SENSE GROUND A T M T Z1 16 BK 5 C107 G106 S132 Z1 18 BK Z1 16 BK OTHER 4 0L M T 5 C107 T41 20 BK WT V30 20 DB RD Z1 18 BK BK 20 Z1 2 5L M T 4 0L 8W 33 4 8W 10 2 8W 12 19 8W 31 6 8W 21 2 8W 21...

Page 756: ...00 E9 1 C201 C100 A9 LHD RHD TORQUE CONVERTER CLUTCH SOLENOID CONTROL F20 18 WT WT 18 F20 F12 18 DB WT DB WT 18 F12 4 0L LHD A T OTHER 11 C107 F20 18 WT S161 2 C1 F12 18 DB WT 10 FUSED IGNITION SWITCH OUTPUT 15A FUSE 10 S136 F12 18 DB WT ST RUN SOLENOID CONTROL S130 S159 8W 12 15 8W 12 16 8W 10 17 8W 12 2 8W 51 6 8W 12 14 8W 12 16 8W 12 15 8W 12 16 8W 12 14 8W 31 2 XJ 8W 30 FUEL IGNITION SYSTEM GA...

Page 757: ...L NO 2 NO 3 DRIVER DRIVER DRIVER DRIVER C1 10 C1 19 18 18 18 K40 BR WT NO 1 4 1 NO 4 VT BK K59 K60 YL BK NO 2 3 NO 3 IDLE AIR 2 K39 18 GY RD B1 C100 F10 K29 18 WT PK RHD LHD DRIVER DRIVER DRIVER DRIVER K29 18 WT PK CONTROL IDLE AIR IDLE AIR CONTROL CONTROL IDLE AIR CONTROL IDLE AIR CONTROL IDLE AIR CONTROL IDLE AIR CONTROL IDLE AIR 8W 15 16 8W 15 16 8W 33 4 8W 31 7 8W 31 3 8W 31 7 8W 30 16 8W 30 F...

Page 758: ... 14 Z1 Z1 20 BK 6 FUSE 5A JUNCTION BLOCK OR 20 E2 C4 S2 S1 C4 TN 20 E1 42 C201 C1 1 SWITCH HEADLAMP S8 C4 F15 20 DB WT 15A FUSE 25 RUN A22 S217 40 C201 43 S315 E2 20 OR PACKAGE POLICE S215 S219 PANEL LAMPS DIMMER SWITCH SIGNAL DIMMER LAMPS PANEL GROUND IDLE ACTUATOR NOT USED RUN OUTPUT SWITCH IGNITION FUSED FUSED SWITCH SIGNAL DB WT 20 F15 K78 18 GY 8W 15 2 8W 15 2 8W 15 14 8W 15 14 8W 12 8 8W 12 ...

Page 759: ... 1 GENERATOR FIELD DRIVER GENERATOR DRIVER RELAY CLUTCH COMPRESSOR A C RADIATOR FAN RELAY A C SWITCH SENSE SENSE SWITCH A C SENSE SWITCH A C SENSE SWITCH PUMP DETECTION LEAK CONTROL SOLENOID PUMP DETECTION LEAK 2 3 WT DG 18 K106 K105 18 WT OR 4 EVAP LEAK DETECTION PUMP 10 C3 14 C3 S166 K20 18 DG K72 18 DG OR C1 C90 20 LG 4 A C SWITCH SENSE SENSE SWITCH A C SWITCH PRESSURE HIGH A C 1 2 5L 4 0L SENS...

Page 760: ...RANSMIT SCI SCI RECEIVE C1 4 F34 18 TN BK SWITCH HEADLAMP B7 B8 D20 18 LG BK D21 18 PK 20 BRAKE ANTI LOCK CONTROLLER 14 PK 20 D21 S139 TRANSMISSION CONTROL MODULE D21 20 PK 2 5L 4 0L LHD EXCEPT BUILT UP EXPORT S218 E6 LHD RHD E7 F2 F1 FUSED B OTHER SCI TRANSMIT ISO 9141K SCI TRANSMIT ISO 9141K ISO 9141K 8W 10 28 8W 10 2 8W 10 11 8W 15 2 8W 50 2 8W 31 7 8W 10 28 8W 10 29 8W 35 2 XJ 8W 30 FUEL IGNIT...

Page 761: ... S144 S145 POWERTRAIN CONTROL MODULE MODULE CONTROL TRANSMISSION BUS CCD CCD BUS D1 18 VT BR WT BK 18 D2 E11 C100 E12 51 C201 52 D2 18 WT BK VT BR 18 D1 AIRBAG CONTROL MODULE PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR TWISTED TWISTED PAIR TWISTED PAIR WT BK 20 D2 VT BR 20 D1 PAIR TWISTED CCD BUS BUS CCD PAIR TWISTED D2 20 WT BK VT BR 20 D1 1 2 S239 S238 OTHER 4 0L A T COMPASS OTHER A T 4 0L COMPA...

Page 762: ...145 POWERTRAIN CONTROL MODULE MODULE CONTROL TRANSMISSION BUS CCD CCD BUS D1 18 VT BR WT BK 18 D2 A11 C100 A12 19 C204 20 D2 18 WT BK VT BR 18 D1 AIRBAG CONTROL MODULE PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR TWISTED TWISTED PAIR TWISTED PAIR WT BK 20 D2 VT BR 20 D1 PAIR TWISTED CCD BUS BUS CCD PAIR TWISTED D2 20 WT BK VT BR 20 D1 1 2 S239 S238 OTHER 4 0L A T 1 COMPASS OTHER COMPASS 4 0L A T OT...

Page 763: ... LG CONTROL RD LG 12 A16 A16 12 RD LG RELAY IN PDC ENGINE CONTROL MODULE 1 C1 27 C1 FUSED IGNITION SWITCH OUTPUT AUTOMATIC SHUT DOWN RELAY OUTPUT OUTPUT RELAY SHUT DOWN AUTOMATIC 33 C1 2 C1 47 C1 28 C1 ST RUN C11 B5 IN PDC RELAY FAN RADIATOR IN PDC RELAY CLUTCH COMPRESSOR A C A142 18DG OR A142 18 DG OR ECM GROUND GROUND ECM B3 C13 8W 12 15 8W 10 17 8W 10 19 8W 12 2 8W 10 19 8W 10 7 8W 10 13 8W 15 ...

Page 764: ...ATIC SHUT DOWN RELAY AUTOMATIC SHUT DOWN RELAY OUTPUT 22 C1 2 C1 C1 C1 SOURCE GENERATOR DRIVER FIELD GENERATOR 1 2 GENERATOR DG 18 K20 10 C2 5 C120 DG 18 K20 7 K72 18 DG OR DG OR 18 K72 25 C3 GENERATOR FIELD DRIVER SOURCE GENERATOR C3 12 OUTPUT RELAY SHUT DOWN AUTOMATIC A142 16 DG OR 8W 10 19 8W 10 7 8W 15 3 8W 15 3 8W 10 19 8W 10 19 8W 10 19 8W 30 22 8W 20 4 XJ 8W 30 FUEL IGNITION SYSTEM DIESEL 8...

Page 765: ...ND SOLENOID EGR Z1 18 BK EGR SOLENOID CONTROL ELECTRONIC VACUUM MODULATOR D S156 A B BLOCK JUNCTION DG OR 16 F142 GY YL 18 K35 Z1 16 BK G106 BK 18 Z1 2 FUEL HEATER 1 BATT A0 CENTER DISTRIBUTION POWER 30A FUSE 6 DB WT 18 F12 C2 5 ST RUN A21 A93 14 RD BK D4 D2 D8 D6 11 FUSE 20A G106 A14 8W 30 22 8W 15 11 8W 12 15 8W 15 11 8W 15 11 8W 10 19 8W 10 7 8W 10 19 8W 10 34 8W 10 34 8W 12 2 8W 15 12 8W 10 13...

Page 766: ...O 1 NO 2 PLUG GLOW NO 3 PLUG GLOW NO 4 PLUG GLOW 2 FUSE 50A 50A FUSE 3 RD GY 12 A54 A54 12 RD GY BATT A0 8 1 9 2 A14 A13 DG OR 16 A142 DG OR 16 F142 S156 RELAY ENGINE CONTROL MODULE GLOW PLUG RELAY CONTROL 42 C1 S137 A142 16 DG OR 8W 10 7 8W 10 19 8W 10 34 8W 10 19 8W 10 19 8W 10 13 8W 10 34 8W 30 22 8W 10 19 8W 10 19 XJ 8W 30 FUEL IGNITION SYSTEM DIESEL 8W 30 25 XJI03025 J008W 7 ...

Page 767: ...TION PUMP A13 A14 21 FUSE 20A F142 16 DG OR S156 DG OR 16 F142 A142 16 DG OR DG OR 16 A142 BATT A16 SIGNAL RELAY DOWN SHUT AUTOMATIC ENGINE CONTROL MODULE 59 C2 66 C2 80 C2 77 C2 79 C2 53 C2 61 C2 QUANTITY ACTUATOR FUEL TIMING GROUND SENSOR FUEL SOLENOID SOLENOID FUEL DOWN SHUT CONTROL SOLENOID SHUT DOWN FUEL FUEL TIMING SOLENOID CONTROL 8W 10 7 8W 10 19 8W 10 19 8W 70 4 8W 10 34 8W 10 34 8W 30 22...

Page 768: ...20 DG RD K9 20 LB 1 2 4 3 K4 20 BK LB SENSOR PRESSURE BOOST TURBO 13 C1 40 C1 39 C1 SENSOR GROUND SIGNAL TEMPERATURE AIR INTAKE GROUND SENSOR C2 61 K4 20 BK LB S149 BOOST PRESSURE SIGNAL SUPPLY 5V SIGNAL PRESSURE BOOST 5V SUPPLY MIDDLE TAP SENSOR MEASURE CONTROL SIGNAL SIGNAL SENSOR TEMPERATURE AIR INTAKE SENSOR COIL C8 C11 C13 RELAY DOWN SHUT AUTOMATIC RADIATOR FAN RELAY A142 18DG OR A142 18 DG O...

Page 769: ...K 18 K67 SIGNAL SENSOR MOVEMENT NEEDLE LG YL 18 K68 NEEDLE MOVEMENT SENSOR GROUND SENSOR MOVEMENT NEEDLE NEEDLE MOVEMENT SENSOR PAIR TWISTED 55 C2 11 C1 12 C1 24 C1 23 C1 61 C2 62 C2 ENGINE CONTROL MODULE GROUND SIGNAL ACCELERATOR SENSOR POSITION PEDAL ACCELERATOR ACCELERATOR SIGNAL SIGNAL SWITCH POSITION IDLE LOW POSITION ACCELERATOR PEDAL ACCELERATOR GROUND SENSOR POSITION PEDAL 8W 70 4 8W 30 28...

Page 770: ...20 BK LB S149 K4 20 BK LB 9 C120 K4 18 BK LB 2 8 10 C120 WT OR 20 G7 SIGNAL VEHICLE SPEED OIL SENSOR PRESSURE 2 K7 20 OR 1 S124 3 K167 20 BR YL OR 20 K7 1 3 C116 BR YL 18 K167 OR 18 K7 2 C116 G60 18 GY YL ENGINE CONTROL MODULE 51 C1 54 C2 61 C2 ENGINE OIL PRESSURE SENSOR SIGNAL NO 2 SENSOR TEMPERATURE COOLANT ENGINE 2 4 C1 SENSOR GROUND K167 18 BR YL S138 12 K167 18 BR YL NO 1 SENSOR TEMPERATURE C...

Page 771: ...C2 ENGINE DISABLE SIGNAL 30 C1 38 C1 8 C1 10 C1 67 C2 69 C2 ENGINE CONTROL MODULE C1 34 C3 22 OR RD 18 K48 K159 18 VT RD 8 C1 6 C1 ENGINE SPEED SENSOR SENSOR GROUND PRESSURE SPEED CONTROL INDICATOR SIGNAL ENGINE SPEED FAULT INPUT REQUEST INDICATOR C1 REQUEST FAN RADIATOR 13 2 C1 48 RADIATOR FAN REQUEST C48 18 TN C48 18 TN SENSOR SIGNAL SIGNAL DISABLE ENGINE A C REQUEST OUTPUT SIGNAL SENSOR INDICAT...

Page 772: ...ATER IN FUEL SENSOR SENSOR FUEL IN WATER SIGNAL SWITCH LEVEL COOLANT G18 18 PK BK LOW COOLANT SWITCH 2 K167 20 BR YL 1 B3 C100 K167 20 BR YL C100 F12 RHD LHD F11 4 C1 26 C3 12 C1 27 C1 1 2 BATTERY TEMPERATURE SENSOR K167 20 BR YL K118 18 PK YL C3 15 SIGNAL SENSOR TEMPERATURE BATTERY K167 20 BR YL K167 20 BR YL K226 20 DB LG K226 20 DB LG C204 6 SIGNAL 8W 70 4 XJ 8W 30 FUEL IGNITION SYSTEM DIESEL 8...

Page 773: ...T RIGHT SPEED CONTROL SWITCH B A B6 GROUND SENSOR BK LB 20 K4 3 S149 1 2 K167 20 BR YL 2 1 S221 S222 BR YL 20 K167 V37 20 RD LG RD LG 20 V37 K167 20 BR YL WT PK 20 K29 LHD RHD F8 PK DB 20 F32 SENSE SWITCH LAMP K4 20 BK LB C2 C2 C1 C1 ENGINE CONTROL MODULE 60 C2 61 C2 9 C1 20 C1 F18 F17 RHD LHD E1 F10 K4 20 BK RD SPEED CONTROL SWITCH SIGNAL SENSOR GROUND GROUND SENSOR SIGNAL SWITCH CONTROL SPEED OT...

Page 774: ... CENTER DRIVER INDICATOR COOLANT LOW E17 C100 18 G154 VT LG 8 INDICATOR LOW COOLANT LEVEL WARNING WT BK 20 F87 S225 C11 C13 RADIATOR FAN RELAY POWER DISTRIBUTION CENTER C27 20 DB PK ENGINE CONTROL MODULE 17 C1 32 C1 9 C3 8 C3 K185 20 OR LB G86 20 TN OR G154 20 VT LG RADIATOR FAN RELAY CONTROL DG OR 18 A142 AUTOMATIC SHUT DOWN RELAY IN PDC C8 C2 BATT A16 8W 12 13 8W 12 2 8W 10 17 8W 12 13 8W 12 13 ...

Page 775: ...BRAKE ANTI LOCK CONTROLLER S139 D21 20 PK D21 18 PK S146 Z12 12 BK TN C1 4 A18 LHD RHD SWITCH HEADLAMP A7 27 C3 29 C3 45 C1 ENGINE CONTROL MODULE S218 F34 18 TN BK F34 18 TN BK HEADLAMP SWITCH OUPUT F1 F2 SCI TRANSMIT ISO 9141K ISO 9141K TRANSMIT SCI ISO 9141K TRANSMIT SCI E7 BK TN 18 Z12 Z12 20 BK TN Z12 18 BK TN RHD LHD 8W 10 29 8W 10 7 8W 10 13 8W 15 3 8W 35 3 8W 15 3 8W 50 3 8W 10 29 8W 30 34 ...

Page 776: ...nsor 8W 31 5 Junction Block 8W 31 2 3 4 6 7 Component Page Lock Up Solenoid 8W 31 4 Output Speed Sensor 8W 31 5 Park Neutral Position Switch 8W 31 2 Power Distribution Center 8W 31 2 4 Powertrain Control Module 8W 31 2 3 5 7 Shift Lock Solenoid 8W 31 3 7 Throttle Position Sensor 8W 31 5 Torque Converter Clutch Solenoid 8W 31 2 Transmission Control Module 8W 31 4 5 6 7 Transmission Range Sensor 8W ...

Page 777: ...K DB WT 18 F12 5 C2 ST RUN A21 20A FUSE 11 BLOCK JUNCTION F12 18 DB WT C107 10 S130 S161 WT 18 F20 1 3 BR LG 18 L10 10 FUSE 15A C4 S12 2 C1 11 C107 1 C201 C100 E9 S159 F20 18 WT SOLENOID CLUTCH E3 C100 C107 12 C200 16 A9 C100 FUSED IGNITION SWITCH OUTPUT RHD LHD F20 18 WT F20 18 WT ST RUN F20 18 WT A15 RHD LHD 23 C204 TO S303 LHD RHD 8W 10 2 8W 12 19 8W 12 20 8W 21 2 8W 30 14 8W 30 15 8W 10 17 8W ...

Page 778: ...3 24 POWERTRAIN CONTROL MODULE F15 20 DB WT F15 20 DB WT 40 C201 S217 F10 BRAKE SWITCH SENSE LHD RHD LAMP WT PK 20 K29 LHD RHD K29 18 WT PK F15 20 DB WT LHD RHD WT PK 18 K29 RHD LHD K29 20 WT PK 8W 15 16 8W 15 16 8W 33 4 8W 10 18 8W 12 22 8W 12 23 8W 12 2 8W 12 22 8W 12 23 8W 30 16 8W 12 22 XJ 8W 31 TRANSMISSION CONTROL SYSTEM 2 5L GAS 8W 31 3 XJI03103 J008W 7 ...

Page 779: ...9 C107 BK TN 18 Z12 FUSED B 25 S135 M1 20 PK 12 WT 20 T19 3 2 T60 20 OR WT 13 4 T22 20 DB WT 11 SOLENOID TRANSMISSION 3 4 AND 1 2 SOLENOID 2 3 SOLENOID LOCK UP SOLENOID SOLENOID A SOLENOID B SOLENOID C CONTROL CONTROL CONTROL LHD RHD S130 F12 18 DB WT OUTPUT ST RUN 8W 12 16 8W 10 27 8W 10 2 8W 10 17 8W 12 2 8W 12 16 8W 10 11 8W 15 2 8W 10 27 8W 12 16 8W 31 4 8W 31 TRANSMISSION CONTROL SYSTEM 4 0L ...

Page 780: ... CONTROL POWERTRAIN S115 K7 18 OR OR 20 K7 17 C1 3 SENSOR POSITION THROTTLE K22 20 OR DB 4 C1 THROTTLE POSITION SENSOR SIGNAL 2 OR DB 20 K22 17 6 C107 S112 1 S114 K167 20 BR YL BR YL 20 K167 16 K167 20 BR YL S138 BR YL 20 K167 SENSOR GROUND BR YL 20 K167 3 C107 K22 20 OR DB OTHER BR YL 18 K167 BUILT UP CALIFORNIA 4 0L BR YL 20 K167 BR YL 18 K167 S123 EXPORT S111 8W 30 5 8W 70 2 8W 30 7 8W 70 3 8W ...

Page 781: ... 15A FUSE 10 F20 18 WT S12 ST RUN A21 JUNCTION BLOCK C4 S159 S141 Z1 16 BK G106 ENGINE STARTER MOTOR RELAY FROM BR LG 18 L10 S142 F20 18 WT F20 18 WT 1 C201 C100 E9 RHD LHD A9 LHD RHD F20 18 WT F20 18 WT TRS TRS TRS SENSE SENSE SENSE 8W 12 14 8W 10 17 8W 12 2 8W 12 14 8W 15 5 8W 15 6 8W 15 8 8W 15 7 8W 15 10 8W 21 3 8W 51 6 8W 31 6 8W 31 TRANSMISSION CONTROL SYSTEM 4 0L XJ J008W 7 XJI03106 ...

Page 782: ...WT PK RUN A22 25 FUSE 15A DB WT 20 F15 C4 S8 BLOCK JUNCTION 1 2 SHIFT LOCK SOLENOID RHD LHD F15 20 DB WT K29 18 WT PK C3 24 POWERTRAIN CONTROL MODULE D2 20 WT BK D1 20 VT BR S239 S238 B8 A11 A12 B1 LHD RHD BRAKE SWITCH SENSE F15 20 DB WT S217 40 C201 K29 20 WT PK S219 F15 20 DB WT ISO9141K LAMP WT PK 18 K29 LHD RHD BRAKE LAMP 8W 15 16 8W 15 16 8W 30 19 8W 30 19 8W 30 20 8W 30 21 8W 30 20 8W 30 21 ...

Page 783: ......

Page 784: ... Module 8W 33 3 5 Fuel Injection Pump 8W 33 5 Fuse 19 PDC 8W 33 5 Fuse 23 PDC 8W 33 4 Component Page G106 8W 33 4 G108 8W 33 4 5 Left Speed Control Switch 8W 33 2 3 Power Distribution Center 8W 33 4 5 Powertrain Control Module 8W 33 2 4 5 Right Speed Control Switch 8W 33 2 3 Vehicle Speed Control Servo 8W 33 4 XJ 8W 33 VEHICLE SPEED CONTROL 8W 33 1 ...

Page 785: ...ED CONTROL SWITCH 3 3 COAST 2 CANCEL 1 RESUME ACCEL 2 ON OFF 1 SET 1 2 2 1 B A S222 S221 V37 20 RD LG K167 20 BR YL RD LG 20 V37 BR YL 20 K167 BR YL 20 K167 K167 20 BR YL C2 C2 C1 C1 F17 LHD RHD B6 BK RD 20 K4 OTHER BR YL 18 K167 BUILT UP CALIFORNIA 4 0L BR YL 18 K167 BR YL 20 K167 S123 EXPORT 1 2 8W 70 3 8W 70 3 8W 30 13 8W 70 2 8W 33 2 8W 33 VEHICLE SPEED CONTROL GAS XJ J008W 7 XJI03302 ...

Page 786: ... 2 RIGHT SPEED CONTROL SWITCH 3 3 COAST 2 CANCEL 1 RESUME ACCEL 2 ON OFF 1 SET 1 2 2 1 B A S222 S221 V37 20 RD LG K167 20 BR YL RD LG 20 V37 BR YL 20 K167 K167 20 BR YL V37 20 RD LG RD LG 20 V37 C2 C2 C1 C1 F17 F18 C2 C2 LHD RHD ENGINE CONTROL MODULE BK RD 20 K4 1 2 8W 70 4 8W 30 32 XJ 8W 33 VEHICLE SPEED CONTROL DIESEL 8W 33 3 XJI03303 J008W 7 ...

Page 787: ...0 B1 C100 S204 WT PK 20 K29 1 2 Z1 18 BK S207 BK 14 Z1 G108 BRAKE LAMP SWITCH S132 Z1 16 BK WT PK 18 K29 C100 WT PK 18 K29 K29 20 WT PK RHD LHD 5 6 23 FUSE 15A A10 BATT A0 A9 CENTER DISTRIBUTION POWER F8 C100 L50 20 WT TN TO S203 F32 20 PK DB F10 SUPPLY LHD RHD LHD RHD V32 20 YL RD V32 18 YL RD K29 18 WT PK LAMP 8W 15 7 8W 15 10 8W 31 7 8W 31 3 8W 31 7 8W 15 16 8W 15 16 8W 15 4 8W 15 5 8W 15 6 8W ...

Page 788: ...INJECTION FUEL 8 K140 16 TN WT FUEL QUANTITY ACTUATOR CONTROL POWERTRAIN 18 MODULE F8 F32 20 PK DB C1 C1 C1 C1 C1 C1 C2 C2 C2 B4 B1 LHD RHD ENGINE CONTROL MODULE C2 RHD LHD WT PK 18 K29 ACCELERATOR ACCELERATOR GROUND SENSOR POSITION PEDAL SENSOR POSITION PEDAL ACCELERATOR ACCELERATOR SIGNAL SENSOR POSITION PEDAL PEDAL POSITION SENSOR GROUND ACCELERATOR SENSE SWITCH LAMP BRAKE SPEED CONTROL INDICAT...

Page 789: ......

Page 790: ... 35 4 Fuse 9 JB 8W 35 4 5 Fuse 12 PDC 8W 35 2 3 Fuse 13 PDC 8W 35 2 Fuse 14 PDC 8W 35 3 Fuse 19 PDC 8W 35 3 Component Page Fuse 23 PDC 8W 35 2 Fuse 25 JB 8W 35 4 5 G Switch 8W 35 2 3 G102 8W 35 2 3 G106 8W 35 4 5 Instrument Cluster 8W 35 4 5 Junction Block 8W 35 4 5 Left Front Wheel Speed Sensor 8W 35 6 Left Rear Wheel Speed Sensor 8W 35 6 Power Distribution Center 8W 35 2 3 Right Front Wheel Spee...

Page 791: ...TEST G SWITCH SENSE NO 1 G SWITCH SENSE NO 2 G SWITCH PK D21 12 PK DB 20 F32 23 FUSE 15A A10 A9 F8 C100 F32 20 PK DB 5 6 BRAKE LAMP SWITCH WT TN L50 S203 BRAKE LAMP SWITCH OUTPUT 7 18 18 18 18 18 20 L50 WT TN 20 PK D21 20 D21 20 PK LINK DATA CONNECTOR SCI TRANSMIT F2 C100 B8 LHD RHD 18 D21 PK 4 0L 2 5L S139 ISO 9141K RHD LHD C100 B4 C100 E1 L50 20 WT TN 8W 10 25 8W 10 2 8W 10 11 8W 15 2 8W 10 25 8...

Page 792: ... B43 SIGNAL TEST G SWITCH SENSE NO 1 G SWITCH SENSE NO 2 G SWITCH DATA LINK CONNECTOR 12 PK DB 20 F32 19 FUSE 15A A17 A18 F8 C100 F32 20 PK DB 5 6 BRAKE LAMP SWITCH B4 C100 S203 BRAKE LAMP SWITCH OUTPUT L50 20 WT TN S147 WT TN 18 L50 D21 18 PK S139 20 D21 20 PK B8 L50 20 WT TN L50 20 WT TN PK 20 D21 7 SCI TRANSMIT E1 F2 LHD RHD ISO 9141K 8W 10 26 8W 10 7 8W 10 13 8W 15 3 8W 10 26 8W 30 34 8W 10 32...

Page 793: ...INSTRUMENT ABS INDICATOR 9 FUSE 10A WT BK 20 F87 C4 S13 ST RUN A21 F87 20 WT BK S216 F13 C100 G19 20 LG OR F15 20 DB WT RHD LHD BASE FULL OPTIONS C201 5 S225 OUTPUT RUN B8 Z1 20 BK EXCEPT 4 0L ABS IN PDC NO 1 RELAY LAMP FOG DRL GROUND 8W 12 2 8W 12 22 8W 12 23 8W 10 18 8W 15 5 8W 15 6 8W 15 8 8W 15 9 8W 15 7 8W 15 10 8W 40 2 8W 40 6 8W 40 8 8W 12 13 8W 10 17 8W 12 13 8W 12 13 8W 12 22 8W 12 23 8W ...

Page 794: ...OR 9 FUSE 10A WT BK 20 F87 C4 S13 ST RUN A21 F13 C100 G19 20 LG OR RHD LHD BASE FULL OPTIONS C201 5 S216 B13 IN PDC RELAY LAMP FOG Z1 20 BK S225 GROUND OUTPUT RUN D13 S141 S132 G106 Z1 12 BK Z1 12 BK Z1 20 BK Z1 20 BK YL IN PDC RELAY MOTOR STARTER ENGINE GROUND 8W 12 2 8W 12 22 8W 12 23 8W 10 18 8W 40 7 8W 40 8 8W 12 13 8W 10 17 8W 12 13 8W 50 17 8W 12 13 8W 15 11 8W 15 11 8W 15 12 8W 21 6 XJ 8W 3...

Page 795: ... FRONT WHEEL SPEED SENSOR SENSOR SPEED WHEEL FRONT RIGHT 3 SENSOR SPEED WHEEL FRONT RIGHT B A 17 RIGHT REAR WHEEL SPEED SENSOR SENSOR SPEED WHEEL REAR RIGHT B8 RD DB RD 18 B9 WT DB B6 WT B7 B3 LG DB B3 20 LG DB F C109 G LG 20 B4 LG B4 YL 20 B2 YL B2 B1 YL DB B1 20 YL DB 1 RIGHT REAR WHEEL SPEED SENSOR D C109 E 18 18 18 18 18 18 18 PAIR TWISTED TWISTED PAIR TWISTED PAIR TWISTED PAIR 8W 35 6 8W 35 A...

Page 796: ...itch 8W 39 6 7 Component Page Horn Relay 8W 39 8 9 Ignition Switch 8W 39 6 7 Instrument Cluster 8W 39 8 9 Junction Block 8W 39 2 3 4 5 6 7 8 9 Left Rear Door Jamb Switch 8W 39 6 7 Liftgate Switch 8W 39 6 7 Overhead Module 8W 39 2 3 6 7 8 9 Passenger Door Jamb Switch 8W 39 6 7 Passenger Power Lock Window Switch 8W 39 2 3 Power Distribution Center 8W 39 2 3 4 5 8 9 Right Rear Door Jamb Switch 8W 39 ...

Page 797: ...P59 20 LB RD DB PK 20 P55 2 SWITCH WINDOW LOCK POWER PASSENGER BK 14 Z1 14 G107 S208 C2 C2 C201 Z1 14 BK Z1 1 UNDERHOOD LAMP FUSED B M1 20 PK DOOR LOCK CONTROL DOOR UNLOCK RELAY CONTROL S135 DIESEL GAS SWITCH DIESEL SKIM S361 OTHERS S314 8W 10 27 8W 10 30 8W 10 11 8W 10 13 8W 10 28 8W 10 29 8W 10 30 8W 10 2 8W 10 7 8W 15 13 8W 12 2 8W 12 2 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 61 2 8W 44 7 8W 10 ...

Page 798: ...W LOCK POWER PASSENGER BK 14 Z1 G107 S208 C2 C2 C203 1 2 Z1 14 BK Z1 20 BK 1 M1 20 PK FUSED B SWITCH LAMP UNDERHOOD GAS DIESEL S135 DOOR LOCK CONTROL UNLOCK RELAY CONTROL DOOR P55 20 DB PK P55 20 DB PK DIESEL P59 20 LB RD P59 20 LB RD OTHERS SKIM S347 8W 10 27 8W 10 30 8W 10 11 8W 10 13 8W 10 28 8W 10 29 8W 10 2 8W 10 7 8W 15 13 8W 12 2 8W 12 2 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 61 3 8W 44 7 8...

Page 799: ... 9 S13 C4 F87 20 WT BK WT BK 20 F87 FULL OPTIONS BASE 5 C201 Z2 20 20 Z2 WT BK 20 F87 4 F87 20 WT BK S216 FUSED IGNITION SWITCH OUTPUT ST RUN MODULE IMMOBILIZER KEY SENTRY BK LG BK LG BK LG 8W 10 22 8W 10 32 8W 10 17 8W 12 13 8W 10 2 8W 10 7 8W 10 22 8W 10 32 8W 15 16 8W 15 16 8W 12 2 8W 12 13 8W 12 13 8W 39 4 8W 39 VEHICLE THEFT SECURITY SYSTEM LHD XJ J008W 7 XJI03904 ...

Page 800: ...N BLOCK ST RUN A21 10A FUSE 9 S13 C4 F87 20 WT BK Z2 20 20 Z2 4 F87 20 WT BK S216 FUSED IGNITION SWITCH ST RUN OUTPUT MODULE IMMOBILIZER KEY SENTRY BK LG BK LG BK LG 8W 10 22 8W 10 32 8W 10 17 8W 10 2 8W 10 7 8W 10 22 8W 10 32 8W 15 16 8W 15 16 8W 12 2 8W 12 13 8W 12 13 XJ 8W 39 VEHICLE THEFT SECURITY SYSTEM RHD 8W 39 5 XJI03905 J008W 7 ...

Page 801: ... CARGO GY BK 20 M4 7 C314 M4 20 GY BK VT YL 20 M4 C311 C310 5 10 1 3 LIFTGATE SWITCH Z1 20 BK G304 S304 S334 9 C310 6 Z1 18 BK C311 BK 18 Z1 M2 20 BK LB 18 G16 2 17 C200 S200 BK LB 20 G16 6 SWITCH HEADLAMP C1 C2 IGNITION SWITCH 2 G16 20 BK LB G16 20 BK LB B SWITCH 6 C314 YL 20 M2 G302 3 C326 GY BK 20 M4 2 G16 18 BK LB B 20 M2 YL YL YL YL YL NOT USED DOOR JAMB SWITCH SENSE DOOR AJAR SWITCH SENSE DR...

Page 802: ...Y BK 20 M4 7 C314 M4 20 GY BK VT YL 20 M4 C311 C310 5 10 2 3 Z1 20 BK G304 S304 S334 9 C310 6 C311 BK 18 Z1 M2 20 BK LB 18 G16 4 C203 S200 BK LB 20 G16 6 SWITCH HEADLAMP C1 C2 IGNITION SWITCH 2 G16 20 BK LB G16 20 BK LB B SWITCH 6 C314 YL 20 M2 G302 C318 2 S310 Z1 18 BK 3 C326 GY BK 20 M4 M2 20 2 G16 18 BK LB B YL YL YL YL YL YL NOT USED SWITCH LIFTGATE DOOR JAMB SWITCH SENSE DOOR JAMB SWITCH SENS...

Page 803: ...TT A7 C5 RELAY HORN MODULE OVERHEAD TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR CCD BUS CCD BUS D1 20 VT BR 1 2 WT BK 20 D2 S238 S239 S346 S344 OTHER COMPASS OTHER COMPASS OTHER A T A T OTHER S144 S145 PAIR TWISTED TWISTED PAIR MODULE IMMOBILIZER KEY SENTRY C1 38 MODULE CONTROL ENGINE 16 C3 ENGINE DISABLE SIGNAL SIGNAL DISABLE ENGINE G55 18 OR BK 4 0L 4 0L D2 20 WT BK D1 18 VT...

Page 804: ...WISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR CCD BUS CCD BUS D1 20 VT BR 1 2 WT BK 20 D2 S238 S239 S145 OTHER A T OTHER 4 0L A T S144 COMPASS OTHER COMPASS OTHER S344 S346 PAIR TWISTED MODULE IMMOBILIZER KEY SENTRY ENGINE DISABLE SIGNAL ENGINE CONTROL MODULE 38 C1 OR BK 18 G55 SIGNAL DISABLE ENGINE C3 16 4 0L D2 20 WT BK D1 18 VT BR 2 C301 1 D2 20 WT BK D1 20 VT BR VT BR 20 D1 W...

Page 805: ......

Page 806: ...h 8W 40 14 Headlamp Switch 8W 40 11 15 High Beam Indicator 8W 40 14 Component Page Ignition Switch 8W 40 9 10 11 Instrument Cluster 8W 40 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Junction Block 8W 40 2 12 13 15 17 Left Turn Signal Indicator 8W 40 14 Liftgate Ajar Indicator 8W 40 15 Liftgate Switch 8W 40 15 Low Coolant Switch 8W 40 17 Low Fuel Warning Indicator 8W 40 3 Low Washer Fluid Indicator 8W 40 ...

Page 807: ...ION CENTER A24 A23 PK 20 M1 S135 C4 S18 C1 12 BLOCK JUNCTION PK 20 M1 RHD LHD C201 6 S214 C1 9 FUSED B S225 1 M1 20 PK UNDERHOOD LAMP OUTPUT ST RUN F87 20 WT BK S227 POLICE POSTAL OTHER SWITCH DIESEL DIESEL GAS M1 20 PK FUSED B 8W 12 2 8W 10 17 8W 12 13 8W 12 13 8W 15 16 8W 10 27 8W 10 30 8W 10 11 8W 10 13 8W 10 2 8W 10 7 8W 10 27 8W 12 2 8W 10 27 8W 10 30 8W 12 13 8W 44 7 8W 15 16 8W 40 2 8W 40 I...

Page 808: ...R CONTROL SPEEDOMETER LOW FUEL WARNING INDICATOR INDICATOR WARNING GAUGES CHECK LOW FUEL WARNING INDICATOR INDICATOR WARNING CHECK GAUGES CONTROL CONTROL UPSHIFT INDICATOR CONTROL UPSHIFT INDICATOR M T LHD RHD C204 6 PAIR TWISTED TWISTED PAIR PAIR TWISTED S239 S238 E12 E11 A T 4 0L OTHER OTHER A T 4 0L F11 RHD LHD SENSOR LEVEL FUEL 3 DIESEL GAS C111 1 S152 G7 20 WT OR DIESEL GAS G7 18 WT OR D1 20 ...

Page 809: ...GINE COOLANT TEMPERATURE K2 18 TN BK 16 C1 ENGINE COOLANT TEMPERATURE SENSOR C2 23 GY YL 18 G60 ENGINE OIL PRESSURE SENSOR ENGINE COOLANT OIL CONTROL PAIR TWISTED TWISTED PAIR SENSOR PRESSURE OIL ENGINE S239 S238 E11 E12 S145 S144 A T 4 0L A T 4 0L OTHER OTHER SIGNAL SENSOR TEMPERATURE COOLANT ENGINE SIGNAL SENSOR PRESSURE OIL ENGINE LHD RHD ST RUN OUTPUT SIGNAL D1 18 VT BR D2 18 WT BK D2 20 WT BK...

Page 810: ...ERATURE 1 2 ENGINE COOLANT TEMPERATURE SENSOR PRESSURE OIL K222 18 TN RD 16 ENGINE COOLANT TEMPERATURE SENSOR 23 GY YL 18 G60 OIL PRESSURE SENSOR SIGNAL ENGINE COOLANT OIL CONTROL PAIR TWISTED TWISTED PAIR 10 C120 TN RD 18 K222 S239 S238 E11 E12 K167 18 BR YL 12 4 BR YL 18 K167 2 S138 K167 18 BR YL NO 2 C1 C1 C2 C3 C3 SIGNAL SENSOR PRESSURE OIL ENGINE ENGINE ENGINE LHD RHD C116 2 G60 18 GY YL ST R...

Page 811: ...LUID WASHER LOW BK LB 20 G29 LOW WASHER FLUID SENSE BK LB 20 G29 C1 7 A B SWITCH LEVEL FLUID WASHER BK 16 Z1 G106 S141 BK 20 Z1 SEAT BELT SWITCH A B 10 C2 G10 20 LG RD 69 C201 SENSE SWITCH BELT SEAT G10 20 LG RD Z1 20 BK S314 Z1 14 BK BK 14 Z1 S208 G107 14 C201 Z1 14 BK SEAT BELT WARNING SEAT BELT WARNING INDICATOR INDICATOR CONTROL PAIR TWISTED PAIR TWISTED PAIR TWISTED S132 Z1 16 BK OTHER 4 0L A...

Page 812: ... LOW WASHER FLUID SENSE BK LB 20 G29 C1 7 A B SWITCH LEVEL FLUID WASHER G106 BK 20 Z1 SEAT BELT SWITCH A B 10 C2 G10 20 LG RD 69 C201 SENSE SWITCH BELT SEAT G10 20 LG RD Z1 20 BK S314 Z1 14 BK BK 14 Z1 S208 G107 14 C201 Z1 14 BK SEAT BELT WARNING SEAT BELT WARNING INDICATOR INDICATOR CONTROL PAIR TWISTED PAIR TWISTED PAIR TWISTED FOG LAMP RELAY IN PDC B13 E8 S239 S238 ST RUN OUTPUT Z1 20 BK Z1 12 ...

Page 813: ...2 G10 20 LG RD 11 C203 SENSE SWITCH BELT SEAT G10 20 LG RD Z1 20 BK S313 Z1 20 BK BK 12 Z1 S309 G302 SEAT BELT WARNING SEAT BELT WARNING INDICATOR INDICATOR CONTROL PAIR TWISTED PAIR TWISTED PAIR TWISTED S132 BK 12 Z1 FOG LAMP RELAY IN PDC B13 Z1 20 BK S239 S238 LG OR 20 G19 CONTROLLER ANTI LOCK BRAKE RELAY IN PDC B19 B16 DIESEL GAS Z1 20 BK S132 Z1 16 BK DIESEL GAS Z1 16 BK G106 FUSED IGNITION SW...

Page 814: ... PRESSURE BRAKE G9 20 GY BK A14 C100 G9 20 GY BK GY BK 20 G9 S211 C1 1 C1 2 3 0 2 1 4 4 ACC 3 LOCK 0 OFF 2 RUN 1 START SWITCH IGNITION BK 14 Z1 BK 20 Z1 S207 G108 PARK BRAKE SWITCH G9 20 GY BK 66 C201 LHD RHD C203 13 BK 20 Z1 SWITCH TRANSFER CASE SWITCH E14 E2 LHD RHD WARNING 2 C112 3 1 C112 3 C112 C112 1 4 0L A T OTHER 4 0L A T OTHER Z1 20 BK Z1 20 BK G106 20 BK WT G107 20 BK RD WARNING BRAKE IND...

Page 815: ...9 20 GY BK A14 C100 G9 20 GY BK GY BK 20 G9 S211 C1 1 C1 2 3 0 2 1 4 4 ACC 3 LOCK 0 OFF 2 RUN 1 START SWITCH IGNITION BK 14 Z1 BK 20 Z1 S207 G108 PARK BRAKE SWITCH G9 20 GY BK 66 C201 LHD RHD C203 13 BK 20 Z1 TRANSFER CASE SWITCH 4 C111 Z1 18 BK Z1 12 BK S157 E14 E2 LHD RHD 231 4WD WARNING RED 8W 12 13 8W 15 12 8W 15 11 8W 10 16 8W 10 16 8W 15 16 8W 15 11 8W 15 16 8W 40 10 8W 40 INSTRUMENT CLUSTER...

Page 816: ...IVER LHD RHD BK LB 20 G16 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 6 0 1 2 S210 CHIME CONTROL BATT M1 FUSED B C C317 G302 S309 Z1 18 BK Z1 20 BK Z1 12 BK 3 3 BK 12 Z1 BK 20 Z1 BK 18 Z1 S310 G303 C318 C G16 20 BK LB BK LB 20 G16 8W 39 6 8W 39 7 8W 50 2 8W 50 3 8W 10 17 8W 10 15 8W 10 16 8W 10 27 8W 10 30 8W 15 17 8W 15 17 8W 15 20 8W 15 20 8W 10 17 XJ 8W 40 INSTRUMENT CLUSTER 8W 40 11 XJI04011 J008W 7 ...

Page 817: ... D2 20 WT BK VT BR 20 D1 6 S344 VT BR 20 D1 1 WT BK 20 D2 VT BR 20 D1 C2 1 2 C2 CCD BUS BUS CCD OVERHEAD MODULE VTSS INDICATOR PAIR TWISTED PAIR TWISTED PAIR TWISTED 55 KEY SENTRY CCD BUS BUS CCD PAIR TWISTED IMMOBILIZER MODULE D1 20 VT BR D2 20 WT BK 1 2 C81 20 LB WT S238 S239 D1 20 VT BR D2 20 WT BK COMPASS COMPASS OTHER OTHER 8W 12 2 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 48 2 8W 48 2 8W 12 17 ...

Page 818: ...BK VT BR 20 D1 6 S344 VT BR 20 D1 1 WT BK 20 D2 VT BR 20 D1 C2 1 2 C2 CCD BUS BUS CCD OVERHEAD MODULE VTSS INDICATOR PAIR TWISTED PAIR TWISTED PAIR TWISTED KEY SENTRY CCD BUS BUS CCD PAIR TWISTED IMMOBILIZER MODULE D1 20 VT BR D2 20 WT BK 1 2 S238 S239 EXCEPT POLICE POSTAL COMPASS COMPASS OTHER OTHER D1 20 VT BR D2 20 WT BK 8W 12 2 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 48 3 8W 48 3 8W 12 18 8W 10...

Page 819: ...AZARD SWITCH D3 C100 OTHER S227 Z2 20 BK LG Z2 20 BK LG Z2 20 BK LG HEADLAMP SWITCH HIGH BEAM OUTPUT SIGNAL TURN LEFT RIGHT TURN SIGNAL POLICE POSTAL OTHER DRL DIMMER B10 IN PDC NO 1 RELAY LAMP FOG 4 MODULE LAMP RUNNING DAYTIME G34 16 RD GY G34 16 RD GY HIGH BEAM INDICATOR DRIVER DRIVER INDICATOR BEAM HIGH 8W 50 4 8W 50 5 8W 50 6 8W 50 7 8W 50 4 8W 50 5 8W 50 6 8W 50 7 8W 15 16 8W 52 7 8W 52 8 8W ...

Page 820: ... RHD LHD 2 1 0 1 3 4 4 BRIGHT 3 DIM 2 HEAD 1 PARK 0 OFF SWITCH HEADLAMP 1 C1 LIFTGATE AJAR INDICATOR G78 20 TN BK G78 20 TN BK C311 3 C310 6 G78 20 TN BK 1 C327 G78 20 TN BK 40 C200 C204 5 LHD RHD 2 SWITCH LIFTGATE LIFTGATE AJAR SWITCH SENSE AJAR LIFTGATE CONTROL INDICATOR 4 8W 12 2 8W 12 8 8W 12 9 8W 10 28 8W 10 29 8W 12 8 8W 12 8 8W 12 9 8W 50 2 8W 50 3 8W 44 8 8W 44 9 XJ 8W 40 INSTRUMENT CLUSTE...

Page 821: ...STED PAIR 18 RD LG 18 V66 30 SPEED CONTROL INDICATOR SIGNAL CONTROL INDICATOR SIGNAL SPEED S239 S238 ENGINE CONTROL MODULE DIESEL E11 E12 S144 S145 4 0L A T OTHER OTHER 4 0L A T 30 C3 28 C3 C2 C1 FUSED IGNITION SWITCH OUTPUT ST RUN LHD RHD D2 20 WT BK D2 18 WT BK D1 18 VT BR D1 20 VT BR 8W 12 13 8W 30 20 8W 30 21 8W 30 30 8W 30 20 8W 30 21 8W 30 20 8W 30 21 8W 30 30 8W 30 20 8W 30 21 8W 30 20 8W 3...

Page 822: ...OLANT LOW E17 C100 18 G154 VT LG 8 8 INDICATOR LOW COOLANT LEVEL WARNING WT BK 20 F87 S225 27 DG WT G123 18 1 SENSOR FUEL IN WATER LOW COOLANT SWITCH 1 18 G18 PK BK 12 COOLANT LEVEL SWITCH FUEL IN WATER SENSOR ENGINE CONTROL MODULE C1 C3 C3 C1 C1 COOLANT LEVEL SWITCH SENSE WATER IN FUEL SENSOR K185 20 OR LB G86 20 TN OR G154 20 VT LG DRIVER SIGNAL SIGNAL SIGNAL 8W 12 13 8W 12 2 8W 10 17 8W 12 13 8...

Page 823: ......

Page 824: ...ng 8W 41 2 3 Fuse 1 JB 8W 41 2 3 Fuse 2 JB 8W 41 2 3 Fuse 21 JB 8W 41 2 3 G107 8W 41 2 3 Component Page High Note Horn 8W 41 2 3 Horn Relay 8W 41 2 3 Horn Switch 8W 41 2 3 Junction Block 8W 41 2 3 Low Note Horn 8W 41 2 3 Overhead Module 8W 41 2 3 Power Outlet 8W 41 2 3 XJ 8W 41 HORN CIGAR LIGHTER POWER OUTLET 8W 41 1 ...

Page 825: ...BATT A7 RELAY HORN 86 30 87 85 C4 S22 CLOCKSPRING HORN SWITCH C201 26 BK RD 20 X3 X3 20 BK RD 21 FUSE 15A G107 S5 C4 1 C5 1 14 Z1 14 BK Z1 14 BK Z1 14 BK Z1 14 BK S314 S208 10 MODULE OVERHEAD X3 20 BK RD X3 20 BK RD 7 C301 C1 HORN HORN HORN RELAY CONTROL 8W 12 2 8W 12 5 8W 12 5 8W 12 21 8W 10 15 8W 10 16 8W 10 20 8W 10 26 8W 15 14 8W 15 15 8W 15 13 8W 15 14 8W 15 15 8W 49 4 8W 10 20 8W 10 26 8W 41...

Page 826: ... RUN ACC A31 BATT A7 RELAY HORN 86 30 87 85 C5 1 CLOCKSPRING HORN SWITCH BK RD 20 X3 21 FUSE 15A G107 S5 C4 S22 C4 1 Z1 14 BK Z1 14 BK S208 10 MODULE OVERHEAD X3 20 BK RD X3 20 BK RD 7 C301 C1 HORN HORN HORN RELAY CONTROL 8W 12 2 8W 12 5 8W 12 5 8W 12 21 8W 10 15 8W 10 16 8W 10 20 8W 10 26 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 49 5 8W 10 20 8W 10 26 XJ 8W 41 HORN CIGAR LIGHTER POWER OUTLET RHD 8W...

Page 827: ......

Page 828: ...wer Motor 8W 42 2 3 4 5 Blower Motor Relay 8W 42 2 3 4 5 Blower Motor Resistor Block 8W 42 2 3 4 5 Engine Control Module 8W 42 8 10 Fuse 6 PDC 8W 42 2 3 4 5 Component Page Fuse 11 PDC 8W 42 2 3 4 5 Fuse 25 JB 8W 42 2 3 4 5 7 G106 8W 42 8 9 10 G107 8W 42 7 G108 8W 42 2 3 4 5 Heater Control 8W 42 2 3 Junction Block 8W 42 2 3 4 5 7 Power Distribution Center 8W 42 2 3 4 5 7 8 9 10 Powertrain Control M...

Page 829: ... CONTROL HEATER 7 5 4 2 1 17 24 11 FUSE 40A DIESEL GAS 8 9 BI LEVEL BLOCK RESISTOR MOTOR BLOWER S219 2 C209 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12 RD LG S228 C1 12 DG C7 12 BK TN BLOWER MOTOR RELAY MOTOR BLOWER B A 1 G108 25 C201 C209 10 Z1 20 BK Z8 20 BK VT Z8 16 BK VT C1 C1 C1 C1 C1 C1 A111 12 RD LG FROM S215 E2 20 OR 9 5 DEFROST M 8W 12 2 8W 10 2 8W 10 7 8W 10 11 8W 10 13 8W 1...

Page 830: ...G 8 9 BI LEVEL 2 3 4 C4 14 TN LG 14 C5 LB 14 C6 BK TN 12 C7 F15 20 DB WT A111 12 RD LG 5 4 2 1 2 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12 RD LG S228 C1 12 DG C7 12 BK TN BLOWER MOTOR RELAY MOTOR BLOWER B A 1 G108 6 C202 C209 10 Z1 20 BK Z8 12 BK VT Z8 16 BK VT BLOCK RESISTOR MOTOR BLOWER C209 C1 C1 C1 C1 C1 C1 S349 FROM S215 E2 20 OR F15 20 DB WT F15 20 DB WT 9 5 DEFROST M 8W 12 2 ...

Page 831: ...ENTER DISTRIBUTION POWER A111 12 RD LG A 8W 42 6 TO C100 S219 2 3 4 C4 14 TN LG 14 C5 LB 14 C6 BK TN 12 C7 F15 20 DB WT A111 12 RD LG 5 4 2 1 2 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12 RD LG S228 C1 12 DG C7 12 BK TN BLOWER MOTOR RELAY MOTOR BLOWER B A 1 G108 25 C201 C209 10 Z1 20 BK Z8 20 BK VT Z8 16 BK VT BLOCK RESISTOR MOTOR BLOWER C209 C1 C1 C1 C1 C1 C1 C1 FROM S215 E2 20 OR F1...

Page 832: ...A111 12 RD LG A 8W 42 6 TO C100 S219 2 3 4 C4 14 TN LG 14 C5 LB 14 C6 BK TN 12 C7 F15 20 DB WT A111 12 RD LG 5 4 2 1 2 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12 RD LG S228 C1 12 DG C7 12 BK TN BLOWER MOTOR RELAY MOTOR BLOWER B A 1 G108 6 C202 C209 10 Z1 20 BK Z8 12 BK VT Z8 16 BK VT BLOCK RESISTOR MOTOR BLOWER C209 C1 C1 C1 C1 C1 C1 C1 F15 20 DB WT S349 1 C204 F15 20 DB WT F15 20 DB...

Page 833: ...8 C22 A C HIGH PRESSURE SWITCH A C LOW PRESSURE SWITCH C3 23 MODULE CONTROL POWERTRAIN 22 C3 1 2 4 2 3 1 C3 13 RADIATOR FAN REQUEST C48 18 TN FROM CONTROL HEATER A C 1 2 1 SWITCH PRESSURE HIGH A C C21 20 DB PK A C LOW PRESSURE SWITCH 2 C90 20 LG 4 0L 2 5L 8W 30 18 8W 30 30 8W 42 5 8W 42 6 8W 42 AIR CONDITIONING HEATER XJ J008W 7 XJI04206 ...

Page 834: ... 8 D3 20 YL 4 C201 7 D1 20 DB WT Z1 20 BK S237 F15 20 DB WT LHD RHD GAS GAS C204 18 LHD RHD GROUND BLEND DOOR FEEDBACK SIGNAL RHD LHD 17 C204 C201 7 RUN C36 18 RD WT C36 20 RD WT G107 BK 20 Z1 10 OR 20 D2 RHD LHD S349 1 C204 6 5 1 C209 F15 20 DB WT C2 C2 C2 CONTROL HEATER A C C36 20 RD WT ACTUATOR DOOR BLEND RUN OUTPUT SWITCH IGNITION FUSED F15 20 DB WT Z1 20 BK OTHER EXPORT OTHER EXPORT BUILT UP ...

Page 835: ...ONTROL MODULE A C COMPRESSOR CLUTCH RELAY CONTROL SENSE SWITCH PRESSURE C22 20 DB WT 3 C22 20 DB WT C21 20 DB PK C120 2 Z1 20BK C8 C11 C13 RELAY DOWN SHUT AUTOMATIC RADIATOR FAN RELAY A142 18DG OR A142 18 DG OR BATT A16 A C S170 Z1 16 BK 3 2 RADIATOR FAN REQUEST 48 C1 C48 18 TN 13 C120 C48 18 TN Z1 18 BK IN PDC IN PDC 8W 10 7 8W 10 32 8W 15 12 8W 15 11 8W 15 11 8W 30 27 8W 30 30 8W 30 22 8W 42 10 ...

Page 836: ...RADIATOR D13 D14 D10 D11 RADIATOR FAN RELAY 1 2 C27 18 DB PK MOTOR FAN RADIATOR G106 Z1 12 BK FAN BATT F141 ST RUN F20 LB 12 C25 RELAY CONTROL M 8W 10 2 8W 30 18 8W 15 7 8W 15 10 8W 10 21 8W 12 14 XJ 8W 42 AIR CONDITIONING HEATER GAS 8W 42 9 XJI04209 J008W 7 ...

Page 837: ...ATOR G106 Z1 12 BK FAN BATT F141 LB 12 C25 RELAY CONTROL C2 C8 RELAY DOWN SHUT AUTOMATIC BATT A16 A142 18 DG OR B5 A142 18 DG OR IN PDC RELAY CLUTCH COMPRESSOR A C FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT M 8W 10 7 8W 30 33 8W 15 12 8W 10 26 8W 30 22 8W 10 19 8W 42 8 8W 42 10 8W 42 AIR CONDITIONING HEATER DIESEL XJ J008W 7 XJI04210 ...

Page 838: ...odule 8W 43 2 3 4 Clockspring 8W 43 4 Data Link Connector 8W 43 2 3 Driver Airbag 8W 43 4 Fuse 26 JB 8W 43 2 3 Component Page Fuse 27 JB 8W 43 2 3 G200 8W 43 2 G300 8W 43 3 Junction Block 8W 43 2 3 Passenger Airbag 8W 43 4 XJ 8W 43 AIRBAG SYSTEM 8W 43 1 ...

Page 839: ...NK CONNECTOR RUN A22 ST RUN A21 D2 18 WT BK D1 18 VT BR VT BR 20 D1 WT BK 20 D2 D2 18 WT BK D1 18 VT BR BUS CCD CCD BUS BK YL 18 Z6 G200 GROUND 10 PAIR TWISTED PAIR TWISTED PAIR TWISTED Z6 18 BK PK BASE FULL OPTIONS RUN OUTPUT OUTPUT ST RUN S238 S239 8W 12 2 8W 12 25 8W 12 25 8W 30 20 8W 10 18 8W 10 17 8W 15 17 8W 30 20 8W 30 20 8W 43 2 8W 43 AIRBAG SYSTEM LHD XJ J008W 7 XJI04302 ...

Page 840: ...ONNECTOR RUN A22 ST RUN A21 D2 18 WT BK D1 18 VT BR VT BR 20 D1 WT BK 20 D2 D2 18 WT BK D1 18 VT BR BUS CCD CCD BUS BK PK 18 Z6 G300 GROUND 10 14 C204 15 DB YL 18 F23 LG YL 18 F14 PAIR TWISTED PAIR TWISTED PAIR TWISTED RUN OUTPUT ST RUN OUTPUT S238 S239 8W 12 2 8W 12 26 8W 12 26 8W 30 21 8W 10 18 8W 10 17 8W 15 18 8W 30 21 8W 30 21 XJ 8W 43 AIRBAG SYSTEM RHD 8W 43 3 XJI04303 J008W 7 ...

Page 841: ...AIRBAG LINE 1 PASSENGER 6 4 PASSENGER LINE 2 AIRBAG 3 5 PASSENGER AIRBAG LINE 1 LINE 2 AIRBAG PASSENGER R45 18 DG LB R43 18 BK LB R42 18 BK YL R44 18 DG YL 2 C205 1 3 4 DG YL 18 R44 BK YL 18 R42 BK LB 18 R43 DG LB 18 R45 PAIR TWISTED TWISTED PAIR PAIR TWISTED TWISTED PAIR 1 C3 C3 2 CLOCKSPRING 8W 43 4 8W 43 AIRBAG SYSTEM XJ J008W 7 XJI04304 ...

Page 842: ... 3 4 6 7 Component Page Instrument Cluster 8W 44 2 3 4 8 9 Junction Block 8W 44 2 3 4 5 6 7 Left Courtesy Lamp 8W 44 6 7 Left Rear Door Jamb Switch 8W 44 8 9 Left Visor Vanity Lamp 8W 44 5 Liftgate Switch 8W 44 8 9 Passenger Door Jamb Switch 8W 44 8 9 Power Distribution Center 8W 44 6 7 PRNDL Illumination 8W 44 2 3 4 Radio 8W 44 2 3 4 Rear Fog Lamp Switch 8W 44 3 4 Rear Window Defogger Switch 8W 4...

Page 843: ...Z1 20 BK 1 1 4 SWITCH WASHER WIPER REAR G107 Z1 20 BK Z1 14 BK Z1 BK 20 1 Z1 20 BK S208 BK VT 12 Z8 G108 EXTENDED IDLE SWITCH 1 4 20 BK Z1 OTHERS C201 14 PACKAGE POLICE TN 20 E1 SWITCH ILLUMINATION BK 20 Z1 Z1 14 BK Z1 14 BK BK 14 Z1 OR 20 E2 A T PANEL LAMPS DIMMER SWITCH SIGNAL SIGNAL SWITCH DIMMER LAMPS PANEL FUSED C1 C1 8W 12 2 8W 50 2 8W 47 2 8W 47 9 8W 48 2 8W 40 15 8W 42 4 8W 15 13 8W 15 14 ...

Page 844: ...107 Z1 20 BK 1 1 4 SWITCH WASHER WIPER REAR G107 Z1 20 BK Z1 14 BK Z1 BK 20 1 Z1 20 BK S208 BK VT 12 Z8 G108 C201 14 TN 20 E1 SWITCH ILLUMINATION BK 20 Z1 Z1 14 BK Z1 14 BK BK 14 Z1 OR 20 E2 A T 20 BK GY Z15 1 4 REAR FOG LAMP SWITCH OR 20 E2 PANEL LAMPS DIMMER SWITCH SIGNAL FUSED PANEL LAMPS SWITCH SIGNAL DIMMER C1 C1 8W 12 2 8W 50 3 8W 47 2 8W 47 9 8W 48 2 8W 40 15 8W 42 4 8W 15 13 8W 15 15 8W 15...

Page 845: ...Z1 BK 20 1 Z1 20 BK S208 BK VT 12 Z8 G108 12 C203 OR 20 E2 BK 20 Z1 Z1 12 BK OR BK 20 E2 SWITCH ILLUMINATION 18 BK GY Z15 1 SWITCH FOG REAR 4 LAMP OR 20 E2 G107 ILLUMINATION A T PANEL LAMPS DIMMER SWITCH SIGNAL E2 20 OR BUILT UP EXPORT FUSED PANEL LAMPS DIMMER SWITCH SIGNAL E2 20 OR E2 20 OR A C HEATER CONTROL C1 C1 8W 12 2 8W 50 5 8W 50 7 8W 47 3 8W 47 10 8W 48 3 8W 40 15 8W 15 18 8W 15 18 8W 15 ...

Page 846: ... 7 S345 S342 A 8W 44 6 TO BLOCK JUNCTION C4 S5 C3 BLOCK JUNCTION Z1 14 BK 2 VISOR VISOR COMPASS SKIM OTHERS M1 20 PK S361 MIDLINE BASE POLICE 3 2 LAMP DOME M2 20 YL B B S342 Z1 20 BK Z1 20 BK A A M1 20PK 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 15 13 8W 12 2 8W 10 28 8W 10 29 8W 10 30 8W 12 2 8W 10 27 8W 10 30 8W 12 30 8W 15 13 8W 12 2 8W 49 2 8W 49 3 8W 49 4 8W 49 5 8W 10 28 8W 10 29 8W 15 13 8W 44...

Page 847: ...HEADLAMP DELAY MODULE 4 Z1 18 BK M2 20 YL A 8W 44 5 C3 1 YL 20 M2 1 C207 A 2 C207 B M1 18 PK 5 C314 UNDERHOOD M1 20 PK 1 BK 20 Z1 2 S132 G106 Z1 16 BK LAMP M1 20 PK M1 20 PK M2 18BK WT M2 18BK WT C4 SWITCH GROUND FROM COMPASS FROM SWITCH LAMPS DOME FULL OPTIONS MIDLINE M2 20 YL M2 20 YL M2 20 YL CARGO LAMP SWITCH TO C 8W 44 9 E 8W 44 9 TO S304 LHD RHD 8W 12 2 8W 10 2 8W 10 11 8W 10 27 8W 10 27 8W ...

Page 848: ...M1 18 PK 5 C314 UNDERHOOD M1 20 PK 1 BK 20 Z1 2 S132 G106 Z1 12 BK LAMP S157 M1 20 PK M1 20 PK M2 18BK WT M2 18BK WT SWITCH MIDLINE OPTIONS FULL DOME LAMPS SWITCH FROM COMPASS FROM M2 20 YL 1 C3 A 8W 44 5 GROUND M2 20 YL M2 20 YL M2 20 YL C 8W 44 9 TO SWITCH LAMP CARGO CARGO LAMP SWITCH TO B 8W 44 8 RHD LHD M1 18 PK PK 20 M1 RHD LHD S304 TO E 8W 44 9 YL 20 M2 D 8W 44 8 TO S304 8W 12 2 8W 10 7 8W 1...

Page 849: ...18 Z1 Z1 20 BK S309 Z1 12 BK G303 BK 20 Z1 Z1 18 BK C317 C LEFT REAR DOOR JAMB SWITCH 3 2 YL 18 M2 C317 A DRIVER DOOR JAMB SWITCH 1 3 3 1 SWITCH JAMB DOOR PASSENGER BK 18 Z1 Z1 18 BK C311 6 C310 9 S334 G304 BK 20 Z1 YL YL YL YL M4 20 VT YL 1 2 C326 3 M4 20 GY BK C1 1 CLUSTER INSTRUMENT C311 3 1 C327 40 C200 C310 G78 20 TN BK 6 G78 20 TN BK G78 20 TN BK SWITCH AJAR LIFTGATE SENSE 8W 39 6 8W 15 19 8...

Page 850: ... BK 18 Z1 Z1 20 BK S309 Z1 12 BK BK 20 Z1 Z1 18 BK C317 C LEFT REAR DOOR JAMB SWITCH 3 2 YL 18 M2 C317 A PASSENGER DOOR JAMB SWITCH 1 3 3 1 SWITCH JAMB DOOR DRIVER BK 18 Z1 Z1 18 BK C311 6 C310 9 S334 G304 BK 20 Z1 BK 12 Z1 G303 YL YL YL YL M4 20 VT YL 1 2 C326 3 M4 20 GY BK C1 1 C311 3 1 C327 C204 5 C310 6 CLUSTER INSTRUMENT G78 20 TN BK SWITCH AJAR LIFTGATE SENSE 8W 39 7 8W 15 20 8W 15 18 8W 39 ...

Page 851: ......

Page 852: ...7 2 3 9 10 Junction Block 8W 47 2 3 9 10 Component Page Left Front Door Speaker 8W 47 5 6 9 10 Left Front Door Tweeter 8W 47 5 6 Left Soundbar Speaker 8W 47 5 6 11 Power Amplifier 8W 47 2 3 4 5 6 7 8 Power Antenna 8W 47 4 Power Antenna Relay 8W 47 4 Power Distribution Center 8W 47 2 3 4 Radio 8W 47 2 3 4 5 6 7 8 9 10 11 Right Front Door Speaker 8W 47 7 8 9 10 Right Front Door Tweeter 8W 47 7 8 Rig...

Page 853: ...TN 20 E1 PK 20 M1 FUSED B FUSED B F75 16 VT VT 16 F75 1 C2 2 C2 14 C200 C4 C100 F75 16 VT VT 16 F75 F75 14 VT S301 G301 8 C2 GROUND BK LB 16 Z5 7 C2 GROUND Z5 16 BK LB PK 20 M1 1 PK 20 M1 22 FUSE 20A A11 A12 A3 A4 20A FUSE 26 DIESEL GAS DIESEL GAS S135 DIESEL SWITCH LAMP UNDERHOOD RUN ACC OUTPUT LAMPS FUSED B EXPORT BUILT UP EXCEPT ANTENNA M1 20 PK DIMMER SWITCH SIGNAL 8W 12 10 8W 12 11 8W 10 28 8...

Page 854: ...301 8 C2 GROUND BK LB 16 Z5 7 C2 GROUND Z5 16 BK LB PK 20 M1 1 PK 20 M1 LAMPS OUTPUT RUN ACC FUSED B PANEL FUSED G108 BK 14 Z9 GROUND FUSED IGNITION SWITCH HEADLAMP SWITCH OUTPUT RADIO S135 GAS DIESEL UNDERHOOD LAMP SWITCH DIESEL GAS DIESEL 26 FUSE 20A A4 A3 A12 A11 20A FUSE 22 FUSED B EXPORT BUILT UP EXCEPT ANTENNA M1 20 PK DIMMER SWITCH SIGNAL 8W 12 10 8W 12 11 8W 10 28 8W 10 29 8W 50 2 8W 50 3 ...

Page 855: ...K 18 Z1 1 UP 2 DOWN 2 1 1 2 GAS DIESEL 19 FUSE 20A A18 A17 A3 A4 20A FUSE 26 BATT A0 CENTER DISTRIBUTION POWER A18 C100 E6 11 C200 14 C203 LHD RHD LHD RHD 5 GROUND FLASHER COMBINATION Z1 20 BK Z1 14 BK S208 LHD RHD OUTPUT 12V RADIO X60 18 DG RD X60 18 DG RD RADIO ANTENNA COAX COAX ANTENNA 8W 10 29 8W 15 15 8W 10 29 8W 10 29 8W 10 11 8W 10 13 8W 10 2 8W 10 7 8W 52 3 8W 52 4 8W 15 15 8W 47 4 8W 47 A...

Page 856: ...87 BK RD 18 X85 1 2 BR RD 18 X85 DG 18 X87 LEFT SOUNDBAR SPEAKER 4 C2 1 2 C2 12 C305 X87 LG VT X85 BR RD BR DB 16 X91 WT BK X91 BR YL 16 X93 WT RD 18 X93 4 C314 3 14 C2 B A C2 6 S327 S326 LG BK 18 X87 LG RD 18 X85 2 1 LEFT FRONT SPEAKER SPEAKER FRONT LEFT OUTPUT 12V RADIO LEFT FRONT SPEAKER SPEAKER FRONT LEFT SPEAKER DOOR FRONT LEFT LEFT FRONT DOOR TWEETER RADIO 12V OUTPUT AMPLIFIED AMPLIFIED S229...

Page 857: ... S326 S327 X85 18 LG RD X87 18 LG BK SOUNDBAR 18 18 18 SPEAKER DOOR FRONT LEFT LEFT FRONT DOOR TWEETER RADIO 12V OUTPUT LEFT FRONT SPEAKER SPEAKER FRONT LEFT SPEAKER REAR LEFT LEFT REAR SPEAKER RADIO EXCEPT BUILT UP EXPORT S229 BUILT UP EXPORT AMPLIFIED AMPLIFIED OUTPUT 12V RADIO LEFT FRONT SPEAKER SPEAKER FRONT LEFT LEFT REAR SPEAKER SPEAKER REAR LEFT SPEAKER DOOR LEFT DOOR SPEAKER LEFT LEFT REAR...

Page 858: ...314 2 C303 10 C2 2 1 C2 11 SPEAKER SOUNDBAR RIGHT SPEAKER DOOR RIGHT DOOR SPEAKER 1 2 5 4 S320 RIGHT X94 18 TN RD X92 18 TN BK TN BK 16 X92 TN RD 16 X94 X82 18 LB RD X80 18 LB BK LB BK 18 X80 LB RD 18 X82 LB BK 18 X80 S321 X82 18 LB RD X82 18 LB RD LB BK 18 X80 RIGHT SPEAKER REAR RIGHT REAR SPEAKER RIGHT FRONT SPEAKER SPEAKER FRONT RIGHT SPEAKER DOOR FRONT RIGHT RIGHT FRONT DOOR TWEETER AMPLIFIED ...

Page 859: ... X82 18 LB RD X80 18 LB BK LB BK 18 X80 LB RD 18 X82 LB BK 18 X80 S321 X82 18 LB RD X82 18 LB RD LB BK 18 X80 SPEAKER DOOR FRONT RIGHT RIGHT FRONT DOOR TWEETER RIGHT FRONT SPEAKER SPEAKER FRONT RIGHT SPEAKER REAR RIGHT RIGHT REAR SPEAKER AMPLIFIED AMPLIFIED SPEAKER REAR RIGHT REAR SPEAKER RIGHT RIGHT SPEAKER DOOR RIGHT DOOR SPEAKER FRONT RIGHT SPEAKER SPEAKER RIGHT FRONT SPEAKER REAR RIGHT SPEAKER...

Page 860: ... 1 LEFT FRONT LEFT FRONT 16 16 2 1 BR RD 18 X55 DG 18 X53 4 C1 1 2 C2 2 X53 DG X55 BR RD SPEAKER SPEAKER C200 3 C2 2 1 C1 5 4 5 X54 16 VT X56 16 DB RD DB RD 18 X56 VT 18 X54 SPEAKER DOOR FRONT LEFT RIGHT FRONT DOOR SPEAKER OUTPUT RUN ACC LAMPS SPEAKER SPEAKER FRONT RIGHT FRONT RIGHT 2 1 5 C303 4 X53 18 LG BK X82 18 LB RD C305 EXPORT BUILT UP EXCEPT ANTENNA X80 18 LB BK X55 18 LG RD SWITCH DIMMER S...

Page 861: ...5 16 BR RD BR RD 18 X55 DG 18 X53 SPEAKER DOOR FRONT RIGHT LEFT FRONT DOOR SPEAKER LEFT FRONT LEFT FRONT SPEAKER SPEAKER SWITCH SIGNAL RUN ACC OUTPUT SPEAKER SPEAKER FRONT RIGHT FRONT RIGHT FUSED B LAMPS DIMMER FUSED PANEL GROUND FUSED IGNITION SWITCH HEADLAMP SWITCH OUTPUT 5 C303 4 2 C305 1 C4 EXPORT BUILT UP EXCEPT ANTENNA X53 18 LG BK X82 18 LB RD X80 18 LB BK LG RD 18 X55 8W 12 10 8W 12 11 8W ...

Page 862: ...A B C1 7 2 C314 1 SPEAKER SOUNDBAR RIGHT X52 16 DB WT X58 16 DB OR DB OR 18 X58 DB WT 18 X52 RIGHT REAR SPEAKER SPEAKER REAR RIGHT LHD RHD LHD RHD LHD RHD LHD RHD 22 C203 C200 6 7 C200 C203 16 9 C200 C203 21 10 C200 C203 15 X51 18 BR YL X57 18 BR LB X52 18 DB WT X58 18 DB OR XJ 8W 47 AUDIO SYSTEM 4 SPEAKER SYSTEM 8W 47 11 XJI04711 J008W 7 ...

Page 863: ......

Page 864: ...8 2 3 G107 8W 48 2 3 G302 8W 48 2 3 G303 8W 48 3 G304 8W 48 2 3 Component Page Instrument Cluster 8W 48 2 3 Junction Block 8W 48 2 3 Passenger Power Mirror 8W 48 2 3 Rear Window Defogger 8W 48 2 3 Rear Window Defogger Relay 8W 48 2 3 Rear Window Defogger Switch 8W 48 2 3 XJ 8W 48 REAR WINDOW DEFOGGER 8W 48 1 ...

Page 865: ...K 12 Z1 Z1 16 BK C4 S5 C9 11 BLOCK JUNCTION Z1 18 BK C201 S309 3 C307 C80 20 DB WT Z1 14 BK Z1 14 BK C201 14 S314 S208 REAR WINDOW DEFOGGER REAR WINDOW DEFOGGER BK WT 12 C15 BK 12 Z1 BK 14 Z1 C16 20 LB YL 4 BK 18 Z1 FULL OPTIONS MIRRORS POWER POWER MIRRORS OPTIONS FULL BK 18 Z1 S319 Z1 16 BK C16 20 LB YL C16 20 BK WT MIRRORS POWER FULL OPTIONS S329 S329 Z1 16 BK Z1 12 BK E2 20 OR FROM S215 8W 12 2...

Page 866: ... BK C80 20 DB WT Z1 14 BK REAR WINDOW REAR WINDOW DEFOGGER DEFOGGER Z1 12 BK BK 12 Z1 S310 BK 14 Z1 Z1 12 BK G303 5 C5 LB YL 20 C16 5 C303 4 Z1 14 BK S208 BK 14 Z1 JUNCTION BLOCK 11 C9 S5 C4 G107 Z1 16 BK S319 Z1 16 BK POWER MIRRORS OPTIONS FULL OPTIONS FULL POWER MIRRORS C16 20 LB YL C16 20BK WT Z1 20BK OPTIONS MIRRORS BK WT 20 C16 LB YL 20 C16 POWER FULL 3 C307 FROM S215 E2 20 OR Z1 12 BK 8W 12 ...

Page 867: ......

Page 868: ...r Jamb Switch 8W 49 4 5 Fuse 9 JB 8W 49 2 3 Fuse 16 PDC 8W 49 2 3 G107 8W 49 2 3 Component Page G108 8W 49 2 3 Horn Relay 8W 49 4 5 Junction Block 8W 49 2 3 4 5 Overhead Module 8W 49 2 3 4 5 6 Passenger Power Lock Window Switch 8W 49 4 5 Power Distribution Center 8W 49 2 3 Underhood Lamp Switch 8W 49 2 3 XJ 8W 49 OVERHEAD CONSOLE 8W 49 1 ...

Page 869: ...WER CENTER BATT A0 15A FUSE 16 A23 A24 12 C1 BLOCK JUNCTION M1 20 PK 2 3 C3 2 PK 20 M1 S225 FUSED B B FUSED OUTPUT S135 ST RUN S361 S347 SKIM OTHERS FULL OPTIONS M1 20 PK DIESEL GAS 1 DIESEL SWITCH LAMP UNDERHOOD M1 20 PK F87 20 WT BK FUSED B 8W 12 13 8W 15 16 8W 12 2 8W 15 14 8W 15 15 8W 15 13 8W 15 14 8W 15 15 8W 12 2 8W 10 17 8W 10 2 8W 10 7 8W 10 11 8W 10 13 8W 10 27 8W 10 30 8W 12 2 8W 12 13 ...

Page 870: ...ER CENTER BATT A0 15A FUSE 16 A23 A24 12 C1 BLOCK JUNCTION M1 20 PK 2 3 C3 2 PK 20 M1 S216 F87 20 WT BK FUSED B B FUSED S135 OUTPUT ST RUN S347 S361 SKIM OTHERS M1 20 PK DIESEL GAS 1 DIESEL SWITCH LAMP UNDERHOOD M1 20 PK FUSED B 8W 12 13 8W 15 16 8W 12 2 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 12 2 8W 10 17 8W 10 2 8W 10 7 8W 10 11 8W 10 13 8W 10 27 8W 10 30 8W 12 2 8W 12 13 8W 15 13 8W 10 27 8W 10...

Page 871: ...R C301 3 4 BK LB 20 G32 G31 20 VT LG 32 35 C201 VT LG 20 G31 G32 20 BK LB 2 F15 F14 C100 BK LB 20 G32 G31 20 VT LG LAMPS COURTESY 1 YL 20 M2 7 1 C3 JUNCTION BLOCK S345 M2 20 YL YL 20 M2 7 C7 1 DRIVER M2 18 YL A C317 S304 SENSOR TEMPERATURE AMBIENT SIGNAL GROUND SENSOR CONTROL RELAY UNLOCK DOOR LOCK CONTROL DOOR CONTROL RELAY UNLOCK DOOR SWITCH JAMB DOOR SENSOR TEMPERATURE AMBIENT COURTESY LAMPS DR...

Page 872: ...MPERATURE SENSOR C301 3 4 VT LG 20 G31 G32 20 BK LB 2 F15 F14 C100 BK LB 20 G32 G31 20 VT LG LAMPS COURTESY 1 7 1 C3 JUNCTION BLOCK S345 M2 20 YL 7 C7 1 SWITCH JAMB DOOR DRIVER M2 18 YL A C318 S304 M2 20 YL M2 20 YL YL 20 M2 12 3 C305 P55 20 DB PK LB RD 20 P59 YL 20 M2 CONTROL UNLOCK DOOR DOOR LOCK CONTROL SENSOR TEMPERATURE AMBIENT SIGNAL GROUND SENSOR RELAY RELAY SENSOR TEMPERATURE AMBIENT COURT...

Page 873: ... BR 20 D1 MODULE OVERHEAD D1 20 VT BR D2 20 WT BK TWISTED PAIR PAIR TWISTED COMPASS BUS CCD BUS CCD RHD LHD 55 C201 C201 56 LHD RHD VT BR 20 D1 5 11 WT BK 20 D2 PAIR TWISTED S239 S238 COMPASS COMPASS OTHER OTHER 8W 30 20 8W 30 21 8W 30 20 8W 30 21 8W 30 20 8W 30 21 8W 30 20 8W 30 21 8W 30 20 8W 30 21 8W 49 6 8W 49 OVERHEAD CONSOLE XJ J008W 7 XJI04906 ...

Page 874: ...dlamp Switch 8W 50 2 3 8 9 10 11 12 13 14 16 17 Component Page Instrument Cluster 8W 50 4 5 6 7 16 18 Junction Block 8W 50 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 Left City Lamp 8W 50 11 14 17 Left Fog Lamp 8W 50 15 16 17 Left Front Park Turn Signal Lamp No 1 8W 50 10 Left Front Park Turn Signal Lamp No 2 8W 50 10 Left Front Turn Signal Lamp No 1 8W 50 11 Left Front Turn Signal Lamp No 2 8W 50 11 L...

Page 875: ...SE 20A TN BK 18 F34 F34 18 TN BK YL 20 M2 S201 FROM LG 14 L2 LG 14 L2 6 2 BK YL 18 L7 9 LB 20 G26 5 FROM S210 6 G16 20 BK LB TO S200 TO S206 MODULE HEADLAMP DELAY A 8W 50 4 B 8W 50 4 HEAD LAMP SWITCH OUTPUT HEADLAMP BEAM SELECT SWITCH TO TO SWITCH SELECT BEAM HEADLAMP 1 E1 20 TN C201 42 LHD RHD FUSE 6 JB TO LHD RHD A18 E6 S218 8W 10 2 8W 10 11 8W 10 22 8W 50 18 8W 15 16 8W 15 16 8W 50 8 8W 50 8 8W...

Page 876: ... G26 5 FROM S210 6 G16 20 BK LB TO S200 TO S206 SWITCH HEADLAMP MODULE HEADLAMP DELAY 14 C 8W 50 6 D 8W 50 6 S218 DIODE MODULE 1 OUTPUT 14 16 S226 L2 LG L2 LG L2 LG 20A FUSE 19 A18 A17 A18 RHD LHD DIESEL GAS HEADLAMP BEAM SELECT SWITCH TO TO SWITCH SELECT BEAM HEADLAMP GAS DIESEL 14 7 8 FUSE 30A 4 5 FUSE TO 1 E1 20 TN 6 JB 8W 10 2 8W 10 7 8W 10 11 8W 10 13 8W 10 22 8W 15 16 8W 15 16 8W 50 9 8W 50 ...

Page 877: ...0 A 8W 50 2 DELAY HEADLAMP FROM MODULE SWITCH FROM HEADLAMP B 8W 50 2 S213 RD OR 16 L3 D3 C100 OTHER DRL L3 16 RD RD GY 16 G34 BK 20 Z1 Z1 20 BK WT DAYTIME RUNNING LAMP MODULE 1 D4 C100 G34 16 RD GY CLUSTER INSTRUMENT 5 C1 1 2 3 1 2 3 1 3 3 HIGH 2 LOW 1 FLASH 2 4 HIGH BEAM INDICATOR DRIVER DIMMER SWITCH HIGH BEAM OUTPUT L33 20RD SWITCH SELECT BEAM HEADLAMP L44 20 VT RD E 8W 50 14 C106 12 C106 FOG ...

Page 878: ...0 RD OR G106 S133 VT RD 20 L44 B12 A 8W 50 2 DELAY HEADLAMP FROM MODULE SWITCH FROM HEADLAMP B 8W 50 2 S213 RD OR 16 L3 BK 20 Z1 Z1 20 BK WT CLUSTER INSTRUMENT 5 C1 C100 1 2 3 1 2 3 1 3 3 HIGH 2 LOW 1 FLASH 2 4 L33 20RD SWITCH SELECT BEAM HEADLAMP DIMMER SWITCH HIGH BEAM OUTPUT NOT USED C106 TO IN PDC NO 1 RELAY LAMP FOG E 8W 50 14 EXCEPT DRL C106 12 L33 20 RD WT 8W 12 7 8W 12 6 8W 12 6 8W 12 7 8W...

Page 879: ... G106 S133 VT RD 20 L44 C 8W 50 3 FROM S226 SWITCH FROM HEADLAMP D 8W 50 3 S213 RD OR 16 L3 D3 C100 RD GY 16 G34 BK 20 Z1 Z1 20 BK WT D4 C100 G34 16 RD GY CLUSTER INSTRUMENT 5 C1 1 2 3 1 2 3 1 3 3 HIGH 2 LOW 1 FLASH 2 4 C100 F6 L44 20 VT RD 3 HEADLAMP LEVELING SWITCH S162 S163 HIGH BEAM INDICATOR DRIVER SWITCH SELECT BEAM HEADLAMP FUSED RIGHT LOW BEAM OUTPUT 8W 12 7 8W 12 6 8W 12 6 8W 12 7 8W 12 2...

Page 880: ...0 RD OR G106 S133 VT RD 20 L44 C 8W 50 3 FROM S226 SWITCH FROM HEADLAMP D 8W 50 3 S213 BK 20 Z1 Z1 20 BK WT L3 16 RD OR CLUSTER INSTRUMENT 5 C1 1 2 3 1 2 3 1 3 3 HIGH 2 LOW 1 FLASH 2 4 C100 B12 L44 20 VT RD 3 HEADLAMP LEVELING SWITCH S162 S163 DIMMER SWITCH HIGH BEAM OUTPUT SWITCH SELECT BEAM HEADLAMP FUSED RIGHT LOW BEAM OUTPUT 8W 12 7 8W 12 6 8W 12 6 8W 12 7 8W 12 2 8W 15 10 8W 15 12 8W 15 10 8W...

Page 881: ...1 14 BK S225 FUSED B SWITCH HEADLAMP TIMER HEADLAMP 4 6 SWITCH OUTPUT HEADLAMP HEADLAMP SWITCH GROUND FULL OPTIONS BASE F87 20 WT BK MODULE LAMP RUNNING DAYTIME F87 20 WT BK 5 C201 S216 F87 20 WT BK 8 LHD RHD SWITCH SELECT BEAM HEADLAMP HEAD LAMP SWITCH OUTPUT OUTPUT ST RUN 8W 10 2 8W 10 11 8W 10 22 8W 12 2 8W 12 13 8W 10 17 8W 15 16 8W 15 16 8W 12 13 8W 50 2 8W 50 2 8W 50 18 8W 12 13 8W 50 4 8W 5...

Page 882: ...Z1 14 BK S225 WT BK 20 F87 FUSED B TIMER HEADLAMP LHD RHD 4 6 SWITCH OUTPUT HEADLAMP HEADLAMP SWITCH GROUND L2 14 LG S226 BASE FULL OPTIONS F87 20 WT BK F87 20 WT BK SWITCH SELECT BEAM HEADLAMP HEAD LAMP SWITCH OUTPUT 14 7 8 FUSE 30A DIESEL GAS SWITCH HEADLAMP OUTPUT ST RUN 8W 10 2 8W 10 7 8W 10 11 8W 10 13 8W 10 22 8W 12 13 8W 12 2 8W 12 13 8W 10 17 8W 15 16 8W 15 16 8W 12 13 8W 50 3 8W 50 3 8W 5...

Page 883: ...WITCH HAZARD SIGNAL TURN PART OF MULTI FUNCTION SWITCH B6 IN PDC NO 1 RELAY LAMP FOG S105 L77 20 BR YL BR YL 20 L77 LG 20 L61 L61 20 LG WT C106 BK WT 20 Z1 BR 20 L77 7 C106 BK YL 18 L7 LHD RHD LEFT TURN SIGNAL F4 RHD LHD NO 1 LAMP SIGNAL TURN PARK FRONT LEFT NO 2 LAMP SIGNAL TURN PARK FRONT LEFT S103 BK 18 Z1 Z1 18 BK B9 8W 12 10 8W 12 2 8W 15 7 8W 12 10 8W 50 2 8W 10 28 8W 52 5 8W 52 2 8W 50 14 8...

Page 884: ...H HAZARD SIGNAL TURN B6 S105 L77 18 BR YL BR YL 20 L77 GY 18 L61 L61 20 LG WT C106 BK WT 20 Z1 BK WT 18 Z1 7 C106 BK YL 18 L7 LHD RHD 2 1 LEFT CITY LAMP BK 18 Z1 Z1 20 BK 2 C114 1 C114 LG 18 L61 BK 18 Z1 LEFT TURN SIGNAL F4 NO 1 NO 2 S158 BR YL 20 L77 GAS DIESEL LHD RHD Z1 18 BK S169 IN PDC NO 1 RELAY LAMP FOG B9 L77 20 BR YL 8W 12 11 8W 12 2 8W 15 10 8W 15 12 8W 15 10 8W 15 12 8W 12 11 8W 50 3 8W...

Page 885: ... 5 C1 23 FUSE 10A G106 L7 18 BK YL 45 C201 S206 2 1 0 9 SWITCH HEADLAMP 1 PARK 2 HEAD 0 OFF BATT F34 L7 18 BK YL C106 10 C100 B9 TN 20 L60 1 S212 L60 20 TN SWITCH HAZARD SIGNAL TURN TN 20 L60 LHD RHD BK YL 18 L7 BK 20 Z1 14 C106 DG YL 20 L78 RIGHT TURN SIGNAL F3 FRONT FRONT NO 1 NO 2 LHD RHD Z1 18BK 8W 12 2 8W 15 7 8W 12 24 8W 15 7 8W 12 10 8W 50 2 8W 10 28 8W 52 7 8W 52 2 8W 50 12 8W 50 FRONT LIG...

Page 886: ...D SIGNAL TURN S116 C106 BK 20 Z1 BK 18 Z1 DG YL 20 L78 14 C106 BK YL 18 L7 LHD RHD 2 1 RIGHT CITY LAMP BK 18 Z1 Z1 20 BK 2 C115 1 C115 BK 18 Z1 L78 20 DG YL RIGHT RIGHT RIGHT TN 20 L60 TN 20 L60 TN 20 L60 TN 18 L60 TN 18 L60 GY 18 L60 L60 18 TN L78 18 DG YL DIESEL GAS F3 NO 1 NO 2 RIGHT TURN SIGNAL LHD RHD 8W 12 24 8W 12 2 8W 15 10 8W 15 12 8W 15 10 8W 15 12 8W 12 11 8W 50 3 8W 10 29 8W 52 8 8W 52...

Page 887: ...L77 20 BR YL L77 20 BR YL C106 7 EXCEPT BUILT UP EXPORT BUILT UP EXPORT TO S104 1 LEFT CITY LAMP BATT F34 0 OFF 9 0 1 2 HEADLAMP SWITCH S206 RHD LHD C201 45 7 FUSE 10A M3 C4 6 C2 BLOCK JUNCTION L7 18 BK YL L7 18 BK YL BR YL 20 L77 L7 18 BK YL Z1 20 BK F 8W 50 15 FOG LAMP RELAY NO 2 IN PDC FROM 4 0L A T 2 HEAD 1 PARK Z1 20 BK Z1 20 BK FUSED HEAD LAMP SWITCH OUTPUT GROUND GROUND Z1 20 BK 8W 10 2 8W ...

Page 888: ...SWITCH 2 3 S106 BK 20 Z1 BK 20 Z1 LAMP FOG RIGHT 1 2 LEFT FOG LAMP 2 1 G106 S103 S102 BK 18 Z1 BK WT 18 Z1 4 C106 11 CENTER DISTRIBUTION POWER F 8W 50 14 Z1 20 BK TO IN PDC RELAY NO 1 FOG LAMP S230 G 8W 50 14 FROM IN PDC RELAY NO 1 FOG LAMP L139 20 VT Z1 18 BK EXCEPT BUILT UP EXPORT EXPORT BUILT UP FOG LAMP SWITCH OUTPUT 8W 15 14 8W 15 14 8W 51 9 8W 51 10 8W 10 33 8W 15 7 8W 15 10 8W 15 7 8W 15 10...

Page 889: ... 20 L39 BK 20 Z1 BK WT 20 Z1 1 4 BATT F61 L39 20 LB L77 20 BR YL RD GY S208 L39 20 LB L39 20 LB 8 C106 L139 20 VT L139 20 VT A5 C100 Z1 20 BK Z1 20BK Z1 14 BK Z1 20 BK L92 20 PK A4 C100 RD GY 16 G34 G34 16 4 MODULE LAMP RUNNING DAYTIME G107 CLUSTER INSTRUMENT C100 D4 G34 16 RD GY HIGH BEAM INDICATOR DRIVER DRIVER INDICATOR BEAM HIGH 5 C1 G106 Z1 16 BK S132 C106 7 L77 20 BR YL L77 20 BR TO S104 8W ...

Page 890: ... 7 C106 A5 C100 L139 20 VT L77 20 BR YL L77 20 BR YL L77 20 BR L77 18 BR YL D13 G106 S230 IN PDC RELAY MOTOR STARTER ENGINE S141 S132 Z1 20 BK Z1 12 BK Z1 12 BK L92 20 PK A4 C100 3 MODULE DIODE L39 20 LB L39 20 LB TO LAMP CITY LEFT L39 18 LB RHD LHD C201 45 S169 BK YL 20 Z1 L39 20 LB L39 20 LB B19 Z1 20 BK YL IN PDC RELAY BRAKE ANTI LOCK CONTROLLER FOG LAMP SWITCH OUTPUT GROUND GROUND 8W 15 12 8W ...

Page 891: ...8 WT OR G7 20 WT OR 4 DRIVER BEAM INDICATOR HIGH RD GY 16 G34 B10 IN PDC NO 1 RELAY LAMP FOG D4 C100 C1 5 CLUSTER INSTRUMENT G34 16 RD GY G34 16 RD GY SPEED VT RD 18 L44 S133 10 L44 20 VT RD 13 C106 VT RD 18 L44 FUSED RIGHT LOW BEAM OUTPUT B SENSOR SPEED VEHICLE HIGH BEAM INDICATOR DRIVER L3 16 RD OR SIGNAL FUSED RIGHT LOW BEAM OUTPUT OUTPUT 1 C201 C100 E9 S159 B13 ST RUN WT 18 F20 L3 16 RD OR RD ...

Page 892: ...13 L13 18 BR YL S164 L13 18 BR YL LOGIC LOGIC M M L44 18 VT RD 1 VT RD 18 L44 BR YL 20 L13 E18 C100 C100 B12 VT RD 20 L44 L44 20 VT RD 3 BK GY 20 Z15 G107 HEADLAMP LEVELING SWITCH 5 2 L13 20 BR YL L43 18 VT LEFT HEADLAMP B 1 VT 18 L43 S162 L44 20 VT RD L44 18 VT RD 9 C106 L43 18 VT BEAM F6 HEADLAMP LHD RHD S163 DIMMER 8W 12 2 8W 12 7 8W 50 6 8W 50 7 8W 50 6 8W 50 7 8W 15 10 8W 15 12 8W 12 7 8W 15 ...

Page 893: ......

Page 894: ...Up Lamp 8W 51 8 Left License Lamp 8W 51 4 Component Page Left Rear Fog Lamp 8W 51 11 12 Left Tail Stop Lamp 8W 51 3 Left Turn Signal Lamp 8W 51 5 License Lamp 8W 51 4 Park Neutral Position Switch 8W 51 6 Power Distribution Center 8W 51 2 Powertrain Control Module 8W 51 6 Rear Fog Lamp Indicator 8W 51 11 12 Rear Fog Lamp Relay 8W 51 9 10 Rear Fog Lamp Switch 8W 51 11 12 Right Back Up Lamp 8W 51 8 R...

Page 895: ...20 PK DB L50 20 WT TN S203 7 C321 BK YL 18 L7 WT TN 20 L50 WT TN 20 L50 A 8W 51 3 B 8W 51 3 C 8W 51 3 TO S311 S302 TO RIGHT TAIL STOP LAMP TO DG YL 18 L78 A18 A17 19 FUSE 15A DIESEL GAS 24 C200 24 C204 LHD RHD LHD RHD C201 45 4 8W 12 10 8W 12 11 8W 12 2 8W 12 24 8W 12 10 8W 12 11 8W 50 2 8W 50 3 8W 10 28 8W 10 29 8W 33 4 8W 33 5 8W 10 33 8W 10 2 8W 10 7 8W 10 11 8W 10 13 8W 10 32 8W 10 33 8W 10 32...

Page 896: ...N BR YL 20 L77 L77 18 BR TRAILER TOW OTHERS WT TN 18 L50 WT TN 18 L50 BK 18 Z1 L77 18 BR YL BR YL 20 L77 5 TRAILER TOW OTHER Z1 14 BK L77 18 BR YL 7 C322 7 C323 2 C322 C323 2 S340 OTHER TRAILER TOW C323 6 S336 Z1 18 BK Z1 16 BK EXCEPT BUILT UP EXPORT BUILT UP EXPORT RHD LHD BK 12 Z1 BK 16 Z1 S311 Z1 14 BK 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W 15 19 8W 15 20 8W 15 19 8W 15 20 8W 15 17 8W 15 18 8W ...

Page 897: ...8 BK 5 C326 2 1 LICENSE LAMP S334 9 C310 C311 6 Z1 18 BK S311 2 C310 C311 4 11 BK 18 Z1 BK 18 Z1 BR YL 18 L77 WT TN 20 L50 L77 18 BR YL BR YL 18 L77 L50 18 WT TN C327 1 C333 L50 18 DG WT C333 2 Z1 18 BK 1 C330 L78 18 BK YL C330 2 Z1 18 BK BUILT UP EXPORT BUILT UP EXPORT EXCEPT 8W 15 21 8W 12 11 8W 10 32 8W 10 33 8W 15 21 8W 15 21 8W 12 10 8W 12 11 8W 51 4 8W 51 REAR LIGHTING XJ J008W 7 XJI05104 ...

Page 898: ...8 L63 BR RD 18 L62 1 C322 TRAILER TOW OTHERS S335 LEFT TURN SIGNAL SIGNAL TURN RIGHT L62 20 BR RD Z1 14 BK 11 C204 25 C200 LHD RHD 2 C323 C323 1 RHD LHD 26 C200 12 C204 S337 2 C322 Z1 18 BK BK 16 Z1 BUILT UP EXPORT UP EXPORT EXCEPT BUILT Z1 12 BK RHD LHD L63 20 DG RD Z1 14 BK 8W 52 2 8W 52 3 8W 70 2 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W 15 19 8W 15 20 8W 15 19 8W 15 20 8W 15 17 8W 15 18 8W 54 2 8...

Page 899: ...A T LHD RHD 4 0L A T S161 A15 A B MODULE CONTROL POWERTRAIN CONTROL SOLENOID CLUTCH CONVERTER TORQUE C2 11 K54 18 OR BK F20 18 WT S159 L10 18 BR LG E 8W 51 8 S303 TO BR LG 18 L10 18 4 0L MODULE CONTROL TRANSMISSION BACK UP LAMP FEED 11 C107 F20 18 WT SWITCH F20 18 WT WT 18 F20 C113 1 C113 2 BR LG 18 L10 4 0L M T 2 5L A T 11 C107 2 5L M T 12 C107 2 5L M T SOLENOID CLUTCH TORQUE CONVERTER 8W 12 2 8W...

Page 900: ... F20 LHD RHD 23 C204 16 C200 A15 C100 5 C111 WT 18 F20 7 C111 F20 18 WT TO S303 D 8W 51 8 BR LG 18 L10 R BR LG 18 L10 L10 18 BR LG E3 A9 C100 E9 LHD RHD 1 C201 RHD LHD L10 18 BR LG E 8W 51 8 S303 TO LAMP 8W 12 2 8W 12 14 8W 10 17 XJ 8W 51 REAR LIGHTING DIESEL 8W 51 7 XJI05107 J008W 7 ...

Page 901: ...Z1 CONNECTOR TOW TRAILER 8 BK 18 Z1 BK 18 Z1 S339 TOW TRAILER OTHERS Z1 16 BK LHD RHD 2 C323 2 C322 C323 5 C322 5 S337 FROM C200 C204 FROM E 8W 51 6 LHD RHD Z1 18 BK Z1 16 BK BUILT UP EXPORT UP EXPORT EXCEPT BUILT Z1 14BK Z1 14 BK 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W 15 19 8W 15 20 8W 15 19 8W 15 20 8W 15 17 8W 15 18 8W 15 19 8W 15 20 8W 54 2 8W 54 2 8W 15 17 8W 15 18 8W 51 7 8W 51 7 8W 51 8 8W ...

Page 902: ...SWITCH WINDOW LOCK POWER DRIVER F 8W 51 11 G 8W 51 11 REAR FOG LAMP SWITCH TO TO C200 TO SWITCH LAMP FOG REAR H 8W 51 11 L38 18 BR WT FOG LAMP SWITCH OUTPUT HEAD LAMP SWITCH OUTPUT FUSED IGNITION SWITCH OUTPUT RUN ACC 85 87 30 86 B15 L92 20 PK IN PDC NO 2 RELAY LAMP FOG FOG LAMP RELAY IN PDC PK 20 L92 B15 GAS DIESEL OUTPUT SWITCH LAMP FOG FOG LAMP SWITCH OUTPUT 8W 12 2 8W 12 19 8W 15 15 8W 10 15 8...

Page 903: ... SWITCH TO TO S220 YL DG 18 F83 C300 3 FOG LAMP RELAY OUTPUT HEAD LAMP SWITCH OUTPUT C2 3 SWITCH WINDOW LOCK POWER DRIVER F83 18 YL DG FUSED IGNITION SWITCH OUTPUT RUN ACC S352 F83 18 YL DG L92 20 PK S232 DIESEL GAS B15 L92 20 PK IN PDC RELAY LAMP FOG FOG LAMP RELAY NO 2 IN PDC PK 20 L92 B15 FOG LAMP RELAY OUTPUT OUTPUT RELAY LAMP FOG 8W 12 2 8W 12 20 8W 15 15 8W 10 15 8W 10 16 8W 50 3 8W 50 15 8W...

Page 904: ...S348 S341 Z1 18 BK Z1 14 BK Z1 12 BK Z1 18 BK Z1 16 BK ILLUMINATION F 8W 51 9 G 8W 51 9 H 8W 51 9 FROM RELAY FOG REAR LAMP LAMP REAR FOG RELAY FROM LAMP REAR FOG RELAY FROM BR WT 18 L38 OR WT 18 L38 OR WT 18 L38 BK 16 Z1 Z1 18 BK BK 18 Z1 L38 18 BR WT L38 18 BR WT 4 FROM S215 E2 20 OR 8W 15 15 8W 15 17 8W 15 19 8W 15 19 8W 15 17 8W 15 19 8W 15 17 8W 12 8 XJ 8W 51 REAR LIGHTING LHD BUILT UP EXPORT ...

Page 905: ...03 S310 S309 S348 S341 Z1 18 BK Z1 14 BK Z1 12 BK Z1 18 BK Z1 12 BK ILLUMINATION I 8W 51 10 J 8W 51 10 FROM RELAY FOG REAR LAMP LAMP REAR FOG RELAY FROM BR WT 18 L38 OR WT 18 L38 OR WT 18 L38 BK 16 Z1 Z1 18 BK BK 18 Z1 L38 18 BR WT L38 18 BR WT 4 FROM S215 E2 20 OR S220 8W 15 15 8W 15 18 8W 15 20 8W 15 20 8W 15 18 8W 15 20 8W 15 18 8W 12 9 8W 51 12 8W 51 REAR LIGHTING RHD BUILT UP EXPORT XJ J008W ...

Page 906: ...al Lamp No 1 8W 52 6 Left Front Turn Signal Lamp No 2 8W 52 6 Component Page Left Repeater Lamp 8W 52 6 Left Side Marker Lamp 8W 52 5 Left Turn Signal Lamp 8W 52 5 6 Power Antenna Relay 8W 52 3 4 Power Distribution Center 8W 52 2 3 4 Right Front Park Turn Signal Lamp No 1 8W 52 7 Right Front Park Turn Signal Lamp No 2 8W 52 7 Right Front Turn Signal Lamp No 1 8W 52 8 Right Front Turn Signal Lamp N...

Page 907: ...L12 20 VT TN L6 20 RD WT R L L R R L L R FUSED IGNITION SWITCH FUSED B HAZARD FLASHER SELECT OUTPUT FLASHER GROUND 4 11 L55 20 RD WT LHD RHD C201 3 BR RD 20 L62 3 DG RD 20 L63 9 A 8W 52 7 B 8W 52 5 C 8W 52 7 D 8W 52 5 C200 C204 TO TO C204 C200 TO S212 TO S209 BK PK 20 L9 BK 20 L5 F5 OUTPUT SIGNAL LHD RHD RUN A22 RUN 8W 12 2 8W 12 17 8W 12 18 8W 10 2 8W 10 31 8W 10 11 8W 15 14 8W 15 14 8W 10 18 8W ...

Page 908: ...R L L R R L L R FUSED IGNITION SWITCH FUSED B HAZARD FLASHER SELECT OUTPUT FLASHER GROUND 4 11 L55 20 RD WT LHD RHD C201 3 BR RD 20 L62 3 DG RD 20 L63 9 E 8W 52 8 F 8W 52 6 G 8W 52 8 H 8W 52 6 C200 C204 TO TO C204 C200 TO S212 TO S209 BK PK 20 L9 BK 20 L5 C1 A POWER ANTENNA RELAY BK 18 Z1 RHD F5 GROUND SIGNAL OUTPUT LHD RHD RUN RUN A22 8W 12 2 8W 12 17 8W 12 18 8W 10 2 8W 10 31 8W 10 11 8W 15 15 8...

Page 909: ... R L L R R L L R FUSED IGNITION SWITCH FUSED B HAZARD FLASHER SIGNAL OUTPUT FLASHER GROUND 4 11 L55 20 RD WT LHD RHD C201 3 BR RD 20 L62 3 DG RD 20 L63 9 E 8W 52 8 F 8W 52 6 G 8W 52 8 H 8W 52 6 C200 C204 TO TO C204 C200 TO S212 TO S209 BK PK 20 L9 BK 20 L5 C1 A POWER ANTENNA RELAY BK 18 Z1 RHD GROUND C100 F5 OUTPUT SELECT LHD RHD RUN RUN A22 8W 12 2 8W 12 17 8W 12 18 8W 10 7 8W 10 35 8W 10 13 8W 1...

Page 910: ...C200 C204 12 C322 1 L63 18 DG RD 1 2 LEFT TURN SIGNAL LAMP Z1 18 BK S341 BK 18 Z1 Z1 18 BK S337 Z1 14 BK LHD RHD OTHERS TRAILER TOW Z1 12 BK G302 LG WT 20 L61 10 C1 CLUSTER INSTRUMENT S309 LEFT TURN SIGNAL Z1 14 BK S335 TRAILER TOW OTHER L63 20 DG RD L63 20 DG RD L63 20 DG RD L63 20 DG RD L63 20 DG RD F4 FRONT FRONT NO 2 NO 1 S103 1 C323 C322 2 C323 2 LHD RHD Z1 18 BK Z1 14 BK 8W 15 7 8W 12 10 8W ...

Page 911: ... S105 GY 18 L61 L61 20 LG WT C106 BK WT 20 Z1 BK WT 18 Z1 BK 18 Z1 2 C114 1 C114 LG 18 L61 BK 18 Z1 INSTRUMENT CLUSTER C1 10 L61 20 LG WT S209 LEFT TURN SIGNAL Z1 14 BK DG RD 20 L63 DG RD 20 L63 DG RD 20 L63 DG RD 20 L63 DG RD 20 L63 OTHER TOW TRAILER S335 RHD LHD DG RD 18 L63 1 C322 12 C204 C200 26 L63 20 DG RD F4 NO 1 NO 2 S158 1 C323 C322 2 C323 2 LHD RHD 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W ...

Page 912: ...HD RHD 25 C200 C204 11 L62 20 BR RD S312 L62 20 BR RD 1 C321 L62 18 BR RD 1 2 BK 18 Z1 S348 Z1 18 BK 2 C321 BK 18 Z1 S310 BK 16 Z1 G303 FROM SWITCH HAZARD SIGNAL TURN TURN SIGNAL HAZARD SWITCH FROM S101 LAMP SIGNAL TURN RIGHT L60 20 TN C2 6 CLUSTER INSTRUMENT RIGHT TURN SIGNAL Z1 12 BK RHD LHD F3 FRONT FRONT NO 1 NO 2 LHD RHD Z1 18BK 8W 15 7 8W 15 7 8W 70 2 8W 15 19 8W 15 20 8W 15 19 8W 15 20 8W 1...

Page 913: ...SIGNAL TURN FRONT G106 10 C100 B9 S116 C106 BK 20 Z1 BK 18 Z1 BK 18 Z1 2 C115 1 C115 BK 18 Z1 RIGHT RIGHT RIGHT TN 20 L60 TN 20 L60 TN 20 L60 TN 18 L60 TN 18 L60 GY 18 L60 L60 18 TN INSTRUMENT CLUSTER 6 C2 TN 20 L60 S212 LHD RHD BK 12 Z1 G303 Z1 16 BK S310 Z1 18 BK C321 2 RIGHT TURN SIGNAL F3 NO 1 NO 2 RHD LHD 8W 70 2 8W 15 19 8W 15 20 8W 15 10 8W 15 12 8W 15 10 8W 15 12 8W 40 14 8W 15 19 8W 15 20...

Page 914: ...06 8W 53 2 3 4 5 6 7 G107 8W 53 4 5 6 7 G108 8W 53 2 3 G304 8W 53 4 5 6 7 Component Page Headlamp Switch 8W 53 4 5 6 7 Junction Block 8W 53 2 3 4 5 6 7 Rear Washer Pump 8W 53 2 4 5 6 7 Rear Wiper Motor 8W 53 4 5 6 7 Rear Wiper Washer Switch 8W 53 4 5 6 7 Windshield Washer Pump 8W 53 2 3 4 6 Wipe Wash Switch 8W 53 2 3 Wiper Motor Relay 8W 53 2 3 XJ 8W 53 WIPERS 8W 53 1 ...

Page 915: ... ACC A31 8 C1 1 V6 16 DB G106 S141 PUMP WASHER WINDSHIELD Z1 16 BK Z1 16 BK PUMP WASHER REAR LHD RHD C201 8 5 INTERMITTENT 4 WASH 2 LOW 3 HIGH 1 DELAY 0 OFF 5 3 2 1 0 3 2 1 0 BK 14 Z1 BR WT 16 V3 BR VT 16 V4 DG YL 16 V5 OTHER Z1 18BK C100 E4 Z1 16 BK GROUND LHD 4 0L EXCEPT BUILT UP EXPORT 2 5L A16 RHD LHD OTHER M 8W 12 2 8W 15 4 8W 15 6 8W 15 8 8W 15 9 8W 15 16 8W 15 16 8W 12 27 8W 15 7 8W 15 10 8...

Page 916: ...Z1 18 BK Z1 12 BK RELAY MOTOR WIPER 20A 30 BREAKER CIRCUIT RUN ACC A31 8 C1 1 V6 16 DB Z1 16 BK G106 S157 PUMP WASHER WINDSHIELD Z1 12 BK LHD RHD C201 8 5 INTERMITTENT 4 WASH 2 LOW 3 HIGH 1 DELAY 0 OFF 5 3 2 1 0 3 2 1 0 BK 14 Z1 BR WT 16 V3 BR VT 16 V4 DG YL 16 V5 S141 Z1 12 BK C100 E4 A16 LHD RHD M 8W 12 2 8W 15 11 8W 15 16 8W 15 16 8W 12 27 8W 15 12 8W 15 11 8W 15 11 8W 10 16 XJ 8W 53 WIPERS DIE...

Page 917: ...1 2 0 1 PARK 2 RUN BR PK 18 V23 8 1 C313 C310 3 1 BK WT 18 V20 BK 16 Z1 S141 G106 BK 18 Z1 4 0L EXCEPT BUILT UP EXPORT OTHER Z1 18 BK GROUND 3 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEADLAMP JUNCTION BLOCK 6 FUSE 5A S1 C4 S2 C4 E1 20 TN E1 20 TN S215 43 C201 E2 20OR 42 S315 V23 18 BR PK V13 18 BR V20 18 BK WT V23 18 BR PK V13 18 BR LG V20 18 BK WT M 8W 12 22 8W 12 2 8W 10 18 8W 15 14 8W 15 15 8...

Page 918: ... C200 2 WIPE 1 WASH 0 OFF 1 2 0 1 PARK 2 RUN BR PK 18 V23 8 1 C313 C310 3 1 BK WT 18 V20 BK 12 Z1 S141 V23 18 BR PK V20 18 BK WT V13 18 BR LG 3 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEADLAMP JUNCTION BLOCK 6 FUSE 5A S1 C4 S2 C4 E1 20 TN E1 20 TN S215 43 C201 E2 20OR 42 S315 V23 18 BR PK V13 18 BR V20 18 BK WT V13 18 BR LG V23 18 BR PK V20 18 BK WT M 8W 12 22 8W 12 23 8W 12 2 8W 10 18 8W 15 15 ...

Page 919: ...RK 2 RUN BK WT 18 V20 1 8 3 1 C310 C313 Z1 18 BK GROUND V13 18 BR LG V23 18 BR PK V20 18 BK WT 3 Z1 18 BK 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEADLAMP JUNCTION BLOCK 6 FUSE 5A S1 C4 S2 C4 E1 20 TN E1 20 TN A C HEATER CONTROL 7 S215 E2 20 OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL V23 18 BR PK V13 18 BR V20 18 BK WT C1 S324 BASE FULL OPTIONS V20 18 BK WT M 8W 12 23 8W 12 2 8W 10 18 8W 15 14 8W...

Page 920: ...BLOCK 6 FUSE 5A S1 C4 S2 C4 E1 20 TN E1 20 TN A C HEATER CONTROL 7 S215 E2 20 OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL C1 OPTIONS FULL BASE S324 BK WT 18 V20 BR 18 V13 BR PK 18 V23 BK WT 18 V20 BR PK 18 V23 BR LG 18 V13 BK 18 Z1 C313 C310 1 3 8 1 2 RUN 1 PARK 5 C327 2 3 6 C311 C310 9 S334 G304 M 2 1 3 REAR WIPER MODULE 7 2 4 REAR WIPER MOTOR 1 4 V20 18 BK WT M 8W 12 23 8W 12 2 8W 10 18 8W 15 15 8...

Page 921: ......

Page 922: ...unction Block 8W 54 2 3 Left Back Up Lamp 8W 54 2 Component Page Left Tail Stop Lamp 8W 54 3 Left Turn Signal Lamp 8W 54 3 Trailer Tow Connector 8W 54 2 3 Trailer Tow Electric Brake Provision 8W 54 2 Trailer Tow Left Turn Relay 8W 54 3 Trailer Tow Right Turn Relay 8W 54 3 Turn Signal Hazard Switch 8W 54 3 XJ 8W 54 TRAILER TOW 8W 54 1 ...

Page 923: ...C323 L77 18 BR YL BK 14 Z1 7 B40 14 LB 3 S339 2 LEFT BACK UP LAMP C323 5 L10 18 BR LG 5 C322 FROM S303 L10 18 BR LG BR LG 18 L10 BR LG 18 L10 TRAILER TOW ELECTRIC BRAKE PROVISION BACK UP LAMP FEED 4 L10 18 BR LG 8W 12 2 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W 15 17 8W 15 18 8W 12 10 8W 12 11 8W 10 28 8W 10 29 8W 50 2 8W 50 3 8W 12 10 8W 12 11 8W 12 10 8W 12 11 8W 12 10 8W 12 11 8W 51 8 8W 51 8 8W 5...

Page 924: ...T WT TN 20 L50 WT TN 20 L50 WT TN 20 L50 24 C204 C200 24 RHD LHD S203 BRAKE LAMP SWITCH 5 WT TN 20 L50 L63 18 DG RD RD OR 20 A6 A6 20 RD OR A6 20 RD OR L50 18 WT TN DG RD 20 L63 TRAILER TOW LEFT TURN RELAY RELAY TURN RIGHT TOW TRAILER LEFT TURN SIGNAL SIGNAL TURN RIGHT BRAKE LAMP SWITCH OUTPUT LEFT TURN SIGNAL BRAKE LAMP SWITCH SIGNAL S338 S302 L62 20 BR RD 8W 12 2 8W 12 21 8W 10 20 8W 10 26 8W 51...

Page 925: ......

Page 926: ... 8W 60 2 3 G302 8W 60 2 4 G303 8W 60 3 5 Junction Block 8W 60 2 3 Component Page Left Rear Window Motor 8W 60 4 5 Left Rear Window Switch 8W 60 2 3 4 5 Passenger Power Lock Window Switch 8W 60 2 3 Passenger Power Window Motor 8W 60 2 3 Right Rear Window Motor 8W 60 4 5 Right Rear Window Switch 8W 60 2 3 4 5 XJ 8W 60 POWER WINDOWS 8W 60 1 ...

Page 927: ... WT 14 Q16 Q26 14 VT WT 4 C306 2 Z1 14 BK S329 Z1 12 BK 3 C307 S309 Z1 12 BK Z1 12 BK G302 6 SWITCH WINDOW REAR RIGHT LEFT REAR WINDOW SWITCH 6 2 Q1 14 YL S305 YL 14 Q1 3 C304 Q1 14 YL YL 14 Q1 C309 3 Q1 14 YL Q1 14 YL Q1 14 YL 1 UP 2 DOWN 3 LOCK 4 UNLOCK PASSENGER POWER LOCK WINDOW SWITCH C1 C1 C1 C1 C1 C303 3 POWER WINDOW SWITCH FEED FEED SWITCH WINDOW POWER F81 14TN F81 12TN F81 12 TN M 8W 12 2...

Page 928: ... Q26 14 VT WT 4 C306 Z1 14 BK S319 Z1 14 BK S310 G303 6 SWITCH WINDOW REAR RIGHT LEFT REAR WINDOW SWITCH 6 Q1 14 YL S305 3 C304 Q1 14 YL YL 14 Q1 C309 3 Q1 14 YL 1 UP 2 DOWN 3 LOCK 4 UNLOCK PASSENGER POWER LOCK WINDOW SWITCH C1 C1 C1 C1 C1 8 7 Z1 12 BK Q1 14 YL C307 2 C303 M Q16 14 BR WT Q26 14 VT WT 4 Q1 14 YL POWER WINDOW SWITCH FEED POWER WINDOW SWITCH FEED 5 C303 YL 14 Q1 YL 14 Q1 8W 12 26 8W ...

Page 929: ...14 Q18 1 1 Q28 14 DG WT 2 C306 2 Z1 14 BK S329 3 C307 S309 Z1 12 BK G302 2 Q1 14 YL YL 14 Q1 3 C304 Q1 14 YL MOTOR WINDOW REAR RIGHT 2 1 2 1 RIGHT REAR WINDOW SWITCH 2 4 6 RUN ACC F81 C1 C1 C1 C1 C1 C2 2 1 4 10 8 8 3 4 2 1 2 1 2 1 1 2 SWITCH WINDOW LOCK POWER DRIVER 4 UNLOCK 3 LOCK 2 DOWN 1 UP GY 14 Q14 DG 14 Q24 5 1 M M Z1 12 BK 8W 60 2 8W 15 17 8W 15 17 8W 15 17 8W 12 25 8W 60 4 8W 60 POWER WIND...

Page 930: ... Q18 1 1 Q28 14 DG WT 2 2 Z1 14 BK S319 S310 Z1 12 BK G303 Q1 14 YL 3 C304 Q1 14 YL MOTOR WINDOW REAR RIGHT 2 1 2 1 RIGHT REAR WINDOW SWITCH 2 4 6 RUN ACC F81 C1 C1 C1 C1 C1 C2 2 1 4 10 8 8 3 4 2 1 2 1 2 1 1 2 SWITCH WINDOW LOCK POWER DRIVER 4 UNLOCK 3 LOCK 2 DOWN 1 UP GY 14 Q14 DG 14 Q24 5 1 BK 14 Z1 M M YL 14 Q1 Z1 14 BK 4 5 C303 8W 60 3 8W 15 20 8W 15 20 8W 15 20 8W 12 26 XJ 8W 60 POWER WINDOWS...

Page 931: ......

Page 932: ... 2 3 G107 8W 61 2 G302 8W 61 2 3 G303 8W 61 3 Ignition Switch 8W 61 2 3 Component Page Junction Block 8W 61 2 3 4 5 Left Rear Door Lock Motor 8W 61 4 5 Liftgate Lock Motor 8W 61 4 5 Overhead Module 8W 61 2 3 Passenger Door Lock Motor 8W 61 4 5 Passenger Power Lock Window Switch 8W 61 2 3 4 5 Right Rear Door Lock Motor 8W 61 4 5 XJ 8W 61 POWER DOOR LOCKS 8W 61 1 ...

Page 933: ...1 2 C2 P59 20 LB RD DB 20 P55 5 11 MODULE OVERHEAD 4 C300 3 P55 20 DB PK LB RD 20 P59 8 C301 9 P55 20 DB PK LB RD 20 P59 CONTROL DOOR UNLOCK LOCK DOOR CONTROL P36 18 18 P35 OR VT PK VT OR VT PK VT CONTROL DOOR LOCK UNLOCK DOOR RELAY RELAY CONTROL LOCK LOCK DOOR DOOR LOCK UNLOCK Z1 12 BK OUTPUT RUN ACC G26 20 LB C2 8 SENSE SWITCH IGNITION KEY IN 5 C300 G26 20 LB 29 C201 G26 20 LB S210 G26 20 LB C2 ...

Page 934: ...B RD DB 20 P55 5 11 MODULE OVERHEAD 2 C203 1 8 C301 9 P55 20 DB LB RD 20 P59 CONTROL DOOR UNLOCK LOCK DOOR CONTROL 5 C303 P36 20 PK VT OR VT 20 P35 P35 20 OR VT PK VT 20 P36 CONTROL DOOR LOCK UNLOCK DOOR RELAY P55 20 DB PK RELAY F81 12 TN OUTPUT RUN ACC LOCK SWITCH SWITCH LOCK DOOR DOOR CONTROL IGNITION KEY IN SWITCH SENSE G26 20 LB C2 8 C2 1 SENSE SWITCH KEY IN IGNITION SWITCH IGNITION 2 C306 3 C...

Page 935: ...BK 16 P33 P33 16 OR BK P33 16 OR BK P33 16 OR BK C326 1 4 C304 OR BK 16 P33 4 C309 OR BK 16 P33 P33 16 OR BK S306 C305 4 OR BK 16 P33 12 C9 5 C7 C7 1 C9 1 BLOCK JUNCTION MOTOR LOCK DOOR PASSENGER 2 1 P33 16 OR BK S317 P33 16 OR BK OR BK 16 P33 P34 16 PK BK PK BK 16 P34 S316 PK BK 16 P34 5 C1 DOOR LOCK UNLOCK DOOR C1 1 SWITCH PASSENGER POWER LOCK WINDOW DRIVER DRIVER M M M M M 8W 12 2 8W 12 31 8W 1...

Page 936: ...K 16 P33 OR BK 16 P33 C310 C311 1 4 OR BK 16 P33 LOCK DRIVER DOOR MOTOR 2 2 MOTOR DOOR LEFT REAR LOCK LOCK REAR RIGHT DOOR MOTOR 2 A MOTOR LIFTGATE LOCK 1 1 P34 16 PK BK 1 P34 16 PK BK B P34 16 PK BK 5 5 P34 16 PK BK PK BK 16 P34 PK BK 16 P34 PK BK 16 P34 5 2 2 S307 OR BK 16 P33 P34 16 PK BK 4 C305 5 PK BK 16 P34 P33 16 OR BK 12 C9 C9 1 1 C7 5 C7 DRIVER P34 16 PK BK P33 16 OR BK M M M M M 8W 12 2 ...

Page 937: ......

Page 938: ...Driver Power Mirror 8W 62 2 3 4 5 6 7 8 Fuse 18 JB 8W 62 2 3 5 G107 8W 62 8 G302 8W 62 2 3 4 7 Component Page G303 8W 62 5 6 Junction Block 8W 62 2 3 4 5 6 7 8 Passenger Power Mirror 8W 62 4 6 7 8 Power Mirror Switch 8W 62 7 8 Rear Fog Lamp Relay 8W 62 3 XJ 8W 62 POWER MIRRORS 8W 62 1 ...

Page 939: ...R LOCK WINDOW P76 20 OR YL BK 14 Z1 DB WT 20 P75 P71 20 YL 2 4 OR YL 20 P76 P76 20 OR YL G302 S328 S329 3 C307 S309 Z1 12 BK F83 18 YL DG RUN ACC A31 44 C201 F83 18 YL DG YL DG 18 F83 C200 39 Z1 12 BK Z1 12 BK 5 6 6 PASSENGER MIRROR 5 DRIVER MIRROR 8W 10 15 8W 12 19 8W 12 2 8W 15 17 8W 12 34 8W 15 17 8W 15 17 8W 62 2 8W 62 POWER MIRRORS LHD EXCEPT BUILT UP EXPORT FULL OPTIONS XJ J008W 7 XJI06202 ...

Page 940: ... 20 P75 P71 20 YL 2 4 OR YL 20 P76 P76 20 OR YL G302 S328 S329 3 C307 S309 Z1 12 BK F83 18 YL DG RUN ACC A31 44 C201 F83 18 YL DG YL DG 18 F83 C200 39 1 F83 18 YL DG RELAY LAMP FOG REAR FUSED IGNITION SWITCH OUTPUT RUN ACC Z1 12 BK Z1 12 BK 6 5 6 PASSENGER MIRROR 5 DRIVER MIRROR 8W 10 15 8W 10 16 8W 12 19 8W 12 2 8W 15 17 8W 12 34 8W 15 17 8W 15 17 8W 51 9 XJ 8W 62 POWER MIRRORS LHD BUILT UP EXPOR...

Page 941: ...305 8 9 C5 2 C9 C9 6 C5 10 BLOCK JUNCTION 5 C2 OR YL 20 P76 P76 20 OR YL S318 MIRROR POWER PASSENGER 3 1 M M 4 DOWN 3 UP 2 RIGHT 1 LEFT 3 2 1 4 2 C2 6 5 5 6 4 C2 C2 7 0 0 REST 0 4 1 2 3 3 2 1 4 0 SWITCH DRIVER POWER LOCK WINDOW P76 20 OR YL P74 20 DB YL BK 20 P72 2 4 RUN ACC F83 MIRROR MIRROR 5 6 6 PASSENGER MIRROR 5 DRIVER MIRROR COMMON DRIVER DRIVER COMMON 8W 62 2 8W 62 3 8W 15 17 8W 15 17 8W 15...

Page 942: ...R YL BK 16 Z1 DB 20 P74 P72 20 YL BK 2 4 OR YL 20 P76 P76 20 OR YL G303 S318 S319 S310 Z1 12 BK YL DG 18 F83 F83 18 YL DG RUN ACC A31 S4 C4 Z1 14 BK BUILT UP EXPORT EXCEPT BUILT UP EXPORT 3 C300 5 C303 Z1 14 BK 5 6 6 PASSENGER MIRROR 5 DRIVER MIRROR S352 8W 10 15 8W 12 20 8W 12 2 8W 12 20 8W 15 20 8W 12 36 8W 15 20 8W 15 20 8W 12 20 XJ 8W 62 POWER MIRRORS RHD FULL OPTIONS 8W 62 5 XJI06205 J008W 7 ...

Page 943: ... POWER MIRROR S328 OR YL 20 P76 P76 20 OR YL C2 5 9 C204 8 8 C305 9 S318 10 10 P76 20 OR YL P76 20 OR YL DRIVER POWER MIRROR 2 4 P76 20 OR YL P76 20 OR YL BLOCK JUNCTION 2 C5 10 C9 2 C9 6 C9 10 C5 9 C5 P72 20 YL BK DB 20 P74 Z1 14 BK RUN ACC F83 5 6 5 C303 MIRROR MIRROR 6 PASSENGER MIRROR 5 DRIVER MIRROR P76 20 OR YL COMMON DRIVER DRIVER COMMON 8W 15 20 8W 15 20 8W 15 20 8W 12 20 8W 62 5 8W 12 2 8...

Page 944: ...76 20 OR YL 12 C200 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 8 7 P71 20 YL P75 20 DB WT S329 P91 20 WT BK P76 20 OR YL 1 2 3 4 4 DOWN 3 LEFT 1 RIGHT 2 UP P91 20 WT BK P76 20 OR YL C305 28 C201 67 20 24 C201 BLOCK JUNCTION RUN ACC F83 P74 20 DB P72 20 YL BK P72 20 YL BK P74 20 DB Z1 16 BK 3 C307 Z1 12 BK S309 Z1 12 BK G302 8W 12 2 8W 12 2 8W 12 19 8W 15 17 8W 15 17 8W 15 17 XJ 8W 62 PO...

Page 945: ...4 10 P76 20 OR YL 10 C203 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 3 4 P74 20 DB P72 20 YL BK S319 S5 C4 G107 P91 20 WT BK P76 20 OR YL Z1 14 BK S208 Z1 14 BK 1 2 3 4 4 DOWN 3 LEFT 1 RIGHT 2 UP P91 20 WT BK P76 20 OR YL BLOCK JUNCTION RUN ACC F83 P74 20 DB P72 20 YL BK C305 Z1 16 BK 3 C7 S359 POWER MIRRORS BASE WT BK 20 P91 8W 12 2 8W 15 14 8W 15 15 8W 15 14 8W 15 15 8W 12 2 8W 12 20 ...

Page 946: ...t Heated Seat Back 8W 63 5 Left Heated Seat Cushion 8W 63 5 Left Heated Seat Switch 8W 63 4 Component Page Left Power Seat Motors 8W 63 2 Left Power Seat Switch 8W 63 2 3 6 Rear Motor 8W 63 2 3 Right Heated Seat Back 8W 63 5 Right Heated Seat Cushion 8W 63 5 Right Heated Seat Switch 8W 63 4 Right Power Seat Motors 8W 63 3 Right Power Seat Switch 8W 63 3 6 Seat Heat Interface Module 8W 63 4 5 6 XJ ...

Page 947: ...LB P17 14 RD LB FORWARD REARWARD MOTOR MOTOR FRONT REAR MOTOR C6 1 FRONT DOWN 2 FRONT UP 3 REAR DOWN 4 REAR UP 5 FORWARD 6 REARWARD C316 2 SWITCH SEAT POWER LEFT Z1 14 MOTORS SEAT POWER LEFT F37 14 RD LB S356 G306 1 C362 BK C362 2 F37 14 RD BK 14 Z1 M M M 8W 12 2 8W 12 27 8W 10 20 8W 10 26 8W 12 27 8W 15 22 8W 63 2 8W 63 POWER SEAT XJ J008W 7 XJI06302 ...

Page 948: ...WARD REARWARD MOTOR MOTOR FRONT REAR MOTOR MOTORS SEAT POWER C6 1 FRONT UP 2 FRONT DOWN 3 REAR UP 4 REAR DOWN 5 FORWARD 6 REARWARD C316 2 RIGHT LEFT SWITCH SEAT POWER A RD LB 14 F37 RIGHT FUSED B S356 RD LB 14 F37 BK 14 Z1 G306 C363 2 1 C363 F37 14 RD 1 C362 F37 14 RD BK 14 Z1 M M M 8W 12 2 8W 12 27 8W 10 20 8W 10 26 8W 63 2 8W 12 27 8W 15 22 XJ 8W 63 POWER SEAT 8W 63 3 XJI06303 J008W 7 ...

Page 949: ...HT RIGHT SEAT LOW HEAT LED DRIVER DRIVER LED HEAT HIGH SEAT RIGHT 3 5 1 2 6 4 P137 18 VT P139 18 VT WT P133 18 TN DG P134 18 TN RD P140 18 VT BK P138 18 VT LG P137 18 VT P139 18 VT WT P133 18 TN DG P134 18 TN RD P140 18 VT BK P138 18 VT LG 10A FUSE 18 RUN ACC A31 RHD LHD SEAT HEAT INTERFACE MODULE C329 BK 18 Z1 3 S355 G306 G306 S355 3 Z1 18 BK Z1 18 BK 1 2 1 2 1 HIGH 2 LOW 2 LOW 1 HIGH FUSED IGNIT...

Page 950: ...BK BK YL 18 P144 P141 18 TN LB C B D A D A C B P141 18 TN LB P141 18 TN LB C332 1 8 C329 P141 18 TN LB P88 18 BR BK P141 18 TN LB S357 P89 18 BR B A B A BACK SEAT HEATED RIGHT BACK SEAT HEATED LEFT Z1 18 BK BK 18 Z1 C332 4 S354 Z1 18 BK C329 12 Z1 18 BK S355 G306 Z1 18 BK Z2 18 BK LG C329 13 Z2 18 BK LG G306 CUSHION SEAT HEATED LEFT CUSHION SEAT HEATED RIGHT LEFT 8W 15 22 8W 15 22 8W 15 22 8W 15 2...

Page 951: ... Z1 18 BK Z1 18 BK S354 RELAY SEAT HEATED MODULE INTERFACE HEAT SEAT B A A B F37 14 RD LB F37 14 RD LB SWITCH SEAT POWER LEFT SWITCH SEAT POWER RIGHT G306 Z1 14 BK Z1 14 BK S356 BLOCK JUNCTION 25A BREAKER 29 CIRCUIT BATT A7 FUSED B B FUSED GROUND GROUND 1 C362 F37 14 RD 1 C363 C362 2 C363 2 RD 14 F37 RELAY OUTPUT OUTPUT RELAY SEAT HEATED 8W 10 15 8W 10 16 8W 12 19 8W 12 20 8W 12 20 8W 12 19 8W 63 ...

Page 952: ... 14 15 S209 8W 52 5 6 S210 8W 10 17 S211 8W 10 15 16 S212 8W 52 7 8 S213 8W 50 4 5 6 7 S214 8W 10 27 30 Component Page S214 8W 12 28 29 S215 8W 12 8 9 S216 8W 12 13 S217 8W 12 22 S218 8W 10 28 29 S219 8W 12 22 23 S220 8W 51 12 S221 8W 30 13 32 S222 8W 30 13 32 S225 8W 12 13 S226 8W 50 3 S227 8W 15 16 S228 8W 42 2 3 4 5 S229 8W 47 4 S230 8W 12 11 12 S232 8W 12 20 S237 8W 15 15 S238 8W 30 20 21 S239...

Page 953: ... L62 BR RD 20 L62 3 L62 20 BR RD S312 GAS RELAY TURN RIGHT TOW TRAILER C1 MODULE CONTROL POWERTRAIN UPSTREAM 1 1 SENSOR OXYGEN 2 1 2 2 1 2 OXYGEN SENSOR UPSTREAM DOWNSTREAM SENSOR OXYGEN OXYGEN SENSOR DOWNSTREAM K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 20 BR YL K167 18 BR YL K167 20 BR YL A 8W 70 3 TO S111 EUROPEAN III CALIFORNIA 4 0L S123 4 3 3 3 3 8W 52 7 8W 52 8 8W 30 7 8W 30 12 8W 30 5 8...

Page 954: ...SENSOR 1 1 BR YL 20 K167 S138 K167 20 BR YL MODULE CONTROL TRANSMISSION 16 C100 B6 B3 C100 SENSOR TEMPERATURE BATTERY 2 BR YL 20 K167 3 C204 7 30 C200 BR YL 20 K167 4 FUEL MODULE PUMP K167 20 BR YL LHD RHD BR YL 20 K167 4 0L K167 20 BR YL SENSOR PRESSURE OIL ENGINE 4 0L C1 RHD LHD F12 F18 CLOCKSPRING 3 3 BK RD 20 K4 CALIFORNIA EXCEPT 4 0L EUROPEAN III EUROPEAN III EXCEPT 4 0L CALIFORNIA CALIFORNIA...

Page 955: ... FUEL INJECTION C100 B6 9 C120 BK LB 18 K4 COOLANT SENSOR TEMPERATURE 2 PUMP 1 RIGHT SPEED CONTROL SWITCH A ENGINE S222 K167 20 BR YL C1 C2 3 C116 K167 18 BR YL ENGINE CONTROL MODULE 61 C2 1 SENSOR PRESSURE BOOST TURBO K4 20 BK LB K4 20 BK RD F18 RHD LHD F12 4 C1 2 BATTERY TEMPERATURE SENSOR K167 20 BR YL 2 SENSOR TEMPERATURE COOLANT ENGINE K167 18 BR YL C120 12 NO 1 ENGINE NO 2 ACCELERATOR PEDAL ...

Page 956: ...80 30 C327 8W 80 30 C329 8W 80 31 C330 8W 80 31 C332 8W 80 31 C333 8W 80 32 C362 8W 80 32 C363 8W 80 32 Camshaft Position Sensor 8W 80 32 Cargo Lamp Switch 8W 80 32 Center High Mounted Stop Lamp 8W 80 33 Cigar Lighter 8W 80 33 Clockspring C1 8W 80 33 Clockspring C2 8W 80 33 Clockspring C3 8W 80 33 Clutch Interlock Switch 8W 80 34 Clutch Interlock Switch Jumper 8W 80 34 Combination Flasher 8W 80 34...

Page 957: ...Lamp 8W 80 64 Left Visor Vanity Lamp 8W 80 64 License Lamp 8W 80 64 Liftgate Lock Motor 8W 80 64 Component Page Liftgate Switch 8W 80 64 Low Coolant Switch 8W 80 64 Manifold Absolute Pressure Sensor 8W 80 65 Needle Movement Sensor 8W 80 65 Overhead Module 8W 80 65 Oxygen Sensor 1 1 Upstream 8W 80 65 Oxygen Sensor 1 2 Downstream 8W 80 66 Oxygen Sensor 2 1 Upstream 8W 80 66 Oxygen Sensor 2 2 Downstr...

Page 958: ...8W 80 86 Sentry Key Immobilizer Module 8W 80 86 Shift Lock Solenoid 8W 80 86 Component Page Throttle Position Sensor 8W 80 87 Torque Converter Clutch Solenoid 8W 80 87 Trailer Tow Connector 8W 80 87 Trailer Tow Left Turn Relay 8W 80 87 Trailer Tow Right Turn Relay 8W 80 87 Transfer Case Switch 8W 80 88 Transfer Case Switch Illumination 8W 80 88 Transmission Solenoid 8W 80 88 Transmission Control M...

Page 959: ... CIRCUIT FUNCTION 1 C22 18DB WT A C SWITCH SENSE 2 C21 20DB PK A C SWITCH SENSE A C ONLY OR HEATER CONTROL C1 FUSED PANEL LAMPS DIMMER SWITCH SIGNAL RADIATOR FAN REQUEST C48 18TN 2 A C SWITCH SENSE C21 20DB PK 1 FUNCTION CIRCUIT CAV A C HIGH PRESSURE SWITCH 4 0L GAS 1 2 4 3 3 C90 20LG A C SWITCH SENSE 3 Z1 18BK GROUND BLEND DOOR FEEDBACK SIGNAL C36 18RD WT 3 NATURAL 1 5 F15 20DB WT 4 BLEND DOOR FE...

Page 960: ... SWITCH SENSE CIRCUIT FUNCTION CAV C21 20DB PK 1 2 C90 20LG A C SWITCH SENSE GAS SWITCH PRESSURE A C LOW 10 2 1 FUNCTION CIRCUIT CAV DIESEL SWITCH PRESSURE A C LOW GROUND 2 C21 20DB PK 1 2 A C SWITCH SENSE C21 20DB PK 2 1 C22 18DB WT PRESSURE SWITCH OUTPUT 2 5L 4 0L 1 Z1 20BK A C SWITCH SENSE BLACK 10 5 6 1 5V SUPPLY K6 20VT WT 10 9 6 5 K151 20WT LOW IDLE POSITION SWITCH SIGNAL ACCELERATOR PEDAL P...

Page 961: ...TION SWITCH OUTPUT ST RUN F20 18WT A BACK UP LAMP FEED L10 18BR LG A FUNCTION CIRCUIT CAV SENSOR GROUND G32 20BK LB 2 1 G31 20VT LG CAV FUNCTION CIRCUIT AMBIENT TEMPERATURE SENSOR SIGNAL SENSOR TEMPERATURE AMBIENT BLACK 2 1 9 10 D2 20OR FUSED IGNITION SWITCH OUTPUT RUN ACTUATOR BLEND DOOR 10 5 BLEND DOOR FEEDBACK SIGNAL D3 20YL 8 GROUND D1 20DB WT 7 6 5 FUNCTION CIRCUIT CAV B L10 18BR LG BACK UP L...

Page 962: ...OR DRIVER 2 G99 20GY WT 1 2 BLACK BRAKE WARNING PRESSURE SWITCH B BLOWER MOTOR RELAY OUTPUT C1 12DG A FUNCTION CIRCUIT CAV C7 12BK TN BLOWER MOTOR HIGH DRIVER B A MOTOR BLOWER 5 F15 20DB WT FUSED IGNITION SWITCH OUTPUT RUN FUSED B A111 12RD LG 4 3 2 BLOWER MOTOR RELAY OUTPUT C1 12DG 1 FUNCTION CIRCUIT CAV Z1 20BK GROUND 1 3 4 5 2 RELAY BLOWER MOTOR BLACK 1 4 BLOCK RESISTOR BLOWER MOTOR BLOWER MOTO...

Page 963: ... Z1 18BK A2 G106 20BK WT A3 G107 20BK RD A4 L92 20PK A5 L139 20VT A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 C1 V3 16BR WT C2 A1 12RD C3 V4 16BR VT C4 F75 16VT C5 V5 16DG YL C6 A2 12PK BK D1 A3 14RD WT D2 A141 14DG WT D4 G34 16RD GY D5 A111 12RD LG D6 C100 CONTINUED ON NEXT PAGE F6 E1 D6 D2 D4 B6 F12 F18 B12 B18 A13 C5 C1 C3 A1 E7 E1...

Page 964: ...K167 20BR YL K226 20DB LG K29 20WT PK L44 20VT RD L9 20BK PK L61 20LG WT L60 20TN D21 20PK D20 20LG BK F1 D2 20WT BK D1 20VT BR F1 20DB GY F20 18WT Z12 18BK TN L50 20WT TN G9 20GY BK L10 18BR LG V10 18BR V20 18BK WT E12 E3 L13 20BR YL F17 G154 20VT LG G86 20TN OR K185 20OR LB F34 18TN BK E7 E1 E6 E5 E4 E2 G19 20LG OR F16 G32 20BK LB F15 G31 20VT LG F14 F13 F12 F10 V32 18YL RD F9 F32 20PK DB F8 V30...

Page 965: ... 20DB LG K29 18WT PK F34 18TN BK V20 18BK WT V10 18BR L10 18BR LG G9 20GY BK D2 20WT BK D1 20VT BR G99 20GY WT F20 18WT G29 20BK LB Z12 18BK TN D6 A111 12RD LG D5 D4 A141 16DG WT D2 A3 14RD WT D1 A2 12PK BK C6 V5 16DG YL C5 F75 16VT C4 V4 16BR VT C3 A1 12RD C2 V3 16BR WT C1 B18 B17 B16 B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 A18 A17 A16 A15 A14 A13 A12 A11 A10 A9 A8 A7 L139 20VT A5 L39 ...

Page 966: ... GY E10 E9 T141 20YL E8 CIRCUIT CAV F11 F11 CAV CIRCUIT E8 T141 20YL E9 E10 F1 20DB GY E11 E13 E14 E15 E16 E17 E18 F1 F2 F3 F4 F5 F6 F7 V30 20DB RD F8 F32 20PK DB F9 V32 18YL RD F10 F12 F13 F14 G31 20VT LG F15 G32 20BK LB F16 F18 D20 18LG BK G19 20LG OR E2 E3 E4 E5 E6 E1 E7 F45 20YL RD E12 K185 20OR LB G86 18TN OR G154 18VT LG F17 L13 20BR YL SENTRY KEY IMMOBILIZER MODULE ABS MESSAGE CENTER HEADLA...

Page 967: ...14 7 8 1 L78 20DG YL 14 L44 20VT RD 13 L33 20RD WT 12 Z1 20BK WT 11 L60 20TN 10 L43 20VT 9 L39 20LB 8 L77 20BR YL 7 L34 20RD OR 6 5 Z1 20BK 4 L61 20LG WT 3 L33 20RD 2 1 CIRCUIT CAV L78 20DG YL 14 L44 18VT RD 13 L33 20RD 12 Z1 18BK 11 L60 20TN 10 L43 18VT 9 L39 20LB 8 L77 20BR 7 L34 18RD OR 6 Z15 18BK GY 5 Z1 18BK 4 L61 20LG 3 L33 18RD 2 L13 18BR YL 1 CIRCUIT CAV BLACK BLACK BLACK BLACK FOG LAMPS E...

Page 968: ...1 C107 LHD 2 5L GAS LHD 2 5L GAS C107 14 7 8 1 14 7 8 1 A61 14DG BK 14 13 L10 18BR LG 12 F20 18WT 11 F12 18DB WT 10 9 G107 20BK RD 8 F142 20DG WT 7 6 Z1 20 BK 5 G7 20WT OR 4 K167 20BR YL 3 K20 18DG 2 A142 18DG OR 1 CIRCUIT CAV CAV CIRCUIT 1 A142 18DG OR 2 K20 18DG 3 K167 20BR YL 4 G7 20WT OR 5 T41 20BK WT 6 7 F142 18DG WT 8 G107 20BK RD 9 10 F12 18DB WT 11 F20 18WT 12 13 14 A61 16DG BK BLACK BLACK...

Page 969: ...12 L10 18BR LG 13 14 A61 16DG BK BLACK BLACK BLACK BLACK 4 0L GAS EXCEPT M T 2WD DRL A T M T 4WD A T 4WD 4 0L A T 2WD CALIFORNIA BUILT UP EXPORT CAV CIRCUIT 1 A142 18DG OR 2 K20 18DG 3 K167 20BR YL 4 G7 20WT OR 5 T41 18BK WT 6 K22 20OR DB 7 A42 20DG 8 G107 20BK RD 9 Z12 16BK TN 10 F12 18DB WT 11 13 A242 20VT OR 13 A242 20DG OR 14 A61 14DG BK A61 14DG BK 14 13 L10 18BR LG 12 F20 18WT 11 F12 18DB WT...

Page 970: ...2 G7 20WT OR 1 CIRCUIT CAV DIESEL C111 C109 C109 BLACK E D H A BLACK E D H A B4 20LG G B3 20LG DB F B2 20YL E B1 20YL DB D B43 20PK OR C B42 20TN WT B B41 20YL VT A CIRCUIT CAV B4 18LG G B3 18LG DB F B2 18YL E B1 18YL DB D B43 18PK OR C B42 18TN WT B B41 18YL VT A CIRCUIT CAV 1 3 1 3 GRAY GRAY 2 1 CIRCUIT CAV 2 Z1 20BK 1 CIRCUIT CAV C112 C112 3 G106 20BK WT 3 G107 20BK RD G107 20BK RD G106 20BK WT...

Page 971: ...K 9 10 K222 18TN RD CAV CIRCUIT 1 K3 20LG BK 2 3 C22 20DB WT 4 K24 20GY BK 5 K20 18DG 6 C3 14DB BK 7 K72 18DG OR 8 K2 18TN BK 9 10 K222 18TN RD K24 20GY BK K167 20BR YL 3 G60 18GY YL 3 G60 18GY YL DIESEL C116 K7 18OR C116 DIESEL CAV CIRCUIT 1 K7 20OR 2 CAV CIRCUIT 1 K167 18BR YL 2 BLACK BLACK BLACK BLACK DIESEL C120 BLACK 8 1 14 7 2 1 3 1 3 1 1 2 BLACK BLACK BUILT UP EXPORT C114 C114 BUILT UP EXPO...

Page 972: ...B 7 X51 16BR YL 6 X56 16DB RD 5 X54 16VT 4 3 X55 16BR RD 2 X53 16DG 1 CIRCUIT CAV C16 20LB YL 37 P76 20OR YL 36 P74 20DB 35 P72 20YL BK 34 F81 12TN 33 P36 20PK VT 32 P35 20OR VT 31 K167 20BR YL 30 V23 18BR PK 29 V20 18BK WT 28 V13 18BR 27 L63 20DG RD 26 L62 20BR RD 25 L50 20WT TN 24 L38 18BR WT 23 22 21 20 19 18 G16 20BK LB 17 L10 18BR LG 16 K226 20DB LG 15 F75 14VT 14 A141 16DG WT 13 12 X60 18DG ...

Page 973: ...12TN P72 20YL BK P74 20DB P35 20OR VT P76 20OR YL P36 20PK VT NATURAL 10 11 14 15 16 17 20 29 31 37 68 74 72 65 64 61 60 59 58 55 46 44 38 7 1 38 37 68 29 20 17 16 14 11 13 10 12 1 3 50 72 63 65 59 61 62 64 58 47 55 46 NATURAL CONTINUED E2 20OR 43 E1 20TN 42 41 F15 20DB WT 40 V23 18BR PK 39 38 37 36 G32 20BK LB 35 34 33 G31 20VT LG 32 31 30 G26 20LB 29 28 27 X3 20BK RD 26 Z8 16BK VT 25 24 23 L4 16...

Page 974: ...16RD LB 66 G9 20GY BK 67 P91 20WT BK 68 69 G10 20LG RD 70 71 72 CONTINUED F83 18YL DG F83 18YL DG 72 71 70 G10 20LG RD 69 68 P91 20WT BK 67 G9 20GY BK 66 F38 16RD LB 65 A21 12DB 64 A41 14YL 63 A22 12BK OR 62 C6 14LB 61 C5 14LG 60 C4 14TN 59 Z2 20BK LG 58 57 D2 20WT BK 56 D1 20VT BR 55 X12 16RD WT 54 53 D2 18WT BK 52 D1 18VT BR 51 F30 16RD 50 49 48 47 M2 20YL 46 L7 18BK YL 45 44 CIRCUIT CAV XJ 8W 8...

Page 975: ...0 18DG RD 14 X58 18DB OR 15 X57 18BR LB 16 X56 18DB RD 17 X55 18BR RD 18 X54 18VT 19 X53 18DG 20 X52 18DB WT 21 X51 18BR YL 22 CIRCUIT CAV P55 20DB PK 22 P59 20LB RD 21 G26 20LB 20 G16 20BK LB 19 V20 18BK WT 18 V23 18BR PK 17 V13 18BR LG 16 15 14 13 G10 20LG RD 12 E2 20OR 11 G9 20GY BK 10 X60 16DG RD 9 X58 16DB OR 8 X57 16BR LB 7 X56 16DB RD 6 X55 16BR RD 5 X54 16VT 4 X53 16DG 3 X52 16DB WT 2 X51 ...

Page 976: ...0BR RD 7 L50 20WT TN 6 L10 18BR LG 5 A141 16DG WT 4 F75 16VT 3 D2 18WT BK 2 D1 18VT BR 1 CIRCUIT CAV C204 C204 F23 18DB YL 10 9 L63 20DG RD 8 L62 20BR RD 7 L50 20WT TN 6 L10 18BR LG 5 A141 16DG WT 4 F75 16VT 3 D2 20WT BK 2 D1 20VT BR 1 CIRCUIT CAV 4 1 YELLOW YELLOW 1 4 C205 R45 18DG LB 4 R43 18BK LB 3 R44 18DG YL 2 R42 18BK YL 1 CIRCUIT CAV C205 R45 18DG LB 4 R43 18BK LB 3 R44 18DG YL 2 R42 18BK Y...

Page 977: ...PK 3 P36 20PK VT 2 P35 20OR VT 1 CIRCUIT CAV 6 G26 20LB 5 P59 20LB RD 4 P55 20DB PK 3 P36 20PK VT 2 P35 20OR VT 1 CIRCUIT CAV BLACK BLACK 2 1 BLACK 1 2 BLACK Z8 20BK VT 10 CAV CIRCUIT 1 2 C4 14TN 3 C5 14LG 4 C6 14LB 5 6 7 C7 12BK TN 8 A111 12RD LG 9 F15 20DB WT 10 Z8 12BK VT 5 10 1 6 BLACK C209 C36 20RD WT F15 20DB WT Z1 20BK 10 Z1 20BK F15 20DB WT 9 A111 12RD LG 8 7 D3 20YL 6 C7 12BK TN C4 14TN C...

Page 978: ...V D1 20VT BR 1 1 5 4 4 10 1 5 10 WHITE C301 C301 CIRCUIT CAV 6 6 BASE 4 SPEAKER SYSTEM 6 SPEAKER SYSTEM 2 D2 20WT BK G31 20VT LG 4 3 G32 20BK LB X3 20BK RD 7 8 P55 20DB F87 20WT BK 6 5 Z2 20BK LG 9 P59 20LB RD 10 10 P59 20LB RD 9 Z2 20BK LG 5 6 F87 20WT BK P55 20DB PK 8 7 X3 20BK RD G32 20BK LB 3 4 G31 20VT LG D2 20WT BK 2 CAV CIRCUIT 1 D1 20VT BR FULL OPTIONS EXCEPT RHD EXCEPT RHD 5 4 X56 18DB RD...

Page 979: ...6 P35 20OR VT 7 P36 20PK VT 8 P72 20YL BK 9 P74 20DB 10 P76 20OR YL 11 C16 20LB YL 12 13 P91 20WT BK 2 X87 18DG X87 18LG VT 2 1 X53 18DG LHD C305 LHD C305 WHITE 13 8 3 9 4 1 WHITE 13 3 8 9 1 4 P91 20WT BK 13 12 C16 20LB YL 11 P76 20OR YL 10 P74 20DB 9 P72 20YL BK 8 P36 18PK VT 7 P35 18OR VT 6 P34 16PK BK 5 P33 16OR BK 4 F83 18YL DG 3 X55 18BR RD 2 X85 18BR RD 1 CIRCUIT CAV CAV 6 6 6 SPEAKERS 4 SPE...

Page 980: ...CAV FULL OPTIONS POWER WINDOWS POWER WINDOWS FULL OPTIONS LHD C306 RHD C306 RHD C306 LHD C306 WHITE WHITE 3 6 2 1 WHITE 2 6 3 1 WHITE 3 6 2 1 2 6 3 1 6 5 Q26 14VT WT 4 Q16 14BR WT 3 G26 20LB 2 F35 16RD 1 CIRCUIT CAV 6 5 Q26 14VT WT 4 Q16 14BR WT 3 G26 20LB 2 F35 16RD 1 CIRCUIT CAV Q27 14RD BK 6 Q17 14DB WT 5 Q26 14VT WT 4 Q16 14BR WT 3 Q28 14DG WT 2 Q18 14GY BK 1 CIRCUIT CAV Q27 14RD BK 6 Q17 14DB...

Page 981: ... CIRCUIT CAV C310 G78 20TN BK BLACK L77 18BR YL 11 M4 20VT YL 10 Z1 18BK 9 V13 18BR LG 8 V23 18BR PK 7 6 P34 16PK BK 5 P33 16OR BK 4 C15 12BK WT 3 Z1 12BK 2 V20 18BK WT 1 CIRCUIT CAV C311 G78 20TN BK 3 4 6 1 BLACK Z1 18BK 6 M4 20GY BK 5 L77 18BR YL 4 3 P34 16PK BK 2 P33 16OR BK 1 CIRCUIT CAV C312 2 1 GREEN C15 12BK WT 2 Z1 12BK 1 CIRCUIT CAV C313 GRAY 3 2 1 V20 18BK WT 3 V23 18BR PK 2 V13 18BR LG ...

Page 982: ...B OR 4 X51 18BR YL 3 X57 18BR LB 2 X52 18DB WT 1 X58 18DB OR C314 C314 3 1 7 6 2 8 8 6 2 7 3 1 8 M4 20GY BK 7 M2 20YL 6 M1 20PK 5 X93 18WT RD 4 X91 18WT BK 3 X94 18TN RD 2 X92 18TN BK 1 CIRCUIT CAV 8 M4 20GY BK 7 M2 20YL 6 M1 20PK 5 X93 16BR YL 4 X91 16BR DB 3 X94 16TN RD 2 X92 16TN BK 1 CIRCUIT CAV 4 SPEAKER 6 SPEAKER RHD 5 M1 18PK LHD 1 2 BLACK WHITE WHITE A B C A C C A 2 1 BLACK HEATED SEATS XJ...

Page 983: ...18BK 3 4 L38 18BR WT 5 L10 18BR LG 6 L50 20WT TN 7 L78 18DG YL 8 CAV CIRCUIT 1 L62 18BR RD 2 Z1 18BK 3 4 5 L10 18BR LG 6 L50 18WT TN 7 L78 18DG YL 8 1 3 4 4 8 1 3 8 BLACK BLACK C321 C321 L38 18OR WT Z1 18BK 2 L38 18OR WT 8 L77 18BR 7 L50 18WT TN 6 L10 18BR LG 5 4 3 Z1 16BK 2 L63 18DG RD 1 CIRCUIT CAV EXCEPT BUILT UP EXPORT BUILT UP EXPORT L62 20BR RD A6 20RD OR CAV CIRCUIT 1 L63 20DG RD 2 Z1 14BK ...

Page 984: ...CAV 2 3 1 3 1 3 2 1 CIRCUIT CAV X80 18LB BK X82 18LB RD F83 18YL DG A6 20RD OR L62 20BK RD A6 20RD OR L62 20BR RD CAV CIRCUIT 1 L63 20DG RD 2 Z1 18BK 3 4 L38 18BR WT 5 L10 18BR LG 6 L50 20WT TN 7 L77 18BR YL 8 CAV CIRCUIT 1 L63 18DG RD 2 Z1 16BK 3 4 5 L10 18BR LG 6 L50 18WT TN 7 L77 18BR 8 1 3 4 4 8 1 3 8 BLACK BLACK C322 C322 L38 18OR WT TRAILER TOW TRAILER TOW 2 Z1 18BK EXCEPT BUILT UP EXPORT BU...

Page 985: ...4 C15 12BK WT 5 L50 20WT TN C326 C326 FULL OPTIONS V20 18BK WT V23 18BR PK V13 18BR LG L77 18BR YL G78 20TN BK CAV CIRCUIT 1 G78 20TN BK 2 L77 18BR YL 3 V13 18BR 4 V23 18BR PK 5 V20 18BK WT 6 CAV CIRCUIT 1 2 3 4 5 6 C327 C327 6 2 3 1 BLACK 3 1 6 2 BLACK BLACK 1 3 2 5 BLACK 2 5 1 3 8W 80 30 8W 80 CONNECTOR PIN OUTS XJ J008W 7 XJI08030 ...

Page 986: ...11 F37 14RD LB 10 9 P141 18TN LB 8 P87 18BK OR 7 6 P139 18VT WT 5 P138 18VT LG 4 P137 18VT 3 P134 18TN RD 2 P133 18TN DG 1 CIRCUIT CAV 1 8 7 14 1 8 7 14 C329 C329 CIRCUIT 2 Z1 18BK CAV 1 L78 18BK YL 2 CAV 1 Z1 18BK CIRCUIT L77 18BR YL C330 C330 BLACK BLACK 2 1 2 1 C332 C332 NATURAL NATURAL Z1 18BK 4 P87 18BK OR 3 P143 18BK DG 2 P141 18TN LB 1 CIRCUIT CAV CAV CIRCUIT 1 P141 18TN LB 2 P143 18BK DG 3...

Page 987: ... SUPPLY K7 18OR 1 FUNCTION CIRCUIT CAV FUSED B C363 CAV CIRCUIT 1 F37 14RD LB 2 Z1 14BK BLACK 2 1 1 2 BLACK Z1 14BK 2 F37 14RD LB 1 CIRCUIT CAV C362 CAV CIRCUIT 1 F37 14RD 2 Z1 14BK Z1 14BK 2 F37 14RD 1 CIRCUIT CAV C363 C362 BLACK CIRCUIT 2 Z1 18BK CAV 1 L50 18DG WT 2 CAV 1 Z1 18BK CIRCUIT L50 18WT TN C333 C333 1 2 2 1 BLACK 1 2 BLACK BLACK 2 1 GRAY 1 3 GAS SENSOR POSITION CAMSHAFT 8W 80 32 8W 80 ...

Page 988: ...K4 20BK RD 3 SPEED CONTROL SWITCH SIGNAL V37 20RD LG 2 HORN RELAY CONTROL X3 20BK RD 1 FUNCTION CIRCUIT CAV B A CLOCKSPRING C2 CAV CIRCUIT FUNCTION A K167 20BR YL SENSOR GROUND B V37 20RD LG SPEED CONTROL SWITCH SIGNAL BRAKE LAMP SWITCH OUTPUT L50 18DG WT CLOCKSPRING C3 2 1 YELLOW DRIVER AIRBAG LINE 2 R43 18BK LB 2 DRIVER AIRBAG LINE 1 R45 18DG LB 1 FUNCTION CIRCUIT CAV XJ 8W 80 CONNECTOR PIN OUTS...

Page 989: ... COMBINATION FLASHER CAV CIRCUIT FUNCTION 1 L5 20BK FUSED IGNITION SWITCH OUTPUT RUN 2 L9 20BK PK FUSED B 3 L12 20VT TN HAZARD FLASHER SELECT SIGNAL 4 L6 20RD WT FLASHER OUTPUT 5 Z1 18BK GROUND GREEN 2 1 2 1 BLACK IGNITION SWITCH OUTPUT START FUSED B ENGINE STARTER MOTOR RELAY FUSED B ENGINE STARTER MOTOR RELAY FUSED B ENGINE STARTER MOTOR RELAY RHD BUILT UP EXPORT LHD DIESEL EXCEPT LHD DIESEL Z1 ...

Page 990: ...9141K D21 18PK 20 19 RIGHT REAR WHEEL SPEED SENSOR B6 18WT DB 18 RIGHT REAR WHEEL SPEED SENSOR B2 18YL 17 ABS RELAY CONTROL G83 18GY BK 16 15 14 G SWITCH TEST SIGNAL B43 18PK OR 13 BRAKE LAMP SWITCH OUTPUT L50 18WT TN 12 LEFT FRONT WHEEL SPEED SENSOR B8 18RD DB 11 LEFT REAR WHEEL SPEED SENSOR B4 18LG 10 FUSED B A20 12RD DB 9 GROUND Z1 12BK 8 G SWITCH NO 2 SENSE B42 18TN WT 7 G SWITCH NO 1 SENSE B4...

Page 991: ... DATA LINK BLACK 1 8 9 16 FUSED B F34 18TN BK 16 15 14 13 12 CCD BUS D2 18WT BK 11 10 9 8 SCI TRANSMIT ISO 9141K D21 20PK 7 SCI RECEIVE D20 20LG BK 6 GROUND Z12 18BK TN 5 GROUND Z1 18BK 4 CCD BUS D1 18VT BR 3 2 1 FUNCTION CIRCUIT CAV CRANKSHAFT POSITION SENSOR GAS 3 1 BLACK 8W 80 36 8W 80 CONNECTOR PIN OUTS XJ J008W 7 XJI08036 ...

Page 992: ...TPUT L3 16RD 1 FUNCTION CIRCUIT CAV HEADLAMP RELAY OUTPUT FOG LAMP SWITCH OUTPUT 3 L39 18LB L2 16LG 1 2 FUNCTION CIRCUIT CAV DIODE MODULE BUILT UP EXPORT L25 18BR REAR FOG LAMP FEED 3 1 BLACK BASE POLICE 1 3 SWITCH DOME LAMPS C A BLACK GROUND Z1 20BK C COURTESY LAMPS DRIVER M2 20YL B A FUNCTION CIRCUIT CAV MIDLINE M1 20PK FUSED B CAV CIRCUIT FUNCTION 1 2 M1 20PK COURTESY LAMPS DRIVER 3 M2 20YL FUS...

Page 993: ...ER WINDOW SWITCH PASSENGER UP 6 7 8 9 F81 14TN FUSED IGNITION SWITCH OUTPUT RUN ACC 10 Q27 14RD BK LEFT REAR WINDOW DRIVER DOWN 11 12 BLUE 1 6 5 12 P35 18OR VT Q21 14VT Z1 14BK P36 18PK VT Q26 14VT WT DRIVER WINDOW DRIVER DOWN DOOR LOCK SWITCH OUTPUT LOCK GROUND DOOR LOCK SWITCH OUTPUT UNLOCK MASTER WINDOW SWITCH PASSENGER DOWN DRIVER POWER LOCK WINDOW SWITCH C1 MASTER WINDOW SWITCH PASSENGER DOWN...

Page 994: ...ER RELAY OUTPUT C16 20BK WT 5 MIRROR COMMON DRIVER P91 20WT BK LEFT POWER MIRROR HORIZONTAL DRIVER P75 20DB WT 3 MIRROR COMMON DRIVER P76 20OR YL 2 LEFT POWER MIRROR VERTICAL DRIVER P71 20YL 1 FUNCTION CIRCUIT CAV 3 2 P75 20DB WT LEFT POWER MIRROR HORIZONTAL DRIVER RHD 3 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER MIRROR COMMON DRIVER P76 20OR YL 4 6 Z1 18BK GROUND RED 4 1 3 6 MIRROR DRIVER POWE...

Page 995: ...VER DOWN BLACK 2 1 WINDOW MOTOR DRIVER POWER DUTY CYCLE EVAP PURGE SOLENOID GAS CAV CIRCUIT FUNCTION 1 K52 18PK BK DUTY CYCLE EVAP PURGE SOLENOID CONTROL 2 F20 18WT FUSED IGNITION SWITCH OUTPUT ST RUN D A ELECTRONIC VACUUM MODULATOR DIESEL GROUND Z1 18BK D C EGR SOLENOID CONTROL K35 18GY YL B FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT F142 18DG OR A FUNCTION CIRCUIT CAV BLACK 2 1 8W 80 40 8W 80 CONNEC...

Page 996: ... SIGNAL K22 20OR DB GROUND Z12 16BK TN AUTOMATIC SHUT DOWN RELAY OUTPUT A142 16DG OR EGR SOLENOID CONTROL K35 18GY YL SPEED CONTROL INDICATOR SIGNAL V66 18RD LG WAIT TO START INDICATOR DRIVER K185 20OR LB AUTOMATIC SHUT DOWN RELAY CONTROL K51 20DB YL FAULT INDICATOR REQUEST INPUT K48 18OR RD ENGINE DISABLE SIGNAL G55 18OR BK K9 20LB BOOST PRESSURE SENSOR SIGNAL K1 20DG RD GLOW PLUG RELAY CONTROL K...

Page 997: ...6 18LG K153 18OR K3 20LG BK K24 20GY BK K140 18TN WT FUEL TIMING SOLENOID CONTROL FUEL SHUTDOWN SOLENOID CONTROL ENGINE SPEED SENSOR SIGNAL FUEL QUANTITY ACTUATOR CONTROL NEEDLE MOVEMENT SENSOR SIGNAL SENSOR GROUND SPEED CONTROL SWITCH SIGNAL FUEL QUANTITY ACTUATOR CONTROL CONTROL SLEEVE POSITION SENSOR MEASURE COIL CONTROL SLEEVE POSITION SENSOR MIDDLE TAP CONTROL SLEEVE POSITION SENSOR SIGNAL NE...

Page 998: ...R YL 2 1 K222 18TN RD CAV FUNCTION CIRCUIT ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 5V SUPPLY K6 18VT OR 3 PRESSURE SENSOR ENGINE OIL SENSOR GROUND G60 18GY YL 2 5V SUPPLY K7 18OR 1 FUNCTION CIRCUIT CAV 3 1 BLACK DIESEL DIESEL BLACK BLACK 1 2 GAS DIESEL 1 K167 18BR YL ENGINE OIL PRESSURE SENSOR SIGNAL SENSOR NO 1 SENSOR NO 2 ENGINE SPEED SENSOR GROUND CAV CIRCUIT FUNCTION 1 2 K3 20LG BK 3 ENGINE S...

Page 999: ...FRONT WIPER 6 3 4 1 BLACK WIPER HIGH SPEED OUTPUT V4 16BR VT 6 WIPER LOW SPEED OUTPUT V3 16BR WT 5 GROUND Z1 16BK 4 3 WIPER PARK SWITCH SENSE V5 16DG YL 2 FUSED IGNITION SWITCH OUTPUT RUN ACC V6 16DB 1 FUNCTION CIRCUIT CAV PUMP DETECTION EVAP LEAK LEAK DETECTION PUMP SWITCH SENSE GENERATOR DRIVER CIRCUIT 2 4 3 1 CAV K72 18DG OR K105 18WT OR K106 18WT DG FUNCTION LEAK DETECTION PUMP SOLENOID CONTRO...

Page 1000: ...UTPUT 2 1 2 5L GAS FUEL INJECTOR NO 1 NO 2 FUEL INJECTOR 2 5L GAS 1 2 2 1 2 5L GAS FUEL INJECTOR NO 4 NO 3 FUEL INJECTOR 2 5L GAS 1 2 FUEL SHUT DOWN SOLENOID CONTROL K153 18OR 6 5 SENSOR GROUND K4 20BK LB 4 CONTROL SLEEVE POSITION SENSOR MEASURE COIL K135 20WT BK 3 2 CONTROL SLEEVE POSITION SENSOR SIGNAL K134 20LB BK 1 FUNCTION CIRCUIT CAV 7 K156 20GY FUEL TEMPERATURE SENSOR SIGNAL FUEL QUANITY AC...

Page 1001: ...UEL INJECTOR NO 3 DRIVER K13 18YL WT 2 A142 18DG OR 1 FUNCTION CIRCUIT CAV FUEL INJECTOR NO 2 DRIVER K12 18TN 2 A142 18DG OR 1 FUNCTION CIRCUIT CAV FUEL INJECTOR NO 1 4 0L GAS 1 2 BLACK BLACK 2 1 4 0L GAS FUEL INJECTOR NO 2 BLACK 2 1 4 0L GAS FUEL INJECTOR NO 3 BLACK 2 1 4 0L GAS FUEL INJECTOR NO 4 BLACK 2 1 4 0L GAS FUEL INJECTOR NO 5 BLACK 2 1 4 0L GAS FUEL INJECTOR NO 6 FUSED AUTOMATIC SHUT DOW...

Page 1002: ...OR G SWITCH TEST SIGNAL 2 B41 20YL VT G SWITCH NO 1 SENSE 3 B42 20TN WT G SWITCH NO 2 SENSE G SWITCH 3 1 2 1 BLACK BLACK 6 5 3 2 1 4 FUEL LEVEL SENSOR DIESEL FUEL LEVEL SENSOR SIGNAL FUEL LEVEL SENSOR SIGNAL CAV CIRCUIT FUNCTION 1 A141 16DG WT NOT USED 2 3 K226 20DB LG 4 K167 20BR YL SENSOR GROUND 5 6 Z1 16BK NOT USED K20 18DG GENERATOR FIELD GENERATOR FIELD K20 16DG 2 DIESEL GAS K72 16DG OR 1 GEN...

Page 1003: ...2 14LG 2 DIMMER SWITCH HIGH BEAM OUTPUT L3 16RD OR 3 FUSED B L20 14LG WT 4 FUNCTION CIRCUIT CAV DELAY MODULE HEADLAMP BLACK 8 6 4 2 7 5 3 1 FUSED IGNITION SWITCH OUTPUT ST RUN F87 20WT BK 8 7 L2 14LG HEADLAMP SWITCH OUTPUT L2 14LG 6 5 GROUND Z1 18BK 4 3 FUSED B A3 14RD WT 2 1 FUNCTION CIRCUIT CAV DIESEL EXCEPT BUILT UP EXPORT HEADLAMP SWITCH OUTPUT GLOW PLUG RELAY OUTPUT GLOW PLUG RELAY CONTROL 8W...

Page 1004: ... 7 9 2 BLACK HEADLAMP SWITCH OUTPUT L7 18BK YL 9 FUSED B A3 14RD WT FUSED B A3 14RD WT 8 FUSED B L20 14LG WT 7 DRIVER DOOR AJAR SWITCH SENSE G16 20BK LB 6 KEY IN IGNITION SWITCH SENSE G26 20LB 5 F34 18TN BK 4 COURTESY LAMPS DRIVER M2 20YL 3 HEADLAMP SWITCH OUTPUT L2 14LG 2 PANEL LAMPS DIMMER SWITCH SIGNAL E1 20TN 1 FUNCTION CIRCUIT CAV LHD EXCEPT BUILT UP EXPORT FUSED B XJ 8W 80 CONNECTOR PIN OUTS...

Page 1005: ...ON CIRCUIT CAV 7 6 FUSED IGNITION SWITCH OUTPUT RUN ACC IDLE AIR CONTROL NO 1 DRIVER K39 18GY RD 4 IDLE AIR CONTROL NO 2 DRIVER K60 18YL BK 3 IDLE AIR CONTROL NO 3 DRIVER K40 18BR WT 2 IDLE AIR CONTROL NO 4 DRIVER K59 18VT BK 1 FUNCTION CIRCUIT CAV 1 4 7 2 5 8 9 6 3 BLACK 1 4 MOTOR CONTROL IDLE AIR 8W 80 50 8W 80 CONNECTOR PIN OUTS XJ J008W 7 XJI08050 ...

Page 1006: ... WT 8 FUSED B A1 12RD 7 6 5 IGNITION SWITCH OUTPUT RUN A22 12BK OR 4 FUSED B A2 12PK BK 3 RED BRAKE WARNING INDICATOR DRIVER G9 20GY BK 2 GROUND Z1 20BK 1 FUNCTION CIRCUIT CAV SWITCH C2 IGNITION 2 1 GREEN DRIVER DOOR AJAR SWITCH SENSE G16 20BK LB 2 KEY IN IGNITION SWITCH SENSE G26 20LB 1 FUNCTION CIRCUIT CAV IGNITION SWITCH OUTPUT RUN ACC IGNITION SWITCH OUTPUT START 2 5L GAS XJ 8W 80 CONNECTOR PI...

Page 1007: ...0TN BK 1 FUNCTION CIRCUIT CAV LEFT TURN SIGNAL L61 20LG WT 10 FUSED B M1 20PK 9 FUSED IGNITION SWITCH OUTPUT START RUN F87 20WT BK 8 LOW WASHER FLUID SENSE G29 20BK LB 7 GROUND Z2 20BK LG 6 HIGH BEAM INDICATOR DRIVER G34 16RD GY 5 ABS WARNING INDICATOR DRIVER G19 20LG OR 4 FUSED PANEL LAMPS DIMMER SWITCH SIGNAL E2 20OR 3 RED BRAKE WARNING INDICATOR DRIVER G99 20GY WT 2 LIFTGATE AJAR SWITCH SENSE G...

Page 1008: ...ITION SWITCH OUTPUT RUN F15 20DB WT 6 L78 20DG YL 5 4 FUSED B ENGINE STARTER MOTOR RELAY F45 20YL RD 3 2 FUSED RIGHT LOW BEAM OUTPUT L44 20VT RD 1 FUNCTION CIRCUIT CAV 6 L77 18BR YL JUNCTION BLOCK C2 WHITE 3 6 1 2 FUSED HEADLAMP SWITCH OUTPUT L77 20BR YL 6 FUSED IGNITION SWITCH OUTPUT ST RUN F12 18DB WT 5 HORN RELAY OUTPUT X2 20DG RD 4 3 A7 10RD BK 2 FUSED B A4 12BK PK 1 FUNCTION CIRCUIT CAV FUSED...

Page 1009: ...DIMMER SWITCH SIGNAL E2 20OR S2 PANEL LAMPS DIMMER SWITCH SIGNAL E1 20TN S1 F30 16RD M6 FUSED B F38 16RD LB M5 FUSED IGNITION SWITCH OUTPUT RUN ACC V6 16DB M4 HEADLAMP SWITCH OUTPUT L7 18BK YL M3 IGNITION SWITCH OUTPUT RUN A22 12BK OR M2 IGNITION SWITCH OUTPUT ST A41 14YL M1 IGNITION SWITCH OUTPUT ST RUN A21 12DB L2 IGNITION SWITCH OUTPUT RUN ACC A31 12BK WT L1 FUNCTION CIRCUIT CAV F20 18WT FUSED ...

Page 1010: ... FUSED B F37 14RD LB 2 REAR WINDOW DEFOGGER RELAY OUTPUT C15 12BK WT 1 FUNCTION CIRCUIT CAV BLOCK C7 JUNCTION 8 3 4 1 NATURAL FUSED B A6 20RD OR 8 COURTESY LAMPS DRIVER M2 20YL 7 FUSED HEADLAMP SWITCH OUTPUT L78 18DG YL 6 DOOR UNLOCK DRIVER P34 16PK BK 5 FUSED B M1 20PK 4 MIRROR COMMON DRIVER P91 20WT BK 3 FUSED HEADLAMP SWITCH OUTPUT L77 18BR YL 2 DOOR LOCK DRIVER P33 16OR BK 1 FUNCTION CIRCUIT C...

Page 1011: ... BLOCK C9 JUNCTION NATURAL 6 1 12 5 FUNCTION P33 16OR BK CAV 1 CIRCUIT DOOR LOCK DRIVER P75 20DB WT C16 20BK WT 2 3 5 4 P91 20WT BK P76 20OR YL 7 8 9 10 6 P71 20YL LB 11 LEFT POWER MIRROR HORIZONTAL DRIVER FUSED REAR WINDOW DEFOGGER RELAY OUTPUT LEFT POWER MIRROR VERTICAL DRIVER 11 12 P34 16PK BK Z1 18BK GROUND P33 16OR BK F35 16RD 12 P34 16PK BK DOOR LOCK DRIVER DOOR UNLOCK DRIVER MIRROR COMMON D...

Page 1012: ...T FRONT SPEAKER X55 18LG RD 1 2 1 BLACK AMPLIFIED LEFT FRONT DOOR SPEAKER X87 18DG 2 AMPLIFIED LEFT FRONT DOOR SPEAKER X85 18BK RD 1 FUNCTION CIRCUIT CAV FUSED B 6 SPEAKER RHD 4 SPEAKER AMPLIFIED LEFT FRONT DOOR SPEAKER AMPLIFIED LEFT FRONT DOOR SPEAKER 6 SPEAKER LHD AMPLIFIED LEFT FRONT DOOR SPEAKER X85 18LG RD 1 2 X87 18LG BK AMPLIFIED LEFT FRONT DOOR SPEAKER 2 1 BUILT UP EXPORT LAMP LEFT CITY C...

Page 1013: ...ILT UP 1 3 GRAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L77 18BR FUSED HEADLAMP SWITCH OUTPUT 3 L61 18LG LEFT TURN SIGNAL CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L77 18BR 3 L61 18LG LEFT TURN SIGNAL FUNCTION LEFT TURN SIGNAL GROUND L61 18LG Z1 18BK CIRCUIT 1 2 CAV 1 EXPORT EXPORT FUSED HEADLAMP SWITCH OUTPUT SIGNAL LAMP NO 1 SIGNAL LAMP NO 2 LAMP NO 1 TURN SIGNAL LAMP NO 2 8W 80 58 8W 80 CONNECTOR...

Page 1014: ...M OUTPUT L43 18VT B FUSED LEFT HIGH BEAM OUTPUT L33 20RD FUSED LEFT HIGH BEAM OUTPUT L33 18RD A FUNCTION CIRCUIT CAV LEFT HEADLAMP LEFT FRONT WHEEL SPEED SENSOR FOG LAMPS SEAT BACK CAV CIRCUIT FUNCTION A P88 18BR BK LEFT HEATED SEAT BACK DRIVER B Z1 18BK GROUND LEFT HEATED B A LEFT HEATED SEAT BACK DRIVER P88 18BR BK LEFT HEAT SENSE INPUT SENSOR FEED P141 18TN LB P143 18BK DG C D LEFT HEATED B LEF...

Page 1015: ... YELLOW VERTICAL MOTOR SEAT FRONT CAV CIRCUIT FUNCTION 1 P19 14YL LG LEFT POWER SEAT FRONT UP 2 P21 14RD LG LEFT POWER SEAT FRONT DOWN LEFT POWER YELLOW MOTOR SEAT HORIZONTAL CAV CIRCUIT FUNCTION 1 P17 14RD LB LEFT POWER SEAT HORIZONTAL REARWARD 2 P15 14YL LB LEFT POWER SEAT HORIZONTAL FORWARD LEFT POWER LEFT POWER LEFT POWER SEAT REAR UP P11 14YL WT 2 LEFT POWER SEAT REAR DOWN P13 14RD WT 1 FUNCT...

Page 1016: ...NLOCK DRIVER P34 16PK BK 1 FUNCTION CIRCUIT CAV SWITCH MOTOR LEFT POWER SEAT HORIZONTAL REARWARD LEFT POWER SEAT FRONT DOWN LEFT POWER SEAT FRONT UP P19 14YL LG P21 14RD LG M N CAV CIRCUIT FUNCTION A B P15 14YL LB J P17 14RD LB E LEFT POWER SEAT HORIZONTAL FORWARD LEFT POWER SEAT REAR DOWN LEFT POWER SEAT REAR UP K P13 14RD WT L P11 14YL WT SEAT SWITCH LEFT POWER N M L K J B E A C F H G C F G H BL...

Page 1017: ...OWER WINDOW LEFT REAR B UP Q13 14DB 1 FUNCTION CIRCUIT CAV WHEEL SPEED LEFT REAR BLACK A B LEFT REAR WHEEL SPEED SENSOR B4 20LG B LEFT REAR WHEEL SPEED SENSOR B3 20LG DB A FUNCTION CIRCUIT CAV 1 2 BUILT UP EXPORT LEFT GROUND Z1 18BK 2 LEFT TURN SIGNAL L61 18GY 1 FUNCTION CIRCUIT CAV POWER WINDOW LEFT REAR B UP LAMP REPEATER SENSOR LEFT REAR WINDOW DRIVER DOWN LEFT REAR WINDOW DRIVER DOWN 8W 80 62 ...

Page 1018: ...UNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 3 Z1 18BK GROUND 1 2 3 BLACK 2 L77 18BR FUSED LEFT HEADLAMP SWITCH OUTPUT LEFT TAIL STOP LAMP SWITCH EXCEPT BUILT UP EXPORT CAV CIRCUIT FUNCTION A X57 18BR LB LEFT REAR SPEAKER A X91 16BR DB AMPLIFIED LEFT REAR SPEAKER SPEAKER SOUNDBAR LEFT B B X51 18BR YL X93 16BR YL AMPLIFIED LEFT REAR SPEAKER LEFT REAR SPEAKER 4 SPEAKER SYSTEM 6 SPEAKER SYSTEM 1 2 ...

Page 1019: ...DOOR UNLOCK DRIVER BLACK A B LIFTGATE LOCK MOTOR CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 3 M4 20VT YL LIFTGATE COURTESY LAMP DRIVER BLACK 3 1 G78 20TN BK LIFTGATE AJAR SWITCH SENSE LIFTGATE SWITCH CAV CIRCUIT FUNCTION A M1 20PK FUSED B B Z1 20BK GROUND B A LEFT VISOR VANITY LAMP DIESEL SENSOR GROUND K167 20BR YL 2 COOLANT LEVEL SWITCH SIGNAL G18 18PK BK 1 FUNCTION CIRCUIT CAV LOW COOLANT SWITCH 1 ...

Page 1020: ...OUND K167 20BR YL 1 FUNCTION CIRCUIT CAV UPSTREAM SENSOR 1 1 OXYGEN 3 1 4 2 GRAY OXYGEN SENSOR 1 1 SIGNAL K41 18BK DG 4 SENSOR GROUND K167 20BR YL 3 GROUND Z1 20BK 2 FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT A42 20DG 1 FUNCTION CIRCUIT CAV SENSOR MODULE 2 5L 4 0L 2 Z1 18BK GROUND ABSOLUTE MANIFOLD PRESSURE SENSOR 3 1 BLACK 6 5 WAIT TO START INDICATOR DRIVER K185 20OR LB 8 4 FUSED IGNITION SWITCH OUTPU...

Page 1021: ... 4 2 BLACK OXYGEN SENSOR 1 2 SIGNAL K141 18TN WT 4 SENSOR GROUND K167 20BR YL 3 GROUND Z1 20BK 2 FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT F142 20DG WT 1 FUNCTION CIRCUIT CAV 1 A242 20VT OR OXYGEN SENSOR RELAY OUTPUT 4 0L 2 5L GRAY 2 4 1 3 OXYGEN SENSOR 2 1 UPSTREAM OXYGEN SENSOR 2 1 SIGNAL K241 18LG RD 4 SENSOR GROUND K167 20BR YL 3 2 1 FUNCTION CIRCUIT CAV A42 20DG Z1 20BK GROUND OXYGEN SENSOR RELA...

Page 1022: ...DOOR LOCK CONTROL 2 P55 20DB PK DOOR UNLOCK RELAY CONTROL 3 P35 20OR VT DOOR LOCK SWITCH OUTPUT LOCK 4 F81 14TN FUSED IGNITION SWITCH OUTPUT RUN ACC 5 F35 16RD FUSED B 6 Z1 14BK GROUND 7 P35 18OR VT 8 G26 20LB KEY IN IGNITION SWITCH SENSE BLUE 1 5 4 8 PASSENGER POWER LOCK WINDOW SWITCH C2 3 P36 18PK VT 7 P36 20PK VT DOOR LOCK SWITCH OUTPUT UNLOCK DOOR LOCK SWITCH OUTPUT UNLOCK DOOR LOCK SWITCH OUT...

Page 1023: ... CAV CIRCUIT FUNCTION 2 P76 20OR YL 4 P76 20OR YL 5 C16 20BK WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 6 5 4 1 2 3 RED PASSENGER POWER MIRROR 1 2 3 6 3 P71 20YL P75 20DB WT P91 20WT BK P75 20DB RD 5 C16 20LB YL Z1 16BK GROUND LEFT POWER MIRROR VERTICAL DRIVER LEFT POWER MIRROR HORIZONTAL DRIVER MIRROR COMMON DRIVER LEFT POWER MIRROR HORIZONTAL DRIVER FULL OPTIONS POWER MIRRORS LHD RHD FUSED REAR ...

Page 1024: ...IT CAV C A BUILT UP EXPORT POWER ANTENNA POWER ANTENNA B DOWN X14 18DG C POWER ANTENNA UP X17 18GY B RADIO CHOKE OUTPUT X13 18WT A FUNCTION CIRCUIT CAV C B A GROUND Z1 18BK BUILT UP EXPORT RELAY C1 POWER ANTENNA RADIO 12V OUTPUT X60 18DG RD C FUSED B F34 18TN BK B A FUNCTION CIRCUIT CAV BLACK BLACK CAV CIRCUIT FUNCTION 1 X55 18BR RD LEFT FRONT SPEAKER 2 X56 18DB RD RIGHT FRONT SPEAKER 3 X58 18DB O...

Page 1025: ...S 4 1 8 5 SWITCH MIRROR POWER LEFT POWER MIRROR VERTICAL DRIVER P71 20YL LB 8 GROUND CAV CIRCUIT FUNCTION 1 Z1 20BK 2 F83 18YL DG FUSED IGNITION SWITCH OUTPUT RUN ACC 3 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER 4 P72 20YL BK RIGHT POWER MIRROR VERTICAL DRIVER 5 P76 20OR YL P76 20OR YL 6 P91 20WT BK MIRROR COMMON DRIVER P91 20WT BK MIRROR COMMON DRIVER 7 P75 20 DB WT LEFT POWER MIRROR HORIZONTA...

Page 1026: ...LG 22 21 20 19 FUEL MONITOR OUTPUT SIGNAL G8 18LB BK 18 5V SUPPLY K7 18OR 17 ENGINE COOLANT TEMP SENSOR SIGNAL K222 18TN RD 16 15 14 13 COOLANT LEVEL SWITCH SIGNAL G18 18PK BK 12 11 10 9 ENGINE SPEED SENSOR SIGNAL K159 18VT RD 8 7 6 SENSOR GROUND K167 18BR YL 4 3 AUTOMATIC SHUT DOWN RELAY OUTPUT A142 16DG DR 2 1 FUNCTION CIRCUIT CAV XJ 8W 80 CONNECTOR PIN OUTS 8W 80 71 XJI08071 J008W 7 ...

Page 1027: ...K 16 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18BK RD 15 14 13 IDLE ACTUATOR K78 18GY 12 POWER STEERING PRESSURE SWITCH SENSE K10 18DB BR 12 K40 18BR WT 11 IDLE AIR CONTROL NO 2 DRIVER K60 18YL BK 10 9 CRANKSHAFT POSITION SENSOR SIGNAL K24 18GY BK 8 IGNITION COIL NO 1 DRIVER K19 18GY 7 GROUND Z1 18BK PARK NEUTRAL POSITION SWITCH SENSE T41 18BK WT 6 SENSOR GROUND K167 18BR YL 4 3 FUSED IGNITION SWI...

Page 1028: ...21 12 22 11 1 32 31 30 29 28 VEHICLE SPEED SENSOR SIGNAL G7 18WT OR 27 26 25 24 ENGINE OIL PRESSURE SENSOR SIGNAL G60 18GY YL 23 22 21 20 19 18 17 16 15 14 13 12 11 GENERATOR FIELD K20 18DG 10 9 8 7 6 5 4 3 2 1 FUNCTION CIRCUIT CAV XJ 8W 80 CONNECTOR PIN OUTS 8W 80 73 XJI08073 J008W 7 ...

Page 1029: ... DRIVER GAS CONTROL MODULE C2 POWERTRAIN 32 21 12 22 11 1 32 31 30 29 28 VEHICLE SPEED SENSOR SIGNAL G7 18WT OR 27 26 25 24 ENGINE OIL PRESSURE SENSOR SIGNAL G60 18GY YL 23 22 21 20 19 18 17 16 15 14 13 12 11 GENERATOR FIELD K20 18DG 10 9 8 7 6 5 4 3 2 1 FUNCTION CIRCUIT CAV K54 18OR BK 4 0L 2 5L A T TORQUE CONVERTER CLUTCH SOLENOID CONTROL K17 18DB TN IGNITION COIL NO 2 DRIVER WHITE 8W 80 74 8W 8...

Page 1030: ...NDICATOR DRIVER LOW COOLANT INDICATOR DRIVER A C REQUEST OUTPUT D1 18VT BR D20 18LG BK D2 18WT BK D21 18PK K226 18DB LG K72 18DG OR C90 18LG K48 18OR RD G55 18OR BK K118 18PK YL A142 16DG OR G86 18TN OR G154 18VT LG C103 18DG DIESEL CONTROL MODULE C3 POWERTRAIN GRAY 32 21 12 22 11 1 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 FUNCTION CIRCUIT CAV XJ 8W 80...

Page 1031: ...18BR 19 18 17 16 BATTERY TEMPERATURE SENSOR SIGNAL K118 18PK YL 15 14 13 FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT F142 18DG WT 12 SPEED CONTROL POWER SUPPLY V32 18YL RD 11 LEAK DETECTION PUMP SOLENOID CONTROL K106 18WT DG 10 9 8 7 6 SPEED CONTROL VENT SOLENOID CONTROL V35 18LG RD 5 SPEED CONTROL VACUUM SOLENOID CONTROL V36 18TN RD 4 AUTOMATIC SHUT DOWN RELAY CONTROL K51 18DB YL 3 RADIATOR FAN RELAY ...

Page 1032: ...SPEAKER X51 16BR YL 2 RADIO 12V OUTPUT X60 16DG RD 1 FUNCTION CIRCUIT CAV FUSED B RADIO C2 GRAY 1 7 M1 20PK 7 FUSED IGNITION SWITCH OUTPUT RUN ACC X12 16RD WT 6 FUSED PANEL LAMPS DIMMER SWITCH SIGNAL E2 20OR 5 HEADLAMP SWITCH OUTPUT L7 18BK YL 4 RIGHT FRONT SPEAKER X56 16DB RD 3 LEFT FRONT SPEAKER X55 16BR RD 2 1 FUNCTION CIRCUIT CAV BLACK 4 1 RAIL COIL 4 0L GAS IGNITION COIL NO 3 DRIVER FUSED AUT...

Page 1033: ...OR 4 FUSED REAR WINDOW DEFOGGER RELAY OUTPUT C16 20LB YL 3 REAR WINDOW DEFOGGER SWITCH SENSE C80 20DB WT 2 GROUND Z1 20BK 1 FUNCTION CIRCUIT CAV 1 2 BLACK GROUND Z1 18BK REAR WASHER MOTOR CONTROL V20 18BK WT 1 FUNCTION CIRCUIT CAV REAR FOG LAMP FEED 2 GROUND Z1 18BK 1 Z15 20BK GY GROUND RHD CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 V20 18BK WT REAR WASHER MOTOR CONTROL 3 V13 18BR LG REAR REAR WIPER ...

Page 1034: ...CK UP 1 2 GRAY GROUND Z1 18BK 1 BACK UP LAMP FEED L10 18BR LG 2 FUNCTION CIRCUIT CAV LAMP RIGHT COURTESY BLACK COURTESY LAMPS DRIVER M2 18BK WT 2 FUSED B M1 18PK 1 FUNCTION CIRCUIT CAV 1 2 GRAY FOG LAMP RELAY OUTPUT L39 20LB 2 GROUND Z1 20BK 1 FUNCTION CIRCUIT CAV RIGHT FOG LAMP FUSED IGNITION SWITCH OUTPUT RUN 2 1 BUILT UP EXPORT LAMP RIGHT CITY GROUND Z1 20BK 2 FUSED HEADLAMP SWITCH OUTPUT L78 2...

Page 1035: ...8 18DG YL 2 RIGHT TURN SIGNAL L60 18TN 1 FUNCTION CIRCUIT CAV 3 1 BLACK RIGHT TURN SIGNAL L60 18TN 2 GROUND Z1 18BK 1 FUNCTION CIRCUIT CAV 2 1 GRAY CAV CIRCUIT FUNCTION 1 X80 18LB BK AMPLIFIED RIGHT FRONT DOOR SPEAKER 2 X82 18LB RD BLACK 1 2 RIGHT FRONT DOOR SPEAKER FUSED HEADLAMP SWITCH OUTPUT AMPLIFIED RIGHT FRONT DOOR SPEAKER AMPLIFIED RIGHT FRONT DOOR SPEAKER EXCEPT BUILT UP EXPORT SIGNAL LAMP...

Page 1036: ...ORT LEVELING MOTOR RIGHT HEADLAMP CAV CIRCUIT FUNCTION 1 L44 18VT RD FUSED RIGHT LOW BEAM OUTPUT 2 L13 18BK HEADLAMP ADJUST SIGNAL 3 Z15 18BK GY GROUND RIGHT FRONT WHEEL SPEED SENSOR BUILT UP EXPORT LAMP NO 2 SENSOR RIGHT HEATED SEAT BACK DRIVER GROUND A B CAV CIRCUIT FUNCTION A P89 18BR B Z1 18BK RIGHT HEATED SEAT BACK RIGHT HEAT SEAT DRIVER RIGHT HEATED SEAT BACK DRIVER SENSOR FEED D C B A RIGHT...

Page 1037: ...IGHT POWER RIGHT POWER SEAT FRONT DOWN P20 14RD LG 2 RIGHT POWER SEAT FRONT UP P18 14YL LG 1 FUNCTION CIRCUIT CAV SEAT FRONT VERTICAL MOTOR YELLOW YELLOW MOTOR SEAT HORIZONTAL CAV CIRCUIT FUNCTION 1 P16 14RD LB RIGHT POWER SEAT HORIZONTAL REARWARD 2 P14 14YL LB RIGHT POWER SEAT HORIZONTAL FORWARD RIGHT POWER YELLOW VERTICAL MOTOR SEAT REAR CAV CIRCUIT FUNCTION 1 P10 14YL WT RIGHT POWER SEAT REAR U...

Page 1038: ...LAMPS DRIVER M2 18YL 3 GROUND Z1 18BK 2 1 FUNCTION CIRCUIT RIGHT POWER SEAT HORIZONTAL FORWARD RIGHT POWER SEAT FRONT DOWN RIGHT POWER SEAT FRONT UP P18 14YL LG P20 14RD LG M N CAV CIRCUIT FUNCTION A B P16 14RD LB J P14 14YL LB E RIGHT POWER SEAT HORIZONTAL REARWARD RIGHT POWER SEAT REAR UP RIGHT POWER SEAT REAR DOWN K P10 14YL WT L P12 14RD WT SEAT SWITCH RIGHT POWER N M L K J B E A C F H G C F G...

Page 1039: ...REAR DOWN REPEATER WHEEL SPEED RIGHT REAR RED B A RIGHT REAR WHEEL SPEED SENSOR B1 20YL DB B RIGHT REAR WHEEL SPEED SENSOR B2 20YL A FUNCTION CIRCUIT CAV CAV CIRCUIT FUNCTION 1 Q14 14GY POWER WINDOW RIGHT REAR B UP 2 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN 2 BLACK 1 RIGHT REAR WINDOW MOTOR SENSOR AMPLIFIED RIGHT REAR SPEAKER X92 16TN BK A RIGHT REAR SPEAKER X58 18DB OR A FUNCTION CIRCUIT CAV B B X5...

Page 1040: ... RIGHT TAIL 3 1 GROUND Z1 18BK 3 FUSED HEADLAMP SWITCH OUTPUT L78 18DG YL 2 BRAKE LAMP SWITCH OUTPUT L50 18WT TN 1 FUNCTION CIRCUIT CAV CONTROL SWITCH RIGHT SPEED CAV CIRCUIT FUNCTION 1 K167 20BR YL SENSOR GROUND 2 V37 20RD LG SPEED CONTROL SWITCH SIGNAL 2 1 GROUND Z1 20BK B FUSED B M1 20PK A FUNCTION CIRCUIT CAV LAMP VANITY RIGHT VISOR A B B A BLACK XJ 8W 80 CONNECTOR PIN OUTS 8W 80 85 XJI08085 J...

Page 1041: ...R Z2 18BK LG RIGHT SEAT LOW HEAT LED DRIVER LEFT SEAT HIGH HEAT LED DRIVER RIGHT SEAT HEATER SWITCH MUX P143 18BK DG RIGHT HEAT SENSE INPUT HEATED SEAT RELAY OUTPUT P87 18BK OR HEATED SEAT RELAY OUTPUT INTERFACE HEAT BLACK 6 14 1 7 SEAT 9 10 11 12 13 14 8 7 4 5 6 LEFT SEAT HEATER SWITCH MUX CAV CIRCUIT FUNCTION 1 P86 18PK BK 2 3 CCD BUS D1 20VT BR 1 CCD BUS D2 20WT BK 2 GROUND Z2 20BK LG 3 FUSED I...

Page 1042: ...MP SWITCH OUTPUT RIGHT TURN RELAY TRAILER TOW 1 4 2 5 3 BLACK BRAKE LAMP SWITCH OUTPUT L74 20LG 5 4 FUSED B A6 20RD OR 3 BRAKE LAMP SWITCH OUTPUT L50 20WT TN 2 RIGHT TURN SIGNAL L62 20BK RD 1 FUNCTION CIRCUIT CAV 2 5L GAS A T CLUTCH SOLENOID TORQUE CONVERTER FUNCTION FUSED IGNITION SWITCH OUTPUT ST RUN CIRCUIT F20 18WT A CAV B A TORQUE CONVERTER CLUTCH SOLENOID CONTROL K54 18OR BK B THROTTLE POSIT...

Page 1043: ...L LAMPS DIMMER SWITCH SIGNAL E2 20OR 1 FUNCTION CIRCUIT CAV SOLENOID TRANSMISSION SOLENOID B CONTROL T60 20OR WT OUTPUT SPEED SENSOR SIGNAL T14 20LG WT 7 8 8 4 4 1 BLACK OUTPUT SPEED SENSOR GROUND T13 20DB BK 6 INPUT SPEED SENSOR GROUND T31 20VT LG 5 SOLENOID C CONTROL T22 20DB WT 4 SOLENOID A CONTROL T19 20WT 3 2 INPUT SPEED SENSOR SIGNAL T52 20RD BK 1 FUNCTION CIRCUIT CAV 4WD SWITCH SENSE PART T...

Page 1044: ...22 20DB WT 11 10 TRS T3 SENSE T3 18VT 9 8 D1 20VT BR 7 CCD BUS D2 20WT BK 6 5 OUTPUT SPEED SENSOR SIGNAL T14 20LG WT 4 3 2 1 FUNCTION CIRCUIT CAV 4 0L A T RANGE TRANSMISSION 3 6 GRAY 7 4 1 8 5 2 GROUND Z1 18BK 8 T41 20BK WT 7 BACK UP LAMP FEED L10 18BR LG 6 5 T1 18LG BK 4 FUSED IGNITION SWITCH OUTPUT ST RUN F20 18WT 3 T3 18VT 2 T42 18VT WT 1 FUNCTION CIRCUIT CAV DIESEL TURBO BOOST PRESSURE CAV CIR...

Page 1045: ... V36 18TN RD 1 FUNCTION CIRCUIT CAV DIESEL CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 M1 20PK FUSED B BLACK 1 2 CAV CIRCUIT FUNCTION 1 L60 20TN RIGHT TURN SIGNAL 2 3 L62 20BR RD RIGHT TURN SIGNAL 4 L55 20RD WT COMBINATION FLASHER INPUT 5 L6 20RD WT FLASHER OUTPUT 6 L12 20VT TN HAZARD FLASHER SELECT SIGNAL 7 8 9 L63 20DG RD LEFT TURN SIGNAL 10 L61 20LG WT LEFT TURN SIGNAL 11 L55 20RD WT COMBINATION FL...

Page 1046: ...UND BLACK A B WINDSHIELD WASHER PUMP SWITCH WIPE WASH 1 6 NATURAL WIPER HIGH SPEED OUTPUT V4 16BR VT 6 FUSED IGNITION SWITCH OUTPUT RUN ACC V6 16DB 5 WIPER LOW SPEED OUTPUT V3 16BR WT 4 WASHER PUMP CONTROL V10 18BR 3 WIPER PARK SWITCH SENSE V5 16DG YL 2 GROUND Z1 16BK 1 FUNCTION CIRCUIT CAV GAS SENSOR VEHICLE SPEED CAV CIRCUIT FUNCTION 1 K6 18VT OR 5V SUPPLY 2 K167 20BR YL SENSOR GROUND 3 G7 18WT ...

Page 1047: ......

Page 1048: ...ressure Switch 4 0L RHD Left Side of Engine Compartment Near T O for A C Compressor Clutch 15 A C High Pressure Switch Diesel Left Side of Engine 41 42 A C Low Pressure Switch Diesel LHD Right Rear of Engine Compartment 39 Connector Name Number Color Location Fig A C Low Pressure Switch Diesel RHD Left Rear of Engine Compartment 37 A C Low Pressure Switch Gas LHD Right Rear of Engine Compartment 4...

Page 1049: ...ent 12 17 C114 Built Up Export BK T O at Left Headlamp T O 1 C115 Built Up Export BK T O at Right Headlamp T O N S C116 Diesel BK Right Side of Engine 39 40 41 C120 Diesel BK Rear of Engine 36 37 41 Connector Name Number Color Location Fig C200 LHD GY Left Lower Instrument Panel 21 26 C201 LHD NAT Lower Center of Instrument Panel 21 C202 RHD GY Lower Center of Instrument Panel 24 27 C203 RHD BL Lo...

Page 1050: ...BK Center of Liftgate 31 Connector Name Number Color Location Fig C332 NAT Under Left Front Seat 26 27 C333 BK At Center High Mounted Stop Lamp Jumper N S C362 BK Under Left Front Seat 26 27 C363 BK Under Right Front Seat 26 27 Camshaft Position Sensor GAS GY Right Side of Engine 16 17 Cargo Lamp Switch BK At Lamp N S Center High Mounted Stop Lamp BK At Liftgate N S Cigar Lighter RD Lower Center o...

Page 1051: ...nter of Cowl Under Instrument Panel 38 Connector Name Number Color Location Fig Engine Coolant Temperature Sensor GAS BK Front of Engine 16 17 Engine Coolant Temperature Sensor NO 1 Diesel BK Left Rear of Engine 41 Engine Coolant Temperature Sensor NO 2 Diesel BK Left Side of Engine 41 42 Engine Oil Pressure Sensor BK Right Side of Engine 16 17 41 Engine Speed Sensor Diesel BK Left Side of Engine ...

Page 1052: ...r Location Fig G300 In T O for Airbag Control Module N S G301 Near T O for Power Amplifier 28 G302 At Left Rear Quarter Panel 28 G303 Under Right Front Seat 26 27 29 G304 T O at T O s for C326 and C327 N S G306 Under Right Front Seat 26 27 G Switch BK Under Rear Seat 28 29 Generator 2 5L BK At Generator N S Generator 4 0L BK At Generator 18 Generator Diesel BK At Generator 41 42 Glow Plug Relay Di...

Page 1053: ...f Instrument Panel 21 24 Left Fog Lamp GY At Lamp 1 Left Front Door Speaker BK At Speaker 30 Left Front Door Tweeter BK Left Front Door 30 Connector Name Number Color Location Fig Left Front Park Turn Signal Lamp NO 1 Except Built Up Export GY At Lamp 1 Left Front Park Turn Signal Lamp NO 2 Except Built Up Export GY At Lamp 1 Left Front Turn Signal Lamp NO 1 Built Up Export GY At Lamp 1 Left Front...

Page 1054: ...ment sensor Diesel Rear of Engine Compartment 36 37 Connector Name Number Color Location Fig Overhead Module BK Front Center of Headliner 34 Oxygen Sensor 1 1 Upstream 2 5L GY Left Side of Engine 16 Oxygen Sensor 1 1 Upstream 4 0L GY Right Side of Transmission 20 Oxygen Sensor 1 1 Upstream California European III GY Left Side of Engine 17 Oxygen Sensor 1 2 Downstream 2 5L BK Right Side of Transmis...

Page 1055: ...Side of Engine Compartment 39 40 Powertrain Control Module C3 Gas GY Left Side of Engine Compartment 8 9 2 3 10 11 PRNDL Illumination A T At Center Console 26 27 Connector Name Number Color Location Fig Radiator Fan Motor LT GY Front of Engine Compartment 2 3 6 7 10 11 14 15 36 37 38 Radio C1 BK Center of Instrument Panel 22 23 Radio C2 GY Center of Instrument Panel 22 23 Rail Coil 4 0L BK Right S...

Page 1056: ... Power Seat Switch BK At Switch N S Connector Name Number Color Location Fig Right Rear Door Jamb Switch BK At Right B Pillar 29 Right Rear Door Lock Motor BK In Right Rear Door 30 Right Rear Fog Lamp Built Up Export BK At Lamp N S Right Rear Wheel Speed Sensor RD Under Rear Seat 28 Right Rear Window Motor BK In Right Rear Door 30 Right Rear Window Switch BL In Right Rear Door 30 Right Repeater La...

Page 1057: ... 25 Transmission Range Sensor 4 0L A T BK GY Rear of Engine Compartment 12 13 Connector Name Number Color Location Fig Turbo Boost Pressure Sensor Diesel BK Rear of Engine Compartment 36 37 Turn Signal Hazard Switch BK At Steering Column 21 24 35 Underhood Lamp Switch BK At Lamp 2 5 10 11 36 37 Vehicle Speed Control Servo LHD BK Right Front of Engine Compartment 4 12 14 Vehicle Speed Control Servo...

Page 1058: ...Fig 1 Front End Lighting XJ 8W 90 CONNECTOR LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued ...

Page 1059: ...Fig 2 Left Engine Compartment 2 5L Engine LHD 8W 90 12 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1060: ...Fig 3 Left Engine Compartment 2 5L Engine RHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued ...

Page 1061: ...Fig 4 Right Engine Compartment 2 5L Engine LHD Fig 5 Right Engine Compartment 2 5L Engine RHD 8W 90 14 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1062: ...Fig 6 Engine Compartment Auxiliary Views 2 5L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued ...

Page 1063: ...Fig 7 Engine Compartment Auxiliary Views 2 5L Engine RHD 8W 90 16 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1064: ...Fig 8 Engine Compartment Components LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued ...

Page 1065: ...Fig 9 Engine Compartment Components RHD 8W 90 18 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1066: ...Fig 10 Left Engine Compartment 4 0L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued ...

Page 1067: ...Fig 11 Left Engine Compartment 4 0L Engine RHD 8W 90 20 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1068: ...Fig 12 Right Engine Compartment 4 0L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued ...

Page 1069: ...Fig 13 Right Engine Compartment 4 0L Engine RHD 8W 90 22 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1070: ...Fig 14 Engine Compartment Auxiliary Views 4 0L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 23 DESCRIPTION AND OPERATION Continued ...

Page 1071: ...Fig 15 Engine Compartment Auxiliary Views 4 0L Engine RHD 8W 90 24 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1072: ...Fig 16 2 5L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 25 DESCRIPTION AND OPERATION Continued ...

Page 1073: ...Fig 17 4 0L Engine 8W 90 26 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1074: ...Fig 18 4 0L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 27 DESCRIPTION AND OPERATION Continued ...

Page 1075: ...Fig 19 Transmission Connectors 2 5L Engine 8W 90 28 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1076: ...Fig 20 Transmission Connectors 4 0L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 29 DESCRIPTION AND OPERATION Continued ...

Page 1077: ...Fig 21 Instrument Panel LHD 8W 90 30 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1078: ...Fig 22 Instrument Panel LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 31 DESCRIPTION AND OPERATION Continued ...

Page 1079: ...Fig 23 Instrument Panel RHD 8W 90 32 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1080: ...Fig 24 Instrument Panel RHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 33 DESCRIPTION AND OPERATION Continued ...

Page 1081: ...Fig 25 Under Dash Components 8W 90 34 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1082: ...Fig 26 Left Side Body LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 35 DESCRIPTION AND OPERATION Continued ...

Page 1083: ...Fig 27 Left Side Body RHD 8W 90 36 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1084: ...Fig 28 Left Rear Body XJ 8W 90 CONNECTOR LOCATIONS 8W 90 37 DESCRIPTION AND OPERATION Continued ...

Page 1085: ...Fig 29 Right Side Body and Junction Block 8W 90 38 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1086: ...Fig 30 Front and Rear Doors Left Side Shown Right Side Similar XJ 8W 90 CONNECTOR LOCATIONS 8W 90 39 DESCRIPTION AND OPERATION Continued ...

Page 1087: ...Fig 31 Liftgate 8W 90 40 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1088: ...Fig 32 Center Console LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 41 DESCRIPTION AND OPERATION Continued ...

Page 1089: ...Fig 33 Trailer Tow Fig 34 Headliner 8W 90 42 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1090: ...Fig 35 Steering Column XJ 8W 90 CONNECTOR LOCATIONS 8W 90 43 DESCRIPTION AND OPERATION Continued ...

Page 1091: ...Fig 36 Left Engine Compartment Diesel Engine LHD 8W 90 44 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1092: ...Fig 37 Left Engine Compartment Diesel Engine RHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 45 DESCRIPTION AND OPERATION Continued ...

Page 1093: ...Fig 38 Engine Compartment Auxiliary Views Diesel Engine 8W 90 46 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1094: ...Fig 39 Right Engine Compartment Diesel Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 47 DESCRIPTION AND OPERATION Continued ...

Page 1095: ...Fig 40 Right Engine Compartment Diesel Engine RHD 8W 90 48 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1096: ...Fig 41 Diesel Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 49 DESCRIPTION AND OPERATION Continued ...

Page 1097: ...Fig 42 Engine and Battery Diesel Engine 8W 90 50 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1098: ...Fig 43 Transmission Diesel Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 51 DESCRIPTION AND OPERATION Continued ...

Page 1099: ......

Page 1100: ...r T O s 11 S109 4 0L Near Fuel Injector T O s 10 S110 Near Fuel Injector T O s 11 S111 2 5L Near T O for G101 11 S111 4 0L Near Fuel Injector T O s 10 S112 Near Fuel Injector T O s 10 S113 2 5L Near T O for Fuel Injector NO 3 11 Splice Number Location Fig S113 4 0L Between Fuel Injector NO 2 and Fuel Injector NO 3 T O s 10 S114 2 5L Near T O for Fuel Injector NO 2 11 S114 4 0L Between Fuel Injecto...

Page 1101: ...7 S135 LHD 4 0L Near T O for C107 3 Splice Number Location Fig S135 LHD 4 0L M T ABS Near T O for Right Front Wheel Speed Sensor 3 S135 RHD Near T O for Underhood Lamp 4 8 S135 RHD ABS Near Grommet T O for C100 4 8 S136 Near T O for C107 3 S137 LHD Between Power Distribution Center T O and Glow Plug Relay T O 24 S137 RHD Near T O for A C Low Pressure Switch 25 S138 2 5L Near Grommet T O for Front ...

Page 1102: ...Fig S156 RHD Near Grommet T O for Engine Control Module C1 and C2 25 S157 LHD Near T O for Glow Plug Relay 24 S157 RHD Near T O for A C Low Pressure Switch 25 S158 Near T O for Left Headlamp 9 S159 Near Grommet T O for Junction Block C2 3 4 7 8 S161 A T Near T O for Vehicle Speed Sensor 11 S162 Near T O for Left Headlamp 9 S163 Near T O for Left Headlamp 9 S164 Near T O for Right Headlamp 9 S165 N...

Page 1103: ...ckspring C2 N S Splice Number Location Fig S222 Near T O for Clockspring C2 N S S225 In T O for C301 14 S226 In T O for Headlamp Switch 12 13 S227 In T O for Headlamp Switch 12 13 S228 Near T O for Blower Motor Resistor Block N S S229 LHD Near T O for Diode Module and Rear Fog Lamp Relay 12 S229 RHD Near T O for C202 C203 and C204 13 S230 Near T O for Cigar Lighter 12 13 S232 Near T O for Junction...

Page 1104: ...335 Near T O for Trailer Tow Right Turn Relay 18 S336 Near T O for C322 18 S337 Near T O for C322 18 S338 Near T O for C323 18 Splice Number Location Fig S339 Near T O for C323 18 S340 Near Grommet for Trailer Tow Connector 18 S341 In Left Tail Lamp Harness near C321 N S S342 With Remote Keyless Entry In T O for Overhead Module 23 S344 In T O for Overhead Module 23 S345 With Remote Keyless Entry I...

Page 1105: ...Fig 1 Left Engine Compartment Splices 4 0L Engine LHD 8W 95 6 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1106: ...Fig 2 Left Engine Compartment Splices 4 0L Engine RHD XJ 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued ...

Page 1107: ...Fig 3 Right Engine Compartment Splices 4 0L Engine LHD 8W 95 8 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1108: ...Fig 4 Right Engine Compartment Splices 4 0L Engine RHD XJ 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued ...

Page 1109: ...Fig 5 Left Engine Compartment Splices 2 5L Engine LHD 8W 95 10 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1110: ...Fig 6 Left Engine Compartment Splices 2 5L Engine RHD XJ 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued ...

Page 1111: ...Fig 7 Right Engine Compartment Splices 2 5L Engine LHD 8W 95 12 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1112: ...Fig 8 Right Engine Compartment Splices 2 5L Engine RHD XJ 8W 95 SPLICE LOCATIONS 8W 95 13 DESCRIPTION AND OPERATION Continued ...

Page 1113: ...Fig 9 Front End Lighting Splices 8W 95 14 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1114: ...Fig 10 Engine Wiring Splices 4 0L Engine XJ 8W 95 SPLICE LOCATIONS 8W 95 15 DESCRIPTION AND OPERATION Continued ...

Page 1115: ...Fig 11 Engine Wiring Splices 2 5L Engine 8W 95 16 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1116: ...Fig 12 Instrument Panel Wiring Splices LHD XJ 8W 95 SPLICE LOCATIONS 8W 95 17 DESCRIPTION AND OPERATION Continued ...

Page 1117: ...Fig 13 Instrument Panel Wiring Splices RHD 8W 95 18 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1118: ...Fig 14 Instrument Panel to Body Harness Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 19 DESCRIPTION AND OPERATION Continued ...

Page 1119: ...Fig 15 Left Side Body Harness Splices 8W 95 20 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1120: ...Fig 16 Right Side Body Harness Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 21 DESCRIPTION AND OPERATION Continued ...

Page 1121: ...Fig 17 Left Side Body Harness Splices Fig 18 Trailer Tow Splices 8W 95 22 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1122: ...Fig 19 Power Seat Splices Fig 20 Right Front Door Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 23 DESCRIPTION AND OPERATION Continued ...

Page 1123: ...Fig 21 Left Front Door Splices Fig 22 Liftgate Splices 8W 95 24 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1124: ...Fig 23 Headliner Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 25 DESCRIPTION AND OPERATION Continued ...

Page 1125: ...Fig 24 Left Engine Compartment Splices Diesel LHD 8W 95 26 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1126: ...Fig 25 Left Engine Compartment Splices Diesel RHD XJ 8W 95 SPLICE LOCATIONS 8W 95 27 DESCRIPTION AND OPERATION Continued ...

Page 1127: ...Fig 26 Right Engine Compartment Splices Diesel LHD 8W 95 28 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued ...

Page 1128: ...Fig 27 Right Engine Compartment Splices Diesel RHD XJ 8W 95 SPLICE LOCATIONS 8W 95 29 DESCRIPTION AND OPERATION Continued ...

Page 1129: ......

Page 1130: ...NG 18 CONNECTING ROD BEARINGS FITTING 21 FITTING CRANKSHAFT MAIN BEARINGS 23 FORM IN PLACE GASKETS 25 ENGINE PERFORMANCE 26 HONING CYLINDER BORES 26 REPAIR DAMAGED OR WORN THREADS 27 SERVICE ENGINE ASSEMBLY SHORT BLOCK 27 HYDROSTATIC LOCK 27 ENGINE OIL SERVICE 27 REMOVAL AND INSTALLATION ENGINE MOUNTS FRONT 29 ENGINE MOUNT REAR 30 ENGINE 31 INTAKE MANIFOLD 33 EXHAUST MANIFOLD 35 CYLINDER HEAD COVE...

Page 1131: ...r 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 the inlet side of the full flow ...

Page 1132: ...s provided by the hydraulic valve tappets which pass oil through hollow push rods to a hole in the corresponding rocker arm Oil from the rocker arm lubricates the valve train components then passes down through the push rod guide holes in the cylinder head past the valve tappet area and returns to the oil pan XJ 2 5L ENGINE 9 3 DESCRIPTION AND OPERATION Continued ...

Page 1133: ...em 2 5L Engine 1 CAM CRANK MAIN GALLERY 7 2 TAPPET GALLERY 3 TAPPET GALLERY 4 CAMSHAFT BEARING 5 NUMBER 1 CAMSHAFT BEARING JOURNAL 6 CAMSHAFT SPROCKET 7 TAPPET GALLERY 9 4 2 5L ENGINE XJ DESCRIPTION AND OPERATION Continued ...

Page 1134: ...s 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 CRANKSHAFT DESCRIPTION The crankshaft is constructed of nodular cast iron Fig 3 Cylinder Block 2 5L 1 C...

Page 1135: ...de of stamped steel and have a operational ratio of 1 6 1 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 The valves are made of heat resistant steel and have chrome plated stems to preven...

Page 1136: ...et bores above the camshaft VALVE GUIDE DESCRIPTION The valve guides are integral to the cylinder head They are not replaceable However they are service able OIL PAN DESCRIPTION The oil pan is made of stamped steel The oil pan gasket is a one piece steel backbone silicone coated gasket Fig 9 Valve and Keeper Configuration 2 5L Engine 1 VALVE LOCKS 3 BEAD 2 RETAINER 3 VALVE STEM OIL SEAL 4 INTAKE V...

Page 1137: ...l in determining the causes of malfunctions not detected and remedied by routine maintenance These malfunctions may be classified as either per formance e g engine idles rough and stalls or mechanical e g a strange noise Refer to the Service Diagnosis Performance chart and the Service Diagnosis Mechanical chart for pos sible causes and corrections of malfunctions Refer to Group 14 Fuel System for ...

Page 1138: ...rocedures 2 No fuel 2 Perform fuel pressure test and if necessary inspect fuel injector s and driver circuits Refer to Group 14 Fuel System for correct procedures 3 Low or no engine compression 3 Perform cylinder compression pressure test Refer to Group 9 Engine for correct procedures ENGINE LOSS OF POWER 1 Worn or burned distributor rotor 1 Install new distributor rotor 2 Worn distributor shaft 2...

Page 1139: ...fer 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 ACCELERATION 1 Worn or incorrectly gapped spark plugs 1 Replace spark plugs or clean and set gap Refer to group 8D Ignition System 2 Spark plug cables defective or crossed 2 Check Idle Air Control circuit Refer to Group 14 Fuel...

Page 1140: ...onnecting rod bearing clearance Measure bearings for correct clearance with plasti gage Repair as necessary 5 Connecting rod journal out of round 5 Replace crankshaft or grind journals 6 Misaligned connecting rods 6 Replace bent connecting rods MAIN BEARING NOISE 1 Insufficient oil supply 1 Check engine oil level Refer to group 0 Lubrication and Maintenance 2 Low oil pressure 2 Check engine oil le...

Page 1141: ...teriorated gaskets 1 Replace gasket 2 Loose fastener broken or porous metal part 2 Tighten repair or replace the part 3 Front or rear crankshaft oil seal leaking 3 Replace seal 4 Leaking oil gallery plug or cup plug 4 Remove and reseal threaded plug Replace cup style plug EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED 1 PCV System malfunction 1 Refer to group 25 Emission Control System for co...

Page 1142: ...n adjacent cylinders follow the proce dures outlined in Cylinder Compression Pressure Test An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50 70 reduction in compression pressure CYLINDER TO WATER JACKET LEAKAGE TEST WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PUL...

Page 1143: ... and repeat inspection 4 If the oil leak source is not positively identified at this time proceed with the air leak detection test method Air Leak Detection Test Method 1 Disconnect the breather cap to air cleaner hose at the breather cap end Cap or plug breather cap nipple 2 Remove the PCV valve from the cylinder head cover Cap or plug the PCV valve grommet 3 Attach an air hose with pressure gaug...

Page 1144: ...he front of the engine until the dial indicator pointer indicates 0 305 mm 0 012 inch travel dis tance lift The timing notch index on the vibration damper should be aligned with the TDC mark on the timing degree scale If the timing notch is more than 13 mm 1 2 inch away from the TDC mark in either direction the valve timing is incorrect If the valve timing is incorrect the cause may be a broken ca...

Page 1145: ...RED 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 4 Remove and measure telescoping gauge with a micrometer 5 Repeat the measurement with contacts length wise to engine cylinder head 6 Compare the cross...

Page 1146: ... bore at a point 49 5 mm 1 15 16 inches below top of bore Start perpendicular across or at 90 degrees to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B Fig 19 3 The coated pistons will be serviced with the piston pin and connecting rod pre assembled The coated piston connecting rod assembly can be used to service previous built engines ...

Page 1147: ...tween the ring land and ring Fig 20 Fig 21 Rotate the ring in the groove It must move freely around circumference of the groove Fig 18 Moly Coated Piston 1 MOLY COATED 2 MOLY COATED Fig 19 Bore Gauge 1 FRONT 2 BORE GAUGE 3 CYLINDER BORE 4 49 5 MM 1 15 16 in PISTON SIZE CHART CYLINDER BORE SIZE PISTON LETTER SIZE 98 438 98 448 mm 3 8755 3 8759 in A 98 448 98 458 mm 3 8759 3 8763 in B 98 458 98 468 ...

Page 1148: ...ll the second com pression ring with the dot facing up Fig 24 Fig 26 9 Using a ring installer install the top compres sion ring either side up Ring Gap Orientation Position the gaps on the piston as shown Fig 27 Oil spacer Gap on center line of piston skirt Oil rails gap 180 apart on centerline of piston pin bore No 2 Compression ring Gap 180 from top oil rail gap No 1 Compression ring Gap 180 fro...

Page 1149: ...N RING 2 SECOND COMPRESSION RING 3 PISTON 4 CHAMFER Fig 26 Compression Ring Installation 1 COMPRESSION RING 2 RING EXPANDER RECOMMENDED Fig 27 Ring Gap Orientation 1 TOP COMPRESSION RING 2 BOTTOM COMPRESSION RING 3 TOP OIL CONTROL RAIL 4 OIL RAIL SPACER 5 BOTTOM OIL CONTROL RAIL 6 IMAGINARY LINE PARALLEL TO PISTON PIN 7 IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT 9 20 2 5L ENGINE XJ SERVICE PROC...

Page 1150: ...int to the front of the engine Fig 31 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 5 Install the lower bearing insert in the bearing cap The lower insert must be dry Place strip of Plas tigage across full width of the lower insert at the cen ter of bearing cap Plastigage must not crumble in use If brittle obtain fres...

Page 1151: ...ed with a pair of 0 0254 mm 0 001 inch undersize bearing inserts installed This will determine if two 0 0254 mm 0 001 inch undersize inserts or another combination is needed to provide the correct clearance refer to Connecting Rod Bearing Fitting Chart CONNECTING ROD BEARING FITTING CHART CRANKSHAFT JOURNAL CORRESPONDING CONNECTING ROD BEARING INSERT Color Code Diameter Upper Insert Size Lower Ins...

Page 1152: ... bearing inserts FITTING BEARINGS CRANKSHAFT INSTALLED The main bearing caps numbered front to rear from 1 through 5 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 th...

Page 1153: ...he specified clearance FOR EXAMPLE If the clear ance 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 original clearance an add...

Page 1154: ...ifferent properties and cannot be used inter changeably MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant normally black in color is available in 3 ounce tubes Moisture in the air causes the sealant material to cure This material is normally used on flexible metal flanges It has a shelf life of a year and will not properly cure if over aged Always inspect the package fo...

Page 1155: ...p 8D for specifications 7 Test fuel pump for pressure Refer to Group 14 Fuel System Specifications 8 The air filter elements should be replaced as specified in Lubrication and Maintenance Group 0 9 Inspect crankcase ventilation system as out lined in Group 0 Lubrication and Maintenance For emission controls see Group 25 Emission Controls for service procedures 10 Road test vehicle as a final test ...

Page 1156: ...ll spark plugs removed rotate the crank shaft using a breaker bar and socket 6 Identify the fluid in the cylinders i e coolant fuel oil etc 7 Make sure all fluid has been removed from the cylinders 8 Repair engine or components as necessary to prevent this problem from occurring again 9 Squirt engine oil into the cylinders to lubricate the walls This will prevent damage on restart 10 Install new s...

Page 1157: ...r oil to settle to bottom of crankcase remove engine oil dipstick 3 Wipe dipstick clean 4 Install dipstick and verify it is seated in the tube 5 Remove dipstick with handle held above the tip note oil level reading Fig 39 6 Add oil only if level is below the ADD mark on dipstick ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules Run engine until ac...

Page 1158: ... Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine Refer to the WARNING at beginning of this section REMOVAL AND INSTALLATION ENGINE MOUNTS FRONT The front mounts support the engine at each side These supports are made of resilient rubber REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Support the engine 4 Remove through ...

Page 1159: ...ive cable from battery 2 Raise the vehicle and support the transmission 3 Remove the nuts holding the support cushion to the crossmember Fig 45 Fig 46 Remove the crossmember MANUAL TRANSMISSION a Remove the support cushion nuts and remove the cushion b If necessary remove the bolts holding the trans mission support bracket to the transmission Fig 45 Remove the bracket Fig 42 Front Mounts 1 ENGINE ...

Page 1160: ...he nuts Tighten the nuts to 22 N m 192 in lbs torque 2 Install the crossmember to sill bolts and tighten to 41 N m 30 ft lbs torque 3 Remove the transmission support 4 Lower the vehicle 5 Connect negative cable to battery ENGINE REMOVAL 1 Disconnect the battery cables Remove the bat tery 2 Mark the hinge locations on the hood panel for alignment reference during installation Remove the engine comp...

Page 1161: ...s 18 Disconnect suction discharge hose from A C compressor and cap off ports to prevent intrusion of foreign material or refrigerant oil loss 19 Remove the power brake vacuum check valve from the booster if equipped 20 If equipped with power steering a Disconnect the power steering hoses from the fittings at the steering gear b Drain the pump reservoir c Cap the fittings on the hoses and steering ...

Page 1162: ...lbs torque c Fill the pump reservoir with fluid 19 Remove the pulley to water pump flange alignment capscrew and install the fan assembly 20 Install the fan shroud and radiator and con denser if equipped with air conditioning 21 Connect the radiator hoses 22 Connect the oxygen sensor wire connector 23 Connect the throttle cable and install the rod Connect the transmission and speed control cables ...

Page 1163: ... Remove bolts 2 through 5 securing the intake manifold to the cylinder head Fig 51 Slightly loosen bolt No 1 and nuts 6 and 7 15 Remove the intake manifold and gaskets Drain the coolant from the manifold INSTALLATION 1 Clean the intake manifold and cylinder head mating surfaces DO NOT allow foreign material to enter either the intake manifold or the ports in the cylinder head 2 Install the new int...

Page 1164: ... DO NOT allow foreign material to enter either the intake man ifold or the ports in the cylinder head 2 Install a new intake manifold gasket over the alignment dowels on the cylinder head 3 Install the engine exhaust manifold assembly Exhaust manifold must be centrally located over the end studs and spacer Fig 51 4 Tighten bolt No 1 to 41 N m 30 ft lbs torque Fig 51 5 Install the intake manifold o...

Page 1165: ... 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...

Page 1166: ... Spring Compressor Tool MD 998772A to compress the spring and remove the locks Fig 54 9 Remove valve spring and retainer Fig 54 10 Remove valve stem oil seals Fig 54 Note the valve seals are different for intake and exhaust valves The top of each seal is marked either INT intake black in color or EXH exhaust brown in color DO NOT mix the seals INSTALLATION Inspect the valve stems especially the gr...

Page 1167: ...NOT disconnect the hoses 10 Perform fuel pressure release procedure Refer to Group 14 fuel systems for proper proce dures 11 Remove the latch clip and disconnect the fuel supply hose 12 Remove the intake and engine exhaust mani folds from the engine cylinder head refer to Group 11 Exhaust System and Intake Manifold for the proper procedures 13 Number and disconnect the ignition wires and remove th...

Page 1168: ...e 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 ...

Page 1169: ...ntinue operating the engine until the thermostat opens Add coolant if required 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 file to remove any burrs on the top of the valve stem especially around the groove ...

Page 1170: ...kshaft key and tap the damper onto the crankshaft 2 Install the vibration damper retaining bolt and washer 3 Tighten the damper retaining bolt to 108 N m 80 ft lbs torque 4 Install the serpentine drive belt and tighten to the specified tension refer to Group 7 Cooling Sys tems for the proper specifications and procedures 5 Connect negative cable to battery TIMING CASE COVER OIL SEAL REMOVAL This p...

Page 1171: ...ration damper Fig 63 7 Remove the oil pan to timing case cover bolts and timing case cover to cylinder block bolts 8 Remove the timing case cover and gasket from the engine 9 Pry the crankshaft oil seal from the front of the timing case cover Fig 63 INSTALLATION 1 Clean the timing case cover oil pan and cylin der block gasket surfaces 2 Install a new crankshaft oil seal in the timing case cover Th...

Page 1172: ... cover 6 Rotate crankshaft until the 0 timing mark is closest to and on the center line with camshaft sprocket timing mark Fig 65 7 Remove the oil slinger from the crankshaft 8 Remove the camshaft retaining bolt and remove the sprockets and chain as an assembly Fig 66 9 To replace the timing chain tensioner the oil pan must be removed INSTALLATION 1 Turn the tensioner lever to the unlocked down po...

Page 1173: ...ibutor housing near the clamp and continue the scribe mark on the cylin der block in line with the distributor mark 6 For ease of installation note the position of the rotor and distributor housing in relation to adjacent engine components 7 Remove the distributor and ignition wires 8 Remove the engine cylinder head cover 9 Remove the rocker arms bridges and pivots 10 Remove the push rods 11 Remov...

Page 1174: ...e tappets 16 Install the push rods 17 Install the rocker arms bridges and pivots 18 Install the engine cylinder head cover 19 Position the oil pump gear Refer to Distribu tor in the Component Removal Installation section of Group 8D Ignition Systems 20 Install the distributor and ignition wires Refer to Distributor in the Component Removal In stallation section of Group 8D Ignition Systems 21 Inst...

Page 1175: ...an the camshaft pin hole 2 Compress the center of the replacement spring pin with vise grips 3 Carefully drive the pin into the camshaft pin hole until it is seated 4 Install the camshaft sprocket crankshaft sprocket and timing chain with the timing marks aligned Fig 72 5 To verify correct installation of the timing chain turn the crankshaft to position the camshaft sprocket timing mark as shown i...

Page 1176: ...pressure lubricated 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 Camshaft end play is maintained by the load placed on the camshaft by the oil pump and distrib utor drive gear The helical cut of the gear holds the camshaft sprocket thrust face against th...

Page 1177: ...ket 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 strike the cap more than twice for proper engage ment 8 Tighten the bolts of caps 1 3 4 and 5 to 54 N m 40 ft lbs torque Now tighten these bolts to 95 N m 70 ft lbs torque Finally tighten these...

Page 1178: ...ue 18 Fill the oil pan with engine oil to the safe mark on the dipstick level 19 Connect negative cable to battery OIL PAN REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Remove the oil pan drain plug and drain the engine oil 4 Disconnect the exhaust pipe at the engine exhaust manifold 5 Disconnect the exhaust hanger at the catalytic converter and lower the pipe 6 Remove the...

Page 1179: ...ive cable to battery 18 Fill the oil pan with engine oil to the specified level WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 19 Start the engine and inspect for leaks OIL PUMP The positive displacement gear type oil pump is driven by the distributor shaft which is d...

Page 1180: ...STON AND CONNECTING ROD REMOVAL 1 Remove the engine cylinder head cover 2 Remove the rocker arms bridges and pivots 3 Remove the push rods 4 Remove the engine cylinder head 5 Position the pistons one at a time near the bot tom of the stroke Use a ridge reamer to remove the ridge from the top end of the cylinder walls Use a protective cloth to collect the cuttings 6 Raise the vehicle 7 Drain the en...

Page 1181: ...d the flange rear end of the crankshaft The color codes used to indi cate journal sizes are listed in the Connecting Rod Bearing Fitting Chart 10 When required upper and lower bearing inserts of different sizes may be used as a pair refer to Connecting Rod Bearing Fitting Chart A stan dard size insert is sometimes used in combination with a 0 025 mm 0 001 inch undersize insert to reduce clearance ...

Page 1182: ...n and gasket 12 Remove the timing chain tensioner 13 Remove the front and rear oil galley plugs 14 Remove the connecting rods and the pistons Remove the connecting rod and piston assemblies through the top of the cylinder bores 15 Remove the crankshaft ASSEMBLY 1 Install the crankshaft 2 Install the connecting rods and the pistons through the top of the cylinder bores 3 Install the front and rear ...

Page 1183: ...ightedge 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 Use compressed air to clean out 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 ...

Page 1184: ...T Hydraulic Tappet Clearance Zero Lash Bearing Clearance 0 025 0 076 mm 0 001 0 003 in DESCRIPTION SPECIFICATION Bearing Journal Diameter No 1 51 54 51 56 mm 2 029 2 030 in No 2 51 28 51 31 mm 2 019 2 020 in No 3 51 03 51 05 mm 2 009 2 010 in No 4 50 78 50 80 mm 1 999 2 000 in Base Circle Runout Max 0 03 mm 0 001 in Camshaft Lobe Lift Exhaust 6 579 mm 0 259 in Intake 6 477 mm 0 255 in Camshaft Dur...

Page 1185: ...ATION Main Bearing Journal Width No 1 27 58 to 27 89 mm 1 086 to 1 098 in No 2 32 28 to 32 33 mm 1 271 to 1 273 in No 3 4 5 30 02 to 30 18 mm 1 182 to 1 188 in Main Bearing Clearance 0 03 to 0 06 mm 0 001 to 0 0025 in Main Bearing Clearance Preferred 0 051 mm 0 002 in Connecting Rod Journal Diameter 53 17 to 53 23 mm 2 0934 to 2 0955 in Connecting Rod Journal Width 27 18 to 27 33 mm 1 070 to 1 076...

Page 1186: ...lve Seat Width 1 01 to 1 52 mm 0 040 to 0 060 in DESCRIPTION SPECIFICATION Valve Seat Runout 0 064 mm 0 0025 in Flatness 0 03 mm per 25 mm 0 001 in per 1 in 0 05 mm per 152 mm 0 002 in per 6 in Flatness Max 0 20 mm for total length 0 008 in for total length ROCKER ARMS PUSH RODS TAPPETS Rocker Arm Ratio 1 6 1 Push Rod Length Blue 241 300 to 241 808 mm 9 500 to 9 520 in Push Rod Diameter 7 92 to 8 ...

Page 1187: ...Compression Rings 0 042 to 0 084 mm 0 0017 to 0 0033 in Oil Control Rings 0 06 to 0 21 mm 0 0024 to 0 0083 in DESCRIPTION SPECIFICATION OIL PUMP AND OIL PRESSURE Gear to Body Clearance Radial 0 051 to 0 102 mm 0 002 to 0 004 in Radial Preferred 0 051 mm 0 002 in Gear End Clearance Plastigage 0 051 to 0 152 mm 0 002 to 0 006 in Plastigage Preferred 0 051 mm 0 002 in Feeler Gauge 0 1016 to 0 2032 mm...

Page 1188: ...nsmission Support Adaptor 75 55 Bracket Bolts Exhaust Manifold Pipe Nuts 27 20 DESCRIPTION N m Ft Lbs In Lbs Exhaust Manifold Bolt 1 41 30 Bolts 2 5 31 23 Nuts 6 and 7 14 126 Flywheel Converter Housing Bolts 38 28 Flywheel to Crankshaft Bolts 143 105 Front Cover to Block Bolts 1 4 20 7 60 Front Cover to Block 5 16 18 22 192 Generator Mounting Bolts 57 42 Generator Mounting 47 35 Bracket to Engine ...

Page 1189: ...ve Spring Compressor Tool MD 998772A Timing Case Cover Alignment and Seal installation Tool 6139 Vibration Damper Removal Tool 7697 Rear Main Seal Installer Tool 6271A Hydraulic Valve Tappet Removal Installation Tool C 4129 A 9 60 2 5L ENGINE XJ ...

Page 1190: ...N BEARINGS 83 FORM IN PLACE GASKETS 86 ENGINE PERFORMANCE 87 HONING CYLINDER BORES 87 REPAIR DAMAGED OR WORN THREADS 88 SERVICE ENGINE ASSEMBLY SHORT BLOCK 88 HYDROSTATIC LOCK 88 ENGINE OIL SERVICE 88 REMOVAL AND INSTALLATION ENGINE MOUNTS FRONT 90 ENGINE MOUNT REAR 91 ENGINE ASSEMBLY 92 INTAKE AND EXHAUST MANIFOLD 95 EXHAUST MANIFOLD 4 0L ENGINE 96 CYLINDER HEAD COVER 96 ROCKER ARMS AND PUSH RODS...

Page 1191: ...RICATION 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...

Page 1192: ... provided by the hydraulic valve tappets which pass oil through hollow push rods to a hole in the corresponding rocker arm Oil from the rocker arm lubricates the valve train components then passes down through the push rod guide holes in the cylinder head past the valve tappet area and returns to the oil pan XJ 4 0L ENGINE 9 63 DESCRIPTION AND OPERATION Continued ...

Page 1193: ...m 4 0L Engine 1 CAM CRANK MAIN GALLERY 7 2 TAPPET GALLERY 3 TAPPET GALLERY 4 CAMSHAFT BEARING 5 NUMBER 1 CAMSHAFT BEARING JOURNAL 6 CAMSHAFT SPROCKET 7 TAPPET GALLERY 9 64 4 0L ENGINE XJ DESCRIPTION AND OPERATION Continued ...

Page 1194: ...g 4 CRANKSHAFT DESCRIPTION The crankshaft is constructed of nodular cast iron The crankshaft is a crosshaped four throw design with eight counterweights for balancing purposes The crankshaft is supported by seven select main bearings with the number three serving as the thrust washer location The main journals of the crankshaft are cross drilled to improve rod bearing lubrication The select fit ma...

Page 1195: ...lobes actuate the tappets and push rods forcing upward on the rocker arms which applies downward force on the valves 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 ...

Page 1196: ...mshaft VALVE GUIDE DESCRIPTION The valve guides are integral to the cylinder head They are not replaceable However they are service able OIL PAN DESCRIPTION The oil pan is made of stamped steel The oil pan gasket is a one piece steel backbone silicone coated gasket VALVE STEM SEAL DESCRIPTION The valve stem seals are made of rubber and incor porate a garter spring to maintain consistent lubrica ti...

Page 1197: ...noise Refer to the Service Diagnosis Performance chart and the Service Diagnosis Mechanical chart for pos sible causes and corrections of malfunctions Refer to Group 14 Fuel System for the fuel system diagnosis Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts Information concerning additional tes...

Page 1198: ...rocedures 2 No fuel 2 Perform fuel pressure test and if necessary inspect fuel injector s and driver circuits Refer to Group 14 Fuel System for correct procedures 3 Low or no engine compression 3 Perform cylinder compression pressure test Refer to Group 9 Engine for correct procedures ENGINE LOSS OF POWER 1 Worn or burned distributor rotor 1 Install new distributor rotor 2 Worn distributor shaft 2...

Page 1199: ...fer 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 ACCELERATION 1 Worn or incorrectly gapped spark plugs 1 Replace spark plugs or clean and set gap Refer to group 8D Ignition System 2 Spark plug cables defective or crossed 2 Check Idle Air Control circuit Refer to Group 14 Fuel...

Page 1200: ...onnecting rod bearing clearance Measure bearings for correct clearance with plasti gage Repair as necessary 5 Connecting rod journal out of round 5 Replace crankshaft or grind journals 6 Misaligned connecting rods 6 Replace bent connecting rods MAIN BEARING NOISE 1 Insufficient oil supply 1 Check engine oil level Refer to group 0 Lubrication and Maintenance 2 Low oil pressure 2 Check engine oil le...

Page 1201: ...al 4 Leaking oil gallery plug or cup plug 4 Remove and reseal threaded plug Replace cup style plug EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED 1 PCV System malfunction 1 Refer to group 25 Emission 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 wall...

Page 1202: ...roximately a 50 70 reduction in compression pressure CYLINDER TO WATER JACKET LEAKAGE TEST WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING Remove the radiator cap Start the engine and allow it to warm up until the engine thermostat opens If a large combustion compr...

Page 1203: ... and repeat inspection 4 If the oil leak source is not positively identified at this time proceed with the air leak detection test method Air Leak Detection Test Method 1 Disconnect the breather cap to air cleaner hose at the breather cap end Cap or plug breather cap nipple 2 Remove the PCV valve from the cylinder head cover Cap or plug the PCV valve grommet 3 Attach an air hose with pressure gaug...

Page 1204: ...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 Rotate the crankshaft clockwise viewed from the front of the engine until the dial indicator pointer indicates 0 305 mm 0 012 inch tr...

Page 1205: ...nch oversize stems NOTE If the valve guides are reamed oversize the valve seats must be ground to ensure that the valve seat is concentric to the valve guide VALVE STEM TO GUIDE CLEARANCE MEASUREMENT Valve stem to guide clearance may be measured by either of the following two methods PREFERRED METHOD 1 Remove the valve from the head 2 Clean the valve stem guide bore with solvent and a bristle brus...

Page 1206: ...sets Tin coated pistons should not be used as replacements for coated pistons 4 The coating material is applied to the piston after the final piston machining process Measuring the outside diameter of a coated piston will not pro vide accurate results Fig 19 Therefore measuring the inside diameter of the cylinder bore with a dial Bore Gauge is MANDATORY To correctly select the proper size piston a...

Page 1207: ...er sealing surface and can be installed with either side up Fig 24 Fig 19 Moly Coated Piston 1 MOLY COATED 2 MOLY COATED Fig 20 Bore Gauge 1 FRONT 2 BORE GAUGE 3 CYLINDER BORE 4 49 5 MM 1 15 16 in PISTON SIZE CHART CYLINDER BORE SIZE PISTON LETTER SIZE 98 438 98 448 mm 3 8755 3 8759 in A 98 448 98 458 mm 3 8759 3 8763 in B 98 458 98 468 mm 3 8763 3 8767 in C 98 468 98 478 mm 3 8767 3 8771 in D 98 ...

Page 1208: ...ing Gap 180 from top oil rail gap No 1 Compression ring Gap 180 from No 2 compression ring gap Fig 22 Ring Side Clearance Measurement 1 FEELER GAUGE RING SIDE CLEARANCE CHART ITEM SPECIFICATION Top Compression Ring 0 042 0 084 mm 0 0017 0 0033 in Second Compression Ring 0 042 0 084 mm 0 0017 0 0033 in Oil Control Ring 0 06 0 21 mm 0 0024 0 0083 in Fig 23 Gap Measurement 1 FEELER GAUGE RING GAP MEA...

Page 1209: ...d journals If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod inspect it for correct rod Fig 25 Second Compression Ring Identification 1 SECOND COMPRESSION RING 2 CHAMFER 3 ONE DOT Fig 26 Compression Ring Chamfer Location 1 TOP COMPRESSION RING 2 SECOND COMPRESSION RING 3 PISTON 4 CHAMFER Fig 27 Compression Ring Installation 1 COMPRESSION ...

Page 1210: ...ft Plastigage will smear resulting in inaccurate indication 7 Remove the bearing cap and determine amount of bearing to journal clearance by measuring the width of compressed Plastigage Fig 33 Refer to Engine Specifications for the proper clearance Plas tigage should indicate the same clearance across the entire width of the insert If the clearance varies it may be caused by either a tapered journ...

Page 1211: ... 2 0934 in 0 0356 mm 0 0014 in 0 025 mm 0 001 in 0 025 mm 0 001 in Undersize Red 52 9717 52 9539 mm Red Undersize Red Undersize 2 0855 2 0848 in 0 254 mm 0 010 in 0 254 mm 0 010 in 0 254 mm 0 010 in Undersize 11 FOR EXAMPLE If the initial clearance was 0 0762 mm 0 003 inch 0 025 mm 0 001 inch undersize inserts would reduce the clearance by 0 025 mm 0 001 inch The clearance would be 0 002 inch and ...

Page 1212: ...aint mark on the crank shaft rear flange When required upper and lower bearing inserts of different sizes may be used as a pair A standard size insert is sometimes used in combination with a 0 025 mm 0 001 inch undersize insert to reduce the clear ance by 0 013 mm 0 0005 inch Never use a pair of bearing inserts with greater than a 0 025 mm 0 001 inch difference in size Refer to the Bearing Insert ...

Page 1213: ... 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...

Page 1214: ...le taper and out of round is 0 013 mm 0 0005 inch Compare the measured diameter with the journal diameter specification Main Bearing Fitting Chart Select inserts required to obtain the specified bearing to journal clearance Install the crankshaft into the cylinder block refer to Cylinder Block Assemble and Crankshaft Main Bearings Installation MAIN BEARING FITTING CHART Crankshaft Journals 1 6 Cor...

Page 1215: ...ly black in color is available in 3 ounce tubes Moisture in the air causes the sealant material to cure This material is normally used on flexible metal flanges It has a shelf life of a year and will not properly cure if over aged Always inspect the package for the expi ration date before use MOPAR GASKET MAKER Mopar Gasket Maker normally red in color is available in 6 cc tubes This anaerobic type...

Page 1216: ...ilation system as out lined in Group 0 Lubrication and Maintenance For emission controls see Group 25 Emission Controls for service procedures 10 Road test vehicle as a final test HONING CYLINDER BORES Before honing stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area 1 Used carefully the Cylinder Bore Sizing Hone C ...

Page 1217: ...l spark plugs removed rotate the crank shaft using a breaker bar and socket 6 Identify the fluid in the cylinders i e coolant fuel oil etc 7 Make sure all fluid has been removed from the cylinders 8 Repair engine or components as necessary to prevent this problem from occurring again 9 Squirt engine oil into the cylinders to lubricate the walls This will prevent damage on restart 10 Install new sp...

Page 1218: ...y ten min utes for oil to settle to bottom of crankcase remove engine oil dipstick 3 Wipe dipstick clean 4 Install dipstick and verify it is seated in the tube 5 Remove dipstick with handle held above the tip take oil level reading Fig 41 6 Add oil only if level is below the ADD mark on dipstick ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance Schedules Ru...

Page 1219: ... The front mounts support the engine at each side These supports are made of resilient rubber REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Support the engine 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 support cushions Fig 44 6 Remove the through bolt 7 Remove the support cushions INSTALLATION...

Page 1220: ...et from the transmission AUTOMATIC TRANSMISSION Fig 47 a Remove the support cushion bolts and remove the cushion and the support bracket from the trans mission 4WD or from the adaptor bracket 2WD b On 2WD vehicles remove the bolts holding the transmission support adaptor bracket to the trans mission Fig 47 Remove the adaptor bracket INSTALLATION MANUAL TRANSMISSION a Install the transmission suppo...

Page 1221: ...ation Remove the engine compartment lamp Remove the hood WARNING THE COOLANT IN A RECENTLY OPER ATED ENGINE IS HOT AND PRESSURIZED USE CARE TO PREVENT SCALDING BY HOT COOLANT CAREFULLY RELEASE THE PRESSURE BEFORE REMOVING THE RADIATOR DRAIN COCK AND CAP 3 Remove the air cleaner assembly 4 Loosen the radiator drain cock and radiator cap to drain the coolant DO NOT waste usable coolant If the soluti...

Page 1222: ...e from the booster if equipped 23 If equipped with power steering a Disconnect the hoses from the fittings at the steering gear b Drain the pump reservoir c Cap the fittings on the hoses and steering gear to prevent foreign objects from entering the system 24 Identify tag and disconnect all necessary wire connectors and vacuum hoses 25 Raise and support the vehicle 26 Disconnect the wires from the...

Page 1223: ...tall the starter motor and connect the cable 16 Connect the wires to the starter motor sole noid 17 Lower the vehicle 18 Connect all the vacuum hoses and wire con nectors identified during engine removal 19 Vehicles with Power Steering a Remove the protective caps b Connect the hoses to the fittings at the steer ing gear Tighten the nut to 52 N m 38 ft lbs torque c Fill the pump reservoir with flu...

Page 1224: ...e transferred to the replacement mani fold 1 Install a new engine exhaust intake manifold gasket over the alignment dowels on the cylinder head 2 Position the engine exhaust manifolds to the cylinder head Install fastener Number 3 and finger tighten at this time Fig 50 3 Install intake manifold on the cylinder head dowels 4 Install washer and fastener Numbers 1 2 4 5 8 9 10 and 11 Fig 50 5 Install...

Page 1225: ...the engine cylinder head cover and gasket INSTALLATION 1 If a replacement cover is installed transfer the CCV valve grommet and oil filler cap from the origi nal cover to the replacement cover 2 Install cylinder head cover and gasket Tighten the mounting bolts to 10 N m 85 in lbs torque 3 Connect the CCV hoses 4 Install control cables and bracket on intake manifold and tighten bolts to 8 7 N m 77 ...

Page 1226: ... 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 cylinde...

Page 1227: ...e accessory drive belt at the power steering pump Refer to Group 7 Cooling System for the correct procedure Slip the belt off of the power steering pulley 8 Remove the A C compressor mounting bolts and secure the compressor to the side 9 Remove the power steering pump and bracket from the intake manifold and water pump Set the pump and bracket aside DO NOT disconnect the hoses 10 Perform the Fuel ...

Page 1228: ... Check all bolts in sequence to verify the cor rect torque f If not already done clean and mark each bolt with a dab of paint after tightening Should you encounter bolts which were painted in an earlier service operation replace them 6 Install the spark plugs and tighten to 37 N m 27 ft lbs torque 7 Connect the temperature sending unit wire connector 8 Install the ignition coil rail and coil rail ...

Page 1229: ... the top of the valve stem especially around the groove for the locks 5 Remove the valves and place them in a rack in the same order as removed INSTALLATION 1 Thoroughly clean the valve stems and the valve guide bores 2 Lightly lubricate the stem 3 Install the valve in the original valve guide bore 4 Install the replacement valve stem oil seals on the valve stems If the 0 381 mm 0 015 inch over si...

Page 1230: ... the damper retaining bolt to 108 N m 80 ft lbs torque 4 Install the serpentine drive belt Refer to Group 7 Cooling Systems for the proper specifica tions and procedures 5 Connect negative cable to battery TIMING CASE COVER REMOVAL 1 Disconnect negative cable from battery 2 Remove the vibration damper 3 Remove the fan and hub assembly and remove the fan shroud 4 Remove the accessory drive brackets...

Page 1231: ...the A C compressor if equipped and generator bracket assembly 11 Install the engine fan and hub assembly and shroud 12 Install the serpentine drive belt 13 Connect negative cable to battery TIMING CHAIN AND SPROCKETS REMOVAL 1 Disconnect negative cable from battery 2 Remove the fan and shroud 3 Remove the serpentine drive belt 4 Remove the crankshaft vibration damper 5 Remove the timing case cover...

Page 1232: ... cooling system DO NOT waste reus able coolant If the solution is clean drain it into a clean container for reuse 3 Remove the radiator or radiator and condenser if equipped with A C refer to Group 7 Cooling Sys tem for the proper procedure 4 Remove the engine cylinder head cover 5 Remove the rocker arms bridges and pivots 6 Remove the push rods 7 Remove the engine cylinder head and gasket 8 Remov...

Page 1233: ...the proper procedure 21 Check the ignition timing and adjust as nec essary 22 Install the grille and bumper if removed 23 Connect negative cable to battery CAMSHAFT BEARINGS REMOVAL The camshaft rotates within four steel shelled bab bitt lined bearings that are pressed into the cylinder block and then line reamed The camshaft bearing bores and bearing diameters are not the same size They are stepp...

Page 1234: ...n in Fig 66 11 Install the timing chain cover refer to the pro cedure in this section CRANKSHAFT MAIN BEARINGS REMOVAL 1 Disconnect negative cable from battery 2 Remove the spark plugs 3 Raise the vehicle 4 Remove the oil pan and oil pump 5 Remove main bearing cap brace Fig 67 6 Remove only one main bearing cap and lower insert at a time Fig 68 7 Remove the lower insert from the bearing cap 8 Remo...

Page 1235: ... Finally tighten these bolts to 108 N m 80 ft lbs torque 8 Push the crankshaft forward and backward Load the crankshaft front or rear and tighten cap bolt No 3 to 54 N m 40 ft lbs torque Then tighten to 95 N m 70 ft lbs torque and finally tighten to 108 N m 80 ft lbs torque 9 Rotate the crankshaft after tightening each main bearing cap to ensure the crankshaft rotates freely 10 Check crankshaft en...

Page 1236: ... cable to battery OIL PAN REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Remove the oil pan drain plug and drain the engine oil 4 Disconnect the exhaust pipe at the exhaust manifold 5 Disconnect the exhaust hanger at the catalytic converter and lower the pipe 6 Remove the starter motor 7 Remove the engine flywheel and transmission torque converter housing access cover 8 If ...

Page 1237: ...cover 13 Install the engine starter motor 14 Connect the exhaust pipe to the hanger and to the engine exhaust manifold 15 Install transmission oil cooling lines if equipped and oxygen sensor wiring supports that attach to the oil pan studs 16 Install the oil pan drain plug Fig 75 Tighten the plug to 34 N m 25 ft lbs torque 17 Lower the vehicle 18 Connect negative cable to battery 19 Fill the oil p...

Page 1238: ...Have an assistant push the piston and con necting rod assemblies up and through the top of the cylinder bores Fig 78 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 CAUTION Ensure that connecting rod bolts DO...

Page 1239: ...3 Lower the vehicle 14 Install the engine cylinder head push rods rocker arms bridges pivots and engine cylinder head cover 15 Fill the crankcase with engine oil CRANKSHAFT OIL SEALS REAR The crankshaft rear main bearing oil seal consists of two half pieces of viton with a single lip that effec tively seals the rear of the crankshaft Replace the upper and lower seal halves as a unit to ensure leak...

Page 1240: ...stributor 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 CAUTION If the oil pump is not to be serviced DO NOT disturb position of oil inlet tube and strainer assembly in pump body If the tube is moved within the pump body a replacement tube and stra...

Page 1241: ...Cooling Systems for the proper specifications and procedures 6 Install the radiator shroud 7 Connect negative cable to battery DISASSEMBLY AND ASSEMBLY CYLINDER BLOCK DISASSEMBLY Refer to the applicable sections for detailed instructions 1 Drain the engine oil Remove and discard the oil filter 2 Remove the water pump from the cylinder block 3 Remove the vibration damper 4 Remove the timing case co...

Page 1242: ...sively worn 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...

Page 1243: ...01 in INCREMENTS is required If a bore gauge is not available do not use an inside micrometer 2 Measure the inside diameter of the cylinder bore at three levels below top of bore Start perpen dicular across or at 90 degrees to the axis of the crankshaft and then take two additional reading 3 Measure the cylinder bore diameter crosswise to the cylinder block near the top of the bore Repeat the meas...

Page 1244: ...2 030 in No 2 51 28 to 51 31 mm 2 019 to 2 020 in No 3 51 03 to 51 05 mm 2 009 to 2 010 in No 4 50 78 to 50 80 mm 1 999 to 2 000 in DESCRIPTION SPECIFICATION Base Circle Runout MAX 0 03 mm 0 001 in Valve Lift Intake 10 350 mm 0 4075 in Exhaust 10 528 mm 0 4145 in Valve Timing Intake Opens 12 4 BTDC Closes 60 9 ABDC Exhaust Opens 49 8 BBDC Closes 29 2 ATDC Valve Overlap 41 6 Intake Duration 253 3 E...

Page 1245: ...ength Center to Center 155 52 to 155 62 mm 6 123 to 6 127 in Piston Pin Bore Diameter 23 59 to 23 62 mm 0 9288 to 0 9298 in DESCRIPTION SPECIFICATION Bore Less Bearings 56 08 to 56 09 mm 2 2080 to 2 2085 in Bearing Clearance 0 025 to 0 076 mm 0 001 to 0 003 in Preferred 0 044 to 0 050 mm 0 0015 to 0 0020 in Side Clearance 0 25 to 0 48 mm 0 010 to 0 019 in Twist Max 0 002 mm per mm 0 002 in per inc...

Page 1246: ...25 mm 0 010 in DESCRIPTION SPECIFICATION VALVE SPRINGS Free Length Approx 47 65 mm 1 876 in Spring Load Valve Closed 316 to 351 N 41 656 mm 71 to 79 lbf 1 64 in Valve Open 898 6 to 969 7 N 30 89 mm 202 to 218 lbf 1 216 in Inside Diameter 21 0 mm to 21 51 mm 0 827 to 0 847 in Installed Height 41 656 mm 1 64 in PISTONS Weight Less Pin 417 to 429 grams 14 7 to 15 1 oz Piston Pin Bore Centerline 40 61...

Page 1247: ...0 rpm Higher 255 to 517 kPa 37 to 75 psi Oil Pressure Relief 517 kPa 75 psi TORQUE SPECIFICATIONS 4 0L ENGINE DESCRIPTION N m Ft In Lbs Lbs A C Compressor Bolts 28 250 Block Heater Nut 2 16 Camshaft Sprocket Bolt 68 50 Camshaft Thrust Plate to Cylinder Block Screws 24 18 Clutch Cover to Flywheel Bolts 54 40 Coil Bracket to Block Bolts 22 192 Connecting Rod Nuts 45 33 Cylinder Block Drain Plugs 34 ...

Page 1248: ...47 35 Block 68 50 Adaptor Bolts 102 50 Oil Galley Plug 41 30 Oil Pan Bolts 1 4 20 9 5 84 5 16 18 15 132 Oil Pan Drain Plug 34 25 Oil Pump Mounting Bolts 23 204 Cover Bolts 8 70 Rocker Arm Assembly to Cylinder Head Capscrews 30 21 Spark Plugs 37 27 Starter Motor Mounting Bolts 45 33 Thermostat Housing Bolts 18 156 Throttle Body Bolts 10 90 Vibration Damper Bolt 108 80 Water Pump to Block Bolts 23 1...

Page 1249: ......

Page 1250: ... INTERNAL VACUUM PUMP 33 OIL PUMP PRESSURE RELIEF VALVE 34 OIL FILTER ADAPTER AND ENGINE OIL COOLER 35 PISTONS AND CONNECTING ROD ASSEMBLY 35 CYLINDER WALL LINER ASSEMBLY 38 CRANKSHAFT MAIN BEARINGS 40 DISASSEMBLY AND ASSEMBLY HYDRAULIC TAPPETS 43 CLEANING AND INSPECTION CYLINDER HEAD 43 ROCKER ARMS AND PUSH RODS 43 PISTONS AND CONNECTING ROD ASSEMBLY 44 CYLINDER WALL LINER ASSEMBLY 45 OIL PUMP 46...

Page 1251: ...ge Replace battery if a charge cannot be held Displacement 2 5L 2499 cc Bore 92 00 Stroke 94 00 Compression Ratio 21 1 Vacuum at idle 600 mm Hg 23 6 In Hg Belt Tension 400 500 N Automatic Tensioner Thermostat Opening 80 C 6 2 C Generator Rating Denso 12V 95A Cooling System Capacity 9 5 Liter P S Capacity 0 75 Liter Engine Oil Capacity 7 2L w filter change Timing System Pushrod operated overhead va...

Page 1252: ... bleed fuel system 7 Worn or inoperative injection pump 7 Visually check delivery with externally connected injector to one of the pump outlets Repair or replace the pump if fuel is not being delivered ENGINE HARD TO START OR WILL NOT START SMOKE FROM EXHAUST 1 Incorrect starting procedure 1 The fuel shutoff solenoid control must be in the run position Ensure proper procedure is being used 2 Crank...

Page 1253: ...tive 1 Verify system is working Repair replace inoperative parts 2 One or more cylinder head heater plugs defective 2 Verify system is working Repair replace inoperative parts 3 Intake air or exhaust system restricted 3 Visually check for exhaust restriction and inspect the air intake 4 Air in the fuel supply system or the fuel supply is inadequate 4 Check flow through the filter and bleed the sys...

Page 1254: ...resence of gasoline Replace fuel water separator filter 4 Incorrect valve operation 4 Check for a bent push rod and adjust valves Replace push rod if necessary 5 Injection pump timing incorrect 5 Check time pump refer to Group 14 Fuel System 6 Improperly operating injectors 6 Replace inoperative injectors 7 Defective injection pump delivery valve 7 Repair or replace injection pump 8 Camshaft out o...

Page 1255: ...ck correct the restriction in the exhaust system 8 High fuel temperature 8 Verify that fuel heater is off when engine is warm Check for restricted fuel drain tubes Repair replace as needed 9 Poor quality fuel or fuel contaminated with gasoline 9 Verify by operating from a temporary tank with good fuel Check for presence of gasoline Replace fuel water separator filter 10 Air leak between the turboc...

Page 1256: ...cked replace manifold 8 Improperly operating turbocharger 8 Inspect replace turbocharger 9 Improperly operating injectors 9 Check and replace inoperative injectors 10 Improperly operating or overfueled injector pump 10 Repair or replace injection pump 11 Piston rings not sealing blue smoke 11 Perform blow by check Correct as required ENGINE WILL NOT SHUT OFF 1 Fuel shutoff solenoid inoperative 1 C...

Page 1257: ...ure the fill rate is not being exceeded and the correct vented thermostat is installed B Check for loose hose clamps Tighten if loose C If aeration continued check for a compresssion leak through the head gasket 10 Inoperative water pump 10 Check and replace the water pump 11 Incorrect injection pump timing 11 Verify pump timing marks are aligned Check time the injector pump refer to Group 14 Fuel...

Page 1258: ... remove shipping plugs 7 Worn oil pump 7 Check and replace oil pump 8 Suction tube loose or seal leaking 8 Check and replace seal 9 Loose main bearing cap Check and install new bearing and tighten cap to proper torque 10 Worn bearings or wrong bearings installed 10 Inspect and replace connecting rod or main bearings Check and replace piston cooling nozzles 11 Oil jet under piston bad fit into main...

Page 1259: ...er gasoline contaminated fuel 2 Verify by operating from a temporary tank with good fuel Clean and flush the fuel supply tanks Replace fuel water separator 3 Engine overloaded 3 Verify the engine load rating is not being exceeded 4 Incorrect injection pump timing 4 Check and time injection pump refer to Group 14 Fuel System 5 Improperly operating injectors 5 Check and replace inoperative injectors...

Page 1260: ... ends for wear 3 Valve tappet noise ranges from light noise to a heavy click A light noise is usually caused by exces sive leak down around the unit plunger or by the plunger partially sticking in the tappet body cylinder The tappet should be replaced A heavy click is caused by a tappet check valve not seating or by for eign particles becoming wedged between the plunger and the tappet body This wi...

Page 1261: ...th finish 2 Use tapered stones to obtain the specified seat width when required VALVE STAND DOWN Valve stand down is to maintain the adequate com pression ratio 1 Invert cylinder head 2 Fit each valve to its respective valve guide 3 Using a straight edge and feeler gauge Fig 4 check valve head stand down Inlet valve head stand down 1 08 to 1 34 mm 042 to 052 ins and exhaust valve stand down 99 to ...

Page 1262: ...ION ENGINE MOUNTS LHD DIESEL The engine mounts support the engine at each side These supports are made of resilient rubber REMOVAL RIGHT SIDE 1 Disconnect the negative battery cable 2 Remove the innercooler inlet hose from the tur bocharger and position it out of the way Fig 6 3 Remove the right engine mount upper sill plate nuts 4 Raise the vehicle on a hoist 5 Remove the oil filter and adaptor f...

Page 1263: ... the unlocked position Raise the vehicle on a hoist 6 Remove the steering shaft pinchbolt Remove the shaft from the gearbox by sliding it straight off the gearbox input shaft CAUTION Do not rotate the steering shaft while removed from the gearbox input shaft Damage to the steering column clockspring will occur 7 Remove the left engine mount throughbolt nut only Fig 8 Do not remove the bolt at this...

Page 1264: ...1 N m 30 ft lbs Fig 10 9 Torque all the H Block retaining bolts to 18 N m 159 in lbs 10 Torque the engine mount throughbolt nut to 65 N m 48 ft lbs Fig 10 11 Install the steering shaft Torque the pinch bolt to 49 N m 36 ft lbs 12 Lower the vehicle from the hoist 13 Install the engine mount upper sill plate nuts Torque to 41 N m 30 ft lbs Fig 11 14 Install the refrigerant line support bracket on th...

Page 1265: ...45 ft lbs 4 Torque the engine mount lower sill plate bolts to 41 N m 30 ft lbs 5 Torque the larger trackbar support bracket bolts to 125 N m 92 ft lbs 6 Install the oil filter and adaptor on the engine Torque oil filter adaptor retaining bolt to 69 N m 51 ft lbs 7 Remove the jack stand 8 Install the engine mount upper sill plate nuts Torque to 41 N m 30 ft lbs 9 Torque the engine mount throughbolt...

Page 1266: ...t lower sill plate bolts 3 Install the 4 engine mount bracket to engine block retaining bolts Torque to 61 N m 45 ft lbs 4 Torque the 2 lower engine mount sill plate bolts to 41 N m 30 ft lbs 5 Install the 2 engine mount upper sill plate nuts Torque to 41 N m 30 ft lbs 6 Remove the jack stand 7 Position the H Block and the A C Compressor in there original positions and install the retaining bolts ...

Page 1267: ...nd outlet hoses from the engine Fig 15 20 Remove the coolant reservoir supply hose from the engine Fig 15 21 On L H D vehicles disconnect the heater core coolant supply and the brake vacuum supply hoses from the engine 22 On R H D vehicles disconnect the heater core coolant supply and the brake vacuum supply hoses from the right side of the engine compartment Remove the line assembly retaining bol...

Page 1268: ...NE MOUNT THROUGHBOLT NUT 2 ENGINE GROUND WIRE 3 OIL PAN Fig 17 Exhaust System Inlet Pipe Connection 1 OIL PAN 2 EXHAUST INLET PIPE FLANGE RETAINING BOLTS 3 EXHAUST SYSTEM SUPPORT CLAMP Fig 18 Clutch Slave Cylinder 1 CLUTCH SLAVE CYLINDER 2 CLUTCH SLAVE CYLINDER RETAINING NUTS 3 FRONT DRIVESHAFT Fig 19 Transfer Case Shift Linkage 4x4 1 FRONT DRIVESHAFT 2 SHIFTER LINKAGE RETAINING NUTS 3 TRANSFER CA...

Page 1269: ...oose at this time 3 Install the fuel water separator and mounting bracket on the bulkhead 4 Install the fuel lines on the fuel water sepa rator 5 Connect the electrical connectors to the bottom of the fuel water separator 6 Install the power steering fluid pressure line on the steering gear 7 Install the oil filter and adaptor on the engine Torque adaptor retaining bolt to 69 N m 51 ft lbs Fill th...

Page 1270: ... System for the procedure 33 Connect the oil pressure sensor electrical con nector Fig 24 34 Connect the EGR vacuum supply hose on the engine Fig 24 35 Install the air filter outlet hose and connect the breather hose on the engine Fig 24 36 Install the refrigerant suction and discharge lines Torque the retaining bolts on the A C compres sor to 22 N m 200 in lbs Make sure the O Rings are well lubri...

Page 1271: ...ditioning for the procedure Remove the A C line support bracket attached to cylinder head cover and move the A C vacuum lines away from the cylinder head 5 Remove the generator support brace 6 Remove the Crankcase breather hose from the rear of the valve cover 7 Remove the cylinder head cover bolts 8 Remove the cylinder head cover INSTALLATION 1 Install the cylinder head cover Torque the bolts to ...

Page 1272: ... at fast idle Run engine for a suf ficient time to allow all of the air inside the tappets to be bled out HYDRAULIC TAPPETS REMOVAL 1 Disconnect the negative battery cable 2 Discharge the air conditioning system if equipped Refer to Group 24 Heating and Air Condi tioning for procedure 3 If equipped with air conditioning remove the A C lines at the compressor and cap 4 Remove the A C line bracket a...

Page 1273: ...ds and place them on a bench in the same order as removed INSTALLATION WARNING During the installation of the rocker arm assemblies it is possible to cause valve interfer ence between the piston and valve if the piston is near Top Dead Center TDC This is due to the slow bleed down rate of the tappets when adjusting the rocker arm assemblies Follow the procedure below to ensure that engine damage d...

Page 1274: ...t 6 Install the rocker arm assemblies in their orig inal locations Torque nuts to 29 4 N m 264 in lbs 7 Install the cylinder head cover Refer to cylin der head cover removal and installation in this sec tion 8 Connect the negative battery cable ENGINE CYLINDER HEAD REMOVAL 1 Disconnect the negative battery cable WARNING DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAIN COCK...

Page 1275: ...e the engine cylinder head cover 29 Remove the rocker retaining nuts Fig 33 30 Remove the rocker arm assemblies Place them on a bench in the same order as removed 31 Remove the push rods and place them on a bench in the same order as removed 32 Mark the cylinder head positions 33 Remove the engine cylinder head bolts with special tool VM 1018 and VM 1019 34 Remove the engine cylinder head and gask...

Page 1276: ...the piston of cylinder no 1 exactly to top dead center 3 Zero the dial indicator on the cylinder block mating surface 4 Setup the dial indicator on the piston crown above the center of the piston pin 5mm 1 8 in Fig 32 Fuel Injector Fig 33 Rocker Arm Retaining Nuts 1 ROCKER ARM ASSEMBLY 2 ROCKER ARM RETAINING NUTS 3 ROCKER ARM SPRING PLATE Fig 34 Steel Type Cylinder Head Gasket identification HOW T...

Page 1277: ...hat the various clamps are installed correctly and the head gasket remains in it s proper position completely covered Then lubricate and install the eight small bolts 12mm also finger tight 6 Install the intake and exhaust manifolds with a new gasket partially tightening the nuts to a max imum of 5 N m 44 in lbs This will align the heads Refer to Group 11 Exhaust System and Turbo charger for the p...

Page 1278: ...29 Install the EGR valve to intake manifold tighten bolts to 27 N m 20 ft lbs 30 Install the EGR tube to EGR valve tighten bolts to 27 N m 20 ft lbs 31 Install the lower charge air cooler hose to tur bocharger 32 Install the air cleaner assembly and hose 33 Install the oil breather hose to air cleaner hose 34 Install the upper charge cooler hose to turbo charger 35 Connect the recover bottle hose ...

Page 1279: ...l VM 1015A 2 Install the vibration damper Refer to vibration damper removal and installation in this section 3 Connect the negative battery cable TIMING GEAR COVER REMOVAL 1 Disconnect the negative battery cable 2 Remove the fan and set fan inside fan shroud then remove fan shroud and fan as an assembly 3 Remove the accessary drive belt Refer to Group 7 Cooling System for procedure 4 Remove the vi...

Page 1280: ...to Group 24 Heating and Air Conditioning for procedure 9 Remove the vibration damper Refer to vibra tion damper removal and installation in this section 10 Remove the power steering pump pulley 11 Remove timing gear cover Refer to timing gear cover removal and installation in this section 12 Rotate the engine to align the timing marks as shown Fig 41 13 Unscrew the flange bolts and remove cam shaf...

Page 1281: ...E EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN DIRECT LINE WITH THE FAN DO NOT PUT HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 14 Operate the engine with the radiator cap off Inspect for leaks and continue operating the engine until the thermostat opens Add coolant if required CAMSHAFT BEARINGS This procedure requires that the engine is removed from the vehicle R...

Page 1282: ...us 3 mm bead of Silicone Sealer to oil pan install within 10 minutes Install the oil pan 3 Install the inside oil pan bolts Torque bolts to 11 N m 8 ft lbs 4 Torque the smaller oil pan bolts to 11 N m 8 ft lbs Torque the larger oil pan bolts to 25 N m 18 ft lbs 5 Install the oil drain plug Torque to 79 N m 58 ft lbs 6 Lower the vehicle from hoist 7 Fill engine with proper amount of oil 8 Connect t...

Page 1283: ...RESSURE RELIEF VALVE REMOVAL 1 Disconnect the negative battery cable 2 Remove the oil pan Refer to oil pan removal and installation procedure in this section 3 Remove the relief valve snap ring 4 Remove the relief valve cap spring and plunger Fig 51 5 Check the relief valve spring length Relief valve spring free length is 57 5mm 2 263 in If spring length is less or spring is distorted it must be r...

Page 1284: ...ig 52 4 Remove the oil filter adapter 5 Disconnect the engine oil cooler coolant hoses and remove the oil cooler INSTALLATION 1 Connect the engine oil cooler coolant hoses 2 Install a new o ring on the oil cooler 3 Install the oil filter adapter to the engine oil cooler with a new o ring using the oil filter adapter oil cooler retaining bolt Fig 52 Torque bolt to 69 N m 51 ft lbs 4 Install the oil...

Page 1285: ...ng expander from piston 4 Carefully clean carbon from piston crowns skirts and ring grooves ensuring the 4 oil holes in the oil control ring groove are clear PISTON RING FITTING 1 Wipe cylinder bore clean Insert ring and push down with piston to ensure it is square in bore The ring gap measurement must be made with the ring positioning at least 12 mm 0 50 in from bottom of cylinder bore Check gap ...

Page 1286: ...d also face in the same direction To insert piston into cylinder use a ring compressor as shown in Fig 57 PISTON PIN INSTALLATION 1 Secure connecting rod in soft jawed vice 2 Lubricate piston pin and piston with clean oil 3 Position piston on connecting rod CAUTION Ensure combustion recess in piston crown and the bearing cap numbers on the con necting rod are on the same side 4 Install piston pin ...

Page 1287: ...same time guide connecting rod into position on connecting rod journal 7 Install rod caps Install rod bolts and tighten to 29 N m 21 ft lb plus 60 CYLINDER WALL LINER ASSEMBLY REMOVAL 1 Remove cylinder heads 2 Remove Oil pan 3 Remove pistons 4 Use tool VM 1001 to remove liners Fig 61 5 Remove shims from cylinder liner or cylinder block recess Keep shims with each cylinder liner INSTALLATION 1 Care...

Page 1288: ...ly to the upper part of the liner at area 8 Fit the liners in the crankcase making sure that the shim is positioned correctly in the seat Lock the liners in position using special tool VM 1016 and bolts Fig 64 Clean the residual LOCTITE on the upper surface of the block deck 9 Recheck the liner protrusion It should be 0 01 0 06 mm NOTE A period of six hours must elapse between the liners being ins...

Page 1289: ...e the oil pan and oil pick up 12 Remove the pistons and connecting rods 13 Remove the vibration damper Refer to vibra tion damper removal and installation in this section 14 Remove the timing gear cover Refer to timing gear cover removal and installation in this section 15 Remove the oil pump and vacuum pump from block 16 Install special tool VM 1004 onto crankshaft over gear Fig 66 17 Remove the ...

Page 1290: ... clean crankcase and oil passages and blow dry with compressed air 6 Install new main bearing shells in each of the carrier halves Assemble the carriers to the crank shaft journals ensuring that the carriers are installed in their original locations and that the pis ton jet notch is towards the front of the crank shaft Secure each carrier with the two bolts tightening evenly to 44 N m 32 ft lbs Ch...

Page 1291: ...t end play should not exceed 153 to 304mm 0060 to 0119 in Fig 70 CAUTION Use NEW flywheel bolts for the following procedure 27 Install a new O ring on flywheel Install fly wheel on crankshaft The 6 flywheel bolts must be tightened as follows a Lubricate and install the 6 new flywheel bolts b Torque the 6 flywheel bolts to 49 N m 36 ft lbs starting one bolt and following with the opposite one cross...

Page 1292: ... are unfit for further ser vice with new assemblies 3 If plunger shows signs of scoring or wear install a new tappet assembly If valve is pitted or valve seat on end of plunger is prevented from seat ing install a new tappet assembly 4 Assemble tappets CLEANING AND INSPECTION CYLINDER HEAD CLEANING Thoroughly clean the engine cylinder head and cyl inder block mating surfaces Clean the intake and e...

Page 1293: ...g INSPECTION CONNECTING ROD 1 Assemble bearing shells and bearing caps to their respective connecting rods ensuring that the serrations on the cap and reference marks are aligned 2 Tighten bearing cap bolts to 29N m 21 ft lbs plus 60 3 Check and record internal diameter of crank end of connecting rod NOTE When changing connecting rods all four must have the same weight and be stamped with the same...

Page 1294: ...ECTION The cylinder walls should be checked for out of round and taper with dail bore gauge The cylinder bore out of round is 0 100 mm 0039 inch maximum and cylinder bore taper is 0 100 mm 0 0039 inch maximum If the cylinder walls are badly scuffed or scored new liners should be installed and honed and new pistons and rings fitted Measure the cylinder bore at three levels in direc tions A and B Fi...

Page 1295: ...4 mm Capacity 2499 5cc Injection order 1 3 4 2 Compression ratio 21 1 0 5 Gasket Asbestos free Crankshaft Front journal diameter Nominal 62 985 63 005 mm 0 25 62 735 62 755 mm 0 125 62 860 62 880 mm Front bearing diameter Nominal 63 043 63 088 mm 0 25 62 793 62 838 0 125 62 919 62 964 mm Clearance between journal and bearing 0 038 0 103 mm Center journal diameter Nominal 63 005 63 020 mm 0 25 62 7...

Page 1296: ...otches 1 61 mm 0 08 1 notch 1 51 mm 0 08 2 notches DESCRIPTION SPECIFICATIONS End plates Height 89 92 90 00 mm Connecting rods Weight without the crank bearing 966 grams Small end bearing Internal diameter Minimum 30 035 mm Maximum 30 050 mm Crankshaft bearings Standard Internal diameter 53 977 54 016 mm Pistons Skirt diameter 91 918 91 932 mm measured at approximately 10 mm above the bottom of th...

Page 1297: ... m Automatic Belt Tensioner to Mounting Bracket Bolt 1 75 N m Generator belt Tensioner 79 N m Generator bracket Mounting bolts 6 mm 10 N m Mounting bolts 8 mm 24 4 N m DESCRIPTION TORQUE Generator Mounting bolt 47 N m Camshaft thrust plate Bolts 24 N m Connecting rod Mounting bolt 29 5 N m 60 Crankshaft bearing Carrier screw 42 N m Crankshaft pulley Locknut 160 N m Crossmember Bolts 42 N m Diesel ...

Page 1298: ...5 N m Oil pump Mounting screw 27 N m Oil sump drain plug Torque 54 N m Power steering pressure hose Nut 28 N m Power steering pulley Nut 130 N m Rear crankshaft bearing carrier Allen Bolts Torque 11 N m Rocker cover Bolts 19 N m Rocker mounting Lock Nut 35 N m Steering pump Bolts 28 N m Turbocharger Mounting nuts 32 5 N m Turbocharger Oil delivery fitting 27 5 N m Turbocharger oil drain Plug 10 8 ...

Page 1299: ...retainer VM 1003 Crankshaft Remover Replacer Sleeve VM 1004 Torque Angle Gauge VM 1005 Cylinder Head Bolt Wrench VM 1006A Cylinder Head Guide Studs VM 1009 Cylinder Liner Protrusion Tool VM 1010 9 50 ENGINE XJ SPECIAL TOOLS Continued ...

Page 1300: ...r Remover Replacer Socket VM 1012B Dial Indicator Gauge VM 1013 Flywheel Locking Tool VM 1014 Timing Cover Oil Seal Replacer VM 1015A Cylinder Retainer VM 1016 1 VM 1016 2 CYLINDER LINER 3 CYLINDER BLOCK XJ ENGINE 9 51 SPECIAL TOOLS Continued ...

Page 1301: ...er Pump Pulley Holder VM 1017 Cylinder Head Bolt Wrench M12 VM 1018 Cylinder Head Bolt Wrench M14 VM 1019 Cylinder Leakage Tester Adapter VM 1021 Fig 81 Top Dead Center Tool VM 1043 9 52 ENGINE XJ SPECIAL TOOLS Continued ...

Page 1302: ...FICATIONS 12 DESCRIPTION AND OPERATION EXHAUST SYSTEM DESCRIPTION The basic exhaust system consists of exhaust man ifold s exhaust pipe with oxygen sensors catalytic converter s heat shield s muffler and tailpipe Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 Fig 1 Exhaust Pipe 2 5L Early Build 1 NUT 2 TRANSMISSION SUPPORT 3 MINI CATALYTIC CONVERTER 4 EXHAUST PIPE 5 EXHAUST MANIFOLD Fig 2 Exhaust Pipe 2 5L L...

Page 1303: ...0L Early Build 1 STUD 2 TAIL PIPE HANGER 3 CLAMP 4 ISOLATOR 5 BOLT 6 TAIL PIPE HANGER 7 NUT 8 MUFFLER 9 CLAMP 10 CATALYTIC CONVERTER 11 HEAT SHIELD Fig 3 Exhaust Pipe 4 0L Early Build 1 NUT 2 EXHAUST MANIFOLD 3 TRANSMISSION SUPPORT 4 EXHAUST PIPE 5 MINI CATALYTIC CONVERTER 6 BOLT 11 2 EXHAUST SYSTEM XJ DESCRIPTION AND OPERATION Continued 2000 XJ Service Manual Publication No 81 370 0046 TSB 26 03 ...

Page 1304: ...LD 2 STUD 3 BOLT 4 TAILPIPE HANGER 5 ISOLATOR 6 TAILPIPE HANGER 7 CLAMP 8 NUT 9 MUFFLER 10 FLANGE JOINT 11 CATALYTIC CONVERTER 12 NUT XJ EXHAUST SYSTEM 11 3 DESCRIPTION AND OPERATION Continued 2000 XJ Service Manual Publication No 81 370 0046 TSB 26 03 00 March 2000 ...

Page 1305: ...d Also inspect all other components of the exhaust system for heat damage Unleaded gasoline must be used to avoid con taminating the catalyst core Federal emission vehicles use only one catalytic converter However California emission vehicles incorporate two mini catalytic converters located after the exhaust manifolds and before the inline cat alytic converter Fig 7 MUFFLER DESCRIPTION Both the 2...

Page 1306: ...4 Exhaust pipe leaking at manifold flange 4 Tighten replace flange attaching nuts bolts 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold 6 Leak between exhaust manifold and cylinder head 6 Tighten exhaust manifold to cylinder head bolts 7 Catalytic converter rusted or blown out 7 Replace catalytic converter assy 8 Restriction in exhaust system 8 Remove restriction if possible Replac...

Page 1307: ...it 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 10 Fig 11 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 torque 4 Install the rear crossmember Install and tighten the four 4 crossmember to rear mount nuts to 22 ...

Page 1308: ...ransmission sup port 3 Position exhaust pipe onto exhaust manifold Fig 12 Fig 13 Install mounting nuts and bolts DO NOT tighten nuts and bolts at this time 4 Position catalytic converter flange onto exhaust pipe flange Install three nuts and tighten to 28 5 N m 21 ft lbs 5 Tighten exhaust pipe to exhaust manifold mounting bolts and nuts to 31 N m 23 ft lbs 6 Connect the oxygen sensor connector s 7...

Page 1309: ...ehicle 6 Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels Adjust the alignment if needed CATALYTIC CONVERTER LATE BUILD WARNING IF TORCHES ARE USED WHEN WORK ING ON THE EXHAUST SYSTEM DO NOT ALLOW THE FLAME NEAR THE FUEL LINES CAUTION When servicing exhaust system compo nents disconnect the oxygen sensor connector Allowing the exhaust system to hang by...

Page 1310: ...on Fig 17 4 Heat the catalytic converter to muffler connec tion with an oxyacetylene torch until the metal becomes cherry red 5 While the metal is still cherry red remove the exhaust muffler tailpipe assembly from the catalytic converter 6 Slide the muffler tailpipe assy rearward and out of the rear exhaust tailpipe mounting bracket Fig 17 7 Remove the muffler from the exhaust tailpipe To remove a...

Page 1311: ...s and exhaust system contact with the body panels Adjust the alignment if needed MUFFLER AND TAILPIPE LATE BUILD All original equipment exhaust systems are manu factured with the exhaust tailpipe welded to the muf fler Service replacement mufflers and exhaust tailpipes are either clamped together or welded together WARNING IF TORCHES ARE USED WHEN WORK ING ON THE EXHAUST SYSTEM DO NOT ALLOW THE FL...

Page 1312: ...assembly into vehicle 2 Install clamp retaining tailpipe to the rear tailpipe hanger Fig 18 DO NOT 2 tighten clamp at this time 3 Install mounting nuts onto the muffler to cata lytic converter flange studs Fig 18 DO NOT tighten nuts at this time Fig 18 Muffler Tailpipe Removal and Installation Late Build 1 EXHAUST PIPE FLANGE JOINT 2 REAR TAILPIPE HANGER 3 FRONT TAILPIPE HANGER 4 MUFFLER 5 FLANGE ...

Page 1313: ...ECIFICATIONS TORQUE SPECIFICATIONS Fig 19 Heat Shield Removal Installation 1 BOLTS 2 MUFFLER HEAT SHIELD 3 NUTS 4 FLOOR PAN DESCRIPTION N m Ft In Lbs Lbs Catalytic Converter Exhaust Pipe Exhaust Clamp Nuts 61 45 Crossmember to Sill Bolts 42 31 Crossmember to Transmission Mount Nuts 22 16 Exhaust Pipe to Manifold Nuts Early Build 31 23 Exhaust Manifold to Engine 2 5L Engine Bolt 1 41 40 Bolts 2 5 3...

Page 1314: ...pair When replacement is required use original equip ment parts or equivalent This will assure proper alignment and provide acceptable exhaust noise lev els CAUTION Avoid application of rust prevention compounds or undercoating materials to exhaust system floor pan exhaust heat shields Light over spray near the edges is permitted Application of coating will result in excessive floor pan tempera tu...

Page 1315: ...and muffler connection 3 Remove the rear exhaust tailpipe hanger clamp and remove the exhaust tailpipe from the front exhaust tailpipe hanger 4 Remove the exhaust tailpipe assembly from the muffler INSTALLATION 1 Install the muffler onto the exhaust pipe Install the clamp and tighten the nuts finger tight 2 Install the exhaust tailpipe into the rear of the muffler 3 Install the exhaust tailpipe mu...

Page 1316: ...6 13 Disconnect the turbocharger oil return hose from the engine block Fig 7 14 Lower the vehicle from the hoist 15 Remove the EGR tube from exhaust manifold 16 Remove the 2 exhaust manifold heatshield retaining bolts and remove the heatshield 17 Remove the heater supply and return hoses from the vehicle 18 Remove the oil pressure supply line bango bolt from the turbocharger Fig 4 Engine Compartme...

Page 1317: ... 23 ft lbs 5 Install the exhaust manifold downpipe Torque bolts to 32 N m 23 ft lbs CAUTION Heatshield is very sharp Wear gloves to prevent injury 6 Slide the exhaust downpipe heatshield down over pipe Do not attempt to strap heatshield in posi tion at this time wait until vehicle is raised on hoist 7 Install the oil supply line on turbocharger Torque bango bolt fitting to 27 N m 20 ft lbs 8 Conne...

Page 1318: ...o Group 7 Cooling System for procedure 23 Connect the negative battery cable 24 Start the engine and check for leaks EXHAUST MANIFOLD AND TURBOCHARGER RHD REMOVAL 1 Disconnect the negative battery cable 2 Disconnect the breather hose from the air cleaner outlet hose Fig 9 Turbocharger Oil Return Hose 1 VEHICLE UNDERBODY 2 RIGHT ENGINE MOUNT THROUGHBOLT NUT 3 TURBOCHARGER OIL RETURN HOSE 4 EXHAUST ...

Page 1319: ...cle from the hoist 12 Disconnect the heater supply and return hoses from the right side of the engine Remove the steel line support bracket from the top of the rocker cover and position the assembly out of the way 13 Remove the EGR vacuum supply hose from the EGR valve 14 Remove the innercooler inlet and outlet hoses from the engine 15 Remove the 2 bolts holding the EGR tube to the EGR valve Fig 1...

Page 1320: ...ght off of the gearbox input shaft Posi tion aside 29 Remove the exhaust manifold and the turbo charger assembly from the vehicle 30 Place the turbo assembly in a vice to remove the 3 exhaust manifold to turbocharger retaining nuts Fig 17 Cleaning Always use new gaskets during assembly All gas ket mating surfaces must be cleaned of all old gasket material to produce a smooth and dirt free sealing ...

Page 1321: ...13 Connect the exhaust system at the 3 bolt flange Fig 22 Torque the bolts to 23 N m 17 ft lbs 14 Lower the vehicle on hoist 15 Install the clutch master cylinder through the bulkhead Fig 17 Turbocharger Exhaust Manifold Assembly 1 OIL RETURN LINE 2 WASTEGATE VACUUM SUPPLY HOSE 3 TURBO TO EXHAUST MANIFOLD RETAINING NUTS 4 BENCH VISE 5 TURBOCHARGER ASSEMBLY REMOVED FROM VEHICLE 6 WASTEGATE VACUUM A...

Page 1322: ...supply hose on the EGR valve 25 Install the air filter cover and outlet hose on the turbocharger 26 Connect the breather hose on the air cleaner outlet hose 27 Install the heater core coolant supply and the brake vacuum supply lines in there original position 28 Connect the negative battery cable 29 Fill the cooling system Refer to Group 7 Cooling System for the procedure 30 Start the engine and c...

Page 1323: ... and turbocharger assembly 7 Install charge air cooler hose to intake mani fold 8 Connect the battery negative cable 9 Start engine and check for leaks SPECIFICATIONS TORQUE SPECIFICATIONS Description Torque EGR Attaching Bolts 27N m EGR Tube Nut 34 N m EGR Tube Flange Bolts 27 N m Exhaust Manifold Nuts 32 N m Exhaust Manifold Heat Shield Bolts 11 N m Exhaust Pipe Support Clamp Bolts 22 5 N m Exha...

Page 1324: ...igh strength steel and coated metals This process reduces weight and provides strength to withstand the forces applied against structural members The structural members provide a unibody that has great structural strength BUMPERS DESCRIPTION The bumpers on the Jeep Cherokee are made up of the main bumper beam the end caps air deflector front bumper and mounting brackets Some Chero kee models also ...

Page 1325: ...e screws attaching the end cap to the front fender 4 Lifting the end cap from the bottom tilt slightly upward and slide it outward to disengage the retainer tab from the bumper Fig 2 5 Separate the end cap from the bumper INSTALLATION 1 Position the end cap on the bumper and engage the retaining tab 2 Install the screws attaching the end cap to the front fender 3 Install the bolts attaching the en...

Page 1326: ...Connect vacuum line to reservoir 5 If equipped engage fog lamp wire harness con nectors 6 Install bumper end caps FRONT TOW HOOK REMOVAL 1 Remove bolts attaching tow hook to tow hook reinforcement Fig 4 2 Separate tow hook from reinforcement 3 If necessary remove bolt attaching tow hook reinforcement to frame INSTALLATION 1 If removed install bolt attaching tow hook reinforcement to frame Tighten ...

Page 1327: ...ing bumper If necessary refer to removal procedure within Group 13 Frame and Bumpers 2 Remove bumper end caps 3 Remove upper nuts that attach bumper to bumper support brackets Fig 5 4 Remove lower bolts that attach bumper to bumper support brackets 5 Remove bumper from vehicle 6 If necessary remove bumper support brackets from the rear sill INSTALLATION 1 If removed install bumper support brackets...

Page 1328: ...ION 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 Fig 6 Rear Tow Hook 1 WELD NUT 2 FRAME REINFORCEMENT BRACKET 3 RIVET 4 SUPPORT BRACKET 5 BOLT 6 TOW HOOK 7 BOLT 8 BOLT 9 FRAME RAIL XJ FRAME AND BUMPERS 13 5 REMOVAL AND INSTALLATION Continued ...

Page 1329: ...o attach the skid plate to crossmember 3 Install the screws to attach skid plate to side sills TRANSFER CASE SKID PLATE REMOVAL 1 Support skid plate 2 Remove bolts that attach skid plate to trans mission support crossmember and frame sill Fig 2 3 Remove support and skid plate from vehicle INSTALLATION 1 Position and support skid plate at frame sill and transmission support crossmember 2 Attach ski...

Page 1330: ...cle rear sill open ings and attach to the frame sills with blind rivets 2 Using an adequate lifting device position hitch at the proper location for installation on vehicle and support it 3 If equipped position fuel tank skid plate on vehicle frame sills 4 Loosely install the bolts to attach the trailer hitch and the skid plate to frame sills and reinforce ment brackets 5 Tighten all bolts nuts to...

Page 1331: ...Fig 6 Frame Dimensions 13 8 FRAME AND BUMPERS XJ SPECIFICATIONS Continued ...

Page 1332: ...N m 7 ft lbs Front Bumper Mounting Bracket to Frame Bolt 55 N m 41 ft lbs Front Bumper to Mounting Bracket Bolt 55 N m 41 ft lbs Front Tow Hook Bolt 100 N m 74 ft lbs Front Tow Hook Reinforcement Bolt 30 N m 22 ft lbs Rear Bumper to Mtg Bracket Nut 55 N m 41 ft lbs Rear Bumper Mtg Bracket to Rear Sill Bolt 55 N m 41 ft lbs Rear Tow Hook Bolt 94 N m 70 ft lbs Trailer Tow Reinforcement Brkt Bolt 74 ...

Page 1333: ......

Page 1334: ... front hole is for short towing use only and the rear angled hole is for shipping use only The rear tow eye has one hole and is intended for short towing use only CAUTION Do not use the angled hole for towing You could damage your vehicle CAUTION Tow eyes are for emergency use only to rescue a vehicle stranded off road Do not use tow eyes for tow truck hookup or highway towing You could damage you...

Page 1335: ......

Page 1336: ... INSTALLATION FUEL FILTER FUEL PRESSURE REGULATOR 13 FUEL PUMP MODULE 14 FUEL PUMP INLET FILTER 15 FUEL GAUGE SENDING UNIT 16 FUEL INJECTOR RAIL FUEL DAMPER 2 5L ENGINE 16 FUEL INJECTOR RAIL FUEL DAMPER 4 0L ENGINE 17 FUEL INJECTORS 19 FUEL TANK 19 FUEL TANK FILLER TUBE CAP 21 ACCELERATOR PEDAL 21 THROTTLE CABLE 22 SPECIFICATIONS FUEL TANK CAPACITY 23 FUEL SYSTEM PRESSURE 23 FUEL REQUIREMENTS 23 T...

Page 1337: ...ed service They do not require normal sched uled maintenance Filters should only be replaced if a diagnostic procedure indicates to do so FUEL PUMP MODULE DESCRIPTION The fuel pump module is installed in the top of the fuel tank Fig 1 or Fig 2 The fuel pump module contains the following components A combination fuel filter fuel pressure regulator A separate fuel pick up filter strainer An electric...

Page 1338: ...age As fuel level decreases the float and arm move down which increases voltage The varied voltage signal is returned back to the PCM through the sensor return circuit Both of the electrical circuits between the fuel gauge sending unit and the PCM are hard wired not multi plexed After the voltage signal is sent from the resistor track and back to the PCM the PCM will interpret the resistance volta...

Page 1339: ... injector Fig 4 is used for each individual cylinder OPERATION The top fuel entry end of the injector Fig 4 is attached into an opening on the fuel rail The fuel injectors are electrical solenoids The injector contains a pintle that closes off an orifice at the nozzle end When electric current is supplied to the injector the armature and needle move a short distance against a spring allowing fuel ...

Page 1340: ...he fuel rail is not repairable FUEL RAIL FUEL DAMPER 4 0L ENGINE DESCRIPTION The fuel rail is mounted to the intake manifold Fig 6 It is used to mount the fuel injectors to the engine On the 4 0L 6 cylinder engine a fuel damper is located near the center of the fuel rail Fig 6 OPERATION The fuel injector rail supplies the necessary fuel to each individual fuel injector The fuel damper is used only...

Page 1341: ...s QUICK CONNECT FITTINGS DESCRIPTION Different types of quick connect fittings are used to attach various fuel system components lines and tubes These are a single tab type a two tab type or a plastic retainer ring type Some are equipped with safety latch clips Some may require the use of a spe cial tool for disconnection and removal Refer to Quick Connect Fittings Removal Installation for more in...

Page 1342: ... Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty a If capacity is lower than specification but fuel pump can be heard operating through fuel fill cap opening check for a kinked damaged fuel sup ply line somewhere between fuel rail and fuel pump module b If line is not kinked damaged and fuel pres sure is OK but capacity is ...

Page 1343: ...ehicle fuel line and test port T on Adapter Tool If pressure now holds at or above 30 psi a leak may be found at a fuel tube line If no leaks are found at fuel tubes or lines one of the check valves in either the electric fuel pump or filter regulator may be leaking Note A quick loss of pressure usually indicates a defective check valve in the filter regulator A slow loss of pressure usually indic...

Page 1344: ...ach test leads from LCS adapter into PDC relay cavities number 30 and 87 For location of these cav ities refer to numbers stamped to bottom of relay Fig 10 15 If equipped with type 2 relay Fig 11 attach test leads from LCS adapter into PDC relay cavities number 30 and 87 For location of these cav ities refer to numbers stamped to bottom of relay Fig 11 16 If equipped with type 3 relay Fig 12 attac...

Page 1345: ...position CAUTION Steps 1 2 3 and 4 must be performed to relieve high pressure fuel from within fuel rail Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced into a cyl inder chamber 6 Unplug connector from any fuel injector 7 Attach one end of a jumper wire with alligator clips 18 gauge or smaller to either injector terminal 8 Connect other end of jumper...

Page 1346: ...pped with tabs located on both sides of fitting Fig 16 The tabs are supplied for disconnecting quick connect fitting from component being serviced a To disconnect quick connect fitting squeeze plastic retainer tabs Fig 16 against sides of quick connect fitting with your fingers Tool use is not required for removal and may damage plastic retainer b Pull fitting from fuel system component being serv...

Page 1347: ...Pry up on latch clip with a screw driver Fig 18 b Type 2 Separate and unlatch 2 small arms on end of clip Fig 19 and swing away from fuel line c Slide latch clip toward fuel rail while lifting with screwdriver Fig 15 Removing Pull Tab 1 FUEL TUBE OR FUEL SYSTEM COMPONENT 2 PULL TAB 3 QUICK CONNECT FITTING 4 FUEL TUBE STOP Fig 16 Typical Two Tab Type Quick Connect Fitting 1 TAB S 2 QUICK CONNECT FI...

Page 1348: ...perly installed to fuel rail or other fuel line Recheck fuel line con nection 8 Connect negative cable to battery 9 Start engine and check for leaks REMOVAL AND INSTALLATION FUEL FILTER FUEL PRESSURE REGULATOR The combination Fuel Filter Fuel Pressure Regula tor is located on the fuel pump module The fuel pump module is located on top of fuel tank The filter regulator may be removed without removi...

Page 1349: ...w retainer clamp clamp snaps over top of filter regulator and locks to flanges on pump module 9 Connect fuel line at filter regulator Refer to Quick Connect Fittings in this group for procedures 10 Install fuel tank Refer to Fuel Tank Removal Installation FUEL PUMP MODULE Fuel tank removal will be necessary for fuel pump module removal REMOVAL WARNING THE FUEL SYSTEM IS UNDER A CON STANT PRESSURE ...

Page 1350: ... Install Special Tool 6856 to locknut 7 Tighten locknut to 74 N m 55 ft lbs torque 8 Rotate fuel filter fuel pressure regulator until its fitting is pointed toward front of vehicle 12 o clock position 9 Connect fuel line at filter regulator Refer to Quick Connect Fittings in this group for procedures 10 Install fuel tank Refer to Fuel Tank Installa tion in this section FUEL PUMP INLET FILTER The f...

Page 1351: ...k Refer to Fuel Tank Removal Installation FUEL INJECTOR RAIL FUEL DAMPER 2 5L ENGINE REMOVAL The fuel damper is not serviced separately WARNING THE FUEL SYSTEM IS UNDER CON STANT FUEL PRESSURE EVEN WITH ENGINE OFF THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL RAIL 1 Remove fuel tank filler tube cap 2 Perform Fuel System Pressure Release Proce dure as described in this Group 3 Disconnect neg...

Page 1352: ... bore in intake manifold Seat injec tors into manifold 4 Install and tighten fuel rail mounting bolts to 11 63 N m 100 625 in lbs torque 5 Position crankshaft position sensor pigtail wire harness clamp and wire harness to fuel rail mount ing stud Install nut securing harness to fuel rail mounting stud 6 Connect tagged injector harness connectors to appropriate injector 7 Connect fuel line and fuel...

Page 1353: ... rail mounting nuts bolts Fig 31 14 Remove fuel rail by gently rocking until all the fuel injectors are out of intake manifold INSTALLATION 1 Clean each injector bore at intake manifold 2 Apply a small amount of clean engine oil to each injector o ring This will aid in installation 3 Position tips of all fuel injectors into the corre sponding injector bore in intake manifold Seat injec tors into m...

Page 1354: ...ne at fuel rail release fuel pressure Refer to the Fuel System Pressure Release Procedure in this group for procedures Attach end of special test hose tool num ber 6541 6539 6631 or 6923 at fuel rail disconnec tion tool number will depend on model and or engine application Position opposite end of this hose tool to an approved gasoline draining station Activate fuel pump and drain tank until empty...

Page 1355: ...er than top of tank 14 Continue lowering tank until clear of vehicle Place tank on floor with left side hose side higher than right side 15 Drain tank by removing fuel fill hose at tank Fuel fill hose is largest of 2 hoses Fig 37 Insert the Fig 33 Fuel Hose Shield 1 FUEL HOSE SHIELD 2 MOUNTING BOLTS 4 Fig 34 Fuel Fill and Vent Hoses 1 CLAMPS 2 FUEL FILL HOSE 3 FUEL VENT HOSE Fig 35 Fuel Tank Conne...

Page 1356: ...E CAP REMOVAL INSTALLATION If replacement of the 1 4 turn fuel tank filler tube cap is necessary it must be replaced with an identi cal cap to be sure of correct system operation CAUTION Remove the fuel tank filler tube cap to relieve fuel tank pressure The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank ACCELERATOR PEDAL REMOVAL The accelerato...

Page 1357: ...all socket towards rear of vehi cle ball snaps off throttle body pin Fig 39 6 Remove throttle cable from throttle body mounting bracket by compressing release tabs Fig 39 and pushing cable through hole in bracket 7 Remove throttle cable from vehicle INSTALLATION 1 Slide throttle cable through hole in throttle body bracket until retainer tabs lock into bracket 2 Connect cable ball end to throttle b...

Page 1358: ...containing METH ANOL Gasoline containing methanol may damage critical fuel system components MMT IN GASOLINE MMT is a manganese containing metallic additive that is blended into some gasoline to increase octane Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane num ber without MMT Gasoline blended with MMT reduce spark plug life and reduce emission system...

Page 1359: ...and the tem perature is high use a premium unleaded fuel to help prevent spark knock If spark knock persists 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 of these products contain high concentrations of methanol Fuel system damage or vehicle perfor mance problems resulting from the use of such fue...

Page 1360: ...POSITION SENSOR TPS 45 IDLE AIR CONTROL IAC MOTOR 45 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 46 POWERTRAIN CONTROL MODULE PCM 46 POWER STEERING PRESSURE SWITCH 2 5L ENGINE 47 OXYGEN SENSOR 47 AIR CLEANER ELEMENT FILTER 49 ENGINE COOLANT TEMPERATURE SENSOR 49 INTAKE MANIFOLD AIR TEMPERATURE SENSOR 50 VEHICLE SPEED SENSOR 51 SPECIFICATIONS TORQUE CHART 51 SPECIAL TOOLS FUEL SYSTEM 52 DESCRIPTION AND O...

Page 1361: ...ground Speed control multiplexed single wire input Throttle position sensor Vehicle speed sensor NOTE PCM Outputs A C clutch relay Auto shutdown ASD relay CCD bus circuits for speedometer voltme ter fuel gauge oil pressure gauge lamp engine temp gauge and speed control warn lamp Data link connection for DRB scan tool EGR valve control solenoid if equipped EVAP canister purge solenoid Five volt sen...

Page 1362: ...shaft position sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TPS Camshaft position sensor signal The PCM monitors the crankshaft position sensor If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine it will shut down the fuel injection system The fuel pump is activated by the PCM throug...

Page 1363: ...is high This will raise engine speed Refer to Power Steering Pressure Switch in this group for additional information The 4 0L 6 cylinder engine does not use this switch CRUISE MODE When the engine is at operating temperature this is a Closed Loop mode At cruising speed the PCM receives inputs from Air conditioning select signal if equipped Air conditioning request signal if equipped Battery volta...

Page 1364: ...a tion OPERATION A 12 volt signal at this input indicates to the PCM that the ASD has been activated The relay is used to connect the oxygen sensor heater element ignition coil and fuel injectors to 12 volt power supply This input is used only to sense that the ASD relay is energized If the powertrain control module PCM does not see 12 volts at this input when the ASD should be activated it will s...

Page 1365: ...ment panel OPERATION The extended idle switch is used to raise the engine idle speed to approximately 1000 rpm by sup plying a ground circuit to the Powertrain Control Module PCM This idle speed control can only be operated when the shifter is in either the Park or Neutral position OXYGEN SENSOR PCM INPUT DESCRIPTION The Oxygen Sensors O2S are attached to and protrude into the vehicle exhaust syst...

Page 1366: ... the upstream oxygen sensor volt age and changes fuel delivery until the upstream sensor voltage changes enough to correct the down stream sensor voltage oxygen content The downstream oxygen sensor also provides an input to determine catalyst efficiency Upstream Sensors California Emissions Two upstream sensors are used 1 1 and 2 1 The 1 1 sen sor is the first sensor to receive exhaust gases from ...

Page 1367: ...tion of the MAP sensor is to determine baromet ric pressure The PCM needs to know if the vehicle is at sea level or at a higher altitude because the air density changes with altitude It will also help to cor rect for varying barometric pressure Barometric pressure and altitude have a direct inverse correla tion as altitude goes up barometric goes down At key on the PCM powers up and looks at MAP v...

Page 1368: ...uges lamp Ground for the sensor is provided by the PCM through a low noise sensor return POWER GROUNDS OPERATION The Powertrain Control Module PCM has 2 main grounds Both of these grounds are referred to as power grounds All of the high current noisy electri cal devices are connected to these grounds as well as all of the sensor returns The sensor return comes into the sensor return circuit passes...

Page 1369: ...ing at WOT 2 608 volts above learned idle voltage A C WOT cutoff certain automatic transmis sions only VEHICLE SPEED AND DISTANCE SENSOR PCM INPUT DESCRIPTION The 3 wire Vehicle Speed Sensor VSS is located on the speedometer pinion gear adapter If equipped with 4WD this adapter is located on the extension housing of the transfer case drivers side If equipped with 2WD this adapter is located on the...

Page 1370: ...ased on various inputs it receives Battery voltage 12 volts is supplied to the injec tors through the ASD relay The ASD relay will shut down the 12 volt power source to the fuel injectors if the PCM senses the ignition is on but the engine is not running This occurs after the engine has not been running for approximately 1 8 seconds The PCM determines injector on time pulse width based on various ...

Page 1371: ...ory program which occurs when the power steering switch if equipped or the A C request circuit requires that the IAC step per motor control engine rpm is the recording of the last targeted steps into the memory cell The PCM can anticipate A C compressor loads This is accom plished by delaying compressor operation for approx imately 0 5 seconds until the PCM moves the IAC stepper motor to the recor...

Page 1372: ...n and tight 3 Inspect fuel pump relay and air conditioning compressor clutch relay if equipped Inspect ASD relay connections Inspect starter motor relay connec tions Inspect relays for signs of physical damage and corrosion The relays are located in Power Distribu tion Center PDC Fig 4 Refer to label on PDC cover for relay location 4 2 5L Engine Inspect ignition coil primary con nection Verify coi...

Page 1373: ... cleaner ele ment for dirt or restrictions 16 Inspect radiator grille area radiator fins and air conditioning condenser for restrictions 17 Verify intake manifold air temperature sensor wire connector is firmly connected to harness connec tor Fig 7 or Fig 8 18 Verify MAP sensor electrical connector is firmly connected to MAP sensor Fig 8 Also verify rubber L shaped fitting from MAP sensor to throt...

Page 1374: ...OR 4 ELEC CONN 5 TPS 6 MAP SENSOR 7 ELEC CONN 8 IAT SENSOR 9 ELEC CONN Fig 9 Rubber L Shaped Fitting MAP Sensor to Throttle Body 1 THROTTLE BODY 2 MAP SENSOR 3 RUBBER FITTING 4 MOUNTING SCREWS 2 Fig 10 Engine Coolant Temperature Sensor Typical 1 THERMOSTAT HOUSING 2 ENGINE COOLANT TEMPERATURE SENSOR 3 ELECTRICAL CONNECTOR Fig 11 Front Oxygen Sensor 4 0L Federal Emissions 1 1 1 O2S XJ FUEL SYSTEM 1...

Page 1375: ...ctions at fuel pump module connector at front of fuel tank Fig 17 30 Verify good EVAP canister vent line connec tion at front of fuel tank Fig 17 31 Verify good fuel supply line connection at front of fuel tank Fig 17 32 Inspect all fuel lines hoses for cracks or leaks 33 Inspect transmission torque convertor housing automatic transmission or clutch housing manual transmission for damage to timing...

Page 1376: ...CLE SPEED SENSOR 5 RELEASE LOCK Fig 16 Power Steering Pressure Switch 2 5L Engine 1 POWER STEERING PRESSURE SWITCH 2 ELECTRICAL CONNECTOR 3 POWER STEERING PUMP Fig 17 Fuel Tank Connections at Front of Fuel Tank 1 FUEL PUMP MODULE CONNECTOR 2 LEFT REAR SHOCK ABSORBER 3 EVAP CANISTER VENT LINE CONNECTION 4 FRONT OF FUEL TANK 5 FUEL SUPPLY LINE CONNECTION TERMINAL LEGEND NUMBER IDENTIFICATION 30 COMM...

Page 1377: ...er wire 16 gauge or smaller to the power side of the 12 volt power source Do not attach the other end of the jumper wire to the relay at this time WARNING DO NOT ALLOW OHMMETER TO CON TACT TERMINALS 85 OR 86 DURING THIS TEST 7 Attach the other end of the jumper wire to relay terminal 86 This activates the relay The ohm meter should now show continuity between relay ter minals 87 and 30 The ohmmete...

Page 1378: ...ics select Engine select Sys tem Test select Minimum Air Flow 8 The DRB scan tool will count down to stabilize idle rpm and display minimum air flow idle rpm The idle rpm should be between 500 and 900 rpm If idle speed is outside these specifications replace throttle body Refer to Throttle Body Removal Installation 9 Disconnect DRB scan tool from vehicle 10 Remove orifice tool and connect CCV tube...

Page 1379: ...ody 2 Disconnect throttle body electrical connectors at MAP sensor IAC motor and TPS Fig 24 or Fig 25 3 Remove all control cables from throttle body lever arm Refer to the Accelerator Pedal and Throt tle Cable section of this group for additional informa tion 4 Remove four throttle body mounting bolts 5 Remove throttle body from intake manifold 6 Discard old throttle body to intake manifold gasket...

Page 1380: ...ng engine 5 Install air cleaner tube to throttle body IDLE AIR CONTROL IAC MOTOR The IAC motor is located on the side of the throttle body Fig 24 or Fig 25 REMOVAL 1 Remove air cleaner tube at throttle body 2 Disconnect electrical connector from IAC motor 3 Remove two mounting bolts screws Fig 28 4 Remove IAC motor from throttle body INSTALLATION 1 Install IAC motor to throttle body 2 Install and ...

Page 1381: ...next to the air cleaner assembly Fig 30 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 3 Carefully unplug the three 32 way connectors Fig 31 from PCM 4 Remove three PCM moun...

Page 1382: ...er steering fluid Add fluid if necessary OXYGEN SENSOR REMOVAL Never apply any type of grease to the oxygen sensor electrical connector or attempt any sol dering of the sensor wiring harness For sensor operation it must have a comparison source of oxygen from outside the exhaust system This fresh air is supplied to the sensor through its pigtail wiring harness Refer to Fig 33 Fig 34 Fig 35 or Fig ...

Page 1383: ...hreads of a new oxygen sensor Fig 33 Front Oxygen Sensor 4 0L Federal Emissions 1 1 1 O2S Fig 34 Oxygen Sensors 4 0L California Emissions 1 1 1 O2S 2 2 1 O2S 3 2 2 O2S 4 1 2 O2S Fig 35 Front Oxygen Sensor 2 5L Federal Emissions 1 1 1 O2S Fig 36 Rear Oxygen Sensor 2 5L 4 0L Federal Emissions 1 1 2 O2S 14 48 FUEL SYSTEM XJ REMOVAL AND INSTALLATION Continued ...

Page 1384: ...seated to air cleaner housing 3 Install air tube and clamp to cover Compress clamp snugly with adjustable pliers as shown in Fig 39 ENGINE COOLANT TEMPERATURE SENSOR WARNING HOT PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING COOLING SYSTEM MUST BE PARTIALLY DRAINED BEFORE REMOV ING THE COOLANT TEMPERATURE SENSOR REFER TO GROUP 7 COOLING The coolant temperature sensor is installed in the thermost...

Page 1385: ...throttle body Fig 41 or Fig 42 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 2 Connect electrical connector to sensor Fig 40 Engine Coolant Temperature Sensor Typical 1 THERMOSTAT 2 ENGINE COOLANT TEMPERATURE SENSOR 3 ELECTRICAL CONNECTOR Fig 41 IAT Sen...

Page 1386: ...s fully seated mounted flush to speedometer pinion gear adapter 3 Tighten sensor mounting bolt to 2 2 N m 20 in lbs torque 4 Connect electrical connector to sensor SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Air Cleaner Housing Mount Bolts 8 N m 71 in lbs Engine Coolant Temperature Sensor 11 N m 96 in lbs IAC Motor To Throttle Body Bolts 7 N m 60 in lbs Intake Manifold Air Temp Sensor 28 N m 20...

Page 1387: ... Wrench 6856 Adapters Fuel Pressure Test 6539 and or 6631 Fitting Air Metering 6714 O2S Oxygen Sensor Remover Installer C 4907 Test Kit Fuel Pressure 5069 Test Kit Fuel Pressure C 4799 B Fuel Line Removal Tool 6782 14 52 FUEL SYSTEM XJ ...

Page 1388: ...NS 11 FUEL SHUTDOWN SOLENOID TEST 11 HIGH PRESSURE FUEL LINE LEAK TEST 11 SERVICE PROCEDURES AIR BLEED PROCEDURES 12 FUEL INJECTION PUMP TIMING 13 REMOVAL AND INSTALLATION ACCELERATOR PEDAL 13 FUEL DRAIN TUBES 14 FUEL FILTER WATER SEPARATOR 14 FUEL HEATER 15 FUEL HEATER RELAY 15 FUEL LEVEL SENSOR 15 FUEL INJECTION PUMP 15 FUEL INJECTORS 19 FUEL TANK 20 FUEL RESERVOIR MODULE 21 HIGH PRESSURE LINES ...

Page 1389: ...lter Strainer FUEL GAUGE SENDING UNIT DESCRIPTION The fuel gauge sending unit is attached to the side of the fuel pump module The sending unit consists of a float an arm and a variable resistor track The track is used to send an electrical signal used for fuel gauge operation As the fuel level increases the float and arm move up This decreases the sending unit resistance caus ing the PCM to send a...

Page 1390: ... ECM is used in place of the mechanical gov ernor assembly and it moves a control sleeve inside the pump that regulates the amount of fuel being injected There is no mechanical connection between the accelerator pedal and the electronically controlled injection pump Instead a sensor connected to the accelerator pedal sends a signal to the ECM that rep resents the actual position of the accelerator...

Page 1391: ...njector This injector is called instrumented injector 1 or needle movement sensor It is used to tell the ECM when the 1 injector s internal spring loaded valve seat has been forced open by pressurized fuel being delivered to the cylin der which is at the end of its compression stroke When the instrumented injector s valve seat is force open it sends a small voltage spike pulse to the ECM This tell...

Page 1392: ...pe or a plastic retainer ring type Fig 6 Refer to Quick Connect Fittings in the Removal Installation section for more informa tion CAUTION The interior components o rings spac ers of quick connect fitting are not serviced sepa rately but new pull tabs are available for some types Do not attempt to repair damaged fittings or fuel lines tubes If repair is necessary replace the complete fuel tube ass...

Page 1393: ...When the temperature is above 29 C 85 F the PTC element s resistance rises and current flow through the heater element stops Voltage to operate the fuel heater is supplied from the ignition key switch and through the fuel heater relay Refer to the following Fuel Heater Relay for additional information The fuel heater and fuel heater relay are not controlled by the Power train Control Module PCM FU...

Page 1394: ... Pump electrical connector is firmly connected Inspect the connector for corrosion or damaged wires The solenoid is mounted to the rear of the injection pump Fig 13 10 Verify that the fuel heater electrical connector is firmly attached to the filter bowl at the bottom of the fuel filter water separator Inspect the connector for corrosion or damaged wires 11 Verify that the electrical pigtail conne...

Page 1395: ... lines for signs of leakage Fig 12 Glow Plug Relay Location 1 MOUNTING BOLT 2 GLOW PLUG RELAY 3 ELECTRICAL CONNECTOR Fig 13 Fuel Shutdown Solenoid Location 1 FUEL INJECTION PUMP ASSEMBLY 2 FUEL RETURN LINE 3 FUEL SUPPLY LINE 4 FUEL INJECTION PUMP 10 WAY CONNECTOR 5 TIMING SOLENOID 6 OVERFLOW VALVE Fig 14 Fuel Injector Sensor 1 NEEDLE MOVEMENT SENSOR 2 FUEL INJECTOR NUMBER 1 CYLINDER ONLY 3 COPPER ...

Page 1396: ...stem whenever the fuel supply lines fuel filter water separator fuel filter bowl injection pump high pressure lines or injectors are removed or disconnected Air will also enter the fuel system whenever the fuel tank has been run empty Air trapped in the fuel system can result in hard starting a rough running engine engine misfire low power excessive smoke and fuel knock After service is performed ...

Page 1397: ...njector may be malfunctioning After test ing tighten the line nut to 19 N m 14 ft lbs torque Test all injectors in the same manner one at a time Once an injector has been found to be malfunction ing remove it from the engine and test it Refer to the Removal Installation section of this group for pro cedures After the injector has been removed install it to a bench mount injector tester Refer to op...

Page 1398: ...lamped securely in place in the holders The lines cannot contact each other or other components Do not attempt to weld high pressure fuel lines or to repair lines that are damaged Only use the recom mended lines when replacement of high pressure fuel line is necessary FUEL SHUTDOWN SOLENOID TEST Refer to 2000 XJ 2 5L Diesel Powertrain Diagnos tic Manual for the Fuel Shutdown Solenoid test HIGH PRE...

Page 1399: ... up or start up after an extended period of no engine operation Running fuel tank empty FUEL INJECTION PUMP BLEEDING 1 If the fuel injection pump has been replaced air should be bled at the overflow valve before attempting to start engine a Loosen the overflow valve Fig 21 at the rear of the injection pump b Place a towel below the valve WARNING WHEN CRANKING THE ENGINE TO BLEED AIR FROM THE INJEC...

Page 1400: ...nger than 30 seconds Wait 2 minutes between cranking intervals 3 Start the engine and bleed one injector at a time until the engine runs smoothly FUEL INJECTION PUMP TIMING Refer to the Fuel Injection Pump Removal and Installation procedure in Service Procedures later in this Group REMOVAL AND INSTALLATION ACCELERATOR PEDAL REMOVAL 1 Disconnect electrical connector 2 Remove accelerator pedal mount...

Page 1401: ...the filter separator bowl To gain access to this fitting the two filter to mounting bracket nuts Fig 25 may have to be loos ened a few turns 5 Hold the drain open until clean fuel exits the drain 6 After draining close drain valve 7 Remove rubber drain hose 8 Dispose of mixture in drain pan according to applicable local or federal regulations FUEL FILTER REMOVAL 1 Drain all fuel and or water from ...

Page 1402: ...ttery cable 2 Thoroughly clean the area around the injection pump and fuel lines of all dirt grease and other con taminants Due to the close internal tolerances of the injection pump this step must be per formed before removing pump 3 Remove the engine accessory drive belt Refer to Group 7 Cooling System for procedures 4 Remove the generator assembly 5 Remove the rubber fuel return and supply hose...

Page 1403: ...ol from the clutch housing c Rotate the crankshaft one quarter turn clock wise and counter clockwise while observing the rocker arm through the oil fill cap hole If the rocker arm moves you are not at 1 TDC Compression d If 1 TDC Compression was found continue if not rotate the crankshaft one revolution until the alignment tool can be re installed in the flywheel You are now at TDC for the 1 cylin...

Page 1404: ...ss remove the drive gear from injection pump shaft while driving injection pump rearward from timing gear cover mounting studs 16 Remove pump from engine Do not rotate engine while gear puller is installed Engine damage will occur INSTALLATION ADJUSTING PUMP TIMING 1 Clean the mating surfaces of injection pump and timing gear cover 2 Install a new injection pump to timing gear cover gasket 3 Remov...

Page 1405: ...o 0mm Be sure the tip of the dial indicator is touching the tip inside the adapter tool 12 Rotate the engine clockwise until special alignment tool VM 1043 can be inserted through the hole in the bottom of the clutch housing stopping the flywheel rotation This position is 1Cylinder TDC Compression Engine must be at TDC 1 com pression firing stroke 13 The gauge reading should be at 0 55 mm with new...

Page 1406: ... fitting fuel return line assembly Replace copper gaskets before installing 23 Connect the rubber fuel return and supply hoses to metal lines at pump Tighten hose clamps to 2 N m 20 in lbs torque 24 Install generator assembly 25 Install engine accessory drive belt Refer to Group 7 Cooling System for procedures 26 Install negative battery cable to battery 27 Start the engine and bring to normal ope...

Page 1407: ... cable from battery 2 Insert fuel siphon hose into fuel filler neck and push it into the tank 3 Drain fuel tank dry into holding tank or a properly labeled diesel safety container 4 Raise vehicle on hoist 5 Disconnect both the fuel fill and fuel vent rub ber hoses at the fuel tank 6 Disconnect fuel supply and return lines from the steel supply line Fig 41 The fuel reservoir module electrical conne...

Page 1408: ... WARNING THE FUEL RESERVOIR OF THE FUEL MODULE DOES NOT EMPTY OUT WHEN THE TANK IS DRAINED THE FUEL IN THE RESERVOIR WILL SPILL OUT WHEN THE MODULE IS REMOVED 1 Disconnect negative cable from battery 2 Drain fuel tank dry into holding tank or a properly labeled diesel safety container 3 Raise vehicle on hoist 4 Use a transmission jack to support the fuel tank Remove bolts from fuel tank straps Low...

Page 1409: ... of each line while remov ing Do not bend the line while removing CAUTION Be sure that the high pressure fuel lines are installed in the same order that they were removed Prevent the injection pump delivery valve holders from turning when removing or installing high pressure lines from injection pump INSTALLATION 1 Carefully position each high pressure fuel line to the fuel injector and fuel injec...

Page 1410: ...LUTCH RELAY 35 ENGINE SPEED SENSOR 35 ENGINE COOLANT TEMPERATURE SENSOR 35 GLOW PLUGS 35 GLOW PLUG RELAY 36 POWERTRAIN CONTROL MODULE PCM 36 VEHICLE SPEED SENSOR 37 SPECIFICATIONS GLOW PLUG CURRENT DRAW 38 TORQUE CHART 2 5L DIESEL 38 DESCRIPTION AND OPERATION FUEL INJECTION SYSTEM DESCRIPTION This section will cover components either regulated or controlled by the ECM controller and the Power trai...

Page 1411: ...us engine and vehicle operations through different system components These compo nents are referred to as ECM Outputs The sensors and switches that provide inputs to the ECM are considered ECM Inputs ECM Inputs are Air Conditioning Selection Theft Alarm ASD Relay Control Sleeve Position Sensor Fuel Temperature Sensor Mass Air Flow Sensor Accelerator Pedal Position Sensor Engine Coolant Temperature...

Page 1412: ...ling effect on the ceramic element and its resistance changes This causes the voltage flowing through the intake air temperature circuit to vary The voltage signal pro duced by the Intake Air Temperature Sensor changes inversely to the temperature and is measured by the PCM As a general rule when the temperature of the air in the intake is high the voltage signal produced by the Intake Air Tempera...

Page 1413: ...to the fuel timing sole noid the fuel timing solenoid is located on the fuel injection pump Also refer to Fuel Injection Pump for additional information The first injector sensor is a magnetic inductive type The first injector sensor is used only on the fuel injector for the number 1 cylinder Fig 4 It is not used on the injectors for cylinders number 2 3 or 4 FUEL INJECTOR SENSOR GROUND DESCRIPTIO...

Page 1414: ...st mode has been selected and the A C low and high pressure switches are closed an input signal is sent to the ECM The ECM uses this input to cycle the A C compressor through the A C relay If the A C low or high pressure switch opens the ECM will not receive an A C request signal The PCM will then remove the ground from the A C relay This will deactivate the A C compressor clutch Also if the engin...

Page 1415: ...e ECM to determine vehicle speed and dis tance traveled The speed sensor generates 8 pulses per sensor revolution These signals in conjunction with a closed throttle signal from the accelerator pedal posi tion sensor indicate an idle deceleration to the ECM When the vehicle is stopped at idle a released pedal signal is received by the ECM but a speed sensor signal is not received In addition to de...

Page 1416: ...nstrument Panel and Gauges group for additional information GLOW PLUG LAMP PCM OUTPUT DESCRIPTION The Glow Plug lamp malfunction indicator lamp illuminates on the message center each time the igni tion key switch is turned on It will stay on for about two seconds as a bulb test SPEED CONTROL PCM OUTPUTS DESCRIPTION These two circuits control the fuel quantity actua tor to regulate vehicle speed Re...

Page 1417: ...ure time comparison of glow plug relay operation In this chart Pre Heat and Post Heat times are mentioned Pre heat is the amount of time the glow plug relay circuit is activated when the ignition key switch is ON but the engine has yet to be started Post heat is the amount of time the glow plug relay circuit is activated after the engine is operating The Glow Plug lamp will not be illuminated duri...

Page 1418: ...TEST The sensor is located on the side of cylinder head near the rear of fuel injection pump Fig 15 For a list of Diagnostic Trouble Codes DTC s for certain fuel system components refer to On Board Diagnostics in Group 25 Emission Control System To test the sensor only refer to the following 1 Disconnect wire harness connector from coolant temperature sensor 2 Test the resistance of the sensor wit...

Page 1419: ...ug Before discarding the glow plug check the position of the circuit breaker on the bottom of the plug tester It may have to be reset Reset if necessary b Continue to hold the tester button while observing the amp gauge and the 4 timer lamps When all 4 lamps are illuminated indicating a 20 second time lapse the amp gauge reading should indicate a 9 12 amp current draw If not replace the glow plug ...

Page 1420: ... plugs With the engine cool or cold and the key in the ON position check for 10 12 volts at each electrical connector 10 12 volts should be at each connector whenever the ECM is operating in the pre heat or post heat cycles refer to the following Glow Plug Control chart Be very careful not to allow any of the four discon nected glow plug electrical connectors to con tact a metal surface When the k...

Page 1421: ...ity between terminals 30 and 87A 4 Connect the ohmmeter between terminals 87 and 30 The ohmmeter should not show continuity at this time 5 Connect one end of a jumper wire 16 gauge or smaller to relay terminal 85 Connect the other end of the jumper wire to the ground side of a 12 volt power source 6 Connect one end of another jumper wire 16 gauge or smaller to the power side of the 12 volt power s...

Page 1422: ...Fig 21 REMOVAL 1 Disconnect the harness on the sensor from the main electrical harness 2 Remove the sensor mounting bolts 3 Remove the sensor INSTALLATION 1 Install the sensor flush against the opening in the transmission housing 2 Install and tighten the sensor mounting bolt to 19 N m 14 ft lbs torque 3 Connect the electrical connector to the sensor ENGINE COOLANT TEMPERATURE SENSOR The sensor is...

Page 1423: ...all electrical connector to relay 3 Install relay to inner fender 4 Connect battery cable to battery POWERTRAIN CONTROL MODULE PCM The PCM is mounted to a bracket mounted to the inner side of the right fender well behind the air cleaner assembly Fig 25 REMOVAL 1 Disconnect the negative battery cable at the battery 2 Loosen the 60 Way connector Fig 25 The electrical connector has a sliding bar whic...

Page 1424: ...from the speedometer pinion gear adapter for removal INSTALLATION 1 Install new sensor into speedometer gear adapter 2 Tighten sensor mounting bolt To prevent dam age to sensor or speedometer adapter be sure the sensor is mounted flush to the adapter before tight ening 3 Connect electrical connector to sensor Fig 25 PCM Location 1 PCM HARNESS CONNECTOR C1 2 PCM HARNESS CONNECTOR C2 3 PCM HARNESS C...

Page 1425: ... Hose Tube Clamps For Rubber Hose 2 N m 20 in lbs Fuel Injector 70 N m 52 ft lbs Fuel Injector Line At Injector 30 N m 22 ft lbs Fuel Injector Line At Injector Pump 30 N m 22 ft lbs Fuel Injection Pump Mounting Nuts 30 N m 22 ft lbs Fuel Injection Pump Drive Gear 88 N m 65 ft lbs Fuel Line Clamp Bracket Bolts 24 N m 18 ft lbs Fuel Tank Nuts 11 N m 100 in lbs Glow Plugs 23 N m 203 in lbs Powertrain...

Page 1426: ...ll type gear with 14 1 gear ratio A tilt and non tilt column provide steering input NOTE Right hand drive RHD and left hand drive LHD service procedures and torque specifications for steering linkage gear and column are the same The power steering pump procedures are different Refer to appropriate service procedures regarding each component in the system OPERATION The steering gear acts as a rolli...

Page 1427: ...LE OR CLUNK 1 Gear mounting bolts loose 1 Tighten bolts to specification 2 Loose or damaged suspension components track bar 2 Inspect and repair suspension 3 Loose or damaged steering linkage 3 Inspect and repair steering linkage 4 Internal gear noise 4 Replace gear 5 Pressure hose in contact with other components 5 Reposition hose CHIRP OR SQUEAL 1 Loose belt 1 Adjust or replace WHINE OR GROWL 1 ...

Page 1428: ...ASE IN TURNING EFFORT 1 Tire pressure 1 Adjust tire pressure 2 Low fluid level 2 Fill to proper level 3 Loose belt 3 Adjust or replace 4 Lack of lubrication 4 Inspect and lubricate steering and suspension compnents 5 Low pump pressure 5 Pressure test and repair as necessary 6 Internal gear leak 6 Pressure and flow test and repair as necessary STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITI...

Page 1429: ...LE PULLS TO ONE SIDE DURING BRAKING 1 Tire Pressure 1 Adjust tire pressure 2 Air in brake hydrauliics system 2 Bleed brake system 3 Worn brake components 3 Repair as necessary VEHICLE LEADS OR DRIFTS FROM STRAIGHT AHEAD DIRECTION ON UNCROWNED ROAD 1 Tire pressure 1 Adjust tire pressure 2 Radial tire lead 2 Cross front tires 3 Brakes dragging 3 Repair as necessary 4 Wheel alignment 4 Align vehicle ...

Page 1430: ...s on the 4 0L engine A remote pump reservoir is used on the 2 5L engine mounted to the fan shroud The power steering pump is connected to the steering gear by the pressure and return hoses 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 T...

Page 1431: ...off engine 9 Check fluid level add fluid as necessary Start engine again and let idle 10 Gauge should read below 862 kPa 125 psi if above inspect the hoses for restrictions and repair as necessary The initial pressure reading should be in the range of 345 552 kPa 50 80 psi 11 Increase the engine speed to 1500 RPM and read the flow meter The reading should be 2 4 2 8 GPM if the reading is below thi...

Page 1432: ... repeat the procedure CAUTION Do not run a vehicle with foamy fluid for an extended period This may cause pump damage REMOVAL AND INSTALLATION POWER STEERING PUMP NOTE The power steering pump is mounted in the same position on LHD and RHD vehicles On 4 0L RHD vehicles the front bracket is different The ser vice procedures are the same REMOVAL 1 Remove serpentine drive belt refer to Group 7 Cooling...

Page 1433: ...assembly 4 With Serpentine Belt run engine until warm 5 min and note any belt chirp If chirp exists move pulley outward approximately 0 5 mm 0 020 in If noise increases press on 1 0 mm 0 040 in Be careful that pulley does not contact mounting bolts PUMP RESERVOIR DISASSEMBLY 1 Remove power steering pump 2 Clean exterior of pump 3 Clamp the pump body in a soft jaw vice 4 Pry up tab and slide the re...

Page 1434: ...ll power steering pump 6 Add power steering fluid refer to Pump Initial Operation Fig 4 Pump Mounting 4 0L RHD 1 BRACKET 2 PUMP ASSEMBLY Fig 5 Pulley Removal 1 POWER STEERING PUMP DRIVE PULLEY 2 SPECIAL TOOL C 4333 Fig 6 Pulley Installation 1 POWER STEERING PUMP DRIVE PULLEY 2 SPECIAL TOOL C 4063 B XJ STEERING 19 9 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1435: ... Valve 75 N m 55 ft lbs Pressure Line 28 N m 21 ft lbs SPECIAL TOOLS POWER STEERING PUMP Fig 7 Pump Reservoir Clips 1 RESERVOIR 2 RETAINING CLIPS Analyzer Set Power Steering Flow Pressure 6815 Adapters Power Steering Flow Pressure Tester 6893 Puller C 4333 Installer Power Steering Pulley C 4063B 19 10 STEERING XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1436: ...ecirculating ball type gear with a 14 1 ratio 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 s...

Page 1437: ...SING END PLUG DISASSEMBLY 1 Unseat and remove retaining ring from groove with a punch through the hole in the end of the housing Fig 2 2 Slowly rotate stub shaft with 12 point socket COUNTER CLOCKWISE to force the end plug out from housing CAUTION Do not turn stub shaft any further than necessary The rack piston balls will drop out of the rack piston circuit if the stub shaft is turned too far 3 R...

Page 1438: ...asher from the housing 10 Remove oil seal from the housing with a seal pick 11 Remove pitman shaft bearing from housing with a bearing driver and handle Fig 7 ASSEMBLY 1 Install pitman shaft bearing into housing with a bearing driver and handle 2 Coat the oil seal and washer with special grease supplied with the new seal 3 Install the oil seal with a driver and handle 4 Install backup washer Fig 3...

Page 1439: ...ig 8 2 Remove adjuster nut with Spanner Wrench C 4381 3 Remove thrust support assembly out of the housing Fig 9 4 Pull stub shaft and valve assembly from the housing Fig 10 5 Remove stub shaft from valve assembly by lightly tapping shaft on a block of wood to loosen shaft Then disengage stub shaft pin from hole in spool valve and separate the valve assembly from stub shaft Fig 11 6 Remove spool va...

Page 1440: ... and engage locating pin on stub shaft into spool valve hole Fig 14 NOTE Notch in stub shaft cap must fully engage valve body pin and seat against valve body shoul der Fig 9 Thrust Support Assembly 1 STUB SHAFT 2 HOUSING 3 THRUST SUPPORT ASSEMBLY Fig 10 Valve Assembly With Stub Shaft 1 GEAR 2 THRUST SUPPORT 3 LOCK NUT 4 ADJUSTER NUT 5 STUB SHAFT 6 VALVE ASSEMBLY Fig 11 Stub Shaft 1 STUB SHAFT 2 VA...

Page 1441: ...e side cover and pitman shaft 4 Turn stub shaft COUNTERCLOCKWISE until the rack piston begins to come out of the housing 5 Insert Arbor C 4175 into bore of rack piston Fig 17 and hold tool tightly against worm shaft 6 Turn the stub shaft with a 12 point socket COUNTERCLOCKWISE this will force the rack pis ton onto the tool and hold the rack piston balls in place 7 Remove the rack piston and tool t...

Page 1442: ...heck for scores nicks or burrs on the rack piston finished surface Slight wear is normal on the worm gear surfaces Fig 16 Rack Piston End Plug 1 EXTENSION 2 END PLUG 3 RACK PISTON 4 RATCHET Fig 17 Rack Piston with Arbor 1 RACK PISTON 2 SPECIAL TOOL C 4175 Fig 18 Rack Piston 1 CLAMP 2 BALLS 3 RACK PISTON 4 BALL GUIDE Fig 19 Rack Piston Teflon Ring and O Ring 1 TEFLON SEAL 2 BACK UP O RING MUST BE I...

Page 1443: ...OCKWISE while pushing on the arbor This will force the rack piston onto the arbor and hold the rack piston balls in place 9 Install the races and thrust bearing on the worm shaft and install shaft in the housing Fig 20 10 Install the stub shaft with spool valve thrust support assembly and adjuster nut in the housing 11 Install the rack piston and arbor tool into the housing 12 Hold arbor tightly a...

Page 1444: ...2 point socket to drain the remaining fluid 4 Turn the adjuster in with Spanner Wrench C 4381 Tighten the plug and thrust bearing in the housing until firmly bottomed in the housing about 34 N m 25 ft lbs 5 Place an index mark on the housing even with one of the holes in adjuster plug Fig 24 6 Measure back counterclockwise 5 08 mm 0 20 in and mark housing Fig 25 7 Rotate adjustment cap back counte...

Page 1445: ...left of center and record the left off center pre load Repeat this to the right of center and record the right off center preload The average of these two recorded readings is the Preload Rotating Torque 5 The Over Center Rotating Torque should be 0 40 0 70 N m 3 7 in lbs higher than the Preload Rotating Torque 6 If an adjustment to the Over Center Rotating Torque is necessary first loosen the adj...

Page 1446: ...0 45 0 90 N m 4 8 in lbs Worm Shaft Preload Used Gear over 400 miles 0 5 0 6 N m 4 5 in lbs Worm Shaft Preload TORQUE CHART DESCRIPTION TORQUE Power Steering Gear Adjustment Cap Locknut 108 N m 80 ft lbs 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 Lin...

Page 1447: ...linkage consist of a pitman arm drag link tie rod tie rod ends and a steering damper Fig 1 and Fig 2 The service procedures and torque specifications are the same for LHD and RHD vehi cles CAUTION Components attached with a nut and cotter pin must be torqued to specification Then if the slot in the nut does not line up with the cotter pin hole tighten nut until it is aligned Never loosen the nut t...

Page 1448: ...en nut until it is aligned Never loosen the nut to align the cotter pin hole REMOVAL AND INSTALLATION TIE ROD CAUTION Use a Puller tool C 3894 A for tie rod removal Failure to use this tool could damage the ball stud and seal Fig 3 REMOVAL 1 Remove the cotter pins and nuts at the tie rod ball studs and drag link 2 Loosen the ball studs with a puller tool to remove the tie rod 3 Loosen clamp bolts ...

Page 1449: ...emove cotter pins and nuts from drag link 2 Remove the steering damper ball stud from the drag link 3 Remove tie rod from drag link 4 Remove drag link from the steering knuckle and pitman arm INSTALLATION 1 Install the drag link onto steering knuckle and pitman arm 2 Install nut at steering knuckle and tighten to 47 N m 35 ft lbs Install new cotter pins 3 Install nut at pitman arm and tighten to 7...

Page 1450: ...ag 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 SPECIFICATIONS TORQUE CHART 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 lb...

Page 1451: ...DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGINALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COAT INGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES ANYTIME A NEW FASTENER IS NEEDED REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR FASTENERS LISTED IN THE PARTS BOOKS REMOVAL AN...

Page 1452: ...mounting bracket on non tilt column Fig 6 Remove the bracket from the column and note the mount ing location and orientation of the bracket 13 Remove clock spring switches SKIM if equipped and ignition key cylinder refer to Group 8 Electrical for service procedures INSTALLATION 1 Install upper column mounting bracket on non tilt column Install the mounting bolt and tighten the nut to 17 N m 150 in...

Page 1453: ... Install knee blocker and knee blocker cover Refer to Group 8E Instrument Panel Systems 13 Install steering wheel and tighten nut to 54 N m 40 ft lbs NOTE If equipped with cruise control connect clock spring harness to cruise switch harness on the steering wheel 14 Install airbag refer to Group 8M Restraint Systems for service procedures 15 Install negative battery terminal SPECIFICATIONS TORQUE C...

Page 1454: ...CRIPTION AND OPERATION POWER STEERING PUMP 1 DESCRIPTION AND OPERATION POWER STEERING PUMP The power steering pump used with the 2 5L VM Diesel engine operates the same way as the power steering pump used with the 2 5 4 0L gasoline engines Refer to the Description and Operation sec tion for the 2 5 4 0L gasoline engine power steering pump for more information XJ STEERING 19 1 ...

Page 1455: ...els off the ground 5 Slowly turn the steering wheel right and left lightly contacting the wheel stops at least 20 times 6 Check the fluid level add if necessary 7 Lower the vehicle start the engine and turn the steering wheel slowly from lock to lock 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 f...

Page 1456: ... from the compres sor 16 Support the A C compressor with mechanics wire before proceding to the next step 17 Remove the 4 A C compressor retaining bolts 18 Remove the left engine mount throughbolt nut only Do not remove the bolt at this time 19 Position a jack stand and raise weight off left engine mount 20 Remove the track bar support bracket retain ing bolts and remove bracket Fig 3 21 Remove th...

Page 1457: ...25 N m 92ft lbs 10 Remove the jack stand 11 Install the H Block on the A C compressor in its original position and leave the bolts loose at this time 12 Position and install the A C compressor 13 Slide the drive coupler in its original position and install the remaining 2 H Block bolts 14 Install the power steering pump pulley Fig 7 Torque nut to 166 N m 120 ft lbs 15 Install the accessory drive b...

Page 1458: ...racket bolt from below radiator 8 Remove the engine mount upper sill plate nuts 9 Loosen the 4 H Block retaining bolts Do not remove at this time 10 Remove the accessory drive belt from the power steering pump pulley See Group 7 Cooling System for procedure 11 Remove the power steering pump pulley Use a hex socket to secure the pump shaft while remov ing the pulley nut with a box wrench Fig 9 NOTE...

Page 1459: ...nt replacement system should be flushed and filled with Mopar Power Steering Fluid or equivalent 1 Install the pressure line on pump in original position 2 Transfer the drive coupler to new pump leaving pinch bolt lose at this time Fig 11 3 Install the power steering pump in the engine block Torque retaining nuts to 24 N m 18 ft lbs Fig 11 4 Install the engine mount and engine mount bracket in veh...

Page 1460: ...oist 21 Install the refrigerent line support bracket and bolt on the top of the radiator 22 Install the A C filter drier assembly support bracket nuts on the left fender well 23 Reconnect the A C compressor electrical con nector 24 Re fill the power steering fluid Refer to Group 19 Steering for Power Steering Pump Initial Operation for procedure 25 Connect the negative battery cable STEERING GEAR ...

Page 1461: ...all the 3 steering gear retaining bolts Torque to 95 N m 70 ft lbs 4 Install the small right front splash on the vehi cle 5 Install the Pittman arm on the steering gear Refer to Group 19 Steering for the procedure Torque nut to 251 N m 185 ft lbs 6 Position the stabilizer bar and install the clamp retaining bolts Refer to Group 2 Suspension for a detailed procedure Torque the bolts to 75 N m 40 ft...

Page 1462: ...ive speed manual transmission with fifth gear being the overdrive range An adapter hous ing is used to attach the transmission to the transfer case on 4 wheel drive applications A standard style extension housing is used for the 2 wheel drive appli cations The shift mechanism is integral to the trans mission assembly and mounted in the shift tower portion of the adapter extension housing Fig 1 GEA...

Page 1463: ...o the mainshaft or the countershaft in some cases and moving the blocker ring into contact with the gear s friction cone As the blocker ring and friction cone come together the gear speed is brought up or down to the speed of the synchronizer As the two speeds match the splines on the inside of the synchronizer sleeve become aligned with the teeth on the blocker ring and the friction cone and even...

Page 1464: ...l 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 p...

Page 1465: ...od block between jack and oil pan to avoid damaging pan 21 Support transmission with transmission jack 22 Secure transmission to jack with safety chains 23 Disconnect rear cushion and bracket from transmission 24 Remove rear crossmember 25 Disconnect transmission shift lever as follows a Lower transmission approximately 7 8 cm 3 in for access to shift lever b Reach up and around transmission case ...

Page 1466: ...er bolts to 37 N m 27 ft lbs Tighten 7 16 diameter bolts to 58 N m 43 ft lbs Tighten M12 bolts to 75 N m 55 ft lbs 8 Install clutch housing brace rod 9 Lower transmission approximately 7 8 cm 3 in for access to shift tower Be sure transmission is in first or third gear 10 Reach up and around transmission and insert shift lever in shift tower Press lever retainer down ward and turn it clockwise to ...

Page 1467: ...0 in lbs torque 31 Fill transmission and transfer case if equipped with recommended lubricants Refer to the Lubricant Recommendation sections of the appropri ate component for correct fluid 32 Lower vehicle FRONT BEARING RETAINER SEAL REMOVAL 1 Remove release bearing and lever from the transmission 2 Remove the bolts holding the front bearing retainer to the transmission case 3 Remove the front be...

Page 1468: ...nts 5 Lower vehicle ADAPTER HOUSING SEAL REMOVAL 1 Hoist and support vehicle 2 Remove transfer case 3 Using a suitable pry tool or a slide hammer mounted screw remove the adapter housing seal Fig 13 INSTALLATION 1 Clean seal bore of adapter housing of any residual sealer material from original seal 2 Using Tool Handle C 4171 and Seal Installer 8208 install new seal so that the seal is located 0 6 ...

Page 1469: ...to transmis sion case 6 Remove shift tower from transmission case Fig 15 7 Remove shift tower gasket from shift tower or transmission case Fig 16 8 Remove detent ball plug Fig 18 9 Remove detent spring and ball with pencil magnet Fig 19 Fig 20 Fig 14 Install Adapter Housing Seal 1 SPECIAL TOOL 8208 2 ADAPTER HOUSING 3 SPECIAL TOOL C 4171 Fig 15 Remove Shift Tower 1 SHIFT TOWER 2 ADAPTER EXTENSION ...

Page 1470: ...H HOUSING 3 TRANSMISSION Fig 18 Remove Detent Ball Plug 1 TORX BIT 2 DETENT BALL PLUG Fig 19 Remove Detent Spring 1 PENCIL MAGNET 2 DETENT BALL SPRING Fig 20 Remove Detent Ball 1 PENCIL MAGNET 2 SHIFT DETENT BALL XJ AX5 MANUAL TRANSMISSION 21 9 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1471: ...ove shifter shaft with large magnet Fig 24 14 Remove the shift arm from the adapter hous ing 15 Remove adapter extension housing bolts 16 Loosen adapter extension housing by tapping it loose with plastic mallet Fig 25 Fig 21 Shift Arm Retainer Bolt Removal 1 RETAINER BOLT 2 SHIFT ARM Fig 22 Shift Arm Restrictor Pins 1 RESTRICTOR PINS Fig 23 Removing Shift Lever Shaft Plug 1 SHIFT LEVER SHAFT PLUG ...

Page 1472: ... the bearing retainer from transmis sion case Fig 28 21 Remove input shaft bearing snap ring Fig 29 22 Remove countershaft front bearing snap ring Fig 25 Loosen Adapter Extension Housing 1 INTERMEDIATE PLATE 2 ADAPTER HOUSING 3 RUBBER FACED MALLET Fig 26 Remove Adapter Extension Housing Typical 1 ADAPTER HOUSING 2 INTERMEDIATE PLATE Fig 27 Speedometer Drive Gear Assembly 1 SNAP RING 2 LOCK BALL 3 ...

Page 1473: ... and shift rails with mating holes in transmission case and install transmission case to the intermediate plate Fig 33 Verify that the transmission case is seated on the intermediate plate locating pins Fig 29 Remove Input Shaft Bearing Snap ring 1 SNAP RING PLIERS 2 INPUT SHAFT 3 INPUT SHAFT BEARING SNAP RING Fig 30 Separate Intermediate Plate and Transmission Case 1 INTERMEDIATE PLATE 2 RUBBER M...

Page 1474: ...iquid Gasket TB1281 P N 83504038 to seal ing surface of adapter extension housing making sure to keep sealer bead to inside of bolt holes 9 Install adapter or extension housing on inter mediate plate Fig 37 Tighten housing bolts to 34 N m 25 ft lbs torque 10 Position shift arm in shifter tower opening of adapter or extension housing Fig 38 Be sure that the shifter arm is engaged into the shift rai...

Page 1475: ...ift 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 36 Speedometer Drive Gear Assembly 1 SNAP RING 2 LOCK BALL 3 SNAP RING 4 OUTPUT SHAFT GROOVES 5 SPEEDOMETER GEAR Fig 37 Install Adapter Extension Housing Typical 1 ADAPTER HOUSING 2 INTERMEDIATE PLATE Fig 38 Position Shift Arm in Adapter or Extension Hous...

Page 1476: ...ent ball in detent opening of case Fig 43 17 Install detent spring in case Fig 44 18 Install detent plug and tighten to 19 N m 14 ft lbs Fig 45 Fig 40 Install Shift Arm Retainer Bolt 1 RETAINER BOLT 2 SHIFT ARM Fig 41 Shifter Arm Shaft Plug Installation 1 SHAFT PLUG Fig 42 Install Shifter Restrictor Pins 1 RESTRICTOR PINS Fig 43 Install Detent Ball 1 PENCIL MAGNET 2 SHIFT DETENT BALL XJ AX5 MANUAL...

Page 1477: ...ckup lamp switch Fig 47 Tighten switch to 44 N m 32 5 ft lbs torque 25 Install new seal in adapter extension housing 26 Install vehicle speed sensor if necessary 27 Install clutch housing release bearing release fork and retainer clip Fig 44 Install Detent Spring 1 PENCIL MAGNET 2 DETENT BALL SPRING Fig 45 Install Detent Ball Plug 1 TORX BIT 2 DETENT BALL PLUG Fig 46 Install Shift Tower 1 SHIFT TO...

Page 1478: ...s 2 Remove countershaft fifth gear retaining snap ring Fig 49 3 Remove bolt holding fifth gear shift fork to shift rail Fig 50 Fig 48 Positioning Intermediate Plate In Vise 1 INTERMEDIATE PLATE 2 BOLTS Fig 49 Remove Fifth Gear Snap ring 1 FIFTH GEAR SNAP RING SELECT FIT Fig 50 Remove Shift Fork Retainer Bolt 1 SHIFT FORK RETAINER BOLT 2 FIFTH GEAR SHIFT RAIL 3 FIFTH GEAR SHIFT FORK XJ AX5 MANUAL T...

Page 1479: ...nd interlock pins used in various places in the transmission Whenever a pin or ball is removed it should be identified in such a way that it can be reinstalled in the same location from which it was removed Fig 51 Remove Fifth Gear Blocker Ring 1 FIFTH GEAR BLOCKER RING Fig 52 Remove Fifth Gear Synchro Ring 1 FIFTH GEAR SYNCHRO RING Fig 53 Remove Fifth Gear and Synchro Assembly 1 FIFTH GEAR SYNCHR...

Page 1480: ...olts holding 1 2 and 3 4 shift forks to the shift rails Fig 58 and discard bolts 13 Remove bolts holding reverse shift arm bracket to intermediate plate Fig 59 Fig 55 Remove Fifth Gear Thrust Ring Lock Ball 1 PENCIL MAGNET 2 CLUSTER GEAR 3 LOCK BALL RECESS 4 THRUST RING LOCK BALL Fig 56 Remove Reverse Idler Shaft 1 REVERSE IDLER SHAFT Fig 57 Remove Output Shaft Rear Bearing Retainer 1 OUTPUT SHAFT...

Page 1481: ...he main shaft forward until the mainshaft rear bearing is clear of the intermediate plate and then rotating the mainshaft downward out of the shift forks Fig 62 18 Remove the 3 4 shift fork from the 3 4 shift rail Fig 63 19 Remove the snap ring from near the end of the 1 2 shift rail to allow the removal of the 1 2 shift fork Fig 59 Remove Reverse Shift Arm Bracket Bolts 1 REVERSE SHIFT ARM BOLTS ...

Page 1482: ...vise using the same bolt and washer mounting set up CAUTION The interlock balls and pins are different sizes and shapes Be sure to correctly identify which position an item is removed from to ensure that it is reinstalled in the same location Fig 63 Remove 3 4 Shift Fork 1 3 4 SHIFT FORK 2 3 4 SHIFT RAIL 3 1 2 SHIFT RAIL 4 1 2 SHIFT FORK Fig 64 Remove 1 2 Shift Fork 1 1 2 SHIFT FORK 2 3 4 SHIFT RA...

Page 1483: ...l and reverse shift fork and arm assembly from intermediate plate Fig 69 Fig 66 Remove Fifth Gear Shift Rail 1 INTERMEDIATE PLATE 2 FIFTH GEAR SHIFT RAIL Fig 67 Remove Fifth Gear Check Ball 1 FIFTH GEAR CHECK BALL Fig 68 Remove Reverse Shift Head And Rail Assembly 1 REVERSE SHIFT HEAD AND RAIL ASSEMBLY Fig 69 Remove Reverse Shift Rail 1 REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY 21 22 AX5 MANUAL...

Page 1484: ...ft rail elongated check ball from intermediate plate Fig 73 34 Remove 3 4 shift rail from intermediate plate Fig 70 Remove Interlock Pin From Reverse Shift Rail 1 REVERSE SHIFT RAIL 2 INTERLOCK PIN Fig 71 Remove Reverse Check Ball 1 REVERSE CHECK BALL Fig 72 Remove 1 2 Shift Rail Interlock Pin 1 INTERLOCK PIN 2 1 2 SHIFT RAIL Fig 73 Remove 1 2 Check Ball 1 1 2 CHECK BALL 2 3 4 SHIFT RAIL XJ AX5 MA...

Page 1485: ...e 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 74 Shift Rail Components 1 3 4 FORK 2 3 4 SHIFT RAIL 3 1 2 FORK 4 INTERMEDIATE PLATE 5 FIFTH GEAR FORK 6 FIFTH GEAR SHIFT RAIL 7 1 2 SHIFT RAIL 8 REVERSE SHIFT RAIL Fig 75 Install 1 2 Check Ball 1 1 2 CHECK BALL 2 3 4 ...

Page 1486: ...hift rail into intermediate plate and position reverse arm bracket to intermediate plate Fig 80 Fig 76 Install 1 2 Shift Rail Interlock Pin 1 INTERLOCK PIN 2 1 2 SHIFT RAIL Fig 77 Install Reverse Check Ball 1 REVERSE CHECK BALL Fig 78 Install Reverse Interlock Pin 1 REVERSE SHIFT RAIL 2 INTERLOCK PIN Fig 79 Install Reverse Arm Bracket to Fork 1 REVERSE SHIFT FORK 2 REVERSE ARM BRACKET XJ AX5 MANUA...

Page 1487: ...d reinstall the plate in the vise using the same bolt and washer mounting set up 15 Install the shift rail detent balls in the inter mediate plate Fig 80 Install Reverse Shift Rail 1 REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY Fig 81 Install Reverse Snap ring 1 SNAP RING 2 REVERSE SHIFT RAIL Fig 82 Install Fifth Gear Check Ball 1 FIFTH GEAR CHECK BALL Fig 83 Install Fifth Gear Shift Rail 1 INTERM...

Page 1488: ...ter mediate plate and the rear of the countershaft into the rear countershaft bearing It may be necessary to occasionally hold the countershaft into the intermedi ate plate and tap the countershaft rear bearing onto the countershaft and into the intermediate plate 25 Install snap rings onto the rear mainshaft and countershaft bearings 26 Install the bolts to hold the reverse shift arm bracket to t...

Page 1489: ...is aligned with the proper slot the opposite slot has an oil drain hole which the pin will drop into The assembly will then be locked onto the shaft and will need to be disassembled in order to be removed 35 Depress compression spring and pin in reverse idler gear shaft Fig 91 36 Install the reverse idler gear shaft the remainder of the way through the reverse idler gear assembly Fig 87 Reverse Sh...

Page 1490: ...sition the fifth gear blocker ring onto the countershaft 46 Using a suitable mallet and spacer tap the fifth gear blocker ring onto the countershaft 47 Install new bolt to hold fifth gear shift fork to the fifth gear shift rail Fig 94 48 Measure countershaft fifth gear thrust clear ance 49 Select a snap ring so that the thrust clearance is 0 10 0 30 mm 0 004 0 010 in 50 Install snap ring to hold f...

Page 1491: ...n uncaged roller type bearing 3 Remove the output shaft pilot bearing rollers from the input shaft and the output shaft 4 Remove the fourth gear synchronizer ring from the input shaft Fig 97 5 Remove the select fit snap ring holding the input shaft bearing onto the input shaft 6 Using Bearing Splitter P 334 and a shop press remove the bearing from the input shaft ASSEMBLY 1 Position input shaft be...

Page 1492: ... 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 I D Mark Snap Ring Thickness mm in 0 1 2 3 4 5 2 05 2 10 0 0807 0 0827 2 10 2 15 0 0827 0 0846 2 15 2 20 0 0846 0 0866 2 20 2 25 0 0866 0 0886 2 25 2 30 0 0886 0 0906 2 30 2 35 0 0906 0 0925 Fig 98 Select Input Shaft Bearing Snap ring Fig ...

Page 1493: ...ar and second gear from output shaft Fig 104 9 Remove second gear needle roller bearing from the output shaft or second gear 10 Remove select fit snap ring holding the 3 4 synchronizer onto the output shaft Fig 105 11 Using Bearing Splitter P 334 or suitable press plates positioned under third gear press the 3 4 syn chronizer and third gear from output shaft Fig 106 12 Remove third gear needle rol...

Page 1494: ...ig 108 3 Install third gear needle bearing onto the out put shaft 4 Install third gear over bearing and onto output shaft flange 5 Install third gear synchronizer ring to third gear 6 Position the 3 4 synchronizer onto the output shaft 7 Using Adapter 6747 1A and a shop press press the 3 4 synchronizer onto the output shaft Fig 104 Remove Second Gear Reverse Gear And 1 2 Synchronizer 1 PRESS RAM 2...

Page 1495: ...7 1A and a shop press press the 1 2 synchronizer onto the output shaft 16 Install first gear synchronizer ring into 1 2 synchronizer 17 Install first gear bearing inner race lock ball in output shaft Fig 111 18 Install first gear needle bearing onto output shaft Fig 112 Fig 107 Geartrain Components 1 SNAP RING 2 FIFTH GEAR 3 COUNTER GEAR 4 BEARING 5 LOCK BALL 6 SYNCHRO HUB SLEEVE 7 SNAP RING 8 SPA...

Page 1496: ... is out of specification refer to Cleaning and Inspection section within this group 25 Position fifth gear onto output shaft with the gear s short shoulder toward the rear of shaft Ensure that the gear and output shaft splines are aligned 26 Using Adapter 6747 1A Driver L 4507 and a shop press press fifth gear onto output shaft 27 Select the thickest snap ring that will fit into the snap ring groo...

Page 1497: ...Fig 118 I D Mark Snap Ring Thickness mm in A 2 67 2 72 0 1051 0 1071 B 2 73 2 78 0 1075 0 1094 C 2 79 2 84 0 1098 0 1118 D 2 85 2 90 0 1122 0 1142 E 2 91 2 96 0 1146 0 1165 F 2 97 3 02 0 1169 0 1189 G 3 03 3 08 0 1193 0 1213 H 3 09 3 14 0 1217 0 1236 J 3 15 3 20 0 1240 0 1260 K 3 21 3 26 0 1264 0 1283 L 3 27 3 32 0 1287 0 1307 Fig 114 Select Install Fifth Gear Snap Ring Fig 115 Remove Reverse Idle...

Page 1498: ... with solvent and dry with compressed air Replace the case if cracked porous or if any of the bearing and gear bores are damaged Inspect the threads in the case housing and plate Minor thread damage can be repaired with steel thread inserts if necessary Do not attempt to repair any threads which show evidence of cracks around the threaded hole OUTPUT SHAFT Check thickness of the output shaft and i...

Page 1499: ...tween the gears and shaft with a dial indicator Fig 122 Oil clearance for all three gears is 0 009 0 0013 mm 0 0004 0 0013 in Check synchronizer ring wear Fig 123 Insert each ring in matching gear Measure clearance between each ring and gear with feeler gauge Replace ring if clearance exceeds 2 0 mm 0 078 in Check shift fork to synchronizer hub clearance with a feeler gauge Fig 124 Replace the for...

Page 1500: ...mber 41 68 N m 30 50 ft lbs Pins Restrictor 27 4 N m 20 ft lbs Bolts Reverse Shift Arm Bracket 18 N m 13 ft lbs 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 Fig 122 Check Gear To Shaft Oil Clearanc...

Page 1501: ...icator Set C 3995 A Installer Extension Housing Seal C 4171 Handle Universal Tool 8211 Installer Seal 8212 Installer Seal 8208 Installer Seal P 334 Splitter Bearing 8109 Cup Installer L 4507 Tube Driver 21 40 AX5 MANUAL TRANSMISSION XJ ...

Page 1502: ...6747 1A Adapter Fixture MD 998805 Installer Seal XJ AX5 MANUAL TRANSMISSION 21 41 SPECIAL TOOLS Continued ...

Page 1503: ...1 REVERSE 3 55 1 IDENTIFICATION The NV3550 identification and part number bar code tags Fig 2 are located on the top of the trans mission forward of the shift tower OPERATION The manual transmission receives power through the clutch assembly from the engine The clutch disc is splined to the transmission input shaft and is turned at engine speed at all times that the clutch is engaged The input sha...

Page 1504: ...3500 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 DRAIN AND FILL PLUG LOCATIONS The NV3550 fill plug is located in the front hous ing The drain plug is at the bottom rear of the hous ing Fig 3 Fig 1 NV3550 Shift Mechanism 1 3 4 FORK 2 SHIFT SHAFT LEVER AND BUSHING 3 1 2 FORK 4 FIFTH REVERSE F...

Page 1505: ...ant 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 ...

Page 1506: ...ssion and transfer case if equipped 16 Disconnect transfer case vent hose if equipped 17 Disengage any wire connectors attached to transmission or transfer case if equipped compo nents 18 Support transfer case if equipped with trans mission jack 19 Secure transfer case if equipped to jack with safety chains 20 Disconnect transfer case shift linkage at transfer case if equipped 21 Remove nuts attac...

Page 1507: ...rame bolts to 41 N m 31 ft lbs torque 10 Install fasteners to hold rear cushion and bracket to transmission Then tighten transmission to rear support bolts nuts to 54 N m 40 ft lbs torque 11 Remove support stands from engine and transmission 12 Install and connect crankshaft position sensor 13 Position transfer case on transmission jack if equipped 14 Secure transfer case to jack with safety chain...

Page 1508: ...into third gear 2 Clean the mating surfaces of shift tower and transmission gear case with suitable wax and grease remover 3 Install the shift tower onto the transmission case No sealant is necessary between the shift tower and transmission case 4 Install the bolts to hold the shift tower to the isolator plate and the transmission gear case Tighten the shift tower bolts to 8 5 N m 6 3 ft lbs 5 Ins...

Page 1509: ...n during removal remove drain plug and drain lubricant into container at this time 3 Inspect drain plug magnet for debris 4 Remove backup light switch Switch is located on passenger side of rear housing Fig 14 5 If necessary remove shift tower bolts and remove tower and lever assembly Fig 15 6 Remove shift shaft lock bolt Fig 16 Bolt is located at top of front housing just forward of shift tower B...

Page 1510: ...ft Tower Removal 1 SHIFT TOWER AND LEVER ASSEMBLY 2 SHIFT SOCKET 3 SEAL Fig 16 Shift Shaft Lock Bolt Removal 1 SHIFT SHAFT LOCK BOLT 2 SHAFT SOCKET Fig 17 Detent Plunger And Spring Removal 1 FRONT HOUSING 2 PLUG 3 SPRING 4 PLUNGER Fig 18 Input Shaft Bearing Retainer Bolt Removal Typical 1 INPUT SHAFT BEARING RETAINER 2 RETAINER BOLTS XJ NV3550 MANUAL TRANSMISSION 21 49 DISASSEMBLY AND ASSEMBLY Con...

Page 1511: ...ssary to remove all three bolts at this time Leave at least one bolt in place until geartrain is ready to be removed from case Fig 19 Loosening Bearing Retainer Sealer Bead Typical 1 PRY TOOL 2 INPUT SHAFT BEARING RETAINER Fig 20 Input Shaft Bearing Retainer Removal Typical 1 SHAFT BEARING 2 BEARING RETAINER 3 INPUT SHAFT Fig 21 Input Shaft Snap Ring Removal Typical 1 INPUT SHAFT SNAP RING 2 OIL F...

Page 1512: ...c Tighten the tool punch to press the roll pin downward and out of the shift socket Fig 26 The roll pin does not have to be completely removed from the shift socket The roll pin must only be clear of the shift shaft Be careful not to push the pin into the geartrain 2 Using a hammer and suitable punch drive out roll pin that secures shift bushing and lever to shift shaft Fig 27 NOTE Be sure to use ...

Page 1513: ...e the reverse idler shaft support bolt front bolt Fig 32 Fig 26 Removing the Shift Socket Roll Pin 1 SPECIAL TOOL 6858 2 SHIFT SOCKET Fig 27 Removing Shift Shaft Lever And Bushing Roll Pin 1 PIN PUNCH 2 BUSHING AND LEVER 3 SHIFT SHAFT Fig 28 Shift Shaft Removal 1 SHIFT SHAFT 2 3 4 FORK 3 SHAFT DETENT NOTCHES Fig 29 Shift Socket And Roll Pin 1 SHAFT BORE 2 ROLL PIN 3 SHIFT SOCKET Fig 30 Removing Sh...

Page 1514: ...g upright on fixture Fig 34 Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position 11 Remove rear bolt holding reverse idler shaft in housing Fig 31 Removing 3 4 Shift Fork 1 3 4 FORK 2 1 2 AND 5TH REVERSE FORK ARMS 3 3 4 SYNCHRO SLEEVE Fig 32 Reverse Idler Shaft Support Bolts 1 SUPPORT BOLT 2 SHAFT BOLT Fig 33 Installing Assembly Fixture On Geart...

Page 1515: ... 5 Examine condition of bearing bore and idler shaft notch in rear housing Replace housing if any of these components are damaged REAR ADAPTER HOUSING REMOVAL 4WD 1 Locate dimples in face of rear seal Fig 39 Use a suitable slide hammer mounted screw to remove seal by inserting screw into seal at dimple locations Fig 40 Fig 35 Removing Installing Output Shaft Bearing Retainer Bolts 2WD 1 OUTPUT SHA...

Page 1516: ...Removal 2WD 1 REAR HOUSING 2 SHIFT FORKS AND GEARTRAIN Fig 38 Remove Countershaft Rear Bearing 1 COUNTERSHAFT REAR BEARING 2 OUTPUT SHAFT 3 COUNTER SHAFT Fig 39 Location Of Dimples In Seal Face 4WD 1 LOCATION OF DIMPLES 2 SEAL FACE Fig 40 Rear Seal Removal 4WD 1 SLIDE HAMMER 2 REMOVER TOOL 3 REAR SEAL XJ NV3550 MANUAL TRANSMISSION 21 55 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1517: ...ut of fixture tool 4 Remove output shaft bearing retainer from rear surface of fifth gear retainer will drop onto gear after bolts are removed 5 Lift and remove output shaft and gears off input shaft 6 Lift and remove input shaft pilot bearing and fourth gear synchro ring from assembly fixture tool Fig 41 Rear Bearing Snap Ring Removal 4WD 1 HEAVY DUTY SNAP RING PLIERS 2 REAR BEARING SNAP RING 3 O...

Page 1518: ...ing ring 5 Remove two piece thrust washer Fig 46 Note position of washer locating lugs in shaft notches for installation reference 6 Remove second gear and needle bearing Fig 47 7 Remove second gear synchro ring synchro fric tion cone and synchro cone Fig 48 8 Remove interm ring 9 Remove 1 2 synchro hub snap ring 10 Remove 1 2 synchro hub and sleeve and first gear from output shaft with shop press...

Page 1519: ...NTERM RING 3 SYNCHRO FRICTION CONE 4 SYNCHRO CONE 5 SYNCHRO RING Fig 49 Hub And Sleeve Removal 1 2 Synchro 1 1 2 SYNCHRO HUB AND SLEEVE 2 SPECIAL TOOL 1130 Fig 50 First Gear Needle Bearing Removal 1 FIRST GEAR NEEDLE BEARING Fig 51 Output Shaft Bearing Snap Ring Removal 1 OUTPUT SHAFT BEARING 2 BEARING SNAP RING 3 SNAP RING PLIERS Fig 52 Fifth Gear Removal 1 FIFTH GEAR AND SYNCHRO RING 21 58 NV355...

Page 1520: ...edle Bearing Removal 1 FIFTH GEAR NEEDLE BEARING SPREAD BEARING TO CLEAR SHOULDER ON SHAFT Fig 54 Fifth Reverse Synchro Hub Snap Ring Removal 1 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 2 SYNCHRO HUB SNAP RING 3 SNAP RING PLIERS Fig 55 Fifth Reverse Synchro Hub And Sleeve Removal 1 PRESS 2 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 3 REVERSE GEAR 4 OUTPUT SHAFT Fig 56 Reverse Gear And Needle Bearing Removal ...

Page 1521: ...tall the springs struts and detent balls one at a time as follows 1 Slide the sleeve part way onto the hub Leave enough room to install the spring in the hub and the strut in the hub groove 2 Install the first spring in the hub Then install a strut over the spring Be sure the spring is seated in the spring bore in the strut 3 Slide the sleeve onto the hub just far enough to hold the first strut an...

Page 1522: ...ant before installation 4 Lubricate and install reverse gear needle bear ing on shaft Fig 59 Slide bearing up against shoul der on output shaft 5 Install reverse gear over needle bearing Fig 60 6 Install solid brass synchro ring on reverse gear Fig 61 Fig 58 Assembled View Of Synchro Components 1 SLEEVE 2 HUB SHOULDER 3 SPRING 3 4 STRUT 3 5 DETENT BALL 3 6 HUB Fig 59 Reverse Gear Bearing Installat...

Page 1523: ... mm to 2 20 mm 0 078 to 0 086 in b Install thickest snap ring that will fit in shaft groove c Verify that snap ring is completely seated in groove before proceeding 10 Install fifth gear synchro ring in synchro hub and sleeve Fig 64 11 Install fifth gear bearing Spread bearing only enough to clear shoulder on output shaft Fig 65 Be sure bearing is properly seated after installation 12 Install fift...

Page 1524: ... over bearing Fig 68 Make sure bearing synchro cone is facing up as shown Fig 65 Installing Fifth Gear Bearing 1 SHAFT SHOULDER 2 FIFTH GEAR BEARING Fig 66 Fifth Gear Installation 1 FIFTH GEAR 2 BEARING Fig 67 First Gear Bearing Installation 1 FIRST GEAR BEARING 2 SHAFT SHOULDER 3 SPECIAL TOOL 6310 1 4 PRESS BLOCKS Fig 68 First Gear Installation 1 FIRST GEAR 2 SPECIAL TOOL 6310 1 3 BEARING XJ NV35...

Page 1525: ...t becomes mis aligned 20 Install interm ring 21 Install new 1 2 synchro hub snap ring Fig 72 as follows a Snap rings are available in thicknesses from 1 80 mm to 2 00 mm 0 070 to 0 078 in b Install thickest snap ring that will fit in shaft groove c Verify that snap ring is completely seated in groove before proceeding 22 Install second gear synchro ring in 1 2 syn chro hub and sleeve Fig 73 Be sur...

Page 1526: ...alling 1 2 Synchro Hub Snap Ring 1 1 2 SYNCHRO 2 SPECIAL TOOL 6310 1 3 SYNCHRO SNAP RING Fig 73 Second Gear Synchro Ring Installation 1 SECOND GEAR SYNCHRO RING 2 1 2 SYNCHRO 3 SPECIAL TOOL 6310 1 Fig 74 Second Gear Bearing Installation 1 SECOND GEAR BEARING 2 SPECIAL TOOL 6310 1 Fig 75 Second Gear Installation 1 SPECIAL TOOL 6310 1 2 1 2 SYNCHRO ASSEMBLY 3 BEARING 4 SECOND GEAR XJ NV3550 MANUAL T...

Page 1527: ...e is between the thrust washer halves 28 Seat thrust washer retaining ring with plastic mallet Fig 78 Fig 76 Installing Two Piece Thrust Washer 1 WASHER GROOVE IN SHAFT 2 LUG BORE 3 THRUST WASHER LUGS 4 LUG BORE 5 LUG 6 WASHER HALF Fig 77 Starting Retaining Ring Over Two Piece Thrust Washer 1 THRUST WASHER RETAINING RING 2 THRUST WASHER HALVES 3 SECOND GEAR 4 LOCATING DIMPLE Fig 78 Seating Thrust ...

Page 1528: ...4 synchro hub on output shaft splines by hand Fig 82 34 Press 3 4 synchro assembly onto output shaft with shop press and suitable size pipe tool Fig 83 Make sure that the tool presses on hub as close to output shaft as possible but does not contact the shaft splines Fig 79 Third Gear Bearing Installation 1 THIRD GEAR BEARING Fig 80 Installing Third Gear 1 THIRD GEAR 2 BEARING Fig 81 Third Speed Sy...

Page 1529: ...rse sleeve should be facing forward REVERSE IDLER ASSEMBLY 1 Lubricate idler components with gear lube 2 Slide idler gear bearing on shaft Fig 87 Bearing fits either way on shaft 3 Slide gear onto shaft Side of gear with recess goes to rear Fig 87 4 Place first lock ball in dimple at rear end of idler shaft Fig 87 Petroleum jelly can be used to hold ball in place if desired 5 Slide thrust rear thr...

Page 1530: ...ion 1 DOUBLE GROOVE FORWARD 2 GROOVE FORWARD 3 FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 4 TAPER FORWARD 5 GROOVE FORWARD 6 5TH REV SYNCHRO SLEEVE 7 1 2 SYNCHRO SLEEVE 8 3 4 SYNCHRO SLEEVE Fig 87 Idler Gear And Bearing Installation 1 IDLER GEAR 2 BEARING 3 LOCK BALL 4 REAR OF SHAFT Fig 88 Idler Gear Rear Thrust Washer Installation 1 LOCK BALL 2 SNAP RING GROOVE 3 THRUST WASHER XJ NV3550 MANUAL TRA...

Page 1531: ...me restricted 5 If necessary the detent plunger bushings can be replaced as follows a Using the long end of Installer 8119 drive the detent bushings through the outer case and into the shift shaft bore b Remove the bushings from the shift shaft bore c Install a new detent plunger bushing on the long end of Installer 8118 d Start the bushing in the detent plunger bore in the case e Drive the bushin...

Page 1532: ...e 3 4 synchro ring seats in synchro hub and sleeve Fig 90 Preparing Assembly Fixture For Geartrain Build up 1 SPECIAL TOOL 6747 2A INSTALL ON COUNTERSHAFT FRONT HUB 2 SPECIAL TOOL 8115 3 SPECIAL TOOL 6747 1A 4 SPECIAL TOOL 6747 Fig 91 Installing Pilot Bearing In Input Shaft 1 PILOT BEARING 2 INPUT SHAFT Fig 92 Installing Fourth Gear Synchro Ring On Input Shaft 1 FOURTH GEAR SYNCHRO RING 2 INPUT SH...

Page 1533: ...ly A difference in height of 1 57 to 3 18 mm 1 16 to 1 8 in will probably exist This difference will not interfere with assembly However if the difference is greater than this the countershaft adapter tool is probably upside down Remove countershaft reverse adapter tool reinstall countershaft and check align ment again Fig 94 Output Shaft And Geartrain Installed In Input Shaft 1 OUTPUT SHAFT AND G...

Page 1534: ... Then position retainer on fifth gear as shown Fig 97 12 Assemble 1 2 and fifth reverse shift forks Fig 98 Arm of fifth reverse fork goes through slot in 1 2 fork Fig 96 Reverse Idler Assembly Positioned On Assembly Fixture Pedestal 1 OUTPUT SHAFT AND GEARTRAIN 2 COUNTERSHAFT 3 REVERSE IDLER ASSEMBLY 4 TOOL PEDESTAL Fig 97 Positioning Output Shaft Bearing Retainer For Rear Housing Installation 1 S...

Page 1535: ...n place when housing is installed 5 Apply light coat of petroleum jelly to shift shaft bushing bearing in rear housing Fig 102 6 Reach into countershaft rear bearing with fin ger and push each bearing roller outward against race Then apply extra petroleum jelly to hold rollers in place This avoids having rollers becoming dis placed during housing installation This will result in misalignment betwe...

Page 1536: ...anks and under bolt heads Fig 104 b Start first two bolts in retainer Fig 105 It may be necessary to move retainer rearward with pilot stud in order to start bolts in retainer c Remove Pilot Stud 8120 and install last retainer bolt Fig 105 d Tighten all three retainer bolts to 30 35 N m 22 26 ft lbs torque Fig 102 Countershaft Rear Bearing Seated In Seated in Race 1 SHIFT SHAFT BUSHING BEARING 2 C...

Page 1537: ...t coat of petroleum jelly to shift shaft bushing bearing in adapter housing Fig 102 8 Install adapter housing on geartrain 9 Install rear bearing snap ring on output shaft Fig 107 10 Lubricate lip of new rear seal Fig 108 with Mopart Door Ease or transmission fluid 11 Install new rear seal in adapter housing bore with Installer C 3860 A Be sure seal is fully seated in housing bore Fig 108 SHIFT SH...

Page 1538: ...sembled lever and bushing on shift shaft Fig 112 6 Slide shift shaft through 1 2 and fifth reverse fork and into shift lever opening in rear housing Fig 113 7 Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing Fig 114 8 Rotate shift shaft so detent notches in shaft are facing the TOP of the transmission housing Fig 109 Installing 3 4 Shift For...

Page 1539: ...h Fig 117 CAUTION The shaft lever roll pin must be flush with the surface of the lever The lever bushing will bind on the roll pin if the pin is not seated flush 12 Before proceeding verify that lock pin slot in lever bushing is positioned as shown Fig 117 13 Align roll pin holes in shift socket and shift shaft Then start roll pin into shift shaft by hand Fig 118 Fig 113 Inserting Shaft Into Lever...

Page 1540: ... to seat bearing Bearing goes in from front side of housing only Fig 117 Correct Seating Of Shift Shaft Lever Roll Pin 1 BUSHING LOCK PIN SLOT 2 SEAT ROLL PIN FLUSH WITH LEVER Fig 118 Starting Roll Pin In Shift Socket 1 ROLL PIN 2 SHIFT SOCKET 3 SHIFT SHAFT Fig 119 Seating Shift Socket Roll Pin 1 PIN PUNCH 2 SHIFT SOCKET 3 SEAT ROLL PIN FLUSH 4 SHIFT SOCKET Fig 120 Input Shaft Bearing And Counters...

Page 1541: ...ing CAUTION If the front housing will not seat on the rear housing either the shift components are not in Neutral or one or more components are mis aligned Do not force the front housing into place This will only result in damaged components 8 Tap rear housing alignment dowels back into place with hammer and pin punch Both dowels should be flush fit in each housing Have helper hold transmission up...

Page 1542: ...Installer 8123 b Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore c Drive detent plug into transmission case until plug seats 16 Install backup light switch Fig 126 17 Install input shaft snap ring Fig 127 18 Install new oil seal in front bearing retainer with Installer Tool 6448 Fig 128 19 Apply bead of Mopart silicone sealer or equivalent to flan...

Page 1543: ...ission into third gear 3 Align and install shift tower and lever assem bly Fig 132 Be sure shift ball is seated in socket and the offset in the tower is toward the passenger side of the vehicle before installing tower bolts Fig 128 Installing Oil Seal In Front Bearing Retainer 1 SPECIAL TOOL 6448 2 FRONT BEARING RETAINER Fig 129 Applying Sealer To Bearing Retainer And Housing Typical 1 APPLY SEALE...

Page 1544: ...ould be smooth and free of nicks or scores The plunger spring should be straight and not collapsed or distorted Minor scratches or nicks on the plunger can be smoothed with 320 400 grit emery soaked in oil Replace the plunger and spring if in doubt about condition Check condition of detent plunger bushings Replace if dam aged Inspect the shift shaft shift shaft bushing and bearing the shaft lever ...

Page 1545: ...If a bear ing race becomes damaged it will be necessary to replace the front or rear housing as necessary A new countershaft bearing will be supplied with each new housing for service use The countershaft bearings can be installed back wards if care is not exercised The bearing roller cage is a different diameter on each side Be sure the bearing is installed so the large diameter side of the cage ...

Page 1546: ...nes and bearings surfaces Minor nicks on the bearing surfaces can be smoothed with 320 420 grit emery and final polished with cro cus cloth Replace the shaft if the splines are dam aged or bearing surfaces are deeply scored worn or brinnelled SPECIFICATIONS TORQUE SPECIAL TOOLS NV3550 MANUAL TRANSMISSION Fig 135 Correct Countershaft Bearing Installation 1 COUNTERSHAFT 2 BEARING CAGE Description To...

Page 1547: ...ushing 6951 Handle C 4171 Remover 8117 Remover Installer NV3550 Shift Rail Roll Pin 6858 Fixture NV3550 6747 Adapter Fixture 6747 1A Adapter Fixture 6747 2A Cup Fixture 8115 21 86 NV3550 MANUAL TRANSMISSION XJ SPECIAL TOOLS Continued ...

Page 1548: ... Bearing 1130 Tube 6310 1 Installer 8118 Remover Installer 8119 Stud Alignment 8120 Installer Seal C 3860 A Installer 8123 Installer Bearing Cone 6448 XJ NV3550 MANUAL TRANSMISSION 21 87 SPECIAL TOOLS Continued ...

Page 1549: ...ION TRANSMISSION 144 TORQUE CONVERTER 146 YOKE SEAL REPLACEMENT 147 EXTENSION HOUSING BUSHING 147 ADAPTER HOUSING 147 SPEEDOMETER ADAPTER 148 PARK NEUTRAL POSITION SWITCH 149 GEARSHIFT CABLE 150 BRAKE TRANSMISSION SHIFT INTERLOCK 150 VALVE BODY 151 OUTPUT SHAFT REAR BEARING 153 GOVERNOR AND PARK GEAR 153 PARK LOCK 154 DISASSEMBLY AND ASSEMBLY GOVERNOR AND PARK GEAR 154 VALVE BODY 156 TRANSMISSION ...

Page 1550: ...nts in the front and rear planetary gear set transfer the engine power from the input shaft through to the output shaft The transmissions contain a governor that is mounted on the output shaft and supplies pressure to the valve body based on the output shaft speed The valve body is mounted to the lower side of the transmission and contains the valves to control pres sure regulation fluid flow cont...

Page 1551: ...Fig 1 30RH Automatic Transmission 21 90 AUTOMATIC TRANSMISSION 30RH XJ DESCRIPTION AND OPERATION Continued ...

Page 1552: ...ssemblies which com bine with the overrunning clutch assembly to gener ate the different gear ratios The torque converter clutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control TCC solenoid on the valve body The torque converter clutch is controlled by the Powertrain Control Module PCM The torque con verter clutch engages in ...

Page 1553: ...hub and rear clutch retainer stops at the rear clutch retainer Therefore no power flow to the output shaft occurs because no clutches are applied The only mechanism in use at this time is the parking sprag Fig 3 which locks the parking gear on the output shaft to the transmission case NEUTRAL POWERFLOW With the gear selector in the neutral position Fig 4 the power flow of the transmission is essen...

Page 1554: ...s transferred to the rear annulus gear which is splined to the output shaft The output shaft in turn rotates with the annulus gear in a counterclockwise direction giving a reverse gear output The entire transmission of torque is applied to the rear plane tary gearset only Although there is torque input to the front gearset through the sun gear no other member of the gearset is being held During th...

Page 1555: ... in a clockwise direction With the rear annulus gear stationary the rear planet rotation on the annulus gear causes the rear planet carrier to revolve in a counterclockwise direc tion The rear planet carrier is splined into the low reverse drum and the low reverse drum is splined to the inner race of the over running clutch With the over running clutch locked the planet carrier is held and the res...

Page 1556: ...nary the annulus rotation causes the front planets to rotate in a clockwise direction The front carrier is then also made to rotate in a clockwise direction but at a reduced speed This will transmit the torque to the output shaft which is directly connected to the front planet carrier The rear planetary annulus gear will also be turning because it is directly splined to the output shaft All power ...

Page 1557: ...o not turn at all in direct drive The only rotation is the input from the engine to the connected parts which are acting as one common unit to the output shaft FLUID NOTE Refer to the maintenance schedules in Group 0 Lubrication and Maintenance for the rec ommended maintenance fluid filter change inter vals for this transmission NOTE Refer to Service Procedures in this group for fluid level checki...

Page 1558: ... 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 transm...

Page 1559: ...t or driven mem ber of the converter The turbine is mounted within the housing opposite the impeller but is not attached 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 10 Impeller 1 ENGINE FLEXPLATE 2 OIL FLOW FR...

Page 1560: ...or 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 Fig 11 Turbine 1 TURBINE VANE 2 ENGINE ROTATION 3 INPUT SHAFT 4 PORTION OF TORQUE CONVERTER COVER 5 ENGINE ROTATION 6 OIL FLOW WITHIN TURBINE SECTION Fig 12 Stator Components 1 CAM OUTER RACE 2 ROLLER 3 SPRING 4 INNER RACE X...

Page 1561: ...f the fluid is not redirected before it strikes the impeller it will strike the impeller in such a direction that it would tend to slow it down STATOR Torque multiplication is achieved by locking the stator s over running clutch to its shaft Fig 16 Under stall conditions the turbine is stationary the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a...

Page 1562: ...converter clutch is engaged by the clutch solenoid on the valve body The clutch will engage at approximately 56 km h 35 mph with light throttle after the shift to third gear OIL PUMP DESCRIPTION The oil pump Fig 17 is located in the pump hous ing inside the bell housing of the transmission case The oil pump consists of an inner and outer gear a housing and a cover that also serves as the reaction ...

Page 1563: ...s 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 2 3 shift valve 2 3 governor plug Throttle valve Throttle pressure plug Switch valve Manual valve Converter clutch control valve Fail safe valve Shuttle...

Page 1564: ...e oil at specific pressures With the engine run ning fluid flows from the pump to the pressure reg ulator valve manual valve and the interconnected circuits As fluid is sent through passages to the reg ulator valve the pressure pushes the valve to the right against the large spring It is also sent to the reaction areas on the left side of the throttle pressure plug and the line pressure plug With ...

Page 1565: ...he 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 land meters the fluid to the sump it causes the pres sure to reduce and the spring decreases the size of the metering passage When the size of the metering passage is reduced the pressure rises again and the s...

Page 1566: ...erse is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land 4 With this pressure blocked there is less area for pressure to act on to balance the force of the spring on the right This allows line pressure to push the valve train to the right reducing the amount of fluid returned to the pump s inlet increasing line pressure Fig 21 Regulator Valve in N...

Page 1567: ...Fig 23 Regulator Valve in Reverse Position Fig 22 Regulator Valve in Drive Position 21 106 AUTOMATIC TRANSMISSION 30RH XJ DESCRIPTION AND OPERATION Continued ...

Page 1568: ...event a 3 2 downshift at higher speeds when a part throttle downshift is not desirable At these higher speeds only a full throttle 3 2 downshift will occur At low road speeds Fig 25 the limit valve does not come into play and does not affect the downshifts As the vehicle s speed increases Fig 26 the governor pres sure also increases The increased governor pressure acts on the reaction area of the ...

Page 1569: ...ow Speeds Fig 26 Kickdown Limit Valve High Speeds 1 GOVERNOR PRESSURE CLOSES LIMIT VALVE 2 THROTTLE PRESSURE 3 LIMIT VALVE 4 2 3 SHIFT VALVE 5 GOVERNOR PLUG 21 108 AUTOMATIC TRANSMISSION 30RH XJ DESCRIPTION AND OPERATION Continued ...

Page 1570: ... valve assembly With throttle pressure applied to the right side of the valve there is now both spring pressure and throttle pressure acting on the valve holding it against the governor plug As the vehicle begins to move and build speed governor pressure is created and is applied to the left of the valve at the governor plug Fig 27 1 2 Shift Valve Before Shift 1 TO FRONT SERVO AND 2 3 SHIFT VALVE ...

Page 1571: ...hing the plug back against the end plate overcoming governor pressure With the combi nation of the line pressure and spring pressure the valve cannot move preventing any upshift 1 2 SHIFT CONTROL VALVE It contains a valve with four lands and a spring It is used as both a relay and balanced valve The valve has two specific operations Fig 29 Aid in quality of the 1 2 upshift Aid in the quality and t...

Page 1572: ...he rate of fluid discharge from the front clutch and servo release circuits During a 3 2 kickdown fluid dis charges through the shuttle by pass circuit When the shuttle valve closes the by pass circuit fluid dis charge is restricted and controlled for the application of the front band During a 2 3 lift foot upshift the shuttle valve by passes the restriction to allow full fluid flow through the by...

Page 1573: ...has been in the other gears During a manual 1 or manual 2 gear selection line pressure is sent between the two lands of the 2 3 governor plug This line pressure at the governor plug locks the shift valve into the second gear position preventing an upshift into direct drive The theory for the blocking of the valve is the same as that of the 1 2 shift valve THROTTLE VALVE In all gear positions the t...

Page 1574: ...Fig 31 2 3 Shift Valve After Shift Fig 32 Throttle Valve XJ AUTOMATIC TRANSMISSION 30RH 21 113 DESCRIPTION AND OPERATION Continued ...

Page 1575: ...re the TCC application occurs Fig 33 the pres sure regulator valve is supplying torque converter pressure to the switch valve The switch valve directs this pressure through the transmission input shaft into the converter through the converter back out between the input shaft and the reaction shaft and back up to the switch valve From the switch valve the fluid pressure is directed to the transmiss...

Page 1576: ...Fig 33 Switch Valve Torque Converter Unlocked XJ AUTOMATIC TRANSMISSION 30RH 21 115 DESCRIPTION AND OPERATION Continued ...

Page 1577: ...Fig 34 Switch Valve Torque Converter Locked 21 116 AUTOMATIC TRANSMISSION 30RH XJ DESCRIPTION AND OPERATION Continued ...

Page 1578: ... the piston Fig 37 bottoming it against the accumulator plate The accumulator stays in this position after the transmission is placed into a Drive position When the 1 2 upshift occurs Fig 38 line pressure is directed to the large end of the piston and then to the kickdown servo As the line pressure reaches the accumulator the combination of spring pressure and line pressure forces the piston away ...

Page 1579: ... 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 PRESSURE ON A CONFINED FLUID Pressure is exerted on a confine...

Page 1580: ...area The pressure created with the smaller 100 lb input is 10 PSI The concept pressure is the same every where means that the pressure underneath the larger piston is also 10 PSI Pressure is equal to the force applied divided by the contact area Therefore by means of simple algebra the output force may be found This concept is extremely important as it is also used in the design and operation of a...

Page 1581: ...the input shaft into the driving discs and into the clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the application of the clutch pack In some transmissions the snap ring is selective and used to adjust clutch pack clearance When pressure is released from the piston the spring returns the piston to its fully released position and disen...

Page 1582: ...ch through the hub of the reaction shaft support With pressure applied between the clutch retainer and piston the piston moves away from the clutch retainer and compresses the clutch pack This action applies the clutch pack allowing torque to flow through the input shaft into the driving discs and into the clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring ...

Page 1583: ...n the same direction as the race aided by the pushing of the springs As the rollers try to move in the same direction as the inner race they are wedged between the inner and outer races due to the design of the cam In this condition the clutch is locked and acts as one unit PLANETARY GEARSET DESCRIPTION The planetary gearsets Fig 46 are designated as the front and rear planetary gear assemblies an...

Page 1584: ...e sun gear The application of the band by the servo is typ ically done by an apply lever and link bar LOW REVERSE REAR BAND The rear band holds the rear planet carrier sta tionary by being mounted around and applied to the low reverse drum SERVOS DESCRIPTION KICKDOWN FRONT SERVO The kickdown servo Fig 49 consists of a two land piston with an inner piston a piston rod and guide and a return spring ...

Page 1585: ...alve and down to the governor valve When the output shaft starts to rotate with vehicle motion Fig 52 the gov ernor weight assembly will start to move outward due to centrifugal force As the weight is moved out ward it will pull the valve with it until the land of the valve uncovers the line pressure port As the port begins to become uncovered governor pressure is metered As the vehicle s speed co...

Page 1586: ...connects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 54 OPERATION The system locks the shifter into the PARK posi tion The Interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY posi tion An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at lea...

Page 1587: ...ith a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve clutch and servo operation Foaming also causes fluid expansion which can result in fluid over flow from the transmission vent or fill tube Fluid overflow can easily be mistaken for a leak if inspec tion is not careful CAUSES OF BURNT FLUID Burnt discolored fluid is a result...

Page 1588: ...n failure to reverse flush cooler and lines after repair Fig 54 Ignition Interlock Cable Routing 1 SHIFT MECHANISM 2 LOCK TAB 3 IGNITION LOCK INTERLOCK 4 STEERING COLUMN 5 SOLENOID 6 WIRE CONNECTOR 7 LEVER 8 MOUNT BRACKET 9 SHIFT CABLE 10 AUTOMATIC TRANSMISSION 11 TIE STRAP 12 PARK BRAKE INTERLOCK CABLE Fig 55 Ignition Key Cylinder Actuation 1 SLIDER LOCKED 2 CAM RETURN SPRING 3 INTERLOCK CABLE 4 ...

Page 1589: ...ressure test if shift prob lems were noted during road test 7 Perform air pressure test to check clutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission into...

Page 1590: ...lutch is applied in all forward ranges D 2 1 The transmission overrunning clutch is applied in first gear D 2 and 1 ranges only The rear band is applied in 1 and R range only Verify that the overdrive clutch is applied only in fourth gear and the overdrive direct clutch and over running clutch are applied in all ranges except fourth gear For example If slippage occurs in first gear in D and 2 rang...

Page 1591: ...ear servo port Fig 57 and Fig 58 3 Disconnect throttle and gearshift rods from manual and throttle levers 4 Start and run engine at 1000 rpm 5 Move shift lever on manual lever shaft all the way forward into 1 range 6 Move transmission throttle lever from full for ward to full rearward position and note pressures on both gauges 7 Line pressure at accumulator port should be 54 60 psi 372 414 kPa wit...

Page 1592: ...0 psi Test Gauge C 3292 to governor pressure port Fig 57 and Fig 58 2 Move shift lever to D range 3 Start and run engine at curb idle speed and note pressure At idle and with vehicle stopped pres sure should be zero to 1 5 psi maximum If pressure exceeds this figure governor valve or weights are sticking open 4 Slowly increase engine speed and observe speedometer and pressure test gauge Governor p...

Page 1593: ...the result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the transmission for repair Pump seal leaks tend to move along the drive hub and onto the rear of the converter Pump O ring or pump body leaks follow ...

Page 1594: ... kickdown lever pin access plug three turns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 9 Install transmission and converter housing dust shield 10 Lower vehicle DIAGNOSIS CHARTS The diagnosis charts provide additional ref...

Page 1595: ...11 Converter Clutch if equipped Faulty 11 Replace converter and flush cooler and line before installing new converter DELAYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE 1 Fluid Level Low 1 Correct level and check for leaks 2 Filter Clogged 2 Change filter 3 Gearshift Linkage Misadjusted 3 Adjust linkage and repair linkage if worn or damaged 4 Rear Band Misadjusted 4 Adjust band 5 Valve Body Filte...

Page 1596: ...orn damaged parts 3 U Joint Axle Transfer Case Broken 3 Perform preliminary inspection procedure for vehicle that will not move Refer to procedure in diagnosis section 4 Filter Plugged 4 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test...

Page 1597: ... bolts defective gasket Replace pump assembly if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Misadjusted Damaged 1 Repair or replace linkage parts as needed 2 Park Sprag Sticking 2 Inspect and replace as necessary 3 Rear Band Misadjusted Worn 3 Adjust band replace 4 Valve Body Malfunction 4 Remove and service valve body Replace valve body if any valves or valve bores are worn or damage...

Page 1598: ...draulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 5 Valve Body Malfunction 5 Sticking 1 2 2 3 shift valves or governor plugs STUCK IN LOW GEAR WILL NOT UPSHIFT 1 Throttle Linkage Misadjusted Stuck 1 Adjust linkage and repair linkage if worn or damaged Check for binding cable or missing return spring 2 Gearshift Linkage Misadjusted ...

Page 1599: ... Air pressure check clutch servo operation and repair as required 7 Band Linkage Binding 7 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshif...

Page 1600: ...nternally 4 Check for leakage between passages in case 5 Servo Band or Linkage Malfunction 5 Air pressure check servo operation and repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 8 Converter Clutch Dragging 8 Check for plugged cooler Perform flow check Inspect pu...

Page 1601: ...e Leaks Damaged 3 Replace O ring seal Inspect tube for cracks in tube 4 Pressure Port Plug Loose Loose Damaged 4 Tighten to correct torque Replace plug or reseal if leak persists 5 Pan Gasket Leaks 5 Tighten pan screws to 150 inch pounds If leaks persist replace gasket Do no over tighten screws 6 Valve Body Manual Lever Shaft Seal Leaks Worn 6 Replace shaft seal 7 Rear Bearing Access Plate Leaks 7...

Page 1602: ...CEMENT Refer to the Maintenance Schedules in Group 0 Lubrication and Maintenance for proper service intervals The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts REMOVAL 1 Hoist and support vehicle on safety stands 2 Remove the transmission skip plate as neces sary to access the transmission oil pan 3 Place a large diameter shallow drain pan beneath the transmission...

Page 1603: ...eck 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 CAUTION Do not overfill transmission fluid foam ing and shifting problems can result 9 Add fluid to bring level up to MAX arrow mark When fluid level is correct shut engine off rel...

Page 1604: ...FLUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER SEEK MEDICAL ATTENTION COOLER FLUSH USING TOOL 6906A 1 Remove cover plate filler plug on Tool 6906A Fill reservoir 1 2 to 3 4 full of fre...

Page 1605: ...avoid component damage The converter drive plate pump bushing or oil seal can be damaged if the converter is left attached to the driveplate during removal REMOVAL 1 Disconnect battery negative cable 2 Disconnect and lower or remove necessary exhaust components 3 Remove engine to transmission bending braces 4 Disconnect fluid cooler lines at transmission 5 Remove starter motor 6 Disconnect and rem...

Page 1606: ...igh Temp Grease 8 Position transmission on jack and secure it with safety chains 9 Check condition of converter driveplate Replace the plate if cracked distorted or damaged Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment 10 Raise transmission and align converter with drive plate and converter housing with engine block 11 Mov...

Page 1607: ...nsmission is secure on the lifting device or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque convert...

Page 1608: ...Installer C 3995 A or C 3972 Fig 72 3 Carefully guide propeller shaft slip yoke into housing and onto output shaft splines Align marks made at removal and connect propeller shaft to rear axle pinion yoke EXTENSION HOUSING BUSHING REMOVAL 1 Remove housing yoke seal 2 Insert Remover 6957 into extension housing Tighten tool to bushing and remove bushing Fig 73 INSTALLATION 1 Align bushing oil hole wi...

Page 1609: ...ts 8 Install rear transmission mount and skid plate 9 Lower vehicle and verify transmission fluid level Add fluid as necessary SPEEDOMETER ADAPTER Rear axle gear ratio and tire size determine speed ometer pinion requirements REMOVAL 1 Raise vehicle 2 Disconnect wires from vehicle speed sensor 3 Remove adapter clamp and screw Fig 76 4 Remove speed sensor and speedometer adapter as assembly 5 Remove...

Page 1610: ...equired range numbers 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 ing screw Tighten clamp screw to 10 12 N m 90 110 in lbs torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary PARK NEUTRAL POSITION SWITCH REMOVAL 1 Raise vehicle and p...

Page 1611: ...e that the pawl is seated within the confines of the adjustment gauge clip 5 Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual control lever ball stud 6 Lock shift cable into position by pushing upward on the adjusting lock button 7 Remove and discard the shift cable adjustment gauge clip from the park gate of the shifter B...

Page 1612: ...trim 10 Install tie strap to hold cable to base of steer ing column 11 Install lower steering column shroud and igni tion lock 12 Install lower steering column cover VALVE BODY REMOVAL 1 Raise vehicle 2 Remove oil pan and drain fluid 3 Loosen clamp bolts and remove throttle and manual valve levers from manual lever shaft 4 Remove park neutral position switch 5 Remove filter from valve body 6 Depre...

Page 1613: ...main in position 7 Hold valve body in position and install valve body screws finger tight 8 Install park neutral position switch 9 Tighten valve body screws alternately and evenly to 11 N m 100 in lbs torque 10 Install new fluid filter on valve body Install and tighten filter screws to 4 N m 35 in lbs torque 11 Connect solenoid wire to case connector 12 Install manual and throttle levers on thrott...

Page 1614: ...sion on a suitable lifting device 5 Remove skid plate and rear transmission mount 6 Remove extension housing 7 Loosen but do not remove bolts that hold gov ernor body to park gear 8 Rotate transmission output shaft until gover nor weight assembly is accessible 9 Remove E clip at end of governor valve shaft Fig 85 10 Remove governor valve and shaft from gover nor body Fig 85 11 Remove snap rings an...

Page 1615: ...e ment in housing and sprag Inspect sprag and control rod springs for distortion and loss of tension replace worn damaged parts as necessary 2 Inspect square lug on sprag for broken edges Check lugs on park gear for damage Inspect knob on end of control rod for wear grooves or being seized on rod Replace rod if bent if knob is worn grooved or it has seized on rod Replace park gear if lugs are dama...

Page 1616: ...E CLIP 6 SPRING 7 CONTROL ROD 8 SNAP RING 9 PLUG AND PIN 10 SPRING Fig 89 Governor Filter 1 GOVERNOR FILTER 2 PARK GEAR Fig 90 Snap Ring Washer and Outer Weight 1 SNAP RING 2 E CLIP 3 PARK GEAR 4 GOVERNOR VALVE 5 SHAFT 6 GOVERNOR 7 OUTER WEIGHT 8 INTERMEDIATE WEIGHT 9 WASHER Fig 91 Inner Weight Snap Ring 1 NUT DRIVER 2 SUITABLE SIZE SOCKET 3 INTERMEDIATE WEIGHT 4 INNER WEIGHT SNAP RING 5 SPECIAL T...

Page 1617: ... plate resulting in valve bind Slide valves and plugs out carefully Do not use force at any time The valves and valve body will be damaged if force is used Also tag or mark the valve body springs for reference as they are removed Do not allow them to become inter mixed 1 Remove screws attaching adjusting screw bracket to valve body and transfer plate Hold bracket firmly against spring force while ...

Page 1618: ...aching transfer plate to valve body Fig 102 17 Remove transfer plate and separator plate from valve body Fig 102 Note position of filter and clutch solenoid for reference Remove valve body check balls Fig 94 Adjusting Screw Bracket Springs Valve Removal 1 ADJUSTER BRACKET 2 LINE PRESSURE ADJUSTER 3 PRESSURE REGULATOR VALVE 4 SWITCH VALVE 5 VALVE BODY 6 TRANSFER PLATE 7 THROTTLE VALVE 8 SLEEVE 9 KI...

Page 1619: ...uttle valve E clip and remove sec ondary spring and spring guides from end of valve Fig 106 Fig 100 Clutch Module And Connecting Tube 1 MODULE AND CONNECTING TUBE Fig 98 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD Fig 99 Converter Clutch Solenoid 1 VALVE BODY 2 TORQUE CONVERTER CLUTCH SOLENOID Fig 101 Converter Clutch and Fail Safe Valves 1 COVER PLATE 2 CONVERTER CLUTCH VALVE 3 TORQUE CONVERTER C...

Page 1620: ...t valve and spring from kickdown limit valve body Fig 107 33 Remove regulator valve end plate from valve body Fig 107 34 Remove regulator valve line pressure plug pressure plug sleeve regulator valve throttle pres sure plug and spring Fig 107 ASSEMBLY Clean and inspect all valve body components for damage or wear Refer to the Cleaning and Inspec tion section of this group for proper procedure Fig ...

Page 1621: ...g in kick down limit valve body Fig 107 Verify valve compo nents slide freely 5 Compress spring into kickdown limit valve body 6 Install retainer in grooves at end of kickdown limit valve body Fig 107 7 Install throttle pressure plug in kickdown limit valve body Fig 107 8 Install 1 2 shift valve and spring into valve body Fig 107 9 Install 2 3 shift valve and spring into valve body Fig 107 10 Inst...

Page 1622: ...ert filter into opening in separator plate Fig 111 24 Place separator plate in position on transfer plate and install screws to attach separator plate to transfer plate Fig 111 25 Place one 11 32 in check ball and six 1 4 in check balls in the proper cavities in the valve body Fig 112 26 Place transfer plate in position on valve body Fig 113 27 Install screws to attach transfer plate to valve body...

Page 1623: ...valve into valve body Fig 119 42 Insert throttle lever through transfer plate side of valve body and upward Fig 120 43 Insert throttle lever into groove in manual valve Fig 121 44 Install seal washer and E clip to retain man ual shaft to valve body Fig 120 45 Install switch valve and spring pressure reg ulator valve and spring kickdown valve and spring and throttle valve into valve body Fig 122 Fi...

Page 1624: ...er shaft 6 Mount transmission in repair stand C 3750 B or similar type stand Fig 123 7 Remove extension housing 8 Remove fluid pan 9 Remove park neutral position switch and seal Fig 124 10 Remove valve body 11 Remove accumulator spring and piston Fig 125 12 Loosen front band adjusting screw lock nut Fig 126 4 5 turns Then tighten band adjusting Fig 113 Valve Body Transfer Plate Screws 1 TRANSFER P...

Page 1625: ... front band together and remove band strut Fig 128 Fig 119 Manual Valve 1 MANUAL VALVE 2 VALVE BODY Fig 120 Manual And Throttle Levers 1 PARK ROD 2 E RING 3 WASHER 4 MANUAL LEVER 5 MANUAL VALVE 6 SPRING 7 DETENT BALL 8 VALVE BODY Fig 121 Manual Valve And Throttle Lever Alignment 1 THROTTLE LEVER 2 MANUAL LEVER VALVE ARM 3 MANUAL VALVE 4 KICKDOWN VALVE Fig 122 Adjusting Screw Bracket Springs and Va...

Page 1626: ...ccumulator Piston And Spring 1 ACCUMULATOR PISTON 2 PISTON SPRING Fig 126 Front Band Adjusting Screw Lock Nut 1 LOCK NUT 2 FRONT BAND ADJUSTER Fig 127 Oil Pump Reaction Shaft Support 1 OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 2 SLIDE HAMMER TOOLS C 3752 XJ AUTOMATIC TRANSMISSION 30RH 21 165 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1627: ...e 24 Remove governor body and park gear from output shaft 25 Remove output shaft and planetary geartrain as assembly Fig 133 Support geartrain with both hands during removal Do not allow machined sur faces on output shaft to become nicked or scratched Fig 129 Front Rear Clutch Assemblies 1 FRONT BAND 2 FRONT CLUTCH AND DRUM 3 TRANSMISSION HOUSING 4 REAR CLUTCH Fig 128 Front Band Strut 1 BAND LEVER...

Page 1628: ... clutch cam and low reverse drum to transmission case Fig 137 Fig 132 Front Band 1 FRONT BAND 2 TRANSMISSION HOUSING Fig 133 Planetary Geartrain 1 SLOTS 2 LOW REVERSE DRUM 3 PLANETARY GEARTRAIN 4 TRANSMISSION HOUSING 5 LUGS Fig 134 Rear Band Adjuster Location 1 PLANETARY GEARTRAIN 2 REAR BAND 3 LEVER 4 SERVO 5 ADJUSTER Fig 135 Low Reverse Drum Snap Ring 1 REAR BAND 2 REAR SUPPORT HUB 3 LOW REVERSE...

Page 1629: ...agnet Pin is accessible from converter housing side of case Fig 141 c Remove front band lever Fig 142 d Using snap ring plier pull rear band lever pivot from transmission case Fig 143 e Separate rear band servo lever from trans mission Fig 136 Rear Support 1 OIL PAN FACE 2 TRANSMISSION HOUSING 3 REAR SUPPORT Fig 137 Overrunning Clutch Cam Bolt Locations 1 OVERRUNNING CLUTCH CAM BOLTS Fig 138 Rear ...

Page 1630: ... 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 mission case 5 Insert hook on band onto...

Page 1631: ...ansmission case 14 Insert low reverse drum and overrunning clutch into front of transmission case and into rear band 15 Insert awl tip into the threaded hole next to the non threaded hole in the overrunning clutch cam Verify that non threaded hole is aligned with wide space area on transmission case 16 Push low reverse drum rearward to close gap between cam and case 17 Install overrunning clutch c...

Page 1632: ...e properly joined and ends of metal ring are correctly hooked together Also be sure rings are installed in sequence shown b Align teeth on clutch discs in line c Insert input shaft on rear clutch into center of front clutch Fig 151 d Engage teeth on rear clutch hub into teeth on clutch Fig 153 Rotate front clutch retainer back and forth until completely seated on rear clutch Fig 149 Output Shaft A...

Page 1633: ...opening at front of transmission case Fig 156 34 Install front and rear clutch units as assembly Fig 157 Align rear clutch with front annulus gear and install assembly in driving shell Be sure out put shaft thrust washer and thrust plate are not displaced during installation 35 Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear Verify that f...

Page 1634: ...um jelly to hold it in place Then install washer over reaction shaft hub and seat it on pump Fig 160 CAUTION The thrust washer bore I D is cham fered on one side Make sure the chamfered side is installed so it faces the pump Fig 156 Front Band 1 FRONT BAND 2 TRANSMISSION HOUSING Fig 157 Installing Front Rear Clutch 1 FRONT BAND 2 FRONT CLUTCH AND DRUM 3 TRANSMISSION HOUSING 4 REAR CLUTCH Fig 158 F...

Page 1635: ...dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266 7 to secure it to the input shaft d Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indica tor e Move input shaft in and out and record read ing End play should be 0 56 2 31 mm 0 022 0 091 in 47 Positi...

Page 1636: ...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 Fig 164 Removing Overrunning Clutch From Low Reverse Drum 1 CAM BOLTS 2 LOW REVERSE DRUM 3 OVERRUNNING CLUTCH AND CAM Fig 165 Overrunning Clutch Rollers Springs Retainer 1 RETAINER 2 SPRING 3 ROLLER Fig 166 Ass...

Page 1637: ...s ASSEMBLY 1 Lubricate new O ring and seal rings with petroleum jelly and install them on piston guide and rod 2 Install rod in piston Install spring and washer on rod Compress spring and install snap ring Fig 169 3 Set servo components aside for installation dur ing transmission reassembly Fig 167 Temporary Assembly Of Clutch And Drum To Check Operation 1 LOW REVERSE DRUM 2 CLUTCH RACE ON HUB OF ...

Page 1638: ...embly for alignment reference 3 Remove bolts attaching pump body to support Fig 172 4 Separate support from pump housing Fig 173 5 Remove inner and outer gears from reaction shaft support Fig 174 6 If pump seal was not removed during transmis sion disassembly remove seal with punch and ham mer 7 Remove front clutch thrust washer from sup port hub Fig 175 Fig 171 Removing Pump Seal Ring 1 PUMP HOUS...

Page 1639: ...33 firmly against reaction shaft and thread remover SP 5324 into bushing as far as possible by hand Then thread remover tool 3 4 additional turns into bushing with a wrench 3 Turn remover tool hex nut down against remover cup to pull bushing from shaft Clean all chips from shaft after bushing removal Fig 174 Pump Gear Removal 1 REACTION SHAFT SUPPORT 2 INNER GEAR 3 OUTER GEAR Fig 175 Support Hub T...

Page 1640: ...tion shaft seal rings are being replaced install new seal rings on support hub Fig 181 Lubricate seal rings with transmission fluid or petro leum jelly after installation Squeeze each ring until ring ends are securely hooked together CAUTION The reaction shaft support seal rings will break if overspread or twisted If new rings are being installed spread them only enough for instal lation Also be v...

Page 1641: ... reference 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 retainer hub Discard both seals as they are not reus able ASSEMBLY 1 Soak clutch discs in transmission fluid while assembling other clutch parts 2 Install new seals on piston and in hub of retainer Be sure lip of each seal faces interior of clutch ...

Page 1642: ... the pressure plate Fig 189 b Using two small screw drivers lift the pres sure plate and compress the waved snap ring This will assure that the snap ring is at the top of the groove c Release the pressure plate and zero the dial indicator d Lift the pressure plate until it contacts the waved snap ring and record the dial indicator read ing Clearance should be 1 70 to 3 40 mm 0 067 to 0 134 in If c...

Page 1643: ...ool Use a suitably Fig 185 Compressing Front Clutch Piston Spring 1 FRONT CLUTCH SPRING 2 COMPRESSOR TOOL C 3575 A 3 RETAINER SNAP RING 4 SPRING RETAINER Fig 186 Front Clutch Piston Installation 1 CLUTCH PISTON 2 FRONT CLUTCH RETAINER Fig 187 Clutch Piston Spring Installation 1 RETAINER 2 CLUTCH SPRING 3 PISTON Fig 188 Correct Spring Retainer Installed Position 1 SMALL TABS ON RETAINER FACE UPWARD...

Page 1644: ...t Door Ease Then lubricate retainer hub and bore with light coat of transmission fluid 8 Install clutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 020 thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition neve...

Page 1645: ...talling Input Shaft Snap Ring 1 REAR CLUTCH RETAINER 2 INPUT SHAFT SNAP RING 3 SNAP RING PLIERS Fig 192 Rear Clutch Retainer And Input Shaft Seal Ring Installation 1 REAR CLUTCH RETAINER HUB SEAL RING 2 INPUT SHAFT SEAL RINGS Fig 193 Input Shaft Seal Ring Identification 1 PLASTIC REAR SEAL RING 2 TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT Fig 194 Press...

Page 1646: ...he selective snap ring thicknesses are 107 109 in 098 100 in 095 097 in 083 085 in 076 078 in 071 073 in 060 062 in 16 Coat rear clutch thrust washer with petro leum jelly and install washer over input shaft and into clutch retainer Fig 197 Use enough petroleum jelly to hold washer in place PLANETARY GEARTRAIN OUTPUT SHAFT DISASSEMBLY 1 Remove planetary snap ring Fig 198 2 Remove front annulus and...

Page 1647: ...ar Use enough petroleum jelly to hold washer in place Also be sure all four washer tabs are properly engaged in gear slots 4 Install rear annulus over and onto rear plane tary gear Fig 202 5 Install assembled rear planetary and annulus gear on output shaft Fig 203 Verify that assembly is fully seated on shaft 6 Install front thrust washer on rear planetary gear Fig 204 Use enough petroleum jelly t...

Page 1648: ...Assembling Rear Annulus And Planetary Gear 1 REAR ANNULUS GEAR 2 TABBED THRUST WASHER 3 REAR PLANETARY Fig 203 Installing Rear Annulus And Planetary On Output Shaft 1 REAR ANNULUS AND PLANETARY GEAR ASSEMBLY 2 OUTPUT SHAFT Fig 204 Installing Rear Planetary Front Thrust Washer 1 FRONT TABBED THRUST WASHER 2 REAR PLANETARY GEAR Fig 205 Installing Spacer On Sun Gear 1 SUN GEAR 2 SUN GEAR SPACER XJ AU...

Page 1649: ...ng shell and sun gear on output shaft Fig 210 13 Install rear thrust washer on front planetary gear Fig 211 Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated Fig 207 Installing Driving Shell Rear Thrust Plate 1 DRIVING SHELL 2 SUN GEAR 3 REAR THRUST PLATE Fig 206 Installing Driving Shell Front Thrust Plate On Sun Gear 1 SPACER 2 SUN GEAR 3 THRUST PLATE ...

Page 1650: ...1 Install planetary selective snap ring with snap ring pliers Fig 216 Be sure ring is fully seated 22 Turn planetary geartrain assembly over so driving shell is facing workbench Then support geartrain on wood block positioned under forward end of output shaft This allows geartrain compo nents to move forward for accurate end play check 23 Check planetary geartrain end play with feeler gauge Fig 21...

Page 1651: ...Thrust Washer 1 WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB 2 FRONT ANNULUS THRUST WASHER 3 TAB FACES FRONT Fig 215 Installing Front Annulus Snap Ring 1 SNAP RING PLIERS 2 FRONT ANNULUS SNAP RING Fig 216 Installing Planetary Selective Snap Ring 1 SELECTIVE SNAP RING 2 SNAP RING PLIERS Fig 217 Checking Planetary Geartrain End Play 1 OUTPUT SHAFT 2 REAR ANNULUS GEAR 3 FEELER GAUGE 21 190 AUTOMATIC...

Page 1652: ...en EXTENSION HOUSING AND PARK LOCK Clean the housing and park lock components in solvent and dry them with compressed air Examine the park lock components in the housing If replacement is necessary remove the shaft with parallel jaw snap ring pliers Fig 220 and remove the sprag and spring Then remove the spring clip and reaction plug Fig 221 Compress the reac tion plug spring clip only enough to r...

Page 1653: ...alve body mating surface may be corrected by smoothing the surface with cro cus cloth The cloth should be in sheet form and be positioned on a surface plate sheet of plate glass or equally flat surface However if distortion is severe or any surfaces are heavily scored the valve body will have to be replaced CAUTION Many of the valve body valves and plugs are made of coated aluminum Aluminum compo ...

Page 1654: ...if any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Trial fit each valve and plug in its bore to check freedom of operation When clean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will contin...

Page 1655: ... way into the case Be sure the screw turns freely and does not bind Install the locknut on the screw after checking screw thread operation Inspect all the transmission bushings during over haul Bushing condition is important as worn scored bushings contribute to low pressures clutch slip and accelerated wear of other components Replace worn or scored bushings or if doubt exists about bushing condi...

Page 1656: ...Replace the drum and race as an assembly if either component is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace the retainer if worn or damaged FRONT SERVO Clean the servo piston components with solvent and dry them with compressed air Wipe the band clean with lint free shop towels R...

Page 1657: ... scored warped or broken Be sure the driving lugs on the plates are in good condition The lugs must not be bent cracked or damaged in any way Replace the clutch spring and spring retainer if either is distorted warped or broken Check the lug grooves in the clutch retainer The steel plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Check action of the c...

Page 1658: ...ges are open and clear Replace the shaft if scored pitted or damaged Inspect the sun gear and driving shell If either component is worn or damaged remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell Then replace the necessary component Replace the sun gear as an assembly if the gear teeth are chipped or worn Also replace the gear as an assembly...

Page 1659: ...ve TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT The transmission throttle valve is operated by a cam on the throttle lever The throttle lever is oper ated by an adjustable cable Fig 230 The cable is attached to an arm mounted on the throttle lever shaft A retaining clip at the engine end of the cable is removed to provide for cable adjustment The retaining clip is then installed back onto the thro...

Page 1660: ...on the throttle lever stud the cable housing moves smoothly with the cable Due to the angle at which the cable housing enters the spring housing the cable housing may bind slightly and create an incorrect adjustment 7 Install retaining clip onto cable housing 8 Check cable adjustment Verify transmission throttle lever and lever on throttle body move simul taneously FRONT BAND ADJUSTMENT The front ...

Page 1661: ...e inner edge of the adjusting screw with an accurate steel scale Fig 234 Distance should be 33 4 mm 1 5 16 in If adjustment is required turn the adjusting screw in or out to obtain required distance setting NOTE The 33 4 mm 1 5 16 in setting is an approximate setting Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure One complete turn of the adjus...

Page 1662: ...ment SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS Fig 234 Line Pressure Adjustment 1 WRENCH 2 1 5 16 INCH Fig 235 Throttle Pressure Adjustment 1 HEX WRENCH IN THROTTLE LEVER ADJUSTING SCREW 2 SPECIAL TOOL C 3763 POSITIONED BETWEEN THROTTLE LEVER AND KICKDOWN VALVE XJ AUTOMATIC TRANSMISSION 30RH 21 201 ADJUSTMENTS Continued ...

Page 1663: ...HYDRAULIC FLOW IN PARK NEUTRAL 21 202 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1664: ...HYDRAULIC FLOW IN D FIRST GEAR XJ AUTOMATIC TRANSMISSION 30RH 21 203 SCHEMATICS AND DIAGRAMS Continued ...

Page 1665: ...HYDRAULIC FLOW IN D SECOND GEAR 21 204 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1666: ...HYDRAULIC FLOW IN D THIRD GEAR XJ AUTOMATIC TRANSMISSION 30RH 21 205 SCHEMATICS AND DIAGRAMS Continued ...

Page 1667: ...HYDRAULIC FLOW IN D THIRD GEAR CONVERTER CLUTCH APPLIED 21 206 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1668: ...HYDRAULIC FLOW AT PART THROTTLE 3 2 KICKDOWN XJ AUTOMATIC TRANSMISSION 30RH 21 207 SCHEMATICS AND DIAGRAMS Continued ...

Page 1669: ...HYDRAULIC FLOW AT FULL THROTTLE 3 2 KICKDOWN 21 208 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1670: ...HYDRAULIC FLOW IN MANUAL SECOND XJ AUTOMATIC TRANSMISSION 30RH 21 209 SCHEMATICS AND DIAGRAMS Continued ...

Page 1671: ...HYDRAULIC FLOW IN MANUAL LOW 21 210 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued ...

Page 1672: ...HYDRAULIC FLOW IN REVERSE XJ AUTOMATIC TRANSMISSION 30RH 21 211 SCHEMATICS AND DIAGRAMS Continued ...

Page 1673: ...ub 1 55 mm 0 061 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in Output shaft thrust plate output shaft pilot hub 1 5 1 6mm 0 060 0 063 in Output shaft thrust washer rear clutch hub 1 3 1 4 mm 0 052 0 054 in 1 7 1 8 mm 0 068 0 070 in 2 1 2 2 mm 0 083 0 086 in Rear clutch pack snap ring 1 5 1 6 mm 0 06 0 062 in 1 7 1 8 mm 0 068 0 070 in 1 9 2 0 mm 0 076 0 078 in Planetary geartrain sn...

Page 1674: ...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 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 1...

Page 1675: ... B Fixture Engine Support C 3487 A Spring Compressor C 3575 A Spring Compressor C 3863 A Adapter Band Adjuster C 3705 Transmission Repair Stand C 3750 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 21 214 AUTOMATIC TRANSMISSION 30RH XJ SPECIAL TOOLS Continued ...

Page 1676: ... J Cup Remover SP 3633 Remover Bushing SP 5301 Installer Bushing SP 5118 Installer Bushing SP 5302 Remover Bushing SP 3550 Remover Bushing SP 3629 Installer Bushing SP 5511 Snap ring Plier C 3915 XJ AUTOMATIC TRANSMISSION 30RH 21 215 SPECIAL TOOLS Continued ...

Page 1677: ...r C 3985 B Bushing Remover 6957 Flusher Oil Cooler 6906 Installer C 3995 A Universal Handle C 4171 Remover Installer C 4470 Nut Bushing Remover SP 1191 21 216 AUTOMATIC TRANSMISSION 30RH XJ SPECIAL TOOLS Continued ...

Page 1678: ...OL MODULE TCM SERVICE 248 OIL PUMP VOLUME CHECK 248 FLUSHING COOLERS AND TUBES 248 ALUMINUM THREAD REPAIR 249 REMOVAL AND INSTALLATION TRANSMISSION AND TORQUE CONVERTER 250 TORQUE CONVERTER 252 ADAPTER HOUSING SEAL 252 SPEED SENSOR 252 SPEEDOMETER ADAPTER 253 SPEED SENSOR ROTOR SPEEDOMETER DRIVE GEAR 254 PARK NEUTRAL POSITION SWITCH 255 GEARSHIFT CABLE 256 BRAKE TRANSMISSION SHIFT INTERLOCK 256 TR...

Page 1679: ... 3 and D ranges Controls consist of the transmission control module TCM valve body solenoids and various sen sors The sensors monitor vehicle speed throttle opening shift lever position and brake pedal applica tion TRANSMISSION GEAR RATIOS Fourth gear is an 0 75 1 ratio overdrive range First second third and reverse gear are conventional ranges Third gear ratio is 1 1 A separate planetary gear set...

Page 1680: ...ents front and rear sun gear from turning either clockwise or counter clockwise Second Brake Prevents outer race of number 1 one way clutch from turning either clockwise or counter clockwise thus preventing the front and rear sun gears from turning counter clockwise First Reverse Brake Prevents the rear planetary carrier from turning either clockwise or counter clockwise Number 1 One way Clutch Wh...

Page 1681: ...d and applied through transmission valve body solenoid number two In fourth gear the overdrive brake prevents the overdrive sun gear from turning The overdrive input shaft and planetary carrier rotate as a unit The sun gear and overdrive direct clutch drum are in mesh and operate as a single unit The direct clutch splines function as the hub for the overdrive brake The one way clutch outer race is...

Page 1682: ...ers also claim to improve converter clutch operation and inhibit overheating oxidation varnish and sludge These claims have not been sup ported to the satisfaction of DaimlerChrysler and these additives must not be used The use of trans mission sealers should also be avoided since they may adversely affect the integrity of transmission seals OPERATION The automatic transmission fluid is selected b...

Page 1683: ...ter 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 CAUTION The torque converter must be replaced if a transmission failure resulted in large amounts of metal or f...

Page 1684: ...e converter As the converter housing is rotated by the engine so is the impeller because they are one in the same and are the driving member of the system Fig 6 Impeller 1 ENGINE FLEXPLATE 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 3 IMPELLER VANES AND COVER ARE INTEGRAL 4 ENGINE ROTATION 5 ENGINE ROTATION XJ AW 4 AUTOMATIC TRANSMISSION 21 223 DESCRIPTION AND OPERATION Continued ...

Page 1685: ...ugh 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 2 ENGINE ROTATION 3 INPUT SHAFT 4 PORTION OF TORQUE CONVERTER COVER 5 ENGINE ROTATION 6 OIL FLOW WITHIN TURBINE SECTION 21 224 AW 4 AUTOMATIC TRANSMISSION XJ DESCRIPTION AND OPERATION Con...

Page 1686: ...ne and a friction mate rial was added to the inside of the impeller housing to provide this mechanical lock up 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 ...

Page 1687: ...s the stator vanes and is redirected into a helping direction before it enters the impeller This circulation of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum torque multiplication of about 2 2 1 As the turbine begins to match the speed of the impeller the fluid that was hitting the stator in such as way as to cause it to lock up is no longer doing so I...

Page 1688: ...solenoid channels line pressure to the clutch through the relay valve at clutch engagement speeds OIL PUMP DESCRIPTION The oil pump Fig 13 is located in the pump hous ing inside the bell housing of the transmission case The oil pump consists of an inner and outer gear a housing and a cover that also serves as the reaction shaft support OPERATION As the torque converter rotates the converter hub ro...

Page 1689: ...ower body section Fig 15 The remaining control and shift valves plus check balls and one additional oil strainer are located in the upper body section Fig 16 TRANSMISSION VALVE BODY SOLENOIDS The solenoids are mounted on the valve body and operated by the TCM The solenoids control operation of the converter clutch and shift valves in response to input signals from the module Fig 14 Two Section Tra...

Page 1690: ... Fig 17 Fig 16 Lower Body Components 1 DOWNSHIFT PLUG 2 LOCK UP RELAY VALVE 3 SECONDARY REGULATOR VALVE 4 UPPER BODY 5 CUT BACK VALVE 6 THROTTLE VALVE 7 LOW COAST MODULATOR VALVE 8 SECONDARY COAST MODULATOR VALVE 9 2 3 SHIFT VALVE 10 3 4 SHIFT VALVE 11 THROTTLE CAM Fig 17 Manual Valve XJ AW 4 AUTOMATIC TRANSMISSION 21 229 DESCRIPTION AND OPERATION Continued ...

Page 1691: ... by throttle pres sure and by line pressure from the second brake The valve also helps regulate line pressure by controlling the amount of cut back pressure to the throttle valve SECONDARY REGULATOR VALVE The secondary regulator valve Fig 21 regulates converter clutch and transmission lubrication pres sure When primary regulator valve pressure exceeds requirements for clutch engagement or transmis...

Page 1692: ...lator feed port As the solenoid is activated and the drain port opens spring force moves the valve up exposing the second brake feed port for the shift to second gear 2 3 SHIFT VALVE The 2 3 shift valve Fig 24 controls the 2 3 upshifts and downshifts The valve is actuated by the No 1 valve body solenoid and by line pressure from the manual valve and primary regulator valve Fig 20 Cut Back Valve 1 ...

Page 1693: ...ing tension moves the valve up to hold the valve in second gear position As the solenoid is deactivated line pressure then moves the valve down exposing the direct clutch feed port for the shift to third gear Fig 23 1 2 Shift Valve Fig 24 2 3 Shift Valve 21 232 AW 4 AUTOMATIC TRANSMISSION XJ DESCRIPTION AND OPERATION Continued ...

Page 1694: ...he valve upward closing off the overdrive brake feed port preventing a shift into fourth gear SECOND COAST MODULATOR VALVE The second coast modulator valve Fig 26 momen tarily reduces line pressure from the 1 2 shift valve This cushions application of the second coast brake The valve is operative when the shift lever and man ual valve are in the 3 position LOW COAST MODULATOR VALVE The low coast m...

Page 1695: ...ure is provided by the transmission control module The No 3 solenoid controls operation of the torque converter clutch The solenoid operates in response to signals from the transmission control module When the No 1 and 2 solenoids are activated the solenoid plunger is moved off its seat opening the drain port to release line pressure When either sole noid is deactivated the plunger closes the drai...

Page 1696: ...ton that is closely fitted to the cylinder wall If a force is applied to the piston pressure will be developed in the fluid Of course no pressure will be created if the fluid is not confined It will simply leak past the piston There must be a resistance to flow in order to create pres sure Piston sealing is extremely important in hydraulic operation Several kinds of seals are used to accomplish th...

Page 1697: ... body as well as the pistons of the transmission which activate the clutches and bands It is nothing more than using a difference of area to create a difference in pressure to move an object PISTON TRAVEL The relationship between hydraulic lever and a mechanical lever is the same With a mechanical lever it s a weight to distance output rather than a pressure to area output Using the same forces an...

Page 1698: ...itch prevents engine starting in all gears other than Park or Neutral The brake switch is in circuit with the torque con verter clutch solenoid The switch disengages the converter clutch whenever the brakes are applied The switch is mounted on the brake pedal bracket and signals the transmission control module when the pedal is pressed or released HYDRAULIC SYSTEM DESCRIPTION The hydraulic system ...

Page 1699: ...LOCK or ACCESSORY posi tion An additional electrically activated feature will prevent shifting out of the PARK position unless the 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 the RUN position When the key is in the RUN posi tion and the brake pedal is depressed the shifter is unlocked ...

Page 1700: ...echanical or electrical The first procedure step is Initial Inspection and Adjustment EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid Air in the fluid will cause fluid pressures to be low and develop slower than normal Fig 37 Ignition Interlock Cable Routing 1 SHIFT MECHANISM 2 LOCK TAB 3 IGNITION LOCK INTERLOCK 4 STEERING COLUMN 5 SOLENOID 6 ...

Page 1701: ...ow through the main and or auxiliary cooler This condition is usu ally the result of a faulty or improperly installed drainback valve a damaged main cooler or severe restrictions in the coolers and lines caused by debris or kinked lines 2 Heavy duty operation with a vehicle not prop erly equipped for this type of operation Trailer tow ing or similar high load operation will overheat the transmissi...

Page 1702: ... level when fluid is at normal operating temperature Start engine Shift transmission through all gear ranges then back to Neutral Correct level is to Full or Add mark on dip stick with engine at curb idle speed 5 Check and adjust park neutral position switch if necessary 6 Check throttle position sensor adjustment and operation Adjust the sensor if necessary MANUAL SHIFTING TEST 1 This test determ...

Page 1703: ...e low in D range only check for fol lowing forward clutch worn or damaged fluid leakage in D range circuit component seal and O rings If pressures are low in Reverse only check for fol lowing shift cable and manual valve out of adjustment fluid leakage in reverse circuit component seal and O rings direct clutch worn or damaged first reverse brake worn or damaged TIME LAG TEST This test checks gene...

Page 1704: ...erter drive plate broken Replace drive plate Oil pump intake screen blocked Clean screen Transmission faulty Disassemble and repair transmission SHIFT LEVER POSITION INCORRECT Shift cable out of adjustment Adjust cable Manual valve and lever faulty Repair valve body HARSH ENGAGEMENT Throttle cable out of adjustment Adjust throttle cable Valve body or primary regulator faulty Repair valve body Accu...

Page 1705: ...RING COAST Throttle cable faulty Replace cable 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 BRAKIN...

Page 1706: ... 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 TRANSMISSION SOLENOID TESTING Test solenoid resistance with an ohmmeter Con nect the ohmmeter leads to the solenoid mounting bracket and to the solenoid wire terminal Fig 40 Soleno...

Page 1707: ...ly shifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive Refer to the Adjust ments section for the proper adjustment procedure SPEED SENSOR TESTING Test the speed sensor with an ohmmeter Place the ohmmeter leads on the terminals in the sensor con nector Fig 42 Rotate the transmission output shaft and obse...

Page 1708: ...rec tion Converter clutch should lock 5 Replace converter if clutch binds or will not lock 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 throug...

Page 1709: ... 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 TRANSMISSION CONTROL MODULE TCM SERVICE Use the DRB scan tool to diagnose transmission control module function whenever a fault is sus pected Replace the module only when the scan tool indicates the module is actually faulty OIL PUMP VOLUME CHECK M...

Page 1710: ...the transmission oil cooler from the vehicle Refer to the Group 7 Cooling System for the proper procedures 8 Remove the transmission oil cooler thermostat Refer to the Group 7 Cooling System for the proper procedures 9 Re install the thermostat cover onto the oil cooler and install the snap ring 10 Re connect the oil cooler to the transmission cooler lines 11 Turn pump ON for two to three minutes ...

Page 1711: ...n remove shafts from vehicle 10 Remove rear crossmember 11 Disconnect transmission shift cable at trans mission Then disconnect transmission throttle valve cable at engine 12 Disconnect necessary vacuum and fluid hoses 13 Remove transfer case from transmission 14 Disconnect and remove crankshaft position sensor Fig 46 CAUTION The crankshaft position sensor can be damaged during transmission remova...

Page 1712: ...and position transmission and converter on engine 5 Remove clamp or strap used to hold torque con verter in place 6 Move transmission forward seat and it on engine Be sure torque converter hub is fully seated 7 Install converter housing to engine bolts Fig 47 8 Install converter to drive plate bolts 9 Install and connect starter motor 10 Install and connect crankshaft position sensor 11 Install tr...

Page 1713: ... inserting torque converter into the front of the transmission 3 Align torque converter to oil pump seal open ing 4 Insert torque converter hub into oil pump 5 While pushing torque converter inward rotate converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge Fig 48 Surface of converter lugs should be 1 2 in to rear of straightedge w...

Page 1714: ...ghly clean adapter flange and adapter 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 if necessary Fig 51 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 ...

Page 1715: ...ng to the transmission case 7 Tap the adapter housing at the joint line gently with a rubber mallet to separate the adapter housing from the transmission case 8 Remove the adapter housing from the trans mission case 9 Remove speedometer drive gear snap ring Fig 53 10 Remove the speedometer drive gear and spacer if equipped 11 Remove rotor from the output shaft It may be necessary to use a wood dow...

Page 1716: ...nstall components removed to gain access to rotor and drive gear PARK NEUTRAL POSITION SWITCH REMOVAL 1 Raise vehicle 2 Disconnect switch wire harness connector 3 Pry washer lock tabs upward and remove switch attaching nut and tabbed washer Fig 55 4 Remove switch adjusting bolt Fig 55 5 Slide switch off manual valve shaft Fig 55 Park Neutral Position Switch Removal Installation 1 ADJUSTING BOLT 2 ...

Page 1717: ...nto dash panel 2 Place the auto transmission manual shift con 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 snapping cable retaining ears into shifter bracket and press cable end fitting onto lever ball stud 4 Place the floor shifter lever in park position Ensure that the pawl is seated within the c...

Page 1718: ...ter interlock cable Refer to the Adjustment portion of this section for proper procedures 7 Verify that the cable adjuster lock clamp is pushed downward to the locked position 8 Test the park lock cable operation 9 Install the floor console and related trim Fig 58 Cable and Shifter 1 SHIFT MECHANISM 2 LOCK TAB 3 IGNITION LOCK INTERLOCK 4 STEERING COLUMN 5 SOLENOID 6 WIRE CONNECTOR 7 LEVER 8 MOUNT ...

Page 1719: ...mpressed air 8 Remove old sealer material from oil pan and transmission case INSTALLATION 1 Position solenoids on valve body and install solenoid bolts Tighten bolts to 10 N m 7 ft lbs torque 2 Connect feed wires to solenoids 3 Install new gaskets on oil screen and install screen Tighten screen bolts to 10 N m 7 ft lbs torque 4 Apply bead of Threeebondt Liquid Gasket TB1281 P N 83504038 sealer to ...

Page 1720: ...ll and spring Fig 67 3 Position accumulator springs and spacers on valve body 4 Align valve body manual valve with shift sector Fig 68 and carefully position valve body on case 5 Install valve body bolts Fig 65 Tighten bolts evenly to 10 N m 7 ft lbs torque 6 Install valve body oil tubes Be sure tube ends L and M are installed as shown in Fig 69 7 Remove old sealer material from oil pan and transm...

Page 1721: ...he instrument panel On left hand drive models it is at the driver side of the lower finish panel Fig 70 On right hand drive models it is at the passenger side of the lower finish panel Fig 71 To remove the module disconnect the wire har ness remove the mounting screws and remove the Fig 65 Transmission Valve Body Bolt Locations Fig 66 Accumulator Springs 1 OVERDRIVE BRAKE ACCUMULATOR SPRING 2 SECO...

Page 1722: ...ket securing solenoid harness adaptor Fig 73 to case 4 Pull harness adapter and wires out of case Fig 69 Installing Transmission Valve Body Oil Tubes Fig 70 TCM Location Left Hand Drive 1 TCM 2 LOWER FINISH PANEL Fig 71 TCM Location Right Hand Drive 1 REAR SIDE OF INSTRUMENT PANEL 2 TCM AND HARNESS Fig 72 Solenoid Wire Connectors 1 SOLENOID WIRE CONNECTORS Fig 73 Harness Adapter Removal Installati...

Page 1723: ...er con MANUAL VALVE SHAFT SEAL REMOVAL 1 Remove park neutral position switch and dis connect transmission shift lever Fig 74 2 Remove oil pan and valve body 3 Remove bolts attaching park rod bracket to case Fig 75 4 Remove park rod from shift sector Fig 76 5 Cut spacer sleeve with chisel and remove it from manual valve shaft Fig 77 6 Remove pin from shaft and sector with pin punch 7 Remove shaft a...

Page 1724: ...spacer sleeve on sector Fig 80 4 Lubricate manual valve shaft with petroleum jelly and install it through the left side of the trans mission case Fig 77 Cutting Spacer Sleeve 1 SPACER 2 MANUAL VALVE SHAFT Fig 78 Removing Manual Valve Shaft Seals 1 MANUAL VALVE SHAFT SEAL Fig 79 Installing Manual Valve Shaft Seals 1 SHAFT SEAL INSTALLER Fig 80 Installing Spacer Sleeve On Sector 1 SHIFT SECTOR 2 SPA...

Page 1725: ...h piston out of the bore In addition remove the pistons one at a time and tag the pistons and springs for assembly reference Do not intermix them 3 Remove and discard piston O ring seals Then clean pistons and springs with solvent INSTALLATION 1 Inspect pistons springs and piston bores Replace worn damaged pistons Replace broken col lapsed or distorted springs Replace case if piston bores are dama...

Page 1726: ...snap ring with snap ring pliers Fig 85 3 Remove servo piston and cover with com pressed air Apply compressed air through oil hole in servo boss to ease piston out of bore Fig 86 Fig 84 Accumulator Pistons Springs And Spacers Fig 85 Removing Installing Servo Piston Cover Snap Ring 1 SERVO PISTON COVER SNAP RING 2 SNAP RING PLIERS Fig 86 Removing Servo Cover And Piston 1 PISTON AND COVER 2 OIL HOLE ...

Page 1727: ...ring 5 Install valve body oil screen and oil pan PARK ROD AND PAWL 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 Fig 87 Second Coast Brake Servo Components 1 SERVO PISTON 2 SEAL RING 3 SPRING AND RETAINER 4 PISTON ROD 5 PISTON SPRING 6 SERVO COVER O RINGS 7 ...

Page 1728: ... linkage Then compress cable mounting ears and remove cable from engine bracket Fig 91 2 Raise vehicle 3 Remove transmission oil pan 4 Disengage cable from throttle valve cam Fig 92 5 Remove cable bracket bolt and remove cable and bracket from case Fig 93 6 Remove and discard cable seal Fig 91 Transmission Throttle Cable Attachment 1 THROTTLE CABLE 2 CABLE GUIDE 3 ACCELERATOR CABLE 4 CABLE ENGINE ...

Page 1729: ...n cable adjust ment procedure OIL PUMP SEAL REMOVAL 1 Remove converter 2 Remove old seal Use blunt punch to collapse seal and pry seal out of pump housing Do not scratch or damage seal bore INSTALLATION 1 Lubricate lip of new seal with transmission fluid and install seal in pump with tool 7549 Fig 94 2 Lubricate converter drive hub with transmis sion fluid 3 Align and install converter in oil pump...

Page 1730: ...emove speed sensor 6 Remove converter housing bolts and remove housing Fig 96 from case 7 Remove adapter housing speedometer drive gear and speed sensor rotor 8 Remove transmission oil pan oil screen and screen gaskets Fig 97 Fig 95 Typical Harness And Cable Clamp Attachment 1 CLAMP 2 THROTTLE CABLE 3 TRANSMISSION HARNESS Fig 96 Converter Housing Removal 1 CONVERTER HOUSING Fig 97 Removing Oil Scr...

Page 1731: ... throttle cable from throttle cam Fig 102 14 Remove valve body from case Then remove accumulator springs check ball and spring Fig 103 Fig 98 Valve Body Oil Tube Removal 1 OIL TUBES Fig 99 Solenoid Wire Location 1 SOLENOID WIRE CONNECTORS Fig 100 Removing Bracket And Harness 1 HARNESS ADAPTER 2 BRACKET Fig 101 Valve Body Bolt Locations 21 270 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND ASSEMBLY...

Page 1732: ...on with compressed air Fig 104 Note and identify the original location of all springs 17 Remove overdrive clutch accumulator piston with compressed air Fig 104 18 Remove throttle cable Fig 102 Disconnecting Throttle Cable 1 THROTTLE CABLE 2 THROTTLE CAM Fig 103 Removing Accumulator Springs Spacers And Check Ball 1 CHECK BALL AND SPRING 2 ACCUMULATOR SPRINGS Fig 104 Accumulator Piston Removal XJ AW...

Page 1733: ...g race and overdrive planetary ring gear Fig 109 24 Measure stroke length of overdrive brake pis ton as follows Fig 105 Oil Pump Removal 1 PULLER TOOL 2 OIL PUMP Fig 106 Oil Pump Race Removal 1 OIL PUMP RACE 2 OIL PUMP Fig 107 Removing Overdrive Planetary And Clutch Assembly 1 PLANETARY AND CLUTCH ASSEMBLY Fig 108 Fourth Gear Planetary Race Removal 1 PLANETARY OVERDRIVE 2 RACE 21 272 AW 4 AUTOMATI...

Page 1734: ...ir 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 26 Remove the bolt holding the input speed sen sor to the transmission case 27 Remove the input speed sensor from the transmission case 28 Remove overdrive brake pack snap ring Fig 110 29 Remove overdrive brake pack d...

Page 1735: ...emove piston cover and piston assembly 36 Disassemble second coast brake piston Fig 116 if necessary 37 Remove direct and forward clutch assembly Fig 117 Fig 112 Overdrive Support Snap Ring Removal Installation 1 SNAP RING PLIERS 2 SUPPORT SNAP RING Fig 113 Overdrive Support Bolt Removal 1 SUPPORT BOLTS Fig 114 Removing Overdrive Support 1 BRIDGE TYPE PULLER TOOL 2 OVERDRIVE SUPPORT Fig 115 Remove...

Page 1736: ...NG AND RETAINER 4 PISTON ROD 5 PISTON SPRING 6 SERVO COVER O RINGS 7 SERVO COVER 8 SNAP RING 9 E RING Fig 117 Removing Direct And Forward Clutch Assembly 1 DIRECT AND FORWARD CLUTCH ASSEMBLY Fig 118 Bearing And Race Removal From Clutch Hub 1 BEARING 2 RACE 3 DIRECT CLUTCH Fig 119 Second Coast Brake Band Removal 1 BRAKE BAND E RING 2 SECOND COAST BRAKE BAND XJ AW 4 AUTOMATIC TRANSMISSION 21 275 DIS...

Page 1737: ...ap ring 44 Remove planetary snap ring and remove plan etary gear Fig 122 Fig 120 Front Planetary Ring Gear Removal 1 RING GEAR BEARING RACE FRONT 2 FRONT PLANETARY RING GEAR Fig 121 Removing Ring Gear Bearing And Rear Race 1 BEARING AND REAR RACE 2 FRONT PLANETARY RING GEAR Fig 122 Removing Planetary Snap Ring And Gear 1 PLANETARY SNAP RING 2 PLANETARY GEAR 3 SNAP RING PLIERS 21 276 AW 4 AUTOMATIC...

Page 1738: ...25 48 Remove second brake clutch pack Fig 126 Inspect and replace as necessary Fig 123 Removing Sun Gear Input Drum And One Way Clutch 1 SUN GEAR INPUT DRUM ONE WAY CLUTCH ASSEMBLY Fig 124 Checking Second Brake Clutch Pack Clearance 1 FEELER GAUGE 2 SECOND BRAKE CLUTCH PACK Fig 125 Removing Second Brake Clutch Pack Snap Ring 1 CLUTCH PACK SNAP RING Fig 126 Removing Measuring Second Brake Clutch Di...

Page 1739: ...31 55 Remove planetary and brake drum thrust bearing and race assembly Fig 132 56 Remove second brake drum gasket from case with screwdriver 57 Measure inside diameter of transmission case rear bushing with bore gauge or inside micrometer Fig 133 Maximum allowable diameter is 38 18 mm 1 5031 in Replace transmission case if bush ing I D is greater than specified Bushing is not serviceable Fig 127 R...

Page 1740: ...emove Tool 7539 and remove piston return springs Fig 130 Removing Second Brake Piston Sleeve 1 REMOVER TOOL 2 PISTON SLEEVE Fig 131 Removing Rear Planetary Second Brake Drum And Output Shaft 1 PLANETARY BRAKE DRUM AND OUTPUT SHAFT ASSEMBLY Fig 132 Removing Installing Bearing And Race Assembly 1 BEARING AND RACE ASSEMBLY Fig 133 Checking Rear Bushing Inside Diameter 1 BORE GAUGE 2 REAR BUSHING 3 TR...

Page 1741: ... 1 During assembly lubricate components with transmission fluid or petroleum jelly as indicated 2 Verify thrust bearing and race installation dur ing assembly Refer to the Thrust Bearing Chart Fig Fig 135 Removing Installing Piston Snap Ring 1 RETURN SPRINGS 2 COMPRESSOR TOOL 3 PISTON SNAP RING Fig 134 Checking First Reverse Brake Piston Operation 1 LOW PRESSURE AIR 2 FIRST REVERSE BRAKE IN CASE F...

Page 1742: ...9 Install the spring plate into the No 2 first re verse brake piston 10 Install Spring Compressor 7539 onto the first reverse brake piston 11 Compress the first reverse brake piston spring and install the first reverse brake piston snap ring 12 Remove Spring Compressor 7539 13 Install rear planetary gear second brake drum and output shaft as outlined in following steps 14 Verify No 10 thrust beari...

Page 1743: ...ed in case Remove and reinstall components if necessary 20 Install second brake piston sleeve Fig 144 Sleeve lip faces up and toward case front as shown 21 Install second brake drum gasket Fig 139 Installing Thrust Bearing And No 10 Race 1 THRUST BEARING AND RACE Fig 140 Aligning Second Brake Drum And Clutch Pack Teeth 1 SECOND BRAKE DRUM 2 CLUTCH PACK 3 ALIGN DRUM AND CLUTCH PACK TEETH Fig 141 Ou...

Page 1744: ...ig 146 Fig 143 Checking First Reverse Brake Pack Clearance 1 FEELER GAUGE Fig 144 Second Brake Piston Sleeve Installation 1 PISTON SLEEVE Fig 145 Park Lock Pin Spring And Pawl Installation 1 SPRING 2 PIN 3 PAWL Fig 146 Park Lock Rod Installation 1 SHIFT SECTOR 2 PARK LOCK ROD XJ AW 4 AUTOMATIC TRANSMISSION 21 283 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1745: ...d brake pack Fig 150 Install disc then plate Continue installation sequence until five discs and five plates are installed 29 Install second brake pack retainer with rounded edge of retainer facing disc 30 Install second brake pack snap ring Fig 147 Park Rod Bracket Installation 1 PARK ROD BRACKET Fig 148 Checking Park Pawl Engagement 1 REAR PLANETARY RING GEAR 2 PARK PAWL Fig 149 Installing No 1 ...

Page 1746: ... in drum Use petroleum jelly to hold thrust washer in position if necessary 33 Install front planetary gear on sun gear Fig 153 34 Support output shaft with wood blocks Fig 154 Fig 151 Checking Second Brake Pack Clearance 1 BRAKE PACK 2 FEELER GAUGE Fig 152 Installing Sun Gear And Input Drum 1 SUN GEAR AND INPUT DRUM Fig 153 Installing Front Planetary Gear 1 FRONT PLANETARY GEAR Fig 154 Supporting...

Page 1747: ...hem in place 40 Verify forward direct clutch thrust bearing size Race outer diameter is 48 9 mm 1 925 in and inside diameter is 26 0 mm 1 024 in Bearing outer diameter is 46 7 mm 1 839 in and inside diameter is 26 0 mm 1 024 in 41 Coat front planetary ring gear race with petroleum jelly and install it in ring gear Fig 159 Fig 155 Installing Front Planetary Snap Ring 1 SNAP RING PLIER TOOL 2 FRONT ...

Page 1748: ...ear forward di rect clutch Fig 163 47 Check clearance between sun gear input drum and direct clutch drum Fig 164 Clearance should be 9 8 11 8 mm 0 386 0 465 in If clearance is incorrect planetary gear forward direct clutch assembly is not seated or is improperly assembled Remove and correct if necessary Fig 158 Installing Forward Direct Clutch Thrust Bearing And Race 1 THRUST BEARING 2 RACE 3 FORW...

Page 1749: ... on second coast brake piston cover and install cover in case 52 Install second coast brake piston snap ring with snap ring plier tool Fig 166 53 Check second coast brake piston stroke as fol lows Fig 162 Installing Ring Gear Bearing And Race 1 THRUST BEARING 2 RACE 3 PLANETARY RING GEAR Fig 163 Installing Front Planetary And Forward Direct Clutch Assembly 1 FRONT PLANETARY AND FOWARD DIRECT CLUTC...

Page 1750: ...drive support in case Use two long bolts to help align and guide support into position Fig 170 56 Install overdrive support snap ring with Snap Ring Plier Tool 7540 Fig 171 Chamfered side of snap ring faces up and toward case front Snap ring ends must be aligned with case opening with ring ends approximately 24 mm 0 94 in from center line of case opening 57 Install and tighten overdrive support bo...

Page 1751: ...g Overdrive Support 1 USE LONG BOLTS TO INSTALL SUPPORT 2 OVERDRIVE SUPPORT Fig 171 Installing Overdrive Support Snap Ring 1 SNAP RING TOOL 2 SNAP RING ENDS CENTERED IN CASE OPENING 3 SNAP RING Fig 172 Installing Overdrive Support Bolts 1 OVERDRIVE SUPPORT BOLTS 21 290 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1752: ...led incorrectly Check and correct as neces sary and measure piston stroke again e Remove the dial indicator set up from the transmission 63 Coat overdrive lower race thrust bearing and upper race with petroleum jelly and install them in overdrive support Fig 176 Be sure races and bear ing are assembled and installed as shown 64 Verify bearing race sizes before proceeding Bearing race sizes are Out...

Page 1753: ...nside diameter is 28 9 mm 1 138 in 71 Coat thrust bearing race with petroleum jelly and install it in oil pump Fig 182 Bearing race outer diameter is 47 2 mm 1 858 in and inside diameter is 28 1 mm 1 106 in Fig 176 Installing Overdrive Support Thrust Bearing And Races 1 THRUST BEARING 2 UPPER RACE 3 LOWER RACE Fig 177 Installing Overdrive Planetary Ring Gear 1 OVERDRIVE PLANETARY RING GEAR Fig 178...

Page 1754: ...d rotate smoothly and not bind 76 Lubricate and install new O ring on trans mission throttle cable adapter and install cable in case Fig 183 Fig 180 Installing Overdrive Planetary And Clutch Assembly 1 OVERDRIVE PLANETARY AND CLUTCH ASSEMBLY 2 RING GEAR Fig 181 Installing Input Shaft Thrust Bearing And Race Assembly 1 THRUST BEARING AND RACE ASSEMBLY 2 CLUTCH INPUT SHAFT Fig 182 Installing Oil Pum...

Page 1755: ...spring Fig 186 81 Position valve body on case Fig 187 82 Install detent spring Fig 187 83 Align manual valve detent spring and shift sector Fig 187 84 Connect transmission throttle cable to throttle valve cam Fig 188 85 Install and tighten valve body to case bolts to 10 N m 7 ft lbs torque 86 Connect valve body solenoid wires to solenoids Fig 189 87 Install new O ring on solenoid harness adapter a...

Page 1756: ...ue 92 Install transmission speed sensor rotor and key on output shaft Fig 191 93 Install spacer and speedometer drive gear on output shaft Then install retaining snap ring Fig 192 94 Apply bead of Threebondt Liquid Gasket TB1281 P N 83504038 to sealing surface at rear of case Fig 193 Fig 187 Aligning Manual Valve Shift Sector And Detent Spring 1 DETENT SPRING 2 SHIFT SECTOR 3 VALVE BODY 4 MANUAL V...

Page 1757: ...ift lever fully rearward Then move lever two detent positions forward 100 Mount park neutral position switch on man ual valve shaft and tighten switch adjusting bolt just enough to keep switch from moving Fig 196 101 Install park neutral position switch tabbed washer and retaining nut Fig 196 Tighten nut to Fig 191 Installing Transmission Speed Sensor Rotor And Key 1 SPEED SENSOR ROTOR 2 ROTOR KEY...

Page 1758: ...tal strapping Do this before mounting transmission on jack or moving transmission under vehicle 109 Install lower half of transmission fill tube install upper half after transmission is in vehicle CAUTION The transmission cooler and lines must be reverse flushed if overhaul corrected a malfunc tion that generated sludge metal particles or clutch friction material The torque converter should also b...

Page 1759: ...separate components 5 Remove drive gear and driven gear from pump body Fig 199 Fig 199 Oil Pump Components 1 PUMP SEAL 2 PUMP BODY 3 STATOR SHAFT 4 SEAL RINGS 5 GEAR 6 O RING Fig 198 Checking Converter Installation 1 HOUSING FLANGE 2 CONVERTER MOUNTING PAD 3 STRAIGHTEDGE 4 VERNIER CALIPERS 21 298 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1760: ...ng diameter is greater than specified 3 Measure oil pump clearances Fig 201 Clearance between pump driven gear and pump body should be maximum of 0 3 mm 0 012 in Clearance between tips of pump gear teeth should be maximum of 0 3 mm 0 012 in Clearance between rear surface of pump housing and pump gears should be maximum of 0 1 mm 0 004 in 4 Replace pump body and gears if any clearance is greater th...

Page 1761: ...seal rings on stator shaft 9 Install pump in torque converter and check pump gear rotation Fig 203 Gears must rotate smoothly when turned clockwise and counterclock wise 10 Lubricate pump O ring and seal rings with petroleum jelly Fig 202 Installing Pump Seal 1 SEAL INSTALLER TOOL 2 PUMP SEAL Fig 203 Checking Pump Gear Rotation 1 OIL PUMP 2 TORQUE CONVERTER 21 300 AW 4 AUTOMATIC TRANSMISSION XJ DI...

Page 1762: ...H DRUM 2 CLUTCH PISTON 3 PISTON RETURN SPRING 4 CLUTCH DISCS 5 RETAINER PLATE 6 CLUTCH PACK SNAP RING 7 CLUTCH PLATES 8 PISTON SNAP RING 9 O RINGS 10 ONE WAY CLUTCH 11 CLUTCH DRUM BEARING AND RACE ASSEMBLY 12 PLANETARY GEAR 13 SNAP RING 14 RING GEAR HUB 15 THRUST WASHER 16 BEARING 17 ONE WAY CLUTCH OUTER RACE 18 RETAINING PLATE 19 SNAP RING 20 PLANETARY RING GEAR 21 RACE XJ AW 4 AUTOMATIC TRANSMIS...

Page 1763: ...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 8 Compress piston return spring with Tool 7538 Fig 209 Remove snap ring and remove c...

Page 1764: ...all sealing by applying low pressure compressed air to ball inlet as shown Air should not leak past check ball Fig 207 Removing Clutch Drum Bearing And Race 1 CLUTCH DRUM 2 THRUST BEARING AND RACE Fig 208 Removing Clutch Pack Snap Ring 1 SNAP RING 2 CLUTCH RETAINER Fig 209 Removing Clutch Piston Snap Ring 1 COMPRESSOR TOOL 2 CLUTCH PISTON SNAP RING Fig 210 Removing Overdrive Clutch Piston 1 CLUTCH...

Page 1765: ...ce from ring gear Fig 214 Fig 211 Checking Piston Return Spring Length 1 PISTON RETURN SPRINGS 2 SPRING RETAINER Fig 212 Testing Clutch Piston Check Ball 1 CLUTCH PISTON CHECK BALL 2 USE LOW PRESSURE COMPRESSED AIR TO TEST BALL SEATING Fig 213 Checking Clutch Drum Bushings 1 CLUTCH DRUM Fig 214 Removing Ring Gear Bearing And Race 1 BEARING 2 RACE 3 RING GEAR 21 304 AW 4 AUTOMATIC TRANSMISSION XJ D...

Page 1766: ... and remove retaining plate Fig 217 Fig 215 Removing Ring Gear Hub 1 SNAP RING 2 RING GEAR 3 RING GEAR HUB Fig 216 Remove Planetary Gear Race 1 PLANETARY GEAR 2 RACE Fig 217 Removing Snap Ring And Retaining Plate 1 SNAP RING 2 PLANETARY GEAR 3 RETAINING PLATE XJ AW 4 AUTOMATIC TRANSMISSION 21 305 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1767: ...27 mm 0 4437 in Replace planetary gear if bushing inside diameter is greater then specified Fig 218 Removing One Way Clutch 1 ONE WAY CLUTCH AND OUTER RACE ASSEMBLY 2 PLANETARY GEAR 3 RACE 4 CLUTCH Fig 219 Removing Planetary Thrust Washer 1 THRUST WASHER 2 PLANETARY GEAR Fig 220 Checking Planetary Bushing 1 PLANETARY BUSHING 2 PLANETARY GEAR 21 306 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND AS...

Page 1768: ...of race is 47 8 mm 1 882 in and inside diameter is 24 2 mm 0 953 in Outside diameter of bearing is 46 8 mm 1 843 in and inside diameter is 26 mm 1 024 in 9 Lubricate new clutch piston O rings with Mopart Door Ease or Ru Glyde Then install rings on clutch piston and install piston in clutch drum 10 Install piston return springs in clutch piston Fig 224 11 Install piston snap ring Compress piston re...

Page 1769: ...e tool Fig 225 Installing Clutch Piston Snap Ring 1 PRESS RAM 2 COMPRESSOR TOOL 3 SNAP RING Fig 224 Installing Piston Return Springs 1 RETURN SPRINGS 2 CLUTCH PISTON Fig 226 Installing Overdrive Clutch Discs And Plates 1 CLUTCH DISC 2 STEEL PLATE 3 CLUTCH DRUM Fig 227 Installing Retainer And Snap Ring 1 CLUTCH PACK RETAINER 2 RETAINER SNAP RING 21 308 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND...

Page 1770: ...ke 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 ing and rear race Fig 230 4 Turn overdrive support over and remove bear ing race and clutch drum thrust washer Fig 231 5 Compress piston return spring with Spring Compressor 7537 and remove piston snap ring Fig 232 Fig 228 ...

Page 1771: ...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 Front race outer diameter is 47 8 mm 1 882 in and inside diameter is 30 7 mm 1 209 in Rea...

Page 1772: ... 7 BEARING RACE 8 CLUTCH DRUM THRUST WASHER 9 SUPPORT SEAL RINGS 10 BRAKE PISTON O RINGS 11 PISTON RETURN SPRING Fig 234 Removing Support Seal Rings 1 SEAL RINGS 2 2 SUPPORT Fig 235 Checking Piston Return Spring Length 1 PISTON RETURN SPRINGS 2 SPRING RETAINER XJ AW 4 AUTOMATIC TRANSMISSION 21 311 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1773: ...AL RINGS BEFORE INSTALLATION 2 OVERDRIVE SUPPORT Fig 237 Installing Support Thrust Bearing And Races 1 REAR RACE 2 THRUST BEARING 3 FRONT RACE Fig 238 Separate Direct Clutch From Forward Clutch 1 DIRECT CLUTCH 2 FORWARD CLUTCH Fig 239 Removing Clutch Drum Thrust Washer 1 THRUST WASHER 2 CLUTCH DRUM 21 312 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1774: ...ort Fig 244 Apply compressed air through piston feed hole in support to remove piston Use only enough air to ease piston out 12 Remove and discard clutch piston O rings 13 Measure clutch disc thickness Minimum allowable thickness is 1 84 mm 0 0724 in Replace clutch pack if any disc is below minimum thickness 14 Measure free length of piston return springs with springs in retainer Fig 245 Length sh...

Page 1775: ...ring 1 PRESS RAM 2 COMPRESSOR TOOL 3 SNAP RING PLIERS 4 RETURN SPRING Fig 244 Removing Direct Clutch Piston 1 DIRECT CLUTCH DRUM 2 CLUTCH PISTON 3 OVERDRIVE SUPPORT 4 SUPPORT FEED HOLE Fig 245 Checking Piston Return Spring Length 1 PISTON RETURN SPRINGS 2 SPRING RETAINER Fig 246 Testing Piston Check Ball Seating 1 PISTON CHECK BALL 2 USE LOW PRESSURE AIR TO CHECK SEATING 3 DIRECT CLUTCH PISTON 21 ...

Page 1776: ... snap ring position If necessary shift snap ring until end gap is not aligned with any notches in clutch drum Fig 250 8 Lubricate clutch drum thrust washer with petroleum jelly and install it in drum Fig 240 9 Mount direct clutch assembly on forward clutch assembly and check assembled height Fig 251 Height should be 70 3 to 71 5 mm 2 767 to 2 815 in 10 If assembled height is incorrect clutches are...

Page 1777: ...ER 3 SNAP RING Fig 250 Adjusting Clutch Pack Snap Ring Position 1 CLUTCH PACK SNAP RING 2 DRUM NOTCH 3 SHIFT SNAP RING END GAP AWAY FROM DRUM NOTCHES Fig 251 Checking Direct Clutch Assembled Height 1 DIRECT CLUTCH 2 HEIGHT SHOULD BE 70 3 71 5 mm 2 767 2 815 in 3 FORWARD CLUTCH 21 316 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1778: ...e bearing and race from forward clutch drum Fig 253 4 Install a suitable threaded bolt rod into the side of the overdrive support 5 Mount Miller Tool C 3339 dial indicator compo nents onto the threaded rod as necessary 6 Position dial indicator plunger squarely against clutch piston Fig 252 Forward Clutch Components XJ AW 4 AUTOMATIC TRANSMISSION 21 317 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1779: ... Apply compressed air through feed hole in support to remove piston Fig 256 Use only enough air pressure to ease piston out of drum 16 Remove and discard clutch piston O rings Fig 257 17 Remove clutch drum O ring from rear hub of drum 18 Remove three seal rings from clutch drum shaft Fig 258 19 Remove thrust bearing and race assembly from clutch drum Fig 259 Fig 253 Positioning Drum And Support On...

Page 1780: ...g 257 Removing Installing Clutch Drum O Ring 1 CLUTCH DRUM HUB 2 O RING Fig 258 Removing Clutch Drum Seal Rings 1 SEAL RINGS 2 CLUTCH DRUM SHAFT Fig 259 Removing Clutch Drum Thrust Bearing Assembly 1 THRUST BEARING AND RACE ASSEMBLY XJ AW 4 AUTOMATIC TRANSMISSION 21 319 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1781: ...d ASSEMBLY 1 Lubricate bearing and race assembly with petroleum jelly and install it in clutch drum Fig 263 Race side of assembly faces downward and toward drum Bearing rollers face up Fig 263 2 Coat new clutch drum shaft seal rings with petroleum jelly Before installing drum shaft seal rings squeeze each ring so ring ends overlap Fig 264 This tightens ring making clutch installation easier 3 Inst...

Page 1782: ...stroke length is not within specified limits replace clutch discs 13 Lubricate race and bearing with petroleum jelly and install them in clutch drum Fig 266 Be sure bearing rollers face up and race lip seats in drum as shown 14 Verify bearing and race size Outer diameter of bearing is 46 7 mm 1 839 in Outer diameter of race is 48 9 mm 1 925 in Inner diameter of bearing and race is 26 0 mm 1 024 in...

Page 1783: ...e gear Fig 267 Checking Forward Clutch Assembled Height 1 DIRECT CLUTCH 2 APPROXIMATELY 71 2 mm 2 80 in 3 FORWARD CLUTCH Fig 268 Front Planetary Gear Components 1 FORWARD RACE 2 FRONT PLANETARY RING GEAR 3 FRONT BEARING 4 SNAP RING 5 REAR RACE 6 REAR BEARING 7 FRONT PLANETARY GEAR 8 THRUST RACE 9 FRONT RACE Fig 266 Installing Thrust Bearing And Race 1 THRUST BEARING AND RACE 2 CLUTCH DRUM 21 322 A...

Page 1784: ...er 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 1 878 in Inner diameter is 32 6 1 283 in Outer diameter of forward race is 47 0 mm 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 inst...

Page 1785: ...ve one way clutch second brake hub assembly from drum Fig 273 Fig 272 Checking One Way Clutch Operation 1 SECOND BRAKE HUB 2 SUN GEAR Sun Gear And One Way Clutch Components 1 SNAP RING 2 SUN GEAR 3 SUN GEAR INPUT DRUM 4 THRUST WASHER 5 ONE WAY CLUTCH AND SECOND BRAKE HUB ASSEMBLY 6 SNAP RING 7 SEAL RINGS Fig 273 Removing Installing Brake Hub And Clutch Assembly 1 HUB AND CLUTCH ASSEMBLY 2 DRUM 21 ...

Page 1786: ...ge or inside micrometer Fig 278 Maximum allowable diameter is 27 08 mm 1 0661 in Replace sun gear if bushing inside diameter is greater than specified Fig 274 Removing Installing Thrust Washer 1 THRUST WASHER Fig 275 Removing Installing Sun Gear Seal Rings 1 SEALS RINGS 2 Fig 276 Removing Installing Sun Gear 1 SUN GEAR 2 SNAP RING 3 WOOD BLOCK 4 INPUT DRUM Fig 277 Removing Installing Second Snap R...

Page 1787: ... way clutch second brake hub assembly on sun gear Deep side of hub flange faces upward Fig 279 Fig 279 Installing Clutch And Hub Assembly On Sun Gear 1 CLUTCH AND HUB ASSEMBLY Second Brake Components 1 THRUST WASHER 2 SNAP RING 3 SPRING RETAINER 4 PISTON RETURN SPRINGS 5 REAR PLANETARY OUTPUT SHAFT FIRST REVERSE BRAKE 6 SECOND BRAKE DRUM 7 O RINGS 8 SECOND BRAKE PISTON 9 PISTON SLEEVE Fig 278 Chec...

Page 1788: ...nd brake piston and sleeve from drum with compressed air Fig 283 Use only enough air pressure to ease piston out of drum 6 Remove and discard brake piston O rings 7 Measure free length of piston return springs with springs mounted in retainer Fig 284 Length should be approximately 16 05 mm 0 632 in Replace return springs if length is less than speci fied Fig 280 Removing Installing Second Brake As...

Page 1789: ...Piston should move smoothly when applying releasing air pressure 5 Coat thrust washer with petroleum jelly and install it in drum Be sure washer notches are aligned with tabs on spring retainer Fig 286 Fig 283 Removing Installing Piston And Sleeve 1 PISTON AND SLEEVE 2 DRUM Fig 284 Measuring Second Brake Piston Return Springs 1 PISTON RETURN SPRINGS 2 SPRING RETAINER Fig 285 Checking Second Brake ...

Page 1790: ... 2 SNAP RING 3 NO 2 ONE WAY CLUTCH 4 REAR PLANETARY GEAR 5 REAR THRUST WASHER 6 FRONT THRUST WASHER 7 ONE WAY CLUTCH INNER RACE 8 SNAP RING 9 RING GEAR HUB 10 REAR PLANETARY RING GEAR 11 THRUST BEARING 12 RACES 13 OUTPUT SHAFT 14 SEAL RING XJ AW 4 AUTOMATIC TRANSMISSION 21 329 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1791: ... Race should turn freely counterclockwise but lock when turned clockwise Replace one way clutch if necessary Fig 287 Removing Installing Output Shaft 1 GEAR ASSEMBLY 2 OUTPUT SHAFT Fig 288 Removing Installing Shaft Seal Ring 1 SEAL RING 2 OUTPUT SHAFT Fig 289 Removing Installing First Reverse Brake Pack 1 FIRST REVERSE BRAKE PACK 2 REAR PLANETARY GEAR Fig 290 Removing Installing Rear Planetary 1 R...

Page 1792: ...emove No 2 one way clutch bottom end cap from planetary Fig 291 Checking No 2 One Way Clutch Operation 1 CLUTCH INNER RACE 2 PLANETARY GEAR Fig 292 Removing Installing Clutch Inner Race 1 CLUTCH INNER RACE 2 REAR PLANETARY Fig 293 Removing Installing One Way Clutch 1 CLUTCH SNAP RING 2 NO 2 ONE WAY CLUTCH 3 PLANETARY GEAR XJ AW 4 AUTOMATIC TRANSMISSION 21 331 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1793: ...ns 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 Outer diameter of upper race is 44 8 mm 1 764 in and inner diameter is 28 8 mm 1 134 in 4 Lubricate ring gear thrust bearing and races with petroleum jelly and install them in ring gear Fig 295 Fig 294 Removing Inst...

Page 1794: ...e 11 Install planetary gear in ring 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 TRANSMISSION VALVE BODY The valve body a...

Page 1795: ...INER 7 SLEEVE 8 CLIP 9 PRESSURE REDUCING PLUG 10 NO 3 SOLENOID AND O RING 11 NO 1 SOLENOID AND O RING 12 RETAINER 13 SLEEVE 14 PLUNGER 15 VALVE SPRING 16 WASHER 17 PRIMARY REGULATOR VALVE 18 CHECK VALVE AND BALL 19 LOWER BODY 20 CHECK VALVE 21 1 2 SHIFT VALVE 22 PLUG 21 334 AW 4 AUTOMATIC TRANSMISSION XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1796: ...Fig 299 Upper Body Components XJ AW 4 AUTOMATIC TRANSMISSION 21 335 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1797: ...rom cable mounting bracket on transmission Fig 300 5 Slide cable eyelet off transmission shift lever 6 Verify transmission shift lever is in Park detent by moving lever fully rearward Last rearward detent is Park position 7 Verify positive engagement of transmission park lock by attempting to rotate propeller shaft Shaft will not rotate when park lock is engaged 8 Slide cable eyelt onto transmissi...

Page 1798: ...ut engine off and raise hood 2 Press cable release button Fig 302 3 Push cable conduit back into cable sheath as far as possible Fig 303 4 Rotate lever on throttle body to wide open throttle position Cable will ratchet to correct adjust ment point as lever is rotated Fig 303 Fig 301 Park Lock Cable Attachment 1 PARK LOCK CABLE 2 CABLE LOCK BUTTON 3 SHIFT LEVER ASSEMBLY 4 SHIFT CABLE Fig 302 Thrott...

Page 1799: ...ion Fluid Normal Operating Temperature 50 80 C 122 176 F TPS Input Voltage AU 5 0 Volts approx TPS Output Voltage 4 Cylinder 0 2 Volts approx 6 Cylinder 4 2 Volts approx AW 4 OIL PUMP WEAR LIMITS Drive Gear Tip Clearance Standard 0 11 0 14 mm 0 0043 0 0055 in Maximum Allowance 0 3 mm 0 012 in Gear to Pump Body End Clearance Standard 0 02 0 05 mm 0 0008 0 0020 in Maximum Allowance 0 1 mm 0 004 in D...

Page 1800: ...AW 4 BUSHING AND PISTON CLEARANCE XJ AW 4 AUTOMATIC TRANSMISSION 21 339 SPECIFICATIONS Continued ...

Page 1801: ...AW 4 RETAINER AND PISTON SPECIFICATIONS 21 340 AW 4 AUTOMATIC TRANSMISSION XJ SPECIFICATIONS Continued ...

Page 1802: ...AW 4 VALVE BODY BALL DIMENSIONS AW 4 CLUTCH AND BRAKE PACK REQUIREMENTS XJ AW 4 AUTOMATIC TRANSMISSION 21 341 SPECIFICATIONS Continued ...

Page 1803: ...AW 4 VALVE AND SPRING IDENTIFICATION 21 342 AW 4 AUTOMATIC TRANSMISSION XJ SPECIFICATIONS Continued ...

Page 1804: ...lbs Oil Screen Bolt 9 11 N m 80 96 in lbs Park Pawl Bracket 9 11 N m 80 96 in lbs Propeller Shaft Clamp Screws 16 23N m 140 200 in lbs Rear Mount To Transmission Bolts 60 81N m 44 ft lbs Rear Mount To Clevis Bracket Bolt Nut 54 75 N m 40 55 ft lbs Rear Mount Clevis Bracket To Crossmember Nuts 33 49 N m 24 36 ft lbs Shift Cable Bracket Screws At Transmission 25 39 N m 221 345 in lbs Shift Lever Mou...

Page 1805: ...g Nuts 30 41 N m 22 30 ft lbs Transmission Shift Lever Nut 15 17 N m 134 154 in lbs Transmission To Engine Block Bolts 50 64 N m 37 47 ft lbs Valve Body Bolts to case 9 11 N m 80 96 in lbs Valve Body Bolts to valve body 6 7 N m 54 58 in lbs SPECIAL TOOLS AW 4 C 484 Snap Ring Plier C 3293 SP Gauge C 3339 Dial Indicator Set C 4959 Caliper Metric Vernier C 4960 Micrometer 7536 Puller Oil Pump 7538 Co...

Page 1806: ...nap Ring 7542 Puller Reaction Sleeve 7543 Puller Piston 1 7544 Installer Brake Drum Seal 7549 Installer Seal 7552 Gauge 3 0 mm Wire 7554 Adapter Pressure Port XJ AW 4 AUTOMATIC TRANSMISSION 21 345 SPECIAL TOOLS Continued ...

Page 1807: ...s are for off road use only They are not for use on hard surface roads The only exception being when the road surface is wet or slip pery or covered by ice and snow The low range reduction gear system is operative in 4 Lo range only This range is for extra pulling power in off road situations Low range reduction ratio is 2 72 1 SHIFT MECHANISM Operating ranges are selected with a floor mounted shi...

Page 1808: ... 1 Slow vehicle and shift into desired range 2 If vehicle was operated for an extended period in 4H mode on dry surface driveline torque load may cause difficulty 2 Stop vehicle and shift transfer case to Neutral position Transfer case can then be shifted to the desired mode 3 Transfer case shift linkage binding 3 Repair or replace linkage as necessary 4 Insufficient or incorrect lubricant 4 Drain...

Page 1809: ...e 3 Drain transfer case lubricant 4 Mark front and rear propeller shaft yokes for alignment reference 5 Support transmission with jack stand 6 Remove rear crossmember or skid plate 7 Disconnect front rear propeller shafts at trans fer case 8 Disconnect vehicle speed sensor wires 9 Disconnect transfer case linkage rod from range lever 10 Disconnect transfer case vent hose Fig 3 and indicator switch...

Page 1810: ...ody for proper procedures 6 Remove screws attaching lever assembly to floorpan and remove assembly and shift rod if left attached INSTALLATION 1 If shift rod was not removed from lever assem bly work rod down through floorpan opening Then position lever assembly on floorpan and install assembly attaching screws 2 Install console Refer to Group 23 Body for proper procedures 3 Raise vehicle 4 Connec...

Page 1811: ... 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 6 These numbers will correspond to number of teeth on pinion 8 Install speed...

Page 1812: ... adapter 2 Spread band clamp which holds output shaft boot to slinger with a suitable awl or equivalent 3 Remove output shaft boot from slinger and out put shaft 4 Using Puller MD 998056 A remove rear slinger Fig 9 5 Use a suitable pry tool or a slide hammer mounted screw to remove the seal from the rear retainer Fig 10 6 Remove the rear output bearing I D retaining ring Fig 11 7 Remove the bolts ...

Page 1813: ...Fig 13 12 Remove pick up tube o ring from oil pump Fig 14 if necessary Do not disassemble the oil pump it is not serviceable Fig 9 Rear Slinger Removal 1 TRANSFER CASE 2 SPECIAL TOOL MD998056 A 3 SLINGER Fig 10 Rear Retainer Seal 1 REAR RETAINER 2 OUTPUT SHAFT SEAL Fig 11 Output Shaft Rear Bearing Retaining Ring 1 REAR RETAINER 2 OUTPUT SHAFT SEAL Fig 12 Rear Retainer Removal 1 MAINSHAFT 2 REAR RE...

Page 1814: ...n yoke and not on slinger as slinger will be damaged 4 Remove seal washer from front output shaft Discard washer as it should not be reused 5 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft Fig 17 Fig 14 Pick up Tube O ring Location 1 OIL PUMP 2 O RING Fig 15 Yoke Nut Removal 1 IMPACT WRENCH 2 SOCKET 3 YOKE Fig 16...

Page 1815: ...t case 5 Remove oil pickup tube from rear case Fig 20 6 Remove mode fork spring Fig 21 7 Pull front output shaft upward and out of front output shaft bearing Fig 22 8 Remove front output shaft and chain Fig 18 Rear Case Alignment Bolt Locations 1 DOWEL BOLT AND WASHER 2 2 CASE BOLT 5 3 SPLINE HEAD BOLT 1 Fig 19 Loosening Rear Case 1 REAR CASE 2 PRY TOOL IN CASE SLOT 3 FRONT CASE Fig 20 Oil Pickup ...

Page 1816: ... assembly Fig 25 Note fork position for installation reference 5 Remove shift sector from front case Fig 26 6 Remove shift sector bushing and O ring Fig 27 Fig 22 Remove Front Output Shaft And Chain 1 DRIVE CHAIN 2 FRONT OUTPUT SHAFT 3 SHAFT FRONT BEARING Fig 23 Detent Plug Spring And Plunger Removal 1 POPPET 2 SPRING 3 SCREW 4 POPPET BORE IN CASE Fig 24 Mode Fork And Sleeve Removal 1 MODE SLEEVE ...

Page 1817: ...nshaft Fig 30 Fig 26 Shift Sector Removal 1 SHIFT SECTOR Fig 27 Sector Bushing And O Ring Removal 1 SEAL RETAINER 2 SECTOR SHAFT BORE 3 O RING SEAL Fig 28 Mode Hub Retaining Ring Removal 1 MODE HUB 2 SNAP RING PLIERS HEAVY DUTY 3 MODE HUB RETAINING RING Fig 29 Mode Hub Removal 1 MAINSHAFT 2 MODE HUB 21 356 NV231 TRANSFER CASE XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1818: ...Remove input gear retaining ring with heavy duty snap ring pliers Fig 33 Fig 30 Drive Sprocket Removal 1 DRIVE SPROCKET 2 MAINSHAFT Fig 31 Front Bearing Retainer Bolts 1 FRONT CASE 2 FRONT BEARING RETAINER 3 RETAINER BOLTS Fig 32 Front Bearing Retainer Removal 1 FRONT BEARING RETAINER 2 RETAINER SLOT Fig 33 Removing Input Gear Retaining Ring 1 INPUT GEAR BEARING RETAINING RING 2 INPUT GEAR BEARING...

Page 1819: ... thrust washer Fig 37 4 Remove input gear Fig 38 5 Remove rear tabbed thrust washer from low range gear Fig 39 Fig 34 Input Gear And Planetary Carrier Removal 1 PLANETARY ASSEMBLY 2 INPUT GEAR Fig 35 Input Gear Snap Ring Removal 1 CARRIER LOCK RETAINING RING 2 INPUT GEAR 3 PLANETARY CARRIER 4 SCREWDRIVER Fig 36 Input Gear Retainer Removal 1 INPUT GEAR 2 LOW RANGE GEAR 3 RETAINER Fig 37 Front Tabbe...

Page 1820: ...se with pry tool Fig 40 2 Remove the front output shaft bearing retain ing ring with screwdriver Fig 41 3 Remove bearing with Tool Handle C 4171 and Tool 5065 Fig 42 Fig 38 Input Gear Removal 1 INPUT GEAR 2 LOW RANGE GEAR Fig 39 Rear Tabbed Thrust Washer Removal 1 LOW RANGE GEAR 2 REAR TABBED THRUST WASHER Fig 40 Front Output Seal Removal 1 OUTPUT SHAFT SEAL 2 PRYBAR Fig 41 Front Output Shaft Bear...

Page 1821: ...nstaller tool bottoms against case 7 Remove the output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 46 8 Install new bearing with Tool Handle C 4171 and Installer 5066 Fig 47 The bearing bore is chamfered at the top Install the bearing so it is flush with the lower edge of this chamfer Fig 48 Fig 42 Front Output Shaft Bearing Removal 1 FRONT CASE 2 SPECIAL TOOL C...

Page 1822: ...nto the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 51 14 Install new pilot bearing with Installer 5065 and Handle C 4171 Fig 52 Fig 46 Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 47 Output Shaft Rear Bearing Installation 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 Fig 48 ...

Page 1823: ... pry tool Fig 50 Seating Input Shaft Bearing 1 SNAP RING 2 INPUT SHAFT BEARING Fig 51 Remove Input Gear Pilot Bearing 1 DRIFT 2 INPUT GEAR Fig 52 Install Input Gear Pilot Bearing 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 5065 3 INPUT GEAR Fig 53 Install Front Bearing Retainer Seal 1 FRONT BEARING RETAINER 2 SPECIAL TOOL 7884 21 362 NV231 TRANSFER CASE XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1824: ...ged in annulus gear and that input gear shaft is fully seated in front bearing 2 Install snap ring to hold input low range gear into front bearing Fig 58 3 Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage 4 Apply a 3 mm 1 8 in bead of Mopart gasket maker or silicone adhesive to sealing surface of retainer 5 Align cavity in seal retainer with fluid return ho...

Page 1825: ...g 62 Tighten range lever nut to 27 34 N m 20 25 ft lbs torque 4 Assemble and install range fork and hub Fig 63 Be sure hub is properly seated in low range gear and engaged to the input gear 5 Align and insert range fork pin in shift sector slot 6 Install assembled mainshaft Fig 64 Be sure shaft is seated in pilot bearing and input gear 7 Install new pads on mode fork if necessary Fig 57 Input Low ...

Page 1826: ... 13 Install detent plunger spring and plug Fig 67 14 Verify that plunger is properly engaged in sec tor FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION 1 Lubricate front output shaft sprocket assembly drive chain and drive sprocket with transmission fluid Fig 61 Shift Sector Installation 1 SHIFT SECTOR Fig 62 Range Lever Installation 1 RANGE LEVER 2 LEVER NUT Fig 63 Install Range Fork And Hub Asse...

Page 1827: ...n oil pump inlet 5 Position assembled oil pump and pickup tube in rear case Be sure pickup screen is securely seated in case slot Also be sure oil pump locating tabs are outside rear case Fig 72 6 Apply 3 mm 1 8 in wide bead of Mopart gas ket maker or silicone adhesive sealer to mounting Fig 66 Mode Fork And Sleeve Installation 1 MODE SLEEVE 2 MODE FORK AND RAIL Fig 67 Shift Detent Components 1 PO...

Page 1828: ...ion fluid and install yoke on front shaft 5 Install new seal washer on front shaft 6 Install yoke and new yoke nut on front output shaft Fig 75 7 Tighten yoke nut to 122 176 N m 90 130 ft lbs torque Use Tool C 3281 or similar tool to hold yoke while tightening yoke nut REAR RETAINER INSTALLATION 1 Apply bead of Mopart Sealer P N 82300234 or Loctitey Ultra Gray to mating surface of rear retainer Se...

Page 1829: ...nd Handle MD 998323 Fig 78 7 Install rear slinger with Installer 8408 8 Install boot on output shaft slinger and crimp retaining clamp with tool C 4975 A Fig 79 Fig 74 Range Lever Installation 1 RANGE LEVER 2 WASHER 3 LOCKNUT Fig 75 Output Shaft Yoke Installation 1 OUTPUT SHAFT YOKE 2 YOKE NUT Fig 76 Yoke Seal Washer Installation 1 YOKE SEAL WASHER Fig 77 Output Shaft Seal and Protector 1 OUTPUT S...

Page 1830: ...s 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 INPUT GEAR AND PLANETARY CARRIER Check the teeth on the gear Fig 81 Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken cracked or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery cloth if necessary Exam...

Page 1831: ...specially on the interior teeth Replace the sleeves if wear or damage is evident REAR RETAINER BEARING SEAL SLINGER BOOT Inspect the retainer components Fig 84 Replace the bearing if rough or noisy Check the retainer for Fig 83 Shift Fork And Wear Pad Locations 1 RANGE FORK 2 MODE FORK 3 WEAR PADS SERVICEABLE 4 WEAR PADS NON SERVICEABLE Fig 81 Input Gear And Carrier Components 1 PLANETARY CARRIER ...

Page 1832: ... any sprocket teeth are cracked or broken Examine the drive chain and shaft bearings Replace the chain and both sprockets if the chain is stretched distorted or if any of the links bind Replace the bearings if rough or noisy LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully The gear is only serviced as part of the front case If the gear is damaged it will be necessary to replace the ...

Page 1833: ...vailable separately 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 7 Lower vehicle Fig 85 Seal Contact S...

Page 1834: ... 20 25 ft lbs 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 Puller Slinger MD 998056 A Installer MD 998323 Seal Protector 6992 Installer Boot Clamp C 4975 A Installer Seal 8143 Handle Universal C 4171 XJ NV23...

Page 1835: ... Installer Bearing 5064 Installer Bearing 5065 Installer Bushing 5066 Installer Bearing 8128 Remover L 4454 Cup 8148 Installer Seal 7884 Installer Pump Housing Seal 7888 21 374 NV231 TRANSFER CASE XJ SPECIAL TOOLS Continued ...

Page 1836: ...vides a 2 72 1 reduction ratio The input gear is splined to the transmission out put shaft It drives the mainshaft through the plan etary gear and range hub The front output shaft is operated by a drive chain that connects the shaft to a drive sprocket on the mainshaft The drive sprocket is engaged disengaged by the mode fork which oper ates the mode sleeve and hub The sleeve and hub are not equip...

Page 1837: ...m edge of the fill plug hole Be sure the vehicle is level to ensure an accurate fluid level check DIAGNOSIS AND TESTING NV242 DIAGNOSIS DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION Transfer case difficult to shift or will not shift into desired range 1 Transfer case shift linkage binding 1 Repair or replace linkage as necessary 2 Insufficient or incorrect lubricant 2 Drain and refill transf...

Page 1838: ...ansfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmission shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m 26 ft lbs torque Fig 4 6 Connect vehicle speed sensor wires and vent hose 7 Connect indicator switch harness to transfer case switch i...

Page 1839: ...3 Remove adapter clamp and screw Fig 6 4 Remove speed sensor and speedometer adapter as an assembly 5 Remove speed sensor retaining screw and remove sensor from adapter 6 Remove speedometer pinion from adapter Replace pinion if chipped cracked or worn 7 Inspect sensor and adapter O rings Fig 6 Remove and discard O rings if worn or damaged 8 Inspect terminal pins in speed sensor Clean pins with Mop...

Page 1840: ...on 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers 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 ing screw Tighten clamp screw to 10 12 N m 90 110 in lbs torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if...

Page 1841: ...DISASSEMBLY AND ASSEMBLY 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 2 Using puller MD 998056 A remove rear slinger Fig 11 Fig 8 Remove Front Output Shaft Seal 1 OUTPUT SHAFT SEAL 2 PRYBAR Fig 9 Front Output Seal Installation 1 INSTALLER 6952 A 2 TRANSFER CASE Fi...

Page 1842: ... out put shaft Fig 15 9 Remove pickup tube O ring from pump Fig 16 but do not disassemble pump it is not a repair able part 10 Remove seal from oil pump with pry tool 11 Remove bolts attaching rear case to front case Fig 17 Note position of the two black finish bolts Fig 12 Rear Seal Removal 1 REAR RETAINER 2 OUTPUT SHAFT SEAL Fig 13 Rear Bearing I D Retaining Ring Removal 1 SNAP RING PLIERS 2 REA...

Page 1843: ...to 4L position b Remove nut with socket and impact wrench Fig 20 2 Remove yoke If yoke is difficult to remove by hand remove it with bearing splitter or with stan dard two jaw puller Fig 21 Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged Fig 17 Spline And Dowel Bolt Locations 1 DOWEL BOLT AND WASHER 2 2 CASE BOLT 5 3 SPLINE HEAD BOLT 1 Fig 18 Loosening Remov...

Page 1844: ...ve seal plug from low range fork lockpin access hole Then move shift sector to align low range fork lockpin with access hole 3 Remove range fork lockpin with size number one easy out tool as follows a Insert easy out tool through access hole in side of transfer case and into lock pin b Tap easy out tool into lock pin with hammer until tool is securely engaged into the lock pin Fig 21 Yoke Removal ...

Page 1845: ...emove mode fork and mainshaft as assembly Fig 28 6 Remove mode shift sleeve and mode fork assembly from mainshaft Fig 29 Note position of mode sleeve in fork and remove sleeve Fig 25 Removing Front Output Shaft 1 FRONT OUTPUT SHAFT Fig 26 Detent Component Removal 1 PLUNGER 2 O RING 3 PLUG 4 SPRING Fig 27 Shift Rail Removal 1 SHIFT RAIL 2 MODE FORK Fig 28 Mode Fork And Mainshaft Removal 1 MAINSHAFT...

Page 1846: ...lutch shaft Fig 32 Fig 29 Mode Fork And Sleeve Removal 1 MAINSHAFT 2 SLEEVE 3 MODE FORK ASSEMBLY Fig 30 Intermediate Clutch Shaft Snap Ring Removal 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT Fig 31 Clutch Shaft Thrust Ring Removal 1 CLUTCH SHAFT THRUST RING XJ NV242 TRANSFER CASE 21 385 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1847: ... slot Fig 35 14 Remove low range fork and hub Fig 36 15 Remove shift sector Fig 37 Fig 32 Intermediate Clutch Shaft Removal 1 INTERMEDIATE CLUTCH SHAFT Fig 33 Differential Snap Ring Removal 1 DIFFERENTIAL SNAP RING Fig 34 Differential Removal 1 DIFFERENTIAL 2 MAINSHAFT Fig 35 Disengaging Low Range Fork 1 SHIFT SECTOR 2 LOW RANGE FORK 3 PIN 4 SLOT 21 386 NV242 TRANSFER CASE XJ DISASSEMBLY AND ASSEM...

Page 1848: ...n screwdriver in slots cast into retainer 3 Remove input gear snap ring Fig 40 Fig 36 Low Range Fork And Hub Removal 1 LOW RANGE FORK 2 FORK HUB Fig 37 Shift Sector Position 1 SHIFT SECTOR 2 LOW RANGE FORK 3 PIN 4 SLOT Fig 38 Sector Bushing And O Ring Removal 1 SHIFT SECTOR BUSHING 2 O RING Fig 39 Front Bearing Retainer Removal 1 FRONT BEARING RETAINER 2 RETAINER SLOT XJ NV242 TRANSFER CASE 21 387...

Page 1849: ...t case as assembly 8 Remove oil seals from following components front bearing retainer rear retainer oil pump case halves Fig 40 Input Gear Snap Ring Removal 1 INPUT GEAR 2 SNAP RING Fig 41 Input And Low Range Gear Assembly Removal 1 INPUT LOW RANGE GEARS 2 SPECIAL TOOL 7829A 3 SPECIAL TOOL C 4171 Fig 42 Low Range Gear Snap Ring Removal Installation 1 LOW RANGE GEAR SNAP RING Fig 43 Low Range Gear...

Page 1850: ...em ASSEMBLY Lubricate transfer case components with automatic transmission fluid or petroleum jelly where indi cated during assembly CAUTION The bearing bores in various transfer case components contain oil feed holes Make sure replacement bearings do not block the holes Fig 45 Separating Differential Case Halves 1 TOP CASE 2 CASE BOLTS 3 CASE BOLTS 4 CASE SLOTS 5 CASE BOLTS Fig 44 Inspecting Low ...

Page 1851: ... Remove front output shaft seal using an appro priate pry tool Fig 50 or slide hammer mounted screw 5 Install new front output shaft oil seal with Installer 6952 A Fig 51 Fig 48 Front Output Shaft Front Bearing Snap Ring Removal 1 FRONT BEARING SNAP RING Fig 47 Mainshaft And Sprocket Gear Removal 1 MAINSHAFT GEAR 2 SPROCKET GEAR 3 BOTTOM CASE Fig 49 Front Output Shaft Front Bearing Installation 1 ...

Page 1852: ... drift and a hammer Fig 54 10 Install new pilot bearing with Installer 8128 and Handle C 4171 Fig 55 11 Install new seal in front bearing retainer with Installer 7884 Fig 56 12 Remove output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 57 Fig 51 Install Front Output Shaft Seal 1 INSTALLER 6952 A 2 TRANSFER CASE Fig 52 Input Gear Bearing Removal 1 SPECIAL TOOL C 4...

Page 1853: ...1 HANDLE C 4171 2 INSTALLER 8128 3 INPUT GEAR Fig 56 Front Bearing Retainer Seal Installation 1 FRONT BEARING RETAINER 2 SPECIAL TOOL 7884 Fig 57 Remove Front Output Shaft Rear Bearing 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 Fig 58 Install Front Output Shaft Rear Bearing 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 21 392 NV242 TRANSFER CASE XJ DISASSE...

Page 1854: ... using scribe marks made at disassembly 6 While holding differential case halves together invert the differential and start the differential case bolts 7 Tighten differential case bolts to specified torque INPUT GEAR LOW RANGE ASSEMBLY 1 Assemble low range gear input gear thrust washers input gear and input gear retainer Fig 64 2 Install low range gear snap ring Fig 65 Fig 59 Oil Pump Seal Install...

Page 1855: ... Differential Case Assembly 1 TOP CASE 2 BOTTOM CASE 3 CASE ALIGNMENT MARKS Fig 64 Low Range And Input Gear Assembly 1 THRUST WASHERS 2 LOW RANGE GEAR 3 INPUT GEAR 4 RETAINER Fig 65 Install Low Range Gear Snap Ring 1 LOW RANGE GEAR SNAP RING 21 394 NV242 TRANSFER CASE XJ DISASSEMBLY AND ASSEMBLY Continued ...

Page 1856: ...iner bolts to 16 ft lbs 21 N m torque SHIFT FORKS AND MAINSHAFT INSTALLATION 1 Install new sector shaft O ring and bushing Fig 68 2 Install shift sector 3 Install new pads on low range fork if neces sary Fig 69 4 Assemble low range fork and hub Fig 69 Fig 67 Installing Front Bearing Retainer 1 FRONT BEARING RETAINER Fig 69 Assembling Low Range Fork And Hub 1 LOW RANGE FORK 2 PADS 3 HUB Fig 66 Inpu...

Page 1857: ...rential 10 Install differential snap ring Fig 73 11 Install intermediate clutch shaft Fig 74 12 Install clutch shaft thrust washer Fig 75 13 Install clutch shaft snap ring Fig 76 14 Inspect mode fork assembly Fig 77 Replace pads and bushing if necessary Replace fork tube if bushings inside tube are worn or damaged Also check springs and slider bracket Fig 77 Replace worn damaged components Fig 70 ...

Page 1858: ...alling Intermediate Clutch Shaft 1 INTERMEDIATE CLUTCH SHAFT Fig 75 Installing Clutch Shaft Thrust Washer 1 CLUTCH SHAFT THRUST RING Fig 76 Installing Clutch Shaft Snap Ring 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT XJ NV242 TRANSFER CASE 21 397 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1859: ...red on one end Insert tapered end into fork and rail 21 Insert lockpin through access hole and into shift fork Fig 81 Then remove easy out and seat the pin with pin punch 22 Install plug in lockpin access hole 23 Install detent plunger detent spring and detent plug in case Fig 82 FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION 1 Install front output shaft Fig 83 2 Install drive chain Fig 83 Engage...

Page 1860: ... 80 Shift Rail Installation 1 SHIFT RAIL 2 MODE FORK Fig 81 Installing Low Range Fork Lockpin 1 LOW RANGE FORK LOCK PIN 2 ACCESS HOLE 3 EASY OUT Fig 82 Detent Pin Spring And Plug Installation 1 PLUNGER 2 O RING 3 PLUG 4 SPRING XJ NV242 TRANSFER CASE 21 399 DISASSEMBLY AND ASSEMBLY Continued ...

Page 1861: ...ated in case slot as shown 2 Install magnet in front case pocket Fig 86 Fig 83 Drive Chain And Sprocket Installation 1 FRONT OUTPUT SHAFT 2 DRIVE CHAIN 3 DRIVE SPROCKET Fig 84 Drive Sprocket Snap Ring Installation 1 DRIVE SPROCKET 2 DRIVE SPROCKET SNAP RING Fig 85 Oil Screen And Pickup Tube Installation 1 OIL PUMP 2 OIL SCREEN 3 CONNECTOR 4 PICKUP TUBE Fig 86 Installing Case Magnet 1 MAGNET 21 400...

Page 1862: ...Apply liberal quantity of petroleum jelly to new rear seal and to output shaft Petroleum jelly is needed to protect seal lips during installation 8 Slide seal onto Seal Protector 6992 Fig 89 Slide seal protector and seal onto output shaft 9 Slide Installer C 4076 B onto seal protector with the recessed side of the tool toward the seal Drive seal into rear bearing retainer with Installer C 4076 B a...

Page 1863: ...eplace them if necessary Also replace the lock retaining ring if bent distorted or broken 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 ...

Page 1864: ...ses and retainer for wear and dam age Clean the sealing surfaces with a scraper and all purpose cleaner This will ensure proper sealer adhe sion at assembly Replace the input retainer seal do not reuse it Check case condition If leaks were a problem look for gouges and severe scoring of case sealing sur faces Also make sure the front case mounting studs are in good condition Check the front case m...

Page 1865: ...6 REAR SLINGER 7 REAR BEARING O D RETAINING RING 8 REAR BEARING Fig 95 Seal Contact Surface Of Yoke Slinger 1 FRONT SLINGER PART OF YOKE 2 SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH Fig 96 Low Range Annulus Gear 1 FRONT CASE 2 LOW RANGE ANNULUS GEAR 21 404 NV242 TRANSFER CASE XJ CLEANING AND INSPECTION Continued ...

Page 1866: ...hten adjusting trunnion lock bolt 7 Lower vehicle SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug Detent 16 24 N m 12 18 ft lbs Bolt Diff Case 17 27 N m 15 24 ft lbs Plug Drain Fill 20 25 N m 15 25 ft lbs Bolt Front Brg Retainer 16 27 N m 12 20 ft lbs Bolt Case Half 35 46 N m 26 34 ft lbs Nut Front Yoke 122 176 N m 90 130 ft lbs Screw Oil Pump 1 2 1 8 N m 12 15 in lbs Nut Range Lever 27 34 N m 20 25...

Page 1867: ...LS NV242 Installer C 4076 B Handle Universal C 4171 Remover C 4210 Puller Slinger MD 998056 A Installer MD 998323 Installer Bearing 5064 Installer 8128 Installer 5066 Installer 6952 A 21 406 NV242 TRANSFER CASE XJ ...

Page 1868: ...148 Seal Protector 6992 Installer Input Gear Bearing 7829 A Installer Seal 7884 Installer Pump Housing Seal 7888 Installer Bearing 8033 A Installer Boot Clamp C 4975 A XJ NV242 TRANSFER CASE 21 407 SPECIAL TOOLS Continued ...

Page 1869: ......

Page 1870: ...n fluid Fig 1 5 Remove exhaust pipe and heat shield 6 Mark the front and rear propeller shafts for installation alignment Fig 2 7 Remove the front propeller shaft 8 Remove the rear propeller shaft 9 Remove the transmission skid plate 10 Disconnect the transfer case linkage and vehi cle speed sensor electrical connector and vent tube hose Fig 3 11 Support the engine with an adjustable jack stand 12...

Page 1871: ...bolts Tighten the bolts to 58 3 N m 8 Raise the engine and transmission with the adjustable jackstand 9 Install the transfer case assembly Refer to Transfer Case installation later in this Group 10 Install the rear crossmember 11 Install the rear transmission mount 12 Connect the transfer case linkage and vehicle speed sensor electrical connector and vent tube Fig 3 13 Install the transmission ski...

Page 1872: ...Fig 5 Transmission to Engine Mounting 1 ENGINE BLOCK 2 FLYWHEEL 3 CLUTCH HOUSING AND TRANSMISSION 4 CLUTCH COVER 5 CLUTCH DISC XJ TRANSMISSION AND TRANSFER CASE 21 3 SPECIFICATIONS Continued ...

Page 1873: ...ft lbs Clutch Housing to Transmission bolts 38 0 N m 28 ft lbs Transfer Case to Transmission Attaching Nuts 35 N m 26 ft lbs Propeller Shaft Bolts 26 5 N m 19 5 ft lbs Fig 6 Clutch Housing to Transmission 1 TRANSMISSION 2 CLUTCH HOUSING 3 CLUTCH HOUSING BOLT 4 RELEASE BEARING 5 RELEASE FORK 6 PIVOT Fig 7 Fill Plug Location 1 GEAR CASE 2 FILL PLUG 21 4 TRANSMISSION AND TRANSFER CASE XJ SPECIFICATIO...

Page 1874: ...ure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmission shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m Fig 1 6 Connect vehicle speed sensor wires and vent hose 7 Connect indicator switch harness to transfer case switch if necessary Secure wire harness to clips on transfer case...

Page 1875: ......

Page 1876: ...effect on tire life than any other factor Careful drivers will obtain in most cases much greater mileage than severe use or care less drivers A few of the driving habits which will shorten the life of any tire are Rapid acceleration Severe brake applications High speed driving Excessive speeds on turns Striking curbs and other obstacles Radial ply tires are more prone to irregular tread wear It is...

Page 1877: ... wheel speed signals when the vehicle is equipped with Anti Lock Brakes The use of tires from different manufactures on the same vehicle is NOT recommended The proper tire pressure should be maintained on all four tires 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 reinsta...

Page 1878: ...lation pressure recommendations REPLACEMENT TIRES DESCRIPTION The original equipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Traction Rolling resistance Speed capability It is recommended that tires equivalent to the orig inal equipment tires be used when replacement is needed Failure to use equivalent replacement tires may adversel...

Page 1879: ...de all the tire longevity benefits MATCH MOUNTING Tires and wheels are currently match mounted at the factory Match mounting is a technique used to reduce runout in the wheel tire assembly This means that the high spot of the tire is aligned with the low spot on the wheel rim The high spot on the tire is marked with a paint mark or a bright colored adhe sive label on the outboard sidewall The low ...

Page 1880: ... tire b If the high spot is within 101 6 mm 4 0 in of the first spot on the wheel the wheel may be out of specifications Refer to Wheel and Tire Runout c If the high spot is NOT within 101 6 mm 4 0 in of either high spot draw an arrow on the tread from second high spot to first Break down the tire and remount it 90 degrees on rim in that direction Fig 10 This procedure will normally reduce the run...

Page 1881: ...fore delivery of a vehicle This coating may cause deteri oration of the tires To remove the protective coating apply warm water and let it soak for a few minutes Afterwards scrub the coating away with a soft bristle brush Steam cleaning may also be used to remove the coat ing NOTE DO NOT use gasoline mineral oil oil based solvent or a wire brush for cleaning SPECIFICATIONS TIRE SIZE Fig 10 Remount...

Page 1882: ...nuts with an enlarged nose This enlarged nose is necessary to ensure proper retention of the wheels Do not use replacement studs or nuts with a different design or lesser quality DIAGNOSIS AND TESTING WHEEL INSPECTION Inspect wheels for Excessive run out Dents or cracks Damaged wheel lug nut holes Air Leaks from any area or surface of the rim NOTE Do not attempt to repair a wheel by ham mering hea...

Page 1883: ... Fig 4 STEEL WHEELS Radial runout 0 040 in Lat eral runout 0 045 in maximum ALUMINUM WHEELS Radial runout 0 030 in Lateral runout 0 035 in maximum 3 If point of greatest wheel lateral runout is near original chalk mark remount tire 180 degrees Recheck runout Refer to match mounting procedure SERVICE PROCEDURES WHEEL INSTALLATION The wheel studs and nuts are designed for specific applications They ...

Page 1884: ...nt cone mounting method for steel wheels For aluminum wheel use back cone mounting method without cone spring NOTE Static should be used only when a two plane balancer is not available NOTE Cast aluminum and forged aluminum wheels require coated balance weights and special align ment equipment Wheel balancing can be accomplished with either on or off vehicle equipment When using on vehicle balanci...

Page 1885: ...WEIGHTS HERE 4 CORRECTIVE WEIGHT LOCATION 5 TIRE OR WHEEL TRAMP OR WHEEL HOP Fig 7 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 2 ADD BALANCE WEIGHTS HERE 3 CORRECTIVE WEIGHT LOCATION 4 HEAVY SPOT WHEEL SHIMMY AND VIBRATION 22 10 TIRES AND WHEELS XJ SERVICE PROCEDURES Continued ...

Page 1886: ...SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Lug Nut 1 2 X 20 with 60 Cone 115 150 N m 85 115 ft lbs XJ TIRES AND WHEELS 22 11 ...

Page 1887: ......

Page 1888: ...es of glass with a plastic inner layer Windshields and other stationary glass protect the occupants from the effects of the elements Windshields are also used to retain some airbags in position during deployment Urethane bonded glass is difficult to salvage during removal The urethane bonding is difficult to cut or clean from any surface Before removing the glass check the availability of replacem...

Page 1889: ...l is repairable and adjustable for fit and finish Welded component systems are adjustable as a system Trim components made of composite are stamped with the type of material used DaimlerChrysler uses various fasteners to retain trim items At times it is not pos sible to remove trim items without damaging the fas tener If it is not possible to remove an item without damaging a component cut or brea...

Page 1890: ... result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result Do not hammer or pound on plastic trim panel when servicing interior trim Plastic panels can break DaimlerChrysler Corporation uses many different types of push in fasteners to secure the interior and exterior trim to the body Most of these fasteners can be reused to a...

Page 1891: ...e clear coat finish if equipped Base coat paint must retain clear coat for durability PAINTED SURFACE TOUCH UP DESCRIPTION When a painted metal surface has been scratched or chipped it should be touched up as soon as possi ble to avoid corrosion For best results use Mopart Scratch Filler Primer Touch Up Paints and Clear Top Coat Refer to Introduction group of this manual for Body Code Plate inform...

Page 1892: ... 7MR8B Intense Blue Pearl Coat VB3 5357 B9822 54468 CHA98 VB3 55321 HMR9B Desert Sand WTD 5474 B9884 56153 CHA99 WTD 81764 KGC7B Deep Amethyst Pearl Coat TCN 5246 B9736 52026 CHA97 TCN 54755 FNE4B Black Clear Coat DX8 9700 99 34858 CHA85 DX8 73328 TC60B Gunmetal Pearl Coat TQ7 5248 B9735 52952 CHA97 TQ7 73320 ERA9B Stone White Clear Coat SW1 83542 B9622 51539 CHA96 SW1 15069 8KY5B INTERIOR COLOR I...

Page 1893: ...D PROTECTION WHEN WORKING WITH GLASS CAUTION Protect all painted and trimmed surfaces from coming in contact with urethane or primers Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield OPERATION The windshield is attached to the window frame with urethane adhesive The urethane adhesive is applied cold and seals the surface area between the window...

Page 1894: ...langes 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 CAUTION Avoid spilling or dripping primer on painted surfaces C...

Page 1895: ... vented pressure in the interior of the vehicle may interfere with proper glass bonding 20 Install the rearview mirror INSTALLATION EXTENDED METHOD WARNING REVIEW ALL WARNINGS AND CAU TIONS IN THIS GROUP BEFORE PRECEDING WITH INSTALLATION 1 Remove the all of urethane from all pinchweld flanges Fig 2 Work Surface Set up 1 WINDSHIELD AND MOLDINGS 2 BLOCKS Fig 3 Masking Tape Location For Blackout Pri...

Page 1896: ...he inside of glass Thoroughly mix and apply blackout primer to the 16 mm 5 8 in surface area around the interior side of the glass Fig 4 Allow the primer to dry for at least 10 12 min utes 9 Apply a small amount of adhesive to the bot tom support spacers and attach the support spacers to the bottom of the windshield 170 mm inboard from the outer windshield edge Fig 5 10 Cut the urethane applicator...

Page 1897: ...ad of sealant to the window channel in the weatherstrip seal 3 Install the weatherstrip on the window glass Install the seal installation cord in the window open ing flange channel Fig 9 as follows Moisten a length of 6 mm 1 4 in diameter cord with a soap and water solution Ensure that the cord is long enough to go all the way around the perimeter of the weatherstrip Insert the cord into the windo...

Page 1898: ... 0 1 in level base of ure thane on the flanges 2 Starting in the corners press reveal molding onto glass 3 Place replacement glass into liftgate opening and position glass in the center of the opening against flange 4 Verify the glass lays evenly against the fence at the sides top and bottom If not the flange must be formed to the shape of the new glass 5 Using a grease pencil or equivalent make r...

Page 1899: ... border 12 Position glass into liftgate opening and refer ence marks 13 Push the glass inward until the reveal mold ing is seated onto the liftgate frame Use care to avoid excessive squeeze out of adhesive 14 Open windows to prevent pressure build up while the urethane is curing 15 Apply 150 mm 6 in lengths of 50 mm 2 in masking tape spaced 250 mm 10 in apart to hold glass in place until urethane ...

Page 1900: ...ability of replacement parts before servicing 1 Raise head restraint to the full up position 2 Turn head restraint lock thumbwheel to release head restraint and pull head restraint upward to remove from seat back 3 Insert head restraint sleeve extractor special tool 6773 Fig 1 and Fig 2 into the seat back 4 The retaining tabs are positioned on each side of the sleeve when inserting the extractor e...

Page 1901: ...raint cush ion and roll the cover downward 2 Position the adjuster bar in the head restraint 3 Install the screws attaching the bezel and adjuster bar to the head restraint 4 Install head restraint in the bucket seat Fig 2 Head Restraint Sleeve Extractor Installation 1 SEAT BACK 2 HEAD RESTRAINT SLEEVE 3 EXTRACTOR TOOL 6773 Fig 3 Head Restraint Sleeve Extractor Positioning 1 EXTRACTOR TOOL 6773 2 ...

Page 1902: ...ucket seat from vehicle 2 Remove screws attaching the side shield trim cover from the seat 3 If equipped disengage the power seat connec tor from the power seat switch 4 Remove the nuts attaching the seat track to the bucket seat platform 5 When separating the seat track from the plat form route the power seat switch connector through the access hole in the seat cushion frame if equipped INSTALLAT...

Page 1903: ...n the seatback cover on the seatback cushion and roll seatback cover down over the head restraint sleeves Route the sleeves through the access holes in the cover if equipped 2 Roll the seatback cover downward and engage the hook and loop fastener Engage electrical connec tors for heated seat grid if equipped 3 Continue rolling the cover downward and engage the hogrings attaching the seatback cover...

Page 1904: ...cushion support wires 4 With the cushion side down engage the for ward rearward and inboard J straps 5 Engage the clips attaching the outboard side of the cover to the cushion frame 6 Install seatback 7 Install side shield trim cover 8 Install seat BUCKET SEAT RECLINER REMOVAL 1 Remove side shield trim cover 2 Disengage seatback cover zipper 3 Roll outer seatback cover upward 4 Remove bolts attach...

Page 1905: ...d lift it upward and remove it from the vehicle INSTALLATION 1 Position the seatback in the vehicle 2 Install the pivot bolts and the washer Tighten the bolts with 33 N m 25 ft lbs torque 3 Engage the seatback latch with the striker 4 Insert the shoulder lap belt buckles in the elas tic straps 5 Pivot the seat cushion to the horizontal posi tion and lock it in place by pressing firmly on the cente...

Page 1906: ...TRIKER AND BUMPER REMOVAL 1 Disengage seat cushion at the rear by pulling upward on the release strap 2 Tilt seat cushion forward 3 Release seatback latch from striker 4 Tilt seatback forward for access to striker bracket 5 Remove screws Fig 18 attaching latch striker bracket and shims to trim panel INSTALLATION 1 Position shims and latch striker bracket on trim panel 2 Install screws attaching la...

Page 1907: ...Disengage the J strap attaching the cover to the seat back frame Fig 19 5 Remove the cover from the seatback pad 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 5 Install the seatback in the vehicle SPECIAL TOOLS SPECIAL TOOLS SEATS Fig 19 Seatback Cover Removal 1 SEAT BAC...

Page 1908: ...T DOOR SPACER BLOCKS TWO DOOR VEHICLES 41 FRONT DOOR GLASS 41 REAR DOOR TRIM PANEL 42 REAR DOOR WATERDAM 42 REAR DOOR 43 REAR DOOR RESTRAINT 43 REAR DOOR HINGE 43 REAR DOOR OUTSIDE HANDLE 44 REAR DOOR LATCH 44 REAR DOOR LATCH STRIKER 45 REAR DOOR INSIDE HANDLE ACTUATOR 45 REAR DOOR INNER BELT WEATHERSTRIP 45 REAR DOOR OUTER BELT WEATHERSTRIP 45 REAR DOOR GLASS RUN CHANNEL WEATHERSTRIP 46 REAR DOOR...

Page 1909: ...e conditions as closely as possible If a leak occurs with the vehicle parked in a steady light rain flood the leak area with an open ended garden hose If a leak occurs while driving at highway speeds in a steady rain test the leak area with a reasonable velocity stream or fan spray of water Direct the spray in a direction comparable to actual conditions If a leak occurs when the vehicle is parked ...

Page 1910: ...n create a whistling or howling noise Inspect the exterior of the vehicle to verify that these conditions do not exist VISUAL INSPECTION BEFORE TESTS Verify that floor and body plugs are in place and body components are aligned and sealed If compo nent alignment or sealing is necessary refer to the appropriate section of this group for proper proce dures ROAD TESTING WIND NOISE 1 Drive the vehicle...

Page 1911: ... 38 in lbs torque 5 Install nuts attaching GOP to support bracket Tighten nuts to 4 N m 38 in lbs torque 6 Install headlamps and park turn signal lamps 7 Install grille 8 Install side marker lamps 9 Install headlamp bezels 10 Adjust headlamp aim if necessary HOOD REMOVAL 1 Raise hood 2 Disconnect underhood lamp wire harness con nector if equipped 3 Disconnect release cable from latch release bellc...

Page 1912: ...Fig 3 Hood Components XJ BODY 23 25 REMOVAL AND INSTALLATION Continued ...

Page 1913: ...e screw that attaches the latch to the hood inner panel HOOD LATCH STRIKER REMOVAL 1 Remove headlamp bezel 2 Remove parklamp 3 Release the spring attaching the headlamp mounting bucket to the grille opening panel GOP 4 Remove the headlamp with mounting bucket attached from the adjusting screws 5 Remove the upper bolt attaching the striker to the top of the GOP 6 Remove the lower bolt attaching the...

Page 1914: ...od 2 Remove the nuts attaching the safety latch to the inner hood panel Fig 7 3 Separate the safety latch from the hood 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 SAFETY LATCH STRIKER REMOVAL 1 Remove striker screws from radiator support crossmember Fig 8 2 Remove striker from crossmember INSTALLATION 1 Po...

Page 1915: ...windshield wiper arms from the pivots 2 Remove the screws that attach the grille to the cowl 3 Remove the windshield washer tubes from the nozzles 4 Remove the cowl grille and screen from the cowl Fig 11 INSTALLATION CAUTION The washer fluid tubes must be routed and installed so that they are not pinched 1 Position the cowl grille and screen on the cowl 2 Install the windshield washer tubes on the...

Page 1916: ...LATED AREA ONLY 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 product is used REMOVAL 1 Clean the repaired surface as necessary 2 Start at one end of the decal and apply heat with a heat gun Slowly peel the decal from the panel by pulling it back Do not pull the decal outward from panel INSTALLA...

Page 1917: ... decal 14 Using a squeegee smooth out the decal to remove wrinkles and or air bubbles 15 Inspect the decal with reflected light to find any damage Remove all the air and or moisture bub bles EXTERIOR NAMEPLATES REMOVAL NOTE Exterior nameplates are attached to body panels with adhesive tape 1 Apply a length of masking tape on the body parallel to the top edge of the nameplate to use as a guide if n...

Page 1918: ...LARE REMOVAL 1 Remove the screw attaching the lower part of flare to the bottom of the fender 2 Remove the nuts attaching the fender flare retainer to the wheelhouse splash shield Fig 17 3 Remove the liner from the fender 4 Remove the fasteners attaching the fender flare and retainer to the fender 5 Separate the fender flare and retainer from the fender INSTALLATION 1 Position the fender flare and...

Page 1919: ...ews 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 LEFT FRONT FENDER REMOVAL 1 Raise and support the hood 2 Remove the grille opening panel GOP...

Page 1920: ... INSTALLATION 1 Replace any broken or damaged push in fasten ers 2 Connect the power door locks windows mirrors wire harness connectors if equipped 3 Move the door trim panel outward and connect the handle to latch rods 4 Position the trim panel on the inner belt seal and push down to seat 5 Align the locating pins and push Fig 25 in fasteners Press inward to secure 6 Install the screws attaching ...

Page 1921: ...waterdam and rapidly peel back the waterdam from the door inner panel 5 Separate the waterdam from the door inner panel INSTALLATION 1 Route the latch rods through the waterdam 2 Position the waterdam on the door apply adhe sive as necessary and press into place 3 Route the harnesses connectors through the waterdam Fig 21 Window Crank Typical 1 WINDOW CRANK REMOVAL TOOL 2 WINDOW CRANK Fig 22 Front...

Page 1922: ...ALLATION 1 Position hinge plates and shims on door face 2 Align door hinges and shims with bolt holes and install hinge bolts Tighten bolts to 3 N m 2 ft lbs torque 3 Adjust align latch striker and latch as neces sary 4 Install door restraint check retaining pin FRONT DOOR RESTRAINT REMOVAL 1 Remove door trim panel 2 Remove door radio speaker from door inner panel 3 Remove door restraint check ret...

Page 1923: ...h to lock cylinder rod at the door latch Fig 29 4 Remove the lock cylinder retainer clip 5 Remove the lock cylinder 6 If applicable remove the door latch to lock cyl inder rod from the original lock cylinder Connect it to the replacement lock cylinder INSTALLATION 1 Position the lock cylinder and in the door open ing 2 Install the retainer clip 3 Connect the door latch to lock cylinder rod to the ...

Page 1924: ... of striker 2 Remove screws attaching striker to B pillar Fig 31 3 Separate striker from B pillar 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 FRONT DOOR INSIDE HANDLE ACTUATOR REMOVAL The front door inside handle actuator is heat staked to the front door trim panel during the man ufacturing process 1...

Page 1925: ...nel 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 i...

Page 1926: ...atherstrip on the A pillar Press into place FRONT DOOR GLASS EXTERIOR MOLDING REMOVAL 1 Open the window completely 2 Remove the outer belt weatherstrip 3 Pry and pull the molding sections from the door panel flange Fig 35 INSTALLATION 1 Start at the forward end of the upper molding force the molding onto the door panel and continue rearward until it is completely seated on the flange 2 Mate the re...

Page 1927: ...NSTALLATION 1 Position the regulator in the door and align with key hole slots 2 Attach the regulator to door inner panel with bolts Fig 38 3 Install the window glass 4 Install the waterdam 5 Install the trim panel Fig 38 Front Door Regulator 1 GLASS Fig 36 Power Window Regulator 1 FRONT DOOR 2 LOOSEN BOLTS 3 LOOSEN NUTS Fig 37 Manual Window Regulator 1 FRONT DOOR 2 LOOSEN BOLTS 23 40 BODY XJ REMO...

Page 1928: ... Roll glass up to expose the bolts attaching the glass to the regulator 5 Remove the bolts attaching the glass to the regulator Fig 41 6 Lift the glass upward and out of the door INSTALLATION 1 Position the glass in the door 2 Install the bolts attaching the glass to the reg ulator Tighten the bolts to 4 N m 36 in lbs torque 3 Install inner and outer belt weatherstrip Fig 39 Front Door Upper Space...

Page 1929: ...ow wire harness con nectors if equipped 3 Move the door trim panel outward and connect the handle to latch rods 4 Position the trim panel on the inner belt seal and push down to seat 5 Align the locating pins and push in fasteners Fig 47 Press inward to secure 6 Install the screws attaching the trim panel to the door inner panel 7 Install the window crank if equipped REAR DOOR WATERDAM REMOVAL 1 R...

Page 1930: ...trim panel REAR DOOR RESTRAINT REMOVAL 1 Remove the door trim panel 2 Remove the door restraint check retaining pin from the bracket with a punch 3 Remove the nuts and remove the restraint via the access opening in the door inner panel Fig 48 INSTALLATION 1 Position the door restraint in the door by way of the opening and install the nuts Tighten the nuts to 10 N m 7 ft lbs torque 2 Position the d...

Page 1931: ... door panel 2 Connect the latch to handle rod to the handle latch release lever arm 3 Install nuts attaching the door handle to the door 4 Install the latch 5 Install the waterdam 6 Install the trim panel REAR DOOR LATCH REMOVAL 1 Remove access plug 2 Remove door trim panel 3 Remove waterdam 4 Remove screws attaching door latch to door Fig 51 5 Disconnect all rods from door latch 6 Remove door lat...

Page 1932: ...rim panel 3 Separate the inside handle from the trim panel INSTALLATION 1 Position the inside handle in the trim panel 2 Heat stake the inside handle to the trim panel 3 Install the door trim panel REAR DOOR INNER BELT WEATHERSTRIP REMOVAL 1 Roll window down 2 Remove door trim panel 3 Pull up on the rear corner of the weatherstrip and lift from the door Fig 53 INSTALLATION 1 Position the weatherst...

Page 1933: ...he door panel flange Fig 54 INSTALLATION 1 Starting at the forward end of the upper mold ing force the molding onto the door panel flange and continue rearward until it is completely seated on the flange 2 Mate the rear molding with the upper molding and force the molding edge inward 3 Continue pressing and moving downward to complete the installation 4 Install the outer belt molding REAR DOOR WEA...

Page 1934: ...a tor to the inner door panel 7 Disconnect the wire harness connector from the regulator drive motor if equipped 8 Remove the regulator and drive motor if equipped INSTALLATION 1 Position window regulator and if equipped drive motor within the door panels 2 Install the fasteners attaching the regulator to the door inner panel 3 Connect the regulator wire harness connector 4 Position the window gla...

Page 1935: ...g Fig 60 with a heat gun 2 Lift edge of molding with a putty knife and peel molding from body panel Apply heat to any location where the molding remains adhered to a panel 3 Remove the adhesive from the body panel with Mopar Super Clean solvent or equivalent 4 If the original molding will be installed also remove all adhesive from it INSTALLATION 1 If the original molding will be installed apply 3...

Page 1936: ...flare to the bottom of the fender QUARTER WINDOW APPLIQUE REMOVAL 1 Remove the liftgate pillar trim 2 Remove nuts from inside vehicle Fig 62 3 Using a trim sick or equivalent carefully pry the applique the from panel INSTALLATION 1 Position the replacement applique the on panel and install the nuts 2 Install the liftgate pillar trim DRIP RAIL MOLDING REMOVAL 1 Pry the clips from the roof flange 2 ...

Page 1937: ... skid strip is properly aligned 4 Press each skid strip onto roof panel with a roller or use hand pressure NOTE To prevent water leaks apply 3M Drip Chek Sealant or equivalent 5 Position luggage rack on roof with screw holes aligned 6 Install and tighten slide rail screws AIR EXHAUST GRILLE REMOVAL 1 Remove the screw that attaches the grille to door the opening panel Fig 64 2 Pry the bottom edge o...

Page 1938: ...nner scuff plate 6 Install the assist handles LOWER A PILLAR COWL TRIM REMOVAL 1 Remove the inner scuff plate 2 Remove the nut behind the fuse panel access door Right side only Fig 66 3 Remove the fasteners attaching the lower A pil lar cowl trim to the A pillar lower cowl 4 Separate the lower A pillar cowl trim from the A pillar lower cowl Fig 65 Trim Panels 2 Door Vehicles 1 SPACER 2 LIFTGATE PI...

Page 1939: ...the scuff plate on the door sill 2 Install the screws attaching the door sill scuff plate to the door sill ASSIST HANDLE REMOVAL 1 Using a trim stick or equivalent open the end covers to access the screws 2 Remove the screws Fig 65 3 Separate the assist handle from the trim INSTALLATION 1 Position the handle on the trim 2 Install the screws 3 Install the covers B PILLAR TRIM REMOVAL 1 Remove the i...

Page 1940: ... TRIM REMOVAL 1 Remove the inner scuff plate 2 Remove the upper door opening trim 3 Remove the upper quarter panel trim 4 Remove the quarter panel trim extension 5 Remove the screws attaching the C pillar trim to the C pillar Fig 68 6 Separate the C pillar trim from the C pillar INSTALLATION 1 Position the C pillar trim on the C pillar Fig 68 B Pillar Trim 4 Door Vehicles 1 UPPER DOOR OPENING TRIM...

Page 1941: ...rter panel trim extension 3 Remove liftgate scuff plate 4 Remove the screws attaching the quarter panel trim from the quarter panel and wheelhouse trim cover Fig 68 and Fig 65 5 If necessary remove the tire and mounting brackets from the left quarter panel trim Fig 69 6 Remove the screws attaching the wheelhouse cover to the wheelhouse 7 Separate the wheelhouse cover from the wheel house INSTALLAT...

Page 1942: ...G UPPER TRIM REMOVAL 1 Remove the screws attaching the liftgate open ing upper trim to the roof panel Fig 71 2 Pull downward to disengage steel clips attach ing the liftgate opening upper trim to the roof panel 3 Separate trim from vehicle 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 l...

Page 1943: ...and install the lower anchor bolt with a Torx bit Tighten bolt to 43 N m 32 ft lbs torque 2 Position the support guide washer and shoulder belt upper anchor plate on the trim panel Install the upper anchor bolt with a Torx bit 3 Route belt through 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 ca...

Page 1944: ...e shoulder belt through quarter trim panel slot 5 Position shoulder belt at roof rail and install upper anchor bolt Tighten bolt to 43 N m 32 ft lbs torque 6 Install quarter trim panel 7 Install shoulder belt lower anchor bolt Tighten bolt to 43 N m 32 ft lbs torque 8 Return rear seat cushion to normal position and engage latch FULL FLOOR CONSOLE REMOVAL 1 Remove the transmission shift lever handl...

Page 1945: ...or sill inner scuff plates 5 Install floor console 6 Install the front and rear seats as applicable REAR CARPET MAT REMOVAL 1 Remove the liftgate latch striker and scuff plate 2 Drill out the retaining rivet heads and remove the cargo tie down footman loops from the carpet 3 As necessary remove the trim panels and moldings 4 Remove the all other interfering components 5 Remove the carpet and mat f...

Page 1946: ...he bracket contact surface after the accelerator has been applied 5 Apply adhesive accelerator to the bracket con tact surface on the windshield glass Allow the accel erator to dry for one minute Do not touch the glass contact surface after the accelerator has been applied 6 Install the bracket according to the following instructions Apply one drop of adhesive at the center of the bracket contact ...

Page 1947: ...m support bracket to the headliner and the roof panel HEADLINER The upper trim moldings and the headliner are attached to the roof rail with a combination of screws clip retainers and rail retainers Fig 83 To remove a headliner all of the upper trim mold ings must be removed from the perimeter of the headliner along with as applicable Assist handles Sunvisors Dome cargo lamps Overhead console All ...

Page 1948: ...the retainer clips on upper liftgate opening trim and rails are installed Fig 86 3 Engage rear speaker harness connector 4 Install the upper trim moldings around the perimeter of the headliner Tighten the retaining screws to 1 N m 11 in lbs torque 5 As applicable install Assist handles Sunvisors Dome cargo lamps Overhead console All other attached overlapping components LIFTGATE TRIM PANEL REMOVAL...

Page 1949: ...cklite 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 and install bolts ...

Page 1950: ... rod on the liftgate 2 Install the bolts attaching the support rod to the liftgate 3 Connect the support rod to the ball stud 4 Secure the support rod to the ball stud with the retainer clip 5 Remove the support from the liftgate LIFTGATE SUPPORT ROD BALL STUD REMOVAL 1 Open the liftgate 2 Support the liftgate in the open position 3 Remove the retainer clip attaching the support rod to the ball st...

Page 1951: ...nect power lock connector to handle if equipped 3 Connect latch rod 4 Install screws attaching latch to liftgate Tighten screws to 13 N m 9 ft lbs torque 5 Install liftgate trim panel LIFTGATE LATCH STRIKER REMOVAL 1 From underside of vehicle remove nuts attach ing striker to floor pan Fig 93 2 Separate striker from vehicle INSTALLATION 1 Position striker on vehicle 2 Install nuts Tighten nuts to ...

Page 1952: ...the seal with a roller Move the roller the from top left half of the seal to the right bottom end of the seal ADJUSTMENTS HOOD The hood bolt holes are elongated for fore and aft and side to side adjustment 1 If hood is low to the cowl panel insert shims between the hinge and hood at the rear hinge bolts 2 Adjust the hood bumper Fig 95 in or out to provide proper hood to fender height alignment 3 A...

Page 1953: ...en door hinge bolts to 3 N m 2 ft lbs torque after adjustment is completed 4 Apply general purpose sealant around the door hinges door face mating area DOOR LATCH ADJUSTMENT 1 Locate access hole Fig 98 2 Insert a 5 32 inch hex wrench through hole and into adjustment screw Loosen screw 3 Operate outside handle button several times to release any restriction because of mis alignment 4 Tighten adjust...

Page 1954: ...NTS COMPONENT SERVICE INTERVAL LUBRICANT Door Latches As Required Multi Purpose Grease NLGI GC LB Water Resistant 1 Hood Latch Release Mechanism Safety Latch As Required When Performing Other Underhood Service Multi Purpose Grease NLGI GC LB 2 EP 2 Hood Hinges As Required Engine Oil Seat Track Release Mechanism As Required Multi Purpose Grease NLGI GC LB 2 EP 2 Liftgate Hinge As Required Multi Pur...

Page 1955: ...WELD LOCATIONS UPPER COWL 23 68 BODY XJ SPECIFICATIONS Continued ...

Page 1956: ...UPPER COWL XJ BODY 23 69 SPECIFICATIONS Continued ...

Page 1957: ...COWL 23 70 BODY XJ SPECIFICATIONS Continued ...

Page 1958: ...A PILLAR XJ BODY 23 71 SPECIFICATIONS Continued ...

Page 1959: ...A PILLAR 23 72 BODY XJ SPECIFICATIONS Continued ...

Page 1960: ...A PILLAR XJ BODY 23 73 SPECIFICATIONS Continued ...

Page 1961: ...A PILLAR 23 74 BODY XJ SPECIFICATIONS Continued ...

Page 1962: ...B PILLAR XJ BODY 23 75 SPECIFICATIONS Continued ...

Page 1963: ...D PILLAR 23 76 BODY XJ SPECIFICATIONS Continued ...

Page 1964: ...FUEL FILLER OPENING XJ BODY 23 77 SPECIFICATIONS Continued ...

Page 1965: ...CARGO AREA FLOOR PAN 23 78 BODY XJ SPECIFICATIONS Continued ...

Page 1966: ...ROOF AND D PILLAR XJ BODY 23 79 SPECIFICATIONS Continued ...

Page 1967: ...LIFTGATE OPENING 23 80 BODY XJ SPECIFICATIONS Continued ...

Page 1968: ...ROOF XJ BODY 23 81 SPECIFICATIONS Continued ...

Page 1969: ...ROOF 23 82 BODY XJ SPECIFICATIONS Continued ...

Page 1970: ...FRAME RAIL XJ BODY 23 83 SPECIFICATIONS Continued ...

Page 1971: ...FRAME RAIL 23 84 BODY XJ SPECIFICATIONS Continued ...

Page 1972: ...FRAME RAIL XJ BODY 23 85 SPECIFICATIONS Continued ...

Page 1973: ...FRAME RAIL 23 86 BODY XJ SPECIFICATIONS Continued ...

Page 1974: ...REINFORCEMENT XJ BODY 23 87 SPECIFICATIONS Continued ...

Page 1975: ...FRONT INNER FENDER 23 88 BODY XJ SPECIFICATIONS Continued ...

Page 1976: ...FRONT INNER FENDER AND RADIATOR CLOSURE PANEL XJ BODY 23 89 SPECIFICATIONS Continued ...

Page 1977: ...REINFORCEMENT 23 90 BODY XJ SPECIFICATIONS Continued ...

Page 1978: ...FRONT FENDER XJ BODY 23 91 SPECIFICATIONS Continued ...

Page 1979: ...BODY SIDE 23 92 BODY XJ SPECIFICATIONS Continued ...

Page 1980: ...REAR WHEELHOUSE XJ BODY 23 93 SPECIFICATIONS Continued ...

Page 1981: ...REAR INNER WHEELHOUSE 23 94 BODY XJ SPECIFICATIONS Continued ...

Page 1982: ...BODY SIDE XJ BODY 23 95 SPECIFICATIONS Continued ...

Page 1983: ...BODY SIDE 23 96 BODY XJ SPECIFICATIONS Continued ...

Page 1984: ...BODY SIDE XJ BODY 23 97 SPECIFICATIONS Continued ...

Page 1985: ...BODY SIDE 23 98 BODY XJ SPECIFICATIONS Continued ...

Page 1986: ...BODY SIDE XJ BODY 23 99 SPECIFICATIONS Continued ...

Page 1987: ...BODY SIDE 23 100 BODY XJ SPECIFICATIONS Continued ...

Page 1988: ...UNDERBODY XJ BODY 23 101 SPECIFICATIONS Continued ...

Page 1989: ...UNDERBODY 23 102 BODY XJ SPECIFICATIONS Continued ...

Page 1990: ...UNDERBODY XJ BODY 23 103 SPECIFICATIONS Continued ...

Page 1991: ...UNDERBODY 23 104 BODY XJ SPECIFICATIONS Continued ...

Page 1992: ...UNDERBODY XJ BODY 23 105 SPECIFICATIONS Continued ...

Page 1993: ...UNDERBODY 23 106 BODY XJ SPECIFICATIONS Continued ...

Page 1994: ...UNDERBODY XJ BODY 23 107 SPECIFICATIONS Continued ...

Page 1995: ...UNDERBODY 23 108 BODY XJ SPECIFICATIONS Continued ...

Page 1996: ...UNDERBODY XJ BODY 23 109 SPECIFICATIONS Continued ...

Page 1997: ...UNDERBODY 23 110 BODY XJ SPECIFICATIONS Continued ...

Page 1998: ...UNDERBODY XJ BODY 23 111 SPECIFICATIONS Continued ...

Page 1999: ...BODY SEALING LOCATIONS APPLICATION METHODS 23 112 BODY XJ SPECIFICATIONS Continued ...

Page 2000: ...COWL AND DASH PANEL XJ BODY 23 113 SPECIFICATIONS Continued ...

Page 2001: ...DASH PANEL AND FLOOR PAN 23 114 BODY XJ SPECIFICATIONS Continued ...

Page 2002: ...FLOOR PAN XJ BODY 23 115 SPECIFICATIONS Continued ...

Page 2003: ...REAR INNER WHEELHOUSE 23 116 BODY XJ SPECIFICATIONS Continued ...

Page 2004: ...FRONT INNER WHEELHOUSE XJ BODY 23 117 SPECIFICATIONS Continued ...

Page 2005: ...BODY SIDE 23 118 BODY XJ SPECIFICATIONS Continued ...

Page 2006: ...BODY SIDE XJ BODY 23 119 SPECIFICATIONS Continued ...

Page 2007: ...BODY SIDE 23 120 BODY XJ SPECIFICATIONS Continued ...

Page 2008: ...ROOF PANEL XJ BODY 23 121 SPECIFICATIONS Continued ...

Page 2009: ...FUEL FILLER HOUSING 23 122 BODY XJ SPECIFICATIONS Continued ...

Page 2010: ...LIFTGATE OPENING XJ BODY 23 123 SPECIFICATIONS Continued ...

Page 2011: ...STRUCTURAL ADHESIVE LOCATIONS LEFT QUARTER PANEL 23 124 BODY XJ SPECIFICATIONS Continued ...

Page 2012: ...REAR WHEELHOUSE XJ BODY 23 125 SPECIFICATIONS Continued ...

Page 2013: ...ROOF BOWS 23 126 BODY XJ SPECIFICATIONS Continued ...

Page 2014: ... 1 1 5 0 0 1 5 D Front Door to Fender 6 4 1 5 00 1 5 E Hood to Fender 5 6 1 5 0 5 1 5 F Headlamp to Fender 5 6 1 5 0 5 1 5 G Headlamp to Roof N A 0 74 1 0 H Grille to Hood 6 0 1 5 0 24 1 5 I Liftgate to Roof 7 5 1 5 0 5 1 5 J Liftgate to Aperture 6 5 1 5 0 0 1 5 K Liftgate to Fascia X X 2 0 N A L Rear Door to Quarter Panel 6 4 1 5 0 0 1 5 XJ BODY 23 127 SPECIFICATIONS Continued ...

Page 2015: ...BODY OPENING DIMENSIONS WINDSHIELD OPENING A B Center of radius at bottom to center of radius at top 23 128 BODY XJ SPECIFICATIONS Continued ...

Page 2016: ... front door lower rear radius to cen ter of A pillar radius B Center of radius at bottom rear to center of radius at lower A pillar C Center of radius at bottom front to center of radius at top rear XJ BODY 23 129 SPECIFICATIONS Continued ...

Page 2017: ... front door lower rear radius to cen ter of A pillar radius E Center of radius at bottom rear to center of radius at lower A pillar F Center of radius at bottom front to center of radius at top rear 23 130 BODY XJ SPECIFICATIONS Continued ...

Page 2018: ...body side upper and lower seam B Center of front upper door radius to center of rear lower door radius C Center of front lower door radius to center of rear upper door radius D Flange to rear door striker mount XJ BODY 23 131 SPECIFICATIONS Continued ...

Page 2019: ... of upper and lower rear quarter win dow opening B Center of radius front lower corner to center of radius rear upper corner C Center of radius front upper corner to center of radius rear lower corner 23 132 BODY XJ SPECIFICATIONS Continued ...

Page 2020: ... of upper and lower rear quarter win dow opening B Center of radius front lower corner to center of radius rear upper corner C Center of radius front upper corner to center of radius rear lower corner XJ BODY 23 133 SPECIFICATIONS Continued ...

Page 2021: ...pper liftgate opening to liftgate striker mount B C Center of radius upper corner to center of radius lower corner D Distance between outer quarter panel to tail lamp mounting panel to inner quarter panel seams 23 134 BODY XJ SPECIFICATIONS Continued ...

Page 2022: ...et Nut 4 N m 38 in lbs GOP to Fender Nut 4 N m 38 in lbs Liftgate Hinge to Body and or Liftgate Bolt 26 N m 19 ft lbs Liftgate Latch Screw 13 N m 9 ft lbs Liftgate Latch Striker Nut 54 N m 40 ft lbs Rear Door Hinge Bolt 3 N m 2 ft lbs Rear Door Latch Screw 11 N m 8 ft lbs Rear Door Latch Striker Screw 28 N m 20 ft lbs Rear Shoulder Belt Lower Anchor Bolt 43 N m 32 ft lbs DESCRIPTION TORQUE Rear Se...

Page 2023: ......

Page 2024: ... FUNCTION HIGH PRESSURE SWITCH HIGH PRESSURE CUT OFF SWITCH 16 HEATER PERFORMANCE 16 LOW PRESSURE CYCLING CLUTCH SWITCH 17 REFRIGERANT SYSTEM LEAKS 17 VACUUM SYSTEM 18 SERVICE PROCEDURES REFRIGERANT OIL LEVEL 19 REFRIGERANT RECOVERY 22 REFRIGERANT SYSTEM EVACUATE 22 REFRIGERANT SYSTEM CHARGE 22 REFRIGERANT SYSTEM SERVICE EQUIPMENT 22 REMOVAL AND INSTALLATION SERVICE WARNINGS AND PRECAUTIONS 23 ACC...

Page 2025: ...position The blower motor battery feed circuit is protected by a fuse in the Power Distribution Center PDC Blower motor speed is controlled by regulating the ground path through the heater A C control blower motor switch and the blower motor resistor The blower motor and blower motor wheel cannot be repaired and if faulty or damaged they must be replaced The blower motor and blower wheel are ser v...

Page 2026: ...s a fixed displacement of 150 cubic centimeters 9 375 cubic inches and has both the suction and discharge ports located on the cylinder head A label identifying the use of R 134a refrigerant is located on the com pressor OPERATION The compressor is driven by the engine through an electric clutch drive pulley and belt arrangement The compressor is lubricated by refrigerant oil that is circulated th...

Page 2027: ... con ditioning system Therefore it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow Also any factory installed air seals or shrouds must be properly reinstalled following radia tor or condenser service The condenser cannot be repaired and if faulty or dama...

Page 2028: ...ssure liquid refrigerant from the condenser expands into a low pressure liquid as it passes through the metering orifice and diffuser screen of the fixed orifice tube The fixed orifice tube cannot be repaired and if faulty or plugged the liquid line and fixed orifice tube unit or liquid line jumper and fixed orifice tube unit must be replaced HEATER AND AIR CONDITIONER DESCRIPTION All vehicles are...

Page 2029: ...in the vehicle Refer to the owner s manual in the vehicle glove box for more information on the features use and suggested oper ation of these controls OPERATION The heater only or heater A C control panel is located to the right of the instrument cluster on the instrument panel The control panel contains a rota ry type temperature control knob a rotary type mode control switch knob and a rotary t...

Page 2030: ...vaporator temperature Control ling the evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow The low pressure cycling clutch switch contacts are open when the suction pressure is approximately 141 kPa 20 5 psi or lower The switch contacts will close when the suction pressure rises to approximately 234 to 262 kPa 34 to...

Page 2031: ...e a special tool for disengaging the two coupler halves OPERATION The spring lock coupler is held together by a garter spring inside a circular cage on the male half of the fitting Fig 5 When the two coupler halves are con nected the flared end of the female fitting slips behind the garter spring inside the cage on the male fitting The garter spring and cage prevent the flared end of the female fi...

Page 2032: ...d VACUUM RESERVOIR DESCRIPTION The vacuum reservoir is mounted to the front bumper bar behind the passenger side bumper end cap The bumper end cap must be removed from the vehicle to access the vacuum reservoir for service OPERATION Engine vacuum is stored in the vacuum reservoir The stored vacuum is used to operate the vacuum controlled vehicle accessories during periods of low engine vacuum such...

Page 2033: ...ycles unplug the low pressure cycling clutch switch wire harness connector from the switch located on the accumulator Fig 6 Place a jumper wire across the terminals of the low pressure cycling clutch switch wire harness connector 7 With the compressor clutch engaged record the discharge air temperature and the compressor dis charge pressure 8 Compare the discharge air temperature to the Performanc...

Page 2034: ...witch in this group Test the high pressure cut off switch and replace if required 7 Refer to the proper Diagnostic Procedures manual for testing of the PCM Test the PCM and replace if required Normal pressures but A C Performance Test air temperatures at center panel outlet are too high 1 Excessive refrigerant oil in system 2 Blend Air door inoperative or sealing improperly 3 Blend Air door motor ...

Page 2035: ...be if required 3 See Compressor in this group Replace the compressor if required The low side pressure is too low and the high side pressure is too high 1 Restricted refrigerant flow through the refrigerant lines 2 Restricted refrigerant flow through the fixed orifice tube 3 Restricted refrigerant flow through the condenser 1 See Liquid Line and Suction and Discharge Line in this group Inspect the...

Page 2036: ...LAY CIRCUIT TEST For circuit descriptions and diagrams refer to 8W 42 Air Conditioning Heater in Group 8W Wir ing Diagrams 1 The relay common feed terminal cavity 30 is connected to fused battery feed directly from a fuse in the Power Distribution Center PDC and should be hot at all times Check for battery voltage at the connector cavity for relay terminal 30 If OK go to Step 2 If not OK repair th...

Page 2037: ... between the ground circuit ter minal and each of the blower motor driver circuit ter minals of the heater A C control as you move the blower motor switch knob to each of the four speed positions There should be continuity at each driver circuit terminal in only one blower motor switch speed position If OK test and repair the blower driver circuits between the heater A C control con nector and the...

Page 2038: ...lutch circuit The following components must be checked and repaired as required before you can complete testing of the clutch coil Fuses in the junction block and the Power Dis tribution Center PDC Heater A C mode control switch Compressor clutch relay High pressure cut off switch Low pressure cycling clutch switch Powertrain Control Module PCM 4 The compressor clutch coil is acceptable if the cur...

Page 2039: ...l function high pressure switch check for continuity between terminals C and D On the two terminal switch check for continuity between both terminals of the high pressure cut off switch There should be continuity If OK test and repair the A C switch sense circuit as required If not OK replace the faulty switch HEATER PERFORMANCE Before performing the following tests refer to Group 7 Cooling System...

Page 2040: ...r in Group 8W Wir ing Diagrams 1 Disconnect and isolate the battery negative cable 2 Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accu mulator fitting 3 Install a jumper wire between the two cavities of the low pressure cycling clutch switch wire har ness connector 4 Connect a manifold gauge set to the refrigerant system service ports See Refrigerant ...

Page 2041: ...cuum control system that operates perfectly at engine idle high engine vac uum may not function properly at high engine speeds or loads low engine vacuum This can be caused by leaks in the vacuum system or a faulty vacuum check valve A vacuum system test will help to identify the source of poor vacuum system performance or vac uum system leaks Before starting this test stop the engine and make cer...

Page 2042: ...of the leaking circuit The test set gauge should return to the 27 kPa 8 in Hg setting shortly after each connection is made If OK replace the faulty disconnected component If not OK go to Step 6 6 To locate a leak in a vacuum line leave one end of the line plugged and connect the test set hose or probe to the other end of the line Run your fin gers slowly along the line while watching the test set...

Page 2043: ...ost Actuator Full Position Yellow C Floor Actuator Brown D Defrost Actuator Mid Position Blue E Vacuum Supply Reservoir Black F Panel Actuator Red G Not Used N A Fig 11 Vacuum Circuits Heater Only 24 20 HEATING AND AIR CONDITIONING XJ SERVICE PROCEDURES Continued ...

Page 2044: ...uator Full Position Yellow C Floor Actuator Brown D Defrost Actuator Mid Position Blue E Vacuum Supply Reservoir Black F Panel Actuator Red G Recirculation Actuator Green Fig 12 Vacuum Circuits Heater A C XJ HEATING AND AIR CONDITIONING 24 21 SERVICE PROCEDURES Continued ...

Page 2045: ...e Diagnosis and Testing section of this group for the procedures b If the refrigerant system maintains the spec ified vacuum for five minutes restart the vacuum pump open the suction and discharge valves and evacuate the system for an additional ten minutes 3 Close all of the valves and turn off the charg ing station vacuum pump 4 The refrigerant system is now ready to be charged with R 134a refri...

Page 2046: ...SERVICE PROCEDURES REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSON NEL AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST EXPOSURE MAY IRRITATE THE EYES NOSE AND OR THROAT WEAR EYE PROTECTION WHEN SERVICING THE AIR CONDITIONING REFRIGERANT SYSTEM SERI OUS EYE INJURY CAN RESULT FROM DIRECT CONTACT WITH THE REFRIGERANT IF EYE CON TACT OCCURS SEEK MEDICAL ATTENTION IMME DI...

Page 2047: ...the refrigerant lines or tubes Refrigerant oil will absorb moisture from the atmosphere if left uncapped Do not open a con tainer of refrigerant oil until you are ready to use it Replace the cap on the oil container immediately after using Store refrigerant oil only in a clean air tight and moisture free container Keep service tools and the work area clean Contamination of the refrigerant system t...

Page 2048: ...cover the refrigerant from the refrigerant system See Refrigerant Recovery in this group for the procedures 3 Unplug the wire harness connector from the low pressure cycling clutch switch 4 Loosen the screw that secures the accumulator retaining band to the support bracket on the dash panel Fig 14 5 Disconnect the suction line from the accumula tor outlet tube refrigerant line fitting See Refriger...

Page 2049: ...OVAL 1 If the vehicle is equipped with air conditioning recover the refrigerant from the refrigerant system See Refrigerant Recovery in this group for the proce dures 2 Disconnect and isolate the battery negative cable 3 If the vehicle is equipped with air conditioning the accumulator must be relocated in order to service the blower motor This is done by loosening the accu mulator retaining band s...

Page 2050: ...l Refer to Glove Box in Group 8E Instrument Panel Systems for the procedures 7 Connect the battery negative cable 8 Test the relay operation BLOWER MOTOR RESISTOR WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLUMN OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD ...

Page 2051: ...eplacement compressor is being installed be certain to check the refrigerant oil level See Refrigerant Oil Level in this group for the procedures Use only refrigerant oil of the type rec ommended for the compressor in the vehicle 1 Install the compressor to the mounting bracket Tighten the four mounting bolts as follows All 2 5L and 4 0L engines 27 N m 20 ft lbs 2 Remove the tape or plugs from all...

Page 2052: ...he lip of the rotor puller Special Tool C 6141 1 into the snap ring groove exposed in the previous step and install the shaft protector Special Tool C 6141 2 Fig 23 11 Install the puller through bolts Special Tool C 6461 through the puller flange and into the jaws of the rotor puller and tighten Fig 24 Turn the puller center bolt clockwise until the rotor pulley is free 12 Remove the screw and ret...

Page 2053: ... the nut until the pulley assembly is seated 5 Install the external front snap ring with snap ring pliers The bevel side of the snap ring must be facing outward Press the snap ring to make sure it is properly seated in the groove CAUTION If the snap ring is not fully seated in the groove it will vibrate out resulting in a clutch fail ure and severe damage to the front housing of the compressor 6 I...

Page 2054: ...w 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...

Page 2055: ...ator 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 7 Slide the condenser down from the radiator far enough for the condenser studs to clear the upper radiator bracket holes and for the lower condenser bracket holes to clear the dowel pins on the bott...

Page 2056: ...4a system Use only refrigerant oil of the type recommended for the com pressor in the vehicle 2 Install and tighten the high pressure switch on the discharge line fitting 3 Plug the wire harness connector into the high pressure cut off switch 4 Connect the battery negative cable DUCTS AND OUTLETS WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTI...

Page 2057: ...res to install Tighten the mounting screws to 2 2 N m 20 in lbs CONSOLE REAR DUCT 1 Disconnect and isolate the battery negative cable 2 Remove the floor console from the floor panel transmission tunnel Fig 35 Refer to Group 23 Body for the procedures 3 Lift the rear of the console rear duct out of the console rear mounting bracket on the floor panel transmission tunnel and slide the duct rearward ...

Page 2058: ...orifice has filter screens on the inlet and outlet ends of the tube body If the fixed orifice tube is faulty or plugged the liq uid line unit or liquid line jumper unit must be replaced See Liquid Line in this group for the ser vice procedures HEATER A C CONTROL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COLU...

Page 2059: ...the instru ment panel and secure it with four screws Tighten the screws to 2 2 N m 20 in lbs 6 Reinstall the center bezel onto the instrument panel Refer to Instrument Panel Center Bezel in Group 8E Instrument Panel Systems for the proce dures 7 Connect the battery negative cable HEATER A C HOUSING The heater A C housing assembly must be removed from the vehicle and the two halves of the housing s...

Page 2060: ...Pull the heater A C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes 12 Remove the heater A C housing from the vehi cle 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...

Page 2061: ...heater core and evapo rator coil tube mounting flange of the heater A C housing 6 If the unit is equipped with air conditioning reinstall the evaporator coil tube clamp Tighten the mounting screw to 2 2 N m 20 in lbs 7 Engage the heater A C wire harness connector and blower motor relay wire harness connector push in retainers with their mounting holes in the heater A C housing 8 Engage the vacuum ...

Page 2062: ...L COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 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 pivot hole in the bottom of the lower half of the heat er A C housing Fig 43 3 Reve...

Page 2063: ...e floor door lever and pull the lever out of the pivot shaft from the outside of the lower half of the heater A C housing 4 Reach inside the lower half of the heater A C housing and carefully flex the floor door Fig 46 enough so that the door pivot clears the pivot hole in the housing 5 Remove the floor door from the heater A C housing 6 Reverse the removal procedures to install RECIRCULATION AIR ...

Page 2064: ...ised to make sure that each of the refrigerant system connections is pressure tight and leak free It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION REMOVAL 1 Disconnect and isolate the batt...

Page 2065: ...ghten the low pressure cycling clutch switch on the accumulator fitting The switch should be hand tightened onto the accumulator fit ting 3 Plug the wire harness connector into the low pressure cycling clutch switch 4 Connect the battery negative cable KICK COVER WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL STEERING COL...

Page 2066: ...isconnect and isolate the battery negative cable 2 Remove the instrument panel assembly from the vehicle Refer to Instrument Panel Assembly in Group 8E Instrument Panel Systems for the proce dures 3 Unplug the two vacuum harness connectors from the defrost door actuator Fig 52 4 Insert a trim stick or another suitable wide flat bladed tool into the latch hole on the heater A C housing actuator mou...

Page 2067: ...unt 4 Rotate and tilt the vacuum actuator as required to disengage the hole on the end of the actuator link from the hooked pin on the end of the panel demist door lever 5 Remove the panel demist door vacuum actuator from the vehicle 6 Reverse the removal procedures to install RECIRCULATION AIR DOOR ACTUATOR A recirculation air door and vacuum actuator are used only on models with the optional air...

Page 2068: ...ing is not damaged a If the garter spring is missing install a new spring by pushing it into the coupler cage opening b If the garter spring is damaged remove it from the coupler cage with a small wire hook DO NOT use a screwdriver and install a new garter spring 2 Clean any dirt or foreign material from both halves of the coupler fitting 3 Install new O rings on the male half of the cou pler fitt...

Page 2069: ...he opened refrigerant line fittings 7 Remove the suction and discharge line assem bly from the vehicle INSTALLATION 1 Remove the tape or plugs from the suction and discharge line manifold and the compressor Install the suction and discharge line manifold to the com pressor Tighten the mounting screw to 28 N m 250 in lbs 2 Remove the tape or plugs from the suction line and the accumulator outlet bl...

Page 2070: ...NE Fig 58 Vacuum Reservoir Remove Install 1 VACUUM LINE 2 RESERVOIR SCREWS 3 VACUUM RESERVOIR Item Description Notes Vehicle XJ Cherokee Laredo System R134a w orifice tube Compressor Sanden SD7H15 SP 20 PAG oil Freeze up Control Low Pressure cycling cutout switch accumulator mounted Low psi Control opens 25 psi resets 43 psi High psi Control switch opens 450 490 psi resets 270 330 psi discharge li...

Page 2071: ......

Page 2072: ...GERANT IF EYE CON TACT OCCURS SEEK MEDICAL ATTENTION IMME DIATELY DO NOT EXPOSE THE REFRIGERANT TO OPEN FLAME POISONOUS GAS IS CREATED WHEN REFRIGERANT IS BURNED AN ELEC TRONIC LEAK DETECTOR IS RECOMMENDED IF ACCIDENTAL SYSTEM DISCHARGE OCCURS VENTILATE THE WORK AREA BEFORE RESUMING SERVICE LARGE AMOUNTS OF REFRIGERANT RELEASED IN A CLOSED WORK AREA WILL DISPLACE THE OXYGEN AND CAUSE SUFFOCATION T...

Page 2073: ...the refrigerant lines or tubes Refrigerant oil will absorb moisture from the atmosphere if left uncapped Do not open a con tainer of refrigerant oil until you are ready to use it Replace the cap on the oil container immediately after using Store refrigerant oil only in a clean air tight and moisture free container Keep service tools and the work area clean Contamination of the refrigerant system t...

Page 2074: ...ing pump main shaft The power steering pump is driven by the accessory drive belt The compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the refrigerant The compressor draws in low pres sure refrigerant vapor from the evaporator through its suction port It then compresses the refrigerant into a high pressure high temperature refrigerant vapor whic...

Page 2075: ...f switch 4 Disconnect the discharge line refrigerant line fitting from the condenser inlet tube Fig 2 See Refrigerant Line Coupler in this group for the proce dures Install plugs in or tape over all of the opened refrigerant line fittings 5 Remove the nut that secures the suction line block fitting to the accumulator outlet Install plugs in or tape over all of the opened refrigerant line fit tings...

Page 2076: ...charge line assem bly from the vehicle INSTALLATION 1 Remove the tape or plugs from the suction and discharge line manifold and the compressor Install the suction and discharge line manifold to the com pressor Tighten the mounting screw to 28 N m 250 in lbs 2 Remove the tape or plugs from the suction line and the accumulator outlet block fittings Install the suction line to the accumulator outlet ...

Page 2077: ...ction line to manifold block nut 9 N m 80 in lbs Discharge line to manifold block nut 9 N m 80 in lbs Manifold block to compressor screw 28 N m 250 in lbs COMPRESSOR 2 5L VM DIESEL REMOVAL 1 Disconnect the negative battery cable 2 Recover the refrigerant See Refrigerant Recov ery in this group for the procedure 3 Disconnect the A C compressor clutch electrical connector Fig 5 4 Remove the suction ...

Page 2078: ... and install the 4 spacers and retaining bolts Fig 6 Torque the bolts to 33 N m 25 ft lbs 3 Slide the drive coupler into its original position and start the remaining 2 H Block bolts Fig 6 4 Install the serpentine drive belt See Group 7 Cooling System for the procedure 5 Torque all H Block retaining bolts to 33 N m 25 ft lbs 6 Lower the vehicle from the hoist 7 Install the suction and discharge re...

Page 2079: ...ial Tool C 6461 Fig 8 6 Remove the compressor shaft key and the clutch shims 7 Remove the external front housing snap ring with snap ring pliers Fig 9 8 Install the lip of the rotor puller Special Tool C 6141 1 into the snap ring groove exposed in the previous step and install the shaft protector Special Tool C 6141 2 Fig 10 Fig 7 Clutch Nut Remove 1 CLUTCH PLATE 2 SPANNER Fig 8 Clutch Plate Remov...

Page 2080: ...ing and the compressor must be replaced Check the clutch pulley bearing for roughness or excessive leakage of grease Replace the bearing if required INSTALLATION 1 Install the clutch field coil and snap ring 2 Install the clutch coil lead wire harness retain ing clip on the compressor front housing and tighten the retaining screw 3 Align the rotor assembly squarely on the front compressor housing ...

Page 2081: ...ginal or a new clutch assembly try the original shims first When install ing a new clutch onto a compressor that previously did not have a clutch use 1 0 0 50 and 0 13 milli meter 0 040 0 020 and 0 005 inch shims from the clutch hardware package that is provided with the new clutch 9 Reverse the remaining removal procedures to complete the installation CLUTCH BREAK IN After a new compressor clutch...

Page 2082: ... this section Certain criteria must be met before the PCM stores a DTC in memory The criteria may be a spe cific range of engine RPM engine temperature and or input voltage to the PCM The PCM might not store a DTC for a monitored circuit even though a malfunction has occurred This may happen because one of the DTC criteria for the circuit has not been met For example assume the diagnostic trouble ...

Page 2083: ...ize the difference between a selected switch position versus an open circuit a short circuit or a defective switch If the State Display screen shows the change from HIGH to LOW or LOW to HIGH assume the entire switch circuit to the PCM functions properly Connect the DRB scan tool to the data link connector and access the state display screen Then access either State Display Inputs and Outputs or S...

Page 2084: ...eptable voltage P0113 M Intake Air Temp Sensor Voltage High Intake air charge temperature sensor input above the maximum acceptable voltage P0116 A rationatilty error has been detected in the coolant temp sensor P0117 M ECT Sensor Voltage Too Low Engine coolant temperature sensor input below the minimum acceptable voltage P0118 M ECT Sensor Voltage Too High Engine coolant temperature sensor input ...

Page 2085: ...or Shorted To Ground Oxygen sensor input voltage maintained below normal operating range P0144 M 1 3 O2 Sensor Shorted To Voltage Oxygen sensor input voltage maintained above normal operating range P0145 M 1 3 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency P0146 M 1 3 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxyg...

Page 2086: ...Temp Sensor Voltage Too Low Compressed natural gas temperature sensor voltage below acceptable voltage P0183 M CNG Temp Sensor Voltage Too High Compressed natural gas temperature sensor voltage above acceptable voltage P0201 M Injector 1 Control Circuit An open or shorted condition detected in control circuit for injector 1 or the INJ 1 injector bank P0202 M Injector 2 Control Circuit An open or s...

Page 2087: ...above the maximum acceptable voltage P0251 M Fuel Inj Pump Mech Failure Fuel Valve Feedback Circuit Problem sensed with fuel circuit internal to fuel injection pump P0253 M Fuel Injection Pump Fuel Valve Open Circuit Problem sensed with fuel circuit internal to fuel injection pump P0254 Fuel Injection Pump Fuel Valve Current Too High Problem caused by internal fuel injection pump failure P0300 M M...

Page 2088: ... achieved with maximum dwell time high impedance P0357 M Ignition Coil 7 Primary Circuit Peak primary circuit current not achieved with maximum dwell time high impedance P0358 M Ignition Coil 8 Primary Circuit Peak primary circuit current not achieved with maximum dwell time high impedance P0370 Fuel Injection Pump Speed Position Sensor Sig Lost Problem caused by internal fuel injection pump failu...

Page 2089: ...l sending unit voltage does not change for more than 40 miles P0462 Fuel Level Sending Unit Volts Too Low Fuel level sensor input below acceptable voltage P0462 M Fuel Level Sending Unit Volts Too Low Open circuit between PCM and fuel gauge sending unit P0463 Fuel Level Sending Unit Volts Too High Fuel level sensor input above acceptable voltage P0463 M Fuel Level Sending Unit Volts Too High Circu...

Page 2090: ...ke Switch Stuck Pressed or Released Incorrect input state detected in the brake switch circuit Changed from P1595 P0711 M Trans Temp Sensor No Temp Rise After Start Relationship between the transmission temperature and overdrive operation and or TCC operation indicates a failure of the Transmission Temperature Sensor OBD II Rationality Was MIL code 37 P0712 Trans Temp Sensor Voltage Too Low Transm...

Page 2091: ... overdrive solenoid is unable to engage the gear change from 3rd gear to the overdrive gear P0801 Reverse Gear Lockout Circuit Open or Short An open or shorted condition detected in the transmission reverse gear lock out solenoid control circuit P0830 Clutch Depressed Switch Circuit Problem detected in clutch switch circuit P0833 Clutch Released Switch Circuit Problem detected in clutch switch cir...

Page 2092: ...d Air Intake does not change intake air temperature sensor an acceptable amount P1291 M No Temperature Rise Seen From Intake Air Heaters Problem detected in intake manifold air heating system P1292 CNG Pressure Sensor Voltage Too High Compressed natural gas pressure sensor reading above acceptable voltage P1293 CNG Pressure Sensor Voltage Too Low Compressed natural gas pressure sensor reading belo...

Page 2093: ... range P1479 Transmission Fan Relay Circuit An open or shorted condition detected in the transmission fan relay circuit P1480 PCV Solenoid Circuit An open or shorted condition detected in the PCV solenoid circuit P1481 EATX RPM Pulse Perf EATX RPM pulse generator signal for misfire detection does not correlate with expected value P1482 Catalyst Temperature Sensor Circuit Shorted Low Catalyst tempe...

Page 2094: ...peed radiator fan control relay P1594 G Charging System Voltage Too High Battery voltage sense input above target charging voltage during engine operation P1594 Charging System Voltage Too High Battery voltage sense input above target charging voltage during engine operation P1595 Speed Control Solenoid Circuits An open or shorted condition detected in either of the speed control vacuum or vent so...

Page 2095: ...n ECM and Injection Pump Module Data link circuit failure between ECM and fuel injection pump Low power engine derated or engine stops P1690 M Fuel Injection Pump CKP Sensor Does Not Agree With ECM CKP Sensor Problem in fuel sync signal Possible injection pump timing problem Low power engine derated or engine stops P1691 Fuel Injection Pump Controller Calibration Error Internal fuel injection pump...

Page 2096: ...Zero Pressure Malfunction P1757 M Governor Pressure Above 3 PSI In Gear With 0 MPH Governor pressure greater than 3 psi when requested to be 0 psi 4 speed auto trans only P1762 M Gov Press Sen Offset Volts Too Lo or High The Governor Pressure Sensor input is greater than a calibration limit or is less than a calibration limit for 3 consecutive park neutral calibrations P1762 M Governor Press Sen O...

Page 2097: ...ould produce inaccurate results Conflict There are situations when the Task Manager does not run a test if another monitor is in progress In these situations the effects of another monitor run ning could result in an erroneous failure If this con flict is present the monitor is not run until the conflicting condition passes Most likely the monitor will run later after the conflicting monitor has p...

Page 2098: ...s essential for running monitors and extinguishing the MIL In OBD II terms a trip is a set of vehicle operating conditions that must be met for a specific monitor to run All trips begin with a key cycle Good Trip The Good Trip counters are as follows Specific Good Trip Fuel System Good Trip Misfire Good Trip Alternate Good Trip appears as a Global Good Trip on DRB III Comprehensive Components Majo...

Page 2099: ...aptive to calculate the Adaptive Memory Factor for total fuel correction Upstream O2S Volts A live reading of the Oxygen Sensor to indicate its performance For example stuck lean stuck rich etc SCW Time in Window Similar Conditions Window Time in Window A timer used by the PCM that indicates that after all Similar Conditions have been met if there has been enough good engine running time in the SC...

Page 2100: ... to switch from lean to rich once it is exposed to a richer than optimum A F mixture or vice versa As the sen sor starts malfunctioning it could take longer to detect the changes in the oxygen content of the exhaust gas The output voltage of the O2S ranges from 0 to 1 volt A good sensor can easily generate any output voltage in this range as it is exposed to different con centrations of oxygen To ...

Page 2101: ...ion of the test sequence as the pump diaphragm assembly moves to the full travel position Evaporative system functionality will be verified by using the stricter evap purge flow monitor At an appropriate warm idle the LDP will be energized to seal the canister vent The purge flow will be clocked up from some small value in an attempt to see a shift in the 02 control system If fuel vapor indicated ...

Page 2102: ...turn the MIL OFF In this case it depends on what type of DTC is set to know what a Trip is For the Fuel Monitor or Mis Fire Monitor contin uous monitor the vehicle must be operated in the Similar Condition Window for a specified amount of time to be considered a Good Trip If a Non Contiuous OBDII Monitor such as Oxygen Sensor Catalyst Monitor Purge Flow Monitor Leak Detection Pump Monitor if equip...

Page 2103: ...injector is installed However these could result in a rich or lean condition causing the PCM to store a diagnostic trouble code for either misfire an oxygen sensor or the fuel system EXCESSIVE OIL CONSUMPTION Although the PCM monitors engine exhaust oxygen content when the system is in closed loop it cannot determine excessive oil consumption THROTTLE BODY AIR FLOW The PCM cannot detect a clogged ...

Page 2104: ...acuum to draw vapors into the com bustion chambers during certain operating condi tions All engines use a duty cycle purge system The PCM controls vapor flow by operating the duty cycle EVAP purge solenoid Refer to Duty Cycle EVAP Canister Purge Solenoid When equipped with certain emissions packages a Leak Detection Pump LDP will be used as part of the evaporative system for OBD II requirements Al...

Page 2105: ... is used only with certain emission packages The LDP is a device used to detect a leak in the evaporative system The pump contains a 3 port solenoid a pump that contains a switch a spring loaded canister vent valve seal 2 check valves and a spring diaphragm Immediately after a cold start engine temperature between 40 F and 86 F the 3 port solenoid is briefly energized This initializes the pump by ...

Page 2106: ...ines a molded vacuum tube connects manifold vacuum to top of cylinder head valve cover at dash panel end The vacuum fitting contains a fixed orifice of a calibrated size It meters the amount of crankcase vapors drawn out of the engine On 2 5L 4 cylinder engines a fitting on drivers side of cylinder head valve cover contains the metered orifice It is connected to manifold vacuum A fresh air supply ...

Page 2107: ...ntains an engine vacuum sche matic There are unique labels for vehicles built for sale in the state of California and the country of Canada Canadian labels are written in both the English and French languages These labels are per manently attached and cannot be removed without defacing information and destroying label DIAGNOSIS AND TESTING VACUUM SCHEMATICS A vacuum schematic for emission related ...

Page 2108: ...ote location of lines before removal 2 Remove EVAP canister and mounting bracket assembly from body 3 nuts 3 Remove canister from mounting bracket 2 nuts INSTALLATION 1 Position canister into canister mounting bracket Align 2 canister dowel pins into rubber bushings 2 Install 2 canister nuts and tighten to 5 N m 45 in lbs torque 3 Position canister and bracket assembly to body 4 Install 3 nuts and...

Page 2109: ...ust be firmly connected Check the vapor vacuum lines at the LDP LDP filter and EVAP canister purge solenoid for damage or leaks If a leak is present a Diagnos tic Trouble Code DTC may be set 4 Connect electrical connector to LDP SPECIFICATIONS TORQUE CHART Description Torque EVAP Canister Mounting Nuts canister to mounting bracket 5 N m 45 in lbs EVAP Canister Mounting Bracket Nuts mounting bracke...

Page 2110: ...fuel tempera ture and or input voltage to the ECM A DTC indi cates that the ECM has identified an abnormal signal in a circuit or the system A DTC may indicate the result of a failure but never identify the failed component directly There are several operating conditions that the ECM does not monitor and set a DTC for Refer to the following Monitored Circuits and Non Monitored Circuits in this sec...

Page 2111: ...er DTC criteria are met a DTC will be stored in memory Other DTC criteria might include engine rpm limits or input voltages from other sensors or switches The other inputs might have to be sensed by the ECM when it senses a high or low input voltage from the control system device in question DIAGNOSTIC TROUBLE CODES DESCRIPTION On the following pages a list of DTC s is provided for the 2 5L diesel...

Page 2112: ...eed Sensor Static Plausibilty P1105 Atmosphere Pressure Sensor SRC High Exceeded Atmosphere Pressure Sensor SRC Low Exceeded P1110 Air Temp Sensor SRC High Exceeded Air Temp Sensor SRC Low Exceeded P1201 Needle Movement Sensor SRC High Exceeded Needle Movement Sensor SRC Low Exceeded P1220 Fuel Quantity Actuator Neg Gov Deviation Cold Fuel Quantity Actuator Neg Gov Deviation Warm Fuel Quantity Act...

Page 2113: ...ort Circuit P1660 Redundant Emer Stop Plausibility In After Run Redundant Emer Stop Powerstage Defective P1680 EEPROM Plausibility Checksum Error for Adj EEPROM Plausibility Checksum Error in CC212 EEPROM Plausibility Communication With EEPROM EEPROM Plausibility Func Switch Wrong or Missing EEPROM Plausibility VIN Checksum Error P1685 Vehicle Theft Alarm Immobilizer Signal Lost Vehicle Theft Alar...

Page 2114: ...l Pressure Sense High P0601 Internal Controller Failure P0622 Generator Field Not Switching Properly P1296 5 VDC Output P1391 Loss of Cam or Crank P1492 Ambient Batt temp Sen Volts Too High P1493 Ambient Batt temp Sen Volts Too Low P1594 Charging System Voltage Too High P1682 Charge Output Low P1685 SKIM Invalid Key P1686 No SKIM Bus Message Recieved P1687 No MIC Bus Message P1696 PCM Failure EEPR...

Page 2115: ...lity OPERATION The system consists of An EGR valve assembly The valve is located on the side of the intake manifold An Electric Vacuum Modulator EVM The EVM is sometimes referred to as the EGR control solenoid or EGR duty cycle solenoid The EVM controls the on time of the EGR valve The ECM operates the EVM The ECM is located inside the vehicle under the instrument panel An EGR tube connects a pass...

Page 2116: ...R tube to the EGR valve and remove the EGR tube 4 Remove the two bolts retaining the EGR valve to the intake manifold elbow and remove EGR valve 5 Discard both of the old EGR mounting gaskets INSTALLATION 1 Clean the intake manifold of any old gasket material 2 Clean the end of EGR tube of any old gasket material 3 Position the EGR valve and new gasket to the intake manifold elbow 4 Install two EG...

Page 2117: ...tall electrical connector to EVM 2 Install EVM and tighten mounting screws Fig 3 3 Connect vacuum hoses Fig 3 4 Connect the negative battery cable SPECIFICATIONS TORQUE CHART 2 5L DIESEL Description Torque EGR Valve Mounting Bolts 23 N m 204 in lbs EGR Tube Mounting Bolts 23 N m 204 in lbs EVM Mounting Bolt 2 N m 20 in lbs Fig 3 Electric Vacuum Modulator EVM 1 POWERTRAIN CONTROL MODULE PCM 2 EVM H...

Page 2118: ..._____________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ What comments or suggestions do you have ________________________________________ __________________________________________________________________________...

Page 2119: ...DaimlerChrysler International Operations Attn Publications Dept CIMS 486 02 70 800 Chrysler Drive Auburn Hills MI 48326 2757 ...

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