Jeep Cherokee 1999 Electronic Service Manual Download

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Summary of Contents for Cherokee 1999

Page 1: ...HOFRPH WR WKH HHS KHURNHH OHFWURQLF 6HUYLFH 0DQXDO OLFN 2Q 7KH RJR 7R HJLQ...

Page 2: ...itions that the vehi cle is subjected to Schedule A lists scheduled maintenance to be performed when the vehicle is used for general trans portation Schedule B lists maintenance intervals for vehi cle...

Page 3: ...CLASSIFICA TION This symbol Fig 2 on the front of an oil container means that the oil has been certified by the Ameri can Petroleum Institute API to meet all the lubri cation requirements specified b...

Page 4: ...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 REAR AXLE 194 RBI 1 66 L 3 5...

Page 5: ...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...

Page 6: ...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 8...

Page 7: ...Change engine oil Replace engine oil filter Lubricate steering linkage Drain and refill automatic transmission fluid Drain and refill front and rear axles Inspect brake linings Lubricate steering and...

Page 8: ...ine oil Replace engine oil filter Lubricate steering linkage Drain and refill automatic transmission fluid Drain and refill front and rear axles Inspect brake linings Lubricate steering and suspension...

Page 9: ...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 oil filter Lubricate steering linkage Lubricate steering a...

Page 10: ...O 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...

Page 11: ...rdize the safety of the operator pedestrians or other motorists Do not attach tow chains T hooks J hooks or a tow sling to a bumper steering linkage drive shafts or a non reinforced frame hole GROUND...

Page 12: ...board of shock absorber 3 Place sling crossbar under and forward of bumper 4 Attach safety chains around frame rails 5 Turn ignition switch to OFF position to unlock steering wheel 6 Secure steering...

Page 13: ...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...

Page 14: ...when minimum temperatures consis tently fall below 12 C FLUID CAPACITIES FUEL TANK Diesel Engine Equipped Vehicles 76 4 L ENGINE OIL 2 5L Diesel Engine includes filter 6 5 L COOLING SYSTEM 2 5L Diese...

Page 15: ...ICE 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 necessa...

Page 16: ...eck drive belt tension Check glow plug operation SCHEDULE B 500 KM Check correct torque intake manifold mounting nuts Check correct torque exhaust manifold mount ing nuts Check correct torque turbocha...

Page 17: ...engine oil Change engine oil filter 80 000 KM Change engine oil Change engine oil filter Replace air filter element Check glow plug operation Replace drive belt Check engine smoke Replace engine coola...

Page 18: ...es positive camber Incorrect camber will cause wear on the inside or outside edge of the tire The angle is not adjustable damaged component s must be replaced to correct the camber angle WHEEL TOE POS...

Page 19: ...Fig 1 Wheel Alignment Measurements 2 2 SUSPENSION XJ GENERAL INFORMATION Continued...

Page 20: ...icle to specifications 5 Leaking steering dampener 5 Replace steering dampener VEHICLE INSTABILITY 1 Loose or worn wheel bearings 1 Adjust or replace wheel bearings 2 Loose or worn steering or suspens...

Page 21: ...incorrect caster angle is probable Caster can be adjusted by installing the appropri ate size shims Fig 2 NOTE Changing caster angle will also change the front propeller shaft angle The propeller shaf...

Page 22: ...nd tighten to 49 N m 36 ft lbs NOTE Make sure the toe setting does not change during clamp tightening 4 Adjust the right wheel toe position with the tie rod Turn the sleeve until the right wheel is at...

Page 23: ...TMENT PREFERRED RANGE MAX RT LT DIFFERENCE CASTER 7 0 5 25 to 8 5 1 25 ADJUSTMENT PREFERRED RANGE MAX RT LT DIFFERENCE CAMBER fixed angle 0 25 0 75 to 0 5 1 0 TOTAL TOE IN 0 25 0 to 0 45 05 THRUST ANG...

Page 24: ...SPECIFICATIONS TORQUE CHART 13 SPECIAL TOOLS FRONT SUSPENSION 13 DESCRIPTION AND OPERATION SUSPENSION COMPONENTS The front suspension is a link coil design Fig 1 This suspension is use on Left Hand D...

Page 25: ...ith a nut and cotter pin must be torqued to specification Then if the slot in the nut does not line up with the cotter pin hole tighten nut until it is aligned Never loosen the nut to align the cotter...

Page 26: ...rom the axle 6 Remove the track bar from the body rail bracket 7 Remove the drag link from the pitman arm 8 Lower the axle until the spring is free from the upper mount Remove the coil spring clip and...

Page 27: ...t to 90 N m 66 ft lbs FRONT AXLE BUSHING REMOVAL 1 Remove the upper suspension arm from axle 2 Position Spacer 7932 3 over the axle bushing on a 4x2 vehicle and right side on a 4x4 vehicle 3 Place Rec...

Page 28: ...at the stabilizer bar to 36 N m 27 ft lbs 6 Remove the supports and lower the vehicle TRACK BAR REMOVAL 1 Raise and support the vehicle 2 Remove the cotter pin and nut from the ball stud end at the bo...

Page 29: ...ghten to 102 N m 75 ft lbs 3 Install the hub washer and nut Tighten the hub nut to 237 N m 175 ft lbs Install the nut retainer and a new cotter pin 4 Install the brake rotor caliper and ABS wheel spee...

Page 30: ...r Front Nut 74 N m 55 ft lbs Rear Nut 89 N m 66 ft lbs Suspension Arm Low er Front Nut 115 N m 85 ft lbs Rear Nut 115 N m 85 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40 ft lbs Link Upper Nut 36 N m 27...

Page 31: ...olted to the frame rail above the axle CAUTION Suspension components with rubber urethane bushings except stabilizer bar should be tightened with the vehicle at normal ride height It is important to h...

Page 32: ...ock 3 Leaking shock 3 Replace shock REMOVAL AND INSTALLATION SHOCK ABSORBER REMOVAL 1 Remove the shock absorber upper bolts from the body bracket Fig 1 2 Remove lower attaching nut and washer from the...

Page 33: ...ighten at this time 2 Position the rear eye in the shackle bracket Loosely install the attaching bolt and nut Do not tighten at this time 3 Position the axle Install the spring bracket U bolts and nut...

Page 34: ...ATIONS 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 7...

Page 35: ......

Page 36: ...stantly changing relative angles between the trans mission and axle It must also be capable of changing length while transmitting torque The axle rides sus pended by springs in a floating motion This...

Page 37: ...proper propeller shaft joint work ing angles are maintained A propeller shaft is properly phased when the yoke ends are in the same plane or in line A twisted shaft will make the yokes out of phase an...

Page 38: ...rmation Driveline vibration can also result from loose or damaged engine mounts Refer to Group 9 Engines for additional information Propeller shaft vibration increases as the vehicle speed is increase...

Page 39: ...engine 9 Install a screw clamp at position 1 Fig 5 10 Start the engine and re check for vibration If there is little or no change in vibration move the clamp to one of the other three positions Repeat...

Page 40: ...tion as when the vibration occurred Propeller shaft angles change according to the amount of load in the vehicle Check the condition of all suspension compo nents and verify all fasteners are torqued...

Page 41: ...lace Inclinometer on pinion yoke bearing cap parallel to the shaft Fig 10 Center bubble in sight glass and record measurement This measurement w ill give you the pinion shaft or input yoke angle B 6 S...

Page 42: ...nstallation reference Fig 12 3 Remove the universal joint strap bolts at the pinion shaft yoke 4 Disconnect the propeller shaft at the transfer case and remove the propeller shaft INSTALLA TION 1 Posi...

Page 43: ...stallation reference marks at the axle yoke and install the propeller shaft Fig 15 Replacement universal joint straps and bolts must be installed 2 Tighten the universal joint strap clamp bolts at the...

Page 44: ...fully press the end of the cross until the remaining bearing cap can be removed Fig 19 CAUTION If the cross or bearing cap are not straight during installation the bearing cap will score the walls of...

Page 45: ...ap assembly to loosen snap ring 3 Remove all the bearing cap snap rings Fig 22 4 Set the joint in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap...

Page 46: ...2 Fit a cross into the propeller shaft yoke Fig 26 3 Place a bearing cap over the trunnion and align the cap with the yoke bore Fig 27 Keep the needle bearings upright in the bearing assembly A needle...

Page 47: ...two trun nions and press both bearing caps into place Fig 30 8 Install snap rings 9 Install the centering kit assembly inside the link yoke making sure the spring is properly posi tioned Fig 31 Fig 28...

Page 48: ...ck for proper assembly Flex the joint beyond center it should snap over center in both directions when correctly assembled Fig 35 14 Install the propeller shaft CLEANING AND INSPECTION PROPELLER SHAFT...

Page 49: ...s Fig 37 Adding shims will decrease the pinion gear shaft angle but will increase the caster angle The pinion gear shaft angle has pri ority over the caster angle Refer to Group 2 Suspen sion for addi...

Page 50: ...vapor ization and internal expansion The axles are equipped with semi floating axle shafts meaning that loads are supported by the hub bearings The axle shafts are retained by nuts at the hub bearing...

Page 51: ...en 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 thro...

Page 52: ...arings are loaded Road test the vehicle Turn the vehicle sharply to the left and to the right This will load the bearings and change the noise level Where axle bearing damage is slight the noise is us...

Page 53: ...FRONT AXLES DIAGNOSIS 3 18 DIFFERENTIAL AND DRIVELINE XJ DIAGNOSIS AND TESTING Continued...

Page 54: ...DIAGNOSIS CONTINUED XJ DIFFERENTIAL AND DRIVELINE 3 19 DIAGNOSIS AND TESTING Continued...

Page 55: ...ess from the vehicle wiring harness if necessary 7 Disconnect the vent hose from the axle shaft tube 8 Mark the propeller shaft and yoke for installa tion alignment reference 9 Remove propeller shaft...

Page 56: ...il springs will drop with the axle 14 Remove the coil springs from the axle INSTALLA TION CAUTION The weight of the vehicle must be sup ported by the springs before suspension arms and track bar faste...

Page 57: ...n 3 Place the socket driver against one bearing cap Position the yoke with the socket wrench in a vise 4 Compress the vise to force the bearing caps into the yoke Force the caps enough to install the...

Page 58: ...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 Specifi...

Page 59: ...shield from the hub bearing or knuckle Fig 10 INSTALLA TION 1 Thoroughly clean the axle shaft Fig 10 and apply a thin film of Mopar Wheel Bearing Grease or equivalent to the shaft splines seal contac...

Page 60: ...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 rod or drag link from the steering knuckle arm...

Page 61: ...T Refer to Group 2 Suspension for the proper axle bushing procedures DIFFERENTIAL REMOVAL 1 Raise and support vehicle 2 Remove the lubricant fill hole plug from the differential housing cover 3 Remove...

Page 62: ...hile holding the differential case in position remove the differential bearing cap bolts and caps 12 Remove the differential from the housing Ensure that the differential bearing cups remain in positi...

Page 63: ...th the dial indicator Fig 19 4 Remove the dial indicator 5 Install differential case in the housing Ensure that the differential bearing cups remain in position on the differential bearings Tap the di...

Page 64: ...LLA TION 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 25 Tighten tool...

Page 65: ...e 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 h...

Page 66: ...shim should not require replacement Refer to Pinion Gear Depth to select the proper thickness shim before installing pinion gear 1 Place proper thickness depth shim in rear pin ion bearing cup bore in...

Page 67: ...ase pinion gear bearing rotating torque and never exceed specified preload rotating torque 11 Check bearing preload torque with an inch pound torque wrench Fig 39 The torque necessary to rotate the pi...

Page 68: ...torque remove the pinion yoke and decrease the thickness of the preload shim pack Decreasing the shim pack thick ness 0 025 mm 0 001 in will increase the rotating torque approximately 0 9 N m 8 in lb...

Page 69: ...oll pin holes in shaft and the differential case 4 Install the roll pin to hold the pinion mate shaft in the differential case Fig 42 5 Install the ring gear 6 Lubricate all differential components wi...

Page 70: ...ut any raised edges Raised metal on shoulders of cup bores should be removed with a hand stone Wear and damage to pinion gear mate shaft pinion gears side gears and thrust washers Replace as a matched...

Page 71: ...ce chart Note where Old and New Pinion Marking columns intersect Intersecting figure represents plus or minus the amount needed Note the etched number on the face of the drive pinion gear 1 2 0 1 2 et...

Page 72: ...he rearward surface of the pinion height block Fig 46 Hold scooter block in place and zero the dial indicator face to the pointer Tighten dial indicator face lock screw 7 With scooter block still in p...

Page 73: ...ckness is the total of the dial indicator reading and the preload specifica tion added together The gear backlash measurement determines the thickness of the shim used on the ring gear side of the dif...

Page 74: ...reload the new bearings when the differential is installed 15 Rotate dial indicator out of the way on the guide stud 16 Remove differential case and dummy bearings from axle housing 17 Install the pin...

Page 75: ...l case in 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 59 3...

Page 76: ...l around the pinion yoke to increase the turning resistance of the pinion gear This will provide a more distinct contact pattern 3 Using a boxed end wrench on a ring gear bolt Rotate the differential...

Page 77: ...Fig 61 Gear Tooth Contact Patterns 3 42 DIFFERENTIAL AND DRIVELINE XJ ADJUSTMENTS Continued...

Page 78: ...Rotating Torque Original Bearings 1 2 N m 10 20 in lbs New Bearings 1 5 4 N m 15 35 in lbs 181 FBI AXLE DESCRIPTION TORQUE Fill Hole Plug 34 N m 25 ft lbs Diff Cover Bolt 41 N m 30 ft lbs Bearing Cap...

Page 79: ...Dial Indicator C 3339 Driver C 3716 A Handle C 4171 Installer D 146 Remover D 149 Installer W 162 D Cup 8109 Remover Installer 6289 3 44 DIFFERENTIAL AND DRIVELINE XJ SPECIAL TOOLS Continued...

Page 80: ...nstaller 6761 Installer 6752 Installer Discs 8110 Turnbuckle 6797 Tool Set Pinion Depth 6774 Gauge Block 6733 Spanner 6958 Installer C 3972 A XJ DIFFERENTIAL AND DRIVELINE 3 45 SPECIAL TOOLS Continued...

Page 81: ...Spreader W 129 B Adapter Kit 6987 Pilot Stud C 3288 B Remover D 147 Installer D 144 Installer W 262 3 46 DIFFERENTIAL AND DRIVELINE XJ SPECIAL TOOLS Continued...

Page 82: ...ization and internal expansion 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 diff...

Page 83: ...ve with the pinion mate shaft but do not rotate around it Fig 2 When turning corners the outside wheel must travel a greater distance than the inside wheel to complete a turn The difference must be co...

Page 84: ...appens at a specific speed range The range is 30 to 40 mph or above 50 mph The noise can also occur during a specific type of driving condition These conditions are acceleration deceleration coast or...

Page 85: ...ls and Tires for additional vibration information DRIVELINE SNAP A snap or clunk noise when the vehicle is shifted into gear or the clutch engaged can be caused by High engine idle speed Loose engine...

Page 86: ...DIAGNOSIS CHART XJ DIFFERENTIAL AND DRIVELINE 3 51 DIAGNOSIS AND TESTING Continued...

Page 87: ...DIAGNOSIS CHART CONTINUED 3 52 DIFFERENTIAL AND DRIVELINE XJ DIAGNOSIS AND TESTING Continued...

Page 88: ...ith a flushing oil light engine oil or lint free cloth Do not use w ater steam kerosene or gasoline for cleaning 5 Remove the original sealant from the housing and cover surfaces 6 Apply a bead of Mop...

Page 89: ...hock 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 Br...

Page 90: ...torque or rotating torque is exceeded a new col lapsible spacer must be installed The torque sequence will then have to be repeated 5 Rotate the pinion shaft using a in lbs torque wrench Rotating tor...

Page 91: ...o lightly tap the end of the pinion gear with a rawhide or rub ber mallet if the bearing becomes bound on the pin ion shaft 12 Remove the collapsible spacer REMOVAL W PINION REMOVED 1 Raise and suppor...

Page 92: ...ue 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 9 Using yoke holder 6958 and a torque wrench set at 47...

Page 93: ...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 lock screw is accessible Remove lock screw and pinion...

Page 94: ...r roughness and burrs Remove as necessary INSTALLA TION Do not install the original axle shaft seal Alw ays install a new seal 1 Wipe the axle shaft tube bore clean 2 Install axle shaft bearing with I...

Page 95: ...ups to indicate which side of the differential they were removed from 14 Retrieve differential case preload shims from axle housing Mark or tag the differential case pre load shims to indicate which s...

Page 96: ...remain between the face of the bearing cup and the housing Tap the differential case to ensure the bearings cups and shims are fully seated in the housing 6 Install the bearing caps at their original...

Page 97: ...rential in axle housing and verify gear mesh and contact pattern PINION GEAR The ring and pinion gears are serviced in a matched set Do not replace the pinion gear without replacing the ring gear REMO...

Page 98: ...damage the bearing cage 13 Remove the depth shims from the pinion gear shaft Record the thickness of the depth shims INSTALLA TION 1 Apply Mopar Door Ease or equivalent stick lubricant to outside surf...

Page 99: ...hould not require replacement If required refer to Pinion Gear Depth to select the proper thick ness shim before installing rear pinion bearing 7 Place the proper thickness depth shim on the pinion ge...

Page 100: ...crush collapsible spacer until bearing end play is taken up Fig 46 NOTE If the spacer requires more than 474 N m 350 ft lbs torque to crush the collapsible spacer is defective and must be replaced 15...

Page 101: ...differential can result in lubricant foaming and overheating 3 Refill the differential housing with gear lubri cant Refer to the Lubricant Specifications section of this group for the gear lubricant...

Page 102: ...e and install the pinion gear mate shaft lock screw 5 Lubricate all differential components with hypoid gear lubricant TRAC LOK DIFFERENTIAL The Trac lok differential components are illus trated in Fi...

Page 103: ...a small screw driver in slot of Threaded Adapter C 6960 1 Fig 56 to prevent adapter from turning 9 Tighten forcing screw tool 122 N m 90 ft lbs maximum to compress Belleville springs in clutch packs...

Page 104: ...r lubricant before assembly 1 Assemble the clutch discs into packs and secure disc packs with retaining clips Fig 61 2 Position assembled clutch disc packs on the side gear hubs 3 Install clutch pack...

Page 105: ...case It may be necessary to slightly tighten the forcing screw in order to install the pin ion gears 12 Tighten forcing screw to 122 N m 90 ft lbs maximum to compress the Belleville springs 13 Lubric...

Page 106: ...in cleaning solvent Dry com ponents with compressed air Inspect clutch pack plates for wear scoring or damage Replace both clutch packs if any one component in either pack is damaged Inspect side and...

Page 107: ...t PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion cups and pin ion bearings installed in housing Take measure ments with a Pinion Gauge Set Pinion Block 6735 Arbor Discs 673...

Page 108: ...Bring dial pointer back to zero against the arbor bar do not turn dial face Continue moving the dial probe to the crest of the arbor bar and record the highest reading If the dial indicator can not ac...

Page 109: ...ts 7 Using a dead blow type mallet seat the differ ential dummy bearings to each side of the axle hous ing Fig 72 and Fig 73 8 Thread guide stud C 3288 B into rear cover bolt hole below ring gear Fig...

Page 110: ...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...

Page 111: ...tact patterns will show if the pinion gear depth is correct in the axle housing It will also show if the ring gear back lash has been adjusted correctly The backlash can be adjusted within specificati...

Page 112: ...Fig 79 Gear Tooth Contact Patterns XJ DIFFERENTIAL AND DRIVELINE 3 77 ADJUSTMENTS Continued...

Page 113: ...mm 0 005 0 008 in Pinion Std Depth 92 08 mm 3 625 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 TORQUE 194 RBI AXLE DESCRI...

Page 114: ...Wrench C 3281 Installer C 3972 A Spanner 6958 Installer Screw 8112 Cup 8109 Handle C 4171 Driver C 3716 A Installer D 130 XJ DIFFERENTIAL AND DRIVELINE 3 79 SPECIAL TOOLS Continued...

Page 115: ...Installer D 146 Remover C 4345 Remover D 149 Installer W 262 Installer 6436 Installer 6437 Disc Axle Arbor 6732 Gauge Block 6735 3 80 DIFFERENTIAL AND DRIVELINE XJ SPECIAL TOOLS Continued...

Page 116: ...et Pinion Depth 6774 Trac lok Tool Set 6960 Holder 6965 Puller 7794 A Starting Point Shim 8107 Spreader W 129 B Adapter Kit 6987 Guide Pin C 3288 B XJ DIFFERENTIAL AND DRIVELINE 3 81 SPECIAL TOOLS Con...

Page 117: ...Bearing Remover Tool Set 6310 Hub Puller 6790 Dial Indicator C 3339 3 82 DIFFERENTIAL AND DRIVELINE XJ SPECIAL TOOLS Continued...

Page 118: ...floating axle shafts meaning vehicle loads are supported by the axle shaft and bearings The axle shafts are retained by C clips in the differential side gears The removable stamped steel cover provid...

Page 119: ...In operation power flow occurs as follows The pinion gear rotates the ring gear The ring gear bolted to the differential case rotates the case The differential pinion gears mounted on the pinion mate...

Page 120: ...applied through the ring gear Fig 5 The Trac lok design provides the differential action needed for turning corners and for driving straight ahead during periods of unequal traction When one wheel loo...

Page 121: ...d 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...

Page 122: ...DIAGNOSIS CHART XJ DIFFERENTIAL AND DRIVELINE 3 87 DIAGNOSIS AND TESTING Continued...

Page 123: ...DIAGNOSIS CHART CONTINUED 3 88 DIFFERENTIAL AND DRIVELINE XJ DIAGNOSIS AND TESTING Continued...

Page 124: ...lint free cloth Do not use w ater steam kerosene or gasoline for cleaning 5 Remove the original sealant from the housing and cover surfaces 6 Apply a bead of Mopar Silicone Rubber Seal ant or equival...

Page 125: ...up 5 Brakes for proper proce dures 8 Install 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 Insta...

Page 126: ...Foot 6310 9 Fig 11 INSTALLA TION 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 a...

Page 127: ...and Handle C 4735 1 Fig 14 NOTE The seal is correctly installed when the seal flange contacts the face of the differential housing flange 6 Position the pinion yoke on the end of the shaft with the re...

Page 128: ...th the installa tion reference marks aligned 14 Tighten the universal joint yoke clamp screws to 19 N m 14 ft lbs 15 Install the brake drums 16 Install wheel and tire assemblies and lower the vehicle...

Page 129: ...s and differential housing cover DIFFERENTIAL SIDE BEARINGS REMOVAL 1 Remove differential case from axle housing 2 Remove the bearings from the differential case with Puller Press C 293 PA and Adapter...

Page 130: ...t pattern PINION GEAR The ring and pinion gears are serviced in a matched set Do not replace the pinion gear without replacing the ring gear REMOVAL 1 Remove differential from the axle housing 2 Mark...

Page 131: ...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...

Page 132: ...bearing cup 4 Install the pinion front bearing cup Fig 31 with Installer D 130 and Handle C 4171 5 Install pinion front bearing and oil slinger if equipped 6 Apply a light coating of gear lubricant o...

Page 133: ...be possible at this point to achieve zero bearing end play if a new col lapsible spacer was installed 13 Tighten the nut to 285 N m 210 ft lbs CAUTION Never loosen pinion gear nut to decrease pinion g...

Page 134: ...the differential case and install the pinion gear mate shaft lock screw 5 Lubricate all differential components with hypoid gear lubricant TRAC LOK DIFFERENTIAL The Trac lok differential components a...

Page 135: ...it becomes centered in adapter plate 8 Position a small screw driver in slot of Threaded Adapter 8140 1 Fig 43 to prevent adapter from turning 9 Tighten forcing screw tool 122 N m 90 ft lbs maximum t...

Page 136: ...rs from differential case 15 Remove Forcing Screw 6960 4 Step Plate 8140 2 and Threaded Adapter 8140 1 16 Remove top side gear clutch pack retainer and clutch pack Keep plates in correct order during...

Page 137: ...differential case Fig 49 Be sure clutch pack retaining clips remain in position and are seated in the case pockets 4 Position the differential case on Side Gear Holding Tool 8138 5 Install lubricated...

Page 138: ...h compressed air Cup and bearing must be replaced as matched sets only Clean axle shaft tubes and oil channels in housing Inspect for Smooth appearance with no broken dented sur faces on the bearing r...

Page 139: ...The shims are placed under the rear pinion bearing cone Fig 52 If a new gear set is being installed note the depth variance marked on both the original and replace ment pinion gear Add or subtract the...

Page 140: ...P 6029 in the dif ferential housing Fig 55 20 Center the arbor tool 21 Position the bearing caps on the arbor tool 22 Install the attaching bolts 23 Tighten the cap bolts to 14 N m 10 ft lbs 24 Trial...

Page 141: ...ain the gear teeth engaged meshed as marked The bearings must be seated by rapidly rotat ing the pinion gear a half turn back and forth Do this five to ten times each time the threaded adjusters are a...

Page 142: ...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...

Page 143: ...Fig 59 Gear Tooth Contact Patterns 3 108 DIFFERENTIAL AND DRIVELINE XJ ADJUSTMENTS Continued...

Page 144: ...klash 0 12 0 20 mm 0 005 0 008 in Runout 0 127 mm 0 005 in Pinion Bearing Preload 1 2 N m 10 20 in lbs TORQUE 8 1 4 INCH AXLE DESCRIPTION TORQUE Diff Cover Bolt 41 N m 30 ft lbs Bearing Cap Bolt 136 N...

Page 145: ...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 3 110 DIFFERENTIAL AND DRIVELINE XJ SPECIAL TOOLS Continued...

Page 146: ...Adapters C 293 48 Plug SP 3289 Adapters C 293 47 Installer C 4340 Holder 8138 Installer C 4345 Remover C 4307 Installer C 4308 XJ DIFFERENTIAL AND DRIVELINE 3 111 SPECIAL TOOLS Continued...

Page 147: ...Installer D 130 Installer 6448 Trac lok Tools 8140 Trac lok Tools 6960 Gauge Set C 3715 B 3 112 DIFFERENTIAL AND DRIVELINE XJ SPECIAL TOOLS Continued...

Page 148: ...OCEDURES BRAKE FLUID LEVEL 11 MASTER CYLINDER BLEEDING 11 BASE BRAKE BLEEDING 12 DISC ROTOR MACHINING 12 BRAKE DRUM MACHINING 12 BRAKE TUBE FLARING 13 REMOVAL AND INSTALLATION STOP LAMP SWITCH 14 BRAK...

Page 149: ...ontaining 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...

Page 150: ...e 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...

Page 151: ...ainst the caliper piston and within the caliper bore will be equal Fig 2 Fluid pressure applied to the piston is transmitted directly to the inboard brake shoe This forces the shoe lining against the...

Page 152: ...ng point for the rear cables Fig 5 The rear cables are connected to the actuating lever on each secondary brake shoe The levers are attached to the brake shoes by a pin either pressed into or welded t...

Page 153: ...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 cond...

Page 154: ...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 ti...

Page 155: ...e components However calipers that bind on the slide surfaces can generate a thump or clunk noise In addition worn out improperly adjusted or improperly assembled rear brake shoes can also produce a t...

Page 156: ...uge to booster check valve with short length of hose and T fitting Fig 7 2 Start and run engine at curb idle speed for one minute 3 Observe the vacuum supply If vacuum supply is not adequate repair va...

Page 157: ...ig 9 Excessive lateral runout will cause brake pedal pulsation and rapid uneven wear of the brake shoes Position the dial indicator plunger approximately 25 4 mm 1 in inward from the rotor edge Maximu...

Page 158: ...threaded and tightened to recom mended torque BRAKE FLUID CONTAMINA TION Indications of fluid contamination are swollen or deteriorated rubber parts Swollen rubber parts indicate the presence of petr...

Page 159: ...using pressure equipment Do not exceed the tank manufacturers pressure recommendations Gen erally a tank pressure of 15 20 psi is sufficient for bleeding Fill the bleeder tank with recommended fluid...

Page 160: ...on gauge in the tube Then swing compression disc over gauge and center tapered flar ing screw in recess of compression disc Fig 15 9 Tighten tool handle until plug gauge is squarely seated on jaws of...

Page 161: ...ng the booster to the pedal support bracket and nuts to the column bracket 5 Remove pedal and support bracket as an assembly from the vehicle INSTALLA TION 1 Install pedal and support bracket as an as...

Page 162: ...r 3 Install master cylinder onto brake booster studs 4 Install mounting nuts and tighten to 17 5 N m 155 in lbs 5 Install combination valve and install mounting nuts 6 Connect brake lines to master cy...

Page 163: ...result in vacuum leak 9 Align and install master cylinder on booster studs Install mounting nuts and tighten to 17 5 N m 155 in lbs 10 Connect vacuum hose to booster check valve 11 Connect and secure...

Page 164: ...g ledge Then rotate caliper over rotor and seat notches at upper end of shoes on top mounting ledge Fig 29 3 Coat caliper mounting bolts with silicone grease Then install and tighten bolts to 15 N m 1...

Page 165: ...vehicle 2 Remove wheel and tire assembly 3 Remove caliper 4 Pressing one end of outboard shoe inward to disengage shoe lug Then rotate shoe upward until retainer spring clears caliper Press opposite...

Page 166: ...mary and secondary return springs from anchor pin with brake spring pliers 6 Remove hold down springs retainers and pins with standard retaining spring tool 7 Install spring clamps on wheel cylinders...

Page 167: ...move brake shoe assembly 3 Remove parking brake cable from parking brake lever 4 Compress parking brake cable retainer tabs Then push retainer and cable through and out of support plate 5 Disconnect b...

Page 168: ...from backing plates INSTALLA TION 1 Install new cables in backing plates Be sure cable retainer is seated 2 Attach cable to lever on brake shoe and install brake shoe on backing plate 3 Adjust brake...

Page 169: ...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 bra...

Page 170: ...Y 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 Place this piece in the out board shoe side of the cali...

Page 171: ...rease 3 Install bushing boots in caliper then insert bush ing into boot and push bushing into place Fig 50 4 Install new piston seal into seal groove with finger Fig 51 5 Install new dust boot on cali...

Page 172: ...d insert push rods in boots 5 Install cylinder bleed screw CLEANING AND INSPECTION CALIPER CLEANING Clean the caliper components with clean brake fluid or brake clean only Wipe the caliper and piston...

Page 173: ...iscard the brake springs and retainer components if worn distorted or collapsed Also replace the springs if a brake drag condition had occurred Over heating will distort and weaken the springs Inspect...

Page 174: ...ract brake shoes Continue adjustment until gauge outside legs are light drag fit on shoes 8 Install brake drums and wheels and lower vehicle 9 Drive vehicle and make one forward stop fol lowed by one...

Page 175: ...usting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket 10 Lower vehicle until rear wheels are 15 20 cm 6 8 in off shop floor 11 Release parking brake lever and...

Page 176: ...Cylinder Mounting Nuts 17 5 N m 155 in lbs Brake Lines 19 N m 170 in lbs Combination Valve Mounting Nuts 17 5 N m 155 in lbs Brake Lines 19 N m 170 in lbs Caliper Mounting Bolts 15 N m 11 ft lbs Brak...

Page 177: ...from other electri cal circuits in the vehicle A specially programmed controller antilock brake unit operates the system components ABS system major components include Controller Antilock Brakes CAB...

Page 178: ...switch in the RUN position The CAB contains dual microprocessors A logic block in each microprocessor receives identical sensor signals These signals are processed and compared simultaneously The CAB...

Page 179: ...nd 1300 ohms SPEED SENSOR AIR GAP Front Sensor Front sensor air gap is fixed and not adjustable Only rear sensor air gap is adjustable Although front air gap is not adjustable it can be checked if dia...

Page 180: ...r additional informa tion refer to the Antilock Brake section in Group 8W For test procedures refer to the Chassis Diag nostic Manual SERVICE PROCEDURES BLEEDING ABS BRAKE SYSTEM ABS system bleeding r...

Page 181: ...ht 4 Tighten sensor attaching bolt to 4 7 N m 42 in lbs 5 If original sensor has been installed check sen sor air gap Air gap should be 0 36 to 1 5 mm 0 014 to 0 059 in If gap is incorrect sensor is e...

Page 182: ...bolt if original is worn or damaged 4 Install sensor bolt finger tight only at this time 5 If original rear sensor was installed adjust sensor air gap to 0 92 1 275 mm 0 036 0 05 in Use feeler gauge t...

Page 183: ...to the front of the vehicle Fig 13 1 Position switch in mounting bracket 2 Install switch mounting bolts and tighten to 3 N m 27 5 in lbs 3 Connect harness to switch Be sure harness connector is firm...

Page 184: ...olt 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 Whe...

Page 185: ......

Page 186: ...sure plate The release bearing is operated by a release fork in the clutch housing The fork pivots on a ball stud mounted in the housing The release fork is actuated by a hydraulic slave cylinder moun...

Page 187: ...s and pivot shaft Use Mopar high temperature bearing grease or equivalent for the pilot bearing release bearing bore transmission input shaft and release fork compo nents Apply recommended amounts onl...

Page 188: ...Heat buildup caused by slippage between the clutch cover disc and flywheel can sometimes bake the oil residue onto the components The glaze like residue ranges in color from amber to black Road splash...

Page 189: ...Clutch Components 6 4 CLUTCH XJ DIAGNOSIS AND TESTING Continued...

Page 190: ...essive stock removal can result in flywheel cracking or warpage after installation it can also weaken the flywheel and interfere with proper clutch release Clean the crankshaft flange before mounting...

Page 191: ...and or diaphragm spring warped or distorted 1 Rough handling Impact bent cover spring or disc 1 Replace disc or cover as necessary 2 Improper bolt tightening procedure 2 Tighten clutch cover using pr...

Page 192: ...will not disengage properly 1 Low clutch fluid level 1 Replace hydraulic linkage assembly 2 Clutch cover loose 2 Follow proper bolt tightening procedure 3 Clutch disc bent or distorted 3 Replace clutc...

Page 193: ...and cover clean before removing the cover This will avoid having dirt or foreign material fall into the reservoir during a fluid level check FL YWHEEL Inspect the flywheel whenever the clutch disc cov...

Page 194: ...mbly on a workbench and let it cool in normal shop air CAUTION Do not use water or compressed air to cool the flywheel The rapid cooling produced by water or compressed air can distort or crack the ge...

Page 195: ...is scored worn or cracked 4 Inspect release fork and fork pivot Be sure pivot is secure and in good condition Be sure fork is not distorted or worn Replace release fork retainer spring if bent or dama...

Page 196: ...clutch housing Dirt foreign material trapped between the housing and transmission will cause misalignment If misalignment is severe enough the result will be clutch drag incomplete release and hard sh...

Page 197: ...and tighten slave cylinder attaching nuts to 23 N m 17 ft lbs torque 9 Secure clutch fluid line in body and transmis sion clips 10 Lower vehicle 11 Connect clutch interlock safety switch wires SPECIFI...

Page 198: ...luid level will actually increase as normal clutch wear occurs For this rea son it is important to avoid over filling or remov ing fluid from the reservoir If inspection indicates additional fluid is...

Page 199: ...the fly wheel 5 Insert the clutch alignment tool Fig 3 in clutch disc and pilot bearing 6 Position the clutch cover over disc and on fly wheel 7 Install the clutch cover bolts finger tight 8 Starting...

Page 200: ...earing retainer to the flywheel Fig 4 4 Remove the pilot bearing retainer 5 Support the bearing retainer on two wood blocks 6 Remove the pilot bearing with a suitable sized socket and extension Fig 5...

Page 201: ...nkshaft flange 7 Remove the o ring from the crankshaft flange or the mounting shoulder of the flywheel Fig 9 8 Clean the flywheel in solvent INSPECTION Examine the flywheel mounting surfaces clutch co...

Page 202: ...and expanding the new ring gear is extremely important Every surface of the gear must be heated at the same time to pro duce uniform expansion An oven or similar enclosed heating device must be used...

Page 203: ...N m 34 ft lbs Flyw heel to Crankshaft Bolts See removal and installation procedure Pilot Bearing Retainer to Flyw heel Crankshaft Bolts 28 N m 20 ft lbs Clutch Housing to Engine Top 2 Bolts 37 N m 27...

Page 204: ...ECTRIC COOLING F AN 19 ON BOARD DIAGNOSTICS OBD 8 PRELIMINARY CHECKS 11 RADIATOR CAP TO FILLER NECK SEAL PRESSURE RELIEF CHECK 19 RADIATOR CAP PRESSURE TESTING 20 RADIATOR COOLANT FLOW CHECK 17 VISCOU...

Page 205: ...r pressure cap Thermostat Coolant reserve overflow system Transmission oil cooler if equipped with an automatic transmission Coolant Water pump Hoses and hose clamps COOLING SYSTEM CIRCULA TION Coolin...

Page 206: ...the internal radiator mounted transmission oil cooler engine cool ant may become mixed with transmission fluid or transmission fluid may enter engine cooling system Both cooling system and transmissi...

Page 207: ...RATE ENGINE UNLESS BLOCK HEATER CORD HAS BEEN DISCONNECTED FROM POWER SOURCE AND SECURED IN PLACE BLOCK HEATER SPECIFICATIONS 2 5L 4 Cylinder Engine 115 Volts 400 Watts 4 0L 6 Cylinder Engine 120 Volt...

Page 208: ...cles Propylene glycol ethylene glycol Mixtures can cause the destabilization of various corrosion inhibi tors causing damage to the various cooling system components Also once ethylene glycol and prop...

Page 209: ...o determine if the pump is working is to check if the heater warms properly A defective water pump will not be able to circulate heated cool ant through the long heater hose to the heater core COOLING...

Page 210: ...resent will the vis cous fan drive engage This is when the air flowing through the radiator core causes a reaction to the bimetallic coil It then increases fan speed to provide the necessary additiona...

Page 211: ...ed The cooling fan motor is protected by a 40 amp maxi fuse located in the PDC The fan relay is pro tected by a 15 amp fuse located in the junction block DIAGNOSIS AND TESTING ON BOARD DIAGNOSTICS OBD...

Page 212: ...BELT WEAR 1 Pulley misaligned 1 Align pulley s 2 Abrasive environment 2 Clean pulley s Replace belt if necessary 3 Rusted pulley s 3 Clean rust from pulley s 4 Sharp or jagged pulley groove tips 4 Rep...

Page 213: ...mble is heard or felt while drive belt is in operation 1 Belt slippage 1 Adjust belt 2 Bearing noise 2 Locate and repair 3 Belt misalignment 3 Align belt pulley s 4 Belt to pulley mismatch 4 Install c...

Page 214: ...ling system refill ing possibly under filled or air trapped in system NOTE If investigation reveals none of the previous items as a cause for an engine overheating com plaint refer to following Coolin...

Page 215: ...led tightly If cap is loose boiling point of coolant will be lowered Also refer to the following Step 6 5 Tighten cap 6 Poor seals at the radiator cap 6 a Check condition of cap and cap seals Refer to...

Page 216: ...der head gasket leaking 19 Check for cylinder head gasket leaks Refer to Cooling System Testing For Leaks in this Group For repair refer to Group 9 Engines 20 Heater core leaking 20 Check heater core...

Page 217: ...rrect as necessary 10 Air leak on the suction side of the water pump allows air to build up in cooling system causing thermostat to open late 10 Locate leak and repair as necessary PRESSURE CAP IS BLO...

Page 218: ...H MAX COOLING 1 Blown Fuse in Power Distribution Center PDC 1 Determine reason for blown fuse and repair as necessary 2 Fan relay powertrain control module PCM or coolant temperature sensor defective...

Page 219: ...E GRILL AREA WHEN WEATHER IS WET ENGINE IS WARMED UP AND RUNNING AND VEHICLE IS STATIONARY TEMPERATURE GAUGE IS IN NORMAL RANGE 1 During wet weather moisture snow ice or rain condensation on the radia...

Page 220: ...olant level Push down on the cap to disengage it from the stop tabs Wipe the inner part of the filler neck and examine the lower inside sealing seat for nicks cracks paint dirt and solder residue Insp...

Page 221: ...solution is clean drain the coolant into a clean container for reuse WARNING DO NOT REMOVE THE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIO...

Page 222: ...ode DTC in memory if it detects a problem in the auxiliary cooling fan relay or circuit Refer to Group 25 Emission Control Systems for cor rect DTC retrieval procedures If the electric cooling fan is...

Page 223: ...ement CAP INSPECTION Visually inspect the pressure valve gasket on the cap Replace cap if the gasket is swollen torn or worn Inspect the area around radiator filler neck for white deposits that indica...

Page 224: ...olant If the solution is clean drain the coolant into a clean container for reuse 1 Remove radiator pressure cap 2 For access to radiator draincock Fig 15 remove radiator grille mounting screws and re...

Page 225: ...operating instructions supplied with flushing equipment Remove the lead away hose flushing gun water supply hose and air supply hose Remove the thermo stat housing and install thermostat Install the t...

Page 226: ...r pump impeller is pressed on the rear of the pump shaft and bearing assembly The water pump is serviced only as a complete assembly WARNING DO NOT REMOVE THE BLOCK DRAIN PLUG S OR LOOSEN RADIATOR DRA...

Page 227: ...the heater hose fit ting must be removed Note position of fitting before removal INSTALLA TION 2 5L ENGINE LHD RHD 1 If pump is being replaced install the heater hose pipe to the pump Use a sealant on...

Page 228: ...e viscous fan shroud bolts 2 6 Loosen but do not remove at this time the four water pump pulley to water pump hub mounting bolts Fig 23 and the four viscous fan to idler pulley nuts NOTE The accessory...

Page 229: ...facing the water pump Also the gasket is installed dry Tighten mounting bolts to 23 N m 17 ft lbs torque Rotate the shaft by hand to be sure it turns freely 4 Connect the radiator and heater hoses to...

Page 230: ...UMBER HPC 20 MAY BE USED FOR LARGER CLAMPS ALWAYS WEAR SAFETY GLASSES WHEN SERVIC ING CONSTANT TENSION CLAMPS CAUTION A number or letter is stamped into the tongue of constant tension clamps Fig 7 If...

Page 231: ...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 eq...

Page 232: ...four mounting bolts 4 Install radiator upper crossmember to isolator nuts Tighten nuts to 10 N m 86 in lbs torque If isolator to radiator nuts had been removed tighten them to 5 N m 47 in lbs torque 5...

Page 233: ...ssary use only an original equipment clamp with matching number or letter REMOVAL 1 Disconnect battery negative cable 2 Observe the previous WARNINGS 3 Remove radiator pressure cap 4 For access to rad...

Page 234: ...of engine compartment taking care not to damage fins INSTALLA TION The radiator is supplied with two alignment dowels Fig 35 They are located on the bottom tank and fit into rubber grommets in the rad...

Page 235: ...ch power steering reservoir from fan shroud 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...

Page 236: ...Fig 36 Fan Shroud Removal Installation Fig 37 Fan Module Orientation and Mounting Fig 38 Auxiliary Cooling Fan Remove Install Typical XJ COOLING SYSTEM 7 33 REMOVAL AND INSTALLATION Continued...

Page 237: ...he belt driven engine acces sories There are different types of adjustment gauges for checking either a serpentine or a V type belt Refer to the instructions supplied with the gauge Use the correct ga...

Page 238: ...d correctly tighten idler pulley bolt to 47 N m 35 ft lbs 5 After idler pulley has been tightened into posi tion recheck belt tension Adjust if necessary BELT REPLACEMENT OR ADJUSTMENT RIGHT HAND DRIV...

Page 239: ...s section for proper belt tension 4 Tighten alternator upper and lower mounting bolts 5 After generator and adjust bracket have been tightened into position recheck belt tension Adjust if necessary CO...

Page 240: ...0 ft lbs torque 2 Position mounting flange of fan blade viscous fan drive assembly onto hub Install four nuts and tighten to 24 N m 18 ft lbs torque Tighten the first two nuts 180 degrees apart Then t...

Page 241: ...ceding Removal procedure 2 Remove fan blade assembly from viscous fan drive unit four bolts 3 Lay fan on a flat surface with leading edge fac ing down With tip of blade touching flat surface replace f...

Page 242: ...n lbs Generator Pivot Bolt 38 N m 28 ft lbs Generator Rear Adj Bolt 27 N m 20 ft lbs Isolator to Crossmember Nuts 10 N m 86 in lbs Isolator to Radiator Nuts 5 N m 47 in lbs Radiator 4 0L Engine Mounti...

Page 243: ......

Page 244: ...EANING 25 WATER PUMP 25 SPECIFICA TIONS COOLING SYSTEM CAPACITY 26 THERMOSTAT 26 TORQUE SPECIFICATIONS 26 GENERAL INFORMATION COOLING SYSTEM The cooling system regulates engine operating tem perature...

Page 245: ...times CAUTION When installing a serpentine accessory drive belt the belt MUST be routed correctly If not the engine may overheat due to water pump rotat ing in wrong direction Refer to the engine Bel...

Page 246: ...er Fig 2 A quick test to determine if the pump is working is to check if the heater warms properly A defective water pump will not be able to circulate heated cool ant through the long heater hose to...

Page 247: ...E ETHYLENE GL YCOL MIXTURES The required ethylene glycol antifreeze and water mixture depends upon the climate and vehicle oper ating conditions The recommended mixture of 50 50 ethylene glycol and wa...

Page 248: ...t hoses It controls coolant flow to the heater core when the air conditioning sys tem is in operation Radiator lower hoses are spring reinforced to pre vent collapse from water pump suction at moderat...

Page 249: ...lt in engine overheating 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 occur when am...

Page 250: ...for more air flow is rec ommended 2 TRAILER TOWING Consult Trailer Towing section of owners manual Do not exceed limits 3 RECENT SERVICE OR ACCIDENT REPAIR Determine if any recent service has been pe...

Page 251: ...COOLING SYSTEM DIAGNOSIS DIESEL ENGINE 7 8 COOLING SYSTEM XJ DIAGNOSIS AND TESTING Continued...

Page 252: ...XJ COOLING SYSTEM 7 9 DIAGNOSIS AND TESTING Continued...

Page 253: ...7 10 COOLING SYSTEM XJ DIAGNOSIS AND TESTING Continued...

Page 254: ...XJ COOLING SYSTEM 7 11 DIAGNOSIS AND TESTING Continued...

Page 255: ...7 12 COOLING SYSTEM XJ DIAGNOSIS AND TESTING Continued...

Page 256: ...n This is checked prior to performing the following test It also will ensure against excessively high coolant tem perature WARNING BE SURE OF ADEQUATE FAN BLADE CLEARANCE BEFORE DRILLING 1 Drill a 3 1...

Page 257: ...ing temperature With the engine turned off attach the cooling system pressure tester and test the sys tem as described below Recheck the system cold if the cause of coolant loss is not located during...

Page 258: ...d adapter set Fig 10 must be used to adapt a standard pressure type tester Fig 11 when testing either the coolant tank or pressure cap Use Kent Moore adapter set number J 24460 92 or Snap On numbers T...

Page 259: ...o replace the belt However cracks running along a rib not across are not nor mal Any belt with cracks running along a rib must be replaced Fig 12 Also replace the belt if it has excessive wear frayed...

Page 260: ...SERPENTINE DRIVE BELT DIAGNOSIS XJ COOLING SYSTEM 7 17 DIAGNOSIS AND TESTING Continued...

Page 261: ...ontainer for reuse 1 Observe the previous WARNINGS and remove the coolant tank pressure vent cap 2 The plastic radiator draincock is located on the bottom of the left radiator tank It can be accessed...

Page 262: ...STANT 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 14 ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CO...

Page 263: ...r viscous fan drive removal 1 Disconnect negative battery cable from battery 2 The thermal viscous fan drive fan blade assem bly is attached threaded to the fan pulley shaft Fig 17 Remove fan blade vi...

Page 264: ...rive belts have reverse rotating fans and viscous fan drives They are marked with the word REVERSE to designate their usage Installation of the wrong fan or viscous fan drive can result in engine over...

Page 265: ...s torque 5 Install radiator hose to thermostat housing 6 Be sure that the radiator drain is tightly closed Fill the cooling system to the correct level with the required coolant mixture Refer to Refil...

Page 266: ...ember mounting bolts One of the bolts is mounted vertically at the bottom of the fan shroud 6 Slip the fan shroud rearward Remove the fan shroud and viscous drive fan blade together as one assembly fr...

Page 267: ...e four water pump mounting bolts Torque bolts to 24 N m 18 ft lbs 6 Install drain hose to vent tube at bottom of pump 7 Position the water pump pulley to the water pump 8 Install the water pump pulley...

Page 268: ...TEMPT TO BEND OR STRAIGHTEN FAN BLADES IF NOT WITHIN SPECI FICATIONS 4 Inspect fan assembly for cracks bends loose rivets or broken welds Replace fan if any damage is found CAUTION If fan blade assemb...

Page 269: ...ater control valve is closed heat off This is done to prevent coolant flow with scale and other deposits from entering the heater core Connect the water supply hose and air supply hose to the flushing...

Page 270: ...t glass of the indicator will reveal the battery condition Refer to Built In Test Indicator in the Diagnosis and Testing section of this group for more information This group covers only the battery d...

Page 271: ...f electrical current through the load device attached to the bat tery terminals As the plate materials become more similar chem ically and the electrolyte becomes less acid the volt age potential of e...

Page 272: ...ure Sensor in the Description and Opera tion section of Group 8C Charging System for more information on this component When installing a battery be certain that the hold down fasteners are tightened...

Page 273: ...ne of three ways If the battery has a built in test indicator view the test indicator to determine the state of charge If the battery has no test indicator but has removable cell caps perform the hydr...

Page 274: ...erminal connections if required 4 Determine the battery state of charge Refer to Built In Test Indicator Hydrometer Test or Open Circuit Voltage Test in the Diagnosis and Testing section of this group...

Page 275: ...in the Diagnosis and Testing section of Group 8C Charging System for more information Repair the charging system if required 8 Inspect the vehicle for aftermarket electrical equipment which might cau...

Page 276: ...ted Refer to Load Test in the Diagnosis and Testing section of this group for more information Black or Dark indicates 0 to 75 state of charge The battery is inadequately charged and must be charged u...

Page 277: ...ly battery failure To read the hydrometer correctly hold it with the top surface of the electrolyte at eye level Fig 4 Hydrometer floats are generally calibrated to indi cate the specific gravity corr...

Page 278: ...etely charge the battery Refer to Battery Charging in the Ser vice Procedures section of this group for the proper battery charging procedures 1 Before measuring the open circuit voltage the surface c...

Page 279: ...tions provided by the manufacturer of the tester you are using Check the open circuit voltage no load of the battery Refer to Open Circuit Voltage Test in the Diagnosis and Testing section of this gr...

Page 280: ...CAPS The following operation will require a voltmeter accurate to 1 10 0 10 volt Before performing the tests be certain the following procedures are accom plished The battery is fully charged Refer t...

Page 281: ...nition switch in the Off position and all non ignition controlled circuits in proper working order The twenty five milliamperes are needed to enable the memory functions for the Powertrain Con trol Mo...

Page 282: ...om the generator If the amperage reading now becomes very low or nonexistent refer to Charging System in the Diagnosis and Testing section of Group 8C Charging System to diagnose the condition After t...

Page 283: ...a completely discharged battery Unless this proce dure is properly followed a good battery may be needlessly replaced 1 Measure the voltage at the battery posts with a voltmeter accurate to 1 10 0 10...

Page 284: ...minal clamps for corrosion and damage Remove any corrosion using a wire brush or a post and terminal cleaning tool and a sodium bicarbonate baking soda and warm water cleaning solution Fig 16 Replace...

Page 285: ...ery case and the top cover with a sodium bicarbonate baking soda and warm water cleaning solution to remove any acid film Fig 19 Rinse the battery with clean water Ensure that the cleaning solution do...

Page 286: ...the battery positive cable terminal clamp Then connect and tighten the bat tery negative cable terminal clamp Tighten both bat tery cable terminal clamp bolts to 8 5 N m 75 in lbs 5 Apply a thin coati...

Page 287: ......

Page 288: ...ng an integral starter sole noid Ignition switch Clutch pedal position switch manual transmis sion Park neutral position switch automatic trans mission Wire harnesses and connections including the bat...

Page 289: ...in the Neutral or Park positions When the starter relay coil is energized the nor mally open relay contacts close The relay contacts connect the relay common feed terminal to the relay normally open t...

Page 290: ...relay Relays conforming to the ISO specifications have common physical dimensions current capacities terminal patterns and terminal functions The starter relay cannot be repaired or adjusted and if f...

Page 291: ...y 2 Starting circuit wiring faulty 3 Starter motor faulty 4 Engine seized 1 Refer to Battery in the Diagnosis and Testing section of Group 8A Battery Charge or replace the battery if required 2 Refer...

Page 292: ...rter relay for indications of physical damage and loose or corroded wire harness connections Starter Motor Visually inspect the starter motor for indications of physical damage and loose or corroded w...

Page 293: ...n that the following procedures are accomplished Battery is fully charged and load tested Refer to Battery in the Diagnosis and Testing section of Group 8A Battery for the procedures Fully engage the...

Page 294: ...in the Diagnosis and Testing section of this group CONTROL CIRCUIT TESTING The starter control circuit components should be tested in the order in which they are listed as fol lows Starter Relay Refe...

Page 295: ...lar 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 req...

Page 296: ...or free running test maximum amperage draw specifications 7 If the ammeter reading exceeds the maximum amperage draw specification replace the faulty starter motor assembly STARTER SOLENOID This test...

Page 297: ...Pedal Position Sw itch in the Diag nosis and Testing section of Group 6 Clutch for test ing of the switch 5 The coil ground terminal 85 is connected to the electromagnet in the relay On vehicles with...

Page 298: ...wire harness 8 Remove the starter motor from the engine com partment INSTALLA TION 2 5L ENGINE 1 Position the starter motor in the engine com partment 2 Reconnect the solenoid terminal wire harness co...

Page 299: ...the transmission clutch housing or torque converter housing and loosely install both the upper and lower mounting screws 6 Tighten the lower forward facing starter motor mounting screw Tighten the scr...

Page 300: ...er of Brushes 4 Drive Type Planetary Gear Reduction Free Running Test Voltage 11 2 Volts Free Running Test Maximum Amperage Draw 90 Amperes Free Running Test Minimum Speed 2 5L 2600 rpm 4 0L 2500 rpm...

Page 301: ......

Page 302: ...and plug Fig 2 6 Remove the right engine mount through bolt nut only 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 r...

Page 303: ...e 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 remov...

Page 304: ...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 engin...

Page 305: ...test 350 Amperes Test at operating temperature Cold engine tight new engine or heavy oil will increase starter amperage draw TORQUE SPECIFICA TIONS DESCRIPTION TORQUE Engine Mount Throughbolt 65 N m 4...

Page 306: ...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 b...

Page 307: ...y monitors system line voltage and bat tery temperature refer to Battery Temperature Sen sor for more information It then compensates and regulates generator current output accordingly Also refer to C...

Page 308: ...em REMOVAL AND INSTALLATION GENERA TOR REMOVAL WARNING DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE B WIRE FROM GENERATOR FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE...

Page 309: ...elt adjustment bolts Install generator lower nut bolt 7 RHD Vehicles On vehicles equipped with RHD the generator is used to adjust the serpentine belt Refer to Group 7 Cooling System for belt routing...

Page 310: ...RA TINGS TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS DENSO 56041822AA 124 2 5L 4 0L 90 TORQUE CHART Right Hand Drive RHD Left Hand Drive LHD Description Torque Generator Mounting Bolt L...

Page 311: ......

Page 312: ...Never force a belt over a pulley rim using a screwdriver The synthetic fiber of the belt can be damaged CAUTION When installing a serpentine accessory drive belt the belt must be routed correctly The...

Page 313: ...mounting bolt Fig 3 4 Tighten the mounting bolts to proper torque Upper mounting bolt 27 5 N m 20 ft lbs Lower mounting bolt 47 N m 35 ft lbs 5 Connect the field terminal connector at rear of generat...

Page 314: ...ISTANCE 16 SPARK PLUGS 16 TORQUE CHART 17 DESCRIPTION AND OPERATION IGNITION SYSTEM The ignition systems used on the 2 5L 4 cylinder and the 4 0L 6 cylinder engine are basically identi cal Similaritie...

Page 315: ...roblem exists in the corresponding cylinder Replace spark plugs at the intervals recommended in Group O Lubrication and Maintenance Spark plugs that have low milage may be cleaned and reused if not ot...

Page 316: ...the corresponding piston The engine will not operate if the PCM does not receive a crankshaft position sensor input CAMSHAFT POSITION SENSOR The camshaft position sensor is located in the dis tributo...

Page 317: ...issions for procedures On vehicles equipped with a manual transmission a lever is located on the steering column behind the ignition key lock cylinder The lever must be operated to allow rotation of t...

Page 318: ...or Fig 10 for cracks evi dence of corrosion or the effects of arcing on the metal tip Also check for evidence of mechanical interference with the cap Some charring is normal on the end of the metal ti...

Page 319: ...gnition coil to distributor cap cable do not remove the cable from the cap Connect ohmmeter to rotor button center contact of distributor cap and terminal at ignition coil end of cable If resistance i...

Page 320: ...be either white or yel low Fig 14 They may appear to be harmful but this is a normal condition caused by chemical addi tives in certain fuels These additives are designed to change the chemical nature...

Page 321: ...ion timing detonation and cooling system malfunctions can also cause spark plug overheating REMOVAL AND INSTALLATION SPARK PLUG CABLE REMOVAL CAUTION When disconnecting a high voltage cable from a spa...

Page 322: ...y result in a change in the spark plug gap or a cracked por celain insulator When replacing the spark plug and ignition coil cables route the cables correctly and secure them in the appropriate retain...

Page 323: ...ine combinations may require removal of air cleaner tubes for access to sensor 1 Remove air cleaner tube s at throttle body if necessary 2 Near rear of intake manifold disconnect pigtail harness elect...

Page 324: ...sed to temporarily lock the rotor to the cylinder number 1 position during installation The pin must be removed after install ing the distributor The camshaft position sensor is located in the dis tri...

Page 325: ...otate slightly in a coun terclockwise direction while lifting up distributor This is due to the helical cut gears on distributor and camshaft 13 Note removed position of rotor during distrib utor remo...

Page 326: ...tributor into engine The rotor and distributor will rotate clockwise during installation This is due to the helical cut gears on distributor and camshaft When distributor is fully seated to engine bl...

Page 327: ...group See 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 cyli...

Page 328: ...connectors to rear of ignition switch Make sure that locking tabs are fully seated into wiring connectors 3 Position switch to column and install tamper proof screw Tighten screw to 3 N m 26 in lbs 4...

Page 329: ...shifter will be locked in the PARK position when the ignition key is in the LOCK or ACCESSORY positions The cable can be adjusted or replaced Refer to Group 21 Transmissions for procedures The ignitio...

Page 330: ...kshaft Position Sensor Mounting Bolts 19 N m 14 ft lbs Crankshaft Position Sensor Mounting Nuts 19 N m 14 ft lbs Distributor Hold Down Bolt 23 N m 17 ft lbs Ignition Coil Mounting if tapped bolts are...

Page 331: ......

Page 332: ...e 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 complet...

Page 333: ...a 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...

Page 334: ...mp four wheel drive indicator lamps headlamp high beam indicator lamp low washer fluid warning lamp and turn signal indicator lamps are hard wired The seat belt reminder lamp is controlled by the inst...

Page 335: ...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 ha...

Page 336: ...ired 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...

Page 337: ...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 while driving refer to Antilock B...

Page 338: ...Fig 1 Low Line Instrument Cluster Actuator Test XJ INSTRUMENT PANEL SYSTEMS 8E 7 DIAGNOSIS AND TESTING Continued...

Page 339: ...Fig 2 High Line Instrument Cluster Actuator Test 8E 8 INSTRUMENT PANEL SYSTEMS XJ DIAGNOSIS AND TESTING Continued...

Page 340: ...tion 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 harness connector A and...

Page 341: ...ood 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 Disconnect and...

Page 342: ...p locate a short or open in the indicator lamp circuit For complete circuit diagrams refer to Instrument Cluster in the Contents of Group 8W Wiring Diagrams 1 Disconnect and isolate the battery negati...

Page 343: ...rminal 30 in the ener gized position This terminal supplies battery voltage to the cigar lighter when the relay is energized by the ignition switch There should be continuity between the junction bloc...

Page 344: ...olumn opening cover to the lower instrument panel reinforcement Fig 4 4 Using a trim stick or another suitable wide flat bladed tool gently pry the upper edge of the steering column opening cover just...

Page 345: ...EMS 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 PO...

Page 346: ...o Instrument Panel Center Bezel in the Removal and Installation section of this group for the procedures 6 Reconnect the battery negative cable CIGAR LIGHTER RELA Y WARNING ON VEHICLES EQUIPPED WITH A...

Page 347: ...moval and Installation section of this group for the procedures 3 Remove the center bezel from the instrument panel Refer to Instrument Panel Center Bezel in the Removal and Installation section of th...

Page 348: ...cable 2 Remove the knee blocker from the instrument panel Refer to Knee Blocker in the Removal and Installation section of this group for the procedures 3 Pull the headlamp switch control knob out to...

Page 349: ...5 Reconnect the battery negative cable INSTRUMENT CLUSTER COMPONENTS Some of the components for the instrument cluster used in this vehicle are serviced individually The serviced components include t...

Page 350: ...e the instrument cluster from the instru ment panel Refer to Instrument Cluster in the Removal and Installation section of this group for the procedures 3 Remove the cluster lens from the cluster hous...

Page 351: ...N Always use the correct bulb size and type for replacement An incorrect bulb size or type may overheat and cause damage to the instrument cluster the electronic circuit board and or the gauges 1 Inse...

Page 352: ...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...

Page 353: ...ve box hinge to the instrument panel lower glove box opening reinforcement Fig 17 3 Release the glove box latch 4 Remove the glove box from the instrument panel INSTALLA TION 1 Position the glove box...

Page 354: ...f the glove box latch lock cylinder bore INSTALLA TION GLOVE BOX HINGE BIN INNER DOOR AND LA TCH 1 Position the inner glove box door unit onto the outer glove box door 2 Install and tighten the seven...

Page 355: ...tion section of Group 8M Passive Restraint Systems for the pro cedures 4 Close the glove box 5 Reconnect the battery negative cable INSTRUMENT PANEL END CAP WARNING ON VEHICLES EQUIPPED WITH AIR BAGS...

Page 356: ...nel Top Cover in the Removal and Installation section of this group for the procedures 5 Roll up the glove box into the instrument panel Refer to Glove Box Roll Dow n in the Removal and Installation s...

Page 357: ...e steering column from the vehicle Refer to Steering Column in the Removal and Installation section of Group 19 Steering for the procedures 7 Remove the screws from the centers of the instrument panel...

Page 358: ...val and Installation section of this group for the procedures 8 Reconnect the two wire harness connectors located near the instrument panel to floor wire har ness connector at the floor panel transmis...

Page 359: ...this group for the procedures 15 Install the trim onto the left and right cowl side inner panels Refer to Low er A Pillar Cow l Trim in the Removal and Installation section of Group 23 Body for the p...

Page 360: ...vehicle 5 Depress switch mounting tabs to remove switch from bezel REAR FOG LAMP SWITCH WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY ST...

Page 361: ...ory switch bezel with a small thin bladed screwdriver and pull the switch out of the receptacle 8 Reverse the removal procedures to install Be certain that both of the switch snap retainers in the rec...

Page 362: ...neral 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...

Page 363: ...o 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...

Page 364: ...ground There should be continuity Repair ground if required 5 See Radio in the Diagnosis and Testing section of this group CLOCK WILL NOT KEEP SET TIME 1 Fuse faulty 2 Radio connector faulty 3 Wiring...

Page 365: ...required 5 Connect the battery negative cable Turn the ignition switch to the On position Check for battery voltage at the fused ignition switch output accesso ry run circuit cavity of the left gray r...

Page 366: ...o Step 10 If not OK repair the open circuit to the PDC as required 10 Check for battery voltage at the two fused B circuit cavities of the amplifier wire harness connector If OK go to Step 11 If not O...

Page 367: ...est as follows 1 Connect one ohmmeter test lead to the vehicle fender Connect the other test lead to the battery negative post 2 The resistance should be less than one ohm 3 If the resistance is more...

Page 368: ...et vehicles are available with an extra cost RFI suppressed Powertrain Control Module PCM This unit reduces interference generated by the PCM on some radio frequencies used in two way radio com munica...

Page 369: ...er mounting screws to 2 8 N m 25 in lbs SPEAKER FRONT DOOR LOWER 1 Disconnect and isolate the battery negative cable 2 If the vehicle is so equipped remove the man ual window regulator crank handle wi...

Page 370: ...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...

Page 371: ...NOSIS 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 Remove the rig...

Page 372: ...URY REMOVAL ENGINE TO BODY GROUND STRAP 1 Remove the screw that secures the engine to body ground strap eyelet to the dash panel Fig 16 2 Remove the nut that secures the engine to body ground strap ey...

Page 373: ...rner 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 the screw to 27 N m 2...

Page 374: ...e 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 manua...

Page 375: ...O 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...

Page 376: ...nd 30 If OK perform the Relay Circuit Test that follows If not OK replace the faulty relay RELA Y CIRCUIT TEST 1 The relay common feed terminal cavity 30 is connected to battery voltage and should be...

Page 377: ...required 6 Check for continuity between the horn switch feed wire and the horn switch ground wire on the driver side airbag module There should be no conti nuity If OK go to Step 7 If not OK replace...

Page 378: ...res the trim panel to the right cowl side inner panel Tighten the screw to 2 2 N m 20 in lbs 8 Install the push nut that secures the right cowl side inner trim panel onto the junction block stud 9 Ins...

Page 379: ......

Page 380: ...CY SNOW COVERED OR SLIP PERY OPERA TION When speed control is selected by depressing the ON switch the PCM allows a set speed to be stored in PCM RAM for speed control To store a set speed depress the...

Page 381: ...l for more information on speed control switch functions and setting procedures The individual switches cannot be repaired If one individual switch fails the switch module must be replaced OPERA TION...

Page 382: ...ose damaged or corroded electrical connec tions at the servo Corrosion should be removed from electrical terminals and a light coating of Mopar MultiPurpose Grease or equivalent applied Leaking vacuum...

Page 383: ...ss than the desired set speed before finally achieving the desired set speed The Speed Control has an adaptive strategy that compensates for vehicle to vehicle variations in speed control cable length...

Page 384: ...5 N m 14 in lbs torque 4 Install airbag module Refer to Group 8M Pas sive Restraint Systems for procedures 5 Connect negative battery cable to battery STOP LAMP SWITCH Refer to Stop Lamp Switch in Gro...

Page 385: ...ve 1 Remove front bumper end cap Refer to Front Bumper End Cap in Group 23 Body for procedures 2 Remove vacuum line at reservoir Fig 7 3 Remove 2 reservoir mounting screws 4 Remove reservoir from bump...

Page 386: ...per end cap Refer to Group 23 Body for procedures 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...

Page 387: ......

Page 388: ...km h 35 MPH to 145 km h 90 MPH Inputs to the MSA that allow speed control oper ation are from the vehicle speed sensor and the Speed Control Switch Two separate speed control switch modules are mount...

Page 389: ......

Page 390: ...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...

Page 391: ...itch turn signal and haz ard 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 se...

Page 392: ...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...

Page 393: ...S 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...

Page 394: ...Warning Sys tems in the Diagnosis and Testing section of this group before testing the multi function switch For complete circuit diagrams refer to Turn Signals in the Contents of Group 8W Wiring Diag...

Page 395: ...and Installation section of Group 8E Instrument Panel Systems for the procedures 6 Reconnect the battery negative cable TURN SIGNAL SWITCH AND HAZARD WARNING SWITCH WARNING ON VEHICLES EQUIPPED WITH A...

Page 396: ...s 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 the left side of the...

Page 397: ......

Page 398: ...re 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...

Page 399: ...e 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 glas...

Page 400: ...f 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 swit...

Page 401: ...h 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 sup...

Page 402: ...p 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...

Page 403: ...uld be no continuity If OK go to Step 5 If not OK repair the short circuit as required 5 Check for continuity between the front washer switch output circuit cavities of the front washer pump wire harn...

Page 404: ...y chart Fig 2 4 If the switch fails any of the continuity checks replace the faulty switch If the switch is OK repair the wiper system and or washer system wire harness circuits as required REAR Perfo...

Page 405: ...blade from the wiper arm push the release tab under the arm tip and slide the blade away from the tip towards the rear wiper motor output shaft end of the arm Fig 4 3 To install the wiper blade on th...

Page 406: ...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 t...

Page 407: ...otor output shaft nut Fig 11 4 Pull the rear wiper motor output shaft bezel and rubber gasket away from the liftgate far enough to access the washer supply hose 5 Disconnect the washer supply hose fro...

Page 408: ...ower shrouds from the steering column 11 Remove the two screws that secure the multi function switch water shield and bracket to the top of the steering column Fig 13 12 Remove the one screw located b...

Page 409: ...ceptacle on the back of the accessory switch bezel and pull the switch out of the bezel 8 Reverse the removal procedures to install Be certain that both of the switch snap clip retainers in the recept...

Page 410: ...flat bladed tool gently pry the washer fluid level sen sor out of the rubber grommet seal Care must be taken not to damage the reservoir 3 Remove the rubber grommet seal from the res ervoir and discar...

Page 411: ...elease the snap clip retainers 3 Remove 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...

Page 412: ...t Do not use bulbs with higher candle power than indicated in the Bulb Application table at the end of this group Damage to lamp and or Daytime Run ning Lamp Module can result Do not use fuses circuit...

Page 413: ...epair charging system refer to Group 8A ABOVE IDLE 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations refer to Group 8W 3 High resistance in headlamp circuit 3 Test a...

Page 414: ...NGINE RUNNING ABOVE IDLE 1 Charging system output too low 1 Test and repair charging system Refer to Group 8A 2 Poor lighting circuit Z1 ground 2 Test for voltage drop across Z1 ground locations Refer...

Page 415: ...le connector terminal 8 and vehicle body ground The voltmeter should indicate battery voltage If not repair the open circuit in the wire harness from ignition switch to HDLP delay module 5 Turn headla...

Page 416: ...rpendicu lar to a flat wall 7 62 meters 25 ft away from front of headlamp lens Fig 1 2 If necessary tape a line on the floor 7 62 meters 25 ft away from and parallel to the wall 3 Measure from the flo...

Page 417: ...Clean front of the headlamps 3 Place headlamps on LOW beam 4 Cover front of the headlamp that is not being adjusted 5 Turn vertical adjustment screw Fig 3 until the headlamp beam pattern on screen wal...

Page 418: ...SPECIAL TOOLS HEADLAMP ALIGNMENT Fig 5 Fog Lamp Adjustment Fig 4 Fog Lamp Alignment Typical Headlamp Aiming Kit C 4466 A XJ LAMPS 8L 7 SERVICE PROCEDURES Continued...

Page 419: ...the vehicle INSTALLA TION 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 Rem...

Page 420: ...ousing 3 Install side marker lamp housing BACK UP 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...

Page 421: ...lb wire loop to the terminal closest to the lamp base wire connector 2 Depress the opposite terminal inward and engage the remaining bulb wire loop 3 Position the lamp lens on the lamp base and press...

Page 422: ...s up to snap into housing VISOR VANITY LAMP BULB REMOVAL 1 Using a small flat blade carefully pry each cor ner of lens outward from lamp 2 Separate lens from lamp 3 Grasp bulb and pull outward INSTALL...

Page 423: ...l Fig 2 6 Slide the headlamp bucket downward to disen gage it from the headlamp adjusting screws INSTALLA TION 1 Position the headlamp bucket in the grille opening panel and slide the headlamp bucket...

Page 424: ...rom back side of lamp INSTALLA TION 1 Install bulb and socket in back of side marker lamp 2 Install side marker lamp in grille opening panel BACK UP REAR TURN SIGNAL TAIL LAMP REMOVAL 1 Open the liftg...

Page 425: ...controls the operation The switch provides automatic ON OFF functions each time the hood is opened and closed REMOVAL 1 Disconnect the wire harness connector from the lamp 2 Remove lamp lens 3 Remove...

Page 426: ...removing the overhead console Refer to Group 8C Overhead Console for removal installation procedures VISOR VANITY LAMP REMOVAL 1 Fold down sunvisor 2 Starting at the base of the lamp assembly and work...

Page 427: ...the ignition switch is turned to the ON position and the vehicle is put into motion The DRL module receives a vehicle moving signal from the vehicle speed sen sor This provides a constant headlamps on...

Page 428: ...om the module 2 Remove the screws that attach the module to the fender inner panel 3 Remove the module from the fender inner panel INSTALLA TION 1 Position the module on the right fender inner panel 2...

Page 429: ...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...

Page 430: ...INSTALLA TION 1 Reverse the removal procedures to install SIDE REPEA TER LIGHT REMOVAL 1 Grip the side repeater lamp assembly with your hand and pull from the body to remove 2 Rotate and pull the sock...

Page 431: ...amp body 2 Disconnect the 2 wires from the lamp element 3 Remove the lamp element from the housing INSTALLA TION 1 Install the new lamp element in the housing and reinstall the lower housing BACKUP RE...

Page 432: ...ble 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 Re...

Page 433: ......

Page 434: ...ations 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...

Page 435: ...E 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 A...

Page 436: ...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 depl...

Page 437: ...The clockspring assembly 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 elec...

Page 438: ...ssenger 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...

Page 439: ...T DISCONNECT AND ISOLATE THE BATTERY NEGATIVE GROUND CABLE THEN WAIT TWO MINUTES FOR THE SYS TEM CAPACITOR TO DISCHARGE BEFORE FUR THER SYSTEM SERVICE THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG S...

Page 440: ...spring wire harnesses in the steering wheel hub area are not pinched between the airbag module and the steering wheel 4 From the underside of the steering wheel install and tighten the two driver sid...

Page 441: ...er locking blocks 2 Engage the upper and lower trim cover locking blocks with the lip of the driver side airbag housing then engage the locking blocks on each side of the trim cover with the lip of th...

Page 442: ...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 two minutes for the system capacitor to dis charge befo...

Page 443: ...nt panel Refer to Glove Box Roll Dow n in the Removal and Installation section of Group 8E Instrument Panel Systems for the procedures 6 Install and tighten the two screws that secure the passenger si...

Page 444: ...he top and the bottom of the air bag module housing 4 Install the passenger side airbag module onto the instrument panel Refer to Passenger Side Air bag Module in the Removal and Installation section...

Page 445: ...e procedures 8 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 CLOCKSPRING The clockspring...

Page 446: ...housing NOTE If the clockspring plastic latches are broken be certain to remove the broken pieces from the steering column upper housing 13 Remove the clockspring from the steering col umn The clocks...

Page 447: ...tall the driver side airbag module onto the steering wheel Refer to Driver Side Airbag Mod ule in the Removal and Installation section of this group for the procedures ADJUSTMENTS CLOCKSPRING CENTERIN...

Page 448: ...clockspring case to maintain clockspring centering until it is reinstalled on the steering column This can be done by inserting a stiff wire through the small index hole located at about the 11 o cloc...

Page 449: ......

Page 450: ...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 DEFOGG...

Page 451: ...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 gr...

Page 452: ...ow 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 opera...

Page 453: ...ve 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 harn...

Page 454: ...t 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 Defogger Relay tests as described in this...

Page 455: ...adjacent grid line 7 Apply a thin layer of conductive epoxy to the terminal or bare wire end of the pigtail and place it in the proper location on the bus bar To prevent the terminal or pigtail wire...

Page 456: ...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 ab...

Page 457: ...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 provid...

Page 458: ...re sewn into the seat cushion cover and seat back cover assemblies which are ser viced individually The heating elements and tempera ture sensor cannot be repaired and if faulty or damaged the affecte...

Page 459: ...ition switch output circuit cavity of the 6 way heated seat switch wire harness connector If OK turn the ignition switch to the OFF position disconnect and isolate the battery negative cable and repla...

Page 460: ...way heated seat relay connector 2 Check for continuity between the ground cir cuit cavity of the 8 way heated seat relay wire har ness connector and a good ground There should be continuity If OK go t...

Page 461: ...ow access to the Seat Heat Interface Module SHIM 5 Pull the SHIM upward to release the two mounting fasteners from either the module or the mounting bracket Unplug the wire harness connec tor from the...

Page 462: ...tribution Center PDC J unction Block J B Following are general descriptions of the major components in the power distribution system Refer to the owner s manual in the vehicle glove box for more infor...

Page 463: ...sh nut Fig 2 A finger recess is molded into the front of the fuse access panel for easy removal and a fuse puller and spare fuse holders are located on the back of the fuse access panel The J B combin...

Page 464: ...g and pull the PDC housing upward to disengage the mounting slots from the stanchions of the mounting bracket Fig 4 9 Remove the PDC and the headlamp and dash wire harness from the engine compartment...

Page 465: ...IVE 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...

Page 466: ...and tighten the screw that secures the right cowl side inner trim panel and right front door sill trim to the door opening sill Tighten the screw to 2 2 N m 20 in lbs 7 Install and tighten the screw l...

Page 467: ......

Page 468: ...ucted as mirror image of the LHD versions While most of the illustrations used in this group represent only the LHD version the diagnostic and service procedures outlined can generally be applied to e...

Page 469: ...lock switches and their lamps cannot be repaired If the switches are damaged or faulty the entire PDM or DDM unit must be replaced DOOR MODULE A Driver Door Module DDM and a Passenger Door Module PDM...

Page 470: ...em now operates see the Remote Keyless Entry Receiver diagnosis in this group If the power lock system still fails to operate see the Door Module diagnosis in this group If the power lock system funct...

Page 471: ...inoperative power lock switch illumination proceed as follows If the problem is not power lock switch illumination go to Step 5 Connect the battery negative cable Turn the ignition switch to the Acces...

Page 472: ...he other direc tion If OK repair the short or open circuits between the power lock motor and the PDM as required If not OK replace the faulty power lock motor REMOTE KEYLESS ENTRY TRANSMITTER 1 Replac...

Page 473: ...it cavities of the RKE receiver wire harness connector and the 8 way PDM wire harness connector In each case there should be continuity If OK replace the faulty RKE receiver If not OK repair the open...

Page 474: ...s and away from the inner door panel far enough to disen gage the top of the panel from the inner belt weath erstrip 5 Pull the front door trim panel away from the inner door panel far enough to acces...

Page 475: ...ester saran polyethylene polypropylene PVC and teflon MINI DOME MOUNTED TYPE 1 Disconnect and isolate the battery negative cable 2 Remove the two screws that secure the Remote Keyless Entry RKE mini d...

Page 476: ...7 Reverse the removal procedures to install Tighten the mounting screws to 2 2 N m 20 in lbs Fig 7 RKE Receiver Remove Install XJ POWER LOCK SYSTEMS 8P 9 REMOVAL AND INSTALLATION Continued...

Page 477: ......

Page 478: ...vehicle 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 stor...

Page 479: ...rument cluster to flash the SKIS indicator lamp The SKIM can also send messages to the instrument cluster to flash the lamp and to gen erate a single audible chime tone These functions serve as an ind...

Page 480: ...ty 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 dur...

Page 481: ...ion 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...

Page 482: ...teering col umn jacket 13 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 cyl...

Page 483: ......

Page 484: ...re 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...

Page 485: ...o the On position it sends messages to the instrument cluster to flash the SKIS indicator lamp For diagnosis or initialization of the SKIM and the PCM a DRB scan tool and the proper Diagnostic Procedu...

Page 486: ...EPLOYMENT AND POSSIBLE PERSONAL INJURY NOTE The following tests may not prove conclu sive in the diagnosis of this system The most reli able efficient and accurate means to diagnose the Sentry Key Imm...

Page 487: ...g 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...

Page 488: ...Fig 3 Sentry Key Immobilizer Module Remove Install XJ VEHICLE THEFT SECURITY SYSTEMS 8Q 5 REMOVAL AND INSTALLATION Continued...

Page 489: ......

Page 490: ...tribution Center and a circuit breaker in the junction block regardless of the ignition switch position The power seat system includes the power seat adjuster and motors unit the power seat switch and...

Page 491: ...inal has battery voltage the circuit breaker is faulty and must be replaced If neither ter minal has battery voltage repair the open circuit from the Power Distribution Center PDC as required POWER SE...

Page 492: ...e seat cushion frame far enough to access the power seat switch wire harness connector 4 Unplug the wire harness connector from the power seat switch 5 Remove the seat cushion side shield from the sea...

Page 493: ...r of the seat adjuster frame to the stud on the floor panel 7 Unplug the power seat wire harness connector from the body wire harness connector 8 Remove the driver side power seat and adjuster assembl...

Page 494: ...enger 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 s...

Page 495: ...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 d...

Page 496: ...has battery voltage the circuit breaker is faulty and must be replaced If neither ter minal has battery voltage repair the open circuit from the Power Distribution Center PDC as required If the circu...

Page 497: ...indow 2 Unplug the power window motor wire harness connector Apply 12 volts across the motor terminals to check its operation in one direction Reverse the connections across the motor terminals to che...

Page 498: ...or trim panel to the inner door panel Fig 6 3 Using a trim stick or another suitable wide flat bladed tool gently pry the rear door trim panel away from the door around the perimeter to release the tr...

Page 499: ...hanism is faulty or damaged the entire power window regulator unit must be replaced Refer to Group 23 Body for the front door window regulator service procedures REAR DOOR The rear door power window m...

Page 500: ...eating 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 informat...

Page 501: ...er 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...

Page 502: ...t the battery negative cable Use two jumper wires one connected to a 12 volt battery feed and the other connected to a good body ground See the Power Mirror Test chart for the correct jumper wire conn...

Page 503: ...the front door trim panel away from the door around the perimeter to release the trim panel retainers NOTE To aid in the removal of the trim panel start at the bottom of the panel 4 Lift the front do...

Page 504: ...ront door trim panel away from the inner door far enough to access the inside door latch release and lock linkage rods near the back of the inside door remote controls 7 Unsnap the plastic retainer cl...

Page 505: ...irror wire harness grom met by pushing it out through the hole in the door flag from the inside 15 Pull the mirror and seal from the outside of the door while feeding the wire harness grommet and conn...

Page 506: ...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...

Page 507: ...ster 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 turn...

Page 508: ...with the driver door closed If OK see the diagnosis for Instrument Cluster in this group If not OK repair the circuit to the driver door jamb switch as required HEADLAMP SWITCH For circuit descriptio...

Page 509: ...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 fo...

Page 510: ...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...

Page 511: ...e 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 ve...

Page 512: ...t 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...

Page 513: ...e 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...

Page 514: ...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 duri...

Page 515: ...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...

Page 516: ...er compass and thermom eter display module away from the overhead console housing far enough to access the two wire harness connectors 5 Unplug the overhead console and push button module wire harness...

Page 517: ...of the door into the pivot hole in the overhead console housing Gently depress the pivot pin on the other side of the door until it clears the side of the garage door opener storage bin opening of th...

Page 518: ...the radiator support cross member 5 Remove the ambient temperature sensor from the vehicle 6 Reverse the removal procedures to install Tighten the ambient temperature sensor mounting screw to 3 4 N m...

Page 519: ......

Page 520: ...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...

Page 521: ......

Page 522: ...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...

Page 523: ...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 INFORMA TION XJ DESCRIPTION AND OPERATION Continued...

Page 524: ...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 INFORMA TION 8W 01 3 DESCRIPTION AND OPERATION Continued...

Page 525: ...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 IDEN...

Page 526: ...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...

Page 527: ...Wiring Diagram Symbols 8W 01 6 8W 01 GENERAL INFORMA TION XJ DESCRIPTION AND OPERATION Continued...

Page 528: ...r ground location illustrations The illustrations contain the connector name or number ground number and component identification Connector ground location charts in Section 8W 90 reference the illust...

Page 529: ...e 2 Avoid touching electrical terminals of the part unless instructed to do so by a written procedure 3 When using a voltmeter be sure to connect the ground lead first 4 Do not remove the part from it...

Page 530: ...hat has rubbed through causing a short to ground Some or all of the wiring strands broken inside of the insulation covering Wiring broken inside of the insulation TROUBLESHOOTING TESTS Before beginnin...

Page 531: ...ted symptoms Do this by per forming operational checks on components that are in the same circuit Refer to the wiring diagrams 3 Analyze the symptoms Use the wiring dia grams to determine what the cir...

Page 532: ...nsert the probe end of special tool 6934 into the back of the connector cavity Fig 13 5 Grasp the wire and tool 6934 and slowly remove the wire and terminal from the connector 6 Repair or replace the...

Page 533: ...r cavities For additional connector pin out identification refer to the wiring diagrams 8 Insert the connector locking wedge into the repaired connector if required 9 Connect connector to its mating h...

Page 534: ...13 for each wire 15 Re tape the wire harness starting 1 1 2 inches behind the connector and 2 inches past the repair 16 Re connect the repaired connector 17 Connect the battery and test all affected s...

Page 535: ...ect the battery 2 Locate the diode in the harness and remove the protective covering 3 Remove the diode from the harness pay atten tion to the current flow direction Fig 22 4 Remove the insulation fro...

Page 536: ...SPECIAL TOOLS WIRING TERMINAL Probing Tool Package 6807 Terminal Pick 6680 Terminal Removing Tool 6932 Terminal Removing Tool 6934 XJ 8W 01 GENERAL INFORMA TION 8W 01 15...

Page 537: ......

Page 538: ...Duty Cycle Evap Purge Solenoid 8W 12 Electronic Vacuum Modulator 8W 30 Engine Control Module 8W 30 Engine Coolant Temperature Sensors 8W 30 Engine Oil Pressure Sensor 8W 30 Engine Starter Motor Relay...

Page 539: ...48 Rear Wiper Motor 8W 53 Rear Wiper Washer Switch 8W 53 Component Page Repeater Lamps 8W 50 52 Seat Belt Switch 8W 40 Seat Heat Interface Module 8W 63 Sentry Key Immobilizer Module 8W 39 Shift Lock S...

Page 540: ...Fuse 14 J B 8W 10 22 23 Fuse 14 PDC 8W 10 13 24 Fuse 15 J B 8W 10 19 24 Fuse 15 PDC 8W 10 13 22 Component Page Fuse 16 PDC 8W 10 11 13 25 28 Fuse 17 J B 8W 10 14 15 Fuse 17 PDC 8W 10 11 26 27 Fuse 18...

Page 541: ...TI LOCK BRAKE RELAY LAMP FOG NO 2 A FUSES 8 14 7 6 7 30A 13 5 6 40A 12 4 5 40A 11 3 4 50A 10 2 3 40A 9 1 2 40A 8 21 15 16 17 18 19 20 22 23 24 25 26 27 28 15 14 13 20A 12 40A 11 10 20A 9 20A F21 20A F...

Page 542: ...BK PK A16 16RD LG 15A 16 17 20A 25A 18 19 15A A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A17 16RD BK A3 14RD WT A17 16RD BK 26 10A F1 20DB GY A17...

Page 543: ...RELAY CONTROL G83 18GY BK FUSED IGNITION SWITCH OUTPUT RUN F15 20DB WT GROUND Z1 20BK B18 B20 B16 B19 FUNCTION CAVITY CIRCUIT G19 20LG OR ABS WARNING INDICATOR DRIVER GROUND Z1 20BK T141 20YL IGNITION...

Page 544: ...ELAY NO 1 FOG LAMP RELAY GROUND Z1 20BK B8 FOG LAMP RELAY CONTROL L35 20BR WT FOG LAMP RELAY OUTPUT L139 20VT B7 FUSED LEFT INBOARD TAIL LAMP L77 20BR YL B10 B8 B6 B9 B7 FUSED LEFT INBOARD TAIL LAMP L...

Page 545: ...PRESSOR RELAY CONTROLLER ANTI LOCK BRAKE USED NOT 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 F...

Page 546: ...5A 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 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 F14...

Page 547: ...6RD BK FUSED B A C COMPRESSOR CLUTCH RELAY OUTPUT C3 16DB BK FUNCTION CAVITY CIRCUIT B17 F15 18DB WT FUSED IGNITION SWITCH OUTPUT RUN ABS RELAY CONTROL C8 C5 C2 C6 C4 AUTOMATIC SHUT DOWN RELAY OUTPUT...

Page 548: ...OARD TAIL LAMP L77 18BR YL GROUND Z1 20BK YL B10 B8 B6 B9 B7 FUSED LEFT INBOARD TAIL LAMP L77 20BR YL Z1 20BK YL GROUND F61 20WT OR FUSED B L139 20VT FOG LAMP RELAY OUTPUT FUNCTION CAVITY CIRCUIT RADI...

Page 549: ...40A FUSE 6 A111 12 RD LG C100 TO TO HEADLAMP SWITCH RD WT 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 FUS...

Page 550: ...18 A17 15A FUSE 22 A11 A12 L9 20 BK PK TO C100 PUMP FUEL TO DG BK 14 A61 RELAY A5 A6 25 FUSE 15A 20A FUSE 26 A4 A3 A10 A9 23 FUSE 15A SWITCH F32 20 PK DB TO BRAKE LAMP C100 TO VT 16 F75 RELAY SHUT DOW...

Page 551: ...E 10 A54 12 RD GY 7 14 30A FUSE 8 RD LG 12 A16 A1 12 RD SWITCH IGNITION TO TO S151 A7 10 RD BK BLOCK JUNCTION TO A2 12 PK BK SWITCH IGNITION TO TO C100 RD LG 12 A111 24 17 40A FUSE 11 12 FUSE 40A 18 2...

Page 552: ...ROLLER TO 15A FUSE 19 16 FUSE 15A 20A FUSE 14 A20 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 B...

Page 553: ...Y 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...

Page 554: ...Y 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...

Page 555: ...1 4 A21 12 DB BK LB 20 G16 RHD LHD C306 2 C203 20 LHD RHD 19 C203 2 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 PASSENGE...

Page 556: ...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 21 8W 12 22 8W 12 16 8W 12 17 8W...

Page 557: ...AY CENTER DISTRIBUTION POWER 10A FUSE 24 A7 A8 POWERTRAIN 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 MODULE PUMP FUEL 16 DG OR ASSEMBLY A14 A13 21...

Page 558: ...CENTER 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 8W 12 2 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 12...

Page 559: ...USE 5 4 BATT A0 POWER DISTRIBUTION CENTER RHD LHD C202 7 LG RD 12 F141 IN PDC FAN RADIATOR RELAY LB 12 C25 A111 12 RD LG RD LG 12 A111 RADIATOR FAN MOTOR 8W 42 2 8W 42 3 8W 42 4 8W 42 5 8W 10 10 8W 10...

Page 560: ...TIME 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 1 F1 20 DB GY EXCEPT POLI...

Page 561: ...R 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 START...

Page 562: ...BK PK 12 A4 C2 1 BLOCK JUNCTION BATT A0 20A FUSE 10 23 16 D10 D14 POWER DISTRIBUTION CENTER 30 87 4 0L BRAKE ANTI LOCK CONTROLLER 2 ENGINE STARTER MOTOR RELAY A41 16 YL IN PDC C15 12 BK WT 17 24 11 F...

Page 563: ...LIGHTER RELAY RELAY HORN BLOCK JUNCTION A111 12 RD LG D5 C100 C201 11 UNIT HVAC 8 22 RHD LHD 7 C202 X2 20 DG RD X2 20 DG RD LHD 50 C201 RHD 40A FUSE 13 26 19 LG RD 12 F141 C10 C14 RELAY FAN RADIATOR...

Page 564: ...MP 1 1 M1 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 C 8W 10 26 TO S347 4 0L PK 18 M1 C314 5 LHD RHD RHD LHD S...

Page 565: ...4 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...

Page 566: ...EADLAMP SWITCH 4 C1 S218 F34 18 TN BK SWITCH TN BK 18 F34 C1 B POWER ANTENNA 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...

Page 567: ...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 U...

Page 568: ...1 S137 DG OR 18 A142 C3 C12 C107 7 POWERTRAIN CONTROL MODULE DG WT 20 F142 15A FUSE 24 A8 A7 A14 A13 21 FUSE 20A A142 18 DG OR C8 C2 RD LG 16 A16 25A FUSE 19 A17 A18 CENTER DISTRIBUTION POWER BATT A0...

Page 569: ...NO 3 NO 4 INJECTOR FUEL FUEL INJECTOR NO 2 NO 1 INJECTOR FUEL 1 18 DG OR A142 DG OR 18 A142 S113 D 8W 10 29 FROM S109 4 0L 4 0L A142 18 DG OR 1 1 DG OR 18 A142 A142 18 DG OR 1 8W 30 6 8W 30 6 8W 30 6...

Page 570: ...11 A12 22 FUSE 15A D2 D8 2 COMBINATION FLASHER BATT A0 CENTER DISTRIBUTION POWER 15A FUSE 20 A15 A16 BK PK 20 L9 F5 L9 20 BK PK LHD RHD 4 C204 FUEL PUMP RELAY IN PDC A61 14 DG BK C200 13 B11 RHD LHD 8...

Page 571: ...C COMPRESSOR CLUTCH LHD RHD 6 C204 L50 20 WT TN 2 WT TN 20 L50 RD BK 16 A17 A17 18 RD BK DB GY 20 F1 1 F1 20 DB GY CLUTCH RELAY COMPRESSOR A C IN PDC PK DB 20 F32 E10 C100 C100 B4 C100 E1 L50 20 WT TN...

Page 572: ...VT 16 F75 VT 16 F75 VT 16 F75 S301 AMPLIFIER POWER OTHERS DRL 4 0L 1 C2 C2 2 RHD LHD 6 C204 C204 3 LHD RHD 14 C200 F61 20 WT OR NO 1 FOG LAMP RELAY IN PDC IN PDC RELAY LAMP FOG NO 2 L139 20 VT PK 20...

Page 573: ...16 DG OR CENTER DISTRIBUTION POWER A142 16 DG OR DG OR 16 F142 20A FUSE 21 A13 A14 3 C204 LHD RHD 1 C2 C2 2 MODULATOR VACUUM ELECTRONIC POWER DISTRIBUTION CENTER BATT A16 C2 C8 DG OR 16 A142 S137 AUTO...

Page 574: ...CENTER 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 L39 20 LB LB 18 L39 3 DIODE MODULE S230 B11 C100 F5 C100 LHD RHD LEFT FOG LAMP RIGHT...

Page 575: ...WITCH HEADLAMP 16 CONNECTOR LINK DATA F34 18 TN BK A4 A3 26 FUSE 20A POWER DISTRIBUTION CENTER BATT A0 C1 E6 C100 A18 C100 LHD RHD F34 18 TN BK F34 18 TN BK 8W 47 4 8W 50 4 8W 30 31 8W 10 6 8W 10 12 8...

Page 576: ...trol 8W 12 8 9 High Note Horn 8W 12 20 Horn Relay 8W 12 20 Horn Switch 8W 12 20 HVAC Unit 8W 12 21 22 Instrument Cluster 8W 12 8 9 12 13 16 17 28 29 J unction Block 8W 12 2 5 6 7 8 9 10 11 12 13 14 15...

Page 577: ...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...

Page 578: ...20 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 16R...

Page 579: ...DEFOGGER 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 Z1 14BK 87 86 85 30 FUNCTION CAVITY CIRCUIT 87...

Page 580: ...TLET 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 19 8W 10 24 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 41 2...

Page 581: ...16 L3 SWITCH 3 C201 16 L3 16 RD OR S213 RD OR 16 L3 LHD RHD RD OR 20 L34 B8 UP EXPORT EXCEPT BUILT IN PDC NO 1 RELAY LAMP FOG 12 L35 20 BR WT L33 20 RD BEAM 8W 12 2 8W 50 5 8W 50 6 8W 50 7 8W 50 8 8W...

Page 582: ...EADLAMP LEVELING MOTOR 1 S233 S236 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...

Page 583: ...OW 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 EX...

Page 584: ...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...

Page 585: ...8 L77 L77 18 BR YL S311 C327 2 18 L77 C310 C311 4 11 L77 20 5 TRAILER TOW CONNECTOR 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...

Page 586: ...RAILER TOW CONNECTOR S340 LAMP STOP TAIL LEFT 2 OTHERS TOW TRAILER L77 18 BR YL L77 20 BR YL S206 C1 GAS L77 20 BR YL BR DIESEL 18 L77 FOG LAMP RELAY B10 L77 18 BR YL IN PDC IN PDC C323 7 L77 18 BR C3...

Page 587: ...ECTION PUMP 2 WT 18 F20 RADIATOR FAN RELAY WT 18 F20 F20 18 WT CLUTCH COMPRESSOR A C RELAY C11 B5 EXCEPT POLICE POSTAL SENTRY KEY IMMOBILIZER MODULE 3 SENSOR RANGE TRANSMISSION F20 18 WT 4 0L TO S161...

Page 588: ...20 18 WT F20 18 WT B5 RELAY CLUTCH COMPRESSOR A C EXCEPT POLICE POSTAL SENTRY KEY IMMOBILIZER MODULE 4 0L WT 18 F20 TRANSMISSION RANGE SENSOR 3 C107 11 4 0L A T EXCEPT WT 18 F20 WT 18 F20 C111 7 F20 1...

Page 589: ...N PDC D4 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 C2 K47 DIESEL MODULE CONTROL ENGINE GAS DIESEL...

Page 590: ...L 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 LHD MODULE CONTROL TRANSMISSION 26 F12 18 DB WT F12...

Page 591: ...INDOW REAR 3 DEFOGGER SWITCH LB YL 20 C16 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...

Page 592: ...C16 20 LB YL WINDOW REAR 3 DEFOGGER SWITCH 22 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...

Page 593: ...C2 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 D11 F45 18 YL 2 POWER SWITCH MIRROR F83 18 YL DG FULL OPTIONS...

Page 594: ...WINDOW 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 S3...

Page 595: ...LER 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 TRAIL...

Page 596: ...CH 3 EXTENDED IDLE S217 WASHER POLICE PACKAGE 5 S219 DOOR BLEND 4 ACTUATOR F15 20 DB WT DIESEL GAS DB WT 18 F15 BRAKE CONTROLLER ANTI LOCK 23 RELAY BRAKE CONTROLLER ANTI LOCK B18 F15 20 DB WT IN PDC I...

Page 597: ...ANTI LOCK B20 F15 20 DB WT S134 DB WT 18 F15 F15 20 DB WT IN PDC DB WT 20 F15 F15 20 DB WT S219 DB WT 20 F15 21 C204 F15 20 DB WT WASHER 5 S349 DB WT 20 F15 4 BLEND DOOR ACTUATOR IN PDC DB WT 20 F15 B...

Page 598: ...RHD 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 OTHER NO 1 LAMP SIGNAL TURN PAR...

Page 599: ...T RUN ACC A31 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...

Page 600: ...SE 26 25A 28 BREAKER CIRCUIT RUN ACC A31 8 C5 C8 1 F81 14 TN TN 12 F81 11 C204 10 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...

Page 601: ...10 C329 RIGHT POWER SEAT SWITCH B S356 HEATED SEATS F37 14 RD LB F37 14 RD LB F37 14 RD LB F37 14 RD LB C362 1 C363 1 F37 14 RD LB F37 14 RD LB RD LB 14 F37 1 C362 RD LB 14 F37 LEFT POWER SEAT SWITCH...

Page 602: ...F37 14 RD LB 8 10 C329 F37 14 RD LB HEATED SEAT RELAY WIPE WASH SWITCH S356 OTHER HEATED SEATS C316 2 C316 2 B F37 14 RD LB LEFT RD LB 14 F37 A SEAT POWER SWITCH SWITCH SEAT POWER RIGHT 1 C362 1 C363...

Page 603: ...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...

Page 604: ...FT LAMP 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 ME...

Page 605: ...JAMB SWITCH YL 18 M2 SWITCH JAMB DOOR LEFT REAR M2 18 YL M2 20 YL 1 C317 A C320 C319 A C318 1 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...

Page 606: ...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 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...

Page 607: ...TOR DOOR LEFT 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 P...

Page 608: ...CH 3 DRIVER POWER MIRROR P91 20 WT BK RHD RHD RHD 7 C9 3 C5 3 P91 20 WT BK LHD MIRROR POWER PASSENGER P91 20 WT BK C201 67 P91 20 WT BK 3 C200 P91 20 WT BK 13 C305 P91 20 WT BK 6 LHD SWITCH MIRROR POW...

Page 609: ...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 C...

Page 610: ...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 20 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 20 P71 P74...

Page 611: ...MODULE OVERHEAD 1 COMPASS 3 Z1 14 BK S208 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 POW...

Page 612: ...ated Seat Switch 8W 15 22 Left Power Seat Switch 8W 15 22 Left Rear Door J amb 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 Tur...

Page 613: ...RAIN CONTROL M T 231 Z1 18 BK Z1 20 BK 5 C107 BATTERY BK 8 Z0 G100 2 5L 4 0L Z0 4 BK BK 6 Z0 G101 8 BRAKE CONTROLLER ANTI LOCK 24 BK 12 Z1 G102 Z1 12 BK BK 18 Z1 Z12 18 BK TN A1 C100 A7 BK TN 18 Z12 Z...

Page 614: ...LLER ANTI LOCK 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 K1 C2 K27 C2 A32 C1 A31 C1 E7 C100 A7 C100 Z12 18 BK TN LHD RHD...

Page 615: ...20 Z1 Z1 14 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 B 8W 15 7 TO G106 DRL DRL SWITCH MERCURY LAMP UNDE...

Page 616: ...RAKE B19 IN PDC IN PDC B8 RELAY FOG LAMP NO 1 NO 2 LAMP FOG RELAY B13 IN PDC Z1 20 BK IN PDC D11 MOTOR ENGINE STARTER RELAY Z1 20 BK M T BK 18 Z1 Z1 18 BK C 8W 15 7 TO G106 D 8W 15 7 TO G106 A T M T D...

Page 617: ...S132 2 4 CONTROL VEHICLE SPEED SERVO RELAY ANTI LOCK CONTROLLER BRAKE B19 IN PDC BK 18 Z1 C 8W 15 7 TO G106 D 8W 15 7 TO G106 WINDSHIELD WASHER PUMP REAR WASHER PUMP SWITCH LEVEL FLUID WASHER SWITCH...

Page 618: ...1 18 BK BK 18 Z1 1 NO 1 LAMP SIGNAL TURN PARK FRONT RIGHT 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 C10...

Page 619: ...18 Z1 BK 20 Z1 Z1 14 BK S132 2 4 CONTROL VEHICLE SPEED SERVO RELAY ANTI LOCK CONTROLLER BRAKE B19 IN PDC BK 18 Z1 E 8W 15 10 TO G106 F 8W 15 10 TO G106 SWITCH LEVEL FLUID WASHER SWITCH MERCURY LAMP U...

Page 620: ...2 2 4 CONTROL VEHICLE SPEED SERVO IN PDC D11 MOTOR ENGINE STARTER RELAY Z1 20 BK BK 18 Z1 E 8W 15 10 TO G106 G 8W 15 10 TO G106 SWITCH MERCURY LAMP UNDERHOOD SWITCH LEVEL FLUID WASHER 8W 53 4 8W 53 2...

Page 621: ...R WT 20 L35 12 MOTOR LEVELING RIGHT 3 HEADLAMP Z15 18 BK GY BK GY 18 Z15 HEADLAMP 3 LEFT LEVELING MOTOR 5 C106 Z15 16 BK GY 2 C114 BK GY 18 Z15 S235 C106 2 C115 Z1 18 BK Z1 18 BK S158 NO 2 LAMP SIGNAL...

Page 622: ...Z1 BK 20 Z1 2 UNDERHOOD LAMP HEATER FUEL 2 D MODULATOR ELECTRONIC VACUUM 4 FRONT WIPER MOTOR Z1 20 BK BK 14 Z1 BK 16 Z1 BK 18 Z1 H 8W 15 12 TO G106 TRANSFER CASE BK 16 Z1 2 CLUTCH COMPRESSOR A C 11 C1...

Page 623: ...IGHT Z1 20 BK RIGHT 2 BK 18 Z1 ANTI LOCK CONTROLLER IN PDC B19 RELAY BRAKE RELAY B10 IN PDC FOG LAMP Z1 20 BK YL Z1 20 BK YL 12 C106 BK 20 Z1 REPEATER LAMP LAMP CITY BK 12 Z1 MOTOR LEVELING RIGHT 3 HE...

Page 624: ...LE Z1 20 BK POWER MIRRORS LHD RHD MIRRORS POWER BK 16 Z1 FULL OPTIONS 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 MIRRO...

Page 625: ...ONT EXTENDED IDLE SWITCH 1 OTHERS POLICE PACKAGE I 8W 15 13 C201 FROM BK 14 Z1 2 BLEND DOOR ACTUATOR Z1 20 BK LHD RHD 1 UNIT HVAC 13 C204 Z1 20 BK Z1 20 BK C201 7 J 8W 15 13 JUNCTION BLOCK FROM LHD RH...

Page 626: ...NA RELAY C1 3 BK 18 Z1 RELAY LAMP FOG REAR SWITCH Z15 20 BK GY LEVELING HEADLAMP 2 RHD LHD Z15 20 BK GY Z15 18 BK GY 1 Z1 20 BK UNIT HVAC 7 C201 Z1 20 BK ACTUATOR DOOR BLEND 2 OUTLET POWER RHD LHD C20...

Page 627: ...PASS 12 C301 5 Z2 20 BK LG C201 58 LHD RHD BK LG 20 Z2 4 SENTRY KEY 2 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...

Page 628: ...ITCH 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 OTHERS DRIVER 1 LAMP FOG REAR LEFT BUI...

Page 629: ...LB G301 BK LB 16 Z5 G300 Z6 18 BK PK 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...

Page 630: ...TCH SWITCH JAMB DOOR PASSENGER 3 Z1 18 BK C318 3 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...

Page 631: ...8 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 B...

Page 632: ...C310 6 S334 BK 18 Z1 Z1 20 BK Z1 18 BK 2 LICENSE LAMP SWITCH LIFTGATE 1 MOTOR 1 REAR WIPER LAMP MOUNTED HIGH CENTER STOP 1 C325 2 Z1 18 BK C330 2 Z1 18 BK 8W 48 2 8W 48 3 8W 51 3 8W 53 4 8W 53 5 8W 5...

Page 633: ...Z1 18 BK Z1 18 BK Z1 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...

Page 634: ...gine Starter Motor 8W 20 2 3 Fuse 4 PDC 8W 20 3 Fuse 19 PDC 8W 20 2 Fuse 21 PDC 8W 20 2 Fuse 24 PDC 8W 20 2 Component Page Fusible Link 8W 20 2 3 G100 8W 20 2 G101 8W 20 2 G104 8W 20 3 G105 8W 20 3 Ge...

Page 635: ...RELAY DOWN SHUT AUTOMATIC A14 A13 POWER DISTRIBUTION CENTER DG OR A142 18 20A FUSE 21 1 S137 18 A142 DG OR 3 C108 C107 2 K20 18 DG DG 18 K20 2 K72 16 DG OR DG OR 18 K72 C25 C3 DRIVER GENERATOR DG 10...

Page 636: ...C 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...

Page 637: ......

Page 638: ...Engine Starter Motor Relay 8W 21 2 3 4 5 6 Fuse 7 PDC 8W 21 6 Fuse 10 PDC 8W 21 2 3 4 5 Fuse 19 J B 8W 21 2 3 4 5 6 Component Page G101 8W 21 4 G106 8W 21 3 5 6 J unction Block 8W 21 2 3 4 5 6 Park N...

Page 639: ...ST A41 3 C1 JUNCTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC 1 C108 BR 16 T40 16 E7 C100 2 1 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...

Page 640: ...10A ST A41 3 C1 JUNCTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC 8 Z1 18 BK BK 14 Z1 S141 G106 5 C107 T41 20 BK WT 1 C108 BR 16 T40 16 E7 C100 2 1 JUMPER SWITCH INTERLOCK CLUTCH E8 C100 LHD RHD 1 PUL...

Page 641: ...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 S...

Page 642: ...JUNCTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC Z1 20 BK BK 14 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...

Page 643: ...CK ENGINE STARTER MOTOR RELAY IN PDC Z1 20 BK BK 12 Z1 S141 G106 10 C111 BR 16 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...

Page 644: ...Fuse 21 PDC 8W 30 2 5 6 8 21 22 23 Fuse 22 PDC 8W 30 2 3 4 Fuse 24 PDC 8W 30 2 5 6 8 20 Fuse 25 J B 8W 30 14 Fuse 26 PDC 8W 30 31 Component Page G101 8W 30 2 8 11 14 G102 8W 30 16 19 20 31 G106 8W 30...

Page 645: ...RD 16 A999 A14 A13 POWER DISTRIBUTION CENTER 20A FUSE 21 A142 18 DG OR A11 A12 A61 14 DG BK 15A FUSE 22 D2 FUEL PUMP RELAY 14 C107 A61 16 DG BK DG BK 16 A61 A22 C1 B FUSED A31 Z12 14 14 Z12 A32 G101 G...

Page 646: ...MODULE G302 S309 Z1 16 BK 4 SENSOR GROUND C1 A4 BR YL 18 K167 K226 18 DB LG 3 C107 30 C200 S138 F12 C100 K167 20 BR YL FUSED B C1 A61 16 DG BK A22 14 C107 DG BK 16 A61 3 C26 C3 FUEL LEVEL SENSOR F11 C...

Page 647: ...P MODULE G302 S309 Z1 16 BK BK 12 Z1 4 SENSOR GROUND C1 A4 BR YL 18 K167 K226 18 DB LG 3 C107 17 C204 S138 B3 C100 K167 20 BR YL FUSED C1 A61 16 DG BK A22 14 C107 DG BK 16 A61 3 C26 C3 FUEL LEVEL SENS...

Page 648: ...TION SENSOR SIGNAL A18 C1 TN YL 18 K44 SENSOR POSITION CAMSHAFT S115 K7 20 OR K167 20 BR YL SUPPLY 5V 5V SUPPLY S109 S137 DG OR 18 A142 1 C107 21 FUSE 20A A14 A13 POWER DISTRIBUTION CENTER A999 16 RD...

Page 649: ...18 A142 DG OR 18 A142 DG OR 18 A142 C2 C2 C2 C2 C2 C8 BATT A16 POWER DISTRIBUTION CENTER AUTOMATIC SHUT DOWN RELAY C2 S109 S137 DG OR 18 A142 1 C107 21 FUSE 20A A14 A13 TO 24 PDC FUSE A142 18 DG OR R...

Page 650: ...A17 K7 20 OR SIGNAL SENSOR TEMPERATURE AIR INTAKE ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 20 BR YL K167 S111 K167 18 BR YL BR YL 20 K167 SIGNAL SENSOR POSITION THROTTLE S112 OR DB 20 K22 17 TRANSMISS...

Page 651: ...SIGNAL 1 1 SENSOR OXYGEN BK 16 Z1 S107 S114 BR YL 20 K167 K167 20 BR YL K167 18 BR YL C8 BATT A16 POWER DISTRIBUTION CENTER AUTOMATIC SHUT DOWN RELAY C2 DG WT 20 F142 7 C107 24 FUSE 15A A7 A8 TO 21 P...

Page 652: ...2 3 SIGNAL SENSOR SPEED VEHICLE WT OR 18 G7 S108 K167 18 BR YL A4 C1 SENSOR GROUND S114 SIGNAL SENSOR PRESSURE ABSOLUTE MANIFOLD S111 BR YL 20 K167 K167 18 BR YL WT OR 20 G7 G7 20 WT OR 7 MODULE LAMP...

Page 653: ...SOR SIGNAL G60 18 GY YL B23 C2 3 2 RHD K4 20 BK RD SWITCH CONTROL SPEED LEFT 2 1 1 2 RIGHT SPEED CONTROL SWITCH 3 3 COAST 2 CANCEL 1 RESUME ACCEL 2 ON OFF 1 SET 1 2 2 1 B A S222 S221 V37 20 RD LG K167...

Page 654: ...20 DB RD C11 SPEED CONTROL POWER 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 BK WT 20 T41 5 C107 T41 20 BK WT ST T141 SUPPLY 2 5L A T EXCEPT B...

Page 655: ...00 E9 1 C201 C100 A9 LHD RHD LEAK DETECTION PUMP SOLENOID CONTROL LEAK DETECTION PUMP SWITCH SENSE TORQUE CONVERTER CLUTCH SOLENOID CONTROL F20 18 WT WT 18 F20 F12 18 DB WT DB WT 18 F12 4 0L LHD A T O...

Page 656: ...OL AIR IDLE IAC MOTOR NO 1 NO 4 MOTOR IAC IAC MOTOR NO 2 NO 3 MOTOR IAC DRIVER DRIVER DRIVER DRIVER C1 A10 C1 A19 18 18 18 K40 BR WT NO 1 MOTOR IAC 4 1 IAC MOTOR NO 4 VT BK K59 K60 YL BK NO 2 MOTOR IA...

Page 657: ...0 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 5 UNIT HVAC S217 40 C201 43 S315 E2 20 OR PACKAGE POLICE S215 9 S219 PANEL LAMPS DIMMER SWITCH SIGNAL DIMM...

Page 658: ...90 GENERATOR DRIVER C3 C25 K72 18 DG OR DG OR 16 K72 2 K20 18 DG 2 C107 C108 3 DRIVER FIELD GENERATOR C2 B10 K20 18 DG DB PK 18 C27 RADIATOR FAN RELAY CONTROL C13 C11 C2 C3 ST RUN F20 6 GENERATOR 2 1...

Page 659: ...MIT 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 E...

Page 660: ...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 P...

Page 661: ...RAIN CONTROL MODULE MODULE CONTROL TRANSMISSION BUS CCD CCD BUS D1 18 VT BR WT BK 18 D2 A11 C100 A12 1 C204 2 D2 18 WT BK VT BR 18 D1 AIRBAG CONTROL MODULE PAIR TWISTED PAIR TWISTED TWISTED PAIR PAIR...

Page 662: ...B WT F12 18 DB WT BK TN BK TN G102 AUTOMATIC SHUT DOWN 10 3 S151 A16 12 RD LG CONTROL RD LG 12 A16 A16 12 RD LG RELAY IN PDC ENGINE CONTROL MODULE K1 C2 K27 C2 FUSED IGNITION SWITCH OUTPUT AUTOMATIC S...

Page 663: ...OMATIC SHUT DOWN RELAY AUTOMATIC SHUT DOWN RELAY OUTPUT A22 C1 A2 C1 C1 C1 DRIVER GENERATOR DRIVER FIELD GENERATOR 1 2 GENERATOR DG 18 K20 B10 C2 5 C120 DG 18 K20 7 K72 18 DG OR DG OR 18 K72 C25 C3 GE...

Page 664: ...SE 21 C2 C8 BATT A16 CENTER DISTRIBUTION POWER A61 14 LG RD S137 DG OR 16 A142 A142 16 DG OR DG OR 18 F142 S157 Z1 12 BK S132 BK 12 Z1 S130 DB WT 18 F12 CONTROL BK 12 Z1 S141 RELAY DOWN SHUT AUTOMATIC...

Page 665: ...LOW PLUG NO 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 PLU...

Page 666: ...6 CONTROL SOLENOID SHUT OFF FEED K153 16 OR FUEL PUMP MODULE 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 M...

Page 667: ...BUTION POWER A C COMPRESSOR CLUTCH RELAY A C COMPRESSOR CLUTCH RELAY CONTROL K21 20 BK RD K1 20 DG RD K9 20 LB 1 2 4 3 K4 20 BK LB SENSOR PRESSURE BOOST TURBO K13 C2 K40 C2 K39 C2 SENSOR GROUND SIGNAL...

Page 668: ...TION SENSOR SIGNAL SUPPLY 5V GROUND SENSOR 20 K4 BK LB 1 2 SENSOR MOVEMENT NEEDLE BR BK 18 K67 B SENSOR MOVEMENT NEEDLE LG YL 18 K68 NEEDLE MOVEMENT SENSOR B B SENSOR MOVEMENT NEEDLE NEEDLE MOVEMENT S...

Page 669: ...ANT TEMP SENSOR SENSOR GROUND SIGNAL K4 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 S115D 3 K167 20 BR YL OR 20 K7 1 3 C1...

Page 670: ...N SENSOR SIGNAL 3 G55 18 OR BK SWITCH SIGNAL A C V66 18 RD LG REQUEST INDICATOR CRUISE PRESSURE SWITCH OUTPUT AC SELECT INPUT C23 C3 C1 C3 C16 C3 B18 C2 ENGINE DISABLE SIGNAL K30 C2 K38 C2 K8 C2 SIGNA...

Page 671: ...8 G123 WATER 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 A4 C1 C26 C3 A12 C1 A27 C1 1 2...

Page 672: ...T 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 B...

Page 673: ...RIVER TELL TALE MODULE DRIVER INDICATOR COOLANT LOW E17 C100 18 G154 VT LG 8 INDICATOR LOW COOLANT LEVEL WARNING WT BK 20 F87 S225 C11 C13 ST RUN F20 RADIATOR FAN RELAY POWER DISTRIBUTION CENTER C27 2...

Page 674: ...LG BK D21 18 PK 20 BRAKE ANTI LOCK CONTROLLER S139 D21 20 PK D21 18 PK S146 S150 Z12 12 BK TN Z12 12 BK TN C1 4 A18 LHD RHD SWITCH HEADLAMP A7 C27 C3 C29 C3 K45 C2 ENGINE CONTROL MODULE S218 F34 18 TN...

Page 675: ......

Page 676: ...8W 31 5 J unction 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...

Page 677: ...BK 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 S303 TO 10 FUSE 15A C4 S12 A2 C1 11 C107 1 C201 C100 E9 S159 F20 18 WT SOLENOID CLU...

Page 678: ...N A22 25 FUSE 15A C4 S8 BLOCK JUNCTION 1 2 SHIFT LOCK SOLENOID S219 C3 C24 POWERTRAIN CONTROL MODULE F15 20 DB WT F15 20 DB WT 40 C201 S217 F10 BRAKE SWITCH SENSE LHD RHD LAMP 8W 15 16 8W 15 16 8W 33...

Page 679: ...8 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 ASSEMBLY CONTROL TRANSMISSION 3 4 AND 1 2 SOLENOID 2 3 SOLENOID LOCK UP SOLENOID SOLENOID 1 2 AND 3 4 SOLENOID 2 3 SOL...

Page 680: ...G 20 T31 5 GROUND SENSOR 5V SUPPLY MODULE CONTROL POWERTRAIN S115 K7 18 OR OR 20 K7 A17 C1 3 SENSOR POSITION THROTTLE K22 20 OR DB K167 18 BR YL A4 C1 THROTTLE POSITION SENSOR SIGNAL 2 OR DB 20 K22 17...

Page 681: ...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 G106 BK 14 Z1 BUILT UP EXPORT UP...

Page 682: ...D RHD K29 18 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 C24 POWERTRAIN CONTROL MODULE D2 20 WT BK D1 20 VT BR S239 S238 B8...

Page 683: ......

Page 684: ...8W 33 5 Fuse 19 PDC 8W 33 5 Fuse 23 PDC 8W 33 4 G106 8W 33 4 G108 8W 33 4 5 Component Page Left Speed Control Switch 8W 33 2 3 Pedal Position Sensor 8W 33 5 Power Distribution Center 8W 33 4 5 Powertr...

Page 685: ...TCH 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 BR YL 20 K167 K16...

Page 686: ...T 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...

Page 687: ...THER 4 0L A T S140 B1 C100 S204 WT PK 20 K29 1 2 Z1 18 BK S207 BK 14 Z1 G108 BRAKE LAMP SWITCH S132 Z1 14 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 D...

Page 688: ...14 BK G108 A18 A17 V66 18 RD LG REQUEST INDICATOR CRUISE K30 ACTUATOR CONTROL K140 16 TN WT A66 A59 TN WT 16 K140 K140 16 TN WT A80 S148 MODULE PUMP FUEL 8 K140 16 TN WT FUEL QUANTITY ACTUATOR POSITI...

Page 689: ......

Page 690: ...PDC 8W 35 2 3 Fuse 13 PDC 8W 35 2 Fuse 14 PDC 8W 35 3 Fuse 19 PDC 8W 35 3 Fuse 23 PDC 8W 35 2 Component Page Fuse 25 J B 8W 35 4 5 G Switch 8W 35 2 3 G102 8W 35 2 3 G106 8W 35 4 5 Instrument Cluster...

Page 691: ...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 E1 C100 S203 BRAKE LAMP SWITCH OUTPUT 7 18 18 18 1...

Page 692: ...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 OUTPU...

Page 693: ...G106 Z1 14 BK C1 4 C1 8 CLUSTER 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...

Page 694: ...BS INDICATOR 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 B10 IN PDC RELAY LAMP FOG G106 Z1 20 BK YL Z1 20 BK Z1 18 BK Z1 20 BK 11 C106 S103 12...

Page 695: ...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...

Page 696: ...lay 8W 39 8 9 Component Page Ignition Switch 8W 39 6 7 Instrument Cluster 8W 39 8 9 J unction Block 8W 39 2 3 4 5 6 7 8 9 Left Rear Door J amb Switch 8W 39 6 7 Liftgate Switch 8W 39 6 7 Overhead Modul...

Page 697: ...P59 3 C300 4 1 P59 20 LB RD DB PK 20 P55 2 SWITCH WINDOW LOCK POWER PASSENGER BK 14 Z1 14 G107 S314 S208 C2 C2 C201 Z1 14 BK Z1 1 UNDERHOOD LAMP MERCURY FUSED B M1 20 PK DOOR LOCK CONTROL DOOR UNLOCK...

Page 698: ...2 SWITCH WINDOW LOCK POWER PASSENGER BK 14 Z1 G107 S208 C2 C2 C203 22 21 Z1 14 BK Z1 20 BK 1 M1 20 PK FUSED B SWITCH MERCURY LAMP UNDERHOOD GAS DIESEL S135 DOOR LOCK CONTROL UNLOCK RELAY CONTROL DOOR...

Page 699: ...C4 F87 20 WT BK WT BK 20 F87 FULL OPTIONS BASE 5 C201 Z2 20 BK LG BK LG 20 Z2 WT BK 20 F87 3 F87 20 WT BK S216 FUSED IGNITION SWITCH OUTPUT ST RUN POSTAL POLICE EXCEPT MODULE IMMOBILIZER KEY SENTRY 8...

Page 700: ...CK ST RUN A21 10A FUSE 9 S13 C4 F87 20 WT BK Z2 20 BK LG BK LG 20 Z2 3 F87 20 WT BK S216 FUSED IGNITION SWITCH ST RUN OUTPUT POSTAL POLICE EXCEPT MODULE IMMOBILIZER KEY SENTRY 8W 10 21 8W 10 32 8W 10...

Page 701: ...1 3 C B LAMP CARGO VT 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 S...

Page 702: ...CARGO VT 20 M4 7 C314 M4 20 GY BK VT YL 20 M4 C311 C310 5 10 1 3 Z1 20 BK G304 S304 S334 9 C310 6 C311 BK 18 Z1 M2 20 BK LB 18 G16 19 C203 S200 BK LB 20 G16 6 SWITCH HEADLAMP C1 C2 IGNITION SWITCH 2 G...

Page 703: ...RELAY HORN MODULE OVERHEAD TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR CCD BUS CCD BUS D1 20 VT BR 6 5 WT BK 20 D2 S238 S239 S346 S344 OTHER COMPASS OTHER COMPASS OTHER A T A T O...

Page 704: ...WISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR CCD BUS CCD BUS D1 20 VT BR 6 5 WT BK 20 D2 S238 S239 S145 OTHER A T OTHER 4 0L A T S144 COMPASS OTHER COMPASS OTHER S344 S346 PAIR TWIS...

Page 705: ......

Page 706: ...0 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 J unction Block 8W 40 2 12 13 1...

Page 707: ...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 MERCURY OUTPUT ST RUN F87 20 WT BK S227 POLICE POSTAL OTHER SWITCH DIESEL DI...

Page 708: ...TER 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...

Page 709: ...OOLANT TEMPERATURE K2 18 TN BK A16 C1 ENGINE COOLANT TEMPERATURE SENSOR C2 B23 GY YL 18 G60 ENGINE OIL PRESSURE SENSOR ENGINE COOLANT OIL CONTROL PAIR TWISTED TWISTED PAIR SENSOR PRESSURE OIL ENGINE S...

Page 710: ...ENGINE COOLANT TEMPERATURE SENSOR PRESSURE OIL K222 18 TN RD A16 ENGINE COOLANT TEMPERATURE SENSOR B23 GY YL 18 G60 OIL PRESSURE SENSOR SIGNAL ENGINE COOLANT OIL CONTROL PAIR TWISTED TWISTED PAIR 10...

Page 711: ...FLUID WASHER LOW BK LB 20 G29 LOW WASHER FLUID SWITCH SENSE A8 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...

Page 712: ...LOW WASHER FLUID SWITCH SENSE A8 BK LB 20 G29 C1 7 A B SWITCH LEVEL FLUID WASHER BK 12 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...

Page 713: ...20 Z1 SEAT BELT SWITCH A B 10 C2 G10 20 LG RD 12 C203 SENSE SWITCH BELT SEAT G10 20 LG RD Z1 20 BK S313 Z1 20 BK BK 12 Z1 S309 G302 SEAT BELT WARNING SEAT BELT WARNING INDICATOR INDICATOR CONTROL PAI...

Page 714: ...S107 Z1 18 BK Z1 16 BK 2 C1 G99 20 GY WT A10 C100 GY WT 20 G99 2 1 SWITCH 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 I...

Page 715: ...CH 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 C2...

Page 716: ...LHD RHD BK LB 20 G16 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD C1 6 0 1 2 S210 CHIME CONTROL BATT M1 FUSED B 3 C317 G302 S309 Z1 18 BK Z1 20 BK Z1 12 BK 3 3 BK 12 Z1 BK 20 Z1 BK 18 Z1 S310 G303 C318 3 G16 2...

Page 717: ...K 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 IM...

Page 718: ...K 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 IMMOB...

Page 719: ...INDICATOR INDICATOR SIGNAL TURN LEFT 1 10 TURN SIGNAL HAZARD 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 PO...

Page 720: ...2 1 0 C1 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 15 LHD RHD 2 SWITCH...

Page 721: ...CONTROL PAIR TWISTED TWISTED PAIR B18 RD LG 18 V66 K30 SPEED CONTROL ON SIGNAL CONTROL ON SIGNAL SPEED S239 S238 ENGINE CONTROL MODULE DIESEL E11 E12 S144 S145 4 0L A T OTHER OTHER 4 0L A T C30 C3 C28...

Page 722: ...COOLANT LOW E17 C100 18 G154 VT LG C8 8 INDICATOR LOW COOLANT LEVEL WARNING WT BK 20 F87 S225 A27 DG WT G123 18 1 SENSOR FUEL IN WATER LOW COOLANT SWITCH 1 18 G18 PK BK A12 COOLANT LEVEL SWITCH SENSE...

Page 723: ......

Page 724: ...8W 41 2 3 Fuse 1 J B 8W 41 2 3 Fuse 2 J B 8W 41 2 3 Fuse 21 J B 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 J unction Block 8W 41 2 3 Lo...

Page 725: ...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 2...

Page 726: ...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...

Page 727: ......

Page 728: ...5 Blower Motor Relay 8W 42 2 3 4 5 Engine Control Module 8W 42 7 8 Fuse 6 PDC 8W 42 2 3 4 5 Fuse 11 PDC 8W 42 2 3 4 5 Component Page Fuse 25 J B 8W 42 2 3 4 5 6 G106 8W 42 7 8 G107 8W 42 6 G108 8W 42...

Page 729: ...BK VT BK VT 12 Z8 G108 1 FAN MODE 0 OFF 7 VENT 6 HEAT 5 HEAT DEFROST 4 LOW 3 MEDIUM 1 2 MEDIUM 2 1 HIGH 7 6 5 0 4 3 2 1 CONTROL HEATER 7 F15 20 DB WT 5 FUSED IGNITION SWITCH OUTPUT S219 86 30 85 87 F...

Page 730: ...EFROST 4 LOW 3 MEDIUM 1 2 MEDIUM 2 1 HIGH 7 6 5 0 4 3 2 1 CONTROL HEATER F15 20 DB WT F15 20 DB WT 7 5 S349 BK VT 16 Z8 Z8 12 BK PK C202 6 G108 AMP OTHER POWER GAS DIESEL 40A FUSE 11 24 17 D5 C100 12...

Page 731: ...11 11 10 10 HEATER CONTROL 1 2 3 4 0 5 6 7 8 9 0 8 9 5 A C 1 HIGH 2 MEDIUM 2 3 MEDIUM 1 4 LOW 5 DEFROST 6 HEAT DEF MIX 7 HEAT 8 VENT PANEL 9 BI LEVEL 10 A C 7 6 A C SELECT MODE FAN BK VT 12 Z8 G108 1...

Page 732: ...ONTROL 1 2 3 4 0 5 6 7 8 9 0 8 9 5 A C 1 HIGH 2 MEDIUM 2 3 MEDIUM 1 4 LOW 5 DEFROST 6 HEAT DEF MIX 7 HEAT 8 VENT PANEL 9 BI LEVEL 10 A C 7 6 A C SELECT MODE FAN BK VT 12 Z8 G108 1 S219 21 C204 7 5 S34...

Page 733: ...9 40 C201 F15 20 DB WT S217 F15 20 DB WT 2 4 ACTUATOR DOOR BLEND 3 Z1 20 BK GROUND FUSED IGNITION SWITCH OUTPUT SIGNAL FEEDBACK DOOR BLEND 6 HVAC UNIT C36 20 RD WT 4 C201 C36 20 RD WT 1 Z1 20 BK Z1 20...

Page 734: ...A17 ST RUN F20 2 11 C120 G106 S157 S132 Z1 16 BK C3 14 DB BK Z1 16 BK Z1 12 BK Z1 12 BK C2 K10 C2 K5 ENGINE CONTROL MODULE A C COMPRESSOR CLUTCH RELAY CONTROL SENSE SWITCH A C C22 20 DB WT 3 C120 C22...

Page 735: ...B PK MOTOR FAN RADIATOR G106 Z1 12 BK FAN BATT F141 ST RUN F20 LB 12 C25 RELAY CONTROL CONTROL RELAY FAN RADIATOR MODULE CONTROL ENGINE K17 C2 C27 20 DB PK GAS DIESEL M 8W 10 2 8W 10 6 8W 30 15 8W 15...

Page 736: ...le 8W 43 2 3 4 Clockspring 8W 43 4 Data Link Connector 8W 43 2 3 Driver Airbag 8W 43 4 Fuse 26 J B 8W 43 2 3 Component Page Fuse 27 J B 8W 43 2 3 G200 8W 43 2 G300 8W 43 3 J unction Block 8W 43 2 3 Pa...

Page 737: ...K 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 BAS...

Page 738: ...NECTOR 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 10 C204 11 DB YL 18 F23 LG YL 18 F14 PAIR TWISTED PAIR TWIS...

Page 739: ...IRBAG 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...

Page 740: ...4 6 7 Component Page Instrument Cluster 8W 44 2 3 4 8 9 J unction Block 8W 44 2 3 4 5 6 7 Left Courtesy Lamp 8W 44 6 7 Left Rear Door J amb Switch 8W 44 8 9 Left Visor Vanity Lamp 8W 44 5 Liftgate Sw...

Page 741: ...07 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...

Page 742: ...8 G107 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...

Page 743: ...IPER REAR Z1 20 BK Z1 14 BK Z1 BK 20 1 Z1 20 BK S208 BK VT 12 Z8 G108 11 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 ILLUMINATIO...

Page 744: ...BK 20 Z1 B YL 20 M2 M2 20 YL 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 8W 15 1...

Page 745: ...K S207 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 14 BK LAMP M1 20 PK M1 20 PK M2 18BK WT M2 18BK...

Page 746: ...H C7 7 BK 14 Z1 G108 Z1 18 BK S207 HEADLAMP DELAY MODULE 4 Z1 18 BK M2 20 YL 1 C207 A 2 C207 B 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...

Page 747: ...20 YL 20 M2 A C320 M2 18 YL B C320 BK 18 Z1 Z1 20 BK S309 Z1 12 BK G303 BK 20 Z1 Z1 18 BK C317 3 LEFT REAR DOOR JAMB SWITCH 3 2 YL 18 M2 C317 1 DRIVER DOOR JAMB SWITCH 1 3 3 1 SWITCH JAMB DOOR PASSENG...

Page 748: ...M2 A C320 M2 18 YL B C320 BK 18 Z1 Z1 20 BK S309 Z1 12 BK BK 20 Z1 Z1 18 BK C317 3 LEFT REAR DOOR JAMB SWITCH 3 2 YL 18 M2 C317 1 PASSENGER DOOR JAMB SWITCH 1 3 3 1 SWITCH JAMB DOOR DRIVER BK 18 Z1 Z1...

Page 749: ......

Page 750: ...9 10 J unction 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 Powe...

Page 751: ...E2 1 C1 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...

Page 752: ...T S301 G301 8 C2 GROUND BK LB 16 Z5 7 C2 GROUND Z5 16 BK LB PK 20 M1 1 PK 20 M1 FEED OUTPUT RUN ACC FUSED B LAMPS PANEL G108 BK 14 Z9 GROUND FUSED IGNITION SWITCH HEADLAMP SWITCH OUTPUT RADIO S135 GAS...

Page 753: ...Z1 1 UP 2 DOWN 2 1 1 2 GAS DIESEL 17 FUSE 20A A21 A22 A3 A4 20A FUSE 26 BATT A0 CENTER DISTRIBUTION POWER A18 C100 E6 11 C200 9 C203 LHD RHD LHD RHD 5 GROUND FLASHER COMBINATION Z1 20 BK Z1 14 BK S208...

Page 754: ...8 18 18 DG 18 X87 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 S331 S3...

Page 755: ...RD X87 18 LG BK 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 REA...

Page 756: ...2 A B C2 13 1 C314 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...

Page 757: ...TN RD 16 X94 X82 18 LB RD X80 18 LB BK LB BK 18 X80 LB RD 18 X82 LB BR 18 X80 S321 X82 18 LB RD X82 18 LB RD LB BR 18 X80 SPEAKER DOOR FRONT RIGHT RIGHT FRONT DOOR TWEETER RIGHT FRONT SPEAKER SPEAKER...

Page 758: ...TN 20 E1 E2 20 OR PK 20 M1 C1 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 X...

Page 759: ...2 2 1 C1 4 3 5 X53 16 DG X55 16 BR RD BR RD 18 X55 DG 18 X53 SPEAKER DOOR FRONT RIGHT LEFT FRONT DOOR SPEAKER LEFT FRONT LEFT FRONT SPEAKER SPEAKER FEED RUN ACC OUTPUT SPEAKER SPEAKER FRONT RIGHT FRON...

Page 760: ...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 1 C203 C200 6 7 C200 C203 7 9 C200 C...

Page 761: ......

Page 762: ...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 J unction Block 8W 48 2 3 Passenger Power Mirror 8W 48 2 3 Rear Window Defogger 8W 48 2 3 Re...

Page 763: ...CONTROL SWITCH SENSE BK 12 Z1 Z1 16 BK S329 Z1 12 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...

Page 764: ...K S309 3 C307 S319 Z1 14 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 BLO...

Page 765: ......

Page 766: ...mb Switch 8W 49 4 5 Fuse 9 J B 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 J unction Block 8W 49 2 3 4 5 Overhead Module 8W 49 2 3 4 5 6 Passenger...

Page 767: ...ENTER 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 MERCURY...

Page 768: ...15A FUSE 16 A23 A24 12 C1 BLOCK JUNCTION M1 20 PK 2 3 C3 2 PK 20 M1 S216 F87 20 WT BK COURTESY LAMPS FEED FEED LAMPS COURTESY S135 OUTPUT ST RUN S347 S361 SKIM OTHERS M1 20 PK DIESEL GAS 1 DIESEL SWI...

Page 769: ...1 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 LAMP COURTESY 1 YL 20 M2 7 1 C3 JUNCTION BLOCK S345 M2 20 YL YL 20 M2 7 C7 1 DRIVER M2 18...

Page 770: ...ATURE SENSOR C301 3 4 VT LG 20 G31 G32 20 BK LB 2 F15 F14 C100 BK LB 20 G32 G31 20 VT LG LAMP COURTESY COURTESY LAMP CONTROL 1 7 1 C3 JUNCTION BLOCK S345 M2 20 YL 7 C7 1 SWITCH JAMB DOOR DRIVER M2 18...

Page 771: ...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 O...

Page 772: ...t Page Headlamp Switch 8W 50 2 3 4 9 10 11 12 13 14 15 16 17 18 Instrument Cluster 8W 50 5 6 7 8 16 19 J unction Block 8W 50 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Left City Lamp 8W 50 12 17 18 Le...

Page 773: ...A22 17 FUSE 20A TN BK 18 F34 E6 F34 18 TN BK TN BK 18 F34 16 CONNECTOR LINK DATA YL 20 M2 E1 20 TN S201 FROM TO 6 JB FUSE LG 14 L2 LG 14 L2 6 2 C1 BK YL 18 L7 9 C1 LB 20 G26 C1 5 FROM S210 C1 6 G16 2...

Page 774: ...FUSE 20A TN BK 18 F34 A18 F34 18 TN BK YL 20 M2 E1 20 TN S201 FROM TO 6 JB FUSE LG 14 L2 LG 14 L2 6 2 C1 BK YL 18 L7 9 C1 LB 20 G26 C1 5 FROM S210 C1 6 G16 20 BK LB TO S200 TO S206 MODULE HEADLAMP DEL...

Page 775: ...2 6 2 C1 BK YL 18 L7 9 C1 LB 20 G26 C1 5 FROM S210 C1 6 G16 20 BK LB TO S200 TO S206 SWITCH HEADLAMP MODULE HEADLAMP DELAY 14 E 8W 50 7 F 8W 50 7 S218 DIODE MODULE 1 OUTPUT 14 16 S226 L2 LG L2 LG L2 L...

Page 776: ...8 L44 10 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...

Page 777: ...D L34 20 RD OR G106 S133 VT RD 20 L44 B12 C 8W 50 3 DELAY HEADLAMP FROM MODULE SWITCH FROM HEADLAMP D 8W 50 3 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...

Page 778: ...06 S133 VT RD 20 L44 E 8W 50 4 FROM S226 SWITCH FROM HEADLAMP F 8W 50 4 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...

Page 779: ...D OR G106 S133 VT RD 20 L44 E 8W 50 4 FROM S226 SWITCH FROM HEADLAMP F 8W 50 4 S213 BK 18 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...

Page 780: ...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 SWI...

Page 781: ...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 S...

Page 782: ...SWITCH HAZARD SIGNAL TURN PART OF MULTI FUNCTION SWITCH B10 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...

Page 783: ...HAZARD SIGNAL TURN B10 IN PDC RELAY LAMP FOG S105 L77 20 BR YL BR 20 L77 LG 18 L61 L61 20 LG WT C106 BK WT 20 Z1 BK 18 Z1 BR YL 20 L77 7 C106 BK YL 18 L7 LHD RHD 2 1 LEFT CITY LAMP BK 18 Z1 Z1 20 BK 2...

Page 784: ...23 FUSE 10A G106 L7 18 BK YL 45 C201 S206 2 1 0 9 SWITCH HEADLAMP C1 1 PARK 2 HEAD 0 OFF BATT F34 L7 18 BK YL C106 10 C100 B9 TN 20 L60 1 S212 L60 20 TN SWITCH HAZARD SIGNAL TURN TN 20 L60 LHD RHD BK...

Page 785: ...GNAL 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...

Page 786: ...9 SWITCH HEADLAMP C1 1 PARK 2 HEAD 0 OFF BATT F34 L7 18 BK YL S206 45 C201 RHD LHD VT 20 L139 L77 20 BR YL BK YL 18 L7 TO S104 L77 20 BR BATT F61 12 C106 RD 20 L33 BK 18 Z1 A C B LEFT HEADLAMP L33 20...

Page 787: ...Z1 20 BK Z1 14 BK C2 6 C4 M3 10A FUSE 7 BLOCK JUNCTION 2 1 0 9 SWITCH HEADLAMP C1 1 PARK 2 HEAD 0 OFF BATT F34 L7 18 BK YL S206 45 C201 VT 20 L139 L77 20 BR YL TO S104 L77 20 BR YL G34 16 RD GY G34 16...

Page 788: ...1 0 9 SWITCH HEADLAMP C1 1 PARK 2 HEAD 0 OFF BATT F34 L7 18 BK YL S206 45 C201 RHD LHD VT 20 L139 L77 20 BR YL BK YL 18 L7 TO LEFT L77 20 BR BATT F61 12 C106 BK 20 Z1 BK 20 Z1 BK WT 20 Z1 ON LB 20 L3...

Page 789: ...ITCH HEADLAMP C1 1 PARK 2 HEAD 0 OFF BATT F34 L7 18 BK YL S206 45 C201 RHD LHD VT 20 L139 L77 18 BR YL BK YL 18 L7 TO LEFT L77 20 BR YL BATT F61 12 C106 BK 20 Z1 BK 20 Z1 BK WT 20 Z1 ON LB 20 L39 L39...

Page 790: ...WT OR G7 20 WT OR 4 DRIVER BEAM INDICATOR HIGH RD GY 16 G34 B15 IN PDC NO 2 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...

Page 791: ...18 L13 L13 18 BR YL S234 L13 18 BR YL LOGIC LOGIC M M L44 18 VT RD 1 S236 VT RD 18 L44 BR YL 20 L13 E18 C100 C100 B12 VT RD 20 L44 L44 20 VT RD 4 BK GY 20 Z15 G107 HEADLAMP LEVELING SWITCH 2 5 L13 20...

Page 792: ...51 2 5 6 8 9 Left Back Up Lamp 8W 51 7 Component Page Left Rear Fog Lamp 8W 51 10 11 Left Tail Stop Lamp 8W 51 3 Left Turn Signal Lamp 8W 51 4 License Lamp 8W 51 3 Park Neutral Position Switch 8W 51 5...

Page 793: ...0 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 6 C204...

Page 794: ...WT TN L50 20 WT TN L77 18 BR YL BR YL 18 L77 BR YL 20 L77 L77 18 BR TRAILER TOW OTHERS WT TN 18 L50 L50 18 WT TN WT TN 18 L50 BK 18 Z1 L77 20 BR YL BR YL 20 L77 5 TRAILER TOW OTHER Z1 14 BK L77 18 BR...

Page 795: ...Z1 DG RD 18 L63 BR RD 18 L62 1 C322 TOW TRAILER OTHERS S335 LEFT TURN SIGNAL SIGNAL TURN RIGHT L62 20 BR RD Z1 14 BK 7 C204 25 C200 LHD RHD 2 C323 C323 1 RHD LHD 26 C200 8 C204 S337 2 C322 Z1 18 BK B...

Page 796: ...1 C201 F20 18 WT C100 A9 E9 4 0L A T OTHER LHD RHD 4 0L A T OTHER S161 A15 A B MODULE CONTROL POWERTRAIN CONTROL SOLENOID CLUTCH CONVERTER TORQUE C2 B11 K54 18 OR BK F20 18 WT S159 SOLENOID CLUTCH CO...

Page 797: ...C204 16 C200 A15 C100 5 C111 S159 WT 18 F20 7 C111 F20 18 WT TO S303 D 8W 51 7 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 7 S303 TO 8W 12 2 8W...

Page 798: ...1 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 5 LHD RHD Z1 18 BK Z1 16 BK BUILT UP EXPORT UP EXPORT...

Page 799: ...DULE 5 LG BK 18 L36 2 4 L38 18 BR WT F83 18 YL DG YL DG 18 F83 3 C305 C2 3 SWITCH WINDOW LOCK POWER DRIVER F 8W 51 10 G 8W 51 10 REAR FOG LAMP SWITCH TO TO C200 L39 20 LB TO SWITCH LAMP FOG REAR H 8W...

Page 800: ...MODULE 5 LG BK 18 L36 2 4 L38 18 BR WT I 8W 51 11 J 8W 51 11 REAR FOG LAMP SWITCH TO TO S220 L39 20 LB YL DG 18 F83 C300 3 S232 FOG LAMP RELAY OUTPUT HEAD LAMP SWITCH OUTPUT C2 3 SWITCH WINDOW LOCK PO...

Page 801: ...348 S341 Z1 18 BK Z1 14 BK Z1 12 BK Z1 18 BK Z1 16 BK ILLUMINATION F 8W 51 8 G 8W 51 8 H 8W 51 8 FROM RELAY FOG REAR LAMP LAMP REAR FOG RELAY FROM LAMP REAR FOG RELAY FROM BR WT 18 L38 OR WT 18 L38 OR...

Page 802: ...303 S310 S309 S348 S341 Z1 18 BK Z1 14 BK Z1 12 BK Z1 18 BK Z1 12 BK ILLUMINATION I 8W 51 9 J 8W 51 9 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...

Page 803: ......

Page 804: ...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 Powe...

Page 805: ...12 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 8...

Page 806: ...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 C20...

Page 807: ...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 C2...

Page 808: ...26 C200 C204 8 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 TUR...

Page 809: ...T S105 LG 18 L61 L61 20 LG WT C106 BK WT 20 Z1 BK 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 2...

Page 810: ...D RHD 25 C200 C204 7 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...

Page 811: ...IGNAL 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...

Page 812: ...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 J unction Block 8W 53 2 3 4 5 6 7 Rear Washer Pump 8W 53 2 4 5 6 7 Rear Wiper Mot...

Page 813: ...A31 8 C1 1 V6 16 DB G106 S141 PUMP WASHER WINDSHIELD Z1 14 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...

Page 814: ...1 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...

Page 815: ...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 M T 4 0L EXCEPT BUILT UP EXPORT OTHER Z1 18 BK GROUND 3 C1 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEADLAMP...

Page 816: ...0 2 28 5 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 C1 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEA...

Page 817: ...1 WASH 0 OFF 1 2 0 1 PARK 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 C1 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEADLAMP JUNCTION BLOCK 6...

Page 818: ...PE 1 WASH 0 OFF 1 2 0 1 PARK 2 RUN BK WT 18 V20 1 8 3 1 C310 C313 S141 BK 12 Z1 Z1 18 BK V20 18 BK WT V23 18 BR PK V13 18 BR LG 3 C1 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEADLAMP JUNCTION BLOCK 6...

Page 819: ......

Page 820: ...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...

Page 821: ...3 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 C1 8...

Page 822: ...TURN LEFT WT TN 20 L50 WT TN 20 L50 WT TN 20 L50 6 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 LE...

Page 823: ......

Page 824: ...8W 60 2 3 G302 8W 60 2 4 G303 8W 60 3 5 J unction 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 Pas...

Page 825: ...4 LB M 1 3 BR 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...

Page 826: ...14 Q16 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 PAS...

Page 827: ...4 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...

Page 828: ...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...

Page 829: ......

Page 830: ...2 3 G107 8W 61 2 G302 8W 61 2 3 G303 8W 61 3 Ignition Switch 8W 61 2 3 J unction Block 8W 61 2 3 4 5 Component Page Left Rear Door Lock Motor 8W 61 4 5 Liftgate Lock Motor 8W 61 4 5 Overhead Module 8W...

Page 831: ...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 CONT...

Page 832: ...RD DB 20 P55 5 11 MODULE OVERHEAD 21 C203 22 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...

Page 833: ...K 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 P...

Page 834: ...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...

Page 835: ......

Page 836: ...r Power Mirror 8W 62 2 3 4 5 6 7 8 9 Fuse 18 J B 8W 62 2 3 5 6 G107 8W 62 9 G302 8W 62 2 3 4 8 Component Page G303 8W 62 5 6 7 J unction Block 8W 62 2 3 4 5 6 7 8 9 Passenger Power Mirror 8W 62 4 7 8...

Page 837: ...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...

Page 838: ...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...

Page 839: ...4 C200 35 9 C305 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...

Page 840: ...L 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 Z...

Page 841: ...WINDOW P76 20 OR 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 S232 RUN ACC A31 3 C300 Z1 14 BK 5 6 5 C303 Z1 14 BK 6 PASSENG...

Page 842: ...ASSENGER POWER MIRROR S328 OR YL 20 P76 P76 20 OR YL C2 5 19 C204 18 8 C305 9 S318 10 20 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...

Page 843: ...6 20 OR YL 3 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 C...

Page 844: ...91 20 WT BK 20 C204 10 P76 20 OR YL 13 C203 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 3 4 P74 20 DB P72 20 YL BK S360 S5 C4 G107 P91 20 WT BK P76 20 OR YL Z1 14 BK S208 Z1 14 BK 1 2 3 4 4...

Page 845: ......

Page 846: ...4 6 Left Heated Seat Back 8W 63 5 Left Heated Seat Cushion 8W 63 5 Component Page Left Heated Seat Switch 8W 63 4 Left Power Seat Motors 8W 63 2 Left Power Seat Switch 8W 63 2 3 6 Rear Motor 8W 63 2...

Page 847: ...T REAR MOTOR C6 1 FRONT DOWN 2 FRONT UP 3 REAR DOWN 4 REAR UP 5 FORWARD 6 REARWARD C316 2 RD LB 14 F37 SWITCH SEAT POWER LEFT Z1 14 MOTORS SEAT POWER LEFT F37 14 RD LB S356 OTHER HEATED SEATS G306 G30...

Page 848: ...ER C6 1 FRONT UP 2 FRONT DOWN 3 REAR UP 4 REAR DOWN 5 FORWARD 6 REARWARD C316 2 RD LB 14 F37 RIGHT LEFT SWITCH SEAT POWER A RD LB 14 F37 RIGHT Z1 14 BK FUSED HEADLAMP SWITCH OUTPUT OTHER HEATED SEATS...

Page 849: ...T 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 P13...

Page 850: ...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 PK P141 18 TN LB S357 P89 18 BR B A B A BACK SEAT HEATED RIGHT BACK SEAT HEATED LEFT Z1...

Page 851: ...G306 S355 C329 12 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 BLOC...

Page 852: ...0 25 28 S215 8W 12 8 9 S216 8W 12 12 13 S217 8W 12 21 S218 8W 10 26 27 36 S219 8W 12 21 22 S220 8W 51 11 Component Page S221 8W 33 2 3 S222 8W 33 2 3 S225 8W 12 12 S226 8W 50 4 S227 8W 15 16 S229 8W 4...

Page 853: ...N SENSOR THROTTLE COOLANT SENSOR TEMPERATURE 1 ENGINE UPSTREAM OXYGEN 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 K...

Page 854: ...PUMP C100 B6 9 C120 BK LB 18 K4 COOLANT SENSOR TEMPERATURE 2 MODULE 1 RIGHT SPEED CONTROL SWITCH A ENGINE S222 K167 20 BR YL C1 C2 3 C116 K167 18 BR YL ENGINE CONTROL MODULE A61 C1 1 SENSOR PRESSURE...

Page 855: ...SITION SENSOR CAMSHAFT OR 18 K7 S115 L62 18 BR RD 1 C321 C323 8 BR RD 20 L62 BR RD 20 L62 7 C204 C200 25 RHD LHD TURN SIGNAL HAZARD SWITCH BR RD 20 L62 BR RD 20 L62 3 L62 20 BR RD S312 GAS RELAY TURN...

Page 856: ...haft Position Sensor 8W 80 31 Cargo Lamp Switch 8W 80 31 Center High Mounted Stop Lamp 8W 80 32 Cigar Lighter 8W 80 32 Clockspring C1 8W 80 32 Clockspring C2 8W 80 32 Clockspring C3 8W 80 32 Clutch In...

Page 857: ...rk Neutral Position Switch 8W 80 64 Passenger Airbag 8W 80 64 Component Page Passenger Door J amb Switch 8W 80 64 Passenger Door Lock Motor 8W 80 64 Passenger Power Lock Window Switch 8W 80 65 Passeng...

Page 858: ...80 86 Transfer Case Switch Illumination 8W 80 86 Transmission Control Assembly 8W 80 86 Component Page Transmission Control Module 8W 80 87 Transmission Range Sensor 8W 80 87 Turbo Boost Pressure Sens...

Page 859: ...GH SPEED BLOWER MOTOR 1 Z8 12BK VT GROUND BLACK 7 1 A C HEATER CONTROL CAV CIRCUIT FUNCTION 1 C3 14DB BK A C COMPRESSOR CLUTCH RELAY OUTPUT 2 Z1 16BK GROUND A C COMPRESSOR CLUTCH 2 1 BLACK 2 1 GRAY DI...

Page 860: ...1 R44 18DG YL 3 2 1 CAV FUNCTION CIRCUIT 1 2 BLACK AMBIENT AIR TEMPERATURE SENSOR AMBIENT TEMPERATURE SENSOR SIGNAL CIRCUIT FUNCTION CAV G31 20VT LG 1 2 G32 20BK LB SENSOR GROUND CAV CIRCUIT FUNCTION...

Page 861: ...ACK SIGNAL 4 F15 20DB WT PRESSURE SWITCH BRAKE WARNING BLACK 2 1 20GY WT G99 2 RED BRAKE WARNING INDICATOR DRIVER 20GY BK G9 1 FUNCTION CIRCUIT CAV 5 1 NATURAL RED BRAKE WARNING INDICATOR DRIVER DIESE...

Page 862: ...CUIT A1 Z1 18BK A2 G106 20BK WT A3 G107 20BK RD A4 L39 20LB 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...

Page 863: ...K4 20BK RD F18 V37 20RD LG K78 18GY 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 L50 18WT TN D2 20WT BK D1 20VT BR F1 20DB GY F20 18WT Z12...

Page 864: ...K167 20BR YL K226 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 12RD LG A111 D5 D4 16DG WT A141 D2...

Page 865: ...1 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...

Page 866: ...5 16BK GY 20BR YL L13 C106 GAS GAS C106 14 7 8 1 14 7 8 1 20DG YL L78 14 20VT RD L44 13 L35 20BR WT 12 Z1 20BK WT 11 20TN L60 10 20VT L43 9 20LB L39 8 20BR YL L77 7 20RD OR L34 6 5 20BK Z1 4 20LG WT L...

Page 867: ...8DG OR 1 CIRCUIT CAV C107 LHD 4 0L GAS LHD 4 0L GAS C107 8 1 14 7 14 7 8 1 C107 LHD 2 5L GAS LHD 2 5L GAS C107 14 7 8 1 14 7 8 1 A61 16DG BK 14 13 L10 18BR LG 12 F20 18WT 11 F12 18DB WT 10 9 G107 20BK...

Page 868: ...8DG 2 A142 18DG OR 1 CIRCUIT CAV 1 8 7 14 1 8 7 14 C107 RHD 4 0L GAS RHD 4 0L GAS C107 C107 RHD 2 5L GAS RHD 2 5L GAS C107 14 7 8 1 14 7 8 1 A61 16DG BK 14 13 L10 18BR LG 12 F20 18WT 11 F12 18DB WT 10...

Page 869: ...10 9 K167 20BR YL 8 F20 18WT 7 K7 20OR 6 L10 18BR LG 5 4 G107 20BK RD 3 2 G7 20WT OR 1 CIRCUIT CAV DIESEL C111 2 1 2 L61 18LG 1 CIRCUIT CAV Z1 18BK 2 L61 18LG 1 CIRCUIT CAV Z1 18BK BUILT UP EXPORT C11...

Page 870: ...0DB PK 3 C22 20DB WT 4 5 K20 18DG 6 C3 16DB BK 7 K72 18DG OR 8 K2 20TN BK 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...

Page 871: ...8 16BR LB X57 7 16BR YL X51 6 16DB RD X56 5 16VT X54 4 P91 20WT BK 3 16BR RD X55 2 16DG X53 1 CIRCUIT CAV 20LB YL C16 37 20OR YL P76 36 20DB P74 35 20YL BK P72 34 12TN F81 33 20PK VT P36 32 20OR VT P3...

Page 872: ...2TN 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...

Page 873: ...6RD 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 20LG RD G10 69 68 P91 20WT BK 67 20GY BK G9 66 16RD LB F38 65 12DB A21 64 14YL A41 63 12BK OR...

Page 874: ...13 16 15 14 13 20LG RD G10 12 20OR BK E2 11 20GY BK G9 10 18DG RD X60 9 18DB OR X58 8 18BR LB X57 7 18DB RD X56 6 18BR RD X55 5 18VT X54 4 18DG X53 3 18DB WT X52 2 18BR YL X51 1 CIRCUIT CAV P55 20DB P...

Page 875: ...L F23 10 9 20DG RD L63 8 20BR RD L62 7 20WT TN L50 6 18BR LG L10 5 16DG WT A141 4 16VT F75 3 18WT BK D2 2 18VT BR D1 1 CIRCUIT CAV C204 C204 18DB YL F23 10 9 20DG RD L63 8 20BR RD L62 7 20WT TN L50 6...

Page 876: ...0 LHD C300 6 3 4 NATURAL 1 6 3 4 1 NATURAL 6 20LB G26 5 20LB RD P59 4 20DB PK P55 3 20PK VT P36 2 20OR VT P35 1 CIRCUIT CAV 6 20LB G26 5 20LB RD P59 4 20DB PK P55 3 20PK VT P36 2 20OR VT P35 1 CIRCUIT...

Page 877: ...3 1 5 Q18 14GY BK Q28 14DG WT 1 CAV 4 3 2 5 6 CIRCUIT Q18 14GY BK 6 3 4 1 BLACK BLACK 4 6 1 3 18LB RD X82 5 18LB BK X80 4 Q1 14YL 3 14VT WT Q26 2 14BR WT Q16 1 CIRCUIT CAV D1 20VT BR 1 1 5 4 4 11 1 5...

Page 878: ...5 P34 16PK BK 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 18DG X53 1 2 X87 18DG 18LG VT X87 2 1 X53 18DG LHD C305 LHD C305 WHITE 13 8 3 9 4 1 W...

Page 879: ...18DB RD 2 18BR RD X85 1 CIRCUIT CAV FULL OPTIONS FULL OPTIONS FULL OPTIONS 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 14VT WT Q26 4 1...

Page 880: ...IRCUIT CAV C310 G78 20TN BK BLACK 18BR YL L77 11 20VT YL M4 10 18BK Z1 9 18BR LG V13 8 18BR PK V23 7 6 16PK BK P34 5 16OR BK P33 4 12BK WT C15 3 BK 12 Z1 2 18BK WT V20 1 CIRCUIT CAV C311 G78 20TN BK 3...

Page 881: ...CAV 20BK Z1 3 20BK LB G16 2 20YL M2 1 CIRCUIT CAV 4 18BR YL X51 3 18BR LB X57 2 18DB WT X52 1 18DB OR X58 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 20...

Page 882: ...1 L62 20BR RD 2 Z1 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...

Page 883: ...1 CIRCUIT CAV 2 3 1 3 1 3 2 3 2 1 CIRCUIT CAV X80 18LB BK X82 18LB RD F83 18YL DG X54 18VT X56 18DB RD FULL OPTIONS W O POWER AMPLIFIER A6 20RD OR L62 20BK RD A6 20RD OR L62 20BR RD CAV CIRCUIT 1 L63...

Page 884: ...8BK WT V20 18BR PK V23 18BR LG V13 18BR YL L77 20TN BK G78 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 BLAC...

Page 885: ...VT BK 14 13 Z1 18BK 12 F83 18YL DG 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 CI...

Page 886: ...SUPPLY 5 18OR K7 1 FUNCTION CIRCUIT CAV 1 3 BLACK FUSED B C332 C332 BLACK BLACK 18BK Z1 4 18BK OR P87 3 18BK DG P143 2 18TN LB P141 1 CIRCUIT CAV CAV CIRCUIT 1 P141 18TN LB 2 P143 18BK DG 3 P87 18BK...

Page 887: ...D CONTROL SWITCH SIGNAL 20RD LG V37 2 HORN RELAY CONTROL 20BK RD X3 1 FUNCTION CIRCUIT CAV B A CLOCKSPRING C2 CAV CIRCUIT FUNCTION A K167 20BR YL SENSOR GROUND B V37 20RD LG SPEED CONTROL SWITCH SIGNA...

Page 888: ...NATION FLASHER CAV CIRCUIT FUNCTION 1 L5 20BK FUSED IGNITION SWITCH OUTPUT RUN 2 L9 20BK PK FUSED FLASHER FEED 3 L12 20VT TN HAZARD FLASHER SELECT SIGNAL 4 L6 20RD WT FLASHER OUTPUT 5 Z1 18BK GROUND G...

Page 889: ...WT F15 23 22 21 SCI TRANSMIT ISO 9141K 18PK D21 20 19 RIGHT 18WT DB B6 18 RIGHT 18YL B2 17 ABS RELAY CONTROL 18GY BK G83 16 15 14 G SWITCH TEST SIGNAL 18PK OR B43 13 BRAKE LAMP SWITCH OUTPUT 18WT TN L...

Page 890: ...YL K167 2 CRANKSHAFT POSITION SENSOR SIGNAL 18GY BK K24 1 FUNCTION CIRCUIT CAV CONNECTOR DATA LINK BLACK 1 8 9 16 FUSED B 18TN BK F34 16 15 14 13 12 CCD BUS 18WT BK D2 11 10 9 8 SCI TRANSMIT ISO 9141...

Page 891: ...D L3 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...

Page 892: ...NDOW SWITCH RIGHT FRONT 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 LE...

Page 893: ...R RELAY OUTPUT C16 20BK WT 5 LEFT RIGHT POWER MIRROR HORIZONTAL SUPPLY P91 20WT BK LEFT MIRROR LEFT DRIVER P75 20DB WT 3 COMMON P76 20OR YL 2 LEFT MIRROR UP DRIVER 20YL P71 1 FUNCTION CIRCUIT CAV 3 2...

Page 894: ...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...

Page 895: ...OR SIGNAL SHUT OFF FEED SOLENOID CONTROL K140 16TN WT K24 20GY BK K3 20LG BK K153 16OR K126 16LG K140 16TN WT K4 20BK LB K57 20LG OR K135 20WT BK K68 18LG YL K2 20TN BK A80 A50 A51 A52 A53 A54 A55 A56...

Page 896: ...GROUND Z12 16BK TN AUTOMATIC SHUT DOWN RELAY OUTPUT A142 16DG OR EGR SOLENOID CONTROL K35 18GY YL WIPER PARK SWITCH SENSE V66 18RD LG WAIT TO START INDICATOR K185 20OR LB AUTOMATIC SHUT DOWN RELAY CON...

Page 897: ...SOR GROUND ENGINE COOLANT TEMPERATURE SENSOR NO 1 SENSOR NO 2 TEMPERATURE COOLANT ENGINE SENSOR RETURN K167 18BR YL 2 1 K222 18TN RD CAV FUNCTION CIRCUIT SECONDARY ENGINE COOLANT TEMPERATURE SENSOR 5...

Page 898: ...AV MOTOR FRONT WIPER 6 3 4 1 BLACK WIPER HIGH SPEED OUTPUT 16BR VT V4 6 LOW SPEED WIPER SWITCH OUTPUT 16BR WT V3 5 GROUND 16BK Z1 4 3 WIPER PARK SWITCH SENSE 16DG YL V5 2 FUSED IGNITION SWITCH OUTPUT...

Page 899: ...FUEL INJECTOR NO 1 DRIVER CAV CIRCUIT FUNCTION 1 A142 18DG OR 2 K12 18TN FUEL INJECTOR NO 2 DRIVER CAV CIRCUIT FUNCTION 1 A142 18DG OR 2 K13 18YL WT FUEL INJECTOR NO 3 DRIVER CAV CIRCUIT FUNCTION 1 A...

Page 900: ...CAV FUEL INJECTOR NO 3 DRIVER 18YL WT K13 2 18DG OR A142 1 FUNCTION CIRCUIT CAV FUEL INJECTOR NO 2 DRIVER 18TN K12 2 18DG OR A142 1 FUNCTION CIRCUIT CAV FUEL INJECTOR NO 1 4 0L GAS 1 2 BLACK BLACK 2 1...

Page 901: ...GY 7 CAV CIRCUIT FUNCTION 1 K134 20LB BK SLEEVE POSITION SENSOR 2 3 K135 20WT BK SLEEVE POSITION SENSOR 4 K4 20BK LB SENSOR GROUND 5 6 K153 16OR SHUTOFF FEED GENERATOR DRIVER K72 16DG OR 1 GENERATOR D...

Page 902: ...2 14LG 2 HIGH BEAM INDICATOR DRIVER L3 16RD OR 3 FUSED B OPTICAL HORN FEED 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 20WT BK F8...

Page 903: ...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 DOOR LOCK INHIBIT SENSE G26 20LB 5 F34 18TN BK 4 COURTESY LAMPS DRIVER M2 20YL 3 HEA...

Page 904: ...TN C4 2 1 FUNCTION CIRCUIT CAV GROUND Z1 18BK FUSED B F37 14RD LB 8 HEATED SEAT RELAY 5 F235 16RD 4 B TO HEATED SEAT MODULE 2 F83 18YL DG 3 B TO HEATED SEAT MODULE F235 16RD 2 1 FUNCTION CIRCUIT CAV 7...

Page 905: ...H OUTPUT ST RUN A21 12DB 9 A31 12BK WT 8 B FUSED A1 12RD 7 6 5 FUSED IGNITION SWITCH OUTPUT RUN A22 12BK OR 4 B FUSED 12PK BK A2 3 RED BRAKE INDICATOR WARNING DRIVER 20GY BK G9 2 GROUND 20BK Z1 1 FUNC...

Page 906: ...0LG OR G19 4 20OR E2 3 20GY WT G99 2 G78 20TN BK 1 FUNCTION CIRCUIT CAV LEFT TURN SIGNAL 20LG WT L61 10 FUSED B 20PK M1 9 FUSED IGNITION SWITCH OUTPUT START RUN 20WT BK F87 8 LOW WASHER FLUID SENSE G2...

Page 907: ...IGNITION SWITCH OUTPUT RUN 20DB WT F15 6 20DG YL L78 5 4 FUSED B ENGINE STARTER MOTOR RELAY 20YL RD F45 3 2 FUSED RIGHT LOW BEAM OUTPUT 20VT RD L44 1 FUNCTION CIRCUIT CAV 6 L77 18BR YL JUNCTION BLOCK...

Page 908: ...SIGNAL 20OR E2 S2 PANEL LAMPS DIMMER SWITCH SIGNAL 20TN E1 S1 16RD F30 M6 FUSED B 16RD LB F38 M5 FUSED IGNITION SWITCH OUTPUT RUN ACC 16DB V6 M4 HEADLAMP SWITCH OUTPUT 18BK YL L7 M3 FUSED IGNITION SWI...

Page 909: ...CIRCUIT CAV BLOCK C6 JUNCTION 1 2 NATURAL B FUSED 14RD LB F37 2 REAR WINDOW DEFOGGER RELAY OUTPUT 12BK WT C15 1 FUNCTION CIRCUIT CAV BLOCK C7 JUNCTION 8 3 4 1 NATURAL FUSED B 20RD OR A6 8 COURTESY LA...

Page 910: ...POWER MIRROR HORIZONTAL SUPPLY RHD BLOCK C9 JUNCTION NATURAL 6 1 12 5 FUNCTION P33 CAV 1 CIRCUIT 16OR BK DOOR LOCK DRIVER P75 20DB WT C16 2 3 5 4 P91 20WT BK P76 7 8 9 10 6 P71 20YL LB 20BK WT 20OR YL...

Page 911: ...KER LEFT FRONT SPEAKER X55 18BR RD 1 2 1 BLACK AMPLIFIED LEFT DOOR SPEAKER 18DG X87 2 AMPLIFIED LEFT FRONT DOOR SPEAKER X85 18BK RD 1 FUNCTION CIRCUIT CAV FUSED B 6 SPEAKER RHD 4 SPEAKER AMPLIFIED LEF...

Page 912: ...LT UP 1 3 GRAY CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L77 18BR FUSED LEFT INBOARD TAIL LAMP 3 L61 18LG LEFT TURN SIGNAL CAV CIRCUIT FUNCTION 1 Z1 18BK GROUND 2 L77 18BR 3 L61 18LG LEFT TURN SIGNAL FU...

Page 913: ...UT 18VT L43 B FUSED LEFT HIGH BEAM OUTPUT 20RD L33 FUSED LEFT HIGH BEAM OUTPUT 18RD L33 A FUNCTION CIRCUIT CAV LEFT HEADLAMP LEFT FRONT WHEEL SPEED SENSOR FOG LAMP SEAT BACK CAV CIRCUIT FUNCTION A P88...

Page 914: ...WT 3 4 2 LEFT SEAT LOW HEAT LED DRIVER P137 18VT 1 FUNCTION CIRCUIT CAV 6 5 P133 18TN DG LEFT SEAT HEATER SWITCH MUX SEAT SWITCH LEFT HEATED 6 1 4 3 GROUND FUSED B F37 14RD Z1 14BK BLACK H G F C G H F...

Page 915: ...WER WINDOW LEFT REAR B UP 14DB Q13 1 FUNCTION CIRCUIT CAV WHEEL SPEED LEFT REAR BLACK A B LEFT REAR WHEEL SPEED SENSOR 20LG B4 B LEFT REAR WHEEL SPEED SENSOR 20LG DB B3 A FUNCTION CIRCUIT CAV 1 2 BUIL...

Page 916: ...T FUNCTION 1 L50 18WT TN BRAKE LAMP SWITCH OUTPUT 3 Z1 18BK GROUND 1 2 3 BLACK 2 L77 18BR FUSED LEFT INBOARD TAIL LAMP LEFT TAIL STOP LAMP SWITCH EXCEPT BUILT UP EXPORT CAV CIRCUIT FUNCTION A X57 18BR...

Page 917: ...L78 1 FUNCTION CIRCUIT CAV CAV CIRCUIT FUNCTION A P33 16OR BK DOOR LOCK DRIVER B P34 16PK BK DOOR UNLOCK DRIVER BLACK A B LIFTGATE LOCK MOTOR CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 3 M4 20VT YL LIFTG...

Page 918: ...1 FUNCTION CIRCUIT CAV SENSOR ABSOLUTE MANIFOLD 1 3 BLACK 5V SUPPLY 20OR K7 3 MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL 18DG RD K1 2 SENSOR GROUND 20BR YL K167 1 FUNCTION CIRCUIT CAV 2 1 SWITCH LOW COO...

Page 919: ...UNCTION CIRCUIT CAV 2 5L GAS A T POSITION SWITCH PARK NEUTRAL BLACK 3 1 FUNCTION PARK NETURAL POSITION SWITCH SENSE FUSED IGNITION SWITCH OUTPUT ST RUN TRS REVERSE SENSE CIRCUIT CAV T41 18BK WT 1 2 L1...

Page 920: ...ER UP FULL OPTIONS SWITCH C1 LOCK WINDOW CAV CIRCUIT FUNCTION 1 P59 20LB RD DOOR LOCK CONTROL 2 P55 20DB PK DOOR UNLOCK RELAY CONTROL 3 P35 20OR VT LOCK REQUEST 4 F81 14TN FUSED IGNITION SWITCH OUTPUT...

Page 921: ...IGHT POWER MIRROR UP MOVEMENT COMMON COMMON 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...

Page 922: ...18VT X54 6 LEFT FRONT SPEAKER 18DG X53 5 RADIO 12V OUTPUT 18DG RD X60 4 RIGHT REAR SPEAKER 18DB OR X58 3 RIGHT FRONT SPEAKER 18DB RD X56 2 LEFT FRONT SPEAKER 18BR RD X55 1 FUNCTION CIRCUIT CAV 2 1 CA...

Page 923: ...EFT REAR SPEAKER X93 18WT RD 6 RIGHT REAR SPEAKER X94 18TN RD 5 AMPLIFIED LEFT DOOR SPEAKER X87 18LG VT 4 3 FUSED B F75 16VT 2 FUSED B F75 16VT 1 FUNCTION CIRCUIT CAV BLACK C A BUILT UP EXPORT POWER A...

Page 924: ...ESSURE SWITCH 2 5L GAS 4 1 8 5 SWITCH MIRROR POWER LEFT MIRROR UP 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 M...

Page 925: ...1 A20 A19 FUEL MONITOR OUTPUT SIGNAL 18LB BK G8 A18 5 VOLT SUPPLY 18OR K7 A17 SECONDARY ENGINE COOLANT TEMP SENSOR 18TN RD K222 A16 A15 A14 A13 COOLANT LEVEL SWITCH SENSE 18PK BK G18 A12 A11 A10 A9 EN...

Page 926: ...T POSITION SENSOR SIGNAL 18TN YL K44 A18 5 VOLT SUPPLY 18OR K7 A17 ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 18TN BK K2 A16 INTAKE AIR TEMPERATURE SENSOR SIGNAL 18BK RD K21 A15 A14 A13 IDLE ACTUATOR 18...

Page 927: ...B30 B29 B28 VEHICLE SPEED SENSOR SIGNAL 18WT OR G7 B27 B26 B25 B24 ENGINE OIL PRESSURE SENSOR SIGNAL 18GY YL G60 B23 B22 B21 B20 B19 B18 B17 B16 B15 B14 B13 B12 B11 GENERATOR FIELD DRIVER 18DG K20 B1...

Page 928: ...DRIVER GAS CONTROL MODULE C2 POWERTRAIN B32 B21 B12 B22 B11 B1 B32 B31 B30 B29 B28 VEHICLE SPEED SENSOR SIGNAL 18WT OR G7 B27 B26 B25 B24 ENGINE OIL PRESSURE SENSOR SIGNAL 18GY YL G60 B23 B22 B21 B20...

Page 929: ...INDICATOR DRIVER A C SWITCH SIGNAL 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 DIE...

Page 930: ...OLENOID CONTROL 18PK BK K52 C20 FUEL PUMP RELAY CONTROL 18BR K31 C19 C18 C17 C16 BATTERY TEMPERATURE SENSOR SIGNAL 18PK YL K118 C15 C14 C13 AUTOMATIC SHUT DOWN RELAY OUTPUT 18DG OR A142 C12 SPEED CONT...

Page 931: ...57 6 RIGHT FRONT SPEAKER 16VT X54 5 LEFT FRONT SPEAKER 16DG X53 4 RIGHT REAR SPEAKER 16DB WT X52 3 LEFT REAR SPEAKER 16BR YL X51 2 RADIO 12V OUTPUT 16DG RD X60 1 FUNCTION CIRCUIT CAV FUSED B RADIO C2...

Page 932: ...GGER SWITCH REAR WINDOW 1 4 GRAY FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 20OR E2 4 FUSED REAR WINDOW DEFOGGER RELAY OUTPUT C16 20LB YL 3 REAR WINDOW DEFOGGER RELAY CONTROL 20DB WT C80 2 GROUND 20BK Z1...

Page 933: ...K UP 1 2 GRAY GROUND 18BK Z1 1 BACK UP LAMP FEED 18BR LG L10 2 FUNCTION CIRCUIT CAV LAMP RIGHT COURTESY BLACK COURTESY LAMPS DRIVER 18BK WT M2 2 FUSED B 18PK M1 1 FUNCTION CIRCUIT CAV 1 2 GRAY FOG LAM...

Page 934: ...1 FUNCTION CIRCUIT CAV 3 1 BLACK RIGHT TURN SIGNAL L60 18TN 2 GROUND Z1 18BK 1 FUNCTION CIRCUIT CAV RIGHT FRONT TURN SIGNAL BUILT UP EXPORT 2 1 GRAY CAV CIRCUIT FUNCTION 1 X80 18LB BR RIGHT FRONT DOO...

Page 935: ...XPORT 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...

Page 936: ...UT RUN ACC F83 18YL DG P140 18VT BK 3 4 2 RIGHT SEAT LOW HEAT LED DRIVER P138 18VT LG 1 FUNCTION CIRCUIT CAV 6 5 P134 18TN RD RIGHT SEAT HEATER SWITCH MUX 6 1 4 3 SEAT SWITCH RIGHT HEATED GROUND Z1 14...

Page 937: ...MP MASTER WINDOW SWITCH RIGHT REAR DOWN REPEATER WHEEL SPEED RIGHT REAR RED B A REAR WHEEL SENSOR 20YL DB B1 B REAR WHEEL SENSOR 20YL B2 A FUNCTION CIRCUIT CAV CAV CIRCUIT FUNCTION 1 Q14 14GY POWER WI...

Page 938: ...NSE 20LG RD G10 A FUNCTION CIRCUIT CAV STOP LAMP 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 R...

Page 939: ...ER LEFT HEAT SENSE INPUT LEFT HEAT ELEMENT OUTPUT RIGHT HEAT ELEMENT OUTPUT SENSOR FEED P140 18VT BK LEFT SEAT LOW HEAT LED DRIVER Z2 18BK LG RIGHT SEAT LOW HEAT LED DRIVER LEFT SEAT HIGH HEAT LED DRI...

Page 940: ...LAMP SWITCH OUTPUT RIGHT TURN RELAY TRAILER TOW 1 4 2 5 3 BLACK BRAKE LAMP SWITCH OUTPUT 20LG L74 5 4 FUSED B 20RD OR A6 3 BRAKE LAMP SWITCH OUTPUT 20WT TN L50 2 RIGHT TURN SIGNAL 20BK RD L62 1 FUNCT...

Page 941: ...NAL 20OR E2 1 FUNCTION CIRCUIT CAV CONTROL TRANSMISSION TRANSMISSION SOLENOID A 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 SPEE...

Page 942: ...ENOID CONTROL 20DB WT T22 11 10 TRS T3 SENSE 18VT T3 9 8 20VT BR D1 7 CCD BUS 20WT BK D2 6 5 OUTPUT SPEED SIGNAL 20LG WT T14 4 3 2 1 FUNCTION CIRCUIT CAV 4 0L A T RANGE TRANSMISSION 3 6 BLACK 8 5 2 7...

Page 943: ...1 FUNCTION CIRCUIT CAV DIESEL SWITCH MERCURY CAV CIRCUIT FUNCTION 1 Z1 20BK GROUND 2 M1 20PK FUSED B BLACK 1 2 UNDERHOOD LAMP CAV CIRCUIT FUNCTION 1 L60 20TN RIGHT TURN SIGNAL 2 3 L62 20BR RD RIGHT T...

Page 944: ...1 18BK GROUND BLACK A B WINDSHIELD WASHER PUMP SWITCH WIPE WASH 1 6 NATURAL WIPER SPEED SWITCH OUTPUT 16BR VT V4 6 FUSED IGNITION SWITCH OUTPUT RUN ACC 16DB V6 5 LOW SPEED WIPER SWITCH OUTPUT 16BR WT...

Page 945: ......

Page 946: ...4 5 10 11 34 Back Up Lamp Switch Diesel BK On Transmission 31 39 Back Up Lamp Switch Gas BK On Transmission N S Battery Temperature Sensor 4 0L Gas Diesel BK At Battery 4 0L 2 5L Diesel 16 Blend Door...

Page 947: ...Left Side at Trailer Tow Harness N S C324 RHD Right Kick Panel N S Connector Name Number Color Location Fig C325 BK T O Near Liftgate Grommet N S C326 BK In Liftgate Harness N S C327 BK In Liftgate Ha...

Page 948: ...partment N S Connector Name Number Color Location Fig Engine Control Module C2 Diesel BK Rear of Engine Compartment N S Engine Coolant Temperature Sensor GAS BK Front of Engine GAS 13 14 15 Engine Coo...

Page 949: ...nerator BK At Generator 13 14 16 36 37 Glow Plug Relay Diesel Left Rear Engine Compartment 32 33 Headlamp Beam Select Switch BK On Steering Column 24 HeadLamp Delay Module BK Near Headlamp Switch 17 1...

Page 950: ...ng Motor Built Up Export BK At Headlamp 32 33 Left Heated Seat Back At Seat N S Connector Name Number Color Location Fig Left Heated Seat Cushion At Seat N S Left Heated Seat Switch At Seat N S Left P...

Page 951: ...t Left Side N S Power Amplifier C2 NAT Under Rear Seat Left Side N S Connector Name Number Color Location Fig Power Antenna Built Up Export BK Rear of Engine Compartment N S Power Antenna Relay C1 Bui...

Page 952: ...Engine Compartment 10 11 34 35 Right Headlamp At Headlamp 1 Connector Name Number Color Location Fig Right Headlamp Leveling Motor Built Up Export BK At Headlamp N S Right Heated Seat Back At Seat N...

Page 953: ...1 39 Transfer Case Switch 242 BK On Transfer Case 4 0L A T Only 31 Transfer Switch Illumination BK Near Center Console N S Connector Name Number Color Location Fig Transmission Control Assembly BK On...

Page 954: ...Fig 1 Front End Lighting Right Side Shown Left Side Similar XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 9 DESCRIPTION AND OPERATION Continued...

Page 955: ...Fig 2 Left Engine Compartment 2 5L Engine LHD 8W 90 10 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 956: ...Fig 3 Left Engine Compartment 2 5L Engine RHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 11 DESCRIPTION AND OPERATION Continued...

Page 957: ...Fig 4 Right Engine Compartment 2 5L Engine LHD 8W 90 12 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 958: ...Fig 5 Right Engine Compartment 2 5L Engine RHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 13 DESCRIPTION AND OPERATION Continued...

Page 959: ...Fig 6 Engine Compartment Components LHD 8W 90 14 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 960: ...Fig 7 Engine Compartment Components RHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 15 DESCRIPTION AND OPERATION Continued...

Page 961: ...Fig 8 Left Engine Compartment 4 0L Engine LHD 8W 90 16 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 962: ...Fig 9 Left Engine Compartment 4 0L Engine RHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 17 DESCRIPTION AND OPERATION Continued...

Page 963: ...Fig 10 Right Engine Compartment 4 0L Engine LHD 8W 90 18 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 964: ...Fig 11 Right Engine Compartment 4 0L Engine RHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 19 DESCRIPTION AND OPERATION Continued...

Page 965: ...Fig 12 Under Dash Components 8W 90 20 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 966: ...Fig 13 Engine Connectors 2 5L Engine LHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 21 DESCRIPTION AND OPERATION Continued...

Page 967: ...Fig 14 Engine Connectors 2 5L Engine RHD 8W 90 22 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 968: ...Fig 15 Engine Connectors 4 0L Engine XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 23 DESCRIPTION AND OPERATION Continued...

Page 969: ...Fig 16 Engine and Battery 4 0L Engine 8W 90 24 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 970: ...Fig 17 Instrument Panel Connectors LHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 25 DESCRIPTION AND OPERATION Continued...

Page 971: ...Fig 18 Instrument Panel Connectors RHD 8W 90 26 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 972: ...Fig 19 Instrument Panel Components LHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 27 DESCRIPTION AND OPERATION Continued...

Page 973: ...Fig 20 Instrument Panel Components RHD 8W 90 28 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 974: ...Fig 21 Center Console LHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 29 DESCRIPTION AND OPERATION Continued...

Page 975: ...Fig 22 Center Console RHD 8W 90 30 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 976: ...Fig 23 Instrument Panel to Body Connectors LHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 31 DESCRIPTION AND OPERATION Continued...

Page 977: ...Fig 24 Steering Column 8W 90 32 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 978: ...Fig 25 Left Side Body XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 33 DESCRIPTION AND OPERATION Continued...

Page 979: ...Fig 26 ABS G Sensor 8W 90 34 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 980: ...Fig 27 Rear Lamps XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 35 DESCRIPTION AND OPERATION Continued...

Page 981: ...Fig 28 Front and Rear Doors Left Side Shown Right Side Similar 8W 90 36 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 982: ...Fig 29 Overhead and Junction Block XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 37 DESCRIPTION AND OPERATION Continued...

Page 983: ...Fig 30 Liftgate 8W 90 38 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 984: ...Fig 31 Transmission Wiring Connectors XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 39 DESCRIPTION AND OPERATION Continued...

Page 985: ...Fig 32 Left Engine Compartment Diesel Engine LHD 8W 90 40 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 986: ...Fig 33 Left Engine Compartment Diesel Engine RHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 41 DESCRIPTION AND OPERATION Continued...

Page 987: ...Fig 34 Right Engine Compartment Diesel Engine LHD 8W 90 42 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 988: ...Fig 35 Right Engine Compartment Diesel Engine RHD XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 43 DESCRIPTION AND OPERATION Continued...

Page 989: ...Fig 36 Engine Connectors Diesel Engine 8W 90 44 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 990: ...Fig 37 Engine and Battery Diesel Engine XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 45 DESCRIPTION AND OPERATION Continued...

Page 991: ...Fig 38 Starter and Battery Diesel Engine 8W 90 46 8W 90 CONNECTOR LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 992: ...Fig 39 Transmission Connectors Diesel Engine XJ 8W 90 CONNECTOR LOCA TIONS 8W 90 47 DESCRIPTION AND OPERATION Continued...

Page 993: ......

Page 994: ...Injector Harness 10 S113 Near Fuel Injector Harness 10 11 12 S114 Near Fuel Injector Harness 10 11 12 S115 Near MAP Sensor 11 12 19 20 S116 Built Up Export Near Back Up Switch 11 12 S118 Near Generat...

Page 995: ...Shift Interlock 13 Splice Number Location Fig S212 RHD In Lower Instrument Panel Trough 14 S213 Near Brake Shift Interlock 13 14 S214 Between Glove Box Lamp and Trough 13 14 S215 Near Center Console 1...

Page 996: ...ft Door Tweeter N S S329 LHD Near Left Door Tweeter N S S330 LHD Near Left Front Door Speaker N S S331 LHD Near Left Front Door Speaker N S Splice Number Location Fig S334 Liftgate N S S335 Trailer To...

Page 997: ...Fig 1 Left Engine Compartment Splices 4 0L Engine LHD 8W 95 4 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 998: ...Fig 2 Left Engine Compartment Splices 4 0L Engine RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 5 DESCRIPTION AND OPERATION Continued...

Page 999: ...Fig 3 Right Engine Compartment Splices 4 0L Engine LHD 8W 95 6 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1000: ...Fig 4 Right Engine Compartment Splices 4 0L Engine RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 7 DESCRIPTION AND OPERATION Continued...

Page 1001: ...Fig 5 Left Engine Compartment Splices 2 5L Engine LHD 8W 95 8 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1002: ...Fig 6 Left Engine Compartment Splices 2 5L Engine RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 9 DESCRIPTION AND OPERATION Continued...

Page 1003: ...Fig 7 Right Engine Compartment Splices 2 5L Engine LHD 8W 95 10 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1004: ...Fig 8 Right Engine Compartment Splices 2 5L Engine RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 11 DESCRIPTION AND OPERATION Continued...

Page 1005: ...Fig 9 Front End Lighting Splices 8W 95 12 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1006: ...Fig 10 Engine Wiring Splices 4 0L Engine XJ 8W 95 SPLICE LOCA TIONS 8W 95 13 DESCRIPTION AND OPERATION Continued...

Page 1007: ...Fig 11 Engine Wiring Splices 2 5L Engine LHD 8W 95 14 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1008: ...Fig 12 Engine Wiring Splices 2 5L Engine RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 15 DESCRIPTION AND OPERATION Continued...

Page 1009: ...Fig 13 Instrument Panel Wiring Splices LHD 8W 95 16 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1010: ...Fig 14 Instrument Panel Wiring Splices RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 17 DESCRIPTION AND OPERATION Continued...

Page 1011: ...Fig 15 Instrument Panel to Body Harness Splices 8W 95 18 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1012: ...Fig 16 Left Side Body Harness Splices XJ 8W 95 SPLICE LOCA TIONS 8W 95 19 DESCRIPTION AND OPERATION Continued...

Page 1013: ...Fig 17 Left Engine Compartment Splices Diesel LHD 8W 95 20 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1014: ...Fig 18 Left Engine Compartment Splices Diesel RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 21 DESCRIPTION AND OPERATION Continued...

Page 1015: ...Fig 19 Right Engine Compartment Splices Diesel LHD 8W 95 22 8W 95 SPLICE LOCA TIONS XJ DESCRIPTION AND OPERATION Continued...

Page 1016: ...Fig 20 Right Engine Compartment Splices Diesel RHD XJ 8W 95 SPLICE LOCA TIONS 8W 95 23 DESCRIPTION AND OPERATION Continued...

Page 1017: ......

Page 1018: ...l 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 Mop...

Page 1019: ...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 t...

Page 1020: ...Plastigage approximately 6 35 mm 1 4 inch off cen ter and away from the oil holes In addition suspect areas can be checked by placing the Plastigage in that area Tighten the bearing cap bolts of the b...

Page 1021: ...ropriate procedures for cleaning inspec tion and torque tightening HYDROSTA TIC LOCK When an engine is suspected of hydrostatic lock regardless of what caused the problem follow the steps below 1 Perf...

Page 1022: ...th 2 5L engines and 4 0L engines Inspect engine oil level approximately every 800 kilometers 500 miles Unless the engine has exhibited loss of oil pressure run the engine for about five minutes before...

Page 1023: ...L FILTER REMOVAL 1 Position a drain pan under the oil filter 2 Using a suitable oil filter wrench loosen filter 3 Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter...

Page 1024: ...OIL DISPOSAL 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 XJ ENGINE 9 7 GENERAL INFORMATIO...

Page 1025: ...LINE WITH THE FAN DO NOT PUT YOUR HANDS NEAR THE PULLEYS BELTS OR THE FAN DO NOT WEAR LOOSE CLOTHING 1 Start the engine 2 Spray a small stream of water at the suspected leak area 3 If a change in RPM...

Page 1026: ...e the air cleaner 6 Calibrate the tester according to the manufac turer s instructions The shop air source for testing should maintain 483 kPa 70 psi minimum 1 379 kPa 200 psi maximum and 552 kPa 80 p...

Page 1027: ...PCV valve and breather cap hose 7 Clean the oil off the suspect oil leak area using a suitable solvent Drive the vehicle at various speeds approximately 24 km 15 miles Inspect the engine for signs of...

Page 1028: ...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...

Page 1029: ...6 Faulty coil 6 Test and replace if necessary Refer to group 8D Ignition System 7 Intake manifold vacuum leak 7 Inspect intake manifold gasket and vacuum hoses Replace if necessary Refer to Group 11 E...

Page 1030: ...and seats CONNECTING ROD NOISE 1 Insufficient oil supply 1 Check engine oil level Refer to group 0 Lubrication and Maintenance 2 Low oil pressure 2 Check engine oil level If ok Perform oil pressure t...

Page 1031: ...8 Oil pump suction tube loose broken bent or clogged 8 Inspect suction tube and clean or replace if necessary 9 Oil pump cover warped or cracked 9 Install new oil pump OIL LEAKS 1 Misaligned or deter...

Page 1032: ...38 VALVE SPRINGS AND OIL SEALS 32 VIBRATION DAMPER 36 DISASSEMBLY AND ASSEMBLY CYLINDER BLOCK 50 VALVE SERVICE 48 CLEANING AND INSPECTION CYLINDER BLOCK 51 ENGINE CYLINDER HEAD 50 ROCKER ARMS AND PUSH...

Page 1033: ...oil gallery that channels the oil up to the main gal lery which extends the entire length of the block Galleries extend downward from the main oil gal lery to the upper shell of each main bearing The...

Page 1034: ...Oil Lubrication System 2 5L Engine XJ 2 5L ENGINE 9 17 DESCRIPTION AND OPERATION Continued...

Page 1035: ...es to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to that at point B Fig 4 3 The coated pistons will be serviced with the piston pin and connecting rod pr...

Page 1036: ...to 0 21 mm 0 0024 to 0 0083 in 4 Place ring in the cylinder bore and push down with inverted piston to position near lower end of the ring travel Measure ring gap with a feeler gauge fit ting snugly...

Page 1037: ...ompres sion ring either side up Ring Gap Orientation Position the gaps on the piston as shown Fig 12 Oil spacer Gap on center line of piston skirt Oil rails gap 180 apart on centerline of piston pin b...

Page 1038: ...on the piston crown should point to the front of the engine Fig 16 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 Inst...

Page 1039: ...bottom The sizes of the service replacement bearing inserts are stamped on the backs of the inserts Measure the clearance as described in the previous steps 10 The clearance is measured with a pair o...

Page 1040: ...ar wear patterns Inspect the upper insert locking tabs for damage Replace all damaged or worn bearing inserts FITTING BEARINGS CRANKSHAFT INSTALLED The main bearing caps numbered front to rear from 1...

Page 1041: ...ation will pro vide the specified clearance FOR EXAMPLE If the clearance was 0 0762 mm 0 003 inch originally a pair of 0 0254 mm 0 001 inch undersize inserts would reduce the clearance by 0 0254 mm 0...

Page 1042: ...m 0 010 in Red Undersize 0 254 mm 0 010 in 2 4901 2 4896 in 0 254 mm 0 010 in Undersize CRANKSHAFT JOURNAL 5 ONLY CORRESPONDING CRANKSHAFT BEARING INSERT Color Code Diameter Upper Insert Size Lower In...

Page 1043: ...en the stud nuts to 46 N m 34 ft lbs torque b LEFT SIDE Fig 22 Tighten the bolts to 61 N m 45 ft lbs torque 2 If the support cushion brackets were removed position the brackets onto the lower front si...

Page 1044: ...the bolts Tighten the bolts to 43 N m 32 ft lbs torque b Position the support cushion onto the transmis sion support bracket Install and tighten the nuts to 46 N m 34 ft lbs torque AUTOMA TIC TRANSMIS...

Page 1045: ...p 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 t...

Page 1046: ...to Group 07 Cooling Systems for proper procedures 4 Remove the power steering pump and brackets from the water pump and intake manifold Secure power steering pump and bracket out of the way 5 Perform...

Page 1047: ...pump bolts 11 Tighten the power steering pump bolts to 28 N m 21 ft lbs Tighten the tensioner bracket to water pump bolts to 28 N m 21 ft lbs 12 Connect the accelerator cable cruise control cable if e...

Page 1048: ...er seal ing surface of the engine cylinder head and clean the surface using a fabric cleaner 7 Remove all residue from the sealing surface using a clean dry cloth INSTALLA TION 1 Inspect the engine cy...

Page 1049: ...lies and rocker arms for access to each valve spring to be removed 3 Remove push rods Retain the push rods bridges pivots and rocker arms in the same order and position as removed 4 Inspect the spring...

Page 1050: ...engine or cooling system drain the coolant into a clean container for reuse 3 Remove the air cleaner assembly 4 Remove the engine cylinder head cover Refer to procedure in this section 5 Remove the ca...

Page 1051: ...s 5 Place the engine cylinder head over the dowels CAUTION Engine cylinder head bolts should be reused only once Replace the head bolts if they were used before or if they have a paint dab on the top...

Page 1052: ...NOT PUT HANDS NEAR THE PULLEYS BELTS OR FAN DO NOT WEAR LOOSE CLOTHING 27 Operate the engine with the radiator cap off Inspect for leaks and continue operating the engine until the thermostat opens Ad...

Page 1053: ...crankshaft and insert the key With the key in position align the keyway on the vibration damper hub with the crankshaft key and tap the damper onto the crankshaft 2 Install the vibration damper retai...

Page 1054: ...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 41 INSTALLA TION 1 Clean the tim...

Page 1055: ...ne with camshaft sprocket timing mark Fig 43 7 Remove the oil slinger from the crankshaft 8 Remove the camshaft retaining bolt and remove the sprockets and chain as an assembly Fig 44 9 To replace the...

Page 1056: ...ition wires 8 Remove the engine cylinder head cover 9 Remove the rocker arms bridges and pivots 10 Remove the push rods 11 Remove the hydraulic valve tappets from the engine cylinder head 12 Remove th...

Page 1057: ...rom battery 2 Drain the radiator DO NOT waste reusable coolant Drain the coolant into a clean container 3 Remove the fan and shroud 4 Disconnect the radiator overflow tube radiator hoses automatic tra...

Page 1058: ...t is seated 4 Install the camshaft sprocket crankshaft sprocket and timing chain with the timing marks aligned Fig 50 5 To verify correct installation of the timing chain turn the crankshaft to positi...

Page 1059: ...t to replace camshaft bearings unless special removal and installation tools are available Camshaft end play is maintained by the load placed on the camshaft by the oil pump and distrib utor drive gea...

Page 1060: ...at it is parallel to the center line of the crankshaft c Pry the crankshaft forward position the dial indicator to zero d Pry the crankshaft forward and backward Note the dial indicator readings End p...

Page 1061: ...rter motor 7 Remove the flywheel torque converter housing access cover 8 Position a jack stand directly under the engine vibration damper 9 Place a piece of wood 2 x 2 between the jack stand and the e...

Page 1062: ...bolts to 9 5 N m 84 in lbs torque Install the 5 16 inch oil pan bolts Fig 61 Tighten these bolts to 15 N m 132 in lbs torque 8 Remove the dowels Install the remaining 1 4 inch oil pan bolts Tighten t...

Page 1063: ...in the pump body a replacement tube and strainer assembly must be installed to assure an airtight seal INSTALLA TION 1 Install the oil pump on the cylinder block using a replacement gasket Tighten the...

Page 1064: ...eek or counterweight toward 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 9 When required upper and lower...

Page 1065: ...ce valves displaying any damage VALVE REFACING 1 Use a valve refacing machine to reface the intake and exhaust valves to the specified angle 2 After refacing a margin of at least 0 787 mm 0 031 inch m...

Page 1066: ...head 6 Compare the crosswise to lengthwise measure ments to determine out of roundness If the measure ments differ by more than 0 0635 mm 0 0025 in ream the guide bore to accommodate an oversize valv...

Page 1067: ...he oil pan gasket and oil pan 12 Install the vibration damper 13 Install the water pump Tighten the mounting bolts to 31 N m 270 in lbs torque 14 Remove the distributor from the cylinder block 15 Lubr...

Page 1068: ...92 to the threads of the front and rear oil galley plugs Tighten the plugs to 41 N m 30 ft lbs torque INSPECTION CYLINDER BORE 1 It is mandatory to use a dial bore gauge to measure each cylinder bore...

Page 1069: ...Iron Camshaft Hydraulic Tappet Clearance Zero Lash Bearing Clearance 0 025 to 0 076 mm 0 001 to 0 003 in Bearing Journal Diameter No 1 51 54 to 51 56 mm 2 029 to 2 030 in No 2 51 28 to 51 31 mm 2 019...

Page 1070: ...Arms Push Rods Tappets Rocker Arm Ratio 1 6 1 Push Rod Length 241 300 to 241 808 mm 9 500 to 9 520in Push Rod Diameter 7 92 to 8 00 mm 0 312 to 0 315 in Hydraulic Tappet Diameter 22 962 to 22 974 mm 0...

Page 1071: ...IFICA TIONS DESCRIPTION TORQUE A C Compressor Bracket to Engine Bolts 34 N m 25 ft lbs A C Compressor Mounting Bolts 27 N m 20 ft lbs Block Heater Nut 1 8 N m 16 in lbs DESCRIPTION TORQUE Camshaft Spr...

Page 1072: ...ws 28 N m 21 ft lbs Spark Plugs Plugs 37 N m 27 ft lbs Starter Motor Mounting Bolts 45 N m 33 ft lbs Tensioner Bracket ot Cylinder Block Bolts 19 N m 168 in lbs Thermostat Housing Bolts 18 N m 156 in...

Page 1073: ...ECIFICATIONS 4 0L ENGINE SPECIFICATIONS 93 4 0L TORQUE SPECIFICATIONS 95 SPECIAL TOOLS 4 0L ENGINE 96 DESCRIPTION AND OPERATION ENGINE DESCRIPTION The 4 0 Liter 242 CID six cylinder engine is an In li...

Page 1074: ...nternally to pass oil from the main bearing journals except number 4 main bear ing journal to the connecting rod journals Each con necting rod bearing cap has a small squirt hole oil passes through th...

Page 1075: ...Oil Lubrication System 4 0L Engine 9 58 4 0L ENGINE XJ DESCRIPTION AND OPERATION Continued...

Page 1076: ...e 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 a...

Page 1077: ...17 to 0 0033 in Second Compression Ring 0 042 to 0 084 mm 0 0017 to 0 0033 in Oil Control Ring 0 06 to 0 21 mm 0 0024 to 0 0083 in 4 Place ring in the cylinder bore and push down with inverted piston...

Page 1078: ...second com pression ring with the dot facing up Fig 9 Fig 11 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 Fi...

Page 1079: ...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 ac...

Page 1080: ...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 R...

Page 1081: ...om 1 through 7 have an arrow to indicate the for ward position The upper main bearing inserts are grooved to provide oil channels while the lower inserts are smooth Each bearing insert pair is selecti...

Page 1082: ...ered journal or foreign material trapped behind the insert If the specified clearance is indicated and there are no abnormal wear patterns replacement of the bear ing inserts is not necessary Remove t...

Page 1083: ...accept the appropriate undersize bearing inserts if J ournal diameters 1 through 6 are less than 63 4517 mm 2 4981 inches J ournal 7 diameter is less than 63 4365 mm 2 4975 inches Once the proper cle...

Page 1084: ...254 mm 0 010 in Red Undersize 0 254 mm 0 010 in 2 4901 2 4896 in 0 254 mm 0 010 in Undersize Crankshaft Journal 7 Only Corresponding Bearing Insert Color Code Diameter Upper Insert Size Lower Insert...

Page 1085: ...upport cushion bracket bolts and nuts Tighten the bolts to 54 N m 40 ft lbs torque Tighten the nuts to 41 N m 30 ft lbs torque 3 Place the support cushion into position on the support cushion bracket...

Page 1086: ...ssion support bracket and support cushion to the adaptor bracket 2WD or the transmission 4WD Install the bolts and tighten to 75 N m 55 ft lbs torque 1 Position the crossmember onto the support cushio...

Page 1087: ...M IS UNDER A CON STANT PRESSURE EVEN WITH THE ENGINE TURNED OFF BEFORE DISCONNECTING FUEL LINES THE FUEL SYSTEM PRESSURE MUST BE RELEASED 20 Perform the Fuel System Pressure Release procedure refer to...

Page 1088: ...re connec tions and tighten the screws 14 Connect the exhaust pipe to the manifold 15 Install the starter motor and connect the cable 16 Connect the wires to the starter motor sole noid 17 Lower the v...

Page 1089: ...roup 07 Cooling Systems for proper procedures 13 Remove the power steering pump and bracket from the intake manifold and water pump and set aside 14 Raise the vehicle 15 Disconnect the exhaust pipe fr...

Page 1090: ...ld 4 0L Engine in this sec tion for the proper removal and installation proce dures CYLINDER HEAD COVER The cylinder head cover is isolated from the cylin der head via grommets and a reusable molded r...

Page 1091: ...each bridge tighten the capscrews alter nately one turn at a time to avoid damaging the bridge Tighten the capscrews to 28 N m 21 ft lbs torque 5 Install the engine cylinder head cover VALVE SPRINGS...

Page 1092: ...the engine thermostat housing DO NOT waste reus able coolant If the solution is clean and is being drained only to service the engine or cooling system drain the coolant into a clean container for re...

Page 1093: ...lant or equivalent 5 Tighten the engine cylinder head bolts in sequence according to the following procedure Fig 36 CAUTION During the final tightening sequence bolt No 11 will be tightened to a lower...

Page 1094: ...dd coolant if required VALVES AND VALVE SPRINGS This procedure is done with the engine cylinder head removed from the block REMOVAL 1 Remove the engine cylinder head from the cyl inder block 2 Use Val...

Page 1095: ...damper from the crankshaft Fig 38 INSTALLA TION 1 Apply Mopar Silicone Rubber Adhesive Sealant to the keyway in the crankshaft and insert the key With the key in position align the keyway on the vibra...

Page 1096: ...te and tighten the bolt to 108 N m 80 ft lbs torque 10 Install the A C compressor if equipped and generator bracket assembly 11 Install the engine fan and hub assembly and shroud 12 Install the serpen...

Page 1097: ...on of the rotor 5 Remove the distributor and ignition wires 6 Remove the engine cylinder head cover 7 Remove the rocker arms bridges and pivots 8 Remove the push rods 9 Remove the engine cylinder head...

Page 1098: ...in 0 254 mm 0 010 inch increments from the front bearing larg est to the rear bearing smallest This permits eas ier removal and installation of the camshaft The camshaft bearings are pressure lubricat...

Page 1099: ...er pin tool in place rotate the crankshaft so that the upper bear ing insert will rotate in the direction of its locking tab Because there is no hole in the No 3 main jour nal use a tongue depressor o...

Page 1100: ...ghten the plug to 34 N m 25 ft lbs torque 12 Lower the vehicle 13 Install the spark plugs Tighten the plugs to 37 N m 27 ft lbs torque 14 Fill the oil pan with engine oil to the full mark on the dipst...

Page 1101: ...anifold 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 52 Tighten the plug to 34 N m 25...

Page 1102: ...ubricate the piston and rings with clean engine oil CAUTION Ensure that connecting rod bolts DO NOT scratch the crankshaft journals or cylinder walls Short pieces of rubber hose slipped over the conne...

Page 1103: ...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...

Page 1104: ...ressure relief valve to limit maximum pressure to 517 kPa 75 psi In the relief position the valve permits oil to bypass through a passage in the pump body to the inlet side of the pump Oil pump remova...

Page 1105: ...way in the crankshaft and insert the key With the key inserted in the keyway in the crank shaft install the vibration damper washer and bolt Lubricate and tighten the bolt to 108 N m 80 ft lbs torque...

Page 1106: ...ust be reamed oversize Ser vice valves with oversize stems are available in 0 076 mm 0 003 inch and 0 381 mm 0 015 inch incre ments Corresponding oversize valve stem seals are also available and must...

Page 1107: ...discard the oil filter 2 Remove the water pump from the cylinder block 3 Remove the vibration damper 4 Remove the timing case cover and lay the cover upside down 5 Position a drift punch into the slot...

Page 1108: ...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 excessiv...

Page 1109: ...ge 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...

Page 1110: ...to 1 098 in Main Bearing J ournal Width No 3 32 28 to 32 33 mm 1 271 to 1 273 in Main Bearing J ournal Width No 2 4 5 6 7 30 02 to 30 18 mm 1 182 to 1 188 in Main Bearing Clearance 0 03 to 0 06 mm 0 0...

Page 1111: ...n Valve Springs Free Length Approx 47 65 mm 1 876 in Spring Tension Valve Closed 316 to 351 N 41 656 mm 71 to 79 lbf 1 64 in Spring Tension Valve Open 898 6 to 969 7 N 30 89 mm 202 to 218 lbf 1 216 in...

Page 1112: ...c 41 N m 30 ft lbs Insulator Stud Assembly Nut 41 N m 30 ft lbs DESCRIPTION TORQUE Support Cushion Crossmember Nuts 22 N m 192 in lbs Support Cushion Bracket Nuts Manual 75 N m 55 ft lbs Transmission...

Page 1113: ...s 23 N m 17 ft lbs SPECIAL TOOLS 4 0L ENGINE Valve Spring Compressor Tool MD 998772A Timing Case Cover Alignment and Seal installation Tool 6139 Vibration Damper Removal Tool 7697 Rear Main Seal Insta...

Page 1114: ...TER ADAPTER 34 OIL PAN 32 OIL PUMP 32 OIL PUMP PRESSURE RELIEF VALVE 34 PISTONS AND CONNECTING ROD ASSEMBLY 35 ROCKER ARMS AND PUSH RODS 24 TIMING GEAR COVER 29 TIMING GEAR COVER OIL SEAL 29 VALVE SPR...

Page 1115: ...all of the air inside the tappets to be bled out DIAGNOSIS AND TESTING SERVICE DIAGNOSIS DIESEL PERFORMANCE SERVICE DIAGNOSIS DIESEL MECHANICAL TAPPET NOISE 1 To determine source of tappet noise oper...

Page 1116: ...XJ ENGINE 9 3 DIAGNOSIS AND TESTING Continued...

Page 1117: ...9 4 ENGINE XJ DIAGNOSIS AND TESTING Continued...

Page 1118: ...XJ ENGINE 9 5 DIAGNOSIS AND TESTING Continued...

Page 1119: ...9 6 ENGINE XJ DIAGNOSIS AND TESTING Continued...

Page 1120: ...XJ ENGINE 9 7 DIAGNOSIS AND TESTING Continued...

Page 1121: ...9 8 ENGINE XJ DIAGNOSIS AND TESTING Continued...

Page 1122: ...XJ ENGINE 9 9 DIAGNOSIS AND TESTING Continued...

Page 1123: ...9 10 ENGINE XJ DIAGNOSIS AND TESTING Continued...

Page 1124: ...XJ ENGINE 9 11 DIAGNOSIS AND TESTING Continued...

Page 1125: ...177 inch the valve must be replaced VALVE SEA T REFACING 1 Install a pilot of the correct size in the valve guide bore Reface the valve seat to the specified angle with a good dressing stone Remove o...

Page 1126: ...sition 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 from the engine 6 Remove the engine mount throug...

Page 1127: ...N m 37 ft lbs 8 Lower the vehicle from the hoist 9 Install the engine mount upper sill plate nuts Torque to 41 N m 30 ft lbs 10 Install the innercooler inlet hose on the turbo charger Fig 7 11 Connec...

Page 1128: ...H Block and remove the H Block from the compres sor 13 Position a jack stand and raise the weight off the left engine mount 14 Remove the 4 engine mount bracket bolts from the engine block 15 Remove...

Page 1129: ...position Raise the vehicle on a hoist 3 Remove the steering shaft pinchbolt and slide the steering shaft straight off the gearbox input shaft CAUTION Do not rotate the steering shaft while removed fr...

Page 1130: ...lock retaining bolts Do not remove the bolts at this time NOTE Mark the position of the H Block in relation to the power steering pump and A C Compressor so it may be installed in its original positio...

Page 1131: ...ill out the rivets retaining the hood latch cable control assembly 4 Remove the hood latch assemblies from the hood 5 Disconnect and remove the engine compart ment lamp 6 With assistance from another...

Page 1132: ...ve the engine ground wire Fig 18 29 Remove the right and left engine mount throughbolt nuts only Do not remove the bolts at this time Fig 18 30 Drain the transmission fluid Refer to Group 21 Transmiss...

Page 1133: ...is 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 wate...

Page 1134: ...um supply hoses on the engine 29 Install the coolant reservoir supply hose on the engine Fig 26 30 Install the innercooler inlet and outlet hoses on the engine Fig 26 31 Install the upper and lower ra...

Page 1135: ...COOLANT CAN OCCUR 2 On right hand drive vehicles drain the cooling system Refer to Group 7 Cooling System for the pro cedure 3 Recover the air conditioning system if equipped Refer to Group 24 Heating...

Page 1136: ...ts to ensure installation in original location CAUTION The plunger and tappet bodies are not interchangeable The plunger and valve must always be fitted to the original body It is advisable to work on...

Page 1137: ...be removed only by compressing the valve spring 2 Remove the cylinder head cover Refer to cylin der head cover removal and installation in this sec tion 3 Remove the rocker arms assemblies and push ro...

Page 1138: ...e the water manifold and recovery hose 10 Disconnect the heater hoses and coolant recover bottle hose 11 Disconnect the EGR tube from EGR valve 12 Remove the EGR valve 13 Remove the exhaust heat shiel...

Page 1139: ...ad gasket is used for all four cyl inder heads Cylinder head gaskets are available in three thick nesses Identification holes in the right front corner of the gasket indicate the thickness of the gask...

Page 1140: ...bolts and spacers clamps finger tight only b Ensure that the various clamps are installed correctly and the head gasket remains in it s proper position completely covered Then lubricate and install t...

Page 1141: ...21 Install the turbocharger oil drain line Torque bolts to 11 N m 97 in lbs 22 Install the water manifold Torque bolts to 12 N m 106 in lbs 23 Install the generator support bracket 24 Raise the vehicl...

Page 1142: ...et 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 vibration damper nut 5 Install speci...

Page 1143: ...head cover removal and installation in this sec tion 3 Remove the cylinder heads Refer to cylinder head removal and installation in this section 4 Remove the rocker arm assemblies push rods and hydrau...

Page 1144: ...ies Refer to the respective sections 5 Install the cylinder head cover Refer to cylin der head cover removal and installation in this sec tion 6 Install the timing gear cover Refer to timing gear cove...

Page 1145: ...es into full register with oil passages from the main bearing If the camshaft bearing shell oil holes are not in exact alignment remove and install them correctly Install a new rear plate o ring at th...

Page 1146: ...um pump INSTALLA TION 1 To install the vacuum pump align the outer part of the gear with the inner part using a screw driver or similar tool align with timing marks on gear set and install Fig 48 Torq...

Page 1147: ...k 3 Compress spring and install the snap ring Ensure the snap ring is completely seated in groove 4 Install the oil pan Refer to oil pan removal and installation procedure in this section 5 Connect th...

Page 1148: ...ove 2 clips securing piston pin 3 Push piston pin out of piston and connecting rod PISTON RING REMOVAL 1 ID mark on face of upper and intermediate pis ton rings must point toward piston crown 2 Using...

Page 1149: ...ontrol ring gap to be located 30 degrees to the left of combustion chamber recess 6 When assembling pistons check that compo nents are installed in the same position as before dis assembly determined...

Page 1150: ...nge dur ing this operation 4 Face chamber recess side of piston towards camshaft 5 Install connecting rod bolt protectors on rod bolts 6 Rotate crankshaft so that the connecting rod journal is on the...

Page 1151: ...ft side Zero dial gauge on block deck 3 Move dial gauge to cylinder liner record read ing on dial gauge 4 Remove liner and special tool 5 Then select the correct shim thickness to give proper protrusi...

Page 1152: ...15 Remove the oil pump and vacuum pump from block 16 Install special tool VM 1004 onto crankshaft over gear Fig 67 17 Remove the main bearing oil feed and crank shaft support locators from block 18 Re...

Page 1153: ...nner used for removal 8 Align the holes in the lower supports with the center of the crankcase webs Fig 70 9 Secure each support assembly to the crankcase with the main bearing oil feed and support lo...

Page 1154: ...l groove 25 To verify correct end play install 2 flywheel bolts 180 apart and tighten bolts to 20 N m plus 60 15 ft lbs plus 60 26 Measure crankshaft end play with a dial gauge Crankshaft end play sho...

Page 1155: ...IC TAPPETS DISASSEMBLE 1 Pry out plunger retainer spring clip 2 Clean varnish deposits from inside of tappet body above plunger cap 3 Invert tappet body and remove plunger cap plunger check valve chec...

Page 1156: ...Group B 91 94 91 95mm 3 6196 3 6200 in Maximum wear limit 05mm 0019 in 2 Check piston pin bores in piston for roundness Make 3 checks at 120 intervals Maximum out of roundness 05mm 0019 in 3 The pist...

Page 1157: ...diameter is 53 84 to 53 955mm 2 1196 to 2 1242 in 2 Crankshaft journals worn beyond limits or show signs of out of roundness must be reground or replaced Minimum reground diameter is 53 69mm 2 1137 i...

Page 1158: ...pump check pump bore depth in block A and pump body height B Fig 79 Difference between A and B should be 0 020 0 082 mm 2 Check clearance between rotors Fig 81 Fig 78 Liner Inspection Fig 79 Oil Pump...

Page 1159: ...SPECIFICATIONS ENGINE SPECIFICA TIONS 9 46 ENGINE XJ...

Page 1160: ...XJ ENGINE 9 47 SPECIFICATIONS Continued...

Page 1161: ...aust heat shield Screws 11 N m Exhaust manifold collar Mounting nut 24 5 to 29 5 N m Exhaust manifold Mounting nut 32 5 N m Fan drive To fan hub 56 N m Flyw heel Lock bolt 20 N m 60 DESCRIPTION TORQUE...

Page 1162: ...in Plug 10 8 N m Vacuum pump Torque 27 N m Water manifold Bolts 12 N m Water pump pulley Nut 27 N m SPECIAL TOOLS SPECIAL TOOLS Crankshaft Pulley and Gear Remover VM 1000A Cylinder Liner Puller VM 100...

Page 1163: ...05 Cylinder Head Bolt Wrench VM 1006A Cylinder Head Guide Studs VM 1009 Cylinder Liner Protrusion Tool VM 1010 Bosch Pump Timing Adapter VM 1011 Injector Remover Replacer Socket VM 1012 9 50 ENGINE XJ...

Page 1164: ...1013 Flywheel Locking Tool VM 1014 Timing Cover Oil Seal Replacer VM 1015 Cylinder Retainer VM 1016 Crankshaft and Water Pump Pulley Holder VM 1017 Cylinder Head Bolt Wrench M12 VM 1018 XJ ENGINE 9 51...

Page 1165: ...Cylinder Head Bolt Wrench M14 VM 1019 Cylinder Leakage Tester Adapter VM 1021 9 52 ENGINE XJ SPECIAL TOOLS Continued...

Page 1166: ...s stripped screw or bolt threads corrosion damage and worn cracked or broken hangers Replace all components that are badly corroded or damaged DO NOT attempt to repair When replacement is required use...

Page 1167: ...system to hang by the oxygen sensor harness will damage the wiring and or sen sor REMOVAL 1 Raise and support the vehicle 2 Saturate the bolts and nuts with heat valve lubricant Fig 2 Allow 5 minutes...

Page 1168: ...en sensor from the catalytic converter 4 Heat the catalytic converter and muffler con nection with an oxyacetylene torch until the metal becomes cherry red 5 While the metal is still cherry red twist...

Page 1169: ...oxygen sensor connector Allowing the exhaust system to hang by the oxygen sensor harness will damage the wiring and or sensor REMOVAL 1 Raise and support the vehicle 2 Disconnect front tailpipe hanger...

Page 1170: ...muffler to tailpipe clamp to 61 N m 45 ft lbs 8 Lower the vehicle 9 Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels Adjust the alignment if needed SPECIF...

Page 1171: ......

Page 1172: ...racked or loose joints stripped screw or bolt threads corrosion damage and worn cracked or broken hangers Replace all components that are badly corroded or damaged DO NOT attempt to repair When replac...

Page 1173: ...vice 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 FLAME NEAR THE FUEL LINE...

Page 1174: ...procedure 10 Remove the exhaust system support clamp Fig 5 11 Disconnect the exhaust system at the 3 bolt flange Fig 5 CAUTION Heatshield is very sharp Wear gloves to prevent injury 12 Unstrap the exh...

Page 1175: ...st be cleaned of old gasket material to produce a smooth and dirt free sealing surface for the new gasket INSTALLA TION 1 Transfer the oil return hose to the new turbo charger Fig 9 2 Install the turb...

Page 1176: ...bly Torque bolts to 27 N m 20 ft lbs 17 Install the 2 bolts holding the EGR tube to the EGR valve Torque bolts to 27 N m 20 ft lbs 18 Install the innercooler inlet and outlet hoses on the engine Fig 1...

Page 1177: ...ect the heater core coolant supply and the brake vacuum supply 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...

Page 1178: ...ary to access the bolt behind the manifold outlet from the underneath of the vehicle 29 Remove the steering shaft pinchbolt and slide the shaft straight off of the gearbox input shaft Posi tion aside...

Page 1179: ...ION Heatshield is very sharp Wear gloves to prevent injury 10 Slide the exhaust downpipe heatshield up over the pipe and strap it in its original position Fig 22 11 Install the steering shaft Torque t...

Page 1180: ...tlet hoses on the engine 25 Install the EGR vacuum supply hose on the EGR valve 26 Install the air filter cover and outlet hose on the turbocharger 27 Connect the breather hose on the air cleaner outl...

Page 1181: ...tall exhaust manifold 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 SPECI...

Page 1182: ...stall the screws attaching the end cap to the front fender 3 Install the bolts attaching the end cap to the bumper Tighten the nut to 9 N m 7 ft lbs torque 4 Install the rivet attaching the end cap to...

Page 1183: ...30 N m 22 ft lbs torque 2 Position tow hook on reinforcement 3 Install bolts attaching tow hook to tow hook reinforcement Tighten bolts to 100 N m 74 ft lbs torque REAR BUMPER END CAP REMOVAL 1 Remove...

Page 1184: ...ove hitch before removing 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 Fi...

Page 1185: ...2 Remove bracket and tow hook from frame rail INSTALLA TION 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...

Page 1186: ...crews to attach skid plate to side sills TRANSFER CASE SKID PLA TE REMOVAL 1 Support skid plate 2 Remove bolts that attach skid plate to trans mission support crossmember and frame sill Fig 2 3 Remove...

Page 1187: ...me 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 fr...

Page 1188: ...Fig 6 Frame Dimensions XJ FRAME AND BUMPERS 13 7 SPECIFICATIONS Continued...

Page 1189: ...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...

Page 1190: ...Y SPARE TIRE CARRIER 1 SWING AWAY SPARE TIRE CARRIER INDEX page DISASSEMBLY AND ASSEMBLY SWING AWAY SPARE TIRE CARRIER MOUNTING 1 DISASSEMBLY AND ASSEMBLY SWING A WA Y SPARE TIRE CARRIER MOUNTING Fig...

Page 1191: ...ly and the rear angled hole is for shipping use only CAUTION Do not use the angled hole for towing You could damage your vehicle WARNING Stand clear of vehicles when pulling with tow eyes Tow straps a...

Page 1192: ...L 2 5L ENGINE 16 FUEL INJECTOR RAIL 4 0L ENGINE 17 FUEL INJECTORS 18 FUEL PUMP INLET FILTER 15 FUEL PUMP MODULE 14 FUEL TANK 18 FUEL TANK FILLER TUBE CAP 20 THROTTLE CABLE 21 SPECIFICATIONS FUEL SYSTE...

Page 1193: ...California refor mulated gasoline SULFUR IN GASOLINE If you live in the northeast United States your vehicle may have been designed to meet California low emission standards with clean burning low su...

Page 1194: ...equipped with a Leak Detection Pump LDP The flap will be installed to all fuel filler tubes equipped not equipped with LDP and EVAP monitor system Also to be considered part of the fuel system is the...

Page 1195: ...rements A voltage signal is sent from the resistor track on the sending unit to the PCM to indicate fuel level The pur pose of this feature is to prevent the OBD II system from recording setting false...

Page 1196: ...an attached numerical tag INJ 1 INJ 2 etc This is used to identify each fuel injector The injectors are energized individually in a sequential order by the powertrain control module PCM The PCM will...

Page 1197: ...IAGNOSIS AND TESTING FUEL PUMP PRESSURE TEST ALL ENGINES WITH PRESSURE TEST PORT Use this test in conjunction with the Fuel Pump Capacity Test Fuel Pressure Leak Down Test and Fuel Pump Amperage Test...

Page 1198: ...ening 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 low replace fuel filter fue...

Page 1199: ...r 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 sl...

Page 1200: ...LAY CAVITIES EXACTLY AS SHOWN IN FOLLOWING STEPS Depending upon vehicle model year or engine con figuration three different types of relays may be used Type 1 type 2 and type 3 14 If equipped with typ...

Page 1201: ...n underside of PDC cover 4 Start and run engine until it stalls 5 Attempt restarting engine until it will no longer run 6 Turn ignition key to OFF position CAUTION Steps 1 2 3 and 4 must be performed...

Page 1202: ...el pressure release procedure Refer to Fuel Pressure Release Procedure in this group 2 Disconnect negative battery cable from battery 3 Clean fitting of any foreign material before dis assembly 4 Sing...

Page 1203: ...used Fig 18 or Fig 19 Type 1 is tethered to fuel line and type 2 is not A special tool will be necessary to disconnect fuel line after latch clip is removed The latch clip may be used on certain fuel...

Page 1204: ...on top of fuel tank The filter regulator may be removed without removing fuel pump module although fuel tank must be removed REMOVAL 1 Remove fuel tank Refer to Fuel Tank Removal Installation 2 Clean...

Page 1205: ...ion of this group 2 Thoroughly wash and clean area around pump module to prevent contaminants from entering tank 3 Disconnect fuel line at filter regulator Refer to Quick Connect Fittings in this grou...

Page 1206: ...lation 2 Remove fuel pump module Refer to Fuel Pump Module Removal Installation 3 Remove filter by prying from bottom of module with 2 screwdrivers Filter is snapped to module 4 Clean bottom of pump m...

Page 1207: ...not identify each connector before removal 6 Disconnect fuel supply line latch clip and fuel line at fuel rail Refer to Quick Connect Fittings in this group for procedures 7 Disconnect throttle cable...

Page 1208: ...tle body Note Some engine vehicles may require removal of air cleaner ducts at throttle body 5 Remove injector harness electrical connectors at each injector Each injector connector should have a nume...

Page 1209: ...s section 5 Start engine and check for fuel leaks FUEL TANK WARNING THE FUEL SYSTEM IS UNDER CON STANT FUEL PRESSURE EVEN WITH THE ENGINE OFF THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK...

Page 1210: ...9 Disconnect fuel supply line from fuel extension line near front of fuel tank Fig 35 Refer to Fuel Tubes Lines Hoses and Clamps in this group Also refer to Quick Connect Fittings for procedures 10 Di...

Page 1211: ...el pump module supply line near front of tank Refer to Quick Connect Fittings for procedures 12 Connect EVAP hose near front of tank 13 Install exhaust tailpipe heat shield 14 Install fuel tank skid p...

Page 1212: ...Fig 39 5 Remove throttle cable ball end socket at throt tle body linkage snaps off Fig 40 6 Remove throttle cable from throttle body mounting bracket by compressing squeeze tabs Fig 39 and pushing ca...

Page 1213: ...n lbs Fuel Hose Clamps 3 N m 25 in lbs Fuel Rail Mounting Bolts 11 N m 100 in lbs Fuel Tank Mounting Strap Nuts 10 N m 90 in lbs Fuel Pump Module Locknut 74 N m 55 ft lbs Models Liters U S Gallons All...

Page 1214: ...PCM OUTPUT 35 MALFUNCTION INDICATOR LAMP ECM PCM OUTPUT 35 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR PCM INPUT 31 MODES OF OPERATION 25 OIL PRESSURE SENSOR PCM INPUT 31 OXYGEN SENSOR HO2S PCM INPUT 30 PO...

Page 1215: ...and the brake switch The PCM adjusts idle speed based on inputs it receives from sensors that react to throttle position vehicle speed transmission gear selection engine coolant temperature and from i...

Page 1216: ...uise modes with the engine at operating tem perature are Closed Loop modes IGNITION SWITCH KEY ON MODE This is an Open Loop mode When the fuel system is activated by the ignition switch the following...

Page 1217: ...n these inputs the following occurs Voltage is applied to the fuel injectors with the ASD relay via the PCM The PCM will then control injection sequence and injector pulse width by turn ing the ground...

Page 1218: ...to the coil on and off WIDE OPEN THROTTLE MODE This is an Open Loop mode During wide open throttle operation the powertrain control module PCM receives the following inputs Battery voltage Crankshaft...

Page 1219: ...that the injector is energized This is done to compensate for the reduced flow through injector caused by the lowered voltage BRAKE SWITCH PCM INPUT OPERA TION When the brake light switch is activated...

Page 1220: ...for more crankshaft position sensor information The engine will not operate if the PCM does not receive a crankshaft position sensor input ENGINE COOLANT TEMPERA TURE SENSOR PCM INPUT The engine cool...

Page 1221: ...s the O2S sen sor input The PCM adjusts injector pulse width based on preprogrammed fixed values and inputs from other sensors The Automatic Shutdown ASD relay supplies bat tery voltage to both the up...

Page 1222: ...ed to the throttle body with a rubber L shaped fitting OIL PRESSURE SENSOR PCM INPUT DESCRIPTION The engine oil pressure sensor sending unit is located in an engine oil pressure gallery OPERA TION A s...

Page 1223: ...sed as a con dition for speed control operation THROTTLE POSITION SENSOR TPS PCM INPUT The TPS is mounted on the throttle body Fig 7 The TPS is a variable resistor that provides the Pow ertrain Contro...

Page 1224: ...e load from the A C compressor By switching the ground path for the relay on and off the PCM is able to cycle the A C compressor clutch This is based on changes in engine operating conditions The PCM...

Page 1225: ...el injec tors are used with the 2 5L 4 cylinder engine Fig 15 The fuel injectors are attached to the fuel rail The nozzle ends of the injectors are positioned into openings in the intake manifold just...

Page 1226: ...oned when the ignition key is turned to the On position A factory adjusted set screw is used to mechani cally limit the position of the throttle body throttle plate Never attempt to adjust the engine...

Page 1227: ...diagnose or ser vice the fuel injection system A visual check will help spot these faults and save unnecessary test and diagnostic time A thorough visual inspection will include the following checks 1...

Page 1228: ...fy vacuum booster hose is firmly connected to fitting on intake manifold Also check connection to brake vac uum booster 13 Inspect air cleaner inlet and air cleaner ele ment for dirt or restrictions 1...

Page 1229: ...essure switch Fig 28 This switch is not used with 4 0L engines 27 Verify good electrical connections at fuel pump module connector at front of fuel tank Fig 29 28 Verify good EVAP canister vent line c...

Page 1230: ...the coil side of the relay through terminal number 85 Terminal number 86 supplies voltage to the coil side of the relay When the PCM de energizes the ASD and fuel pump relays terminal number 87A conn...

Page 1231: ...N 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...

Page 1232: ...O2S heating element can be tested with an ohmmeter as follows Disconnect the O2S sensor connector Connect the ohmmeter test leads across the white wire terminals of the sensor connector Resistance sho...

Page 1233: ...or 3 Test resistance of wire harness Do this between PCM wire harness connector A 15 and sen sor connector terminal Also check between PCM con nector A 4 to sensor connector terminal Repair wire harne...

Page 1234: ...riate Powertrain Diagnostics Procedures manual EXTENDED IDLE SWITCH TEST OPTIONAL POLICE PACKAGE ONL Y The extended idle switch is used to raise engine idle speed to approximately 1000 rpm when the sh...

Page 1235: ...eration of the idle air control motor before performing this test A special fixed orifice tool number 6714 Fig 40 must be used for the following test This tool has a fixed internal diameter of 0 185 1...

Page 1236: ...onnector terminals for damage or corrosion Repair if necessary before installing relay 4 Check for pin height pin height should be the same for all terminals within the PDC connector Repair if necessa...

Page 1237: ...TPS INSTALLA TION The throttle shaft end of the throttle body slides into a socket in the TPS Fig 47 The TPS must be installed so that it can be rotated a few degrees If the sensor will not rotate ins...

Page 1238: ...ile removing MAP sensor slide the rubber L shaped fitting Fig 49 from throttle body 4 Remove rubber L shaped fitting from MAP sen sor INSTALLA TION 1 Install rubber L shaped fitting to MAP sensor 2 Po...

Page 1239: ...tch is not used with 4 0L six cylinder engines The power steering pressure switch is installed in the power steering high pressure hose Fig 52 REMOVAL 1 Disconnect electrical connector from power stee...

Page 1240: ...m 22 ft lbs torque 2 Connect O2S sensor wire connector 3 Lower vehicle AIR CLEANER ELEMENT FILTER REMOVAL 1 Unlock air tube clamp Fig 54 at air cleaner cover To unlock clamp attach adjustable pliers...

Page 1241: ...11 N m 8 ft lbs torque 3 Connect wire connector 4 Fill cooling system Refer to Group 7 Cooling System INTAKE MANIFOLD AIR TEMPERA TURE SENSOR The intake manifold air temperature IAT sensor is installe...

Page 1242: ...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...

Page 1243: ...EM Spanner Wrench Fuel Pump Module Locknut 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 F...

Page 1244: ...to electrically shut off the diesel fuel supply to the high pressure fuel injection pump The solenoid is mounted to the rear of the injection pump The solenoid controls starting and stopping of the en...

Page 1245: ...UCTION This Fuel Delivery section will cover components not controlled by the PCM For components con trolled by the PCM refer to the Fuel Injection Sys tem 2 5L Diesel Engine section of this group The...

Page 1246: ...ion fuel filter water separator pro tects the fuel injection pump by helping to remove water and contaminants from the fuel Moisture col lects at the bottom of the filter separator in a plastic bowl T...

Page 1247: ...greater than a preset value a fault will be set Actual electric fuel timing amount of advance is accomplished by the fuel timing solenoid mounted to the bottom of the injection pump Fig 3 Fuel timing...

Page 1248: ...abrasions or scuffing Be sure that the fuel lines tubes are prop erly routed to prevent pinching and to avoid heat sources The lines tubes hoses are of a special construction If it is necessary to rep...

Page 1249: ...which is connected to the same line as the overflow valve which allows a variable quantity to return to the fuel tank The overflow valve is calibrated to open at a preset pressure Excess fuel not requ...

Page 1250: ...hoses should be made before attempting to diagnose or service the diesel fuel injection system A visual check will help find these conditions It also saves unnecessary test and diag nostic time A thor...

Page 1251: ...Inspect for exhaust system restrictions such as pinched exhaust pipes or a collapsed or plugged muffler 13 Verify that the harness connector is firmly connected to the vehicle speed sensor Fig 15 or F...

Page 1252: ...mp are connected and not leaking The vacuum pump is located in the front of engine internal and is driven from the crankshaft gear Fig 18 Discon nect the hose and check for minimum vacuum from the pum...

Page 1253: ...e properly the engine may misfire or cause other driveability problems A leak in the injection pump to injector high pres sure fuel line can cause many of the same symptoms as a malfunctioning injecto...

Page 1254: ...or tampered w ith FUEL SUPPL Y RESTRICTIONS LOW PRESSURE LINES Restricted or Plugged supply lines or fuel filter can cause a timing fault that will cause the ECM to oper ate the engine in a Limp Home...

Page 1255: ...nts are ser viced or replaced Bleed the system as needed after fuel system service according to the following proce dures WARNING DO NOT BLEED AIR FROM THE FUEL SYSTEM OF A HOT ENGINE DO NOT ALLOW FUE...

Page 1256: ...longer than 30 seconds Wait 2 minutes betw een cranking intervals 3 Start the engine and bleed one injector at a time until the engine runs smoothly FUEL INJECTION PUMP TIMING Refer to Removal Install...

Page 1257: ...k WARNING DO NOT ATTEMPT TO DRAIN WATER FROM THE FILTER SEPARATOR WITH THE ENGINE HOT 1 The bottom of the filter separator bowl is equipped with a drain valve Fig 26 The drain valve is equipped with a...

Page 1258: ...Install the electrical connectors at bottom of bowl 8 Tighten the filter to mounting bracket nuts Fig 26 to 28 N m 250 in lbs torque FUEL HEA TER If the fuel heater element needs replacement the plast...

Page 1259: ...k wise and counter clockwise while observing the rocker arm through the oil fill cap hole If the rocker arm moves you are not at TDC d If TDC was found continue if not rotate the crankshaft one revolu...

Page 1260: ...tools from timing cover at this time Gear mis alignment w ill result 4 Place the key way on the pump shaft to the 11 o clock position as viewed from the front of pump Install the pump into the rear of...

Page 1261: ...al indicator to 0mm Be sure the tip of the dial indicator is touching the tip inside the adapter tool 12 The Top Dead Center TDC compression fir ing stroke can be determined as follows a Rotate the en...

Page 1262: ...up 18 Install electrical connector at engine coolant temperature sensor 19 Connect electrical connector at fuel shutdown solenoid 20 Connect the main engine wiring harness to the glow plugs 21 Connect...

Page 1263: ...eck 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...

Page 1264: ...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 f...

Page 1265: ...ved Prevent the injection pump delivery valve holders from turning when removing or installing high pressure lines from injection pump INSTALLA TION 1 Carefully position each high pressure fuel line t...

Page 1266: ...RELAY 34 ENGINE COOLANT TEMPERATURE SENSOR 34 ENGINE SPEED SENSOR 34 GLOW PLUG RELAY 35 GLOW PLUGS 34 POWERTRAIN CONTROL MODULE PCM 35 VEHICLE SPEED SENSOR 36 SPECIFICATIONS GLOW PLUG CURRENT DRAW 37...

Page 1267: ...ed on these inputs the ECM regulates various engine and vehicle operations through different system components These compo nents are referred to as ECM Outputs The sensors and switches that provide in...

Page 1268: ...s 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 Temperature Sensor is low The component of the Boost Pressur...

Page 1269: ...ction 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...

Page 1270: ...round from the A C relay This will deactivate the A C compressor clutch Also if the engine coolant reaches a temperature outside normal of its normal range or it overheats the ECM will deactivate the...

Page 1271: ...n PDC cover This input is used only to sense that the ASD relay is energized If the ECM does not see 12 volts at this input when the ASD relay should be activated it will set a Diagnostic Trouble Code...

Page 1272: ...switch is placed in the ON position a signal is sent to the ECM relating current engine coolant temperature This signal is sent from the engine coolant temperature sensor After receiving this signal t...

Page 1273: ...Y TEST To perform a test of the relay and its related cir cuitry refer to the DRB scan tool To test the relay only refer to Relays Operation Testing in this sec tion of the group Diagnostic Trouble Co...

Page 1274: ...k lead of the tester to the 12V negative side of the battery 4 Fit the glow plug into the top of the tester and secure it with the spring loaded bar Fig 16 5 Attach the third lead wire of the tester t...

Page 1275: ...ect and isolate the electrical connectors Fig 18 at all four glow 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 shoul...

Page 1276: ...r 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 t...

Page 1277: ...MOVAL 1 Disconnect the harness on the sensor from the main electrical harness 2 Remove the sensor mounting bolts 3 Remove the sensor INSTALLA TION 1 Install the sensor flush against the opening in the...

Page 1278: ...connector at relay and remove relay INSTALLA TION 1 Check condition of electrical connector for dam age or corrosion Repair as necessary 2 Install electrical connector to relay 3 Install relay to inne...

Page 1279: ...ocated on the extension housing of the transmission for 2 wheel drive vehicle or on the transfer case housing for 4 wheel drive vehicles Fig 27 REMOVAL 1 Raise and support vehicle 2 Clean the area aro...

Page 1280: ...ONS GLOW PLUG CURRENT DRA W Initial Current Draw Approximately 22 25 amps per plug After 20 seconds of operation Approximately 9 12 amps per plug TORQUE CHART 2 5L DIESEL XJ FUEL SYSTEM 2 5L DIESEL EN...

Page 1281: ......

Page 1282: ...ball type gear The gear acts as a rolling thread between the worm shaft and the rack piston When the steering wheel is turned the worm shaft turns which moves the rack piston The rack piston movement...

Page 1283: ...r 2 Replace steering gear RATTLE OR CLUNK 1 Gear mounting bolts loose 1 Tighten bolts to specification 2 Loose or damaged suspension components 2 Inspect and repair suspension 3 Loose or damaged steer...

Page 1284: ...N HARD TURNING OR MOMENTARY INCREASE 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...

Page 1285: ...s to specification 4 Gear out of adjustment 4 Adjust gear to specification 5 Worn or loose steering coupler 5 Repair as necessary VEHICLE PULLS OR LEADS TO ONE SIDE 1 Tire Pressure 1 Adjust tire press...

Page 1286: ...ure and return hoses The pump shaft has a pressed on drive pulley that is belt driven by the crankshaft pulley Fig 1 NOTE Power steering pumps have different pres sure rates and are not interchangeabl...

Page 1287: ...and w ithin 345 kPa 50 psi of each other Pressures above specifications but not within 345 kPa 50 psi of each other replace pump Pressures within 345 kPa 50 psi of each other but below specifications...

Page 1288: ...refill as required 9 If the fluid is extremely foamy or milky look ing allow the vehicle to stand a few minutes and repeat the procedure CAUTION Do not run a vehicle with foamy fluid for an extended p...

Page 1289: ...es 4 Fill reservoir to proper level Refer to Power Steering Pump Initial Operation DISASSEMBLY AND ASSEMBLY PUMP PULLEY DISASSEMBL Y 1 Remove pump assembly 2 Remove pulley from pump with Puller C 4333...

Page 1290: ...Add power steering fluid refer to Pump Initial Operation FLOW CONTROL VALVE DISASSEMBL Y 1 Clean area around fitting to prevent dirt from entering pump Remove pressure hose from pump fit ting 2 Remov...

Page 1291: ...acket to Engine 47 N m 35 ft lbs Flow Control Valve 75 N m 55 ft lbs Pressure Line 28 N m 21 ft lbs SPECIAL TOOLS POWER STEERING PUMP Analyzer Set Power Steering Flow Pressure 6815 Installer Power Ste...

Page 1292: ...e power steering gear is a recirculating ball type gear Fig 1 The gear acts as a rolling thread between the worm shaft and rack piston The worm shaft is supported by a thrust bearing at the lower end...

Page 1293: ...Fig 1 Recirculating Ball Type Gear 19 12 STEERING XJ DESCRIPTION AND OPERATION Continued...

Page 1294: ...to steering gear 2 Install steering gear and bracket on the frame rail and tighten bolts to 95 N m 70 ft lbs 3 Align and install the pitman arm and tighten nut to 251 N m 185 ft lbs 4 Connect fluid ho...

Page 1295: ...rom stop to stop and count the number of turns 4 Center the stub shaft by rotating it from the stop 1 2 of the total amount of turns 5 Remove side cover bolts and remove side cover gasket and pitman s...

Page 1296: ...o not tighten nut until after Over Center Rotation Torque adjustment has been made 10 Install gasket to side cover and bend tabs around edges of side cover Fig 6 11 Install pitman shaft assembly and s...

Page 1297: ...worm shaft and the stub shaft ASSEMBL Y NOTE Clean and dry all components then lubri cate with power steering fluid 1 Install spool valve spool O ring 2 Install spool valve in valve body by pushing an...

Page 1298: ...Over Cen ter Rotating Torque RACK PISTON AND WORM SHAFT DISASSEMBL Y 1 Remove housing end plug 2 Remove rack piston plug Fig 17 3 Remove side cover and pitman shaft 4 Turn stub shaft COUNTERCLOCKWISE...

Page 1299: ...steering fluid 1 Check for scores nicks or burrs on the rack piston finished surface Slight wear is normal on the worm gear surfaces 2 Install O ring and teflon ring on the rack pis ton 3 Install worm...

Page 1300: ...plug 16 Adjust worm shaft thrust bearing preload and over center rotating torque ADJUSTMENTS STEERING GEAR CAUTION Steering gear must be adjusted in the proper order If adjustments are not performed i...

Page 1301: ...arting at either stop turn the stub shaft back 1 2 the total number of turns This is the center of the gear travel Fig 28 3 Place the torque wrench in the vertical position on the stub shaft Rotate th...

Page 1302: ...que is reached NOTE To increase the Over Center Rotating Torque turn the screw CLOCKWISE 8 Prevent the adjuster screw from turning while tightening adjuster lock nut Tighten the adjuster lock nut to 4...

Page 1303: ...SPECIAL TOOLS POWER STEERING GEAR Remover Installer Steering Plug C 4381 Remover Pitman Arm C 4150A Remover Installer Steering Rack Piston C 4175 19 22 STEERING XJ...

Page 1304: ...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 SERVICE PROCEDURES STEERING LINKAGE The tie rod end and ball stud s...

Page 1305: ...l 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 and unthread the tie rod...

Page 1306: ...steering knuckle and tighten to 47 N m 35 ft lbs Install new cotter pins 3 Install nut at pitman arm and tighten to 75 N m 55 ft lbs Install new cotter pins 4 Install tie rod onto drag link and insta...

Page 1307: ...SPECIAL TOOLS STEERING LINKAGE Puller C 3894 A Remover Pitman C 4150A 19 26 STEERING XJ...

Page 1308: ...BAG 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 FAS...

Page 1309: ...ck spring switches SKIM if equipped and ignition key cylinder refer to Group 8 Electrical for service procedures INSTALLA TION 1 Install upper column mounting bracket on non tilt column Install the mo...

Page 1310: ...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 harne...

Page 1311: ......

Page 1312: ...INFORMATION POWER STEERING PUMP 1 GENERAL INFORMATION 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...

Page 1313: ...re until the fluid level remains constant after run ning the engine 4 Raise the front wheels off the ground 5 Slowly turn the steering wheel right and left lightly contacting the wheel stops at least...

Page 1314: ...ll require you to install the pressure line on the new pump prior to installation 15 Remove the remaining 2 bolts from the H Block and remove the H Block from the compres sor 16 Support the A C compre...

Page 1315: ...essor 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...

Page 1316: ...r steering line support bracket 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...

Page 1317: ...shed 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...

Page 1318: ...the vehicle from hoist 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 Rec...

Page 1319: ...ing wheel switches or airbag refer to Group 8 M and follow all WARNINGS and CAUTIONS WARNING THE AIRBAG SYSTEM IS A SENSITIVE COMPLEX ELECTRO MECHANICAL UNIT BEFORE ATTEMPTING TO DIAGNOSE REMOVE OR IN...

Page 1320: ...p on the ignition switch The ramp fits into the casting until binding no longer occurs REMOVAL AND INSTALLATION STEERING COLUMN WARNING BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE D...

Page 1321: ...t 2 Ensure the ground clip is position Fig 8 3 Install interlock cable from the steering col umn refer to Group 21 Automatic Transmission Shifter Ignition Interlock 4 Install wiring harness connection...

Page 1322: ...er to Group 8M Restraint Systems for service pro cedures 17 Remove the column shaft shipping lock pin installed in service column 18 Connect the battery ground negative cable SPECIFICATIONS TORQUE CHA...

Page 1323: ......

Page 1324: ...S AX5 35 GENERAL INFORMATION AX5 MANUAL TRANSMISSION The AX5 is a five speed manual transmission with fifth gear being the overdrive range An adapter housing is used to attach the transmission to the...

Page 1325: ...applica tions 3 5 liters 3 70 quarts for 2 wheel drive applica tions TRANSMISSION ASSEMBL Y INFORMA TION Lubricate the transmission components with Mopar 75W 90 GL 3 gear lubricant during assem bly U...

Page 1326: ...dations will ensure an accurate check and avoid an underfill or overfill condition Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition HARD SHI...

Page 1327: ...ller shaft and rear axle yokes for installation alignment Fig 5 7 Mark front propeller shaft axle and transfer case yokes for installation alignment if equipped 8 Remove propeller shaft s 9 Unclip wir...

Page 1328: ...bolts 26 Pull transmission jack rearward until input shaft clears clutch Then slide transmission out from under vehicle 27 Remove clutch release bearing release fork and retainer clip 28 Remove clutc...

Page 1329: ...shaft and rear axle yokes Fig 10 26 Install and tighten propeller shaft U joint clamp bolts to 19 N m 170 in lbs torque 27 Align marks on front propeller shaft axle and transfer case yokes if equippe...

Page 1330: ...fer to Group 3 Differ ential and Driveline for proper procedures 4 Check and add fluid to transmission as neces sary Refer to the Recommended Lubricant section for proper fluid requirements 5 Lower ve...

Page 1331: ...if necessary 5 Remove bolts holding shift tower to transmission case 6 Remove shift tower from transmission case Fig 16 7 Remove shift tower gasket from shift tower or transmission case Fig 17 8 Remov...

Page 1332: ...with large magnet Fig 25 14 Remove the shift arm from the adapter hous ing 15 Remove adapter extension housing bolts Fig 19 Remove Detent Ball Plug Fig 20 Remove Detent Spring Fig 21 Remove Detent Ba...

Page 1333: ...ve gear locating snap ring Fig 28 19 Remove the bolts holding the front bearing retainer to the transmission case 20 Remove the bearing retainer from transmis sion case Fig 29 21 Remove input shaft be...

Page 1334: ...e to keep sealer bead to inside of bolt holes Fig 33 3 Align geartrain and shift rails with mating holes in transmission case and install transmission case to the intermediate plate Fig 34 Verify that...

Page 1335: ...rm in shifter tower opening of adapter or extension housing Fig 39 Be sure that the shifter arm is engaged into the shift rails 11 Start shifter arm shaft in hole in back of adapter or extension housi...

Page 1336: ...ft Arm in Adapter or Extension Housing Fig 40 Install Shifter Arm Shaft Fig 41 Install Shift Arm Retainer Bolt Fig 42 Shifter Arm Shaft Plug Installation Fig 43 Install Shifter Restrictor Pins XJ TRAN...

Page 1337: ...Install bolts to hold shift tower to transmis sion case Tighten tower bolts to 18 N m 13 ft lbs torque 23 Install new metal o ring onto the backup lamp switch 24 Install backup lamp switch Fig 48 Tigh...

Page 1338: ...ft Fig 54 7 Remove fifth gear thrust ring from counter shaft Fig 55 8 Remove fifth gear thrust ring lock ball from countershaft Fig 56 NOTE There are many lock balls check balls interlock balls and in...

Page 1339: ...s to the shift rails Fig 59 and discard bolts Fig 52 Remove Fifth Gear Blocker Ring Fig 53 Remove Fifth Gear Synchro Ring Fig 54 Remove Fifth Gear and Synchro Assembly Fig 55 Remove Fifth Gear Thrust...

Page 1340: ...termediate plate The countershaft will release from the countershaft bearing first and can be removed by moving the countershaft rearward and downward Fig 62 17 Remove the mainshaft by moving the main...

Page 1341: ...up CAUTION The interlock balls and pins are different sizes and shapes Be sure to correctly identify which position an item is removed from to ensure that it is reinstalled in the same location 23 Re...

Page 1342: ...m 1 2 shift rail Fig 73 33 Remove 1 2 shift rail elongated check ball from intermediate plate Fig 74 34 Remove 3 4 shift rail from intermediate plate Fig 66 Remove Lock Ball And Spring Fig 67 Remove F...

Page 1343: ...he intermediate plate 2 Install the 1 2 elongated check ball into the intermediate plate Fig 76 3 Install the interlock pin into the 1 2 shift rail Fig 77 4 Install the 1 2 shift rail into the interme...

Page 1344: ...78 7 Install the interlock pin into the reverse shift rail Fig 79 8 Assemble the reverse arm bracket to the reverse fork Fig 80 Fig 75 Shift Rail Components Fig 76 Install 1 2 Check Ball Fig 77 Insta...

Page 1345: ...Install fifth gear shift rail Fig 84 14 Remove the intermediate plate from the vise rotate the plate 180 and reinstall the plate in the vise using the same bolt and washer mounting set up 15 Install t...

Page 1346: ...g gears on the mainshaft 24 Using a suitable rubber mallet tap on the input shaft and the front of the countershaft equally to install the mainshaft rear bearing into the inter mediate plate and the r...

Page 1347: ...transmission 34 Align the pin with the alignment notch in the reverse idler gear assembly Fig 91 The alignment notch in the reverse idler gear race hub is a small relief cut above one of the main lon...

Page 1348: ...the fifth gear fork is installed onto the fifth gear shift rail 44 Install the fifth gear synchro ring 45 Position the fifth gear blocker ring onto the countershaft 46 Using a suitable mallet and spac...

Page 1349: ...bearing rollers from the input shaft and the output shaft 4 Remove the fourth gear synchronizer ring from the input shaft Fig 98 5 Remove the select fit snap ring holding the input shaft bearing onto...

Page 1350: ...ear snap ring with two screwdrivers Fig 102 4 Using Bearing Splitter P 334 or suitable press plates positioned under first gear press fifth gear rear bearing first gear and first gear bearing inner ra...

Page 1351: ...r bearing from the output shaft or second gear 10 Remove select fit snap ring holding the 3 4 synchronizer onto the output shaft Fig 106 11 Using Bearing Splitter P 334 or suitable press plates positi...

Page 1352: ...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 out...

Page 1353: ...hronizer 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 19 Install first gear onto...

Page 1354: ...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 wil...

Page 1355: ...h on the syn chronizer ring are properly engaged into the recesses of the reverse idler gear 3 Install the plate washer over the reverse idler gear hub race and onto the reverse idler gear 4 Install t...

Page 1356: ...535 in Measure output shaft runout with a dial indicator Fig 120 Runout should not exceed 0 05 mm 0 002 in Replace output shaft or first gear inner bearing race if measurement of any surface is out o...

Page 1357: ...039 in 1 Inspect all mainshaft gear teeth Replace any gear which shows any worn or damaged teeth Fig 121 Check Gear To Race Clearance Fig 122 Check Gear To Shaft Oil Clearance Fig 123 Check Synchroniz...

Page 1358: ...vis 54 75 N m 40 55 ft lbs Nuts Rear Mount to Crossmember 33 49 N m 24 36 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 lb...

Page 1359: ...8208 Installer Seal P 334 Splitter Bearing 8109 Cup Installer L 4507 Tube Driver 6747 1A Adapter Fixture MD 998805 Installer Seal 21 36 TRANSMISSION AND TRANSFER CASE XJ SPECIAL TOOLS Continued...

Page 1360: ...4 wheel drive models A standard extension housing is used on 2 wheel drive models The shift mechanism is integral and mounted in the shift tower portion of the adapter housing Fig 1 TRANSMISSION IDENT...

Page 1361: ...erally the result of a leak inadequate lubricant fill or an incor rect lubricant level check Leaks can occur at the mating surfaces of the gear case intermediate plate and adaptor or extension housing...

Page 1362: ...mmended lubricants is noise excessive wear internal bind and hard shift ing Substantial lubricant leaks can result in gear shift rail synchro and bearing damage If a leak goes undetected for an extend...

Page 1363: ...ller shaft and rear axle yokes for installation alignment Fig 6 7 Mark front propeller shaft axle and transfer case yokes for installation alignment if equipped 8 Remove propeller shaft s 9 Unclip wir...

Page 1364: ...olts 26 Pull transmission jack rearward until input shaft clears clutch Then slide transmission out from under vehicle 27 Remove clutch release bearing release fork and retainer clip 28 Remove clutch...

Page 1365: ...1 26 Install and tighten propeller shaft U joint clamp bolts to 19 N m 170 in lbs torque 27 Align marks on front propeller shaft axle and transfer case yokes if equipped 28 Install and tighten propell...

Page 1366: ...Driveline for proper procedures 4 Check and add fluid to transmission as neces sary Refer to the Recommended Lubricant section for proper fluid requirements 5 Lower vehicle ADAPTER HOUSING SEAL REMOV...

Page 1367: ...5 Remove bolts holding shift tower to transmis sion case 6 Remove shift tower from transmission case Fig 17 7 Remove shift tower gasket from shift tower or transmission case Fig 18 8 Remove reverse sh...

Page 1368: ...t with large magnet Fig 26 14 Remove the shift arm from the adapter hous ing Fig 20 Remove Detent Ball Plug Fig 21 Remove Detent Spring Fig 22 Remove Detent Ball Fig 23 Shift Arm Retainer Bolt Removal...

Page 1369: ...drive gear locating snap ring Fig 30 19 Remove the bolts holding the front bearing retainer to the transmission case 20 Remove the bearing retainer from transmis sion case Fig 31 21 Remove input shaf...

Page 1370: ...1281 P N 83504038 as shown making sure to keep sealer bead to inside of bolt holes Fig 36 Fig 28 Loosen Adapter Extension Housing Fig 29 Remove Adapter Extension Housing Fig 30 Speedometer Drive Gear...

Page 1371: ...tighten bolts to 17 N m 12 ft lbs 7 On 4x2 transmissions a Install speedometer drive gear locating snap ring Fig 40 b Install speedometer gear lock ball in output shaft and install speedometer gear o...

Page 1372: ...xtension housing Align shift arm and shifter arm shaft and insert shifter arm shaft through the shifter arm and into the forward portion of the adapter e xtension housing Fig 43 12 Rotate the shifter...

Page 1373: ...7 Install detent spring Fig 48 18 Install detent plug and tighten to 19 N m 14 ft lbs Fig 49 Fig 44 Install Shift Arm Retainer Bolt Fig 45 Shifter Arm Shaft Plug Installation Fig 46 Install Shifter Re...

Page 1374: ...24 Install clutch housing release bearing release fork and retainer clip SHIFT MECHANISM AND GEARTRAIN DISASSEMBL Y 1 Install suitable bolts and washers in intermedi ate plate Fig 51 Then clamp plate...

Page 1375: ...he shift fork 6 Remove the fifth gear shift fork from the syn chronizer sleeve Fig 54 7 Remove the reverse shift head and rail assem bly from the intermediate plate Fig 55 8 Remove fifth gear blocker...

Page 1376: ...ansmission Whenever a pin or ball is removed it should be identified in such a way that it can be reinstalled in the same location from which it was removed Fig 56 Remove Fifth Gear Blocker Ring Fig 5...

Page 1377: ...late Fig 64 17 Remove threaded lock ball plugs from inter mediate plate Fig 65 18 Then remove lock ball and spring from plug holes with pencil magnet Fig 66 Fig 61 Remove Output Shaft Rear Bearing Ret...

Page 1378: ...gear shift rail lock ball from the intermediate plate using a magnet Fig 68 Fig 66 Remove Lock Ball And Spring Fig 67 Shift Rail Identification Fig 68 Remove Fifth Gear Shift Rail Lock Ball XJ TRANSM...

Page 1379: ...1 2 and 3 4 shift forks and the intermediate plate Fig 71 24 Remove the 3 4 shift rail interlock plug from the intermediate plate with a small magnet Fig 72 25 Remove the 3 4 shift fork Fig 73 Fig 69...

Page 1380: ...snap ring holding output shaft rear bearing into the intermediate plate Fig 80 34 Remove countershaft rear bearing snap ring 35 With aid of an assistant support the main shaft and countershaft Tap on...

Page 1381: ...ricate countershaft journal and rear bear ing with petroleum jelly or gear lubricant 2 Position the mainshaft into the intermediate plate Fig 77 Remove Reverse Shift Rail C ring Fig 78 Remove Reverse...

Page 1382: ...ing snap ring NOTE Coat all shift components with petroleum jelly during assembly Petroleum jelly will hold com ponents in position during installation 10 Install interlock pin in reverse shift rail F...

Page 1383: ...late Fig 94 22 Install the fifth gear shift rail into the inter mediate plate Fig 85 Install 1 2 Shift Rail Interlock Plug Fig 86 Install 1 2 Shift Rail Interlock Pin Fig 87 Install 1 2 Shift Rail Fig...

Page 1384: ...t fifth gear assembly onto countershaft Fig 98 30 Install fifth gear synchronizer ring Fig 99 31 Position fifth gear blocker ring onto counter shaft Verify that blocker ring and countershaft splines a...

Page 1385: ...stall detent balls and springs into openings in the intermediate plate Fig 104 39 Install new lock ball plugs into the intermedi ate plate Tighten plugs to 19 N m 14 ft lbs Fig 96 Install Fifth Gear T...

Page 1386: ...emery or crocus cloth 2 Position countershaft front bearing on end of countershaft Be sure the snap ring groove in bearing is facing forward 3 Using Special Tool 8109 and a shop press press bearing o...

Page 1387: ...e bearing is facing forward 2 Using Driver 6052 drive bearing onto input shaft 3 Select the thickest snap ring that will fit into the snap ring groove of the input shaft Fig 109 4 Lubricate output sha...

Page 1388: ...nd and third gear clearance should be 0 10 0 30 mm 0 003 0 0118 in 3 Remove output shaft fifth gear snap ring with two screwdrivers Fig 113 4 Using Bearing Splitter P 334 or suitable press plates posi...

Page 1389: ...ar onto the output shaft 10 Using Bearing Splitter P 334 or suitable press plates positioned under second gear press 1 2 syn chronizer reverse gear and second gear from output shaft Fig 115 11 Remove...

Page 1390: ...est snap ring that will fit into the snap ring groove of the output shaft Fig 119 9 Install snap ring to hold 3 4 synchronizer onto output shaft 10 Verify third gear thrust clearance with feeler gauge...

Page 1391: ...washer locating pin aligns with the notch in the washer 24 Position output shaft rear bearing onto output shaft Ensure that the snap ring groove in bearing outer race is toward rear of output shaft 2...

Page 1392: ...s is within specifica tion but any gear thrust clearance is out of specifica tion replace the necessary gear and gear needle bearing as an assembly GEAR CASE ADAPTER EXTENSION HOUSING INTERMEDIA TE PL...

Page 1393: ...stall the gears on the output shaft Then check oil clearance between the gears and shaft with a dial indicator Fig 126 Oil clearance for all three gears is 0 16 mm 0 0063 in maximum Check synchronizer...

Page 1394: ...N m 40 55 ft lbs Nuts Rear Mount to Crossmember 33 49 N m 24 36 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...

Page 1395: ...r Seal L 4407A Puller Gear P 334 Splitter Bearing 8109 Cup Installer 6052 Tube Driver 6761 Adapter Installer MD 998805 Tube Driver L 4507 Tube Driver 21 72 TRANSMISSION AND TRANSFER CASE XJ SPECIAL TO...

Page 1396: ...ALLATION BRAKE TRANSMISSION SHIFT INTERLOCK 100 EXTENSION HOUSING 98 EXTENSION HOUSING BUSHING 97 GEARSHIFT CABLE 100 GOVERNOR AND PARK GEAR 102 OUTPUT SHAFT REAR BEARING 102 PARK LOCK 103 PARK NEUTRA...

Page 1397: ...n 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 debr...

Page 1398: ...Fig 1 30RH Automatic Transmission XJ TRANSMISSION AND TRANSFER CASE 21 75 GENERAL INFORMATION Continued...

Page 1399: ...on the console next to the gear shift The shift posi tions are Park P Reverse R Neutral N Drive D Manual Second 2 Manual Low 1 Manual low 1 range provides first gear only Over run braking is also pro...

Page 1400: ...ines when the vehicle is shut down for lengthy peri ods Production valves have a hose nipple at one end while the opposite end is threaded for a flare fitting All valves have an arrow or similar mark...

Page 1401: ...f pan is clear remove transmis sion and check for damaged drive plate converter oil pump or input shaft c If propeller shaft does not turn and transmis sion is not noisy perform hydraulic pressure tes...

Page 1402: ...nce during the road test A poorly tuned engine will not allow accurate analy sis of transmission operation Operate the transmission in all gear ranges Check for shift variations and engine flare which...

Page 1403: ...right side of the case The front servo pressure port is at the right side of the case just behind the filler tube opening Connect a tachometer to the engine Position the tachometer so it can be obser...

Page 1404: ...r detents rearward from the full forward position This is Reverse range 4 Move throttle lever all way forward then all way rearward and note gauge readings 5 Pressure should be 145 175 psi 1000 1207 k...

Page 1405: ...ecessary Stall Speed Normal But Acceleration Poor If stall speeds are normal 1800 2300 rpm but abnormal throttle opening is required for accelera tion or to maintain cruise speed the converter over ru...

Page 1406: ...2 Tighten front band adjusting screw until band is tight around front clutch retainer This prevents front rear clutches from coming out when oil pump is removed 3 Remove oil pump and remove pump seal...

Page 1407: ...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 leve...

Page 1408: ...n 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 disa...

Page 1409: ...olts 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 a...

Page 1410: ...aulic 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 L...

Page 1411: ...ir 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...

Page 1412: ...ernally 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 clut...

Page 1413: ...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 Ti...

Page 1414: ...t overfill CAUTION Do not overfill the transmission Overfill ing may cause leakage out the pump vent which can be mistaken for a pump seal leak Overfilling will also cause fluid aeration and foaming a...

Page 1415: ...evel is equal on both sides of the dipstick If one side is noticably higher than the other the dipstick has picked up some oil from the dipstick tube Allow the oil to drain down the dipstick tube and...

Page 1416: ...ransmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nect red al...

Page 1417: ...ill also be necessary to remove bolt attaching transfer case vent tube to converter hous ing 11 Mark torque converter and drive plate for assembly alignment Note that bolt holes in crank shaft flange...

Page 1418: ...r or tilt transmission to align converter housing with engine block dowels 12 Rotate converter so alignment marks scribed on converter are aligned with mark on driveplate 13 Carefully work transmissio...

Page 1419: ...er from the transmission 3 Pull the torque converter forward until the cen ter hub clears the oil pump seal 4 Separate the torque converter from the trans mission INSTALLA TION Check converter hub and...

Page 1420: ...al into extension housing with Seal Installer C 3995 A or C 3972 Fig 22 3 Carefully guide propeller shaft slip yoke into housing and onto output shaft splines Align marks made at removal and connect p...

Page 1421: ...wer 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 Disco...

Page 1422: ...ehicle and top off transmission fluid level if necessary PARK NEUTRAL POSITION SWITCH REMOVAL 1 Raise vehicle and position drain pan under switch 2 Disconnect switch wires 3 Remove switch from case IN...

Page 1423: ...d Refer to Group 19 Steering for proper procedure 3 Remove tie strap near the solenoid retaining the brake transmission interlock cable to the steering column 4 Disengage wire connector from solenoid...

Page 1424: ...f sprag and remove valve body Fig 33 INSTALLA TION 1 Verify that park neutral position switch is NOT installed Valve body cannot be installed with switch in place Remove switch if necessary 2 Install...

Page 1425: ...EMOVAL 1 Remove extension housing 2 Remove snap ring that retains rear bearing on output shaft Fig 34 3 Remove bearing from output shaft INSTALLA TION 1 Install bearing on output shaft Be sure retain...

Page 1426: ...emove sprag and spring Fig 38 4 Remove snap ring and slide reaction plug and pin assembly out of housing 5 If park rod requires service it will be necessary to remove valve body INSTALLA TION 1 Inspec...

Page 1427: ...terme diate weight ASSEMBL Y CAUTION Exercise care when installing the rings They are easily broken if overspread or twisted dur ing installation If it was necessary to remove the park gear inspect th...

Page 1428: ...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 s...

Page 1429: ...ttaching transfer plate to valve body Fig 52 17 Remove transfer plate and separator plate from valve body Fig 52 Note position of filter and clutch solenoid for reference Remove valve body check balls...

Page 1430: ...ove governor plug end plate Fig 57 Fig 50 Clutch Module And Connecting Tube Fig 51 Converter Clutch and Fail Safe Valves Fig 52 Valve Body Transfer Plate Screws Fig 53 Transfer And Separator Plates Fi...

Page 1431: ...t valve body Fig 57 31 Remove retainer from end of kickdown limit valve body Fig 57 32 Remove kickdown limit valve and spring from kickdown limit valve body Fig 57 33 Remove regulator valve end plate...

Page 1432: ...te in position on valve body and compress springs Fig 57 13 Install screws to attach kickdown limit valve body to valve body Fig 57 14 Install shuttle valve throttle plug primary spring and shuttle va...

Page 1433: ...ach con verter clutch module to valve body Fig 65 36 If necessary install a new O ring on converter clutch solenoid Fig 66 37 Insert converter clutch solenoid into transfer plate Fig 66 38 Install scr...

Page 1434: ...y Fig 72 46 Place adjusting screw bracket and line pres sure adjusting screw in position on valve body and compress springs Fig 44 47 Install screws to attach adjuster bracket to valve body Fig 64 Con...

Page 1435: ...nual shaft and throttle lever shaft 6 Mount transmission in repair stand C 3750 B or similar type stand Fig 73 7 Remove extension housing 8 Remove fluid pan 9 Remove park neutral position switch and s...

Page 1436: ...her from out put shaft or from rear clutch hub Fig 81 21 Remove output shaft thrust plate and washer from output shaft hub Fig 81 22 Remove front band from case Fig 82 23 Remove extension housing from...

Page 1437: ...remove front band reaction pin access plug Fig 90 b Remove front band reaction pin with pencil magnet Pin is accessible from converter housing side of case Fig 91 c Remove front band lever Fig 92 d Us...

Page 1438: ...ools and remove front servo rod guide spring and servo piston 37 Compress rear servo spring retainer about 1 16 in with C clamp and Tool C 4470 or SP 5560 Fig 95 Valve Spring Compressor C 3422 B can a...

Page 1439: ...pan opening in trans mission case 5 Insert hook on band onto adjuster lever 6 Align holes in link bar with hole in transmis sion case outboard of rear support opening Fig 92 7 Insert anchor pin into c...

Page 1440: ...l 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 rea...

Page 1441: ...rear clutch 29 Install output shaft thrust plate on shaft hub in planetary geartrain driving shell Fig 102 Use petroleum jelly to hold thrust plate in place 30 Check rear clutch thrust washer Use addi...

Page 1442: ...front band Fig 108 38 Tighten front band adjusting screw until band just grips clutch retainer Verify that front rear clutches are still seated before continuing 39 Verify that reaction shaft support...

Page 1443: ...pump down studs and work it into front clutch hub and case by hand Then install two or three pump bolts to hold pump in place 45 Remove pilot stud tools and install remaining oil pump bolts Tighten b...

Page 1444: ...ring assembly from the overrunning clutch race ASSEMBL Y 1 Assemble clutch rollers and springs in retainer if necessary Fig 115 2 Install overrunning clutch roller spring and retainer assembly in clut...

Page 1445: ...ve plug and spring from servo piston Fig 120 2 Remove and discard servo piston seal ring ASSEMBL Y 1 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with Mopar ATF P...

Page 1446: ...ch and ham mer 7 Remove front clutch thrust washer from sup port hub Fig 125 OIL PUMP BUSHING REPLACEMENT 1 Remove pump bushing with Tool Handle C 4171 and Bushing Remover SP 3551 from Tool Set C 3887...

Page 1447: ...l Bushing Installer SP 5325 bottoms 9 Clean reaction shaft support thoroughly after installing bushing ASSEMBL Y 1 Lubricate gear bore in pump housing with transmission fluid 2 Lubricate pump gears wi...

Page 1448: ...bolts to required torque as follows a Reverse pump assembly and install it in transmission case Position pump so bolts are fac ing out and are accessible b Secure pump assembly in case with 2 or 3 bo...

Page 1449: ...bore and piston with light coat of transmission fluid 4 Install clutch piston in retainer Fig 136 Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 020 thick can...

Page 1450: ...tacts 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 clearance is incorrect clutch discs plates pressure plates and snap ring may h...

Page 1451: ...hub seal ring is fully seated in groove and is not twisted 3 Lubricate splined end of input shaft and clutch retainer with transmission fluid Then press input shaft into retainer Use a suitably sized...

Page 1452: ...h pack is installed 4 discs and 3 plates are required Fig 140 13 Install top pressure plate 14 Install selective snap ring Be sure snap ring is fully seated in retainer groove 15 Using a suitable gaug...

Page 1453: ...from annulus gear hub 7 Separate and remove driving shell rear plane tary and rear annulus from output shaft Fig 151 8 Remove front planetary rear thrust washer from driving shell 9 Remove tabbed thru...

Page 1454: ...all spacer on sun gear Fig 155 8 Install thrust plate on sun gear Fig 156 Note that driving shell thrust plates are interchangeable Use either plate on sun gear and at front rear of shell 9 Hold sun g...

Page 1455: ...r on front planetary gear Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated 16 Assemble front annulus gear and support if necessary Be sure support snap ri...

Page 1456: ...nents to move forward for accurate end play check 23 Check planetary geartrain end play with feeler gauge Fig 167 Gauge goes between shoulder on output shaft and end of rear annulus support 24 Geartr...

Page 1457: ...t the governor weight spring for distortion Replace the spring if distorted collapsed or broken Clean the filter in solvent and dry it with compressed air Replace the filter if damaged Inspect the par...

Page 1458: ...Fig 168 Governor Weights Fig 169 Governor Components XJ TRANSMISSION AND TRANSFER CASE 21 135 CLEANING AND INSPECTION Continued...

Page 1459: ...k lock rod and E clip switch valve and spring pressure adjusting screw bracket throttle valve lever manual lever manual lever shaft seal washer E clip and detent ball fluid filter converter clutch sol...

Page 1460: ...lve body assembly unless it is damaged in han dling TRANSMISSION Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and all fluid passages wi...

Page 1461: ...he 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 Repl...

Page 1462: ...ce between outer gear and pump housing should also be 0 010 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge FRONT CLUTCH Clean and inspect the front clutch components...

Page 1463: ...serviceable However if a pinion carrier is damaged the entire planetary gear set must be replaced as an assembly Replace the annulus gears if the teeth are chipped broken or worn or the gear is cracke...

Page 1464: ...r move column lever b Turn ignition switch to RUN position c Shifting out of park should not be possible d Apply the brake and attempt to shift out of PARK Shifting should be possible e While the tran...

Page 1465: ...throttle lever is in fully closed position Then be sure lever on throttle body is at curb idle position 5 Insert a small screwdriver under edge of retaining clip and remove retaining clip 6 Center ca...

Page 1466: ...h affects shift quality and timing As a result both adjustments must be performed properly and in the correct sequence Adjust line pressure first and throttle pressure last LINE PRESSURE ADJUSTMENT Me...

Page 1467: ...kickdown valve spring Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully compre...

Page 1468: ...HYDRAULIC FLOW IN PARK NEUTRAL XJ TRANSMISSION AND TRANSFER CASE 21 145 SCHEMATICS AND DIAGRAMS Continued...

Page 1469: ...HYDRAULIC FLOW IN D FIRST GEAR 21 146 TRANSMISSION AND TRANSFER CASE XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1470: ...HYDRAULIC FLOW IN D SECOND GEAR XJ TRANSMISSION AND TRANSFER CASE 21 147 SCHEMATICS AND DIAGRAMS Continued...

Page 1471: ...HYDRAULIC FLOW IN D THIRD GEAR 21 148 TRANSMISSION AND TRANSFER CASE XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1472: ...HYDRAULIC FLOW IN D THIRD GEAR CONVERTER CLUTCH APPLIED XJ TRANSMISSION AND TRANSFER CASE 21 149 SCHEMATICS AND DIAGRAMS Continued...

Page 1473: ...HYDRAULIC FLOW AT PART THROTTLE 3 2 KICKDOWN 21 150 TRANSMISSION AND TRANSFER CASE XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1474: ...HYDRAULIC FLOW AT FULL THROTTLE 3 2 KICKDOWN XJ TRANSMISSION AND TRANSFER CASE 21 151 SCHEMATICS AND DIAGRAMS Continued...

Page 1475: ...HYDRAULIC FLOW IN MANUAL SECOND 21 152 TRANSMISSION AND TRANSFER CASE XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1476: ...HYDRAULIC FLOW IN MANUAL LOW XJ TRANSMISSION AND TRANSFER CASE 21 153 SCHEMATICS AND DIAGRAMS Continued...

Page 1477: ...HYDRAULIC FLOW IN REVERSE 21 154 TRANSMISSION AND TRANSFER CASE XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1478: ...HYDRAULIC FLOW IN MANUAL FIRST GEAR 1 XJ TRANSMISSION AND TRANSFER CASE 21 155 SCHEMATICS AND DIAGRAMS Continued...

Page 1479: ...HYDRAULIC FLOW IN MANUAL SECOND GEAR 2 21 156 TRANSMISSION AND TRANSFER CASE XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1480: ...ub 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...

Page 1481: ...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 adapte...

Page 1482: ...9 Spring Compressor C 3422 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 XJ TRANSMISSION AND T...

Page 1483: ...tle Setting C 3763 Seal Installer C 3860 A Bushing Remover Installer C 3887 J Cup Remover SP 3633 Remover Bushing SP 5301 Installer Bushing SP 5118 Installer Bushing SP 5302 21 160 TRANSMISSION AND TR...

Page 1484: ...Remover Bushing SP 3629 Installer Bushing SP 5511 Snap ring Plier C 3915 Seal Remover C 3985 B Bushing Remover 6957 Flusher Oil Cooler 6906 Installer C 3995 A XJ TRANSMISSION AND TRANSFER CASE 21 161...

Page 1485: ...Universal Handle C 4171 Remover Installer C 4470 Nut Bushing Remover SP 1191 21 162 TRANSMISSION AND TRANSFER CASE XJ SPECIAL TOOLS Continued...

Page 1486: ...180 TORQUE CONVERTER STALL TEST 179 TORQUE CONVERTER STATOR CLUTCH INSPECTION 184 TRANSMISSION SOLENOID TESTING 180 SERVICE PROCEDURES ALUMINUM THREAD REPAIR 186 CHECKING FLUID CONDITION 185 CHECKING...

Page 1487: ...various sen sors to the TCM 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 provides o...

Page 1488: ...ailure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick c...

Page 1489: ...nt to the transmission control module The park neutral position switch is mounted on the valve body manual shaft The switch signals shift linkage and manual valve position to the transmis sion control...

Page 1490: ...NENTS First through third and reverse gear components are outlined in Fig 6 The input shaft is meshed with the direct clutch hub and the forward clutch drum These elements rotate as a unit The forward...

Page 1491: ...overdrive sun gear from turning either clockwise or counter clockwise Overdrive One Way Clutch When transmission is driven by engine connects overdrive sun gear and overdrive carrier Forward Clutch C...

Page 1492: ...e pump drive gear is operated by the torque converter hub Drive tangs on the hub engage in drive slots in the drive gear TRANSMISSION VALVE BODY COMPONENTS Transmission operating pressure is supplied...

Page 1493: ...e to the clutches and brakes according to engine load The valve is actuated by throttle valve pressure During high load operation the valve increases line pressure to maintain positive clutch and brak...

Page 1494: ...The valve is actuated 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...

Page 1495: ...second brake accu mulator 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 VAL...

Page 1496: ...feed port to apply the clutch De energizing the solenoid causes the drain port to close Line pressure then moves the valve down exposing the overdrive brake accumulator feed port for the shift to four...

Page 1497: ...3 position LOW COAST MODULA TOR VALVE The low coast modulator valve Fig 20 momen tarily reduces line pressure from the 2 3 shift valve this action cushions application of the first reverse brake The m...

Page 1498: ...piston bore control pressure and spring tension momentarily delay application of full line pressure to cushion engagement The accumulators are all located in the transmission case Fig 22 TRANSMISSION...

Page 1499: ...oved for service or access to other components Auxiliary cooler removal requires that the front bumper and radiator support be removed for access to the cooler lines and attaching bracket BRAKE TRANSM...

Page 1500: ...SPECTION AND ADJUSTMENT 1 Check and adjust transmission shift cable if necessary 2 Verify transmission throttle cable operation Repair or replace cable if necessary 3 Check engine throttle operation O...

Page 1501: ...gear ranges were difficult to distinguish all feel the same or vehicle would not back up refer to diagnosis charts Do not perform stall or time lag tests CAUTION Do not over speed the engine during th...

Page 1502: ...hrottle cable loose worn binding or out of adjustment throttle valve downshift plug throttle cam or primary regulator valve are sticking worn or dam aged If pressures in D and Reverse are lower than s...

Page 1503: ...t checks general condition of the overdrive clutch forward clutch rear clutch and first reverse brake Condition is indicated by the amount of time required for clutch brake engagement with the engine...

Page 1504: ...DIAGNOSIS TABLE XJ TRANSMISSION AND TRANSFER CASE 21 181 DIAGNOSIS AND TESTING Continued...

Page 1505: ...DIAGNOSIS TABLE CONTINUED 21 182 TRANSMISSION AND TRANSFER CASE XJ DIAGNOSIS AND TESTING Continued...

Page 1506: ...essure Engine starts must be possible c NEUTRAL position Normal position Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply forward force on center of shift hand...

Page 1507: ...art and run engine at curb idle speed and immediately note cooler flow Approximately one quart of fluid should flow into test container in 20 second period 7 If cooler flow is intermittent flows less...

Page 1508: ...particles in the oil pan is normal The particles are usually generated during the break in period and indicate normal seating of the vari ous transmission components REFILLING AFTER OVERHAUL OR FLUID...

Page 1509: ...ansmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906 3 Verify pump power switch is turned OFF Con nect red all...

Page 1510: ...mov ing the transmission 15 Remove starter motor 16 Remove bolts attaching converter to drive plate 17 Remove bolts attaching converter housing to engine 18 Secure transmission to jack with safety cha...

Page 1511: ...vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work surface the center of gravity of the t...

Page 1512: ...a brass drift and hammer Fig 37 4 On 4X2 vehicles remove the adapter housing seal with Seal Puller 7550 5 On 4X4 vehicles remove the adapter housing seal using a slide hammer mounted screw INSTALLA T...

Page 1513: ...e speed sensor 12 Lower vehicle and top off transmission fluid level if necessary SPEED SENSOR ROTOR SPEEDOMETER DRIVE GEAR REMOVAL 1 Raise vehicle 2 Remove components necessary to gain access to roto...

Page 1514: ...ay rear ward Then rotate lever forward two detent positions to Neutral 3 Install switch on manual valve shaft and install switch adjusting bolt finger tight Do not tighten bolt at this time 4 Install...

Page 1515: ...able eyelet at transmission shift lever and pull cable adjuster out of mounting bracket Then remove old cable from vehicle INSTALLA TION 1 Route cable through hole in dash panel Fully seat cable gromm...

Page 1516: ...le 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 10 Install tie strap to hold cable to base of steer i...

Page 1517: ...nect solenoid wire connectors Fig 50 Mark wires for assembly reference 4 Remove valve body oil tubes Fig 51 Carefully pry tubes out of valve body with screwdriver 5 Disconnect throttle cable from thro...

Page 1518: ...6 Install valve body oil tubes Be sure tube ends L and M are installed as shown in Fig 57 7 Remove old sealer material from oil pan and transmission case 8 Clean oil screen and oil pan with solvent i...

Page 1519: ...ide of the lower finish panel Fig 59 To remove the module disconnect the wire har ness remove the mounting screws and remove the module from the finish panel Tighten the module mounting screws securel...

Page 1520: ...d Liquid Gasket TB1281 P N 83504038 to oil pan seal surface Sealer bead should be at least 3 mm 1 8 in wide 7 Install oil pan on transmission Tighten pan bolts to 7 N m 65 in lbs torque 8 Install and...

Page 1521: ...and sector with pin punch 7 Remove shaft and sector from case 8 Pry shaft seals out of case Fig 66 INSTALLA TION 1 Inspect the manual valve shaft and sector Replace either component if worn or damaged...

Page 1522: ...securely stake sleeve to sector and shaft 8 Connect park rod to sector Fig 64 9 Install park rod bracket Fig 69 Tighten bracket bolts to 10 N m 7 ft lbs torque 10 Install valve body oil screen and oil...

Page 1523: ...o remove clip A thin wall deep socket or pin punch can be used to seat clip after spring replacement 3 Install new O ring seals on pistons Lubricate seals and pistons and piston bores with transmissio...

Page 1524: ...nd install cover snap ring 5 Install valve body oil screen and oil pan PARK ROD AND PA WL REMOVAL 1 Remove valve body as outlined in this section 2 Remove bolts attaching park rod bracket to case Fig...

Page 1525: ...5 3 Install park rod and bracket Fig 76 Tighten bracket bolts to 10 N m 7 ft lbs torque 4 Install valve body oil screen and oil pan TRANSMISSION THROTTLE CABLE REMOVAL 1 In engine compartment disconne...

Page 1526: ...torque 7 Connect cable to engine bracket and throttle linkage 8 Fill transmission with Mopar Dexron Mercon IIE 9 Adjust the cable as described in cable adjust ment procedure OIL PUMP SEAL REMOVAL 1 Re...

Page 1527: ...ts and remove housing Fig 84 from case 7 Remove adapter housing speedometer drive gear and speed sensor rotor 8 Remove transmission oil pan oil screen and screen gaskets Fig 85 9 Remove valve body oil...

Page 1528: ...hrottle cable from throttle cam Fig 90 Fig 87 Solenoid Wire Location Fig 88 Removing Bracket And Harness Fig 89 Valve Body Bolt Locations Fig 90 Disconnecting Throttle Cable XJ TRANSMISSION AND TRANSF...

Page 1529: ...compressed air Fig 92 Note and identify the original location of all springs 17 Remove overdrive clutch accumulator piston with compressed air Fig 92 18 Remove throttle cable 19 Remove oil pump bolts...

Page 1530: ...mp Removal Fig 94 Oil Pump Race Removal Fig 95 Removing Overdrive Planetary And Clutch Assembly Fig 96 Fourth Gear Planetary Race Removal XJ TRANSMISSION AND TRANSFER CASE 21 207 DISASSEMBLY AND ASSEM...

Page 1531: ...stall a small wire tie strap around the sec ond coast brake piston rod tight against the trans mission case b Apply 57 114 psi air pressure through piston feed hole and check stroke length with Gauge...

Page 1532: ...103 35 Remove second coast brake piston snap ring with Snap Ring Plier Tool 7540 Then remove piston cover and piston assembly 36 Disassemble second coast brake piston Fig 104 if necessary Fig 100 Ove...

Page 1533: ...ve pin and brake band Fig 107 40 Remove front planetary bearing race and remove front planetary ring gear Fig 108 Fig 104 Second Coast Brake Piston Components Fig 105 Removing Direct And Forward Clutc...

Page 1534: ...nap ring and remove plan etary gear Fig 110 45 Remove sun gear input drum one way clutch and thrust washer as assembly Fig 111 Fig 108 Front Planetary Ring Gear Removal Fig 109 Removing Ring Gear Bear...

Page 1535: ...wl Fig 116 51 Measure clearance of first reverse brake clutch pack Fig 117 Clearance should be 0 70 1 2 mm 0 028 0 047 in record measurement for use during re assembly 52 Remove second brake piston sl...

Page 1536: ...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 115 Removing Park Rod And Bracket Fig 116 Removing Park Pawl Pin And...

Page 1537: ...incorrect case or piston may require replacement Fig 119 Removing Rear Planetary Second Brake Drum And Output Shaft Fig 120 Removing Installing Bearing And Race Assembly Fig 121 Checking Rear Bushing...

Page 1538: ...uring 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 126 for...

Page 1539: ...r planetary gear second brake drum and output shaft as outlined in following steps 14 Verify No 10 thrust bearing and race Fig 126 Bearing and race outer diameter is 57 7 mm 2 272 in and inside diamet...

Page 1540: ...ve lip faces up and toward case front as shown 21 Install second brake drum gasket 22 Install park lock pawl spring and pin Fig 133 23 Install the manual valve shift assembly 24 Connect park lock rod...

Page 1541: ...clutch Fig 137 Short flanged side of clutch faces up and toward case front 28 Install second brake pack Fig 138 Install disc then plate Continue installation sequence until five discs and five plates...

Page 1542: ...nstall planetary sun gear and input drum Fig 140 Be sure drum thrust washer tabs are seated in drum Use petroleum jelly to hold thrust washer in position if necessary 33 Install front planetary gear o...

Page 1543: ...tabs face down and toward gear Race outer diameter is 47 8 mm 1 882 in Inside diame ter is 34 3 mm 1 350 in Fig 140 Installing Sun Gear And Input Drum Fig 141 Installing Front Planetary Gear Fig 142 S...

Page 1544: ...is 26 0 mm 1 024 in 41 Coat front planetary ring gear race with petroleum jelly and install it in ring gear Fig 147 42 Verify ring gear race size Outer diameter is 47 0 mm 1 850 in and inside diameter...

Page 1545: ...arance 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 146 Ins...

Page 1546: ...ll wire tie strap around the sec ond coast brake piston rod tight against the trans mission case b Apply 57 114 psi air pressure through piston feed hole and check stroke length with Gauge Tool 7552 c...

Page 1547: ...ay with dial indica tor Fig 161 End play should be 0 27 0 86 mm 0 0106 0 0339 in 59 If output shaft end play is incorrect one or more of installed components is not seated Reassem ble as necessary and...

Page 1548: ...threaded into the transmission case b Verify that the dial indicator is mounted sol idly and square to the direction of the piston travel Fig 159 Installing Overdrive Support Snap Ring Fig 160 Instal...

Page 1549: ...Fig 165 66 Coat ring gear thrust race and thrust bearing assembly with petroleum jelly and install them in gear Fig 166 67 Verify bearing race size before proceeding Outer diameter of ring gear race b...

Page 1550: ...ns mission throttle cable adapter and install cable in case Fig 171 77 Check clutch and brake operation Operate clutches and brakes with compressed air applied through feed holes in case Fig 172 Liste...

Page 1551: ...Install detent spring Fig 175 83 Align manual valve detent spring and shift sector Fig 175 84 Connect transmission throttle cable to throttle valve cam Fig 176 Fig 171 Installing Transmission Throttl...

Page 1552: ...dy oil tubes 91 Apply Threebond Liquid Gasket TB1281 P N 83504038 to sealing surface of oil pan Sealer bead should be at least 3 mm 1 8 in wide Install pan on case and tighten pan bolts to 7 N m 65 in...

Page 1553: ...bolt just enough to keep switch from moving Fig 184 101 Install park neutral position switch tabbed washer and retaining nut Fig 184 Tighten nut to 6 9 N m 61 in lbs torque but do not bend any of the...

Page 1554: ...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 materi...

Page 1555: ...ront and 27 08 mm 1 0661 in at rear Replace stator shaft if bushing diameter is greater than specified 3 Measure oil pump clearances Fig 189 Clearance between pump driven gear and pump body should be...

Page 1556: ...otation Fig 191 Gears must rotate smoothly when turned clockwise and counterclock wise 10 Lubricate pump O ring and seal rings with petroleum jelly Fig 189 Checking Pump Gear Clearances Fig 190 Instal...

Page 1557: ...ton as follows a Mount oil pump on torque converter Then mount clutch on oil pump Fig 194 b Install a suitable threaded bolt rod into oil pump for use in mounting Miller Tool C 3339 dial indicator com...

Page 1558: ...in 7 If the clutch pack stroke length is out of speci fication or any clutch disc fails to meet the minimum thickness new discs will need to be installed during assembly Fig 192 Checking One Way Clut...

Page 1559: ...piston return springs with springs in retainer Fig 199 Length should be 16 8 mm 0 661 in Replace spring and retainer assembly if necessary 13 Check clutch piston check ball Fig 200 Shake piston to se...

Page 1560: ...ter is greater than specified 15 Remove bearing and race from ring gear Fig 202 16 Remove snap ring from ring gear and remove ring gear hub Fig 203 Fig 200 Testing Clutch Piston Check Ball Fig 201 Che...

Page 1561: ...ust washer in planetary gear Fig 209 Grooved side of w asher faces up and tow ard front 2 Install clutch race into planetary gear 3 Install one way clutch into the outer race Fig 210 Be sure flanged s...

Page 1562: ...r 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 212 11 Install piston snap ring Compress piston return sp...

Page 1563: ...all clutch on planetary gear 16 Verify one way clutch operation Hold drum and turn planetary shaft clockwise and counterclock wise Shaft should turn clockwise freely but lock when turned counterclockw...

Page 1564: ...18 4 Turn overdrive support over and remove bear ing race and clutch drum thrust washer Fig 219 5 Compress piston return spring with Spring Compressor 7537 and remove piston snap ring Fig 220 Fig 216...

Page 1565: ...n Replace support and piston if either part is worn or damaged ASSEMBL Y 1 Lubricate new support seal rings Then com press rings and install them on support Fig 224 2 Lubricate and install new O rings...

Page 1566: ...8 in and inside diameter is 32 7 mm 1 287 in 8 Verify brake piston operation Use same proce dure described at beginning of disassembly Piston should operate smoothly and not bind or stick DIRECT CLUTC...

Page 1567: ...either the clutch pack retainer or clutch discs will have to be replaced 8 Remove clutch pack snap ring and remove retainer and clutch pack from drum Fig 230 9 Compress clutch piston return springs wi...

Page 1568: ...k ball Fig 234 Shake piston to see if ball moves freely Then check ball seating by applying low pressure compressed air to ball inlet as shown Air should not leak past check ball 16 Measure inside dia...

Page 1569: ...nap ring end gap is not aligned with spring retainer tab 4 Install clutch discs and plates Fig 236 Install plate then disc until all plates and discs are installed Four plates and discs are required F...

Page 1570: ...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 ag...

Page 1571: ...tch disc thickness Fig 248 Min imum allowable thickness is 1 51 mm 0 0595 in Replace clutch pack if any disc falls below specified minimum thickness 21 Measure free length of piston return springs wit...

Page 1572: ...drum shaft seal rings with petroleum jelly Before installing drum shaft seal rings squeeze each ring so ring ends overlap Fig 252 This tightens ring making clutch installation easier 3 Install seal r...

Page 1573: ...d plate followed by disc until required number of plates and discs are installed Use six plates and discs 11 Install clutch pack snap ring 12 Recheck clutch piston stroke length using same method outl...

Page 1574: ...of bearing and race is 26 0 mm 1 024 in 15 Mount forward clutch on direct clutch and check assembled height Fig 255 Height should be 70 3 71 5 mm 2 767 2 815 in Fig 249 Checking Return Spring Length...

Page 1575: ...y gear 6 Measure inside diameter of ring gear bushing Maximum allowable diameter is 24 08 mm 0 9480 in Replace ring gear if bushing inside diameter is greater than specified 7 Check condition of plane...

Page 1576: ...eter 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...

Page 1577: ...UTCH Fig 259 Front Planetary Front Bearing And Races Installation Fig 258 Front Planetary Thrust Race Installation Sun Gear And One Way Clutch Components 21 254 TRANSMISSION AND TRANSFER CASE XJ DISAS...

Page 1578: ...od block Fig 264 Then remove first sun gear snap ring and separate drum from gear 6 Remove remaining snap ring from sun gear Fig 265 7 Measure inside diameter of sun gear bushings with bore gauge or i...

Page 1579: ...second brake hub clock wise and counterclockwise Hub should turn clock wise freely but lock when turned counterclockwise SECOND BRAKE DISASSEMBL Y 1 Remove second brake drum from output shaft Fig 268...

Page 1580: ...e length of piston return springs with springs mounted in retainer Fig 272 Length should be approximately 16 05 mm 0 632 in Replace return springs if length is less than speci fied Second Brake Compon...

Page 1581: ...m press 4 Check brake piston operation with low pres sure compressed air Fig 273 Apply air pressure through feed hole in drum Piston should move smoothly when applying releasing air pressure Fig 270 R...

Page 1582: ...roleum jelly and install it in drum Be sure washer notches are aligned with tabs on spring retainer Fig 274 Fig 274 Installing Second Brake Thrust Washer XJ TRANSMISSION AND TRANSFER CASE 21 259 DISAS...

Page 1583: ...ove and discard shaft seal ring Fig 276 3 Remove brake pack from planetary gear Fig 277 4 Remove planetary gear from ring gear Fig 278 Rear Planetary Brake Pack Output Shaft Components Fig 275 Removin...

Page 1584: ...race from planetary gear Fig 280 7 Remove clutch snap ring and remove No 2 one way clutch top end cap from planetary 8 Remove No 2 one way clutch from planetary Fig 281 Fig 276 Removing Installing Sh...

Page 1585: ...st bearing and washers from ring gear Fig 283 12 Remove ring gear snap ring and remove ring gear hub Fig 284 13 Inspect and replace any worn or damaged planetary gearcomponents Fig 280 Removing Instal...

Page 1586: ...thrust washers with petroleum jelly and install them in gear Fig 282 6 Install No 2 one way clutch bottom end cap into the planetary gear 7 Install No 2 one way clutch in planetary gear Be sure flange...

Page 1587: ...ng on output shaft Fig 276 Be sure ring ends are interlocked as shown TRANSMISSION VALVE BODY The valve body assembly consists of two sections which are the upper body and lower body Fig 286 and Fig 2...

Page 1588: ...Fig 286 Lower Body Components XJ TRANSMISSION AND TRANSFER CASE 21 265 DISASSEMBLY AND ASSEMBLY Continued...

Page 1589: ...Fig 287 Upper Body Components 21 266 TRANSMISSION AND TRANSFER CASE XJ DISASSEMBLY AND ASSEMBLY Continued...

Page 1590: ...ot both positions If the engine starts in any position other than Park or Neu tral or if the engine will not start at all the park neutral position switch may be faulty Gearshift Adjustment Procedure...

Page 1591: ...ul taneously with the throttle body lever from the idle position Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of or lag behin...

Page 1592: ...is pulled forward and centered on the throttle lever stud the cable housing moves smoothly with the cable Due to the angle at which the cable housing enters the spring housing the cable housing may b...

Page 1593: ...A W 4 GENERAL SPECIFICA TIONS 21 270 TRANSMISSION AND TRANSFER CASE XJ SPECIFICATIONS Continued...

Page 1594: ...A W 4 OIL PUMP WEAR LIMITS A W 4 CLUTCH DISC AND PLA TE THICKNESS XJ TRANSMISSION AND TRANSFER CASE 21 271 SPECIFICATIONS Continued...

Page 1595: ...A W 4 BUSHING AND PISTON CLEARANCE 21 272 TRANSMISSION AND TRANSFER CASE XJ SPECIFICATIONS Continued...

Page 1596: ...A W 4 RETAINER AND PISTON SPECIFICA TIONS XJ TRANSMISSION AND TRANSFER CASE 21 273 SPECIFICATIONS Continued...

Page 1597: ...A W 4 VALVE BODY BALL DIMENSIONS A W 4 CLUTCH AND BRAKE PACK REQUIREMENTS 21 274 TRANSMISSION AND TRANSFER CASE XJ SPECIFICATIONS Continued...

Page 1598: ...A W 4 VALVE AND SPRING IDENTIFICA TION XJ TRANSMISSION AND TRANSFER CASE 21 275 SPECIFICATIONS Continued...

Page 1599: ...A W 4 ACCUMULA TOR COMPONENT IDENTIFICA TION 21 276 TRANSMISSION AND TRANSFER CASE XJ SPECIFICATIONS Continued...

Page 1600: ...A W 4 TORQUE SPECIFICA TIONS XJ TRANSMISSION AND TRANSFER CASE 21 277 SPECIFICATIONS Continued...

Page 1601: ...p Ring Plier C 3293 SP Gauge C 3339 Dial Indicator Set C 4959 Caliper Metric Vernier C 4960 Micrometer 7536 Puller Oil Pump 7538 Compressor Piston 2 Spring 7539 Compressor Piston 3 Spring 21 278 TRANS...

Page 1602: ...p 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 TRANSMISSION AND TRANSFER CASE 21 279 SP...

Page 1603: ...zer mechanism for shifting The geartrain is mounted in two aluminum case halves attached with bolts The mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case h...

Page 1604: ...case components binding worn or damaged 5 Repair or replace components as necessary Transfer case noisy in all drive modes 1 Insufficient or incorrect lubricant 1 Drain and refill transfer case with...

Page 1605: ...proper proce dures and specifications 9 Fill transfer case with correct fluid Check transmission fluid level Correct as necessary 10 Install rear crossmember or skid plate Tighten crossmember bolts to...

Page 1606: ...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 lubricat...

Page 1607: ...rior of case b Start seal in bore with light taps from ham mer Fig 7 Once seal is started continue tapping seal into bore until installer tool seats against case Fig 4 Speedometer Components Fig 5 Loc...

Page 1608: ...ear output bearing I D retaining ring Fig 11 8 Remove the bolts holding the rear retainer to the rear case half 9 Tap rear retainer with rawhide or rubber mal let to loosen sealer bead 10 Remove rear...

Page 1609: ...remove by hand remove it with bearing splitter or with stan dard two jaw puller Fig 16 Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged Fig 11 Output Shaft Rear...

Page 1610: ...pry tool blade only into notches provided at each end of case Fig 19 4 Remove rear case from front case 5 Remove oil pickup tube from rear case Fig 20 6 Remove mode fork spring Fig 21 7 Pull front out...

Page 1611: ...AINSHAFT DISASSEMBL Y 1 Remove mode hub retaining ring with heavy duty snap ring pliers Fig 28 2 Slide mode hub off mainshaft Fig 29 3 Slide drive sprocket off mainshaft Fig 30 INPUT GEAR AND LOW RANG...

Page 1612: ...retainer Fig 32 Fig 27 Sector Bushing And O Ring Removal Fig 28 Mode Hub Retaining Ring Removal Fig 29 Mode Hub Removal Fig 30 Drive Sprocket Removal Fig 31 Front Bearing Retainer Bolts Fig 32 Front...

Page 1613: ...range gear Fig 35 2 Remove retainer Fig 36 3 Remove front tabbed thrust washer Fig 37 4 Remove input gear Fig 38 5 Remove rear tabbed thrust washer from low range gear Fig 39 ASSEMBL Y Lubricate trans...

Page 1614: ...haft front bearing retaining ring Fig 44 Start ring into place by hand Then use small screwdriver to work ring into case groove Be sure ring is fully seated before proceeding 6 Install new front outpu...

Page 1615: ...Handle C 4171 drive input shaft bearing from inside the annulus gear opening in the case Fig 49 10 Install locating ring on new bearing 11 Position case so forward end is facing upward 12 Using Remove...

Page 1616: ...mmer Fig 51 14 Install new pilot bearing with Installer 5065 and Handle C 4171 Fig 52 15 Remove front bearing retainer seal with suit able pry tool Fig 48 Output Shaft Rear Bearing Installation Depth...

Page 1617: ...ligned in gear notches 3 Install input gear in low range gear Be sure input gear is fully seated 4 Install remaining thrust washer in low range gear and on top of input gear Be sure washer tabs are pr...

Page 1618: ...ommended transmission fluid 2 Slide drive sprocket onto mainshaft 3 Slide mode hub onto mainshaft 4 Install mode hub retaining ring Verify that the retaining ring is fully seated in mainshaft groove S...

Page 1619: ...goes through range fork and into case bore Also be sure sleeve is aligned and seated on mainshaft hub 10 Rotate sector to Neutral position 11 Install new O ring on detent plug Fig 67 12 Lubricate det...

Page 1620: ...ig 72 6 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to mounting flange of front case Work sealer bead around bolt holes 7 Lift rear case and oil pump and carefully p...

Page 1621: ...ltra Gray to mating surface of rear retainer Sealer bead should be a maximum of 3 16 inch 2 Install rear retainer on rear case Tighten retainer bolts to 20 27 N m 15 20 ft lbs torque Fig 70 Installing...

Page 1622: ...rs gears and shafts The oil pickup screen can be cleaned with solvent Shake excess solvent from the screen after cleaning and allow it to air dry Do not use compressed air MAINSHAFT SPROCKET HUB INSPE...

Page 1623: ...ck condition of the shift forks and mode fork shift rail Fig 82 Minor nicks on the shift rail can be smoothed with 320 400 grit emery cloth Inspect the shift fork wear pads Fig 83 The mode fork pads a...

Page 1624: ...hain 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...

Page 1625: ...Fig 84 Rear Retainer Components Fig 85 Seal Contact Surface Of Yoke Slinger Fig 86 Low Range Annulus Gear 21 302 TRANSMISSION AND TRANSFER CASE XJ CLEANING AND INSPECTION Continued...

Page 1626: ...ONS TORQUE DESCRIPTION TORQUE Plug Detent 16 24 N m 12 18 ft lbs Plug Drain Fill 20 34 N m 15 25 ft lbs Bolt Front Brg Retainer 21 N m 16 ft lbs Bolt Front Brg Retainer 21 N m 16 ft lbs Bolt Case Half...

Page 1627: ...ller Boot Clamp C 4975 A Installer Seal 8143 Handle Universal C 4171 Installer Seal C 4210 Installer Bearing 5064 Installer Bearing 5065 Installer Bushing 5066 21 304 TRANSMISSION AND TRANSFER CASE XJ...

Page 1628: ...Installer Bearing 8128 Remover L 4454 Cup 8148 Installer Seal 7884 Installer Pump Housing Seal 7888 XJ TRANSMISSION AND TRANSFER CASE 21 305 SPECIAL TOOLS Continued...

Page 1629: ...sprocket is engaged disengaged by the mode fork which oper ates the mode sleeve and hub The sleeve and hub are not equipped with a synchro mechanism for shift ing The geartrain is mounted in two alumi...

Page 1630: ...nding worn or damaged 3 Repair or replace components as necessary Transfer case noisy in all drive modes 1 Insufficient or incorrect lubricant 1 Drain and refill transfer case with the correct type an...

Page 1631: ...proper proce dures and specifications 9 Fill transfer case with correct fluid Check transmission fluid level Correct as necessary 10 Install rear crossmember or skid plate Tighten crossmember bolts to...

Page 1632: ...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 lubricat...

Page 1633: ...erior of case b Start seal in bore with light taps from ham mer Fig 8 Once seal is started continue tapping seal into bore until installer tool seats against case Fig 5 Speedometer Components Fig 6 Lo...

Page 1634: ...retainer Fig 12 Use pry tool or collapse seal with punch to remove it 5 Remove rear output bearing I D retaining ring Fig 13 6 Remove speedometer adapter 7 Remove rear retainer bolts 8 Remove rear ret...

Page 1635: ...e from front case Fig 18 Insert screwdrivers into slots cast into each end of case Then pry upward to break sealer bead and remove rear case CAUTION Do not pry on the sealing surface of either case ha...

Page 1636: ...n Fig 24 3 Remove front output shaft Fig 25 SHIFT FORKS AND MAINSHAFT REMOVAL AND DISASSEMBL Y 1 Remove shift detent plug spring and pin Fig 26 2 Remove seal plug from low range fork lockpin access ho...

Page 1637: ...g it straight up and out of fork Fig 27 5 Remove 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...

Page 1638: ...intermediate clutch shaft Fig 32 10 Remove differential snap ring Fig 33 Fig 27 Shift Rail Removal Fig 28 Mode Fork And Mainshaft Removal Fig 29 Mode Fork And Sleeve Removal Fig 30 Intermediate Clutc...

Page 1639: ...t sector slot Fig 35 14 Remove low range fork and hub Fig 36 15 Remove shift sector Fig 37 16 Remove shift sector bushing and O ring Fig 38 Fig 31 Clutch Shaft Thrust Ring Removal Fig 32 Intermediate...

Page 1640: ...ve low range gear snap ring Fig 42 6 Remove input gear retainer thrust washers and input gear from low range gear Fig 43 7 Inspect low range annulus gear Fig 44 Gear is not a serviceable component If...

Page 1641: ...emove thrust washers and planet gears from case pins Fig 46 6 Remove mainshaft and sprocket gears from bottom case Fig 47 Note gear position for reference before separating them Fig 39 Front Bearing R...

Page 1642: ...er and brass punch to tap bearing out of case 2 Install new front output shaft front bearing with Tool Handle C 4171 and Installer 8033A with the tapered cone upward Fig 49 3 Install front bearing sna...

Page 1643: ...rt ing a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 54 10 Install new pilot bearing with Installer 8128 and Handle C 4171 F...

Page 1644: ...171 and Installer 5066 Fig 58 Lubricate bearing after installation 14 Install new seal in oil pump feed housing with Special Tool 7888 Fig 59 15 Install new pickup tube O ring in oil pump Fig 60 Fig 5...

Page 1645: ...ig 62 5 Align and position differential top case on bot tom case Fig 63 Align using scribe marks made at disassembly 6 While holding differential case halves together invert the differential and start...

Page 1646: ...O Ring Installation Fig 61 Installing Differential Sprocket Gear Fig 62 Installing Mainshaft And Planet Gears Fig 63 Differential Case Assembly XJ TRANSMISSION AND TRANSFER CASE 21 323 DISASSEMBLY AND...

Page 1647: ...f front bearing retainer 8 Install front bearing retainer Fig 67 Tighten retainer bolts to 16 ft lbs 21 N m torque SHIFT FORKS AND MAINSHAFT INSTALLA TION 1 Install new sector shaft O ring and bushing...

Page 1648: ...ld them in place 8 Install remaining bearing spacer on mainshaft Fig 71 Do not displace any bearings while install ing spacer Fig 68 Sector O Ring And Bushing Installation Fig 69 Assembling Low Range...

Page 1649: ...ed Also check springs and slider bracket Fig 77 Replace worn damaged components 15 Install mode sleeve in mode fork Fig 78 Then install assembled sleeve and fork on mainshaft Be sure mode sleeve splin...

Page 1650: ...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...

Page 1651: ...rear case Fig 85 Be sure screen is seated in case slot as shown 2 Install magnet in front case pocket Fig 86 3 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to seal su...

Page 1652: ...with snap ring pliers Fig 88 Be sure retaining ring is fully seated in retainer groove 4 Apply bead of Mopar Sealer P N 82300234 or Loctite Ultra Gray to mating surface of rear Fig 84 Drive Sprocket S...

Page 1653: ...ND INSPECTION NV242 TRANSFER CASE Clean the transfer case parts with a standard parts cleaning solvent Remove all traces of sealer from the cases and retainers with a scraper and all purpose cleaner U...

Page 1654: ...s or wear in the bearing bore Clean the retainer sealing surfaces with a scraper and all pur pose cleaner This will ensure proper adhesion of the sealer during reassembly Replace the slinger and seal...

Page 1655: ...ase If the gear is damaged it will be necessary to replace the gear and front case as an assembly Do not attempt to remove the gear Fig 96 FRONT REAR CASES AND FRONT RETAINER Inspect the cases and ret...

Page 1656: ...OIL PICKUP Examine the oil pump pickup parts Replace the pump if any part appears to be worn or damaged Do not disassemble the pump as individual parts are not available The pump is only available as...

Page 1657: ...6 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 ft lbs Bolt Rear Retainer 35 46 N m 26 34 ft lbs Nuts Mounting 35 N m 26 ft...

Page 1658: ...ler 8128 Installer 5066 Installer 6952 A Remover L 4454 Cup 8148 Seal Protector 6992 Installer Input Gear Bearing 7829 A Installer Seal 7884 XJ TRANSMISSION AND TRANSFER CASE 21 335 SPECIAL TOOLS Cont...

Page 1659: ...Installer Pump Housing Seal 7888 Installer Bearing 8033 A Installer Boot Clamp C 4975 A 21 336 TRANSMISSION AND TRANSFER CASE XJ SPECIAL TOOLS Continued...

Page 1660: ...PATTERN 2 TRANSMISSION SWITCH AND PLUG LOCATIONS 2 DIAGNOSIS AND TESTING HARD SHIFTING 3 LOW LUBRICANT LEVEL 3 TRANSMISSION NOISE 3 REMOVAL AND INSTALLATION TRANSMISSION 3 SPECIFICATIONS TORQUE 6 GEN...

Page 1661: ...must be moved through the Neutral detent before making a shift to reverse TRANSMISSION LUBRICANT Recommended lubricant for AX 15 transmissions is Mopar 75W 90 API Grade GL 3 gear lubricant or equivale...

Page 1662: ...age incorrect clutch adjustment or by a damaged clutch pressure plate or disc Substantial lubricant leaks can result in gear shift rail synchro and bearing damage If a leak goes undetected for an exte...

Page 1663: ...transmission with safety chains 2 Install the transmission to the vehicle Fig 10 3 Install the two 2 lower transmission bolts Tighten the bolts to 74 6 N m 4 Install the clutch slave cylinder to the c...

Page 1664: ...the front and rear propeller shafts 15 Install the exhaust pipe and heat shield 16 Remove the transmission jack 17 Fill the transmission with the proper fluid Fig 12 18 Remove the adjustable jackstan...

Page 1665: ...p 2 Bolts 36 6 N m 27 ft lbs Clutch Housing to Engine Mid Point 2 Bolts 58 3 N m 43 ft lbs Clutch Housing to Engine Bottom 2 Bolts 74 6 N m 55 ft lbs Clutch Housing to Transmission bolts 38 0 N m 28 f...

Page 1666: ...ting ranges are 2WD 2 wheel drive 4x4 4 wheel drive 4 Lo 4 wheel drive low range The 2WD range is for use on any road surface at any time The 4x4 and 4 Lo ranges are for off road use only They are not...

Page 1667: ...refill transfer case with the correct type and quantity of lubricant Transfer case noisy while in or jumps out of 4L mode 1 Transfer case not completely engaged in 4L position 1 Slow vehicle shift tr...

Page 1668: ...hten shaft attaching bolts to 26 5 N m torque 9 Fill transfer case with correct fluid Refer to Recommended Lubricant And Fill Level section for proper fluid and capacity 10 Install rear crossmember an...

Page 1669: ...urface in housing Surfaces must be clean for proper adapter alignment and speedometer oper ation 2 Install new O rings on speed sensor and speed ometer adapter Fig 4 if necessary 3 Lubricate sensor an...

Page 1670: ...output seal in front case with Installer Tool 8143 as follows a Place new seal on tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps from ham mer Fig 7 Once...

Page 1671: ...r C 3995 A install seal in rear retainer Fig 10 5 Install propeller shaft 6 Verify proper fluid level 7 Lower vehicle SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug Drain Fill 40 N m Nuts Mounting 35 N...

Page 1672: ...s 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 applicatio...

Page 1673: ...designed for emer gency use only The original tire should be repaired or replaced at the first opportunity and reinstall Do not exceed speeds of 50 MPH Refer to Owner s Man ual for complete details TI...

Page 1674: ...ion Rolling resistance Speed capability It is recommend that tires equivalent to the origi nal equipment tires be used when replacement is needed Failure to use equivalent replacement tires may advers...

Page 1675: ...y 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 side...

Page 1676: ...ly be made if the defect or puncture is in the tread area Fig 11 The tire should be replaced if the puncture is located in the sidewall Deflate tire completely before removing the tire from the wheel...

Page 1677: ...let it soak for a few minutes Then scrub the coating away with a soft bristle brush Steam cleaning may also be used to remove the coating NOTE DO NOT use gasoline mineral oil oil based solvent or wir...

Page 1678: ...cement 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 an...

Page 1679: ...dynamic balance machine 2 Check wheel radial runout Fig 3 and lateral runout Fig 4 STEEL WHEELS Radial runout 0 040 in Lat eral runout 0 045 in maximum ALUMINUM WHEELS Radial runout 0 030 in Lateral...

Page 1680: ...that a two plane service dynamic balancer be used when a tire and wheel assembly require balancing Refer to balancer opera tion instructions for proper cone mounting proce dures Typically use front co...

Page 1681: ...IONS TORQUE CHART DESCRIPTION TORQUE Lug Nut 1 2 X 20 with 60 Cone 115 150 N m 85 115 ft lbs Fig 6 Static Unbalance Balance Fig 7 Dynamic Unbalance Balance 22 10 TIRES AND WHEELS XJ SERVICE PROCEDURES...

Page 1682: ...asive chemicals or compounds on painted surfaces Damage to finish can result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result...

Page 1683: ...ned automotive paint technician CAUTION Do not remove clear coat finish if equipped Base coat paint must retain clear coat for durability PAINTED SURFACE TOUCH UP When a painted metal surface has been...

Page 1684: ...B9884 56153 CHA99 WTD KGC7B Deep Amethyst Pearl Coat TCN 5246 B9736 52026 CHA97 TCN FNE4B Black Clear Coat DX8 9700 99 34858 CHA85 DX8 TC60B Gunmetal Pearl Coat TQ7 5248 B9735 52952 CHA97 TQ7 ERA9B St...

Page 1685: ...UTION 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 It...

Page 1686: ...ION Avoid spilling or dripping primer on painted surfaces Clean spills or drips immediately The primer will damage the paint if it remains on the surface for any length of time 10 If the replacement w...

Page 1687: ...e w ill not adhere to all color coat paints Allow primer sufficient time to dry NOTE The reveal molding has an adhesive applied to the windshield contact surface to help secure the molding to the wind...

Page 1688: ...ead should be 9 mm 3 8 in wide by 12 7 mm 1 2 in deep for best results CAUTION Be prepared to install the glass immedi ately after applying the adhesive as the adhesive will begin to cure in less than...

Page 1689: ...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 solut...

Page 1690: ...sing a grease pencil or equivalent make ref erences marks on the glass and body 6 Remove replacement glass from liftgate open ing 7 Position the glass inside up on a suitable work surface WARNING DO N...

Page 1691: ...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...

Page 1692: ...aching the bezel and adjuster bar to the head restraint 4 Install head restraint in the bucket seat BUCKET SEA T REMOVAL 1 Remove bolts attaching seat to floor pan Fig 7 2 Remove nut attaching seat to...

Page 1693: ...seat platforms are not repairable If the seat platform is damaged replace platform as a unit BUCKET SEA TBACK COVER REMOVAL 1 Remove head restraint if equipped 2 Remove screws attaching side shield t...

Page 1694: ...the for ward rearward and inboard J straps 5 Disengage the clips attaching the outboard side of the cover to the cushion frame 6 Turn the cushion over and roll the cover off the cushion 7 Remove the...

Page 1695: ...ushion frames Fig 13 3 Roll seatback cover downward 4 Engage seatback cover zipper 5 Install side shield trim cover REAR SEA T CUSHION REMOVAL 1 Disengage seat cushion at rear by pulling upward on rel...

Page 1696: ...of the cushion until the latch engages REAR SEA T CUSHION COVER REMOVAL 1 Remove the seat cushion from the vehicle 2 Remove the cover side front and rear retaining clips from the wire retainers with a...

Page 1697: ...release handle and bezel from the seatback 3 Disengage the cover zippers 4 Disengage the J strap attaching the cover to the seat back frame Fig 19 5 Remove the cover from the seatback pad INSTALLA TIO...

Page 1698: ...T BUCKLE 48 FRONT WHEELHOUSE LINER 27 FULL FLOOR CONSOLE 50 GRILLE 20 GRILLE OPENING PANEL GOP 20 HEADLINER 52 HOOD 20 HOOD HINGE 20 HOOD LATCH 22 HOOD LATCH STRIKER 22 HOOD RELEASE CABLE 22 HOOD SAFE...

Page 1699: ...ate the 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 s...

Page 1700: ...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 bo...

Page 1701: ...Tighten nuts to 4 N m 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...

Page 1702: ...Fig 3 Hood Components XJ BODY 23 21 REMOVAL AND INSTALLATION Continued...

Page 1703: ...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 striker to the GOP 7 Remove...

Page 1704: ...r hood panel 3 Close hood SAFETY LA TCH STRIKER REMOVAL 1 Remove striker screws from radiator support crossmember Fig 8 2 Remove striker from crossmember INSTALLA TION 1 Position striker on radiator s...

Page 1705: ...cowl grille and screen from the cowl Fig 11 INSTALLA TION 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...

Page 1706: ...o not use soap NOTE Too much detergent will reduce the effec tiveness of the mixture 5 Use a clean sponge and apply the wetting solu tion to the adhesive side of the decal and to the painted panel sur...

Page 1707: ...r speaker grille to the door inner panel 3 remove push in fastener attaching trim cover to door inner panel use special tool C 4829 4 Disconnect the power mirror wire connector if equipped 5 Remove th...

Page 1708: ...rness connectors 11 Remove the air deflector 12 Remove the fender lower screws Fig 19 13 Remove the fender top front and the rear screws 14 Remove the screws attaching the fender to the inner support...

Page 1709: ...to the door inner panel Fig 22 and Fig 23 4 Separate the trim panel fasteners from door inner panel with a pry tool use special tool C 4829 Fig 24 5 Lift the trim panel up and outward to separate from...

Page 1710: ...alent 1 Remove door trim panel 2 Disengage clips attaching wire harnesses to the door inner panel 3 Push the harnesses connectors through the waterdam and into the door 4 Grasp the upper and lower rea...

Page 1711: ...orque 3 Install door restraint check pin 4 If applicable route and connect wire harness connectors 5 Install door waterdam and trim panel FRONT DOOR HINGE REMOVAL 1 Remove door restraint check retaini...

Page 1712: ...OOR LOCK CYLINDER REMOVAL 1 Remove the door trim panel 2 Peel back waterdam to access lock cylinder 3 Disconnect the door latch to lock cylinder rod at the door latch Fig 30 4 Remove the lock cylinder...

Page 1713: ...le from the trim panel INSTALLA TION 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 FRONT DOOR INNER BELT WEA THERSTRIP R...

Page 1714: ...el FRONT DOOR OPENING WEA THERSTRIP REMOVAL 1 Remove A pillar trim panel 2 Remove B pillar upper trim panel 3 Remove cowl side trim panel 4 Remove inner scuff plate 5 Remove B pillar lower trim panel...

Page 1715: ...glass 4 Loosen the bolts attaching the regulator to the inner door panel Fig 37 and Fig 38 as applicable 5 Lift the regulator upward to release it from the key hole slots and remove it through the acc...

Page 1716: ...e glass to the regulator 5 Remove the bolts attaching the glass to the regulator Fig 42 6 Lift the glass upward and out of the door INSTALLA TION 1 Position the glass in the door 2 Install the bolts a...

Page 1717: ...cial tool C 4829 Fig 46 5 Lift the trim panel up and outward to separate from the inner belt seal 6 Move the door trim panel outward and discon nect the handle to latch rods Fig 47 7 Disconnect the po...

Page 1718: ...e as necessary and press into place 3 Install door trim panel REAR DOOR REMOVAL 1 Remove door restraint check retaining pin 2 For vehicles equipped with power windows and power door locks remove trim...

Page 1719: ...nel 2 Roll the window to the full up position 3 Peel back the waterdam to access the fasteners for the outside handle 4 Remove the latch 5 Remove the access hole cover 6 Remove the nuts attaching the...

Page 1720: ...rim panel 3 Separate the inside handle from the trim panel INSTALLA TION 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 R...

Page 1721: ...late 3 Remove B pillar lower trim 4 Remove upper door opening trim 5 Grasp seal and separate from door opening Fig 56 INSTALLA TION 1 When installing a door opening weatherstrip seal start at the door...

Page 1722: ...Remove inner and outer beltline weatherstrip 5 Remove the window weatherstrip from the door 6 Remove the division bar stationary glass Fig 60 7 Remove the window glass screw bushing and retainer from...

Page 1723: ...the fender flare retainer to the wheelhouse liner Fig 62 3 Separate the fender flare and retainer from the fender INSTALLA TION 1 Position the fender flare and retainer on the fender 2 Install the nu...

Page 1724: ...erly 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...

Page 1725: ...to the A pillar 3 Install the trim plugs 4 Install the lower A pillar cowl trim 5 Install the inner scuff plate 6 Install the assist handles LOWER A PILLAR COWL TRIM REMOVAL 1 Remove the inner scuff...

Page 1726: ...e screws 3 Install the covers B PILLAR TRIM REMOVAL 1 Remove the inner scuff plate 2 Remove the upper door opening trim 4 door vehicles Fig 69 3 Remove the upper quarter panel trim 2 door vehicles Fig...

Page 1727: ...scuff plate QUARTER PANEL TRIM AND WHEELHOUSE COVER REMOVAL 1 Remove the inner scuff plate 2 Remove quarter panel trim extension 3 Remove liftgate scuff plate 4 Remove the screws attaching the quarte...

Page 1728: ...tgate pillar trim on the liftgate pillar 2 Press the trim panel into place to engage the spring steel clips attaching the trim panel to the pil lar 2 dr vehicles 3 Install the screws attaching the low...

Page 1729: ...r 3 Remove the anchor bolt cover 4 Remove the anchor bolt attaching the buckle to the seat 5 Remove the turning loop cover concealing the shoulder belt upper anchor bolt 6 Use a Torx bit to remove the...

Page 1730: ...buckle anchor plate bolts from floor pan Fig 77 3 Remove shoulder belt lower outer anchor bolt 4 Remove quarter trim panel If necessary refer to removal procedure 5 Remove shoulder belt upper anchor b...

Page 1731: ...tall the screws attaching the console to the mounting bracket 5 Install the shift indicator bezels or cover plate 6 Install the shift lever handle knob FRONT CARPET MA T REMOVAL 1 Remove the door sill...

Page 1732: ...face on the bracket according to the following instructions Crush the vial to saturate the felt applicator Remove the paper sleeve Apply accelerator to the contact surface on the bracket Allow the acc...

Page 1733: ...must be removed from the perimeter of the headliner along with as applicable Assist handles Sunvisors Dome cargo lamps Overhead console All other attached overlapping components Refer to the appropri...

Page 1734: ...o the liftgate 4 Using a trim panel removal tool detach the push in fasteners from the liftgate 5 Remove the trim panel from the liftgate INSTALLA TION 1 Position the trim panel on liftgate 2 Using ne...

Page 1735: ...to liftgate 5 Unplug and connect backlite washer fluid sup ply line 6 Install liftgate trim panel 7 Remove supports and close liftgate 8 Install CHMSL LIFTGA TE HINGE REMOVAL It is not necessary to re...

Page 1736: ...d 4 Remove nut attaching outside handle to liftgate Fig 91 5 Separate outside handle from liftgate 6 If necessary remove lock cylinder Fig 92 INSTALLA TION 1 If necessary install lock cylinder 2 Posit...

Page 1737: ...stall the seal in a clockwise direction 2 Move to the left and mate the seal with the bottom left flange Fig 95 3 Move upward and mate the seal with the left side flange 4 Move to the right and mate t...

Page 1738: ...OR ADJUSTMENT 1 Loosen the latch striker 2 Tap the latch striker downward if the door character line is higher than the body character line or tap the latch striker upward if the door character line i...

Page 1739: ...e the latch into the strikers 8 Verify latch operation SPECIFICATIONS BODY LUBRICANTS COMPONENT SERVICE INTERVAL LUBRICANT Door Latches As Required Multi Purpose Grease NLGI GC LB Water Resistant 1 Ho...

Page 1740: ...WELD LOCA TIONS UPPER COWL XJ BODY 23 59 SPECIFICATIONS Continued...

Page 1741: ...UPPER COWL 23 60 BODY XJ SPECIFICATIONS Continued...

Page 1742: ...COWL XJ BODY 23 61 SPECIFICATIONS Continued...

Page 1743: ...A PILLAR 23 62 BODY XJ SPECIFICATIONS Continued...

Page 1744: ...A PILLAR XJ BODY 23 63 SPECIFICATIONS Continued...

Page 1745: ...A PILLAR 23 64 BODY XJ SPECIFICATIONS Continued...

Page 1746: ...A PILLAR XJ BODY 23 65 SPECIFICATIONS Continued...

Page 1747: ...B PILLAR 23 66 BODY XJ SPECIFICATIONS Continued...

Page 1748: ...D PILLAR XJ BODY 23 67 SPECIFICATIONS Continued...

Page 1749: ...FUEL FILLER OPENING 23 68 BODY XJ SPECIFICATIONS Continued...

Page 1750: ...CARGO AREA FLOOR PAN XJ BODY 23 69 SPECIFICATIONS Continued...

Page 1751: ...ROOF AND D PILLAR 23 70 BODY XJ SPECIFICATIONS Continued...

Page 1752: ...LIFTGA TE OPENING XJ BODY 23 71 SPECIFICATIONS Continued...

Page 1753: ...ROOF 23 72 BODY XJ SPECIFICATIONS Continued...

Page 1754: ...ROOF XJ BODY 23 73 SPECIFICATIONS Continued...

Page 1755: ...FRAME RAIL 23 74 BODY XJ SPECIFICATIONS Continued...

Page 1756: ...FRAME RAIL XJ BODY 23 75 SPECIFICATIONS Continued...

Page 1757: ...FRAME RAIL 23 76 BODY XJ SPECIFICATIONS Continued...

Page 1758: ...FRAME RAIL XJ BODY 23 77 SPECIFICATIONS Continued...

Page 1759: ...REINFORCEMENT 23 78 BODY XJ SPECIFICATIONS Continued...

Page 1760: ...FRONT INNER FENDER XJ BODY 23 79 SPECIFICATIONS Continued...

Page 1761: ...FRONT INNER FENDER AND RADIA TOR CLOSURE PANEL 23 80 BODY XJ SPECIFICATIONS Continued...

Page 1762: ...REINFORCEMENT FRONT FENDER XJ BODY 23 81 SPECIFICATIONS Continued...

Page 1763: ...BODY SIDE 23 82 BODY XJ SPECIFICATIONS Continued...

Page 1764: ...REAR WHEELHOUSE XJ BODY 23 83 SPECIFICATIONS Continued...

Page 1765: ...REAR INNER WHEELHOUSE 23 84 BODY XJ SPECIFICATIONS Continued...

Page 1766: ...BODY SIDE XJ BODY 23 85 SPECIFICATIONS Continued...

Page 1767: ...BODY SIDE 23 86 BODY XJ SPECIFICATIONS Continued...

Page 1768: ...BODY SIDE XJ BODY 23 87 SPECIFICATIONS Continued...

Page 1769: ...BODY SIDE 23 88 BODY XJ SPECIFICATIONS Continued...

Page 1770: ...BODY SIDE XJ BODY 23 89 SPECIFICATIONS Continued...

Page 1771: ...BODY SIDE 23 90 BODY XJ SPECIFICATIONS Continued...

Page 1772: ...UNDERBODY XJ BODY 23 91 SPECIFICATIONS Continued...

Page 1773: ...UNDERBODY 23 92 BODY XJ SPECIFICATIONS Continued...

Page 1774: ...UNDERBODY XJ BODY 23 93 SPECIFICATIONS Continued...

Page 1775: ...UNDERBODY 23 94 BODY XJ SPECIFICATIONS Continued...

Page 1776: ...UNDERBODY XJ BODY 23 95 SPECIFICATIONS Continued...

Page 1777: ...UNDERBODY 23 96 BODY XJ SPECIFICATIONS Continued...

Page 1778: ...UNDERBODY XJ BODY 23 97 SPECIFICATIONS Continued...

Page 1779: ...UNDERBODY 23 98 BODY XJ SPECIFICATIONS Continued...

Page 1780: ...UNDERBODY XJ BODY 23 99 SPECIFICATIONS Continued...

Page 1781: ...UNDERBODY 23 100 BODY XJ SPECIFICATIONS Continued...

Page 1782: ...UNDERBODY XJ BODY 23 101 SPECIFICATIONS Continued...

Page 1783: ...BODY SEALING LOCA TIONS APPLICA TION METHODS 23 102 BODY XJ SPECIFICATIONS Continued...

Page 1784: ...COWL AND DASH PANEL XJ BODY 23 103 SPECIFICATIONS Continued...

Page 1785: ...DASH PANEL AND FLOOR PAN 23 104 BODY XJ SPECIFICATIONS Continued...

Page 1786: ...FLOOR PAN XJ BODY 23 105 SPECIFICATIONS Continued...

Page 1787: ...REAR INNER WHEELHOUSE 23 106 BODY XJ SPECIFICATIONS Continued...

Page 1788: ...FRONT INNER WHEELHOUSE XJ BODY 23 107 SPECIFICATIONS Continued...

Page 1789: ...BODY SIDE 23 108 BODY XJ SPECIFICATIONS Continued...

Page 1790: ...BODY SIDE XJ BODY 23 109 SPECIFICATIONS Continued...

Page 1791: ...BODY SIDE 23 110 BODY XJ SPECIFICATIONS Continued...

Page 1792: ...ROOF PANEL XJ BODY 23 111 SPECIFICATIONS Continued...

Page 1793: ...FUEL FILLER HOUSING 23 112 BODY XJ SPECIFICATIONS Continued...

Page 1794: ...LIFTGA TE OPENING XJ BODY 23 113 SPECIFICATIONS Continued...

Page 1795: ...STRUCTURAL ADHESIVE LOCA TIONS LEFT QUARTER PANEL 23 114 BODY XJ SPECIFICATIONS Continued...

Page 1796: ...REAR WHEELHOUSE XJ BODY 23 115 SPECIFICATIONS Continued...

Page 1797: ...ROOF BOWS 23 116 BODY XJ SPECIFICATIONS Continued...

Page 1798: ...BODY GAP AND FLUSH MEASUREMENTS XJ BODY 23 117 SPECIFICATIONS Continued...

Page 1799: ...BODY OPENING DIMENSIONS WINDSHIELD OPENING A B Center of radius at bottom to center of radius at top 23 118 BODY XJ SPECIFICATIONS Continued...

Page 1800: ...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...

Page 1801: ...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...

Page 1802: ...ody 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 stri...

Page 1803: ...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...

Page 1804: ...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...

Page 1805: ...ENGINE COMPARTMENT 23 124 BODY XJ SPECIFICATIONS Continued...

Page 1806: ...or Bolt 43 N m 32 ft lbs Front Retractor Anchor Bolt 43 N m 32 ft lbs Front Seat Belt Buckle Anchor Bolt 43 N m 32 ft lbs GOP to Support Bracket Nut 4 N m 38 in lbs GOP to Fender Nut 4 N m 38 in lbs L...

Page 1807: ...SPECIAL TOOLS BODY Remover Moldings C 4829 23 126 BODY XJ...

Page 1808: ...ELAY 14 BLOWER MOTOR RESISTOR 15 BLOWER MOTOR SWITCH 15 COMPRESSOR 16 COMPRESSOR CLUTCH COIL 16 COMPRESSOR CLUTCH RELAY 17 HEATER PERFORMANCE 17 HIGH PRESSURE CUT OFF SWITCH 18 LOW PRESSURE CYCLING CL...

Page 1809: ...r the housing with the fresh air Excess debris as well as objectionable odors created by decaying plant matter and growing fungi can be dis charged into the passenger compartment during heater A C sys...

Page 1810: ...y type temperature control knob a rotary type mode control switch knob and a rotary type blower motor speed switch knob The heater only or heater A C control panel cannot be repaired If faulty or dama...

Page 1811: ...f 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...

Page 1812: ...inlet tube Any liquid oil laden refrigerant falls to the bottom of the canister which acts as a separator A desiccant bag is mounted inside the accumulator canister to absorb any moisture which may h...

Page 1813: ...c 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 The compresso...

Page 1814: ...o that all air that enters the housing must pass over the fins of the evaporator before it is distributed through the system ducts and outlets However air passing over the evaporator coil fins will on...

Page 1815: ...The majority of the refrigerant is con served in the system If the valve vents refrigerant it does not mean that the valve is faulty The high pressure relief valve is a factory cali brated unit The v...

Page 1816: ...tegrity of the refrigerant system The refrigerant lines and hoses cannot be repaired and if faulty or damaged they must be replaced REFRIGERANT LINE COUPLER Spring lock type refrigerant line couplers...

Page 1817: ...re hose Red with Black stripe attaches to the discharge service port This port is located on the discharge line between the compressor and the condenser inlet RECOVERY RECYCLING EVACUA TION CHARGING H...

Page 1818: ...e moisture in the air trans fers heat energy into the evaporator fins and tubing This reduces the amount of heat the evaporator can absorb from the air High humidity greatly reduces the ability of the...

Page 1819: ...Equal pressures but the compressor clutch does not engage 1 No refrigerant in the refrigerant system 2 Faulty fuse 3 Faulty compressor clutch coil 4 Faulty compressor clutch relay 5 Improperly install...

Page 1820: ...lace the compressor if required The low side pressure is normal or slightly high and the high side pressure is too high 1 Condenser air flow restricted 2 Inoperative cooling fan 3 Refrigerant system o...

Page 1821: ...aulty blower motor switch Faulty blower motor resistor Faulty blower motor circuit wiring or wire har ness connectors VIBRA TION Possible causes of blower motor vibration include Improper blower motor...

Page 1822: ...ctromagnet coil There should be con tinuity between the connector cavity for relay termi nal 85 and a good ground at all times If not OK repair the open circuit as required BLOWER MOTOR RESISTOR For c...

Page 1823: ...group for the procedures 3 To duplicate a high ambient temperature condi tion high head pressure restrict the air flow through the condenser Install a manifold gauge set to be certain that the dischar...

Page 1824: ...OK go to Step 2 If not OK repair the open circuit to the fuse in the PDC as required 2 The relay normally closed terminal 87A is not used in this application Go to Step 3 3 The relay normally open te...

Page 1825: ...r from the switch on the refrigerant system fitting 3 Check for continuity between the two terminals of the high pressure cut off switch There should be conti nuity If OK test and repair the A C switc...

Page 1826: ...recirculation mode SYSTEM LOW 1 Position the vehicle in a wind free work area This will aid in detecting small leaks 2 Bring the refrigerant system up to operating temperature and pressure This is do...

Page 1827: ...OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect the vacuum harness connector behind the glove box and inboar...

Page 1828: ...Fig 12 Vacuum Circuits Heater Only XJ HEA TING AND AIR CONDITIONING 24 21 DIAGNOSIS AND TESTING Continued...

Page 1829: ...Fig 13 Vacuum Circuits Heater A C 24 22 HEA TING AND AIR CONDITIONING XJ DIAGNOSIS AND TESTING Continued...

Page 1830: ...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 refrigerant See Refrigerant System Charge in the Service Procedures section...

Page 1831: ...r of the slotted hole in the support bracket on the dash panel 8 Remove the accumulator from the vehicle INSTALLA TION 1 Install the accumulator and retaining band as a unit by sliding the screw in th...

Page 1832: ...ed 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 screw and disconnecting the accumulator inlet...

Page 1833: ...firmly into place 6 Roll the glove box back up into the instrument panel Refer to Glove Box in Group 8E Instrument Panel Systems for the procedures 7 Connect the battery negative cable 8 Test the rela...

Page 1834: ...t 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 of the opened refrigerant line fittings Install the suction and discharge li...

Page 1835: ...evious 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 tig...

Page 1836: ...INSTALLA TION 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 rot...

Page 1837: ...ning removal procedures to complete the installation CLUTCH BREAK IN After a new compressor clutch has been installed cycle the compressor clutch approximately twenty times five seconds on then five s...

Page 1838: ...ALLA TION 1 Install the holes of the condenser lower brack ets over the dowel pins on the bottom of the radiator 2 Slide the condenser upwards until both of the condenser studs are installed through t...

Page 1839: ...Fig 33 3 Remove the three screws that secure the defrost duct demister adapter to the instrument panel 4 Remove the defrost duct demister adapter from the instrument panel 5 Reverse the removal proce...

Page 1840: ...rocedures to install Tighten the mounting screws to 2 2 N m 20 in lbs EVAPORA TOR COIL WARNING ON VEHICLES EQUIPPED WITH AIR BAGS REFER TO GROUP 8M PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEE...

Page 1841: ...ontrol half of the vacuum harness around any obstacles while pulling the heater A C control out from the front of the instrument panel INSTALLA TION 1 Plug the wire harness connectors into the back of...

Page 1842: ...ter A C unit wire harness con nector which is fastened to the heater A C housing next to the blower motor relay Fig 39 10 Remove the five nuts from the heater A C housing mounting studs on the engine...

Page 1843: ...r coil tube mounting flange of the heater A C housing 5 Insert the vacuum supply line and connector through the foam seal on the heater core and evapo rator coil tube mounting flange of the heater A C...

Page 1844: ...isassemble the heater A C hous ing See Heater A C Housing in this group for the procedures NOTE If the temperature control cable was not removed with the blend air door lever as a unit dur ing the ins...

Page 1845: ...heater A C housing See Mode Door Vac uum Actuator in this group for the procedures 3 Insert a screwdriver into the latch hole Fig 44 of the floor door pivot shaft to release the latch of the floor do...

Page 1846: ...ve the high pressure cut off switch from the vehicle 5 Remove the O ring seal from the discharge line fitting and discard INSTALLA TION 1 Lubricate a new O ring seal with clean refrig erant oil and in...

Page 1847: ...t refrigerant line couplers See Refrigerant Line Coupler in this group for the procedures 2 Connect the battery negative cable 3 Evacuate the refrigerant system See Refriger ant System Evacuate in thi...

Page 1848: ...r kick cover mounting tabs under the heads of the two loosened heater A C housing screws Tighten the screws to 2 2 N m 20 in lbs 2 Install the two screws that secure the lower kick cover to the heater...

Page 1849: ...l procedures to install PANEL DEMIST DOOR ACTUA TOR 1 Remove the defrost door actuator from the heater A C housing See Defrost Door Actuator in this group for the procedures 2 Unplug the vacuum harnes...

Page 1850: ...ed while pushing it into the coupler cage opening 6 Open and remove the A C line disconnect tool from the disconnected spring lock coupler 7 Complete the separation of the two halves of the coupler fi...

Page 1851: ...e 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...

Page 1852: ...ve the passenger side bumper end cap from the front bumper Refer to Group 23 Body for the procedures 2 Unplug the vacuum supply line connector from the vacuum reservoir Fig 59 3 Remove the two screws...

Page 1853: ......

Page 1854: ...R 19 BLOWER MOTOR SWITCH 19 COMPRESSOR 20 COMPRESSOR CLUTCH COIL 20 COMPRESSOR CLUTCH RELAY 21 HEATER PERFORMANCE 14 HIGH PRESSURE CUT OFF SWITCH 21 LOW PRESSURE CYCLING CLUTCH SWITCH 21 REFRIGERANT S...

Page 1855: ...e control switches use engine vacuum to control the mode doors which are operated by vacuum actuator motors On air conditioned vehicles the outside air intake can be shut off by selecting the Recircul...

Page 1856: ...an cause noise and system failure Recover the refrigerant before opening any fit ting or connection Open the fittings with caution even after the system has been discharged Never open or loosen a conn...

Page 1857: ...loosened tighten the fitting and recover the refrigerant from the system again Do not discharge refrigerant into the atmosphere Use an R 134a refrigerant recovery recycling device that meets SAE Stan...

Page 1858: ...ing the blower motor resistor The blower motor resistor cannot be repaired and if faulty or damaged it must be replaced BLOWER MOTOR SWITCH The heater only or heater A C blower motor is con trolled by...

Page 1859: ...up for more information The compressor clutch relay is located in the Power Distribution Center PDC in the engine compart ment Refer to the PDC label for relay identification and location The compress...

Page 1860: ...CH The high pressure cut off switch is located on the discharge line between the compressor and the con denser inlet The switch is screwed onto a fitting that contains a Schrader type valve which allo...

Page 1861: ...are also labels posted in the engine compartment of the vehi cle and on the compressor identifying to service tech nicians that the air conditioning system is equipped with R 134a REFRIGERANT LINE Th...

Page 1862: ...mineral oil and will absorb any moisture it comes into contact with even moisture in the air The PAG oil container should always be kept tightly capped until it is ready to be used After use recap the...

Page 1863: ...ice 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 as when the vehicle is climb...

Page 1864: ...ire 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 Performance Temper...

Page 1865: ...equired 6 See High Pressure Cut Off Switch in this group Test the high pressure cut off switch and replace if required 7 Refer to the proper Diagnostic Procedures manual for testing of the PCM Test th...

Page 1866: ...Test the cooling system and repair if required The low side pressure is too high and the high side pressure is too low 1 Accessory drive belt slipping 2 Fixed orifice tube not installed 3 Faulty compr...

Page 1867: ...CHANICAL PROBLEMSPossible locations or causes of insufficient heat An obstructed cowl air intake Obstructed heater system outlets A blend air door not functioning properly TEMPERA TURE CONTROL If the...

Page 1868: ...lug as lubricant will ruin the vacuum valve in the switch A drop of clean water in the connector plug holes will help the connector slide onto the switch ports LOCA TING VACUUM LEAKS WARNING ON VEHICL...

Page 1869: ...Fig 10 Vacuum Circuits Heater Only 24 16 HEA TING AND AIR CONDITIONING XJ DIAGNOSIS AND TESTING Continued...

Page 1870: ...Fig 11 Vacuum Circuits Heater A C XJ HEA TING AND AIR CONDITIONING 24 17 DIAGNOSIS AND TESTING Continued...

Page 1871: ...of blower motor vibration include Improper blower motor mounting Improper blower wheel mounting Blower wheel out of balance or bent Blower motor faulty NOISE To verify that the blower is the source o...

Page 1872: ...e the battery negative cable 2 Remove the kick cover from the heater A C housing and unplug the wire harness connector from the blower motor resistor 3 Check for continuity between each of the blower...

Page 1873: ...of this group for more information 5 If the noise is from opening and closing of the high pressure relief valve evacuate and recharge the refrigerant system See Refrigerant System Evacuate and Refrig...

Page 1874: ...s required 4 The relay coil battery terminal 86 is con nected to the fused ignition switch output run start circuit There should be battery voltage at the cavity for relay terminal 86 with the ignitio...

Page 1875: ...e the general location of a possible refrig erant leak However the exact leak location should be confirmed with an electronic leak detector prior to component repair or replacement To detect a leak in...

Page 1876: ...e injected into the system See Refrigerant Charge Capacity for the proper amount of the refrigerant charge A R 134a refrigerant recovery recycling charging station that meets SAE Standard J 2210 must...

Page 1877: ...ter 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...

Page 1878: ...limeters 3 inches from the exhaust manifold High pressures are produced in the refrigerant sys tem when the air conditioning compressor is operat ing Extreme care must be exercised to make sure that e...

Page 1879: ...ecures the suction line block fitting to the accumulator outlet Install plugs in or tape over all of the opened refrigerant line fit tings 6 Remove the screw that secures the suction and discharge lin...

Page 1880: ...OUP BEFORE PERFORMING THE FOLLOWING OPERATION REMOVAL 1 Recover the refrigerant from the refrigerant system See Refrigerant Recovery in this group for the procedures 2 Disconnect and isolate the batte...

Page 1881: ...e pro cedures 3 Install the serpentine drive belt Refer to Group 7 Cooling System for the procedures 4 Plug in the compressor clutch coil wire harness connector 5 Connect the battery negative cable 6...

Page 1882: ...ts Fig 22 4 Install the serpentine drive belt See Group 7 Cooling System for the procedure 5 Torque all H Block retaining bolts to 24 N m 18 ft lbs 6 Lower the vehicle from the hoist 7 Install the suc...

Page 1883: ...41 2 Fig 26 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 27 Turn the puller center bolt clockwise until the r...

Page 1884: ...e 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...

Page 1885: ...of refrigerant in the system A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose In addition the flexible hose refrigeran...

Page 1886: ...uid line and or liquid line jumper from the vehicle INSTALLA TION 1 Remove the tape or plugs from the opened refrigerant line fittings on the condenser outlet tube the liquid line the evaporator inlet...

Page 1887: ...OLLOWING OPERATION REMOVAL 1 Disconnect and isolate the battery negative cable 2 Recover the refrigerant from the refrigerant system See Refrigerant Recovery in this group for the procedures 3 Unplug...

Page 1888: ...le CONDENSER WARNING REVIEW THE WARNINGS AND CAU TIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION CAUTION Before removing the condenser note the location of each of the radia...

Page 1889: ...dures 8 Charge the refrigerant system See Refrigerant System Charge in this group for the procedures NOTE If the condenser is replaced add 30 millili ters 1 fluid ounce of refrigerant oil to the refri...

Page 1890: ...this group for the procedures 7 If the vehicle is equipped with air conditioning charge the refrigerant system See Refrigerant Sys tem Charge in this group for the procedures HEA TER A C CONTROL WARNI...

Page 1891: ...screws Tighten the screws to 2 2 N m 20 in lbs 8 Reinstall the center bezel onto the instrument panel Refer to Instrument Panel Center Bezel in Group 8E Instrument Panel Systems for the proce dures 9...

Page 1892: ...TEERING COLUMN OR INSTRUMENT PANEL COM PONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY 1 Disconnect and iso...

Page 1893: ...group for the proce dures 3 Pull out the lock on the blower motor resistor wire harness connector to unlock the connector latch Fig 48 4 Depress the latch on the blower motor resistor wire harness con...

Page 1894: ...emove the floor door vacuum actuator from the vehicle 7 Reverse the removal procedures to install PANEL DEMIST DOOR ACTUA TOR 1 Remove the defrost door actuator from the heater A C housing See Defrost...

Page 1895: ...the refrigerant from the refrigerant system See Refrigerant Recovery in this group for the procedures 4 Disconnect the liquid line refrigerant line fit ting from the evaporator inlet tube See Refrige...

Page 1896: ...ater A C hous ing half from the lower half ASSEMBL Y 1 Assemble the upper heater A C housing half to the lower half During assembly be certain of the fol lowing a That each of the mode door pivot shaf...

Page 1897: ...or the procedures 11 Connect the battery negative cable 12 Start the engine and check for proper opera tion of the heating and air conditioning systems HEA TER A C HOUSING DOOR WARNING ON VEHICLES EQU...

Page 1898: ...2 Remove the floor door vacuum actuator from the lower heater A C housing See Mode Door Vac uum Actuator in this group for the procedures 3 Insert a screwdriver into the latch hole Fig 57 of the floo...

Page 1899: ...res to install Be certain that the evaporator foam insulator wrap and rubber tube seal are reinstalled NOTE If the evaporator is replaced add 60 millili ters 2 fluid ounces of refrigerant oil to the r...

Page 1900: ...OUTLETS The side window demister outlets are integral to the instrument panel end caps Refer to Instrument Panel End Cap in Group 8E Instrument Panel Sys tems for the procedures DEFROST DUCT DEMISTER...

Page 1901: ...m the floor panel transmission tunnel Fig 66 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...

Page 1902: ...ut 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...

Page 1903: ...ch 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 State Display S...

Page 1904: ...erature sensor input above the maximum acceptable voltage P0121 M TPS Voltage Does Not Agree With MAP TPS signal does not correlate to MAP sensor signal P0121 M Accelerator Position Sensor APPS Signal...

Page 1905: ...3 M 2 1 O2 Sensor Slow Response Oxygen sensor response slower than minimum required switching frequency P0154 M 2 1 O2 Sensor Stays at Center Neither rich or lean condition is detected from the oxygen...

Page 1906: ...respond properly to the control signal P0206 M Injector 6 Control Circuit Injector 6 output driver stage does not respond properly to the control signal P0207 M Injector 7 Control Circuit Injector 7 o...

Page 1907: ...308 M CYLINDER 8 MISFIRE Misfire detected in cylinder 8 P0309 M CYLINDER 9 MISFIRE Misfire detected in cylinder 9 P0310 M CYLINDER 10 MISFIRE Misfire detected in cylinder 10 P0320 M No Crank Referance...

Page 1908: ...ceptable voltage P0401 EGR System Failure Required change in air fuel ration not detected during diagnostic test P0403 EGR Solenoid Circuit An open or shorted condition detected in the EGR solenoid co...

Page 1909: ...0551 Power Steering Switch Failure Incorrect input state detected for the power steering switch circuit PL High pressure seen at high speed P0562 Charging System Voltage Too Low Supply voltage sensed...

Page 1910: ...ue converter clutch part throttle unlock solenoid control circuit Shift solenoid C electrical fault Aisin transmission P0743 M Torque Converter Clutch Solenoid Trans Relay Circuits An open or shorted...

Page 1911: ...t temperature remains below normal operating temperatures during vehicle travel Thermostat P1282 Fuel Pump Relay Control Circuit An open or shorted condition detected in the fuel pump relay control ci...

Page 1912: ...utput Voltage At PCM No Z1 or Z2 voltage sensed when the auto shutdown relay is energized P1389 M No ASD Relay Output Voltage at PCM An open condition detected In the ASD relay output circuit P1390 Ti...

Page 1913: ...fan control relay control circuit This includes PWM solid state relays P1492 Ambient Batt Temp Sen Volts Too High External temperature sensor input above acceptable voltage P1492 M Ambient Batt Temp S...

Page 1914: ...ted condition detected in the speed control servo power control circuit P1683 Spd ctrl pwr rly or s c 12v driver circuit An open or shorted condition detected in the speed control servo power control...

Page 1915: ...verdrive circuits diesel engine with 4 speed auto trans only P1756 M GOV Press Not Equal to Target 15 20 PSI The requested pressure and the actual pressure are not within a tolerance band for the Gove...

Page 1916: ...yst Monitor Leak Detection Pump Monitor if equipped All these system monitors require two consecutive trips with the malfunction present to set a fault Refer to the appropriate Pow ertrain Diagnos tic...

Page 1917: ...enoid is energized and de energized the cycle is repeated creating flow in typical diaphragm pump fashion The pump is con trolled in 2 modes Pump Mode The pump is cycled at a fixed rate to achieve a r...

Page 1918: ...gen there will be a lack of oxygen downstream of the converter The output of the downstream O2S will indicate limited activity in this condition As the converter loses the ability to store oxygen the...

Page 1919: ...systems may cause the PCM to store diagnostic trouble codes for other sys tems or components For example a fuel pressure problem will not register a fault directly but could cause a rich lean conditi...

Page 1920: ...the device If the input voltage is not within limits and other criteria are met the PCM stores a diagnos tic trouble code in memory Other diagnostic trouble code criteria might include engine RPM lim...

Page 1921: ...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 Also refer to Leak Detection Pump...

Page 1922: ...ster 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 1923: ...ube 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 o...

Page 1924: ...and cannot be removed without defacing information and destroying label DIAGNOSIS AND TESTING VACUUM SCHEMA TICS A vacuum schematic for emission related items can be found on the Vehicle Emission Cont...

Page 1925: ...If replacement is necessary the fuel tank must be replaced Refer to Fuel Tank Removal Installation LEAK DETECTION PUMP LDP The LDP is located in the right rear side of engine compartment Fig 10 The L...

Page 1926: ...uts canister to mounting bracket 5 N m 45 in lbs EVAP Canister Mounting Bracket Nuts mounting bracket to body 43 N m 32 in lbs EVAP Canister Purge Solenoid Bracket to Body Mounting Bolt 5 N m 45 in lb...

Page 1927: ......

Page 1928: ...omponent 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 section ECM MONITO...

Page 1929: ...its or input volt ages 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 DESCRIPT...

Page 1930: ...d 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 P120...

Page 1931: ...rt 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 EEP...

Page 1932: ...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 Ambie...

Page 1933: ...tem reduces oxides of nitrogen NOx in the engine exhaust This is accomplished by allow ing a predetermined amount of hot exhaust gas to recirculate and dilute the incoming fuel air mixture A malfuncti...

Page 1934: ...o improve idle quality DIAGNOSIS AND TESTING EGR GAS FLOW TEST Refer to the 1998 XJ ZG Diesel Powertrain Diag nostic Manual for complete test procedure EGR SOLENOID TEST VACUUM TEST With the engine ru...

Page 1935: ...end of tube Tighten bolts to 23 N m 204 in lbs torque 5 Tighten fitting at exhaust manifold end of tube 6 Install hose from turbocharger to metal tube ELECTRIC VACUUM MODULA TOR EVM The EVM EGR Duty...

Page 1936: ...l To protect the 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...

Page 1937: ...fine service information Information reads from left to right starting with line 3 in the center of the plate to line 1 at the bottom of the plate Fig 2 The last code imprinted on a vehicle code plate...

Page 1938: ...es DIGIT 6 Open Space DIGITS 7 THROUGH 23 Vehicle Identification Number VIN Refer to Vehicle Identification Number VIN para graph for proper breakdown of VIN code INTERNA TIONAL VEHICLE CONTROL AND DI...

Page 1939: ...ine marks on the top of each bolt head The actual bolt strength grade corresponds to the number of line marks plus 2 The most commonly used metric bolt strength classes are 9 8 and 12 9 The metric str...

Page 1940: ...FASTENER IDENTIFICATION XJ INTRODUCTION 5 GENERAL INFORMATION Continued...

Page 1941: ...FASTENER STRENGTH 6 INTRODUCTION XJ GENERAL INFORMATION Continued...

Page 1942: ...LT IN COMPONENT DAMAGE OR PER SONAL IJURY Figure art specifications and torque references in this Service Manual are identified in metric and SAE format During any maintenance or repair procedures it...

Page 1943: ...METRIC CONVERSION 8 INTRODUCTION XJ GENERAL INFORMATION Continued...

Page 1944: ...rque Charts appear at the end of many Groups Refer to the Standard Torque Specifi cations Chart for torque references not listed in the individual torque charts TORQUE SPECIFICATIONS XJ INTRODUCTION 9...

Page 1945: ......

Page 1946: ...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...

Page 1947: ...mber Approval Number MANUFACTURER PLA TE 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...

Page 1948: ...mps 8M Passive 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...

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Summary of Contents for Cherokee 1999

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Jeep Cherokee 1999, Electronic Service Manual

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Summary of Contents for Cherokee 1999

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