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Jeep Cherokee 2000, Service Manual

The Jeep Cherokee 2000 Service Manual is a comprehensive manual that provides detailed information on maintenance, repairs, and troubleshooting for your vehicle. You can download it for free from manualshive.com. This manual is essential for ensuring the longevity and performance of your Jeep Cherokee 2000.

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8W-10 POWER DISTRIBUTION

Component

Page

A/C Compressor Clutch . . . . . . . . . . . . . . .

8W-10-14

A/C Compressor Clutch Relay . . . . . . . . . .

8W-10-14

Automatic Shut Down Relay . . . . . . . . . . .

8W-10-15

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-7

Blower Motor . . . . . . . . . . . . . . . . . . . . . .

8W-10-13

Blower Motor Relay . . . . . . . . . . . . . . . .

8W-10-7, 13

Brake Lamp Switch . . . . . . . . . . . . . . . . .

8W-10-20

Brake Warning Pressure Switch . . . . . . . . .

8W-10-9

Cargo Lamp/Switch . . . . . . . . . . . . . . . . . .

8W-10-17

Center High Mounted Stop Lamp . . . . . . .

8W-10-20

Cigar Lighter . . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Cigar Lighter Relay . . . . . . . . . . . . . . . .

8W-10-9, 12

Circuit Breaker 28 (JB) . . . . . . . . . . . . . . .

8W-10-9

Circuit Breaker 29 (JB) . . . . . . . . . . . . . . .

8W-10-12

Circuit Breaker 30 (JB) . . . . . . . . . . . . . . .

8W-10-9

Combination Flasher . . . . . . . . . . . . . . . . .

8W-10-19

Compass . . . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-18

Controller Anti-Lock Brake . . . . . . . . .

8W-10-16, 20

Data Link Connector . . . . . . . . . . . . . . . . .

8W-10-18

Daytime Running Lamp Module . . . . . . . .

8W-10-14

Dome Lamp . . . . . . . . . . . . . . . . . . . . . . .

8W-10-18

Dome Lamps Switch . . . . . . . . . . . . . . . . .

8W-10-18

Driver Door Jamb Switch . . . . . . . . . . . . .

8W-10-10

Engine Starter Motor . . . . . . . . . . . . . .

8W-10-7, 16

Engine Starter Motor Relay . . . . . . . . . . .

8W-10-16

Fog Lamp Relay No. 2 . . . . . . . . . . . . . . .

8W-10-20

Fuel Injector No. 1 . . . . . . . . . . . . . . . . . .

8W-10-15

Fuel Injector No. 2 . . . . . . . . . . . . . . . . . .

8W-10-15

Fuel Injector No. 3 . . . . . . . . . . . . . . . . . .

8W-10-15

Fuel Injector No. 4 . . . . . . . . . . . . . . . . . .

8W-10-15

Fuel Injector No. 5 . . . . . . . . . . . . . . . . . .

8W-10-15

Fuel Injector No. 6 . . . . . . . . . . . . . . . . . .

8W-10-15

Fuel Pump Module . . . . . . . . . . . . . . . . . .

8W-10-19

Fuel Pump Relay . . . . . . . . . . . . . . . . . . .

8W-10-19

Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Fuse 2 (PDC) . . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 9

Fuse 3 (PDC) . . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 9

Fuse 4 (PDC) . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 12

Fuse 5 (PDC) . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 13

Fuse 6 (PDC) . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 13

Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 14

Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-10

Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 15

Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-10

Fuse 9 (PDC) . . . . . . . . . . . . . . . . . . . . .

8W-10-7, 14

Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-10

Fuse 10 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-7, 16

Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-10

Fuse 11 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-7, 16

Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-11

Fuse 12 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 16

Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-16

Fuse 13 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 16

Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-16

Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 17

Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-9

Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 17

Component

Page

Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-9

Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . . . .

8W-10-15

Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-11

Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 18

Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Fuse 20 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 19

Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Fuse 21 (PDC) . . . . . . . . . . . . . . . . . . . . . .

8W-10-15

Fuse 22 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-11

Fuse 22 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 19

Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 20

Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-11

Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-11

Fuse 25 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 20

Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-11

Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . .

8W-10-8, 20

Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . .

8W-10-10

Fuse 27 (PDC) . . . . . . . . . . . . . . . . . . . . . .

8W-10-14

Fusible Link A11 . . . . . . . . . . . . . . . . . . . .

8W-10-7

G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-9

Generator . . . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-7

Headlamp Delay Module . . . . . . . . . . . . . .

8W-10-14

Headlamp Switch . . . . . . . . . . . . . .

8W-10-10, 14, 18

High Note Horn . . . . . . . . . . . . . . . . . . . .

8W-10-12

Horn Relay . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Ignition Coil . . . . . . . . . . . . . . . . . . . . . . .

8W-10-15

Ignition Switch . . . . . . . . . . . . . . . . .

8W-10-9, 10, 11

Instrument Cluster . . . . . . . . . . . . . . .

8W-10-10, 17

Junction Block . . . . . . . . .

8W-10-9, 10, 11, 12, 16, 17

Left Courtesy Lamp . . . . . . . . . . . . . . . . .

8W-10-17

Left Fog Lamp . . . . . . . . . . . . . . . . . . . . .

8W-10-20

Left Tail/Stop Lamp . . . . . . . . . . . . . . . . .

8W-10-20

Left Visor/Vanity Lamp . . . . . . . . . . . . . . .

8W-10-18

Low Note Horn . . . . . . . . . . . . . . . . . . . . .

8W-10-12

Overhead Module . . . . . . . . . . . . . . . . . . .

8W-10-18

Oxygen Sensor 1/1 Upstream . . . . . . . . . .

8W-10-15

Oxygen Sensor 1/2 Downstream . . . . . . . .

8W-10-15

Oxygen Sensor Downstream Relay . . . . . .

8W-10-17

Oxygen Sensor Upstream Relay . . . . . . . .

8W-10-17

Park Brake Switch . . . . . . . . . . . . . . . . . . .

8W-10-9

Passenger Power Lock/Window Switch . . .

8W-10-10

Power Amplifier . . . . . . . . . . . . . . . . . . . .

8W-10-20

Power Distribution Center . .

8W-10-2, 7, 8, 9, 12, 13,

14, 15, 16, 17, 18, 19, 20

Powertrain Control Module . . . . . . . . .

8W-10-15, 19

Radiator Fan Motor . . . . . . . . . . . . . . . . .

8W-10-13

Radiator Fan Relay . . . . . . . . . . . . . . . . . .

8W-10-13

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-17

Rail Coil . . . . . . . . . . . . . . . . . . . . . . . . . .

8W-10-15

Rear Window Defogger . . . . . . . . . . . . . . .

8W-10-16

Rear Window Defogger Relay . . . . . . . .

8W-10-11, 16

Right Courtesy Lamp . . . . . . . . . . . . . . . .

8W-10-17

Right Fog Lamp . . . . . . . . . . . . . . . . . . . .

8W-10-20

Right Tail/Stop Lamp . . . . . . . . . . . . . . . .

8W-10-20

Right Visor/Vanity Lamp . . . . . . . . . . . . . .

8W-10-18

Sentry Key Immobilizer Module . . . . . . . .

8W-10-14

Transmission Control Module . . . . . . . . . .

8W-10-17

Underhood Lamp/Mercury Switch . . . . . . .

8W-10-17

XJ

8W - 10 POWER DISTRIBUTION

8W - 10 - 1

Summary of Contents for Cherokee 2000

Page 1: ...AL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORDING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION DaimlerChrysler Corpo...

Page 2: ...on that lists major topics within the group If you are not sure which Group contains the infor mation you need look up the Component System in the alphabetical index located in the rear of this manual...

Page 3: ...L Lamps 8M Passive Restraint Systems 8N Electrically Heated Systems 8O Power Distribution System 8P Power Lock Systems 8Q Vehicle Theft Security Systems 8R Power Seats Systems 8S Power Window Systems...

Page 4: ......

Page 5: ...e compartment lubricant and fluid inspection and fill locations Fig 1 CLASSIFICATION OF LUBRICANTS Only lubricants bearing designations defined by the following organization should be used to service...

Page 6: ...ts usage LUBRICANTS AND GREASES Lubricating grease is rated for quality and usage by the NLGI All approved products have the NLGI symbol Fig 3 on the label At the bottom NLGI symbol is the usage and q...

Page 7: ...L 3 7 qts AX5 4X4 3 3 L 3 5 qts AX15 4X2 3 15 L 3 3 qts AX15 4X4 3 15 L 3 3 qts TRANSFER CASE SELEC TRAC 242 1 3 L 2 85 pts COMMAND TRAC 231 1 0 L 2 2 pts FRONT AXLE 181 FBI 1 48 L 3 13 pts 186 FBI 1...

Page 8: ...Check all lights and all other electrical items for correct operation At Each Oil Change Inspect exhaust system Inspect brake hoses Rotate the tires at each oil change interval shown on Schedule A 7...

Page 9: ...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...

Page 10: ...000 km Change engine oil Replace engine oil filter Lubricate steering linkage Lubricate steering and suspension ball joints Drain and refill manual transmission fluid 21 000 Miles 34 000 km Change en...

Page 11: ...63 000 Miles 101 000 km Change engine oil Replace engine oil filter Lubricate steering linkage 66 000 Miles 106 000 km Change engine oil Replace engine oil filter Lubricate steering linkage Lubricate...

Page 12: ...fluid Drain and refill front and rear axles Inspect brake linings Lubricate steering and suspension ball joints Drain and refill manual transmission fluid 111 000 Miles 178 000 km Change engine oil R...

Page 13: ...r vehicle TO JUMP START A DISABLED VEHICLE 1 Raise hood on disabled vehicle and visually inspect engine compartment for Battery cable clamp condition clean if necessary Frozen battery Yellow or bright...

Page 14: ...condition 7 Shift the transmission to NEUTRAL TOWING REAR END LIFTED WHEEL LIFT 1 Raise front of vehicle off ground and install tow dollies under front wheels 2 Attach wheel lift to rear wheels 3 Pla...

Page 15: ...ission in park automatic trans mission or first gear manual transmission EMERGENCY TOW HOOKS WARNING REMAIN AT A SAFE DISTANCE FROM A VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS THE TOW STRAPS CHAIN...

Page 16: ...ist A ramp type drive on hoist NOTE When a frame contact type hoist is used verify that the lifting pads are positioned properly WARNING THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLET...

Page 17: ...tenance for the rec ommended maintenance schedule OPERATION CASTER is the forward or rearward tilt of the steering knuckle from vertical Tilting the top of the knuckle rearward provides positive caste...

Page 18: ...nd exces sive tire wear This angle is not adjustable damaged component s must be replaced to correct the thrust angle Fig 1 Wheel Alignment Measurements 1 WHEEL CENTERLINE 2 NEGATIVE CAMBER ANGLE 3 PI...

Page 19: ...wheel bearings 1 Adjust or replace wheel bearings 2 Loose or worn steering or suspension components 2 Tighten or replace components as necessary 3 Tire pressure 3 Adjust tire pressure 4 Alignment 4 Al...

Page 20: ...n Set the front end alignment to specifications with the vehicle at its NORMAL RIDE HEIGHT CAMBER The wheel camber angle is preset This angle is not adjustable and cannot be altered CASTER Before chec...

Page 21: ...the drag link TOE POSITION RHD NOTE The wheel toe position adjustment is the final adjustment The engine must remain running during the entire toe position adjustment 1 Start the engine and turn wheel...

Page 22: ...rn off engine 6 Road test the vehicle on a flat level road to ver ify the steering wheel is centered NOTE Once the toe setting is correct the steering wheel can be re centered by adjusting only the dr...

Page 23: ...ation Then if the slot in the nut does not line up with the cotter pin hole tighten nut until it is aligned Never loosen the nut to align the cotter pin hole CAUTION Suspension components with rubber...

Page 24: ...PERATION The arm and bushings provide location and react to loads from the axle The bushings provide isolation from the axle The lower suspension arms can be used to adjust caster and pinion angle thr...

Page 25: ...amaged and worn bushings and attach ing components Repair as necessary if any of these conditions exist A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be inte...

Page 26: ...lower the vehicle 10 Tighten lower suspension arms nuts to 115 N m 85 ft lbs STEERING KNUCKLE For service procedures on the steering knuckle and ball joints refer to Group 3 Differentials And Driv eli...

Page 27: ...inst other side of the bushing 5 Install bolt 7604 through remover bushing and receiver 6 Install Long Nut 7603 and tighten nut too pull bushing out of the axle bracket 7 Remove nut bolt receiver remo...

Page 28: ...l bracket 3 Use a universal puller tool to separate the ball stud from the frame rail bracket 4 Remove the bolt and flag nut from the axle shaft tube bracket Fig 7 5 Remove the track bar INSTALLATION...

Page 29: ...ove wheel and tire assembly 3 Remove brake caliper caliper adapter and rotor refer to Group 5 Brakes for procedure 4 Remove stud from hub with Remover C 4150A Fig 9 INSTALLATION 1 Install new stud int...

Page 30: ...5 N m 85 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40 ft lbs Link Upper Nut 36 N m 27 ft lbs Link Lower Nut 95 N m 70 ft lbs Track Bar Ball Stud Nut 81 N m 60 ft lbs Axle Bracket Bolt 54 N m 40 ft lbs F...

Page 31: ...m 74 ft lbs Support Bolts 42 N m 31 ft lbs Hub Bearing Bolts 102 N m 75 ft lbs Axle Nut 237 N m 175 ft lbs SPECIAL TOOLS FRONT SUSPENSION Remover Installer Suspension Bushing 7932 Nut Long 7603 Bolt S...

Page 32: ...the weight of the vehicle when the fasteners are torqued If springs are not at their normal ride position vehicle ride comfort could be affected and premature bush ing wear may occur SHOCK ABSORBERS...

Page 33: ...mined periodically Check for broken and shifted leafs loose and missing clips and broken center bolts Refer to Spring and Shock Absorber Diagnosis chart for additional information SPRING AND SHOCK ABS...

Page 34: ...not tighten at this time 3 Position the axle Install the spring bracket U bolts and nuts Tighten the nuts to 70 N m 52 ft lbs 4 Connect the stabilizer bar link to the spring bracket 5 Remove the hydr...

Page 35: ...ings bend tabs up after installa tion SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber Upper Bolt 23 N m 17 ft lbs Lower Nut 62 N m 46 ft lbs Stabilizer Bar Clamp Bolt 54 N m 40 ft lbs Li...

Page 36: ......

Page 37: ...and built with the yoke lugs in line with each other which is called zero phasing This design produces the smoothest running condition an out of phase shaft can cause a vibra tion Tubular propeller s...

Page 38: ...lied when tightening the fasteners PROPELLER SHAFT JOINTS DESCRIPTION Two different types of propeller shaft joints are used Single cardan universal joint Fig 3 Double cardan CV universal joint Fig 4...

Page 39: ...ased when the yoke ends are in the same plane or in line A twisted shaft will make the yokes out of phase and cause a noticeable vibration When taking propeller shaft joint angle measure ments or chec...

Page 40: ...1 Clean exterior of shaft and wash with solvent 2 Loose U joint clamp screws 2 Install new clamps and screws and tighten to proper torque 3 Loose or bent U joint yoke or excessive runout 3 Install new...

Page 41: ...other three positions Repeat the vibration test 11 If there is no difference in vibration at the other positions the source of the vibration may not be propeller shaft 12 If the vibration decreased i...

Page 42: ...rnal bearing snap rings if equipped from universal joint so protractor base sits flat 2 Rotate the shaft until transmission transfer case output yoke bearing is facing downward Always make measurement...

Page 43: ...ample in Fig 12 for additional information Fig 11 Rear Input Angle Measurement B 1 PINION YOKE BEARING CAP 2 SPECIAL TOOL 7663 J 23498A Fig 12 Universal Joint Angle Example 1 4 9 Angle C 2 3 2 Angle B...

Page 44: ...ropeller shaft under vehicle with rear universal joint over the transfer case yoke 2 Place front universal joint into the axle pinion yoke 3 Align mark on the rear link yoke and universal joint to the...

Page 45: ...components of cardan universal joints are not serviceable If worn or leaking they must be replaced as an assembly 1 Remove the propeller shaft 2 Using a soft drift tap the outside of the bear ing cap...

Page 46: ...the end of the cross until the remaining bearing cap can be removed Fig 20 CAUTION If the cross or bearing cap are not straight during installation the bearing cap will score the walls of the yoke bo...

Page 47: ...eceive the bearing cap positioned beneath the link yoke 5 Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from t...

Page 48: ...ng cap over the trunnion and align the cap with the yoke bore Fig 28 Keep the needle bearings upright in the bearing assembly A needle bearing lying at the bottom of the cap will prevent proper assemb...

Page 49: ...un nions and press both bearing caps into place Fig 31 8 Install snap rings 9 Install the centering kit assembly inside the link yoke making sure the spring is properly posi tioned Fig 32 Fig 29 Press...

Page 50: ...3 Check for proper assembly Flex the joint beyond center it should snap over center in both directions when correctly assembled Fig 36 14 Install the propeller shaft CLEANING AND INSPECTION PROPELLER...

Page 51: ...8 Adding shims will decrease the pinion shaft angle but will also increase the caster angle The pinion shaft angle has priority over the caster angle Refer to Group 2 Suspension for additional informa...

Page 52: ...are pressed into the differential housing and welded The integral type housing hypoid gear design has the centerline of the pinion set above the centerline of the ring gear The axle has a fitting for...

Page 53: ...186 FBI axle has the assembly part number and gear ratio listed on a tag The tag is attached to the housing cover by a cover bolt Build date identi fication codes are stamped on the cover side of the...

Page 54: ...torque applied to the gears is divided and distributed equally between the two side gears As a result the pinion gears revolve with the pinion mate shaft but do not rotate around it Fig 1 When turning...

Page 55: ...r backlash between the ring gear and pinion 4 Check adjustment of the ring gear and pinion backlash Correct as necessary 5 Improper adjustment of pinion gear bearings 5 Adjust the pinion bearings pre...

Page 56: ...roke 1 Overloading 1 Replace gears Examine other gears and bearings for possible damage 2 Erratic clutch operation 2 Replace gears and examine the remaining parts for damage Avoid erratic clutch opera...

Page 57: ...e right This will load the bearings and change the noise level Where axle bearing damage is slight the noise is usually not noticeable at speeds above 30 mph LOW SPEED KNOCK Low speed knock is general...

Page 58: ...ets 16 Lower the lifting device enough to remove the axle The coil springs will drop with the axle 17 Remove the coil springs from the axle INSTALLATION CAUTION The weight of the vehicle must be sup p...

Page 59: ...the upper and lower suspension arms in the axle brackets Loosely install bolts and nuts to hold suspension arms to the axle brackets 5 Connect the track bar to the axle bracket Loosely install the bo...

Page 60: ...semblies 3 Remove brake rotors and calipers Refer to Group 5 Brakes for proper procedures 4 Mark the propeller shaft and pinion yoke for installation reference 5 Remove the propeller shaft from the yo...

Page 61: ...t in 6 8 N m 5 ft lbs increments until proper rotating torque is achieved 7 Align the installation reference marks on the propeller shaft and yoke and install the propeller shaft 8 Check and fill the...

Page 62: ...d the minimum tightening torque when installing the pinion yoke retaining nut at this point Damage to collapsible spacer or bear ings may result 3 Install the pinion washer and a new nut on the pinion...

Page 63: ...wrench Record the torque reading for instal lation reference 8 Using Holder 6958 to hold the pinion yoke remove the pinion nut and washer 9 Use Remover C 452 and Wrench C 3281 to remove the pinion yok...

Page 64: ...ig 16 Catch the pinion with your hand to prevent it from falling and being damaged 12 Remove collapsible spacer from pinion shaft INSTALLATION 1 Install a new collapsible preload spacer on pin ion sha...

Page 65: ...cer is defective and must be replaced 9 Slowly tighten the nut in 6 8 N m 5 ft lbs increments until the rotating torque is achieved Measure the rotating torque frequently to avoid over crushing the co...

Page 66: ...cessary Refer to Group 5 Brakes for proper procedures 5 Remove the cotter pin nut retainer and axle hub nut Fig 22 if necessary 6 Remove the hub to knuckle bolts Fig 23 7 Remove the hub from the steer...

Page 67: ...er to Group 5 Brakes for proper procedures 9 Install the wheel and tire assembly 10 Remove support and lower the vehicle STEERING KNUCKLE AND BALL STUDS Ball stud service procedures below require remo...

Page 68: ...2 Install and tighten the bottom retaining nut to 109 N m 80 ft lbs torque Install new cotter pin 3 Install and tighten the top retaining nut to 101 N m 75 ft lbs torque Install new cotter pin 4 Insta...

Page 69: ...ealing surface Fig 28 6 Loosen the differential bearing cap bolts 7 Position Spreader W 129 B utilizing some items from Adapter Kit 6987 with the tool dowel pins seated in the locating holes Fig 29 In...

Page 70: ...2 Remove the differential and the differential preload shims for the 181FBI axles from the hous ing Ensure that the differential bearing cups remain in position on the differential bearings Fig 32 13...

Page 71: ...ugh to install the case in the housing Measure the distance with the dial indicator Fig 31 4 Remove the dial indicator 5 Install differential case and the differential preload shims for the 181FBI axl...

Page 72: ...al assembly 3 Remove the inner axle shaft seals with a pry bay INSTALLATION 1 Remove any sealer remaining from original seals 2 Remove sealer from axle tube to housing junc tion if necessary 3 Install...

Page 73: ...from falling and being damaged 7 Remove the front pinion bearing cup bearing oil slinger if equipped and pinion seal with Remover D 147 and Handle C 4171 Fig 40 Fig 37 Axle Seal Installation 1 TURNBU...

Page 74: ...led ring and pinion gears are reused the pinion depth shim oil baffle should not require replacement Refer to Pinion Gear Depth to select the proper thickness shim before installing pinion gear 1 Inst...

Page 75: ...shim oil baffle onto the pinion gear with Installer W 262 and a shop press Fig 46 7 Install pinion bearing preload shims onto the pinion gear Fig 47 8 Install pinion gear in housing 9 Install yoke wit...

Page 76: ...above the desired amount remove the pinion yoke and increase the preload shim pack thickness Increasing the shim pack thickness 0 025 mm 0 001 in will decrease the rotating torque approximately 0 9 N...

Page 77: ...ssembly from axle hous ing 2 Mark pinion yoke and propeller shaft for installation alignment 3 Disconnect propeller shaft from pinion yoke Using suitable wire tie propeller shaft to underbody 4 Using...

Page 78: ...8 Remove the rear pinion bearing cup from axle housing Fig 54 Use Remover D 149 and Handle C 4171 9 Remove the collapsible preload spacer from pinion gear Fig 55 Fig 52 Remove Pinion 1 RAWHIDE HAMMER...

Page 79: ...rface of rear pinion bearing cup Install the bearing cup with Installer D 146 and Driver Handle C 4171 Fig 57 Verify cup is cor rectly seated 2 Apply Mopart Door Ease or equivalent stick lubricant to...

Page 80: ...e is exceeded a new collapsible spacer must be installed The torque sequence will then have to be repeated 9 Using Holder 6958 and torque wrench set at 352 N m 260 ft lbs crush collapsible spacer unti...

Page 81: ...NOTE The ring gear and pinion are serviced as a matched set Do not replace the ring gear without replacing the pinion REMOVAL 1 Remove differential from axle housing 2 Place differential case in a su...

Page 82: ...te shaft in the differ ential case Fig 67 3 Remove the pinion gear mate shaft from the differential case and the pinion mate gears 4 Rotate differential side gears and remove the pinion mate gears and...

Page 83: ...U JOINT Clean all the U joint yoke bores with cleaning sol vent and a wire brush Ensure that all the rust and foreign matter are removed from the bores Inspect the yokes for distortion cracks and worn...

Page 84: ...graph in this section for additional information Compensation for pinion depth variance is achieved with a select shim oil baffle The shims are placed between the rear pinion bearing and the pin ion g...

Page 85: ...ock D 115 2 and secure set screw 6 Place Scooter Block Dial Indicator in position in axle housing so dial probe and scooter block are flush against the rearward surface of the pinion PINION GEAR DEPTH...

Page 86: ...for the ring gear and pinion are etched into the face of each gear Fig 77 A plus number minus number or zero 0 is etched into the face of the pinion gear head This number is the amount in thousandths...

Page 87: ...C 3339 Fig 79 PINION GEAR DEPTH VARIANCE Original Pinion Gear Depth Variance Replacement Pinion Gear Depth Variance 4 3 2 1 0 1 2 3 4 4 0 008 0 007 0 006 0 005 0 004 0 003 0 002 0 001 0 3 0 007 0 006...

Page 88: ...f the pinion height block 8 Slide the dial indicator probe across the gap between the pinion height block and the arbor bar with the scooter block against the pinion height block Fig 82 When the dial...

Page 89: ...al Fig 83 Differential shim measurements are performed with axle spreader W 129 B removed SHIM SELECTION NOTE It is difficult to salvage the differential side bearings during the removal procedure Ins...

Page 90: ...fferential is installed 15 Rotate dial indicator out of the way on the guide stud 16 Remove differential case and dummy bearings from axle housing Fig 86 Seat Ring Gear Side Differential Dummy Side Be...

Page 91: ...n axle housing and spread axle opening enough to receive differential case 32 Install differential case into the axle housing 33 Remove spreader from axle housing 34 Rotate the differential case sever...

Page 92: ...fication added together The gear backlash measurement determines the thickness of the shim used on the ring gear side of the differential case Subtract the gear backlash shim thickness from the total...

Page 93: ...indicator face to pointer Fig 99 12 Push and hold differential case to ring gear side of the axle housing Fig 100 13 Record dial indicator reading Fig 100 14 Add 0 008 in 0 2 mm to the zero end play...

Page 94: ...dicator face to pointer Fig 101 23 Push and hold differential case to ring gear side of the axle housing Fig 102 24 Record dial indicator reading Fig 102 Fig 99 Hold Differential Case and Zero Dial In...

Page 95: ...Fig 104 39 Verify differential case and ring gear runout by measuring ring to pinion gear backlash at eight locations around the ring gear Readings should not vary more than 0 05 mm 0 002 in If readin...

Page 96: ...Fig 105 Gear Tooth Contact Patterns 3 60 TUBE 181 AND 186 FBI AXLE XJ ADJUSTMENTS Continued...

Page 97: ...thetic Lube Capacity 1 18 L 2 5 pts Axle Ratio 3 07 3 55 3 73 4 10 Differential Side Gear Clearance 0 12 0 20 mm 0 005 0 008 in Ring Gear Diameter 18 59 cm 7 33 in Backlash 0 0 15 mm 0 005 0 008 in Pi...

Page 98: ...ator C 3339 Driver C 3716 A Handle C 4171 Installer D 146 Remover D 149 Installer W 162 D Cup 8109 Remover Installer 6289 Installer 6761 Installer 6752 3 62 TUBE 181 AND 186 FBI AXLE XJ SPECIAL TOOLS...

Page 99: ...0 Turnbuckle 6797 Tool Set Pinion Depth 6774 Gauge Block 6733 Spanner 6958 Installer C 3972 A Spreader W 129 B Adapter Kit 6987 Pilot Stud C 3288 B Remover D 147 XJ TUBE 181 AND 186 FBI AXLE 3 63 SPEC...

Page 100: ...Installer D 144 Installer W 262 3 64 TUBE 181 AND 186 FBI AXLE XJ SPECIAL TOOLS Continued...

Page 101: ...ion The axles are equipped with semi floating axle shafts meaning that loads are supported by the axle shaft and bearings The axle shafts are retained by C clips in the differential side gears The cov...

Page 102: ...rs mounted on the pinion mate shaft in the case rotate the side gears The side gears splined to the axle shafts rotate the shafts During straight ahead driving the differential pin ion gears do not ro...

Page 103: ...vided continuously until both wheels loose traction If both wheels slip due to unequal traction Trac loky operation is normal In extreme cases of differences of traction the wheel with the least trac...

Page 104: ...ch operation 3 Replace broken shaft and avoid or correct erratic clutch operation 4 Grabbing clutch 4 Replace broken shaft and inspect and repair clutch as necessary Differential Cracked 1 Improper ad...

Page 105: ...tic clutch operation 3 Ice spotted pavement 3 Replace gears and examine remaining parts for damage 4 Improper adjustments 4 Replace gears and examine remaining parts for damage Ensure ring gear backla...

Page 106: ...e bearing damage is slight the noise is usually not noticeable at speeds above 30 mph LOW SPEED KNOCK Low speed knock is generally caused by a worn U joint or by worn side gear thrust washers A worn p...

Page 107: ...int free cloth Do not use water steam kerosene or gasoline for cleaning 5 Remove the original sealant from the housing and cover surfaces 6 Apply a bead of Mopart Silicone Rubber Seal ant or equivalen...

Page 108: ...N m 52 ft lbs 3 Install shock absorbers and tighten nuts to 60 N m 44 ft lbs torque 4 Install stabilizer bar links and tighten nuts to 74 N m 55 ft lbs torque 5 Install the wheel speed sensors if nec...

Page 109: ...using a in lbs torque wrench Rotating torque should be equal to the read ing recorded during removal plus an additional 0 56 N m 5 in lbs Fig 10 6 If the rotating torque is low use Holder 6958 to hold...

Page 110: ...dures 4 Mark the propeller shaft and pinion yoke for installation reference 5 Remove the propeller shaft from the yoke 6 Rotate the pinion gear three or four times 7 Measure the amount of torque neces...

Page 111: ...psible spacer must be installed The torque sequence will then have to be repeated 9 Using yoke holder 6958 and a torque wrench set at 474 N m 350 ft lbs crush collapsible spacer until bearing end play...

Page 112: ...AFT REMOVAL 1 Raise and support vehicle Ensure that the transmission is in neutral 2 Remove wheel and tire assembly 3 Remove brake drum Refer to Group 5 Brakes for proper procedure 4 Clean all foreign...

Page 113: ...ubricant Change procedure in this section for procedure and lubricant requirements 6 Install brake drum Refer to Group 5 Brakes for proper procedures 7 Install wheel and tire 8 Lower vehicle AXLE SHAF...

Page 114: ...indicator CAUTION Do not spread over 0 38 mm 0 015 in If the housing is over spread it could be distorted or damaged 9 Spread the housing enough to remove the dif ferential case from the housing Meas...

Page 115: ...ig 25 and zero the indicator CAUTION Do not spread over 0 38 mm 0 015 in If the housing is over spread it could be distorted or damaged 3 Spread the housing enough to install the case in the housing M...

Page 116: ...gear without replacing the pinion REMOVAL 1 Remove differential from axle housing 2 Place differential case in a suitable vise with soft metal jaw protectors Fig 32 3 Remove bolts holding ring gear to...

Page 117: ...ar REMOVAL 1 Remove differential from the axle housing 2 Mark pinion yoke and propeller shaft for installation alignment 3 Disconnect propeller shaft from pinion yoke Using suitable wire tie propeller...

Page 118: ...nd Handle C 4171 11 Remove the collapsible preload spacer Fig 38 12 Remove the rear bearing from the pinion with Puller Press C 293 PA and Adapters C 293 40 Fig 39 Place 4 adapter blocks so they do no...

Page 119: ...pinion seal Install seal with Installer C 3972 A and Handle C 4171 Fig 42 NOTE Pinion depth shims are placed between the rear pinion bearing cone and pinion gear to achieve proper ring and pinion gear...

Page 120: ...oosen pinion gear nut to decrease pinion gear bearing rotating torque and never exceed specified preload torque If preload torque or rotating torque is exceeded a new col lapsible spacer must be insta...

Page 121: ...m the housing and cover mating surfaces Clean the mating surfaces with mineral spirits Apply a bead of Mopart Silicone Rubber Sealant or equivalent on the housing cover Fig 48 Install the housing cove...

Page 122: ...erential pinion gears and thrust washers 3 Install the pinion mate shaft 4 Align the hole in the pinion mate shaft with the hole in the differential case and install the pinion mate shaft lock screw 5...

Page 123: ...e Trac loky differential can be serviced with the ring gear installed 4 Remove the pinion gear mate shaft lock screw Fig 53 5 Remove the pinion gear mate shaft If neces sary use a drift and hammer Fig...

Page 124: ...compress Belleville springs in clutch packs Fig 57 Fig 53 Mate Shaft Lock Screw 1 LOCK SCREW 2 PINION GEAR MATE SHAFT Fig 54 Mate Shaft Removal 1 PINION MATE SHAFT 2 SIDE GEAR 3 DRIFT 4 PINION MATE G...

Page 125: ...rs from differential case 15 Remove Forcing Screw C 6960 4 Step Plate C 6960 3 and Threaded Adapter C 6960 1 16 Remove top side gear clutch pack retainer and clutch pack Keep plates in correct order d...

Page 126: ...ted in the case pockets 4 Position the differential case on Side Gear Holding Tool 6965 5 Install lubricated Step Plate C 6960 3 in lower side gear Fig 63 6 Install the upper side gear and clutch disc...

Page 127: ...and damage to pinion gear mate shaft pinion gears side gears and thrust washers Replace as a matched set only Ring and pinion gear for worn and chipped teeth Ring gear for damaged bolt threads Replac...

Page 128: ...ring onto Screw 6741 Fig 66 2 Insert assembled height gauge components rear bearing and screw into axle housing through pinion bearing cups Fig 67 3 Install front pinion bearing and Cone 6740 hand tig...

Page 129: ...dial pointer back to zero against the arbor bar do not turn dial face Continue moving the dial probe to the crest of the arbor bar and record the highest reading If the dial indicator can not achieve...

Page 130: ...thickness of the shim used on the ring gear side of the differential case Subtract the gear backlash shim thickness from the total overall shim thickness and select that amount for the pinion gear si...

Page 131: ...le housing Fig 75 11 Zero dial indicator face to pointer 12 Push firmly and hold differential case to ring gear side of the axle housing Fig 76 13 Record dial indicator reading Fig 72 Seat Pinion Gear...

Page 132: ...ash 26 Subtract the backlash shim thickness from the total preload shim thickness The remainder is the shim thickness required on the pinion side of the axle housing 27 Rotate dial indicator out of th...

Page 133: ...y a thin coat of hydrated ferric oxide or equivalent to the drive and coast side of the ring gear teeth 2 Wrap twist and hold a shop towel around the pinion yoke to increase the turning resistance of...

Page 134: ...Fig 79 Gear Tooth Contact Patterns 3 98 194 RBI AXLE XJ ADJUSTMENTS Continued...

Page 135: ...ash 0 0 15 mm 0 005 0 008 in Pinion Std Depth 96 85 mm 3 813 in Pinion Bearing Preload Original Bearings 1 2 N m 10 20 in lbs Pinion Bearing Preload New Bearings 1 5 4 N m 15 35 in lbs 194 RBI AXLE DE...

Page 136: ...Spanner 6958 Installer Screw 8112 Cup 8109 Handle C 4171 Driver C 3716 A Installer D 130 Installer D 146 Remover C 4345 Remover D 149 Installer W 262 3 100 194 RBI AXLE XJ SPECIAL TOOLS Continued...

Page 137: ...nstaller 6437 Disc Axle Arbor 6732 Gauge Block 6735 Tool Set Pinion Depth 6774 Trac lok Tool Set 6960 Holder 6965 Puller 7794 A Starting Point Shim 8107 Spreader W 129 B XJ 194 RBI AXLE 3 101 SPECIAL...

Page 138: ...Adapter Kit 6987 Guide Pin C 3288 B Bearing Remover Tool Set 6310 Hub Puller 6790 Dial Indicator C 3339 3 102 194 RBI AXLE XJ SPECIAL TOOLS Continued...

Page 139: ...ped with semi floating axle shafts meaning vehicle loads are supported by the axle shaft and bearings The axle shafts are retained by C locks in the differential side gears The removable stamped steel...

Page 140: ...service The 8 1 4 axle lubricant capacity is 2 08 L 4 4 pts total including the friction modifier if necessary CAUTION If the rear axle is submerged in water the lubricant must be replaced immediatel...

Page 141: ...res from scuffing and skidding through turns To accomplish this the differential allows the axle shafts to turn at unequal speeds Fig 4 In this instance the input torque applied to the pinion gears is...

Page 142: ...NFORMATION Axle bearing problem conditions are usually caused by Insufficient or incorrect lubricant Foreign matter water contamination Incorrect bearing preload torque adjustment Incorrect backlash A...

Page 143: ...operation 3 Replace broken shaft and avoid or correct erratic clutch operation 4 Grabbing clutch 4 Replace broken shaft and inspect and repair clutch as necessary Differential Cracked 1 Improper adju...

Page 144: ...c clutch operation 3 Ice spotted pavement 3 Replace gears and examine remaining parts for damage 4 Improper adjustments 4 Replace gears and examine remaining parts for damage Ensure ring gear backlash...

Page 145: ...bearing damage is slight the noise is usually not noticeable at speeds above 30 mph LOW SPEED KNOCK Low speed knock is generally caused by a worn U joint or by worn side gear thrust washers A worn pin...

Page 146: ...t free cloth Do not use water steam kerosene or gasoline for cleaning 5 Remove the original sealant from the housing and cover surfaces 6 Apply a bead of Mopart Silicone Rubber Seal ant or equivalent...

Page 147: ...xle vent hose 9 Align propeller shaft and pinion yoke reference marks Install universal joint straps and bolts Tighten to 19 N m 14 ft lbs torque 10 Install the wheels and tires 11 Add gear lubricant...

Page 148: ...The seal and bearing can be removed at the same time with the bearing removal tool 3 Remove the axle shaft bearing from the axle tube with Bearing Removal Tool Set 6310 using Adapter Foot 6310 9 Fig...

Page 149: ...with Wrench 6719 Remove the pinion nut and washer 9 Remove the yoke with Remover C 452 Fig 13 10 Remove the pinion seal with suitable pry tool or slide hammer mounted screw INSTALLATION 1 Clean the se...

Page 150: ...torque sequence will then have to be repeated 11 If the rotating torque is low use Yoke Holder 6719 to hold the pinion yoke Fig 15 and tighten the pinion nut in 6 8 N m 5 ft lbs increments until prope...

Page 151: ...the upper bolts to 14 N m 10 ft lbs Tighten the lower bolts finger tight until the bolt head is seated 4 Perform the differential bearing preload and adjustment procedure NOTE Be sure that all bearing...

Page 152: ...nvert the differential case 2 Position ring gear on the differential case and start two ring gear bolts This will provide case to ring gear bolt hole alignment 3 Invert the differential case in the vi...

Page 153: ...Remove oil slinger if equipped and front pin ion bearing 10 Remove the front pinion bearing cup with Remover C 4345 and Handle C 4171 Fig 26 11 Remove the rear bearing cup from housing Fig 27 Use Remo...

Page 154: ...ght coating of gear lubricant on the lip of pinion seal Install seal with Installer C 4076 B and Handle C 4735 1 Fig 32 Fig 26 Front Bearing Cup Removal 1 REMOVER 2 HANDLE Fig 27 Rear Bearing Cup Remo...

Page 155: ...448 9 Install a new collapsible preload spacer on pin ion shaft and install pinion in housing Fig 34 10 Install pinion in housing 11 Install yoke with Installer C 3718 and Yoke Holder 6719 12 Install...

Page 156: ...spacer Fig 35 16 Check bearing rotating torque with an inch pound torque wrench Fig 35 The torque necessary to rotate the pinion gear should be Original Bearings 1 to 2 N m 10 to 20 in lbs New Bearin...

Page 157: ...ustration during repair service DISASSEMBLY 1 Clamp Side Gear Holding Tool 8138 in a vise 2 Position the differential case on Side Gear Holding Tool 8138 Fig 39 3 Remove ring gear if necessary Ring ge...

Page 158: ...g screw tool 122 N m 90 ft lbs maximum to compress Belleville springs in clutch packs Fig 44 10 Using an appropriate size feeler gauge remove thrust washers from behind the differential pinions Fig 45...

Page 159: ...iner and clutch pack Keep plates in correct order during removal Fig 47 17 Remove differential case from Side Gear Hold ing Tool 8138 Remove side gear clutch pack retainer Fig 43 Threaded Adapter Inst...

Page 160: ...p Plate 8140 2 in lower side gear Fig 50 6 Install the upper side gear and clutch disc pack Fig 50 7 Hold assembly in position Insert Threaded Adapter 8140 1 into top side gear 8 Insert Forcing Screw...

Page 161: ...ched set only Ring gear and pinion for worn and chipped teeth Ring gear for damaged bolt threads Replaced as a matched set only Pinion yoke for cracks worn splines pitted areas and a rough corroded se...

Page 162: ...e subtract that value from the thickness of the depth shim If the number is 0 no change is nec essary PINION DEPTH MEASUREMENT AND ADJUSTMENT Measurements are taken with pinion bearing cups and pinion...

Page 163: ...in to the dial indicator reading DIFFERENTIAL BEARING PRELOAD AND GEAR BACKLASH The following must be considered when adjusting bearing preload and gear backlash The maximum ring gear backlash variati...

Page 164: ...llow some ring gear backlash approximately 0 01 inch 0 25 mm between the ring and pinion gear Seat the bearing cups with the procedure described above 2 Install dial indicator and position the plunger...

Page 165: ...ar teeth to Gear Tooth Contact Patterns chart Fig 59 and adjust pinion depth and gear backlash as necessary SIDE GEAR CLEARANCE When measuring side gear clearance check each gear independently If it n...

Page 166: ...Fig 59 Gear Tooth Contact Patterns 3 130 8 1 4 REAR AXLE XJ ADJUSTMENTS Continued...

Page 167: ...Ring Gear Diameter 20 95 cm 8 25 in Backlash 0 12 0 20 mm 0 005 0 008 in Runout 0 127 mm 0 005 in Pinion Bearing Preload Used Bearings 1 2 N m 10 20 in lbs Preload New Bearings 1 5 N m 10 30 in lbs 8...

Page 168: ...andle C 4171 Installer C 4076 B Handle C 4735 1 Holder 6719 Puller C 452 Installer C 3718 Adjustment Rod C 4164 Puller Press C 293 PA Adapters C 293 48 3 132 8 1 4 REAR AXLE XJ SPECIAL TOOLS Continued...

Page 169: ...Plug SP 3289 Adapters C 293 47 Installer C 4340 Holder 8138 Installer C 4345 Remover C 4307 Installer C 4308 Installer D 130 Installer 6448 XJ 8 1 4 REAR AXLE 3 133 SPECIAL TOOLS Continued...

Page 170: ...Trac lokY Tools 8140 Trac lokY Tools 6960 Pinion Gauge Block 8540 Arbor Discs 8541 Pinion Gauge Set 3 134 8 1 4 REAR AXLE XJ SPECIAL TOOLS Continued...

Page 171: ...ROCEDURES BRAKE FLUID LEVEL 12 MASTER CYLINDER BLEEDING 12 BASE BRAKE BLEEDING 13 DISC ROTOR MACHINING 13 BRAKE DRUM MACHINING 14 BRAKE TUBE FLARING 14 REMOVAL AND INSTALLATION BRAKE LAMP SWITCH 15 BR...

Page 172: ...ECTION AGENCY FOR THE HANDLING PROCESSING AND DISPOSITION OF DUST OR DEBRIS THAT MAY CONTAIN ASBESTOS FIBERS CAUTION Never use gasoline kerosene alcohol motor oil transmission fluid or any fluid conta...

Page 173: ...d the diaphragms to atmospheric pres sure The resulting pressure differential provides the extra apply force for power assist The booster check valve check valve grommet and booster seals are servicea...

Page 174: ...to the inboard brake shoe This forces the shoe lining against the inner surface of the disc brake rotor At the same time fluid pressure within the piston bore forces the caliper to slide inward on the...

Page 175: ...econdary design Fig 4 OPERATION When the brake pedal is depressed hydraulic pres sure pushes the rear brake wheel cylinder pistons outward The wheel cylinder push rods then push the brake shoes outwar...

Page 176: ...ver The switch which is in circuit with the red warning light in the dash will illuminate the warn ing light whenever the parking brakes are applied Parking brake adjustment is controlled by a cable t...

Page 177: ...rking 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 bin...

Page 178: ...ds Refer to the Brake Drag information in this section for causes BRAKE PULL Front brake pull condition could result from Contaminated lining in one caliper Seized caliper piston Binding caliper Loose...

Page 179: ...er are out of tolerance rotors brake lining not securely attached to the shoes loose wheel bearings and contaminated brake lining THUMP CLUNK NOISE Thumping or clunk noises during braking are fre quen...

Page 180: ...rottle and immediately turn off igni tion to stop engine 7 Wait a minimum of 90 seconds and try brake action again Booster should provide two or more vac uum assisted pedal applications If vacuum assi...

Page 181: ...ess or if machining would reduce thickness below the allowable minimum Rotor minimum thickness is usually specified on the rotor hub The specification is either stamped or cast into the hub surface RO...

Page 182: ...nnec tions Be sure brake line connections are properly made not cross threaded and tightened to recom mended torque BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deterior...

Page 183: ...r cylinder reservoir once more before proceeding 3 Attach one end of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid Fig 13 Be sure end of bleed...

Page 184: ...rgency repair when factory replacement parts are not readily available Special bending tools are needed to avoid kinking or twisting of metal brake tubes Special flaring tools are needed to make a dou...

Page 185: ...Connect harness wires to switch 3 Press and hold brake pedal in applied position 4 Install switch as follows Align tab on switch with notch in switch bracket Then insert switch in bracket and turn it...

Page 186: ...Do not pull switch wire to disconnect 3 Disconnect brake lines at combination valve Fig 20 4 Remove mounting nut and remove valve INSTALLATION 1 Install valve and tighten mounting nut to 17 N m 155 in...

Page 187: ...les remove the coolant reserve overflow tank Refer to Group 7 Cooling System 2 Disconnect brake lines at master cylinder 3 Disconnect wire at combination valve differen tial pressure switch 4 Remove n...

Page 188: ...ghten bracket mounting nuts to 17 5 N m 155 in lbs 13 Connect wire to combination valve switch 14 On RHD vehicles install the coolant reserve overflow tank Refer to Group 7 Cooling System 15 Fill and...

Page 189: ...m 11 ft lbs CAUTION If new caliper bolts are being installed or if the original reason for repair was a drag pull condition check caliper bolt length before proceed ing Bolts must not have a shank le...

Page 190: ...y suspension part with wire Do not allow brake hose to support caliper weight 7 Wipe caliper off with shop rags or towels CAUTION Do not use compressed air this can unseat dust boot and force dirt int...

Page 191: ...brake cleaner 2 If new drums are being installed remove pro tective coating with carburetor cleaner followed by final rinse with brake cleaner 3 Clean and lubricate anchor pin with light coat of Mopa...

Page 192: ...ress parking brake cable retainer tabs Then push retainer and cable through and out of support plate Fig 34 Drum Brake Components Typical 1 ADJUSTER LEVER 2 ADJUSTER CABLE 3 HOLDDOWN SPRING AND RETAIN...

Page 193: ...slack 2 Disengage cables from equalizer and compress cable retainers with a worm drive hose clamp 3 Remove cables from the cable bracket Fig 36 4 Remove rear wheel and brake drums 5 Remove secondary b...

Page 194: ...the parking brake lever base Insure the cable retainer is seated into the base 5 Attach the front cable to the cable lever Fig 39 6 Connect parking brake lamp switch wire 7 Raise vehicle 8 Install adj...

Page 195: ...ir in grommets Then rock reser voir back and forth while pressing downward to seat it in grommets 3 Install pins that retain reservoir to cylinder body 4 Fill and bleed master cylinder on bench before...

Page 196: ...ION Dirt oil and solvents can damage cali per seals Insure assembly area is clean and dry 1 Lubricate caliper piston bore new piston seal and piston with clean brake fluid 2 Lubricate caliper bushings...

Page 197: ...shing And Boot 1 CALIPER SLIDE BUSHING 2 BOOT Fig 50 Bushings And Boots Installation 1 BUSHING 2 BOOT Fig 51 Piston Seal Installation 1 SEAL GROOVE 2 PISTON SEAL Fig 52 Dust Boot On Piston 1 PISTON 2...

Page 198: ...essure com pressed air CAUTION Do not use gasoline kerosene thinner or similar solvents These products may leave a residue that could damage the piston and seal INSPECTION The piston is made from a ph...

Page 199: ...e replace the support plate if any of the pads are worn or rusted through Also replace the plate if it is bent or distorted Fig 57 WHEEL CYLINDER CLEANING Clean the cylinder and pistons with clean bra...

Page 200: ...n position Fig 58 5 Reverse gauge and install it on brake shoes Position gauge legs at shoe centers as shown Fig 59 If gauge does not fit too loose too tight adjust shoes 6 Pull shoe adjuster lever aw...

Page 201: ...that parking brake cables operate freely and are not binding or seized Replace faulty cables before proceeding 6 Reinstall brake drums and wheel tire assem blies after brake shoe adjustment is comple...

Page 202: ...12 mm 0 005 in Max Thickness Variation 0 013 mm 0 0005 in Min Thickness 22 7 mm 0 8937 in Brake Drum Size 9 in or 10 in Brake Booster Type Dual Diaphragm TORQUE CHART DESCRIPTION TORQUE Brake Pedal Pi...

Page 203: ...dynamic check occurs when vehicle road speed reaches approximately 30 kph 18 mph During the dynamic check the CAB briefly cycles the pump and solenoids to verify oper ation If an ABS component exhibit...

Page 204: ...d the inlet valve is closed during the pressure decrease cycle A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels At this point the CAB clo...

Page 205: ...sure in either hydraulic circuit will cause the switch valve to shut tle to the low pressure side Movement of the valve pushes the switch plunger upward This action closes the switch internal contacts...

Page 206: ...brake section for procedure 2 Connect scan tool to the Data Link Connector 3 Select ANTILOCK BRAKES followed by MIS CELLANEOUS then ABS BRAKES Follow the instructions displayed When scan tool displays...

Page 207: ...mm 0 014 to 0 059 in If gap is incorrect sensor is either loose or damaged 6 Secure sensor wire to steering knuckle and body brackets 7 Route sensor wire forward and behind shock absorber Then attach...

Page 208: ...r face against tone ring Fig 10 Then tighten sensor bolt to 13 N m 115 in lbs Cor rect air gap will be established as tone ring rotates and peels spacer off sensor face 7 Route sensor wires to rear se...

Page 209: ...Be sure harness connector is firmly seated 4 Move seat back to normal position DISASSEMBLY AND ASSEMBLY HYDRAULIC CONTROL UNIT CONTROLLER ANTILOCK BRAKE DISASSEMBLY 1 Remove pump motor connector from...

Page 210: ...UE G Sensor Sensor Bolt 3 N m 27 5 in lbs Bracket Bolt 2 7 N m 24 in lbs Hydraulic Control Unit Controller Antilock Brakes Mounting Nuts 11 5 N m 102 in lbs Brake Lines 19 N m 170 in lbs Controller An...

Page 211: ...The clutch mechanism consists of a flywheel a sin gle dry type disc and a diaphragm style clutch cover Fig 1 A hydraulic linkage is used to operate the clutch release bearing and fork The flywheel is...

Page 212: ...o speed up and slow down in response to the cylinder firing pulses The flywheel dampens these impulses by absorbing energy when the crank shaft speeds and releasing the energy back into the system whe...

Page 213: ...release fork which moves the bear ing into contact with the clutch cover diaphragm spring OPERATION The release bearing is operated by a release fork in the clutch housing Slave cylinder force causes...

Page 214: ...BAGS OR CONTAINERS THIS WILL HELP MINIMIZE EXPOSURE TO YOURSELF AND TO OTHERS FOLLOW ALL REC OMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMIN ISTRATION OSHA AND THE EN...

Page 215: ...Fig 8 Clutch Components And Inspection XJ CLUTCH 6 5 DIAGNOSIS AND TESTING Continued...

Page 216: ...in proper alignment with the crankshaft and transmission input shaft Misalignment caused by excessive runout or warpage of any clutch component will cause grab chatter and improper clutch release CLUT...

Page 217: ...convenient reference when diagnosing faulty clutch operation DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Disc facing worn out 1 Normal wear 1 Replace cover and disc 2 Driver frequently rides...

Page 218: ...ean smooth and lubricate shaft splines if possible Replace input shaft if necessary Clutch disc rusted to flywheel and or pressure plate 1 Clutch not used for and extended period of time e g long term...

Page 219: ...rs bent or distorted 2 Replace clutch disc and cover 3 Clutch disc damaged or distorted 2 Replace clutch disc 4 Clutch misalignment 4 Check alignment and runout of flywheel disc pressure plate and r c...

Page 220: ...in Measure runout at the outer edge of the fly wheel face with a dial indicator Mount the dial indi cator on a stud installed in place of one of the clutch housing attaching bolts Clean the crankshaf...

Page 221: ...Fig 10 INSTALLATION 1 Lightly scuff sand flywheel face with 180 grit emery cloth Then clean surface with a wax and grease remover 2 Lubricate pilot bearing with Mopar high tem perature bearing grease...

Page 222: ...icate input shaft splines bearing retainer slide surface fork pivot and release fork pivot surface with Mopart high temperature grease 3 Install new release bearing Be sure bearing is properly secured...

Page 223: ...te that removal installation pro cedures for right and left hand drive models are basi cally the same Only master cylinder location is different REMOVAL 1 Raise vehicle 2 Remove fasteners attaching sl...

Page 224: ...der attaching nuts to 38 N m 28 ft lbs torque 6 Raise vehicle 7 Insert slave cylinder push rod through clutch housing opening and into release lever Be sure cap on end of rod is securely engaged in le...

Page 225: ...ousing M12 75 N m 55 ft lbs Bolt clutch housing 3 8 37 N m 27 ft lbs Bolt clutch housing 7 16 58 N m 43 ft lbs Bolt clutch housing trans 46 N m 34 ft lbs Bolt dust shield M8 8 N m 72 in lbs Bolt dust...

Page 226: ......

Page 227: ...The clutch mechanism consists of a flywheel a sin gle dry type disc and a diaphragm style clutch cover Fig 1 A hydraulic linkage is used to operate the clutch release bearing and fork The flywheel is...

Page 228: ...o speed up and slow down in response to the cylinder firing pulses The flywheel dampens these impulses by absorbing energy when the crank shaft speeds and releasing the energy back into the system whe...

Page 229: ...release fork which moves the bear ing into contact with the clutch cover diaphragm spring OPERATION The release bearing is operated by a release fork in the clutch housing Slave cylinder force causes...

Page 230: ...BAGS OR CONTAINERS THIS WILL HELP MINIMIZE EXPOSURE TO YOURSELF AND TO OTHERS FOLLOW ALL REC OMMENDED SAFETY PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMIN ISTRATION OSHA AND THE EN...

Page 231: ...Fig 8 Clutch Components And Inspection XJ CLUTCH 6 5 DIAGNOSIS AND TESTING Continued...

Page 232: ...in proper alignment with the crankshaft and transmission input shaft Misalignment caused by excessive runout or warpage of any clutch component will cause grab chatter and improper clutch release CLUT...

Page 233: ...convenient reference when diagnosing faulty clutch operation DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION Disc facing worn out 1 Normal wear 1 Replace cover and disc 2 Driver frequently rides...

Page 234: ...ean smooth and lubricate shaft splines if possible Replace input shaft if necessary Clutch disc rusted to flywheel and or pressure plate 1 Clutch not used for and extended period of time e g long term...

Page 235: ...rs bent or distorted 2 Replace clutch disc and cover 3 Clutch disc damaged or distorted 2 Replace clutch disc 4 Clutch misalignment 4 Check alignment and runout of flywheel disc pressure plate and r c...

Page 236: ...in Measure runout at the outer edge of the fly wheel face with a dial indicator Mount the dial indi cator on a stud installed in place of one of the clutch housing attaching bolts Clean the crankshaf...

Page 237: ...Fig 10 INSTALLATION 1 Lightly scuff sand flywheel face with 180 grit emery cloth Then clean surface with a wax and grease remover 2 Lubricate pilot bearing with Mopar high tem perature bearing grease...

Page 238: ...icate input shaft splines bearing retainer slide surface fork pivot and release fork pivot surface with Mopart high temperature grease 3 Install new release bearing Be sure bearing is properly secured...

Page 239: ...te that removal installation pro cedures for right and left hand drive models are basi cally the same Only master cylinder location is different REMOVAL 1 Raise vehicle 2 Remove fasteners attaching sl...

Page 240: ...der attaching nuts to 38 N m 28 ft lbs torque 6 Raise vehicle 7 Insert slave cylinder push rod through clutch housing opening and into release lever Be sure cap on end of rod is securely engaged in le...

Page 241: ...ousing M12 75 N m 55 ft lbs Bolt clutch housing 3 8 37 N m 27 ft lbs Bolt clutch housing 7 16 58 N m 43 ft lbs Bolt clutch housing trans 46 N m 34 ft lbs Bolt dust shield M8 8 N m 72 in lbs Bolt dust...

Page 242: ......

Page 243: ...34 BLOCK HEATER 35 ENGINE ACCESSORY DRIVE BELTS 35 COOLING SYSTEM FANS 38 VISCOUS FAN DRIVE REMOVAL INSTALLATION 39 CLEANING AND INSPECTION RADIATOR PRESSURE CAP 39 RADIATOR 39 WATER PUMP 39 FAN BLAD...

Page 244: ...ine packages The auxiliary air to oil transmission oil cooler is located in front of the radiator or A C condenser if equipped and behind the grill It is mounted to the front frame crossmember The aux...

Page 245: ...rmal viscous fan drive is a torque and tempera ture sensitive clutch unit It automatically increases or decreases fan speed to provide proper engine cool ing Vehicles with a 2 5L 4 0L engine with air...

Page 246: ...rmostat controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator On all engines the thermostat is closed below 195 F 90 C Above this temperature coola...

Page 247: ...e reaches release range of 83 110 kPa 12 16 psi A rubber gasket seals radiator filler neck This is done to maintain vacuum during coolant cool down and to prevent leakage when system is under pres sur...

Page 248: ...coolant mixture No addi tional lubrication is necessary HOSE CLAMPS DESCRIPTION The cooling system utilizes both worm drive and spring type hose clamps If a spring type clamp replacement is necessary...

Page 249: ...rge air It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point Until additional engine cooling is necessary the fan will remain at a...

Page 250: ...ess the coolant temperature is at least 103 C 218 F at which time the fan will come on and remain on until the coolant temperature drops to 99 C 210 F or below When air conditioning is requested inclu...

Page 251: ...ce technician Refer to Group 25 Emission Control Systems for proper procedures ACCESSING DIAGNOSTIC TROUBLE CODES To read DTC s and to obtain cooling system data refer to Group 25 Emission Control Sys...

Page 252: ...eizure 3 Replace faulty component or bearing 4 Belt glazed or hardened from heat and excessive slippage 4 Replace belt LONGITUDAL BELT CRACKING 1 Belt has mistracked from pulley groove 1 Replace belt...

Page 253: ...ds on the cooling system such as the following may be the cause PROLONGED IDLE VERY HIGH AMBIENT TEMPERATURE SLIGHT TAIL WIND AT IDLE SLOW TRAFFIC TRAFFIC JAMS HIGH SPEED OR STEEP GRADES Driving techn...

Page 254: ...MP ILLUMINATES COOLANT MAY OR MAY NOT BE LOST OR LEAKING FROM THE COOLING SYSTEM 1 Trailer is being towed a steep hill is being climbed vehicle is operated in slow moving traffic or engine is being id...

Page 255: ...ge Repair as necessary 8 Incorrect coolant concentration 8 Check coolant Refer to Coolant section in this Group for correct coolant water mixture ratio 9 Coolant not flowing through system 9 Check for...

Page 256: ...Testing in this group 2 During cold weather operation with the heater blower in the high position the gauge reading may drop slightly 2 A normal condition No correction is necessary 3 Temperature gau...

Page 257: ...System Testing For Leaks in this group DETONATION OR PRE IGNITION NOT CAUSED BY IGNITION SYSTEM GAUGE MAY OR MAY NOT BE READING HIGH 1 engine overheating 1 Check reason for overheating and repair as n...

Page 258: ...e Refer to Viscous Fan Drive in this group 5 A certain amount of fan noise may be evident on models equipped with a thermal viscous fan drive Some of this noise is normal 5 Refer to Viscous Fan Drive...

Page 259: ...level should return to within that range after operation at elevated temperatures 1 A normal condition No repair is necessary RADIATOR COOLANT FLOW CHECK The following procedure will determine if coo...

Page 260: ...nd reinspect the system with pressure applied Drops Quickly Shows that a serious leakage is occurring Examine the system for serious external leakage If no leaks are visible inspect for internal leaka...

Page 261: ...Insert thermometer through the hole in the shroud Be sure that there is adequate clearance from the fan blades 3 Connect a tachometer and an engine ignition timing light timing light is to be used as...

Page 262: ...3 For conducting service procedures 4 When checking for vacuum leaks WARNING IF VEHICLE HAS BEEN RUN RECENTLY WAIT AT LEAST 15 MINUTES BEFORE REMOVING RADIATOR CAP WITH A RAG SQUEEZE RADIATOR UPPER HO...

Page 263: ...lant level inspections The coolant level can be checked at coolant reserve overflow tank The coolant reserve overflow system provides a quick visual method for determining coolant level without removi...

Page 264: ...flushing This will soften scale and other deposits and aid the flushing operation CAUTION Be sure instructions on the container are followed REVERSE FLUSHING RADIATOR Disconnect the radiator hoses fr...

Page 265: ...d torque convertor may not require reconditioning Refer to Group 21 for automatic transmission servicing AIR TO OIL COOLER REMOVAL 1 Remove the grill mounting screws and remove the grill Refer to Grou...

Page 266: ...plete assembly WARNING DO NOT REMOVE THE BLOCK DRAIN PLUG S OR LOOSEN RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE SERIOUS BURNS FROM COOLANT CAN OCCUR DO NOT WASTE reusable coolant If th...

Page 267: ...fore removal INSTALLATION 2 5L ENGINE LHD RHD 1 If pump is being replaced install the heater hose pipe to the pump Use a sealant on the fitting such as Mopart Thread Sealant With Teflon Refer to the d...

Page 268: ...2 6 Loosen but do not remove at this time the four water pump pulley to water pump hub mounting bolts Fig 29 and the four viscous fan to idler pulley nuts NOTE The accessory drive belt must be remove...

Page 269: ...e may overheat due to the water pump rotating in the wrong direction Refer to the Belt Removal and Installation in this group for appropriate belt rout ing You may also refer to the Belt Routing Label...

Page 270: ...or letter is stamped into the tongue of constant tension clamps Fig 11 If replacement is necessary use only an original equipment clamp with matching number or letter 2 Remove radiator upper hose and...

Page 271: ...tor grill mounting screws and remove grill Refer to Group 23 Body for procedures 5 Attach one end of a 24 inch long X 1 4 inch ID hose to the radiator petcock Fig 34 Put the other end into a clean co...

Page 272: ...n fluid cooler lines If equipped with remote cooler attach cooler line to bracket at bottom of radiator 7 Install electric fan if equipped and shroud assembly Insert alignment tabs at bottom of fan sh...

Page 273: ...bserve the previous WARNINGS 3 Remove radiator pressure cap 4 For access to radiator draincock remove radia tor grill mounting screws and remove grill Refer to Group 23 Body for procedures 5 Attach on...

Page 274: ...compartment Posi tion alignment dowels into rubber grommets in radi ator lower crossmember Fig 41 2 If equipped with air conditioning attach con denser to radiator with mounting brackets Fig 40 3 Inst...

Page 275: ...nd lay aside 4 Remove the four viscous fan drive assembly mounting nuts from the water pump studs and remove viscous fan assembly 5 Disconnect cooling fan electrical connector 6 Remove the four upper...

Page 276: ...er Fig 44 2 Disconnect the electric fan connector 3 Lift fan straight up and out of vehicle INSTALLATION 1 Align lower retaining tabs of fan shroud with slots in bracket at bottom of radiator Push fan...

Page 277: ...Seat block heater flush against block face Tighten mounting screw to 3 6 N m 32 in lbs torque 4 Fill cooling system with coolant Pressurize system and inspect for leaks 5 Plug power cord into block h...

Page 278: ...drive RHD Or refer to the Belt Routing Label located in the vehicle engine compartment BELT REPLACEMENT OR ADJUSTMENT LEFT HAND DRIVE Belt tension is adjusted at the power steering pump bracket and i...

Page 279: ...ND DRIVE 4 0L 1 Disconnect negative battery cable from battery 2 Loosen lower alternator mounting bolt and nut 3 Loosen upper alternator mounting nut 4 Loosen adjusting bolt at upper alternator bracke...

Page 280: ...blade viscous fan drive should be removed from the vehicle as one assembly 4 Remove four fan hub mounting nuts Fig 55 Fig 56 and remove fan viscous fan drive assembly from vehicle 5 After removing fan...

Page 281: ...g the cooling system to operate at higher temperatures Inspect the plastic end tanks for cracks damage or leaks Inspect the radiator neck for damage or distortion WATER PUMP CLEANING Clean the gasket...

Page 282: ...ne Belt 800 900 180 200 Used Serpentine Belt 623 712 140 160 Belt is considered new if it has been used 15 minetes or less TORQUE SPECIFICATIONS DESCRIPTION N m Ft In Lbs Lbs Trans Auxiliary Oil Coole...

Page 283: ...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 284: ......

Page 285: ...effectively use DaimlerChrysler wiring diagrams to diagnose and repair a Daimler Chrysler vehicle it is important to understand all of their features and characteristics Diagrams are arranged such th...

Page 286: ...The System shown here is an EXAMPLE ONLY It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION 8W 01 2 8W 01 GENERAL INFORMATION XJ DESCRIPTION AND OPERATION Continued...

Page 287: ...The System shown here is an EXAMPLE ONLY It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION XJ 8W 01 GENERAL INFORMATION 8W 01 3 DESCRIPTION AND OPERATION Continued...

Page 288: ...CODE CHART COLOR CODE COLOR STANDARD TRACER COLOR BL BLUE WT BK BLACK WT BR BROWN WT DB DARK BLUE WT DG DARK GREEN WT GY GRAY BK LB LIGHT BLUE BK LG LIGHT GREEN BK OR ORANGE BK PK PINK BK or WT RD RE...

Page 289: ...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 290: ...Wiring Diagram Symbols 8W 01 6 8W 01 GENERAL INFORMATION XJ DESCRIPTION AND OPERATION Continued...

Page 291: ...ber and provide a written location NOTES CAUTIONS and WARNINGS Throughout this group additional important infor mation is presented in three ways Notes Cautions and Warnings NOTES are used to help des...

Page 292: ...solid state When checking voltages in these circuits use a meter with a 10 me gohm or greater impedance rating Ohmmeter Used to check the resistance between two points of a circuit Low or no resistan...

Page 293: ...o ground in that gen eral area of the wiring harness TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1 Refer to the wiring diagrams and disconnect or isolate all items on the suspected f...

Page 294: ...7 5 Push the two ends of wire together until the strands of wire are close to the insulation example 2 Fig 7 6 Twist the wires together example 3 Fig 7 7 Solder the connection together using rosin cor...

Page 295: ...sconnect the connector from its mating half component 3 Push down on the yellow connector locking tab to release the terminals Fig 13 4 Using special tool 6932 push the terminal to remove it from the...

Page 296: ...ies 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 half com...

Page 297: ...d sealant comes out of both ends of the tubing 14 Repeat steps 8 through 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 conn...

Page 298: ...red wire into the connector 16 Install the connector locking wedge if required and reconnect the connector to its mating half component 17 Re tape the wire harness starting 1 1 2 inches behind the con...

Page 299: ...Solder the connection together using rosin core type solder only Do not use acid core solder 7 Tape the diode to the harness using electrical tape making sure the diode is completely sealed from the...

Page 300: ......

Page 301: ...ture Gauge 8W 40 Engine Coolant Temperature Sensor 8W 30 Engine Oil Pressure Sensor 8W 30 Engine Starter Motor Relay 8W 21 Engine Starter Motor 8W 21 Evap Leak Detection Pump 8W 30 Extended Idle Switc...

Page 302: ...8W 47 Speed Control Switches 8W 33 Speedometer 8W 40 Component Page Splice Information 8W 70 Tachometer 8W 40 Tail Stop Lamps 8W 51 Throttle Position Sensor 8W 30 Torque Converter Clutch Solenoid 8W 3...

Page 303: ...10 12 Fuse 16 PDC 8W 10 8 17 Fuse 17 JB 8W 10 9 Fuse 17 PDC 8W 10 8 17 Component Page Fuse 18 JB 8W 10 9 Fuse 18 PDC 8W 10 15 Fuse 19 JB 8W 10 11 Fuse 19 PDC 8W 10 8 18 Fuse 20 JB 8W 10 12 Fuse 20 PD...

Page 304: ...3 5 6 40A 12 4 5 40A 11 3 4 50A 10 2 3 40A 9 1 2 40A 8 21 15 16 17 18 19 20 22 23 24 25 26 27 28 15 14 13 20A 12 40A 11 10 20A 9 20A F21 15A F27 10A 1 2 F24 F23 15A 4 3 F26 20A F20 15A F17 20A F16 15A...

Page 305: ...16 17 20A 20A 18 19 15A A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A0 6RD A17 16RD BK A3 14RD WT A17 16RD BK 26 10A F1 20DB GY A17 16RD B...

Page 306: ...B20 B16 B19 FUNCTION CAVITY CIRCUIT G19 20LG OR ABS WARNING INDICATOR DRIVER T141 20YL IGNITION SWITCH OUTPUT START C8 PARK NEUTRAL POSITION SWITCH SENSE T41 20BK WT C10 ENGINE STARTER MOTOR RELAY OUT...

Page 307: ...34 16RD GY FOG LAMP RELAY OUTPUT NO 1 L139 20VT B9 FUSED HEADLAMP SWITCH OUTPUT L77 20BR YL B6 B8 B10 B7 B10 FUSED HEADLAMP SWITCH OUTPUT L77 20BR YL Z1 20BK GROUND L33 20RD WT FUSED B G34 16RD GY HIG...

Page 308: ...IATOR FAN RELAY CIRCUIT CAVITY FUNCTION FUSED B F99 18RD FUSED B F99 18RD C17 C20 C16 C18 K74 18BR VT OXYGEN SENSOR DOWNSTREAM RELAY CONTROL A242 18VT OR OXYGEN SENSOR 1 2 DOWNSTREAM F26 18PK OR FUSED...

Page 309: ...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 FUSE TO TO ENGINE STARTER YL 16 A41 MOTOR RELAY TO BLOCK...

Page 310: ...A5 A6 25 FUSE 15A 20A FUSE 26 A4 A3 A10 A9 23 FUSE 15A SWITCH F32 20 PK DB TO BRAKE LAMP S301 TO VT 16 F75 S218 TO F34 18 TN BK RELAY F61 20 WT OR TO FOG LAMP NO 2 IN PDC IN PDC F8 C100 ABS ABS RELAY...

Page 311: ...G9 20 GY BK C100 G9 20 GY BK 66 C201 S211 S210 FROM TO S200 15A FUSE 17 BLOCK JUNCTION L1 C4 18 FUSE 10A 25A 28 BREAKER CIRCUIT CIRCUIT BREAKER 30 20A RUN A22 G108 G9 20 GY BK A31 12 BK WT 4 ACC 3 LO...

Page 312: ...KEY IN C1 7 SWITCH IGNITION C1 9 3 0 2 1 4 A21 12 DB BK LB 20 G16 RHD LHD C306 2 C203 3 LHD RHD 4 C203 B C318 G16 18 BK LB 2 LHD RHD BK LB 20 G16 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD C1 6 0 1 2 8 C2 C2...

Page 313: ...4 ACC BK OR 12 A22 A41 14 YL 4 1 2 0 3 10 C1 3 0 2 1 4 C1 3 C1 4 PK BK 12 A2 BATT A2 C201 63 10A FUSE 19 M1 C4 LHD RHD RHD LHD YL 14 A41 SPARE FUSE 24 85 8W 48 2 8W 48 3 8W 12 20 8W 12 21 8W 12 15 8W...

Page 314: ...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 85 F30 16 RD 8W 12 2 8W 41 2 8W 41 3 8W 41 2...

Page 315: ...LHD C202 7 LG RD 12 F141 IN PDC FAN RADIATOR RELAY LB 12 C25 RD LG 12 A111 RADIATOR FAN MOTOR A111 12 RD LG 8 C209 RELAY MOTOR BLOWER 1 C1 12 DG A MOTOR BLOWER 8W 10 7 8W 10 2 8W 42 8 8W 42 8 8W 42 2...

Page 316: ...HEADLAMP 8 C1 RD WT A3 DAYTIME RUNNING LAMP MODULE 6 D1 C100 A3 RD WT CENTER DISTRIBUTION POWER BATT A0 30A FUSE 7 6 RD WT 14 A3 RHD OTHER 4 0L A17 16 RD BK 14 14 14 A C COMPRESSOR CLUTCH RELAY IN PDC...

Page 317: ...TREAM 15A FUSE 18 A19 A20 A999 16 RD 1 C107 A142 18 DG OR A142 18 DG OR S109 1 COIL IGNITION A142 18 DG OR A142 DG OR 18 18 DG OR A142 FUEL INJECTOR NO 6 NO 5 INJECTOR FUEL 1 1 FUEL INJECTOR NO 3 NO 4...

Page 318: ...RELAY BK PK 12 A4 C2 1 BLOCK JUNCTION BATT A0 20A FUSE 10 23 16 C6 C7 POWER DISTRIBUTION CENTER 30 87 BRAKE ANTI LOCK CONTROLLER 2 ENGINE STARTER MOTOR RELAY A41 16 YL IN PDC C15 12 BK WT 17 24 11 FU...

Page 319: ...K 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 18 TO S347 4 0L PK 18 M1 C314 5 LHD RHD RHD LHD SWITCH SWITCH MERCURY LAMP UNDERHOOD S361 SKIM EXCEPT SKIM 20A FU...

Page 320: ...N BK 18 F34 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 VANI...

Page 321: ...ERTRAIN A11 A12 22 FUSE 15A C1 C2 2 COMBINATION FLASHER BATT A0 CENTER DISTRIBUTION POWER 15A FUSE 20 A15 A16 BK PK 20 L9 F5 L9 20 BK PK LHD RHD 22 C204 FUEL PUMP RELAY IN PDC A61 14 DG BK C200 13 B11...

Page 322: ...A VT 16 F75 F75 16 VT VT 16 F75 VT 16 F75 S301 AMPLIFIER POWER 1 C2 C2 2 RHD LHD 24 C204 C204 21 LHD RHD 14 C200 F61 20 WT OR NO 2 FOG LAMP RELAY IN PDC PK DB 20 F32 WT TN 20 L50 F8 C100 C4 C100 E1 C1...

Page 323: ...ater Control 8W 12 8 9 High Note Horn 8W 12 19 Horn Relay 8W 12 19 Horn Switch 8W 12 19 Instrument Cluster 8W 12 8 9 11 15 16 26 Junction Block 8W 12 2 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22...

Page 324: ...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 325: ...21 22 23 24 25 26 27 L4 16VT WT 10A L44 20VT RD L4 16VT WT A22 12BK OR A22 12BK OR A22 12BK OR A41 14YL A7 10RD BK A7 10RD BK A7 10RD BK A4 12BK PK INTERNAL A31 12BK WT A31 12BK WT A21 12DB L3 16RD OR...

Page 326: ...FOGGER RELAY CONTROL FUSED B HORN RELAY OUTPUT 87A GROUND CIGAR LIGHTER RELAY OUTPUT FUSED IGNITION SWITCH OUTPUT RUN ACC FUSED B F30 16RD A31 12BK WT INTERNAL 87 86 85 30 FUNCTION CAVITY CIRCUIT 87A...

Page 327: ...R OUTLET 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 12 8W 41 2 8W 41 3 8W 41 2 8W 41 3 8W 41 2 8W 4...

Page 328: ...20 L33 HEADLAMP SELECT S7 C4 RD OR 16 L3 SWITCH 3 C201 16 L3 16 RD OR S213 RD OR 16 L3 LHD RHD RD OR 20 L34 EXCEPT DRL IN PDC NO 1 RELAY LAMP FOG 12 L33 20 RD WT L33 20 RD BEAM B10 C106 8W 12 2 8W 50...

Page 329: ...3 C4 SWITCH 1 VT WT 16 L4 L4 16 VT WT S133 LHD RHD C201 22 RHD LHD L44 20 VT RD C100 DRL OTHER VT RD 18 L44 10 MODULE LAMP RUNNING DAYTIME HEADLAMP F6 B12 L43 18 VT L44 18 VT RD L4 16 VT WT L4 16 VT W...

Page 330: ...RADIO C2 5 LAMP 1 FRONT FOG SWITCH SWITCH WINDOW 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 ILLUM...

Page 331: ...DOW REAR 4 DEFOGGER 3 C1 INSTRUMENT 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 ILLUMINATION SWITCH CASE TRANSFE...

Page 332: ...CTOR S340 LAMP STOP TAIL LEFT 2 OTHERS TOW TRAILER L77 18 BR YL L77 20 S206 C1 LAMP BR YL BR YL BR YL BR YL BR YL L77 18 BR YL FRONT FRONT LAMP LAMP C323 7 7 C322 L77 18 BR C2 4 RADIO L7 18 BK YL 1 C3...

Page 333: ...INSTRUMENT 8 C1 F87 20 WT BK WT BK 20 F87 S216 OPTIONS FULL BASE WT BK 20 F87 F87 20 WT BK S225 4 F87 20 WT BK SENTRY KEY IMMOBILIZER MODULE C301 6 LHD RHD RHD LHD F87 20 WT BK F87 20 WT BK F87 20 WT...

Page 334: ...8 WT F20 18 WT F20 18 WT LHD RHD E9 PK OR 18 F26 IN PDC RELAY SENSOR OXYGEN UPSTREAM C13 WT 18 F20 2 B5 IN PDC RELAY CLUTCH COMPRESSOR A C DOWNSTREAM OXYGEN SENSOR RELAY IN PDC 4 0L A T 4 0L A T DRL 4...

Page 335: ...L POWERTRAIN 2 C1 S130 MODULE D4 RELAY DOWN AUTOMATIC SHUT IN PDC C5 RELAY FUEL PUMP IN PDC F12 18 DB WT F12 18 DB WT DB WT 18 F12 10 C107 F12 18 DB WT D6 C3 8W 12 2 8W 10 10 8W 30 2 8W 30 3 8W 30 4 8...

Page 336: ...PUMP IN PDC F12 18 DB WT F12 18 DB WT DB WT 18 F12 10 C107 F12 18 DB WT DB WT 18 F12 26 RHD MODULE CONTROL TRANSMISSION F12 18 DB WT F12 18 DB WT MODULE CONTROL TRANSMISSION 26 F12 18 DB WT F12 18 DB...

Page 337: ...INDOW REAR 3 DEFOGGER SWITCH 37 C200 11 C305 MIRROR 5 DRIVER POWER CLUSTER INSTRUMENT 3 C16 20 LB YL POWER PASSENGER 5 MIRROR DEFOGGER REAR WINDOW 4 C326 C312 2 C310 C15 12 BK WT BK WT 12 C15 C2 17 LB...

Page 338: ...FLASHER C16 20 LB YL WINDOW REAR 3 DEFOGGER SWITCH 2 C204 11 C305 MIRROR 5 PASSENGER POWER CLUSTER INSTRUMENT 3 C16 20 LB YL DEFOGGER REAR WINDOW 4 C326 C312 2 C310 C15 12 BK WT BK WT 12 C15 C2 3 C9...

Page 339: ...3 39 C200 3 C305 YL DG 18 F83 POWER LOCK DRIVER WINDOW SWITCH C2 3 4 0L A T T141 20 YL YL RD 20 F45 CLUTCH INTERLOCK SWITCH 2 1 JUMPER F45 18 YL 2 POWER SWITCH MIRROR F83 18 YL DG FULL OPTIONS POWER M...

Page 340: ...CH RD 16 F35 C5 7 16 C204 1 C306 F35 16 RD RD 16 F35 LOCK WINDOW C100 E8 C4 S4 3 C300 F83 18 YL DG F45 18 YL F83 18 YL DG POWER C2 DRIVER 3 SWITCH LOCK WINDOW 2 POWER MIRROR SWITCH F83 18 YL DG S352 M...

Page 341: ...TRAILER 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...

Page 342: ...WIPER F15 20 DB WT DB WT 20 F15 SWITCH 3 EXTENDED IDLE S217 WASHER POLICE PACKAGE 5 S219 HEATER A C 4 CONTROL F15 20 DB WT IN PDC DB WT 20 F15 S134 DB WT 20 F15 B20 ANTI LOCK CONTROLLER BRAKE RELAY AN...

Page 343: ...RAKE CONTROLLER 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 1 C204 WASHER S349 DB WT 20 F15 4 A C HEATER CONTROL F15 20 DB WT F15 20 DB...

Page 344: ...DG YL DG YL 18 L78 M3 C4 BK YL 18 L7 45 C201 RHD LHD L7 18 BK YL HEADLAMP SWITCH 9 2 RIGHT TAIL STOP LAMP S206 LAMP C1 HEADLAMP SWITCH OUTPUT NO 1 LAMP SIGNAL TURN PARK FRONT RIGHT RIGHT FRONT PARK T...

Page 345: ...1 8 C5 C8 1 F81 14 TN 4 PASSENGER POWER C2 LOCK WINDOW SWITCH SWITCH WINDOW LOCK C1 POWER DRIVER 9 1 C307 TN 12 F81 TN 14 F81 LG YL 18 F14 F23 18 DB YL 13 C201 F81 12 TN 33 C200 TN 12 F81 FULL OPTIONS...

Page 346: ...BREAKER CIRCUIT RUN ACC A31 8 C5 C8 1 F81 14 TN TN 12 F81 15 C204 14 LG YL 18 F14 F23 18 DB YL C202 3 SWITCH WINDOW LOCK C2 POWER PASSENGER 4 F81 14 TN C307 1 SWITCH WINDOW LOCK C1 POWER DRIVER 9 FUL...

Page 347: ...D LHD C201 8 DB 16 V6 WIPE WASH SWITCH SWITCH SEAT POWER LEFT 8 HEATED SEAT RELAY 10 C329 RIGHT POWER SEAT SWITCH B S356 F37 14 RD F37 14 RD LB F37 14 RD LB F37 14 RD C362 1 C363 1 F37 14 RD LB F37 14...

Page 348: ...LAMP 1 1 M1 20 PK M1 20 PK 6 C201 M1 20 PK S18 C4 M1 20 PK M1 20 PK PK 20 M1 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 SW...

Page 349: ...AMB SWITCH YL 18 M2 SWITCH JAMB DOOR LEFT REAR M2 18 YL M2 20 YL A C317 A C320 C319 A C318 A YL 20 M2 YL 18 M2 REAR DOOR JAMB SWITCH M2 18 YL SWITCH JAMB DOOR 3 1 PASSENGER S304 M2 20 YL RIGHT CARGO B...

Page 350: ...4 OR BK 16 P33 LOCK DRIVER DOOR MOTOR 2 2 MOTOR DOOR LEFT REAR LOCK LOCK REAR RIGHT DOOR MOTOR 2 A LIFTGATE LOCK MOTOR 1 PK BK 16 P34 1 C1 P34 16 PK BK S316 PK BK 16 P34 C9 12 C7 5 PK BK 16 P34 1 1 P...

Page 351: ...REAR LOCK LOCK REAR RIGHT DOOR MOTOR 2 A LIFTGATE LOCK MOTOR 1 C1 P34 16 PK BK S322 PK BK 16 P34 1 1 P34 16 PK BK 1 P34 16 PK BK B P34 16 PK BK 5 5 5 P34 16 PK BK PK BK 16 P34 PK BK 16 P34 PK BK 16 P...

Page 352: ...20 OR YL 12 C200 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 8 7 P71 20 YL P75 20 DB WT P91 20 WT BK P76 20 OR YL 1 2 3 4 4 DOWN 3 LEFT 1 RIGHT 2 UP P91 20 WT BK P76 20 OR YL C305 28 C201 6...

Page 353: ...20 34 8 P72 20 YL BK 7 C2 YL BK 20 P72 YL BK 20 P72 YL BK 20 P72 POWER DRIVER MIRROR C2 2 OR YL 20 P76 P76 20 OR YL 2 4 OR YL 20 P76 S328 P76 20 OR YL 10 C305 36 C200 OR YL 20 P76 28 C201 P76 20 OR YL...

Page 354: ...C203 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 3 4 P74 20 DB P72 20 YL BK S319 S5 C4 G107 P91 20 WT BK P76 20 OR YL Z1 14 BK S208 Z1 14 BK 1 2 3 4 4 DOWN 3 LEFT 1 RIGHT 2 UP P91 20 WT BK P...

Page 355: ...8 8 P71 20 YL 1 YL BK 20 P72 POWER PASSENGER MIRROR P76 20 OR YL 2 4 OR YL 20 P76 S328 P76 20 OR YL 10 C305 10 C204 OR YL 20 P76 P76 20 OR YL 2 C5 10 C9 2 OR YL 20 P76 S318 P76 20 OR YL OR YL 20 P76 4...

Page 356: ...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 POWER MIRRORS RHD LHD MIRRORS POW...

Page 357: ...amp 8W 15 10 11 Component Page Left Turn Signal Lamp 8W 15 10 11 Left Visor Vanity Lamp 8W 15 7 License Lamp 8W 15 14 Liftgate Switch 8W 15 14 Overhead Module 8W 15 7 Oxygen Sensor 1 1 Upstream 8W 15...

Page 358: ...R ANTI LOCK 24 BK 12 Z1 G102 Z1 12 BK BK 18 Z1 Z12 18 BK TN A1 C100 A7 BK TN 18 Z12 Z1 18 BK 4 5 LINK DATA CONNECTOR C1 C10 IN PDC 2 5L M T RELAY MOTOR STARTER ENGINE T41 20 BK WT PRESSURE TRANSFER CA...

Page 359: ...K 20 Z1 Z1 16 BK S132 2 4 CONTROL VEHICLE SPEED SERVO IN PDC B8 RELAY FOG LAMP NO 1 NO 2 LAMP FOG RELAY B13 IN PDC Z1 20 BK BK 18 Z1 A 8W 15 6 TO G106 DRL DRL SWITCH MERCURY LAMP UNDERHOOD 8W 53 3 8W...

Page 360: ...BK B 8W 15 6 TO G106 C 8W 15 6 TO G106 REAR WASHER PUMP SWITCH MERCURY C10 Z1 20 BK C107 5 T41 18 BK WT 6 C1 MODULE CONTROL POWERTRAIN IN PDC RELAY MOTOR STARTER ENGINE ABS EXCEPT DRL IN PDC RELAY BR...

Page 361: ...1 D 8W 15 6 TO G106 E 8W 15 6 TO G106 WINDSHIELD WASHER PUMP REAR WASHER PUMP SWITCH LEVEL FLUID WASHER SWITCH MERCURY LAMP UNDERHOOD B8 B13 IN PDC NO 1 RELAY LAMP FOG IN PDC NO 2 RELAY LAMP FOG Z1 20...

Page 362: ...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 C106 BK 16 Z1 C 8W 15 4 S141 FROM BK 16 Z1 B...

Page 363: ...IRRORS POWER BK 16 Z1 S319 PASSENGER POWER MIRROR BK 18 Z1 6 BK 20 Z1 POWER MIRROR SWITCH 1 LHD 6 Z1 18 BK MIRROR DRIVER POWER LHD POWER PASSENGER MIRROR 6 SWITCH WINDOW 6 C2 POWER PASSENGER LOCK BK 1...

Page 364: ...D IDLE SWITCH 1 OTHERS POLICE PACKAGE I 8W 15 7 C201 FROM BK 14 Z1 2 A C HEATER CONTROL Z1 20 BK LHD RHD 7 17 C204 Z1 20 BK Z1 20 BK C201 7 J 8W 15 7 JUNCTION BLOCK FROM LHD RHD Z1 14 BK Z1 14 BK Z1 2...

Page 365: ...BRAKE Z2 20 BK LG COMPASS 12 C301 5 Z2 20 BK LG C201 58 LHD RHD BK LG 20 Z2 3 SENTRY KEY 5 Z2 20 BK LG BK LG 20 Z2 MODULE IMMOBILIZER S227 BK LG 20 Z2 1 CONTROL HEATER OTHER A C Z8 12 BK VT Z8 20 BK...

Page 366: ...OR POWER 6 WINDOW LOCK POWER DRIVER C2 5 C1 8 SWITCH 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 TR...

Page 367: ...IER POWER C2 8 Z5 16 BK LB G301 BK LB 16 Z5 G300 Z6 18 BK YL 10 AIRBAG CONTROL MODULE Z1 14 BK Z1 14 BK BK 18 Z1 8 TRAILER TOW CONNECTOR S337 LAMP STOP TAIL LEFT 1 1 LEFT TURN SIGNAL LAMP LAMP BACK UP...

Page 368: ...1 2 RIGHT REAR DOOR JAMB SWITCH SWITCH JAMB DOOR PASSENGER 3 Z1 18 BK C318 C LAMP STOP TAIL RIGHT 1 1 RIGHT TURN SIGNAL LAMP LAMP BACK UP RIGHT 1 Z1 18 BK BK 18 Z1 BK 18 Z1 S348 8W 39 6 8W 39 6 8W 51...

Page 369: ...MP LAMP BACK UP RIGHT 1 Z1 18 BK BK 18 Z1 BK 18 Z1 S348 SWITCH JAMB DOOR DRIVER 3 Z1 18 BK S319 Z1 18 BK Z1 16 BK BK 14 Z1 BK 14 Z1 6 POWER MIRROR LOCK POWER DRIVER 8 C1 WINDOW SWITCH 5 C2 DRIVER 5 C3...

Page 370: ...2 9 C311 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 C333 2 Z1 18 BK C330 2 Z1 18 BK 8W 48 2 8W 48 3 8W 51 4 8W 53 3 8W 5...

Page 371: ...18 BK SWITCH SWITCH BK 18 Z1 3 RIGHT HEATED SEAT S355 Z1 18 BK SEAT POWER RIGHT A Z1 14 BK SWITCH SWITCH BK 14 Z1 B LEFT POWER SEAT INTERFACE BK LG 18 Z2 13 SEAT HEAT MODULE Z2 18 BK LG C329 13 G306...

Page 372: ......

Page 373: ...3 Engine Starter Motor 8W 20 2 Fuel Pump Relay 8W 20 3 Fuse 8 PDC 8W 20 2 Fuse 18 PDC 8W 20 2 Fuse 21 PDC 8W 20 2 Component Page Fuse 22 PDC 8W 20 3 Fusible Link 8W 20 2 G100 8W 20 2 G101 8W 20 2 Gen...

Page 374: ...C A14 A13 POWER DISTRIBUTION CENTER DG WT F142 18 15A FUSE 21 1 S168 18 F142 DG WT 3 C108 C107 2 K20 18 DG DG 18 K20 2 K72 16 DG OR DG OR 18 K72 25 C3 SOURCE GENERATOR DG 10 A11 FUSIBLE LINK S118 ENGI...

Page 375: ...K167 20 BR YL K167 18 BR YL 4 0L K167 18 BR YL OTHER BR YL 20 K167 BR YL 20 K167 S111 3 C107 BATTERY TEMPERATURE SENSOR SIGNAL K118 18 PK YL 15 C3 SENSOR TEMPERATURE BATTERY 2 1 S138 GROUND SENSOR C1...

Page 376: ......

Page 377: ...ngine Starter Motor Relay 8W 21 2 3 4 5 Fog Lamp Relay No 1 8W 21 5 Fuse 10 PDC 8W 21 2 3 4 5 Fuse 19 JB 8W 21 2 3 4 5 Component Page G101 8W 21 4 G106 8W 21 3 5 Junction Block 8W 21 2 3 4 5 Park Neut...

Page 378: ...9 FUSE 10A ST A41 3 C1 JUNCTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC 1 C108 BR 16 T40 16 E7 C100 1 2 JUMPER SWITCH INTERLOCK CLUTCH E8 C100 LHD RHD 1 PULL IN 2 HOLD IN BK WT 20 T41 C107 5 T41 18 BK...

Page 379: ...AL PARK 19 FUSE 10A ST A41 3 C1 JUNCTION BLOCK ENGINE STARTER MOTOR RELAY IN PDC 8 Z1 18 BK S141 5 C107 T41 20 BK WT 1 C108 BR 16 T40 16 E7 C100 1 2 JUMPER SWITCH INTERLOCK CLUTCH E8 C100 LHD RHD 1 PU...

Page 380: ...NCTION 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...

Page 381: ...MOTOR RELAY IN PDC Z1 20 BK BK 16 Z1 S132 G106 1 C108 16 CLUTCH INTERLOCK SWITCH RHD LHD YL 20 T141 C100 E8 2 1 C100 E7 T40 16 BR 1 PULL IN 2 HOLD IN 1 SWITCH INTERLOCK CLUTCH 2 B8 Z1 20 BK EXCEPT DRL...

Page 382: ......

Page 383: ...8W 30 2 5 6 8 Fuse 22 PDC 8W 30 2 3 4 Fuse 25 JB 8W 30 17 Component Page G101 8W 30 2 8 10 11 14 17 G102 8W 30 19 G106 8W 30 14 G107 8W 30 17 G108 8W 30 16 G302 8W 30 3 4 Generator 8W 30 18 Headlamp S...

Page 384: ...A13 POWER DISTRIBUTION CENTER 15A FUSE 21 F142 18 DG WT A11 A12 A61 14 DG BK 15A FUSE 22 C1 FUEL PUMP RELAY 14 C107 A61 16 DG BK DG BK 14 A61 22 C1 B FUSED 31 Z12 14 14 Z12 32 G101 GROUND C1 C1 GROUN...

Page 385: ...C107 30 C200 S138 F12 C100 K167 20 BR YL FUSED B C1 A61 14 DG BK 22 14 C107 DG BK 16 A61 3 26 C3 FUEL LEVEL SENSOR F11 C100 15 DB LG 20 K226 S111 BR YL 20 K167 BK 12 Z1 SIGNAL K226 20 DB LG OTHER CAL...

Page 386: ...G 3 C107 7 C204 S138 B3 C100 K167 20 BR YL FUSED B C1 A61 14 DG BK 22 14 C107 DG BK 16 A61 3 26 C3 FUEL LEVEL SENSOR B2 C100 6 DB LG 20 K226 S111 BR YL 20 K167 BK 12 Z1 SIGNAL K226 20 DB LG OTHER CALI...

Page 387: ...OR K167 20 BR YL SUPPLY 5V 5V SUPPLY S109 1 C107 18 FUSE 15A A20 A19 POWER DISTRIBUTION CENTER A999 16 RD TO 21 PDC FUSE BR YL 20 K167 K167 20 BR YL A142 18 DG OR A142 18 DG OR OR 18 K7 OR 18 K7 2 SIG...

Page 388: ...18 A142 DG OR 18 A142 DG OR 18 A142 C2 C2 C2 C2 C2 D8 BATT A16 POWER DISTRIBUTION CENTER AUTOMATIC SHUT DOWN RELAY D2 S109 DG OR 18 A142 1 C107 18 FUSE 15A A20 A19 TO 21 PDC FUSE A142 18 DG OR RD 16 A...

Page 389: ...NSOR TEMPERATURE AIR INTAKE ENGINE COOLANT TEMPERATURE SENSOR SIGNAL 20 BR YL K167 S111 BR YL 20 K167 SIGNAL SENSOR POSITION THROTTLE S112 OR DB 20 K22 17 TRANSMISSION CONTROL MODULE 6 C107 K22 20 OR...

Page 390: ...SIGNAL 1 1 SENSOR OXYGEN BK 16 Z1 S107 S114 BR YL 20 K167 K167 20 BR YL K167 20 BR YL D8 BATT A16 POWER DISTRIBUTION CENTER AUTOMATIC SHUT DOWN RELAY D2 DG WT 18 F142 7 C107 21 FUSE 15A A14 A13 A999...

Page 391: ...F20 18 WT F99 18 RD F99 18 RD A42 18 DG A242 18 VT OR K73 18 BR OR K74 18 BR VT A21 A22 EXCEPT DRL OTHER PK OR 18 F26 DRL OTHER WT 18 F20 F26 18 PK OR EXCEPT FOG A T A T FOG C4 A9 LHD RHD OXYGEN SENSO...

Page 392: ...167 K167 20 BR YL K167 20 BR YL 1 4 2 3 S121 S122 B 8W 30 9 A 8W 30 9 7 13 C107 OTHER OTHER CALIFORNIA OXYGEN SENSOR UPSTREAM RELAY FROM OXYGEN SENSOR DOWNSTREAM RELAY TO A42 18 DG A42 20 DG A42 20 DG...

Page 393: ...1 S107 BR YL 20 K167 K167 20 BR YL 1 4 2 3 B 8W 30 9 A 8W 30 9 OXYGEN SENSOR UPSTREAM RELAY FROM OXYGEN SENSOR DOWNSTREAM RELAY FROM 7 13 C107 S121 S122 A42 18 DG A42 20 DG A42 20 DG A42 20 DG A242 18...

Page 394: ...167 20 BR YL WT OR 20 G7 G7 20 WT OR 7 MODULE LAMP RUNNING DAYTIME 4 C107 OTHER DRL SUPPLY 5V VEHICLE SPEED SENSOR SIGNAL SENSOR GROUND VEHICLE SPEED SENSOR SIGNAL NOT USED ENGINE GROUND SENSOR OIL PR...

Page 395: ...K167 20 BR YL K4 20 BK RD SWITCH CONTROL SPEED LEFT 2 1 1 2 RIGHT SPEED CONTROL SWITCH 3 3 COAST 2 CANCEL 1 RESUME ACCEL 2 ON OFF 1 SET 1 2 2 1 B A S222 S221 V37 20 RD LG K167 20 BR YL RD LG 20 V37 B...

Page 396: ...EED 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 ST T141 SUPPLY 2 5L A T OTHER 4 0L A T V32 18 YL RD RHD LHD YL RD 18 V32 PARK NE...

Page 397: ...F20 S12 C4 C100 E9 1 C201 C100 A9 LHD RHD TORQUE CONVERTER CLUTCH SOLENOID CONTROL F20 18 WT WT 18 F20 F12 18 DB WT DB WT 18 F12 4 0L LHD A T OTHER 11 C107 F20 18 WT S161 2 C1 F12 18 DB WT 10 FUSED IG...

Page 398: ...ROL NO 2 NO 3 DRIVER DRIVER DRIVER DRIVER C1 10 C1 19 18 18 18 K40 BR WT NO 1 4 1 NO 4 VT BK K59 K60 YL BK NO 2 3 NO 3 IDLE AIR 2 K39 18 GY RD B1 C100 F10 K29 18 WT PK RHD LHD DRIVER DRIVER DRIVER DRI...

Page 399: ...107 S208 BK 14 Z1 Z1 20 BK 6 FUSE 5A JUNCTION BLOCK OR 20 E2 C4 S2 S1 C4 TN 20 E1 42 C201 C1 1 SWITCH HEADLAMP S8 C4 F15 20 DB WT 15A FUSE 25 RUN A22 S217 40 C201 43 S315 E2 20 OR PACKAGE POLICE S215...

Page 400: ...2 1 GENERATOR FIELD GENERATOR SOURCE RELAY CLUTCH COMPRESSOR A C RADIATOR FAN RELAY A C SWITCH SENSE SENSE SWITCH A C SENSE SWITCH A C SENSE SWITCH PUMP DETECTION LEAK CONTROL SOLENOID PUMP DETECTION...

Page 401: ...0 PK BK TN 18 Z12 TRANSMIT 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 0...

Page 402: ...S144 S145 POWERTRAIN CONTROL MODULE MODULE CONTROL TRANSMISSION BUS CCD CCD BUS D1 18 VT BR WT BK 18 D2 E11 C100 E12 51 C201 52 D2 18 WT BK VT BR 18 D1 AIRBAG CONTROL MODULE PAIR TWISTED PAIR TWISTED...

Page 403: ...45 POWERTRAIN CONTROL MODULE MODULE CONTROL TRANSMISSION BUS CCD CCD BUS D1 18 VT BR WT BK 18 D2 A11 C100 A12 19 C204 20 D2 18 WT BK VT BR 18 D1 AIRBAG CONTROL MODULE PAIR TWISTED PAIR TWISTED TWISTED...

Page 404: ......

Page 405: ...sor 8W 31 5 Junction Block 8W 31 2 3 4 6 7 Component Page Lock Up Solenoid 8W 31 4 Output Speed Sensor 8W 31 5 Park Neutral Position Switch 8W 31 2 Power Distribution Center 8W 31 2 4 Powertrain Contr...

Page 406: ...DB WT 18 F12 5 C2 ST RUN A21 20A FUSE 11 BLOCK JUNCTION F12 18 DB WT C107 10 S130 S161 WT 18 F20 1 3 BR LG 18 L10 10 FUSE 15A C4 S12 2 C1 11 C107 1 C201 C100 E9 S159 F20 18 WT SOLENOID CLUTCH E3 C100...

Page 407: ...C3 24 POWERTRAIN CONTROL MODULE F15 20 DB WT F15 20 DB WT 40 C201 S217 F10 BRAKE SWITCH SENSE LHD RHD LAMP WT PK 20 K29 LHD RHD K29 18 WT PK F15 20 DB WT LHD RHD WT PK 18 K29 RHD LHD K29 20 WT PK 8W...

Page 408: ...9 C107 BK TN 18 Z12 FUSED B 25 S135 M1 20 PK 12 WT 20 T19 3 2 T60 20 OR WT 13 4 T22 20 DB WT 11 SOLENOID TRANSMISSION 3 4 AND 1 2 SOLENOID 2 3 SOLENOID LOCK UP SOLENOID SOLENOID A SOLENOID B SOLENOID...

Page 409: ...MODULE CONTROL POWERTRAIN S115 K7 18 OR OR 20 K7 17 C1 3 SENSOR POSITION THROTTLE K22 20 OR DB 4 C1 THROTTLE POSITION SENSOR SIGNAL 2 OR DB 20 K22 17 6 C107 S112 1 S114 K167 20 BR YL BR YL 20 K167 16...

Page 410: ...T3 T42 15A FUSE 10 F20 18 WT S12 ST RUN A21 JUNCTION BLOCK C4 S159 S141 Z1 16 BK G106 ENGINE STARTER MOTOR RELAY FROM BR LG 18 L10 S142 F20 18 WT F20 18 WT 1 C201 C100 E9 RHD LHD A9 LHD RHD F20 18 WT...

Page 411: ...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 24 POWERTRAIN CONTROL MODULE D2 20 WT BK D1 20 VT BR S239 S238 B8 A11 A12 B...

Page 412: ......

Page 413: ...W 33 2 Fuse 23 PDC 8W 33 3 G106 8W 33 3 G108 8W 33 3 Component Page Left Speed Control Switch 8W 33 2 Power Distribution Center 8W 33 3 Powertrain Control Module 8W 33 2 3 Right Speed Control Switch 8...

Page 414: ...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 K167 20 BR YL C2 C2 C1 C1 F17...

Page 415: ...R 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 16 BK WT PK 18 K29 C100 WT PK 18 K29 K29 20 WT PK RHD LHD 5 6 23 FUSE 15A A10 BATT A0 A9 CENTER DIST...

Page 416: ......

Page 417: ...use 9 JB 8W 35 3 Fuse 12 PDC 8W 35 2 Fuse 13 PDC 8W 35 2 Fuse 23 PDC 8W 35 2 Fuse 25 JB 8W 35 3 Component Page G Switch 8W 35 2 G102 8W 35 2 G106 8W 35 3 Instrument Cluster 8W 35 3 Junction Block 8W 3...

Page 418: ...TEST G SWITCH SENSE NO 1 G SWITCH SENSE NO 2 G SWITCH PK D21 12 PK DB 20 F32 23 FUSE 15A A10 A9 F8 C100 F32 20 PK DB 5 6 BRAKE LAMP SWITCH WT TN L50 S203 BRAKE LAMP SWITCH OUTPUT 7 18 18 18 18 18 20...

Page 419: ...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 B8 Z1 20...

Page 420: ...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 421: ...8W 39 6 7 Component Page Horn Relay 8W 39 8 9 Ignition Switch 8W 39 6 7 Instrument Cluster 8W 39 8 9 Junction Block 8W 39 2 3 4 5 6 7 8 9 Left Rear Door Jamb Switch 8W 39 6 7 Liftgate Switch 8W 39 6 7...

Page 422: ...K RELAY CONTROL DB 20 P55 5 8 C301 9 P55 20 DB PK LB RD 20 P59 3 C300 4 1 P59 20 LB RD DB PK 20 P55 2 SWITCH WINDOW LOCK POWER PASSENGER BK 14 Z1 14 G107 S208 C2 C2 C201 Z1 14 BK Z1 DOOR LOCK CONTROL...

Page 423: ...DB 20 P55 5 8 C301 9 12 C305 3 1 P59 20 LB RD DB 20 P55 2 SWITCH WINDOW LOCK POWER PASSENGER BK 14 Z1 G107 S208 C2 C2 C203 1 2 Z1 14 BK Z1 20 BK S135 DOOR LOCK CONTROL UNLOCK RELAY CONTROL DOOR P55 20...

Page 424: ...A21 10A FUSE 9 S13 C4 F87 20 WT BK WT BK 20 F87 FULL OPTIONS BASE 5 C201 Z2 20 20 Z2 WT BK 20 F87 4 F87 20 WT BK S216 FUSED IGNITION SWITCH OUTPUT ST RUN MODULE IMMOBILIZER KEY SENTRY BK LG BK LG BK...

Page 425: ...GY 6 JUNCTION BLOCK ST RUN A21 10A FUSE 9 S13 C4 F87 20 WT BK Z2 20 20 Z2 4 F87 20 WT BK S216 FUSED IGNITION SWITCH ST RUN OUTPUT MODULE IMMOBILIZER KEY SENTRY BK LG BK LG BK LG 8W 10 14 8W 10 10 8W...

Page 426: ...C B LAMP CARGO GY BK 20 M4 7 C314 M4 20 GY BK VT YL 20 M4 C311 C310 5 10 1 3 LIFTGATE SWITCH Z1 20 BK G304 S304 S334 9 C310 6 Z1 18 BK C311 BK 18 Z1 M2 20 BK LB 18 G16 2 17 C200 S200 BK LB 20 G16 6 S...

Page 427: ...CARGO GY BK 20 M4 7 C314 M4 20 GY BK VT YL 20 M4 C311 C310 5 10 2 3 Z1 20 BK G304 S304 S334 9 C310 6 C311 BK 18 Z1 M2 20 BK LB 18 G16 4 C203 S200 BK LB 20 G16 6 SWITCH HEADLAMP C1 C2 IGNITION SWITCH...

Page 428: ...WT BK WT BK 20 D2 VT BR 20 D1 BK RD 20 X3 JUNCTION BLOCK 86 85 BATT A7 C5 RELAY HORN MODULE OVERHEAD TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR CCD BUS CCD BUS D1 20 VT BR 1 2 WT...

Page 429: ...N BLOCK 86 85 BATT A7 C4 RELAY HORN MODULE OVERHEAD PAIR TWISTED TWISTED PAIR TWISTED PAIR TWISTED PAIR PAIR TWISTED TWISTED PAIR CCD BUS CCD BUS D1 20 VT BR 1 2 WT BK 20 D2 S238 S239 S145 OTHER A T O...

Page 430: ......

Page 431: ...ator 8W 40 11 Ignition Switch 8W 40 7 8 Instrument Cluster 8W 40 2 3 4 5 6 7 8 9 10 11 12 13 Component Page Junction Block 8W 40 2 9 10 12 Left Turn Signal Indicator 8W 40 11 Liftgate Ajar Indicator 8...

Page 432: ...F87 20 WT BK GROUND 16 FUSE 15A BATT A0 POWER DISTRIBUTION CENTER A24 A23 PK 20 M1 S135 C4 S18 C1 12 BLOCK JUNCTION PK 20 M1 RHD LHD C201 6 S214 C1 9 FUSED B S225 OUTPUT ST RUN F87 20 WT BK S227 POLI...

Page 433: ...BUS CCD FUEL GAUGE TACHOMETER VOLT METER SPEEDOMETER CONTROL SPEEDOMETER LOW FUEL WARNING INDICATOR INDICATOR WARNING GAUGES CHECK LOW FUEL WARNING INDICATOR INDICATOR WARNING CHECK GAUGES CONTROL CO...

Page 434: ...NGINE COOLANT TEMPERATURE K2 18 TN BK 16 C1 ENGINE COOLANT TEMPERATURE SENSOR C2 23 GY YL 18 G60 ENGINE OIL PRESSURE SENSOR ENGINE COOLANT OIL CONTROL PAIR TWISTED TWISTED PAIR SENSOR PRESSURE OIL ENG...

Page 435: ...R FLUID WASHER LOW FLUID WASHER LOW BK LB 20 G29 LOW WASHER FLUID SENSE BK LB 20 G29 C1 7 A B SWITCH LEVEL FLUID WASHER BK 16 Z1 G106 S141 BK 20 Z1 SEAT BELT SWITCH A B 10 C2 G10 20 LG RD 69 C201 SENS...

Page 436: ...K LB 20 G29 C1 7 A B SWITCH LEVEL FLUID WASHER S141 BK 20 Z1 SEAT BELT SWITCH A B 10 C2 G10 20 LG RD 11 C203 SENSE SWITCH BELT SEAT G10 20 LG RD Z1 20 BK S313 Z1 20 BK BK 12 Z1 S309 G302 SEAT BELT WAR...

Page 437: ...100 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 IGNITION BK 14 Z1 BK 20 Z1 S207 G108 PARK BRAKE...

Page 438: ...DOOR DRIVER LHD RHD BK LB 20 G16 HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 6 0 1 2 S210 CHIME CONTROL BATT M1 FUSED B C C317 G302 S309 Z1 18 BK Z1 20 BK Z1 12 BK 3 3 BK 12 Z1 BK 20 Z1 BK 18 Z1 S310 G303 C3...

Page 439: ...01 56 S346 D2 20 WT BK VT BR 20 D1 6 S344 VT BR 20 D1 1 WT BK 20 D2 VT BR 20 D1 C2 1 2 C2 CCD BUS BUS CCD OVERHEAD MODULE VTSS INDICATOR PAIR TWISTED PAIR TWISTED PAIR TWISTED 55 KEY SENTRY CCD BUS BU...

Page 440: ...D2 20 WT BK VT BR 20 D1 6 S344 VT BR 20 D1 1 WT BK 20 D2 VT BR 20 D1 C2 1 2 C2 CCD BUS BUS CCD OVERHEAD MODULE VTSS INDICATOR PAIR TWISTED PAIR TWISTED PAIR TWISTED KEY SENTRY CCD BUS BUS CCD PAIR TWI...

Page 441: ...NAL 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 POSTAL OTHER DRL DIMMER B...

Page 442: ...C201 42 RHD LHD 2 1 0 1 3 4 4 BRIGHT 3 DIM 2 HEAD 1 PARK 0 OFF SWITCH HEADLAMP 1 C1 LIFTGATE AJAR INDICATOR G78 20 TN BK G78 20 TN BK C311 3 C310 6 G78 20 TN BK 1 C327 G78 20 TN BK 40 C200 C204 5 LHD...

Page 443: ...POWERTRAIN CONTROL MODULE CCD BUS BUS CCD CONTROL TWISTED PAIR S239 S238 E11 E12 S144 S145 4 0L A T OTHER OTHER 4 0L A T 30 C3 28 C3 FUSED IGNITION SWITCH OUTPUT ST RUN LHD RHD D2 20 WT BK D2 18 WT BK...

Page 444: ......

Page 445: ...g 8W 41 2 3 Fuse 1 JB 8W 41 2 3 Fuse 2 JB 8W 41 2 3 Fuse 21 JB 8W 41 2 3 G107 8W 41 2 3 Component Page High Note Horn 8W 41 2 3 Horn Relay 8W 41 2 3 Horn Switch 8W 41 2 3 Junction Block 8W 41 2 3 Low...

Page 446: ...GHTER RELAY RUN ACC A31 BATT A7 RELAY HORN 86 30 87 85 C4 S22 CLOCKSPRING HORN SWITCH C201 26 BK RD 20 X3 X3 20 BK RD 21 FUSE 15A G107 S5 C4 1 C5 1 14 Z1 14 BK Z1 14 BK Z1 14 BK Z1 14 BK S314 S208 10...

Page 447: ...86 CIGAR LIGHTER RELAY RUN ACC A31 BATT A7 RELAY HORN 86 30 87 85 C5 1 CLOCKSPRING HORN SWITCH BK RD 20 X3 21 FUSE 15A G107 S5 C4 S22 C4 1 Z1 14 BK Z1 14 BK S208 10 MODULE OVERHEAD X3 20 BK RD X3 20...

Page 448: ......

Page 449: ...r Motor 8W 42 2 3 4 5 Blower Motor Relay 8W 42 2 3 4 5 Blower Motor Resistor Block 8W 42 2 3 4 5 Fuse 6 PDC 8W 42 2 3 4 5 Component Page Fuse 25 JB 8W 42 2 3 4 5 7 G106 8W 42 8 G107 8W 42 7 G108 8W 42...

Page 450: ...IUM 2 1 HIGH 7 6 5 0 4 3 2 1 CONTROL HEATER 7 5 4 2 1 8 9 BI LEVEL BLOCK RESISTOR MOTOR BLOWER S219 2 C209 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12 RD LG S228 C1 12 DG C7 12 BK TN BLOW...

Page 451: ...8 9 BI LEVEL 2 3 4 C4 14 TN LG 14 C5 LB 14 C6 BK TN 12 C7 F15 20 DB WT A111 12 RD LG 5 4 2 1 2 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12 RD LG S228 C1 12 DG C7 12 BK TN BLOWER MOTOR RE...

Page 452: ...NTER DISTRIBUTION POWER A111 12 RD LG A 8W 42 6 TO C100 S219 2 3 4 C4 14 TN LG 14 C5 LB 14 C6 BK TN 12 C7 F15 20 DB WT A111 12 RD LG 5 4 2 1 2 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12...

Page 453: ...111 12 RD LG A 8W 42 6 TO C100 S219 2 3 4 C4 14 TN LG 14 C5 LB 14 C6 BK TN 12 C7 F15 20 DB WT A111 12 RD LG 5 4 2 1 2 3 4 7 8 9 C7 12 BK TN C6 14 LB C5 14 LG C4 14 TN A111 12 RD LG S228 C1 12 DG C7 12...

Page 454: ...C HIGH PRESSURE SWITCH A C LOW PRESSURE SWITCH C3 23 MODULE CONTROL POWERTRAIN 22 C3 1 2 4 2 3 1 C3 13 RADIATOR FAN REQUEST C48 18 TN FROM CONTROL HEATER A C 1 2 1 SWITCH PRESSURE HIGH A C C21 20 DB...

Page 455: ...TION SWITCH OUTPUT SIGNAL FEEDBACK DOOR BLEND 8 D3 20 YL 4 C201 7 D1 20 DB WT Z1 20 BK F15 20 DB WT LHD RHD C204 18 LHD RHD GROUND BLEND DOOR FEEDBACK SIGNAL RHD LHD 17 C204 C201 7 RUN C36 18 RD WT C3...

Page 456: ...ODULE RADIATOR D13 D14 D10 D11 RADIATOR FAN RELAY 1 2 C27 18 DB PK MOTOR FAN RADIATOR G106 Z1 12 BK FAN BATT F141 ST RUN F20 LB 12 C25 RELAY CONTROL M 8W 10 2 8W 30 18 8W 15 6 8W 10 13 8W 12 12 8W 42...

Page 457: ...dule 8W 43 2 3 4 Clockspring 8W 43 4 Data Link Connector 8W 43 2 3 Driver Airbag 8W 43 4 Fuse 26 JB 8W 43 2 3 Component Page Fuse 27 JB 8W 43 2 3 G200 8W 43 2 G300 8W 43 3 Junction Block 8W 43 2 3 Pas...

Page 458: ...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 459: ...NNECTOR RUN A22 ST RUN A21 D2 18 WT BK D1 18 VT BR VT BR 20 D1 WT BK 20 D2 D2 18 WT BK D1 18 VT BR BUS CCD CCD BUS BK PK 18 Z6 G300 GROUND 10 14 C204 15 DB YL 18 F23 LG YL 18 F14 PAIR TWISTED PAIR TWI...

Page 460: ...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 461: ...mp Switch 8W 44 2 3 5 Component Page Instrument Cluster 8W 44 2 3 6 7 Junction Block 8W 44 2 3 4 5 Left Courtesy Lamp 8W 44 5 Left Rear Door Jamb Switch 8W 44 6 7 Left Visor Vanity Lamp 8W 44 4 Liftga...

Page 462: ...14 S208 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 EXTENDED IDLE SWITCH 1 4 20 BK Z1 OTHERS C201 14 PACKAGE POLICE TN 20 E1 SWITCH IL...

Page 463: ...0 BK 1 1 4 SWITCH WASHER WIPER REAR Z1 20 BK Z1 14 BK Z1 BK 20 1 Z1 20 BK S208 BK VT 12 Z8 G108 12 C203 OR 20 E2 BK 20 Z1 Z1 12 BK OR BK 20 E2 SWITCH ILLUMINATION G107 ILLUMINATION A T PANEL LAMPS DIM...

Page 464: ...20 Z1 1 BK 20 Z1 B YL 20 M2 M2 20 YL 7 S345 S342 A 8W 44 5 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...

Page 465: ...G108 Z1 18 BK S207 HEADLAMP DELAY MODULE 4 Z1 18 BK M2 20 YL A 8W 44 4 C3 1 YL 20 M2 1 C207 A 2 C207 B M1 18 PK 5 C314 M1 20 PK 1 BK 20 Z1 2 S132 G106 Z1 16 BK M1 20 PK M1 20 PK M2 18BK WT M2 18BK WT...

Page 466: ...320 BK 18 Z1 Z1 20 BK S309 Z1 12 BK G303 BK 20 Z1 Z1 18 BK C317 C LEFT REAR DOOR JAMB SWITCH 3 2 YL 18 M2 C317 A DRIVER DOOR JAMB SWITCH 1 3 3 1 SWITCH JAMB DOOR PASSENGER BK 18 Z1 Z1 18 BK C311 6 C31...

Page 467: ...B C320 BK 18 Z1 Z1 20 BK S309 Z1 12 BK BK 20 Z1 Z1 18 BK C317 C LEFT REAR DOOR JAMB SWITCH 3 2 YL 18 M2 C317 A PASSENGER DOOR JAMB SWITCH 1 3 3 1 SWITCH JAMB DOOR DRIVER BK 18 Z1 Z1 18 BK C311 6 C310...

Page 468: ......

Page 469: ...47 2 3 8 9 Junction Block 8W 47 2 3 8 9 Component Page Left Front Door Speaker 8W 47 4 5 8 9 Left Front Door Tweeter 8W 47 4 5 Left Soundbar Speaker 8W 47 4 4 10 Power Amplifier 8W 47 2 3 4 5 6 7 Powe...

Page 470: ...A0 PK 20 M1 S214 C201 6 7 C2 B FUSED C1 12 S18 C4 RUN ACC A31 S315 X12 16 RD WT M1 20 PK OR 20 E2 1 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...

Page 471: ...0 E2 1 FUSED B FUSED B F75 16 VT VT 16 F75 1 C2 2 C2 21 C204 C4 C100 F75 16 VT VT 16 F75 F75 16 VT S301 G301 8 C2 GROUND BK LB 16 Z5 7 C2 GROUND Z5 16 BK LB PK 20 M1 LAMPS OUTPUT RUN ACC FUSED B PANEL...

Page 472: ...EAR LEFT 18 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...

Page 473: ...X85 18 LG 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...

Page 474: ...14 2 C303 10 C2 2 1 C2 11 SPEAKER SOUNDBAR RIGHT SPEAKER DOOR RIGHT DOOR SPEAKER 1 2 5 4 S320 RIGHT X94 18 TN RD X92 18 TN BK TN BK 16 X92 TN RD 16 X94 X82 18 LB RD X80 18 LB BK LB BK 18 X80 LB RD 18...

Page 475: ...X82 18 LB RD X80 18 LB BK LB BK 18 X80 LB RD 18 X82 LB BK 18 X80 S321 X82 18 LB RD X82 18 LB RD LB BK 18 X80 SPEAKER DOOR FRONT RIGHT RIGHT FRONT DOOR TWEETER RIGHT FRONT SPEAKER SPEAKER FRONT RIGHT S...

Page 476: ...R 20 E2 TN 20 E1 E2 20 OR PK 20 M1 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...

Page 477: ...3 2 C2 2 1 C1 4 20 18 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 SWITCH SIGNAL RUN ACC OUTPUT SPEAKER SPEAKER...

Page 478: ...B C1 7 2 C314 1 SPEAKER SOUNDBAR RIGHT X52 16 DB WT X58 16 DB OR DB OR 18 X58 DB WT 18 X52 RIGHT REAR SPEAKER SPEAKER REAR RIGHT LHD RHD LHD RHD LHD RHD LHD RHD 22 C203 C200 6 7 C200 C203 16 9 C200 C...

Page 479: ...2 3 G107 8W 48 2 3 G302 8W 48 2 3 G303 8W 48 3 G304 8W 48 2 3 Component Page Instrument Cluster 8W 48 2 3 Junction Block 8W 48 2 3 Passenger Power Mirror 8W 48 2 3 Rear Window Defogger 8W 48 2 3 Rear...

Page 480: ...AY CONTROL SWITCH SENSE BK 12 Z1 Z1 16 BK C4 S5 C9 11 BLOCK JUNCTION Z1 18 BK C201 S309 3 C307 C80 20 DB WT Z1 14 BK Z1 14 BK C201 14 S314 S208 REAR WINDOW DEFOGGER REAR WINDOW DEFOGGER BK WT 12 C15 B...

Page 481: ...1 18 BK S309 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 BLOC...

Page 482: ......

Page 483: ...49 6 Driver Door Jamb Switch 8W 49 4 5 Fuse 9 JB 8W 49 2 3 Fuse 16 PDC 8W 49 2 3 G107 8W 49 2 3 Component Page G108 8W 49 2 3 Horn Relay 8W 49 4 5 Junction Block 8W 49 2 3 4 5 Overhead Module 8W 49 2...

Page 484: ...MODULE F87 20 WT BK Z1 20 BK 1 GROUND Z1 20 BK 3 GROUND DISTRIBUTION POWER CENTER BATT A0 15A FUSE 16 A23 A24 12 C1 BLOCK JUNCTION M1 20 PK 2 3 C3 2 PK 20 M1 S225 FUSED B B FUSED OUTPUT S135 ST RUN S3...

Page 485: ...DULE F87 20 WT BK Z1 20 BK 1 GROUND Z1 20 BK 3 GROUND DISTRIBUTION POWER CENTER BATT A0 15A FUSE 16 A23 A24 12 C1 BLOCK JUNCTION M1 20 PK 2 3 C3 2 PK 20 M1 S216 F87 20 WT BK FUSED B B FUSED S135 OUTPU...

Page 486: ...ENSOR C301 3 4 BK LB 20 G32 G31 20 VT LG 32 35 C201 VT LG 20 G31 G32 20 BK LB 2 F15 F14 C100 BK LB 20 G32 G31 20 VT LG LAMPS COURTESY 1 YL 20 M2 7 1 C3 JUNCTION BLOCK S345 M2 20 YL YL 20 M2 7 C7 1 DRI...

Page 487: ...T TEMPERATURE SENSOR C301 3 4 VT LG 20 G31 G32 20 BK LB 2 F15 F14 C100 BK LB 20 G32 G31 20 VT LG LAMPS COURTESY 1 7 1 C3 JUNCTION BLOCK S345 M2 20 YL 7 C7 1 SWITCH JAMB DOOR DRIVER M2 18 YL A C318 S30...

Page 488: ...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 489: ...07 8W 50 9 10 G108 8W 50 2 5 Component Page Headlamp Beam Select Switch 8W 50 3 4 5 Headlamp Delay Module 8W 50 2 5 Headlamp Switch 8W 50 2 5 6 7 8 10 Instrument Cluster 8W 50 3 4 10 11 Junction Block...

Page 490: ...18 A17 19 FUSE 20A TN BK 18 F34 F34 18 TN BK YL 20 M2 S201 FROM LG 14 L2 LG 14 L2 6 2 BK YL 18 L7 9 LB 20 G26 5 FROM S210 6 G16 20 BK LB TO S200 TO S206 MODULE HEADLAMP DELAY A 8W 50 3 B 8W 50 3 HEAD...

Page 491: ...RD 18 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...

Page 492: ...20 RD L34 20 RD OR G106 S133 VT RD 20 L44 B12 A 8W 50 2 DELAY HEADLAMP FROM MODULE SWITCH FROM HEADLAMP B 8W 50 2 S213 RD OR 16 L3 BK 20 Z1 Z1 20 BK WT CLUSTER INSTRUMENT 5 C1 C100 1 2 3 1 2 3 1 3 3 H...

Page 493: ...BK GROUND Z1 14 BK S225 FUSED B SWITCH HEADLAMP TIMER HEADLAMP 4 6 SWITCH OUTPUT HEADLAMP HEADLAMP SWITCH GROUND FULL OPTIONS BASE F87 20 WT BK MODULE LAMP RUNNING DAYTIME F87 20 WT BK 5 C201 S216 F8...

Page 494: ...20 LG WT SWITCH HAZARD SIGNAL TURN PART OF MULTI FUNCTION SWITCH B6 IN PDC NO 1 RELAY LAMP FOG S105 L77 20 BR YL BR YL 20 L77 LG 20 L61 L61 20 LG WT C106 BK WT 20 Z1 BR 20 L77 7 C106 BK YL 18 L7 LHD...

Page 495: ...RIGHT PARK 5 C1 23 FUSE 10A G106 L7 18 BK YL 45 C201 S206 2 1 0 9 SWITCH HEADLAMP 1 PARK 2 HEAD 0 OFF BATT F34 L7 18 BK YL C106 10 C100 B9 TN 20 L60 1 S212 L60 20 TN SWITCH HAZARD SIGNAL TURN TN 20 L...

Page 496: ...9 20 VT FRONT FOG LAMP SWITCH TO L77 20 BR YL L77 20 BR YL C106 7 TO S104 BATT F34 0 OFF 9 0 1 2 HEADLAMP SWITCH S206 RHD LHD C201 45 7 FUSE 10A M3 C4 6 C2 BLOCK JUNCTION L7 18 BK YL L7 18 BK YL BR YL...

Page 497: ...B11 B12 B13 FRONT FOG LAMP SWITCH 2 3 S106 BK 20 Z1 BK 20 Z1 LAMP FOG RIGHT 1 2 LEFT FOG LAMP 2 1 G106 S103 S102 BK 18 Z1 4 C106 11 CENTER DISTRIBUTION POWER F 8W 50 8 Z1 20 BK TO IN PDC RELAY NO 1 F...

Page 498: ...20 L39 BK 20 Z1 BK WT 20 Z1 1 4 BATT F61 L39 20 LB L77 20 BR YL RD GY S208 L39 20 LB L39 20 LB 8 C106 L139 20 VT L139 20 VT A5 C100 Z1 20 BK Z1 20BK Z1 14 BK Z1 20 BK L92 20 PK A4 C100 RD GY 16 G34 G...

Page 499: ...WT OR G7 20 WT OR 4 DRIVER BEAM INDICATOR HIGH RD GY 16 G34 B10 IN PDC NO 1 RELAY LAMP FOG D4 C100 C1 5 CLUSTER INSTRUMENT G34 16 RD GY G34 16 RD GY SPEED VT RD 18 L44 S133 10 L44 20 VT RD 13 C106 VT...

Page 500: ......

Page 501: ...p Lamp 8W 51 7 Left Tail Stop Lamp 8W 51 3 Component Page Left Turn Signal Lamp 8W 51 5 License Lamp 8W 51 4 Park Neutral Position Switch 8W 51 6 Power Distribution Center 8W 51 2 Powertrain Control M...

Page 502: ...BUTION CENTER BATT A0 A10 A9 F8 C100 F32 20 PK DB F32 20 PK DB L50 20 WT TN S203 7 C321 BK YL 18 L7 WT TN 20 L50 WT TN 20 L50 A 8W 51 3 B 8W 51 3 C 8W 51 3 TO S311 S302 TO RIGHT TAIL STOP LAMP TO DG Y...

Page 503: ...77 18 BR YL L50 20 WT TN L50 20 WT TN BR YL 20 L77 L77 18 BR TRAILER TOW OTHERS WT TN 18 L50 WT TN 18 L50 BK 18 Z1 L77 18 BR YL BR YL 20 L77 5 TRAILER TOW OTHER Z1 14 BK L77 18 BR YL 7 C322 7 C323 2 C...

Page 504: ...BK 5 C326 2 1 LICENSE LAMP S334 9 C310 C311 6 Z1 18 BK S311 2 C310 C311 4 11 BK 18 Z1 BK 18 Z1 BR YL 18 L77 WT TN 20 L50 L77 18 BR YL BR YL 18 L77 L50 18 WT TN C327 1 C333 L50 18 DG WT C333 2 Z1 18 BK...

Page 505: ...1 BK 18 Z1 BK 18 Z1 DG RD 18 L63 BR RD 18 L62 1 C322 TRAILER TOW OTHERS S335 LEFT TURN SIGNAL SIGNAL TURN RIGHT L62 20 BR RD Z1 14 BK 11 C204 25 C200 LHD RHD 2 C323 C323 1 RHD LHD 26 C200 12 C204 S337...

Page 506: ...A T LHD RHD 4 0L A T S161 A15 A B MODULE CONTROL POWERTRAIN CONTROL SOLENOID CLUTCH CONVERTER TORQUE C2 11 K54 18 OR BK F20 18 WT S159 L10 18 BR LG E 8W 51 7 S303 TO BR LG 18 L10 18 4 0L MODULE CONTR...

Page 507: ...R LG 18 L10 L10 18 BR LG BK 14 Z1 CONNECTOR TOW TRAILER 8 BK 18 Z1 BK 18 Z1 S339 TOW TRAILER OTHERS Z1 16 BK LHD RHD 2 C323 2 C322 C323 5 C322 5 S337 FROM C200 C204 FROM E 8W 51 6 LHD RHD Z1 18 BK Z1...

Page 508: ......

Page 509: ...ont Park Turn Signal Lamp No 1 8W 52 3 Component Page Left Front Park Turn Signal Lamp No 2 8W 52 3 Left Side Marker Lamp 8W 52 3 Left Turn Signal Lamp 8W 52 3 Power Distribution Center 8W 52 2 Right...

Page 510: ...1 14 BK 6 5 L12 20 VT TN L6 20 RD WT R L L R R L L R FUSED IGNITION SWITCH FUSED B HAZARD FLASHER SELECT OUTPUT FLASHER GROUND 4 11 L55 20 RD WT LHD RHD C201 3 BR RD 20 L62 3 DG RD 20 L63 9 A 8W 52 4...

Page 511: ...20 L63 26 C200 C204 12 C322 1 L63 18 DG RD 1 2 LEFT TURN SIGNAL LAMP Z1 18 BK S341 BK 18 Z1 Z1 18 BK S337 Z1 14 BK LHD RHD OTHERS TRAILER TOW Z1 12 BK G302 LG WT 20 L61 10 C1 CLUSTER INSTRUMENT S309...

Page 512: ...RD 20 L62 LHD RHD 25 C200 C204 11 L62 20 BR RD S312 L62 20 BR RD 1 C321 L62 18 BR RD 1 2 BK 18 Z1 S348 Z1 18 BK 2 C321 BK 18 Z1 S310 BK 16 Z1 G303 FROM SWITCH HAZARD SIGNAL TURN TURN SIGNAL HAZARD SWI...

Page 513: ...B 8W 53 3 4 G106 8W 53 2 3 4 G107 8W 53 3 4 G108 8W 53 2 G304 8W 53 3 4 Component Page Headlamp Switch 8W 53 3 4 Junction Block 8W 53 2 3 4 Rear Washer Pump 8W 53 2 3 4 Rear Wiper Motor 8W 53 3 4 Rear...

Page 514: ...20A 30 BREAKER CIRCUIT RUN ACC A31 8 C1 1 V6 16 DB G106 S141 PUMP WASHER WINDSHIELD Z1 16 BK Z1 16 BK PUMP WASHER REAR LHD RHD C201 8 5 INTERMITTENT 4 WASH 2 LOW 3 HIGH 1 DELAY 0 OFF 5 3 2 1 0 3 2 1 0...

Page 515: ...5 C100 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 16 Z1 S141 G106 BK 18 Z1 4 0L 2 5L Z1 18 BK GROUND 3 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH...

Page 516: ...SH 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 1 PANEL LAMPS DIMMER SWITCH SIGNAL SWITCH HEADLAMP JUNCTION BLOCK 6 FUSE 5A...

Page 517: ...nction Block 8W 54 2 3 Left Back Up Lamp 8W 54 2 Left Tail Stop Lamp 8W 54 3 Component Page Left Turn Signal Lamp 8W 54 3 Trailer Tow Connector 8W 54 2 3 Trailer Tow Electric Brake Provision 8W 54 2 T...

Page 518: ...S311 S340 BR YL 20 L77 7 C323 L77 18 BR YL BK 14 Z1 7 B40 14 LB 3 S339 2 LEFT BACK UP LAMP C323 5 L10 18 BR LG 5 C322 FROM S303 L10 18 BR LG BR LG 18 L10 BR LG 18 L10 TRAILER TOW ELECTRIC BRAKE PROVIS...

Page 519: ...3 20 DG RD 2 C322 1 LAMP SIGNAL TURN LEFT WT TN 20 L50 WT TN 20 L50 WT TN 20 L50 24 C204 C200 24 RHD LHD S203 BRAKE LAMP SWITCH 5 WT TN 20 L50 L63 18 DG RD RD OR 20 A6 A6 20 RD OR A6 20 RD OR L50 18 W...

Page 520: ......

Page 521: ...8W 60 2 3 G302 8W 60 2 4 G303 8W 60 3 5 Junction Block 8W 60 2 3 Component Page Left Rear Window Motor 8W 60 4 5 Left Rear Window Switch 8W 60 2 3 4 5 Passenger Power Lock Window Switch 8W 60 2 3 Pass...

Page 522: ...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 14 Q1 C3...

Page 523: ...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 PASSEN...

Page 524: ...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 525: ...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 526: ......

Page 527: ...2 3 G107 8W 61 2 G302 8W 61 2 3 G303 8W 61 3 Ignition Switch 8W 61 2 3 Component Page Junction Block 8W 61 2 3 4 5 Left Rear Door Lock Motor 8W 61 4 5 Liftgate Lock Motor 8W 61 4 5 Overhead Module 8W...

Page 528: ...ION FUSED 4 C2 SWITCH C2 1 2 C2 P59 20 LB RD DB 20 P55 5 11 MODULE OVERHEAD 4 C300 3 P55 20 DB PK LB RD 20 P59 8 C301 9 P55 20 DB PK LB RD 20 P59 CONTROL DOOR UNLOCK LOCK DOOR CONTROL P36 18 18 P35 OR...

Page 529: ...2 C2 P59 20 LB RD DB 20 P55 5 11 MODULE OVERHEAD 2 C203 1 8 C301 9 P55 20 DB LB RD 20 P59 CONTROL DOOR UNLOCK LOCK DOOR CONTROL 5 C303 P36 20 PK VT OR VT 20 P35 P35 20 OR VT PK VT 20 P36 CONTROL DOOR...

Page 530: ...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 531: ...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 532: ......

Page 533: ...h 8W 62 2 3 4 5 Driver Power Mirror 8W 62 2 3 4 5 6 7 Fuse 18 JB 8W 62 2 4 G107 8W 62 7 Component Page G302 8W 62 2 3 6 G303 8W 62 4 5 Junction Block 8W 62 2 3 4 5 6 7 Passenger Power Mirror 8W 62 3 5...

Page 534: ...DRIVER POWER 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...

Page 535: ...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 2 1 4 0 S...

Page 536: ...INDOW 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 F83 18 YL DG RUN ACC A31 S4 C4 Z1 14 BK 3 C300 5 C303 Z1 14 BK 5 6 6 PASSENGER MIRROR 5 DR...

Page 537: ...POWER MIRROR S328 OR YL 20 P76 P76 20 OR YL C2 5 9 C204 8 8 C305 9 S318 10 10 P76 20 OR YL P76 20 OR YL DRIVER POWER MIRROR 2 4 P76 20 OR YL P76 20 OR YL BLOCK JUNCTION 2 C5 10 C9 2 C9 6 C9 10 C5 9 C5...

Page 538: ...6 20 OR YL 12 C200 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 8 7 P71 20 YL P75 20 DB WT 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...

Page 539: ...BK 10 C204 10 P76 20 OR YL 10 C203 13 C305 P76 20 OR YL P91 20 WT BK SWITCH MIRROR POWER 3 4 P74 20 DB P72 20 YL BK S319 S5 C4 G107 P91 20 WT BK P76 20 OR YL Z1 14 BK S208 Z1 14 BK 1 2 3 4 4 DOWN 3 LE...

Page 540: ......

Page 541: ...Heated Seat Back 8W 63 5 Left Heated Seat Cushion 8W 63 5 Left Heated Seat Switch 8W 63 4 Component Page Left Power Seat Motors 8W 63 2 Left Power Seat Switch 8W 63 2 3 6 Rear Motor 8W 63 2 3 Right H...

Page 542: ...YL LB P17 14 RD LB FORWARD REARWARD MOTOR MOTOR FRONT REAR MOTOR C6 1 FRONT DOWN 2 FRONT UP 3 REAR DOWN 4 REAR UP 5 FORWARD 6 REARWARD C316 2 SWITCH SEAT POWER LEFT Z1 14 MOTORS SEAT POWER LEFT F37 14...

Page 543: ...FORWARD REARWARD MOTOR MOTOR FRONT REAR MOTOR MOTORS SEAT POWER C6 1 FRONT UP 2 FRONT DOWN 3 REAR UP 4 REAR DOWN 5 FORWARD 6 REARWARD C316 2 RIGHT LEFT SWITCH SEAT POWER A RD LB 14 F37 RIGHT FUSED B...

Page 544: ...RIGHT 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 D...

Page 545: ...K BK YL 18 P144 P141 18 TN LB C B D A D A C B P141 18 TN LB P141 18 TN LB C332 1 8 C329 P141 18 TN LB P88 18 BR BK P141 18 TN LB S357 P89 18 BR B A B A BACK SEAT HEATED RIGHT BACK SEAT HEATED LEFT Z1...

Page 546: ...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 BLOCK JUNCTION...

Page 547: ...3 8W 50 3 4 S214 8W 10 17 S215 8W 12 8 9 S216 8W 12 11 S217 8W 12 20 S218 8W 10 18 Component Page S219 8W 12 20 21 S221 8W 30 13 S222 8W 30 13 S225 8W 12 11 S227 8W 15 9 S228 8W 42 2 3 4 5 S238 8W 30...

Page 548: ...CH BR RD 20 L62 BR RD 20 L62 3 L62 20 BR RD S312 RELAY TURN RIGHT TOW TRAILER C1 MODULE CONTROL POWERTRAIN UPSTREAM 1 1 SENSOR OXYGEN 2 1 2 2 1 2 OXYGEN SENSOR UPSTREAM DOWNSTREAM SENSOR OXYGEN OXYGEN...

Page 549: ...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 K167 3 C204 7 30 C200 BR YL 20 K167 4 FUEL MODULE PUMP...

Page 550: ......

Page 551: ...ion Sensor 8W 80 29 Cargo Lamp Switch 8W 80 29 Center High Mounted Stop Lamp 8W 80 30 Cigar Lighter 8W 80 30 Clockspring C1 8W 80 30 Clockspring C2 8W 80 30 Clockspring C3 8W 80 30 Clutch Interlock Sw...

Page 552: ...tch 8W 80 55 Passenger Door Lock Motor 8W 80 56 Passenger Power Lock Window Switch 8W 80 56 Passenger Power Mirror 8W 80 56 57 Component Page Passenger Power Window Motor 8W 80 57 Power Amplifier 8W 8...

Page 553: ...1 Transfer Case Switch Illumination 8W 80 71 Transmission Solenoid 8W 80 71 Transmission Control Module 8W 80 72 Component Page Transmission Range Sensor 8W 80 72 Turn Signal Hazard Switch 8W 80 73 Un...

Page 554: ...DB WT A C SWITCH SENSE 2 C21 20DB PK A C SWITCH SENSE A C ONLY OR HEATER CONTROL C1 FUSED PANEL LAMPS DIMMER SWITCH SIGNAL RADIATOR FAN REQUEST C48 18TN 2 A C SWITCH SENSE C21 20DB PK 1 FUNCTION CIRCU...

Page 555: ...10 9 12 11 AIRBAG CONTROL MODULE 7 8 4 5 6 R42 18BK YL PASSENGER AIRBAG LINE 2 PASSENGER AIRBAG LINE 1 R44 18DG YL 3 2 1 CAV FUNCTION CIRCUIT BASE FUSED IGNITION SWITCH OUTPUT ST RUN FULL OPTIONS A C...

Page 556: ...18WT A FUNCTION CIRCUIT CAV SENSOR GROUND G32 20BK LB 2 1 G31 20VT LG CAV FUNCTION CIRCUIT AMBIENT TEMPERATURE SENSOR SIGNAL SENSOR TEMPERATURE AMBIENT BLACK 2 1 9 10 D2 20OR FUSED IGNITION SWITCH OUT...

Page 557: ...R DRIVER 2 G99 20GY WT 1 2 BLACK BRAKE WARNING PRESSURE SWITCH B BLOWER MOTOR RELAY OUTPUT C1 12DG A FUNCTION CIRCUIT CAV C7 12BK TN BLOWER MOTOR HIGH DRIVER B A MOTOR BLOWER 5 F15 20DB WT FUSED IGNIT...

Page 558: ...RCUIT A1 Z1 18BK A2 G106 20BK WT A3 G107 20BK RD A4 L92 20PK A5 L139 20VT A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 B12 B13 B14 B15 B16 B17 B18 C1 V3 16BR WT C2 A...

Page 559: ...37 20RD LG K78 20GY K167 20BR YL K226 20DB LG K29 20WT PK L9 20BK PK L61 20LG WT L60 20TN D21 20PK D20 20LG BK F1 D2 20WT BK D1 20VT BR F1 20DB GY F20 18WT Z12 18BK TN L50 20WT TN G9 20GY BK L10 18BR...

Page 560: ...LG K29 18WT PK F34 18TN BK V20 18BK WT V10 18BR L10 18BR LG G9 20GY BK D2 20WT BK D1 20VT BR G99 20GY WT F20 18WT G29 20BK LB Z12 18BK TN D6 A111 12RD LG D5 D4 A141 16DG WT D2 A3 14RD WT D1 A2 12PK BK...

Page 561: ...E13 E11 F1 20DB GY E10 E9 T141 20YL E8 CIRCUIT CAV F11 F11 CAV CIRCUIT E8 T141 20YL E9 E10 F1 20DB GY E11 E13 E14 E15 E16 E17 E18 F1 F2 F3 F4 F5 F6 F7 V30 20DB RD F8 F32 20PK DB F9 V32 18YL RD F10 F1...

Page 562: ...1 20LG 3 L33 18RD 2 1 CIRCUIT CAV BLACK BLACK FOG LAMPS 5 T41 18BK WT BLACK BLACK A61 16DG BK 14 13 12 F20 18WT 11 F12 18DB WT 10 9 G107 20BK RD 8 F142 18DG WT 7 6 T41 20BK WT 5 G7 20WT OR 4 K167 20BR...

Page 563: ...0L C107 8 1 14 7 14 7 8 1 BLACK BLACK DRL A T M T 4WD A T 4WD 4 0L A T 2WD CALIFORNIA 5 T41 20BK WT G106 20BK WT G106 20BK WT 12 EXTENDED IDLE 4WD CALIFORNIA 5 T41 18BK WT CAV CIRCUIT 1 A142 18DG OR...

Page 564: ...BK WT 12 4WD CALIFORNIA Z1 18BK 5 CAV CIRCUIT A B41 18YL VT B B42 18TN WT C B43 18PK OR D B1 18YL DB E B2 18YL F B3 18LG DB G B4 18LG CAV CIRCUIT A B41 20YL VT B B42 20TN WT C B43 20PK OR D B1 20YL DB...

Page 565: ...51 16BR YL 6 X56 16DB RD 5 X54 16VT 4 3 X55 16BR RD 2 X53 16DG 1 CIRCUIT CAV C16 20LB YL 37 P76 20OR YL 36 P74 20DB 35 P72 20YL BK 34 F81 12TN 33 P36 20PK VT 32 P35 20OR VT 31 K167 20BR YL 30 V23 18BR...

Page 566: ...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 567: ...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 G10 20LG RD 69 68 P91 20WT BK 67 G9 20GY BK 66 F38 16RD LB 65 A21 12DB 64 A41 14YL 63 A22 12BK...

Page 568: ...60 18DG RD 14 X58 18DB OR 15 X57 18BR LB 16 X56 18DB RD 17 X55 18BR RD 18 X54 18VT 19 X53 18DG 20 X52 18DB WT 21 X51 18BR YL 22 CIRCUIT CAV P55 20DB PK 22 P59 20LB RD 21 G26 20LB 20 G16 20BK LB 19 V20...

Page 569: ...BR RD 7 L50 20WT TN 6 L10 18BR LG 5 A141 16DG WT 4 F75 16VT 3 D2 18WT BK 2 D1 18VT BR 1 CIRCUIT CAV C204 C204 F23 18DB YL 10 9 L63 20DG RD 8 L62 20BR RD 7 L50 20WT TN 6 L10 18BR LG 5 A141 16DG WT 4 F7...

Page 570: ...K 3 P36 20PK VT 2 P35 20OR VT 1 CIRCUIT CAV 6 G26 20LB 5 P59 20LB RD 4 P55 20DB PK 3 P36 20PK VT 2 P35 20OR VT 1 CIRCUIT CAV BLACK BLACK 2 1 BLACK 1 2 BLACK Z8 20BK VT 10 CAV CIRCUIT 1 2 C4 14TN 3 C5...

Page 571: ...D1 20VT BR 1 1 5 4 4 10 1 5 10 WHITE C301 C301 CIRCUIT CAV 6 6 BASE 4 SPEAKER SYSTEM 6 SPEAKER SYSTEM 2 D2 20WT BK G31 20VT LG 4 3 G32 20BK LB X3 20BK RD 7 8 P55 20DB F87 20WT BK 6 5 Z2 20BK LG 9 P59...

Page 572: ...P35 20OR VT 7 P36 20PK VT 8 P72 20YL BK 9 P74 20DB 10 P76 20OR YL 11 C16 20LB YL 12 13 P91 20WT BK 2 X87 18DG X87 18LG VT 2 1 X53 18DG LHD C305 LHD C305 WHITE 13 8 3 9 4 1 WHITE 13 3 8 9 1 4 P91 20WT...

Page 573: ...AV FULL OPTIONS POWER WINDOWS POWER WINDOWS FULL OPTIONS LHD C306 RHD C306 RHD C306 LHD C306 WHITE WHITE 3 6 2 1 WHITE 2 6 3 1 WHITE 3 6 2 1 2 6 3 1 6 5 Q26 14VT WT 4 Q16 14BR WT 3 G26 20LB 2 F35 16RD...

Page 574: ...CIRCUIT CAV C310 G78 20TN BK BLACK L77 18BR YL 11 M4 20VT YL 10 Z1 18BK 9 V13 18BR LG 8 V23 18BR PK 7 6 P34 16PK BK 5 P33 16OR BK 4 C15 12BK WT 3 Z1 12BK 2 V20 18BK WT 1 CIRCUIT CAV C311 G78 20TN BK 3...

Page 575: ...OR 4 X51 18BR YL 3 X57 18BR LB 2 X52 18DB WT 1 X58 18DB OR C314 C314 3 1 7 6 2 8 8 6 2 7 3 1 8 M4 20GY BK 7 M2 20YL 6 M1 20PK 5 X93 18WT RD 4 X91 18WT BK 3 X94 18TN RD 2 X92 18TN BK 1 CIRCUIT CAV 8 M...

Page 576: ...322 CAV CIRCUIT 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...

Page 577: ...G 6 L50 20WT TN 7 L77 18BR YL 8 CAV CIRCUIT 1 L63 18DG RD 3 4 5 L10 18BR LG 6 L50 18WT TN 7 L77 18BR 8 1 3 4 4 8 1 3 8 BLACK BLACK C322 C322 TRAILER TOW TRAILER TOW 2 Z1 18BK W POWER AMPLIFIER FULL OP...

Page 578: ...139 18VT WT 5 P138 18VT LG 4 P137 18VT 3 P134 18TN RD 2 P133 18TN DG 1 CIRCUIT CAV 1 8 7 14 1 8 7 14 C329 C329 CIRCUIT 2 Z1 18BK CAV 1 L78 18BK YL 2 CAV 1 Z1 18BK CIRCUIT L77 18BR YL C330 C330 BLACK B...

Page 579: ...SIGNAL K44 18TN YL 3 SENSOR GROUND K167 20BR YL 2 5V SUPPLY K7 18OR 1 FUNCTION CIRCUIT CAV FUSED B C363 CAV CIRCUIT 1 F37 14RD LB 2 Z1 14BK BLACK 2 1 1 2 BLACK Z1 14BK 2 F37 14RD LB 1 CIRCUIT CAV C362...

Page 580: ...4 20BK RD 3 SPEED CONTROL SWITCH SIGNAL V37 20RD LG 2 HORN RELAY CONTROL X3 20BK RD 1 FUNCTION CIRCUIT CAV B A CLOCKSPRING C2 CAV CIRCUIT FUNCTION A K167 20BR YL SENSOR GROUND B V37 20RD LG SPEED CONT...

Page 581: ...CT SIGNAL 4 L6 20RD WT FLASHER OUTPUT 5 GREEN 2 1 2 1 BLACK FUSED B ENGINE STARTER MOTOR RELAY FUSED B ENGINE STARTER MOTOR RELAY FUSED B ENGINE STARTER MOTOR RELAY Z1 20BK FUSED B CAV CIRCUIT FUNCTIO...

Page 582: ...7 18WT RIGHT FRONT WHEEL SPEED SENSOR 4 B9 18RD LEFT FRONT WHEEL SPEED SENSOR 5 6 B41 18YL VT G SWITCH NO 1 SENSE 7 B42 18TN WT G SWITCH NO 2 SENSE 8 Z1 12BK GROUND 9 A20 12RD DB FUSED B 10 B4 18LG LE...

Page 583: ...T RUN F20 18WT 5 HIGH BEAM INDICATOR DRIVER G34 16RD GY 4 3 2 DIMMER SWITCH HIGH BEAM OUTPUT L3 16RD 1 FUNCTION CIRCUIT CAV BASE POLICE 1 3 SWITCH DOME LAMPS C A BLACK GROUND Z1 20BK C COURTESY LAMPS...

Page 584: ...R WINDOW SWITCH PASSENGER UP 6 7 8 9 F81 14TN FUSED IGNITION SWITCH OUTPUT RUN ACC 10 Q27 14RD BK LEFT REAR WINDOW DRIVER DOWN 11 12 BLUE 1 6 5 12 P35 18OR VT Q21 14VT Z1 14BK P36 18PK VT Q26 14VT WT...

Page 585: ...R RELAY OUTPUT C16 20BK WT 5 MIRROR COMMON DRIVER P91 20WT BK LEFT POWER MIRROR HORIZONTAL DRIVER P75 20DB WT 3 MIRROR COMMON DRIVER P76 20OR YL 2 LEFT POWER MIRROR VERTICAL DRIVER P71 20YL 1 FUNCTION...

Page 586: ...OLENOID CAV CIRCUIT FUNCTION 1 K52 18PK BK DUTY CYCLE EVAP PURGE SOLENOID CONTROL 2 F20 18WT FUSED IGNITION SWITCH OUTPUT ST RUN BLACK 2 1 ENGINE OIL PRESSURE SENSOR SIGNAL K167 18BR YL 2 1 BLACK 1 3...

Page 587: ...RONT WIPER 6 3 4 1 BLACK WIPER HIGH SPEED OUTPUT V4 16BR VT 6 WIPER LOW SPEED OUTPUT V3 16BR WT 5 GROUND Z1 16BK 4 3 WIPER PARK SWITCH SENSE V5 16DG YL 2 FUSED IGNITION SWITCH OUTPUT RUN ACC V6 16DB 1...

Page 588: ...R CAV CIRCUIT FUNCTION 1 A142 18DG OR 2 K14 18LB BR FUEL INJECTOR NO 4 DRIVER FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUSED...

Page 589: ...RCUIT CAV FUEL INJECTOR NO 3 DRIVER K13 18YL WT 2 A142 18DG OR 1 FUNCTION CIRCUIT CAV FUEL INJECTOR NO 2 DRIVER K12 18TN 2 A142 18DG OR 1 FUNCTION CIRCUIT CAV FUEL INJECTOR NO 1 4 0L 1 2 BLACK BLACK 2...

Page 590: ...SENSOR SIGNAL GENERATOR FIELD K20 16DG 2 K72 16DG OR 1 GENERATOR SOURCE HEADLAMP SWITCH OUTPUT CAV CIRCUIT FUNCTION 1 2 A3 14RD WT FUSED B 3 4 Z1 18BK GROUND 5 6 L2 14LG HEADLAMP SWITCH OUTPUT L2 14L...

Page 591: ...L NO 4 DRIVER K59 18VT BK 1 FUNCTION CIRCUIT CAV 1 4 7 2 5 8 9 6 3 BLACK 1 4 MOTOR CONTROL IDLE AIR FUSED B LHD CAV CIRCUIT FUNCTION 1 E1 20TN PANEL LAMPS DIMMER SWITCH SIGNAL 2 L2 14LG HEADLAMP SWITC...

Page 592: ...K WT 8 FUSED B A1 12RD 7 6 5 IGNITION SWITCH OUTPUT RUN A22 12BK OR 4 FUSED B A2 12PK BK 3 RED BRAKE WARNING INDICATOR DRIVER G9 20GY BK 2 GROUND Z1 20BK 1 FUNCTION CIRCUIT CAV SWITCH C2 IGNITION 2 1...

Page 593: ...TN BK 1 FUNCTION CIRCUIT CAV LEFT TURN SIGNAL L61 20LG WT 10 FUSED B M1 20PK 9 FUSED IGNITION SWITCH OUTPUT START RUN F87 20WT BK 8 LOW WASHER FLUID SENSE G29 20BK LB 7 GROUND Z2 20BK LG 6 HIGH BEAM I...

Page 594: ...CH OUTPUT RUN ACC V6 16DB 8 7 FUSED IGNITION SWITCH OUTPUT RUN F15 20DB WT 6 L78 20DG YL 5 4 FUSED B ENGINE STARTER MOTOR RELAY F45 20YL RD 3 2 FUSED RIGHT LOW BEAM OUTPUT L44 20VT RD 1 FUNCTION CIRCU...

Page 595: ...IMMER SWITCH SIGNAL E2 20OR S2 PANEL LAMPS DIMMER SWITCH SIGNAL E1 20TN S1 F30 16RD M6 FUSED B F38 16RD LB M5 FUSED IGNITION SWITCH OUTPUT RUN ACC V6 16DB M4 HEADLAMP SWITCH OUTPUT L7 18BK YL M3 IGNIT...

Page 596: ...FUSED B F37 14RD LB 2 REAR WINDOW DEFOGGER RELAY OUTPUT C15 12BK WT 1 FUNCTION CIRCUIT CAV BLOCK C7 JUNCTION 8 3 4 1 NATURAL FUSED B A6 20RD OR 8 COURTESY LAMPS DRIVER M2 20YL 7 FUSED HEADLAMP SWITCH...

Page 597: ...BLOCK C9 JUNCTION NATURAL 6 1 12 5 FUNCTION P33 16OR BK CAV 1 CIRCUIT DOOR LOCK DRIVER P75 20DB WT C16 20BK WT 2 3 5 4 P91 20WT BK P76 20OR YL 7 8 9 10 6 P71 20YL LB 11 LEFT POWER MIRROR HORIZONTAL DR...

Page 598: ...8LG RD 1 2 1 BLACK AMPLIFIED LEFT FRONT DOOR SPEAKER X87 18DG 2 AMPLIFIED LEFT FRONT DOOR SPEAKER X85 18BK RD 1 FUNCTION CIRCUIT CAV FUSED B 6 SPEAKER RHD 4 SPEAKER AMPLIFIED LEFT FRONT DOOR SPEAKER A...

Page 599: ...LAMPS SEAT BACK CAV CIRCUIT FUNCTION A P88 18BR BK LEFT HEATED SEAT BACK DRIVER B Z1 18BK GROUND LEFT HEATED B A LEFT HEATED SEAT BACK DRIVER P88 18BR BK LEFT HEAT SENSE INPUT SENSOR FEED P141 18TN LB...

Page 600: ...T FRONT CAV CIRCUIT FUNCTION 1 P19 14YL LG LEFT POWER SEAT FRONT UP 2 P21 14RD LG LEFT POWER SEAT FRONT DOWN LEFT POWER YELLOW MOTOR SEAT HORIZONTAL CAV CIRCUIT FUNCTION 1 P17 14RD LB LEFT POWER SEAT...

Page 601: ...A B P15 14YL LB J P17 14RD LB E LEFT POWER SEAT HORIZONTAL FORWARD LEFT POWER SEAT REAR DOWN LEFT POWER SEAT REAR UP K P13 14RD WT L P11 14YL WT SEAT SWITCH LEFT POWER N M L K J B E A C F H G C F G H...

Page 602: ...UTPUT LEFT TAIL STOP LAMP SWITCH CAV CIRCUIT FUNCTION A X57 18BR LB LEFT REAR SPEAKER A X91 16BR DB AMPLIFIED LEFT REAR SPEAKER SPEAKER SOUNDBAR LEFT B B X51 18BR YL X93 16BR YL AMPLIFIED LEFT REAR SP...

Page 603: ...RCUIT 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 LIFTGATE COURTESY LAMP DRIVER BLACK 3...

Page 604: ...1 1 OXYGEN 3 1 4 2 GRAY OXYGEN SENSOR 1 1 SIGNAL K41 18BK DG 4 SENSOR GROUND K167 20BR YL 3 GROUND Z1 20BK 2 FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT A42 20DG 1 FUNCTION CIRCUIT CAV MODULE 2 5L 4 0L 2 Z1...

Page 605: ...EED CIRCUIT CAV T41 18BK WT 1 2 L10 18BR LG 3 F20 18WT PASSENGER DOOR JAMB SWITCH PASSENGER AIRBAG LINE 1 GRAY 2 4 1 3 OXYGEN SENSOR 2 1 UPSTREAM OXYGEN SENSOR 2 1 SIGNAL K241 18LG RD 4 SENSOR GROUND...

Page 606: ...LB KEY IN IGNITION SWITCH SENSE BLUE 1 5 4 8 PASSENGER POWER LOCK WINDOW SWITCH C2 3 P36 18PK VT 7 P36 20PK VT DOOR LOCK SWITCH OUTPUT UNLOCK DOOR LOCK SWITCH OUTPUT UNLOCK DOOR LOCK SWITCH OUTPUT LOC...

Page 607: ...5 X53 18DG LEFT FRONT SPEAKER 6 X54 18VT RIGHT FRONT SPEAKER 7 X51 18BR YL LEFT REAR SPEAKER 8 X57 18BR LB LEFT REAR SPEAKER 9 X52 18DB WT RIGHT REAR SPEAKER 10 4 NATURAL 10 1 5 POWER AMPLIFIER C1 CA...

Page 608: ...GROUND CAV CIRCUIT FUNCTION 1 Z1 20BK 2 F83 18YL DG FUSED IGNITION SWITCH OUTPUT RUN ACC 3 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER 4 P72 20YL BK RIGHT POWER MIRROR VERTICAL DRIVER 5 P76 20OR YL...

Page 609: ...8TN BK 16 INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18BK RD 15 14 13 IDLE ACTUATOR K78 18GY 12 POWER STEERING PRESSURE SWITCH SENSE K10 18DB BR 12 K40 18BR WT 11 IDLE AIR CONTROL NO 2 DRIVER K60 18YL B...

Page 610: ...4 DRIVER CONTROL MODULE C2 POWERTRAIN 32 21 12 22 11 1 32 31 30 29 28 VEHICLE SPEED SENSOR SIGNAL G7 18WT OR 27 26 25 24 ENGINE OIL PRESSURE SENSOR SIGNAL G60 18GY YL 23 22 21 20 19 18 17 16 15 14 13...

Page 611: ...R 19 18 17 16 BATTERY TEMPERATURE SENSOR SIGNAL K118 18PK YL 15 14 13 FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT F142 18DG WT 12 SPEED CONTROL POWER SUPPLY V32 18YL RD 11 LEAK DETECTION PUMP SOLENOID CONT...

Page 612: ...SPEAKER X51 16BR YL 2 RADIO 12V OUTPUT X60 16DG RD 1 FUNCTION CIRCUIT CAV FUSED B RADIO C2 GRAY 1 7 M1 20PK 7 FUSED IGNITION SWITCH OUTPUT RUN ACC X12 16RD WT 6 FUSED PANEL LAMPS DIMMER SWITCH SIGNAL...

Page 613: ...RUN GRAY SWITCH DEFOGGER REAR WINDOW 1 4 REAR WASHER PUMP 4 1 MOTOR REAR WIPER FUSED IGNITION SWITCH OUTPUT RUN V23 18BR PK 4 REAR REAR WIPER MOTOR CONTROL V13 18BR LG 3 REAR WASHER MOTOR CONTROL V20...

Page 614: ...8TN 1 FUNCTION CIRCUIT CAV 3 1 BLACK CAV CIRCUIT FUNCTION 1 X80 18LB BK AMPLIFIED RIGHT FRONT DOOR SPEAKER 2 X82 18LB RD BLACK 1 2 RIGHT FRONT DOOR SPEAKER FUSED HEADLAMP SWITCH OUTPUT AMPLIFIED RIGHT...

Page 615: ...EAT BACK DRIVER SENSOR FEED D C B A RIGHT HEAT SENSE INPUT SEAT CUSHION RIGHT HEATED P89 18BR P141 18TN LB P144 18BK YL C D B P86 18PK BK A FUNCTION CIRCUIT CAV BLUE YELLOW VERTICAL MOTOR SEAT FRONT C...

Page 616: ...J P14 14YL LB E RIGHT POWER SEAT HORIZONTAL REARWARD RIGHT POWER SEAT REAR UP RIGHT POWER SEAT REAR DOWN K P10 14YL WT L P12 14RD WT SEAT SWITCH RIGHT POWER N M L K J B E A C F H G C F G H BLACK F37 1...

Page 617: ...ED B A RIGHT REAR WHEEL SPEED SENSOR B1 20YL DB B RIGHT REAR WHEEL SPEED SENSOR B2 20YL A FUNCTION CIRCUIT CAV CAV CIRCUIT FUNCTION 1 Q14 14GY POWER WINDOW RIGHT REAR B UP 2 Q24 14DG RIGHT REAR WINDOW...

Page 618: ...RIGHT TAIL 3 1 GROUND Z1 18BK 3 FUSED HEADLAMP SWITCH OUTPUT L78 18DG YL 2 BRAKE LAMP SWITCH OUTPUT L50 18WT TN 1 FUNCTION CIRCUIT CAV CONTROL SWITCH RIGHT SPEED CAV CIRCUIT FUNCTION 1 K167 20BR YL SE...

Page 619: ...Z2 18BK LG RIGHT SEAT LOW HEAT LED DRIVER LEFT SEAT HIGH HEAT LED DRIVER RIGHT SEAT HEATER SWITCH MUX P143 18BK DG RIGHT HEAT SENSE INPUT HEATED SEAT RELAY OUTPUT P87 18BK OR HEATED SEAT RELAY OUTPUT...

Page 620: ...AMP SWITCH OUTPUT RIGHT TURN RELAY TRAILER TOW 1 4 2 5 3 BLACK BRAKE LAMP SWITCH OUTPUT L74 20LG 5 4 FUSED B A6 20RD OR 3 BRAKE LAMP SWITCH OUTPUT L50 20WT TN 2 RIGHT TURN SIGNAL L62 20BK RD 1 FUNCTIO...

Page 621: ...PANEL LAMPS DIMMER SWITCH SIGNAL E2 20OR 1 FUNCTION CIRCUIT CAV SOLENOID TRANSMISSION SOLENOID B CONTROL T60 20OR WT OUTPUT SPEED SENSOR SIGNAL T14 20LG WT 7 8 8 4 4 1 BLACK OUTPUT SPEED SENSOR GROUN...

Page 622: ...K167 20BR YL 16 15 SCI TRANSMIT ISO 9141K D21 20PK 14 T60 20OR WT 13 T19 20WT 12 SOLENOID C CONTROL T22 20DB WT 11 10 TRS T3 SENSE T3 18VT 9 8 D1 20VT BR 7 CCD BUS D2 20WT BK 6 5 OUTPUT SPEED SENSOR...

Page 623: ...T TURN SIGNAL 2 3 L62 20BR RD RIGHT TURN SIGNAL 4 L55 20RD WT COMBINATION FLASHER INPUT 5 L6 20RD WT FLASHER OUTPUT 6 L12 20VT TN HAZARD FLASHER SELECT SIGNAL 7 8 9 L63 20DG RD LEFT TURN SIGNAL 10 L61...

Page 624: ...L B Z1 18BK GROUND BLACK A B WINDSHIELD WASHER PUMP SWITCH WIPE WASH 1 6 NATURAL WIPER HIGH SPEED OUTPUT V4 16BR VT 6 FUSED IGNITION SWITCH OUTPUT RUN ACC V6 16DB 5 WIPER LOW SPEED OUTPUT V3 16BR WT 4...

Page 625: ...tch 4 0L RHD Left Side of Engine Compartment Near T O for A C Compressor Clutch 15 A C Low Pressure Switch LHD Right Rear of Engine Compartment 4 12 A C Low Pressure Switch RHD Left Rear of Engine Com...

Page 626: ...Instrument Panel 23 24 C206 BK At Center Console 26 27 32 Connector Name Number Color Location Fig C207 BK Right Lower Instrument Panel 21 24 C208 BK Left Lower Instrument Panel 21 24 C209 LHD BK LT...

Page 627: ...ring C3 YL At Clockspring 35 Connector Name Number Color Location Fig Clutch Interlock Switch GN At Clutch Pedal 14 24 25 Clutch Interlock Switch Jumper LHD BK Lower Steering Column N S Clutch Interlo...

Page 628: ...ght Front of Engine Compartment 12 13 G100 2 5L Right Front of Engine Compartment at Battery Negative Terminal N S G101 Right Side of Engine 16 17 Connector Name Number Color Location Fig G102 Rear of...

Page 629: ...tion Block C6 NAT At Right Kick Panel Area 29 Connector Name Number Color Location Fig Junction Block C7 NAT At Right Kick Panel Area 29 Junction Block C8 NAT At Right Kick Panel Area 29 Junction Bloc...

Page 630: ...sor 1 2 Downstream California BK Left Side of Engine 17 Oxygen Sensor 2 1 Upstream California GY Left Side of Engine 17 Connector Name Number Color Location Fig Oxygen Sensor 2 2 Downstream California...

Page 631: ...or Name Number Color Location Fig Right Heated Seat Back At Right Seat N S Right Heated Seat Cushion At Right Seat N S Right Heated Seat Switch BL At Center Console 26 27 Right Power Seat Front Vertic...

Page 632: ...nsmission Control Assembly or Transmission Solenoid 4 0L BK Rear of Engine Compartment 12 13 Transmission Control Module 4 0L BK Under Instrument Panel near Transmission Tunnel 14 15 25 Connector Name...

Page 633: ...Fig 1 Front End Lighting XJ 8W 90 CONNECTOR LOCATIONS 8W 90 9 DESCRIPTION AND OPERATION Continued...

Page 634: ...Fig 2 Left Engine Compartment 2 5L Engine LHD 8W 90 10 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 635: ...Fig 3 Left Engine Compartment 2 5L Engine RHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 11 DESCRIPTION AND OPERATION Continued...

Page 636: ...Fig 4 Right Engine Compartment 2 5L Engine LHD Fig 5 Right Engine Compartment 2 5L Engine RHD 8W 90 12 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 637: ...Fig 6 Engine Compartment Auxiliary Views 2 5L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 13 DESCRIPTION AND OPERATION Continued...

Page 638: ...Fig 7 Engine Compartment Auxiliary Views 2 5L Engine RHD 8W 90 14 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 639: ...Fig 8 Engine Compartment Components LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 15 DESCRIPTION AND OPERATION Continued...

Page 640: ...Fig 9 Engine Compartment Components RHD 8W 90 16 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 641: ...Fig 10 Left Engine Compartment 4 0L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 17 DESCRIPTION AND OPERATION Continued...

Page 642: ...Fig 11 Left Engine Compartment 4 0L Engine RHD 8W 90 18 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 643: ...Fig 12 Right Engine Compartment 4 0L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 19 DESCRIPTION AND OPERATION Continued...

Page 644: ...Fig 13 Right Engine Compartment 4 0L Engine RHD 8W 90 20 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 645: ...Fig 14 Engine Compartment Auxiliary Views 4 0L Engine LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 21 DESCRIPTION AND OPERATION Continued...

Page 646: ...Fig 15 Engine Compartment Auxiliary Views 4 0L Engine RHD 8W 90 22 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 647: ...Fig 16 2 5L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 23 DESCRIPTION AND OPERATION Continued...

Page 648: ...Fig 17 4 0L Engine 8W 90 24 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 649: ...Fig 18 4 0L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 25 DESCRIPTION AND OPERATION Continued...

Page 650: ...Fig 19 Transmission Connectors 2 5L Engine 8W 90 26 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 651: ...Fig 20 Transmission Connectors 4 0L Engine XJ 8W 90 CONNECTOR LOCATIONS 8W 90 27 DESCRIPTION AND OPERATION Continued...

Page 652: ...Fig 21 Instrument Panel LHD 8W 90 28 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 653: ...Fig 22 Instrument Panel LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 29 DESCRIPTION AND OPERATION Continued...

Page 654: ...Fig 23 Instrument Panel RHD 8W 90 30 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 655: ...Fig 24 Instrument Panel RHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 31 DESCRIPTION AND OPERATION Continued...

Page 656: ...Fig 25 Under Dash Components 8W 90 32 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 657: ...Fig 26 Left Side Body LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 33 DESCRIPTION AND OPERATION Continued...

Page 658: ...Fig 27 Left Side Body RHD 8W 90 34 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 659: ...Fig 28 Left Rear Body XJ 8W 90 CONNECTOR LOCATIONS 8W 90 35 DESCRIPTION AND OPERATION Continued...

Page 660: ...Fig 29 Right Side Body and Junction Block 8W 90 36 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 661: ...Fig 30 Front and Rear Doors Left Side Shown Right Side Similar XJ 8W 90 CONNECTOR LOCATIONS 8W 90 37 DESCRIPTION AND OPERATION Continued...

Page 662: ...Fig 31 Liftgate 8W 90 38 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 663: ...Fig 32 Center Console LHD XJ 8W 90 CONNECTOR LOCATIONS 8W 90 39 DESCRIPTION AND OPERATION Continued...

Page 664: ...Fig 33 Trailer Tow Fig 34 Headliner 8W 90 40 8W 90 CONNECTOR LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 665: ...Fig 35 Steering Column XJ 8W 90 CONNECTOR LOCATIONS 8W 90 41 DESCRIPTION AND OPERATION Continued...

Page 666: ......

Page 667: ...T O for Fuel Injector NO 3 11 S113 4 0L Between Fuel Injector NO 2 and Fuel Injector NO 3 T O s 10 S114 2 5L Near T O for Fuel Injector NO 2 11 S114 4 0L Between Fuel Injector NO 2 and Fuel Injector...

Page 668: ...C Low Pressure Switch 2 S158 Near T O for Left Headlamp 9 S159 Near Grommet T O for Junction Block C2 3 4 7 8 Splice Number Location Fig S161 A T Near T O for Vehicle Speed Sensor 11 S166 Near T O for...

Page 669: ...RHD Near T O for C314 and C321 16 S311 Near T O for C326 and C327 17 S312 Under Left Rear Seat 15 Splice Number Location Fig S312 LHD with Power Amplifier RHD Near T O for C304 and C319 16 S313 Near T...

Page 670: ...ss Entry In T O for Overhead Module 23 Splice Number Location Fig S348 In Right Tail Lamp Harness near C322 N S S349 RHD In T O for C209 N S S351 Near T O for C305 and C306 15 S352 In T O for C300 N S...

Page 671: ...Fig 1 Left Engine Compartment Splices 4 0L Engine LHD XJ 8W 95 SPLICE LOCATIONS 8W 95 5 DESCRIPTION AND OPERATION Continued...

Page 672: ...Fig 2 Left Engine Compartment Splices 4 0L Engine RHD 8W 95 6 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 673: ...Fig 3 Right Engine Compartment Splices 4 0L Engine LHD XJ 8W 95 SPLICE LOCATIONS 8W 95 7 DESCRIPTION AND OPERATION Continued...

Page 674: ...Fig 4 Right Engine Compartment Splices 4 0L Engine RHD 8W 95 8 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 675: ...Fig 5 Left Engine Compartment Splices 2 5L Engine LHD XJ 8W 95 SPLICE LOCATIONS 8W 95 9 DESCRIPTION AND OPERATION Continued...

Page 676: ...Fig 6 Left Engine Compartment Splices 2 5L Engine RHD 8W 95 10 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 677: ...Fig 7 Right Engine Compartment Splices 2 5L Engine LHD XJ 8W 95 SPLICE LOCATIONS 8W 95 11 DESCRIPTION AND OPERATION Continued...

Page 678: ...Fig 8 Right Engine Compartment Splices 2 5L Engine RHD 8W 95 12 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 679: ...Fig 9 Front End Lighting Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 13 DESCRIPTION AND OPERATION Continued...

Page 680: ...Fig 10 Engine Wiring Splices 4 0L Engine 8W 95 14 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 681: ...Fig 11 Engine Wiring Splices 2 5L Engine XJ 8W 95 SPLICE LOCATIONS 8W 95 15 DESCRIPTION AND OPERATION Continued...

Page 682: ...Fig 12 Instrument Panel Wiring Splices LHD 8W 95 16 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 683: ...Fig 13 Instrument Panel Wiring Splices RHD XJ 8W 95 SPLICE LOCATIONS 8W 95 17 DESCRIPTION AND OPERATION Continued...

Page 684: ...Fig 14 Instrument Panel to Body Harness Splices 8W 95 18 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 685: ...Fig 15 Left Side Body Harness Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 19 DESCRIPTION AND OPERATION Continued...

Page 686: ...Fig 16 Right Side Body Harness Splices 8W 95 20 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 687: ...Fig 17 Left Side Body Harness Splices Fig 18 Trailer Tow Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 21 DESCRIPTION AND OPERATION Continued...

Page 688: ...Fig 19 Power Seat Splices Fig 20 Right Front Door Splices 8W 95 22 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 689: ...Fig 21 Left Front Door Splices Fig 22 Liftgate Splices XJ 8W 95 SPLICE LOCATIONS 8W 95 23 DESCRIPTION AND OPERATION Continued...

Page 690: ...Fig 23 Headliner Splices 8W 95 24 8W 95 SPLICE LOCATIONS XJ DESCRIPTION AND OPERATION Continued...

Page 691: ...G 18 CONNECTING ROD BEARINGS FITTING 21 FITTING CRANKSHAFT MAIN BEARINGS 23 FORM IN PLACE GASKETS 25 ENGINE PERFORMANCE 26 HONING CYLINDER BORES 26 REPAIR DAMAGED OR WORN THREADS 27 SERVICE ENGINE ASS...

Page 692: ...type positive displacement pump is mounted at the underside of the block opposite the No 4 main bearing OPERATION The pump draws oil through the screen and inlet tube from the sump at the rear of the...

Page 693: ...provided by the hydraulic valve tappets which pass oil through hollow push rods to a hole in the corresponding rocker arm Oil from the rocker arm lubricates the valve train components then passes dow...

Page 694: ...m 2 5L Engine 1 CAM CRANK MAIN GALLERY 7 2 TAPPET GALLERY 3 TAPPET GALLERY 4 CAMSHAFT BEARING 5 NUMBER 1 CAMSHAFT BEARING JOURNAL 6 CAMSHAFT SPROCKET 7 TAPPET GALLERY 9 4 2 5L ENGINE XJ DESCRIPTION AN...

Page 695: ...The cylinder head uses dual quench type design combustion chambers which cause turbulence in the cylinders allowing faster burning of the air fuel mix ture resulting in better fuel economy The valve...

Page 696: ...e of stamped steel and have a operational ratio of 1 6 1 OPERATION When the push rods are forced upward by the cam shaft lobes the push rod presses upward on the rocker arms the rocker arms pivot forc...

Page 697: ...t bores above the camshaft VALVE GUIDE DESCRIPTION The valve guides are integral to the cylinder head They are not replaceable However they are service able OIL PAN DESCRIPTION The oil pan is made of...

Page 698: ...in determining the causes of malfunctions not detected and remedied by routine maintenance These malfunctions may be classified as either per formance e g engine idles rough and stalls or mechanical...

Page 699: ...ocedures 2 No fuel 2 Perform fuel pressure test and if necessary inspect fuel injector s and driver circuits Refer to Group 14 Fuel System for correct procedures 3 Low or no engine compression 3 Perfo...

Page 700: ...er to Group 11 Exhaust System Intake Manifold 8 EGR valve leaking or stuck open 8 Test and replace if necessary Refer to group 25 Emission Control Systems ENGINE MISSES ON ACCELERATION 1 Worn or incor...

Page 701: ...nnecting rod bearing clearance Measure bearings for correct clearance with plasti gage Repair as necessary 5 Connecting rod journal out of round 5 Replace crankshaft or grind journals 6 Misaligned con...

Page 702: ...eriorated gaskets 1 Replace gasket 2 Loose fastener broken or porous metal part 2 Tighten repair or replace the part 3 Front or rear crankshaft oil seal leaking 3 Replace seal 4 Leaking oil gallery pl...

Page 703: ...adjacent cylinders follow the proce dures outlined in Cylinder Compression Pressure Test An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 50 70 reducti...

Page 704: ...and repeat inspection 4 If the oil leak source is not positively identified at this time proceed with the air leak detection test method Air Leak Detection Test Method 1 Disconnect the breather cap to...

Page 705: ...e front of the engine until the dial indicator pointer indicates 0 305 mm 0 012 inch travel dis tance lift The timing notch index on the vibration damper should be aligned with the TDC mark on the tim...

Page 706: ...ED METHOD 1 Remove the valve from the head 2 Clean the valve stem guide bore with solvent and a bristle brush 3 Insert a telescoping gauge into the valve stem guide bore approximately 9 525 mm 375 inc...

Page 707: ...bore at a point 49 5 mm 1 15 16 inches below top of bore Start perpendicular across or at 90 degrees to the axis of the crankshaft at point A and then take an additional bore reading 90 degrees to tha...

Page 708: ...ween the ring land and ring Fig 20 Fig 21 Rotate the ring in the groove It must move freely around circumference of the groove Fig 18 Moly Coated Piston 1 MOLY COATED 2 MOLY COATED Fig 19 Bore Gauge 1...

Page 709: ...l the second com pression ring with the dot facing up Fig 24 Fig 26 9 Using a ring installer install the top compres sion ring either side up Ring Gap Orientation Position the gaps on the piston as sh...

Page 710: ...RING 2 SECOND COMPRESSION RING 3 PISTON 4 CHAMFER Fig 26 Compression Ring Installation 1 COMPRESSION RING 2 RING EXPANDER RECOMMENDED Fig 27 Ring Gap Orientation 1 TOP COMPRESSION RING 2 BOTTOM COMPR...

Page 711: ...nt to the front of the engine Fig 31 Verify that the oil squirt holes in the rods face the camshaft and that the arrows on the pistons face the front of the engine 5 Install the lower bearing insert i...

Page 712: ...d with a pair of 0 0254 mm 0 001 inch undersize bearing inserts installed This will determine if two 0 0254 mm 0 001 inch undersize inserts or another combination is needed to provide the correct clea...

Page 713: ...bearing inserts FITTING BEARINGS CRANKSHAFT INSTALLED The main bearing caps numbered front to rear from 1 through 5 have an arrow to indicate the for ward position The upper main bearing inserts are g...

Page 714: ...e specified clearance FOR EXAMPLE If the clear ance was 0 0762 mm 0 003 inch originally a pair of 0 0254 mm 0 001 inch undersize inserts would reduce the clearance by 0 0254 mm 0 001 inch The clearanc...

Page 715: ...fferent properties and cannot be used inter changeably MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant normally black in color is available in 3 ounce tubes Moisture in t...

Page 716: ...8D for specifications 7 Test fuel pump for pressure Refer to Group 14 Fuel System Specifications 8 The air filter elements should be replaced as specified in Lubrication and Maintenance Group 0 9 Ins...

Page 717: ...l spark plugs removed rotate the crank shaft using a breaker bar and socket 6 Identify the fluid in the cylinders i e coolant fuel oil etc 7 Make sure all fluid has been removed from the cylinders 8 R...

Page 718: ...oil to settle to bottom of crankcase remove engine oil dipstick 3 Wipe dipstick clean 4 Install dipstick and verify it is seated in the tube 5 Remove dipstick with handle held above the tip note oil...

Page 719: ...Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine Refer to the WARNING at beginning of this section REMOVAL AND INSTALLATION ENGINE MOUNTS FRONT T...

Page 720: ...ve cable from battery 2 Raise the vehicle and support the transmission 3 Remove the nuts holding the support cushion to the crossmember Fig 45 Fig 46 Remove the crossmember MANUAL TRANSMISSION a Remov...

Page 721: ...e nuts Tighten the nuts to 22 N m 192 in lbs torque 2 Install the crossmember to sill bolts and tighten to 41 N m 30 ft lbs torque 3 Remove the transmission support 4 Lower the vehicle 5 Connect negat...

Page 722: ...18 Disconnect suction discharge hose from A C compressor and cap off ports to prevent intrusion of foreign material or refrigerant oil loss 19 Remove the power brake vacuum check valve from the boost...

Page 723: ...bs torque c Fill the pump reservoir with fluid 19 Remove the pulley to water pump flange alignment capscrew and install the fan assembly 20 Install the fan shroud and radiator and con denser if equipp...

Page 724: ...Remove bolts 2 through 5 securing the intake manifold to the cylinder head Fig 51 Slightly loosen bolt No 1 and nuts 6 and 7 15 Remove the intake manifold and gaskets Drain the coolant from the manifo...

Page 725: ...DO NOT allow foreign material to enter either the intake man ifold or the ports in the cylinder head 2 Install a new intake manifold gasket over the alignment dowels on the cylinder head 3 Install the...

Page 726: ...cover Refer to procedure in this section 2 Check for rocker arm bridges which are caus ing misalignment of the rocker arm to valve tip area 3 Remove the capscrews at each bridge and pivot assembly Fig...

Page 727: ...Spring Compressor Tool MD 998772A to compress the spring and remove the locks Fig 54 9 Remove valve spring and retainer Fig 54 10 Remove valve stem oil seals Fig 54 Note the valve seals are different...

Page 728: ...OT disconnect the hoses 10 Perform fuel pressure release procedure Refer to Group 14 fuel systems for proper proce dures 11 Remove the latch clip and disconnect the fuel supply hose 12 Remove the inta...

Page 729: ...bolts DO NOT overtighten bolt No 7 10 Tighten the engine cylinder head bolts in sequence according to the following procedure Fig 59 a Tighten all bolts in sequence 1 through 10 to 30 N m 22 ft lbs t...

Page 730: ...tinue operating the engine until the thermostat opens Add coolant if required CYLINDER HEAD DISASSEMBLY 1 Use Valve Spring Compressor Tool MD 998772A and compress each valve spring 2 Remove the valve...

Page 731: ...shaft key and tap the damper onto the crankshaft 2 Install the vibration damper retaining bolt and washer 3 Tighten the damper retaining bolt to 108 N m 80 ft lbs torque 4 Install the serpentine drive...

Page 732: ...ation damper Fig 63 7 Remove the oil pan to timing case cover bolts and timing case cover to cylinder block bolts 8 Remove the timing case cover and gasket from the engine 9 Pry the crankshaft oil sea...

Page 733: ...cover 6 Rotate crankshaft until the 0 timing mark is closest to and on the center line with camshaft sprocket timing mark Fig 65 7 Remove the oil slinger from the crankshaft 8 Remove the camshaft reta...

Page 734: ...butor housing near the clamp and continue the scribe mark on the cylin der block in line with the distributor mark 6 For ease of installation note the position of the rotor and distributor housing in...

Page 735: ...tappets 16 Install the push rods 17 Install the rocker arms bridges and pivots 18 Install the engine cylinder head cover 19 Position the oil pump gear Refer to Distribu tor in the Component Removal I...

Page 736: ...n the camshaft pin hole 2 Compress the center of the replacement spring pin with vise grips 3 Carefully drive the pin into the camshaft pin hole until it is seated 4 Install the camshaft sprocket cran...

Page 737: ...ressure lubricated NOTE It is not advisable to attempt to replace camshaft bearings unless special removal and installation tools are available such as recom mended tool 8544 Camshaft Bushing Remover...

Page 738: ...et Maker or equivalent on the rear bearing cap Fig 78 The bead should be 3 mm 0 125 in thick DO NOT apply Mopart Gasket Maker or equivalent to the lip of the seal 7 Install the rear main bearing cap D...

Page 739: ...e 18 Fill the oil pan with engine oil to the safe mark on the dipstick level 19 Connect negative cable to battery OIL PAN REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Remove...

Page 740: ...ve cable to battery 18 Fill the oil pan with engine oil to the specified level WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT YOUR HANDS...

Page 741: ...TON AND CONNECTING ROD REMOVAL 1 Remove the engine cylinder head cover 2 Remove the rocker arms bridges and pivots 3 Remove the push rods 4 Remove the engine cylinder head 5 Position the pistons one a...

Page 742: ...the flange rear end of the crankshaft The color codes used to indi cate journal sizes are listed in the Connecting Rod Bearing Fitting Chart 10 When required upper and lower bearing inserts of differ...

Page 743: ...and gasket 12 Remove the timing chain tensioner 13 Remove the front and rear oil galley plugs 14 Remove the connecting rods and the pistons Remove the connecting rod and piston assemblies through the...

Page 744: ...ghtedge and feeler gauge to check the flatness of the engine cylinder head and block mating surfaces CYLINDER BLOCK CLEANING Thoroughly clean the oil pan and engine block gas ket surfaces Use compress...

Page 745: ...Hydraulic Tappet Clearance Zero Lash Bearing Clearance 0 025 0 076 mm 0 001 0 003 in DESCRIPTION SPECIFICATION Bearing Journal Diameter No 1 51 54 51 56 mm 2 029 2 030 in No 2 51 28 51 31 mm 2 019 2...

Page 746: ...TION Main Bearing Journal Width No 1 27 58 to 27 89 mm 1 086 to 1 098 in No 2 32 28 to 32 33 mm 1 271 to 1 273 in No 3 4 5 30 02 to 30 18 mm 1 182 to 1 188 in Main Bearing Clearance 0 03 to 0 06 mm 0...

Page 747: ...ve Seat Width 1 01 to 1 52 mm 0 040 to 0 060 in DESCRIPTION SPECIFICATION Valve Seat Runout 0 064 mm 0 0025 in Flatness 0 03 mm per 25 mm 0 001 in per 1 in 0 05 mm per 152 mm 0 002 in per 6 in Flatnes...

Page 748: ...ompression Rings 0 042 to 0 084 mm 0 0017 to 0 0033 in Oil Control Rings 0 06 to 0 21 mm 0 0024 to 0 0083 in DESCRIPTION SPECIFICATION OIL PUMP AND OIL PRESSURE Gear to Body Clearance Radial 0 051 to...

Page 749: ...smission Support Adaptor 75 55 Bracket Bolts Exhaust Manifold Pipe Nuts 27 20 DESCRIPTION N m Ft Lbs In Lbs Exhaust Manifold Bolt 1 41 30 Bolts 2 5 31 23 Nuts 6 and 7 14 126 Flywheel Converter Housing...

Page 750: ...e Spring Compressor Tool MD 998772A Timing Case Cover Alignment and Seal installation Tool 6139 Vibration Damper Removal Tool 7697 Rear Main Seal Installer Tool 6271A Hydraulic Valve Tappet Removal In...

Page 751: ...BEARINGS 83 FORM IN PLACE GASKETS 86 ENGINE PERFORMANCE 87 HONING CYLINDER BORES 87 REPAIR DAMAGED OR WORN THREADS 88 SERVICE ENGINE ASSEMBLY SHORT BLOCK 88 HYDROSTATIC LOCK 88 ENGINE OIL SERVICE 88...

Page 752: ...ICATION SYSTEM DESCRIPTION A gear type positive displacement pump is mounted at the underside of the block opposite the No 4 main bearing OPERATION The pump draws oil through the screen and inlet tube...

Page 753: ...provided by the hydraulic valve tappets which pass oil through hollow push rods to a hole in the corresponding rocker arm Oil from the rocker arm lubricates the valve train components then passes down...

Page 754: ...4 0L Engine 1 CAM CRANK MAIN GALLERY 7 2 TAPPET GALLERY 3 TAPPET GALLERY 4 CAMSHAFT BEARING 5 NUMBER 1 CAMSHAFT BEARING JOURNAL 6 CAMSHAFT SPROCKET 7 TAPPET GALLERY 9 64 4 0L ENGINE XJ DESCRIPTION AN...

Page 755: ...4 CRANKSHAFT DESCRIPTION The crankshaft is constructed of nodular cast iron The crankshaft is a crosshaped four throw design with eight counterweights for balancing purposes The crankshaft is support...

Page 756: ...obes actuate the tappets and push rods forcing upward on the rocker arms which applies downward force on the valves ROCKER ARM DESCRIPTION The rocker arms are made of stamped steel and have a operatio...

Page 757: ...shaft VALVE GUIDE DESCRIPTION The valve guides are integral to the cylinder head They are not replaceable However they are service able OIL PAN DESCRIPTION The oil pan is made of stamped steel The oil...

Page 758: ...oise Refer to the Service Diagnosis Performance chart and the Service Diagnosis Mechanical chart for pos sible causes and corrections of malfunctions Refer to Group 14 Fuel System for the fuel system...

Page 759: ...ocedures 2 No fuel 2 Perform fuel pressure test and if necessary inspect fuel injector s and driver circuits Refer to Group 14 Fuel System for correct procedures 3 Low or no engine compression 3 Perfo...

Page 760: ...er to Group 11 Exhaust System Intake Manifold 8 EGR valve leaking or stuck open 8 Test and replace if necessary Refer to group 25 Emission Control Systems ENGINE MISSES ON ACCELERATION 1 Worn or incor...

Page 761: ...nnecting rod bearing clearance Measure bearings for correct clearance with plasti gage Repair as necessary 5 Connecting rod journal out of round 5 Replace crankshaft or grind journals 6 Misaligned con...

Page 762: ...l 4 Leaking oil gallery plug or cup plug 4 Remove and reseal threaded plug Replace cup style plug EXCESSIVE OIL CONSUMPTION OR SPARK PLUGS OIL FOULED 1 PCV System malfunction 1 Refer to group 25 Emiss...

Page 763: ...oximately a 50 70 reduction in compression pressure CYLINDER TO WATER JACKET LEAKAGE TEST WARNING USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING DO NOT STAND IN A DIRECT LINE WITH THE FAN DO NOT PUT...

Page 764: ...and repeat inspection 4 If the oil leak source is not positively identified at this time proceed with the air leak detection test method Air Leak Detection Test Method 1 Disconnect the breather cap to...

Page 765: ...troke Rotate the crankshaft counterclockwise viewed from the front of the engine 90 Install a dial indicator on the end of the No 1 cyl inder intake valve push rod Use rubber tubing to secure the indi...

Page 766: ...ch oversize stems NOTE If the valve guides are reamed oversize the valve seats must be ground to ensure that the valve seat is concentric to the valve guide VALVE STEM TO GUIDE CLEARANCE MEASUREMENT V...

Page 767: ...ets Tin coated pistons should not be used as replacements for coated pistons 4 The coating material is applied to the piston after the final piston machining process Measuring the outside diameter of...

Page 768: ...r sealing surface and can be installed with either side up Fig 24 Fig 19 Moly Coated Piston 1 MOLY COATED 2 MOLY COATED Fig 20 Bore Gauge 1 FRONT 2 BORE GAUGE 3 CYLINDER BORE 4 49 5 MM 1 15 16 in PIST...

Page 769: ...ng Gap 180 from top oil rail gap No 1 Compression ring Gap 180 from No 2 compression ring gap Fig 22 Ring Side Clearance Measurement 1 FEELER GAUGE RING SIDE CLEARANCE CHART ITEM SPECIFICATION Top Com...

Page 770: ...journals If wear patterns or damage to any of these components indicate the probability of a misaligned connecting rod inspect it for correct rod Fig 25 Second Compression Ring Identification 1 SECON...

Page 771: ...t Plastigage will smear resulting in inaccurate indication 7 Remove the bearing cap and determine amount of bearing to journal clearance by measuring the width of compressed Plastigage Fig 33 Refer to...

Page 772: ...2 0934 in 0 0356 mm 0 0014 in 0 025 mm 0 001 in 0 025 mm 0 001 in Undersize Red 52 9717 52 9539 mm Red Undersize Red Undersize 2 0855 2 0848 in 0 254 mm 0 010 in 0 254 mm 0 010 in 0 254 mm 0 010 in Un...

Page 773: ...int mark on the crank shaft rear flange When required upper and lower bearing inserts of different sizes may be used as a pair A standard size insert is sometimes used in combination with a 0 025 mm 0...

Page 774: ...003 inch originally a pair of 0 0254 mm 0 001 inch undersize inserts would reduce the clearance by 0 0254 mm 0 001 inch The clearance would then be 0 0508 mm 0 002 inch and within the specification A...

Page 775: ...e taper and out of round is 0 013 mm 0 0005 inch Compare the measured diameter with the journal diameter specification Main Bearing Fitting Chart Select inserts required to obtain the specified bearin...

Page 776: ...y black in color is available in 3 ounce tubes Moisture in the air causes the sealant material to cure This material is normally used on flexible metal flanges It has a shelf life of a year and will n...

Page 777: ...lation system as out lined in Group 0 Lubrication and Maintenance For emission controls see Group 25 Emission Controls for service procedures 10 Road test vehicle as a final test HONING CYLINDER BORES...

Page 778: ...spark plugs removed rotate the crank shaft using a breaker bar and socket 6 Identify the fluid in the cylinders i e coolant fuel oil etc 7 Make sure all fluid has been removed from the cylinders 8 Re...

Page 779: ...ten min utes for oil to settle to bottom of crankcase remove engine oil dipstick 3 Wipe dipstick clean 4 Install dipstick and verify it is seated in the tube 5 Remove dipstick with handle held above...

Page 780: ...The front mounts support the engine at each side These supports are made of resilient rubber REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Support the engine 4 Remove the nut...

Page 781: ...t from the transmission AUTOMATIC TRANSMISSION Fig 47 a Remove the support cushion bolts and remove the cushion and the support bracket from the trans mission 4WD or from the adaptor bracket 2WD b On...

Page 782: ...tion Remove the engine compartment lamp Remove the hood WARNING THE COOLANT IN A RECENTLY OPER ATED ENGINE IS HOT AND PRESSURIZED USE CARE TO PREVENT SCALDING BY HOT COOLANT CAREFULLY RELEASE THE PRES...

Page 783: ...from the booster if equipped 23 If equipped with power steering a Disconnect the hoses from the fittings at the steering gear b Drain the pump reservoir c Cap the fittings on the hoses and steering g...

Page 784: ...all the starter motor and connect the cable 16 Connect the wires to the starter motor sole noid 17 Lower the vehicle 18 Connect all the vacuum hoses and wire con nectors identified during engine remov...

Page 785: ...transferred to the replacement mani fold 1 Install a new engine exhaust intake manifold gasket over the alignment dowels on the cylinder head 2 Position the engine exhaust manifolds to the cylinder h...

Page 786: ...he engine cylinder head cover and gasket INSTALLATION 1 If a replacement cover is installed transfer the CCV valve grommet and oil filler cap from the origi nal cover to the replacement cover 2 Instal...

Page 787: ...rods Retain the push rods bridges pivots and rocker arms in the same order and position as removed 4 Inspect the springs and retainer for cracks and possible signs of weakening 5 Remove the spark plug...

Page 788: ...accessory drive belt at the power steering pump Refer to Group 7 Cooling System for the correct procedure Slip the belt off of the power steering pulley 8 Remove the A C compressor mounting bolts and...

Page 789: ...Check all bolts in sequence to verify the cor rect torque f If not already done clean and mark each bolt with a dab of paint after tightening Should you encounter bolts which were painted in an earlie...

Page 790: ...the top of the valve stem especially around the groove for the locks 5 Remove the valves and place them in a rack in the same order as removed INSTALLATION 1 Thoroughly clean the valve stems and the v...

Page 791: ...the damper retaining bolt to 108 N m 80 ft lbs torque 4 Install the serpentine drive belt Refer to Group 7 Cooling Systems for the proper specifica tions and procedures 5 Connect negative cable to bat...

Page 792: ...he A C compressor if equipped and generator bracket assembly 11 Install the engine fan and hub assembly and shroud 12 Install the serpentine drive belt 13 Connect negative cable to battery TIMING CHAI...

Page 793: ...cooling system DO NOT waste reus able coolant If the solution is clean drain it into a clean container for reuse 3 Remove the radiator or radiator and condenser if equipped with A C refer to Group 7 C...

Page 794: ...he proper procedure 21 Check the ignition timing and adjust as nec essary 22 Install the grille and bumper if removed 23 Connect negative cable to battery CAMSHAFT BEARINGS REMOVAL The camshaft rotate...

Page 795: ...in Fig 66 11 Install the timing chain cover refer to the pro cedure in this section CRANKSHAFT MAIN BEARINGS REMOVAL 1 Disconnect negative cable from battery 2 Remove the spark plugs 3 Raise the vehi...

Page 796: ...Finally tighten these bolts to 108 N m 80 ft lbs torque 8 Push the crankshaft forward and backward Load the crankshaft front or rear and tighten cap bolt No 3 to 54 N m 40 ft lbs torque Then tighten t...

Page 797: ...cable to battery OIL PAN REMOVAL 1 Disconnect negative cable from battery 2 Raise the vehicle 3 Remove the oil pan drain plug and drain the engine oil 4 Disconnect the exhaust pipe at the exhaust mani...

Page 798: ...over 13 Install the engine starter motor 14 Connect the exhaust pipe to the hanger and to the engine exhaust manifold 15 Install transmission oil cooling lines if equipped and oxygen sensor wiring sup...

Page 799: ...ave an assistant push the piston and con necting rod assemblies up and through the top of the cylinder bores Fig 78 INSTALLATION 1 Clean the cylinder bores thoroughly Apply a light film of clean engin...

Page 800: ...Lower the vehicle 14 Install the engine cylinder head push rods rocker arms bridges pivots and engine cylinder head cover 15 Fill the crankcase with engine oil CRANKSHAFT OIL SEALS REAR The crankshaf...

Page 801: ...tributor drive gear remains in mesh with the camshaft gear REMOVAL 1 Drain the engine oil 2 Remove the oil pan 3 Remove the pump to cylinder block attaching bolts Remove the pump assembly with gasket...

Page 802: ...ooling Systems for the proper specifications and procedures 6 Install the radiator shroud 7 Connect negative cable to battery DISASSEMBLY AND ASSEMBLY CYLINDER BLOCK DISASSEMBLY Refer to the applicabl...

Page 803: ...ively worn Inspect the valve stem tip contact surface of each rocker arm and replace any rocker arm that is deeply pitted Inspect each push rod end for excessive wear and replace as required If any pu...

Page 804: ...1 in INCREMENTS is required If a bore gauge is not available do not use an inside micrometer 2 Measure the inside diameter of the cylinder bore at three levels below top of bore Start perpen dicular a...

Page 805: ...030 in No 2 51 28 to 51 31 mm 2 019 to 2 020 in No 3 51 03 to 51 05 mm 2 009 to 2 010 in No 4 50 78 to 50 80 mm 1 999 to 2 000 in DESCRIPTION SPECIFICATION Base Circle Runout MAX 0 03 mm 0 001 in Val...

Page 806: ...ngth Center to Center 155 52 to 155 62 mm 6 123 to 6 127 in Piston Pin Bore Diameter 23 59 to 23 62 mm 0 9288 to 0 9298 in DESCRIPTION SPECIFICATION Bore Less Bearings 56 08 to 56 09 mm 2 2080 to 2 20...

Page 807: ...5 mm 0 010 in DESCRIPTION SPECIFICATION VALVE SPRINGS Free Length Approx 47 65 mm 1 876 in Spring Load Valve Closed 316 to 351 N 41 656 mm 71 to 79 lbf 1 64 in Valve Open 898 6 to 969 7 N 30 89 mm 202...

Page 808: ...rpm Higher 255 to 517 kPa 37 to 75 psi Oil Pressure Relief 517 kPa 75 psi TORQUE SPECIFICATIONS 4 0L ENGINE DESCRIPTION N m Ft In Lbs Lbs A C Compressor Bolts 28 250 Block Heater Nut 2 16 Camshaft Sp...

Page 809: ...7 35 Block 68 50 Adaptor Bolts 102 50 Oil Galley Plug 41 30 Oil Pan Bolts 1 4 20 9 5 84 5 16 18 15 132 Oil Pan Drain Plug 34 25 Oil Pump Mounting Bolts 23 204 Cover Bolts 8 70 Rocker Arm Assembly to C...

Page 810: ......

Page 811: ...PECIFICATIONS 8 DESCRIPTION AND OPERATION EXHAUST SYSTEM DESCRIPTION The basic exhaust system consists of exhaust man ifold s exhaust pipe with oxygen sensors catalytic converter s heat shield s muffl...

Page 812: ...xces sive heat will not be the fault of the converter If unburned fuel enters the converter overheating may occur If a converter is heat damaged correct the cause of the damage at the same time the co...

Page 813: ...c converter Fig 4 MUFFLER DESCRIPTION Both the 2 5L and 4 0L engines use a galvanized steel muffler to control exhaust noise levels and exhaust back pressure Fig 4 4 0L Catalytic Converter and O2 Sens...

Page 814: ...d out exhaust pipe 3 Replace exhaust pipe 4 Exhaust pipe leaking at manifold flange 4 Tighten replace flange attaching nuts bolts 5 Exhaust manifold cracked or broken 5 Replace exhaust manifold 6 Leak...

Page 815: ...old and cata lytic converter loosely to permit proper alignment of all parts 2 Use a new clamp and tighten the nuts to 61 N m 45 ft lbs torque 3 Connect the exhaust pipe to the engine exhaust manifold...

Page 816: ...ti seize com pound Install the sensor and tighten the nut to 27 N m 20 ft lbs torque 5 Lower the vehicle 6 Start the engine and inspect for exhaust leaks and exhaust system contact with the body panel...

Page 817: ...e muffler assembly on the rear exhaust tailpipe mounting bracket Make sure that the exhaust tailpipe has sufficient clear ance from the floor pan 4 Install front tailpipe hanger into the insulator Fig...

Page 818: ...he nuts and or screws to 45 N m 33 ft lbs Fig 12 3 Lower the vehicle SPECIFICATIONS TORQUE SPECIFICATIONS Fig 12 Heat Shield Removal Installation 1 BOLTS 2 MUFFLER HEAT SHIELD 3 NUTS 4 FLOOR PAN DESCR...

Page 819: ...gh strength steel and coated metals This process reduces weight and provides strength to withstand the forces applied against structural members The structural members provide a unibody that has great...

Page 820: ...screws attaching the end cap to the front fender 4 Lifting the end cap from the bottom tilt slightly upward and slide it outward to disengage the retainer tab from the bumper Fig 2 5 Separate the end...

Page 821: ...onnect vacuum line to reservoir 5 If equipped engage fog lamp wire harness con nectors 6 Install bumper end caps FRONT TOW HOOK REMOVAL 1 Remove bolts attaching tow hook to tow hook reinforcement Fig...

Page 822: ...ng bumper If necessary refer to removal procedure within Group 13 Frame and Bumpers 2 Remove bumper end caps 3 Remove upper nuts that attach bumper to bumper support brackets Fig 5 4 Remove lower bolt...

Page 823: ...ON 1 Position bracket and tow hook on frame rail 2 Install bolts that attach tow hook bracket and tow hook to frame rail Tighten bolts to 94 N m 70 ft lbs torque Fig 6 Rear Tow Hook 1 WELD NUT 2 FRAME...

Page 824: ...attach the skid plate to crossmember 3 Install the screws to attach skid plate to side sills TRANSFER CASE SKID PLATE REMOVAL 1 Support skid plate 2 Remove bolts that attach skid plate to trans missi...

Page 825: ...le rear sill open ings and attach to the frame sills with blind rivets 2 Using an adequate lifting device position hitch at the proper location for installation on vehicle and support it 3 If equipped...

Page 826: ...Fig 6 Frame Dimensions 13 8 FRAME AND BUMPERS XJ SPECIFICATIONS Continued...

Page 827: ...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 828: ......

Page 829: ...INSTALLATION FUEL FILTER FUEL PRESSURE REGULATOR 13 FUEL PUMP MODULE 14 FUEL PUMP INLET FILTER 15 FUEL GAUGE SENDING UNIT 16 FUEL INJECTOR RAIL FUEL DAMPER 2 5L ENGINE 16 FUEL INJECTOR RAIL FUEL DAMPE...

Page 830: ...d service They do not require normal sched uled maintenance Filters should only be replaced if a diagnostic procedure indicates to do so FUEL PUMP MODULE DESCRIPTION The fuel pump module is installed...

Page 831: ...ge As fuel level decreases the float and arm move down which increases voltage The varied voltage signal is returned back to the PCM through the sensor return circuit Both of the electrical circuits b...

Page 832: ...injector Fig 4 is used for each individual cylinder OPERATION The top fuel entry end of the injector Fig 4 is attached into an opening on the fuel rail The fuel injectors are electrical solenoids The...

Page 833: ...e fuel rail is not repairable FUEL RAIL FUEL DAMPER 4 0L ENGINE DESCRIPTION The fuel rail is mounted to the intake manifold Fig 6 It is used to mount the fuel injectors to the engine On the 4 0L 6 cyl...

Page 834: ...QUICK CONNECT FITTINGS DESCRIPTION Different types of quick connect fittings are used to attach various fuel system components lines and tubes These are a single tab type a two tab type or a plastic...

Page 835: ...Do not operate fuel pump for longer than 7 seconds with fuel line disconnected as fuel pump module reservoir may run empty a If capacity is lower than specification but fuel pump can be heard operatin...

Page 836: ...hicle fuel line and test port T on Adapter Tool If pressure now holds at or above 30 psi a leak may be found at a fuel tube line If no leaks are found at fuel tubes or lines one of the check valves in...

Page 837: ...ch test leads from LCS adapter into PDC relay cavities number 30 and 87 For location of these cav ities refer to numbers stamped to bottom of relay Fig 10 15 If equipped with type 2 relay Fig 11 attac...

Page 838: ...osition CAUTION Steps 1 2 3 and 4 must be performed to relieve high pressure fuel from within fuel rail Do not attempt to use following steps to relieve this pressure as excessive fuel will be forced...

Page 839: ...ped with tabs located on both sides of fitting Fig 16 The tabs are supplied for disconnecting quick connect fitting from component being serviced a To disconnect quick connect fitting squeeze plastic...

Page 840: ...ry up on latch clip with a screw driver Fig 18 b Type 2 Separate and unlatch 2 small arms on end of clip Fig 19 and swing away from fuel line c Slide latch clip toward fuel rail while lifting with scr...

Page 841: ...erly installed to fuel rail or other fuel line Recheck fuel line con nection 8 Connect negative cable to battery 9 Start engine and check for leaks REMOVAL AND INSTALLATION FUEL FILTER FUEL PRESSURE R...

Page 842: ...retainer clamp clamp snaps over top of filter regulator and locks to flanges on pump module 9 Connect fuel line at filter regulator Refer to Quick Connect Fittings in this group for procedures 10 Ins...

Page 843: ...Install Special Tool 6856 to locknut 7 Tighten locknut to 74 N m 55 ft lbs torque 8 Rotate fuel filter fuel pressure regulator until its fitting is pointed toward front of vehicle 12 o clock position...

Page 844: ...Refer to Fuel Tank Removal Installation FUEL INJECTOR RAIL FUEL DAMPER 2 5L ENGINE REMOVAL The fuel damper is not serviced separately WARNING THE FUEL SYSTEM IS UNDER CON STANT FUEL PRESSURE EVEN WIT...

Page 845: ...bore in intake manifold Seat injec tors into manifold 4 Install and tighten fuel rail mounting bolts to 11 63 N m 100 625 in lbs torque 5 Position crankshaft position sensor pigtail wire harness clamp...

Page 846: ...rail mounting nuts bolts Fig 31 14 Remove fuel rail by gently rocking until all the fuel injectors are out of intake manifold INSTALLATION 1 Clean each injector bore at intake manifold 2 Apply a small...

Page 847: ...e at fuel rail release fuel pressure Refer to the Fuel System Pressure Release Procedure in this group for procedures Attach end of special test hose tool num ber 6541 6539 6631 or 6923 at fuel rail d...

Page 848: ...r than top of tank 14 Continue lowering tank until clear of vehicle Place tank on floor with left side hose side higher than right side 15 Drain tank by removing fuel fill hose at tank Fuel fill hose...

Page 849: ...CAP REMOVAL INSTALLATION If replacement of the 1 4 turn fuel tank filler tube cap is necessary it must be replaced with an identi cal cap to be sure of correct system operation CAUTION Remove the fue...

Page 850: ...ll socket towards rear of vehi cle ball snaps off throttle body pin Fig 39 6 Remove throttle cable from throttle body mounting bracket by compressing release tabs Fig 39 and pushing cable through hole...

Page 851: ...ontaining METH ANOL Gasoline containing methanol may damage critical fuel system components MMT IN GASOLINE MMT is a manganese containing metallic additive that is blended into some gasoline to increa...

Page 852: ...nd the tem perature is high use a premium unleaded fuel to help prevent spark knock If spark knock persists lighten the load or engine piston damage may result The use of fuel additives which are now...

Page 853: ...OSITION SENSOR TPS 45 IDLE AIR CONTROL IAC MOTOR 45 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR 46 POWERTRAIN CONTROL MODULE PCM 46 POWER STEERING PRESSURE SWITCH 2 5L ENGINE 47 OXYGEN SENSOR 47 AIR CLEANER...

Page 854: ...round Speed control multiplexed single wire input Throttle position sensor Vehicle speed sensor NOTE PCM Outputs A C clutch relay Auto shutdown ASD relay CCD bus circuits for speedometer voltme ter fu...

Page 855: ...haft position sensor Intake manifold air temperature sensor Manifold absolute pressure MAP sensor Throttle position sensor TPS Camshaft position sensor signal The PCM monitors the crankshaft position...

Page 856: ...s high This will raise engine speed Refer to Power Steering Pressure Switch in this group for additional information The 4 0L 6 cylinder engine does not use this switch CRUISE MODE When the engine is...

Page 857: ...tion OPERATION A 12 volt signal at this input indicates to the PCM that the ASD has been activated The relay is used to connect the oxygen sensor heater element ignition coil and fuel injectors to 12...

Page 858: ...ent panel OPERATION The extended idle switch is used to raise the engine idle speed to approximately 1000 rpm by sup plying a ground circuit to the Powertrain Control Module PCM This idle speed contro...

Page 859: ...the upstream oxygen sensor volt age and changes fuel delivery until the upstream sensor voltage changes enough to correct the down stream sensor voltage oxygen content The downstream oxygen sensor als...

Page 860: ...ion of the MAP sensor is to determine baromet ric pressure The PCM needs to know if the vehicle is at sea level or at a higher altitude because the air density changes with altitude It will also help...

Page 861: ...ges lamp Ground for the sensor is provided by the PCM through a low noise sensor return POWER GROUNDS OPERATION The Powertrain Control Module PCM has 2 main grounds Both of these grounds are referred...

Page 862: ...ng at WOT 2 608 volts above learned idle voltage A C WOT cutoff certain automatic transmis sions only VEHICLE SPEED AND DISTANCE SENSOR PCM INPUT DESCRIPTION The 3 wire Vehicle Speed Sensor VSS is loc...

Page 863: ...sed on various inputs it receives Battery voltage 12 volts is supplied to the injec tors through the ASD relay The ASD relay will shut down the 12 volt power source to the fuel injectors if the PCM se...

Page 864: ...ry program which occurs when the power steering switch if equipped or the A C request circuit requires that the IAC step per motor control engine rpm is the recording of the last targeted steps into t...

Page 865: ...and tight 3 Inspect fuel pump relay and air conditioning compressor clutch relay if equipped Inspect ASD relay connections Inspect starter motor relay connec tions Inspect relays for signs of physica...

Page 866: ...cleaner ele ment for dirt or restrictions 16 Inspect radiator grille area radiator fins and air conditioning condenser for restrictions 17 Verify intake manifold air temperature sensor wire connector...

Page 867: ...R 4 ELEC CONN 5 TPS 6 MAP SENSOR 7 ELEC CONN 8 IAT SENSOR 9 ELEC CONN Fig 9 Rubber L Shaped Fitting MAP Sensor to Throttle Body 1 THROTTLE BODY 2 MAP SENSOR 3 RUBBER FITTING 4 MOUNTING SCREWS 2 Fig 10...

Page 868: ...tions at fuel pump module connector at front of fuel tank Fig 17 30 Verify good EVAP canister vent line connec tion at front of fuel tank Fig 17 31 Verify good fuel supply line connection at front of...

Page 869: ...LE SPEED SENSOR 5 RELEASE LOCK Fig 16 Power Steering Pressure Switch 2 5L Engine 1 POWER STEERING PRESSURE SWITCH 2 ELECTRICAL CONNECTOR 3 POWER STEERING PUMP Fig 17 Fuel Tank Connections at Front of...

Page 870: ...r wire 16 gauge or smaller to the power side of the 12 volt power source Do not attach the other end of the jumper wire to the relay at this time WARNING DO NOT ALLOW OHMMETER TO CON TACT TERMINALS 85...

Page 871: ...cs select Engine select Sys tem Test select Minimum Air Flow 8 The DRB scan tool will count down to stabilize idle rpm and display minimum air flow idle rpm The idle rpm should be between 500 and 900...

Page 872: ...dy 2 Disconnect throttle body electrical connectors at MAP sensor IAC motor and TPS Fig 24 or Fig 25 3 Remove all control cables from throttle body lever arm Refer to the Accelerator Pedal and Throt t...

Page 873: ...g engine 5 Install air cleaner tube to throttle body IDLE AIR CONTROL IAC MOTOR The IAC motor is located on the side of the throttle body Fig 24 or Fig 25 REMOVAL 1 Remove air cleaner tube at throttle...

Page 874: ...ext to the air cleaner assembly Fig 30 REMOVAL To avoid possible voltage spike damage to the PCM ignition key must be off and negative battery cable must be disconnected before unplugging PCM connecto...

Page 875: ...r steering fluid Add fluid if necessary OXYGEN SENSOR REMOVAL Never apply any type of grease to the oxygen sensor electrical connector or attempt any sol dering of the sensor wiring harness For sensor...

Page 876: ...reads of a new oxygen sensor Fig 33 Front Oxygen Sensor 4 0L Federal Emissions 1 1 1 O2S Fig 34 Oxygen Sensors 4 0L California Emissions 1 1 1 O2S 2 2 1 O2S 3 2 2 O2S 4 1 2 O2S Fig 35 Front Oxygen Sen...

Page 877: ...eated to air cleaner housing 3 Install air tube and clamp to cover Compress clamp snugly with adjustable pliers as shown in Fig 39 ENGINE COOLANT TEMPERATURE SENSOR WARNING HOT PRESSURIZED COOLANT CAN...

Page 878: ...hrottle body Fig 41 or Fig 42 REMOVAL 1 Disconnect electrical connector from IAT sen sor 2 Remove sensor from intake manifold INSTALLATION 1 Install IAT sensor into intake manifold Tighten sensor to 2...

Page 879: ...fully seated mounted flush to speedometer pinion gear adapter 3 Tighten sensor mounting bolt to 2 2 N m 20 in lbs torque 4 Connect electrical connector to sensor SPECIFICATIONS TORQUE CHART DESCRIPTI...

Page 880: ...Wrench 6856 Adapters Fuel Pressure Test 6539 and or 6631 Fitting Air Metering 6714 O2S Oxygen Sensor Remover Installer C 4907 Test Kit Fuel Pressure 5069 Test Kit Fuel Pressure C 4799 B Fuel Line Remo...

Page 881: ...l type gear with 14 1 gear ratio A tilt and non tilt column provide steering input NOTE Right hand drive RHD and left hand drive LHD service procedures and torque specifications for steering linkage g...

Page 882: ...E OR CLUNK 1 Gear mounting bolts loose 1 Tighten bolts to specification 2 Loose or damaged suspension components track bar 2 Inspect and repair suspension 3 Loose or damaged steering linkage 3 Inspect...

Page 883: ...SE IN TURNING EFFORT 1 Tire pressure 1 Adjust tire pressure 2 Low fluid level 2 Fill to proper level 3 Loose belt 3 Adjust or replace 4 Lack of lubrication 4 Inspect and lubricate steering and suspens...

Page 884: ...E PULLS TO ONE SIDE DURING BRAKING 1 Tire Pressure 1 Adjust tire pressure 2 Air in brake hydrauliics system 2 Bleed brake system 3 Worn brake components 3 Repair as necessary VEHICLE LEADS OR DRIFTS F...

Page 885: ...on the 4 0L engine A remote pump reservoir is used on the 2 5L engine mounted to the fan shroud The power steering pump is connected to the steering gear by the pressure and return hoses OPERATION Th...

Page 886: ...ff engine 9 Check fluid level add fluid as necessary Start engine again and let idle 10 Gauge should read below 862 kPa 125 psi if above inspect the hoses for restrictions and repair as necessary The...

Page 887: ...repeat the procedure CAUTION Do not run a vehicle with foamy fluid for an extended period This may cause pump damage REMOVAL AND INSTALLATION POWER STEERING PUMP NOTE The power steering pump is mounte...

Page 888: ...ssembly 4 With Serpentine Belt run engine until warm 5 min and note any belt chirp If chirp exists move pulley outward approximately 0 5 mm 0 020 in If noise increases press on 1 0 mm 0 040 in Be care...

Page 889: ...l power steering pump 6 Add power steering fluid refer to Pump Initial Operation Fig 4 Pump Mounting 4 0L RHD 1 BRACKET 2 PUMP ASSEMBLY Fig 5 Pulley Removal 1 POWER STEERING PUMP DRIVE PULLEY 2 SPECIA...

Page 890: ...Valve 75 N m 55 ft lbs Pressure Line 28 N m 21 ft lbs SPECIAL TOOLS POWER STEERING PUMP Fig 7 Pump Reservoir Clips 1 RESERVOIR 2 RETAINING CLIPS Analyzer Set Power Steering Flow Pressure 6815 Adapters...

Page 891: ...circulating ball type gear with a 14 1 ratio OPERATION The gear acts as a rolling thread between the worm shaft and rack piston The worm shaft is sup ported by a thrust bearing at the lower end and a...

Page 892: ...ING END PLUG DISASSEMBLY 1 Unseat and remove retaining ring from groove with a punch through the hole in the end of the housing Fig 2 2 Slowly rotate stub shaft with 12 point socket COUNTER CLOCKWISE...

Page 893: ...sher from the housing 10 Remove oil seal from the housing with a seal pick 11 Remove pitman shaft bearing from housing with a bearing driver and handle Fig 7 ASSEMBLY 1 Install pitman shaft bearing in...

Page 894: ...g 8 2 Remove adjuster nut with Spanner Wrench C 4381 3 Remove thrust support assembly out of the housing Fig 9 4 Pull stub shaft and valve assembly from the housing Fig 10 5 Remove stub shaft from val...

Page 895: ...and engage locating pin on stub shaft into spool valve hole Fig 14 NOTE Notch in stub shaft cap must fully engage valve body pin and seat against valve body shoul der Fig 9 Thrust Support Assembly 1 S...

Page 896: ...side cover and pitman shaft 4 Turn stub shaft COUNTERCLOCKWISE until the rack piston begins to come out of the housing 5 Insert Arbor C 4175 into bore of rack piston Fig 17 and hold tool tightly agai...

Page 897: ...eck for scores nicks or burrs on the rack piston finished surface Slight wear is normal on the worm gear surfaces Fig 16 Rack Piston End Plug 1 EXTENSION 2 END PLUG 3 RACK PISTON 4 RATCHET Fig 17 Rack...

Page 898: ...CKWISE while pushing on the arbor This will force the rack piston onto the arbor and hold the rack piston balls in place 9 Install the races and thrust bearing on the worm shaft and install shaft in t...

Page 899: ...point socket to drain the remaining fluid 4 Turn the adjuster in with Spanner Wrench C 4381 Tighten the plug and thrust bearing in the housing until firmly bottomed in the housing about 34 N m 25 ft...

Page 900: ...eft of center and record the left off center pre load Repeat this to the right of center and record the right off center preload The average of these two recorded readings is the Preload Rotating Torq...

Page 901: ...45 0 90 N m 4 8 in lbs Worm Shaft Preload Used Gear over 400 miles 0 5 0 6 N m 4 5 in lbs Worm Shaft Preload TORQUE CHART DESCRIPTION TORQUE Power Steering Gear Adjustment Cap Locknut 108 N m 80 ft l...

Page 902: ...inkage consist of a pitman arm drag link tie rod tie rod ends and a steering damper Fig 1 and Fig 2 The service procedures and torque specifications are the same for LHD and RHD vehi cles CAUTION Comp...

Page 903: ...n nut until it is aligned Never loosen the nut to align the cotter pin hole REMOVAL AND INSTALLATION TIE ROD CAUTION Use a Puller tool C 3894 A for tie rod removal Failure to use this tool could damag...

Page 904: ...move cotter pins and nuts from drag link 2 Remove the steering damper ball stud from the drag link 3 Remove tie rod from drag link 4 Remove drag link from the steering knuckle and pitman arm INSTALLAT...

Page 905: ...g link 2 Install steering damper bolt in axle bracket and tighten nut to 75 N m 55 ft lbs 3 Install ball stud nut at the drag link and tighten nut to 75 N m 55 ft lbs Install a new cot ter pin SPECIFI...

Page 906: ...EPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY THE FASTENERS SCREWS AND BOLTS ORIGINALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COAT INGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM...

Page 907: ...ounting bracket on non tilt column Fig 6 Remove the bracket from the column and note the mount ing location and orientation of the bracket 13 Remove clock spring switches SKIM if equipped and ignition...

Page 908: ...Install knee blocker and knee blocker cover Refer to Group 8E Instrument Panel Systems 13 Install steering wheel and tighten nut to 54 N m 40 ft lbs NOTE If equipped with cruise control connect clock...

Page 909: ...ve speed manual transmission with fifth gear being the overdrive range An adapter hous ing is used to attach the transmission to the transfer case on 4 wheel drive applications A standard style extens...

Page 910: ...the mainshaft or the countershaft in some cases and moving the blocker ring into contact with the gear s friction cone As the blocker ring and friction cone come together the gear speed is brought up...

Page 911: ...lubricant leaks can result in gear shift rail synchro and bearing damage If a leak goes undetected for an extended period the first indi cations of component damage are usually hard shift ing and noi...

Page 912: ...d block between jack and oil pan to avoid damaging pan 21 Support transmission with transmission jack 22 Secure transmission to jack with safety chains 23 Disconnect rear cushion and bracket from tran...

Page 913: ...r bolts to 37 N m 27 ft lbs Tighten 7 16 diameter bolts to 58 N m 43 ft lbs Tighten M12 bolts to 75 N m 55 ft lbs 8 Install clutch housing brace rod 9 Lower transmission approximately 7 8 cm 3 in for...

Page 914: ...in lbs torque 31 Fill transmission and transfer case if equipped with recommended lubricants Refer to the Lubricant Recommendation sections of the appropri ate component for correct fluid 32 Lower ve...

Page 915: ...ts 5 Lower vehicle ADAPTER HOUSING SEAL REMOVAL 1 Hoist and support vehicle 2 Remove transfer case 3 Using a suitable pry tool or a slide hammer mounted screw remove the adapter housing seal Fig 13 IN...

Page 916: ...o transmis sion case 6 Remove shift tower from transmission case Fig 15 7 Remove shift tower gasket from shift tower or transmission case Fig 16 8 Remove detent ball plug Fig 18 9 Remove detent spring...

Page 917: ...HOUSING 3 TRANSMISSION Fig 18 Remove Detent Ball Plug 1 TORX BIT 2 DETENT BALL PLUG Fig 19 Remove Detent Spring 1 PENCIL MAGNET 2 DETENT BALL SPRING Fig 20 Remove Detent Ball 1 PENCIL MAGNET 2 SHIFT...

Page 918: ...ve shifter shaft with large magnet Fig 24 14 Remove the shift arm from the adapter hous ing 15 Remove adapter extension housing bolts 16 Loosen adapter extension housing by tapping it loose with plast...

Page 919: ...the bearing retainer from transmis sion case Fig 28 21 Remove input shaft bearing snap ring Fig 29 22 Remove countershaft front bearing snap ring Fig 25 Loosen Adapter Extension Housing 1 INTERMEDIATE...

Page 920: ...and shift rails with mating holes in transmission case and install transmission case to the intermediate plate Fig 33 Verify that the transmission case is seated on the intermediate plate locating pin...

Page 921: ...quid Gasket TB1281 P N 83504038 to seal ing surface of adapter extension housing making sure to keep sealer bead to inside of bolt holes 9 Install adapter or extension housing on inter mediate plate F...

Page 922: ...ft arm retainer bolt and tighten to 38 N m 28 ft lbs Fig 40 14 Install and tighten shifter arm shaft plug to 18 N m 13 ft lbs torque Fig 41 Fig 36 Speedometer Drive Gear Assembly 1 SNAP RING 2 LOCK BA...

Page 923: ...nt ball in detent opening of case Fig 43 17 Install detent spring in case Fig 44 18 Install detent plug and tighten to 19 N m 14 ft lbs Fig 45 Fig 40 Install Shift Arm Retainer Bolt 1 RETAINER BOLT 2...

Page 924: ...kup lamp switch Fig 47 Tighten switch to 44 N m 32 5 ft lbs torque 25 Install new seal in adapter extension housing 26 Install vehicle speed sensor if necessary 27 Install clutch housing release beari...

Page 925: ...2 Remove countershaft fifth gear retaining snap ring Fig 49 3 Remove bolt holding fifth gear shift fork to shift rail Fig 50 Fig 48 Positioning Intermediate Plate In Vise 1 INTERMEDIATE PLATE 2 BOLTS...

Page 926: ...d interlock pins used in various places in the transmission Whenever a pin or ball is removed it should be identified in such a way that it can be reinstalled in the same location from which it was re...

Page 927: ...lts holding 1 2 and 3 4 shift forks to the shift rails Fig 58 and discard bolts 13 Remove bolts holding reverse shift arm bracket to intermediate plate Fig 59 Fig 55 Remove Fifth Gear Thrust Ring Lock...

Page 928: ...e main shaft forward until the mainshaft rear bearing is clear of the intermediate plate and then rotating the mainshaft downward out of the shift forks Fig 62 18 Remove the 3 4 shift fork from the 3...

Page 929: ...ise using the same bolt and washer mounting set up CAUTION The interlock balls and pins are different sizes and shapes Be sure to correctly identify which position an item is removed from to ensure th...

Page 930: ...and reverse shift fork and arm assembly from intermediate plate Fig 69 Fig 66 Remove Fifth Gear Shift Rail 1 INTERMEDIATE PLATE 2 FIFTH GEAR SHIFT RAIL Fig 67 Remove Fifth Gear Check Ball 1 FIFTH GEA...

Page 931: ...t rail elongated check ball from intermediate plate Fig 73 34 Remove 3 4 shift rail from intermediate plate Fig 70 Remove Interlock Pin From Reverse Shift Rail 1 REVERSE SHIFT RAIL 2 INTERLOCK PIN Fig...

Page 932: ...1 2 elongated check ball into the intermediate plate Fig 75 3 Install the interlock pin into the 1 2 shift rail Fig 76 4 Install the 1 2 shift rail into the intermediate plate Fig 74 Shift Rail Compo...

Page 933: ...ift rail into intermediate plate and position reverse arm bracket to intermediate plate Fig 80 Fig 76 Install 1 2 Shift Rail Interlock Pin 1 INTERLOCK PIN 2 1 2 SHIFT RAIL Fig 77 Install Reverse Check...

Page 934: ...reinstall the plate in the vise using the same bolt and washer mounting set up 15 Install the shift rail detent balls in the inter mediate plate Fig 80 Install Reverse Shift Rail 1 REVERSE SHIFT RAIL...

Page 935: ...er mediate plate and the rear of the countershaft into the rear countershaft bearing It may be necessary to occasionally hold the countershaft into the intermedi ate plate and tap the countershaft rea...

Page 936: ...s aligned with the proper slot the opposite slot has an oil drain hole which the pin will drop into The assembly will then be locked onto the shaft and will need to be disassembled in order to be remo...

Page 937: ...ition the fifth gear blocker ring onto the countershaft 46 Using a suitable mallet and spacer tap the fifth gear blocker ring onto the countershaft 47 Install new bolt to hold fifth gear shift fork to...

Page 938: ...uncaged roller type bearing 3 Remove the output shaft pilot bearing rollers from the input shaft and the output shaft 4 Remove the fourth gear synchronizer ring from the input shaft Fig 97 5 Remove t...

Page 939: ...shaft pilot bearing rollers from output shaft 2 Measure and note thrust clearance of output shaft gears Fig 100 Clearance should be 0 10 0 25 mm 0 004 0 010 in I D Mark Snap Ring Thickness mm in 0 1 2...

Page 940: ...r and second gear from output shaft Fig 104 9 Remove second gear needle roller bearing from the output shaft or second gear 10 Remove select fit snap ring holding the 3 4 synchronizer onto the output...

Page 941: ...g 108 3 Install third gear needle bearing onto the out put shaft 4 Install third gear over bearing and onto output shaft flange 5 Install third gear synchronizer ring to third gear 6 Position the 3 4...

Page 942: ...1A and a shop press press the 1 2 synchronizer onto the output shaft 16 Install first gear synchronizer ring into 1 2 synchronizer 17 Install first gear bearing inner race lock ball in output shaft F...

Page 943: ...is out of specification refer to Cleaning and Inspection section within this group 25 Position fifth gear onto output shaft with the gear s short shoulder toward the rear of shaft Ensure that the gear...

Page 944: ...ig 118 I D Mark Snap Ring Thickness mm in A 2 67 2 72 0 1051 0 1071 B 2 73 2 78 0 1075 0 1094 C 2 79 2 84 0 1098 0 1118 D 2 85 2 90 0 1122 0 1142 E 2 91 2 96 0 1146 0 1165 F 2 97 3 02 0 1169 0 1189 G...

Page 945: ...with solvent and dry with compressed air Replace the case if cracked porous or if any of the bearing and gear bores are damaged Inspect the threads in the case housing and plate Minor thread damage ca...

Page 946: ...ween the gears and shaft with a dial indicator Fig 122 Oil clearance for all three gears is 0 009 0 0013 mm 0 0004 0 0013 in Check synchronizer ring wear Fig 123 Insert each ring in matching gear Meas...

Page 947: ...ber 41 68 N m 30 50 ft lbs Pins Restrictor 27 4 N m 20 ft lbs Bolts Reverse Shift Arm Bracket 18 N m 13 ft lbs Screw Shift Arm Set 38 N m 28 ft lbs Screws Shift Fork Set 20 N m 15 ft lbs Nut Shift Kno...

Page 948: ...cator Set C 3995 A Installer Extension Housing Seal C 4171 Handle Universal Tool 8211 Installer Seal 8212 Installer Seal 8208 Installer Seal P 334 Splitter Bearing 8109 Cup Installer L 4507 Tube Drive...

Page 949: ...6747 1A Adapter Fixture MD 998805 Installer Seal XJ AX5 MANUAL TRANSMISSION 21 41 SPECIAL TOOLS Continued...

Page 950: ...REVERSE 3 55 1 IDENTIFICATION The NV3550 identification and part number bar code tags Fig 2 are located on the top of the trans mission forward of the shift tower OPERATION The manual transmission re...

Page 951: ...500 is approximately 2 28 liters 4 8 pints This represents the approxi mate quantity needed to refill the transmission after a lubricant change or overhaul DRAIN AND FILL PLUG LOCATIONS The NV3550 fil...

Page 952: ...nt leaks can result in gear shift component synchro and bearing damage If a leak goes undetected for an extended period the first indi cations of a problem are usually hard shifting and noise Incorrec...

Page 953: ...sion and transfer case if equipped 16 Disconnect transfer case vent hose if equipped 17 Disengage any wire connectors attached to transmission or transfer case if equipped compo nents 18 Support trans...

Page 954: ...ame bolts to 41 N m 31 ft lbs torque 10 Install fasteners to hold rear cushion and bracket to transmission Then tighten transmission to rear support bolts nuts to 54 N m 40 ft lbs torque 11 Remove sup...

Page 955: ...nto third gear 2 Clean the mating surfaces of shift tower and transmission gear case with suitable wax and grease remover 3 Install the shift tower onto the transmission case No sealant is necessary b...

Page 956: ...during removal remove drain plug and drain lubricant into container at this time 3 Inspect drain plug magnet for debris 4 Remove backup light switch Switch is located on passenger side of rear housin...

Page 957: ...t Tower Removal 1 SHIFT TOWER AND LEVER ASSEMBLY 2 SHIFT SOCKET 3 SEAL Fig 16 Shift Shaft Lock Bolt Removal 1 SHIFT SHAFT LOCK BOLT 2 SHAFT SOCKET Fig 17 Detent Plunger And Spring Removal 1 FRONT HOUS...

Page 958: ...sary to remove all three bolts at this time Leave at least one bolt in place until geartrain is ready to be removed from case Fig 19 Loosening Bearing Retainer Sealer Bead Typical 1 PRY TOOL 2 INPUT S...

Page 959: ...Tighten the tool punch to press the roll pin downward and out of the shift socket Fig 26 The roll pin does not have to be completely removed from the shift socket The roll pin must only be clear of t...

Page 960: ...the reverse idler shaft support bolt front bolt Fig 32 Fig 26 Removing the Shift Socket Roll Pin 1 SPECIAL TOOL 6858 2 SHIFT SOCKET Fig 27 Removing Shift Shaft Lever And Bushing Roll Pin 1 PIN PUNCH...

Page 961: ...upright on fixture Fig 34 Have helper hold fixture tool in place while housing and geartrain is being rotated into upright position 11 Remove rear bolt holding reverse idler shaft in housing Fig 31 R...

Page 962: ...5 Examine condition of bearing bore and idler shaft notch in rear housing Replace housing if any of these components are damaged REAR ADAPTER HOUSING REMOVAL 4WD 1 Locate dimples in face of rear seal...

Page 963: ...emoval 2WD 1 REAR HOUSING 2 SHIFT FORKS AND GEARTRAIN Fig 38 Remove Countershaft Rear Bearing 1 COUNTERSHAFT REAR BEARING 2 OUTPUT SHAFT 3 COUNTER SHAFT Fig 39 Location Of Dimples In Seal Face 4WD 1 L...

Page 964: ...t of fixture tool 4 Remove output shaft bearing retainer from rear surface of fifth gear retainer will drop onto gear after bolts are removed 5 Lift and remove output shaft and gears off input shaft 6...

Page 965: ...ng ring 5 Remove two piece thrust washer Fig 46 Note position of washer locating lugs in shaft notches for installation reference 6 Remove second gear and needle bearing Fig 47 7 Remove second gear sy...

Page 966: ...TERM RING 3 SYNCHRO FRICTION CONE 4 SYNCHRO CONE 5 SYNCHRO RING Fig 49 Hub And Sleeve Removal 1 2 Synchro 1 1 2 SYNCHRO HUB AND SLEEVE 2 SPECIAL TOOL 1130 Fig 50 First Gear Needle Bearing Removal 1 FI...

Page 967: ...dle Bearing Removal 1 FIFTH GEAR NEEDLE BEARING SPREAD BEARING TO CLEAR SHOULDER ON SHAFT Fig 54 Fifth Reverse Synchro Hub Snap Ring Removal 1 FIFTH REVERSE SYNCHRO HUB AND SLEEVE 2 SYNCHRO HUB SNAP R...

Page 968: ...all the springs struts and detent balls one at a time as follows 1 Slide the sleeve part way onto the hub Leave enough room to install the spring in the hub and the strut in the hub groove 2 Install t...

Page 969: ...nt before installation 4 Lubricate and install reverse gear needle bear ing on shaft Fig 59 Slide bearing up against shoul der on output shaft 5 Install reverse gear over needle bearing Fig 60 6 Insta...

Page 970: ...mm to 2 20 mm 0 078 to 0 086 in b Install thickest snap ring that will fit in shaft groove c Verify that snap ring is completely seated in groove before proceeding 10 Install fifth gear synchro ring i...

Page 971: ...over bearing Fig 68 Make sure bearing synchro cone is facing up as shown Fig 65 Installing Fifth Gear Bearing 1 SHAFT SHOULDER 2 FIFTH GEAR BEARING Fig 66 Fifth Gear Installation 1 FIFTH GEAR 2 BEARIN...

Page 972: ...becomes mis aligned 20 Install interm ring 21 Install new 1 2 synchro hub snap ring Fig 72 as follows a Snap rings are available in thicknesses from 1 80 mm to 2 00 mm 0 070 to 0 078 in b Install thi...

Page 973: ...lling 1 2 Synchro Hub Snap Ring 1 1 2 SYNCHRO 2 SPECIAL TOOL 6310 1 3 SYNCHRO SNAP RING Fig 73 Second Gear Synchro Ring Installation 1 SECOND GEAR SYNCHRO RING 2 1 2 SYNCHRO 3 SPECIAL TOOL 6310 1 Fig...

Page 974: ...is between the thrust washer halves 28 Seat thrust washer retaining ring with plastic mallet Fig 78 Fig 76 Installing Two Piece Thrust Washer 1 WASHER GROOVE IN SHAFT 2 LUG BORE 3 THRUST WASHER LUGS...

Page 975: ...synchro hub on output shaft splines by hand Fig 82 34 Press 3 4 synchro assembly onto output shaft with shop press and suitable size pipe tool Fig 83 Make sure that the tool presses on hub as close t...

Page 976: ...se sleeve should be facing forward REVERSE IDLER ASSEMBLY 1 Lubricate idler components with gear lube 2 Slide idler gear bearing on shaft Fig 87 Bearing fits either way on shaft 3 Slide gear onto shaf...

Page 977: ...on 1 DOUBLE GROOVE FORWARD 2 GROOVE FORWARD 3 FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 4 TAPER FORWARD 5 GROOVE FORWARD 6 5TH REV SYNCHRO SLEEVE 7 1 2 SYNCHRO SLEEVE 8 3 4 SYNCHRO SLEEVE Fig 87 Idler...

Page 978: ...e restricted 5 If necessary the detent plunger bushings can be replaced as follows a Using the long end of Installer 8119 drive the detent bushings through the outer case and into the shift shaft bore...

Page 979: ...3 4 synchro ring seats in synchro hub and sleeve Fig 90 Preparing Assembly Fixture For Geartrain Build up 1 SPECIAL TOOL 6747 2A INSTALL ON COUNTERSHAFT FRONT HUB 2 SPECIAL TOOL 8115 3 SPECIAL TOOL 6...

Page 980: ...y A difference in height of 1 57 to 3 18 mm 1 16 to 1 8 in will probably exist This difference will not interfere with assembly However if the difference is greater than this the countershaft adapter...

Page 981: ...Then position retainer on fifth gear as shown Fig 97 12 Assemble 1 2 and fifth reverse shift forks Fig 98 Arm of fifth reverse fork goes through slot in 1 2 fork Fig 96 Reverse Idler Assembly Position...

Page 982: ...place when housing is installed 5 Apply light coat of petroleum jelly to shift shaft bushing bearing in rear housing Fig 102 6 Reach into countershaft rear bearing with fin ger and push each bearing...

Page 983: ...nks and under bolt heads Fig 104 b Start first two bolts in retainer Fig 105 It may be necessary to move retainer rearward with pilot stud in order to start bolts in retainer c Remove Pilot Stud 8120...

Page 984: ...coat of petroleum jelly to shift shaft bushing bearing in adapter housing Fig 102 8 Install adapter housing on geartrain 9 Install rear bearing snap ring on output shaft Fig 107 10 Lubricate lip of n...

Page 985: ...embled lever and bushing on shift shaft Fig 112 6 Slide shift shaft through 1 2 and fifth reverse fork and into shift lever opening in rear housing Fig 113 7 Align shift socket with shaft and slide sh...

Page 986: ...Fig 117 CAUTION The shaft lever roll pin must be flush with the surface of the lever The lever bushing will bind on the roll pin if the pin is not seated flush 12 Before proceeding verify that lock p...

Page 987: ...to seat bearing Bearing goes in from front side of housing only Fig 117 Correct Seating Of Shift Shaft Lever Roll Pin 1 BUSHING LOCK PIN SLOT 2 SEAT ROLL PIN FLUSH WITH LEVER Fig 118 Starting Roll Pin...

Page 988: ...ng CAUTION If the front housing will not seat on the rear housing either the shift components are not in Neutral or one or more components are mis aligned Do not force the front housing into place Thi...

Page 989: ...nstaller 8123 b Position plug on detent spring and compress spring until detent plug pilots in detent plunger bore c Drive detent plug into transmission case until plug seats 16 Install backup light s...

Page 990: ...ssion into third gear 3 Align and install shift tower and lever assem bly Fig 132 Be sure shift ball is seated in socket and the offset in the tower is toward the passenger side of the vehicle before...

Page 991: ...uld be smooth and free of nicks or scores The plunger spring should be straight and not collapsed or distorted Minor scratches or nicks on the plunger can be smoothed with 320 400 grit emery soaked in...

Page 992: ...f a bear ing race becomes damaged it will be necessary to replace the front or rear housing as necessary A new countershaft bearing will be supplied with each new housing for service use The countersh...

Page 993: ...es and bearings surfaces Minor nicks on the bearing surfaces can be smoothed with 320 420 grit emery and final polished with cro cus cloth Replace the shaft if the splines are dam aged or bearing surf...

Page 994: ...shing 6951 Handle C 4171 Remover 8117 Remover Installer NV3550 Shift Rail Roll Pin 6858 Fixture NV3550 6747 Adapter Fixture 6747 1A Adapter Fixture 6747 2A Cup Fixture 8115 21 86 NV3550 MANUAL TRANSMI...

Page 995: ...Bearing 1130 Tube 6310 1 Installer 8118 Remover Installer 8119 Stud Alignment 8120 Installer Seal C 3860 A Installer 8123 Installer Bearing Cone 6448 XJ NV3550 MANUAL TRANSMISSION 21 87 SPECIAL TOOLS...

Page 996: ...ON TRANSMISSION 144 TORQUE CONVERTER 146 YOKE SEAL REPLACEMENT 147 EXTENSION HOUSING BUSHING 147 ADAPTER HOUSING 147 SPEEDOMETER ADAPTER 148 PARK NEUTRAL POSITION SWITCH 149 GEARSHIFT CABLE 150 BRAKE...

Page 997: ...ts in the front and rear planetary gear set transfer the engine power from the input shaft through to the output shaft The transmissions contain a governor that is mounted on the output shaft and supp...

Page 998: ...Fig 1 30RH Automatic Transmission 21 90 AUTOMATIC TRANSMISSION 30RH XJ DESCRIPTION AND OPERATION Continued...

Page 999: ...semblies which com bine with the overrunning clutch assembly to gener ate the different gear ratios The torque converter clutch is hydraulically applied and is released when fluid is vented from the h...

Page 1000: ...ub and rear clutch retainer stops at the rear clutch retainer Therefore no power flow to the output shaft occurs because no clutches are applied The only mechanism in use at this time is the parking s...

Page 1001: ...transferred to the rear annulus gear which is splined to the output shaft The output shaft in turn rotates with the annulus gear in a counterclockwise direction giving a reverse gear output The entir...

Page 1002: ...in a clockwise direction With the rear annulus gear stationary the rear planet rotation on the annulus gear causes the rear planet carrier to revolve in a counterclockwise direc tion The rear planet c...

Page 1003: ...ary the annulus rotation causes the front planets to rotate in a clockwise direction The front carrier is then also made to rotate in a clockwise direction but at a reduced speed This will transmit th...

Page 1004: ...not turn at all in direct drive The only rotation is the input from the engine to the connected parts which are acting as one common unit to the output shaft FLUID NOTE Refer to the maintenance sched...

Page 1005: ...thermally stable so that it can maintain a consistent viscosity through a large temperature range If the viscosity stays con stant through the temperature range of operation transmission operation and...

Page 1006: ...or driven mem ber of the converter The turbine is mounted within the housing opposite the impeller but is not attached to the housing The input shaft is inserted through the center of the impeller an...

Page 1007: ...r to rotate only in a clockwise direc tion When the stator is locked against the over run ning clutch the torque multiplication feature of the torque converter is operational Fig 11 Turbine 1 TURBINE...

Page 1008: ...the fluid is not redirected before it strikes the impeller it will strike the impeller in such a direction that it would tend to slow it down STATOR Torque multiplication is achieved by locking the s...

Page 1009: ...onverter clutch is engaged by the clutch solenoid on the valve body The clutch will engage at approximately 56 km h 35 mph with light throttle after the shift to third gear OIL PUMP DESCRIPTION The oi...

Page 1010: ...and frictional clutches The valve body contains the following components Fig 18 and Fig 19 Regulator valve Regulator valve throttle pressure plug Line pressure plug and sleeve Kickdown valve Kickdown...

Page 1011: ...oil at specific pressures With the engine run ning fluid flows from the pump to the pressure reg ulator valve manual valve and the interconnected circuits As fluid is sent through passages to the reg...

Page 1012: ...e size of the metering passage at land 2 land 1 being at the far right of the valve in the diagram As fluid leaks past the land it moves into a groove connected to the filter or sump As the land meter...

Page 1013: ...rse is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land 4 With this pressure blocked there is less area for pressure to act on to balance the force o...

Page 1014: ...Fig 23 Regulator Valve in Reverse Position Fig 22 Regulator Valve in Drive Position 21 106 AUTOMATIC TRANSMISSION 30RH XJ DESCRIPTION AND OPERATION Continued...

Page 1015: ...vent a 3 2 downshift at higher speeds when a part throttle downshift is not desirable At these higher speeds only a full throttle 3 2 downshift will occur At low road speeds Fig 25 the limit valve doe...

Page 1016: ...w Speeds Fig 26 Kickdown Limit Valve High Speeds 1 GOVERNOR PRESSURE CLOSES LIMIT VALVE 2 THROTTLE PRESSURE 3 LIMIT VALVE 4 2 3 SHIFT VALVE 5 GOVERNOR PLUG 21 108 AUTOMATIC TRANSMISSION 30RH XJ DESCRI...

Page 1017: ...valve assembly With throttle pressure applied to the right side of the valve there is now both spring pressure and throttle pressure acting on the valve holding it against the governor plug As the veh...

Page 1018: ...ing the plug back against the end plate overcoming governor pressure With the combi nation of the line pressure and spring pressure the valve cannot move preventing any upshift 1 2 SHIFT CONTROL VALVE...

Page 1019: ...e rate of fluid discharge from the front clutch and servo release circuits During a 3 2 kickdown fluid dis charges through the shuttle by pass circuit When the shuttle valve closes the by pass circuit...

Page 1020: ...as been in the other gears During a manual 1 or manual 2 gear selection line pressure is sent between the two lands of the 2 3 governor plug This line pressure at the governor plug locks the shift val...

Page 1021: ...Fig 31 2 3 Shift Valve After Shift Fig 32 Throttle Valve XJ AUTOMATIC TRANSMISSION 30RH 21 113 DESCRIPTION AND OPERATION Continued...

Page 1022: ...e the TCC application occurs Fig 33 the pres sure regulator valve is supplying torque converter pressure to the switch valve The switch valve directs this pressure through the transmission input shaft...

Page 1023: ...Fig 33 Switch Valve Torque Converter Unlocked XJ AUTOMATIC TRANSMISSION 30RH 21 115 DESCRIPTION AND OPERATION Continued...

Page 1024: ...Fig 34 Switch Valve Torque Converter Locked 21 116 AUTOMATIC TRANSMISSION 30RH XJ DESCRIPTION AND OPERATION Continued...

Page 1025: ...the piston Fig 37 bottoming it against the accumulator plate The accumulator stays in this position after the transmission is placed into a Drive position When the 1 2 upshift occurs Fig 38 line press...

Page 1026: ...in all directions and acts with equal force on equal areas PRESSURE Pressure Fig 39 is nothing more than force lbs divided by area in or ft or force per unit area Given a 100 lb block and an area of 1...

Page 1027: ...rea The pressure created with the smaller 100 lb input is 10 PSI The concept pressure is the same every where means that the pressure underneath the larger piston is also 10 PSI Pressure is equal to t...

Page 1028: ...he input shaft into the driving discs and into the clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the application of the clutch pack In...

Page 1029: ...h through the hub of the reaction shaft support With pressure applied between the clutch retainer and piston the piston moves away from the clutch retainer and compresses the clutch pack This action a...

Page 1030: ...the same direction as the race aided by the pushing of the springs As the rollers try to move in the same direction as the inner race they are wedged between the inner and outer races due to the desi...

Page 1031: ...sun gear The application of the band by the servo is typ ically done by an apply lever and link bar LOW REVERSE REAR BAND The rear band holds the rear planet carrier sta tionary by being mounted arou...

Page 1032: ...lve and down to the governor valve When the output shaft starts to rotate with vehicle motion Fig 52 the gov ernor weight assembly will start to move outward due to centrifugal force As the weight is...

Page 1033: ...onnects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 54 OPERATION The system locks the shifter into the PARK posi tion The Interlock system is engaged wh...

Page 1034: ...th a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve clutch and servo operation Foaming also causes fluid expansion which can re...

Page 1035: ...failure to reverse flush cooler and lines after repair Fig 54 Ignition Interlock Cable Routing 1 SHIFT MECHANISM 2 LOCK TAB 3 IGNITION LOCK INTERLOCK 4 STEERING COLUMN 5 SOLENOID 6 WIRE CONNECTOR 7 L...

Page 1036: ...essure test if shift prob lems were noted during road test 7 Perform air pressure test to check clutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or discon...

Page 1037: ...utch is applied in all forward ranges D 2 1 The transmission overrunning clutch is applied in first gear D 2 and 1 ranges only The rear band is applied in 1 and R range only Verify that the overdrive...

Page 1038: ...ar servo port Fig 57 and Fig 58 3 Disconnect throttle and gearshift rods from manual and throttle levers 4 Start and run engine at 1000 rpm 5 Move shift lever on manual lever shaft all the way forward...

Page 1039: ...psi Test Gauge C 3292 to governor pressure port Fig 57 and Fig 58 2 Move shift lever to D range 3 Start and run engine at curb idle speed and note pressure At idle and with vehicle stopped pres sure...

Page 1040: ...he result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation...

Page 1041: ...kickdown lever pin access plug three turns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in lbs torque 7 Adjust front band 8 Lubricate pump seal and converter hub w...

Page 1042: ...1 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 lev...

Page 1043: ...rn 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 dis...

Page 1044: ...bolts defective gasket Replace pump assembly if needed NO REVERSE D RANGES OK 1 Gearshift Linkage Cable Misadjusted Damaged 1 Repair or replace linkage parts as needed 2 Park Sprag Sticking 2 Inspect...

Page 1045: ...raulic 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...

Page 1046: ...Air pressure check clutch servo operation and repair as required 7 Band Linkage Binding 7 Inspect and repair as required SLIPS IN FORWARD DRIVE RANGES 1 Fluid Level Low 1 Add fluid and check for leaks...

Page 1047: ...ternally 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 clu...

Page 1048: ...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 T...

Page 1049: ...EMENT Refer to the Maintenance Schedules in Group 0 Lubrication and Maintenance for proper service intervals The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts REMOVAL...

Page 1050: ...ck 7 Drive vehicle until transmission fluid is at nor mal operating temperature 8 With the engine running at curb idle speed the gear selector in NEUTRAL and the parking brake applied check the transm...

Page 1051: ...LUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CON...

Page 1052: ...void component damage The converter drive plate pump bushing or oil seal can be damaged if the converter is left attached to the driveplate during removal REMOVAL 1 Disconnect battery negative cable 2...

Page 1053: ...gh Temp Grease 8 Position transmission on jack and secure it with safety chains 9 Check condition of converter driveplate Replace the plate if cracked distorted or damaged Also be sure transmission do...

Page 1054: ...smission is secure on the lifting device or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter...

Page 1055: ...nstaller C 3995 A or C 3972 Fig 72 3 Carefully guide propeller shaft slip yoke into housing and onto output shaft splines Align marks made at removal and connect propeller shaft to rear axle pinion yo...

Page 1056: ...s 8 Install rear transmission mount and skid plate 9 Lower vehicle and verify transmission fluid level Add fluid as necessary SPEEDOMETER ADAPTER Rear axle gear ratio and tire size determine speed ome...

Page 1057: ...quired range numbers are at 6 o clock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install speedometer adapter clamp and retain ing screw Tighten clamp screw t...

Page 1058: ...that the pawl is seated within the confines of the adjustment gauge clip 5 Snap the cable into the transmission bracket so the retaining ears are engaged and connect cable end fitting onto the manual...

Page 1059: ...rim 10 Install tie strap to hold cable to base of steer ing column 11 Install lower steering column shroud and igni tion lock 12 Install lower steering column cover VALVE BODY REMOVAL 1 Raise vehicle...

Page 1060: ...ain in position 7 Hold valve body in position and install valve body screws finger tight 8 Install park neutral position switch 9 Tighten valve body screws alternately and evenly to 11 N m 100 in lbs...

Page 1061: ...ion on a suitable lifting device 5 Remove skid plate and rear transmission mount 6 Remove extension housing 7 Loosen but do not remove bolts that hold gov ernor body to park gear 8 Rotate transmission...

Page 1062: ...ment in housing and sprag Inspect sprag and control rod springs for distortion and loss of tension replace worn damaged parts as necessary 2 Inspect square lug on sprag for broken edges Check lugs on...

Page 1063: ...CLIP 6 SPRING 7 CONTROL ROD 8 SNAP RING 9 PLUG AND PIN 10 SPRING Fig 89 Governor Filter 1 GOVERNOR FILTER 2 PARK GEAR Fig 90 Snap Ring Washer and Outer Weight 1 SNAP RING 2 E CLIP 3 PARK GEAR 4 GOVER...

Page 1064: ...plate resulting in valve bind Slide valves and plugs out carefully Do not use force at any time The valves and valve body will be damaged if force is used Also tag or mark the valve body springs for r...

Page 1065: ...ching transfer plate to valve body Fig 102 17 Remove transfer plate and separator plate from valve body Fig 102 Note position of filter and clutch solenoid for reference Remove valve body check balls...

Page 1066: ...ttle valve E clip and remove sec ondary spring and spring guides from end of valve Fig 106 Fig 100 Clutch Module And Connecting Tube 1 MODULE AND CONNECTING TUBE Fig 98 Park Rod 1 MANUAL LEVER 2 E CLI...

Page 1067: ...valve and spring from kickdown limit valve body Fig 107 33 Remove regulator valve end plate from valve body Fig 107 34 Remove regulator valve line pressure plug pressure plug sleeve regulator valve t...

Page 1068: ...in kick down limit valve body Fig 107 Verify valve compo nents slide freely 5 Compress spring into kickdown limit valve body 6 Install retainer in grooves at end of kickdown limit valve body Fig 107...

Page 1069: ...rt filter into opening in separator plate Fig 111 24 Place separator plate in position on transfer plate and install screws to attach separator plate to transfer plate Fig 111 25 Place one 11 32 in ch...

Page 1070: ...alve into valve body Fig 119 42 Insert throttle lever through transfer plate side of valve body and upward Fig 120 43 Insert throttle lever into groove in manual valve Fig 121 44 Install seal washer a...

Page 1071: ...r shaft 6 Mount transmission in repair stand C 3750 B or similar type stand Fig 123 7 Remove extension housing 8 Remove fluid pan 9 Remove park neutral position switch and seal Fig 124 10 Remove valve...

Page 1072: ...front band together and remove band strut Fig 128 Fig 119 Manual Valve 1 MANUAL VALVE 2 VALVE BODY Fig 120 Manual And Throttle Levers 1 PARK ROD 2 E RING 3 WASHER 4 MANUAL LEVER 5 MANUAL VALVE 6 SPRIN...

Page 1073: ...cumulator Piston And Spring 1 ACCUMULATOR PISTON 2 PISTON SPRING Fig 126 Front Band Adjusting Screw Lock Nut 1 LOCK NUT 2 FRONT BAND ADJUSTER Fig 127 Oil Pump Reaction Shaft Support 1 OIL PUMP AND REA...

Page 1074: ...24 Remove governor body and park gear from output shaft 25 Remove output shaft and planetary geartrain as assembly Fig 133 Support geartrain with both hands during removal Do not allow machined sur f...

Page 1075: ...clutch cam and low reverse drum to transmission case Fig 137 Fig 132 Front Band 1 FRONT BAND 2 TRANSMISSION HOUSING Fig 133 Planetary Geartrain 1 SLOTS 2 LOW REVERSE DRUM 3 PLANETARY GEARTRAIN 4 TRANS...

Page 1076: ...gnet Pin is accessible from converter housing side of case Fig 141 c Remove front band lever Fig 142 d Using snap ring plier pull rear band lever pivot from transmission case Fig 143 e Separate rear b...

Page 1077: ...rear servo spring and retainer with Compressor Tool C 3422 B Fig 145 or a large C clamp 2 Install front servo piston spring and rod guide Compress front servo rod guide with Valve Spring Compressor C...

Page 1078: ...nsmission case 14 Insert low reverse drum and overrunning clutch into front of transmission case and into rear band 15 Insert awl tip into the threaded hole next to the non threaded hole in the overru...

Page 1079: ...properly joined and ends of metal ring are correctly hooked together Also be sure rings are installed in sequence shown b Align teeth on clutch discs in line c Insert input shaft on rear clutch into...

Page 1080: ...pening at front of transmission case Fig 156 34 Install front and rear clutch units as assembly Fig 157 Align rear clutch with front annulus gear and install assembly in driving shell Be sure out put...

Page 1081: ...m jelly to hold it in place Then install washer over reaction shaft hub and seat it on pump Fig 160 CAUTION The thrust washer bore I D is cham fered on one side Make sure the chamfered side is install...

Page 1082: ...ial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266 7 to secure it to the input shaft d Position...

Page 1083: ...65 2 Install overrunning clutch roller spring and retainer assembly in clutch cam Fig 166 3 Temporarily assemble and check overrunning clutch operation as follows a Assemble cam and clutch Fig 164 Rem...

Page 1084: ...ASSEMBLY 1 Lubricate new O ring and seal rings with petroleum jelly and install them on piston guide and rod 2 Install rod in piston Install spring and washer on rod Compress spring and install snap...

Page 1085: ...mbly for alignment reference 3 Remove bolts attaching pump body to support Fig 172 4 Separate support from pump housing Fig 173 5 Remove inner and outer gears from reaction shaft support Fig 174 6 If...

Page 1086: ...3 firmly against reaction shaft and thread remover SP 5324 into bushing as far as possible by hand Then thread remover tool 3 4 additional turns into bushing with a wrench 3 Turn remover tool hex nut...

Page 1087: ...ion shaft seal rings are being replaced install new seal rings on support hub Fig 181 Lubricate seal rings with transmission fluid or petro leum jelly after installation Squeeze each ring until ring e...

Page 1088: ...reference 5 Remove clutch piston from clutch retainer Remove piston by rotating it up and out of retainer 6 Remove seals from clutch piston and clutch retainer hub Discard both seals as they are not r...

Page 1089: ...the pressure plate Fig 189 b Using two small screw drivers lift the pres sure plate and compress the waved snap ring This will assure that the snap ring is at the top of the groove c Release the press...

Page 1090: ...ol Use a suitably Fig 185 Compressing Front Clutch Piston Spring 1 FRONT CLUTCH SPRING 2 COMPRESSOR TOOL C 3575 A 3 RETAINER SNAP RING 4 SPRING RETAINER Fig 186 Front Clutch Piston Installation 1 CLUT...

Page 1091: ...Door Ease Then lubricate retainer hub and bore with light coat of transmission fluid 8 Install clutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin strip of plast...

Page 1092: ...alling Input Shaft Snap Ring 1 REAR CLUTCH RETAINER 2 INPUT SHAFT SNAP RING 3 SNAP RING PLIERS Fig 192 Rear Clutch Retainer And Input Shaft Seal Ring Installation 1 REAR CLUTCH RETAINER HUB SEAL RING...

Page 1093: ...e selective snap ring thicknesses are 107 109 in 098 100 in 095 097 in 083 085 in 076 078 in 071 073 in 060 062 in 16 Coat rear clutch thrust washer with petro leum jelly and install washer over input...

Page 1094: ...r Use enough petroleum jelly to hold washer in place Also be sure all four washer tabs are properly engaged in gear slots 4 Install rear annulus over and onto rear plane tary gear Fig 202 5 Install as...

Page 1095: ...ssembling Rear Annulus And Planetary Gear 1 REAR ANNULUS GEAR 2 TABBED THRUST WASHER 3 REAR PLANETARY Fig 203 Installing Rear Annulus And Planetary On Output Shaft 1 REAR ANNULUS AND PLANETARY GEAR AS...

Page 1096: ...g shell and sun gear on output shaft Fig 210 13 Install rear thrust washer on front planetary gear Fig 211 Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seate...

Page 1097: ...Install planetary selective snap ring with snap ring pliers Fig 216 Be sure ring is fully seated 22 Turn planetary geartrain assembly over so driving shell is facing workbench Then support geartrain...

Page 1098: ...hrust Washer 1 WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB 2 FRONT ANNULUS THRUST WASHER 3 TAB FACES FRONT Fig 215 Installing Front Annulus Snap Ring 1 SNAP RING PLIERS 2 FRONT ANNULUS SNAP RING Fig...

Page 1099: ...n EXTENSION HOUSING AND PARK LOCK Clean the housing and park lock components in solvent and dry them with compressed air Examine the park lock components in the housing If replacement is necessary rem...

Page 1100: ...lve body mating surface may be corrected by smoothing the surface with cro cus cloth The cloth should be in sheet form and be positioned on a surface plate sheet of plate glass or equally flat surface...

Page 1101: ...f any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Trial fit each valve and plug in its bore to check freedom of o...

Page 1102: ...way into the case Be sure the screw turns freely and does not bind Install the locknut on the screw after checking screw thread operation Inspect all the transmission bushings during over haul Bushing...

Page 1103: ...eplace the drum and race as an assembly if either component is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in...

Page 1104: ...scored warped or broken Be sure the driving lugs on the plates are in good condition The lugs must not be bent cracked or damaged in any way Replace the clutch spring and spring retainer if either is...

Page 1105: ...es are open and clear Replace the shaft if scored pitted or damaged Inspect the sun gear and driving shell If either component is worn or damaged remove the sun gear rear retaining ring and separate t...

Page 1106: ...e TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT The transmission throttle valve is operated by a cam on the throttle lever The throttle lever is oper ated by an adjustable cable Fig 230 The cable is at...

Page 1107: ...n the throttle lever stud the cable housing moves smoothly with the cable Due to the angle at which the cable housing enters the spring housing the cable housing may bind slightly and create an incorr...

Page 1108: ...inner edge of the adjusting screw with an accurate steel scale Fig 234 Distance should be 33 4 mm 1 5 16 in If adjustment is required turn the adjusting screw in or out to obtain required distance se...

Page 1109: ...ent SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS Fig 234 Line Pressure Adjustment 1 WRENCH 2 1 5 16 INCH Fig 235 Throttle Pressure Adjustment 1 HEX WRENCH IN THROTTLE LEVER ADJUSTING SCREW 2 SPECIAL T...

Page 1110: ...HYDRAULIC FLOW IN PARK NEUTRAL 21 202 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1111: ...HYDRAULIC FLOW IN D FIRST GEAR XJ AUTOMATIC TRANSMISSION 30RH 21 203 SCHEMATICS AND DIAGRAMS Continued...

Page 1112: ...HYDRAULIC FLOW IN D SECOND GEAR 21 204 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1113: ...HYDRAULIC FLOW IN D THIRD GEAR XJ AUTOMATIC TRANSMISSION 30RH 21 205 SCHEMATICS AND DIAGRAMS Continued...

Page 1114: ...HYDRAULIC FLOW IN D THIRD GEAR CONVERTER CLUTCH APPLIED 21 206 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1115: ...HYDRAULIC FLOW AT PART THROTTLE 3 2 KICKDOWN XJ AUTOMATIC TRANSMISSION 30RH 21 207 SCHEMATICS AND DIAGRAMS Continued...

Page 1116: ...HYDRAULIC FLOW AT FULL THROTTLE 3 2 KICKDOWN 21 208 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1117: ...HYDRAULIC FLOW IN MANUAL SECOND XJ AUTOMATIC TRANSMISSION 30RH 21 209 SCHEMATICS AND DIAGRAMS Continued...

Page 1118: ...HYDRAULIC FLOW IN MANUAL LOW 21 210 AUTOMATIC TRANSMISSION 30RH XJ SCHEMATICS AND DIAGRAMS Continued...

Page 1119: ...HYDRAULIC FLOW IN REVERSE XJ AUTOMATIC TRANSMISSION 30RH 21 211 SCHEMATICS AND DIAGRAMS Continued...

Page 1120: ...b 1 55 mm 0 061 in Rear clutch thrust washer clutch retainer 1 55 mm 0 061 in Output shaft thrust plate output shaft pilot hub 1 5 1 6mm 0 060 0 063 in Output shaft thrust washer rear clutch hub 1 3 1...

Page 1121: ...and adj 34 N m 25 ft lbs Switch park neutral 34 N m 25 ft lbs Bolt fluid pan 17 N m 13 ft lbs Bolt oil pump 20 N m 15 ft lbs Bolt overrunning clutch cam 17 N m 13 ft lbs Plug pressure test port 14 N m...

Page 1122: ...B Fixture Engine Support C 3487 A Spring Compressor C 3575 A Spring Compressor C 3863 A Adapter Band Adjuster C 3705 Transmission Repair Stand C 3750 B Puller Slide Hammer C 3752 Gauge Throttle Settin...

Page 1123: ...J Cup Remover SP 3633 Remover Bushing SP 5301 Installer Bushing SP 5118 Installer Bushing SP 5302 Remover Bushing SP 3550 Remover Bushing SP 3629 Installer Bushing SP 5511 Snap ring Plier C 3915 XJ AU...

Page 1124: ...C 3985 B Bushing Remover 6957 Flusher Oil Cooler 6906 Installer C 3995 A Universal Handle C 4171 Remover Installer C 4470 Nut Bushing Remover SP 1191 21 216 AUTOMATIC TRANSMISSION 30RH XJ SPECIAL TOO...

Page 1125: ...L MODULE TCM SERVICE 248 OIL PUMP VOLUME CHECK 248 FLUSHING COOLERS AND TUBES 248 ALUMINUM THREAD REPAIR 249 REMOVAL AND INSTALLATION TRANSMISSION AND TORQUE CONVERTER 250 TORQUE CONVERTER 252 ADAPTER...

Page 1126: ...3 and D ranges Controls consist of the transmission control module TCM valve body solenoids and various sen sors The sensors monitor vehicle speed throttle opening shift lever position and brake pedal...

Page 1127: ...nts front and rear sun gear from turning either clockwise or counter clockwise Second Brake Prevents outer race of number 1 one way clutch from turning either clockwise or counter clockwise thus preve...

Page 1128: ...and applied through transmission valve body solenoid number two In fourth gear the overdrive brake prevents the overdrive sun gear from turning The overdrive input shaft and planetary carrier rotate...

Page 1129: ...rs also claim to improve converter clutch operation and inhibit overheating oxidation varnish and sludge These claims have not been sup ported to the satisfaction of DaimlerChrysler and these additive...

Page 1130: ...er clutch engagement occurs in second gear in 1 2 posi tion third gear in 3 position and third and fourth gear in D position The torque converter hub drives the transmission oil fluid pump The torque...

Page 1131: ...converter As the converter housing is rotated by the engine so is the impeller because they are one in the same and are the driving member of the system Fig 6 Impeller 1 ENGINE FLEXPLATE 2 OIL FLOW F...

Page 1132: ...gh the center of the impeller and splined into the tur bine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction Fig 7 Turbine 1 T...

Page 1133: ...e and a friction mate rial was added to the inside of the impeller housing to provide this mechanical lock up OPERATION The converter impeller Fig 11 driving member which is integral to the converter...

Page 1134: ...the stator vanes and is redirected into a helping direction before it enters the impeller This circulation of oil from impeller to turbine turbine to stator and stator to impeller can produce a maxim...

Page 1135: ...olenoid channels line pressure to the clutch through the relay valve at clutch engagement speeds OIL PUMP DESCRIPTION The oil pump Fig 13 is located in the pump hous ing inside the bell housing of the...

Page 1136: ...wer body section Fig 15 The remaining control and shift valves plus check balls and one additional oil strainer are located in the upper body section Fig 16 TRANSMISSION VALVE BODY SOLENOIDS The solen...

Page 1137: ...Fig 17 Fig 16 Lower Body Components 1 DOWNSHIFT PLUG 2 LOCK UP RELAY VALVE 3 SECONDARY REGULATOR VALVE 4 UPPER BODY 5 CUT BACK VALVE 6 THROTTLE VALVE 7 LOW COAST MODULATOR VALVE 8 SECONDARY COAST MODU...

Page 1138: ...by throttle pres sure and by line pressure from the second brake The valve also helps regulate line pressure by controlling the amount of cut back pressure to the throttle valve SECONDARY REGULATOR VA...

Page 1139: ...ator feed port As the solenoid is activated and the drain port opens spring force moves the valve up exposing the second brake feed port for the shift to second gear 2 3 SHIFT VALVE The 2 3 shift valv...

Page 1140: ...ng tension moves the valve up to hold the valve in second gear position As the solenoid is deactivated line pressure then moves the valve down exposing the direct clutch feed port for the shift to thi...

Page 1141: ...e valve upward closing off the overdrive brake feed port preventing a shift into fourth gear SECOND COAST MODULATOR VALVE The second coast modulator valve Fig 26 momen tarily reduces line pressure fro...

Page 1142: ...re is provided by the transmission control module The No 3 solenoid controls operation of the torque converter clutch The solenoid operates in response to signals from the transmission control module...

Page 1143: ...on that is closely fitted to the cylinder wall If a force is applied to the piston pressure will be developed in the fluid Of course no pressure will be created if the fluid is not confined It will si...

Page 1144: ...body as well as the pistons of the transmission which activate the clutches and bands It is nothing more than using a difference of area to create a difference in pressure to move an object PISTON TRA...

Page 1145: ...tch prevents engine starting in all gears other than Park or Neutral The brake switch is in circuit with the torque con verter clutch solenoid The switch disengages the converter clutch whenever the b...

Page 1146: ...OCK or ACCESSORY posi tion An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one half an inch A magnetic holding...

Page 1147: ...chanical or electrical The first procedure step is Initial Inspection and Adjustment EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid Air in the f...

Page 1148: ...w through the main and or auxiliary cooler This condition is usu ally the result of a faulty or improperly installed drainback valve a damaged main cooler or severe restrictions in the coolers and lin...

Page 1149: ...level when fluid is at normal operating temperature Start engine Shift transmission through all gear ranges then back to Neutral Correct level is to Full or Add mark on dip stick with engine at curb i...

Page 1150: ...low in D range only check for fol lowing forward clutch worn or damaged fluid leakage in D range circuit component seal and O rings If pressures are low in Reverse only check for fol lowing shift cab...

Page 1151: ...rter drive plate broken Replace drive plate Oil pump intake screen blocked Clean screen Transmission faulty Disassemble and repair transmission SHIFT LEVER POSITION INCORRECT Shift cable out of adjust...

Page 1152: ...ING COAST Throttle cable faulty Replace cable Valve body faulty Repair valve body Transmission faulty Disassembly and repair transmission Solenoid faulty Replace solenoid Electronic control problem Lo...

Page 1153: ...Drain fluid to correct level remove neutral switch and drain through switch hole with suction gun Breather vent in oil pump blocked Inspect and clear blockage Fluid cooler or cooler lines plugged Flus...

Page 1154: ...y shifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive Refer to the Adjust ments section for the proper a...

Page 1155: ...ec tion Converter clutch should lock 5 Replace converter if clutch binds or will not lock SERVICE PROCEDURES CHECKING FLUID LEVEL 1 Be sure transmission fluid is at normal operat ing temperature Norma...

Page 1156: ...be long enough to extend into oil pan 9 When fluid level is correct shut engine off release park brake remove funnel and reseat dip stick in fill tube TRANSMISSION CONTROL MODULE TCM SERVICE Use the D...

Page 1157: ...he transmission oil cooler from the vehicle Refer to the Group 7 Cooling System for the proper procedures 8 Remove the transmission oil cooler thermostat Refer to the Group 7 Cooling System for the pr...

Page 1158: ...remove shafts from vehicle 10 Remove rear crossmember 11 Disconnect transmission shift cable at trans mission Then disconnect transmission throttle valve cable at engine 12 Disconnect necessary vacuu...

Page 1159: ...nd position transmission and converter on engine 5 Remove clamp or strap used to hold torque con verter in place 6 Move transmission forward seat and it on engine Be sure torque converter hub is fully...

Page 1160: ...inserting torque converter into the front of the transmission 3 Align torque converter to oil pump seal open ing 4 Insert torque converter hub into oil pump 5 While pushing torque converter inward rot...

Page 1161: ...hly clean adapter flange and adapter mounting surface in housing Surfaces must be clean for proper adapter alignment and speedometer oper ation 2 Install new O rings on speed sensor and speed ometer a...

Page 1162: ...g to the transmission case 7 Tap the adapter housing at the joint line gently with a rubber mallet to separate the adapter housing from the transmission case 8 Remove the adapter housing from the tran...

Page 1163: ...stall components removed to gain access to rotor and drive gear PARK NEUTRAL POSITION SWITCH REMOVAL 1 Raise vehicle 2 Disconnect switch wire harness connector 3 Pry washer lock tabs upward and remove...

Page 1164: ...to dash panel 2 Place the auto transmission manual shift con trol lever in Park detent rearmost position and rotate prop shaft to ensure transmission is in park 3 Connect shift cable to shifter mechan...

Page 1165: ...er interlock cable Refer to the Adjustment portion of this section for proper procedures 7 Verify that the cable adjuster lock clamp is pushed downward to the locked position 8 Test the park lock cabl...

Page 1166: ...pressed air 8 Remove old sealer material from oil pan and transmission case INSTALLATION 1 Position solenoids on valve body and install solenoid bolts Tighten bolts to 10 N m 7 ft lbs torque 2 Connect...

Page 1167: ...l and spring Fig 67 3 Position accumulator springs and spacers on valve body 4 Align valve body manual valve with shift sector Fig 68 and carefully position valve body on case 5 Install valve body bol...

Page 1168: ...e instrument panel On left hand drive models it is at the driver side of the lower finish panel Fig 70 On right hand drive models it is at the passenger side of the lower finish panel Fig 71 To remove...

Page 1169: ...et securing solenoid harness adaptor Fig 73 to case 4 Pull harness adapter and wires out of case Fig 69 Installing Transmission Valve Body Oil Tubes Fig 70 TCM Location Left Hand Drive 1 TCM 2 LOWER F...

Page 1170: ...r con MANUAL VALVE SHAFT SEAL REMOVAL 1 Remove park neutral position switch and dis connect transmission shift lever Fig 74 2 Remove oil pan and valve body 3 Remove bolts attaching park rod bracket to...

Page 1171: ...pacer sleeve on sector Fig 80 4 Lubricate manual valve shaft with petroleum jelly and install it through the left side of the trans mission case Fig 77 Cutting Spacer Sleeve 1 SPACER 2 MANUAL VALVE SH...

Page 1172: ...piston out of the bore In addition remove the pistons one at a time and tag the pistons and springs for assembly reference Do not intermix them 3 Remove and discard piston O ring seals Then clean pis...

Page 1173: ...nap ring with snap ring pliers Fig 85 3 Remove servo piston and cover with com pressed air Apply compressed air through oil hole in servo boss to ease piston out of bore Fig 86 Fig 84 Accumulator Pist...

Page 1174: ...ing 5 Install valve body oil screen and oil pan PARK ROD AND PAWL REMOVAL 1 Remove valve body as outlined in this section 2 Remove bolts attaching park rod bracket to case Fig 88 3 Remove park rod fro...

Page 1175: ...linkage Then compress cable mounting ears and remove cable from engine bracket Fig 91 2 Raise vehicle 3 Remove transmission oil pan 4 Disengage cable from throttle valve cam Fig 92 5 Remove cable brac...

Page 1176: ...cable adjust ment procedure OIL PUMP SEAL REMOVAL 1 Remove converter 2 Remove old seal Use blunt punch to collapse seal and pry seal out of pump housing Do not scratch or damage seal bore INSTALLATIO...

Page 1177: ...move speed sensor 6 Remove converter housing bolts and remove housing Fig 96 from case 7 Remove adapter housing speedometer drive gear and speed sensor rotor 8 Remove transmission oil pan oil screen a...

Page 1178: ...throttle cable from throttle cam Fig 102 14 Remove valve body from case Then remove accumulator springs check ball and spring Fig 103 Fig 98 Valve Body Oil Tube Removal 1 OIL TUBES Fig 99 Solenoid Wir...

Page 1179: ...n with compressed air Fig 104 Note and identify the original location of all springs 17 Remove overdrive clutch accumulator piston with compressed air Fig 104 18 Remove throttle cable Fig 102 Disconne...

Page 1180: ...race and overdrive planetary ring gear Fig 109 24 Measure stroke length of overdrive brake pis ton as follows Fig 105 Oil Pump Removal 1 PULLER TOOL 2 OIL PUMP Fig 106 Oil Pump Race Removal 1 OIL PUM...

Page 1181: ...r pressure through piston feed hole and check stroke length with Gauge Tool 7552 c Stroke length should be 1 5 3 0 mm 0 059 0 118 in d Record the reading for use during re assem bly 26 Remove the bolt...

Page 1182: ...move piston cover and piston assembly 36 Disassemble second coast brake piston Fig 116 if necessary 37 Remove direct and forward clutch assembly Fig 117 Fig 112 Overdrive Support Snap Ring Removal Ins...

Page 1183: ...G AND RETAINER 4 PISTON ROD 5 PISTON SPRING 6 SERVO COVER O RINGS 7 SERVO COVER 8 SNAP RING 9 E RING Fig 117 Removing Direct And Forward Clutch Assembly 1 DIRECT AND FORWARD CLUTCH ASSEMBLY Fig 118 Be...

Page 1184: ...p ring 44 Remove planetary snap ring and remove plan etary gear Fig 122 Fig 120 Front Planetary Ring Gear Removal 1 RING GEAR BEARING RACE FRONT 2 FRONT PLANETARY RING GEAR Fig 121 Removing Ring Gear...

Page 1185: ...5 48 Remove second brake clutch pack Fig 126 Inspect and replace as necessary Fig 123 Removing Sun Gear Input Drum And One Way Clutch 1 SUN GEAR INPUT DRUM ONE WAY CLUTCH ASSEMBLY Fig 124 Checking Sec...

Page 1186: ...1 55 Remove planetary and brake drum thrust bearing and race assembly Fig 132 56 Remove second brake drum gasket from case with screwdriver 57 Measure inside diameter of transmission case rear bushing...

Page 1187: ...move Tool 7539 and remove piston return springs Fig 130 Removing Second Brake Piston Sleeve 1 REMOVER TOOL 2 PISTON SLEEVE Fig 131 Removing Rear Planetary Second Brake Drum And Output Shaft 1 PLANETAR...

Page 1188: ...1 During assembly lubricate components with transmission fluid or petroleum jelly as indicated 2 Verify thrust bearing and race installation dur ing assembly Refer to the Thrust Bearing Chart Fig Fig...

Page 1189: ...Install the spring plate into the No 2 first re verse brake piston 10 Install Spring Compressor 7539 onto the first reverse brake piston 11 Compress the first reverse brake piston spring and install...

Page 1190: ...d in case Remove and reinstall components if necessary 20 Install second brake piston sleeve Fig 144 Sleeve lip faces up and toward case front as shown 21 Install second brake drum gasket Fig 139 Inst...

Page 1191: ...g 146 Fig 143 Checking First Reverse Brake Pack Clearance 1 FEELER GAUGE Fig 144 Second Brake Piston Sleeve Installation 1 PISTON SLEEVE Fig 145 Park Lock Pin Spring And Pawl Installation 1 SPRING 2 P...

Page 1192: ...brake pack Fig 150 Install disc then plate Continue installation sequence until five discs and five plates are installed 29 Install second brake pack retainer with rounded edge of retainer facing dis...

Page 1193: ...in drum Use petroleum jelly to hold thrust washer in position if necessary 33 Install front planetary gear on sun gear Fig 153 34 Support output shaft with wood blocks Fig 154 Fig 151 Checking Second...

Page 1194: ...em in place 40 Verify forward direct clutch thrust bearing size Race outer diameter is 48 9 mm 1 925 in and inside diameter is 26 0 mm 1 024 in Bearing outer diameter is 46 7 mm 1 839 in and inside di...

Page 1195: ...ar forward di rect clutch Fig 163 47 Check clearance between sun gear input drum and direct clutch drum Fig 164 Clearance should be 9 8 11 8 mm 0 386 0 465 in If clearance is incorrect planetary gear...

Page 1196: ...on second coast brake piston cover and install cover in case 52 Install second coast brake piston snap ring with snap ring plier tool Fig 166 53 Check second coast brake piston stroke as fol lows Fig...

Page 1197: ...rive support in case Use two long bolts to help align and guide support into position Fig 170 56 Install overdrive support snap ring with Snap Ring Plier Tool 7540 Fig 171 Chamfered side of snap ring...

Page 1198: ...Overdrive Support 1 USE LONG BOLTS TO INSTALL SUPPORT 2 OVERDRIVE SUPPORT Fig 171 Installing Overdrive Support Snap Ring 1 SNAP RING TOOL 2 SNAP RING ENDS CENTERED IN CASE OPENING 3 SNAP RING Fig 172...

Page 1199: ...ed incorrectly Check and correct as neces sary and measure piston stroke again e Remove the dial indicator set up from the transmission 63 Coat overdrive lower race thrust bearing and upper race with...

Page 1200: ...side diameter is 28 9 mm 1 138 in 71 Coat thrust bearing race with petroleum jelly and install it in oil pump Fig 182 Bearing race outer diameter is 47 2 mm 1 858 in and inside diameter is 28 1 mm 1 1...

Page 1201: ...rotate smoothly and not bind 76 Lubricate and install new O ring on trans mission throttle cable adapter and install cable in case Fig 183 Fig 180 Installing Overdrive Planetary And Clutch Assembly 1...

Page 1202: ...pring Fig 186 81 Position valve body on case Fig 187 82 Install detent spring Fig 187 83 Align manual valve detent spring and shift sector Fig 187 84 Connect transmission throttle cable to throttle va...

Page 1203: ...e 92 Install transmission speed sensor rotor and key on output shaft Fig 191 93 Install spacer and speedometer drive gear on output shaft Then install retaining snap ring Fig 192 94 Apply bead of Thre...

Page 1204: ...ft lever fully rearward Then move lever two detent positions forward 100 Mount park neutral position switch on man ual valve shaft and tighten switch adjusting bolt just enough to keep switch from mov...

Page 1205: ...al strapping Do this before mounting transmission on jack or moving transmission under vehicle 109 Install lower half of transmission fill tube install upper half after transmission is in vehicle CAUT...

Page 1206: ...eparate components 5 Remove drive gear and driven gear from pump body Fig 199 Fig 199 Oil Pump Components 1 PUMP SEAL 2 PUMP BODY 3 STATOR SHAFT 4 SEAL RINGS 5 GEAR 6 O RING Fig 198 Checking Converter...

Page 1207: ...g diameter is greater than specified 3 Measure oil pump clearances Fig 201 Clearance between pump driven gear and pump body should be maximum of 0 3 mm 0 012 in Clearance between tips of pump gear tee...

Page 1208: ...eal rings on stator shaft 9 Install pump in torque converter and check pump gear rotation Fig 203 Gears must rotate smoothly when turned clockwise and counterclock wise 10 Lubricate pump O ring and se...

Page 1209: ...DRUM 2 CLUTCH PISTON 3 PISTON RETURN SPRING 4 CLUTCH DISCS 5 RETAINER PLATE 6 CLUTCH PACK SNAP RING 7 CLUTCH PLATES 8 PISTON SNAP RING 9 O RINGS 10 ONE WAY CLUTCH 11 CLUTCH DRUM BEARING AND RACE ASSE...

Page 1210: ...lutch pack snap ring and remove the clutch pack Fig 208 6 Measure overdrive clutch disc thickness Mini mum allowable thickness is 1 84 mm 0 0724 in 7 If the clutch pack stroke length is out of speci f...

Page 1211: ...ll sealing by applying low pressure compressed air to ball inlet as shown Air should not leak past check ball Fig 207 Removing Clutch Drum Bearing And Race 1 CLUTCH DRUM 2 THRUST BEARING AND RACE Fig...

Page 1212: ...e from ring gear Fig 214 Fig 211 Checking Piston Return Spring Length 1 PISTON RETURN SPRINGS 2 SPRING RETAINER Fig 212 Testing Clutch Piston Check Ball 1 CLUTCH PISTON CHECK BALL 2 USE LOW PRESSURE C...

Page 1213: ...and remove retaining plate Fig 217 Fig 215 Removing Ring Gear Hub 1 SNAP RING 2 RING GEAR 3 RING GEAR HUB Fig 216 Remove Planetary Gear Race 1 PLANETARY GEAR 2 RACE Fig 217 Removing Snap Ring And Reta...

Page 1214: ...7 mm 0 4437 in Replace planetary gear if bushing inside diameter is greater then specified Fig 218 Removing One Way Clutch 1 ONE WAY CLUTCH AND OUTER RACE ASSEMBLY 2 PLANETARY GEAR 3 RACE 4 CLUTCH Fig...

Page 1215: ...f race is 47 8 mm 1 882 in and inside diameter is 24 2 mm 0 953 in Outside diameter of bearing is 46 8 mm 1 843 in and inside diameter is 26 mm 1 024 in 9 Lubricate new clutch piston O rings with Mopa...

Page 1216: ...tool Fig 225 Installing Clutch Piston Snap Ring 1 PRESS RAM 2 COMPRESSOR TOOL 3 SNAP RING Fig 224 Installing Piston Return Springs 1 RETURN SPRINGS 2 CLUTCH PISTON Fig 226 Installing Overdrive Clutch...

Page 1217: ...e piston movement Fig 229 Piston should move smoothly and not bind or stick If operation is incorrect replace piston and support 3 Remove thrust bearing front race thrust bear ing and rear race Fig 23...

Page 1218: ...eturn springs with Spring Compres sor 7537 Fig 232 and install piston snap ring 5 Install support bearing race and clutch drum thrust washer Fig 231 6 Install thrust bearing and front and rear bear in...

Page 1219: ...7 BEARING RACE 8 CLUTCH DRUM THRUST WASHER 9 SUPPORT SEAL RINGS 10 BRAKE PISTON O RINGS 11 PISTON RETURN SPRING Fig 234 Removing Support Seal Rings 1 SEAL RINGS 2 2 SUPPORT Fig 235 Checking Piston Ret...

Page 1220: ...L RINGS BEFORE INSTALLATION 2 OVERDRIVE SUPPORT Fig 237 Installing Support Thrust Bearing And Races 1 REAR RACE 2 THRUST BEARING 3 FRONT RACE Fig 238 Separate Direct Clutch From Forward Clutch 1 DIREC...

Page 1221: ...rt Fig 244 Apply compressed air through piston feed hole in support to remove piston Use only enough air to ease piston out 12 Remove and discard clutch piston O rings 13 Measure clutch disc thickness...

Page 1222: ...ing 1 PRESS RAM 2 COMPRESSOR TOOL 3 SNAP RING PLIERS 4 RETURN SPRING Fig 244 Removing Direct Clutch Piston 1 DIRECT CLUTCH DRUM 2 CLUTCH PISTON 3 OVERDRIVE SUPPORT 4 SUPPORT FEED HOLE Fig 245 Checking...

Page 1223: ...snap ring position If necessary shift snap ring until end gap is not aligned with any notches in clutch drum Fig 250 8 Lubricate clutch drum thrust washer with petroleum jelly and install it in drum F...

Page 1224: ...R 3 SNAP RING Fig 250 Adjusting Clutch Pack Snap Ring Position 1 CLUTCH PACK SNAP RING 2 DRUM NOTCH 3 SHIFT SNAP RING END GAP AWAY FROM DRUM NOTCHES Fig 251 Checking Direct Clutch Assembled Height 1 D...

Page 1225: ...bearing and race from forward clutch drum Fig 253 4 Install a suitable threaded bolt rod into the side of the overdrive support 5 Mount Miller Tool C 3339 dial indicator compo nents onto the threaded...

Page 1226: ...Apply compressed air through feed hole in support to remove piston Fig 256 Use only enough air pressure to ease piston out of drum 16 Remove and discard clutch piston O rings Fig 257 17 Remove clutch...

Page 1227: ...257 Removing Installing Clutch Drum O Ring 1 CLUTCH DRUM HUB 2 O RING Fig 258 Removing Clutch Drum Seal Rings 1 SEAL RINGS 2 CLUTCH DRUM SHAFT Fig 259 Removing Clutch Drum Thrust Bearing Assembly 1 T...

Page 1228: ...ASSEMBLY 1 Lubricate bearing and race assembly with petroleum jelly and install it in clutch drum Fig 263 Race side of assembly faces downward and toward drum Bearing rollers face up Fig 263 2 Coat n...

Page 1229: ...troke length is not within specified limits replace clutch discs 13 Lubricate race and bearing with petroleum jelly and install them in clutch drum Fig 266 Be sure bearing rollers face up and race lip...

Page 1230: ...gear Fig 267 Checking Forward Clutch Assembled Height 1 DIRECT CLUTCH 2 APPROXIMATELY 71 2 mm 2 80 in 3 FORWARD CLUTCH Fig 268 Front Planetary Gear Components 1 FORWARD RACE 2 FRONT PLANETARY RING GE...

Page 1231: ...r of rear race 47 6 mm 1 874 in Inner diameter is 33 7 mm 1 327 in Outer diameter of front race is 53 6 mm 2 110 in Inner diameter is 30 5 mm 1 201 in Outer diameter of front bearing is 47 7 mm 1 878...

Page 1232: ...e one way clutch second brake hub assembly from drum Fig 273 Fig 272 Checking One Way Clutch Operation 1 SECOND BRAKE HUB 2 SUN GEAR Sun Gear And One Way Clutch Components 1 SNAP RING 2 SUN GEAR 3 SUN...

Page 1233: ...e or inside micrometer Fig 278 Maximum allowable diameter is 27 08 mm 1 0661 in Replace sun gear if bushing inside diameter is greater than specified Fig 274 Removing Installing Thrust Washer 1 THRUST...

Page 1234: ...way clutch second brake hub assembly on sun gear Deep side of hub flange faces upward Fig 279 Fig 279 Installing Clutch And Hub Assembly On Sun Gear 1 CLUTCH AND HUB ASSEMBLY Second Brake Components 1...

Page 1235: ...d brake piston and sleeve from drum with compressed air Fig 283 Use only enough air pressure to ease piston out of drum 6 Remove and discard brake piston O rings 7 Measure free length of piston return...

Page 1236: ...iston should move smoothly when applying releasing air pressure 5 Coat thrust washer with petroleum jelly and install it in drum Be sure washer notches are aligned with tabs on spring retainer Fig 286...

Page 1237: ...2 SNAP RING 3 NO 2 ONE WAY CLUTCH 4 REAR PLANETARY GEAR 5 REAR THRUST WASHER 6 FRONT THRUST WASHER 7 ONE WAY CLUTCH INNER RACE 8 SNAP RING 9 RING GEAR HUB 10 REAR PLANETARY RING GEAR 11 THRUST BEARING...

Page 1238: ...Race should turn freely counterclockwise but lock when turned clockwise Replace one way clutch if necessary Fig 287 Removing Installing Output Shaft 1 GEAR ASSEMBLY 2 OUTPUT SHAFT Fig 288 Removing Ins...

Page 1239: ...move No 2 one way clutch bottom end cap from planetary Fig 291 Checking No 2 One Way Clutch Operation 1 CLUTCH INNER RACE 2 PLANETARY GEAR Fig 292 Removing Installing Clutch Inner Race 1 CLUTCH INNER...

Page 1240: ...s Fig 295 Outer diameter of bottom race is 44 8 mm 1 764 in and inner diameter is 27 6 mm 1 087 in Outer diameter of bearing is 44 7 mm 1 760 in and inner diameter is 30 1 mm 1 185 in Outer diameter o...

Page 1241: ...11 Install planetary gear in ring gear 12 Install thrust bearing and washers onto the ring gear Fig 295 13 Assemble clutch discs and clutch plates Fig 289 Sequence is disc first then a plate Use seve...

Page 1242: ...NER 7 SLEEVE 8 CLIP 9 PRESSURE REDUCING PLUG 10 NO 3 SOLENOID AND O RING 11 NO 1 SOLENOID AND O RING 12 RETAINER 13 SLEEVE 14 PLUNGER 15 VALVE SPRING 16 WASHER 17 PRIMARY REGULATOR VALVE 18 CHECK VALV...

Page 1243: ...Fig 299 Upper Body Components XJ AW 4 AUTOMATIC TRANSMISSION 21 335 DISASSEMBLY AND ASSEMBLY Continued...

Page 1244: ...om cable mounting bracket on transmission Fig 300 5 Slide cable eyelet off transmission shift lever 6 Verify transmission shift lever is in Park detent by moving lever fully rearward Last rearward det...

Page 1245: ...t engine off and raise hood 2 Press cable release button Fig 302 3 Push cable conduit back into cable sheath as far as possible Fig 303 4 Rotate lever on throttle body to wide open throttle position C...

Page 1246: ...on Fluid Normal Operating Temperature 50 80 C 122 176 F TPS Input Voltage AU 5 0 Volts approx TPS Output Voltage 4 Cylinder 0 2 Volts approx 6 Cylinder 4 2 Volts approx AW 4 OIL PUMP WEAR LIMITS Drive...

Page 1247: ...AW 4 BUSHING AND PISTON CLEARANCE XJ AW 4 AUTOMATIC TRANSMISSION 21 339 SPECIFICATIONS Continued...

Page 1248: ...AW 4 RETAINER AND PISTON SPECIFICATIONS 21 340 AW 4 AUTOMATIC TRANSMISSION XJ SPECIFICATIONS Continued...

Page 1249: ...AW 4 VALVE BODY BALL DIMENSIONS AW 4 CLUTCH AND BRAKE PACK REQUIREMENTS XJ AW 4 AUTOMATIC TRANSMISSION 21 341 SPECIFICATIONS Continued...

Page 1250: ...AW 4 VALVE AND SPRING IDENTIFICATION 21 342 AW 4 AUTOMATIC TRANSMISSION XJ SPECIFICATIONS Continued...

Page 1251: ...bs Oil Screen Bolt 9 11 N m 80 96 in lbs Park Pawl Bracket 9 11 N m 80 96 in lbs Propeller Shaft Clamp Screws 16 23N m 140 200 in lbs Rear Mount To Transmission Bolts 60 81N m 44 ft lbs Rear Mount To...

Page 1252: ...Nuts 30 41 N m 22 30 ft lbs Transmission Shift Lever Nut 15 17 N m 134 154 in lbs Transmission To Engine Block Bolts 50 64 N m 37 47 ft lbs Valve Body Bolts to case 9 11 N m 80 96 in lbs Valve Body B...

Page 1253: ...ap Ring 7542 Puller Reaction Sleeve 7543 Puller Piston 1 7544 Installer Brake Drum Seal 7549 Installer Seal 7552 Gauge 3 0 mm Wire 7554 Adapter Pressure Port XJ AW 4 AUTOMATIC TRANSMISSION 21 345 SPEC...

Page 1254: ...are for off road use only They are not for use on hard surface roads The only exception being when the road surface is wet or slip pery or covered by ice and snow The low range reduction gear system...

Page 1255: ...1 Slow vehicle and shift into desired range 2 If vehicle was operated for an extended period in 4H mode on dry surface driveline torque load may cause difficulty 2 Stop vehicle and shift transfer case...

Page 1256: ...3 Drain transfer case lubricant 4 Mark front and rear propeller shaft yokes for alignment reference 5 Support transmission with jack stand 6 Remove rear crossmember or skid plate 7 Disconnect front r...

Page 1257: ...dy for proper procedures 6 Remove screws attaching lever assembly to floorpan and remove assembly and shift rod if left attached INSTALLATION 1 If shift rod was not removed from lever assem bly work r...

Page 1258: ...speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 N m 15 27 in lbs torque 5 Install speedometer pinion in adapter 6 Count number of teeth on speedometer pinion Do this before i...

Page 1259: ...adapter 2 Spread band clamp which holds output shaft boot to slinger with a suitable awl or equivalent 3 Remove output shaft boot from slinger and out put shaft 4 Using Puller MD 998056 A remove rear...

Page 1260: ...ig 13 12 Remove pick up tube o ring from oil pump Fig 14 if necessary Do not disassemble the oil pump it is not serviceable Fig 9 Rear Slinger Removal 1 TRANSFER CASE 2 SPECIAL TOOL MD998056 A 3 SLING...

Page 1261: ...yoke and not on slinger as slinger will be damaged 4 Remove seal washer from front output shaft Discard washer as it should not be reused 5 Remove nut and washer that attach range lever to sector sha...

Page 1262: ...case 5 Remove oil pickup tube from rear case Fig 20 6 Remove mode fork spring Fig 21 7 Pull front output shaft upward and out of front output shaft bearing Fig 22 8 Remove front output shaft and chai...

Page 1263: ...assembly Fig 25 Note fork position for installation reference 5 Remove shift sector from front case Fig 26 6 Remove shift sector bushing and O ring Fig 27 Fig 22 Remove Front Output Shaft And Chain 1...

Page 1264: ...shaft Fig 30 Fig 26 Shift Sector Removal 1 SHIFT SECTOR Fig 27 Sector Bushing And O Ring Removal 1 SEAL RETAINER 2 SECTOR SHAFT BORE 3 O RING SEAL Fig 28 Mode Hub Retaining Ring Removal 1 MODE HUB 2 S...

Page 1265: ...emove input gear retaining ring with heavy duty snap ring pliers Fig 33 Fig 30 Drive Sprocket Removal 1 DRIVE SPROCKET 2 MAINSHAFT Fig 31 Front Bearing Retainer Bolts 1 FRONT CASE 2 FRONT BEARING RETA...

Page 1266: ...thrust washer Fig 37 4 Remove input gear Fig 38 5 Remove rear tabbed thrust washer from low range gear Fig 39 Fig 34 Input Gear And Planetary Carrier Removal 1 PLANETARY ASSEMBLY 2 INPUT GEAR Fig 35 I...

Page 1267: ...e with pry tool Fig 40 2 Remove the front output shaft bearing retain ing ring with screwdriver Fig 41 3 Remove bearing with Tool Handle C 4171 and Tool 5065 Fig 42 Fig 38 Input Gear Removal 1 INPUT G...

Page 1268: ...staller tool bottoms against case 7 Remove the output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 46 8 Install new bearing with Tool Handle C 4171 and Installer 506...

Page 1269: ...to the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 51 14 Install new pilot bearing with Installer 5065 and Handle C 4171 Fig 52 Fig 46 Output Shaft Rear B...

Page 1270: ...pry tool Fig 50 Seating Input Shaft Bearing 1 SNAP RING 2 INPUT SHAFT BEARING Fig 51 Remove Input Gear Pilot Bearing 1 DRIFT 2 INPUT GEAR Fig 52 Install Input Gear Pilot Bearing 1 SPECIAL TOOL C 4171...

Page 1271: ...ed in annulus gear and that input gear shaft is fully seated in front bearing 2 Install snap ring to hold input low range gear into front bearing Fig 58 3 Clean gasket sealer residue from retainer and...

Page 1272: ...62 Tighten range lever nut to 27 34 N m 20 25 ft lbs torque 4 Assemble and install range fork and hub Fig 63 Be sure hub is properly seated in low range gear and engaged to the input gear 5 Align and...

Page 1273: ...13 Install detent plunger spring and plug Fig 67 14 Verify that plunger is properly engaged in sec tor FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION 1 Lubricate front output shaft sprocket assembly...

Page 1274: ...oil pump inlet 5 Position assembled oil pump and pickup tube in rear case Be sure pickup screen is securely seated in case slot Also be sure oil pump locating tabs are outside rear case Fig 72 6 Appl...

Page 1275: ...on fluid and install yoke on front shaft 5 Install new seal washer on front shaft 6 Install yoke and new yoke nut on front output shaft Fig 75 7 Tighten yoke nut to 122 176 N m 90 130 ft lbs torque Us...

Page 1276: ...d Handle MD 998323 Fig 78 7 Install rear slinger with Installer 8408 8 Install boot on output shaft slinger and crimp retaining clamp with tool C 4975 A Fig 79 Fig 74 Range Lever Installation 1 RANGE...

Page 1277: ...and scratches can be smoothed with 320 400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe INPUT GEAR AND PLANETARY CARRIER Check the teeth on the gear Fig 81 Minor ni...

Page 1278: ...pecially on the interior teeth Replace the sleeves if wear or damage is evident REAR RETAINER BEARING SEAL SLINGER BOOT Inspect the retainer components Fig 84 Replace the bearing if rough or noisy Che...

Page 1279: ...any sprocket teeth are cracked or broken Examine the drive chain and shaft bearings Replace the chain and both sprockets if the chain is stretched distorted or if any of the links bind Replace the bea...

Page 1280: ...ailable separately ADJUSTMENTS SHIFT LINKAGE ADJUSTMENT 1 Shift transfer case into 4L position 2 Raise vehicle 3 Loosen lock bolt on adjusting trunnion Fig 87 4 Be sure linkage rod slides freely in tr...

Page 1281: ...20 25 ft lbs Nut Front Yoke 122 176 N m 90 130 ft lbs Nut Range Lever 27 34 N m 20 25 ft lbs Bolt Rear Retainer 35 46 N m 26 34 ft lbs Nuts Mounting 35 47 N m 26 35 ft lbs Switch Indicator 20 34 N m 1...

Page 1282: ...Installer Bearing 5064 Installer Bearing 5065 Installer Bushing 5066 Installer Bearing 8128 Remover L 4454 Cup 8148 Installer Seal 7884 Installer Pump Housing Seal 7888 21 374 NV231 TRANSFER CASE XJ S...

Page 1283: ...ides a 2 72 1 reduction ratio The input gear is splined to the transmission out put shaft It drives the mainshaft through the plan etary gear and range hub The front output shaft is operated by a driv...

Page 1284: ...edge of the fill plug hole Be sure the vehicle is level to ensure an accurate fluid level check DIAGNOSIS AND TESTING NV242 DIAGNOSIS DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION Transfer case...

Page 1285: ...nsfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmission shafts and install transfer case on transmiss...

Page 1286: ...Remove adapter clamp and screw Fig 6 4 Remove speed sensor and speedometer adapter as an assembly 5 Remove speed sensor retaining screw and remove sensor from adapter 6 Remove speedometer pinion from...

Page 1287: ...n 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at 6 o clock position Be sure range index num bers correspond to number of teeth on pinion gear 10 Install...

Page 1288: ...ISASSEMBLY AND ASSEMBLY NV242 TRANSFER CASE DISASSEMBLY REAR RETAINER REMOVAL 1 Remove output shaft boot Spread band clamp that secures boot on slinger with a suitable awl Then slide boot off shaft Fi...

Page 1289: ...out put shaft Fig 15 9 Remove pickup tube O ring from pump Fig 16 but do not disassemble pump it is not a repair able part 10 Remove seal from oil pump with pry tool 11 Remove bolts attaching rear cas...

Page 1290: ...o 4L position b Remove nut with socket and impact wrench Fig 20 2 Remove yoke If yoke is difficult to remove by hand remove it with bearing splitter or with stan dard two jaw puller Fig 21 Be sure pul...

Page 1291: ...e seal plug from low range fork lockpin access hole Then move shift sector to align low range fork lockpin with access hole 3 Remove range fork lockpin with size number one easy out tool as follows a...

Page 1292: ...move mode fork and mainshaft as assembly Fig 28 6 Remove mode shift sleeve and mode fork assembly from mainshaft Fig 29 Note position of mode sleeve in fork and remove sleeve Fig 25 Removing Front Out...

Page 1293: ...utch shaft Fig 32 Fig 29 Mode Fork And Sleeve Removal 1 MAINSHAFT 2 SLEEVE 3 MODE FORK ASSEMBLY Fig 30 Intermediate Clutch Shaft Snap Ring Removal 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT Fig 31 Clutch...

Page 1294: ...slot Fig 35 14 Remove low range fork and hub Fig 36 15 Remove shift sector Fig 37 Fig 32 Intermediate Clutch Shaft Removal 1 INTERMEDIATE CLUTCH SHAFT Fig 33 Differential Snap Ring Removal 1 DIFFERENT...

Page 1295: ...screwdriver in slots cast into retainer 3 Remove input gear snap ring Fig 40 Fig 36 Low Range Fork And Hub Removal 1 LOW RANGE FORK 2 FORK HUB Fig 37 Shift Sector Position 1 SHIFT SECTOR 2 LOW RANGE...

Page 1296: ...case as assembly 8 Remove oil seals from following components front bearing retainer rear retainer oil pump case halves Fig 40 Input Gear Snap Ring Removal 1 INPUT GEAR 2 SNAP RING Fig 41 Input And L...

Page 1297: ...m ASSEMBLY Lubricate transfer case components with automatic transmission fluid or petroleum jelly where indi cated during assembly CAUTION The bearing bores in various transfer case components contai...

Page 1298: ...Remove front output shaft seal using an appro priate pry tool Fig 50 or slide hammer mounted screw 5 Install new front output shaft oil seal with Installer 6952 A Fig 51 Fig 48 Front Output Shaft Fron...

Page 1299: ...drift and a hammer Fig 54 10 Install new pilot bearing with Installer 8128 and Handle C 4171 Fig 55 11 Install new seal in front bearing retainer with Installer 7884 Fig 56 12 Remove output shaft rear...

Page 1300: ...HANDLE C 4171 2 INSTALLER 8128 3 INPUT GEAR Fig 56 Front Bearing Retainer Seal Installation 1 FRONT BEARING RETAINER 2 SPECIAL TOOL 7884 Fig 57 Remove Front Output Shaft Rear Bearing 1 REAR CASE 2 SP...

Page 1301: ...using scribe marks made at disassembly 6 While holding differential case halves together invert the differential and start the differential case bolts 7 Tighten differential case bolts to specified to...

Page 1302: ...Differential Case Assembly 1 TOP CASE 2 BOTTOM CASE 3 CASE ALIGNMENT MARKS Fig 64 Low Range And Input Gear Assembly 1 THRUST WASHERS 2 LOW RANGE GEAR 3 INPUT GEAR 4 RETAINER Fig 65 Install Low Range G...

Page 1303: ...ner bolts to 16 ft lbs 21 N m torque SHIFT FORKS AND MAINSHAFT INSTALLATION 1 Install new sector shaft O ring and bushing Fig 68 2 Install shift sector 3 Install new pads on low range fork if neces sa...

Page 1304: ...ential 10 Install differential snap ring Fig 73 11 Install intermediate clutch shaft Fig 74 12 Install clutch shaft thrust washer Fig 75 13 Install clutch shaft snap ring Fig 76 14 Inspect mode fork a...

Page 1305: ...lling Intermediate Clutch Shaft 1 INTERMEDIATE CLUTCH SHAFT Fig 75 Installing Clutch Shaft Thrust Washer 1 CLUTCH SHAFT THRUST RING Fig 76 Installing Clutch Shaft Snap Ring 1 SNAP RING 2 INTERMEDIATE...

Page 1306: ...ed 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 acc...

Page 1307: ...80 Shift Rail Installation 1 SHIFT RAIL 2 MODE FORK Fig 81 Installing Low Range Fork Lockpin 1 LOW RANGE FORK LOCK PIN 2 ACCESS HOLE 3 EASY OUT Fig 82 Detent Pin Spring And Plug Installation 1 PLUNGER...

Page 1308: ...ted in case slot as shown 2 Install magnet in front case pocket Fig 86 Fig 83 Drive Chain And Sprocket Installation 1 FRONT OUTPUT SHAFT 2 DRIVE CHAIN 3 DRIVE SPROCKET Fig 84 Drive Sprocket Snap Ring...

Page 1309: ...pply liberal quantity of petroleum jelly to new rear seal and to output shaft Petroleum jelly is needed to protect seal lips during installation 8 Slide seal onto Seal Protector 6992 Fig 89 Slide seal...

Page 1310: ...place them if necessary Also replace the lock retaining ring if bent distorted or broken SHIFT FORKS HUBS SLEEVES Check condition of the shift forks and mode fork shift rail Fig 93 Minor nicks on the...

Page 1311: ...es and retainer for wear and dam age Clean the sealing surfaces with a scraper and all purpose cleaner This will ensure proper sealer adhe sion at assembly Replace the input retainer seal do not reuse...

Page 1312: ...REAR SLINGER 7 REAR BEARING O D RETAINING RING 8 REAR BEARING Fig 95 Seal Contact Surface Of Yoke Slinger 1 FRONT SLINGER PART OF YOKE 2 SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH Fig 96 Low Range...

Page 1313: ...ten adjusting trunnion lock bolt 7 Lower vehicle SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug Detent 16 24 N m 12 18 ft lbs Bolt Diff Case 17 27 N m 15 24 ft lbs Plug Drain Fill 20 25 N m 15 25 ft lb...

Page 1314: ...S NV242 Installer C 4076 B Handle Universal C 4171 Remover C 4210 Puller Slinger MD 998056 A Installer MD 998323 Installer Bearing 5064 Installer 8128 Installer 5066 Installer 6952 A 21 406 NV242 TRAN...

Page 1315: ...48 Seal Protector 6992 Installer Input Gear Bearing 7829 A Installer Seal 7884 Installer Pump Housing Seal 7888 Installer Bearing 8033 A Installer Boot Clamp C 4975 A XJ NV242 TRANSFER CASE 21 407 SPE...

Page 1316: ......

Page 1317: ...ffect on tire life than any other factor Careful drivers will obtain in most cases much greater mileage than severe use or care less drivers A few of the driving habits which will shorten the life of...

Page 1318: ...wheel speed signals when the vehicle is equipped with Anti Lock Brakes The use of tires from different manufactures on the same vehicle is NOT recommended The proper tire pressure should be maintained...

Page 1319: ...ation pressure recommendations REPLACEMENT TIRES DESCRIPTION The original equipment tires provide a proper bal ance of many characteristics such as Ride Noise Handling Durability Tread life Traction R...

Page 1320: ...e all the tire longevity benefits MATCH MOUNTING Tires and wheels are currently match mounted at the factory Match mounting is a technique used to reduce runout in the wheel tire assembly This means t...

Page 1321: ...tire b If the high spot is within 101 6 mm 4 0 in of the first spot on the wheel the wheel may be out of specifications Refer to Wheel and Tire Runout c If the high spot is NOT within 101 6 mm 4 0 in...

Page 1322: ...ore delivery of a vehicle This coating may cause deteri oration of the tires To remove the protective coating apply warm water and let it soak for a few minutes Afterwards scrub the coating away with...

Page 1323: ...uts with an enlarged nose This enlarged nose is necessary to ensure proper retention of the wheels Do not use replacement studs or nuts with a different design or lesser quality DIAGNOSIS AND TESTING...

Page 1324: ...Fig 4 STEEL WHEELS Radial runout 0 040 in Lat eral runout 0 045 in maximum ALUMINUM WHEELS Radial runout 0 030 in Lateral runout 0 035 in maximum 3 If point of greatest wheel lateral runout is near or...

Page 1325: ...t cone mounting method for steel wheels For aluminum wheel use back cone mounting method without cone spring NOTE Static should be used only when a two plane balancer is not available NOTE Cast alumin...

Page 1326: ...EIGHTS HERE 4 CORRECTIVE WEIGHT LOCATION 5 TIRE OR WHEEL TRAMP OR WHEEL HOP Fig 7 Dynamic Unbalance Balance 1 CENTER LINE OF SPINDLE 2 ADD BALANCE WEIGHTS HERE 3 CORRECTIVE WEIGHT LOCATION 4 HEAVY SPO...

Page 1327: ...SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Lug Nut 1 2 X 20 with 60 Cone 115 150 N m 85 115 ft lbs XJ TIRES AND WHEELS 22 11...

Page 1328: ......

Page 1329: ...s of glass with a plastic inner layer Windshields and other stationary glass protect the occupants from the effects of the elements Windshields are also used to retain some airbags in position during...

Page 1330: ...is repairable and adjustable for fit and finish Welded component systems are adjustable as a system Trim components made of composite are stamped with the type of material used DaimlerChrysler uses v...

Page 1331: ...result Do not use harsh alkaline based cleaning sol vents on painted or upholstered surfaces Damage to finish or color can result Do not hammer or pound on plastic trim panel when servicing interior t...

Page 1332: ...clear coat finish if equipped Base coat paint must retain clear coat for durability PAINTED SURFACE TOUCH UP DESCRIPTION When a painted metal surface has been scratched or chipped it should be touche...

Page 1333: ...7MR8B Intense Blue Pearl Coat VB3 5357 B9822 54468 CHA98 VB3 55321 HMR9B Desert Sand WTD 5474 B9884 56153 CHA99 WTD 81764 KGC7B Deep Amethyst Pearl Coat TCN 5246 B9736 52026 CHA97 TCN 54755 FNE4B Blac...

Page 1334: ...PROTECTION WHEN WORKING WITH GLASS CAUTION Protect all painted and trimmed surfaces from coming in contact with urethane or primers Be careful not to damage painted surfaces when removing moldings or...

Page 1335: ...anges and adhesive 7 Using a grease pencil or equivalent make alignment marks on the glass and body 8 Remove replacement windshield from wind shield opening 9 Position the windshield inside up on a su...

Page 1336: ...vented pressure in the interior of the vehicle may interfere with proper glass bonding 20 Install the rearview mirror INSTALLATION EXTENDED METHOD WARNING REVIEW ALL WARNINGS AND CAU TIONS IN THIS GRO...

Page 1337: ...e inside of glass Thoroughly mix and apply blackout primer to the 16 mm 5 8 in surface area around the interior side of the glass Fig 4 Allow the primer to dry for at least 10 12 min utes 9 Apply a sm...

Page 1338: ...d of sealant to the window channel in the weatherstrip seal 3 Install the weatherstrip on the window glass Install the seal installation cord in the window open ing flange channel Fig 9 as follows Moi...

Page 1339: ...0 1 in level base of ure thane on the flanges 2 Starting in the corners press reveal molding onto glass 3 Place replacement glass into liftgate opening and position glass in the center of the opening...

Page 1340: ...border 12 Position glass into liftgate opening and refer ence marks 13 Push the glass inward until the reveal mold ing is seated onto the liftgate frame Use care to avoid excessive squeeze out of adhe...

Page 1341: ...bility of replacement parts before servicing 1 Raise head restraint to the full up position 2 Turn head restraint lock thumbwheel to release head restraint and pull head restraint upward to remove fro...

Page 1342: ...aint cush ion and roll the cover downward 2 Position the adjuster bar in the head restraint 3 Install the screws attaching the bezel and adjuster bar to the head restraint 4 Install head restraint in...

Page 1343: ...cket seat from vehicle 2 Remove screws attaching the side shield trim cover from the seat 3 If equipped disengage the power seat connec tor from the power seat switch 4 Remove the nuts attaching the s...

Page 1344: ...the seatback cover on the seatback cushion and roll seatback cover down over the head restraint sleeves Route the sleeves through the access holes in the cover if equipped 2 Roll the seatback cover d...

Page 1345: ...ushion support wires 4 With the cushion side down engage the for ward rearward and inboard J straps 5 Engage the clips attaching the outboard side of the cover to the cushion frame 6 Install seatback...

Page 1346: ...lift it upward and remove it from the vehicle INSTALLATION 1 Position the seatback in the vehicle 2 Install the pivot bolts and the washer Tighten the bolts with 33 N m 25 ft lbs torque 3 Engage the...

Page 1347: ...RIKER AND BUMPER REMOVAL 1 Disengage seat cushion at the rear by pulling upward on the release strap 2 Tilt seat cushion forward 3 Release seatback latch from striker 4 Tilt seatback forward for acces...

Page 1348: ...isengage the J strap attaching the cover to the seat back frame Fig 19 5 Remove the cover from the seatback pad INSTALLATION 1 Install the cover on the seatback 2 Attach the cover J strap to the seatb...

Page 1349: ...DOOR SPACER BLOCKS TWO DOOR VEHICLES 41 FRONT DOOR GLASS 41 REAR DOOR TRIM PANEL 42 REAR DOOR WATERDAM 42 REAR DOOR 43 REAR DOOR RESTRAINT 43 REAR DOOR HINGE 43 REAR DOOR OUTSIDE HANDLE 44 REAR DOOR...

Page 1350: ...conditions as closely as possible If a leak occurs with the vehicle parked in a steady light rain flood the leak area with an open ended garden hose If a leak occurs while driving at highway speeds i...

Page 1351: ...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 b...

Page 1352: ...38 in lbs torque 5 Install nuts attaching GOP to support bracket Tighten nuts to 4 N m 38 in lbs torque 6 Install headlamps and park turn signal lamps 7 Install grille 8 Install side marker lamps 9 In...

Page 1353: ...Fig 3 Hood Components XJ BODY 23 25 REMOVAL AND INSTALLATION Continued...

Page 1354: ...screw that attaches the latch to the hood inner panel HOOD LATCH STRIKER REMOVAL 1 Remove headlamp bezel 2 Remove parklamp 3 Release the spring attaching the headlamp mounting bucket to the grille op...

Page 1355: ...d 2 Remove the nuts attaching the safety latch to the inner hood panel Fig 7 3 Separate the safety latch from the hood INSTALLATION 1 Position the safety latch on the hood 2 Install the nuts attaching...

Page 1356: ...indshield wiper arms from the pivots 2 Remove the screws that attach the grille to the cowl 3 Remove the windshield washer tubes from the nozzles 4 Remove the cowl grille and screen from the cowl Fig...

Page 1357: ...ATED AREA ONLY A decal removal solution can be used for removal at areas where a heat gun is ineffective Follow the manufacturers instructions whenever this type of product is used REMOVAL 1 Clean the...

Page 1358: ...decal 14 Using a squeegee smooth out the decal to remove wrinkles and or air bubbles 15 Inspect the decal with reflected light to find any damage Remove all the air and or moisture bub bles EXTERIOR N...

Page 1359: ...ARE REMOVAL 1 Remove the screw attaching the lower part of flare to the bottom of the fender 2 Remove the nuts attaching the fender flare retainer to the wheelhouse splash shield Fig 17 3 Remove the l...

Page 1360: ...ws attaching the fender to the body panels 4 Install the air deflector 5 Install the fender flare and retainers 6 Install the wheelhouse liner 7 Install the front bumper end cap 8 Install the wheel re...

Page 1361: ...INSTALLATION 1 Replace any broken or damaged push in fasten ers 2 Connect the power door locks windows mirrors wire harness connectors if equipped 3 Move the door trim panel outward and connect the ha...

Page 1362: ...aterdam and rapidly peel back the waterdam from the door inner panel 5 Separate the waterdam from the door inner panel INSTALLATION 1 Route the latch rods through the waterdam 2 Position the waterdam...

Page 1363: ...LLATION 1 Position hinge plates and shims on door face 2 Align door hinges and shims with bolt holes and install hinge bolts Tighten bolts to 3 N m 2 ft lbs torque 3 Adjust align latch striker and lat...

Page 1364: ...to lock cylinder rod at the door latch Fig 29 4 Remove the lock cylinder retainer clip 5 Remove the lock cylinder 6 If applicable remove the door latch to lock cyl inder rod from the original lock cy...

Page 1365: ...of striker 2 Remove screws attaching striker to B pillar Fig 31 3 Separate striker from B pillar INSTALLATION 1 Position and align striker on B pillar 2 Install screws attaching striker to B pillar Ti...

Page 1366: ...el Continue working pressing the weatherstrip into the channel along the upper window frame Press weatherstrip into lower rear corner Work press the weatherstrip upward and to the upper rear corner se...

Page 1367: ...therstrip on the A pillar Press into place FRONT DOOR GLASS EXTERIOR MOLDING REMOVAL 1 Open the window completely 2 Remove the outer belt weatherstrip 3 Pry and pull the molding sections from the door...

Page 1368: ...STALLATION 1 Position the regulator in the door and align with key hole slots 2 Attach the regulator to door inner panel with bolts Fig 38 3 Install the window glass 4 Install the waterdam 5 Install t...

Page 1369: ...Roll glass up to expose the bolts attaching the glass to the regulator 5 Remove the bolts attaching the glass to the regulator Fig 41 6 Lift the glass upward and out of the door INSTALLATION 1 Positio...

Page 1370: ...w wire harness con nectors if equipped 3 Move the door trim panel outward and connect the handle to latch rods 4 Position the trim panel on the inner belt seal and push down to seat 5 Align the locati...

Page 1371: ...rim panel REAR DOOR RESTRAINT REMOVAL 1 Remove the door trim panel 2 Remove the door restraint check retaining pin from the bracket with a punch 3 Remove the nuts and remove the restraint via the acce...

Page 1372: ...door panel 2 Connect the latch to handle rod to the handle latch release lever arm 3 Install nuts attaching the door handle to the door 4 Install the latch 5 Install the waterdam 6 Install the trim pa...

Page 1373: ...im panel 3 Separate the inside handle from the trim panel INSTALLATION 1 Position the inside handle in the trim panel 2 Heat stake the inside handle to the trim panel 3 Install the door trim panel REA...

Page 1374: ...e door panel flange Fig 54 INSTALLATION 1 Starting at the forward end of the upper mold ing force the molding onto the door panel flange and continue rearward until it is completely seated on the flan...

Page 1375: ...tor to the inner door panel 7 Disconnect the wire harness connector from the regulator drive motor if equipped 8 Remove the regulator and drive motor if equipped INSTALLATION 1 Position window regula...

Page 1376: ...Fig 60 with a heat gun 2 Lift edge of molding with a putty knife and peel molding from body panel Apply heat to any location where the molding remains adhered to a panel 3 Remove the adhesive from th...

Page 1377: ...lare to the bottom of the fender QUARTER WINDOW APPLIQUE REMOVAL 1 Remove the liftgate pillar trim 2 Remove nuts from inside vehicle Fig 62 3 Using a trim sick or equivalent carefully pry the applique...

Page 1378: ...skid strip is properly aligned 4 Press each skid strip onto roof panel with a roller or use hand pressure NOTE To prevent water leaks apply 3M Drip Chek Sealant or equivalent 5 Position luggage rack o...

Page 1379: ...ner scuff plate 6 Install the assist handles LOWER A PILLAR COWL TRIM REMOVAL 1 Remove the inner scuff plate 2 Remove the nut behind the fuse panel access door Right side only Fig 66 3 Remove the fast...

Page 1380: ...he scuff plate on the door sill 2 Install the screws attaching the door sill scuff plate to the door sill ASSIST HANDLE REMOVAL 1 Using a trim stick or equivalent open the end covers to access the scr...

Page 1381: ...TRIM REMOVAL 1 Remove the inner scuff plate 2 Remove the upper door opening trim 3 Remove the upper quarter panel trim 4 Remove the quarter panel trim extension 5 Remove the screws attaching the C pil...

Page 1382: ...ter panel trim extension 3 Remove liftgate scuff plate 4 Remove the screws attaching the quarter panel trim from the quarter panel and wheelhouse trim cover Fig 68 and Fig 65 5 If necessary remove the...

Page 1383: ...UPPER TRIM REMOVAL 1 Remove the screws attaching the liftgate open ing upper trim to the roof panel Fig 71 2 Pull downward to disengage steel clips attach ing the liftgate opening upper trim to the r...

Page 1384: ...nd install the lower anchor bolt with a Torx bit Tighten bolt to 43 N m 32 ft lbs torque 2 Position the support guide washer and shoulder belt upper anchor plate on the trim panel Install the upper an...

Page 1385: ...shoulder belt through quarter trim panel slot 5 Position shoulder belt at roof rail and install upper anchor bolt Tighten bolt to 43 N m 32 ft lbs torque 6 Install quarter trim panel 7 Install should...

Page 1386: ...r sill inner scuff plates 5 Install floor console 6 Install the front and rear seats as applicable REAR CARPET MAT REMOVAL 1 Remove the liftgate latch striker and scuff plate 2 Drill out the retaining...

Page 1387: ...e bracket contact surface after the accelerator has been applied 5 Apply adhesive accelerator to the bracket con tact surface on the windshield glass Allow the accel erator to dry for one minute Do no...

Page 1388: ...support bracket to the headliner and the roof panel HEADLINER The upper trim moldings and the headliner are attached to the roof rail with a combination of screws clip retainers and rail retainers Fi...

Page 1389: ...he retainer clips on upper liftgate opening trim and rails are installed Fig 86 3 Engage rear speaker harness connector 4 Install the upper trim moldings around the perimeter of the headliner Tighten...

Page 1390: ...klite washer fluid supply line and rear wiper and liftgate power lock wire harness grommets through access hole and separate from lift gate 7 Remove retainer clips that secure support rods to ball stu...

Page 1391: ...rod on the liftgate 2 Install the bolts attaching the support rod to the liftgate 3 Connect the support rod to the ball stud 4 Secure the support rod to the ball stud with the retainer clip 5 Remove t...

Page 1392: ...ect power lock connector to handle if equipped 3 Connect latch rod 4 Install screws attaching latch to liftgate Tighten screws to 13 N m 9 ft lbs torque 5 Install liftgate trim panel LIFTGATE LATCH ST...

Page 1393: ...he seal with a roller Move the roller the from top left half of the seal to the right bottom end of the seal ADJUSTMENTS HOOD The hood bolt holes are elongated for fore and aft and side to side adjust...

Page 1394: ...n door hinge bolts to 3 N m 2 ft lbs torque after adjustment is completed 4 Apply general purpose sealant around the door hinges door face mating area DOOR LATCH ADJUSTMENT 1 Locate access hole Fig 98...

Page 1395: ...TS COMPONENT SERVICE INTERVAL LUBRICANT Door Latches As Required Multi Purpose Grease NLGI GC LB Water Resistant 1 Hood Latch Release Mechanism Safety Latch As Required When Performing Other Underhood...

Page 1396: ...WELD LOCATIONS UPPER COWL 23 68 BODY XJ SPECIFICATIONS Continued...

Page 1397: ...UPPER COWL XJ BODY 23 69 SPECIFICATIONS Continued...

Page 1398: ...COWL 23 70 BODY XJ SPECIFICATIONS Continued...

Page 1399: ...A PILLAR XJ BODY 23 71 SPECIFICATIONS Continued...

Page 1400: ...A PILLAR 23 72 BODY XJ SPECIFICATIONS Continued...

Page 1401: ...A PILLAR XJ BODY 23 73 SPECIFICATIONS Continued...

Page 1402: ...A PILLAR 23 74 BODY XJ SPECIFICATIONS Continued...

Page 1403: ...B PILLAR XJ BODY 23 75 SPECIFICATIONS Continued...

Page 1404: ...D PILLAR 23 76 BODY XJ SPECIFICATIONS Continued...

Page 1405: ...FUEL FILLER OPENING XJ BODY 23 77 SPECIFICATIONS Continued...

Page 1406: ...CARGO AREA FLOOR PAN 23 78 BODY XJ SPECIFICATIONS Continued...

Page 1407: ...ROOF AND D PILLAR XJ BODY 23 79 SPECIFICATIONS Continued...

Page 1408: ...LIFTGATE OPENING 23 80 BODY XJ SPECIFICATIONS Continued...

Page 1409: ...ROOF XJ BODY 23 81 SPECIFICATIONS Continued...

Page 1410: ...ROOF 23 82 BODY XJ SPECIFICATIONS Continued...

Page 1411: ...FRAME RAIL XJ BODY 23 83 SPECIFICATIONS Continued...

Page 1412: ...FRAME RAIL 23 84 BODY XJ SPECIFICATIONS Continued...

Page 1413: ...FRAME RAIL XJ BODY 23 85 SPECIFICATIONS Continued...

Page 1414: ...FRAME RAIL 23 86 BODY XJ SPECIFICATIONS Continued...

Page 1415: ...REINFORCEMENT XJ BODY 23 87 SPECIFICATIONS Continued...

Page 1416: ...FRONT INNER FENDER 23 88 BODY XJ SPECIFICATIONS Continued...

Page 1417: ...FRONT INNER FENDER AND RADIATOR CLOSURE PANEL XJ BODY 23 89 SPECIFICATIONS Continued...

Page 1418: ...REINFORCEMENT 23 90 BODY XJ SPECIFICATIONS Continued...

Page 1419: ...FRONT FENDER XJ BODY 23 91 SPECIFICATIONS Continued...

Page 1420: ...BODY SIDE 23 92 BODY XJ SPECIFICATIONS Continued...

Page 1421: ...REAR WHEELHOUSE XJ BODY 23 93 SPECIFICATIONS Continued...

Page 1422: ...REAR INNER WHEELHOUSE 23 94 BODY XJ SPECIFICATIONS Continued...

Page 1423: ...BODY SIDE XJ BODY 23 95 SPECIFICATIONS Continued...

Page 1424: ...BODY SIDE 23 96 BODY XJ SPECIFICATIONS Continued...

Page 1425: ...BODY SIDE XJ BODY 23 97 SPECIFICATIONS Continued...

Page 1426: ...BODY SIDE 23 98 BODY XJ SPECIFICATIONS Continued...

Page 1427: ...BODY SIDE XJ BODY 23 99 SPECIFICATIONS Continued...

Page 1428: ...BODY SIDE 23 100 BODY XJ SPECIFICATIONS Continued...

Page 1429: ...UNDERBODY XJ BODY 23 101 SPECIFICATIONS Continued...

Page 1430: ...UNDERBODY 23 102 BODY XJ SPECIFICATIONS Continued...

Page 1431: ...UNDERBODY XJ BODY 23 103 SPECIFICATIONS Continued...

Page 1432: ...UNDERBODY 23 104 BODY XJ SPECIFICATIONS Continued...

Page 1433: ...UNDERBODY XJ BODY 23 105 SPECIFICATIONS Continued...

Page 1434: ...UNDERBODY 23 106 BODY XJ SPECIFICATIONS Continued...

Page 1435: ...UNDERBODY XJ BODY 23 107 SPECIFICATIONS Continued...

Page 1436: ...UNDERBODY 23 108 BODY XJ SPECIFICATIONS Continued...

Page 1437: ...UNDERBODY XJ BODY 23 109 SPECIFICATIONS Continued...

Page 1438: ...UNDERBODY 23 110 BODY XJ SPECIFICATIONS Continued...

Page 1439: ...UNDERBODY XJ BODY 23 111 SPECIFICATIONS Continued...

Page 1440: ...BODY SEALING LOCATIONS APPLICATION METHODS 23 112 BODY XJ SPECIFICATIONS Continued...

Page 1441: ...COWL AND DASH PANEL XJ BODY 23 113 SPECIFICATIONS Continued...

Page 1442: ...DASH PANEL AND FLOOR PAN 23 114 BODY XJ SPECIFICATIONS Continued...

Page 1443: ...FLOOR PAN XJ BODY 23 115 SPECIFICATIONS Continued...

Page 1444: ...REAR INNER WHEELHOUSE 23 116 BODY XJ SPECIFICATIONS Continued...

Page 1445: ...FRONT INNER WHEELHOUSE XJ BODY 23 117 SPECIFICATIONS Continued...

Page 1446: ...BODY SIDE 23 118 BODY XJ SPECIFICATIONS Continued...

Page 1447: ...BODY SIDE XJ BODY 23 119 SPECIFICATIONS Continued...

Page 1448: ...BODY SIDE 23 120 BODY XJ SPECIFICATIONS Continued...

Page 1449: ...ROOF PANEL XJ BODY 23 121 SPECIFICATIONS Continued...

Page 1450: ...FUEL FILLER HOUSING 23 122 BODY XJ SPECIFICATIONS Continued...

Page 1451: ...LIFTGATE OPENING XJ BODY 23 123 SPECIFICATIONS Continued...

Page 1452: ...STRUCTURAL ADHESIVE LOCATIONS LEFT QUARTER PANEL 23 124 BODY XJ SPECIFICATIONS Continued...

Page 1453: ...REAR WHEELHOUSE XJ BODY 23 125 SPECIFICATIONS Continued...

Page 1454: ...ROOF BOWS 23 126 BODY XJ SPECIFICATIONS Continued...

Page 1455: ...1 1 5 0 0 1 5 D Front Door to Fender 6 4 1 5 00 1 5 E Hood to Fender 5 6 1 5 0 5 1 5 F Headlamp to Fender 5 6 1 5 0 5 1 5 G Headlamp to Roof N A 0 74 1 0 H Grille to Hood 6 0 1 5 0 24 1 5 I Liftgate t...

Page 1456: ...BODY OPENING DIMENSIONS WINDSHIELD OPENING A B Center of radius at bottom to center of radius at top 23 128 BODY XJ SPECIFICATIONS Continued...

Page 1457: ...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 1458: ...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 1459: ...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 1460: ...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 1461: ...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 1462: ...per liftgate opening to liftgate striker mount B C Center of radius upper corner to center of radius lower corner D Distance between outer quarter panel to tail lamp mounting panel to inner quarter pa...

Page 1463: ...t Nut 4 N m 38 in lbs GOP to Fender Nut 4 N m 38 in lbs Liftgate Hinge to Body and or Liftgate Bolt 26 N m 19 ft lbs Liftgate Latch Screw 13 N m 9 ft lbs Liftgate Latch Striker Nut 54 N m 40 ft lbs Re...

Page 1464: ......

Page 1465: ...FUNCTION HIGH PRESSURE SWITCH HIGH PRESSURE CUT OFF SWITCH 16 HEATER PERFORMANCE 16 LOW PRESSURE CYCLING CLUTCH SWITCH 17 REFRIGERANT SYSTEM LEAKS 17 VACUUM SYSTEM 18 SERVICE PROCEDURES REFRIGERANT OI...

Page 1466: ...osition The blower motor battery feed circuit is protected by a fuse in the Power Distribution Center PDC Blower motor speed is controlled by regulating the ground path through the heater A C control...

Page 1467: ...a fixed displacement of 150 cubic centimeters 9 375 cubic inches and has both the suction and discharge ports located on the cylinder head A label identifying the use of R 134a refrigerant is located...

Page 1468: ...con ditioning system Therefore it is important that there are no objects placed in front of the radiator grille openings in the front of the vehicle or foreign material on the condenser fins that migh...

Page 1469: ...sure liquid refrigerant from the condenser expands into a low pressure liquid as it passes through the metering orifice and diffuser screen of the fixed orifice tube The fixed orifice tube cannot be r...

Page 1470: ...n the vehicle Refer to the owner s manual in the vehicle glove box for more information on the features use and suggested oper ation of these controls OPERATION The heater only or heater A C control p...

Page 1471: ...aporator temperature Control ling the evaporator temperature prevents condensate water on the evaporator fins from freezing and obstructing air conditioning system air flow The low pressure cycling cl...

Page 1472: ...a special tool for disengaging the two coupler halves OPERATION The spring lock coupler is held together by a garter spring inside a circular cage on the male half of the fitting Fig 5 When the two c...

Page 1473: ...VACUUM RESERVOIR DESCRIPTION The vacuum reservoir is mounted to the front bumper bar behind the passenger side bumper end cap The bumper end cap must be removed from the vehicle to access the vacuum...

Page 1474: ...cles unplug the low pressure cycling clutch switch wire harness connector from the switch located on the accumulator Fig 6 Place a jumper wire across the terminals of the low pressure cycling clutch s...

Page 1475: ...itch in this group Test the high pressure cut off switch and replace if required 7 Refer to the proper Diagnostic Procedures manual for testing of the PCM Test the PCM and replace if required Normal p...

Page 1476: ...e if required 3 See Compressor in this group Replace the compressor if required The low side pressure is too low and the high side pressure is too high 1 Restricted refrigerant flow through the refrig...

Page 1477: ...AY CIRCUIT TEST For circuit descriptions and diagrams refer to 8W 42 Air Conditioning Heater in Group 8W Wir ing Diagrams 1 The relay common feed terminal cavity 30 is connected to fused battery feed...

Page 1478: ...between the ground circuit ter minal and each of the blower motor driver circuit ter minals of the heater A C control as you move the blower motor switch knob to each of the four speed positions There...

Page 1479: ...utch circuit The following components must be checked and repaired as required before you can complete testing of the clutch coil Fuses in the junction block and the Power Dis tribution Center PDC Hea...

Page 1480: ...function high pressure switch check for continuity between terminals C and D On the two terminal switch check for continuity between both terminals of the high pressure cut off switch There should be...

Page 1481: ...in Group 8W Wir ing Diagrams 1 Disconnect and isolate the battery negative cable 2 Unplug the low pressure cycling clutch switch wire harness connector from the switch on the accu mulator fitting 3 I...

Page 1482: ...uum control system that operates perfectly at engine idle high engine vac uum may not function properly at high engine speeds or loads low engine vacuum This can be caused by leaks in the vacuum syste...

Page 1483: ...f the leaking circuit The test set gauge should return to the 27 kPa 8 in Hg setting shortly after each connection is made If OK replace the faulty disconnected component If not OK go to Step 6 6 To l...

Page 1484: ...st Actuator Full Position Yellow C Floor Actuator Brown D Defrost Actuator Mid Position Blue E Vacuum Supply Reservoir Black F Panel Actuator Red G Not Used N A Fig 11 Vacuum Circuits Heater Only 24 2...

Page 1485: ...ator Full Position Yellow C Floor Actuator Brown D Defrost Actuator Mid Position Blue E Vacuum Supply Reservoir Black F Panel Actuator Red G Recirculation Actuator Green Fig 12 Vacuum Circuits Heater...

Page 1486: ...Diagnosis and Testing section of this group for the procedures b If the refrigerant system maintains the spec ified vacuum for five minutes restart the vacuum pump open the suction and discharge valv...

Page 1487: ...ERVICE PROCEDURES REPAIRS SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSON NEL AVOID BREATHING THE REFRIGERANT AND REFRIGERANT OIL VAPOR OR MIST EXPOSURE MAY IRRITATE THE EYES NOSE AND OR THROAT W...

Page 1488: ...he refrigerant lines or tubes Refrigerant oil will absorb moisture from the atmosphere if left uncapped Do not open a con tainer of refrigerant oil until you are ready to use it Replace the cap on the...

Page 1489: ...over the refrigerant from the refrigerant system See Refrigerant Recovery in this group for the procedures 3 Unplug the wire harness connector from the low pressure cycling clutch switch 4 Loosen the...

Page 1490: ...VAL 1 If the vehicle is equipped with air conditioning recover the refrigerant from the refrigerant system See Refrigerant Recovery in this group for the proce dures 2 Disconnect and isolate the batte...

Page 1491: ...Refer to Glove Box in Group 8E Instrument Panel Systems for the procedures 7 Connect the battery negative cable 8 Test the relay operation BLOWER MOTOR RESISTOR WARNING ON VEHICLES EQUIPPED WITH AIR...

Page 1492: ...placement compressor is being installed be certain to check the refrigerant oil level See Refrigerant Oil Level in this group for the procedures Use only refrigerant oil of the type rec ommended for t...

Page 1493: ...e lip of the rotor puller Special Tool C 6141 1 into the snap ring groove exposed in the previous step and install the shaft protector Special Tool C 6141 2 Fig 23 11 Install the puller through bolts...

Page 1494: ...the nut until the pulley assembly is seated 5 Install the external front snap ring with snap ring pliers The bevel side of the snap ring must be facing outward Press the snap ring to make sure it is p...

Page 1495: ...compressor clutch has been installed cycle the compressor clutch approximately twenty times five seconds on then five seconds off During this procedure set the heater A C control to the Recirculation...

Page 1496: ...tor and the condenser from the vehicle as a unit Refer to Group 7 Cooling Sys tem for the procedures 6 Remove the two nuts that secure the condenser studs to the upper brackets of the radiator Fig 31...

Page 1497: ...a system Use only refrigerant oil of the type recommended for the com pressor in the vehicle 2 Install and tighten the high pressure switch on the discharge line fitting 3 Plug the wire harness connec...

Page 1498: ...es to install Tighten the mounting screws to 2 2 N m 20 in lbs CONSOLE REAR DUCT 1 Disconnect and isolate the battery negative cable 2 Remove the floor console from the floor panel transmission tunnel...

Page 1499: ...rifice has filter screens on the inlet and outlet ends of the tube body If the fixed orifice tube is faulty or plugged the liq uid line unit or liquid line jumper unit must be replaced See Liquid Line...

Page 1500: ...he instru ment panel and secure it with four screws Tighten the screws to 2 2 N m 20 in lbs 6 Reinstall the center bezel onto the instrument panel Refer to Instrument Panel Center Bezel in Group 8E In...

Page 1501: ...ull the heater A C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes 12 Remove the heater A C housing from the vehi cle DISASSEM...

Page 1502: ...eater core and evapo rator coil tube mounting flange of the heater A C housing 6 If the unit is equipped with air conditioning reinstall the evaporator coil tube clamp Tighten the mounting screw to 2...

Page 1503: ...COMPONENT DIAGNOSIS OR SERVICE FAILURE TO TAKE THE PROPER PRE CAUTIONS COULD RESULT IN ACCIDENTAL AIR BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY BLEND AIR DOOR 1 Remove and disassemble the heater A...

Page 1504: ...floor door lever and pull the lever out of the pivot shaft from the outside of the lower half of the heater A C housing 4 Reach inside the lower half of the heater A C housing and carefully flex the...

Page 1505: ...sed to make sure that each of the refrigerant system connections is pressure tight and leak free It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure...

Page 1506: ...hten the low pressure cycling clutch switch on the accumulator fitting The switch should be hand tightened onto the accumulator fit ting 3 Plug the wire harness connector into the low pressure cycling...

Page 1507: ...sconnect and isolate the battery negative cable 2 Remove the instrument panel assembly from the vehicle Refer to Instrument Panel Assembly in Group 8E Instrument Panel Systems for the proce dures 3 Un...

Page 1508: ...nt 4 Rotate and tilt the vacuum actuator as required to disengage the hole on the end of the actuator link from the hooked pin on the end of the panel demist door lever 5 Remove the panel demist door...

Page 1509: ...ng is not damaged a If the garter spring is missing install a new spring by pushing it into the coupler cage opening b If the garter spring is damaged remove it from the coupler cage with a small wire...

Page 1510: ...e opened refrigerant line fittings 7 Remove the suction and discharge line assem bly from the vehicle INSTALLATION 1 Remove the tape or plugs from the suction and discharge line manifold and the compr...

Page 1511: ...E Fig 58 Vacuum Reservoir Remove Install 1 VACUUM LINE 2 RESERVOIR SCREWS 3 VACUUM RESERVOIR Item Description Notes Vehicle XJ Cherokee Laredo System R134a w orifice tube Compressor Sanden SD7H15 SP 2...

Page 1512: ......

Page 1513: ...MBLY FINAL 3 47 3 85 ASSEMBLY INSTRUMENT PANEL 8E 26 ASSEMBLY SHORT BLOCK SERVICE ENGINE 9 27 9 88 ASSEMBLY TUBE AXLE 3 23 ASSIST HANDLE 23 52 AUDIO SYSTEM 8F 1 8F 2 AUDIO SYSTEM 8W 47 8W 1 AUDIO SYST...

Page 1514: ...B HEADLAMP 8L 10 BULB LICENSE PLATE LAMP 8L 12 BULB MAP READING LAMP 8L 13 BULB READING AND COURTESY LAMP 8V 8 BULB SERVICE LAMP 8L 10 BULB SIDE MARKER LAMP 8L 11 BULB UNDERHOOD LAMP 8L 12 BULB VISOR...

Page 1515: ...CER 3 27 3 74 COLUMN OPENING COVER STEERING 8E 13 COLUMN STEERING 19 26 COMBINATION FLASHER 8J 3 8J 5 COMBINATION VALVE 5 11 5 16 5 3 5 35 COMBUSTION PRESSURE LEAKAGE TEST CYLINDER 9 13 9 73 COMPASS 8...

Page 1516: ...IAGNOSIS PUMP LEAKAGE 19 7 DIAGNOSIS SERVICE 21 243 DIAGNOSIS SHOCK 2 9 DIAGNOSIS SYSTEM 8L 3 DIAGNOSIS INTRODUCTION ENGINE 9 68 9 8 DIAGNOSIS MECHANICAL SERVICE 9 10 9 70 DIAGNOSIS PERFORMANCE SERVIC...

Page 1517: ...LESS 8P 2 8P 5 EQUIPMENT REFRIGERANT SYSTEM SERVICE 24 22 EVACUATE REFRIGERANT SYSTEM 24 22 EVAP CANISTER 25 24 25 27 EVAP CANISTER PURGE SOLENOID DUTY CYCLE 25 24 25 27 EVAPORATION CONTROL SYSTEM 25...

Page 1518: ...ON 3 91 GEAR FRONT PLANETARY 21 322 GEAR GOVERNOR AND PARK 21 153 21 154 21 191 GEAR LEAKAGE POWER STEERING 19 11 GEAR NOISE 3 109 3 21 3 70 GEAR PINION 3 117 3 81 GEAR POWER STEERING 19 11 19 21 GEAR...

Page 1519: ...NPUT INTAKE MANIFOLD AIR TEMPERATURE SENSOR PCM 14 32 INPUT MANIFOLD ABSOLUTE PRESSURE MAP SENSOR PCM 14 32 INPUT OIL PRESSURE SENSOR PCM 14 33 INPUT OXYGEN SENSOR PCM 14 30 INPUT POWER STEERING PRESS...

Page 1520: ...LINE AND HOSES BRAKE 5 12 LINE COUPLER REFRIGERANT 24 45 LINE COUPLERS REFRIGERANT 24 8 LINE LIQUID 24 41 LINE POWER STEERING PRESSURE 19 5 LINE POWER STEERING RETURN 19 6 LINE SUCTION AND DISCHARGE...

Page 1521: ...DOOR GARAGE DOOR 8V 8 OPENER STORAGE BIN GARAGE DOOR 8V 3 OPENING COVER STEERING COLUMN 8E 13 OPENING DIMENSIONS BODY 23 128 OPENING PANEL GOP GRILLE 23 24 OPENING SECONDARY WEATHERSTRIP FRONT DOOR 23...

Page 1522: ...MP ALIGNMENT VEHICLE 8L 6 PREPARATION LAMP ALIGNMENT SCREEN 8L 6 PRESSURE CAP RADIATOR 7 39 7 5 PRESSURE CUT OFF SWITCH DUAL FUNCTION HIGH PRESSURE SWITCH HIGH 24 16 24 33 PRESSURE CUT OFF SWITCH HIGH...

Page 1523: ...N DRIVE 7 39 REPAIR ALUMINUM THREAD 21 144 21 249 REPAIR AUGAT CONNECTORS TERMINAL CONNECTOR 8W 11 REPAIR DAMAGED OR WORN THREADS 9 27 9 88 REPAIR PRODUCTS AFTERMARKET PAINT 23 5 REPAIR REAR GLASS HEA...

Page 1524: ...AFTS AND U JOINTS PROPELLER 3 15 SHAFTS PROPELLER 3 1 SHAFT SEALS BEARING PITMAN 19 12 SHIELDS HEAT 11 8 SHIFT INTERLOCK BRAKE TRANSMISSION 21 150 21 256 SHIFT INTERLOCK CABLE ADJUSTMENT BRAKE TRANSMI...

Page 1525: ...WER LOCK 8P 2 SWITCH POWER MIRROR 8T 1 8T 3 SWITCH POWER SEAT 8R 1 8R 2 8R 3 SWITCH POWER WINDOW 8S 1 8S 4 8S 5 SWITCH SPEED CONTROL 8H 5 SWITCH TURN SIGNAL SWITCH AND HAZARD WARNING 8J 2 8J 5 8J 6 SW...

Page 1526: ...OW HOOK FRONT 13 3 TOW HOOK REAR 13 5 TOW HOOKS EMERGENCY 0 11 TOWER SHIFT 21 47 TOWING AND HOISTING JUMP STARTING 0 9 TOWING FOUR WHEEL DRIVE VEHICLE 0 10 TOWING TWO WHEEL DRIVE VEHICLE 0 10 TPS PCM...

Page 1527: ...7 VISCOUS FAN DRIVE REMOVAL INSTALLATION 7 39 VISOR VANITY LAMP 8L 18 VISOR VANITY LAMP BULB 8L 13 VISUAL INSPECTION 14 37 VOLT SENSOR SUPPLIES PRIMARY AND SECONDARY FIVE 14 29 VOLTAGE REGULATOR ELEC...

Page 1528: ......

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