Jeep Cherokee Service Manual 2000

SERVICE MANUAL
2000
JEEP
CHEROKEE
To order the speci al servi ce tool s used and
i l l ustrated, pl ease refer to the i nstructi ons on
i nsi de back cover.
NO PART OF THI S PUBLI CATI ON MAY BE
REPRODUCED, STORED I N A RETRI EVAL
SYSTEM, OR TRANSMI TTED, I N ANY FORM OR
BY ANY MEANS, ELECTRONI C, MECHANI CAL,
PHOTOCOPYI NG, RECORDI NG, OR OTHERWI SE,
WI THOUT THE PRI OR WRI TTEN PERMI SSI ON
OF DAI MLERCHRYSLER CORPORATI ON.
DaimlerChrysler Corporation reserves the right to make changes in design or
to make additions to or improvements in its products without imposing any
obligations upon itself to install them on its products previously manufac-
tured.
FOREWORD
The i nformati on contai ned i n thi s servi ce manual has been prepared for the professi onal automoti ve tech-
ni ci an i nvol ved i n dai l y repai r operati ons. I nformati on descri bi ng the operati on and use of standard and
opti onal equi pment i s i ncl uded i n the Owners Manual provi ded wi th the vehi cl e.
I nformati on i n thi s manual i s di vi ded i nto groups. These groups contai n general i nformati on, di agnosi s,
testi ng, adjustments, removal , i nstal l ati on, di sassembl y, and assembl y procedures for the systems and compo-
nents. To assi st i n l ocati ng a group ti tl e page, use the Group Tab Locator on the fol l owi ng page. The sol i d bar
after the group ti tl e i s al i gned to a sol i d tab on the fi rst page of each group. The fi rst page of the group has
a contents secti on that l i sts major topi cs wi thi n the group. I f you are not sure whi ch Group contai ns the i nfor-
mati on you need, l ook up the Component/System i n the al phabeti cal i ndex l ocated i n the rear of thi s manual .
A Servi ce Manual Comment form i s i ncl uded at the rear of thi s manual . Use the form to provi de
Dai ml erChrysl er Corporati on wi th your comments and suggesti ons.
Ti ghteni ng torques are provi ded as a speci fi c val ue throughout thi s manual . Thi s val ue represents the
mi dpoi nt of the acceptabl e engi neeri ng torque range for a gi ven fastener appl i cati on. These torque val ues are
i ntended for use i n servi ce assembl y and i nstal l ati on procedures usi ng the correct OEM fasteners. When
repl aci ng fasteners, al ways use the same type (part number) fastener as removed.
Dai ml erChrysl er Corporati on reserves the ri ght to change testi ng procedures, speci fi cati ons, di agnosi s,
repai r methods, or vehi cl e wi ri ng at any ti me wi thout pri or noti ce or i ncurri ng obl i gati on.
GROUP TAB LOCATOR
Introduction
0
Lubrication and Maintenance
2
Suspension
3
Differential and Driveline
5
Brakes
6
Clutch
7
Cooling System
8A
Battery
8B
Starting System
8C
Charging System
8D
Ignition System
8E
Instrument Panel Systems
8F
Audio Systems
8G
Horn Systems
8H
Vehicle Speed Control System
8J
Turn Signal and Hazard Warning Systems
8K
Wiper and Washer Systems
8L
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
8T
Power Mirror Systems
8U
Chime/Buzzer Warning Systems
8V
Overhead Console Systems
8W
Wiring Diagrams
9
Engine
11
Exhaust System
13
Frame and Bumpers
14
Fuel System
19
Steering
21
Transmission and Transfer Case
22
Tires and Wheels
23
Body
24
Heating and Air Conditioning
25
Emission Control Systems
Component and System Index
Service Manual Comment Forms (Rear of Manual)
LUBRICATION AND MAINTENANCE
TABLE OF CONTENTS
page page
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . . 4
JUMP STARTING, TOWING AND HOISTING . . . . . 9
LUBRICANTS
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . 1
INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . . . 1
CLASSIFICATION OF LUBRICANTS. . . . . . . . . . . . 1
SPECIFICATIONS
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
PARTS AND LUBRICANT RECOMMENDATIONS
RECOMMENDATIONS
When servi ce i s requi red, Dai ml erChrysl er Corpo-
rati on recommends that onl y Mopar brand parts,
l ubri cants and chemi cal s be used. Mopar provi des
the best engi neered products for servi ci ng Dai ml er-
Chrysl er Corporati on vehi cl es.
INTERNATIONAL SYMBOLS
Dai ml erChrysl er Corporati on uses i nternati onal
symbol s to i denti fy engi ne compartment l ubri cant
and fl ui d i nspecti on and fi l l l ocati ons (Fi g. 1).
CLASSIFICATION OF LUBRICANTS
Onl y l ubri cants beari ng desi gnati ons defi ned by
the fol l owi ng organi zati on shoul d be used to servi ce a
Dai ml erChrysl er Corporati on vehi cl e.
Soci ety of Automoti ve Engi neers (SAE)
Ameri can Petrol eum I nsti tute (API ) (Fi g. 2)
Nati onal Lubri cati ng Grease I nsti tute (NLGI )
(Fi g. 3)
ENGINE OIL
SAE VISCOSITY RATING INDICATES ENGINE OIL VISCOSITY
An SAE vi scosi ty grade i s used to speci fy the vi s-
cosi ty of engi ne oi l . SAE 30 speci fi es a si ngl e vi scos-
i ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range.
SAE 30 = si ngl e grade engi ne oi l .
SAE 10W-30 = mul ti pl e grade engi ne oi l .
Dai ml erChrysl er Corporati on onl y recommends
mul ti pl e grade engi ne oi l s.
Fig. 1 International Symbols
XJ LUBRICATION AND MAINTENANCE 0 - 1
API QUALITY CLASSIFICATION
Thi s symbol (Fi g. 2) on the front of an oi l contai ner
means that the oi l has been certi fi ed by the Ameri -
can Petrol eum I nsti tute (API ) to meet al l the l ubri -
cati on requi rements speci fi ed by Dai l ml erChrysl er
Corporati on.
Refer to Group 9, Engi ne for gasol i ne engi ne oi l
speci fi cati on.
GEAR LUBRICANTS
SAE rati ngs al so appl y to mul ti pl e grade gear
l ubri cants. I n addi ti on, API cl assi fi cati on defi nes the
l ubri cants usage.
LUBRICANTS AND GREASES
Lubri cati ng grease i s rated for qual i ty and usage
by the NLGI . Al l approved products have the NLGI
symbol (Fi g. 3) on the l abel . At the bottom NLGI
symbol i s the usage and qual i ty i denti fi cati on l etters.
Wheel beari ng l ubri cant i s i denti fi ed by the l etter
G. Chassi s l ubri cant i s i denti fi ed by the l atter L.
The l etter fol l owi ng the usage l etter i ndi cates the
qual i ty of the l ubri cant. The fol l owi ng symbol s i ndi -
cate the hi ghest qual i ty.
Fig. 2 API Symbol
Fig. 3 NLGI Symbol
1 WHEEL BEARINGS
2 CHASSIS LUBRICATION
3 CHASSIS AND WHEEL BEARINGS
0 - 2 LUBRICATION AND MAINTENANCE XJ
SERVICE PROCEDURES (Continued)
SPECIFICATIONS
FLUID CAPACITIES
FUEL TANK
Al l . . . . . . . . . . . . . . . . . . . . . . . . 76.4 L (20.2 gal .)
ENGINE OIL W/FILTER CHANGE
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 L (4.0 qts.)
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . 5.7 L (6.0 qts.)
COOLING SYSTEM
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 L (10 qts.)*
4.0L . . . . . . . . . . . . . . . . . . . . . . . 11.4 L (12 qts.)**
*I ncl udes 2.2 L (2.3 qts) for cool ant recovery reser-
voi r.
**I ncl udes 0.9 L (1.0 qt) for cool ant recovery reser-
voi r.
AUTOMATIC TRANSMISSION
Dry fi l l capaci ty*
AW4 . . . . . . . . . . . . . . . . . . . . . . . . 7.8 L (16.5 pts.)
30RH . . . . . . . . . . . . . . . . . . . . . . . 4.67 L (9.86pts.)
*Dependi ng on type and si ze of i nternal cool er,
l ength and i nsi de di ameter of cool er l i nes, or use of an
auxi l i ary cool er, these fi gures may vary. Refer to
Group 21, Transmi ssi on for proper fl ui d fi l l procedure.
MANUAL TRANSMISSION
AX5 (4X2) . . . . . . . . . . . . . . . . . . . . 3.5 L (3.7 qts.)
AX5 (4X4) . . . . . . . . . . . . . . . . . . . . 3.3 L (3.5 qts.)
AX15 (4X2) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qts.)
AX15 (4X4) . . . . . . . . . . . . . . . . . . . 3.15 L (3.3 qts.)
TRANSFER CASE
SELEC-TRAC 242 . . . . . . . . . . . . . 1.3 L (2.85 pts.)
COMMAND-TRAC 231 . . . . . . . . . . 1.0 L (2.2 pts.)
FRONT AXLE
181FBI . . . . . . . . . . . . . . . . . . . . 1.48 L (3.13 pts.)
186FBI . . . . . . . . . . . . . . . . . . . . . . 1.18L (2.5pts.)
REAR AXLE
194RBI . . . . . . . . . . . . . . . . . . . . 1.66 L (3.5 pts.*)
8-1/4 . . . . . . . . . . . . . . . . . . . . . . 2.08 L (4.4 pts.**)
* When equi pped wi th TRAC-LOK, i ncl ude 3.5
ounces of Fri cti on Modi fi er Addi ti ve.
** When equi pped wi th TRAC-LOK, i ncl ude 4
ounces of Fri cti on Modi fi er Addi ti ve.
POWER STEERING
Power steeri ng fl ui d capaci ti es are dependent on
engi ne/chassi s opti ons as wel l as steeri ng gear/cool er
opti ons. Dependi ng on type and si ze of i nternal
cool er, l ength and i nsi de di ameter of cool er l i nes, or
use of an auxi l i ary cool er, these capaci ti es may vary.
Refer to Secti on 19 of the servi ce manual for proper
fi l l and bl eed procedures.
MAINTENANCE SCHEDULES
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNSCHEDULED INSPECTION. . . . . . . . . . . . . . . . 4
SERVICE PROCEDURES
DESCRIPTION
Servi ce and mai ntenance procedures for compo-
nents and systems l i sted i n Schedul e A or B can
be found by usi ng the Group Tab Locator i ndex at
the front of thi s manual . I f i t i s not cl ear whi ch
group contai ns the i nformati on needed, refer to the
i ndex at the back of thi s manual .
There are two mai ntenance schedul es that show
proper servi ce based on the condi ti ons that the vehi -
cl e i s subjected to.
Schedul e A, l i sts schedul ed mai ntenance to be
performed when the vehi cl e i s used for general trans-
portati on.
Schedul e B, l i sts mai ntenance i nterval s for vehi -
cl es that are operated under the condi ti ons l i sted at
the begi nni ng of that schedul e secti on.
Use the schedul e that best descri bes the dri vi ng
condi ti ons.
Where ti me and mi l eage are l i sted, fol l ow the
i nterval that occurs fi rst.
UNSCHEDULED INSPECTION
At Each Stop For Fuel
Check engi ne oi l l evel , add as requi red.
Check wi ndshi el d washer sol vent and add i f
requi red.
Once A Month
Check ti re pressure and l ook for unusual wear
or damage.
I nspect battery and cl ean and ti ghten termi nal s
as requi red. Check el ectrol yte l evel and add water as
needed.
Check fl ui d l evel s of cool ant reservoi r, power
steeri ng, brake master cyl i nder, and transmi ssi on
and add as needed.
Check al l l i ghts and al l other el ectri cal i tems for
correct operati on.
At Each Oil Change
I nspect exhaust system.
I nspect brake hoses.
Rotate the ti res at each oi l change i nterval
shown on Schedul e A (7,500 mi l es) or every other
i nterval shown on Schedul e B (6,000 mi l es).
Check cool ant l evel , hoses, and cl amps.
After compl eti on of off-road operati on, the
undersi de of the vehi cl e shoul d be thoroughl y
i nspected. Exami ne threaded fasteners for l ooseness.
EMISSION CONTROL SYSTEM MAINTENANCE
The schedul ed emi ssi on mai ntenance l i sted i n bold
type on the Mai ntenance Schedul es, must be done at
the mi l eage speci fi ed to assure the conti nued proper
functi oni ng of the emi ssi on control system. These,
and al l other mai ntenance servi ces i ncl uded i n thi s
manual , shoul d be done to provi de the best vehi cl e
performance and rel i abi l i ty. More frequent mai nte-
nance may be needed for vehi cl es i n severe operati ng
condi ti ons such as dusty areas and very short tri p
dri vi ng.
FLUID FILL LOCATIONS AND LUBRICATION
POINTS
The fl ui d fi l l /check l ocati ons and l ubri cati on poi nts
are l ocated i n each appl i cabl e group.
SCHEDULE A
7,500 Miles (12 000 km) or at 6 months
Change engi ne oi l .
Repl ace engi ne oi l fi l ter.
Lubri cate steeri ng l i nkage (4x4 onl y).
Lubri cate steeri ng l i nkage.
Lubri cate steeri ng and suspensi on bal l joi nts.
I nspect brake l i ni ngs.
Replace air cleaner element.
Replace spark plugs.
I nspect dri ve bel t, adjust tensi on as necessary.
Drai n and refi l l automati c transmi ssi on fl ui d.
Drai n and refi l l transfer case fl ui d.
Drai n and refi l l manual transmi ssi on fl ui d.
Fl ush and repl ace engi ne cool ant at 36 months,
regardl ess of mi l eage.
Fl ush and repl ace engi ne cool ant i f not done at
36 months.
Replace engine air cleaner element.
Replace ignition cables.
Fl ush and repl ace engi ne cool ant i f i t has been
30,000 mi l es (48 000 km) or 24 months si nce l ast
change.
change.
change.
change.
Important: I nspecti on and servi ce shoul d al so be
performed any ti me a mal functi on i s observed or sus-
pected.
SCHEDULE B
Fol l ow Schedul e B i f the vehi cl e i s usual l y oper-
ated under one or more of the fol l owi ng condi ti ons.
Frequent short tri ps dri vi ng l ess than 5 mi l es (8
km).
Frequent dri vi ng i n dusty condi ti ons.
Frequent trai l er towi ng.
Extensi ve i dl i ng.
More than 50% of dri vi ng i s at sustai ned hi gh
speeds duri ng hot weather, above 90F (32C).
Off-road dri vi ng.
Desert operati on.
3,000 Miles (5 000 km)
6,000 Miles (10 000 km)
9,000 Miles (14 000 km)
12,000 Miles (19 000 km)
Drai n and refi l l front and rear axl es.
15,000 Miles (24 000 km)
Inspect engine air cleaner element, replace
as necessary.
18,000 Miles (29 000 km)
21,000 Miles (34 000 km)
24,000 Miles (38 000 km)
27,000 Miles (43 000 km)
30,000 Miles (48 000 km)
33,000 Miles (53 000 km)
36,000 Miles (58 000 km)
39,000 Miles (62 000 km)
42,000 Miles (67 000 km)
45,000 Miles (72 000 km)
as necessary.
48,000 Miles (77 000 km)
51,000 Miles (82 000 km)
Fl ush and repl ace engi ne cool ant.
54,000 Miles (86 000 km)
57,000 Miles (91 000 km)
60,000 Miles (96 000 km)
63,000 Miles (101 000 km)
66,000 Miles (106 000 km)
69,000 Miles (110 000 km)
72,000 Miles (115 000 km)
75,000 Miles (120 000 km)
as necessary.
78,000 Miles (125 000 km)
81,000 Miles (130 000 km)
30,000 mi l es (48 000 km) si nce l ast change.
84,000 Miles (134 000 km)
87,000 Miles (139 000 km)
90,000 Miles (144 000 km)
93,000 Miles (149 000 km)
96,000 Miles (154 000 km)
99,000 Miles (158 000 km)
102,000 Miles (163 000 km)
105,000 Miles (168 000 km)
as necessary.
108,000 Miles (173 000 km)
111,000 Miles (178 000 km)
30,000 mi l es (48 000 km) si nce l ast change.
114,000 Miles (182 000 km)
117,000 Miles (187 000 km)
120,000 Miles (192 000 km)
Off-hi ghway operati on, trai l er towi ng, taxi , l i mou-
si ne, bus, snow pl owi ng, or other types of commerci al
servi ce or prol onged operati on wi th heavy l oadi ng,
especi al l y i n hot weather, requi re front and rear axl e
servi ce i ndi cated wi th a i n Schedul e B. Perform
these servi ces i f the vehi cl e i s usual l y operated under
these condi ti ons.
Important: I nspecti on and servi ce shoul d al so be
performed any ti me a mal functi on i s observed or sus-
pected.
J UMP STARTING, TOWING AND HOISTING
TABLE OF CONTENTS
page page
SERVICE PROCEDURES
JUMP STARTING PROCEDURE. . . . . . . . . . . . . . . 9
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . . . 10
FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . . . 10
EMERGENCY TOW HOOKS. . . . . . . . . . . . . . . . . 11
HOISTING RECOMMENDATIONS. . . . . . . . . . . . . 11
SERVICE PROCEDURES
JUMP STARTING PROCEDURE
WARNING: REVIEW ALL SAFETY PRECAUTIONS
AND WARNINGS IN GROUP 8A, BATTERY/START-
ING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT
JUMP START A FROZEN BATTERY, PERSONAL
INJURY CAN RESULT. DO NOT JUMP START WHEN
MAINTENANCE FREE BATTERY INDICATOR DOT IS
YELLOW OR BRIGHT COLOR. DO NOT JUMP
START A VEHICLE WHEN THE BATTERY FLUID IS
BELOW THE TOP OF LEAD PLATES. DO NOT
ALLOW JUMPER CABLE CLAMPS TO TOUCH
EACH OTHER WHEN CONNECTED TO A BOOSTER
SOURCE. DO NOT USE OPEN FLAME NEAR BAT-
TERY. REMOVE METALLIC JEWELRY WORN ON
HANDS OR WRISTS TO AVOID INJURY BY ACCI-
DENTAL ARCING OF BATTERY CURRENT. WHEN
USING A HIGH OUTPUT BOOSTING DEVICE, DO
NOT ALLOW BATTERY VOLTAGE TO EXCEED 16
VOLTS. REFER TO INSTRUCTIONS PROVIDED
WITH DEVICE BEING USED.
CAUTION: When using another vehicle as a
booster, do not allow vehicles to touch. Electrical
systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE:
(1) Rai se hood on di sabl ed vehi cl e and vi sual l y
i nspect engi ne compartment for:
Battery cabl e cl amp condi ti on, cl ean i f necessary.
Frozen battery.
Yel l ow or bri ght col or test i ndi cator, i f equi pped.
Low battery fl ui d l evel .
Generator dri ve bel t condi ti on and tensi on.
Fuel fumes or l eakage, correct i f necessary.
CAUTION: If the cause of starting problem on dis-
abled vehicle is severe, damage to booster vehicle
charging system can result.
(2) When usi ng another vehi cl e as a booster
source, turn off al l accessori es, pl ace gear sel ector i n
park or neutral , set park brake and operate engi ne at
1200 rpm.
(3) On di sabl ed vehi cl e, pl ace gear sel ector i n park
or neutral and set park brake. Turn off al l accesso-
ri es.
(4) Connect jumper cabl es to booster battery. RED
cl amp to posi ti ve termi nal (+). BLACK cl amp to neg-
ati ve termi nal (-). DO NOT al l ow cl amps at opposi te
end of cabl es to touch, el ectri cal arc wi l l resul t.
Revi ew al l warni ngs i n thi s procedure.
(5) On di sabl ed vehi cl e, connect RED jumper cabl e
cl amp to posi ti ve (+) termi nal . Connect BLACK
jumper cabl e cl amp to engi ne ground as cl ose to the
ground cabl e attachi ng poi nt as possi bl e (Fi g. 1).
Fig. 1 Jumper Cable ConnectionsTypical
1 POSITIVE CABLE CONNECTION
2 BOOSTER BATTERY
3 NEGATIVE OR GROUND CABLE CONNECTION
CAUTION: Do not crank starter motor on disabled
vehicle for more than 15 seconds, starter will over-
heat and could fail.
(6) Al l ow battery i n di sabl ed vehi cl e to charge to
at l east 12.4 vol ts (75% charge) before attempti ng to
start engi ne. I f engi ne does not start wi thi n 15 sec-
onds, stop cranki ng engi ne and al l ow starter to cool
(15 mi n.), before cranki ng agai n.
DISCONNECT CABLE CLAMPS AS FOLLOWS:
Di sconnect BLACK cabl e cl amp from engi ne
ground on di sabl ed vehi cl e.
When usi ng a Booster vehi cl e, di sconnect
BLACK cabl e cl amp from battery negati ve termi nal .
Di sconnect RED cabl e cl amp from battery posi ti ve
termi nal .
Di sconnect RED cabl e cl amp from battery posi -
ti ve termi nal on di sabl ed vehi cl e.
TWO-WHEEL-DRIVE VEHICLE TOWING
TOWING-REAR END LIFTED (SLING-TYPE)
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
CAUTION: Do not use steering column lock to
secure steering wheel during towing operation.
2WD XJ vehi cl es can be towed wi th the front
wheel s on the surface for extended di stances at
speeds not exceedi ng 48 km/h (30 mph). I f the vehi cl e
i s equi pped wi th a factory i nstal l ed trai l er tow pack-
age, use a SAE approved wheel l i ft devi ce.
(1) Attach J-hooks around the axl e shaft tube out-
board of the shock absorber.
(2) Pl ace the sl i ng crossbar under and forward of
the bumper.
(3) Attach safety chai ns around the frame rai l s.
(4) Turn the i gni ti on swi tch to the OFF posi ti on to
unl ock the steeri ng wheel .
(5) Secure steeri ng wheel i n the strai ght ahead
posi ti on wi th a cl amp devi ce desi gned for towi ng.
(6) Veri fy that steeri ng components are i n good
condi ti on.
(7) Shi ft the transmi ssi on to NEUTRAL.
TOWING-REAR END LIFTED (WHEEL LIFT)
(1) Rai se front of vehi cl e off ground and i nstal l tow
dol l i es under front wheel s.
(2) Attach wheel l i ft to rear wheel s.
(3) Pl ace transmi ssi on i n neutral .
(4) Rai se vehi cl e to towi ng hei ght.
(5) Pl ace transmi ssi on i n park (automati c trans-
mi ssi on) or fi st gear (manual transmi ssi on).
TOWING-FRONT END LIFTED
To prevent damage to front fasci a components, use
onl y a Wheel -Li ft type towi ng devi ce or Fl at-Bed
haul i ng equi pment.
I f usi ng the wheel -l i ft towi ng method:
(1) Rai se rear of vehi cl e off ground and i nstal l tow
dol l i es under rear wheel s.
(2) Attach wheel l i ft to front wheel s.
mi ssi on) or fi st gear (manual transmi ssi on).
FOUR-WHEEL-DRIVE VEHICLE TOWING
Dai ml erChrysl er Corporati on recommends that a
4WD vehi cl e be transported on a fl at bed devi ce. A
wheel l i ft or sl i ng type devi ce can be used provi ded
al l wheel s are l i fted off the ground usi ng tow dol l i es.
I f the vehi cl e i s equi pped wi th a factory i nstal l ed
trai l er tow package, use a SAE approved wheel l i ft
devi ce.
WARNING: WHEN TOWING A DISABLED VEHICLE
AND THE DRIVE WHEELS ARE SECURED IN A
WHEEL LIFT OR TOW DOLLIES, ENSURE THE
TRANSMISSION IS IN THE PARK POSITION (AUTO-
MATIC TRANSMISSION) OR A FORWARD DRIVE
GEAR (MANUAL TRANSMISSION).
TOWING-REAR END LIFTED (SLING TYPE)
(2) Attach J-hooks around rear axl e shaft tube out-
board of shock absorber.
(3) Pl ace sl i ng crossbar under and forward of
bumper.
(4) Attach safety chai ns around frame rai l s.
(5) Turn i gni ti on swi tch to OFF posi ti on to unl ock
steeri ng wheel .
(6) Secure steeri ng wheel i n the strai ght ahead
posi ti on wi th a cl amp devi ce desi gned for towi ng.
(7) Shi ft transfer case to neutral .
TOWING-REAR END LIFTED (WHEEL LIFT)
(2) Attach wheel l i ft to rear wheel s.
mi ssi on) or fi rst gear (manual transmi ssi on).
TOWING-FRONT END LIFTED
To prevent damage to front fasci a components, use
onl y a Wheel -Li ft type towi ng devi ce or Fl at-Bed
haul i ng equi pment.
(1) Rai se the rear of the vehi cl e off the ground and
i nstal l tow dol l i es under rear wheel s.
(2) Attach wheel l i ft to front wheel s.
mi ssi on) or fi rst gear (manual transmi ssi on).
EMERGENCY TOW HOOKS
WARNING: REMAIN AT A SAFE DISTANCE FROM A
VEHICLE THAT IS BEING TOWED VIA ITS TOW
HOOKS. THE TOW STRAPS/CHAINS COULD BREAK
AND CAUSE SERIOUS INJURY.
Some Jeep vehi cl es are equi pped wi th front and
rear emergency tow hooks. The tow hooks shoul d be
used for EMERGENCY purposes onl y.
CAUTION: DO NOT use emergency tow hooks for
tow truck hook-up or highway towing.
HOISTING RECOMMENDATIONS
Refer to the Owners Manual for emergency vehi cl e
l i fti ng procedures.
FLOOR JACK
When properl y posi ti oned, a fl oor jack can be used
to l i ft a Jeep vehi cl e (Fi g. 2) and (Fi g. 3). Support the
vehi cl e i n the rai sed posi ti on wi th jack stands at the
front and rear ends of the frame rai l s.
Fig. 2 Vehicle Lifting Locations
CAUTION: Do not attempt to lift a Jeep vehicle with
a floor jack positioned under:
An axl e tube.
A body si de si l l .
A steeri ng l i nkage component.
A dri ve shaft.
The engi ne or transmi ssi on oi l pan.
The fuel tank.
A front suspensi on arm.
NOTE: Use the correct sub-frame rail or frame rail
lifting locations only.
HOIST
A vehi cl e can be l i fted wi th:
A si ngl e-post, frame-contact hoi st.
A twi n-post, chassi s hoi st.
A ramp-type, dri ve-on hoi st.
NOTE: When a frame-contact type hoist is used,
verify that the lifting pads are positioned properly.
WARNING: THE HOISTING AND JACK LIFTING
POINTS PROVIDED ARE FOR A COMPLETE VEHI-
CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO-
NENT IS REMOVED FROM A VEHICLE, THE
CENTER OF GRAVITY IS ALTERED MAKING SOME
HOISTING CONDITIONS UNSTABLE. PROPERLY
SUPPORT OR SECURE VEHICLE TO HOISTING
DEVICE WHEN THESE CONDITIONS EXIST.
Fig. 3 Correct Vehicle Lifting Locations
1 SUB-FRAME RAIL LOCATION
2 SUB-FRAME RAIL LOCATION
SUSPENSION
TABLE OF CONTENTS
page page
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 7
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . 16
ALIGNMENT
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
SUSPENSION AND STEERING SYSTEM. . . . . . . . 3
SERVICE PROCEDURES
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WHEEL ALIGNMENT
DESCRIPTION
Wheel al i gnment i nvol ves the correct posi ti oni ng of
the wheel s i n rel ati on to the vehi cl e. The posi ti oni ng
i s accompl i shed through suspensi on and steeri ng
l i nkage adjustments. An al i gnment i s consi dered
essenti al for effi ci ent steeri ng, good di recti onal stabi l -
i ty and to mi ni mi ze ti re wear. The most i mportant
measurements of an al i gnment are caster, camber
and toe posi ti on (Fi g. 1).
CAUTION: Never attempt to modify suspension or
steering components by heating or bending.
CAUTION: Components attached with a nut and
cotter pin must be torqued to specification. Then if
the slot in the nut does not line up with the cotter
pin hole, tighten nut until it is aligned. Never loosen
the nut to align the cotter pin hole.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
OPERATION
CASTER i s the forward or rearward ti l t of the
steeri ng knuckl e from verti cal . Ti l ti ng the top of the
knuckl e rearward provi des posi ti ve caster. Ti l ti ng the
top of the knuckl e forward provi des negati ve caster.
Caster i s a di recti onal stabi l i ty angl e. Thi s angl e
enabl es the front wheel s to return to a strai ght
ahead posi ti on after turns.
CAMBER i s the i nward or outward ti l t of the
wheel rel ati ve to the center of the vehi cl e. Ti l ti ng the
top of the wheel i nward provi des negati ve camber.
Ti l ti ng the top of the wheel outward provi des posi ti ve
camber. I ncorrect camber wi l l cause wear on the
i nsi de or outsi de edge of the ti re. The angl e i s not
adjustabl e, damaged component(s) must be repl aced
to correct the camber angl e.
WHEEL TOE POSITION i s the di fference
between the l eadi ng i nsi de edges and trai l i ng i nsi de
edges of the front ti res. I ncorrect wheel toe posi ti on
i s the most common cause of unstabl e steeri ng and
uneven ti re wear. The wheel toe posi ti on i s the final
front wheel al i gnment adjustment.
STEERING AXIS INCLINATION ANGLE i s
measured i n degrees and i s the angl e that the steer-
i ng knuckl es are ti l ted. The i ncl i nati on angl e has a
fi xed rel ati onshi p wi th the camber angl e. I t wi l l not
change except when a spi ndl e or bal l stud i s dam-
aged or bent. The angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the steeri ng
axi s i ncl i nati on angl e.
XJ SUSPENSION 2 - 1
THRUST ANGLE i s the angl e of the rear axl e
rel ati ve to the centerl i ne of the vehi cl e. I ncorrect
thrust angl e can cause off-center steeri ng and exces-
si ve ti re wear. Thi s angl e i s not adjustabl e, damaged
component(s) must be repl aced to correct the thrust
angl e.
Fig. 1 Wheel Alignment Measurements
1 WHEEL CENTERLINE
2 NEGATIVE CAMBER ANGLE
3 PIVOT CENTERLINE
4 SCRUB RADIUS
5 TRUE VERTICAL
6 KING PIN
7 VERTICAL
8 POSITIVE CASTER
2 - 2 SUSPENSION XJ
DESCRIPTION AND OPERATION (Continued)
SUSPENSION AND STEERING SYSTEM
CONDITION POSSIBLE CAUSES CORRECTION
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
2. Loose or worn steering or
suspension components.
2. Tighten or replace components as
necessary.
EXCESSIVE PLAY IN
STEERING
1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Tires worn or out of balance. 3. Replace or balance tires.
4. Alignment. 4. Align vehicle to specifications.
5. Leaking steering dampener. 5. Replace steering dampener.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
necessary.
3. Tire pressure. 3. Adjust tire pressure.
EXCESSIVE STEERING
EFFORT
1. Loose or worn steering gear. 1. Adjust or replace steering gear.
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
VEHICLE PULLS TO ONE
SIDE DURING BRAKING
1. Uneven tire pressure. 1. Adjust tire pressure.
2. Worn brake components. 2. Repair brakes as necessary.
3. Air in brake line. 3. Repair as necessary.
VEHICLE LEADS OR
DRIFTS FROM STRAIGHT
AHEAD DIRECTION ON
UNCROWNED ROAD
1. Radial tire lead. 1. Cross front tires.
2. Brakes dragging. 2. Repair brake as necessary.
3. Weak or broken spring. 3. Replace spring.
4. Uneven tire pressure. 4. Adjust tire pressure.
5. Wheel Alignment. 5. Align vehicle.
6. Repair as necessary.
7. Cross caster out of spec. 7. Align vehicle.
XJ SUSPENSION 2 - 3
KNOCKING, RATTLING
OR SQUEAKING
1. Worn shock bushings. 1. Replace shock.
2. Loose, worn or bent steering/
2. Inspect, tighten or replace components
as necessary.
3. Shock valve. 3. Replace shock.
IMPROPER TRACKING 1. Loose, worn or bent track bar. 1. Inspect, tighten or replace component as
necessary.
2. Loose, worn or bent steering/
2. Inspect, tighten or replace components
as necessary.
SERVICE PROCEDURES
PRE-ALIGNMENT
Before starti ng wheel al i gnment, the fol l owi ng
i nspecti on and necessary correcti ons must be com-
pl eted. Refer to Suspensi on and Steeri ng System
Di agnosi s Chart for addi ti onal i nformati on.
(1) I nspect ti res for si ze and tread wear.
(2) Set ti re ai r pressure.
(3) I nspect front wheel beari ngs for wear.
(4) I nspect front wheel s for excessi ve radi al or l at-
eral runout and bal ance.
(5) I nspect bal l studs, l i nkage pi vot poi nts and
steeri ng gear for l ooseness, roughness or bi ndi ng.
(6) I nspect suspensi on components for wear and
noi se.
WHEEL ALIGNMENT
Before each al i gnment readi ng, the vehi cl e shoul d
be jounced (rear fi rst, then front). Grasp each
bumper at the center and jounce the vehi cl e up and
down several ti mes. Al ways rel ease the bumper i n
the down posi ti on. Set the front end al i gnment to
speci fi cati ons wi th the vehi cl e at i ts NORMAL RI DE
HEI GHT.
CAMBER
The wheel camber angl e i s preset. Thi s angl e i s not
adjustabl e and cannot be al tered.
CASTER
Before checki ng the caster of the front axl e for cor-
rect angl e, be sure the axl e i s not bent or twi sted.
Road test the vehi cl e, make l eft and ri ght turns. I f
the steeri ng wheel returns to the center posi ti on
unassi sted, the caster angl e i s correct. I f steeri ng
wheel does not return toward the center posi ti on
unassi sted, an i ncorrect caster angl e i s probabl e.
Caster can be adjusted by i nstal l i ng the appropri -
ate si ze shi ms (Fi g. 2).
NOTE: Changing caster angle will also change the
front propeller shaft angle. The propeller shaft
angle has priority over caster. Refer to Group 3 Dif-
ferential & Driveline for additional information.
TOE POSITION (LHD)
NOTE: The wheel toe position adjustment is the
final adjustment. The engine must remain running
during the entire toe position adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the wheel s. Secure the steeri ng
wheel wi th the front wheel s i n the strai ght-ahead
posi ti on.
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
3).
(3) Adjust the ri ght wheel toe posi ti on wi th the
drag l i nk. Turn the sl eeve unti l the ri ght wheel i s at
correct TOE-I N speci fi cati ons. Posi ti on the cl amp
Fig. 2 Caster Adjustment
1 SHIM
2 SUSPENSION ARM
2 - 4 SUSPENSION XJ
DIAGNOSIS AND TESTING (Continued)
bol ts as shown (Fi g. 4) and ti ghten to 49 Nm (36 ft.
l bs.).
NOTE: Make sure the toe setting does not change
during clamp tightening.
(4) Adjust the l eft wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the l eft wheel i s at speci fi -
cati ons. Posi ti on the cl amp bol ts as shown (Fi g. 4)
and ti ghten to 27 Nm (20 ft. l bs.).
(5) Veri fy the ri ght toe setti ng and turn off engi ne.
(6) Road test the vehi cl e on a fl at l evel road to ver-
i fy the steeri ng wheel i s centered.
NOTE: Once the toe setting is correct, the steering
wheel can be re-centered by adjusting only the drag
link.
TOE POSITION (RHD)
NOTE: The wheel toe position adjustment is the
final adjustment. The engine must remain running
during the entire toe position adjustment.
(1) Start the engi ne and turn wheel s both ways
before strai ghteni ng the wheel s. Secure the steeri ng
wheel wi th the front wheel s i n the strai ght-ahead
posi ti on.
(2) Loosen the adjustment sl eeve cl amp bol ts (Fi g.
5).
(3) Adjust the l eft wheel toe posi ti on wi th the drag
l i nk. Turn the sl eeve unti l the l eft wheel i s at the
correct TOE-I N speci fi cati ons. Posi ti on the cl amp
bol ts to thei r ori gi nal posi ti on and ti ghten to 49 Nm
(36 ft. l bs.).
Fig. 3 Steering Linkage (LHD)
1 PITMAN ARM
2 ADJUSTMENT SLEEVE
3 DRAG LINK
4 TIE ROD
5 STEERING DAMPENER
Fig. 4 Drag Link and Tie Rod Clamp (LHD)
1 TIE ROD CLAMP
2 DRAG LINK CLAMPS
XJ SUSPENSION 2 - 5
(4) Adjust the ri ght wheel toe posi ti on wi th the ti e
rod. Turn the sl eeve unti l the ri ght wheel i s at cor-
rect TOE-I N speci fi cati ons. Posi ti on the cl amp bol ts
to thei r ori gi nal posi ti on and ti ghten to 27 Nm (20
ft. l bs.).
(5) Veri fy the ri ght toe setti ng and turn off engi ne.
(6) Road test the vehi cl e on a fl at l evel road to ver-
i fy the steeri ng wheel i s centered.
NOTE: Once the toe setting is correct, the steering
wheel can be re-centered by adjusting only the drag
link.
SPECIFICATIONS
ALIGNMENT
NOTE: All alignment specifications are in degrees.
ANGLE PREFERRED RANGE MAX RT/LT DIFFERENCE
CASTER + 7.0 + 5.25to + 8.5 1.25
CAMBER
(fixed angle)
0.25 0.75to + 0.5 1.0
TOTAL TOE-IN + 0.25 0to + 0.45 .05
THRUST ANGLE 0 0.15
Fig. 5 Steering Linkage (RHD)
1 PITMAN ARM
2 DRAG LINK
3 STEERING DAMPNER
4 TIE ROD
5 ADJUSTMENT SLEEVE
2 - 6 SUSPENSION XJ
FRONT SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION COMPONENTS. . . . . . . . . . . . . . . . 7
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . 7
JOUNCE BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . 7
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . . . 8
LOWER SUSPENSION ARMS AND BUSHINGS . . . 8
UPPER SUSPENSION ARMS AND BUSHINGS . . . 8
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . . 9
TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HUB/BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL AND INSTALLATION
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . . 9
COIL SPRING/JOUNCE BUMPER . . . . . . . . . . . . . 9
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . . . 10
LOWER SUSPENSION ARM . . . . . . . . . . . . . . . . 10
UPPER SUSPENSION ARM . . . . . . . . . . . . . . . . . 11
FRONT AXLE BUSHING. . . . . . . . . . . . . . . . . . . . 11
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . 12
TRACK BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HUB BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WHEEL MOUNTING STUDS. . . . . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 14
SPECIAL TOOLS
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . 15
SUSPENSION COMPONENTS
The front suspensi on i s a l i nk/coi l desi gn (Fi g. 1).
Thi s suspensi on i s use on Left Hand Dri ve (LHD)
and Ri ght Hand Dri ve (RHD) vehi cl es. The suspen-
si on i s compri sed of:
Dri ve axl e (4WD), tube axl e (2WD)
Dual -acti on shock absorbers
Coi l spri ngs
Upper and l ower suspensi on arms
Stabi l i zer bar
Track bar
Jounce bumpers
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
NOTE: Periodic lubrication of the front suspension/
steering system components may be required. Rub-
ber bushings must never be lubricated. Refer to
Group 0, Lubrication And Maintenance for the rec-
ommended maintenance schedule.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bol ted to a
frame bracket. The bottom of the shocks are bol ted to
the axl e brackets.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
JOUNCE BUMPER
DESCRIPTION
The jounce bumpers are mounted under the frame
rai l i nsi de of the coi l spri ng.
OPERATION
The jounce bumpers are used to l i mi t suspensi on
travel i n compressi on.
XJ SUSPENSION 2 - 7
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The coi l spri ngs mount up i n the wheel house whi ch
i s part of the uni ti zed body bracket. A rubber dough-
nut i sol ator i s l ocated between the top of the spri ng
and the bracket. The bottom of the spri ng seats on a
axl e pad and retai ned wi th a cl i p.
OPERATION
The coi l spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght. The i sol ators provi de road noi se
i sol ati on.
LOWER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The l ower suspensi on arms are steel and use bush-
i ngs at one end of the arm. The arms mount to the
frame rai l bracket and the axl e brackets.
OPERATION
The arm and bushi ngs provi de l ocati on and react
to l oads from the axl e. The bushi ngs provi de i sol ati on
from the axl e. The l ower suspensi on arms can be
used to adjust caster and pi ni on angl e, through the
use of shi ms at the frame rai l bracket.
UPPER SUSPENSION ARMS AND BUSHINGS
DESCRIPTION
The upper suspensi on arms are steel and use rub-
ber bushi ngs at each end of the arm. The arms
mount to the frame rai l bracket and the axl e brack-
ets.
OPERATION
The arm and bushi ngs provi de l ocati on and react
to l oads from the axl e. The bushi ngs provi de i sol ati on
from the axl e.
Fig. 1 Suspension Components (LHD)
1 LINKS
2 SHOCK ABSORBER
3 UPPER SUSPENSION ARM
4 STABILIZER BAR
5 COIL SPRING
6 JOUNCE BUMPER
7 LOWER SUSPENSION ARM
8 TRACK BAR
9 AXLE
2 - 8 SUSPENSION XJ
STABILIZER BAR
DESCRIPTION
The spri ng steel bar extends across the undersi de
of the chassi s frame rai l s. Li nks are connected from
the bar to the axl e brackets. The stabi l i zer bar and
l i nks are i sol ated by rubber bushi ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l duri ng turns. The bar hel ps to control the vehi cl e
body i n rel ati onshi p to the suspensi on.
TRACK BAR
DESCRIPTION
The bar i s attached to a frame rai l bracket wi th a
bal l stud and an axl e bracket wi th a bushi ng. The
bar i s forged and has non repl aceabl e i sol ator bush-
i ng and bal l stud.
OPERATION
The track bar i s used to control front axl e l ateral
movement and provi des cross car l ocati on of the axl e
assembl y.
HUB/BEARING
DESCRIPTION
The beari ng used on the front hub of thi s vehi cl e i s
the combi ned hub and beari ng uni t type assembl y.
Thi s uni t assembl y combi nes the front wheel mount-
i ng hub (fl ange) and the front wheel beari ng i nto a
one pi ece uni t. The wheel mounti ng studs are the
onl y repl aceabl e component of the hub/beari ng
assembl y.
OPERATION
The hub/beari ng assembl y i s mounted to the steer-
i ng knuckl e and i s retai ned by three mounti ng bol ts
accessi bl e from the back of the steeri ng knuckl e. The
hub/beari ng uni t i s not servi ceabl e and must be
repl aced as an assembl y i f the beari ng or the hub i s
determi ned to be defecti ve.
SHOCK DIAGNOSIS
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The shock absorber bushi ngs do not requi re any
type of l ubri cati on. Do not attempt to stop bushi ng
noi se by l ubri cati ng them. Grease and mi neral oi l -
base l ubri cants wi l l deteri orate the bushi ng.
SHOCK ABSORBER
REMOVAL
(1) Remove the nut, retai ner and grommet from
the upper stud i n the engi ne compartment (Fi g. 2).
(2) Remove the l ower nuts and bol ts from the axl e
bracket.
(3) Remove the shock absorber.
INSTALLATION
(1) Posi ti on the l ower retai ner and grommet on the
shock stud. I nsert the shock absorber through the
shock tower hol e.
(2) I nstal l the l ower bol ts and nuts. Ti ghten nuts
to 23 Nm (17 ft. l bs.).
(3) I nstal l the upper grommet and retai ner on the
stud. I nstal l the nut and ti ghten to 22 Nm (16 ft.
l bs.).
COIL SPRING/JOUNCE BUMPER
REMOVAL
(1) Rai se and support the vehi cl e. Posi ti on a
hydraul i c jack under the axl e to support i t.
(2) Remove the wheel and ti re assembl i es.
(3) Mark and di sconnect the front propel l er shaft
from the axl e.
(4) Remove l ower suspensi on arms mounti ng nuts
and bol ts from the axl e (Fi g. 2).
(5) Remove the stabi l i zer bar l i nk and shock
absorber from the axl e.
(6) Remove the track bar from the body rai l
bracket.
(7) Remove the drag l i nk from the pi tman arm.
XJ SUSPENSION 2 - 9
(8) Lower the axl e unti l the spri ng i s free from the
upper mount. Remove the coi l spri ng cl i p and remove
the spri ng.
(9) Pul l jounce bumper out of mount.
INSTALLATION
(1) I nstal l jounce bumper i nto mount.
(2) Posi ti on the coi l spri ng on the axl e pad. I nstal l
the spri ng cl i p and bol t. Ti ghten bol t to 21 Nm (16
ft. l bs.).
(3) Rai se the axl e i nto posi ti on unti l the spri ng
seats i n the upper mount.
(4) I nstal l the stabi l i zer bar l i nks and shock
absorbers to the axl e bracket.
(5) I nstal l the track bar to the body rai l bracket.
(6) I nstal l the l ower suspensi on arms to the axl e.
I nstal l mounti ng bol ts and nuts fi nger ti ght.
(7) I nstal l the front propel l er shaft to the axl e.
(8) I nstal l the wheel and ti re assembl i es.
(9) Remove the supports and l ower the vehi cl e.
(10) Ti ghten l ower suspensi on arms nuts to 115
Nm (85 ft. l bs.).
STEERING KNUCKLE
For servi ce procedures on the steeri ng knuckl e and
bal l joi nts refer to Group 3 Di fferenti al s And Dri v-
el i ne.
LOWER SUSPENSION ARM
REMOVAL
(1) Rai se and support the vehi cl e.
(2) Remove the l ower suspensi on arm nut and bol t
from the axl e bracket.
(3) Remove the nut and bol t from the rear bracket
and remove the l ower suspensi on arm (Fi g. 3).
INSTALLATION
(1) Posi ti on the l ower suspensi on arm at the axl e
bracket and rear bracket.
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(3) Remove support and l ower the vehi cl e.
(4) Ti ghten the front and rear nuts to 115 Nm (85
ft. l bs.).
Fig. 2 Coil Spring & Shock Absorber
1 SPRING
2 SCREW
3 SPRING RETAINER
4 NUT
5 RETAINER
6 GROMMET
7 ISOLATOR
8 BUMPER
9 SPRING
10 NUT
11 SCREW
12 SHOCK ABSORBER
13 RETAINER
14 GROMMET
15 FRAME
16 CONTROL ARM
2 - 10 SUSPENSION XJ
REMOVAL AND INSTALLATION (Continued)
UPPER SUSPENSION ARM
REMOVAL
(2) Remove the upper suspensi on arm nut and bol t
at the axl e bracket.
(3) Remove the nut and bol t at the frame rai l and
remove the upper suspensi on arm (Fi g. 3).
INSTALLATION
(1) Posi ti on the upper suspensi on arm at the axl e
and frame rai l .
(2) I nstal l the bol ts and fi nger ti ghten the nuts.
(4) Ti ghten the nut at the axl e to 75 Nm (55 ft.
l bs.). Ti ghten the nut at the frame bracket to 90 Nm
(66 ft. l bs.).
FRONT AXLE BUSHING
REMOVAL
(1) Remove the upper suspensi on arm from axl e.
(2) Posi ti on Spacer 7932-3 over the axl e bushi ng
on a 4x2 vehi cl e and ri ght si de on a 4x4 vehi cl e.
(3) Pl ace Recei ver 7932-1 over fl anged end of the
bushi ng. (Fi g. 4).
(4) Pl ace smal l end of Remover/I nstal l 7932-2
agai nst other si de of the bushi ng.
(5) I nstal l bol t 7604 through remover, bushi ng and
recei ver.
(6) I nstal l Long Nut 7603 and ti ghten nut too pul l
bushi ng out of the axl e bracket.
(7) Remove nut, bol t, recei ver, remover and bush-
i ng.
NOTE: On 4x2 vehicle and right side of 4x4 vehicle,
leave Spacer 7932-3 in position for bushing instal-
lation.
INSTALLATION
(1) Pl ace Recei ver 7932-1 on the other si de of the
axl e bracket.
(2) Posi ti on new bushi ng up to the axl e bracket.,
and l arge end of Remover/I nstal l 7932-2 agai nst the
bushi ng (Fi g. 5).
(3) I nstal l bol t 7604 through recei ver, bushi ng and
i nstal l er.
(4) I nstal l Long Nut 7603 and ti ghten nut to draw
the bushi ng i nto the axl e bracket.
(5) Remove tool s and i nstal l the upper suspensi on
arm.
Fig. 3 Upper and Lower Suspension Arms
1 BOLT
2 UPPER ARM
3 NUT
4 BOLT
5 NUT
6 FRAME RAIL
7 LOWER ARM
8 NUT
9 BOLT
10 NUT
Fig. 4 Bushing Removal
1 RECEIVER
2 AXLE BRACKET
3 BOLT
4 REMOVER/INSTALLER
5 LONG NUT
XJ SUSPENSION 2 - 11
STABILIZER BAR
REMOVAL
(2) Remove nuts, retai ners and grommets from the
l i nks at the stabi l i zer bar (Fi g. 6).
(3) Remove the l i nks mounti ng nuts and bol ts
from the axl e brackets.
(4) Remove the stabi l i zer bar cl amps from the
body rai l s. Remove the stabi l i zer bar.
INSTALLATION
(1) I nspect stabi l i zer bar bushi ngs. Repl ace bush-
i ngs i f cracked, cut, di storted, or worn.
(2) Posi ti on the stabi l i zer bar on the body rai l and
i nstal l the bushi ngs and cl amps. Ensure the bar i s
centered wi th equal spaci ng on both si des. Ti ghten
the bol ts to 75 Nm (40 ft. l bs.).
(3) I nstal l the l i nks and grommets onto the stabi -
l i zer bar and axl e brackets.
(4) Ti ghten the l i nk nuts at the axl e bracket to 95
Nm (70 ft. l bs.).
(5) Ti ghten the l i nk nuts at the stabi l i zer bar to 36
Nm (27 ft. l bs.).
TRACK BAR
REMOVAL
(2) Remove the cotter pi n and nut from the bal l
stud end at the body rai l bracket.
(3) Use a uni versal pul l er tool to separate the bal l
stud from the frame rai l bracket.
(4) Remove the bol t and fl ag nut from the axl e
shaft tube bracket (Fi g. 7).
(5) Remove the track bar.
INSTALLATION
(1) I nstal l the track bar at axl e tube bracket.
Loosel y i nstal l the retai ni ng bol t and fl ag nut.
(2) I t may be necessary to pry the axl e assembl y
over to i nstal l the track bar at the body rai l . I nstal l
track bar at the body rai l bracket. I nstal l the retai n-
i ng nut on the stud.
(4) Ti ghten the retai ni ng bol t at the axl e shaft
tube bracket to 54 Nm (40 ft. l bs.).
(5) Ti ghten the bal l stud nut to 81 Nm (60 ft.
l bs.). I nstal l a new cotter pi n.
HUB BEARING
REMOVAL
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per, rotor and ABS wheel
speed sensor, refer to Group 5 Brakes.
(4) Remove the cotter pi n, nut retai ner and axl e
hub nut (Fi g. 8).
Fig. 5 Bushing Installation
1 REMOVER/INSTALLER
2 AXLE BRACKET
3 BOLT
4 RECEIVER
5 LONG NUT
Fig. 6 Stabilizer Bar (LHD)
1 RETAINER
2 GROMMET
3 BUSHING
4 CLAMP
5 STABILIZER BAR
6 LINK
(5) Remove the hub beari ng mounti ng bol ts from
the back of the steeri ng knuckl e. Remove hub bear-
i ng from the steeri ng knuckl e and off the axl e shaft.
INSTALLATION
(1) I nstal l the hub beari ng and brake dust shi el d
to the knuckl e.
(2) I nstal l the hub beari ng to knuckl e bol ts and
ti ghten to 102 Nm (75 ft. l bs.).
(3) I nstal l the hub washer and nut. Ti ghten the
hub nut to 237 Nm (175 ft. l bs.). I nstal l the nut
retai ner and a new cotter pi n.
(4) I nstal l the brake rotor, cal i per and ABS wheel
speed sensor, refer to Group 5 Brakes.
(5) I nstal l the wheel and ti re assembl y.
WHEEL MOUNTING STUDS
CAUTION: Do not use a hammer to remove wheel
studs.
REMOVAL
(1) Rai se and support vehi cl e.
(2) Remove wheel and ti re assembl y.
(3) Remove brake cal i per, cal i per adapter and
rotor, refer to Group 5 Brakes for procedure.
(4) Remove stud from hub wi th Remover C-4150A
(Fi g. 9).
INSTALLATION
(1) I nstal l new stud i nto hub fl ange.
(2) I nstal l three washers onto stud, then i nstal l
l ug nut wi th the fl at si de of the nut agai nst the
washers.
(3) Ti ghten l ug nut unti l the stud i s pul l ed i nto
the hub fl ange. Veri fy that the stud i s properl y
seated i nto the fl ange.
(4) Remove l ug nut and washers.
(5) I nstal l the brake rotor, cal i per adapter, and cal -
i per, refer to Group 5 Brakes for procedure.
(6) I nstal l wheel and ti re assembl y, use new l ug
nut on stud or studs that were repl aced.
(7) Remove support and l ower vehi cl e.
Fig. 7 Track Bar (LHD)
1 NUT
2 SUPPORT BRACKET
3 LEFT FRAME RAIL
4 STUD
5 SCREW
6 COTTER PIN
7 NUT
8 FRAME BRACKET
9 NUT PLATE
10 TRACK BAR
11 BALL STUD END
12 NUT
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Nut . . . . . . . . . . . . . . . 22 Nm (16 ft. l bs.)
Lower Nut . . . . . . . . . . . . . . . 23 Nm (17 ft. l bs.)
Suspension ArmUpper
Front Nut . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Rear Nut . . . . . . . . . . . . . . . . 89 Nm (66 ft. l bs.)
Suspension ArmLower
Front Nut . . . . . . . . . . . . . . . 115 Nm (85 ft. l bs.)
Rear Nut . . . . . . . . . . . . . . . 115 Nm (85 ft. l bs.)
Stabilizer Bar
Cl amp Bol t . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Li nk Upper Nut . . . . . . . . . . . 36 Nm (27 ft. l bs.)
Li nk Lower Nut . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Track Bar
Bal l Stud Nut . . . . . . . . . . . . 81 Nm (60 ft. l bs.)
Axl e Bracket Bol t . . . . . . . . . . 54 Nm (40 ft. l bs.)
Fig. 8 Hub Bearing & Knuckle
1 BRAKE SHIELD
2 WASHER
3 RETAINER
4 COTTER PIN
5 NUT
6 HUB AND BEARING ASSEMBLY
7 STEERING KNUCKLE
8 BOLT
9 TONE WHEEL (ABS)
Fig. 9 Wheel Stud Removal
1 REMOVER
2 WHEEL STUD
DESCRIPTION TORQUE
Track Bar Bracket
Bol ts . . . . . . . . . . . . . . . . . . 125 Nm (92 ft. l bs.)
Nut . . . . . . . . . . . . . . . . . . . 100 Nm (74 ft. l bs.)
Support Bol ts . . . . . . . . . . . . . 42 Nm (31 ft. l bs.)
Hub/Bearing
Bol ts . . . . . . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Axl e Nut . . . . . . . . . . . . . . 237 Nm (175 ft. l bs.)
SPECIAL TOOLS
FRONT SUSPENSION
Remover/Installer Suspension Bushing 7932
Nut, Long 7603
Bolt, Special 7604
Remover C-4150A
SPECIFICATIONS (Continued)
REAR SUSPENSION
TABLE OF CONTENTS
page page
SUSPENSION COMPONENT . . . . . . . . . . . . . . . . 16
SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . 16
JOUNCE BUMPERS. . . . . . . . . . . . . . . . . . . . . . . 16
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . 16
COIL SPRINGS AND ISOLATORS . . . . . . . . . . . . 16
SPRING AND SHOCK . . . . . . . . . . . . . . . . . . . . . 17
SHOCK ABSORBER. . . . . . . . . . . . . . . . . . . . . . . 17
STABILIZER BAR. . . . . . . . . . . . . . . . . . . . . . . . . 17
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LEAF SPRING AND SHACKLE BUSHING. . . . . . . 18
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 19
SUSPENSION COMPONENT
The rear suspensi on i s compri sed of:
Shock Absorbers
Jounce Bumpers
Stabi l i zer Bar (opti onal )
Leaf Spri ngs
Dri ve Axl e
CAUTION: A vehicle should always be loaded so
the vehicle weight center-line is located immedi-
ately forward of the rear axle. Correct vehicle load-
ing provides proper front tire-to-road contact. This
results in maximum vehicle handling stability and
safety. Incorrect vehicle weight distribution can
cause excessive tire tread wear, spring fatigue or
failure, and erratic steering.
CAUTION: Suspension components with rubber/
urethane bushings (except stabilizer bar) should be
tightened with the vehicle at normal ride height. It is
important to have the springs supporting the weight
of the vehicle when the fasteners are torqued. If
springs are not at their normal ride position, vehicle
ride comfort could be affected and premature bush-
ing wear may occur.
SHOCK ABSORBERS
DESCRIPTION
The top of the shock absorbers are bol ted to the
body crossmember. The bottom of the shocks are
bol ted to the axl e brackets.
OPERATION
The shock absorbers dampen jounce and rebound
moti on of the vehi cl e over vari ous road condi ti ons
and l i mi t suspensi on rebound travel .
JOUNCE BUMPERS
DESCRIPTION
The jounce bumpers are bol ted to the bottom of the
frame rai l .
OPERATION
The jounce bumpers are used to l i mi t suspensi on
travel i n compressi on.
STABILIZER BAR
DESCRIPTION
The spri ng steel bar extends across the axl e and
mounts to l eaf spri ng brackets. Li nks are connected
from the bar to the undersi de of the frame rai l . The
stabi l i zer bar and l i nks are i sol ated by rubber bush-
i ngs.
OPERATION
The stabi l i zer bar i s used to control vehi cl e body
rol l duri ng turns. The bar hel ps to control the vehi cl e
body i n rel ati onshi p to the suspensi on.
COIL SPRINGS AND ISOLATORS
DESCRIPTION
The front of the mul ti -l eaf spri ngs mount to frame
rai l brackets. The rear of the spri ng mounts to shack-
l es whi ch mount the frame. The spri ngs and shackl es
have bushi ng at the mounti ng poi nts.
OPERATION
The l eaf spri ngs control ri de qual i ty and mai ntai n
proper ri de hei ght. The shackl es al l ow the spri ngs to
change thei r l ength as the vehi cl e moves over vari ous
road condi ti ons. The bushi ngs are used to i sol ate
axl e/road noi se.
SPRING AND SHOCK
A knocki ng or rattl i ng noi se from a shock absorber
may be caused by movement between mounti ng
bushi ngs and metal brackets or attachi ng compo-
nents. These noi ses can usual l y be stopped by ti ght-
eni ng the attachi ng nuts. I f the noi se persi sts,
i nspect for damaged and worn bushi ngs, and attach-
i ng components. Repai r as necessary i f any of these
condi ti ons exi st.
A squeaki ng noi se from the shock absorber may be
caused by the hydraul i c val vi ng and may be i ntermi t-
tent. Thi s condi ti on i s not repai rabl e and the shock
absorber must be repl aced.
The shock absorbers are not refi l l abl e or adjust-
abl e. I f a mal functi on occurs, the shock absorber
must be repl aced. To test a shock absorber, hol d i t i n
an upri ght posi ti on and force the pi ston i n and out of
the cyl i nder four or fi ve ti mes. The acti on throughout
each stroke shoul d be smooth and even.
The spri ng eye and shock absorber bushi ngs do not
requi re any type of l ubri cati on. Do not attempt to
stop spri ng bushi ng noi se by l ubri cati ng them.
Grease and mi neral oi l -base l ubri cants wi l l deteri o-
rate the bushi ng rubber.
I f the vehi cl e i s used for severe, off-road operati on,
the spri ngs shoul d be exami ned peri odi cal l y. Check
for broken and shi fted l eafs, l oose and mi ssi ng cl i ps,
and broken center bol ts. Refer to Spri ng and Shock
Absorber Di agnosi s chart for addi ti onal i nformati on.
SPRING AND SHOCK ABSORBER
SPRING SAGS 1. Broken leaf. 1. Replace spring.
2. Spring fatigue. 2. Replace spring.
SPRING NOISE 1. Loose spring clamp bolts. 1. Tighten to specification.
2. Worn bushings. 2. Replace bushings.
3. Worn or missing spring tip inserts. 3. Replace spring tip inserts.
SHOCK NOISE 1. Loose mounting fastener. 1. Tighten to specification.
2. Worn bushings. 2. Replace shock.
3. Leaking shock. 3. Replace shock.
SHOCK ABSORBER
REMOVAL
(1) Remove the shock absorber upper bol ts from
the body bracket (Fi g. 1).
(2) Remove l ower attachi ng nut and washer from
the bracket stud. Remove the shock absorber.
INSTALLATION
(1) I nstal l the shock absorber l ower eye on the
spri ng bracket stud. I nstal l the shock absorber and
upper bol ts on the body bracket.
(2) Ti ghten the l ower nut to 62 Nm (46 ft. l bs.).
(3) Ti ghten the upper bol ts to 23 Nm (17 ft. l bs.).
STABILIZER BAR
REMOVAL
(2) Di sconnect stabi l i zer bar l i nks from spri ng
brackets (Fi g. 2).
(3) Di sconnect the stabi l i zer bar brackets from the
body rai l s. Remove the stabi l i zer bar and l i nks.
INSTALLATION
(1) Posi ti on the stabi l i zer bar l i nks at the spri ng
brackets. I nstal l the attachi ng bol ts and nuts and
(2) Attach the stabi l i zer bar to the body rai l brack-
ets wi th the bol ts. Ti ghten to 54 Nm (40 ft. l bs.).
LEAF SPRING
REMOVAL
(1) Rai se vehi cl e at body rai l s.
(3) Support axl e wi th hydraul i c jack to rel i eve axl e
wei ght.
(4) Di sconnect the stabi l i zer bar l i nk from the
spri ng bracket stud.
(5) Remove nuts, U-bol ts and spri ng bracket from
axl e.
(6) Remove nut and bol t attachi ng spri ng front eye
to shackl e.
(7) Remove nut and bol t from spri ng rear eye.
(8) Remove spri ng from vehi cl e.
INSTALLATION
(1) Posi ti on the spri ng front eye i n the bracket.
Loosel y i nstal l the attachi ng bol t and nut. Do not
ti ghten at thi s ti me.
(2) Posi ti on the rear eye i n the shackl e bracket.
Loosel y i nstal l the attachi ng bol t and nut. Do not
ti ghten at thi s ti me.
(3) Posi ti on the axl e. I nstal l the spri ng bracket,
U-bol ts and nuts. Ti ghten the nuts to 70 Nm (52 ft.
l bs.).
(4) Connect the stabi l i zer bar l i nk to the spri ng
bracket.
(5) Remove the hydraul i c jack.
(6) Lower the vehi cl e.
(7) Ti ghten the spri ng front eye attachi ng bol ts to
156 Nm (115 ft. l bs.).
(8) Ti ghten the spri ng rear eye attachi ng bol ts to
108 Nm (80 ft. l bs.).
(9) Ti ghten the stabi l i zer bar l i nk to 74 Nm (55 ft.
l bs.).
LEAF SPRING AND SHACKLE BUSHING
For front bushi ngs bend tabs DOWN before
removal . Use an appropri ate dri ver tool and force the
ori gi nal bushi ng out of the spri ng eye.
Fig. 1 Rear Suspension Components
1 SHOCK ABSORBER
2 SPRING BRACKET
3 NUT
4 BUSHING
5 BUMPER
6 BRACKET
7 NUT
8 RETAINER
9 SHOCK ABSORBER
10 SPRING
11 U-BOLTS
12 BUSHING
13 SHACKLE
(1) Assembl e tool s shown (Fi g. 3). Ti ghten nut at
the socket wrench end of the threaded rod unti l the
bushi ng i s forced out.
(2) Assembl e and al i gn the bushi ng i nstal l ati on
tool s.
(3) Al i gn the bushi ng wi th the spri ng eye or
shackl e eye and ti ghten the nut at the socket wrench
end of the threaded rod. Ti ghten unti l the bushi ng i s
forced i nto the spri ng eye.
NOTE: The bushing must be centered in the spring
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the
spring eye.
(4) For front bushi ngs bend tabs up after i nstal l a-
ti on.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Shock Absorber
Upper Bol t . . . . . . . . . . . . . . . 23 Nm (17 ft. l bs.)
Lower Nut . . . . . . . . . . . . . . . 62 Nm (46 ft. l bs.)
Stabilizer Bar
Cl amp Bol t . . . . . . . . . . . . . . . 54 Nm (40 ft. l bs.)
Li nk Upper Bol t . . . . . . . . . . . 12 Nm (9 ft. l bs.)
Li nk Lower Nut . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Spring
U-Bol t Nut . . . . . . . . . . . . . . . 70 Nm (52 ft. l bs.)
Front Pi vot Bol t . . . . . . . . . 156 Nm (115 ft. l bs.)
Upper Shackl e Bol t . . . . . . 156 Nm (115 ft. l bs.)
Lower Shackl e Bol t . . . . . . . 108 Nm (80 ft. l bs.)
Fig. 2 Stabilizer Bar
1 LINK
2 BUSHING
3 GROMMET
4 FRAME RAIL
5 CLAMP
6 SCREW
7 NUT
8 SPRING BRACKET
9 BOLT
10 SWAY BAR
11 SCREW
Fig. 3 Spring Eye Bushing Removal
1 NUT
2 PIPE
(RECEIVER)
3 SPRING EYE
4 NUT
5 THREADED ROD
6 FLAT WASHER
7 SOCKET WRENCH
(DRIVER)
DIFFERENTIAL AND DRIVELINE
TABLE OF CONTENTS
page page
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . 1
TUBE, 181, AND 186 FBI AXLE. . . . . . . . . . . . . . 16
194 RBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8 1/4 REAR AXLE. . . . . . . . . . . . . . . . . . . . . . . . 103
PROPELLER SHAFTS
TABLE OF CONTENTS
page page
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . . 1
PROPELLER SHAFT JOINTS. . . . . . . . . . . . . . . . . 2
PROPELLER SHAFT JOINT ANGLE. . . . . . . . . . . . 3
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE PROCEDURES
DRIVELINE ANGLE MEASUREMENT
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PROPELLER SHAFT ANGLE MEASUREMENT. . . . 6
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . . . 8
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . . . 8
DISASSEMBLY AND ASSEMBLY
SINGLE CARDAN UNIVERSAL JOINT . . . . . . . . . . 9
DOUBLE CARDAN JOINT. . . . . . . . . . . . . . . . . . . 11
CLEANING AND INSPECTION
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 14
ADJUSTMENTS
REAR AXLE PINION INPUT ANGLE . . . . . . . . . . . 15
FRONT AXLE PINION INPUT ANGLE . . . . . . . . . . 15
SPECIFICATIONS
PROPELLER SHAFTS AND UJOINTS. . . . . . . . . 15
SPECIAL TOOLS
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . . . 15
PROPELLER SHAFT
DESCRIPTION
A propel l er shaft (Fi g. 2) i s the shaft whi ch con-
nects the transmi ssi on/transfer case to the axl e di f-
ferenti al . Thi s i s the l i nk through whi ch the engi ne
power i s transmi tted to the axl e.
The propel l er shaft i s desi gned and bui l t wi th the
yoke l ugs i n l i ne wi th each other whi ch i s cal l ed zero
phasi ng. Thi s desi gn produces the smoothest runni ng
condi ti on, an out-of-phase shaft can cause a vi bra-
ti on.
Tubul ar propel l er shafts are bal anced by the man-
ufacturer wi th wei ghts spot wel ded to the tube.
PRECAUTIONS
Use the exact repl acement parts when i nstal l i ng
the propel l er shafts. The use of the correct repl ace-
ment parts hel ps to ensure safe operati on. Al l fasten-
ers must be torqued to the speci fi ed val ues for safe
operati on.
Al so make al i gnment reference marks (Fi g. 1) on
the propel l er shaft yoke and axl e, or transmi ssi on,
yoke pri or to servi ci ng. Thi s hel ps to el i mi nate possi -
bl e vi brati on.
CAUTION: Do not allow the propeller shaft to drop
or hang from any propeller shaft joint during
removal. Attach the propeller shaft to the vehicle
underside with wire to prevent damage to the joints.
OPERATION
The propel l er shaft must operate through con-
stantl y changi ng rel ati ve angl es between the trans-
mi ssi on and axl e when goi ng over vari ous road
surfaces. I t must al so be capabl e of changi ng l ength
whi l e transmi tti ng torque. The axl e ri des suspended
by spri ngs i n a fl oati ng moti on.Thi s i s accompl i shed
through uni versal joi nts, whi ch permi t the propel l er
XJ DIFFERENTIAL AND DRIVELINE 3 - 1
shaft to operate at di fferent angl es. The sl i p joi nts (or
yokes) permi t contracti on or expansi on (Fi g. 2).
Before undercoating a vehicle, the propeller
shaft and the U-joints should be covered to pre-
vent an out-of-balance condition and driveline
vibration.
CAUTION: Use original equipment replacement
parts for attaching the propeller shafts. The speci-
fied torque must always be applied when tightening
the fasteners.
PROPELLER SHAFT JOINTS
DESCRIPTION
Two di fferent types of propel l er shaft joi nts are
used:
Si ngl e cardan uni versal joi nt (Fi g. 3)
Doubl e cardan (CV) uni versal joi nt (Fi g. 4)
None of the uni versal joi nts are servi ceabl e. I f one
becomes worn or damaged, the compl ete uni versal
joi nt assembl y must be repl aced.
Fig. 2 Propeller Shafts
1 FRONT AXLE
2 FRONT PROPELLER SHAFT
3 TRANSFER CASE
4 BOOT
5 REAR AXLE
6 STRAP
7 REAR PROPELLER SHAFT
8 STRAP
Fig. 1 Reference Marks on Yokes
1 REFERENCE MARKS
3 - 2 PROPELLER SHAFTS XJ
PROPELLER SHAFT JOINT ANGLE
DESCRIPTION
When two shafts come together at a common joi nt,
the bend that i s formed i s cal l ed the operati ng angl e.
The l arger the angl e, the l arger the amount of angu-
l ar accel erati on and decel erati on of the joi nt. Thi s
speedi ng up and sl owi ng down of the joi nt must be
cancel l ed to produce a smooth power fl ow.
OPERATION
Thi s cancel l ati on i s done through the phasi ng of a
propel l er shaft and ensuri ng that the proper propel -
l er shaft joi nt worki ng angl es are mai ntai ned.
A propel l er shaft i s properl y phased when the yoke
ends are i n the same pl ane, or i n l i ne. A twi sted
shaft wi l l make the yokes out of phase and cause a
noti ceabl e vi brati on.
When taki ng propel l er shaft joi nt angl e measure-
ments, or checki ng the phasi ng, of two pi ece shafts,
consi der each shaft separatel y.
I deal l y the dri vel i ne system shoul d have;
Angl es that are equal or opposi te wi thi n 1
degree of each other.
Have a 3 degree maxi mum operati ng angl e.
Have at l east a 1/2 degree conti nuous operati ng
(propel l er shaft) angl e.
Fig. 4 Double Cardan (CV) Universal Joint
Fig. 3 Single Cardan Universal Joint
1 NEEDLE BEARING 6 BEARING CAP
2 BEARING CAP 7 RETAINING CLIP
3 SEAL 8 YOKE
4 SPIDER 9 SEAL
5 NEEDLE BEARING
XJ PROPELLER SHAFTS 3 - 3
Propel l er shaft speed (rpm) i s the mai n factor i n
determi ni ng the maxi mum al l owabl e operati ng angl e.
As a gui de to the maxi mum normal operati ng angl es
refer to (Fi g. 5).
VIBRATION
Ti res that are out-of-round, or wheel s that are
unbal anced, wi l l cause a l ow frequency vi brati on.
Refer to Group 22, Ti res and Wheel s, for addi ti onal
i nformati on.
Brake drums that are unbal anced wi l l cause a
harsh, l ow frequency vi brati on. Refer to Group 5,
Brakes, for addi ti onal i nformati on.
Dri vel i ne vi brati on can al so resul t from l oose or
damaged engi ne mounts. Refer to Group 9, Engi nes,
for addi ti onal i nformati on.
Propel l er shaft vi brati on i ncreases as the vehi cl e
speed i s i ncreased. A vi brati on that occurs wi thi n a
speci fi c speed range i s not usual l y caused by a pro-
pel l er shaft bei ng unbal anced. Defecti ve uni versal
joi nts, or an i ncorrect propel l er shaft angl e, are usu-
al l y the cause of such a vi brati on.
DRIVELINE VIBRATION
Drive Condition Possible Cause Correction
Propeller Shaft Noise 1) Undercoating or other foreign
material on shaft.
1) Clean exterior of shaft and wash
with solvent.
2) Loose U-joint clamp screws. 2) Install new clamps and screws
and tighten to proper torque.
3) Loose or bent U-joint yoke or
excessive runout.
3) Install new yoke.
4) Incorrect driveline angularity. 4) Measure and correct driveline
angles.
5) Rear spring center bolt not in
seat.
5) Loosen spring u-bolts and seat
center bolt.
6) Worn U-joint bearings. 6) Install new U-joint.
7) Propeller shaft damaged or out
of balance.
7) Installl new propeller shaft.
8) Broken rear spring. 8) Install new rear spring.
9) Excessive runout or unbalanced
condition.
9) Re-index propeller shaft, test,
and evaluate.
10) Excessive drive pinion gear
shaft runout.
10) Re-index propeller shaft and
evaluate.
11) Excessive axle yoke deflection. 11) Inspect and replace yoke if
necessary.
12) Excessive transfer case runout. 12) Inspect and repair as necessary.
Universal Joint Noise 1) Loose U-joint clamp screws. 1) Install new clamps and screws
and tighten to proper torque.
2) Lack of lubrication. 2) Replace as U-joints as
necessary.
PROPELLER SHAFT MAX. NORMAL
R.P.M. OPERATING ANGLES
5000 3
4500 3
4000 4
3500 5
3000 5
2500 7
2000 8
1500 11
Fig. 5 Maximum Angles And Propeller Shaft Speed
UNBALANCE
NOTE: Removing and re-indexing the propeller
shaft 180 relative to the yoke may eliminate some
vibrations.
I f propel l er shaft i s suspected of bei ng unbal anced,
i t can be veri fi ed wi th the fol l owi ng procedure:
(1) Rai se the vehi cl e.
(2) Cl ean al l the forei gn materi al from the propel -
l er shaft and the uni versal joi nts.
(3) I nspect the propel l er shaft for mi ssi ng bal ance
wei ghts, broken wel ds, and bent areas. If the pro-
peller shaft is bent, it must be replaced.
(4) I nspect the uni versal joi nts to ensure that they
are not worn, are properl y i nstal l ed, and are cor-
rectl y al i gned wi th the shaft.
(5) Check the uni versal joi nt cl amp screws torque.
(6) Remove the wheel s and ti res. I nstal l the wheel
l ug nuts to retai n the brake drums or rotors.
(7) Mark and number the shaft si x i nches from the
yoke end at four posi ti ons 90 apart.
(8) Run and accel erate the vehi cl e unti l vi brati on
occurs. Note the i ntensi ty and speed the vi brati on
occurred. Stop the engi ne.
(9) I nstal l a screw cl amp at posi ti on 1 (Fi g. 6).
(10) Start the engi ne and re-check for vi brati on. I f
there i s l i ttl e or no change i n vi brati on, move the
cl amp to one of the other three posi ti ons. Repeat the
vi brati on test.
(11) I f there i s no di fference i n vi brati on at the
other posi ti ons, the source of the vi brati on may not
be propel l er shaft.
(12) I f the vi brati on decreased, i nstal l a second
cl amp (Fi g. 7) and repeat the test.
(13) I f the addi ti onal cl amp causes an addi ti onal
vi brati on, separate the cl amps (1/4 i nch above and
bel ow the mark). Repeat the vi brati on test (Fi g. 8).
(14) I ncrease di stance between the cl amp screws
and repeat the test unti l the amount of vi brati on i s
at the l owest l evel . Bend the sl ack end of the cl amps
so the screws wi l l not l oosen.
(15) I f the vi brati on remai ns unacceptabl e, appl y
the same steps to the front end of the propel l er shaft.
(16) I nstal l the wheel and ti res. Lower the vehi cl e.
RUNOUT
(1) Remove di rt, rust, pai nt, and undercoati ng
from the propel l er shaft surface where the di al i ndi -
cator wi l l contact the shaft.
(2) The di al i ndi cator must be i nstal l ed perpendi c-
ul ar to the shaft surface.
(3) Measure runout at the center and ends of the
shaft suffi ci entl y far away from wel d areas to ensure
that the effects of the wel d process wi l l not enter i nto
the measurements.
Fig. 6 Clamp Screw At Position 1
1 CLAMP
2 SCREWDRIVER
Fig. 7 Two Clamp Screws At The Same Position
Fig. 8 Clamp Screws Separated
1
1
2 INCH
(4) Refer to Runout Speci fi cati ons chart.
(5) I f the propel l er shaft runout i s out of speci fi ca-
ti on, remove the propel l er shaft, i ndex the shaft 180,
and re-i nstal l the propel l er shaft. Measure shaft
runout agai n.
(6) I f the propel l er shaft runout i s now wi thi n
speci fi cati ons, mark the shaft and yokes for proper
ori entati on.
(7) I f the propel l er shaft runout i s not wi thi n spec-
i fi cati ons, veri fy that the runout of the transmi ssi on/
transfer case and axl e are wi thi n speci fi cati ons.
Correct as necessary and re-measure propel l er shaft
runout.
(8) Repl ace the propel l er shaft i f the runout sti l l
exceeds the l i mi ts.
SERVICE PROCEDURES
PREPARATION
Before measuri ng uni versal joi nt angl es, the fol -
l owi ng must be done;
I nfl ate al l ti res to correct pressure.
Check the angl es i n the same l oaded or
unl oaded condi ti on as when the vi brati on occurred.
Propel l er shaft angl es change accordi ng to the
amount of l oad i n the vehi cl e.
Check the condi ti on of al l suspensi on compo-
nents and veri fy al l fasteners are torqued to speci fi -
cati ons.
Check the condi ti on of the engi ne and transmi s-
si on mounts and veri fy al l fasteners are torqued to
speci fi cati ons.
PROPELLER SHAFT ANGLE MEASUREMENT
To accuratel y check dri vel i ne al i gnment, rai se and
support the vehi cl e at the axl es as l evel as possi bl e.
Al l ow the wheel s and propel l er shaft to turn.
(1) Remove any external beari ng snap ri ngs, i f
equi pped, from uni versal joi nt so protractor base si ts
fl at.
(2) Rotate the shaft unti l transmi ssi on/transfer
case output yoke beari ng i s faci ng downward.
Always make measurements from front to
rear. Also, be sure to take all measurements
while working from the same side of the vehi-
cle.
(3) Pl ace I ncl i nometer on yoke beari ng (A) paral l el
to the shaft (Fi g. 9). Center bubbl e i n si ght gl ass and
record measurement.
This measurement will give you the transmis-
sion or Output Yoke Angle (A).
(4) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on yoke beari ng paral l el to the shaft
(Fi g. 10). Center bubbl e i n si ght gl ass and record
measurement. Thi s measurement can al so be taken
at the rear end of the shaft.
This measurement will give you the Propeller
Shaft Angle (C).
(5) Subtract smal l er fi gure from l arger (C mi nus
A) to obtai n Transmi ssi on Output Operati ng Angl e.
(6) Rotate propel l er shaft 90 degrees and pl ace
I ncl i nometer on pi ni on yoke beari ng paral l el to the
shaft (Fi g. 11). Center bubbl e i n si ght gl ass and
record measurement.
RUNOUT SPECIFICATIONS
Front of Shaft 0.020 in. (0.50 mm)
Center of Shaft 0.025 in. (0.63 mm)
Rear of Shaft 0.020 in. (0.50 mm)
Measure front/rear runout approximately 3 inches
(76 mm) from the weld seam at each end of the shaft
tube for tube lengths over 30 inches. For tube lengths
under 30 inches, the maximum allowed runout is
0.020 in. (0.50 mm) for the full length of the tube.
Fig. 9 Front (Output) Angle Measurement (A)
1 SLIP YOKE BEARING CAP
2 SPECIAL TOOL 7663 (J-23498A)
This measurement will give you the pinion
shaft or Input Yoke Angle (B).
(7) Subtract smal l er fi gure from l arger (C mi nus
B) to obtai n axl e I nput Operati ng Angl e.
Refer to rul es gi ven bel ow and the exampl e i n
(Fi g. 12) for addi ti onal i nformati on.
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 4.9Angle (C)
2 3.2Angle (B)
3 Input Yoke
4 3.0Angle (A)
5 Output Yoke
Fig. 10 Propeller Shaft Angle Measurement (C)
1 SHAFT YOKE BEARING CAP
2 SPECIAL TOOL 7663 (J23498A)
Good cancel l ati on of Ujoi nt operati ng angl es
(wi thi n 1).
Operati ng angl es l ess than 3.
At l east 1/2 of one degree conti nuous operati ng
(propel l er shaft) angl e.
FRONT PROPELLER SHAFT
REMOVAL
(1) Hoi st and support vehi cl e on safety stands.
(2) Remove the crossmember/ski d pl ate as neces-
sary to gai n access to the propel l er shaft.
(3) Shi ft the transmi ssi on and transfer case, i f nec-
essary, i nto the Neutral posi ti on.
(4) Usi ng a sui tabl e marker, mark a l i ne across
the yoke at the transfer case, the l i nk yoke, and pro-
pel l er shaft yoke at the rear of the front propel l er
shaft for i nstal l ati on reference (Fi g. 13).
(5) Mark a l i ne across the propel l er shaft yoke and
the pi ni on shaft yoke for i nstal l ati on reference.
(6) Remove the U-joi nt strap bol ts at the pi ni on
shaft yoke (Fi g. 14).
(7) Remove bol ts hol di ng rear uni versal joi nt to
the transfer case yoke.
(8) Separate the rear uni versal joi nt from the
transfer case yoke.
(9) Push rear of propel l er shaft upward to cl ear
transfer case yoke.
(10) Separate front uni versal joi nt from front axl e.
(11) Separate propel l er shaft from vehi cl e.
INSTALLATION
(1) Posi ti on front propel l er shaft under vehi cl e
wi th rear uni versal joi nt over the transfer case yoke.
(2) Pl ace front uni versal joi nt i nto the axl e pi ni on
yoke.
(3) Al i gn mark on the rear l i nk yoke and uni versal
joi nt to the mark on the transfer case yoke (Fi g. 13).
(4) Loosel y i nstal l bol ts to hol d uni versal joi nt to
transfer case yoke.
(5) Al i gn mark on front uni versal joi nt to the mark
on the axl e pi ni on yoke.
(6) Ti ghten the U-joi nt strap/cl amp bol ts at the
axl e yoke to 19 Nm (14 ft. l bs.) torque.
(7) Ti ghten the uni versal joi nt to transfer case
bol ts to 27 Nm (20 ft. l bs.) torque.
REAR PROPELLER SHAFT
REMOVAL
(1) Shi ft the transmi ssi on and transfer case i nto
Neutral .
(3) Scri be al i gnment marks at the pi ni on shaft and
at each end of the propel l er shaft. These marks wi l l
be used for i nstal l ati on reference.
(4) Remove the U-joi nt strap bol ts at the pi ni on
shaft yoke.
(5) Pry open cl amp hol di ng the dust boot to propel -
l er shaft yoke (Fi g. 15).
(6) Sl i de the sl i p yoke off of the transmi ssi on/
transfer case output shaft and remove the propel l er
shaft (Fi g. 16).
Fig. 13 Reference Marks on Yokes
1 REFERENCE MARKS
Fig. 14 Front Propeller Shaft
1 FRONT AXLE
2 BOOT
3 PROPELLER SHAFT
4 CV-JOINT
5 TRANSFER CASE
6 BOOT
7 SLINGER
8 CLAMP
9 YOKE
INSTALLATION
(1) Sl i de the sl i p yoke on the transmi ssi on/transfer
case output shaft. Al i gn the i nstal l ati on reference
marks at the axl e yoke and i nstal l the propel l er shaft
(Fi g. 16).
(2) Ti ghten the U-joi nt strap/cl amp bol ts at the
axl e yoke to 19 Nm (14 ft. l bs.) torque.
(3) Cri mp cl amp to hol d dust boot to propel l er
shaft yoke (Fi g. 17).
SINGLE CARDAN UNIVERSAL JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
repl aced as an assembl y.
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
(3) Remove snap ri ngs from both si des of yoke
(Fi g. 18).
Fig. 15 Dust Boot Clamp
1 SLINGER
2 BOOT
3 AWL
4 TRANSFER CASE
Fig. 16 Rear Propeller Shaft
1 CLAMP
2 YOKE
3 PROPELLER SHAFT
4 AXLE YOKE
5 CLAMP
6 OUTPUT SHAFT
7 BOOT
Fig. 17 Crimping Dust Boot Clamp
1 SPECIAL TOOL C-4975A
2 SLINGER
3 BOOT
4 CLAMP
Fig. 18 Remove Snap Ring
1 SNAP RING
(4) Set the yoke i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the yoke.
(5) Posi ti on the yoke wi th the grease fi tti ng, i f
equi pped, poi nti ng up.
(6) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and press the cap through the yoke to
rel ease the l ower beari ng cap (Fi g. 19).
(7) I f the beari ng cap wi l l not pul l out of the yoke
by hand after pressi ng, tap the yoke ear near the
beari ng cap to di sl odge the cap.
(8) To remove the opposi te beari ng cap, turn the
yoke over and strai ghten the cross i n the open hol e.
Then, careful l y press the end of the cross unti l the
remai ni ng beari ng cap can be removed (Fi g. 20).
CAUTION: If the cross or bearing cap are not
straight during installation, the bearing cap will
score the walls of the yoke bore and damage can
occur.
ASSEMBLY
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Posi ti on the cross i n the yoke wi th i ts l ube fi t-
ti ng, i f equi pped, poi nti ng up (Fi g. 21).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 22). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
Fig. 19 Press Out Bearing
1 PRESS
2 SOCKET
Fig. 20 Press Out Remaining Bearing
1 CROSS
2 BEARING CAP
Fig. 21 Install Cross In Yoke
1 CROSS
2 YOKE
DISASSEMBLY AND ASSEMBLY (Continued)
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng.
(5) I nstal l a snap ri ng.
(6) Repeat Step 3 and Step 4to i nstal l the opposi te
beari ng cap. I f the joi nt i s sti ff or bi ndi ng, stri ke the
yoke wi th a soft hammer to seat the needl e beari ngs.
(7) Add grease to l ube fi tti ng, i f equi pped.
(8) I nstal l the propel l er shaft.
DOUBLE CARDAN JOINT
DISASSEMBLY
I ndi vi dual components of cardan uni versal joi nts
are not servi ceabl e. I f worn or l eaki ng, they must be
(1) Remove the propel l er shaft.
(2) Usi ng a soft dri ft, tap the outsi de of the bear-
i ng cap assembl y to l oosen snap ri ng.
(3) Remove al l the beari ng cap snap ri ngs (Fi g. 23).
(4) Set the joi nt i n an arbor press or vi se wi th a
socket whose i nsi de di ameter i s l arge enough to
recei ve the beari ng cap posi ti oned beneath the l i nk
yoke.
(5) Pl ace a socket wi th an outsi de di ameter
smal l er than the upper beari ng cap on the upper
beari ng cap and parti al l y press one beari ng cap from
the outboard si de of the l i nk yoke enough to grasp
the beari ng cap wi th vi se jaws (Fi g. 24). Be sure to
remove grease fi tti ngs that i nterfere wi th removal .
(6) Grasp the protrudi ng beari ng by vi se jaws. Tap
the l i nk yoke wi th a mal l et and dri ft to di sl odge the
beari ng cap from the yoke (Fi g. 25).
(7) Fl i p assembl y and repeat Step 4, Step 5, and
Step 6 to remove the opposi te beari ng cap. Thi s wi l l
then al l ow removal of the cross centeri ng ki t assem-
bl y and spri ng (Fi g. 26).
(8) Press the remai ni ng beari ng caps out the other
end of the l i nk yoke as descri bed above to compl ete
the di sassembl y.
Fig. 22 Install Bearing On Trunnion
1 BEARING CAP
2 TRUNNION
Fig. 23 Remove Snap Rings
Fig. 24 Press Out Bearing
ASSEMBLY
During assembly, ensure that the alignment
marks on the link yoke and propeller shaft
yoke are aligned.
(1) Appl y extreme pressure (EP) N.L.G.I . Grade 1
or 2 grease to i nsi de of yoke bores to ai d i n i nstal l a-
ti on.
(2) Fi t a cross i nto the propel l er shaft yoke (Fi g. 27).
(3) Pl ace a beari ng cap over the trunni on and
al i gn the cap wi th the yoke bore (Fi g. 28). Keep the
needl e beari ngs upri ght i n the beari ng assembl y. A
needl e beari ng l yi ng at the bottom of the cap wi l l
prevent proper assembl y.
(4) Press the beari ng cap i nto the yoke bore
enough to i nstal l a snap ri ng (Fi g. 29).
(5) I nstal l a snap ri ng.
Fig. 25 Remove Bearing From Yoke
Fig. 26 Remove Centering Kit
Fig. 27 Install Cross In Yoke
Fig. 28 Install Bearing Cap
(6) Fl i p the propel l er shaft yoke and i nstal l the
beari ng cap onto the opposi te trunni on. I nstal l a
snap ri ng (Fi g. 30).
(7) Fi t the l i nk yoke on the remai ni ng two trun-
ni ons and press both beari ng caps i nto pl ace (Fi g.
31).
(8) I nstal l snap ri ngs.
(9) I nstal l the centeri ng ki t assembl y i nsi de the
l i nk yoke maki ng sure the spri ng i s properl y posi -
ti oned (Fi g. 32).
Fig. 29 Press In Bearing Cap
Fig. 31 Install Link Yoke
Fig. 32 Install Centering Kit
(10) Pl ace two beari ng caps on opposi te trunni ons
of the remai ni ng cross. Fi t the open trunni ons i nto
the l i nk yoke bores and the beari ng caps i nto the
centeri ng ki t (Fi g. 33).
(11) Press the remai ni ng two beari ng caps i nto
pl ace and i nstal l snap ri ngs (Fi g. 34).
(12) Tap the snap ri ngs to al l ow them to seat i nto
the grooves (Fi g. 35).
(13) Check for proper assembl y. Fl ex the joi nt
beyond center, i t shoul d snap over-center i n both
di recti ons when correctl y assembl ed (Fi g. 36).
(14) I nstal l the propel l er shaft.
PROPELLER SHAFT
(1) Cl ean al l uni versal joi nt bores wi th cl eani ng
sol vent and a wi re brush.
(2) I nspect the yokes for di storti on, cracks, and
worn beari ng cap bores.
Fig. 33 Install Remaining Cross
Fig. 35 Seat Snap Rings In Groove
Fig. 36 Check Assembly
ADJ USTMENTS
REAR AXLE PINION INPUT ANGLE
Adjust the rear axl e pi ni on i nput angl e on vehi cl es
equi pped wi th l eaf spri ngs wi th tapered shi ms (Fi g.
37). I nstal l tapered shi ms between the spri ngs and
axl e pad to correct the angl e. Refer to Group 2, Sus-
pensi on, for addi ti onal i nformati on.
FRONT AXLE PINION INPUT ANGLE
Adjust the front axl e pi ni on i nput angl e at the
l ower suspensi on arms wi th shi ms (Fi g. 38). Addi ng
shi ms wi l l decrease the pi ni on shaft angl e but wi l l
al so i ncrease the caster angl e. The pi ni on shaft angl e
has pri ori ty over the caster angl e. Refer to Group 2,
Suspensi on, for addi ti onal i nformati on.
SPECIFICATIONS
PROPELLER SHAFTS AND UJOINTS
DESCRIPTION TORQUE
Bol ts, Transfer Case Yoke . . . . . 27 Nm (20 ft. l bs.)
Bol ts, Axl e Yoke . . . . . . . . . . . . . 19 Nm (14 ft. l bs.)
Bol ts, Axl e Yoke . . . . . . . . . . . . . 19 Nm (14 ft. l bs.)
SPECIAL TOOLS
PROPELLER SHAFT
Fig. 37 Pinion Angle Adjustment at Leaf Springs
1 WEDGE
Fig. 38 Front Axle Angle Adjustment
1 SHIM
2 SUSPENSION ARM
Inclinometer7663
Boot Clamp InstallerC-4975-A
TUBE, 181, AND 186 FBI AXLE
TABLE OF CONTENTS
page page
181 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
186 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
STANDARD DIFFERENTIAL. . . . . . . . . . . . . . . . . 18
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 19
GEAR NOISE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 21
LOW SPEED KNOCK. . . . . . . . . . . . . . . . . . . . . . 21
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 21
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . . . 22
TUBE AXLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . 23
AXLE SHAFTCARDAN U-JOINT . . . . . . . . . . . . 23
181 FBI PINION SHAFT SEAL . . . . . . . . . . . . . . . 24
186 FBI PINION SHAFT SEAL . . . . . . . . . . . . . . . 26
COLLAPSIBLE SPACER. . . . . . . . . . . . . . . . . . . . 27
HUB BEARING AND AXLE SHAFT . . . . . . . . . . . . 30
STEERING KNUCKLE AND BALL STUDS. . . . . . . 31
AXLE BUSHING REPLACEMENT. . . . . . . . . . . . . 33
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIFFERENTIAL SIDE BEARINGS. . . . . . . . . . . . . 36
AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . . . . 36
181 FBI PINION . . . . . . . . . . . . . . . . . . . . . . . . . . 36
186 FBI PINION . . . . . . . . . . . . . . . . . . . . . . . . . . 41
RING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 47
CARDAN U-JOINT . . . . . . . . . . . . . . . . . . . . . . . . 47
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 47
ADJUSTMENTS
181 FBI PINION GEAR DEPTH. . . . . . . . . . . . . . . 48
186 FBI PINION GEAR DEPTH. . . . . . . . . . . . . . . 50
181 FBI DIFFERENTIAL BEARING PRELOAD
AND GEAR BACKLASH . . . . . . . . . . . . . . . . . . 52
AND GEAR BACKLASH . . . . . . . . . . . . . . . . . . 56
GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 59
SPECIFICATIONS
181 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
186 FBI AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SPECIAL TOOLS
181 and 186 FBI AXLE . . . . . . . . . . . . . . . . . . . . . 61
181 FBI AXLE
DESCRIPTION
The 181 Front Beam-desi gn I ron (FBI ) axl e con-
si sts of a cast i ron di fferenti al housi ng wi th axl e
shaft tubes extendi ng from ei ther si de. The tubes are
pressed i nto the di fferenti al housi ng and wel ded.
The i ntegral type housi ng, hypoi d gear desi gn has
the centerl i ne of the pi ni on set above the centerl i ne
of the ri ng gear.
The axl e has a fi tti ng for a vent hose used to
rel i eve i nternal pressure caused by l ubri cant vapor-
i zati on and i nternal expansi on.
The axl es are equi pped wi th semi fl oati ng axl e
shafts, meani ng that l oads are supported by the hub
beari ngs. The axl e shafts are retai ned by nuts at the
hub beari ngs. The hub beari ngs are bol ted to the
steeri ng knuckl e at the outboard end of the axl e tube
yoke. The hub beari ngs are servi ced as an assembl y.
For vehi cl es wi th ABS brakes, the ABS wheel
speed sensors are attached to the knuckl e assem-
bl i es. The tone ri ngs for the ABS system are pressed
onto the axl e shaft. Do not damage ABS tone
wheel or the sensor when removing axle shafts.
The stamped steel cover provi des a means for
i nspecti on and servi ci ng the di fferenti al .
The 181 FBI axl e has the assembl y part number
and gear rati o l i sted on a tag. The tag i s attached to
the housi ng cover by a cover bol t. Bui l d date i denti -
fi cati on codes are stamped on the cover si de of the
axl e shaft tube.
The di fferenti al case i s a onepi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a rol l
pi n. Di fferenti al beari ng prel oad and ri ng gear back-
l ash i s adjusted by the use of shi ms (sel ect thi ck-
ness). The shi ms are l ocated between the di fferenti al
beari ng cones and case. Pi ni on beari ng prel oad i s set
and mai ntai ned by the use of shi ms (sel ect thi ck-
ness).
3 - 16 TUBE, 181, AND 186 FBI AXLE XJ
OPERATION
The axl e recei ves power from the transfer case
through the front propel l er shaft. The front propel l er
shaft i s connected to the pi ni on gear whi ch rotates
the di fferenti al through the gear mesh wi th the ri ng
gear bol ted to the di fferenti al case. The engi ne power
i s transmi tted to the axl e shafts through the pi ni on
mate and si de gears. The si de gears are spl i ned to
the axl e shafts.
186 FBI AXLE
DESCRIPTION
The 186 Front Beam-desi gn I ron (FBI ) axl e con-
si sts of a cast i ron di fferenti al housi ng wi th axl e
shaft tubes extendi ng from ei ther si de. The tubes are
pressed i nto the di fferenti al housi ng and wel ded.
The i ntegral type housi ng, hypoi d gear desi gn has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a fi tti ng for a vent hose used to
rel i eve i nternal pressure caused by l ubri cant vapor-
i zati on and i nternal expansi on.
shafts, meani ng that l oads are supported by the hub
beari ngs. The axl e shafts are retai ned by nuts at the
hub beari ngs. The hub beari ngs are bol ted to the
steeri ng knuckl e at the outboard end of the axl e tube
yoke. The hub beari ngs are servi ced as an assembl y.
For vehi cl es wi th ABS brakes, the ABS wheel
speed sensors are attached to the knuckl e assem-
bl i es. The tone ri ngs for the ABS system are pressed
onto the axl e shaft. Do not damage ABS tone
wheel or the sensor when removing axle shafts.
The stamped steel cover provi des a means for
i nspecti on and servi ci ng the di fferenti al .
The 186 FBI axl e has the assembl y part number
the housi ng cover by a cover bol t. Bui l d date i denti -
fi cati on codes are stamped on the cover si de of the
axl e shaft tube.
The di fferenti al case i s a onepi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a rol l
pi n. Di fferenti al beari ng prel oad and ri ng gear back-
l ash i s adjusted by the use of shi ms (sel ect thi ck-
ness). The shi ms are l ocated between the di fferenti al
beari ng cones and case. Pi ni on beari ng prel oad i s set
and mai ntai ned by the use of a col l apsi bl e spacer.
OPERATION
The axl e recei ves power from the transfer case
through the front propel l er shaft. The front propel l er
shaft i s connected to the pi ni on gear whi ch rotates
the di fferenti al through the gear mesh wi th the ri ng
gear bol ted to the di fferenti al case. The engi ne power
i s transmi tted to the axl e shafts through the pi ni on
mate and si de gears. The si de gears are spl i ned to
the axl e shafts.
LUBRICANT
DESCRIPTION
A mul ti purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
The l ubri cant shoul d have MI LL2105C and
API GL 5 qual i ty speci fi cati ons.
Lubri cant i s a thermal l y stabl e SAE 80W90
gear l ubri cant.
Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W140 SYNTHETI C gear
l ubri cant.
The 181 FBI axl e l ubri cant capaci ty i s 1.2 L (2.5
pts.). The 186 FBI axl e l ubri cant capaci ty i s 1.18 L
(2.5 pts.).
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
XJ TUBE, 181, AND 186 FBI AXLE 3 - 17
STANDARD DIFFERENTIAL
DESCRIPTION
The di fferenti al gear system di vi des the torque
between the axl e shafts. I t al l ows the axl e shafts to
rotate at di fferent speeds when turni ng corners.
Each di fferenti al si de gear i s spl i ned to an axl e
shaft. The pi ni on gears are mounted on a pi ni on
mate shaft and are free to rotate on the shaft. The
pi ni on gear i s fi tted i n a bore i n the di fferenti al case
and i s posi ti oned at a ri ght angl e to the axl e shafts.
OPERATION
I n operati on, power fl ow occurs as fol l ows:
The pi ni on gear rotates the ri ng gear
The ri ng gear (bol ted to the di fferenti al case)
rotates the case
The di fferenti al pi ni on gears (mounted on the
pi ni on mate shaft i n the case) rotate the si de gears
The si de gears (spl i ned to the axl e shafts) rotate
the shafts
Duri ng strai ght-ahead dri vi ng, the di fferenti al pi n-
i on gears do not rotate on the pi ni on mate shaft. Thi s
occurs because i nput torque appl i ed to the gears i s
di vi ded and di stri buted equal l y between the two si de
gears. As a resul t, the pi ni on gears revol ve wi th the
pi ni on mate shaft but do not rotate around i t (Fi g. 1).
When turni ng corners, the outsi de wheel must
travel a greater di stance than the i nsi de wheel to
compl ete a turn. The di fference must be compensated
for to prevent the ti res from scuffi ng and ski ddi ng
through turns. To accompl i sh thi s, the di fferenti al
al l ows the axl e shafts to turn at unequal speeds (Fi g.
2). I n thi s i nstance, the i nput torque appl i ed to the
pi ni on gears i s not di vi ded equal l y. The pi ni on gears
now rotate around the pi ni on mate shaft i n opposi te
di recti ons. Thi s al l ows the si de gear and axl e shaft
attached to the outsi de wheel to rotate at a faster
speed.
Fig. 1 Differential OperationStraight Ahead Driving
1 IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT
100% OF CASE SPEED
2 PINION GEAR
3 SIDE GEAR
4 PINION GEARS ROTATE WITH CASE
Fig. 2 Differential OperationOn Turns
1 PINION GEARS ROTATE ON PINION SHAFT
GENERAL INFORMATION
Axl e beari ng probl em condi ti ons are usual l y caused
by:
I nsuffi ci ent or i ncorrect l ubri cant.
Forei gn matter/water contami nati on.
I ncorrect beari ng prel oad torque adjustment.
I ncorrect backl ash.
Axl e gear probl em condi ti ons are usual l y the resul t
of:
I nsuffi ci ent l ubri cati on.
I ncorrect or contami nated l ubri cant.
Overl oadi ng (excessi ve engi ne torque) or exceed-
i ng vehi cl e wei ght capaci ty.
I ncorrect cl earance or backl ash adjustment.
Axl e component breakage i s most often the resul t
of:
Severe overl oadi ng.
I nsuffi ci ent l ubri cant.
I ncorrect l ubri cant.
I mproperl y ti ghtened components.
Di fferenti al housi ng bores not square to each
other.
DIAGNOSTIC CHART
Condition Possible Causes Correction
Wheel Noise 1. Wheel loose. 1. Tighten loose nuts.
2. Faulty, brinelled wheel bearing. 2. Replace bearing.
Axle Shaft
Noise
1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.
2. Bent or sprung axle shaft. 2. Inspect and correct as necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load information and correct
as necessary.
4. Excessive gear backlash between
the ring gear and pinion.
4. Check adjustment of the ring gear and pinion
backlash. Correct as necessary.
5. Improper adjustment of pinion gear
bearings.
5. Adjust the pinion bearings pre-load.
6. Loose pinion yoke nut. 6. Tighten the pinion yoke nut.
7. Scuffed gear tooth contact surfaces. 7. Inspect and replace as necessary.
Axle Shaft
Broke
1. Misaligned axle tube. 1. Replace the broken shaft after correcting tube
mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive weight
on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct erratic
clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and repair
clutch as necessary.
Differential
Cracked
1. Improper adjustment of the
differential bearings.
1. Replace case and inspect gears and bearings for
further damage. Set differential bearing pre-load
properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and bearings for
further damage. Set ring gear backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and bearings for
further damage. Avoid excessive vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and bearings for
further damage. Avoid erratic use of clutch.
Differential
Gears Scored
1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the
correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with the
correct fluid type and quantity.
3. Excessive spinning of one wheel/tire. 3. Replace scored gears. Inspect all gears, pinion
bores, and shaft for damage. Service as necessary.
Loss Of
Lubricant
1. Lubricant level too high. 1. Drain lubricant to the correct level.
2. Worn axle shaft seals. 2. Replace seals.
3. Cracked differential housing. 3. Repair as necessary.
4. Worn pinion seal. 4. Replace seal.
5. Worn/scored yoke. 5. Replace yoke and seal.
6. Axle cover not properly sealed. 6. Remove, clean, and re-seal cover.
Axle
Overheating
1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid type and
quantity.
3. Bearing pre-loads too high. 3. Re-adjust bearing pre-loads.
4. Insufficient ring gear backlash. 4. Re-adjust ring gear backlash.
Gear Teeth
Broke
1. Overloading. 1. Replace gears. Examine other gears and bearings
for possible damage.
2. Erratic clutch operation. 2. Replace gears and examine the remaining parts
for damage. Avoid erratic clutch operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining parts for
damage.
4. Improper adjustments. 4. Replace gears and examine remaining parts for
damage. Ensure ring gear backlash is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and
quantity.
2. Improper ring gear and pinion
adjustment.
2. Check ring gear and pinion contact pattern.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear and
pinion.
4. Worn teeth on ring gear and/or
pinion.
4. Replace ring gear and pinion.
5. Loose pinion bearings. 5. Adjust pinion bearing pre-load.
6. Loose differential bearings. 6. Adjust differential bearing pre-load.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace components
as necessary.
8. Loose differential bearing cap bolts. 8. Inspect differential components and replace as
necessary. Ensure that the bearing caps are torqued
tot he proper specification.
9. Housing not machined properly. 9. Replace housing.
GEAR NOISE
Axl e gear noi se can be caused by i nsuffi ci ent l ubri -
cant, i ncorrect backl ash, tooth contact, worn/damaged
gears, or the carri er housi ng not havi ng the proper
offset and squareness.
Gear noi se usual l y happens at a speci fi c speed
range. The noi se can al so occur duri ng a speci fi c type
of dri vi ng condi ti on. These condi ti ons are accel era-
ti on, decel erati on, coast, or constant l oad.
When road testi ng, fi rst warm-up the axl e fl ui d by
dri vi ng the vehi cl e at l east 5 mi l es and then accel er-
ate the vehi cl e to the speed range where the noi se i s
the greatest. Shi ft out-of-gear and coast through the
peaknoi se range. I f the noi se stops or changes
greatl y:
Check for i nsuffi ci ent l ubri cant.
I ncorrect ri ng gear backl ash.
Gear damage.
Di fferenti al si de gears and pi ni ons can be checked
by turni ng the vehi cl e. They usual l y do not cause
noi se duri ng strai ghtahead dri vi ng when the gears
are unl oaded. The si de gears are l oaded duri ng vehi -
cl e turns. A worn pi ni on mate shaft can al so cause a
snappi ng or a knocki ng noi se.
BEARING NOISE
The axl e shaft, di fferenti al and pi ni on beari ngs can
al l produce noi se when worn or damaged. Beari ng
noi se can be ei ther a whi ni ng, or a growl i ng sound.
Pi ni on beari ngs have a constantpi tch noi se. Thi s
noi se changes onl y wi th vehi cl e speed. Pi ni on beari ng
noi se wi l l be hi gher pi tched because i t rotates at a
faster rate. Dri ve the vehi cl e and l oad the di fferen-
ti al . I f beari ng noi se occurs, the rear pi ni on beari ng
i s the source of the noi se. I f the beari ng noi se i s
heard duri ng a coast, the front pi ni on beari ng i s the
source.
Worn or damaged di fferenti al beari ngs usual l y pro-
duce a l ow pi tch noi se. Di fferenti al beari ng noi se i s
si mi l ar to pi ni on beari ng noi se. The pi tch of di fferen-
ti al beari ng noi se i s al so constant and vari es onl y
wi th vehi cl e speed.
Axl e shaft beari ngs produce noi se and vi brati on
when worn or damaged. The noi se general l y changes
when the beari ngs are l oaded. Road test the vehi cl e.
Turn the vehi cl e sharpl y to the l eft and to the ri ght.
Thi s wi l l l oad the beari ngs and change the noi se
l evel . Where axl e beari ng damage i s sl i ght, the noi se
i s usual l y not noti ceabl e at speeds above 30 mph.
LOW SPEED KNOCK
Low speed knock i s general l y caused by a worn
Ujoi nt or by worn si degear thrust washers. A worn
pi ni on shaft bore wi l l al so cause l ow speed knock.
VIBRATION
Vi brati on at the rear of the vehi cl e i s usual l y
caused by a:
Damaged dri ve shaft.
Mi ssi ng dri ve shaft bal ance wei ght(s).
Worn or outofbal ance wheel s.
Loose wheel l ug nuts.
Worn Ujoi nt(s).
Loose/broken spri ngs.
Damaged axl e shaft beari ng(s).
Loose pi ni on gear nut.
Excessi ve pi ni on yoke run out.
Bent axl e shaft(s).
Check for l oose or damaged frontend components
or engi ne/transmi ssi on mounts. These components
can contri bute to what appears to be a rearend
vi brati on. Do not overl ook engi ne accessori es, brack-
ets and dri ve bel ts.
Al l dri vel i ne components shoul d be exami ned
before starti ng any repai r.
Refer to Group 22, Wheel s and Ti res, for addi ti onal
vi brati on i nformati on.
DRIVELINE SNAP
A snap or cl unk noi se when the vehi cl e i s shi fted
i nto gear (or the cl utch engaged), can be caused by:
Hi gh engi ne i dl e speed.
Transmi ssi on shi ft operati on.
Loose engi ne/transmi ssi on/transfer case mounts.
Worn Ujoi nts.
Loose spri ng mounts.
Loose pi ni on gear nut and yoke.
Excessi ve ri ng gear backl ash.
Excessi ve si de gear to case cl earance.
The source of a snap or a cl unk noi se can be deter-
mi ned wi th the assi stance of a hel per. Rai se the vehi -
cl e on a hoi st wi th the wheel s free to rotate. I nstruct
the hel per to shi ft the transmi ssi on i nto gear. Li sten
for the noi se, a mechani cs stethoscope i s hel pful i n
i sol ati ng the source of a noi se.
SERVICE PROCEDURES
LUBRICANT CHANGE
(2) Remove the l ubri cant fi l l hol e pl ug from the
di fferenti al housi ng cover.
(3) Remove the di fferenti al housi ng cover and
drai n the l ubri cant from the housi ng.
(4) Cl ean the housi ng cavi ty wi th a fl ushi ng oi l ,
l i ght engi ne oi l or l i nt free cl oth. Do not use water,
steam, kerosene or gasoline for cleaning.
(5) Remove the seal ant from the housi ng and cover
surfaces. Use sol vent to cl ean the mati ng surfaces.
(6) Appl y a bead of Mopar Si l i cone Rubber Seal -
ant, or equi val ent, to the housi ng cover (Fi g. 3).
Install the housing cover within 5 minutes
after applying the sealant.
(7) I nstal l the cover and any i denti fi cati on tag.
Ti ghten the cover bol ts i n a cri sscross pattern to 41
Nm (30 ft. l bs.) torque.
(8) Refi l l the di fferenti al wi th Mopar Hypoi d
Gear Lubri cant, or equi val ent, to bottom of the fi l l
pl ug hol e. Refer to the Lubri cant Speci fi cati ons i n
thi s group for the quanti ty necessary.
(9) I nstal l the fi l l hol e pl ug and l ower the vehi cl e.
Ti ghten fi l l pl ug to 34 Nm (25 ft. l bs.).
DRIVE AXLE ASSEMBLY
REMOVAL
(2) Posi ti on a sui tabl e l i fti ng devi ce under the
axl e.
(3) Secure axl e to devi ce.
(4) Remove the wheel s and ti res.
(5) Remove the brake rotors and cal i pers from the
axl e. Refer to Group 5, Brakes, for proper procedures.
(6) Di sconnect the wheel sensor wi ri ng harness
from the vehi cl e wi ri ng harness, i f necessary.
(7) Di sconnect the vent hose from the axl e shaft
tube.
(8) Mark the propel l er shaft and yoke for i nstal l a-
ti on al i gnment reference.
(9) Remove propel l er shaft.
(10) Di sconnect stabi l i zer bar l i nks at the axl e.
(11) Di sconnect shock absorbers from axl e brack-
ets.
(12) Di sconnect track bar.
(13) Di sconnect the ti e rod and drag l i nk from the
steeri ng knuckl e. Refer to Group 2, Suspensi on, for
proper procedures.
(14) Di sconnect the steeri ng damper from the axl e
bracket.
(15) Di sconnect the upper and l ower suspensi on
arms from the axl e brackets.
(16) Lower the l i fti ng devi ce enough to remove the
axl e. The coi l spri ngs wi l l drop wi th the axl e.
(17) Remove the coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
ported by the springs before suspension arms and
track bar fasteners can be tightened. If the springs
are not at their normal ride position, ride height and
handling could be affected.
(1) I nstal l the spri ngs and retai ner cl i ps. Ti ghten
the retai ner bol ts to 21 Nm (16 ft. l bs.) torque.
(2) Support the axl e on a sui tabl e l i fti ng devi ce
and posi ti on axl e under the vehi cl e.
(3) Rai se the axl e and al i gn i t wi th the spri ng
pads.
(4) Posi ti on the upper and l ower suspensi on arms
i n the axl e brackets. Loosel y i nstal l bol ts and nuts to
hol d suspensi on arms to the axl e brackets.
(5) Connect the vent hose to the axl e shaft tube.
(6) Connect the track bar to the axl e bracket.
Loosel y i nstal l the bol t to hol d the track bar to the
axl e bracket.
(7) I nstal l the shock absorbers and ti ghten the
(8) I nstal l the stabi l i zer bar l i nks to the axl e
brackets. Ti ghten the nut to 95 Nm (70 ft. l bs.)
torque.
(9) I nstal l the drag l i nk and ti e rod to the steeri ng
knuckl es. Refer to Group 2, Suspensi on, for proper
procedures.
(10) I nstal l the steeri ng damper to the axl e
bracket and ti ghten the nut to 75 Nm (55 ft. l bs.)
torque.
(11) I nstal l the brake rotors and cal i pers. Refer to
Group 5, Brakes, for the proper procedures.
(12) Connect the wheel speed sensor wi ri ng har-
ness to the vehi cl e wi ri ng harness, i f necessary.
Fig. 3 Typical Housing Cover With Sealant
1 SEALING SURFACE
2 CONTOUR OF BEAD
3 BEAD THICKNESS 6.35mm (1/4)
(13) Al i gn the previ ousl y made marks on the pro-
pel l er shaft and the yoke.
(14) I nstal l the straps and bol ts to hol d the propel -
l er shaft to the yoke.
(15) Check and fi l l axl e l ubri cant. Refer to the
Lubri cant Speci fi cati ons i n thi s group for the quan-
ti ty necessary.
(17) Remove the l i fti ng devi ce from the axl e and
l ower the vehi cl e.
(18) Ti ghten the upper suspensi on arm nuts to 75
Nm (55 ft. l bs.) torque. Ti ghten the l ower suspensi on
arm nuts to 115 Nm (85 ft. l bs.) torque.
(19) Ti ghten the track bar bol t at the axl e bracket
to 100 Nm (74 ft. l bs.) torque.
(20) Check the front wheel al i gnment.
TUBE AXLE ASSEMBLY
REMOVAL
axl e.
(5) Remove the brake rotors and cal i pers from the
axl e. Refer to Group 5, Brakes, for proper procedures.
(6) Di sconnect the wheel sensor wi ri ng harness
from the vehi cl e wi ri ng harness, i f necessary.
(7) Di sconnect stabi l i zer bar l i nks at the axl e.
(8) Di sconnect shock absorbers from axl e brackets.
(9) Di sconnect track bar.
(10) Di sconnect the ti e rod and drag l i nk from the
steeri ng knuckl e. Refer to Group 2, Suspensi on, for
proper procedures.
(11) Di sconnect the steeri ng damper from the axl e
bracket.
(12) Di sconnect the upper and l ower suspensi on
arms from the axl e brackets.
(13) Lower the l i fti ng devi ce enough to remove the
axl e. The coi l spri ngs wi l l drop wi th the axl e.
(14) Remove the coi l spri ngs from the axl e.
INSTALLATION
CAUTION: The weight of the vehicle must be sup-
are not at their normal ride position, ride height and
handling could be affected.
(1) I nstal l the spri ngs and retai ner cl i ps. Ti ghten
the retai ner bol ts to 21 Nm (16 ft. l bs.) torque.
(2) Support the axl e on a sui tabl e l i fti ng devi ce
and posi ti on axl e under the vehi cl e.
(3) Rai se the axl e and al i gn i t wi th the spri ng
pads.
(4) Posi ti on the upper and l ower suspensi on arms
i n the axl e brackets. Loosel y i nstal l bol ts and nuts to
hol d suspensi on arms to the axl e brackets.
(5) Connect the track bar to the axl e bracket.
Loosel y i nstal l the bol t to hol d the track bar to the
axl e bracket.
(6) I nstal l the shock absorbers and ti ghten the
(7) I nstal l the stabi l i zer bar l i nks to the axl e
brackets. Ti ghten the nut to 95 Nm (70 ft. l bs.)
torque.
(8) I nstal l the drag l i nk and ti e rod to the steeri ng
knuckl es. Refer to Group 2, Suspensi on, for proper
procedures.
(9) I nstal l the steeri ng damper to the axl e bracket
and ti ghten the nut to 75 Nm (55 ft. l bs.) torque.
Group 5, Brakes, for the proper procedures.
(11) Connect the wheel speed sensor wi ri ng har-
ness to the vehi cl e wi ri ng harness, i f necessary.
(13) Remove the l i fti ng devi ce from the axl e and
(14) Ti ghten the upper suspensi on arm nuts to 75
Nm (55 ft. l bs.) torque. Ti ghten the l ower suspensi on
arm nuts to 115 Nm (85 ft. l bs.) torque.
(15) Ti ghten the track bar bol t at the axl e bracket
(16) Check the front wheel al i gnment.
AXLE SHAFT CARDAN U-JOINT
Si ngl e cardan Ujoi nt components are not servi ce-
abl e. I f defecti ve, they must be repl aced as a uni t. I f
the beari ngs, seal s, spi der, or beari ng caps are dam-
aged or worn, repl ace the compl ete Ujoi nt.
REMOVAL
CAUTION: Clamp only the narrow forged portion of
the yoke in the vise. Also, to avoid distorting the
yoke, do not over tighten the vise jaws.
(1) Remove axl e shaft.
(2) Remove the beari ng cap retai ni ng snap ri ngs
(Fi g. 4).
It can be helpful to saturate the bearing caps
with penetrating oil prior to removal.
(3) Locate a socket where the i nsi de di ameter i s
l arger i n di ameter than the beari ng cap. Pl ace the
socket (recei ver) agai nst the yoke and around the
peri meter of the beari ng cap to be removed.
(4) Locate a socket where the outsi de di ameter i s
smal l er i n di ameter than the beari ng cap. Pl ace the
socket (dri ver) agai nst the opposi te beari ng cap.
(5) Posi ti on the yoke wi th the sockets i n a vi se
(Fi g. 5).
(6) Compress the vi se jaws to force the beari ng cap
i nto the l arger socket (recei ver).
(7) Rel ease the vi se jaws. Remove the sockets and
beari ng cap that was parti al l y forced out of the yoke.
(8) Repeat the above procedure for the remai ni ng
beari ng cap.
(9) Remove the remai ni ng beari ng cap, beari ngs,
seal s and spi der from the propel l er shaft yoke.
INSTALLATION
(1) Pack the beari ng caps 1/3 ful l of wheel beari ng
l ubri cant. Appl y extreme pressure (EP), l i thi umbase
l ubri cant to ai d i n i nstal l ati on.
(2) Posi ti on the spi der i n the yoke. I nsert the seal s
and beari ngs. Tap the beari ng caps i nto the yoke
bores far enough to hol d the spi der i n posi ti on.
(3) Pl ace the socket (dri ver) agai nst one beari ng
cap. Posi ti on the yoke wi th the socket wrench i n a
vi se.
(4) Compress the vi se to force the beari ng caps
i nto the yoke. Force the caps enough to i nstal l the
retai ni ng cl i ps.
(5) I nstal l the beari ng cap retai ni ng cl i ps.
(6) I nstal l axl e shaft.
181 FBI PINION SHAFT SEAL
REMOVAL
(2) Remove wheel and ti re assembl i es.
(3) Remove brake rotors and cal i pers. Refer to
Group 5, Brakes, for proper procedures.
(4) Mark the propel l er shaft and pi ni on yoke for
i nstal l ati on reference.
(5) Remove the propel l er shaft from the yoke.
(6) Rotate the pi ni on gear three or four ti mes.
(7) Measure the amount of torque necessary to
rotate the pi ni on gear wi th a (i n. l bs.) di al -type
torque wrench. Record the torque readi ng for i nstal -
l ati on reference.
(8) Usi ng Hol der 6958 to hol d the pi ni on yoke,
remove the pi ni on nut and washer.
(9) Use Remover C-452 and Wrench C-3281 to
remove the pi ni on yoke (Fi g. 6).
(10) Use a sui tabl e pry tool or a sl i de hammer
mounted screw to remove the pi ni on shaft seal .
INSTALLATION
(1) Appl y a l i ght coati ng of gear l ubri cant on the
l i p of pi ni on seal . I nstal l seal wi th I nstal l er C-3972-A
and Handl e C-4171 (Fi g. 7).
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
W-162D, Cup 8109, and Hol der 6958 (Fi g. 8).
Fig. 4 Axle Shaft Outer UJoint
1 SHAFT YOKE
2 BEARING CAP
3 SNAP RINGS
4 BEARING CAP
5 SPINDLE YOKE
6 BEARING
7 BEARING CAP
8 SNAP RINGS
9 BEARING CAP
Fig. 5 Yoke Bearing Cap Removal
1 LARGE-DIAMETER SOCKET WRENCH
2 VISE
3 SMALL-DIAMETER SOCKET WRENCH
CAUTION: Do not exceed the minimum tightening
torque when installing the pinion yoke retaining nut
at this point. Damage to the pinion bearings may
result.
(3) I nstal l the pi ni on washer and a new nut on the
pi ni on gear. Tighten the nut only enough to
remove the shaft end play.
(4) Ti ghten pi ni on nut to 217 Nm (160 ft. l bs.).
(5) Rotate the pi ni on shaft usi ng a (i n. l bs.) torque
wrench. Rotati ng torque shoul d be equal to the read-
i ng recorded duri ng removal , pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 9).
(6) I f the rotati ng torque i s l ow, use Hol der 6958 to
hol d the pi ni on yoke, and ti ghten the pi ni on shaft
nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l proper
rotati ng torque i s achi eved.
(7) Al i gn the i nstal l ati on reference marks on the
propel l er shaft and yoke, and i nstal l the propel l er
shaft.
(8) Check and fi l l the gear l ubri cant. Refer to the
Lubri cant Speci fi cati ons for gear l ubri cant requi re-
ments.
(10) I nstal l wheel and ti re assembl i es.
Fig. 6 Pinion Yoke Removal
1 SPECIAL TOOL C-3281
2 YOKE
Fig. 7 Pinion Seal Installation
Fig. 8 Pinion Yoke Installation
1 PINION YOKE
2 AXLE HOUSING
Fig. 9 Check Pinion Rotation Torque
1 PINION YOKE
2 INCH POUND TORQUE WRENCH
186 FBI PINION SHAFT SEAL
REMOVAL
l ati on reference.
mounted screw to remove the pi ni on seal .
INSTALLATION
(2) I nstal l yoke on the pi ni on gear wi th I nstal l er
W-162D, Cup 8109, and Hol der 6958 (Fi g. 12).
at this point. Damage to collapsible spacer or bear-
ings may result.
pi ni on gear. Tighten the nut only enough to
remove the shaft end play.
Nm (5 i n. l bs.) (Fi g. 13).
hol d the pi ni on yoke (Fi g. 14), and ti ghten the pi ni on
shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l
proper rotati ng torque i s achi eved.
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
propel l er shaft and yoke and i nstal l the propel l er
shaft.
2 YOKE
1 PINION YOKE
2 AXLE HOUSING
(7) Check and fi l l the gear l ubri cant. Refer to the
Lubri cant Speci fi cati ons for gear l ubri cant requi re-
ments.
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
l ati on reference.
mounted screw, remove the pi ni on seal .
(11) Remove the front pi ni on beari ng usi ng a pai r
of sui tabl e pi ck tool s to pul l the beari ng strai ght off
the pi ni on gear shaft. I t may be necessary to l i ghtl y
tap the end of the pi ni on gear wi th a rawhi de or rub-
ber mal l et i f the beari ng becomes bound on the pi n-
i on shaft.
(12) Remove the col l apsi bl e spacer.
1 PINION YOKE
Fig. 14 Tightening Pinion Shaft NutTypical
1 PINION FLANGE
2 FRONT AXLE
3 TOOL 6958
2 YOKE
REMOVAL W/PINION REMOVED
l ati on reference.
(8) Remove di fferenti al assembl y from axl e hous-
i ng.
(9) Usi ng Hol der 6958 to hol d yoke, remove the
pi ni on nut and washer.
(10) Usi ng Remover C-452 and Wrench C-3281,
remove the pi ni on yoke from pi ni on shaft (Fi g. 15).
(11) Remove the pi ni on gear from housi ng (Fi g.
16). Catch the pi ni on wi th your hand to prevent i t
from fal l i ng and bei ng damaged.
(12) Remove col l apsi bl e spacer from pi ni on shaft.
INSTALLATION
(1) I nstal l a new col l apsi bl e prel oad spacer on pi n-
i on shaft (Fi g. 17).
(2) I f pi ni on gear was removed, i nstal l pi ni on gear
i n housi ng.
(3) I nstal l pi ni on front beari ng, i f necessary.
and Handl e C-4171 (Fi g. 18), i f necessary.
(5) I nstal l yoke wi th I nstal l er W-162-D, Cup 8109,
and hol der 6958 (Fi g. 19).
(6) I f the ori gi nal pi ni on beari ngs are bei ng used,
i nstal l di fferenti al assembl y and axl e shafts, i f neces-
sary.
Fig. 16 Remove Pinion Gear
1 RAWHIDE HAMMER
Fig. 17 Collapsible Preload Spacer
1 COLLAPSIBLE SPACER
2 SHOULDER
3 PINION GEAR
4 OIL SLINGER
5 REAR BEARING
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
pi ni on gear. Ti ghten the nut to 217 Nm (160 ft. l bs.)
mi ni mum. Do not over-tighten. Maxi mum torque i s
353 Nm (260 ft. l bs.).
CAUTION: Never loosen pinion gear nut to
decrease pinion gear bearing rotating torque and
never exceed specified preload torque. If preload
torque is exceeded, a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
(8) Usi ng yoke hol der 6958 and a torque wrench
set at 353 Nm (260 ft. l bs.), crush col l apsi bl e spacer
unti l beari ng end pl ay i s taken up (Fi g. 20). I f more
than 353 Nm (260 ft. l bs.) i s needed to begi n to col -
l apse the spacer, the spacer i s defecti ve and must be
repl aced.
(9) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l the rotati ng torque i s achi eved.
Measure the rotati ng torque frequentl y to avoi d over
crushi ng the col l apsi bl e spacer (Fi g. 21).
(10) Check rotati ng torque wi th an i nch pound
torque wrench (Fi g. 21). The torque necessary to
rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs The readi ng recorded dur-
i ng removal , pl us an addi ti onal 0.56 Nm (5 i n. l bs.).
New Beari ngs 1.5 to 4 Nm (15 to 35 i n. l bs.).
(11) I nstal l di fferenti al assembl y and axl e shafts, i f
necessary.
(12) Al i gn marks made previ ousl y on yoke and
propel l er shaft and i nstal l propel l er shaft.
(13) I nstal l brake rotors and cal i pers. Refer to
1 PINION YOKE
2 AXLE HOUSING
Fig. 20 Tightening Pinion Nut
1 PINION FLANGE
2 FRONT AXLE
3 TOOL 6958
Fig. 21 Check Pinion Gear Rotation TorqueTypical
1 PINION YOKE
(14) Add gear l ubri cant, i f necessary. Refer to
Lubri cant Speci fi cati ons of thi s secti on for l ubri cant
requi rements.
(16) Lower vehi cl e.
HUB BEARING AND AXLE SHAFT
I f the axl e shaft and hub beari ng are bei ng
removed i n order to servi ce another component, the
axl e shaft and hub beari ng can be removed as an
assembl y.
REMOVAL
(2) Remove the wheel and ti re assembl y.
(3) Remove the brake cal i per and rotor. Refer to
(4) Remove ABS wheel speed sensor, i f necessary.
Refer to Group 5, Brakes, for proper procedures.
(5) Remove the cotter pi n, nut retai ner, and axl e
hub nut (Fi g. 22), i f necessary.
(6) Remove the hub to knuckl e bol ts (Fi g. 23).
(7) Remove the hub from the steeri ng knuckl e and
axl e shaft, i f necessary.
(8) Remove hub beari ng and axl e shaft assembl y
(Fi g. 24), or axl e shaft from axl e. Avoid damaging
the axle shaft oil seals in the axle housing.
(9) Remove the brake rotor shi el d from the hub
beari ng or knuckl e (Fi g. 22).
Fig. 22 Hub, Knuckle and Axle Shaft
1 BRAKE SHIELD
2 WASHER
3 RETAINER
4 COTTER PIN
5 NUT
6 HUB AND BEARING ASSEMBLY
7 STEERING KNUCKLE
8 BOLT
9 TONE WHEEL (ABS)
Fig. 23 Hub Bearing Bolts
1 AXLE SHAFT
2 AXLE
3 KNUCKLE
4 HUB BEARING
INSTALLATION
(1) Thoroughl y cl ean the axl e shaft (Fi g. 22) and
appl y a thi n fi l m of Mopar Wheel Beari ng Grease,
or equi val ent, to the shaft spl i nes, seal contact sur-
face, and hub bore.
(2) I nstal l the brake rotor shi el d to the knuckl e.
(3) I nstal l the hub beari ng and axl e shaft assem-
bl y, or axl e shaft, i nto the housi ng and di fferenti al
si de gears. Avoi d damagi ng the axl e shaft oi l seal s i n
the axl e housi ng.
(4) I nstal l the hub beari ng, i f necessary.
(5) I nstal l the hub to knuckl e bol ts and ti ghten to
102 Nm (75 ft. l bs.) torque.
(6) I nstal l the hub washer and nut, i f necessary.
Ti ghten the hub nut to 237 Nm (175 ft. l bs.) torque.
I nstal l the nut retai ner and a new cotter pi n (Fi g.
22).
(7) I nstal l ABS wheel speed sensor, i f necessary.
(8) I nstal l the brake rotor and cal i per. Refer to
(9) I nstal l the wheel and ti re assembl y.
STEERING KNUCKLE AND BALL STUDS
Bal l stud servi ce procedures bel ow requi re removal
of the hub beari ng and axl e shaft. Removal and
i nstal l ati on of upper and l ower bal l studs requi re the
use of Tool Ki t 6289.
KNUCKLE REMOVAL
(1) Remove hub beari ng and axl e shaft.
(2) Di sconnect the ti e-rod or drag l i nk from the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
for proper procedures.
(3) Remove the cotter pi ns from the upper and
l ower bal l studs.
(4) Remove the upper and l ower bal l stud nuts.
(5) Stri ke the steeri ng knuckl e wi th a brass ham-
mer to l oosen knuckl e from the bal l studs. Remove
knuckl e from bal l studs (Fi g. 25). Fig. 24 Hub Bearing and Axle Assembly
1 AXLE
2 KNUCKLE
3 HUB BEARING
4 AXLE SHAFT
Fig. 25 Steering Knuckle Removal/Installation
1 AXLE YOKE
2 UPPER BALL STUD
3 LOWER BALL STUD
4 STEERING KNUCKLE
UPPER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 26).
LOWER BALL STUD REPLACEMENT
(1) Posi ti on tool s as shown to remove and i nstal l
bal l stud (Fi g. 27).
KNUCKLE INSTALLATION
(1) Posi ti on the steeri ng knuckl e on the bal l studs.
(2) I nstal l and ti ghten the bottom retai ni ng nut to
109 Nm (80 ft. l bs.) torque. I nstal l new cotter pi n.
(3) I nstal l and ti ghten the top retai ni ng nut to 101
Nm (75 ft. l bs.) torque. I nstal l new cotter pi n.
(4) I nstal l the hub beari ng and axl e shaft.
(5) Connect the ti e-rod or drag l i nk end to the
steeri ng knuckl e arm. Refer to Group 2, Suspensi on,
Fig. 26 Upper Ball Stud Remove/Install
AXLE BUSHING REPLACEMENT
Refer to Group 2, Suspensi on, for the proper axl e
bushi ng procedures.
DIFFERENTIAL
REMOVAL
al l ow fl ui d to drai n.
(4) Remove hub beari ngs and axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 28).
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Posi ti on Spreader W129B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 29). I nstal l the
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
gerti ght.
Fig. 27 Lower Ball Stud Remove/Install
1 SPECIAL TOOL 628912
3 SPECIAL TOOL 4212F
4 SPECIAL TOOL 4212F
Fig. 28 Bearing Cap Identification
1 INSTALLATION REFERENCE LETTERS
(8) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
the di fferenti al housi ng. Attach Di al I ndi cator C-3339
to gui de pi n. Load the l ever adapter agai nst the
opposi te si de of the housi ng (Fi g. 30) and zero the
i ndi cator.
CAUTION: Do not spread over 0.50 mm (0.020 in). If
the housing is over-spread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 31).
(10) Remove the di al i ndi cator.
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
(12) Remove the di fferenti al , and the di fferenti al
prel oad shi ms for the 181FBI axl es, from the hous-
i ng. Ensure that the di fferenti al beari ng cups remai n
i n posi ti on on the di fferenti al beari ngs (Fi g. 32).
(13) Mark or tag the di fferenti al beari ng cups, and
the di fferenti al prel oad shi ms for the 181FBI axl es,
to i ndi cate whi ch si de of the di fferenti al they were
removed from.
(14) Remove spreader from housi ng.
Fig. 29 Install Axle Housing Spreader
1 AXLE HOUSING
2 DOWEL
3 SAFETY HOLD DOWN
4 SPECIAL TOOL
W-129B
5 TURNBUCKLE
Fig. 30 Install Dial Indicator
1 SPECIAL TOOL
C-3339
2 DIAL INDICATOR
3 LEVER ADAPTER
4 SPECIAL TOOL
W-129B
5 SPECIAL TOOL
C-3288B
Fig. 31 Spread Axle Housing
1 SPECIAL TOOL
C-3339
2 SPECIAL TOOL
W-129B
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) Posi ti on Spreader W-129-B, uti l i zi ng some
i tems from Adapter Ki t 6987, wi th the tool dowel
pi ns seated i n the l ocati ng hol es (Fi g. 33). I nstal l the
hol ddown cl amps and ti ghten the tool turnbuckl e fi n-
gerti ght.
(2) I nstal l a Gui de Pi n C-3288-B at the l eft si de of
to gui de pi n. Load the l ever adapter agai nst the
i ndi cator.
the housing is over-spread, it could be distorted or
damaged.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 31).
(5) I nstal l di fferenti al case, and the di fferenti al
prel oad shi ms for the 181FBI axl es, i n the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs. Tap the di ffer-
enti al case to ensure the beari ngs cups are ful l y
seated i n the housi ng.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 34).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
(9) Ti ghten the beari ng cap bol ts to 61 Nm (45 ft.
l bs.) torque.
(10) I nstal l the hub beari ngs and axl e shafts.
Fig. 32 Differential Case Removal
1 AXLE HOUSING
2 DIFFERENTIAL CASE
3 BEARING CUPS
1 AXLE HOUSING
2 DOWEL
3 SAFETY HOLD DOWN
4 SPECIAL TOOL
W-129B
5 TURNBUCKLE
Fig. 34 Differential Bearing Cap Reference Letters
DIFFERENTIAL SIDE BEARINGS
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
(2) Remove the beari ngs from the di fferenti al case
wi th Pul l er/Press C-293-PA, C-293-39 Adapter
Bl ocks, and Pl ug SP-3289 (Fi g. 35).
INSTALLATION
I f repl acement di fferenti al si de beari ngs or di ffer-
enti al case are bei ng i nstal l ed, di fferenti al si de bear-
i ng shi m requi rements may change. Refer to the
Di fferenti al Beari ng Prel oad and Gear Backl ash pro-
cedures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) I nstal l di fferenti al si de beari ng shi ms onto di f-
ferenti al case hubs, for 186FBI axl es.
(2) Usi ng I nstal l er C-3716-A and Handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 36).
(3) I nstal l di fferenti al i n axl e housi ng.
AXLE SHAFT OIL SEAL
REMOVAL
(2) Remove di fferenti al assembl y.
(3) Remove the i nner axl e shaft seal s wi th a pry
bay.
INSTALLATION
(1) Remove any seal er remai ni ng from ori gi nal
seal s.
(2) Remove seal er from axl e tube to housi ng junc-
ti on, i f necessary.
(3) I nstal l oi l seal s wi th Di scs 8110 and Turn-
buckl e 6797 (Fi g. 37). Ti ghten tool unti l di sc bottoms
i n housi ng.
(4) I nstal l di fferenti al assembl y.
181 FBI PINION
The ri ng gear and pi ni on are servi ced as a matched
set. Do not repl ace the pi ni on wi thout repl aci ng the
ri ng gear.
REMOVAL
i ng.
(2) Mark pi ni on yoke and propel l er shaft for
i nstal l ati on al i gnment.
(3) Di sconnect propel l er shaft from pi ni on yoke.
Usi ng sui tabl e wi re, ti e propel l er shaft to underbody.
Fig. 35 Differential Bearing Removal
1 SPECIAL TOOL C29339
2 BEARING
3 DIFFERENTIAL
4 SPECIAL TOOL SP3289
5 SPECIAL TOOL C293PA
Fig. 36 Differential Side Bearing Installation
(5) Usi ng Remover C-452 and Hol der C-3281,
(6) Remove the pi ni on gear and prel oad shi ms
from housi ng (Fi g. 39). Catch the pi ni on wi th your
hand to prevent i t from fal l i ng and bei ng damaged.
(7) Remove the front pi ni on beari ng cup, beari ng,
oi l sl i nger, i f equi pped, and pi ni on seal wi th Remover
D-147 and Handl e C4171 (Fi g. 40).
Fig. 37 Axle Seal Installation
1 TURNBUCKLE 6797
2 DISCS 8110
2 YOKE
1 RAWHIDE HAMMER
Fig. 40 Front Bearing Cup Removal
1 REMOVER
2 HANDLE
(8) Remove the rear pi ni on beari ng cup and oi l
sl i nger from the axl e housi ng (Fi g. 41). Use Remover
D-149 and Handl e C4171. Record the thi ckness of
the oi l sl i nger for future reference.
(9) Remove the rear pi ni on beari ng from the pi n-
i on wi th Pul l er/Press C293-PA and Adapters
C-293-39 (Fi g. 42).
Place 4 adapter blocks so they do not damage
the bearing cage.
(10) Remove the pi ni on depth shi m/oi l baffl e from
the pi ni on shaft. Record the thi ckness of the depth
shi m/oi l baffl e.
INSTALLATION
NOTE: A pinion depth shim/oil baffle is placed
between the rear pinion bearing cone and pinion
gear. If the factory installed ring and pinion gears
are reused, the pinion depth shim/oil baffle should
not require replacement. Refer to Pinion Gear Depth
to select the proper thickness shim before installing
pinion gear.
(1) I nstal l a new oi l sl i nger of the same thi ckness
as the ori gi nal i nto the rear pi ni on beari ng bore of
the axl e housi ng.
(2) Appl y Mopar Door Ease, or equi val ent, sti ck
l ubri cant to outsi de surface of rear pi ni on beari ng
cup. I nstal l the beari ng cup wi th I nstal l er D-146 and
Handl e C4171 (Fi g. 43). Veri fy cup i s correctl y
seated.
Fig. 41 Rear Bearing Cup Removal
1 DRIVER
2 HANDLE
Fig. 42 Rear Bearing Removal
1 SPECIAL TOOL C-293PA
2 VISE
3 ADAPTERS
4 DRIVE PINION GEAR SHAFT
Fig. 43 Rear Pinion Bearing Cup Installation
1 INSTALLER
2 HANDLE
l ubri cant to outsi de surface of front pi ni on beari ng
Handl e C4171 (Fi g. 44).
(4) I nstal l front pi ni on beari ng, and oi l sl i nger, i f
equi pped.
and Handl e C4171 (Fi g. 45).
(6) I nstal l the rear pi ni on beari ng and pi ni on
depth shi m/oi l baffl e onto the pi ni on gear wi th
I nstal l er W-262 and a shop press (Fi g. 46).
(7) I nstal l pi ni on beari ng prel oad shi ms onto the
pi ni on gear (Fi g. 47).
(8) I nstal l pi ni on gear i n housi ng.
(9) I nstal l yoke wi th I nstal l er W-162-B, Cup 8109,
and Hol der 6958 (Fi g. 48).
Fig. 44 Pinion Outer Bearing Cup Installation
1 INSTALLER
2 HANDLE
Fig. 46 Rear Pinion Bearing Installation
1 PRESS
2 INSTALLATION TOOL
3 PINION DEPTH SHIM/OIL BAFFLE
4 DRIVE PINION
5 DRIVE PINION SHAFT REAR BEARING
(10) I nstal l the pi ni on washer and a new nut on
the pi ni on gear. Ti ghten the nut to 217 Nm (160 ft.
l bs.).
never exceed specified preload rotating torque.
(11) Check beari ng prel oad torque wi th an i nch
pound torque wrench (Fi g. 49). The torque necessary
to rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs1 to 2 Nm (10 to 20 i n. l bs.).
New Beari ngs1.5 to 4 Nm (15 to 35 i n. l bs.).
(12) I f rotati ng torque i s above the desi red
amount, remove the pi ni on yoke and i ncrease the
prel oad shi m pack thi ckness. I ncreasi ng the shi m
pack thi ckness 0.025 mm (0.001 i n.) wi l l decrease the
rotati ng torque approxi matel y 0.9 Nm (8 i n. l bs.).
(13) Ti ghten pi ni on shaft nut i n 6.8 Nm (5 ft. l bs.)
i ncrements unti l the maxi mum ti ghteni ng or desi red
rotati ng torque i s reached. Maxi mum ti ghteni ng
torque i s 271 Nm (200 ft.l bs.).
Fig. 47 Pinion Preload ShimsTypical
1 PINION PRELOAD SHIMS
2 FRONT BEARING CUP
3 SLINGER
4 PINION YOKE
5 WASHER
6 PINION NUT
7 PINION OIL SEAL
8 FRONT BEARING CONE
1 PINION YOKE
2 AXLE HOUSING
(14) I f the maxi mum ti ghteni ng torque i s reached
pri or to achi evi ng the desi red rotati ng torque, remove
the pi ni on yoke and decrease the thi ckness of the
prel oad shi m pack. Decreasi ng the shi m pack thi ck-
ness 0.025 mm (0.001 i n.) wi l l i ncrease the rotati ng
torque approxi matel y 0.9 Nm (8 i n. l bs.).
186 FBI PINION
The ri ng gear and pi ni on are servi ced as a matched
ri ng gear.
REMOVAL
i ng.
(4) Usi ng Hol der 6958 to the hol d yoke, remove
the pi ni on nut and washer (Fi g. 50).
(5) Usi ng Remover C452 and Hol der C-3281,
Fig. 49 Check Pinion Gear Rotating Torque
1 in. lbs. TORQUE WRENCH
2 PINION YOKE
Fig. 50 Pinion Yoke HolderTypical
1 1 in. PIPE
2 PINION YOKE
3 SPECIAL TOOL
6958
4 LOWER CONTROL ARM
2 YOKE
(6) Remove the pi ni on and col l apsi bl e spacer from
housi ng (Fi g. 52). Catch the pi ni on wi th your hand to
prevent i t from fal l i ng and bei ng damaged.
(7) Remove the front pi ni on beari ng cup, beari ng,
oi l sl i nger, i f equi pped, and pi ni on seal wi th Remover
C-4345 and Handl e C4171 (Fi g. 53).
(8) Remove the rear pi ni on beari ng cup from axl e
housi ng (Fi g. 54). Use Remover D-149 and Handl e
C4171.
(9) Remove the col l apsi bl e prel oad spacer from
pi ni on gear (Fi g. 55).
Fig. 52 Remove Pinion
1 RAWHIDE HAMMER
1 REMOVER
2 HANDLE
1 DRIVER
2 HANDLE
Fig. 55 Collapsible Spacer
2 SHOULDER
3 PINION
4 PINION DEPTH SHIM
5 REAR BEARING
(10) Remove the rear pi ni on beari ng from the pi n-
i on wi th Pul l er/Press C293-PA and Adapters
C29339 (Fi g. 56).
the bearing cage.
(11) Remove the depth shi m/oi l sl i nger from the
pi ni on shaft. Record the thi ckness of the depth shi m/
oi l sl i nger.
INSTALLATION
NOTE: A pinion depth shim/oil slinger is placed
between the rear pinion bearing cone and the pin-
ion head to achieve proper ring gear and pinion
mesh. If the factory installed ring gear and pinion
are reused, the pinion depth shim/oil slinger should
not require replacement. Refer to Pinion Gear Depth
to select the proper thickness shim/oil slinger
before installing pinion.
l ubri cant to outsi de surface of rear pi ni on beari ng
Dri ver Handl e C4171 (Fi g. 57). Veri fy cup i s cor-
rectl y seated.
l ubri cant to outsi de surface of front pi ni on beari ng
Handl e C4171 (Fi g. 58).
(3) I nstal l front pi ni on beari ng, and oi l sl i nger, i f
equi pped.
(5) I nstal l the rear pi ni on beari ng and the pi ni on
depth shi m/oi l sl i nger onto the pi ni on wi th I nstal l er
W-262 and a shop press (Fi g. 60).
Fig. 56 Inner Bearing Removal
2 VISE
3 ADAPTERS
Fig. 57 Rear Pinion Bearing Cup Installation
1 INSTALLER
2 HANDLE
Fig. 58 Pinion Outer Bearing Cup Installation
1 INSTALLER
2 HANDLE
i on shaft and i nstal l pi ni on i n housi ng (Fi g. 61).
(7) I nstal l yoke wi th I nstal l er W-162-B, Cup 8109,
and Hol der 6958 (Fi g. 62).
(8) I nstal l the pi ni on washer and a new nut onto
the pi ni on. Ti ghten the nut to 216 Nm (160 ft. l bs.)
mi ni mum. Do not overtighten. Maxi mum torque
i s 352 Nm (260 ft. l bs.).
CAUTION: Never loosen the pinion nut to decrease
pinion bearing rotating torque and never exceed
specified preload torque. If preload torque is
exceeded a new collapsible spacer must be
installed. The torque sequence will then have to be
repeated.
(9) Usi ng Hol der 6958 and torque wrench (set at
352 Nm (260 ft. l bs.)), crush col l apsi bl e spacer unti l
Fig. 60 Rear Pinion Bearing Installation
1 PRESS
2 INSTALLATION TOOL
3 PINION DEPTH SHIM/OIL BAFFLE
4 DRIVE PINION
2 SHOULDER
3 PINION GEAR
4 OIL SLINGER
5 REAR BEARING
1 PINION YOKE
2 AXLE HOUSING
beari ng end pl ay i s taken up (Fi g. 63). I f more than
353 Nm (260 ft. l bs.) i s needed to begi n to col l apse
the spacer, the spacer i s defecti ve and must be
repl aced.
(10) Sl owl y ti ghten the nut i n 6.8 Nm (5 ft. l b.)
(11) Check beari ng rotati ng torque wi th an i nch
to rotate the pi ni on shoul d be:
Ori gi nal Beari ngs 1 to 2 Nm (10 to 20 i n.
l bs.).
RING GEAR
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 di fferenti al from axl e housi ng.
(2) Pl ace di fferenti al case i n a sui tabl e vi se wi th
soft metal jaw protectors. (Fi g. 65)
(3) Remove bol ts hol di ng ri ng gear to di fferenti al
case.
(4) Usi ng a soft hammer, dri ve ri ng gear from di f-
ferenti al case (Fi g. 65).
INSTALLATION
CAUTION: Do not reuse the bolts that held the ring
gear to the differential case. The bolts can fracture
causing extensive damage.
Fig. 63 Tightening Pinion NutTypical
1 PINION FLANGE
2 FRONT AXLE
3 TOOL 6958
1 in. lbs. TORQUE WRENCH
2 PINION YOKE
Fig. 65 Ring Gear Removal
1 CASE
2 RING GEAR
3 RAWHIDE HAMMER
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
(2) I nvert the di fferenti al case i n the vi se.
(3) I nstal l new ri ng gear bol ts and al ternatel y
ti ghten to 95122 Nm (7090 ft. l bs.) torque (Fi g.
66).
(4) I nstal l di fferenti al i n axl e housi ng and veri fy
gear mesh and contact pattern.
DISASSEMBLY
(1) Remove the ri ng gear.
(2) Usi ng a sui tabl e rol l pi n punch, dri ve out the
rol l pi n hol di ng pi ni on gear mate shaft i n the di ffer-
enti al case (Fi g. 67).
(3) Remove the pi ni on gear mate shaft from the
di fferenti al case and the pi ni on mate gears.
(4) Rotate di fferenti al si de gears and remove the
pi ni on mate gears and thrust washers (Fi g. 68).
(5) Remove the di fferenti al si de gears and thrust
washers.
ASSEMBLY
(1) I nstal l the di fferenti al si de gears and thrust
washers.
(2) I nstal l the pi ni on mate gears and thrust wash-
ers.
Fig. 66 Ring Gear Bolt Installation
1 TORQUE WRENCH
2 RING GEAR BOLT
3 RING GEAR
4 CASE
Fig. 67 Mate Shaft Roll Pin Removal
1 DRIFT
2 LOCKPIN
3 MATE SHAFT
Fig. 68 Pinion Mate Gear Removal
1 THRUST WASHER
2 SIDE GEAR
3 PINION MATE GEAR
(3) I nstal l the pi ni on gear mate shaft. Al i gn the
rol l pi n hol es i n shaft and the di fferenti al case.
(4) I nstal l the rol l pi n to hol d the pi ni on mate
shaft i n the di fferenti al case (Fi g. 69).
(5) I nstal l the ri ng gear.
(6) Lubri cate al l di fferenti al components wi th
hypoi d gear l ubri cant.
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar Si l i cone
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 70).
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 Nm (30 ft. l bs.) torque.
CAUTION: Overfilling the differential can result in
lubricant foaming and overheating.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
CARDAN U-JOINT
Cl ean al l the Ujoi nt yoke bores wi th cl eani ng sol -
vent and a wi re brush. Ensure that al l the rust and
forei gn matter are removed from the bores.
I nspect the yokes for di storti on, cracks and worn
beari ng cap bores.
Repl ace the compl ete Ujoi nt i f any of the compo-
nents are defecti ve.
AXLE COMPONENTS
Wash di fferenti al components wi th cl eani ng sol vent
and dry wi th compressed ai r. Do not steam clean
the differential components.
Wash beari ngs wi th sol vent and towel dry, or dry
wi th compressed ai r. DO NOT spi n beari ngs wi th
compressed ai r. Cup and bearing must be
replaced as matched sets only.
Cl ean axl e shaft tubes and oi l channel s i n housi ng.
I nspect for;
Smooth appearance wi th no broken/dented sur-
faces on the beari ng rol l ers or the rol l er contact sur-
faces.
Beari ng cups must not be di storted or cracked.
Machi ned surfaces shoul d be smooth and wi th-
out any rai sed edges.
Rai sed metal on shoul ders of cup bores shoul d
be removed wi th a hand stone.
Fig. 69 Mate Shaft Roll Pin Installation
1 PUNCH
2 PINION MATE SHAFT
3 MATE SHAFT LOCKPIN
1 SEALING SURFACE
2 CONTOUR OF BEAD
Wear and damage to pi ni on gear mate shaft,
pi ni on gears, si de gears and thrust washers. Repl ace
as a matched set onl y.
Ri ng and pi ni on gear for worn and chi pped
teeth.
Ri ng gear for damaged bol t threads. Repl aced as
a matched set onl y.
Pi ni on yoke for cracks, worn spl i nes, pi tted
areas, and a rough/corroded seal contact surface.
Repai r or repl ace as necessary.
Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
ADJ USTMENTS
181 FBI PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
71). A pl us (+) number, mi nus () number or zero (0)
i s etched i nto the face of the pi ni on gear. Thi s num-
ber i s the amount (i n thousandths of an i nch) the
depth vari es from the standard depth setti ng of a
pi ni on etched wi th a (0). The standard setti ng from
the center l i ne of the ri ng gear to the back face of the
pi ni on i s 92.08 mm (3.625 i n.). The standard depth
provi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
thi s secti on for addi ti onal i nformati on.
Compensati on for pi ni on depth vari ance i s
achi eved wi th a sel ect shi m/oi l baffl e. The shi ms are
pl aced between the rear pi ni on beari ng and the pi n-
i on gear head (Fi g. 72).
I f a new gear set i s bei ng i nstal l ed, note the depth
vari ance etched i nto both the ori gi nal and repl ace-
ment pi ni on. Add or subtract thi s number from the
thi ckness of the ori gi nal depth shi m/oi l sl i nger to
compensate for the di fference i n the depth vari ances.
Refer to the Depth Vari ance chart.
Note where Ol d and New Pi ni on Marki ng col umns
i ntersect. I ntersecti ng fi gure represents pl us or
mi nus the amount needed.
Note the etched number on the face of the pi ni on
gear head (1, 2, 0, +1, +2, etc.). The numbers rep-
resent thousands of an i nch devi ati on from the stan-
dard. I f the number i s negati ve, add that val ue to the
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Fig. 71 Pinion Gear ID Numbers
1 PRODUCTION NUMBERS
2 DRIVE PINION GEAR DEPTH VARIANCE
3 GEAR MATCHING NUMBER (SAME AS RING GEAR
NUMBER)
Fig. 72 Shim Locations
1 PINION GEAR DEPTH SHIM/OIL BAFFLE
2 DIFFERENTIAL BEARING SHIM
CLEANING AND INSPECTION (Continued)
PINION DEPTH MEASUREMENT AND ADJUSTMENT
Measurements are taken wi th pi ni on beari ng cups
and pi ni on beari ngs i nstal l ed i n the axl e housi ng.
Take measurements wi th Pi ni on Gauge Set and Di al
I ndi cator C-3339 (Fi g. 73).
(1) Assembl e Pi ni on Hei ght Bl ock 6739, Pi ni on
Bl ock 6733, and rear pi ni on beari ng onto Screw 6741
(Fi g. 73).
(2) I nsert assembl ed hei ght gauge components,
rear beari ng and screw i nto axl e housi ng through
pi ni on beari ng cups (Fi g. 74).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
hand ti ght (Fi g. 73).
(4) Pl ace Arbor Di sc 6732 on Arbor D-115-3 i n posi -
ti on i n axl e housi ng si de beari ng cradl es (Fi g. 75).
I nstal l di fferenti al beari ng caps on Arbor Di scs and
ti ghten cap bol ts to 41 Nm (30 ft. l bs.).
NOTE: Arbor Discs 6732 has different step diame-
ters to fit other axles. Choose proper step for axle
being serviced.
(5) Assembl e Di al I ndi cator C-3339 i nto Scooter
Bl ock D-115-2 and secure set screw.
(6) Pl ace Scooter Bl ock/Di al I ndi cator i n posi ti on
i n axl e housi ng so di al probe and scooter bl ock are
fl ush agai nst the rearward surface of the pi ni on
PINION GEAR DEPTH VARIANCE
Original Pinion
Gear Depth
Variance
Replacement Pinion Gear Depth Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
Fig. 73 Pinion Gear Depth Gauge ToolsTypical
1 DIAL INDICATOR
2 ARBOR
3 PINION HEIGHT BLOCK
4 CONE
5 SCREW
6 PINION BLOCK
7 SCOOTER BLOCK
8 ARBOR DISC
Fig. 74 Pinion Height BlockTypical
1 PINION BLOCK
ADJ USTMENTS (Continued)
hei ght bl ock (Fi g. 73). Hol d scooter bl ock i n pl ace and
zero the di al i ndi cator face to the poi nter. Ti ghten
di al i ndi cator face l ock screw.
(7) Wi th scooter bl ock sti l l i n posi ti on agai nst the
pi ni on hei ght bl ock, sl owl y sl i de the di al i ndi cator
probe over the edge of the pi ni on hei ght bl ock.
(8) Sl i de the di al i ndi cator probe across the gap
between the pi ni on hei ght bl ock and the arbor bar
wi th the scooter bl ock agai nst the pi ni on hei ght bl ock
(Fi g. 76). When the di al probe contacts the arbor bar,
the di al poi nter wi l l turn cl ockwi se. Bri ng di al
poi nter back to zero agai nst the arbor bar, do not
turn di al face. Conti nue movi ng the di al probe to the
crest of the arbor bar and record the hi ghest readi ng.
I f the di al i ndi cator can not achi eve the zero readi ng,
the rear beari ng cup or the pi ni on depth gauge set i s
not i nstal l ed correctl y.
(9) Sel ect a shi m/oi l baffl e equal to the di al i ndi ca-
tor readi ng pl us the pi ni on depth vari ance number
etched i n the face of the pi ni on (Fi g. 71). For exam-
pl e, i f the depth vari ance i s 2, add +0.002 i n. to the
di al i ndi cator readi ng.
186 FBI PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng gear and pi ni on are suppl i ed as matched sets
onl y. The i denti fyi ng numbers for the ri ng gear and
pi ni on are etched i nto the face of each gear (Fi g. 77).
A pl us (+) number, mi nus () number or zero (0) i s
etched i nto the face of the pi ni on gear head. Thi s
number i s the amount (i n thousandths of an i nch)
the depth vari es from the standard depth setti ng of a
provi des the best gear tooth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s paragraph i n
achi eved wi th a sel ect shi m/oi l sl i nger. The shi m/oi l
sl i nger i s pl aced between the rear pi ni on beari ng and
the pi ni on gear head (Fi g. 78).
ment pi ni on. Add or subtract the thi ckness of the
ori gi nal depth shi ms to compensate for the di fference
i n the depth vari ances. Refer to the Depth Vari ance
chart.
Fig. 75 Gauge Tools In HousingTypical
1 ARBOR DISC
2 PINION BLOCK
3 ARBOR
Fig. 76 Pinion Gear Depth MeasurementTypical
1 ARBOR
2 SCOOTER BLOCK
3 DIAL INDICATOR
NUMBER)
Note the etched number on the face of the dri ve
pi ni on (1, 2, 0, +1, +2, etc.). The numbers repre-
sent thousands of an i nch devi ati on from the stan-
requi red thi ckness of the depth shi m/oi l sl i nger. I f
the number i s posi ti ve, subtract that val ue from the
thi ckness of the depth shi m/oi l sl i nger. I f the number
i s 0 no change i s necessary.
Take measurements wi th Pi ni on Gauge Set 6774 and
Di al I ndi cator C-3339 (Fi g. 79).
Original Pinion
Gear Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
1 DIAL INDICATOR
2 ARBOR
4 CONE
5 SCREW
6 PINION BLOCK
7 SCOOTER BLOCK
8 ARBOR DISC
(Fi g. 79).
(3) I nstal l front pi ni on beari ng and Cone-nut 6740
being serviced.
(9) Sel ect a shi m/oi l sl i nger equal to the di al i ndi -
cator readi ng pl us the dri ve pi ni on depth vari ance
number etched i n the face of the pi ni on (Fi g. 77). For
exampl e, i f the depth vari ance i s 2, add +0.002 i n.
to the di al i ndi cator readi ng.
AND GEAR BACKLASH
INTRODUCTION
Di fferenti al si de beari ng prel oad and gear backl ash
i s achi eved by sel ecti ve shi ms posi ti oned behi nd the
1 PINION BLOCK
1 ARBOR DISC
2 PINION BLOCK
3 ARBOR
1 ARBOR
2 SCOOTER BLOCK
3 DIAL INDICATOR
di fferenti al si de beari ng cones. The proper shi m
thi ckness can be determi ned usi ng sl i p-fi t dummy
beari ngs D-348 i n pl ace of the di fferenti al si de bear-
i ngs and a di al i ndi cator C-3339. Before proceedi ng
wi th the di fferenti al beari ng prel oad and gear back-
l ash measurements, measure the pi ni on gear depth
and prepare the pi ni on for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on i s i nstal l ed, and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng and the prel oad speci fi cati on added together.
The gear backl ash measurement determi nes the
thi ckness of the shi m used on the ri ng gear si de of
the di fferenti al case. Subtract the gear backl ash shi m
thi ckness from the total overal l shi m thi ckness and
sel ect that amount for the pi ni on gear si de of the di f-
ferenti al (Fi g. 83). Di fferenti al shi m measurements
are performed wi th axl e spreader W-129-B removed.
SHIM SELECTION
NOTE: It is difficult to salvage the differential side
bearings during the removal procedure. Install
replacement bearings if necessary.
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
(4) I nstal l dummy si de beari ngs D-348 on di fferen-
ti al case.
(5) I nstal l di fferenti al case i n axl e housi ng.
(6) I nstal l the marked beari ng caps i n thei r correct
posi ti ons. I nstal l and snug the bol ts (Fi g. 84).
(7) Usi ng a dead-bl ow type mal l et, seat the di ffer-
enti al dummy beari ngs to each si de of the axl e hous-
i ng (Fi g. 85) and (Fi g. 86).
(8) Thread gui de stud C-3288-B i nto rear cover
bol t hol e bel ow ri ng gear (Fi g. 87).
Fig. 83 Axle Adjustment Shim Locations
Fig. 84 Tighten Bolts Holding Bearing Caps
1 BEARING CAP
2 AXLE HOUSING
3 DIFFERENTIAL CASE
Fig. 85 Seat Pinion Gear Side Differential Dummy
Side Bearing
1 MALLET
2 AXLE HOUSING
3 DIFFERENTIAL CASE
(9) Attach a di al i ndi cator C-3339 to gui de stud.
Posi ti on the di al i ndi cator pl unger on a fl at surface
between the ri ng gear bol t heads (Fi g. 87).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of axl e housi ng (Fi g. 88).
(11) Zero di al i ndi cator face to poi nter (Fi g. 88).
(12) Push and hol d di fferenti al case to ri ng gear
si de of the axl e housi ng (Fi g. 89).
(13) Record di al i ndi cator readi ng (Fi g. 89).
(14) Add 0.008 i n. (0.2 mm) to the zero end pl ay
total . Thi s new total represents the thi ckness of
shi ms to compress, or prel oad the new beari ngs when
the di fferenti al i s i nstal l ed.
(15) Rotate di al i ndi cator out of the way on the
gui de stud.
(16) Remove di fferenti al case and dummy beari ngs
from axl e housi ng.
Fig. 86 Seat Ring Gear Side Differential Dummy
Side Bearing
1 AXLE HOUSING
2 MALLET
3 DIFFERENTIAL CASE
Fig. 87 Differential Side play Measurement
1 DIFFERENTIAL CASE
2 AXLE HOUSING
3 SPECIAL TOOL C-3288B
Fig. 88 Hold Differential Case and Zero Dial
Indicator
1 FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE
4 ZERO DIAL INDICATOR FACE
Fig. 89 Hold Differential Case and Read Dial
Indicator
1 READ DIAL INDICATOR
2 FORCE DIFFERENTIAL CASE TO RING GEAR SIDE
3 AXLE HOUSING
(17) I nstal l the pi ni on gear i n axl e housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
(18) I nstal l di fferenti al case and dummy beari ngs
D-348 i n axl e housi ng (wi thout shi ms), i nstal l bear-
i ng caps and ti ghten bol ts snug.
(19) Seat ri ng gear si de dummy beari ng (Fi g. 86).
(20) Posi ti on the di al i ndi cator pl unger on a fl at
surface between the ri ng gear bol t heads. (Fi g. 87).
(21) Push and hol d di fferenti al case toward pi ni on
gear (Fi g. 90).
(25) Subtract 0.002 i n. (0.05 mm) from the di al
i ndi cator readi ng to compensate for backl ash between
ri ng and pi ni on gears. Thi s total i s the thi ckness
shi m requi red to achi eve proper backl ash.
(26) Subtract the backl ash shi m thi ckness from
the total prel oad shi m thi ckness. The remai nder i s
the shi m thi ckness requi red on the pi ni on si de of the
axl e housi ng.
(27) Rotate di al i ndi cator out of the way on gui de
stud.
(29) I nstal l the sel ected si de beari ng shi ms onto
the di fferenti al case hubs.
(30) I nstal l si de beari ngs and cups on di fferenti al
case.
(31) I nstal l spreader W-129-B, uti l i zi ng some i tems
from Adapter Set 6987, on axl e housi ng and spread
axl e openi ng enough to recei ve di fferenti al case.
(32) I nstal l di fferenti al case i nto the axl e housi ng.
(33) Remove spreader from axl e housi ng.
(34) Rotate the di fferenti al case several ti mes to
seat the si de beari ngs.
(35) Posi ti on the i ndi cator pl unger agai nst a ri ng
gear tooth (Fi g. 92).
(36) Push and hol d ri ng gear upward whi l e not
al l owi ng the pi ni on gear to rotate.
(37) Zero di al i ndi cator face to poi nter.
(38) Push and hol d ri ng gear downward whi l e not
al l owi ng the pi ni on gear to rotate. Di al i ndi cator
readi ng shoul d be between 0.12 mm (0.005 i n.) and
0.20 mm (0.008 i n.). I f backl ash i s not wi thi n speci fi -
cati ons transfer the necessary amount of shi m thi ck-
ness from one si de of the axl e housi ng to the other
(Fi g. 93).
(39) Veri fy di fferenti al case and ri ng gear runout
by measuri ng ri ng to pi ni on gear backl ash at ei ght
l ocati ons around the ri ng gear. Readi ngs shoul d not
vary more than 0.05 mm (0.002 i n.). I f readi ngs vary
more than speci fi ed, the ri ng gear or the di fferenti al
case i s defecti ve.
After the proper backl ash i s achi eved, perform
Gear Contact Pattern Anal ysi s procedure.
Indicator
3 PINION GEAR
4 AXLE HOUSING
5 DIFFERENTIAL CASE
Indicator
3 PINION GEAR
4 AXLE HOUSING
5 DIFFERENTIAL CASE
AND GEAR BACKLASH
INTRODUCTION
i s achi eved by sel ecti ve shi ms posi ti oned behi nd the
di fferenti al si de beari ng cones. The proper shi m
and prepare the pi ni on for i nstal l ati on. Establ i shi ng
proper pi ni on gear depth i s essenti al to establ i shi ng
gear backl ash and tooth contact patterns. After the
overal l shi m thi ckness to take up di fferenti al si de
pl ay i s measured, the pi ni on i s i nstal l ed, and the
gear backl ash shi m thi ckness i s measured. The over-
al l shi m thi ckness i s the total of the di al i ndi cator
readi ng and the prel oad speci fi cati on added together.
ferenti al (Fi g. 94). Di fferenti al shi m measurements
are performed wi th axl e spreader W-129-B removed.
SHIM SELECTION
(1) Remove di fferenti al si de beari ngs from di ffer-
enti al case.
(2) Remove factory i nstal l ed shi ms from di fferen-
ti al case.
(3) I nstal l ri ng gear on di fferenti al case and
ti ghten bol ts to speci fi cati on.
ti al case.
Fig. 92 Ring Gear Backlash Measurement
1 DIAL INDICATOR
Fig. 93 Backlash Shim Adjustment
posi ti ons. I nstal l and snug the bol ts (Fi g. 95).
i ng (Fi g. 96) and (Fi g. 97).
(9) Attach a di al i ndi cator C-3339 to gui de stud.
between the ri ng gear bol t heads (Fi g. 98).
(10) Push and hol d di fferenti al case to pi ni on gear
si de of axl e housi ng (Fi g. 99).
Fig. 95 Tighten Bolts Holding Bearing Caps
1 BEARING CAP
2 AXLE HOUSING
3 DIFFERENTIAL CASE
Fig. 96 Seat Pinion Gear Side Differential Dummy
Side Bearing
1 MALLET
2 AXLE HOUSING
3 DIFFERENTIAL CASE
Fig. 97 Seat Ring Gear Side Differential Dummy
Side Bearing
1 AXLE HOUSING
2 MALLET
3 DIFFERENTIAL CASE
1 DIFFERENTIAL CASE
2 AXLE HOUSING
(15) Rotate di al i ndi cator out of the way on the
gui de stud.
(17) I nstal l the pi ni on i n the axl e housi ng. I nstal l
the pi ni on yoke and establ i sh the correct pi ni on
rotati ng torque.
D-348 i n axl e housi ng (wi thout shi ms), i nstal l bear-
i ng caps and ti ghten bol ts snug.
(19) Seat ri ng gear si de dummy beari ng (Fi g. 97).
surface between the ri ng gear bol t heads. (Fi g. 98).
gear (Fi g. 101).
Indicator
Indicator
3 AXLE HOUSING
Indicator
3 PINION GEAR
4 AXLE HOUSING
5 DIFFERENTIAL CASE
Indicator
3 PINION GEAR
4 AXLE HOUSING
5 DIFFERENTIAL CASE
ri ng and pi ni on gears. Thi s total i s the thi ckness
axl e housi ng.
stud.
(29) I nstal l si de beari ng shi ms on di fferenti al case
hubs.
(30) I nstal l si de beari ngs and cups on di fferenti al
case.
(31) I nstal l spreader W-129-B, uti l i zi ng some i tems
from Adapter Set 6987, on axl e housi ng and spread
axl e openi ng enough to recei ve di fferenti al case.
(33) Remove spreader from axl e housi ng.
ness from one si de of the axl e housi ng to the other
(Fi g. 104).
After the proper backl ash i s achi eved, perform
GEAR CONTACT PATTERN ANALYSIS
The ri ng gear and pi ni on teeth contact patterns
wi l l show i f the pi ni on depth i s correct i n the axl e
housi ng. I t wi l l al so show i f the ri ng gear backl ash
has been adjusted correctl y. The backl ash can be
adjusted wi thi n speci fi cati ons to achi eve desi red
tooth contact patterns.
(1) Appl y a thi n coat of hydrated ferri c oxi de, or
equi val ent, to the dri ve and coast si de of the ri ng
gear teeth.
(2) Wrap, twi st, and hol d a shop towel around the
pi ni on yoke to i ncrease the turni ng resi stance of the
pi ni on. Thi s wi l l provi de a more di sti nct contact pat-
tern.
(3) Usi ng a boxed end wrench on a ri ng gear bol t,
Rotate the di fferenti al case one compl ete revol uti on
i n both di recti ons whi l e a l oad i s bei ng appl i ed from
shop towel .
The areas on the ri ng gear teeth wi th the greatest
degree of contact agai nst the pi ni on teeth wi l l squee-
gee the compound to the areas wi th the l east amount
of contact. Note and compare patterns on the ri ng
gear teeth to Gear Tooth Contact Patterns chart (Fi g.
105) and adjust pi ni on depth and gear backl ash as
necessary.
1 DIAL INDICATOR
Fig. 105 Gear Tooth Contact Patterns
SPECIFICATIONS
181 FBI AXLE
Axl e Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hypoi d
Lubri cantStd. . . . . SAE Thermal l y Stabl e 80W90
Lubri cantHeavy Duty . . . SAE 75W140 Syntheti c
Lube Capaci ty . . . . . . . . . . . . . . . 1.48 L (3.13 pts.)
Axl e Rati o . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Di fferenti al Si de Gear Cl earance . . . 0.120.20 mm
(0.0050.008 i n.)
Ri ng Gear Di ameter . . . . . . . . . 18.09 cm (7.125 i n.)
Backl ash . . . . . . . . . . . 00.15 mm (0.0050.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . . 92.1 mm (3.625 i n.)
Pi ni on Beari ng Rotati ng Torque . . . . . . . . . . . . . . .
Ori gi nal Beari ngs . . . . . . . 12 Nm (1020 i n. l bs.)
New Beari ngs . . . . . . . . . 1.54 Nm (1535 i n. l bs.)
186 FBI AXLE
Axl e Type . . . . . . . . . . . . . . . . . . . . . . . . . . Hypoi d
Lubri cantStd. . . . . SAE Thermal l y Stabl e 80W90
Lubri cantHeavy Duty . . . SAE 75W140 Syntheti c
Lube Capaci ty . . . . . . . . . . . . . . . . 1.18 L (2.5 pts.)
Axl e Rati o . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73, 4.10
Di fferenti al Si de Gear Cl earance . . . 0.120.20 mm
(0.0050.008 i n.)
Backl ash . . . . . . . . . . . 00.15 mm (0.0050.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . . 92.1 mm (3.625 i n.)
Pi ni on Beari ng Rotati ng Torque . . . . . . . . . . . . . . .
Ori gi nal Beari ngs . . . . . . . 12 Nm (1020 i n. l bs.)
New Beari ngs . . . . . . . . . 1.54 Nm (1535 i n. l bs.)
TORQUE
DESCRIPTION TORQUE
Fi l l Hol e Pl ug . . . . . . . . . . . . . . 34 Nm (25 ft. l bs.)
Di ff. Cover Bol t . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Beari ng Cap Bol t . . . . . . . . . . . . 61 Nm (45 ft. l bs.)
Ri ng Gear Bol t . . . . . . . 95122 Nm (7090 ft. l bs.)
Axl e Nut . . . . . . . . . . . . . . . . 237 Nm (175 ft. l bs.)
Hub Brg. Bol t . . . . . . . . . . . . . 102 Nm (75 ft. l bs.)
Lower Bal l Stud . . . . . . . . . . . 108 Nm (80 ft. l bs.)
Upper Bal l Stud . . . . . . . . . . . 101 Nm (75 ft. l bs.)
SPECIAL TOOLS
181 and 186 FBI AXLE
PullerC-293-PA
PlugSP-3289
AdapterC-293-39
PullerC-452
WrenchC-3281
Dial IndicatorC-3339
DriverC-3716-A
HandleC-4171
InstallerD-146
RemoverD-149
InstallerW-162-D
Cup8109
Remover/Installer6289
Installer6761
Installer6752
SPECIAL TOOLS (Continued)
Installer Discs8110
Turnbuckle6797
Tool Set, Pinion Depth6774
Gauge Block6733
Spanner6958
InstallerC-3972-A
SpreaderW-129-B
Adapter Kit6987
Pilot StudC-3288-B
RemoverD-147
InstallerD-144
InstallerW-262
194 RBI AXLE
TABLE OF CONTENTS
page page
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . . 66
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 67
GEAR NOISE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . . 70
LOW SPEED KNOCK. . . . . . . . . . . . . . . . . . . . . . 70
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . . 70
TRACLOK DIFFERENTIAL NOISE . . . . . . . . . . 70
TRACLOK TEST . . . . . . . . . . . . . . . . . . . . . . . 71
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . 71
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
PINION SHAFT SEAL. . . . . . . . . . . . . . . . . . . . . . 72
COLLAPSIBLE SPACER. . . . . . . . . . . . . . . . . . . . 74
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
AXLE SHAFT SEAL AND BEARING . . . . . . . . . . . 77
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . 78
DIFFERENTIAL SIDE BEARINGS. . . . . . . . . . . . . 80
RING GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 85
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . . 87
AXLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . 91
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ADJUSTMENTS
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . . . . 91
DIFFERENTIAL BEARING PRELOAD AND
GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . . 94
GEAR CONTACT PATTERN ANALYSIS . . . . . . . . 97
SPECIFICATIONS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
SPECIAL TOOLS
194 RBI AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
194 RBI AXLE
DESCRIPTION
The 194 Rear Beam-desi gn I ron (RBI ) axl e housi ng
has an i ron center casti ng (di fferenti al housi ng) wi th
axl e shaft tubes extendi ng from ei ther si de. The
tubes are pressed i nto and wel ded to the di fferenti al
housi ng to form a one-pi ece axl e housi ng.
The i ntegral type, hypoi d gear desi gn, housi ng has
the centerl i ne of the pi ni on set bel ow the centerl i ne
of the ri ng gear.
The axl e has a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
shafts, meani ng that l oads are supported by the axl e
shaft and beari ngs. The axl e shafts are retai ned by
Ccl i ps i n the di fferenti al si de gears.
The cover provi des a means for servi ci ng the di ffer-
enti al wi thout removi ng the axl e.
For vehi cl es equi pped wi th ABS brakes, the axl es
have a tone ri ng pressed onto the axl e shaft. Use care
when removi ng axl e shafts to ensure that the tone
wheel or the wheel speed sensor are not damaged.
The 194 RBI axl e has the assembl y part number
the di fferenti al housi ng by a cover bol t. Bui l d date
i denti fi cati on codes are stamped on the cover si de of
an axl e shaft tube.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash i s adjusted by the use of sel ecti ve
spacer shi ms. Pi ni on beari ng prel oad i s set and
mai ntai ned by the use of a col l apsi bl e spacer (Fi g. 1).
Axl es equi pped wi th a Trac-Lok di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
XJ 194 RBI AXLE 3 - 65
LUBRICANT
DESCRIPTION
A mul ti -purpose, hypoi d gear l ubri cant whi ch con-
forms to the fol l owi ng speci fi cati ons shoul d be used.
Mopar Hypoi d Gear Lubri cant conforms to al l of
these speci fi cati ons.
The l ubri cant shoul d have MI LL2105C and
API GL 5 qual i ty speci fi cati ons.
Lubri cant i s a thermal l y stabl e SAE 80W90
gear l ubri cant.
Lubri cant for axl es i ntended for heavy-duty or
trai l er tow use i s SAE 75W140 SYNTHETI C gear
l ubri cant.
Trac-l ok di fferenti al s requi re the addi ti on of 3.5 oz.
of fri cti on modi fi er to the axl e l ubri cant. The 194 RBI
axl e l ubri cant capaci ty i s 1.66L (3.50 pts.) total ,
i ncl udi ng the fri cti on modi fi er i f necessary.
CAUTION: If axle is submerged in water, lubricant
must be replaced immediately to avoid possible
premature axle failure.
DESCRIPTION
OPERATION
rotates the case
the shafts
speed.
TRAC-LOK DIFFERENTIAL
DESCRIPTION
I n a standard di fferenti al , i f one wheel spi ns, the
opposi te wheel wi l l generate onl y as much torque as
the spi nni ng wheel .
1 PINION GEAR DEPTH SHIM
2 DIFFERENTIAL BEARING SHIM-PINION GEAR SIDE
3 RING GEAR
4 DIFFERENTIAL BEARING SHIM-RING GEAR SIDE
100% OF CASE SPEED
2 PINION GEAR
3 SIDE GEAR
3 - 66 194 RBI AXLE XJ
I n the Trac-l ok di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
OPERATION
I n operati on, the Trac-l ok cl utches are engaged
by two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 4).
The Trac-l ok desi gn provi des the di fferenti al
acti on needed for turni ng corners and for dri vi ng
strai ght ahead duri ng peri ods of unequal tracti on.
When one wheel l ooses tracti on, the cl utch packs
transfer addi ti onal torque to the wheel havi ng the
most tracti on. Trac-l ok di fferenti al s resi st wheel
spi n on bumpy roads and provi de more pul l i ng power
when one wheel l ooses tracti on. Pul l i ng power i s pro-
vi ded conti nuousl y unti l both wheel s l oose tracti on. I f
both wheel s sl i p due to unequal tracti on, Trac-l ok
operati on i s normal . I n extreme cases of di fferences
of tracti on, the wheel wi th the l east tracti on may
spi n.
GENERAL INFORMATION
by:
of:
of:
other.
Fig. 4 Trac-lok Limited Slip Differential Operation
1 CASE
2 RING GEAR
3 DRIVE PINION
4 PINION GEAR
5 MATE SHAFT
6 CLUTCH PACK
7 SIDE GEAR
8 CLUTCH PACK
DIAGNOSTIC CHART
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load information and
correct as necessary.
4. Excessive gear 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.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting
tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive
weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct
erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and
repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
1. Replace case and inspect gears and
bearings for further damage. Set differential
bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid excessive
vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid erratic use
of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with
the correct fluid type and quantity.
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all gears,
pinion bores, and shaft for damage. Service
as necessary.
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid type
and quantity.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and
bearings for possible damage.
2. Erratic clutch operation. 2. Replace gears and examine the remaining
parts for damage. Avoid erratic clutch
operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining
parts for damage.
4. Improper adjustments. 4. Replace gears and examine remaining
parts for damage. Ensure ring gear backlash
is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type
and quantity.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear
and pinion.
pinion.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
components as necessary.
8. Loose differential bearing cap
bolts.
8. Inspect differential components and replace
as necessary. Ensure that the bearing caps
are torqued tot he proper specification.
GEAR NOISE
greatl y:
Gear damage.
BEARING NOISE
source.
LOW SPEED KNOCK
VIBRATION
caused by a:
Worn Ujoi nt(s).
DRIVELINE SNAP
Worn Ujoi nts.
TRACLOK DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t
for repai r, drai n, fl ush and refi l l the axl e wi th the
speci fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar Trac-l ok Lubri cant (fri c-
ti on modi fi er) shoul d be added after repai r servi ce or
duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
TRACLOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRACLOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRACLOK AXLE CAN
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON-
TACT WITH A SURFACE TO CAUSE THE VEHICLE
TO MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 5).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Ti ghten the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(8) For Tracl ok di fferenti al s, a quanti ty of
Mopar Tracl ok l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
(11) Tracl ok di fferenti al equi pped vehi cl es
shoul d be road tested by maki ng 10 to 12 sl ow fi gure-
ei ght turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
Fig. 5 Trac-lok Test Typical
1 SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 TORQUE WRENCH
Fig. 6 Apply Sealant
1 SEALANT
2 AXLE HOUSING COVER
REAR AXLE
REMOVAL
axl e.
(5) Remove the brake drums from the axl e. Refer
to Group 5, Brakes, for proper procedures.
(6) Di sconnect parki ng brake cabl es from brackets
and l ever.
(7) Remove wheel speed sensors, i f necessary.
(8) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Group 5, Brakes, for
proper procedures.
(9) Di sconnect the vent hose from the axl e shaft
tube.
(10) Mark the propel l er shaft and yokes for i nstal -
l ati on al i gnment reference.
(12) Di sconnect stabi l i zer bar l i nks.
(13) Di sconnect shock absorbers from axl e.
(14) Remove the U-bol ts whi ch hol d the axl e to the
spri ng brackets.
(15) Separate the axl e from the vehi cl e.
INSTALLATION
NOTE: The weight of the vehicle must be sup-
are not at their normal ride position, vehicle ride
height and handling could be affected.
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn the
spri ng centeri ng bol ts wi th the mati ng hol es i n the
axl e spri ng perch.
(2) I nstal l the U-bol ts whi ch hol d the axl e to the
spri ng brackets. Ti ghten nuts to 70 Nm (52 ft. l bs.).
(3) I nstal l shock absorbers and ti ghten nuts to 60
(4) I nstal l stabi l i zer bar l i nks and ti ghten nuts to
(5) I nstal l the wheel speed sensors, i f necessary.
(6) Connect parki ng brake cabl e to brackets and
l ever.
(7) I nstal l the brake drums. Refer to Group 5,
Brakes, for proper procedures.
(8) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(9) I nstal l axl e vent hose.
(10) Al i gn propel l er shaft and pi ni on yoke refer-
ence marks. I nstal l U-joi nt straps and bol ts. Ti ghten
(11) I nstal l the wheel s and ti res.
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(13) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
PINION SHAFT SEAL
REMOVAL
(3) Remove the brake drums. Refer to Group 5,
i nstal l ati on al i gnment reference.
l ati on reference.
2 YOKE
(10) Use a sui tabl e pry tool or sl i de hammer
mounted screw to remove the pi ni on gear seal .
INSTALLATION
(2) I nstal l yoke on the pi ni on gear wi th Screw
8112, Cup 8109, and Hol der 6958 (Fi g. 9).
torque when installing the pinion yoke at this point.
Damage to the collapsible spacer or bearings may
result.
(3) I nstal l the yoke washer and a new nut on the
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
(4) Ti ghten the nut to 271 Nm (200 ft. l bs.).
torque or rotating torque is exceeded a new col-
lapsible spacer must be installed. The torque
sequence will then have to be repeated.
i ng recorded duri ng removal pl us an addi ti onal 0.56
Nm (5 i n. l bs.) (Fi g. 10).
hol d the pi ni on yoke (Fi g. 11), and ti ghten the pi ni on
shaft nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l the
CAUTION: If the maximum tightening torque is
reached prior to reaching the required rotating
torque, the collapsible spacer may have been dam-
aged. Replace the collapsible spacer.
propel l er shaft and yoke and i nstal l the propel l er
shaft.
(8) Add gear l ubri cant to the di fferenti al housi ng,
i f necessary. Refer to the Lubri cant Speci fi cati ons for
gear l ubri cant requi rements.
1 PINION YOKE
2 AXLE HOUSING
1 PINION YOKE
COLLAPSIBLE SPACER
REMOVAL W/PINION INSTALLED
(3) Remove rear brake drums. Refer to Group 5,
l ati on reference.
(11) Remove the front pi ni on beari ng usi ng a pai r of
sui tabl e pi ck tool s to pul l the beari ng strai ght off the
pi ni on gear shaft. I t may be necessary to l i ghtl y tap the
end of the pi ni on gear wi th a rawhi de or rubber mal l et
i f the beari ng becomes bound on the pi ni on shaft.
(12) Remove the col l apsi bl e spacer.
REMOVAL W/PINION REMOVED
(3) Remove rear brake drums. Refer to Group 5,
l ati on reference.
i ng.
pi ni on yoke nut and washer.
(10) Usi ng Remover C452 and Wrench C3281,
(11) Remove the pi ni on gear from housi ng (Fi g.
13). Catch the pi ni on wi th your hand to prevent i t
from fal l i ng and bei ng damaged.
(12) Remove col l apsi bl e spacer from pi ni on shaft.
INSTALLATION
i on shaft (Fi g. 14).
(2) I f pi ni on gear was removed, i nstal l pi ni on gear
i n housi ng.
(3) I nstal l pi ni on front beari ng, i f necessary.
(5) I nstal l yoke wi th Screw 8112, Cup 8109, and
Hol der 6958 (Fi g. 16).
(6) I f the ori gi nal pi ni on beari ngs are bei ng used,
i nstal l di fferenti al assembl y and axl e shafts, i f neces-
sary.
Fig. 11 Tightening Pinion Shaft NutTypical
1 SPECIAL TOOL 6958
2 1 in. PIPE
3 3/4 DRIVE TORQUE WRENCH
2 YOKE
NOTE: If new pinion bearings were installed, do not
install the differential assembly and axle shafts until
after the pinion bearing preload and rotating torque
are set.
pi ni on gear. Ti ghten the pi ni on nut unti l there i s zero
beari ng end-pl ay.
unti l beari ng end pl ay i s taken up (Fi g. 17).
NOTE: If more than 474 Nm (350 ft. lbs.) of torque
is necessary to remove the bearing end play, the
collapsible spacer is defective and must be
replaced.
1 RAWHIDE HAMMER
2 SHOULDER
3 PINION GEAR
4 OIL SLINGER
5 REAR BEARING
1 PINION YOKE
2 AXLE HOUSING
(11) Check rotati ng torque wi th a (i n. l bs.) torque
wrench (Fi g. 18). The torque necessary to rotate the
pi ni on gear shoul d be:
Ori gi nal Beari ngs The readi ng recorded dur-
i ng removal , pl us an addi ti onal 0.56 Nm (5 i n. l bs.).
(12) I nstal l di fferenti al assembl y and axl e shafts,
i f necessary.
(13) Al i gn marks made previ ousl y on yoke and
propel l er shaft and i nstal l propel l er shaft.
(14) I nstal l rear brake drums. Refer to Group 5,
Lubri cant Speci fi cati ons of thi s secti on for l ubri cant
requi rements.
AXLE SHAFT
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure.
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Loosen housi ng cover bol ts. Drai n l ubri cant
from the housi ng and axl e shaft tubes. Remove hous-
i ng cover.
(6) Rotate di fferenti al case so that pi ni on mate
gear shaft l ock screw i s accessi bl e. Remove l ock
screw and pi ni on mate gear shaft from di fferenti al
case (Fi g. 19).
(7) Push axl e shaft i nward and remove axl e shaft
Ccl i p l ock from the axl e shaft (Fi g. 20).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e shaft tube. Al so, exerci se care not to damage the
1 SPECIAL TOOL 6958
2 1 in. PIPE
Fig. 18 Check Pinion Gear Rotation Torque
1 PINION YOKE
Fig. 19 Mate Shaft Lock Screw
1 LOCK SCREW
2 PINION GEAR MATE SHAFT
wheel speed sensor on vehi cl es equi pped wi th ABS
brakes.
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip. Also, exercise care not to
damage the wheel speed sensor on vehicles
equipped with ABS brakes
(2) I nsert Ccl i p l ock i n end of axl e shaft. Push
axl e shaft outward to seat Ccl i p l ock i n si de gear.
(3) I nsert pi ni on mate shaft i nto di fferenti al case
and through thrust washers and pi ni on gears.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 19 Nm (14 ft. l bs.)
torque.
(5) I nstal l cover and add fl ui d. Refer to Lubri cant
Change procedure i n thi s secti on for procedure and
l ubri cant requi rements.
(6) I nstal l brake drum. Refer to Group 5, Brakes,
(7) I nstal l wheel and ti re.
AXLE SHAFT SEAL AND BEARING
REMOVAL
(1) Remove the axl e shaft.
(2) Remove the axl e shaft seal from the end of the
axl e shaft tube wi th a smal l pry bar.
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the axl e
tube wi th Beari ng Removal Tool Set 6310 usi ng
Adapter Foot 6310-5 (Fi g. 21).
(4) I nspect the axl e shaft tube bore for roughness
and burrs. Remove as necessary.
INSTALLATION
Do not install the original axle shaft seal.
Always install a new seal.
(1) Wi pe the axl e shaft tube bore cl ean.
(2) I nstal l axl e shaft beari ng wi th I nstal l er 6436
and Handl e C4171. Ensure that the part number on
the beari ng i s agai nst the i nstal l er.
(3) I nstal l the new axl e shaft seal wi th I nstal l er
6437 and Handl e C4171 (Fi g. 22).
Fig. 20 Axle Shaft CClip Lock
1 C-CLIP LOCK
2 AXLE SHAFT
3 SIDE GEAR
Fig. 21 Axle Shaft Bearing Removal
1 AXLE SHAFT TUBE
2 NUT
3 GUIDE PLATE
4 GUIDE
5 THREADED ROD
6 ADAPTER
7 FOOT
(4) I nstal l the axl e shaft.
DIFFERENTIAL
REMOVAL
al l ow fl ui d to drai n.
(4) Remove axl e shafts.
(5) Note the i nstal l ati on reference l etters stamped
on the beari ng caps and housi ng machi ned seal i ng
surface (Fi g. 23).
(6) Loosen the di fferenti al beari ng cap bol ts.
(7) Posi ti on Spreader W129B, uti l i zi ng some
i tems from Adapter set 6987, wi th the tool dowel pi ns
seated i n the l ocati ng hol es (Fi g. 24). I nstal l the hol d-
down cl amps and ti ghten the tool turnbuckl e fi nger
ti ght.
(8) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
to pi l ot stud. Load the i ndi cator pl unger agai nst the
i ndi cator.
the housing is overspread, it could be distorted or
damaged.
(9) Spread the housi ng enough to remove the di f-
ferenti al case from the housi ng. Measure the di s-
tance wi th the di al i ndi cator (Fi g. 26).
(11) Whi l e hol di ng the di fferenti al case i n posi ti on,
remove the di fferenti al beari ng cap bol ts and caps.
(12) Remove the di fferenti al from the housi ng.
Ensure that the di fferenti al beari ng cups remai n i n
posi ti on on the di fferenti al beari ngs (Fi g. 27).
(13) Mark or tag the di fferenti al beari ng cups to
i ndi cate whi ch si de of the di fferenti al they were
removed from.
Fig. 22 Axle Shaft Seal Installation
1 SPECIAL TOOL 6437
2 SEAL
3 AXLE SHAFT TUBE
Fig. 23 Bearing Cap Identification
1 AXLE HOUSING
2 DOWEL
3 SAFETY HOLD DOWN
4 SPECIAL TOOL W-129B
5 TURNBUCKLE
(14) Retri eve di fferenti al case prel oad shi ms from
axl e housi ng. Mark or tag the di fferenti al case pre-
l oad shi ms to i ndi cate whi ch si de of the di fferenti al
they were removed from.
(15) Remove spreader from housi ng.
INSTALLATION
I f repl acement di fferenti al beari ngs or di fferenti al
case are bei ng i nstal l ed, di fferenti al si de beari ng
shi m requi rements may change. Refer to the Di ffer-
enti al Beari ng Prel oad and Gear Backl ash proce-
dures i n thi s secti on to determi ne the proper shi m
sel ecti on.
(1) Posi ti on Spreader W129B, uti l i zi ng some i tems
from Adapter set 6987, wi th the tool dowel pi ns seated
i n the l ocati ng hol es (Fi g. 28). I nstal l the hol ddown
cl amps and ti ghten the tool turnbuckl e fi ngerti ght.
(2) I nstal l a Pi l ot Stud C-3288-B at the l eft si de of
to pi l ot stud. Load the i ndi cator pl unger agai nst the
i ndi cator.
the housing is overspread, it could be distorted or
damaged.
(3) Spread the housi ng enough to i nstal l the case
i n the housi ng. Measure the di stance wi th the di al
i ndi cator (Fi g. 26).
(5) I nstal l di fferenti al case i n the housi ng. Ensure
that the di fferenti al beari ng cups remai n i n posi ti on
on the di fferenti al beari ngs and that the prel oad
shi ms remai n between the face of the beari ng cup
and the housi ng. Tap the di fferenti al case to ensure
the beari ngs cups and shi ms are ful l y seated i n the
housi ng.
(6) I nstal l the beari ng caps at thei r ori gi nal l oca-
ti ons (Fi g. 29).
(7) Loosel y i nstal l di fferenti al beari ng cap bol ts.
(8) Remove axl e housi ng spreader.
Fig. 25 Install Dial Indicator
1 SPECIAL TOOLC-3339
2 DIAL INDICATOR
3 LEVER ADAPTER
Fig. 26 Spread Axle Housing
Fig. 27 Differential Case Removal
1 AXLE HOUSING
2 DIFFERENTIAL CASE
3 BEARING CUPS
(9) Ti ghten the beari ng cap bol ts to 77 Nm (57 ft.
l bs.) torque.
(10) I nstal l the axl e shafts.
REMOVAL
wi th Pul l er/Press C-293-PA, C-293-39 Bl ocks, and
Pl ug SP-3289 (Fi g. 30).
INSTALLATION
(1) Usi ng tool C-3716-A wi th handl e C-4171,
i nstal l di fferenti al si de beari ngs (Fi g. 31).
(2) I nstal l di fferenti al i n axl e housi ng.
RING GEAR
NOTE: The ring gear and pinion are serviced as a
matched set. Do not replace the ring gear without
replacing the pinion.
REMOVAL
soft metal jaw protectors. (Fi g. 32)
case.
1 AXLE HOUSING
2 DOWEL
3 SAFETY HOLD DOWN
5 TURNBUCKLE
Fig. 29 Differential Bearing Cap Reference Letters
2 BEARING
3 DIFFERENTIAL
4 SPECIAL TOOL SP-3289
INSTALLATION
(1) I nvert the di fferenti al case and start two ri ng
gear bol ts. Thi s wi l l provi de case-to-ri ng gear bol t
hol e al i gnment.
ti ghten to 95122 Nm (7090 ft. l bs.) torque (Fi g.
33).
PINION GEAR
The ri ng and pi ni on gears are servi ced i n a
matched set. Do not repl ace the pi ni on gear wi thout
repl aci ng the ri ng gear.
REMOVAL
(1) Remove di fferenti al from the axl e housi ng.
pi ni on yoke nut and washer.
(5) Usi ng Remover C452 and Wrench C3281,
(6) Remove the pi ni on gear from housi ng (Fi g. 35).
Catch the pi ni on wi th your hand to prevent i t from
fal l i ng and bei ng damaged.
Fig. 31 Install Differential Side Bearings
1 HANDLE C-4171
2 DIFFERENTIAL
3 BEARING
4 TOOL C-3716A
1 CASE
2 RING GEAR
3 RAWHIDE HAMMER
1 TORQUE WRENCH
2 RING GEAR BOLT
3 RING GEAR
4 CASE
(8) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(9) Remove the front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C4171 (Fi g. 36).
(10) Remove the rear beari ng cup from housi ng
(Fi g. 37). Use Remover D-149 and Handl e C4171.
(11) Remove the col l apsi bl e prel oad spacer (Fi g.
38).
(12) Remove the rear beari ng from the pi ni on wi th
Pul l er/Press C-293-PA and Adapters C-293-40 (Fi g.
39).
the bearing cage.
2 YOKE
1 RAWHIDE HAMMER
1 REMOVER
2 HANDLE
1 DRIVER
2 HANDLE
(13) Remove the depth shi ms from the pi ni on gear
shaft. Record the thi ckness of the depth shi ms.
INSTALLATION
l ubri cant to outsi de surface of beari ng cup.
(2) I nstal l the pi ni on rear beari ng cup wi th
I nstal l er D-146 and Dri ver Handl e C4171 (Fi g. 40).
Ensure cup i s correctl y seated.
(4) I nstal l the pi ni on front beari ng cup wi th
I nstal l er D130 and Handl e C4171 (Fi g. 41).
(5) I nstal l pi ni on front beari ng, and oi l sl i nger, i f
equi pped.
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion gear to achieve
proper ring and pinion gear mesh. If the factory
installed ring and pinion gears are reused, the pin-
ion depth shim should not require replacement. If
required, refer to Pinion Gear Depth to select the
proper thickness shim before installing rear pinion
bearing.
(7) Pl ace the proper thi ckness depth shi m on the
pi ni on gear.
2 SHOULDER
3 PINION GEAR
4 OIL SLINGER
5 REAR BEARING
2 VISE
3 ADAPTERS
Fig. 40 Pinion Rear Bearing Cup Installation
1 INSTALLER
2 HANDLE
(8) I nstal l the rear beari ng and sl i nger, i f
equi pped, on the pi ni on gear wi th I nstal l er W-262
(Fi g. 43).
i on shaft and i nstal l pi ni on gear i n housi ng (Fi g. 44).
(10) I nstal l pi ni on gear i n housi ng.
(11) I nstal l yoke wi th I nstal l er Screw 8112, Cup
8109, and hol der 6958 (Fi g. 45).
pi ni on gear and ti ghten the pi ni on nut unti l there i s
zero beari ng end-pl ay.
Fig. 41 Pinion Front Bearing Cup Installation
1 INSTALLER
2 HANDLE
Fig. 43 Shaft Rear Bearing Installation
1 PRESS
2 INSTALLATION TOOL
3 DRIVE PINION GEAR
4 DRIVE PINION GEAR SHAFT REAR BEARING
2 SHOULDER
3 PINION GEAR
4 OIL SLINGER
5 REAR BEARING
unti l beari ng end pl ay i s taken up (Fi g. 46).
NOTE: If the spacer requires more than 474 Nm
(350 ft. lbs.) torque to crush, the collapsible spacer
is defective and must be replaced.
(16) Check beari ng rotati ng torque wi th a (i n. l bs.)
torque wrench (Fi g. 47). The torque necessary to
rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs 1 to 2 Nm (10 to 20 i n.
l bs.).
(17) I nstal l di fferenti al i n housi ng.
FINAL ASSEMBLY
(1) Scrape the resi dual seal ant from the housi ng
and cover mati ng surfaces. Cl ean the mati ng surfaces
wi th mi neral spi ri ts. Appl y a bead of Mopar Si l i cone
Rubber Seal ant, or equi val ent, on the housi ng cover
(Fi g. 48).
(2) I nstal l the cover on the di fferenti al wi th the
attachi ng bol ts. I nstal l the i denti fi cati on tag. Ti ghten
the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(3) Refi l l the di fferenti al housi ng wi th gear l ubri -
cant. Refer to the Lubri cant Speci fi cati ons secti on of
thi s group for the gear l ubri cant requi rements.
(4) I nstal l the fi l l hol e pl ug.
1 PINION YOKE
2 AXLE HOUSING
1 SPECIAL TOOL 6958
2 1 in. PIPE
Fig. 47 Check Pinion Gear Rotating Torque
1 PINION YOKE
DISASSEMBLY
(1) Remove pi ni on mate shaft l ock screw (Fi g. 49).
(2) Remove pi ni on mate shaft.
(3) Rotate the di fferenti al si de gears and remove
the di fferenti al pi ni on gears and thrust washers (Fi g.
50).
washers.
ASSEMBLY
washers.
(2) I nstal l the di fferenti al pi ni on gears and thrust
washers.
(3) I nstal l the pi ni on mate shaft.
(4) Al i gn the hol e i n the pi ni on mate shaft wi th
the hol e i n the di fferenti al case and i nstal l the pi ni on
mate shaft l ock screw.
1 SEALING SURFACE
2 CONTOUR OF BEAD
Fig. 49 Pinion Mate Shaft Lock Screw
1 LOCK SCREW
2 PINION MATE SHAFT
1 THRUST WASHER
2 SIDE GEAR
3 PINION MATE GEAR
The Tracl ok di fferenti al components are i l l us-
trated i n (Fi g. 51). Refer to thi s i l l ustrati on duri ng
repai r servi ce.
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 6965 i n a vi se.
(2) Posi ti on the di fferenti al case on Si de Gear
Hol di ng Tool 6965 (Fi g. 52).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
(4) Remove the pi ni on gear mate shaft l ock screw
(Fi g. 53).
(5) Remove the pi ni on gear mate shaft. I f neces-
sary, use a dri ft and hammer (Fi g. 54).
(6) I nstal l and l ubri cate Step Pl ate C-6960-3 (Fi g.
55).
Fig. 51 Traclok Differential Components
1 THRUST WASHER
2 PINION
3 SHAFT LOCK SCREW
4 PINION MATE SHAFT
5 SIDE GEAR
6 RETAINER
7 DISC
8 CLUTCH PACK
9 DIFFERENTIAL CASE
10 RETAINER
Fig. 52 Differential Case Holding Tool
1 SPECIAL TOOL 6965
2 VISE
3 DIFFERENTIAL
(7) Assembl e Threaded Adapter C-6960-1 i nto top
si de gear. Thread Forci ng Screw C-6960-4 i nto
adapter unti l i t becomes centered i n adapter pl ate.
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter C-6960-1 (Fi g. 56) to prevent
adapter from turni ng.
(9) Ti ghten forci ng screw tool 122 Nm (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 57).
1 LOCK SCREW
2 PINION GEAR MATE SHAFT
Fig. 54 Mate Shaft Removal
1 PINION MATE SHAFT
2 SIDE GEAR
3 DRIFT
4 PINION MATE GEAR
Fig. 55 Step Plate Tool Installation
1 LOWER SIDE GEAR
2 DIFFERENTIAL CASE
Fig. 56 Threaded Adapter Installation
1 SOCKET
2 SLOT IN ADAPTER
3 SCREWDRIVER
4 DISC C-69603
5 THREADED ROD C-69604
6 THREADED ADAPTER DISC C69601
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the pi ni on gears
(Fi g. 58).
(11) I nsert Turni ng Bar C-6960-2 i n case (Fi g. 59).
(12) Loosen the Forci ng Screw C-6960-4 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar C-6960-2.
(13) Rotate di fferenti al case unti l the pi ni on gears
can be removed.
(14) Remove pi ni on gears from di fferenti al case.
(15) Remove Forci ng Screw C-6960-4, Step Pl ate
C-6960-3, and Threaded Adapter C-6960-1.
(16) Remove top si de gear, cl utch pack retai ner,
and cl utch pack. Keep pl ates i n correct order duri ng
removal (Fi g. 60).
Fig. 57 Tighten Belleville Spring Compressor Tool
1 TORQUE WRENCH
2 TOOL ASSEMBLED
3 DIFFERENTIAL CASE
Fig. 58 Remove Pinion Gear Thrust Washer
1 THRUST WASHER
2 FEELER GAUGE
Fig. 59 Pinion Gear Removal
1 PINION GEARS
2 TOOL
Fig. 60 Side Gear & Clutch Disc Removal
1 DIFFERENTIAL CASE
2 RETAINER
3 SIDE GEAR AND CLUTCH DISC PACK
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 6965. Remove si de gear, cl utch pack retai ner,
removal .
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 61).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 62). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Hol di ng Tool 6965.
(5) I nstal l l ubri cated Step Pl ate C-6960-3 i n l ower
si de gear (Fi g. 63).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 63).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter C-6960-1 i nto top si de gear.
(8) I nsert Forci ng Screw C-6960-4.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace pi ni on gears i n posi ti on i n si de gears
and veri fy that the pi ni on mate shaft hol e i s al i gned.
Fig. 61 Clutch Disc Pack
1 CLUTCH PACK
2 RETAINER
3 SIDE GEAR
4 RETAINER
Fig. 62 Clutch Discs & Lower Side Gear Installation
1 DIFFERENTIAL CASE
2 LOWER SIDE GEAR AND CLUTCH DISC PACK
Fig. 63 Upper Side Gear & Clutch Disc Pack
Installation
1 UPPER SIDE GEAR AND CLUTCH DISC PACK
2 DIFFERENTIAL CASE
(11) Rotate case wi th Turni ng Bar C-6960-2 unti l
the pi ni on mate shaft hol es i n pi ni on gears al i gn
wi th hol es i n case. I t may be necessary to sl i ghtl y
ti ghten the forci ng screw i n order to i nstal l the pi n-
i on gears.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni on gears and al i gn washers wi th a smal l screw
dri ver. I nsert mate shaft i nto each pi ni on gear to ver-
i fy al i gnment.
(14) Remove Forci ng Screw C-6960-4, Step Pl ate
C-6960-3, and Threaded Adapter C-6960-1.
(15) I nstal l pi ni on gear mate shaft and al i gn hol es
i n shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
If replacement gears and thrust washers were
installed, it is not necessary to measure the
gear backlash. Correct fit is due to close
machining tolerances during manufacture.
AXLE COMPONENTS
and dry wi th compressed ai r. Do not steam clean
the differential components.
Cl ean axl e shaft tubes and oi l channel s i n housi ng.
I nspect for;
faces.
Wear and damage to pi ni on gear mate shaft,
pi ni on gears, si de gears and thrust washers. Repl ace
as a matched set onl y.
Ri ng and pi ni on gear for worn and chi pped
teeth.
Prel oad shi ms for damage and di storti on. I nstal l
new shi ms, i f necessary.
TRAC-LOK
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
ADJ USTMENTS
PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng and pi ni on gears are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng and
pi ni on gear are etched i nto the face of each gear (Fi g.
i s etched i nto the face of the pi ni on gear. Thi s num-
ber i s the amount (i n thousandths of an i nch) the
depth vari es from the standard depth setti ng of a
provi des the best teeth contact pattern. Refer to
Backl ash and Contact Pattern Anal ysi s Paragraph i n
NUMBER)
achi eved wi th sel ect shi ms. The shi ms are pl aced
under the i nner pi ni on beari ng cone (Fi g. 65).
ment pi ni on gear. Add or subtract the thi ckness of
the ori gi nal depth shi ms to compensate for the di ffer-
ence i n the depth vari ances. Refer to the Depth Vari -
ance charts.
mi nus amount needed.
Note the etched number on the face of the dri ve
pi ni on gear (1, 2, 0, +1, +2, etc.). The numbers rep-
requi red thi ckness of the depth shi m(s). I f the num-
ber i s posi ti ve, subtract that val ue from the thi ckness
of the depth shi m(s). I f the number i s 0 no change i s
necessary. Refer to the Pi ni on Gear Depth Vari ance
Chart.
Measurements are taken wi th pi ni on cups and pi n-
i on beari ngs i nstal l ed i n housi ng. Take measure-
ments wi th a Pi ni on Gauge Set, Pi ni on Bl ock 6735,
Arbor Di scs 6732, and Di al I ndi cator C-3339 (Fi g.
66).
(Fi g. 66).
(3) I nstal l front pi ni on beari ng and Cone 6740
ti ghten cap bol ts. Refer to the Torque Speci fi cati ons
i n thi s secti on.
NOTE: Arbor Discs 6732 have different step diame-
ters to fit other axle sizes. Pick correct size step for
axle being serviced.
3 RING GEAR
Original Pinion
Gear Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
fl ush agai nst the surface of the pi ni on hei ght bl ock.
Hol d scooter bl ock i n pl ace and zero the di al i ndi ca-
tor face to the poi nter. Ti ghten di al i ndi cator face
l ock screw.
Observe how many revol uti ons countercl ockwi se the
di al poi nter travel s (approxi matel y 0.125 i n.) to the
out-stop of the di al i ndi cator.
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on gear (Fi g. 64) usi ng
the opposi te si gn on the vari ance number. For exam-
(10) Remove the pi ni on depth gauge components
from the axl e housi ng
1 DIAL INDICATOR
2 ARBOR
4 CONE
5 SCREW
6 PINION BLOCK
7 SCOOTER BLOCK
8 ARBOR DISC
1 PINION BLOCK
1 ARBOR DISC
2 PINION BLOCK
3 ARBOR
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
i s achi eved by sel ecti ve shi ms i nserted between the
beari ng cup and the axl e housi ng. The proper shi m
and prepare the pi ni on gear for i nstal l ati on. Estab-
l i shi ng proper pi ni on gear depth i s essenti al to estab-
l i shi ng gear backl ash and tooth contact patterns.
After the overal l shi m thi ckness to take up di fferen-
ti al si de pl ay i s measured, the pi ni on gear i s
i nstal l ed, and the gear backl ash shi m thi ckness i s
measured. The overal l shi m thi ckness i s the total of
the di al i ndi cator readi ng, starti ng poi nt shi m thi ck-
ness, and the prel oad speci fi cati on added together.
ferenti al (Fi g. 70).
SHIM SELECTION
(1) Remove si de beari ngs from di fferenti al case.
(2) I nstal l ri ng gear, i f necessary, on di fferenti al
case and ti ghten bol ts to speci fi cati on.
ti al case.
(5) I nsert Dummy Shi ms 8107 (0.118 i n. (3.0 mm))
starti ng poi nt shi ms between the dummy beari ng
and the axl e housi ng (Fi g. 71).
1 ARBOR
2 SCOOTER BLOCK
3 DIAL INDICATOR
3 RING GEAR
Fig. 71 Insert Starting Point Shims
1 SPECIAL TOOL 8107
2 AXLE HOUSING
3 DIFFERENTIAL CASE
4 SPECIAL TOOL D-348
posi ti ons. I nstal l and snug the bol ts.
i ng (Fi g. 72) and (Fi g. 73).
(9) Attach di al i ndi cator C-3339 to gui de stud.
on a ri ng gear bol t head (Fi g. 74).
(10) Push fi rml y and hol d di fferenti al case to pi n-
i on gear si de of axl e housi ng (Fi g. 75).
(12) Push fi rml y and hol d di fferenti al case to ri ng
gear si de of the axl e housi ng (Fi g. 76).
(13) Record di al i ndi cator readi ng.
Fig. 72 Seat Pinion Gear Dummy Side Bearing
1 MALLET
2 AXLE HOUSING
3 DIFFERENTIAL CASE
Fig. 73 Seat Ring Gear Side Dummy Bearing
1 AXLE HOUSING
2 MALLET
3 DIFFERENTIAL CASE
1 DIFFERENTIAL CASE
2 AXLE HOUSING
Indicator
(14) Add the di al i ndi cator readi ng to the starti ng
poi nt shi m thi ckness to determi ne total shi m thi ck-
ness to achi eve zero di fferenti al end pl ay.
stud.
(17) Remove di fferenti al case, dummy beari ngs,
and starti ng poi nt shi ms from axl e housi ng.
(18) I nstal l pi ni on gear i n axl e housi ng. I nstal l the
yoke and establ i sh the correct pi ni on rotati ng torque.
i n axl e housi ng (wi thout shi ms) and ti ghten retai ni ng
cap bol ts.
surface between the ri ng gear bol t heads (Fi g. 74).
gear.
si de of the axl e housi ng.
(24) Record di al i ndi cator readi ng.
ri ng and pi ni on gears. Thi s total i s the thi ckness of
axl e housi ng.
stud.
(29) I nstal l new si de beari ng cones and cups on
di fferenti al case.
(30) I nstal l spreader W-129-B, uti l i zi ng some com-
ponents of Adapter Set 6987, on axl e housi ng and
spread axl e openi ng enough to recei ve di fferenti al
case.
(31) Pl ace si de beari ng shi ms i n axl e housi ng
agai nst axl e tubes.
ness from one si de of the di fferenti al housi ng to the
other (Fi g. 78).
Indicator
3 AXLE HOUSING
After the proper backl ash i s achi eved, perform the
gear teeth.
tern.
shop towel .
necessary.
1 DIAL INDICATOR
SPECIFICATIONS
194 RBI AXLE
DESCRIPTION SPECIFICATION
Axl e Type . . . . . . . . . . . . . . . Semi Fl oati ng Hypoi d
Lubri cant . . . . . . . . SAE Thermal l y Stabl e 80W90
Lubri cant Trai l er Tow . . . . . . . Syntheti c 75W140
Lube Capaci ty . . . . . . . . . . . . . . . 1.66 L (3.50 pts.)
Fri cti on Modi fi er . . . . . . . . . . . . . 0.12 L (3.50 ozs.)
Axl e Rati os . . . . . . . . . . . . . . . . . . . 3.07, 3.55, 3.73
Di fferenti al Beari ng Prel oad . . . 0.1 mm (0.008 i n.)
Di fferenti al Si de Gear Cl earance . . . . . . 00.15 mm
(00.006 i n.)
Ri ng Gear Backl ash . . 00.15 mm (0.0050.008 i n.)
Pi ni on Std. Depth . . . . . . . . . . 96.85 mm (3.813 i n.)
Pi ni on Beari ng Prel oad-Ori gi nal
Beari ngs . . . . . . . . . . . . 12 Nm (1020 i n. l bs.)
Pi ni on Beari ng Prel oad-New Beari ngs . . 1.54 Nm
(1535 i n. l bs.)
194 RBI AXLE
DESCRIPTION TORQUE
Bol t, Di ff. Cover . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bol t, Beari ng Cap . . . . . . . . . . . 77 Nm (57 ft. l bs.)
Nut, Pi ni on . . . . . . . 271474 Nm (200350 ft. l bs.)
Screw, Pi ni on Mate Shaft Lock . . . . . . . . 16.25 Nm
(12 ft. l bs.)
Bol t, Ri ng Gear . . . . . . 95122 Nm (7090 ft. l bs.)
Bol t, RWAL/ABS Sensor . . . . . . . 8 Nm (70 i n. l bs.)
SPECIAL TOOLS
194 RBI AXLE
PullerC-293-PA
AdapterC-293-39
AdapterC-293-40
PlugSP-3289
PullerC-452
WrenchC-3281
InstallerC-3972-A
Spanner6958
Installer Screw8112
Cup8109
HandleC-4171
DriverC-3716-A
InstallerD-130
InstallerD-146
RemoverC-4345
RemoverD-149
InstallerW-262
3 - 100 194 RBI AXLE XJ
Installer6436
Installer6437
Disc, Axle Arbor6732
Gauge Block6735
Tool Set, Pinion Depth6774
Trac-lok Tool Set6960
Holder6965
Puller7794-A
Starting Point Shim8107
SpreaderW-129-B
XJ 194 RBI AXLE 3 - 101
Adapter Kit6987
Guide PinC-3288-B
Bearing Remover Tool Set6310
Hub Puller6790
3 - 102 194 RBI AXLE XJ
8 1/4 REAR AXLE
TABLE OF CONTENTS
page page
8 1/4 AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 105
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . 105
GENERAL INFORMATION . . . . . . . . . . . . . . . . . 106
GEAR NOISE. . . . . . . . . . . . . . . . . . . . . . . . . . . 109
BEARING NOISE . . . . . . . . . . . . . . . . . . . . . . . . 109
LOW SPEED KNOCK. . . . . . . . . . . . . . . . . . . . . 109
VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
DRIVELINE SNAP . . . . . . . . . . . . . . . . . . . . . . . 109
TRACLOK DIFFERENTIAL NOISE . . . . . . . . . 109
TRACLOK TEST . . . . . . . . . . . . . . . . . . . . . . 110
SERVICE PROCEDURES
LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . 110
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
AXLE SEAL AND BEARING . . . . . . . . . . . . . . . . 112
PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DIFFERENTIAL. . . . . . . . . . . . . . . . . . . . . . . . . . 114
DIFFERENTIAL SIDE BEARINGS . . . . . . . . . . . . 115
RING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
PINION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . 117
STANDARD DIFFERENTIAL . . . . . . . . . . . . . . . . 120
TRAC-LOK DIFFERENTIAL . . . . . . . . . . . . . . . 121
8 1/4 AXLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
TRAC-LOK . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
ADJUSTMENTS
8 1/4 AXLE PINION GEAR DEPTH . . . . . . . . . . . 126
GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . 127
GEAR CONTACT PATTERN ANALYSIS. . . . . . . . 129
SIDE GEAR CLEARANCE . . . . . . . . . . . . . . . . . 129
SPECIFICATIONS
8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . . . 131
8 1/4 INCH AXLE . . . . . . . . . . . . . . . . . . . . . . . . 131
SPECIAL TOOLS
8 1/4 AXLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
8 1/4 AXLE
DESCRIPTION
The 8 1/4 i nch axl e housi ngs consi st of a cast i ron
center secti on wi th axl e tubes extendi ng from ei ther
si de. The tubes are pressed i nto and wel ded to the
di fferenti al housi ng to form a one-pi ece axl e housi ng
(Fi g. 1).
The axl es have a vent hose to rel i eve i nternal pres-
sure caused by l ubri cant vapori zati on and i nternal
expansi on.
The axl es are equi pped wi th semi -fl oati ng axl e
shafts, meani ng vehi cl e l oads are supported by the
axl e shaft and beari ngs. The axl e shafts are retai ned
by C-l ocks i n the di fferenti al si de gears.
The removabl e, stamped steel cover provi des a
means for i nspecti on and servi ce wi thout removi ng
the compl ete axl e from the vehi cl e.
The 8 1/4 axl e have a date tag and a gear rati o tag.
The tags are attached to the di fferenti al housi ng by a
cover bol t.
The di fferenti al case i s a one-pi ece desi gn. The di f-
ferenti al pi ni on mate shaft i s retai ned wi th a
threaded pi n. Di fferenti al beari ng prel oad and ri ng
gear backl ash are set and mai ntai ned by threaded
adjusters at the outsi de of the di fferenti al housi ng.
Pi ni on beari ng prel oad i s set and mai ntai ned by the
use of a col l apsi bl e spacer.
Axl es equi pped wi th a Trac-Lok di fferenti al are
opti onal . A Trac-Lok di fferenti al has a one-pi ece di f-
ferenti al case, and the same i nternal components as
a standard di fferenti al , pl us two cl utch di sc packs.
AXLE IDENTIFICATION
The axl e di fferenti al cover can be used for i denti fi -
cati on of the axl e (Fi g. 2). A tag i s al so attached to
the cover.
OPERATION
The axl e recei ves power from the transmi ssi on/
transfer case through the rear propel l er shaft. The
rear propel l er shaft i s connected to the pi ni on gear
whi ch rotates the di fferenti al through the gear mesh
wi th the ri ng gear bol ted to the di fferenti al case. The
engi ne power i s transmi tted to the axl e shafts
through the pi ni on mate and si de gears. The si de
gears are spl i ned to the axl e shafts.
XJ 8 1/4 REAR AXLE 3 - 103
LUBRICANT
DESCRIPTION
Mul ti -purpose, hypoi d gear l ubri cant shoul d be
used for rear axl es wi th a standard di fferenti al . The
l ubri cant shoul d have a MI L-L-2105C and API GL 5
qual i ty speci fi cati ons.
Trac-Lok di fferenti al s requi re the addi ti on of 4 oz.
of fri cti on modi fi er to the axl e l ubri cant after servi ce.
The 8 1/4 axl e l ubri cant capaci ty i s 2.08 L (4.4 pts.)
total , i ncl udi ng the fri cti on modi fi er, i f necessary.
CAUTION: If the rear axle is submerged in water,
the lubricant must be replaced immediately. Avoid
the possibility of premature axle failure resulting
from water contamination of the lubricant.
Fig. 1 8 1/4 Axle
Fig. 2 Differential Cover 8 1/4 Inch Axle
1 DIFFERENTIAL COVER
2 IDENTIFICATION TAG
3 PUSH-IN FILL PLUG
4 DATE TAG
3 - 104 8 1/4 REAR AXLE XJ
DESCRIPTION
OPERATION
rotates the case
the shafts
speed.
DESCRIPTION
I n a standard di fferenti al , i f one wheel spi ns, the
opposi te wheel wi l l generate onl y as much torque as
the spi nni ng wheel .
I n the Trac-l ok di fferenti al , part of the ri ng gear
torque i s transmi tted through cl utch packs whi ch
contai n mul ti pl e di scs. The cl utches wi l l have radi al
grooves on the pl ates, and concentri c grooves on the
di scs or bonded fi ber materi al that i s smooth i n
appearance.
OPERATION
I n operati on, the Trac-l ok cl utches are engaged
by two concurrent forces. The fi rst bei ng the prel oad
force exerted through Bel l evi l l e spri ng washers
wi thi n the cl utch packs. The second i s the separati ng
forces generated by the si de gears as torque i s
appl i ed through the ri ng gear (Fi g. 5).
100% OF CASE SPEED
2 PINION GEAR
3 SIDE GEAR
XJ 8 1/4 REAR AXLE 3 - 105
The Trac-l ok desi gn provi des the di fferenti al
acti on needed for turni ng corners and for dri vi ng
strai ght ahead duri ng peri ods of unequal tracti on.
When one wheel l ooses tracti on, the cl utch packs
transfer addi ti onal torque to the wheel havi ng the
most tracti on. Trac-l ok di fferenti al s resi st wheel
spi n on bumpy roads and provi de more pul l i ng power
when one wheel l ooses tracti on. Pul l i ng power i s pro-
vi ded conti nuousl y unti l both wheel s l oose tracti on. I f
both wheel s sl i p due to unequal tracti on, Trac-l ok
operati on i s normal . I n extreme cases of di fferences
of tracti on, the wheel wi th the l east tracti on may
spi n.
GENERAL INFORMATION
by:
of:
of:
other.
Fig. 5 Trac-lok Limited Slip Differential Operation
1 CASE
2 RING GEAR
3 DRIVE PINION
4 PINION GEAR
5 MATE SHAFT
6 CLUTCH PACK
7 SIDE GEAR
8 CLUTCH PACK
3 - 106 8 1/4 REAR AXLE XJ
DIAGNOSTIC CHART
Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as
necessary.
3. End-play in pinion bearings. 3. Refer to pinion pre-load information and
correct as necessary.
4. Excessive gear 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.
7. Scuffed gear tooth contact
surfaces.
7. Inspect and replace as necessary.
Axle Shaft Broke 1. Misaligned axle tube. 1. Replace the broken shaft after correcting
tube mis-alignment.
2 Vehicle overloaded. 2. Replace broken shaft and avoid excessive
weight on vehicle.
3. Erratic clutch operation. 3. Replace broken shaft and avoid or correct
erratic clutch operation.
4. Grabbing clutch. 4. Replace broken shaft and inspect and
repair clutch as necessary.
Differential Cracked 1. Improper adjustment of the
1. Replace case and inspect gears and
bearings for further damage. Set differential
bearing pre-load properly.
2. Excessive ring gear backlash. 2. Replace case and inspect gears and
bearings for further damage. Set ring gear
backlash properly.
3. Vehicle overloaded. 3. Replace case and inspect gears and
bearings for further damage. Avoid excessive
vehicle weight.
4. Erratic clutch operation. 4. Replace case and inspect gears and
bearings for further damage. Avoid erratic use
of clutch.
Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with
2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with
3. Excessive spinning of one
wheel/tire.
3. Replace scored gears. Inspect all gears,
pinion bores, and shaft for damage. Service
as necessary.
XJ 8 1/4 REAR AXLE 3 - 107
Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level.
Axle Overheating 1. Lubricant level low. 1. Fill differential to correct level.
2. Improper grade of lubricant. 2. Fill differential with the correct fluid type
and quantity.
Gear Teeth Broke 1. Overloading. 1. Replace gears. Examine other gears and
bearings for possible damage.
2. Erratic clutch operation. 2. Replace gears and examine the remaining
parts for damage. Avoid erratic clutch
operation.
3. Ice-spotted pavement. 3. Replace gears and examine remaining
parts for damage.
4. Improper adjustments. 4. Replace gears and examine remaining
parts for damage. Ensure ring gear backlash
is correct.
Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type
and quantity.
adjustment.
3. Unmatched ring gear and pinion. 3. Replace gears with a matched ring gear
and pinion.
pinion.
7. Mis-aligned or sprung ring gear. 7. Measure ring gear run-out. Replace
8. Loose differential bearing cap
bolts.
8. Inspect differential components and replace
as necessary. Ensure that the bearing caps
are torqued tot he proper specification.
3 - 108 8 1/4 REAR AXLE XJ
GEAR NOISE
greatl y:
Gear damage.
BEARING NOISE
source.
LOW SPEED KNOCK
VIBRATION
caused by a:
Worn Ujoi nt(s).
DRIVELINE SNAP
Worn Ujoi nts.
TRACLOK DIFFERENTIAL NOISE
The most common probl em i s a chatter noi se when
turni ng corners. Before removi ng a Trac-l ok uni t
for repai r, drai n, fl ush and refi l l the axl e wi th the
speci fi ed l ubri cant. Refer to Lubri cant change i n thi s
Group.
A contai ner of Mopar Trac-l ok Lubri cant (fri c-
ti on modi fi er) shoul d be added after repai r servi ce or
duri ng a l ubri cant change.
After changi ng the l ubri cant, dri ve the vehi cl e and
make 10 to 12 sl ow, fi gure-ei ght turns. Thi s maneu-
ver wi l l pump l ubri cant through the cl utches. Thi s
wi l l correct the condi ti on i n most i nstances. I f the
chatter persi sts, cl utch damage coul d have occurred.
XJ 8 1/4 REAR AXLE 3 - 109
TRACLOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRACLOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRACLOK AXLE CAN
EXERT ENOUGH FORCE IF ONE WHEEL IS IN CON-
TACT WITH A SURFACE TO CAUSE THE VEHICLE
TO MOVE.
The di fferenti al can be tested wi thout removi ng the
di fferenti al case by measuri ng rotati ng torque. Make
sure brakes are not draggi ng duri ng thi s measure-
ment.
(1) Pl ace bl ocks i n front and rear of both front
wheel s.
(2) Rai se one rear wheel unti l i t i s compl etel y off
the ground.
(3) Engi ne off, transmi ssi on i n neutral , and park-
i ng brake off.
(4) Remove wheel and bol t Speci al Tool 6790 to
studs.
(5) Use torque wrench on speci al tool to rotate
wheel and read rotati ng torque (Fi g. 6).
(6) I f rotati ng torque i s l ess than 22 Nm (30 ft.
l bs.) or more than 271 Nm (200 ft. l bs.) on ei ther
wheel the uni t shoul d be servi ced.
SERVICE PROCEDURES
LUBRICANT CHANGE
l i ght engi ne oi l , or l i nt free cl oth. Do not use water,
steam, kerosene, or gasoline for cleaning.
(5) Remove the ori gi nal seal ant from the housi ng
and cover surfaces.
Ti ghten the cover bol ts to 41 Nm (30 ft. l bs.) torque.
(8) For Tracl ok di fferenti al s, a quanti ty of
Mopar Tracl ok l ubri cant (fri cti on modi fi er), or
equi val ent, must be added after repai r servi ce or a
l ubri cant change. Refer to the Lubri cant Speci fi ca-
ti ons secti on of thi s group for the quanti ty necessary.
(9) Fi l l di fferenti al wi th Mopar Hypoi d Gear
Lubri cant, or equi val ent, to bottom of the fi l l pl ug
hol e. Refer to the Lubri cant Speci fi cati ons secti on of
(11) Tracl ok di fferenti al equi pped vehi cl es
shoul d be road tested by maki ng 10 to 12 sl ow fi gure-
ei ght turns. Thi s maneuver wi l l pump the l ubri cant
through the cl utch di scs to el i mi nate a possi bl e chat-
ter noi se compl ai nt.
Fig. 6 Trac-lok Test Typical
1 SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE
2 TORQUE WRENCH
Fig. 7 Apply Sealant
1 SEALANT
2 AXLE HOUSING COVER
3 - 110 8 1/4 REAR AXLE XJ
REAR AXLE
REMOVAL
axl e.
(5) Secure brake drums to the axl e shaft.
(6) Di sconnect the brake hose at the axl e juncti on
bl ock. Do not di sconnect the brake hydraul i c l i nes at
the wheel cyl i nders. Refer to Group 5, Brakes, for
proper procedures.
(7) Di sconnect the parki ng brake cabl es and cabl e
brackets.
(8) Di sconnect the vent hose from the axl e tube.
(9) Mark the propel l er shaft and yoke for i nstal l a-
ti on al i gnment reference.
(11) Di sconnect shock absorbers from axl e.
(12) Remove the stabi l i zer l i nks.
(13) Remove the spri ng cl amps and spri ng brack-
ets. Refer to Group 2, Suspensi on, for proper proce-
dures.
(14) Separate the axl e from the vehi cl e.
INSTALLATION
(1) Rai se the axl e wi th l i fti ng devi ce and al i gn to
the l eaf spri ng centeri ng bol ts.
(2) I nstal l the spri ng cl amps and spri ng brackets.
Refer to Group 2, Suspensi on, for proper procedures.
(3) I nstal l shock absorbers and ti ghten nuts to 60
(4) I nstal l the stabi l i zer l i nks. Ti ghten sway bar
l i nks to 74 Nm (55 ft. l bs.).
(5) Connect the parki ng brake cabl es and cabl e
brackets.
(7) Connect the brake hose to the axl e juncti on
bl ock. Refer to Group 5, Brakes, for proper proce-
dures.
(8) I nstal l axl e vent hose.
(9) Al i gn propel l er shaft and pi ni on yoke reference
marks. I nstal l uni versal joi nt straps and bol ts.
Ti ghten to 19 Nm (14 ft. l bs.) torque.
(10) I nstal l the wheel s and ti res.
Lubri cant Speci fi cati ons i n thi s secti on for l ubri cant
requi rements.
(12) Remove l i fti ng devi ce from axl e and l ower the
vehi cl e.
AXLE SHAFT
REMOVAL
(1) Rai se and support vehi cl e. Ensure that the
transmi ssi on i s i n neutral .
(3) Remove brake drum. Refer to Group 5, Brakes,
for proper procedure.
(4) Cl ean al l forei gn materi al from housi ng cover
area.
(5) Loosen housi ng cover bol ts. Drai n l ubri cant
from the housi ng and axl e tubes. Remove housi ng
cover.
(6) Rotate di fferenti al case so that pi ni on mate
shaft l ock screw i s accessi bl e. Remove l ock screw and
pi ni on mate shaft from di fferenti al case (Fi g. 8).
(7) Push axl e shaft i nward and remove axl e shaft
Cl ock from the axl e shaft (Fi g. 9).
(8) Remove axl e shaft. Use care to prevent damage
to axl e shaft beari ng and seal , whi ch wi l l remai n i n
axl e tube.
(9) I nspect axl e shaft seal for l eakage or damage.
(10) I nspect rol l er beari ng contact surface on axl e
shaft for si gns of bri nel l i ng, gal l i ng and pi tti ng. I f
any of these condi ti ons exi st, the axl e shaft and/or
beari ng and seal must be repl aced.
INSTALLATION
(1) Lubri cate beari ng bore and seal l i p wi th gear
l ubri cant. I nsert axl e shaft through seal , beari ng,
and engage i t i nto si de gear spl i nes.
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip.
1 LOCK SCREW
2 PINION MATE SHAFT
XJ 8 1/4 REAR AXLE 3 - 111
(2) I nsert Cl ock i n end of axl e shaft. Push axl e
shaft outward to seat Cl ock i n si de gear.
(3) I nsert pi ni on shaft i nto di fferenti al case and
through thrust washers and di fferenti al pi ni ons.
(4) Al i gn hol e i n shaft wi th hol e i n the di fferenti al
case and i nstal l l ock screw wi th Locti te on the
threads. Ti ghten l ock screw to 11 Nm (8 ft. l bs.)
torque.
(5) I nstal l cover and add fl ui d. Refer to Lubri cant
Change procedure i n thi s secti on for procedure and
l ubri cant requi rements.
(6) I nstal l brake drum. Refer to Group 5, Brakes,
(7) I nstal l wheel and ti re.
AXLE SEAL AND BEARING
REMOVAL
(1) Remove axl e shaft.
(2) Remove axl e shaft seal from the end of the axl e
tube wi th a smal l pry bar (Fi g. 10).
NOTE: The seal and bearing can be removed at the
same time with the bearing removal tool.
(3) Remove the axl e shaft beari ng from the axl e
tube wi th Beari ng Removal Tool Set 6310, usi ng
Adapter Foot 6310-9 (Fi g. 11).
INSTALLATION
NOTE: Do not install the original axle shaft seal.
Always install a new seal.
(1) Wi pe the axl e tube bore cl ean. Remove any ol d
seal er or burrs from the tube.
(2) I nstal l the axl e shaft beari ng wi th I nstal l er
C-4198 and Handl e C-4171 (Fi g. 12). Ensure that the
beari ng part number i s agai nst the i nstal l er. Veri fy
that the beari ng i n i nstal l ed strai ght and the tool
ful l y contacts the axl e tube when seati ng the beari ng.
Fig. 9 Axle Shaft CLock
1 CLOCK
2 AXLE SHAFT
3 SIDE GEAR
Fig. 10 Axle Seal Removal
1 AXLE TUBE
2 AXLE SEAL
3 PRY BAR
Fig. 11 Axle Shaft Bearing Removal Tool
1 NUT
2 GUIDE PLATE
3 GUIDE
4 THREADED ROD
5 ADAPTER
6 FOOT
7 AXLE TUBE
3 - 112 8 1/4 REAR AXLE XJ
(3) I nstal l a new axl e seal wi th I nstal l er C-4076-B
and Handl e C-4735-1. When the tool contacts the
axl e tube, the seal i s i nstal l ed to the correct depth.
(4) Coat the l i p of the seal wi th axl e l ubri cant for
protecti on pri or to i nstal l i ng the axl e shaft.
(5) I nstal l the axl e shaft.
PINION SEAL
REMOVAL
(2) Scri be a mark on the uni versal joi nt, pi ni on
yoke, and pi ni on shaft for reference.
(3) Di sconnect the propel l er shaft from the pi ni on
yoke. Secure the propel l er shaft i n an upri ght posi -
ti on to prevent damage to the rear uni versal joi nt.
(5) Remove the brake drums to prevent any drag.
The drag may cause a fal se beari ng prel oad torque
measurement.
(6) Rotate the pi ni on yoke three or four ti mes.
l ati on reference.
(8) Hol d the yoke wi th Wrench 6719. Remove the
(9) Remove the yoke wi th Remover C-452 (Fi g. 13).
(10) Remove the pi ni on seal wi th sui tabl e pry tool
or sl i de-hammer mounted screw.
INSTALLATION
(1) Cl ean the seal contact surface i n the housi ng
bore.
(2) Exami ne the spl i nes on the pi ni on shaft for
burrs or wear. Remove any burrs and cl ean the shaft.
(3) I nspect pi ni on yoke for cracks, worn spl i nes
and worn seal contact surface. Repl ace yoke i f neces-
sary.
NOTE: The outer perimeter of the seal is pre-coated
with a special sealant. An additional application of
sealant is not required.
l i p of pi ni on seal .
(5) I nstal l the new pi ni on seal wi th I nstal l er
C-4076-B and Handl e C-4735-1 (Fi g. 14).
NOTE: The seal is correctly installed when the seal
flange contacts the face of the differential housing
flange.
Fig. 12 Axle Shaft Seal and Bearing Installation
1 HANDLE
2 INSTALLER
3 AXLE TUBE
Fig. 13 Yoke Removal
1 PINION YOKE
2 TOOL C452
Fig. 14 8 1/4 Axle Pinion Seal Installation
2 DIFFERENTIAL HOUSING
3 SPECIAL TOOL C-4076-A
XJ 8 1/4 REAR AXLE 3 - 113
(6) Posi ti on the pi ni on yoke on the end of the shaft
wi th the reference marks al i gned.
(7) Seat yoke on pi ni on shaft wi th I nstal l er C-3718
and Wrench 6719.
(8) Remove the tool s and i nstal l the pi ni on yoke
washer. The convex si de of the washer must face out-
ward.
at this point. Damage to collapsible spacer or bear-
ings may result.
(9) Hol d pi ni on yoke wi th Yoke Hol der 6719 and
ti ghten shaft nut to 285 Nm (210 ft. l bs.) (Fi g. 15).
Rotate the pi ni on several revol uti ons to ensure the
beari ng rol l ers are seated.
(10) Rotate the pi ni on usi ng an (i n. l bs.) torque
Nm (5 i n. l bs.) (Fi g. 16).
CAUTION: Never loosen pinion nut to decrease pin-
ion gear bearing rotating torque and never exceed
specified preload torque. If preload torque is
exceeded a new collapsible spacer must be
installed. The torque sequence will then have to be
repeated.
(11) I f the rotati ng torque i s l ow, use Yoke Hol der
6719 to hol d the pi ni on yoke (Fi g. 15) and ti ghten the
pi ni on nut i n 6.8 Nm (5 ft. l bs.) i ncrements unti l
NOTE: The bearing rotating torque should be con-
stant during a complete revolution of the pinion. If
the rotating torque varies, this indicates a binding
condition.
(12) The seal repl acement i s unacceptabl e i f the
fi nal pi ni on nut torque i s l ess than 285 Nm (210 ft.
l bs.).
(13) I nstal l the propel l er shaft wi th the i nstal l a-
ti on reference marks al i gned.
(14) Ti ghten the uni versal joi nt yoke cl amp screws
to 19 Nm (14 ft. l bs.).
(15) I nstal l the brake drums.
(16) I nstal l wheel and ti re assembl i es and l ower
the vehi cl e.
(17) Check the di fferenti al housi ng l ubri cant l evel .
DIFFERENTIAL
REMOVAL
(1) Remove the axl e shafts.
NOTE: Side play resulting from bearing races being
loose on case hubs requires replacement of the dif-
ferential case.
Fig. 15 Tightening Pinion Nut
2 YOKE HOLDER
3 TORQUE WRENCH
1 PINION YOKE
3 - 114 8 1/4 REAR AXLE XJ
(2) Mark the di fferenti al housi ng and the di fferen-
ti al beari ng caps for i nstal l ati on reference (Fi g. 17).
(3) Remove beari ng threaded adjuster l ock from
each beari ng cap. Loosen the bol ts, but do not
remove the beari ng caps.
(4) Loosen the threaded adjusters wi th Wrench
C-4164 (Fi g. 18).
(5) Hol d the di fferenti al case whi l e removi ng bear-
i ng caps and adjusters.
(6) Remove the di fferenti al case.
NOTE: Each differential bearing cup and threaded
adjuster must be kept with their respective bearing.
INSTALLATION
(1) Appl y a coati ng of hypoi d gear l ubri cant to the
di fferenti al beari ngs, beari ng cups, and threaded
adjusters. A dab of grease can be used to keep the
adjusters i n posi ti on. Careful l y posi ti on the assem-
bl ed di fferenti al case i n the housi ng.
(2) Observe the reference marks and i nstal l the
di fferenti al beari ng caps at thei r ori gi nal l ocati ons
(Fi g. 19).
(3) I nstal l beari ng cap bol ts and ti ghten the upper
bol ts to 14 Nm (10 ft. l bs.). Ti ghten the l ower bol ts
fi nger-ti ght unti l the bol t head i s seated.
(4) Perform the di fferenti al beari ng prel oad and
adjustment procedure.
NOTE: Be sure that all bearing cap bolts are tight-
ened to the final torque of 95 Nm (70 ft.lbs) before
proceeding.
(5) I nstal l axl e shafts and di fferenti al housi ng
cover.
REMOVAL
(1) Remove di fferenti al case from axl e housi ng.
wi th Pul l er/Press C-293-PA and Adapters C-293-48
and Pl ug SP-3289 (Fi g. 20).
INSTALLATION
(1) I nstal l di fferenti al si de beari ngs. Use I nstal l er
C-4340 wi th handl e C-4171 (Fi g. 21).
Fig. 17 Mark For Installation Reference
1 INSTALLATION REFERENCE MARKS
4 BEARING CAP
Fig. 18 Threaded Adjuster Tool
1 AXLE TUBE
2 BACKING PLATE
3 TOOL C-4164
Fig. 19 Bearing Caps & Bolts
4 BEARING CAP
XJ 8 1/4 REAR AXLE 3 - 115
RING GEAR
The ri ng gear and pi ni on are servi ced i n a matched
set. Do not repl ace the ri ng gear wi thout repl aci ng
the pi ni on.
REMOVAL
soft metal jaw protectors. (Fi g. 22).
case.
INSTALLATION
(1) I nvert the di fferenti al case.
(2) Posi ti on ri ng gear on the di fferenti al case and
start two ri ng gear bol ts. Thi s wi l l provi de case-to-
ri ng gear bol t hol e al i gnment.
ti ghten to 102 Nm (75 ft. l bs.) torque (Fi g. 23).
3 BEARING
4 DIFFERENTIAL
Fig. 21 Install Differential Side Bearings
1 HANDLE C-4171
2 DIFFERENTIAL
3 BEARING
4 TOOL C-4340
1 CASE
2 RING GEAR
3 RAWHIDE HAMMER
3 - 116 8 1/4 REAR AXLE XJ
PINION GEAR
The ri ng gear and pi ni on are servi ced i n a matched
ri ng gear.
REMOVAL
(1) Remove di fferenti al from the axl e housi ng.
(4) Usi ng Yoke Hol der 6719 to hol d yoke and
remove the pi ni on yoke nut and washer.
(5) Usi ng Remover C452, remove the pi ni on yoke
from pi ni on shaft (Fi g. 24).
(6) Parti al l y i nstal l pi ni on nut onto pi ni on to pro-
tect the threads.
(7) Remove the pi ni on from housi ng (Fi g. 25).
Catch the pi ni on wi th your hand to prevent i t from
fal l i ng and bei ng damaged.
(8) Remove the pi ni on shaft seal wi th sui tabl e pry
tool or sl i de-hammer mounted screw.
(9) Remove oi l sl i nger, i f equi pped, and front pi n-
i on beari ng.
(10) Remove the front pi ni on beari ng cup wi th
Remover C-4345 and Handl e C4171 (Fi g. 26).
(11) Remove the rear beari ng cup from housi ng
(Fi g. 27). Use Remover C-4307 and Handl e C4171.
(12) Remove the col l apsi bl e prel oad spacer (Fi g. 28).
(13) Remove the rear beari ng from the pi ni on (Fi g.
29) wi th Pul l er/Press C-293-PA and Adapters C-293-47.
the bearing cage.
(14) Remove the depth shi ms from the pi ni on
shaft. Record the thi ckness of the depth shi ms.
INSTALLATION
(2) I nstal l the pi ni on rear beari ng cup (Fi g. 30)
wi th I nstal l er C-4308 and Dri ver Handl e C4171.
1 TORQUE WRENCH
2 RING GEAR BOLT
3 RING GEAR
4 CASE
1 PINION YOKE
2 TOOL C452
1 RAWHIDE HAMMER
XJ 8 1/4 REAR AXLE 3 - 117
(2) Ensure cup i s correctl y seated.
(4) I nstal l the pi ni on front beari ng cup (Fi g. 31)
wi th I nstal l er D130 and Handl e C4171.
(5) I nstal l pi ni on front beari ng, and oi l sl i nger, i f
equi pped.
l i p of pi ni on seal . I nstal l seal wi th I nstal l er
C-4076B and Handl e C-4735-1 (Fi g. 32).
1 REMOVER
2 HANDLE
1 DRIVER
2 HANDLE
2 SHOULDER
3 PINION
4 PINION DEPTH SHIM
5 REAR BEARING
2 VISE
3 ADAPTERS
3 - 118 8 1/4 REAR AXLE XJ
NOTE: Pinion depth shims are placed between the
rear pinion bearing cone and pinion head to
achieve proper ring and pinion gear mesh. If the
factory installed ring gear and pinion are reused,
the pinion depth shim should not require replace-
ment. If required, refer to Pinion Gear Depth to
select the proper thickness shim before installing
rear pinion bearing.
(7) Pl ace the proper thi ckness depth shi m on the
pi ni on.
(8) I nstal l the rear beari ng and sl i nger, i f
equi pped, on the pi ni on (Fi g. 33) wi th I nstal l er 6448.
i on shaft and i nstal l pi ni on i n housi ng (Fi g. 34).
(10) I nstal l pi ni on i n housi ng.
(11) I nstal l yoke wi th I nstal l er C-3718 and Yoke
Hol der 6719.
pi ni on and ti ghten the pi ni on nut unti l there i s zero
Fig. 30 Pinion Rear Bearing Cup Installation
1 INSTALLER
2 HANDLE
Fig. 31 Pinion Front Bearing Cup Installation
1 INSTALLER
2 HANDLE
Fig. 33 Shaft Rear Bearing Installation
1 PRESS
2 INSTALLATION TOOL
3 DRIVE PINION
XJ 8 1/4 REAR AXLE 3 - 119
beari ng end-pl ay. I t wi l l not be possi bl e at thi s poi nt
to achi eve zero beari ng end-pl ay i f a new col l apsi bl e
spacer was i nstal l ed.
CAUTION: Never loosen pinion nut to decrease pin-
ion bearing rotating torque and never exceed spec-
ified preload torque. If preload torque or rotating
torque is exceeded a new collapsible spacer must
be installed. The torque sequence will then have to
be repeated.
(14) Usi ng Yoke Hol der 6719, crush col l apsi bl e
spacer unti l beari ng end pl ay i s taken up.
i ncrements unti l the desi red rotati ng torque i s
achi eved. Measure the rotati ng torque frequentl y to
avoi d over crushi ng the col l apsi bl e spacer (Fi g. 35).
(16) Check beari ng rotati ng torque wi th an i nch
to rotate the pi ni on gear shoul d be:
Ori gi nal Beari ngs 1 to 2 Nm (10 to 20 i n. l bs.).
New Beari ngs 1 to 5 Nm (10 to 30 i n. l bs.).
(17) I nstal l propel l er shaft.
(18) I nstal l di fferenti al i n housi ng.
DISASSEMBLY
(1) Remove pi ni on mate shaft l ock screw (Fi g. 36).
(2) Remove pi ni on mate shaft.
(3) Rotate the di fferenti al si de gears and remove the
di fferenti al pi ni on gears and thrust washers (Fi g. 37).
washers.
2 SHOULDER
3 PINION
4 PINION DEPTH SHIM
5 REAR BEARING
Fig. 35 Check Pinion Rotating Torque
1 PINION YOKE
1 LOCK SCREW
2 PINION MATE SHAFT
3 - 120 8 1/4 REAR AXLE XJ
ASSEMBLY
washers.
(2) I nstal l the di fferenti al pi ni on gears and thrust
washers.
(3) I nstal l the pi ni on mate shaft.
(4) Al i gn the hol e i n the pi ni on mate shaft wi th
the hol e i n the di fferenti al case and i nstal l the pi ni on
mate shaft l ock screw.
The Tracl ok di fferenti al components are i l l us-
trated i n (Fi g. 38). Refer to thi s i l l ustrati on duri ng
repai r servi ce.
DISASSEMBLY
(1) Cl amp Si de Gear Hol di ng Tool 8138 i n a vi se.
Hol di ng Tool 8138 (Fi g. 39).
(3) Remove ri ng gear, i f necessary. Ri ng gear
removal i s necessary onl y i f the ri ng gear i s to be
repl aced. The Trac-l ok di fferenti al can be servi ced
wi th the ri ng gear i nstal l ed.
1 THRUST WASHER
2 SIDE GEAR
3 PINION MATE GEAR
Fig. 38 Traclok Differential Components
1 THRUST WASHER
2 PINION
3 SHAFT LOCK SCREW
4 PINION MATE SHAFT
5 SIDE GEAR
6 RETAINER
7 DISC
8 CLUTCH PACK
9 DIFFERENTIAL CASE
10 RETAINER
XJ 8 1/4 REAR AXLE 3 - 121
(4) Remove the pi ni on mate shaft l ock screw (Fi g.
40).
(5) Remove the pi ni on mate shaft. I f necessary, use
a dri ft and hammer (Fi g. 41).
(6) I nstal l and l ubri cate Step Pl ate 81402 (Fi g.
42).
(7) Assembl e Threaded Adapter 8140-1 i nto top
si de gear. Thread Forci ng Screw 6960-4 i nto adapter
unti l i t becomes centered i n adapter pl ate.
(8) Posi ti on a smal l screw dri ver i n sl ot of
Threaded Adapter 8140-1 (Fi g. 43) to prevent adapter
from turni ng.
(9) Ti ghten forci ng screw tool 122 Nm (90 ft. l bs.)
maxi mum to compress Bel l evi l l e spri ngs i n cl utch
packs (Fi g. 44).
(10) Usi ng an appropri ate si ze feel er gauge,
remove thrust washers from behi nd the di fferenti al
pi ni ons (Fi g. 45).
(11) I nsert Turni ng Bar 6960-2 i n case (Fi g. 46).
Fig. 39 Differential Case Holding Tool
1 SIDE GEAR HOLDING TOOL
2 VISE
3 DIFFERENTIAL
1 LOCK SCREW
2 PINION MATE SHAFT
Fig. 41 Mate Shaft Removal
1 PINION MATE SHAFT
2 SIDE GEAR
3 DRIFT
4 PINION MATE GEAR
Fig. 42 Step Plate Tool Installation
2 LOWER SIDE GEAR
3 DIFFERENTIAL CASE
3 - 122 8 1/4 REAR AXLE XJ
(12) Loosen the Forci ng Screw 6960-4 i n smal l
i ncrements unti l the cl utch pack tensi on i s rel i eved
and the di fferenti al case can be turned usi ng Turni ng
Bar 6960-2.
(13) Rotate di fferenti al case unti l the di fferenti al
pi ni ons can be removed.
(14) Remove pi ni ons from di fferenti al case.
(15) Remove Forci ng Screw 6960-4, Step Pl ate
81402, and Threaded Adapter 81401.
(16) Remove top si de gear, cl utch pack retai ner,
removal (Fi g. 47).
(17) Remove di fferenti al case from Si de Gear Hol d-
i ng Tool 8138. Remove si de gear, cl utch pack retai ner,
Fig. 43 Threaded Adapter Installation
1 SOCKET
2 SLOT IN ADAPTER
3 SCREWDRIVER
4 DISC 81402
5 THREADED ROD C-69604
6 THREADED ADAPTER DISC 81401
Fig. 44 Tighten Belleville Spring Compressor Tool
1 TORQUE WRENCH
2 TOOL ASSEMBLED
3 DIFFERENTIAL CASE
Fig. 45 Remove Pinion Thrust Washer
1 THRUST WASHER
2 FEELER GAUGE
Fig. 46 Pinion Gear Removal
1 PINION GEARS
2 TOOL
XJ 8 1/4 REAR AXLE 3 - 123
removal .
ASSEMBLY
NOTE: The clutch discs are replaceable as com-
plete sets only. If one clutch disc pack is damaged,
both packs must be replaced.
Lubri cate each component wi th gear l ubri cant
before assembl y.
(1) Assembl e the cl utch di scs i nto packs and
secure di sc packs wi th retai ni ng cl i ps (Fi g. 48).
(2) Posi ti on assembl ed cl utch di sc packs on the
si de gear hubs.
(3) I nstal l cl utch pack and si de gear i n the ri ng
gear si de of the di fferenti al case (Fi g. 49). Be sure
clutch pack retaining clips remain in position
and are seated in the case pockets.
Hol di ng Tool 8138.
(5) I nstal l l ubri cated Step Pl ate 81402 i n l ower
si de gear (Fi g. 50).
(6) I nstal l the upper si de gear and cl utch di sc pack
(Fi g. 50).
(7) Hol d assembl y i n posi ti on. I nsert Threaded
Adapter 8140-1 i nto top si de gear.
(8) I nsert Forci ng Screw 6960-4.
(9) Ti ghten forci ng screw tool to sl i ghtl y compress
cl utch di scs.
(10) Pl ace di fferenti al pi ni ons i n posi ti on i n si de
gears and veri fy that the pi ni on mate shaft hol es are
al i gned.
(11) Rotate case wi th Turni ng Bar 6960-2 unti l the
pi ni on mate shaft hol es i n the di fferenti al pi ni ons
al i gn wi th hol es i n case. I t may be necessary to
Fig. 47 Side Gear & Clutch Disc Removal
1 DIFFERENTIAL CASE
2 RETAINER
3 SIDE GEAR AND CLUTCH DISC PACK
Fig. 48 Clutch Disc Pack
1 CLUTCH PACK
2 RETAINER
3 SIDE GEAR
4 RETAINER
Fig. 49 Clutch Discs & Lower Side Gear Installation
1 DIFFERENTIAL CASE
2 LOWER SIDE GEAR AND CLUTCH DISC PACK
3 - 124 8 1/4 REAR AXLE XJ
sl i ghtl y ti ghten the forci ng screw i n order to i nstal l
the pi ni ons.
(12) Ti ghten forci ng screw to 122 Nm (90 ft. l bs.)
maxi mum to compress the Bel l evi l l e spri ngs.
(13) Lubri cate and i nstal l thrust washers behi nd
pi ni ons and al i gn washers wi th a smal l screw dri ver.
I nsert mate shaft i nto each pi ni on to veri fy al i gn-
ment.
(14) Remove Forci ng Screw 6960-4, Step Pl ate
81402, and Threaded Adapter 8140-1.
(15) I nstal l pi ni on mate shaft and al i gn hol es i n
shaft and case.
(16) I nstal l the pi ni on mate shaft l ock screw fi nger
ti ght to hol d shaft duri ng di fferenti al i nstal l ati on.
8 1/4 AXLE
and dry wi th dry compressed ai r. Do not steam
clean the differential components.
Be sure that the axl e tubes and oi l channel s are
thoroughl y cl eaned i n the housi ng.
I nspect for:
faces.
Wear and damage to pi ni on mate shaft, pi ni ons,
si de gears and thrust washers. Repl ace as a matched
set onl y.
Ri ng gear and pi ni on for worn and chi pped
teeth.
Pi ni on depth shi ms for damage and di storti on.
I nstal l new shi ms i f necessary.
The di fferenti al case. Repl ace the case i f cracked
or damaged.
The axl e shaft C-l ocks for cracks and excessi ve
wear. Repl ace them i f necessary.
Each threaded adjuster to determi ne i f i t rotates
freel y. I f an adjuster bi nds, repai r the damaged
threads or repl ace the adjuster.
Pol i sh each axl e shaft seal i ng surface wi th No. 600
crocus cl oth. Thi s can remove sl i ght surface damage.
Do not reduce the di ameter of the axl e shaft seal con-
tact surface. When pol i shi ng, the crocus cl oth shoul d
be moved around the ci rcumference of the shaft (not
i n-l i ne wi th the shaft).
TRAC-LOK
Cl ean al l components i n cl eani ng sol vent. Dry com-
ponents wi th compressed ai r. I nspect cl utch pack
pl ates for wear, scori ng or damage. Repl ace both
cl utch packs i f any one component i n ei ther pack i s
damaged. I nspect si de gears and pi ni ons. Repl ace
any gear that i s worn, cracked, chi pped or damaged.
I nspect di fferenti al case and pi ni on shaft. Repl ace i f
worn or damaged.
PRESOAK PLATES AND DISC
Pl ates and di scs wi th fi ber coati ng (no grooves or
l i nes) must be presoaked i n Fri cti on Modi fi er before
assembl y. Soak pl ates and di scs for a mi ni mum of 20
mi nutes.
Fig. 50 Upper Side Gear & Clutch Disc Pack
Installation
1 UPPER SIDE GEAR AND CLUTCH DISC PACK
2 DIFFERENTIAL CASE
XJ 8 1/4 REAR AXLE 3 - 125
ADJ USTMENTS
8 1/4 AXLE PINION GEAR DEPTH
GENERAL INFORMATION
Ri ng gears and pi ni ons are suppl i ed as matched
sets onl y. The i denti fyi ng numbers for the ri ng gear
and pi ni on are etched i nto the face of each gear (Fi g.
i s etched i nto the face of the pi ni on. Thi s number i s
the amount (i n thousandths of an i nch) the depth
vari es from the standard depth setti ng of a pi ni on
etched wi th a (0). The standard depth provi des the
best gear tooth contact pattern. Refer to Backl ash
and Contact Pattern Anal ysi s paragraph i n thi s sec-
ti on for addi ti onal i nformati on.
achi eved wi th sel ect shi ms. The shi ms are pl aced
behi nd the rear pi ni on beari ng (Fi g. 52).
ment pi ni on. Add or subtract the thi ckness of the
ori gi nal depth shi ms to compensate for the di fference
i n the depth vari ances. Refer to the Depth Vari ance
chart.
Note the etched number on the face of the pi ni on
gear head (1, 2, 0, +1, +2, etc.). The numbers rep-
requi red thi ckness of the depth shi ms. I f the number
i s posi ti ve, subtract that val ue from the thi ckness of
the depth shi m. I f the number i s 0 no change i s nec-
essary.
Take measurements wi th Pi ni on Gauge Set and Di al
I ndi cator C-3339 (Fi g. 53).
(Fi g. 53).
rear beari ng, and screw i nto axl e housi ng through
(3) I nstal l front pi ni on beari ng and Cone-Nut 6740
being serviced.
NUMBER)
1 AXLE HOUSING
3 PINION BEARING
4 PINION DEPTH SHIM
5 PINION GEAR
6 BEARING CUP
3 - 126 8 1/4 REAR AXLE XJ
(9) Sel ect a shi m equal to the di al i ndi cator read-
i ng pl us the dri ve pi ni on gear depth vari ance number
etched i n the face of the pi ni on (Fi g. 51). For exam-
DIFFERENTIAL BEARING PRELOAD AND GEAR
BACKLASH
The fol l owi ng must be consi dered when adjusti ng
beari ng prel oad and gear backl ash:
The maxi mum ri ng gear backl ash vari ati on i s
0.003 i nch (0.076 mm).
Original Pinion
Gear Depth
Variance
4 3 2 1 0 +1 +2 +3 +4
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003
0 +0.004 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004
1 +0.003 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005
2 +0.002 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006
3 +0.001 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007
4 0 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
1 DIAL INDICATOR
2 ARBOR
4 CONE
5 SCREW
6 PINION BLOCK
7 SCOOTER BLOCK
8 ARBOR DISC
1 PINION BLOCK
XJ 8 1/4 REAR AXLE 3 - 127
Mark the gears so the same teeth are meshed
duri ng al l backl ash measurements.
Mai ntai n the torque whi l e adjusti ng the beari ng
prel oad and ri ng gear backl ash.
Excessi ve adjuster torque wi l l i ntroduce a hi gh
beari ng l oad and cause premature beari ng fai l ure.
I nsuffi ci ent adjuster torque can resul t i n excessi ve
di fferenti al case free-pl ay and ri ng gear noi se.
I nsuffi ci ent adjuster torque wi l l not support the
ri ng gear correctl y and can cause excessi ve di fferen-
ti al case free-pl ay and ri ng gear noi se.
NOTE: The differential bearing cups will not always
immediately follow the threaded adjusters as they
are moved during adjustment. To ensure accurate
bearing cup responses to the adjustments:
Maintain the gear teeth engaged (meshed) as
marked.
The bearings must be seated by rapidly rotat-
ing the pinion gear a half turn back and forth.
Do this five to ten times each time the threaded
adjusters are adjusted.
(1) Use Wrench C-4164 to adjust each threaded
adjuster i nward unti l the di fferenti al beari ng free-
pl ay i s el i mi nated (Fi g. 57). Al l ow some ri ng gear
backl ash (approxi matel y 0.01 i nch/0.25 mm) between
the ri ng and pi ni on gear. Seat the beari ng cups wi th
the procedure descri bed above.
(2) I nstal l di al i ndi cator and posi ti on the pl unger
agai nst the dri ve si de of a ri ng gear tooth (Fi g. 58).
Measure the backl ash at 4 posi ti ons (90 degrees
apart) around the ri ng gear. Locate and mark the
area of mi ni mum backl ash.
(3) Rotate the ri ng gear to the posi ti on of the l east
backl ash. Mark the gear so that al l future backl ash
measurements wi l l be taken wi th the same gear
teeth meshed.
(4) Loosen the ri ght-si de, ti ghten the l eft-si de
threaded adjuster. Obtai n backl ash of 0.003 to 0.004
i nch (0.076 to 0.102 mm) wi th each adjuster ti ght-
ened to 14 Nm (10 ft. l bs.). Seat the beari ng cups
wi th the procedure descri bed above.
(5) Ti ghten the di fferenti al beari ng cap bol ts 95
Nm (70 ft. l bs.).
(6) Ti ghten the ri ght-si de threaded adjuster to 102
Nm (75 ft. l bs.). Seat the beari ng cups wi th the pro-
1 ARBOR DISC
2 PINION BLOCK
3 ARBOR
1 ARBOR
2 SCOOTER BLOCK
3 DIAL INDICATOR
Fig. 57 Threaded Adjuster Tool
1 AXLE TUBE
2 BACKING PLATE
3 TOOL C-4164
3 - 128 8 1/4 REAR AXLE XJ
cedure descri bed above. Conti nue to ti ghten the
ri ght-si de adjuster and seat beari ng cups unti l the
torque remai ns constant at 102 Nm (75 ft. l bs.)
(7) Measure the ri ng gear backl ash. The range of
backl ash i s 0.006 to 0.008 i nch (0.15 to 0.203 mm).
(8) Conti nue i ncreasi ng the torque at the ri ght-
si de threaded adjuster unti l the speci fi ed backl ash i s
obtai ned.
NOTE: The left-side threaded adjuster torque
should have approximately 102 Nm (75 ft. lbs.). If
the torque is considerably less, the complete
adjustment procedure must be repeated.
(9) Ti ghten the l eft-si de threaded adjuster unti l
102 Nm (75 ft. l bs.) torque i s i ndi cated. Seat the
beari ng rol l ers wi th the procedure descri bed above.
Do thi s unti l the torque remai ns constant.
(10) I nstal l the threaded adjuster l ocks and
ti ghten the l ock screws to 10 Nm (90 i n. l bs.).
After the proper backl ash i s achi eved, perform the
Gear Contact Anal ysi s procedure.
gear teeth.
tern.
shop towel .
necessary.
SIDE GEAR CLEARANCE
When measuri ng si de gear cl earance, check each
gear i ndependentl y. I f i t necessary to repl ace a si de
gear, repl ace both gears as a matched set.
(1) I nstal l the axl e shafts and C-l ocks and pi ni on
mate shaft.
(2) Measure each si de gear cl earance. I nsert a
matched pai r of feel er gauge bl ades between the gear
and di fferenti al housi ng on opposi te si des of the hub
(Fi g. 60).
(3) I f si de gear cl earances i s no more than 0.005
i nch. Determi ne i f the axl e shaft i s contacti ng the
pi ni on mate shaft. Do not remove the feeler
gauges, inspect the axle shaft with the feeler
gauge inserted behind the side gear. I f the end of
the axl e shaft i s not contacti ng the pi ni on mate
shaft, the si de gear cl earance i s acceptabl e.
(4) I f cl earance i s more than 0.005 i nch (axl e shaft
not contacti ng mate shaft), record the si de gear cl ear-
ance. Remove the thrust washer and measure i ts
thi ckness wi th a mi crometer. Add the washer thi ck-
ness to the recorded si de gear cl earance. The sum of
gear cl earance and washer thi ckness wi l l determi ne
requi red thi ckness of repl acement thrust washer
(Fi g. 61).
I n some cases, the end of the axl e shaft wi l l move
and contact the mate shaft when the feel er gauge i s
i nserted. The C-l ock i s preventi ng the si de gear from
sl i di ng on the axl e shaft.
(5) I f there i s no si de gear cl earance, remove the
C-l ock from the axl e shaft. Use a mi crometer to mea-
sure the thrust washer thi ckness. Record the thi ck-
ness and re-i nstal l the thrust washer. Assembl e the
di fferenti al case wi thout the C-l ock i nstal l ed and re-
measure the si de gear cl earance.
(6) Compare both cl earance measurements. I f the
di fference i s l ess than 0.012 i nch (0.305 mm), add
cl earance recorded when the C-l ock was i nstal l ed to
thrust washer thi ckness measured. The sum wi l l
determi ne the requi red thi ckness of the repl acement
thrust washer.
1 DIAL INDICATOR
2 RING GEAR
3 EXCITER RING
XJ 8 1/4 REAR AXLE 3 - 129
3 - 130 8 1/4 REAR AXLE XJ
(7) I f cl earance i s 0.012 i nch (0.305 mm) or
greater, both si de gears must be repl aced (matched
set) and the cl earance measurements repeated.
(8) I f cl earance (above) conti nues to be 0.012 i nch
(0.305 mm) or greater, the case must be repl aced.
SPECIFICATIONS
8 1/4 INCH AXLE
Axl e Type . . . . . . . . . . . . . . . Semi -fl oati ng, hypoi d
Lubri cant . . . . . . . . . . . . . . . . . . . . . . SAE 80W-90
Lube Capaci ty . . . . . . . . . . . . . . . . 2.08 L (4.4 pts.)
Trac-Lok Addi ti ve . . . . . . . . . . . . . . . 118 ml (4 oz.)
Axl e Rati o . . . . . . . . . . . . . . . . . . . . 3.07, 3.55,.4.10
Differential
Case Cl earance . . . . . . . . . . . . . 0.12 mm (0.005 i n.)
Case Fl ange Runout . . . . . . . . 0.076 mm (0.003 i n.)
Ring Gear
Di ameter . . . . . . . . . . . . . . . . . . 20.95 cm (8.25 i n.)
Backl ash . . . . . . . . . 0.12-0.20 mm (0.005-0.008 i n.)
Runout . . . . . . . . . . . . . . . . . . 0.127 mm (0.005 i n.)
Pinion Bearing
Prel oad-Used Beari ngs . . . . 1-2 Nm (10-20 i n.l bs.)
Prel oad-New Beari ngs . . . . . 1-5 Nm (10-30 i n.l bs.)
8 1/4 INCH AXLE
DESCRIPTION TORQUE
Di ff. Cover Bol t . . . . . . . . . . . . . 41 Nm (30 ft. l bs.)
Beari ng Cap Bol t . . . . . . . . . . 136 Nm (100 ft. l bs.)
Pi ni on NutMi ni mum . . . . . . 285 Nm (210 ft. l bs.)
Ri ng Gear Bol t . . . . . . . . . . . . . 95 Nm (70 ft. l bs.)
Backi ng Pl ate Bol t . . . . . . . . . 614 Nm (45 ft. l bs.)
RWAL/ABS Sensor Bol t . . . . . . 24 Nm (18. ft. l bs.)
SPECIAL TOOLS
8 1/4 AXLES
Fig. 60 Side Gear Clearance Measurement
1 FEELER GAUGE BLADES
2 SIDE GEAR
Fig. 61 Side Gear Calculations
Puller, Hub6790
Remover, Bearing6310
InstallerC-4198
XJ 8 1/4 REAR AXLE 3 - 131
HandleC-4171
InstallerC-4076-B
HandleC-4735-1
Holder6719
PullerC-452
InstallerC-3718
Adjustment RodC-4164
Puller/PressC-293PA
AdaptersC-293-48
3 - 132 8 1/4 REAR AXLE XJ
PlugSP-3289
AdaptersC-293-47
InstallerC-4340
Holder8138
InstallerC-4345
RemoverC-4307
InstallerC-4308
InstallerD-130
Installer6448
XJ 8 1/4 REAR AXLE 3 - 133
Trac-lok Tools8140
Trac-lok Tools6960
Pinion Gauge Block8540
Arbor Discs8541
Pinion Gauge Set
3 - 134 8 1/4 REAR AXLE XJ
BRAKES
TABLE OF CONTENTS
page page
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 1 ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . . 33
BASE BRAKE SYSTEM
TABLE OF CONTENTS
page page
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SERVICE WARNINGS & CAUTIONS . . . . . . . . . . . 2
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 2
RED BRAKE WARNING LAMP. . . . . . . . . . . . . . . . 3
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . 3
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 3
COMBINATION VALVE. . . . . . . . . . . . . . . . . . . . . . 3
FRONT DISC BRAKES. . . . . . . . . . . . . . . . . . . . . . 4
REAR DRUM BRAKE. . . . . . . . . . . . . . . . . . . . . . . 5
PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . 5
BRAKE HOSES AND LINES. . . . . . . . . . . . . . . . . . 7
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 7
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . 9
RED BRAKE WARNING LAMP. . . . . . . . . . . . . . . . 9
MASTER CYLINDER/POWER BOOSTER. . . . . . . 10
COMBINATION VALVE . . . . . . . . . . . . . . . . . . . . . 11
DISC BRAKE ROTOR. . . . . . . . . . . . . . . . . . . . . . 11
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . . . . 12
BRAKE FLUID CONTAMINATION . . . . . . . . . . . . . 12
SERVICE PROCEDURES
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 12
MASTER CYLINDER BLEEDING . . . . . . . . . . . . . 12
BASE BRAKE BLEEDING. . . . . . . . . . . . . . . . . . . 13
DISC ROTOR MACHINING. . . . . . . . . . . . . . . . . . 13
BRAKE DRUM MACHINING . . . . . . . . . . . . . . . . . 14
BRAKE TUBE FLARING. . . . . . . . . . . . . . . . . . . . 14
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 15
BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . 16
POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . 17
FRONT DISC BRAKE CALIPER . . . . . . . . . . . . . . 18
FRONT DISC BRAKE SHOES . . . . . . . . . . . . . . . 20
DISC BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . 21
DRUM BRAKE SHOES. . . . . . . . . . . . . . . . . . . . . 21
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 21
BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . . . 22
REAR PARKING BRAKE CABLES . . . . . . . . . . . . 23
PARKING BRAKE LEVER. . . . . . . . . . . . . . . . . . . 23
MASTER CYLINDER RESERVOIR . . . . . . . . . . . . 24
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 25
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 28
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
REAR DRUM BRAKE. . . . . . . . . . . . . . . . . . . . . . 29
WHEEL CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 29
ADJUSTMENTS
BRAKE LAMP SWITCH . . . . . . . . . . . . . . . . . . . . 30
REAR DRUM BRAKE. . . . . . . . . . . . . . . . . . . . . . 30
PARKING BRAKE CABLE TENSIONER . . . . . . . . 31
SPECIFICATIONS
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . . . 32
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 32
SPECIAL TOOLS
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . 32
XJ BRAKES 5 - 1
BRAKE SYSTEM
DESCRIPTION
Power assi st front di sc and rear drum brakes are
standard equi pment. Di sc brake components consi st
of si ngl e pi ston cal i pers and venti l ated rotors. Rear
drum brakes are dual shoe uni ts wi th cast brake
drums.
The parki ng brake mechani sm i s l ever and cabl e
operated. The cabl es are attached to l evers on the
rear drum brake secondary shoes. The parki ng
brakes are operated by a hand l ever.
A dual di aphragm vacuum power brake booster i s
used for al l appl i cati ons. Al l model s have an al umi -
num master cyl i nder wi th pl asti c reservoi r.
Al l model s are equi pped wi th a combi nati on val ve.
The val ve contai ns a pressure di fferenti al val ve and
swi tch and a fi xed rate rear proporti oni ng val ve.
Factory brake l i ni ng on al l model s consi sts of an
organi c base materi al combi ned wi th metal l i c parti -
cl es. The ori gi nal equi pment l i ni ngs do not contai n
asbestos.
SERVICE WARNINGS & CAUTIONS
DESCRIPTION
WARNING: DUST AND DIRT ACCUMULATING ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM AFTERMARKET
LININGS. BREATHING EXCESSIVE CONCENTRA-
TIONS OF ASBESTOS FIBERS CAN CAUSE SERI-
OUS BODILY HARM. EXERCISE CARE WHEN
SERVICING BRAKE PARTS. DO NOT CLEAN
BRAKE PARTS WITH COMPRESSED AIR OR BY
DRY BRUSHING. USE A VACUUM CLEANER SPE-
CIFICALLY DESIGNED FOR THE REMOVAL OF
ASBESTOS FIBERS FROM BRAKE COMPONENTS.
IF A SUITABLE VACUUM CLEANER IS NOT AVAIL-
ABLE, CLEANING SHOULD BE DONE WITH A
WATER DAMPENED CLOTH. DO NOT SAND, OR
GRIND BRAKE LINING UNLESS EQUIPMENT USED
IS DESIGNED TO CONTAIN THE DUST RESIDUE.
DISPOSE OF ALL RESIDUE CONTAINING ASBES-
TOS FIBERS IN SEALED BAGS OR CONTAINERS
TO MINIMIZE EXPOSURE TO YOURSELF AND OTH-
ERS. FOLLOW PRACTICES PRESCRIBED BY THE
OCCUPATIONAL SAFETY AND HEALTH ADMINIS-
TRATION AND THE ENVIRONMENTAL PROTECTION
AGENCY FOR THE HANDLING, PROCESSING, AND
DISPOSITION OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol,
motor oil, transmission fluid, or any fluid containing
mineral oil to clean the system components. These
fluids damage rubber cups and seals. Use only
fresh brake fluid or Mopar brake cleaner to clean or
flush brake system components. These are the only
cleaning materials recommended. If system contam-
ination is suspected, check the fluid for dirt, discol-
oration, or separation into distinct layers. Also
check the reservoir cap seal for distortion. Drain
and flush the system with new brake fluid if con-
tamination is suspected.
CAUTION: Use Mopar brake fluid, or an equivalent
quality fluid meeting SAE/DOT standards J1703 and
DOT 3. Brake fluid must be clean and free of con-
taminants. Use fresh fluid from sealed containers
only to ensure proper antilock component opera-
tion.
CAUTION: Use Mopar multi-mileage or high temper-
ature grease to lubricate caliper slide surfaces,
drum brake pivot pins, and shoe contact points on
the backing plates. Use multi-mileage grease or GE
661 or Dow 111 silicone grease on caliper slide pins
to ensure proper operation.
BRAKE PEDAL
DESCRIPTION
A suspended-type brake pedal i s used, the pedal
pi vots on a shaft mounted i n the pedal support
bracket. The bracket i s attached to the dash panel
and steeri ng support bracket. The uni t i s servi ced as
an assembl y, except for the pedal pad.
OPERATION
The brake pedal i s attached to the booster push
rod. When the pedal i s depressed, the pri mary
booster push rod i s depressed whi ch move the booster
secondary rod. The booster secondary rod depress the
master cyl i nder pi ston.
BRAKE LAMP SWITCH
DESCRIPTION
The pl unger type brake l amp swi tch i s mounted on
a bracket attached to the brake pedal support. The
swi tch can be adjusted when necessary.
OPERATION
The brake l amp swi tch i s used to for the brake
l amp, speed control and brake sensor ci rcui ts.
5 - 2 BRAKES XJ
RED BRAKE WARNING LAMP
DESCRIPTION
A red warni ng l amp i s used for the servi ce brake
porti on of the hydraul i c system. The l amp i s l ocated
i n the i nstrument cl uster.
OPERATION
The red warni ng l i ght al erts the dri ver i f a pres-
sure di fferenti al exi sts between the front and rear
hydraul i c systems or the parki ng brakes are appl i ed.
The l amp i s turned on momentari l y when the i gni -
ti on swi tch i s turn to the on posi ti on. Thi s i s a sel f
test to veri fy the l amp i s operati onal .
POWER BRAKE BOOSTER
DESCRIPTION
The booster assembl y consi sts of a housi ng di vi ded
i nto separate chambers by two i nternal di aphragms.
The outer edge of each di aphragm i s attached to the
booster housi ng. The di aphragms are connected to
the booster pri mary push rod.
Two push rods are used i n the booster. The pri -
mary push rod connects the booster to the brake
pedal . The secondary push rod connects the booster
to the master cyl i nder to stroke the cyl i nder pi stons.
OPERATION
The atmospheri c i nl et val ve i s opened and cl osed
by the pri mary push rod. Booster vacuum suppl y i s
through a hose attached to an i ntake mani fol d fi tti ng
at one end and to the booster check val ve at the
other. The vacuum check val ve i n the booster housi ng
i s a one-way devi ce that prevents vacuum l eak back.
Power assi st i s generated by uti l i zi ng the pressure
di fferenti al between normal atmospheri c pressure
and a vacuum. The vacuum needed for booster oper-
ati on i s taken di rectl y from the engi ne i ntake mani -
fol d. The entry poi nt for atmospheri c pressure i s
through a fi l ter and i nl et val ve at the rear of the
housi ng (Fi g. 1).
The chamber areas forward of the booster di a-
phragms are exposed to vacuum from the i ntake
mani fol d. The chamber areas to the rear of the di a-
phragms, are exposed to normal atmospheri c pres-
sure of 101.3 ki l opascal s (14.7 pounds/square i n.).
Brake pedal appl i cati on causes the pri mary push
rod to open the atmospheri c i nl et val ve. Thi s exposes
the area behi nd the di aphragms to atmospheri c pres-
sure. The resul ti ng pressure di fferenti al provi des the
extra appl y force for power assi st.
The booster check val ve, check val ve grommet and
booster seal s are servi ceabl e.
MASTER CYLINDER
DESCRIPTION
The master cyl i nder has a removabl e nyl on reser-
voi r. The cyl i nder body i s made of al umi num and
contai ns a pri mary and secondary pi ston assembl y.
The cyl i nder body i ncl udi ng the pi ston assembl i es
are not servi ceabl e. I f di agnosi s i ndi cates an i nternal
probl em wi th the cyl i nder body, i t must be repl aced
as an assembl y. The reservoi r and grommets are the
onl y repl aceabl e parts on the master cyl i nder.
OPERATION
The master cyl i nder bore contai ns a pri mary and
secondary pi ston. The pri mary pi ston suppl i es
hydraul i c pressure to the front brakes. The secondary
pi ston suppl i es hydraul i c pressure to the rear brakes.
The master cyl i nder reservoi r stores reserve brake
fl ui d for the hydraul i c brake ci rcui ts.
COMBINATION VALVE
DESCRIPTION
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e and must be
repl aced as an assembl y i f di agnosi s i ndi cates thi s i s
necessary.
OPERATION
PRESSURE DIFFERENTIAL VALVE
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs to the
brake system are made.
PROPORTIONING VALVE
The proporti oni ng val ve i s used to bal ance front-
rear brake acti on at hi gh decel erati ons. The val ve
al l ows normal fl ui d fl ow duri ng moderate braki ng.
The val ve onl y control s fl ui d fl ow duri ng hi gh decel -
erati ons brake stops.
XJ BRAKES 5 - 3
FRONT DISC BRAKES
DESCRIPTION
The cal i pers are a si ngl e pi ston type. The cal i pers
are free to sl i de l ateral l y, thi s al l ows conti nuous com-
pensati on for l i ni ng wear.
OPERATION
When the brakes are appl i ed fl ui d pressure i s
exerted agai nst the cal i per pi ston. The fl ui d pressure
i s exerted equal l y and i n al l di recti ons. Thi s means
pressure exerted agai nst the cal i per pi ston and
wi thi n the cal i per bore wi l l be equal (Fi g. 2).
Fl ui d pressure appl i ed to the pi ston i s transmi tted
di rectl y to the i nboard brake shoe. Thi s forces the
shoe l i ni ng agai nst the i nner surface of the di sc
brake rotor. At the same ti me, fl ui d pressure wi thi n
the pi ston bore forces the cal i per to sl i de i nward on
the mounti ng bol ts. Thi s acti on bri ngs the outboard
brake shoe l i ni ng i nto contact wi th the outer surface
of the di sc brake rotor.
Fig. 1 Power Brake BoosterTypical
1 VACUUM CHECK VALVE
2 FRONT DIAPHRAGM
3 REAR DIAPHRAGM
4 HOUSING
5 SEAL
6 AIR FILTER
7 PRIMARY PUSH ROD (TO BRAKE PEDAL)
8 ATMOSPHERIC INLET VALVE ASSEMBLY
9 BOOSTER MOUNTING STUDS (4)
10 SECONDARY PUSH ROD (TO MASTER CYLINDER)
11 MASTER CYLINDER MOUNTING STUD (2)
12 SPRING
5 - 4 BRAKES XJ
I n summary, fl ui d pressure acti ng si mul taneousl y
on both pi ston and cal i per, produces a strong cl amp-
i ng acti on. When suffi ci ent force i s appl i ed, fri cti on
wi l l attempt to stop the rotors from turni ng and
bri ng the vehi cl e to a stop.
Appl i cati on and rel ease of the brake pedal gener-
ates onl y a very sl i ght movement of the cal i per and
pi ston. Upon rel ease of the pedal , the cal i per and pi s-
ton return to a rest posi ti on. The brake shoes do not
retract an appreci abl e di stance from the rotor. I n
fact, cl earance i s usual l y at, or cl ose to zero. The rea-
sons for thi s are to keep road debri s from getti ng
between the rotor and l i ni ng and i n wi pi ng the rotor
surface cl ear each revol uti on.
The cal i per pi ston seal control s the amount of pi s-
ton extensi on needed to compensate for normal l i ni ng
wear.
Duri ng brake appl i cati on, the seal i s defl ected out-
ward by fl ui d pressure and pi ston movement (Fi g. 3).
When the brakes (and fl ui d pressure) are rel eased,
the seal rel axes and retracts the pi ston.
The amount of pi ston retracti on i s determi ned by
the amount of seal defl ecti on. General l y the amount
i s just enough to mai ntai n contact between the pi s-
ton and i nboard brake shoe.
REAR DRUM BRAKE
DESCRIPTION
The rear brakes use a l eadi ng shoe (pri mary) and
trai l i ng shoe (secondary) desi gn (Fi g. 4).
OPERATION
When the brake pedal i s depressed hydraul i c pres-
sure pushes the rear brake wheel cyl i nder pi stons
outward. The wheel cyl i nder push rods then push the
brake shoes outward agai nst the brake drum. When
the brake pedal i s rel eased return spri ngs attached
to the brake shoes pul l the shoes back to there ori g-
i nal posi ti on.
PARKING BRAKE
DESCRIPTION
The parki ng bake i s a hand l ever and cabl e oper-
ated system used to appl y the rear brakes.
OPERATION
A hand operated l ever i n the passenger compart-
ment i s the mai n appl i cati on devi ce. The front cabl e
i s connected between the hand l ever and the ten-
si oner. The tensi oner rod i s attached to the equal i zer
whi ch i s the connecti ng poi nt for the rear cabl es (Fi g.
5).
The rear cabl es are connected to the actuati ng
l ever on each secondary brake shoe. The l evers are
attached to the brake shoes by a pi n ei ther pressed
i nto, or wel ded to the l ever. A cl i p i s used to secure
the pi n i n the brake shoe. The pi n al l ows each l ever
to pi vot i ndependentl y of the brake shoe.
To appl y the parki ng brakes, the hand l ever i s
pul l ed upward. Thi s pul l s the rear brake shoe actu-
Fig. 2 Brake Caliper Operation
1 CALIPER
2 PISTON
3 PISTON BORE
4 SEAL
5 INBOARD SHOE
6 OUTBOARD SHOE
Fig. 3 Lining Wear Compensation By Piston Seal
1 PISTON
2 CYLINDER BORE
3 PISTON SEAL BRAKE PRESSURE OFF
4 CALIPER HOUSING
5 DUST BOOT
6 PISTON SEAL BRAKE PRESSURE ON
XJ BRAKES 5 - 5
ati ng l evers forward, by means tensi oner and cabl es.
As the actuati ng l ever i s pul l ed forward, the parki ng
brake strut (whi ch i s connected to both shoes), exerts
a l i near force agai nst the pri mary brake shoe. Thi s
acti on presses the pri mary shoe i nto contact wi th the
drum. Once the pri mary shoe contacts the drum,
force i s exerted through the strut. Thi s force i s trans-
ferred through the strut to the secondary brake shoe
causi ng i t to pi vot i nto the drum as wel l .
A gear type ratcheti ng mechani sm i s used to hol d
the l ever i n an appl i ed posi ti on. Parki ng brake
rel ease i s accompl i shed by the hand l ever rel ease
button.
A parki ng brake swi tch i s mounted on the parki ng
brake l ever and i s actuated by movement of the
l ever. The swi tch, whi ch i s i n ci rcui t wi th the red
warni ng l i ght i n the dash, wi l l i l l umi nate the warn-
i ng l i ght whenever the parki ng brakes are appl i ed.
Parki ng brake adjustment i s control l ed by a cabl e
tensi oner mechani sm. The cabl e tensi oner, once
adjusted at the factory, shoul d not need further
adjustment under normal ci rcumstances. Adjustment
Fig. 4 Brake Components
1 ADJUSTER LEVER
2 ADJUSTER CABLE
3 HOLDDOWN SPRING AND RETAINERS
4 ADJUSTER LEVER SPRING
5 TRAILING SHOE
6 CYLINDER-TO-SUPPORT SEAL
7 HOLDDOWN PINS
8 ACCESS PLUGS
9 SUPPORT PLATE
10 CABLE HOLE PLUG
11 PARK BRAKE STRUT AND SPRING
12 ADJUSTER SCREW ASSEMBLY
14 LEADING SHOE
15 CABLE GUIDE
16 SHOE RETURN SPRINGS
17 SHOE GUIDE PLATE
18 PIN
19 SHOE SPRING
20 PARK BRAKE LEVER
Fig. 5 Parking Brake Components
1 REAR CABLES
2 EQUALIZER
3 FRONT CABLE
4 TENSIONER ROD
5 - 6 BRAKES XJ
may be requi red i f a new tensi oner, or cabl es are
i nstal l ed, or di sconnected.
BRAKE HOSES AND LINES
DESCRIPTION
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. Doubl e wal l ed
steel tubi ng i s used to connect the master cyl i nder to
the major hydraul i c braki ng components and then to
the fl exi bl e rubber hoses. Doubl e i nverted styl e and
I SO styl e fl ares are used on the brake l i nes.
BASE BRAKE SYSTEM
Base brake components consi st of the brake shoes,
cal i pers, wheel cyl i nders, brake drums, rotors, brake
l i nes, master cyl i nder, booster, and parki ng brake
components.
Brake di agnosi s i nvol ves determi ni ng i f the prob-
l em i s rel ated to a mechani cal , hydraul i c, or vacuum
operated component.
The fi rst di agnosi s step i s the prel i mi nary check.
PRELIMINARY BRAKE CHECK
(1) Check condi ti on of ti res and wheel s. Damaged
wheel s and worn, damaged, or underi nfl ated ti res
can cause pul l , shudder, vi brati on, and a condi ti on
si mi l ar to grab.
(2) I f compl ai nt was based on noi se when braki ng,
check suspensi on components. Jounce front and rear
of vehi cl e and l i sten for noi se that mi ght be caused
by l oose, worn or damaged suspensi on or steeri ng
components.
(3) I nspect brake fl ui d l evel and condi ti on. Note
that the brake reservoi r fl ui d l evel wi l l decrease i n
proporti on to normal l i ni ng wear. Also note that
brake fluid tends to darken over time. This is
normal and should not be mistaken for contam-
ination.
(a) I f fl ui d l evel i s abnormal l y l ow, l ook for evi -
dence of l eaks at cal i pers, wheel cyl i nders, brake
l i nes, and master cyl i nder.
(b) I f fl ui d appears contami nated, drai n out a
sampl e to exami ne. System wi l l have to be fl ushed
i f fl ui d i s separated i nto l ayers, or contai ns a sub-
stance other than brake fl ui d. The system seal s
and cups wi l l al so have to be repl aced after fl ush-
i ng. Use cl ean brake fl ui d to fl ush the system.
(4) Check parki ng brake operati on. Veri fy free
movement and ful l rel ease of cabl es and pedal . Al so
note i f vehi cl e was bei ng operated wi th parki ng
brake parti al l y appl i ed.
(5) Check brake pedal operati on. Veri fy that pedal
does not bi nd and has adequate free pl ay. I f pedal
l acks free pl ay, check pedal and power booster for
bei ng l oose or for bi nd condi ti on. Do not road test
unti l condi ti on i s corrected.
(6) Check booster vacuum check val ve and hose.
(7) I f components checked appear OK, road test
the vehi cl e.
ROAD TESTING
(1) I f compl ai nt i nvol ved l ow brake pedal , pump
pedal and note i f i t comes back up to normal hei ght.
(2) Check brake pedal response wi th transmi ssi on
i n Neutral and engi ne runni ng. Pedal shoul d remai n
fi rm under constant foot pressure.
(3) Duri ng road test, make normal and fi rm brake
stops i n 25-40 mph range. Note faul ty brake opera-
ti on such as l ow pedal , hard pedal , fade, pedal pul sa-
ti on, pul l , grab, drag, noi se, etc.
(4) Attempt to stop the vehi cl e wi th the parki ng
brake onl y and note grab, drag, noi se, etc.
PEDAL FALLS AWAY
A brake pedal that fal l s away under steady foot
pressure i s general l y the resul t of a system l eak. The
l eak poi nt coul d be at a brake l i ne, fi tti ng, hose, or
cal i per/wheel cyl i nder. I f l eakage i s severe, fl ui d wi l l
be evi dent at or around the l eaki ng component.
I nternal l eakage (seal by-pass) i n the master cyl i n-
der caused by worn or damaged pi ston cups, may
al so be the probl em cause.
An i nternal l eak i n the ABS or RWAL system may
al so be the probl em wi th no physi cal evi dence.
LOW PEDAL
I f a l ow pedal i s experi enced, pump the pedal sev-
eral ti mes. I f the pedal comes back up worn l i ni ngs,
rotors, drums, or rear brakes out of adjustment are
the most l i kel y causes. The proper course of acti on i s
to i nspect and repl ace al l worn component and make
the proper adjustments.
SPONGY PEDAL
A spongy pedal i s most often caused by ai r i n the
system. However, thi n brake drums or substandard
brake l i nes and hoses can al so cause a spongy pedal .
The proper course of acti on i s to bl eed the system,
and repl ace thi n drums and substandard qual i ty
brake hoses i f suspected.
HARD PEDAL OR HIGH PEDAL EFFORT
A hard pedal or hi gh pedal effort may be due to
l i ni ng that i s water soaked, contami nated, gl azed, or
badl y worn. The power booster or check val ve coul d
al so be faul ty.
XJ BRAKES 5 - 7
PEDAL PULSATION
Pedal pul sati on i s caused by components that are
l oose, or beyond tol erance l i mi ts.
The pri mary cause of pul sati on are di sc brake
rotors wi th excessi ve l ateral runout or thi ckness vari -
ati on, or out of round brake drums. Other causes are
l oose wheel beari ngs or cal i pers and worn, damaged
ti res.
NOTE: Some pedal pulsation may be felt during
ABS activation.
BRAKE DRAG
Brake drag occurs when the l i ni ng i s i n constant
contact wi th the rotor or drum. Drag can occur at one
wheel , al l wheel s, fronts onl y, or rears onl y.
Drag i s a product of i ncompl ete brake shoe rel ease.
Drag can be mi nor or severe enough to overheat the
l i ni ngs, rotors and drums.
Mi nor drag wi l l usual l y cause sl i ght surface char-
ri ng of the l i ni ng. I t can al so generate hard spots i n
rotors and drums from the overheat-cool down pro-
cess. I n most cases, the rotors, drums, wheel s and
ti res are qui te warm to the touch after the vehi cl e i s
stopped.
Severe drag can char the brake l i ni ng al l the way
through. I t can al so di stort and score rotors and
drums to the poi nt of repl acement. The wheel s, ti res
and brake components wi l l be extremel y hot. I n
severe cases, the l i ni ng may generate smoke as i t
chars from overheati ng.
Common causes of brake drag are:
Sei zed or i mproperl y adjusted parki ng brake
cabl es.
Loose/worn wheel beari ng.
Sei zed cal i per or wheel cyl i nder pi ston.
Cal i per bi ndi ng on corroded bushi ngs or rusted
sl i de surfaces.
Loose cal i per mounti ng.
Drum brake shoes bi ndi ng on worn/damaged
support pl ates.
Mi s-assembl ed components.
Long booster output rod.
I f brake drag occurs at al l wheel s, the probl em
may be rel ated to a bl ocked master cyl i nder return
port, or faul ty power booster (bi nds-does not rel ease).
BRAKE FADE
Brake fade i s usual l y a product of overheati ng
caused by brake drag. However, brake overheati ng
and resul ti ng fade can al so be caused by ri di ng the
brake pedal , maki ng repeated hi gh decel erati on stops
i n a short ti me span, or constant braki ng on steep
mountai n roads. Refer to the Brake Drag i nformati on
i n thi s secti on for causes.
BRAKE PULL
Front brake pul l condi ti on coul d resul t from:
Contami nated l i ni ng i n one cal i per
Sei zed cal i per pi ston
Bi ndi ng cal i per
Loose cal i per
Rusty cal i per sl i de surfaces
I mproper brake shoes
Damaged rotor
A worn, damaged wheel beari ng or suspensi on
component are further causes of pul l . A damaged
front ti re (brui sed, pl y separati on) can al so cause
pul l .
A common and frequentl y mi sdi agnosed pul l condi -
ti on i s where di recti on of pul l changes after a few
stops. The cause i s a combi nati on of brake drag fol -
l owed by fade at one of the brake uni ts.
As the draggi ng brake overheats, effi ci ency i s so
reduced that fade occurs. Si nce the opposi te brake
uni t i s sti l l functi oni ng normal l y, i ts braki ng effect i s
magni fi ed. Thi s causes pul l to swi tch di recti on i n
favor of the normal l y functi oni ng brake uni t.
An addi ti onal poi nt when di agnosi ng a change i n
pul l condi ti on concerns brake cool down. Remember
that pul l wi l l return to the ori gi nal di recti on, i f the
draggi ng brake uni t i s al l owed to cool down (and i s
not seri ousl y damaged).
REAR BRAKE GRAB OR PULL
Rear grab or pul l i s usual l y caused by i mproperl y
adjusted or sei zed parki ng brake cabl es, contami -
nated l i ni ng, bent or bi ndi ng shoes and support
pl ates, or i mproperl y assembl ed components. Thi s i s
parti cul arl y true when onl y one rear wheel i s
i nvol ved. However, when both rear wheel s are
affected, the master cyl i nder or proporti oni ng val ve
coul d be at faul t.
BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP
WATER PUDDLES
Thi s condi ti on i s general l y caused by water soaked
l i ni ng. I f the l i ni ng i s onl y wet, i t can be dri ed by
dri vi ng wi th the brakes very l i ghtl y appl i ed for a
mi l e or two. However, i f the l i ni ng i s both soaked and
di rt contami nated, cl eani ng and/or repl acement wi l l
be necessary.
BRAKE LINING CONTAMINATION
Brake l i ni ng contami nati on i s mostl y a product of
l eaki ng cal i pers or wheel cyl i nders, worn seal s, dri v-
i ng through deep water puddl es, or l i ni ng that has
become covered wi th grease and gri t duri ng repai r.
Contami nated l i ni ng shoul d be repl aced to avoi d fur-
ther brake probl ems.
5 - 8 BRAKES XJ
WHEEL AND TIRE PROBLEMS
Some condi ti ons attri buted to brake components
may actual l y be caused by a wheel or ti re probl em.
A damaged wheel can cause shudder, vi brati on and
pul l . A worn or damaged ti re can al so cause pul l .
Severel y worn ti res wi th very l i ttl e tread l eft can
produce a grab-l i ke condi ti on as the ti re l oses and
recovers tracti on. Fl at-spotted ti res can cause vi bra-
ti on and generate shudder duri ng brake operati on. A
ti re wi th i nternal damage such as a severe brui se,
cut, or pl y separati on can cause pul l and vi brati on.
BRAKE NOISES
Some brake noi se i s common wi th rear drum
brakes and on some di sc brakes duri ng the fi rst few
stops after a vehi cl e has been parked overni ght or
stored. Thi s i s pri mari l y due to the formati on of trace
corrosi on (l i ght rust) on metal surfaces. Thi s l i ght
corrosi on i s typi cal l y cl eared from the metal surfaces
after a few brake appl i cati ons causi ng the noi se to
subsi de.
BRAKE SQUEAK/SQUEAL
Brake squeak or squeal may be due to l i ni ngs that
are wet or contami nated wi th brake fl ui d, grease, or
oi l . Gl azed l i ni ngs and rotors wi th hard spots can
al so contri bute to squeak. Di rt and forei gn materi al
embedded i n the brake l i ni ng wi l l al so cause squeak/
squeal .
A very l oud squeak or squeal i s frequentl y a si gn of
severel y worn brake l i ni ng. I f the l i ni ng has worn
through to the brake shoes i n spots, metal -to-metal
contact occurs. I f the condi ti on i s al l owed to conti nue,
rotors and drums can become so scored that repl ace-
ment i s necessary.
BRAKE CHATTER
Brake chatter i s usual l y caused by l oose or worn
components, or gl azed/burnt l i ni ng. Rotors wi th hard
spots can al so contri bute to chatter. Addi ti onal causes
of chatter are out-of-tol erance rotors, brake l i ni ng not
securel y attached to the shoes, l oose wheel beari ngs
and contami nated brake l i ni ng.
THUMP/CLUNK NOISE
Thumpi ng or cl unk noi ses duri ng braki ng are fre-
quentl y not caused by brake components. I n many
cases, such noi ses are caused by l oose or damaged
steeri ng, suspensi on, or engi ne components. However,
cal i pers that bi nd on the sl i de surfaces can generate
a thump or cl unk noi se. I n addi ti on, worn out,
i mproperl y adjusted, or i mproperl y assembl ed rear
brake shoes can al so produce a thump noi se.
BRAKE LAMP SWITCH
The brake l amp swi tch operati on can be tested
wi th an ohmmeter. The ohmmeter i s used to check
conti nui ty between the pi n termi nal s (Fi g. 6).
SWITCH CIRCUIT IDENTIFICATION
Termi nal s 1 and 2: brake sensor ci rcui t
Termi nal s 3 and 4: speed control ci rcui t i f
equi pped
Termi nal s 5 and 6: brake l amp ci rcui t
SWITCH CONTINUITY TEST
NOTE: Disconnect switch harness before testing
switch continuity.
Wi th the swi tch pl unger retracted, attach test
l eads to termi nal pi ns 1 and 2. Repl ace swi tch i f
meter i ndi cates no conti nui ty.
Wi th the swi tch pl unger retracted, attach test
Wi th the swi tch pl unger extended, attach test
RED BRAKE WARNING LAMP
The red brake warni ng l amp wi l l i l l umi nate under
the fol l owi ng condi ti ons:
Sel f test at start-up.
Parki ng brakes are appl i ed.
Leak i n front/rear brake hydraul i c ci rcui t.
I f the red l i ght remai ns on after start-up, fi rst ver-
i fy that the parki ng brakes are ful l y rel eased. Then
check pedal acti on and fl ui d l evel . I f the l amp on and
the brake pedal i s l ow thi s i ndi cates the pressure di f-
Fig. 6 Brake Lamp Switch Terminal Identification
1 TERMINAL PINS
2 PLUNGER TEST POSITIONS
XJ BRAKES 5 - 9
ferenti al swi tch and val ve have been actuated due to
a l eak i n the hydraul i c system.
On model s wi th ABS brakes, the amber warni ng
l amp onl y i l l umi nates duri ng the sel f test and when
an ABS mal functi on has occurred. The ABS l amp
operates i ndependentl y of the red warni ng l amp.
For addi ti onal i nformati on refer to Group 8W.
MASTER CYLINDER/POWER BOOSTER
(1) Start engi ne and check booster vacuum hose
connecti ons. A hi ssi ng noi se i ndi cates vacuum l eak.
Correct any vacuum l eak before proceedi ng.
(2) Stop engi ne and shi ft transmi ssi on i nto Neu-
tral .
(3) Pump brake pedal unti l al l vacuum reserve i n
booster i s depl eted.
(4) Press and hol d brake pedal under l i ght foot
pressure. The pedal shoul d hol d fi rm, i f the pedal
fal l s away master cyl i nder i s faul ty (i nternal l eak-
age).
(5) Start engi ne and note pedal acti on. I t shoul d
fal l away sl i ghtl y under l i ght foot pressure then hol d
fi rm. I f no pedal acti on i s di scerni bl e, power booster,
vacuum suppl y, or vacuum check val ve i s faul ty. Pro-
ceed to the POWER BOOSTER VACUUM TEST.
(6) I f the POWER BOOSTER VACUUM TEST
passes, rebui l d booster vacuum reserve as fol l ows:
Rel ease brake pedal . I ncrease engi ne speed to 1500
rpm, cl ose the throttl e and i mmedi atel y turn off i gni -
ti on to stop engi ne.
(7) Wai t a mi ni mum of 90 seconds and try brake
acti on agai n. Booster shoul d provi de two or more vac-
uum assi sted pedal appl i cati ons. I f vacuum assi st i s
not provi ded, booster i s faul ty.
POWER BOOSTER VACUUM TEST
(1) Connect vacuum gauge to booster check val ve
wi th short l ength of hose and T-fi tti ng (Fi g. 7).
(2) Start and run engi ne at curb i dl e speed for one
mi nute.
(3) Observe the vacuum suppl y. I f vacuum suppl y
i s not adequate, repai r vacuum suppl y.
(4) Cl amp hose shut between vacuum source and
check val ve.
(5) Stop engi ne and observe vacuum gauge.
(6) I f vacuum drops more than one i nch HG (33
mi l l i bars) wi thi n 15 seconds, booster di aphragm or
check val ve i s faul ty.
POWER BOOSTER CHECK VALVE TEST
(1) Di sconnect vacuum hose from check val ve.
(2) Remove check val ve and val ve seal from
booster.
(3) Use a hand operated vacuum pump for test.
(4) Appl y 15-20 i nches vacuum at l arge end of
check val ve (Fi g. 8).
(5) Vacuum shoul d hol d steady. I f gauge on pump
i ndi cates vacuum l oss, check val ve i s faul ty and
shoul d be repl aced.
Fig. 7 Typical Booster Vacuum Test Connections
1 TEE FITTING
2 SHORT CONNECTING HOSE
3 CHECK VALVE
4 CHECK VALVE HOSE
5 CLAMP TOOL
6 INTAKE MANIFOLD
7 VACUUM GAUGE
Fig. 8 Vacuum Check Valve And Seal
1 BOOSTER CHECK VALVE
2 APPLY TEST VACUUM HERE
3 VALVE SEAL
5 - 10 BRAKES XJ
COMBINATION VALVE
PRESSURE DIFFERENTIAL SWITCH
(1) Have hel per si t i n dri vers seat to appl y brake
pedal and observe red brake warni ng l i ght.
(2) Rai se vehi cl e on hoi st.
(3) Connect bl eed hose to a rear wheel cyl i nder
and i mmerse hose end i n contai ner parti al l y fi l l ed
wi th brake fl ui d.
(4) Have hel per press and hol d brake pedal to fl oor
and observe warni ng l i ght.
(a) I f warni ng l i ght i l l umi nates, swi tch i s operat-
i ng correctl y.
(b) I f l i ght fai l s to i l l umi nate, check ci rcui t fuse,
bul b, and wi ri ng. The parki ng brake swi tch can be
used to ai d i n i denti fyi ng whether or not the brake
l i ght bul b and fuse i s functi onal . Repai r or repl ace
parts as necessary and test di fferenti al pressure
swi tch operati on agai n.
(5) I f warni ng l i ght sti l l does not i l l umi nate,
swi tch i s faul ty. Repl ace combi nati on val ve assembl y,
bl eed brake system and veri fy proper swi tch and
val ve operati on.
REAR PROPORTIONING VALVE
The val ve control s fl ui d fl ow. I f fl ui d enters the
val ve and does not exi t the val ve the combi nati on
val ve must be repl aced.
DISC BRAKE ROTOR
The rotor braki ng surfaces shoul d not be refi ni shed
unl ess necessary.
Li ght surface rust and scal e can be removed wi th a
l athe equi pped wi th dual sandi ng di scs. The rotor
surfaces can be restored by machi ni ng i n a di sc brake
l athe i f surface scori ng and wear are l i ght.
Repl ace the rotor under the fol l owi ng condi ti ons:
severel y scored
tapered
hard spots
cracked
bel ow mi ni mum thi ckness
ROTOR MINIMUM THICKNESS
Measure rotor thi ckness at the center of the brake
shoe contact surface. Repl ace the rotor i f worn bel ow
mi ni mum thi ckness, or i f machi ni ng woul d reduce
thi ckness bel ow the al l owabl e mi ni mum.
Rotor mi ni mum thi ckness i s usual l y speci fi ed on
the rotor hub. The speci fi cati on i s ei ther stamped or
cast i nto the hub surface.
ROTOR RUNOUT
Check rotor l ateral runout wi th di al i ndi cator
C-3339 (Fi g. 9). Excessi ve l ateral runout wi l l cause
brake pedal pul sati on and rapi d, uneven wear of the
brake shoes. Posi ti on the di al i ndi cator pl unger
approxi matel y 25.4 mm (1 i n.) i nward from the rotor
edge. Maxi mum al l owabl e rotor runout i s 0.102 mm
(0.004 i n.).
ROTOR THICKNESS VARIATION
Vari ati ons i n rotor thi ckness wi l l cause pedal pul -
sati on, noi se and shudder.
Measure rotor thi ckness at 6 to 12 poi nts around
the rotor face (Fi g. 10).
Posi ti on the mi crometer approxi matel y 25.4 mm (1
i n.) from the rotor outer ci rcumference for each mea-
surement.
Thi ckness shoul d not vary by more than 0.013 mm
(0.0005 i n.) from poi nt-to-poi nt on the rotor. Machi ne
or repl ace the rotor i f necessary.
BRAKE DRUM
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s i ndi cated on the drum outer edge.
General l y, a drum can be machi ned to a maxi mum of
1.52 mm (0.060 i n.) oversi ze. Al ways repl ace the
drum i f machi ni ng woul d cause drum di ameter to
exceed the si ze l i mi t i ndi cated on the drum.
BRAKE DRUM RUNOUT
Measure drum di ameter and runout wi th an accu-
rate gauge. The most accurate method of measure-
ment i nvol ves mounti ng the drum i n a brake l athe
and checki ng vari ati on and runout wi th a di al i ndi -
cator.
Vari ati ons i n drum di ameter shoul d not exceed
0.076 mm (0.003 i n.). Drum runout shoul d not exceed
0.20 mm (0.008 i n.) out of round. Machi ne the drum
i f runout or vari ati on exceed these val ues. Repl ace
Fig. 9 Checking Rotor Runout And Thickness
Variation
1 DIAL INDICATOR
XJ BRAKES 5 - 11
the drum i f machi ni ng causes the drum to exceed the
maxi mum al l owabl e di ameter.
BRAKE LINE AND HOSES
Fl exi bl e rubber hose i s used at both front brakes
and at the rear axl e juncti on bl ock. I nspect the hoses
whenever the brake system i s servi ced, at every
engi ne oi l change, or whenever the vehi cl e i s i n for
servi ce.
I nspect the hoses for surface cracki ng, scuffi ng, or
worn spots. Repl ace any brake hose i mmedi atel y i f
the fabri c casi ng of the hose i s exposed due to cracks
or abrasi ons.
Al so check brake hose i nstal l ati on. Faul ty i nstal l a-
ti on can resul t i n ki nked, twi sted hoses, or contact
wi th the wheel s and ti res or other chassi s compo-
nents. Al l of these condi ti ons can l ead to scuffi ng,
cracki ng and eventual fai l ure.
The steel brake l i nes shoul d be i nspected peri odi -
cal l y for evi dence of corrosi on, twi sts, ki nks, l eaks, or
other damage. Heavi l y corroded l i nes wi l l eventual l y
rust through causi ng l eaks. I n any case, corroded or
damaged brake l i nes shoul d be repl aced.
Factory repl acement brake l i nes and hoses are rec-
ommended to ensure qual i ty, correct l ength and supe-
ri or fati gue l i fe. Care shoul d be taken to make sure
that brake l i ne and hose mati ng surfaces are cl ean
and free from ni cks and burrs. Al so remember that
ri ght and l eft brake hoses are not i nterchangeabl e.
Use new copper seal washers at al l cal i per connec-
ti ons. Be sure brake l i ne connecti ons are properl y
made (not cross threaded) and ti ghtened to recom-
mended torque.
BRAKE FLUID CONTAMINATION
I ndi cati ons of fl ui d contami nati on are swol l en or
deteri orated rubber parts.
Swol l en rubber parts i ndi cate the presence of
petrol eum i n the brake fl ui d.
To test for contami nati on, put a smal l amount of
drai ned brake fl ui d i n cl ear gl ass jar. I f fl ui d sepa-
rates i nto l ayers, there i s mi neral oi l or other fl ui d
contami nati on of the brake fl ui d.
I f brake fl ui d i s contami nated, drai n and thor-
oughl y fl ush system. Repl ace master cyl i nder, propor-
ti oni ng val ve, cal i per seal s, wheel cyl i nder seal s,
Anti l ock Brakes hydraul i c uni t and al l hydraul i c
fl ui d hoses.
SERVICE PROCEDURES
BRAKE FLUID LEVEL
Al ways cl ean the master cyl i nder reservoi r and cap
before addi ng fl ui d. Thi s wi l l prevent di rt from fal l -
i ng i n the reservoi r and contami nati ng the brake
fl ui d.
The reservoi r has a ADD and a FULL mark on the
si de (Fi g. 11) fi l l to the FULL mark.
MASTER CYLINDER BLEEDING
A new master cyl i nder shoul d be bl ed before i nstal -
l ati on on the vehi cl e. Requi red bl eedi ng tool s i ncl ude
bl eed tubes and a wood dowel to stroke the pi stons.
Bl eed tubes can be fabri cated from brake l i ne.
BLEEDING PROCEDURE
(1) Mount master cyl i nder i n vi se.
(2) Attach bl eed tubes to cyl i nder outl et ports.
Then posi ti on each tube end i nto reservoi r (Fi g. 12).
Fig. 10 Measuring Rotor Thickness
1 MICROMETER
2 ROTOR
Fig. 11 Master Cylinder Fluid Level
1 FLUID LEVEL MARKS
2 RESERVOIR
5 - 12 BRAKES XJ
(3) Fi l l reservoi r wi th fresh brake fl ui d.
(4) Press cyl i nder pi stons i nward wi th wood dowel .
Then rel ease pi stons and al l ow them to return under
spri ng pressure. Conti nue bl eedi ng operati ons unti l
ai r bubbl es are no l onger vi si bl e i n fl ui d.
BASE BRAKE BLEEDING
Use Mopar brake fl ui d, or an equi val ent qual i ty
fl ui d meeti ng SAE J1703-F and DOT 3 standards
onl y. Use fresh, cl ean fl ui d from a seal ed contai ner at
al l ti mes.
Do not pump the brake pedal at any ti me whi l e
bl eedi ng. Ai r i n the system wi l l be compressed i nto
smal l bubbl es that are di stri buted throughout the
hydraul i c system. Thi s wi l l make addi ti onal bl eedi ng
operati ons necessary.
Do not al l ow the master cyl i nder to run out of fl ui d
duri ng bl eed operati ons. An empty cyl i nder wi l l al l ow
addi ti onal ai r to be drawn i nto the system. Check the
cyl i nder fl ui d l evel frequentl y and add fl ui d as
needed.
Bl eed onl y one brake component at a ti me i n the
fol l owi ng sequence:
Master Cyl i nder
Combi nati on Val ve
Ri ght Rear Wheel
Left Rear Wheel
Ri ght Front Wheel
Left Front Wheel
MANUAL BLEEDING
(1) Remove reservoi r fi l l er caps and fi l l reservoi r.
(2) I f cal i pers, or wheel cyl i nders were overhaul ed,
open al l cal i per and wheel cyl i nder bl eed screws.
Then cl ose each bl eed screw as fl ui d starts to dri p
from i t. Top off master cyl i nder reservoi r once more
before proceedi ng.
(3) Attach one end of bl eed hose to bl eed screw
and i nsert opposi te end i n gl ass contai ner parti al l y
fi l l ed wi th brake fl ui d (Fi g. 13). Be sure end of bl eed
hose i s i mmersed i n fl ui d.
(4) Open up bl eeder, then have a hel per press
down the brake pedal . Once the pedal i s down cl ose
the bl eeder. Repeat bl eedi ng unti l fl ui d stream i s
cl ear and free of bubbl es. Then move to the next
wheel .
PRESSURE BLEEDING
Fol l ow the manufacturers i nstructi ons careful l y
when usi ng pressure equi pment. Do not exceed the
tank manufacturers pressure recommendati ons. Gen-
eral l y, a tank pressure of 15-20 psi i s suffi ci ent for
bl eedi ng.
Fi l l the bl eeder tank wi th recommended fl ui d and
purge ai r from the tank l i nes before bl eedi ng.
Do not pressure bl eed wi thout a proper master cyl -
i nder adapter. The wrong adapter can l ead to l eak-
age, or drawi ng ai r back i nto the system. Use
adapter provi ded wi th the equi pment or Adapter
6921.
DISC ROTOR MACHINING
The di sc brake rotor can be machi ned i f scored or
worn. The l athe must machi ne both si des of the rotor
si mul taneousl y wi th dual cutter heads. The rotor
mounti ng surface must be cl ean before pl aci ng on the
l athe. Equi pment capabl e of machi ni ng onl y one si de
at a ti me may produce a tapered rotor. A hub
Fig. 12 Master Cylinder BleedingTypical
1 BLEEDING TUBES
2 RESERVOIR
Fig. 13 Bleed Hose Setup
1 BLEED HOSE
2 FLUID CONTAINER PARTIALLY FILLED WITH FLUID
XJ BRAKES 5 - 13
mounted on-vehi cl e l athe i s recommended. Thi s type
of l athe trues the rotor to the vehi cl es hub/beari ng.
CAUTION: Brake rotors that do not meet minimum
thickness specifications before or after machining
must be replaced.
BRAKE DRUM MACHINING
The brake drums can be machi ned on a drum l athe
when necessary. I ni ti al machi ni ng cuts shoul d be l i m-
i ted to 0.12 - 0.20 mm (0.005 - 0.008 i n.) at a ti me as
heavi er feed rates can produce taper and surface
vari ati on. Fi nal fi ni sh cuts of 0.025 to 0.038 mm
(0.001 to 0.0015 i n.) are recommended and wi l l gen-
eral l y provi de the best surface fi ni sh.
Be sure the drum i s securel y mounted i n the l athe
before machi ni ng operati ons. A damper strap shoul d
al ways be used around the drum to reduce vi brati on
and avoi d chatter marks.
The maxi mum al l owabl e di ameter of the drum
braki ng surface i s stamped or cast i nto the drum
outer edge.
CAUTION: Replace the drum if machining will
cause the drum to exceed the maximum allowable
diameter.
BRAKE TUBE FLARING
A preformed metal brake tube i s recommended and
preferred for al l repai rs. However, doubl e-wal l steel
tube can be used for emergency repai r when factory
repl acement parts are not readi l y avai l abl e.
Speci al bendi ng tool s are needed to avoi d ki nki ng
or twi sti ng of metal brake tubes. Speci al fl ari ng tool s
are needed to make a doubl e i nverted fl are or I SO
fl are (Fi g. 14).
DOUBLE INVERTED FLARING
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Ream cut edges of tubi ng to ensure proper
fl are.
(3) I nstal l repl acement tube nut on the tube.
(4) I nsert tube i n fl ari ng tool .
(5) Pl ace gauge form over the end of the tube.
(6) Push tubi ng through fl ari ng tool jaws unti l
tube contacts recessed notch i n gauge that matches
tube di ameter.
(7) Ti ghten the tool bar on the tube
(8) I nsert pl ug on gauge i n the tube. Then swi ng
compressi on di sc over gauge and center tapered fl ar-
i ng screw i n recess of compressi on di sc (Fi g. 15).
(9) Ti ghten tool handl e unti l pl ug gauge i s
squarel y seated on jaws of fl ari ng tool . Thi s wi l l start
the i nverted fl are.
(10) Remove the pl ug gauge and compl ete the
i nverted fl are.
ISO FLARING
To make a I SO fl are use Snap-On Fl ari ng Tool
TFM-428 or equi val ent.
(1) Cut off damaged tube wi th Tubi ng Cutter.
(2) Remove any burrs from the i nsi de of the tube.
(3) I nstal l tube nut on the tube.
Fig. 14 Inverted Flare And ISO Flare
1 ISO-STYLE FLARE
2 DOUBLE INVERTED-STYLE FLARE
Fig. 15 Inverted Flare Tools
5 - 14 BRAKES XJ
(4) Posi ti on the tube i n the fl ari ng tool fl ush wi th
the top of the tool bar (Fi g. 16). Then ti ghten the tool
bar on the tube.
(5) I nstal l the correct si ze adaptor on the fl ari ng
tool yoke screw.
(6) Lubri cate the adaptor.
(7) Al i gn the adaptor and yoke screw over the tube
(Fi g. 16).
(8) Turn the yoke screw i n unti l the adaptor i s
squarel y seated on the tool bar.
BRAKE LAMP SWITCH
REMOVAL
(1) Remove steeri ng col umn cover and l ower tri m
panel for swi tch access (i f necessary).
(2) Press brake pedal downward to ful l y appl i ed
posi ti on.
(3) Rotate swi tch approxi matel y 30 i n counter-
cl ockwi se di recti on to unl ock swi tch retai ner. Then
pul l swi tch rearward and out of bracket.
(4) Di sconnect swi tch harness and remove swi tch
from vehi cl e (Fi g. 17).
INSTALLATION
(1) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(2) Connect harness wi res to swi tch.
(3) Press and hol d brake pedal i n appl i ed posi ti on.
(4) I nstal l swi tch as fol l ows: Al i gn tab on swi tch
wi th notch i n swi tch bracket. Then i nsert swi tch i n
bracket and turn i t cl ockwi se about 30 to l ock i t i n
pl ace.
(5) Rel ease brake pedal . Then pul l pedal l i ghtl y
rearward. Pedal wi l l set pl unger to correct posi ti on
as pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make ratcheti ng sound as i t sel f adjusts.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs..
BRAKE PEDAL
REMOVAL
(1) Remove knee bl ocker under the steeri ng col -
umn.
(2) Remove retai ner cl i p securi ng booster push rod
to pedal (Fi g. 18).
(3) Remove brake l amp swi tch.
(4) Remove nuts securi ng the booster to the pedal
support bracket and nuts to the col umn bracket.
(5) Remove pedal and support bracket as an
assembl y from the vehi cl e.
Fig. 16 ISO Flaring
1 ADAPTER
2 LUBRICATE HERE
3 PILOT
4 FLUSH WITH BAR
5 TUBING
6 BAR ASSEMBLY
Fig. 17 Brake Lamp Switch
1 SWITCH
2 HARNESS CONNECTOR
XJ BRAKES 5 - 15
INSTALLATION
(1) I nstal l pedal and support bracket as an assem-
bl y i nto the vehi cl e.
(2) I nstal l nuts securi ng the booster to the pedal
support bracket and nuts to the col umn bracket.
(3) Ti ghten nuts to 39 Nm (29 ft. l bs.).
(4) Lubri cate the brake pedal pi n and bushi ngs
wi th Mopar mul ti -mi l eage grease.
(5) I nstal l booster push rod on pedal pi n and
i nstal l new retai ner cl i p.
(6) I nstal l knee bl ocker.
COMBINATION VALVE
NOTE: The combination valve is not repairable. The
valve is serviced as an assembly only.
REMOVAL
(1) Remove ai r cl eaner cover and hose for access to
val ve.
(2) Unsnap connector l ock tabs and di sconnect di f-
ferenti al pressure swi tch wi re at combi nati on val ve
(Fi g. 19). Do not pul l swi tch wi re to di sconnect.
(3) Di sconnect brake l i nes at combi nati on val ve
(Fi g. 20).
(4) Remove mounti ng nut and remove val ve.
INSTALLATION
(1) I nstal l val ve and ti ghten mounti ng nut to 17
Nm (155 i n. l bs.).
(2) Connect brake l i nes to repl acement val ve. Start
l i ne fi tti ngs by hand to avoi d cross threadi ng.
(3) Ti ghten brake l i ne fi tti ngs to 14 Nm (124 i n.
l bs.).
(4) Connect wi re to pressure di fferenti al swi tch.
(5) Bl eed base brakes.
MASTER CYLINDER
REMOVAL
(1) Remove brake l i nes at master cyl i nder and
combi nati on val ve (Fi g. 20).
(2) Di sconnect di fferenti al pressure swi tch wi re
from the combi nati on val ve.
Fig. 18 Booster Push Rod
1 BRAKE PEDAL
2 BOOSTER ROD
3 BUSHING
Fig. 19 Differential Pressure Switch
1 SWITCH TERMINAL
2 COMBINATION VALVE
3 WIRE HARNESS CONNECTOR
Fig. 20 Combination Valve
1 COMBINATION VALVE
2 MASTER CYLINDER
5 - 16 BRAKES XJ
(3) Remove mounti ng nuts from the combi nati on
val ve bracket and remove the val ve (Fi g. 20).
(4) Remove mounti ng nuts from the master cyl i n-
der (Fi g. 21).
(5) Remove master cyl i nder.
(6) Remove cyl i nder cover and drai n fl ui d.
(7) I f master cyl i nder reservoi r requi res servi ce,
refer to reservoi r repl acement procedure i n thi s sec-
ti on.
INSTALLATION
NOTE: If master cylinder is replaced, bleed cylinder
before installation.
(1) Remove protecti ve sl eeve from pri mary pi ston
shank on new master cyl i nder.
(2) Cl ean cyl i nder mounti ng surface of brake
booster.
(3) I nstal l master cyl i nder onto brake booster
studs.
(4) I nstal l mounti ng nuts and ti ghten to 17 Nm
(155 i n. l bs.).
(5) I nstal l combi nati on val ve and i nstal l mounti ng
nuts.
(6) Connect brake l i nes to master cyl i nder and
combi nati on val ve and ti ghten to 14 Nm (124 i n.
l bs.).
(7) Connect di fferenti al pressure swi tch wi re to the
combi nati on val ve.
(8) On RHD vehi cl es i nstal l the cool ant reserve/
overfl ow tank. Refer to Group 7 Cool i ng System.
(9) Fi l l and bl eed base brake system.
POWER BRAKE BOOSTER
REMOVAL
(1) On RHD vehi cl es remove the cool ant reserve/
(2) Di sconnect brake l i nes at master cyl i nder.
(3) Di sconnect wi re at combi nati on val ve di fferen-
ti al pressure swi tch.
(4) Remove nut mounti ng combi nati on val ve
bracket to booster studs and remove val ve.
(5) Remove nuts mounti ng master cyl i nder to
booster studs and remove cyl i nder.
(6) Di sconnect vacuum hose from booster check
val ve.
(7) Remove knee bl ocker under the steeri ng col -
umn.
(8) Remove retai ni ng cl i p that secures booster
push rod to brake pedal (Fi g. 22).
(9) Remove nuts attachi ng booster to passenger
compartment si de of dash panel (Fi g. 23).
(10) I n engi ne compartment, sl i de booster studs
out of dash panel , ti l t booster upward, and remove
booster from engi ne compartment.
(11) Remove dash seal from booster.
INSTALLATION
(1) I nstal l dash seal on booster.
(2) Al i gn and posi ti on booster on dash panel .
(3) I n passenger compartment, i nstal l booster
mounti ng nuts. Ti ghten nuts just enough to hol d
booster i n pl ace.
(4) Sl i de booster push rod onto the brake pedal .
Then secure push rod to pedal pi n wi th retai ni ng
cl i p.
Fig. 21 Master Cylinder
1 BOOSTER
2 MASTER CYLINDER
Fig. 22 Booster Push Rod
1 BRAKE PEDAL
2 BOOSTER ROD
3 BUSHING
XJ BRAKES 5 - 17
NOTE: Lubricate the pedal pin and bushing with
Mopar multi-mileage grease before installation.
(5) Ti ghten booster mounti ng nuts to 39 Nm (29
ft. l bs.).
(6) I nstal l the knee bl ocker.
(7) I f ori gi nal master cyl i nder i s bei ng i nstal l ed,
check condi ti on of seal at rear of master cyl i nder.
Repl ace seal i f cut, or torn.
(8) Cl ean cyl i nder mounti ng surface of brake
booster. Use shop towel wetted wi th brake cl eaner for
thi s purpose. Di rt, grease, or si mi l ar materi al s wi l l
prevent proper cyl i nder seati ng and coul d resul t i n
vacuum l eak.
(9) Al i gn and i nstal l master cyl i nder on booster
studs. I nstal l mounti ng nuts and ti ghten to 17.5 Nm
(155 i n. l bs.).
(10) Connect vacuum hose to booster check val ve.
(11) Connect and secure brake l i nes to combi nati on
val ve and master cyl i nder. Start al l brake l i ne fi t-
ti ngs by hand to avoi d cross threadi ng.
(12) I nstal l combi nati on val ve on booster studs.
Ti ghten bracket mounti ng nuts to 17.5 Nm (155 i n.
l bs.).
(13) Connect wi re to combi nati on val ve swi tch.
(14) On RHD vehi cl es i nstal l the cool ant reserve/
(15) Fi l l and bl eed base brake system.
(16) Veri fy proper brake operati on before movi ng
vehi cl e.
FRONT DISC BRAKE CALIPER
REMOVAL
(2) Remove front wheel and ti re assembl y.
(3) Drai n smal l amount of fl ui d from master cyl i n-
der brake reservoi r wi th sucti on gun.
(4) Bottom cal i per pi ston i n bore wi th C-cl amp.
Posi ti on cl amp screw on outboard brake shoe and
cl amp frame on rear of cal i per (Fi g. 24). Do not
allow clamp screw to bear directly on outboard
shoe retainer spring. Use wood or metal spacer
between shoe and clamp screw.
(5) Remove brake hose mounti ng bol t and di scard
washers (Fi g. 25).
(6) Remove cal i per mounti ng bol ts (Fi g. 26).
Fig. 23 Booster Mounting
1 BOOSTER
Fig. 24 Bottoming Caliper Piston With C-Clamp
1 CALIPER BOSS
2 OUTBOARD BRAKESHOE
3 C-CLAMP
Fig. 25 Brake Hose And Bolt
1 FITTING WASHERS
2 CALIPERS
5 - 18 BRAKES XJ
(7) Ti l t top of cal i per outward wi th pry tool i f nec-
essary (Fi g. 27) and remove cal i per.
(8) Remove cal i per from vehi cl e.
INSTALLATION
(1) Cl ean brake shoe mounti ng l edges wi th wi re
brush and appl y l i ght coat of Mopar mul ti -mi l eage
grease to surfaces (Fi g. 28).
(2) I nstal l cal i per by posi ti on notches at l ower end
of brake shoes on bottom mounti ng l edge. Then
rotate cal i per over rotor and seat notches at upper
end of shoes on top mounti ng l edge (Fi g. 29).
(3) Coat cal i per mounti ng bol ts wi th si l i cone
grease. Then i nstal l and ti ghten bol ts to 15 Nm (11
ft. l bs.).
CAUTION: If new caliper bolts are being installed,
or if the original reason for repair was a drag/pull
condition, check caliper bolt length before proceed-
ing. Bolts must not have a shank length greater
than 67.6 mm (2.66 in.) (Fig. 30).
(4) I nstal l brake hose to cal i per wi th new seal
washers and ti ghten fi tti ng bol t to 31 Nm (23 ft.
l bs.).
Fig. 26 Caliper Mounting Bolts
1 CALIPER MOUNTING BOLT (2)
2 CALIPER
Fig. 27 Caliper Removal
1 TILT CALIPER OUTBOARD TO REMOVE
Fig. 28 Caliper Lubrication Points
1 BUSHINGS
2 CALIPER MOUNTING BOLTS
3 MOUNTING LEDGES
Fig. 29 Caliper Installation
1 TOP LEDGE
2 BRAKESHOE TAB ON LEDGE OUTER SURFACE
3 LEDGE SEATED IN BRAKESHOE NOTCH
4 BOTTOM LEDGE
XJ BRAKES 5 - 19
CAUTION: Verify brake hose is not twisted or
kinked before tightening fitting bolt.
(5) Bl eed base brake system.
(7) Remove supports and l ower vehi cl e.
(8) Veri fy fi rm pedal before movi ng vehi cl e.
FRONT DISC BRAKE SHOES
REMOVAL
(3) Remove cal i per.
(4) Pressi ng one end of outboard shoe i nward to
di sengage shoe l ug. Then rotate shoe upward unti l
retai ner spri ng cl ears cal i per. Press opposi te end of
shoe i nward to di sengage shoe l ug and rotate shoe up
and out of cal i per (Fi g. 31).
(5) Grasp ends of i nboard shoe and ti l t shoe out-
ward to rel ease spri ngs from cal i per pi ston (Fi g. 32)
and remove shoe from cal i per.
NOTE: If original brake shoes will be used, keep
them in sets left and right. They are not inter-
changeable.
(6) Secure cal i per to nearby suspensi on part wi th
wi re. Do not allow brake hose to support caliper
weight.
(7) Wi pe cal i per off wi th shop rags or towel s.
CAUTION: Do not use compressed air, this can
unseat dust boot and force dirt into piston bore.
INSTALLATION
(1) I nstal l i nboard shoe i n cal i per and veri fy shoe
retai ni ng i s ful l y seated i nto the pi ston.
(2) Starti ng one end of outboard shoe i n cal i per
and rotati ng shoe downward i nto pl ace. Veri fy shoe
l ocati ng l ugs and shoe spri ng are seated.
(3) I nstal l cal i per.
(4) I nstal l wheel and ti re assembl y.
(5) Remove support and l ower vehi cl e.
(6) Pump brake pedal unti l cal i per pi stons and
brake shoes are seated.
(7) Top off brake fl ui d l evel i f necessary.
Fig. 30 Mounting Bolt Dimensions
1 67 mm ( 0.6 mm) 2.637 in. ( 0.0236 in.)
2 22 mm (0.866 in.) THREAD LENGTH
3 CALIPER BOLT
Fig. 31 Outboard Brake Shoe Removal
1 OUTBOARD BRAKESHOE
2 SHOE SPRING
3 LOCATING LUG
4 CALIPER
5 LOCATING LUG
Fig. 32 Inboard Brake Shoe Removal
1 CALIPER PISTON
2 SHOE SPRINGS
3 INBOARD BRAKESHOE
5 - 20 BRAKES XJ
DISC BRAKE ROTOR
REMOVAL
(1) Remove wheel and ti re assembl e.
(2) Remove cal i per.
(3) Remove retai ners securi ng rotor to hub studs
(Fi g. 33).
(4) Remove rotor from hub.
(5) I f rotor shi el d requi res servi ce, remove front
hub and beari ng assembl y.
INSTALLATION
(1) I f new rotor i s bei ng i nstal l ed, remove protec-
ti ve coati ng from rotor surfaces wi th carburetor
cl eaner.
(2) I nstal l rotor on hub.
(3) I nstal l cal i per.
DRUM BRAKE SHOES
REMOVAL
(1) Rai se vehi cl e and remove rear wheel s.
(2) Remove and di scard spri ng nuts securi ng
drums to wheel studs.
(3) Remove brake drums. I f drums prove di ffi cul t
to remove, retract brake shoes. Remove access pl ug
at the rear of backi ng pl ate and back off adjuster
screw wi th brake tool and screwdri ver.
(4) Remove U-cl i p and washer securi ng adjuster
cabl e to parki ng brake l ever (Fi g. 34).
(5) Remove pri mary and secondary return spri ngs
from anchor pi n wi th brake spri ng pl i ers.
(6) Remove hol d-down spri ngs, retai ners and pi ns
wi th standard retai ni ng spri ng tool .
(7) I nstal l spri ng cl amps on wheel cyl i nders to
hol d pi stons i n pl ace.
(8) Remove adjuster l ever, adjuster screw and
spri ng.
(9) Remove adjuster cabl e and cabl e gui de.
(10) Remove brake shoes and parki ng brake strut.
(11) Di sconnect cabl e from parki ng brake l ever and
remove l ever.
INSTALLATION
(1) Cl ean support pl ate wi th brake cl eaner.
(2) I f new drums are bei ng i nstal l ed, remove pro-
tecti ve coati ng wi th carburetor cl eaner fol l owed by
fi nal ri nse wi th brake cl eaner.
(3) Cl ean and l ubri cate anchor pi n wi th l i ght coat
of Mopar mul ti -mi l eage grease.
(4) Appl y Mopar mul ti -mi l eage grease to brake
shoe contact surfaces of support pl ate (Fi g. 35).
(5) Lubri cate adjuster screw threads and pi vot
wi th spray l ube.
(6) Attach parki ng brake l ever to secondary brake
shoe. Use new washer and U-cl i p to secure l ever.
(7) Remove wheel cyl i nder cl amps.
(8) Attach parki ng brake cabl e to l ever.
(9) I nstal l brake shoes on support pl ate. Secure
shoes wi th new hol d-down spri ngs, pi ns and retai n-
ers.
(10) I nstal l parki ng brake strut and spri ng.
(11) I nstal l gui de pl ate and adjuster cabl e on
anchor pi n.
(12) I nstal l pri mary and secondary return spri ngs.
(13) I nstal l adjuster cabl e gui de on secondary
shoe.
(14) Lubri cate and assembl e adjuster screw.
(15) I nstal l adjuster screw, spri ng and l ever and
connect to adjuster cabl e.
(16) Adjust shoes to drum.
(17) I nstal l wheel /ti re assembl i es and l ower vehi -
cl e.
(18) Veri fy fi rm brake pedal before movi ng vehi cl e.
WHEEL CYLINDER
REMOVAL
(2) Remove brake drum.
(3) Di sconnect wheel cyl i nder brake l i ne.
(4) Remove brake shoe return spri ngs and move
shoes out of engagement wi th cyl i nder push rods.
(5) Remove cyl i nder attachi ng bol ts and remove
cyl i nder from support pl ate.
Fig. 33 Rotor & Hub
1 ROTOR
2 RETAINER
3 BEARING NUT
4 NUT LOCK
5 COTTER PIN
6 WASHER
XJ BRAKES 5 - 21
INSTALLATION
(1) Appl y bead of si l i cone seal er around cyl i nder
mounti ng surface of support pl ate.
(2) I nstal l cyl i nder mounti ng bol ts and ti ghten to
20 Nm (15 ft. l bs.).
(3) Connect brake l i ne to cyl i nder.
(4) I nstal l brake shoe return spri ng.
(5) I nstal l brake drum.
(7) Bl eed base brake system.
BRAKE SUPPORT PLATE
REMOVAL
(1) Remove wheel and ti re assembl y and brake
drum.
(2) Remove brake shoe assembl y.
(3) Remove parki ng brake cabl e from parki ng
brake l ever.
(4) Compress parki ng brake cabl e retai ner tabs.
Then push retai ner and cabl e through and out of
support pl ate.
Fig. 34 Drum Brake ComponentsTypical
1 ADJUSTER LEVER
2 ADJUSTER CABLE
4 ADJUSTER LEVER SPRING
5 TRAILING SHOE
6 CYLINDER-TO-SUPPORT SEAL
7 HOLDDOWN PINS
8 ACCESS PLUGS
9 SUPPORT PLATE
10 CABLE HOLE PLUG
11 PARK BRAKE STRUT AND SPRING
12 ADJUSTER SCREW ASSEMBLY
14 LEADING SHOE
15 CABLE GUIDE
16 SHOE RETURN SPRINGS
17 SHOE GUIDE PLATE
18 PIN
19 SHOE SPRING
20 PARK BRAKE LEVER
Fig. 35 Shoe Contact Surfaces
1 ANCHOR PIN
2 SUPPORT PLATE
3 SHOE CONTACT SURFACES
5 - 22 BRAKES XJ
(5) Di sconnect brake l i ne at wheel cyl i nder.
(6) Remove wheel cyl i nder from support pl ate.
(7) Remove axl e shaft, refer to Group 3 for proce-
dures.
(8) Remove bol ts attachi ng support pl ate to axl e
and remove support pl ate.
INSTALLATION
(1) Appl y bead of si l i cone seal er around axl e
mounti ng surface of support pl ate.
(2) I nstal l support pl ate on axl e fl ange. Ti ghten
attachi ng bol ts to 115 Nm (85 ft. l bs.).
(3) Appl y bead of si l i cone seal er around wheel cyl -
i nder mounti ng surface and i nstal l wheel cyl i nder.
(4) I nstal l brake l i ne i n wheel cyl i nder.
(5) I nstal l parki ng brake cabl e i n support pl ate.
(6) I nstal l axl e shaft, refer to Group 3 for proce-
dure.
(7) Connect parki ng brake cabl e to l ever on sec-
ondary shoe and i nstal l brake shoes on support pl ate.
(8) Adjust brake shoes to drum wi th brake gauge.
(9) I nstal l brake drum and wheel and ti re assem-
bl y.
(10) Bl eed brake system.
REAR PARKING BRAKE CABLES
REMOVAL
(1) Rai se vehi cl e and l oosen equal i zer nuts unti l
rear cabl es are sl ack.
(2) Di sengage cabl es from equal i zer and compress
cabl e retai ners wi th a worm dri ve hose cl amp.
(3) Remove cabl es from the cabl e bracket (Fi g. 36).
(4) Remove rear wheel and brake drums.
(5) Remove secondary brake shoe and di sconnect
cabl e from l ever on brake shoe.
(6) Compress cabl es retai ner wi th worm dri ve hose
cl amp (Fi g. 37) and remove cabl es from backi ng
pl ates.
INSTALLATION
(1) I nstal l new cabl es i n backi ng pl ates. Be sure
cabl e retai ner i s seated.
(2) Attach cabl e to l ever on brake shoe and i nstal l
brake shoe on backi ng pl ate.
(3) Adjust brake shoes to drum wi th brake gauge.
(4) I nstal l brake drums and wheel s.
(5) I nstal l cabl es i nto the cabl e bracket and i nsure
retai ners are seated i n the bracket.
(6) Engage the cabl e ends i nto the equal i zer and
i nstal l equal i zer nut.
(7) Adjust parki ng brakes. PARKING BRAKE LEVER
The center consol e must be removed to servi ce the
parki ng brake l ever. Refer to Group 23 I nteri or Com-
ponents for servi ce procedures.
Fig. 36 Parking Brake Cables
1 REAR CABLES
2 EQUALIZER
3 FRONT CABLE
4 TENSIONER ROD
Fig. 37 Cable Retainer
1 CABLE RETAINER
2 REAR CABLE
3 WORM DRIVE HOSE CLAMP
XJ BRAKES 5 - 23
REMOVAL
(1) Rel ease parki ng brakes.
(2) Rai se vehi cl e.
(3) Remove adjusti ng nut from tensi oner rod at the
equal i zer (Fi g. 38).
(5) Di sengage front cabl e from the cabl e l ever.
(6) Compress cabl e retai ner wi th worm dri ve hose
cl amp and remove the cabl e from the parki ng brake
l ever base.
(7) Di sconnect parki ng brake l amp swi tch wi re
(Fi g. 39).
(8) Remove parki ng brake l ever assembl y mount-
i ng bol ts (Fi g. 39).
(9) Remove l ever assembl y.
(10) Remove parki ng brake l amp swi tch.
INSTALLATION
(1) I nstal l parki ng brake l amp swi tch.
(2) Posi ti on l ever assembl y on fl oorpan and i nstal l
l ever mounti ng bol ts.
(3) Ti ghten l ever mounti ng bol ts to 10 to 14 Nm
(7 to 10 ft. l bs.).
(4) I nsert front cabl e through the parki ng brake
l ever base. I nsure the cabl e retai ner i s seated i nto
the base.
(5) Attach the front cabl e to the cabl e l ever (Fi g.
39).
(6) Connect parki ng brake l amp swi tch wi re.
(8) I nstal l adjusti ng nut to the tensi oner rod and
adjust parki ng brakes.
(10) Veri fy correct parki ng brake operati on.
MASTER CYLINDER RESERVOIR
REMOVAL
(1) Remove reservoi r cap and empty fl ui d i nto
drai n contai ner.
(2) Remove pi ns that retai n reservoi r to master
cyl i nder. Use hammer and pi n punch to remove pi ns
(Fi g. 40).
Fig. 38 Parking Brake Equalizer
1 REAR CABLES
2 EQUALIZER
3 FRONT CABLE
4 TENSIONER ROD
Fig. 39 Parking Brake Lever Assembly
1 MOUNTING BOLTS
2 FRONT CABLE LEVER
3 PARKING BRAKE SWITCH
4 PARKING BRAKE LEVER
Fig. 40 Reservoir Retaining Pins
1 PIN PUNCH
2 RESERVOIR
3 BODY
4 ROLL PINS
5 - 24 BRAKES XJ
(3) Cl amp cyl i nder body i n vi se wi th brass protec-
ti ve jaws.
(4) Loosen reservoi r from grommets wi th pry tool
(Fi g. 41).
(5) Remove reservoi r by rocki ng i t to one si de and
pul l i ng free of grommets (Fi g. 42).
(6) Remove ol d grommets from cyl i nder body (Fi g.
43).
INSTALLATION
CAUTION: Do not use any type of tool to install the
grommets. Tools may cut, or tear the grommets cre-
ating a leak problem after installation. Install the
grommets using finger pressure only.
(1) Lubri cate new grommets wi th cl ean brake fl ui d
and I nstal l new grommets i n cyl i nder body (Fi g. 44).
Use fi nger pressure to i nstal l and seat grommets.
(2) Start reservoi r i n grommets. Then rock reser-
voi r back and forth whi l e pressi ng downward to seat
i t i n grommets.
(3) I nstal l pi ns that retai n reservoi r to cyl i nder
body.
(4) Fi l l and bl eed master cyl i nder on bench before
i nstal l ati on i n vehi cl e.
DISC BRAKE CALIPER
DISASSEMBLY
(1) Remove brake shoes from cal i per.
(2) Drai n brake fl ui d out of cal i per.
(3) Take a pi ece of wood and pad i t wi th one-i nch
thi ckness of shop towel s. Pl ace thi s pi ece i n the out-
board shoe si de of the cal i per i n front of the pi ston.
Fig. 41 Loosening Reservoir
1 PRY TOOL
2 RESERVOIR
3 GROMMET
4 MASTER CYLINDER BODY
Fig. 42 Reservoir Removal
1 RESERVOIR
2 GROMMETS
Fig. 43 Grommet Removal
1 MASTER CYLINDER BODY
2 GROMMETS
Fig. 44 Grommet Installation
1 WORK NEW GROMMETS INTO PLACE USING FINGER
PRESSURE ONLY
XJ BRAKES 5 - 25
Thi s wi l l cushi on and protect cal i per pi ston duri ng
removal (Fi g. 45).
(4) Remove cal i per pi ston wi th short bursts of
l ow pressure compressed ai r. Di rect ai r through fl ui d
i nl et port and ease pi ston out of bore (Fi g. 46).
CAUTION: Do not blow the piston out of the bore
with sustained air pressure. This could result in a
cracked piston. Use only enough air pressure to
ease the piston out.
WARNING: NEVER ATTEMPT TO CATCH THE PIS-
TON AS IT LEAVES THE BORE. THIS MAY RESULT
IN PERSONAL INJURY.
(5) Remove cal i per pi ston dust boot wi th sui tabl e
pry tool (Fi g. 47).
(6) Remove cal i per pi ston seal wi th wood or pl asti c
tool (Fi g. 48). Do not use metal tool s as they wi l l
scratch pi ston bore.
(7) Remove cal i per mounti ng bol t bushi ngs and
boots (Fi g. 49).
ASSEMBLY
CAUTION: Dirt, oil, and solvents can damage cali-
per seals. Insure assembly area is clean and dry.
(1) Lubri cate cal i per pi ston bore, new pi ston seal
and pi ston wi th cl ean brake fl ui d.
(2) Lubri cate cal i per bushi ngs and i nteri or of
bushi ng boots wi th si l i cone grease.
(3) I nstal l bushi ng boots i n cal i per, then i nsert
bushi ng i nto boot and push bushi ng i nto pl ace (Fi g.
50).
(4) I nstal l new pi ston seal i nto seal groove wi th
fi nger (Fi g. 51).
(5) I nstal l new dust boot on cal i per pi ston and seat
boot i n pi ston groove (Fi g. 52).
(6) Press pi ston i nto cal i per bore by hand, use a
turn and push moti on to work pi ston i nto seal (Fi g.
53).
(7) Press cal i per pi ston to bottom of bore.
Fig. 45 Padding Caliper Interior
1 SHOP TOWELS OR CLOTHS
2 CALIPER
Fig. 46 Caliper Piston Removal
1 AIR GUN
2 CALIPER PISTON
3 PADDING MATERIAL
Fig. 47 Caliper Piston Dust Boot Removal
1 COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER
2 PISTON DUST BOOT
5 - 26 BRAKES XJ
Fig. 48 Piston Seal Removal
1 REMOVE SEAL WITH WOOD PENCIL OR SIMILAR TOOL
2 PISTON SEAL
Fig. 49 Mounting Bolt Bushing And Boot
1 CALIPER SLIDE BUSHING
2 BOOT
Fig. 50 Bushings And Boots Installation
1 BUSHING
2 BOOT
Fig. 51 Piston Seal Installation
1 SEAL GROOVE
2 PISTON SEAL
Fig. 52 Dust Boot On Piston
1 PISTON
2 DUST BOOT
Fig. 53 Caliper Piston Installation
1 PISTON
2 BOOT
XJ BRAKES 5 - 27
(8) Seat dust boot i n cal i per wi th I nstal l er Tool
C-4842 and Tool Handl e C-4171 (Fi g. 54).
(9) Repl ace cal i per bl eed screw i f removed.
WHEEL CYLINDER
DISASSEMBLY
(1) Remove push rods and boots (Fi g. 55).
(2) Press pi stons, cups and spri ng and expander
out of cyl i nder bore.
(3) Remove bl eed screw.
ASSEMBLY
(1) Lubri cate wheel cyl i nder bore, pi stons, pi ston
cups and spri ng and expander wi th cl ean brake fl ui d.
(2) I nstal l fi rst pi ston i n cyl i nder bore. Then
i nstal l fi rst cup i n bore and agai nst pi ston. Be sure
lip of piston cup is facing inward (toward
spring and expander) and flat side is against
piston.
(3) I nstal l spri ng and expander fol l owed by
remai ni ng pi ston cup and pi ston.
(4) I nstal l boots on each end of cyl i nder and i nsert
push rods i n boots.
(5) I nstal l cyl i nder bl eed screw.
CALIPER
CLEANING
Cl ean the cal i per components wi th cl ean brake
fl ui d or brake cl ean onl y. Wi pe the cal i per and pi ston
dry wi th l i nt free towel s or use l ow pressure com-
pressed ai r.
CAUTION: Do not use gasoline, kerosene, thinner,
or similar solvents. These products may leave a
residue that could damage the piston and seal.
INSPECTION
The pi ston i s made from a phenol i c resi n (pl asti c
materi al ) and shoul d be smooth and cl ean.
The pi ston must be repl aced i f cracked or scored.
Do not attempt to restore a scored pi ston surface by
sandi ng or pol i shi ng.
CAUTION: If the caliper piston is replaced, install
the same type of piston in the caliper. Never inter-
change phenolic resin and steel caliper pistons.
The pistons, seals, seal grooves, caliper bore and
piston tolerances are different.
The bore can be lightly pol i shed wi th a brake
hone to remove very mi nor surface i mperfecti ons
(Fi g. 56). The cal i per shoul d be repl aced i f the bore i s
severel y corroded, rusted, scored, or i f pol i shi ng
woul d i ncrease bore di ameter more than 0.025 mm
(0.001 i nch).
Fig. 54 Piston Dust Boot Installation
1 HANDLE C-4171
2 INSTALLER C-4842
3 DUST BOOT
Fig. 55 Wheel Cylinder ComponentsTypical
1 SPRING
2 CYLINDER
3 PISTON CLIP
4 BOOT
5 PUSH ROD
6 PISTON
7 BLEED SCREW
8 CUP EXPANDERS
5 - 28 BRAKES XJ
REAR DRUM BRAKE
CLEANING
Cl ean the i ndi vi dual brake components, i ncl udi ng
the support pl ate and wheel cyl i nder exteri or, wi th a
water dampened cl oth or wi th brake cl eaner. Do not
use any other cl eani ng agents. Remove l i ght rust and
scal e from the brake shoe contact pads on the sup-
port pl ate wi th fi ne sandpaper.
INSPECTION
As a general rul e, ri veted brake shoes shoul d be
repl aced when worn to wi thi n 0.78 mm (1/32 i n.) of
the ri vet heads. Bonded l i ni ng shoul d be repl aced
when worn to a thi ckness of 1.6 mm (1/16 i n.).
Exami ne the l i ni ng contact pattern to determi ne i f
the shoes are bent or the drum i s tapered. The l i ni ng
shoul d exhi bi t contact across i ts enti re wi dth. Shoes
exhi bi ti ng contact onl y on one si de shoul d be
repl aced and the drum checked for runout or taper.
I nspect the adjuster screw assembl y. Repl ace the
assembl y i f the star wheel or threads are damaged,
or the components are severel y rusted or corroded.
Di scard the brake spri ngs and retai ner components
i f worn, di storted or col l apsed. Al so repl ace the
spri ngs i f a brake drag condi ti on had occurred. Over-
heati ng wi l l di stort and weaken the spri ngs.
I nspect the brake shoe contact pads on the support
pl ate, repl ace the support pl ate i f any of the pads are
worn or rusted through. Al so repl ace the pl ate i f i t i s
bent or di storted (Fi g. 57).
WHEEL CYLINDER
CLEANING
Cl ean the cyl i nder and pi stons wi th cl ean brake
fl ui d or brake cl eaner onl y. Do not use any other
cl eani ng agents.
Dry the cyl i nder and pi stons wi th compressed ai r.
Do not use rags or shop towel s to dry the cyl i nder
components. Li nt from cl oth materi al wi l l adhere to
the cyl i nder bores and pi stons.
INSPECTION
I nspect the cyl i nder bore. Li ght di scol orati on and
dark stai ns i n the bore are normal and wi l l not
i mpai r cyl i nder operati on.
The cyl i nder bore can be l i ghtl y pol i shed but onl y
wi th crocus cl oth. Repl ace the cyl i nder i f the bore i s
scored, pi tted or heavi l y corroded. Honi ng the bore to
restore the surface i s not recommended.
I nspect the cyl i nder pi stons. The pi ston surfaces
shoul d be smooth and free of scratches, scori ng and
corrosi on. Repl ace the pi stons i f worn, scored, or cor-
roded. Do attempt to restore the surface by sandi ng
or pol i shi ng.
Di scard the ol d pi ston cups and the spri ng and
expander. These parts are not reusabl e. The ori gi nal
dust boots may be reused but onl y i f they are i n good
condi ti on.
Fig. 56 Polishing Piston Bore
1 SPECIAL HONE
2 CALIPER
3 PISTON BORE
Fig. 57 Shoe Contact Surfaces
1 ANCHOR PIN
2 SUPPORT PLATE
3 SHOE CONTACT SURFACES
XJ BRAKES 5 - 29
ADJ USTMENTS
BRAKE LAMP SWITCH
(1) Press and hol d brake pedal i n appl i ed posi ti on.
(2) Pul l swi tch pl unger al l the way out to ful l y
extended posi ti on.
(3) Rel ease brake pedal . Then pul l pedal l i ghtl y
rearward. Pedal wi l l set pl unger to correct posi ti on
as pedal pushes pl unger i nto swi tch body. Swi tch wi l l
make ratcheti ng sound as i t sel f adjusts.
CAUTION: Booster damage may occur if the pedal
pull exceeds 20 lbs..
REAR DRUM BRAKE
The rear drum brakes are equi pped wi th a sel f-ad-
justi ng mechani sm. Under normal ci rcumstances, the
onl y ti me adjustment i s requi red i s when the shoes
are repl aced, removed for access to other parts, or
when one or both drums are repl aced.
Adjustment can be made wi th a standard brake
gauge or wi th adjusti ng tool . Adjustment i s per-
formed wi th the compl ete brake assembl y i nstal l ed
on the backi ng pl ate.
ADJUSTMENT WITH BRAKE GAUGE
(1) Be sure parki ng brakes are ful l y rel eased.
(2) Rai se rear of vehi cl e and remove wheel s and
brake drums.
(3) Veri fy that l eft and ri ght automati c adjuster
l evers and cabl es are properl y connected.
(4) I nsert brake gauge i n drum. Expand gauge
unti l gauge i nner l egs contact drum braki ng surface.
Then l ock gauge i n posi ti on (Fi g. 58).
(5) Reverse gauge and i nstal l i t on brake shoes.
Posi ti on gauge l egs at shoe centers as shown (Fi g.
59). I f gauge does not fi t (too l oose/too ti ght), adjust
shoes.
(6) Pul l shoe adjuster l ever away from adjuster
screw star wheel .
(7) Turn adjuster screw star wheel (by hand) to
expand or retract brake shoes. Conti nue adjustment
unti l gauge outsi de l egs are l i ght drag-fi t on shoes.
(8) I nstal l brake drums and wheel s and l ower
vehi cl e.
(9) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
ADJUSTMENT WITH ADJUSTING TOOL
(1) Be sure parki ng brake l ever i s ful l y rel eased.
(2) Rai se vehi cl e so rear wheel s can be rotated
freel y.
(3) Remove pl ug from each access hol e i n brake
support pl ates.
(4) Loosen parki ng brake cabl e adjustment nut
unti l there i s sl ack i n front cabl e.
(5) I nsert adjusti ng tool through support pl ate
access hol e and engage tool i n teeth of adjusti ng
screw star wheel (Fi g. 60).
(6) Rotate adjuster screw star wheel (move tool
handl e upward) unti l sl i ght drag can be fel t when
wheel i s rotated.
Fig. 58 Adjusting Gauge On Drum
1 BRAKE GAUGE
2 BRAKE DRUM
Fig. 59 Adjusting Gauge On Brake Shoes
1 BRAKE GAUGE
2 BRAKE SHOES
5 - 30 BRAKES XJ
(7) Push and hol d adjuster l ever away from star
wheel wi th thi n screwdri ver.
(8) Back off adjuster screw star wheel unti l brake
drag i s el i mi nated.
(9) Repeat adjustment at opposi te wheel . Be sure
adjustment i s equal at both wheel s.
(10) I nstal l support pl ate access hol e pl ugs.
(11) Adjust parki ng brake cabl e and l ower vehi cl e.
(12) Dri ve vehi cl e and make one forward stop fol -
l owed by one reverse stop. Repeat procedure 8-10
ti mes to operate automati c adjusters and equal i ze
adjustment.
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate
automatic adjusters.
PARKING BRAKE CABLE TENSIONER
NOTE: Parking brake adjustment is only necessary
when the tensioner, or a cable has been replaced or
disconnected.
ADJUSTMENT
(2) Back off tensi oner adjusti ng nut to create sl ack
i n cabl es.
(3) Remove rear wheel /ti re assembl i es and remove
brake drums.
(4) Check rear brake shoe adjustment wi th stan-
dard brake gauge.
CAUTION: Excessive shoe-to-drum clearance, or
worn brake components will result in faulty parking
brake adjustment and operation.
(5) Veri fy that parki ng brake cabl es operate freel y
and are not bi ndi ng, or sei zed. Repl ace faul ty cabl es,
before proceedi ng.
(6) Rei nstal l brake drums and wheel /ti re assem-
bl i es after brake shoe adjustment i s compl ete.
(7) Lower vehi cl e enough for access to parki ng
brake l ever. Then fully appl y parki ng brakes. Leave
brakes appl i ed unti l adjustment i s compl ete.
(8) Rai se vehi cl e and mark tensi oner rod 6.5 mm
(1/4 i n.) from tensi oner bracket (Fi g. 61).
(9) Ti ghten adjusti ng nut at equal i zer unti l mark
on tensi oner rod moves i nto al i gnment wi th tensi oner
bracket.
(10) Lower vehi cl e unti l rear wheel s are 15-20 cm
(6-8 i n.) off shop fl oor.
(11) Rel ease parki ng brake l ever and veri fy that
rear wheel s rotate freel y wi thout drag.
NOTE: Do not loosen/tighten equalizer adjusting
nut for any reason after completing adjustment.
SPECIFICATIONS
BRAKE FLUID
The brake fl ui d used i n thi s vehi cl e must conform
to DOT 3 speci fi cati ons and SAE J1703 standards.
No other type of brake fl ui d i s recommended or
approved for usage i n the vehi cl e brake system. Use
Fig. 60 Brake Adjustment
1 STAR WHEEL
2 LEVER
3 BRAKE SHOE WEB
4 SCREWDRIVER
5 ADJUSTING TOOL
6 ADJUSTER SPRING
Fig. 61 Tensioner Rod Measurement
1 TENSIONER BRACKET
2 6.5 mm (1/4 in.)
3 TENSIONER ROD
4 ROD TO EQUALIZER
XJ BRAKES 5 - 31
onl y Mopar brake fl ui d or an equi val ent from a
ti ghtl y seal ed contai ner.
CAUTION: Never use reclaimed brake fluid or fluid
from an container which has been left open. An
open container will absorb moisture from the air
and contaminate the fluid.
CAUTION: Never use any type of a petroleum-
based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the
vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids
would be items such as engine oil, transmission
fluid, power steering fluid, etc.
BRAKE COMPONENTS
Disc Brake Caliper
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sl i di ng
Disc Brake Rotor
Type . . . . . . . . . . . . . . . . . . . . . . . . . . Venti l ated
Max. Runout . . . . . . . . . . . . . 0.12 mm (0.005 i n.)
Max. Thi ckness Vari ati on . . 0.013 mm (0.0005 i n.)
Mi n. Thi ckness . . . . . . . . . . 22.7 mm (0.8937 i n.)
Brake Drum
Si ze . . . . . . . . . . . . . . . . . . . . . . . . 9 i n. or 10 i n.
Brake Booster
Type . . . . . . . . . . . . . . . . . . . . . Dual Di aphragm
TORQUE CHART
DESCRIPTION TORQUE
Brake Pedal
Pi vot Bol t/Nut . . . . . . . . . . . . 35 Nm (26 ft. l bs.)
Brake Booster
Mounti ng Nuts . . . . . . . . . . . 39 Nm (29 ft. l bs.)
Master Cylinder
Mounti ng Nuts . . . . . . . . . 17.5 Nm (155 i n. l bs.)
Brake Li nes . . . . . . . . . . . . . 14 Nm (124 i n. l bs.)
Combination Valve
Caliper
Mounti ng Bol ts . . . . . . . . . . . 15 Nm (11 ft. l bs.)
Brake Hose Bol t . . . . . . . . . . . 31 Nm (23 ft. l bs.)
Wheel Cylinder
Mounti ng Bol ts . . . . . . . . . . . . 10 Nm (7 ft. l bs.)
Brake Li ne . . . . . . . . . . . . . 14 Nm (124 i n. l bs.)
Parking Brake
Lever Screws . . . . . . . . . 10-14 Nm (7-10 ft. l bs.)
Lever Bracket Screws . . 10-14 Nm (7-10 ft. l bs.)
Cabl e Retai ner Nut . . . . . . . 1.5 Nm (14 i n. l bs.)
SPECIAL TOOLS
BASE BRAKES
Installer Caliper Dust Boot 8280
Handle C-4171
Adapter Pressure Bleeder 6921
5 - 32 BRAKES XJ
ANTILOCK BRAKES
TABLE OF CONTENTS
page page
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . . . 33
CONTROLLER ANTILOCK BRAKES. . . . . . . . . . . 33
HYDRAULIC CONTROL UNIT. . . . . . . . . . . . . . . . 34
WHEEL SPEED SENSORS AND TONE WHEEL . . 34
G-SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . . . . 35
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . . . . . 36
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . . . 36
HYDRAULIC CONTROL UNIT/CONTROLLER
ANTILOCK BRAKES . . . . . . . . . . . . . . . . . . . . . 36
FRONT WHEEL SPEED SENSOR . . . . . . . . . . . . 37
REAR WHEEL SPEED SENSOR . . . . . . . . . . . . . 37
G-SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ANTILOCK BRAKE . . . . . . . . . . . . . . . . . . . . . . 39
SPECIFICATIONS
T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 40
ANTILOCK BRAKE SYSTEM
DESCRIPTION
The purpose of the anti l ock system i s to prevent
wheel l ockup duri ng peri ods of hi gh wheel sl i p. Pre-
venti ng l ockup hel ps mai ntai n vehi cl e braki ng acti on
and steeri ng control .
The anti l ock CAB acti vates the system whenever
sensor si gnal s i ndi cate peri ods of hi gh wheel sl i p.
Hi gh wheel sl i p can be descri bed as the poi nt where
wheel rotati on begi ns approachi ng 20 to 30 percent of
actual vehi cl e speed duri ng braki ng. Peri ods of hi gh
wheel sl i p occur when brake stops i nvol ve hi gh pedal
pressure and rate of vehi cl e decel erati on.
Battery vol tage i s suppl i ed to the CAB i gni ti on ter-
mi nal when the i gni ti on swi tch i s turned to Run posi -
ti on. The CAB performs a system i ni ti al i zati on
procedure at thi s poi nt. I ni ti al i zati on consi sts of a
stati c and dynami c sel f check of system el ectri cal
components.
The stati c check occurs after the i gni ti on swi tch i s
turned to Run posi ti on. The dynami c check occurs
when vehi cl e road speed reaches approxi matel y 30
kph (18 mph). Duri ng the dynami c check, the CAB
bri efl y cycl es the pump and sol enoi ds to veri fy oper-
ati on.
I f an ABS component exhi bi ts a faul t duri ng i ni -
ti al i zati on, the CAB i l l umi nates the amber warni ng
l i ght and regi sters a faul t code i n the mi croprocessor
memory.
OPERATION
Duri ng normal braki ng, the master cyl i nder, power
booster and wheel brake uni ts al l functi on as they
woul d i n a vehi cl e wi thout ABS. The HCU compo-
nents are not acti vated.
Duri ng anti l ock braki ng fl ui d pressure i s modu-
l ated accordi ng to wheel speed, degree of sl i p and
rate of decel erati on. A sensor at each wheel converts
wheel speed i nto el ectri cal si gnal s. These si gnal s are
transmi tted to the CAB for processi ng and determi -
nati on of wheel sl i p and decel erati on rate.
The ABS system has three fl ui d pressure control
channel s. The front brakes are control l ed separatel y
and the rear brakes i n tandem. A speed sensor i nput
si gnal i ndi cati ng a hi gh sl i p condi ti on acti vates the
CAB anti l ock program. Two sol enoi d val ves are used
i n each anti l ock control channel . The val ves are al l
l ocated wi thi n the HCU val ve body and work i n pai rs
to ei ther i ncrease, hol d, or decrease appl y pressure as
needed i n the i ndi vi dual control channel s. The sol e-
noi d val ves are not stati c duri ng anti l ock braki ng.
They are cycl ed conti nuousl y to modul ate pressure.
Sol enoi d cycl e ti me i n anti l ock mode can be mea-
sured i n mi l l i seconds.
CONTROLLER ANTILOCK BRAKES
DESCRIPTION
The CAB i s mounted to the HCU and operates the
ABS system (Fi g. 1) separate from other vehi cl e el ec-
tri cal ci rcui ts.
OPERATION
The CAB vol tage source i s through the i gni ti on
swi tch i n the RUN posi ti on. The CAB contai ns dual
XJ BRAKES 5 - 33
mi croprocessors. A l ogi c bl ock i n each mi croprocessor
recei ves i denti cal sensor si gnal s. These si gnal s are
processed and compared si mul taneousl y. The CAB
contai ns a sel f check program that i l l umi nates the
ABS warni ng l i ght when a system faul t i s detected.
Faul ts are stored i n a di agnosti c program memory
and are accessi bl e wi th the DRB scan tool . ABS
faul ts remai n i n memory unti l cl eared, or unti l after
the vehi cl e i s started approxi matel y 50 ti mes. Stored
faul ts are not erased i f the battery i s di sconnected.
HYDRAULIC CONTROL UNIT
DESCRIPTION
The HCU consi sts of a val ve body, pump motor,
and wi re harness (Fi g. 1).
OPERATION
Accumul ators i n the val ve body store extra fl ui d
rel eased to the system for ABS mode operati on. The
pump provi des the fl ui d vol ume needed and i s oper-
ated by a DC type motor. The motor i s control l ed by
the CAB.
The val ves modul ate brake pressure duri ng
anti l ock braki ng and are control l ed by the CAB.
The HCU provi des three channel pressure control
to the front and rear brakes. One channel control s
the rear wheel brakes i n tandem. The two remai ni ng
channel s control the front wheel brakes i ndi vi dual l y.
Duri ng anti l ock braki ng, the sol enoi d val ves are
opened and cl osed as needed. The val ves are not
stati c. They are cycl ed rapi dl y and conti nuousl y to
modul ate pressure and control wheel sl i p and decel -
erati on.
Duri ng normal braki ng, the HCU sol enoi d val ves
and pump are not acti vated. The master cyl i nder and
power booster operate the same as a vehi cl e wi thout
an ABS brake system.
Duri ng anti l ock braki ng, sol enoi d val ve pressure
modul ati on occurs i n three stages, pressure i ncrease,
pressure hol d, and pressure decrease. The val ves are
al l contai ned i n the val ve body porti on of the HCU.
PRESSURE DECREASE
The outl et val ve i s opened and the i nl et val ve i s
cl osed duri ng the pressure decrease cycl e.
A pressure decrease cycl e i s i ni ti ated when speed
sensor si gnal s i ndi cate hi gh wheel sl i p at one or
more wheel s. At thi s poi nt, the CAB cl oses the i nl et
then opens the outl et val ve, whi ch al so opens the
return ci rcui t to the accumul ators. Fl ui d pressure i s
al l owed to bl eed off (decrease) as needed to prevent
wheel l ock.
Once the peri od of hi gh wheel sl i p has ended, the
CAB cl oses the outl et val ve and begi ns a pressure
i ncrease or hol d cycl e as needed.
PRESSURE HOLD
Both sol enoi d val ves are cl osed i n the pressure
hol d cycl e. Fl ui d appl y pressure i n the control chan-
nel i s mai ntai ned at a constant rate. The CAB mai n-
tai ns the hol d cycl e unti l sensor i nputs i ndi cate a
pressure change i s necessary.
PRESSURE INCREASE
The i nl et val ve i s open and the outl et val ve i s
cl osed duri ng the pressure i ncrease cycl e. The pres-
sure i ncrease cycl e i s used to counteract unequal
wheel speeds. Thi s cycl e control s re-appl i cati on of
fl ui d appl y pressure due to changi ng road surfaces or
wheel speed.
WHEEL SPEED SENSORS AND TONE WHEEL
DESCRIPTION
A speed sensor i s used at each wheel . The front
sensors are mounted to the steeri ng knuckl es. The
rear sensors at the outboard end of the axl e.
OPERATION
The sensors convert wheel speed i nto a smal l AC
el ectri cal si gnal . Thi s si gnal i s transmi tted to the
CAB. The CAB converts the AC si gnal i nto a di gi tal
si gnal for each wheel . Thi s vol tage i s generated by
magneti c i nducti on when a tone wheel passes by the
stati onary magnet of the wheel speed sensor.
A gear type tone ri ng serves as the tri gger mecha-
ni sm for each sensor. The tone ri ngs are mounted at
the outboard ends of the front and rear axl e shafts.
Di fferent sensors are used at the front and rear
wheel s (Fi g. 2). The front/rear sensors have the same
el ectri cal val ues but are not i nterchangeabl e. The
Fig. 1 Controller Antilock Brakes
1 HCU
2 MOTOR
3 CAB
5 - 34 BRAKES XJ
sensors have a resi stance between 900 and 1300
ohms.
FRONT SENSOR AIR GAP
Front sensor ai r gap i s fi xed and not adjustabl e.
Onl y rear sensor ai r gap i s adjustabl e.
Al though front ai r gap i s not adjustabl e, i t can be
checked i f di agnosi s i ndi cates thi s i s necessary. Front
ai r gap shoul d be 0.36 to 1.5 mm (0.014 to 0.059 i n.). I f
gap i s i ncorrect, the sensor i s ei ther l oose, or damaged.
REAR SENSOR AIR GAP
A rear sensor ai r gap adjustment i s onl y needed
when rei nstal l i ng an ori gi nal sensor. Repl acement
sensors have an ai r gap spacer attached to the sensor
pi ckup face. The spacer establ i shes correct ai r gap
when pressed agai nst the tone ri ng duri ng i nstal l a-
ti on. As the tone ri ng rotates, i t peel s the spacer off
the sensor to create the requi red ai r gap. Rear sensor
ai r gap i s 0.92-1.275 mm (0.036-0.05 i n.).
Sensor ai r gap measurement, or adjustment proce-
dures are provi ded i n thi s secti on. Refer to the front,
or rear sensor removal and i nstal l ati on procedures as
requi red.
COMBINATION VALVE
DESCRIPTION
The combi nati on val ve contai ns a pressure di ffer-
enti al val ve and swi tch and a rear brake proporti on-
i ng val ve. The val ve i s not repai rabl e and must be
repl aced as an assembl y i f di agnosi s i ndi cates thi s i s
necessary.
OPERATION
PRESSURE DIFFERENTIAL VALVE
The pressure di fferenti al swi tch i s connected to the
brake warni ng l i ght. The swi tch i s actuated by move-
ment of the swi tch val ve. The swi tch moni tors fl ui d
pressure i n the separate front/rear brake hydraul i c
ci rcui ts.
A decrease or l oss of fl ui d pressure i n ei ther
hydraul i c ci rcui t wi l l cause the swi tch val ve to shut-
tl e to the l ow pressure si de. Movement of the val ve
pushes the swi tch pl unger upward. Thi s acti on cl oses
the swi tch i nternal contacts compl eti ng the el ectri cal
ci rcui t to the red warni ng l i ght. The swi tch val ve wi l l
remai n i n an actuated posi ti on unti l repai rs to the
brake system are made.
PROPORTIONING VALVE
The proporti oni ng val ve i s used to bal ance front-
rear brake acti on at hi gh decel erati ons. The val ve
al l ows normal fl ui d fl ow duri ng moderate braki ng.
The val ve onl y control s fl ui d fl ow duri ng hi gh decel -
erati ons brake stops.
G-SWITCH
DESCRIPTION
The G-swi tch i s l ocated under the rear seat. The
swi tch has di recti onal arrow and must be mounted
wi th the arrow poi nti ng towards the front of the
vehi cl e.
OPERATION
The swi tch (Fi g. 3), provi des an addi ti onal vehi cl e
decel erati on reference duri ng 4x4 operati on. The
swi tch i s moni tored by the CAB at al l ti mes. The
swi tch reference si gnal i s uti l i zed by the CAB when
al l wheel s are decel erati ng at the same speed.
ABS WARNING LAMP
DESCRIPTION
The amber ABS warni ng l amp i s l ocated i n the
i nstrument cl uster. The l amp i l l umi nates at start-up
to perform a sel f check. The l amp goes out when the
sel f check program determi nes the system i s operat-
i ng normal .
OPERATION
I f an ABS component exhi bi ts a faul t the CAB wi l l
i l l umi nate the l amp and regi ster a troubl e code i n
the mi croprocessor. The l amp i s control l ed by the
CAB. The l amp i s i l l umi nated when the CAB sends a
ground si gnal to the ABS rel ay. The ABS rel ay then
grounds the l amp ci rcui t and i l l umi nates the l amp.
Fig. 2 Wheel Speed Sensors
1 FRONT SENSOR
2 REAR SENSOR
3 PICKUP FACE
XJ BRAKES 5 - 35
ANTILOCK BRAKES
The ABS brake system performs several sel f-tests
every ti me the i gni ti on swi tch i s turned on and the
vehi cl e i s dri ven. The CAB moni tors the systems
i nput and output ci rcui ts to veri fy the system i s oper-
ati ng correctl y. I f the on board di agnosti c system
senses that a ci rcui t i s mal functi oni ng the system
wi l l set a troubl e code i n i ts memory.
NOTE: An audible noise may be heard during the
self-test. This noise should be considered normal.
NOTE: The MDS or DRB III scan tool is used to
diagnose the ABS system. For additional informa-
tion refer to the Antilock Brake section in Group
8W. For test procedures refer to the Chassis Diag-
nostic Manual.
SERVICE PROCEDURES
BLEEDING ABS BRAKE SYSTEM
ABS system bl eedi ng requi res conventi onal bl eed-
i ng methods pl us use of the DRB scan tool . The pro-
cedure i nvol ves performi ng a base brake bl eedi ng,
fol l owed by use of the scan tool to cycl e and bl eed the
HCU pump and sol enoi ds. A second base brake bl eed-
i ng procedure i s then requi red to remove any ai r
remai ni ng i n the system.
(1) Perform base brake bl eedi ng. Refer to base
brake secti on for procedure.
(2) Connect scan tool to the Data Li nk Connector.
(3) Sel ect ANTI LOCK BRAKES, fol l owed by MI S-
CELLANEOUS, then ABS BRAKES. Fol l ow the
i nstructi ons di spl ayed. When scan tool di spl ays TEST
COMPLETE, di sconnect scan tool and proceed.
(4) Perform base brake bl eedi ng a second ti me.
Refer to base brake secti on for procedure.
(5) Top off master cyl i nder fl ui d l evel and veri fy
proper brake operati on before movi ng vehi cl e.
ANTILOCK BRAKES
REMOVAL
(1) Remove negati ve battery cabl e from the bat-
tery.
(2) Pul l up on the CAB harness connector rel ease
(Fi g. 4) and remove connector.
(3) Remove brake l i nes from the HCU.
(4) Remove HCU/CAB mounti ng nuts and bol t
(Fi g. 5) and remove HCU/CAB.
INSTALLATION
(1) I nstal l HCU/CAB on the mounti ng studs.
(2) I nstal l mounti ng nuts and bol t. Ti ghten to 11.5
Nm (102 i n. l bs.).
(3) I nstal l brake l i nes to the HCU and ti ghten to
19 Nm (170 i n. l bs.).
(4) I nstal l wi ri ng harness connector to the CAB
and push down on the rel ease to secure the connec-
tor.
(5) I nstal l negati ve battery cabl e to the battery.
(6) Bl eed ABS brake system.
Fig. 3 G-Switch
1 SWITCH PART NUMBER
2 ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
Fig. 4 CAB Harness Connector Release
1 CAB
2 CAB HARNESS RELEASE
5 - 36 BRAKES XJ
FRONT WHEEL SPEED SENSOR
REMOVAL
(1) Rai se vehi cl e and turn wheel outward for eas-
i er access to sensor.
(2) Remove sensor wi re from mounti ng brackets.
(3) Cl ean sensor and surroundi ng area wi th shop
towel before removal .
(4) Remove bol t attachi ng sensor to steeri ng
knuckl e and remove sensor (Fi g. 6).
(5) Remove sensor wi re from brackets on body and
steeri ng knuckl e.
(6) Unseat sensor wi re grommet i n wheel house
panel .
(7) I n engi ne compartment, di sconnect sensor wi re
connector at harness pl ug. Then remove sensor and
wi re.
INSTALLATION
(1) I f original sensor wi l l be i nstal l ed, wi pe al l
traces of ol d spacer materi al off sensor pi ckup face.
Use a dry shop towel for thi s purpose.
(2) Appl y Mopar Lock N Seal or Locti te 242 to
bol t that secures sensor i n steeri ng knuckl e. Use new
sensor bol t i f ori gi nal bol t i s worn or damaged.
(3) Posi ti on sensor on steeri ng knuckl e. Seat sen-
sor l ocati ng tab i n hol e i n knuckl e and i nstal l sensor
attachi ng bol t fi nger ti ght.
(4) Ti ghten sensor attachi ng bol t to 4.7 Nm (42 i n.
l bs.).
(5) I f ori gi nal sensor has been i nstal l ed, check sen-
sor ai r gap. Ai r gap shoul d be 0.36 to 1.5 mm (0.014
to 0.059 i n.). I f gap i s i ncorrect, sensor i s ei ther l oose,
or damaged.
(6) Secure sensor wi re to steeri ng knuckl e and
body brackets.
(7) Route sensor wi re forward and behi nd shock
absorber. Then attach sensor wi re to spri ng seat
bracket wi th grommets on sensor wi re.
(8) Route sensor wi re to outer si l l bracket. Remove
al l twi sts or ki nks from wi re.
(9) Attach sensor wi re to si l l bracket wi th grom-
met. Be sure wi re i s free of twi sts and ki nks.
(10) Veri fy sensor wi re routi ng. Wi re shoul d l oop
forward and above si l l bracket. Loose end of wi re
shoul d be bel ow si l l bracket and towards brake hose.
(11) Seat sensor wi re grommet i n body panel and
cl i p wi re to brake l i ne at grommet l ocati on.
(12) Connect sensor wi re to harness i n engi ne com-
partment.
REAR WHEEL SPEED SENSOR
REMOVAL
(1) Rai se and fol d rear seat forward for access to
rear sensor connectors (Fi g. 7).
(2) Di sconnect sensors at rear harness connectors.
(3) Push sensor grommets and sensor wi res
through fl oorpan.
(5) Di sconnect sensor wi res at rear axl e connec-
tors.
Fig. 5 HCU/CAB Mounting
1 HCU
2 CAB
3 HCU/CAB BRACKET
4 MOTOR
Fig. 6 Front Wheel Speed Sensor
1 WHEEL SPEED SENSOR PIGTAIL
2 STEERING KNUCKLE
3 TONE WHEEL
4 FRONT WHEEL SPEED SENSOR
XJ BRAKES 5 - 37
(7) Remove brake drum.
(8) Remove cl i ps securi ng sensor wi res to brake
l i nes, rear axl e and, brake hose.
(9) Unseat sensor wi re support pl ate grommet.
(10) Remove bol t attachi ng sensor to bracket and
remove sensor (Fi g. 8).
INSTALLATION
(1) I f original sensor i s bei ng i nstal l ed, remove
any remai ni ng pi eces of cardboard spacer from sen-
sor pi ckup face. Use dry shop towel onl y to remove
ol d spacer materi al .
(2) I nsert sensor wi re through support pl ate hol e.
Then seat sensor grommet i n support pl ate.
(3) Appl y Mopar Lock N Seal or Locti te 242 to
ori gi nal sensor bol t. Use new bol t i f ori gi nal i s worn
or damaged.
(4) I nstal l sensor bol t fi nger ti ght onl y at thi s
ti me.
(5) I f original rear sensor was i nstal l ed, adjust
sensor ai r gap to 0.92-1.275 mm (0.036-0.05 i n.). Use
feel er gauge to measure ai r gap (Fi g. 9). Ti ghten sen-
sor bol t to 13 Nm (115 i n. l bs.).
(6) I f new sensor was i nstal l ed, push cardboard
spacer on sensor face agai nst tone ri ng (Fi g. 10).
Then ti ghten sensor bol t to 13 Nm (115 i n. l bs.). Cor-
rect ai r gap wi l l be establ i shed as tone ri ng rotates
and peel s spacer off sensor face.
(7) Route sensor wi res to rear seat area.
(8) Feed sensor wi res through fl oorpan access hol e
and seat sensor grommets i n fl oorpan.
(9) Veri fy that rear sensor wi res are secured to
rear brake hose and axl e wi th cl i ps. Veri fy that wi re
i s cl ear of rotati ng components.
(10) I nstal l brake drum and wheel and ti re assem-
bl y.
(12) Connect sensor wi re to harness connector.
Then reposi ti on carpet and fol d rear seat down.
G-SWITCH
REMOVAL
(1) Rai se and fol d rear seat assembl y forward for
access to sensor.
Fig. 7 Acceleration Switch And Rear Sensor
Connections
1 REAR SEAT CROSSMEMBER
2 ACCELERATION SENSOR
3 SENSOR MOUNTING BRACKET
4 TO R. R. WHEEL SENSOR
5 TO L. R. WHEEL SENSOR
6 FLOORPAN
7 SENSOR HARNESS
Fig. 8 Rear Wheel Speed Sensor
1 TONE WHEEL
2 WHEEL SPEED SENSOR
Fig. 9 Setting Air Gap On Original Rear Sensor
1 WHEEL SPEED SENSOR
2 BRASS FEELER GAUGE
3 TONE RING
5 - 38 BRAKES XJ
(2) Di sconnect swi tch harness.
(3) Remove swi tch mounti ng screws (Fi g. 11)
(4) Remove the accel erati on swi tch.
INSTALLATION
CAUTION: The mercury switch (inside the
G-switch), will not function properly if the switch is
installed incorrectly. Verify that the switch locating
arrow is pointing to the front of the vehicle (Fig.
12).
(1) Posi ti on swi tch i n mounti ng bracket.
(2) I nstal l swi tch mounti ng bol ts and ti ghten to 3
Nm (27.5 i n. l bs.).
(3) Connect harness to swi tch. Be sure harness
connector i s fi rml y seated.
(4) Move seat back to normal posi ti on.
ANTILOCK BRAKE
DISASSEMBLY
(1) Remove pump motor connector from the CAB.
(2) Remove CAB mounti ng screws from the HCU
(Fi g. 13).
(3) Remove CAB from the HCU.
Fig. 10 New Rear Sensor
1 REAR SENSOR
2 AIR GAP SPACER ATTACHED TO SENSOR FACE
Fig. 11 G-Switch Mounting
1 ACCELERATION SWITCH
2 SWITCH BRACKET
3 REAR SEAT CROSSMEMBER
Fig. 12 G-Switch
1 SWITCH PART NUMBER
2 ARROW INDICATES FRONT OF SWITCH FOR PROPER
MOUNTING
Fig. 13 CAB Mounting Screws
1 MOUNTING SCREWS
2 CAB
XJ BRAKES 5 - 39
ASSEMBLY
(1) I nstal l the CAB onto the HCU.
(2) I nstal l the CAB mounti ng screws and ti ghten
to 1.8 Nm (16 i n. l bs.).
(3) I nstal l pump motor connector to the CAB.
SPECIFICATIONS
T0RQUE CHART
DESCRIPTION TORQUE
G-Sensor
Sensor Bol t . . . . . . . . . . . . . . 3 Nm (27.5 i n. l bs.)
Bracket Bol t . . . . . . . . . . . . . 2.7 Nm (24 i n. l bs.)
Hydraulic Control Unit/Controller Antilock
Brakes
Controller Antilock Brakes
Mounti ng Screws . . . . . . . . . 1.8 Nm (16 i n. l bs.)
Wheel Speed Sensors
Front Mounti ng Bol t . . . . . . 4.7 Nm (42 i n. l bs.)
Rear Mounti ng Bol t . . . . . . . 13 Nm (115 i n. l bs.)
5 - 40 BRAKES XJ
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLUTCH DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLUTCH PRESSURE PLATE. . . . . . . . . . . . . . . . . 2
CLUTCH RELEASE BEARING . . . . . . . . . . . . . . . . 3
HYDRAULIC CLUTCH LINKAGE . . . . . . . . . . . . . . 4
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION METHODS AND PARTS
USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLUTCH DIAGNOSTIC INFORMATION. . . . . . . . . 4
CLUTCH CONTAMINATION. . . . . . . . . . . . . . . . . . 6
IMPROPER CLUTCH RELEASE OR
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH MISALIGNMENT. . . . . . . . . . . . . . . . . . . 6
CLUTCH HOUSING MISALIGNMENT . . . . . . . . . . 6
CLUTCH FLYWHEEL RUNOUT . . . . . . . . . . . . . . . 6
CLUTCH COVER AND DISC RUNOUT . . . . . . . . . 7
CLUTCH DIAGNOSIS CHARTS . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION . . . . . . . . . 9
CLUTCH LINKAGE FLUID. . . . . . . . . . . . . . . . . . . 9
CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 10
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . 11
RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . . 12
PILOT BEARING. . . . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH HOUSING. . . . . . . . . . . . . . . . . . . . . . . 13
CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLUTCH
DESCRIPTION
The cl utch mechani sm consi sts of a fl ywheel , a si n-
gl e, dry-type di sc, and a di aphragm styl e cl utch cover
(Fi g. 1). A hydraul i c l i nkage i s used to operate the
cl utch rel ease beari ng and fork. The fl ywheel i s
bol ted to the rear fl ange of the crankshaft. The
cl utch pressure pl ate i s bol ted to the fl ywheel wi th
the cl utch di sc l ocated between these two compo-
nents. The cl utch system provi des the mechani cal ,
but sti l l easi l y detachabl e, l i nk between the engi ne
and the transmi ssi on. The system i s desi gned to
ensure that the ful l torque output of the engi ne i s
transfered to the transmi ssi on whi l e i sol ati ng the
transmi ssi on from the engi ne fi ri ng pul ses to mi ni -
mi ze concerns such as gear rattl e.
OPERATION
Leverage, cl ampi ng force, and fri cti on are what
make the cl utch work. The di sc serves as the fri cti on
el ement and a di aphragm spri ng and pressure pl ate
provi de the cl ampi ng force. The cl utch pedal , hydrau-
l i c l i nkage, rel ease l ever and beari ng provi de the
l everage.
Fig. 1 Engine Powerflow
XJ CLUTCH 6 - 1
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . When the cl utch pedal i s
depressed, the sl ave cyl i nder i s operated by the
cl utch master cyl i nder mounted on the dash panel .
The rel ease fork i s actuated by the hydraul i c sl ave
cyl i nder mounted on the transmi ssi on housi ng. The
rel ease beari ng i s operated by a rel ease fork pi voti ng
on a bal l stud mounted i n the transmi ssi on housi ng.
The rel ease beari ng then depresses the pressure
pl ate spri ng fi ngers, thereby rel easi ng pressure on
the cl utch di sc and al l owi ng the engi ne crankshaft to
spi n i ndependentl y of the transmi ssi on i nput shaft
(Fi g. 2).
FLYWHEEL
DESCRIPTION
The fl ywheel (Fi g. 3) i s a heavy pl ate bol ted to the
rear of the crankshaft. The fl ywheel i ncorporates the
ri ng gear around the outer ci rcumference to mesh
wi th the starter to permi t engi ne cranki ng. The rear
face of the fl ywheel serves as the dri vi ng member to
the cl utch di sc.
OPERATION
The fl ywheel serves to dampen the engi ne fi ri ng
pul ses. The heavy wei ght of the fl ywheel rel ati ve to
the rotati ng mass of the engi ne components serves to
stabi l i ze the fl ow of power to the remai nder of the
dri vetrai n. The crankshaft has the tendency to
attempt to speed up and sl ow down i n response to
the cyl i nder fi ri ng pul ses. The fl ywheel dampens
these i mpul ses by absorbi ng energy when the crank-
shaft speeds and rel easi ng the energy back i nto the
system when the crankshaft sl ows down.
CLUTCH DISC
DESCRIPTION
The cl utch di sc fri cti on materi al i s ri veted to the
di sc hub (Fi g. 4). The hub bore i s spl i ned for i nstal l a-
ti on on the transmi ssi on i nput shaft. The cl utch di sc
has cushi on spri ngs i n the di sc hub to dampen di sc
vi brati ons duri ng appl i cati on and rel ease of the cl utch.
OPERATION
The cl utch di sc i s hel d onto the surface of the fl y-
wheel by the force exerted by the pressure pl ates di a-
phragm spri ng. The fri cti on materi al of the cl utch di sc
then transfers the engi ne torque from the fl ywheel and
pressure pl ate to the i nput shaft of the transmi ssi on.
CLUTCH PRESSURE PLATE
DESCRIPTION
The cl utch pressure pl ate assembl y i s a di aphragm
type wi th a one-pi ece spri ng and mul ti pl e rel ease fi n-
gers (Fi g. 5). The pressure pl ate rel ease fi ngers are
preset duri ng manufacture and are not adjustabl e.
The assembl y al so contai ns the cover, pressure pl ate,
and ful crum components.
Fig. 2 Clutch Operation
1 FLYWHEEL
2 PRESSURE PLATE FINGERS
3 PIVOT POINT
4 RELEASE BEARING PUSHED IN
5 CLUTCH DISC ENGAGED
7 RELEASE BEARING
Fig. 3 Flywheel
1 CRANKSHAFT
2 RING GEAR
3 FLYWHEEL
6 - 2 CLUTCH XJ
OPERATION
The cl utch pressure pl ate assembl y cl amps the
cl utch di sc agai nst the fl ywheel . When the rel ease
beari ng i s depressed by the shi ft fork, the pressure
exerted on the cl utch di sc by the pressure pl ate
spri ng i s decreased. As addi ti onal force i s appl i ed,
the beari ng presses the di aphragm spri ng fi ngers
i nward on the ful crums. Thi s acti on moves the pres-
sure pl ate rearward rel i evi ng cl amp force on the di sc.
The cl utch di sc i s di sengaged and freewheel i ng at
thi s poi nt.
CLUTCH RELEASE BEARING
DESCRIPTION
A conventi onal rel ease beari ng (Fi g. 6) i s used to
engage and di sengage the cl utch pressure pl ate
assembl y. The cl utch rel ease beari ng i s mounted on
the transmi ssi on front beari ng retai ner. The beari ng
i s attached to the rel ease fork, whi ch moves the bear-
i ng i nto contact wi th the cl utch cover di aphragm
spri ng.
OPERATION
The rel ease beari ng i s operated by a rel ease fork i n
the cl utch housi ng. Sl ave cyl i nder force causes the
rel ease l ever to move the rel ease beari ng i nto contact
wi th the di aphragm spri ng. As addi ti onal force i s
appl i ed, the beari ng presses the di aphragm spri ng
fi ngers i nward on the ful crums. Thi s acti on moves
the pressure pl ate rearward rel i evi ng cl amp force on
the di sc. Rel easi ng pedal pressure removes cl utch
hydraul i c pressure. The rel ease beari ng then moves
away from the di aphragm spri ng whi ch al l ows the
pressure pl ate to exert cl ampi ng force on the cl utch
di sc.
Fig. 4 Clutch Disc-Typical
1 FACING MATERIAL
2 DAMPER SPRINGS
3 HUB
Fig. 5 Clutch Pressure Plate-Typical
1 COVER
2 RELEASE FINGERS
3 PRESSURE PLATE
Fig. 6 Clutch Release Bearing
1 RELEASE BEARING
2 RELEASE FORK
XJ CLUTCH 6 - 3
HYDRAULIC CLUTCH LINKAGE
DESCRIPTION
The hydraul i c l i nkage consi sts of a cl utch master
cyl i nder wi th i ntegral reservoi r, a cl utch sl ave cyl i n-
der and an i nterconnecti ng fl ui d l i ne (Fi g. 7).
The cl utch master cyl i nder push rod i s connected to
the cl utch pedal . The sl ave cyl i nder push rod i s con-
nected to the cl utch rel ease fork. The master cyl i nder i s
mounted on the dri ver si de of the dash panel adjacent
to the brake master cyl i nder and booster assembl y.
OPERATION
The cl utch l i nkage uses hydraul i c pressure to oper-
ate the cl utch. Depressi ng the cl utch pedal devel ops
fl ui d pressure i n the cl utch master cyl i nder. Thi s
pressure i s transmi tted to the sl ave cyl i nder through
a connecti ng l i ne. I n turn, the sl ave cyl i nder operates
the cl utch rel ease l ever.
Sl ave cyl i nder force causes the rel ease l ever to
move the rel ease beari ng i nto contact wi th the di a-
phragm spri ng. As addi ti onal force i s appl i ed, the
beari ng presses the di aphragm spri ng fi ngers i nward
on the ful crums. Thi s acti on moves the pressure
pl ate rearward rel i evi ng cl amp force on the di sc.
SAFETY PRECAUTIONS
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMARKET
COMPONENTS. BREATHING EXCESSIVE CONCEN-
TRATIONS OF THESE FIBERS CAN CAUSE SERIOUS
BODILY HARM. WEAR A RESPIRATOR DURING SER-
VICE AND NEVER CLEAN CLUTCH COMPONENTS
WITH COMPRESSED AIR OR WITH A DRY BRUSH.
EITHER CLEAN THE COMPONENTS WITH A WATER
DAMPENED RAGS OR USE A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR REMOVING ASBES-
TOS FIBERS AND DUST. DO NOT CREATE DUST BY
SANDING A CLUTCH DISC. REPLACE THE DISC IF
THE FRICTION MATERIAL IS DAMAGED OR CON-
TAMINATED. DISPOSE OF ALL DUST AND DIRT CON-
TAINING ASBESTOS FIBERS IN SEALED BAGS OR
CONTAINERS. THIS WILL HELP MINIMIZE EXPOSURE
TO YOURSELF AND TO OTHERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
SAFETY AGENCY (EPA), FOR THE HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBESTOS.
INSTALLATION METHODS AND PARTS USAGE
Di storti on of cl utch components duri ng i nstal l ati on
and the use of non-standard components are common
causes of cl utch mal functi on.
I mproper cl utch cover bol t ti ghteni ng can di stort
the cover. The usual resul t i s cl utch grab, chatter
and rapi d wear. Ti ghten the cover bol ts as descri bed
i n Removal and I nstal l ati on secti on.
An i mproperl y seated fl ywheel and/or cl utch hous-
i ng are addi ti onal causes of cl utch fai l ure. I mproper
seati ng wi l l produce mi sal i gnment and addi ti onal
cl utch probl ems.
The use of non-standard or l ow qual i ty parts wi l l
al so l ead to probl ems and wear. Use recommended
factory qual i ty parts to avoi d comebacks.
A cocked pi l ot beari ng i s another cause of cl utch
noi se, drag, hard shi fti ng, and rapi d beari ng wear.
Al ways use an al i gnment tool to i nstal l a new bear-
i ng. Thi s practi ce hel ps avoi d cocki ng the beari ng
duri ng i nstal l ati on.
CLUTCH DIAGNOSTIC INFORMATION
Unl ess the cause of a cl utch probl em i s obvi ous, accu-
rate probl em di agnosi s wi l l usual l y requi re a road test to
confi rm a probl em. Component i nspecti on (Fi g. 8) wi l l
then be requi red to determi ne the actual probl em cause.
Duri ng a road test, dri ve the vehi cl e at normal
speeds. Shi ft the transmi ssi on through al l gear
ranges and observe cl utch acti on. I f chatter, grab,
sl i p, or i mproper rel ease i s experi enced, remove and
i nspect the cl utch components. However, i f the prob-
l em i s noi se or hard shi fti ng, further di agnosi s may
be needed as the transmi ssi on or another dri vel i ne
component may be at faul t. Careful observati on dur-
i ng the test wi l l hel p narrow the probl em area.
Fig. 7 Clutch Master Cylinder
1 CAP
2 FILL LINE
3 CLUTCH MASTER CYLINDER
4 RESERVOIR
6 - 4 CLUTCH XJ
Fig. 8 Clutch Components And Inspection
XJ CLUTCH 6 - 5
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , water, or cl utch fl ui d on the cl utch
di sc and pressure pl ate surfaces wi l l cause chatter,
sl i p and grab.
Duri ng i nspecti on, note i f any components are con-
tami nated wi th oi l , hydraul i c fl ui d, or water/road
spl ash.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Oi l l eak-
age produces a resi due of oi l on the housi ng i nteri or
and on the cl utch cover and fl ywheel . Heat bui l dup
caused by sl i ppage between the cover, di sc and fl y-
wheel , can someti mes bake the oi l resi due onto the
components. The gl aze-l i ke resi due ranges i n col or
from amber to bl ack.
Road spl ash contami nati on means di rt/water i s
enteri ng the cl utch housi ng due to l oose bol ts, hous-
i ng cracks, or through hydraul i c l i ne openi ngs. Dri v-
i ng through deep water puddl es can force water/road
spl ash i nto the housi ng through such openi ngs.
Cl utch fl ui d l eaks are usual l y from damaged sl ave
cyl i nder push rod seal s. Thi s type of l eak can onl y be
confi rmed by vi sual i nspecti on.
ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear, or damage to one or more cl utch compo-
nents. A vi sual i nspecti on of the rel ease components
wi l l usual l y reveal the probl em part.
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. I tems to l ook for are: l eaks at the cl utch cyl i n-
ders and i nterconnecti ng l i ne; l oose sl ave cyl i nder
bol ts; worn/l oose rel ease fork and pi vot stud; dam-
aged rel ease beari ng; and a worn cl utch di sc, or pres-
sure pl ate.
Normal condensati on i n vehi cl es that are stored or
out of servi ce for l ong peri ods of ti me can generate
enough corrosi on to make the di sc sti ck to the fl y-
wheel , or pressure pl ate. I f thi s condi ti on i s experi -
enced, correcti on onl y requi res that the di sc be
l oosened manual l y through the i nspecti on pl ate open-
i ng.
Engagement probl ems usual l y resul t i n sl i p, chat-
ter/shudder, and noi sy operati on. The pri mary causes
are cl utch di sc contami nati on; cl utch di sc wear; mi s-
al i gnment, or di storti on; fl ywheel damage; or a com-
bi nati on of the foregoi ng. A vi sual i nspecti on i s
requi red to determi ne the part actual l y causi ng the
probl em.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
CLUTCH HOUSING MISALIGNMENT
Cl utch housi ng al i gnment i s i mportant to proper
cl utch operati on. The housi ng mai ntai ns al i gnment
between the crankshaft and transmi ssi on i nput
shaft. Mi sal i gnment can cause cl utch noi se, hard
shi fti ng, i ncompl ete rel ease and chatter. I t can al so
resul t i n premature wear of the pi l ot beari ng, cover
rel ease fi ngers and cl utch di sc. I n severe cases, mi s-
al i gnment can al so cause premature wear of the
transmi ssi on i nput shaft and front beari ng.
Housi ng mi sal i gnment i s general l y caused by
i ncorrect seati ng on the engi ne or transmi ssi on, l oose
housi ng bol ts, mi ssi ng al i gnment dowel s, or housi ng
damage. I nfrequentl y, mi sal i gnment may al so be
caused by housi ng mounti ng surfaces that are not
compl etel y paral l el . Mi sal i gnment can be corrected
wi th shi ms.
CLUTCH FLYWHEEL RUNOUT
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
heat warpage
i mproper machi ni ng
i ncorrect bol t ti ghteni ng
i mproper seati ng on crankshaft fl ange shoul der
forei gn materi al on crankshaft fl ange
Fl ywheel machi ni ng i s not recommended. The fl y-
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. However,
mi nor fl ywheel scori ng can be cl eaned up by hand
wi th 180 gri t emery, or wi th surface gri ndi ng equi p-
ment. Remove onl y enough materi al to reduce scor-
i ng (approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
Cl ean the crankshaft fl ange before mounti ng the
fl ywheel . Di rt and grease on the fl ange surface may
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal . Ti ghten fl ywheel
bol ts to speci fi ed torque onl y. Overti ghteni ng can di s-
tort the fl ywheel hub causi ng runout.
6 - 6 CLUTCH XJ
CLUTCH COVER AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
CLUTCH DIAGNOSIS CHARTS
The cl utch i nspecti on chart (Fi g. 8) outl i nes i tems
to be checked before and duri ng cl utch i nstal l ati on.
Use the chart as a check l i st to hel p avoi d overl ook-
i ng potenti al probl em sources duri ng servi ce opera-
ti ons.
The di agnosi s charts descri be common cl utch prob-
l ems, causes and correcti on. Faul t condi ti ons are
l i sted at the top of each chart. Condi ti ons, causes and
correcti ve acti on are outl i ned i n the i ndi cated col -
umns.
The charts are provi ded as a conveni ent reference
when di agnosi ng faul ty cl utch operati on.
DIAGNOSIS CHART
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
2. Replace cover and disc.
3. Insufficient clutch cover
diaphragm spring tension.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
XJ CLUTCH 6 - 7
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
1. Correct condition of flywheel and
pressure plate surface. Replace
clutch cover and disc. Alert driver to
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
problem cause.
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
during installation.
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
6 - 8 CLUTCH XJ
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
Clutch master or slave cylinder
plunger dragging andr binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
fingers bent or distorted.
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
1. Replace clutch disc and cover.
2. Clutch cover, spring, or release
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andr
clutch housing. Correct as
necessary.
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION
Proper cl utch component l ubri cati on i s i mportant
to sati sfactory operati on. Usi ng the correct l ubri cant
and not over l ubri cati ng are equal l y i mportant. Appl y
recommended l ubri cant spari ngl y to avoi d di sc and
pressure pl ate contami nati on.
Cl utch and transmi ssi on components requi ri ng
l ubri cati on are:
Pi l ot beari ng.
Rel ease l ever pi vot bal l stud.
Rel ease l ever contact surfaces.
Rel ease beari ng bore.
Cl utch di sc hub spl i nes.
Cl utch pedal pi vot shaft bore.
Cl utch pedal bushi ngs.
I nput shaft spl i nes.
I nput shaft pi l ot hub.
Transmi ssi on front beari ng retai ner sl i de sur-
face.
NOTE: Never apply grease to any part of the clutch
cover, or disc.
RECOMMENDED LUBRICANTS
Use Mopar mul ti -purpose grease for the cl utch
pedal bushi ngs and pi vot shaft. Use Mopar hi gh
temperature grease (or equi val ent) for al l other l ubri -
cati on requi rements. Appl y recommended amounts
and do not over l ubri cate.
CLUTCH LINKAGE FLUID
I f i nspecti on or di agnosi s i ndi cates addi ti onal fl ui d
may be needed, use Mopar brake fl ui d, or an equi v-
XJ CLUTCH 6 - 9
al ent meeti ng standards SAE J1703 and DOT 3. Do
not use any other type of fl ui d.
CLUTCH FLUID LEVEL
The cl utch fl ui d reservoi r, master cyl i nder, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed wi th fl ui d at
the factory duri ng assembl y operati ons.
The hydraul i c system shoul d not requi re addi ti onal
fl ui d under normal ci rcumstances. I n fact, the reser-
voir fluid level will actually increase as normal
clutch wear occurs. For this reason, it is impor-
tant to avoid overfilling, or removing fluid from
the reservoir.
Cl utch fl ui d l evel i s checked at the master cyl i nder
reservoi r (Fi g. 9). An i ndi cator ri ng i s provi ded on the
outsi de ri m of the reservoi r.
Be sure to wi pe the reservoi r and cover cl ean
before removi ng the cover. Thi s wi l l avoi d havi ng di rt
or forei gn materi al fal l i nto the reservoi r duri ng a
fl ui d l evel check.
FLYWHEEL
I nspect the fl ywheel whenever the cl utch di sc,
cover and housi ng are removed for servi ce. Check
condi ti on of the fl ywheel face, hub, ri ng gear teeth,
and fl ywheel bol ts.
Mi nor scratches, burrs, or gl azi ng on the fl ywheel
face can be reduced wi th 180 gri t emery cl oth. How-
ever, the fl ywheel shoul d be repl aced i f the di sc con-
tact surface i s severel y scored, heat checked, cracked,
or obvi ousl y worn.
wheel surface i s manufactured wi th a uni que contour
that woul d be negated by machi ni ng. However,
cl eanup of mi nor fl ywheel scori ng can be performed
by hand wi th 180 gri t emery, or wi th surface gri nd-
i ng equi pment. Repl ace the fl ywheel i f scori ng i s
deeper than 0.0762 mm (0.003 i n.).
Heavy stock removal by gri ndi ng i s not recom-
mended. Excessi ve stock removal can resul t i n fl y-
wheel cracki ng or warpage after i nstal l ati on. I t can
al so weaken the fl ywheel and i nterfere wi th proper
cl utch rel ease.
Check fl ywheel runout i f mi sal i gnment i s sus-
pected. Runout shoul d not exceed 0.08 mm (0.003
i n.). Measure runout at the outer edge of the fl y-
wheel face wi th a di al i ndi cator. Mount the di al i ndi -
cator on a stud i nstal l ed i n pl ace of one of the cl utch
housi ng attachi ng bol ts.
cock the fl ywheel causi ng excessi ve runout.
Check condi ti on of the fl ywheel hub and attachi ng
bol ts. Repl ace the fl ywheel i f the hub exhi bi ts cracks
i n the area of the attachi ng bol t hol es.
I nstal l new attachi ng bol ts whenever the fl ywheel
i s repl aced and use Mopar Lock N Seal , or Locti te
242 on the repl acement bol t threads.
Recommended fl ywheel bol t torques are:
142 Nm (105 ft. l bs.) for 6-cyl i nder fl ywheel s
I nspect the teeth on the starter ri ng gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
I n cases where a new fl ywheel i s not readi l y avai l -
abl e, a repl acement ri ng gear can be i nstal l ed. How-
ever, the fol l owi ng precauti ons must be observed to
avoi d damagi ng the fl ywheel and repl acement gear.
(1) Mark posi ti on of the ol d gear for al i gnment ref-
erence on the fl ywheel . Use a scri ber for thi s pur-
pose.
(2) Wear protecti ve goggl es or approved safety
gl asses. Al so wear heat resi stent gl oves when han-
dl i ng a heated ri ng gear.
(3) Remove the ol d gear by cutti ng most of the way
through i t (at one poi nt) wi th an abrasi ve cut-off
wheel . Then compl ete removal wi th a col d chi sel or
punch.
(4) The ri ng gear i s a shri nk fi t on the fl ywheel .
Thi s means the gear must be expanded by heati ng i n
order to i nstal l i t. The method of heating and
expanding the gear is extremely important.
Every surface of the gear must be heated at the same
ti me to produce uni form expansi on. An oven or si mi -
l ar encl osed heati ng devi ce must be used. Tempera-
ture requi red for uni form expansi on i s approxi matel y
375 F.
Fig. 9 Clutch Master Cylinder Reservoir And Cap
1 CAP
2 FILL LINE
4 RESERVOIR
6 - 10 CLUTCH XJ
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
(5) The heated gear must be i nstal l ed evenl y to
avoi d mi sal i gnment or di storti on. A shop press and
sui tabl e press pl ates shoul d be used to i nstal l the
gear i f at al l possi bl e.
(6) Be sure to wear eye and hand protecti on. Heat
resi stent gl oves and safety goggl es are needed for
personal safety. Al so use metal tongs, vi se gri ps, or
si mi l ar tool s to posi ti on the gear as necessary for
i nstal l ati on.
(7) Al l ow the fl ywheel and ri ng gear to cool down
before i nstal l ati on. Set the assembl y on a workbench
and l et i t cool i n normal shop ai r.
CAUTION: Do not use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.
CLUTCH COVER AND DISC
REMOVAL
(1) Remove transmi ssi on. Refer to procedures i n
Group 21.
(2) I f ori gi nal cl utch cover wi l l be rei nstal l ed, mark
posi ti on of cover on fl ywheel for assembl y reference.
Use pai nt or a scri ber for thi s purpose.
(3) I f cl utch cover i s to be repl aced, cover bol ts can
be removed i n any sequence. However, i f ori gi nal
cover wi l l be rei nstal l ed, l oosen cover bol ts evenl y
and i n rotati on to rel i eve spri ng tensi on equal l y. Thi s
i s necessary to avoi d warpi ng cover.
(4) Remove cover bol ts and remove cover and di sc
(Fi g. 10).
INSTALLATION
(1) Li ghtl y scuff sand fl ywheel face wi th 180 gri t
emery cl oth. Then cl ean surface wi th a wax and
grease remover.
(2) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature beari ng grease.
(3) Check runout and free operati on of new cl utch
di sc as fol l ows:
(a) Sl i de di sc onto transmi ssi on i nput shaft
spl i nes. Di sc shoul d sl i de freel y on spl i nes.
(b) Leave di sc on shaft and check face runout
wi th di al i ndi cator. Check runout at di sc hub and
about 6 mm (1/4 i n.) from outer edge of faci ng.
(c) Face runout shoul d not exceed 0.5 mm (0.020
i n.). Obtai n another cl utch di sc i f runout exceeds
thi s l i mi t.
(4) Posi ti on cl utch di sc on fl ywheel . Be sure si de of
di sc marked fl ywheel si de i s posi ti oned agai nst fl y-
wheel (Fi g. 10). I f di sc i s not marked, be sure fl at
si de of di sc hub i s toward fl ywheel .
(5) I nspect condi ti on of pressure pl ate surface of
cl utch cover (Fi g. 10). Repl ace cover i f thi s surface i s
worn, heat checked, cracked, or scored.
(6) I nsert cl utch al i gnment tool i n cl utch di sc (Fi g.
11).
(7) I nsert al i gnment tool i n pi l ot beari ng and posi -
ti on di sc on fl ywheel . Be sure di sc hub i s posi ti oned
correctl y. Si de of hub marked Fl ywheel Si de shoul d
face fl ywheel (Fi g. 10). I f di sc i s not marked, pl ace
fl at si de of di sc agai nst fl ywheel .
(8) Posi ti on cl utch cover over di sc and on fl ywheel
(Fi g. 11).
(9) I nstal l cl utch cover bol ts fi nger ti ght.
(10) Ti ghten cover bol ts evenl y and i n rotati on a
few threads at a ti me. Cover bolts must be tight-
ened evenly and to specified torque to avoid
distorting cover. Tightening torques are 31 Nm
(23 ft. lbs.) on 2.5L engines and 50Nm(37ft. lbs.)
on 4.0 L engines.
(a) Start al l 6 bol ts by hand.
(b) Ti ghten 3 pi l ot hol e bol ts 3/4s of the way
(any sequence).
Fig. 10 Clutch Disc And Pressure Plate Inspection
1 DISC
2 INSPECT THIS SURFACE
3 CLUTCH COVER
4 FLYWHEEL SIDE STAMPED ON THIS SURFACE
XJ CLUTCH 6 - 11
(c) Starti ng 180 degrees from the l ast pi l ot bol t,
ti ghten 3 l arge hol e bol ts 3/4s of the way (any
sequence).
(d) Ti ghten 3 pi l ot hol e bol ts al l the way (any
sequence).
(e) Starti ng 180 degrees from l ast pi l ot bol t,
ti ghten 3 l arge bol ts al l the way (any sequence).
(11) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease to cl utch di sc hub and spl i nes of
transmi ssi on i nput shaft. Do not over lubricate
shaft splines. This will result in grease contam-
ination of disc.
(12) I nstal l transmi ssi on.
RELEASE BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Di sconnect rel ease beari ng from rel ease l ever
and remove beari ng (Fi g. 12).
(3) I nspect beari ng sl i de surface of transmi ssi on
front beari ng retai ner. Repl ace retai ner i f sl i de sur-
face i s scored, worn, or cracked.
(4) I nspect rel ease fork and fork pi vot. Be sure
pi vot i s secure and i n good condi ti on. Be sure fork i s
not di storted or worn. Repl ace rel ease fork retai ner
spri ng i f bent or damaged.
INSTALLATION
(1) Lubri cate crankshaft pi l ot beari ng wi th Mopar
hi gh temperature beari ng grease. Appl y grease to
end of l ong shank, smal l di ameter fl at bl ade screw-
dri ver. Then i nsert tool through cl utch di sc hub to
reach beari ng.
(2) Lubri cate i nput shaft spl i nes, beari ng retai ner
sl i de surface, fork pi vot and rel ease fork pi vot surface
wi th Mopar hi gh temperature grease.
(3) I nstal l new rel ease beari ng. Be sure beari ng i s
properl y secured to rel ease fork.
PILOT BEARING
REMOVAL
(1) Remove transmi ssi on. Refer to Group 21,
Transmi ssi on and Transfer Case, for proper proce-
dures.
(2) Remove cl utch cover and di sc.
(3) Use a sui tabl e bl i nd hol e pul l er to remove pi l ot
beari ng.
INSTALLATION
(1) Cl ean beari ng bore wi th sol vent and wi pe dry
wi th shop towel .
(2) Lubri cate new pi l ot beari ng wi th Mopar hi gh
temperature grease.
(3) Posi ti on and start new beari ng i n beari ng bore
by hand. Note that pi l ot beari ng has seal at one end.
I nstal l beari ng so seal i s faci ng outward toward
transmi ssi on.
(4) Seat pi l ot beari ng wi th cl utch al i gnment tool
(Fi g. 13). Keep beari ng strai ght duri ng i nstal l ati on.
Do not al l ow beari ng to become cocked. Tap beari ng
i nto pl ace unti l fl ush wi th edge of beari ng bore. Do
not recess beari ng.
(5) I nstal l transmi ssi on. Refer to Group 21, Trans-
mi ssi on and Transfer Case, for proper procedures.
Fig. 11 Typical Method Of Aligning Clutch Disc
1 FLYWHEEL
2 CLUTCH COVER AND DISC
3 CLUTCH DISC ALIGNMENT TOOL
Fig. 12 Release Bearing Attachment
1 RETURN SPRING
2 PIVOT BALL STUD
3 CLUTCH HOUSING
4 RELEASE FORK
5 RELEASE BEARING
6 - 12 CLUTCH XJ
CLUTCH HOUSING
The cl utch housi ng i s removabl e and can be
repl aced when the transmi ssi on i s out of the vehi cl e.
The bol ts attachi ng the housi ng to the transmi s-
si on case are l ocated i nsi de the housi ng (Fi g. 14).
Recommended ti ghteni ng torque for the cl utch hous-
i ng-to-transmi ssi on bol ts i s 46 Nm (34 ft. l bs.).
NOTE: Be sure the transmission and housing mat-
ing surfaces are clean before installing an original,
or replacement clutch housing. Dirt/foreign material
trapped between the housing and transmission will
cause misalignment. If misalignment is severe
enough, the result will be clutch drag, incomplete
release and hard shifting.
CLUTCH HYDRAULIC LINKAGE
The cl utch master cyl i nder, sl ave cyl i nder and con-
necti ng l i ne are servi ced as an assembl y onl y. The
l i nkage components cannot be overhaul ed or servi ced
separatel y. The cyl i nders and connecti ng l i ne are
seal ed uni ts. Al so note that removal /i nstal l ati on pro-
cedures for ri ght and l eft hand dri ve model s are basi -
cal l y the same. Onl y master cyl i nder l ocati on i s
di fferent.
REMOVAL
(2) Remove fasteners attachi ng sl ave cyl i nder to
cl utch housi ng.
(3) Remove sl ave cyl i nder from cl utch housi ng
(Fi g. 15).
(4) Di sengage cl utch fl ui d l i ne from body cl i ps, i f
appl i cabl e.
(6) Veri fy that cap on cl utch master cyl i nder reser-
voi r i s ti ght. Thi s i s necessary to avoi d spi l l i ng fl ui d
duri ng removal .
(7) Remove cl utch master cyl i nder attachi ng nuts
(Fi g. 16) or (Fi g. 17).
(8) Di sengage captured bushi ng on cl utch master
cyl i nder actuator from pi vot pi n on pedal arm (Fi g.
18).
(9) Sl i de actuator off pi vot pi n.
(10) Di sconnect cl utch i nterl ock safety swi tch
wi res.
(11) Remove cl utch hydraul i c l i nkage through
engi ne compartment.
Fig. 13 Typical Method Of Installing Pilot Bearing
1 PILOT BEARING
2 ALIGNMENT TOOL
3 BEARING SEAL MUST FACE TRANSMISSION
Fig. 14 Clutch Housing Attachment
1 HOUSING-TO-TRANSMISSION BOLTS (46 Nm/34 ft. lbs.)
2 CLUTCH HOUSING
3 TRANSMISSION
XJ CLUTCH 6 - 13
INSTALLATION
(1) Be sure reservoi r cover on cl utch master cyl i n-
der i s ti ght to avoi d spi l l s.
(2) Posi ti on cl utch l i nkage components i n vehi cl e.
Work connecti ng l i ne and sl ave cyl i nder downward
past engi ne and adjacent to cl utch housi ng (Fi g. 16)
or (Fi g. 17).
(3) Posi ti on cl utch master cyl i nder on dash panel
(Fi g. 16) or (Fi g. 17).
(4) Attach cl utch master cyl i nder actuator to pi vot
pi n on cl utch pedal (Fi g. 18).
(5) I nstal l and ti ghten cl utch master cyl i nder
attachi ng nuts to 38 Nm (28 ft. l bs.) torque.
(7) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure cap
on end of rod i s securel y engaged i n l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
(8) I nstal l and ti ghten sl ave cyl i nder attachi ng
nuts to 23 Nm (17 ft. l bs.) torque.
Fig. 15 Slave Cylinder
1 CLUTCH SLAVE CYLINDER
Fig. 16 Left Hand Drive Clutch Master Cylinder
Fig. 17 Right Hand Drive Clutch Master Cylinder
Fig. 18 Clutch Pedal Attachment
6 - 14 CLUTCH XJ
(9) Secure cl utch fl ui d l i ne i n body and transmi s-
si on cl i ps.
(11) Connect cl utch i nterl ock safety swi tch wi res.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Bol ts, cl utch cover 2.5 L . . . . . . . 31 Nm (23 ft. l bs)
Bol t/Nut, cl utch cyl . mount . . . 23 Nm (200 i n. l bs)
Bol t, cl utch housi ng M12 . . . . . . 75 Nm (55 ft. l bs)
Bol t, cl utch housi ng 3/8 . . . . . . . 37 Nm (27 ft. l bs)
Bol t, cl utch housi ng 7/16 . . . . . . 58 Nm (43 ft. l bs)
Bol t, cl utch housi ng/trans. . . . . . 46 Nm (34 ft. l bs)
Bol t, dust shi el d M8 . . . . . . . . . . 8 Nm (72 i n. l bs)
Bol t, dust shi el d l ower . . . . . . . . 50 Nm (37 ft. l bs)
Bol t, X-member/frame . . . . . . . . 41 Nm (30 ft. l bs)
Bol t, X-member/rear support . . . 45 Nm (33 ft. l bs.)
Bol ts, fl ywheel 4.0 L . . . . . . . . 142 Nm (105 ft. l bs)
Bol ts, fl ywheel 2.5 L . . . . . . . . . 95 Nm (70 ft. l bs)
Bol t, starter motor . . . . . . . . . . . 45 Nm (33 ft. l bs)
Bol ts, U-joi nts . . . . . . . . . . . . . 19 Nm (170 i n. l bs.)
XJ CLUTCH 6 - 15
CLUTCH
TABLE OF CONTENTS
page page
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLUTCH DISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CLUTCH PRESSURE PLATE. . . . . . . . . . . . . . . . . 2
CLUTCH RELEASE BEARING . . . . . . . . . . . . . . . . 3
HYDRAULIC CLUTCH LINKAGE . . . . . . . . . . . . . . 4
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . 4
USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CLUTCH DIAGNOSTIC INFORMATION. . . . . . . . . 4
CLUTCH CONTAMINATION. . . . . . . . . . . . . . . . . . 6
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CLUTCH MISALIGNMENT. . . . . . . . . . . . . . . . . . . 6
CLUTCH HOUSING MISALIGNMENT . . . . . . . . . . 6
CLUTCH FLYWHEEL RUNOUT . . . . . . . . . . . . . . . 6
CLUTCH COVER AND DISC RUNOUT . . . . . . . . . 7
CLUTCH DIAGNOSIS CHARTS . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION . . . . . . . . . 9
CLUTCH LINKAGE FLUID. . . . . . . . . . . . . . . . . . . 9
CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . . . 10
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . 11
RELEASE BEARING . . . . . . . . . . . . . . . . . . . . . . 12
PILOT BEARING. . . . . . . . . . . . . . . . . . . . . . . . . 12
CLUTCH HOUSING. . . . . . . . . . . . . . . . . . . . . . . 13
CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . . 13
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CLUTCH
DESCRIPTION
The cl utch mechani sm consi sts of a fl ywheel , a si n-
gl e, dry-type di sc, and a di aphragm styl e cl utch cover
(Fi g. 1). A hydraul i c l i nkage i s used to operate the
cl utch rel ease beari ng and fork. The fl ywheel i s
bol ted to the rear fl ange of the crankshaft. The
cl utch pressure pl ate i s bol ted to the fl ywheel wi th
the cl utch di sc l ocated between these two compo-
nents. The cl utch system provi des the mechani cal ,
but sti l l easi l y detachabl e, l i nk between the engi ne
and the transmi ssi on. The system i s desi gned to
ensure that the ful l torque output of the engi ne i s
transfered to the transmi ssi on whi l e i sol ati ng the
transmi ssi on from the engi ne fi ri ng pul ses to mi ni -
mi ze concerns such as gear rattl e.
OPERATION
Leverage, cl ampi ng force, and fri cti on are what
make the cl utch work. The di sc serves as the fri cti on
el ement and a di aphragm spri ng and pressure pl ate
provi de the cl ampi ng force. The cl utch pedal , hydrau-
l i c l i nkage, rel ease l ever and beari ng provi de the
l everage.
Fig. 1 Engine Powerflow
XJ CLUTCH 6 - 1
The cl utch master cyl i nder push rod i s connected
to the cl utch pedal . When the cl utch pedal i s
depressed, the sl ave cyl i nder i s operated by the
cl utch master cyl i nder mounted on the dash panel .
The rel ease fork i s actuated by the hydraul i c sl ave
cyl i nder mounted on the transmi ssi on housi ng. The
rel ease beari ng i s operated by a rel ease fork pi voti ng
on a bal l stud mounted i n the transmi ssi on housi ng.
The rel ease beari ng then depresses the pressure
pl ate spri ng fi ngers, thereby rel easi ng pressure on
the cl utch di sc and al l owi ng the engi ne crankshaft to
spi n i ndependentl y of the transmi ssi on i nput shaft
(Fi g. 2).
FLYWHEEL
DESCRIPTION
The fl ywheel (Fi g. 3) i s a heavy pl ate bol ted to the
rear of the crankshaft. The fl ywheel i ncorporates the
ri ng gear around the outer ci rcumference to mesh
wi th the starter to permi t engi ne cranki ng. The rear
face of the fl ywheel serves as the dri vi ng member to
the cl utch di sc.
OPERATION
The fl ywheel serves to dampen the engi ne fi ri ng
pul ses. The heavy wei ght of the fl ywheel rel ati ve to
the rotati ng mass of the engi ne components serves to
stabi l i ze the fl ow of power to the remai nder of the
dri vetrai n. The crankshaft has the tendency to
attempt to speed up and sl ow down i n response to
the cyl i nder fi ri ng pul ses. The fl ywheel dampens
these i mpul ses by absorbi ng energy when the crank-
shaft speeds and rel easi ng the energy back i nto the
system when the crankshaft sl ows down.
CLUTCH DISC
DESCRIPTION
The cl utch di sc fri cti on materi al i s ri veted to the
di sc hub (Fi g. 4). The hub bore i s spl i ned for i nstal l a-
ti on on the transmi ssi on i nput shaft. The cl utch di sc
has cushi on spri ngs i n the di sc hub to dampen di sc
vi brati ons duri ng appl i cati on and rel ease of the cl utch.
OPERATION
The cl utch di sc i s hel d onto the surface of the fl y-
wheel by the force exerted by the pressure pl ates di a-
phragm spri ng. The fri cti on materi al of the cl utch di sc
then transfers the engi ne torque from the fl ywheel and
pressure pl ate to the i nput shaft of the transmi ssi on.
CLUTCH PRESSURE PLATE
DESCRIPTION
The cl utch pressure pl ate assembl y i s a di aphragm
type wi th a one-pi ece spri ng and mul ti pl e rel ease fi n-
gers (Fi g. 5). The pressure pl ate rel ease fi ngers are
preset duri ng manufacture and are not adjustabl e.
The assembl y al so contai ns the cover, pressure pl ate,
and ful crum components.
Fig. 2 Clutch Operation
1 FLYWHEEL
2 PRESSURE PLATE FINGERS
3 PIVOT POINT
4 RELEASE BEARING PUSHED IN
7 RELEASE BEARING
Fig. 3 Flywheel
1 CRANKSHAFT
2 RING GEAR
3 FLYWHEEL
6 - 2 CLUTCH XJ
OPERATION
The cl utch pressure pl ate assembl y cl amps the
cl utch di sc agai nst the fl ywheel . When the rel ease
beari ng i s depressed by the shi ft fork, the pressure
exerted on the cl utch di sc by the pressure pl ate
spri ng i s decreased. As addi ti onal force i s appl i ed,
the beari ng presses the di aphragm spri ng fi ngers
i nward on the ful crums. Thi s acti on moves the pres-
sure pl ate rearward rel i evi ng cl amp force on the di sc.
The cl utch di sc i s di sengaged and freewheel i ng at
thi s poi nt.
CLUTCH RELEASE BEARING
DESCRIPTION
A conventi onal rel ease beari ng (Fi g. 6) i s used to
engage and di sengage the cl utch pressure pl ate
assembl y. The cl utch rel ease beari ng i s mounted on
the transmi ssi on front beari ng retai ner. The beari ng
i s attached to the rel ease fork, whi ch moves the bear-
i ng i nto contact wi th the cl utch cover di aphragm
spri ng.
OPERATION
The rel ease beari ng i s operated by a rel ease fork i n
the cl utch housi ng. Sl ave cyl i nder force causes the
rel ease l ever to move the rel ease beari ng i nto contact
wi th the di aphragm spri ng. As addi ti onal force i s
appl i ed, the beari ng presses the di aphragm spri ng
fi ngers i nward on the ful crums. Thi s acti on moves
the pressure pl ate rearward rel i evi ng cl amp force on
the di sc. Rel easi ng pedal pressure removes cl utch
hydraul i c pressure. The rel ease beari ng then moves
away from the di aphragm spri ng whi ch al l ows the
pressure pl ate to exert cl ampi ng force on the cl utch
di sc.
Fig. 4 Clutch Disc-Typical
1 FACING MATERIAL
2 DAMPER SPRINGS
3 HUB
Fig. 5 Clutch Pressure Plate-Typical
1 COVER
2 RELEASE FINGERS
3 PRESSURE PLATE
Fig. 6 Clutch Release Bearing
1 RELEASE BEARING
2 RELEASE FORK
XJ CLUTCH 6 - 3
HYDRAULIC CLUTCH LINKAGE
DESCRIPTION
The hydraul i c l i nkage consi sts of a cl utch master
cyl i nder wi th i ntegral reservoi r, a cl utch sl ave cyl i n-
der and an i nterconnecti ng fl ui d l i ne (Fi g. 7).
The cl utch master cyl i nder push rod i s connected to
the cl utch pedal . The sl ave cyl i nder push rod i s con-
nected to the cl utch rel ease fork. The master cyl i nder i s
mounted on the dri ver si de of the dash panel adjacent
to the brake master cyl i nder and booster assembl y.
OPERATION
The cl utch l i nkage uses hydraul i c pressure to oper-
ate the cl utch. Depressi ng the cl utch pedal devel ops
fl ui d pressure i n the cl utch master cyl i nder. Thi s
pressure i s transmi tted to the sl ave cyl i nder through
a connecti ng l i ne. I n turn, the sl ave cyl i nder operates
the cl utch rel ease l ever.
Sl ave cyl i nder force causes the rel ease l ever to
move the rel ease beari ng i nto contact wi th the di a-
phragm spri ng. As addi ti onal force i s appl i ed, the
beari ng presses the di aphragm spri ng fi ngers i nward
on the ful crums. Thi s acti on moves the pressure
pl ate rearward rel i evi ng cl amp force on the di sc.
SAFETY PRECAUTIONS
WARNING: EXERCISE CARE WHEN SERVICING
CLUTCH COMPONENTS. FACTORY INSTALLED
CLUTCH DISCS DO NOT CONTAIN ASBESTOS
FIBERS. DUST AND DIRT ON CLUTCH PARTS MAY
CONTAIN ASBESTOS FIBERS FROM AFTERMARKET
COMPONENTS. BREATHING EXCESSIVE CONCEN-
TRATIONS OF THESE FIBERS CAN CAUSE SERIOUS
BODILY HARM. WEAR A RESPIRATOR DURING SER-
VICE AND NEVER CLEAN CLUTCH COMPONENTS
WITH COMPRESSED AIR OR WITH A DRY BRUSH.
EITHER CLEAN THE COMPONENTS WITH A WATER
DAMPENED RAGS OR USE A VACUUM CLEANER
SPECIFICALLY DESIGNED FOR REMOVING ASBES-
TOS FIBERS AND DUST. DO NOT CREATE DUST BY
SANDING A CLUTCH DISC. REPLACE THE DISC IF
THE FRICTION MATERIAL IS DAMAGED OR CON-
TAMINATED. DISPOSE OF ALL DUST AND DIRT CON-
TAINING ASBESTOS FIBERS IN SEALED BAGS OR
CONTAINERS. THIS WILL HELP MINIMIZE EXPOSURE
TO YOURSELF AND TO OTHERS. FOLLOW ALL REC-
OMMENDED SAFETY PRACTICES PRESCRIBED BY
THE OCCUPATIONAL SAFETY AND HEALTH ADMIN-
ISTRATION (OSHA) AND THE ENVIRONMENTAL
SAFETY AGENCY (EPA), FOR THE HANDLING AND
DISPOSAL OF PRODUCTS CONTAINING ASBESTOS.
INSTALLATION METHODS AND PARTS USAGE
Di storti on of cl utch components duri ng i nstal l ati on
and the use of non-standard components are common
causes of cl utch mal functi on.
I mproper cl utch cover bol t ti ghteni ng can di stort
the cover. The usual resul t i s cl utch grab, chatter
and rapi d wear. Ti ghten the cover bol ts as descri bed
i n Removal and I nstal l ati on secti on.
An i mproperl y seated fl ywheel and/or cl utch hous-
i ng are addi ti onal causes of cl utch fai l ure. I mproper
seati ng wi l l produce mi sal i gnment and addi ti onal
cl utch probl ems.
The use of non-standard or l ow qual i ty parts wi l l
al so l ead to probl ems and wear. Use recommended
factory qual i ty parts to avoi d comebacks.
A cocked pi l ot beari ng i s another cause of cl utch
noi se, drag, hard shi fti ng, and rapi d beari ng wear.
Al ways use an al i gnment tool to i nstal l a new bear-
i ng. Thi s practi ce hel ps avoi d cocki ng the beari ng
CLUTCH DIAGNOSTIC INFORMATION
Unl ess the cause of a cl utch probl em i s obvi ous, accu-
rate probl em di agnosi s wi l l usual l y requi re a road test to
confi rm a probl em. Component i nspecti on (Fi g. 8) wi l l
then be requi red to determi ne the actual probl em cause.
Duri ng a road test, dri ve the vehi cl e at normal
speeds. Shi ft the transmi ssi on through al l gear
ranges and observe cl utch acti on. I f chatter, grab,
sl i p, or i mproper rel ease i s experi enced, remove and
i nspect the cl utch components. However, i f the prob-
l em i s noi se or hard shi fti ng, further di agnosi s may
be needed as the transmi ssi on or another dri vel i ne
component may be at faul t. Careful observati on dur-
i ng the test wi l l hel p narrow the probl em area.
Fig. 7 Clutch Master Cylinder
1 CAP
2 FILL LINE
4 RESERVOIR
6 - 4 CLUTCH XJ
Fig. 8 Clutch Components And Inspection
XJ CLUTCH 6 - 5
CLUTCH CONTAMINATION
Fl ui d contami nati on i s a frequent cause of cl utch
mal functi ons. Oi l , water, or cl utch fl ui d on the cl utch
di sc and pressure pl ate surfaces wi l l cause chatter,
sl i p and grab.
Duri ng i nspecti on, note i f any components are con-
tami nated wi th oi l , hydraul i c fl ui d, or water/road
spl ash.
Oi l contami nati on i ndi cates a l eak at ei ther the
rear mai n seal or transmi ssi on i nput shaft. Oi l l eak-
age produces a resi due of oi l on the housi ng i nteri or
and on the cl utch cover and fl ywheel . Heat bui l dup
caused by sl i ppage between the cover, di sc and fl y-
wheel , can someti mes bake the oi l resi due onto the
components. The gl aze-l i ke resi due ranges i n col or
from amber to bl ack.
Road spl ash contami nati on means di rt/water i s
enteri ng the cl utch housi ng due to l oose bol ts, hous-
i ng cracks, or through hydraul i c l i ne openi ngs. Dri v-
i ng through deep water puddl es can force water/road
spl ash i nto the housi ng through such openi ngs.
Cl utch fl ui d l eaks are usual l y from damaged sl ave
cyl i nder push rod seal s. Thi s type of l eak can onl y be
confi rmed by vi sual i nspecti on.
ENGAGEMENT
Cl utch rel ease or engagement probl ems are caused
by wear, or damage to one or more cl utch compo-
nents. A vi sual i nspecti on of the rel ease components
wi l l usual l y reveal the probl em part.
Rel ease probl ems can resul t i n hard shi fti ng and
noi se. I tems to l ook for are: l eaks at the cl utch cyl i n-
ders and i nterconnecti ng l i ne; l oose sl ave cyl i nder
bol ts; worn/l oose rel ease fork and pi vot stud; dam-
aged rel ease beari ng; and a worn cl utch di sc, or pres-
sure pl ate.
Normal condensati on i n vehi cl es that are stored or
out of servi ce for l ong peri ods of ti me can generate
enough corrosi on to make the di sc sti ck to the fl y-
wheel , or pressure pl ate. I f thi s condi ti on i s experi -
enced, correcti on onl y requi res that the di sc be
l oosened manual l y through the i nspecti on pl ate open-
i ng.
Engagement probl ems usual l y resul t i n sl i p, chat-
ter/shudder, and noi sy operati on. The pri mary causes
are cl utch di sc contami nati on; cl utch di sc wear; mi s-
al i gnment, or di storti on; fl ywheel damage; or a com-
bi nati on of the foregoi ng. A vi sual i nspecti on i s
requi red to determi ne the part actual l y causi ng the
probl em.
CLUTCH MISALIGNMENT
Cl utch components must be i n proper al i gnment
wi th the crankshaft and transmi ssi on i nput shaft.
Mi sal i gnment caused by excessi ve runout or warpage
of any cl utch component wi l l cause grab, chatter and
i mproper cl utch rel ease.
CLUTCH HOUSING MISALIGNMENT
Cl utch housi ng al i gnment i s i mportant to proper
cl utch operati on. The housi ng mai ntai ns al i gnment
between the crankshaft and transmi ssi on i nput
shaft. Mi sal i gnment can cause cl utch noi se, hard
shi fti ng, i ncompl ete rel ease and chatter. I t can al so
resul t i n premature wear of the pi l ot beari ng, cover
rel ease fi ngers and cl utch di sc. I n severe cases, mi s-
al i gnment can al so cause premature wear of the
transmi ssi on i nput shaft and front beari ng.
Housi ng mi sal i gnment i s general l y caused by
i ncorrect seati ng on the engi ne or transmi ssi on, l oose
housi ng bol ts, mi ssi ng al i gnment dowel s, or housi ng
damage. I nfrequentl y, mi sal i gnment may al so be
caused by housi ng mounti ng surfaces that are not
compl etel y paral l el . Mi sal i gnment can be corrected
wi th shi ms.
CLUTCH FLYWHEEL RUNOUT
Check fl ywheel runout whenever mi sal i gnment i s
suspected. Fl ywheel runout shoul d not exceed 0.08
mm (0.003 i n.). Measure runout at the outer edge of
the fl ywheel face wi th a di al i ndi cator. Mount the
i ndi cator on a stud i nstal l ed i n pl ace of one of the fl y-
wheel bol ts.
Common causes of runout are:
heat warpage
i mproper machi ni ng
i ncorrect bol t ti ghteni ng
i mproper seati ng on crankshaft fl ange shoul der
forei gn materi al on crankshaft fl ange
wheel cl utch surface i s machi ned to a uni que contour
and machi ni ng wi l l negate thi s feature. However,
mi nor fl ywheel scori ng can be cl eaned up by hand
wi th 180 gri t emery, or wi th surface gri ndi ng equi p-
ment. Remove onl y enough materi al to reduce scor-
i ng (approxi matel y 0.001 - 0.003 i n.). Heavy stock
removal i s not recommended. Repl ace the fl ywheel
i f scori ng i s severe and deeper than 0.076 mm (0.003
i n.). Excessi ve stock removal can resul t i n fl ywheel
cracki ng or warpage after i nstal l ati on; i t can al so
weaken the fl ywheel and i nterfere wi th proper cl utch
rel ease.
cock the fl ywheel causi ng excessi ve runout. Use new
bol ts when remounti ng a fl ywheel and secure the
bol ts wi th Mopar Lock And Seal . Ti ghten fl ywheel
bol ts to speci fi ed torque onl y. Overti ghteni ng can di s-
tort the fl ywheel hub causi ng runout.
6 - 6 CLUTCH XJ
CLUTCH COVER AND DISC RUNOUT
Check the cl utch di sc before i nstal l ati on. Axi al
(face) runout of a new di sc shoul d not exceed 0.50
mm (0.020 i n.). Measure runout about 6 mm (1/4 i n.)
from the outer edge of the di sc faci ng. Obtai n
another di sc i f runout i s excessi ve.
Check condi ti on of the cl utch before i nstal l ati on. A
warped cover or di aphragm spri ng wi l l cause grab
and i ncompl ete rel ease or engagement. Be careful
when handl i ng the cover and di sc. I mpact can di stort
the cover, di aphragm spri ng, rel ease fi ngers and the
hub of the cl utch di sc.
Use an al i gnment tool when posi ti oni ng the di sc on
the fl ywheel . The tool prevents acci dental mi sal i gn-
ment whi ch coul d resul t i n cover di storti on and di sc
damage.
A frequent cause of cl utch cover di storti on (and
consequent mi sal i gnment) i s i mproper bol t ti ghten-
i ng.
CLUTCH DIAGNOSIS CHARTS
The cl utch i nspecti on chart (Fi g. 8) outl i nes i tems
to be checked before and duri ng cl utch i nstal l ati on.
Use the chart as a check l i st to hel p avoi d overl ook-
i ng potenti al probl em sources duri ng servi ce opera-
ti ons.
The di agnosi s charts descri be common cl utch prob-
l ems, causes and correcti on. Faul t condi ti ons are
l i sted at the top of each chart. Condi ti ons, causes and
correcti ve acti on are outl i ned i n the i ndi cated col -
umns.
The charts are provi ded as a conveni ent reference
when di agnosi ng faul ty cl utch operati on.
DIAGNOSIS CHART
Disc facing worn out 1. Normal wear. 1. Replace cover and disc.
2. Driver frequently rides (slips) the
clutch. Results in rapid overheating
and wear.
3. Insufficient clutch cover
diaphragm spring tension.
Clutch disc facing contaminated with
oil, grease, or clutch fluid.
1. Leak at rear main engine seal or
transmission input shaft seal.
1. Replace appropriate seal.
2. Excessive amount of grease
applied to the input shaft splines.
2. Remove grease and apply the
correct amount of grease.
3. Road splash, water entering
housing.
3. Replace clutch disc. Clean clutch
cover and reuse if in good condition.
4. Slave cylinder leaking. 4. Replace hydraulic clutch linkage.
Clutch is running partially
disengaged.
1. Release bearing sticking or
binding and does not return to the
normal running position.
1. Verify failure. Replace the release
bearing and transmission front
bearing retainer as necessary.
Flywheel below minimum thickness
specification.
1. Improper flywheel machining.
Flywheel has excessive taper or
excessive material removal.
1. Replace flywheel.
Clutch disc, cover and/or diaphragm
spring warped or distorted.
1. Rough handling. Impact bent
cover, spring, or disc.
1. Replace disc or cover as
necessary.
2. Improper bolt tightening
procedure.
2. Tighten clutch cover using proper
procedure.
XJ CLUTCH 6 - 7
Facing on flywheel side of disc torn,
gouged, or worn.
1. Flywheel surface scored or
nicked.
2. Correct surface condition if
possible. Replace flywheel and disc
as necessary.
2. Clutch disc sticking or binding on
transmission input shaft.
2. Inspect components and
correct/replace as necessary.
Clutch disc facing burnt. Flywheel
and cover pressure plate surfaces
heavily glazed.
1. Frequent operation under high
loads or hard acceleration
conditions.
problem cause.
2. Driver frequently rides (slips)
clutch. Results in rapid wear and
overheating of disc and cover.
problem cause.
Clutch disc binds on input shaft
splines.
1. Clutch disc hub splines damaged
1. Clean, smooth, and lubricate hub
splines if possible. Replace disc if
necessary.
2. Input shaft splines rough,
damaged, or corroded.
2. Clean, smooth, and lubricate
shaft splines if possible. Replace
input shaft if necessary.
Clutch disc rusted to flywheel and/or
pressure plate.
1. Clutch not used for and extended
period of time (e.g. long term
vehicle storage).
1. Sand rusted surfaces with 180
grit sanding paper. Replace clutch
cover and flywheel if necessary.
Pilot bearing seized, loose, or rollers
are worn.
1. Bearing cocked during
installation.
1. Install and lubricate a new
bearing.
2. Bearing defective. 2. Install and lubricate a new
bearing.
3. Bearing not lubricated. 3. Install and lubricate a new
bearing.
4. Clutch misalignment. 4. Inspect clutch and correct as
necessary. Install and lubricate a
new bearing.
Clutch will not disengage properly. 1. Low clutch fluid level. 1. Replace hydraulic linkage
assembly.
2. Clutch cover loose. 2. Follow proper bolt tightening
procedure.
3. Clutch disc bent or distorted. 3. Replace clutch disc.
4. Clutch cover diaphragm spring
bent or warped.
4. Replace clutch cover.
5. Clutch disc installed backwards. 5. Remove and install clutch disc
correctly.
6. Release fork bent or fork pivot
loose or damaged.
6. Replace fork or pivot as
necessary.
7. Clutch master or slave cylinder
failure.
7. Replace hydraulic linkage
assembly.
6 - 8 CLUTCH XJ
Clutch pedal squeak. 1. Pivot pin loose. 1. Tighten pivot pin if possible.
Replace clutch pedal if necessary.
2. Master cylinder bushing not
lubricated.
2. Lubricate master cylinder
bushing.
3. Pedal bushings worn out or
cracked.
3. Replace and lubricate bushings.
Clutch master or slave cylinder
plunger dragging andr binding
1. Master or slave cylinder
components worn or corroded.
1. Replace clutch hydraulic linkage
assembly.
Release bearing is noisy. 1. Release bearing defective or
damaged.
1. Replace release bearing.
Contact surface of release bearing
damaged.
1. Clutch cover incorrect or release
1. Replace clutch cover and release
bearing.
2. Release bearing defective or
damaged.
2. Replace the release bearing.
3. Release bearing misaligned. 3. Check and correct runout of
clutch components. Check front
bearing sleeve for damage/
alignment. Repair as necessary.
Partial engagement of clutch disc.
One side of disc is worn and the
other side is glazed and lightly
worn.
1. Clutch pressure plate position
incorrect.
2. Clutch cover, spring, or release
3. Clutch disc damaged or
distorted.
2. Replace clutch disc.
4. Clutch misalignment. 4. Check alignment and runout of
flywheel, disc, pressure plate, andr
clutch housing. Correct as
necessary.
SERVICE PROCEDURES
CLUTCH COMPONENT LUBRICATION
Proper cl utch component l ubri cati on i s i mportant
to sati sfactory operati on. Usi ng the correct l ubri cant
and not over l ubri cati ng are equal l y i mportant. Appl y
recommended l ubri cant spari ngl y to avoi d di sc and
pressure pl ate contami nati on.
Cl utch and transmi ssi on components requi ri ng
l ubri cati on are:
Pi l ot beari ng.
Rel ease l ever pi vot bal l stud.
Rel ease l ever contact surfaces.
Rel ease beari ng bore.
Cl utch di sc hub spl i nes.
Cl utch pedal pi vot shaft bore.
Cl utch pedal bushi ngs.
I nput shaft spl i nes.
I nput shaft pi l ot hub.
Transmi ssi on front beari ng retai ner sl i de sur-
face.
NOTE: Never apply grease to any part of the clutch
cover, or disc.
RECOMMENDED LUBRICANTS
Use Mopar mul ti -purpose grease for the cl utch
pedal bushi ngs and pi vot shaft. Use Mopar hi gh
temperature grease (or equi val ent) for al l other l ubri -
cati on requi rements. Appl y recommended amounts
and do not over l ubri cate.
CLUTCH LINKAGE FLUID
I f i nspecti on or di agnosi s i ndi cates addi ti onal fl ui d
may be needed, use Mopar brake fl ui d, or an equi v-
XJ CLUTCH 6 - 9
al ent meeti ng standards SAE J1703 and DOT 3. Do
not use any other type of fl ui d.
CLUTCH FLUID LEVEL
The cl utch fl ui d reservoi r, master cyl i nder, sl ave
cyl i nder and fl ui d l i nes are pre-fi l l ed wi th fl ui d at
the factory duri ng assembl y operati ons.
The hydraul i c system shoul d not requi re addi ti onal
fl ui d under normal ci rcumstances. I n fact, the reser-
voir fluid level will actually increase as normal
clutch wear occurs. For this reason, it is impor-
tant to avoid overfilling, or removing fluid from
the reservoir.
Cl utch fl ui d l evel i s checked at the master cyl i nder
reservoi r (Fi g. 9). An i ndi cator ri ng i s provi ded on the
outsi de ri m of the reservoi r.
Be sure to wi pe the reservoi r and cover cl ean
before removi ng the cover. Thi s wi l l avoi d havi ng di rt
or forei gn materi al fal l i nto the reservoi r duri ng a
fl ui d l evel check.
FLYWHEEL
I nspect the fl ywheel whenever the cl utch di sc,
cover and housi ng are removed for servi ce. Check
condi ti on of the fl ywheel face, hub, ri ng gear teeth,
and fl ywheel bol ts.
Mi nor scratches, burrs, or gl azi ng on the fl ywheel
face can be reduced wi th 180 gri t emery cl oth. How-
ever, the fl ywheel shoul d be repl aced i f the di sc con-
tact surface i s severel y scored, heat checked, cracked,
or obvi ousl y worn.
wheel surface i s manufactured wi th a uni que contour
that woul d be negated by machi ni ng. However,
cl eanup of mi nor fl ywheel scori ng can be performed
by hand wi th 180 gri t emery, or wi th surface gri nd-
i ng equi pment. Repl ace the fl ywheel i f scori ng i s
deeper than 0.0762 mm (0.003 i n.).
Heavy stock removal by gri ndi ng i s not recom-
mended. Excessi ve stock removal can resul t i n fl y-
wheel cracki ng or warpage after i nstal l ati on. I t can
al so weaken the fl ywheel and i nterfere wi th proper
cl utch rel ease.
Check fl ywheel runout i f mi sal i gnment i s sus-
pected. Runout shoul d not exceed 0.08 mm (0.003
i n.). Measure runout at the outer edge of the fl y-
wheel face wi th a di al i ndi cator. Mount the di al i ndi -
cator on a stud i nstal l ed i n pl ace of one of the cl utch
housi ng attachi ng bol ts.
cock the fl ywheel causi ng excessi ve runout.
Check condi ti on of the fl ywheel hub and attachi ng
bol ts. Repl ace the fl ywheel i f the hub exhi bi ts cracks
i n the area of the attachi ng bol t hol es.
I nstal l new attachi ng bol ts whenever the fl ywheel
i s repl aced and use Mopar Lock N Seal , or Locti te
242 on the repl acement bol t threads.
Recommended fl ywheel bol t torques are:
I nspect the teeth on the starter ri ng gear. If the
teeth are worn or damaged, the flywheel should
be replaced as an assembly. This is the recom-
mended and preferred method of repair.
I n cases where a new fl ywheel i s not readi l y avai l -
abl e, a repl acement ri ng gear can be i nstal l ed. How-
ever, the fol l owi ng precauti ons must be observed to
avoi d damagi ng the fl ywheel and repl acement gear.
(1) Mark posi ti on of the ol d gear for al i gnment ref-
erence on the fl ywheel . Use a scri ber for thi s pur-
pose.
(2) Wear protecti ve goggl es or approved safety
gl asses. Al so wear heat resi stent gl oves when han-
dl i ng a heated ri ng gear.
(3) Remove the ol d gear by cutti ng most of the way
through i t (at one poi nt) wi th an abrasi ve cut-off
wheel . Then compl ete removal wi th a col d chi sel or
punch.
(4) The ri ng gear i s a shri nk fi t on the fl ywheel .
Thi s means the gear must be expanded by heati ng i n
order to i nstal l i t. The method of heating and
expanding the gear is extremely important.
Every surface of the gear must be heated at the same
ti me to produce uni form expansi on. An oven or si mi -
l ar encl osed heati ng devi ce must be used. Tempera-
ture requi red for uni form expansi on i s approxi matel y
375 F.
Fig. 9 Clutch Master Cylinder Reservoir And Cap
1 CAP
2 FILL LINE
4 RESERVOIR
6 - 10 CLUTCH XJ
CAUTION: Do not use an oxy/acetylene torch to
remove the old gear, or to heat and expand a new
gear. The high temperature of the torch flame can
cause localized heating that will damage the fly-
wheel. In addition, using the torch to heat a replace-
ment gear will cause uneven heating and
expansion. The torch flame can also anneal the
gear teeth resulting in rapid wear and damage after
installation.
(5) The heated gear must be i nstal l ed evenl y to
avoi d mi sal i gnment or di storti on. A shop press and
sui tabl e press pl ates shoul d be used to i nstal l the
gear i f at al l possi bl e.
(6) Be sure to wear eye and hand protecti on. Heat
resi stent gl oves and safety goggl es are needed for
personal safety. Al so use metal tongs, vi se gri ps, or
si mi l ar tool s to posi ti on the gear as necessary for
i nstal l ati on.
(7) Al l ow the fl ywheel and ri ng gear to cool down
before i nstal l ati on. Set the assembl y on a workbench
and l et i t cool i n normal shop ai r.
CAUTION: Do not use water, or compressed air to
cool the flywheel. The rapid cooling produced by
water or compressed air can distort, or crack the
gear and flywheel.
CLUTCH COVER AND DISC
REMOVAL
(1) Remove transmi ssi on. Refer to procedures i n
Group 21.
(2) I f ori gi nal cl utch cover wi l l be rei nstal l ed, mark
posi ti on of cover on fl ywheel for assembl y reference.
Use pai nt or a scri ber for thi s purpose.
(3) I f cl utch cover i s to be repl aced, cover bol ts can
be removed i n any sequence. However, i f ori gi nal
cover wi l l be rei nstal l ed, l oosen cover bol ts evenl y
and i n rotati on to rel i eve spri ng tensi on equal l y. Thi s
i s necessary to avoi d warpi ng cover.
(4) Remove cover bol ts and remove cover and di sc
(Fi g. 10).
INSTALLATION
(1) Li ghtl y scuff sand fl ywheel face wi th 180 gri t
emery cl oth. Then cl ean surface wi th a wax and
grease remover.
(2) Lubri cate pi l ot beari ng wi th Mopar hi gh tem-
perature beari ng grease.
(3) Check runout and free operati on of new cl utch
di sc as fol l ows:
(a) Sl i de di sc onto transmi ssi on i nput shaft
spl i nes. Di sc shoul d sl i de freel y on spl i nes.
(b) Leave di sc on shaft and check face runout
wi th di al i ndi cator. Check runout at di sc hub and
about 6 mm (1/4 i n.) from outer edge of faci ng.
(c) Face runout shoul d not exceed 0.5 mm (0.020
i n.). Obtai n another cl utch di sc i f runout exceeds
thi s l i mi t.
(4) Posi ti on cl utch di sc on fl ywheel . Be sure si de of
di sc marked fl ywheel si de i s posi ti oned agai nst fl y-
wheel (Fi g. 10). I f di sc i s not marked, be sure fl at
si de of di sc hub i s toward fl ywheel .
(5) I nspect condi ti on of pressure pl ate surface of
cl utch cover (Fi g. 10). Repl ace cover i f thi s surface i s
worn, heat checked, cracked, or scored.
(6) I nsert cl utch al i gnment tool i n cl utch di sc (Fi g.
11).
(7) I nsert al i gnment tool i n pi l ot beari ng and posi -
ti on di sc on fl ywheel . Be sure di sc hub i s posi ti oned
correctl y. Si de of hub marked Fl ywheel Si de shoul d
face fl ywheel (Fi g. 10). I f di sc i s not marked, pl ace
fl at si de of di sc agai nst fl ywheel .
(8) Posi ti on cl utch cover over di sc and on fl ywheel
(Fi g. 11).
(9) I nstal l cl utch cover bol ts fi nger ti ght.
(10) Ti ghten cover bol ts evenl y and i n rotati on a
few threads at a ti me. Cover bolts must be tight-
ened evenly and to specified torque to avoid
distorting cover. Tightening torques are 31 Nm
(23 ft. lbs.) on 2.5L engines and 50Nm(37ft. lbs.)
on 4.0 L engines.
(a) Start al l 6 bol ts by hand.
(b) Ti ghten 3 pi l ot hol e bol ts 3/4s of the way
(any sequence).
Fig. 10 Clutch Disc And Pressure Plate Inspection
1 DISC
2 INSPECT THIS SURFACE
3 CLUTCH COVER
4 FLYWHEEL SIDE STAMPED ON THIS SURFACE
XJ CLUTCH 6 - 11
(c) Starti ng 180 degrees from the l ast pi l ot bol t,
ti ghten 3 l arge hol e bol ts 3/4s of the way (any
sequence).
(d) Ti ghten 3 pi l ot hol e bol ts al l the way (any
sequence).
(e) Starti ng 180 degrees from l ast pi l ot bol t,
ti ghten 3 l arge bol ts al l the way (any sequence).
(11) Appl y l i ght coat of Mopar hi gh temperature
beari ng grease to cl utch di sc hub and spl i nes of
transmi ssi on i nput shaft. Do not over lubricate
shaft splines. This will result in grease contam-
ination of disc.
RELEASE BEARING
REMOVAL
(1) Remove transmi ssi on.
(2) Di sconnect rel ease beari ng from rel ease l ever
and remove beari ng (Fi g. 12).
(3) I nspect beari ng sl i de surface of transmi ssi on
front beari ng retai ner. Repl ace retai ner i f sl i de sur-
face i s scored, worn, or cracked.
(4) I nspect rel ease fork and fork pi vot. Be sure
pi vot i s secure and i n good condi ti on. Be sure fork i s
not di storted or worn. Repl ace rel ease fork retai ner
spri ng i f bent or damaged.
INSTALLATION
(1) Lubri cate crankshaft pi l ot beari ng wi th Mopar
hi gh temperature beari ng grease. Appl y grease to
end of l ong shank, smal l di ameter fl at bl ade screw-
dri ver. Then i nsert tool through cl utch di sc hub to
reach beari ng.
(2) Lubri cate i nput shaft spl i nes, beari ng retai ner
sl i de surface, fork pi vot and rel ease fork pi vot surface
wi th Mopar hi gh temperature grease.
(3) I nstal l new rel ease beari ng. Be sure beari ng i s
properl y secured to rel ease fork.
PILOT BEARING
REMOVAL
(1) Remove transmi ssi on. Refer to Group 21,
Transmi ssi on and Transfer Case, for proper proce-
dures.
(2) Remove cl utch cover and di sc.
(3) Use a sui tabl e bl i nd hol e pul l er to remove pi l ot
beari ng.
INSTALLATION
(1) Cl ean beari ng bore wi th sol vent and wi pe dry
wi th shop towel .
(2) Lubri cate new pi l ot beari ng wi th Mopar hi gh
temperature grease.
(3) Posi ti on and start new beari ng i n beari ng bore
by hand. Note that pi l ot beari ng has seal at one end.
I nstal l beari ng so seal i s faci ng outward toward
transmi ssi on.
(4) Seat pi l ot beari ng wi th cl utch al i gnment tool
(Fi g. 13). Keep beari ng strai ght duri ng i nstal l ati on.
Do not al l ow beari ng to become cocked. Tap beari ng
i nto pl ace unti l fl ush wi th edge of beari ng bore. Do
not recess beari ng.
(5) I nstal l transmi ssi on. Refer to Group 21, Trans-
mi ssi on and Transfer Case, for proper procedures.
Fig. 11 Typical Method Of Aligning Clutch Disc
1 FLYWHEEL
2 CLUTCH COVER AND DISC
3 CLUTCH DISC ALIGNMENT TOOL
Fig. 12 Release Bearing Attachment
1 RETURN SPRING
2 PIVOT BALL STUD
3 CLUTCH HOUSING
4 RELEASE FORK
5 RELEASE BEARING
6 - 12 CLUTCH XJ
CLUTCH HOUSING
The cl utch housi ng i s removabl e and can be
repl aced when the transmi ssi on i s out of the vehi cl e.
The bol ts attachi ng the housi ng to the transmi s-
si on case are l ocated i nsi de the housi ng (Fi g. 14).
Recommended ti ghteni ng torque for the cl utch hous-
i ng-to-transmi ssi on bol ts i s 46 Nm (34 ft. l bs.).
NOTE: Be sure the transmission and housing mat-
ing surfaces are clean before installing an original,
or replacement clutch housing. Dirt/foreign material
trapped between the housing and transmission will
cause misalignment. If misalignment is severe
enough, the result will be clutch drag, incomplete
release and hard shifting.
CLUTCH HYDRAULIC LINKAGE
The cl utch master cyl i nder, sl ave cyl i nder and con-
necti ng l i ne are servi ced as an assembl y onl y. The
l i nkage components cannot be overhaul ed or servi ced
separatel y. The cyl i nders and connecti ng l i ne are
seal ed uni ts. Al so note that removal /i nstal l ati on pro-
cedures for ri ght and l eft hand dri ve model s are basi -
cal l y the same. Onl y master cyl i nder l ocati on i s
di fferent.
REMOVAL
(2) Remove fasteners attachi ng sl ave cyl i nder to
cl utch housi ng.
(3) Remove sl ave cyl i nder from cl utch housi ng
(Fi g. 15).
(4) Di sengage cl utch fl ui d l i ne from body cl i ps, i f
appl i cabl e.
(6) Veri fy that cap on cl utch master cyl i nder reser-
voi r i s ti ght. Thi s i s necessary to avoi d spi l l i ng fl ui d
duri ng removal .
(7) Remove cl utch master cyl i nder attachi ng nuts
(Fi g. 16) or (Fi g. 17).
(8) Di sengage captured bushi ng on cl utch master
cyl i nder actuator from pi vot pi n on pedal arm (Fi g.
18).
(9) Sl i de actuator off pi vot pi n.
(10) Di sconnect cl utch i nterl ock safety swi tch
wi res.
(11) Remove cl utch hydraul i c l i nkage through
Fig. 13 Typical Method Of Installing Pilot Bearing
1 PILOT BEARING
2 ALIGNMENT TOOL
3 BEARING SEAL MUST FACE TRANSMISSION
Fig. 14 Clutch Housing Attachment
2 CLUTCH HOUSING
3 TRANSMISSION
XJ CLUTCH 6 - 13
INSTALLATION
(1) Be sure reservoi r cover on cl utch master cyl i n-
der i s ti ght to avoi d spi l l s.
(2) Posi ti on cl utch l i nkage components i n vehi cl e.
Work connecti ng l i ne and sl ave cyl i nder downward
past engi ne and adjacent to cl utch housi ng (Fi g. 16)
or (Fi g. 17).
(3) Posi ti on cl utch master cyl i nder on dash panel
(Fi g. 16) or (Fi g. 17).
(4) Attach cl utch master cyl i nder actuator to pi vot
pi n on cl utch pedal (Fi g. 18).
(5) I nstal l and ti ghten cl utch master cyl i nder
attachi ng nuts to 38 Nm (28 ft. l bs.) torque.
(7) I nsert sl ave cyl i nder push rod through cl utch
housi ng openi ng and i nto rel ease l ever. Be sure cap
on end of rod i s securel y engaged i n l ever. Check thi s
before i nstal l i ng cyl i nder attachi ng nuts.
(8) I nstal l and ti ghten sl ave cyl i nder attachi ng
Fig. 16 Left Hand Drive Clutch Master Cylinder
Fig. 17 Right Hand Drive Clutch Master Cylinder
Fig. 18 Clutch Pedal Attachment
6 - 14 CLUTCH XJ
(9) Secure cl utch fl ui d l i ne i n body and transmi s-
si on cl i ps.
(11) Connect cl utch i nterl ock safety swi tch wi res.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Bol t/Nut, cl utch cyl . mount . . . 23 Nm (200 i n. l bs)
Bol t, cl utch housi ng M12 . . . . . . 75 Nm (55 ft. l bs)
Bol t, cl utch housi ng 3/8 . . . . . . . 37 Nm (27 ft. l bs)
Bol t, cl utch housi ng 7/16 . . . . . . 58 Nm (43 ft. l bs)
Bol t, cl utch housi ng/trans. . . . . . 46 Nm (34 ft. l bs)
Bol t, dust shi el d M8 . . . . . . . . . . 8 Nm (72 i n. l bs)
Bol t, dust shi el d l ower . . . . . . . . 50 Nm (37 ft. l bs)
Bol t, X-member/frame . . . . . . . . 41 Nm (30 ft. l bs)
Bol t, X-member/rear support . . . 45 Nm (33 ft. l bs.)
Bol ts, fl ywheel 4.0 L . . . . . . . . 142 Nm (105 ft. l bs)
Bol ts, fl ywheel 2.5 L . . . . . . . . . 95 Nm (70 ft. l bs)
Bol t, starter motor . . . . . . . . . . . 45 Nm (33 ft. l bs)
Bol ts, U-joi nts . . . . . . . . . . . . . 19 Nm (170 i n. l bs.)
XJ CLUTCH 6 - 15
COOLING SYSTEM
TABLE OF CONTENTS
page page
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
AUTOMATIC TRANSMISSION OIL COOLER. . . . . 2
COOLANT RESERVE/OVERFLOW SYSTEM . . . . . 2
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . . . 3
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 4
THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
RADIATOR PRESSURE CAP. . . . . . . . . . . . . . . . . 5
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HOSE CLAMPS. . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VISCOUS FAN DRIVE. . . . . . . . . . . . . . . . . . . . . . 7
ELECTRIC COOLING FAN. . . . . . . . . . . . . . . . . . . 8
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . . . 9
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 9
ACCESSORY DRIVE BELT DIAGNOSIS. . . . . . . . . 9
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . . 11
RADIATOR COOLANT FLOW CHECK . . . . . . . . . 17
COOLING SYSTEMTESTING FOR LEAKS. . . . 17
VISCOUS FAN DRIVE. . . . . . . . . . . . . . . . . . . . . 19
ELECTRIC COOLING FAN. . . . . . . . . . . . . . . . . . 19
RADIATOR CAP-TO-FILLER NECK
SEALPRESSURE RELIEF CHECK. . . . . . . . . 20
RADIATOR CAPPRESSURE TESTING. . . . . . . 20
COOLANTLOW LEVEL AERATION . . . . . . . . . 21
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE PROCEDURES
COOLANTROUTINE LEVEL CHECK. . . . . . . . . 21
COOLANTADDING ADDITIONAL. . . . . . . . . . . 21
COOLANTLEVEL CHECK. . . . . . . . . . . . . . . . . 21
COOLING SYSTEMDRAINING AND
FILLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COOLING SYSTEMREVERSE FLUSHING . . . . 22
TRANSMISSION OIL COOLERS . . . . . . . . . . . . . 23
COOLANT RESERVE TANK. . . . . . . . . . . . . . . . . 23
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 24
THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
RADIATOR2.5L . . . . . . . . . . . . . . . . . . . . . . . . 29
RADIATOR4.0L . . . . . . . . . . . . . . . . . . . . . . . . 31
ELECTRIC COOLING FAN2.5L . . . . . . . . . . . . 33
ELECTRIC COOLING FAN4.0L . . . . . . . . . . . . 34
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . . . . . . 35
ENGINE ACCESSORY DRIVE BELTS. . . . . . . . . . 35
COOLING SYSTEM FANS . . . . . . . . . . . . . . . . . . 38
VISCOUS FAN DRIVE REMOVAL/
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 39
RADIATOR PRESSURE CAP. . . . . . . . . . . . . . . . 39
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 39
FAN BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
COOLING SYSTEM HOSES. . . . . . . . . . . . . . . . . 40
SPECIFICATIONS
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . 40
SPECIAL TOOLS
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
COOLING SYSTEM
DESCRIPTION
The cool i ng system regul ates engi ne operati ng tem-
perature. I t al l ows the engi ne to reach normal oper-
ati ng temperature as qui ckl y as possi bl e, mai ntai ns
normal operati ng temperature and prevents over-
heati ng.
The cool i ng system al so provi des a means of heat-
i ng the passenger compartment and cool i ng the auto-
mati c transmi ssi on fl ui d (i f equi pped). The cool i ng
system i s pressuri zed and uses a centri fugal water
pump to ci rcul ate cool ant throughout the system.
An opti onal factory i nstal l ed heavy duty cool i ng
package i s avai l abl e on most model s. The package
consi sts of a radi ator that has an i ncreased number
of cool i ng fi ns. Vehi cl es equi pped wi th a 2.5L/4.0L
engi ne and heavy duty cool i ng and/or ai r condi ti on-
i ng al so have an auxi l i ary el ectri c cool i ng fan.
The cool i ng system consi sts of:
A radi ator
Cool i ng fan (mechani cal and/or el ectri cal )
Thermal vi scous fan dri ve
XJ COOLING SYSTEM 7 - 1
Fan shroud
Radi ator pressure cap
Thermostat
Cool ant reserve/overfl ow system
Transmi ssi on oi l cool er (i f equi pped wi th an
automati c transmi ssi on)
Cool ant
Water pump
Hoses and hose cl amps
Cool i ng system ci rcul ati on for 2.5L/4.0L model s i s
shown i n (Fi g. 1).
AUTOMATIC TRANSMISSION OIL COOLER
DESCRIPTION
Al l model s equi pped wi th an automati c transmi s-
si on are equi pped wi th a transmi ssi on oi l cool er
mounted i nternal l y wi thi n the radi ator tank. Thi s
i nternal cool er i s suppl i ed as standard equi pment on
al l model s equi pped wi th an automati c transmi ssi on.
Transmi ssi on oi l i s cool ed when i t passes through
thi s separate cool er. I n case of a l eak i n the i nternal
radi ator mounted transmi ssi on oi l cool er, engi ne cool -
ant may become mi xed wi th transmi ssi on fl ui d or
transmi ssi on fl ui d may enter engi ne cool i ng system.
Both cool i ng system and transmi ssi on shoul d be
drai ned and i nspected i f the i nternal radi ator
mounted transmi ssi on cool er i s l eaki ng.
An auxi l i ary ai r-to-oi l transmi ssi on oi l cool er i s
avai l abl e wi th most engi ne packages.
The auxi l i ary ai r-to-oi l transmi ssi on oi l cool er i s
l ocated i n front of the radi ator or A/C condenser (i f
equi pped) and behi nd the gri l l . I t i s mounted to the
front frame crossmember.
The auxi l i ary oi l cool ers on al l model s operate i n
conjuncti on wi th the i nternal radi ator mounted mai n
oi l cool er. The transmi ssi on oi l i s routed through the
mai n cool er fi rst, then the auxi l i ary cool er, before
returni ng to the transmi ssi on.
COOLANT RESERVE/OVERFLOW SYSTEM
DESCRIPTION
The system works al ong wi th the radi ator pressure
cap. Thi s i s done by usi ng thermal expansi on and
contracti on of the cool ant to keep the cool ant free of
trapped ai r. I t provi des:
A vol ume for cool ant expansi on and contracti on.
A conveni ent and safe method for checki ng/ad-
justi ng cool ant l evel at atmospheri c pressure. Thi s i s
done wi thout removi ng the radi ator pressure cap.
Some reserve cool ant to the radi ator to cover
mi nor l eaks and evaporati on or boi l i ng l osses.
Fig. 1 Coolant Circulation2.5L/4.0L Engines
1 HEATER CORE
2 TO COOLANT RESERVE/OVERFLOW TANK
3 THERMOSTAT HOUSING
4 RADIATOR
5 WATER PUMP
Fig. 2 Auxiliary Transmission Oil Cooler
1 AUXILIARY TRANSMISSION OIL COOLER
7 - 2 COOLING SYSTEM XJ
The cool ant reserve/overfl ow system consi sts of a
radi ator mounted pressuri zed cap, a pl asti c reserve/
overfl ow tank (Fi g. 3) (Fi g. 4), a tube (hose) connect-
i ng the radi ator and tank, and an overfl ow tube on
the si de of the tank.
OPERATION
As the engi ne cool s, a vacuum i s formed i n the
cool i ng system of both the radi ator and engi ne. Cool -
ant wi l l then be drawn from the cool ant tank and
returned to a proper l evel i n the radi ator.
COOLING SYSTEM FANS
DESCRIPTION
Al l model s are equi pped wi th a vi scous fan. Thi s
thermal vi scous fan dri ve i s a torque-and-tempera-
ture-sensi ti ve cl utch uni t. I t automati cal l y i ncreases
or decreases fan speed to provi de proper engi ne cool -
i ng. Vehi cl es wi th a 2.5L/4.0L engi ne wi th ai r condi -
ti oni ng, or 4.0L wi th max cool i ng al so have an
auxi l i ary el ectri cal cool i ng fan.
Fig. 3 Reserve/Overflow TankExcept Right Hand
Drive
1 COOLANT RESERVE/OVERFLOW TANK
2 CLAMP
3 MOUNTING BOLTS
4 TUBE TO RADIATOR
Fig. 4 Reserve/Overflow TankWith Right Hand
Drive
1 CLAMP
3 MOUNTING BOLTS
4 LOWER BRACKET
5 TUBE TO RADIATOR
Fig. 5 Viscous Fan Drive and Fan Blade Assembly
1 VISCOUS FAN DRIVE
2 FAN BLADE ASSEMBLY
BLOCK HEATER
DESCRIPTION
WARNING: DO NOT OPERATE ENGINE UNLESS
BLOCK HEATER CORD HAS BEEN DISCONNECTED
FROM POWER SOURCE AND SECURED IN PLACE.
An opti onal engi ne bl ock heater i s avai l abl e for al l
model s. The heater i s equi pped wi th a power cord.
The cord i s attached to an engi ne compartment com-
ponent wi th ti e-straps. The heater warms the engi ne
provi di ng easi er engi ne starti ng and faster warm-up
i n l ow temperatures. The heater i s mounted i n a core
hol e of the engi ne cyl i nder bl ock (i n pl ace of a freeze
pl ug) wi th the heati ng el ement i mmersed i n engi ne
cool ant.
BLOCK HEATER SPECIFICATIONS
2.5L 4-Cyl i nder Engi ne: 115 Vol ts 400 Watts
4.0L 6-Cyl i nder Engi ne: 120 Vol ts 600 Watts
OPERATION
Connecti ng the power cord to a grounded 110-120
vol t AC el ectri cal outl et wi th a grounded, three-wi re
extensi on cord acti vates the bl ock heater.
THERMOSTAT
DESCRIPTION
CAUTION: Do not operate an engine without a ther-
mostat, except for servicing or testing.
A pel l et-type thermostat control s the operati ng
temperature of the engi ne by control l i ng the amount
of cool ant fl ow to the radi ator. On al l engi nes the
thermostat i s cl osed bel ow 195F (90C). Above thi s
temperature, cool ant i s al l owed to fl ow to the radi a-
tor. Thi s provi des qui ck engi ne warm-up and overal l
temperature control .
An arrow pl us the word UP i s stamped on the
front fl ange next to the ai r bl eed. The words TO
RAD are stamped on one arm of the thermostat.
They i ndi cate the proper i nstal l ed posi ti on.
The same thermostat i s used for wi nter and sum-
mer seasons. An engi ne shoul d not be operated wi th-
out a thermostat, except for servi ci ng or testi ng.
Operati ng wi thout a thermostat causes other prob-
l ems. These are: A check engi ne l i ght and a DTC
wi l l eventual l y be set, l onger engi ne warm-up ti me,
unrel i abl e warm-up performance, i ncreased exhaust
emi ssi ons and crankcase condensati on. Thi s conden-
sati on can resul t i n sl udge formati on.
Fig. 6 Engine Block Heater
1 BLOCK HEATER
2 CYLINDER BLOCK
3 BLOCK HEATER POWER CORD
Fig. 7 Thermostat and Housing
1 LONG BOLT
2 GASKET
3 THERMOSTAT
5 SHORT BOLT
RADIATOR
DESCRIPTION
CAUTION: Plastic tanks, while stronger than brass,
are subject to damage by impact, such as
wrenches.
Radi ators for both engi nes are the cross fl ow type.
Pl asti c tanks are used on al l radi ators.
RADIATOR PRESSURE CAP
DESCRIPTION
Al l radi ators are equi pped wi th a pressure cap.
Thi s cap rel eases pressure at some poi nt wi thi n a
range of 83-110 kPa (12-16 psi ). The pressure rel i ef
poi nt (i n pounds) i s engraved on top of the cap (Fi g.
9).
The cool i ng system wi l l operate at pressures
sl i ghtl y above atmospheri c pressure. Thi s resul ts i n a
hi gher cool ant boi l i ng poi nt al l owi ng i ncreased radi -
ator cool i ng capaci ty. The cap contai ns a spri ng-
l oaded pressure rel i ef val ve that opens when system
pressure reaches rel ease range of 83-110 kPa (12-16
psi ).
A rubber gasket seal s radi ator fi l l er neck. Thi s i s
done to mai ntai n vacuum duri ng cool ant cool -down
and to prevent l eakage when system i s under pres-
sure.
OPERATION
A vent val ve i n the center of cap al l ows a smal l
cool ant fl ow through cap when cool ant i s bel ow boi l -
i ng temperature. The val ve i s compl etel y cl osed when
boi l i ng poi nt i s reached. As the cool ant cool s, i t con-
tracts and creates a vacuum i n the cool i ng system.
Thi s causes the vacuum val ve to open and cool ant i n
the reserve/overfl ow tank to be drawn through i ts
connecti ng hose i nto radi ator. I f the vacuum val ve i s
stuck shut, the radi ator hoses wi l l col l apse on cool -
down.
Fig. 8 Cross Flow Radiator
1 RADIATOR
Fig. 9 Radiator Pressure Cap and Filler Neck
Typical
1 FILLER NECK SEAL
2 VACUUM VENT VALVE
3 PRESSURE RATING
4 PRESSURE VALVE
WATER PUMP
DESCRIPTION
CAUTION: All engines are equipped with a reverse
(counter-clockwise) rotating water pump and vis-
cous fan drive assembly. REVERSE is stamped or
imprinted on the cover of the viscous fan drive and
inner side of the fan. The letter R is stamped into
the back of the water pump impeller (Fig. 10).
A centri fugal water pump ci rcul ates cool ant
through the water jackets, passages, i ntake mani fol d,
radi ator core, cool i ng system hoses and heater core.
The pump i s dri ven from the engi ne crankshaft by a
dri ve bel t on al l engi nes.
The water pump i mpel l er i s pressed onto the rear
of a shaft that rotates i n beari ngs pressed i nto the
housi ng. The housi ng has a smal l hol e to al l ow seep-
age to escape. The water pump seal s are l ubri cated
by the anti freeze i n the cool ant mi xture. No addi -
ti onal l ubri cati on i s necessary.
HOSE CLAMPS
DESCRIPTION
The cool i ng system uti l i zes both worm dri ve and
spri ng type hose cl amps. I f a spri ng type cl amp
repl acement i s necessary, repl ace wi th the ori gi nal
Mopar equi pment spri ng type cl amp.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 11).
OPERATION
The worm type hose cl amp uses a speci fi ed torque
val ue to mai ntai n proper tensi on on a hose connec-
ti on.
The spri ng type hose cl amp appl i es constant ten-
si on on a hose connecti on. To remove a spri ng type
hose cl amp, use Speci al Tool 6094 or equi val ent, con-
stant tensi on cl amp pl i ers (Fi g. 12) to compress the
hose cl amp.
Fig. 10 Reverse Rotating Water PumpTypical
1 R STAMPED INTO IMPELLER
Fig. 11 Spring Clamp Size Location
1 SPRING CLAMP SIZE LOCATION
VISCOUS FAN DRIVE
DESCRIPTION
CAUTION: Engines equipped with polyV drive
belts have reverse rotating fans and viscous fan
drives. They are marked with the word REVERSE to
designate their usage. Installation of the wrong fan
or viscous fan drive can result in engine overheat-
ing.
The thermal vi scous fan dri ve i s a si l i cone-fl ui d-
fi l l ed coupl i ng used to connect the fan bl ades to
ei ther the engi ne or the water pump shaft. The cou-
pl i ng al l ows the fan to be dri ven i n a normal manner.
Thi s i s done at l ow engi ne speeds whi l e l i mi ti ng the
top speed of the fan to a predetermi ned maxi mum
l evel at hi gher engi ne speeds.
2.5L vehi cl es wi th A/C are equi pped wi th a vi scous
fan dri ve whi ch i s desi gned to free wheel duri ng
most of the ambi ent condi ti ons encountered by the
vehi cl e and wi l l onl y engage duri ng hi gh heat l oads
as seen i n trai l er towi ng or hi gh ambi ent tempera-
tures.
A thermostati c bi metal l i c spri ng coi l i s l ocated on
the front face of the vi scous fan dri ve uni t. A typi cal
vi scous uni t i s shown i n (Fi g. 13). Thi s spri ng coi l
reacts to the temperature of the radi ator di scharge
ai r. I t engages the vi scous fan dri ve for hi gher fan
speed i f the ai r temperature from the radi ator ri ses
above a certai n poi nt. Unti l addi ti onal engi ne cool i ng
i s necessary, the fan wi l l remai n at a reduced rpm
regardl ess of engi ne speed.
Vehi cl es equi pped wi th 2.5L engi nes have what i s
know as an hybri d cool i ng fan system. Thi s means
that not onl y do they have a vi scous fan but they al so
have an el ectri c fan as wel l . The hybri d vi scous fan
dri ve has a l ow speed characteri sti c. Thi s causes the
mechani cal fan speeds to be very l ow 200400 rpm
range when not engaged al l owi ng the engi ne to have
addi ti onal performance and horsepower gai nes.
OPERATION
Onl y when suffi ci ent heat i s present, wi l l the vi s-
cous fan dri ve engage. Thi s i s when the ai r fl owi ng
through the radi ator core causes a reacti on to the
bi metal l i c coi l . I t then i ncreases fan speed to provi de
the necessary addi ti onal engi ne cool i ng.
Once the engi ne has cool ed, the radi ator di scharge
temperature wi l l drop. The bi metal l i c coi l agai n
reacts and the fan speed i s reduced to the previ ous
di sengaged speed.
Fig. 12 Hose Clamp Tool
1 HOSE CLAMP TOOL 6094
2 HOSE CLAMP
Fig. 13 Typical Viscous Fan Drive
1 VISCOUS FAN DRIVE
2 MOUNTING HUB
3 THERMOSTATIC SPRING
ELECTRIC COOLING FAN
DESCRIPTION
Vehi cl es equi pped wi th a 2.5L/4.0L engi ne and ai r
condi ti oni ng and 4.0L vehi cl es equi pped wi th the
max cool i ng package al so have an el ectri cal cool i ng
fan. The fan i s control l ed by the cool i ng fan rel ay,
whi ch i s l ocated i n the power di stri buti on center
(PDC) (Fi g. 15). For the l ocati on of rel ay wi thi n the
PDC, refer to the l abel on PDC cover.
The el ectri c fan on the 2.5L engi ne equi pped vehi -
cl es i s consi dered the pri mary fan (l ow to moderate
ambi ent condi ti ons) and i s energi zed when the JTEC
recei ves i nput from the cool ant temperature sensor
or the a/c system and suppl i es ground to the cool i ng
fan rel ay.
The cool i ng fan motor i s protected by a 40 amp
maxi -fuse l ocated i n the PDC. The fan rel ay i s pro-
tected by a 15 amp fuse l ocated i n the juncti on bl ock.
OPERATION
Electric cooling fan 2.5L: When ai r condi ti oni ng
i s not requested, the el ectri c fan wi l l not come on
unl ess the cool ant temperature i s at l east 103 C
(218 F), at whi ch ti me the fan wi l l come on and
remai n on unti l the cool ant temperature drops to 99
C (210 F) or bel ow. When ai r condi ti oni ng i s
requested (i ncl udi ng defroster operati on), the fan wi l l
cycl e on and off i n conjuncti on wi th the A/C compres-
sor unl ess the cool ant temperature i s at l east 97 C
(207 F), at whi ch ti me the fan wi l l come on and
remai n on unti l the cool ant temperature drops to 93
C (199 F) or bel ow. Then, the cycl e fan operati on
wi l l resume. When the fan i s schedul ed to be on, the
powertrai n control modul e (PCM) provi des a ground
path for the fan rel ay. Thi s ground i s provi ded to the
cool i ng fan rel ay through pi n C2 of PCM connector
C3. Battery vol tage i s then appl i ed to the fan
through the rel ay. When the fan i s schedul ed to be
off, the PCM opens the ground path to the rel ay. Thi s
wi l l prevent the cool i ng fan from bei ng energi zed.
Fig. 14 Electric Cooling Fan
1 (LHD)
2 (RHD)
3 VISCOUS FAN SHROUD
4 ELECTRIC FAN MODULE
5 ISOLATOR
6 RADIATOR
7 LOWER CROSSMEMBER
8 U-NUT
9 UPPER CROSSMEMBER
Electric cooling fan 4.0L: Wi th or wi thout A/C
request the el ectri c fan wi l l come on onl y when the
cool ant temperature i s at l east 106 C (223 F), and
wi l l remai n on unti l the cool ant temperature drops to
103 C (217 F) or bel ow. Regardl ess of cool ant tem-
perature, When ai r condi ti oni ng system pressures
reach 2068.5 138 kPa (300 20 psi ) the el ectri c
fan wi l l engage and conti nue to run unti l the A/C
system pressure drops to 1620.3 kPa (235 psi ) mi ni -
mum, then the el ectri c fan wi l l shut off.
ON-BOARD DIAGNOSTICS (OBD)
COOLING SYSTEM RELATED DIAGNOSTICS
The Powertrai n Control Modul e (PCM) has been
programmed to moni tor the certai n fol l owi ng cool i ng
system components:
I f the engi ne has remai ned cool for too l ong a
peri od, such as wi th a stuck open thermostat, a Di ag-
nosti c Troubl e Code (DTC) can be set.
I f an open or shorted condi ti on has devel oped i n
the rel ay ci rcui t control l i ng the el ectri c radi ator fan,
a Di agnosti c Troubl e Code (DTC) can be set.
I f the probl em i s sensed i n a moni tored ci rcui t
often enough to i ndi cate an actual probl em, a DTC i s
stored. The DTC wi l l be stored i n the PCM memory
for eventual di spl ay to the servi ce techni ci an. (Refer
to Group 25, Emi ssi on Control Systems for proper
procedures)
ACCESSING DIAGNOSTIC TROUBLE CODES
To read DTCs and to obtai n cool i ng system data,
refer to Group 25, Emi ssi on Control Systems for
proper procedures.
DRB SCAN TOOL
For operati on of the DRB scan tool , refer to the
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce manual .
ACCESSORY DRIVE BELT DIAGNOSIS
VISUAL DIAGNOSIS
When di agnosi ng serpenti ne accessory dri ve bel ts,
smal l cracks that run across the ri bbed surface of the
bel t from ri b to ri b (Fi g. 16), are consi dered normal .
These are not a reason to repl ace the bel t. However,
cracks runni ng al ong a ri b (not across) are not nor-
mal . Any bel t wi th cracks runni ng al ong a ri b must
be repl aced (Fi g. 16). Al so repl ace the bel t i f i t has
excessi ve wear, frayed cords or severe gl azi ng.
Refer to the Accessory Dri ve Bel t Di agnosi s charts
for further bel t di agnosi s.
NOISE DIAGNOSIS
Noi ses generated by the accessory dri ve bel t are
most noti ceabl e at i dl e. Before repl aci ng a bel t to
resol ve a noi se condi ti on, i nspect al l of the accessory
dri ve pul l eys for al i gnment, gl azi ng, or excessi ve end
pl ay.
Fig. 15 Power Distribution Center (PDC)
1 RIGHT FENDER
2 BATTERY
3 POWER DISTRIBUTION CENTER
Fig. 16 Belt Wear Patterns
1 NORMAL CRACKS BELT OK
2 NOT NORMAL CRACKS REPLACE BELT
ACCESSORY DRIVE BELT DIAGNOSIS CHART
RIB CHUNKING (One or more ribs
has separated from belt body)
1. Foreign objects imbedded in
pulley grooves.
1. Remove foreign objects from
pulley grooves. Replace belt.
2. Installation damage 2. Replace belt
RIB OR BELT WEAR 1. Pulley misaligned 1. Align pulley(s)
2. Abrasive environment 2. Clean pulley(s). Replace belt if
necessary
3. Rusted pulley(s) 3. Clean rust from pulley(s)
4. Sharp or jagged pulley groove
tips
4. Replace pulley. Inspect belt.
5. Belt rubber deteriorated 5. Replace belt
BELT SLIPS 1. Belt slipping because of
insufficient tension
1. Adjust tension (2.5L)
2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)
2. Replace belt and clean pulleys
3. Driven component bearing failure
(seizure)
3. Replace faulty component or
bearing
4. Belt glazed or hardened from
heat and excessive slippage
4. Replace belt.
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove
1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member
2. Replace belt
GROOVE JUMPING
(Belt does not maintain correct
position on pulley)
1. Belt tension either too low or too
high
1. Adjust belt tension (2.5L)
2. Pulley(s) not within design
tolerance
2. Replace pulley(s)
3. Foreign object(s) in grooves 3. Remove foreign objects from
grooves
4. Pulley misalignment 4. Align component
5. Belt cordline is broken 5. Replace belt
BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)
1. Excessive tension 1. Replace belt and adjust tension
to specification
2. Tensile member damaged during
belt installation
2. Replace belt
3. Severe misalignment 3. Align pulley(s)
4. Bracket, pulley, or bearing failure 4. Replace defective component
and belt
NOISE (Objectionable squeal,
squeak, or rumble is heard or felt
while drive belt is in operation)
1. Belt slippage 1. Adjust belt tension (2.5L)
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration
5. Locate defective driven
component and repair
6. System resonant frequency
induced vibration
6. Vary belt tension within
specifications.
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)
1. Tension sheeting contacting
stationary object
1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age
2. Replace belt
3. Tension sheeting splice has
fractured
3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)
1. Excessive tension 1. Adjust belt tension (2.5L)
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix
4. Replace belt and adjust tension
to specifications
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING
Establ i sh what dri vi ng condi ti ons caused the com-
pl ai nt. Abnormal l oads on the cool i ng system such as
the fol l owi ng may be the cause:
PROLONGED IDLE, VERY HIGH AMBIENT TEMPERATURE,
SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC
JAMS, HIGH SPEED OR STEEP GRADES.
Dri vi ng techni ques that avoi d overheati ng are:
I dl e wi th A/C off when temperature gauge i s at
end of normal range.
I ncreasi ng engi ne speed for more ai r fl ow i s rec-
ommended.
TRAILER TOWING:
Consul t Trai l er Towi ng secti on of owners manual .
Do not exceed l i mi ts.
AIR CONDITIONING; ADD-ON OR AFTER MARKET:
A maxi mum cool i ng package shoul d have been
ordered wi th vehi cl e i f add-on or after market A/C i s
i nstal l ed. I f not, maxi mum cool i ng system compo-
nents shoul d be i nstal l ed for model i nvol ved per
manufacturers speci fi cati ons.
RECENT SERVICE OR ACCIDENT REPAIR:
Determi ne i f any recent servi ce has been per-
formed on vehi cl e that may effect cool i ng system.
Thi s may be:
Engi ne adjustments (i ncorrect ti mi ng)
Sl i ppi ng engi ne accessory dri ve bel t(s)
Brakes (possi bl y draggi ng)
Changed parts. I ncorrect water pump or pump
rotati ng i n wrong di recti on due to bel t not correctl y
routed
Recondi ti oned radi ator or cool i ng system refi l l -
i ng (possi bl y under fi l l ed or ai r trapped i n system).
NOTE: If investigation reveals none of the previous
items as a cause for an engine overheating com-
plaint, refer to following Cooling System Diagnosis
charts.
These charts are to be used as a qui ck-reference
onl y. Refer to the group text for i nformati on.
COOLING SYSTEM DIAGNOSIS CHART
TEMPERATURE GAUGE READS
LOW
1. Has a Diagnostic Trouble Code
(DTC) been set indicating a stuck
open thermostat?
1. Refer to Group 25, Emission
Systems for On-Board Diagnostics
and DTC information. Replace
thermostat if necessary.
2. Is the temperature sending unit
connected?
2. Check the temperature sensor
connector. Refer to Group 8E.
Repair connector if necessary.
3. Is the temperature gauge
operating OK?
3. Check gauge operation. Refer to
Group 8E. Repair as necessary.
4. Coolant level low in cold ambient
temperatures accompanied with
poor heater performance.
4. Check coolant level in the coolant
reserve/overflow tank and the
radiator. Inspect system for leaks.
Repair leaks as necessary. Refer to
the Coolant section of the manual
text for WARNINGS and
CAUTIONS associated with
removing the radiator cap.
5. Improper operation of internal
heater doors or heater controls.
5. Inspect heater and repair as
necessary. Refer to Group 24,
Heating and Air Conditioning for
procedures.
HIGH OR THE COOLANT
WARNING LAMP ILLUMINATES.
COOLANT MAY OR MAY NOT BE
LOST OR LEAKING FROM THE
COOLING SYSTEM
1. Trailer is being towed, a steep
hill is being climbed, vehicle is
operated in slow moving traffic, or
engine is being idled with very high
ambient (outside) temperatures and
the air conditioning is on. Higher
altitudes could aggravate these
conditions.
1. This may be a temporary
condition and repair is not
necessary. Turn off the air
conditioning and attempt to drive the
vehicle without any of the previous
conditions. Observe the temperature
gauge. The gauge should return to
the normal range. If the gauge does
not return to the normal range,
determine the cause for overheating
and repair. Refer to Possible
Causes (2-20).
2. Is the temperature gauge reading
correctly?
2. Check gauge. Refer to Group 8E.
Repair as necessary.
3. Is the temperature warning
illuminating unnecessarily?
3. Check warning lamp operation.
Refer to Group 8E. Repair as
necessary.
4. Coolant low in coolant reserve/
overflow tank and radiator?
4. Check for coolant leaks and
repair as necessary. Refer to
Testing Cooling System for Leaks in
this Group.
5. Pressure cap not installed tightly.
If cap is loose, boiling point of
coolant will be lowered. Also refer
to the following Step 6.
5. Tighten cap
HIGH OR THE COOLANT
COOLING SYSTEM (CONTINUED)
6. Poor seals at the radiator cap. 6. (a) Check condition of cap and
cap seals. Refer to Radiator Cap.
Replace cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
7. Coolant level low in radiator but
not in coolant reserve/overflow
tank. This means the radiator is not
drawing coolant from the coolant
reserve/overflow tank as the engine
cools
7. (a) Check condition of radiator
cap and cap seals. Refer to
Radiator Cap in this Group. Replace
cap if necessary.
(b) Check condition of radiator filler
neck. If neck is bent or damaged,
replace radiator.
(c) Check condition of the hose from
the radiator to the coolant tank. It
should fit tight at both ends without
any kinks or tears. Replace hose if
necessary.
(d) Check coolant reserve/overflow
tank and tanks hoses for blockage.
Repair as necessary.
8. Incorrect coolant concentration 8. Check coolant. Refer to Coolant
section in this Group for correct
coolant/water mixture ratio.
9. Coolant not flowing through
system
9. Check for coolant flow at radiator
filler neck with some coolant
removed, engine warm and
thermostat open. Coolant should be
observed flowing through radiator. If
flow is not observed, determine area
of obstruction and repair as
necessary.
10. Radiator or A/C condenser fins
are dirty or clogged.
10. Remove insects and debris.
Refer to Radiator Cleaning in this
Group.
11. Radiator core is corroded or
plugged.
11. Have radiator re-cored or
replaced.
12. Aftermarket A/C installed
without proper radiator.
12. Install proper radiator.
13. Fuel or ignition system
problems.
13. Refer to Fuel and Ignition
System Groups for diagnosis.
14. Dragging brakes. 14. Check and correct as
necessary. Refer to Group 5,
Brakes for correct procedures.
15. Bug screen or cardboard is
being used, reducing airflow.
15. Remove bug screen or
cardboard.
16. Thermostat partially or
completely shut.
16. Check thermostat operation and
replace as necessary. Refer to
Thermostats in this Group.
HIGH OR THE COOLANT
COOLING SYSTEM (CONTINUED)
17. Viscous fan drive not operating
properly.
17. Check fan drive operation and
replace as necessary. Refer to
Viscous Fan Drive in this Group.
18. Electric cooling fan not
operating properly (vehicles
equipped with 2.5L/4.0L and air
conditioning
18. Check electric fan operation and
repair as necessary. Refer to
Electric Cooling Fan in this Group.
19. Cylinder head gasket leaking. 19. Check for cylinder head gasket
leaks. Refer to Cooling System-
Testing For Leaks in this Group. For
repair, refer to Group 9, Engines.
20. Heater core leaking. 20. Check heater core for leaks.
Refer to Group 24, Heating and Air
Conditioning. Repair as necessary.
TEMPERATURE GAUGE READING
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)
1. On vehicles equipped with an
electric fan, the gauge may cycle
up and down. This is due to the
cycling of the electric radiator fan.
1. This is a normal condition. No
correction is necessary unless the
gauge cycles into the red (overheat)
zone. Refer to Electric Cooling Fan
Diagnosis and Testing in this group.
2. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.
2. A normal condition. No correction
is necessary.
3. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.
3. Check operation of gauge and
repair if necessary. Refer to Group
8E, Instrument Panel and Gauges.
4. Gauge reading rises when
vehicle is brought to a stop after
heavy use (engine still running)
is necessary. Gauge should return
to normal range after vehicle is
driven.
5. Gauge reading high after
re-starting a warmed up (hot)
engine.
is necessary. The gauge should
return to normal range after a few
minutes of engine operation.
6. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open
late).
6. Check and correct coolant leaks.
Refer to Cooling System-Testing for
leaks in this group.
7. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a
thermostat to open late.
7. (a) Check for cylinder head
gasket leaks. Refer to Cooling
System-Testing for Leaks in this
group.
(b) Check for coolant in the engine
oil. Inspect for white steam emitting
from the exhaust system. Repair as
necessary.
IS INCONSISTENT (FLUCTUATES,
CYCLES OR IS ERRATIC)
(CONTINUED)
8. Water pump impeller loose on
shaft.
8. Check water pump and replace
as necessary. Refer to water Pumps
in this group.
9. Loose accessory drive belt.
(water pump slipping)
9. Refer to Accessory Drive Belts in
this group. Check and correct as
necessary.
10. Air leak on the suction side of
the water pump allows air to build
up in cooling system causing
thermostat to open late.
10. Locate leak and repair as
necessary.
PRESSURE CAP IS BLOWING
OFF STEAM AND/OR COOLANT
TO COOLANT TANK.
MAY BE ABOVE NORMAL BUT
NOT HIGH. COOLANT LEVEL MAY
BE HIGH IN COOLANT RESERVE/
OVERFLOW TANK
1. Pressure relief valve in radiator
cap is defective.
1. Check condition of radiator cap
and cap seals. Refer to Radiator
Caps in this group. Replace cap as
necessary.
COOLANT LOSS TO THE
GROUND WITHOUT PRESSURE
CAP BLOWOFF. GAUGE READING
HIGH OR HOT
1. Coolant leaks in radiator, cooling
system hoses, water pump or
engine.
1. Pressure test and repair as
necessary. Refer to Cooling
System-Testing For Leaks in this
group.
DETONATION OR PRE-IGNITION
(NOT CAUSED BY IGNITION
SYSTEM). GAUGE MAY OR MAY
NOT BE READING HIGH
1. engine overheating. 1. Check reason for overheating
and repair as necessary.
2. Freeze point of coolant not
correct. Mixture is too rich or too
lean.
2. Check coolant concentration.
Refer to the Coolant section of this
group and adjust ratio as required.
HOSE OR HOSES COLLAPSE
WHILE ENGINE IS RUNNING
1. Vacuum created in cooling
system on engine cool-down is not
being relieved through coolant
reserve/overflow system.
1. (a) Radiator cap relief valve
stuck. Refer to Radiator Cap in this
group. Replace if necessary
(b) Hose between coolant
reserve/overflow tank and radiator is
kinked. Repair as necessary.
(c) Vent at coolant reserve/overflow
tank is plugged. Clean vent and
repair as necessary.
(d) Reserve/overflow tank is
internally blocked or plugged. Check
for blockage and repair as
necessary.
ELECTRIC RADIATOR FAN RUNS
ALL OF THE TIME (2.5L/4.0L
MODELS EQUIPPED WITH A/C
AND 4.0L MODELS EQUIPPED
WITH MAX COOLING)
1. Fan relay, powertrain control
module (PCM) or coolant
temperature sensor defective.
1. Refer to Electric Cooling Fan
Diagnosis and Testing. Also refer to
Group 8W, Wiring Diagrams. Repair
as necessary.
ELECTRIC RADIATOR FAN WILL
NOT RUN AT ALL. GAUGE
READING HIGH OR HOT
(2.5L/4.0L MODELS EQUIPPED
WITH A/C AND 4.0L MODELS
EQUIPPED WITH MAX COOLING)
1. Blown Fuse in Power Distribution
Center (PDC)
1. Determine reason for blown fuse
2. Fan relay, powertrain control
module (PCM) or coolant
temperature sensor defective.
2. Refer to Electric Cooling Fan
as necessary.
3. Fan Motor Defective 3. Refer to Electric Cooling Fan
as necessary.
NOISY VISCOUS FAN/DRIVE 1. Fan blades loose. 1. Replace fan blade assembly.
Refer to Cooling System Fans in
this Group
2. Fan blades striking a surrounding
object.
2. Locate point of fan blade contact
3. Air obstructions at radiator or air
conditioning condenser.
3. Remove obstructions and/or
clean debris or insects from radiator
or A/C condenser.
4. Thermal viscous fan drive has
defective bearing.
4. Replace fan drive. Bearing is not
serviceable. Refer to Viscous Fan
Drive in this group.
5. A certain amount of fan noise
may be evident on models
equipped with a thermal viscous fan
drive. Some of this noise is normal.
5. Refer to Viscous Fan Drive in this
group for an explanation of normal
fan noise.
INADEQUATE HEATER
PERFORMANCE. THERMOSTAT
FAILED IN OPEN POSITION
1. Has a Diagnostic trouble Code
(DTC) been set?
1. Refer to Group 25, Emissions for
correct procedures and replace
thermostat if necessary
2. Coolant level low 2. Refer to Cooling System-Testing
For Leaks in this group.
3. Obstructions in heater hose/
fittings
3. Remove heater hoses at both
ends and check for obstructions
4. Heater hose kinked 4. Locate kinked area and repair as
necessary
5. Water pump is not pumping
water to/through the heater core.
When the engine is fully warmed
up, both heater hoses should be
hot to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly or the
heater core may be plugged.
Accessory drive belt may be
slipping causing poor water pump
operation.
5. Refer to Water Pump in this
group. If a slipping belt is detected,
refer to Accessory Drive Belts in this
group. If heater core obstruction is
detected, refer to Group 24, Heating
and Air Conditioning.
STEAM IS COMING FROM THE
FRONT OF VEHICLE NEAR THE
GRILL AREA WHEN WEATHER IS
WET, ENGINE IS WARMED UP
AND RUNNING, AND VEHICLE IS
STATIONARY. TEMPERATURE
GAUGE IS IN NORMAL RANGE
1. During wet weather, moisture
(snow, ice or rain condensation) on
the radiator will evaporate when the
thermostat opens. This opening
allows heated water into the
radiator. When the moisture
contacts the hot radiator, steam
may be emitted. This usually occurs
in cold weather with no fan or
airflow to blow it away.
1. Occasional steam emitting from
this area is normal. No repair is
necessary.
COOLANT COLOR 1. Coolant color is not necessarily
an indication of adequate corrosion
or temperature protection. Do not
rely on coolant color for determining
condition of coolant.
1. Refer to Coolant in this group for
coolant concentration information.
Adjust coolant mixture as
necessary.
COOLANT LEVEL CHANGES IN
COOLANT RESERVE/OVERFLOW
TANK. TEMPERATURE GAUGE IS
IN NORMAL RANGE
1. Level changes are to be
expected as coolant volume
fluctuates with engine temperature.
If the level in the tank was between
the FULL and ADD marks at normal
operating temperature, the level
should return to within that range
after operation at elevated
temperatures.
1. A normal condition. No repair is
necessary.
RADIATOR COOLANT FLOW CHECK
The fol l owi ng procedure wi l l determi ne i f cool ant i s
fl owi ng through the cool i ng system.
I f engi ne i s col d, i dl e engi ne unti l normal operati ng
temperature i s reached. Then feel the upper radi ator
hose. I f hose i s hot, the thermostat i s open and water
i s ci rcul ati ng through cool i ng system.
COOLING SYSTEM TESTING FOR LEAKS
ULTRAVIOLET LIGHT METHOD
Al l Jeep model s have a l eak detecti on addi ti ve
added to the cool i ng system before they l eave the fac-
tory. The addi ti ve i s hi ghl y vi si bl e under ul travi ol et
l i ght (bl ack l i ght). I f the factory ori gi nal cool ant has
been drai ned, pour one ounce of addi ti ve i nto the
cool i ng system. The addi ti ve i s avai l abl e through the
parts department. Pl ace the heater control uni t i n
HEAT posi ti on. Start and operate the engi ne unti l
the radi ator upper hose i s warm to the touch. Ai m
the commerci al l y avai l abl e bl ack l i ght tool at the
components to be checked. I f l eaks are present, the
bl ack l i ght wi l l cause the addi ti ve to gl ow a bri ght
green col or.
The bl ack l i ght can be used al ong wi th a pressure
tester to determi ne i f any external l eaks exi st (Fi g.
17).
Fig. 17 Leak Detection Using Black LightTypical
1 TYPICAL BLACK LIGHT TOOL
PRESSURE TESTER METHOD
The engi ne shoul d be at the normal operati ng tem-
perature. Recheck the system col d i f the cause of
cool ant l oss i s not l ocated duri ng warm engi ne exam-
i nati on.
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING.
Careful l y remove the radi ator pressure cap from
the fi l l er neck and check the cool ant l evel . Push
down on the cap to di sengage i t from the stop tabs.
Wi pe the i nner part of the fi l l er neck and exami ne
the l ower i nsi de seal i ng seat for ni cks, cracks, pai nt,
di rt and sol der resi due. I nspect the reserve/overfl ow
tank tube for i nternal obstructi ons. I nsert a wi re
through the tube to be sure i t i s not obstructed.
I nspect the cams on the outsi de part of the fi l l er
neck. I f the cams are bent, seati ng of pressure cap
val ve and tester seal wi l l be affected. Repl ace cap i f
cams are bent.
Attach pressure tester 7700 (or an equi val ent) to
the radi ator fi l l er neck (Fi g. 18).
Operate the tester pump to appl y 124 kPa (18 psi )
pressure to the system. I f the hoses enl arge exces-
si vel y or bul ge whi l e testi ng, repl ace as necessary.
Observe the gauge poi nter and determi ne the condi -
ti on of the cool i ng system accordi ng to the fol l owi ng
cri teri a:
Hol ds Steady: I f the poi nter remai ns steady for
two mi nutes, there are no seri ous cool ant l eaks i n
the system. However, there coul d be an i nternal l eak
that does not appear wi th normal system test pres-
sure. I nspect for i nteri or l eakage or do the I nternal
Leakage Test. Do thi s i f i t i s certai n that cool ant i s
bei ng l ost and no l eaks can be detected.
Drops Sl owl y: Shows a smal l l eak or seepage i s
occurri ng. Exami ne al l connecti ons for seepage or
sl i ght l eakage wi th a fl ashl i ght. I nspect the radi ator,
hoses, gasket edges and heater. Seal any smal l l eak
hol es wi th a Seal er Lubri cant or equi val ent. Repai r
l eak hol es and rei nspect the system wi th pressure
appl i ed.
Drops Qui ckl y: Shows that a seri ous l eakage i s
occurri ng. Exami ne the system for seri ous external
l eakage. I f no l eaks are vi si bl e, i nspect for i nternal
l eakage. Large radi ator l eak hol es shoul d be repai red
by a reputabl e radi ator repai r shop.
INTERNAL LEAKAGE INSPECTION
Remove the engi ne oi l pan drai n pl ug and drai n a
smal l amount of engi ne oi l . Cool ant, bei ng heavi er
than engi ne oi l , wi l l drai n fi rst. Another way of test-
i ng i s to operate the engi ne and check for water gl ob-
ul es on the engi ne oi l di psti ck. Al so i nspect the
automati c transmi ssi on oi l di psti ck for water gl ob-
ul es. I nspect the automati c transmi ssi on fl ui d cool er
for l eakage. Operate the engi ne wi thout the pressure
cap on the radi ator unti l thermostat opens.
Attach a pressure tester to the fi l l er neck. I f pres-
sure bui l ds up qui ckl y, a l eak exi sts as a resul t of a
faul ty cyl i nder head gasket or crack i n the engi ne.
Repai r as necessary.
WARNING: DO NOT ALLOW PRESSURE TO
EXCEED 124 KPA (18 PSI). TURN THE ENGINE OFF.
TO RELEASE THE PRESSURE, ROCK THE TESTER
FROM SIDE TO SIDE. WHEN REMOVING THE
TESTER, DO NOT TURN THE TESTER MORE THAN
1/2 TURN IF THE SYSTEM IS UNDER PRESSURE.
I f there i s no i mmedi ate pressure i ncrease, pump
the pressure tester unti l the i ndi cated pressure i s
wi thi n the system range. Vi brati on of the gauge
poi nter i ndi cates compressi on or combusti on l eakage
i nto the cool i ng system.
WARNING: DO NOT DISCONNECT THE SPARK
PLUG WIRES WHILE THE ENGINE IS OPERATING.
CAUTION: Do not operate the engine with a spark
plug shorted for more than a minute. The catalytic
converter may be damaged.
I sol ate the compressi on l eak by shorti ng each
spark pl ug to the cyl i nder bl ock. The gauge poi nter
shoul d stop or decrease vi brati on when spark pl ug
for l eaki ng cyl i nder i s shorted. Thi s happens because
of the absence of combusti on pressure.
Fig. 18 Pressurizing SystemTypical
1 TYPICAL COOLING SYSTEM PRESSURE TESTER
COMBUSTION LEAKAGE TEST (WITHOUT
PRESSURE TESTER)
DO NOT WASTE reusabl e cool ant. I f the sol uti on
i s cl ean, drai n the cool ant i nto a cl ean contai ner for
reuse.
WARNING: DO NOT REMOVE THE CYLINDER
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
Drai n suffi ci ent cool ant to al l ow for thermostat
removal . Refer to Thermostat Repl acement. Di scon-
nect the water pump dri ve bel t.
Di sconnect the upper radi ator hose from the ther-
mostat housi ng. Remove the housi ng and thermostat.
I nstal l the thermostat housi ng.
Add cool ant to the radi ator to bri ng the l evel to
wi thi n 6.3 mm (1/4 i n) of the top of the thermostat
housi ng.
CAUTION: Avoid overheating. Do not operate the
engine for an excessive period of time. Open the
draincock immediately after the test to eliminate
boil over of coolant.
Start the engi ne and accel erate rapi dl y three ti mes
(to approxi matel y 3000 rpm) whi l e observi ng the
cool ant. I f i nternal engi ne combusti on gases are l eak-
i ng i nto the cool i ng system, bubbl es wi l l appear i n
the cool ant. I f bubbl es do not appear, there i s no
i nternal combusti on gas l eakage.
VISCOUS FAN DRIVE
LEAKS
Vi scous fan dri ve operati on i s not affected by smal l
oi l stai ns near the dri ve beari ng. I f l eakage appears
excessi ve, repl ace the fan dri ve uni t.
TESTING
I f the fan assembl y free-wheel s wi thout drag (the
fan bl ades wi l l revol ve more than fi ve turns when
spun by hand), repl ace the fan dri ve. Thi s spi n test
must be performed when the engi ne i s cool .
For the fol l owi ng test, the cool i ng system must be
i n good condi ti on. I t al so wi l l ensure agai nst exces-
si vel y hi gh cool ant temperature.
WARNING: BE SURE THAT THERE IS ADEQUATE
FAN BLADE CLEARANCE BEFORE DRILLING.
(1) Dri l l a 3.18-mm (1/8-i n) di ameter hol e i n the
top center of the fan shroud.
(2) Obtai n a di al thermometer wi th an 8 i nch stem
(or equi val ent). I t shoul d have a range of -18-to-
105C (0-to-220 F). I nsert thermometer through the
hol e i n the shroud. Be sure that there i s adequate
cl earance from the fan bl ades.
(3) Connect a tachometer and an engi ne i gni ti on
ti mi ng l i ght (ti mi ng l i ght i s to be used as a strobe
l i ght).
(4) Bl ock the ai r fl ow through the radi ator. Secure
a sheet of pl asti c i n front of the radi ator (or ai r con-
di ti oner condenser). Use tape at the top to secure the
pl asti c and be sure that the ai r fl ow i s bl ocked.
(5) Be sure that the ai r condi ti oner (i f equi pped) i s
turned off.
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
(6) Start the engi ne and operate at 2400 rpm.
Wi thi n ten mi nutes the ai r temperature (i ndi cated on
the di al thermometer) shoul d be up to 88 C (190 F).
Fan dri ve engagement shoul d have started to occur
at between 74 to 82 C (165 to 180 F). Engage-
ment i s di sti ngui shabl e by a defi ni te increase i n fan
fl ow noi se (roari ng). The ti mi ng l i ght al so wi l l i ndi -
cate an i ncrease i n the speed of the fan.
(7) When the ai r temperature reaches 88 C (190
F), remove the pl asti c sheet. Fan dri ve disengage-
ment shoul d have started to occur at between 57 to
79 C (135 to 175 F). A defi ni te decrease of fan
fl ow noi se (roari ng) shoul d be noti ced. I f not, repl ace
the defecti ve vi scous fan dri ve uni t.
ELECTRIC COOLING FAN
ELECTRIC COOLING FAN AND RELAY DIAGNOSIS
NOTE: Refer to Electrical Group 8W for electric
cooling fan and relay circuit schematic.
The powertrai n control modul e (PCM) wi l l enter a
di agnosti c troubl e code (DTC) i n memory i f i t detects
a probl em i n the auxi l i ary cool i ng fan rel ay or ci rcui t.
Refer to Group 25, Emi ssi on Control Systems for cor-
rect DTC retri eval procedures.
I f the el ectri c cool i ng fan i s i noperati ve, check the
15A fuse i n the juncti on bl ock and the 40A fuse i n
the Power Di stri buti on Center (PDC) wi th a 12 vol t
test l amp or DVOM. Refer to the i nsi de of the PDC
cover for the exact l ocati on of the fuse. I f fuses are
o.k., refer to Group 8W for el ectri c cool i ng fan and
rel ay ci rcui t schemati c.
RADIATOR CAP-TO-FILLER NECK SEAL
PRESSURE RELIEF CHECK
Wi th radi ator cap i nstal l ed on fi l l er neck, remove
cool ant reserve/ overfl ow tank hose from ni ppl e on
fi l l er neck. Connect a hand operated vacuum pump
to ni ppl e. Operate pump unti l a readi ng of 47-to-61
kPa (14- to-18 i n. Hg) appears on gauge. I f the read-
i ng stays steady, or drops sl i ghtl y and then remai ns
steady, the pressure val ve seal i s good. Repl ace radi -
ator cap i f readi ng does not hol d.
WARNING: THE WARNING WORDS -DO NOT OPEN
HOT- ON THE RADIATOR PRESSURE CAP (Fig. 19)
ARE A SAFETY PRECAUTION. WHEN HOT, PRES-
SURE BUILDS UP IN COOLING SYSTEM. TO PRE-
VENT SCALDING OR INJURY, THE RADIATOR CAP
SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT AND/OR UNDER PRESSURE.
There i s no need to remove the radi ator cap
except for the fol l owi ng purposes:
(1) To check and adjust anti freeze freeze poi nt.
(2) To refi l l system wi th new anti freeze.
(3) For conducti ng servi ce procedures.
(4) When checki ng for vacuum l eaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,
WAIT AT LEAST 15 MINUTES BEFORE REMOVING
RADIATOR CAP. WITH A RAG, SQUEEZE RADIATOR
UPPER HOSE TO CHECK IF SYSTEM IS UNDER
PRESSURE. PLACE A RAG OVER THE CAP AND
WITHOUT PUSHING DOWN, ROTATE CAP
COUNTER-CLOCKWISE TO THE FIRST STOP.
ALLOW FLUID TO ESCAPE THROUGH OVERFLOW
HOSE INTO COOLANT RESERVE/OVERFLOW
TANK. SQUEEZE RADIATOR UPPER HOSE TO
DETERMINE WHEN PRESSURE HAS BEEN
RELEASED. WHEN COOLANT AND STEAM STOP
BEING PUSHED INTO TANK AND SYSTEM PRES-
SURE DROPS, REMOVE RADIATOR CAP COM-
PLETELY.
RADIATOR CAP PRESSURE TESTING
Remove cap from radi ator. Be sure that seal i ng
surfaces are cl ean. Moi sten rubber gasket wi th water
and i nstal l the cap on pressure tester (tool 7700 or
an equi val ent) (Fi g. 20).
Fig. 19 Radiator Pressure Cap
1 FILLER NECK SEAL
2 VACUUM VENT VALVE
3 PRESSURE RATING
4 PRESSURE VALVE
Fig. 20 Pressure Testing Radiator Pressure
CapTypical
1 PRESSURE CAP
2 TYPICAL COOLING SYSTEM PRESSURE TESTER
Operate the tester pump and observe the gauge
poi nter at i ts hi ghest poi nt. The cap rel ease pressure
shoul d be 83-to-110 kPa (12-to-16 psi ). The cap i s sat-
i sfactory when the pressure hol ds steady. I t i s al so
good i f i t hol ds pressure wi thi n the 83-to-110 kPa
(12-to-16 psi ) range for 30 seconds or more. I f the
poi nter drops qui ckl y, repl ace the cap.
CAUTION: Radiator pressure testing tools are very
sensitive to small air leaks, which will not cause
cooling system problems. A pressure cap that does
not have a history of coolant loss should not be
replaced just because it leaks slowly when tested
with this tool. Add water to tool. Turn tool upside
down and recheck pressure cap to confirm that cap
needs replacement.
CAP INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
COOLANT LOW LEVEL AERATION
I f the cool ant l evel i n radi ator drops bel ow top of
radi ator core tubes, ai r wi l l enter cool i ng system.
Low cool ant l evel can cause thermostat pel l et to be
suspended i n ai r i nstead of cool ant. Thi s wi l l cause
thermostat to open l ater, whi ch i n turn causes hi gher
cool ant temperature. Ai r trapped i n cool i ng system
al so reduces amount of cool ant ci rcul ati ng i n heater
core resul ti ng i n l ow heat output.
DEAERATION
As the engi ne operates, any ai r trapped i n cool i ng
system gathers under the radi ator cap. The next ti me
the engi ne i s operated, thermal expansi on of cool ant
wi l l push any trapped ai r past radi ator cap i nto the
cool ant reserve/overfl ow tank. Here i t escapes to the
atmosphere i nto the tank. When the engi ne cool s
down the cool ant, i t wi l l be drawn from the reserve/
overfl ow tank i nto the radi ator to repl ace any
removed ai r.
SERVICE PROCEDURES
COOLANT ROUTINE LEVEL CHECK
NOTE: Do not remove radiator cap for routine
coolant level inspections. The coolant level can be
checked at coolant reserve/overflow tank.
The cool ant reserve/overfl ow system provi des a
qui ck vi sual method for determi ni ng cool ant l evel
wi thout removi ng radi ator pressure cap. Wi th engi ne
col d and not runni ng, observe cool ant l evel i n
reserve/overfl ow tank. The cool ant l evel shoul d be
between ADD and FULL marks.
COOLANT ADDING ADDITIONAL
Do not remove radiator cap to add coolant to
system. When addi ng cool ant to mai ntai n correct
l evel , do so at cool ant reserve/overfl ow tank. Use a
50/50 mi xture of ethyl ene-gl ycol anti freeze contai ni ng
Al ugard 340-2 and l ow mi neral content water.
Remove radi ator cap onl y for testi ng or when refi l l -
i ng system after servi ce. Removi ng cap unnecessari l y
can cause l oss of cool ant and al l ow ai r to enter sys-
tem, whi ch produces corrosi on.
COOLANT LEVEL CHECK
The cool i ng system i s cl osed and desi gned to mai n-
tai n cool ant l evel to top of radi ator.
WARNING: DO NOT OPEN RADIATOR DRAINCOCK
WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
AND COOLING SYSTEM IS UNDER PRESSURE.
When vehi cl e servi ci ng requi res a cool ant l evel
check i n radi ator, drai n several ounces of cool ant
from radi ator drai n cock. Do thi s whi l e observi ng
cool ant reserve/overfl ow system tank. The cool ant
l evel i n reserve/overfl ow tank shoul d drop sl i ghtl y. I f
not, i nspect for a l eak between radi ator and cool ant
reserve/overfl ow system connecti on. Remove radi ator
cap. The cool ant l evel shoul d be to top of radi ator. I f
not and i f cool ant l evel i n reserve/overfl ow tank i s at
ADD mark, check for:
An ai r l eak i n cool ant reserve/overfl ow tank or
i ts hose
An ai r l eak i n radi ator fi l l er neck
Leak i n pressure cap seal to radi ator fi l l er neck
COOLING SYSTEM DRAINING AND FILLING
DRAINING
DRAINCOCK WITH SYSTEM HOT AND UNDER
PRESSURE. SERIOUS BURNS FROM COOLANT
CAN OCCUR.
reuse.
(1) Remove radi ator pressure cap.
(2) For access to radi ator drai ncock (Fi g. 21),
remove radi ator gri l l e mounti ng screws and remove
gri l l . Refer to Group 23, Body for correct procedure.
(3) Attach one end of a 24 i nch l ong X 1/4 i nch I D
hose to the radi ator drai ncock. Put the other end i nto
a cl ean contai ner. Open drai ncock and drai n cool ant
from radi ator.
(4) Drai n cool ant from engi ne by removi ng the
drai n pl ug and cool ant temperature sensor on l eft
si de of bl ock.
REFILLING
(1) Ti ghten the radi ator petcock and the cyl i nder
bl ock drai n pl ug(s).
(2) I nstal l gri l l e.
(3) Fi l l system usi ng a 50/50 mi xture of water and
anti freeze as descri bed i n the Cool ant secti on of thi s
group. Fi l l radi ator to top and i nstal l radi ator cap.
Add suffi ci ent cool ant to reserve/overfl ow tank to
rai se l evel to FULL mark.
(4) Wi th heater control uni t i n the HEAT posi ti on,
operate engi ne wi th radi ator cap i n pl ace.
(5) After engi ne has reached normal operati ng
temperature, shut engi ne off and al l ow i t to cool .
(6) Add cool ant to reserve/overfl ow tank as neces-
sary. Only add coolant when the engine is cold.
Coolant level in a warm engine will be higher
due to thermal expansion.
COOLING SYSTEM REVERSE FLUSHING
CAUTION: The cooling system normally operates at
97-to-124 kPa (14- to-18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Reverse fl ushi ng of the cool i ng system i s the forc-
i ng of water through the cool i ng system. Thi s i s done
usi ng ai r pressure i n the opposi te di recti on of normal
cool ant fl ow. I t i s usual l y onl y necessary wi th very
di rty systems wi th evi dence of parti al pl uggi ng.
CHEMICAL CLEANING
I f vi sual i nspecti on i ndi cates the formati on of
sl udge or scal y deposi ts, use a radi ator cl eaner
(Mopar Radi ator Kl een or equi val ent) before fl ushi ng.
Thi s wi l l soften scal e and other deposi ts and ai d the
fl ushi ng operati on.
CAUTION: Be sure instructions on the container
are followed.
REVERSE FLUSHING RADIATOR
Di sconnect the radi ator hoses from the radi ator fi t-
ti ngs. Attach a secti on of radi ator hose to the radi a-
tor bottom outl et fi tti ng and i nsert the fl ushi ng gun.
Connect a water suppl y hose and ai r suppl y hose to
the fl ushi ng gun.
CAUTION: The cooling system normally operates at
97-to-124 kPa (14- to-18 psi) pressure. Exceeding
this pressure may damage the radiator or hoses.
Al l ow the radi ator to fi l l wi th water. When radi ator
i s fi l l ed, appl y ai r i n short bl asts al l owi ng radi ator to
refi l l between bl asts. Conti nue thi s reverse fl ushi ng
unti l cl ean water fl ows out through rear of radi ator
cool i ng tube passages. For more i nformati on, refer to
operati ng i nstructi ons suppl i ed wi th fl ushi ng equi p-
ment. Have radi ator cl eaned more extensi vel y by a
radi ator repai r shop.
REVERSE FLUSHING ENGINE
Drai n the cool i ng system. Remove the thermostat
housi ng and thermostat. I nstal l the thermostat hous-
i ng. Di sconnect the radi ator upper hose from the
radi ator and attach the fl ushi ng gun to the hose. Di s-
connect the radi ator l ower hose from the water
pump. Attach a l ead away hose to the water pump
i nl et fi tti ng.
CAUTION: Be sure that the heater control valve is
closed (heat off). This is done to prevent coolant
flow with scale and other deposits from entering
the heater core.
Connect the water suppl y hose and ai r suppl y hose
to the fl ushi ng gun. Al l ow the engi ne to fi l l wi th
water. When the engi ne i s fi l l ed, appl y ai r i n short
bl asts, al l owi ng the system to fi l l between ai r bl asts.
Conti nue unti l cl ean water fl ows through the l ead
away hose. For more i nformati on, refer to operati ng
i nstructi ons suppl i ed wi th fl ushi ng equi pment.
Fig. 21 Radiator Petcock2.5L/4.0L (LHD/RHD)
1 RADIATOR PETCOCK
Remove the l ead away hose, fl ushi ng gun, water
suppl y hose and ai r suppl y hose. Remove the thermo-
stat housi ng and i nstal l thermostat. I nstal l the ther-
mostat housi ng wi th a repl acement gasket. Refer to
Thermostat Repl acement. Connect the radi ator
hoses. Refi l l the cool i ng system wi th the correct anti -
freeze/water mi xture.
TRANSMISSION OIL COOLERS
WATER-TO-OIL COOLER
The i nternal transmi ssi on oi l cool er l ocated wi thi n
the radi ator i s not servi ceabl e. I f i t requi res servi ce,
the radi ator must be repl aced.
Once the repai red or repl acement radi ator has been
i nstal l ed, fi l l the cool i ng system and i nspect for l eaks.
Refer to the Refi l l i ng Cool i ng System and Testi ng
Cool i ng System For Leaks secti ons i n thi s group. I f
the transmi ssi on operates properl y after repai ri ng the
l eak, drai n the transmi ssi on and remove the transmi s-
si on oi l pan. I nspect for sl udge and/or rust. I nspect for
a di rty or pl ugged i nl et fi l ter. I f none of these condi -
ti ons are found, the transmi ssi on and torque convertor
may not requi re recondi ti oni ng. Refer to Group 21 for
automati c transmi ssi on servi ci ng.
AIR-TO-OIL COOLER
REMOVAL
(1) Remove the gri l l mounti ng screws and remove
the gri l l . Refer to Group 23, Body for procedures.
(2) Pl ace a drai n pan bel ow the transmi ssi on oi l
cool er.
(3) Remove the two constant tensi on cl amps at oi l
cool er i nl et and outl et tubes.
(4) Remove the two oi l cool er mounti ng bol ts (Fi g.
22).
(5) Remove the oi l cool er from vehi cl e.
INSTALLATION
(1) Posi ti on and secure oi l cool er to vehi cl e.
Ti ghten mounti ng bol ts to 8 Nm (72 i n. l bs.) torque.
(2) Secure i nl et and outl et tubes wi th constant
tensi on cl amps.
I nstal l the gri l l .
(3) Start engi ne and check transmi ssi on fl ui d l evel .
Add fl ui d i f necessary.
COOLANT RESERVE TANK
REMOVAL
(1) Remove the tube cl amp at the tank and remove
tube.
(2) Remove the tank mounti ng bol ts and remove
tank (Fi g. 23) (Fi g. 24).
Fig. 22 Auxiliary Air-To-Oil Cooler
1 AIR CONDITIONING CONDENSER
2 HOSE CLAMPS (2)
3 AUXILIARY AUTOMATIC TRANSMISSION OIL COOLER
4 MOUNTING BOLT
5 MOUNTING BOLT
Fig. 23 Reserve/Overflow TankExcept Right Hand
Drive
2 CLAMP
3 MOUNTING BOLTS
4 TUBE TO RADIATOR
INSTALLATION
(1) Posi ti on tank and ti ghten to 2 Nm (17 i n. l bs.)
torque.
(2) Posi ti on tube and secure cl amp.
WATER PUMP
CAUTION: If the water pump is replaced because of
mechanical damage, the fan blades and viscous fan
drive should also be inspected. These components
could have been damaged due to excessive vibra-
tion.
The water pump can be removed wi thout di scharg-
i ng the ai r condi ti oni ng system (i f equi pped).
CAUTION: All engines have a reverse (counter-
clockwise) rotating water pump. The letter R is
stamped into the back of the water pump impeller
(Fig. 25) to identify. Engines from previous model
years, depending upon application, may be
equipped with a forward (clockwise) rotating water
pump. Installation of the wrong water pump will
cause engine over heating.
The water pump i mpel l er i s pressed on the rear of
the pump shaft and beari ng assembl y. The water
pump i s servi ced onl y as a compl ete assembl y.
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.
i s cl ean, drai n cool ant i nto a cl ean contai ner for
reuse.
REMOVAL-2. 5L ENGINE (LHD/RHD)
(1) Di sconnect battery negati ve cabl e.
(2) Drai n cool i ng system. Refer to Cool i ng System-
Drai ni ng and Fi l l i ng i n thi s group.
(3) Remove upper radi ator hose.
(4) Loosen (but do not remove at thi s ti me) the
four fan hub-to-water pump pul l ey mounti ng nuts
(Fi g. 26).
(5) Remove accessory dri ve bel t. (Refer to Acces-
sory Dri ve Bel t, Removal and I nstal l ati on i n thi s
group)
(6) Di sconnect el ectri c cool i ng fan connector (i f
equi pped).
(7) Unbol t fan shroud.
(8) Remove the four fan hub-to-water pump pul l ey
nuts and remove fan and shroud together.
Fig. 24 Reserve/Overflow TankWith Right Hand
Drive
1 CLAMP
3 MOUNTING BOLTS
4 LOWER BRACKET
5 TUBE TO RADIATOR
Fig. 25 Reverse Rotating Water PumpTypical
1 R STAMPED INTO IMPELLER
CAUTION: After removing fan blade/viscous fan
drive assembly, do not place thermal viscous fan
drive in horizontal position. If stored horizontally,
silicone fluid in viscous fan drive could drain into
its bearing assembly and contaminate lubricant.
(9) Remove power steeri ng pump and bracket (Fi g.
27), refer to Group 19 Steeri ng for correct procedure.
(10) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump pi pe.
(11) Remove the four pump mounti ng bol ts (Fi g.
28) and remove pump from vehi cl e. Di scard ol d gas-
ket. Note that one of the four bol ts i s l onger than the
other bol ts.
(12) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
INSTALLATION-2. 5L ENGINE (LHD/RHD)
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose pi pe to the pump. Use a seal ant on the fi tti ng
such as Mopar Thread Seal ant Wi th Tefl on. Refer to
the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
Fig. 26 Fan Mounting Nuts
1 THERMAL VISCOUS FAN DRIVE
2 (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 (4) FAN HUB-TO-PUMP PULLEY STUDS
4 WATER PUMP
5 WATER PUMP PULLEY
6 FAN BLADE
7 (4) FAN HUB-TO-PUMP PULLEY NUTS
Fig. 27 Power Steering Pump Attachment-2.5L
1 INTAKE MANIFOLD
2 PUMP ASSEMBLY 2.5L
3 PUMP BRACKET
Fig. 28 Water Pump Remove/InstallTypical
1 HEATER HOSE FITTING
2 UPPER VENT HOLE
3 PUMP GASKET
4 WATER PUMP
5 LOWER VENT HOLE
6 LONG BOLT
7 BOLTS (3) SHORT
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 23 Nm (17 ft. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) I nstal l power steeri ng pump and bracket. Refer
to Group 19, Steeri ng.
(6) Posi ti on water pump pul l ey to water pump
hub.
(7) I nstal l shroud and fan together and i nstal l four
nuts to water pump hub studs. Ti ghten nuts to 27
(8) I nstal l and ti ghten upper fan shroud nuts to 4
Nm (31 i n. l bs.).
(9) Connect el ectri c fan connector (i f equi pped).
CAUTION: When installing the accessory drive belt,
the belt MUST be routed correctly. If not, the engine
may overheat due to the water pump rotating in the
wrong direction. Refer to the Belt Removal and
Installation in this group for appropriate belt rout-
ing. You may also refer to the Belt Routing Label in
the vehicle engine compartment.
(10) I nstal l and tensi on accessory dri ve bel t, refer
to Accessory Dri ve Bel t removal and i nstal l ati on i n
thi s group.
(11) I nstal l upper radi ator hose.
(12) Fi l l cool i ng system wi th cool ant and check for
l eaks. Refer to Refi l l i ng Cool i ng System i n thi s
group.
(13) Connect battery negati ve cabl e.
(14) Start and warm the engi ne. Check for l eaks.
REMOVAL-4. 0L ENGINE (LHD/RHD)
(2) Drai n the cool i ng system. (Refer to Cool i ng
System-Drai ni ng and Fi l l i ng i n thi s group.)
(3) Di sconnect el ectri c cool i ng fan connector.
(4) Remove el ectri c cool i ng fan/shroud assembl y (i f
equi pped).
(5) Remove vi scous fan shroud bol ts (2).
(6) Loosen (but do not remove at thi s ti me) the
four water pump pul l ey-to-water pump hub mounti ng
bol ts (Fi g. 29) and the four vi scous fan to i dl er pul l ey
nuts.
NOTE: The accessory drive belt must be removed
prior to removing the fan (if installed at pump) or
fan pulley.
(7) Remove accessory dri ve bel t (refer to Accessory
Dri ve Bel t, Removal and I nstal l ati on i n thi s group)
(8) Remove the four vi scous fan to i dl er pul l ey
nuts and remove the fan and shroud together.
CAUTION: After removing fan blade/viscous fan
drive assembly, do not place thermal viscous fan
drive in horizontal position. If stored horizontally,
silicone fluid in viscous fan drive could drain into
its bearing assembly and contaminate lubricant.
(9) Remove the four water pump pul l ey bol ts and
remove the pul l ey.
(10) Remove power steeri ng pump and bracket
(Fi g. 30), refer to Group 19 Steeri ng.
(11) Remove l ower radi ator hose from water pump.
Remove heater hose from water pump fi tti ng.
(12) Remove the four pump mounti ng bol ts (Fi g.
31) and remove pump from vehi cl e. Di scard ol d gas-
ket. Note that one of the four bol ts i s l onger than the
other bol ts.
(13) I f pump i s to be repl aced, the heater hose fi t-
ti ng must be removed. Note posi ti on of fi tti ng before
removal .
INSTALLATION-4. 0L ENGINE (LHD/RHD)
(1) I f pump i s bei ng repl aced, i nstal l the heater
hose fi tti ng to the pump. Use a seal ant on the fi tti ng
such as Mopar Thread Seal ant Wi th Tefl on. Refer to
the di recti ons on the package.
(2) Cl ean the gasket mati ng surfaces. I f the ori gi -
nal pump i s used, remove any deposi ts or other for-
ei gn materi al . I nspect the cyl i nder bl ock and water
pump mati ng surfaces for erosi on or damage from
cavi tati on.
(3) I nstal l the gasket and water pump. The si l i -
cone bead on the gasket shoul d be faci ng the water
Fig. 29 Water Pump Pulley Bolts
1 WATER PUMP HUB
2 BOLTS (4)
3 PUMP PULLEY
pump. Al so, the gasket i s i nstal l ed dry. Ti ghten
mounti ng bol ts to 23 Nm (17 ft. l bs.) torque. Rotate
the shaft by hand to be sure i t turns freel y.
(4) Connect the radi ator and heater hoses to the
water pump.
(5) Posi ti on water pump pul l ey to water pump
hub.
(6) I nstal l four pump pul l ey bol ts. Ti ghten bol ts (or
nuts) to 27 Nm (20 ft. l bs.) torque.
(7) I nstal l power steeri ng pump. Refer to Group
19, Steeri ng for proper procedure and torque val ues.
(8) I nstal l the vi scous fan and shroud together.
I nstal l the four fan to i dl er pul l ey nuts and ti ghten
to 27 Nm (20 ft. l bs.).
CAUTION: When installing the accessory drive belt,
the belt MUST be routed correctly. If not, the engine
may overheat due to the water pump rotating in the
wrong direction. Refer to the Belt Removal and
Installation in this group for appropriate belt rout-
ing. You may also refer to the Belt Routing Label in
the vehicle engine compartment.
(9) I nstal l and ti ghten vi scous fan shroud bol ts to
4 Nm (31 i n. l bs.).
(10) I nstal l and tensi on the accessory dri ve bel t,
refer to Accessory Dri ve Bel t removal and i nstal l a-
ti on i n thi s group.
(11) I nstal l the el ectri c cool i ng fan/shroud assy.
(12) I nstal l and ti ghten el ectri c fan shroud bol ts to
4 Nm (31 i n. l bs.). Connect fan connector.
Fig. 30 Power Steering Pump Attachment-4.0L
1 PUMP ASSEMBLY
2 PUMP BRACKET
Fig. 31 Water Pump Remove/InstallTypical
1 HEATER HOSE FITTING
2 UPPER VENT HOLE
3 PUMP GASKET
4 WATER PUMP
5 LOWER VENT HOLE
6 LONG BOLT
7 BOLTS (3) SHORT
(13) Fi l l cool i ng system wi th cool ant and check for
l eaks. Refer to Refi l l i ng Cool i ng System i n thi s
group.
THERMOSTAT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
reuse.
(1) Drai n the cool ant from the radi ator unti l the
l evel i s bel ow the thermostat housi ng.
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 12). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
tongue of constant tension clamps (Fig. 11). If
replacement is necessary, use only an original
equipment clamp with matching number or letter.
(2) Remove radi ator upper hose and heater hose at
thermostat housi ng.
(3) Di sconnect wi ri ng connector at engi ne cool ant
temperature sensor.
(4) Remove thermostat housi ng mounti ng bol ts,
thermostat housi ng, gasket and thermostat (Fi g. 32).
Di scard ol d gasket.
(5) Cl ean the gasket mati ng surfaces.
INSTALLATION
(1) I nstal l the repl acement thermostat so that the
pel l et, whi ch i s enci rcl ed by a coi l spri ng, faces the
engi ne. Al l thermostats are marked on the outer
fl ange to i ndi cate the proper i nstal l ed posi ti on.
(a) Observe the recess groove i n the engi ne cyl -
i nder head (Fi g. 33).
(b) Posi ti on thermostat i nto thi s groove wi th
arrow and ai r bl eed hol e on outer fl ange poi nti ng
up.
(2) I nstal l repl acement gasket and thermostat
housi ng.
Fig. 32 Thermostat Removal/Installation
1 LONG BOLT
2 GASKET
3 THERMOSTAT
5 SHORT BOLT
Fig. 33 Thermostat Recess
1 GROOVE
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess
may result in a cracked housing.
(3) Ti ghten the housi ng bol ts to 20 Nm (15 ft. l bs.)
torque.
(4) I nstal l hoses to thermostat housi ng.
(5) I nstal l el ectri cal connector to cool ant tempera-
ture sensor.
(6) Be sure that the radi ator drai ncock i s ti ghtl y
cl osed. Fi l l the cool i ng system to the correct l evel
wi th the requi red cool ant mi xture. Refer to Refi l l i ng
Cool i ng System i n thi s group.
RADIATOR 2. 5L
CAN OCCUR.
DO NOT WASTE reusabl e cool ant. I f sol uti on i s
cl ean, drai n cool ant i nto a cl ean contai ner for reuse.
REMOVAL
(2) Observe the previ ous WARNINGS.
(4) For access to radi ator drai ncock, remove radi a-
tor gri l l mounti ng screws and remove gri l l . Refer to
Group 23, Body for procedures.
hose to the radi ator petcock (Fi g. 34). Put the other
end i nto a cl ean contai ner. Open petcock and drai n
radi ator.
(6) Detach power steeri ng fl ui d reservoi r from fan
shroud and l ay asi de.
(7) Di sconnect el ectri c cool i ng fan el ectri cal con-
nector, i f equi pped.
(8) Di sconnect CRS hose from radi ator fi l l er neck
and remove from shroud retai ni ng l oops.
(9) Remove the four (4) vi scous fan/dri ve assembl y
nuts from the water pump pul l ey and remove fan/
dri ve assy.
(10) Remove the four (4) fan shroud to core sup-
port mounti ng screws.
(11) Remove the el ectri c fan (i f equi pped) and
shroud assembl y from the vehi cl e (Fi g. 36).
(12) Remove radi ator upper crossmember (Fi g. 36).
(13) I f equi pped wi th ai r condi ti oni ng, separate
radi ator from condenser by removi ng condenser-to-ra-
di ator mounti ng brackets (Fi g. 35).
(14) Di sconnect upper and l ower radi ator hoses.
(15) I f equi pped, di sconnect and pl ug automati c
transmi ssi on fl ui d cool er l i nes. Qui ck Connect Fi tti ng
Rel ease Tool 6935 may be needed. I f equi pped wi th
remote transmi ssi on cool er, remove l i ne to cool er
from bracket at bottom of radi ator.
(16) Li ft radi ator strai ght up and out of engi ne
compartment taki ng care not to damage fi ns.
(17) I f radi ator i s to be repl aced, be sure to remove
and transfer any components not i ncl uded wi th
repl acement radi ator.
INSTALLATION
The radi ator i s suppl i ed wi th two al i gnment dowel s
(Fi g. 41). They are l ocated on the bottom tank and fi t
i nto rubber grommets i n the radi ator l ower cross-
member.
Fig. 34 Radiator PetcockTypical
1 RADIATOR PETCOCK
(1) Lower radi ator i nto engi ne compartment. Posi -
ti on al i gnment dowel s i nto rubber grommets i n radi -
ator l ower crossmember (Fi g. 41).
(2) I f equi pped wi th ai r condi ti oni ng, attach con-
denser to radi ator wi th mounti ng brackets (Fi g. 35).
(3) I nstal l radi ator upper crossmember and four
mounti ng bol ts.
(4) I nstal l radi ator upper crossmember-to-i sol ator
nuts. Ti ghten nuts to 10 Nm (86 i n. l bs.) torque. I f
i sol ator-to-radi ator nuts had been removed, ti ghten
them to 5 Nm (47 i n. l bs.) torque.
(5) Connect radi ator upper and l ower hoses.
(6) I f equi pped, connect automati c transmi ssi on
fl ui d cool er l i nes. I f equi pped wi th remote cool er,
attach cool er l i ne to bracket at bottom of radi ator.
(7) I nstal l el ectri c fan (i f equi pped) and shroud
assembl y.. I nsert al i gnment tabs at bottom of fan
shroud i nto sl ots i n bracket at bottom of radi ator.
Ti ghten mounti ng bol ts to 3 Nm (31 i n. l bs.) torque.
(8) Connect el ectri c cool i ng fan el ectri cal connector.
(9) I nstal l power steeri ng reservoi r to fan shroud.
(10) I nstal l gri l l .
Fig. 35 Condenser-to-Radiator Mounting Brackets
1 CONDENSER TO RADIATOR MOUNTING BRACKETS
Fig. 36 Radiator Removal/Installation2.5L Engines
1 ELECTRIC FAN/SHROUD ASSEMBLY
2 UPPER CROSSMEMBER
3 ISOLATOR
4 RADIATOR
5 LOWER CROSSMEMBER
6 U-NUT
(12) Fi l l cool i ng system wi th correct cool ant. Refer
to the Cool ant secti on of thi s group.
(13) I nstal l pressure cap.
(14) Check and adjust automati c transmi ssi on
fl ui d l evel (i f equi pped).
(15) Start engi ne and vi sual l y check for l eaks.
RADIATOR 4. 0L
CAN OCCUR.
REMOVAL
(2) Observe the previ ous WARNINGS.
(4) For access to radi ator drai ncock, remove radi a-
tor gri l l mounti ng screws and remove gri l l . Refer to
Group 23, Body for procedures.
hose to the radi ator petcock (Fi g. 38). Put the other
end i nto a cl ean contai ner. Open petcock and drai n
radi ator.
(6) Di sconnect el ectri c cool i ng fan el ectri cal con-
(7) I f equi pped, remove two el ectri c cool i ng fan
mounti ng bol ts. Li ft cool i ng fan strai ght up unti l
al i gnment tabs at the bottom are cl ear of sl ots i n
bracket at bottom of radi ator (Fi g. 39).
(8) Remove the two mechani cal (non-el ectri cal ) fan
shroud mounti ng bol ts. Li ft shroud strai ght up unti l
al i gnment tabs at the bottom are cl ear of sl ots i n
bracket at bottom of radi ator (Fi g. 39). Pl ace shroud
over mechani cal fan.
(9) I f equi pped, di sconnect and pl ug automati c
transmi ssi on fl ui d cool er l i nes. Qui ck Connect Fi tti ng
Rel ease Tool 6935 may be needed. I f equi pped wi th
remote transmi ssi on cool er, remove l i ne to cool er
from bracket at bottom of radi ator.
Fig. 37 Radiator Alignment DowelsTypical
1 ALIGNMENT DOWEL
2 RADIATOR
4 GROMMET
Fig. 38 Radiator PetcockTypical
1 RADIATOR PETCOCK
(10) Di sconnect radi ator upper and l ower hoses
cl amps. Di sconnect radi ator upper and l ower hoses.
(11) Mark the posi ti on of the hood l atch stri ker on
the radi ator crossmember and remove hood l atch
stri ker.
(12) Remove two radi ator upper crossmember to
i sol ator nuts (Fi g. 39).
(13) Remove four radi ator upper crossmember
bol ts and remove upper crossmember.
(14) I f equi pped wi th ai r condi ti oni ng, separate
radi ator from condenser by removi ng condenser-to-ra-
di ator mounti ng brackets (Fi g. 40).
(15) Li ft radi ator strai ght up and out of engi ne
compartment taki ng care not to damage fi ns.
INSTALLATION
The radi ator i s suppl i ed wi th two al i gnment dowel s
(Fi g. 41). They are l ocated on the bottom tank and fi t
i nto rubber grommets i n the radi ator l ower cross-
member.
(1) Lower radi ator i nto engi ne compartment. Posi -
ti on al i gnment dowel s i nto rubber grommets i n radi -
ator l ower crossmember (Fi g. 41)
(2) I f equi pped wi th ai r condi ti oni ng, attach con-
denser to radi ator wi th mounti ng brackets (Fi g. 40).
(3) I nstal l radi ator upper crossmember and four
mounti ng bol ts.
(4) I nstal l radi ator upper crossmember-to-i sol ator
nuts. Ti ghten nuts to 10 Nm (86 i n. l bs.) torque. I f
i sol ator-to-radi ator nuts had been removed, ti ghten
them to 5 Nm (47 i n. l bs.) torque.
(5) I nstal l hood l atch stri ker. Note previ ousl y
marked posi ti on.
(6) Connect radi ator upper and l ower hoses.
(7) I f equi pped, connect automati c transmi ssi on
fl ui d cool er l i nes. Refer to Group 21, Transmi ssi ons
for procedures. I f equi pped wi th remote cool er, attach
cool er l i ne to bracket at bottom of radi ator.
Fig. 39 Radiator Removal/Installation4.0L Engines
1 (LHD)
2 (RHD)
3 VISCOUS FAN SHROUD
4 ELECTRIC FAN MODULE
5 ISOLATOR
6 RADIATOR
7 LOWER CROSSMEMBER
8 U-NUT
9 UPPER CROSSMEMBER
(8) I nstal l el ectri c cool i ng fan (i f equi pped). I nsert
al i gnment tabs at bottom of fan shroud i nto sl ots i n
bracket at bottom of radi ator. Ti ghten mounti ng bol ts
to 3 Nm (31 i n. l bs.) torque.
(9) Connect el ectri c cool i ng fan el ectri cal connector.
(10) I nstal l mechani cal cool i ng fan shroud. I nsert
al i gnment tabs at bottom of shroud i nto sl ots i n
bracket at bottom of radi ator. Ti ghten mounti ng bol ts
(11) Cl ose radi ator drai ncock.
(12) I nstal l gri l l .
(13) Connect negati ve battery cabl e.
(14) Fi l l cool i ng system wi th correct cool ant. Refer
to the Cool ant secti on of thi s group.
(15) I nstal l pressure cap.
(16) Check and adjust automati c transmi ssi on
fl ui d l evel (i f equi pped).
ELECTRIC COOLING FAN 2. 5L
The el ectri c fan modul e i s onl y to be servi ced as an
assembl y.
REMOVAL
(2) Di sconnect CRS hose from radi ator fi l l er neck
and pul l through (remove) the shroud retai ni ng
l oops.
(3) Detach power steeri ng reservoi r from fan
shroud and l ay asi de.
(4) Remove the four vi scous fan/dri ve assembl y
mounti ng nuts from the water pump studs and
remove vi scous fan assembl y.
(5) Di sconnect cool i ng fan el ectri cal connector.
(6) Remove the four upper fan shroud to radi ator
crossmember mounti ng screws (Fi g. 42).
(7) Li ft fan and shroud assy. from vehi cl e
(8) Detach fan harness from shroud.
(9) Remove four fan modul e to shroud phi l l i ps
head screws (Fi g. 43) and remove modul e from
shroud.
INSTALLATION
(1) Posi ti on fan modul e i n shroud so that the har-
ness exi ts the motor at the 12 ocl ock posti on (Fi g.
43).
(2) I nstal l and ti ghten fan modul e to shroud
screws to 3 Nm (31 i n. l bs.).
(3) Route fan harness through the shroud and
attach to shroud at correct posi ti on.
(4) Lower fan and shroud assembl y i nto pl ace,
maki ng sure the shroud al i gnment tabs rest i n thei r
correspondi ng l ower radi ator sl ots.
(5) I nstal l upper fan shroud screws and ti ghten to
3 Nm (31 i n. l bs.).
Fig. 40 Condenser to Radiator Mounting Brackets
4.0L Engine
1 CONDENSER TO RADIATOR MOUNTING BRACKETS
Fig. 41 Radiator Alignment DowelsTypical
1 ALIGNMENT DOWEL
2 RADIATOR
4 GROMMET
(6) Connect fan el ectri cal connector.
(7) I nstal l power steeri ng reservoi r to shoud.
(8) I nstal l vi scous fan dri ve assy. to water pump
hub and ti ghten nuts to 27 Nm (20 ft. l bs.)
ELECTRIC COOLING FAN 4. 0L
REMOVAL
The auxi l i ary cool i ng fan i s attached to the radi a-
tor upper crossmember behi nd the radi ator.
(1) Remove the two fan mounti ng bol ts from radi -
ator upper crossmember (Fi g. 44).
(2) Di sconnect the el ectri c fan connector.
(3) Li ft fan strai ght up and out of vehi cl e.
INSTALLATION
(1) Al i gn l ower retai ni ng tabs of fan shroud wi th
sl ots i n bracket at bottom of radi ator. Push fan down
i nto posi ti on.
(2) Ti ghten the mounti ng bol ts to 4 Nm (31 i n.
l bs.) torque.
Fig. 42 Fan Shroud Removal/Installation
1 ELECTRIC FAN/SHROUD ASSEMBLY
2 UPPER CROSSMEMBER
3 ISOLATOR
4 RADIATOR
5 LOWER CROSSMEMBER
6 U-NUT
Fig. 43 Fan Module Orientation and Mounting
1 FAN MOTOR HARNESS AT 12 OCLOCK POSITION
2 MOUNTING SCREWS (4)
3 FAN CONNECTOR
(3) Connect auxi l i ary cool i ng fan el ectri cal connec-
tor.
BLOCK HEATER
REMOVAL
Refer to correct i l l ustrati on (Fi g. 45) (Fi g. 46) when
servi ci ng bl ock heater.
CAN OCCUR.
(1) Drai n cool ant from radi ator and engi ne cyl i n-
der bl ock.
(2) Unpl ug power cord from bl ock heater.
(3) Loosen screw i n center of bl ock heater (Fi g. 45)
(Fi g. 46).
(4) Remove bl ock heater from cyl i nder bl ock.
INSTALLATION
(1) Thoroughl y cl ean the engi ne core hol e and the
bl ock heater seat.
(2) I nsert bl ock heater assembl y i nto core hol e
wi th el ement l oop poi nti ng Up.
(3) Seat bl ock heater fl ush agai nst bl ock face.
Ti ghten mounti ng screw to 3.6 Nm (32 i n. l bs.)
torque.
(4) Fi l l cool i ng system wi th cool ant. Pressuri ze
system and i nspect for l eaks.
(5) Pl ug power cord i nto bl ock heater. Route cord
away from movi ng parts, l i nkages and exhaust sys-
tem components. Secure cord i n pl ace wi th ti e-straps.
ENGINE ACCESSORY DRIVE BELTS
Correct dri ve bel t tensi on i s requi red to ensure
opti mum performance of the bel t dri ven engi ne acces-
sori es. There are di fferent types of adjustment
gauges for checki ng ei ther a serpenti ne or a V-type
bel t. Refer to the i nstructi ons suppl i ed wi th the
Fig. 44 Auxiliary Cooling FanRemove/Install
Typical
1 ELECTRIC COOLING FAN
2 MOUNTING BOLT
3 ELECTRIC COOLING FAN CONNECTOR
4 MOUNTING BOLT
Fig. 45 Heater and Cord 2.5L 4-Cylinder Engine
1 POWER CORD LOCATION
2 BLOCK HEATER
Fig. 46 Heater and Cord4.0L 6-Cylinder Engine
1 POWER CORD LOCATION
2 BLOCK HEATER
gauge. Use the correct gauge when checki ng bel t ten-
si on. Pl ace gauge i n the mi ddl e of the secti on of bel t
bei ng tested (between two pul l eys) to check tensi on.
Do not al l ow the gauge (or gauge adapter) to contact
anythi ng but the bel t.
BELT SCHEMATICS
The bel t routi ng schemati cs are publ i shed from the
l atest i nformati on avai l abl e at the ti me of publ i ca-
ti on. If anything differs between these schemat-
ics and the Belt Routing Label, use the
schematics on Belt Routing Label. Thi s l abel i s
l ocated i n the engi ne compartment.
Refer to (Fi g. 47) (Fi g. 48) (Fi g. 49) (Fi g. 50) for
proper bel t routi ng on vehi cl es wi th conventi onal l eft
hand dri ve. Refer to (Fi g. 51) (Fi g. 52) for proper bel t
routi ng on vehi cl es wi th ri ght hand dri ve (RHD). Or,
refer to the Bel t Routi ng Label l ocated i n the vehi cl e
BELT REPLACEMENT OR ADJUSTMENT LEFT
HAND DRIVE
Bel t tensi on i s adjusted at the power steeri ng
pump bracket and i dl er pul l ey assembl y.
(1) Di sconnect negati ve battery cabl e from battery.
(2) Loosen i dl er pul l ey bol t at the power steeri ng
bracket (Fi g. 53).
(3) Loosen adjusti ng bol t unti l bel t can be removed
from pul l eys.
(4) Remove bel t.
INSTALLATION
(1) Check condi ti on of al l pul l eys.
CAUTION: When installing the serpentine acces-
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction. Refer to (Fig.
47) (Fig. 48) (Fig. 49) (Fig. 50) for correct belt rout-
ing.
Fig. 47 Models with 2.5L EngineWith A/C
Fig. 48 Models with 2.5L EngineWithout A/C
Fig. 49 Models with 4.0L EngineWithout A/C
Except RHD
(2) I nstal l new bel t.
(3) Usi ng serpenti ne bel t tensi on gauge, ti ghten
adjusti ng bol t unti l bel t reaches proper tensi on. Refer
to Bel t Tensi on at the rear of thi s secti on for proper
bel t tensi on.
(4) After bel t i s tensi oned correctl y, ti ghten i dl er
pul l ey bol t to 47 Nm (35 ft. l bs.)
(5) After i dl er pul l ey has been ti ghtened i nto posi -
ti on, recheck bel t tensi on. Adjust i f necessary.
BELT REPLACEMENT OR ADJUSTMENT RIGHT
HAND DRIVE (4. 0L)
(2) Loosen l ower al ternator mounti ng bol t and nut.
(3) Loosen upper al ternator mounti ng nut.
(4) Loosen adjusti ng bol t at upper al ternator bracket
(Fi g. 54) unti l bel t can be removed from pul l eys.
(5) Remove bel t.
INSTALLATION
(1) Check condi ti on of al l pul l eys.
Fig. 50 Models With 4.0L EngineWith A/CExcept
RHD
Fig. 51 Models With 4.0L EngineWith A/CWith
RHD
Fig. 52 Models With 4.0L EngineWithout A/C
With RHD
Fig. 53 Power Steering Pump Bracket and Idler
Pulley
1 ADJUSTING BOLT
2 IDLER PULLEY BOLT
CAUTION: When installing the serpentine acces-
sory drive belt, the belt MUST be routed correctly. If
not, the engine may overheat due to the water
pump rotating in the wrong direction. Refer to (Fig.
51) (Fig. 52) for correct belt routing.
(2) I nstal l new bel t.
(3) Usi ng serpenti ne bel t tensi on gauge, ti ghten
adjusti ng bol t unti l bel t reaches proper tensi on. Refer
to Bel t Tensi on at the rear of thi s secti on for proper
bel t tensi on.
(4) Ti ghten al ternator upper and l ower mounti ng
bol ts.
(5) After generator and adjust bracket have been
ti ghtened i nto posi ti on, recheck bel t tensi on. Adjust i f
necessary.
COOLING SYSTEM FANS
REMOVAL
Some engi nes have the mechani cal fan/vi scous fan
dri ve assembl y mounted di rectl y to the water pump
hub (Fi g. 55). I t may al so be mounted to a hub/bear-
i ng attached to an al umi num bracket on the ri ght
front si de of engi ne (Fi g. 56).
(1) Loosen but do not remove at thi s ti me, the four
fan hub mounti ng nuts (Fi g. 55) (Fi g. 56).
(2) Remove accessory serpenti ne dri ve bel t. Refer
to Bel t Servi ce i n the Engi ne Accessory Dri ve Bel t
secti on of thi s group.
(3) Some model s wi th certai n engi nes may requi re
the removal of the fan shroud to remove the vi scous
fan dri ve. The fan shroud and fan bl ade/vi scous fan
dri ve shoul d be removed from the vehi cl e as one
assembl y.
(4) Remove four fan hub mounti ng nuts (Fi g. 55)
(Fi g. 56) and remove fan/vi scous fan dri ve assembl y
from vehi cl e.
(5) After removi ng fan bl ade/vi scous fan dri ve
assembl y, do not pl ace thermal vi scous fan dri ve i n
hori zontal posi ti on. I f stored hori zontal l y, si l i cone
fl ui d i n vi scous fan dri ve coul d drai n i nto i ts beari ng
assembl y and contami nate l ubri cant.
INSTALLATION
(1) Assembl e fan bl ade to vi scous fan dri ve.
Ti ghten mounti ng bol ts to 27 Nm (20 ft. l bs.) torque.
(2) Posi ti on mounti ng fl ange of fan bl ade/vi scous
fan dri ve assembl y onto hub. I nstal l four nuts and
ti ghten to 24 Nm (18 ft. l bs.) torque. Ti ghten the
fi rst two nuts 180 degrees apart. Then ti ghten l ast
two nuts.
CAUTION: When installing a serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction. Refer to appropriate
Engine Accessory Drive Belt Schematic in this
group for correct belt routing.
Fig. 54 Generator Belt Tension Adjust Bracket
1 TENSION ADJUSTMENT BOLT
2 UPPER ALTERNATOR NUT
Fig. 55 Water Pump Mounted Cooling Fan
1 THERMAL VISCOUS FAN DRIVE
2 (4) FAN BLADE-TO-VISCOUS DRIVE BOLTS
3 (4) FAN HUB-TO-PUMP PULLEY STUDS
4 WATER PUMP
5 WATER PUMP PULLEY
6 FAN BLADE
7 (4) FAN HUB-TO-PUMP PULLEY NUTS
(3) I nstal l accessory dri ve bel ts. Tensi on bel ts to
speci fi cati ons. Refer to the Speci fi cati ons secti on at
the end of thi s group.
VISCOUS FAN DRIVE REMOVAL/INSTALLATION
Refer to Cool i ng System Fan for removal and
i nstal l ati on procedures of the vi scous dri ve uni t.
Viscous Fan Drive Fluid Pump Out Requirement:
After i nstal l i ng a new vi scous fan dri ve, bri ng the
engi ne speed up to approxi matel y 2000 rpm and hol d
for approxi matel y two mi nutes. Thi s wi l l ensure
proper fl ui d di stri buti on wi thi n the dri ve.
RADIATOR PRESSURE CAP
CLEANING
Cl ean the radi ator pressure cap usi ng a mi l d soap
and water onl y.
INSPECTION
Vi sual l y i nspect the pressure val ve gasket on the
cap. Repl ace cap i f the gasket i s swol l en, torn or
worn. I nspect the area around radi ator fi l l er neck for
whi te deposi ts that i ndi cate a l eaki ng cap.
RADIATOR
CLEANING
Cl ean radi ator fi ns Wi th the engi ne col d, appl y col d
water and compressed ai r to the back (engi ne si de) of
the radi ator to fl ush the radi ator and/or A/C con-
denser of debri s.
INSPECTION
The radi ator cool i ng fi ns shoul d be checked for
damage or deteri orati on. I nspect cool i ng fi ns to make
sure they are not bent or crushed, these areas resul t
i n reduced heat exchange causi ng the cool i ng system
to operate at hi gher temperatures. I nspect the pl asti c
end tanks for cracks, damage or l eaks.
I nspect the radi ator neck for damage or di storti on.
WATER PUMP
CLEANING
Cl ean the gasket mati ng surface. Use cauti on not
to damage the gasket seal i ng surface.
INSPECTION
I nspect the water pump assembl y for cracks i n the
housi ng, Water l eaks from shaft seal , Loose or rough
turni ng beari ng or I mpel l er rubbi ng ei ther the pump
body or ti mi ng chai n case/cover.
FAN BLADE
CLEANING
Cl ean the fan bl ades usi ng a mi l d soap and water.
Do not use an abrasi ve to cl ean the bl ades.
INSPECTION
WARNING: DO NOT ATTEMPT TO BEND OR
STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN
SPECIFICATIONS.
CAUTION: If fan blade assembly is replaced
because of mechanical damage, water pump and
viscous fan drive should also be inspected. These
components could have been damaged due to
excessive vibration.
(1) Remove fan bl ade assembl y from vi scous fan
dri ve uni t (four bol ts).
(2) Lay fan on a fl at surface wi th l eadi ng edge fac-
i ng down. Wi th ti p of bl ade touchi ng fl at surface,
repl ace fan i f cl earance between opposi te bl ade and
surface i s greater than 2.0 mm (.090 i nch). Rocki ng
moti on of opposi te bl ades shoul d not exceed 2.0 mm
(.090 i nch). Test al l bl ades i n thi s manner.
Fig. 56 Bracket Mounted Cooling Fan
1 WATER PUMP (2.5L ENGINE)
2 HUB/BEARING (4.0L ENGINE)
3 PULLEY NUTS
4 PULLEY
5 BRACKET
(3) I nspect fan assembl y for cracks, bends, l oose
ri vets or broken wel ds. Repl ace fan i f any damage i s
found.
COOLING SYSTEM HOSES
INSPECTION
I nspect the hoses at regul ar i nterval s. Repl ace
hoses that are cracked, feel bri ttl e when squeezed or
swel l excessi vel y when the system i s pressuri zed.
The use of mol ded repl acement hoses i s recom-
mended. When performi ng a hose i nspecti on, i nspect
the radi ator l ower hose for proper posi ti on and con-
di ti on of the spri ng.
SPECIFICATIONS
BELT TENSION
Bel t tensi on must be adjusted. Refer to the fol l ow-
i ng Bel t Tensi on chart for speci fi cati ons.
DESCRIPTION Nf Lbs. ft.
New Serpentine 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 Nm Ft. In.
Lbs. Lbs.
Trans. Auxiliary Oil
CoolerScrews
2 18
Block HeaterScrew 4 20
Condenser-to-Radiator
Bolts
6 55
Electric Cooling FanBolts 3 31
Fan Blade Assy to Viscous
Fan DriveBolts 24 18
Fan ShroudBolts 3 31
Isolator-to-Crossmember
Nuts
10 86
Isolator-to-RadiatorNuts 5 47
RadiatorBolts
4.0L Engine 8 70
2.5L Engine 6 55
Thermostat HousingBolts 20 15
Viscous Fan Drive Assy. to
Lbs. Lbs.
Water Pump or Hub
BearingNuts
27 20
Water PumpBolts 23 17
SPECIAL TOOLS
COOLING
Hose Clamp Tool6094
Cooling System Pressure Tester7700A
3/8 Quick Connect Release Tool6935
WIRING DIAGRAMS
CONTENTS
page page
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1
ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . . 8W-35-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1
COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1
CONNECTOR LOCATIONS. . . . . . . . . . . . . . 8W-90-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
FRONT LIGHTING. . . . . . . . . . . . . . . . . . . . 8W-50-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1
GENERAL INFORMATION . . . . . . . . . . . . . . 8W-01-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1
JUNCTION BLOCK. . . . . . . . . . . . . . . . . . . . 8W-12-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1
POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
POWER SEAT . . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1
SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . 8W-95-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
XJ WIRING DIAGRAMS 8W - 1
8W-01 GENERAL INFORMATION
INDEX
page page
CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . 4
CIRCUIT INFORMATION . . . . . . . . . . . . . . . . . . . . 4
CONNECTOR INFORMATION . . . . . . . . . . . . . . . . 7
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . . . 8
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
NOTES, CAUTIONS, and WARNINGS . . . . . . . . . . 7
SECTION IDENTIFICATION . . . . . . . . . . . . . . . . . . 5
SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 7
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TAKE OUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INTERMITTENT AND POOR CONNECTIONS. . . . . 8
TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . 8
TROUBLESHOOTING WIRING PROBLEMS. . . . . . 9
SERVICE PROCEDURES
CONNECTOR AND TERMINAL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 12
CONNECTOR REPLACEMENT . . . . . . . . . . . . . . 12
DIODE REPLACEMENT . . . . . . . . . . . . . . . . . . . . 14
TERMINAL REPLACEMENT. . . . . . . . . . . . . . . . . 13
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 11
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 10
TERMINAL/CONNECTOR REPAIRTHOMAS
AND BETTS CONNECTORS . . . . . . . . . . . . . . . 10
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . . . . 15
INTRODUCTION
Dai ml erChrysl er wi ri ng di agrams are desi gned to
provi de i nformati on regardi ng the vehi cl es wi ri ng
content. I n order to effecti vel y use Dai ml erChrysl er
wi ri ng di agrams to di agnose and repai r a Dai ml er-
Chrysl er vehi cl e, i t i s i mportant to understand al l of
thei r features and characteri sti cs.
Di agrams are arranged such that the power (B+)
si de of the ci rcui t i s pl aced near the top of the page,
and the ground (B-) si de of the ci rcui t i s pl aced near
the bottom of the page.
Al l swi tches, components, and modul es are shown
i n the at rest posi ti on wi th the doors cl osed and the
key removed from the i gni ti on.
Components are shown two ways. A sol i d l i ne
around a component i ndi cates that the component i s
compl ete. A dashed l i ne around a component i ndi -
cates that the component bei ng shown i s not com-
pl ete. I ncompl ete components have a reference
number to i ndi cate the page where the component i s
shown compl ete.
I t i s i mportant to real i ze that no attempt i s made
on the di agrams to represent components and wi ri ng
as they appear on the vehi cl e. For exampl e, a short
pi ece of wi re i s treated the same as a l ong one. I n
addi ti on, swi tches and other components are shown
as si mpl y as possi bl e, wi th regard to functi on onl y.
XJ 8W - 01 GENERAL INFORMATION 8W - 01 - 1
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
The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
CIRCUIT INFORMATION
Each wi re shown i n the di agrams contai ns a code
whi ch i denti fi es the mai n ci rcui t, part of the mai n
ci rcui t, gage of wi re, and col or (Fi g. 1).
CIRCUIT FUNCTIONS
Al l ci rcui ts i n the di agrams use an al pha/numeri c
code to i denti fy the wi re and i ts functi on. To i denti fy
whi ch ci rcui t code appl i es to a system, refer to the
Ci rcui t I denti fi cati on Code Chart. Thi s chart shows
the mai n ci rcui ts onl y and does not show the second-
ary codes that may appl y to some model s.
Fig. 1 Wire Code Identification
1 COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER)
2 GAUGE OF WIRE (18 GAUGE)
3 PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 MAIN CIRCUIT IDENTIFICATION
WIRE COLOR CODE CHART
COLOR CODE COLOR
STANDARD
TRACER
COLOR
BL BLUE WT
BK BLACK WT
BR BROWN WT
DB DARK BLUE WT
DG DARK GREEN WT
GY GRAY BK
LB LIGHT BLUE BK
LG LIGHT GREEN BK
OR ORANGE BK
PK PINK BK or WT
RD RED WT
TN TAN WT
VT VIOLET WT
WT WHITE BK
YL YELLOW BK
* WITH TRACER
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY FEED)
Q POWER OPTIONS (IGNITION FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/
TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
SECTION IDENTIFICATION
The wi ri ng di agrams are grouped i nto i ndi vi dual
secti ons. I f a component i s most l i kel y found i n a par-
ti cul ar group, i t wi l l be shown compl ete (al l wi res,
connectors, and pi ns) wi thi n that group. For exam-
pl e, the Auto Shutdown Rel ay i s most l i kel y to be
found i n Group 30, so i t i s shown there compl ete. I t
can, however, be shown parti al l y i n another group i f
i t contai ns some associ ated wi ri ng.
SYMBOLS
I nternati onal symbol s are used throughout the wi r-
i ng di agrams. These symbol s are consi stent wi th
those bei ng used around the worl d
GROUP TOPIC
8W-01 thru
8W-09
General Information and Diagram
Overview
8W-10 thru
8W-19
Main Sources of Power and Vehicle
Grounding
8W-20 thru
8W-29
Starting and Charging
8W-30 thru
8W-39
Powertrain/Drivetrain Systems
8W-40 thru
8W-49
Body Electrical items and A/C
8W-50 thru
8W-59
Exterior Lighting, Wipers, and Trailer
Tow
8W-60 thru
8W-69
Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations (including
grounds)
8W-95 Splice Locations
Wiring Diagram Symbols
CONNECTOR INFORMATION
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ-
ical example might be the Supplemental Restraint
System connectors. Always check parts availability
before attempting a repair.
IDENTIFICATION
I n-l i ne connectors are i denti fi ed by a number, as
fol l ows:
I n-l i ne connectors l ocated on the engine com-
partment harness are C100 seri es numbers.
Connectors l ocated on the instrument panel
harness are C200 seri es numbers.
Connectors l ocated on the body harness are
C300 seri es numbers.
J umper harness connectors are C400 seri es
numbers.
Grounds and ground connectors are i denti -
fi ed wi th a G and fol l ow the same seri es number-
i ng as the i n-l i ne connector.
Component connectors are i denti fi ed by the compo-
nent name i nstead of a number. Mul ti pl e connectors
on a component use a C1, C2, etc. i denti fi er.
LOCATIONS
Secti on 8W-90 contai ns connector/ground l ocati on
i l l ustrati ons. The i l l ustrati ons contai n the connector
name (or number)/ground number and component
i denti fi cati on. Connector/ground l ocati on charts i n
Secti on 8W-90 reference the i l l ustrati on number for
components and connectors.
Secti on 8W-80 shows each connector and the ci r-
cui ts i nvol ved wi th that connector. The connectors
are i denti fi ed usi ng the name/number on the Di a-
gram pages.
SPLICE LOCATIONS
Spl i ce Locati on charts i n Secti on 8W-70 show the
enti re spl i ce, and provi de references to other secti ons
the spl i ce serves.
Secti on 8W-95 contai ns i l l ustrati ons that show the
general l ocati on of the spl i ces i n each harness. The
i l l ustrati ons show the spl i ce by number, and provi de
a wri tten l ocati on.
NOTES, CAUTIONS, and WARNINGS
Throughout thi s group addi ti onal i mportant i nfor-
mati on i s presented i n three ways; Notes, Cauti ons,
and Warni ngs.
NOTES are used to hel p descri be how swi tches or
components operate to compl ete a parti cul ar ci rcui t.
They are al so used to i ndi cate di fferent condi ti ons
that may appear on the vehi cl e. For exampl e, an
up-to and after condi ti on.
CAUTIONS are used to i ndi cate i nformati on that
coul d prevent maki ng an error that may damage the
vehi cl e.
WARNINGS provi de i nformati on to prevent per-
sonal i njury and vehi cl e damage. Bel ow i s a l i st of
general warni ngs that shoul d be fol l owed any ti me a
vehi cl e i s bei ng servi ced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR
EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO-
CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
WARNING: SET THE PARKING BRAKE WHEN
WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL
TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A
WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS
WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
LYTIC CONVERTER, AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS
NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOOSE HANGING JEWELRY, AND LOOSE CLOTH-
ING.
TAKE OUTS
The abbrevi ati on T/O i s used i n the component
l ocati on secti on to i ndi cate a poi nt i n whi ch the wi r-
i ng harness branches out to a component.
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
Al l ESD sensi ti ve components are sol i d state and a
symbol (Fi g. 2) i s used to i ndi cate thi s. When han-
dl i ng any component wi th thi s symbol compl y wi th
the fol l owi ng procedures to reduce the possi bi l i ty of
el ectrostati c charge bui l d up on the body and i nad-
vertent di scharge i nto the component. I f i t i s not
known whether the part i s ESD sensi ti ve, assume
that i t i s.
(1) Al ways touch a known good ground before han-
dl i ng the part. Thi s shoul d be repeated whi l e han-
dl i ng the part and more frequentl y after sl i di ng
across a seat, si tti ng down from a standi ng posi ti on,
or wal ki ng a di stance.
(2) Avoi d touchi ng el ectri cal termi nal s of the part,
unl ess i nstructed to do so by a wri tten procedure.
(3) When usi ng a vol tmeter, be sure to connect the
ground l ead fi rst.
(4) Do not remove the part from i ts protecti ve
packi ng unti l i t i s ti me to i nstal l the part.
(5) Before removi ng the part from i ts package,
ground the package to a known good ground on the
vehi cl e.
TROUBLESHOOTING TOOLS
When di agnosi ng a probl em i n an el ectri cal ci rcui t
there are several common tool s necessary. These tool s
are l i sted and expl ai ned bel ow.
Jumper Wi re - Thi s i s a test wi re used to con-
nect two poi nts of a ci rcui t. I t can be used to bypass
an open i n a ci rcui t.
WARNING: NEVER USE A JUMPER WIRE ACROSS
A LOAD, SUCH AS A MOTOR, CONNECTED
BETWEEN A BATTERY FEED AND GROUND.
Vol tmeter - Used to check for vol tage on a ci r-
cui t. Al ways connect the bl ack l ead to a known good
ground and the red l ead to the posi ti ve si de of the
ci rcui t.
CAUTION: Most of the electrical components used
in todays vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-me-
gohm or greater impedance rating.
Ohmmeter - Used to check the resi stance
between two poi nts of a ci rcui t. Low or no resi stance
i n a ci rcui t means good conti nui ty.
CAUTION: - Most of the electrical components used
in todays vehicle are Solid State. When checking
resistance in these circuits use a meter with a
10-megohm or greater impedance rating. In addi-
tion, make sure the power is disconnected from the
circuit. Circuits that are powered up by the vehicle
electrical system can cause damage to the equip-
ment and provide false readings.
Probi ng Tool s - These tool s are used for probi ng
termi nal s i n connectors (Fi g. 3). Sel ect the proper
si ze tool from Speci al Tool Package 6807, and i nsert
i t i nto the termi nal bei ng tested. Use the other end
of the tool to i nsert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most i ntermi ttent el ectri cal probl ems are caused
by faul ty el ectri cal connecti ons or wi ri ng. I t i s al so
possi bl e for a sti cki ng component or rel ay to cause a
probl em. Before condemni ng a component or wi ri ng
assembl y check the fol l owi ng i tems.
Connectors are ful l y seated
Spread termi nal s, or termi nal push out
Termi nal s i n the wi ri ng assembl y are ful l y
seated i nto the connector/component and l ocked i n
posi ti on
Di rt or corrosi on on the termi nal s. Any amount
of corrosi on or di rt coul d cause an i ntermi ttent prob-
l em
Damaged connector/component casi ng exposi ng
the i tem to di rt and moi sture
Wi re i nsul ati on that has rubbed through causi ng
a short to ground
Some or al l of the wi ri ng strands broken i nsi de
of the i nsul ati on coveri ng.
Wi ri ng broken i nsi de of the i nsul ati on
Fig. 2 Electrostatic Discharge Symbol
Fig. 3 Probing Tool
1 SPECIAL TOOL 6801
2 PROBING END
TROUBLESHOOTING TESTS
Before begi nni ng any tests on a vehi cl es el ectri cal
system use the Wi ri ng Di agrams and study the ci r-
cui t. Al so refer to the Troubl eshooti ng Wi ri ng Prob-
l ems i n thi s secti on.
TESTING FOR VOLTAGE POTENTIAL
(1) Connect the ground l ead of a vol tmeter to a
known good ground (Fi g. 4).
(2) Connect the other l ead of the vol tmeter to the
sel ected test poi nt. The vehi cl e i gni ti on may need to
be turned ON to check vol tage. Refer to the appropri -
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the ci rcui t bei ng checked
or, di sconnect the battery.
(2) Connect one l ead of the ohmmeter to one si de
of the ci rcui t bei ng tested (Fi g. 5).
(3) Connect the other l ead to the other end of the
ci rcui t bei ng tested. Low or no resi stance means good
conti nui ty.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and di sconnect al l i tems
i nvol ved wi th the fuse.
(2) Connect a test l i ght or a vol tmeter across the
termi nal s of the fuse.
(3) Starti ng at the fuse bl ock, wi ggl e the wi ri ng
harness about si x to ei ght i nches apart and watch
the vol tmeter/test l amp.
(4) I f the vol tmeter regi sters vol tage or the test
l amp gl ows, there i s a short to ground i n that gen-
eral area of the wi ri ng harness.
TESTING FOR A SHORT TO GROUND ON FUSES
POWERING SEVERAL LOADS
(1) Refer to the wi ri ng di agrams and di sconnect or
i sol ate al l i tems on the suspected fused ci rcui ts.
(2) Repl ace the bl own fuse.
(3) Suppl y power to the fuse by turni ng ON the
i gni ti on swi tch or re-connecti ng the battery.
(4) Start connecti ng the i tems i n the fuse ci rcui t
one at a ti me. When the fuse bl ows the ci rcui t wi th
the short to ground has been i sol ated.
TESTING FOR A VOLTAGE DROP
(1) Connect the posi ti ve l ead of the vol tmeter to
the si de of the ci rcui t cl osest to the battery (Fi g. 6).
(2) Connect the other l ead of the vol tmeter to the
other si de of the swi tch or component.
(3) Operate the i tem.
(4) The vol tmeter wi l l show the di fference i n vol t-
age between the two poi nts.
TROUBLESHOOTING WIRING PROBLEMS
When troubl eshooti ng wi ri ng probl ems there are
si x steps whi ch can ai d i n the procedure. The steps
are l i sted and expl ai ned bel ow. Al ways check for non-
factory i tems added to the vehi cl e before doi ng any
di agnosi s. I f the vehi cl e i s equi pped wi th these i tems,
di sconnect them to veri fy these add-on i tems are not
the cause of the probl em.
(1) Veri fy the probl em.
Fig. 4 Testing for Voltage Potential
Fig. 5 Testing for Continuity
1 FUSE REMOVED FROM CIRCUIT
(2) Veri fy any rel ated symptoms. Do thi s by per-
formi ng operati onal checks on components that are
i n the same ci rcui t. Refer to the wi ri ng di agrams.
(3) Anal yze the symptoms. Use the wi ri ng di a-
grams to determi ne what the ci rcui t i s doi ng, where
the probl em most l i kel y i s occurri ng and where the
di agnosi s wi l l conti nue.
(4) I sol ate the probl em area.
(5) Repai r the probl em.
(6) Veri fy proper operati on. For thi s step check for
proper operati on of al l i tems on the repai red ci rcui t.
Refer to the wi ri ng di agrams.
SERVICE PROCEDURES
WIRING REPAIR
When repl aci ng or repai ri ng a wi re, i t i s i mportant
that the correct gage be used as shown i n the wi ri ng
di agrams. The wi res must al so be hel d securel y i n
pl ace to prevent damage to the i nsul ati on.
(1) Di sconnect battery negati ve cabl e
(2) Remove 1 i nch of i nsul ati on from each end of
the wi re.
(3) Pl ace a pi ece of heat shri nk tubi ng over one
si de of the wi re. Make sure the tubi ng wi l l be l ong
enough to cover and seal the enti re repai r area.
(4) Spread the strands of the wi re apart on each
part of the exposed wi re (exampl e 1). (Fi g. 7)
(5) Push the two ends of wi re together unti l the
strands of wi re are cl ose to the i nsul ati on (exampl e
2) (Fi g. 7)
(6) Twi st the wi res together (exampl e 3) (Fi g. 7)
(7) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(8) Center the heat shri nk tubi ng over the joi nt,
and heat usi ng a heat gun. Heat the joi nt unti l the
tubi ng i s ti ghtl y seal ed and seal ant comes out of both
ends of the tubi ng.
(9) Secure the wi re to the exi sti ng ones to prevent
chafi ng or damage to the i nsul ati on
(10) Connect battery and test al l affected systems.
CONNECTORS
(1) Di sconnect battery.
(2) Di sconnect the connector from i ts mati ng hal f/
component.
(3) I nsert the termi nal rel easi ng speci al tool 6742
i nto the termi nal end of the connector (Fi g. 8).
(4) Usi ng speci al tool 6742 rel ease the l ocki ng fi n-
gers on the termi nal (Fi g. 9).
(5) Pul l on the wi re to remove i t from the connec-
tor.
(6) Repai r or repl ace the connector or termi nal , as
necessary.
TERMINAL/CONNECTOR REPAIR THOMAS
AND BETTS CONNECTORS
component.
Fig. 6 Testing for Voltage Drop
Fig. 7 Wire Repair
1 EXAMPLE 1
2 EXAMPLE 2
3 EXAMPLE 3
(3) Push i n the two l ock tabs on the si de of the
connector (Fi g. 10).
(4) I nsert the probe end of speci al tool 6934 i nto
the back of the connector cavi ty (Fi g. 11).
(5) Grasp the wi re and tool 6934 and sl owl y
remove the wi re and termi nal from the connector.
(6) Repai r or repl ace the termi nal .
(7) I nstal l the wi re and termi nal i n the connector.
Ful l y seat the termi nal i n the connector.
(8) Push i n the si ngl e l ock tab on the si de of the
connector (Fi g. 12).
CONNECTORS
component.
(3) Push down on the yel l ow connector l ocki ng tab
to rel ease the termi nal s (Fi g. 13).
(4) Usi ng speci al tool 6932, push the termi nal to
remove i t from the connector (Fi g. 14).
(5) Repai r or repl ace the connector or termi nal as
necessary.
(6) When re-assembl i ng the connector, the l ocki ng
wedge must be pl aced i n the l ocked posi ti on to pre-
vent termi nal push out.
Fig. 8 Molex Connector Repair
1 CONNECTOR
2 SPECIAL TOOL 6742
Fig. 9 Using Special Tool 6742
1 CONNECTOR
2 SPECIAL TOOL 6742
Fig. 10 Thomas and Betts Connector Lock Release
Tabs
1 LOCK TABS
Fig. 11 Removing Wire Terminal
1 SPECIAL TOOL 6934
CONNECTOR REPLACEMENT
(2) Di sconnect the connector that i s to be repai red
from i ts mati ng hal f/component
(3) Remove the connector l ocki ng wedge, i f
requi red (Fi g. 15)
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 16) (Fi g. 17).
(5) Reset the termi nal l ocki ng tang, i f i t has one.
(6) I nsert the removed wi re i n the same cavi ty on
the repai r connector.
(7) Repeat steps four through si x for each wi re i n
the connector, bei ng sure that al l wi res are i nserted
i nto the proper cavi ti es. For addi ti onal connector pi n-
out i denti fi cati on, refer to the wi ri ng di agrams.
(8) I nsert the connector l ocki ng wedge i nto the
repai red connector, i f requi red.
(9) Connect connector to i ts mati ng hal f/compo-
nent.
(10) Connect battery and test al l affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(2) Di sconnect the connector (that i s to be
repai red) from i ts mati ng hal f/component.
(3) Cut off the exi sti ng wi re connector di rectl y
behi nd the i nsul ator. Remove si x i nches of tape from
the harness.
Fig. 12 Single Lock Tab
1 SINGLE LOCK TAB
Fig. 13 Augat Connector Repair
1 LOCKING TAB
2 CONNECTOR
Fig. 14 Using Special Tool 6932
1 SPECIAL TOOL 6932
2 CONNECTOR
Fig. 15 Connector Locking Wedge
1 CONNECTOR
2 CONNECTOR LOCKING WEDGE TAB
(4) Stagger cut al l wi res on the harness si de at 1/2
i nch i nterval s (Fi g. 18).
(5) Remove 1 i nch of i nsul ati on from each wi re on
the harness si de.
(6) Stagger cut the matchi ng wi res on the repai r
connector assembl y i n the opposi te order as was done
on the harness si de of the repai r. Al l ow extra l ength
for sol dered connecti ons. Check that the overal l
l ength i s the same as the ori gi nal (Fi g. 18).
(7) Remove 1 i nch of i nsul ati on from each wi re.
si de of the wi re. Be sure the tubi ng wi l l be l ong
part of the exposed wi res.
strands of wi re are cl ose to the i nsul ati on.
(11) Twi st the wi res together.
(12) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(13) Center the heat shri nk tubi ng over the joi nt
ends of the tubi ng
(14) Repeat steps 8 through 13 for each wi re.
(15) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(16) Re-connect the repai red connector.
(17) Connect the battery, and test al l affected sys-
tems.
TERMINAL REPLACEMENT
(2) Di sconnect the connector bei ng repai red from
i ts mati ng hal f. Remove connector l ocki ng wedge, i f
requi red (Fi g. 19).
(3) Remove connector l ocki ng wedge, i f requi red
(Fi g. 19).
(4) Posi ti on the connector l ocki ng fi nger away from
the termi nal usi ng the proper pi ck from speci al tool
ki t 6680. Pul l on the wi re to remove the termi nal
from the connector (Fi g. 20) (Fi g. 21).
(5) Cut the wi re 6 i nches from the back of the con-
nector.
(6) Remove 1 i nch of i nsul ati on from the wi re on
the harness si de.
(7) Sel ect a wi re from the termi nal repai r assem-
bl y that best matches the col or wi re bei ng repai red.
Fig. 16 Terminal Removal
1 CONNECTOR
2 FROM SPECIAL TOOL KIT 6680
Fig. 17 Terminal Removal Using Special Tool
2 CONNECTOR
Fig. 18 Stagger Cutting Wires
1 REPAIR SIDE WIRES
2 STAGER CUTS
3 HARNESS WIRES
(8) Cut the repai r wi re to the proper l ength and
remove 1 i nch of i nsul ati on.
si de of the wi re. Make sure the tubi ng wi l l be l ong
part of the exposed wi res.
strands of wi re are cl ose to the i nsul ati on.
(12) Twi st the wi res together.
(13) Sol der the connecti on together usi ng rosi n
core type sol der onl y. Do not use acid core solder.
(14) Center the heat shri nk tubi ng over the joi nt
ends of the tubi ng.
(15) I nsert the repai red wi re i nto the connector.
(16) I nstal l the connector l ocki ng wedge, i f
requi red, and reconnect the connector to i ts mati ng
hal f/component.
(17) Re-tape the wi re harness starti ng 1-1/2 i nches
behi nd the connector and 2 i nches past the repai r.
(18) Connect battery, and test al l affected systems.
DIODE REPLACEMENT
(1) Di sconnect the battery.
(2) Locate the di ode i n the harness, and remove
the protecti ve coveri ng.
(3) Remove the di ode from the harness, pay atten-
ti on to the current fl ow di recti on (Fi g. 22).
Fig. 19 Connector Locking Wedge Tab (Typical)
1 CONNECTOR
2 CONNECTOR LOCKING WEDGE TAB
Fig. 20 Terminal Removal
1 CONNECTOR
Fig. 21 Terminal Removal Using Special Tool
2 CONNECTOR
Fig. 22 Diode Identification
1 CURRENT FLOW
2 BAND AROUND DIODE INDICATES CURRENT FLOW
3 DIODE AS SHOWN IN THE DIAGRAMS
(4) Remove the i nsul ati on from the wi res i n the
harness. Onl y remove enough i nsul ati on to sol der i n
the new di ode.
(5) I nstal l the new di ode i n the harness, maki ng
sure current fl ow i s correct. I f necessary refer to the
appropri ate wi ri ng di agram for current fl ow.
(6) Sol der the connecti on together usi ng rosi n core
type sol der onl y. Do not use acid core solder.
(7) Tape the di ode to the harness usi ng el ectri cal
tape maki ng, sure the di ode i s compl etel y seal ed
from the el ements.
(8) Re-connect the battery, and test affected sys-
tems.
SPECIAL TOOLS
WIRING/TERMINAL
Probing Tool Package 6807
Terminal Pick 6680
Terminal Removing Tool 6932
Terminal Removing Tool 6934
8W-02 COMPONENT INDEX
Component Page
1-2 And 3-4 Sol enoi d . . . . . . . . . . . . . . . . . . . 8W-31
2-3 Sol enoi d . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . 8W-42
A/C Compressor Cl utch . . . . . . . . . . . . . . . . . 8W-42
A/C- Heater Control . . . . . . . . . . . . . . . . . . . 8W-42
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . . . 8W-42
A/C Low Pressure Swi tch . . . . . . . . . . . . . . . 8W-42
Ai rbag Control Modul e . . . . . . . . . . . . . . . . . 8W-43
Ai rbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Ambi ent Temperature Sensor . . . . . . . . . . . . 8W-49
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Automati c Shut Down Rel ay . . . . . . . . . . . . . 8W-30
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-51
Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Bl end Door Actuator . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . . . 8W-42
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . . . 8W-42
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-33
Brake Warni ng Pressure Swi tch . . . . . . . . . . 8W-40
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . . 8W-30
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . . . . 8W-44
Center Hi gh Mounted Stop Lamp . . . . . . . . . 8W-51
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . . 8W-41
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Ci rcui t Breakers (JB) . . . . . . . . . . . . . . . . . . 8W-12
Cl ockspri ng . . . . . . . . . . . . . . . . . . 8W-30, 33, 41, 43
Cl uster I l l umi nati on Lamps . . . . . . . . . . . . . 8W-40
Cl utch I nterl ock Swi tch Jumper . . . . . . . . 8W-12, 21
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . 8W-12, 21
Combi nati on Fl asher . . . . . . . . . . . . . . . . . . . 8W-52
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49
Control l er Anti -Lock Brake Rel ay . . . . . . . . . 8W-35
Control l er Anti -Lock Brake . . . . . . . . . . . . . . 8W-35
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-44
Crankshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-30
Data Li nk Connector . . . . . . . . . . . . . . . . . . . 8W-30
Dayti me Runni ng Lamp Modul e . . . . . . . . . . 8W-50
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Dome Lamps Swi tch . . . . . . . . . . . . . . . . . . . 8W-44
Door Jamb Swi tches . . . . . . . . . . . . . . . . . 8W-39, 44
Door Lock Motors . . . . . . . . . . . . . . . . . . . . . 8W-61
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . 8W-30
Engi ne Cool ant Temperature Gauge . . . . . . . 8W-40
Engi ne Cool ant Temperature Sensor . . . . . . . 8W-30
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . . . 8W-30
Engi ne Starter Motor Rel ay . . . . . . . . . . . . . 8W-21
Engi ne Starter Motor . . . . . . . . . . . . . . . . . . 8W-21
Evap Leak Detecti on Pump . . . . . . . . . . . . . . 8W-30
Extended I dl e Swi tch . . . . . . . . . . . . . . . . . . 8W-30
Component Page
Fog Lamp Rel ays . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Front Fog Lamp Swi tch . . . . . . . . . . . . . . 8W-44, 50
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . 8W-53
Fuel I njectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Fusi bl e Li nk A11 . . . . . . . . . . . . . . . . . . . . . . 8W-10
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Headl amp Beam Sel ect Swi tch . . . . . . . . . . . 8W-50
Headl amp Del ay Modul e . . . . . . . . . . . . . . . . 8W-50
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-50
Headl amps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Heated Seat Backs . . . . . . . . . . . . . . . . . . . . 8W-63
Heated Seat Cushi ons . . . . . . . . . . . . . . . . . . 8W-63
Heated Seat Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-63
Heated Seat Swi tches . . . . . . . . . . . . . . . . . . 8W-63
Heater Control . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
I ndi cators . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-31
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . . 8W-40
I ntake Ai r Temperature Sensor . . . . . . . . . . . 8W-30
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . . . 8W-61
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Lock-Up Sol enoi d . . . . . . . . . . . . . . . . . . . . . . 8W-31
Mani fol d Absol ute Pressure Sensor . . . . . . . . 8W-30
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Output Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31
Overhead Modul e . . . . . . . . . . . . . . . . . . . . . 8W-49
Oxygen Sensor Downstream Rel ay . . . . . . . . 8W-30
Oxygen Sensor Upstream Rel ay . . . . . . . . . . 8W-30
Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . . 8W-40
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . . 8W-31
Park/Turn Si gnal Lamps . . . . . . . . . . . . . 8W-50, 52
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Power Di stri buti on Center . . . . . . . . . . . . . . . 8W-10
Power Lock/Wi ndow Swi tches . . . . . . . 8W-60, 61, 62
XJ 8W - 02 COMPONENT INDEX 8W - 02 - 1
Component Page
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . . . 8W-62
Power Mi rrors . . . . . . . . . . . . . . . . . . . . . 8W-48, 62
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Power Seat Motors . . . . . . . . . . . . . . . . . . . . 8W-63
Power Seat Swi tches . . . . . . . . . . . . . . . . . . . 8W-63
Power Steeri ng Pressure Swi tch . . . . . . . . . . 8W-30
Power Wi ndow Motors . . . . . . . . . . . . . . . . . . 8W-60
Powertrai n Control Modul e . . . . . . . . . . . . . . 8W-30
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . . . . 8W-44
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . . . 8W-42
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . 8W-42
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Rai l Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Rear Washer Pump . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger Swi tch . . . . . . . . . . . 8W-48
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . . 8W-48
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-53
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . . 8W-53
Red Brake Warni ng I ndi cator . . . . . . . . . . . . 8W-40
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-40
Seat Heat I nterface Modul e . . . . . . . . . . . . . . 8W-63
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . 8W-39
Shi ft Lock Sol enoi d . . . . . . . . . . . . . . . . . . . . 8W-31
Si de Marker Lamps . . . . . . . . . . . . . . . . . 8W-50, 52
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Speed Control Swi tches . . . . . . . . . . . . . . . . . 8W-33
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Component Page
Spl i ce I nformati on . . . . . . . . . . . . . . . . . . . . . 8W-70
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Tai l /Stop Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-51
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . . 8W-30
Torque Converter Cl utch Sol enoi d . . . . . . . . . 8W-31
Trai l er Tow Connector . . . . . . . . . . . . . . . . . . 8W-54
Trai l er Tow El ectri c Brake Provi si on . . . . . . . 8W-54
Trai l er Tow Rel ays . . . . . . . . . . . . . . . . . . . . . 8W-54
Transfer Case Swi tch I l l umi nati on . . . . . . . . 8W-44
Transfer Case Swi tch . . . . . . . . . . . . . . . . . . 8W-40
Transmi ssi on Control Modul e . . . . . . . . . . . . 8W-31
Transmi ssi on Range Sensor . . . . . . . . . . . . . . 8W-31
Transmi ssi on Sol enoi d . . . . . . . . . . . . . . . . . . 8W-31
Tri p Reset Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-40
Turn Si gnal Lamps . . . . . . . . . . . . . . . . . 8W-51, 52
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . . 8W-52
Underhood Lamp/Mercury Swi tch . . . . . . . . . 8W-44
Vehi cl e Speed Control Servo . . . . . . . . . . . . . 8W-33
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-30
Vi sor/Vani ty Lamps . . . . . . . . . . . . . . . . . . . . 8W-44
Vol t Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Washer Fl ui d Level Swi tch . . . . . . . . . . . . . . 8W-40
Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . 8W-35
Wi ndow Motors . . . . . . . . . . . . . . . . . . . . . . . 8W-60
Wi ndow Swi tches . . . . . . . . . . . . . . . . . . . . . . 8W-60
Wi ndshi el d Washer Pump . . . . . . . . . . . . . . . 8W-53
Wi pe/Wash Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-53
Wi per Motor Rel ay . . . . . . . . . . . . . . . . . . . . 8W-53
8W - 02 - 2 8W - 02 COMPONENT INDEX XJ
8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . 8W-10-14
A/C Compressor Cl utch Rel ay . . . . . . . . . . 8W-10-14
Automati c Shut Down Rel ay . . . . . . . . . . . 8W-10-15
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . 8W-10-13
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . 8W-10-7, 13
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . 8W-10-20
Brake Warni ng Pressure Swi tch . . . . . . . . . 8W-10-9
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . . 8W-10-17
Center Hi gh Mounted Stop Lamp . . . . . . . 8W-10-20
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . 8W-10-9, 12
Ci rcui t Breaker 28 (JB) . . . . . . . . . . . . . . . 8W-10-9
Combi nati on Fl asher . . . . . . . . . . . . . . . . . 8W-10-19
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Control l er Anti -Lock Brake . . . . . . . . . 8W-10-16, 20
Data Li nk Connector . . . . . . . . . . . . . . . . . 8W-10-18
Dayti me Runni ng Lamp Modul e . . . . . . . . 8W-10-14
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
Dome Lamps Swi tch . . . . . . . . . . . . . . . . . 8W-10-18
Dri ver Door Jamb Swi tch . . . . . . . . . . . . . 8W-10-10
Engi ne Starter Motor . . . . . . . . . . . . . . 8W-10-7, 16
Engi ne Starter Motor Rel ay . . . . . . . . . . . 8W-10-16
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . . . 8W-10-20
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . 8W-10-15
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-10-19
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . 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
Fusi bl e Li nk A11 . . . . . . . . . . . . . . . . . . . . 8W-10-7
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7
Headl amp Del ay Modul e . . . . . . . . . . . . . . 8W-10-14
Headl amp Swi tch . . . . . . . . . . . . . . 8W-10-10, 14, 18
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . 8W-10-12
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
I gni ti on Swi tch . . . . . . . . . . . . . . . . . 8W-10-9, 10, 11
I nstrument Cl uster . . . . . . . . . . . . . . . 8W-10-10, 17
Juncti on Bl ock . . . . . . . . . 8W-10-9, 10, 11, 12, 16, 17
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-10-17
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-10-20
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . 8W-10-20
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . 8W-10-18
Low Note Horn . . . . . . . . . . . . . . . . . . . . . 8W-10-12
Overhead Modul e . . . . . . . . . . . . . . . . . . . 8W-10-18
Oxygen Sensor 1/1 Upstream . . . . . . . . . . 8W-10-15
Oxygen Sensor 1/2 Downstream . . . . . . . . 8W-10-15
Oxygen Sensor Downstream Rel ay . . . . . . 8W-10-17
Oxygen Sensor Upstream Rel ay . . . . . . . . 8W-10-17
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . 8W-10-9
Passenger Power Lock/Wi ndow Swi tch . . . 8W-10-10
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . 8W-10-20
Power Di stri buti on Center . . 8W-10-2, 7, 8, 9, 12, 13,
14, 15, 16, 17, 18, 19, 20
Powertrai n Control Modul e . . . . . . . . . 8W-10-15, 19
Radi ator Fan Motor . . . . . . . . . . . . . . . . . 8W-10-13
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . 8W-10-13
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
Rai l Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
Rear Wi ndow Defogger . . . . . . . . . . . . . . . 8W-10-16
Rear Wi ndow Defogger Rel ay . . . . . . . . 8W-10-11, 16
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8W-10-17
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-10-20
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . 8W-10-20
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . 8W-10-18
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-10-14
Transmi ssi on Control Modul e . . . . . . . . . . 8W-10-17
Underhood Lamp/Mercury Swi tch . . . . . . . 8W-10-17
XJ 8W - 10 POWER DISTRIBUTION 8W - 10 - 1
16
19 18 20
17
11
13 15 14
12 2
4 5 3
1
7
10 8 9
6
13
12 14
11
10 2
4
8 5
6
POWER DISTRIBUTION CENTER
MOTOR
STARTER
ENGINE
RELAY
D
C
RELAY
FUEL
PUMP
DOWN
SHUT
AUTOMATIC
RELAY
B
LAMP
FOG
RELAY
NO. 1
RELAY
CLUTCH
A/C
COMPRESSOR
RELAY
CONTROLLER
ANTI-LOCK
BRAKE
RELAY
LAMP
FOG
NO. 2
A
FUSES
8
14 7
6
7
30A
13
5
6
40A
12
4
5
40A
11
3
4
50A
10
2
3
40A
9
1
2
40A
8
21
15
16
17
18
19
20
22
23
24
25
26
27
28 15
14
13
20A
12
40A
11
10
20A
9
20A
F21 15A F27 10A
1 2
F24
F23 15A
4 3
F26 20A F20 15A F17 20A
F16 15A F19 20A F25 15A
5 6
F22 15A
8 7
9 10
12 11
14 13
15 16
18 17
20 19
21 22
24 23
GENERATOR BATTERY
M1 M2
30A
6
9 8 10
7
1
3 5 4
2 12
14 15 13
11
17
20 18 19
16
FAN
RADIATOR
RELAY
RELAY
OXYGEN
SENSOR
DOWNSTREAM
UPSTREAM
SENSOR
OXYGEN
RELAY
F18 15A
30A
8W - 10 - 2 8W-10 POWER DISTRIBUTION XJ
J008W-7 XJD01002
FUSES
FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT
1
- - -
A1 12RD 40A
2
3
40A A2 12PK/BK
A7 10RD/BK 50A
4
F141 12LG/RD 40A
5
6
40A A111 12RD/LG
7
30A
A3 14RD/WT
8
10
20A
A4 12BK/PK
9
20A
A10 12RD/DG
30A
11
A20 12RD/DB
40A
12
-
20A
13
14
-
-
15
M1 20PK
F99 18RD
L9 20BK/PK
F34 18TN/BK
15A
16
17
20A
20A
18
19
15A
-
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A0 6RD
A17 16RD/BK
A3 14RD/WT
A17 16RD/BK
26
10A F1 20DB/GY A17 16RD/BK
20
15A F142 18DG/WT A999 16RD
21
15A A61 14DG/BK A0 6RD
22
15A F32 20PK/DB A0 6RD
23
24
15A F61 20WT/OR A0 6RD
25
20A F75 16VT A0 6RD
A41 16YL
A0 6RD
ABS
27
DRL
30A A16 14RD/LG A0 6RD
15A A142 18DG/OR A999 16RD
4.0L
- - -
XJ 8W-10 POWER DISTRIBUTION 8W - 10 - 3
XJD01003 J008W-7
B5
B3
B1
B4
B2
FUSED IGNITION SWITCH OUTPUT (ST-RUN) F20 18WT
C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
A17 16RD/BK FUSED B(+)
-
A/C COMPRESSOR CLUTCH RELAY OUTPUT C3 16DB/BK
-
FUNCTION CAVITY CIRCUIT
D8
D5
D2
D6
D4
A999 16RD
- -
A16 14RD/LG FUSED B(+)
K51 18DB/YL
FUSED IGNITION SWITCH OUTPUT (ST-RUN) F12 18DB/WT
AUTOMATIC SHUT DOWN RELAY CONTROL
A999 16RD
CLUTCH
COMPRESSOR
A/C
RELAY
T41 20BK/WT
B17
ABS RELAY CONTROL G83 18GY/BK
FUSED IGNITION SWITCH OUTPUT (RUN) F15 20DB/WT
- -
GROUND Z1 20BK
B18
B20
B16
B19
G19 20LG/OR ABS WARNING INDICATOR DRIVER
T141 20YL IGNITION SWITCH OUTPUT (START)
C8
PARK/NEUTRAL POSITION SWITCH SENSE T41 20BK/WT
C10
- -
ENGINE STARTER MOTOR RELAY OUTPUT T40 16BR
PARK/NEUTRAL POSITION SWITCH SENSE
FUSED B(+) ENGINE STARTER MOTOR RELAY F45 20YL/RD
C9
C7
C6
C8
A41 16YL FUSED B(+)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
RELAY
AUTOMATIC
SHUT
DOWN
RELAY
ENGINE
STARTER
MOTOR
AUTOMATIC SHUT DOWN RELAY OUTPUT
B19
Z1 20BK GROUND
4.0L M/T
4.0L ABS EXCEPT DRL LHD 4.0 A/T
EXCEPT 4.0L M/T
2.5L, 4.0L M/T, RHD 4.0L A/T
LHD 4.0L M/T EXCEPT ABS EXCEPT DRL
C10
Z1 20BK GROUND
C10
Z1 20BK GROUND
4.0L A/T
C10
J008W-7 XJD01004
CIRCUIT CAVITY FUNCTION
C2
C1
C3
C5
FUEL PUMP RELAY CONTROL K31 18BR
F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
A61 14DG/BK FUSED B(+)
A141 14DG/WT FUEL PUMP RELAY OUTPUT
A61 16DG/BK FUSED B(+)
NO. 2
FOG
LAMP
RELAY
NO. 1
FOG
LAMP
RELAY
GROUND Z1 20BK
HIGH BEAM INDICATOR DRIVER G34 16RD/GY
FOG LAMP RELAY OUTPUT NO. 1 L139 20VT
B9
FUSED HEADLAMP SWITCH OUTPUT L77 20BR/YL
B6
B8
B10
B7
B10
Z1 20BK GROUND
L33 20RD/WT FUSED B(+)
- -
G34 16RD/GY HIGH BEAM INDICATOR DRIVER
- -
FUSED B(+) F61 20WT/OR
GROUND Z1 20BK
L92 20PK FOG LAMP SWITCH OUTPUT
B12
B14
B11
B13
B15
RELAY
PUMP
FUEL
DRL
L39 20LB FOG LAMP RELAY OUTPUT
EXCEPT DRL
-
C4
-
XJD01005 J008W-7
- -
FUSED B(+) F141 12LG/RD
D13
D10
D12
D14
C27 18DB/PK RADIATOR FAN RELAY CONTROL
C25 12LB RADIATOR FAN RELAY OUTPUT
F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
(GAS)
RELAY
OXYGEN
SENSOR
UPSTREAM
C15
C11
C14
C12
KNOCK SENSOR SIGNAL (-) K73 18BR/OR
F99 18RD FUSED B(+)
- -
A42 18DG OXYGEN SENSOR 1/1 UPSTREAM
RADIATOR
FAN
RELAY
FUSED B(+) F99 18RD
- -
FUSED B(+) F99 18RD
C17
C20
C16
C18
K74 18BR/VT OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
A242 18VT/OR OXYGEN SENSOR 1/2 DOWNSTREAM
F26 18PK/OR FUSED IGNITION SWITCH OUTPUT (ST-RUN)
C19
DOWNSTREAM
SENSOR
OXYGEN
RELAY
(GAS)
C13
2.5L, 4.0L A/T FOG EXCEPT DRL
4.0L (A/T DRL), (A/T EXCEPT FOG), (M/T)
C18
C13
D11
J008W-7 XJD01006
CENTER
DISTRIBUTION
POWER
BATTERY
ENGINE
STARTER
MOTOR
A0
6
RD RD
6
A0
2
FUSE
40A 40A
FUSE
3 4
FUSE
50A
5
FUSE
40A
30A
FUSE
7 9
FUSE
20A
GENERATOR
A11
6
BK/WT
S118
A11
LINK
FUSIBLE
10
DG
A
(8W-10-8)
TO
FUSE 12
(PDC)
1
8 9
2
A2
12
PK/BK
10
3
11
4
13
6
A3
14
RD/WT
TO
22
15
RD
12
A1
SWITCH
IGNITION
TO TO
IGNITION
SWITCH
TO
JUNCTION
BLOCK
RD/BK
10
A7
5
12
40A
FUSE
6
A111
12
RD/LG
BLOWER
TO
TO
HEADLAMP
SWITCH
RD/WT
14
A3
23
16
20A
FUSE
10
A4
12
BK/PK
F141
12
LG/RD
FAN
RADIATOR
TO
RELAY
TO
A/C
COMPRESSOR
RD/BK
16
A17
CLUTCH
RELAY
(IN PDC)
A17
16
RD/BK
27
FUSE
TO
TO
ENGINE
STARTER
YL
16
A41
MOTOR
RELAY
TO
BLOCK
JUNCTION
(IN PDC) (IN PDC)
11
FUSE
30A
17
24
C6
C100
C2
(IN PDC)
MODULE
LAMP
RUNNING
DAYTIME
D1 C100
7
14
30A
FUSE
8
TO
RD/LG
14
A16
(IN PDC)
RELAY
AUTOMATIC
SHUT DOWN
D5 C100
C201 11 7 C202
8 C209
MOTOR
RELAY
LHD RHD
(8W-20-2)
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
(8W-10-9) (8W-10-9) (8W-10-12) (8W-10-13)
(8W-10-14)
(8W-20-2)
(8W-10-14)
(8W-10-13)
(8W-10-16) (8W-10-16)
(8W-10-2)
(8W-10-15)
XJD01007 J008W-7
A15
A16
A22
A21 A24
A23
26
19 25
18
17
FUSE
20A
TO
RD
18
F99
(PDC)
FUSE 11
FROM
RD/DG
12
A10
12
FUSE
40A
20A
FUSE
13
A20
12
RD/DB
TO
15A
FUSE
16
20
FUSE
15A
TO
CONTROLLER
ANTI-LOCK
POWER
DISTRIBUTION
CENTER
A
(8W-10-7)
BRAKE BRAKE
ANTI-LOCK
CONTROLLER S135
TO
PK
20
M1
20A
FUSE
19
A18
A17
15A
FUSE
22
A11
A12
L9
20
BK/PK
TO
COMBINATION
PUMP
FUEL
TO
DG/BK
14
A61
RELAY
A5
A6
25
FUSE
15A 20A
FUSE
26
A4
A3 A10
A9
23
FUSE
15A
SWITCH
F32
20
PK/DB
TO
BRAKE
LAMP
S301
TO
VT
16
F75
S218
TO
F34
18
TN/BK
RELAY
F61
20
WT/OR
TO
FOG
LAMP
NO. 2
(IN PDC)
(IN PDC)
F8 C100
(ABS)
(ABS)
RELAY
OXYGEN
SENSOR
DOWNSTREAM
E6
C100
A18
LHD
RHD
B11
C100
F5
FLASHER
C4 C100
C200 14 21 C204
LHD RHD
TO
HEADLAMP
SWITCH
LHD RHD
(4.0L)
F75
16
VT
F75
14
VT
(IN PDC)
DATA
TO
CONNECTOR
C107 14
MODULE
TO
POWERTRAIN
CONTROL
(8W-10-17)
(8W-10-17)
(8W-10-16)
(8W-10-16)
(8W-10-19)
(8W-10-18)
(8W-10-19) (8W-10-20) (8W-10-20) (8W-10-20)
(8W-10-2)
J008W-7 XJD01008
POWER
DISTRIBUTION
CENTER
BATT A0
1
2
FUSE
40A
A1
12
RD
C2
RD
12
A1
2
C2
1 C2
G26
20
LB
SWITCH
KEY-IN
C1
3
0
2
1 4
4
C1
3 C1
4 1
2
0
3
C1
10
C1 7
3
0
2
1 4
C1
9
3
0
2
1 4
8
C1
2 C1
G9
20
GY/BK
A2
12
PK/BK
C100
C6
PK/BK
12
A2
40A
FUSE
3
2
1
BK
20
Z1
3
0
2
1 4
YL
14
A41 A22
12
BK/OR
A21
12
DB
ST-RUN A21
BK/WT
12
A31
BK/LB
20
G16
8 9
PARK
BRAKE
SWITCH
SWITCH
PRESSURE
BRAKE
1
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 LOCK
0 OFF
2 RUN
1 START
SWITCH
IGNITION
S207
Z1
14
BK
86
ST A41
CIGAR
LIGHTER
RELAY
C203 13
LHD RHD
RHD LHD
C201 10
85
E2
A14
RHD
LHD
WARNING
(8W-10-2)
(8W-10-7)
(8W-10-10)
(8W-40-7)
(8W-40-7)
(8W-10-10)
(8W-10-10)
(8W-12-17)
(8W-12-18)
(8W-12-2)
(8W-12-17)
(8W-12-18) (8W-12-23)
(8W-12-24)
(8W-12-25)
(8W-10-11)
(8W-15-9)
(8W-15-9)
(8W-10-11)
(8W-41-2)
(8W-41-3)
XJD01009 J008W-7
A31
12
BK/WT
RUN-ACC A31
3
0
2
1 4
8
C1
29 C201
5 C300
G26
20
LB
LB
20
G26
5 C1
DB
12
A21
C201 64
27
FUSE
10A 20A
FUSE
11 10
FUSE
15A
BLOCK
JUNCTION
SPARE
FUSE
8
L2 C4
9
FUSE
10A
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
2
BK/LB
18
G16
C317 B
C200 17
S200
S210
LB
20
G26
PASSENGER
POWER
LOCK/
WINDOW
SWITCH
C2
8
CLUSTER
INSTRUMENT
BATT A1
G26
20
LB
RD
12
A1
2
C2
1 C2
SWITCH
KEY-IN
C1 7
SWITCH
IGNITION
C1
9
3
0
2
1 4
A21
12
DB BK/LB
20
G16
RHD LHD
C306 2
C203 3
LHD RHD
4 C203
B C318
G16
18
BK/LB
2
LHD RHD
BK/LB
20
G16
HEADLAMP
SWITCH
0 OFF
1 PARK
2 HEAD
C1
6
0
1
2
8
C2 C2
8
SWITCH
WINDOW
LOCK/
POWER
PASSENGER
LB
20
G26
LB
20
G26 G26
20
LB
BK/LB
20
G16 G16
20
BK/LB
SWITCH
JAMB
DOOR
DRIVER
SWITCH
JAMB
DOOR
DRIVER
OPTIONS)
(FULL
OPTIONS)
(FULL
(8W-10-9)
(8W-12-23)
(8W-12-24)
(8W-12-13)
(8W-12-14)
(8W-12-12)
(8W-12-2)
(8W-12-11) (8W-12-11)
(8W-40-8)
(8W-10-9)
(8W-10-9)
(8W-50-2)
(8W-61-2) (8W-61-3)
(8W-39-6)
(8W-39-7)
J008W-7 XJD01010
BK/OR
12
A22
62
RELAY
DEFOGGER
WINDOW
REAR
86
20A
FUSE
22
C4 M2
12
FUSE
10A
JUNCTION
BLOCK
15A
FUSE
25
26
FUSE
10A
IGNITION
SWITCH
1 START
2 RUN
0 OFF
3 LOCK
4 ACC
BK/OR
12
A22 A41
14
YL
4 1
2
0
3
10
C1
3
0
2
1 4
C1 3
C1
4
PK/BK
12
A2
BATT A2
C201
63
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-12-16)
(8W-12-2)
(8W-12-20)
(8W-12-21)
(8W-12-23)
(8W-12-24)
(8W-10-9)
(8W-10-9)
(8W-12-17)
(8W-12-18)
(8W-12-20)
(8W-12-21)
XJD01011 J008W-7
10
JUNCTION
BLOCK
HORN
RELAY
RELAY
LIGHTER
CIGAR
CIRCUIT
BREAKER
29
25A
15A
FUSE
20
15A
FUSE
21 15
FUSE
25A
2
FUSE
25A 25A
FUSE
1
C2 2
A7
10
RD/BK
3
4
FUSE
50A
BATT A0
POWER
DISTRIBUTION
CENTER
30
87 87
30 86
M6
C4
1
LIGHTER
CIGAR
50 C201
F30
16
RD DG/RD
20
X2
C2
4
S131
LHD RHD
X2
20
DG/RD
X2
20
DG/RD
RD
16
F30
LOW
NOTE
HORN
HIGH
NOTE
HORN
85
F30
16
RD
(8W-12-2)
(8W-41-2)
(8W-41-3) (8W-41-2)
(8W-41-3)
(8W-12-25)
(8W-12-19) (8W-12-19) (8W-12-5) (8W-12-5) (8W-12-17)
(8W-12-18)
(8W-10-7)
(8W-10-2)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
J008W-7 XJD01012
12 11
4
11 C201
C100 D5
RD/LG
12
A111
40A
FUSE
6
5
1
D10
D14
40A
FUSE
5
4
BATT A0
POWER
DISTRIBUTION
CENTER
RHD 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)
(8W-42-3)
(8W-42-4)
(8W-42-5)
(8W-42-2)
(8W-42-3)
(8W-42-4)
(8W-42-5)
XJD01013 J008W-7
CLUTCH
COMPRESSOR
A/C
DB/BK
16
C3
C108 4
C100 E10
DB/GY
20
F1
10A
FUSE
27
A2
A1
C3
16
DB/BK
A17
16
RD/BK
B2
B1
22 13
15
9
FUSE
20A
RD/WT
A3
MODULE
DELAY
HEADLAMP
2
SWITCH
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)
6
F1
20
DB/GY
MODULE
IMMOBILIZER
KEY
SENTRY
(8W-42-7)
(8W-50-5)
(8W-50-2)
(8W-50-11)
(8W-10-2)
(8W-10-7)
(8W-42-7)
(8W-39-4)
(8W-39-5)
J008W-7 XJD01014
DG/WT
18
F142
S110
F142
20
DG/WT
F142
20
DG/WT
DG/WT
20
F142
7
S168
DG/WT
18
F142
C3 12
C107
POWERTRAIN
CONTROL
MODULE
A14
A13
21
FUSE
15A
F142
18
DG/WT
D8
D2
RD/LG
14
A16
30A
FUSE
8
7
14
CENTER
DISTRIBUTION
POWER
BATT A0
RELAY
DOWN
SHUT
AUTOMATIC
POWER
DISTRIBUTION
CENTER
(IN PDC)
RD
16
A999
4.0L 2.5L
1 1
UPSTREAM
1/1
SENSOR
OXYGEN OXYGEN
SENSOR
1/2
DOWNSTREAM
15A
FUSE
18
A19
A20
A999
16
RD
1 C107
A142
18
DG/OR
A142
18
DG/OR
S109
1
COIL
IGNITION
A142
18
DG/OR
A142
DG/OR
18 18
DG/OR
A142
FUEL
INJECTOR
NO. 6
NO. 5
INJECTOR
FUEL
1
1
FUEL
INJECTOR
NO. 3
NO. 4
INJECTOR
FUEL
FUEL
INJECTOR
NO. 2
NO. 1
INJECTOR
FUEL
1
18
DG/OR
A142
DG/OR
18
A142
S113
(4.0L)
(4.0L)
A142
18
DG/OR
1
1
DG/OR
18
A142 A142
18
DG/OR
1
2.5L 4.0L
DG/OR
18
A142
RAIL
COIL
2
(8W-30-2)
(8W-10-2)
(8W-10-7)
(8W-30-2)
(8W-10-2)
(8W-30-8) (8W-30-8)
(8W-30-5)
(8W-30-6)
(8W-30-6)
(8W-30-6)
(8W-30-6)
(8W-30-6)
(8W-30-6)
(8W-30-5)
XJD01015 J008W-7
BK/WT
12
C15
C310
C312
3
C326 4
9 25
RD/DB
12
A20 A10
12
RD/DG
20A
FUSE
13
26
19 18
25
12
FUSE
40A
BR
16
T40
1 C108
T40
16
BR
ENGINE
STARTER
MOTOR
REAR
WINDOW
DEFOGGER
BK/WT
12
C15
C6
1
SPARE
FUSE
13 14
FUSE
10A
REAR
WINDOW
DEFOGGER
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
FUSE
30A
(ABS) (ABS)
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
(8W-48-2)
(8W-48-3)
(8W-48-2)
(8W-48-3)
(8W-12-2)
(8W-10-7)
(8W-10-2)
(8W-35-2)
(8W-12-15)
(8W-12-16)
(8W-12-15)
(8W-12-16)
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
J008W-7 XJD01016
M1
20
PK PK
20
M1
RADIO
7 C2
M1
20
PK
4
C7
12 C1
JUNCTION
BLOCK
1
MODULE
CONTROL
TRANSMISSION
25
S135
PK
20
M1
M1
20
PK
A23
A24
16
FUSE
15A
CENTER
DISTRIBUTION
POWER
BATT A0
C1 9
S214
INSTRUMENT
CLUSTER
RIGHT
COURTESY
LAMP
COURTESY
LEFT
LAMP
1 1
M1
20
PK
M1
20
PK
6 C201
M1
20
PK
S18
C4
M1
20
PK
M1
20
PK
PK
20
M1
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
FUSE
17
A22
A21
RD
18
F99
C16
(IN PDC)
RELAY
DOWNSTREAM
SENSOR
OXYGEN
F99
18
RD
C11
OXYGEN
SENSOR
RELAY
(IN PDC)
UPSTREAM
(4.0L)
(8W-47-2)
(8W-47-3)
(8W-47-8)
(8W-47-9)
(8W-12-2)
(8W-31-4)
(8W-10-2)
(8W-10-7)
(8W-40-2)
(8W-44-5) (8W-44-5)
(8W-44-6)
(8W-44-7)
(8W-44-5)
(8W-30-9)
(8W-30-9)
XJD01017 J008W-7
2
COMPASS
PK
20
M1
C
DOME
LAMPS
OVERHEAD
MODULE
2
PK
20
M1
S347
M1
20
PK
M1
20
PK
PK
20
M1
JUNCTION
BLOCK
FROM
C
(8W-10-17)
BATT A0
CENTER
DISTRIBUTION
POWER
20A
FUSE
19
A17
A18
TN/BK
18
F34
C1 4
SWITCH
HEADLAMP
16
CONNECTOR
LINK
DATA
F34
18
TN/BK TN/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/
VANITY
LAMP
M1
20
PK
S361
OTHERS SKIM
MIDLINE BASE/POLICE
LAMP
DOME
2
M1
20
PK
A
A
(8W-49-2)
(8W-49-3)
(8W-44-4)
(8W-49-2)
(8W-49-3)
(8W-10-7)
(8W-10-2)
(8W-50-2)
(8W-30-19) (8W-30-19)
(8W-50-2)
(8W-44-4)
(8W-44-4) (8W-44-4)
J008W-7 XJD01018
DG/BK
14
A61
C1 22
MODULE
PUMP
FUEL
1
DG/WT
16
A141
DG/WT
16
A141
DG/BK
16
A61
14 C107
C100
D2
A141
14
DG/WT
MODULE
CONTROL
POWERTRAIN
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
RHD
LHD
(8W-30-3)
(8W-30-4)
(8W-30-2)
(8W-52-2)
(8W-10-7)
(8W-10-2)
(8W-30-3)
(8W-30-4)
XJD01019 J008W-7
POWER
DISTRIBUTION
CENTER
BATT A0
15A
FUSE
23
A10
A9
F32
20
PK/DB
5
6
BRAKE
LAMP
SWITCH
L50
20
WT/TN
S203
12
CONTROLLER
ANTI-LOCK
BRAKE
C200 24
MOUNTED
HIGH
CENTER
2
STOP
LAMP
5 C326
L50
20
WT/TN
WT/TN
20
L50
S302
LAMP
STOP
TAIL/
LEFT
C322 6
WT/TN
18
L50
3
L50
18
WT/TN
6 C321
RIGHT
TAIL/
STOP
LAMP
L50
20
WT/TN
A6
A5
25
FUSE
15A
B12
B11
A4
A3
26
FUSE
20A
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 C100 B4 C100
RHD LHD
3
L50
18
WT/TN
1 C333
L50
18
DG/WT
L50
20
WT/TN
L50
18
WT/TN
L39
20
LB
8 C106
2
LEFT
FOG
LAMP
LAMP
FOG
RIGHT
2
L39
20
LB
L39
20
LB
S106
F75
14
VT
F75
16
VT
(8W-10-2)
(8W-10-7)
(8W-33-3)
(8W-35-2)
(8W-51-4)
(8W-51-3) (8W-51-3)
(8W-47-2)
(8W-47-3)
(8W-50-9)
(8W-50-10)
(8W-50-9)
(8W-50-10)
(8W-50-9)
(8W-50-10)
J008W-7 XJD01020
8W-12 J UNCTION BLOCK
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . . . . . . 8W-12-12
A/C- Heater Control . . . . . . . . . . . . . . . 8W-12-8, 9, 20, 21
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-12-23, 24
Automati c Shut Down Rel ay . . . . . . . . . . . . 8W-12-13, 14
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-12-12
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-12-20, 21
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-12-20, 21
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . . 8W-12-26, 27
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . . 8W-12-5, 34
Ci rcui t Breaker 28 (JB) . . . . . . . . . . . . . . . 8W-12-23, 24
Ci rcui t Breaker 29 (JB) . . . . . . . . . . . . . . . . . . 8W-12-25
Ci rcui t Breaker 30 (JB) . . . . . . . . . . . . . . . . . . 8W-12-25
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . . 8W-12-17, 18
Cl utch I nterl ock Swi tch Jumper . . . . . . . . . . 8W-12-17, 18
Combi nati on Fl asher . . . . . . . . . . . . . . . . . 8W-12-15, 16
Compass . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11, 27, 34
Control l er Anti -Lock Brake . . . . . . . . . . . . . 8W-12-20, 21
Control l er Anti -Lock Brake Rel ay . . . . . . . . . 8W-12-20, 21
Dayti me Runni ng Lamp Modul e . . . . . . . . . . 8W-12-7, 12
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
Dome Lamps Swi tch . . . . . . . . . . . . . . . . . 8W-12-27, 34
Dri ver Door Jamb Swi tch . . . . . . . . . . . . . . . . 8W-12-27
Dri ver Door Lock Motor . . . . . . . . . . . . . . . 8W-12-28, 29
Dri ver Power Lock/Wi ndow Swi tch . . . 8W-12-17, 18, 23, 24,
31, 33
Dri ver Power Mi rror . . . . . . 8W-12-15, 16, 30, 31, 32, 33, 34
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . . . . . 8W-12-12
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-12-17, 18
Extended I dl e Swi tch . . . . . . . . . . . . . . . . . . . 8W-12-20
Extended I dl e Swi tch . . . . . . . . . . . . . . . . . . . . 8W-12-8
Fog Lamp Rel ay No. 1 . . . . . . . . . . . . . . . . . 8W-12-6, 10
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . . . . . . . 8W-12-10
Front Fog Lamp Swi tch . . . . . . . . . . . . . . 8W-12-8, 9, 10
Front Wi per Motor . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-13, 14
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8, 9
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Fuse 8 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-11
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13, 14
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15, 16
Fuse 13 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15, 16
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-15, 16
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17, 18
Fuse 16 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-26
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17, 18
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17, 18
Fuse 19 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17, 18
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Fuse 22 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20, 21
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22
Fuse 24 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20, 21
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20, 21
Fuse 26 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23, 24
Fuse 27 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-12-23, 24
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-32, 34
Headl amp Beam Sel ect Swi tch . . . . . . . . . . . . 8W-12-6, 7
Component Page
Headl amp Del ay Modul e . . . . . . . . . . . . . . . . . 8W-12-11
Headl amp Swi tch . . . . . . . . . . . . . . 8W-12-8, 9, 10, 22, 27
Heated Seat Rel ay . . . . . . . . . . . . . . . . . . . . . 8W-12-25
Heater Control . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8, 9
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
I nstrument Cl uster . . . . . . . . . . . 8W-12-8, 9, 11, 15, 16, 26
Juncti on Bl ock . . 8W-12-2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15,
16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32,
33, 34
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . 8W-12-26, 27
Left Front Park/Turn Si gnal Lamp No. 1 . . . . . . 8W-12-10
Left Front Park/Turn Si gnal Lamp No. 2 . . . . . . 8W-12-10
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 7
Left Heated Seat Swi tch . . . . . . . . . . . . . . . 8W-12-17, 18
Left Power Seat Swi tch . . . . . . . . . . . . . . . . . . 8W-12-25
Left Rear Door Jamb Swi tch . . . . . . . . . . . . . . 8W-12-27
Left Rear Door Lock Motor . . . . . . . . . . . . . 8W-12-28, 29
Left Si de Marker Lamp . . . . . . . . . . . . . . . . . . 8W-12-10
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . . 8W-12-10
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . . 8W-12-34
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . . 8W-12-28, 29
Low Note Horn . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
Overhead Modul e . . . . . . . . . . . . . . . . . 8W-12-19, 27, 34
Oxygen Sensor Downstream Rel ay . . . . . . . . . . 8W-12-12
Oxygen Sensor Upstream Rel ay . . . . . . . . . . . . 8W-12-12
Passenger Door Jamb Swi tch . . . . . . . . . . . . . . 8W-12-27
Passenger Door Lock Motor . . . . . . . . . . . . . 8W-12-28, 29
Passenger Power Lock/Wi ndow Swi tch . . . 8W-12-17, 18, 23,
24, 28, 29, 34
Passenger Power Mi rror . . . 8W-12-15, 16, 30, 31, 32, 33, 34
Power Di stri buti on Center . . . . . . . . . . . . . . . . 8W-12-26
Power Mi rror Swi tch . . . . . . . . . . 8W-12-17, 18, 30, 32, 34
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-5
Powertrai n Control Modul e . . . . . . . . . . . . . 8W-12-13, 14
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . . . . 8W-12-8, 9
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . . 8W-12-12
Radi o . . . . . . . . . . . . . . . . . . . . 8W-12-8, 9, 10, 17, 18, 26
Rear Wi ndow Defogger . . . . . . . . . . . . . . . . 8W-12-15, 16
Rear Wi ndow Defogger Rel ay . . . . . . . . . . . . 8W-12-15, 16
Rear Wi ndow Defogger Swi tch . . . . . . . . 8W-12-8, 9, 15, 16
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-12-20, 21
Rear Wi per/Washer Swi tch . . . . . . . . . . 8W-12-8, 9, 20, 21
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-12-26, 27
Ri ght Front Park/Turn Si gnal Lamp No. 1 . . . . . 8W-12-22
Ri ght Front Park/Turn Si gnal Lamp No. 2 . . . . . 8W-12-22
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-12-6, 7
Ri ght Heated Seat Swi tch . . . . . . . . . . . . . . 8W-12-17, 18
Ri ght Power Seat Swi tch . . . . . . . . . . . . . . . . . 8W-12-25
Ri ght Rear Door Jamb Swi tch . . . . . . . . . . . . . 8W-12-27
Ri ght Rear Door Lock Motor . . . . . . . . . . . . 8W-12-28, 29
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . . . . 8W-12-22
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . . 8W-12-22
Ri ght Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . . 8W-12-34
Sentry Key I mmobi l i zer Modul e . . . . . . . . . . . . 8W-12-11
Shi ft Lock Sol enoi d . . . . . . . . . . . . . . . . . . 8W-12-20, 21
Trai l er Tow Connector . . . . . . . . . . . . . . . . 8W-12-10, 19
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . . . . 8W-12-19
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . . . . 8W-12-19
Transfer Case Swi tch I l l umi nati on . . . . . . . . . 8W-12-8, 9
Transmi ssi on Control Modul e . . . . . . . . . . . 8W-12-14, 26
Transmi ssi on Range Sensor . . . . . . . . . . . . . . . 8W-12-12
Underhood Lamp/Mercury Swi tch . . . . . . . . . . . 8W-12-26
Wi pe/Wash Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-12-25
XJ 8W - 12 JUNCTION BLOCK 8W - 12 - 1
JUNCTION BLOCK
FRONT OF
27 10A 14
13 26
12 10A 25 15A
10A 23 10
24 20A 11
9 10A 22 20A
8 21 15A
10A 16 10A 3
5 10A 18
4 10A 17 15A
10A 19 5A 6
15A 20 10A 7
C1
C2
C8
C4
C5
C7 C6
C9
C3
1 25A
25A 2 25A 15
SPARE
RELAY
30
28
29
10A
10A
25A 25A
20A
CIGAR
LIGHTER
RELAY
HORN
WINDOW
REAR
RELAY
RELAY
DEFOGGER
10A
15A
8W - 12 - 2 8W-12 JUNCTION BLOCK XJ
J008W-7 XJD01202
FUSES
FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT
1
25A A7 10RD/BK
2
3
L33 20RD
L43 20VT
4
5
6
E2 20OR
7
INTERNAL
8
10
F12 18DB/WT
9
F87 20WT/BK
11
12
L3 16RD/OR
L7 18BK/YL
A21 12DB
25A
10A
10A
10A
10A
20A
10A
E1 20TN
A22 12BK/OR
A7 10RD/BK
A21 12DB
A21 12DB
A21 12DB
- -
15A F20 18WT
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
L4 16VT/WT
10A L44 20VT/RD L4 16VT/WT
A22 12BK/OR
A22 12BK/OR
A22 12BK/OR
A41 14YL
A7 10RD/BK
A7 10RD/BK
A7 10RD/BK
A4 12BK/PK
INTERNAL
A31 12BK/WT
A31 12BK/WT
A21 12DB
L3 16RD/OR
L7 18BK/YL
INTERNAL
- -
10A
25A F35 16RD
15A X12 16RD/WT
10A F45 20YL/RD
15A A6 20RD/OR
15A
20A V23 18BR/PK
- -
15A F15 20DB/WT
10A F14 18LG/YL
10A F23 18DB/YL
10A L34 20RD/OR
10A
10A F83 18YL/DG
A22 12BK/OR
F38 16RD/LB
INTERNAL
INTERNAL
INTERNAL
INTERNAL
5A
XJ 8W-12 JUNCTION BLOCK 8W - 12 - 3
XJD01203 J008W-7
HORN RELAY CONTROL
FUSED B(+)
30
85
86
87
X3 20BK/RD
INTERNAL
X2 20DG/RD
- -
87A
30
85
86
87
A4 12BK/PK
C81 20LB/WT
INTERNAL
INTERNAL
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (RUN)
REAR WINDOW DEFOGGER RELAY OUTPUT
REAR WINDOW DEFOGGER RELAY CONTROL
FUSED B(+)
HORN RELAY OUTPUT
87A
- -
GROUND
CIGAR LIGHTER RELAY OUTPUT
FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
FUSED B(+)
F30 16RD
A31 12BK/WT
INTERNAL
87
86
85
30
87A
- -
INTERNAL
INTERNAL
CIRCUIT BREAKERS
FEED CIRCUIT FUSED CIRCUIT AMPS CB NO.
V6 16DB 20A
F37 14RD/LB 25A
INTERNAL 25A
A7 10RD/BK
A31 12BK/WT
A31 12BK/WT
30
29
28
RELAY
LIGHTER
CIGAR
HORN
RELAY
DEFOGGER
WINDOW
REAR
RELAY
J008W-7 XJD01204
JUNCTION
BLOCK
1
FUSE
25A
BATT A7
F38
16
RD/LB
1
POWER
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-41-3)
XJD01205 J008W-7
JUNCTION
BLOCK
3
FUSE
10A
9
C1
10A
FUSE
16
C1
11
2
A
LEFT
HEADLAMP
C106 6
L34
18
RD/OR RD
18
L33
HEADLAMP
RIGHT
A
RD
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-50-3)
(8W-50-4)
(8W-50-3)
(8W-50-4)
(8W-50-3)
(8W-50-4)
(8W-50-3)
(8W-50-4)
(8W-50-8)
J008W-7 XJD01206
JUNCTION
BLOCK
4
FUSE
10A
10
C1
10A
FUSE
5
C1
1
9
B
LEFT
HEADLAMP
C106
13
HEADLAMP
RIGHT
B
L44
20
VT/RD VT
20
L43
BEAM
SELECT
S3 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/WT
L4
16
VT/WT
(8W-12-2)
(8W-50-3)
(8W-50-4)
(8W-50-3)
(8W-50-4)
(8W-50-3)
(8W-50-4)
(8W-50-11)
XJD01207 J008W-7
43 C201
JUNCTION
BLOCK
6
FUSE
5A
S2
C4
E2
20
OR
S1 C4
42 C201
E1
20
TN
HEADLAMP
SWITCH
1
S315
E2
20
OR OR
20
E2
1 C206
E2
20
OR
E2
20
OR
1 1
ILLUMINATION
PRNDL
(A/T)
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
E2
20
OR
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/
ILLUMINATION
SWITCH
CASE
TRANSFER
S215
CONTROL
HEATER
A/C
HEATER ONLY
C1
(8W-12-2)
(8W-50-2)
(8W-47-2)
(8W-47-8)
(8W-44-2)
(8W-48-2)
(8W-40-12)
(8W-42-4)
(8W-53-3)
(8W-30-17)
(8W-44-2)
(8W-44-2)
(8W-42-2)
8W - 12 - 8 8W-12 JUNCTION BLOCK
LHD
XJ
J008W-7 XJD01208
OR/BK
20
E2
C203 12
OR
20
E2
1 C206
E2
20
OR
E2
20
OR
1 1
ILLUMINATION
PRNDL
(A/T)
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
S215
RADIO
C2 5
LAMP
1
FRONT
FOG
SWITCH
SWITCH
WINDOW
REAR
4
DEFOGGER
3 C1
INSTRUMENT
CLUSTER
HEATER
A/C- 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
TRANSFER
CONTROL
HEATER
A/C
HEATER ONLY
C1
(8W-44-2)
(8W-47-3)
(8W-47-9)
(8W-44-3)
(8W-48-3)
(8W-40-12)
(8W-42-5)
(8W-53-4)
(8W-12-2)
(8W-50-2)
(8W-44-3)
(8W-42-3)
XJ 8W-12 JUNCTION BLOCK
RHD
8W - 12 - 9
XJD01209 J008W-7
JUNCTION
BLOCK
7
FUSE
10A
6
C2 C7
2
L77
20
BR/YL
M3 C4
18
L77
45 C201
RHD LHD
L7
18
BK/YL
HEADLAMP
SWITCH
9
B6
NO. 1
RELAY
LAMP
FOG
(IN PDC)
L77
20
BR/YL
7 C106
L77
20
BR
1
LICENSE
LAMP
S104
L77
18
BR BR
18
L77 L77
20
BR
SIDE
LEFT
1
MARKER
TURN
2
LEFT
PARK/
NO. 2
SIGNAL
SIGNAL
NO. 1
PARK/
LEFT
2
TURN
18
L77 L77
18
BR/YL
S311
C327 2
18
L77
C310
C311 4
11
L77
20
5
TRAILER
TOW
CONNECTOR
S340
LAMP
STOP
TAIL/
LEFT
2
OTHERS TOW
TRAILER
L77
18
BR/YL
L77
20
S206
C1
LAMP
BR/YL
BR/YL
BR/YL
BR/YL
BR/YL
L77
18
BR/YL
FRONT
FRONT
LAMP
LAMP
C323 7
7 C322
L77
18
BR
C2 4
RADIO
L7
18
BK/YL
1 C330
L78
18
BK/YL
L77
18
BR/YL
B9
4
3
A5 C100
B15
B13
SWITCH
LAMP
FOG
FRONT
A4 C100
2
(IN PDC)
NO. 2
RELAY
LAMP
FOG
L92
20
PK
L39
20
LB
L139
20
VT
ON
INDICATOR
(8W-12-2)
(8W-50-2)
(8W-50-8)
(8W-50-10)
(8W-51-4)
(8W-50-6)
(8W-52-3)
(8W-50-6)
(8W-52-3)
(8W-54-2)
(8W-51-3)
(8W-50-6)
(8W-52-3)
(8W-47-2)
(8W-47-3)
(8W-47-8)
(8W-47-9)
(8W-50-9)
(8W-50-10)
(8W-50-9)
(8W-50-10)
J008W-7 XJD01210
JUNCTION
BLOCK
8
FUSE
SPARE
ST-RUN A21
C4
S13
COMPASS
6
9
FUSE
10A
F87
20
WT/BK
F87
20
WT/BK
C201 5
DELAY
HEADLAMP
8
MODULE
CLUSTER
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/BK
F87
20
WT/BK
(8W-12-2)
(8W-10-10)
(8W-49-2)
(8W-49-3)
(8W-50-5)
(8W-40-2)
(8W-39-4)
(8W-39-5)
XJD01211 J008W-7
JUNCTION
BLOCK
ST-RUN A21
15A
FUSE
10
S12
C4
F20
18
WT
1 C201
F20
18
WT
C100
A9
S159
SOLENOID
PURGE
EVAP/
CYCLE
DUTY
WT
18
F20
D11
3
SENSOR
RANGE
TRANSMISSION
F20
18
WT
(4.0L A/T)
TO
S161
A
BACK-UP
SWITCH
F20
18
WT
F20
18
WT
F20
18
WT
4.0L M/T
5
F20
18
WT
MODULE
LAMP
RUNNING
DAYTIME
LAMP
(GAS)
OTHER DIESEL
RHD LHD
C18
C13
B5
(IN PDC)
RELAY
CLUTCH
COMPRESSOR
A/C
(IN PDC)
RELAY
SENSOR
OXYGEN
DOWNSTREAM
UPSTREAM
OXYGEN
SENSOR
RELAY
(IN PDC)
F20
18
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)
(4.0L M/T)
(2.5L)
(4.0L A/T FOG
(IN PDC)
D11
RELAY
FAN
RADIATOR
WT
18
F20
F20
18
WT
PK/OR
18
F26
EXCEPT FOG)
(4.0L A/T
(4.0L A/T DRL)
(4.0L M/T)
(IN PDC)
RELAY
FAN
RADIATOR
C18
1 C113
11 C107
2.5L A/T
F20
18
WT
F20
18
WT
EXCEPT FOG) EXCEPT DRL)
WT
18
F20
C107 11
WT
18
F20
2.5L M/T
(8W-12-2)
(8W-10-10)
(8W-30-15)
(8W-31-6)
(8W-51-6)
(8W-51-6)
(8W-50-11)
(8W-42-7)
(8W-30-9)
(8W-30-9)
(8W-30-9)
(8W-42-7)
(8W-30-9)
(8W-42-8)
(8W-42-8)
J008W-7 XJD01212
JUNCTION
BLOCK
11
FUSE
20A
ST-RUN A21
C2
5
F12
18
DB/WT
CONTROL
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)
(8W-30-2)
2.5L
8W - 12 - 13
XJD01213 J008W-7
JUNCTION
BLOCK
11
FUSE
20A
ST-RUN A21
C2
5
F12
18
DB/WT
CONTROL
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
DB/WT
18
F12
26
(RHD)
MODULE
CONTROL
TRANSMISSION
F12
18
DB/WT
F12
18
DB/WT
MODULE
CONTROL
TRANSMISSION
26
F12
18
DB/WT
F12
18
DB/WT
S136
RHD LHD
C3 D6
(8W-12-2)
(8W-10-10)
(8W-30-2)
(8W-30-2)
(8W-30-3)
(8W-30-4)
(8W-31-4)
(8W-31-4)
4.0L
XJ
J008W-7 XJD01214
JUNCTION
BLOCK
12
FUSE
10A
RUN A22
S20
C4
85 87
30 86
BATT A4
10A
FUSE
14
C4
S26 3
C9
REAR
WINDOW
DEFOGGER
C81
20
LB/WT
L5
20
BK
RELAY
13
FUSE
SPARE
C4
S19
BK/WT
20
C16
1
C6
BK/WT
12
C15
3
BK
20
L5
1
COMBINATION
FLASHER
LB/YL
20
C16
WINDOW
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/WT
20
C81
LB/YL
20
C16
2 C201
3
LB/YL
20
C16
BK/WT
20
C16
OPTIONS
FULL
MIRRORS
POWER
C16
20
LB/YL
(8W-12-2)
(8W-10-11)
(8W-10-16)
(8W-52-2)
(8W-48-2)
(8W-48-2)
(8W-40-9)
(8W-48-2)
(8W-48-2)
(8W-48-2)
LHD
8W - 12 - 15
XJD01215 J008W-7
5
C5
LB/YL
20
C16
JUNCTION
BLOCK
12
FUSE
10A
RUN A22
S20
C4
85 87
30 86
BATT A4
10A
FUSE
14
C4
S26
REAR
WINDOW
DEFOGGER
C81
20
LB/WT
RELAY
13
FUSE
SPARE
C16
20
BK/WT
C4
S19 1
C6
BK/WT
12
C15
BK
20
L5
1
COMBINATION
FLASHER
C16
20
LB/YL
WINDOW
REAR
3
DEFOGGER
SWITCH
2 C204
11 C305
MIRROR
5
PASSENGER
POWER
CLUSTER
INSTRUMENT
3
C16
20
LB/YL
DEFOGGER
REAR
WINDOW
4 C326
C312 2
C310
C15
12
BK/WT
BK/WT
12
C15
C2
3
C9
BK/WT
20
C16
POWER
DRIVER
5
MIRROR
3
BK/WT
20
C16
MIRRORS
POWER FULL
OPTIONS
(8W-12-2)
(8W-10-11)
(8W-10-16)
(8W-52-2)
(8W-48-3)
(8W-48-3)
(8W-40-10)
(8W-48-3)
(8W-48-3)
(8W-48-3)
RHD
XJ
J008W-7 XJD01216
JUNCTION
BLOCK
15
FUSE
25A
BATT A7
9
C9
RUN-ACC A31
15A
FUSE
17 19
FUSE
10A
C4
S9 3
C1
F35
16
RD
SWITCH
WINDOW
5
PASSENGER
C2
LOCK/
POWER
RD/WT
16
X12
18
FUSE
10A
ST A41
54
X12
16
RD/WT
C2
RADIO
6
M/T 2.5L A/T
MOTOR
RELAY
STARTER
ENGINE
(IN PDC)
C8
1
2
SWITCH
INTERLOCK
CLUTCH
YL/RD
20
F45 F45
20
YL/RD
YL
20
T141
44
C201
F83
18
YL/DG
S4
C4
YL/DG
18
F83
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 MIRRORS
OTHER
HEATED
SEATS
F83
18
YL/DG
F83
18
YL/DG
S351
C316 1
F83
18
YL/DG
F83
18
YL/DG
4
SWITCH
SEAT
HEATED
RIGHT
LEFT
HEATED
SEAT
SWITCH
4
S353
OPTIONS)
(FULL
C10
(8W-12-2)
(8W-10-12) (8W-10-9)
(8W-10-11)
(8W-47-2)
(8W-47-8)
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
(8W-61-2)
(8W-62-2)
(8W-62-6)
(8W-63-4)
(8W-63-4)
(8W-63-4)
LHD
8W - 12 - 17
XJD01217 J008W-7
JUNCTION
BLOCK
15
FUSE
25A
BATT A7 RUN-ACC A31
15A
FUSE
17 19
FUSE
10A
C4
S9 3
C1
18
FUSE
10A
F45
20
YL/RD
ST A41
X12
16
RD/WT
C2
RADIO
6
M/T A/T
1
2
SWITCH
INTERLOCK
CLUTCH
F45
20
YL/RD
YL
20
T141
C8
(IN PDC)
ENGINE
STARTER
RELAY
MOTOR
E7 C100
YL/RD
20
F45
CLUTCH
INTERLOCK
SWITCH
2
1
YL/RD
20
F45
JUMPER
T141
20
YL
T141
20
YL
POWER
C2
PASSENGER
5
SWITCH
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
MIRRORS
POWER
FULL OPTIONS
1 C324
C316 1
4
SWITCH
SEAT
HEATED
LEFT
RIGHT
HEATED
SEAT
SWITCH
4
F83
18
YL/DG
F83
18
YL/DG
S353
OPTIONS)
(FULL
C10
F83
18
YL/DG
F83
18
YL/DG
(8W-12-2)
(8W-10-12) (8W-10-9)
(8W-10-11)
(8W-47-3)
(8W-47-9)
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
(8W-61-3)
(8W-62-4)
(8W-62-7)
(8W-63-4)
(8W-63-4)
(8W-63-4)
RHD
XJ
J008W-7 XJD01218
JUNCTION
BLOCK
20
FUSE
15A
BATT A7
8
C7
21
FUSE
15A
85 87
30 86
HORN
RELAY
C5
1 S22
C4 C2
4
C323
A6
20
RD/OR
3
RD/OR
20
A6
BK/RD
20
X3
7 C301
X3
20
BK/RD
X3
20
BK/RD
26 C201
BK/RD
20
X3
DG/RD
20
X2
X2
20
DG/RD DG/RD
20
X2
S131
4
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 TRAILER
TOW
RIGHT
TURN
RELAY
NOTE NOTE
C1
(8W-12-2)
(8W-10-12)
(8W-54-3)
(8W-49-4)
(8W-49-5)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-54-3) (8W-54-3)
(8W-41-2)
(8W-41-3)
XJD01219 J008W-7
JUNCTION
BLOCK
22
FUSE
20A
RUN A22
S11
C4
SPARE
FUSE
24 25
FUSE
15A
C4
S8
V23
18
BR/PK
39 C201
BR/PK
18
V23
10
DB/WT
20
F15
F15
20
DB/WT
C201 40
F15
20
DB/WT
LOCK
SHIFT
2
SOLENOID
SWITCH
5
REAR
WIPER/
6
V23
18
BR/PK
C200 29
BR/PK
18
V23
4 C327
V23
18
BR/PK
2 C313
C310 7
BR/PK
18
V23
MOTOR
4
REAR
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
ANTI-LOCK
CONTROLLER
BRAKE
C1
6
F15
18
DB/WT
23
F15
20
DB/WT
F15
20
DB/WT
MOTOR
BLOWER
RELAY
ACTUATOR
BLEND
DOOR
C209
9
5
OR
20
D2
C2
B18
(8W-12-2)
(8W-10-11)
(8W-31-3)
(8W-31-7)
(8W-53-3)
(8W-53-3)
(8W-30-17)
(8W-42-7)
(8W-35-3)
(8W-35-3)
(8W-42-2)
(8W-42-4)
(8W-42-7)
LHD
XJ
J008W-7 XJD01220
JUNCTION
BLOCK
22
FUSE
20A
RUN A22
S11
C4
6
C1
SPARE
FUSE
24 25
FUSE
15A
C4
S8
BR/PK
18
V23
5
LOCK
SHIFT
2
SOLENOID
SWITCH
6
REAR
WIPER/
5
V23
18
BR/PK
C203 6
BR/PK
18
V23
4 C327
V23
18
BR/PK
2 C313
C310 7
BR/PK
18
V23
MOTOR
4
REAR
WIPER
BRAKE
CONTROLLER
ANTI-LOCK
23
RELAY
BRAKE
CONTROLLER
ANTI-LOCK
B20
F15
20
DB/WT
S134
DB/WT
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/WT
1
C303
NOT
USED
V23
18
BR/PK
S324
FULL
OPTIONS BASE
RELAY
MOTOR
BLOWER
DOOR
BLEND
10
ACTUATOR
D2
20
OR
5
C2
C209
9
B18
(8W-12-2)
(8W-10-11)
(8W-31-3)
(8W-31-7)
(8W-53-4)
(8W-53-4)
(8W-35-3)
(8W-35-3)
(8W-42-7)
(8W-42-3)
(8W-42-5)
(8W-42-7)
RHD
8W - 12 - 21
XJD01221 J008W-7
7 C321
DG/YL
18
L78
DG/YL
L78
DG/YL
L78
DG/YL
L78
S101
18 18 20
SIDE
RIGHT
1
MARKER
2 2
DG/YL
20
L78
14 C106
JUNCTION
BLOCK
23
FUSE
10A
5
C1 C7
6
L78
20
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/
TURN
SIGNAL
LAMP
NO. 2
(8W-12-2)
(8W-50-2)
(8W-51-3)
(8W-12-10)
(8W-50-7)
(8W-52-4)
(8W-50-7)
(8W-52-4)
(8W-50-7)
(8W-52-4)
J008W-7 XJD01222
RUN A22
MODULE
AIRBAG
CONTROL
JUNCTION
BLOCK
27
FUSE
10A
ST-RUN A21
C4
S23
17 20
S21
C4
10A
FUSE
26
25A
28
BREAKER
CIRCUIT
RUN-ACC A31
8
C5 C8
1
F81
14
TN
4
PASSENGER
POWER
C2
LOCK/
WINDOW
SWITCH SWITCH
WINDOW
LOCK/
C1
POWER
DRIVER
9
1 C307
TN
12
F81
TN
14
F81
LG/YL
18
F14 F23
18
DB/YL
13 C201
F81
12
TN
33 C200
TN
12
F81
(FULL OPTIONS) (FULL OPTIONS)
(8W-10-11)
(8W-43-2)
(8W-12-2)
(8W-10-10)
(8W-10-9)
(8W-60-2)
(8W-60-4)
(8W-61-2)
LHD
8W - 12 - 23
XJD01223 J008W-7
TN
12
F81
RUN A22
MODULE
AIRBAG
CONTROL
JUNCTION
BLOCK
27
FUSE
10A
ST-RUN A21
C4
S23
DB/YL
18
F23
17
F14
18
LG/YL
20
S21
C4
10A
FUSE
26
25A
28
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
(8W-10-11)
(8W-43-3)
(8W-12-2)
(8W-10-10)
(8W-10-9)
(8W-60-3)
(8W-60-5)
(8W-61-3)
RHD
XJ
J008W-7 XJD01224
5
MOTOR
FRONT
WIPER
1
DB
16
V6
DB
16
V6
A
RD/LB
14
F37
CIRCUIT
BREAKER
30
20A
BATT A7
JUNCTION
BLOCK
C4
M4 2
C6
25A
29
BREAKER
CIRCUIT
RUN-ACC A31
C1
8
RHD 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
RD/LB
C316 2
F37
14
RD/LB
POWER SEATS
(8W-53-2)
(8W-10-12)
(8W-12-2)
(8W-10-9)
(8W-53-2)
(8W-63-2)
(8W-63-6)
(8W-63-3)
XJD01225 J008W-7
M1
20
PK PK
20
M1
RADIO
7 C2
M1
20
PK
4
C7
12 C1
JUNCTION
BLOCK
1
MODULE
CONTROL
TRANSMISSION
25
S135
PK
20
M1
M1
20
PK
A23
A24
16
FUSE
15A
CENTER
DISTRIBUTION
POWER
BATT A0
C1 9
S214
INSTRUMENT
CLUSTER
RIGHT
COURTESY
LAMP
COURTESY
LEFT
LAMP
1 1
M1
20
PK
M1
20
PK
6 C201
M1
20
PK
S18
C4
M1
20
PK
M1
20
PK
PK
20
M1
A C207
M1
18
PK
C208 A
PK
18
M1
M1
20
PK
A
LAMP/
CARGO
C3
3
PK
20
M1
TO
S347
(4.0L)
PK
18
M1
C314 5
LHD RHD
RHD LHD
SWITCH
SWITCH
MERCURY
LAMP/
UNDERHOOD
S361
TO
OTHERS SKIM
(8W-47-2)
(8W-47-3)
(8W-47-8)
(8W-47-9)
(8W-12-2)
(8W-31-4)
(8W-10-2)
(8W-10-7)
(8W-40-2)
(8W-44-5) (8W-44-5)
(8W-44-6)
(8W-44-7)
(8W-10-18)
(8W-10-17)
(8W-44-5)
(8W-10-18)
J008W-7 XJD01226
JUNCTION
BLOCK
7
C7
HEADLAMP
SWITCH
3
C1
M2
20
YL BK/WT
18
M2
2
LAMP
LEFT
COURTESY COURTESY
RIGHT
LAMP
2
M2
18
BK/WT
B C207 C208 B
YL
20
M2 M2
20
YL
YL
20
M2
46 C201
S25 C4
S201
LHD RHD
YL
20
M2
C3
1
COMPASS
7
1
OVERHEAD
MODULE
3
OVERHEAD MODULE BASE/POLICE
S345
M2
20
YL
M2
20
YL
M2
20
YL
M2
20
YL
YL
20
M2
DRIVER
1 3
DOOR
JAMB
SWITCH
YL
18
M2
SWITCH
JAMB
DOOR
LEFT
REAR
M2
18
YL
M2
20
YL
A
C317
A C320 C319 A
C318
A
YL
20
M2
YL
18
M2
REAR
DOOR
JAMB
SWITCH
M2
18
YL
SWITCH
JAMB
DOOR
3 1
PASSENGER
S304
M2
20
YL
RIGHT CARGO
B
SWITCH
LAMP/
M2
20
YL
M2
20
YL
6 C314
SWITCH
YL
20
M2
LAMPS
DOME
B
FULL OPTIONS MIDLINE
DOME
LAMP
LHD
RHD
C317 C318
(8W-12-2)
(8W-50-2)
(8W-44-5) (8W-44-5)
(8W-49-4)
(8W-49-5)
(8W-49-4)
(8W-49-5)
(8W-39-6)
(8W-39-7)
(8W-39-6)
(8W-39-7)
(8W-39-6)
(8W-39-7)
(8W-39-6)
(8W-39-7)
(8W-44-6)
(8W-44-7)
(8W-44-4)
(8W-44-4)
XJD01227 J008W-7
JUNCTION
BLOCK
1
C7
P33
16
OR/BK
LOCK/
PASSENGER
POWER
WINDOW
SWITCH
C1
5
OR/BK
16
P33 P33
16
OR/BK
2
MOTOR
DOOR
PASSENGER
LOCK
S317
1 C9
P33
16
OR/BK
4 C305
S306
OR/BK
16
P33 P33
16
OR/BK
C309 4
P33
16
OR/BK
C304 4 1
C326
OR/BK
16
P33
OR/BK
16
P33
OR/BK
16
P33 P33
16
OR/BK
C310
C311 1
4
OR/BK
16
P33
LOCK
DRIVER
DOOR
MOTOR
2 2
MOTOR
DOOR
LEFT
REAR
LOCK LOCK
REAR
RIGHT
DOOR
MOTOR
2 A
LIFTGATE
LOCK
MOTOR
1
PK/BK
16
P34
1
C1
P34
16
PK/BK
S316
PK/BK
16
P34
C9 12
C7
5
PK/BK
16
P34
1 1
P34
16
PK/BK
1
P34
16
PK/BK
B
P34
16
PK/BK
5 5 5
P34
16
PK/BK PK/BK
16
P34
PK/BK
16
P34
PK/BK
16
P34
5
2
2
S307
PK/BK
16
P34
PK/BK
16
P34 P33
16
OR/BK
FULL OPTIONS
(FULL OPTIONS)
(8W-12-2)
(8W-61-4)
(8W-61-4)
(8W-61-4) (8W-61-4)
(8W-61-4)
(8W-61-4)
LHD
XJ
J008W-7 XJD01228
JUNCTION
BLOCK
LOCK/
PASSENGER
POWER
WINDOW
C1
5
OR/BK
16
P33
MOTOR
DOOR
PASSENGER
LOCK
S323
P33
16
OR/BK
4
C305
S306
OR/BK
16
P33
P33
16
OR/BK
C309 4
P33
16
OR/BK
C304 4 1
C326
OR/BK
16
P33
OR/BK
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
LIFTGATE
LOCK
MOTOR
1
C1
P34
16
PK/BK
S322
PK/BK
16
P34
1 1
P34
16
PK/BK
1
P34
16
PK/BK
B
P34
16
PK/BK
5
5 5
P34
16
PK/BK
PK/BK
16
P34
PK/BK
16
P34
PK/BK
16
P34
5
2
2
S307
P34
16
PK/BK OR/BK
16
P33
SWITCH
PK/BK
16
P34
1 2
P33
16
OR/BK
12
C9 C9
1
5 C7 1 C7
P34
16
PK/BK
P33
16
OR/BK
PK/BK
16
P34 P33
16
OR/BK
(FULL OPTIONS)
FULL OPTIONS
(8W-12-2)
(8W-61-5)
(8W-61-5)
(8W-61-5) (8W-61-5)
(8W-61-5)
(8W-61-5)
RHD
8W - 12 - 29
XJD01229 J008W-7
1
2
3 4
6
10
5
7
6
P74
20
DB
P72
20
YL/BK
P76
20
OR/YL
P91
20
WT/BK
6
5
3 4
M M
2 1
DRIVER
POWER
MIRROR
MIRROR
POWER
PASSENGER
2 1
M M
3 4
5
6
9 10
BLOCK
JUNCTION
C9 C9
C9 C9
C5 C5
C5
3 2
C5
P74
20
DB
P72
20
YL/BK
35
C200
34
9 8
P91
20
WT/BK
36
10
P76
20
OR/YL
12
C200
13
C305
P76
20
OR/YL
P91
20
WT/BK
SWITCH
MIRROR
POWER
8 7
P71
20
YL
P75
20
DB/WT
P91
20
WT/BK
P76
20
OR/YL
1
2 3
4
4 DOWN
3 LEFT
1 RIGHT
2 UP
P91
20
WT/BK
P76
20
OR/YL
C305
28 C201 67
20 24 C201
BLOCK
JUNCTION
RUN-ACC F83
P74
20
DB
P72
20
YL/BK
P72
20
YL/BK
P74
20
DB
6 PASSENGER
5 DRIVER MIRROR
MIRROR
6 5 6 5
(8W-12-2)
(8W-12-2)
(8W-12-17)
(8W-62-6)
(8W-62-6)
(8W-62-6)
LHD EXCEPT FULL OPTIONS
XJ
J008W-7 XJD01230
JUNCTION
BLOCK
2
C9
LOCK/
DRIVER
POWER
WINDOW
SWITCH
C2
4
9 C5
DB
20
P74
9
35
24
P74
20
DB
P74
20
DB
P74
20
DB
3
MIRROR
PASSENGER
POWER
DB
20
P74 P72
20
YL/BK
1
C9
6
C5 10
20
34
8
P72
20
YL/BK
7
C2
YL/BK
20
P72
YL/BK
20
P72
YL/BK
20
P72
POWER
DRIVER
MIRROR
C2
2
OR/YL
20
P76 P76
20
OR/YL
2 4
OR/YL
20
P76
S328
P76
20
OR/YL
10
C305
36
C200
OR/YL
20
P76
28
C201
P76
20
OR/YL
OR/YL
20
P76
2 C5
10
C9
2
OR/YL
20
P76
S318
P76
20
OR/YL OR/YL
20
P76
4
(8W-12-2)
(8W-62-3)
(8W-62-3)
(8W-62-2)
LHD FULL OPTIONS
8W - 12 - 31
XJD01231 J008W-7
1
11 2
7 8
6
10
5
7
6
Z1
20
BK
P75
20
DB/WT
P71
20
YL/LB
P76
20
OR/YL
P91
20
WT/BK
6
5
4 3
M M
1 2
DRIVER
POWER
MIRROR
MIRROR
POWER
PASSENGER
2 1
M M
3 4
5
6
9 10
BLOCK
JUNCTION
C9 C9 C9
C9 C9
C5 C5
C5
3 2
C5
P74
20
DB
P72
20
YL/BK
9
C204
8
9 8
P75
20
DB/WT
P71
20
YL
P91
20
WT/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 LEFT
1 RIGHT
2 UP
P91
20
WT/BK
P76
20
OR/YL
BLOCK
JUNCTION
RUN-ACC F83
P74
20
DB
P72
20
YL/BK
C305
Z1
16
BK
3
C7
S359
P91
20
WT/BK
POWER
MIRRORS BASE
6 5 6 5
5 DRIVER MIRRIOR
6 PASSENGER
MIRROR
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-12-2)
(8W-12-18)
(8W-15-7)
(8W-62-7)
(8W-62-7)
(8W-62-7)
RHD EXCEPT FULL OPTIONS
XJ
J008W-7 XJD01232
JUNCTION
BLOCK
2
C9
LOCK/
DRIVER
POWER
WINDOW
SWITCH
3
9 C5
DB/RD
20
P75
9
9
P74
20
DB
6
MIRROR
DRIVER
POWER
DB/WT
20
P75 P71
20
YL/LB
1
C9
6
C5 10
8
8
P71
20
YL
1
YL/BK
20
P72
POWER
PASSENGER
MIRROR
P76
20
OR/YL
2 4
OR/YL
20
P76
S328
P76
20
OR/YL
10
C305
10
C204
OR/YL
20
P76
P76
20
OR/YL
2 C5
10
C9
2
OR/YL
20
P76
S318
P76
20
OR/YL OR/YL
20
P76
4
YL/BK
20
P72 P74
20
DB
OR/YL
20
P76
2 C2 C2 C2
(8W-12-2)
(8W-62-5)
(8W-62-4)
(8W-62-5)
RHD FULL OPTIONS
8W - 12 - 33
XJD01233 J008W-7
JUNCTION
BLOCK
S5
C4
Z1
14
BK
11 C9
S314
BK
14
Z1
C201 14
G107
Z1
14
BK
85
CIGAR
LIGHTER
RELAY
Z1
16
BK
S319
BK
14
Z1
Z1
18
BK
LOCK/
PASSENGER
POWER
C2
6
WINDOW
SWITCH
6
MIRROR
PASSENGER
POWER
C3
2
(LHD)
POWER
DRIVER
MIRROR
BK
18
Z1
6
Z1
14
BK
RHD LHD
Z1
20
BK
BK
20
Z1
BK
20
Z1
MODULE
OVERHEAD
1
COMPASS
3
Z1
14
BK
S208
9
BK
20
Z1
(LHD)
1
SWITCH
MIRROR
POWER
Z1
20
BK
DOME
A
Z1
20
BK
LAMPS
SWITCH
OTHER COMPASS
6
Z1
18
BK
MIRROR
POWER
PASSENGER
S319
FULL OPTIONS
S342
Z1
16
BK
POWER
MIRRORS
RHD LHD
MIRRORS
POWER
(OVERHEAD
CONSOLE)
BK
20
Z1
B
Z1
20
BK
B
LAMP
VANITY
VISOR/
RIGHT
LEFT
VISOR/
VANITY
LAMP
(8W-12-2)
(8W-15-7)
(8W-15-8)
(8W-41-2)
(8W-41-3)
(8W-61-2)
(8W-48-2)
(8W-48-3)
(8W-49-2)
(8W-49-3)
(8W-49-2)
(8W-49-3)
(8W-15-8)
(8W-62-7)
(8W-44-4)
(8W-48-2)
(8W-15-7)
(8W-15-7)
(8W-15-7)
(8W-44-4)
(8W-44-4)
J008W-7 XJD01234
8W-15 GROUND DISTRIBUTION
Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-15-8, 9
Ai rbag Control Modul e . . . . . . . . . . . . . 8W-15-10, 11
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Bl end Door Actuator . . . . . . . . . . . . . . . . . . 8W-15-8
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-15-9
Brake Lamp Swi tch . . . . . . . . . . . . . . . . . . 8W-15-9
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . . . 8W-15-7
Compass . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 9
Control l er Anti -Lock Brake . . . . . . . . . . . . . 8W-15-2
Control l er Anti -Lock Brake Rel ay . . . . . . 8W-15-4, 5
Dayti me Runni ng Lamp Modul e . . . . . . . . . 8W-15-6
Dome Lamps Swi tch . . . . . . . . . . . . . . . . . . 8W-15-7
Dri ver Door Jamb Swi tch . . . . . . . . . . 8W-15-10, 13
Dri ver Power Lock/Wi ndow Swi tch . . . 8W-15-10, 13
Dri ver Power Mi rror . . . . . . . . . . . . 8W-15-7, 10, 13
Engi ne Starter Motor Rel ay . . . . . . . . . . 8W-15-2, 4
Extended I dl e Swi tch . . . . . . . . . . . . . . . . . 8W-15-8
Fog Lamp Rel ay No. 1 . . . . . . . . . . . . . 8W-15-3, 4, 5
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . 8W-15-3, 4, 5
Front Fog Lamp Swi tch . . . . . . . . . . . . . . . 8W-15-8
Front Wi per Motor . . . . . . . . . . . . . . . 8W-15-4, 5, 6
Fuel Pump Modul e . . . . . . . . . . . . . . . 8W-15-10, 11
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 11
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 11
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12, 13
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
G306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . . 8W-15-9
Heated Seat Rel ay . . . . . . . . . . . . . . . . . . 8W-15-15
Heater Control . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-15-9
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-15-7, 8
Left Back-Up Lamp . . . . . . . . . . . . . . . 8W-15-10, 11
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Left Front Park/Turn Si gnal Lamp No. 1 . . 8W-15-6
Left Headl amp . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Left Heated Seat Back . . . . . . . . . . . . . . . 8W-15-15
Left Heated Seat Swi tch . . . . . . . . . . . . . . 8W-15-15
Left Power Seat Swi tch . . . . . . . . . . . . . . . 8W-15-15
Left Rear Door Jamb Swi tch . . . . . . . . 8W-15-10, 11
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . 8W-15-10, 11
Component Page
Left Turn Si gnal Lamp . . . . . . . . . . . . 8W-15-10, 11
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . 8W-15-7
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-15-14
Overhead Modul e . . . . . . . . . . . . . . . . . . . . 8W-15-7
Oxygen Sensor 1/1 Upstream . . . . . . . . . . . 8W-15-2
Oxygen Sensor 1/2 Downstream . . . . . . . . . 8W-15-2
Oxygen Sensor 2/1 Upstream . . . . . . . . . . . 8W-15-2
Oxygen Sensor 2/2 Downstream . . . . . . . . . 8W-15-2
Passenger Door Jamb Swi tch . . . . . . . . 8W-15-11, 12
Passenger Power Lock/Wi ndow Swi tch . 8W-15-7, 11
Passenger Power Mi rror . . . . . . . . . . . . 8W-15-7, 11
Power Ampl i fi er . . . . . . . . . . . . . . . . . . 8W-15-10, 11
Power Mi rror Swi tch . . . . . . . . . . . . . . . 8W-15-7, 10
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
Power Steeri ng Pressure Swi tch . . . . . . . . . 8W-15-2
Powertrai n Control Modul e . . . . . . . . . . . 8W-15-2, 4
PRNDL I l l umi nati on . . . . . . . . . . . . . . . 8W-15-7, 11
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . 8W-15-6
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
Rear Washer Pump . . . . . . . . . . . . . . . 8W-15-3, 4, 5
Rear Wi ndow Defogger . . . . . . . . . . . . . . . 8W-15-14
Rear Wi ndow Defogger Swi tch . . . . . . . . . . 8W-15-8
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-15-14
Rear Wi per/Washer Swi tch . . . . . . . . . . . . . 8W-15-8
Ri ght Back-Up Lamp . . . . . . . . . . . . . . 8W-15-12, 13
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Ri ght Front Park/Turn Si gnal Lamp No. 1 . 8W-15-6
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-15-6
Ri ght Heated Seat Back . . . . . . . . . . . . . . 8W-15-15
Ri ght Heated Seat Swi tch . . . . . . . . . . . . . 8W-15-15
Ri ght Power Seat Swi tch . . . . . . . . . . . . . 8W-15-15
Ri ght Rear Door Jamb Swi tch . . . . . . . 8W-15-12, 13
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . 8W-15-12, 13
Ri ght Turn Si gnal Lamp . . . . . . . . . . . 8W-15-12, 13
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . 8W-15-7, 11
Seat Heat I nterface Modul e . . . . . . . . . . . 8W-15-15
Sentry Key I mmobi l i zer Modul e . . . . . . . . . 8W-15-9
Trai l er Tow Connector . . . . . . . . . . . . . 8W-15-10, 11
Transfer Case Swi tch . . . . . . . . . . . . . . . . . 8W-15-2
Transfer Case Swi tch I l l umi nati on . . . . 8W-15-7, 11
Transmi ssi on Control Modul e . . . . . . . . . . . 8W-15-2
Transmi ssi on Range Sensor . . . . . . . . . . 8W-15-4, 5
Underhood Lamp/Mercury Swi tch . . . . 8W-15-3, 4, 5
Vehi cl e Speed Control Servo . . . . . . . . 8W-15-3, 4, 5
Washer Fl ui d Level Swi tch . . . . . . . . . 8W-15-3, 4, 5
Wi ndshi el d Washer Pump . . . . . . . . . . 8W-15-3, 4, 5
Wi pe/Wash Swi tch . . . . . . . . . . . . . . . . . . . 8W-15-9
XJ 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1
24
MODULE
TRANSMISSION
CONTROL
(4.0L)
Z12
18
BK/TN
9 C107
BK/TN
16
Z12
Z1
16
BK
S107
Z12
14
BK/TN BK/TN
14
Z12
CONTROL
POWERTRAIN
MODULE
31 32
SWITCH
CASE
TRANSFER
B A
242 4WD 231 4WD
1/2
OXYGEN
SENSOR
DOWNSTREAM
UPSTREAM
SENSOR
OXYGEN
1/1
BK
18
Z1
Z1
20
BK
(2.5L)
STEERING
POWER
SWITCH
1
BK
20
Z1
6
MODULE
POWERTRAIN
CONTROL
(2.5L M/T)
Z1
18
BK
Z1
20
BK
5 C107
BATTERY
BK
8
Z0
G100
2.5L 4.0L
Z0
4
BK BK
6
Z0
G101
8
BRAKE
CONTROLLER
ANTI-LOCK
24
BK
12
Z1
G102
Z1
12
BK
BK
18
Z1 Z12
18
BK/TN
A1
C100
A7
BK/TN
18
Z12 Z1
18
BK
4 5
LINK
DATA
CONNECTOR
C1
C10
(IN PDC)
(2.5L M/T)
RELAY
MOTOR
STARTER
ENGINE
T41
20
BK/WT
PRESSURE
TRANSFER
CASE
SWITCH
Z1
20
BK
Z1
20
BK
E7
LHD
RHD
C1 C1
Z1
20
BK
4.0L 2.5L
BK
20
Z1
2/2
OXYGEN
SENSOR
DOWNSTREAM
Z1
20
BK
(4.0L
CALIFORNIA)
CALIFORNIA)
(4.0L
UPSTREAM
SENSOR
OXYGEN
2/1
S117
Z12
14
BK/TN
4.0L A/T OTHER
C112 1
C112 1
2
2 2
2
C8
Z1
20
BK
(8W-31-4)
(8W-30-2)
(8W-40-7)
(8W-30-8)
(8W-30-10)
(8W-30-8)
(8W-30-10)
(8W-30-17)
(8W-30-14)
(8W-20-2)
(8W-35-2)
(8W-30-19)
(8W-21-4)
(8W-40-7)
(8W-30-11)
(8W-30-11)
8W - 15 - 2 8W-15 GROUND DISTRIBUTION XJ
J008W-7 XJD01502
Z1
20
BK
2
PUMP
REAR
WASHER
B
PUMP
WINDSHIELD
WASHER
BK
18
Z1
SWITCH
FLUID
WASHER
LEVEL
A
BK
18
Z1 Z1
20
BK
BK
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-53-2)
(8W-40-5)
(8W-33-3)
(8W-50-10) (8W-50-10)
(8W-44-5)
XJ 8W-15 GROUND DISTRIBUTION
LHD 2.5L
8W - 15 - 3
XJD01503 J008W-7
S141
BK
16
Z1
Z1
18
BK BK
16
Z1 Z1
20
BK
Z1
18
BK
2 B
PUMP
WINDSHIELD
WASHER
BK
18
Z1 WIPER
FRONT
MOTOR
4 A 8
TRANSMISSION
RANGE
(A/T)
SENSOR
BK
18
Z1
BK
18
Z1
Z1
20
BK
BK
20
Z1
Z1
16
BK
S132
2
UNDERHOOD
LAMP/
4
CONTROL
VEHICLE
SPEED
SERVO
(IN PDC)
RELAY
FOG
LAMP
NO. 2 NO. 1
LAMP
FOG
RELAY
B8
(IN PDC)
Z1
20
BK
B19
Z1
20
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
BRAKE
ANTI-LOCK
CONTROLLER
B13
Z1
20
BK
Z1
20
BK
(M/T)
BK
20
Z1
EXCEPT DRL)
EXCEPT ABS
(M/T
(DRL)
EXCEPT ABS)
(A/T
(M/T)
LEVEL
SWITCH
FLUID
WASHER
(8W-53-2)
(8W-31-6)
(8W-44-5)
(8W-33-3)
(8W-50-9)
(8W-50-10)
(8W-50-8)
(8W-50-10)
(8W-53-2) (8W-53-3)
(8W-30-14)
(8W-21-5)
(8W-35-3)
(8W-40-5)
8W - 15 - 4 8W-15 GROUND DISTRIBUTION
LHD 4.0L
XJ
J008W-7 XJD01504
S141
BK
16
Z1
BK
16
Z1 Z1
20
BK
Z1
18
BK
2 B
BK
18
Z1
4 A 8
TRANSMISSION
RANGE
(4.0L A/T)
SENSOR
BK
20
Z1
BK
18
Z1
BK
20
Z1
Z1
16
BK
S132
2
4
CONTROL
VEHICLE
SPEED
SERVO
RELAY
ANTI-LOCK
CONTROLLER
BRAKE
B19
(IN PDC)
BK
18
Z1
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
BK
Z1
20
BK
Z1
20
BK
ABS OTHER
Z1
20
BK
MOTOR
(4.0L)
WIPER
FRONT
(8W-31-6)
(8W-33-3)
(8W-35-3)
(8W-53-2) (8W-53-4)
(8W-40-6)
(8W-44-5)
(8W-50-8)
(8W-50-10)
(8W-50-9)
(8W-50-10)
(8W-53-2)
RHD
8W - 15 - 5
XJD01505 J008W-7
FROM
S132
BK
16
Z1
A
(8W-15-3)
Z1
16
BK
G106
BK
12
Z1
2
MODULE
LAMP
8
DAYTIME
RUNNING
Z12
16
BK/TN
3
Z1
18
BK BK
18
Z1
3 C
RIGHT
HEADLAMP
Z1
18
BK BK
20
Z1
FOG
RIGHT
1
LAMP
S102
BK
18
Z1
4
Z1
20
BK BK/WT
20
Z1
11
Z1
18
BK
S103
LAMP
1
LEFT
FOG
Z1
20
BK BK
18
Z1
HEADLAMP
LEFT
C 3
Z1
18
BK BK
18
Z1
3
NO. 1
LAMP
SIGNAL
TURN
PARK/
FRONT
RIGHT
NO. 2
LAMP
SIGNAL
TURN
PARK/
FRONT
RIGHT
LEFT
FRONT
PARK/
TURN
SIGNAL
LAMP
NO. 1
LEFT
FRONT
PARK/
TURN
SIGNAL
LAMP
NO. 2
S158
RADIATOR
FAN
MOTOR
C106
BK
16
Z1
C
(8W-15-4)
S141
FROM
BK
16
Z1
B
(8W-15-4)
S132
FROM
Z1
18
BK
4
(2.5L)
MOTOR
WIPER
FRONT
FROM
S132
D
(8W-15-5)
Z1
16
BK
FROM
S141
E
(8W-15-5)
Z1
16
BK
(8W-50-11)
(8W-50-3)
(8W-50-4)
(8W-50-9)
(8W-50-10)
(8W-50-9)
(8W-50-10)
(8W-50-3)
(8W-50-4)
(8W-50-7)
(8W-52-4)
(8W-50-7)
(8W-52-4)
(8W-50-6)
(8W-52-3)
(8W-50-6)
(8W-52-3)
(8W-42-8)
(8W-53-2)
J008W-7 XJD01506
JUNCTION
BLOCK
S5
C4
Z1
14
BK
BK
14
Z1
C201 14
85
CIGAR
LIGHTER
RELAY
Z1
14
BK
RHD LHD
Z1
20
BK
BK
20
Z1
S342
MODULE
OVERHEAD
3
Z1
14
BK
9
BK
20
Z1
SWITCH
BELT
SEAT
B
Z1
20
BK
2 C206
BK
20
Z1 Z1
20
BK
(A/T)
ILLUMINATION
PRNDL
2 2
COMPASS
1
I
(8W-15-8)
TO
S208
C3 2
ILLUMINATION
SWITCH
CASE
TRANSFER
DOME
LAMPS
SWITCH
A
OTHERS COMPASS
Z1
20
BK
POWER
MIRRORS
LHD RHD
MIRRORS
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
18
Z1
Z1
14
BK
S319
BK
16
Z1
C9 11
S208
TO
J
(8W-15-8)
(OVERHEAD
CONSOLE)
FULL
OPTIONS
Z1
20
BK BK
20
Z1
B
B
LAMP
VANITY
VISOR/
LEFT
LAMP
VANITY
VISOR/
RIGHT
Z1
20
BK
S314
(8W-12-2)
(8W-41-2)
(8W-41-3)
(8W-49-2)
(8W-49-3)
(8W-40-5) (8W-44-2)
(8W-49-2)
(8W-49-3)
(8W-44-2)
(8W-44-4)
(8W-48-2)
(8W-62-7)
(8W-48-3)
(8W-48-2)
(8W-61-2)
(8W-44-4)
(8W-44-4)
XJ 8W-15 GROUND DISTRIBUTION 8W - 15 - 7
XJD01507 J008W-7
3
CIGAR
LIGHTER
BK
16
Z1
G107
Z1
16
BK
OUTLET
POWER
3
Z1
14
BK
S208
Z1
20
BK BK
20
Z1 Z1
20
BK
Z1
20
BK
SWITCH
DEFOGGER
WINDOW
REAR
1
4
1
REAR
WIPER/
WASHER
SWITCH
FLASHER
COMBINATION
5
SWITCH
LAMP
FOG
FRONT EXTENDED
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
20
BK
DB/WT
20
D1
C209 1
ACTUATOR
DOOR
BLEND
C2
(8W-41-2)
(8W-41-3)
(8W-41-2)
(8W-41-3)
(8W-48-2)
(8W-48-3)
(8W-53-3)
(8W-53-4)
(8W-52-2)
(8W-44-2)
(8W-44-3)
(8W-30-17)
(8W-42-7) (8W-42-7)
J008W-7 XJD01508
C201 25
C202 6
Z8
12
BK/VT
LHD RHD
2
BK/VT
16
Z8
CONTROL
HEATER
A/C-
1
Z2
20
BK/LG
6
C1
CLUSTER
INSTRUMENT
C2
9
BK/VT
12
Z8
BK/LG
18
Z2
BK
18
Z1
4
HEADLAMP
DELAY
MODULE
SWITCH
HEADLAMP
1
C1
2 1
WIPE/
WASH
BK
16
Z1 Z1
18
BK
IGNITION
SWITCH
BK
20
Z1
BK
18
Z1
S207
BK
14
Z1
Z9
14
BK
RADIO
G108
SWITCH SWITCH
LAMP
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/VT
POSTAL OTHER
POLICE/
Z8
12
BK/VT
BK
20
Z1
10
C209
BLOWER
MOTOR
RELAY
C1
C1
(8W-42-4)
(8W-42-5)
(8W-40-2)
(8W-50-5)
(8W-50-2)
(8W-53-2)
(8W-10-9)
(8W-47-2)
(8W-47-3)
(8W-47-8)
(8W-47-9)
(8W-33-3)
(8W-49-2)
(8W-49-3)
(8W-39-4)
(8W-39-5)
(8W-42-2)
(8W-42-3)
(8W-42-2)
(8W-42-3)
(8W-42-4)
(8W-42-5)
XJD01509 J008W-7
10
AIRBAG
CONTROL
MODULE
BK/YL
18
Z6
BASE
Z6
18
BK/PK
OPTIONS
FULL
G200
7
C2
AMPLIFIER
POWER
C2
8
Z5
16
BK/LB
G301
BK/LB
16
Z5
BK
12
Z1
BK
20
Z1
S309
G302
Z1
12
BK
Z1
20
BK
Z1
16
BK BK
14
Z1
Z1
14
BK
MODULE
PUMP
FUEL
6
B C320
BK
18
Z1
2
LEFT
REAR
DOOR
JAMB
SWITCH
SWITCH
JAMB
DOOR
DRIVER
3
Z1
18
BK
C317 C
3 C307
S329
Z1
16
BK BK
14
Z1 Z1
14
BK
MIRROR
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
TRAILER
TOW OTHER
DRIVER
2 C323
Z1
18
BK
(GAS)
DRIVER
6
POWER
MIRROR
SWITCH
MIRROR
1
POWER
S329
Z1
18
BK
Z1
14
BK
FULL
OPTIONS MIRRORS
POWER
Z1
12
BK
Z1
16
BK
2 C322
Z1
14
BK
(8W-43-2)
(8W-43-3)
(8W-47-2)
(8W-30-3)
(8W-44-6)
(8W-39-6)
(8W-48-2)
(8W-60-2)
(8W-61-2)
(8W-54-2)
(8W-51-3)
(8W-52-3)
(8W-51-7) (8W-48-2)
(8W-62-6)
LHD
XJ
J008W-7 XJD01510
2
2
PRNDL
ILLUMINATION
(A/T)
BK
20
Z1
Z1
20
BK
WINDOW
LOCK/
POWER
PASSENGER
C2
6
SWITCH
MIRROR
POWER
PASSENGER
6
SWITCH
BELT
SEAT
B
C206 2
S313
BK
20
Z1
BK
20
Z1
BK
20
Z1
S329
Z1
16
BK Z1
14
BK
SWITCH
JAMB
DOOR
PASSENGER
3
Z1
18
BK
C317 C
3 C307 B C320
BK
18
Z1
2
LEFT
REAR
DOOR
JAMB
SWITCH
MODULE
PUMP
FUEL
6
BK
12
Z1
G302
BK
20
Z1
S309
Z1
12
BK
Z1
20
BK
Z1
16
BK BK
14
Z1
7
C2
AMPLIFIER
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
LEFT
1
Z1
18
BK BK
18
Z1
BK
18
Z1
S341
BK
14
Z1
ILLUMINATION
SWITCH
CASE
TRANSFER
2 C323
FULL
OPTIONS
POWER
MIRRORS
Z1
12
BK
Z1
16
BK
(GAS)
2 C322
Z1
18
BK
TRAILER
TOW OTHER
BK/PK
18
Z6
BASE
FULL
OPTIONS
(8W-44-2)
(8W-40-6)
(8W-39-7)
(8W-44-7)
(8W-30-4)
(8W-47-3)
(8W-43-2)
(8W-43-3)
(8W-54-2)
(8W-51-3) (8W-52-3)
(8W-51-7)
(8W-44-3)
(8W-61-3)
(8W-48-3)
RHD
8W - 15 - 11
XJD01511 J008W-7
BK
16
Z1
BK
20
Z1
S310
G303
Z1
20
BK
BK
18
Z1
2 C321
Z1
18
BK
B C319
BK
18
Z1
2
RIGHT
REAR
DOOR
JAMB
SWITCH
SWITCH
JAMB
DOOR
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-51-3) (8W-52-4)
(8W-51-7)
LHD
XJ
J008W-7 XJD01512
BK
12
Z1
BK
20
Z1
S310
G303
Z1
20
BK BK
18
Z1
2 C321 B C319
BK
18
Z1
2
RIGHT
REAR
DOOR
JAMB
SWITCH
C318 C
Z1
18
BK
LAMP
STOP
TAIL/
RIGHT
1 1
RIGHT
TURN
SIGNAL
LAMP
LAMP
BACK-UP
RIGHT
1
Z1
18
BK BK
18
Z1
BK
18
Z1
S348
SWITCH
JAMB
DOOR
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 C303
Z1
14
BK
(FULL
OPTIONS)
OPTIONS)
(FULL
(8W-39-7)
(8W-51-3) (8W-52-4)
(8W-51-7)
(8W-39-7)
(8W-48-3)
(8W-60-3)
(8W-61-3)
RHD
8W - 15 - 13
XJD01513 J008W-7
BK
18
Z1
G304
BK
18
Z1
Z1
18
BK
Z1
12
BK
DEFOGGER
WINDOW
REAR
BK
12
Z1
1
C310
C312
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-53-4)
(8W-44-6)
(8W-44-7)
(8W-51-4)
J008W-7 XJD01514
S354
BK
18
Z1
BK
18
Z1 Z1
18
BK BK
18
Z1
6 B B
BACK
SEAT
HEATED
LEFT RIGHT
HEATED
SEAT
BACK
HEATED
SEAT
RELAY
C332 4 C329 12
SEAT
HEATED
LEFT
3
Z1
18
BK
Z1
18
BK
Z1
18
BK
SWITCH SWITCH
BK
18
Z1
3
RIGHT
HEATED
SEAT
S355
Z1
18
BK
SEAT
POWER
RIGHT
A
Z1
14
BK
SWITCH SWITCH
BK
14
Z1
B
LEFT
POWER
SEAT INTERFACE
BK/LG
18
Z2
13
SEAT
HEAT
MODULE
Z2
18
BK/LG
C329 13
G306
(HEATED SEATS)
C362 2 2 C363
Z1
14
BK
Z1
14
BK
(8W-63-5) (8W-63-5)
(8W-63-6)
(8W-63-4) (8W-63-4)
(8W-63-3) (8W-63-2) (8W-63-5)
XJD01515 J008W-7
8W-20 CHARGING SYSTEM
Component Page
Automati c Shut Down Rel ay . . . . . . . . . . . . 8W-20-2
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Battery Temperature Sensor . . . . . . . . . . . . 8W-20-3
Engi ne Starter Motor . . . . . . . . . . . . . . . . . 8W-20-2
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . . . . 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
Fusi bl e Li nk . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2
Power Di stri buti on Center . . . . . . . . . . . 8W-20-2, 3
XJ 8W - 20 CHARGING SYSTEM 8W - 20 - 1
BK/WT
6
A11
4
BK
A0
6
RD
DG
16
K20
10 C2
GENERATOR
FIELD
BK
8
Z0
G100
BATTERY
GENERATOR
2
MODULE
CONTROL
POWERTRAIN
8
FUSE
30A
14
A16
RD/LG
CENTER
DISTRIBUTION
POWER
7
14
D2
D8
RELAY
DOWN
SHUT
AUTOMATIC
RD
A999
16 16
A999
RD
TO
18 (PDC)
FUSE
12 C3
OUTPUT
RELAY
DOWN
SHUT
AUTOMATIC
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
ENGINE
STARTER
MOTOR
RD
6
A0
Z0
G101
(IN PDC)
B(+)
4.0L 2.5L
Z0
BK
6
2.5L 4.0L
S166
K72
18
DG/OR
FUSED
(8W-30-2)
(8W-30-18)
(8W-10-15)
(8W-10-2)
(8W-30-2)
(8W-10-15)
(8W-10-2)
(8W-10-15)
(8W-10-15)
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
(8W-15-2)
(8W-15-2)
(8W-30-18)
8W - 20 - 2 8W-20 CHARGING SYSTEM XJ
J008W-7 XJD02002
BR/YL
20
K167
B(+)
FUSED
(IN PDC)
FUSED
B(+)
C1 22
A61
14
DG/BK
DG/BK
16
A61
C107 14
RELAY
PUMP
FUEL
C1
22
FUSE
15A
DG/BK
14
A61
A12
A11
POWER
DISTRIBUTION
CENTER
BATT A0
CALIFORNIA
S123
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 4
POWERTRAIN
CONTROL
MODULE
(8W-30-13)
(8W-30-3)
(8W-30-4)
(8W-10-19)
(8W-10-2)
(8W-10-7)
(8W-70-2)
(8W-70-3)
(8W-70-3)
(8W-30-3)
(8W-30-4)
(8W-30-13)
XJ 8W-20 CHARGING SYSTEM 8W - 20 - 3
XJD02003 J008W-7
8W-21 STARTING SYSTEM
Component Page
Battery . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4, 5
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . 8W-21-4, 5
Cl utch I nterl ock Swi tch Jumper . . . . . . . 8W-21-2, 3
Engi ne Starter Motor . . . . . . . . . . . . 8W-21-2, 3, 4, 5
Engi ne Starter Motor Rel ay . . . . . . . 8W-21-2, 3, 4, 5
Fog Lamp Rel ay 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
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-21-2, 3, 4, 5
Park/Neutral Posi ti on Swi tch . . . . . . . . . . . 8W-21-2
Power Di stri buti on Center . . . . . . . . 8W-21-2, 3, 4, 5
Transmi ssi on Range Sensor . . . . . . . . . . . . 8W-21-3
XJ 8W - 21 STARTING SYSTEM 8W - 21 - 1
C10 C7
C6 C8
T40
16
BR
MOTOR
STARTER
ENGINE
2
20A
FUSE
10
23
A0
6
RD
CENTER
DISTRIBUTION
POWER
1 2
P/N
BATTERY
YL/RD
20
F45
BK/WT
18
T41
RD
6
A0
YL
16
A41
POSITION
NEUTRAL
PARK/
BK/WT
18
T41
C1 6
POWERTRAIN
CONTROL
MODULE
SENSE
SWITCH
POSITION
NEUTRAL
PARK/
19
FUSE
10A
ST A41
3
C1
JUNCTION
BLOCK
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
1 C108
BR
16
T40
16
E7 C100
1
2
JUMPER
SWITCH
INTERLOCK
CLUTCH
E8 C100
LHD RHD
1 PULL-IN
2 HOLD-IN
BK/WT
20
T41
C107 5
T41
18
BK/WT
SWITCH
S120
CLUTCH
INTERLOCK
SWITCH
JUMPER
2
1
F45
18
YL
F45
18
YL
F45
20
YL/RD
T141
20
YL
YL
20
T141
F45
20
YL/RD
M
(8W-10-16)
(8W-10-2)
(8W-20-2)
(8W-30-14)
(8W-12-17)
(8W-12-18)
(8W-10-11)
(8W-12-2)
(8W-31-2)
8W - 21 - 2 8W-21 STARTING SYSTEM
2.5L A/T
XJ
J008W-7 XJD02102
C10 C7
C6 C8
T40
16
BR
MOTOR
STARTER
ENGINE
7
20A
FUSE
10
23
A0
6
RD
CENTER
DISTRIBUTION
POWER
1 2
P/N
BATTERY
YL/RD
20
F45
BK/WT
18
T41
RD
6
A0
YL
16
A41
SENSOR
RANGE
TRANSMISSION
BK/WT
20
T41
C1 6
POWERTRAIN
CONTROL
MODULE
SENSE
POSITION
NEUTRAL
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 PULL-IN
2 HOLD-IN
F45
18
YL
T141
20
YL
G106
Z1
16
BK
F45
20
YL/RD
F45
20
YL/RD
SWITCH
M
(8W-10-16)
(8W-10-2)
(8W-20-2)
(8W-31-6)
(8W-30-14)
(8W-12-17)
(8W-12-18)
(8W-10-11)
(8W-12-2)
(8W-15-4)
(8W-15-5)
(8W-15-6)
XJ 8W-21 STARTING SYSTEM
4.0L A/T
8W - 21 - 3
XJD02103 J008W-7
C10 C7
C6 C8
T40
16
BR
MOTOR
STARTER
ENGINE
20A
FUSE
10
23
A0
6
RD
CENTER
DISTRIBUTION
POWER
1 2
BATTERY
YL/RD
20
F45
RD
6
A0
YL
16
A41
19
FUSE
10A
ST A41
3
C1
JUNCTION
BLOCK
ENGINE
STARTER
MOTOR
RELAY
(IN PDC)
1 C108
BR
16
T40
16
CLUTCH
INTERLOCK
SWITCH
G101
S107
Z1
16
BK
BK/WT
20
T41
5 C107
Z1
20
BK
RHD LHD
YL
20
T141
C100 E8
2
1
C100 E7
1 PULL-IN
2 HOLD-IN
1
SWITCH
INTERLOCK
CLUTCH
2
M
(8W-10-16)
(8W-10-2)
(8W-20-2)
(8W-12-17)
(8W-12-18)
(8W-10-11)
(8W-12-2)
(8W-15-2)
(8W-15-2)
8W - 21 - 4 8W-21 STARTING SYSTEM
2.5L M/T
XJ
J008W-7 XJD02104
C10 C7
C6 C8
T40
16
BR
MOTOR
STARTER
ENGINE
20A
FUSE
10
23
A0
6
RD
CENTER
DISTRIBUTION
POWER
1 2
BATTERY
YL/RD
20
F45
RD
6
A0
YL
16
A41
19
FUSE
10A
ST A41
3
C1
JUNCTION
BLOCK
ENGINE
STARTER
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)
(EXCEPT ABS)
(IN PDC)
NO. 1
RELAY
LAMP
FOG
GROUND
M
(8W-10-16)
(8W-10-2)
(8W-20-2)
(8W-12-17)
(8W-12-18)
(8W-10-11)
(8W-12-2)
(8W-15-4)
(8W-15-6)
(8W-50-8)
XJ 8W-21 STARTING SYSTEM
4.0L M/T
8W - 21 - 5
XJD02105 J008W-7
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Cl utch Rel ay . . . . . . . . 8W-30-9, 18
A/C Hi gh Pressure Swi tch . . . . . . . . . . . . . 8W-30-18
A/C Low Pressure Swi tch . . . . . . . . . . . . . 8W-30-18
A/C- Heater Control . . . . . . . . . . . . . . . . . 8W-30-18
Ai rbag Control Modul e . . . . . . . . . . . . 8W-30-20, 21
Automati c Shut Down Rel ay . . . . . . 8W-30-2, 5, 6, 8
Battery Temperature Sensor . . . . . . . . . . . 8W-30-13
Brake Lamp Swi tch . . . . . . . . . . . . . . . 8W-30-14, 16
Camshaft Posi ti on Sensor . . . . . . . . . . . . . . 8W-30-5
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-13
Compass . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
Control l er Anti -Lock Brake . . . . . . . . . . . . 8W-30-19
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8W-30-5
Data Li nk Connector . . . . . . . . . . . 8W-30-19, 20, 21
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . 8W-30-15
Engi ne Cool ant Temperature Sensor . . . . . 8W-30-7
Engi ne Oi l Pressure Sensor . . . . . . . . . . . 8W-30-12
Engi ne Starter Motor Rel ay . . . . . . . . . . . 8W-30-14
Evap Leak Detecti on Pump . . . . . . . . . . . . 8W-30-18
Extended I dl e Swi tch . . . . . . . . . . . . . . . . 8W-30-17
Fuel I njector No. 1 . . . . . . . . . . . . . . . . . . . 8W-30-6
Fuel Pump Modul e . . . . . . . . . . . . . . . . . 8W-30-3, 4
Fuel Pump Rel ay . . . . . . . . . . . . . . . . . 8W-30-2, 3, 4
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-17
Fuse 8 (PDC) . . . . . . . . . . . . . . . . . . . . . . . 8W-30-2
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . 8W-30-9, 15
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . 8W-30-2, 3, 4, 15
Fuse 17 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-30-9
Fuse 18 (PDC) . . . . . . . . . . . . . . . . . . . 8W-30-2, 5, 6
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-30-19
Fuse 21 (PDC) . . . . . . . . . . . . . . . . . 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
Headl amp Swi tch . . . . . . . . . . . . . . . . . 8W-30-17, 19
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . 8W-30-16
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5
I nstrument Cl uster . . . . . . . . . . . . . . . 8W-30-20, 21
I ntake Ai r Temperature Sensor . . . . . . . . . 8W-30-7
Juncti on Bl ock . . . . . . . . . . . . 8W-30-2, 3, 4, 9, 15, 17
Left Speed Control Swi tch . . . . . . . . . . . . 8W-30-13
Mani fol d Absol ute Pressure Sensor . . . . . . 8W-30-12
Overhead Modul e . . . . . . . . . . . . . . . . . 8W-30-20, 21
Oxygen Sensor 1/1 Upstream . . . . . . 8W-30-8, 10, 11
Oxygen Sensor 1/2 Downstream . . . . 8W-30-8, 10, 11
Oxygen Sensor Downstream Rel ay . . 8W-30-9, 10, 11
Oxygen Sensor Upstream Rel ay . . . . 8W-30-9, 10, 11
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-30-14
Power Di stri buti on Center . . 8W-30-2, 3, 4, 5, 6, 8, 9,
14, 18, 19
Power Steeri ng Pressure Swi tch . . . . . . . . 8W-30-17
Powertrai n Control Modul e . 8W-30-2, 3, 4, 5, 6, 7, 8,
9, 10, 11, 12, 13, 14,
15, 16, 17, 18, 19, 20, 21
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . 8W-30-9, 18
Rai l Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5
Ri ght Speed Control Swi tch . . . . . . . . . . . 8W-30-13
Sentry Key I mmobi l i zer Modul e . . . . . 8W-30-20, 21
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . 8W-30-7
Torque Converter Cl utch Sol enoi d . . . . . . . 8W-30-15
Transmi ssi on Control Modul e . . . 8W-30-7, 19, 20, 21
Transmi ssi on Range Sensor . . . . . . . . . . . 8W-30-14
Vehi cl e Speed Control Servo . . . . . . . . . . . 8W-30-14
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . 8W-30-12
XJ 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1
POWERTRAIN
CONTROL
MODULE
20A
FUSE
11
C1 2
DB/WT
18
F12
F12
18
DB/WT
8
FUSE
30A
RD/LG
14
A16
D6 D8
D2 D4
K51
18
DB/YL
3 C3 C3 12
DG/WT
18
F142
AUTOMATIC
SHUT
DOWN
RELAY
(IN PDC)
CONTROL
RELAY
DOWN
SHUT
AUTOMATIC
SHUT
DOWN
RELAY
OUTPUT
5
S130
10 C107
SWITCH
IGNITION
FUSED
CENTER
DISTRIBUTION
POWER
7
ST-RUN A21
14
JUNCTION
BLOCK
C2
AUTOMATIC
BATT A0
F12
18
DB/WT
RD
16
A999
A14
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
GROUND
BK/TN BK/TN
A999
16
RD
TO
18 (PDC)
FUSE
S168
DB/WT
18
F12
(IN PDC)
FUSED
B(+)
OUTPUT
S136
F12
18
DB/WT
F12
18
DB/WT
OTHER LHD A/T
4.0L
(ST-RUN)
4.0L 2.5L
S117
FUSED
(8W-12-13)
(8W-12-14)
(8W-10-15)
(8W-12-13)
(8W-12-14)
(8W-10-2)
(8W-10-10)
(8W-12-2)
(8W-10-7)
(8W-10-2)
(8W-10-15)
(8W-10-19)
(8W-30-3)
(8W-30-4)
(8W-15-2)
(8W-10-15)
(8W-10-15)
(8W-12-14)
(8W-15-2)
8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM XJ
J008W-7 XJD03002
POWERTRAIN
CONTROL
MODULE
20A
FUSE
11
C3 C2
C1 C5
K31
18
BR
19 C3
CONTROL
RELAY
PUMP
FUEL
5
S130
CENTER
DISTRIBUTION
POWER
ST-RUN A21
JUNCTION
BLOCK
C2
BATT A0
A11
A12
A61
14
DG/BK
15A
FUSE
22
FUEL
PUMP
RELAY
(IN PDC)
1
6
M
FUEL
PUMP
MODULE
G302
S309
Z1
16
BK
4
SENSOR
GROUND
C1 4
K226
18
DB/LG
3 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
CALIFORNIA
4.0L
BR/YL
18
K167
BR/YL
18
K167
BR/YL
20
K167
S123
F12 18DB/WT
C200 13
D2 C100
A141 14DG/WT
A141
16
DG/WT
(8W-12-13)
(8W-12-14)
(8W-12-13)
(8W-12-14)
(8W-10-2)
(8W-10-10)
(8W-12-2)
(8W-10-7)
(8W-10-19)
(8W-15-10)
(8W-15-10)
(8W-70-3)
(8W-70-3)
(8W-70-2)
XJ 8W-30 FUEL/IGNITION SYSTEM
LHD
8W - 30 - 3
XJD03003 J008W-7
POWERTRAIN
CONTROL
MODULE
20A
FUSE
11
C3 C2
C1 C5
K31
18
BR
19 C3
CONTROL
RELAY
PUMP
FUEL
5
S130
CENTER
DISTRIBUTION
POWER
ST-RUN A21
JUNCTION
BLOCK
C2
BATT A0
A11
A12
A61
14
DB/BK
15A
FUSE
22
FUEL
PUMP
RELAY
(IN PDC)
1
6
M
FUEL
PUMP
MODULE
G302
S309
Z1
16
BK
4
SENSOR
GROUND
C1 4
K226
18
DB/LG
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
CALIFORNIA
4.0L
BR/YL
18
K167
BR/YL
18
K167
BR/YL
20
K167
S123
F12 18DB/WT
D2 C100
A141 14DG/WT
A141
16
DG/WT
4 C204
(8W-12-13)
(8W-12-14)
(8W-12-13)
(8W-12-14)
(8W-10-2)
(8W-10-10)
(8W-12-2)
(8W-10-7)
(8W-10-19)
(8W-15-11)
(8W-15-11)
(8W-70-3)
(8W-70-3)
(8W-70-2)
8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM
RHD
XJ
J008W-7 XJD03004
POWERTRAIN
CONTROL
MODULE
DRIVER
COIL
IGNITION
7 C1
D8
BATT A16
GY
18
K19
POWER
DISTRIBUTION
CENTER
AUTOMATIC
SHUT
DOWN
RELAY
D2
2
1
IGNITION
COIL
DG/OR
18
A142
2 1
3
3
SENSOR
POSITION
CRANKSHAFT
C1 4
SENSOR
GROUND
S114
S111
K24
18
GY/BK
C1 8
SIGNAL
SENSOR
POSITION
CRANKSHAFT
GROUND
SENSOR
SENSOR
GROUND
1
5V
SUPPLY
17 C1
CAMSHAFT
POSITION
SENSOR
SIGNAL
18 C1
TN/YL
18
K44
SENSOR
POSITION
CAMSHAFT
S115
K7
20
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
SIGNAL
SENSOR
POSITION
CAMSHAFT
CRANKSHAFT
POSITION
SENSOR
SIGNAL
2
1
4.0L
2.5L
A999 16RD
OTHER
BR/YL
18
K167
CALIFORNIA
4.0L
BR/YL
18
K167
BR/YL
20
K167
S123
COIL
RAIL
3
K17
18
DB/TN
C2 9
NO. 1
1 C1
RD/YL
18
K18
1
NO. 2
IGNITION
COIL
DRIVER DRIVER
COIL
IGNITION
NO. 3
(8W-10-15)
(8W-10-2)
(8W-30-2)
(8W-70-3)
(8W-70-3)
(8W-70-2)
(8W-10-15)
(8W-10-15)
(8W-10-2)
(8W-10-15)
(8W-70-2)
XJ 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5
XJD03005 J008W-7
POWERTRAIN
CONTROL
MODULE
2
1
C2 4
NO. 1
INJECTOR
FUEL
FUEL
INJECTOR
NO. 2
15
2
K11
18
WT/DB YL/WT
K13
2
1
5
NO. 3
INJECTOR
FUEL
K15
PK/BK
FUEL
INJECTOR
NO. 4
16
K14
LB/BR
1
2 2
1
LG/BK
K16
12
NO. 6
INJECTOR
FUEL
2
1
TN
K12
6
NO. 5
INJECTOR
FUEL
1
S113
18 18 18 18 18
A142
18
DG/OR DG/OR
18
A142
DG/OR
18
A142
DG/OR
18
A142
DG/OR
18
A142
DG/OR
18
A142
C2 C2 C2 C2 C2
D8
BATT A16
POWER
DISTRIBUTION
CENTER
AUTOMATIC
SHUT
DOWN
RELAY
D2
S109
DG/OR
18
A142
1 C107
18
FUSE
15A
A20
A19
TO
21 (PDC)
FUSE
A142
18
DG/OR
RD
16
A999 A999
16
RD
(4.0L)
(4.0L)
FUEL
INJECTOR
NO. 1
DRIVER DRIVER
NO. 2
INJECTOR
FUEL
DRIVER
NO. 3
INJECTOR
FUEL
DRIVER
NO. 4
INJECTOR
FUEL
DRIVER
NO. 5
INJECTOR
FUEL
DRIVER
NO. 6
INJECTOR
FUEL
A142
18
DG/OR
(8W-10-15)
(8W-10-15)
(8W-10-2)
(8W-30-2)
(8W-10-15)
(8W-10-15)
(8W-10-15)
J008W-7 XJD03006
MODULE
CONTROL
POWERTRAIN
GROUND
SENSOR
4 C1
SENSOR
POSITION
THROTTLE
3
1
K21
18
BK/RD
15 C1
2
1
SENSOR
TEMPERATURE
AIR
INTAKE
2
BR/YL
20
K167
S115
ENGINE
COOLANT
TEMPERATURE
SENSOR
1
2
C1 16
TN/BK
18
K2
S114
23 C1
K22
18
OR/DB
SUPPLY
5V
C1 17
K7
20
OR
SIGNAL
SENSOR
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/DB
OR
18
K7
OR/DB
20
K22
K167
BR/YL
20
OTHER 4.0L A/T
THROTTLE
POSITION
SENSOR
SIGNAL
K22
18
OR/DB
OTHER
BR/YL
18
K167
CALIFORNIA
4.0L
BR/YL
18
K167
BR/YL
20
K167
S123
(8W-70-2)
(8W-70-3)
(8W-70-3)
(8W-31-5)
(8W-70-2)
XJD03007 J008W-7
POWERTRAIN
CONTROL
MODULE
24 C1
BK
18
Z1
1 4
2 3
Z1
20
BK
C1 4
K41
18
BK/DG
K167
18
BR/YL
S111
GROUND
SENSOR OXYGEN
SENSOR
1/2
SIGNAL
C1 25
TN/WT
18
K141
OXYGEN
SENSOR
1/1
UPSTREAM DOWNSTREAM
1/2
SENSOR
OXYGEN
S110
G101
SIGNAL
1/1
SENSOR
OXYGEN
BK
16
Z1
S107
S114
BR/YL
20
K167
K167
20
BR/YL
K167
20
BR/YL
D8
BATT A16
POWER
DISTRIBUTION
CENTER
AUTOMATIC
SHUT
DOWN
RELAY
D2
DG/WT
18
F142
7 C107
21
FUSE
15A
A14
A13
A999
16
RD
F142
20
DG/WT
DG/WT
20
F142 F142
20
DG/WT
1 4
2 3
S168
F142
18
DG/WT
(8W-70-3)
(8W-15-2)
(8W-15-2)
(8W-70-3)
(8W-10-15)
(8W-10-2)
(8W-30-2)
(8W-10-15)
(8W-10-15)
(8W-10-15)
2.5L
XJ
J008W-7 XJD03008
POWER
DISTRIBUTION
CENTER
20A
FUSE
17
BATT A0
POWERTRAIN
CONTROL
MODULE
10
FUSE
15A
ST-RUN A21
BLOCK
JUNCTION
S12
1 C201
LHD RHD
D11
(IN PDC)
RELAY
FAN
RADIATOR
S159
C100
E9
C20 C17
C16 C18
C13 C11
C12 C15
B
(8W-30-10)
8 C3
A
(8W-30-10)
C3 9
OXYGEN
SENSOR
DOWNSTREAM
RELAY
(IN PDC)
OXYGEN
SENSOR
UPSTREAM
RELAY
(IN PDC)
TO
C107
TO
C107
F20
18
WT
F20
18
WT
F20
18
WT
F20
18
WT
F99
18
RD
F99
18
RD
A42
18
DG
A242
18
VT/OR
K73
18
BR/OR
K74
18
BR/VT
A21
A22
EXCEPT DRL OTHER
PK/OR
18
F26
DRL OTHER
WT
18
F20 F26
18
PK/OR
EXCEPT
FOG
A/T
A/T FOG
C4
A9
LHD
RHD
OXYGEN
SENSOR
DOWNSTREAM
RELAY
CONTROL CONTROL
RELAY
UPSTREAM
SENSOR
OXYGEN
FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)
B5
(EXCEPT DRL)
(A/T FOG)
(IN PDC)
RELAY
CLUTCH
COMPRESSOR
A/C
WT
18
F20
(ST-RUN)
OUTPUT
SWITCH
IGNITION
FUSED
(8W-10-2)
(8W-10-17)
(8W-10-7)
(8W-12-12)
(8W-10-10)
(8W-12-2)
(8W-42-8)
(8W-12-12)
(8W-42-7)
(8W-30-11)
(8W-30-11)
4.0L
8W - 30 - 9
XJD03009 J008W-7
POWERTRAIN
CONTROL
MODULE
24 C1
BK
20
Z1
1 4
2 3
Z1
20
BK
C1 4
K41
18
BK/DG
K167
18
BR/YL
S111
GROUND
SENSOR OXYGEN
SENSOR
1/2
SIGNAL
C1 25
TN/WT
18
K141
OXYGEN
SENSOR
1/1
UPSTREAM DOWNSTREAM
1/2
SENSOR
OXYGEN
G101
SIGNAL
1/1
SENSOR
OXYGEN
BK
16
Z1
S107
S114
BR/YL
20
K167
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
A42
20
DG
A242
20
VT/OR
A242
20
DG/OR
A242
20
VT/OR
A242
18
VT/OR
CALIFORNIA
OTHER
S123
CALIFORNIA
EXCEPT CALIFORNIA
VT/OR
20
A242
4WD 2WD
CALIFORNIA
(8W-70-3)
(8W-15-2)
(8W-15-2)
(8W-70-3)
(8W-30-11)
(8W-30-11)
(8W-70-2)
4.0L
XJ
J008W-7 XJD03010
POWERTRAIN
CONTROL
MODULE
26 C1
BK
20
Z1
1 4
2 3
Z1
20
BK
C1 4
K241
18
LG/RD
K167
18
BR/YL
S123
GROUND
SENSOR OXYGEN
SENSOR
2/2
SIGNAL
C1 29
TN
18
K341
OXYGEN
SENSOR
2/1
UPSTREAM DOWNSTREAM
2/2
SENSOR
OXYGEN
G101
SIGNAL
2/1
SENSOR
OXYGEN
BK
16
Z1
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
VT/OR
A242
20
VT/OR
A242
20
DG/OR
A242
20
VT/OR
A242
20
VT/OR
1 1
UPSTREAM
1/1
SENSOR
OXYGEN
DOWNSTREAM
1/2
SENSOR
OXYGEN
4WD 2WD
(8W-70-2)
(8W-15-2)
(8W-15-2)
(8W-30-10) (8W-30-10)
4.0L CALIFORNIA
8W - 30 - 11
XJD03011 J008W-7
MODULE
CONTROL
POWERTRAIN
1
C2 31
VT/OR
18
K6
C1 27
2
3
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
K1
18
DG/RD
OR
20
K7
S115
K7
18
OR
SUPPLY
5V
17 C1
2 1
BR/YL
20
K167
SENSOR
SPEED
VEHICLE
5V
SUPPLY
G7
18
WT/OR
27 C2
3
SIGNAL
SENSOR
SPEED
VEHICLE
WT/OR
18
G7
S108
4 C1
SENSOR
GROUND
S114
SIGNAL
SENSOR
PRESSURE
ABSOLUTE
MANIFOLD
S111
BR/YL
20
K167
K167
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
PRESSURE
SENSOR
SIGNAL
5V
SUPPLY
2
ENGINE
OIL
PRESSURE
SENSOR
1
3
C2 23
K167
18
BR/YL
S119
K6
18
VT/OR
K6
18
VT/OR
G60
18
GY/YL
SIGNAL
SENSOR
PRESSURE
OIL
ENGINE
OTHER
BR/YL
18
K167
CALIFORNIA
4.0L
BR/YL
18
K167
BR/YL
20
K167
S123
BR/YL
18
K167
(8W-70-2)
(8W-70-3)
(8W-70-3)
(8W-50-11)
(8W-70-2)
J008W-7 XJD03012
MODULE
CONTROL
POWERTRAIN
4 C1
SENSOR
GROUND
S138
C3 32
SIGNAL
SWITCH
CONTROL
SPEED
V37
18
RD/LG
B5
20
1
2
BATTERY
TEMPERATURE
SENSOR
C3 15
PK/YL
18
K118
SIGNAL
SENSOR
TEMPERATURE
BATTERY
CLOCKSPRING
C107 3
S111
V37
RD/LG
2 3
B6
C100
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
BR/YL
20
K167
C2 C2
C1 C1
RHD
F17
F18
LHD
K167
20
BR/YL
K167
20
BR/YL
OTHER
BR/YL
18
K167
CALIFORNIA
4.0L
BR/YL
18
K167
BR/YL
20
K167
S123
(8W-70-3)
(8W-70-3)
(8W-33-2)
(8W-33-2)
(8W-70-2)
XJD03013 J008W-7
POWERTRAIN
CONTROL
MODULE
SOLENOID
VACUUM
CONTROL
SPEED
4 C3
TN/RD
18
V36
1 2
V35
18
LG/RD
C3 5
SERVO
CONTROL
SPEED
VEHICLE
6 C1
C10
C8
CENTER
DISTRIBUTION
POWER
7
P/N
T41
20
ST F45
CONTROL CONTROL
SPEED
CONTROL
VENT
SOLENOID
SENSOR
RANGE
TRANSMISSION
ENGINE
STARTER
MOTOR
RELAY
8
BK/WT
S141
G106
2.5L M/T OTHER
S107
G101
Z1
16
BK
(4.0L A/T)
3
YL/RD
4
20
V32
3
DB/RD
20
V30
C100
T41
18
BK/WT
11
SPEED
CONTROL
POWER
C3
F9
F7
Z1
18
BK
BRAKE
LAMP
SWITCH
SWITCH
PARK/
NEUTRAL
POSITION
P/N
BK/WT
18
T41 T41
18
BK/WT
2
S120
ST T141
SUPPLY
2.5L A/T
OTHER 4.0L A/T
V32
18
YL/RD
RHD LHD
YL/RD
18
V32
PARK/NEUTRAL
POSITION
SWITCH
SENSE
GROUND
A/T M/T
Z1
16
BK
5 C107
G106
S132
Z1
18
BK
Z1
16
BK
OTHER 4.0L M/T
5 C107
T41
20
BK/WT
V30
20
DB/RD
Z1
18
BK
BK
20
Z1
2.5L M/T 4.0L
(8W-33-3)
(8W-10-2)
(8W-12-17)
(8W-12-18)
(8W-31-6)
(8W-21-2)
(8W-21-3)
(8W-21-4)
(8W-21-5)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-15-2)
(8W-15-2)
(8W-33-3)
(8W-31-2)
(8W-12-17)
(8W-12-18)
(8W-21-2)
(8W-15-6)
(8W-15-4)
J008W-7 XJD03014
MODULE
CONTROL
POWERTRAIN
11
WT
18
F20
11
FUSE
20A
ST-RUN A21
1
2
C3 20
PURGE
EVAP/
CYCLE
DUTY
K52
18
PK/BK
PURGE
EVAP/
CYCLE
DUTY
SOLENOID
C2
5
C2
JUNCTION
BLOCK
F20
18
WT
A
B
OR/BK
18
K54
(2.5L A/T)
SOLENOID
CLUTCH
CONVERTER
TORQUE
WT
18
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
IGNITION
SWITCH
OUTPUT
15A
FUSE
10
S136
F12
18
DB/WT
(ST-RUN) SOLENOID
CONTROL
S130
S159
(8W-12-13)
(8W-12-14)
(8W-10-10)
(8W-12-2)
(8W-51-6)
(8W-12-12)
(8W-12-14)
(8W-12-13)
(8W-12-14)
(8W-12-12)
(8W-31-2)
XJD03015 J008W-7
POWERTRAIN
CONTROL
MODULE
24
C3
OTHER 4.0L A/T
2
1
WT/PK
20
K29
S140
WT/PK
20
K29
S204
BK
18
Z1
Z1
14
BK
S207
G108
11
C1
WT/PK
18
K29
C1
20
BRAKE
LAMP
SWITCH
SENSE
BRAKE
LAMP
SWITCH
LHD RHD
K29
18
WT/PK
MOTOR
CONTROL
AIR
IDLE
NO. 1 NO. 4
CONTROL
NO. 2 NO. 3
DRIVER DRIVER DRIVER DRIVER
C1
10
C1
19
18 18 18
K40
BR/WT
NO. 1
4 1
NO. 4
VT/BK
K59 K60
YL/BK
NO. 2
3
NO. 3
IDLE AIR
2
K39
18
GY/RD
B1
C100
F10
K29
18
WT/PK
RHD
LHD
DRIVER DRIVER DRIVER DRIVER
K29
18
WT/PK
CONTROL
IDLE AIR IDLE AIR
CONTROL CONTROL
IDLE AIR
CONTROL
IDLE AIR
CONTROL
IDLE AIR
CONTROL
IDLE AIR
CONTROL
IDLE AIR
(8W-15-9)
(8W-15-9)
(8W-33-3)
(8W-31-7)
(8W-31-3)
(8W-31-7)
J008W-7 XJD03016
POWERTRAIN
CONTROL
MODULE
ACTUATOR
IDLE
C100 F16
OTHERS
POLICE
PACKAGE (LHD)
12
C1
K78
18
GY
11 C107
GY
18
K78
C107 11
C1
12
POWER
STEERING
PRESSURE
SWITCH
SIGNAL
4.0L A/T 2.5L
4.0L A/T 2.5L
2
K10
18
DB/BR
SWITCH
PRESSURE
STEERING
POWER
1
Z1
20
BK
S107
G101
BK
16
Z1
K78
20
GY
1
2
EXTENDED
IDLE
SWITCH
OR
20
E2
4
DB/WT
20
F15
3
G107
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
S219
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL
DIMMER
LAMPS
PANEL
GROUND
IDLE
ACTUATOR
NOT
USED
(RUN)
OUTPUT
SWITCH
IGNITION
FUSED FUSED
SWITCH
SIGNAL
DB/WT
20
F15
K78
18
GY
(8W-15-2)
(8W-15-2)
(8W-15-8)
(8W-15-8)
(8W-12-8)
(8W-12-2)
(8W-50-2)
(8W-12-20)
(8W-10-11)
(8W-12-20)
(8W-12-8)
(8W-12-8)
(8W-12-20)
XJD03017 J008W-7
C3 1
POWERTRAIN
CONTROL
MODULE
B5
B3
CONTROL
RELAY
CLUTCH
COMPRESSOR
A/C
C13
18
DB/OR
CENTER
DISTRIBUTION
POWER
C22
18
DB/WT
1
22
C3 C3
23
3
LG
18
C90
A6 C100
C90
20
LG
CONTROL
HEATER
A/C-
SWITCH
PRESSURE
HIGH
A/C
A/C
LOW
PRESSURE
SWITCH
A/C
SELECT
INPUT SENSE
SWITCH
A/C
LG
20
C90
S143
LG
20
C90
GENERATOR
SOURCE
C3 25
K72
18
DG/OR
DG/OR
16
K72
2
K20
18
DG
2 C107
C108
3
FIELD
GENERATOR
C2 10
K20
16
DG
DB/PK
18
C27
RADIATOR
FAN
RELAY
CONTROL
D13
D11
2 C3
ST-RUN F20
6
GENERATOR
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
LEAK
2
3
WT/DG
18
K106 K105
18
WT/OR
4
EVAP
LEAK
DETECTION
PUMP
10 C3 14 C3
S166
K20
18
DG
K72
18
DG/OR
C1
C90
20
LG
4
A/C
SWITCH
SENSE SENSE
SWITCH
A/C
SWITCH
PRESSURE
HIGH
A/C
1
2.5L 4.0L
SENSE
SWITCH
A/C
SWITCH
PRESSURE
LOW
A/C
2
C90
20
LG
4.0L 2.5L
K72
18
DG/OR
SIGNAL
A/C
LED
INDICATOR
TN
18
C48
13
C3
2
INDICATOR
LED
A/C
SIGNAL
(8W-10-2)
(8W-42-4)
(8W-42-5)
(8W-42-6)
(8W-42-6)
(8W-12-12)
(8W-20-2)
(8W-42-7)
(8W-42-8)
(8W-42-6)
(8W-42-6)
J008W-7 XJD03018
C3 29
POWERTRAIN
CONTROL
MODULE
27 C3
CONNECTOR
LINK
DATA
PK
18
D21
19
FUSE
20A
A17
POWER
DISTRIBUTION
CENTER
BATT A0
A18
16
A18 C100
F34
18
TN/BK
Z12
18
BK/TN
5
A7
C100
A1
4
BK
18
Z1
Z1
18
BK
G102
6 7
LG/BK
20
D20 D21
20
PK
BK/TN
18
Z12
TRANSMIT/
SCI SCI
RECEIVE
C1 4
F34
18
TN/BK
SWITCH
HEADLAMP
B7 B8
D20
18
LG/BK
D21
18
PK
20
BRAKE
ANTI-LOCK
CONTROLLER
14
PK
20
D21
S139
TRANSMISSION
CONTROL
MODULE
D21
20
PK
2.5L 4.0L
LHD
S218
E6
LHD
RHD
E7
F2 F1
FUSED
B(+)
RHD
SCI
TRANSMIT/
ISO 9141K
SCI
TRANSMIT/
ISO 9141K ISO 9141K
(8W-10-18)
(8W-10-2)
(8W-10-7)
(8W-15-2)
(8W-50-2)
(8W-31-7)
(8W-10-18)
(8W-35-2)
XJD03019 J008W-7
CONNECTOR
LINK
DATA
VT/BR
18
D1 D2
18
WT/BK
11 3
6
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
12
INSTRUMENT
CLUSTER
1 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
2 C2
5 11
6 7
19
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
18
28 C3
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
30 C3
OVERHEAD
MODULE
D2
20
WT/BK VT/BR
20
D1
CCD
BUS
(+) (-)
BUS
CCD
COMPASS
D1
20
VT/BR WT/BK
20
D2
55
1
VT/BR
20
D1
S346 S344
C301
2
C201
56
D2
20
WT/BK
S144
S145
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
TRANSMISSION
(+)
BUS
CCD CCD
BUS
(-)
D1
18
VT/BR WT/BK
18
D2
E11
C100
E12
51
C201
52
D2
18
WT/BK VT/BR
18
D1
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
WT/BK
20
D2
VT/BR
20
D1
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
PAIR
TWISTED
D2
20
WT/BK VT/BR
20
D1
1 2
S239
S238
OTHER 4.0L A/T
COMPASS
OTHER A/T
4.0L
COMPASS
MODULE
IMMOBILIZER
KEY
SENTRY
OTHER OTHER
D1
20
VT/BR
D1
18
VT/BR
D2
20
WT/BK
D2
18
WT/BK
D2
18
WT/BK
(8W-40-3)
(8W-49-6)
(8W-49-6)
(8W-31-7)
(8W-43-2)
(8W-39-8)
LHD
XJ
J008W-7 XJD03020
CONNECTOR
LINK
DATA
VT/BR
18
D1 D2
18
WT/BK
11 3
6
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
12
INSTRUMENT
CLUSTER
1 C2
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
2 C2
5 11
6 7
19
D1
20
VT/BR WT/BK
20
D2
(+)
BUS
CCD CCD
BUS
(-)
18
28 C3
(-)
BUS
CCD CCD
BUS
(+)
D2
20
WT/BK VT/BR
20
D1
30 C3
OVERHEAD
MODULE
D2
20
WT/BK VT/BR
20
D1
CCD
BUS
(+) (-)
BUS
CCD
COMPASS
D1
20
VT/BR WT/BK
20
D2
VT/BR
20
D1
S346 S344
C301
2
D2
20
WT/BK
S144
S145
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
TRANSMISSION
(+)
BUS
CCD CCD
BUS
(-)
D1
18
VT/BR WT/BK
18
D2
A11
C100
A12
19 C204 20
D2
18
WT/BK VT/BR
18
D1
AIRBAG
CONTROL
MODULE
PAIR
TWISTED
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
TWISTED
PAIR
TWISTED
PAIR
WT/BK
20
D2
VT/BR
20
D1
PAIR
TWISTED
CCD
BUS
(+) (-)
BUS
CCD
PAIR
TWISTED
D2
20
WT/BK VT/BR
20
D1
1 2
S239
S238
OTHER 4.0L A/T
1
COMPASS OTHER
COMPASS
4.0L
A/T OTHER
MODULE
IMMOBILIZER
KEY
SENTRY
OTHER
D2
18
WT/BK
D2
18
WT/BK
D2
20
WT/BK
D1
20
VT/BR
D1
18
VT/BR
(8W-40-3)
(8W-49-6)
(8W-49-6)
(8W-31-7)
(8W-43-3)
(8W-39-9)
RHD
8W - 30 - 21
XJD03021 J008W-7
8W-31 TRANSMISSION CONTROL SYSTEM
Component Page
Brake Lamp Swi tch . . . . . . . . . . . . . . . . 8W-31-3, 7
Engi ne Starter Motor Rel ay . . . . . . . . . . 8W-31-2, 6
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 6
Fuse 11 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 4
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
Fuse 25 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 7
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-6
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 7
I nput Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-31-5
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-31-2, 3, 4, 6, 7
Component Page
Lock-Up Sol enoi d . . . . . . . . . . . . . . . . . . . . 8W-31-4
Output Speed Sensor . . . . . . . . . . . . . . . . . 8W-31-5
Powertrai n Control Modul e . . . . . . . 8W-31-2, 3, 5, 7
Shi ft Lock Sol enoi d . . . . . . . . . . . . . . . . . 8W-31-3, 7
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . . 8W-31-5
Transmi ssi on Control Modul e . . . . . 8W-31-4, 5, 6, 7
Transmi ssi on Sol enoi d . . . . . . . . . . . . . . 8W-31-4, 5
XJ 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
POWERTRAIN
CONTROL
MODULE
F20
18
WT
DB/WT
18
F12
A
B
CLUTCH
CONVERTER
TORQUE
6 C1
C10
C8
CENTER
DISTRIBUTION
POWER
ST T141
SENSE
SWITCH
POSITION
PARK/NEUTRAL
ENGINE
STARTER
MOTOR
RELAY
SWITCH
PARK/
NEUTRAL
POSITION
P/N
BK/WT
18
T41
T41
18
BK/WT
2
S120
BK/WT
20
T41
5 C107
T41
18
BK/WT
R
TORQUE
CONVERTER
SOLENOID
CONTROL
C2 11
K54
18
OR/BK
DB/WT
18
F12
5
C2
ST-RUN A21
20A
FUSE
11
BLOCK
JUNCTION
F12
18
DB/WT
C107 10
S130
S161
WT
18
F20
1
3
BR/LG
18
L10
10
FUSE
15A
C4
S12
2 C1
11 C107
1 C201
C100 E9
S159
F20
18
WT
SOLENOID
CLUTCH
E3
C100
C107 12
C200 16
A9 C100
FUSED
IGNITION
SWITCH
OUTPUT
RHD LHD
F20
18
WT
F20
18
WT
(ST-RUN)
F20
18
WT
A15
RHD
LHD
23 C204
TO
S303
LHD RHD
(8W-10-2)
(8W-12-17)
(8W-12-18)
(8W-21-2)
(8W-30-2)
(8W-30-14)
(8W-30-15)
(8W-10-10)
(8W-12-2)
(8W-12-13)
(8W-12-13)
(8W-51-6)
(8W-12-12)
(8W-12-12)
(8W-21-2)
(8W-51-7)
8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM
2.5L
XJ
J008W-7 XJD03102
2
1
BK
18
Z1
Z1
14
BK
S207
G108
C100
B1
WT/PK
18
K29
BRAKE
LAMP
SWITCH
S204
WT/PK
18
K29
RUN A22
25
FUSE
15A
C4
S8
BLOCK
JUNCTION
1
2
SHIFT
LOCK
SOLENOID
S219
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-15-9)
(8W-15-9)
(8W-33-3)
(8W-10-11)
(8W-12-20)
(8W-12-21)
(8W-12-2)
(8W-12-20)
(8W-12-21)
(8W-30-16)
(8W-12-20)
XJ 8W-31 TRANSMISSION CONTROL SYSTEM
2.5L
8W - 31 - 3
XJD03103 J008W-7
TRANSMISSION
CONTROL
MODULE
20A
FUSE
11
26
DB/WT
18
F12
F12
18
DB/WT
16
FUSE
15A
PK
20
M1
5
SWITCH
IGNITION
FUSED
CENTER
DISTRIBUTION
POWER
A24
ST-RUN A21
A23
JUNCTION
BLOCK
C2
S136
BATT A0
24
Z12
16
G101
GROUND
BK/TN
9 C107
BK/TN
18
Z12
FUSED
B(+)
25
S135
M1
20
PK
12
WT
20
T19
3 2
T60
20
OR/WT
13
4
T22
20
DB/WT
11
SOLENOID
TRANSMISSION
3-4
AND
1-2
SOLENOID
2-3
SOLENOID
LOCK-UP
SOLENOID
SOLENOID A SOLENOID B SOLENOID C
CONTROL CONTROL CONTROL
LHD RHD
S130
F12
18
DB/WT
OUTPUT
(ST-RUN)
(8W-12-14) (8W-10-17)
(8W-10-2)
(8W-10-10)
(8W-12-2)
(8W-12-14)
(8W-10-7)
(8W-15-2)
(8W-10-17)
(8W-12-14)
4.0L
XJ
J008W-7 XJD03104
TRANSMISSION
CONTROL
MODULE
2
RD/BK
20
T52
1 7
T14
20
LG/WT
4
SOLENOID
TRANSMISSION
SENSOR
OUTPUT
SPEED
SPEED
OUTPUT
SENSOR
SIGNAL
SPEED
INPUT
SENSOR
SIGNAL
SENSOR
INPUT
SPEED SPEED
INPUT
SENSOR
GROUND GROUND
SENSOR
OUTPUT
SPEED
3
DB/BK
20
T13
6
1
VT/LG
20
T31
5
GROUND
SENSOR 5V
SUPPLY
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
K167
20
BR/YL
S138
BR/YL
20
K167
SENSOR
GROUND
BR/YL
20
K167
3 C107
K22
20
OR/DB
OTHER
BR/YL
18
K167
4.0L
BR/YL
20
K167
BR/YL
18
K167
S123
CALIFORNIA
S111
(8W-30-7)
(8W-70-2)
(8W-30-7)
(8W-70-3)
(8W-70-3)
(8W-30-7)
(8W-70-2)
(8W-70-3)
4.0L
8W - 31 - 5
XJD03105 J008W-7
TRANSMISSION
CONTROL
MODULE
3
R D D3 1-2
TRANSMISSION
RANGE
SENSOR
P/N
8 6 4 2 1
BK
18
Z1
L10
18
BR/LG
T1
18
LG/BK
T3
18
VT
T42
18
VT/WT
T41
20
BK/WT
7
18 22 9 21
FEED
LAMP
BACK-UP
T1 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
F20
18
WT
TRS TRS TRS
SENSE SENSE SENSE
(8W-12-12)
(8W-10-10)
(8W-12-2)
(8W-12-12)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-21-3)
(8W-51-6)
4.0L
XJ
J008W-7 XJD03106
TRANSMISSION
CONTROL
MODULE
14
2
1
BK
18
Z1
Z1
14
BK
S207
G108
23
WT/PK
20
K29
7
D21
20
PK
F2
D21
20
PK
S139
SCI
TRANSMIT/
PK
20
D21
CONNECTOR
LINK
DATA
VT/BR
18
D1 D2
18
WT/BK
11 3
6 7
S144 S145
(+)
BUS
CCD CCD
BUS
(-)
E11 E12
PAIR
TWISTED
WT/BK
20
D2
VT/BR
20
D1
D1
20
VT/BR
D2
20
WT/BK
S140
C100
F10
WT/PK
20
K29
TWISTED
PAIR
SENSE
SWITCH
BRAKE
LAMP
SWITCH
WT/PK
20
K29
S204
WT/PK
18
K29
LHD RHD
K29
18
WT/PK
RUN A22
25
FUSE
15A
DB/WT
20
F15
C4
S8
BLOCK
JUNCTION
1
2
SHIFT
LOCK
SOLENOID
RHD LHD
F15
20
DB/WT
K29
18
WT/PK
C3 24
POWERTRAIN
CONTROL
MODULE
D2
20
WT/BK
D1
20
VT/BR
S239 S238
B8 A11 A12 B1
LHD
RHD
BRAKE
SWITCH
SENSE
F15
20
DB/WT
S217
40 C201
K29
20
WT/PK
S219
F15
20
DB/WT
ISO9141K
LAMP
WT/PK
18
K29
LHD RHD
BRAKE
LAMP
(8W-15-9)
(8W-15-9)
(8W-30-19)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-33-3)
(8W-10-11)
(8W-12-20)
(8W-12-21)
(8W-12-2)
(8W-30-16)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-12-20)
(8W-12-20)
(8W-12-21)
4.0L
8W - 31 - 7
XJD03107 J008W-7
8W-33 VEHICLE SPEED CONTROL
Component Page
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3
Component Page
Left Speed Control Swi tch . . . . . . . . . . . . . 8W-33-2
Power Di stri buti on Center . . . . . . . . . . . . . 8W-33-3
Ri ght Speed Control Swi tch . . . . . . . . . . . . 8W-33-2
Vehi cl e Speed Control Servo . . . . . . . . . . . . 8W-33-3
XJ 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1
MODULE
CONTROL
POWERTRAIN
4 C1
SENSOR
GROUND
S138
C3 32
SIGNAL
SWITCH
CONTROL
SPEED
V37
18
RD/LG
B5
20
CLOCKSPRING
C107 3
S111
V37
RD/LG
2 3
F18
C100
SWITCH
CONTROL
SPEED
LEFT
2 1 1 2
RIGHT
SPEED
CONTROL
SWITCH
3
3 COAST
2 CANCEL
1 RESUME/ACCEL
2 ON/OFF
1 SET
1 2 2 1
B A
S222
S221
V37
20
RD/LG
K167
20
BR/YL RD/LG
20
V37
BR/YL
20
K167
BR/YL
20
K167
K167
20
BR/YL
C2 C2
C1 C1
F17
LHD
RHD
B6
BK/RD
20
K4
OTHER
BR/YL
18
K167
4.0L
BR/YL
18
K167
BR/YL
20
K167
S123
CALIFORNIA
(8W-70-3)
(8W-70-3)
(8W-30-13)
(8W-70-2)
8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL XJ
J008W-7 XJD03302
POWERTRAIN
CONTROL
MODULE
SOLENOID
VACUUM
CONTROL
SPEED
4 C3
TN/RD
18
V36
1 2
V35
18
LG/RD
C3 5
SERVO
CONTROL
SPEED
VEHICLE
CONTROL CONTROL
SPEED
CONTROL
VENT
SOLENOID
3
YL/RD
4
18
V32
3
DB/RD
20
V30
C100
V30
20
DB/RD
11
SPEED
CONTROL
POWER
C3
F9
F7
4
BK
18
Z1
G106
C3 24
WT/PK
18
K29
SENSE
SWITCH
BRAKE
OTHER 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
DISTRIBUTION
POWER
F8 C100
L50
20
WT/TN
TO
S203
F32
20
PK/DB
F10
SUPPLY
LHD
RHD
LHD RHD
V32
20
YL/RD
V32
18
YL/RD
K29
18
WT/PK
LAMP
(8W-15-6)
(8W-31-7)
(8W-31-3)
(8W-31-7)
(8W-15-9)
(8W-15-9)
(8W-15-3)
(8W-15-4)
(8W-15-5)
(8W-30-14)
(8W-30-16)
(8W-10-20)
(8W-10-7)
(8W-10-2)
(8W-10-20)
XJ 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3
XJD03303 J008W-7
8W-35 ANTI-LOCK BRAKES
Component Page
ABS I ndi cator . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Control l er Anti -Lock Brake . . . . . . . . . 8W-35-2, 3, 4
Control l er Anti -Lock Brake Rel ay . . . . . . . . 8W-35-3
Fuse 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 Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
I nstrument Cl uster . . . . . . . . . . . . . . . . . . . 8W-35-3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Left Front Wheel Speed Sensor . . . . . . . . . 8W-35-4
Left Rear Wheel Speed Sensor . . . . . . . . . . 8W-35-4
Ri ght Front Wheel Speed Sensor . . . . . . . . 8W-35-4
Ri ght Rear Wheel Speed Sensor . . . . . . . . . 8W-35-4
XJ 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1
12
FUSE
40A
25
POWER
DISTRIBUTION
CENTER
BATT A0
BRAKE
ANTI-LOCK
CONTROLLER
B(+)
FUSED
25
RD/DG
12
A10
8 24
GROUND GROUND
Z1
12
BK
Z1
12
BK
G102
18 19
26
20A
FUSE
13
A20
12
RD/DB
9
FUSED
B(+)
1 2 3
SWITCH
G
C
C109
13 7
B43
PK/OR YL/VT
B41
6
A
B42
TN/WT
B
TN/WT
20
B42 B41
20
YL/VT PK/OR
20
B43
SIGNAL
TEST
G SWITCH
SENSE
NO. 1
G SWITCH
SENSE
NO. 2
G SWITCH
PK
D21
12
PK/DB
20
F32
23
FUSE
15A
A10
A9
F8 C100
F32
20
PK/DB
5
6
BRAKE
LAMP
SWITCH
WT/TN
L50
S203
BRAKE
LAMP
SWITCH
OUTPUT
7
18 18 18 18 18
20
L50
WT/TN
20
PK
D21
20
D21
20
PK
LINK
DATA
CONNECTOR
SCI
TRANSMIT/
F2
C100
B8
LHD
RHD
18
D21
PK
4.0L 2.5L
S139
ISO 9141K
RHD LHD
C100 B4 C100 E1
L50
20
WT/TN
(8W-10-16)
(8W-10-2)
(8W-10-7)
(8W-15-2)
(8W-10-16) (8W-10-20)
(8W-33-3)
(8W-10-20)
(8W-30-19)
(8W-30-19)
8W - 35 - 2 8W-35 ANTI-LOCK BRAKES XJ
J008W-7 XJD03502
SWITCH
IGNITION
FUSED
23
BRAKE
ANTI-LOCK
CONTROLLER
6
C1
F15
20
DB/WT
BLOCK
JUNCTION
15A
FUSE
25
RUN A22
G83
18
GY/BK
16
S134
B19 B18
B20 B16
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
DB/WT
18
F15
CONTROL
RELAY
ABS
BK
20
Z1
S132
G106
Z1
16
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
BK
EXCEPT
(4.0L ABS
(IN PDC)
NO. 1
RELAY
LAMP
FOG
DRL)
GROUND
(8W-12-2)
(8W-12-20)
(8W-12-21)
(8W-10-11)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-40-5)
(8W-12-11)
(8W-10-10)
(8W-12-11)
(8W-12-11)
(8W-12-20)
(8W-12-21)
(8W-50-8)
XJ 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3
XJD03503 J008W-7
CONTROLLER
ANTI-LOCK
BRAKE
LEFT
FRONT
WHEEL
SPEED
SENSOR
4
LEFT
FRONT
WHEEL
SPEED
SENSOR
(+) (-)
SENSOR
SPEED
WHEEL
FRONT
LEFT
11
1 2
B A
2
LEFT
REAR
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
REAR
LEFT
10
SENSOR
SPEED
WHEEL
REAR
LEFT
2 1
18
RIGHT
FRONT
WHEEL
SPEED
SENSOR
(-) (+)
SENSOR
SPEED
WHEEL
FRONT
RIGHT
3
SENSOR
SPEED
WHEEL
FRONT
RIGHT
B A
17
RIGHT
REAR
WHEEL
SPEED
SENSOR
(+)
SENSOR
SPEED
WHEEL
REAR
RIGHT
B8
RD/DB RD
18
B9
WT/DB
B6
WT
B7 B3
LG/DB
B3
20
LG/DB
F
C109
G
LG
20
B4
LG
B4
YL
20
B2
YL
B2 B1
YL/DB
B1
20
YL/DB
1
RIGHT
REAR
WHEEL
SPEED
SENSOR
(-)
D
C109
E
18 18 18 18 18 18 18
PAIR
TWISTED TWISTED
PAIR
TWISTED
PAIR
TWISTED
PAIR
8W - 35 - 4 8W-35 ANTI-LOCK BRAKES XJ
J008W-7 XJD03504
8W-39 VEHICLE THEFT SECURITY SYSTEM
Component Page
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-39-8, 9
Dri ver Door Jamb Swi tch . . . . . . . . . . . . 8W-39-6, 7
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3
Fuse 27 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-4, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
Headl amp Swi tch . . . . . . . . . . . . . . . . . . 8W-39-6, 7
Component Page
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-39-8, 9
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
I nstrument Cl uster . . . . . . . . . . . . . . . . . 8W-39-8, 9
Juncti on Bl ock . . . . . . . . . . 8W-39-2, 3, 4, 5, 6, 7, 8, 9
Left Rear Door Jamb Swi tch . . . . . . . . . . 8W-39-6, 7
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
Overhead Modul e . . . . . . . . . . . 8W-39-2, 3, 6, 7, 8, 9
Passenger Door Jamb Swi tch . . . . . . . . . 8W-39-6, 7
Passenger Power Lock/Wi ndow Swi tch . . 8W-39-2, 3
Power Di stri buti on Center . . . . . . . . 8W-39-2, 3, 4, 5
Ri ght Rear Door Jamb Swi tch . . . . . . . . . 8W-39-6, 7
Sentry Key I mmobi l i zer Modul e . . . 8W-39-4, 5, 8, 9
XJ 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
MODULE
OVERHEAD
11
BATT A0
20
BK
9
GROUND
3
BK
20
Z1
GROUND
16
FUSE
15A
2
M1
20
PK
12
3
FUSED
B(+)
A24
A23
C1
C3
M1
20
PK
S347
CENTER
DISTRIBUTION
POWER
S342
JUNCTION
BLOCK
BLOCK
JUNCTION
C4
C3
S5
2
P59
20
LB/RD
CONTROL
LOCK
DOOR DOOR
UNLOCK
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
DOOR
UNLOCK
RELAY
CONTROL
S135
SKIM
S361
OTHERS
S314
(8W-10-17)
(8W-10-7)
(8W-10-18)
(8W-10-2)
(8W-15-7)
(8W-12-2)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-61-2)
(8W-10-17)
(8W-49-2)
(8W-10-18)
(8W-15-7)
8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM
LHD
XJ
J008W-7 XJD03902
MODULE
OVERHEAD
11
BATT A0
9
GROUND
3
BK
20
Z1
GROUND
16
FUSE
15A
2
M1
20
PK
12
3
FUSED
B(+)
A24
A23
C1
C3
M1
20
PK
S361
CENTER
DISTRIBUTION
POWER
S342
JUNCTION
BLOCK
BLOCK
JUNCTION
C4
C3
S5
2
P59
20
LB/RD
CONTROL
LOCK
DOOR DOOR
UNLOCK
RELAY
CONTROL
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
DB/PK
P55
20
DB/PK
P59
20
LB/RD
P59
20
LB/RD
OTHERS SKIM
S347
(8W-10-17)
(8W-10-7)
(8W-10-18)
(8W-10-2)
(8W-15-7)
(8W-12-2)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-61-3)
(8W-10-17)
(8W-49-3)
(8W-49-5)
(8W-10-18)
XJ 8W-39 VEHICLE THEFT SECURITY SYSTEM
RHD
8W - 39 - 3
XJD03903 J008W-7
10A
FUSE
27
DB/GY
20
F1
B(+)
FUSED
3
GROUND
5
20
Z2
GROUND
S225
CENTER
DISTRIBUTION
POWER
BATT A17
A1
A2
C100 E10
S227
G108
F1
20
DB/GY
6
JUNCTION
BLOCK
ST-RUN 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/LG
(8W-10-14)
(8W-10-10)
(8W-12-11)
(8W-10-2)
(8W-10-14)
(8W-15-9)
(8W-15-9)
(8W-12-2)
(8W-12-11)
(8W-12-11)
LHD
XJ
J008W-7 XJD03904
10A
FUSE
27
DB/GY
20
F1
B(+)
FUSED
3
GROUND
5
20
Z2
GROUND
CENTER
DISTRIBUTION
POWER
BATT A17
A1
A2
C100 E10
S227
G108
F1
20
DB/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-10-2)
(8W-10-14)
(8W-15-9)
(8W-15-9)
(8W-12-2)
(8W-12-11)
(8W-12-11)
RHD
8W - 39 - 5
XJD03905 J008W-7
MODULE
OVERHEAD
1
M2
20
YL
S345
3
1
SWITCH
JAMB
DOOR
DRIVER
1
JUNCTION
BLOCK
C3
7
C7
COURTESY
LAMPS
DRIVER
A
C317
M2
18
YL
2
3
SWITCH
JAMB
DOOR
REAR
LEFT
C C317
BK
18
Z1
Z1
20
BK
G303
BK
12
Z1
S309
BK
20
Z1
Z1
18
BK
C320 B
YL
18
M2
C320 A
M2
20
YL
20
M2 M2
20 20
M2
A C319
M2
18
YL
B C319
BK
18
Z1
Z1
20
BK
S310
Z1
16
BK
BK
20
Z1
Z1
18
BK
C318 C
RIGHT
REAR
DOOR
JAMB
SWITCH
3
2
YL
18
M2
C318 A
PASSENGER
DOOR
JAMB
SWITCH
1
3
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
SWITCH
HEADLAMP
C1
C2
IGNITION
SWITCH
2
G16
20
BK/LB
G16
20
BK/LB
B
SWITCH
6 C314
YL
20
M2
G302
3 C326
GY/BK
20
M4
2
G16
18
BK/LB
B
20
M2
YL YL YL
YL YL
NOT
USED
DOOR
JAMB
SWITCH
SENSE
DOOR
AJAR
SWITCH
SENSE
DRIVER
BK/LB
20
G16
A
(8W-12-27)
(8W-12-2)
(8W-15-12)
(8W-15-10) (8W-15-12)
(8W-15-14)
(8W-44-6)
(8W-15-14)
(8W-50-2)
(8W-10-9)
(8W-44-6)
(8W-15-10)
(8W-44-6)
(8W-49-4)
(8W-10-10)
LHD
XJ
J008W-7 XJD03906
MODULE
OVERHEAD
1
M2
20
YL
S345
3
1
SWITCH
JAMB
DOOR
PASSENGER
1
JUNCTION
BLOCK
C3
7
C7
COURTESY
LAMP
CONTROL
A
C317
M2
18
YL
2
3
SWITCH
JAMB
DOOR
REAR
LEFT
C C317
BK
18
Z1
Z1
20
BK
G303
BK
12
Z1
S309
BK
20
Z1
Z1
18
BK
C320 B
YL
18
M2
C320 A
M2
20
20
M2
M2
20
20
M2
A C319
M2
18
YL
B C319
BK
18
Z1
Z1
20
BK
Z1
12
BK
BK
20
Z1
Z1
18
BK
C318 C
RIGHT
REAR
DOOR
JAMB
SWITCH
3
2
YL
18
M2
A
DRIVER
DOOR
JAMB
SWITCH
1
3
C
B
LAMP/
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
2
G16
20
BK/LB
G16
20
BK/LB
B
SWITCH
6 C314
YL
20
M2
G302
C318
2
S310
Z1
18
BK
3 C326
GY/BK
20
M4
M2
20
2
G16
18
BK/LB
B
YL
YL YL
YL
YL
YL
NOT
USED
SWITCH
LIFTGATE
DOOR
JAMB
SWITCH
SENSE
DOOR
JAMB
SWITCH
SENSE
G16
20
BK/LB
1
(8W-12-27)
(8W-12-2)
(8W-15-13)
(8W-15-11)
(8W-15-14)
(8W-44-7)
(8W-15-14)
(8W-50-2)
(8W-10-9)
(8W-44-7)
(8W-15-11)
(8W-15-13)
(8W-44-7)
(8W-49-5)
(8W-10-10)
RHD
8W - 39 - 7
XJD03907 J008W-7
D1
18
VT/BR
30 C3
E11
VT/BR
20
D1
D1
18
VT/BR
CCD
BUS
(+)
E12
C100
C3 28
WT/BK
18
D2
CCD
BUS
(-)
D2
20
WT/BK
WT/BK
18
D2
3 11
DATA LINK
CONNECTOR
D2
20
WT/BK
C2
1 2
C2
VT/BR
20
D1
CLUSTER
INSTRUMENT
(-)
BUS
CCD
(+)
BUS
CCD
POWERTRAIN
CONTROL
MODULE
CCD
BUS
(+)
CCD
BUS
(-)
6 12
WT/BK
20
D2
VT/BR
20
D1
1
BK/RD
20
X3
10
HORN
RELAY
CONTROL
7 C301
56 55 C201
2 C301
1
D1
20
VT/BR
D2
20
WT/BK
D1
20
VT/BR
D2
20
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/BK
20
D2
S238
S239
S346
S344
OTHER COMPASS
OTHER COMPASS
OTHER A/T
A/T OTHER
S144
S145
PAIR
TWISTED
TWISTED
PAIR
MODULE
IMMOBILIZER
KEY
SENTRY
4.0L
4.0L
D2
20
WT/BK
D1
18
VT/BR
18
D2
WT/BK
VT/BR
20
D1
(8W-30-20) (8W-40-3)
(8W-30-20)
(8W-12-2)
(8W-10-12)
(8W-41-2)
(8W-30-20)
(8W-30-20)
(8W-30-20)
(8W-30-20)
(8W-30-20)
(8W-30-20)
(8W-49-6)
LHD
XJ
J008W-7 XJD03908
D1
18
VT/BR
30 C3
A11
VT/BR
20
D1
D1
18
VT/BR
CCD
BUS
(+)
A12
C100
C3 28
WT/BK
18
D2
CCD
BUS
(-)
D2
20
WT/BK
WT/BK
18
D2
3 11
DATA LINK
CONNECTOR
D2
20
WT/BK
C2
1 2
C2
VT/BR
20
D1
CLUSTER
INSTRUMENT
(-)
BUS
CCD
(+)
BUS
CCD
POWERTRAIN
CONTROL
MODULE
CCD
BUS
(+)
CCD
BUS
(-)
6 12
WT/BK
20
D2
VT/BR
20
D1
S22
BK/RD
20
X3
10
HORN
RELAY
CONTROL
7 C301
D1
20
VT/BR
D2
20
WT/BK
BK/RD
20
X3
JUNCTION
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
OTHER 4.0L A/T
S144
COMPASS OTHER
COMPASS OTHER
S344
S346
PAIR
TWISTED
MODULE
IMMOBILIZER
KEY
SENTRY
4.0L
D2
20
WT/BK
D1
18
VT/BR
2
C301
1
D2
20
WT/BK
D1
20
VT/BR
VT/BR
20
D1
WT/BK
18
D2
(8W-30-21) (8W-40-3)
(8W-30-21)
(8W-12-2)
(8W-10-12)
(8W-41-3)
(8W-30-21)
(8W-30-21)
(8W-30-21)
(8W-30-21)
(8W-30-21)
(8W-30-21)
(8W-49-6)
RHD
8W - 39 - 9
XJD03909 J008W-7
8W-40 INSTRUMENT CLUSTER
Component Page
ABS I ndi cator . . . . . . . . . . . . . . . . . . . . . 8W-40-5, 6
Ai rbag Control Modul e . . . . . . . . . . . . . . 8W-40-5, 6
Ai rbag Warni ng I ndi cator . . . . . . . . . . . . 8W-40-5, 6
Check Engi ne Warni ng I ndi cator . . . . . . . . 8W-40-4
Check Gauges Warni ng I ndi cator . . . . . . . . 8W-40-3
Cl uster I l l umi nati on Lamps . . . . . . . . . . . 8W-40-12
Control l er Anti -Lock Brake Rel ay . . . . . . 8W-40-5, 6
Crui se Engaged I ndi cator . . . . . . . . . . . . . 8W-40-13
Dri ver Door Jamb Swi tch . . . . . . . . . . . . . . 8W-40-8
Engi ne Cool ant Temperature Gauge . . . . . . 8W-40-4
Engi ne Oi l Pressure Sensor . . . . . . . . . . . . 8W-40-4
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . . 8W-40-3
Ful l Ti me 4WD I ndi cator . . . . . . . . . . . . . . 8W-40-7
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-12
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . 8W-40-9, 10
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-40-2
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-7
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5, 6
G107 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-5, 9, 10
G108 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2, 7, 11
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-6, 8
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-8
Headl amp Beam Sel ect Swi tch . . . . . . . . . 8W-40-11
Headl amp Swi tch . . . . . . . . . . . . . . . . . 8W-40-8, 12
Hi gh Beam I ndi cator . . . . . . . . . . . . . . . . . 8W-40-11
I nstrument Cl uster . . . 8W-40-2, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-40-2, 9, 10, 12
Left Turn Si gnal I ndi cator . . . . . . . . . . . . 8W-40-11
Li ftgate Ajar I ndi cator . . . . . . . . . . . . . . . 8W-40-12
Low Fuel Warni ng I ndi cator . . . . . . . . . . . . 8W-40-3
Low Washer Fl ui d I ndi cator . . . . . . . . . . 8W-40-5, 6
Odometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-12
Oi l Pressure Gauge . . . . . . . . . . . . . . . . . . . 8W-40-4
Overhead Modul e . . . . . . . . . . . . . . . . . 8W-40-9, 10
Park Brake Swi tch . . . . . . . . . . . . . . . . . . . 8W-40-7
Part Ti me 4WD I ndi cator . . . . . . . . . . . . . . 8W-40-7
Powertrai n Control Modul e . . . . . . . . 8W-40-3, 4, 13
Rear Wi ndow Defogger Rel ay . . . . . . . . 8W-40-9, 10
Rear Wi ndow Defogger Swi tch . . . . . . . 8W-40-9, 10
Red Brake Warni ng I ndi cator . . . . . . . . . . . 8W-40-7
Ri ght Turn Si gnal I ndi cator . . . . . . . . . . . 8W-40-11
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . 8W-40-5, 6
Seat Bel t Warni ng I ndi cator . . . . . . . . . . 8W-40-5, 6
Sentry Key I mmobi l i zer Modul e . . . . . . 8W-40-9, 10
Speedometer . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
Transfer Case Swi tch . . . . . . . . . . . . . . . . . 8W-40-7
Tri p Reset Swi tch . . . . . . . . . . . . . . . . . . . 8W-40-12
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . 8W-40-11
Upshi ft I ndi cator . . . . . . . . . . . . . . . . . . . . 8W-40-3
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . 8W-40-3
Vol t Meter . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3
VTSS I ndi cator . . . . . . . . . . . . . . . . . . . 8W-40-9, 10
Washer Fl ui d Level Swi tch . . . . . . . . . . . 8W-40-5, 6
XJ 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1
JUNCTION
BLOCK
ST-RUN A21
10A
FUSE
9
CLUSTER
INSTRUMENT
S13
C4
8
SWITCH
IGNITION
FUSED
F87
20
WT/BK
C1
FULL
OPTIONS BASE
S216
5 C201
6
C1 C2
9
Z2
20
BK/LG
Z2
18
BK/LG
G108
LHD RHD
F87
20
WT/BK
GROUND
16
FUSE
15A
BATT A0
POWER
DISTRIBUTION
CENTER
A24
A23
PK
20
M1
S135
C4
S18
C1 12
BLOCK
JUNCTION
PK
20
M1
RHD LHD
C201 6
S214
C1 9
FUSED
B(+)
S225
OUTPUT
(ST-RUN)
F87
20
WT/BK
S227
POLICE/
POSTAL OTHER
(8W-12-2)
(8W-10-10)
(8W-12-11)
(8W-12-11)
(8W-15-9)
(8W-10-17)
(8W-10-7)
(8W-10-2)
(8W-10-17)
(8W-12-2)
(8W-10-17)
(8W-12-11)
(8W-15-9)
8W - 40 - 2 8W-40 INSTRUMENT CLUSTER XJ
J008W-7 XJD04002
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
TACHOMETER
CONTROL CONTROL
GAUGE
ST-RUN F87
CLUSTER
INSTRUMENT
(ST-RUN)
IGN.
FUSED
2
C2 C2
1
A12
C100 A11
S145
S144
D1
18
VT/BR
D2
18
WT/BK
C3 30 28 C3
POWERTRAIN
CONTROL
MODULE
MODULE
CONTROL
TRANSMISSION
CCD
BUS
(+) (-)
BUS
CCD
FUEL
VOLT METER
CONTROL
3
3
FUEL
PUMP
MODULE
SENSOR
SPEED
VEHICLE
K226
20
DB/LG
15 C200
B2
C100
K226
18
DB/LG
26 C3
FUEL
LEVEL
SENSOR
SIGNAL
K226
20
DB/LG
WT/OR
18
G7
C2 27
VEHICLE
SPEED
SENSOR
SIGNAL
S108
6 7
20
D2
VT/BR
20
D1
WT/BK
CCD
BUS
(-) (+)
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 CONTROL
UPSHIFT
INDICATOR
CONTROL
UPSHIFT
INDICATOR
(M/T)
LHD RHD
C204 6
PAIR
TWISTED
TWISTED
PAIR
PAIR
TWISTED
S239 S238
E12
E11
A/T
4.0L
OTHER
OTHER A/T
4.0L
F11
RHD
LHD
G7
18
WT/OR
D1
20
VT/BR
D2
20
WT/BK
SIGNAL
SENSOR
LEVEL
FUEL
SIGNAL
SENSOR
SPEED
VEHICLE
D1
18
VT/BR
D2
18
WT/BK
(8W-12-11)
(8W-30-3)
(8W-30-4)
(8W-30-12)
(8W-30-20)
(8W-30-21)
(8W-31-7)
(8W-30-3)
(8W-30-4)
(8W-30-12)
(8W-30-12)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
XJ 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3
XJD04003 J008W-7
INDICATOR
WARNING
ENGINE
CHECK
INDICATOR
WARNING
CHECK ENGINE
SENSOR
SIGNAL
OIL
PRESSURE
GAUGE
PRESSURE
GAUGE
TEMPERATURE
COOLANT
ENGINE
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
GAUGE
CONTROL CONTROL
GAUGE
ST-RUN F87
CLUSTER
INSTRUMENT
SWITCH
IGNITION
FUSED
2
C2 C2
1
VT/BR
20
D1 D2
20
WT/BK
A12 C100
A11
D1
18
VT/BR
D2
18
WT/BK
C3 30 28 C3
POWERTRAIN
CONTROL
MODULE
CCD
BUS
(+) (-)
BUS
CCD
TEMPERATURE
2
2
ENGINE
COOLANT
TEMPERATURE
K2
18
TN/BK
16 C1
ENGINE
COOLANT
TEMPERATURE
SENSOR
C2 23
GY/YL
18
G60
ENGINE
OIL
PRESSURE
SENSOR
ENGINE
COOLANT
OIL
CONTROL
PAIR
TWISTED
TWISTED
PAIR
SENSOR
PRESSURE
OIL
ENGINE
S239 S238
E11
E12
S145 S144
A/T
4.0L
A/T
4.0L
OTHER
OTHER
SIGNAL
SENSOR
TEMPERATURE
COOLANT
ENGINE
SIGNAL
SENSOR
PRESSURE
OIL
ENGINE
LHD
RHD
(ST-RUN)
OUTPUT
SIGNAL
D1
18
VT/BR
D2
18
WT/BK
D2
20
WT/BK
D1
20
VT/OR
(8W-12-11)
(8W-30-7)
(8W-30-12)
(8W-30-20)
(8W-30-21)
(8W-30-7)
(8W-30-12)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
J008W-7 XJD04004
INDICATOR
WARNING
AIRBAG
INDICATOR
WARNING
AIRBAG
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
ST-RUN F87
CLUSTER
INSTRUMENT
SWITCH
IGNITION
FUSED
2
C2 C2
1
VT/BR
20
D1 D2
20
WT/BK
52
C201 51
D1
18
VT/BR
D2
18
WT/BK
19 18
AIRBAG
CONTROL
MODULE
CCD
BUS
(+) (-)
BUS
CCD
ABS
INDICATOR
B16
B19
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
4
C1
G19
20
LG/OR
F13
C100
Z1
20
BK
S132
Z1
16
BK
CONTROL
G19
20
LG/OR
CONTROL
INDICATOR
INDICATOR
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
SENSE
SWITCH
BELT
SEAT
G10
20
LG/RD
Z1
20
BK
S314
Z1
14
BK
BK
14
Z1
S208
G107
14 C201
Z1
14
BK
SEAT
BELT
WARNING
SEAT
BELT
WARNING
INDICATOR
INDICATOR
CONTROL
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
S132
Z1
16
BK
OTHER 4.0L A/T
S239 S238
E8
OUTPUT
(ST-RUN)
(8W-12-11)
(8W-43-2)
(8W-35-3)
(8W-15-4)
(8W-15-6)
(8W-15-4)
(8W-15-7)
(8W-15-8)
(8W-15-8)
(8W-15-3)
(8W-15-4)
(8W-30-20) (8W-30-20)
XJ 8W-40 INSTRUMENT CLUSTER
LHD
8W - 40 - 5
XJD04005 J008W-7
INDICATOR
WARNING
AIRBAG
INDICATOR
WARNING
AIRBAG
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
ST-RUN F87
CLUSTER
INSTRUMENT
2
C2 C2
1
VT/BR
20
D1 D2
20
WT/BK
20
C204
19
D1
18
VT/BR
D2
18
WT/BK
19 18
AIRBAG
CONTROL
MODULE
CCD
BUS
(+) (-)
BUS
CCD
ABS
INDICATOR
4
C1
G19
20
LG/OR
F13
C100
CONTROL
CONTROL
INDICATOR
INDICATOR
FLUID
WASHER
LOW
FLUID
WASHER
LOW
BK/LB
20
G29
LOW
WASHER
FLUID
SENSE
A8
BK/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
WARNING
SEAT
BELT
WARNING
INDICATOR
INDICATOR
CONTROL
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
S239 S238
LG/OR
20
G19
CONTROLLER
ANTI-LOCK
BRAKE
RELAY
(IN PDC)
B19
B16
Z1
20
BK
S132
Z1
16
BK
Z1
16
BK
G106
FUSED
IGNITION
SWITCH
OUTPUT
(ST-RUN)
(8W-12-11)
(8W-43-3)
(8W-15-5)
(8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-30-21) (8W-30-21)
(8W-35-3)
(8W-15-5)
(8W-15-6)
8W - 40 - 6 8W-40 INSTRUMENT CLUSTER
RHD
XJ
J008W-7 XJD04006
4WD
TIME
PART
ST-RUN F87
CLUSTER
INSTRUMENT
INDICATOR
7
C2
G106
20
BK/WT
A2
INDICATOR
WARNING
BRAKE
A3
BK/RD
20
G107
C2
5
INDICATOR
FULL
TIME
4WD
G107
20
BK/RD BK/WT
20
G106
G106
20
BK/WT BK/RD
20
G107
8
C107 12
B
A
242 4WD 231 4WD
TRANSFER
CASE
D
A
B
PART
TIME TIME
FULL
G101
S107
Z1
20
BK
Z1
16
BK
2
C1
G99
20
GY/WT
A10
C100
GY/WT
20
G99
2
1
SWITCH
PRESSURE
BRAKE
G9
20
GY/BK
A14
C100
G9
20
GY/BK GY/BK
20
G9
S211
C1
1
C1 2
3
0
2
1 4
4 ACC
3 LOCK
0 OFF
2 RUN
1 START
SWITCH
IGNITION
BK
14
Z1
BK
20
Z1
S207
G108
PARK
BRAKE
SWITCH
G9
20
GY/BK
66 C201
LHD RHD
C203 13
BK
20
Z1
SWITCH
TRANSFER
CASE
SWITCH
E14
E2
LHD
RHD
WARNING
2 C112
3
1 C112
3 C112
C112 1
4.0L A/T OTHER
4.0L A/T OTHER
Z1
20
BK
Z1
20
BK
G106
20
BK/WT
G107
20
BK/RD
RED
(8W-12-11)
(8W-15-2)
(8W-15-2)
(8W-10-9)
(8W-15-9)
(8W-15-9)
(8W-10-9)
XJD04007 J008W-7
5
DRIVER
DOOR
JAMB
SWITCH
2
BK/LB
18
G16
C317 B
C200 17
S200
LB
20
G26
C2
8
CLUSTER
INSTRUMENT
2
C2
1 C2
SWITCH
KEY-IN
SWITCH
IGNITION
BK/LB
20
G16
4 C203
B C318
G16
18
BK/LB
2
SWITCH
JAMB
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
C318 C
G16
20
BK/LB BK/LB
20
G16
(8W-39-6) (8W-39-7)
(8W-50-2)
(8W-10-10)
(8W-10-9)
(8W-10-17)
(8W-10-18)
(8W-15-10)
(8W-15-10) (8W-15-13)
(8W-15-13)
(8W-10-10)
J008W-7 XJD04008
BLOCK
JUNCTION
BK
14
Z1
BK
20
Z1
S208
G107
DB/WT
20
C80
C2
4
WINDOW
REAR
DEFOGGER
SENSE
SWITCH
REAR
WINDOW
DEFOGGER
SWITCH
2
1
RELAY
CONTROL
DEFOGGER
REAR
WINDOW
C2 3
CLUSTER
INSTRUMENT
C201 17
LB/WT
20
C81
C4
S26
RELAY
DEFOGGER
WINDOW
REAR
85
86
12
FUSE
10A
RUN A22
(+)
CCD
BUS BUS
CCD
(-)
12
WT/BK
20
D2
C301
2
C201
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 BUS
CCD
(+)
PAIR
TWISTED
IMMOBILIZER
MODULE
D1
20
VT/BR
D2
20
WT/BK
1 2
C81
20
LB/WT
S238
S239
D1
20
VT/BR
D2
20
WT/BK
COMPASS COMPASS OTHER OTHER
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-48-2)
(8W-48-2)
(8W-12-15)
(8W-10-11)
(8W-30-20) (8W-30-20)
(8W-49-6)
(8W-39-8)
(8W-30-20)
(8W-30-20)
XJ 8W-40 INSTRUMENT CLUSTER
LHD
8W - 40 - 9
XJD04009 J008W-7
BLOCK
JUNCTION
BK
14
Z1
BK
20
Z1
S208
G107
DB/WT
20
C80
C2
4
WINDOW
REAR
DEFOGGER
SENSE
SWITCH
REAR
WINDOW
DEFOGGER
SWITCH
2
1
RELAY
CONTROL
DEFOGGER
REAR
WINDOW
C2 3
CLUSTER
INSTRUMENT
LB/WT
20
C81
C4
S26
RELAY
DEFOGGER
WINDOW
REAR
85
86
12
FUSE
10A
RUN A22
(+)
CCD
BUS BUS
CCD
(-)
12
WT/BK
20
D2
C301
2
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 KEY
SENTRY
(-)
CCD
BUS BUS
CCD
(+)
PAIR
TWISTED
IMMOBILIZER
MODULE
D1
20
VT/BR
D2
20
WT/BK
1 2
S238
S239
(EXCEPT
POLICE/
POSTAL)
D1
20
VT/BR
D2
20
WT/BK
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-48-3)
(8W-48-3)
(8W-12-16)
(8W-10-11)
(8W-30-21) (8W-30-21)
(8W-49-6)
(8W-39-9)
(8W-30-21)
(8W-30-21)
8W - 40 - 10 8W-40 INSTRUMENT CLUSTER
RHD
XJ
J008W-7 XJD04010
RD/GY
16
G34
RD/OR
16
L3
S213
RD/OR
16
L3
SWITCH
SELECT
BEAM
3
RHD LHD
L3
16
RD/OR
C100 D4
RD/GY
16
G34
BK/LG
18
Z2
C2
9 6
C1
G108
INSTRUMENT
CLUSTER
INDICATOR
BEAM
HIGH
5 C1
L60
20
TN
L60
20
TN
S212 S209
LG/WT
20
L61
LG/WT
20
L61
C2 6 10 C1
RIGHT
TURN
SIGNAL
INDICATOR INDICATOR
SIGNAL
TURN
LEFT
1 10
TURN
SIGNAL/
HAZARD
SWITCH
D3 C100
OTHER
S227
Z2
20
BK/LG
Z2
20
BK/LG
Z2
20
BK/LG
HEADLAMP
SWITCH
HIGH
BEAM
OUTPUT
SIGNAL
TURN
LEFT RIGHT
TURN
SIGNAL
POLICE/POSTAL
OTHER DRL
DIMMER
B10
(IN PDC)
NO. 1
RELAY
LAMP
FOG
4
MODULE
LAMP
RUNNING
DAYTIME
G34
16
RD/GY
G34
16
RD/GY
HIGH
BEAM
INDICATOR
DRIVER
DRIVER
INDICATOR
BEAM
HIGH
(8W-50-3)
(8W-50-4)
(8W-50-3)
(8W-50-4)
(8W-15-9)
(8W-52-4) (8W-52-3)
(8W-52-2)
(8W-15-9)
(8W-50-10)
(8W-50-11)
XJD04011 J008W-7
3 C1
BLOCK
JUNCTION
TRIP
RESET
SENSE
SWITCH
CLUSTER
INSTRUMENT
6
FUSE
5A
BATT F34
TRIP
RESET
SWITCH
CLUSTER
ILLUMINATION
LAMPS
ODOMETER
CONTROL
ODOMETER
S2
C4
E2
20
OR
S315
43 C201
E2
20
OR
LHD RHD
S215
TN
20
E1
C4 S1
C201 42
RHD LHD
2
1
0
1
3 4
4 BRIGHT
3 DIM
2 HEAD
1 PARK
0 OFF
SWITCH
HEADLAMP
1 C1
LIFTGATE
AJAR
INDICATOR
G78
20
TN/BK
G78
20
TN/BK
C311 3
C310 6
G78
20
TN/BK
1 C327
G78
20
TN/BK
40 C200 C204 5
LHD RHD
2
SWITCH
LIFTGATE
LIFTGATE
AJAR
SWITCH
SENSE
AJAR
LIFTGATE
CONTROL
INDICATOR
4
(8W-12-2)
(8W-12-8)
(8W-12-9)
(8W-10-18)
(8W-12-8)
(8W-12-8)
(8W-12-9)
(8W-50-2)
(8W-44-6)
(8W-44-7)
J008W-7 XJD04012
INDICATOR
ENGAGED
CRUISE
INDICATOR
ENGAGED
CRUISE
WT/BK
20
D2 D1
20
VT/BR
CCD
BUS
(+) (-)
BUS
CCD
ST-RUN F87
CLUSTER
INSTRUMENT
2
C2 C2
1
VT/BR
20
D1 D2
20
WT/BK
A12
C100
A11
D1
18
VT/BR
D2
18
WT/BK
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
D1
18
VT/BR
D1
20
VT/BR
PAIR
TWISTED
(8W-12-11)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
XJD04013 J008W-7
8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
Component Page
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Ci gar Li ghter Rel ay . . . . . . . . . . . . . . . . 8W-41-2, 3
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse 1 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse 2 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Fuse 21 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Component Page
Hi gh Note Horn . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Horn Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Horn Swi tch . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Low Note Horn . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Overhead Modul e . . . . . . . . . . . . . . . . . . 8W-41-2, 3
Power Outl et . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3
XJ 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
C4
M6
BLOCK
JUNCTION
M5
C4
25A
FUSE
1
25A
FUSE
2
3
1
CIGAR
LIGHTER
F30
16
RD
F30
16
RD
50
Z1
16
BK
65
BK
16
Z1
OUTLET
POWER
3
1
F38
16
RD/LB
F38
16
RD/LB
4
C2
HIGH
NOTE NOTE
LOW
S131
X2
20
DG/RD
X2
20
DG/RD
X2
20
DG/RD
85 87
30 86
CIGAR
LIGHTER
RELAY
RUN-ACC A31 BATT A7
RELAY
HORN
86 30
87 85
C4
S22
CLOCKSPRING
HORN
SWITCH
C201
26
BK/RD
20
X3
X3
20
BK/RD
21
FUSE
15A
G107
S5
C4
1
C5
1
14
Z1
14
BK
Z1
14
BK
Z1
14
BK
Z1
14
BK
S314
S208
10
MODULE
OVERHEAD
X3
20
BK/RD
X3
20
BK/RD
7 C301
C1
HORN HORN
HORN
RELAY
CONTROL
(8W-12-2)
(8W-12-5) (8W-12-5) (8W-12-19)
(8W-10-9) (8W-10-12)
(8W-15-8)
(8W-15-7)
(8W-15-8)
(8W-49-4)
(8W-12-19)
8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
LHD
XJ
J008W-7 XJD04102
C4
M6
BLOCK
JUNCTION
M5
C4
25A
FUSE
1
25A
FUSE
2
3
1
CIGAR
LIGHTER
F30
16
RD
Z1
16
BK BK
16
Z1
OUTLET
POWER
3
1
F38
16
RD/LB
4
C2
HIGH
NOTE NOTE
LOW
S131
X2
20
DG/RD
X2
20
DG/RD
X2
20
DG/RD
85 87
30 86
CIGAR
LIGHTER
RELAY
RUN-ACC A31 BATT A7
RELAY
HORN
86 30
87 85
C5
1
CLOCKSPRING
HORN
SWITCH
BK/RD
20
X3
21
FUSE
15A
G107
S5
C4
S22
C4
1
Z1
14
BK
Z1
14
BK
S208
10
MODULE
OVERHEAD
X3
20
BK/RD
X3
20
BK/RD
7 C301
C1
HORN HORN
HORN
RELAY
CONTROL
(8W-12-2)
(8W-12-5) (8W-12-5) (8W-12-19)
(8W-10-9) (8W-10-12)
(8W-15-8)
(8W-15-8)
(8W-49-5)
(8W-12-19)
XJ 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET
RHD
8W - 41 - 3
XJD04103 J008W-7
8W-42 AIR CONDITIONING-HEATER
Component Page
A/C Compressor Cl utch . . . . . . . . . . . . . . . . 8W-42-7
A/C Compressor Cl utch Rel ay . . . . . . . . . . . 8W-42-7
A/C Low Pressure Swi tch . . . . . . . . . . . . . . 8W-42-6
A/C- Heater Control . . . . . . . . . . . . . 8W-42-4, 5, 6, 7
Bl ower Motor . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5
Bl ower Motor Rel ay . . . . . . . . . . . . . 8W-42-2, 3, 4, 5
Bl ower Motor Resi stor Bl ock . . . . . . 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-42-2, 3, 4, 5
Heater Control . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3
Juncti on Bl ock . . . . . . . . . . . . . . . 8W-42-2, 3, 4, 5, 7
Power Di stri buti on Center . . . . 8W-42-2, 3, 4, 5, 7, 8
Powertrai n Control Modul e . . . . . . . . . 8W-42-6, 7, 8
Radi ator Fan Motor . . . . . . . . . . . . . . . . . . 8W-42-8
Radi ator Fan Rel ay . . . . . . . . . . . . . . . . . . . 8W-42-8
XJ 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1
BLOCK
JUNCTION
5 2 3 4
2 3 4
12
C201
61 60 59
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
POWER
DISTRIBUTION
CENTER
S8
C4
F15
20
DB/WT
F15
20
DB/WT
BATT A0 RUN A22
40A
FUSE
6
15A
FUSE
25
A111
12
RD/LG
11
A111
12
RD/LG
5
12
C100 D5
BK/VT
12
Z8
G108
1
FAN MODE
0 OFF
8 VENT
7 HEAT
6 HEAT/DEFROST
4 LOW
3 MEDIUM 1
2 MEDIUM 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
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
B
A
1
G108
25 C201
C209 10
Z1
20
BK
Z8
20
BK/VT
Z8
16
BK/VT
C1
C1 C1 C1 C1 C1
A111
12
RD/LG
FROM
S215
E2
20
OR
9
5 DEFROST
M
(8W-12-2)
(8W-10-2)
(8W-10-7)
(8W-10-11)
(8W-10-13)
(8W-12-20)
(8W-15-9)
(8W-12-20)
(8W-15-9)
(8W-12-8)
8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER
LHD HEATER ONLY
XJ
J008W-7 XJD04202
BLOCK
JUNCTION
5 2 3 4
1
C202
8 9 10
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
S8
C4
F15
20
DB/WT
RUN A22
15A
FUSE
25
7
BK/VT
12
Z8
G108
1
S219
1 C204
FAN MODE
0 OFF
7 VENT
7 HEAT
6 HEAT/DEFROST
4 LOW
3 MEDIUM 1
2 MEDIUM 2
1 HIGH
7
6
5
0
4
3 2
1
CONTROL
HEATER
F15
20
DB/WT
7
D5 C100
12
5
RD/LG
12
A111
6
FUSE
40A
BATT A0
CENTER
DISTRIBUTION
POWER
A111
12
RD/LG
8
9 BI-LEVEL
2 3 4
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
F15
20
DB/WT
A111
12
RD/LG
5 4
2 1
2 3 4 7 8
9
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
A111
12
RD/LG
S228
C1
12
DG
C7
12
BK/TN
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
B
A
1
G108
6 C202
C209 10
Z1
20
BK
Z8
12
BK/VT
Z8
16
BK/VT
BLOCK
RESISTOR
MOTOR
BLOWER
C209
C1
C1 C1 C1 C1 C1
S349
FROM
S215
E2
20
OR
F15
20
DB/WT
F15
20
DB/WT
9
5 DEFROST
M
(8W-12-2)
(8W-10-11)
(8W-12-21)
(8W-15-9)
(8W-12-21)
(8W-10-13)
(8W-10-7)
(8W-10-2)
(8W-15-9)
(8W-12-21)
(8W-12-9)
XJ 8W-42 AIR CONDITIONING-HEATER
RHD HEATER ONLY
8W - 42 - 3
XJD04203 J008W-7
BLOCK
JUNCTION
5 2 3 4
12
C201
61 60 59
S8
C4
6
F15
20
DB/WT
RUN A22
15A
FUSE
25
11
0 OFF
11 MAX
11
11
10 10
HEATER
CONTROL
1
2 3
4
0
5
6
7
8
9
0
8
9
5
A/C-
1 HIGH
2 MEDIUM 2
3 MEDIUM 1
4 LOW
5 DEFROST
6 HEAT/DEF(MIX)
7 HEAT
8 VENT(PANEL)
9 BI-LEVEL
10 A/C
7
6
A/C
SELECT
MODE
FAN
BK/VT
12
Z8
G108
1
7
C90
20
LG
D5 C100
12
5
RD/LG
12
A111
6
FUSE
40A
BATT A0
CENTER
DISTRIBUTION
POWER
A111
12
RD/LG
A
(8W-42-6)
TO
C100
S219
2 3 4
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
F15
20
DB/WT
A111
12
RD/LG
5 4
2 1
2 3 4 7 8
9
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
A111
12
RD/LG
S228
C1
12
DG
C7
12
BK/TN
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
B
A
1
G108
25 C201
C209 10
Z1
20
BK
Z8
20
BK/VT
Z8
16
BK/VT
BLOCK
RESISTOR
MOTOR
BLOWER
C209
C1
C1 C1 C1 C1 C1 C1
FROM
S215
E2
20
OR
F15
20
DB/WT
M
(8W-12-2)
(8W-10-11)
(8W-12-20)
(8W-15-9)
(8W-10-13)
(8W-10-7)
(8W-10-2)
(8W-12-20)
(8W-15-9)
(8W-12-8)
8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER
LHD
XJ
J008W-7 XJD04204
1
C202
8 9 10
7
BLOCK
JUNCTION
5 2 3 4
S8
C4
6
F15
20
DB/WT
RUN A22
15A
FUSE
25
0 OFF
11 MAX
11
11
10 10
HEATER
CONTROL
1
2 3
4
0
5
6
7
8
9
0
8
9
5
A/C-
1 HIGH
2 MEDIUM 2
3 MEDIUM 1
4 LOW
5 DEFROST
6 HEAT/DEF(MIX)
7 HEAT
8 VENT(PANEL)
9 BI-LEVEL
10 A/C
7
6
A/C
SELECT
MODE
FAN
BK/VT
12
Z8
G108
1
7
C90
20
LG
D5 C100
12
5
RD/LG
12
A111
6
FUSE
40A
BATT A0
CENTER
DISTRIBUTION
POWER
A111
12
RD/LG
A
(8W-42-6)
TO
C100
S219
2 3 4
C4
14
TN LG
14
C5
LB
14
C6
BK/TN
12
C7
F15
20
DB/WT
A111
12
RD/LG
5 4
2 1
2 3 4 7 8
9
C7
12
BK/TN
C6
14
LB
C5
14
LG
C4
14
TN
A111
12
RD/LG
S228
C1
12
DG
C7
12
BK/TN
BLOWER
MOTOR
RELAY
MOTOR
BLOWER
B
A
1
G108
6 C202
C209 10
Z1
20
BK
Z8
12
BK/VT
Z8
16
BK/VT
BLOCK
RESISTOR
MOTOR
BLOWER
C209
C1
C1 C1 C1 C1 C1 C1
F15
20
DB/WT
S349
1 C204
F15
20
DB/WT
F15
20
DB/WT
FROM
S215
E2
20
OR
M
(8W-12-2)
(8W-10-11)
(8W-12-21)
(8W-15-9)
(8W-10-13)
(8W-10-7)
(8W-10-2)
(8W-12-21)
(8W-15-9)
(8W-12-21)
(8W-12-9)
XJ 8W-42 AIR CONDITIONING-HEATER
RHD
8W - 42 - 5
XJD04205 J008W-7
A
(8W-42-4)
C100 A6
C90
20
LG
LG
20
C90
DB/PK
20
C21
LG
18
C90
A/C
SWITCH
SENSE SENSE
SWITCH
A/C
LG
20
C90
S143
DB/WT
18
C22
A/C
HIGH
PRESSURE
SWITCH
A/C
LOW
PRESSURE
SWITCH
C3 23
MODULE
CONTROL
POWERTRAIN
22 C3
1
2
4
2
3
1
C3 13
RADIATOR
FAN
REQUEST
C48
18
TN
FROM
CONTROL
HEATER
A/C-
1
2
1
SWITCH
PRESSURE
HIGH
A/C
C21
20
DB/PK
A/C
LOW
PRESSURE
SWITCH
2
C90
20
LG
4.0L 2.5L
(8W-30-18)
(8W-42-5)
8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER XJ
J008W-7 XJD04206
POWER
DISTRIBUTION
CENTER
POWERTRAIN
CONTROL
MODULE
B5 B1
B2 B3
A/C
COMPRESSOR
CLUTCH
RELAY
1 C3
CLUTCH
COMPRESSOR
A/C
4 C108
4.0L RHD OTHER
C13
18
DB/OR
C3
16
DB/BK
ST-RUN F20 BATT A17
DB/BK
16
C3
A/C
COMPRESSOR
CLUTCH
RELAY
CONTROL
C4
S8
15A
FUSE
25
BLOCK
JUNCTION
RUN A22
F15
20
DB/WT
F15
20
DB/WT
S219
40 C201
F15
20
DB/WT
S217
F15
20
DB/WT
2
4 3
GROUND
FUSED
IGNITION
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
C36
20
RD/WT
G107
BK
20
Z1
10
OR
20
D2
RHD LHD
S349
1 C204
6 5
1 C209
F15
20
DB/WT
C2 C2
C2
CONTROL
HEATER
A/C-
C36
20
RD/WT
ACTUATOR
DOOR
BLEND
(RUN)
OUTPUT
SWITCH
IGNITION
FUSED
F15
20
DB/WT
Z1
20
BK
(8W-10-2)
(8W-30-18)
(8W-10-14) (8W-12-12)
(8W-12-20)
(8W-12-21)
(8W-12-2)
(8W-10-11)
(8W-12-20)
(8W-12-21)
(8W-12-20)
(8W-15-8)
(8W-12-21)
XJ 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7
XJD04207 J008W-7
POWER
DISTRIBUTION
CENTER
C3 2
POWERTRAIN
CONTROL
MODULE
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 - 8 8W-42 AIR CONDITIONING-HEATER XJ
J008W-7 XJD04208
8W-43 AIRBAG SYSTEM
Component Page
Ai rbag Control Modul e . . . . . . . . . . . . 8W-43-2, 3, 4
Cl ockspri ng . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-4
Data Li nk Connector . . . . . . . . . . . . . . . . 8W-43-2, 3
Dri ver Ai rbag . . . . . . . . . . . . . . . . . . . . . . . 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
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-43-2, 3
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . . 8W-43-4
XJ 8W - 43 AIRBAG SYSTEM 8W - 43 - 1
C4
S21
BLOCK
JUNCTION
S23
C4
10A
FUSE
26
10A
FUSE
27
20
MODULE
CONTROL
AIRBAG
FUSED
IGNITION
SWITCH
17
SWITCH
IGNITION
FUSED
F14
18
LG/YL
F23
18
DB/YL
18 19
52 51
C201
11 3
DATA
LINK
CONNECTOR
RUN A22 ST-RUN A21
D2
18
WT/BK
D1
18
VT/BR
VT/BR
20
D1
WT/BK
20
D2
D2
18
WT/BK
D1
18
VT/BR
(+)
BUS
CCD CCD
BUS
(-)
BK/YL
18
Z6
G200
GROUND
10
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
Z6
18
BK/PK
BASE FULL OPTIONS
(RUN)
OUTPUT OUTPUT
(ST-RUN)
S238 S239
(8W-12-2)
(8W-12-23) (8W-12-23)
(8W-30-20)
(8W-10-11) (8W-10-10)
(8W-15-10)
(8W-30-20) (8W-30-20)
8W - 43 - 2 8W-43 AIRBAG SYSTEM
LHD
XJ
J008W-7 XJD04302
C4
S21
BLOCK
JUNCTION
S23
C4
10A
FUSE
26
10A
FUSE
27
20
MODULE
CONTROL
AIRBAG
FUSED
IGNITION
SWITCH
17
SWITCH
IGNITION
FUSED
F14
18
LG/YL
F23
18
DB/YL
18 19
20 19 C204
11 3
DATA
LINK
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/PK
18
Z6
G300
GROUND
10
14
C204
15
DB/YL
18
F23
LG/YL
18
F14
PAIR
TWISTED
PAIR
TWISTED
PAIR
TWISTED
(RUN)
OUTPUT
(ST-RUN)
OUTPUT
S238 S239
(8W-12-2)
(8W-12-24) (8W-12-24)
(8W-30-21)
(8W-10-11) (8W-10-10)
(8W-15-11)
(8W-30-21) (8W-30-21)
XJ 8W-43 AIRBAG SYSTEM
RHD
8W - 43 - 3
XJD04303 J008W-7
1
MODULE
CONTROL
AIRBAG
DRIVER
AIRBAG
LINE 1
AIRBAG
LINE 1
DRIVER
2
DRIVER
LINE 2
AIRBAG
LINE 2
AIRBAG
DRIVER
DRIVER
AIRBAG AIRBAG
PASSENGER
AIRBAG
LINE 1
PASSENGER
6
4
PASSENGER
LINE 2
AIRBAG
3
5
PASSENGER
AIRBAG
LINE 1 LINE 2
AIRBAG
PASSENGER
R45
18
DG/LB
R43
18
BK/LB
R42
18
BK/YL
R44
18
DG/YL
2
C205
1 3 4
DG/YL
18
R44
BK/YL
18
R42
BK/LB
18
R43
DG/LB
18
R45
PAIR
TWISTED
TWISTED
PAIR PAIR
TWISTED
TWISTED
PAIR
1 C3 C3 2
CLOCKSPRING
8W - 43 - 4 8W-43 AIRBAG SYSTEM XJ
J008W-7 XJD04304
8W-44 INTERIOR LIGHTING
Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . 8W-44-2, 3
Cargo Lamp/Swi tch . . . . . . . . . . . . . . . . . 8W-44-6, 7
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4
Dome Lamps Swi tch . . . . . . . . . . . . . . . . . . 8W-44-4
Extended I dl e Swi tch . . . . . . . . . . . . . . . . . 8W-44-2
Front Fog Lamp Swi tch . . . . . . . . . . . . . 8W-44-2, 3
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-44-5
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-5
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 5
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3, 6, 7
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7
Headl amp Swi tch . . . . . . . . . . . . . . . . 8W-44-2, 3, 5
Component Page
I nstrument Cl uster . . . . . . . . . . . . . 8W-44-2, 3, 6, 7
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-44-2, 3, 4, 5
Left Courtesy Lamp . . . . . . . . . . . . . . . . . . 8W-44-5
Left Rear Door Jamb Swi tch . . . . . . . . . . 8W-44-6, 7
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . . 8W-44-4
Li ftgate Swi tch . . . . . . . . . . . . . . . . . . . . 8W-44-6, 7
Passenger Door Jamb Swi tch . . . . . . . . . 8W-44-6, 7
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . . 8W-44-2
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3
Rear Wi ndow Defogger Swi tch . . . . . . . . 8W-44-2, 3
Rear Wi per/Washer Swi tch . . . . . . . . . . . 8W-44-2, 3
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-44-5
Ri ght Rear Door Jamb Swi tch . . . . . . . . . 8W-44-6, 7
Transfer Case Swi tch I l l umi nati on . . . . . 8W-44-2, 3
Underhood Lamp/Mercury Swi tch . . . . . . . 8W-44-5
XJ 8W - 44 INTERIOR LIGHTING 8W - 44 - 1
43 C201
JUNCTION
BLOCK
6
FUSE
5A
S2
C4
E2
20
OR
S1 C4
42 C201
E1
20
TN
HEADLAMP
SWITCH
1
S315
1 C206
1
1
TRANSFER
CASE
ILLUMINATION
PRNDL
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
S215
E2
20
OR
RADIO
C2 5
LAMP
1
FRONT
FOG
SWITCH
SWITCH
WINDOW
REAR
4
DEFOGGER
3 C1
INSTRUMENT
CLUSTER
HEATER
A/C-
7
CONTROL
3
2
2
2 C206
Z1
20
BK
S314
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
ILLUMINATION
BK
20
Z1
Z1
14
BK
Z1
14
BK
BK
14
Z1
OR
20
E2
(A/T)
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL
SIGNAL
SWITCH
DIMMER
LAMPS
PANEL
FUSED
C1
C1
(8W-12-2)
(8W-50-2)
(8W-47-2)
(8W-47-8)
(8W-48-2)
(8W-40-12)
(8W-42-4)
(8W-15-7)
(8W-15-8)
(8W-15-8)
(8W-53-3)
(8W-15-8)
(8W-15-8)
(8W-15-9)
(8W-30-17)
(8W-12-8)
(8W-12-8)
(8W-12-8)
8W - 44 - 2 8W-44 INTERIOR LIGHTING
LHD
XJ
J008W-7 XJD04402
JUNCTION
BLOCK
6
FUSE
5A
S2
C4
S1 C4
E1
20
TN
HEADLAMP
SWITCH
1 C206
1 1
TRANSFER
CASE ILLUMINATION
PRNDL
E2
20
OR
E2
20
OR
E2
20
OR
E2
20
OR OR
20
E2
S215
E2
20
OR
RADIO
C2 5
LAMP
1
FRONT
FOG
SWITCH
SWITCH
WINDOW
REAR
4
DEFOGGER
3 C1
INSTRUMENT
CLUSTER
7
3
2 2
2 C206
Z1
20
BK
S313
S309
G302
Z1
20
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
DIMMER
SWITCH
SIGNAL
E2
20
OR
FUSED
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL
E2
20
OR
E2
20
OR
A/C-
HEATER
CONTROL
C1
C1
(8W-12-2)
(8W-50-2)
(8W-47-3)
(8W-47-9)
(8W-48-3)
(8W-40-12)
(8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-53-4)
(8W-15-8)
(8W-15-9)
(8W-12-9)
(8W-15-8)
(8W-12-9)
(8W-42-5)
XJ 8W-44 INTERIOR LIGHTING
RHD
8W - 44 - 3
XJD04403 J008W-7
Z1
14
BK
G107
S208
Z1
14
BK
C201 14
S314
LHD RHD
BK
14
Z1
JUNCTION
BLOCK
2 C3
S5
C4
S347
LAMP
VANITY
RIGHT
PK
20
M1 M1
20
PK
LEFT
VANITY
LAMP
DOME
LAMPS
SWITCH
C
C3
3
BLOCK
JUNCTION
BATT M1
2
FULL OPTIONS OTHERS
A
BK
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
B
B
S342
Z1
20
BK
Z1
20
BK
A
A
M1 20PK
(8W-15-8)
(8W-15-8)
(8W-15-7)
(8W-12-2)
(8W-10-18)
(8W-12-2)
(8W-10-17)
(8W-10-18)
(8W-12-27) (8W-15-7)
(8W-12-2)
(8W-49-2)
(8W-49-3)
(8W-10-18)
(8W-15-7)
8W - 44 - 4 8W-44 INTERIOR LIGHTING XJ
J008W-7 XJD04404
4
C7
12 C1
JUNCTION
BLOCK
S135
M1
20
PK
A23
A24
16
FUSE
15A
CENTER
DISTRIBUTION
POWER
BATT A0
S214
6 C201
S18
PK
20
M1
M1
20
PK PK
18
M1
LHD RHD
RHD LHD
B
(8W-44-6)
TO
SWITCH
LAMP/
CARGO
S304
TO
D
(8W-44-6)
PK
18
M1
B C208
2
A C208
1
LAMP
LEFT
COURTESY
LAMP
COURTESY
RIGHT
C201 46
RHD LHD
S201
YL
20
M2
S25
C4
C1 3
SWITCH
HEADLAMP
DOME
LAMP
SWITCH
C7
7
BK
14
Z1
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
C4
GROUND
FROM
COMPASS
FROM
SWITCH
LAMPS
DOME
FULL
OPTIONS
MIDLINE
M2
20
YL
M2
20
YL
M2
20
YL
CARGO
LAMP/
SWITCH
TO
C
(8W-44-7)
E
(8W-44-7)
TO
S304
LHD RHD
SWITCH
MERCURY
LAMP/
UNDERHOOD
(8W-12-2)
(8W-10-2)
(8W-10-7)
(8W-10-17)
(8W-10-17)
(8W-10-17)
(8W-50-2)
(8W-15-9)
(8W-15-9)
(8W-50-5)
(8W-15-3)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-12-27)
XJ 8W-44 INTERIOR LIGHTING 8W - 44 - 5
XJD04405 J008W-7
B
(8W-44-5)
FROM
C314
JUNCTION
BLOCK
FROM
D
(8W-44-5)
20
M2
6 C314
A
G302
SWITCH
S304
SWITCH
LIFTGATE
3
10
5
C310
C311
C314 7
M4
20
GY/BK
CARGO
LAMP/
B
C
A C318
M2
18
YL
2
3
SWITCH
JAMB
DOOR
REAR
RIGHT
C C318
BK
18
Z1
Z1
20
BK
BK
16
Z1
S310
BK
20
Z1
Z1
18
BK
C319 B
YL
18
M2
C319 A
M2
20 20
M2 M2
20
YL
20
M2
A C320
M2
18
YL
B C320
BK
18
Z1
Z1
20
BK
S309
Z1
12
BK
G303
BK
20
Z1
Z1
18
BK
C317 C
LEFT
REAR
DOOR
JAMB
SWITCH
3
2
YL
18
M2
C317 A
DRIVER
DOOR
JAMB
SWITCH
1
3 3
1
SWITCH
JAMB
DOOR
PASSENGER
BK
18
Z1
Z1
18
BK
C311 6
C310 9
S334
G304
BK
20
Z1
YL YL YL YL
M4
20
VT/YL
1
2
C326 3
M4
20
GY/BK
C1 1
CLUSTER
INSTRUMENT
C311 3
1 C327
40 C200
C310
G78
20
TN/BK
6
G78
20
TN/BK
G78
20
TN/BK
SWITCH
AJAR
LIFTGATE
SENSE
(8W-39-6)
(8W-15-12) (8W-15-10)
(8W-15-12)
(8W-39-6)
(8W-15-14)
(8W-15-14)
(8W-15-10)
(8W-40-12)
8W - 44 - 6 8W-44 INTERIOR LIGHTING
LHD
XJ
J008W-7 XJD04406
C
(8W-44-5)
FROM
C314
JUNCTION
BLOCK
FROM
E
(8W-44-5)
20
M2
6 C314
A
G302
SWITCH
S304
SWITCH
LIFTGATE
3
10
5
C310
C311
C314 7
M4
20
GY/BK
CARGO
LAMP/
B
C
A C318
M2
18
YL
2
3
SWITCH
JAMB
DOOR
REAR
RIGHT
C C318
BK
18
Z1
Z1
20
BK
S310
BK
20
Z1
Z1
18
BK
C319 B
YL
18
M2
C319 A
M2
20 20
M2 M2
20
YL
20
M2
A C320
M2
18
YL
B C320
BK
18
Z1
Z1
20
BK
S309
Z1
12
BK
BK
20
Z1
Z1
18
BK
C317 C
LEFT
REAR
DOOR
JAMB
SWITCH
3
2
YL
18
M2
C317 A
PASSENGER
DOOR
JAMB
SWITCH
1
3 3
1
SWITCH
JAMB
DOOR
DRIVER
BK
18
Z1
Z1
18
BK
C311 6
C310 9
S334
G304
BK
20
Z1
BK
12
Z1
G303
YL YL YL YL
M4
20
VT/YL
1
2
C326 3
M4
20
GY/BK
C1 1
C311 3
1 C327
C204 5
C310 6
CLUSTER
INSTRUMENT
G78
20
TN/BK
SWITCH
AJAR
LIFTGATE
SENSE
(8W-39-7)
(8W-15-13) (8W-15-11)
(8W-39-7)
(8W-15-14)
(8W-15-14)
(8W-15-13)
(8W-15-11)
(8W-40-12)
XJ 8W-44 INTERIOR LIGHTING
RHD
8W - 44 - 7
XJD04407 J008W-7
8W-47 AUDIO SYSTEM
Component Page
Antenna . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 8, 9
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 8, 9
Fuse 16 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
Fuse 17 (JB) . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 8, 9
Fuse 26 (PDC) . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
G108 . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3, 8, 9
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 3
Headl amp Swi tch . . . . . . . . . . . . . . . 8W-47-2, 3, 8, 9
Juncti on Bl ock . . . . . . . . . . . . . . . . . 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 Ampl i fi er . . . . . . . . . . . . 8W-47-2, 3, 4, 5, 6, 7
Radi o . . . . . . . . . . . . . . 8W-47-2, 3, 4, 5, 6, 7, 8, 9, 10
Ri ght Front Door Speaker . . . . . . . . 8W-47-6, 7, 8, 9
Ri ght Front Door Tweeter . . . . . . . . . . . . 8W-47-6, 7
Ri ght Soundbar Speaker . . . . . . . . . . 8W-47-6, 7, 10
XJ 8W - 47 AUDIO SYSTEM 8W - 47 - 1
RADIO
POWER
AMPLIFIER
OUTPUT
SWITCH
HEADLAMP
C2 4
S206
2
1
0
9
SWITCH
HEADLAMP
BATT F34
L7
18
BK/YL
SWITCH
IGNITION
FUSED
GROUND
Z9
14
BK
G108
3 4
1 PARK
2 HEAD
3 DIM
4 BRIGHT
0 OFF
42 C201
C4
S2
C4 S1
BLOCK
JUNCTION
5A
FUSE
6
FUSED
PANEL
C2 5
43
S215
E2
20
OR
E1
20
TN
L7
18
BK/YL
17
FUSE
15A
S9
C4
6 C2
RD/WT
16
X12
54
POWER
DISTRIBUTION
CENTER
16
FUSE
15A
A23
A24
BATT A0
PK
20
M1
S214
C201
6
7 C2
B(+)
FUSED
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
F75
14
VT
S301
G301
8
C2
GROUND
BK/LB
16
Z5
7
C2
GROUND
Z5
16
BK/LB
PK
20
M1
A3
A4
20A
FUSE
26
S135
(RUN-ACC)
OUTPUT
LAMPS
ANTENNA
M1
20
PK
DIMMER
SWITCH
SIGNAL
(8W-12-10)
(8W-10-18)
(8W-15-9)
(8W-50-2)
(8W-12-2)
(8W-12-8)
(8W-12-8)
(8W-12-17)
(8W-10-9)
(8W-10-2)
(8W-10-17)
(8W-10-7)
(8W-10-17)
(8W-12-8)
(8W-15-10)
(8W-10-20)
(8W-10-17)
8W - 47 - 2 8W-47 AUDIO SYSTEM
LHD 6 SPEAKER SYSTEM
XJ
J008W-7 XJD04702
POWER
AMPLIFIER
C2 4
S206
2
1
0
9
SWITCH
HEADLAMP
BATT F34
L7
18
BK/YL
3 4
1 PARK
2 HEAD
3 DIM
4 BRIGHT
0 OFF
C4
S2
C4 S1
BLOCK
JUNCTION
5A
FUSE
6
C2 5
S215
E2
20
OR
E1
20
TN
L7
18
BK/YL
17
FUSE
15A
S9
C4
6 C2
POWER
DISTRIBUTION
CENTER
16
FUSE
15A
A23
A24
BATT A0
S214
7 C2
C1 12
S18
C4
M1
20
PK
RUN-ACC A31
X12
16
RD/WT
M1
20
PK OR
20
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
FUSED
G108
BK
14
Z9
GROUND
FUSED
IGNITION
SWITCH
HEADLAMP
SWITCH
OUTPUT
RADIO
S135
26
FUSE
20A
A4
A3
ANTENNA
M1
20
PK
DIMMER
SWITCH
SIGNAL
(8W-12-10)
(8W-10-18)
(8W-50-2)
(8W-12-2)
(8W-12-9)
(8W-12-9)
(8W-12-18)
(8W-10-9)
(8W-10-2)
(8W-10-7)
(8W-10-17)
(8W-15-11)
(8W-15-9)
(8W-10-17)
(8W-10-20)
XJ 8W-47 AUDIO SYSTEM
RHD 6 SPEAKER SYSTEM
8W - 47 - 3
XJD04703 J008W-7
7 C1
RADIO
POWER
AMPLIFIER
LEFT
REAR
SPEAKER
(+)
(+)
SPEAKER
REAR
LEFT
C1
2
6
C200
11 7
6
C1
C1 8
(-)
SPEAKER
REAR
LEFT
LEFT
REAR
SPEAKER
(-)
1
4
C1
C1 5
2
2
C2
C1 1
X51
16
BR/YL
X57
16
BR/LB
X57
BR/LB BR/YL
18
X51
X53
16
DG
X55
16
BR/RD
X55
BR/RD DG
X53
C1
1
4 C1
X60
DG/RD
18 18 18 18
LEFT
(-)
SPEAKER
DOOR
LEFT
DOOR
SPEAKER
(+)
LEFT
REAR
SPEAKER
(+) (-)
SPEAKER
REAR
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
6
S327
S326
LG/BK
18
X87
LG/RD
18
X85
2
1
LEFT
FRONT
SPEAKER
(+) (-)
SPEAKER
FRONT
LEFT
OUTPUT
12V
RADIO
LEFT
FRONT
SPEAKER
(-) (+)
SPEAKER
FRONT
LEFT
SPEAKER
DOOR
FRONT
LEFT LEFT
FRONT
DOOR
TWEETER
RADIO
12V
OUTPUT
AMPLIFIED AMPLIFIED
X60
16
DG/RD
AMPLIFIED AMPLIFIED
FRONT FRONT
XJ
J008W-7 XJD04704
7 C1
POWER
AMPLIFIER
C1
2
22 C203
6
C1
C1 8
4
C1
C1 5
2
C2
C1 1
X51
16
BR/YL
X57
16
BR/LB
X57
BR/LB BR/YL
18
X51
X53
16
DG
X55
16
BR/RD
X55
BR/RD DG
X53
DG/RD
16
X60
C1
1
4 C1
X60
DG/RD
18 18 18 18
6
C2
A
B
C2
14
X93
18
WT/RD
X93
16
BR/YL
X91
WT/BK
X91
16
BR/DB
BR/RD
X85
LG/VT
X87
12
C2
2
1
C2
4
SPEAKER
LEFT
X87
18
DG
X85
18
BR/RD
1
2
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 LEFT
REAR
SPEAKER
(+)
RADIO
AMPLIFIED AMPLIFIED
OUTPUT
12V
RADIO LEFT
FRONT
SPEAKER
(+) (-)
SPEAKER
FRONT
LEFT
LEFT
REAR
SPEAKER
(-) (+)
SPEAKER
REAR
LEFT
(+)
SPEAKER
DOOR
LEFT
DOOR
SPEAKER
(-)
LEFT
LEFT
REAR
SPEAKER
(-) (+)
SPEAKER
REAR
LEFT
3
C314 4 C305 2
1
16 20 18 14
AMPLIFIED AMPLIFIED
FRONT FRONT
8W - 47 - 5
XJD04705 J008W-7
RADIO
POWER
AMPLIFIER
C200
3
C2
C1 2 3 C1
C1
7
10
9 C1
C1
3
9
RIGHT
REAR
SPEAKER
(-)
RIGHT
REAR
SPEAKER
(+)
(+)
SPEAKER
REAR
RIGHT
4
5
C1
C1 6
RIGHT
REAR
SPEAKER
(-)
FRONT
RIGHT
SPEAKER
(-) (+)
SPEAKER
RIGHT
FRONT
X52
16
DB/WT
X58
16
DB/OR
X54
16
VT
X56
16
DB/RD
DB/RD
X56
VT
X54
DB/OR
X58
DB/WT
X52
5
18 18 18 18
5
C2
A
B
C2
13
1
C314 2
C303
10
C2
2
1
C2
11
SPEAKER
SOUNDBAR
RIGHT
(+)
SPEAKER
DOOR
RIGHT
DOOR
SPEAKER
(-)
1
2
5 4
S320
RIGHT
X94
18
TN/RD
X92
18
TN/BK
TN/BK
16
X92
TN/RD
16
X94
X82
18
LB/RD
X80
18
LB/BK
LB/BK
18
X80
LB/RD
18
X82
LB/BK
18
X80
S321
X82
18
LB/RD
X82
18
LB/RD
LB/BK
18
X80
RIGHT
(-)
SPEAKER
REAR
RIGHT
REAR
SPEAKER
(+)
RIGHT
FRONT
SPEAKER
(+) (-)
SPEAKER
FRONT
RIGHT
SPEAKER
DOOR
FRONT
RIGHT RIGHT
FRONT
DOOR
TWEETER
AMPLIFIED AMPLIFIED
AMPLIFIED AMPLIFIED
FRONT FRONT
XJ
J008W-7 XJD04706
RADIO
POWER
AMPLIFIER
C203
3
C2
C1 2 3 C1
C1
7
15
9 C1
C1
3
21
19
5
C1
C1 6
X52
16
DB/WT
X58
16
DB/OR
X54
16
VT
X56
16
DB/RD
DB/RD
X56
VT
X54
DB/OR
X58
DB/WT
X52
17
18 18 18 18
5
C2
A
B
C2
13
1
C314 2
C324
10
C2
2
1
C2
11
SPEAKER
SOUNDBAR
RIGHT
1
2
3 2
S320
X94
18
TN/RD
X92
18
TN/BK
TN/BK
16
X92
TN/RD
16
X94
X82
18
LB/RD
X80
18
LB/BK
LB/BK
18
X80
LB/RD
18
X82
LB/BK
18
X80
S321
X82
18
LB/RD
X82
18
LB/RD
LB/BK
18
X80
SPEAKER
DOOR
FRONT
RIGHT RIGHT
FRONT
DOOR
TWEETER
RIGHT
FRONT
SPEAKER
(-) (+)
SPEAKER
FRONT
RIGHT
(-)
SPEAKER
REAR
RIGHT RIGHT
REAR
SPEAKER
(+)
AMPLIFIED AMPLIFIED
(+)
SPEAKER
REAR
RIGHT
REAR
SPEAKER
(-)
RIGHT
RIGHT
(-)
SPEAKER
DOOR
RIGHT
DOOR
SPEAKER
(+)
FRONT
RIGHT
SPEAKER
(+) (-)
SPEAKER
RIGHT
FRONT
(+)
SPEAKER
REAR
RIGHT
(-)
SPEAKER
REAR
RIGHT
FRONT FRONT
AMPLIFIED AMPLIFIED
8W - 47 - 7
XJD04707 J008W-7
RADIO
OUTPUT
SWITCH
HEADLAMP
C2 4
S206
2
1
0
9
SWITCH
HEADLAMP
BATT F34
L7
18
BK/YL
SWITCH
IGNITION
FUSED
GROUND
Z9
14
BK
G108
3 4
1 PARK
2 HEAD
3 DIM
4 BRIGHT
0 OFF
42 C201
C4
S2
C4 S1
BLOCK
JUNCTION
5A
FUSE
6
FUSED
PANEL
C2 5
43
S215
E2
20
OR
E1
20
TN
L7
18
BK/YL
17
FUSE
15A
S9
C4
6 C2
RD/WT
16
X12
54
BATT M1
PK
20
M1
S214
C201
6
7 C2
B(+)
FUSED
S18
C4
RUN-ACC A31
S315
X12
16
RD/WT
M1
20
PK OR
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
18
X54
SPEAKER
DOOR
FRONT
LEFT RIGHT
FRONT
DOOR
SPEAKER
OUTPUT
(RUN-ACC)
(+) (-)
LAMPS
(-) (+)
SPEAKER SPEAKER
FRONT
RIGHT
FRONT
RIGHT
2 1 5
C303
4
X53
18
LG/BK
X82
18
LB/RD
C305
ANTENNA
X80
18
LB/BK
X55
18
LG/RD
SWITCH
DIMMER
SIGNAL
(8W-12-10)
(8W-10-18)
(8W-15-9)
(8W-50-2)
(8W-12-2)
(8W-12-8)
(8W-12-8)
(8W-12-17)
(8W-10-9) (8W-10-17)
(8W-10-18)
(8W-10-17)
(8W-12-8)
XJ
J008W-7 XJD04708
RADIO
C2 4
S206
2
1
0
9
SWITCH
HEADLAMP
BATT F34
L7
18
BK/YL
Z9
14
BK
G108
3 4
1 PARK
2 HEAD
3 DIM
4 BRIGHT
0 OFF
C4
S2
C4 S1
BLOCK
JUNCTION
5A
FUSE
6
C2 5
S215
E1
20
TN
L7
18
BK/YL
17
FUSE
15A
S9
C4
6 C2
BATT M1
S214
7 C2
S18
RUN-ACC A31
X12
16
RD/WT
M1
20
PK OR
20
E2
E2
20
OR PK
20
M1
1
16 16
17
19
DB/RD
18
X56
VT
18
X54
5
C1
1
2
C2
3
X54
VT
X56
DB/RD
C203
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
FRONT
RIGHT
FRONT
RIGHT
FUSED
B(+) LAMPS DIMMER
FUSED PANEL
GROUND
FUSED
IGNITION
SWITCH
HEADLAMP
SWITCH
OUTPUT
(-) (+) (-) (+)
5 C303
4
2 C305
1
C4
ANTENNA
X53
18
LG/BK
X82
18
LB/RD
X80
18
LB/BK LG/RD
18
X55
(8W-12-10)
(8W-10-18)
(8W-15-9)
(8W-50-2)
(8W-12-2)
(8W-12-9)
(8W-12-9)
(8W-12-18)
(8W-10-9) (8W-10-17)
(8W-10-18)
(8W-10-17)
8W - 47 - 9
XJD04709 J008W-7
RADIO
LEFT
REAR
SPEAKER(-) SPEAKER(+)
REAR
LEFT
16
LEFT
SOUNDBAR
SPEAKER
BR/LB
18
X57
BR/LB
X57
BR/YL
18
X51
BR/YL
16
X51
3 4
6
C1
B
A
C1
2 3
C1
A
B
C1
7
2
C314
1
SPEAKER
SOUNDBAR
RIGHT
X52
16
DB/WT
X58
16
DB/OR
DB/OR
18
X58
DB/WT
18
X52
RIGHT
REAR
SPEAKER(+) SPEAKER(-)
REAR
RIGHT
LHD RHD LHD RHD LHD RHD LHD RHD
22 C203 C200 6 7 C200 C203 16 9 C200 C203 21 10 C200 C203 15
X51
18
BR/YL
X57
18
BR/LB
X52
18
DB/WT
X58
18
DB/OR
4 SPEAKER SYSTEM
XJ
J008W-7 XJD04710
8W-48 REAR WINDOW DEFOGGER
Component Page
Dri ver Power Mi rror . . . . . . . . . . . . . . . . 8W-48-2, 3
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
Fuse 14 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-48-2, 3
Passenger Power Mi rror . . . . . . . . . . . . . 8W-48-2, 3
Rear Wi ndow Defogger . . . . . . . . . . . . . . 8W-48-2, 3
Rear Wi ndow Defogger Rel ay . . . . . . . . . 8W-48-2, 3
Rear Wi ndow Defogger Swi tch . . . . . . . . 8W-48-2, 3
XJ 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1
BLOCK
JUNCTION
S19
C4
10A
FUSE
12
86 30
87 85
REAR
WINDOW
DEFOGGER
RELAY
RUN A22 BATT A4
14
FUSE
10A
C4
S26 3
C9
6
5
PASSENGER
POWER
MIRROR
5
6
1
C6
2 C312
C310 3
C312
C310 2
1
DEFOGGER
WINDOW
REAR
C15
12
BK/WT
C16
20
BK/WT
3
1
SWITCH
DEFOGGER
WINDOW
REAR
DEFOGGER
ON
INDICATOR
2
Z1
20
BK
2 C201
37 C200
11 C305
ILLUM.
SWITCH
C2
4
C2 3
CLUSTER
INSTRUMENT
17
C81
20
LB/WT
G302
G107
G304
G107
S208
MIRROR
POWER
DRIVER
4 C326
C16
20
LB/YL
RELAY 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
BK
12
Z1
BK
14
Z1
C16
20
LB/YL
4
BK
18
Z1
FULL
OPTIONS MIRRORS
POWER
POWER
MIRRORS OPTIONS
FULL
BK
18
Z1
S319
Z1
16
BK
C16
20
LB/YL
C16
20
BK/WT
MIRRORS
POWER FULL
OPTIONS
S329 S329
Z1
16
BK
Z1
12
BK
E2
20
OR
FROM
S215
(8W-12-2)
(8W-12-15)
(8W-10-11)
(8W-10-16)
(8W-12-15)
(8W-40-9)
(8W-15-10)
(8W-15-8)
(8W-15-14)
(8W-15-8)
(8W-15-8)
(8W-12-2)
(8W-15-10)
(8W-15-7)
(8W-15-8)
(8W-15-7)
(8W-15-10) (8W-15-10)
(8W-12-8)
8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER
LHD
XJ
J008W-7 XJD04802
BLOCK
JUNCTION
S19
C4
10A
FUSE
12
86 30
87 85
REAR
WINDOW
DEFOGGER
RELAY
RUN A22 BATT A4
14
FUSE
10A
C4
S26 3
C9
6
5
DRIVER
POWER
MIRROR
5
6
1
C6
2 C312
C310 3
C312
C310 2
1
DEFOGGER
WINDOW
REAR
C15
12
BK/WT
C16
20
BK/WT
3
1
SWITCH
DEFOGGER
WINDOW
REAR
DEFOGGER
ON
INDICATOR
2
2 C204
11 C305
ILLUM.
SWITCH
C2
4
C2 3
CLUSTER
INSTRUMENT
C81
20
LB/WT
G302
G304
G107
S208
MIRROR
POWER
PASSENGER
4 C326
TIMER
SWITCH SENSE
BK
12
Z1 Z1
16
BK
S329
Z1
12
BK
Z1
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
BLOCK
11 C9
S5
C4
G107
Z1
16
BK
S319
Z1
16
BK
POWER
MIRRORS OPTIONS
FULL
OPTIONS
FULL POWER
MIRRORS
C16
20
LB/YL
C16 20BK/WT
Z1 20BK
OPTIONS MIRRORS
BK/WT
20
C16
LB/YL
20
C16
POWER FULL
3 C307
FROM
S215
E2
20
OR
Z1
12
BK
(8W-12-2)
(8W-12-16)
(8W-10-11)
(8W-10-16)
(8W-12-16)
(8W-40-10)
(8W-15-11)
(8W-15-14)
(8W-15-8)
(8W-15-8)
(8W-15-11)
(8W-15-11)
(8W-15-13)
(8W-15-13)
(8W-15-13)
(8W-15-8)
(8W-12-2)
(8W-15-8)
(8W-15-13)
(8W-12-9)
XJ 8W-48 REAR WINDOW DEFOGGER
RHD
8W - 48 - 3
XJD04803 J008W-7
8W-49 OVERHEAD CONSOLE
Component Page
Ambi ent Temperature Sensor . . . . . . . . . 8W-49-4, 5
Compass . . . . . . . . . . . . . . . . . . . . 8W-49-2, 3, 4, 5, 6
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 Rel ay . . . . . . . . . . . . . . . . . . . . . . . 8W-49-4, 5
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-49-2, 3, 4, 5
Overhead Modul e . . . . . . . . . . . . . 8W-49-2, 3, 4, 5, 6
XJ 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1
COMPASS
10A
FUSE
9
WT/BK
20
F87
6
Z2
20
BK/LG
12
G108
GROUND
9
BK
20
Z1
GROUND
S342
BLOCK
JUNCTION
C4
C3
S5
2
5 C301
58 C201
Z2
20
BK/LG
14
G107
S314
S208
JUNCTION
BLOCK
ST-RUN A21
S13
C4
6 C301
SWITCH
IGNITION
FUSED
Z1
14
BK
C201
Z2
20
BK/LG
OVERHEAD
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)
S361
S347
SKIM OTHERS
(FULL
OPTIONS)
F87
20
WT/BK
M1
20
PK
(8W-12-11)
(8W-15-9)
(8W-12-2)
(8W-15-8)
(8W-15-7)
(8W-15-8)
(8W-12-2)
(8W-10-10)
(8W-10-2)
(8W-10-7)
(8W-10-17)
(8W-12-2)
(8W-12-11) (8W-10-17)
(8W-15-7)
(8W-10-18)
(8W-10-18)
8W - 49 - 2 8W-49 OVERHEAD CONSOLE
LHD
XJ
J008W-7 XJD04902
COMPASS
10A
FUSE
9
WT/BK
20
F87
6
Z2
20
BK/LG
12
G108
GROUND
9
BK
20
Z1
GROUND
S342
BLOCK
JUNCTION
C4
C3
S5
2
5 C301
Z2
20
BK/LG
BK
14
Z1
G107
S208
JUNCTION
BLOCK
ST-RUN A21
S13
C4
6 C301
SWITCH
IGNITION
FUSED
Z1
14
BK
OVERHEAD
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
S216
F87
20
WT/BK
FUSED
B (+)
B (+)
FUSED
S135
OUTPUT
(ST-RUN)
S347
S361
SKIM OTHERS
M1
20
PK
(8W-12-11)
(8W-15-9)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-12-2)
(8W-10-10)
(8W-10-2)
(8W-10-7)
(8W-10-17)
(8W-12-2)
(8W-12-11)
(8W-15-7)
(8W-10-17)
(8W-10-18)
(8W-10-18)
XJ 8W-49 OVERHEAD CONSOLE
RHD
8W - 49 - 3
XJD04903 J008W-7
COMPASS
BK/RD
20
X3
10
JUNCTION
BLOCK
1
C5
GROUND
SENSOR
OVERHEAD
MODULE
DRIVER
HORN
RELAY
CONTROL
BATT A7
86
85
RELAY
HORN
7 C301
X3
20
BK/RD
1
VT/LG
20
G31
4
SWITCH
WINDOW
LOCK/
POWER
PASSENGER
C2
1
P59
20
LB/RD DB/PK
20
P55
2
C2
11 5
P55
20
DB LB/RD
20
P59
9 8
P59
20
LB/RD DB/PK
20
P55
4 3 C300
CONTROL
LOCK
DOOR
10
G32
20
BK/LB
SIGNAL
AMBIENT
TEMPERATURE
SENSOR
C301
3 4
BK/LB
20
G32 G31
20
VT/LG
32 35
C201
VT/LG
20
G31 G32
20
BK/LB
2
F15 F14
C100
BK/LB
20
G32 G31
20
VT/LG
LAMPS
COURTESY
1
YL
20
M2
7
1 C3
JUNCTION
BLOCK
S345
M2
20
YL
YL
20
M2
7 C7
1
DRIVER
M2
18
YL
A C317
S304
SENSOR
TEMPERATURE
AMBIENT
SIGNAL GROUND
SENSOR
CONTROL
RELAY
UNLOCK DOOR
LOCK
CONTROL
DOOR
CONTROL
RELAY
UNLOCK
DOOR
SWITCH
JAMB
DOOR
SENSOR
TEMPERATURE
AMBIENT
COURTESY
LAMPS
DRIVER
M2 20YL
COURTESY
LAMPS
DRIVER
(8W-12-2)
(8W-10-12)
(8W-41-2)
(8W-61-2)
(8W-12-2)
(8W-12-27)
(8W-39-6)
(8W-12-27)
8W - 49 - 4 8W-49 OVERHEAD CONSOLE
LHD
XJ
J008W-7 XJD04904
COMPASS
BK/RD
20
X3
10
JUNCTION
BLOCK
S22
C4
GROUND
SENSOR
OVERHEAD
MODULE
DRIVER
HORN
RELAY
CONTROL
BATT A7
86
85
RELAY
HORN
7
C301
X3
20
BK/RD
1
VT/LG
20
G31
4
SWITCH
WINDOW
LOCK/
POWER
PASSENGER
C2
1
P59
20
LB/RD DB
20
P55
2
C2
11 5
P55
20
DB LB/RD
20
P59
9 8
P59
20
LB/RD DB/PK
20
P55
2 1
C203
CONTROL
LOCK
DOOR DOOR
UNLOCK
CONTROL
10
G32
20
BK/LB
SIGNAL
AMBIENT
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
S304
M2
20
YL
M2
20
YL YL
20
M2
12 3
C305
P55
20
DB/PK LB/RD
20
P59
YL
20
M2
CONTROL
UNLOCK
DOOR
DOOR
LOCK
CONTROL
SENSOR
TEMPERATURE
AMBIENT
SIGNAL GROUND
SENSOR
RELAY
RELAY
SENSOR
TEMPERATURE
AMBIENT
COURTESY
LAMPS
DRIVER
COURTESY
LAMPS
DRIVER
(8W-12-2)
(8W-10-12)
(8W-41-3)
(8W-61-3)
(8W-12-2)
(8W-39-7)
(8W-12-27)
(8W-12-27)
XJ 8W-49 OVERHEAD CONSOLE
RHD
8W - 49 - 5
XJD04905 J008W-7
D1
18
VT/BR WT/BK
18
D2
3 11
DATA LINK
CONNECTOR
CCD
BUS
(-)
CCD
BUS
(+)
6 12
WT/BK
20
D2
VT/BR
20
D1
2
C301
1
S344 S346
D1
20
VT/BR
D2
20
WT/BK
WT/BK
20
D2
VT/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
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
(8W-30-20)
(8W-30-21)
8W - 49 - 6 8W-49 OVERHEAD CONSOLE XJ
J008W-7 XJD04906
8W-50 FRONT LIGHTING
Component Page
Control l er Anti -Lock Brake Rel ay . . . . . . . . 8W-50-8
Dayti me Runni ng Lamp
Modul e . . . . . . . . . . . . . . . . . 8W-50-2, 3, 5, 10, 11
Engi ne Starter Motor Rel ay . . . . . . . . . . . . 8W-50-8
Fog Lamp Rel ay No. 1 . . . . . . . . . 8W-50-6, 8, 10, 11
Fog Lamp Rel ay No. 2 . . . . . . . . . . . . . . 8W-50-9, 10
Front Fog Lamp Swi tch . . . . . . . . . . . . . 8W-50-9, 10
Fuse 3 (JB) . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 11
Fuse 4 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4
Fuse 5 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . 8W-50-6, 8, 10
Fuse 7 (PDC) . . . . . . . . . . . . . . . . . . . 8W-50-2, 5, 11
Fuse 9 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-5
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-50-11
Fuse 16 (JB) . . . . . . . . . . . . . . . . . . . 8W-50-3, 4, 11
Fuse 19 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-50-2
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
G106 . . . . . . . . . . . . . . . 8W-50-3, 4, 6, 7, 8, 9, 10, 11
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-9, 10
G108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 5
Component Page
Headl amp Beam Sel ect Swi tch . . . . . . 8W-50-3, 4, 5
Headl amp Del ay Modul e . . . . . . . . . . . . . 8W-50-2, 5
Headl amp Swi tch . . . . . . . . . . 8W-50-2, 5, 6, 7, 8, 10
I nstrument Cl uster . . . . . . . . . . . . 8W-50-3, 4, 10, 11
Juncti on Bl ock . . . . . . . . 8W-50-3, 4, 5, 6, 7, 8, 10, 11
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-50-9, 10
Left Headl amp . . . . . . . . . . . . . . . . . . . . 8W-50-3, 4
Left Si de Marker Lamp . . . . . . . . . . . . . . . 8W-50-6
Power Di stri buti on Center . . . 8W-50-2, 5, 8, 9, 10, 11
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . 8W-50-9, 10
Ri ght Front Park/Turn Si gnal
Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
Ri ght Headl amp . . . . . . . . . . . . . . . . . 8W-50-3, 4, 11
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . 8W-50-7
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . 8W-50-6, 7
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . . 8W-50-11
XJ 8W - 50 FRONT LIGHTING 8W - 50 - 1
HEADLAMP
SWITCH
1 PARK
2 HEAD
3 DOME
4 DIM
5 BRIGHT
8
0 1 2
7
5 4
POWER
DISTRIBUTION
CENTER
BATT A0
30A
FUSE
7
D1
C100
A3
14
RD/WT
A3
14
RD/WT
6
13
2
L20
14
LG/WT
A3
14
RD/WT
RD/WT
14
A3
6
MODULE
LAMP
RUNNING
DAYTIME
B(+)
FUSED
DELAY
HEADLAMP
BK
18
Z1
G108
S207
Z1
18
BK
Z1
14
BK
3 0 0 2 1 0 2 1
0 OFF
MODULE
FUSED
B(+)
GROUND
MODULE
HEADLAMP
DELAY
4
3 4
A18
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
LAMP
SWITCH
OUTPUT
HEADLAMP
BEAM
SELECT
SWITCH
TO TO
SWITCH
SELECT
BEAM
HEADLAMP
1
E1
20
TN
C201 42
LHD RHD
FUSE
6 (JB)
TO
LHD RHD
A18
E6
S218
(8W-10-2)
(8W-10-7)
(8W-10-14)
(8W-50-11)
(8W-15-9)
(8W-15-9)
(8W-50-5)
(8W-50-5)
(8W-10-18)
(8W-12-27) (8W-10-10)
(8W-10-10)
(8W-12-10)
(8W-50-5)
(8W-12-8)
(8W-12-9)
(8W-10-18)
(8W-50-4) (8W-50-4)
8W - 50 - 2 8W-50 FRONT LIGHTING XJ
J008W-7 XJD05002
A
C
B
LEFT
HEADLAMP
HEADLAMP
RIGHT
B
C
A
11 C106 4
9
C106
2
6
C106
13
L43
18
VT
L33
18
RD
L44
18
VT/RD
L34
18
RD/OR
Z1
18
BK
Z1
18
BK
C1
10
C4 S7
10A
FUSE
4 3
FUSE
10A
9
C1
10A
FUSE
16 5
FUSE
10A
C1
11 1
C1
BLOCK
JUNCTION
S3 C4
16
C201
22
L3
16
RD/OR
L4
16
VT/WT
S102 S103
16
L3
RD/OR VT/WT
16
L4
VT
20
L43
VT/RD
20
L44 L33
20
RD
L34
20
RD/OR
G106
S133
MODULE
LAMP
RUNNING
DAYTIME
FUSED
RIGHT
LOW
BEAM
OUTPUT
VT/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
16
RD/GY
CLUSTER
INSTRUMENT
5
C1
1
2
3 1
2
3
1 3
3 HIGH
2 LOW
1 FLASH
2 4
HIGH
BEAM
INDICATOR
DRIVER
DIMMER
SWITCH
HIGH
BEAM
OUTPUT
L33 20RD
SWITCH
SELECT
BEAM
HEADLAMP
L44
20
VT/RD
E
(8W-50-8)
C106 12
C106
FOG
LAMP
RELAY
NO. 1
(IN PDC)
(EXCEPT DRL)
TO
L33
20
RD/WT
(8W-12-7) (8W-12-6) (8W-12-6) (8W-12-7)
(8W-12-2)
(8W-15-6) (8W-15-6)
(8W-15-6)
(8W-50-11)
(8W-50-11)
(8W-40-11)
(8W-12-7)
XJ 8W-50 FRONT LIGHTING
LHD
8W - 50 - 3
XJD05003 J008W-7
A
C
B
LEFT
HEADLAMP
HEADLAMP
RIGHT
B
C
A
11 C106 4
9
C106
2
6
C106
13 L43
18
VT
L33
18
RD
Z1
18
BK
L44
18
VT/RD
L34
18
RD/OR
Z1
18
BK
Z1
18
BK
C1
10
C4 S7
10A
FUSE
4 3
FUSE
10A
9
C1
10A
FUSE
16 5
FUSE
10A
C1
11 1
C1
BLOCK
JUNCTION
S3 C4
L3
16
RD/OR
L4
16
VT/WT
S102 S103
16
L3
RD/OR
VT
20
L43
VT/RD
20
L44 L33
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 HIGH
2 LOW
1 FLASH
2 4
L33 20RD
SWITCH
SELECT
BEAM
HEADLAMP
DIMMER
SWITCH
HIGH
BEAM
OUTPUT
NOT
USED
C106
TO
(IN PDC)
NO. 1
RELAY
LAMP
FOG
E
(8W-50-8)
(EXCEPT DRL)
C106 12
L33
20
RD/WT
(8W-12-7) (8W-12-6) (8W-12-6) (8W-12-7)
(8W-12-2)
(8W-15-6) (8W-15-6)
(8W-15-6)
(8W-40-11)
(8W-12-7)
8W - 50 - 4 8W-50 FRONT LIGHTING
RHD
XJ
J008W-7 XJD05004
2
8
2
POWER
DISTRIBUTION
CENTER
BATT A0
30A
FUSE
7
D1 C100
A3
14
RD/WT
A3
14
RD/WT
6
13
2
HEADLAMP
DELAY
MODULE
L2
14
LG
L2
14
LG
A3
14
RD/WT
B(+)
FUSED
RD/WT
14
A3
6
B(+)
FUSED
FUSED
IGNITION
SWITCH
C4
S13
BLOCK
JUNCTION
9
FUSE
10A
ST-RUN A21
BK
18
Z1
G108
S207
Z1
18
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
F87
20
WT/BK
8
LHD RHD
SWITCH
SELECT
BEAM
HEADLAMP
HEAD-
LAMP
SWITCH
OUTPUT
OUTPUT
(ST-RUN)
(8W-10-2)
(8W-10-7)
(8W-10-14)
(8W-12-2)
(8W-12-11)
(8W-10-10)
(8W-15-9)
(8W-15-9)
(8W-12-11)
(8W-50-2)
(8W-50-2)
(8W-50-11)
(8W-12-11)
(8W-50-3)
(8W-50-4)
XJ 8W-50 FRONT LIGHTING 8W - 50 - 5
XJD05005 J008W-7
1
3
2
2
3
1
1
2
LAMP
MARKER
SIDE
LEFT
11 C106
S104
Z1
18
BK
L77
18
BR
L77
18
BR
L77
20
BR
L61
18
LG
L61
18
LG
L61
20
LG
C2
6
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
S158
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
3
C100 B10
L61
20
LG/WT
10
S209
L61
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 RHD
LEFT
TURN
SIGNAL
F4
RHD
LHD
NO. 1
LAMP
SIGNAL
TURN
PARK/
FRONT
LEFT
NO. 2
LAMP
SIGNAL
TURN
PARK/
FRONT
LEFT
S103
BK
18
Z1
Z1
18
BK
B9
(8W-12-10)
(8W-12-2)
(8W-15-6)
(8W-12-10)
(8W-50-2)
(8W-10-18)
(8W-52-3)
(8W-52-2)
(8W-50-8)
(8W-50-10)
(8W-15-6)
(8W-12-10)
(8W-15-6)
8W - 50 - 6 8W-50 FRONT LIGHTING XJ
J008W-7 XJD05006
1 2
PARK/
RIGHT
2 1
3
LAMP
SIGNAL
TURN
3
C106
4
S100
S101
RIGHT
SIDE
MARKER
LAMP
2
1
Z1
18
BK
Z1
18
BK
L78
18
DG/YL
L78
18
DG/YL
L78
20
DG/YL
L78
20
DG/YL
L60
18
TN
L60
18
TN
L60
20
TN
L60
20
TN
C4 M3
BLOCK
JUNCTION
S102
TURN
SIGNAL
LAMP
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
L60
LHD RHD
BK/YL
18
L7
BK
20
Z1
14 C106
DG/YL
20
L78
RIGHT
TURN
SIGNAL
F3
FRONT FRONT
NO. 1 NO. 2
LHD
RHD
Z1 18BK
(8W-12-2)
(8W-15-6)
(8W-12-22)
(8W-15-6)
(8W-12-10)
(8W-50-2)
(8W-10-18)
(8W-52-4)
(8W-52-2)
XJ 8W-50 FRONT LIGHTING 8W - 50 - 7
XJD05007 J008W-7
POWER
DISTRIBUTION
CENTER
NO. 1
RELAY
LAMP
FOG
B10 B6
B9 B8
E
(8W-50-3)
C106
FROM
L33
20
RD/WT
C10 B19
(IN PDC)
RELAY
BRAKE
ANTI-LOCK
CONTROLLER
(IN PDC)
RELAY
MOTOR
STARTER
ENGINE
Z1
16
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
Z1
20
BK
S132
G106
(4.0L
ABS)
EXCEPT ABS)
(4.0L LHD M/T
(2.5L)
EXCEPT ABS)
G
(8W-50-9)
A5 C100
L139
20
VT
L139
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
20
L77
L7
18
BK/YL
Z1
20
BK
F
(8W-50-9)
FOG
LAMP
RELAY
NO. 2
(IN PDC)
FROM
(4.0L A/T
2 HEAD
1 PARK
Z1
20
BK
Z1
20
BK
GROUND GROUND
Z1
20
BK
(8W-10-2)
(8W-35-3) (8W-21-5)
(8W-15-3)
(8W-15-4)
(8W-15-5)
(8W-15-6)
(8W-12-10)
(8W-10-18)
(8W-50-2)
(8W-12-10)
(8W-12-10)
(8W-12-2)
(8W-50-4)
EXCEPT DRL
XJ
J008W-7 XJD05008
C100 A4
PK
20
L92
BK
20
Z1
BK
14
Z1
C106 8
LB
20
L39
LB
20
L39
S208
G107
LB
20
L39
BATT F61
4
1
Z1
20
BK/WT
Z1
20
BK
L39
20
LB
L39
20
LB
ON
INDICATOR
SWITCH
ILLUM.
NO. 2
RELAY
LAMP
FOG
B15 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
FOG LAMP
G
(8W-50-8)
FROM
(IN PDC)
RELAY NO. 1
FOG LAMP
L139
20
VT
Z1
18
BK
(8W-15-8)
(8W-15-8)
(8W-10-20)
(8W-15-6)
(8W-15-6) (8W-15-6)
(8W-10-2)
EXCEPT DRL
8W - 50 - 9
XJD05009 J008W-7
11
C106
4
Z1
18
BK
Z1
18
BK
S102 S103
G106
1
2
LAMP
FOG
LEFT
2
1
RIGHT
FOG
LAMP
Z1
20
BK
Z1
20
BK
S106
3
2
SWITCH
LAMP
FOG
FRONT
B13 B12
B11 B15
POWER
DISTRIBUTION
CENTER
FOG
LAMP
RELAY
NO. 2
NO. 1
RELAY
LAMP
FOG
B10 B6
B9 B8
ILLUM.
SWITCH
INDICATOR
ON
C2
6
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
2
1
0
9
SWITCH
HEADLAMP
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
S206
45 C201
BK/YL
18
L7
L7
18
BK/YL
LB
20
L39
LB
20
L39
BK
20
Z1
BK/WT
20
Z1
1
4
BATT F61
L39
20
LB
L77
20
BR/YL RD/GY
S208
L39
20
LB
L39
20
LB
8 C106
L139
20
VT
L139
20
VT
A5 C100
Z1
20
BK
Z1 20BK
Z1
14
BK
Z1
20
BK
L92
20
PK
A4 C100
RD/GY
16
G34 G34
16
4
MODULE
LAMP
RUNNING
DAYTIME
G107
CLUSTER
INSTRUMENT
C100 D4
G34
16
RD/GY
HIGH
BEAM
INDICATOR
DRIVER
DRIVER
INDICATOR
BEAM
HIGH
5
C1
G106
Z1
16
BK
S132
C106 7
L77
20
BR/YL
L77
20
BR
TO
S104
(8W-15-6) (8W-15-6)
(8W-15-6)
(8W-10-2)
(8W-12-10)
(8W-12-2)
(8W-50-2)
(8W-10-18)
(8W-12-10)
(8W-10-20)
(8W-15-8)
(8W-50-11)
(8W-15-8)
(8W-40-11)
(8W-15-6)
(8W-15-3)
(8W-15-4)
(8W-12-10)
DRL
XJ
J008W-7 XJD05010
MODULE
LAMP
RUNNING
DAYTIME
GROUND
8
G106
6
FUSED
B(+)
5
SWITCH
IGNITION
FUSED
OUTPUT
BEAM
HIGH
SWITCH
1
DIMMER
A3
14
RD/WT
F20
18
WT
F20
18
WT
D3 C100
L3
16
RD
POWER
DISTRIBUTION
CENTER
13
6
30A
FUSE
7
BATT A0
S12
C4
10
FUSE
15A
JUNCTION
BLOCK
ST-RUN A21
HEADLAMP
RIGHT
Z12
16
BK/TN
S213
16 C201
C4 S7
BLOCK
JUNCTION
10A
FUSE
3 16
FUSE
10A
SIGNAL
SENSOR
SPEED
VEHICLE
7
S108
4 C107
3
VEHICLE
SENSOR
G7
20
WT/OR
G7
18
WT/OR
G7
20
WT/OR
4
DRIVER
BEAM
INDICATOR
HIGH
RD/GY
16
G34
B10
(IN PDC)
NO. 1
RELAY
LAMP
FOG
D4 C100
C1 5
CLUSTER
INSTRUMENT
G34
16
RD/GY
G34
16
RD/GY
SPEED
VT/RD
18
L44
S133
10
L44
20
VT/RD
13 C106
VT/RD
18
L44
FUSED
RIGHT
LOW
BEAM
OUTPUT
B
SENSOR
SPEED
VEHICLE
HIGH
BEAM
INDICATOR
DRIVER
L3
16
RD/OR
SIGNAL
FUSED
RIGHT
LOW
BEAM
OUTPUT
OUTPUT
1 C201
C100 E9
S159
B13
(ST-RUN)
WT
18
F20
L3
16
RD/OR
RD/OR
16
L3
(8W-15-6)
(8W-10-2)
(8W-10-14)
(8W-10-7)
(8W-12-12)
(8W-12-2)
(8W-50-3)
(8W-50-3)
(8W-12-2)
(8W-12-6) (8W-12-6)
(8W-30-12)
(8W-30-12)
(8W-50-10)
(8W-40-11)
(8W-12-7)
(8W-12-12)
(8W-10-10)
DRL
8W - 50 - 11
XJD05011 J008W-7
8W-51 REAR LIGHTING
Component Page
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-51-6
Center Hi gh Mounted Stop Lamp . . . . . . . . 8W-51-4
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
Fuse 10 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
Fuse 23 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
Fuse 23 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-51-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 5, 7
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 5, 7
G304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-51-2, 6
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . 8W-51-7
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . 8W-51-3
Component Page
Left Turn Si gnal Lamp . . . . . . . . . . . . . . . . 8W-51-5
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-51-4
Powertrai n Control Modul e . . . . . . . . . . . . 8W-51-6
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . . 8W-51-7
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . . 8W-51-3
Ri ght Turn Si gnal Lamp . . . . . . . . . . . . . . . 8W-51-5
Trai l er Tow Connector . . . . . . . . . . . . . 8W-51-3, 5, 7
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . . 8W-51-5
XJ 8W - 51 REAR LIGHTING 8W - 51 - 1
L77
18
BR/YL
L78
18
DG/YL
C7
2
C4 M3
10A
FUSE
7
BLOCK
JUNCTION
6
C7
23
FUSE
10A
L7
18
BK/YL
S206
2
1
0
9
SWITCH
HEADLAMP
1 PARK
2 HEAD
0 OFF
BATT F34
L7
18
BK/YL
5
6
BRAKE
LAMP
SWITCH
15A
FUSE
23
POWER
DISTRIBUTION
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/YL
18
L78
24 C200 24 C204
LHD RHD
LHD RHD
C201 45
4
(8W-12-10)
(8W-12-2)
(8W-12-22)
(8W-12-10)
(8W-50-2)
(8W-10-18)
(8W-33-3)
(8W-10-20)
(8W-10-2)
(8W-10-7)
(8W-10-20)
(8W-51-4) (8W-51-4)
8W - 51 - 2 8W-51 REAR LIGHTING XJ
J008W-7 XJD05102
3
1
2 LEFT
TAIL/
STOP
LAMP
2 3
1
L77
18
BR/YL
L78
18
DG/YL
Z1
18
BK
LAMP
STOP
TAIL/
RIGHT
G302
S309
BK
18
Z1
S310
G303
S341
8
TRAILER
TOW
CONNECTOR
Z1
14
BK
Z1
14
BK
Z1
12
BK
S348
2 C321
S337
S302
C321 6
C322 6
A
(8W-51-2)
B
(8W-51-2)
C
(8W-51-2)
WT/TN
20
L50
S203
FROM
FROM
FUSE
23 (JB)
7 (JB)
FUSE
FROM
Z1
18
BK
Z1
18
BK
L77
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 C322
C323 2
S340
OTHER TRAILER TOW
C323 6
S336
Z1
18
BK
RHD LHD
BK
12
Z1
BK
16
Z1
S311
Z1
14
BK
(8W-15-10)
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-12)
(8W-15-13)
(8W-15-10)
(8W-15-11)
(8W-54-2)
(8W-15-12)
(8W-15-13)
(8W-10-20)
(8W-15-10)
(8W-15-11)
(8W-12-10)
(8W-54-3)
(8W-12-10)
XJ 8W-51 REAR LIGHTING 8W - 51 - 3
XJD05103 J008W-7
S203
FROM
FROM
7 (JB)
FUSE
WT/TN
20
L50
BR/YL
18
L77
A
(8W-51-2)
C
(8W-51-2)
S302
MOUNTED
CENTER
HIGH
STOP
LAMP
2
1
G304
Z1
18
BK
5 C326
2
1
LICENSE
LAMP
S334
9 C310
C311 6
Z1
18
BK
S311
2
C310
C311 4
11
BK
18
Z1
BK
18
Z1
BR/YL
18
L77
WT/TN
20
L50
L77
18
BR/YL
BR/YL
18
L77
L50
18
WT/TN
C327
1 C333
L50
18
DG/WT
C333 2
Z1
18
BK
1 C330
L78
18
BK/YL
C330 2
Z1
18
BK
(8W-10-20)
(8W-15-14)
(8W-15-14)
(8W-12-10)
J008W-7 XJD05104
9 3
SWITCH
HAZARD
SIGNAL/
TURN
1
2
LAMP
SIGNAL
TURN
LEFT
RIGHT
TURN
SIGNAL
LAMP
2
1
L62
20
BR/RD
S312
L63
20
DG/RD
C321 1
Z1
18
BK
G302
S309
BK
18
Z1
BK
16
Z1
S310
G303
S341
8
TRAILER
TOW
CONNECTOR
Z1
14
BK
Z1
14
BK
Z1
12
BK
OTHERS TRAILER TOW
S348
2 C321
BK
18
Z1
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
2 C322
Z1
18
BK
Z1
12
BK
RHD LHD
L63
20
DG/RD
Z1
14
BK
(8W-52-2)
(8W-70-2)
(8W-15-10)
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-12)
(8W-15-13)
(8W-15-10)
(8W-15-11)
(8W-54-2)
(8W-15-12)
(8W-15-13)
(8W-54-3)
(8W-15-10)
(8W-15-11)
XJD05105 J008W-7
B
A
BACK-UP
LAMP
BLOCK
JUNCTION
ST-RUN A21
6
TRANSMISSION
RANGE
SENSOR
L10
18
BR/LG
S142
LHD RHD
23 C204
16 C200
E3
C100
12 C107
L10
18
BR/LG
L10
18
BR/LG
NEUTRAL
PARK/
1
3
POSITION
SWITCH
4.0L M/T 2.5L A/T
TO
S303
D
(8W-51-7)
BR/LG
18
L10
3
LHD RHD
R
R R
10
FUSE
15A
S12
C4
F20
18
WT
1 C201
F20
18
WT
C100
A9
E9
4.0L 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
CONTROL
TRANSMISSION
BACK-UP
LAMP
FEED
11 C107
F20
18
WT
SWITCH
F20
18
WT
WT
18
F20
C113 1
C113 2
BR/LG
18
L10
4.0L M/T 2.5L A/T
11 C107
2.5L M/T
12 C107
2.5L M/T
SOLENOID
CLUTCH
TORQUE
CONVERTER
(8W-12-2)
(8W-10-10)
(8W-31-6)
(8W-12-12)
(8W-30-15)
(8W-12-12)
(8W-31-6)
(8W-31-2)
(8W-31-2)
J008W-7 XJD05106
1
2
2
1
Z1
18
BK
G302
S309
BK
18
Z1
BK
12
Z1
S310
G303
S341
Z1
14
BK
Z1
12
BK
OTHER
TRAILER
TOW
S348
2 C321
LAMP
BACK-UP
LEFT
RIGHT
BACK-UP
LAMP
S303
5 C321
Z1
18
BK
BR/LG
18
L10
BR/LG
18
L10
D
(8W-51-6)
BR/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 14BK
Z1
14
BK
(8W-15-10)
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-15-12)
(8W-15-13)
(8W-15-10)
(8W-15-11)
(8W-15-12)
(8W-15-13)
(8W-54-2)
(8W-54-2)
(8W-15-10)
(8W-15-11)
XJD05107 J008W-7
8W-52 TURN SIGNALS
Component Page
Fuse 12 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
Fuse 20 (PDC) . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
G106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3, 4
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . . . 8W-52-2
Component Page
Ri ght Si de Marker Lamp . . . . . . . . . . . . . . 8W-52-4
Ri ght Turn Si gnal Lamp . . . . . . . . . . . . . . . 8W-52-4
XJ 8W - 52 TURN SIGNALS 8W - 52 - 1
1 10
L61
20
LG/WT
L60
20
TN
SWITCH
HAZARD
SIGNAL/
TURN
(PART OF
MULTI-
FUNCTION
SWITCH)
1
3
COMBINATION
FLASHER
5
2
4
C4
S20
BLOCK
JUNCTION
10A
FUSE
12
POWER
DISTRIBUTION
CENTER
20
FUSE
15A
A15
A16
BATT A0
B11
C100
L5
20
BK
L9
20
BK/PK
S208
G107
Z1
20
BK
Z1
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)
B
(8W-52-3)
C
(8W-52-4)
D
(8W-52-3)
C200
C204
TO TO
C204
C200
TO
S212
TO
S209
BK/PK
20
L9
BK
20
L5
F5
OUTPUT
SIGNAL
LHD
RHD
RUN A22
(RUN)
(8W-12-2)
(8W-12-15)
(8W-12-16)
(8W-10-2)
(8W-10-19)
(8W-10-7)
(8W-15-8)
(8W-15-8)
(8W-10-11)
8W - 52 - 2 8W-52 TURN SIGNALS XJ
J008W-7 XJD05202
1
3
2
LEFT
PARK/
TURN
SIGNAL
LAMP
2
3
1
1
2
LAMP
MARKER
SIDE
LEFT
11 C106
Z1
18
BK
Z1
18
BK
L77
18
BR
L77
18
BR
20
BR
L61
18
LG
L61
18
LG
L61
20
LG
S158
LAMP
SIGNAL
TURN
PARK/
LEFT
G106
3
C100
B10
L61
20
LG/WT
S209
L61
20
LG/WT
S105
LG
20
L61
L61
20
LG/WT
C106
BK/WT
20
Z1
S104
L77
B
(8W-52-2)
FROM
SWITCH
HAZARD
SIGNAL/
TURN TURN
SIGNAL/
HAZARD
SWITCH
FROM
D
(8W-52-2)
DG/RD
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
LEFT
TURN
SIGNAL
Z1
14
BK
S335
TRAILER
TOW OTHER
L63
20
DG/RD
L63
20
DG/RD
L63
20
DG/RD
L63
20
DG/RD
L63
20
DG/RD
F4
FRONT FRONT
NO. 2 NO. 1
S103
1 C323
C322 2
C323 2
LHD
RHD
Z1
18
BK
Z1
14
BK
(8W-15-6)
(8W-12-10)
(8W-15-10)
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-40-11)
(8W-15-10)
(8W-15-11)
(8W-54-3)
(8W-15-6)
(8W-50-6)
(8W-15-6)
XJ 8W-52 TURN SIGNALS 8W - 52 - 3
XJD05203 J008W-7
1 2
PARK/
RIGHT
2 1
3
LAMP
SIGNAL
TURN
3
C106 4
S100
RIGHT
SIDE
MARKER
LAMP
2
1
Z1
18
BK
Z1
18
BK
L78
18
DG/YL
L78
18
DG/YL
L78
20
DG/YL
L60
18
TN
L60
18
TN
L60
20
TN
L60
20
TN
S102
TURN
SIGNAL
LAMP
RIGHT
PARK/
G106
C106 10
C100
B9
TN
20
L60
S212
L60
20
TN
TN
20
L60
BK
20
Z1
C
(8W-52-2)
A
(8W-52-2)
BR/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
SWITCH
FROM
S101
LAMP
SIGNAL
TURN
RIGHT
L60
20
TN
C2 6
CLUSTER
INSTRUMENT
RIGHT
TURN
SIGNAL
Z1
12
BK
RHD LHD
F3
FRONT FRONT
NO. 1 NO. 2
LHD
RHD
Z1 18BK
(8W-15-6)
(8W-15-6)
(8W-70-2)
(8W-15-12)
(8W-15-13)
(8W-15-12)
(8W-15-13)
(8W-15-12)
(8W-15-13)
(8W-50-7)
(8W-40-11)
(8W-50-7)
8W - 52 - 4 8W-52 TURN SIGNALS XJ
J008W-7 XJD05204
8W-53 WIPERS
Component Page
A/C- Heater Control . . . . . . . . . . . . . . . . . . 8W-53-4
Front Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-53-2
Fuse 6 (JB) . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4
Fuse 22 (JB) . . . . . . . . . . . . . . . . . . . . . . 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
Headl amp Swi tch . . . . . . . . . . . . . . . . . . 8W-53-3, 4
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . 8W-53-2, 3, 4
Rear Washer Pump . . . . . . . . . . . . . . . 8W-53-2, 3, 4
Rear Wi per Motor . . . . . . . . . . . . . . . . . . 8W-53-3, 4
Rear Wi per/Washer Swi tch . . . . . . . . . . . 8W-53-3, 4
Wi ndshi el d Washer Pump . . . . . . . . . . 8W-53-2, 3, 4
Wi per Motor Rel ay . . . . . . . . . . . . . . . . . . . 8W-53-2
XJ 8W - 53 WIPERS 8W - 53 - 1
C4
M4
BLOCK
JUNCTION
5
4
SWITCH
WASH
WIPE/
INTERMITTENT WIPER
LOGIC
0
1 2
3
1 3
MAX
MIN
4
2 6
V6
16
DB
V10
18
BR
Z1
16
BK
V5
16
DG/YL
V4
16
BR/VT
V3
16
BR/WT
A
B
2
S132
C1
C100
C3
C5
6
4
M
2
RUN
PARK
5
MOTOR
WIPER
FRONT
S207
G108
Z1
18
BK
RELAY
MOTOR
WIPER
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
BK
14
Z1
BR/WT
16
V3
BR/VT
16
V4
DG/YL
16
V5
OTHER
Z1 18BK
C100
E4
Z1
16
BK
GROUND
LHD 4.0L 2.5L
A16
RHD
LHD
OTHER
M
(8W-12-2)
(8W-15-3)
(8W-15-5)
(8W-15-9)
(8W-15-9)
(8W-12-25)
(8W-15-6)
(8W-15-4)
(8W-15-5)
(8W-53-3)
(8W-53-4)
(8W-10-9)
8W - 53 - 2 8W-53 WIPERS XJ
J008W-7 XJD05302
C4
S11
20A
FUSE
22
BLOCK
JUNCTION
RUN A22
39 C201
V23
18
BR/PK
6
SWITCH
WASHER
WIPER/
REAR
5
2
0 1
1
G107
Z1
20
BK
4
1
MOTOR
WIPER
REAR
V13
18
BR/LG
V20
18
BK/WT
V23
18
BR/PK
29
4
2
7
S208
Z1
14
BK
2 4
REAR WIPER MODULE
3
1 2
M
1
2
PUMP
WASHER
REAR
G304
S334
9 C310
C311 6
B
PUMP
WASHER
WINDSHIELD
Z1
18
BK
Z1
18
BK
G106
S132
Z1
16
BK
C200
27 S205
3
C327
E5 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
HEADLAMP
JUNCTION
BLOCK
6
FUSE
5A
S1 C4
S2
C4
E1
20
TN
E1
20
TN
S215
43
C201
E2 20OR
42
S315
V23
18
BR/PK
V13
18
BR
V20
18
BK/WT
V23
18
BR/PK
V13
18
BR/LG
V20
18
BK/WT
M
(8W-12-20)
(8W-12-2)
(8W-10-11)
(8W-15-8)
(8W-15-8)
(8W-15-14)
(8W-15-14)
(8W-53-2)
(8W-15-6)
(8W-15-3)
(8W-15-4)
(8W-15-6)
(8W-50-2)
(8W-12-2)
(8W-12-8)
(8W-12-8)
(8W-12-8)
XJ 8W-53 WIPERS
LHD
8W - 53 - 3
XJD05303 J008W-7
C4
S11
20A
FUSE
22
BLOCK
JUNCTION
RUN A22
V23
18
BR/PK
5
SWITCH
WASHER
WIPER/
REAR
6
2
0 1
1
G107
Z1
20
BK
4
1
MOTOR
WIPER
REAR
V13
18
BR/LG
V20
18
BK/WT
V23
18
BR/PK
6
4
2
7
S208
Z1
14
BK
2 4
REAR WIPER MODULE
3
1 2
M
1
2
PUMP
WASHER
REAR
G304
S334
9 C310
C311 6
B
PUMP
WASHER
WINDSHIELD
Z1
18
BK
G106
S132
Z1
16
BK
7 S205
3
E5 C100
2
C203 5
C327
5
2 WIPE
1 WASH
0 OFF
1
2
0
1 PARK
2 RUN
BK/WT
18
V20 1
8
3
1
C310
C313
Z1
18
BK
GROUND
V13
18
BR/LG
V23
18
BR/PK
V20
18
BK/WT
3
Z1
18
BK
1
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL
SWITCH
HEADLAMP
JUNCTION
BLOCK
6
FUSE
5A
S1 C4
S2
C4
E1
20
TN
E1
20
TN
A/C-
HEATER
CONTROL
7
S215
E2
20
OR
FUSED
PANEL
LAMPS
DIMMER
SWITCH
SIGNAL
V23
18
BR/PK
V13
18
BR
V20
18
BK/WT
C1
S324
BASE
FULL
OPTIONS
V20
18
BK/WT
M
(8W-12-21)
(8W-12-2)
(8W-10-11)
(8W-15-8)
(8W-15-8)
(8W-15-14)
(8W-15-14)
(8W-53-2)
(8W-15-6)
(8W-15-5)
(8W-50-2)
(8W-12-2)
(8W-12-9)
(8W-42-5)
(8W-12-9)
(8W-12-21)
8W - 53 - 4 8W-53 WIPERS
RHD
XJ
J008W-7 XJD05304
8W-54 TRAILER TOW
Component Page
Fuse 7 (JB) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Fuse 20 (JB) . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . . 8W-54-3
Component Page
Trai l er Tow Connector . . . . . . . . . . . . . . . 8W-54-2, 3
Trai l er Tow El ectri c Brake Provi si on . . . . . 8W-54-2
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . . 8W-54-3
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . . 8W-54-3
XJ 8W - 54 TRAILER TOW 8W - 54 - 1
BLOCK
JUNCTION
TRAILER
TOW
CONNECTOR
8
G302
S309
2 C323
Z1
14
BK
S337
Z1
12
BK
7
FUSE
10A
C7
2
RHD
C201 45
LHD
BK/YL
18
L7
BATT F34
0 OFF
2 HEAD
1 PARK
HEADLAMP
SWITCH
9
0
1
2
S206
BK/YL
18
L7
C4 M3
5
L77
18
BR/YL
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
PROVISION
BACK-UP
LAMP
FEED
4
L10
18
BR/LG
(8W-12-2)
(8W-15-10)
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-15-10)
(8W-15-11)
(8W-12-10)
(8W-10-18)
(8W-50-2)
(8W-12-10)
(8W-12-10)
(8W-12-10)
(8W-51-7)
(8W-51-7)
8W - 54 - 2 8W-54 TRAILER TOW XJ
J008W-7 XJD05402
C7
8
BLOCK
JUNCTION
15A
FUSE
20
5
3
5
3
2 10
TRAILER TOW CONNECTOR
BATT A7
4
L73
20
YL
L74
20
LG
A6
20
RD/OR
3 C323
2
1
2
8
S336
6
L50
20
WT/TN
C322 6
3
LAMP
STOP
TAIL/
LEFT
3
SWITCH
HAZARD
SIGNAL/
TURN
LHD
25 C200
RHD
C204 11
L62
20
BR/RD
C323
1
S335
C323 1
C323
BK/RD
20
L62
S312
DG/RD
20
L63
12 C204
RHD
C200 26
LHD
TURN
SIGNAL/
HAZARD
SWITCH
9
L63
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
WT/TN
DG/RD
20
L63
TRAILER
TOW
LEFT
TURN
RELAY
RELAY
TURN
RIGHT
TOW
TRAILER
LEFT
TURN
SIGNAL SIGNAL
TURN
RIGHT
BRAKE
LAMP
SWITCH
OUTPUT
LEFT
TURN
SIGNAL
BRAKE
LAMP
SWITCH
SIGNAL
S338
S302
L62
20
BR/RD
(8W-12-2)
(8W-12-19)
(8W-10-12)
(8W-51-3)
(8W-52-2)
(8W-70-2)
(8W-52-2)
(8W-52-3)
(8W-10-20)
(8W-33-3)
(8W-12-19)
(8W-10-20)
XJ 8W-54 TRAILER TOW 8W - 54 - 3
XJD05403 J008W-7
8W-60 POWER WINDOWS
Component Page
Ci rcui t Breaker 28 (JB) . . . . . . . . . . . . . . 8W-60-2, 3
Dri ver Power Lock/Wi ndow
Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3, 4, 5
Dri ver Power Wi ndow Motor . . . . . . . . . . 8W-60-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 4
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3, 5
Juncti on Bl ock . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
Component Page
Left Rear Wi ndow Motor . . . . . . . . . . . . . 8W-60-4, 5
Left Rear Wi ndow Swi tch . . . . . . . . 8W-60-2, 3, 4, 5
Passenger Power Wi ndow Motor . . . . . . . 8W-60-2, 3
Ri ght Rear Wi ndow Motor . . . . . . . . . . . . 8W-60-4, 5
Ri ght Rear Wi ndow Swi tch . . . . . . . 8W-60-2, 3, 4, 5
XJ 8W - 60 POWER WINDOWS 8W - 60 - 1
C1 C1 C1 C1 C1 C2
C1
3 6 5 12 8 8
3 4
2 1 2 1 2 1 1
9
2
SWITCH
WINDOW
LOCK/
POWER
DRIVER
4 UNLOCK
3 LOCK
2 DOWN
1 UP
25A
28
BREAKER
CIRCUIT
C5
8
RUN-ACC A31
BLOCK
JUNCTION
13 C201
C200 33
1 C307
BR
14
Q12
2 1
VT
14
Q22
MOTOR
WINDOW
POWER
PASSENGER
3
2 9
4
2 1
10
1 2
DRIVER
POWER
WINDOW
MOTOR
Q21
14
WT
Q11
14
LB
M
1
3
BR/WT
14
Q16 Q26
14
VT/WT
4
C306
2
Z1
14
BK
S329
Z1
12
BK
3
C307
S309
Z1
12
BK
Z1
12
BK
G302
6
SWITCH
WINDOW
REAR
RIGHT LEFT
REAR
WINDOW
SWITCH
6
2
Q1
14
YL
S305
YL
14
Q1
3 C304
Q1
14
YL YL
14
Q1
C309 3
Q1
14
YL
Q1
14
YL
Q1
14
YL
1 UP
2 DOWN
3 LOCK
4 UNLOCK
PASSENGER
POWER
LOCK/
WINDOW
SWITCH
C1 C1
C1 C1 C1
C303
3
POWER
WINDOW
SWITCH
FEED FEED
SWITCH
WINDOW
POWER
F81 14TN
F81 12TN
F81
12
TN
M
(8W-12-23)
(8W-10-9)
(8W-12-2)
(8W-15-10)
(8W-15-10)
(8W-15-10)
(8W-60-4) (8W-60-4)
8W - 60 - 2 8W-60 POWER WINDOWS
LHD
XJ
J008W-7 XJD06002
C1 C1 C1 C1 C1 C2
C1
5 12 3 6 8 8
3 4
2 1 2 1 2 1 1
9
2
SWITCH
WINDOW
LOCK/
POWER
DRIVER
4 UNLOCK
3 LOCK
2 DOWN
1 UP
25A
28
BREAKER
CIRCUIT
C8
1
RUN-ACC A31
BLOCK
JUNCTION
F81
14
TN
BR
14
Q12
2 1
VT
14
Q22
MOTOR
WINDOW
POWER
PASSENGER
3
2 9
4
2 1
10
1 2
DRIVER
POWER
WINDOW
MOTOR
Q21
14
VT
Q11
14
BR
M
3
BR/WT
14
Q16 Q26
14
VT/WT
4
C306
Z1
14
BK
S319
Z1
14
BK
S310
G303
6
SWITCH
WINDOW
REAR
RIGHT
LEFT
REAR
WINDOW
SWITCH
6
Q1
14
YL
S305
3 C304
Q1
14
YL
YL
14
Q1
C309 3
Q1
14
YL
1 UP
2 DOWN
3 LOCK
4 UNLOCK
PASSENGER
POWER
LOCK/
WINDOW
SWITCH
C1 C1
C1 C1 C1
8
7
Z1
12
BK
Q1
14
YL
C307 2
C303
M
Q16
14
BR/WT
Q26
14
VT/WT
4
Q1
14
YL
POWER
WINDOW
SWITCH
FEED
POWER
WINDOW
SWITCH
FEED
5
C303
YL
14
Q1
YL
14
Q1
(8W-12-24)
(8W-10-9)
(8W-12-2)
(8W-15-13)
(8W-15-13)
(8W-15-13)
(8W-60-5)
(8W-60-5)
XJ 8W-60 POWER WINDOWS
RHD
8W - 60 - 3
XJD06003 J008W-7
2 DOWN
1 UP
2 DOWN
1 UP
S305
Q27
14
RD/BK
Q17
14
DB/WT
DB/WT
14
Q17
RD/BK
14
Q27
DG/WT
14
Q28
GY/BK
14
Q18
YL
14
Q1
6
5
C309
3 2
1
1 5
Q23
14
RD/WT
Q13
14
DB
6 4 2
SWITCH
WINDOW
REAR
LEFT
1 2
1 2
LEFT
REAR
WINDOW
MOTOR
GY/BK
14
Q18
1
1
Q28
14
DG/WT
2
C306
2
Z1
14
BK
S329
3
C307
S309
Z1
12
BK
G302
2
Q1
14
YL
YL
14
Q1
3
C304
Q1
14
YL
MOTOR
WINDOW
REAR
RIGHT
2 1
2 1
RIGHT
REAR
WINDOW
SWITCH
2 4 6
RUN-ACC F81
C1 C1 C1 C1 C1 C2
2 1 4 10 8 8
3 4
2 1 2 1 2 1 1 2
SWITCH
WINDOW
LOCK/
POWER
DRIVER
4 UNLOCK
3 LOCK
2 DOWN
1 UP
GY
14
Q14
DG
14
Q24
5 1
M M
Z1
12
BK
(8W-60-2)
(8W-15-10)
(8W-15-10)
(8W-15-10)
(8W-12-23)
8W - 60 - 4 8W-60 POWER WINDOWS
LHD
XJ
J008W-7 XJD06004
2 DOWN
1 UP
2 DOWN
1 UP
S305
Q27
14
RD/BK
Q17
14
DB/WT
DB/WT
14
Q17
RD/BK
14
Q27
DG/WT
14
Q28
GY/BK
14
Q18
YL
14
Q1
6
3
C309
3 2
1
1 5
Q23
14
RD/WT
Q13
14
DB
6 4 2
SWITCH
WINDOW
REAR
LEFT
1 2
1 2
LEFT
REAR
WINDOW
MOTOR
GY/BK
14
Q18
1
1
Q28
14
DG/WT
2
2
Z1
14
BK
S319
S310
Z1
12
BK
G303
Q1
14
YL
3
C304
Q1
14
YL
MOTOR
WINDOW
REAR
RIGHT
2 1
2 1
RIGHT
REAR
WINDOW
SWITCH
2 4 6
RUN-ACC F81
C1 C1 C1 C1 C1 C2
2 1 4 10 8 8
3 4
2 1 2 1 2 1 1 2
SWITCH
WINDOW
LOCK/
POWER
DRIVER
4 UNLOCK
3 LOCK
2 DOWN
1 UP
GY
14
Q14
DG
14
Q24
5 1
BK
14
Z1
M M
YL
14
Q1
Z1
14
BK
4 5
C303
(8W-60-3)
(8W-15-13)
(8W-15-13)
(8W-15-13)
(8W-12-24)
XJ 8W-60 POWER WINDOWS
RHD
8W - 60 - 5
XJD06005 J008W-7
8W-61 POWER DOOR LOCKS
Component Page
Ci rcui t Breaker 28 (JB) . . . . . . . . . . . . . . 8W-61-2, 3
Dri ver Door Lock Motor . . . . . . . . . . . . . 8W-61-4, 5
Dri ver Power Lock/Wi ndow Swi tch . . . . . 8W-61-2, 3
Fuse 15 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3
G107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-3
Component Page
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 5
Left Rear Door Lock Motor . . . . . . . . . . . 8W-61-4, 5
Li ftgate Lock Motor . . . . . . . . . . . . . . . . 8W-61-4, 5
Overhead Modul e . . . . . . . . . . . . . . . . . . 8W-61-2, 3
Passenger Door Lock Motor . . . . . . . . . . 8W-61-4, 5
Passenger Power Lock/Wi ndow
Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 5
Ri ght Rear Door Lock Motor . . . . . . . . . . 8W-61-4, 5
XJ 8W - 61 POWER DOOR LOCKS 8W - 61 - 1
BATT A7
25A
FUSE
15
C9
9
BLOCK
JUNCTION
F35
16
RD
C2
3
C2 5
SWITCH
PASSENGER
POWER
LOCK/
WINDOW
FUSED
B(+)
SWITCH
OUTPUT OUTPUT
SWITCH
7
C2
P35
20
OR/VT
P35
20
7 C1
1
23
31
6 C305
7
C200
32
C201
9
C300
2
C1 11
20
P36
PK/VT
20
P36
SWITCH
DRIVER
POWER
LOCK/
WINDOW
5
C2
G302
3 C307
S309
S329
Z1
14
BK
BK
14
Z1
S319
C2
6
Z1
16
BK
C4
S5
C9 11
JUNCTION
BLOCK
BK
14
Z1
S208
Z1
14
BK
G107
14 C201
S314
Z1
14
BK
GROUND
25A
28
BREAKER
CIRCUIT
RUN-ACC A31
TN
14
F81
1
C8
IGNITION
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/VT PK/VT
OR/VT PK/VT
CONTROL
DOOR
LOCK UNLOCK
DOOR
RELAY
RELAY
CONTROL LOCK LOCK
DOOR DOOR
(LOCK) (UNLOCK)
Z1
12
BK
OUTPUT
(RUN-ACC)
G26
20
LB
C2
8
SENSE
SWITCH
IGNITION
KEY-IN
5 C300
G26
20
LB
29 C201
G26
20
LB
S210
G26
20
LB
C2 1
KEY-IN
IGNITION
SWITCH
SENSE
SWITCH
IGNITION
(8W-10-12)
(8W-12-17)
(8W-12-2)
(8W-15-10)
(8W-15-10)
(8W-15-10)
(8W-15-7)
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-15-7)
(8W-12-23)
(8W-10-9)
(8W-49-4)
(8W-10-10)
(8W-10-9)
8W - 61 - 2 8W-61 POWER DOOR LOCKS
LHD
XJ
J008W-7 XJD06102
16 C204
C306 1
RD
16
F35 F81
14
TN
1 C307
C202 3
12 C305
3
C307 3
BATT A7
25A
FUSE
15
C5
7
BLOCK
JUNCTION
F35
16
RD
C2
7
C2 5
SWITCH
PASSENGER
POWER
LOCK/
WINDOW
FUSED
B(+)
OUTPUT
(LOCK) (UNLOCK)
OUTPUT
3
C2
P35
18
OR/VT
P35
18
OR/VT
7 C1
6
3
1 C300
2
C204
4
C305
7
C1 11
PK/VT
18
P36
PK/VT
18
P36
SWITCH
DRIVER
POWER
LOCK/
WINDOW
5
C2
G303
S310 Z1
16
BK
BK
14
Z1
S329
C2
6
Z1
12
BK
BK
12
Z1
Z1
12
BK
G302
S309
GROUND
25A
28
BREAKER
CIRCUIT
RUN-ACC A31
TN
12
F81
8
C5
IGNITION
FUSED
4 C2
SWITCH
C2 1 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
LOCK UNLOCK
DOOR
RELAY
P55
20
DB/PK
RELAY
F81
12
TN
OUTPUT
(RUN-ACC)
LOCK
SWITCH SWITCH
LOCK
DOOR DOOR
CONTROL
IGNITION
KEY-IN
SWITCH
SENSE
G26
20
LB
C2
8
C2 1
SENSE
SWITCH
KEY-IN
IGNITION
SWITCH
IGNITION
2 C306
3 C203
S210
G26
20
LB
S319
Z1
12
BK
Z1
14
BK
Z1
14
BK
F35
16
RD
P59
20
LB/RD
P59
20
LB/RD
P55
20
DB/PK
(8W-10-12)
(8W-12-18)
(8W-12-2)
(8W-15-13)
(8W-15-13)
(8W-15-11)
(8W-15-11)
(8W-15-11)
(8W-12-24)
(8W-10-9)
(8W-49-5)
(8W-10-9)
(8W-10-10)
(8W-15-13)
XJ 8W-61 POWER DOOR LOCKS
RHD
8W - 61 - 3
XJD06103 J008W-7
P34
16
PK/BK
S307
2
2
5
P34
16
PK/BK
P34
16
PK/BK
P34
16
PK/BK PK/BK
16
P34
5 5 5
PK/BK
16
P34
B
PK/BK
16
P34
1
PK/BK
16
P34
1 1
P34
16
PK/BK
MOTOR
LIFTGATE
LOCK
A 2
MOTOR
DOOR
RIGHT
REAR
LOCK LOCK
REAR
LEFT
DOOR
MOTOR
2 2
MOTOR
DOOR
DRIVER
LOCK
P33
16
OR/BK
4
1 C311
C310
OR/BK
16
P33 P33
16
OR/BK
P33
16
OR/BK
P33
16
OR/BK
C326
1
4 C304
OR/BK
16
P33
4 C309
OR/BK
16
P33 P33
16
OR/BK
S306
C305 4
OR/BK
16
P33
12 C9
5
C7 C7
1
C9 1
BLOCK
JUNCTION
MOTOR
LOCK
DOOR
PASSENGER
2 1
P33
16
OR/BK
S317
P33
16
OR/BK OR/BK
16
P33 P34
16
PK/BK PK/BK
16
P34
S316
PK/BK
16
P34
5
C1
DOOR
LOCK UNLOCK
DOOR
C1
1
SWITCH
PASSENGER
POWER
LOCK/
WINDOW
DRIVER DRIVER
M
M M M M
(8W-12-2)
(8W-12-28)
(8W-12-28)
(8W-12-28) (8W-12-28)
8W - 61 - 4 8W-61 POWER DOOR LOCKS
LHD
XJ
J008W-7 XJD06104
WINDOW
LOCK/
POWER
PASSENGER
SWITCH
1
C1
UNLOCK
DOOR
DRIVER
LOCK
DOOR
C1
5
P34
16
PK/BK
S322
P34
16
PK/BK PK/BK
16
P34 P33
16
OR/BK OR/BK
16
P33
S323
OR/BK
16
P33
1 2
PASSENGER
DOOR
LOCK
MOTOR
JUNCTION
BLOCK
S306
OR/BK
16
P33
P33
16
OR/BK
C309
4
P33
16
OR/BK
C304
4
1
C326
OR/BK
16
P33
OR/BK
16
P33
OR/BK
16
P33
C310
C311 1
4
OR/BK
16
P33
LOCK
DRIVER
DOOR
MOTOR
2 2
MOTOR
DOOR
LEFT
REAR
LOCK LOCK
REAR
RIGHT
DOOR
MOTOR
2 A
MOTOR
LIFTGATE
LOCK
1 1
P34
16
PK/BK
1
P34
16
PK/BK
B
P34
16
PK/BK
5
5
P34
16
PK/BK
PK/BK
16
P34
PK/BK
16
P34
PK/BK
16
P34
5
2
2
S307
OR/BK
16
P33 P34
16
PK/BK
4 C305
5
PK/BK
16
P34 P33
16
OR/BK
12
C9 C9
1
1 C7 5 C7
DRIVER
P34
16
PK/BK
P33
16
OR/BK
M M M M
M
(8W-12-2)
(8W-12-29)
(8W-12-29)
(8W-12-29) (8W-12-29)
XJ 8W-61 POWER DOOR LOCKS
RHD
8W - 61 - 5
XJD06105 J008W-7
8W-62 POWER MIRRORS
Component Page
Dri ver Power Lock/Wi ndow
Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 3, 4, 5
Dri ver Power Mi rror . . . . . . . . . 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
Juncti on Bl ock . . . . . . . . . . . . . 8W-62-2, 3, 4, 5, 6, 7
Passenger Power Mi rror . . . . . . . . . 8W-62-3, 5, 6, 7
Power Mi rror Swi tch . . . . . . . . . . . . . . . . 8W-62-6, 7
XJ 8W - 62 POWER MIRRORS 8W - 62 - 1
MIRROR
POWER
DRIVER
3 1
18
FUSE
10A
M M
4 DOWN
3 UP
2 RIGHT
1 LEFT
3 2
1 4
2
C2
6 5 5 6
C2
6 1
C2
5
C2
3 C2
0
0 REST
0
4 1
2 3 3 2
1 4
0
C4
S4
BLOCK
JUNCTION
YL/DG
18
F83
3 C305
SWITCH
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 39
Z1
12
BK
Z1
12
BK
5
6
6 PASSENGER MIRROR
5 DRIVER MIRROR
(8W-10-9)
(8W-12-17)
(8W-12-2)
(8W-15-10) (8W-12-31)
(8W-15-10)
(8W-15-10)
8W - 62 - 2 8W-62 POWER MIRRORS
LHD FULL OPTIONS
XJ
J008W-7 XJD06202
BK
12
Z1
BK
12
Z1
OR/YL
20
P76
OR/YL
20
P76
4 2
MIRROR
POWER
DRIVER
OR/YL
20
P76
OR/YL
20
P76
OR/YL
20
P76
10
36
28
S328
DB
20
P74
DB
20
P74
DB
20
P74
YL/BK
20
P72
YL/BK
20
P72
YL/BK
20
P72
BK
14
Z1
G302
S329
3 C307
S309
Z1
12
BK
P76
20
OR/YL
2 C5
10
C9
P72
20
YL/BK DB
20
P74
24
C201
20
34
C200
35
9
C305
8
9 C5
2
C9 C9
6
C5 10
BLOCK
JUNCTION
5
C2
OR/YL
20
P76 P76
20
OR/YL
S318
MIRROR
POWER
PASSENGER
3 1
M M
4 DOWN
3 UP
2 RIGHT
1 LEFT
3 2
1 4
2
C2
6 5 5 6
4
C2 C2
7
0
0 REST
0
4 1
2 3 3 2
1 4
0
SWITCH
DRIVER
POWER
LOCK/
WINDOW
P76
20
OR/YL
P74
20
DB YL/BK
20
P72
2 4
RUN-ACC F83
MIRROR MIRROR
5
6
6 PASSENGER MIRROR
5 DRIVER MIRROR
COMMON
DRIVER DRIVER
COMMON
(8W-62-2)
(8W-15-10)
(8W-15-10)
(8W-15-10)
(8W-12-2)
(8W-12-17)
(8W-12-31)
(8W-12-31)
XJ 8W-62 POWER MIRRORS
LHD FULL OPTIONS
8W - 62 - 3
XJD06203 J008W-7
MIRROR
POWER
DRIVER
3 1
18
FUSE
10A
JUNCTION
BLOCK
M M
4 DOWN
3 UP
2 RIGHT
1 LEFT
3 2
1 4
2
C2
6 5 5 6
C2
4 7
C2
5
C2
3 C2
0
0 REST
0
4 1
2 3 3 2
1 4
0
SWITCH
DRIVER
POWER
LOCK/
WINDOW
P76
20
OR/YL
BK
16
Z1
DB
20
P74 P72
20
YL/BK
2 4
OR/YL
20
P76 P76
20
OR/YL
G303 S318
S319
S310
Z1
12
BK
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 DRIVER MIRROR
S352
F83
18
YL/DG
F83
18
YL/DG
(8W-10-9)
(8W-12-18)
(8W-12-2)
(8W-15-13) (8W-12-33)
(8W-15-13)
(8W-15-13)
(8W-12-18)
RHD FULL OPTIONS
XJ
J008W-7 XJD06204
OR/YL
20
P76
P71
20
YL/LB DB/WT
20
P75
P74
20
DB YL/BK
20
P72
P71
20
YL DB/RD
20
P75
BK
14
Z1
BK
16
Z1
G303
S319
S310
Z1
12
BK
2 4
OR/YL
20
P76
WINDOW
LOCK/
POWER
DRIVER
SWITCH
0
4 1
2 3 3 2
1 4
0
0 REST
0
1
C2 C2
6
6 5 5 6
C2
2
4 1
2 3
1 LEFT
2 RIGHT
3 UP
4 DOWN
M M
1 3
PASSENGER
POWER
MIRROR
S328
OR/YL
20
P76 P76
20
OR/YL
C2
5
9
C204
8
8
C305
9
S318
10
10
P76
20
OR/YL
P76
20
OR/YL
DRIVER
POWER
MIRROR
2 4
P76
20
OR/YL
P76
20
OR/YL
BLOCK
JUNCTION
2
C5
10 C9 2 C9 6 C9
10
C5
9
C5
P72
20
YL/BK DB
20
P74
Z1
14
BK
RUN-ACC F83
5
6
5 C303
MIRROR MIRROR
6 PASSENGER MIRROR
5 DRIVER MIRROR
P76
20
OR/YL
COMMON
DRIVER DRIVER
COMMON
(8W-15-13)
(8W-15-13)
(8W-15-13)
(8W-12-18)
(8W-62-4)
(8W-12-2)
(8W-12-33)
(8W-12-33)
RHD FULL OPTIONS
8W - 62 - 5
XJD06205 J008W-7
1
2
3 4
6
10
5
7
6
Z1
14
BK
P74
20
DB
P72
20
YL/BK
P76
20
OR/YL
P91
20
WT/BK
6
5
3 4
M M
2 1
DRIVER
POWER
MIRROR
MIRROR
POWER
PASSENGER
2 1
M M
3 4
5
6
9 10
BLOCK
JUNCTION
C9 C9
C9 C9
C5 C5
C5
3 2
C5
P74
20
DB
P72
20
YL/BK
35
C200
34
9 8
P91
20
WT/BK
36
10
P76
20
OR/YL
12
C200
13
C305
P76
20
OR/YL
P91
20
WT/BK
SWITCH
MIRROR
POWER
8 7
P71
20
YL
P75
20
DB/WT
S329
P91
20
WT/BK
P76
20
OR/YL
1
2 3
4
4 DOWN
3 LEFT
1 RIGHT
2 UP
P91
20
WT/BK
P76
20
OR/YL
C305
28 C201 67
20 24 C201
BLOCK
JUNCTION
RUN-ACC F83
P74
20
DB
P72
20
YL/BK
P72
20
YL/BK
P74
20
DB
Z1
16
BK
3 C307
Z1
12
BK
S309
Z1
12
BK
G302
(8W-12-2)
(8W-12-2)
(8W-12-17)
(8W-15-10)
(8W-15-10)
(8W-15-10)
LHD EXCEPT FULL OPTIONS
XJ
J008W-7 XJD06206
1
11 2
7 8
6
10
5
7
6
Z1
20
BK
P75
20
DB/WT
P71
20
YL/LB
P76
20
OR/YL
P91
20
WT/BK
6
5
4 3
M M
1 2
DRIVER
POWER
MIRROR
MIRROR
POWER
PASSENGER
2 1
M M
3 4
5
6
9 10
BLOCK
JUNCTION
C9 C9 C9
C9 C9
C5 C5
C5
3 2
C5
P74
20
DB
P72
20
YL/BK
9
C204
8
9 8
P75
20
DB/WT
P71
20
YL
P91
20
WT/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 LEFT
1 RIGHT
2 UP
P91
20
WT/BK
P76
20
OR/YL
BLOCK
JUNCTION
RUN-ACC F83
P74
20
DB
P72
20
YL/BK
C305
Z1
16
BK
3
C7
S359
POWER
MIRRORS BASE
WT/BK
20
P91
(8W-12-2)
(8W-15-8)
(8W-15-8)
(8W-12-2)
(8W-12-18)
(8W-15-13)
(8W-12-32)
8W - 62 - 7
XJD06207 J008W-7
8W-63 POWER SEAT
Component Page
Ci rcui t Breaker 29 (JB) . . . . . . . . . . . . 8W-63-2, 3, 6
Forward/Rearward Motor . . . . . . . . . . . . 8W-63-2, 3
Front Motor . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3
Fuse 18 (JB) . . . . . . . . . . . . . . . . . . . . . . 8W-63-4, 6
G306 . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4, 5, 6
Heated Seat Rel ay . . . . . . . . . . . . . . . . . 8W-63-4, 6
Juncti on Bl ock . . . . . . . . . . . . . . . . . 8W-63-2, 3, 4, 6
Left Heated Seat Back . . . . . . . . . . . . . . . . 8W-63-5
Left Heated Seat Cushi on . . . . . . . . . . . . . . 8W-63-5
Left Heated Seat Swi tch . . . . . . . . . . . . . . . 8W-63-4
Component Page
Left Power Seat Motors . . . . . . . . . . . . . . . 8W-63-2
Left Power Seat Swi tch . . . . . . . . . . . . 8W-63-2, 3, 6
Rear Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 3
Ri ght Heated Seat Back . . . . . . . . . . . . . . . 8W-63-5
Ri ght Heated Seat Cushi on . . . . . . . . . . . . 8W-63-5
Ri ght Heated Seat Swi tch . . . . . . . . . . . . . . 8W-63-4
Ri ght Power Seat Motors . . . . . . . . . . . . . . 8W-63-3
Ri ght Power Seat Swi tch . . . . . . . . . . . . . 8W-63-3, 6
Seat Heat I nterface Modul e . . . . . . . . . 8W-63-4, 5, 6
XJ 8W - 63 POWER SEAT 8W - 63 - 1
2
BLOCK
JUNCTION
25A
29
BREAKER
CIRCUIT
F37
14
RD/LB
BATT A7
N
A
E M J L K B
1 2 4 3 5 6
P19
14
YL/LG
P21
14
RD/LG
P11
14
YL/WT
P13
14
RD/WT
P15
14
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
RD/LB
S356
G306
1 C362
BK
C362 2
F37
14
RD
BK
14
Z1
M M M
(8W-12-2)
(8W-12-25)
(8W-10-12)
(8W-12-25)
(8W-15-15)
8W - 63 - 2 8W-63 POWER SEAT XJ
J008W-7 XJD06302
2
BLOCK
JUNCTION
25A
29
BREAKER
CIRCUIT
F37
14
RD/LB
BATT A7
POWER
SEAT
SWITCH
N
B
J M E K L A
1 2 4 3 5 6
P18
14
YL/LG
P20
14
RD/LG
P10
14
YL/WT
P12
14
RD/WT
P14
14
YL/LB
P16
14
RD/LB
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(+)
S356
RD/LB
14
F37
BK
14
Z1
G306
C363 2
1 C363
F37
14
RD
1 C362
F37
14
RD
BK
14
Z1
M M M
(8W-12-2)
(8W-12-25)
(8W-10-12)
(8W-63-2)
(8W-12-25)
(8W-15-15)
XJ 8W-63 POWER SEAT 8W - 63 - 3
XJD06303 J008W-7
C4
S4
BLOCK
JUNCTION
F83
18
YL/DG
F83
18
YL/DG
C300 3 44 C201
F83
18
YL/DG
F83
18
YL/DG
39 C200 S352
S351 1 C324
C316 1
F83
18
YL/DG
4
HEATED
SEAT
RELAY
F83
18
YL/DG
C329 11
F83
18
YL/DG
S353
6
4
SWITCH
SEAT
HEATED
LEFT RIGHT
HEATED
SEAT
SWITCH
4
12 1 14
5 1 6 5
11 10 9
1
LEFT
SEAT
LOW
HEAT
LED
DRIVER DRIVER
LED
HEAT
HIGH
SEAT
LEFT LEFT
SEAT
HEATER
SWITCH
MUX MUX
SWITCH
HEATER
SEAT
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/DG
P134
18
TN/RD
P140
18
VT/BK
P138
18
VT/LG
10A
FUSE
18
RUN-ACC A31
RHD LHD
SEAT
HEAT
INTERFACE
MODULE
C329
BK
18
Z1
3
S355
G306
G306
S355
3
Z1
18
BK
Z1
18
BK
1 2 1 2
1 HIGH
2 LOW 2 LOW
1 HIGH
FUSED
IGNITION
SWITCH
OUTPUT
(RUN-ACC)
(8W-12-2)
(8W-12-18)
(8W-12-17)
(8W-63-6)
(8W-12-17)
(8W-12-18)
(8W-10-9)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-15-15)
8W - 63 - 4 8W-63 POWER SEAT
HEATED SEATS
XJ
J008W-7 XJD06304
5
SEAT
HEAT
INTERFACE
MODULE
13
GROUND
HEATED
SEAT
DRIVER INPUT
SENSE
HEAT
LEFT
8 2
SENSOR
FEED INPUT
SENSE
HEAT
RIGHT
7
DRIVER
SEAT
HEATED
RIGHT
3
P87
18
BK/OR
P87
18
BK/OR
7
3
P87
18
BK/OR BK/DG
18
P143
C332
2
9
C329
BK/DG
18
P143
BK/DG
18
P143 P86
18
PK/BK BK/YL
18
P144
P141
18
TN/LB
C B
D A D A
C B
P141
18
TN/LB
P141
18
TN/LB
C332 1
8 C329
P141
18
TN/LB
P88
18
BR/BK
P141
18
TN/LB
S357
P89
18
BR
B
A
B
A
BACK
SEAT
HEATED
RIGHT
BACK
SEAT
HEATED
LEFT
Z1
18
BK BK
18
Z1
C332 4
S354
Z1
18
BK
C329 12
Z1
18
BK
S355
G306
Z1
18
BK
Z2
18
BK/LG
C329 13
Z2
18
BK/LG
G306
CUSHION
SEAT
HEATED
LEFT
CUSHION
SEAT
HEATED
RIGHT
LEFT
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-15-15)
XJ 8W-63 POWER SEAT
HEATED SEATS
8W - 63 - 5
XJD06305 J008W-7
S4
C4
RUN-ACC A31
10A
FUSE
18
C6
2
F83
18
YL/DG
C300 3
S352
F83
18
YL/DG
F83
18
YL/DG
1 C324
F83
18
YL/DG
44 C201
F83
18
YL/DG
C200 39
F83
18
YL/DG
S351
F83
18
YL/DG
F37
14
RD/LB
RHD LHD
1 C316
2
F37
14
RD/LB
F83
18
YL/DG
F83
18
YL/DG
F37
14
RD/LB
S353
11
10
C329
F37
14
RD/LB
F83
18
YL/DG
4
6 2
8
4 6
F235
16
RD
F235
16
RD
HEATED
SEAT
G306
S355
C329 12
Z1
18
BK
Z1
18
BK
S354
RELAY
SEAT
HEATED
MODULE
INTERFACE
HEAT
SEAT
B
A
A
B
F37
14
RD/LB
F37
14
RD/LB
SWITCH
SEAT
POWER
LEFT
SWITCH
SEAT
POWER
RIGHT
G306
Z1
14
BK
Z1
14
BK
S356
BLOCK
JUNCTION
25A
BREAKER
29
CIRCUIT
BATT A7
FUSED
B(+)
B(+)
FUSED
GROUND
GROUND
1 C362
F37
14
RD
1 C363
C362 2 C363 2
RD
14
F37
RELAY
OUTPUT OUTPUT
RELAY
SEAT
HEATED
(8W-10-9)
(8W-12-17)
(8W-12-18)
(8W-12-18)
(8W-12-17)
(8W-63-4)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-15-15)
(8W-12-2)
(8W-63-2)
(8W-63-3)
(8W-12-25)
(8W-12-25)
(8W-10-12)
8W - 63 - 6 8W-63 POWER SEAT
HEATED SEATS
XJ
J008W-7 XJD06306
8W-70 SPLICE INFORMATION
Component Page
S100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-7
S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-22
S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-6
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-7
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-7
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-12
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-11
S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-13, 14
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-12
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3, -4, 5
S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-7
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-20, 21
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-14
S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-19
S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4, 5
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
S143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-6
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S145 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
S159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-12
S161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
S166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-18
S168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-15
S200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 7
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3, 4
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-3
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-10
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-9
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4
S213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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-30-20, 21
S239 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20
S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2, 3
S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-28, 29
S309 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 11
S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12, 13
S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2
S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
S314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
S315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-8
S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-28
S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-28
S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31, 33
S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7, 13
S320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6, 7
S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6, 7
S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-29
S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-29
S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4, 5
S327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-4, 5
S328 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-31, 33
S329 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 11
S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3
S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 11
S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-19
S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2
S340 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-10
S341 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 11
S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-7
S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-27
S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21
S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12, 13
S349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-21
S351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-17
S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-18
S353 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-4
S354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-25
S357 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-5
S359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12-32
S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-18
XJ 8W - 70 SPLICE INFORMATION 8W - 70 - 1
BK/RD
20
L62
1 2
RIGHT
TURN
SIGNAL
LAMP
POSITION
SENSOR
THROTTLE
ABSOLUTE
SENSOR
PRESSURE
MANIFOLD
CRANKSHAFT
SENSOR
POSITION
POWERTRAIN
MODULE
CONTROL
C1
17
K7
20
OR
K7
20
OR
K7
20
OR
K7
18
OR
3
3
3 3
POSITION
SENSOR
CAMSHAFT
OR
18
K7
S115
L62
18
BR/RD
1 C321 C323 8
BR/RD
20
L62
BR/RD
20
L62
11 C204 C200 25
RHD LHD
TURN
SIGNAL/
HAZARD
SWITCH
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
SENSOR
DOWNSTREAM
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
18
BR/YL
K167
20
BR/YL
A
(8W-70-3)
TO
S111
CALIFORNIA)
(4.0L
S123
4
3 3
3 3
(8W-52-4)
(8W-30-7)
(8W-30-12)
(8W-30-5) (8W-30-5)
(8W-30-7)
(8W-30-12)
(8W-30-5)
(8W-52-2)
(8W-54-3)
(8W-30-10)
(8W-30-11)
(8W-30-10) (8W-30-11)
(8W-30-11) (8W-30-10)
8W - 70 - 2 8W-70 SPLICE INFORMATION XJ
J008W-7 XJD07002
S111
BR/YL
18
K167
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
20
BR/YL
K167
18
BR/YL
4
POWERTRAIN
CONTROL
MODULE
C1
SENSOR
POSITION
CAMSHAFT
2
2
S114
3 C107
3
1/2
SENSOR
OXYGEN
DOWNSTREAM
K167
20
BR/YL BR/YL
20
K167
BR/YL
20
K167
BR/YL
20
K167
BR/YL
20
K167
BR/YL
20
K167
1
AIR
TEMPERATURE
SENSOR
INTAKE
CRANKSHAFT
SENSOR
POSITION
2
VEHICLE
SPEED
SENSOR
SENSOR
1
MANIFOLD
ABSOLUTE
PRESSURE
1
POSITION
SENSOR
THROTTLE
COOLANT
SENSOR
TEMPERATURE
1
ENGINE
UPSTREAM
OXYGEN
SENSOR
1/1
BR/YL
20
K167
S138
K167
20
BR/YL
MODULE
CONTROL
TRANSMISSION
16
C100
B6
B3
C100
SENSOR
TEMPERATURE
BATTERY
2
BR/YL
20
K167
3
C204 7
30 C200
BR/YL
20
K167
4
FUEL
MODULE
PUMP
K167
20
BR/YL
LHD RHD
BR/YL
20
K167
(4.0L)
K167
20
BR/YL
SENSOR
PRESSURE
OIL
ENGINE
(4.0L)
C1
RHD
LHD
F12
F18
CLOCKSPRING
3
3
BK/RD
20
K4
CALIFORNIA)
(EXCEPT 4.0L
(EXCEPT 4.0L
CALIFORNIA)
CALIFORNIA)
(EXCEPT 4.0L
A
(8W-70-2)
FROM
S123
BR/YL
20
K167
(8W-30-8)
(8W-30-10)
(8W-30-12)
(8W-30-5)
(8W-30-8)
(8W-30-10)
(8W-30-7)
(8W-30-5)
(8W-30-12)
(8W-30-12)
(8W-30-7)
(8W-30-7)
(8W-30-8)
(8W-30-10)
(8W-30-13)
(8W-30-3)
(8W-30-4)
(8W-31-5)
(8W-30-12)
(8W-33-2)
XJ 8W-70 SPLICE INFORMATION 8W - 70 - 3
XJD07003 J008W-7
8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Heater Control . . . . . . . . . . . . . . . . . . . 8W-80-4
A/C Low Pressure Swi tch . . . . . . . . . . . . . . 8W-80-5
Ai rbag Control Modul e . . . . . . . . . . . . . . . . 8W-80-5
Ambi ent Temperature Sensor . . . . . . . . . . . 8W-80-6
Back-Up Lamp Swi tch . . . . . . . . . . . . . . . . 8W-80-6
Battery Temperature Sensor . . . . . . . . . . . . 8W-80-6
Bl ower Motor . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7
Bl ower Motor Rel ay . . . . . . . . . . . . . . . . . . 8W-80-7
Bl ower Motor Resi stor Bl ock . . . . . . . . . . . 8W-80-7
C100 . . . . . . . . . . . . . . . . . . . . . . . 8W-80-8, 9, 10, 11
C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12
C107 . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-12, 13, 14
C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-14
C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-15
C201 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-16, 17
C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18
C204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19
C206 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19, 20
C207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20
C300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20, 21
C301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-21
C304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
C305 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22, 23
C306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C309 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-24
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
C318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26
C322 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-26, 27
C323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
C324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
Component Page
C326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
C327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
C329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
C330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
C332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
C333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
C362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
C363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
Camshaft Posi ti on Sensor . . . . . . . . . . . . . 8W-80-29
Ci gar Li ghter . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Cl ockspri ng-C1 . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Cl ockspri ng-C2 . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Cl ockspri ng-C3 . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Cl utch I nterl ock Swi tch Jumper . . . . . . . . 8W-80-31
Cl utch I nterl ock Swi tch . . . . . . . . . . . . . . 8W-80-31
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Control l er Anti -Lock Brake . . . . . . . . . . . . 8W-80-32
Crankshaft Posi ti on Sensor . . . . . . . . . . . . 8W-80-32
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
Dome Lamps Swi tch . . . . . . . . . . . . . . . . . 8W-80-33
Dri ver Door Jamb Swi tch . . . . . . . . . . . . . 8W-80-34
Dri ver Door Lock Motor . . . . . . . . . . . . . . 8W-80-34
Dri ver Power Lock/Wi ndow Swi tch . . . 8W-80-34, 35
Dri ver Power Mi rror . . . . . . . . . . . . . . . . . 8W-80-35
Dri ver Power Wi ndow Motor . . . . . . . . . . . 8W-80-36
Duty Cycl e Evap/Purge Sol enoi d . . . . . . . . 8W-80-36
Engi ne Oi l Pressure Sensor . . . . . . . . . . . 8W-80-36
Evap Leak Detecti on Pump . . . . . . . . . . . . 8W-80-37
Extended I dl e Swi tch . . . . . . . . . . . . . . . . 8W-80-37
Front Fog Lamp Swi tch . . . . . . . . . . . . . . 8W-80-37
Front Wi per Motor . . . . . . . . . . . . . . . . . . 8W-80-37
Fuel I njector No. 1 . . . . . . . . . . . . . . . . 8W-80-38, 39
Fuel Pump Modul e . . . . . . . . . . . . . . . . . . 8W-80-40
G Swi tch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
Generator . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-40
Headl amp Beam Sel ect Swi tch . . . . . . . . . 8W-80-40
Headl amp Swi tch . . . . . . . . . . . . . . . . . . . 8W-80-41
Heated Seat Rel ay . . . . . . . . . . . . . . . . . . 8W-80-41
Heater Control . . . . . . . . . . . . . . . . . . . . . . 8W-80-4
I dl e Ai r Control Motor . . . . . . . . . . . . . . . . 8W-80-41
XJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1
Component Page
I gni ti on Coi l . . . . . . . . . . . . . . . . . . . . . . . 8W-80-42
I gni ti on Swi tch . . . . . . . . . . . . . . . . . . . . . 8W-80-42
I nstrument Cl uster . . . . . . . . . . . . . . . . . . 8W-80-43
I ntake Ai r Temperature Sensor . . . . . . . . . 8W-80-44
Juncti on Bl ock . . . . . . . . . . . . . 8W-80-44, 45, 46, 47
Left Courtesy Lamp . . . . . . . . . . . . . . . . . 8W-80-48
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . 8W-80-48
Left Front Door Speaker . . . . . . . . . . . . . . 8W-80-48
Left Front Door Tweeter . . . . . . . . . . . . . . 8W-80-48
Left Front Park/Turn Si gnal Lamp No. 1 . 8W-80-48
Left Front Park/Turn Si gnal Lamp No. 2 . 8W-80-49
Left Front Wheel Speed Sensor . . . . . . . . . 8W-80-49
Left Headl amp . . . . . . . . . . . . . . . . . . . . . 8W-80-49
Left Heated Seat Back . . . . . . . . . . . . . . . 8W-80-49
Left Heated Seat Cushi on . . . . . . . . . . . . . 8W-80-49
Left Heated Seat Swi tch . . . . . . . . . . . . . . 8W-80-50
Left Power Seat Front Verti cal Motor . . . . 8W-80-50
Left Power Seat Hori zontal Motor . . . . . . 8W-80-50
Left Power Seat Rear Verti cal Motor . . . . 8W-80-50
Left Power Seat Swi tch . . . . . . . . . . . . . . . 8W-80-51
Left Rear Door Jamb Swi tch . . . . . . . . . . . 8W-80-51
Left Rear Door Lock Motor . . . . . . . . . . . . 8W-80-51
Left Rear Wheel Speed Sensor . . . . . . . . . 8W-80-51
Left Rear Wi ndow Motor . . . . . . . . . . . . . . 8W-80-51
Left Rear Wi ndow Swi tch . . . . . . . . . . . . . 8W-80-52
Left Soundbar Speaker . . . . . . . . . . . . . . . 8W-80-52
Left Speed Control Swi tch . . . . . . . . . . . . 8W-80-52
Left Tai l /Stop Lamp . . . . . . . . . . . . . . . . . 8W-80-52
Left Turn Si gnal Lamp . . . . . . . . . . . . . . . 8W-80-53
Left Vi sor/Vani ty Lamp . . . . . . . . . . . . . . . 8W-80-53
Li cense Lamp . . . . . . . . . . . . . . . . . . . . . . 8W-80-53
Li ftgate Lock Motor . . . . . . . . . . . . . . . . . 8W-80-53
Mani fol d Absol ute Pressure Sensor . . . . . . 8W-80-54
Overhead Modul e . . . . . . . . . . . . . . . . . . . 8W-80-54
Park/Neutral Posi ti on Swi tch . . . . . . . . . . 8W-80-55
Passenger Ai rbag . . . . . . . . . . . . . . . . . . . 8W-80-55
Passenger Door Jamb Swi tch . . . . . . . . . . 8W-80-55
Passenger Door Lock Motor . . . . . . . . . . . 8W-80-56
Passenger Power Lock/Wi ndow Swi tch . . . 8W-80-56
Passenger Power Mi rror . . . . . . . . . . . 8W-80-56, 57
Component Page
Passenger Power Wi ndow Motor . . . . . . . . 8W-80-57
Power Ampl i fi er . . . . . . . . . . . . . . . . . . . . 8W-80-57
Power Mi rror Swi tch . . . . . . . . . . . . . . . . . 8W-80-58
Power Outl et . . . . . . . . . . . . . . . . . . . . . . . 8W-80-58
Power Steeri ng Pressure Swi tch . . . . . . . . 8W-80-58
Powertrai n Control Modul e . . . . . . 8W-80-59, 60, 61
PRNDL I l l umi nati on . . . . . . . . . . . . . . . . . 8W-80-62
Radi ator Fan Motor . . . . . . . . . . . . . . . . . 8W-80-62
Radi o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
Rai l Coi l . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
Rear Washer Pump . . . . . . . . . . . . . . . . . . 8W-80-63
Rear Wi ndow Defogger Swi tch . . . . . . . . . 8W-80-63
Rear Wi per Motor . . . . . . . . . . . . . . . . . . . 8W-80-63
Rear Wi per/Washer Swi tch . . . . . . . . . . . . 8W-80-63
Ri ght Back-Up Lamp . . . . . . . . . . . . . . . . 8W-80-63
Ri ght Courtesy Lamp . . . . . . . . . . . . . . . . 8W-80-64
Ri ght Fog Lamp . . . . . . . . . . . . . . . . . . . . 8W-80-64
Ri ght Front Door Speaker . . . . . . . . . . . . . 8W-80-64
Ri ght Front Door Tweeter . . . . . . . . . . . . . 8W-80-64
Lamp No. 1 . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Lamp No. 2 . . . . . . . . . . . . . . . . . . . . . . 8W-80-64
Ri ght Front Wheel Speed Sensor . . . . . . . 8W-80-65
Ri ght Headl amp . . . . . . . . . . . . . . . . . . . . 8W-80-65
Ri ght Heated Seat Back . . . . . . . . . . . . . . 8W-80-65
Ri ght Heated Seat Cushi on . . . . . . . . . . . . 8W-80-65
Ri ght Heated Seat Swi tch . . . . . . . . . . . . . 8W-80-65
Ri ght Power Seat Front Verti cal Motor . . . 8W-80-65
Ri ght Power Seat Hori zontal Motor . . . . . 8W-80-66
Ri ght Power Seat Rear Verti cal Motor . . . 8W-80-66
Ri ght Power Seat Swi tch . . . . . . . . . . . . . 8W-80-66
Ri ght Rear Door Jamb Swi tch . . . . . . . . . . 8W-80-66
Ri ght Rear Door Lock Motor . . . . . . . . . . . 8W-80-66
Ri ght Rear Wheel Speed Sensor . . . . . . . . 8W-80-67
Ri ght Rear Wi ndow Motor . . . . . . . . . . . . 8W-80-67
Ri ght Rear Wi ndow Swi tch . . . . . . . . . . . . 8W-80-67
Ri ght Si de Marker Lamp . . . . . . . . . . . . . 8W-80-67
Ri ght Soundbar Speaker . . . . . . . . . . . . . . 8W-80-67
Ri ght Speed Control Swi tch . . . . . . . . . . . 8W-80-68
Ri ght Tai l /Stop Lamp . . . . . . . . . . . . . . . . 8W-80-68
Ri ght Turn Si gnal Lamp . . . . . . . . . . . . . . 8W-80-68
Seat Bel t Swi tch . . . . . . . . . . . . . . . . . . . . 8W-80-68
Seat Heat I nterface Modul e . . . . . . . . . . . 8W-80-69
Sentry Key I mmobi l i zer Modul e . . . . . . . . 8W-80-69
Shi ft Lock Sol enoi d . . . . . . . . . . . . . . . . . . 8W-80-69
8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS XJ
Component Page
Throttl e Posi ti on Sensor . . . . . . . . . . . . . . 8W-80-70
Trai l er Tow Connector . . . . . . . . . . . . . . . . 8W-80-70
Trai l er Tow Left Turn Rel ay . . . . . . . . . . . 8W-80-70
Trai l er Tow Ri ght Turn Rel ay . . . . . . . . . . 8W-80-70
Transfer Case Swi tch . . . . . . . . . . . . . . . . 8W-80-71
Transfer Case Swi tch I l l umi nati on . . . . . . 8W-80-71
Transmi ssi on Sol enoi d . . . . . . . . . . . . . . . 8W-80-71
Transmi ssi on Control Modul e . . . . . . . . . . 8W-80-72
Component Page
Transmi ssi on Range Sensor . . . . . . . . . . . 8W-80-72
Turn Si gnal /Hazard Swi tch . . . . . . . . . . . . 8W-80-73
Underhood Lamp/Swi tch . . . . . . . . . . . . . . 8W-80-73
Vehi cl e Speed Control Servo . . . . . . . . . . . 8W-80-73
Vehi cl e Speed Sensor . . . . . . . . . . . . . . . . 8W-80-73
Washer Fl ui d Level Swi tch . . . . . . . . . . . . 8W-80-74
Wi ndshi el d Washer Pump . . . . . . . . . . . . . 8W-80-74
XJ 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3
CAV CIRCUIT FUNCTION
7
E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
E2 20OR
6 C90 20LG A/C SWITCH SENSE
5 C4 14TN BLOWER MOTOR LOW DRIVER
4 C5 14LG BLOWER MOTOR M1 DRIVER
3 C6 14LB BLOWER MOTOR M2 DRIVER
2 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
1 Z8 12BK/VT GROUND
BLACK
7 1
A/C-HEATER
CONTROL-C1
RHD
(2.5L)
SWITCH
PRESSURE
A/C HIGH
2 1
1 C22 18DB/WT A/C SWITCH SENSE
2 C21 20DB/PK A/C SWITCH SENSE
A/C ONLY
OR
HEATER
CONTROL-C1
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
RADIATOR FAN REQUEST C48 18TN 2
A/C SWITCH SENSE C21 20DB/PK 1
FUNCTION CIRCUIT CAV
A/C HIGH
PRESSURE
SWITCH
(4.0L)
1 2
4 3
BLEND DOOR FEEDBACK SIGNAL C36 18RD/WT 3
NATURAL
1
5
F15 20DB/WT 4
BLEND DOOR FEEDBACK SIGNAL C36 20RD/WT 3
GROUND Z1 20BK 2
- 1
5
-
- -
FUSED IGNITION SWITCH OUTPUT (RUN) A/C-HEATER
CONTROL-C2
A/C SWITCH SENSE C90 20LG 4
LHD
8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS XJ
J008W-7 XJD08004
YELLOW
1
11 22
12
- -
DRIVER AIRBAG LINE 2 R43 18BK/LB
R45 18DG/LB DRIVER AIRBAG LINE 1
- -
- -
- -
- -
- -
- -
- -
- -
- -
D2 18WT/BK CCD BUS(-) 18
FUSED IGNITION SWITCH OUTPUT (RUN) F14 18LG/YL 20
19 D1 18VT/BR CCD BUS(+)
16
17 F23 18DB/YL
13
14
15
Z6 18BK/YL GROUND
GROUND Z6 18BK/PK 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 SWITCH SENSE
CIRCUIT FUNCTION CAV
C21 20DB/PK 1
SWITCH
PRESSURE
A/C LOW
10
1 2
A/C SWITCH SENSE C21 20DB/PK 2
1 C22 18DB/WT PRESSURE SWITCH OUTPUT
2.5L
4.0L
XJ 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5
XJD08005 J008W-7
BATTERY
2 1
BLACK
SENSOR GROUND K167 20BR/YL 2
BATTERY TEMPERATURE SENSOR SIGNAL K118 18PK/YL 1
TEMPERATURE
SENSOR
SWITCH
BACK-UP LAMP
BLACK
B A
FUSED IGNITION SWITCH OUTPUT (ST-RUN) F20 18WT A
SENSOR GROUND G32 20BK/LB 2
1 G31 20VT/LG
CAV FUNCTION CIRCUIT
AMBIENT TEMPERATURE SENSOR SIGNAL
SENSOR
TEMPERATURE
AMBIENT
BLACK
2 1
- -
- - 9
10 D2 20OR FUSED IGNITION SWITCH OUTPUT (RUN)
ACTUATOR
BLEND
DOOR
10 5
BLEND DOOR FEEDBACK SIGNAL D3 20YL 8
GROUND D1 20DB/WT 7
6
- - 5
B L10 18BR/LG BACK UP LAMP FEED
BLACK
J008W-7 XJD08006
V32 18YL/RD SPEED CONTROL POWER SUPPLY 3
LHD
RHD
2 GROUND Z1 18BK
BRAKE LAMP SWITCH SENSE K29 18WT/PK 1
SWITCH
BRAKE LAMP
1 2 3 4 5 6
GRAY
FUSED B(+) F32 20PK/DB 6
BRAKE LAMP SWITCH OUTPUT L50 20WT/TN 5
SPEED CONTROL BRAKE SWITCH OUTPUT V30 20DB/RD 4
SPEED CONTROL POWER SUPPLY V32 20YL/RD 3
RED BRAKE WARNING INDICATOR DRIVER
1 G9 20GY/BK RED BRAKE WARNING INDICATOR DRIVER
2 G99 20GY/WT
1 2
BLACK
BRAKE WARNING
PRESSURE SWITCH
B
BLOWER MOTOR RELAY OUTPUT C1 12DG A
C7 12BK/TN BLOWER MOTOR HIGH DRIVER
B A
MOTOR
BLOWER
- -
5 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
FUSED B(+) A111 12RD/LG 4
3
2
BLOWER MOTOR RELAY OUTPUT C1 12DG 1
Z1 20BK GROUND
1
3
4
5 2
RELAY
BLOWER
MOTOR
BLACK
1 4
BLOCK
RESISTOR
BLOWER
MOTOR
BLOWER MOTOR M1 DRIVER C5 14LG
1 C4 14TN BLOWER MOTOR LOW DRIVER
2
3 C6 14LB BLOWER MOTOR M2 DRIVER
4 C7 12BK/TN BLOWER MOTOR HIGH DRIVER
BLACK
XJD08007 J008W-7
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
D6
A111 12RD/LG D5
G34 16RD/GY D4
L3 16RD/OR D3
A141 16DG/WT D2
A3 14RD/WT D1
A2 12PK/BK C6
V5 16DG/YL C5
F75 16VT C4
V4 16BR/VT C3
A1 12RD C2
V3 16BR/WT C1
- B18
- B17
- B16
- B15
- B14
- B13
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A18
A17
A16
A15
A14
- A13
A12
A11
A10
A9
A8
A7
L139 20VT A5
L39 20LB A4
G107 20BK/RD A3
G106 20BK/WT A2
Z1 18BK A1
CIRCUIT CAV
A6 C90 20LG
G34 16RD/GY D3
C90 20LG A6
C100
CAV CIRCUIT
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 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 14RD/WT
D2 A141 14DG/WT
D4 G34 16RD/GY
D5 A111 12RD/LG
D6
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
C100
(CONTINUED ON NEXT PAGE)
F6 E1
D6
D2
D4
B6
F12
F18
B12
B18 A13
C5
C1
C3
A1
E7
E13
A7
BLACK
E1
A13
C5
C1
C3
A1
E7
E13
A7
D6
D2
D4
B6
B18
F12
F18
F6
B12
BLACK
4.0L A/T
POWER AMPLIFIER
FOG LAMPS
DRL
(LHD)
(LHD)
EXCEPT DRL
J008W-7 XJD08008
F11
CAV CIRCUIT
E8
E9
E10
G29 20BK/LB
E11
E13
E14
E15
E16
E17
E18
F2
F3
F4
F5
F6
F7 V30 20DB/RD
F8 F32 20PK/DB
F9 V32 18YL/RD
F10
F12
F13
F14 G31 20VT/LG
F15 G32 20BK/LB
F16
F17
G19 20LG/OR
E2
E4
E5
E6
E1
E7
F34 18TN/BK
E12
K185 20OR/LB
G86 18TN/OR
G154 18VT/LG
-
E3
E11
E12
V20 18BK/WT
V10 18BR
L10 18BR/LG
G9 20GY/BK
L50 20WT/TN
Z12 18BK/TN
F20 18WT
F1 20DB/GY
D1 20VT/BR
D1 18VT/BR
D2 20WT/BK
D2 18WT/BK
F1 D20 18LG/BK
D21 20PK
L60 20TN
L61 20LG/WT
L9 20BK/PK
L44 20VT/RD
K29 18WT/PK
K226 18DB/LG
K167 20BR/YL
K78 18GY
V37 18RD/LG
K4 20BK/RD F18
V37 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/LG
V10 18BR
V20 18BK/WT
E12
E3
F17
G154 20VT/LG
G86 20TN/OR
K185 20OR/LB
F34 18TN/BK
E7
E1
E6
E5
E4
E2
G19 20LG/OR
F16
G32 20BK/LB F15
G31 20VT/LG F14
F13
F12
F10
V32 18YL/RD F9
F32 20PK/DB F8
V30 20DB/RD F7
F6
F5
F4
F3
F2
E18
E17
E16
E15
E14
E13
E11
G29 20BK/LB
E10
E9
E8
CIRCUIT CAV
-
F11
G99 20GY/WT G99 20GY/WT
ABS
4.0L A/T
EXCEPT 4.0L A/T
SPEED CONTROL
(CONTINUED)
D21 18PK
2.5L
F2
K167 20BR/YL F18
SENTRY KEY IMMOBILIZER MODULE
F10 K29 20WT/PK
F26 18PK/OR
4.0L A/T
EXCEPT 4.0L A/T
EXCEPT 2.5L
-
-
XJD08009 J008W-7
D3
CAV CIRCUIT
A1 Z1 18BK
A2 G106 20BK/WT
A3 G107 20BK/RD
A4 L92 20PK
A7
A8
A9
A10
A11
A12
A13 -
A14
A15
A16
A17
A18
B2
B3
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14 -
B15 -
B16 -
B17 -
B18 -
C1 V3 16BR/WT
C2 A1 12RD
C3 V4 16BR/VT
C4 F75 16VT
C5 V5 16DG/YL
C6 A2 12PK/BK
D1 A3 14RD/WT
D2 A141 14DG/WT
D4
D5 A111 12RD/LG
D6 -
Z12 18BK/TN
G29 20BK/LB
F20 18WT
G99 20GY/WT
D1 18VT/BR
D2 18WT/BK
G9 20GY/BK
L10 18BR/LG
V10 18BR
V20 18BK/WT
F34 18TN/BK
K226 18DB/LG
K167 20BR/YL
V37 18RD/LG
K167 20BR/YL
D20 18LG/BK
D21 18PK
L60 20TN
L61 20LG/WT
L9 20BK/PK
L44 20VT/RD
-
-
- -
-
-
L9 20BK/PK
L61 20LG/WT
L60 20TN
D21 20PK
D20 20LG/BK
K4 20BK/RD
V37 20RD/LG
L50 20WT/TN
K167 20BR/YL
K226 20DB/LG
K29 18WT/PK
F34 18TN/BK
V20 18BK/WT
V10 18BR
L10 18BR/LG
G9 20GY/BK
D2 20WT/BK
D1 20VT/BR
G99 20GY/WT
F20 18WT
G29 20BK/LB
Z12 18BK/TN
- D6
A111 12RD/LG D5
D4
A141 16DG/WT D2
A3 14RD/WT D1
A2 12PK/BK C6
V5 16DG/YL C5
F75 16VT C4
V4 16BR/VT C3
A1 12RD C2
V3 16BR/WT C1
- B18
- B17
- B16
- B15
- B14
B13
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A18
A17
A16
A15
A14
- A13
A12
A11
A10
A9
A8
A7
L139 20VT A5
L39 20LB A4
G107 20BK/RD A3
G106 20BK/WT A2
Z1 18BK A1
CIRCUIT CAV
D3
C100 C100
(CONTINUED ON NEXT PAGE)
F6
E1
D6
D2
D4
B6
F12
F18
B12
B18 A13
C5
C1
C3
A1
E7
E13
A7
E1
A13
C5
C1
C3
A1
E7
E13
A7
D6
D2
D4
B6
B18
F12
F18
F6
B12
ABS
4.0L A/T
DRL
(RHD) (RHD)
D21 20PK B8
2.5L FOG LAMPS
POWER AMP EXCEPT 4.0L A/T
A11 D1 20VT/BR
A12 D2 20WT/BK
WHITE WHITE
C90 20LG A6 A6 C90 20LG
L139 20VT A5
K29 18WT/PK B1
L50 18WT/TN B4
-
J008W-7 XJD08010
(CONTINUED)
F17
E12
F45 20YL/RD E7
E1
E6
E5
E4
E3
E2
G19 20LG/OR
F18
F16
G32 20BK/LB F15
G31 20VT/LG F14
F13
F12
F10
V32 20YL/RD F9
F32 20PK/DB F8
V30 20DB/RD F7
F6
F5
F4
F3
F2
F1
E18
E17
E16
E15
E14
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
F12
F13
F14 G31 20VT/LG
F15 G32 20BK/LB
F16
F18
D20 18LG/BK
G19 20LG/OR
E2
E3
E4
E5
E6
E1
E7 F45 20YL/RD
E12
F17
SENTRY KEY IMMOBILIZER MODULE
ABS
-
-
-
- -
-
-
-
XJD08011 J008W-7
C106 C106
14
7
8
1
14
7
8
1
L78 20DG/YL 14
L44 20VT/RD 13
L33 20RD/WT 12
Z1 20BK/WT 11
L60 20TN 10
L43 20VT 9
L39 20LB 8
L77 20BR/YL 7
L34 20RD/OR 6
5
Z1 20BK 4
L61 20LG/WT 3
L33 20RD 2
1
CIRCUIT CAV
L78 20DG/YL 14
L44 18VT/RD 13
L33 20RD 12
Z1 18BK 11
L60 20TN 10
L43 18VT 9
L39 20LB 8
L77 20BR 7
L34 18RD/OR 6
5
Z1 18BK 4
L61 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/YL 3
K20 18DG 2
A142 18DG/OR 1
CIRCUIT CAV CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 Z1 20 BK
6 -
7 F142 20DG/WT
8 G107 20BK/RD
9 -
10 F12 18DB/WT
11 F20 18WT
12 L10 18BR/LG
13 -
14 A61 14DG/BK
1
8
7
14
1
8
7
14
C107
(LHD 2.5L) (LHD 2.5L)
C107
DRL
A/T
M/T
J008W-7 XJD08012
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 18BK/WT
6 K22 20OR/DB
7 A42 20DG
8 G107 20BK/RD
9 Z12 16BK/TN
10 F12 18DB/WT
11 K78 18GY
13 A242 20VT/OR
13 A242 20DG/OR
14 A61 14DG/BK A61 16DG/BK 14
A242 18VT/OR 13
12
K78 18GY 11
F12 18DB/WT 10
Z12 18BK/TN 9
G107 20BK/RD 8
A42 18DG 7
K22 20OR/DB 6
Z1 18BK 5
G7 20WT/OR 4
K167 20BR/YL 3
K20 18DG 2
A142 18DG/OR 1
CIRCUIT CAV
C107
(LHD 4.0L) (LHD 4.0L)
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
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 Z1 20 BK
6 -
7 F142 20DG/WT
8 G107 20BK/RD
9 -
10 F12 18DB/WT
11 F20 18WT
12 L10 18BR/LG
13 -
14 A61 14DG/BK
BLACK
BLACK
A61 16DG/BK 14
- 13
L10 18BR/LG 12
F20 18WT 11
F12 18DB/WT 10
- 9
G107 20BK/RD 8
F142 18DG/WT 7
- 6
T41 20BK/WT 5
4
K167 20BR/YL 3
K20 18DG 2
A142 18DG/OR 1
CIRCUIT CAV
1
8
7
14
1
8
7
14
C107
(RHD 2.5L) (RHD 2.5L)
C107
XJD08013 J008W-7
A61 16DG/BK 14
A242 18VT/OR 13
G106 20BK/WT 12
11
F12 18DB/WT 10
Z12 18BK/TN 9
G107 20BK/RD 8
A42 18DG 7
K22 20OR/DB 6
T41 20BK/WT 5
G7 20WT/OR 4
K167 20BR/YL 3
K20 18DG 2
A142 18DG/OR 1
CIRCUIT CAV
1
8
7
14
1
8
7
14
C107
(RHD 4.0L) (RHD 4.0L)
C107
BLACK BLACK
4.0L GAS (EXCEPT M/T 2WD)
DRL
A/T
M/T
4WD A/T
4WD
4.0L A/T
2WD CALIFORNIA
CAV CIRCUIT
1 A142 18DG/OR
2 K20 18DG
3 K167 20BR/YL
4 G7 20WT/OR
5 T41 18BK/WT
6 K22 20OR/DB
7 A42 20DG
8 G107 20BK/RD
9 Z12 16BK/TN
10 F12 18DB/WT
11
13 A242 20VT/OR
13 A242 20DG/OR
14 A61 14DG/BK
G106 20BK/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
E B2 20YL
F B3 20LG/DB
G B4 20LG
A
H
D
E
BLACK
A
H
D
E
BLACK
C109
C109
CAV CIRCUIT
1 T40 16BR
2 K72 18DG/OR
3 K20 18DG
4 C3 16DB/BK
CAV CIRCUIT
1 T40 16BR
2 K72 16DG/OR
3 K20 16DG
4 C3 16DB/BK
1 4
1 4
BLACK BLACK
C108
C108
F20 18WT F20 18WT
(4.0L A/T 4WD)
(4.0L A/T 4WD)
1 2
(M/T) (M/T)
C113
L10 18BR/LG
CIRCUIT CAV
L10 18BR/LG
CIRCUIT CAV
C113
1
2 2
1
1 2
Z1 20BK
G106 20BK/WT
G107 20BK/RD G107 20BK/RD
3
G106 20BK/WT
3
C112
C112
CAV CIRCUIT
1 Z1 20BK
2
CAV CIRCUIT
1
2
GRAY
GRAY
3 1 3 1
J008W-7 XJD08014
C200
(LHD) (LHD)
C200
F83 18YL/DG
G78 20TN/BK
-
40
39
38 - 38
G78 20TN/BK 40
39 F83 18YL/DG
1
GRAY
36
GRAY
40 36
5
C16 20LB/YL
37
P76 20OR/YL 36
P74 20DB 35
P72 20YL/BK 34
F81 12TN 33
P36 20PK/VT 32
P35 20OR/VT 31
K167 20BR/YL 30
V23 18BR/PK 29
V20 18BK/WT 28
V13 18BR/LG 27
L63 20DG/RD 26
L62 20BR/RD 25
L50 20WT/TN 24
23
- 22
- 21
- 20
- 19
- 18
G16 20BK/LB 17
L10 18BR/LG 16
K226 20DB/LG 15
F75 16VT 14
A141 16DG/WT 13
12
X60 16DG/RD 11
X58 16DB/OR 10
X52 16DB/WT 9
- 8
X57 16BR/LB 7
X51 16BR/YL 6
X56 16DB/RD 5
X54 16VT 4
3
X55 16BR/RD 2
X53 16DG 1
CIRCUIT CAV
C16 20LB/YL 37
P76 20OR/YL 36
P74 20DB 35
P72 20YL/BK 34
F81 12TN 33
P36 20PK/VT 32
P35 20OR/VT 31
K167 20BR/YL 30
V23 18BR/PK 29
V20 18BK/WT 28
V13 18BR 27
L63 20DG/RD 26
L62 20BR/RD 25
L50 20WT/TN 24
L38 18BR/WT 23
- 22
- 21
- 20
- 19
- 18
G16 20BK/LB 17
L10 18BR/LG 16
K226 20DB/LG 15
F75 14VT 14
A141 16DG/WT 13
12
X60 18DG/RD 11
X58 18DB/OR 10
X52 18DB/WT 9
- 8
X57 18BR/LB 7
X51 18BR/YL 6
X56 18DB/RD 5
X54 18VT 4
3
X55 18BR/RD 2
X53 18DG 1
CIRCUIT CAV
FULL OPTIONS (WITH POWER AMPLIFIER)
FULL OPTIONS
1 5
40
P91 20WT/BK
- -
P91 20WT/BK
C16 20LB/YL
-
XJD08015 J008W-7
CAV CIRCUIT
1 F20 18WT
2 C16 20LB/YL
3 L5 20BK
4 C36 20RD/WT
5 F87 20WT/BK
6 M1 20PK
7 Z1 20BK
8 V6 16DB
9
10 A31 12BK/WT
11 A111 12RD/LG
12 C7 12BK/TN
13
14 Z1 14BK
15 -
16 L3 16RD/OR
17 C81 20LB/WT
18 -
19
20
21 -
22 L4 16VT/WT
23
24
25 Z8 20BK/VT
26 X3 20BK/RD
27 -
28
29 G26 20LB
30 -
31 -
32 G31 20VT/LG
33 -
34 -
35 G32 20BK/LB
36 -
37 -
38 -
39 V23 18BR/PK
40 F15 20DB/WT
41 -
42 E1 20TN
43 E2 20OR
P36 20PK/VT
P76 20OR/YL
P35 20OR/VT
P74 20DB
-
P72 20YL/BK
F81 12TN
C201
(LHD) (LHD)
C201
F81 12TN
P72 20YL/BK
-
P74 20DB
P35 20OR/VT
P76 20OR/YL
P36 20PK/VT
NATURAL
10
11
14
15
16
17
20
29
31 37 68
74
72
65
64
61
60
59
58
55
46
44 38 7 1 38
37 68
29
20
17
16
14
11
13
10
12
1
3
50
72
63
65
59
61
62
64
58
47
55
46
NATURAL
(CONTINUED)
E2 20OR 43
E1 20TN 42
- 41
F15 20DB/WT 40
V23 18BR/PK 39
- 38
- 37
- 36
G32 20BK/LB 35
- 34
- 33
G31 20VT/LG 32
- 31
- 30
G26 20LB 29
28
- 27
X3 20BK/RD 26
Z8 16BK/VT 25
24
23
L4 16VT/WT 22
- 21
20
19
- 18
C81 20LB/WT 17
L3 16RD/OR 16
- 15
Z1 14BK 14
13
C7 12BK/TN 12
A111 12RD/LG 11
A31 12BK/WT 10
9
V6 16DB 8
Z1 20BK 7
M1 20PK 6
F87 20WT/BK 5
C36 20RD/WT 4
L5 20BK 3
C16 20LB/YL 2
F20 18WT 1
CIRCUIT CAV
J008W-7 XJD08016
- -
-
74
73 - 73
74
CAV CIRCUIT
44
45 L7 18BK/YL
46 M2 20YL
47
48
49
50 F30 16RD
51 D1 20VT/BR
52 D2 20WT/BK
53 -
54 X12 16RD/WT
55 D1 20VT/BR
56 D2 20WT/BK
57 -
58 Z2 20BK/LG
59 C4 14TN
60 C5 14LG
61 C6 14LB
62 A22 12BK/OR
63 A41 14YL
64 A21 12DB
65 F38 16RD/LB
66 G9 20GY/BK
67 P91 20WT/BK
68 -
69 G10 20LG/RD
70 -
71 -
72 -
(CONTINUED)
F83 18YL/DG
-
-
- -
-
-
F83 18YL/DG
- 72
- 71
- 70
G10 20LG/RD 69
- 68
P91 20WT/BK 67
G9 20GY/BK 66
F38 16RD/LB 65
A21 12DB 64
A41 14YL 63
A22 12BK/OR 62
C6 14LB 61
C5 14LG 60
C4 14TN 59
Z2 20BK/LG 58
- 57
D2 20WT/BK 56
D1 20VT/BR 55
X12 16RD/WT 54
- 53
D2 18WT/BK 52
D1 18VT/BR 51
F30 16RD 50
49
48
47
M2 20YL 46
L7 18BK/YL 45
44
CIRCUIT CAV
XJD08017 J008W-7
CAV CIRCUIT
1 C7 12BK/TN
2 -
3 F81 12TN
4 -
5 -
6 Z8 12BK/VT
7 A111 12RD/LG
8 C6 14LB
9 C5 14LG
10 C4 14TN C4 14TN 10
C5 14LG 9
C6 14LB 8
A111 12RD/LG 7
Z8 16BK/VT 6
- 5
- 4
F81 12TN 3
- 2
C7 12BK/TN 1
CIRCUIT CAV
(RHD)
C203
(RHD)
C203
P91 20WT/BK
P91 20WT/BK
-
-
L38 18BR/WT
BLUE
1
5
9
15
4
8
14
22
BLUE
P55 20DB/PK 1
P59 20LB/RD 2
G26 20LB 3
G16 20BK/LB 4
V20 18BK/WT 5
V23 18BR/PK 6
V13 18BR 7
8
9
10
G10 20LG/RD 11
E2 20OR/BK 12
G9 20GY/BK 13
X60 18DG/RD 14
X58 18DB/OR 15
X57 18BR/LB 16
X56 18DB/RD 17
X55 18BR/RD 18
X54 18VT 19
X53 18DG 20
X52 18DB/WT 21
X51 18BR/YL 22
CIRCUIT CAV
P55 20DB/PK
22
P59 20LB/RD
21
G26 20LB
20
G16 20BK/LB
19
V20 18BK/WT
18
V23 18BR/PK
17
V13 18BR/LG
16
15
14
13
G10 20LG/RD
12 E2 20OR
11
G9 20GY/BK
10
X60 16DG/RD
9
X58 16DB/OR
8
X57 16BR/LB
7
X56 16DB/RD
6
X55 16BR/RD
5
X54 16VT
4
X53 16DG
3
X52 16DB/WT
2
X51 16BR/YL
1
CIRCUIT CAV
GRAY
(RHD)
C202
GRAY
C202
(RHD)
BASE AND FULL OPTIONS W/O POWER AMPLIFIER
FULL OPTIONS
22
14
8
4
15
9
5
1
6
1 5
10
5
10 6
1
FULL OPTIONS W/ POWER AMPLIFIER
-
J008W-7 XJD08018
G78 20TN/BK G78 20TN/BK
P36 20PK/VT
24
P35 20OR/VT
23
C16 20LB/YL
22
F15 20DB/WT
21
P76 20OR/YL
20
P74 20DB
19
P72 20YL/BK
18
K167 20BR/YL
17
K226 20DB/LG
16
15
C36 20RD/WT
14
Z1 20BK
13
F35 16RD
12
F14 18LG/YL
11
P36 20PK/VT
24
P35 20OR/VT
23
C16 20BK/WT
22
F15 20DB/WT
21
P76 20OR/YL
20
P74 20DB
19
P72 20YL/BK
18
K167 20BR/YL
17
K226 20DB/LG
16
15
C36 18RD/WT
14
Z1 20BK
13
F35 16RD
12
F14 18LG/YL
11
WHITE
24
18
10
4
19
11
5
1
WHITE
F23 18DB/YL
10
9
L63 20DG/RD
8
L62 20BR/RD
7
L50 20WT/TN
6
L10 18BR/LG
5
A141 16DG/WT
4
F75 16VT
3
D2 18WT/BK
2
D1 18VT/BR
1
CIRCUIT CAV
C204 C204
F23 18DB/YL
10
-
9
L63 20DG/RD
8
L62 20BR/RD
7
L50 20WT/TN
6
L10 18BR/LG
5
A141 16DG/WT
4
F75 16VT
3
D2 20WT/BK
2
D1 20VT/BR
1
CIRCUIT CAV
4 1
YELLOW
YELLOW
1 4
C205
R45 18DG/LB 4
R43 18BK/LB 3
R44 18DG/YL 2
R42 18BK/YL 1
CIRCUIT CAV
C205
R45 18DG/LB 4
R43 18BK/LB 3
R44 18DG/YL 2
R42 18BK/YL 1
CIRCUIT CAV
Z1 20BK
2
Z1 20BK
E2 20OR
E2 20OR
1
CIRCUIT CAV
Z1 20BK 2
CIRCUIT CAV
2
1
BLACK
C206
(A/T)
1
2
BLACK
C206
(A/T)
FULL OPTIONS
(RHD)
(RHD)
-
E2 20OR/BK
E2 20OR
1
1
RHD
LHD
1
5
11
19
4
10
18
24
FULL OPTIONS W/POWER AMP
XJD08019 J008W-7
(M/T)
C206
(M/T)
C206
Z1 20BK 2
E2 20OR 1
CIRCUIT CAV
Z1 20BK 2
E2 20OR 1
CIRCUIT CAV
C207 C207
A B
B A
M2 20YL B
M1 20PK A
CIRCUIT CAV
M2 18BK/WT B
M1 18PK A
CIRCUIT CAV
C208 C208
BLACK BLACK
A B
B A
M2 20YL B
M1 20PK A
CIRCUIT CAV
M2 18BK/WT B
M1 18PK A
CIRCUIT CAV
(LHD)
C300
(LHD)
C300
6
3
4
NATURAL
1
6
3
4
1
NATURAL
- 6
G26 20LB 5
P59 20LB/RD 4
P55 20DB/PK 3
P36 20PK/VT 2
P35 20OR/VT 1
CIRCUIT CAV
- 6
G26 20LB 5
P59 20LB/RD 4
P55 20DB/PK 3
P36 20PK/VT 2
P35 20OR/VT 1
CIRCUIT CAV
BLACK BLACK
2
1
BLACK
1
2
BLACK
Z8 20BK/VT 10
CAV CIRCUIT
1
2 C4 14TN
3 C5 14LG
4 C6 14LB
5
6
7 C7 12BK/TN
8 A111 12RD/LG
9 F15 20DB/WT
10 Z8 12BK/VT
5
10
1
6
BLACK
C209
C36 20RD/WT
F15 20DB/WT
Z1 20BK
10 Z1 20BK
F15 20DB/WT 9
A111 12RD/LG 8
7
D3 20YL 6
C7 12BK/TN
C4 14TN
CAV CIRCUIT
1 D1 20DB/WT
2
3 C5 14LG
4 C6 14LB
D2 20OR 5
C209
6
1
10
5
RHD
LHD
LT. GREEN
E2 20OR/BK 1
J008W-7 XJD08020
Z1 14BK
Q1 14YL
8
4 1
5
Q16 14BR/WT 1
CAV CIRCUIT
1 V23 18BR/PK
2 Q26 14VT/WT
3 Q1 14YL
4 X80 18LB/BK
5 X82 18LB/RD
4
X54 18VT 5
X56 18DB/RD
(RHD FULL
C303
C303
(RHD FULL
C303
C303
WHITE
4
8 5
1
8
4
Q27 14RD/BK
Q17 14DB/WT
Q17 14DB/WT
Q27 14RD/BK
Q26 14VT/WT Q26 14VT/WT 8
7 Q16 14BR/WT
8
7 Q16 14BR/WT
Q1 14YL
Q28 14DG/WT
CIRCUIT
Z1 14BK
WHITE
1
CAV
4
3
2
5
6
2
6 7
3 1
5
Q18 14GY/BK
Q28 14DG/WT
1
CAV
4
3
2
5
6
CIRCUIT
Q18 14GY/BK
6
3
4
1
BLACK
NATURAL
4 6
1 3
X82 18LB/RD 5
X80 18LB/BK 4
Q1 14YL 3
Q26 14VT/WT 2
Q16 14BR/WT 1
CIRCUIT CAV
D1 20VT/BR 1
1
5
4
4
10
1
5
10
WHITE
C301 C301
CIRCUIT CAV
6 - 6 -
BASE
4 SPEAKER SYSTEM
6 SPEAKER SYSTEM
2 D2 20WT/BK
G31 20VT/LG 4
3 G32 20BK/LB
X3 20BK/RD 7
8 P55 20DB
F87 20WT/BK 6
5 Z2 20BK/LG
9 P59 20LB/RD
10 - - 10
P59 20LB/RD 9
Z2 20BK/LG 5
6 F87 20WT/BK
P55 20DB/PK 8
7 X3 20BK/RD
G32 20BK/LB 3
4 G31 20VT/LG
D2 20WT/BK 2
CAV CIRCUIT
1 D1 20VT/BR
FULL OPTIONS
(EXCEPT RHD (EXCEPT RHD
5
4 X56 18DB/RD
X54 18VT
1 V23 18BR/PK
WHITE
FULL OPTIONS AND POWER MIRRORS
3
6
1
4
WHITE
CIRCUIT
6
5
3
4
2
F83 18YL/DG
P36 20PK/VT
CAV
1 P35 20OR/VT
-
4
1
6
3
2
5
6
4
3
WHITE
CAV
1
P36 18PK/VT
-
CIRCUIT
P35 18OR/VT
- -
- -
F83 18YL/DG
C300
(RHD)
C300
(RHD)
OVERHEAD CONSOLE
FULL OPTIONS) FULL OPTIONS)
OPTIONS)
OPTIONS)
XJD08021 J008W-7
(LHD) (LHD)
(RHD) (RHD)
P34 16PK/BK 5
P33 16OR/BK 4
Q1 14YL 3
2
1
CIRCUIT CAV CIRCUIT
1
2
3 Q1 14YL
4 P33 16OR/BK
5 P34 16PK/BK
3 1
6 4
BLACK
BLACK
1
4
3
6
C304 C304
C304 C304
- - 6 6
6
3
4
1
BLACK
BLACK
4 6
1 3
P34 16PK/BK 5
P33 16OR/BK 4
Q1 14YL 3
Q28 14DG/WT 2
Q18 14GY/BK 1
CIRCUIT CAV
P34 16PK/BK 5
P33 16OR/BK 4
Q1 14YL 3
Q28 14DG/WT 2
Q18 14GY/BK 1
CIRCUIT CAV
CAV CIRCUIT
1 X85 18BR/RD
3 F83 18YL/DG
4 P33 16OR/BK
5 P34 16PK/BK
6 P35 20OR/VT
7 P36 20PK/VT
8 P72 20YL/BK
9 P74 20DB
10 P76 20OR/YL
11 C16 20LB/YL
12 -
13 P91 20WT/BK
2 X87 18DG X87 18LG/VT 2
1
X53 18DG
(LHD)
C305
(LHD)
C305
WHITE
13
8
3
9
4
1
WHITE
13
3
8
9
1
4
P91 20WT/BK 13
- 12
C16 20LB/YL 11
P76 20OR/YL 10
P74 20DB 9
P72 20YL/BK 8
P36 18PK/VT 7
P35 18OR/VT 6
P34 16PK/BK 5
P33 16OR/BK 4
F83 18YL/DG 3
X55 18BR/RD
2
X85 18BR/RD 1
CIRCUIT CAV
CAV
-
6 6
-
6 SPEAKERS
4 SPEAKERS
FULL OPTIONS AND POWER MIRRORS
POWER LOCK/WINDOWS
FULL OPTIONS
POWER MIRRORS
Q28 14DG/WT
Q18 14GY/BK
Q28 14DG/WT
Q18 14GY/BK
11 C16 20BK/WT
1 X55 18LG/RD
2 X53 18LG/BK
J008W-7 XJD08022
CAV CIRCUIT
1 X85 18BR/RD
3 P59 20LB/RD
4 P33 16OR/BK
5 P34 16PK/BK
6 P35 20OR/VT
7 P36 20PK/VT
8 P71 20YL
9 P75 20DB/RD
10 P76 20OR/YL
11 C16 20LB/YL
12 P55 20DB
13 P91 20WT/BK
4
1
9
8
3
13
WHITE
1
4
9
3
8
13
WHITE
C305
(RHD)
C305
(RHD)
2 X87 18DG
9 P75 20DB/WT
1 X55 18BR/RD
X87 18LG/VT 2
P91 20WT/BK 13
P55 20DB/PK 12
C16 20LB/YL 11
P76 20OR/YL 10
P74 20DB 9
P72 20YL/BK 8
P36 18PK/VT 7
P35 18OR/VT 6
P34 16PK/BK 5
P33 16OR/BK 4
P59 20LB/RD 3
X53 18DG 2
X85 18BR/RD 1
CIRCUIT CAV
(FULL OPTIONS) (POWER WINDOWS)
(POWER WINDOWS) (FULL OPTIONS)
(LHD)
C306
(RHD)
C306
(RHD)
C306
(LHD)
C306
WHITE
WHITE
3
6
2
1
WHITE
2
6 3
1
WHITE
3
6
2 1
2
6 3
1
- 6
- 5
Q26 14VT/WT 4
Q16 14BR/WT 3
G26 20LB 2
F35 16RD 1
CIRCUIT CAV
- 6
- 5
Q26 14VT/WT 4
Q16 14BR/WT 3
G26 20LB 2
F35 16RD 1
CIRCUIT CAV
Q27 14RD/BK 6
Q17 14DB/WT 5
Q26 14VT/WT 4
Q16 14BR/WT 3
Q28 14DG/WT 2
Q18 14GY/BK 1
CIRCUIT CAV
Q27 14RD/BK 6
Q17 14DB/WT 5
Q26 14VT/WT 4
Q16 14BR/WT 3
Q28 14DG/WT 2
Q18 14GY/BK 1
CIRCUIT CAV
POWER LOCK/WINDOW SWITCHES
POWER MIRRORS W/O FULL OPTIONS
4 SPEAKERS
6 SPEAKERS
FULL OPTIONS
11 C16 20BK/WT
POWER MIRRORS
1 X55 18LG/RD
X53 18LG/BK 2
XJD08023 J008W-7
C307 C307
WHITE
1 3
WHITE
1 3
Z1 12BK 3
Q1 14YL 2
F81 12TN 1
CIRCUIT CAV
Z1 12BK 3
Q1 14YL 2
F81 14TN 1
CIRCUIT CAV
C309 C309
- -
6 6
6
3
4
1
BLACK
BLACK
4 6
1 3
P34 16PK/BK 5
P33 16OR/BK 4
Q1 14YL 3
Q27 14RD/BK 2
Q17 14DB/WT 1
CIRCUIT CAV
P34 16PK/BK 5
P33 16OR/BK 4
Q1 14YL 3
Q27 14RD/BK 2
Q17 14DB/WT 1
CIRCUIT CAV
C310
G78 20TN/BK
BLACK
L77 18BR/YL 11
M4 20VT/YL 10
Z1 18BK 9
V13 18BR/LG 8
V23 18BR/PK 7
6
P34 16PK/BK 5
P33 16OR/BK 4
C15 12BK/WT 3
Z1 12BK 2
V20 18BK/WT 1
CIRCUIT CAV
C311
G78 20TN/BK
3
4
6
1
BLACK
Z1 18BK 6
M4 20GY/BK 5
L77 18BR/YL 4
3
P34 16PK/BK 2
P33 16OR/BK 1
CIRCUIT CAV
C312
2
1
GREEN
C15 12BK/WT 2
Z1 12BK 1
CIRCUIT CAV
C313
GRAY
3 2
1
V20 18BK/WT 3
V23 18BR/PK 2
V13 18BR/LG 1
CIRCUIT CAV
8
1
7
2
3
9
11 6
4
3 Z1 16BK
POWER MIRRORS
FULL OPTIONS
5 10
J008W-7 XJD08024
F83 18YL/DG 1
CIRCUIT CAV
2 F37 14RD/LB
C316 C316
F37 14RD/LB 2
CAV CIRCUIT
1 F83 18YL/DG
C317
C317
BLACK
BLACK
Z1 18BK C
G16 18BK/LB B
M2 18YL A
CIRCUIT CAV
Z1 20BK
G16 20BK/LB
M2 20YL
CIRCUIT CAV
4
X51 18BR/YL 3
X57 18BR/LB
2
X52 18DB/WT 1
X58 18DB/OR
4
X51 18BR/YL
3
X57 18BR/LB
2
X52 18DB/WT 1
X58 18DB/OR
C314 C314
3
1
7
6
2
8
8
6
2
7
3
1
- 8
M4 20GY/BK 7
M2 20YL 6
M1 20PK 5
X93 18WT/RD 4
X91 18WT/BK 3
X94 18TN/RD 2
X92 18TN/BK 1
CIRCUIT CAV
- 8
M4 20GY/BK 7
M2 20YL 6
M1 20PK 5
X93 16BR/YL 4
X91 16BR/DB 3
X94 16TN/RD 2
X92 16TN/BK 1
CIRCUIT CAV
4 SPEAKER
6 SPEAKER
RHD
5 M1 18PK
LHD
1 2
BLACK
WHITE
WHITE
A
B
C
A C C A
2 1
BLACK
HEATED SEATS
XJD08025 J008W-7
C318 C318
Z1 18BK C
G16 18BK/LB B
M2 18YL A
CIRCUIT CAV
20BK Z1 C
G16 20BK/LB B
M2 20YL A
CIRCUIT CAV
C319 C319
B A
BLACK
A B
BLACK
Z1 18BK B
M2 18YL A
CIRCUIT CAV
Z1 20BK B
M2 20YL A
CIRCUIT CAV
C320 C320
BLACK
B A
BLACK
A B
Z1 18BK B
M2 18YL A
CIRCUIT CAV
Z1 20BK B
M2 20YL A
CIRCUIT CAV
RHD
1 3
4
4 8
1 3
8
BLACK
BLACK
C322 C322
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
BLACK
BLACK
C321 C321
-
Z1 18BK 2
8
L77 18BR 7
L50 18WT/TN 6
L10 18BR/LG 5
4
3
L63 18DG/RD 1
CIRCUIT CAV
-
L62 20BR/RD
A6 20RD/OR
CAV CIRCUIT
1 L63 20DG/RD
2 Z1 14BK
3
4 L38 18BR/WT
5 L10 18BR/LG
6 L50 20WT/TN
7 L77 18BR/YL
8
(W/O TRAILER TOW) (W/O TRAILER TOW)
BLACK
BLACK
A C
C A
-
-
J008W-7 XJD08026
F83 18YL/DG
X82 18LB/RD
X80 18LB/BK
(RHD)
C324
(RHD)
C324
CAV CIRCUIT
1
2
3
(TRAILER TOW) (TRAILER TOW)
L38 20OR/WT
C323 C323
BLACK
BLACK
8
3 1
8 4
4
3 1
8
L77 20BR/YL 7
L50 20WT/TN 6
L10 18BR/LG 5
4
3
Z1 14BK 2
L63 20DG/RD 1
CIRCUIT CAV
8
L77 18BR/YL 7
L50 20WT/TN 6
L10 18BR/LG 5
L38 18BR/WT 4
3
Z1 14BK 2
L63 20DG/RD 1
CIRCUIT CAV
2 3 1
3 1
3
2
1
CIRCUIT CAV
X80 18LB/BK
X82 18LB/RD
F83 18YL/DG
A6 20RD/OR
L62 20BK/RD
A6 20RD/OR
L62 20BR/RD
- -
CAV CIRCUIT
1 L63 20DG/RD
2 Z1 18BK
3
4 L38 18BR/WT
5 L10 18BR/LG
6 L50 20WT/TN
7 L77 18BR/YL
8
CAV CIRCUIT
1 L63 18DG/RD
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
WHITE
WHITE
-
3
1
5
2
BLACK
5
2
3
1
BLACK
BLACK
2
6
1
3
BLACK
1
3
2
6
C327 C327
6
5
4
3
2
1
CIRCUIT CAV
6
V20 18BK/WT 5
V23 18BR/PK 4
V13 18BR 3
L77 18BR/YL 2
G78 20TN/BK 1
CIRCUIT CAV
-
-
G78 20TN/BK
L77 18BR/YL
V13 18BR/LG
V23 18BR/PK
V20 18BK/WT
FULL OPTIONS
C326 C326
L50 20WT/TN 5
C15 12BK/WT 4
M4 20GY/BK 3
P34 16PK/BK 2
P33 16OR/BK 1
1 P33 16OR/BK
2 P34 16PK/BK
3 M4 20GY/BK
4 C15 12BK/WT
5 L50 18WT/TN
XJD08027 J008W-7
CAV CIRCUIT
1 P133 18TN/DG
2 P134 18TN/RD
3 P137 18VT
4 P138 18VT/LG
5 P139 18VT/WT
6
7 P87 18BK/OR
8 P141 18TN/LB
9
10 F37 14RD/LB
11 F83 18YL/DG
12 Z1 18BK
13
14 -
P140 18VT/BK
P143 18BK/DG
Z2 18BK/LG
NATURAL
NATURAL
Z2 18BK/LG
P143 18BK/DG
P140 18VT/BK
14
13
Z1 18BK 12
F83 18YL/DG 11
F37 14RD/LB 10
9
P141 18TN/LB 8
P87 18BK/OR 7
6
P139 18VT/WT 5
P138 18VT/LG 4
P137 18VT 3
P134 18TN/RD 2
P133 18TN/DG 1
CIRCUIT CAV
1
8
7
14
1
8
7
14
C329 C329
CIRCUIT
2 Z1 18BK
CAV
1 L78 18BK/YL
2
CAV
1
Z1 18BK
CIRCUIT
L77 18BR/YL
C330 C330
BLACK
BLACK
-
2 1
2 1
C332 C332
NATURAL
NATURAL
Z1 18BK 4
P87 18BK/OR 3
P143 18BK/DG 2
P141 18TN/LB 1
1 P141 18TN/LB
2 P143 18BK/DG
3 P87 18BK/OR
4 Z1 18BK
1 4
1 4
BLACK
1 2
2 1
C333 C333
L50 18WT/TN
CIRCUIT
Z1 18BK
1
CAV
2
L50 18DG/WT 1
CAV
Z1 18BK 2
CIRCUIT
BLACK
J008W-7 XJD08028
LHD
RHD
A M1 20PK
LAMP/SWITCH
CARGO
A C
BLACK
LIFTGATE COURTESY LAMP DRIVER M4 20GY/BK C
COURTESY LAMPS DRIVER M2 20YL B
FUSED B(+) M1 18PK A
CAMSHAFT POSITION SENSOR SIGNAL K44 18TN/YL
3
5V SUPPLY K7 18OR
1
FUSED B(+)
C363
CAV CIRCUIT
1 F37 14RD/LB
2 Z1 14BK
BLACK
2 1
1 2
BLACK
Z1 14BK 2
F37 14RD/LB 1
CIRCUIT CAV
C362
CAV CIRCUIT
1 F37 14RD
2 Z1 14BK
Z1 14BK 2
F37 14RD 1
CIRCUIT CAV
C363
C362
1 2
BLACK
BLACK
2 1
GRAY
1 3
SENSOR
POSITION
CAMSHAFT
XJD08029 J008W-7
LAMP
MOUNTED STOP
CENTER HIGH
BLACK
2
1
GROUND Z1 18BK
2
1
LIGHTER
CIGAR
- -
3
3
1 2
RED
GROUND Z1 16BK
2
CIGAR LIGHTER RELAY OUTPUT F30 16RD 1
CLOCKSPRING - C1
4 1
NATURAL
- - 4
SENSOR GROUND K4 20BK/RD 3
SPEED CONTROL SWITCH SIGNAL V37 20RD/LG 2
HORN RELAY CONTROL X3 20BK/RD 1
B A
CLOCKSPRING - C2
A K167 20BR/YL SENSOR GROUND
B V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
BRAKE LAMP SWITCH OUTPUT L50 18DG/WT
CLOCKSPRING - C3
2 1
YELLOW
DRIVER AIRBAG LINE 2 R43 18BK/LB 2
DRIVER AIRBAG LINE 1 R45 18DG/LB 1
J008W-7 XJD08030
2
1 T141 20YL IGNITION SWITCH OUTPUT (START)
SWITCH
CLUTCH INTERLOCK
F45 20YL/RD
SWITCH JUMPER
CLUTCH INTERLOCK
F45 18YL 2
F45 18YL 1
GROUND
BLACK
2 5
4
3
1
COMBINATION
FLASHER
1 L5 20BK FUSED IGNITION SWITCH OUTPUT (RUN)
2 L9 20BK/PK FUSED B (+)
3 L12 20VT/TN HAZARD FLASHER SELECT SIGNAL
4 L6 20RD/WT FLASHER OUTPUT
5
GREEN
2 1
2 1
BLACK
FUSED B(+) ENGINE STARTER MOTOR RELAY
Z1 20BK
FUSED B(+)
1 Z1 20BK GROUND
2 M1 20PK
3
4
- -
5 D1 20VT/BR CCD BUS (+)
6 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
7 M2 20YL COURTESY LAMPS DRIVER
8
G32 20BK/LB SENSOR GROUND
9
D2 20WT/BK CCD BUS (-)
10
11
12 Z2 20BK/LG GROUND
6 1
12 7
BLACK
AMBIENT TEMPERATURE SENSOR SIGNAL G31 20VT/LG
- -
- -
COMPASS
XJD08031 J008W-7
5V SUPPLY K7 20OR 3
CRANKSHAFT POSITION SENSOR SIGNAL K24 18GY/BK 1
CONNECTOR
DATA LINK
- -
-
-
-
-
-
-
- -
-
-
-
-
BLACK
1 8
9 16
FUSED B(+) F34 18TN/BK 16
15
14
13
12
CCD BUS (-) D2 18WT/BK 11
10
9
8
SCI TRANSMIT/ ISO 9141K D21 20PK 7
SCI RECEIVE D20 20LG/BK 6
GROUND Z12 18BK/TN 5
GROUND Z1 18BK 4
CCD BUS (+) D1 18VT/BR 3
- - 2
- - 1
CRANKSHAFT
POSITION
SENSOR
3 1
BLACK
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2 B3 18LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
3 B7 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 LEFT REAR WHEEL SPEED SENSOR (+)
11 B8 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-)
12 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
13 B43 18PK/OR G SWITCH TEST SIGNAL
14 - -
15 - -
16 G83 18GY/BK ABS RELAY CONTROL
17 B2 18YL RIGHT REAR WHEEL SPEED SENSOR (+)
18 B6 18WT/DB RIGHT REAR WHEEL SPEED SENSOR (-)
19 - -
20 D21 18PK SCI TRANSMIT/ ISO 9141K
21 - -
22 - -
23 F15 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
24 Z1 12BK GROUND
25 A10 12RD/DG FUSED B(+)
10
16
1 17
9 25
BLACK
CONTROLLER
ANTI-LOCK
BRAKE
J008W-7 XJD08032
LAMP MODULE
DAYTIME RUNNING
10
5
6
1
BLACK
FUSED RIGHT LOW BEAM OUTPUT L44 18VT/RD 10
- - 9
SIGNAL SENSOR SPEED VEHICLE G7 20WT/OR 7
FUSED B(+) A3 14RD/WT 6
FUSED IGNITION SWITCH OUTPUT (ST-RUN) F20 18WT 5
HIGH BEAM INDICATOR DRIVER G34 16RD/GY 4
- - 3
- - 2
DIMMER SWITCH HIGH BEAM OUTPUT L3 16RD 1
(BASE/POLICE)
1 3
SWITCH
DOME LAMPS
C A
BLACK
GROUND Z1 20BK
C
COURTESY LAMPS DRIVER M2 20YL B
A
(MIDLINE)
M1 20PK FUSED B(+)
1 -
2 M1 20PK
COURTESY LAMPS DRIVER 3 M2 20YL
FUSED B(+)
DOME LAMP
-
XJD08033 J008W-7
1 Q28 14DG/WT
2 Q18 14GY/BK RIGHT REAR WINDOW DRIVER UP
3 Q16 14BR/WT MASTER WINDOW SWITCH PASSENGER UP
4 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
5 Q11 14LB
6 Q26 14VT/WT
7 P35 18OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
8 Z1 14BK GROUND
9 F81 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
10 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
11 P36 18PK/VT DOOR LOCK SWITCH OUPUT (UNLOOK)
12 Q21 14WT DRIVER WINDOW DRIVER DOWN
BLUE
1
6
5
12
DRIVER POWER
LOCK/WINDOW
SWITCH-C1
1 Q28 14DG/WT
2 Q18 14GY/BK RIGHT REAR WINDOW DRIVER UP
3 Q11 14BR DRIVER WINDOW DRIVER UP
4 Q17 14DB/WT LEFT REAR WINDOW DRIVER UP
5 Q16 14BR/WT MASTER WINDOW SWITCH PASSENGER UP
6
7
8
10 Q27 14RD/BK LEFT REAR WINDOW DRIVER DOWN
11
12
BLUE
1
6
5
12
P35 18OR/VT
Q21 14VT
Z1 14BK
P36 18PK/VT
Q26 14VT/WT
DRIVER WINDOW DRIVER DOWN
DOOR LOCK SWITCH OUTPUT (LOCK)
GROUND
DOOR LOCK SWITCH OUTPUT (UNLOCK)
MASTER WINDOW SWITCH PASSENGER DOWN
DRIVER POWER
LOCK/WINDOW
SWITCH-C1
MASTER WINDOW SWITCH PASSENGER DOWN
DRIVER WINDOW DRIVER UP
(LHD)
(RHD)
(FULL OPTIONS)
(FULL OPTIONS)
MASTER WINDOW SWITCH RIGHT REAR DOWN
1 2
DOOR LOCK DRIVER P33 16OR/BK 2
DOOR UNLOCK DRIVER P34 16PK/BK 1
DRIVER DOOR
LOCK MOTOR
JAMB SWITCH
DRIVER DOOR
2 3
1
BLACK
GROUND Z1 18BK 3
DRIVER DOOR AJAR SWITCH SENSE G16 18BK/LB 2
COURTESY LAMPS DRIVER M2 18YL 1
J008W-7 XJD08034
1 P71 20YL LEFT POWER MIRROR VERTICAL DRIVER
2 P76 20OR/YL MIRROR COMMON DRIVER
3 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
4 P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER
5 Z1 14BK GROUND
6 P75 20DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
7 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER
8 Q1 14YL POWER WINDOW SWITCH FEED
8 5
4 1
WHITE
DRIVER POWER
LOCK/WINDOW
SWITCH-C2
(FULL OPTIONS)
(LHD)
MIRROR COMMON DRIVER P76 20OR/YL 4
FUSED REAR WINDOW DEFOGGER RELAY OUTPUT C16 20LB/YL 5
6 Z1 18BK GROUND
RED
4
1
3
6
MIRROR
DRIVER POWER
GROUND Z1 16BK 6
FUSED REAR WINDOW DEFOGGER RELAY OUTPUT C16 20BK/WT 5
MIRROR COMMON DRIVER P91 20WT/BK
LEFT POWER MIRROR HORIZONTAL DRIVER P75 20DB/WT 3
LEFT POWER MIRROR VERTICAL DRIVER P71 20YL 1
3
2 P75 20DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
(RHD)
6 Z1 18BK GROUND
RED
4
1
3
6
MIRROR
DRIVER POWER
P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER 1
3
P74 20DB RIGHT POWER MIRROR HORIZONTAL DRIVER 2
POWER MIRRORS
FULL OPTIONS
5 GROUND Z1 16BK
LHD
RHD
1 P71 20YL/LB LEFT POWER MIRROR VERTICAL DRIVER
XJD08035 J008W-7
1 Q11 14LB LEFT FRONT WINDOW DRIVER UP
2 Q21 14WT LEFT FRONT WINDOW DRIVER DOWN
DRIVER POWER
WINDOW MOTOR
(LHD)
1 2
BLACK
(RHD)
1 Q11 14BR LEFT WINDOW DRIVER UP
2 Q21 14VT LEFT FRONT WINDOW DRIVER DOWN
BLACK
2 1
WINDOW MOTOR
DRIVER POWER
DUTY CYCLE
EVAP/PURGE
SOLENOID
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
1
2 G60 18GY/YL
SENSOR GROUND
ENGINE OIL
PRESSURE SENSOR 3
K6 18VT/OR 5V SUPPLY
BLACK
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K2 18TN/BK 2
ENGINE COOLANT
TEMPERATURE
SENSOR
J008W-7 XJD08036
(POLICE PACKAGE)
SWITCH
EXTENDED IDLE
FUNCTION
E2 20OR
F15 20DB/WT
Z1 20BK
K78 20GY
CAV
4
3
1
2
CIRCUIT
IDLE ACTUATOR
GROUND
WHITE
4 1
GROUND Z1 20BK 4
FUSED HEADLAMP SWITCH OUTPUT L139 20VT 3
FOG LAMP SWITCH OUTPUT L39 20LB 2
E2 20OR 1
MOTOR
FRONT WIPER
6
3
4
1
BLACK
WIPER HIGH SPEED OUTPUT V4 16BR/VT 6
WIPER LOW SPEED OUTPUT V3 16BR/WT 5
GROUND Z1 16BK 4
- - 3
WIPER PARK SWITCH SENSE V5 16DG/YL 2
FUSED IGNITION SWITCH OUTPUT (RUN-ACC) V6 16DB 1
PUMP
DETECTION
EVAP LEAK
LEAK DETECTION PUMP SWITCH SENSE
GENERATOR DRIVER
-
CIRCUIT
2
4
3
1
CAV
K72 18DG/OR
K105 18WT/OR
K106 18WT/DG
-
FUNCTION
LEAK DETECTION PUMP SOLENOID CONTROL
1 4
4 1
FRONT FOG
LAMP
SWITCH
BLACK
BLACK
XJD08037 J008W-7
1 A142 18DG/OR
2 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
1 A142 18DG/OR
2 K12 18TN FUEL INJECTOR NO. 2 DRIVER
1 A142 18DG/OR
2 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
1 A142 18DG/OR
2 K14 18LB/BR FUEL INJECTOR NO. 4 DRIVER
FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 1
(2.5L)
FUEL INJECTOR
NO. 1
NO. 2
FUEL INJECTOR
(2.5L)
1 2
2 1
(2.5L)
FUEL INJECTOR
NO. 4
NO. 3
FUEL INJECTOR
(2.5L)
1 2
BLACK
BLACK
BLACK
BLACK
J008W-7 XJD08038
FUEL INJECTOR NO. 6 DRIVER K16 18LG/BK 2
A142 18DG/OR 1
FUEL INJECTOR NO. 5 DRIVER K15 18PK/BK 2
A142 18DG/OR 1
FUNCTION
K11 18WT/DB
A142 18DG/OR
2
1
CAV CIRCUIT
FUEL INJECTOR NO. 1 DRIVER
FUEL INJECTOR NO. 4 DRIVER K14 18LB/BR 2
FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT A142 18DG/OR 1
FUEL INJECTOR NO. 3 DRIVER K13 18YL/WT 2
A142 18DG/OR 1
FUEL INJECTOR NO. 2 DRIVER K12 18TN 2
A142 18DG/OR 1
FUEL INJECTOR NO. 1
(4.0L)
1 2
BLACK
BLACK
2 1
(4.0L)
FUEL INJECTOR NO. 2
BLACK
2 1
(4.0L)
FUEL INJECTOR NO. 3
BLACK
2 1
(4.0L)
FUEL INJECTOR NO. 4
BLACK
2 1
(4.0L)
FUEL INJECTOR NO. 5
BLACK
2 1
(4.0L)
FUEL INJECTOR NO. 6
XJD08039 J008W-7
MODULE
FUEL PUMP
4
1 2 3
5 6
BLACK
GROUND Z1 16BK 6
- - 5
K226 20DB/LG 3
- - 2
FUEL PUMP RELAY OUTPUT A141 16DG/WT 1
BLACK
GENERATOR
1
B43 20PK/OR G SWITCH TEST SIGNAL
2 B41 20YL/VT G SWITCH NO.1 SENSE
3
B42 20TN/WT G SWITCH NO. 2 SENSE
G SWITCH
3 1
2
1
BLACK
FUEL LEVEL SENSOR SIGNAL
GENERATOR FIELD K20 16DG 2
K72 16DG/OR 1
GENERATOR SOURCE
HEADLAMP SWITCH OUTPUT
1 - -
2 A3 14RD/WT FUSED B(+)
3 - -
4 Z1 18BK GROUND
5 - -
6
L2 14LG HEADLAMP SWITCH OUTPUT
L2 14LG
7 - -
8 F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN)
1 3 5 7
2 4 6 8
BLACK
HEADLAMP
DELAY MODULE
4 L20 14LG/WT FUSED B (+)
3 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
2 L2 14LG HEADLAMP SWITCH OUTPUT
1 L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT
4 1
BLACK
HEADLAMP BEAM
SELECT SWITCH
J008W-7 XJD08040
GROUND Z1 18BK
FUSED B(+) F37 14RD/LB
- -
- -
- -
8
HEATED SEAT
RELAY
5
F235 16RD
4
B(+) TO HEATED SEAT MODULE
F83 18YL/DG
3
B(+) TO HEATED SEAT MODULE F235 16RD
2
- - 1
7
6
IDLE AIR CONTROL NO. 1 DRIVER K39 18GY/RD 4
IDLE AIR CONTROL NO. 2 DRIVER K60 18YL/BK 3
IDLE AIR CONTROL NO. 3 DRIVER K40 18BR/WT 2
IDLE AIR CONTROL NO. 4 DRIVER K59 18VT/BK 1
1
4
7
2
5
8 9
6
3
BLACK
1 4
MOTOR
CONTROL
IDLE AIR
FUSED B(+)
LHD
1 E1 20TN PANEL LAMPS DIMMER SWITCH SIGNAL
2 L2 14LG HEADLAMP SWITCH OUTPUT
3 M2 20YL COURTESY LAMPS DRIVER
4
F34 18TN/BK
5 G26 20LB KEY-IN IGNITION SWITCH SENSE
6 G16 20BK/LB DRIVER DOOR AJAR SWITCH SENSE
7 L20 14LG/WT FUSED B (+)
8
A3 14RD/WT FUSED B (+)
A3 14RD/WT FUSED B (+)
9 L7 18BK/YL HEADLAMP SWITCH OUTPUT
BLACK
2
9
7
6
3
4
5 8
1
SWITCH
HEADLAMP
F34 18TN/BK FUSED B(+)
XJD08041 J008W-7
K19 18GY 2
IGNITION COIL
2
BLACK
1
IGNITION COIL NO. 1 DRIVER
A142 18DG/OR 1
SWITCH - C1
IGNITION
6 10
1 5
BLACK
A41 14YL 10
IGNITION SWITCH OUTPUT (ST-RUN) A21 12DB 9
A31 12BK/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
SWITCH - C2
IGNITION
2 1
GREEN
KEY-IN IGNITION SWITCH SENSE G26 20LB 1
IGNITION SWITCH OUTPUT (RUN-ACC)
IGNITION SWITCH OUTPUT (START)
(2.5L)
J008W-7 XJD08042
1 D2 20WT/BK CCD BUS (-)
2 D1 20VT/BR CCD BUS (+)
3 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL
4 C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE
5
G106 20BK/WT 4WD SWITCH SENSE (FULL-TIME)
6 L60 20TN RIGHT TURN SIGNAL
7
G107 20BK/RD 4WD SWITCH SENSE (PART-TIME)
9 Z2 18BK/LG GROUND
10 G10 20LG/RD SEAT BELT SWITCH SENSE
INSTRUMENT
CLUSTER - C2
(RHD)
CLUSTER - C1
INSTRUMENT
(LHD)
CLUSTER - C1
INSTRUMENT
BLACK
L61 20LG/WT 10
M1 20PK 9
F87 20WT/BK 8
G29 20BK/LB 7
Z2 20BK/LG 6
L3 16RD/OR 5
G19 20LG/OR 4
E2 20OR 3
G99 20GY/WT 2
G78 20TN/BK 1
LEFT TURN SIGNAL L61 20LG/WT 10
FUSED B(+) M1 20PK 9
FUSED IGNITION SWITCH OUTPUT (START-RUN) F87 20WT/BK 8
LOW WASHER FLUID SENSE G29 20BK/LB 7
GROUND Z2 20BK/LG 6
HIGH BEAM INDICATOR DRIVER G34 16RD/GY 5
ABS WARNING INDICATOR DRIVER G19 20LG/OR 4
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL E2 20OR 3
RED BRAKE WARNING INDICATOR DRIVER G99 20GY/WT 2
LIFTGATE AJAR SWITCH SENSE G78 20TN/BK 1
LEFT TURN SIGNAL
FUSED B(+)
FUSED IGNITION SWITCH OUTPUT (START-RUN)
LOW WASHER FLUID SENSE
GROUND
DIMMER SWITCH HIGH BEAM OUTPUT
ABS WARNING INDICATOR DRIVER
FUSED PANEL LAMPS SWITCH SIGNAL
RED BRAKE WARNING INDICATOR DRIVER
LIFTGATE AJAR SWITCH SENSE
5
10
1
6
6
1
10
5
BLACK
BLACK
5
10
1
6
XJD08043 J008W-7
SENSOR
TEMPERATURE
INTAKE AIR
GRAY
INTAKE AIR TEMPERATURE SENSOR SIGNAL K21 18BK/RD 2
BLOCK - C1
JUNCTION
NATURAL
8
1
3
12
2
7
M1 20PK 12
FUSED RIGHT HIGH BEAM OUTPUT L34 20RD/OR 11
FUSED LEFT LOW BEAM OUTPUT L43 20VT 10
FUSED LEFT HIGH BEAM OUTPUT L33 20RD 9
- - 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
JUNCTION
BLOCK - C2
WHITE
3
6
1
2
FUSED HEADLAMP SWITCH OUTPUT L77 20BR/YL 6
FUSED IGNITION SWITCH OUTPUT (ST-RUN) F12 18DB/WT 5
HORN RELAY OUTPUT X2 20DG/RD 4
- - 3
A7 10RD/BK 2
FUSED B(+) A4 12BK/PK 1
FUSED HEADLAMP SWITCH OUTPUT
FUSED B(+)
4.0L
FUSED B(+)
2 1
J008W-7 XJD08044
S7 L3 16RD/OR DIMMER SWITCH HIGH BEAM OUTPUT
S8 F15 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN)
S9 X12 16RD/WT
S10 - -
S11 V23 18BR/PK
S12
S13 F87 20WT/BK
S14 - -
S15 - -
S16 - -
S17 - -
S18 M1 20PK FUSED B(+)
S19 C16 20LB/YL FUSED REAR WINDOW DEFFOGGER RELAY OUTPUT
C16 20BK/WT
S20 L5 20BK FUSED IGNITION SWITCH OUTPUT (RUN)
S21 F14 18LG/YL
S22 X3 20BK/RD HORN RELAY CONTROL
S23 F23 18DB/YL
S24 -
S25 M2 20YL COURTESY LAMPS DRIVER
S26 C81 20LB/WT REAR WINDOW DEFOGGER RELAY CONTROL
BLOCK - C4
JUNCTION
FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F83 18YL/DG
WHITE
S20 L2 S13
S14 L1 S7
M6
M5
M4
M3
M2
M1
S26
S25
S24
S3
S2
S1 - - S6
GROUND Z1 14BK S5
S4
DIMMER SWITCH LOW BEAM OUTPUT L4 16VT/WT S3
FUSED PANEL LAMPS DIMMER SWITCH SIGNAL E2 20OR S2
PANEL LAMPS DIMMER SWITCH SIGNAL E1 20TN S1
F30 16RD M6
FUSED B(+) F38 16RD/LB M5
FUSED IGNITION SWITCH OUTPUT (RUN-ACC) V6 16DB M4
HEADLAMP SWITCH OUTPUT L7 18BK/YL M3
IGNITION SWITCH OUTPUT (RUN) A22 12BK/OR M2
IGNITION SWITCH OUTPUT (ST) A41 14YL M1
IGNITION SWITCH OUTPUT (ST-RUN) A21 12DB L2
IGNITION SWITCH OUTPUT (RUN-ACC) A31 12BK/WT L1
BLOCK - C3
JUNCTION
3 1
NATURAL
GROUND Z1 20BK 2
CIGAR LIGHTER RELAY OUTPUT
FUSED REAR WINDOW DEFFOGGER RELAY OUTPUT
OVERHEAD CONSOLE
LHD
RHD
S19
XJD08045 J008W-7
BLOCK - C5
JUNCTION
WHITE
10 8 7 5
4 1
RIGHT POWER MIRROR VERTICAL DRIVER P72 20YL/BK 10
RIGHT POWER MIRROR HORIZONTAL DRIVER P74 20DB 9
FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F81 12TN 8
- -
7 FUSED B(+) F35 16RD
6
FUSED REAR WINDOW DEFOGGER RELAY OUTPUT C16 20LB/YL 5
- - 4
3
BLOCK - C6
JUNCTION
1 2
NATURAL
FUSED B(+) F37 14RD/LB 2
REAR WINDOW DEFOGGER RELAY OUTPUT C15 12BK/WT 1
BLOCK - C7
JUNCTION
8
3
4
1
NATURAL
FUSED B(+) A6 20RD/OR 8
FUSED HEADLAMP SWITCH OUTPUT L78 18DG/YL 6
MIRROR COMMON DRIVER P91 20WT/BK 3
FUSED HEADLAMP SWITCH OUTPUT L77 18BR/YL 2
RHD
BASE
FULL OPTIONS
POWER SEATS
9 P74 20DB
10 P72 20YL/BK LEFT POWER MIRROR VERTICAL DRIVER
LEFT POWER MIRROR HORIZONTAL DRIVER
LHD
J008W-7 XJD08046
BLOCK - C8
JUNCTION
1 2
NATURAL
- - 2
FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F81 14TN 1
(LHD)
BLOCK - C9
JUNCTION
1
6
5
12
NATURAL
GROUND Z1 16BK 11
P76 20OR/YL 10
9
- - 8
COMMON MIRROR DRIVER P91 20WT/BK 7
RIGHT POWER MIRROR VERTICAL DRIVER P72 20YL/BK 6
- - 5
- - 4
RIGHT POWER MIRROR HORIZONTAL DRIVER P74 20DB 2
1
GROUND Z1 16BK
MIRROR COMMON DRIVER
(RHD)
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
FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
LEFT POWER MIRROR VERTICAL DRIVER
11
12 P34 16PK/BK
Z1 18BK GROUND
P33 16OR/BK
F35 16RD
12 P34 16PK/BK
DOOR LOCK DRIVER
DOOR UNLOCK DRIVER
DOOR UNLOCK DRIVER
FUSED B(+)
POWER MIRROR
FULL OPTIONS
1
L10 18BR/LG BACK-UP LAMP FEED 2
Z1 18BK GROUND
GRAY
2 1
LEFT BACK-UP
LAMP
XJD08047 J008W-7
1 2
GRAY
FOG LAMP RELAY OUTPUT L39 20LB 2
GROUND Z1 20BK 1
LEFT FOG
LAMP
COURTESY LAMP
LEFT
BLACK
COURTESY LAMPS DRIVER M2 18BK/WT 2
M1 18PK 1
DOOR TWEETER
LEFT FRONT
2
1
BLACK
X87 18LG/BK 2
X85 18LG/RD 1
LEFT FRONT
DOOR SPEAKER
2 X53 18LG/BK LEFT FRONT SPEAKER (+)
LEFT FRONT SPEAKER (-) X55 18LG/RD 1
2 1
BLACK
AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X87 18DG 2
AMPLIFIED LEFT FRONT DOOR SPEAKER (-) X85 18BK/RD 1
FUSED B(+)
6 SPEAKER RHD
4 SPEAKER
AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
6 SPEAKER LHD
AMPLIFIED LEFT FRONT DOOR SPEAKER (-) X85 18LG/RD 1
2 X87 18LG/BK AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
SIGNAL LAMP NO. 1
LEFT TURN SIGNAL L61 18LG 1
FUSED HEADLAMP SWITCH OUTPUT L77 18BR 2
GROUND Z1 18BK 3
GRAY
3 1
PARK/TURN
LEFT FRONT
J008W-7 XJD08048
SENSOR
WHEEL SPEED
LEFT FRONT
1 2
GRAY
B9 18RD 2
LEFT FRONT WHEEL SPEED SENSOR (-) B8 18RD/DB 1
A C
B
GROUND Z1 18BK C
FUSED LEFT LOW BEAM OUTPUT L43 18VT B
FUSED LEFT HIGH BEAM OUTPUT L33 20RD
FUSED LEFT HIGH BEAM OUTPUT L33 18RD
A
LEFT HEADLAMP
LEFT FRONT WHEEL SPEED SENSOR (+)
FOG LAMPS
SEAT BACK
A P88 18BR/BK LEFT HEATED SEAT BACK DRIVER
B Z1 18BK GROUND
LEFT HEATED
B A
LEFT HEATED SEAT BACK DRIVER P88 18BR/BK
LEFT HEAT SENSE INPUT
SENSOR FEED P141 18TN/LB
P143 18BK/DG
C
D
LEFT HEATED
B
LEFT HEATED SEAT DRIVER P87 18BK/OR A
SEAT CUSHION
A
B
C D
SIGNAL LAMP NO. 2
LEFT TURN SIGNAL L61 18LG 1
L77 18BR 2
GROUND Z1 18BK 3
LEFT FRONT
PARK/TURN
1 3
GRAY
XJD08049 J008W-7
GROUND Z1 18BK
LEFT SEAT HIGH HEAT LED DRIVER
FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F83 18YL/DG
P139 18VT/WT
3
4
2
LEFT SEAT LOW HEAT LED DRIVER P137 18VT 1
6
5
P133 18TN/DG
- -
LEFT SEAT HEATER SWITCH MUX
SEAT SWITCH
LEFT HEATED
6
1
4
3
YELLOW
VERTICAL MOTOR
SEAT FRONT
1 P19 14YL/LG LEFT POWER SEAT FRONT UP
2 P21 14RD/LG LEFT POWER SEAT FRONT DOWN
LEFT POWER
YELLOW
MOTOR
SEAT HORIZONTAL
1 P17 14RD/LB LEFT POWER SEAT HORIZONTAL REARWARD
2 P15 14YL/LB LEFT POWER SEAT HORIZONTAL FORWARD
LEFT POWER
LEFT POWER
LEFT POWER SEAT REAR UP P11 14YL/WT 2
LEFT POWER SEAT REAR DOWN P13 14RD/WT 1
SEAT REAR
VERTICAL MOTOR
YELLOW
RED
J008W-7 XJD08050
DOOR JAMB
LEFT REAR
BLACK
1
3 2
GROUND Z1 18BK 2
- - 1
DOOR LOCK
LEFT REAR
2 1
BLACK
SWITCH
MOTOR
LEFT POWER SEAT HORIZONTAL REARWARD
LEFT POWER SEAT FRONT DOWN
LEFT POWER SEAT FRONT UP P19 14YL/LG
P21 14RD/LG
M
N
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
BLACK
Z1 14BK
F37 14RD FUSED B(+)
GROUND
LEFT REAR WINDOW DRIVER DOWN
SENSOR
A B3 20LG/DB LEFT REAR WHEEL SPEED SENSOR (-)
B B4 20LG LEFT REAR WHEEL SPEED SENSOR (+)
B A
BLACK
LEFT REAR
WHEEL SPEED
1 Q13 14DB POWER WINDOW LEFT REAR B(+) UP
2 Q23 14RD/WT
BLACK
2 1
LEFT REAR
WINDOW MOTOR
XJD08051 J008W-7
1 2
LEFT SPEED
CONTROL
1 L77 20BR FUSED LEFT HEADLAMP SWITCH OUTPUT
2 L61 20LG LEFT TURN SIGNAL
NATURAL
LEFT SIDE
MARKER LAMP
CAV CIRCUIT
FUNCTION
1
L50 18WT/TN BRAKE LAMP SWITCH OUTPUT 3
Z1 18BK GROUND
1 2 3
BLACK
2 L77 18BR FUSED LEFT HEADLAMP SWITCH OUTPUT
LEFT TAIL/
STOP LAMP
SWITCH
A X57 18BR/LB LEFT REAR SPEAKER (-)
A X91 16BR/DB AMPLIFIED LEFT REAR SPEAKER (+)
SPEAKER
SOUNDBAR
LEFT
B
B X51 18BR/YL
X93 16BR/YL AMPLIFIED LEFT REAR SPEAKER (-)
LEFT REAR SPEAKER (+)
4 SPEAKER SYSTEM
6 SPEAKER SYSTEM
1 2
LEFT REAR WINDOW DRIVER DOWN
POWER WINDOW LEFT REAR B(+) UP
WINDOW SWITCH
LEFT REAR
BLUE
4
1
6
3
POWER WINDOW SWITCH FEED Q1 14YL 6
Q23 14RD/WT 5
LEFT REAR WINDOW DRIVER UP Q17 14DB/WT 4
- 3
LEFT REAR WINDOW DRIVER DOWN Q27 14RD/BK 2
Q13 14DB 1
CIRCUIT CAV
J008W-7 XJD08052
LEFT TURN SIGNAL L63 18DG/RD 2
GROUND Z1 18BK 1
LEFT TURN
SIGNAL LAMP
2 1
LICENSE LAMP
2 1
GROUND Z1 18BK 2
FUSED HEADLAMP SWITCH OUTPUT L78 18BK/YL 1
A P33 16OR/BK DOOR LOCK DRIVER
B P34 16PK/BK DOOR UNLOCK DRIVER
BLACK
A B
LIFTGATE
LOCK MOTOR
1 Z1 20BK GROUND
2
3 M4 20VT/YL LIFTGATE COURTESY LAMP DRIVER
BLACK
3 1 G78 20TN/BK LIFTGATE AJAR SWITCH SENSE
LIFTGATE
SWITCH
A M1 20PK FUSED B(+)
B Z1 20BK GROUND
B A
LEFT VISOR/
VANITY
LAMP
BLACK
XJD08053 J008W-7
- -
OVERHEAD
- -
1 6
7 12
BUS(-) CCD D2 20WT/BK 12
DOOR LOCK CONTROL P59 20LB/RD 11
GROUND Z1 20BK 9
8
- - 7
BUS(+) CCD D1 20VT/BR 6
DOOR UNLOCK RELAY CONTROL P55 20DB 5
4
GROUND Z1 20BK 3
5V SUPPLY K7 20OR 3
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL K1 18DG/RD 2
UPSTREAM
SENSOR 1/1
OXYGEN
3
1
4
2
GRAY
OXYGEN SENSOR 1/1 SIGNAL K41 18BK/DG 4
GROUND Z1 20BK 2
FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT A42 20DG 1
MODULE
2.5L
4.0L
2 Z1 18BK GROUND
ABSOLUTE
MANIFOLD
PRESSURE
SENSOR
3 1
BLACK
BLACK
1 F142 20DG/WT FUSED AUTOMATIC SHUTDOWN RELAY OUTPUT
OXYGEN SENSOR RELAY OUTPUT A242 20VT/OR 1
1 F142 20DG/WT FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT
2 Z1 20BK GROUND
3 K167 20BR/YL SENSOR GROUND
4 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL
BLACK
2
4
1
3
OXYGEN
SENSOR 1/2
DOWNSTREAM
J008W-7 XJD08054
BLACK
1
3 2
GROUND Z1 18BK 3
1 - -
2 - -
3 R42 18BK/YL PASSENGER AIRBAG LINE 2
4 R44 18DG/YL
YELLOW
1 4
PASSENGER
AIRBAG
(2.5L A/T)
POSITION SWITCH
PARK/NEUTRAL
BLACK
FUNCTION
PARK/NETURAL POSITION SWITCH SENSE
BACK-UP LAMP FEED
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
2
1
A42 20DG
Z1 20BK GROUND
OXYGEN SENSOR RELAY OUTPUT
OXYGEN SENSOR RELAY OUTPUT
GROUND Z1 20BK
A242 20VT/OR
1
2
4 K341 18TN OXYGEN SENSOR 2/2 SIGNAL
DOWNSTREAM
SENSOR 2/2
OXYGEN
3
1
4
2
BLACK
3 1
(4.0L CALIFORNIA)
(4.0L CALIFORNIA)
XJD08055 J008W-7
1 P34 16PK/BK DOOR UNLOCK DRIVER
2 Q22 14VT PASSENGER FRONT WINDOW DRIVER DOWN
3 Q26 14VT/WT MASTER WINDOW SWITCH PASSENGER FRONT DOWN
4 Q16 14BR/WT MASTER WINDOW SWITCH PASSENGER FRONT UP
5 P33 16OR/BK DOOR LOCK DRIVER
6 - -
7 - -
8 - -
9 Q12 14BR
10 Q1 14YL POWER WINDOW SWITCH FEED
11 - -
12 - -
BLUE
1
6
5
12
PASSENGER
POWER
PASSENGER FRONT WINDOW DRIVER UP
(FULL OPTIONS)
SWITCH - C1
LOCK/WINDOW
1 P59 20LB/RD DOOR LOCK CONTROL
2 P55 20DB/PK DOOR UNLOCK RELAY CONTROL
3 P35 20OR/VT DOOR LOCK SWITCH OUTPUT (LOCK)
5 F35 16RD FUSED B(+)
6 Z1 14BK GROUND
7 P35 18OR/VT
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 (LOCK)
(FULL OPTIONS)
DOOR UNLOCK RELAY CONTROL P55 20DB 2
LHD
RHD
1 2
PASSENGER DOOR
LOCK MOTOR
FULL OPTIONS
POWER MIRRORS
(LHD)
RIGHT POWER MIRROR VERTICAL DRIVER 1 P72 20YL/BK
RIGHT POWER MIRROR HORIZONTAL DRIVER 3 P74 20DB
2 P76 20OR/YL
4 P76 20OR/YL
5 C16 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
6 Z1 18BK GROUND
6 5 4
1 2 3
RED
PASSENGER
POWER MIRROR
2
3
P74 20DB
P91 20WT/BK
RIGHT POWER MIRROR HORIZONTAL DRIVER
J008W-7 XJD08056
AMPLIFIER - C2
POWER
14
6
7
1
NATURAL
AMPLIFIED LEFT REAR SPEAKER (+) X91 18WT/BK 14
AMPLIFIED RIGHT REAR SPEAKER (-) X92 18TN/BK 13
AMPLIFIED LEFT FRONT DOOR SPEAKER (-) X85 18BR/RD 12
AMPLIFIED RIGHT FRONT DOOR SPEAKER (+) X82 18LB/RD 11
AMPLIFIED RIGHT FRONT DOOR SPEAKER (-) X80 18LB/BK 10
- - 9
GROUND Z5 16BK/LB 8
GROUND Z5 16BK/LB 7
AMPLIFIED LEFT REAR SPEAKER (-) X93 18WT/RD 6
AMPLIFIED RIGHT REAR SPEAKER (+) X94 18TN/RD 5
AMPLIFIED LEFT FRONT DOOR SPEAKER (+) X87 18LG/VT 4
- - 3
FUSED B(+) F75 16VT 2
FUSED B(+) F75 16VT 1
-
1 X55 18BR/RD LEFT FRONT SPEAKER (-)
2 X56 18DB/RD RIGHT FRONT SPEAKER (-)
3 X58 18DB/OR RIGHT REAR SPEAKER (-)
4 X60 18DG/RD RADIO 12V OUTPUT
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
CAV
2
1
CIRCUIT
Q12 14BR
Q22 14VT
RIGHT FRONT WINDOW DRIVER (UP)
RIGHT FRONT WINDOW DRIVER (DOWN)
FUNCTION
BLACK
2 1
PASSENGER POWER
WINDOW MOTOR
FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
(RHD)
POWER MIRRORS
FULL OPTIONS
LEFT POWER MIRROR VERTICAL DRIVER
GROUND Z1 16BK
C16 20LB/YL 5
P75 20DB/RD
P91 20WT/BK
P75 20DB/WT
P71 20YL
3
6
3
2
1
POWER MIRROR
PASSENGER
RED
3 2 1
4 5 6
P76 20OR/YL 4
P76 20OR/YL
2
XJD08057 J008W-7
FUSED B(+) F38 16RD/LB
1
Z1 16BK GROUND
2
RED
2 1
3
3
- -
POWER OUTLET
1 Z1 20BK GROUND
2 K10 18DB/BR POWER STEERING PRESSURE SWITCH SENSE
WHITE
2 1
POWER STEERING
PRESSURE SWITCH
(2.5L)
4
1
8
5
SWITCH
MIRROR
POWER
LEFT POWER MIRROR VERTICAL DRIVER P71 20YL/LB 8
GROUND
1 Z1 20BK
2 F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
4 P72 20YL/BK RIGHT POWER MIRROR VERTICAL DRIVER
5
P76 20OR/YL
P76 20OR/YL
6
P91 20WT/BK
P91 20WT/BK
7 P75 20 DB/WT LEFT POWER MIRROR HORIZONTAL DRIVER
Z1 14BK GROUND 1
8 P71 20YL LEFT POWER MIRROR VERTICAL DRIVER
RHD
LHD
J008W-7 XJD08058
CONTROL MODULE - C1
POWERTRAIN
IDLE AIR CONTROL NO. 3 DRIVER
6
5
BLACK
32
21 12
22
11 1
- - 30
29
- - 28
MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL K1 18DG/RD 27
26
OXYGEN SENSOR 1/2 SIGNAL K141 18TN/WT 25
OXYGEN SENSOR 1/1 SIGNAL K41 18BK/DG 24
THROTTLE POSITION SENSOR SIGNAL K22 18OR/DB 23
FUSED B(+) A61 14DG/BK 22
- - 21
K59 18VT/BK 20
IDLE AIR CONTROL NO. 1 DRIVER K39 18GY/RD 19
CAMSHAFT POSITION SENSOR SIGNAL K44 18TN/YL 18
5V SUPPLY K7 18OR 17
ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K2 18TN/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/BK 10
- - 9
CRANKSHAFT POSITION SENSOR SIGNAL K24 18GY/BK 8
IGNITION COIL NO. 1 DRIVER K19 18GY 7
GROUND Z1 18BK
PARK/NEUTRAL POSITION SWITCH SENSE T41 18BK/WT 6
- -
- - 3
1
IDLE AIR CONTROL NO. 4 DRIVER
2.5L A/T
4.0L A/T
2.5L
4.0L
K341 18TN OXYGEN SENSOR 2/2 SIGNAL
K241 18LG/RD OXYGEN SENSOR 2/1 SIGNAL
K18 18RD/YL IGNITION COIL NO. 3 DRIVER
EXCEPT 2.5L M/T
2.5L M/T
4.0L CALIFORNIA
XJD08059 J008W-7
- -
K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
K15 18PK/BK FUEL INJECTOR NO. 5 DRIVER
5V SUPPLY K6 18VT/OR
FUEL INJECTOR NO. 6 DRIVER K16 18LG/BK
- -
K12 18TN FUEL INJECTOR NO. 2 DRIVER
K14 18LB/BR FUEL INJECTOR NO. 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
12
11
GENERATOR FIELD K20 18DG 10
9
- - 8
- - 7
6
5
4
- - 3
- - 2
- - 1
K54 18OR/BK
4.0L
2.5L A/T
TORQUE CONVERTER CLUTCH SOLENOID CONTROL
- -
K17 18DB/TN IGNITION COIL NO. 2 DRIVER
WHITE
J008W-7 XJD08060
LEAK DETECTION PUMP SWITCH SENSE K105 18WT/OR
CONTROL
POWERTRAIN
GRAY
32
21 12
22
11 1
- - 31
(+) BUS CCD D1 18VT/BR 30
RECEIVE SCI D20 18LG/BK 29
(-) BUS CCD D2 18WT/BK 28
SCI TRANSMIT/ ISO 9141K D21 18PK 27
FUEL LEVEL SENSOR SIGNAL K226 18DB/LG 26
GENERATOR SOURCE K72 18DG/OR 25
A/C SELECT INPUT C90 18LG 23
A/C SWITCH SENSE C22 18DB/WT 22
- - 21
DUTY CYCLE EVAP/PURGE SOLENOID CONTROL K52 18PK/BK 20
FUEL PUMP RELAY CONTROL K31 18BR 19
- - 18
- - 17
- - 16
BATTERY TEMPERATURE SENSOR SIGNAL K118 18PK/YL 15
14
13
FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT F142 18DG/WT 12
SPEED CONTROL POWER SUPPLY V32 18YL/RD 11
LEAK DETECTION PUMP SOLENOID CONTROL K106 18WT/DG 10
9
8
- - 7
- - 6
SPEED CONTROL VENT SOLENOID CONTROL V35 18LG/RD 5
SPEED CONTROL VACUUM SOLENOID CONTROL V36 18TN/RD 4
AUTOMATIC SHUT DOWN RELAY CONTROL K51 18DB/YL 3
RADIATOR FAN RELAY CONTROL C27 18DB/PK 2
A/C COMPRESSOR CLUTCH RELAY CONTROL C13 18DB/OR 1
LEAK DETECT
MODULE - C3
K74 18BR/VT
K73 18BR/OR OXYGEN SENSOR UPSTREAM RELAY CONTROL
OXYGEN SENSOR DOWNSTREAM RELAY CONTROL
C48 18TN RADIATOR FAN REQUEST
4.0L
XJD08061 J008W-7
PRNDL
ILLUMINATION
(A/T)
2 1
GROUND Z1 20BK 2
FAN MOTOR
RADIATOR
1 2
LT.GRAY
GROUND Z1 12BK 2
RADIATOR FAN RELAY OUTPUT C25 12LB 1
RADIO - C1
BLACK
7 1
RIGHT REAR SPEAKER (-) X58 16DB/OR 7
LEFT REAR SPEAKER (-) X57 16BR/LB 6
RIGHT FRONT SPEAKER (+) X54 16VT 5
LEFT FRONT SPEAKER (+) X53 16DG 4
RIGHT REAR SPEAKER (+) X52 16DB/WT 3
LEFT REAR SPEAKER (+) X51 16BR/YL 2
RADIO 12V OUTPUT X60 16DG/RD 1
FUSED B(+)
RADIO - C2
GRAY
1 7
M1 20PK 7
FUSED IGNITION SWITCH OUTPUT (RUN-ACC) X12 16RD/WT 6
HEADLAMP SWITCH OUTPUT L7 18BK/YL 4
RIGHT FRONT SPEAKER (-) X56 16DB/RD 3
LEFT FRONT SPEAKER (-) X55 16BR/RD 2
- - 1
BLACK
4 1
RAIL COIL
(4.0L)
IGNITION COIL NO. 3 DRIVER
K18 18RD/YL
A142 18DG/OR
4
2
IGNITION COIL NO. 2 DRIVER K17 18DB/TN 3
IGNITION COIL NO. 1 DRIVER K19 18GY 1
J008W-7 XJD08062
WASHER SWITCH
REAR WIPER/
3
1
6
2
BLACK
V23 18BR/PK 6
FUSED IGNITION SWITCH OUTPUT (RUN) V23 18BR/PK 5
REAR WIPER MOTOR CONTROL V13 18BR/LG 4
REAR WASHER MOTOR CONTROLLER V20 18BK/WT 2
GROUND Z1 20BK 1
LAMP
RIGHT BACK-UP
1 2
GRAY
GROUND Z1 18BK 1
BACK-UP LAMP FEED L10 18BR/LG 2
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 18BK/WT 2
GROUND Z1 18BK 1
Z1 18BK GROUND
2
1 V20 18BK/WT REAR WASHER MOTOR CONTROL
Z1 18BK GROUND
BLACK
2
1
1 Z1 20BK GROUND
2 C80 20DB/WT REAR WINDOW DEFOGGER SWITCH SENSE
3 C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
4 E2 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL
XJD08063 J008W-7
BLACK
1
3
2 L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT
3 Z1 18BK GROUND
RIGHT FRONT
PARK/TURN
DOOR TWEETER
RIGHT FRONT
2
1
BLACK
X82 18LB/RD 2
AMPLIFIED RIGHT FRONT DOOR SPEAKER (-) X80 18LB/BK 1
PARK/TURN
RIGHT FRONT
GROUND Z1 18BK 3
L78 18DG/YL 2
RIGHT TURN SIGNAL L60 18TN 1
3
1
BLACK
1 X80 18LB/BK AMPLIFIED RIGHT FRONT DOOR SPEAKER (-)
2 X82 18LB/RD
BLACK
1 2
RIGHT FRONT
DOOR SPEAKER
AMPLIFIED RIGHT FRONT DOOR SPEAKER (+)
AMPLIFIED RIGHT FRONT DOOR SPEAKER (+)
SIGNAL LAMP NO. 1
SIGNAL LAMP NO. 2
FOG LAMP
RIGHT
1 Z1 20BK GROUND
2 L39 20LB FOG LAMP RELAY OUTPUT
GRAY
2 1
1 M1 18PK FUSED B(+)
2 M2 18BK/WT COURTESY LAMPS DRIVER
BLACK
RIGHT COURTESY
LAMP
J008W-7 XJD08064
1 2
1 B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-)
2 B7 18WT
RIGHT FRONT
WHEEL SPEED
A C
B
RIGHT
HEADLAMP
GROUND Z1 18BK C
FUSED RIGHT LOW BEAM OUTPUT L44 18VT/RD B
FUSED RIGHT HIGH BEAM OUTPUT L34 18RD/OR A
RIGHT FRONT WHEEL SPEED SENSOR (+)
SENSOR
RIGHT HEATED SEAT BACK DRIVER
GROUND
A B
A P89 18BR
B Z1 18BK
RIGHT HEATED
SEAT BACK
RIGHT HEAT SEAT DRIVER
RIGHT HEATED SEAT BACK DRIVER
SENSOR FEED
D C
B A
RIGHT HEAT SENSE INPUT
SEAT CUSHION
RIGHT HEATED
P89 18BR
P141 18TN/LB
P144 18BK/YL
C
D
B
P86 18PK/BK A
BLUE
YELLOW
VERTICAL MOTOR
SEAT FRONT
1 P18 14YL/LG RIGHT POWER SEAT FRONT UP
2 P20 14RD/LG RIGHT POWER SEAT FRONT DOWN
RIGHT POWER
RIGHT HEATED
SEAT SWITCH
3
4
1
6
RIGHT SEAT HEATER SWITCH MUX
- -
P134 18TN/RD
5
6
1 P138 18VT/LG RIGHT SEAT LOW HEAT LED DRIVER
2
4
3
P140 18VT/BK
F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
RIGHT SEAT HIGH HEAT LED DRIVER
Z1 18BK GROUND
XJD08065 J008W-7
CAV
SWITCH
1 P34 16PK/BK DOOR UNLOCK DRIVER
2 P33 16OR/BK DOOR LOCK DRIVER
BLACK
1 2
RIGHT REAR
DOOR LOCK
MOTOR
DOOR JAMB
RIGHT REAR
BLACK
1
3 2
GROUND Z1 18BK 2
- - 1
FUNCTION CIRCUIT
RIGHT POWER SEAT HORIZONTAL FORWARD
RIGHT POWER SEAT FRONT DOWN
RIGHT POWER SEAT FRONT UP P18 14YL/LG
P20 14RD/LG
M
N
A
B
P16 14RD/LB
J
P14 14YL/LB
E
RIGHT POWER SEAT HORIZONTAL REARWARD
RIGHT POWER SEAT REAR UP
RIGHT POWER SEAT REAR DOWN
K
P10 14YL/WT
L
P12 14RD/WT
SEAT SWITCH
RIGHT POWER
N
M
L
K
J
B
E
A
C
F
H G
C - -
F - -
G - -
- - H
BLACK
F37 14RD FUSED B(+)
Z1 14BK GROUND
RIGHT POWER
RIGHT POWER SEAT REAR DOWN P12 14RD/WT 2
RIGHT POWER SEAT REAR UP P10 14YL/WT 1
SEAT REAR
VERTICAL MOTOR
YELLOW
RIGHT POWER
RIGHT POWER SEAT HORIZONTAL FORWARD P14 14YL/LB 2
RIGHT POWER SEAT HORIZONTAL REARWARD P16 14RD/LB 1
SEAT HORIZONTAL
MOTOR
YELLOW
J008W-7 XJD08066
WINDOW SWITCH
RIGHT REAR
BLUE
4
1
6
3
POWER WINDOW SWITCH FEED Q1 14YL
6
Q24 14DG
5
RIGHT REAR WINDOW DRIVER (UP) Q18 14GY/BK
4
-
3
Q28 14DG/WT
2
POWER WINDOW RIGHT REAR B(+) UP Q14 14GY
1
FUNCTION CIRCUIT
CAV
CAV
CIRCUIT FUNCTION
1
L78 20DG/YL FUSED HEADLAMP SWITCH OUTPUT
RIGHT SIDE
MARKER LAMP
-
WHEEL SPEED
RIGHT REAR
RED
B A
RIGHT REAR WHEEL SPEED SENSOR (-) B1 20YL/DB
B RIGHT REAR WHEEL SPEED SENSOR (+) B2 20YL
A
1 Q14 14GY POWER WINDOW RIGHT REAR B(+) UP
2 Q24 14DG RIGHT REAR WINDOW DRIVER DOWN
2
BLACK
1
RIGHT REAR
WINDOW MOTOR
SENSOR
AMPLIFIED RIGHT REAR SPEAKER (-) X92 16TN/BK A
RIGHT REAR SPEAKER (-) X58 18DB/OR A
B
B X52 18DB/WT
X94 16TN/RD AMPLIFIED RIGHT REAR SPEAKER (+)
RIGHT REAR SPEAKER (+)
SOUNDBAR
RIGHT
SPEAKER
RIGHT REAR WINDOW DRIVER (DOWN)
2 1
NATURAL
4 SPEAKER SYSTEM
6 SPEAKER SYSTEM
XJD08067 J008W-7
1 2
SIGNAL LAMP
RIGHT TURN
1 Z1 18BK GROUND
2 L62 18BR/RD RIGHT TURN SIGNAL
SWITCH
SEAT BELT
BLACK
GROUND Z1 20BK B
SEAT BELT SWITCH SENSE G10 20LG/RD A
STOP LAMP
RIGHT TAIL/
3 1
GROUND Z1 18BK
3
FUSED HEADLAMP SWITCH OUTPUT L78 18DG/YL 2
BRAKE LAMP SWITCH OUTPUT L50 18WT/TN
1
CONTROL SWITCH
RIGHT SPEED
2 V37 20RD/LG SPEED CONTROL SWITCH SIGNAL
2 1
GROUND Z1 20BK B
FUSED B(+) M1 20PK A
LAMP
VANITY
RIGHT VISOR/
A B
B A
BLACK
J008W-7 XJD08068
1 K29 20WT/PK BRAKE SWITCH SENSE
1 K29 18WT/PK BRAKE SWITCH SENSE
FUSED IGNITION SWITCH OUTPUT (RUN) F15 20DB/WT 2
LHD
RHD
MODULE
P139 18VT/WT
P137 18VT
P138 18VT/LG
P134 18TN/RD
P144 18BK/YL
F235 16RD
F235 16RD
P133 18TN/DG
P141 18TN/LB
GROUND
RIGHT SEAT HIGH HEAT LED DRIVER
LEFT HEAT SENSE INPUT
LEFT HEAT ELEMENT OUTPUT
RIGHT HEAT ELEMENT OUTPUT
SENSOR FEED
P140 18VT/BK
LEFT SEAT LOW HEAT LED DRIVER
Z2 18BK/LG
RIGHT SEAT LOW HEAT LED DRIVER
LEFT SEAT HIGH HEAT LED DRIVER
RIGHT SEAT HEATER SWITCH MUX
P143 18BK/DG
RIGHT HEAT SENSE INPUT
HEATED SEAT RELAY OUTPUT
P87 18BK/OR
HEATED SEAT RELAY OUTPUT
INTERFACE
HEAT
BLACK
6
14
1
7
SEAT
9
10
11
12
13
14
8
7
4
5
6
LEFT SEAT HEATER SWITCH MUX
1
P86 18PK/BK
2
3
CCD BUS (+) D1 20VT/BR 1
GROUND Z2 20BK/LG 3
FUSED IGNITION SWITCH OUTPUT (ST-RUN) F87 20WT/BK 4
GROUND Z2 20BK/LG 5
FUSED B(+) F1 20DB/GY 6
SENTRY KEY
IMMOBILIZER
MODULE
6 1
BLACK
SOLENOID
SHIFT LOCK
WHITE
XJD08069 J008W-7
5
10 6
1
LT GRAY
10 BRAKE LAMP SWITCH OUTPUT L73 20YL
- 9 -
BRAKE LAMP SWITCH OUTPUT L74 20LG
BACK-UP LAMP FEED L10 18BR/LG
CONNECTOR
TRAILER TOW
6
5
FUSED B(+) A6 20RD/OR
2
1
7
8 Z1 14BK GROUND
3
4
B40 14LB TRAILER TOW BRAKE B(+)
- -
- -
BLACK
3 5
2
4
1
TRAILER TOW
LEFT TURN RELAY
1 L63 20DG/RD LEFT TURN SIGNAL
2 L50 20WT/TN BRAKE LAMP SWITCH OUTPUT
3 A6 20RD/OR FUSED B(+)
4 - -
5 L73 20YL BRAKE LAMP 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
(2.5L A/T)
CLUTCH SOLENOID
TORQUE CONVERTER
FUNCTION
CIRCUIT
F20 18WT A
CAV
B A
TORQUE CONVERTER CLUTCH SOLENOID CONTROL K54 18OR/BK B
THROTTLE POSITION SENSOR SIGNAL
4.0L A/T
EXCEPT 4.0L A/T
2 K22 20OR/DB
5V SUPPLY K7 20OR 3
WHITE
1 3
SENSOR
POSITION
THROTTLE
J008W-7 XJD08070
BLACK
B A
A G107 20BK/RD 4WD SWITCH SENSE (PART-TIME)
B Z1 20BK GROUND
CASE SWITCH
TRANSFER
D C
B
A
BLACK
A Z1 20BK GROUND
B G106 20BK/WT 4WD SWITCH SENSE (FULL-TIME)
C
G107 20BK/RD D
- -
CASE SWITCH
TRANSFER
1 2
SWITCH
TRANSFER CASE
BLACK
GROUND Z1 20BK 2
SOLENOID
TRANSMISSION
SOLENOID B CONTROL T60 20OR/WT
-
OUTPUT SPEED SENSOR SIGNAL
-
T14 20LG/WT 7
8
8 4
4 1
BLACK
OUTPUT SPEED SENSOR GROUND T13 20DB/BK 6
INPUT SPEED SENSOR GROUND T31 20VT/LG 5
SOLENOID C CONTROL T22 20DB/WT 4
SOLENOID A CONTROL T19 20WT 3
2
INPUT SPEED SENSOR SIGNAL T52 20RD/BK 1
4WD SWITCH SENSE (PART-TIME)
(231 4WD)
(242 4WD)
ILLUMINATION
(4.0L)
XJD08071 J008W-7
SOLENOID B CONTROL
SOLENOID A CONTROL
CONTROL
TRANSMISSION
INPUT SPEED SENSOR GROUND T31 20VT/LG
T52 20RD/BK INPUT SPEED SENSOR SIGNAL
OUTPUT SPEED SENSOR GROUND T13 20DB/BK
14
1
26
13
BLACK
T1 18LG/BK 22
T42 18VT/WT 21
- - 20
- - 19
- - 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
- - 5
OUTPUT SPEED SENSOR SIGNAL T14 20LG/WT 4
3
2
1
(4.0L A/T)
RANGE
TRANSMISSION
3
6
GRAY
7
4
1
8
5
2
GROUND Z1 18BK 8
T41 20BK/WT 7
- - 5
T1 18LG/BK 4
FUSED IGNITION SWITCH OUTPUT (ST-RUN) F20 18WT 3
T3 18VT 2
T42 18VT/WT 1
CCD BUS (+)
TRS T42 SENSE
TRS T1 SENSE
TRS T42 SENSE
TRS T1 SENSE
PARK/ NEUTRAL POSITION SWITCH SENSE
TRS T3 SENSE
MODULE
SENSOR
(4.0L)
J008W-7 XJD08072
CONTROL SERVO
VEHICLE SPEED
4 1
BLACK
GROUND Z1 18BK 4
SPEED CONTROL BRAKE SWITCH OUTPUT V30 20DB/RD 3
SPEED CONTROL VENT SOLENOID CONTROL V35 18LG/RD 2
SPEED CONTROL VACUUM SOLENOID CONTROL V36 18TN/RD 1
1
Z1 20BK GROUND 2
M1 20PK FUSED B(+)
BLACK
1
2
2 - -
3 L62 20BR/RD RIGHT TURN SIGNAL
4 L55 20RD/WT COMBINATION FLASHER INPUT
5 L6 20RD/WT FLASHER OUTPUT
6 L12 20VT/TN HAZARD FLASHER SELECT SIGNAL
7 - -
8 - -
9 L63 20DG/RD LEFT TURN SIGNAL
10 L61 20LG/WT LEFT TURN SIGNAL
11 L55 20RD/WT COMBINATION FLASHER INPUT
BLACK
6 1
11 7
TURN SIGNAL/
HAZARD SWITCH
UNDERHOOD
LAMP/
SWITCH
BLACK
3 1
VEHICLE SPEED SENSOR SIGNAL G7 18WT/OR 3
5V SUPPLY K6 18VT/OR 1
VEHICLE SPEED
SENSOR
XJD08073 J008W-7
SWITCH
FLUID LEVEL
WASHER
B A
BLACK
LOW WASHER FLUID SENSE G29 20BK/LB B
GROUND Z1 20BK A
A V10 18BR WASHER PUMP CONTROL
B Z1 18BK GROUND
BLACK
A B
WINDSHIELD
WASHER PUMP
SWITCH
WIPE/WASH
1 6
NATURAL
WIPER HIGH SPEED OUTPUT V4 16BR/VT 6
WIPER LOW SPEED OUTPUT V3 16BR/WT 4
WASHER PUMP CONTROL V10 18BR 3
WIPER PARK SWITCH SENSE V5 16DG/YL 2
GROUND Z1 16BK 1
J008W-7 XJD08074
8W-90 CONNECTOR LOCATIONS
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng com-
ponent and connector l ocati ons i n the vehi cl e. A con-
nector i ndex i s provi ded. Use the wi ri ng di agrams i n
each secti on for connector number i denti fi cati on.
Refer to the i ndex for the proper fi gure number.
CONNECTOR/GROUND LOCATIONS
For i tems that are not shown i n thi s secti on N/S i s
pl aced i n the Fi g. col umn.
Connector
Name/Number
Color Location Fig.
A/C-Heater
Control or Heater
Control - C1
BK Center of
Instrument
Panel
22,
23
A/C-Heater
Control - C2
NAT Center of
Instrument
Panel
22,
23
A/C High Pressure
Switch
(2.5L)(LHD)
Near T/O for
C107
8
A/C High Pressure
Switch
(2.5L)(RHD)
Right Side of
Engine
Compartment
Near Power
Distribution
Center
7
A/C High Pressure
Switch
(4.0L)(LHD)
Right Side of
Engine
Compartment
Near Power
Distribution
Center
12,
14
A/C High Pressure
Switch
(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
Compartment
3, 11
Airbag Control
Module
YL Under Center
Console
27,
32
Ambient
Temperature
Sensor
BK Center Grill
Opening
4, 5,
12,
13
Connector
Name/Number
Color Location Fig.
Back-Up Lamp
Switch (2.5L)
BK Right Side of
Transmission
Near Shifter
19
Back-Up Lamp
Switch (4.0L)
BK Left Side of
Transmission
20
Battery
Temperature
Sensor
BK At Battery 6, 7,
12,
13,
14,
15
Blend Door
Actuator
BK T/O at T/O for
C209 on
HVAC
Harness
N/S
Blower Motor On HVAC
Harness
N/S
Blower Motor
Relay
BK Near T/O for
C209
N/S
Blower Motor
Resistor Block
BK On HVAC
Harness
N/S
Brake Lamp
Switch
GY Near Brake
Pedal
21,
24,
25
Brake Warning
Pressure Switch
(LHD)
BK Left Side of
Engine
Compartment
2, 10
Brake Warning
Pressure Switch
(RHD)
BK Right Side of
Engine
Compartment
5, 7,
13,
15
C100 (LHD) BK Left Lower
Instrument
Panel
6,
14,
21,
25
C100 (RHD) WT Right Lower
Instrument
Panel
24
XJ 8W - 90 CONNECTOR LOCATIONS 8W - 90 - 1
Connector
Name/Number
Color Location Fig.
C106 BK Left Front
Engine
Compartment
1, 6,
7,
14,
15
C107 (2.5L) BK Rear of
Engine
Compartment
2, 3,
4, 5,
16
C107 (4.0L) BK Rear of
Engine
Compartment
12,
13,
17
C108 BK Right Side of
Engine
Compartment
4, 5,
6, 7,
12,
13,
14,
15
C109 BK Left Lower
Instrument
Panel
14,
15,
26,
27
C112 (4.0L A/T
4WD)
GY Left Side of
Transfer Case
20
C113 (M/T) Rear Center of
Engine
Compartment
12,
17
C200 (LHD) GY Left Lower
Instrument
Panel
21,
26
C201 (LHD) NAT Lower Center
of Instrument
Panel
21
C202 (RHD) GY Lower Center
of Instrument
Panel
24,
27
C203 (RHD) BL Lower Center
of Instrument
Panel
24,
27
C204 (RHD) WT Lower Center
of Instrument
Panel
24,
27
C205 (LHD) YL Left Lower
Instrument
Panel
21,
22
C205 (RHD) YL Right Lower
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
GN
Right Lower
Instrument
Panel
32
C209 (RHD) BK/LT
GN
Left Lower
Instrument
Panel
27
C300 (LHD) NAT At Right Kick
Panel
32
C300 (RHD) WT At Right Kick
Panel
24
C301 WT At Right Kick
Panel
24,
32
C303 NAT/
BK
(LHD)
WT
(RHD)
T/O at
Junction Block
- C7 T/O
N/S
C304 BK Right Lower B
Pillar
29
C305 WT At Left Kick
Panel
26,
27
Panel
26,
27
Panel
26,
27
C309 BK Left Lower B
Pillar
26,
27
C310 BK Top Center of
Liftgate
31
C311 BK Top Center of
Liftgate
31
C312 GN Top Center of
Liftgate
31
C313 GY Top Center of
Liftgate
31
C314 WT At Soundbar N/S
C316 BK Under Right
Front Seat
26,
27,
29
C317 BK Left Lower A
Pillar
26,
27
8W - 90 - 2 8W - 90 CONNECTOR LOCATIONS XJ
Connector
Name/Number
Color Location Fig.
C318 BK Right Lower A
Pillar
29
C319 BK Right Lower B
Pillar
29
C320 BK Left Lower B
Pillar
26,
27
C321 BK At Right Tail
Lamp Harness
N/S
C322 (Trailer Tow) BK At Left Tail
Lamp Harness
33
C322 (Without
Trailer Tow)
BK At Left Tail
Lamp Harness
28
C323 (Trailer Tow) BK At Trailer Tow
Harness
28,
33
C324 (RHD) WT In T/O for
Junction Block
- C7
N/S
C326 BK At Left Rear
Quarter Panel
28
C327 BK At Left Rear
Quarter Panel
28
C329 NAT Under Right
Front Seat
26,
27
C330 BK Center of
Liftgate
31
C332 NAT Under Left
Front Seat
26,
27
C333 BK At Center High
Mounted Stop
Lamp Jumper
N/S
C362 BK Under Left
Front Seat
26,
27
C363 BK Under Right
Front Seat
26,
27
Camshaft Position
Sensor
GY Right Side of
Engine
16,
17
Cargo Lamp/
Switch
BK At Lamp N/S
Center High
Mounted Stop
Lamp
BK At Liftgate N/S
Cigar Lighter RD Lower Center
of Instrument
Panel
22,
23
Clockspring - C1 NAT At Clockspring 35
Clockspring - C2 At Clockspring N/S
Clockspring - 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 Interlock
Switch Jumper
(RHD)
BK Lower
Steering
Column
24
Combination
Flasher
BK Lower Left of
Instrument
Panel
21
Compass BK In Headliner 34
Controller
Anti-Lock Brake
BK Left Side of
Engine
Compartment
10,
11
Crankshaft
Position Sensor
BK Left Side of
Transmission
20
Data Link
Connector (LHD)
BK Lower Left of
Instrument
Panel
21
Data Link
Connector (RHD)
BK Lower Right of
Instrument
Panel
N/S
Daytime Running
Lamp Module
BK Right Rear of
Engine
Compartment
6, 8,
14
Dome Lamp
(Base/Police)
At Lamp N/S
Dome Lamps
Switch (Midline)
BK At Switch N/S
Driver Door Jamb
Switch
BK Left Lower A
Pillar
N/S
Driver Door Lock
Motor
At Motor 30
Driver Power
Lock/Window
Switch-C1
BL At Switch 30
Driver Power Door
Lock/Window
Switch-C2
WT At Switch 30
Driver Power
Mirror
RD At Mirror 30
Driver Power
Window Motor
BK At Motor 30
Duty Cycle
EVAP/Purge
Solenoid (LHD)
BK Right Rear of
Engine
Compartment
2, 4,
10,
12
Connector
Name/Number
Color Location Fig.
Duty Cycle
EVAP/Purge
Solenoid (RHD)
BK Left Rear of
Engine
Compartment
3, 11
Engine Coolant
Temperature
Sensor
BK Front of
Engine
16,
17
Engine Oil
Pressure Sensor
BK Right Side of
Engine
16,
17
EVAP Leak
Detection Pump
BK In T/O for
Power
Distribution
Center
N/S
Extended Idle
Switch (Police
Package)
WT Instrument
Panel Harness
Near T/O to
Power Outlet
N/S
Front Fog Lamp
Switch
BK Lower Center
of Instrument
Panel
22,
23
Front Wiper Motor BK At Wiper
Motor
8, 9
Fuel Injector No. 1 BK At Injector 16,
17
17
17
17
Fuel Injector No. 5
(4.0L)
BK At Injector 17
Fuel Injector No. 6
(4.0L)
BK At Injector 17
Fuel Pump Module BK At Fuel Pump
Module
28
G100 (4.0L) Right 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
Engine
Compartment
2, 3,
4, 5,
12,
13
G104 T/O at Engine
Starter Motor
T/O on Battery
Harness
N/S
G106 Left Side of
Engine
Compartment
2, 3,
10,
11
G107 (LHD) Right Side of
Instrument
Panel
21
G107 (RHD) Left Side of
Instrument
Panel
24
G108 (LHD) Left Side of
Instrument
Panel
21
G108 (RHD) Right Side of
Instrument
Panel
24
G200 Under Left
Front Seat
27,
32
G300 In T/O for
Airbag Control
Module
N/S
G301 Near T/O for
Power
Amplifier
28
G302 At Left Rear
Quarter Panel
28
G303 Under Right
Front Seat
26,
27,
29
G304 T/O at T/Os
for C326 and
C327
N/S
G306 Under Right
Front Seat
26,
27
G Switch BK Under Rear
Seat
28,
29
Generator (2.5L) BK At Generator N/S
Generator (4.0L) BK At Generator 18
Headlamp Beam
Select Switch
BK On Steering
Column
35
Connector
Name/Number
Color Location Fig.
HeadLamp Delay
Module (LHD)
BK Lower Left of
Instrument
Panel
21
Headlamp Delay
Module (RHD)
BK Lower Right of
Instrument
Panel
N/S
Headlamp Switch
(LHD)
BK Left Side of
Instrument
Panel
22
Headlamp Switch
(RHD)
BK Right Side of
Instrument
Panel
23
Heated Seat Relay Under Right
Front Seat
N/S
Idle Air Control
Motor
BK Left Side of
Engine
16,
17
Ignition Coil (2.5L) BK Right Side of
Engine
16
Ignition Switch -
C1
BK At Steering
Column
21,
24,
35
Ignition Switch -
C2
GN At Steering
Column
21,
24,
35
Instrument Cluster
- C1
BK At Instrument
Cluster
21,
22,
23,
24
Instrument Cluster
- C2
BK At Instrument
Cluster
21,
22,
23,
24
Intake Air
Temperature
Sensor
GY Left Side of
Engine
16,
17
Junction Block -
C1
NAT At Right Kick
Panel Area
25,
29
Junction Block -
C2
WT At Right Kick
Panel Area
25,
29
Junction Block -
C3
NAT At Right Kick
Panel Area
29
Junction Block -
C4
WT At Right Kick
Panel Area
24,
29
Junction Block -
C5
WT At Right Kick
Panel Area
24,
29
Junction 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 Block -
C9
NAT At Right Kick
Panel Area
29
Left Back-Up
Lamp
GY At Lamp N/S
Left Courtesy
Lamp
BK Lower Left of
Instrument
Panel
21,
24
Left Fog Lamp GY At Lamp 1
Left Front Door
Speaker
BK At Speaker 30
Left Front Door
Tweeter
BK Left Front
Door
30
Left Front
Park/Turn Signal
Lamp NO.1
GY At Lamp 1
Left Front
Park/Turn Signal
Lamp NO.2
GY At Lamp 1
Left Front Wheel
Speed Sensor
GY Left Side of
Engine
Compartment
10,
11
Left Headlamp At Headlamp 1
Left Heated Seat
Back
At Left Seat N/S
Left Heated Seat
Cushion
At Left Seat N/S
Left Heated Seat
Switch
RD At Center
Console
26,
27
Left Power Seat
Front Vertical
Motor
YL Under Left
Seat
N/S
Left Power Seat
Horizontal Motor
YL Under Left
Seat
N/S
Left Power Seat
Rear Vertical
Motor
YL Under Left
Seat
N/S
Left Power Seat
Switch
BK At Switch N/S
Left Rear Door
Jamb Switch
BK At Left B Pillar N/S
Left Rear Door
Lock Motor
BK In Left Rear
Door
30
Connector
Name/Number
Color Location Fig.
Left Rear Wheel
Speed Sensor
BK Under Rear
Seat
28
Left Rear Window
Motor
BK In Left Rear
Door
30
Left Rear Window
Switch
BL In Left Rear
Door
30
Left Side Marker
Lamp
NAT At Lamp 1
Left Soundbar
Speaker
At Soundbar N/S
Left Speed Control
Switch
On Steering
Wheel
N/S
Left Tail/Stop
Lamp
BK At Lamp N/S
Left Turn Signal
Lamp
At Rear Lamp N/S
Left Visor/Vanity
Lamp
BK Left Side of
Headliner
34
License Lamp At Lamp N/S
Liftgate Lock
Motor
BK In Liftgate 31
Liftgate Switch BK In Liftgate 31
Manifold Absolute
Pressure Sensor
BK Left Side of
Engine
16,
17
Overhead Module BK Front Center
of Headliner
34
Oxygen Sensor
1/1 Upstream
(2.5L)
GY Left Side of
Engine
16
Oxygen Sensor
1/1 Upstream
(4.0L)
GY Right Side of
Transmission
20
Oxygen Sensor
1/1 Upstream
(California)
GY Left Side of
Engine
17
Oxygen Sensor
1/2 Downstream
(2.5L)
BK Right Side of
Transmission
19
Oxygen Sensor
1/2 Downstream
(4.0L)
BK Right Side of
Transmission
20
Oxygen Sensor
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)
BK Left Side of
Engine
20
Park/Neutral
Position Switch
(2.5L A/T)
BK Left Side of
Transmission
19
Passenger Airbag YL At Airbag 21,
22,
23,
24
Passenger Door
Jamb Switch
BK Kick Panel
Area at Door
Opening
N/S
Passenger Door
Lock Motor
At Motor 30
Passenger Power
Lock/Window
Switch - C1
BL At Switch 30
Passenger Power
Lock/Window
Switch - C2
BL At Switch 30
Passenger Power
Mirror
RD At Mirror 30
Passenger Power
Window Motor
BK At Motor 30
Power Amplifier -
C1
NAT Under Left
Rear Seat
28
Power Amplifier -
C2
NAT Under Left
Rear Seat
28
Power Mirror
Switch
At Switch N/S
Power Outlet RD Lower Center
of Instrument
Panel
22,
23
Power Steering
Pressure Switch
(2.5L)
WT Front of
Engine
16
Powertrain Control
Module - C1
BK Left Side of
Engine
Compartment
8, 9,
16,
17
Powertrain Control
Module - C2
WT Left Side of
Engine
Compartment
8, 9,
16,
17
Powertrain Control
Module - C3
GY Left Side of
Engine
Compartment
8, 9,
2, 3,
10,
11
Connector
Name/Number
Color Location Fig.
PRNDL
Illumination (A/T)
At Center
Console
26,
27
Radiator Fan
Motor
LT GY Front of
Engine
Compartment
2, 3,
6, 7,
10,
11,
14,
15
Radio - C1 BK Center of
Instrument
Panel
22,
23
Radio - C2 GY Center of
Instrument
Panel
22,
23
Rail Coil (4.0L) BK Right Side of
Engine
17
Rear Washer
Pump
BK Left Front of
Engine
Compartment
2, 3,
8, 9,
10,
11
Rear Window
Defogger Switch
GY Center of
Instrument
Panel
22,
23
Rear Wiper Motor In Liftgate 31
Rear Wiper/
Washer Switch
BK Center of
Instrument
Panel
22,
23
Right Back-Up
Lamp
GY At Lamp N/S
Right Courtesy
Lamp
BK Lower Right of
Instrument
Panel
21,
24
Right Fog Lamp GY At Lamp 1
Right Front Door
Speaker
BK At Speaker 30
Right Front Door
Tweeter
BK At Right Front
Door
30
Right Front
Park/Turn Signal
Lamp NO.1
BK At Lamp 1
Right Front
Park/Turn Signal
lamp NO.2
BK At Lamp 1
Right Front Wheel
Speed Sensor
Right Side of
Engine
Compartment
11,
12
Right Headlamp At Headlamp 1
Connector
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 Vertical
Motor
YL Under Right
Seat
N/S
Right Power Seat
Horizontal Motor
YL Under Right
Seat
N/S
Right Power Seat
Rear Vertical
Motor
YL Under Right
Seat
N/S
Right Power Seat
Switch
BK At Switch N/S
Right Rear Door
Jamb Switch
BK At Right B
Pillar
29
Right Rear Door
Lock Motor
BK In Right Rear
Door
30
Right Rear Wheel
Speed Sensor
RD Under Rear
Seat
28
Right Rear
Window Motor
BK In Right Rear
Door
30
Right Rear
Window Switch
BL In Right Rear
Door
30
Right Side Marker
Lamp
NAT At Lamp 1
Right Sound Bar
Speaker
At Soundbar N/S
Right Speed
Control Switch
On Steering
Wheel
N/S
Right Tail/Stop
Lamp
At Lamp N/S
Right Turn Signal
Lamp
At Rear Lamp N/S
Right Visor/Vanity
Lamp
BK Right Side of
Headliner
34
Seat Belt Switch
(LHD)
BK T/O at T/O for
Airbag Control
Module
32
Seat Belt Switch
(RHD)
BK T/O at T/O for
C206
N/S
Seat Heat
Interface Module
BK Under Right
Front Seat
N/S
Connector
Name/Number
Color Location Fig.
Sentry Key
Immobilizer
Module
BK At Steering
Column
21,
24
Shift Lock
Solenoid (LHD)
WT At Steering
Column
21,
35
Shift Lock
Solenoid (RHD)
WT At Steering
Column
35
Throttle Position
Sensor
WT Left Side of
Engine
16,
17
Torque Converter
Clutch Solenoid
(2.5L A/T)
Left Side of
Transmission
19
Trailer Tow
Connector
LT GY At Rear
Bumper
33
Trailer Tow Left
Turn Relay
BK At Left Rear
Quarter Panel
33
Trailer Tow Right
Turn Relay
BK At Left Rear
Quarter Panel
33
Transfer Case
Switch (231 4WD)
BK Left Side of
Transmission
19,
20
Transfer Case
Switch (242 4WD)
BK Left Side of
Transmission
20
Transfer Case
Switch Illumination
BK At Center
Console
26,
27
Transmission
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/Number
Color Location Fig.
Transmission
Range Sensor
(4.0L A/T)
BK/GY Rear of
Engine
Compartment
12,
13
Turn Signal/
Hazard Switch
BK At Steering
Column
21,
24,
35
Underhood
Lamp/Switch
BK At Lamp 2, 5,
10,
11
Vehicle Speed
Control Servo
(LHD)
BK Right Front of
Engine
Compartment
4,
12,
14
Vehicle Speed
Control Servo
(RHD)
BK Right Rear of
Engine
Compartment
5, 9,
13,
15
Vehicle Speed
Sensor
BK Left Side of
Transmission
19,
20
Washer Fluid
Level Switch
BK Left Front of
Engine
Compartment
2, 3,
8, 9,
10,
11
Windshield
Washer Pump
BK Left Front of
Engine
Compartment
2, 3,
8, 9,
10,
11
Wipe/Wash Switch NAT At Steering
Column
21,
24,
35
F
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.
1
F
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F
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2
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5
L
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L
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F
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.
3
L
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C
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p
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2
.
5
L
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R
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Fig. 4 Right Engine Compartment 2.5L Engine LHD
Fig. 5 Right Engine Compartment 2.5L Engine RHD
F
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.
6
E
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e
C
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p
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A
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V
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2
.
5
L
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F
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.
7
E
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V
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2
.
5
L
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.
8
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C
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L
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F
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.
9
E
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C
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p
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C
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R
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F
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.
1
0
L
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C
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p
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4
.
0
L
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L
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F
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.
1
1
L
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C
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R
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F
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.
1
2
R
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C
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F
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3
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R
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F
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.
1
4
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4
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F
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.
1
5
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F
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1
6
2
.
5
L
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F
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.
1
7
4
.
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L
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Fig. 18 4.0L Engine
F
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.
1
9
T
r
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s
m
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s
i
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C
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c
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s
2
.
5
L
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F
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.
2
0
T
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s
m
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s
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C
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c
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s
4
.
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L
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F
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.
2
1
I
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P
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L
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F
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.
2
2
I
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s
t
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P
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L
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F
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.
2
3
I
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s
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P
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R
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F
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.
2
4
I
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P
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R
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F
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.
2
5
U
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D
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C
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p
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s
F
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.
2
6
L
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S
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B
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y
L
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F
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.
2
7
L
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S
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e
B
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y
R
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F
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.
2
8
L
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R
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a
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B
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y
F
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.
2
9
R
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t
S
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B
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a
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J
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t
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B
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c
k
F
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.
3
0
F
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t
a
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d
R
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a
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D
o
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s
(
L
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S
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S
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n
,
R
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t
S
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S
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)
Fig. 31 Liftgate
F
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.
3
2
C
e
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t
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r
C
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s
o
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e
L
H
D
Fig. 33 Trailer Tow
Fig. 34 Headliner
F
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.
3
5
S
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C
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n
8W-95 SPLICE LOCATIONS
INTRODUCTION
Thi s secti on provi des i l l ustrati ons i denti fyi ng the
general l ocati on of the spl i ces i n thi s vehi cl e. A spl i ce
i ndex i s provi ded. Use the wi ri ng di agrams i n each
secti on for spl i ce number i denti fi cati on. Refer to the
i ndex for proper spl i ce number.
SPLICE LOCATIONS
For spl i ces that are not shown i n the fi gures i n
thi s secti on a N/S i s pl aced i n the Fi g. col umn.
Splice
Number
Location Fig.
S100 Near T/O for Right Headlamp 9
S103 Near T/O for Left Headlamp 9
S107 (2.5L) Near T/O for G101 11
S107 (4.0L) Near T/O for Fuel Injector
NO. 6
10
S108 (2.5L) Near Fuel Injector T/Os 11
S108 (4.0L) Near T/O for Ignition Coil
Pack
10
S108 (4.0L)
(California)
Near Fuel Injector T/Os 10
S110 Near Fuel Injector T/Os 11
S111 (2.5L) Near T/O for G101 11
NO. 3
11
S113 (4.0L) Between Fuel Injector NO. 2
and Fuel Injector NO. 3
T/Os
10
NO. 2
11
S114 (4.0L) Between Fuel Injector NO. 2
and Fuel Injector NO. 3
T/Os
10
S115 (2.5L) Near T/O for Crankshaft
Position Sensor
11
S115 (4.0L) Near T/O for Idle Air Control
Motor
10
Splice
Number
Location Fig.
S117 Near T/O for Powertrain
Control Module - C2
N/S
S118 In T/O for Generator
Terminal
N/S
S119 (2.5L) In T/O for Engine Oil
Pressure Sensor
11
S120 (A/T)
(2.5L)
Near Fuel Injector T/Os 11
S122 Near T/O for Ignition Coil
Pack
10
S123 (4.0L)
(California)
Near T/O for Powertrain
Control Module - C2
N/S
S130 Near Grommet T/O for
Junction Block - C2
3, 4,
7, 8
Junction Block - C2
3, 4,
7, 8
S132 (LHD)
(2.5L)
Near Grommet T/O for
Junction Block - C2
7
S132 (LHD)
(4.0L)
Near T/O for A/C Low
Pressure Switch
3
S132 (LHD)
(M/T ABS)
Near T/O for Underhood
Lamp
3
S132 (RHD) Near Grommet T/O for C100 4, 8
S133 (DRL) Near Grommet T/O for
Junction Block - C2 or A/C
Low Pressure Switch
3, 7
S133 (LHD) Near Grommet T/O for Front
Wiper Motor
1, 5
S133 (RHD) Near T/O for A/C Low
Pressure Switch
2, 6
S134 (LHD) Near T/O for Underhood
Lamp or C107
3
S134 (RHD)
(ABS)
Near T/O for Transmission
Control Module
2
XJ 8W - 95 SPLICE LOCATIONS 8W - 95 - 1
Splice
Number
Location Fig.
S135 (LHD)
(2.5L)
Near T/O for A/C High
Pressure Switch
7
S135 (LHD)
(4.0L)
Near T/O for C107 3
S135 (LHD)
(4.0L) (M/T
ABS)
Near T/O for Right Front
Wheel Speed Sensor
3
S135 (RHD) Near T/O for Underhood
Lamp
4, 8
S135 (RHD)
(ABS)
Near Grommet T/O for C100 4, 8
S136 Near T/O for C107 3
S138 (2.5L) Near Grommet T/O for Front
Wiper Motor
5, 6
S138 (4.0L) Near T/O for Transmission
Control Module or C107
1, 2
S139 (LHD)
(A/T)
Near T/O for Brake Warning
Pressure Switch
1
S139
(LHD)(M/T
ABS)
Near Grommet T/O for C100 1
S139 (RHD) Near T/O for A/C Low
Pressure Switch
2
S140 Near T/O for Transmission
Control Module
1, 2
S141 (LHD) Near Grommet T/O for Front
Wiper Motor
1
S141 (RHD) Near T/O for C107 2, 6
S142 (4.0L
LHD)
Near Grommet T/O for Front
Wiper Motor
1
S142 (4.0L
RHD)
Near Grommet T/O for
Transmission Control Module
4
S143 (LHD) Near Grommet T/O for C100 1, 5
S143 (RHD) Near T/O for C107 4, 8
S144 (LHD) Near Grommet T/O for C100 1
S144 (RHD) Near T/O for G106 2
S144 (RHD)
(ABS)
Pressure Switch
2
S145 (LHD) Near Grommet T/O for C100 1
S145 (RHD) Near T/O for G106 2
S145 (RHD)
(ABS)
Pressure Switch
2
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 Power
Distribution Center
3, 7
S168 Near T/O for C107 5, 6
S200 In T/O for Headlamp Switch 12,
13
S201 (LHD) Near T/O for C200 12
S201 (RHD) Near T/O for Data Link
Connector
13
S203 In T/O for Brake Lamp
Switch
12,
13
S204 (LHD) In T/O for Brake Lamp
Switch
12
S204 (RHD) Near T/O for Shift Lock
Solenoid
13
S205 (LHD) In T/O for C100 12
S205 (RHD) Near T/O for C202, C203
and C204
13
S206 In Lower Instrument Panel
Trough
12,
13
Trough
12,
13
S208 (LHD) In Lower Instrument Panel
Trough
12
S208 (RHD) Near T/O for Cigar Lighter 13
Trough
12,
13
Trough
12,
13
Trough
12,
13
S212 (LHD) Between Trough and T/O to
Turn Signal/Hazard Switch
12
S212 (RHD) In Lower Instrument Panel
Trough
13
S213 Near T/O to Turn Signal/
Hazard Switch
12,
13
S214 (LHD) Near T/O for A/C-Heater
Control - C1, C2 and G107
12
S214 (RHD) Near T/O for Instrument
Cluster - C1
13
S215 (LHD) Near T/O for Cigar Lighter 12
S215 (RHD) Near T/O for A/C-Heater
Control - C2
13
8W - 95 - 2 8W - 95 SPLICE LOCATIONS XJ
Splice
Number
Location Fig.
S216 (LHD) Near T/O for Instrument
Cluster - C2
12
S216 (RHD) Near T/O for Junction Block
-C4 and C5
13
S217 (Police
Package)
In Lower Instrument Panel
Trough
12
S218 (RHD) In T/O for C100 13
S219 (LHD) In T/O for C209 14
S219 (RHD) Near T/O for Junction Block -
C4 and C5
13
S221 Near T/O for Clockspring -
C2
N/S
S222 Near T/O for Clockspring -
C2
N/S
S225 In T/O for C301 14
S227 In T/O for Headlamp Switch 12,
13
S228 Near T/O for Blower Motor
Resistor Block
N/S
S238 In T/O for Combination
Flasher
12,
13
S239 In T/O for Combination
Flasher
12,
13
S301 In T/O for Power Amplifier 15
S302 Near T/O for Fuel Pump
Module
15
S303 Near T/O for C326 and C327 15
S304 Near T/O for G303 16
S305 Under Right Rear Seat 16
S306 Under Right Rear Seat 16
S307 (LHD
With Power
Amplifier,
RHD)
Under Right Rear Seat 16
S307 (LHD
Without
Power
Amplifier)
Under Left Rear Seat 15
S310 (LHD) Near T/O for C304 and C319 16
S310 (RHD) Near T/O for C314 and C321 16
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/O for C206 at Center
Console
N/S
S316 Near T/O for Power Window
Motor
20
Motor
20
S318 Near T/O for Front Door
Speaker
20
Speaker
20
Speaker
20
Speaker
20
Motor
21
Motor
21
Speaker
21
Speaker
21
Speaker
21
Speaker
21
S334 Near T/O for Liftgate Switch 22
S335 Near T/O for Trailer Tow
Right Turn Relay
18
S340 Near Grommet for Trailer
Tow Connector
18
S341 In Left Tail Lamp Harness
near C321
N/S
Splice
Number
Location Fig.
S342 (With
Remote
Keyless
Entry)
In T/O for Overhead Module 23
S344 In T/O for Overhead Module 23
S345 (With
Remote
Keyless
Entry)
S346 In T/O for Overhead Module 23
S347 (With
Remote
Keyless
Entry)
In T/O for Compass N/S
S347
(Without
Remote
Keyless
Entry)
Splice
Number
Location Fig.
S348 In Right Tail Lamp Harness
near C322
N/S
S349 (RHD) In T/O for C209 N/S
S352 In T/O for C300 N/S
S354 In T/O for C329 N/S
S357 Near T/O for Heated Seat
Relay
N/S
S359 (RHD) Near T/O for C209 N/S
S361 Near T/O for Right
Visor/Vanity Lamp
23
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Fig. 17 Left Side Body Harness Splices
Fig. 18 Trailer Tow Splices
Fig. 19 Power Seat Splices
Fig. 20 Right Front Door Splices
Fig. 21 Left Front Door Splices
Fig. 22 Liftgate Splices
Fig. 23 Headliner Splices
ENGINE
TABLE OF CONTENTS
page page
2. 5L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4. 0L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5L ENGINE
TABLE OF CONTENTS
page page
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . 2
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . 5
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . . 5
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PISTON AND CONNECTING ROD . . . . . . . . . . . . . 6
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ROCKER ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . 7
HYDRAULIC TAPPET. . . . . . . . . . . . . . . . . . . . . . . 7
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . 8
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . 8
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 8
ENGINE DIAGNOSISINTRODUCTION. . . . . . . . . 8
SERVICE DIAGNOSISPERFORMANCE . . . . . . . 9
SERVICE DIAGNOSISMECHANICAL. . . . . . . . . 10
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 13
CYLINDER COMPRESSION PRESSURE TEST . . 13
ENGINE CYLINDER HEAD GASKET FAILURE
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CYLINDER COMBUSTION PRESSURE
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 13
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 14
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 15
SERVICE PROCEDURES
VALVE TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
VALVE, GUIDE AND SEAL . . . . . . . . . . . . . . . . . . 15
PISTONFITTING . . . . . . . . . . . . . . . . . . . . . . . . 17
PISTON RINGFITTING . . . . . . . . . . . . . . . . . . . 18
CONNECTING ROD BEARINGSFITTING . . . . . 21
FITTING CRANKSHAFT MAIN BEARINGS . . . . . . 23
FORM-IN-PLACE GASKETS. . . . . . . . . . . . . . . . . 25
ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . . 26
HONING CYLINDER BORES . . . . . . . . . . . . . . . . 26
REPAIR DAMAGED OR WORN THREADS. . . . . . 27
SERVICE ENGINE ASSEMBLY (SHORT BLOCK). . . . 27
HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . . 27
ENGINE OIL SERVICE. . . . . . . . . . . . . . . . . . . . . 27
ENGINE MOUNTSFRONT. . . . . . . . . . . . . . . . . 29
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . . . 30
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 33
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 35
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . 35
ROCKER ARMS AND PUSH RODS . . . . . . . . . . . 36
VALVE SPRING AND SEAL . . . . . . . . . . . . . . . . . 37
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 38
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 40
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . . 40
VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . . 41
TIMING CASE COVER OIL SEAL . . . . . . . . . . . . . 41
TIMING CASE COVER. . . . . . . . . . . . . . . . . . . . . 42
TIMING CHAIN AND SPROCKETS. . . . . . . . . . . . 43
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
CAMSHAFT PIN REPLACEMENT. . . . . . . . . . . . . 45
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . . 47
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . . 47
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PISTON AND CONNECTING ROD . . . . . . . . . . . . 51
REAR MAIN OIL SEAL . . . . . . . . . . . . . . . . . . . . . 52
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINE CYLINDER HEAD. . . . . . . . . . . . . . . . . . 54
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 54
SPECIFICATIONS
ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . 55
SPECIFICATIONSTORQUE. . . . . . . . . . . . . . . . 59
SPECIAL TOOLS
2.5L ENGINE SPECIAL TOOLS . . . . . . . . . . . . . . 60
XJ ENGINE 9 - 1
ENGINE
DESCRIPTION
The 2.5 l i ter (150 CI D) four-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Thi s engi ne i s desi gned for unl eaded fuel . The engi ne
cyl i nder head has dual quench-type combusti on cham-
bers that create turbul ence and fast burni ng of the ai r/
fuel mi xture. Thi s resul ts i n good fuel economy.
The cyl i nders are numbered 1 through 4 from front
to rear. The fi ri ng order i s 1-3-4-2 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n fi ve mai n beari ngs and the camshaft rotates
wi thi n four beari ngs.
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.3 and No.4 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (8 = 1998).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (HX = A 2.5 l i ter (150 CI D) 9.1:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
6th & 7th Di gi tsThe day of engi ne bui l d (01 - 31).
FOR EXAMPLE: Code * 801HX23 * i denti fi es a
2.5 l i ter (150 CI D) engi ne wi th a mul ti -poi nt fuel
i njecti on system, 9.1:1 compressi on rati o and bui l t on
January 23, 1998.
LUBRICATION SYSTEM
DESCRIPTION
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng.
OPERATION
The pump draws oi l through the screen and i nl et
tube from the sump at the rear of the oi l pan. The oi l
i s dri ven between the dri ve and i dl er gears and
pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal l ery
to the upper shel l of each mai n beari ng. The crankshaft
i s dri l l ed i nternal l y to pass oi l from the mai n beari ng
journal s (except number 4 mai n beari ng journal ) to the
connecti ng rod journal s. Each connecti ng rod beari ng
cap has a smal l squi rt hol e, oi l passes through the
squi rt hol e and i s thrown off as the rod rotates. Thi s oi l
throwoff l ubri cates the camshaft l obes, di stri butor dri ve
gear, cyl i nder wal l s, and pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
1 NO. 4 CYLINDER
2 NO. 3 CYLINDER
3 DAY
4 MONTH
5 YEAR
6 MACHINED SURFACE
9 - 2 2. 5L ENGINE XJ
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
XJ 2. 5L ENGINE 9 - 3
Oil Lubrication System2.5L 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
CYLINDER BLOCK
DESCRIPTION
The cyl i nder bl ock i s a cast i ron i nl i ne four cyl i n-
der desi gn. The cyl i nder bl ock i s dri l l ed formi ng gal -
l eri es for both oi l and cool ant.
CYLINDER HEAD
DESCRIPTION
The cyl i nder head i s made of cast i ron contai ni ng
ei ght val ves made of chrome pl ated heat resi stant
steel , val ve stem seal s, spri ngs, retai ners and keep-
ers. The cyl i nder head, val ve seats and gui des can be
resurfaced for servi ce purposes.
The cyl i nder head uses dual quench-type desi gn
combusti on chambers whi ch cause turbul ence i n the
cyl i nders al l owi ng faster burni ng of the ai r/fuel mi x-
ture, resul ti ng i n better fuel economy.
The val ve gui des are i ntegral to the cyl i nder head,
They are not repl aceabl e. However, they are servi ce-
abl e.
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
Fig. 3 Cylinder Block2.5L
1 CYLINDER BLOCK
Fig. 4 Cylinder Head
1 CYLINDER HEAD BOLTS
2 CYLINDER HEAD GASKET
3 CYLINDER HEAD
Fig. 5 CrankshaftTypical
1 MAIN BEARING JOURNALS
2 COUNTER BALANCE WEIGHTS
PISTON AND CONNECTING ROD
DESCRIPTION
The pi stons are made of a hi gh strength al umi num
al l oy, the pi ston ski rts are coated wi th a sol i d l ubri -
cant (Mol ykote) to reduce fri cti on and provi de scuff
resi stance. The connecti ng rods are made of cast i ron.
CAMSHAFT
DESCRIPTION
The camshaft i s made of cast i ron wi th ei ght
machi ned l obes and four beari ng journal s.
OPERATION
When the camshaft rotates, the l obes actuate the
tappets and push rods forci ng upward on the rocker
arms whi ch appl i es downward force on the val ves.
ROCKER ARM
DESCRIPTION
The rocker arms are made of stamped steel and
have a operati onal rati o of 1.6:1.
OPERATION
When the push rods are forced upward by the cam-
shaft l obes the push rod presses upward on the
rocker arms, the rocker arms pi vot, forci ng down-
ward pressure on the val ves forci ng the val ves to
move downward and off from thei r seats.
VALVES
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Al l
val ves use three bead l ock keepers to retai n the val ve
spri ng and promote val ve rotati on (Fi g. 9).
Fig. 6 Piston and Connecting Rod Assembly
Fig. 7 CamshaftTypical
1 CAMSHAFT
2 LOBES
3 BEARING JOURNAL
Fig. 8 Rocker ArmsTypical
1 CAPSCREWS
2 BRIDGE
3 PIVOT ASSEMBLY
4 PUSH RODS
5 ROCKER ARMS
VALVE SPRING
DESCRIPTION
The val ve spri ngs are made of hi gh strength
chrome si l i con steel . The spri ngs are common for
both i ntake and exhaust val ves.
CYLINDER HEAD COVER
DESCRIPTION
The cyl i nder head cover i s made of di e cast al umi -
num and i ncorporates the Crankcase Venti l ati on
(CCV) Hoses and the oi l fi l l openi ng.
HYDRAULIC TAPPET
DESCRIPTION
Val ve l ash i s control l ed by hydraul i c tappets
l ocated i nsi de the cyl i nder bl ock, i n tappet bores
above the camshaft.
VALVE GUIDE
DESCRIPTION
abl e.
OIL PAN
DESCRIPTION
The oi l pan i s made of stamped steel . The oi l pan
gasket i s a one pi ece steel backbone si l i cone coated
gasket.
Fig. 9 Valve and Keeper Configuration 2.5L Engine
1 VALVE LOCKS (3BEAD)
2 RETAINER
3 VALVE STEM OIL SEAL
4 INTAKE VALVE
5 EXHAUST VALVE
6 VALVE SPRING
Fig. 10 Cylinder Head Cover
1 AIR INLET FITTING
2 CYLINDER HEAD COVER
3 FIXED ORIFICE FITTING
Fig. 11 Oil Pan
1 OIL PAN
2 OIL PAN DRAIN PLUG
VALVE STEM SEAL
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate a garter spri ng to mai ntai n consi stent l ubri ca-
ti on control (Fi g. 9).
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of cast al umi num and
uses seven bol ts to mount to the cyl i nder head. Thi s
mounti ng styl e i mproves seal i ng and reduces the
chance of l eaks.
EXHAUST MANIFOLD
DESCRIPTION
The exhaust mani fol d i s l og styl e and i s made of
hi gh si l i con mol ybdenum cast i ron. The exhaust man-
i fol d shares a common gasket wi th the i ntake mani -
fol d. The exhaust mani fol d al so i ncorporates a bal l
fl ange outl et for i mproved seal i ng and strai n free
connecti ons (Fi g. 12).
ENGINE DIAGNOSIS INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
Refer to the Servi ce Di agnosi sPerformance chart
and the Servi ce Di agnosi sMechani cal chart for pos-
si bl e causes and correcti ons of mal functi ons. Refer to
Group 14, Fuel System for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test.
Cyl i nder Combusti on Pressure Leakage Test.
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s.
I ntake Mani fol d Leakage Di agnosi s.
Fig. 12 Intake and Exhaust Manifold
SERVICE DIAGNOSIS PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to
Group 8A, Battery, for correct
procedures. Check charging system.
Refer to Group 8C, Charging
Systems, for correct procedures.
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to
Group 8B, Starting Systems, for
correct diagnostics/procedures
4. Siezed accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical
failure or hydro-static lock
5. Refer to Group 9, Engine, for
ENGINE CRANKS BUT WILL NOT
START
1. No spark 1. Check for spark. Refer to Group
8D, Ignition System, for correct
procedures.
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. Refer to Group
14, Fuel System, for correct
procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. Refer to Group 9,
Engine, for correct procedures.
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to group 8D, Ignition System
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
to group 8D, Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to Group 8D, ignition system)
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to Group 14 for
correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit.
(Refer to Group 14, Fuel System)
3. Worn or incorrectly gapped spark
plugs
3. Replace or clean and re-gap
spark plugs (Refer to group 8D,
Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
5. Spark plug cables defective or
crossed
5. Check for correct firing order or
replace spark plug cables. (Refer to
Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary
(Refer to group 8D, Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary (Refer to Group 11,
Exhaust System & Intake Manifold)
8. EGR valve leaking or stuck open 8. Test and replace, if necessary
(Refer to group 25, Emission
Control Systems)
ENGINE MISSES ON
ACCELERATION
plugs
1. Replace spark plugs or clean and
set gap. (Refer to group 8D, Ignition
System)
crossed
2. Check Idle Air Control circuit.
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(refer to group 8D, Ignition System)
SERVICE DIAGNOSIS MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil
Service in this group)
3. Low oil pressure 3. Check engine oil level. If ok,
Perform oil pressure test. Refer to
this group for engine oil pressure
test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
group 0, Lubrication and
Maintenance)
test/specifications
3. Thin or diluted oil 3. Change oil to correct viscosity.
Refer to this group for correct
procedure/engine oil specifications
4. Excessive connecting rod
bearing clearance
Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
Maintenance)
test/specifications
4. Excessive main bearing
clearance
4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace worn gears or oil pump
assy
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED
1. PCV System malfunction 1. Refer to group 25, Emission
Control System for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed ai r.
(2) Remove the spark pl ugs.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sabl e the fuel system. (Refer to Group 14,
Fuel System for the correct procedure)
(5) Di sconnect the i gni ti on coi l .
(6) I nsert a compressi on pressure gauge and rotate the
engi ne wi th the engi ne starter motor for three revol uti ons.
(7) Record the compressi on pressure on the 3rd revo-
l uti on. Conti nue the test for the remai ni ng cyl i nders.
Refer to Engi ne Speci fi cati ons for the correct
engi ne compressi on pressures.
DIAGNOSIS
A l eaki ng engi ne cyl i nder head gasket usual l y resul ts
i n l oss of power, l oss of cool ant and engi ne mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
dures outl i ned i n Cyl i nder Compressi on Pressure
Test. An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders wi l l resul t i n approxi matel y a
50-70% reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seati ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns nor-
mal operati ng temperature, then turn the engi ne OFF.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufactur-
ers i nstructi ons. The shop ai r source for testi ng shoul d
mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379 kPa (200
psi ) maxi mum and 552 kPa (80 psi ) recommended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to the Cyl i nder Combusti on Pressure Leak-
age Test Di agnosi s chart.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
Inspect valve and valve seat.
Reface or replace, as necessary
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Remove cylinder head and inspect.
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
ENGINE OIL LEAK INSPECTION
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(4) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
ENGINE OIL PRESSURE
(1) Di sconnect connector and remove oi l pressure
sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 or equi val ent. Start engi ne and record pres-
sure. Refer to Oi l Pressure i n Engi ne Speci fi cati ons
for the correct pressures.
SERVICE PROCEDURES
VALVE TIMING
Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assem-
bl y, and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.4 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90.
I nstal l a di al i ndi cator on the end of the No.1
cyl i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
Set the di al i ndi cator poi nter at zero.
Rotate the crankshaft cl ockwi se (vi ewed from
the front of the engi ne) unti l the di al i ndi cator
poi nter i ndi cates 0.305 mm (0.012 i nch) travel di s-
tance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2
i nch) away from the TDC mark i n ei ther di recti on,
the val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be
a broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
VALVE, GUIDE AND SEAL
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 13). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 14).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems, 0.076mm (.003i n.)
oversi ze stems do not requi re oversi ze seal s.
NOTE: If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the valve
seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD:
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 15).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
Fig. 13 Valve Facing Margin
1 0.787 MM (1/32 INCH) VALVE MARGIN
2 NO MARGIN
Fig. 14 Measurement of Valve Seat Runout
1 DIAL INDICATOR
Fig. 15 Measurement of Valve Guide Bore Diameter
1 GAUGE
2 9.525 MM (3/8 INCH)
3 VALVE STEM GUIDE
4 CYLINDER HEAD
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
ALTERNATIVE METHOD:
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 16).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a Uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 17).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
PISTON FITTING
BORE GAUGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm
(.0001 i n.) I NCREMENTS i s requi red. I f a bore
gauge i s not avai l abl e, do not use an i nsi de mi crome-
ter.
(2) Measure the i nsi de di ameter of the cyl i nder
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 19).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 18). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
Fig. 16 Measurement of Lateral Movement Of Valve
Stem
1 DIAL INDICATOR
Fig. 17 Valve Spring Tester
1 TORQUE WRENCH
2 VALVE SPRING TESTER
PISTON RING FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 20) (Fi g. 21). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
Fig. 18 Moly Coated Piston
1 MOLY COATED
2 MOLY COATED
Fig. 19 Bore Gauge
1 FRONT
2 BORE GAUGE
3 CYLINDER BORE
4 49.5 MM
(115/16 in)
PISTON SIZE CHART
CYLINDER BORE SIZE PISTON LETTER SIZE
98.438 - 98.448 mm
(3.8755 - 3.8759 in.)
A
98.448 - 98.458 mm
(3.8759 - 3.8763 in.)
B
98.458 - 98.468 mm
(3.8763 - 3.8767 in.)
C
98.468 - 98.478 mm
(3.8767 - 3.8771 in.)
D
98.478 - 98.488 mm
(3.8771 - 3.8775 in.)
E
98.488 - 98.498 mm
(3.8775 - 3.8779 in.)
F
Fig. 20 Piston Dimensions
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 22).
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 23).
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 24).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 24) (Fi g.
26).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g.
27).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
Fig. 21 Ring Side Clearance Measurement
1 FEELER GAUGE
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
Top Compression Ring 0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Second Compression
Ring
0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
Oil Control Ring 0.06 - 0.21 mm
(0.0024 - 0.0083 in.)
Fig. 22 Gap Measurement
1 FEELER GAUGE
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
(0.0090 - 0.0240 in.)
Second Compression
Ring
0.483 - 0.965 mm
(0.0190 - 0.080 in.)
(0.010 - 0.060 in.)
Fig. 23 Top Compression ring identification
1 TOP COMPRESSION RING
Fig. 24 Second Compression Ring Identification
1 SECOND COMPRESSION RING
2 CHAMFER
3 ONE DOT
Fig. 25 Compression Ring Chamfer Location
3 PISTON
4 CHAMFER
Fig. 26 Compression Ring Installation
1 COMPRESSION RING
2 RING EXPANDER RECOMMENDED
Fig. 27 Ring Gap Orientation
2 BOTTOM COMPRESSION RING
3 TOP OIL CONTROL RAIL
4 OIL RAIL SPACER
5 BOTTOM OIL CONTROL RAIL
6 IMAGINARY LINE PARALLEL TO PISTON PIN
7 IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
CONNECTING ROD BEARINGS FITTING
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 28) (Fi g. 29). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 30). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
31). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to-journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 32). Refer to
Fig. 28 Connecting Rod Bearing Inspection
1 UPPER BEARING HALF
2 MATING EDGES
3 GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 WEAR PATTERN ALWAYS GREATER ON UPPER
BEARING
5 LOWER BEARING HALF
Fig. 29 Locking Tab Inspection
1 ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 30 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
Fig. 31 Rod and Piston Assembly Installation
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING CONNECTING ROD BEARING INSERT
Color Code Diameter Upper Insert Size Lower Insert Size
Yellow 53.2257-53.2079 mm Yellow - Standard Yellow - Standard
(2.0955-2.0948 in.)
Orange 53.2079 - 53.1901 mm Yellow - Standard Blue - Undersize
(2.0948 - 2.0941 in.) 0.025 mm (0.001 in.)
0.0178 mm (0.0007 in.)
Undersize
Blue 53.1901 - 53.1724 mm Blue - Undersize Blue - Undersize
(2.0941 - 2.0934 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
0.0356 mm (0.0014 in.)
Undersize
Red 52.9717 - 52.9539 mm Red - Undersize Red - Undersize
(2.0855 - 2.0848 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
0.254 mm (0.010 in.)
Undersize
Fig. 32 Measuring Bearing Clearance with
Plastigage
1 PLASTIGAGE SCALE
2 COMPRESSED PLASTIGAGE
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
cl earance woul d then be 0.038 mm (0.0015 i nch).
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 33).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 34). I n general the
l ower beari ng hal f wi l l a heaver wear pattern.
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 5 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark on the adjacent
cheek. The rear mai n journal , i s i denti fi ed by a col or-
coded pai nt mark on the crankshaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.
Fig. 33 Checking Connecting Rod Side Clearace
Typical
Fig. 34 Main Bearing Wear Patterns
1 UPPER INSERT
2 NO WEAR IN THIS AREA
3 LOW AREA IN BEARING LINING
4 LOWER INSERT
BEARING INSERT PAIR CHART
INSERT CORRECT INCORRECT
UPPER STANDARD STANDARD
LOWER 0.025 mm
(0.001 in.)
UNDERSIZE
0.051 mm
(0.002 in.)
UNDERSIZE
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, pro-
ceed to Crankshaft Mai n Beari ngI nstal l ati on.
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
(Fi g. 35). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
I f the cl earance exceeds speci fi cati on, i nstal l a pai r of
0.025 mm (0.001 i nch) undersi ze beari ng i nserts and mea-
sure the cl earance as descri bed i n the previ ous steps.
The cl earance i ndi cated wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l provi de
the speci fi ed cl earance. FOR EXAMPLE: I f the cl ear-
ance was 0.0762 mm (0.003 i nch) ori gi nal l y, a pai r of
0.0254 mm (0.001 i nch) undersi ze i nserts woul d
reduce the cl earance by 0.0254 mm (0.001 i nch). The
cl earance woul d then be 0.0508 mm (0.002 i nch) and
wi thi n the speci fi cati on. A 0.051 mm (0.002 i nch)
undersi ze beari ng i nsert and a 0.0254 mm (0.001
i nch) undersi ze i nsert woul d reduce the ori gi nal
cl earance an addi ti onal 0.0127 mm (0.0005 i nch). The
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
I f journal s 1 through 5 di ameters are l ess than
63.4517 mm (2.4981 i nches), repl ace crankshaft or
gri nd crankshaft down to accept the appropri ate
undersi ze beari ng i nserts.
Once the proper cl earances have been obtai ned,
proceed to Crankshaft Mai n Beari ngI nstal l ati on.
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
Plastigage
1 PLASTIGAGE SCALE
MAIN BEARING FITTING CHART
CRANKSHAFT JOURNALS CORRESPONDING CRANKSHAFT BEARING INSERT
Yellow
63.5025 - 63.4898 mm
Yellow - Standard Yellow - Standard
(2.5001 - 2.4996 in.)
Orange
63.4898 - 63.4771mm
Yellow - Standard
Blue- Undersize 0.025 mm
(0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4771 - 63.4644 mm
(0.001 in.)
(0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4644 - 63.4517 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize 0.051 mm
(0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
Red
63.2485 - 63.2358 mm
Red - Undersize 0.254 mm
(0.010 in.)
Red - Undersize 0.254 mm
(0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
FORM-IN-PLACE GASKETS
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when appl yi ng form-i n-pl ace gaskets.
Bead si ze, conti nui ty and l ocati on are of great i mpor-
tance. Too thi n a bead can resul t i n l eakage whi l e too
much can resul t i n spi l l -over. A conti nuous bead of
the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar Si l i cone Rubber
Adhesi ve Seal ant and Mopar Gasket Maker). Each
have di fferent properti es and cannot be used i nter-
changeabl y.
MOPAR SILICONE RUBBER ADHESIVE SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant, normal l y
bl ack i n col or, i s avai l abl e i n 3 ounce tubes. Moi sture
i n the ai r causes the seal ant materi al to cure. Thi s
materi al i s normal l y used on fl exi bl e metal fl anges.
I t has a shel f l i fe of a year and wi l l not properl y cure
i f over aged. Al ways i nspect the package for the expi -
rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normal l y red i n col or, i s
avai l abl e i n 6 cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et or other sui tabl e tool to break the seal
between the mati ng surfaces. A fl at gasket scraper
may al so be l i ghtl y tapped i nto the joi nt but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
gasket rai l s are fl at. Fl atten rai l s wi th a hammer on
a fl at pl ate, i f requi red. Gasket surfaces must be free
of oi l and di rt. Make sure the ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar Si l i cone Rubber Adhesi ve Seal ant shoul d be
appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n 10
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can easi l y be wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
ENGINE PERFORMANCE
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and the l owest emi ssi on l evel s. I f vehi cl e i s not oper-
ati ng to these standards, refer to Engi ne Di agnosi s
outl i ned i n thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. Refer to El ectri -
cal Group 8B, Col d Cranki ng Test.
(2) Check i ntake mani fol d bol t torque; Refer to
Group 11, Exhaust System and I ntake Mani fol d.
(3) Perform cyl i nder compressi on test. Refer to
Cyl i nder Compressi on Pressure Test i n the Engi ne
Di agnosi s area of thi s secti on.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n El ectri cal Group 8D.
Ti ghten to speci fi cati ons.
(5) Test resi stance of spark pl ug cabl es. Refer to
El ectri cal Group 8D, Spark Pl ug Cabl es.
(6) I nspect the pri mary wi res. Test coi l output vol t-
age and pri mary resi stance. Repl ace parts as neces-
sary. Refer to El ectri cal Group 8D, for speci fi cati ons.
(7) Test fuel pump for pressure. Refer to Group 14,
Fuel System Speci fi cati ons.
(8) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Lubri cati on and Mai ntenance, Group 0.
(9) I nspect crankcase venti l ati on system as out
l i ned i n Group 0, Lubri cati on and Mai ntenance. For
emi ssi on control s see Group 25, Emi ssi on Control s
for servi ce procedures.
(10) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). 20-60 strokes,
dependi ng on the bore condi ti on, wi l l be suffi ci ent to
provi de a sati sfactory surface. Usi ng honi ng oi l
C-3501-3880 or a l i ght honi ng oi l avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 36).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
Fig. 36 Cylinder Bore Crosshatch Pattern
1 CROSSHATCH PATTERN
2 INTERSECT ANGLE
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter S
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
HYDROSTATIC LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(refer to Group 14, Fuel System).
(2) Di sconnect the negati ve cabl e from the battery.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 37 Nm (27 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(12) I nstal l the drai n pl ug. Ti ghten the pl ug to 34
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l (refer to Group 0, Lubri ca-
ti on and Mai ntenance).
(15) Connect the negati ve cabl e to the battery.
(16) Start the engi ne and check for any l eaks.
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
I n gasol i ne engi nes. use an engi ne oi l that i s API
Servi ce Grade Certi fi ed (Fi g. 37).
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 37).
SAE VISCOSITY
cosi ty of engi ne oi l . SAE 10W-30 speci fi es a mul ti pl e
vi scosi ty engi ne oi l .
When choosi ng an engi ne oi l , consi der the range of
temperatures the vehi cl e wi l l be operated i n before
the next oi l change. Sel ect an engi ne oi l that i s best
sui ted to your areas parti cul ar ambi ent temperature
range and vari ati on (Fi g. 38).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
The engi ne oi l l evel i ndi cator (Di psti ck) i s l ocated
at the ri ght rear of the 2.5L engi ne. I nspect engi ne
oi l l evel approxi matel y every 800 ki l ometers (500
mi l es). Unl ess the engi ne has exhi bi ted l oss of oi l
pressure, run the engi ne for about fi ve mi nutes
before checki ng oi l l evel . Checki ng engi ne oi l l evel on
a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 39).
(1) Posi ti on vehi cl e on l evel surface.
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, note oi l l evel readi ng (Fi g. 39).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
Fig. 37 Engine Oil Container Standard Notations
Fig. 38 Temperature/Engine Oil Viscosity
Fig. 39 Engine Oil Dipstick2.5L Engine
1 DIPSTICK
2 SAFE
3 ADD
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Chrysl er Corpo-
rati on recommends a Mopar or equi val ent oi l fi l ter be
used.
OIL FILTER REMOVAL
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss (Fi g. 40).
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Wi th a wi pi ng cl oth, cl ean the gasket seal i ng
surface (Fi g. 41) of oi l and gri me.
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 41) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
ENGINE MOUNTS FRONT
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
REMOVAL
(1) Di sconnect negati ve cabl e from battery.
(3) Support the engi ne.
(4) Remove through bol t nut (Fi g. 42). DO NOT
remove the through bol t.
(5) Remove the retai ni ng bol ts and nuts from the
support cushi ons (Fi g. 42).
(6) Remove the through bol t.
(7) Remove the support cushi ons.
INSTALLATION
(1) I f the engi ne support bracket was removed,
posi ti on the LEFT bracket (Fi g. 42) and the RI GHT
bracket (Fi g. 43) onto the cyl i nder bl ock. I nstal l the
bol ts and stud nuts.
(a) RI GHT SI DE (Fi g. 43) Ti ghten the bol ts to
61 Nm (45 ft. l bs.) torque. Ti ghten the stud nuts to
(b) LEFT SI DE (Fi g. 42) Ti ghten the bol ts to
(2) I f the support cushi on brackets were removed,
posi ti on the brackets onto the l ower front si l l (Fi g.
42) (Fi g. 44). I nstal l the bol ts and stud nuts. Ti ghten
the bol ts to 54 Nm (40 ft. l bs.) torque and the stud
Fig. 40 Oil Filter2.5L Engine
1 OIL FILTER
Fig. 41 Oil Filter Sealing SurfaceTypical
1 SEALING SURFACE
2 RUBBER GASKET
3 OIL FILTER
(3) Pl ace the support cushi ons onto the support
cushi on brackets (Fi g. 42). Ti ghten the ri ght support
cushi on nuts to 65 Nm (48 ft. l bs.) torque. Ti ghten
the l eft support cushi on bol t and nut to 41 Nm (30
ft. l bs.) torque.
(4) I nstal l the through bol t and the retai ni ng nut
(Fi g. 42). Ti ghten the through bol t nut to 65 Nm (48
ft. l bs.) torque.
(5) Remove the engi ne support.
(7) Connect negati ve cabl e to battery.
ENGINE MOUNT REAR
A resi l i ent rubber cushi on supports the transmi s-
si on at the rear between the transmi ssi on extensi on
housi ng and the rear support crossmember or ski d
pl ate.
REMOVAL
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the crossmember (Fi g. 45) (Fi g. 46). Remove the
crossmember.
MANUAL TRANSMISSION:
a. Remove the support cushi on nuts and remove
the cushi on.
b. I f necessary, remove the bol ts hol di ng the trans-
mi ssi on support bracket to the transmi ssi on (Fi g. 45).
Remove the bracket.
Fig. 42 Front Mounts
1 ENGINE SUPPORT BRACKET
2 THROUGH BOLT
3 RETAINING BOLT
4 SUPPORT CUSHION
5 ATTACHING BOLT
6 SUPPORT CUSHION
7 THROUGH BOLT
9 SUPPORT CUSHION BRACKET
10 SILL
Fig. 43 Engine Support BracketRight Side
Fig. 44 Support Cushion BracketLeft Side
1 LOWER FRONT SILL
2 TRACK BAR MOUNTING PLATE
AUTOMATIC TRANSMISSION:
a. Remove the support cushi on bol ts and remove
the cushi on and the transmi ssi on support bracket.
b. I f necessary on 2WD vehi cl es, remove the bol ts
hol di ng the transmi ssi on support adaptor bracket to
the transmi ssi on (Fi g. 46). Remove the adaptor
bracket.
INSTALLATION
a. I f removed, posi ti on the transmi ssi on support
bracket to the transmi ssi on and i nstal l the bol ts.
Ti ghten the bol ts to 43 Nm (32 ft. l bs.) torque.
b. Posi ti on the support cushi on onto the transmi s-
si on support bracket. I nstal l and ti ghten the nuts to
a. I f removed, posi ti on the transmi ssi on support
adaptor bracket (2WD vehi cl es) to the transmi ssi on
and i nstal l the bol ts. Ti ghten the bol ts to 75 Nm (55
ft. l bs.) torque.
b. Posi ti on the transmi ssi on support bracket and
support cushi on to the transmi ssi on and i nstal l the
bol ts. Ti ghten the bol ts to 75 Nm (55 ft. l bs.) torque.
(1) Posi ti on the crossmember onto the support
cushi on studs and i nstal l the nuts. Ti ghten the nuts
(2) I nstal l the crossmember to si l l bol ts and
ti ghten to 41 Nm (30 ft. l bs.) torque.
(3) Remove the transmi ssi on support.
ENGINE
REMOVAL
(1) Di sconnect the battery cabl es. Remove the bat-
tery.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
WARNING: THE COOLANT IN A RECENTLY OPER-
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(3) Loosen the radi ator drai n cock and radi ator cap
to drai n the cool ant. DO NOT waste usabl e cool ant.
I f the sol uti on i s cl ean, drai n the cool ant i nto a cl ean
contai ner for reuse.
(4) Remove the ai r cl eaner assembl y (Fi g. 47).
(5) Remove the l ower radi ator hose.
Fig. 45 Rear Mount (Manual Transmission)
1 TRANSMISSION SUPPORT BRACKET
2 SUPPORT CUSHION
Fig. 46 Rear Mount (Automatic Transmission)
1 44
2 24
3 TRANSMISSION SUPPORT ADAPTOR BRACKET
4 SUPPORT CUSHION
5 CROSSMEMBER ASSEMBLY
(6) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 48).
(7) Remove the fan shroud (Fi g. 48).
(8) Remove the radi ator/condenser (i f equi pped
wi th ai r condi ti oni ng).
(9) Remove fan assembl y and i nstal l a 5/16 x 1/2-
i nch SAE capscrew through fan pul l ey i nto water
pump fl ange. Thi s wi l l mai ntai n the pul l ey and
water pump i n al i gnment when crankshaft i s rotated.
(10) Di sconnect the heater hoses.
(11) Di sconnect the throttl e cabl e, speed control
cabl e (i f equi pped) and transmi ssi on cabl e (i f
equi pped).
(12) Di sconnect the body ground at the fi rewal l .
(13) Di sconnect the wi res from the starter motor
sol enoi d.
(14) Di sconnect al l fuel i njecti on harness connec-
ti ons.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE DISCONNECTING FUEL
LINES, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(15) Perform fuel pressure rel ease procedure.
(refer to Group 14, Fuel System for the proper proce-
dure).
(16) Remove l atch cl i p and di sconnect the qui ck-
connect fuel l i ne at the fuel rai l
(17) Recover refri gerant (i f equi pped wi th A/C).
(Refer to group 24, Heati ng and Ai r Condi ti oni ng for
proper procedures.)
(18) Di sconnect sucti on/di scharge hose from A/C
compressor and cap off ports to prevent i ntrusi on of
forei gn materi al or refri gerant oi l l oss.
(19) Remove the power brake vacuum check val ve
from the booster, i f equi pped.
(20) I f equi pped wi th power steeri ng :
(a) Di sconnect the power steeri ng hoses from the
fi tti ngs at the steeri ng gear.
(b) Drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn materi al from enteri ng the
system.
(21) I denti fy, tag and di sconnect al l necessary wi re
connectors and vacuum hoses.
(23) Remove the oi l fi l ter.
(24) Remove the starter motor.
(25) Di sconnect the exhaust pi pe from the exhaust
mani fol d.
(26) Remove the fl ywheel housi ng access cover.
(27) Remove the upper fl ywheel and converter
housi ng bol ts and l oosen the bottom bol ts.
(28) Remove the engi ne support cushi on-to-engi ne
compartment bracket bol ts.
(29) Remove the engi ne shock damper bracket
from the si l l .
(31) Attach a l i fti ng devi ce to the engi ne.
Fig. 47 Air Cleaner and Resonator Removal and
Installation
1 AIR CLEANER ASSEMBLY
2 NUT AND WASHER
3 RESONATOR ASSEMBLY
4 AIR INLET HOSE
Fig. 48 Upper Radiator Hose, Coolant Recovery
Hose & Fan Shroud
1 UPPER RADIATOR HOSE
2 FAN SHROUD
3 COOLANT RECOVERY HOSE
(32) Rai se the engi ne sl i ghtl y off the front sup-
ports.
(33) Pl ace a support stand under the converter or
fl ywheel housi ng.
(34) Li ft the engi ne out of the engi ne compartment
and i nstal l on an engi ne stand.
(35) I nstal l the oi l fi l ter to keep forei gn materi al
out of the engi ne.
INSTALLATION
(1) Remove the oi l fi l ter.
(2) Li ft the engi ne off the stand and l ower i t i nto
the engi ne compartment. For easi er i nstal l ati on, i t
may be useful to remove the engi ne support cushi ons
from the engi ne support brackets as an ai de for
al i gnment of the engi ne-to-transmi ssi on.
(3) I nsert the transmi ssi on shaft i nto the cl utch
spl i ne. (M/T model s)
(4) Al i gn the fl ywheel housi ng wi th the engi ne.
(5) I nstal l and ti ghten the fl ywheel housi ng l ower
bol ts.
(6) I nstal l the engi ne support cushi ons (i f
removed).
(7) Lower the engi ne and engi ne support cushi ons
onto the engi ne compartment brackets.
(8) Remove the engi ne l i fti ng devi ce.
(10) I nstal l the converter-housi ng access cover.
(11) I nstal l the exhaust pi pe support.
(12) I nstal l the starter motor and connect the
cabl e. Ti ghten the bol ts to 45 Nm (33 ft. l bs.) torque.
(13) Ti ghten the engi ne support cushi on through-
bol t nuts.
(14) Connect the exhaust pi pe to the mani fol d.
(15) I nstal l the oi l fi l ter.
(17) Connect the cool ant hoses and ti ghten the
cl amps.
(18) I f equi pped wi th power steeri ng:
(a) Remove the protecti ve caps
(b) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(c) Fi l l the pump reservoi r wi th fl ui d.
(19) Remove the pul l ey-to-water pump fl ange
al i gnment capscrew and i nstal l the fan assembl y.
(20) I nstal l the fan shroud and radi ator and con-
denser (i f equi pped wi th ai r condi ti oni ng).
(21) Connect the radi ator hoses.
(22) Connect the oxygen sensor wi re connector.
(23) Connect the throttl e cabl e and i nstal l the rod.
Connect the transmi ssi on and speed control cabl es (i f
equi pped)
(24) Connect the fuel suppl y l i ne to the i njector
rai l . push unti l a cl i ck i s heard. Re-i nstal l l atch
cl i p.
(25) Connect al l the vacuum hoses and wi re con-
nectors.
(26) Connect sucti on/di scharge hose to compressor.
(i f equi pped)
(27) Fi l l the power steeri ng reservoi r.
(28) Connect the battery cabl es.
(29) I nstal l the ai r cl eaner (Fi g. 47).
(30) I nstal l the hood.
(31) Add engi ne oi l and cool ant.
(32) Start the engi ne and i nspect for l eaks.
(33) Stop the engi ne and check the fl ui d l evel s.
Add fl ui d, as requi red.
(34) Recharge ai r condi ti oni ng (Refer to group 24,
Heati ng and Ai r Condi ti oni ng for proper procedures).
INTAKE MANIFOLD
REMOVAL
(1) Di sconnect the battery negati ve cabl e.
(2) Remove the ai r i nl et hose and resonator from
the throttl e body and ai r cl eaner (Fi g. 49).
(3) Loosen the accessory dri ve bel t tensi on and
remove the bel t from the power steeri ng pump (refer
to Group 07, Cool i ng Systems for proper procedures).
(4) Remove the power steeri ng pump and brackets
from the water pump and i ntake mani fol d. Secure
power steeri ng pump and bracket out of the way.
Fig. 49 Air Cleaner, Resonator and air Inlet Hose
Removal and Installation
1 AIR CLEANER ASSEMBLY
2 NUT AND WASHER
3 RESONATOR ASSEMBLY
4 AIR INLET HOSE
(5) Perform fuel system pressure rel ease procedure
(refer to Group 14, Fuel System for correct proce-
dure).
(6) Di sconnect fuel suppl y tube from the fuel rai l .
Some fuel l i nes requi re a speci al tool for removal /i n-
stal l ati on (refer to Group 14, Fuel System - Qui ck
Connect Fi tti ngs).
(7) Di sconnect the accel erator cabl e, the crui se
control cabl e (i f equi pped), and the transmi ssi on l i ne
pressure cabl e (i f equi pped) from the throttl e body
and remove them from the cabl e bracket.
CAUTION: When disconnecting the cruise control
connector at the throttle body, DO NOT pry the con-
nector off with pliers or screwdriver. Use finger
pressure only. Prying the connector off could break
it.
(8) Di sconnect the el ectri cal connectors. Pul l the
harnesses away from the mani fol d and secure them
so they do not i nterfere wi th the mani fol d removal
and i nstal l ati on process.
The throttl e posi ti on sensor.
The i dl e ai r control motor.
The cool ant temperature sensor at the thermo-
stat.
The mani fol d ai r temperature sensor at the
i ntake mani fol d.
The fuel i njectors.
The oxygen sensor.
(9) Di sconnect the crankcase venti l ati on (CCV)
vacuum hose and mani fol d absol ute pressure (MAP)
sensor vacuum hose connector at the i ntake mani -
fol d.
(10) Di sconnect vacuum hose from vacuum port on
the i ntake mani fol d.
(11) Di sconnect CCV hose at the cyl i nder head
cover (Fi g. 50).
(12) Remove the mol ded vacuum harness.
(13) Di sconnect the vacuum brake booster hose at
the i ntake mani fol d.
(14) Remove bol ts 2 through 5 securi ng the i ntake
mani fol d to the cyl i nder head (Fi g. 51). Sl i ghtl y
l oosen bol t No.1 and nuts 6 and 7.
(15) Remove the i ntake mani fol d and gaskets.
Drai n the cool ant from the mani fol d.
INSTALLATION
(1) Cl ean the i ntake mani fol d and cyl i nder head
mati ng surfaces. DO NOT allow foreign material
to enter either the intake manifold or the ports
in the cylinder head.
(2) I nstal l the new i ntake mani fol d gasket over the
l ocati ng dowel s.
(3) Posi ti on the mani fol d i n pl ace and fi nger
ti ghten the mounti ng bol ts.
(4) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 51).
Fastener No.1Ti ghten to 41 Nm (30 ft. l bs.)
torque.
Fasteners Nos.2 through 5Ti ghten to 31 Nm
(23 ft. l bs.) torque.
Fasteners Nos.6 and 7Ti ghten to 23 Nm (17
ft. l bs.) torque.
(5) Connect fuel suppl y tube to the fuel rai l i nl et.
Push tube unti l a cl i ck i s heard. Before connect-
ing the fuel line to the fuel rail replace the
O-rings at the quick-connect fuel line coupling.
(6) Pul l out on the fuel suppl y tube to ensure that
i t i s l ocked i n pl ace.
(7) Connect the mol ded vacuum hoses to the vac-
uum port on the i ntake mani fol d and the cyl i nder
head cover.
(8) Connect the el ectri cal connectors.
The throttl e posi ti on sensor.
The i dl e ai r control motor.
The cool ant temperature sensor at the thermo-
stat housi ng.
The fuel i njectors.
The ai r mani fol d temperature sensor.
The oxygen sensor.
(9) Connect the CCV vacuum hose and MAP sen-
sor vacuum hose connectors to the throttl e body.
Fig. 50 Crankcase Ventilation (CCV) Hose2.5L
Engine
1 AIR INLET FITTING
2 AIR FILTER COVER
(10) I nstal l the power steeri ng pump and bracket
assembl y to the water pump and i ntake mani fol d.
Hand start the three (3) tensi oner bracket to p/s
pump to i ntake mani fol d bol ts and the two (2) ten-
si oner bracket to water pump bol ts.
(11) Ti ghten the power steeri ng pump bol ts to 28
Nm (21 ft. l bs.) Ti ghten the tensi oner bracket to
water pump bol ts to 28 Nm (21 ft. l bs.).
(12) Connect the accel erator cabl e, crui se control
cabl e (i f equi pped), and the transmi ssi on l i ne pres-
sure cabl e (i f equi pped) to the hol d-down bracket and
the throttl e l ever.
(13) I nstal l and tensi on the accessory dri ve bel t.
Refer to Group 7, Cool i ng System for the proper pro-
cedure.
CAUTION: Ensure that the accessory drive belt is
routed correctly. Failure to do so can cause the
water pump to turn in the opposite direction result-
ing in engine overheating. Refer to Group 7, Cool-
ing System for the proper procedure.
(14) Connect the ai r i nl et hose and resonator to
the throttl e body and the ai r cl eaner.
(15) Connect the battery negati ve cabl e.
(16) Start the engi ne and check for l eaks.
EXHAUST MANIFOLD
REMOVAL
(3) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d.
(5) Remove i ntake mani fol d (refer to procedure i n
thi s secti on)
(6) Remove fasteners 2 through 5 and remove the
i ntake mani fol d (Fi g. 51).
(7) Remove fasteners 1, 6 and 7 and remove the
engi ne exhaust mani fol d (Fi g. 51).
INSTALLATION
(1) Cl ean the i ntake and engi ne exhaust mani fol ds
and cyl i nder head mati ng surfaces. DO NOT allow
foreign material to enter either the intake man-
ifold or the ports in the cylinder head.
(2) I nstal l a new i ntake mani fol d gasket over the
al i gnment dowel s on the cyl i nder head.
(3) I nstal l the engi ne exhaust mani fol d assembl y.
Exhaust manifold must be centrally located
over the end studs and spacer (Fig. 51).
(4) Ti ghten bol t No.1 to 41 Nm (30 ft. l bs.) torque
(Fi g. 51).
(5) I nstal l the i ntake mani fol d on the cyl i nder
head dowel s (Fi g. 51).
(6) I nstal l bol ts 2 through 5 (Fi g. 51). Ti ghten
these bol ts to 31 Nm (23 ft. l bs.) torque.
(7) I nstal l new engi ne exhaust mani fol d spacers
over the engi ne exhaust mani fol d mounti ng studs i n
the cyl i nder head (Fi g. 51).
(8) Ti ghten nuts 6 and 7 to 23 Nm (17 ft. l bs.)
torque (Fi g. 51).
(9) I nstal l al l components to the i ntake mani fol d.
(11) Connect the exhaust pi pe to the engi ne
exhaust mani fol d. Ti ghten the bol ts to 31 Nm (23 ft.
l bs.) torque.
CYLINDER HEAD COVER
A cured gasket i s part of the engi ne cyl i nder head
cover.
REMOVAL
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover (Fi g.
52).
(3) Remove the ai r i nl et hose and resonator from
the ai r cl eaner and throttl e body.
(4) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(5) Remove the engi ne cyl i nder head cover (Fi g.
52).
(6) Remove any ori gi nal seal er from the cover seal -
i ng surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
(7) Remove al l resi due from the seal i ng surface
usi ng a cl ean, dry cl oth.
Fig. 51 Intake/Exhaust Manifold Removal/
Installation2.5L Engine
INSTALLATION
(1) I nspect the engi ne cyl i nder head cover for
cracks. Repl ace the cover, i f cracked.
NOTE: The original dark grey gasket material
should NOT be removed. If sections of the gasket
material are missing or are compressed, replace the
engine cylinder head cover. However, sections with
minor damage such as small cracks, cuts or chips
may be repaired with a hand held applicator. The
new material must be smoothed over to maintain
gasket height. Allow the gasket material to cure
prior to engine cylinder head cover installation.
(2) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet the oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(3) I nstal l engi ne cyl i nder head cover. Ti ghten the
mounti ng bol ts to 13 Nm (115 i n. l bs.) torque.
(4) Connect the CCV hoses (Fi g. 52).
(6) I nstal l the ai r i nl et hose and resonator.
ROCKER ARMS AND PUSH RODS
Thi s procedure can be done wi th the engi ne i n or
out of the vehi cl e.
REMOVAL
(1) Remove the engi ne cyl i nder head cover. (Refer
to procedure i n thi s secti on)
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 53). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 53). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
(6) Cl ean al l the components wi th cl eani ng sol -
vent.
(7) Use compressed ai r to bl ow out the oi l passages
i n the rocker arms and push rods.
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
Fig. 52 Engine Cylinder Head Cover
1 AIR INLET FITTING
2 AIR FILTER COVER
Fig. 53 Rocker Arm Assembly
1 CAPSCREWS
2 BRIDGE
3 PIVOT ASSEMBLY
4 PUSH RODS
5 ROCKER ARMS
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
(5) I nstal l the engi ne cyl i nder head cover.
VALVE SPRING AND SEAL
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(1) Remove the engi ne cyl i nder head cover. Refer
to procedure i n thi s secti on.
(2) Remove cap screws, bri dge and pi vot assem-
bl i es and rocker arms for access to each val ve spri ng
to be removed.
(3) Remove push rods. Retain the push rods,
bridges, pivots and rocker arms in the same
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) I nstal l a 14 mm (1/2 i nch) (thread si ze) ai r hose
adaptor i n the spark pl ug hol e.
(7) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(8) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 54).
(9) Remove val ve spri ng and retai ner (Fi g. 54).
(10) Remove val ve stem oi l seal s (Fi g. 54). Note
the val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(i ntake/bl ack i n col or) or EXH (exhaust/brown i n
col or). DO NOT mi x the seal s.
INSTALLATION
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge cap screws al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
cap screws to 28 Nm (21 ft. l bs.) torque.
Fig. 54 Valve and Valve Components
2 RETAINER
4 INTAKE VALVE
5 EXHAUST VALVE
6 VALVE SPRING
CYLINDER HEAD
REMOVAL
DRAIN COCK WITH THE SYSTEM HOT AND PRES-
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean and i s bei ng
drai ned onl y to servi ce the engi ne or cool i ng system,
drai n the cool ant i nto a cl ean contai ner for reuse.
(3) Remove the ai r cl eaner assembl y.
(4) Remove the engi ne cyl i nder head cover. (Refer
to procedure i n thi s secti on)
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms (Fi g. 55).
(6) Remove the push rods (Fi g. 55). Retain the
push rods, bridges, pivots and rocker arms in
the same order as removed.
(7) Loosen the accessory dri ve bel t at the power
steeri ng pump bracket, i f equi pped or at the i dl er
pul l ey bracket (refer to Group 7, Cool i ng System for
the proper procedure).
(8) I f equi pped wi th ai r condi ti oni ng, perform the
fol l owi ng:
(a) Remove the bol ts from the A/C compressor
mounti ng bracket and set the compressor asi de.
(b) Remove the ai r condi ti oner compressor
bracket bol ts from the engi ne cyl i nder head.
(c) Loosen the through bol t at the bottom of the
bracket.
(9) I f equi pped, di sconnect the power steeri ng
pump bracket. Set the pump and bracket asi de. DO
NOT di sconnect the hoses.
(10) Perform fuel pressure rel ease procedure
(Refer to Group 14, fuel systems for proper proce-
dures).
(11) Remove the l atch cl i p and di sconnect the fuel
suppl y hose.
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head (refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures).
(13) Number and di sconnect the i gni ti on wi res and
remove the spark pl ugs.
(14) Di sconnect the cool ant temperature sendi ng
uni t connector.
(15) Remove the engi ne cyl i nder head bol ts.
(16) Remove the engi ne cyl i nder head and gasket
(Fi g. 56).
(17) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(18) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If valves, springs, or seals are to be inspect-
ed/replaced at this time, refer to Valves and Valve
Springs later in this section for proper inspection
procedures.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
1 CAPSCREWS
2 BRIDGE
3 PIVOT ASSEMBLY
4 PUSH RODS
5 ROCKER ARMS
(1) Fabri cate two engi ne cyl i nder head al i gnment
dowel s from used head bol ts (Fi g. 57). Use the l ong-
est head bol t. Cut the head of the bol t off bel ow the
hex head. Then cut a sl ot i n the top of the dowel to
al l ow easi er removal wi th a screwdri ver.
(2) I nstal l one dowel i n bol t hol e No.10 and the
other dowel i n bol t hol e No.8 (Fi g. 58).
(3) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(4) Pl ace the engi ne cyl i nder head gasket (wi th the
numbers faci ng up) over the dowel s.
(5) Pl ace the engi ne cyl i nder head over the dowel s.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(6) Coat the threads of bol t No.7, onl y, wi th Locti te
PST seal ant or equi val ent.
(7) I nstal l al l head bol ts, except No.8 and No.10.
(8) Remove the dowel s.
(9) I nstal l No.8 and No.10 head bol ts.
CAUTION: During the final tightening sequence,
bolt No.7 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt No.7.
(10) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
59) :
(a) Ti ghten al l bol ts i n sequence (1 through 10)
(b) Ti ghten al l bol ts i n sequence (1 through 10)
(c) Check al l bol ts to veri fy they are set to 61
(d) Ti ghten bol ts (i n sequence):
Bol ts 1 through 6 to 149 Nm (110 ft. l bs.)
torque.
Bol t 7 to 136 Nm (100 ft. l bs.) torque.
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(11) Connect the cool ant temperature sendi ng uni t
connector.
(12) I nstal l the spark pl ugs and ti ghten to 37 Nm
(27 ft. l bs.) torque. Connect the i gni ti on wi res.
Fig. 56 Engine Cylinder Head Assembly
1 BRIDGE
2 PIVOT ASM.
3 ROCKER ARM
4 CYLINDER HEAD
5 HEAD GASKET
6 PUSH ROD
Fig. 57 Fabricate Alignment Dowels
1 USED CYLINDER HEAD BOLT
2 SLOT
Fig. 58 Alignment Dowel Locations
1 ALIGNMENT DOWEL
2 ALIGNMENT DOWEL
(13) I nstal l the i ntake and exhaust mani fol ds
(refer to Group 11, Exhaust System and I ntake Man-
i fol d for the proper procedures).
(14) I nstal l the fuel suppl y l i ne. Push unti l a
cl i ck i s heard. Rei nstal l l atch cl i p.
(15) I f equi pped, attach the power steeri ng pump
and bracket.
(16) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed.
(18) Attach the ai r condi ti oni ng compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
(19) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
CAUTION: The accessory drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(20) I nstal l the accessory dri ve bel t and correctl y
tensi on the bel t (refer to Group 7, Cool i ng System for
the proper procedure).
(21) I nstal l the ai r cl eaner assembl y.
(22) Connect the hoses to the thermostat housi ng
and fi l l the cool i ng system to the speci fi ed l evel (refer
to Group 7, Cool i ng Systems for the proper proce-
dure).
(23) I nstal l the cool ant temperature sendi ng uni t
connector.
(25) Connect the upper radi ator hose and heater
hose at the thermostat housi ng.
(26) Fi l l the cool i ng system. Check for l eaks.
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(27) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the thermostat opens. Add cool ant, i f requi red.
CYLINDER HEAD
DISASSEMBLY
(1) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(2) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
(3) Use an Arkansas smooth stone or a jewel ers
fi l e to remove any burrs on the top of the val ve stem,
especi al l y around the groove for the l ocks.
(4) Remove the val ves, and pl ace them i n a rack i n
ASSEMBLY
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
HYDRAULIC TAPPETS
REMOVAL
Retai n al l the components i n the same order as
removed.
(1) Remove the engi ne cyl i nder head cover (refer to
procedure earl i er i n thi s secti on)
(2) Remove the bri dge and pi vot assembl i es and
rocker arms by removi ng the capscrews at each
bri dge. Al ternatel y l oosen each capscrew, one turn at
a ti me, to avoi d damagi ng the bri dges.
(3) Remove the push rods.
(4) Remove the tappets through the push rod open-
i ngs i n the cyl i nder head wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 60).
Fig. 59 Engine cylinder head Bolt Tightening
Sequence
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the push rods i n thei r ori gi nal l ocati ons.
(4) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(5) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
VIBRATION DAMPER
REMOVAL
(2) Remove the serpenti ne dri ve bel t and fan
shroud.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 61).
INSTALLATION
(1) Appl y Mopar Si l i cone Rubber Adhesi ve Seal ant
to the keyway i n the crankshaft and i nsert the key.
Wi th the key i n posi ti on, al i gn the keyway on the
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
(4) I nstal l the serpenti ne dri ve bel t and ti ghten to
the speci fi ed tensi on (refer to Group 7, Cool i ng Sys-
tems for the proper speci fi cati ons and procedures).
TIMING CASE COVER OIL SEAL
REMOVAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
(2) Remove the serpenti ne dri ve bel t.
(3) Remove the vi brati on damper.
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 62). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
Fig. 60 Hydraulic Valve Tappet Removal/Installation
Tool
1 HYDRAULIC VALVE TAPPET REMOVAL/INSTALLATION TOOL
Fig. 61 Vibration Damper Removal Tool 7697
1 VIBRATION DAMPER REMOVAL TOOL
2 WRENCH
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
Wi th the key i nserted i n the keyway i n the crank-
shaft, i nstal l the vi brati on damper, washer and bol t.
Lubri cate and ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
TIMING CASE COVER
REMOVAL
(2) Remove accessory dri ve bel t (Refer to Group
07, Cool i ng System for proper procedure)
(3) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(4) Remove the fan and hub assembl y and remove
the fan shroud.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the vi brati on damper (Fi g. 63).
(7) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(8) Remove the ti mi ng case cover and gasket from
the engi ne.
(9) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 63).
INSTALLATION
(1) Cl ean the ti mi ng case cover, oi l pan and cyl i n-
der bl ock gasket surfaces.
(2) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(3) Posi ti on the gasket on the cyl i nder bl ock.
(4) Posi ti on the ti mi ng case cover on the oi l pan
gasket and the cyl i nder bl ock.
(5) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
the cover (Fi g. 64).
Fig. 62 Timing Case Cover Oil Seal Installation
1 SEAL INSTALLATION TOOL
2 DRAW SCREW TOOL
Fig. 63 Timing Case Cover Components
1 TIMING CASE COVER
2 OIL SLINGER
3 CRANKSHAFT OIL SEAL
4 VIBRATION DAMPER PULLEY
Fig. 64 Timing Case Cover Alignment and Seal
Installation Tool 6139
1 TIMING CASE COVER ALIGNMENT AND SEAL
INSTALLATION TOOL
(6) I nstal l the ti mi ng case cover-to-cyl i nder bl ock
and the oi l pan-to-ti mi ng case cover bol ts.
(7) Ti ghten the 1/4 i nch cover-to-bl ock bol ts to 7
Nm (60 i n. l bs.) torque. Ti ghten the 5/16 i nch front
cover-to-bl ock bol ts to 22 Nm (192 i n. l bs.) torque.
Ti ghten the oi l pan-to-cover bol ts to 9.5 Nm (84 i n.
l bs.) torque.
(8) Remove the cover al i gnment tool .
(9) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
(10) Appl y Mopar Si l i cone Rubber Adhesi ve Seal -
ant to the keyway i n the crankshaft and i nsert the
key. Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper, washer and
bol t. Lubri cate and ti ghten the bol t to 108 Nm (80 ft.
l bs.) torque.
(11) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(12) I nstal l the engi ne fan and hub assembl y and
shroud.
(13) I nstal l the accessory dri ve bel t and ti ghten to
obtai n the speci fi ed tensi on.
TIMING CHAIN AND SPROCKETS
The chai n dri ve system i e equi pped wi th a ti mi ng
chai n tensi oner whi ch reduces noi se and prol ongs
ti mi ng chai n l i fe. I n addi ti on, i t compensates for
wear and temperature changes on the val ve trai n for
proper engi ne operati on.
REMOVAL
(2) Remove the fan and shroud.
(4) Remove the crankshaft vi brati on damper.
(5) Remove the ti mi ng case cover.
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 65).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft retai ni ng bol t and
remove the sprockets and chai n as an assembl y (Fi g.
66).
(9) To repl ace the ti mi ng chai n tensi oner, the oi l
pan must be removed.
INSTALLATION
(1) Turn the tensi oner l ever to the unl ocked (down)
posi ti on (Fi g. 67).
(2) Pul l the tensi oner bl ock toward the tensi oner
l ever to compress the spri ng. Hol d the bl ock and turn
the tensi oner l ever to the l ock posi ti on (Fi g. 67).
Wi th the key i n the crankshaft keyway, i nstal l the
crankshaft, camshaft sprockets and ti mi ng chai n.
Ensure the ti mi ng marks on the sprockets are prop-
erl y al i gned (Fi g. 65).
(4) I nstal l the camshaft sprocket retai ni ng bol t
and washer. Ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(5) To veri fy correct i nstal l ati on of the ti mi ng
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 68). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 20 pi ns.
(6) Turn the chai n tensi oner l ever to the unl ocked
(down) posi ti on (Fi g. 67).
(7) I nstal l the oi l sl i nger.
(8) Repl ace the oi l seal i n the ti mi ng case cover.
(9) I nstal l the ti mi ng case cover and gasket.
Fig. 65 CrankshaftCamshaft Alignment
1 TIMING MARKS
Fig. 66 Camshaft and Crankshaft Sprockets and
Chain
1 CAMSHAFT SPROCKET
2 CRANKSHAFT SPROCKET
3 CHAIN
(10) Wi th the key i nserted i n the keyway i n the
crankshaft, i nstal l the vi brati on damper, washer and
bol t. Lubri cate and ti ghten the bol t to 108 Nm (80 ft.
l bs.) torque.
(11) I nstal l the fan and shroud.
CAMSHAFT
REMOVAL
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
cl ean contai ner for reuse.
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C.
(4) Scri be a mark on the di stri butor housi ng i n
l i ne wi th the l i p of the rotor.
(5) Scri be a mark on the di stri butor housi ng near
the cl amp and conti nue the scri be mark on the cyl i n-
der bl ock i n l i ne wi th the di stri butor mark.
(6) For ease of i nstal l ati on, note the posi ti on of the
rotor and di stri butor housi ng i n rel ati on to adjacent
engi ne components.
(7) Remove the di stri butor and i gni ti on wi res.
(8) Remove the engi ne cyl i nder head cover.
(9) Remove the rocker arms, bri dges and pi vots.
(11) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder head.
(14) Remove the ti mi ng chai n and sprockets.
(15) Remove the camshaft (Fi g. 69).
INSTALLATION
(1) I nspect the cam l obes for wear.
Fig. 67 Loading Timing Chain Tensioner
1 LOCK
2 UNLOCK
3 TENSIONER BLOCK
4 TENSIONER LEVER
Fig. 68 Verify SprocketChain Installation
1 CAMSHAFT SPROCKET
2 20 PINS
4 TIMING MARKS
Fig. 69 Camshaft
1 CAMSHAFT
2 CRANKSHAFT
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the ti mi ng case cover, exami ne the oi l pres-
sure rel i ef hol es i n the rear cam journal . The oi l
pressure rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
(7) Careful l y i nstal l the camshaft to prevent dam-
age to the camshaft beari ngs (Fi g. 69).
(8) Turn the tensi oner l ever to the unl ocked (down)
posi ti on (Fi g. 70).
(9) Pul l the tensi oner bl ock toward the tensi oner
l ever to compress the spri ng. Hol d the bl ock and turn
the tensi oner l ever to the l ock posi ti on (Fi g. 70).
(10) I nstal l the ti mi ng chai n, crankshaft sprocket
and camshaft sprocket wi th the ti mi ng marks
al i gned.
(11) I nstal l the camshaft sprocket retai ni ng bol t
and washer. Ti ghten the bol t to 108 Nm (80 ft. l bs.)
torque.
(12) Rel ease the ti mi ng chai n tensi oner by movi ng
the l ever to the unl ock posi ti on (Fi g. 70).
(13) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 71). Refer to Ti mi ng Case Cover
I nstal l ati on.
(14) I nstal l the vi brati on damper.
(15) I nstal l the hydraul i c val ve tappets.
(16) I nstal l the push rods.
(17) I nstal l the rocker arms, bri dges and pi vots.
(19) Posi ti on the oi l pump gear. Refer to Di stri bu-
tor i n the Component Removal /I nstal l ati on secti on of
Group 8D, I gni ti on Systems.
(20) I nstal l the di stri butor and i gni ti on wi res.
Refer to Di stri butor i n the Component Removal /I n-
stal l ati on secti on of Group 8D, I gni ti on Systems.
(21) I nstal l the radi ator or radi ator and condenser,
i f equi pped wi th A/C.
(22) Fi l l the cool i ng system.
CAMSHAFT PIN REPLACEMENT
REMOVAL
WARNING: DO NOT LOOSEN THE RADIATOR
SURIZED BECAUSE SERIOUS BURNS FROM COOL-
ANT CAN OCCUR.
(2) Drai n the radi ator. DO NOT waste reusabl e
cool ant. Drai n the cool ant i nto a cl ean contai ner.
(4) Di sconnect the radi ator overfl ow tube, radi ator
hoses, automati c transmi ssi on fl ui d cool er pi pes (i f
equi pped).
(5) Remove the radi ator.
(6) I f equi pped wi th ai r condi ti oni ng:
CAUTION: DO NOT loosen or disconnect any air
conditioner system fittings. Move the condenser
and receiver/drier aside as a complete assembly.
Fig. 70 Loading Timing Chain Tensioner
1 LOCK
2 UNLOCK
3 TENSIONER BLOCK
4 TENSIONER LEVER
Fig. 71 Timing Case Cover
1 TIMING CASE COVER
2 CAMSHAFT
3 CRANKSHAFT
(a) Remove the A/C compressor serpenti ne dri ve
bel t i dl er pul l ey.
(b) Di sconnect and remove the generator.
(c) Remove the A/C condenser attachi ng bol ts
and move the condenser and recei ver/dri er assem-
bl y up and out of the way.
(9) Remove the ti mi ng case cover. Cl ean the gasket
materi al from the cover.
(10) Rotate crankshaft unti l the crankshaft
sprocket ti mi ng mark i s cl osest to and on the center
l i ne wi th the camshaft sprocket ti mi ng mark (Fi g.
72).
(11) Remove camshaft sprocket retai ni ng bol t.
(12) Remove the crankshaft oi l sl i nger.
(13) Remove the sprockets and chai n as an assem-
bl y (Fi g. 73).
CAUTION: The following procedural step must be
accomplished to prevent the camshaft from damag-
ing the rear camshaft plug during pin installation.
(14) I nspect the damaged camshaft pi n.
(15) I f the pi n i s a spri ng-type pi n, remove the bro-
ken pi n by i nserti ng a sel f-tappi ng screw i nto the pi n
and careful l y pul l i ng the pi n from the camshaft.
(16) I f the pi n i s a dowel -type pi n, center-punch i t.
Ensure the exact center i s l ocated when center-
punchi ng the pi n.
CAUTION: Cover the opened oil pan area to pre-
vent metal chips from entering the pan.
(17) Dri l l i nto the pi n center wi th a 4 mm (5/32
i nch) dri l l bi t.
(18) I nsert a sel f-tappi ng screw i nto the dri l l ed pi n
and careful l y pul l the pi n from the camshaft.
INSTALLATION
(1) Cl ean the camshaft pi n hol e.
(2) Compress the center of the repl acement spri ng
pi n wi th vi se gri ps.
(3) Careful l y dri ve the pi n i nto the camshaft pi n
hol e unti l i t i s seated.
(4) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
al i gned (Fi g. 72).
chai n, turn the crankshaft to posi ti on the camshaft
sprocket ti mi ng mark as shown i n (Fi g. 74). Count
the number of chai n pi ns between the ti mi ng marks
of both sprockets. There must be 20 pi ns.
(6) I nstal l the crankshaft oi l sl i nger.
(7) Ti ghten the camshaft sprocket bol t to 108 Nm
(8) Check the val ve ti mi ng.
(9) Coat both si des of the repl acement ti mi ng case
cover gasket wi th gasket seal er. Appl y a 3 mm (1/8
i nch) bead of Mopar Si l i cone Rubber Adhesi ve Seal -
ant, or equi val ent to the joi nt formed at the ti mi ng
case cover and cyl i nder bl ock.
(11) Pl ace Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng of
bol ts. I nstal l the oi l pan-to-ti mi ng case cover bol ts.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 14 Nm
Fig. 72 Timing Chain Alignment
1 TIMING MARKS
Fig. 73 Camshaft and Crankshaft Sprocket and
Chain
1 CAMSHAFT SPROCKET
3 CHAIN
(120 i n. l bs.) torque. Ti ghten the oi l pan-to-cover 5/16
i nch bol ts to 18 Nm (156 i n. l bs.) torque.
(14) Remove the cover al i gnment tool and i nstal l a
repl acement oi l seal i nto the cover.
(15) I nstal l the vi brati on damper on the crank-
shaft.
(16) Lubri cate and ti ghten the damper bol t to 108
(17) I f equi pped wi th ai r condi ti oni ng:
(a) I nstal l the A/C compressor serpenti ne dri ve
bel t i dl er pul l ey.
(b) I nstal l the generator.
(c) I nstal l the A/C condenser and recei ver/dri er
assembl y.
(18) I nstal l the serpenti ne dri ve bel t on the pul l eys
and ti ghten (refer to Group 7, Cool i ng System for the
speci fi cati ons and procedures).
(19) I nstal l the radi ator. Connect the radi ator
hoses and automati c transmi ssi on fl ui d cool er pi pes,
i f equi pped. Fi l l the cool i ng system.
(20) I nstal l the fan and shroud.
CAMSHAFT BEARINGS
The camshaft rotates wi thi n four steel -shel l ed,
babbi tt-l i ned beari ngs that are pressed i nto the cyl -
i nder bl ock and then l i ne reamed. The camshaft
beari ng bores and beari ng di ameters are not the
same si ze. They are stepped down i n 0.254 mm
(0.010 i nch) i ncrements from the front beari ng (l arg-
est) to the rear beari ng (smal l est). Thi s permi ts eas-
i er removal and i nstal l ati on of the camshaft. The
camshaft beari ngs are pressure l ubri cated.
NOTE: It is not advisable to attempt to replace
camshaft bearings unless special removal and
installation tools are available, such as recom-
mended tool 8544 Camshaft Bushing Remover
Installer.
Camshaft end pl ay i s mai ntai ned by the l oad
pl aced on the camshaft by the oi l pump and di stri b-
utor dri ve gear. The hel i cal cut of the gear hol ds the
camshaft sprocket thrust face agai nst the cyl i nder
bl ock face.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(4) Remove the oi l pan and oi l pump.
(5) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 76).
(6) Remove the l ower i nsert from the beari ng cap.
(7) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 77). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
Fig. 74 Verify CrankshaftCamshaft Installation
1 CAMSHAFT SPROCKET
2 20 PINS
4 TIMING MARKS
INSTALLATION TOOL
to remove the beari ng i nsert (Fi g. 77). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(8) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(5) Cl ean the rear mai n beari ng cap (No.5) mati ng
surfaces.
(6) Appl y Mopar Gasket Maker, or equi val ent on
the rear beari ng cap (Fi g. 78). The bead shoul d be 3
mm (0.125 i n) thi ck. DO NOT appl y Mopar Gasket
Maker, or equi val ent to the l i p of the seal .
(7) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(8) Ti ghten the bol ts of caps 1, 3, 4 and 5 to 54
Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to 95
Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these bol ts to
Fig. 76 Removing Main Bearing Caps and Lower
Inserts
1 CONNECTING ROD JOURNAL
2 MAIN BEARING CAPS
Fig. 77 Removing Upper Inserts
1 COTTER PIN
2 FABRICATED TOOL
3 BEARING INSERT
4 TONGUE DEPRESSOR
Fig. 78 Location of Mopar Gasket Maker
1 MOPAR GASKET MAKER (OR EQUIVALENT)
2 19 mm (.75 IN)
3 6 mm (0.025 IN)
(9) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.2 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
(10) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(11) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi -
ti on.
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 79). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(12) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
(13) I nstal l the oi l pan.
(15) I nstal l new rearmai n seal . Refer to Rear Mai n
Seal i n thi s secti on.
(17) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(18) Fi l l the oi l pan wi th engi ne oi l to the safe
mark on the di psti ck l evel .
OIL PAN
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the engi ne
exhaust mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(6) Remove the engi ne starter motor.
(7) Remove the fl ywheel /torque converter housi ng
access cover.
(8) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(9) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(10) Remove the engi ne mount through bol ts.
(11) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(12) I f equi pped, di sconnect the transmi ssi on
cool er l i nes and oxygen sensor harness from oi l pan
mounti ng studs.
(13) Remove the oi l pan bol ts and studs. Careful l y
remove the oi l pan and gasket.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1/4 x 1 1/2
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 80).
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 81).
(4) Appl y Mopar Si l i cone Adhesi ve Seal ant onto
the cyl i nder bl ock i n four l ocati on as shown (Fi g. 82)
(5) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(6) Posi ti on the oi l pan over the dowel s and onto
the gasket.
(7) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
Fig. 79 Crankshaft End Play Measurement
1 DIAL INDICATOR
2 CRANKSHAFT
i nch oi l pan bol ts (Fi g. 83). Ti ghten these bol ts to 15
Nm (132 i n. l bs.) torque.
(8) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
(9) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(10) I nstal l the through bol ts and ti ghten the nuts.
(11) Lower the jack stand and remove the pi ece of
wood.
(12) I nstal l the fl ywheel and torque converter
housi ng access cover.
(13) I nstal l the engi ne starter motor.
(14) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(15) I nstal l the oi l pan drai n pl ug (Fi g. 83).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(18) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
OIL PUMP
The posi ti ve-di spl acement gear-type oi l pump i s
dri ven by the di stri butor shaft, whi ch i s dri ven by a
gear on the camshaft. Oi l i s si phoned i nto the pump
Fig. 80 Fabrication of Alignment Dowels
1 1/4 1 1/2 BOLT
2 DOWEL
3 SLOT
Fig. 81 Position of Dowels in Cylinder Block
1 5/16 HOLES
2 DOWEL HOLES
3 CYLINDER BLOCK
4 5/16 HOLES
Fig. 82 Location of Mopar Silicone Adhesive
Sealant on Cylinder Block
1 SEALER LOCATIONS
Fig. 83 Position of 5/16 inch Oil Pan Bolts
1 OIL PAN
through an i nl et tube and strai ner assembl y that i s
pressed i nto the pump body.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(1) Drai n the engi ne oi l .
(2) Remove the oi l pan.
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
84).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(2) I nstal l the oi l pan and gasket.
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
REMOVAL
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(8) Remove the oi l pan and gasket.
(9) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 85).
(10) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
CAUTION: Ensure that the connecting rod bolts DO
NOT scratch the crankshaft journals or cylinder
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(11) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 86).
Fig. 84 Oil Pump Assembly
1 OIL FILTER ADAPTOR
2 BLOCK
3 GASKET
4 OIL INLET TUBE
5 OIL PUMP
6 STRAINER ASSEMBLY
7 ATTACHING BOLTS
Fig. 85 Stamped Connecting Rods and Caps
1 CONNECTING ROD CAP
2 CONNECTING ROD
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts do not
scratch the crankshaft journals or cylinder walls.
Short pieces of rubber hose slipped over the con-
necting rod bolts will provide protection during
installation.
(5) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 87).
(6) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 87).
(8) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(9) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(10) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(11) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(13) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(15) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(16) Fi l l the crankcase wi th engi ne oi l .
REAR MAIN OIL SEAL
REMOVAL
(1) Remove the fl ywheel or converter dri ve pl ate.
Di scard the ol d bol ts.
Fig. 86 Removal of Connecting Rod and Piston
Assembly
1 PISTON
2 CONNECTING ROD
3 CYLINDER BLOCK
(2) Pry out the seal from around the crankshaft
fl ange, maki ng sure not to scratch or ni ck the crank-
shaft. (Fi g. 88).
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Coat the outer l i p of the repl acement rear mai n
beari ng seal wi th engi ne oi l .
(3) Careful l y posi ti on the seal i nto pl ace. Use rear
mai n Seal I nstal l er Tool 6271A to i nstal l the seal
fl ush wi th the cyl i nder bl ock.
CAUTION: The felt lip must be located inside the
flywheel mounting surface. If the lip is not posi-
tioned correctly the flywheel could tear the seal.
(4) I nstal l the fl ywheel or converter dri ve pl ate.
New bol ts MUST be used when i nstal l i ng the fl y-
wheel or converter pl ate. Ti ghten the new bol ts to 68
Nm (50 ft. l bs.) torque. Turn the bol ts an addi ti onal
60.
CYLINDER BLOCK
DISASSEMBLY
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
(2) Remove the water pump from the cyl i nder
bl ock.
(3) Remove the di stri butor from the cyl i nder bl ock.
(5) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(6) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(7) Remove the ti mi ng chai n bumper.
(8) Remove the oi l sl i nger from crankshaft.
remove the sprockets and chai n as an assembl y.
(10) Remove the camshaft.
(12) Remove the ti mi ng chai n tensi oner.
(13) Remove the front and rear oi l gal l ey pl ugs.
(14) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
through the top of the cyl i nder bores.
(15) Remove the crankshaft.
ASSEMBLY
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
(3) I nstal l the front and rear oi l gal l ey pl ugs.
(4) I nstal l the ti mi ng chai n tensi oner.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger to the crankshaft.
(8) I nstal l the ti mi ng chai n bumper.
(9) I nstal l the ti mi ng case cover seal .
(10) I nstal l the ti mi ng case cover.
(11) I nstal l the oi l pan gasket and oi l pan.
(13) I nstal l the water pump. Ti ghten the mounti ng
bol ts to 31 Nm (270 i n. l bs.) torque.
(14) Remove the di stri butor from the cyl i nder
bl ock.
(15) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 Nm (13 ft. l bs.) torque.
(16) I nstal l the engi ne i nto the vehi cl e.
(17) Fi l l the engi ne wi th cl ean l ubri cati on oi l .
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
Fig. 88 Replacement of Rear Crankshaft Oil Seal
1 CRANKSHAFT
I nspect the val ve stem ti p contact surface of each rocker
arm and repl ace any rocker arm that i s deepl y pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
ENGINE CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
exhaust mani fol d and engi ne cyl i nder head mati ng
surfaces. Remove al l gasket materi al and carbon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e, the fi l ter
bypass hol e (Fi g. 89).
The front and rear oi l gal l ey hol es (Fi g. 90) (Fi g.
91).
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Mopar Thread Seal ant wi th Tefl on to the threads of
the front and rear oi l gal l ey pl ugs. Ti ghten the pl ugs
INSPECTION
I nspect the cyl i nder bores for si gns of scorri ng, pi t-
ti ng or cracks. I f the cyl i nder bores are scorred or
pi tted the cyl i nder bores wi l l requi re borei ng or hon-
i ng to cl ean them up. Refer to Honi ng Cyl i nder Bores
i n thi s Secti on. I f the cyl i nder bore(s) are cracked the
cyl i nder bl ock must be repl aced.
I nspect the cyl i nder bl ock to cyl i nder head mati ng
surface for fl atness and/or pi tti ng.
Fig. 89 Oil Filter Adaptor Hole
1 FILTER BYPASS HOLE
2 OIL FILTER ADAPTOR HOLE
Fig. 90 Front Oil Galley Hole
1 FRONT OIL GALLEY HOLE
Fig. 91 Rear Oil Galley Hole
1 REAR OIL GALLEY HOLE
SPECIFICATIONS
ENGINE SPECIFICATIONS
ENGINE DESCRIPTION
Engine Type In-line 4 Cylinder
Bore and Stroke 98.4 x 81.0 mm
(3.88 x 3.19 in.)
Displacement 2.5L (150 cu. in.)
Compression Ratio 9.1:1
Compression Pressure
Range
827 to 1,034 kPa
(120 to 150 psi)
Max. Variation Between
Cylinders
206 kPa (30 psi)
Firing Order 1342
Lubrication Pressure FeedFull Flow
Filtration
Cooling System Liquid CooledForced
Circulation
Cylinder Block Cast Iron
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron
Camshaft Cast Iron
Pistons Aluminum Alloy
Cylinder Combustion
Cavity
Double Quench
Connecting Rods Cast Iron
CAMSHAFT
Hydraulic Tappet
Clearance
Zero Lash
Bearing Clearance 0.025 - 0.076 mm
(0.001 - 0.003 in.)
Bearing Journal Diameter
No. 1 51.54 - 51.56 mm
(2.029 - 2.030 in.)
No. 2 51.28 - 51.31 mm
(2.019 - 2.020 in.)
No. 3 51.03 - 51.05 mm
(2.009 - 2.010 in.)
No. 4 50.78 - 50.80 mm
(1.999 - 2.000 in.)
Base Circle Runout
(Max)
0.03 mm
(0.001 in.)
Camshaft Lobe Lift
Exhaust 6.579 mm (0.259 in.)
Intake 6.477 mm (0.255 in.)
Camshaft Duration
Intake 253.3
Exhaust 259
VALVES
Valve Lift
Exhaust 10.528 mm (0.4145 in.)
Intake 10.350 mm (0.4075 in.)
Intake Valve Timing
Opens 15.4(BTDC)
Closes 58(ABDC)
Duration 253.3
Exhaust Valve Timing
Opens 52.8(BBDC)
Closes 26.2(ATDC)
Duration 259
Valve Overlap 41.6
Valve Lenght (Overall)
Intake 124.435 - 125.070 mm
(4.899 - 4.924 in.)
Exhaust 125.120 - 125.755 mm
(4.927 - 4.952 in.)
Valve Stem Diameter 7.899 - 7.925 mm
(0.311 - 0.312 in.)
Stem to Guide Clearance 0.025 - 0.076 mm
(0.001 - 0.003 in.)
ValveFace Angle
Intake 46.5
Exhaust 46.5
Valve Head Diameter
Intake 48.387 - 48.641 mm
(1.905 - 1.915 in.)
Exhaust 37.973 - 38.227 mm
(1.495 - 1.505 in.)
Tip Refinishing (Max
Alowable)
0.25 mm (0.010 in.)
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 Lbs. @ 1.64
in.)
Valve Open 898.6 to 969.7 N @
30.89 mm
(202 to 218 Lbs. @ 1.216
in.)
Inside Diameter (Top) 21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height 41.656 mm (1.640 in.)
CRANKSHAFT
End Play 0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Main Bearing Journal
Diameter
63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
Width
No. 1 27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 2 32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 3-4-5 30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance 0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Main Bearing Clearance
(Preferred) 0.051 mm
(0.002 in.)
Connecting Rod Journal
Diameter 53.17 to 53.23 mm
(2.0934 to 2.0955 in.)
Width
27.18 to 27.33 mm
(1.070 to 1.076 in.)
Out of Round - Max 0.013 mm (0.0005 in.)
Taper - Max 0.013 mm (0.0005 in.)
CYLINDER BLOCK
Deck Height 236.73 mm (9.320 in.)
Deck Clearance 0.000 mm (0.000 in.)
Cylinder Bore Diameter
Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Taper (Max) 0.025 mm
(0.001 in.)
Out of Round (Max) 0.025 mm
(0.001 in.)
Tappet Bore Diameter 23.000 to 23.025 mm
(0.9055 to 0.9065 in.)
Flatness 0.03 mm per 25 mm
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max 0.20 mm for total length
(0.008 in. for total length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING RODS
Total Weight (Less
Bearing)
663 to 671 grams
(23.39 to 23.67 oz.)
Length (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.)
Bore (Less Bearings) 56.08 to 56.09 mm
(2.2080 to 2.2085 in.)
Bearing Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Bearing Clearance
(Preferred)
0.044 to 0.050 mm
(0.0015 to 0.0020 in.)
Side Clearance 0.25 to 0.48 mm
(0.010 to 0.019 in.)
Twist (Max) 0.002 mm per mm
(0.002 in. per in.)
Bend (Max) 0.006 mm per mm
(0.006 in. per inch.)
CYLINDER HEAD
Combustion Chamber 49.9 to 52.9 cc
(3.04 to 3.23 cu. in.)
Valve Guide I. D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
Valve Seat Angle
Intake 44.5
Exhaust 44.5
Valve Seat Width 1.01 to 1.52 mm
(0.040 to 0.060 in.)
Valve Seat Runout 0.064 mm
(0.0025 in.)
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness (Max) 0.20 mm for total length
(0.008 in. for total length)
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio 1.6:1
Push Rod Length (Blue) 241.300 to 241.808 mm
(9.500 to 9.520 in.)
Push Rod Diameter 7.92 to 8.00 mm
(0.312 to 0.315 in.)
Hydraulic Tappet
Diameter
22.962 to 22.974 mm
(0.904 to 0.9045 in.)
Tappet to Bore Clearance 0.025 to 0.063 mm
(0.001 to 0.0025 in.)
PISTON
Weight (Less Pin) 417 to 429 grams
(14.7 to 15.1 oz.)
Compression Height 40.61 to 40.72 mm
(1.599 to 1.603 in.)
Piston to Bore Clearance 0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
Piston Ring Groove
Height
Compression Rings 1.530 to 1.555 mm
(0.0602 to 0.0612 in.)
Oil Control Ring 4.035 to 4.060 mm
(0.1589 to 0.1598 in.)
Piston Ring Groove
Diameter
Compression Ring #1 88.39 to 88.65 mm
(3.48 to 3.49 in.)
Compression Ring #2 87.63 to 87.88 mm
(89.66 to 89.92 in.)
(3.53 to 3.54 in.)
(0.9312 to 0.9315 in.)
Piston Pin Diameter 23.637 to 23.640 mm
(0.9306 to 0.9307 in.)
Piston to Pin Clearance 0.0102 to 0.0208 mm
(0.0005 to 0.0009 in.)
PISTON RINGS
Ring Gap Clearance
Top Compression Ring 0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring 0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
(0.010 to 0.060 in.)
Ring Side Clearance
(0.0017 to 0.0033 in.)
Oil Control Rings 0.06 to 0.21 mm
(0.0024 to 0.0083 in.)
OIL PUMP AND OIL PRESSURE
Gear to Body Clearance
(Radial) 0.051 to 0.102 mm
(0.002 to 0.004 in.)
(Radial Preferred) 0.051 mm
(0.002 in.)
Gear End Clearance
Plastigage 0.051 to 0.152 mm
(0.002 to 0.006 in.)
Plastigage Preferred 0.051 mm
(0.002 in.)
Feeler Gauge 0.1016 to 0.2032 mm
(0.004 to 0.008 in.)
Feeler Gauge Preferred 0.1778 mm
(0.007 in.)
Min. Pressure (600 rpm) 89.6 kPa
(13 psi)
Min. Pressure at Idle
(800 rpm)
172 to 241 kPa
(25 to 35 psi)
Min. Pressure at 1600
rpm
and Higher 255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief 517 kPa
(75 psi)
SPECIFICATIONS TORQUE
TORQUE CHART 2.5L ENGINE
DESCRIPTION Nm Ft.
Lbs.
In. Lbs
A/C Compressor Bracket 47 35
to EngineBolts
A/C Compressor Mounting
Bolts
28 250
Block Heater Nut 1.8 16
Camshaft Sprocket Bolt 108 80
Clutch Cover to Flywheel
Bolts
31 23
Connecting Rod Cap Nuts 45 33
Cylinder Block Drain Plugs 41 30
Cylinder Head Bolts #110 149 110
& #1214
Cylinder Head Bolt #11 135 100
Cylinder Head Cover Bolts 13 115
Dipstick Tube Bracket to 19 168
Cylinder BlockBolt
Distributor Hold-Down
Clamp Bolt
23 204
Engine Front Insulator
Bracket
81 60
Bolts
Insulator BracketNuts 47 35
InsulatorThrough Bolt 81 60
Engine Rear Support
Cushion
22 192
/CrossmemberNuts
Support Cushion/Bracket
Nuts
46 34
Transmission Support
Bracket
43 32
Bolts
Bracket
75 55
/CushionBolt
Adaptor
75 55
BracketBolts
Exhaust Manifold/Pipe
Nuts
27 20
DESCRIPTION Nm Ft.
Lbs.
In. Lbs
Exhaust Manifold
Bolt #1 41 30
Bolts #2-5 31 23
Nuts 6 and 7 14 126
Flywheel/Converter
Housing Bolts
38 28
Flywheel to Crankshaft
Bolts
143 105
Front Cover to Block Bolts
1/4-20
7 60
Front Cover to Block
5/16-18
22 192
Generator Mounting
Bolts
57 42
Generator Mounting 47 35
Bracket to EngineBolts
Main Bearing Cap Bolts 108 80
Oil Filter Adaptor Bolt 102 75
Oil Filter Connector 68 50
Oil Filter 18 13
Oil Galley Plug 41 30
Oil Pan 1/4-20 Bolts 9.5 84
Oil Pan 5/16-18 Bolts 15 132
Oil Pan Drain Plug 34 25
Oil Pressure Sending Unit 15 130
Oil Pump Short Attaching
Bolts
23 204
Oil Pump Long Attaching
Bolts
23 204
Oil Pump Cover Bolts 8 70
Rocker ArmBolts 28 21
Spark Plugs 37 27
Starter Motor Mounting
Bolts
45 33
Thermostat Housing Bolts 18 156
Throttle Body Bolts 10 90
Vibration Damper Bolt 108 80
Water Pump to Block Bolts 31 23
SPECIAL TOOLS
2. 5L ENGINE SPECIAL TOOLS
Valve Spring Compressor Tool MD-998772A
Timing Case Cover Alignment and Seal installation
Tool 6139
Vibration Damper Removal Tool 7697
Rear Main Seal Installer Tool 6271A
Hydraulic Valve Tappet Removal/Installation Tool
C-4129A
4.0L ENGINE
TABLE OF CONTENTS
page page
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . 62
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . . 65
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 65
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
PISTON AND CONNECTING ROD . . . . . . . . . . . . 66
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
VALVE SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . 67
HYDRAULIC TAPPET. . . . . . . . . . . . . . . . . . . . . . 67
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . 67
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 67
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . 68
ENGINE DIAGNOSISINTRODUCTION. . . . . . . . 68
SERVICE DIAGNOSISPERFORMANCE . . . . . . 69
SERVICE DIAGNOSISMECHANICAL. . . . . . . . . 70
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . . . 72
CYLINDER COMPRESSION PRESSURE TEST . . 73
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 73
ENGINE OIL LEAK INSPECTION . . . . . . . . . . . . . 74
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 75
SERVICE PROCEDURES
VALVE TIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . 75
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . . . . 77
PISTON RINGFITTING . . . . . . . . . . . . . . . . . . . 77
FITTING CONNECTING ROD BEARINGS. . . . . . . 80
FITTING CRANKSHAFT MAIN 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
ENGINE MOUNTSFRONT. . . . . . . . . . . . . . . . . 90
ENGINE MOUNTREAR . . . . . . . . . . . . . . . . . . . 91
ENGINE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . 92
INTAKE AND EXHAUST MANIFOLD. . . . . . . . . . . 95
EXHAUST MANIFOLD4.0L ENGINE . . . . . . . . . 96
VALVE SPRINGS AND OIL SEALS . . . . . . . . . . . . 97
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . . 98
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 100
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . 100
VIBRATION DAMPER. . . . . . . . . . . . . . . . . . . . . 101
TIMING CASE COVER . . . . . . . . . . . . . . . . . . . . 101
TIMING CHAIN AND SPROCKETS . . . . . . . . . . . 102
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
CAMSHAFT BEARINGS . . . . . . . . . . . . . . . . . . . 104
CRANKSHAFT MAIN BEARINGS . . . . . . . . . . . . 105
OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
PISTONS AND CONNECTING RODS . . . . . . . . . 108
CRANKSHAFT OIL SEALSREAR. . . . . . . . . . . 110
OIL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
TIMING CASE COVER OIL SEAL . . . . . . . . . . . . 112
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 112
CYLINDER HEAD. . . . . . . . . . . . . . . . . . . . . . . . 113
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 113
ROCKER ARMS AND PUSH RODS . . . . . . . . . . 113
HYDRAULIC TAPPETS. . . . . . . . . . . . . . . . . . . . 113
CYLINDER BLOCK. . . . . . . . . . . . . . . . . . . . . . . 114
SPECIFICATIONS
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 115
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 118
SPECIAL TOOLS
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
ENGINE
DESCRIPTION
The 4.0 Li ter (242 CI D) si x-cyl i nder engi ne i s an
I n-l i ne, l i ghtwei ght, overhead val ve engi ne.
Thi s engi ne i s desi gned for unl eaded fuel . The
engi ne cyl i nder head has dual quench-type combus-
ti on chambers that create turbul ence and fast burn-
i ng of the ai r/fuel mi xture. Thi s resul ts i n good fuel
economy.
The cyl i nders are numbered 1 through 6 from front
to rear. The fi ri ng order i s 1-5-3-6-2-4 (Fi g. 1).
The crankshaft rotati on i s cl ockwi se, when vi ewed
from the front of the engi ne. The crankshaft rotates
wi thi n seven mai n beari ngs. The camshaft rotates
wi thi n four beari ngs.
BUI LD DATE CODE
The engi ne Bui l d Date Code i s l ocated on a
machi ned surface on the ri ght si de of the cyl i nder
bl ock between the No.2 and No.3 cyl i nders (Fi g. 2).
The di gi ts of the code i denti fy:
1st Di gi tThe year (8 = 1998).
2nd & 3rd Di gi tsThe month (01 - 12).
4th & 5th Di gi tsThe engi ne type/fuel system/
compressi on rati o (MX = A 4.0 Li ter (242 CI D) 8.7:1
compressi on rati o engi ne wi th a mul ti -poi nt fuel
i njecti on system).
6th & 7th Di gi tsThe day of engi ne bui l d (01 -
31).
(1) FOR EXAMPLE: Code * 801MX12 * i denti -
fi es a 4.0 Li ter (242 CI D) engi ne wi th a mul ti -poi nt
fuel i njecti on system, 8.7:1 compressi on rati o and
bui l t on January 12, 1998.
LUBRICATION SYSTEM
DESCRIPTION
A geartype posi ti ve di spl acement pump i s
mounted at the undersi de of the bl ock opposi te the
No. 4 mai n beari ng.
OPERATION
The pump draws oi l through the screen and i nl et
tube from the sump at the rear of the oi l pan. The oi l
i s dri ven between the dri ve and i dl er gears and
pump body, then forced through the outl et to the
bl ock. An oi l gal l ery i n the bl ock channel s the oi l to
the i nl et si de of the ful l fl ow oi l fi l ter. After passi ng
through the fi l ter el ement, the oi l passes from the
center outl et of the fi l ter through an oi l gal l ery that
channel s the oi l up to the mai n gal l ery whi ch
extends the enti re l ength of the bl ock.
Gal l eri es extend downward from the mai n oi l gal -
l ery to the upper shel l of each mai n beari ng. The
crankshaft i s dri l l ed i nternal l y to pass oi l from the
mai n beari ng journal s (except number 4 mai n bear-
i ng journal ) to the connecti ng rod journal s. Each con-
necti ng rod beari ng cap has a smal l squi rt hol e, oi l
passes through the squi rt hol e and i s thrown off as
the rod rotates. Thi s oi l throwoff l ubri cates the cam-
shaft l obes, di stri butor dri ve gear, cyl i nder wal l s, and
pi ston pi ns.
The hydraul i c val ve tappets recei ve oi l di rectl y
from the mai n oi l gal l ery. Oi l i s provi ded to the cam-
shaft beari ng through gal l eri es. The front camshaft
beari ng journal passes oi l through the camshaft
Fig. 1 Engine Firing Order
Fig. 2 Build Date Code Location
1 YEAR
2 MONTH
3 DAY
sprocket to the ti mi ng chai n. Oi l drai ns back to the
oi l pan under the number one mai n beari ng cap.
The oi l suppl y for the rocker arms and bri dged
pi vot assembl i es i s provi ded by the hydraul i c val ve
tappets whi ch pass oi l through hol l ow push rods to a
hol e i n the correspondi ng rocker arm. Oi l from the
rocker arm l ubri cates the val ve trai n components,
then passes down through the push rod gui de hol es
i n the cyl i nder head past the val ve tappet area, and
returns to the oi l pan.
Oil Lubrication System4.0L 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
CYLINDER BLOCK
DESCRIPTION
The cyl i nder bl ock i s a cast i ron i nl i ne si x cyl i nder
desi gn. The cyl i nder bl ock i s dri l l ed formi ng gal l eri es
for both oi l and cool ant (Fi g. 3).
CYLINDER HEAD
DESCRIPTION
The cyl i nder head i s made of cast i ron contai ni ng
twel ve val ves made of chrome pl ated heat resi stant
steel , val ve stem seal s, spri ngs, retai ners and keep-
ers. The cyl i nder head and val ve seats can be resur-
faced for servi ce purposes.
abl e.
The cyl i nder head uses dual quench-type desi gn
combusti on chambers whi ch cause turbul ence i n the
cyl i nders al l owi ng faster burni ng of the ai r/fuel mi x-
ture, resul ti ng i n better fuel economy (Fi g. 4).
CRANKSHAFT
DESCRIPTION
The crankshaft i s constructed of nodul ar cast i ron.
The crankshaft i s a crosshaped four throw desi gn
wi th ei ght counterwei ghts for bal anci ng purposes.
The crankshaft i s supported by seven sel ect mai n
beari ngs wi th the number three servi ng as the thrust
washer l ocati on. The mai n journal s of the crankshaft
are cross dri l l ed to i mprove rod beari ng l ubri cati on.
The sel ect fi t mai n beari ng marki ngs are l ocated on
the crankshaft counter wei ghts. The crankshaft rear
oi l seal i s a two pi ece desi gn. The front oi l seal i s a
one pi ece desi gn retai ned i n the ti mi ng chai n cover
(Fi g. 5).
Fig. 3 4.0L Cylinder Block with Main Bearing Caps
and Cap Brace
1 BLOCK
2 MAIN BEARING CAP BRACE
Fig. 4 Cylinder Head 4.0L Engine
3 CYLINDER HEAD
Fig. 5 Crankshaft with Select Fit Marking Location
1 1/4 LETTERS
2 (ROD)
3 (MAIN)
DESCRIPTION
The pi stons are made of a hi gh strength al umi num
al l oy wi th an anodi zed top ri ng groove and crown.
Pi ston ski rts are coated wi th a sol i d l ubri cant
(Mol ykote) to reduce fri cti on and provi de scuff resi s-
tance. The connecti ng rods are made of ducti l e i ron.
A pressed fi t pi ston pi n i s used to attach the pi ston
and connecti ng rod.
CAMSHAFT
DESCRIPTION
The camshaft i s made of gray cast i ron wi th twel ve
machi ned l obes and four beari ng journal s. When the
camshaft rotates the l obes actuate the tappets and
push rods, forci ng upward on the rocker arms whi ch
appl i es downward force on the val ves.
ROCKER ARM
DESCRIPTION
The rocker arms are made of stamped steel and
have a operati onal rati o of 1.6:1. When the push rods
are forced upward by the camshaft l obes the push
rod presses upward on the rocker arms, the rocker
arms pi vot, forci ng downward pressure on the val ves
forci ng the val ves to move downward and off from
thei r seats (Fi g. 8).
Fig. 6 Piston and Connecting Rod Assembly
Fig. 7 CamshaftTypical
1 CAMSHAFT
2 LOBES
3 BEARING JOURNAL
Fig. 8 Rocker Arms 4.0L Engine
1 CAPSCREWS
2 BRIDGE
3 PIVOT ASSEMBLY
4 PUSH RODS
5 ROCKER ARMS
VALVES
DESCRIPTION
The val ves are made of heat resi stant steel and
have chrome pl ated stems to prevent scuffi ng. Al l
val ves use three bead l ocks to promote val ve rotati on
(Fi g. 9).
VALVE SPRING
DESCRIPTION
The val ve spri ngs are made of hi gh strength si l i con
chrome spri ng steel . The spri ngs are common for
both i ntake and exhaust val ves. (Fi g. 9).
CYLINDER HEAD COVER
DESCRIPTION
The cyl i nder head cover (Fi g. 10) i s made of
stamped steel and i ncorporates the Crankcase Venti -
l ati on (CCV) Hoses and the oi l fi l l openi ng.
HYDRAULIC TAPPET
DESCRIPTION
Val ve l ash i s control l ed by hydraul i c tappets
l ocated i nsi de the cyl i nder bl ock, i n tappet bores
above the camshaft.
VALVE GUIDE
DESCRIPTION
abl e.
OIL PAN
DESCRIPTION
The oi l pan i s made of stamped steel . The oi l pan
gasket i s a one pi ece steel backbone si l i cone coated
gasket.
VALVE STEM SEAL
DESCRIPTION
The val ve stem seal s are made of rubber and i ncor-
porate a garter spri ng to mai ntai n consi stent l ubri ca-
ti on control (Fi g. 9).
INTAKE MANIFOLD
DESCRIPTION
The i ntake mani fol d i s made of cast al umi num and
uses el even bol ts to mount to the cyl i nder head. Thi s
mounti ng styl e i mproves seal i ng and reduces the
chance of l eaks.
Fig. 9 Valve and Keeper Configuration 4.0L Engine
2 RETAINER
4 INTAKE VALVE
5 EXHAUST VALVE
6 VALVE SPRING
Fig. 10 Cylinder Head Cover
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust mani fol ds are l og styl e and are
made of hi gh si l i con mol ybdenum cast i ron. The
exhaust mani fol ds share a common gasket wi th the
i ntake mani fol d. The exhaust mani fol ds al so i ncorpo-
rate bal l fl ange outl ets for i mproved seal i ng and
strai n free connecti ons.
ENGINE DIAGNOSIS INTRODUCTION
Engi ne di agnosi s i s hel pful i n determi ni ng the
causes of mal functi ons not detected and remedi ed by
routi ne mai ntenance.
These mal functi ons may be cl assi fi ed as ei ther per-
formance (e.g., engi ne i dl es rough and stal l s) or
mechani cal (e.g., a strange noi se).
Refer to the Servi ce Di agnosi sPerformance chart
and the Servi ce Di agnosi sMechani cal chart for pos-
si bl e causes and correcti ons of mal functi ons. Refer to
Group 14, Fuel System for the fuel system di agnosi s.
Addi ti onal tests and di agnosti c procedures may be
necessary for speci fi c engi ne mal functi ons that can
not be i sol ated wi th the Servi ce Di agnosi s charts.
I nformati on concerni ng addi ti onal tests and di agno-
si s i s provi ded wi thi n the fol l owi ng di agnosi s:
Cyl i nder Compressi on Pressure Test.
Cyl i nder Combusti on Pressure Leakage Test.
Engi ne Cyl i nder Head Gasket Fai l ure Di agnosi s.
I ntake Mani fol d Leakage Di agnosi s.
Fig. 13 Exhaust Manifolds 4.0L Engine
Fig. 11 Oil Pan
1 OIL PAN
Fig. 12 Intake Manifold 4.0L Engine
SERVICE DIAGNOSIS PERFORMANCE
ENGINE PERFORMANCE DIAGNOSIS CHART
ENGINE WILL NOT CRANK 1. Weak or dead battery 1. Charge/Replace Battery. Refer to
Group 8A, Battery, for correct
procedures. Check charging system.
Refer to Group 8C, Charging
Systems, for correct procedures.
2. Corroded or loose battery
connections
2. Clean/tighten suspect battery/
starter connections
3. Faulty starter or related circuit(s) 3. Check starting system. Refer to
Group 8B, Starting Systems, for
4. Siezed accessory drive
component
4. Remove accessory drive belt and
attempt to start engine. If engine
starts, repair/replace siezed
component.
5. Engine internal mechanical
failure or hydro-static lock
5. Refer to Group 9, Engine, for
ENGINE CRANKS BUT WILL NOT
START
1. No spark 1. Check for spark. Refer to Group
8D, Ignition System, for correct
procedures.
2. No fuel 2. Perform fuel pressure test, and if
necessary, inspect fuel injector(s)
and driver circuits. Refer to Group
14, Fuel System, for correct
procedures.
3. Low or no engine compression 3. Perform cylinder compression
pressure test. Refer to Group 9,
Engine, for correct procedures.
ENGINE LOSS OF POWER 1. Worn or burned distributor rotor 1. Install new distributor rotor
2. Worn distributor shaft 2. Remove and repair distributor
(Refer to group 8D, Ignition System
3. Worn or incorrect gapped spark
plugs
3. Clean plugs and set gap. (Refer
to group 8D, Ignition System)
4. Dirt or water in fuel system 4. Clean system and replace fuel
filter
5. Faulty fuel pump 5. Install new fuel pump
6. Incorrect valve timing 6. Correct valve timing
7. Blown cylinder head gasket 7. Install new cylinder head gasket
8. Low compression 8. Test cylinder compression
9. Burned, warped, or pitted valves 9. Install/Reface valves as
necessary
10. Plugged or restricted exhaust
system
10. Install new parts as necessary
11. Faulty ignition cables 11. Replace any cracked or shorted
cables
12. Faulty ignition coil 12. Test and replace, as necessary
(Refer to Group 8D, ignition system)
ENGINE STALLS OR ROUGH IDLE 1. Carbon build-up on throttle plate 1. Remove throttle body and
de-carbon. (Refer to Group 14 for
correct procedures)
2. Engine idle speed too low 2. Check Idle Air Control circuit.
plugs
3. Replace or clean and re-gap
spark plugs (Refer to group 8D,
Ignition System)
4. Worn or burned distributor rotor 4. Install new distributor rotor
crossed
5. Check for correct firing order or
replace spark plug cables. (Refer to
Group 8D, Ignition System for
correct procedures.)
6. Faulty coil 6. Test and replace, if necessary
(Refer to group 8D, Ignition System)
7. Intake manifold vacuum leak 7. Inspect intake manifold gasket
and vacuum hoses. Replace if
necessary (Refer to Group 11,
Exhaust System & Intake Manifold)
8. EGR valve leaking or stuck open 8. Test and replace, if necessary
(Refer to group 25, Emission
Control Systems)
ENGINE MISSES ON
ACCELERATION
plugs
1. Replace spark plugs or clean and
set gap. (Refer to group 8D, Ignition
System)
crossed
2. Check Idle Air Control circuit.
3. Dirt in fuel system 3. Clean fuel system
4. Burned, warped or pitted valves 4. Install new valves
5. Faulty coil 5. Test and replace as necessary
(refer to group 8D, Ignition System)
SERVICE DIAGNOSIS MECHANICAL
ENGINE MECHANICAL DIAGNOSIS CHART
NOISY VALVES/LIFTERS 1. High or low oil level in crankcase 1. Check for correct oil level. Adjust
oil level by draining or adding as
needed
2. Thin or diluted oil 2. Change oil (Refer to Engine Oil
Service in this group)
test/specifications
4. Dirt in tappets/lash adjusters 4. Clean/replace hydraulic
tappets/lash adjusters
5. Bent push rod(s) 5. Install new push rods
6. Worn rocker arms 6. Inspect oil supply to rocker arms
and replace worn arms as needed
7. Worn tappets/lash adjusters 7. Install new hydraulic tappets/lash
adjusters
8. Worn valve guides 8. Inspect all valve guides and
replace as necessary
9. Excessive runout of valve seats
or valve faces
9. Grind valves and seats
CONNECTING ROD NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
Maintenance)
test/specifications
4. Excessive connecting rod
bearing clearance
Measure bearings for correct
clearance with plasti-gage. Repair
as necessary
5. Connecting rod journal out of
round
5. Replace crankshaft or grind
journals
6. Misaligned connecting rods 6. Replace bent connecting rods
MAIN BEARING NOISE 1. Insufficient oil supply 1. Check engine oil level. (Refer to
Maintenance)
test/specifications
4. Excessive main bearing
clearance
4. Measure bearings for correct
clearance. Repair as necessary
5. Excessive end play 5. Check crankshaft thrust bearing
for excessive wear on flanges
6. Crankshaft main journal out of
round or worn
6. Grind journals or replace
crankshaft
7. Loose flywheel or torque
converter
7. Inspect crankshaft, flexplate/
flywheel and bolts for damage.
Tighten to correct torque
LOW OIL PRESSURE 1. Low oil level 1. Check oil level and fill if
necessary
2. Faulty oil pressure sending unit 2. Install new sending unit
3. Clogged oil filter 3. Install new oil filter
4. Worn oil pump 4. Replace worn gears or oil pump
assy
6. Excessive bearing clearance 6. Measure bearings for correct
clearance
7. Oil pump relief valve stuck 7. Remove valve to inspect, clean
and reinstall
8. Oil pump suction tube loose,
broken, bent or clogged
8. Inspect suction tube and clean or
replace if necessary
9. Oil pump cover warped or
cracked
9. Install new oil pump
OIL LEAKS 1. Misaligned or deteriorated
gaskets
1. Replace gasket
2. Loose fastener, broken or porous
metal part
2. Tighten, repair or replace the part
3. Front or rear crankshaft oil seal
leaking
3. Replace seal
4. Leaking oil gallery plug or cup
plug
4. Remove and reseal threaded
plug. Replace cup style plug
EXCESSIVE OIL CONSUMPTION
OR SPARK PLUGS OIL FOULED
1. PCV System malfunction 1. Refer to group 25, Emission
Control System for correct operation
2. Defective valve stem seal(s) 2. Repair or replace seal(s)
3. Worn or broken piston rings 3. Hone cylinder bores. Install new
rings
4. Scuffed pistons/cylinder walls 4. Hone cylinder bores and replace
pistons as required
5. Carbon in oil control ring groove 5. Remove rings and de-carbon
piston
6. Worn valve guides 6. Inspect/replace valve guides as
necessary
7. Piston rings fitted too tightly in
grooves
7. Remove rings and check ring end
gap and side clearance. Replace if
necessary
INTAKE MANIFOLD LEAKAGE DIAGNOSIS
An i ntake mani fol d ai r l eak i s characteri zed by
l ower than normal mani fol d vacuum. Al so, one or
more cyl i nders may not be functi oni ng.
(1) Start the engi ne.
(2) Spray a smal l stream of water at the suspected
l eak area.
(3) I f a change i n RPM i s observed the area of the
suspected l eak has been found.
(4) Repai r as requi red.
CYLINDER COMPRESSION PRESSURE TEST
The resul ts of a cyl i nder compressi on pressure test
can be uti l i zed to di agnose several engi ne mal func-
ti ons.
Ensure the battery i s compl etel y charged and the
engi ne starter motor i s i n good operati ng condi ti on.
Otherwi se the i ndi cated compressi on pressures may
not be val i d for di agnosi s purposes.
(1) Cl ean the spark pl ug recesses wi th compressed
ai r.
(3) Secure the throttl e i n the wi de-open posi ti on.
(4) Di sabl e the fuel system. (Refer to Group 14,
Fuel System for the correct procedure)
(5) Di sconnect the i gni ti on coi l .
(6) I nsert a compressi on pressure gauge and rotate
the engi ne wi th the engi ne starter motor for three
revol uti ons.
(7) Record the compressi on pressure on the 3rd
revol uti on. Conti nue the test for the remai ni ng cyl i n-
ders.
Refer to Engi ne Speci fi cati ons for the correct
engi ne compressi on pressures.
DIAGNOSIS
A l eaki ng engi ne cyl i nder head gasket usual l y
resul ts i n l oss of power, l oss of cool ant and engi ne
mi sfi ri ng.
An engi ne cyl i nder head gasket l eak can be l ocated
between adjacent cyl i nders or between a cyl i nder and
the adjacent water jacket.
adjacent cyl i nders i s i ndi cated by a l oss of power
and/or engi ne mi sfi re.
a cyl i nder and an adjacent water jacket i s i ndi cated
by cool ant foami ng or overheati ng and l oss of cool ant.
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determi ne i f an engi ne cyl i nder head gasket i s
l eaki ng between adjacent cyl i nders; fol l ow the proce-
dures outl i ned i n Cyl i nder Compressi on Pressure
Test. An engi ne cyl i nder head gasket l eaki ng between
adjacent cyl i nders wi l l resul t i n approxi matel y a
50-70% reducti on i n compressi on pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
Remove the radi ator cap.
Start the engi ne and al l ow i t to warm up unti l the
engi ne thermostat opens.
I f a l arge combusti on/compressi on pressure l eak
exi sts, bubbl es wi l l be vi si bl e i n the cool ant.
I f bubbl es are not vi si bl e, i nstal l a radi ator pres-
sure tester and pressuri ze the cool ant system.
I f a cyl i nder i s l eaki ng combusti on pressure i nto
the water jacket, the tester poi nter wi l l pul sate wi th
every combusti on stroke of the cyl i nder.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combusti on pressure l eakage test provi des an
accurate means for determi ni ng engi ne condi ti on.
Combusti on pressure l eakage testi ng wi l l detect:
Exhaust and i ntake val ve l eaks (i mproper seat-
i ng).
Leaks between adjacent cyl i nders or i nto water
jacket.
Any causes for combusti on/compressi on pressure
l oss.
(1) Check the cool ant l evel and fi l l as requi red. DO
NOT i nstal l the radi ator cap.
(2) Start and operate the engi ne unti l i t attai ns
normal operati ng temperature, then turn the engi ne
OFF.
(4) Remove the oi l fi l l er cap.
(5) Remove the ai r cl eaner.
(6) Cal i brate the tester accordi ng to the manufac-
turers i nstructi ons. The shop ai r source for testi ng
shoul d mai ntai n 483 kPa (70 psi ) mi ni mum, 1,379
kPa (200 psi ) maxi mum and 552 kPa (80 psi ) recom-
mended.
(7) Perform the test procedures on each cyl i nder
accordi ng to the tester manufacturers i nstructi ons.
Whi l e testi ng, l i sten for pressuri zed ai r escapi ng
through the throttl e body, tai l pi pe and oi l fi l l er cap
openi ng. Check for bubbl es i n the radi ator cool ant.
Al l gauge pressure i ndi cati ons shoul d be equal ,
wi th no more than 25% l eakage.
FOR EXAMPLE: At 552 kPa (80 psi ) i nput pres-
sure, a mi ni mum of 414 kPa (60 psi ) shoul d be mai n-
tai ned i n the cyl i nder.
Refer to the Cyl i nder Combusti on Pressure Leak-
age Test Di agnosi s chart.
CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART
AIR ESCAPES THROUGH
THROTTLE BODY
Intake valve bent, burnt, or not
seated properly
AIR ESCAPES THROUGH
TAILPIPE
Exhaust valve bent, burnt, or not
seated properly
AIR ESCAPES THROUGH
RADIATOR
Head gasket leaking or cracked
cylinder head or block
Replace defective part
MORE THAN 50% LEAKAGE
FROM ADJACENT CYLINDERS
Head gasket leaking or crack in
cylinder head or block between
adjacent cylinders
Replace gasket, head, or block as
necessary
MORE THAN 25% LEAKAGE AND
AIR ESCAPES THROUGH OIL
FILLER CAP OPENING ONLY
Stuck or broken piston rings;
cracked piston; worn rings and/or
cylinder wall
Inspect for broken rings or piston.
Measure ring gap and cylinder
diameter, taper and out-of-round.
Replace defective part as necessary
ENGINE OIL LEAK INSPECTION
Begi n wi th a thorough vi sual i nspecti on of the
engi ne, parti cul arl y at the area of the suspected l eak.
I f an oi l l eak source i s not readi l y i denti fi abl e, the
fol l owi ng steps shoul d be fol l owed:
(1) Do not cl ean or degrease the engi ne at thi s
ti me because some sol vents may cause rubber to
swel l , temporari l y stoppi ng the l eak.
(2) Add an oi l sol ubl e dye (use as recommended by
manufacturer). Start the engi ne and l et i dl e for
approxi matel y 15 mi nutes. Check the oi l di psti ck to
make sure the dye i s thoroughl y mi xed as i ndi cated
wi th a bri ght yel l ow col or under a bl ack l i ght.
(3) Usi ng a bl ack l i ght, i nspect the enti re engi ne
for fl uorescent dye, parti cul arl y at the suspected area
of oi l l eak. I f the oi l l eak i s found and i denti fi ed,
repai r per servi ce manual i nstructi ons.
(4) I f dye i s not observed, dri ve the vehi cl e at var-
i ous speeds for approxi matel y 24km (15 mi l es), and
repeat i nspecti on.
(4) If the oil leak source is not positively
identified at this time, proceed wi th the ai r l eak
detecti on test method.
Air Leak Detection Test Method
(1) Di sconnect the breather cap to ai r cl eaner hose
at the breather cap end. Cap or pl ug breather cap
ni ppl e.
(2) Remove the PCV val ve from the cyl i nder head
cover. Cap or pl ug the PCV val ve grommet.
(3) Attach an ai r hose wi th pressure gauge and
regul ator to the di psti ck tube.
CAUTION: Do not subject the engine assembly to
more than 20.6 kpa (3 PSI) of test pressure.
(4) Gradual l y appl y ai r pressure from 1 psi to 2.5
psi maxi mum whi l e appl yi ng soapy water at the sus-
pected source. Adjust the regul ator to the sui tabl e
test pressure that provi de the best bubbl es whi ch
wi l l pi npoi nt the l eak source. I f the oi l l eak i s
detected and i denti fi ed, repai r per servi ce manual
procedures.
(5) I f the l eakage occurs at the rear oi l seal area,
refer to the secti on, I nspecti on for Rear Seal Area
Leak.
(6) I f no l eaks are detected, turn off the ai r suppl y
and remove the ai r hose and al l pl ugs and caps.
I nstal l the PCV val ve and breather cap hose.
(7) Cl ean the oi l off the suspect oi l l eak area usi ng
a sui tabl e sol vent. Dri ve the vehi cl e at vari ous
speeds approxi matel y 24 km (15 mi l es). I nspect the
engi ne for si gns of an oi l l eak by usi ng a bl ack l i ght.
INSPECTION FOR REAR SEAL AREA LEAKS
Si nce i t i s someti mes di ffi cul t to determi ne the
source of an oi l l eak i n the rear seal area of the
engi ne, a more i nvol ved i nspecti on i s necessary. The
fol l owi ng steps shoul d be fol l owed to hel p pi npoi nt
the source of the l eak.
I f the l eakage occurs at the crankshaft rear oi l seal
area:
(3) Remove torque converter or cl utch housi ng
cover and i nspect rear of bl ock for evi dence of oi l .
Use a bl ack l i ght to check for the oi l l eak:
(a) Ci rcul ar spray pattern general l y i ndi cates
seal l eakage or crankshaft damage.
(b) Where l eakage tends to run strai ght down,
possi bl e causes are a porous bl ock, di stri butor seal ,
camshaft bore cup pl ugs oi l gal l ey pi pe pl ugs, oi l
fi l ter runoff, and mai n beari ng cap to cyl i nder
bl ock mati ng surfaces.
(4) I f no l eaks are detected, pressuri ze the crank-
case as outl i ned i n the, I nspecti on (Engi ne oi l Leaks
i n general )
CAUTION: Do not exceed 20.6 kPa (3 psi).
(5) I f the l eak i s not detected, very sl owl y turn the
crankshaft and watch for l eakage. I f a l eak i s
detected between the crankshaft and seal whi l e
sl owl y turni ng the crankshaft, i t i s possi bl e the
crankshaft seal surface i s damaged. The seal area on
the crankshaft coul d have mi nor ni cks or scratches
that can be pol i shed out wi th emery cl oth.
CAUTION: Use extreme caution when crankshaft
polishing is necessary to remove minor nicks and
scratches. The crankshaft seal flange is especially
machined to complement the function of the rear oil
seal.
(6) For bubbl es that remai n steady wi th shaft
rotati on, no further i nspecti on can be done unti l di s-
assembl ed.
ENGINE OIL PRESSURE
(1) Di sconnect connector and remove oi l pressure
sendi ng uni t.
(2) I nstal l Oi l Pressure Li ne and Gauge Tool
C-3292 or equi val ent. Start engi ne and record pres-
sure. Refer to Oi l Pressure i n Engi ne Speci fi cati ons
for the correct pressures.
SERVICE PROCEDURES
VALVE TIMING
Di sconnect the spark pl ug wi res and remove the
spark pl ugs.
Remove the engi ne cyl i nder head cover.
Remove the capscrews, bri dge and pi vot assembl y,
and rocker arms from above the No.1 cyl i nder.
Al ternatel y l oosen each capscrew, one turn at a
ti me, to avoi d damagi ng the bri dge.
Rotate the crankshaft unti l the No.6 pi ston i s at
top dead center (TDC) on the compressi on stroke.
Rotate the crankshaft countercl ockwi se (vi ewed
from the front of the engi ne) 90.
I nstal l a di al i ndi cator on the end of the No.1 cyl -
i nder i ntake val ve push rod. Use rubber tubi ng to
secure the i ndi cator stem on the push rod.
Rotate the crankshaft cl ockwi se (vi ewed from the
front of the engi ne) unti l the di al i ndi cator poi nter
i ndi cates 0.305 mm (0.012 i nch) travel di stance (l i ft).
The ti mi ng notch i ndex on the vi brati on damper
shoul d be al i gned wi th the TDC mark on the ti mi ng
degree scal e.
I f the ti mi ng notch i s more than 13 mm (1/2 i nch)
away from the TDC mark i n ei ther di recti on, the
val ve ti mi ng i s i ncorrect.
I f the val ve ti mi ng i s i ncorrect, the cause may be a
broken camshaft pi n. I t i s not necessary to repl ace
the camshaft because of pi n fai l ure. A spri ng pi n i s
avai l abl e for servi ce repl acement.
VALVE SERVICE
Cl ean al l carbon deposi ts from the combusti on
chambers, val ve ports, val ve stems, val ve stem
gui des and head.
Cl ean al l gri me and gasket materi al from the
engi ne cyl i nder head machi ned gasket surface.
I nspect for cracks i n the combusti on chambers and
val ve ports.
I nspect for cracks on the exhaust seat.
I nspect for cracks i n the gasket surface at each
cool ant passage.
I nspect val ves for burned, cracked or warped
heads.
I nspect for scuffed or bent val ve stems.
Repl ace val ves di spl ayi ng any damage.
VALVE REFACING
(1) Use a val ve refaci ng machi ne to reface the
i ntake and exhaust val ves to the speci fi ed angl e.
(2) After refaci ng, a margi n of at l east 0.787 mm
(0.031 i nch) must remai n (Fi g. 14). I f the margi n i s
l ess than 0.787 mm (0.031 i nch), the val ve must be
repl aced.
Fig. 14 Valve Facing Margin
1 VALVE MARGIN
2 NO MARGIN
VALVE SEAT REFACING
(1) I nstal l a pi l ot of the correct si ze i n the val ve
gui de bore. Reface the val ve seat to the speci fi ed
angl e wi th a good dressi ng stone. Remove onl y
enough metal to provi de a smooth fi ni sh.
(2) Use tapered stones to obtai n the speci fi ed seat
wi dth when requi red.
(3) Control val ve seat runout to a maxi mum of
0.0635 mm (0.0025 i n.) (Fi g. 15).
VALVE STEM OIL SEAL REPLACEMENT
Val ve stem oi l seal s are i nstal l ed on each val ve
stem to prevent rocker arm l ubri cati ng oi l from
enteri ng the combusti on chamber through the val ve
gui de bores. One seal i s marked I NT (i ntake val ve)
and the other i s marked EXH (exhaust val ve).
Repl ace the oi l seal s whenever val ve servi ce i s per-
formed or i f the seal s have deteri orated.
VALVE GUIDES
The val ve gui des are an i ntegral part of the engi ne
cyl i nder head and are not repl aceabl e.
When the val ve stem gui de cl earance i s excessi ve,
the val ve gui de bores must be reamed oversi ze. Ser-
vi ce val ves wi th oversi ze stems are avai l abl e i n 0.076
mm (0.003 i nch) and 0.381 mm (0.015 i nch) i ncre-
ments.
Correspondi ng oversi ze val ve stem seal s are al so
avai l abl e and must be used wi th val ves havi ng 0.381
mm (0.015 i nch) oversi ze stems.
NOTE: If the valve guides are reamed oversize, the
valve seats must be ground to ensure that the valve
seat is concentric to the valve guide.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
Val ve stem-to-gui de cl earance may be measured by
ei ther of the fol l owi ng two methods.
PREFERRED METHOD
(1) Remove the val ve from the head.
(2) Cl ean the val ve stem gui de bore wi th sol vent
and a bri stl e brush.
(3) I nsert a tel escopi ng gauge i nto the val ve stem
gui de bore approxi matel y 9.525 mm (.375 i nch) from
the val ve spri ng si de of the head (Fi g. 16).
(4) Remove and measure tel escopi ng gauge wi th a
mi crometer.
(5) Repeat the measurement wi th contacts l ength-
wi se to engi ne cyl i nder head.
(6) Compare the crosswi se to l engthwi se measure-
ments to determi ne out-of-roundness. I f the measure-
ments di ffer by more than 0.0635 mm (0.0025 i n.),
ream the gui de bore to accommodate an oversi ze
val ve stem.
(7) Compare the measured val ve gui de bore di am-
eter wi th speci fi cati ons (7.95-7.97 mm or 0.313-0.314
i nch). I f the measurement di ffers from speci fi cati on
by more than 0.076 mm (0.003 i nch), ream the gui de
bore to accommodate an oversi ze val ve stem.
Fig. 15 Measurement of Valve Seat Runout
1 DIAL INDICATOR
Fig. 16 Measurement of Valve Guide Bore Diameter
1 GAUGE
2 9.525 MM (3/8 INCH)
3 VALVE STEM GUIDE
4 CYLINDER HEAD
ALTERNATIVE METHOD
(1) Use a di al i ndi cator to measure the l ateral
movement of the val ve stem (stem-to-gui de cl ear-
ance). Thi s must be done wi th the val ve i nstal l ed i n
i ts gui de and just off the val ve seat (Fi g. 17).
(2) Correct cl earance i s 0.025-0.0762 mm
(0.001-0.003 i nch). I f i ndi cated movement exceeds the
speci fi cati on ream the val ve gui de to accommodate
an oversi ze val ve stem.
NOTE: Valve seats must be ground after reaming
the valve guides to ensure that the valve seat is
concentric to the valve guide.
VALVE SPRING TENSION TEST
Use a uni versal Val ve Spri ng Tester and a torque
wrench to test each val ve spri ng for the speci fi ed ten-
si on val ue (Fi g. 18).
Repl ace val ve spri ngs that are not wi thi n speci fi ca-
ti ons.
PISTON FITTING
BORE GAGE METHOD
(1) To correctl y sel ect the proper si ze pi ston, a cyl -
i nder bore gauge, capabl e of readi ng i n 0.003 mm
(.0001 i n.) I NCREMENTS i s requi red. I f a bore
gauge i s not avai l abl e, do not use an i nsi de mi crome-
ter.
bore at a poi nt 49.5 mm (1-15/16 i nches) bel ow top of
bore. Start perpendi cul ar (across or at 90 degrees) to
the axi s of the crankshaft at poi nt A and then take
an addi ti onal bore readi ng 90 degrees to that at poi nt
B (Fi g. 20).
(3) The coated pi stons wi l l be servi ced wi th the
pi ston pi n and connecti ng rod pre-assembl ed. The
coated piston connecting rod assembly can be
used to service previous built engines and
MUST be replaced as complete sets. Ti n coated
pi stons shoul d not be used as repl acements for coated
pi stons.
(4) The coati ng materi al i s appl i ed to the pi ston
after the fi nal pi ston machi ni ng process. Measuri ng
the outsi de di ameter of a coated pi ston wi l l not pro-
vi de accurate resul ts (Fi g. 19). Therefore measuri ng
the i nsi de di ameter of the cyl i nder bore wi th a di al
Bore Gauge i s MANDATORY. To correctl y sel ect the
proper si ze pi ston, a cyl i nder bore gauge capabl e of
readi ng i n 0.003 mm (.0001 i n.) i ncrements i s
requi red.
(5) Pi ston i nstal l ati on i nto the cyl i nder bore
requi res sl i ghtl y more pressure than that requi red
for non-coated pi stons. The bonded coati ng on the
pi ston wi l l gi ve the appearance of a l i ne-to-l i ne fi t
wi th the cyl i nder bore.
PISTON RING FITTING
(1) Careful l y cl ean the carbon from al l ri ng
grooves. Oi l drai n openi ngs i n the oi l ri ng groove and
pi n boss must be cl ear. DO NOT remove metal from
the grooves or l ands. Thi s wi l l change ri ng-to-groove
cl earances and wi l l damage the ri ng-to-l and seati ng.
(2) Be sure the pi ston ri ng grooves are free of
ni cks and burrs.
(3) Measure the ri ng si de cl earance wi th a feel er
gauge fi tted snugl y between the ri ng l and and ri ng
(Fi g. 21) (Fi g. 22). Rotate the ri ng i n the groove. I t
must move freel y around ci rcumference of the groove.
(4) Pl ace ri ng i n the cyl i nder bore and push down
wi th i nverted pi ston to posi ti on near l ower end of the
ri ng travel . Measure ri ng gap wi th a feel er gauge fi t-
ti ng snugl y between ri ng ends (Fi g. 23).
Fig. 17 Measurement of Lateral Movement of Valve
Stem
1 DIAL INDICATOR
Fig. 18 Valve Spring Tester
1 TORQUE WRENCH
2 VALVE SPRING TESTER
(5) The oi l control ri ngs are symmetri cal , and can
be i nstal l ed wi th ei ther si de up. I t i s not necessary to
use a tool to i nstal l the upper and l ower rai l s. I nsert
oi l rai l spacer fi rst, then si de rai l s.
(6) The two compressi on ri ngs are di fferent and
cannot be i nterchanged. The top compressi on ri ng
can be i denti fi ed by the shi ny coati ng on the outer
seal i ng surface and can be i nstal l ed wi th ei ther si de
up. (Fi g. 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 (115/16 in)
PISTON SIZE CHART
CYLINDER BORE SIZE PISTON LETTER SIZE
98.438 - 98.448 mm
(3.8755 - 3.8759 in.)
A
98.448 - 98.458 mm
(3.8759 - 3.8763 in.)
B
98.458 - 98.468 mm
(3.8763 - 3.8767 in.)
C
98.468 - 98.478 mm
(3.8767 - 3.8771 in.)
D
98.478 - 98.488 mm
(3.8771 - 3.8775 in.)
E
98.488 - 98.498 mm
(3.8775 - 3.8779 in.)
F
Fig. 21 Piston Dimensions
(7) The second compressi on ri ng has a sl i ght
chamfer on the bottom of the i nsi de edge and a dot
on the top for correct i nstal l ati on (Fi g. 25).
(8) Usi ng a ri ng i nstal l er, i nstal l the second com-
pressi on ri ng wi th the dot faci ng up (Fi g. 25) (Fi g.
27).
(9) Usi ng a ri ng i nstal l er, i nstal l the top compres-
si on ri ng (ei ther si de up).
Ring Gap Orientation
Posi ti on the gaps on the pi ston as shown (Fi g.
28).
Oi l spacer - Gap on center l i ne of pi ston ski rt.
Oi l rai l s - gap 180 apart on centerl i ne of pi ston
pi n bore.
No. 2 Compressi on ri ng - Gap 180 from top oi l
rai l gap.
No. 1 Compressi on ri ng - Gap 180 from No. 2
compressi on ri ng gap.
Fig. 22 Ring Side Clearance Measurement
1 FEELER GAUGE
RING SIDE CLEARANCE CHART
ITEM SPECIFICATION
(0.0017 - 0.0033 in.)
Second Compression
Ring
0.042 - 0.084 mm
(0.0017 - 0.0033 in.)
(0.0024 - 0.0083 in.)
Fig. 23 Gap Measurement
1 FEELER GAUGE
RING GAP MEASUREMENT CHART
ITEM SPECIFICATION
(0.0090 - 0.0240 in.)
Second Compression
Ring
0.483 - 0.965 mm
(0.0190 - 0.080 in.)
(0.010 - 0.060 in.)
Fig. 24 Top Compression ring identification
FITTING CONNECTING ROD BEARINGS
INSPECTION
BEARINGS
I nspect the connecti ng rod beari ngs for scori ng and
bent al i gnment tabs (Fi g. 29) (Fi g. 30). Check the
beari ngs for normal wear patterns, scori ng, groovi ng,
fati gue and pi tti ng (Fi g. 31). Repl ace any beari ng
that shows abnormal wear.
I nspect the connecti ng rod journal s for si gns of
scori ng, ni cks and burrs.
CONNECTING RODS
Mi sal i gned or bent connecti ng rods can cause
abnormal wear on pi stons, pi ston ri ngs, cyl i nder
wal l s, connecti ng rod beari ngs and crankshaft con-
necti ng rod journal s. I f wear patterns or damage to
any of these components i ndi cate the probabi l i ty of a
mi sal i gned connecti ng rod, i nspect i t for correct rod
Fig. 25 Second Compression Ring Identification
2 CHAMFER
3 ONE DOT
Fig. 26 Compression Ring Chamfer Location
3 PISTON
4 CHAMFER
Fig. 27 Compression Ring Installation
1 COMPRESSION RING
2 RING EXPANDER RECOMMENDED
Fig. 28 Ring Gap Orientation
2 BOTTOM COMPRESSION RING
3 TOP OIL CONTROL RAIL
4 OIL RAIL SPACER
5 BOTTOM OIL CONTROL RAIL
6 IMAGINARY LINE PARALLEL TO PISTON PIN
7 IMAGINARY LINE THROUGH CENTER OF PISTON SKIRT
al i gnment. Repl ace mi sal i gned, bent or twi sted con-
necti ng rods.
BEARING-TO-JOURNAL CLEARANCE
(1) Wi pe the oi l from the connecti ng rod journal .
(2) Use short rubber hose secti ons over rod bol ts
(3) Lubri cate the upper beari ng i nsert and i nstal l
i n connecti ng rod.
(4) Use pi ston ri ng compressor to i nstal l the rod
and pi ston assembl i es. The oi l squi rt hol es i n the
rods must face the camshaft. The arrow on the pi ston
crown shoul d poi nt to the front of the engi ne (Fi g.
32). Veri fy that the oi l squi rt hol es i n the rods face
the camshaft and that the arrows on the pi stons face
the front of the engi ne.
(5) I nstal l the l ower beari ng i nsert i n the beari ng
cap. The l ower i nsert must be dry. Pl ace stri p of Pl as-
ti gage across ful l wi dth of the l ower i nsert at the cen-
ter of beari ng cap. Pl asti gage must not crumbl e i n
use. I f bri ttl e, obtai n fresh stock.
(6) I nstal l beari ng cap and connecti ng rod on the
journal and ti ghten nuts to 45 Nm (33 ft. l bs.)
torque. DO NOT rotate crankshaft. Pl asti gage wi l l
smear, resul ti ng i n i naccurate i ndi cati on.
(7) Remove the beari ng cap and determi ne amount
of beari ng-to- journal cl earance by measuri ng the
wi dth of compressed Pl asti gage (Fi g. 33). Refer to
Engi ne Speci fi cati ons for the proper cl earance. Plas-
tigage should indicate the same clearance
across the entire width of the insert. If the
clearance varies, it may be caused by either a
tapered journal, bent connecting rod or foreign
material trapped between the insert and cap or
rod.
(8) I f the correct cl earance i s i ndi cated, repl ace-
ment of the beari ng i nserts i s not necessary. Remove
the Pl asti gage from crankshaft journal and beari ng
i nsert. Proceed wi th i nstal l ati on.
Fig. 29 Connecting Rod Bearing Inspection
1 UPPER BEARING HALF
2 MATING EDGES
3 GROOVES CAUSED BY ROD BOLTS SCRATCHING
JOURNAL DURING INSTALLATION
4 WEAR PATTERN ALWAYS GREATER ON UPPER
BEARING
5 LOWER BEARING HALF
Fig. 30 Locking Tab Inspection
1 ABNORMAL CONTACT AREA CAUSED BY LOCKING TABS
NOT FULLY SEATED OR BEING BENT
Fig. 31 Scoring Caused by Insufficient Lubrication
or by Damaged Crankshaft Pin Journal
(9) I f beari ng-to-journal cl earance exceeds the
speci fi cati on, i nstal l a pai r of 0.0254 mm (0.001 i nch)
undersi ze beari ng i nserts. Al l the odd si ze i nserts
must be on the bottom. The si zes of the servi ce
repl acement beari ng i nserts are stamped on the
backs of the i nserts. Measure the cl earance as
descri bed i n the previ ous steps.
(10) The cl earance i s measured wi th a pai r of
0.0254 mm (0.001 i nch) undersi ze beari ng i nserts
i nstal l ed. Thi s wi l l determi ne i f two 0.0254 mm
(0.001 i nch) undersi ze i nserts or another combi nati on
i s needed to provi de the correct cl earance (refer to
Connecti ng Rod Beari ng Fi tti ng Chart).
CONNECTING ROD BEARING FITTING CHART
CRANKSHAFT JOURNAL CORRESPONDING ROD BEARING INSERT
Yellow
53.2257 - 53.2079 mm
(2.0955 - 2.0948 in.)
Orange
53.2079 - 53.1901 mm
Yellow - Standard
Blue - Undersize (2.0948 - 2.0941 in.)
0.0178 mm (0.0007 in.) 0.025 mm (0.001 in.)
Undersize
Blue
53.1901 - 53.1724 mm
Blue - Undersize Blue - Undersize (2.0941 - 2.0934 in.)
0.0356 mm (0.0014 in.) 0.025 mm (0.001 in.) 0.025 mm (0.001 in.)
Undersize
Red
52.9717 - 52.9539 mm
Red - Undersize Red - Undersize (2.0855 - 2.0848 in.)
0.254 mm (0.010 in.) 0.254 mm (0.010 in.) 0.254 mm (0.010 in.)
Undersize
(11) FOR EXAMPLE: I f the i ni ti al cl earance was
0.0762 mm (0.003 i nch), 0.025 mm (0.001 i nch)
undersi ze i nserts woul d reduce the cl earance by
0.025 mm (0.001 i nch). The cl earance woul d be 0.002
i nch and wi thi n speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze i nsert woul d reduce the i ni ti al cl ear-
ance an addi ti onal 0.013 mm (0.0005 i nch). The
(12) Repeat the Pl asti gage measurement to veri fy
your beari ng sel ecti on pri or to fi nal assembl y.
(13) Once you have sel ected the proper i nsert,
i nstal l the i nsert and cap. Ti ghten the connecti ng rod
SIDE CLEARANCE MEASUREMENT
Sl i de snug-fi tti ng feel er gauge between the con-
necti ng rod and crankshaft journal fl ange (Fi g. 34).
Refer to Engi ne Speci fi cati ons for the proper cl ear-
ance. Repl ace the connecti ng rod i f the si de cl earance
i s not wi thi n speci fi cati on.
Plastigage
1 PLASTIGAGE SCALE
FITTING CRANKSHAFT MAIN BEARINGS
INSPECTION
Wi pe the i nserts cl ean and i nspect for abnormal
wear patterns and for metal or other forei gn materi al
i mbedded i n the l i ni ng. Normal mai n beari ng i nsert
wear patterns are i l l ustrated (Fi g. 35). I n general the
l ower beari ng hal f wi l l have a heaver wear pattern.
NOTE: If any of the crankshaft journals are scored,
remove the engine for crankshaft repair.
I nspect the back of the i nserts for fractures, scrap-
i ngs or i rregul ar wear patterns.
I nspect the upper i nsert l ocki ng tabs for damage.
Repl ace al l damaged or worn beari ng i nserts.
FITTING BEARINGS (CRANKSHAFT INSTALLED)
The mai n beari ng caps, numbered (front to rear)
from 1 through 7 have an arrow to i ndi cate the for-
ward posi ti on. The upper mai n beari ng i nserts are
grooved to provi de oi l channel s whi l e the l ower
i nserts are smooth.
Each beari ng i nsert pai r i s sel ecti vel y fi tted to i ts
respecti ve journal to obtai n the speci fi ed operati ng
cl earance. I n producti on, the sel ect fi t i s obtai ned by
usi ng vari ous-si zed col or-coded beari ng i nsert pai rs
as l i sted i n the Mai n Beari ng Fi tti ng Chart. The
beari ng col or code appears on the edge of the i nsert.
The size is not stamped on bearing inserts used
for engine production.
The mai n beari ng journal si ze (di ameter) i s i denti -
fi ed by a col or-coded pai nt mark (Fi g. 36) on the
adjacent cheek or counterwei ght towards the rear of
the crankshaft (fl ange end). The rear mai n journal , i s
i denti fi ed by a col or-coded pai nt mark on the crank-
shaft rear fl ange.
When requi red, upper and l ower beari ng i nserts of
di fferent si zes may be used as a pai r. A standard si ze
i nsert i s someti mes used i n combi nati on wi th a 0.025
mm (0.001 i nch) undersi ze i nsert to reduce the cl ear-
ance by 0.013 mm (0.0005 i nch). Never use a pair
of bearing inserts with greater than a 0.025 mm
(0.001 inch) difference in size. Refer to the
Bearing Insert Pair Chart.
NOTE: When replacing inserts, the odd size inserts
must be either all on the top (in cylinder block) or
all on the bottom (in main bearing cap).
Once the beari ngs have been properl y fi tted, pro-
BEARING-TO-JOURNAL CLEARANCE (CRANKSHAFT
INSTALLED)
When usi ng Pl asti gage, check onl y one beari ng
cl earance at a ti me.
I nstal l the grooved mai n beari ngs i nto the cyl i nder
bl ock and the non-grooved beari ngs i nto the beari ng
caps.
I nstal l the crankshaft i nto the upper beari ngs dry.
Pl ace a stri p of Pl asti gage across ful l wi dth of the
crankshaft journal to be checked.
I nstal l the beari ng cap and ti ghten the bol ts to 108
NOTE: DO NOT rotate the crankshaft. This will
cause the Plastigage to shift, resulting in an inaccu-
rate reading. Plastigage must not be permitted to
crumble. If brittle, obtain fresh stock.
Remove the beari ng cap. Determi ne the amount of
cl earance by measuri ng the wi dth of the compressed
Pl asti gage wi th the scal e on the Pl asti gage envel ope
Fig. 34 Checking Connecting Rod Side Clearance
Typical
Fig. 35 Main Bearing Wear Patterns
1 UPPER INSERT
2 NO WEAR IN THIS AREA
3 LOW AREA IN BEARING LINING
4 LOWER INSERT
(Fi g. 37). Refer to Engi ne Speci fi cati ons for the
proper cl earance.
Pl asti gage shoul d i ndi cate the same cl earance
across the enti re wi dth of the i nsert. I f cl earance var-
i es, i t may i ndi cate a tapered journal or forei gn
materi al trapped behi nd the i nsert.
I f the speci fi ed cl earance i s i ndi cated and there are
no abnormal wear patterns, repl acement of the bear-
i ng i nserts i s not necessary. Remove the Pl asti gage
from the crankshaft journal and beari ng i nsert. Pro-
I f the cl earance exceeds speci fi cati on, i nstal l a pai r
of 0.025 mm (0.001 i nch) undersi ze beari ng i nserts
and measure the cl earance as descri bed i n the previ -
ous steps.
The cl earance i ndi cate wi th the 0.025 mm (0.001
i nch) undersi ze i nsert pai r i nstal l ed wi l l determi ne i f
thi s i nsert si ze or some other combi nati on wi l l pro-
vi de the speci fi ed cl earance. FOR EXAMPLE: I f the
cl earance was 0.0762 mm (0.003 i nch) ori gi nal l y, a
pai r of 0.0254 mm (0.001 i nch) undersi ze i nserts
woul d reduce the cl earance by 0.0254 mm (0.001
i nch). The cl earance woul d then be 0.0508 mm (0.002
i nch) and wi thi n the speci fi cati on. A 0.051 mm (0.002
i nch) undersi ze beari ng i nsert and a 0.0254 mm
(0.001 i nch) undersi ze i nsert woul d reduce the ori gi -
nal cl earance an addi ti onal 0.0127 mm (0.0005 i nch).
The cl earance woul d then be 0.0381 mm (0.0015
i nch).
CAUTION: Never use a pair of inserts that differ
more than one bearing size as a pair.
FOR EXAMPLE: DO NOT use a standard si ze
upper i nsert and a 0.051 mm (0.002 i nch) undersi ze
l ower i nsert.
Fig. 36 Crankshaft Journal Size Paint I. D. Location
1 NO. 7 MAIN JOURNAL SIZE PAINT MARK
2 NO. 6 CONNECTING ROD JOURNAL SIZE PAINT MARK
3 NO. 1 CONNECTING ROD JOURNAL SIZE PAINT MARK
4 NO. 1 MAIN JOURNAL SIZE PAINT MARK
BEARING INSERT PAIRS CHART
INSERT CORRECT INCORRECT
UPPER STANDARD STANDARD
LOWER 0.025 mm
(0.001 in.)
UNDERSIZE
0.051 mm
(0.002 in.)
UNDERSIZE
Plastigage
1 PLASTIGAGE SCALE
I f the cl earance exceeds speci fi cati on usi ng a pai r
of 0.051 mm (0.002 i nch) undersi ze beari ng i nserts,
measure crankshaft journal di ameter wi th a
mi crometer. I f the journal di ameter i s correct, the
crankshaft bore i n the cyl i nder bl ock may be mi s-
al i gned, whi ch requi res cyl i nder bl ock repl acement or
machi ni ng to true bore.
Repl ace the crankshaft or gri nd to accept the
appropri ate undersi ze beari ng i nserts i f:
Journal di ameters 1 through 6 are l ess than
63.4517 mm (2.4981 i nches)
Journal 7 di ameter i s l ess than 63.4365 mm
(2.4975 i nches).
MAIN BEARING JOURNAL DIAMETER
(CRANKSHAFT REMOVED)
Remove the crankshaft from the cyl i nder bl ock
(refer to Cyl i nder Bl ock - Di sassembl e).
Cl ean the oi l off the mai n beari ng journal .
Determi ne the maxi mum di ameter of the journal
wi th a mi crometer. Measure at two l ocati ons 90
apart at each end of the journal .
The maxi mum al l owabl e taper and out of round i s
0.013 mm (0.0005 i nch). Compare the measured
di ameter wi th the journal di ameter speci fi cati on
(Mai n Beari ng Fi tti ng Chart). Sel ect i nserts requi red
to obtai n the speci fi ed beari ng-to-journal cl earance.
I nstal l the crankshaft i nto the cyl i nder bl ock (refer
to Cyl i nder Bl ock - Assembl e and Crankshaft Mai n
Beari ngs - I nstal l ati on).
MAIN BEARING FITTING CHART
Crankshaft Journals #1-6 Corresponding Crankshaft Bearing Insert
Yellow
63.5025 -63.4898 mm
(2.5001 - 2.4996 in.)
Orange
63.4898 - 63.4771 mm
Yellow - Standard
Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4771 - 63.4644 mm
Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4991 - 2.4986 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4644 - 63.4517 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4986 - 2.4981 in.)
0.0381 mm (0.0015 in.)
Undersize
Red
63.2485 - 63.2358 mm
Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4901 - 2.4896 in.)
0.254 mm (0.010 in.)
Undersize
Crankshaft Journal #7 Only Corresponding Bearing Insert
Yellow
63.4873 - 63.4746 mm
(2.4995 - 2.4990 in.)
Orange
63.4746 - 63.4619 mm
Yellow - Standard
Blue - Undersize
0.025 mm (0.001 in.)
(2.4996 - 2.4991 in.)
0.0127 mm (0.0005 in.)
Undersize
Blue
63.4619 - 63.4492 mm
Blue - Undersize
0.025 mm (0.001 in.)
Blue - Undersize
0.025 mm (0.001 in.)
(2.4985 - 2.4980 in.)
0.0254 mm (0.001 in.)
Undersize
Green
63.4492 - 63.4365 mm
Blue - Undersize
0.025 mm (0.001 in.)
Green - Undersize
0.051 mm (0.002 in.)
(2.4980 - 2.4975 in.)
0.0381 mm (0.0015 in.)
Undersize
Red
63.2333 - 63.2206 mm
Red - Undersize
0.254 mm (0.010 in.)
Red - Undersize
0.254 mm (0.010 in.)
(2.4895 - 2.4890 in.)
0.254 mm (0.010 in.)
Undersize
FORM-IN-PLACE GASKETS
There are several pl aces where form-i n-pl ace gas-
kets are used on the engi ne. DO NOT use form-in-
place gasket material unless specified. Care
must be taken when appl yi ng form-i n-pl ace gaskets.
Bead si ze, conti nui ty and l ocati on are of great i mpor-
tance. Too thi n a bead can resul t i n l eakage whi l e too
much can resul t i n spi l l -over. A conti nuous bead of
the proper wi dth i s essenti al to obtai n a l eak-free
joi nt.
Two types of form-i n-pl ace gasket materi al s are
used i n the engi ne area (Mopar Si l i cone Rubber
Adhesi ve Seal ant and Mopar Gasket Maker). Each
have di fferent properti es and cannot be used i nter-
changeabl y.
MOPAR SILICONE RUBBER ADHESIVE SEALANT
Mopar Si l i cone Rubber Adhesi ve Seal ant, normal l y
bl ack i n col or, i s avai l abl e i n 3 ounce tubes. Moi sture
i n the ai r causes the seal ant materi al to cure. Thi s
materi al i s normal l y used on fl exi bl e metal fl anges.
I t has a shel f l i fe of a year and wi l l not properl y cure
i f over aged. Al ways i nspect the package for the expi -
rati on date before use.
MOPAR GASKET MAKER
Mopar Gasket Maker, normal l y red i n col or, i s
avai l abl e i n 6 cc tubes. Thi s anaerobi c type gasket
materi al cures i n the absence of ai r when squeezed
between smooth machi ned metal l i c surfaces. I t wi l l
not cure i f l eft i n the uncovered tube. DO NOT use
on fl exi bl e metal fl anges.
SURFACE PREPARATION
Parts assembl ed wi th form-i n-pl ace gaskets may be
di sassembl ed wi thout unusual effort. I n some
i nstances, i t may be necessary to l i ghtl y tap the part
wi th a mal l et or other sui tabl e tool to break the seal
between the mati ng surfaces. A fl at gasket scraper
may al so be l i ghtl y tapped i nto the joi nt but care
must be taken not to damage the mati ng surfaces.
Scrape or wi re brush al l gasket surfaces to remove
al l l oose materi al . I nspect stamped parts to ensure
gasket rai l s are fl at. Fl atten rai l s wi th a hammer on
a fl at pl ate, i f requi red. Gasket surfaces must be free
of oi l and di rt. Make sure the ol d gasket materi al i s
removed from bl i nd attachi ng hol es.
GASKET APPLICATION
Assembl i ng parts usi ng a form-i n-pl ace gasket
requi res care.
Mopar Si l i cone Rubber Adhesi ve Seal ant shoul d be
appl i ed i n a conti nuous bead approxi matel y 3 mm
(0.12 i nch) i n di ameter. Al l mounti ng hol es must be
ci rcl ed. For corner seal i ng, a 3 or 6 mm (1/8 or 1/4
i nch) drop i s pl aced i n the center of the gasket con-
tact area. Uncured seal ant may be removed wi th a
shop towel . Components shoul d be torqued i n pl ace
whi l e the seal ant i s sti l l wet to the touch (wi thi n 10
mi nutes). The use of a l ocati ng dowel i s recom-
mended duri ng assembl y to prevent smeari ng the
materi al off l ocati on.
Mopar Gasket Maker shoul d be appl i ed spari ngl y
to one gasket surface. The seal ant di ameter shoul d
be 1.00 mm (0.04 i nch) or l ess. Be certai n the mate-
ri al surrounds each mounti ng hol e. Excess materi al
can easi l y be wi ped off. Components shoul d be
torqued i n pl ace wi thi n 15 mi nutes. The use of a
l ocati ng dowel i s recommended duri ng assembl y to
prevent smeari ng the materi al off l ocati on.
ENGINE PERFORMANCE
I t i s i mportant that the vehi cl e i s operati ng to i ts
opti mum performance l evel to mai ntai n fuel economy
and the l owest emi ssi on l evel s. I f vehi cl e i s not oper-
ati ng to these standards, refer to Engi ne Di agnosi s
outl i ned i n thi s secti on. The fol l owi ng procedures can
assi st i n achi evi ng the proper engi ne di agnosi s.
(1) Test cranki ng amperage draw. Refer to El ectri -
cal Group 8B, Col d Cranki ng Test.
(2) Check i ntake mani fol d bol t torque; Refer to
Group 11, Exhaust System and I ntake Mani fol d.
(3) Perform cyl i nder compressi on test. Refer to
Cyl i nder Compressi on Pressure Test i n the Engi ne
Di agnosi s area of thi s secti on.
(4) Cl ean or repl ace spark pl ugs as necessary and
adjust gap as speci fi ed i n El ectri cal Group 8D.
Ti ghten to speci fi cati ons.
(5) Test resi stance of spark pl ug cabl es. Refer to
El ectri cal Group 8D, Spark Pl ug Cabl es.
(6) I nspect the pri mary wi res. Test coi l output vol t-
age and pri mary resi stance. Repl ace parts as neces-
sary. Refer to El ectri cal Group 8D, for speci fi cati ons.
(7) Test fuel pump for pressure. Refer to Group 14,
Fuel System Speci fi cati ons.
(8) The ai r fi l ter el ements shoul d be repl aced as
speci fi ed i n Lubri cati on and Mai ntenance, Group 0.
(9) I nspect crankcase venti l ati on system as out
l i ned i n Group 0, Lubri cati on and Mai ntenance. For
emi ssi on control s see Group 25, Emi ssi on Control s
(10) Road test vehi cl e as a fi nal test.
HONING CYLINDER BORES
Before honi ng, stuff pl enty of cl ean shop towel s
under the bores and over the crankshaft to keep
abrasi ve materi al s from enteri ng the crankshaft
area.
(1) Used careful l y, the Cyl i nder Bore Si zi ng Hone
C-823 equi pped wi th 220 gri t stones, i s the best tool
for thi s job. I n addi ti on to degl azi ng, i t wi l l reduce
taper and out-of-round as wel l as removi ng l i ght
scuffi ng, scori ng or scratches. Usual l y a few strokes
wi l l cl ean up a bore and mai ntai n the requi red l i m-
i ts.
CAUTION: DO NOT use rigid type hones to remove
cylinder wall glaze.
(2) Degl azi ng of the cyl i nder wal l s may be done i f
the cyl i nder bore i s strai ght and round. Use a cyl i n-
der surfaci ng hone, Honi ng Tool C-3501, equi pped
wi th 280 gri t stones (C-3501-3810). 20-60 strokes,
dependi ng on the bore condi ti on, wi l l be suffi ci ent to
provi de a sati sfactory surface. Usi ng honi ng oi l
C-3501-3880 or a l i ght honi ng oi l avai l abl e from
major oi l di stri butors.
CAUTION: DO NOT use engine or transmission oil,
mineral spirits or kerosene.
(3) Honi ng shoul d be done by movi ng the hone up
and down fast enough to get a crosshatch pattern.
The hone marks shoul d I NTERSECT at 50 to 60
for proper seati ng of ri ngs (Fi g. 38).
(4) A control l ed hone motor speed between 200 and
300 RPM i s necessary to obtai n the proper cross-
hatch angl e. The number of up and down strokes per
mi nute can be regul ated to get the desi red 50 to 60
angl e. Faster up and down strokes i ncrease the cross-
hatch angl e.
(5) After honi ng, i t i s necessary that the bl ock be
cl eaned to remove al l traces of abrasi ve. Use a brush
to wash parts wi th a sol uti on of hot water and deter-
gent. Dry parts thoroughl y. Use a cl ean, whi te, l i nt-
free cl oth to check that the bore i s cl ean. Oi l the
bores after cl eani ng to prevent rusti ng.
Fig. 38 Cylinder Bore Crosshatch Pattern
1 CROSSHATCH PATTERN
2 INTERSECT ANGLE
REPAIR DAMAGED OR WORN THREADS
CAUTION: Be sure that the tapped holes maintain
the original center line.
Damaged or worn threads can be repai red. Essen-
ti al l y, thi s repai r consi sts of:
Dri l l i ng out worn or damaged threads.
Tappi ng the hol e wi th a speci al Hel i -Coi l Tap, or
equi val ent.
I nstal l i ng an i nsert i nto the tapped hol e to bri ng
the hol e back to i ts ori gi nal thread si ze.
SERVICE ENGINE ASSEMBLY (SHORT BLOCK)
A servi ce repl acement engi ne assembl y (short
bl ock) may be i nstal l ed whenever the ori gi nal cyl i n-
der bl ock i s defecti ve or damaged beyond repai r. I t
consi sts of the cyl i nder bl ock, crankshaft, pi ston and
rod assembl i es. I f needed, the camshaft must be pro-
cured separatel y and i nstal l ed before the engi ne i s
i nstal l ed i n the vehi cl e.
A short bl ock i s i denti fi ed wi th the l etter S
stamped on the same machi ned surface where the
bui l d date code i s stamped for compl ete engi ne
assembl i es.
I nstal l ati on i ncl udes the transfer of components
from the defecti ve or damaged ori gi nal engi ne. Fol -
l ow the appropri ate procedures for cl eani ng, i nspec-
ti on and torque ti ghteni ng.
HYDROSTATIC LOCK
When an engi ne i s suspected of hydrostati c l ock
(regardl ess of what caused the probl em), fol l ow the
steps bel ow.
(1) Perform the Fuel Pressure Rel ease Procedure
(refer to Group 14, Fuel System).
(2) Di sconnect the negati ve cabl e from the battery.
(3) I nspect ai r cl eaner, i nducti on system and
i ntake mani fol d to ensure system i s dry and cl ear of
forei gn materi al .
(4) Pl ace a shop towel around the spark pl ugs to
catch any fl ui d that may possi bl y be under pressure
i n the cyl i nder head. Remove the pl ugs from the
engi ne.
CAUTION: DO NOT use the starter motor to rotate
the crankshaft. Severe damage could occur.
(5) Wi th al l spark pl ugs removed, rotate the crank-
shaft usi ng a breaker bar and socket.
(6) I denti fy the fl ui d i n the cyl i nders (i .e. cool ant,
fuel , oi l , etc.).
(7) Make sure al l fl ui d has been removed from the
cyl i nders.
(8) Repai r engi ne or components as necessary to
prevent thi s probl em from occurri ng agai n.
(9) Squi rt engi ne oi l i nto the cyl i nders to l ubri cate
the wal l s. Thi s wi l l prevent damage on restart.
(10) I nstal l new spark pl ugs. Ti ghten the spark
pl ugs to 37 Nm (27 ft. l bs.) torque.
(11) Drai n engi ne oi l . Remove and di scard the oi l
fi l ter.
(13) I nstal l a new oi l fi l ter.
(14) Fi l l engi ne crankcase wi th the speci fi ed
amount and grade of oi l (refer to Group 0, Lubri ca-
ti on and Mai ntenance).
(15) Connect the negati ve cabl e to the battery.
(16) Start the engi ne and check for any l eaks.
ENGINE OIL SERVICE
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight
mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engi ne oi l that i s API Servi ce Grade Certi -
fi ed. MOPAR provi des engi ne oi l s that conform to the
l atest recommended servi ce grades.
Standard engi ne oi l i denti fi cati on notati ons have
been adopted to ai d i n the proper sel ecti on of engi ne
oi l . The i denti fyi ng notati ons are l ocated on the l abel
of engi ne oi l pl asti c bottl es and the top of engi ne oi l
cans (Fi g. 39).
Fig. 39 Engine Oil Container Standard Notations
SAE VISCOSITY
cosi ty of engi ne oi l . SAE 10W30 speci fi es a mul ti pl e
vi scosi ty engi ne oi l . Engi ne oi l s al so have mul ti pl e
vi scosi ti es. These are speci fi ed wi th a dual SAE vi s-
cosi ty grade whi ch i ndi cates the col d-to-hot tempera-
ture vi scosi ty range. Sel ect an engi ne oi l that i s best
sui ted to your parti cul ar temperature range and vari -
ati on (Fi g. 40).
ENERGY CONSERVING OIL
An Energy Conservi ng type oi l i s recommended for
gasol i ne engi nes. The desi gnati on of ENERGY CON-
SERVI NG i s l ocated on the l abel of an engi ne oi l con-
tai ner.
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil,
oil foaming and oil pressure loss can result.
The engi ne oi l l evel i ndi cator (Di psti ck) i s l ocated
at the ri ght rear of the 4.0L engi ne. I nspect engi ne
oi l l evel approxi matel y every 800 ki l ometers (500
mi l es). Unl ess the engi ne has exhi bi ted l oss of oi l
pressure, run the engi ne for about fi ve mi nutes
before checki ng oi l l evel . Checki ng engi ne oi l l evel on
a col d engi ne i s not accurate.
To ensure proper l ubri cati on of an engi ne, the
engi ne oi l must be mai ntai ned at an acceptabl e l evel .
The acceptabl e l evel s are i ndi cated between the ADD
and SAFE marks on the engi ne oi l di psti ck (Fi g. 41).
(2) Wi th engi ne OFF, al l ow approxi matel y ten mi n-
utes for oi l to settl e to bottom of crankcase, remove
engi ne oi l di psti ck.
(3) Wi pe di psti ck cl ean.
(4) I nstal l di psti ck and veri fy i t i s seated i n the
tube.
(5) Remove di psti ck, wi th handl e hel d above the
ti p, take oi l l evel readi ng (Fi g. 41).
(6) Add oi l onl y i f l evel i s bel ow the ADD mark on
di psti ck.
ENGINE OIL CHANGE
Change engi ne oi l at mi l eage and ti me i nterval s
descri bed i n Mai ntenance Schedul es.
Run engi ne unti l achi evi ng normal operati ng tem-
perature.
(1) Posi ti on the vehi cl e on a l evel surface and turn
engi ne off.
(3) Remove oi l fi l l cap.
(4) Pl ace a sui tabl e drai n pan under crankcase
drai n.
(5) Remove drai n pl ug from crankcase and al l ow
oi l to drai n i nto pan. I nspect drai n pl ug threads for
stretchi ng or other damage. Repl ace drai n pl ug i f
damaged.
(6) I nstal l drai n pl ug i n crankcase.
(7) Lower vehi cl e and fi l l crankcase wi th speci fi ed
type and amount of engi ne oi l descri bed i n thi s sec-
ti on.
(8) I nstal l oi l fi l l cap.
(9) Start engi ne and i nspect for l eaks.
(10) Stop engi ne and i nspect oi l l evel .
ENGINE OIL FILTER CHANGE
FILTER SPECIFICATION
CAUTION: Do not use oil filter with metric threads.
The proper oil filter has SAE type 3/4 X 16 threads.
An oil filter with metric threads can result in oil
leaks and engine failure.
Al l Jeep engi nes are equi pped wi th a hi gh qual i ty
ful l -fl ow, throw-away type oi l fi l ter. Dai ml erChrysl er
Fig. 40 Temperature/Engine Oil Viscosity
Fig. 41 Engine Oil Dipstick4.0L Engine
1 DIPSTICK
2 ADD
3 SAFE
Corporati on recommends a Mopar or equi val ent oi l
fi l ter be used.
OIL FILTER REMOVAL
(1) Posi ti on a drai n pan under the oi l fi l ter.
(2) Usi ng a sui tabl e oi l fi l ter wrench l oosen fi l ter.
(3) Rotate the oi l fi l ter countercl ockwi se to remove
i t from the cyl i nder bl ock oi l fi l ter boss or fi l ter
adapter housi ng (Fi g. 42).
(4) When fi l ter separates from adapter ni ppl e, ti p
gasket end upward to mi ni mi ze oi l spi l l . Remove fi l -
ter from vehi cl e.
(5) Make sure ol d gasket comes off wi th oi l fi l ter.
Wi th a wi pi ng cl oth, cl ean the gasket seal i ng surface
(Fi g. 43) of oi l and gri me.
OIL FILTER INSTALLATION
(1) Li ghtl y l ubri cate oi l fi l ter gasket wi th engi ne
oi l or chassi s grease.
(2) Thread fi l ter onto adapter ni ppl e. When gasket
makes contact wi th seal i ng surface, (Fi g. 43) hand
ti ghten fi l ter one ful l turn, do not over ti ghten.
(3) Add oi l , veri fy crankcase oi l l evel and start
engi ne. I nspect for oi l l eaks.
USED ENGINE OIL DISPOSAL
Care shoul d be exerci sed when di sposi ng used
engi ne oi l after i t has been drai ned from a vehi cl e
engi ne. Refer to the WARNI NG at begi nni ng of thi s
secti on.
ENGINE MOUNTS FRONT
The front mounts support the engi ne at each si de.
These supports are made of resi l i ent rubber.
REMOVAL
(3) Support the engi ne.
(4) Remove the nut from the through bol t (Fi g. 44).
DO NOT remove the through bol t.
(5) Remove the retai ni ng bol ts and nuts from the
support cushi ons (Fi g. 44).
(6) Remove the through bol t.
(7) Remove the support cushi ons.
INSTALLATION
(1) I f the engi ne support bracket was removed,
posi ti on the bracket onto the bl ock and i nstal l the
attachi ng bol ts (Fi g. 44). Ti ghten the engi ne support
bracket bol ts to 61 Nm (45 ft. l bs.) torque.
(2) I f the support cushi on bracket was removed,
posi ti on the bracket onto the l ower front si l l (Fi g.
45). I nstal l support cushi on bracket bol ts and nuts.
Ti ghten the nuts to 41 Nm (30 ft. l bs.) torque.
(3) Pl ace the support cushi on i nto posi ti on on the
support cushi on bracket (Fi g. 44). I nstal l and ti ghten
the bol ts and nuts to 41 Nm (30 ft. l bs.) torque.
(4) I nstal l the through bol t and the retai ni ng nut
(Fi g. 44). Ti ghten the through bol t nut to 65 Nm (48
ft. l bs.) torque.
Fig. 42 Oil Filter4.0L Engine
1 CYLINDER BLOCK
2 ADAPTER
3 OIL FILTER
Fig. 43 Oil Filter Sealing SurfaceTypical
1 SEALING SURFACE
2 RUBBER GASKET
3 OIL FILTER
(5) Remove the engi ne support.
ENGINE MOUNT REAR
A resi l i ent rubber cushi on supports the transmi s-
si on at the rear between the transmi ssi on extensi on
housi ng and the rear support crossmember or ski d
pl ate.
REMOVAL
(2) Rai se the vehi cl e and support the transmi ssi on.
(3) Remove the nuts hol di ng the support cushi on
to the crossmember (Fi g. 46) (Fi g. 47). Remove the
crossmember.
MANUAL TRANSMISSION
(Fi g. 46)
a. Remove the support cushi on nuts and remove
the cushi on.
b. Remove the transmi ssi on support bracket bol ts
and remove the bracket from the transmi ssi on.
(Fi g. 47)
a. Remove the support cushi on bol ts and remove
the cushi on and the support bracket from the trans-
mi ssi on (4WD) or from the adaptor bracket (2WD).
b. On 2WD vehi cl es, remove the bol ts hol di ng the
transmi ssi on support adaptor bracket to the trans-
mi ssi on (Fi g. 47). Remove the adaptor bracket.
INSTALLATION
a. I nstal l the transmi ssi on support bracket to the
transmi ssi on. I nstal l the bol ts and ti ghten to 46 Nm
Fig. 44 Front Mounts
2 THROUGH BOLT
3 SUPPORT CUSHION
6 THROUGH BOLT
8 SUPPORT CUSHION
Fig. 45 Support Cushion Bracket
b. I nstal l the support cushi on to the support
bracket. I nstal l the nuts and ti ghten to 75 Nm (55
ft. l bs.) torque.
a. On 2WD vehi cl es, posi ti on the transmi ssi on
support adaptor bracket to the transmi ssi on. I nstal l
the bol ts and ti ghten to 75 Nm (55 ft. l bs.) torque.
b. Posi ti on the transmi ssi on support bracket and
support cushi on to the adaptor bracket (2WD) or the
transmi ssi on (4WD). I nstal l the bol ts and ti ghten to
(1) Posi ti on the crossmember onto the support
cushi on studs. I nstal l the stud nuts and ti ghten to 22
Nm (192 i n. l bs) torque.
(2) I nstal l crossmember-to-si l l bol ts and ti ghten to
(3) Remove the transmi ssi on support.
ENGINE ASSEMBLY
REMOVAL
(1) Di sconnect the battery cabl es. Remove the bat-
tery.
(2) Mark the hi nge l ocati ons on the hood panel for
al i gnment reference duri ng i nstal l ati on. Remove the
engi ne compartment l amp. Remove the hood.
ATED ENGINE IS HOT AND PRESSURIZED. USE
CARE TO PREVENT SCALDING BY HOT COOLANT.
CAREFULLY RELEASE THE PRESSURE BEFORE
REMOVING THE RADIATOR DRAIN COCK AND CAP.
(4) Loosen the radi ator drai n cock and radi ator cap
to drai n the cool ant. DO NOT waste usabl e cool ant.
I f the sol uti on i s cl ean, drai n the cool ant i nto a cl ean
contai ner for reuse.
(5) Remove the l ower radi ator hose.
(6) Remove the upper radi ator hose and cool ant
recovery hose (Fi g. 48).
(7) Remove upper radi ator support retai ni ng bol ts
and remove radi ator support.
(8) Remove the fan shroud (Fi g. 48) and el ectri c
cool i ng fan.
(9) Di sconnect the transmi ssi on fl ui d cool er tubi ng
(automati c transmi ssi on).
Fig. 46 Rear Mount(Manual Transmission)
2 SUPPORT CUSHION
Fig. 47 Rear Mount(Automatic Transmission)
1 44
2 24
3 TRANSMISSION SUPPORT ADAPTOR BRACKET
4 SUPPORT CUSHION
(10) Di sconnect radi ator fan swi tch wi re connector.
(11) Vehicles with Air Conditioning:
(a) Di scharge A/C system (refer to group 24,
Heati ng and Ai r Condi ti oni ng for proper proce-
dures)
(b) Di sconnect the sucti on/di scharge hose and
cap off compressor ports to prevent forei gn mate-
ri al and refri gerant oi l l oss.
(12) Remove the radi ator or radi ator and con-
denser (i f equi pped wi th A/C).
(13) Remove the fan assembl y from the i dl er pul -
l ey.
(14) Di sconnect the heater hoses at the engi ne
thermostat housi ng and water pump (Fi g. 48) (Fi g.
49).
(15) Di sconnect the throttl e cabl e.
(16) Di sconnect the speed control cabl e (i f
equi pped).
(17) Di sconnect the l i ne pressure cabl e (i f equi pped
wi th automati c transmi ssi on).
(18) Di sconnect the fuel i njector harness at the
i njectors.
(19) Di sconnect the di stri butor el ectri cal connec-
ti on and the oi l pressure swi tch connector.
STANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE DISCONNECTING FUEL
LINES, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(20) Perform the Fuel System Pressure Rel ease
procedure (refer to Group 14, Fuel System).
(21) Remove the l atch cl i p and di sconnect fuel sup-
pl y l i ne.
(22) Remove the power brake vacuum check val ve
from the booster, i f equi pped.
(23) I f equi pped wi th power steeri ng :
(a) Di sconnect the hoses from the fi tti ngs at the
steeri ng gear.
(b) Drai n the pump reservoi r.
(c) Cap the fi tti ngs on the hoses and steeri ng
gear to prevent forei gn objects from enteri ng the
system.
(24) I denti fy, tag and di sconnect al l necessary wi re
connectors and vacuum hoses.
(26) Di sconnect the wi res from the starter motor
sol enoi d.
(28) Di sconnect the exhaust pi pe from the mani -
fol d.
(29) Di sconnect the engi ne speed sensor wi re con-
necti on.
(30) Remove the exhaust pi pe support.
(31) Remove the fl ywheel and converter housi ng
access cover.
(32) Vehicles with Automatic Transmission:
(a) Mark the converter and dri ve pl ate l ocati on.
(b) Remove the converter-to-dri ve pl ate bol ts.
(33) Remove the upper fl ywheel and converter
housi ng bol ts and l oosen the bottom bol ts.
(34) Remove the engi ne mount cushi on-to-engi ne
compartment bracket bol ts.
(36) Attach a l i fti ng devi ce to the engi ne.
(37) Rai se the engi ne off the front supports.
(38) Pl ace a support or fl oor jack under the con-
verter (or fl ywheel ) housi ng.
Fig. 48 Upper Radiator Hose, Coolant Recovery
Hose, Fan Shroud & Heater hoses
1 UPPER RADIATOR HOSE
2 HEATER HOSES
3 FAN SHROUDS
4 COOLANT RECOVERY HOSE
Fig. 49 Heater Hoses (RH Drive Vehicle)
1 HEATER HOSES
(39) Remove the remai ni ng converter (or fl ywheel )
housi ng bol ts.
(40) Li ft the engi ne out of the engi ne compart-
ment.
INSTALLATION
CAUTION: When installing the engine into a vehicle
equipped with an automatic transmission, be care-
ful not to damage the trigger wheel on the flywheel.
(1) Attach a l i fti ng devi ce to the engi ne and l ower
the engi ne i nto the engi ne compartment. For easi er
i nstal l ati on, i t may be necessary to remove the
engi ne mount cushi ons from the engi ne mount
bracket as an ai de i n al i gnment of the engi ne to the
transmi ssi on.
(2) Vehicles with Manual Transmission:
(a) I nsert the transmi ssi on shaft i nto the cl utch
spl i ne.
(b) Al i gn the fl ywheel housi ng wi th the engi ne.
(c) I nstal l and ti ghten the fl ywheel housi ng
l ower bol ts fi nger ti ght.
(a) Al i gn the transmi ssi on torque converter
housi ng wi th the engi ne.
(b) Loosel y i nstal l the converter housi ng l ower
bol ts and i nstal l the next hi gher bol t and nut on
each si de.
(c) Ti ghten al l 4 bol ts fi nger ti ght.
(4) I nstal l the engi ne mount cushi ons (i f removed).
(5) Lower the engi ne and engi ne mount cushi ons
onto the engi ne compartment brackets. I nstal l the
bol ts and fi nger ti ghten the nuts.
(6) Remove the engi ne l i fti ng devi ce.
(8) I nstal l the remai ni ng fl ywheel and converter
housi ng bol ts. Ti ghten al l bol ts to 38 Nm (28 ft. l bs.)
torque.
(a) I nstal l the converter-to-dri ve pl ate bol ts.
(b) Ensure the i nstal l ati on reference marks are
al i gned.
(10) I nstal l the fl ywheel and converter housi ng
access cover.
(11) I nstal l the exhaust pi pe support and ti ghten
the screw.
(12) Ti ghten the engi ne mount-to-bracket bol ts.
(13) Connect the engi ne speed sensor wi re connec-
ti ons and ti ghten the screws.
(14) Connect the exhaust pi pe to the mani fol d.
(15) I nstal l the starter motor and connect the
cabl e.
(16) Connect the wi res to the starter motor sol e-
noi d.
(18) Connect al l the vacuum hoses and wi re con-
nectors i denti fi ed duri ng engi ne removal .
(19) Vehicles with Power Steering:
(a) Remove the protecti ve caps
(b) Connect the hoses to the fi tti ngs at the steer-
i ng gear. Ti ghten the nut to 52 Nm (38 ft. l bs.)
torque.
(c) Fi l l the pump reservoi r wi th fl ui d.
(20) I nstal l the power brake vacuum check val ve
to the booster, i f equi pped.
(21) Connect the fuel suppl y hose the fuel rai l .
Push unti l a cl i ck i s heard. I nstal l l atch cl i p
(22) Connect the fuel i njector harness to the i njec-
tors.
(23) Connect the di stri butor el ectri cal connector
and oi l pressure swi tch connector.
(24) Connect the l i ne pressure cabl e (i f equi pped
wi th automati c transmi ssi on).
(25) Connect the speed control cabl e, i f equi pped.
(26) Connect the throttl e cabl e.
(27) Connect the heater hoses at the engi ne ther-
mostat housi ng and water pump.
(28) I nstal l the fan assembl y to the i dl er pul l ey.
(29) Connect the sucti on/di scharge hose to the
compressor.
(30) Connect automati c transmi ssi on fl ui d cool er
l i nes, i f equi pped.
(31) I nstal l the fan shroud, el ectri c cool i ng fan and
radi ator and condenser (i f equi pped wi th A/C).
(32) Connect the el ectri c fan connector.
(33) I nstal l upper radi ator support.
(34) Connect the upper radi ator hose.
(35) Connect the l ower radi ator hose.
(36) Al i gn the hood to the scri be marks. I nstal l the
hood.
(37) I nstal l the ai r cl eaner assembl y.
(38) I nstal l the battery and connect the battery
cabl e.
(39) Add the proper amount of engi ne oi l and cool -
ant.
(40) Start the engi ne, i nspect for l eaks and correct
the fl ui d l evel s, as necessary.
(41) Charge the ai r condi ti oni ng system (refer to
Group 24, Heati ng and Ai r Condi ti oni ng for proper
procedures).
INTAKE AND EXHAUST MANIFOLD
REMOVAL
NOTE: THE ENGINE INTAKE AND EXHAUST MANI-
FOLD MUST BE REMOVED AND INSTALLED
TOGETHER. THE MANIFOLDS USE A COMMON
GASKET AT THE CYLINDER HEAD.
(2) Remove ai r cl eaner i nl et hose from the resona-
tor assembl y.
(4) Remove the throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped) and the transmi ssi on l i ne pres-
sure cabl e.
(5) Di sconnect the fol l owi ng el ectri cal connecti ons
and secure thei r harness out of the way:
Throttl e Posi ti on Sensor
I dl e Ai r Control Motor
Cool ant Temperature Sensor (at thermostat
housi ng)
I ntake Ai r Temperature Sensor
Oxygen Sensor
Crank Posi ti on Sensor
Si x (6) Fuel I njector Connectors
Mani fol d Absol ute Pressure (MAP) Sensor.
(6) Di sconnect HVAC, and Brake Booster vacuum
suppl y hoses at the i ntake mani fol d.
(7) Perform the fuel pressure rel ease procedure.
(Refer to Group 14, Fuel Systems for correct proce-
dure)
(8) Di sconnect and remove the fuel system suppl y
l i ne from the fuel rai l assembl y. (Refer to Group 14,
Qui ck Connect Fi tti ngs for correct procedures)
(9) Remove the accessory dri ve bel t (refer to Group
7, Cool i ng System). Loosen the tensi oner.
(10) Remove the power steeri ng pump from the
i ntake mani fol d and set asi de.
(12) Di sconnect the exhaust pi pes from the engi ne
exhaust mani fol ds.
(14) Remove the i ntake mani fol d and engi ne
exhaust mani fol ds.
INSTALLATION
I f the mani fol d i s bei ng repl aced, ensure al l the fi t-
ti ng, etc. are transferred to the repl acement mani -
fol d.
(1) I nstal l a new engi ne exhaust/i ntake mani fol d
gasket over the al i gnment dowel s on the cyl i nder
head.
(2) Posi ti on the engi ne exhaust mani fol ds to the
cyl i nder head. I nstal l fastener Number 3 and fi nger
ti ghten at thi s ti me (Fi g. 50).
(3) I nstal l i ntake mani fol d on the cyl i nder head
dowel s.
(4) I nstal l washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fi g. 50).
(5) I nstal l washer and fastener Numbers 6 and 7
(Fi g. 50).
(6) Ti ghten the fasteners i n sequence and to the
speci fi ed torque (Fi g. 50).
Fastener Numbers 1 through 5Ti ghten to 33
Fastener Numbers 6 and 7Ti ghten to 31 Nm
Fastener Numbers 8 through 11Ti ghten to 33
(7) I nstal l the power steeri ng pump to the i ntake
mani fol d.
(8) I nstal l the accessory dri ve bel t. (Refer to Group
7, Cool i ng System for the correct procedures)
(9) I nstal l the fuel system suppl y l i ne to the fuel
rai l assembl y. Before connecting the fuel supply
line to the fuel rail inspect the O-rings and
replace if necessary. Refer to Group 14, Fuel
System for the correct procedure.
(10) Connect al l el ectri cal connecti ons on the
i ntake mani fol d.
(11) Connect the vacuum hoses previ ousl y
removed.
(12) I nstal l throttl e cabl e, vehi cl e speed control
cabl e (i f equi pped).
(13) I nstal l the transmi ssi on l i ne pressure cabl e (i f
equi pped). Refer to Group 21, Transmi ssi on for the
adjustment procedures.
(14) I nstal l ai r cl eaner assembl y.
(15) Connect ai r i nl et hose to the resonator assem-
bl y.
(17) Connect the exhaust pi pes to the engi ne
exhaust mani fol ds. Ti ghten the bol ts to 31 Nm (23
ft. l bs.)
Fig. 50 Intake and Exhaust Manifolds4.0L
EXHAUST MANIFOLD 4. 0L ENGINE
The i ntake and engi ne exhaust mani fol ds on the
4.0L engi ne must be removed and i nstal l ed together.
The mani fol ds use a common gasket at the cyl i nder
head.
Refer to I ntake Mani fol d4.0L Engi ne i n thi s sec-
ti on for the proper removal and i nstal l ati on proce-
dures.
CYLINDER HEAD COVER
The cyl i nder head cover i s i sol ated from the cyl i n-
der head vi a grommets and a reusabl e mol ded rubber
gasket. The grommet and l i mi ter are retai ned i n the
cyl i nder head cover.
There are two cyl i nder head bol ts that have a pi n
to l ocate the cyl i nder head cover gasket, they are
l ocated at posi ti on 8 and 9 (Fi g. 52)
REMOVAL
(2) Di sconnect the Crankcase Venti l ati on (CCV)
vacuum hose from engi ne cyl i nder head cover.
(3) Di sconnect the fresh ai r i nl et hose from the
engi ne cyl i nder head cover.
(4) Di sconnect the accel erator, transmi ssi on, and
speed (i f equi pped) control cabl es from the throttl e
body (Fi g. 51).
(5) Remove the three bol ts that fasten the control
cabl e bracket to the i ntake mani fol d.
(6) Remove control cabl es from cyl i nder head cover
cl i p.
(7) Posi ti on control cabl es and bracket away from
cyl i nder head cover secure wi th ti e straps.
(8) Remove the engi ne cyl i nder head cover mount-
i ng bol ts.
(9) Remove the engi ne cyl i nder head cover and
gasket.
INSTALLATION
(1) I f a repl acement cover i s i nstal l ed, transfer the
CCV val ve grommet and oi l fi l l er cap from the ori gi -
nal cover to the repl acement cover.
(2) I nstal l cyl i nder head cover and gasket. Ti ghten
the mounti ng bol ts to 10 Nm (85 i n. l bs.) torque.
(3) Connect the CCV hoses.
(4) I nstal l control cabl es and bracket on i ntake
mani fol d and ti ghten bol ts to 8.7 Nm (77 i n. l bs.)
torque.
(5) Connect control cabl es to throttl e body l i nkage.
(6) Snap control cabl es i nto cyl i nder head cover
cl i p.
REMOVAL
(2) Check for rocker arm bri dges whi ch are caus-
i ng mi sal i gnment of the rocker arm to val ve ti p area.
(3) Remove the capscrews at each bri dge and pi vot
assembl y (Fi g. 53). Al ternatel y l oosen the capscrews
one turn at a ti me to avoi d damagi ng the bri dges.
(4) Remove the bri dges, pi vots and correspondi ng
pai rs of rocker arms (Fi g. 53). Pl ace them on a bench
i n the same order as removed.
(5) Remove the push rods and pl ace them on a
bench i n the same order as removed.
INSTALLATION
(1) Lubri cate the bal l ends of the push rods wi th
Mopar Engi ne Oi l Suppl ement, or equi val ent and
i nstal l push rods i n thei r ori gi nal l ocati ons. Ensure
Fig. 51 Engine Cylinder Head Cover
1 TRANS CONTROL CABLE
2 ACCELERATOR CABLE
3 CONTROL CABLE BRACKET
4 CYLINDER HEAD COVER
Fig. 52 Cylinder Head Cover Gasket Locator Pins at
#8 & #9
that the bottom end of each push rod i s centered i n
the tappet pl unger cap seat.
(2) Usi ng Mopar Engi ne Oi l Suppl ement, or equi v-
al ent, l ubri cate the area of the rocker arm that the
pi vot contacts. I nstal l rocker arms, pi vots and bri dge
above each cyl i nder i n thei r ori gi nal l y posi ti on.
(3) Loosel y i nstal l the capscrews through each
bri dge.
(4) At each bri dge, ti ghten the capscrews al ter-
natel y, one turn at a ti me, to avoi d damagi ng the
bri dge. Ti ghten the capscrews to 28 Nm (21 ft. l bs.)
torque.
VALVE SPRINGS AND OIL SEALS
Thi s procedure can be done wi th the engi ne cyl i n-
der head i nstal l ed on the bl ock.
REMOVAL
I nspect the val ve stems, especi al l y the grooves. An
Arkansas smooth stone shoul d be used to remove
ni cks and hi gh spots.
Each val ve spri ng i s hel d i n pl ace by a retai ner
and a set of coni cal val ve l ocks. The l ocks can be
removed onl y by compressi ng the val ve spri ng.
(2) Remove cap screws, bri dge and pi vot assem-
bl i es and rocker arms for access to each val ve spri ng
to be removed.
(3) Remove push rods. Retain the push rods,
order and position as removed.
(4) I nspect the spri ngs and retai ner for cracks and
possi bl e si gns of weakeni ng.
(5) Remove the spark pl ug(s) adjacent to the cyl i n-
der(s) bel ow the val ve spri ngs to be removed.
(6) Connect an ai r hose to the adapter and appl y
ai r pressure sl owl y. Mai ntai n at l east 621 kPa (90
psi ) of ai r pressure i n the cyl i nder to hol d the val ves
agai nst thei r seats. For vehi cl es equi pped wi th an ai r
condi ti oner, use a fl exi bl e ai r adaptor when servi ci ng
the No.1 cyl i nder.
(7) Tap the retai ner or ti p wi th a rawhi de hammer
to l oosen the l ock from the retai ner. Use Val ve Spri ng
Compressor Tool MD-998772A to compress the spri ng
and remove the l ocks (Fi g. 54).
(8) Remove val ve spri ng and retai ner (Fi g. 54).
(9) Remove val ve stem oi l seal s (Fi g. 54). Note the
val ve seal s are di fferent for i ntake and exhaust
val ves. The top of each seal i s marked ei ther I NT
(i ntake/bl ack i n col or) or EXH (exhaust/brown i n
col or). DO NOT mi x the seal s.
1 CAPSCREWS
2 BRIDGE
3 PIVOT ASSEMBLY
4 PUSH RODS
5 ROCKER ARMS
Fig. 54 Valve and Valve Components
1 VALVE LOCKS
(3BEAD)
2 RETAINER
4 INTAKE VALVE
5 EXHAUST VALVE
6 VALVE SPRING
INSTALLATION
CAUTION: Install oil seals carefully to prevent dam-
age from the sharp edges of the valve spring lock
grove.
(1) Li ghtl y push the val ve seal over the val ve stem
and val ve gui de boss. Be sure the seal i s compl etel y
seated on the val ve gui de boss.
(2) I nstal l val ve spri ng and retai ner.
(3) Compress the val ve spri ng wi th Val ve Spri ng
Compressor Tool MD-998772A and i nsert the val ve
l ocks. Rel ease the spri ng tensi on and remove the
tool . Tap the spri ng from si de-to-si de to ensure that
the spri ng i s seated properl y on the engi ne cyl i nder
head.
(4) Rel ease ai r pressure and di sconnect the ai r
hose. Remove the adaptor from the spark pl ug hol e
and i nstal l the spark pl ug.
(5) Repeat the procedures for each remai ni ng val ve
spri ng to be removed.
(6) I nstal l the push rods. Ensure the bottom end of
each rod i s centered i n the pl unger cap seat of the
hydraul i c val ve tappet.
(7) I nstal l the rocker arms, pi vots and bri dge at
thei r ori gi nal l ocati on.
(8) Ti ghten the bri dge cap screws al ternatel y, one
at a ti me, to avoi d damagi ng the bri dge. Ti ghten the
cap screws to 28 Nm (21 ft. l bs.) torque.
CYLINDER HEAD
REMOVAL
SURIZED BECAUSE SERIOUS BURNS FROM THE
COOLANT CAN OCCUR.
(2) Drai n the cool ant and di sconnect the hoses at
the engi ne thermostat housi ng and the water pump
i nl et. DO NOT waste reusabl e cool ant. I f the sol uti on
i s cl ean and i s bei ng drai ned onl y to servi ce the
engi ne or cool i ng system, drai n the cool ant i nto a
(5) Remove the capscrews, bri dge and pi vot assem-
bl i es and rocker arms.
(6) Remove the push rods. Retain the push rods,
order as removed.
(7) Loosen the accessory dri ve bel t at the power
steeri ng pump. (Refer to Group 7, Cool i ng System for
the correct procedure). Sl i p the bel t off of the power
steeri ng pul l ey.
(8) Remove the A/C compressor mounti ng bol ts
and secure the compressor to the si de.
(9) Remove the power steeri ng pump and bracket
from the i ntake mani fol d and water pump. Set the
pump and bracket asi de. DO NOT di sconnect the
hoses.
(10) Perform the Fuel System Pressure Rel ease
procedure. (Refer to Group 14, Fuel System)
(11) Di sconnect the fuel suppl y l i ne at the fuel rai l .
(Refer to Group 14, Qui ck-Connect Fi tti ngs for the
correct procedures)
(12) Remove the i ntake and engi ne exhaust mani -
fol ds from the engi ne cyl i nder head. (Refer to Group
11, Exhaust System and I ntake Mani fol d for the
proper procedures)
(13) Di sconnect the coi l rai l el ectri cal connectors
and remove the coi l rai l .
(14) Remove spark pl ugs.
(15) Di sconnect the temperature sendi ng uni t wi re
connector.
(16) Remove the engi ne cyl i nder head bol ts. Bol t
No.14 cannot be removed unti l the head i s moved for-
ward (Fi g. 55). Pul l bol t No.14 out as far as i t wi l l go
and then suspend the bol t i n thi s posi ti on (tape
around the bol t).
(17) Remove the engi ne cyl i nder head and gasket
(Fi g. 55).
(18) I f thi s was the fi rst ti me the bol ts were
removed, put a pai nt dab on the top of the bol t. I f the
bol ts have a pai nt dab on the top of the bol t or i t
i snt known i f they were used before, di scard the
bol ts.
(19) Stuff cl ean l i nt free shop towel s i nto the cyl -
i nder bores.
NOTE: If the valves, springs, or seals are to be
inspected/replaced at this time, refer to Valves and
Valve Springs in this section for proper inspection
procedures.
INSTALLATION
The engi ne cyl i nder head gasket i s a composi ti on
gasket. The gasket i s to be i nstal l ed DRY. DO NOT
use a gasket sealing compound on the gasket.
I f the engi ne cyl i nder head i s to be repl aced and
the ori gi nal val ves used, measure the val ve stem
di ameter. Onl y standard si ze val ves can be used wi th
a servi ce repl acement engi ne cyl i nder head unl ess
the repl acement head val ve stem gui de bores are
reamed to accommodate oversi ze val ve stems.
Remove al l carbon bui l dup and reface the val ves.
(1) Remove the shop towel s from the cyl i nder
bores. Coat the bores wi th cl ean engi ne oi l .
(2) Posi ti on the engi ne cyl i nder head gasket (wi th
the numbers faci ng up) usi ng the al i gnment dowel s
i n the cyl i nder bl ock, to posi ti on the gasket.
CAUTION: Engine cylinder head bolts should be
reused only once. Replace the head bolts if they
were used before or if they have a paint dab on the
top of the bolt.
(3) Wi th bol t No.14 hel d i n pl ace (tape around
bol t), i nstal l the engi ne cyl i nder head over the same
dowel s used to l ocate the gasket. Remove the tape
from bol t No.14.
(4) Coat the threads of stud bol t No.11 wi th Loc-
ti te 592 seal ant, or equi val ent.
(5) Ti ghten the engi ne cyl i nder head bol ts i n
sequence accordi ng to the fol l owi ng procedure (Fi g.
56).
CAUTION: During the final tightening sequence,
bolt No.11 will be tightened to a lower torque than
the rest of the bolts. DO NOT overtighten bolt
No.11.
(a) Ti ghten al l bol ts i n sequence (1 through 14)
(b) Ti ghten al l bol ts i n sequence (1 through 14)
(c) Check al l bol ts to veri fy they are set to 61
(d) Ti ghten bol ts i n sequence:
torque.
Bol t 11 to 135 Nm (100 ft. l bs.) torque.
torque.
(e) Check al l bol ts i n sequence to veri fy the cor-
rect torque.
(f) I f not al ready done, cl ean and mark each bol t
wi th a dab of pai nt after ti ghteni ng. Shoul d you
encounter bol ts whi ch were pai nted i n an earl i er
servi ce operati on, repl ace them.
(6) I nstal l the spark pl ugs and ti ghten to 37 Nm
(7) Connect the temperature sendi ng uni t wi re
connector.
(8) I nstal l the i gni ti on coi l rai l and coi l rai l el ectri -
cal connectors.
(9) I nstal l the i ntake and engi ne exhaust mani -
fol ds (refer to procedures i n thi s secti on).
(10) I nstal l the fuel l i ne and the vacuum advance
hose.
(11) Attach the power steeri ng pump and bracket.
(12) I nstal l the push rods, rocker arms, pi vots and
bri dges i n the order they were removed (refer to
Rocker Arms and Push Rods i n thi s secti on).
(14) Attach the ai r condi ti oner compressor mount-
i ng bracket to the engi ne cyl i nder head and bl ock.
(15) Attach the ai r condi ti oni ng compressor to the
bracket. Ti ghten the bol ts to 27 Nm (20 ft. l bs.)
torque.
Fig. 55 Engine Cylinder Head Assembly
3 CYLINDER HEAD
CYLINDER HEAD BOLTS
POSITION DESCRIPTION
1,4,5,12,13 1/2 in.-13 BOLT
8,9 1/2 in.-13 BOLT WITH DOWEL
POINT
2,3,6,7,10,11,14 1/2 in.-13 WITH 7/16 in.-14 STUD
END
All bolts are 12 point drives for rocker cover clearance
Fig. 56 Engine Cylinder Head Bolt Tightening
Sequence
CAUTION: The serpentine drive belt must be routed
correctly. Incorrect routing can cause the water
pump to turn in the opposite direction causing the
engine to overheat.
(16) I nstal l the serpenti ne dri ve bel t. (refer to
Group 7, Cool i ng System for the proper procedure).
(17) I nstal l the ai r cl eaner and ducti ng.
(18) Connect the hoses to the engi ne thermostat
housi ng and fi l l the cool i ng system to the speci fi ed
l evel (refer to Group 7, Cool i ng Systems for the
proper procedure).
(19) The automati c transmi ssi on throttl e l i nkage
and cabl e must be adjusted after compl eti ng the
engi ne cyl i nder head i nstal l ati on (refer to Group 21,
Transmi ssi ons for the proper procedures).
(20) I nstal l the temperature sendi ng uni t and con-
nect the wi re connector.
(21) I f equi pped wi th ai r condi ti oni ng, i nstal l A/C
compressor and charge A/C system (refer to Group 24
Heati ng and Ai r Condi ti oni ng).
ENGINE IS OPERATING. DO NOT STAND IN DIRECT
LINE WITH THE FAN. DO NOT PUT HANDS NEAR
THE PULLEYS, BELTS OR FAN. DO NOT WEAR
LOOSE CLOTHING.
(23) Operate the engi ne wi th the radi ator cap off.
I nspect for l eaks and conti nue operati ng the engi ne
unti l the engi ne thermostat opens. Add cool ant, i f
requi red.
VALVES AND VALVE SPRINGS
Thi s procedure i s done wi th the engi ne cyl i nder
head removed from the bl ock.
REMOVAL
(1) Remove the engi ne cyl i nder head from the cyl -
i nder bl ock.
(2) Use Val ve Spri ng Compressor Tool
MD-998772A and compress each val ve spri ng.
(3) Remove the val ve l ocks, retai ners, spri ngs and
val ve stem oi l seal s. Di scard the oi l seal s.
(4) Use a smooth stone or a jewel ers fi l e to remove
any burrs on the top of the val ve stem, especi al l y
around the groove for the l ocks.
(5) Remove the val ves, and pl ace them i n a rack i n
INSTALLATION
(1) Thoroughl y cl ean the val ve stems and the val ve
gui de bores.
(2) Li ghtl y l ubri cate the stem.
(3) I nstal l the val ve i n the ori gi nal val ve gui de
bore.
(4) I nstal l the repl acement val ve stem oi l seal s on
the val ve stems. I f the 0.381 mm (0.015 i nch) over-
si ze val ve stems are used, oversi ze oi l seal s are
requi red.
(5) Posi ti on the val ve spri ng and retai ner on the
engi ne cyl i nder head and compress the val ve spri ng
wi th Val ve Spri ng Compressor Tool MD-998772A.
(6) I nstal l the val ve l ocks and rel ease the tool .
(7) Tap the val ve spri ng from si de to si de wi th a
hammer to ensure that the spri ng i s properl y seated
at the engi ne cyl i nder head. Al so tap the top of the
retai ner to seat the val ve l ocks.
(8) I nstal l the engi ne cyl i nder head.
HYDRAULIC TAPPETS
Retai n al l the components i n the same order as
removed.
REMOVAL
(1) Remove the engi ne cyl i nder head (Refer to cyl -
i nder head r&i i n thi s secti on).
(3) Remove the tappets through the push rod open-
i ngs i n the cyl i nder bl ock wi th a Hydraul i c Val ve
Tappet Removal /I nstal l ati on Tool (Fi g. 57).
INSTALLATION
I t i s not necessary to charge the tappets wi th
engi ne oi l . They wi l l charge themsel ves wi thi n a very
short peri od of engi ne operati on.
(1) Di p each tappet i n Mopar Engi ne Oi l Suppl e-
ment, or equi val ent.
(2) Use Hydraul i c Val ve Tappet Removal /I nstal l a-
ti on Tool to i nstal l each tappet i n the same bore from
where i t was ori gi nal l y removed.
(3) I nstal l the cyl i nder head assy (Refer to cyl i nder
head r&i i n thi s secti on).
(4) I nstal l the push rods i n thei r ori gi nal l ocati ons.
Fig. 57 Hydraulic Valve Tappet Removal
Installation Tool
1 HYDRAULIC TAPPET REMOVAL TOOL
2 CYLINDER BLOCK
9 - 100 4. 0L ENGINE XJ
(5) I nstal l the rocker arms and bri dge and pi vot
assembl i es at thei r ori gi nal l ocati ons. Loosel y i nstal l
the capscrews at each bri dge.
(6) Ti ghten the capscrews al ternatel y, one turn at
a ti me, to avoi d damagi ng the bri dges. Ti ghten the
capscrews to 28 Nm (21 ft. l bs.) torque.
(7) Pour the remai ni ng Mopar Engi ne Oi l Suppl e-
ment, or equi val ent over the enti re val ve actuati ng
assembl y. The Mopar Engi ne Oi l Suppl ement, or
equi val ent must remai n wi th the engi ne oi l for at
l east 1 609 km (1,000 mi l es). The oi l suppl ement
need not be drai ned unti l the next schedul ed oi l
change.
VIBRATION DAMPER
REMOVAL
(2) Remove the serpenti ne dri ve bel t and fan
shroud. Refer to Group 7, Cool i ng Systems for the
procedures.
(3) Remove the vi brati on damper retai ni ng bol t
and washer.
(4) Use Vi brati on Damper Removal Tool 7697 to
remove the damper from the crankshaft (Fi g. 58).
INSTALLATION
Wi th the key i n posi ti on, al i gn the keyway on the
vi brati on damper hub wi th the crankshaft key and
tap the damper onto the crankshaft.
(2) I nstal l the vi brati on damper retai ni ng bol t and
washer.
(3) Ti ghten the damper retai ni ng bol t to 108 Nm
(4) I nstal l the serpenti ne dri ve bel t. (Refer to
Group 7, Cool i ng Systems for the proper speci fi ca-
ti ons and procedures).
TIMING CASE COVER
REMOVAL
(3) Remove the fan and hub assembl y and remove
the fan shroud.
(4) Remove the accessory dri ve brackets that are
attached to the ti mi ng case cover.
(5) Remove the A/C compressor (i f equi pped) and
generator bracket assembl y from the engi ne cyl i nder
head and move to one si de.
(6) Remove the oi l pan-to-ti mi ng case cover bol ts
and ti mi ng case cover-to-cyl i nder bl ock bol ts.
(7) Remove the ti mi ng case cover and gasket from
the engi ne.
(8) Pry the crankshaft oi l seal from the front of the
ti mi ng case cover (Fi g. 59).
INSTALLATION
Cl ean the ti mi ng case cover, oi l pan and cyl i nder
bl ock gasket surfaces.
(1) I nstal l a new crankshaft oi l seal i n the ti mi ng
case cover. The open end of the seal shoul d be toward
the i nsi de of the cover. Support the cover at the seal
area whi l e i nstal l i ng the seal . Force i t i nto posi ti on
wi th Seal I nstal l ati on Tool 6139.
(2) Posi ti on the gasket on the cyl i nder bl ock.
Fig. 58 Vibration Damper Removal Tool 7697
1 VIBRATION DAMPER REMOVAL TOOL
2 WRENCH
1 TIMING CASE COVER
2 OIL SLINGER
XJ 4. 0L ENGINE 9 - 101
(4) I nsert Ti mi ng Case Cover Al i gnment and Seal
I nstal l ati on Tool 6139 i n the crankshaft openi ng i n
and the oi l pan-to-ti mi ng case cover bol ts.
Ti ghten the oi l pan-to-cover 1/4 i nch bol ts to 9.5 Nm
(84 i n. l bs.) torque.
(7) Remove the cover al i gnment tool .
(8) Appl y a l i ght fi l m of engi ne oi l on the vi brati on
damper hub contact surface of the seal .
torque.
(10) I nstal l the A/C compressor (i f equi pped) and
generator bracket assembl y.
(11) I nstal l the engi ne fan and hub assembl y and
shroud.
(12) I nstal l the serpenti ne dri ve bel t.
TIMING CHAIN AND SPROCKETS
REMOVAL
(6) Rotate crankshaft unti l the 0 ti mi ng mark i s
cl osest to and on the center l i ne wi th camshaft
sprocket ti mi ng mark (Fi g. 61).
(7) Remove the oi l sl i nger from the crankshaft.
(8) Remove the camshaft sprocket bol t and washer
(Fi g. 62).
(9) Remove the crankshaft sprocket, camshaft
sprocket and ti mi ng chai n as an assembl y.
INSTALLATION TOOL
Fig. 61 CrankshaftCamshaft Alignment
1 CAMSHAFT SPROCKET
2 TIMING MARKS
Fig. 62 Camshaft Sprocket and Thrust Plate
1 CAMSHAFT
2 CAMSHAFT SPROCKET W/INTEGRAL KEY
3 BOLT & CUP WASHER
4 THRUST PLATE
9 - 102 4. 0L ENGINE XJ
(10) I nstal l ati on of the ti mi ng chai n wi th the ti m-
i ng marks on the crankshaft and camshaft sprockets
properl y al i gned ensures correct val ve ti mi ng. A worn
or stretched ti mi ng chai n wi l l adversel y affect val ve
ti mi ng. I f the ti mi ng chai n defl ects more than 12.7
mm (1/2 i nch) repl ace i t.
INSTALLATION
Assembl e the ti mi ng chai n, crankshaft sprocket
al i gned (Fi g. 61).
Wi th the key i n the keyway on the crankshaft, i nstal l
the assembl y on the crankshaft and camshaft.
(2) I nstal l the camshaft sprocket bol t and washer
(Fi g. 62). Ti ghten the bol t to 68 Nm (50 ft. l bs.)
torque.
chai n, rotate the crankshaft 2 revol uti ons. The cam-
shaft and crankshaft sprocket ti mi ng mark shoul d
al i gn (Fi g. 61).
(4) I nstal l the crankshaft oi l sl i nger.
(5) Repl ace the oi l seal i n the ti mi ng case cover.
(6) I nstal l the ti mi ng case cover and gasket.
(7) Wi th the key i nstal l ed i n the crankshaft key-
way, i nstal l the vi brati on damper, washer and bol t.
torque.
(9) I nstal l the fan and hub assembl y. I nstal l the
shroud.
CAMSHAFT
REMOVAL
ATED ENGINE IS HOT AND PRESSURIZED.
RELEASE THE PRESSURE BEFORE REMOVING
THE DRAIN COCK, CAP AND DRAIN PLUGS.
(2) Drai n the cool i ng system. DO NOT waste reus-
abl e cool ant. I f the sol uti on i s cl ean, drai n i t i nto a
(3) Remove the radi ator or radi ator and condenser,
i f equi pped wi th A/C (refer to Group 7, Cool i ng Sys-
tem for the proper procedure).
(7) Remove the engi ne cyl i nder head and gasket.
(8) Remove the hydraul i c val ve tappets from the
engi ne cyl i nder bl ock.
(11) Rotate the crankshaft unti l the crankshaft
sprocket ti mi ng mark i s al i gned on centerl i ne wi th
the camshaft sprocket ti mi ng mark (Fi g. 64).
(12) Remove the ti mi ng chai n and sprockets.
(13) Remove the front bumper and/or gri l l e, as
requi red.
(14) Remove the two thrust pl ate retai ni ng screws,
thrust pl ate and camshaft (Fi g. 63).
INSTALLATION
(1) I nspect the cam l obes for wear.
(2) I nspect the beari ng journal s for uneven wear
pattern or fi ni sh.
(3) I nspect the beari ngs for wear.
(4) I nspect the di stri butor dri ve gear for wear.
(5) I f the camshaft appears to have been rubbi ng
agai nst the thrust washer, exami ne the oi l pressure
rel i ef hol es i n the rear cam journal . The oi l pressure
rel i ef hol es must be free of debri s.
(6) Lubri cate the camshaft wi th Mopar Engi ne Oi l
Suppl ement, or equi val ent.
age to the camshaft beari ngs (Fi g. 63).
(8) Posi ti on thrust pl ate and i nstal l retai ni ng
screws. Ti ghten screws to 24 Nm (18 ft. l bs.).
(9) I nstal l the ti mi ng chai n, crankshaft sprocket
al i gned.
(10) I nstal l the camshaft sprocket bol t/cup washer.
Ti ghten the bol t to 68 Nm (50 ft. l bs.).
Fig. 63 Camshaft
1 CAMSHAFT
2 CRANKSHAFT
XJ 4. 0L ENGINE 9 - 103
(11) I nstal l the ti mi ng case cover wi th a repl ace-
ment oi l seal (Fi g. 65). Refer to Ti mi ng Case Cover
I nstal l ati on.
(12) I nstal l the vi brati on damper (Fi g. 65).
(13) I nstal l the hydraul i c val ve tappets.
(14) I nstal l the cyl i nder head gasket wi th the
numbers faci ng up.
(15) I nstal l the cyl i nder head and head bol ts
(Refer to cyl i nder head R&I i n thi s secti on for torque
val ues and ti ghteni ng sequence).
(16) I nstal l the push rods.
(17) I nstal l the rocker arms and pi vot and bri dge
assembl i es. Ti ghten each of the capscrews for each
bri dge al ternatel y, one turn at a ti me, to avoi d dam-
agi ng the bri dge (Refer to Rocker Arms and Push
Rods i n thi s secti on).
NOTE: During installation, lubricate the hydraulic
valve tappets and all valve components with Mopar
Engine Oil Supplement, or equivalent. The Mopar
Engine Oil Supplement, or equivalent must remain
with the engine oil for at least 1609 km (1,000
miles). The oil supplement need not be drained until
the next scheduled oil change.
(20) I nstal l the radi ator, connect the hoses and fi l l
the cool i ng system to the speci fi ed l evel (refer to
(21) Check the i gni ti on ti mi ng and adjust as nec-
essary.
(22) I nstal l the gri l l e and bumper, i f removed.
CAMSHAFT BEARINGS
REMOVAL
The camshaft rotates wi thi n four steel -shel l ed, bab-
bi tt-l i ned beari ngs that are pressed i nto the cyl i nder
bl ock and then l i ne reamed. The camshaft beari ng bores
and beari ng di ameters are not the same si ze. They are
stepped down i n 0.254 mm (0.010 i nch) i ncrements from
the front beari ng (l argest) to the rear beari ng (smal l est).
Thi s permi ts easi er removal and i nstal l ati on of the cam-
shaft. The camshaft beari ngs are pressure l ubri cated.
Camshaft end pl ay i s mai ntai ned by the thrust pl ate.
(1) Remove the camshaft. Refer to Camshaft i n
thi s secti on for procedure.
NOTE: It is not advisable to attempt to replace cam-
shaft bearings unless special removal and installa-
tion tools are available, such as recommended tool
8544 Camshaft Bushing Remover Installer.
(2) Usi ng Speci al tool , remove the camshaft bear-
i ngs.
INSTALLATION
(1) I nspect the camshaft beari ng journal s for
uneven wear pattern or fi ni sh.
(2) I nspect the camshaft l obes and di stri butor gear
for wear.
Fig. 64 Crankshaft / Camshaft Sprocket Timing Mark
Alignment
1 CAMSHAFT SPROCKET
2 TIMING MARKS
1 TIMING CASE COVER
2 OIL SLINGER
9 - 104 4. 0L ENGINE XJ
(3) I nspect the camshaft thrust pl ate for wear. I f
the pl ate shows excessi ve wear i nspect the camshaft
oi l pressure rel i ef hol es i n the rear cam jounral . The
rel i ef hol es must be cl ean and free of debri s.
CAUTION: Make sure outside diameter of number 1
bearing is clean. Make sure that the bearing is
properly installed in the engine block, align the oil
hole in the bearing with the oil gallery in the bear-
ing bore. Failure to do so will cause inadequate oil
supply for the sprockets and timing chain.
(4) Usi ng speci al tool , i nstal l new camshaft bear-
i ngs.
(5) Lubri cate the camshaft wi th Mopar engi ne oi l
suppl ement, or equi val ent.
age to the camshaft beari ngs
(7) Posi ti on the thrust pl ate and i nstal l the two
retai ni ng screws. Ti ghten screws to 24 Nm (18 ft.
l bs.).
(8) I nstal l the camshaft sprocket, crankshaft
sprocket and ti mi ng chai n wi th the ti mi ng marks
al i gned. I nstal l the sprocket bol t.
(9) Ti ghten the camshaft sprocket bol t and washer
to 68 Nm (50 ft. l bs.).
chai n, turn the crankshaft two ful l revol uti ons then
posi ti on the camshaft sprocket ti mi ng mark as shown
i n (Fi g. 66).
(11) I nstal l the ti mi ng chai n cover refer to the pro-
cedure i n thi s secti on.
CRANKSHAFT MAIN BEARINGS
REMOVAL
(4) Remove the oi l pan and oi l pump.
(5) Remove mai n beari ng cap brace (Fi g. 67).
(6) Remove onl y one mai n beari ng cap and l ower
i nsert at a ti me (Fi g. 68).
(7) Remove the l ower i nsert from the beari ng cap.
(8) Remove the upper i nsert by LOOSENI NG (DO
NOT REMOVE) al l of the other beari ng caps. Now
i nsert a smal l cotter pi n tool i n the crankshaft jour-
nal oi l hol e. Bend the cotter pi n as i l l ustrated to fab-
ri cate the tool (Fi g. 69). Wi th the cotter pi n tool i n
pl ace, rotate the crankshaft so that the upper bear-
i ng i nsert wi l l rotate i n the di recti on of i ts l ocki ng
tab. Because there i s no hol e i n the No.3 mai n jour-
nal , use a tongue depressor or si mi l ar soft-faced tool
to remove the beari ng i nsert (Fi g. 69). After movi ng
the i nsert approxi matel y 25 mm (1 i nch), i t can be
removed by appl yi ng pressure under the tab.
(9) Usi ng the same procedure descri bed above,
remove the remai ni ng beari ng i nserts one at a ti me
for i nspecti on.
Fig. 66 Crankshaft / Camshaft Chain Drive
InstallationTypical
1 CAMSHAFT SPROCKET
2 TIMING MARKS
Fig. 67 Main Bearing Caps and Brace.
1 BLOCK
XJ 4. 0L ENGINE 9 - 105
INSTALLATION
(1) Lubri cate the beari ng surface of each i nsert
wi th engi ne oi l .
(2) Loosen al l the mai n beari ng caps. I nstal l the
mai n beari ng upper i nserts.
(3) I nstal l the l ower beari ng i nserts i nto the mai n
beari ng caps.
(4) On the rear mai n cap, appl y Mopar Gasket
Maker seal er on both si des of cyl i nder bl ock as
shown i n (Fi g. 70). The dab of seal er shoul d be 3 mm
(0.125 i n.) i n di ameter.
(5) Appl y Mopar Gasket Maker on the rear bear-
i ng cap. The bead shoul d be 2.3 mm (0.09 i n.) i n
di ameter. DO NOT appl y seal er to the l i p of the seal .
(6) I nstal l the mai n beari ng cap(s) and l ower
i nsert(s).
(7) Ti ghten the bol ts of caps 1, 2, 4, 5, 6, and 7 to
54 Nm (40 ft. l bs.) torque. Now ti ghten these bol ts to
95 Nm (70 ft. l bs.) torque. Fi nal l y, ti ghten these
(8) Push the crankshaft forward and backward.
Load the crankshaft front or rear and ti ghten cap
bol t No.3 to 54 Nm (40 ft. l bs.) torque. Then ti ghten
to 95 Nm (70 ft. l bs.) torque and fi nal l y ti ghten to
(9) Rotate the crankshaft after ti ghteni ng each
mai n beari ng cap to ensure the crankshaft rotates
freel y.
(10) Check crankshaft end pl ay. Crankshaft end
pl ay i s control l ed by the thrust beari ng whi ch i s
fl ange and i nstal l ed at the No.2 mai n beari ng posi ti on.
Fig. 68 Removing Main Bearing Caps and Lower
Inserts
1 CONNECTING ROD JOURNAL
2 MAIN BEARING CAPS
Fig. 69 Removing Upper Inserts
1 COTTER PIN
2 BEARING INSERT
3 TONGUE DEPRESSOR
Fig. 70 Location of Sealer
1 DOWEL
2 SEALER LOCATIONS
3 CYLINDER BLOCK
4 HALFWAY BETWEEN
5 REAR FACE OF CYLINDER BLOCK
6 3mm (0.125 in.)
9 - 106 4. 0L ENGINE XJ
(a) Attach a magneti c base di al i ndi cator to the
cyl i nder bl ock at ei ther the front or rear of the
engi ne.
(b) Posi ti on the di al i ndi cator rod so that i t i s
paral l el to the center l i ne of the crankshaft.
(c) Pry the crankshaft forward, posi ti on the di al
i ndi cator to zero.
(d) Pry the crankshaft forward and backward.
Note the di al i ndi cator readi ngs. End pl ay i s the
di fference between the hi gh and l ow measurements
(Fi g. 71). Correct end pl ay i s 0.038-0.165 mm
(0.0015-0.0065 i nch). The desi red speci fi cati ons are
0.051-0.064 mm (0.002-0.0025 i nch).
(e) I f end pl ay i s not wi thi n speci fi cati on, i nspect
crankshaft thrust faces for wear. I f no wear i s
apparent, repl ace the thrust beari ng and measure
end pl ay. I f end pl ay i s sti l l not wi thi n speci fi ca-
ti on, repl ace the crankshaft.
(11) I f the crankshaft was removed, i nstal l the
crankshaft i nto the cyl i nder bl ock (refer to Cyl i nder
Bl ock - Assembl e).
(12) I nstal l mai n beari ng cap brace ti ghten nuts to
(13) I nstal l oi l pump assy. and ti ghten attachi ng
bol ts to 23 Nm (17 ft. l bs.)
(17) I nstal l the spark pl ugs. Ti ghten the pl ugs to
(18) Fi l l the oi l pan wi th engi ne oi l to the ful l
mark on the di psti ck l evel .
OIL PAN
REMOVAL
(3) Remove the oi l pan drai n pl ug and drai n the
engi ne oi l .
(4) Di sconnect the exhaust pi pe at the exhaust
mani fol d.
(5) Di sconnect the exhaust hanger at the catal yti c
converter and l ower the pi pe.
(7) Remove the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(8) I f equi pped wi th an oi l l evel sensor, di sconnect
the sensor.
(9) Posi ti on a jack stand di rectl y under the engi ne
vi brati on damper.
(10) Pl ace a pi ece of wood (2 x 2) between the jack
stand and the engi ne vi brati on damper.
(11) Remove the engi ne mount through bol ts.
(12) Usi ng the jack stand, rai se the engi ne unti l
adequate cl earance i s obtai ned to remove the oi l pan.
(13) Remove transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
are attached to the oi l pan studs.
(14) Remove the oi l pan bol ts and studs. Careful l y
sl i de the oi l pan and gasket to the rear. I f equi pped
wi th an oi l l evel sensor, take care not to damage the
sensor.
INSTALLATION
(1) Cl ean the bl ock and pan gasket surfaces.
(2) Fabri cate 4 al i gnment dowel s from 1 1/2 x 1/4
i nch bol ts. Cut the head off the bol ts and cut a sl ot
i nto the top of the dowel . Thi s wi l l al l ow easi er
i nstal l ati on and removal wi th a screwdri ver (Fi g. 72).
Fig. 71 Crankshaft End Play Measurement
1 DIAL INDICATOR
2 CRANKSHAFT
Fig. 72 Fabrication of Alignment Dowels
1 1/4 1 1/2 BOLT
2 DOWEL
3 SLOT
XJ 4. 0L ENGINE 9 - 107
(3) I nstal l two dowel s i n the ti mi ng case cover.
I nstal l the other two dowel s i n the cyl i nder bl ock
(Fi g. 73).
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 74).
(5) Sl i de the one-pi ece gasket over the dowel s and
onto the bl ock and ti mi ng case cover.
(6) Posi ti on the oi l pan over the dowel s and onto
the gasket. I f equi pped wi th an oi l l evel sensor, take
care not to damage the sensor.
(7) I nstal l the 1/4 i nch oi l pan bol ts. Ti ghten these
bol ts to 9.5 Nm (84 i n. l bs.) torque. I nstal l the 5/16
i nch oi l pan bol ts (Fi g. 75). Ti ghten these bol ts to 15
(8) Remove the dowel s. I nstal l the remai ni ng 1/4
i nch oi l pan bol ts. Ti ghten these bol ts to 9.5 Nm (84
i n. l bs.) torque.
(9) Lower the engi ne unti l i t i s properl y l ocated on
the engi ne mounts.
(10) I nstal l the through bol ts and ti ghten the nuts.
(11) Lower the jack stand and remove the pi ece of
wood.
(12) I nstal l the engi ne fl ywheel and transmi ssi on
torque converter housi ng access cover.
(13) I nstal l the engi ne starter motor.
(14) Connect the exhaust pi pe to the hanger and to
the engi ne exhaust mani fol d.
(15) I nstal l transmi ssi on oi l cool i ng l i nes (i f
equi pped) and oxygen sensor wi ri ng supports that
attach to the oi l pan studs.
(16) I nstal l the oi l pan drai n pl ug (Fi g. 75).
Ti ghten the pl ug to 34 Nm (25 ft. l bs.) torque.
(19) Fi l l the oi l pan wi th engi ne oi l to the speci fi ed
l evel .
PISTONS AND CONNECTING RODS
REMOVAL
(4) Remove the engi ne cyl i nder head.
(5) Posi ti on the pi stons one at a ti me near the bot-
tom of the stroke. Use a ri dge reamer to remove the
Fig. 73 Position of Dowels in Cylinder Block
1 DOWEL HOLES
2 CYLINDER BLOCK
3 5/16 HOLES
4 5/16 HOLES
Fig. 74 Oil Pan Sealer Location
1 SEALER LOCATIONS
Fig. 75 Position of 5/16 inch Oil Pan Bolts
1 OIL PAN
9 - 108 4. 0L ENGINE XJ
ri dge from the top end of the cyl i nder wal l s. Use a
protecti ve cl oth to col l ect the cutti ngs.
(9) Remove mai n beari ng cap brace (Fi g. 76).
(10) Remove the connecti ng rod beari ng caps and
i nserts. Mark the caps and rods wi th the cyl i nder
bore l ocati on. The connecti ng rods and caps are
stamped wi th a two l etter combi nati on (Fi g. 77).
(11) Lower the vehi cl e unti l i t i s about 2 feet from
the fl oor.
CAUTION: Ensure that the connecting rod bolts DO
walls. Short pieces of rubber hose, slipped over the
rod bolts will provide protection during removal.
(12) Have an assi stant push the pi ston and con-
necti ng rod assembl i es up and through the top of the
cyl i nder bores (Fi g. 78).
INSTALLATION
(1) Cl ean the cyl i nder bores thoroughl y. Appl y a
l i ght fi l m of cl ean engi ne oi l to the bores wi th a cl ean
l i nt-free cl oth.
(2) I nstal l the pi ston ri ngs on the pi stons i f
removed.
(3) Lubri cate the pi ston and ri ngs wi th cl ean
engi ne oi l .
CAUTION: Ensure that connecting rod bolts DO
walls. Short pieces of rubber hose slipped over the
connecting rod bolts will provide protection during
installation.
Fig. 76 Main Bearings Caps and Brace
1 BLOCK
Fig. 77 Stamped Connecting Rods and Caps
1 CONNECTING ROD CAP
2 CONNECTING ROD
Fig. 78 Removal of Connecting Rod and Piston
Assembly
1 PISTON
2 CONNECTING ROD
3 BLOCK
XJ 4. 0L ENGINE 9 - 109
(4) Use a pi ston ri ng compressor to i nstal l the con-
necti ng rod and pi ston assembl i es through the top of
the cyl i nder bores (Fi g. 79).
(5) Ensure the arrow on the pi ston top poi nts to
the front of the engi ne (Fi g. 79).
(7) Each beari ng i nsert i s fi tted to i ts respecti ve
journal to obtai n the speci fi ed cl earance between the
beari ng and the journal . I n producti on, the sel ect fi t
i s obtai ned by usi ng vari ous-si zed, col or-coded bear-
i ng i nserts as l i sted i n the Connecti ng Rod Beari ng
Fi tti ng Chart. The col or code appears on the edge of
the beari ng i nsert. The si ze i s not stamped on i nserts
used for producti on of engi nes.
(8) The rod journal i s i denti fi ed duri ng the engi ne
producti on by a col or-coded pai nt mark on the adja-
cent cheek or counterwei ght toward the fl ange (rear)
end of the crankshaft. The col or codes used to i ndi -
cate journal si zes are l i sted i n the Connecti ng Rod
Beari ng Fi tti ng Chart.
(9) When requi red, upper and l ower beari ng
i nserts of di fferent si zes may be used as a pai r (refer
to Connecti ng Rod Beari ng Fi tti ng Chart). A stan-
dard si ze i nsert i s someti mes used i n combi nati on
wi th a 0.025 mm (0.001 i nch) undersi ze i nsert to
reduce cl earance 0.013 mm (0.0005 i nch).
CAUTION: DO NOT intermix bearing caps. Each
connecting rod and bearing cap are stamped with
the cylinder number. The stamp is located on a
machined surface adjacent to the oil squirt hole
that faces the camshaft side of the cylinder block.
(10) I nstal l the connecti ng rod beari ng caps and
i nserts i n the same posi ti ons as removed.
CAUTION: Verify that the oil squirt holes in the
rods face the camshaft and that the arrows on the
pistons face the front of the engine.
(11) I nstal l mai n beari ng cap brace (Fi g. 76).
Ti ghten nuts to 47 Nm (35 ft. l bs.).
(12) I nstal l the oi l pan and gaskets as outl i ned i n
the i nstal l ati on procedure.
(14) I nstal l the engi ne cyl i nder head, push rods,
rocker arms, bri dges, pi vots and engi ne cyl i nder head
cover.
(15) Fi l l the crankcase wi th engi ne oi l .
CRANKSHAFT OIL SEALS REAR
The crankshaft rear mai n beari ng oi l seal consi sts
of two hal f pi eces of vi ton wi th a si ngl e l i p that effec-
ti vel y seal s the rear of the crankshaft. Repl ace the
upper and l ower seal hal ves as a uni t to ensure l eak-
free operati on.
REMOVAL
(1) Remove transmi ssi on i nspecti on cover.
(2) Remove oi l pan. Refer to procedure i n thi s sec-
ti on
(3) Remove mai n beari ng cap brace.
(4) Remove rear mai n beari ng cap (No.7).
(5) Push upper seal out of the groove. Ensure that
the crankshaft and seal groove are not damaged.
(6) Remove l ower hal f of the seal from the beari ng
cap.
INSTALLATION
(1) Wi pe the seal surface area of the crankshaft
unti l i t i s cl ean.
(2) Appl y a thi n coat of engi ne oi l .
(3) Coat l i p of the seal wi th engi ne oi l .
(4) Careful l y posi ti on the upper seal i nto the
groove i n the cyl i nder bl ock. The l i p of the seal faces
toward the front of the engi ne.
(5) Appl y Mopar Gasket Maker seal er on both
si des of cyl i nder bl ock as shown i n (Fi g. 80). The dab
of seal er shoul d be 3 mm (0.125 i n.) i n di ameter.
(6) Appl y Mopar Gasket Maker on the rear bear-
i ng cap (Fi g. 80). The bead shoul d be 2.3 mm (0.09
i n.) i n di ameter. DO NOT appl y seal er to the l i p of
the seal .
(7) Posi ti on the l ower seal i nto the beari ng cap
recess and seat i t fi rml y. Be sure the seal i s fl ush
wi th the cyl i nder bl ock pan rai l .
(8) Coat the outer curved surface of the l ower seal
wi th soap and the l i p of the seal wi th engi ne oi l .
(9) I nstal l the rear mai n beari ng cap. DO NOT
stri ke the cap more than twi ce for proper engage-
ment.
(10) Ti ghten al l mai n beari ng bol ts to 108 Nm (80
ft. l bs.) torque.
(11) I nstal l the mai n beari ng cap brace. Ti ghten
nuts to 47 Nm (35 ft. l bs.).
(12) I nstal l the oi l pan gasket and oi l pan. Ti ghten
1/4 20 screws to 14 Nm (120 i n. l bs.). Ti ghten 5/16
18 screws to 18 Nm (156 i n. l bs.)
9 - 110 4. 0L ENGINE XJ
ant on cyl i nder bl ock to rear mai n beari ng cap cor-
ners and cyl i nder bl ock to front cover joi nts (four
pl aces) (Fi g. 81)
(14) I nstal l transmi ssi on i nspecti on cover.
OIL PUMP
A gear-type oi l pump i s mounted at the undersi de
of the cyl i nder bl ock opposi te the No.4 mai n beari ng.
The pump i ncorporates a nonadjustabl e pressure
rel i ef val ve to l i mi t maxi mum pressure to 517 kPa
(75 psi ). I n the rel i ef posi ti on, the val ve permi ts oi l to
bypass through a passage i n the pump body to the
i nl et si de of the pump.
Oi l pump removal or repl acement wi l l not affect
the di stri butor ti mi ng because the di stri butor dri ve
gear remai ns i n mesh wi th the camshaft gear.
REMOVAL
(2) Remove the oi l pan.
(3) Remove the pump-to-cyl i nder bl ock attachi ng
bol ts. Remove the pump assembl y wi th gasket (Fi g.
82).
CAUTION: If the oil pump is not to be serviced, DO
NOT disturb position of oil inlet tube and strainer
assembly in pump body. If the tube is moved within
the pump body, a replacement tube and strainer
assembly must be installed to assure an airtight
seal.
Fig. 80 Location of Sealer
1 DOWEL
2 SEALER LOCATIONS
3 CYLINDER BLOCK
4 HALFWAY BETWEEN
5 REAR FACE OF CYLINDER BLOCK
6 3mm (0.125 in.)
Fig. 81 Oil Pan Sealer Location
1 SEALER LOCATIONS
1 OIL FILTER ADAPTOR
2 BLOCK
3 GASKET
4 OIL INLET TUBE
5 OIL PUMP
6 STRAINER ASSEMBLY
7 ATTACHING BOLTS
XJ 4. 0L ENGINE 9 - 111
INSTALLATION
(1) I nstal l the oi l pump on the cyl i nder bl ock usi ng
a repl acement gasket. Ti ghten the bol ts to 23 Nm
(3) Fi l l the oi l pan wi th oi l to the speci fi ed l evel .
TIMING CASE COVER OIL SEAL
Thi s procedure i s done wi th the ti mi ng case cover
i nstal l ed.
REMOVAL
(4) Remove the radi ator shroud.
(5) Careful l y remove the oi l seal . Make sure seal
bore i s cl ean.
INSTALLATION
(1) Posi ti on the repl acement oi l seal on Ti mi ng
Case Cover Al i gnment and Seal I nstal l ati on Tool
6139 wi th seal open end faci ng i nward. Appl y a l i ght
fi l m of Perfect Seal , or equi val ent, on the outsi de
di ameter of the seal . Li ghtl y coat the crankshaft wi th
engi ne oi l .
(2) Posi ti on the tool and seal over the end of the
crankshaft and i nsert a draw screw tool i nto Seal
I nstal l ati on Tool 6139 (Fi g. 83). Ti ghten the nut
agai nst the tool unti l i t contacts the cover.
(3) Remove the tool s. Appl y a l i ght fi l m of engi ne
oi l on the vi brati on damper hub contact surface of
the seal .
torque.
(5) I nstal l the serpenti ne bel t and ti ghten to the
speci fi ed tensi on (refer to Group 7, Cool i ng Systems
for the proper speci fi cati ons and procedures).
(6) I nstal l the radi ator shroud.
CYLINDER BLOCK
DISASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) Drai n the engi ne oi l . Remove and di scard the
oi l fi l ter.
(2) Remove the water pump from the cyl i nder
bl ock.
(4) Remove the ti mi ng case cover and l ay the cover
upsi de down.
(5) Posi ti on a dri ft punch i nto the sl ot i n the back
of the cover and tap the ol d seal out.
(6) Remove the oi l sl i nger from crankshaft.
remove the sprockets and chai n as an assembl y.
(8) Remove the camshaft.
(10) Remove the front and rear oi l gal l ey pl ugs.
(11) Remove the oi l pump.
(12) Remove the connecti ng rods and the pi stons.
Remove the connecti ng rod and pi ston assembl i es
(13) Remove the crankshaft.
ASSEMBLY
Refer to the appl i cabl e secti ons for detai l ed
i nstructi ons.
(1) I nstal l the crankshaft.
(2) I nstal l the connecti ng rods and the pi stons
(3) I nstal l the oi l pump.
(4) I nstal l the oi l pan and gasket.
(5) I nstal l the camshaft.
(6) I nstal l the sprockets and chai n as an assembl y.
(7) I nstal l the oi l sl i nger from the crankshaft.
(8) I nstal l the ti mi ng case cover seal .
(9) I nstal l the ti mi ng case cover.
(11) I nstal l the water pump. Ti ghten the mounti ng
Fig. 83 Timing Case Cover Oil Seal Installation
1 SEAL INSTALLATION TOOL
2 DRAW SCREW TOOL
9 - 112 4. 0L ENGINE XJ
(12) Lubri cate the oi l fi l ter seal wi th cl ean engi ne
oi l . Ti ghten oi l fi l ter to 18 Nm (156 i n. l bs.) torque.
(13) I nstal l the engi ne i nto the vehi cl e.
(14) Fi l l the engi ne wi th cl ean l ubri cati on oi l (refer
to Group 0, Lubri cati on and Mai ntenance).
CYLINDER HEAD
CLEANING
Thoroughl y cl ean the engi ne cyl i nder head and cyl -
i nder bl ock mati ng surfaces. Cl ean the i ntake and
engi ne exhaust mani fol d and engi ne cyl i nder head
mati ng surfaces. Remove al l gasket materi al and car-
bon.
Check to ensure that no cool ant or forei gn materi al
has fal l en i nto the tappet bore area.
Remove the carbon deposi ts from the combusti on
chambers and top of the pi stons.
INSPECTION
Use a strai ghtedge and feel er gauge to check the
fl atness of the engi ne cyl i nder head and bl ock mati ng
surfaces.
CYLINDER HEAD COVER
CLEANING
Remove any ori gi nal seal er from the cover seal i ng
surface of the engi ne cyl i nder head and cl ean the
surface usi ng a fabri c cl eaner.
Remove al l resi due from the seal i ng surface usi ng
a cl ean, dry cl oth.
INSPECTION
I nspect the engi ne cyl i nder head cover for cracks.
Repl ace the cover, i f cracked.
The ori gi nal dark grey gasket materi al shoul d
NOT be removed. I f secti ons of the gasket materi al
are mi ssi ng or are compressed, repl ace the engi ne
cyl i nder head cover. However, secti ons wi th mi nor
damage such as smal l cracks, cuts or chi ps may be
repai red wi th a hand hel d appl i cator. The new mate-
ri al must be smoothed over to mai ntai n gasket
hei ght. Al l ow the gasket materi al to cure pri or to
engi ne cyl i nder head cover i nstal l ati on.
CLEANING
Cl ean al l the components wi th cl eani ng sol vent.
Use compressed ai r to bl ow out the oi l passages i n
the rocker arms and push rods.
INSPECTION
I nspect the pi vot surface area of each rocker arm.
Repl ace any that are scuffed, pi tted, cracked or
excessi vel y worn.
I nspect the val ve stem ti p contact surface of each
rocker arm and repl ace any rocker arm that i s deepl y
pi tted.
I nspect each push rod end for excessi ve wear and
repl ace as requi red. I f any push rod i s excessi vel y
worn because of l ack of oi l , repl ace i t and i nspect the
correspondi ng hydraul i c tappet for excessi ve wear.
I nspect the push rods for strai ghtness by rol l i ng
them on a fl at surface or by shi ni ng a l i ght between
the push rod and the fl at surface.
A wear pattern al ong the l ength of the push rod i s
not normal . I nspect the engi ne cyl i nder head for
obstructi on i f thi s condi ti on exi sts.
HYDRAULIC TAPPETS
CLEANING
Cl ean each tappet assembl y i n cl eani ng sol vent to
remove al l varni sh, gum and sl udge deposi ts.
INSPECTION
I nspect for i ndi cati ons of scuffi ng on the si de and
base of each tappet body.
I nspect each tappet base for concave wear wi th a
strai ghtedge posi ti oned across the base. I f the base i s
concave, the correspondi ng l obe on the camshaft i s
al so worn. Repl ace the camshaft and defecti ve tap-
pets.
After cl eani ng and i nspecti on, test each tappet for
speci fi ed l eak-down rate tol erance to ensure zero-l ash
operati on (Fi g. 84).
Swi ng the wei ghted arm of the hydraul i c val ve tap-
pet tester away from the ram of the Leak-Down
Tester.
(1) Pl ace a 7.925-7.950 mm (0.312-0.313 i nch)
di ameter bal l beari ng on the pl unger cap of the tap-
pet.
(2) Li ft the ram and posi ti on the tappet (wi th the
bal l beari ng) i nsi de the tester cup.
(3) Lower the ram, then adjust the nose of the ram
unti l i t contacts the bal l beari ng. DO NOT ti ghten
the hex nut on the ram.
(4) Fi l l the tester cup wi th hydraul i c val ve tappet
test oi l unti l the tappet i s compl etel y submerged.
(5) Swi ng the wei ghted arm onto the push rod and
pump the tappet pl unger up and down to remove ai r.
When the ai r bubbl es cease, swi ng the wei ghted arm
away and al l ow the pl unger to ri se to the normal
posi ti on.
(6) Adjust the nose of the ram to al i gn the poi nter
wi th the SET mark on the scal e of the tester and
ti ghten the hex nut.
XJ 4. 0L ENGINE 9 - 113
(7) Sl owl y swi ng the wei ghted arm onto the push
rod.
(8) Rotate the cup by turni ng the handl e at the
base of the tester cl ockwi se one revol uti on every 2
seconds.
(9) Observe the l eak-down ti me i nterval from the
i nstant the poi nter al i gns wi th the START mark on
the scal e unti l the poi nter al i gns wi th the 0.125
mark. A normal l y functi oni ng tappet wi l l requi re
20-110 seconds to l eak-down. Di scard tappets wi th
l eak-down ti me i nterval not wi thi n thi s speci fi cati on.
CYLINDER BLOCK
CLEANING
Thoroughl y cl ean the oi l pan and engi ne bl ock gas-
ket surfaces.
Use compressed ai r to cl ean out:
The gal l ey at the oi l fi l ter adaptor hol e.
The front and rear oi l gal l ey hol es.
The feed hol es for the crankshaft mai n beari ngs.
Once the bl ock has been compl etel y cl eaned, appl y
Locti te PST pi pe seal ant wi th Tefl on 592 to the
threads of the front and rear oi l gal l ey pl ugs. Ti ghten
the pl ugs to 34 Nm (25 ft. l bs.) torque.
INSPECTION
(1) I t i s mandatory to use a di al bore gauge to
measure each cyl i nder bore di ameter (Fi g. 85). To
correctl y sel ect the proper si ze pi ston, a cyl i nder bore
gauge, capabl e of readi ng i n 0.003 mm (.0001 i n.)
I NCREMENTS i s requi red. I f a bore gauge i s not
avai l abl e, do not use an i nsi de mi crometer.
bore at three l evel s bel ow top of bore. Start perpen-
di cul ar (across or at 90 degrees) to the axi s of the
crankshaft and then take two addi ti onal readi ng.
(3) Measure the cyl i nder bore di ameter crosswi se
to the cyl i nder bl ock near the top of the bore. Repeat
the measurement near the mi ddl e of the bore, then
repeat the measurement near the bottom of the bore.
(4) Determi ne taper by subtracti ng the smal l er
di ameter from the l arger di ameter.
(5) Rotate measuri ng devi ce 90 and repeat steps
above.
(6) Determi ne out-of-roundness by compari ng the
di fference between each measurement.
(7) I f cyl i nder bore taper does not exceed 0.025
mm (0.001 i nch) and out-of-roundness does not
exceed 0.025 mm (0.001 i nch), the cyl i nder bore can
be honed. I f the cyl i nder bore taper or out- of-round
condi ti on exceeds these maxi mum l i mi ts, the cyl i nder
must be bored and then honed to accept an oversi ze
pi ston. A sl i ght amount of taper al ways exi sts i n the
cyl i nder bore after the engi ne has been i n use for a
peri od of ti me.
Fig. 84 Leak-Down Tester
1 POINTER
2 WEIGHTED ARM
3 RAM
4 CUP
5 HANDLE
6 PUSH ROD
Fig. 85 Cylinder Bore Measurement
9 - 114 4. 0L ENGINE XJ
SPECIFICATIONS
SPECIFICATIONS
4.0L ENGINE
Engine Type In-line 6 Cylinder
Bore and Stroke 98.4 x 86.69 mm
(3.88 x 3.413 in.)
Displacement 4.0L (242 cu. in.)
Compression Ratio 8.8:1
Firing Order 153624
Lubrication Pressure FeedFull Flow
Filtration
Cooling System Liquid CooledForced
Circulation
Cylinder Block Cast Iron
Crankshaft Cast Nodular Iron
Cylinder Head Cast Iron
Camshaft Cast Iron
Pistons Aluminum Alloy
Combustion Chamber Dual-Quench
Connecting Rods Cast Malleable Iron
CAMSHAFT
Hydraulic Tappet
Clearance
Zero Lash
(0.001 to 0.003 in.)
Bearing Journal Diameter
No. 1 51.54 to 51.56 mm
(2.029 to 2.030 in.)
No. 2 51.28 to 51.31 mm
(2.019 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.)
Base Circle Runout
(MAX)
0.03 mm
(0.001 in.)
Valve Lift
Intake 10.350 mm (0.4075 in.)
Exhaust 10.528 mm (0.4145 in.)
Valve Timing
Intake
Opens 12.4BTDC
Closes 60.9ABDC
Exhaust
Opens 49.8 BBDC
Closes 29.2ATDC
Valve Overlap 41.6
Intake Duration 253.3
Exhaust Duration 259.
CRANKSHAFT
End Play 0.038 to 0.165 mm
(0.0015 to 0.0065 in.)
Diameter
No. 1-6 63.489 to 63.502 mm
(2.4996 to 2.5001 in.)
No. 7 63.449 to 63.487 mm
(2.4980 to 2.4995 in.)
Width
No. 1 27.58 to 27.89 mm
(1.086 to 1.098 in.)
No. 3 32.28 to 32.33 mm
(1.271 to 1.273 in.)
No. 2-4-5-6-7 30.02 to 30.18 mm
(1.182 to 1.188 in.)
Main Bearing Clearance 0.03 to 0.06 mm
(0.001 to 0.0025 in.)
Preferred 0.051 mm (0.002 in.)
XJ 4. 0L ENGINE 9 - 115
Diameter 53.17 to 53.23 mm
(2.0934 to 2.0955 in.)
Width
27.18 to 27.33 mm
(1.070 to 1.076 in.)
Out-of-Round (MAX) 0.013 mm (0.0005 in.)
Taper (MAX) 0.013 mm (0.0005 in.)
CYLINDER BLOCK
Deck Height 240.03 to 240.18 mm
(9.450 to 9.456 in.)
Deck Clearance (Below
Block)
0.546 mm (0.0215 in.)
Standard 98.45 to 98.48 mm
(3.8759 to 3.8775 in.)
Taper 0.025 mm (0.001 in.)
Out-ofRound 0.025 mm (0.001 in.)
Tappet Bore Diameter 23.000 to 23.025 mm
(0.9055 to 0.9065 in.)
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
Flatness Max. 0.20 mm max. for total
length
(0.008 in. max. for total
length)
Main Bearing Bore
Diameter
68.3514 to 68.3768 mm
(2.691 to 2.692 in.)
CONNECTING ROD
Total Weight (Less
Bearing)
663 to 671 grams
(23.39 to 23.67 oz.)
Length (Center-to-Center) 155.52 to 155.62 mm
(6.123 to 6.127 in.)
(0.9288 to 0.9298 in.)
Bore (Less Bearings) 56.08 to 56.09 mm
(2.2080 to 2.2085 in.)
(0.001 to 0.003 in.)
Preferred 0.044 to 0.050 mm
(0.0015 to 0.0020 in.)
Side Clearance 0.25 to 0.48 mm
(0.010 to 0.019 in.)
Twist (Max.) 0.002 mm per mm
(0.002 in. per inch)
Bend (Max.) 0.002 mm per mm
(0.002 in. per inch.)
CYLINDER COMPRESSION PRESSURE
Pressure Range 827 to 1,034 kPa
(120 to 150 psi)
Max. Variation Between
Cylinders 206 kPa (30 psi)
CYLINDER HEAD
Combustion Chamber 55.22 to 58.22 cc
(3.37 to 3.55 cu. in.)
Valve Guide I. D.
(Integral)
7.95 to 7.97 mm
(0.313 to 0.314 in.)
Valve Stem-to-Guide 0.025 to 0.076 mm
Clearance (0.001 to 0.003 in.)
Valve Seat Angle
Intake 44.5
Exhaust 44.5
Valve Seat Width 1.02 to 1.52 mm
(0.040 to 0.060 in.)
Valve Seat Runout 0.064 mm (0.0025 in.)
(0.001 in. per 1 in.)
0.05 mm per 152 mm
(0.002 in. per 6 in.)
9 - 116 4. 0L ENGINE XJ
Flatness Max. 0.20 mm - max. for total
length
(0.008 in. max. for total
length)
ROCKER ARMS, PUSH RODS & TAPPETS
Rocker Arm Ratio 1.6:1
Push Rod Length 244.856 to 245.364 mm
(Pink) (9.640 to 9.660 in.)
Push Rod Diameter 7.92 to 8.00 mm
(0.312 to 0.315 in.)
Hydraulic Tappet
Diameter
22.962 to 22.974 mm
(0.904 to 0.9045 in.)
Tappet-to-Bore Clearance 0.025 to 0.063 mm
(0.001 to 0.0025 in.)
VALVES
Valve Length (Overall)
Intake 122.479 to 122.860 mm
(4.822 to 4.837 in.)
Exhaust 122.860 to 123.241 mm
(4.837 to 4.852 in.)
Valve Stem Diameter 7.899 to 7.925 mm
(0.311 to 0.312 in.)
Stem-to-Guide Clearance 0.025 to 0.076 mm
(0.001 to 0.003 in.)
Valve Head Diameter
Intake 48.387 to 48.641 mm
(1.905 to 1.915 in.)
Exhaust 37.973 to 38.227 mm
(1.495 to 1.505 in.)
Valve Face Angle
Intake 46.5
Exhaust 46.5
Tip Refinishing (Max.
Allowable)
0.25 mm (0.010 in.)
VALVE SPRINGS
Free Length (Approx.) 47.65 mm (1.876 in.)
Spring Load
Valve Closed 316 to 351 N @ 41.656
mm
(71 to 79 lbf. @ 1.64 in.)
Valve Open 898.6 to 969.7 N @
30.89 mm
(202 to 218 lbf @ 1.216
in.)
Inside Diameter 21.0 mm to 21.51 mm
(0.827 to 0.847 in.)
Installed Height 41.656 mm (1.64 in.)
PISTONS
Weight (Less Pin) 417 to 429 grams
(14.7 to 15.1 oz.)
Piston Pin Bore
(Centerline
40.61 to 40.72 mm
to Piston Top) (1.599 to 1.603 in.)
Piston-to-Bore Clearance 0.018 to 0.038 mm
(0.0008 to 0.0015 in.)
Ring Gap Clearance
Top Compression Ring 0.229 to 0.610 mm
(0.0090 to 0.0240 in.)
2nd Compression Ring 0.483 to 0.965 mm
(0.0190 to 0.0380 in.)
Oil Control Steel Rails 0.254 to 1.500 mm
(0.010 to 0.060 in.)
Ring Side Clearance
(0.0017 to 0.0033 in.)
Oil Control Rings 0.06 to 0.21 mm
(0.0024 to 0.0083 in.)
Piston Ring Groove
Height
(0.0602 to 0.0612 in.)
(0.1589 to 0.1598 in.)
XJ 4. 0L ENGINE 9 - 117
Piston Ring Groove
Diameter
No.1 Compression Ring 88.39 to 88.65 mm
(3.48 to 3.49 in.)
No.2 Compression Ring 87.63 to 87.88 mm
(3.45 to 3.46 in.)
(3.53 to 3.54 in.)
(0.9312 to 0.9315 in.)
Piston Pin Diameter 23.637 to 23.640 mm
(0.9306 to 0.9307 in.)
Piston-to-Pin Clearance 0.0102 to 0.0208 mm
(0.0005 to 0.0009 in.)
Piston-to-Pin Connecting
Rod (Press Fit) 8.9 kN (2000 lbf.)
OIL PUMP
Gear-to-Body Clearance 0.051 to 0.102 mm
(Radial) (0.002 to 0.004 in.)
Gear-to-Body Clearance
(Radial) Preferred 0.051 mm (0.002 in.)
Gear End Clearance 0.051 to 0.152 mm
Plastigage (0.002 to 0.006 in.)
Gear End Clearance
Plastigage (Preferred) 0.051 mm (0.002 in.)
Gear End Clearance 0.1016 to 0.2032 mm
Feeler Gauge (0.004 to 0.008 in.)
Gear End Clearance
Feeler Gauge (Preferred) 0.1778 mm (0.007 in.)
Oil Pressure
At Idle Speed 89.6 kPa (13 psi)
At 1600 rpm & Higher 255 to 517 kPa
(37 to 75 psi)
Oil Pressure Relief 517 kPa (75 psi)
4.0L ENGINE
Lbs. Lbs.
A/C CompressorBolts 28 250
Block HeaterNut 2 16
Camshaft SprocketBolt 68 50
Camshaft Thrust Plate to
Cylinder BlockScrews 24 18
Clutch Cover to Flywheel
Bolts
54 40
Coil Bracket to BlockBolts 22 192
Connecting RodNuts 45 33
Cylinder BlockDrain Plugs 34 25
Cylinder HeadBolts 135 100
Cylinder Head CoverBolts 10 85
Distributor ClampBolts 23 204
Engine MountsFront
Support Bracket Bolts 61 45
Support Cushion Bolts/Nuts 41 30
Support Cushion Bracket
Bolts
54 40
Support Cushion Bracket Stud
Nuts
41 30
Support Cushion Thru-Bolt 65 48
Engine MountsRear
Crossmember to Sill Bolts
(Automatic) 41 30
Insulator Stud AssemblyNut 41 30
Support Cushion/
Crossmember
Nuts 22 192
Support Cushion/Bracket
Nuts
(Manual) 75 55
BracketBolt
(Manual) 46 34
Transmission Support Bracket/
CushionBolt (4WD Auto) 75 55
Transmission Support Adaptor
BracketBolts (2WD Auto) 75 55
Exhaust Manifold/PipeNuts 27 20
9 - 118 4. 0L ENGINE XJ
Lbs. Lbs.
Intake/Exhaust Manifold
Fasteners #1-5 33 24
Fasteners #6 and 7 14 126
Fasteners #8-11 33 24
Flywheel to Converter
HousingBolts
38 28
Flywheel to CrankshaftBolts 143 105
Front Cover to BlockBolts
1/4-20 7 60
5/16-18 22 192
Fuel RailBolts/Stud 12 108
GeneratorBolts 57 42
Generator Bracket to
EngineBolts
47 35
Idler Pulley to Cylinder
HeadBolt
47 35
Main Bearing CapBolts 108 80
Oil Filter 18 156
Oil Filter Connector to
Adaptor 47 35
Block 68 50
Adaptor Bolts 102 50
Oil GalleyPlug 41 30
Oil PanBolts
1/4-20 9.5 84
5/16-18 15 132
Oil PanDrain Plug 34 25
Oil Pump
Mounting Bolts 23 204
Cover Bolts 8 70
Rocker Arm Assembly to
Cylinder
HeadCapscrews 30 21
Spark Plugs 37 27
Starter MotorMounting Bolts 45 33
Thermostat HousingBolts 18 156
Throttle BodyBolts 10 90
Vibration DamperBolt 108 80
Water Pump to BlockBolts 23 17
SPECIAL TOOLS
4. 0L ENGINE
Valve Spring Compressor Tool MD-998772A
Timing Case Cover Alignment and Seal installation
Tool 6139
Vibration Damper Removal Tool 7697
Hydraulic Valve Tappet Removal/Installation Tool
C-4129A
XJ 4. 0L ENGINE 9 - 119
EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 1
CATALYTIC CONVERTERS . . . . . . . . . . . . . . . . . . 2
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TAILPIPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EXHAUST SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . 4
EXHAUST PIPE. . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CATALYTIC CONVERTER. . . . . . . . . . . . . . . . . . . . 6
MUFFLER AND TAILPIPE . . . . . . . . . . . . . . . . . . . 6
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . 8
EXHAUST SYSTEM
DESCRIPTION
The basi c exhaust system consi sts of exhaust man-
i fol d(s), exhaust pi pe wi th oxygen sensors, catal yti c
converter(s), heat shi el d(s), muffl er and tai l pi pe
(Fi g. 1) (Fi g. 2) (Fi g. 3)
Fig. 1 Exhaust Pipe2.5L
1 NUT
2 TRANSMISSION SUPPORT
3 MINI CATALYTIC CONVERTER
4 EXHAUST PIPE
5 EXHAUST MANIFOLD
Fig. 2 Exhaust Pipe4.0L
1 NUT
2 EXHAUST MANIFOLD
4 EXHAUST PIPE
6 BOLT
XJ EXHAUST SYSTEM 11 - 1
CATALYTIC CONVERTERS
DESCRIPTION
Cal i forni a emi ssi ons vehi cl es i ncorporate two mi ni
catal yti c converters i nto the exhaust system. These
catal yti c converters are made of stai nl ess steel
desi gned to operate at extremel y hi gh temperatures.
The stai nl ess steel catal yti c converter body i s
desi gned to l ast the l i fe of the vehi cl e. Excessi ve heat
can resul t i n bul gi ng or other di storti on, but exces-
si ve heat wi l l not be the faul t of the converter. I f
unburned fuel enters the converter, overheati ng may
occur. I f a converter i s heat-damaged, correct the
cause of the damage at the same ti me the converter
i s repl aced. Al so, i nspect al l other components of the
exhaust system for heat damage.
Unleaded gasoline must be used to avoid con-
taminating the catalyst core.
Fig. 3 Exhaust SystemTypical
1 STUD
2 TAIL PIPE HANGER
3 CLAMP
4 ISOLATOR
5 BOLT
6 TAIL PIPE HANGER
7 NUT
8 MUFFLER
9 CLAMP
10 CATALYTIC CONVERTER
11 HEAT SHIELD
11 - 2 EXHAUST SYSTEM XJ
Federal emi ssi on vehi cl es use onl y one catal yti c
converter, However, Cal i forni a emi ssi on vehi cl es
i ncorporate two mi ni catal yti c converters l ocated
after the exhaust mani fol ds and before the i nl i ne cat-
al yti c converter (Fi g. 4).
MUFFLER
DESCRIPTION
Both the 2.5L and 4.0L engi nes use a gal vani zed
steel muffl er to control exhaust noi se l evel s and
exhaust back pressure.
Fig. 4 4.0L Catalytic Converter and O2 Sensor Configuration(California Emissions only)
1 O2 SENSOR
2 O2 SENSOR
3 O2 SENSOR
4 O2 SENSOR
5 O2 SENSOR
6 O2 SENSOR
Fig. 5 MufflerTypical
1 MUFFLER
TAILPIPE
DESCRIPTION
The tai l pi pe i s al so made of gal vani zed steel .
OPERATION
The tai l pi pe channel s the exhaust out of the muf-
fl er and out from under the vehi cl e to control noi se
and prevent exhaust gas fumes from enteri ng the
passenger compartment.
EXHAUST SYSTEM
EXHAUST SYSTEM DIAGNOSIS CHART
EXCESSIVE EXHAUST NOISE OR
LEAKING EXHAUST GASES
1. Leaks at pipe joints. 1. Tighten clamps/bolts at leaking
joints.
2. Rusted or blown out muffler. 2. Replace muffler. Inspect exhaust
system.
3. Broken or rusted out exhaust
pipe.
3. Replace exhaust pipe.
4. Exhaust pipe leaking at manifold
flange.
4. Tighten/replace flange attaching
nuts/bolts.
5. Exhaust manifold cracked or
broken.
5. Replace exhaust manifold.
6. Leak between exhaust manifold
and cylinder head.
6. Tighten exhaust manifold to
cylinder head bolts.
7. Catalytic converter rusted or
blown out.
7. Replace catalytic converter assy.
8. Restriction in exhaust system. 8. Remove restriction, if possible.
Replace restricted part if necessary.
When servicing and replacing exhaust system components, disconnect the oxygen sensor connector(s). Allowing
the exhaust to hang by the oxygen sensor wires will damage the harness and/or sensor.
Fig. 6 TailpipeTypical
1 TAILPIPE
EXHAUST PIPE
WARNING: IF TORCHES ARE USED WHEN WORK-
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
CAUTION: When servicing exhaust system compo-
nents, disconnect the oxygen sensor connector.
Allowing the exhaust system to hang by the oxygen
sensor harness will damage the wiring and/or sen-
sor.
REMOVAL
(2) Saturate the bol ts and nuts wi th Mopar Rust
Penetrant (Fi g. 7) (Fi g. 8). Al l ow 5 mi nutes for pene-
trati on.
(3) Di sconnect the oxygen sensor connector(s).
(4) Di sconnect the exhaust pi pe from the engi ne
exhaust mani fol d. Di scard the seal (4.0L engi ne,
onl y).
(5) Support the transmi ssi on and remove the rear
crossmember.
(6) Remove the cl amp nuts and cl amp. To remove
the exhaust pi pe from the catal yti c converter, appl y
heat unti l the metal becomes cherry red. Di sconnect
the exhaust pi pe from the catal yti c converter.
Remove the exhaust pi pe.
INSTALLATION
(1) Assembl e exhaust pi pe to mani fol d and cata-
l yti c converter l oosel y to permi t proper al i gnment of
al l parts.
(2) Use a new cl amp and ti ghten the nuts to 61
(3) Connect the exhaust pi pe to the engi ne exhaust
mani fol d (Fi g. 7) (Fi g. 8). I nstal l a new seal between
the exhaust mani fol d and the exhaust pi pe (4.0L
engi ne onl y). Ti ghten the nuts to 31 Nm (23 ft. l bs.)
torque.
(4) I nstal l the rear crossmember. I nstal l and
ti ghten the four (4) crossmember to rear mount nuts
to 22 Nm (16 ft. l bs.) I nstal l and ti ghten the cross-
member to si l l bol ts to 42 Nm (31 ft. l bs.) torque.
Remove the support from the transmi ssi on.
(5) Careful l y coat the threads on the oxygen sen-
sor(s) wi th anti -sei ze compound. I nstal l the sensor
and ti ghten the nut to 27 Nm (20 ft. l bs.) torque.
(7) Start the engi ne and i nspect for exhaust l eaks
and exhaust system contact wi th the body panel s.
Adjust the al i gnment, i f needed.
Fig. 7 Exhaust Pipe Removal2.5L
1 NUT
4 EXHAUST PIPE
5 EXHAUST MANIFOLD
Fig. 8 Exhaust Pipe Removal4.0L
1 NUT
2 EXHAUST MANIFOLD
4 EXHAUST PIPE
6 BOLT
CATALYTIC CONVERTER
THE FLAME NEAR THE FUEL LINES.
sor.
REMOVAL
(2) Remove the cl amps from the catal yti c converter
and muffl er connecti on (Fi g. 9).
(3) Di sconnect and remove the oxygen sensor from
the catal yti c converter.
(4) Heat the catal yti c converter and muffl er con-
necti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(5) Whi l e the metal i s sti l l cherry red, twi st the
muffl er assembl y back and forth to separate i t from
the catal yti c converter.
(6) Di sconnect the exhaust pi pe from the catal yti c
converter (Fi g. 9). I f needed, heat up the pi pes to sep-
arate.
INSTALLATION
(1) Connect the catal yti c converter to the exhaust
pi pe and the muffl er/tai l pi pe assy. (Fi g. 9). Use a new
cl amp and ti ghten the nuts to 61 Nm (45 ft. l bs.)
torque.
(2) I nstal l the muffl er onto the catal yti c converter
unti l the al i gnment tab i s i nserted i nto the al i gn-
ment sl ot.
(3) I nstal l a new cl amp at the muffl er and cata-
l yti c converter connecti on (Fi g. 9). Ti ghten the cl amp
nut to 61 Nm (45 ft. l bs.) torque.
(4) Coat the oxygen sensor wi th anti -sei ze com-
pound. I nstal l the sensor and ti ghten the nut to 27
MUFFLER AND TAILPIPE
Al l ori gi nal equi pment exhaust systems are manu-
factured wi th the exhaust tai l pi pe wel ded to the muf-
fl er. Servi ce repl acement muffl ers and exhaust
tai l pi pes are ei ther cl amped together or wel ded
together.
THE FLAME NEAR THE FUEL LINE.
sor.
REMOVAL
(2) Di sconnect front tai l pi pe hanger from the i nsu-
l ator (Fi g. 10).
(3) Remove the front exhaust cl amp from the cat-
al yti c converter and muffl er connecti on (Fi g. 11).
(4) Heat the catal yti c converter-to-muffl er connec-
ti on wi th an oxyacetyl ene torch unti l the metal
becomes cherry red.
(5) Whi l e the metal i s sti l l cherry red, remove the
exhaust muffl er/tai l pi pe assembl y from the catal yti c
converter.
(6) Sl i de the muffl er/tai l pi pe assy. rearward and
out of the rear exhaust tai l pi pe mounti ng bracket
(Fi g. 11).
Fig. 9 Catalytic Converter to Muffler and Exhaust
Pipe Connection
1 EXHAUST CLAMP ASSEMBLY
2 OXYGEN SENSOR
3 MUFFLER
5 EXHAUST PIPE
(7) Remove the muffl er from the exhaust tai l pi pe:
To remove an ori gi nal equi pment exhaust muf-
fl er/tai l pi pe combi nati on, cut the exhaust tai l pi pe
cl ose to the muffl er. Col l apse the part remai ni ng i n
the muffl er and remove.
To remove a servi ce exhaust tai l pi pe/muffl er
combi nati on, appl y heat unti l the metal becomes
cherry red. Remove the exhaust tai l pi pe/muffl er
cl amp and twi st the exhaust tai l pi pe out of the muf-
fl er.
INSTALLATION
(1) I nstal l the muffl er onto the catal yti c converter.
I nstal l the cl amp and ti ghten the nut fi nger ti ght.
(2) I nstal l the exhaust tai l pi pe i nto the rear of the
muffl er.
(3) I nstal l the exhaust tai l pi pe/muffl er assembl y
on the rear exhaust tai l pi pe mounti ng bracket. Make
sure that the exhaust tai l pi pe has suffi ci ent cl ear-
ance from the fl oor pan.
(4) I nstal l front tai l pi pe hanger i nto the i nsul ator
(Fi g. 10).
(5) Al i gn the muffl er and ti ghten the nuts on the
muffl er-to-catal yti c converter cl amp to 61 Nm (45 ft.
l bs.) torque (Fi g. 11).
(6) Al i gn the tai l pi pe and i nstal l a new cl amp at
the muffl er to tai l pi pe connecti on.
(7) Ti ghten the muffl er to tai l pi pe cl amp to 61 Nm
(45 ft. l bs.)
Fig. 11 Muffler/Tailpipe Removal and Installation
1 MUFFLER AND TAIL PIPE HANGER
2 CLAMP
4 MUFFLER AND TAIL PIPE ASSEMBLY
5 TAIL PIPE
6 TAIL PIPE HANGER CLAMP
Fig. 10 Front Exhaust Tailpipe Hanger
1 MUFFLER
2 INSULATOR
3 TAILPIPE
4 FRONT TAILPIPE HANGER
HEAT SHIELDS
REMOVAL
(2) Remove the screws and/or nuts hol di ng the
heat shi el ds to the frame and/or fl oor pan (Fi g. 12).
(3) When removi ng muffl er heat shi el d, the muf-
fl er front support bracket must be removed fi rst.
(4) Sl i de the shi el ds out around the exhaust sys-
tem.
INSTALLATION
(1) Posi ti on the heat shi el ds to the fl oor pan or the
frame and i nstal l the screws and/or nuts.
(2) Ti ghten the nuts and/or screws to 45 Nm (33
ft. l bs.) (Fi g. 12).
SPECIFICATIONS
Fig. 12 Heat Shield Removal/Installation
1 BOLTS
2 MUFFLER HEAT SHIELD
3 NUTS
4 FLOOR PAN
Lbs. Lbs.
Catalytic Converter/Exhaust
Pipe
Exhaust ClampNuts 61 45
Crossmember to SillBolts 42 31
Crossmember to Transmission
MountNuts 22 16
Exhaust Pipe to Manifold
Nuts
31 23
Exhaust Manifold to Engine
2.5L
Engine
Bolt #1 41 40
Bolts #25 31 23
Nuts #6&7 31 23
Exhaust Manifold to Engine
4.0L
Engine
Nuts #6&7 31 23
Nuts/Bolts
#1,2,3,4,5,8,9,10&11
33 24
Muffler to Catalytic
Converter
Exhaust Clamp Nut 61 45
Oxygen Sensors 27 20
Rear Tail Pipe HangerNuts 54 40
FRAME AND BUMPERS
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . 1
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TABLE OF CONTENTS
page
FRAME AND BUMPERS. . . . . . . . . . . . . . . . . . . . . 1
FRAME AND BUMPERS
FRAME
DESCRIPTION
Jeep Cherokee vehi cl es do not have a conventi onal
frame. They are constructed as a uni ti zed body and
frame. Jeep uni bodi es are constructed from speci al
hi gh strength steel and coated metal s. Thi s process
reduces wei ght and provi des strength to wi thstand
the forces appl i ed agai nst structural members. The
structural members provi de a uni body that has great
structural strength.
BUMPERS
DESCRIPTION
The bumpers on the Jeep Cherokee are made up of
the mai n bumper beam, the end caps, ai r defl ector
(front bumper) and mounti ng brackets. Some Chero-
kee model s al so have a tow hook support bracket.
OPERATION
The bumpers are fastened to the uni ti zed body
frame rai l s. The bumper end caps are fastened to the
bumper and the body si de sheet metal .
XJ FRAME AND BUMPERS 13 - 1
BUMPERS
TABLE OF CONTENTS
page page
FRONT BUMPER END CAP. . . . . . . . . . . . . . . . . . 2
FRONT BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT TOW HOOK. . . . . . . . . . . . . . . . . . . . . . . . 3
REAR BUMPER END CAP. . . . . . . . . . . . . . . . . . . 4
REAR BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . 4
REAR TOW HOOK. . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT BUMPER END CAP
REMOVAL
(1) Remove the ri vet attachi ng the end cap to the
ai r defl ector.
(2) Remove the bol ts and nuts attachi ng the end
cap to the bumper (Fi g. 1).
(3) Pul l back the wheel house l i ner and remove the
screws attachi ng the end cap to the front fender.
(4) Li fti ng the end cap from the bottom, ti l t
sl i ghtl y upward and sl i de i t outward to di sengage the
retai ner tab from the bumper (Fi g. 2).
(5) Separate the end cap from the bumper.
INSTALLATION
(1) Posi ti on the end cap on the bumper and engage
the retai ni ng tab.
(2) I nstal l the screws attachi ng the end cap to the
front fender.
(3) I nstal l the bol ts attachi ng the end cap to the
bumper. Ti ghten the nut to 9 Nm (7 ft. l bs.) torque.
Fig. 1 Front Bumper
1 U-NUT
2 TOW HOOK SUPPORT BRACKET
3 END CAP
4 RIVET
5 AIR DEFLECTOR
6 MOUNTING BRACKET
7 BUMPER
13 - 2 FRAME AND BUMPERS XJ
(4) I nstal l the ri vet attachi ng the end cap to ai r
defl ector.
FRONT BUMPER
REMOVAL
(1) Remove bumper end caps.
(2) I f equi pped, di sengage fog l amp wi re harness
connectors.
(3) Di sconnect vacuum l i ne from reservoi r (Fi g. 3).
(4) Remove Torx-head bol ts that attach bumper to
mounti ng brackets (Fi g. 1).
(5) Remove bumper from vehi cl e.
(6) I f necessary, remove bol ts attachi ng bumper
mounti ng brackets to frame.
INSTALLATION
(1) I f removed, i nstal l bol ts attachi ng bumper
mounti ng brackets to frame. Ti ghten bol ts to 55 Nm
(2) Posi ti on bumper on front of vehi cl e.
(3) I nstal l Torx-head bol ts that attach bumper to
mounti ng brackets. Ti ghten bol ts to 55 Nm (41 ft.
l bs.) torque.
(4) Connect vacuum l i ne to reservoi r.
(5) I f equi pped, engage fog l amp wi re harness con-
nectors.
(6) I nstal l bumper end caps.
FRONT TOW HOOK
REMOVAL
(1) Remove bol ts attachi ng tow hook to tow hook
rei nforcement (Fi g. 4).
(2) Separate tow hook from rei nforcement.
(3) I f necessary, remove bol t attachi ng tow hook
rei nforcement to frame.
INSTALLATION
(1) I f removed, i nstal l bol t attachi ng tow hook
rei nforcement to frame. Ti ghten bol t to 30 Nm (22 ft.
l bs.) torque.
(2) Posi ti on tow hook on rei nforcement.
(3) I nstal l bol ts attachi ng tow hook to tow hook
rei nforcement. Ti ghten bol ts to 100 Nm (74 ft. l bs.)
torque.
Fig. 2 Bumper End Cap
1 RETAINER TAB
2 BUMPER END CAP
3 BUMPER
4 GRILLE
Fig. 3 Vacuum Reservoir
1 VACUUM LINE
2 RESERVOIR SCREWS
3 VACUUM RESERVOIR
Fig. 4 Front Tow Hook
1 MOUNTING BRACKET
2 TOW HOOK
3 TOW HOOK REINFORCEMENT
REAR BUMPER END CAP
REMOVAL
(1) Remove the screws attachi ng the bumper end
cap to the quarter panel and the bumper (Fi g. 5).
(2) Li ft the end cap sl i ghtl y upward and sl i de i t
rearward to rel ease i t from the retai ner.
(3) Separate the end cap from the vehi cl e.
INSTALLATION
(1) Posi ti on the end cap on the rear of the retai ner
and the outer edge of the bumper.
(2) Sl i de the end cap forward onto the retai ner.
Ensure the end cap overl aps the l i p of the rear
wheel house l i ner.
(3) I nstal l the screw attachi ng the front of the end
cap to the undersi de of the quarter panel and
bumper.
REAR BUMPER
REMOVAL
(1) For vehi cl es equi pped wi th a trai l er hi tch,
remove hi tch before removi ng bumper. I f necessary,
refer to removal procedure wi thi n Group 13, Frame
and Bumpers.
(2) Remove bumper end caps.
(3) Remove upper nuts that attach bumper to
bumper support brackets (Fi g. 5).
(4) Remove l ower bol ts that attach bumper to
bumper support brackets.
(5) Remove bumper from vehi cl e.
(6) I f necessary, remove bumper support brackets
from the rear si l l .
INSTALLATION
(1) I f removed, i nstal l bumper support brackets on
the rear si l l . Ti ghten bol ts to 55 Nm (41 ft. l bs.)
torque.
(2) Posi ti on bumper on support brackets.
(3) I nstal l bol ts that attach bumper to bumper
support brackets. Ti ghten nuts to 55 Nm (41 ft. l bs.)
torque.
(4) I nstal l bumper end caps.
(5) I f removed, i nstal l trai l er hi tch.
Fig. 5 REAR BUMPER END CAP
1 SPLASH SHIELD
2 REAR SILL
3 BRACKET
4 STUD
5 RIVET
6 RETAINER
7 END CAP
8 PLASTIC BLIND RIVET
9 BUMPER
REAR TOW HOOK
REMOVAL
(1) Remove bol ts that attach tow hook bracket and
tow hook to frame rai l (Fi g. 6).
(2) Remove bracket and tow hook from frame rai l .
INSTALLATION
(1) Posi ti on bracket and tow hook on frame rai l .
(2) I nstal l bol ts that attach tow hook bracket and
tow hook to frame rai l . Ti ghten bol ts to 94 Nm (70
ft. l bs.) torque.
Fig. 6 Rear Tow Hook
1 WELD NUT
2 FRAME REINFORCEMENT BRACKET
3 RIVET
4 SUPPORT BRACKET
5 BOLT
6 TOW HOOK
7 BOLT
8 BOLT
9 FRAME RAIL
FRAME
TABLE OF CONTENTS
page page
FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSFER CASE SKID PLATE . . . . . . . . . . . . . . . 6
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . . . . . 7
TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . 7
FRAME TORQUE SPECIFICATIONS . . . . . . . . . . . 9
FRONT SKID PLATE
REMOVAL
(1) Remove the screws that attach ski d pl ate to
si de si l l s.
(2) Remove the nuts that attach the ski d pl ate to
the crossmember (Fi g. 1).
(3) Remove the ski d pl ate from the vehi cl e.
INSTALLATION
(1) Posi ti on the ski d pl ate at front crossmember
and si de si l l s.
(2) I nstal l the nuts to attach the ski d pl ate to
crossmember.
(3) I nstal l the screws to attach ski d pl ate to si de si l l s.
TRANSFER CASE SKID PLATE
REMOVAL
(1) Support ski d pl ate.
(2) Remove bol ts that attach ski d pl ate to trans-
mi ssi on support crossmember and frame si l l (Fi g. 2).
(3) Remove support and ski d pl ate from vehi cl e.
INSTALLATION
(1) Posi ti on and support ski d pl ate at frame si l l
and transmi ssi on support crossmember.
(2) Attach ski d pl ate to frame si l l and crossmember
wi th bol ts. Ti ghten bol ts to 22 Nm (16 ft. l bs.) torque.
Fig. 1 Front Skid Plate
1 STUD
2 PUSH NUT
3 SPLASH SHIELD
4 SKID PLATE
5 SCREW
6 NUT
7 SCREW
Fig. 2 Transfer Case Skid Plate
1 FRAME SILL
2 NUT-SERT
3 TRANSFER CASE
4 BOLT
5 SKID PLATE
6 NUT-SERT
7 CROSSMEMBER
FUEL TANK SKID PLATE
REMOVAL
(1) Posi ti on a support under ski d pl ate.
(2) Remove bol ts that attach ski d pl ate to under-
body si de rai l s (Fi g. 3).
(3) Remove support and ski d pl ate from vehi cl e.
INSTALLATION
(1) Posi ti on and support ski d pl ate under fuel tank.
(2) I nstal l bol ts to attach ski d pl ate to underbody
rai l s. Ti ghten bol ts to 74 Nm (55 ft. l bs.) torque.
(3) Remove support from under ski d pl ate.
TRAILER HITCH
REMOVAL
(1) I f necessary, remove the trai l er tow wi re har-
ness connector from the hi tch (Fi g. 4).
(2) Support the hi tch.
(3) Remove the bol ts that attach the trai l er hi tch
to the frame si l l s and rei nforcement brackets (Fi g. 5).
(4) I f equi pped, remove the fuel tank ski d pl ate.
NOTE: The reinforcement brackets are held on the
frame sills with two blind rivets.
INSTALLATION
(1) I nstal l frame rei nforcement brackets, i f removed.
Sl i de the brackets through the vehi cl e rear si l l open-
i ngs and attach to the frame si l l s wi th bl i nd ri vets.
(2) Usi ng an adequate l i fti ng devi ce, posi ti on hi tch
at the proper l ocati on for i nstal l ati on on vehi cl e and
support i t.
(3) I f equi pped, posi ti on fuel tank ski d pl ate on
vehi cl e frame si l l s.
(4) Loosel y i nstal l the bol ts to attach the trai l er
hi tch (and the ski d pl ate) to frame si l l s and rei nforce-
ment brackets.
(5) Ti ghten al l bol ts/nuts to 74 Nm (55 ft. l bs.)
torque.
(6) Remove the l i ft/support.
(7) I f removed, attach the trai l er wi re harness con-
nector to the hi tch.
SPECIFICATIONS
FRAME DIMENSIONS
Frame di mensi ons are l i sted i n mi l l i meter scal e.
Al l di mensi ons are from center to center of Pri nci pal
Locati ng Poi nt (PLP), or from center to center of PLP
and fastener l ocati on (Fi g. 6).
Fig. 3 Fuel Tank Skid Plate
1 RIVET HOLES
2 REINFORCEMENT
3 FUEL TANK SKID PLATE
4 BLIND RIVET
Fig. 4 Trailer Hitch Harness Connector
1 CONNECTOR
2 TRAILER HITCH
Fig. 5 Trailer Hitch
1 TRAILER HITCH
2 BLIND RIVET
3 RIVET HOLES
4 REINFORCEMENT
Fig. 6 Frame Dimensions
FRAME TORQUE SPECIFICATIONS
DESCRIPTION TORQUE
Front Ski d Pl ate Screw . . . . . . . 42 Nm (31 ft. l bs.)
Front Ski d Pl ate Nut . . . . . . . 17 Nm (125 i n. l bs.)
Transfer Case Ski d Pl ate Bol t . . 22 Nm (16 ft. l bs.)
Fuel Tank Ski d Pl ate Bol t . . . . . 74 Nm (55 ft. l bs.)
Front Bumper End Cap to Mounti ng
Bracket Nut . . . . . . . . . . . . . . . 9 Nm (7 ft. l bs.)
Front Bumper Mounti ng Bracket to
Frame Bol t . . . . . . . . . . . . . . 55 Nm (41 ft. l bs.)
Front Bumper to Mounti ng Bracket Bol t . . 55 Nm
(41 ft. l bs.)
Front Tow Hook Bol t . . . . . . . . 100 Nm (74 ft. l bs.)
Front Tow Hook Rei nforcement Bol t . . . . . . 30 Nm
(22 ft. l bs.)
Rear Bumper to Mtg. Bracket Nut . . . . . . . 55 Nm
(41 ft. l bs.)
Rear Bumper Mtg. Bracket to Rear
Si l l Bol t . . . . . . . . . . . . . . . . . 55 Nm (41 ft. l bs.)
Rear Tow Hook Bol t . . . . . . . . . 94 Nm (70 ft. l bs.)
Trai l er Tow Rei nforcement Brkt Bol t . . . . . 74 Nm
(55 ft. l bs.)
FUEL SYSTEM
TABLE OF CONTENTS
page page
FUEL DELIVERY SYSTEM. . . . . . . . . . . . . . . . . . . . 1 FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . 25
FUEL DELIVERY SYSTEM
TABLE OF CONTENTS
page page
PCM VIN REPROGRAMMING . . . . . . . . . . . . . . . . 1
FUEL DELIVERY SYSTEM. . . . . . . . . . . . . . . . . . . 1
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . . 2
FUEL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL GAUGE SENDING UNIT. . . . . . . . . . . . . . . . 3
FUEL FILTER/FUEL PRESSURE REGULATOR. . . . 3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL INJECTOR RAIL/FUEL DAMPER2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL RAIL/FUEL DAMPER4.0L ENGINE. . . . . . . 5
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . . 6
FUEL TUBES/LINES/HOSES AND CLAMPS . . . . . . 6
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . . 6
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . . . 6
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . . . 7
FUEL PRESSURE LEAK DOWN TEST. . . . . . . . . . 7
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . . . 8
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 10
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . 10
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . 10
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 10
FUEL FILTER/FUEL PRESSURE REGULATOR. . . 13
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 14
FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . . . 15
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . 21
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . 21
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . . 23
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . 23
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 23
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 24
PCM VIN REPROGRAMMING
OPERATION
USE THE DRB SCAN TOOL TO REPROGRAM
THE NEW POWERTRAIN CONTROL MODULE
(PCM) WITH THE VEHICLES ORIGINAL IDEN-
TIFICATION NUMBER (VIN) AND THE VEHI-
CLES ORIGINAL MILEAGE. IF THIS STEP IS
NOT DONE, A DIAGNOSTIC TROUBLE CODE
(DTC) MAY BE SET.
FUEL DELIVERY SYSTEM
DESCRIPTION
The fuel del i very system consi sts of:
the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel fi l ter/fuel pressure regul ator, fuel
gauge sendi ng uni t (fuel l evel sensor) and a separate
fuel fi l ter l ocated at bottom of pump modul e
XJ FUEL SYSTEM 14 - 1
fuel tubes/l i nes/hoses
qui ck-connect fi tti ngs
fuel i njector rai l
fuel i njectors
fuel tank
fuel tank fi l l er/vent tube assembl y
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
OPERATION
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and rol l over val ve (refer to Group 25,
Emi ssi on Control System for rol l over val ve i nforma-
ti on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum, 1/4 turn fuel fi l l er cap i s used. The fuel
fi l l er tube contai ns a fl ap door l ocated bel ow the fuel
fi l l cap.
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s found i n Group 25, Emi ssi on
Control Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
FUEL PUMP MODULE
DESCRIPTION
The fuel pump modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 1) or (Fi g. 2). The fuel pump modul e
contai ns the fol l owi ng components:
A combi nati on fuel fi l ter/fuel pressure regul ator
A separate fuel pi ck-up fi l ter (strai ner)
An el ectri c fuel pump
A threaded l ocknut to retai n modul e to tank
A gasket between tank fl ange and modul e
Fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel suppl y tube (l i ne) connecti on
The fuel gauge sendi ng uni t, pi ck-up fi l ter and fuel
fi l ter/fuel pressure regul ator may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump requi res servi ce,
the enti re fuel pump modul e must be repl aced.
OPERATION
Refer to Fuel Pump, Fuel Fi l ter/Fuel Pressure Reg-
ul ator and Fuel Gauge Sendi ng Uni t.
Fig. 1 Fuel Tank/Fuel Pump Module (Top View)
1 ROLLOVER VALVE
2 RETAINER CLAMP
3 LOCKNUT
4 FUEL PUMP MODULE
5 FUEL FILTER/FUEL PRESSURE REGULATOR
6 ALIGNMENT ARROW
7 PIGTAIL HARNESS
8 FUEL SUPPLY TUBE
9 EVAP CANISTER VENT LINE
Fig. 2 Fuel Pump Module Components
1 FUEL GAUGE FLOAT
2 PICK-UP FILTER
3 FUEL GAUGE SENDING UNIT
5 ELECTRIC FUEL PUMP
6 PIGTAIL WIRING HARNESS
14 - 2 FUEL SYSTEM XJ
FUEL PUMP
DESCRIPTION
The fuel pump i s l ocated i nsi de of the fuel pump
modul e. A 12 vol t, permanent magnet, el ectri c motor
powers the fuel pump.
OPERATION
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
Fuel i s drawn i n through a fi l ter at the bottom of
the modul e and pushed through the el ectri c motor
gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test for more i nformati on.
FUEL GAUGE SENDING UNIT
DESCRIPTION
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor track (card).
OPERATION
The fuel pump modul e has 4 di fferent ci rcui ts
(wi res). Two of these ci rcui ts are used for the fuel
gauge sendi ng uni t for fuel gauge operati on, and for
certai n OBD I I emi ssi on requi rements. The other 2
wi res are used for el ectri c fuel pump operati on.
For Fuel Gauge Operation: A constant i nput
vol tage source of about 12 vol ts (battery vol tage) i s
suppl i ed to the resi stor track on the fuel gauge send-
i ng uni t. Thi s i s fed di rectl y from the Powertrai n
Control Modul e (PCM). NOTE: For diagnostic pur-
poses, this 12V power source can only be veri-
fied with the circuit opened (fuel pump module
electrical connector unplugged). With the con-
nectors plugged, output voltages will vary from
about.6 volts at FULL, to about 8.6 volts at
EMPTY (about 8.6 volts at EMPTY for J eep
models, and about 7.0 volts at EMPTY for
Dodge Truck models). The resi stor track i s used to
vary the vol tage (resi stance) dependi ng on fuel tank
fl oat l evel . As fuel l evel i ncreases, the fl oat and arm
move up, whi ch decreases vol tage. As fuel l evel
decreases, the fl oat and arm move down, whi ch
i ncreases vol tage. The vari ed vol tage si gnal i s
returned back to the PCM through the sensor return
ci rcui t.
Both of the el ectri cal ci rcui ts between the fuel
gauge sendi ng uni t and the PCM are hard-wi red (not
mul ti -pl exed). After the vol tage si gnal i s sent from
the resi stor track, and back to the PCM, the PCM
wi l l i nterpret the resi stance (vol tage) data and send
a message across the mul ti -pl ex bus ci rcui ts to the
i nstrument panel cl uster. Here i t i s transl ated i nto
the appropri ate fuel gauge l evel readi ng. Refer to
I nstrument Panel for addi ti onal i nformati on.
For OBD II Emission Monitor Requirements:
The PCM wi l l moni tor the vol tage output sent from
the resi stor track on the sendi ng uni t to i ndi cate fuel
l evel . The purpose of thi s feature i s to prevent the
OBD I I system from recordi ng/setti ng fal se mi sfi re
and fuel system moni tor di agnosti c troubl e codes.
The feature i s acti vated i f the fuel l evel i n the tank
i s l ess than approxi matel y 15 percent of i ts rated
capaci ty. I f equi pped wi th a Leak Detecti on Pump
(EVAP system moni tor), thi s feature wi l l al so be acti -
vated i f the fuel l evel i n the tank i s more than
approxi matel y 85 percent of i ts rated capaci ty.
FUEL FILTER/FUEL PRESSURE REGULATOR
DESCRIPTION
The combi nati on fuel fi l ter and fuel pressure regu-
l ator i s l ocated on the top of fuel pump modul e (Fi g.
1).
OPERATION
A combi nati on fuel fi l ter and fuel pressure regul a-
tor i s used on al l engi nes. A separate frame mounted
fuel fi l ter i s not used wi th any engi ne.
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 kPa 34
kPa (49.2 psi 5 psi ) at the fuel i njectors. I t con-
tai ns a di aphragm, cal i brated spri ngs and a fuel
return val ve. The i nternal fuel fi l ter i s al so part of
the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 3).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump. Refer to Fuel PumpDescription and
Operation for more information. Also refer to
the Fuel Pressure Leak Down Test and the Fuel
Pump Pressure Tests.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49 psi , an i nternal di aphragm cl oses
and excess fuel i s routed back i nto the tank through
the pressure regul ator. A separate fuel return l i ne i s
not used.
FUEL TANK
DESCRIPTION
The fuel tank i s constructed of a pl asti c materi al .
I ts mai n functi ons are for fuel storage and for pl ace-
ment of the fuel pump modul e.
OPERATION
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
A rol l over val ve(s) i s mounted i nto the top of the
fuel tank (or pump modul e). Refer to Emi ssi on Con-
trol System for rol l over val ve i nformati on.
An evaporati on control system i s connected to the
rol l over val ve(s) to reduce emi ssi ons of fuel vapors
i nto the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP). Refer to Emi ssi on Control
System for addi ti onal i nformati on.
FUEL INJECTORS
DESCRIPTION
An i ndi vi dual fuel i njector (Fi g. 4) i s used for each
i ndi vi dual cyl i nder.
OPERATION
The top (fuel entry) end of the i njector (Fi g. 4) i s
attached i nto an openi ng on the fuel rai l .
The fuel i njectors are el ectri cal sol enoi ds. The
i njector contai ns a pi ntl e that cl oses off an ori fi ce at
the nozzl e end. When el ectri c current i s suppl i ed to
the i njector, the armature and needl e move a short
di stance agai nst a spri ng, al l owi ng fuel to fl ow out
the ori fi ce. Because the fuel i s under hi gh pressure, a
fi ne spray i s devel oped i n the shape of a penci l
stream. The sprayi ng acti on atomi zes the fuel , add-
i ng i t to the ai r enteri ng the combusti on chamber.
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
Fig. 3 Fuel Filter/Fuel Pressure Regulator
2 TO FUEL INJECTORS
3 FUEL SUPPLY TUBE
4 O-RINGS
5 FUEL INLET FROM PUMP
6 FUEL RETURN TO TANK
Fig. 4 Fuel InjectorTypical
1 FUEL INJECTOR
2 NOZZLE
3 TOP (FUEL ENTRY)
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage i s suppl i ed to the i njectors through
the ASD rel ay.
The PCM determi nes i njector pul se wi dth based on
vari ous i nputs.
FUEL INJECTOR RAIL/FUEL DAMPER 2. 5L
ENGINE
DESCRIPTION
The fuel i njector rai l i s used to mount the fuel
i njectors to the engi ne (Fi g. 5). On the 2.5L 4cyl i n-
der engi ne, a fuel damper i s l ocated at the front of
the fuel rai l (Fi g. 5).
OPERATION
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
The fuel rai l i s not repai rabl e.
FUEL RAIL/FUEL DAMPER 4. 0L ENGINE
DESCRIPTION
The fuel rai l i s mounted to the i ntake mani fol d
(Fi g. 6). I t i s used to mount the fuel i njectors to the
engi ne. On the 4.0L 6cyl i nder engi ne, a fuel
damper i s l ocated near the center of the fuel rai l
(Fi g. 6).
OPERATION
The fuel i njector rai l suppl i es the necessary fuel to
each i ndi vi dual fuel i njector.
The fuel damper i s used onl y to hel p control fuel
pressure pul sati ons. These pul sati ons are the resul t
of the fi ri ng of the fuel i njectors. I t i s not used as a
fuel pressure regul ator. The fuel pressure regul ator i s
not mounted to the fuel rai l on any engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Fig. 5 Fuel Injector Rail/Fuel Damper2.5L Engine
1 FUEL DAMPER
2 FUEL INJECTOR
3 NUMBERED TAG
4 FUEL RAIL
5 FUEL RAIL MOUNTING BOLTS/NUTS
6 TEST PORT
7 CABLE BRACKET
Fig. 6 Fuel Rail/Fuel Damper4.0L Engine
1 INJ. #1
2 INJ. #2
3 INJ. #3
4 INJ. #4
5 INJ. #5
6 INJ. #6
7 FUEL INJECTOR RAIL
8 FUEL DAMPER
9 PRESSURE TEST PORT CAP
10 MOUNTING BOLTS (4)
11 QUICK-CONNECT FITTING
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
The fuel rai l i s not repai rabl e.
FUEL TANK FILLER TUBE CAP
DESCRIPTION
The pl asti c fuel tank fi l l er tube cap i s threaded
onto the end of the fuel fi l l tube. Certai n model s are
equi pped wi th a 1/4 turn cap.
OPERATION
The l oss of any fuel or vapor out of fuel fi l l er tube
i s prevented by the use of a pressure-vacuum fuel fi l l
cap. Rel i ef val ves i nsi de the cap wi l l rel ease fuel tank
pressure at predetermi ned pressures. Fuel tank vac-
uum wi l l al so be rel eased at predetermi ned val ues.
Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fill cap before servicing any fuel
system component to relieve tank pressure. If
equipped with a California emissions package and a
Leak Detection Pump (LDP), the cap must be tight-
ened securely. If cap is left loose, a Diagnostic
Trouble Code (DTC) may be set.
FUEL TUBES/LINES/HOSES AND CLAMPS
DESCRIPTION
Al so refer to Qui ck-Connect Fi tti ngs.
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
QUICK-CONNECT FITTINGS
DESCRIPTION
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Some are equi pped wi th
safety l atch cl i ps. Some may requi re the use of a spe-
ci al tool for di sconnecti on and removal . Refer to
Qui ck-Connect Fi tti ngs Removal /I nstal l ati on for more
i nformati on.
CAUTION: The interior components (o-rings, clips)
of quick-connect fittings are not serviced sepa-
rately, but new plastic spacers are available for
some types. If service parts are not available, do
not attempt to repair the damaged fitting or fuel line
(tube). If repair is necessary, replace the complete
fuel line (tube) assembly.
FUEL PUMP PRESSURE TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found el sewhere i n thi s
group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove protecti ve cap at fuel rai l test port.
Connect the 0414 kPa (0-60 psi ) fuel pressure gauge
(from gauge set 5069) to test port pressure fi tti ng on
fuel rai l (Fi g. 7). The DRB III Scan Tool along
with the PEP module, the 500 psi pressure
transducer, and the transducer-to-test port
adapter may also be used in place of the fuel
pressure gauge.
(2) Start and warm engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs, but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, but speci fi cati ons for ei ther the Fuel Pump
Capaci ty, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, repl ace fuel pump
modul e assembl y. Refer to Fuel Pump Modul e
Removal /I nstal l ati on.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for more i nformati on.
(5) I nstal l protecti ve cap to fuel rai l test port.
FUEL PUMP CAPACITY TEST
Before performing this test, verify fuel pump
pressure. Refer to Fuel Pump Pressure Test.
Use this test in conjunction with the Fuel Pres-
sure Leak Down Test.
(1) Rel ease fuel system pressure. Refer to Fuel
Pressure Rel ease Procedure.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs. Some engi nes may requi re
ai r cl eaner housi ng removal before l i ne di sconnecti on.
(3) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(4) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose i nto di sconnected fuel suppl y l i ne.
I nsert other end of Adaptor Tool Hose i nto a gradu-
ated contai ner.
(5) Remove fuel fi l l cap.
(6) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(7) A good fuel pump wi l l del i ver at l east 1/4 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter/
fuel pressure regul ator. The fi l ter/regul ator may be
servi ced separatel y on certai n appl i cati ons. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for addi ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace fuel pump modul e assembl y. Refer to Fuel
Pump Modul e Removal /I nstal l ati on.
FUEL PRESSURE LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
Fuel pressure bl eedi ng past a fuel i njector(s).
Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
(1) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Fuel Tubes/Li nes/Hoses and Cl amps i n thi s secti on
of the group for procedures. On some engi nes, ai r
Fig. 7 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)
1 SERVICE (TEST) PORT
2 FUEL PRESSURE TEST GAUGE
3 FUEL RAIL
cl eaner housi ng removal may be necessary before
fuel l i ne di sconnecti on.
(2) Obtai n correct Fuel Li ne Pressure Test Adapter
Tool Hose. Tool number 6539 i s used for 5/16 fuel
l i nes and tool number 6631 i s used for 3/8 fuel l i nes.
(3) Connect correct Fuel Li ne Pressure Test
Adapter Tool Hose between di sconnected fuel l i ne
and fuel rai l (Fi g. 8).
(4) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . The DRB III Scan
Tool along with the PEP module, the 500 psi
pressure transducer, and the transducer-to-test
port adapter may also be used in place of the
fuel pressure gauge.
The fittings on both tools must be in good
condition and free from any small leaks before
performing the proceeding test.
(5) Start engi ne and bri ng to normal operati ng
temperature.
(6) Observe test gauge. Normal operati ng pressure
shoul d be 339 kPa 34 kPa (49.2 psi 5 psi ).
(7) Shut engi ne off.
(8) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
(9) I f pressure fal l s bel ow 30 psi , i t must be deter-
mi ned i f a fuel i njector, the check val ve wi thi n the
fuel pump modul e, or a fuel tube/l i ne i s l eaki ng.
(10) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(11) Shut engi ne off.
(12) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of Adaptor
Tool between the fuel rai l and the test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a fuel i njector or the fuel rai l i s l eaki ng.
(13) Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Cl amp off the rubber hose porti on of Adaptor Tool
between the vehi cl e fuel l i ne and test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a l eak may be found at a fuel tube/l i ne. I f no
l eaks are found at fuel tubes or l i nes, one of the
check val ves i n ei ther the el ectri c fuel pump or fi l ter/
regul ator may be l eaki ng.
Note: A qui ck l oss of pressure usual l y i ndi cates a
defecti ve check val ve i n the fi l ter/regul ator. A sl ow
l oss of pressure usual l y i ndi cates a defecti ve check
val ve i n the el ectri c fuel pump.
The el ectri c fuel pump i s not servi ced separatel y.
Repl ace the fuel pump modul e assembl y. The fi l ter/
regul ator may be repl aced separatel y on certai n
appl i cati ons. Refer to Fuel Fi l ter/Fuel Pressure Reg-
ul ator Removal /I nstal l ati on for addi ti onal i nforma-
ti on.
FUEL PUMP AMPERAGE TEST
Thi s amperage (current draw) test i s to be done i n
conjuncti on wi th the Fuel Pump Pressure Test, Fuel
Pump Capaci ty Test and Fuel Pressure Leak Down
Test. Before performi ng the amperage test, be sure
the temperature of the fuel tank i s above 50 F (10
C).
The DRB Scan Tool al ong wi th the DRB Low Cur-
rent Shunt (LCS) adapter (Fi g. 9) and i ts test l eads
wi l l be used to check fuel pump amperage speci fi ca-
ti ons.
(1) Be sure fuel tank contai ns fuel before starti ng
test. I f tank i s empty or near empty, amperage read-
i ngs wi l l be i ncorrect.
(2) Obtai n LCS adapter.
(3) Pl ug cabl e from LCS adapter i nto DRB scan
tool at SET 1 receptacl e.
(4) Pl ug DRB i nto vehi cl e 16way connector (data
l i nk connector).
(5) Connect (-) and (+) test cabl e l eads i nto LCS
adapter receptacl es. Use 10 amp (10A +) receptacl e
and common (-) receptacl es.
(6) Gai n access to MAI N MENU on DRB screen.
(7) Press DVOM button on DRB.
Fig. 8 Connecting Adapter ToolTypical
1 VEHICLE FUEL LINE
2 TEST PORT T
3 SPECIAL TOOL 6923, 6631, 6541 OR 6539
4 FUEL PRESSURE TEST GAUGE
5 FUEL LINE CONNECTION AT RAIL
6 FUEL RAIL
(8) Usi ng l eft/ri ght arrow keys, hi ghl i ght CHAN-
NEL 1 functi on on DRB screen.
(9) Press ENTER three ti mes.
(10) Usi ng up/down arrow keys, hi ghl i ght RANGE
on DRB screen (screen wi l l defaul t to 2 amp scal e).
(11) Press ENTER to change 2 amp scal e to 10
amp scal e. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(12) Remove cover from Power Di stri buti on Center
(PDC).
(13) Remove fuel pump rel ay from PDC. Refer to
l abel on PDC cover for rel ay l ocati on.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND FUEL
SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: TO PREVENT POSSIBLE DAMAGE TO
THE VEHICLE ELECTRICAL SYSTEM AND LCS
ADAPTER, THE TEST LEADS MUST BE CON-
NECTED INTO RELAY CAVITIES EXACTLY AS
SHOWN IN FOLLOWING STEPS.
Dependi ng upon vehi cl e model , year or engi ne con-
fi gurati on, three di fferent types of rel ays may be
used: Type-1, type-2 and type3.
(14) I f equi pped wi th type1 relay (Fi g. 10),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 10).
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 11).
cavi ti es number 3 and 5. For l ocati on of these cavi -
ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 12).
(17) When LCS adapter test l eads are attached
i nto rel ay cavi ti es, fuel pump will be activated.
Determi ne fuel pump amperage on DRB screen.
Amperage shoul d be bel ow 10.0 amps. I f amperage i s
bel ow 10.0 amps, and speci fi cati ons for the Fuel
Pump Pressure, Fuel Pump Capaci ty and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ul e i s OK.
(18) I f amperage i s more than 10.0 amps, repl ace
fuel pump modul e assembl y. The el ectri c fuel pump
i s not servi ced separatel y.
(19) Di sconnect test l eads from rel ay cavi ti es
i mmedi atel y after testi ng.
Fig. 9 Low Current Shunt Adapter
1 LOW CURRENT SHUNT ADAPTER
2 PLUG TO DRB
3 TEST LEAD RECEPTACLES
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 10 Type1 Relay
The fuel gauge sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to I nstrument
Panel and Gauges for Fuel Gauge testi ng. To test the
gauge sendi ng uni t onl y, i t must be removed from
vehi cl e. The uni t i s part of the fuel pump modul e.
Refer to Fuel Pump Modul e Removal /I nstal l ati on for
procedures. Measure the resi stance across the send-
i ng uni t termi nal s. Wi th fl oat i n up posi ti on, resi s-
tance shoul d be 20 ohms (+/- 5%). Wi th fl oat i n down
posi ti on, resi stance shoul d be 270 ohms (+/- 5%).
FUEL INJECTOR TEST
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, use the DRB scan tool and refer to the
appropri ate Powertrai n Di agnosti cs Procedures man-
ual . To test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. The i njector i s equi pped wi th 2
el ectri cal termi nal s (pi ns). Pl ace an ohmmeter across
the termi nal s. Resi stance readi ng shoul d be approxi -
matel y 12 ohms 1.2 ohms at 20C (68F).
SERVICE PROCEDURES
PROCEDURE
Use following procedure if the fuel injector
rail is, or is not equipped with a fuel pressure
test port.
(1) Remove fuel fi l l cap.
(2) Remove fuel pump rel ay from Power Di stri bu-
ti on Center (PDC). For l ocati on of rel ay, refer to l abel
on undersi de of PDC cover.
(3) Start and run engi ne unti l i t stal l s.
(4) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
(5) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within fuel rail. Do
not attempt to use following steps to relieve this
pressure as excessive fuel will be forced into a cyl-
inder chamber.
(6) Unpl ug connector from any fuel i njector.
(7) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(8) Connect other end of jumper wi re to posi ti ve
si de of battery.
(9) Connect one end of a second jumper wi re to
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(10) Momentari l y touch other end of jumper wi re
to negati ve termi nal of battery for no more than a
few seconds.
(11) Pl ace a rag or towel bel ow fuel l i ne qui ck-con-
nect fi tti ng at fuel rai l .
(12) Di sconnect qui ck-connect fi tti ng at fuel rai l .
Refer to Qui ck-Connect Fi tti ngs.
(13) Return fuel pump rel ay to PDC.
(14) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n PCM memory due to fuel
pump rel ay removal . The DRB scan tool must be
used to erase a DTC.
QUICK-CONNECT FITTINGS
Al so refer to Fuel Tubes/Li nes/Hoses and Cl amps.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components, l i nes and
tubes. These are: a si ngl e-tab type, a two-tab type or
a pl asti c retai ner ri ng type. Safety l atch cl i ps are
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 11 Type2 Relay
TERMINAL LEGEND
1 COIL BATTERY
2 COIL GROUND
3 COMMON FEED
4 NORMALLY CLOSED
5 NORMALLY OPEN
Fig. 12 Type3 Relay
used on certai n components/l i nes. Certai n fi tti ngs
may requi re use of a speci al tool for di sconnecti on.
DISCONNECTING
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
CAUTION: The interior components (o-rings, spac-
ers) of some types of quick-connect fitting are not
serviced separately. If service parts are not avail-
able, do not attempt to repair a damaged fitting or
fuel line. If repair is necessary, replace complete
fuel line assembly.
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure i n thi s group.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) Single-Tab Type Fitting: Thi s type of fi tti ng
i s equi pped wi th a si ngl e pul l tab (Fi g. 13). The tab
i s removabl e. After tab i s removed, qui ck-connect fi t-
ti ng can be separated from fuel system component.
(a) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 14). If release tab is not pressed
prior to releasing pull tab, pull tab will be
damaged.
(b) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use screwdri ver to pry up pul l tab (Fi g. 14).
(c) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 15).
(5) Two-Tab Type Fitting: Thi s type of fi tti ng i s
equi pped wi th tabs l ocated on both si des of fi tti ng
(Fi g. 16). The tabs are suppl i ed for di sconnecti ng
qui ck-connect fi tti ng from component bei ng servi ced.
(a) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 16) agai nst si des of
qui ck-connect fi tti ng wi th your fi ngers. Tool use i s
not requi red for removal and may damage pl asti c
retai ner.
(b) Pul l fi tti ng from fuel system component
bei ng servi ced.
(c) The pl asti c retai ner wi l l remai n on compo-
nent bei ng servi ced after fi tti ng i s di sconnected.
The o-ri ngs and spacer wi l l remai n i n qui ck-con-
nect fi tti ng connector body.
(6) Plastic Retainer Ring Type Fitting: Thi s
type of fi tti ng can be i denti fi ed by the use of a ful l -
round pl asti c retai ner ri ng (Fi g. 17) usual l y bl ack i n
col or.
(a) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 17). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plas-
tic retainer ring must be pressed squarely
into fitting body. If this retainer is cocked
during removal, it may be difficult to discon-
nect fitting. Use an open-end wrench on
shoulder of plastic retainer ring to aid in dis-
connection.
(b) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
Fig. 13 Single-Tab Type Fitting
1 PULL TAB
3 PRESS HERE TO REMOVE PULL TAB
4 INSERTED TUBE END
Fig. 14 Disconnecting Single-Tab Type Fitting
1 PULL TAB
2 SCREWDRIVER
(c) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage.
Repl ace as necessary.
(7) Latch Clips: Dependi ng on vehi cl e model and
engi ne, 2 di fferent types of safety l atch cl i ps are used
(Fi g. 18) or (Fi g. 19). Type-1 i s tethered to fuel l i ne
and type-2 i s not. A speci al tool wi l l be necessary to
di sconnect fuel l i ne after l atch cl i p i s removed. The
l atch cl i p may be used on certai n fuel l i ne/fuel rai l
connecti on, or to joi n fuel l i nes together.
(a) Type 1: Pry up on l atch cl i p wi th a screw-
dri ver (Fi g. 18).
(b) Type 2: Separate and unl atch 2 smal l arms
on end of cl i p (Fi g. 19) and swi ng away from fuel
l i ne.
(c) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
Fig. 15 Removing Pull Tab
1 FUEL TUBE OR FUEL SYSTEM COMPONENT
2 PULL TAB
4 FUEL TUBE STOP
Fig. 16 Typical Two-Tab Type Quick-Connect Fitting
1 TAB(S)
Fig. 17 Plastic Retainer Ring Type Fitting
1 FUEL TUBE
2 QUICK CONNECT FITTING
3 PUSH
4 PLASTIC RETAINER
5 PUSH
6 PUSH
7 PUSH
8 PUSH
Fig. 18 Latch ClipType 1
1 TETHER STRAP
2 FUEL LINE
3 SCREWDRIVER
4 LATCH CLIP
5 FUEL RAIL
(d) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne
(Fi g. 20). Use tool to rel ease l ocki ng fi ngers i n end
of l i ne.
(e) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(f) After di sconnecti on, l ocki ng fi ngers wi l l
remai n wi thi n qui ck-connect fi tti ng at end of fuel
l i ne.
(8) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
CONNECTING
(1) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(2) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(3) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(4) Conti nue pushi ng unti l a cl i ck i s fel t.
(5) Si ngl e-tab type fi tti ng: Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(6) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(7) Latch Cl i p Equi pped: I nstal l l atch cl i p (snaps
i nto posi ti on). If latch clip will not fit, this indi-
cates fuel line is not properly installed to fuel
rail (or other fuel line). Recheck fuel line con-
nection.
(9) Start engi ne and check for l eaks.
FUEL FILTER/FUEL PRESSURE REGULATOR
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s l ocated on the fuel pump modul e. The fuel
pump modul e i s l ocated on top of fuel tank.
The fi l ter/regul ator may be removed wi thout
removi ng fuel pump modul e al though fuel tank must
be removed.
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Cl ean area around fi l ter/regul ator.
(3) Di sconnect fuel l i ne at fi l ter/regul ator. Refer to
Qui ck-Connect Fi tti ngs i n thi s group for procedures.
(4) Remove retai ner cl amp from top of fi l ter/regu-
l ator (Fi g. 21). Cl amp snaps to tabs on pump modul e.
Di scard ol d cl amp.
(5) Pry fi l ter/regul ator from top of pump modul e
wi th 2 screwdri vers. Uni t i s snapped i nto modul e.
(6) Di scard gasket bel ow fi l ter/regul ator (Fi g. 22).
(7) Before di scardi ng fi l ter/regul ator assembl y,
i nspect assembl y to veri fy that o-ri ngs (Fi g. 23) are
i ntact. I f the smal l est of the two o-ri ngs can not be
found on bottom of fi l ter/regul ator, i t may be neces-
sary to remove i t from the fuel i nl et passage i n fuel
pump modul e.
Fig. 19 Latch ClipType 2
1 LATCH CLIP
Fig. 20 Fuel Line Disconnection Using Special Tool
1 SPECIAL FUEL LINE TOOL
2 FUEL LINE
3 FUEL RAIL
INSTALLATION
(1) Cl ean recessed area i n pump modul e where fi l -
ter/regul ator i s to be i nstal l ed.
(2) Obtai n new fi l ter/regul ator (two new o-ri ngs
shoul d al ready be i nstal l ed).
(3) Appl y a smal l amount of cl ean engi ne oi l to
o-ri ngs. Do not install o-rings separately into
fuel pump module. They will be damaged when
installing filter/regulator.
(4) I nstal l new gasket to top of fuel pump modul e.
(5) Press new fi l ter/regul ator i nto top of pump
modul e unti l i t snaps i nto posi ti on (a posi ti ve cl i ck
must be heard or fel t).
(6) The arrow (Fi g. 21) mol ded i nto top of fuel
pump modul e shoul d be poi nted towards front of
vehi cl e (12 ocl ock posi ti on).
(7) Rotate fi l ter/regul ator unti l fuel suppl y tube
(fi tti ng) i s poi nted towards front of vehi cl e (12 ocl ock
posi ti on).
(8) I nstal l new retai ner cl amp (cl amp snaps over
top of fi l ter/regul ator and l ocks to fl anges on pump
modul e).
(9) Connect fuel l i ne at fi l ter/regul ator. Refer to
(10) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL PUMP MODULE
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
REMOVAL
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL PUMP MODULE,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
Fig. 21 Fuel Filter/Fuel Pressure Regulator
1 RETAINER CLAMP
3 FUEL SUPPLY TUBE
4 ALIGNMENT ARROW
Fig. 22 Fuel Filter/Fuel Pressure Regulator Gasket
1 TOP OF MODULE
2 GASKET
Fig. 23 Fuel Filter/Fuel Pressure Regulator O-Rings
2 TO FUEL INJECTORS
3 FUEL SUPPLY TUBE
4 O-RINGS
5 FUEL INLET FROM PUMP
6 FUEL RETURN TO TANK
(1) Drai n fuel tank and remove tank. Refer to the
Fuel Tank Removal /I nstal l ati on secti on of thi s group.
(2) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(3) Di sconnect fuel l i ne at fi l ter/regul ator. Refer to
(4) The pl asti c fuel pump modul e l ocknut i s
threaded onto fuel tank (Fi g. 24). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 25). The fuel pump modul e wi l l spri ng up
when l ocknut i s removed.
(5) Remove modul e from fuel tank.
INSTALLATION
CAUTION: Whenever fuel pump module is serviced,
module gasket must be replaced.
(1) Thoroughl y cl ean l ocknut threads and mati ng
fuel tank threads. Use a soap/water sol uti on. Do not
use carburetor cl eaner to cl ean threads.
(2) Usi ng a new gasket, posi ti on gasket and fuel
pump modul e i nto openi ng i n fuel tank.
(3) Appl y cl ean water to gasket and l ocknut
threads.
(4) Posi ti on l ocknut over top of fuel pump modul e.
(5) Rotate modul e unti l mol ded arrow (Fi g. 24) i s
poi nted toward front of vehi cl e (12 ocl ock posi ti on).
Thi s step must be done to prevent fl oat/fl oat rod
assembl y from contacti ng si des of fuel tank.
(6) I nstal l Speci al Tool 6856 to l ocknut.
(7) Ti ghten l ocknut to 74 Nm (55 ft. l bs.) torque.
(8) Rotate fuel fi l ter/fuel pressure regul ator unti l
i ts fi tti ng i s poi nted toward front of vehi cl e (12
ocl ock posi ti on).
(9) Connect fuel l i ne at fi l ter/regul ator. Refer to
(10) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on i n thi s secti on.
FUEL PUMP INLET FILTER
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 26). The fuel
pump modul e i s l ocated on top of fuel tank.
REMOVAL
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove fi l ter by pryi ng from bottom of modul e
wi th 2 screwdri vers. Fi l ter i s snapped to modul e.
(4) Cl ean bottom of pump modul e.
INSTALLATION
(1) Snap new fi l ter to bottom of modul e.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
I nstal l ati on.
Fig. 24 Top View of Fuel Tank and Fuel Pump
Module
1 ROLLOVER VALVE
2 RETAINER CLAMP
3 LOCKNUT
4 FUEL PUMP MODULE
6 ALIGNMENT ARROW
7 PIGTAIL HARNESS
8 FUEL SUPPLY TUBE
9 EVAP CANISTER VENT LINE
Fig. 25 Locknut Removal/InstallationTypical
1 SPECIAL TOOL 6856
2 LOCKNUT
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 27). The fuel pump modul e i s l ocated
wi thi n the fuel tank.
REMOVAL
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 28) to remove send-
i ng uni t from pump modul e.
INSTALLATION
(1) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(2) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
I nstal l ati on.
ENGINE
REMOVAL
The fuel damper i s not servi ced separatel y.
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure as descri bed i n thi s Group.
Fig. 26 Fuel Pump Inlet Filter
1 FUEL PUMP MODULE
2 FUEL PUMP INLET FILTER
Fig. 27 Fuel Gauge Sending Unit Location
1 FUEL GAUGE FLOAT
2 PICK-UP FILTER
5 ELECTRIC FUEL PUMP
6 PIGTAIL WIRING HARNESS
Fig. 28 Fuel Gauge Sending Unit Release Tab
1 ELECTRICAL CONNECTOR
3 RELEASE TAB
4 FUEL PUMP MODULE
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Remove i njector harness el ectri cal connectors
at each i njector. Each i njector connector shoul d have
a numeri cal tag attached i denti fyi ng i ts correspond-
i ng cyl i nder (Fi g. 29). I f not, i denti fy each connector
before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs i n
thi s group for procedures.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on i n thi s group
for procedures.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System for procedures.
(9) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(10) Remove cabl e routi ng bracket (Fi g. 29) at
i ntake mani fol d.
(11) Remove nut securi ng crankshaft posi ti on sen-
sor pi gtai l harness to fuel rai l mounti ng stud.
Remove cl amp and harness from fuel rai l mounti ng
stud.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
29).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
INSTALLATION
(1) Cl ean each i njector bore at i ntake mani fol d.
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 3 Nm (100 25 i n. l bs.) torque.
(5) Posi ti on crankshaft posi ti on sensor pi gtai l wi re
harness cl amp and wi re harness to fuel rai l mount-
i ng stud. I nstal l nut securi ng harness to fuel rai l
mounti ng stud.
(6) Connect tagged i njector harness connectors to
appropri ate i njector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs i n thi s group for
procedures.
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
(15) Connect negati ve battery cabl e to battery.
(16) Start engi ne and check for fuel l eaks.
ENGINE
REMOVAL
The fuel damper i s not servi ced separatel y.
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
Fig. 29 Fuel Rail Mounting2.5L Engine
1 FUEL DAMPER
2 FUEL INJECTOR
3 NUMBERED TAG
4 FUEL RAIL
5 FUEL RAIL MOUNTING BOLTS/NUTS
6 TEST PORT
7 CABLE BRACKET
(5) Di sconnect el ectri cal connectors at al l 6 fuel
i njectors. To remove connector refer to (Fi g. 30). Push
red col ored sl i der away from i njector (1). Whi l e push-
i ng sl i der, depress tab (2) and remove connector (3)
from i njector. The factory fuel i njecti on wi ri ng har-
ness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on. I f harness i s not
tagged, note wi ri ng l ocati on before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System.
(9) Di sconnect automati c transmi ssi on cabl e at
(10) Remove cabl e routi ng bracket at i ntake man-
i fol d.
(11) I f equi pped, remove wi ri ng harnesses at i njec-
ti on rai l studs by removi ng nuts.
(12) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(13) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
31).
(14) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
INSTALLATION
(1) Cl ean each i njector bore at i ntake mani fol d.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 3 Nm (100 25 i n. l bs.) torque.
(5) I f equi pped, connect wi ri ng harnesses to i njec-
ti on rai l studs.
(6) Connect el ectri cal connectors at al l fuel i njec-
tors. To i nstal l connector, refer to (Fi g. 30). Push con-
nector onto i njector (1) and then push and l ock red
col ored sl i der (2). Veri fy connector i s l ocked to i njec-
tor by l i ghtl y tuggi ng on connector.
(7) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs..
Fig. 30 Remove/Install Fuel Injector Connector
2.5L/4.0L Engine
Fig. 31 Fuel Rail Mounting4.0L Engine
1 INJ. #1
2 INJ. #2
3 INJ. #3
4 INJ. #4
5 INJ. #5
6 INJ. #6
8 FUEL DAMPER
9 PRESSURE TEST PORT CAP
(8) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(9) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(10) Connect throttl e cabl e at throttl e body.
(11) Connect speed control cabl e at throttl e body (i f
equi pped).
(12) Connect automati c transmi ssi on cabl e at
(13) I nstal l ai r tube (or duct) at top of throttl e
body.
(14) I nstal l fuel tank cap.
(15) Connect negati ve battery cabl e to battery.
FUEL INJECTORS
REMOVAL
(1) Remove fuel rai l . Refer to Fuel I njector Rai l
Removal i n thi s secti on.
(2) Di sconnect cl i p(s) that retai n fuel i njector(s) to
fuel rai l (Fi g. 32).
INSTALLATION
(1) I nstal l fuel i njector(s) i nto fuel rai l assembl y
and i nstal l retai ni ng cl i p(s).
(2) I f same i njector(s) i s bei ng rei nstal l ed, i nstal l
new o-ri ng(s).
(4) I nstal l fuel rai l . Refer to Fuel Rai l I nstal l ati on.
FUEL TANK
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING FUEL TANK.
Two di fferent procedures may be used to drai n fuel
tank (l oweri ng tank or usi ng DRB scan tool ).
The qui ckest drai ni ng procedure i nvol ves l oweri ng
the fuel tank.
As an al ternati ve procedure, the el ectri c fuel pump
may be acti vated al l owi ng tank to be drai ned at fuel
rai l connecti on. Refer to DRB scan tool for fuel pump
acti vati on procedures. Before di sconnecti ng fuel l i ne
at fuel rai l , rel ease fuel pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group for
procedures. Attach end of speci al test hose tool num-
ber 6541, 6539, 6631 or 6923 at fuel rai l di sconnec-
ti on (tool number wi l l depend on model and/or engi ne
appl i cati on). Posi ti on opposi te end of thi s hose tool to
an approved gasol i ne drai ni ng stati on. Acti vate fuel
pump and drai n tank unti l empty.
I f el ectri c fuel pump i s not operati ng, tank must be
l owered for fuel drai ni ng. Refer to fol l owi ng proce-
dures.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Rel ease fuel system pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group.
(4) I f Equi pped: Remove fuel tank ski d pl ate. Refer
to Group 23, Body for procedures.
(5) Remove 4 fuel hose shi el d mounti ng bol ts and
remove fuel hose shi el d (Fi g. 33) from body.
(6) Remove fuel tank fi l l hose and vent hose
cl amps at fuel tank fi l l er tube (Fi g. 34). Remove both
hoses at fuel fi l l er tube (Fi g. 34).
(7) Remove exhaust tai l pi pe heat shi el d mounti ng
bol ts and remove shi el d.
CAUTION: To protect fuel tank from exhaust heat,
this shield must reinstalled after tank installation.
(8) Pl ace a hydraul i c jack to bottom of fuel tank.
WARNING: PLACE A SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
(9) Di sconnect fuel suppl y l i ne from fuel extensi on
l i ne near front of fuel tank (Fi g. 35). Refer to Fuel
Tubes/Li nes/Hoses and Cl amps i n thi s group. Al so
refer to Qui ck-Connect Fi tti ngs for procedures.
(10) Di sconnect EVAP cani ster vent l i ne near front
of tank (Fi g. 35).
Fig. 32 Fuel Injector Mounting
1 INLET FITTING
3 CLIP
4 FUEL INJECTOR
(11) Di sconnect fuel pump modul e el ectri cal con-
nector (pi gtai l harness) near front of tank (Fi g. 35).
Harness connector i s cl i pped to body.
(12) Remove two fuel tank strap nuts (Fi g. 36).
Posi ti on both tank support straps away from tank.
(13) Careful l y l ower ri ght si de of tank whi l e feed-
i ng both fuel hoses through access hol e i n body. Fuel
Tank Full And Not Drained Using DRB Scan
Tool: To prevent fuel l oss through hoses, keep l eft
si de of tank hi gher than ri ght si de whi l e l oweri ng.
Do not al l ow hose openi ngs to drop l ower than top of
tank.
(14) Conti nue l oweri ng tank unti l cl ear of vehi cl e.
Pl ace tank on fl oor wi th l eft si de (hose si de) hi gher
than ri ght si de.
(15) Drai n tank by removi ng fuel fi l l hose at tank.
Fuel fi l l hose i s l argest of 2 hoses (Fi g. 37). I nsert the
Fig. 33 Fuel Hose Shield
1 FUEL HOSE SHIELD
Fig. 34 Fuel Fill and Vent Hoses
1 CLAMPS
2 FUEL FILL HOSE
3 FUEL VENT HOSE
Fig. 35 Fuel Tank Connections at Front of Fuel Tank
1 FUEL PUMP MODULE CONNECTOR
2 LEFT-REAR SHOCK ABSORBER
3 EVAP CANISTER VENT LINE CONNECTION
4 FRONT OF FUEL TANK
5 FUEL SUPPLY LINE CONNECTION
Fig. 36 Fuel Tank Mounting Straps/Nuts
2 NUTS (2)
3 STRAPS (2)
drai n hose (from an approved gasol i ne drai ni ng sta-
ti on) i nto hose openi ng. Drai n tank unti l empty.
(16) I f fuel pump modul e removal i s necessary,
refer to Fuel Pump Modul e Removal /I nstal l ati on i n
thi s group for procedures.
INSTALLATION
(1) I f fuel pump modul e i s bei ng i nstal l ed, refer to
Fuel Pump Modul e Removal /I nstal l ati on i n thi s
group for procedures.
(2) I nstal l fuel fi l l /vent hoses to tank fi tti ngs. To
prevent hose from ki nki ng, rotate each hose unti l
i ndex mark on hose i s al i gned to i ndex tang on fuel
tank (Fi g. 37).
(3) I nstal l hose cl amps to hoses. Posi ti on cl amps
between i ndex marks on each hose (Fi g. 37).
(4) Posi ti on fuel tank to hydraul i c jack.
(5) Rai se tank i nto posi ti on whi l e gui di ng fuel fi l l
and vent hoses i nto and through access hol e i n body.
(6) Conti nue rai si ng tank unti l posi ti oned to body.
(7) Attach two fuel tank mounti ng straps and
mounti ng nuts. Ti ghten nuts to 10 Nm (90 i n. l bs.)
torque. Do not over ti ghten nuts.
(8) I nstal l both fuel hoses to fuel fi l l tube. Ti ghten
both retai ni ng cl amps.
(9) Posi ti on fuel hose shi el d to body. I nstal l and
ti ghten 4 mounti ng bol ts.
(10) Connect fuel pump modul e pi gtai l harness
el ectri cal connector near front of tank.
(11) Connect fuel pump modul e suppl y l i ne near
front of tank. Refer to Qui ck-Connect Fi tti ngs for
procedures.
(12) Connect EVAP hose near front of tank.
(13) I nstal l exhaust tai l pi pe heat shi el d.
(14) I nstal l fuel tank ski d pl ate (i f equi pped).
(15) Lower vehi cl e and connect battery cabl e to
battery.
FUEL TANK FILLER TUBE CAP
REMOVAL/INSTALLATION
I f repl acement of the 1/4 turn fuel tank fi l l er tube
cap i s necessary, i t must be repl aced wi th an i denti -
cal cap to be sure of correct system operati on.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
ACCELERATOR PEDAL
REMOVAL
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the upper part of the accel erator pedal arm by a
pl asti c retai ner (cl i p) (Fi g. 38). Thi s retai ner (cl i p)
snaps i nto the top of the accel erator pedal arm.
Retai ner tabs (bui l t i nto the cabl e sheathi ng) (Fi g.
38) fasten the cabl e to the dash panel .
Dual throttl e return spri ngs (attached to the throt-
tl e shaft) are used to cl ose the throttl e.
CAUTION: Never attempt to remove or alter these
springs.
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing the accelerator pedal or throttle cable.
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of accel erator
pedal arm (Fi g. 38). Pl asti c cabl e retai ner (cl i p) snaps
i nto pedal arm.
(2) Remove accel erator pedal mounti ng bracket
nuts. Remove accel erator pedal assembl y.
Fig. 37 Fuel Fill/Vent Hose Index Marks
1 FUEL TANK
2 CLAMP INDEX MARKS
3 TANK INDEX TANGS
4 HOSE INDEX MARKS
5 FUEL FILL HOSE
6 CLAMP INDEX MARKS
7 CLAMPS
8 FUEL VENT HOSE
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
5 Nm (36 i n. l bs.) torque.
(2) Sl i de throttl e cabl e i nto openi ng i n top of pedal
arm. Push pl asti c cabl e retai ner (cl i p) i nto accel era-
tor pedal arm openi ng unti l i t snaps i nto pl ace.
(3) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
THROTTLE CABLE
REMOVAL
(1) From i nsi de vehi cl e, hol d up accel erator pedal .
Remove pl asti c cabl e retai ner (cl i p) and throttl e cabl e
core wi re from upper end of accel erator pedal arm
(Fi g. 38). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal
arm.
(2) Remove cabl e core wi re at pedal arm.
(3) From i nsi de vehi cl e, pi nch both si des of cabl e
housi ng retai ner tabs (Fi g. 38) at dash panel .
Remove cabl e housi ng from dash panel and pul l i nto
(4) Remove cabl e from cabl e gui de on engi ne cyl i n-
der head (val ve) cover.
(5) Remove throttl e cabl e bal l end socket at throt-
tl e body by pushi ng bal l socket towards rear of vehi -
cl e (bal l snaps off throttl e body pi n) (Fi g. 39).
(6) Remove throttl e cabl e from throttl e body
mounti ng bracket by compressi ng rel ease tabs (Fi g.
39) and pushi ng cabl e through hol e i n bracket.
(7) Remove throttl e cabl e from vehi cl e.
INSTALLATION
(1) Sl i de throttl e cabl e through hol e i n throttl e
body bracket unti l retai ner tabs l ock i nto bracket.
(2) Connect cabl e bal l end to throttl e body l i nkage
bal l (snaps on).
(3) Snap cabl e i nto cabl e gui de on engi ne cyl i nder
head (val ve) cover.
(4) Push other end of cabl e through openi ng i n
dash panel unti l retai ni ng tabs l ock i nto panel .
(5) From i nsi de dri vers compartment, sl i de throttl e
cabl e core wi re i nto openi ng i n top of accel erator
pedal arm. Push cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i n pl ace.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
Fig. 38 Accelerator Pedal MountingTypical
1 RETAINER TABS
2 CLIP
3 MOUNTING NUTS
4 CABLE
Fig. 39 Throttle Cable at Throttle Body
1 ACCELERATOR CABLE
2 OFF
3 OFF
4 THROTTLE BODY BELLCRANK
5 SPEED CONTROL CABLE
6 RELEASE TABS
7 BRACKET
SPECIFICATIONS
FUEL TANK CAPACITY
FUEL SYSTEM PRESSURE
339 kPa 34 kPa (49.2 psi 2 psi ).
FUEL REQUIREMENTS
Your engi ne i s desi gned to meet al l emi ssi ons reg-
ul ati ons and provi de excel l ent fuel economy and per-
formance when usi ng hi gh qual i ty unl eaded gasol i ne
havi ng an octane rati ng of 87. The use of premi um
gasol i ne i s not recommended. The use of premi um
gasol i ne wi l l provi de no benefi t over hi gh qual i ty reg-
ul ar gasol i ne, and i n some ci rcumstances may resul t
i n poorer performance.
Li ght spark knock at l ow engi ne speeds i s not
harmful to your engi ne. However, conti nued heavy
spark knock at hi gh speeds can cause damage and
i mmedi ate servi ce i s requi red. Engi ne damage resul t-
i ng from operati on wi th a heavy spark knock may
not be covered by the new vehi cl e warranty.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng and hesi tati ons. I f you experi -
ence these symptoms, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
Over 40 auto manufacturers worl d-wi de have
i ssued and endorsed consi stent gasol i ne speci fi cati ons
(the Worl dwi de Fuel Charter, WWFC) to defi ne fuel
properti es necessary to del i ver enhanced emi ssi ons,
performance and durabi l i ty for your vehi cl e. We rec-
ommend the use of gasol i nes that meet the WWFC
speci fi cati ons i f they are avai l abl e.
REFORMULATED GASOLINE
Many areas of the country requi re the use of
cl eaner burni ng gasol i ne referred to as reformul at-
ed gasol i ne. Reformul ated gasol i ne contai n oxygen-
ates, and are speci fi cal l y bl ended to reduce vehi cl e
emi ssi ons and i mprove ai r qual i ty.
We strongl y supports the use of reformul ated gas-
ol i ne. Properl y bl ended reformul ated gasol i ne wi l l
provi de excel l ent performance and durabi l i ty for the
engi ne and fuel system components.
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
oxygenates such as 10% ethanol , MTBE, and ETBE.
Oxygenates are requi red i n some areas of the country
duri ng the wi nter months to reduce carbon monoxi de
emi ssi ons. Fuel s bl ended wi th these oxygenates may
be used i n your vehi cl e.
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage
critical fuel system components.
MMT IN GASOLINE
MMT i s a manganese-contai ni ng metal l i c addi ti ve
that i s bl ended i nto some gasol i ne to i ncrease octane.
Gasol i ne bl ended wi th MMT provi de no performance
advantage beyond gasol i ne of the same octane num-
ber wi thout MMT. Gasol i ne bl ended wi th MMT
reduce spark pl ug l i fe and reduce emi ssi on system
performance i n some vehi cl es. We recommend that
gasol i nes free of MMT be used i n your vehi cl e. The
MMT content of gasol i ne may not be i ndi cated on the
gasol i ne pump; therefore, you shoul d ask your gaso-
l i ne retai l er whether or not hi s/her gasol i ne contai ns
MMT.
I t i s even more i mportant to l ook for gasol i ne wi th-
out MMT i n Canada because MMT can be used at
l evel s hi gher than al l owed i n the Uni ted States.
MMT i s prohi bi ted i n Federal and Cal i forni a refor-
mul ated gasol i ne.
SULFUR IN GASOLINE
I f you l i ve i n the northeast Uni ted States, your
vehi cl e may have been desi gned to meet Cal i forni a
l ow emi ssi on standards wi th Cl eaner-Burni ng Cal i -
forni a reformul ated gasol i ne wi th l ow sul fur. I f such
fuel s are not avai l abl e i n states adopti ng Cal i forni a
emi ssi on standards, your vehi cl es wi l l operate sati s-
factori l y on fuel s meeti ng federal speci fi cati ons, but
emi ssi on control system performance may be
adversel y affected. Gasol i ne sol d outsi de of Cal i forni a
i s permi tted to have hi gher sul fur l evel s whi ch may
affect the performance of the vehi cl es catal yti c con-
verter. Thi s may cause the Mal functi on I ndi cator
Lamp (MI L), Check Engi ne or Servi ce Engi ne Soon
l i ght to i l l umi nate. We recommend that you try a di f-
ferent brand of unl eaded gasol i ne havi ng l ower sul fur
to determi ne i f the probl em i s fuel rel ated pri or to
returni ng your vehi cl e to an authori zed deal er for
servi ce.
CAUTION: If the Malfunction Indicator Lamp (MIL),
Check Engine or Service Engine Soon light is flash-
ing, immediate service is required; see on-board
diagnostics system section.
MATERIALS ADDED TO FUEL
Al l gasol i ne sol d i n the Uni ted States and Canada
are requi red to contai n effecti ve detergent addi ti ves.
Models Liters U. S. Gallons
All 76 20
Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
Use of addi ti onal detergents or other addi ti ves i s not
needed under normal condi ti ons.
FUEL SYSTEM CAUTIONS
CAUTION: Follow these guidelines to maintain your
vehicles performance:
The use of l eaded gas i s prohi bi ted by Federal
l aw. Usi ng l eaded gasol i ne can i mpai r engi ne perfor-
mance, damage the emi ssi on control system, and
coul d resul t i n l oss of warranty coverage.
An out-of-tune engi ne, or certai n fuel or i gni ti on
mal functi ons, can cause the catal yti c converter to
overheat. I f you noti ce a pungent burni ng odor or
some l i ght smoke, your engi ne may be out of tune or
mal functi oni ng and may requi re i mmedi ate servi ce.
Contact your deal er for servi ce assi stance.
When pul l i ng a heavy l oad or dri vi ng a ful l y
l oaded vehi cl e when the humi di ty i s l ow and the tem-
perature i s hi gh, use a premi um unl eaded fuel to
hel p prevent spark knock. I f spark knock persi sts,
l i ghten the l oad, or engi ne pi ston damage may resul t.
The use of fuel addi ti ves whi ch are now bei ng
sol d as octane enhancers i s not recommended. Most
of these products contai n hi gh concentrati ons of
methanol . Fuel system damage or vehi cl e perfor-
mance probl ems resul ti ng from the use of such fuel s
or addi ti ves i s not the responsi bi l i ty of Dai ml er-
Chrysl er Corporati on and may not be covered under
the new vehi cl e warranty.
NOTE: Intentional tampering with emissions control
systems can result in civil penalties being assessed
against you.
TORQUE CHART
DESCRIPTION TORQUE
Accel erator Pedal Bracket Mounti ng Nuts . . 5 Nm
(36 i n. l bs.)
Fuel Hose Cl amps . . . . . . . . . . . 3 Nm (25 i n. l bs.)
Fuel Rai l Mounti ng Bol ts . . . . 11 Nm (100 i n. l bs.)
Fuel Tank Mounti ng Strap Nuts . . . . . . . . . 10 Nm
(90 i n. l bs.)
Fuel Pump Modul e Locknut . . . 74 Nm (55 ft. l bs.)
FUEL INJ ECTION SYSTEM
TABLE OF CONTENTS
page page
POWERTRAIN CONTROL MODULE (PCM) . . . . . 25
MODES OF OPERATION . . . . . . . . . . . . . . . . . . . 26
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSEPCM INPUT . . . . . . . . . . . . . . . . . . . . 29
BATTERY VOLTAGEPCM INPUT. . . . . . . . . . . . 29
BRAKE SWITCHPCM INPUT. . . . . . . . . . . . . . . 29
FIVE VOLT SENSOR SUPPLIESPRIMARY
AND SECONDARY . . . . . . . . . . . . . . . . . . . . . . 29
FUEL LEVEL SENSORPCM INPUT . . . . . . . . . . 30
ENGINE COOLANT TEMPERATURE
SENSORPCM INPUT. . . . . . . . . . . . . . . . . . . 30
EXTENDED IDLE SWITCHPCM INPUT . . . . . . . 30
OXYGEN SENSORPCM INPUT. . . . . . . . . . . . . 30
IGNITION CIRCUIT SENSEPCM INPUT . . . . . . 31
INTAKE MANIFOLD AIR TEMPERATURE
SENSORPCM INPUT. . . . . . . . . . . . . . . . . . . 32
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORPCM INPUT. . . . . . . . . . . . . . . . . . . 32
OIL PRESSURE SENSORPCM INPUT . . . . . . . 33
POWER GROUNDS . . . . . . . . . . . . . . . . . . . . . . . 33
POWER STEERING PRESSURE SWITCH
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SENSOR RETURNPCM INPUT. . . . . . . . . . . . . 34
THROTTLE POSITION SENSOR (TPS)PCM
INPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
VEHICLE SPEED AND DISTANCE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
AUTO SHUTDOWN (ASD) RELAYPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS. . . . . . 35
DATA LINK CONNECTORPCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FUEL INJECTORSPCM OUTPUT . . . . . . . . . . . 35
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . . . . . 35
IDLE AIR CONTROL (IAC) MOTORPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
RADIATOR FAN RELAYPCM OUTPUT . . . . . . . 36
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 36
VISUAL INSPECTION. . . . . . . . . . . . . . . . . . . . . . 37
ASD AND FUEL PUMP RELAYS. . . . . . . . . . . . . . 41
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE. . . . . . . . . . . . . . . . . . . . 42
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . . 43
FUEL PUMP RELAY. . . . . . . . . . . . . . . . . . . . . . . 44
THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . 44
THROTTLE POSITION SENSOR (TPS) . . . . . . . . 45
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . . . . . 45
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
POWERTRAIN CONTROL MODULE (PCM) . . . . . 46
POWER STEERING PRESSURE SWITCH
2.5L ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
OXYGEN SENSOR. . . . . . . . . . . . . . . . . . . . . . . . 47
AIR CLEANER ELEMENT (FILTER) . . . . . . . . . . . 49
ENGINE COOLANT TEMPERATURE SENSOR. . . 49
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . 51
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 51
SPECIAL TOOLS
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
POWERTRAIN CONTROL MODULE (PCM)
DESCRIPTION
The Powertrai n Control Modul e (PCM) i s l ocated
i n the engi ne compartment (Fi g. 1). The PCM i s
referred to as JTEC.
OPERATION
The PCM operates the fuel system. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, certai n
transmi ssi on features, speed control , ai r condi ti oni ng
compressor cl utch engagement and i dl e speed. The
PCM can adapt i ts programmi ng to meet changi ng
operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed, power
steeri ng pump pressure (2.5L engi ne onl y), and the
brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
A/C request (i f equi pped wi th factory A/C)
A/C sel ect (i f equi pped wi th factory A/C)
Auto shutdown (ASD) sense
Battery temperature
Battery vol tage
Brake swi tch
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Camshaft posi ti on sensor si gnal
Crankshaft posi ti on sensor
Data l i nk connecti on for DRB scan tool
Engi ne cool ant temperature sensor
Extended i dl e swi tch (4.0L engi ne wi th pol i ce
package)
Fuel l evel
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
I ntake mani fol d ai r temperature sensor
Leak detecti on pump (swi tch) sense (i f equi pped)
Mani fol d absol ute pressure (MAP) sensor
Oi l pressure
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Power steeri ng pressure swi tch (2.5L engi ne
onl y)
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Vehi cl e speed sensor
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
CCD bus (+/-) ci rcui ts for: speedometer, vol tme-
ter, fuel gauge, oi l pressure gauge/l amp, engi ne temp.
gauge and speed control warn. l amp
Data l i nk connecti on for DRB scan tool
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fi ve vol t sensor suppl y (pri mary)
Fi ve vol t sensor suppl y (secondary)
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
I dl e ai r control (I AC) motor
I gni ti on coi l
Leak detecti on pump (i f equi pped)
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through CCD ci rcui ts.
Radi ator cool i ng fan rel ay
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through CCD
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t
MODES OF OPERATION
OPERATION
As i nput si gnal s to the Powertrai n Control Modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the PCM recei ves i nput
si gnal s and responds onl y accordi ng to preset PCM
programmi ng. I nput from the oxygen (O2S) sensors
i s not moni tored duri ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
Fig. 1 PCM Location
1 (3) 32WAY CONNECTORS
2 PCM
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
The PCM pre-posi ti ons the i dl e ai r control (I AC)
motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the ASD rel ay. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The PCM recei ves i nputs from:
Battery vol tage
Throttl e posi ti on sensor (TPS)
Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the PCM recei ves i nputs from:
Battery vol tage
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
The PCM operates the A/C compressor cl utch
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the PCM
recei ves i nputs from:
Battery vol tage
Extended i dl e swi tch (4.0L engi ne wi th pol i ce
package onl y)
tor)
Battery vol tage
trans. onl y)
Oxygen sensors
Power steeri ng pressure swi tch (2.5L engi ne
onl y)
Based on these i nputs, the fol l owi ng occurs:
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
through the A/C compressor cl utch rel ay. Thi s i s done
i f A/C has been sel ected by the vehi cl e operator and
speci fi ed pressures are met at the hi gh and l owpres-
sure A/C swi tches. Refer to Group 24, Heati ng and
Ai r Condi ti oni ng for addi ti onal i nformati on.
The opti onal Extended I dl e Swi tch i s used to rai se
and hol d the engi ne i dl e speed to approxi matel y 1000
rpm. Thi s i s when the shi fter i s i n ei ther the Park or
Neutral posi ti on and throttl e pedal i s not used. A
rocker-type swi tch (extended i dl e swi tch) i s mounted
to the i nstrument panel . Thi s swi tch wi l l suppl y a
ground ci rcui t (i nput) to the PCM. The switch is
available only with 4.0L engine when supplied
with optional police package.
On 2.5L 4cyl i nder engi nes, a power steeri ng pres-
sure swi tch i s used to suppl y an i nput to the PCM
when steeri ng pump pressure i s hi gh. Thi s wi l l rai se
engi ne speed. Refer to Power Steeri ng Pressure
Swi tch i n thi s group for addi ti onal i nformati on. The
4.0L 6cylinder engine does not use this switch.
CRUISE MODE
i s a Cl osed Loop mode. At crui si ng speed, the PCM
recei ves i nputs from:
Battery vol tage
tor)
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The PCM recogni zes
an abrupt i ncrease i n throttl e posi ti on or MAP pres-
sure as a demand for i ncreased engi ne output and
vehi cl e accel erati on. The PCM i ncreases i njector
pul se wi dth i n response to i ncreased throttl e openi ng.
DECELERATION MODE
i s an Open Loop mode. Duri ng hard decel erati on, the
PCM recei ves the fol l owi ng i nputs.
Battery vol tage
tor)
trans. onl y)
Vehi cl e speed sensor
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the PCM recei ves the fol l owi ng
i nputs.
Battery vol tage
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
SENSE PCM INPUT
DESCRIPTION
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated i n the engi ne com-
partment. Refer to l abel on PDC cover for rel ay l oca-
ti on.
OPERATION
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The rel ay i s used to
connect the oxygen sensor heater el ement, i gni ti on
coi l and fuel i njectors to 12 vol t + power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the powertrai n control modul e (PCM)
does not see 12 vol ts at thi s i nput when the ASD
shoul d be acti vated, i t wi l l set a di agnosti c troubl e
code (DTC).
BATTERY VOLTAGE PCM INPUT
OPERATION
The battery vol tage i nput provi des power to the
Powertrai n Control Modul e (PCM). I t al so i nforms
the PCM what vol tage l evel i s suppl i ed to the i gni -
ti on coi l and fuel i njectors.
I f battery vol tage i s l ow, the PCM wi l l i ncrease
i njector pul se wi dth (peri od of ti me that the i njector
i s energi zed). Thi s i s done to compensate for the
reduced fl ow through i njector caused by the l owered
vol tage.
BRAKE SWITCH PCM INPUT
OPERATION
When the brake l i ght swi tch i s acti vated, the Pow-
ertrai n Control Modul e (PCM) recei ves an i nput i ndi -
cati ng that the brakes are bei ng appl i ed. After
recei vi ng thi s i nput, the PCM mai ntai ns i dl e speed to
a schedul ed rpm through control of the I dl e Ai r Con-
trol (I AC) motor. The brake swi tch i nput i s al so used
to di sabl e vent and vacuum sol enoi d output si gnal s
to the speed control servo.
FIVE VOLT SENSOR SUPPLIES PRIMARY
AND SECONDARY
DESCRIPTION
Two di fferent Powertrai n Control Modul e (PCM)
fi ve vol t suppl y ci rcui ts are used; pri mary and sec-
ondary.
OPERATION
These 2 ci rcui ts wi l l :
suppl y the requi red 5 vol t power source to the
Crankshaft Posi ti on (CKP) sensor.
Camshaft Posi ti on (CMP) sensor.
suppl y a reference vol tage for the Mani fol d Abso-
l ute Pressure (MAP) sensor.
suppl y a reference vol tage for the Throttl e Posi -
ti on Sensor (TPS) sensor.
oi l pressure sensor.
suppl y the requi red 5 vol t power source for the
Vehi cl e Speed Sensor (VSS) (i f equi pped).
suppl y the 5 vol t power source to the transmi s-
si on pressure sensor (i f equi pped wi th an RE auto-
mati c transmi ssi on).
FUEL LEVEL SENSOR PCM INPUT
DESCRIPTION
The fuel l evel sensor (fuel gauge sendi ng uni t) i s
l ocated on the fuel pump modul e.
OPERATION
Refer to Fuel Gauge Sendi ng Uni t i n the Fuel
Del i very secti on for i nformati on.
ENGINE COOLANT TEMPERATURE SENSOR
PCM INPUT
DESCRIPTION
The Engi ne Cool ant Temperature (ECT) sensor i s
used to sense engi ne cool ant temperature. The sensor
protrudes i nto an engi ne water jacket.
The ECT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as engi ne cool ant
temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
At key-on, the Powertrai n Control Modul e (PCM)
sends out a regul ated 5 vol t si gnal to the ECT sensor.
The PCM then moni tors the si gnal as i t passes
through the ECT sensor to the sensor ground (sensor
return).
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
The PCM uses i nputs from the ECT sensor for the
fol l owi ng cal cul ati ons:
for engi ne cool ant temperature gauge operati on
through CCD or PCI (J1850) communi cati ons
I njector pul se-wi dth
Spark-advance curves
ASD rel ay shut-down ti mes
I dl e Ai r Control (I AC) motor key-on steps
Pul se-wi dth pri me-shot duri ng cranki ng
O2 sensor cl osed l oop ti mes
Purge sol enoi d on/off ti mes
EGR sol enoi d on/off ti mes (i f equi pped)
Leak Detecti on Pump operati on (i f equi pped)
Radi ator fan rel ay on/off ti mes (i f equi pped)
Target i dl e speed
EXTENDED IDLE SWITCH PCM INPUT
DESCRIPTION
USED ONLY WITH OPTIONAL POLICE
PACKAGE WHEN EQUIPPED WITH A 4.0L
ENGINE: The extended i dl e swi tch i s a rocker-type
swi tch mounted to the i nstrument panel .
OPERATION
The extended i dl e swi tch i s used to rai se the
engi ne i dl e speed to approxi matel y 1000 rpm by sup-
pl yi ng a ground ci rcui t to the Powertrai n Control
Modul e (PCM). Thi s i dl e speed control can onl y be
operated when the shi fter i s i n ei ther the Park or
Neutral posi ti on.
OXYGEN SENSOR PCM INPUT
DESCRIPTION
The Oxygen Sensors (O2S) are attached to, and
protrude i nto the vehi cl e exhaust system. Dependi ng
on the emi ssi on package, the vehi cl e may contai n
ei ther 2 or 4 sensors. On non-Cal i forni a emi ssi ons
packages, 2 sensors are used: upstream (referred to
as 1/1) and downstream (referred to as 1/2). On Cal -
i forni a emi ssi ons packages, 4 sensors are used: 2
upstream (referred to as 1/1 and 2/1) and 2 down-
stream (referred to as 1/2 and 2/2).
OPERATION
An O2 sensor i s a gal vani c battery that provi des
the PCM wi th a vol tage si gnal (0-1 vol t) i nversel y
proporti onal to the amount of oxygen i n the exhaust.
I n other words, i f the oxygen content i s l ow, the vol t-
age output i s hi gh; i f the oxygen content i s hi gh the
output vol tage i s l ow. The PCM uses thi s i nformati on
to adjust i njector pul se-wi dth to achi eve the
14.7to1 ai r/fuel rati o necessary for proper engi ne
operati on and to control emi ssi ons.
An O2 sensor must have a source of oxygen from
outsi de of the exhaust stream for compari son. Cur-
rent O2 sensors recei ve thei r fresh oxygen (outsi de
ai r) suppl y through the wi re harness. Thi s i s why i t
i s i mportant to never sol der an O2 sensor connector,
or pack the connector wi th grease.
Four wi res (ci rcui ts) are used on each O2 sensor: a
12vol t feed ci rcui t for the sensor heati ng el ement; a
ground ci rcui t for the heater el ement; a l ow-noi se
sensor return ci rcui t to the PCM, and an i nput ci r-
cui t from the sensor back to the PCM to detect sen-
sor operati on.
Oxygen Sensor Heaters/Heater Relays: On a
certai n non-Cal i forni a emi ssi on package, the heaters
on both sensors are fed battery vol tage from the ASD
rel ay whi ch i s control l ed by the PCM. Refer to ASD
rel ay for more i nformati on. On another non-Cal i for-
ni a emi ssi on package, the heaters on both sensors
are fed battery vol tage from the two O2S heater
rel ays. The O2S rel ays are al so control l ed by the
PCM. On the Cal i forni a emi ssi on package, the heat-
ers on al l 4 sensors are fed battery vol tage from the
two O2S Heater Rel ays.
The O2 sensor uses a Posi ti ve Thermal Co-effi ci ent
(PTC) heater el ement. As temperature i ncreases,
resi stance i ncreases. At ambi ent temperatures
around 70F, the resi stance of the heati ng el ement i s
approxi matel y 6 ohms. As the sensors temperature
i ncreases, resi stance i n the heater el ement i ncreases.
Thi s al l ows the heater to mai ntai n the opti mum
operati ng temperature of approxi matel y 930-1100F
(500-600 C). Al though the sensors operate the
same, there are physi cal di fferences, due to the envi -
ronment that they operate i n, that keep them from
bei ng i nterchangeabl e.
Mai ntai ni ng correct sensor temperature at al l
ti mes al l ows the system to enter i nto cl osed l oop
operati on sooner. Al so, i t al l ows the system to remai n
i n cl osed l oop operati on duri ng peri ods of extended
i dl e.
I n Cl osed Loop operati on, the PCM moni tors cer-
tai n O2 sensor i nput(s) al ong wi th other i nputs, and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
Upstream Sensor (Non-California Emissions):
The upstream O2S sensor (1/1 sensor) i s l ocated i n
the exhaust downpi pe before the catal yti c convertor.
I t provi des an i nput vol tage to the PCM. The i nput
tel l s the PCM the oxygen content of the exhaust gas.
The PCM uses thi s i nformati on to fi ne tune fuel
del i very to mai ntai n the correct oxygen content at
the downstream oxygen sensor. The PCM wi l l change
the ai r/fuel rati o unti l the upstream sensor i nputs a
vol tage that the PCM has determi ned wi l l make the
downstream sensor output (oxygen content) correct.
The upstream oxygen sensor al so provi des an i nput
to determi ne catal yst effi ci ency.
Downstream Sensor (Non-California Emis-
sions): The downstream heated oxygen sensor (1/2
sensor) i s l ocated near the outl et end of the catal yti c
convertor. The downstream sensor i s al so used to
determi ne the correct ai r fuel rati o. As the oxygen
content changes at the downstream the PCM cal cu-
l ates how much ai r fuel rati o change i s requi red. The
PCM then l ooks at the upstream oxygen sensor vol t-
age and changes fuel del i very unti l the upstream
sensor vol tage changes enough to correct the down-
stream sensor vol tage (oxygen content).
The downstream oxygen sensor al so provi des an
i nput to determi ne catal yst effi ci ency.
Upstream Sensors (California Emissions): Two
upstream sensors are used (1/1 and 2/1). The 1/1 sen-
sor i s the fi rst sensor to recei ve exhaust gases from
the #1 cyl i nder. Both of the upstream O2S sensors
are l ocated i n the exhaust mani fol d just before the
mi ni -catal yti c convertors. They provi de an i nput vol t-
age to the PCM. The i nput tel l s the PCM the oxygen
content of the exhaust gas. The PCM uses thi s i nfor-
mati on to fi ne tune fuel del i very to mai ntai n the cor-
rect oxygen content at the downstream oxygen
sensors. The PCM wi l l change the ai r/fuel rati o unti l
the upstream sensors i nput a vol tage that the PCM
has determi ned wi l l make the downstream sensors
output (oxygen content) correct.
The upstream oxygen sensors al so provi de an i nput
to determi ne mi ni -catal yst effi ci ency.
Downstream Sensors (California Emissions):
Two downstream sensors are used (1/2 and 2/2). The
downstream sensors are l ocated i n the exhaust down-
pi pes just after the mi ni -catal yti c convertors. The
downstream i s al so used to determi ne the correct ai r
fuel rati o. As the oxygen content changes at the
downstream the PCM cal cul ates how much ai r fuel
rati o change i s requi red. The PCM then l ooks at the
upstream oxygen sensor vol tage and changes fuel
del i very unti l the upstream sensor vol tage changes
enough to correct the downstream sensor vol tage
(oxygen content).
The downstream oxygen sensors al so provi de an
i nput to determi ne mi ni -catal yst effi ci ency.
IGNITION CIRCUIT SENSE PCM INPUT
DESCRIPTION
Thi s ci rcui t ti es the i gni ti on swi tch to the Power-
trai n Control Modul e (PCM).
OPERATION
The i gni ti on ci rcui t sense i nput tel l s the PCM the
i gni ti on swi tch has energi zed the i gni ti on ci rcui t.
Battery vol tage i s al so suppl i ed to the PCM
through the i gni ti on swi tch when the i gni ti on i s i n
the RUN or START posi ti on. Thi s i s referred to as
the i gni ti on sense ci rcui t and i s used to wake up
the PCM. Vol tage on the i gni ti on i nput can be as l ow
as 6 vol ts and the PCM wi l l sti l l functi on. Vol tage i s
suppl i ed to thi s ci rcui t to power the PCMs 8-vol t reg-
ul ator and to al l ow the PCM to perform fuel , i gni ti on
and emi ssi ons control functi ons. The battery vol tage
on thi s l i ne i s suppl i ed to the 8-vol t regul ator whi ch
then passes on a power-up suppl y to the 5-vol t regu-
l ator.
SENSOR PCM INPUT
DESCRIPTION
The 2wi re I ntake Mani fol d Ai r Temperature (I AT)
sensor i s i nstal l ed i n the i ntake mani fol d wi th the
sensor el ement extendi ng i nto the ai r stream.
The I AT sensor i s a two-wi re Negati ve Thermal
Coeffi ci ent (NTC) sensor. Meani ng, as i ntake mani -
fol d temperature i ncreases, resi stance (vol tage) i n the
sensor decreases. As temperature decreases, resi s-
tance (vol tage) i n the sensor i ncreases.
OPERATION
The I AT sensor provi des an i nput vol tage to the
Powertrai n Control Modul e (PCM) i ndi cati ng the
densi ty of the ai r enteri ng the i ntake mani fol d based
upon i ntake mani fol d temperature. At key-on, a
5vol t power ci rcui t i s suppl i ed to the sensor from
the PCM. The sensor i s grounded at the PCM
through a l ow-noi se, sensor-return ci rcui t.
The PCM uses thi s i nput to cal cul ate the fol l owi ng:
Adjustment of spark ti mi ng (to hel p prevent
spark knock wi th hi gh i ntake mani fol d ai r-charge
temperatures)
The resi stance val ues of the I AT sensor i s the same
as for the Engi ne Cool ant Temperature (ECT) sensor.
SENSOR PCM INPUT
DESCRIPTION
The Mani fol d Absol ute Pressure (MAP) sensor i s
attached to the si de of the engi ne throttl e body wi th
2 screws. The sensor i s connected to the throttl e body
wi th a rubber L-shaped fi tti ng.
OPERATION
The MAP sensor i s used as an i nput to the Power-
trai n Control Modul e (PCM). I t contai ns a si l i con
based sensi ng uni t to provi de data on the mani fol d
vacuum that draws the ai r/fuel mi xture i nto the com-
busti on chamber. The PCM requi res thi s i nformati on
to determi ne i njector pul se wi dth and spark advance.
When mani fol d absol ute pressure (MAP) equal s
Barometri c pressure, the pul se wi dth wi l l be at max-
i mum.
A 5 vol t reference i s suppl i ed from the PCM and
returns a vol tage si gnal to the PCM that refl ects
mani fol d pressure. The zero pressure readi ng i s 0.5V
and ful l scal e i s 4.5V. For a pressure swi ng of 015
psi , the vol tage changes 4.0V. To operate the sensor,
i t i s suppl i ed a regul ated 4.8 to 5.1 vol ts. Ground i s
provi ded through the l ow-noi se, sensor return ci rcui t
at the PCM.
The MAP sensor i nput i s the number one contri b-
utor to fuel i njector pul se wi dth. The most i mportant
functi on of the MAP sensor i s to determi ne baromet-
ri c pressure. The PCM needs to know i f the vehi cl e i s
at sea l evel or at a hi gher al ti tude, because the ai r
densi ty changes wi th al ti tude. I t wi l l al so hel p to cor-
rect for varyi ng barometri c pressure. Barometri c
pressure and al ti tude have a di rect i nverse correl a-
ti on; as al ti tude goes up, barometri c goes down. At
key-on, the PCM powers up and l ooks at MAP vol t-
age, and based upon the vol tage i t sees, i t knows the
current barometri c pressure (rel ati ve to al ti tude).
Once the engi ne starts, the PCM l ooks at the vol tage
agai n, conti nuousl y every 12 mi l l i seconds, and com-
pares the current vol tage to what i t was at key-on.
The di fference between current vol tage and what i t
was at key-on, i s mani fol d vacuum.
Duri ng key-on (engi ne not runni ng) the sensor
reads (updates) barometri c pressure. A normal range
can be obtai ned by moni tori ng a known good sensor.
As the al ti tude i ncreases, the ai r becomes thi nner
(l ess oxygen). I f a vehi cl e i s started and dri ven to a
very di fferent al ti tude than where i t was at key-on,
the barometri c pressure needs to be updated. Any
ti me the PCM sees Wi de Open Throttl e (WOT), based
upon Throttl e Posi ti on Sensor (TPS) angl e and RPM,
i t wi l l update barometri c pressure i n the MAP mem-
ory cel l . Wi th peri odi c updates, the PCM can make
i ts cal cul ati ons more effecti vel y.
The PCM uses the MAP sensor i nput to ai d i n cal -
cul ati ng the fol l owi ng:
Mani fol d pressure
Barometri c pressure
Engi ne l oad
Spark-advance programs
Shi ft-poi nt strategi es (certai n automati c trans-
mi ssi ons onl y)
I dl e speed
Decel fuel shutoff
The MAP sensor si gnal i s provi ded from a si ngl e
pi ezoresi sti ve el ement l ocated i n the center of a di a-
phragm. The el ement and di aphragm are both made
of si l i cone. As mani fol d pressure changes, the di a-
phragm moves causi ng the el ement to defl ect, whi ch
stresses the si l i cone. When si l i cone i s exposed to
stress, i ts resi stance changes. As mani fol d vacuum
i ncreases, the MAP sensor i nput vol tage decreases
proporti onal l y. The sensor al so contai ns el ectroni cs
that condi ti on the si gnal and provi de temperature
compensati on.
The PCM recogni zes a decrease i n mani fol d pres-
sure by moni tori ng a decrease i n vol tage from the
readi ng stored i n the barometri c pressure memory
cel l . The MAP sensor i s a l i near sensor; meani ng as
pressure changes, vol tage changes proporti onatel y.
The range of vol tage output from the sensor i s usu-
al l y between 4.6 vol ts at sea l evel to as l ow as 0.3
vol ts at 26 i n. of Hg. Barometri c pressure i s the pres-
sure exerted by the atmosphere upon an object. At
sea l evel on a standard day, no storm, barometri c
pressure i s approxi matel y 29.92 i n Hg. For every 100
feet of al ti tude, barometri c pressure drops.10 i n. Hg.
I f a storm goes through i t can change barometri c
pressure from what shoul d be present for that al ti -
tude. You shoul d know what the average pressure
and correspondi ng barometri c pressure i s for your
area.
OIL PRESSURE SENSOR PCM INPUT
DESCRIPTION
The 3wi re, sol i d-state engi ne oi l pressure sensor
(sendi ng uni t) i s l ocated i n an engi ne oi l pressure
gal l ery.
OPERATION
The oi l pressure sensor uses three ci rcui ts. They
are:
A 5vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM)
A sensor ground through the PCMs sensor
return
A si gnal to the PCM rel ati ng to engi ne oi l pres-
sure
The oi l pressure sensor has a 3wi re el ectri cal
functi on very much l i ke the Mani fol d Absol ute Pres-
sure (MAP) sensor. Meani ng di fferent pressures
rel ate to di fferent output vol tages.
A 5vol t suppl y i s sent to the sensor from the PCM
to power up the sensor. The sensor returns a vol tage
si gnal back to the PCM rel ati ng to engi ne oi l pres-
sure. Thi s si gnal i s then transferred (bussed) to the
i nstrument panel on ei ther a CCD or PCI bus ci rcui t
(dependi ng on vehi cl e l i ne) to operate the oi l pressure
gauge and the check gauges l amp. Ground for the
sensor i s provi ded by the PCM through a l ow-noi se
sensor return.
POWER GROUNDS
OPERATION
The Powertrai n Control Modul e (PCM) has 2 mai n
grounds. Both of these grounds are referred to as
power grounds. Al l of the hi gh-current, noi sy, el ectri -
cal devi ces are connected to these grounds as wel l as
al l of the sensor returns. The sensor return comes
i nto the sensor return ci rcui t, passes through noi se
suppressi on, and i s then connected to the power
ground.
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng PCM l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l (s)
Certai n rel ays/sol enoi ds
Certai n sensors
POWER STEERING PRESSURE SWITCH PCM
INPUT
DESCRIPTION
A pressure sensi ng swi tch (Fi g. 2) i s i ncl uded i n
the power steeri ng system (mounted on the hi gh-
pressure l i ne). Thi s swi tch wi l l be used onl y on vehi -
cl es equi pped wi th a 2.5L engi ne and power steeri ng.
OPERATION
The power steeri ng pressure swi tch provi des an
i nput to the Powertrai n Control Modul e (PCM). Thi s
i nput i s provi ded duri ng peri ods of hi gh pump l oad
and l ow engi ne rpm; such as duri ng parki ng maneu-
vers. The PCM wi l l then i ncrease the i dl e speed
through the I dl e Ai r Control (I AC) motor. Thi s i s
done to prevent the engi ne from stal l i ng under the
i ncreased l oad.
When steeri ng pump pressure exceeds 3275 kPa
690 kPa (475 psi 100 psi ), the normal l y cl osed
swi tch wi l l open and the PCM wi l l i ncrease the
engi ne i dl e speed. Thi s wi l l prevent the engi ne from
stal l i ng.
Fig. 2 Power Steering Pump Pressure Switch2.5L
Engine
1 POWER STEERING PRESSURE SWITCH
3 POWER STEERING PUMP
When pump pressure drops to approxi matel y 1379
kPa (200 psi ), the swi tch ci rcui t wi l l re-cl ose and
engi ne i dl e speed wi l l return to i ts previ ous setti ng.
SENSOR RETURN PCM INPUT
OPERATION
The Sensor Return ci rcui ts are i nternal to the Pow-
ertrai n Control Modul e (PCM).
Sensor Return provi des a l ownoi se ground refer-
ence for al l engi ne control system sensors. Refer to
Power Grounds for more i nformati on.
THROTTLE POSITION SENSOR (TPS) PCM
INPUT
DESCRIPTION
The 3wi re Throttl e Posi ti on Sensor (TPS) i s
mounted on the throttl e body and i s connected to the
throttl e bl ade.
OPERATION
The TPS i s a 3wi re vari abl e resi stor that provi des
the Powertrai n Control Modul e (PCM) wi th an i nput
si gnal (vol tage) that represents the throttl e bl ade
posi ti on of the throttl e body. The sensor i s connected
to the throttl e bl ade shaft. As the posi ti on of the
throttl e bl ade changes, the resi stance (output vol t-
age) of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from.26
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.49 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
The PCM needs to i denti fy the acti ons and posi ti on
of the throttl e bl ade at al l ti mes. Thi s i nformati on i s
needed to assi st i n performi ng the fol l owi ng cal cul a-
ti ons:
I gni ti on ti mi ng advance
Fuel i njecti on pul se-wi dth
I dl e (l earned val ue or mi ni mum TPS)
Off-i dl e (0.06 vol t)
Wi de Open Throttl e (WOT) open l oop (2.608
vol ts above l earned i dl e vol tage)
Decel erati on fuel l ean out
Fuel cutoff duri ng cranki ng at WOT (2.608 vol ts
above l earned i dl e vol tage)
A/C WOT cutoff (certai n automati c transmi s-
si ons onl y)
VEHICLE SPEED AND DISTANCE SENSOR
PCM INPUT
DESCRIPTION
The 3wi re Vehi cl e Speed Sensor (VSS) i s l ocated
on the speedometer pi ni on gear adapter. I f equi pped
wi th 4WD, thi s adapter i s l ocated on the extensi on
housi ng of the transfer case (dri vers si de). I f
equi pped wi th 2WD, thi s adapter i s l ocated on the
l eft si de of the transmi ssi on extensi on housi ng.
OPERATION
The VSS i s a 3ci rcui t (3wi re), magneti c, hal l -ef-
fect sensor.
The 3 ci rcui ts are:
A 5vol t power suppl y from the Powertrai n Con-
trol Modul e (PCM).
A ground i s provi ded for the sensor though a
l ow-noi se sensor return ci rcui t i n the PCM.
An i nput to the PCM i s used to determi ne vehi -
cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Under decel erati on condi ti ons, the PCM adjusts
the I dl e Ai r Control (I AC) motor to mai ntai n a
desi red MAP val ue. Under i dl e condi ti ons, the PCM
adjusts the I AC motor to mai ntai n a desi red engi ne
speed.
AUTO SHUTDOWN (ASD) RELAY PCM
OUTPUT
DESCRIPTION
The 5pi n, 12vol t, Automati c Shutdown (ASD)
rel ay i s l ocated i n the Power Di stri buti on Center
(PDC). Refer to l abel on PDC cover for rel ay l ocati on.
OPERATION
The ASD rel ay suppl i es battery vol tage (12+ vol ts)
to the fuel i njectors and i gni ti on coi l (s). Wi th certai n
emi ssi ons packages i t al so suppl i es 12vol ts to the
oxygen sensor heati ng el ements.
The ground ci rcui t for the coi l wi thi n the ASD
rel ay i s control l ed by the Powertrai n Control Modul e
(PCM). The PCM operates the ASD rel ay by swi tch-
i ng i ts ground ci rcui t on and off.
The ASD rel ay wi l l be shutdown, meani ng the
12vol t power suppl y to the ASD rel ay wi l l be de-ac-
ti vated by the PCM i f:
the i gni ti on key i s l eft i n the ON posi ti on. Thi s
i s i f the engi ne has not been runni ng for approxi -
matel y 1.8 seconds.
there i s a crankshaft posi ti on sensor si gnal to
the PCM that i s l ower than pre-determi ned val ues.
The PCM wi l l sense i f or when the ASD rel ay has
been acti vated through a sense ci rcui t. Refer to
Automati c Shut-Down (ASD) Rel ay Sense-PCM I nput
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS
OPERATION
The Powertrai n Control Modul e (PCM) sends cer-
tai n output si gnal s through the CCD bus ci rcui ts.
These si gnal s are used to control certai n i nstrument
panel l ocated i tems and to determi ne certai n i denti -
fi cati on numbers.
Refer to Group 8E, I nstrument Panel and Gauges
DATA LINK CONNECTOR PCM INPUT AND
OUTPUT
DESCRIPTION
The data l i nk connector i s l ocated at the l ower
edge of the i nstrument panel near the steeri ng col -
umn.
OPERATION
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the Powertrai n Control Modul e (PCM).
FUEL INJECTORS PCM OUTPUT
DESCRIPTION
The fuel i njectors are connected to the engi ne wi th
the fuel i njector rai l .
OPERATION
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the Powertrai n Control Modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Battery vol tage (12 vol ts +) i s suppl i ed to the i njec-
tors through the ASD rel ay. The ASD rel ay wi l l shut-
down the 12 vol t power source to the fuel i njectors i f
the PCM senses the i gni ti on i s on, but the engi ne i s
not runni ng. Thi s occurs after the engi ne has not
been runni ng for approxi matel y 1.8 seconds.
The PCM determi nes i njector on-ti me (pul se wi dth)
based on vari ous i nputs.
FUEL PUMP RELAY-PCM OUTPUT
DESCRIPTION
The 5pi n, 12vol t, fuel pump rel ay i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
l abel on the PDC cover for rel ay l ocati on.
OPERATION
The Powertrai n Control Modul e (PCM) energi zes
the el ectri c fuel pump through the fuel pump rel ay.
The fuel pump rel ay i s energi zed by fi rst appl yi ng
battery vol tage to i t when the i gni ti on key i s turned
ON, and then appl yi ng a ground si gnal to the rel ay
from the PCM.
Whenever the i gni ti on key i s turned ON, the el ec-
tri c fuel pump wi l l operate. But, the PCM wi l l shut-
down the ground ci rcui t to the fuel pump rel ay i n
approxi matel y 13 seconds unl ess the engi ne i s oper-
ati ng or the starter motor i s engaged.
IDLE AIR CONTROL (IAC) MOTOR PCM
OUTPUT
DESCRIPTION
The I AC stepper motor i s mounted to the throttl e
body, and regul ates the amount of ai r bypassi ng the
control of the throttl e pl ate. As engi ne l oads and
ambi ent temperatures change, engi ne rpm changes. A
pi ntl e on the I AC stepper motor protrudes i nto a pas-
sage i n the throttl e body, control l i ng ai r fl ow through
the passage. The I AC i s control l ed by the Powertrai n
Control Modul e (PCM) to mai ntai n the target engi ne
i dl e speed.
OPERATION
At i dl e, engi ne speed can be i ncreased by retract-
i ng the I AC motor pi ntl e and al l owi ng more ai r to
pass through the port, or i t can be decreased by
restri cti ng the passage wi th the pi ntl e and di mi ni sh-
i ng the amount of ai r bypassi ng the throttl e pl ate.
The I AC i s cal l ed a stepper motor because i t i s
moved (rotated) i n steps, or i ncrements. Openi ng the
I AC opens an ai r passage around the throttl e bl ade
whi ch i ncreases RPM.
The PCM uses the I AC motor to control i dl e speed
(al ong wi th ti mi ng) and to reach a desi red MAP dur-
i ng decel (keep engi ne from stal l i ng).
The I AC motor has 4 wi res wi th 4 ci rcui ts. Two of
the wi res are for 12 vol ts and ground to suppl y el ec-
tri cal current to the motor wi ndi ngs to operate the
stepper motor i n one di recti on. The other 2 wi res are
al so for 12 vol ts and ground to suppl y el ectri cal cur-
rent to operate the stepper motor i n the opposi te
di recti on.
To make the I AC go i n the opposi te di recti on, the
PCM just reverses pol ari ty on both wi ndi ngs. I f onl y
1 wi re i s open, the I AC can onl y be moved 1 step
(i ncrement) i n ei ther di recti on. To keep the I AC
motor i n posi ti on when no movement i s needed, the
PCM wi l l energi ze both wi ndi ngs at the same ti me.
Thi s l ocks the I AC motor i n pl ace.
I n the I AC motor system, the PCM wi l l count
every step that the motor i s moved. Thi s al l ows the
PCM to determi ne the motor pi ntl e posi ti on. I f the
memory i s cl eared, the PCM no l onger knows the
posi ti on of the pi ntl e. So at the fi rst key ON, the
PCM dri ves the I AC motor cl osed, regardl ess of
where i t was before. Thi s zeros the counter. From
thi s poi nt the PCM wi l l back out the I AC motor and
keep track of i ts posi ti on agai n.
When engi ne rpm i s above i dl e speed, the I AC i s
used for the fol l owi ng:
Off-i dl e dashpot (throttl e bl ade wi l l cl ose qui ckl y
but i dl e speed wi l l not stop qui ckl y)
Decel erati on ai r fl ow control
A/C compressor l oad control (al so opens the pas-
sage sl i ghtl y before the compressor i s engaged so
that the engi ne rpm does not di p down when the
compressor engages)
Power steeri ng l oad control
The PCM can control pol ari ty of the ci rcui t to con-
trol di recti on of the stepper motor.
IAC Stepper Motor Program: The PCM i s al so
equi pped wi th a memory program that records the
number of steps the I AC stepper motor most recentl y
advanced to duri ng a certai n set of parameters. For
exampl e: The PCM was attempti ng to mai ntai n a
1000 rpm target duri ng a col d start-up cycl e. The l ast
recorded number of steps for that may have been
125. That val ue woul d be recorded i n the memory
cel l so that the next ti me the PCM recogni zes the
i denti cal condi ti ons, the PCM recal l s that 125 steps
were requi red to mai ntai n the target. Thi s program
al l ows for greater customer sati sfacti on due to
greater control of engi ne i dl e.
Another functi on of the memory program, whi ch
occurs when the power steeri ng swi tch (i f equi pped),
or the A/C request ci rcui t, requi res that the I AC step-
per motor control engi ne rpm, i s the recordi ng of the
l ast targeted steps i nto the memory cel l . The PCM
can anti ci pate A/C compressor l oads. Thi s i s accom-
pl i shed by del ayi ng compressor operati on for approx-
i matel y 0.5 seconds unti l the PCM moves the I AC
stepper motor to the recorded steps that were l oaded
i nto the memory cel l . Usi ng thi s program hel ps el i m-
i nate i dl e-qual i ty changes as l oads change. Fi nal l y,
the PCM i ncorporates a No-Load engi ne speed l i m-
i ter of approxi matel y 1800 - 2000 rpm, when i t rec-
ogni zes that the TPS i s i ndi cati ng an i dl e si gnal and
I AC motor cannot mai ntai n engi ne i dl e.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the I AC motor through the PCM.
RADIATOR FAN RELAY PCM OUTPUT
DESCRIPTION
The el ectri c radi ator cool i ng fan rel ay i s l ocated i n
the Power Di stri buti on Center (PDC).
OPERATION
An el ectri c radi ator cool i ng fan i s used wi th certai n
model s/engi nes. I t i s control l ed by the Powertrai n
Control Modul e (PCM) through the radi ator fan
rel ay. Not Equipped With A/C: The rel ay i s ener-
gi zed when cool ant temperature i s above 103C
(217F). I t wi l l then de-energi ze when cool ant tem-
perature drops to 98C (208F). Refer to Cool i ng Sys-
tems for addi ti onal i nformati on. Equipped With
A/C: I n addi ti on to usi ng cool ant temperatures to
control cool i ng fan operati on, a two-gang A/C hi gh-
pressure swi tch i s al so used to control cool i ng fan
operati on. When equi pped wi th thi s hi gh-pressure
swi tch, the cool i ng fan will not operate each ti me
the A/C cl utch i s engaged. Refer to Heati ng and Ai r
Condi ti oni ng for addi ti onal i nformati on.
THROTTLE BODY
DESCRIPTION
The throttl e body i s l ocated on the i ntake mani fol d.
Fuel does not enter the i ntake mani fol d through the
throttl e body. Fuel i s sprayed i nto the mani fol d by
the fuel i njectors.
OPERATION
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body. The throttl e body
contai ns an ai r control passage control l ed by an I dl e
Ai r Control (I AC) motor. The ai r control passage i s
used to suppl y ai r for i dl e condi ti ons. A throttl e val ve
(pl ate) i s used to suppl y ai r for above i dl e condi ti ons.
Certai n sensors are attached to the throttl e body.
The accel erator pedal cabl e, speed control cabl e and
transmi ssi on control cabl e (when equi pped) are con-
nected to the throttl e body l i nkage arm.
control l ed by the PCM.
VISUAL INSPECTION
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy the three 32way el ectri cal connectors
are ful l y i nserted i nto the connector of the Power-
trai n Control Modul e (PCM) (Fi g. 3).
(2) I nspect battery cabl e connecti ons. Be sure they
are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect ASD
rel ay connecti ons. I nspect starter motor rel ay connec-
ti ons. I nspect rel ays for si gns of physi cal damage and
corrosi on. The rel ays are l ocated i n Power Di stri bu-
ti on Center (PDC) (Fi g. 4). Refer to l abel on PDC
cover for rel ay l ocati on.
(4) 2.5L Engi ne: I nspect i gni ti on coi l pri mary con-
necti on. Veri fy coi l secondary cabl e i s fi rml y con-
nected to coi l (Fi g. 5).
(5) 4.0L Engi ne: I nspect i gni ti on coi l connecti on
(Fi g. 6).
(6) 2.5L Engi ne: Veri fy that di stri butor cap i s cor-
rectl y attached to di stri butor. Be sure that spark
pl ug cabl es are fi rml y connected to the di stri butor
cap and spark pl ugs are i n thei r correct fi ri ng order.
Be sure that coi l cabl e i s fi rml y connected to di stri b-
utor cap and coi l .
Fig. 3 Powertrain Control Module (PCM)
2 PCM
1 POWER DISTRIBUTION CENTER (PDC)
Fig. 5 Ignition Coil2.5L Engine
1 IGNITION COIL
3 MOUNTING BOLTS
4 SECONDARY CABLE
(7) Connect vehi cl e to an osci l l oscope and i nspect
spark events for foul ed or damaged spark pl ugs or
cabl es.
(8) Veri fy generator output wi re, generator connec-
tor and ground wi re are fi rml y connected to genera-
tor.
(9) I nspect system body grounds for l oose or di rty
connecti ons. Refer to Group 8, Wi ri ng for ground
l ocati ons.
(10) Veri fy crankcase venti l ati on (CCV) operati on.
Refer to Group 25, Emi ssi on Control System for addi -
ti onal i nformati on.
(11) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(12) Veri fy hose connecti ons to al l ports of vacuum
fi tti ngs on i ntake mani fol d are ti ght and not l eaki ng.
(13) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and crui se control cabl e con-
necti ons (i f equi pped). Check thei r connecti ons to
throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(14) I f equi pped wi th vacuum brake booster, veri fy
vacuum booster hose i s fi rml y connected to fi tti ng on
i ntake mani fol d. Al so check connecti on to brake vac-
uum booster.
(15) I nspect ai r cl eaner i nl et and ai r cl eaner el e-
ment for di rt or restri cti ons.
(16) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(17) Veri fy i ntake mani fol d ai r temperature sensor
wi re connector i s fi rml y connected to harness connec-
tor (Fi g. 7) or (Fi g. 8).
(18) Veri fy MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 8). Al so veri fy
rubber L-shaped fi tti ng from MAP sensor to throttl e
body i s fi rml y connected (Fi g. 9).
(19) Veri fy fuel i njector wi re harness connectors
are fi rml y connected to i njectors i n correct order.
Each harness connector i s numeri cal l y tagged wi th
i njector number (I NJ 1, I NJ 2 etc.) of i ts correspond-
i ng fuel i njector and cyl i nder number.
(20) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor and throttl e
posi ti on sensor (TPS) (Fi g. 8).
(21) Veri fy wi re harness connector i s fi rml y con-
nected to engi ne cool ant temperature sensor (Fi g.
10).
Fig. 6 Ignition Coil4.0L Engine
1 REAR OF VALVE COVER
2 COIL RAIL
3 SLIDE TAB
4 RELEASE LOCK
5 COIL CONNECTOR
Fig. 7 Intake Manifold Air Temp. Sensor Location
2.5L Engine
2 INTAKE MANIFOLD TEMPERATURE SENSOR
3 FUEL INJECTOR
(23) Veri fy that al l oxygen sensor wi re connectors
are fi rml y connected to sensors. I nspect sensors and
connectors for damage (Fi g. 11), (Fi g. 12), (Fi g. 13) or
(Fi g. 14).
Fig. 8 Sensor Locations4.0L Engine
2 THROTTLE BODY
3 IAC MOTOR
4 ELEC. CONN.
5 TPS
6 MAP SENSOR
7 ELEC. CONN.
8 IAT SENSOR
9 ELEC. CONN.
Fig. 9 Rubber L-Shaped FittingMAP Sensor-to-
Throttle Body
1 THROTTLE BODY
2 MAP SENSOR
3 RUBBER FITTING
Fig. 10 Engine Coolant Temperature Sensor
Typical
2 ENGINE COOLANT TEMPERATURE SENSOR
Fig. 11 Front Oxygen Sensor4.0LFederal
Emissions
1 1/1 O2S
(24) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(25) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(26) I f equi pped wi th automati c transmi ssi on, ver-
i fy el ectri cal harness i s fi rml y connected to park/neu-
tral swi tch. Refer to Automati c Transmi ssi on secti on
of Group 21.
(27) Veri fy that el ectri cal harness connector i s
fi rml y connected to the vehi cl e speed sensor (Fi g. 15).
(28) 2.5L 4Cyl i nder Engi ne Onl y: Veri fy good
el ectri cal connecti on at power steeri ng pressure
swi tch (Fi g. 16). Thi s swi tch i s not used wi th 4.0L
engi nes.
(29) Veri fy good el ectri cal connecti ons at fuel pump
modul e connector at front of fuel tank (Fi g. 17).
(30) Veri fy good EVAP cani ster vent l i ne connec-
ti on at front of fuel tank (Fi g. 17).
(31) Veri fy good fuel suppl y l i ne connecti on at
front of fuel tank (Fi g. 17).
(32) I nspect al l fuel l i nes/hoses for cracks or l eaks.
(33) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
(34) Veri fy battery cabl e and sol enoi d feed wi re
connecti ons to starter sol enoi d are ti ght and cl ean.
I nspect for chaffed wi res or wi res rubbi ng up agai nst
other components.
Fig. 12 Oxygen Sensors4.0LCalifornia
Emissions
1 1/1 O2S
2 2/1 O2S
3 2/2 O2S
4 1/2 O2S
Emissions
1 1/1 O2S
Fig. 14 Rear Oxygen Sensor2.5L/4.0LFederal
Emissions
1 1/2 O2S
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered. Two di fferent
types of rel ays may be used, (Fi g. 18) or (Fi g. 19).
Fig. 15 Vehicle Speed SensorTypical
4WD Shown
1 SENSOR ELECTRICAL CONNECTOR
2 SLIDE TAB
3 4WD TRANSFER CASE EXTENSION
4 VEHICLE SPEED SENSOR
5 RELEASE LOCK
Fig. 16 Power Steering Pressure Switch
2.5L Engine
Fig. 17 Fuel Tank Connections at Front of Fuel Tank
1 FUEL PUMP MODULE CONNECTOR
2 LEFT-REAR SHOCK ABSORBER
3 EVAP CANISTER VENT LINE CONNECTION
5 FUEL SUPPLY LINE CONNECTION
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 18 ASD and Fuel Pump Relay Terminals
Type 1
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to the Wi ri ng
Di agrams.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
The fol l owi ng test procedure has been devel oped to
check throttl e body cal i brati ons for correct i dl e condi -
ti ons. The procedure shoul d be used to di agnose the
throttl e body for condi ti ons that may cause i dl e prob-
l ems. This procedure should be used only after
normal diagnostic procedures have failed to
produce results that indicate a throttle body
related problem. Be sure to check for proper
operation of the idle air control motor before
performing this test.
A speci al fi xed ori fi ce tool (number 6714) (Fi g. 20)
must be used for the fol l owi ng test. Thi s tool has a
fi xed i nternal di ameter of 0.185.
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 19 ASD and Fuel Pump Relay Terminals
Type 2
Fig. 20 6714 Fixed Orifice Tool
(1) Start the engi ne and bri ng to operati ng tem-
perature. Be sure al l accessori es are off before per-
formi ng thi s test.
(2) Shut off engi ne and remove ai r duct at throttl e
body.
(3) 2.5L 4Cylinder Engine: Near front/top of
val ve cover, di sconnect CCV tube at fi xed ori fi ce fi t-
ti ng (Fi g. 21). I nsert Speci al Tool 6714 i nto end of
di sconnected CCV tube (i nsert ei ther end of tool i nto
tube). Let tool and tube hang di sconnected at si de of
engi ne.
(4) 4.0L 6Cylinder Engine: Di sconnect CCV
tube (Fi g. 22) at i ntake mani fol d fi tti ng. Attach a
short pi ece of rubber hose to speci al tool 6714 (i nsert
rubber hose to ei ther end of tool ). I nstal l rubber hose/
tool to i ntake mani fol d fi tti ng. Let CCV tube hang
di sconnected at si de of engi ne.
(5) Connect DRB scan tool to 16way data l i nk
connector. Thi s connector i s l ocated at l ower edge of
i nstrument panel near steeri ng col umn. Refer to
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce manual for DRB operati on.
(6) Start engi ne and al l ow to warm up.
(7) Usi ng the DRB scan tool , scrol l through menus
as fol l ows: sel ectStand Al one DRB I I I , sel ect the
year 2000 Di agnosti cs, sel ectEngi ne, sel ectSys-
tem Test, sel ectMi ni mum Ai r Fl ow.
(8) The DRB scan tool wi l l count down to stabi l i ze
i dl e rpm and di spl ay mi ni mum ai r fl ow i dl e rpm. The
i dl e rpm shoul d be between 500 and 900 rpm. I f i dl e
speed i s outsi de these speci fi cati ons, repl ace throttl e
body. Refer to Throttl e Body Removal /I nstal l ati on.
(9) Di sconnect DRB scan tool from vehi cl e.
(10) Remove ori fi ce tool and connect CCV tube to
engi ne.
(11) I nstal l ai r duct to throttl e body.
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 23). Refer to l abel on PDC cover
for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
Fig. 21 Install Orifice Tool 2.5L 4Cylinder Engine
1 AIR INLET FITTING
2 AIR FILTER COVER
Fig. 22 Install Orifice Tool 4.0L 6Cylinder Engine
1 AIR INLET FITTING
3 AIR FILTER COVER
FUEL PUMP RELAY
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 23). Refer to l abel on PDC
cover for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
THROTTLE BODY
control l ed by the Powertrai n Control Modul e (PCM).
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 24) or (Fi g.
25).
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(4) Remove four throttl e body mounti ng bol ts.
(5) Remove throttl e body from i ntake mani fol d.
(6) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
(1) Cl ean mati ng surfaces of throttl e body and
i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
(7) I nstal l ai r cl eaner at throttl e body.
1 POWER DISTRIBUTION CENTER (PDC)
Fig. 24 Throttle Body and Sensor Locations4.0L
Engine
2 THROTTLE BODY
3 IAC MOTOR
4 ELEC. CONN.
5 TPS
6 MAP SENSOR
7 ELEC. CONN.
8 IAT SENSOR
9 ELEC. CONN.
THROTTLE POSITION SENSOR (TPS)
The TPS i s mounted to the throttl e body (Fi g. 24)
or (Fi g. 25).
REMOVAL
(2) Di sconnect TPS el ectri cal connector.
(3) Remove TPS mounti ng screws (Fi g. 26).
(4) Remove TPS.
INSTALLATION
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 27). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs).
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate throttl e (by hand) to check
for any TPS bi ndi ng before starti ng engi ne.
(5) I nstal l ai r cl eaner tube to throttl e body.
IDLE AIR CONTROL (IAC) MOTOR
The I AC motor i s l ocated on the si de of the throttl e
body (Fi g. 24) or (Fi g. 25).
REMOVAL
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 28).
(4) Remove I AC motor from throttl e body.
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
(3) I nstal l el ectri cal connector.
(4) I nstal l ai r cl eaner tube to throttl e body.
Fig. 25 Throttle Body and Sensor Locations2.5L
Engine
1 IDLE AIR CONTROL MOTOR
2 IAT SENSOR
3 THROTTLE BODY
4 THROTTLE POSITION SENSOR
5 MAP SENSOR
6 IDLE AIR CONTROL PASSAGE INLET
7 THROTTLE BODY MOUNTING BOLTS (4)
Fig. 26 TPS Mounting Screws
1 MOUNTING SCREWS
2 TPS
Fig. 27 Throttle Position SensorInstallation
1 TANGS
2 THROTTLE SHAFT
3 THROTTLE BODY
4 TPS
SENSOR
The MAP sensor i s mounted to the si de of the
throttl e body (Fi g. 24) or (Fi g. 25). An L-shaped rub-
ber fi tti ng i s used to connect the MAP sensor to
throttl e body (Fi g. 29).
REMOVAL
(1) Remove ai r cl eaner i ntake tube at throttl e
body.
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 29).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 29) from throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
(4) I nstal l ai r cl eaner i ntake tube.
POWERTRAIN CONTROL MODULE (PCM)
The PCM i s l ocated i n the engi ne compartment
next to the ai r cl eaner assembl y (Fi g. 30).
REMOVAL
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(3) Careful l y unpl ug the three 32way connectors
(Fi g. 31) from PCM.
(4) Remove three PCM mounti ng bol ts and remove
PCM from vehi cl e.
INSTALLATION
(1) I nstal l PCM and mounti ng bol ts to vehi cl e.
(2) Ti ghten bol ts to 4 Nm (35 i n. l bs.).
(3) Check pi n connectors i n the PCM and the three
32way connectors for corrosi on or damage. Al so, the
pi n hei ghts i n connectors shoul d al l be same. Repai r
as necessary before i nstal l i ng connectors.
Fig. 28 Mounting Bolts (Screws)IAC Motor
1 IDLE AIR CONTROL MOTOR
2 MOUNTING SCREWS
Fig. 29 MAP Sensor Mounting
1 THROTTLE BODY
2 MAP SENSOR
3 RUBBER FITTING
Fig. 30 PCM Location
2 PCM
(4) I nstal l three 32way connectors.
(5) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(6) I nstal l battery cabl e.
(7) Use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal I denti fi cati on Number (VI N)
and ori gi nal vehi cl e mi l eage.
POWER STEERING PRESSURE SWITCH 2. 5L
ENGINE
Thi s swi tch i s not used wi th 4.0L si x-cyl i nder
engi nes.
The power steeri ng pressure swi tch i s i nstal l ed i n
the power steeri ng hi gh-pressure hose (Fi g. 32).
REMOVAL
(1) Di sconnect el ectri cal connector from power
steeri ng pressure swi tch.
(2) Pl ace a smal l contai ner or shop towel beneath
swi tch to col l ect any excess fl ui d.
(3) Remove swi tch. Use back-up wrench on power
steeri ng l i ne to prevent l i ne bendi ng.
INSTALLATION
(1) I nstal l power steeri ng swi tch i nto power steer-
i ng l i ne.
(2) Ti ghten to 1422 Nm (124195 i n. l bs.) torque.
(3) Connect el ectri cal connector to swi tch.
(4) Check power steeri ng fl ui d and add as neces-
sary.
(5) Start engi ne and agai n check power steeri ng
fl ui d. Add fl ui d i f necessary.
OXYGEN SENSOR
REMOVAL
Never apply any type of grease to the oxygen
sensor electrical connector, or attempt any sol-
dering of the sensor wiring harness. For sensor
operation, it must have a comparison source of
oxygen from outside the exhaust system. This
fresh air is supplied to the sensor through its
pigtail wiring harness.
Refer to (Fi g. 33), (Fi g. 34), (Fi g. 35) or (Fi g. 36) for
O2S (oxygen sensor) l ocati on.
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(2) Di sconnect wi re connector from O2S sensor.
CAUTION: When disconnecting sensor electrical
connector, do not pull directly on wire going into
sensor.
(3) Remove O2S sensor wi th an oxygen sensor
removal and i nstal l ati on tool .
(4) Cl ean threads i n exhaust pi pe usi ng appropri -
ate tap.
Fig. 31 PCM Mounting
1 PCM
2 L. F. FENDER
3 PCM MOUNTING BOLTS (3)
Fig. 32 Power Steering Pressure Switch
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
Emissions
1 1/1 O2S
Fig. 34 Oxygen Sensors4.0LCalifornia
Emissions
1 1/1 O2S
2 2/1 O2S
3 2/2 O2S
4 1/2 O2S
Emissions
1 1/1 O2S
Fig. 36 Rear Oxygen Sensor2.5L/4.0LFederal
Emissions
1 1/2 O2S
(1) I nstal l O2S sensor. Ti ghten to 30 Nm (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector.
AIR CLEANER ELEMENT (FILTER)
REMOVAL
(1) Unl ock ai r tube cl amp (Fi g. 37) at ai r cl eaner
cover. To unl ock cl amp, attach adjustabl e pl i ers to
cl amp and rotate pl i ers as shown i n (Fi g. 38).
(2) Remove ai r tube at cover.
(3) Pry back three cl i ps retai ni ng ai r cl eaner cover
to ai r cl eaner housi ng.
(4) Remove housi ng cover and remove ai r cl eaner
el ement.
(5) Cl ean i nsi de of housi ng before repl aci ng el e-
ment.
INSTALLATION
(1) I nstal l ai r cl eaner el ement i nto housi ng.
(2) I nstal l ai r cl eaner cover to housi ng (three
cl i ps). Be sure cover i s properl y seated to ai r cl eaner
housi ng.
(3) I nstal l ai r tube and cl amp to cover. Compress
cl amp snugl y wi th adjustabl e pl i ers as shown i n (Fi g.
39).
ENGINE COOLANT TEMPERATURE SENSOR
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
The cool ant temperature sensor i s i nstal l ed i n the
thermostat housi ng (Fi g. 40).
REMOVAL
(1) Parti al l y drai n cool i ng system unti l cool ant
l evel i s bel ow cyl i nder head. Observe the WARN-
INGS i n Group 7, Cool i ng.
Fig. 37 Air Cleaner Housing and Element (Filter)
1 COVER
2 AIR TUBE
3 CLAMPS (2)
4 HOUSING
5 CLIPS (3)
6 ELEMENT (FILTER)
Fig. 38 Clamp Removal
1 CLAMP
2 ADJUSTABLE PLIERS
3 REMOVAL
Fig. 39 Clamp Installation
1 CLAMP
2 ADJUSTABLE PLIERS
(2) Di sconnect cool ant temperature sensor wi re
connector.
(3) Remove sensor from thermostat housi ng.
INSTALLATION
(1) Appl y seal ant to sensor threads (new repl ace-
ment sensors wi l l have seal ant al ready appl i ed).
(2) I nstal l cool ant temperature sensor i nto thermo-
stat housi ng. Ti ghten to 11 Nm (8 ft. l bs.) torque.
(3) Connect wi re connector.
(4) Fi l l cool i ng system. Refer to Group 7, Cool i ng
System.
SENSOR
The i ntake mani fol d ai r temperature (I AT) sensor
i s i nstal l ed i nto i ntake mani fol d pl enum near throttl e
body (Fi g. 41) or (Fi g. 42).
REMOVAL
(1) Di sconnect el ectri cal connector from I AT sen-
sor.
(2) Remove sensor from i ntake mani fol d.
INSTALLATION
(1) I nstal l I AT sensor i nto i ntake mani fol d.
Ti ghten sensor to 28 Nm (20 ft. l bs.) torque.
(2) Connect el ectri cal connector to sensor.
Fig. 40 Engine Coolant Temperature Sensor
Typical
1 THERMOSTAT
2 ENGINE COOLANT TEMPERATURE SENSOR
Fig. 41 IAT Sensor Location4.0L Engine
2 THROTTLE BODY
3 IAC MOTOR
4 ELEC. CONN.
5 TPS
6 MAP SENSOR
7 ELEC. CONN.
8 IAT SENSOR
9 ELEC. CONN.
Fig. 42 IAT Sensor Location2.5L Engine
2 INTAKE MANIFOLD TEMPERATURE SENSOR
3 FUEL INJECTOR
VEHICLE SPEED SENSOR
The Vehi cl e Speed Sensor (VSS) i s l ocated on the
speedometer pi ni on gear adapter. I f equi pped wi th
4WD, thi s adapter i s l ocated on the transfer case
extensi on (l eft si de) (Fi g. 43). I f equi pped wi th 2WD,
thi s adapter i s l ocated on the extensi on housi ng of
the transmi ssi on (l eft si de).
REMOVAL
(2) Di sconnect el ectri cal connector from sensor by
pushi ng sl i de tab (Fi g. 43). After sl i de tab has been
posi ti oned, push i n on secondary rel ease l ock (Fi g. 43)
on si de of connector and pul l connector from sensor.
(3) Remove sensor mounti ng bol t (Fi g. 44).
(4) Remove sensor (pul l strai ght out) from speed-
ometer pi ni on gear adapter (Fi g. 44). Do not remove
gear adapter from transmi ssi on.
INSTALLATION
(1) Cl ean i nsi de of speedometer pi ni on gear
adapter before i nstal l i ng speed sensor.
(2) I nstal l sensor i nto speedometer gear adapter
and i nstal l mounti ng bol t. Before tightening bolt,
verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
(3) Ti ghten sensor mounti ng bol t to 2.2 Nm (20 i n.
l bs.) torque.
(4) Connect el ectri cal connector to sensor.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Ai r Cl eaner Housi ng Mount. Bol ts . . . . . . . . 8 Nm
(71 i n. l bs.)
Engi ne Cool ant Temperature Sensor . . . . . . 11 Nm
(96 i n. l bs.)
I AC Motor-To-Throttl e Body Bol ts . . . . . . . . 7 Nm
(60 i n. l bs.)
I ntake Mani fol d Ai r Temp. Sensor . . . . . . . 28 Nm
(20 ft. l bs.)
MAP Sensor Mounti ng Screws . . 3 Nm (25 i n. l bs.)
Oxygen Sensor . . . . . . . . . . . . . 30 Nm (22 ft. l bs.)
PCM Mounti ng Screws . . . . . . . . 4 Nm (35 i n. l bs.)
Power Steeri ng Pressure Swi tch . . . . . . 1422 Nm
(124195 i n. l bs.)
Throttl e Body Mounti ng Bol ts . . . . . . . . . . . 11 Nm
(100 i n. l bs.)
Throttl e Posi ti on Sensor Mounti ng Screws . . 7 Nm
(60 i n. l bs.)
Vehi cl e Speed Sensor Mounti ng Bol t . . . . . 2.2 Nm
(20 i n. l bs.)
Fig. 43 VSS Location4WD Shown
1 SENSOR ELECTRICAL CONNECTOR
2 SLIDE TAB
3 4WD TRANSFER CASE EXTENSION
5 RELEASE LOCK
Fig. 44 VSS Removal/Installation
2 SENSOR MOUNTING BOLT
3 O-RING
4 SPEEDOMETER PINION GEAR
5 SPEEDOMETER PINION GEAR ADAPTER
6 O-RING
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench6856
Adapters, Fuel Pressure Test6539 and/or 6631
Fitting, Air Metering6714
O2S (Oxygen Sensor) Remover/InstallerC-4907
Test Kit, Fuel Pressure5069
Test Kit, Fuel PressureC-4799-B
Fuel Line Removal Tool6782
STEERING
TABLE OF CONTENTS
page page
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . 1
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . . 5
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . . 11
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . 22
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . 26
POWER STEERING
TABLE OF CONTENTS
page page
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
POWER STEERING SYSTEM DIAGNOSIS
CHARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STEERING SYSTEM
DESCRIPTION
The power steeri ng system has a hydraul i c pump.
The pump i s a constant fl ow rate and di spl acement,
vane-type pump. The pump on the 4.0L engi ne has a
reservoi r mounted to i t (Fi g. 1). The 2.5L engi ne has
a remote mounted reservoi r.
The steeri ng gear (Fi g. 1) used i s a reci rcul ati ng
bal l type gear wi th 14:1 gear rati o. A ti l t and non-ti l t
col umn provi de steeri ng i nput.
NOTE: Right hand drive (RHD) and left hand drive
(LHD) service procedures and torque specifications
for steering linkage, gear and column are the same.
The power steering pump procedures are different.
Refer to appropriate service procedures regarding
each component in the system.
OPERATION
The steeri ng gear acts as a rol l i ng thread between
the worm shaft and the rack pi ston. Power assi st i s
provi ded by the hydraul i c pump. When the steeri ng
wheel i s turned the worm shaft turns whi ch moves
the rack pi ston. The rack pi ston movement turns the
pi tman shaft whi ch i s connected to the steeri ng l i nk-
age by the pi tman arm.
Fig. 1 Power Steering Gear & Pump - 4.0L
1 4.0 L PUMP
2 RETURN HOSE
3 STEERING GEAR
4 PRESSURE HOSE
5 RESERVOIR
XJ STEERING 19 - 1
POWER STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There i s some noi se i n al l power steeri ng systems. One of the most common i s a hi ssi ng sound evi dent at a
standsti l l parki ng. Or when the steeri ng wheel i s at the end of i ts travel . Hi ss i s a hi gh frequency noi se si mi l ar
to that of a water tap bei ng cl osed sl owl y. The noi se i s present i n al l val ves that have a hi gh vel oci ty fl ui d passi ng
through an ori fi ce. There i s no rel ati onshi p between thi s noi se and steeri ng performance.
OBJECTIONAL HISS OR
WHISTLE
1. Steering intermediate shaft to dash panel
seal.
1. Check and repair seal at dash
panel.
2. Noisy valve in power steering gear. 2. Replace steering gear.
RATTLE OR CLUNK 1. Gear mounting bolts loose. 1. Tighten bolts to specification.
2. Loose or damaged suspension
components/track bar.
2. Inspect and repair suspension.
3. Loose or damaged steering linkage. 3. Inspect and repair steering
linkage.
4. Internal gear noise. 4. Replace gear.
5. Pressure hose in contact with other
components.
5. Reposition hose.
CHIRP OR SQUEAL 1. Loose belt. 1. Adjust or replace.
WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level.
2. Pressure hose in contact with other
components.
2. Reposition hose.
3. Internal pump noise. 3. Replace pump.
4. Air in the system. 4. Perform pump initial operation.
SUCKING AIR SOUND 1. Loose return line clamp. 1. Replace clamp.
2. O-ring missing or damaged on hose
fitting.
2. Replace o-ring.
3. Low fluid level. 3. Fill to proper level.
4. Air leak between pump and reservoir. 4. Repair as necessary.
SCRUBBING OR
KNOCKING
1. Wrong tire size. 1. Verify tire size.
2. Wrong gear. 2. Verify gear.
19 - 2 STEERING XJ
BINDING AND STICKING
DIFFICULT TO TURN WHEEL
STICKS OR BINDS
3. Steering component. 3. Inspect and lube.
4. Loose belt. 4. Adjust or replace.
5. Low pump pressure. 5. Pressure test and replace if
necessary.
6. Column shaft coupler binding. 6. Replace coupler.
7. Steering gear worn or out of
adjustment.
7. Repair or replace gear.
8. Ball joints binding. 8. Inspect and repair as necessary.
INSUFFICIENT ASSIST OR POOR RETURN TO CENTER
HARD TURNING OR MOMENTARY
INCREASE IN TURNING EFFORT
3. Loose belt. 3. Adjust or replace.
4. Lack of lubrication. 4. Inspect and lubricate steering and
suspension compnents.
5. Low pump pressure. 5. Pressure test and repair as
necessary.
6. Internal gear leak. 6. Pressure and flow test, and repair
as necessary.
STEERING WHEEL
DOES NOT WANT TO RETURN TO
CENTER POSITION
2. Wheel alignment. 2. Align front end.
3. Lack of lubrication. 3. Inspect and lubricate steering and
suspension compnents.
4. High friction in steering gear. 4. Test and adjust as necessary.
5. Ball joints binding. 5. Inspect and repair as necessary.
Some roads will cause a vehicle to drift, due to the
crown in the road.
XJ STEERING 19 - 3
LOOSE STEERING AND VEHICLE LEADS/DRIFTS
EXCESSIVE PLAY IN STEERING
WHEEL
1. Worn or loose suspension or
steering components.
2. Worn or loose wheel bearings. 2. Repair as necessary.
3. Steering gear mounting. 3. Tighten gear mounting bolts to
specification.
4. Gear out of adjustment. 4. Adjust gear to specification.
5. Worn or loose steering coupler. 5. Repair as necessary.
VEHICLE PULLS TO ONE SIDE
DURING BRAKING
1. Tire Pressure. 1. Adjust tire pressure.
2. Air in brake hydrauliics system. 2. Bleed brake system.
3. Worn brake components. 3. Repair as necessary.
VEHICLE LEADS OR DRIFTS
FROM STRAIGHT AHEAD
DIRECTION ON UNCROWNED
ROAD.
2. Radial tire lead. 2. Cross front tires.
3. Brakes dragging. 3. Repair as necessary.
4. Wheel alignment. 4. Align vehicle.
5. Weak or broken spring. 5. Replace spring.
6. Loose or worn steering/
7. Cross caster out of spec. 7. Adjust or replace axle as
necessary.
19 - 4 STEERING XJ
POWER STEERING PUMP
TABLE OF CONTENTS
page page
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 5
POWER STEERING PRESSURE LINE. . . . . . . . . . 5
POWER STEERING RETURN LINE . . . . . . . . . . . . 6
POWER FLOW AND PRESSURE. . . . . . . . . . . . . . 6
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
POWER STEERING PUMP - INITIAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 7
PUMP RESERVOIR-2.5L . . . . . . . . . . . . . . . . . . . . 7
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 10
POWER STEERING PUMP
DESCRIPTION
Hydraul i c pressure for the power steeri ng system
i s provi ded by a bel t dri ven power steeri ng pump
(Fi g. 1). The pump shaft has a pressed-on hi gh
strength pl asti c dri ve pul l ey that i s bel t dri ven by
the crankshaft pul l ey. The reservoi r i s attached to
the pump body wi th spri ng cl i ps on the 4.0L engi ne.
A remote pump reservoi r i s used on the 2.5L engi ne
mounted to the fan shroud. The power steeri ng pump
i s connected to the steeri ng gear by the pressure and
return hoses.
OPERATION
The power steeri ng pump i s a constant fl ow rate
and di spl acement, vane-type pump. The pump i nter-
nal parts operate submerged i n fl ui d. The fl ow con-
trol ori fi ce i s part of the hi gh pressure l i ne fi tti ng.
The pressure rel i ef val ve i nsi de the fl ow control val ve
l i mi ts the pump pressure.
NOTE: Power steering pumps have different pres-
sure rates and are not interchangeable with other
pumps.
POWER STEERING PRESSURE LINE
DESCRIPTION
The hose consi sts of two metal ends and rubber
center secti on that contai ns a tuni ng cabl e.
OPERATION
Power steeri ng pressure l i ne, i s used to transfer
hi gh pressure power steeri ng fl ui d, from the power
steeri ng pump to the power steeri ng gear.
Fig. 1 Pump With Integral Reservoir
1 CAP
2 FLUID RESERVOIR (TYPICAL)
3 HIGH-PRESSURE FITTING
4 DRIVE PULLEY
5 PUMP BODY
6 RESERVOIR CLIP
XJ STEERING 19 - 5
POWER STEERING RETURN LINE
DESCRIPTION
Power steeri ng return l i ne i s a hose whi ch i s
cl amped at the pump and the gear.
OPERATION
Power steeri ng return l i ne, i s used to transfer l ow
pressure power steeri ng fl ui d, from the power steer-
i ng gear to the power steeri ng pump.
POWER FLOW AND PRESSURE
The fol l owi ng procedure i s used to test the opera-
ti on of the power steeri ng system on the vehi cl e. Thi s
test wi l l provi de the gal l ons per mi nute (GPM) or
fl ow rate of the power steeri ng pump al ong wi th the
maxi mum rel i ef pressure. Perform test any ti me a
power steeri ng system probl em i s present. Thi s test
wi l l determi ne i f the power steeri ng pump or power
steeri ng gear i s not functi oni ng properl y. The fol l ow-
i ng pressure and fl ow test i s performed usi ng Power
Steeri ng Anal yzer Tool Ki t 6815 (Fi g. 2) and Adapter
Ki t 6893.
FLOW AND PRESSURE TEST
(1) Check the power steeri ng bel t to ensure i t i s i n
good condi ti on and adjusted properl y.
(2) Connect pressure gauge hose from the Power
Steeri ng Anal yzer to Tube 6865.
(3) Connect Adapter 6826 to Power Steeri ng Ana-
l yzer test val ve end.
(4) Di sconnect hi gh pressure hose at the pump.
Use a contai ner for dri ppi ng fl ui d.
(5) Connect Tube 6865 to the pump hose fi tti ng.
(6) Connect the power steeri ng hose from the
steeri ng gear to Adapter 6826.
(7) Open the test val ve compl etel y.
(8) Start engi ne and l et i dl e l ong enough to ci rcu-
l ate power steeri ng fl ui d through fl ow/pressure test
gauge and to get ai r out of the fl ui d. Then shut off
engi ne.
(9) Check fl ui d l evel , add fl ui d as necessary. Start
engi ne agai n and l et i dl e.
(10) Gauge shoul d read bel ow 862 kPa (125 psi ), i f
above, i nspect the hoses for restri cti ons and repai r as
necessary. The i ni ti al pressure readi ng shoul d be i n
the range of 345-552 kPa (50-80 psi ).
(11) I ncrease the engi ne speed to 1500 RPM and
read the fl ow meter. The readi ng shoul d be 2.4 - 2.8
GPM, i f the readi ng i s bel ow thi s speci fi cati on the
pump shoul d be repl aced.
CAUTION: The next step involves testing maximum
pump pressure output and flow control valve oper-
ation. Do not leave valve closed for more than three
seconds as the pump could be damaged.
(12) Cl ose val ve ful l y three ti mes and record hi gh-
est pressure i ndi cated each ti me. All three read-
ings must be above specifications and within
345 kPa (50 psi) of each other.
Pressures above speci fi cati ons but not wi thi n
345 kPa (50 psi ) of each other, repl ace pump.
Pressures wi thi n 345 kPa (50 psi ) of each other
but bel ow speci fi cati ons, repl ace pump.
(13) Open the test val ve, turn steeri ng wheel
extreme l eft and ri ght posi ti ons agai nst the stops.
Record the hi ghest i ndi cated pressure at each posi -
ti on. Compare readi ngs to speci fi cati ons. I f hi ghest
output pressures are not the same agai nst ei ther
stop, the gear i s l eaki ng i nternal l y and must be
repai red.
CAUTION: Do not force the pump to operate
against the stops for more than 2 to 3 seconds at a
time because, pump damage will result.
Fig. 2 Power Steering Analyzer
1 TUBE
2 ADAPTER FITTINGS
3 ANALYZER
4 GAUGE HOSE
PUMP SPECIFICATIONS
ENGINE
RELIEF
PRESSURE 50
FLOW RATE (GPM)
2.5L
9653 kPa
(1400 psi)
1500 RPM 2.4 - 2.8
GPM
4.0L
9653 kPa
(1400 psi)
19 - 6 STEERING XJ
PUMP LEAKAGE DIAGNOSIS
SERVICE PROCEDURES
OPERATION
WARNING: THE FLUID LEVEL SHOULD BE
CHECKED WITH ENGINE OFF TO PREVENT INJURY
FROM MOVING COMPONENTS.
CAUTION: Use MOPAR Power Steering Fluid or
equivalent. Do not use automatic transmission fluid
and do not overfill.
Wi pe fi l l er cap cl ean, then check the fl ui d l evel .
The di psti ck shoul d i ndi cate COLD when the fl ui d i s
at normal ambi ent temperature.
(1) Fi l l the pump fl ui d reservoi r to the proper l evel
and l et the fl ui d settl e for at l east two mi nutes.
(2) Start the engi ne and l et run for a few seconds
then turn engi ne off.
(3) Add fl ui d i f necessary. Repeat the above proce-
dure unti l the fl ui d l evel remai ns constant after run-
ni ng the engi ne.
(4) Rai se the front wheel s off the ground.
(5) Sl owl y turn the steeri ng wheel ri ght and l eft,
l i ghtl y contacti ng the wheel stops at l east 20 ti mes.
(6) Check the fl ui d l evel add i f necessary.
(7) Lower the vehi cl e, start the engi ne and turn
the steeri ng wheel sl owl y from l ock to l ock.
(8) Stop the engi ne and check the fl ui d l evel and
refi l l as requi red.
(9) I f the fl ui d i s extremel y foamy or mi l ky l ook-
i ng, al l ow the vehi cl e to stand a few mi nutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for
an extended period. This may cause pump damage.
POWER STEERING PUMP
NOTE: The power steering pump is mounted in the
same position on LHD and RHD vehicles. On 4.0L
RHD vehicles the front bracket is different. The ser-
vice procedures are the same.
REMOVAL
(1) Remove serpenti ne dri ve bel t, refer to Group 7
Cool i ng.
(2) Remove pressure and return hoses from pump,
and drai n pump.
(3) Remove 3 pump mounti ng bol ts through pul l ey
access hol es.
(4) Loosen the 3 pump bracket bol ts (Fi g. 3) and
(Fi g. 4).
(5) Ti l t pump downward and remove from engi ne.
(6) Remove pul l ey from pump.
INSTALLATION
(1) I nstal l pul l ey on pump.
(2) I nstal l pump on engi ne.
(3) Ti ghten pump bracket bol ts to 47 Nm (35 ft.
l bs.).
(4) I nstal l 3 pump mounti ng bol ts and ti ghten to
27 Nm (20 ft. l bs.).
(5) I nstal l the pressure and return hoses to pump.
(6) I nstal l dri ve bel t, refer to Group 7 Cool i ng.
(7) Add power steeri ng fl ui d and perform Power
Steeri ng Pump I ni ti al Operati on.
PUMP RESERVOIR-2. 5L
REMOVAL
(1) Remove the hoses from the bottom of the res-
ervoi r and drai n the reservoi r.
(2) Remove the push-i n fastener from the top of
the fan shroud.
(3) Sl i de reservoi r up off the fan shroud.
INSTALLATION
(1) Sl i de reservoi r down onto fan shroud.
(2) I nstal l the push-i n fastener i n the top of fan
shroud.
XJ STEERING 19 - 7
(3) I nstal l the pump hoses.
(4) Fi l l reservoi r to proper l evel . Refer to Power
Steeri ng Pump I ni ti al Operati on.
PUMP PULLEY
DISASSEMBLY
(1) Remove pump assembl y.
(2) Remove pul l ey from pump wi th Pul l er C-4333
or equi val ent pul l er (Fi g. 5).
ASSEMBLY
NOTE: The pulley is marked front for installation.
(1) Repl ace pul l ey i f bent, cracked, or l oose.
(2) I nstal l pul l ey on pump wi th I nstal l er C-4063-B
or equi val ent i nstal l er (Fi g. 6). The pul l ey must be
fl ush wi th the end of the shaft. Ensure the tool and
pul l ey are al i gned wi th the pump shaft.
(3) I nstal l pump assembl y.
(4) Wi th Serpenti ne Bel t, run engi ne unti l warm (5
mi n.) and note any bel t chi rp. I f chi rp exi sts, move
pul l ey outward approxi matel y 0.5 mm (0.020 i n.). I f
noi se i ncreases, press on 1.0 mm (0.040 i n.). Be
careful that pulley does not contact mounting
bolts.
PUMP RESERVOIR
DISASSEMBLY
(1) Remove power steeri ng pump.
(2) Cl ean exteri or of pump.
(3) Cl amp the pump body i n a soft jaw vi ce.
(4) Pry up tab and sl i de the retai ni ng cl i ps off (Fi g.
7).
NOTE: Use new retaining clips for installation.
(5) Remove fl ui d reservoi r from pump body.
Remove and di scard O-ri ng seal .
ASSEMBLY
(1) Lubri cate new O-ri ng Seal wi th Mopar Power
Steeri ng Fl ui d or equi val ent.
Fig. 3 Pump Mounting LHD
1 PUMP BRACKET
19 - 8 STEERING XJ
(2) I nstal l O-ri ng seal i n housi ng.
(3) I nstal l reservoi r onto housi ng.
(4) Sl i de and tap i n new reservoi r retai ner cl i ps
unti l tab l ocks to housi ng.
(5) I nstal l power steeri ng pump.
(6) Add power steeri ng fl ui d, refer to Pump I ni ti al
Operati on.
Fig. 4 Pump Mounting 4.0L RHD
1 BRACKET
2 PUMP ASSEMBLY
Fig. 5 Pulley Removal
1 POWER STEERING PUMP DRIVE PULLEY
Fig. 6 Pulley Installation
1 POWER STEERING PUMP DRIVE PULLEY
XJ STEERING 19 - 9
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Pump
Bracket to Pump . . . . . . . . . . 28 Nm (21 ft. l bs.)
Bracket to Engi ne . . . . . . . . . 47 Nm (35 ft. l bs.)
Fl ow Control Val ve . . . . . . . . 75 Nm (55 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . 28 Nm (21 ft. l bs.)
SPECIAL TOOLS
POWER STEERING PUMP
Fig. 7 Pump Reservoir Clips
1 RESERVOIR
2 RETAINING CLIPS
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
Puller C-4333
Installer, Power Steering Pulley C-4063B
19 - 10 STEERING XJ
POWER STEERING GEAR
TABLE OF CONTENTS
page page
POWER STEERING GEAR. . . . . . . . . . . . . . . . . . 11
POWER STEERING GEAR LEAKAGE . . . . . . . . . 11
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 12
HOUSING END PLUG . . . . . . . . . . . . . . . . . . . . . 12
PITMAN SHAFT/SEALS/BEARING . . . . . . . . . . . . 12
SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
RACK PISTON AND WORM SHAFT . . . . . . . . . . . 16
ADJUSTMENTS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . 19
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 21
SPECIAL TOOLS
POWER STEERING GEAR
DESCRIPTION
The power steeri ng gear i s a reci rcul ati ng bal l type
gear wi th a 14:1 rati o.
OPERATION
The gear acts as a rol l i ng thread between the
worm shaft and rack pi ston. The worm shaft i s sup-
ported by a thrust beari ng at the l ower end and a
beari ng assembl y at the upper end. When the worm
shaft i s turned the rack pi ston moves. The rack pi s-
ton teeth mesh wi th the pi tman shaft. Turni ng the
worm shaft turns the pi tman shaft, whi ch turns the
steeri ng l i nkage.
POWER STEERING GEAR LEAKAGE
XJ STEERING 19 - 11
STEERING GEAR
REMOVAL
(1) Pl ace the front wheel s i n the strai ght ahead
posi ti on wi th the steeri ng wheel centered.
(2) Di sconnect and cap the fl ui d hoses from steer-
i ng gear.
(3) Remove the col umn coupl er shaft from the
gear.
(4) Remove pi tman arm from gear.
(5) Remove the steeri ng gear retai ni ng bol ts and
remove the gear (Fi g. 1).
INSTALLATION
(1) I nstal l steeri ng gear (and bracket) on the frame
rai l and ti ghten bol ts to 95 Nm (70 ft. l bs.).
(2) Al i gn the col umn coupl er shaft to steeri ng gear.
I nstal l a new pi nch bol t and ti ghten to 49 Nm (36
ft. l bs.).
(3) Al i gn and i nstal l the pi tman arm and ti ghten
nut to 251 Nm (185 ft. l bs.).
(4) Connect fl ui d hoses to steeri ng gear and
(5) Fi l l power steeri ng system to proper l evel .
HOUSING END PLUG
DISASSEMBLY
(1) Unseat and remove retai ni ng ri ng from groove
wi th a punch through the hol e i n the end of the
housi ng (Fi g. 2).
(2) Sl owl y rotate stub shaft wi th 12 poi nt socket
COUNTER-CLOCKWI SE to force the end pl ug out
from housi ng.
CAUTION: Do not turn stub shaft any further than
necessary. The rack piston balls will drop out of the
rack piston circuit if the stub shaft is turned too far.
(3) Remove O-ri ng from the housi ng (Fi g. 3).
ASSEMBLY
(1) Lubri cate O-ri ng wi th power steeri ng fl ui d and
i nstal l i nto the housi ng.
(2) I nstal l end pl ug by tappi ng the pl ug l i ghtl y
wi th a pl asti c mal l et i nto the housi ng.
(3) I nstal l retai ni ng ri ng so one end of the ri ng
covers the housi ng access hol e (Fi g. 4).
PITMAN SHAFT/SEALS/BEARING
DISASSEMBLY
(1) Cl ean exposed end of pi tman shaft and housi ng
wi th a wi re brush.
(2) Remove prel oad adjuster nut (Fi g. 5).
Fig. 1 Steering Gear Mounting (LHD)
1 FRAME
2 WASHER
3 SCREW
4 ADAPTER
5 GEAR
Fig. 2 End Plug Retaining Ring
1 RETAINING RING
19 - 12 STEERING XJ
(3) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(4) Center the stub shaft by rotati ng i t from the
stop 1/2 of the total amount of turns.
(5) Remove si de cover bol ts and remove si de cover,
gasket and pi tman shaft as an assembl y (Fi g. 5).
NOTE: The pitman shaft will not clear the housing
if it is not centered.
(6) Remove pi tman shaft from the si de cover.
(7) Remove dust seal from the housi ng wi th a seal
pi ck (Fi g. 6).
CAUTION: Use care not to score the housing bore
when prying out seals and washer.
(8) Remove retai ni ng ri ng wi th snap ri ng pl i ers.
(9) Remove washer from the housi ng.
(10) Remove oi l seal from the housi ng wi th a seal
pi ck.
(11) Remove pi tman shaft beari ng from housi ng
wi th a beari ng dri ver and handl e (Fi g. 7).
ASSEMBLY
(1) I nstal l pi tman shaft beari ng i nto housi ng wi th
a beari ng dri ver and handl e.
(2) Coat the oi l seal and washer wi th special
grease suppl i ed wi th the new seal .
(3) I nstal l the oi l seal wi th a dri ver and handl e.
(4) I nstal l backup washer.
Fig. 3 End Plug Components
1 HOUSING ASSEMBLY
2 HOUSING END PLUG O-RING SEAL
3 HOUSING END PLUG
4 RETAINING RING
Fig. 4 Installing The Retaining Ring
1 RING CAP
2 PUNCH ACCESS HOLE
3 RETAINER RING
Fig. 5 Side Cover and Pitman Shaft
1 SIDE COVER BOLTS
2 PRELOAD ADJUSTER NUT
3 SIDE COVER
4 GASKET SEAL
5 PITMAN SHAFT GEAR
6 HOUSING ASSEMBLY
XJ STEERING 19 - 13
(5) I nstal l the retai ner ri ng wi th snap ri ng pl i ers.
(6) Coat the dust seal wi th special grease sup-
pl i ed wi th the new seal .
(7) I nstal l dust seal wi th a dri ver and handl e.
(8) I nstal l pi tman shaft to si de cover by screwi ng
shaft i n unti l i t ful l y seats to si de cover.
(9) I nstal l prel oad adjuster nut. Do not tighten
nut until after Over-Center Rotation Torque
adjustment has been made.
(10) I nstal l gasket to si de cover and bend tabs
around edges of si de cover (Fi g. 5).
(11) I nstal l pi tman shaft assembl y and si de cover
to housi ng.
(12) I nstal l si de cover bol ts and ti ghten to 60 Nm
(44 ft. l bs.).
(13) Perform over-center rotati on torque adjust-
ment.
SPOOL VALVE
DISASSEMBLY
(1) Remove l ock nut (Fi g. 8).
(2) Remove adjuster nut wi th Spanner Wrench
C-4381.
(3) Remove thrust support assembl y out of the
housi ng (Fi g. 9).
(4) Pul l stub shaft and val ve assembl y from the
housi ng (Fi g. 10).
(5) Remove stub shaft from val ve assembl y by
l i ghtl y tappi ng shaft on a bl ock of wood to l oosen
shaft. Then di sengage stub shaft pi n from hol e i n
spool val ve and separate the val ve assembl y from
stub shaft (Fi g. 11).
(6) Remove spool val ve from val ve body by pul l i ng
and rotati ng the spool val ve from the val ve body (Fi g.
12).
(7) Remove spool val ve O-ri ng and val ve body
tefl on ri ngs and O-ri ngs underneath the tefl on ri ngs
(Fi g. 13).
Fig. 6 Pitman Shaft Seals & Bearing
1 BEARING
2 WASHER
3 DUST SEAL
4 RETAINER
5 OIL SEAL
Fig. 7 Needle Bearing Removal
1 REMOVER
2 SIDE COVER AREA
Fig. 8 Lock Nut and Adjuster Nut
1 ADJUSTER NUT
2 STEERING GEAR
3 LOCK NUT
4 PUNCH
19 - 14 STEERING XJ
(8) Remove the O-ri ng between the worm shaft
and the stub shaft.
ASSEMBLY
NOTE: Clean and dry all components, then lubri-
cate with power steering fluid.
(1) I nstal l spool val ve spool O-ri ng.
(2) I nstal l spool val ve i n val ve body by pushi ng
and rotati ng. Hol e i n spool val ve for stub shaft pi n
must be accessi bl e from opposi te end of val ve body.
(3) I nstal l stub shaft i n val ve spool and engage
l ocati ng pi n on stub shaft i nto spool val ve hol e (Fi g.
14).
NOTE: Notch in stub shaft cap must fully engage
valve body pin and seat against valve body shoul-
der.
Fig. 9 Thrust Support Assembly
1 STUB SHAFT
2 HOUSING
3 THRUST SUPPORT ASSEMBLY
Fig. 10 Valve Assembly With Stub Shaft
1 GEAR
2 THRUST SUPPORT
3 LOCK NUT
4 ADJUSTER NUT
5 STUB SHAFT
6 VALVE ASSEMBLY
Fig. 11 Stub Shaft
1 STUB SHAFT
2 VALVE BODY
3 HOLE IN SPOOL
4 SHAFT PIN
5 6mm (1/4)
Fig. 12 Spool Valve
1 SPOOL VALVE
2 ROTATE VALVE TO REMOVE
3 VALVE BODY
XJ STEERING 19 - 15
(4) I nstal l O-ri ngs and tefl on ri ngs over the
O-ri ngs on val ve body.
(5) I nstal l O-ri ng i nto the back of the stub shaft
cap (Fi g. 15).
(6) I nstal l stub shaft and val ve assembl y i n the
housi ng. Li ne up worm shaft to sl ots i n the val ve
assembl y.
(7) I nstal l thrust support assembl y.
NOTE: The thrust support is serviced as an assem-
bly. If any component of the thrust support is dam-
aged the assembly must be replaced.
(8) I nstal l adjuster nut and l ock nut.
(9) Adjust Thrust Beari ng Prel oad and Over-Cen-
ter Rotati ng Torque.
RACK PISTON AND WORM SHAFT
DISASSEMBLY
(1) Remove housi ng end pl ug.
(2) Remove rack pi ston pl ug (Fi g. 16).
(3) Remove si de cover and pi tman shaft.
(4) Turn stub shaft COUNTERCLOCKWI SE unti l
the rack pi ston begi ns to come out of the housi ng.
(5) I nsert Arbor C-4175 i nto bore of rack pi ston
(Fi g. 17) and hol d tool ti ghtl y agai nst worm shaft.
(6) Turn the stub shaft wi th a 12 poi nt socket
COUNTERCLOCKWI SE, thi s wi l l force the rack pi s-
ton onto the tool and hol d the rack pi ston bal l s i n
pl ace.
(7) Remove the rack pi ston and tool together from
housi ng.
(8) Remove tool from rack pi ston.
(9) Remove rack pi ston bal l s.
(10) Remove cl amp bol ts, cl amp and bal l gui de
(Fi g. 18).
(11) Remove tefl on ri ng and O-ri ng from the rack
pi ston (Fi g. 19).
Fig. 13 Valve Seals
1 O-RING SEALS
Fig. 14 Stub Shaft Installation
1 NOTCH IN CAP
2 VALVE BODY PIN
Fig. 15 Stub Shaft Cap O-Ring
1 VALVE BODY
2 STUB SHAFT CAP
3 O-RING
19 - 16 STEERING XJ
(12) Remove the adjuster l ock nut and adjuster
nut from the stub shaft.
(13) Pul l the stub shaft wi th the spool val ve and
thrust support assembl y out of the housi ng.
(14) Remove the worm shaft from the housi ng
(Fi g. 20).
ASSEMBLY
NOTE: Clean and dry all components and lubricate
with power steering fluid.
(1) Check for scores, ni cks or burrs on the rack
pi ston fi ni shed surface. Sl i ght wear i s normal on the
worm gear surfaces.
Fig. 16 Rack Piston End Plug
1 EXTENSION
2 END PLUG
3 RACK PISTON
4 RATCHET
Fig. 17 Rack Piston with Arbor
1 RACK PISTON
Fig. 18 Rack Piston
1 CLAMP
2 BALLS
3 RACK PISTON
4 BALL GUIDE
Fig. 19 Rack Piston Teflon Ring and O-Ring
1 TEFLON SEAL
2 BACK-UP O-RING MUST BE INSTALLED UNDER PISTON
RING
3 RACK PISTON NUT
XJ STEERING 19 - 17
(2) I nstal l O-ri ng and tefl on ri ng on the rack pi s-
ton.
(3) I nstal l worm shaft i n the rack pi ston and al i gn
worm shaft spi ral groove wi th rack pi ston bal l gui de
hol e (Fi g. 21).
CAUTION: The rack piston balls must be installed
alternately into the rack piston and ball guide. This
maintains worm shaft preload. There are 12 black
balls and 12 silver (Chrome) balls. The black balls
are smaller than the silver balls.
(4) Lubri cate and i nstal l rack pi ston bal l s through
return gui de hol e whi l e turni ng worm shaft COUN-
TERCLOCKWI SE (Fi g. 21).
(5) I nstal l remai ni ng bal l s i n gui de usi ng grease to
hol d the bal l s i n pl ace (Fi g. 22).
(6) I nstal l the gui de onto rack pi ston and i nstal l
cl amp and cl amp bol ts. Ti ghten bol ts to 4.8 Nm (43
i n. l bs.).
(7) I nsert Arbor C-4175 i nto bore of rack pi ston
and hol d tool ti ghtl y agai nst worm shaft.
(8) Turn the worm shaft COUNTERCLOCKWI SE
whi l e pushi ng on the arbor. Thi s wi l l force the rack
pi ston onto the arbor and hol d the rack pi ston bal l s
i n pl ace.
(9) I nstal l the races and thrust beari ng on the
worm shaft and i nstal l shaft i n the housi ng (Fi g. 20).
(10) I nstal l the stub shaft wi th spool val ve, thrust
support assembl y and adjuster nut i n the housi ng.
(11) I nstal l the rack pi ston and arbor tool i nto the
housi ng.
(12) Hol d arbor ti ghtl y agai nst worm shaft and
turn stub shaft CLOCKWI SE unti l rack pi ston i s
seated on worm shaft.
(13) I nstal l pi tman shaft and si de cover i n the
housi ng.
(14) I nstal l rack pi ston pl ug and ti ghten to 150
Nm (111 ft. l bs.).
(15) I nstal l housi ng end pl ug.
(16) Adjust worm shaft thrust beari ng prel oad and
over-center rotati ng torque.
Fig. 20 Worm Shaft
1 GEAR HOUSING
2 BEARING RACE
3 WORM SHAFT
4 BEARING
Fig. 21 Installing Balls in Rack Piston
1 INSTALL BALLS IN THIS HOLE WHILE SLOWLY ROTATING
WORM COUNTER CLOCKWISE
2 WORM FLANGE
Fig. 22 Balls in the Return Guide
1 GUIDE
2 PETROLEUM JELLY
3 BALLS
19 - 18 STEERING XJ
ADJ USTMENTS
STEERING GEAR
CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
order, gear damage and improper steering response
may result.
NOTE: Adjusting the steering gear in the vehicle is
not recommended. Remove gear from the vehicle
and drain the fluid. Then mount gear in a vise to
perform adjustments.
WORM THRUST BEARING PRELOAD
(1) Mount the gear careful l y i nto a vi se.
CAUTION: Do not overtighten the vise on the gear
case. This may affect the adjustment
(2) Remove adjuster pl ug l ocknut (Fi g. 23).
(3) Rotate the stub shaft back and forth wi th a 12
poi nt socket to drai n the remai ni ng fl ui d.
(4) Turn the adjuster i n wi th Spanner Wrench
C-4381. Ti ghten the pl ug and thrust beari ng i n the
housi ng unti l fi rml y bottomed i n the housi ng about
34 Nm (25 ft. l bs.).
(5) Pl ace an i ndex mark on the housi ng even wi th
one of the hol es i n adjuster pl ug (Fi g. 24).
(6) Measure back (countercl ockwi se) 5.08 mm (0.20
i n) and mark housi ng (Fi g. 25).
(7) Rotate adjustment cap back (countercl ockwi se)
wi th spanner wrench unti l hol e i s al i gned wi th the
second mark (Fi g. 26).
(8) I nstal l and ti ghten l ocknut to 108 Nm (80 ft.
l bs.). Be sure adjustment cap does not turn whi l e
ti ghteni ng the l ocknut.
Fig. 23 Adjuster Lock Nut
1 ADJUSTER NUT
2 STEERING GEAR
3 LOCK NUT
4 PUNCH
Fig. 24 Alignment Marking On Housing
1 INDEX
Fig. 25 Second Marking On Housing
1 REFERENCE MARK
XJ STEERING 19 - 19
OVER-CENTER
NOTE: Before performing this procedure, the worm
bearing preload adjustment must be performed.
(1) Rotate the stub shaft wi th a 12 poi nt socket
from stop to stop and count the number of turns.
(2) Starti ng at ei ther stop, turn the stub shaft
back 1/2 the total number of turns. Thi s i s the center
of the gear travel (Fi g. 27).
(3) Pl ace the torque wrench i n the verti cal posi ti on
on the stub shaft. Rotate the wrench 45 degrees each
si de of the center and record the hi ghest rotati onal
torque i n thi s range (Fi g. 28). Thi s i s the Over-Cen-
ter Rotati ng Torque.
NOTE: The stub shaft must rotate smoothly without
sticking or binding.
(4) Rotate the stud shaft between 90 and 180 to
the l eft of center and record the l eft off-center pre-
l oad. Repeat thi s to the ri ght of center and record the
ri ght off-center prel oad. The average of these two
recorded readi ngs i s the Prel oad Rotati ng Torque.
(5) The Over-Center Rotati ng Torque shoul d be
0.40-0.70 Nm (3-7 i n. l bs.) higher than the Prel oad
Rotati ng Torque.
(6) I f an adjustment to the Over-Center Rotati ng
Torque i s necessary, fi rst l oosen the adjuster l ock
nut. Then turn the pi tman shaft adjuster screw back
(COUNTERCLOCKWI SE) unti l ful l y extended, then
turn back i n (CLOCKWI SE) one ful l turn.
(7) Remeasure Over-Center Rotati ng Torque. I f
necessary turn the adjuster screw and repeat mea-
Fig. 26 Aligning To The Second Mark
1 FIRST MARK
2 SECOND MARK
3 SPANNER WRENCH
Fig. 27 Steering Gear Centered
1 ADJUSTMENT SCREW
2 MASTER SPLINE
Fig. 28 Checking Over-center Rotation Torque
1 CENTER
19 - 20 STEERING XJ
surement unti l correct Over-Center Rotati ng Torque
i s reached.
NOTE: To increase the Over-Center Rotating Torque
turn the screw CLOCKWISE.
(8) Prevent the adjuster screw from turni ng whi l e
ti ghteni ng adjuster l ock nut. Ti ghten the adjuster
l ock nut to 49 Nm (36 ft. l bs.).
SPECIFICATIONS
POWER STEERING GEAR
Steering Gear
Type . . . . . . . . . . . . . . . . . . . . Reci rcul ati ng Bal l
Gear Ratio
RHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:1
LHD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14:1
WormShaft Bearing
Prel oad . . . . . . . . . . 0.451.13 Nm (410 i n. l bs.)
Pitman Shaft Overcenter Drag
New Gear (under 400 mi l es) . . . . . 0.450.90 Nm
(48 i n. l bs.) + Worm Shaft Prel oad
Used Gear (over 400 mi l es) . . . . . . . 0.50.6 Nm
(45 i n. l bs.) + Worm Shaft Prel oad
TORQUE CHART
DESCRIPTION TORQUE
Power Steering Gear
Adjustment Cap Locknut . . . 108 Nm (80 ft. l bs.)
Adjustment Screw Locknut . . 49 Nm (36 ft. l bs.)
Gear to Frame Bol ts . . . . . . . 95 Nm (70 ft. l bs.)
Pi tman Shaft Nut . . . . . . . 251 Nm (185 ft. l bs.)
Rack Pi ston Pl ug . . . . . . . . . 102 Nm (75 ft. l bs.)
Si de Cover Bol ts . . . . . . . . . . 60 Nm (44 ft. l bs.)
Pressure Li ne . . . . . . . . . . . . . 28 Nm (21 ft. l bs.)
Return Li ne . . . . . . . . . . . . . . 28 Nm (21 ft. l bs.)
Return Gui de Cl amp Bol t . . . 58 Nm (43 ft. l bs.)
SPECIAL TOOLS
POWER STEERING GEAR
Remover/Installer, Steering Plug C-4381
Remover, Pitman Arm C-4150A
Remover/Installer Steering Rack Piston C-4175
XJ STEERING 19 - 21
STEERING LINKAGE
TABLE OF CONTENTS
page page
STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE PROCEDURES
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PITMAN ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
STEERING DAMPER . . . . . . . . . . . . . . . . . . . . . . 25
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPECIAL TOOLS
STEERING LINKAGE
DESCRIPTION
The steeri ng l i nkage consi st of a pi tman arm, drag
l i nk, ti e rod, ti e rod ends and a steeri ng damper (Fi g.
1) and (Fi g. 2). The servi ce procedures and torque
speci fi cati ons are the same for LHD and RHD vehi -
cl es.
Fig. 1 Steering LinkageLHD
1 PITMAN ARM
2 ADJUSTMENT SLEEVE
3 DRAG LINK
4 TIE ROD
5 STEERING DAMPENER
19 - 22 STEERING XJ
SERVICE PROCEDURES
STEERING LINKAGE
The ti e rod end and bal l stud seal s shoul d be
i nspected duri ng al l oi l changes. I f a seal i s damaged,
i t shoul d be repl aced. Before i nstal l i ng a new seal ,
i nspect bal l stud at the throat openi ng. Check for
l ubri cant l oss, contami nati on, bal l stud wear or cor-
rosi on. I f these condi ti ons exi st, repl ace the ti e rod. A
repl acement seal can be i nstal l ed i f l ubri cant i s i n
good condi ti on. Otherwi se, a compl ete repl acement
bal l stud end shoul d be i nstal l ed.
CAUTION: If any steering components are replaced
or serviced an alignment must be performed, to
ensure the vehicle meets all alignment specifica-
tions.
TIE ROD
CAUTION: Use a Puller tool C-3894-A for tie rod
removal. Failure to use this tool could damage the
ball stud and seal (Fig. 3).
REMOVAL
(1) Remove the cotter pi ns and nuts at the ti e rod
bal l studs and drag l i nk.
(2) Loosen the bal l studs wi th a pul l er tool to
remove the ti e rod.
(3) Loosen cl amp bol ts and unthread the ti e rod
end from the tube.
INSTALLATION
(1) Thread the ti e rod end i nto the tube and posi -
ti on the cl amp to i ts ori gi nal posi ti on (Fi g. 4).
Ti ghten the cl amp bol ts to 27 Nm (20 ft. l bs.).
(2) I nstal l the ti e rod on the drag l i nk and steeri ng
knuckl e. I nstal l the retai ni ng nuts.
(3) Ti ghten the bal l stud nut on the steeri ng
knuckl e to 47 Nm (35 ft. l bs.). Ti ghten the bal l stud
nut to drag l i nk to 74 Nm (55 ft. l bs.). I nstal l new
cotter pi ns.
Fig. 2 Steering LinkageRHD
1 PITMAN ARM
2 DRAG LINK
3 STEERING DAMPNER
4 TIE ROD
5 ADJUSTMENT SLEEVE
XJ STEERING 19 - 23
PITMAN ARM
REMOVAL
(1) Remove the cotter pi n and nut from the drag
l i nk at the pi tman arm.
(2) Remove the drag l i nk bal l stud from the pi t-
man arm wi th a pul l er.
(3) Remove the nut and washer from the steeri ng
gear shaft. Mark the pi tman shaft and pi tman arm
for i nstal l ati on reference. Remove the pi tman arm
from steeri ng gear wi th Pul l er C-4150-A (Fi g. 5).
INSTALLATION
(1) Al i gn and i nstal l the pi tman arm on steeri ng
gear shaft.
(2) I nstal l the washer and nut on the shaft and
ti ghten nut to 251 Nm (185 ft. l bs.).
(3) I nstal l drag l i nk bal l stud to pi tman arm
i nstal l nut and ti ghten to 74 Nm (55 ft. l bs.). I nstal l
a new cotter pi n.
DRAG LINK
REMOVAL
(1) Remove cotter pi ns and nuts from drag l i nk
(2) Remove the steeri ng damper bal l stud from the
drag l i nk.
(3) Remove ti e rod from drag l i nk
(4) Remove drag l i nk from the steeri ng knuckl e
and pi tman arm.
INSTALLATION
(1) I nstal l the drag l i nk onto steeri ng knuckl e and
pi tman arm.
(2) I nstal l nut at steeri ng knuckl e and ti ghten to
47 Nm (35 ft. l bs.). I nstal l new cotter pi ns.
(3) I nstal l nut at pi tman arm and ti ghten to 74
Nm (55 ft. l bs.). I nstal l new cotter pi ns.
(4) I nstal l ti e rod onto drag l i nk and i nstal l nut.
Ti ghten nut to 74 Nm (55 ft. l bs.) and i nstal l new
cotter pi ns.
Fig. 3 Ball Stud Puller
1 CLAMP
2 ADJUSTMENT SLEEVE
3 PULLER TOOL C-3894A
4 SEAL
5 TIE-ROD END
Fig. 4 Tie Rod/Drag Link Clamps
1 TIE ROD CLAMP
2 DRAG LINK CLAMPS
Fig. 5 Pitman Arm Puller
1 PITMAN ARM
3 WRENCH
19 - 24 STEERING XJ
(5) I nstal l steeri ng damper onto drag l i nk and
i nstal l nut. Ti ghten nut to 74 Nm (55 ft. l bs.) and
i nstal l a new cotter pi n.
STEERING DAMPER
REMOVAL
(1) Remove the steeri ng damper retai ni ng bol t
from the axl e bracket.
(2) Remove the cotter pi n and nut from the bal l
stud at the drag l i nk.
(3) Remove the steeri ng damper bal l stud from the
drag l i nk wi th Pul l er C-3894-A.
INSTALLATION
(1) I nstal l steeri ng damper onto the axl e bracket
and drag l i nk.
(2) I nstal l steeri ng damper bol t i n axl e bracket
and ti ghten nut to 75 Nm (55 ft. l bs.).
(3) I nstal l bal l stud nut at the drag l i nk and
ti ghten nut to 75 Nm (55 ft. l bs.). I nstal l a new cot-
ter pi n.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Pitman Arm
Shaft . . . . . . . . . . . . . . . . . 251 Nm (185 ft. l bs.)
Drag Link
Bal l Studs . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Cl amp . . . . . . . . . . . . . . . . . . 49 Nm (36 ft. l bs.)
Tie Rod Ends
Bal l Studs . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Cl amp . . . . . . . . . . . . . . . . . . 27 Nm (20 ft. l bs.)
Tie Rod
Bal l Stud . . . . . . . . . . . . . . . . 47 Nm (35 ft. l bs.)
Steering Damper
Frame . . . . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
Drag Li nk . . . . . . . . . . . . . . . 74 Nm (55 ft. l bs.)
SPECIAL TOOLS
STEERING LINKAGE
Puller C-3894A
Remover Pitman C-4150A
XJ STEERING 19 - 25
STEERING COLUMN
TABLE OF CONTENTS
page page
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 26
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 26
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 28
STEERING COLUMN
DESCRIPTION
The standard non-ti l t and ti l t steeri ng col umn has
been desi gned to be servi ced as an assembl y. The key
cyl i nder, swi tches, cl ock spri ng, tri m shrouds and
steeri ng wheel are servi ced separatel y. On the non-
ti l t col umn the upper mounti ng bracket i s al so ser-
vi ced separatel y.
The col umn i s mounted to the col umn support
bracket studs and secured by four nuts. The col umn
i s connected to the steeri ng gear by a one pi ece col -
l apsi bl e shaft wi th a coupl er at each end. The cou-
pl ers secure the shaft to the steeri ng col umn and
steeri ng gear.
SERVICE PRECAUTIONS
Safety goggl es shoul d be worn at al l ti mes when
worki ng on steeri ng col umns.
To servi ce the steeri ng wheel , swi tches or ai rbag,
refer to Group 8M and fol l ow al l WARNI NGS and
CAUTI ONS.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL
THE AIRBAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. THEN WAIT TWO
MINUTES FOR THE SYSTEM CAPACITOR TO DIS-
CHARGE. FAILURE TO DO SO COULD RESULT IN
ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIRBAG COMPONENTS, HAVE SPECIAL COAT-
INGS AND ARE SPECIFICALLY DESIGNED FOR THE
AIRBAG SYSTEM. THEY MUST NEVER BE
REPLACED WITH ANY SUBSTITUTES. ANYTIME A
NEW FASTENER IS NEEDED, REPLACE WITH THE
CORRECT FASTENERS PROVIDED IN THE SERVICE
PACKAGE OR FASTENERS LISTED IN THE PARTS
BOOKS.
STEERING COLUMN
WARNING: BEFORE SERVICING THE STEERING
COLUMN THE AIRBAG SYSTEM MUST BE DIS-
ARMED. REFER TO GROUP 8M RESTRAINT SYS-
TEMS FOR SERVICE PROCEDURES. FAILURE TO
DO SO MAY RESULT IN ACCIDENTAL DEPLOY-
MENT OF THE AIRBAG AND POSSIBLE PERSONAL
INJURY.
CAUTION: Keep clock spring from turning during
removal and installation. Failure to do so may dam-
age the clock spring.
REMOVAL
(1) Posi ti on front wheel s straight ahead.
(2) Remove and i sol ate the negati ve battery
ground cabl e.
(3) Remove the ai rbag, refer to Group 8M
Restrai nt Systems for servi ce procedures.
NOTE: If equipped with cruise control, disconnect
clock spring harness from cruise switch harness on
the steering wheel.
(4) Remove the steeri ng wheel wi th an appropri ate
pul l er (Fi g. 1).
CAUTION: Ensure the puller bolts are fully engaged
into the steering wheel and not into the clock-
spring, before attempting to remove the wheel. Fail-
ure to do so may damage the steering wheel.
(5) Turn i gni ti on cyl i nder to the on posi ti on and
remove cyl i nder by pressi ng rel ease through l ower
shroud access hol e (Fi g. 2).
19 - 26 STEERING XJ
(6) Remove knee bl ocker cover and knee bl ocker,
Refer to Group 8E I nstrument Panel Systems.
(7) Remove screws from the l ower col umn shroud
(Fi g. 3) and remove l ower shroud.
(8) Remove the steeri ng coupl er bol t and col umn
mounti ng nuts (Fi g. 4) then l ower col umn off the
mounti ng stud.
(9) Remove upper col umn shroud (Fi g. 3).
(10) Di sconnect and remove the wi ri ng harness
from the col umn (Fi g. 5).
NOTE: If vehicle is equipped with automatic trans-
mission, remove shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for pro-
cedure.
(11) Remove col umn.
(12) Remove nut and bol t from the upper col umn
mounti ng bracket on non-ti l t col umn (Fi g. 6). Remove
the bracket from the col umn and note the mount-
ing location and orientation of the bracket..
(13) Remove cl ock spri ng, swi tches, (SKI M i f
equi pped) and i gni ti on key cyl i nder, refer to Group 8
El ectri cal for servi ce procedures.
INSTALLATION
(1) I nstal l upper col umn mounti ng bracket on non-
ti l t col umn. I nstal l the mounti ng bol t and ti ghten the
nut to 17 Nm (150 i n. l bs.).
(2) I nstal l swi tches, refer to Group 8 El ectri cal for
servi ce procedures.
Fig. 1 Steering Wheel
1 PULLER
2 STEERING WHEEL
Fig. 2 Key Cylinder Release Access Hole
1 LOWER SHROUD
2 RELEASE ACCESS HOLE
Fig. 3 Column Shrouds
1 UPPER SHROUD
2 LOWER SHROUD
Fig. 4 Tilt Steering Column Mounting
1 STEERING COLUMN
2 MOUNTING NUTS
3 COUPLER BOLT
XJ STEERING 19 - 27
(3) Al i gn and i nstal l col umn i nto the steeri ng cou-
pl er.
(4) I nstal l col umn harness and connect harness to
swi tches.
NOTE: If vehicle is equipped with automatic trans-
mission install shifter interlock cable. Refer to
Group 21 Transmission and Transfer Case for
installation and adjustment.
(5) I nstal l upper col umn shrouds.
(6) I nstal l col umn onto the mounti ng studs.
(7) I nstal l mounti ng nuts and ti ghten to 23 Nm
(17 ft. l bs.).
(8) I nstal l steeri ng col umn coupl er bol t and ti ghten
to 49 Nm (36 ft. l bs.).
(9) Center the cl ock spri ng (i f necessary) and
i nstal l i t on the col umn, refer to Group 8 El ectri cal
(10) I nstal l l ower col umn shroud and i nstal l
mounti ng screws.
(11) I nstal l i gni ti on cyl i nder.
(12) I nstal l knee bl ocker and knee bl ocker cover,
Refer to Group 8E I nstrument Panel Systems.
(13) I nstal l steeri ng wheel and ti ghten nut to 54
Nm (40 ft. l bs.).
NOTE: If equipped with cruise control, connect
clock spring harness to cruise switch harness on
the steering wheel.
(14) I nstal l ai rbag, refer to Group 8M Restrai nt
Systems for servi ce procedures.
(15) I nstal l negati ve battery termi nal .
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Tilt Steering Column
Steeri ng Wheel Nut . . . . . . . . 54 Nm (40 ft. l bs.)
Coupl er Bol t . . . . . . . . . . . . . . 49 Nm (36 ft. l bs.)
Non-Tilt Steering Column
Steeri ng Wheel Nut . . . . . . . . 54 Nm (40 ft. l bs.)
Coupl er Bol t . . . . . . . . . . . . . . 49 Nm (36 ft. l bs.)
Upper Bracket Nut . . . . . . . 17 Nm (150 i n. l bs.)
Fig. 5 Steering Column Harness
1 STEERING COLUMN
2 INTERLOCK CABLE
3 COLUMN HARNESS
Fig. 6 Non-Tilt Column
1 NON-TILT COLUMN
2 UPPER BRACKET
19 - 28 STEERING XJ
TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . . 1
NV3550 MANUAL TRANSMISSION . . . . . . . . . . . 42
AUTOMATIC TRANSMISSION 30RH . . . . . . . . . 88
AW4 AUTOMATIC TRANSMISSION . . . . . . . . . 217
NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . 346
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . . 375
AX5 MANUAL TRANSMISSION
TABLE OF CONTENTS
page page
AX5 MANUAL TRANSMISSION . . . . . . . . . . . . . . . 1
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LOW LUBRICANT LEVEL. . . . . . . . . . . . . . . . . . . . 3
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION NOISE. . . . . . . . . . . . . . . . . . . . . 3
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT BEARING RETAINER SEAL. . . . . . . . . . . . 6
EXTENSION HOUSING SEAL . . . . . . . . . . . . . . . . 7
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . . . 7
ADAPTER/EXTENSION HOUSING AND
FRONT BEARING RETAINER . . . . . . . . . . . . . . . 8
SHIFT MECHANISM AND GEARTRAIN . . . . . . . . 17
COUNTERSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . 30
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 31
SEMI-SYNCHRONIZED REVERSE IDLER
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
AX5 MANUAL TRANSMISSION COMPONENTS . . 37
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
SPECIAL TOOLS
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION
The AX5 i s a fi ve speed manual transmi ssi on wi th
fi fth gear bei ng the overdri ve range. An adapter hous-
i ng i s used to attach the transmi ssi on to the transfer
case on 4-wheel dri ve appl i cati ons. A standard styl e
extensi on housi ng i s used for the 2-wheel dri ve appl i -
cati ons. The shi ft mechani sm i s i ntegral to the trans-
mi ssi on assembl y and mounted i n the shi ft tower
porti on of the adapter/extensi on housi ng (Fi g. 1).
GEAR RATIOS
Gear rati os for the AX5 manual transmi ssi on are
as fol l ows:
Fi rst gear: 3.93:1
Second gear: 2.33:1
Thi rd gear: 1.45:1
Fourth gear: 1.00:1
Fi fth gear: 0.85:1
Reverse gear: 4.74:1
TRANSMISSION IDENTIFICATION
The AX5 i denti fi cati on code i s on the bottom sur-
face of the transmi ssi on case near the fi l l pl ug (Fi g.
2). The fi rst number i s year of manufacture. The sec-
ond and thi rd numbers i ndi cate month of manufac-
ture. The next seri es of numbers i s the transmi ssi on
seri al number.
OPERATION
The manual transmi ssi on recei ves power through
the cl utch assembl y from the engi ne. The cl utch di sc
i s spl i ned to the transmi ssi on i nput shaft and i s
turned at engi ne speed at al l ti mes that the cl utch i s
XJ TRANSMISSION AND TRANSFER CASE 21 - 1
engaged. The i nput shaft i s connected to the trans-
mi ssi on countershaft through the mesh of fourth
speed gear on the i nput shaft and the fourth counter-
shaft gear. At thi s poi nt, al l the transmi ssi on gears
are spi nni ng.
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether we are
up-shi fti ng or down-shi fti ng). The synchroni zer does
thi s by havi ng the synchroni zer hub spl i ned to the
mai nshaft, or the countershaft i n some cases, and
movi ng the bl ocker ri ng i nto contact wi th the gears
fri cti on cone. As the bl ocker ri ng and fri cti on cone
come together, the gear speed i s brought up or down
to the speed of the synchroni zer. As the two speeds
match, the spl i nes on the i nsi de of the synchroni zer
sl eeve become al i gned wi th the teeth on the bl ocker
ri ng and the fri cti on cone and eventual l y wi l l sl i de
over the teeth, l ocki ng the gear to the mai nshaft, or
countershaft, through the synchroni zer.
LUBRICANT
DESCRIPTION
Recommended l ubri cant for AX5 transmi ssi ons i s
Mopar 75W90, API Grade GL3 gear l ubri cant, or
equi val ent.
Correct l ubri cant l evel i s from the bottom edge, to
no more than 6 mm (1/4 i n.) bel ow the bottom edge of
the fi l l pl ug hol e.
The fi l l pl ug i s on the passenger si de of the
adapter housi ng (Fi g. 3). The drai n pl ug i s on the
bottom of the case.
Fig. 1 AX5 Manual Transmission
Fig. 2 Transmission Identification
1 I. D. CODE ON CASE NEAR DRAIN PLUG
21 - 2 AX5 MANUAL TRANSMISSION XJ
Approxi mate dry fi l l l ubri cant capaci ty i s:
3.3 l i ters (3.49 quarts) for 4wheel dri ve appl i ca-
ti ons.
3.5 l i ters (3.70 quarts) for 2wheel dri ve appl i ca-
ti ons.
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adaptor or extensi on
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l probabl y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a nonrecommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng the di sc to sl i p, grab, and/or chatter.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel . Al so al l ow the l ubri cant to
settl e for a mi nute or so before checki ng. These rec-
ommendati ons wi l l ensure an accurate check and
avoi d an underfi l l or overfi l l condi ti on. Al ways check
the l ubri cant l evel after any addi ti on of fl ui d to avoi d
an i ncorrect l ubri cant l evel condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper, or contami nated l ubri cants. The con-
sequence of usi ng nonrecommended l ubri cants i s
noi se, excessi ve wear, i nternal bi nd, and hard shi ft-
i ng. Substanti al l ubri cant l eaks can resul t i n gear,
shi ft rai l , synchro, and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of component damage are usual l y hard shi ft-
i ng and noi se.
Component damage, i ncorrect cl utch adjustment,
or a damaged cl utch pressure pl ate or di sc are addi -
ti onal probabl e causes of i ncreased shi ft effort. I ncor-
rect adjustment or a worn/damaged pressure pl ate or
di sc can cause i ncorrect rel ease. I f the cl utch probl em
i s advanced, gear cl ash duri ng shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear cl ash
when shi fti ng i nto any forward gear. I n some new or
rebui l t transmi ssi ons, new synchro ri ngs may tend to
sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n most
cases, thi s condi ti on wi l l decl i ne as the ri ngs wear
i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears generate a mi l d
whi ne that i s audi bl e, but general l y onl y at extreme
speeds.
Severe, hi ghl y audi bl e transmi ssi on noi se i s gener-
al l y the i ni ti al i ndi cator of a l ubri cant probl em.
I nsuffi ci ent, i mproper, or contami nated l ubri cant wi l l
promote rapi d wear of gears, synchros, shi ft rai l s,
forks and beari ngs. The overheati ng caused by a
l ubri cant probl em, can al so l ead to gear breakage.
TRANSMISSION
REMOVAL
(1) Shi ft transmi ssi on i nto fi rst or thi rd gear.
(2) Rai se and support vehi cl e on sui tabl e safety
stands.
(3) Support engi ne wi th adjustabl e jack stand.
Posi ti on wood bl ock between jack and oi l pan to
avoi d damagi ng pan.
(4) Remove crossmember/ski d pl ate.
(5) Di sconnect necessary exhaust system compo-
nents.
(6) Remove ski d pl ate, i f equi pped.
(7) Remove sl ave cyl i nder (Fi g. 4) from cl utch
housi ng.
(8) Mark rear propel l er shaft and rear axl e yokes
for i nstal l ati on al i gnment (Fi g. 5).
Fig. 3 Fill Plug Location
1 FILL PLUG LOCATION
XJ AX5 MANUAL TRANSMISSION 21 - 3
(9) Mark front propel l er shaft, axl e, and transfer
case yokes for i nstal l ati on al i gnment, i f equi pped.
(10) Remove propel l er shaft(s).
(11) Uncl i p wi re harnesses from transmi ssi on and
transfer case, i f equi pped.
(12) Di sconnect transfer case vent hose, i f
equi pped.
(13) Di sengage any wi re connectors attached to
transmi ssi on or transfer case, i f equi pped, compo-
nents.
(14) Support transfer case, i f equi pped, wi th trans-
mi ssi on jack.
(15) Secure transfer case, i f equi pped, to jack wi th
safety chai ns.
(16) Di sconnect transfer case shi ft l i nkage at
(17) Remove nuts attachi ng transfer case to trans-
mi ssi on, i f equi pped.
(18) Remove transfer case, i f equi pped.
(19) Remove crankshaft posi ti on sensor (Fi g. 6).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.
(21) Support transmi ssi on wi th transmi ssi on jack.
(22) Secure transmi ssi on to jack wi th safety
chai ns.
(23) Di sconnect rear cushi on and bracket from
transmi ssi on.
(24) Remove rear crossmember.
(25) Di sconnect transmi ssi on shi ft l ever as fol l ows:
(a) Lower transmi ssi on approxi matel y 78 cm (3
i n.) for access to shi ft l ever.
(b) Reach up and around transmi ssi on case and
unseat shi ft l ever dust boot from transmi ssi on shi ft
tower (Fi g. 7). Move boot upward on shi ft l ever for
access to retai ner that secures l ever i n shi ft tower.
(c) Reach up and around transmi ssi on case and
press shi ft l ever retai ner downward wi th fi nger
pressure. Turn retai ner countercl ockwi se to rel ease
i t.
(d) Li ft l ever and retai ner out of shi ft tower (Fi g.
7). Do not remove the shi ft l ever from the fl oor con-
Fig. 4 Slave CylinderTypical
Fig. 5 Marking Propeller Shaft And Axle Yokes
1 REFERENCE MARKS
Fig. 6 Crankshaft Position Sensor 2.5 and 4.0L
Engine
1 ENGINE SPEED SENSOR
2 GROMMET
3 MOUNTING BOLT(S)
4 LEFT REAR OF ENGINE
5 TRANSMISSION
sol e shi fter boots. Leave the l ever i n pl ace for
transmi ssi on i nstal l ati on.
(26) Remove cl utch housi ng brace rod.
(27) Remove cl utch housi ng-to-engi ne bol ts.
(28) Pul l transmi ssi on jack rearward unti l i nput
shaft cl ears cl utch. Then sl i de transmi ssi on out from
under vehi cl e.
(29) Remove cl utch rel ease beari ng, rel ease fork,
and retai ner cl i p.
(30) Remove cl utch housi ng from transmi ssi on
(Fi g. 8).
INSTALLATION
(1) I nstal l cl utch housi ng (Fi g. 8) on transmi ssi on.
Ti ghten housi ng bol ts to 46 Nm (34 ft. l bs.) torque.
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork, and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l and ti ghten cl utch housi ng-to-engi ne
bol ts to the appropri ate torque: Be sure the hous-
ing is properly seated on engine block before
tightening bolts.
Ti ghten 3/8 di ameter bol ts to 37 Nm (27
ft.l bs.).
ft.l bs.).
Ti ghten M12 bol ts to 75 Nm (55 ft.l bs.).
(8) I nstal l cl utch housi ng brace rod.
(9) Lower transmi ssi on approxi matel y 78 cm (3
i n.) for access to shi ft tower. Be sure transmi ssi on i s
i n fi rst or thi rd gear.
(10) Reach up and around transmi ssi on and i nsert
shi ft l ever i n shi ft tower. Press l ever retai ner down-
ward and turn i t cl ockwi se to l ock i t i n pl ace. Then
i nstal l l ever dust boot on shi ft tower.
(11) I nstal l rear crossmember. Ti ghten crossmem-
ber-to-frame bol ts to 41 Nm (31 ft. l bs.) torque.
(12) I nstal l fasteners to hol d rear cushi on and
bracket to transmi ssi on. Then ti ghten transmi ssi on-
to-rear support bol ts/nuts to 54 Nm (40 ft. l bs.)
torque.
(13) Remove support stands from engi ne and
transmi ssi on.
(14) I nstal l and connect crankshaft posi ti on sensor.
(15) Posi ti on transfer case on transmi ssi on jack, i f
equi pped.
(16) Secure transfer case to jack wi th safety
chai ns, i f equi pped.
(17) Rai se transfer case, i f equi pped, and al i gn
transfer case i nput shaft to the transmi ssi on output
shaft.
Fig. 7 Removing/Installing Shift Lever
1 SHIFT LEVER RETAINER
2 DUST BOOT
3 SHIFT TOWER
Fig. 8 Clutch Housing
2 CLUTCH HOUSING
3 TRANSMISSION
(18) Sl i de transfer case forward unti l case i s
seated on transmi ssi on, i f necessary.
(19) I nstal l nuts to attach transfer case to trans-
mi ssi on, i f equi pped. Ti ghten transfer case-to-trans-
mi ssi on nuts to 35 Nm (26 ft. l bs.) torque.
(20) Connect transfer case shi ft l i nkage at transfer
case, i f equi pped.
(21) Connect transfer case vent hose, i f equi pped.
(22) Secure wi re harnesses i n cl i ps/ti e straps on
transmi ssi on and transfer case, i f equi pped.
(23) Engage wi re connectors attached to al l neces-
sary transmi ssi on or transfer case, i f equi pped, com-
ponents.
(24) I nstal l rear propel l er shaft sl i p yoke to trans-
mi ssi on or transfer case, i f equi pped, output shaft.
(25) Al i gn marks on rear propel l er shaft and rear
axl e yokes (Fi g. 9).
(26) I nstal l and ti ghten propel l er shaft Ujoi nt
cl amp bol ts to 19 Nm (170 i n. l bs.) torque.
(27) Al i gn marks on front propel l er shaft, axl e,
and transfer case yokes, i f equi pped.
(29) I nstal l sl ave cyl i nder i n cl utch housi ng.
(30) I nstal l ski d pl ate, i f equi pped. Ti ghten bol ts to
42 Nm (31 ft. l bs.) torque. Ti ghten stud nuts to 17
(31) Fi l l transmi ssi on and transfer case, i f
equi pped, wi th recommended l ubri cants. Refer to the
Lubri cant Recommendati on secti ons of the appropri -
ate component for correct fl ui d.
FRONT BEARING RETAINER SEAL
REMOVAL
(1) Remove rel ease beari ng and l ever from the
transmi ssi on.
(2) Remove the bol ts hol di ng the front beari ng
retai ner to the transmi ssi on case.
(3) Remove the front beari ng retai ner from the
transmi ssi on case.
(4) Usi ng a sui tabl e pry tool , remove the front
beari ng retai ner seal .
INSTALLATION
(1) Usi ng Tool Handl e C-4171 and Seal I nstal l er
8211, i nstal l new seal i n to the front beari ng retai ner
(Fi g. 10).
(2) Remove any resi dual gasket materi al from the
seal i ng surfaces of the beari ng retai ner and the
(3) I nstal l new front beari ng retai ner gasket to the
front beari ng retai ner.
(4) I nstal l the front beari ng retai ner onto the
(5) I nstal l the bol ts to hol d the beari ng retai ner
onto the transmi ssi on case.
(6) Ti ghten the bol ts to 17 Nm (12 ft. l bs.).
(7) I nstal l rel ease beari ng and l ever onto the
transmi ssi on.
Fig. 9 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks
1 REFERENCE MARKS
Fig. 10 Install Front Bearing Retainer Seal
2 SPECIAL TOOL 8211 (AX5) OR 8209 (AX15)
EXTENSION HOUSING SEAL
REMOVAL
(2) Remove propel l er shaft. Refer to Group 3, Di f-
ferenti al and Dri vel i ne, for proper procedures.
(3) Usi ng a sui tabl e seal pul l er or screw wi th a
sl i de hammer, remove the extensi on housi ng seal
(Fi g. 11).
INSTALLATION
(1) Cl ean seal bore of extensi on housi ng of any
resi dual seal er materi al from ori gi nal seal .
8212, i nstal l new extensi on housi ng seal so that the
seal i s l ocated 0 0.5 mm (0 0.02 i n.) to the face
of the extensi on housi ng (Fi g. 12).
(3) I nstal l propel l er shaft. Refer to Group 3, Di ffer-
enti al and Dri vel i ne, for proper procedures.
(4) Check and add fl ui d to transmi ssi on as neces-
sary. Refer to the Recommended Lubri cant secti on for
proper fl ui d requi rements.
ADAPTER HOUSING SEAL
REMOVAL
(1) Hoi st and support vehi cl e.
(2) Remove transfer case.
(3) Usi ng a sui tabl e pry tool , or a sl i de hammer
mounted screw, remove the adapter housi ng seal
(Fi g. 13).
INSTALLATION
(1) Cl ean seal bore of adapter housi ng of any
resi dual seal er materi al from ori gi nal seal .
8208, i nstal l new seal so that the seal i s l ocated 0
0.2 mm (0 0.008 i n.) to the seal bore face of
adapter housi ng (Fi g. 14).
(3) I nstal l transfer case.
(4) Check and add fl ui d to transmi ssi on as neces-
sary. Refer to the Recommended Lubri cant secti on for
proper fl ui d requi rements.
Fig. 11 Remove Extension Housing Seal
1 SLIDE HAMMER
2 SEAL PULLER
3 2WD EXTENSION HOUSING
Fig. 12 Install Extension Housing Seal
1 SPECIAL TOOL
C-4171
2 SPECIAL TOOL
8212
3 EXTENSION HOUSING
Fig. 13 Remove Adapter Housing Seal
1 ADAPTER HOUSING OIL SEAL
ADAPTER/EXTENSION HOUSING AND FRONT
BEARING RETAINER
DISASSEMBLY
(1) Drai n transmi ssi on l ubri cant, i f necessary.
(2) Remove rel ease beari ng and l ever.
(3) Remove cl utch housi ng bol ts and remove hous-
i ng (Fi g. 17).
(4) Remove vehi cl e speed sensor and speedometer
adapter, i f necessary.
(5) Remove bol ts hol di ng shi ft tower to transmi s-
si on case.
(6) Remove shi ft tower from transmi ssi on case
(Fi g. 15).
(7) Remove shi ft tower gasket from shi ft tower or
transmi ssi on case (Fi g. 16).
(8) Remove detent bal l pl ug (Fi g. 18).
(9) Remove detent spri ng and bal l wi th penci l
magnet (Fi g. 19), (Fi g. 20).
Fig. 14 Install Adapter Housing Seal
1 SPECIAL TOOL 8208
2 ADAPTER HOUSING
Fig. 15 Remove Shift Tower
1 SHIFT TOWER
2 ADAPTER/EXTENSION HOUSING
Fig. 16 Remove Shift Tower Gasket
1 SHIFT TOWER
2 GASKET
2 CLUTCH HOUSING
3 TRANSMISSION
Fig. 18 Remove Detent Ball Plug
1 TORX BIT
2 DETENT BALL PLUG
Fig. 19 Remove Detent Spring
1 PENCIL MAGNET
2 DETENT BALL SPRING
Fig. 20 Remove Detent Ball
1 PENCIL MAGNET
2 SHIFT DETENT BALL
(10) Remove shi ft arm retai ner bol t (Fi g. 21).
(11) Remove shi ft arm restri ctor pi ns (Fi g. 22).
NOTE: The restrictor pins are not interchangeable
and are color coded. Note which color restrictor pin
is removed from each side of the transmission and
be sure to install it into the same location.
(12) Remove shi ft l ever shaft pl ug (Fi g. 23).
(13) Remove shi fter shaft wi th l arge magnet (Fi g.
24).
(14) Remove the shi ft arm from the adapter hous-
i ng.
(15) Remove adapter/extensi on housi ng bol ts.
(16) Loosen adapter/extensi on housi ng by tappi ng
i t l oose wi th pl asti c mal l et (Fi g. 25).
Fig. 21 Shift Arm Retainer Bolt Removal
1 RETAINER BOLT
2 SHIFT ARM
Fig. 22 Shift Arm Restrictor Pins
1 RESTRICTOR PINS
Fig. 23 Removing Shift Lever Shaft Plug
1 SHIFT LEVER SHAFT PLUG
Fig. 24 Remove Shifter Shaft
1 SHIFT ARM SHAFT
2 LARGE MAGNET
(17) Remove adapter/extensi on housi ng (Fi g. 26).
(18) On 4x2 transmi ssi ons;
(a) Remove speedometer gear retai ni ng snap-
ri ng from output shaft.
(b) Remove speedometer gear from output shaft
and remove speedometer gear l ock bal l from output
shaft.
(c) Remove speedometer dri ve gear l ocati ng
snap-ri ng (Fi g. 27).
(19) Remove the bol ts hol di ng the front beari ng
retai ner to the transmi ssi on case.
(20) Remove the beari ng retai ner from transmi s-
si on case (Fi g. 28).
(21) Remove i nput shaft beari ng snap-ri ng (Fi g.
29).
(22) Remove countershaft front beari ng snap-ri ng.
Fig. 25 Loosen Adapter/Extension Housing
1 INTERMEDIATE PLATE
2 ADAPTER HOUSING
3 RUBBER FACED MALLET
Fig. 26 Remove Adapter/Extension HousingTypical
1 ADAPTER HOUSING
Fig. 27 Speedometer Drive Gear Assembly
1 SNAP RING
2 LOCK BALL
3 SNAP RING
4 OUTPUT SHAFT GROOVES
5 SPEEDOMETER GEAR
Fig. 28 Remove Front Bearing Retainer
1 FRONT BEARING RETAINER
(23) Separate i ntermedi ate pl ate and transmi ssi on
case by tappi ng them l oose wi th pl asti c mal l et (Fi g.
30).
(24) Separate the i ntermedi ate pl ate from the
ASSEMBLY
(1) Remove any resi dual seal er from transmi ssi on
case, i ntermedi ate pl ate, and adapter/extensi on hous-
i ng.
(2) Appl y a 1/8 to 3/16 i nch wi de bead of Threeb-
ond Li qui d Gasket TB1281, P/N 83504038, as
shown, maki ng sure to keep seal er bead to i nsi de of
bol t hol es (Fi g. 32).
(3) Al i gn geartrai n and shi ft rai l s wi th mati ng
hol es i n transmi ssi on case and i nstal l transmi ssi on
case to the i ntermedi ate pl ate (Fi g. 33). Veri fy that
the transmi ssi on case i s seated on the i ntermedi ate
pl ate l ocati ng pi ns.
Fig. 29 Remove Input Shaft Bearing Snap-ring
1 SNAP RING PLIERS
2 INPUT SHAFT
3 INPUT SHAFT BEARING SNAP RING
Fig. 30 Separate Intermediate Plate and
Transmission Case
2 RUBBER MALLET
3 GEAR CASE
Fig. 31 Remove Intermediate Plate from
Transmission Case
1 GEAR CASE
Fig. 32 Apply Sealer to Transmission Gear Case
1 SEALER BEAD (1/8 - 3/16 WIDE)
2 GEAR CASE
(4) I nstal l new front beari ng snap ri ngs (Fi g. 34).
(5) I nstal l front beari ng retai ner gasket to front
beari ng retai ner.
(6) I nstal l the front beari ng retai ner (Fi g. 35) and
ti ghten bol ts to 17 Nm (12 ft. l bs.).
(7) On 4x2 transmi ssi ons;
(a) I nstal l speedometer dri ve gear l ocati ng snap-
ri ng (Fi g. 36).
(b) I nstal l speedometer gear l ock bal l i n output
shaft and i nstal l speedometer gear onto output
shaft.
(c) I nstal l speedometer gear retai ni ng snap-ri ng
onto output shaft.
(8) Appl y a 1/8 to 3/16 i nch wi de bead of Threeb-
ond Li qui d Gasket TB1281, P/N 83504038, to seal -
i ng surface of adapter/extensi on housi ng, maki ng
sure to keep seal er bead to i nsi de of bol t hol es.
(9) I nstal l adapter or extensi on housi ng on i nter-
medi ate pl ate (Fi g. 37). Ti ghten housi ng bol ts to 34
(10) Posi ti on shi ft arm i n shi fter tower openi ng of
adapter or extensi on housi ng (Fi g. 38). Be sure that
the shi fter arm i s engaged i nto the shi ft rai l s.
Fig. 33 Install Transmission Gear Case to the
Intermediate Plate
1 GEAR CASE
Fig. 34 Install Front Bearing Snap-rings
1 FRONT BEARING SNAP RINGS
Fig. 35 Install Front Bearing Retainer
(11) Start shi fter arm shaft i n hol e i n back of
adapter or extensi on housi ng. Al i gn shi ft arm and
shi fter arm shaft and i nsert shi fter arm shaft
through the shi fter arm and i nto the forward porti on
of the adapter or extensi on housi ng (Fi g. 39).
(12) Rotate the shi fter arm shaft unti l the hol e i n
the shi ft arm i s al i gned wi th the hol e i n the shaft.
(13) I nstal l the shi ft arm retai ner bol t and ti ghten
to 38 Nm (28 ft. l bs.) (Fi g. 40).
(14) I nstal l and ti ghten shi fter arm shaft pl ug to
18 Nm (13 ft. l bs.) torque (Fi g. 41).
Fig. 36 Speedometer Drive Gear Assembly
1 SNAP RING
2 LOCK BALL
3 SNAP RING
4 OUTPUT SHAFT GROOVES
5 SPEEDOMETER GEAR
Fig. 37 Install Adapter/Extension HousingTypical
1 ADAPTER HOUSING
Fig. 38 Position Shift Arm in Adapter or Extension
Housing
1 SHIFT ARM
Fig. 39 Install Shifter Arm Shaft
1 SHIFT ARM
2 ADAPTER OR EXTENSION HOUSING
(15) I nstal l shi ft restri ctor pi ns i n shi ft tower and
ti ghten to 27 Nm (20 ft. l bs.) (Fi g. 42).
NOTE: The restrictor pins are not interchangeable
and are color coded. Be sure to install the pin into
the same location from which it was removed.
(16) I nstal l shi ft detent bal l i n detent openi ng of
case (Fi g. 43).
(17) I nstal l detent spri ng i n case (Fi g. 44).
(18) I nstal l detent pl ug and ti ghten to 19 Nm (14
ft. l bs.) (Fi g. 45).
Fig. 40 Install Shift Arm Retainer Bolt
1 RETAINER BOLT
2 SHIFT ARM
Fig. 41 Shifter Arm Shaft Plug Installation
1 SHAFT PLUG
Fig. 42 Install Shifter Restrictor Pins
1 RESTRICTOR PINS
Fig. 43 Install Detent Ball
1 PENCIL MAGNET
2 SHIFT DETENT BALL
(19) I nstal l shi ft tower gasket onto shi ft tower.
(20) I nstal l the shi ft tower oi l defl ector and gasket
onto the adapter or extensi on housi ng.
(21) I nstal l shi ft tower onto transmi ssi on case
(Fi g. 46).
(22) I nstal l bol ts to hol d shi ft tower to transmi s-
si on case. Ti ghten tower bol ts to 18 Nm (13 ft. l bs.)
torque.
(23) I nstal l new metal o-ri ng onto the backup l amp
swi tch.
(24) I nstal l backup l amp swi tch (Fi g. 47). Ti ghten
swi tch to 44 Nm (32.5 ft. l bs.) torque.
(25) I nstal l new seal i n adapter/extensi on housi ng.
(26) I nstal l vehi cl e speed sensor, i f necessary.
(27) I nstal l cl utch housi ng, rel ease beari ng, rel ease
fork and retai ner cl i p.
Fig. 44 Install Detent Spring
1 PENCIL MAGNET
2 DETENT BALL SPRING
Fig. 45 Install Detent Ball Plug
1 TORX BIT
2 DETENT BALL PLUG
Fig. 46 Install Shift Tower
1 SHIFT TOWER
2 ADAPTER/EXTENSION HOUSING
Fig. 47 Install Backup Lamp Switch
1 SHIFT TOWER
2 BACKUP LAMP SWITCH
SHIFT MECHANISM AND GEARTRAIN
DISASSEMBLY
(1) I nstal l sui tabl e bol ts and washers i n i ntermedi -
ate pl ate (Fi g. 48). Then cl amp pl ate and gear assem-
bl y i n vi se. Use enough washers to prevent bol ts
from touchi ng. Al so be sure vi se jaws are cl amped on
bol t heads.
(2) Remove countershaft fi fth gear retai ni ng snap-
ri ng (Fi g. 49).
(3) Remove bol t hol di ng fi fth gear shi ft fork to
shi ft rai l (Fi g. 50).
Fig. 48 Positioning Intermediate Plate In Vise
2 BOLTS
Fig. 49 Remove Fifth Gear Snap-ring
1 FIFTH GEAR SNAP RING (SELECT FIT)
Fig. 50 Remove Shift Fork Retainer Bolt
1 SHIFT FORK RETAINER BOLT
2 FIFTH GEAR SHIFT RAIL
3 FIFTH GEAR SHIFT FORK
(4) Remove fi fth gear bl ocker ri ng from counter-
shaft assembl y wi th Pul l er L-4407 (Fi g. 51).
(5) Remove fi fth gear synchro ri ng (Fi g. 52).
(6) Remove the countershaft fi fth gear assembl y
from countershaft (Fi g. 53).
(7) Remove fi fth gear thrust ri ng from counter-
shaft (Fi g. 54).
(8) Remove fi fth gear thrust ri ng l ock bal l from
countershaft (Fi g. 55).
NOTE: There are many lock balls, check balls,
interlock balls, and interlock pins used in various
places in the transmission. Whenever a pin or ball
is removed, it should be identified in such a way
that it can be reinstalled in the same location from
which it was removed.
Fig. 51 Remove Fifth Gear Blocker Ring
1 FIFTH GEAR BLOCKER RING
Fig. 52 Remove Fifth Gear Synchro Ring
1 FIFTH GEAR SYNCHRO RING
Fig. 53 Remove Fifth Gear and Synchro Assembly
1 FIFTH GEAR SYNCHRO SLEEVE ASSEMBLY
2 COUNTER FIFTH GEAR
Fig. 54 Remove Fifth Gear Thrust Ring
1 LOCK BALL NOTCH
2 FIFTH GEAR THRUST RING
(9) Remove bol t hol di ng reverse i dl er gear shaft
l ock pl ate to the i ntermedi ate pl ate.
(10) Remove reverse i dl er gear shaft and reverse
i dl er gear assembl y (Fi g. 56).
NOTE: Be sure to retrieve the pin and compression
spring from the reverse idler shaft.
(11) Remove bol ts hol di ng output shaft rear bear-
i ng retai ner to the i ntermedi ate pl ate and remove
retai ner (Fi g. 57).
(12) Remove bol ts hol di ng 12 and 34 shi ft forks
to the shi ft rai l s (Fi g. 58) and di scard bol ts.
(13) Remove bol ts hol di ng reverse shi ft arm
bracket to i ntermedi ate pl ate (Fi g. 59).
Fig. 55 Remove Fifth Gear Thrust Ring Lock Ball
1 PENCIL MAGNET
2 CLUSTER GEAR
3 LOCK BALL RECESS
4 THRUST RING LOCK BALL
Fig. 56 Remove Reverse Idler Shaft
1 REVERSE IDLER SHAFT
Fig. 57 Remove Output Shaft Rear Bearing Retainer
1 OUTPUT SHAFT REAR BEARING RETAINER
Fig. 58 Remove Shift Fork To Shift Rail Bolts
1 12 SHIFT FORK
2 34 SHIFT FORK
(14) Remove snap-ri ng hol di ng output shaft rear
beari ng i nto the i ntermedi ate pl ate (Fi g. 60).
(15) Remove countershaft rear beari ng snap-ri ng.
(16) Wi th ai d of an assi stant, support the mai n-
shaft and countershaft. Tap on the rear of the mai n-
shaft and countershaft wi th a sui tabl e pl asti c mal l et.
Thi s wi l l rel ease the countershaft from the counter-
shaft rear beari ng and the mai nshaft rear beari ng
from the i ntermedi ate pl ate. The countershaft wi l l
rel ease from the countershaft beari ng fi rst and can
be removed by movi ng the countershaft rearward and
downward (Fi g. 61).
(17) Remove the mai nshaft by movi ng the mai n-
shaft forward unti l the mai nshaft rear beari ng i s
cl ear of the i ntermedi ate pl ate and then rotati ng the
mai nshaft downward out of the shi ft forks (Fi g. 62).
(18) Remove the 34 shi ft fork from the 34 shi ft
rai l (Fi g. 63).
(19) Remove the snap-ri ng from near the end of
the 12 shi ft rai l to al l ow the removal of the 12
shi ft fork.
Fig. 59 Remove Reverse Shift Arm Bracket Bolts
1 REVERSE SHIFT ARM BOLTS
Fig. 60 Remove Output Shaft Rear Bearing
Snap-ring
1 OUTPUT SHAFT REAR BEARING SNAP-RING
2 COUNTERSHAFT REAR BEARING SNAP-RING
Fig. 61 Remove Countershaft and Countershaft
Rear Bearing
1 INPUT SHAFT
3 OUTPUT SHAFT
4 COUNTERSHAFT
5 COUNTERSHAFT REAR BEARING
Fig. 62 Remove Mainshaft
1 SHIFT FORKS
2 MAINSHAFT
(20) Remove the 12 shi ft fork from the 12 and
the 34 shi ft rai l s (Fi g. 64).
(21) Remove threaded pl ugs from i ntermedi ate
pl ate. Then remove l ock bal l and spri ng from pl ug
hol es wi th penci l magnet (Fi g. 65). Note that the bot-
tom spri ng i s shorter i n l ength than the other two
spri ngs.
(22) Remove the i ntermedi ate pl ate from the vi se,
rotate the pl ate 180, and rei nstal l the pl ate i n the
vi se usi ng the same bol t and washer mounti ng set-
up.
CAUTION: The interlock balls and pins are different
sizes and shapes. Be sure to correctly identify
which position an item is removed from to ensure
that it is reinstalled in the same location.
Fig. 63 Remove 34 Shift Fork
1 34 SHIFT FORK
2 34 SHIFT RAIL
3 12 SHIFT RAIL
4 12 SHIFT FORK
Fig. 64 Remove 12 Shift Fork
1 12 SHIFT FORK
2 34 SHIFT RAIL
3 12 SHIFT RAIL
Fig. 65 Remove Lock Ball And Spring
1 THREADED PLUGS
2 LOCK BALL
3 SPRING
4 PENCIL MAGNET
(23) Remove fi fth gear shi ft rai l (Fi g. 66).
(24) Remove fi fth gear check bal l (Fi g. 67) and
i nterl ock pi n.
(25) Remove reverse shi ft head and rai l assembl y
(Fi g. 68).
(26) Remove snap-ri ng hol di ng reverse shi ft rai l
i nto i ntermedi ate pl ate.
(27) Remove reverse shi ft rai l and reverse shi ft
fork and arm assembl y from i ntermedi ate pl ate (Fi g.
69).
Fig. 66 Remove Fifth Gear Shift Rail
Fig. 67 Remove Fifth Gear Check Ball
1 FIFTH GEAR CHECK BALL
Fig. 68 Remove Reverse Shift Head And Rail
Assembly
1 REVERSE SHIFT HEAD AND RAIL ASSEMBLY
Fig. 69 Remove Reverse Shift Rail
1 REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY
(28) Remove i nterl ock pi n from reverse shi ft rai l
(Fi g. 70).
(29) Remove reverse el ongated check bal l (Fi g. 71).
(30) Remove snap-ri ng on 34 shi ft rai l .
(31) Remove 12 shi ft rai l from i ntermedi ate pl ate.
(32) Remove i nterl ock pi n from 12 shi ft rai l (Fi g.
72).
(33) Remove 12 shi ft rai l el ongated check bal l
from i ntermedi ate pl ate (Fi g. 73).
(34) Remove 34 shi ft rai l from i ntermedi ate pl ate.
Fig. 70 Remove Interlock Pin From Reverse Shift
Rail
1 REVERSE SHIFT RAIL
2 INTERLOCK PIN
Fig. 71 Remove Reverse Check Ball
1 REVERSE CHECK BALL
Fig. 72 Remove 12 Shift Rail Interlock Pin
1 INTERLOCK PIN
2 12 SHIFT RAIL
Fig. 73 Remove 12 Check Ball
1 12 CHECK BALL
2 34 SHIFT RAIL
ASSEMBLY
Refer to (Fi g. 74) whi l e assembl i ng and i nstal l i ng
the shi ft rai l components. Al so, veri fy that al l shi ft
rai l components are i n thei r neutral posi ti on when
i nstal l i ng the check bal l s and i nterl ock pi ns.
(1) I nstal l the 34 shi ft rai l i nto the i ntermedi ate
pl ate.
(2) I nstal l the 12 el ongated check bal l i nto the
i ntermedi ate pl ate (Fi g. 75).
(3) I nstal l the i nterl ock pi n i nto the 12 shi ft rai l
(Fi g. 76).
(4) I nstal l the 12 shi ft rai l i nto the i ntermedi ate
pl ate.
Fig. 74 Shift Rail Components
1 34 FORK
2 34 SHIFT RAIL
3 12 FORK
5 FIFTH GEAR FORK
7 12 SHIFT RAIL
Fig. 75 Install 12 Check Ball
1 12 CHECK BALL
2 34 SHIFT RAIL
(5) I nstal l snap-ri ng onto 34 shi ft rai l .
(6) I nstal l the reverse check bal l i nto the i nterme-
di ate pl ate (Fi g. 77).
(7) I nstal l the i nterl ock pi n i nto the reverse shi ft
rai l (Fi g. 78).
(8) Assembl e the reverse arm bracket to the
reverse fork (Fi g. 79).
(9) I nstal l reverse shi ft rai l i nto i ntermedi ate pl ate
and posi ti on reverse arm bracket to i ntermedi ate
pl ate (Fi g. 80).
Fig. 76 Install 12 Shift Rail Interlock Pin
1 INTERLOCK PIN
2 12 SHIFT RAIL
Fig. 77 Install Reverse Check Ball
1 REVERSE CHECK BALL
Fig. 78 Install Reverse Interlock Pin
2 INTERLOCK PIN
Fig. 79 Install Reverse Arm Bracket to Fork
1 REVERSE SHIFT FORK
2 REVERSE ARM BRACKET
(10) I nstal l snap-ri ng onto reverse shi ft rai l (Fi g.
81).
(11) I nstal l reverse shi ft head and rai l assembl y
i nto the i ntermedi ate pl ate.
(12) I nstal l the fi fth gear i nterl ock bal l and check
bal l (Fi g. 82).
(13) I nstal l fi fth gear shi ft rai l (Fi g. 83).
(14) Remove the i ntermedi ate pl ate from the vi se,
rotate the pl ate 180, and rei nstal l the pl ate i n the
vi se usi ng the same bol t and washer mounti ng set-
up.
(15) I nstal l the shi ft rai l detent bal l s i n the i nter-
medi ate pl ate.
Fig. 80 Install Reverse Shift Rail
1 REVERSE SHIFT RAIL AND REVERSE FORK ASSEMBLY
Fig. 81 Install Reverse Snap-ring
1 SNAP RING
Fig. 82 Install Fifth Gear Check Ball
1 FIFTH GEAR CHECK BALL
Fig. 83 Install Fifth Gear Shift Rail
(16) I nstal l the shi ft rai l detent spri ngs i n the
i ntermedi ate pl ate. Note that the bottom detent
spri ng i s shorter than the others.
(17) I nstal l the shi ft rai l detent pl ugs i n the i nter-
medi ate pl ate.
(18) I nstal l the 12 shi ft fork onto the 12 and 34
shi ft rai l s (Fi g. 84).
(19) I nstal l the snap-ri ng onto the 12 shi ft rai l .
(20) I nstal l the 34 shi ft fork onto the 34 shi ft
rai l (Fi g. 85).
(21) I nstal l mai nshaft i nto the i ntermedi ate pl ate
by gui di ng the output shaft through openi ng i n i nter-
medi ate pl ate unti l the shi ft forks are al i gned wi th
the appropri ate synchroni zer sl eeves. The mai nshaft
rear beari ng wi l l be started i n the i ntermedi ate pl ate
but not ful l y dri ven i n at thi s poi nt.
(22) Whi l e an assi stant supports the mai nshaft,
al i gn rear of countershaft wi th i nner race of counter-
shaft rear beari ng.
(23) Rai se countershaft upward unti l gears mesh
wi th the mati ng gears on the mai nshaft.
(24) Usi ng a sui tabl e rubber mal l et, tap on the
i nput shaft and the front of the countershaft equal l y
to i nstal l the mai nshaft rear beari ng i nto the i nter-
medi ate pl ate and the rear of the countershaft i nto
the rear countershaft beari ng. I t may be necessary to
occasi onal l y hol d the countershaft i nto the i ntermedi -
ate pl ate and tap the countershaft rear beari ng onto
the countershaft and i nto the i ntermedi ate pl ate.
(25) I nstal l snap-ri ngs onto the rear mai nshaft and
countershaft beari ngs.
(26) I nstal l the bol ts to hol d the reverse shi ft arm
bracket to the i ntermedi ate pl ate.
(27) I nstal l new bol ts to hol d the shi ft forks to the
shi ft rai l s (Fi g. 86).
(28) Posi ti on the mai nshaft rear beari ng retai ner
over the output shaft and onto the i ntermedi ate
pl ate.
(29) I nstal l new bol ts to hol d the beari ng retai ner
to the i ntermedi ate pl ate.
(30) Move the reverse shi ft arm i nto the reverse
gear posi ti on. The reverse gear posi ti on i s wi th the
arm moved away from the i ntermedi ate pl ate (Fi g.
87).
(31) I nstal l the reverse i dl er gear assembl y i nto
posi ti on on the mai nshaft and reverse shi ft arm.
Fig. 84 Install 12 Shift Fork
1 12 SHIFT FORK
2 34 SHIFT RAIL
3 12 SHIFT RAIL
Fig. 85 Install 34 Shift Fork
1 34 SHIFT FORK
2 34 SHIFT RAIL
3 12 SHIFT RAIL
4 12 SHIFT FORK
Fig. 86 Install Shift Fork Bolts
1 12 SHIFT FORK
2 34 SHIFT FORK
(32) I nstal l the compressi on spri ng and pi n i nto
the reverse i dl er gear shaft (Fi g. 88).
(33) I nstal l the reverse i dl er shaft through the
i ntermedi ate pl ate and reverse i dl er gear assembl y
(Fi g. 89) unti l the i dl er shaft pi n contacts the gear
assembl y. Make sure that the notched cut-out i n the
i dl er shaft i s to the rear of the transmi ssi on.
(34) Al i gn the pi n wi th the al i gnment notch i n the
reverse i dl er gear assembl y (Fi g. 90). The al i gnment
notch i n the reverse i dl er gear race/hub i s a smal l
rel i ef cut above one of the mai n l ongi tudi nal sl ots. Be
sure that the pi n i s al i gned wi th the proper sl ot, the
opposi te sl ot has an oi l drai n hol e whi ch the pi n wi l l
drop i nto. The assembl y wi l l then be l ocked onto the
shaft and wi l l need to be di sassembl ed i n order to be
removed.
(35) Depress compressi on spri ng and pi n i n
reverse i dl er gear shaft (Fi g. 91).
(36) I nstal l the reverse i dl er gear shaft the
remai nder of the way through the reverse i dl er gear
assembl y.
Fig. 87 Reverse Shift Arm Position
1 REVERSE SHIFT ARM
Fig. 88 Install Compression Spring And Pin
1 REVERSE IDLER GEAR SHAFT
2 PIN
3 COMPRESSION SPRING
Fig. 89 Install Reverse Idler Shaft
1 REVERSE IDLER SHAFT
Fig. 90 Align Idler Shaft Pin
1 REVERSE IDLER GEAR ASSEMBLY
2 ALIGNMENT NOTCH
(37) Posi ti on the reverse i dl er gear shaft l ock pl ate
onto the i ntermedi ate pl ate.
(38) I nstal l a new bol t to hol d the i dl er gear shaft
l ock pl ate to the i ntermedi ate pl ate.
(39) I nstal l the fi fth gear thrust ri ng l ock bal l to
the countershaft (Fi g. 92).
(40) I nstal l the fi fth gear thrust ri ng onto the
countershaft and over the l ock bal l (Fi g. 93).
(41) I nstal l fi fth gear shi ft fork to the countershaft
fi fth gear assembl y.
(42) I nstal l the countershaft fi fth gear beari ngs
i nto the countershaft fi fth gear assembl y.
(43) Posi ti on the countershaft fi fth gear assembl y
on the countershaft. Ensure that the fi fth gear fork i s
i nstal l ed onto the fi fth gear shi ft rai l .
(44) I nstal l the fi fth gear synchro ri ng.
(45) Posi ti on the fi fth gear bl ocker ri ng onto the
countershaft.
(46) Usi ng a sui tabl e mal l et and spacer, tap the
fi fth gear bl ocker ri ng onto the countershaft.
(47) I nstal l new bol t to hol d fi fth gear shi ft fork to
the fi fth gear shi ft rai l (Fi g. 94).
(48) Measure countershaft fi fth gear thrust cl ear-
ance.
(49) Sel ect a snap-ri ng so that the thrust cl earance
i s 0.100.30 mm (0.0040.010 i n.).
(50) I nstal l snap-ri ng to hol d fi fth gear bl ocker
ri ng onto countershaft.
Fig. 91 Depress Pin In Reverse Idler Gear Shaft
1 DEPRESS PIN
Fig. 92 Install Fifth Gear Thrust Ring Lock Ball
1 PENCIL MAGNET
2 CLUSTER GEAR
3 LOCK BALL RECESS
4 THRUST RING LOCK BALL
Fig. 93 Install Fifth Gear Thrust Ring
1 LOCK BALL NOTCH
2 FIFTH GEAR THRUST RING
Fig. 94 Install Fifth Gear Retainer Bolt
1 SHIFT FORK RETAINER BOLT
3 FIFTH GEAR SHIFT FORK
(51) Remove i ntermedi ate pl ate from vi se and
remove bol ts and washers from i ntermedi ate.
COUNTERSHAFT
DISASSEMBLY
(1) Remove sel ect fi t snap-ri ng hol di ng the coun-
tershaft front beari ng onto the countershaft (Fi g. 95).
(2) Usi ng Beari ng Spl i tter P-334, a sui tabl e spacer
on center of countershaft, and a shop press, remove
the countershaft front beari ng from the countershaft.
ASSEMBLY
(1) Remove any ni cks or burrs on countershaft hub
wi th fi ne emery or crocus cl oth.
(2) Posi ti on countershaft front beari ng on end of
countershaft.
(3) Usi ng Speci al Tool 8109 and a shop press,
press beari ng onto countershaft.
(4) Sel ect the thi ckest snap-ri ng that wi l l fi t i nto
the snap-ri ng groove of the countershaft (Fi g. 95).
(5) I nstal l snap-ri ng to hol d countershaft front
beari ng onto countershaft.
INPUT SHAFT
DISASSEMBLY
(1) Veri fy that the 34 synchroni zer i s i n the neu-
tral posi ti on.
(2) Separate i nput shaft from output shaft (Fi g.
96). Note that the output shaft pi l ot beari ng i s an
uncaged rol l er type beari ng.
(3) Remove the output shaft pi l ot beari ng rol l ers
from the i nput shaft and the output shaft.
(4) Remove the fourth gear synchroni zer ri ng from
the i nput shaft (Fi g. 97).
(5) Remove the sel ect fi t snap-ri ng hol di ng the
i nput shaft beari ng onto the i nput shaft.
(6) Usi ng Beari ng Spl i tter P-334 and a shop press,
remove the beari ng from the i nput shaft.
ASSEMBLY
(1) Posi ti on i nput shaft beari ng onto i nput shaft.
(2) Usi ng Dri ver L-4507, dri ve beari ng onto i nput
shaft.
the snap-ri ng groove of the i nput shaft (Fi g. 98).
(4) Lubri cate output shaft pi l ot beari ng bore of
i nput shaft wi th petrol eum jel l y.
I. D.
MARK
SNAP RING THICKNESS MM (IN.)
1
2
3
4
5
6
2.05 - 2.10
2.10 - 2.15
2.15 - 2.20
2.20 - 2.25
2.25 - 2.30
2.30 - 2.35
(0.0807 - 0.0827)
(0.0827 - 0.0846)
(0.0846 - 0.0866)
(0.0866 - 0.0886)
(0.0886 - 0.0906)
(0.0906 - 0.0925)
Fig. 95 Countershaft Front Bearing Snap-ring
Fig. 96 Separate Input and Output Shafts
1 INPUT SHAFT ASSEMBLY
2 OUTPUT SHAFT AND GEAR ASSEMBLY
Fig. 97 Input Shaft Components
1 BEARING
2 SYNCHRO RING
3 INPUT SHAFT
4 BEARING SNAP RING
(5) I nstal l output shaft pi l ot beari ng rol l ers i n
i nput shaft bore (Fi g. 99). Ensure to use suffi ci ent
petrol eum jel l y to hol d rol l ers i n posi ti on.
(6) I nstal l the fourth gear synchroni zer ri ng onto
the i nput shaft.
(7) I nstal l i nput shaft to output shaft. Use care
when mati ng the two shafts not to di spl ace any out-
put shaft pi l ot beari ng rol l ers.
OUTPUT SHAFT
DISASSEMBLY
(1) Remove i nput shaft and output shaft pi l ot
beari ng rol l ers from output shaft.
(2) Measure and note thrust cl earance of output
shaft gears (Fi g. 100). Cl earance shoul d be 0.10
0.25 mm (0.004 0.010 i n.).
I. D. Mark Snap Ring Thickness mm (in.)
0
1
2
3
4
5
2.05-2.10 (0.0807-0.0827)
2.10-2.15 (0.0827-0.0846)
2.15-2.20 (0.0846-0.0866)
2.20-2.25 (0.0866-0.0886)
2.25-2.30 (0.0886-0.0906)
2.30-2.35 (0.0906-0.0925)
Fig. 98 Select Input Shaft Bearing Snap-ring
Fig. 99 Install Output Shaft Pilot Bearing Rollers
1 INPUT SHAFT
2 BEARING ROLLERS
Fig. 100 Check Output Shaft Gear Thrust Clearance
(3) Remove output shaft fi fth gear snap ri ng wi th
two screwdri vers (Fi g. 101).
(4) Usi ng Beari ng Spl i tter P-334 or sui tabl e press
pl ates posi ti oned under fi rst gear, press fi fth gear,
rear beari ng, fi rst gear, and fi rst gear beari ng i nner
race off output shaft (Fi g. 102).
(5) Remove fi rst gear needl e rol l er beari ng from
output shaft.
(6) Remove fi rst gear beari ng i nner race l ock bal l
wi th penci l magnet (Fi g. 103).
(7) Remove fi rst gear synchroni zer ri ng.
pl ates posi ti oned under second gear, press 12 syn-
chroni zer, reverse gear, and second gear from output
shaft (Fi g. 104).
(9) Remove second gear needl e rol l er beari ng from
the output shaft or second gear.
(10) Remove sel ect fi t snap-ri ng hol di ng the 34
synchroni zer onto the output shaft (Fi g. 105).
pl ates posi ti oned under thi rd gear, press the 34 syn-
chroni zer and thi rd gear from output shaft (Fi g. 106).
(12) Remove thi rd gear needl e rol l er beari ng from
output shaft or gear.
Fig. 101 Remove Fifth Gear Snap-ring
1 SNAP RING
Fig. 102 Remove Fifth Gear, First Gear Bearing, And
Race
1 PRESS RAM
2 OUTPUT SHAFT
3 FIRST-FIFTH GEAR-BEARING ASSEMBLY
Fig. 103 Remove First Gear Bearing Inner Race
Lock Ball
1 LOCK BALL
2 PENCIL MAGNET
ASSEMBLY
TRANSMISSION ASSEMBLY INFORMATION
Lubri cate the transmi ssi on components wi th
Mopar 75W90, GL 3 gear l ubri cant duri ng assem-
bl y. Use petrol eum jel l y to l ubri cate seal l i ps and/or
hol d parts i n pl ace duri ng i nstal l ati on.
Refer to (Fi g. 107) duri ng assembl y for AX5 gear
assembl y i denti fi cati on.
(1) Lubri cate transmi ssi on components wi th speci -
fi ed gear l ubri cant.
(2) I f necessary, assembl e 12 and 34 synchro-
ni zer hubs, sl eeves, spri ngs and key i nserts (Fi g.
108).
(3) I nstal l thi rd gear needl e beari ng onto the out-
put shaft.
(4) I nstal l thi rd gear over beari ng and onto output
shaft fl ange.
(5) I nstal l thi rd gear synchroni zer ri ng to thi rd
gear.
(6) Posi ti on the 34 synchroni zer onto the output
shaft.
(7) Usi ng Adapter 6747-1A and a shop press, press
the 34 synchroni zer onto the output shaft.
Fig. 104 Remove Second Gear, Reverse Gear, And
12 Synchronizer
1 PRESS RAM
2 SECOND GEAR
3 12 SYNCHRONIZER HUB
Fig. 105 Remove 34 Synchronizer Snap Ring
1 34 SYNCHRONIZER SNAP RING
Fig. 106 Remove 34 Synchronizer And Third Gear
1 34 SYNCHRONIZER
2 THIRD GEAR
the snap-ri ng groove of the output shaft (Fi g. 109).
(9) I nstal l snap-ri ng to hol d 34 synchroni zer onto
output shaft.
(10) Veri fy thi rd gear thrust cl earance wi th feel er
gauge (Fi g. 110). Cl earance shoul d be 0.10 0.25 mm
(0.004 0.010 i n.). I f cl earance i s out of speci fi cati on,
refer to Cl eani ng and I nspecti on secti on wi thi n thi s
group.
(11) I nstal l second gear needl e beari ng onto output
shaft.
(12) I nstal l second gear over beari ng and onto out-
put shaft fl ange.
(13) I nstal l second gear synchroni zer ri ng onto sec-
ond gear.
(14) Posi ti on 12 synchroni zer assembl y onto
spl i nes of output shaft.
(15) Usi ng Dri ver MD-998805, Adapter 6747-1A,
and a shop press, press the 12 synchroni zer onto
the output shaft.
(16) I nstal l fi rst gear synchroni zer ri ng i nto 12
synchroni zer.
(17) I nstal l fi rst gear beari ng i nner race l ock bal l
i n output shaft (Fi g. 111).
(18) I nstal l fi rst gear needl e beari ng onto output
shaft (Fi g. 112).
Fig. 107 Geartrain Components
1 SNAP RING
2 FIFTH GEAR
3 COUNTER GEAR
4 BEARING
5 LOCK BALL
6 SYNCHRO HUB/SLEEVE
7 SNAP RING
8 SPACER
9 COUNTER 5TH GEAR
10 SYNCHRO RING
11 5TH SPLINE GEAR
12 SNAP RING
Fig. 108 Synchronizer Identification
1 SLEEVES
2 HUBS
C-1 1.75-1.80 (0.0689-0.0709)
D 1.80-1.85 (0.0709-0.0728)
D-1 1.85-1.90 (0.0728-0.0748)
E 1.90-1.95 (0.0748-0.0768)
E-1 1.95-2.00 (0.0768-0.0787)
F 2.00-2.05 (0.0788-0.0807)
F-1 2.05-2.10 (0.0807-0.0827)
Fig. 109 Select 34 Synchronizer Snap-ring
(19) I nstal l fi rst gear onto output shaft and over
beari ng.
(20) I nstal l fi rst gear beari ng i nner race onto out-
put shaft and i nsi de fi rst gear beari ng. Rotate bear-
i ng race unti l race i nstal l s over l ock bal l .
(21) Posi ti on output shaft rear beari ng onto output
shaft. Ensure that the snap ri ng groove i n beari ng
outer race i s toward rear of output shaft.
(22) Usi ng Dri ver L-4507 and sui tabl e mal l et,
dri ve beari ng onto output shaft.
(23) I nstal l snap-ri ng onto output shaft rear bear-
i ng outer race.
(24) Check fi rstsecond gear thrust cl earance (Fi g.
113). Standard cl earance i s 0.10 0.25 mm (0.004
0.010 i n.). I f cl earance i s out of speci fi cati on, refer to
Cl eani ng and I nspecti on secti on wi thi n thi s group.
(25) Posi ti on fi fth gear onto output shaft wi th the
gears short shoul der toward the rear of shaft.
Ensure that the gear and output shaft spl i nes are
al i gned.
(26) Usi ng Adapter 6747-1A, Dri ver L-4507, and a
shop press, press fi fth gear onto output shaft.
the snap-ri ng groove of the output shaft (Fi g. 114).
Fig. 110 Check Third Gear Clearance
1 FEELER GAUGE
2 THIRD GEAR
Fig. 111 Install First Gear Bearing Inner Race Lock
Ball
1 FIRST GEAR LOCK BALL
Fig. 112 First Gear Components
1 REAR BEARING
2 INNER RACE
3 FIRST GEAR
4 NEEDLE BEARING
5 FIRST GEAR LOCK BALL
Fig. 113 Check FirstSecond Gear Thrust Clearance
(28) I nstal l snap-ri ng to hol d fi fth gear onto output
shaft.
SEMI-SYNCHRONIZED REVERSE IDLER GEAR
DISASSEMBLY
(1) Remove snap-ri ng hol di ng the reverse i dl er
gear onto the reverse i dl er gear hub/race (Fi g. 115).
(2) Remove the pl ate washer from the reverse i dl er
gear hub/race (Fi g. 116).
(3) Remove the reverse i dl er gear from the reverse
i dl er gear hub/race (Fi g. 117).
(4) Remove the reverse i dl er gear synchroni zer
ri ng from the reverse i dl er gear hub/race (Fi g. 118).
A 2.67-2.72 (0.1051-0.1071)
B 2.73-2.78 (0.1075-0.1094)
C 2.79-2.84 (0.1098-0.1118)
D 2.85-2.90 (0.1122-0.1142)
E 2.91-2.96 (0.1146-0.1165)
F 2.97-3.02 (0.1169-0.1189)
G 3.03-3.08 (0.1193-0.1213)
H 3.09-3.14 (0.1217-0.1236)
J 3.15-3.20 (0.1240-0.1260)
K 3.21-3.26 (0.1264-0.1283)
L 3.27-3.32 (0.1287-0.1307)
Fig. 114 Select/Install Fifth Gear Snap Ring
Fig. 115 Remove Reverse Idler Gear Snap-ring
1 REVERSE IDLER GEAR
2 SNAP-RING
3 REVERSE IDLER GEAR HUB
4 PLATE WASHER
Fig. 116 Remove Reverse Idler Gear Plate Washer
2 PLATE WASHER
ASSEMBLY
(1) I nstal l the reverse i dl er gear synchroni zer ri ng
onto the reverse i dl er gear hub/race. Appl y a fi l m of
75W-90 GL-3 transmi ssi on oi l to the contact surface
of the synchroni zer ri ng pri or to assembl y.
(2) I nstal l the reverse i dl er gear onto the reverse
i dl er gear hub/race. Appl y a fi l m of 75W-90 GL-3
transmi ssi on oi l to the reverse i dl er gear bushi ng
pri or to assembl y. Veri fy that the teeth on the syn-
chroni zer ri ng are properl y engaged i nto the recesses
of the reverse i dl er gear.
(3) I nstal l the pl ate washer over the reverse i dl er
gear hub/race and onto the reverse i dl er gear.
(4) I nstal l the snap-ri ng to hol d the reerse i dl er
gear onto the reverse i dl er hub/race.
AX5 MANUAL TRANSMISSION COMPONENTS
GENERAL INFORMATION
Cl ean the transmi ssi on components i n sol vent. Dry
the cases, gears, shi ft mechani sm and shafts wi th
compressed ai r. Dry the beari ngs wi th cl ean, dry
shop towel s onl y. Never use compressed ai r on the
beari ngs. Thi s coul d cause severe damage to the
beari ng rol l er and race surfaces.
I f output shaft or i nner race fl ange thi ckness i s
wi thi n speci fi cati on but any gear thrust cl earance i s
out of speci fi cati on, repl ace the necessary gear and
gear needl e beari ng as an assembl y.
GEAR CASE, ADAPTER/EXTENSION HOUSING,
INTERMEDIATE PLATE
Cl ean the case, housi ng, and i ntermedi ate pl ate
wi th sol vent and dry wi th compressed ai r. Repl ace
the case i f cracked, porous, or i f any of the beari ng
and gear bores are damaged.
I nspect the threads i n the case, housi ng, and pl ate.
Mi nor thread damage can be repai red wi th steel
thread i nserts, i f necessary. Do not attempt to repai r
any threads whi ch show evi dence of cracks around
the threaded hol e.
OUTPUT SHAFT
Check thi ckness of the output shaft and i nner
beari ng race fl anges wi th a mi crometer or verni er
cal i pers (Fi g. 119).
Mi ni mum thi ckness for shaft fl ange i s 4.80 mm
(0.189 i n.)
Mi ni mum thi ckness for fi rst gear beari ng i nner
race fl ange i s 3.99 mm (0.157 i n.)
Measure di ameter of the output shaft journal sur-
faces wi th a mi crometer. Repl ace the shaft i f ei ther of
these surfaces are worn beyond speci fi ed l i mi ts.
Second gear surface mi ni mum di ameter i s
37.964 mm (1.495 i n.)
Thi rd gear surface mi ni mum di ameter i s 34.984
mm (1.377 i n.)
Measure di ameter of the fi rst gear beari ng i nner
race. Mi ni mum di ameter i s 38.985 mm (1.535 i n.).
Measure output shaft runout wi th a di al i ndi cator
(Fi g. 120). Runout shoul d not exceed 0.05 mm (0.002
i n.).
Repl ace output shaft or fi rst gear i nner beari ng
race i f measurement of any surface i s out of speci fi -
cati on. Do not attempt to repai r out of speci fi cati on
components.
Fig. 117 Remove Reverse Idler Gear
1 REVERSE SYNCHRONIZER RING
Fig. 118 Remove Reverse Idler Gear Synchronizer
Ring
1 REVERSE SYNCHRONIZER RING
COUNTERSHAFT
I nspect the countershaft gear teeth. Repl ace the
countershaft i f any teeth are worn or damaged.
I nspect the beari ng surfaces and repl ace shaft i f any
surface shows damage or wear.
Check condi ti on of the countershaft front beari ng.
Repl ace the beari ng i f worn, noi sy, or damaged.
GEAR AND SYNCHRONIZER
I nstal l the needl e beari ng and i nner race i n the
fi rst gear. Then check oi l cl earance between the gear
and i nner race (Fi g. 121). Cl earance shoul d be 0.009
0.032 mm (0.0004 0.0013 i n.).
I nstal l the needl e beari ngs and the second, thi rd
and counter fi fth gears on the output shaft. Then
check oi l cl earance between the gears and shaft wi th
a di al i ndi cator (Fi g. 122). Oi l cl earance for al l three
gears i s 0.009 0.0013 mm (0.0004 0.0013 i n.).
Check synchroni zer ri ng wear (Fi g. 123). I nsert
each ri ng i n matchi ng gear. Measure cl earance
between each ri ng and gear wi th feel er gauge.
Repl ace ri ng i f cl earance exceeds 2.0 mm (0.078 i n.).
Check shi ft forktosynchroni zer hub cl earance
wi th a feel er gauge (Fi g. 124). Repl ace the fork i f
cl earance exceeds 1.0 mm (0.039 i n.).
(1) I nspect al l mai nshaft gear teeth. Repl ace any
gear whi ch shows any worn or damaged teeth.
Fig. 119 Check Shaft And Bearing Race Flange
Thickness
1 OUTPUT SHAFT FLANGE
2 INNER RACE FLANGE
Fig. 120 Check Output Shaft Runout
1 OUTPUT SHAFT JOURNAL
Fig. 121 Check GearToRace Clearance
1 GEAR
2 INNER RACE
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ugs, Access . . . . . . . . . . . . . . . 19 Nm (14 ft.l bs.)
Bol ts, Adapter Housi ng . . . . . . . 34 Nm (25 ft.l bs.)
Swi tch, Back-up Li ght . . . . . . . 44 Nm (32.5 ft.l bs.)
Pl ugs, Drai n and Fi l l . . . . . . . . 44 Nm (32.5 ft.l bs.)
Bol ts, Front Beari ng Retai ner . . 17 Nm (12 ft.l bs.)
Pl ugs, I nterl ock and Detent . . . . 19 Nm (14 ft.l bs.)
Screws, Propel l er Shaft Cl amp . . . . . . . 1623 Nm
(140200 i n.l bs.)
Bol ts, Rear Mount to Transmi ssi on . . . . 3360 Nm
(2444 ft.l bs.)
Nut, Rear Mount Cl evi s . . 5475 Nm (4055 ft.l bs.)
Nuts, Rear Mount to Crossmember . . . . 4168 Nm
(3050 ft.l bs.)
Pi ns, Restri ctor . . . . . . . . . . . . 27.4 Nm (20 ft.l bs.)
Bol ts, Reverse Shi ft Arm Bracket . . . . . . . . 18 Nm
(13 ft.l bs.)
Screw, Shi ft Arm Set . . . . . . . . . 38 Nm (28 ft.l bs.)
Screws, Shi ft Fork Set . . . . . . . . 20 Nm (15 ft.l bs.)
Nut, Shi ft Knob . . . . . . . . 2034 Nm (1525 ft.l bs.)
Screws, Shi fter Fl oor Cover . . . . . . . . . . . . 23 Nm
(1730 i n.l bs.)
Bol ts, Shi ft Tower . . . . . . . . . . . . 18 Nm (13 ft.l bs.)
Nuts, Transfer Case Mounti ng . . . . . . . 3041 Nm
(2230 ft.l bs.)
Fig. 122 Check GearToShaft Oil Clearance
1 GEAR BEING CHECKED
2 OUTPUT SHAFT
Fig. 123 Check Synchronizer Ring Wear
1 FEELER GAUGE
2 SYNCHRONIZER RING
Fig. 124 Check ForkToHub Clearance
1 SHIFT FORK
2 FEELER GAUGE
3 SYNCHRONIZER SLEEVE
SPECIAL TOOLS
AX5
C-3339 Dial Indicator Set
C-3995-A Installer, Extension Housing Seal
C-4171 Handle, Universal Tool
8211 Installer, Seal
P-334 Splitter, Bearing
8109 Cup, Installer
L-4507 Tube, Driver
67471A Adapter, Fixture
MD-998805 Installer, Seal
NV3550 MANUAL TRANSMISSION
TABLE OF CONTENTS
page page
GENERAL INFORMATION
NV3550 MANUAL TRANSMISSION. . . . . . . . . . . . 42
LUBRICANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
LOW LUBRICANT LEVEL. . . . . . . . . . . . . . . . . . . 44
HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . 44
TRANSMISSION NOISE. . . . . . . . . . . . . . . . . . . . 44
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 44
SHIFT TOWER. . . . . . . . . . . . . . . . . . . . . . . . . . . 47
YOKE SEAL2WD . . . . . . . . . . . . . . . . . . . . . . . 47
REAR HOUSING YOKE BUSHING . . . . . . . . . . . . 48
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . 48
TRANSMISSION COMPONENTS . . . . . . . . . . . . . 83
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
SPECIAL TOOLS
NV3550 MANUAL TRANSMISSION. . . . . . . . . . . . 85
GENERAL INFORMATION
DESCRIPTION
The NV3550 i s a medi um-duty, 5-speed, constant
mesh, ful l y synchroni zed manual transmi ssi on. Fi fth
gear i s an overdri ve range wi th a rati o of 0.78:1. The
NV3550 i s avai l abl e i n two and fourwheel dri ve con-
fi gurati ons.
The transmi ssi on gear case consi sts of two al umi -
num housi ngs. The cl utch housi ng i s a removabl e
component. I t i s not an i ntegral part of the transmi s-
si on front housi ng.
A combi nati on of rol l er and bal l beari ngs are used
to support the transmi ssi on shafts i n the two hous-
i ngs. The transmi ssi on gears al l rotate on caged type
needl e beari ngs. A rol l er beari ng i s used between the
i nput and output shaft.
The NV3550 has a si ngl e shaft shi ft mechani sm
wi th three shi ft forks al l mounted on the shaft. The
shaft i s supported i n the front and rear housi ngs by
bushi ngs and one l i near bal l beari ng. I nternal shi ft
components consi st of the forks, shaft, shi ft l ever
socket, and detent components (Fi g. 1).
GEAR RATIOS
Gear rati os for the NV3550 are as fol l ows:
RANGE RATIO
FIRST 4.01:1
SECOND 2.32:1
THIRD = 1.40:1
FOURTH = 1:1
FIFTH = 0.78:1
REVERSE = 3.55:1
IDENTIFICATION
The NV3550 i denti fi cati on and part number bar
code tags (Fi g. 2) are l ocated on the top of the trans-
mi ssi on, forward of the shi ft tower.
OPERATION
The manual transmi ssi on recei ves power through
the cl utch assembl y from the engi ne. The cl utch di sc
i s spl i ned to the transmi ssi on i nput shaft and i s
turned at engi ne speed at al l ti mes that the cl utch i s
engaged. The i nput shaft i s connected to the trans-
mi ssi on countershaft through the mesh of fourth
speed gear on the i nput shaft and the fourth counter-
shaft gear. At thi s poi nt, al l the transmi ssi on gears
are spi nni ng.
The dri ver sel ects a parti cul ar gear by movi ng the
shi ft l ever to the desi red gear posi ti on. Thi s move-
ment moves the i nternal transmi ssi on shi ft compo-
nents to begi n the shi ft sequence. As the shi ft l ever
moves the sel ected shi ft rai l , the shi ft fork attached
to that rai l begi ns to move. The fork i s posi ti oned i n
a groove i n the outer ci rcumference of the synchro-
ni zer sl eeve. As the shi ft fork moves the synchroni zer
sl eeve, the synchroni zer begi ns to speed-up or sl ow
down the sel ected gear (dependi ng on whether we are
up-shi fti ng or down-shi fti ng). The synchroni zer does
thi s by havi ng the synchroni zer hub spl i ned to the
mai nshaft, or the countershaft i n some cases, and
movi ng the bl ocker ri ng i nto contact wi th the gears
fri cti on cone. As the bl ocker ri ng and fri cti on cone
come together, the gear speed i s brought up or down
to the speed of the synchroni zer. As the two speeds
match, the spl i nes on the i nsi de of the synchroni zer
sl eeve become al i gned wi th the teeth on the bl ocker
ri ng and the fri cti on cone and eventual l y wi l l sl i de
over the teeth, l ocki ng the gear to the mai nshaft, or
countershaft, through the synchroni zer.
21 - 42 NV3550 MANUAL TRANSMISSION XJ
LUBRICANT
DESCRIPTION
Requi red l ubri cant for the NV3550 i s Mopar Man-
ual Transmi ssi on Lubri cant, P/N 4761526. Thi s i s the
only l ubri cant to be used i n NV3550 transmi ssi ons.
No other l ubri cants are acceptabl e, or recommended.
The correct transmi ssi on l ubri cant l evel i s to the
bottom edge of the fi l l pl ug hol e (Fi g. 3).
The transmi ssi on must be l evel to obtai n an accu-
rate l ubri cant l evel check. A dri veon type of hoi st i s
recommended for thi s purpose.
Lubri cant capaci ty of the NV3500 i s approxi matel y
2.28 l i ters (4.8 pi nts). Thi s represents the approxi -
mate quanti ty needed to refi l l the transmi ssi on after
a l ubri cant change or overhaul .
DRAIN AND FILL PLUG LOCATIONS
The NV3550 fi l l pl ug i s l ocated i n the front hous-
i ng. The drai n pl ug i s at the bottom rear of the hous-
i ng (Fi g. 3).
Fig. 1 NV3550 Shift Mechanism
1 3-4 FORK
2 SHIFT SHAFT LEVER AND BUSHING
3 1-2 FORK
4 FIFTH-REVERSE FORK
5 SHIFT SHAFT
6 REAR HOUSING
7 ROLL PIN
8 SHIFT LEVER SOCKET
9 SHAFT RAIL DETENTS
10 FRONT HOUSING
11 SHIFT SHAFT
Fig. 2 NV3550 Identification
1 PART NUMBER TAG
2 IDENTIFICATION TAG
3 FRONT OF REAR HOUSING
XJ NV3550 MANUAL TRANSMISSION 21 - 43
GENERAL INFORMATION (Continued)
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the
housi ngs, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at component mati ng surfaces wi l l probabl y
be the resul t of i nadequate seal er, gaps i n the seal er,
i ncorrect bol t ti ghteni ng, or use of a nonrecom-
mended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther a l oose or damaged, front beari ng retai ner or
retai ner seal . Lubri cant may al so dri p from the
transmi ssi on cl utch housi ng after extended opera-
ti on. I f the l eak i s severe, i t wi l l contami nate the
cl utch di sc causi ng sl i p, grab and chatter.
Transmi ssi ons fi l l ed from ai r or el ectri cal l y pow-
ered l ubri cant contai ners can be under fi l l ed. Al ways
check the l ubri cant l evel after fi l l i ng to avoi d an
under fi l l condi ti on.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel ; use a dri veon hoi st to
ensure thi s. Al so al l ow the l ubri cant to settl e for a
mi nute or so before checki ng. These recommenda-
ti ons wi l l ensure an accurate check and avoi d an
under-or-overfi l l condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper or contami nated l ubri cants, transmi s-
si on component damage, cl utch l i nkage mal functi on,
or by a damaged cl utch pressure pl ate or di sc.
Substanti al l ubri cant l eaks can resul t i n gear, shi ft
component, synchro and beari ng damage. I f a l eak
goes undetected for an extended peri od, the fi rst i ndi -
cati ons of a probl em are usual l y hard shi fti ng and
noi se.
I ncorrect or contami nated l ubri cants can al so con-
tri bute to hard shi fti ng. The consequence of usi ng
nonrecommended l ubri cants i s noi se, excessi ve
wear, i nternal bi nd and hard shi fti ng.
I mproper cl utch rel ease i s a frequent cause of hard
shi fti ng. I ncorrect adjustment or a worn, damaged
pressure pl ate or di sc can cause i ncorrect rel ease. I f
the cl utch probl em i s advanced, gear cl ash duri ng
shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear
cl ash when shi fti ng i nto any forward gear. I n some
new or rebui l t transmi ssi ons, new synchro ri ngs may
tend to sti ck sl i ghtl y causi ng sti ff and/or noi sy shi fts.
I n most cases, thi s condi ti on wi l l decl i ne as the ri ngs
wear i n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears can generate a
mi l d whi ne that may onl y be audi bl e at extreme
speeds.
Severe, obvi ousl y audi bl e transmi ssi on noi se i s
general l y the resul t of a l ubri cant probl em. I nsuffi -
ci ent, i mproper, or contami nated l ubri cant can pro-
mote rapi d wear of gears, synchros, shi ft rai l s, forks
and beari ngs. The overheati ng caused by a l ubri cant
probl em, can al so l ead to gear breakage.
TRANSMISSION
REMOVAL
(1) Shi ft transmi ssi on i nto fi rst or thi rd gear.
(2) Remove the fl oor consol e and shi ft boot as nec-
essary to access the bottom of the shi ft l ever at the
shi ft tower attachment.
Fig. 3 Drain and Fill Plug Locations
1 DRAIN PLUG
2 FILL PLUG
GENERAL INFORMATION (Continued)
(3) I nstal l nuts on two M6X1.0 bol ts and thread
the bol ts i nto the threaded hol es at the base of the
shi ft l ever.
(4) Ti ghten the nuts equal l y unti l the shi ft l ever
l oosens on the shi ft tower stub shaft.
(5) Remove the shi ft l ever from the shi ft tower.
(6) Rai se and support vehi cl e on sui tabl e safety
stands.
(8) Remove crossmember/ski d pl ate.
(9) Di sconnect necessary exhaust system compo-
nents.
(10) Remove ski d pl ate, i f equi pped.
(11) Remove sl ave cyl i nder (Fi g. 4) from cl utch
housi ng.
(12) Mark rear propel l er shaft and rear axl e yokes
for i nstal l ati on al i gnment (Fi g. 5).
(13) Mark front propel l er shaft, axl e, and transfer
case yokes for i nstal l ati on al i gnment, i f equi pped.
(14) Remove propel l er shaft(s).
(15) Uncl i p wi re harnesses from transmi ssi on and
(16) Di sconnect transfer case vent hose, i f
equi pped.
(17) Di sengage any wi re connectors attached to
transmi ssi on or transfer case, i f equi pped, compo-
nents.
(18) Support transfer case, i f equi pped, wi th trans-
mi ssi on jack.
(19) Secure transfer case, i f equi pped, to jack wi th
safety chai ns.
(20) Di sconnect transfer case shi ft l i nkage at
mi ssi on, i f equi pped.
(22) Remove transfer case, i f equi pped.
(23) Remove crankshaft posi ti on sensor (Fi g. 6).
CAUTION: It is important that the crankshaft posi-
tion sensor be removed prior to transmission
removal. The sensor can easily be damaged if left
in place during removal operations.
Fig. 5 Marking Propeller Shaft And Axle Yokes
1 REFERENCE MARKS
Fig. 6 Crankshaft Position Sensor 2.5 and 4.0L
Engine
1 ENGINE SPEED SENSOR
2 GROMMET
3 MOUNTING BOLT(S)
4 LEFT REAR OF ENGINE
5 TRANSMISSION
(25) Support transmi ssi on wi th transmi ssi on jack.
chai ns.
(27) Di sconnect rear cushi on and bracket from
transmi ssi on.
(29) Remove cl utch housi ng-to-engi ne bol ts.
(30) Pul l transmi ssi on jack rearward unti l i nput
shaft cl ears cl utch. Then sl i de transmi ssi on out from
under vehi cl e.
(31) Remove cl utch rel ease beari ng, rel ease fork,
and retai ner cl i p.
(32) Remove cl utch housi ng from transmi ssi on
(Fi g. 7).
INSTALLATION
(1) I nstal l cl utch housi ng (Fi g. 7) on transmi ssi on.
Ti ghten housi ng bol ts to 46 Nm (34 ft. l bs.) torque.
(2) Lubri cate contact surfaces of rel ease fork pi vot
bal l stud and rel ease fork wi th hi gh temp grease.
(3) I nstal l rel ease beari ng, fork, and retai ner cl i p.
(4) Posi ti on and secure transmi ssi on on transmi s-
si on jack.
(5) Li ghtl y l ubri cate pi l ot beari ng and transmi s-
si on i nput shaft spl i nes wi th Mopar hi gh temp
grease.
(6) Rai se transmi ssi on and al i gn transmi ssi on
i nput shaft and cl utch di sc spl i nes. Then sl i de trans-
mi ssi on i nto pl ace.
(7) I nstal l and ti ghten cl utch housi ng-to-engi ne
bol ts to the appropri ate torque: Be sure the hous-
ing is properly seated on engine block before
tightening bolts.
ft.l bs.).
ft.l bs.).
Ti ghten M12 bol ts to 75 Nm (55 ft.l bs.).
(8) Be sure transmi ssi on i s i n fi rst or thi rd gear.
(9) I nstal l rear crossmember. Ti ghten crossmem-
ber-to-frame bol ts to 41 Nm (31 ft. l bs.) torque.
(10) I nstal l fasteners to hol d rear cushi on and
bracket to transmi ssi on. Then ti ghten transmi ssi on-
to-rear support bol ts/nuts to 54 Nm (40 ft. l bs.)
torque.
(11) Remove support stands from engi ne and
transmi ssi on.
(13) Posi ti on transfer case on transmi ssi on jack, i f
equi pped.
(14) Secure transfer case to jack wi th safety
chai ns, i f equi pped.
(15) Rai se transfer case, i f equi pped, and al i gn
transfer case i nput shaft to the transmi ssi on output
shaft.
(16) Sl i de transfer case forward unti l case i s
seated on transmi ssi on, i f necessary.
(17) I nstal l nuts to attach transfer case to trans-
mi ssi on, i f equi pped. Ti ghten transfer case-to-trans-
mi ssi on nuts to 35 Nm (26 ft. l bs.) torque.
(18) Connect transfer case shi ft l i nkage at transfer
case, i f equi pped.
(19) Connect transfer case vent hose, i f equi pped.
(20) Secure wi re harnesses i n cl i ps/ti e straps on
transmi ssi on and transfer case, i f equi pped.
(21) Engage wi re connectors attached to al l neces-
sary transmi ssi on or transfer case, i f equi pped, com-
ponents.
(22) I nstal l rear propel l er shaft sl i p yoke to trans-
mi ssi on or transfer case, i f equi pped, output shaft.
(23) Al i gn marks on rear propel l er shaft and rear
axl e yokes (Fi g. 8).
(25) Al i gn marks on front propel l er shaft, axl e,
and transfer case yokes, i f equi pped.
(27) I nstal l sl ave cyl i nder i n cl utch housi ng.
2 CLUTCH HOUSING
3 TRANSMISSION
(28) I nstal l ski d pl ate, i f equi pped. Ti ghten bol ts to
42 Nm (31 ft. l bs.) torque. Ti ghten stud nuts to 17
(29) Fi l l transmi ssi on and transfer case, i f
equi pped, wi th recommended l ubri cants. Refer to the
Lubri cant Recommendati on secti ons of the appropri -
ate component for correct fl ui d.
(31) I nstal l nuts on two M6X1.0 bol ts and thread
the bol ts i nto the threaded hol es at the base of the
shi ft l ever.
(32) Ti ghten the nuts equal l y unti l the shi ft l ever
wi l l sl i de over the shi ft tower stub shaft.
(33) I nstal l the fl oor consol e and shi ft boot.
SHIFT TOWER
REMOVAL
(1) Shi ft transmi ssi on i nto Neutral .
(2) Unscrew and remove the shi ft l ever extensi on
from the shi ft
(3) Remove any fl oor consol e components neces-
sary to access the transmi ssi on shi ft tower.
(4) Remove the bol ts hol di ng the shi ft tower to the
i sol ator pl ate and transmi ssi on gear case.
(5) Remove the shi ft tower (Fi g. 9) from the trans-
mi ssi on.
INSTALLATION
(1) Shi ft transmi ssi on i nto thi rd gear.
(2) Cl ean the mati ng surfaces of shi ft tower and
transmi ssi on gear case wi th sui tabl e wax and grease
remover.
(3) I nstal l the shi ft tower onto the transmi ssi on
case. No seal ant i s necessary between the shi ft tower
and transmi ssi on case.
(4) I nstal l the bol ts to hol d the shi ft tower to the
i sol ator pl ate and the transmi ssi on gear case.
Ti ghten the shi ft tower bol ts to 8.5 Nm (6.3 ft. l bs.).
(5) I nstal l the shi ft l ever extensi on and any fl oor
consol e components previ ousl y removed.
YOKE SEAL 2WD
REMOVAL
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(3) Di sconnect and remove propel l er shaft.
(4) Remove ol d seal wi th Seal Remover C-3985-B
(Fi g. 10) from transmi ssi on housi ng.
INSTALLATION
(1) Pl ace seal i n posi ti on on transmi ssi on housi ng.
(2) Dri ve seal i nto transmi ssi on housi ng wi th Seal
I nstal l er C-3972-A (Fi g. 11).
Fig. 8 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks
1 REFERENCE MARKS
Fig. 9 Remove Shift Tower
1 SHIFT TOWER AND LEVER ASSEMBLY
2 SHIFT SOCKET
3 SEAL
Fig. 10 Removing Transmission Housing Yoke Seal
2 SEAL
(3) Careful l y gui de propel l er shaft sl i p yoke i nto
housi ng and onto output shaft spl i nes.
(4) Al i gn marks made at removal and connect pro-
pel l er shaft to rear axl e pi ni on yoke.
REAR HOUSING YOKE BUSHING
REMOVAL
(1) Remove housi ng yoke seal .
(2) I nsert Remover 6957 i nto rear housi ng. Ti ghten
tool to bushi ng and remove bushi ng (Fi g. 12).
INSTALLATION
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n rear
housi ng.
(2) Tap bushi ng i nto pl ace wi th I nstal l er 6951 and
Handl e C-4171.
(3) I nstal l new oi l seal i n housi ng usi ng Seal
I nstal l er C-3972A (Fi g. 13).
TRANSMISSION
DISASSEMBLY
FRONT HOUSING
(1) I f necessary, temporari l y rei nstal l shi ft l ever
assembl y. Shi ft transmi ssi on i nto Neutral .
(2) I f l ubri cant was not drai ned out of transmi s-
si on duri ng removal , remove drai n pl ug and drai n
l ubri cant i nto contai ner at thi s ti me.
(3) I nspect drai n pl ug magnet for debri s.
(4) Remove backup l i ght swi tch. Swi tch i s l ocated
on passenger si de of rear housi ng (Fi g. 14).
(5) I f necessary, remove shi ft tower bol ts and
remove tower and l ever assembl y (Fi g. 15).
(6) Remove shi ft shaft l ock bol t (Fi g. 16). Bol t i s
l ocated at top of front housi ng just forward of shi ft
tower. Bol t i s a shoul der bol t that secures the shi ft
shaft bushi ng and l ever.
(7) Use Remover 8117 and sui tabl e sl i de hammer
to remove shi ft shaft detent pl ug.
Fig. 11 Installing Transmission Housing Yoke Seal
Fig. 12 Bushing RemovalTypical
1 REMOVER 6957
2 EXTENSION HOUSING BUSHING
Fig. 13 Rear Housing Seal Installation
Fig. 14 Backup Light Switch Location
1 BACKUP LIGHT SWITCH
(8) Remove shi ft shaft detent pl unger and spri ng
(Fi g. 17). Use penci l magnet to remove spri ng then
pl unger, i f necessary.
(9) Remove bol ts attachi ng i nput shaft beari ng
retai ner to front housi ng (Fi g. 18).
Fig. 15 Shift Tower Removal
2 SHIFT SOCKET
3 SEAL
Fig. 16 Shift Shaft Lock Bolt Removal
1 SHIFT SHAFT LOCK BOLT
2 SHAFT SOCKET
Fig. 17 Detent Plunger And Spring Removal
1 FRONT HOUSING
2 PLUG
3 SPRING
4 PLUNGER
Fig. 18 Input Shaft Bearing Retainer Bolt Removal
Typical
1 INPUT SHAFT BEARING RETAINER
2 RETAINER BOLTS
(10) Remove i nput shaft beari ng retai ner. Use pry
tool to careful l y l i ft retai ner and break seal er bead
(Fi g. 19).
(11) Remove beari ng retai ner from i nput shaft
(Fi g. 20).
(12) Remove snap ri ng that secures i nput shaft i n
front beari ng (Fi g. 21).
(13) Remove bol ts that attach front housi ng to rear
housi ng (Fi g. 22). Three bol ts at extreme rear of
housi ng are actual l y for the output shaft beari ng
retai ner. I t i s not necessary to remove al l three bol ts
at thi s ti me. Leave at l east one bol t i n pl ace unti l
geartrai n i s ready to be removed from case.
Fig. 19 Loosening Bearing Retainer Sealer
BeadTypical
1 PRY TOOL
Fig. 20 Input Shaft Bearing Retainer Removal
Typical
1 SHAFT BEARING
2 BEARING RETAINER
3 INPUT SHAFT
Fig. 21 Input Shaft Snap Ring RemovalTypical
1 INPUT SHAFT SNAP RING
2 OIL FEED
Fig. 22 Housing And Bearing Retainer Bolt
Locations
1 RETAINER BOLTS
2 HOUSING BOLTS
3 RETAINER BOLT
4 HOUSING BOLT LOCATIONS
(14) Separate front housi ng from rear housi ng
(Fi g. 23). Use pl asti c mal l et to tap front housi ng off
al i gnment dowel s.
(15) Remove and i nspect i nput shaft beari ng.
I nspect countershaft front beari ng race (Fi g. 24).
(16) Note posi ti on of i nput shaft, shi ft shaft and
forks, and geartrai n components i n housi ng (Fi g. 25).
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT
(1) Unseat the rol l pi n that secures the shi ft
socket tot he shi ft shaft wi th Speci al Tool 6858 as fol -
l ows:
(a) Posi ti on Tool 6858 on the shi ft shaft. Center
the tool over the rol l pi n and veri fy that the tool
l egs are fi rml y seated on the shi ft socket (Fi g. 26).
(b) Ti l t the socket toward the si de of the case.
Thi s posi ti ons the rol l pi n at a sl i ght angl e to avoi d
trappi ng the pi n between the gear teeth.
(c) Ti ghten the tool punch to press the rol l pi n
downward and out of the shi ft socket (Fi g. 26). The
rol l pi n does not have to be compl etel y removed
from the shi ft socket. The rol l pi n must onl y be
cl ear of the shi ft shaft. Be careful not to push the
pi n i nto the geartrai n.
(2) Usi ng a hammer and sui tabl e punch, dri ve out
rol l pi n that secures shi ft bushi ng and l ever to shi ft
shaft (Fi g. 27).
NOTE: Be sure to use the proper size punch to
avoid bending the shift shaft.
Fig. 23 Front Housing Removal
1 FRONT HOUSING
2 REAR HOUSING
3 DOWELS (2)
4 PLASTIC MALLET
Fig. 24 Input Shaft Bearing and Countershaft Front
Bearing Race Location
1 INPUT SHAFT BEARING
2 FRONT HOUSING
3 COUNTERSHAFT FRONT BEARING
Fig. 25 Geartrain And Shift Component
Identification
1 SHIFT SHAFT
2 BUSHING
3 REAR HOUSING
4 REVERSE IDLER AND SUPPORT
5 OUTPUT SHAFT AND GEARS
6 COUNTERSHAFT
7 12 FORK
8 INPUT SHAFT
9 34 FORK
(3) Pul l shi ft shaft strai ght out of rear housi ng,
shi ft socket, fi fth-reverse fork, and 1-2 fork (Fi g. 28).
(4) Remove shi ft socket from rear housi ng (Fi g.
29).
(5) Remove l ever and bushi ng (Fi g. 30).
(6) Remove 3-4 fork. Rotate 3-4 fork around syn-
chro sl eeve unti l fork cl ears shi ft arms on 1-2 and
fi fth-reverse forks. Then remove 3-4 fork (Fi g. 31).
(7) Remove the reverse i dl er shaft support bol t
(front bol t) (Fi g. 32).
Fig. 26 Removing the Shift Socket Roll Pin
1 SPECIAL TOOL
6858
2 SHIFT SOCKET
Fig. 27 Removing Shift Shaft Lever And Bushing
Roll Pin
1 PIN PUNCH
2 BUSHING AND LEVER
3 SHIFT SHAFT
Fig. 28 Shift Shaft Removal
1 SHIFT SHAFT
2 34 FORK
3 SHAFT DETENT NOTCHES
Fig. 29 Shift Socket And Roll Pin
1 SHAFT BORE
2 ROLL PIN
3 SHIFT SOCKET
Fig. 30 Removing Shift Shaft Lever And Bushing
1 SHAFT LEVER AND BUSHING
2 34 FORK
(8) Loosen rear reverse i dl er shaft bol t (rear bol t)
(Fi g. 32).
(9) Remove reverse i dl er shaft support segment by
sl i di ng i t strai ght out of housi ng.
(10) Support geartrai n and rear housi ng on Assem-
bl y Fi xture Tool 6747 as fol l ows:
(a) Adjust hei ght of reverse i dl er pedestal rod
unti l the reverse i dl e shaft bottoms i n Cup 8115.
(b) Posi ti on Adapters 6747-1A and 6747-2A on
Assembl y Fi xture 6747.
(c) Sl i de fi xture tool onto i nput shaft, counter-
shaft and i dl er gear (Fi g. 33).
(d) Stand geartrai n and rear housi ng upri ght on
fi xture (Fi g. 34). Have hel per hol d fi xture tool i n
pl ace whi l e housi ng and geartrai n i s bei ng rotated
i nto upri ght posi ti on.
(11) Remove rear bol t hol di ng reverse i dl er shaft
i n housi ng.
Fig. 31 Removing 3-4 Shift Fork
1 34 FORK
2 12 AND 5TH-REVERSE FORK ARMS
3 34 SYNCHRO SLEEVE
Fig. 32 Reverse Idler Shaft/Support Bolts
1 SUPPORT BOLT
2 SHAFT BOLT
Fig. 33 Installing Assembly Fixture On Geartrain
1 SPECIAL TOOL 6747
2 SPECIAL TOOL 67471A
3 SPECIAL TOOL 8115
4 REVERSE IDLER PEDESTAL
Fig. 34 Geartrain And Housing Mounted On Fixture
Tool
1 INPUT SHAFT
2 COUNTERSHAFT
3 SPECIAL TOOL 6747
REAR HOUSING REMOVAL 2WD
(1) On 2-wheel dri ve transmi ssi on, remove three
bol ts that attach output shaft beari ng retai ner to
rear case (Fi g. 35). Bol ts are rear of shi ft tower open-
i ng.
(2) Unseat output shaft beari ng from beari ng bore
i n rear housi ng. Use pl asti c or rawhi de mal l et to tap
rear housi ng upward and off output shaft beari ng as
shown (Fi g. 36).
(3) Li ft rear housi ng up and off geartrai n (Fi g. 37).
(4) Remove countershaft rear beari ng from coun-
tershaft (Fi g. 38).
(5) Exami ne condi ti on of beari ng bore and i dl er
shaft notch i n rear housi ng. Repl ace housi ng i f any of
these components are damaged.
REAR ADAPTER HOUSING REMOVAL 4WD
(1) Locate di mpl es i n face of rear seal (Fi g. 39).
Use a sui tabl e sl i de hammer mounted screw to
remove seal by i nserti ng screw i nto seal at di mpl e
l ocati ons (Fi g. 40).
Fig. 35 Removing/Installing Output Shaft Bearing
Retainer Bolts2WD
1 OUTPUT SHAFT BEARING RETAINER BOLTS (THIRD BOLT
IS AT OPPOSITE SIDE OF CASE)
Fig. 36 Unseating Rear Housing From Output Shaft
Bearing2WD
1 REAR HOUSING
2 PLASTIC OR RAWHIDE MALLET
3 FIXTURE TOOL
(2) Remove rear beari ng snap ri ng from output
shaft wi th heavy duty snap ri ng pl i ers (Fi g. 41).
(3) Li ft rear adapter housi ng upward and off
geartrai n (Fi g. 42).
Fig. 37 Rear Housing Removal2WD
1 REAR HOUSING
2 SHIFT FORKS AND GEARTRAIN
Fig. 38 Remove Countershaft Rear Bearing
2 OUTPUT SHAFT
3 COUNTER SHAFT
Fig. 39 Location Of Dimples In Seal Face4WD
1 LOCATION OF DIMPLES
2 SEAL FACE
Fig. 40 Rear Seal Removal4WD
1 SLIDE HAMMER
2 REMOVER TOOL
3 REAR SEAL
(4) Remove beari ng retai ner bol ts and remove rear
beari ng retai ner and rear beari ng (Fi g. 43). Use ham-
mer handl e to push or tap beari ng out of housi ng i f
needed.
(5) Exami ne condi ti on of beari ng bore, counter-
shaft rear beari ng race and i dl er shaft notch i n rear
housi ng. Repl ace housi ng i f race, bore or notch are
worn or damaged.
GEARTRAIN DISASSEMBLY FROM FIXTURE
(1) Remove reverse i dl er gear assembl y from
assembl y fi xture cup.
(2) Remove 1-2 and fi fth-reverse forks from syn-
chro sl eeves.
(3) Sl i de countershaft out of fi xture tool .
(4) Remove output shaft beari ng retai ner from
rear surface of fi fth gear (retai ner wi l l drop onto gear
after bol ts are removed).
(5) Li ft and remove output shaft and gears off
i nput shaft.
(6) Li ft and remove i nput shaft, pi l ot beari ng and
fourth gear synchro ri ng from assembl y fi xture tool .
Fig. 41 Rear Bearing Snap Ring Removal4WD
1 HEAVY DUTY SNAP RING PLIERS
2 REAR BEARING SNAP RING
3 OUTPUT SHAFT
Fig. 42 Rear Adapter Housing Removal
1 REAR ADAPTER HOUSING
2 OUTPUT SHAFT
Fig. 43 Rear Adapter Housing Components
1 BEARING RETAINER
2 RETAINER BOLTS (3)
3 IDLER SHAFT NOTCH
4 COUNTERSHAFT REAR BEARING RACE
5 REAR BEARING
OUTPUT SHAFT
NOTE: The synchronizer hubs and sleeves are dif-
ferent and must not be intermixed. It is recom-
mended that each synchronizer unit be removed as
an assembly to avoid intermixing parts. It is also
recommended that each synchro hub and sleeve be
marked with a scriber or paint for correct assembly
reference.
(1) Remove snap ri ng that secures 3-4 synchro hub
on output shaft.
(2) Remove 3-4 synchro assembl y, thi rd gear syn-
chro ri ng, and thi rd gear wi th shop press and
Remover Tool 1130. Posi ti on Tool 1130 between sec-
ond and thi rd gears.
(3) Remove thi rd gear needl e beari ng (Fi g. 44).
(4) Remove retai ni ng ri ng that secures two-pi ece
thrust washer on shaft (Fi g. 45). Use smal l pry tool
to remove retai ni ng ri ng.
(5) Remove two-pi ece thrust washer (Fi g. 46). Note
posi ti on of washer l ocati ng l ugs i n shaft notches for
(6) Remove second gear and needl e beari ng (Fi g.
47).
(7) Remove second gear synchro ri ng, synchro fri c-
ti on cone, and synchro cone (Fi g. 48).
(8) Remove i nterm ri ng.
(9) Remove 1-2 synchro hub snap ri ng.
(10) Remove 1-2 synchro hub and sl eeve and fi rst
gear from output shaft wi th shop press and Remover
Tool 1130 (Fi g. 49). Posi ti on Tool 1130 between fi rst
and reverse gears.
Fig. 44 Third Gear Needle Bearing Removal
1 THIRD GEAR NEEDLE BEARING
Fig. 45 Thrust Washer Retaining Ring Removal
1 PRY TOOL
2 THRUST WASHER RETAINING RING
Fig. 46 Two-Piece Thrust Washer Removal
1 SECOND GEAR
2 THRUST WASHER (2PIECE)
3 WASHER LOCATING LUG
Fig. 47 Second Gear And Needle Bearing Removal
1 SECOND GEAR
2 SECOND GEAR NEEDLE BEARING
(11) Remove fi rst gear needl e beari ng (Fi g. 50).
(12) Remove output shaft beari ng snap ri ng (Fi g.
51).
(13) On 2-wheel dri ve model s, remove output shaft
beari ng.
(14) Remove fi fth gear (Fi g. 52).
Fig. 48 Second Gear Synchro Ring And Cones
Removal
1 12 SYNCHRO HUB AND SLEEVE
2 INTERM RING
3 SYNCHRO FRICTION CONE
4 SYNCHRO CONE
5 SYNCHRO RING
Fig. 49 Hub And Sleeve Removal1-2 Synchro
1 12 SYNCHRO HUB AND SLEEVE
2 SPECIAL TOOL
1130
Fig. 50 First Gear Needle Bearing Removal
1 FIRST GEAR NEEDLE BEARING
Fig. 51 Output Shaft Bearing Snap Ring Removal
1 OUTPUT SHAFT BEARING
2 BEARING SNAP RING
3 SNAP RING PLIERS
Fig. 52 Fifth Gear Removal
1 FIFTH GEAR AND SYNCHRO RING
(15) Remove fi fth gear needl e beari ng. Spread
beari ng apart just enough to cl ear shoul der on output
shaft (Fi g. 53).
(16) Remove fi fth-reverse synchro hub snap ri ng
(Fi g. 54).
(17) Remove fi fth-reverse synchro hub and sl eeve
wi th shop press (Fi g. 55).
(18) Remove reverse gear and needl e beari ng (Fi g.
56).
Fig. 53 Fifth Gear Needle Bearing Removal
1 FIFTH GEAR NEEDLE BEARING (SPREAD BEARING TO
CLEAR SHOULDER ON SHAFT)
Fig. 54 Fifth-Reverse Synchro Hub Snap Ring
Removal
1 FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
2 SYNCHRO HUB SNAP RING
3 SNAP RING PLIERS
Fig. 55 Fifth-Reverse Synchro Hub And Sleeve
Removal
1 PRESS
2 FIFTH-REVERSE SYNCHRO HUB AND SLEEVE
3 REVERSE GEAR
4 OUTPUT SHAFT
Fig. 56 Reverse Gear And Needle Bearing Removal
1 REVERSE GEAR AND NEEDLE BEARING
REVERSE IDLER DISASSEMBLY
(1) Remove i dl er gear snap ri ngs (Fi g. 57).
(2) Remove thrust washer, wave washer, thrust
pl ate and i dl er gear from shaft.
(3) Remove i dl er gear needl e beari ng from shaft.
ASSEMBLY
Gaskets are not used i n the NV3550 transmi ssi on.
Seal ers are used at al l case joi nts. Recommended
seal ers are Mopar Gasket Maker for al l case joi nts
and Mopar si l i cone seal er, or equi val ent, for the
i nput shaft beari ng retai ner. Appl y these products as
i ndi cated i n the assembl y procedures.
NOTE: It is very important that the transmission
shift components be in Neutral position during
assembly. This is necessary to prevent damaging
synchro and shift components when the housings
are installed.
The 3-4, 1-2 and fi fth-reverse synchro hub snap
ri ngs can be fi tted sel ecti vel y. New snap ri ngs are
avai l abl e i n 0.05 mm (0.0019 i n.) thi ckness i ncre-
ments. Use the thi ckest snap ri ng that wi l l fi t i n
each snap ri ng groove.
SYNCHRONIZER
The easi est method of assembl i ng each synchro i s
to i nstal l the spri ngs, struts and detent bal l s one at a
ti me as fol l ows:
(1) Sl i de the sl eeve part way onto the hub. Leave
enough room to i nstal l the spri ng i n the hub and the
strut i n the hub groove.
(2) I nstal l the fi rst spri ng i n the hub. Then i nstal l
a strut over the spri ng. Be sure the spri ng i s seated
i n the spri ng bore i n the strut.
(3) Sl i de the sl eeve onto the hub just far enough to
hol d the fi rst strut and spri ng i n pl ace.
(4) Pl ace the detent bal l i n the top of the strut.
Then careful l y work the sl eeve over the bal l to hol d
i t i n pl ace. A smal l fl at bl ade screwdri ver can be used
to press the bal l i nto pl ace whi l e movi ng the sl eeve
over i t.
(5) Repeat the procedure for the remai ni ng
spri ngs, struts and bal l s. Tape, or a rubber band can
be used to temporari l y secure each strut and bal l as
they are i nstal l ed.
(6) Veri fy synchro assembl y. Be sure the three
spri ngs, struts and detent bal l s are al l i n pl ace (Fi g.
58).
Fig. 57 Reverse Idler Components
1 SNAP RING
2 FLAT WASHER
3 WAVE WASHER
4 THRUST WASHER
6 IDLER GEAR BEARING
7 IDLER SHAFT
8 THRUST WASHER
9 SNAP RING
10 THRUST WASHER LOCK BALLS
OUTPUT SHAFT
(1) Lubri cate shaft, gears and beari ngs wi th rec-
ommended l ubri cant duri ng assembl y. Petrol eum
jel l y can be used to hol d parts i n pl ace.
(2) Check beari ng surfaces of output shaft for
ni cks or scratches. Smooth surfaces wi th 320/400 gri t
emery cl oth i f necessary. Appl y oi l to emery cl oth and
shaft surface before pol i shi ng.
(3) I nspect and repl ace any synchro ri ng that
exhi bi ts wear or damage. Compl etel y i mmerse each
synchro ri ng i n l ubri cant before i nstal l ati on.
(4) Lubri cate and i nstal l reverse gear needl e bear-
i ng on shaft (Fi g. 59). Sl i de beari ng up agai nst shoul -
der on output shaft.
(5) I nstal l reverse gear over needl e beari ng (Fi g.
60).
(6) I nstal l sol i d brass synchro ri ng on reverse gear
(Fi g. 61).
Fig. 58 Assembled View Of Synchro Components
1 SLEEVE
2 HUB SHOULDER
3 SPRING (3)
4 STRUT (3)
5 DETENT BALL (3)
6 HUB
Fig. 59 Reverse Gear Bearing Installation
1 REVERSE GEAR BEARING
2 SHOULDER
Fig. 60 Reverse Gear Installation
1 REVERSE GEAR
Fig. 61 Reverse Gear Synchro Ring Installation
1 REVERSE GEAR
2 SYNCHRO RING (SOLID BRASS)
(7) Assembl e fi fth-reverse synchro hub, sl eeve,
struts, spri ngs and detent bal l s, i f not previ ousl y
done.
CAUTION: The fifth-reverse synchro hub and
sleeve can be installed backwards if care is not
exercised. One side of the hub has shoulders
around the hub bore. Make sure this side of the hub
is facing the front of the shaft. In addition, one side
of the sleeve is tapered. Be sure the sleeve is
installed so the tapered side will be facing the front
of the shaft.
(8) Start fi fth-reverse synchro assembl y on output
shaft spl i nes by hand. Then seat synchro onto shaft
wi th shop press and Remover 6310-1 (Fi g. 62).
(9) I nstal l new fi fth-reverse hub snap ri ng (Fi g.
63) as fol l ows:
(a) Snap ri ngs are avai l abl e i n thi cknesses from
2.00 mm to 2.20 mm (0.078 to 0.086 i n.).
(b) I nstal l thi ckest snap ri ng that wi l l fi t i n
shaft groove.
(c) Veri fy that snap ri ng i s compl etel y seated i n
groove before proceedi ng.
(10) I nstal l fi fth gear synchro ri ng i n synchro hub
and sl eeve (Fi g. 64).
(11) I nstal l fi fth gear beari ng. Spread beari ng onl y
enough to cl ear shoul der on output shaft (Fi g. 65). Be
sure beari ng i s properl y seated after i nstal l ati on.
(12) I nstal l fi fth gear on shaft and onto beari ng
(Fi g. 66).
Fig. 62 Fifth-Reverse Synchro Assembly Installation
1 SPACER
2 PRESS RAM
3 REVERSE GEAR
4 FIFTH-REVERSE SYNCHRO ASSEMBLY
5 SPECIAL TOOL
63101
6 PRESS BLOCKS
7 OUTPUT SHAFT
Fig. 63 Installing Fifth-Reverse Synchro Hub Snap
Ring
2 SNAP RING
3 PRESS BED
4 PRESS BLOCKS
Fig. 64 Installing Fifth Gear Synchro Ring
1 FIFTH-SPEED SYNCHRO RING
(13) I nvert output shaft and set the shaft i n
Remover 6310-1 so that fi fth gear i s seated on the
tool (Fi g. 67).
(14) I nstal l fi rst gear beari ng on output shaft (Fi g.
67). Be sure beari ng i s seated on shaft shoul der and
i s properl y joi ned.
(15) I nstal l fi rst gear on shaft and over beari ng
(Fi g. 68). Make sure beari ng synchro cone i s faci ng
up as shown.
Fig. 65 Installing Fifth Gear Bearing
1 SHAFT SHOULDER
2 FIFTH GEAR BEARING
Fig. 66 Fifth Gear Installation
1 FIFTH GEAR
2 BEARING
Fig. 67 First Gear Bearing Installation
1 FIRST GEAR BEARING
2 SHAFT SHOULDER
3 SPECIAL TOOL
63101
4 PRESS BLOCKS
Fig. 68 First Gear Installation
1 FIRST GEAR
2 SPECIAL TOOL
63101
3 BEARING
(16) I nstal l fi rst gear synchro ri ng (Fi g. 69).
(17) Assembl e 1-2 synchro hub sl eeve, spri ngs,
struts and detent bal l s.
CAUTION: The 1-2 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the synchro sleeve is marked First Gear
Side. Be sure this side of the sleeve will face first
gear after installation.
(18) Start 1-2 synchro assembl y on shaft by hand
(Fi g. 70). Be sure synchro sl eeve i s properl y posi ti oned.
Si de marked fi rst si de must be faci ng fi rst gear.
(19) Press 1-2 synchro onto output shaft usi ng
sui tabl e si ze pi pe tool and shop press (Fi g. 71).
CAUTION: Take time to align the synchro ring and
sleeve as hub the is being pressed onto the shaft.
The synchro ring can be cracked if it becomes mis-
aligned.
(20) I nstal l i nterm ri ng.
(21) I nstal l new 1-2 synchro hub snap ri ng (Fi g.
72) as fol l ows:
1.80 mm to 2.00 mm (0.070 to 0.078 i n.).
shaft groove.
(22) I nstal l second gear synchro ri ng i n 1-2 syn-
chro hub and sl eeve (Fi g. 73). Be sure synchro ri ng i s
properl y seated i n sl eeve.
Fig. 69 First Gear Synchro Ring Installation
1 FIRST GEAR SYNCHRO RING
3 FIRST GEAR
Fig. 70 Starting 1-2 Synchro On Shaft
1 12 SYNCHRO ASSEMBLY
3 BE SURE THIS IS FIRST GEAR SIDE OF SYNCHRO
SLEEVE
Fig. 71 Pressing 1-2 Synchro Assembly Onto Output
Shaft
1 SUITABLE SIZE PIPE TOOL
2 SYNCHRO RING
3 SPECIAL TOOL
63101
5 PRESS RAM
(23) I nstal l synchro fri cti on cone and synchro cone
i n synchro ri ng.
(24) I nstal l second gear needl e beari ng on shaft
(Fi g. 74).
(25) I nstal l second gear onto shaft and beari ng
(Fi g. 75). Make sure that second gear i s ful l y seated
on synchro components.
Fig. 72 Installing 1-2 Synchro Hub Snap Ring
1 12 SYNCHRO
2 SPECIAL TOOL
63101
3 SYNCHRO SNAP RING
Fig. 73 Second Gear Synchro Ring Installation
1 SECOND GEAR SYNCHRO RING
2 12 SYNCHRO
3 SPECIAL TOOL
63101
Fig. 74 Second Gear Bearing Installation
1 SECOND GEAR BEARING
2 SPECIAL TOOL
63101
Fig. 75 Second Gear Installation
1 SPECIAL TOOL
63101
3 BEARING
4 SECOND GEAR
(26) I nstal l two-pi ece thrust washer (Fi g. 76). Be
sure washer hal ves are seated i n shaft groove and
that washer l ugs are seated i n shaft l ug bores. Al so,
ensure that the i .d. grooves and marki ngs noted dur-
i ng removal are faci ng the correct di recti on.
(27) Start retai ni ng ri ng around two-pi ece thrust
washer (Fi g. 77). Make sure that the l ocati ng di mpl e
i s between the thrust washer hal ves.
(28) Seat thrust washer retai ni ng ri ng wi th pl asti c
mal l et (Fi g. 78).
Fig. 76 Installing Two-Piece Thrust Washer
1 WASHER GROOVE IN SHAFT
2 LUG BORE
3 THRUST WASHER LUGS
4 LUG BORE
5 LUG
6 WASHER HALF
Fig. 77 Starting Retaining Ring Over Two-Piece
Thrust Washer
2 THRUST WASHER HALVES
3 SECOND GEAR
4 LOCATING DIMPLE
Fig. 78 Seating Thrust Washer Retaining Ring
1 PLASTIC MALLET
(29) I nstal l thi rd gear needl e beari ng on shaft (Fi g.
79).
(30) I nstal l thi rd gear on shaft and beari ng (Fi g.
80).
(31) I nstal l thi rd speed synchro ri ng on thi rd gear
(Fi g. 81).
(32) Assembl e 3-4 synchro hub, sl eeve, spri ngs,
struts and detent bal l s.
CAUTION: The 3-4 synchro hub and sleeve can be
installed backwards if care is not exercised. One
side of the sleeve has grooves in it. Be sure this
side of sleeve is also facing the front of the shaft.
(33) Start 3-4 synchro hub on output shaft spl i nes
by hand (Fi g. 82).
(34) Press 3-4 synchro assembl y onto output shaft
wi th shop press and sui tabl e si ze pi pe tool (Fi g. 83).
Make sure that the tool presses on hub as cl ose to
output shaft as possi bl e but does not contact the
shaft spl i nes.
Fig. 79 Third Gear Bearing Installation
1 THIRD GEAR BEARING
Fig. 80 Installing Third Gear
1 THIRD GEAR
2 BEARING
Fig. 81 Third Speed Synchro Ring Installation
1 THIRD SPEED SYNCHRO RING
2 THIRD GEAR
Fig. 82 Starting 3-4 Synchro Hub On Output Shaft
1 GROOVED SIDE OF SLEEVE (TO FRONT)
(35) I nstal l 3-4 synchro hub snap ri ng (Fi g. 84) as
fol l ows:
2.00 mm to 2.30 mm (0.078 to 0.090 i n.).
shaft groove. Use heavy duty snap ri ng pl i ers to
i nstal l new ri ng.
(36) I nstal l output shaft beari ng.
(37) I nstal l output shaft beari ng snap ri ng (Fi g.
85). Use heavy duty snap ri ng pl i ers and spread snap
ri ng onl y enough to i nstal l i t. Be sure snap ri ng i s
compl etel y seated i n shaft groove before proceedi ng.
(38) Veri fy correct posi ti on of synchro sl eeves
before proceedi ng wi th assembl y operati ons (Fi g. 86).
Grooved si de of 3-4 sl eeve shoul d be faci ng forward.
Fi rst gear si de of 1-2 sl eeve shoul d be faci ng fi rst
gear. Tapered si de of fi fth-reverse sl eeve shoul d be
faci ng forward.
REVERSE IDLER ASSEMBLY
(1) Lubri cate i dl er components wi th gear l ube.
(2) Sl i de i dl er gear beari ng on shaft (Fi g. 87).
Beari ng fi ts ei ther way on shaft.
(3) Sl i de gear onto shaft. Si de of gear wi th recess
goes to rear (Fi g. 87).
(4) Pl ace fi rst l ock bal l i n di mpl e at rear end of
i dl er shaft (Fi g. 87). Petrol eum jel l y can be used to
hol d bal l i n pl ace i f desi red.
(5) Sl i de thrust rear thrust washer onto shaft and
over l ock bal l (Fi g. 88).
(6) I nstal l snap ri ng i n groove at rear of shaft (Fi g.
88).
(7) I nstal l l ock bal l i n di mpl e at front of shaft.
Hol d bal l i n pl ace wi th petrol eum jel l y i f desi red.
Fig. 83 Pressing 3-4 Synchro Assembly On Output
Shaft
1 PRESS RAM
2 PIPE TOOL
3 34 SYNCHRO
4 THIRD SPEED SYNCHRO RING
Fig. 84 Installing 3-4 Synchro Hub Snap Ring
1 34 SYNCHRO HUB SNAP RING
Fig. 85 Installing Output Shaft Bearing Snap Ring
1 BEARING SNAP RING
(8) I nstal l front thrust washer on shaft and sl i de
washer up agai nst gear and over l ock bal l (Fi g. 89).
(9) I nstal l wave washer, fl at washer and remai n-
i ng snap ri ng on i dl er shaft (Fi g. 89). Be sure snap
ri ng i s ful l y seated.
Fig. 86 Correct Synchro Sleeve Position
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 12 SYNCHRO SLEEVE
8 34 SYNCHRO SLEEVE
Fig. 87 Idler Gear And Bearing Installation
1 IDLER GEAR
2 BEARING
3 LOCK BALL
4 REAR OF SHAFT
Fig. 88 Idler Gear Rear Thrust Washer Installation
1 LOCK BALL
2 SNAP RING GROOVE
3 THRUST WASHER
SHIFT SHAFT AND DETENT PLUNGER BUSHINGS/BEARINGS
(1) I nspect shi ft shaft bushi ng and beari ng for
damage.
(2) I f necessary, the shi ft shaft bushi ng can be
repl aced as fol l ows:
(a) Locate a bol t that wi l l thread i nto the bush-
i ng wi thout great effort.
(b) Thread the bol t i nto the bushi ng, al l owi ng
the bol t to make i ts own threads i n the bushi ng.
(c) Attach a sl i de hammer or sui tabl e pul l er to
the bol t and remove bushi ng.
(d) Use the short end of I nstal l er 8119 to i nstal l
the new bushi ng.
(e) The bushi ng i s correctl y i nstal l ed i f the bush-
i ng i s fl ush wi th the transmi ssi on case.
(3) I f necessary, the shi ft shaft beari ng can be
repl aced as fol l ows:
(a) Locate a bol t that wi l l thread i nto the bear-
i ng wi thout great effort.
(b) Thread the bol t i nto the beari ng as much as
possi bl e.
(c) Attach a sl i de hammer or sui tabl e pul l er to
the bol t and remove the beari ng.
(d) Use the short end of I nstal l er 8119 to i nstal l
the new beari ng.
(e) The beari ng i s correctl y i nstal l ed i f the bear-
i ng i s fl ush wi th the transmi ssi on case.
(4) I nspect detent pl unger bushi ngs for damage.
NOTE: The detent plunger bushings are installed to
a specific depth. The space between the two bush-
ings when correctly installed contain an oil feed
hole. Do not attempt to install the bushings with
anything other than the specified tool or this oil
hole may become restricted.
(5) I f necessary, the detent pl unger bushi ngs can
be repl aced as fol l ows:
(a) Usi ng the l ong end of I nstal l er 8119, dri ve
the detent bushi ngs through the outer case and
i nto the shi ft shaft bore.
(b) Remove the bushi ngs from the shi ft shaft
bore.
(c) I nstal l a new detent pl unger bushi ng on the
l ong end of I nstal l er 8118.
(d) Start the bushi ng i n the detent pl unger bore
i n the case.
(e) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
(f) I nstal l a new detent pl unger bushi ng on the
short end of I nstal l er 8118.
(g) Start the bushi ng i n the detent pl unger bore
i n the case.
(h) Dri ve the bushi ng i nto the bore unti l the tool
contacts the transmi ssi on case.
GEARTRAIN ASSEMBLY
(1) I nstal l Adapter 6747-1A on i nput shaft hub of
fi xture tool (Fi g. 90). Then i nstal l Adapter 6747-2A
on front beari ng hub of countershaft. Adapter
6747-2A has a rai sed shoul der on one si de. Be sure
the shoul der i s seated agai nst the countershaft.
(2) I nstal l i nput shaft i n fi xture tool . Make sure
Adapter Tool 6747-1A i s posi ti oned under shaft as
shown (Fi g. 91).
(3) I nstal l pi l ot beari ng i n i nput shaft (Fi g. 91).
NOTE: There is a correct and an incorrect way to
install the pilot bearing into the input shaft. The
side of the pilot bearing with the small diameter
goes toward the input shaft.
Fig. 89 Idler Gear And Shaft Assembly
1 REAR OF SHAFT
2 GEAR
3 THRUST WASHER AND BALL
4 WAVE WASHER
5 FLAT WASHER
6 FRONT OF SHAFT
7 SNAP RING
8 SNAP RING
(4) I nstal l fourth gear synchro ri ng on i nput shaft
(Fi g. 92).
(5) Adjust hei ght of i dl er gear pedestal on assem-
bl y fi xture (Fi g. 93). Start wi th a basi c hei ght of 18.4
cm (7-1/4 i n.). Fi nal adjustment can be made after
gear i s posi ti oned on pedestal .
(6) I nstal l assembl ed output shaft and geartrai n i n
i nput shaft (Fi g. 94). Careful l y rotate output shaft
unti l the 34 synchro ri ng seats i n synchro hub and
sl eeve.
Fig. 90 Preparing Assembly Fixture For Geartrain
Build-up
1 SPECIAL TOOL 67472A (INSTALL ON COUNTERSHAFT
FRONT HUB)
2 SPECIAL TOOL 8115
4 SPECIAL TOOL 6747
Fig. 91 Installing Pilot Bearing In Input Shaft
1 PILOT BEARING
2 INPUT SHAFT
Fig. 92 Installing Fourth Gear Synchro Ring On
Input Shaft
1 FOURTH GEAR SYNCHRO RING
2 INPUT SHAFT
Fig. 93 Idler Pedestal Basic Height Adjustment
1 REVERSE IDLER PEDESTAL
(7) I nstal l Adapter 6747-2A on front beari ng hub of
countershaft, i f not previ ousl y done. The adapter has
a shoul der on one si de. The shoul der goes toward the
countershaft.
(8) Sl i de countershaft (and adapter) i nto fi xture
sl ot. Veri fy that countershaft and output shaft gears
are ful l y meshed wi th the mai nshaft gears before
proceedi ng (Fi g. 95).
(9) Check al i gnment of countershaft and output
shaft gear teeth. Note that gears may not al i gn per-
fectl y. A di fference i n hei ght of 1.57 to 3.18 mm (1/16
to 1/8 i n.) wi l l probabl y exi st. Thi s di fference wi l l not
i nterfere wi th assembl y. However, i f the di fference i s
greater than thi s, the countershaft adapter tool i s
probabl y upsi de down. Remove countershaft, reverse
adapter tool , rei nstal l countershaft and check al i gn-
ment agai n.
Fig. 94 Output Shaft And Geartrain Installed In Input
Shaft
1 OUTPUT SHAFT AND GEARTRAIN
2 INPUT SHAFT
3 SPECIAL TOOL
6747
Fig. 95 Countershaft Installed On Fixture Tool
2 COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)
(10) Posi ti on reverse i dl er i n support cup of assem-
bl y fi xture (Fi g. 96). Be sure i dl er gear i s properl y
meshed and al i gned wi th shaft gear teeth and that
bol t hol es are faci ng out and not toward geartrai n.
Adjust pedestal up or down i f necessary. Al so be sure
that short end of i dl er shaft i s faci ng up as shown.
(11) On 2-wheel dri ve transmi ssi on, thread one
Pi l ot Stud 8120 i n center or passenger si de hol e of
output shaft beari ng retai ner. Then posi ti on retai ner
on fi fth gear as shown (Fi g. 97).
(12) Assembl e 1-2 and fi fth reverse-shi ft forks (Fi g.
98). Arm of fi fth-reverse fork goes through sl ot i n 1-2
fork.
Fig. 96 Reverse Idler Assembly Positioned On
Assembly Fixture Pedestal
2 COUNTERSHAFT
3 REVERSE IDLER ASSEMBLY
4 TOOL PEDESTAL
Fig. 97 Positioning Output Shaft Bearing Retainer
For Rear Housing Installation
1 SPECIAL TOOL
8120
2 OUTPUT SHAFT BEARING RETAINER
Fig. 98 Assembling 1-2 And Fifth-Reverse Shift
Forks
1 INSERT ARM THROUGH 12 FORK
2 12 FORK
3 FIFTH-REVERSE FORK
(13) I nstal l assembl ed shi ft forks i n synchro
sl eeves (Fi g. 99). Be sure forks are properl y seated i n
sl eeves.
REAR HOUSING 2WD
(1) Dri ve adapter housi ng al i gnment dowel s back
i nto housi ng unti l dowel s are fl ush wi th mounti ng
surface (Fi g. 100).
(2) Appl y l i beral quanti ty of petrol eum jel l y to
countershaft rear beari ng and beari ng race.
(3) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 101).
CAUTION: The countershaft bearings can be
installed backwards if care is not exercised. Be
sure the large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 102).
(4) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
(5) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n rear housi ng (Fi g. 102).
(6) Reach i nto countershaft rear beari ng wi th fi n-
ger, and push each beari ng rol l er outward agai nst
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace. Thi s avoi ds havi ng rol l ers becomi ng di s-
pl aced duri ng housi ng i nstal l ati on. Thi s wi l l resul t i n
mi sal i gnment between beari ng and countershaft
beari ng hub.
Fig. 99 Shift Forks Installed In Synchro Sleeves
1 SYNCHRO SLEEVES
2 FORK ARMS
3 SHIFT FORKS
Fig. 100 Preparing Rear Housing Dowels For
Installation
1 HOUSING ALIGNMENT DOWELS
2 REAR HOUSING
3 DOWEL FLUSH WITH SURFACE
Fig. 101 Lubricating Countershaft Rear Bearing
2 REAR BEARING RACE
3 REAR HOUSING
4 PETROLEUM JELLY (APPLY TO BEARING AND RACE)
(7) I nstal l rear housi ng onto geartrai n (Fi g. 103).
Be sure beari ng retai ner pi l ot stud i s i n correct bol t
hol e i n housi ng. Al so be sure countershaft and output
shaft beari ngs are al i gned i n housi ng and on counter-
shaft. I t may be necessary to l i ft upward on counter-
shaft sl i ghtl y to ensure that the countershaft rear
beari ng engages to the countershaft before the rear
output shaft beari ng engages the housi ng.
(8) Seat rear housi ng on output shaft rear beari ng
and countershaft. Use pl asti c or rawhi de mal l et to
tap housi ng i nto pl ace.
(9) I nstal l the three bol ts that secure rear beari ng
retai ner to rear housi ng as fol l ows:
(a) Appl y Mopar Gasket Maker, or equi val ent,
to bol t threads, bol t shanks and under bol t heads
(Fi g. 104).
(b) Start fi rst two bol ts i n retai ner (Fi g. 105). I t
may be necessary to move retai ner rearward (wi th
pi l ot stud) i n order to start bol ts i n retai ner.
(c) Remove Pi l ot Stud 8120 and i nstal l l ast
retai ner bol t (Fi g. 105).
(d) Ti ghten al l three retai ner bol ts to 30-35 Nm
(22-26 ft. l bs.) torque.
Fig. 102 Countershaft Rear Bearing Seated In
Seated in Race
1 SHIFT SHAFT BUSHING/BEARING
2 COUNTERSHAFT REAR BEARING (SEATED IN RACE)
Fig. 103 Rear Housing Installation2WD
1 REAR HOUSING
2 SHIFT FORKS AND GEARTRAIN
Fig. 104 Applying Sealer To Retainer And Housing
Bolts
1 MOPAR GASKET MAKER (OR LOCTITE 518)
2 RETAINER AND HOUSING BOLTS
3 APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK
AND THREADS
Fig. 105 Removing Pilot Stud Tool And Installing
Retainer Bolts2WD
1 BEARING RETAINER BOLT
2 SPECIAL TOOL 8120
ADAPTER HOUSING 4WD
(1) I nstal l rear beari ng i n adapter housi ng. Use
wood hammer handl e or wood dowel to tap beari ng
i nto pl ace.
(2) Posi ti on rear beari ng retai ner i n adapter hous-
i ng (Fi g. 106).
(3) Appl y Mopar Gasket Maker, or equi val ent, to
threads, bol t shanks and under hex heads of beari ng
retai ner bol ts (Fi g. 107).
countershaft rear beari ng and beari ng race.
(5) I nstal l countershaft rear beari ng i n beari ng
race (Fi g. 102).
CAUTION: The countershaft bearings can be
installed backwards if care is not exercised. Be
sure the large diameter side of the roller retainer
faces the countershaft and the small diameter side
faces the race and housing (Fig. 102).
(6) Appl y extra petrol eum jel l y to hol d counter-
shaft rear beari ng i n pl ace when housi ng i s i nstal l ed.
(7) Appl y l i ght coat of petrol eum jel l y to shi ft shaft
bushi ng/beari ng i n adapter housi ng (Fi g. 102).
(8) I nstal l adapter housi ng on geartrai n.
(9) I nstal l rear beari ng snap ri ng on output shaft
(Fi g. 107).
(10) Lubri cate l i p of new rear seal (Fi g. 108) wi th
Mopar Door Ease, or transmi ssi on fl ui d.
(11) I nstal l new rear seal i n adapter housi ng bore
wi th I nstal l er C-3860-A. Be sure seal i s ful l y seated
i n housi ng bore (Fi g. 108).
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT
SOCKET
(1) Before proceedi ng, veri fy that al l synchro
sl eeves are i n Neutral posi ti on (centered on hub).
Move sl eeves i nto neutral i f necessary.
Fig. 106 Preparing Adapter Housing For
Installation4WD
1 BEARING RETAINER
2 RETAINER BOLTS (3)
3 IDLER SHAFT NOTCH
4 COUNTERSHAFT REAR BEARING RACE
5 REAR BEARING
Fig. 107 Installing Rear Bearing Snap Ring4WD
2 REAR BEARING SNAP RING
3 OUTPUT SHAFT
Fig. 108 Rear Seal Installation4WD
1 REAR SEAL
2 SEAL LIP
3 OUTPUT SHAFT
CAUTION: The transmission synchros must all be
in Neutral position for proper reassembly. Other-
wise, the housings, shift forks and gears can be
damaged during installation of the two housings.
(2) I nstal l 3-4 shi ft fork i n synchro sl eeve (Fi g.
109). Veri fy that groove i n fork arm i s al i gned wi th
grooves i n 1-2 and fi fth-reverse fork arms as shown.
(3) Sl i de shi ft shaft through 3-4 shi ft fork (Fi g.
110). Be sure shaft detent notches are to front.
(4) Assembl e shi ft shaft shi ft l ever and bushi ng
(Fi g. 111). Be sure sl ot i n bushi ng i s faci ng up and
rol l pi n hol e for l ever i s al i gned wi th hol e i n shaft.
(5) I nstal l assembl ed l ever and bushi ng on shi ft
shaft (Fi g. 112).
(6) Sl i de shi ft shaft through 1-2 and fi fth-reverse
fork and i nto shi ft l ever openi ng i n rear housi ng (Fi g.
113).
(7) Al i gn shi ft socket wi th shaft and sl i de shaft
through socket and i nto shi ft shaft beari ng i n rear
(8) Rotate shi ft shaft so detent notches i n shaft are
faci ng the TOP of the transmi ssi on housi ng.
Fig. 109 Installing 3-4 Shift Fork
1 34 FORK
2 ALIGN GROOVES IN FORK ARMS
Fig. 110 Shift Shaft Installation
1 SHIFT SHAFT
2 34 FORK
3 SHAFT DETENT NOTCHES
Fig. 111 Assembling Shift Shaft Lever And Bushing
1 SHAFT LEVER
2 LEVER BUSHING
3 BUSHING LOCK PIN SLOT
Fig. 112 Installing Shift Shaft Lever And Bushing
1 SHIFT SHAFT
2 SHAFT LEVER AND BUSHING
3 34 FORK
CAUTION: Correct positioning of the shift shaft
detent notch is important. Both of the shaft roll pins
can be installed even when the shaft is 180 off. If
this occurs, the transmission will have to be disas-
sembled again to correct shaft alignment.
(9) Sel ect correct new rol l pi n for shi ft shaft l ever
(Fi g. 115). Shaft l ever rol l pi n i s approxi matel y 22
mm (7/8 i n.) l ong. Shi ft socket rol l pi n i s approxi -
matel y 33 mm (1-1/4 i n.) l ong.
(10) Al i gn rol l pi n hol es i n shi ft shaft, l ever and
bushi ng. Then start rol l pi n i nto shaft l ever by hand
(Fi g. 116).
(11) Seat shaft l ever rol l pi n wi th pi n punch (Fi g.
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 proceedi ng, veri fy that l ock pi n sl ot i n
l ever bushi ng i s posi ti oned as shown (Fi g. 117).
(13) Al i gn rol l pi n hol es i n shi ft socket and shi ft
shaft. Then start rol l pi n i nto shi ft shaft by hand
(Fi g. 118).
Fig. 113 Inserting Shaft Into Lever Opening In
Housing
1 SHIFT SHAFT
Fig. 114 Shift Socket Installation
1 SHIFT SOCKET
2 SHIFT SHAFT
Fig. 115 Roll Pin IdentificationShaft Lever And
Shift Socket
1 SHAFT LEVER ROLL PIN
2 SHIFT SOCKET ROLL PIN
Fig. 116 Starting Roll Pin In Shift Shaft Lever
1 SHAFT LEVER ROLL PIN (
7
8 LONG)
2 LEVER AND BUSHING
(14) Seat rol l pi n i n shi ft socket wi th pi n punch.
Rol l pi n must be fl ush wi th socket after i nstal l ati on
(Fi g. 119).
(15) Veri fy that notches i n shi ft fork arms are
al i gned. Real i gn arms i f necessary.
FRONT HOUSING AND INPUT SHAFT BEARING RETAINER
(1) I f previ ousl y removed, i nstal l i nput shaft bear-
i ng i n front housi ng bore (Fi g. 120). I nstal l snap ri ng
and use pl asti c mal l et to seat beari ng. Beari ng goes
i n from front si de of housi ng onl y.
Fig. 117 Correct Seating Of Shift Shaft Lever Roll
Pin
1 BUSHING LOCK PIN SLOT
2 SEAT ROLL PIN FLUSH WITH LEVER
Fig. 118 Starting Roll Pin In Shift Socket
1 ROLL PIN
2 SHIFT SOCKET
3 SHIFT SHAFT
Fig. 119 Seating Shift Socket Roll Pin
1 PIN PUNCH
2 SHIFT SOCKET
3 SEAT ROLL PIN FLUSH
4 SHIFT SOCKET
Fig. 120 Input Shaft Bearing And Countershaft Front
Bearing
3 SHIFT SHAFT BUSHING
countershaft front beari ng. Then i nsert beari ng i n
front housi ng race (Fi g. 120). Large di ameter si de of
beari ng cage goes toward countershaft (Fi g. 121).
Smal l di ameter si de goes toward beari ng race i n
housi ng.
(3) Reach i nto countershaft front beari ng wi th fi n-
ger, and push each beari ng rol l er outward agai nst
race. Then appl y extra petrol eum jel l y to hol d rol l ers
i n pl ace. Thi s avoi ds havi ng rol l ers becomi ng di s-
pl aced duri ng housi ng i nstal l ati on. Thi s wi l l resul t i n
mi sal i gnment between beari ng and countershaft
beari ng hub.
(4) Appl y smal l amount of petrol eum jel l y to shi ft
shaft bushi ng i n front housi ng.
(5) Appl y 1/8 i n. wi de bead of Mopar Gasket
Maker, or equi val ent, to mati ng surfaces of front and
rear housi ngs (Fi g. 122).
(6) Have hel per hol d rear housi ng and geartrai n i n
upri ght posi ti on. Then i nstal l front housi ng on rear
housi ng and geartrai n.
(7) Work front housi ng downward onto geartrai n
unti l seated on rear housi 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.
This will only result in damaged components.
(8) Tap rear housi ng al i gnment dowel s back i nto
pl ace wi th hammer and pi n punch. Both dowel s
shoul d be fl ush fi t i n each housi ng. Have hel per hol d
transmi ssi on upri ght whi l e dowel s are tapped back
i nto pl ace.
(9) Pl ace transmi ssi on i n hori zontal posi ti on.
(10) Appl y Mopar Gasket Maker, or equi val ent, to
housi ng attachi ng bol ts. Appl y seal er materi al seal er
to undersi de of bol t heads and to bol t shanks and
threads (Fi g. 123).
(11) I nstal l and start housi ng attachi ng bol ts by
hand (Fi g. 123). Then ti ghten bol ts to 34 Nm (25 ft.
l bs.) torque.
Fig. 121 Lubricating/Positioning Countershaft Front
Bearing
1 BEARING RACE
2 PETROLEUM JELLY
Fig. 122 Applying Sealer To Front/Rear Housings
1 HOUSING FLANGE SURFACE
2 MOPAR GASKET MAKER (OR LOCTITE 518)
Fig. 123 Installing Housing Attaching Bolts
1 HOUSING ATTACHING BOLTS (APPLY SEALER
BEFOREHAND)
(12) I nstal l shi ft shaft bushi ng l ock bol t (Fi g. 124).
Appl y Mopar Gasket Maker, or equi val ent, to bol t
threads, shank and undersi de of bol t head before
i nstal l ati on.
CAUTION: If the lock bolt cannot be fully installed,
do not try to force it into place. Either the shift
shaft is not in Neutral, or the shaft bushing (or
lever) is misaligned.
(13) Lubri cate then i nstal l shi ft shaft detent
pl unger i n housi ng bore (Fi g. 125). Lubri cate pl unger
wi th petrol eum jel l y or gear l ubri cant. Be sure
plunger is fully seated in detent notch in shift
shaft.
(14) I nstal l detent spri ng i nsi de pl unger (Fi g. 125).
(15) I nstal l detent pl ug as fol l ows:
(a) I nstal l detent pl ug i n end of I nstal l er 8123.
(b) Posi ti on pl ug on detent spri ng and compress
spri ng unti l detent pl ug pi l ots i n detent pl unger
bore.
(c) Dri ve detent pl ug i nto transmi ssi on case
unti l pl ug seats.
(16) I nstal l backup l i ght swi tch (Fi g. 126).
(17) I nstal l i nput shaft snap ri ng (Fi g. 127).
(18) I nstal l new oi l seal i n front beari ng retai ner
wi th I nstal l er Tool 6448 (Fi g. 128).
(19) Appl y bead of Mopar si l i cone seal er, or
equi val ent, to fl ange surface of front beari ng retai ner
(Fi g. 129).
Fig. 124 Installing Shift Shaft Bushing Lock Bolt
1 SHIFT SHAFT LOCK BOLT
2 SHAFT SOCKET
Fig. 125 Installing Shift Shaft Detent Plunger,
Spring, and Plug
1 FRONT HOUSING
2 PLUG
3 SPRING
4 PLUNGER
Fig. 126 Installing Backup Light Switch
1 BACKUP LIGHT SWITCH
Fig. 127 Installing Input Shaft Snap RingTypical
(20) Al i gn and i nstal l front beari ng retai ner over
i nput shaft and onto housi ng mounti ng surface (Fi g.
130). Al though retai ner i s one-way fi t on housi ng, be
sure bol t hol es are al i gned before seati ng retai ner.
NOTE: Be sure that no sealer gets into the oil feed
hole in the transmission case or bearing retainer.
(21) I nstal l and ti ghten beari ng retai ner bol ts to
7-10 Nm (5-7 ft. l bs.) torque (Fi g. 131).
SHIFT TOWER AND LEVER ASSEMBLY
(1) Appl y petrol eum jel l y to bal l end of shi ft l ever
and i nteri or of shi ft socket.
(2) Shi ft the transmi ssi on i nto thi rd gear.
(3) Al i gn and i nstal l shi ft tower and l ever assem-
bl y (Fi g. 132). Be sure shi ft bal l i s seated i n socket
and the offset i n the tower i s toward the passenger
si de of the vehi cl e before i nstal l i ng tower bol ts.
Fig. 128 Installing Oil Seal In Front Bearing Retainer
1 SPECIAL TOOL
6448
Fig. 129 Applying Sealer To Bearing Retainer And
HousingTypical
1 APPLY SEALER BEAD
Fig. 130 Installing Input Shaft Bearing Retainer
Typical
1 INPUT SHAFT
2 OIL FEED
3 BEARING RETAINER
Fig. 131 Installing Input Shaft Bearing Retainer
BoltsTypical
2 RETAINER BOLTS
(4) I nstal l shi ft tower bol ts (Fi g. 133). Ti ghten
bol ts to 8.5 Nm (75.2 i n. l bs.) torque.
(5) Fi l l transmi ssi on to bottom edge of fi l l pl ug
hol e wi th Mopar Transmi ssi on Lubri cant, P/N
4761526.
(6) I nstal l and ti ghten fi l l pl ug to 34 Nm (25 ft.
l bs.) torque.
(7) Check transmi ssi on vent. Be sure vent i s open
and not restri cted.
TRANSMISSION COMPONENTS
Cl ean the gears, shafts, shi ft components and
transmi ssi on housi ngs wi th a standard parts cl ean-
i ng sol vent. Do not use aci d or corrosi ve base sol -
vents. Dry al l parts except beari ngs wi th compressed
ai r.
Cl ean the shaft beari ngs wi th a mi l d sol vent such
as Mopar degreasi ng sol vent, Gunk, or si mi l ar sol -
vents. Do not dry the beari ngs wi th compressed ai r.
Al l ow the beari ngs to ei ther ai r dry, or wi pe them dry
wi th cl ean shop towel s.
SHIFT LEVER ASSEMBLY
The shi ft l ever assembl y i s not servi ceabl e. Repl ace
the l ever and shi ft tower as an assembl y i f the tower,
l ever, l ever bal l , or i nternal components are worn, or
damaged.
SHIFT SHAFT AND FORKS
I nspect the shi ft fork i nterl ock arms and synchro
sl eeve contact surfaces (Fi g. 134). Repl ace any fork
exhi bi ti ng wear or damage i n these areas. Do not
attempt to sal vage shi ft forks.
Check condi ti on of the shi ft shaft detent pl unger
and spri ng. The pl unger shoul d be smooth and free of
ni cks, or scores. The pl unger spri ng shoul d be
strai ght and not col l apsed, or di storted. Mi nor
scratches, or ni cks on the pl unger can be smoothed
wi th 320/400 gri t emery soaked i n oi l . Repl ace the
pl unger and spri ng i f i n doubt about condi ti on. Check
condi ti on of detent pl unger bushi ngs. Repl ace i f dam-
aged.
I nspect the shi ft shaft, shi ft shaft bushi ng and
beari ng, the shaft l ever, and the l ever bushi ng that
fi ts over the l ever. Repl ace the shaft i f bent, cracked,
or severel y scored. Mi nor burrs, ni cks, or scratches
can be smoothed off wi th 320/400 gri t emery cl oth
fol l owed by pol i shi ng wi th crocus cl oth. Repl ace the
shi ft shaft bushi ng or beari ng i f damaged.
Repl ace the shaft l ever and bushi ng i f ei ther part
i s deformed, or worn. Do not attempt to sal vage these
parts as shi ft fork bi ndi ng wi l l occur. Repl ace the rol l
pi n that secures the l ever to the shaft.
FRONT/REAR HOUSINGS AND BEARING
RETAINERS
I nspect the housi ngs careful l y. Look for cracks,
stri pped threads, scored mati ng surfaces, damaged
beari ng bores, or worn dowel pi n hol es. Mi nor ni cks
on mati ng surfaces can be dressed off wi th a fi ne fi l e,
or emery cl oth. Damaged threads can be renewed by
ei ther re-tappi ng or i nstal l i ng Hel i coi l i nserts.
Fig. 132 Shift Tower Installation
2 SHIFT SOCKET
3 SEAL
Fig. 133 Shift Tower Bolt Installation
NOTE: The front housing contains the countershaft
front bearing race. The rear housing contains the
countershaft rear bearing race. Be advised that
these components are NOT serviceable items. The
front housing will have to be replaced if the coun-
tershaft bearing race is loose, worn, or damaged.
The rear housing will have to be replaced if the
countershaft rear bearing race is loose, worn, or
damaged.
I nspect the i nput shaft beari ng retai ner. Be sure
the rel ease beari ng sl i de surface of the retai ner i s i n
good condi ti on. Mi nor ni cks on the surface can be
smoothed off wi th 320/420 gri t emery cl oth and fi nal
pol i shed wi th oi l coated crocus cl oth. Repl ace the
retai ner seal i f necessary.
I nspect the output shaft beari ng retai ner. Be sure
the U-shaped retai ner i s fl at and free of di storti on.
Repl ace the retai ner i f the threads are damaged, or i f
the retai ner i s bent, or cracked.
COUNTERSHAFT BEARINGS AND RACES
The countershaft beari ngs and races are machi ne
l apped duri ng manufacture to form matched sets.
The beari ngs and races shoul d not be i nterchanged.
NOTE: The bearing races are a permanent press fit
in the housings and are NOT serviceable. If a bear-
ing race becomes damaged, it will be necessary to
replace the front or rear housing as necessary. A
new countershaft bearing will be supplied with each
new housing for service use.
The countershaft beari ngs can be i nstal l ed back-
wards i f care i s not exerci sed. The beari ng rol l er cage
i s a di fferent di ameter on each si de. Be sure the
beari ng i s i nstal l ed so the l arge di ameter si de of the
cage i s faci ng the countershaft gear (Fi g. 135). The
smal l di ameter si de goes i n the beari ng race.
REVERSE IDLER COMPONENTS
I nspect the i dl er gear, beari ng, shaft, thrust
washer, wave washer and thrust pl ate. Repl ace the
beari ng i f any of the needl e beari ng rol l ers are worn,
chi pped, cracked, fl at-spotted, or bri nnel l ed. Al so
repl ace the beari ng i f the pl asti c beari ng cage i s
damaged or di storted.
Repl ace the thrust washer, wave washer, or thrust
pl ate i f cracked, chi pped, or worn. Repl ace the i dl er
gear i f the teeth are chi pped, cracked or worn thi n.
Repl ace the shaft i f worn, scored, or the bol t threads
are damaged beyond repai r. Repl ace the support seg-
ment i f cracked, or chi pped and repl ace the i dl er
attachi ng bol ts i f the threads are damaged.
Fig. 134 Shift Forks And Shaft
1 SHIFT SHAFT
2 SHAFT LEVER
3 SHAFT LEVER BUSHING
4 3-4 SHIFT FORK
5 1-2 SHIFT FORK
6 FIFTH-REVERSE SHIFT FORK
Shift Socket
I nspect the shi ft socket for wear or damage.
repl ace the socket i f the rol l pi n, or shi ft shaft bores
are damaged. Mi nor ni cks i n the shi ft l ever bal l seat
i n the socket can be smoothed down wi th 400 gri t
emery or wet/dry paper. Repl ace the socket i f the bal l
seat i s worn, or cracked. Do not reuse the ori gi nal
shi ft socket rol l pi n. I nstal l a new pi n duri ng reas-
sembl y. The socket rol l pi n i s approxi matel y i s
approxi matel y 33 mm (1-1/4 i n.) l ong.
Output Shaft And Geartrain
I nspect al l of the gears for worn, cracked, chi pped,
or broken teeth. Al so check condi ti on of the beari ng
bore i n each gear. The bores shoul d be smooth and
free of surface damage. Di scol orati on of the gear
bores i s a normal occurrence and i s not a reason for
repl acement. Repl ace gears onl y when tooth damage
has occurred, or i f the bores are bri nnel l ed or
severel y scored.
I nspect the shaft spl i nes and beari ngs surfaces.
Mi nor ni cks on the beari ng surfaces can be smoothed
wi th 320/420 gri t emery and fi nal pol i shed wi th cro-
cus cl oth. Repl ace the shaft i f the spl i nes are dam-
aged or beari ng surfaces are deepl y scored, worn, or
bri nnel l ed.
SPECIFICATIONS
TORQUE
SPECIAL TOOLS
Fig. 135 Correct Countershaft Bearing Installation
1 COUNTERSHAFT
2 BEARING CAGE
Description Torque
Cl utch Housi ng Bol ts . . . 5461 Nm (4045 ft. l bs.)
Crossmember-To-Frame Bol ts . . . . . . . . 6175 Nm
(4455 ft. l bs.)
Crossmember-To-I nsul ator Nuts . . . . . . 5461 Nm
(4045 ft. l bs.)
Drai n/Fi l l Pl ug . . . . . . . . . 927 Nm (1420 ft. l bs.)
Front-To-Rear Housi ng Bol ts . . . . . . . . . 3035 Nm
(2226 ft. l bs.)
Front Beari ng Retai ner Bol ts . . . . . . . . . 710 Nm
(57 ft. l bs.)
I dl er Shaft Bol ts . . . . . . 1925 Nm (1418 ft. l bs.)
Rear Beari ng Retai ner Bol ts . . . . . . . . . 3035 Nm
(2226 ft. l bs.)
Shi ft Tower Bol ts . . . . . . . . . 710 Nm (57 ft. l bs.)
Sl ave Cyl i nder Attachi ng Nuts . . . . . . . . . . 23 Nm
(200 i n. l bs.)
Transfer Case Attachi ng Nuts . . 47 Nm (35 ft. l bs.)
U-Joi nt Cl amp Bol ts . . . . . . . . 19 Nm (170 i n. l bs.)
Remover, SealC-3985-B
Installer, SealC-3972-A
Remover, Bushing6957
Installer, Bushing6951
HandleC-4171
Remover8117
Remover/Installer, NV3550 Shift Rail Roll Pin6858
Fixture, NV35506747
Adapter, Fixture6747-1A
Adapter, Fixture6747-2A
Cup, Fixture8115
Splitter, Bearing1130
Tube6310-1
Installer8118
Remover/Installer8119
Stud, Alignment8120
Installer, SealC-3860-A
Installer8123
Installer, Bearing Cone6448
AUTOMATIC TRANSMISSION30RH
TABLE OF CONTENTS
page page
30RH AUTOMATIC TRANSMISSION. . . . . . . . . . . 89
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . 97
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
ACCUMULATOR. . . . . . . . . . . . . . . . . . . . . . . . . 117
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 120
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 121
OVERRUNNING CLUTCH . . . . . . . . . . . . . . . . . 122
PLANETARY GEARSET . . . . . . . . . . . . . . . . . . . 122
BANDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
SERVOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
GOVERNOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
GEARSHIFT MECHANISM . . . . . . . . . . . . . . . . . 124
CONVERTER DRAINBACK VALVE . . . . . . . . . . . 125
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . 125
AUTOMATIC TRANSMISSION DIAGNOSIS. . . . . 126
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 126
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 126
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 127
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . . . 128
PARK/NEUTRAL POSITION SWITCH . . . . . . . . . 128
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 128
THROTTLE VALVE CABLE. . . . . . . . . . . . . . . . . 129
ROAD TESTING. . . . . . . . . . . . . . . . . . . . . . . . . 129
ANALYZING ROAD TEST . . . . . . . . . . . . . . . . . . 129
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 129
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION . . . . . . . . . . . . . . . . . . . . . 131
CONVERTER HOUSING FLUID LEAK
DIAGNOSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . 132
DIAGNOSIS CHARTS. . . . . . . . . . . . . . . . . . . . . 133
SERVICE PROCEDURES
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . . . . 141
FLUID AND FILTER REPLACEMENT . . . . . . . . . 141
TRANSMISSION FILL PROCEDURE. . . . . . . . . . 142
CONVERTER DRAINBACK CHECK VALVE
SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 142
FLUSHING COOLERS AND TUBES . . . . . . . . . . 143
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 144
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 144
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . 146
YOKE SEAL REPLACEMENT . . . . . . . . . . . . . . . 147
EXTENSION HOUSING BUSHING . . . . . . . . . . . 147
ADAPTER HOUSING . . . . . . . . . . . . . . . . . . . . . 147
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . . 148
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 150
BRAKE TRANSMISSION SHIFT INTERLOCK . . . 150
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
OUTPUT SHAFT REAR BEARING . . . . . . . . . . . 153
GOVERNOR AND PARK GEAR . . . . . . . . . . . . . 153
PARK LOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 163
OVERRUNNING CLUTCH/LOW-REVERSE
DRUM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
FRONT SERVO PISTON . . . . . . . . . . . . . . . . . . 176
REAR SERVO PISTON. . . . . . . . . . . . . . . . . . . . 177
OIL PUMP AND REACTION SHAFT SUPPORT. . 177
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 180
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 181
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . . 185
EXTENSION HOUSING AND PARK LOCK . . . . . 191
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 194
DRUM/OVERDRIVE PISTON RETAINER . . . . . 195
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . . . . 195
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . 195
OIL PUMP AND REACTION SHAFT SUPPORT. . 195
FRONT CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 196
REAR CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 196
PLANETARY GEARTRAIN/OUTPUT SHAFT . . . . 197
ADJUSTMENTS
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 197
CABLE ADJUSTMENT. . . . . . . . . . . . . . . . . . . 198
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 198
FRONT BAND ADJUSTMENT. . . . . . . . . . . . . . . 199
REAR BAND ADJUSTMENT . . . . . . . . . . . . . . . . 200
VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . 201
SPECIFICATIONS
30RH AUTOMATIC TRANSMISSION. . . . . . . . . . 212
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
SPECIAL TOOLS
30RH TRANSMISSIONS. . . . . . . . . . . . . . . . . . . 213
21 - 88 AUTOMATIC TRANSMISSION 30RH XJ
30RH AUTOMATIC TRANSMISSION
DESCRIPTION
The 30RH automati c transmi ssi on i s used wi th the
2.5L engi ne (Fi g. 1). The 30RH i s three speed trans-
mi ssi ons wi th a l ock-up cl utch i n the torque con-
verter. The transmi ssi ons contai n a front and rear
cl utch whi ch functi on as the i nput dri vi ng compo-
nents. They al so contai n the ki ckdown (front) and the
l ow/reverse (rear) bands whi ch, al ong wi th the over-
runni ng cl utch, serve as the hol di ng components. The
dri vi ng and hol di ng components combi ne to sel ect the
necessary pl anetary gear components, i n the front
and rear pl anetary gear set, transfer the engi ne
power from the i nput shaft through to the output
shaft. The transmi ssi ons contai n a governor that i s
mounted on the output shaft and suppl i es pressure
to the val ve body based on the output shaft speed.
The val ve body i s mounted to the l ower si de of the
transmi ssi on and contai ns the val ves to control pres-
sure regul ati on, fl ui d fl ow control , and cl utch/band
appl i cati on. The oi l pump i s mounted at the front of
the transmi ssi on and i s dri ven by the torque con-
verter hub. The pump suppl i es the oi l pressure nec-
essary for cl utch/band actuati on and transmi ssi on
l ubri cati on. The 30RH transmi ssi on i s cool ed by an
i ntegral fl ui d cool er i nsi de the radi ator.
XJ AUTOMATIC TRANSMISSION 30RH 21 - 89
Fig. 1 30RH Automatic Transmission
Transmi ssi on i denti fi cati on numbers are stamped
on the l eft si de of the case just above the oi l pan gas-
ket surface (Fi g. 2). Refer to thi s i nformati on when
orderi ng repl acement parts.
TRANSMISSION GEAR RATIOS
Forward gear rati os are:
2.74:1 (fi rst gear)
1.54:1 (second gear)
1.00:1 (thi rd gear)
OPERATION
The appl i cati on of each dri vi ng or hol di ng compo-
nent i s control l ed by the val ve body based upon the
manual l ever posi ti on and governor pressure. The
governor pressure i s a vari abl e pressure i nput to the
val ve body and i s one of the si gnal s that a shi ft i s
necessary. Fi rst through thi rd gear are obtai ned by
sel ecti vel y appl yi ng and rel easi ng the di fferent
cl utches and bands. Engi ne power i s thereby routed
to the vari ous pl anetary gear assembl i es whi ch com-
bi ne wi th the overrunni ng cl utch assembl y to gener-
ate the di fferent gear rati os. The torque converter
cl utch i s hydraul i cal l y appl i ed and i s rel eased when
fl ui d i s vented from the hydraul i c ci rcui t by the
torque converter control (TCC) sol enoi d on the val ve
body. The torque converter cl utch i s control l ed by the
Powertrai n Control Modul e (PCM). The torque con-
verter cl utch engages i n thi rd gear when the vehi cl e
i s crui si ng on a l evel pl ane after the vehi cl e has
warmed up. The torque converter cl utch wi l l di sen-
gage momentari l y when an i ncrease i n engi ne l oad i s
sensed by the PCM, such as when the vehi cl e begi ns
to go uphi l l or the throttl e pressure i s i ncreased. The
torque converter cl utch feature i ncreases fuel econ-
omy and reduces the transmi ssi on fl ui d temperature.
Fig. 2 Transmission Part Number And Serial
Number Location
1 PART NUMBER
2 BUILD DATE
3 SERIAL NUMBER
PARK POWERFLOW
As the engi ne i s runni ng and the crankshaft i s
rotati ng, the fl expl ate and torque converter, whi ch
are al so bol ted to i t, are al l rotati ng i n a cl ockwi se
di recti on as vi ewed from the front of the engi ne. The
notched hub of the torque converter i s connected to
the oi l pumps i nternal gear, suppl yi ng the transmi s-
si on wi th oi l pressure. As the converter turns, i t
turns the i nput shaft i n a cl ockwi se di recti on. As the
i nput shaft i s rotati ng, the front cl utch hubrear
cl utch retai ner and al l thei r associ ated parts are al so
rotati ng, al l bei ng di rectl y connected to the i nput
shaft. The power fl ow from the engi ne through the
frontcl utchhub and rearcl utchretai ner stops at
the rearcl utchretai ner. Therefore, no power fl ow to
the output shaft, occurs because no cl utches are
appl i ed. The onl y mechani sm i n use at thi s ti me i s
the parki ng sprag (Fi g. 3), whi ch l ocks the parki ng
gear on the output shaft to the transmi ssi on case.
NEUTRAL POWERFLOW
Wi th the gear sel ector i n the neutral posi ti on (Fi g.
4), the power fl ow of the transmi ssi on i s essenti al l y
the same as i n the park posi ti on. The onl y opera-
ti onal di fference i s that the parki ng sprag has been
di sengaged, unl ocki ng the output shaft from the
transmi ssi on case and al l owi ng i t to move freel y.
Fig. 3 Park Powerflow
1 LEVER ENGAGED FOR PARK
2 PARK SPRAG
3 OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 LEVER DISENGAGED FOR NEUTRAL
2 PARK SPRAG
3 OUTPUT SHAFT
4 CAM
5 LEVER
REVERSE POWERFLOW
When the gear sel ector i s moved i nto the reverse
posi ti on (Fi g. 5), the front cl utch and the rear band
are appl i ed. Wi th the appl i cati on of the front cl utch,
engi ne torque i s appl i ed to the sun gear, turni ng i t i n
a cl ockwi se di recti on. The cl ockwi se rotati on of the
sun gear causes the rear pl anet pi ni ons to rotate
agai nst engi ne rotati on i n a countercl ockwi se di rec-
ti on. The rear band i s hol di ng the l ow reverse drum,
whi ch i s spl i ned to the rear carri er. Si nce the rear
carri er i s bei ng hel d, the torque from the pl anet pi n-
i ons i s transferred to the rear annul us gear, whi ch i s
spl i ned to the output shaft. The output shaft i n turn
rotates wi th the annul us gear i n a countercl ockwi se
di recti on gi vi ng a reverse gear output. The enti re
transmi ssi on of torque i s appl i ed to the rear pl ane-
tary gearset onl y. Al though there i s torque i nput to
the front gearset through the sun gear, no other
member of the gearset i s bei ng hel d. Duri ng the
enti re reverse stage of operati on, the front pl anetary
gears are i n an i dl i ng condi ti on.
Fig. 5 Reverse Powerflow
1 FRONT CLUTCH ENGAGED
2 OUTPUT SHAFT
3 LOW/REVERSE BAND APPLIED
4 INPUT SHAFT
5 OUTPUT SHAFT
6 INPUT SHAFT
7 FRONT CLUTCH ENGAGED
8 LOW/REVERSE BAND APPLIED
FIRST GEAR POWERFLOW
When the gearshi ft l ever i s moved i nto the dri ve
posi ti on the transmi ssi on goes i nto fi rst gear (Fi g. 6).
As soon as the transmi ssi on i s shi fted from park or
neutral to dri ve, the rear cl utch appl i es, appl yi ng the
rear cl utch pack to the front annul us gear. Engi ne
torque i s now appl i ed to the front annul us gear turn-
i ng i t i n a cl ockwi se di recti on. Wi th the front annul us
gear turni ng i n a cl ockwi se di recti on, i t causes the
front pl anets to turn i n a cl ockwi se di recti on. The
rotati on of the front pl anets cause the sun to revol ve
i n a countercl ockwi se di recti on. The sun gear now
transfers i ts countercl ockwi se rotati on to the rear
pl anets whi ch rotate back i n a cl ockwi se di recti on.
Wi th the rear annul us gear stati onary, the rear
pl anet rotati on on the annul us gear causes the rear
pl anet carri er to revol ve i n a countercl ockwi se di rec-
ti on. The rear pl anet carri er i s spl i ned i nto the l ow
reverse drum, and the l ow reverse drum i s spl i ned to
the i nner race of the overrunni ng cl utch. Wi th the
overrunni ng cl utch l ocked, the pl anet carri er i s
hel d, and the resul ti ng torque provi ded by the pl anet
pi ni ons i s transferred to the rear annul us gear. The
rear annul us gear i s spl i ned to the output shaft and
rotated al ong wi th i t (cl ockwi se) i n an underdri ve
gear reducti on mode.
Fig. 6 First Gear Powerflow
1 OUTPUT SHAFT
2 OVER-RUNNING CLUTCH HOLDING
3 REAR CLUTCH APPLIED
4 OUTPUT SHAFT
5 OVER-RUNNING CLUTCH HOLDING
6 INPUT SHAFT
8 INPUT SHAFT
SECOND GEAR POWERFLOW
I n dri vesecond (Fi g. 7), the same el ements are
appl i ed as i n manual second. Therefore, the power fl ow
wi l l be the same, and both gears wi l l be di scussed as
one i n the same. I n dri vesecond, the transmi ssi on has
proceeded from fi rst gear to i ts shi ft poi nt, and i s shi ft-
i ng from fi rst gear to second. The second gear shi ft i s
obtai ned by keepi ng the rear cl utch appl i ed and appl y-
i ng the front (ki ckdown) band. The front band hol ds the
front cl utch retai ner that i s l ocked to the sun gear dri v-
i ng shel l . Wi th the rear cl utch sti l l appl i ed, the i nput i s
sti l l on the front annul us gear turni ng i t cl ockwi se at
engi ne speed. Now that the front band i s hol di ng the
sun gear stati onary, the annul us rotati on causes the
front pl anets to rotate i n a cl ockwi se di recti on. The
front carri er i s then al so made to rotate i n a cl ockwi se
di recti on but at a reduced speed. Thi s wi l l transmi t the
torque to the output shaft, whi ch i s di rectl y connected
to the front pl anet carri er. The rear pl anetary annul us
gear wi l l al so be turni ng because i t i s di rectl y spl i ned
to the output shaft. Al l power fl ow has occurred i n the
front pl anetary gear set duri ng the dri vesecond stage
of operati on, and now the overrunni ng cl utch, i n the
rear of the transmi ssi on, i s di sengaged and freewheel -
i ng on i ts hub.
Fig. 7 Second Gear Powerflow
1 KICKDOWN BAND APPLIED
2 OUTPUT SHAFT
3 REAR CLUTCH ENGAGED
4 OUTPUT SHAFT
5 OVER-RUNNING CLUTCH FREE-WHEELING
6 INPUT SHAFT
8 KICKDOWN BAND APPLIED
9 INPUT SHAFT
DIRECT DRIVE POWERFLOW
The vehi cl e has accel erated and reached the shi ft
poi nt for the 23 upshi ft i nto di rect dri ve (Fi g. 8).
When the shi ft takes pl ace, the front band i s
rel eased, and the front cl utch i s appl i ed. The rear
cl utch stays appl i ed as i t has been i n al l the forward
gears. Wi th the front cl utch now appl i ed, engi ne
torque i s now on the front cl utch retai ner, whi ch i s
l ocked to the sun gear dri vi ng shel l . Thi s means that
the sun gear i s now turni ng i n engi ne rotati on (cl ock-
wi se) and at engi ne speed. The rear cl utch i s sti l l
appl i ed so engi ne torque i s al so sti l l on the front
annul us gear. I f two members of the same pl anetary
set are dri ven, di rect dri ve resul ts. Therefore, when
two members are rotati ng at the same speed and i n
the same di recti on, i t i s the same as bei ng l ocked up.
The rear pl anetary set i s al so l ocked up, gi ven the
sun gear i s sti l l the i nput, and the rear annul us gear
must turn wi th the output shaft. Both gears are
turni ng i n the same di recti on and at the same speed.
The front and rear pl anet pi ni ons do not turn at al l
i n di rect dri ve. The onl y rotati on i s the i nput from
the engi ne to the connected parts, whi ch are acti ng
as one common uni t, to the output shaft.
FLUID
NOTE: Refer to the maintenance schedules in
Group 0, Lubrication and Maintenance for the rec-
ommended maintenance (fluid/filter change) inter-
vals for this transmission.
NOTE: Refer to Service Procedures in this group
for fluid level checking procedures.
DESCRIPTION
Mopar ATF Pl us 3, Type 7176, automati c trans-
mi ssi on fl ui d i s the recommended fl ui d for Dai ml er-
Chrysl er automati c transmi ssi ons.
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar ATF Pl us 3, Type 7176, automati c trans-
mi ssi on fl ui d when new i s red i n col or. The ATF i s
dyed red so i t can be i denti fi ed from other fl ui ds used
i n the vehi cl e such as engi ne oi l or anti freeze. The
red col or i s not permanent and i s not an i ndi cator of
Fig. 8 Direct Drive Powerflow
1 FRONT CLUTCH APPLIED
3 OUTPUT SHAFT
5 OUTPUT SHAFT
6 INPUT SHAFT
9 FRONT CLUTCH APPLIED
10 INPUT SHAFT
fl ui d condi ti on. As the vehi cl e i s dri ven, the ATF wi l l
begi n to l ook darker i n col or and may eventual l y
become brown. This is normal. A dark brown/bl ack
fl ui d accompani ed wi th a burnt odor and/or deteri o-
rati on i n shi ft qual i ty may i ndi cate fl ui d deteri ora-
ti on or transmi ssi on component fai l ure.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous speci al addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on seal ers shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
OPERATION
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 9) i s a hydraul i c devi ce
that coupl es the engi ne crankshaft to the transmi s-
si on. The torque converter consi sts of an outer shel l
wi th an i nternal turbi ne, a stator, an overrunni ng
cl utch, an i mpel l er and an el ectroni cal l y appl i ed con-
verter cl utch. The converter cl utch provi des reduced
engi ne speed and greater fuel economy when
engaged. Cl utch engagement al so provi des reduced
transmi ssi on fl ui d temperatures. The converter
cl utch engages i n thi rd gear. The torque converter
hub dri ves the transmi ssi on oi l (fl ui d) pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
Fig. 9 Torque Converter Assembly
1 TURBINE
2 IMPELLER
3 HUB
4 STATOR
5 CONVERTER CLUTCH DISC
6 DRIVE PLATE
IMPELLER
The i mpel l er (Fi g. 10) i s an i ntegral part of the
converter housi ng. The i mpel l er consi sts of curved
bl ades pl aced radi al l y al ong the i nsi de of the housi ng
on the transmi ssi on si de of the converter. As the con-
verter housi ng i s rotated by the engi ne, so i s the
i mpel l er, because they are one and the same and are
the dri vi ng member of the system.
TURBINE
The turbi ne (Fi g. 11) i s the output, or dri ven, mem-
ber of the converter. The turbi ne i s mounted wi thi n
the housi ng opposi te the i mpel l er, but i s not attached
to the housi ng. The i nput shaft i s i nserted through
the center of the i mpel l er and spl i ned i nto the tur-
bi ne. The desi gn of the turbi ne i s si mi l ar to the
i mpel l er, except the bl ades of the turbi ne are curved
i n the opposi te di recti on.
Fig. 10 Impeller
1 ENGINE FLEXPLATE
2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
3 IMPELLER VANES AND COVER ARE INTEGRAL
4 ENGINE ROTATION
5 ENGINE ROTATION
STATOR
The stator assembl y (Fi g. 12) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator i s l ocated between the i mpel l er and
turbi ne wi thi n the torque converter case (Fi g. 13).
The stator contai ns an over-runni ng cl utch, whi ch
al l ows the stator to rotate onl y i n a cl ockwi se di rec-
ti on. When the stator i s l ocked agai nst the over-run-
ni ng cl utch, the torque mul ti pl i cati on feature of the
torque converter i s operati onal .
Fig. 11 Turbine
1 TURBINE VANE
2 ENGINE ROTATION
3 INPUT SHAFT
4 PORTION OF TORQUE CONVERTER COVER
5 ENGINE ROTATION
6 OIL FLOW WITHIN TURBINE SECTION
Fig. 12 Stator Components
1 CAM (OUTER RACE)
2 ROLLER
3 SPRING
4 INNER RACE
TORQUE CONVERTER CLUTCH (TCC)
The TCC (Fi g. 14) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shockfree power transfer, i t
i s natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel -
l er and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the front cover to pro-
vi de thi s mechani cal l ock-up.
OPERATION
The converter i mpel l er (Fi g. 15) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi nes bl ades i t con-
ti nues i n a hi nderi ng di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
stators over-runni ng cl utch to i ts shaft (Fi g. 16).
Under stal l condi ti ons (the turbi ne i s stati onary), the
oi l l eavi ng the turbi ne bl ades stri kes the face of the
stator bl ades and tri es to rotate them i n a counter-
cl ockwi se di recti on. When thi s happens the overrun-
ni ng cl utch of the stator l ocks and hol ds the stator
from rotati ng. Wi th the stator l ocked, the oi l stri kes
the stator bl ades and i s redi rected i nto a hel pi ng
di recti on before i t enters the i mpel l er. Thi s ci rcul a-
ti on of oi l from i mpel l er to turbi ne, turbi ne to stator,
and stator to i mpel l er, can produce a maxi mum
torque mul ti pl i cati on of about 2.4:1. As the turbi ne
begi ns to match the speed of the i mpel l er, the fl ui d
that was hi tti ng the stator i n such as way as to
cause i t to l ockup i s no l onger doi ng so. I n thi s con-
di ti on of operati on, the stator begi ns to free wheel
and the converter acts as a fl ui d coupl i ng.
I n a standard torque converter, the i mpel l er and
turbi ne are rotati ng at about the same speed and the
Fig. 13 Stator Location
1 STATOR
2 IMPELLER
3 FLUID FLOW
4 TURBINE
Fig. 14 Torque Converter Clutch (TCC)
1 IMPELLER FRONT COVER
2 THRUST WASHER ASSEMBLY
3 IMPELLER
4 STATOR
5 TURBINE
6 FRICTION DISC
stator i s freewheel i ng, provi di ng no torque mul ti pl i -
cati on. By appl yi ng the turbi nes pi ston to the front
covers fri cti on materi al , a total converter engage-
ment can be obtai ned. The resul t of thi s engagement
i s a di rect 1:1 mechani cal l i nk between the engi ne
and the transmi ssi on.
The engagement and di sengagement of the TCC
are automati c and control l ed by the Powertrai n Con-
trol Modul e (PCM). The engagement cannot be acti -
vated i n the l ower gears because i t el i mi nates the
torque mul ti pl i cati on effect of the torque converter
necessary for accel erati on. I nputs that determi ne
cl utch engagement are: cool ant temperature, vehi cl e
speed and throttl e posi ti on. The torque converter
cl utch i s engaged by the cl utch sol enoi d on the val ve
body. The cl utch wi l l engage at approxi matel y 56
km/h (35 mph) wi th l i ght throttl e, after the shi ft to
thi rd gear.
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 17) i s l ocated i n the pump hous-
i ng i nsi de the bel l housi ng of the transmi ssi on case.
The oi l pump consi sts of an i nner and outer gear, a
housi ng, and a cover that al so serves as the reacti on
shaft support.
Fig. 15 Torque Converter Fluid Operation
1 APPLY PRESSURE
2 THE PISTON MOVES SLIGHTLY FORWARD
3 RELEASE PRESSURE
4 THE PISTON MOVES SLIGHTLY REARWARD
Fig. 16 Stator Operation
1 DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 FRONT OF ENGINE
3 INCREASED ANGLE AS OIL STRIKES VANES
4 DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
OPERATION
As the torque converter rotates, the converter hub
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
VALVE BODY
DESCRIPTION
The val ve body consi sts of a cast al umi num val ve
body, a separator pl ate, and transfer pl ate. The val ve
body contai ns val ves and check bal l s that control
fl ui d del i very to the torque converter cl utch, bands,
and fri cti onal cl utches. The val ve body contai ns the
fol l owi ng components (Fi g. 18) and (Fi g. 19):
Regul ator val ve
Regul ator val ve throttl e pressure pl ug
Li ne pressure pl ug and sl eeve
Ki ckdown val ve
Ki ckdown l i mi t val ve
12 shi ft val ve
12 control val ve
23 shi ft val ve
23 governor pl ug
Throttl e val ve
Throttl e pressure pl ug
Swi tch val ve
Manual val ve
Converter cl utch control val ve
Fai l -safe val ve
Shuttl e val ve
Shuttl e val ve throttl e pl ug
9 check bal l s
By adjusti ng the spri ng pressure acti ng on the reg-
ul ator val ve, transmi ssi on l i ne pressure can be
adjusted.
OPERATION
NOTE: Refer to the Hydraulic Schematics for a
visual aid in determining valve location, operation
and design.
1 OIL SEAL
2 OIL PUMP BODY
3 VENT
4 REACTION SHAFT SUPPORT
5 INNER ROTOR
6 OUTER ROTOR
7 O RING
REGULATOR VALVE
The pressure regul ator val ve i s needed to control
the hydraul i c pressure wi thi n the system and reduce
the amount of heat produced i n the fl ui d. The pres-
sure regul ator val ve i s l ocated i n the val ve body near
the manual val ve. The pressure regul ator val ve trai n
control s the maxi mum pressure i n the l i nes by
meteri ng the dumpi ng of fl ui d back i nto the sump.
Regul ated pressure i s referred to as l i ne pressure.
The regul ator val ve (Fi g. 20) has a spri ng on one
end that pushes the val ve to the l eft. Thi s cl oses a
dump (vent) that i s used to l ower pressure. The cl os-
i ng of the dump wi l l cause the oi l pressure to
i ncrease. Oi l pressure on the opposi te end of the
val ve pushes the val ve to the ri ght, openi ng the
dump and l oweri ng oi l pressure. The resul t i s spri ng
pressure worki ng agai nst oi l pressure to mai ntai n
the oi l at speci fi c pressures. Wi th the engi ne run-
ni ng, fl ui d fl ows from the pump to the pressure reg-
ul ator val ve, manual val ve, and the i nterconnected
ci rcui ts. As fl ui d i s sent through passages to the reg-
ul ator val ve, the pressure pushes the val ve to the
ri ght agai nst the l arge spri ng. I t i s al so sent to the
reacti on areas on the l eft si de of the throttl e pressure
pl ug and the l i ne pressure pl ug. Wi th the gear sel ec-
tor i n the park posi ti on, fl ui d reci rcul ates through
the regul ator and manual val ves back to the sump.
Fig. 18 Valve Body Assembly
1 GOVERNOR PLUG END PLATE
2 SHUTTLE VALVE
3 12 GOVERNOR PLUG
4 VALVE BODY
5 REGULATOR VALVE THROTTLE PRESSURE PLUG
6 SLEEVE
7 LINE PRESSURE PLUG
8 RETAINER
9 12 SHIFT VALVE
10 12 SHIFT CONTROL VALVE
11 KICKDOWN LIMIT VALVE
12 END PLATE
13 THROTTLE PRESSURE PLUG
14 KICKDOWN LIMIT VALVE BODY
15 E-RING
16 23 SHIFT VALVE
17 GUIDES
18 23 GOVERNOR PLUG
19 PRIMARY SPRING
20 SHUTTLE VALVE THROTTLE PLUG
Meanwhi l e, the torque converter i s fi l l ed sl owl y. I n
al l other gear posi ti ons (Fi g. 21), fl ui d fl ows between
two ri ght si de l ands to the swi tch val ve and torque
converter. At l ow pump speeds, the fl ow i s control l ed
by the pressure val ve groove to reduce pressure to
the torque converter. After the torque converter and
swi tch val ve fi l l wi th fl ui d, the swi tch val ve becomes
the control l i ng meteri ng devi ce for torque converter
pressure. The regul ator val ve then begi ns to control
the l i ne pressure for the other transmi ssi on ci rcui ts.
The bal ance of the fl ui d pressure pushi ng the val ve
to the ri ght and the spri ng pressure pushi ng to the
l eft determi nes the si ze of the meteri ng passage at
l and #2 (l and #1 bei ng at the far ri ght of the val ve i n
the di agram). As fl ui d l eaks past the l and, i t moves
i nto a groove connected to the fi l ter or sump. As the
l and meters the fl ui d to the sump, i t causes the pres-
sure to reduce and the spri ng decreases the si ze of
the meteri ng passage. When the si ze of the meteri ng
passage i s reduced, the pressure ri ses agai n and the
si ze of the l and i s i ncreased agai n. Pressure i s regu-
l ated by thi s constant bal ance of hydraul i c and
spri ng pressure.
Fig. 20 Regulator Valve in Park Position
1 ADJUSTER BRACKET
2 LINE PRESSURE ADJUSTER
3 PRESSURE REGULATOR VALVE
4 SWITCH VALVE
5 VALVE BODY
6 TRANSFER PLATE
7 THROTTLE VALVE
8 SLEEVE
9 KICKDOWN VALVE
10 THROTTLE PRESSURE ADJUSTER
The meteri ng at l and #2 establ i shes the l i ne pres-
sure throughout the transmi ssi on. I t i s vari ed accord-
i ng to changes i n throttl e posi ti on, engi ne speed, and
transmi ssi on condi ti on wi thi n a range of 5794 psi
(except i n reverse) (Fi g. 22). The regul ated l i ne pres-
sure i n reverse (Fi g. 23) i s hel d at much hi gher pres-
sures than i n the other gear posi ti ons: 145280 psi .
The hi gher pressure for reverse i s achi eved by the
manual val ve bl ocki ng the suppl y of l i ne pressure to
the reacti on area l eft of l and #4. Wi th thi s pressure
bl ocked, there i s l ess area for pressure to act on to
bal ance the force of the spri ng on the ri ght. Thi s
al l ows l i ne pressure to push the val ve trai n to the
ri ght, reduci ng the amount of fl ui d returned to the
pumps i nl et, i ncreasi ng l i ne pressure.
Fig. 21 Regulator Valve in Neutral Position
1 MANUAL VALVE
2 TO SHIFT VALVE
3 FROM THROTTLE VALVE
4 REGULATOR VALVE
Fig. 23 Regulator Valve in Reverse Position
Fig. 22 Regulator Valve in Drive Position
KICKDOWN VALVE
When the throttl e val ve i s as far over to the l eft as
i t can go, the maxi mum l i ne pressure possi bl e wi l l
enter the throttl e pressure ci rcui t. I n thi s case, throt-
tl e pressure wi l l equal l i ne pressure. Wi th the ki ck-
down val ve (Fi g. 24) pushed i nto the bore as far as i t
wi l l go, fl ui d i ni ti al l y fl ows through the annul ar
groove of the 23 shi ft val ve (whi ch wi l l be i n the
di rect dri ve posi ti on to the ri ght).
After passi ng the annul ar groove, the fl ui d i s
routed to the spri ng end of the 23 shi ft val ve. Fl ui d
pressure reacti ng on the area of l and #1 overcomes
governor pressure, downshi fti ng the 23 shi ft val ve
i nto the ki ckdown, or second gear stage of operati on.
The val ve i s hel d i n the ki ckdown posi ti on by throttl e
pressure routed from a seated check bal l (#2). Agai n,
i f vehi cl e speed i s l ow enough, throttl e pressure wi l l
al so push the 12 shi ft val ve l eft to seat i ts governor
pl ug, and downshi ft to dri ve breakaway.
KICKDOWN LIMIT VALVE
The purpose of the l i mi t val ve i s to prevent a 32
downshi ft at hi gher speeds when a partthrottl e
downshi ft i s not desi rabl e. At these hi gher speeds
onl y a ful l throttl e 32 downshi ft wi l l occur. At l ow
road speeds (Fi g. 25) the l i mi t val ve does not come
i nto pl ay and does not affect the downshi fts. As the
vehi cl es speed i ncreases (Fi g. 26), the governor pres-
sure al so i ncreases. The i ncreased governor pressure
acts on the reacti on area of the bottom l and of the
l i mi t val ve overcomi ng the spri ng force tryi ng to
push the val ve toward the bottom of i ts bore. Thi s
pushes the val ve upward agai nst the spri ng and bot-
toms the val ve agai nst the top of the housi ng. Wi th
the val ve bottomed agai nst the housi ng, the throttl e
pressure suppl i ed to the val ve wi l l be cl osed off by
the bottom l and of the l i mi t val ve. When the suppl y
of throttl e pressure has been shut off, the 32 part
throttl e downshi ft pl ug becomes i noperati ve, because
no pressure i s acti ng on i ts reacti on area.
Fig. 24 Kickdown Valve
1 GOVERNOR PLUG
2 2-3 SHIFT VALVE
3 KICKDOWN VALVE
4 THROTTLE VALVE
5 MAXIMUM THROTTLE PRESSURE
6 THROTTLE VALVE
7 MANUAL VALVE
8 1-2 SHIFT VALVE
9 GOVERNOR PLUG
Fig. 25 Kickdown Limit Valve-Low 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
12 SHIFT VALVE
The 12 shi ft val ve assembl y (Fi g. 27), or mecha-
ni sm, consi sts of: the 12 shi ft val ve, governor pl ug,
and a spri ng on the end of the val ve. After the man-
ual val ve has been pl aced i nto a forward gear range,
l i ne pressure i s di rected to the 12 shi ft val ve. As the
throttl e i s depressed, throttl e pressure i s appl i ed to
the ri ght si de of the 12 shi ft val ve assembl y. Wi th
throttl e pressure appl i ed to the ri ght si de of the
val ve, there i s now both spri ng pressure and throttl e
pressure acti ng on the val ve, hol di ng i t agai nst the
governor pl ug. As the vehi cl e begi ns to move and
bui l d speed, governor pressure i s created and i s
appl i ed to the l eft of the val ve at the governor pl ug.
Fig. 27 12 Shift Valve-Before Shift
1 TO FRONT SERVO AND 2-3 SHIFT VALVE
2 THROTTLE PRESSURE
3 LINE PRESSURE
4 LINE PRESSURE PASSAGE FOR MANUAL LOW POSITION
When governor pressure bui l ds to a poi nt where i t
can overcome the combi ned force of the spri ng and
throttl e pressure on the other si de of the val ve, the
val ve wi l l begi n to move over to the ri ght. As the
val ve moves to the ri ght, the mi ddl e l and of the val ve
wi l l cl ose off the ci rcui t suppl yi ng the throttl e pres-
sure to the ri ght si de of the val ve. When the throttl e
pressure i s cl osed off, the val ve wi l l move even far-
ther to the ri ght, al l owi ng l i ne pressure to enter
another ci rcui t and energi ze the front servo, appl yi ng
the front band (Fi g. 28).
The governor pl ug serves a dual purpose: [0001]
I t al l ows the shi ft val ves to move ei ther l eft or
ri ght, al l owi ng both upshi fts and downshi fts.
When i n a manual sel ecti on posi ti on, i t wi l l be
hydraul i cal l y bl ocked i nto posi ti on so no upshi ft can
occur.
The physi cal bl ocki ng of the upshi ft whi l e i n the
manual 1 posi ti on i s accompl i shed by the di recti ng
of l i ne pressure between both l ands of the governor
pl ug. The l i ne pressure reacts agai nst the l arger l and
of the pl ug, pushi ng the pl ug back agai nst the end
pl ate overcomi ng governor pressure. Wi th the combi -
nati on of the l i ne pressure and spri ng pressure, the
val ve cannot move, preventi ng any upshi ft.
12 SHIFT CONTROL VALVE
I t contai ns a val ve wi th four l ands and a spri ng. I t
i s used as both a rel ay and bal anced val ve.
The val ve has two speci fi c operati ons (Fi g. 29):
Ai d i n qual i ty of the 12 upshi ft.
Ai d i n the qual i ty and ti mi ng of the 32 ki ck-
down ranges.
When the manual val ve i s set to the Dri ve posi ti on
and the transmi ssi on i s i n the fi rst or second gear
range, 12 shi ft control or modul ated throttl e pres-
sure i s suppl i ed to the mi ddl e of the accumul ator
pi ston by the 12 shi ft control val ve. Duri ng the 12
upshi ft, thi s pressure i s used to control the ki ckdown
servo appl y pressure that i s needed to appl y the ki ck-
down and accumul ator pi stons. Thus, the 12 shi ft
poi nt i s cushi oned and the qual i ty i s i mproved.
Duri ng a WOT ki ckdown, ki ckdown pressure i s
appl i ed between the ki ckdown val ve and the 12
Fig. 28 12 Shift Valve-After Shift
1 TO FRONT SERVO AND 2-3 SHIFT VALVE
2 THROTTLE PRESSURE
3 LINE PRESSURE
4 LINE PRESSURE PASSAGE FOR MANUAL LOW POSITION
shi ft control val ve. Thi s addi ti onal pressure i s
di rected to the 12 shi ft control s spri ng cavi ty, add-
i ng to the spri ng l oad on the val ve. The resul t of thi s
i ncreased modul ated throttl e pressure i s a fi rmer
WOT upshi ft.
SHUTTLE VALVE
The assembl y i s contai ned i n a bore i n the val ve
body above the shi ft val ves. When the manual val ve
i s posi ti oned i n the Dri ve range, throttl e pressure
acts on the throttl e pl ug of the shuttl e val ve (Fi g. 29)
to move i t agai nst a spri ng, i ncreasi ng the spri ng
force on the shuttl e val ve. Duri ng a part or ful l throt-
tl e 12 upshi ft, the throttl e pl ug i s bottomed by
throttl e pressure, hol di ng the shuttl e val ve to the
ri ght agai nst governor pressure, and openi ng a
bypass ci rcui t. The shuttl e val ve control s the qual -
i ty of the ki ckdown shi ft by restri cti ng the rate of
fl ui d di scharge from the front cl utch and servo
rel ease ci rcui ts. Duri ng a 32 ki ckdown, fl ui d di s-
charges through the shuttl e bypass ci rcui t. When
the shuttl e val ve cl oses the bypass ci rcui t, fl ui d di s-
charge i s restri cted and control l ed for the appl i cati on
of the front band. Duri ng a 23 l i ft foot upshi ft, the
shuttl e val ve bypasses the restri cti on to al l ow ful l
fl ui d fl ow through the bypass groove for a faster
rel ease of the band.
23 SHIFT VALVE
The 23 shi ft val ve mechani sm (Fi g. 30) consi sts of
the 23 shi ft val ve, governor pl ug and spri ng, and a
throttl e pl ug. After the 12 shi ft val ve has compl eted
i ts operati on and appl i ed the front band, l i ne pres-
sure i s di rected to the 23 shi ft val ve through the
connecti ng passages from the 12 shi ft val ve. The
l i ne pressure wi l l then deadend at l and #2 unti l the
Fig. 29 12 Shift Control Valve
1 THROTTLE PLUG 2 SHUTTLE VALVE
3 1-2 SHIFT CONTROL VALVE
23 val ve i s ready to make i ts shi ft. Now that the
vehi cl e i s i n moti on and under accel erati on, there i s
throttl e pressure bei ng appl i ed to the spri ng si de of
the val ve and between l ands #3 and #4.
As vehi cl e speed i ncreases, governor pressure
i ncreases proporti onatel y, unti l i t becomes great
enough to overcome the combi ned throttl e and spri ng
pressure on the ri ght si de of the val ve. When thi s
happens, the governor pl ug i s forced agai nst the shi ft
val ve movi ng i t to the ri ght. The shi ft val ve causes
l and #4 to cl ose the passage suppl yi ng throttl e pres-
sure to the 23 shi ft val ve. Wi thout throttl e pressure
present i n the ci rcui t now, the governor pl ug wi l l
push the val ve over far enough to bottom the val ve i n
i ts bore. Thi s al l ows l and #2 to di rect l i ne pressure to
the front cl utch.
After the shi ft (Fi g. 31), l i ne pressure i s di rected to
the l and between the shi ft val ve and the governor
pl ug, and to the rel ease si de of the ki ckdown servo.
Thi s rel eases the front band and appl i es the front
cl utch, shi fti ng i nto thi rd gear or di rect dri ve. The
rear cl utch remai ns appl i ed, as i t has been i n the
other gears. Duri ng a manual 1 or manual 2 gear
sel ecti on, l i ne pressure i s sent between the two l ands
of the 23 governor pl ug. Thi s l i ne pressure at the
governor pl ug l ocks the shi ft val ve i nto the second
gear posi ti on, preventi ng an upshi ft i nto di rect dri ve.
The theory for the bl ocki ng of the val ve i s the same
as that of the 12 shi ft val ve.
THROTTLE VALVE
I n al l gear posi ti ons the throttl e val ve (Fi g. 32) i s
bei ng suppl i ed wi th l i ne pressure. The throttl e val ve
meters and reduces the l i ne pressure that now
becomes throttl e pressure. The throttl e val ve i s
moved by a spri ng and the ki ckdown val ve, whi ch i s
mechani cal l y connected to the throttl e. The l arger
the throttl e openi ng, the hi gher the throttl e pressure
(to a maxi mum of l i ne pressure). The smal l er the
throttl e openi ng, the l ower the throttl e pressure (to a
mi ni mum of zero at i dl e). As engi ne speed i ncreases,
the i ncrease i n pump speed i ncreases pump output.
The i ncrease i n pressure and vol ume must be regu-
l ated to mai ntai n the bal ance wi thi n the transmi s-
si on. To do thi s, throttl e pressure i s routed to the
reacti on area on the ri ght si de of the throttl e pres-
sure pl ug (i n the regul ator val ve).
Fig. 30 23 Shift Valve-Before Shift
Fig. 31 23 Shift Valve-After Shift
Fig. 32 Throttle Valve
The hi gher engi ne speed and l i ne pressure woul d
open the vent too far and reduce l i ne pressure too
much. Throttl e pressure, whi ch i ncreases wi th engi ne
speed (throttl e openi ng), i s used to oppose the move-
ment of the pressure val ve to hel p control the meter-
i ng passage at the vent. The throttl e pressure i s
combi ned wi th spri ng pressure to reduce the force of
the throttl e pressure pl ug on the pressure val ve. The
l arger spri ng at the ri ght cl oses the regul ator val ve
passage and mai ntai ns or i ncreases l i ne pressure.
The i ncreased l i ne pressure works agai nst the reac-
ti on area of the l i ne pressure pl ug and the reacti on
area l eft of l and #3 si mul taneousl y moves the regu-
l ator val ve trai n to the ri ght and control s the meter-
i ng passage.
The ki ckdown val ve, al ong wi th the throttl e val ve,
serve to del ay upshi fts unti l the correct vehi cl e and
engi ne speed have been reached. I t al so control s
downshi fts upon dri ver demand, or i ncreased engi ne
l oad. I f these val ves were not i n pl ace, the shi ft
poi nts woul d be at the same speed for al l throttl e
posi ti ons. The ki ckdown val ve i s actuated by a cam
connected to the throttl e. Thi s i s accompl i shed
through ei ther a l i nkage or a cabl e. The cam forces
the ki ckdown val ve toward the throttl e val ve com-
pressi ng the spri ng between them and movi ng the
throttl e val ve. As the throttl e val ve l and starts to
uncover i ts port, l i ne pressure i s metered out i nto
the ci rcui ts and vi ewed as throttl e pressure. Thi s
i ncreased throttl e pressure i s metered out i nto the
ci rcui ts i t i s appl i ed to: the 12 and 23 shi ft val ves.
When the throttl e pressure i s hi gh enough, a 32
downshi ft wi l l occur. I f the vehi cl e speed i s l ow
enough, a 21 downshi ft wi l l occur.
SWITCH VALVE
When the transmi ssi on i s i n Dri ve Second just
before the TCC appl i cati on occurs (Fi g. 33), the pres-
sure regul ator val ve i s suppl yi ng torque converter
pressure to the swi tch val ve. The swi tch val ve di rects
thi s pressure through the transmi ssi on i nput shaft,
i nto the converter, through the converter, back out
between the i nput shaft and the reacti on shaft, and
back up to the swi tch val ve. From the swi tch val ve,
the fl ui d pressure i s di rected to the transmi ssi on
cool er, and l ubri cati on pressure returns from the
cool er to l ubri cate di fferent porti ons of the transmi s-
si on.
Once the TCC control val ve has moved to the l eft
(Fi g. 34), l i ne pressure i s di rected to the fai l safe
val ve, and then to the ti p of the swi tch val ve, forci ng
the val ve downward. The swi tch val ve now vents oi l
from the front of the pi ston i n the torque converter,
and suppl i es l i ne pressure to the (rear) appl y si de of
the torque converter pi ston. Thi s pressure di fferen-
ti al causes the pi ston to appl y agai nst the fri cti on
materi al , cutti ng off any further fl ow of l i ne pressure
oi l . After the swi tch val ve i s shuttl ed downward
al l owi ng l i ne pressure to engage the TCC, torque
converter pressure i s di rected past the swi tch val ve
i nto the transmi ssi on cool er and l ubri cati on ci rcui ts.
CONVERTER CLUTCH CONTROL VALVE
The torque converter cl utch (TCC) control val ve
control s the back (ON) si de of the torque converter
cl utch. When the PCM energi zes the TCC sol enoi d to
engage the converter cl utch pi ston, pressure i s
appl i ed to the TCC control val ve whi ch moves to the
l eft and appl i es pressure to the fai l safe val ve.
FAIL-SAFE VALVE
The pressure comi ng from the TCC control val ve
deadends at the fai l safe val ve unti l governor pres-
sure on the ri ght si de of the val ve i ncreases. The
pressure must be hi gh enough to overcome the throt-
tl e and spri ng pressure on the l eft si de of the val ve
and push the val ve to the l eft. The pressure wi l l then
fl ow to the swi tch val ve.
Fig. 33 Switch Valve-Torque Converter Unlocked
Fig. 34 Switch Valve-Torque Converter Locked
MANUAL VALVE
The manual val ve (Fi g. 35) i s a rel ay val ve. The
purpose of the manual val ve i s to di rect fl ui d to the
correct ci rcui t needed for a speci fi c gear or dri vi ng
range. The manual val ve, as the name i mpl i es, i s
manual l y operated by the dri ver wi th a l ever l ocated
on the si de of the val ve body. The val ve i s connected
mechani cal l y by ei ther a cabl e or l i nkage to the gear-
shi ft mechani sm. The val ve i s hel d i n each of i ts
posi ti ons by a spri ngl oaded rol l er or bal l that
engages the roostercomb of the manual val ve.
ACCUMULATOR
DESCRIPTION
The accumul ator (Fi g. 36) i s a hydraul i c devi ce
that has the sol e purpose of cushi oni ng the appl i ca-
ti on of a band or cl utch. The accumul ator consi sts of
a dual l and pi ston and a spri ng l ocated i n a bore i n
the transmi ssi on case.
OPERATION
Li ne pressure i s di rected between the l ands of the
pi ston (Fi g. 37), bottomi ng i t agai nst the accumul ator
pl ate. The accumul ator stays i n thi s posi ti on after
the transmi ssi on i s pl aced i nto a Dri ve posi ti on.
When the 12 upshi ft occurs (Fi g. 38), l i ne pressure
i s di rected to the l arge end of the pi ston and then to
the ki ckdown servo. As the l i ne pressure reaches the
accumul ator, the combi nati on of spri ng pressure and
l i ne pressure forces the pi ston away from the accu-
mul ator pl ate. Thi s causes a bal anced pressure si tu-
ati on, whi ch resul ts i n a cushi oned band appl i cati on.
After the ki ckdown servo has become i mmovabl e, l i ne
pressure wi l l fi ni sh pushi ng the accumul ator up i nto
i ts bore. When the l arge end of the accumul ator pi s-
ton i s seated i n i ts bore, the band or cl utch i s ful l y
appl i ed.
Fig. 35 Manual Valve
1 1-2 GOVERNOR PLUG
2 2-3 GOVERNOR PLUG
3 GOVERNOR REAR CLUTCH ACCUMULATOR
4 THROTTLE VALVE
5 LAND #1
6 PUMP
7 PRESSURE REGULATOR
8 LAND #2
Fig. 36 Accumulator
1 ACCUMULATOR PISTON
2 PISTON SPRING
NOTE: The accumulator is shown in the inverted
position for illustrative purposes.
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches, whi l e others are used to appl y bands.
They al l have i n common the fact that they are round or
ci rcul ar i n shape, l ocated wi thi n a smooth wal l ed cyl i n-
der, whi ch i s cl osed at one end and converts fl ui d pres-
sure i nto mechani cal movement. The fl ui d pressure
exerted on the pi ston i s contai ned wi thi n the system
through the use of pi ston ri ngs or seal s.
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e i s
known as Pascal s Law. Pascal s Law can be stated as:
Pressure on a confi ned fl ui d i s transmi tted equal l y i n
al l di recti ons and acts wi th equal force on equal areas.
PRESSURE
Pressure (Fi g. 39) i s nothi ng more than force (l bs.)
di vi ded by area (i n or ft.), or force per uni t area.
Gi ven a 100 l b. bl ock and an area of 100 sq. i n. on
the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 40) by
appl yi ng a force to some gi ven area i n contact wi th the
fl ui d. A good exampl e of thi s i s a cyl i nder fi l l ed wi th
fl ui d and equi pped wi th a pi ston that i s cl osel y fi tted to
the cyl i nder wal l . I f a force i s appl i ed to the pi ston,
pressure wi l l be devel oped i n the fl ui d. Of course, no
Fig. 37 Accumulator in Neutral and Drive Positions
Fig. 38 Accumulator in Second Gear Position
1 BOTTOM IN BORE
2 SHUTTLE VALVE
Fig. 39 Force and Pressure Relationship
pressure wi l l be created i f the fl ui d i s not confi ned. I t
wi l l si mpl y l eak past the pi ston. There must be a
resi stance to fl ow i n order to create pressure. Pi ston
seal i ng i s extremel y i mportant i n hydraul i c operati on.
Several ki nds of seal s are used to accompl i sh thi s
wi thi n a transmi ssi on. These i ncl ude but are not l i mi ted
to Ori ngs, Dri ngs, l i p seal s, seal i ng ri ngs, or
extremel y cl ose tol erances between the pi ston and the
cyl i nder wal l . The force exerted i s downward (gravi ty),
however, the pri nci pl e remai ns the same no matter
whi ch di recti on i s taken. The pressure created i n the
fl ui d i s equal to the force appl i ed, di vi ded by the pi ston
area. I f the force i s 100 l bs., and the pi ston area i s 10
sq. i n., then the pressure created equal s 10 PSI .
Another i nterpretati on of Pascal s Law i s that regard-
l ess of contai ner shape or si ze, the pressure wi l l be
mai ntai ned throughout, as l ong as the fl ui d i s confi ned.
I n other words, the pressure i n the fl ui d i s the same
everywhere wi thi n the contai ner.
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 41), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 41), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept pressure i s the same every-
where means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal
l ever i ts a wei ghttodi stance output rather than a
pressuretoarea output. Usi ng the same forces and
areas as i n the previ ous exampl e, the smal l er pi ston
(Fi g. 42) has to move ten ti mes the di stance requi red
to move the l arger pi ston one i nch. Therefore, for
every i nch the l arger pi ston moves, the smal l er pi s-
ton moves ten i nches. Thi s pri nci pl e i s true i n other
i nstances al so. A common garage fl oor jack i s a good
exampl e. To rai se a car wei ghi ng 2000 l bs., an effort
of onl y 100 l bs. may be requi red. For every i nch the
car moves upward, the i nput pi ston at the jack han-
dl e must move 20 i nches downward.
Fig. 40 Pressure on a Confined Fluid
Fig. 41 Force Multiplication
Fig. 42 Piston Travel
FRONT CLUTCH
DESCRIPTION
The front cl utch assembl y (Fi g. 43) i s composed of
the front cl utch retai ner, pressure pl ate, four cl utch
pl ates, four dri vi ng di scs, pi ston, pi ston return
spri ng, return spri ng retai ner, and snap ri ngs. The
front cl utch i s the forwardmost component i n the
transmi ssi on geartrai n and i s di rectl y behi nd the oi l
pump and i s consi dered a dri vi ng component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To appl y the cl utch, pressure i s appl i ed between
the cl utch retai ner and pi ston. The fl ui d pressure i s
provi ded by the oi l pump, transferred through the
control val ves and passageways, and enters the
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved snap ri ng i s
used to cushi on the appl i cati on of the cl utch pack. I n
some transmi ssi ons, the snap ri ng i s sel ecti ve and
used to adjust cl utch pack cl earance.
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and oneway bal l checkval ve l ocated i n the
cl utch retai ner. The checkval ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
Fig. 43 Front Clutch
1 RETAINER HUB SEAL
2 CLUTCH PISTON
3 PISTON SPRING
4 SPRING RETAINER SNAP RING
5 CLUTCH DISCS
6 PRESSURE PLATE
7 SNAP RING (WAVED)
8 CLUTCH PLATES
9 SPRING RETAINER
10 PISTON SEAL
11 FRONT CLUTCH RETAINER
REAR CLUTCH
DESCRIPTION
The rear cl utch assembl y (Fi g. 44) i s composed of
the rear cl utch retai ner, pressure pl ate, three cl utch
pl ates, four dri vi ng di scs, pi ston, Bel l evi l l e spri ng,
and snap ri ngs. The Bel l evi l l e spri ng acts as a l ever
to mul ti pl y the force appl i ed on to i t by the appl y pi s-
ton. The i ncreased appl y force on the rear cl utch
pack, i n compari son to the front cl utch pack, i s
needed to hol d agai nst the greater torque l oad
i mposed onto the rear pack. The rear cl utch i s
di rectl y behi nd the front cl utch and i s consi dered a
dri vi ng component.
NOTE: The number of discs and plates may vary
with each engine and vehicle combination.
OPERATION
To appl y the cl utch, pressure i s appl i ed between
the cl utch retai ner and pi ston. The fl ui d pressure i s
provi ded by the oi l pump, transferred through the
control val ves and passageways, and enters the
cl utch through the hub of the reacti on shaft support.
Wi th pressure appl i ed between the cl utch retai ner
and pi ston, the pi ston moves away from the cl utch
retai ner and compresses the cl utch pack. Thi s acti on
appl i es the cl utch pack, al l owi ng torque to fl ow
through the i nput shaft i nto the dri vi ng di scs, and
i nto the cl utch pl ates and pressure pl ate that are
l ugged to the cl utch retai ner. The waved snap ri ng i s
used to cushi on the appl i cati on of the cl utch pack. I n
some transmi ssi ons, the snap ri ng i s sel ecti ve and
used to adjust cl utch pack cl earance.
Fig. 44 Rear Clutch
1 PISTON SPRING
2 REAR CLUTCH PISTON
3 CLUTCH PISTON SEALS
4 OUTPUT SHAFT THRUST WASHER (METAL)
6 REAR CLUTCH RETAINER
7 INPUT SHAFT
8 REAR CLUTCH THRUST WASHER (FIBER)
9 SHAFT FRONT SEAL RING (TEFLON)
10 SHAFT REAR SEAL RING (METAL)
11 CLUTCH PACK SNAP RING (SELECTIVE)
12 RETAINER SEAL RING
13 CLUTCH PLATES (3)
14 TOP PRESSURE PLATE
15 CLUTCH DISCS (4)
16 BOTTOM PRESSURE PLATE
17 WAVE SPRING
When pressure i s rel eased from the pi ston, the
spri ng returns the pi ston to i ts ful l y rel eased posi ti on
and di sengages the cl utch. The rel ease spri ng al so
hel ps to cushi on the appl i cati on of the cl utch assem-
bl y. When the cl utch i s i n the process of bei ng
rel eased by the rel ease spri ng, fl ui d fl ows through a
vent and oneway bal l checkval ve l ocated i n the
cl utch retai ner. The checkval ve i s needed to el i mi -
nate the possi bi l i ty of pl ate drag caused by centri fu-
gal force acti ng on the resi dual fl ui d trapped i n the
cl utch pi ston retai ner.
OVERRUNNING CLUTCH
DESCRIPTION
The overrunni ng cl utch (Fi g. 45) consi sts of an
i nner race, an outer race (or cam), rol l ers and
spri ngs, and the spri ng retai ner. The number of rol l -
ers and spri ngs depends on what transmi ssi on and
whi ch overrunni ng cl utch i s bei ng deal t wi th.
OPERATION
As the i nner race i s rotated i n a cl ockwi se di recti on
(as vi ewed from the front of the transmi ssi on), the
race causes the rol l ers to rol l toward the spri ngs,
causi ng them to compress agai nst thei r retai ner. The
compressi on of the spri ngs i ncreases the cl earance
between the rol l ers and cam. Thi s i ncreased cl ear-
ance between the rol l ers and cam resul ts i n a free-
wheel i ng condi ti on. When the i nner race attempts to
rotate countercl ockwi se, the acti on causes the rol l ers
to rol l i n the same di recti on as the race, ai ded by the
pushi ng of the spri ngs. As the rol l ers try to move i n
the same di recti on as the i nner race, they are
wedged between the i nner and outer races due to the
desi gn of the cam. I n thi s condi ti on, the cl utch i s
l ocked and acts as one uni t.
PLANETARY GEARSET
DESCRIPTION
The pl anetary gearsets (Fi g. 46) are desi gnated as
the front and rear pl anetary gear assembl i es and
l ocated i n such order. A si mpl e pl anetary gearset con-
si sts of three mai n members:
The sun gear whi ch i s at the center of the system.
The pl anet carri er wi th pl anet pi ni on gears
whi ch are free to rotate on thei r own shafts and are
i n mesh wi th the sun gear.
The annul us gear, whi ch rotates around and i s
i n mesh wi th the pl anet pi ni on gears.
NOTE: The number of pinion gears does not affect
the gear ratio, only the duty rating.
OPERATION
Wi th any gi ven pl anetary gearset, several condi -
ti ons must be met for power to be abl e to fl ow:
One member must be hel d.
Another member must be dri ven or used as an
i nput.
The thi rd member may be used as an output for
power fl ow.
For di rect dri ve to occur, two gear members i n
the front pl anetary gearset must be dri ven.
NOTE: Gear ratios are dependent on the number of
teeth on the annulus and sun gears.
Fig. 45 Overrunning Clutch
1 OUTER RACE (CAM)
2 ROLLER
3 SPRING
4 SPRING RETAINER
5 INNER RACE (HUB)
Fig. 46 Planetary Gearset
1 ANNULUS GEAR
2 SUN GEAR
3 PLANET CARRIER
4 PLANET PINIONS (4)
BANDS
DESCRIPTION
KICKDOWN (FRONT) BAND
The ki ckdown, or front, band (Fi g. 47) hol ds the
common sun gear of the pl anetary gear sets. The
front (ki ckdown) band i s made of steel , and faced on
i ts i nner ci rcumference wi th a fri cti ontype l i ni ng.
One end of the band i s anchored to the transmi ssi on
case, and the other i s acted on wi th a pushi ng force
by a servo pi ston. The front band i s a si ngl ewrap
desi gn (the band does not compl etel y encompass/
wrap the drum that i t hol ds).
LOW/REVERSE (REAR) BAND
The l ow/reverse band, or rear, band (Fi g. 48) i s
si mi l ar i n appearance and operati on to the front
band. The rear band of the 32RH i s sl i ghtl y di fferent
i n that i t does not use a l i nk bar, but i s acted di rectl y
on by the appl y l ever. Thi s i s referred to as a doubl e
wrap band desi gn (the drum i s compl etel y encom-
passed/wrapped by the band). The doubl ewrap band
provi des a greater hol di ng power i n compari son to
the si ngl ewrap desi gn.
OPERATION
KICKDOWN (FRONT) BAND
The ki ckdown band hol ds the common sun gear of
the pl anetary gear sets by appl yi ng and hol di ng the
front cl utch retai ner, whi ch i s spl i ned to the sun gear
dri vi ng shel l , and i n turn spl i ned di rectl y to the sun
gear. The appl i cati on of the band by the servo i s typ-
i cal l y done by an appl y l ever and l i nk bar.
LOW/REVERSE (REAR) BAND
The rear band hol ds the rear pl anet carri er sta-
ti onary by bei ng mounted around and appl i ed to the
l ow/reverse drum.
SERVOS
DESCRIPTION
KICKDOWN (FRONT) SERVO
The ki ckdown servo (Fi g. 49) consi sts of a twol and
pi ston wi th an i nner pi ston, a pi ston rod and gui de,
and a return spri ng. The dual l and pi ston uses seal
ri ngs on i ts outer di ameters and an Ori ng for the
i nner pi ston.
LOW/REVERSE (REAR) SERVO
The rear (l ow/reverse) servo consi sts of a si ngl e
stage or di ameter pi ston and a spri ng l oaded pl ug.
The spri ng i s used to cushi on the appl i cati on of the
rear (l ow/reverse) band.
OPERATION
KICKDOWN (FRONT) SERVO
The appl i cati on of the pi ston i s accompl i shed by
appl yi ng pressure between the two l ands of the pi s-
ton. The pressure acts agai nst the l arger l ower l and
to push the pi ston downward, al l owi ng the pi ston rod
to extend though i ts gui de agai nst the appl y l ever.
Rel ease of the servo at the 23 upshi ft i s accom-
pl i shed by a combi nati on of spri ng and l i ne pressure,
acti ng on the bottom of the l arger l and of the pi ston.
Fig. 47 Front Band
1 FRONT BAND
2 TRANSMISSION HOUSING
Fig. 48 Rear Band
1 PLANETARY GEARTRAIN
2 REAR BAND
3 LEVER
4 SERVO
5 ADJUSTER
The smal l pi ston i s used to cushi on the appl i cati on of
the band by bl eedi ng oi l through a smal l ori fi ce i n
the l arger pi ston. The rel ease ti mi ng of the ki ckdown
servo i s very i mportant to obtai n a smooth but fi rm
shi ft. The rel ease has to be very qui ck, just as the
front cl utch appl i cati on i s taki ng pl ace. Otherwi se,
engi ne runaway or a shi ft hesi tati on wi l l occur. To
accompl i sh thi s, the band retai ns i ts hol di ng capaci ty
unti l the front cl utch i s appl i ed, gi vi ng a smal l
amount of overl ap between them.
LOW/REVERSE (REAR) SERVO
Whi l e i n the de-energi zed state (no pressure
appl i ed), the pi ston i s hel d up i n i ts bore by the pi s-
ton spri ng. The pl ug i s hel d down i n i ts bore, i n the
pi ston, by the pl ug spri ng. When pressure i s appl i ed
to the top of the pi ston, the pl ug i s forced down i n i ts
bore, taki ng up any cl earance. As the pi ston moves, i t
causes the pl ug spri ng to compress, and the pi ston
moves down over the pl ug. The pi ston conti nues to
move down unti l i t hi ts the shoul der of the pl ug and
ful l y appl i es the band. The peri od of ti me from the
i ni ti al appl i cati on, unti l the pi ston i s agai nst the
shoul der of the pl ug, represents a reduced shocki ng
of the band that cushi ons the shi ft.
GOVERNOR
DESCRIPTION
The governor (Fi g. 50) val ve body i s attached to
the output shaft of the transmi ssi on.
OPERATION
The governor meters hydraul i c pressure (Fi g. 51), and
thi s metered pressure i s used to si gnal the transmi ssi on
when i t i s ti me for a shi ft to occur. I t does thi s by bal -
anci ng governor pressure on one si de of a shi ft val ve,
and throttl e pressure on the other. When governor pres-
sure i ncreases far enough to overcome the throttl e pres-
sure on the val ve, a shi ft occurs.
Wi th the gearshi ft sel ector i n a forward dri vi ng
range, l i ne pressure fl ows from the manual val ve and
down to the governor val ve. When the output shaft
starts to rotate wi th vehi cl e moti on (Fi g. 52), the gov-
ernor wei ght assembl y wi l l start to move outward
due to centri fugal force. As the wei ght i s moved out-
ward, i t wi l l pul l the val ve wi th i t unti l the l and of
the val ve uncovers the l i ne pressure port. As the port
begi ns to become uncovered, governor pressure i s
metered. As the vehi cl es speed conti nues to i ncrease
(Fi g. 53), the wei ght assembl y wi l l be at a poi nt at
whi ch governor pressure i s acti ng on the l eft si de of
the reacti on area of the val ve. Thi s produces suffi -
ci ent force to compress the spri ng and al l ow the
outer wei ght to move out agai nst the outer governor
body retai ni ng ri ng. At a very hi gh speed, the gover-
nor val ve wi l l be opened as far as possi bl e. I n thi s
condi ti on, i t i s possi bl e for governor pressure to meet,
but not to exceed, l i ne pressure. General l y governor
pressure ranges from 0100 psi from i dl e to maxi -
mum speed, and ri ses proporti onal l y wi th the
i ncrease i n output shaft speed. Governor pressure
and throttl e pressure are acti ng upon the shi ft val ves
to determi ne when a shi ft wi l l occur. Governor pres-
sure i s a di rect i ndi cati on of road speed, and throttl e
pressure i s an i ndi cati on of engi ne l oad. When both
parameters have been met by the throttl e and gover-
nor pressures, an upshi ft or downshi ft wi l l occur.
GEARSHIFT MECHANISM
DESCRIPTION
The shi ft mechani sm i s cabl e operated and pro-
vi des si x shi ft posi ti ons. The shi ft i ndi cator i s l ocated
on the consol e next to the gear shi ft. The shi ft posi -
ti ons are:
Park (P)
Reverse (R)
Neutral (N)
Dri ve (D)
Manual Second (2)
Manual Low (1)
OPERATION
Manual l ow (1) range provi des fi rst gear onl y. Over
run braki ng i s al so provi ded i n thi s range. Manual
second (2) range provi des fi rst and second gear onl y.
Fig. 49 Front Servo
1 VENT
2 INNER PISTON
3 PISTON
4 SPRING
5 RELEASE PRESSURE
6 APPLY PRESSURE
7 PISTON ROD
Dri ve range provi des fi rst, second, and thi rd gear
ranges.
CONVERTER DRAINBACK VALVE
DESCRIPTION
The drai nback val ve i s l ocated i n the transmi ssi on
cool er outl et (pressure) l i ne.
OPERATION
The val ve prevents fl ui d from drai ni ng from the
converter i nto the cool er and l i nes when the vehi cl e
i s shut down for l engthy peri ods. Producti on val ves
have a hose ni ppl e at one end, whi l e the opposi te end
i s threaded for a fl are fi tti ng. Al l val ves have an
arrow (or si mi l ar mark) to i ndi cate di recti on of fl ow
through the val ve.
MECHANISM
DESCRIPTION
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 54).
OPERATION
The system l ocks the shi fter i nto the PARK posi -
ti on. The I nterl ock system i s engaged whenever the
i gni ti on swi tch i s i n the LOCK or ACCESSORY posi -
ti on. An addi ti onal el ectri cal l y acti vated feature wi l l
prevent shi fti ng out of the PARK posi ti on unl ess the
brake pedal i s depressed at l east one-hal f an i nch. A
magneti c hol di ng devi ce i n l i ne wi th the park/brake
i nterl ock cabl e i s energi zed when the i gni ti on i s i n
Fig. 50 Governor
1 SEAL RING (PLAIN END)
2 SEAL RING (HOOK END)
3 PARK GEAR
4 GOVERNOR BODY
5 GOVERNOR VALVE
6 VALVE SHAFT
7 E-CLIPS (2)
8 FILTER
9 SNAP RING (THIN)
10 SNAP RING (THICK)
11 SNAP RING
12 RETAINER WASHER
13 GOVERNOR WEIGHT ASSEMBLY
14 GOVERNOR BODY BOLTS (4)
15 WASHER
the RUN posi ti on. When the key i s i n the RUN posi -
ti on and the brake pedal i s depressed, the shi fter i s
unl ocked and wi l l move i nto any posi ti on. The i nter-
l ock system al so prevents the i gni ti on swi tch from
bei ng turned to the LOCK or ACCESSORY posi ti on
(Fi g. 55) unl ess the shi fter i s ful l y l ocked i nto the
PARK posi ti on.
AUTOMATIC TRANSMISSION DIAGNOSIS
Automati c transmi ssi on probl ems can be a resul t of
poor engi ne performance, i ncorrect fl ui d l evel , i ncor-
rect l i nkage or cabl e adjustment, band or hydraul i c
control pressure adjustments, hydraul i c system mal -
functi ons or el ectri cal /mechani cal component mal -
functi ons. Begi n di agnosi s by checki ng the easi l y
accessi bl e i tems such as: fl ui d l evel and condi ti on,
l i nkage adjustments and el ectri cal connecti ons. A
road test wi l l determi ne i f further di agnosi s i s neces-
sary.
EFFECTS OF INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve, cl utch and servo operati on. Foami ng al so
causes fl ui d expansi on whi ch can resul t i n fl ui d over-
fl ow from the transmi ssi on vent or fi l l tube. Fl ui d
overfl ow can easi l y be mi staken for a l eak i f i nspec-
ti on i s not careful .
CAUSES OF BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
Fig. 51 GovernorNo Output Shaft Rotation
1 GOVERNOR PRESSURE
2 LINE PRESSURE
3 OUTPUT SHAFT
4 GOVERNOR
5 VENT
Fig. 52 GovernorModerate Output Shaft Rotation
Fig. 53 GovernorHigh Output Shaft Rotation
FLUID CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to reverse fl ush cool er and l i nes after
repai r
Fig. 54 Ignition Interlock Cable Routing
1 SHIFT MECHANISM
2 LOCK-TAB
3 IGNITION LOCK INTERLOCK
4 STEERING COLUMN
5 SOLENOID
6 WIRE CONNECTOR
7 LEVER
8 MOUNT BRACKET
9 SHIFT CABLE
10 AUTOMATIC TRANSMISSION
11 TIE STRAP
12 PARK/BRAKE INTERLOCK CABLE
Fig. 55 Ignition Key Cylinder Actuation
1 SLIDER LOCKED
2 CAM RETURN SPRING
3 INTERLOCK CABLE
4 CAM
5 SLIDER
fai l ure to repl ace contami nated converter after
repai r
The use of non recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on for some ti me, an overhaul
may al so be necessary; especi al l y i f shi ft probl ems
had devel oped.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool -
ers as wel l . The torque converter shoul d al so be
repl aced whenever a fai l ure generates sl udge and
debri s. Thi s i s necessary because normal converter
fl ushi ng procedures wi l l not remove al l contami -
nants.
PRELIMINARY DIAGNOSIS
Two basi c procedures are requi red. One procedure
for vehi cl es that are dri vabl e and an al ternate proce-
dure for di sabl ed vehi cl es (wi l l not back up or move
forward).
VEHICLE IS DRIVEABLE
(1) Check for transmi ssi on faul t codes usi ng DRB
scan tool .
(2) Check fl ui d l evel and condi ti on.
(3) Adjust throttl e and gearshi ft l i nkage i f com-
pl ai nt was based on del ayed, errati c, or harsh shi fts.
(4) Road test and note how transmi ssi on upshi fts,
downshi fts, and engages.
(5) Perform stal l test i f compl ai nt i s based on sl ug-
gi sh accel erati on. Or, i f abnormal throttl e openi ng i s
needed to mai ntai n normal speeds wi th a properl y
tuned engi ne.
(6) Perform hydraul i c pressure test i f shi ft prob-
l ems were noted duri ng road test.
(7) Perform ai r-pressure test to check cl utch-band
operati on.
VEHICLE IS DISABLED
(1) Check fl ui d l evel and condi ti on.
(2) Check for broken or di sconnected gearshi ft or
throttl e l i nkage.
(3) Check for cracked, l eaki ng cool er l i nes, or l oose
or mi ssi ng pressure-port pl ugs.
(4) Rai se and support vehi cl e on safety stands,
start engi ne, shi ft transmi ssi on i nto gear, and note
fol l owi ng:
(a) I f propel l er shaft turns but wheel s do not,
probl em i s wi th di fferenti al or axl e shafts.
(b) I f propel l er shaft does not turn and transmi s-
si on i s noi sy, stop engi ne. Remove oi l pan, and
check for debri s. I f pan i s cl ear, remove transmi s-
si on and check for damaged dri ve pl ate, converter,
oi l pump, or i nput shaft.
(c) I f propel l er shaft does not turn and transmi s-
si on i s not noi sy, perform hydraul i c-pressure test to
determi ne i f probl em i s hydraul i c or mechani cal .
PARK/NEUTRAL POSITION SWITCH
The center termi nal of the park/neutral posi ti on
swi tch i s the starter-ci rcui t termi nal . I t provi des the
ground for the starter sol enoi d ci rcui t through the
sel ector l ever i n PARK and NEUTRAL posi ti ons onl y.
The outer termi nal s on the swi tch are for the backup
l amp ci rcui t.
SWITCH TEST
To test the swi tch, remove the wi ri ng connector.
Test for conti nui ty between the center termi nal and
the transmi ssi on case. Conti nui ty shoul d exi st onl y
when the transmi ssi on i s i n PARK or NEUTRAL.
Shi ft the transmi ssi on i nto REVERSE and test
conti nui ty at the swi tch outer termi nal s. Conti nui ty
shoul d exi st onl y when the transmi ssi on i s i n
REVERSE. Conti nui ty shoul d not exi st between the
outer termi nal s and the case.
Check gearshi ft l i nkage adjustment before repl ac-
i ng a swi tch that tests faul ty.
GEARSHIFT CABLE
(1) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti onAppl y forward force on cen-
ter of handl e and remove pressure. Engi ne starts
must be possi bl e.
(b) PARK posi ti onAppl y rearward force on cen-
must be possi bl e.
(c) NEUTRAL posi ti onNormal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti onEngi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from neutral to reverse.
THROTTLE VALVE CABLE
Transmi ssi on throttl e val ve cabl e adjustment i s
extremel y i mportant to proper operati on. Thi s adjust-
ment posi ti ons the throttl e val ve, whi ch control s shi ft
speed, qual i ty, and part-throttl e downshi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve. Refer to the Adjust-
ments secti on for the proper adjustment procedure.
ROAD TESTING
Before road testi ng, be sure the fl ui d l evel and con-
trol cabl e adjustments have been checked and
adjusted i f necessary. Veri fy that di agnosti c troubl e
codes have been resol ved.
Observe engi ne performance duri ng the road test.
A poorl y tuned engi ne wi l l not al l ow accurate anal y-
si s of transmi ssi on operati on.
Operate the transmi ssi on i n al l gear ranges. Check
for shi ft vari ati ons and engi ne fl are whi ch i ndi cates
sl i ppage. Note i f shi fts are harsh, spongy, del ayed,
earl y, or i f part throttl e downshi fts are sensi ti ve.
Sl i ppage i ndi cated by engi ne fl are, usual l y means
cl utch, band or overrunni ng cl utch probl ems. I f the
condi ti on i s advanced, an overhaul wi l l be necessary
to restore normal operati on.
A sl i ppi ng cl utch or band can often be determi ned
by compari ng whi ch i nternal uni ts are appl i ed i n the
vari ous gear ranges. The Cl utch and Band Appl i ca-
ti on chart provi des a basi s for anal yzi ng road test
resul ts.
ANALYZING ROAD TEST
Refer to the Cl utch and Band Appl i cati on chart
and note whi ch el ements are i n use i n the vari ous
gear ranges.
Veri fy that the rear cl utch i s appl i ed i n al l forward
ranges (D, 2, 1). The transmi ssi on overrunni ng cl utch
i s appl i ed i n fi rst gear (D, 2 and 1 ranges) onl y. The
rear band i s appl i ed i n 1 and R range onl y.
Veri fy that the overdri ve cl utch i s appl i ed onl y i n
fourth gear and the overdri ve di rect cl utch and over-
runni ng cl utch are appl i ed i n al l ranges except fourth
gear. For exampl e: I f sl i ppage occurs i n fi rst gear i n
D and 2 range but not i n 1 range, the transmi ssi on
overrunni ng cl utch i s faul ty. Si mi l arl y, i f sl i ppage
occurs i n any two forward gears, the rear cl utch i s
sl i ppi ng.
Appl yi ng the same method of anal ysi s, veri fy that
the front and rear cl utches are appl i ed si mul ta-
neousl y onl y i n D range thi rd gear. I f the transmi s-
si on sl i ps i n thi rd gear, ei ther the front cl utch or the
rear cl utch i s sl i ppi ng.
I f sl i ppage occurs duri ng the thi rd gear and the
di rect cl utch were to fai l , the transmi ssi on woul d l ose
both reverse gear and overrun braki ng i n 2 posi ti on
(manual second gear). I f the transmi ssi on sl i ps i n
any other forward gears, the transmi ssi on rear cl utch
i s probabl y sl i ppi ng.
Thi s process of el i mi nati on can be used to i denti fy
a sl i ppi ng uni t and check operati on. Proper use of
the Cl utch and Band Appl i cati on Chart i s the key.
Al though road test anal ysi s wi l l hel p determi ne the
sl i ppi ng uni t, the actual cause of a mal functi on usu-
al l y cannot be determi ned unti l hydraul i c and ai r
pressure tests are performed. Practi cal l y any condi -
ti on can be caused by l eaki ng hydraul i c ci rcui ts or
sti cki ng val ves.
Unl ess a mal functi on i s obvi ous, such as no dri ve
i n D range fi rst gear, do not di sassembl e the trans-
mi ssi on. Perform the hydraul i c and ai r pressure tests
to hel p determi ne the probabl e cause.
HYDRAULIC PRESSURE TEST
Hydraul i c test pressures range from a l ow of one
psi (6.895 kPa) governor pressure, to 300 psi (2068
kPa) at the rear servo pressure port i n reverse.
An accurate tachometer and two test gauges are
requi red for the pressure test. Test Gauge C-3292
has a 100 psi range and i s used at the accumul ator,
Fig. 56 Clutch And Band Application
governor, and front servo pressure ports. Test Gauge
C-3293-SP has a 300 psi range and i s used at the
rear servo port and overdri ve test ports where pres-
sures are hi gher. I n cases where two test gauges are
requi red, the 300 psi gauge can be used at any of the
other test ports.
Pressure Test Port Locations
Pressure test ports l ocati ons are provi ded at the
accumul ator, front servo, and rear servo, governor
passage, and overdri ve cl utch pressure passage (Fi g.
57), (Fi g. 58) and (Fi g. 59).
Li ne pressure i s checked at the accumul ator port
on the ri ght si de of the case. The front servo pressure
port i s at the ri ght si de of the case just behi nd the
fi l l er tube openi ng.
Connect a tachometer to the engi ne. Posi ti on the
tachometer so i t can be observed from under the
vehi cl e. Rai se the vehi cl e on a hoi st that wi l l al l ow
the wheel s to rotate freel y.
PRESSURE TEST PROCEDURE
Test One - Transmission In 1 Range
Thi s test checks pump output, pressure regul ati on,
and condi ti on of the rear cl utch and servo ci rcui t.
Test Gauges C-3292 and C-3293-SP are requi red for
thi s test. Gauge C-3292 has a 100 psi range. Gauge
C-3293-SP has a 300 psi range.
(1) Connect 100 psi Gauge C-3292 to accumul ator
port.
(2) Connect 300 psi Gauge C-3293-SP to rear servo
port (Fi g. 57) and (Fi g. 58).
(3) Di sconnect throttl e and gearshi ft rods from
manual and throttl e l evers.
(4) Start and run engi ne at 1000 rpm.
(5) Move shi ft l ever (on manual l ever shaft) al l the
way forward i nto 1 range.
(6) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and note pressures on
both gauges.
(7) Li ne pressure at accumul ator port shoul d be
54-60 psi (372-414 kPa) wi th throttl e l ever forward
and gradual l y i ncrease to 90-96 psi (621-662 kPa) as
l ever i s moved rearward.
(8) Rear servo pressure shoul d be same as l i ne
pressure wi thi n 3 psi (20.68 kPa).
Test Two - Transmission In 2 Range
Thi s test checks pump output and pressure regul a-
ti on. Use 100 psi Test Gauge C-3292 for thi s test.
(1) Connect test gauge to accumul ator pressure
port (Fi g. 57) and (Fi g. 58).
(2) Start and run engi ne at 1000 rpm.
(3) Move shi ft l ever on val ve body manual l ever
shaft, one detent rearward from ful l forward posi ti on.
Thi s i s 2 range.
(4) Move transmi ssi on throttl e l ever from ful l for-
ward to ful l rearward posi ti on and read pressure at
both gauges.
Fig. 57 Pressure Test Ports At Side Of Case
1 REAR SERVO PORT
2 LINE PRESSURE PORT
3 FRONT SERVO PORT
Fig. 58 Pressure Test Ports At Rear Of Case2WD
1 GOVERNOR PRESSURE PORT
2 REAR SERVO PRESSURE PORT
Fig. 59 Pressure Test Ports At Rear Of Case4WD
1 ADAPTER HOUSING
2 GOVERNOR PRESSURE PORT PLUG
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease to 90-96 psi (621-662 kPa) as l ever i s moved
rearward.
Test Three - Transmission In D Range
Thi s test checks pressure regul ati on and condi ti on
of the cl utch ci rcui ts. Use both pressure Test Gauges
C-3292 and C-3293-SP for thi s test.
(1) Connect test gauges to accumul ator and front
servo ports (Fi g. 57) and (Fi g. 58). Use ei ther test
gauge at the two ports.
(2) Start and run engi ne at 1600 rpm for thi s test.
(3) Move sel ector l ever to D range. Thi s i s two
detents rearward from ful l forward posi ti on.
(4) Read pressures on both gauges as transmi ssi on
throttl e l ever i s moved from ful l forward to ful l rear-
ward posi ti on.
(5) Li ne pressure shoul d be 54-60 psi (372-414
kPa) wi th throttl e l ever forward and gradual l y
i ncrease as l ever i s moved rearward.
(6) Front servo i s pressuri zed onl y i n D range and
shoul d be same as l i ne pressure wi thi n 3 psi (21 kPa)
up to downshi ft poi nt.
Test Four - Transmission In Reverse
Thi s test checks pump output, pressure regul ati on
and the front cl utch and rear servo ci rcui ts. Use 300
psi Test Gauge C-3293-SP for thi s test.
(1) Connect 300 psi gauge to rear servo port (Fi g.
57) and (Fi g. 58).
(2) Start and run engi ne at 1600 rpm for test.
(3) Move val ve body sel ector l ever four detents
rearward from the ful l forward posi ti on. Thi s i s
Reverse range.
(4) Move throttl e l ever al l way forward then al l
way rearward and note gauge readi ngs.
(5) Pressure shoul d be 145 - 175 psi (1000-1207
kPa) wi th l ever forward and i ncrease to 230 - 280 psi
(1586-1931 kPa) as l ever i s moved rearward.
Test Five - Governor Pressure
Thi s test checks governor operati on by measuri ng
governor pressure response to changes i n engi ne
speed. I t i s usual l y not necessary to check governor
operati on unl ess shi ft speeds are i ncorrect or i f the
transmi ssi on wi l l not downshi ft.
(1) Connect 100 psi Test Gauge C-3292 to governor
pressure port (Fi g. 57) and (Fi g. 58).
(2) Move shi ft l ever to D range.
(3) Start and run engi ne at curb i dl e speed and
note pressure. At i dl e and wi th vehi cl e stopped, pres-
sure shoul d be zero to 1.5 psi maxi mum. I f pressure
exceeds thi s fi gure, governor val ve or wei ghts are
sti cki ng open.
(4) Sl owl y i ncrease engi ne speed and observe
speedometer and pressure test gauge. Governor pres-
sure shoul d i ncrease i n proporti on to vehi cl e speed.
(5) Pressure ri se shoul d be smooth and drop back
to 0 to 1.5 psi when wheel s stop rotati ng.
(6) Compare resul ts of pressure tests wi th anal ysi s
charts (Fi g. 60).
AIR TESTING TRANSMISSION CLUTCH AND
BAND OPERATION
Ai r-pressure testi ng can be used to check transmi s-
si on front/rear cl utch and band operati on. The test
can be conducted wi th the transmi ssi on ei ther i n the
vehi cl e or on the work bench, as a fi nal check, after
overhaul .
Ai r-pressure testi ng requi res that the oi l pan and
val ve body be removed from the transmi ssi on. The
servo and cl utch appl y passages are shown (Fi g. 61).
TEST CONDITION INDICATION
Line pressure OK during
any one test
Pump and regulator valve
OK
Line pressure OK in R
but low in D, 2, 1
Leakage in rear clutch
area (servo, clutch seals,
governor support seal
rings on park gear)
Pressure OK in 1, 2 but
low in D3 and R
Leakage in front clutch
area (servo, clutch seals,
retainer bore, pump seal
rings)
Pressure OK in 2 but low
in R and 1
Leakage in rear servo
Front servo pressure in 2 Leakage in servo (broken
servo ring or cracked
servo piston)
Pressure low in all
positions
Clogged filter, stuck
pressure regulator valve,
worn or defective pump
Governor pressure too
high at idle speed
Governor valve sticking
open
Governor pressure low at
all mph figures
Governor valve sticking
closed
Lubrication pressure low
at all throttle positions
Clogged drainback valve,
oil cooler or lines, seal
rings leaking, output shaft
plugged with devris, worn
bushings in pump or
clutch retainer
Fig. 60 Pressure Test Analysis
Front Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through front cl utch appl y pas-
sage. Pi ston movement can be fel t and a soft thump
heard as the cl utch appl i es.
Rear Clutch Air Test
Pl ace one or two fi ngers on the cl utch housi ng and
appl y ai r pressure through rear cl utch appl y passage.
Pi ston movement can be fel t and a soft thump heard
as the cl utch appl i es.
Front Servo Apply Air Test
Appl y ai r pressure to the front servo appl y pas-
sage. The servo rod shoul d extend and cause the
band to ti ghten around the drum. Spri ng pressure
shoul d rel ease the servo when ai r pressure i s
removed.
Rear Servo Air Test
Appl y ai r pressure to the rear servo appl y passage.
The servo rod shoul d extend and cause the band to
ti ghten around the drum. Spri ng pressure shoul d
rel ease the servo when ai r pressure i s removed.
DIAGNOSIS
When di agnosi ng converter housi ng fl ui d l eaks,
two i tems must be establ i shed before repai r.
(1) Veri fy that a l eak condi ti on actual l y exi sts.
(2) Determi ned the true source of the l eak.
Some suspected converter housi ng fl ui d l eaks may
not be l eaks at al l . They may onl y be the resul t of
resi dual fl ui d i n the converter housi ng, or excess
fl ui d spi l l ed duri ng factory fi l l or fi l l after repai r.
Converter housi ng l eaks have several potenti al
sources. Through careful observati on, a l eak source
can be i denti fi ed before removi ng the transmi ssi on
for repai r. Pump seal l eaks tend to move al ong the
dri ve hub and onto the rear of the converter. Pump
O-ri ng or pump body l eaks fol l ow the same path as a
seal l eak (Fi g. 62). Pump vent or pump attachi ng bol t
l eaks are general l y deposi ted on the i nsi de of the
converter housi ng and not on the converter i tsel f
(Fi g. 62). Pump seal or gasket l eaks usual l y travel
down the i nsi de of the converter housi ng. Front band
l ever pi n pl ug l eaks are general l y deposi ted on the
housi ng and not on the converter.
TORQUE CONVERTER LEAK POINTS
Possi bl e sources of converter l eaks are:
(1) Leaks at the wel d joi nt around the outsi de
di ameter wel d (Fi g. 63).
Fig. 61 Air Pressure Test Passages
1 REAR SERVO APPLY
2 FRONT SERVO APPLY
3 PUMP SUCTION
4 FRONT CLUTCH APPLY
5 FRONT SERVO RELEASE
6 LINE PRESSURE TO ACCUMULATOR
7 PUMP PRESSURE
8 TO CONVERTER
9 REAR CLUTCH APPLY
10 FROM CONVERTER
11 TO COOLER
Fig. 62 Converter Housing Leak Paths
1 PUMP SEAL
2 PUMP VENT
3 PUMP BOLT
4 PUMP GASKET
5 CONVERTER HOUSING
6 CONVERTER
7 REAR MAIN SEAL LEAK
(2) Leaks at the converter hub wel d (Fi g. 63).
CONVERTER HOUSING AREA LEAK CORRECTION
(1) Remove converter.
(2) Ti ghten front band adjusti ng screw unti l band
i s ti ght around front cl utch retai ner. Thi s prevents
front/rear cl utches from comi ng out when oi l pump i s
removed.
(3) Remove oi l pump and remove pump seal .
I nspect pump housi ng drai nback and vent hol es for
obstructi ons. Cl ear hol es wi th sol vent and wi re.
(4) I nspect pump bushi ng and converter hub. I f
bushi ng i s scored, repl ace i t. I f converter hub i s
scored, ei ther pol i sh i t wi th crocus cl oth or repl ace
converter.
(5) I nstal l new pump seal , O-ri ng, and gasket.
Repl ace oi l pump i f cracked, porous or damaged i n
any way. Be sure to l oosen the front band before
i nstal l i ng the oi l pump, damage to the oi l pump seal
may occur i f the band i s sti l l ti ghtened to the front
cl utch retai ner.
(6) Loosen ki ckdown l ever pi n access pl ug three
turns. Appl y Locti te 592, or Permatex No. 2 to pl ug
threads and ti ghten pl ug to 17 Nm (150 i n. l bs.)
torque.
(7) Adjust front band.
(8) Lubri cate pump seal and converter hub wi th
transmi ssi on fl ui d or petrol eum jel l y and i nstal l con-
verter.
(9) I nstal l transmi ssi on and converter housi ng
dust shi el d.
DIAGNOSIS CHARTS
The di agnosi s charts provi de addi ti onal reference
when di agnosi ng a transmi ssi on faul t. The charts
provi de general i nformati on on a vari ety of transmi s-
si on, overdri ve uni t and converter cl utch faul t condi -
ti ons.
The hydraul i c fl ow charts, i n the Schemati cs and
Di agrams secti on of thi s group, outl i ne fl ui d fl ow and
hydraul i c ci rcui try. Ci rcui t operati on i s provi ded for
neutral , thi rd, fourth and reverse gear ranges. Nor-
mal worki ng pressures are al so suppl i ed for each of
the gear ranges.
Fig. 63 Converter Leak PointsTypical
1 OUTSIDE DIAMETER WELD
2 TORQUE CONVERTER HUB WELD
3 STARTER RING GEAR
4 LUG
DIAGNOSIS CHART
HARSH ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE
1. Fluid Level Low 1. Add Fluid
2. Throttle Linkage Misadjusted 2. Adjust linkage - setting may be too long.
3. Mount and Driveline Bolts Loose 3. Check engine mount, transmission
mount, propeller shaft, rear spring to body
bolts, rear control arms, crossmember and
axle bolt torque. Tighten loose bolts and
replace missing bolts.
4. U-Joint Worn/Broken 4. Remove propeller shaft and replace
U-Joint.
5. Axle Backlash Incorrect 5. Check per Service Manual. Correct as
needed.
6. Hydraulic Pressure Incorrect 6. Check pressure. Remove, overhaul or
adjust valve body as needed.
7. Band Misadjusted. 7. Adjust rear band.
8. Valve Body Check Balls Missing. 8. Inspect valve body for proper check ball
installation.
9. Axle Pinion Flange Loose. 9. Replace nut and check pinion threads
before installing new nut. Replace pinion
gear if threads are damaged.
10. Clutch, band or planetary
component Damaged.
10. Remove, disassemble and repair
transmission as necessary.
11. Converter Clutch (if equipped)
Faulty.
11. Replace converter and flush cooler and
line before installing new converter.
DELAYED ENGAGEMENT
FROM NEUTRAL TO
DRIVE OR REVERSE
1. Fluid Level Low. 1. Correct level and check for leaks.
2. Filter Clogged. 2. Change filter.
3. Gearshift Linkage Misadjusted. 3. Adjust linkage and repair linkage if worn
or damaged.
4. Rear Band Misadjusted. 4. Adjust band.
5. Valve Body Filter Plugged. 5. Replace fluid and filter. If oil pan and old
fluid were full of clutch disc material and/or
metal particles, overhaul will be necessary.
6. Oil Pump Gears Worn/Damaged. 6. Remove transmission and replace oil
pump.
7. Hydraulic Pressure Incorrect. 7. Perform pressure test, remove
transmission and repair as needed.
8. Reaction Shaft Seal Rings
Worn/Broken.
8. Remove transmission, remove oil pump
and replace seal rings.
9. Rear Clutch/Input Shaft, Rear
Clutch Seal Rings Damaged.
9. Remove and disassemble transmission
10. Governor Valve Stuck. 10. Remove and inspect governor
components. Replace worn or damaged
parts.
11. Regulator Valve Stuck. 11. Clean.
12. Cooler Plugged. 12. Flush transmission cooler and inspect
convertor drainback valve.
NO DRIVE RANGE
(REVERSE OK)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.
2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission
and rear clutch and seals. Repair/replace
worn or damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body.
Replace assembly if any valves or bores
are damaged.
5. Transmission Overrunning Clutch
Broken.
5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings Worn/
Damaged.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR REVERSE
(VEHICLE WILL NOT
MOVE)
1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
Loose/Misadjusted.
2. Inspect, adjust and reassemble linkage
as needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.
3. Perform preliminary inspection procedure
for vehicle that will not move. Refer to
procedure in diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission.
Repair or replace failed components as
needed. Replace filter. If filter and fluid
contained clutch material or metal particles,
an overhaul may be necessary. Perform
lube flow test. Flush oil. Replace cooler as
necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low
pressure. Replace pump body assembly if
necessary.
6. Valve Body Malfunctioned. 6. Check press and inspect valve body.
Replace valve body (as assembly) if any
valve or bore is damaged. Clean and
reassemble correctly if all parts are in good
condition.
7. Transmission Internal Component
Damaged.
Repair or replace failed components as
needed. Remove and disassemble
transmission. Repair or replace failed
components as needed.
8. Park Sprag not Releasing 8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Check Stall Speed, Worn/Damaged/
Stuck. Inspect and replace as required.
SHIFTS DELAYED OR
ERRATIC (SHIFTS ALSO
HARSH AT TIMES)
1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if
low.
2. Throttle Linkage Misadjusted. 2. Adjust linkage as described in service
section.
3. Throttle Linkage Binding. 3. Check cable for binding. Check for return
to closed throttle at transmission.
Misadjusted.
4. Adjust linkage/cable as described in
service section.
5. Fluid Filter Clogged. 5. Replace filter. If filter and fluid contained
clutch material or metal particles, an
overhaul may be necessary. Perform lube
flow test.
6. Governor Valve Sticking. 6. Inspect, clean or repair.
7. Governor Seal Rings Worn/
Damaged.
7. Inspect/replace.
8. Clutch or Servo Failure. 8. Remove valve body and air test clutch,
and band servo operation. Disassemble
and repair transmission as needed.
9. Front Band Misadjusted. 9. Adjust band.
10. Pump Suction Passage Leak. 10. Check for excessive foam on dipstick
after normal driving. Check for loose pump
bolts, defective gasket. Replace pump
assembly if needed.
NO REVERSE (D RANGES
OK)
Misadjusted/Damaged.
1. Repair or replace linkage parts as
needed.
2. Park Sprag Sticking. 2. Inspect and replace as necessary.
3. Rear Band Misadjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace
valve body if any valves or valve bores are
worn or damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as
necessary.
6. Front Clutch Burnt. 6. Remove and disassemble transmission.
Replace worn, damaged clutch parts as
required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)
1. Governor Valve, Shaft, Weights or
Body Damaged/Stuck.
1. Remove governor assembly and clean or
repair as necessary.
2. Valve Body Malfunction. 2. Stuck 1-2 shift valve or governor plug.
3. Front Servo/Kickdown Band
Damaged/Burned.
3. Repair/replace.
MOVES IN 2ND OR 3RD
GEAR, ABRUPTLY
DOWNSHIFTS TO LOW
1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for
stuck 1-2 valve or governor plug.
2. Governor Valve Sticking. 2. Remove, clean and inspect. Replace
faulty parts.
NO LOW GEAR (MOVES
IN 2ND OR 3RD GEAR
ONLY)
1. Governor Valve Sticking. 1. Remove governor, clean, inspect and
repair as required.
2. Valve Body Malfunction. 2. Remove, clean and inspect. Look for
sticking 1-2 shift valve, 2-3 shift valve,
governor plug or broken springs.
3. Front Servo Piston Cocked in
Bore.
3. Inspect servo and repair as required.
4. Front Band Linkage Malfunction 4. Inspect linkage and look for bind in
linkage.
NO KICKDOWN OR
NORMAL DOWNSHIFT
1. Throttle Linkage Misadjusted. 1. Adjust linkage.
2. Accelerator Pedal Travel
Restricted.
2. Floor mat under pedal, accelerator cable
worn or brackets bent.
3. Governor/Valve Body Hydraulic
Pressures Too High or Too Low Due
to Sticking Governor, Valve Body
Malfunction or Incorrect Hydraulic
Control Pressure Adjustments.
3. Perform hydraulic pressure tests to
determine cause and repair as required.
Correct valve body pressure adjustments as
required.
4. Valve Body Malfunction. 4. Perform hydraulic pressure tests to
Correct valve body pressure adjustments as
required.
5. Valve Body Malfunction. 5. Sticking 1-2, 2-3 shift valves, or governor
plugs.
STUCK IN LOW GEAR
(WILL NOT UPSHIFT)
1. Throttle Linkage Misadjusted/
Stuck.
1. Adjust linkage and repair linkage if worn
or damaged. Check for binding cable or
missing return spring.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage and repair linkage if worn
or damaged.
3. Governor/Valve Body, Governor
Valve Stuck Closed; Loose Output
Shaft Support or Governor Housing
Bolts, Leaking Seal Rings or Valve
Body Problem (i.e., Stuck 1- 2 Shift
Valve/Gov. Plug).
3. Check line and governor pressures to
determine cause. Correct as required.
4. Front Band Out of Adjustment. 4. Adjust Band.
5. Clutch or Servo Malfunction. 5. Air pressure check operation of clutches
and bands. Repair faulty component.
CREEPS IN NEUTRAL 1. Gearshift Linkage Misadjusted. 1. Adjust linkage.
2. Rear Clutch Dragging/Warped
Welded.
2. Disassemble and repair.
3. Valve Body Malfunction. 3. Perform hydraulic pressure test to
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Misassembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Misassembled. 3. Remove, disassemble, inspect valve
body. Reassemble correctly if necessary.
Replace assembly if valves or springs are
damaged. Check for loose bolts or screws.
4. Pump Passages Leaking 4. Check pump for porous casting, scores
on mating surfaces and excess rotor
clearance. Repair as required. Loose pump
bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as
needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE ONLY 1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Misadjusted. 2. Adjust linkage.
4. Rear Band Worn. 4. Replace as required.
5. Hydraulic Pressure Too Low. 5. Perform hydraulic pressure tests to
determine cause.
6. Rear Servo Leaking. 6. Air pressure check clutch-servo operation
and repair as required.
7. Band Linkage Binding. 7. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump
gasket or seals, dirt between pump halves
and loose pump bolts. Replace pump if
necessary.
3. Throttle Linkage Misadjusted. 3. Adjust linkage.
4. Gearshift Linkage Misadjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking
Governor, Leaking Seal Rings,
Clutch Seals Leaking, Servo Leaks,
Clogged Filter or Cooler Lines
6. Perform hydraulic and air pressure tests
to determine cause.
7. Rear Clutch Malfunction, Leaking
Seals or Worn Plates.
7. Air pressure check clutch-servo operation
and repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).
8. Replace Clutch.
SLIPS IN LOW GEAR D
ONLY, BUT NOT IN 1
POSITION
Overrunning Clutch Faulty. Replace overrunning clutch.
GROWLING, GRATING OR
SCRAPING NOISES
1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.
2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.
3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/Broken. 4. Inspect and check for debris in oil pan.
Repair as required.
5. Oil Pump Components Scored/
Binding.
5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.
6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Misadjusted.
8. Adjust bands.
DRAGS OR LOCKS UP 1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and
repair as required.
3. Front or Rear Band Misadjusted. 3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in
case.
5. Servo Band or Linkage
Malfunction.
5. Air pressure check servo operation and
repair as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as
required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required
(look for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow
check. Inspect pump for excessive side
clearance. Replace pump as required.
WHINE/NOISE RELATED
TO ENGINE SPEED
1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing.
Should not touch engine or bell housing.
TORQUE CONVERTER
LOCKS UP IN SECOND
AND/OR THIRD GEAR
Lockup Solenoid, Relay or Wiring
Shorted/Open.
Test solenoid, relay and wiring for
continuity, shorts or grounds. Replace
solenoid and relay if faulty. Repair wiring
and connectors as necessary.
HARSH 1-2 OR 2-3
SHIFTS
Lockup Solenoid Malfunction. Remove valve body and replace solenoid
assembly.
NO START IN PARK OR
NEUTRAL
Misadjusted.
1. Adjust linkage/cable.
2. Neutral Switch Wire Open/Cut. 2. Check continuity with test lamp. Repair
as required.
3. Neutral Switch Faulty. 3. Refer to service section for test and
replacement procedure.
4. Neutral Switch Connect Faulty. 4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.
5. Inspect lever assembly and replace if
damaged.
NO REVERSE (OR SLIPS
IN REVERSE)
1. Direct Clutch Pack (front clutch)
Worn.
1. Disassemble unit and rebuild clutch
pack.
3. Front Clutch Malfunctioned/Burnt. 3. Air pressure test clutch operation.
Remove and rebuild if necessary.
OIL LEAKS (ITEMS
LISTED REPRESENT
POSSIBLE LEAK POINTS
AND SHOULD ALL BE
CHECKED.
1. Speedometer Adapter Leaks. 1. Replace both adapter seals.
2. Fluid Lines and Fittings Loose/
Leaks/Damaged.
2. Tighten fittings. If leaks persist, replace
fittings and lines if necessary.
3. Filler Tube (where tube enters
case) Leaks/Damaged.
3. Replace O-ring seal. Inspect tube for
cracks in tube.
4. Pressure Port Plug Loose
Loose/Damaged.
4. Tighten to correct torque. Replace plug
or reseal if leak persists.
5. Pan Gasket Leaks. 5. Tighten pan screws to 150 inch pounds.
If leaks persist, replace gasket. Do no over
tighten screws.
6. Valve Body Manual Lever Shaft
Seal Leaks/Worn.
6. Replace shaft seal.
7. Rear Bearing Access Plate Leaks. 7. Replace gasket. Tighten screws.
8. Gasket Damaged or Bolts are
Loose.
8. Replace bolts or gasket or tighten both.
9. Adapter/Extension Gasket
Damaged Leaks/Damaged.
9. Replace gasket.
10. Neutral Switch Leaks/Damaged. 10. Replace switch and gasket.
11. Converter Housing Area Leaks. 11. Check for leaks at seal caused by worn
seal or burr on converter hub (cutting seal),
worn bushing, missing oil return, oil in front
pump housing or hole plugged. Check for
leaks past O-ring seal on pump or past
pump-to-case bolts; pump housing porous,
oil coming out vent due to overfill or leak
past front band shaft access plug.
12. Pump Seal Leaks/Worn/
Damaged.
12. Replace seal.
13. Torque Converter Weld
Leak/Cracked Hub.
13. Replace converter.
14. Case Porosity Leaks. 14. Replace case.
SERVICE PROCEDURES
FLUID LEVEL CHECK
Transmi ssi on fl ui d l evel shoul d be checked monthl y
under normal operati on. I f the vehi cl e i s used for
trai l er towi ng or si mi l ar heavy l oad haul i ng, check
fl ui d l evel and condi ti on weekl y. Fl ui d l evel i s
checked wi th the engi ne runni ng at curb i dl e speed,
the transmi ssi on i n NEUTRAL and the transmi ssi on
fl ui d at normal operati ng temperature.
FLUID LEVEL CHECK PROCEDURE
(1) Transmi ssi on fl ui d must be at normal operat-
i ng temperature for accurate fl ui d l evel check. Dri ve
vehi cl e i f necessary to bri ng fl ui d temperature up to
normal hot operati ng temperature of 82C (180F).
(3) Start and run engi ne at curb i dl e speed.
(4) Appl y parki ng brakes.
(5) Shi ft transmi ssi on momentari l y i nto al l gear
ranges. Then shi ft transmi ssi on back to Neutral .
(6) Cl ean top of fi l l er tube and di psti ck to keep
di rt from enteri ng tube.
(7) Remove di psti ck (Fi g. 64) and check fl ui d l evel
as fol l ows:
(a) Correct acceptabl e l evel i s i n crosshatch area.
(b) Correct maxi mum l evel i s to MAX arrow
mark.
(c) I ncorrect l evel i s at or bel ow MI N l i ne.
(d) I f fl ui d i s l ow, add onl y enough Mopar ATF
Pl us 3 to restore correct l evel . Do not overfi l l .
CAUTION: Do not overfill the transmission. Overfill-
ing may cause leakage out the pump vent which
can be mistaken for a pump seal leak. Overfilling
will also cause fluid aeration and foaming as the
excess fluid is picked up and churned by the gear
train. This will significantly reduce fluid life.
FLUID AND FILTER REPLACEMENT
Refer to the Mai ntenance Schedul es i n Group 0,
Lubri cati on and Mai ntenance, for proper servi ce
i nterval s. The servi ce fl ui d fi l l after a fi l ter change i s
approxi matel y 3.8 l i ters (4.0 quarts).
REMOVAL
(2) Remove the transmi ssi on/ski p pl ate as neces-
sary to access the transmi ssi on oi l pan.
(3) Pl ace a l arge di ameter shal l ow drai n pan
beneath the transmi ssi on pan.
(4) Remove bol ts hol di ng front and si des of pan to
transmi ssi on (Fi g. 65).
(5) Loosen bol ts hol di ng rear of pan to transmi s-
si on.
(6) Sl owl y separate front of pan away from trans-
mi ssi on al l owi ng the fl ui d to drai n i nto drai n pan.
(7) Hol d up pan and remove remai ni ng bol ts hol d-
i ng pan to transmi ssi on.
(8) Whi l e hol di ng pan l evel , l ower pan away from
transmi ssi on.
(9) Pour remai ni ng fl ui d i n pan i nto drai n pan.
(10) Remove screws hol di ng fi l ter to val ve body
(Fi g. 66).
(11) Separate fi l ter from val ve body and pour fl ui d
i n fi l ter i nto drai n pan.
(12) Di spose used trans fl ui d and fi l ter properl y.
INSPECTION
I nspect bottom of pan and magnet for excessi ve
amounts of metal or fi ber contami nati on. A l i ght
coati ng of cl utch or band materi al on the bottom of
the pan does not i ndi cate a probl em unl ess accompa-
ni ed by sl i ppi ng condi ti on or shi ft l ag. I f fl ui d and
pan are contami nated wi th excessi ve amounts or
debri s, refer to the di agnosi s secti on of thi s group.
Check the adjustment of the front and rear bands,
adjust i f necessary. Refer to Adjustment secti on of
thi s group for proper procedure.
Fig. 64 Dipstick Fluid Level MarksTypical
1 DIPSTICK
2 MAXIMUM CORRECT FLUID LEVEL
3 ACCEPTABLE FLUID LEVEL
Fig. 65 Transmission PanTypical
1 GASKET
2 PAN
3 TRANSMISSION
CLEANING
(1) Usi ng a sui tabl e sol vent, cl ean pan and magnet.
(2) Usi ng a sui tabl e gasket scraper, cl ean gasket
materi al from gasket surface of transmi ssi on case
and the gasket fl ange around the pan.
INSTALLATION
(1) Pl ace repl acement fi l ter i n posi ti on on val ve
body.
(2) I nstal l screws to hol d fi l ter to val ve body (Fi g.
66). Ti ghten screws to 4 Nm (35 i n. l bs.) torque.
(3) Pl ace new gasket i n posi ti on on pan. and
i nstal l pan on transmi ssi on.
(4) Pl ace pan i n posi ti on on transmi ssi on.
(5) I nstal l screws to hol d pan to transmi ssi on (Fi g.
65). Ti ghten bol ts to 17 Nm (150 i n. l bs.) torque.
(6) I nstal l the transmi ssi on/ski p pl ate.
(7) Lower vehi cl e and fi l l transmi ssi on wi th
Mopar ATF Pl us 3, type 7176 fl ui d.
TRANSMISSION FILL PROCEDURE
To avoi d overfi l l i ng transmi ssi on after a fl ui d
change or overhaul , perform the fol l owi ng procedure:
(1) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(2) Add fol l owi ng i ni ti al quanti ty of Mopar ATF
Pl us 3 to transmi ssi on:
(a) I f onl y fl ui d and fi l ter were changed, add 3
pints (1-1/2 quarts) of ATF Pl us 3 to transmi ssi on.
(b) I f transmi ssi on was compl etel y overhaul ed,
torque converter was repl aced or drai ned, and
cool er was fl ushed, add 12 pints (6 quarts) of ATF
Pl us 3 to transmi ssi on.
(4) Start and run engi ne at normal curb i dl e speed.
(5) Appl y servi ce brakes, shi ft transmi ssi on through
al l gear ranges then back to NEUTRAL, set parki ng
brake, and l eave engi ne runni ng at curb i dl e speed.
(6) Remove funnel , i nsert di psti ck and check fl ui d
l evel . I f l evel i s l ow, add fluid to bring level to
MIN mark on dipstick. Check to see i f the oi l l evel
i s equal on both si des of the di psti ck. I f one si de i s
noti cabl y hi gher than the other, the di psti ck has
pi cked up some oi l from the di psti ck tube. Al l ow the
oi l to drai n down the di psti ck tube and re-check.
(7) Dri ve vehi cl e unti l transmi ssi on fl ui d i s at nor-
mal operati ng temperature.
(8) Wi th the engi ne runni ng at curb i dl e speed, the
gear sel ector i n NEUTRAL, and the parki ng brake
appl i ed, check the transmi ssi on fl ui d l evel .
CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.
(9) Add fl ui d to bri ng l evel up to MAX arrow mark.
When fl ui d l evel i s correct, shut engi ne off, rel ease
park brake, remove funnel , and i nstal l di psti ck i n fi l l
tube.
SERVICE
The converter drai nback check val ve i s l ocated i n
the cool er outl et (pressure) l i ne near the radi ator
tank. The val ve prevents fl ui d drai nback when the
vehi cl e i s parked for l engthy peri ods. The val ve check
bal l i s spri ng l oaded and has an openi ng pressure of
approxi matel y 2 psi .
The val ve i s servi ced as an assembl y; i t i s not repai r-
abl e. Do not cl ean the val ve i f restri cted, or contami -
nated by sl udge, or debri s. I f the val ve fai l s, or i f a
transmi ssi on mal functi on occurs that generates si gni fi -
cant amounts of sl udge and/or cl utch parti cl es and
metal shavi ngs, the val ve must be repl aced.
The val ve must be removed whenever the cool er
and l i nes are reverse fl ushed. The val ve can be fl ow
tested when necessary. The procedure i s exactl y the
same as for fl ow testi ng a cool er.
I f the val ve i s restri cted, i nstal l ed backwards, or i n
the wrong l i ne, i t wi l l cause an overheati ng condi ti on
and possi bl e transmi ssi on fai l ure.
CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.
OIL PUMP VOLUME CHECK
Measuri ng the oi l pump output vol ume wi l l deter-
mi ne i f suffi ci ent oi l fl ow to the transmi ssi on oi l
Fig. 66 Transmission FilterTypical
1 FILTER
2 TRANSMISSION
cool er exi sts, and whether or not an i nternal trans-
mi ssi on fai l ure i s present.
Veri fy that the transmi ssi on fl ui d i s at the proper
l evel . Refer to the Fl ui d Level Check procedure i n
thi s secti on. I f necessary, fi l l the transmi ssi on to the
proper l evel wi th Mopar ATF+3, type 7176, Auto-
mati c Transmi ssi on Fl ui d.
(1) Di sconnect the To cooler l i ne at the cool er
i nl et and pl ace a col l ecti ng contai ner under the di s-
connected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed , wi th the
shi ft sel ector i n neutral .
(3) I f one quart of transmi ssi on fl ui d i s col l ected i n
the contai ner i n 20 seconds or l ess, oi l pump fl ow vol -
ume i s wi thi n acceptabl e l i mi ts. I f fl ui d fl ow i s i nter-
mi ttent, or i t takes more than 20 seconds to col l ect
one quart of fl ui d, refer to the Hydraul i c Pressure
tests i n thi s secti on for further di agnosi s.
(4) Re-connect the To cooler l i ne to the transmi s-
si on cool er i nl et.
(5) Refi l l the transmi ssi on to proper l evel .
FLUSHING COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The torque
converter must al so be repl aced. Thi s wi l l i nsure that
metal parti cl es or sl udged oi l are not l ater trans-
ferred back i nto the recondi ti oned (or repl aced) trans-
mi ssi on.
The onl y recommended procedure for fl ushi ng cool -
ers and l i nes i s to use Tool 6906A Cool er Fl usher.
CAUTION: The transmission oil cooler requires a
two stage flushing procedure due to an internally
mounted thermostat. Failure to follow the procedure
can result in severe transmission damage.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover pl ate fi l l er pl ug on Tool 6906A.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906A.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Remove the transmi ssi on oi l cool er from the
vehi cl e. Refer to the Group 7, Cool i ng System, for the
proper procedures.
(8) Remove the transmi ssi on oi l cool er thermostat.
Refer to the Group 7, Cool i ng System, for the proper
procedures.
(9) Re-i nstal l the thermostat cover onto the oi l
cool er and i nstal l the snap ri ng.
(10) Re-connect the oi l cool er to the transmi ssi on
cool er l i nes.
(11) Turn pump ON for two to three mi nutes to
fl ush cool er(s) and l i nes.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
(13) Remove the thermostat cover from the oi l
cool er.
(14) I nstal l Speci al Tool Cool er Pl ug 8414 i nto the
transmi ssi on oi l cool er.
NOTE: This flushes the main oil cooler core pas-
sages only.
(16) Turn pump OFF.
cool er.
(18) Remove Speci al Tool Cool er Pl ug 8414 from
the transmi ssi on oi l cool er.
(19) I nstal l a new thermostat spri ng, thermostat,
cover, and snap-ri ng i nto the transmi ssi on oi l cool er.
(20) I nstal l the transmi ssi on oi l cool er onto the
vehi cl e.
(21) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(22) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(23) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF Pl us 3, type 7176 automati c
transmi ssi on fl ui d.
(24) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(25) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts
of dri l l i ng out the worn-out damaged threads. Then
tap the hol e wi th a speci al Hel i -Coi l tap, or equi va-
l ent, and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent,
i nto the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are readi l y
avai l abl e from most automoti ve parts suppl i ers.
TRANSMISSION
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid 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
(2) Di sconnect and l ower or remove necessary
exhaust components.
(3) Remove engi ne-to-transmi ssi on bendi ng braces.
(4) Di sconnect fl ui d cool er l i nes at transmi ssi on.
(5) Remove starter motor.
(6) Di sconnect and remove crankshaft posi ti on sen-
sor (Fi g. 67). Retai n sensor attachi ng bol ts.
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is left in place. To avoid damage,
remove the sensor before removing the transmis-
sion.
(7) Remove torque converter access cover.
(8) I f transmi ssi on i s bei ng removed for overhaul ,
remove transmi ssi on oi l pan, drai n fl ui d and rei nstal l
pan.
(9) Remove ski d pl ate for access.
(10) Remove the fi l l tube bracket bol ts and pul l tube
out of transmi ssi on. Retai n fi l l tube seal . On 4 x 4 mod-
el s, i t wi l l al so be necessary to remove bol t attachi ng
transfer case vent tube to converter housi ng.
(11) Rotate crankshaft i n cl ockwi se di recti on unti l
converter bol ts are accessi bl e. Then remove bol ts one
at a ti me. Rotate crankshaft wi th socket wrench on
dampener bol t.
(12) Mark propel l er shaft and axl e yokes for
assembl y al i gnment. Then di sconnect and remove
propel l er shafts.
(13) Di sconnect wi res from park/neutral posi ti on
swi tch and vehi cl e speed sensor.
(14) Di sconnect gearshi ft cabl e from transmi ssi on
manual val ve l ever.
(15) Di sconnect throttl e val ve cabl e from transmi s-
si on bracket and throttl e val ve l ever.
(16) Di sconnect shi ft rod from transfer case shi ft
l ever or remove shi ft l ever from transfer case.
Fig. 67 Crankshaft Position Sensor2.5L Engine
1 EXHAUST DOWN PIPE
3 CRANKSHAFT POSITION SENSOR
(17) Support rear of engi ne wi th safety stand or
jack.
(18) Rai se transmi ssi on sl i ghtl y wi th servi ce jack
to rel i eve l oad on crossmember and supports.
(19) Remove bol ts securi ng rear support and cush-
i on to transmi ssi on and crossmember. Rai se trans-
mi ssi on sl i ghtl y, sl i de exhaust hanger arm from
bracket and remove rear support.
(20) Remove bol ts attachi ng crossmember to frame
and remove crossmember.
(21) Di sconnect transfer case vent hose. Then di s-
connect vacuum swi tch harness.
(23) Remove al l converter housi ng bol ts.
(24) Careful l y work transmi ssi on and torque con-
verter assembl y rearward off engi ne bl ock dowel s.
(25) Hol d torque converter i n pl ace duri ng trans-
mi ssi on removal .
(26) Lower transmi ssi on and remove assembl y
from under the vehi cl e.
(27) To remove torque converter, careful l y sl i de
torque converter out of the transmi ssi on.
INSTALLATION
(1) Check torque converter hub and hub dri ve
notches for sharp edges burrs, scratches, or ni cks.
Pol i sh the hub and notches wi th 320/400 gri t paper
and crocus cl oth i f necessary. The hub must be
smooth to avoi d damagi ng pump seal at i nstal l ati on.
(2) Lubri cate converter dri ve hub and oi l pump
seal l i p wi th transmi ssi on fl ui d.
(3) Al i gn converter and oi l pump.
(4) Careful l y i nsert converter i n oi l pump. Then
rotate converter back and forth unti l ful l y seated i n
pump gears.
(5) Check converter seati ng wi th steel scal e and
strai ghtedge (Fi g. 68). Surface of converter l ugs
shoul d be 1/2 i n. to rear of strai ghtedge when con-
verter i s ful l y seated.
(6) Temporari l y secure converter wi th C-cl amp.
(7) Lubri cate the pocket i n the rear of the crank-
shaft, i n whi ch the converter pi l ot hub ri des, wi th a
l i ght coati ng of Mopar Hi gh-Temp Grease.
(8) Posi ti on transmi ssi on on jack and secure i t
wi th safety chai ns.
(9) Check condi ti on of converter dri vepl ate.
Repl ace the pl ate i f cracked, di storted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Rai se transmi ssi on and al i gn converter wi th
dri ve pl ate and converter housi ng wi th engi ne bl ock.
(11) Move transmi ssi on forward. Then rai se, l ower
or ti l t transmi ssi on to al i gn converter housi ng wi th
engi ne bl ock dowel s.
(12) Careful l y work transmi ssi on forward and over
engi ne bl ock dowel s unti l converter hub i s seated i n
crankshaft.
(13) I nstal l and ti ghten bol ts that attach transmi s-
si on converter housi ng to engi ne bl ock (Fi g. 69).
CAUTION: Be sure the converter housing is fully
seated on the engine block dowels before tighten-
ing any bolts.
(14) I nstal l torque converter attachi ng bol ts.
Ti ghten bol ts to fol l owi ng torque.
54 Nm (40 ft. l bs.) wi th 9.5 i n. 3-l ug converter
31 Nm (270 i n. l bs.) wi th 10.75 i n. 4-l ug con-
verter
(15) I nstal l crankshaft posi ti on sensor.
(16) I nstal l transmi ssi on fi l l tube and seal . I nstal l
new fi l l tube seal i n transmi ssi on before i nstal l ati on.
(17) Connect transmi ssi on cool er l i nes to transmi s-
si on.
(18) I nstal l transfer case onto transmi ssi on.
(19) I nstal l rear crossmember and attach trans-
mi ssi on rear support to crossmember.
(20) Remove engi ne support fi xture.
(21) Remove transmi ssi on jack.
(22) Connect vehi cl e speed sensor wi res.
(23) Connect wi res to park/neutral posi ti on swi tch.
(24) I nstal l crankshaft posi ti on sensor.
(25) I nstal l converter housi ng access cover.
(26) I nstal l exhaust pi pes and support brackets, i f
removed.
Fig. 68 Typical Method Of Checking Converter Seating
1 SCALE
2 STRAIGHTEDGE
(27) I nstal l starter motor and cool er l i ne bracket.
(28) I nstal l new pl asti c retai ner grommet on any
shi ft l i nkage rod or l ever that was di sconnected.
Grommets shoul d not be reused. Use pry tool to
remove rod from grommet and cut away ol d grom-
met. Use pl i ers to snap new grommet i nto l ever and
to snap rod i nto grommet at assembl y.
(29) Connect gearshi ft and l i nkage and throttl e
cabl e.
(30) Connect transfer case shi ft l i nkage.
(31) Adjust gearshi ft l i nkage and throttl e val ve
cabl e i f necessary.
(32) Al i gn and connect propel l er shaft(s).
(33) I nstal l ski d pl ate, rear cushi on and bracket, i f
removed.
(34) Fi l l transfer case to bottom edge of fi l l pl ug
hol e.
(35) Lower vehi cl e and fi l l transmi ssi on to correct
l evel wi th Mopar ATF Pl us 3, type 7176 fl ui d.
TORQUE CONVERTER
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate converter hub and oi l pump seal l i p
wi th transmi ssi on fl ui d.
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
Fig. 69 Transmission Attachment
BOLT SET-TO SERVE
TORQUE
A 35 Nm (26 ft-lbs)
B 33 Nm (24 ft-lbs)
C 57 Nm (42 ft-lbs)
D 16 Nm (138 in-lbs)
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
YOKE SEAL REPLACEMENT
REMOVAL
(2) Mark propel l er shaft and axl e yoke for al i gn-
ment reference.
(3) Di sconnect and remove propel l er shaft.
(4) Remove ol d seal wi th Seal Remover C-3985-B
(Fi g. 71) from extensi on housi ng.
INSTALLATION
(1) Pl ace seal i n posi ti on on extensi on housi ng.
(2) Dri ve seal i nto extensi on housi ng wi th Seal
I nstal l er C-3995-A or C-3972 (Fi g. 72).
(3) Careful l y gui de propel l er shaft sl i p yoke i nto
housi ng and onto output shaft spl i nes. Al i gn marks
made at removal and connect propel l er shaft to rear
axl e pi ni on yoke.
EXTENSION HOUSING BUSHING
REMOVAL
(1) Remove housi ng yoke seal .
(2) I nsert Remover 6957 i nto extensi on housi ng.
Ti ghten tool to bushi ng and remove bushi ng (Fi g.
73).
INSTALLATION
(1) Al i gn bushi ng oi l hol e wi th oi l sl ot i n extensi on
housi ng.
(2) Tap bushi ng i nto pl ace wi th I nstal l er 6951 and
Handl e C-4171.
(3) I nstal l new oi l seal i n housi ng usi ng Seal
I nstal l er C-3995A (Fi g. 74).
ADAPTER HOUSING
REMOVAL
(2) Support transmi ssi on wi th a sui tabl e l i fti ng
devi ce.
(3) Remove transmi ssi on ski d pl ate. Refer to
Group 13, Frame and Bumpers, for proper procedure.
Fig. 70 Checking Torque Converter Seating
1 SCALE
2 STRAIGHTEDGE
Fig. 71 Removing Extension Housing Yoke Seal
2 SEAL
Fig. 72 Installing Extension Housing Yoke Seal
(4) Remove propel l er shafts. Refer to Group 3, Di f-
ferenti al and Dri vel i ne, for proper procedure.
(6) Remove bol ts hol di ng adapter housi ng to trans-
mi ssi on case (Fi g. 75).
(7) Separate adapter housi ng from transmi ssi on.
(8) Sl i de adapter housi ng rearward and off output
shaft (Fi g. 75).
INSTALLATION
Cl ear gasket materi al from seal i ng surfaces on
adapter housi ng and rear of transmi ssi on. Repl ace
output shaft beari ng, i f necessary.
(1) I nstal l new rear seal i n adapter housi ng. Use
Tool Handl e C-4171 and Seal I nstal l er C-3860-A to
i nstal l seal .
(2) Pl ace adapter housi ng gasket i n posi ti on on
rear of transmi ssi on.
(3) Sl i de adapter housi ng forward and over output
shaft (Fi g. 75).
(4) Gui de park shaft i nto park sprag and push
adapter housi ng forward unti l rod passes through
openi ng behi nd sprag. I t may be necessary to use a
wi re to hol d sprag to the si de for rod to pass through.
(5) I nstal l bol ts to hol d adapter housi ng to rear of
transmi ssi on.
(6) I nstal l transfer case.
(7) I nstal l propel l er shafts.
(8) I nstal l rear transmi ssi on mount and ski d pl ate.
(9) Lower vehi cl e and veri fy transmi ssi on fl ui d
l evel . Add fl ui d as necessary.
SPEEDOMETER ADAPTER
Rear axl e gear rati o and ti re si ze determi ne speed-
ometer pi ni on requi rements.
REMOVAL
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 76).
(4) Remove speed sensor and speedometer adapter
as assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 76).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
Fig. 73 Bushing RemovalTypical
1 REMOVER 6957
2 EXTENSION HOUSING BUSHING
Fig. 74 Extension Housing Seal Installation
Fig. 75 Adapter Housing
1 TRANSMISSION
2 GASKET
3 ADAPTER HOUSING
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter i f necessary (Fi g. 76).
(3) Lubri cate sensor and adapter O-ri ngs wi th
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 Nm
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 77).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 ocl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 Nm (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel , i f necessary.
REMOVAL
(1) Rai se vehi cl e and posi ti on drai n pan under
swi tch.
(2) Di sconnect swi tch wi res.
(3) Remove swi tch from case.
Fig. 76 Speedometer Pinion Adapter Components
1 SENSOR O-RING
2 SPEEDOMETER ADAPTER
3 ADAPTER O-RING
4 SPEEDOMETER PINION
5 ADAPTER CLAMP
ITEM TORQUE
A 2-3 Nm (15-27 in. lbs.)
B 10-12 Nm (90-110 in. lbs.)
Fig. 77 Index Numbers On Speedometer Pinion
Adapter
2 INDEX NUMBER LOCATION
INSTALLATION
(1) Move shi ft l ever to Park and Neutral posi ti ons.
Veri fy that swi tch operati ng l ever fi ngers are cen-
tered i n swi tch openi ng i n case (Fi g. 78).
(2) I nstal l new seal on swi tch and i nstal l swi tch i n
case. Ti ghten swi tch to 34 Nm (25 ft. l bs.) torque.
(3) Test conti nui ty of new swi tch wi th 12V test
l amp.
(4) Connect swi tch wi res and l ower vehi cl e.
(5) Top off transmi ssi on fl ui d l evel .
GEARSHIFT CABLE
REMOVAL
(1) Shi ft transmi ssi on i nto Park.
(2) Remove shi ft l ever bezel and necessary consol e
parts for access to shi ft l ever assembl y.
(3) Di sconnect cabl e at shi ft l ever and feed cabl e
through dash panel openi ng to undersi de of vehi cl e.
(5) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng
bracket. Then remove ol d cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n dash panel . Ful l y
seat cabl e grommet i nto dash panel .
(2) Pl ace the auto transmi ssi on manual shi ft con-
trol l ever i n Park detent (rearmost) posi ti on and
rotate prop shaft to ensure transmi ssi on i s i n park.
(3) Connect shi ft cabl e to shi fter mechani sm by
snappi ng cabl e retai ni ng ears i nto shi fter bracket
and press cabl e end fi tti ng onto l ever bal l stud.
(4) Pl ace the fl oor shi fter l ever i n park posi ti on.
Ensure that the pawl i s seated wi thi n the confi nes of
the adjustment gauge cl i p.
(5) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
(6) Lock shi ft cabl e i nto posi ti on by pushi ng
upward on the adjusti ng l ock button.
(7) Remove and di scard the shi ft cabl e adjustment
gauge cl i p from the park gate of the shi fter.
REMOVAL
(1) Remove l ower steeri ng col umn cover. Refer to
Group 8E, I nstrument Panel and Gauges, for proper
procedure.
(2) Remove l ower steeri ng col umn shroud. Refer to
Group 19, Steeri ng, for proper procedure.
(3) Remove ti e strap near the sol enoi d retai ni ng
the brake transmi ssi on i nterl ock cabl e to the steeri ng
col umn.
(4) Di sengage wi re connector from sol enoi d.
(5) Wi th the i gni ti on removed or i n the unl ocked
posi ti on, di sengage l ock tab hol di ng cabl e end to
steeri ng col umn (Fi g. 79).
(6) Pul l cabl e end from steeri ng col umn.
(7) Remove the fl oor consol e and rel ated tri m.
Refer to Group 23, Body, for proper procedure.
(8) Di sconnect the cabl e eyel et from the bel l crank
(Fi g. 80).
(9) Di sconnect and remove the cabl e from the shi ft
bracket.
Fig. 78 Park/Neutral Position Switch
1 NEUTRAL CONTACT
2 MANUAL LEVER AND SWITCH PLUNGER IN REVERSE
POSITION
3 PARK CONTACT
4 SWITCH
Fig. 79 Brake/Park Interlock Cable
1 IGNITION LOCK
2 LOCK TAB
3 CABLE END
INSTALLATION
(1) Route repl acement cabl e behi nd i nstrument
panel and under fl oor consol e area to shi ft mecha-
ni sm (Fi g. 80).
(2) I nsert cabl e end i nto openi ng i n steeri ng col -
umn hub under i gni ti on l ock. Push cabl e i nward
unti l l ock tab engages.
(3) Connect the cabl e end eyel et onto shi fter
bel l crank pi n.
(4) Pl ace gear sel ector i n PARK.
(5) Push the spri ng-l oaded cabl e adjuster forward
and snap cabl e i nto bracket.
(6) Adjust the brake transmi ssi on shi fter i nterl ock
cabl e. Refer to the Adjustment porti on of thi s secti on
(7) Veri fy that the cabl e adjuster l ock cl amp i s
pushed downward to the l ocked posi ti on.
(8) Test the park-l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
(10) I nstal l ti e strap to hol d cabl e to base of steer-
i ng col umn.
(11) I nstal l l ower steeri ng col umn shroud and i gni -
ti on l ock.
(12) I nstal l l ower steeri ng col umn cover.
VALVE BODY
REMOVAL
(2) Remove oi l pan and drai n fl ui d.
(3) Loosen cl amp bol ts and remove throttl e and
manual val ve l evers from manual l ever shaft.
(4) Remove park/neutral posi ti on swi tch.
(5) Remove fi l ter from val ve body.
(6) Depress retai ni ng cl i p and pul l sol enoi d wi re
from case connector (Fi g. 81).
(7) Remove val ve body attachi ng screws.
(8) Lower val ve body enough to remove accumul a-
tor pi ston and pi ston spri ng (Fi g. 82).
Fig. 80 Cable and Shifter
1 SHIFT MECHANISM
2 LOCK-TAB
4 STEERING COLUMN
5 SOLENOID
6 WIRE CONNECTOR
7 LEVER
8 MOUNT BRACKET
9 SHIFT CABLE
11 TIE STRAP
(9) Pul l val ve body forward to di sengage park rod.
(10) Push manual l ever shaft and sol enoi d case
connector out of transmi ssi on case.
(11) Lower val ve body, rotate i t away from case,
pul l park l ock rod out of sprag, and remove val ve
body (Fi g. 83).
INSTALLATION
(1) Veri fy that park/neutral posi ti on swi tch i s NOT
i nstal l ed. Val ve body cannot be i nstal l ed wi th swi tch
i n pl ace. Remove swi tch i f necessary.
(2) I nstal l new seal s on accumul ator pi ston i f nec-
essary, and i nstal l pi ston i n case. Use smal l amount
of petrol eum jel l y to hol d pi ston i n pl ace.
(3) Pl ace val ve body manual l ever i n l ow (1 posi -
ti on) to ease i nserti ng park rod i nto sprag.
(4) Use screwdri ver to push park sprag i nto
engagement wi th park gear. Thi s makes cl earance for
knob on l ock rod to move past sprag when val ve body
i s i nstal l ed. Rotate output shaft to veri fy sprag
engagement.
(5) Posi ti on accumul ator spri ng between accumul a-
tor pi ston and val ve body.
(6) Posi ti on val ve body on transmi ssi on and work
knob on park l ock rod past sprag. Be sure accumul a-
tor pi ston and spri ng remai n i n posi ti on.
(7) Hol d val ve body i n posi ti on and i nstal l val ve
body screws fi nger ti ght.
(8) I nstal l park/neutral posi ti on swi tch.
(9) Ti ghten val ve body screws al ternatel y and
evenl y to 11 Nm (100 i n. l bs.) torque.
(10) I nstal l new fl ui d fi l ter on val ve body. I nstal l
and ti ghten fi l ter screws to 4 Nm (35 i n. l bs.) torque.
(11) Connect sol enoi d wi re to case connector.
(12) I nstal l manual and throttl e l evers on throttl e
l ever shaft. Ti ghten l ever cl amp screws and check for
free operati on. Shaft and l evers must operate freel y
wi thout any bi nd.
(13) I nstal l oi l pan and new gasket. Ti ghten pan
bol ts to 17 Nm (150 i n. l bs.) torque. I nstal l gasket
dry; do not use seal er.
(14) Connect park/neutral posi ti on swi tch and con-
verter cl utch sol enoi d wi res.
(15) I nstal l speedometer pi ni on gear, adapter and
speed sensor.
Fig. 81 Solenoid Wire Connector
1 PUSH CLIP IN
2 PULL
3 CONVERTER CLUTCH SOLENOID CONNECTOR
Fig. 82 Accumulator Piston And Springs
2 OUTER SPRING
3 PISTON SEAL RINGS
4 INNER SPRING (32RH)
Fig. 83 Valve Body
1 VALVE BODY
2 CONVERTER CLUTCH MODULE
3 SOLENOID
4 PARK ROD
6 MANUAL VALVE
7 MANUAL LEVER
(17) Fi l l transmi ssi on wi th Mopar ATF Pl us 3,
Type 7176 fl ui d.
(18) Adjust gearshi ft and throttl e cabl e i f neces-
sary.
OUTPUT SHAFT REAR BEARING
REMOVAL
(1) Remove extensi on housi ng.
(2) Remove snap ri ng that retai ns rear beari ng on
output shaft (Fi g. 84).
(3) Remove beari ng from output shaft.
INSTALLATION
(1) I nstal l beari ng on output shaft. Be sure retai n-
i ng ri ng groove i n outer ci rcumference of beari ng i s
toward the governor.
(2) I nstal l rear beari ng retai ni ng snap ri ng (Fi g.
84).
(3) I nstal l extensi on housi ng.
GOVERNOR AND PARK GEAR
REMOVAL
(2) Mark propel l er shaft and axl e yoke for assem-
bl y reference. Then di sconnect and remove shaft.
(3) Di sconnect parki ng brake cabl e at equal i zer
and di sconnect exhaust components as necessary.
(4) Support transmi ssi on on a sui tabl e l i fti ng
devi ce.
(5) Remove ski d pl ate and rear transmi ssi on
mount.
(7) Loosen but do not remove bol ts that hol d gov-
ernor body to park gear.
(8) Rotate transmi ssi on output shaft unti l gover-
nor wei ght assembl y i s accessi bl e.
(9) Remove E-cl i p at end of governor val ve shaft
(Fi g. 85).
(10) Remove governor val ve and shaft from gover-
nor body (Fi g. 85).
(11) Remove snap ri ngs and spacer that retai n
governor body and park gear assembl y on output
shaft (Fi g. 86).
(12) Remove bol ts hol di ng governor body to park
gear (Fi g. 87).
(13) Separate governor from park gear.
(14) Pul l park gear from rear support.
Fig. 84 Output Shaft Rear BearingTypical
1 BEARING SNAP RING GROOVE
2 PARK LOCK CONTROL ROD
3 REAR SNAP RING
Fig. 85 Governor Valve
1 E-CLIP
2 PARK GEAR
3 CURVER BOSS
4 GOVERNOR VALVE
5 GOVERNOR
Fig. 86 Snap Rings And Spacer
1 GOVERNOR BODY
2 THIN SNAP RING
3 THRUST WASHER
4 THICK SNAP RING
INSTALLATION
(1) I nstal l park gear i nto rear support so crown on
curved boss i s i n l i ne wi th hol e through output shaft.
(2) I nstal l governor fi l ter i n park gear.
(3) Sl i p governor body over output shaft and al i gn
port to fi l ter.
(4) I nstal l bol ts to hol d governor body to park gear.
Ti ghten bol ts to 11 Nm (95 i n. l bs.) torque (Fi g. 87).
(5) I nstal l governor body-park gear snap ri ngs and
washer on output shaft as fol l ows:
(a) I nstal l thi n snap ri ng fi rst. Then i nstal l
thrust washer second, and thi ck snap ri ng l ast
(Fi g. 86).
(b) Veri fy correct posi ti on of snap ri ngs. Be sure
flat side of each snap ring is toward governor
body.
(6) I nsert governor val ve and shaft through gover-
nor and i nstal l E-cl i p (Fi g. 85).
(7) I nstal l extensi on housi ng and gasket on trans-
mi ssi on. Ti ghten housi ng bol ts to 32 Nm (24 ft. l bs.).
(8) I nstal l rear transmi ssi on mount and ski d pl ate.
(9) I nstal l speed sensor and speedometer compo-
nents and connect speed sensor wi res.
(10) Connect exhaust components and brake cabl e,
i f removed.
(11) I nstal l propel l er shaft.
(12) Remove supports and l ower vehi cl e.
(13) Check transmi ssi on fl ui d l evel . Add fl ui d i f
necessary.
PARK LOCK
REMOVAL
(1) Rai se vehi cl e and remove propel l er shaft.
(3) Sl i de sprag shaft out of extensi on housi ng and
remove sprag and spri ng (Fi g. 88).
(4) Remove snap ri ng and sl i de reacti on pl ug and
pi n assembl y out of housi ng.
(5) I f park rod requi res servi ce, i t wi l l be necessary
to remove val ve body.
INSTALLATION
(1) I nspect sprag shaft for scores and free move-
ment i n housi ng and sprag. I nspect sprag and control
rod spri ngs for di storti on and l oss of tensi on. repl ace
worn, damaged parts as necessary.
(2) I nspect square l ug on sprag for broken edges.
Check l ugs on park gear for damage. I nspect knob on
end of control rod for wear grooves, or bei ng sei zed
on rod. Repl ace rod i f bent, i f knob i s worn/grooved,
or i t has sei zed on rod. Repl ace park gear i f l ugs are
damaged. Repl ace the park l ock rod i f i t i s suspected
that the rod i s not the correct l ength.
(3) I nstal l reacti on pl ug and pi n assembl y i n hous-
i ng and secure wi th new snap ri ng (Fi g. 88).
(4) Posi ti on sprag and spri ng i n housi ng and i nsert
sprag shaft. Be sure square l ug on sprag i s toward
park gear. Al so be sure spri ng i s posi ti oned so i t
moves sprag away from gear.
(5) I nstal l extensi on housi ng.
(6) I nstal l propel l er shaft and l ower vehi cl e.
(7) Check transmi ssi on fl ui d l evel . Add fl ui d i f nec-
essary.
DISASSEMBLY
(1) Remove governor body from transmi ssi on.
(2) Cl ean and i nspect governor fi l ter (Fi g. 89).
(3) Remove snap ri ng and washer that secure gov-
ernor wei ght assembl y i n body (Fi g. 90).
(4) Remove governor wei ght assembl y from gover-
nor body bore.
(5) Sl i de i ntermedi ate and i nner wei ght from outer
wei ght.
(6) Posi ti on i ntermedi ate wei ght on sui tabl e si ze
socket (Fi g. 91).
(7) Push i nner wei ght downward wi th nut dri ver.
Then remove i nner wei ght snap ri ng wi th Mi l l er
Pl i er Tool 6823 (Fi g. 91).
(8) Remove i nner wei ght and spri ng from i nterme-
di ate wei ght.
Fig. 87 Governor Body
1 GOVERNOR/PARK ASSEMBLY
2 GOVERNOR VALVE SHAFT BORE
3 REAR SUPPORT
4 OUTPUT SHAFT SPLINES
5 SEAL RINGS
ASSEMBLY
CAUTION: Exercise care when installing the rings.
They are easily broken if overspread or twisted dur-
ing installation.
I f i t was necessary to remove the park gear,
i nspect the seal ri ngs and bore i n rear support.
Fig. 88 Park Lock
1 EXTENSION HOUSING
2 SPRAG
3 8
4 SHAFT
5 E-CLIP
6 SPRING
7 CONTROL ROD
8 SNAP RING
9 PLUG AND PIN
10 SPRING
Fig. 89 Governor Filter
1 GOVERNOR FILTER
2 PARK GEAR
Fig. 90 Snap Ring, Washer, and Outer Weight
1 SNAP-RING
2 E-CLIP
3 PARK GEAR
4 GOVERNOR VALVE
5 SHAFT
6 GOVERNOR
7 OUTER WEIGHT
8 INTERMEDIATE WEIGHT
9 WASHER
Fig. 91 Inner Weight Snap Ring
1 NUT DRIVER
2 SUITABLE SIZE SOCKET
4 INNER WEIGHT SNAP RING
5 SPECIAL TOOL 6823
I nstal l new seal ri ngs on park gear hub onl y i f ori g-
i nal ri ngs are damaged, or worn. I nstal l ri ng wi th
i nterl ock ends fi rst and ri ng wi th pl ai n ends l ast.
Sl i p each ri ng on hub and seat them i n grooves. Ver-
i fy that rear ri ng ends are securel y i nterl ocked before
proceedi ng. I f the bore i n rear support i s damaged,
repl ace the rear support.
(1) Lubri cate governor components wi th Mopar
ATF Pl us 3, Type 7176 transmi ssi on fl ui d before
assembl y.
(2) Cl ean and i nspect governor wei ghts and bores
for scori ng or wear. Repl ace the governor body and
wei ghts i f damaged. Refer to Cl eani ng and I nspecti on
secti on of thi s group for proper procedure.
(3) I nsert spri ng i nto i ntermedi ate wei ght.
(4) I nsert i nner wei ght i nto i ntermedi ate wei ght
and i nstal l snap-ri ng (Fi g. 92). Veri fy snap-ri ng i s
ful l y seated i n groove i n i ntermedi ate wei ght (Fi g.
91).
(5) Assembl e governor wei ghts i nto governor body
(Fi g. 90).
(6) I nstal l washer and snap ri ng to hol d wei ghts i n
governor body.
(7) I nstal l governor body i n transmi ssi on
VALVE BODY
DISASSEMBLY
Posi ti on the val ve body on a cl ean work surface to
avoi d contami nati on.
CAUTION: Do not clamp any part of the valve body
assembly (Fig. 93) in a vise. This practice will dis-
tort the valve body and transfer plate resulting in
valve bind. Slide valves and plugs out carefully. Do
not use force at any time. The valves and valve
body will be damaged if force is used. Also tag or
mark the valve body springs for reference as they
are removed. Do not allow them to become inter-
mixed.
(1) Remove screws attachi ng adjusti ng screw
bracket to val ve body and transfer pl ate. Hol d
bracket fi rml y agai nst spri ng force whi l e removi ng
l ast screw.
(2) Remove adjusti ng screw bracket, l i ne pressure
adjusti ng screw (Fi g. 94).
(3) Remove swi tch val ve and spri ng, pressure reg-
ul ator val ve and spri ng, ki ckdown val ve and spri ng,
and throttl e val ve from val ve body (Fi g. 94).
(4) Secure detent bal l and spri ng i n housi ng wi th
Retai ner Tool 6583 (Fi g. 95).
(5) Remove manual shaft E-cl i p, washer, and seal
(Fi g. 96).
(6) Pul l manual shaft and park rod assembl y
upward out of val ve body and off throttl e l ever (Fi g.
96).
(7) Remove manual val ve from val ve body (Fi g. 97)
(8) Remove Retai ner Tool 6583. Then remove and
retai n detent bal l and spri ng (Fi g. 96).
(9) Remove throttl e l ever (Fi g. 96).
(10) Remove park rod E-cl i p and separate rod from
manual l ever (Fi g. 98).
Fig. 92 Intermediate and Inner Governor Weights
2 INNER WEIGHT
3 SNAP-RING
1 VALVE BODY
2 CONVERTER CLUTCH MODULE
3 SOLENOID
4 PARK ROD
6 MANUAL VALVE
7 MANUAL LEVER
(11) Remove converter cl utch sol enoi d from separa-
tor pl ate (Fi g. 99). A T25 torx bi t i s requi red to
remove sol enoi d attachi ng screw.
(12) Remove screws attachi ng converter cl utch
modul e to val ve body and remove modul e and con-
necti ng tube (Fi g. 100).
(13) Remove screws attachi ng end cover pl ate to
torque converter modul e (Fi g. 101).
(14) Remove converter cl utch val ve, fai l safe val ve,
and spri ngs (Fi g. 101)
(15) Turn val ve body over so transfer pl ate i s fac-
i ng upward (Fi g. 102). Wi th val ve body i n thi s posi -
ti on, val ve body check bal l s wi l l remai n i n pl ace and
not fal l out when transfer pl ate i s removed.
(16) Remove screws attachi ng transfer pl ate to
val ve body (Fi g. 102).
(17) Remove transfer pl ate and separator pl ate
from val ve body (Fi g. 102). Note posi ti on of fi l ter and
cl utch sol enoi d for reference. Remove val ve body
check bal l s.
Fig. 94 Adjusting Screw Bracket, Springs, Valve
Removal
1 ADJUSTER BRACKET
4 SWITCH VALVE
5 VALVE BODY
6 TRANSFER PLATE
7 THROTTLE VALVE
8 SLEEVE
9 KICKDOWN VALVE
Fig. 95 Securing Detent Ball And Spring With
Retainer Tool
1 SPECIAL TOOL 6583
2 DETENT BALL AND SPRING HOUSING
Fig. 96 Manual And Throttle Levers
1 PARK ROD
2 E-RING
3 WASHER
4 MANUAL LEVER
5 MANUAL VALVE
6 SPRING
7 DETENT BALL
8 VALVE BODY
1 MANUAL VALVE
2 VALVE BODY
(18) Posi ti on transfer pl ate on bench so separator
pl ate, and fi l ter are faci ng up. Thi s wi l l avoi d havi ng
rear cl utch and rear servo check bal l s fal l out when
pl ates are separated.
(19) Remove screws attachi ng separator pl ate to
transfer pl ate (Fi g. 103).
(20) Note posi ti on of fi l ter, rear cl utch servo and
rear servo check bal l s for assembl y reference (Fi g.
103) and (Fi g. 104).
(21) Remove shuttl e val ve end pl ate (Fi g. 105).
(22) Remove shuttl e val ve E-cl i p and remove sec-
ondary spri ng and spri ng gui des from end of val ve
(Fi g. 106).
Fig. 100 Clutch Module And Connecting Tube
1 MODULE AND CONNECTING TUBE
Fig. 98 Park Rod
1 MANUAL LEVER
2 E-CLIP
3 PARK ROD
Fig. 99 Converter Clutch Solenoid
1 VALVE BODY
2 TORQUE CONVERTER CLUTCH SOLENOID
Fig. 101 Converter Clutch and Fail Safe Valves
1 COVER PLATE
2 CONVERTER CLUTCH VALVE
3 TORQUE CONVERTER CLUTCH MODULE
4 MODULE CONNECTING TUBE
5 FAIL-SAFE VALVE
Fig. 102 Valve Body Transfer Plate Screws
1 TRANSFER PLATE
2 VALVE BODY
3 SEPARATOR PLATE
(23) Remove governor pl ug end pl ate (Fi g. 107).
(24) Remove 1-2 and 2-3 shi ft val ve governor pl ugs
from val ve body (Fi g. 107).
(25) Remove shuttl e val ve throttl e pl ug, pri mary
spri ng and shuttl e val ve from val ve body (Fi g. 107).
(26) Remove screws attachi ng ki ckdown l i mi t
val ve body to val ve body (Fi g. 107).
(27) Remove 1-2 shi ft control val ve and spri ng
from val ve body (Fi g. 107).
(28) Remove 2-3 shi ft val ve and spri ng from val ve
body (Fi g. 107).
(29) Remove 1-2 shi ft val ve and spri ng from val ve
body (Fi g. 107).
(30) Remove throttl e pressure pl ug from ki ckdown
l i mi t val ve body (Fi g. 107).
(31) Remove retai ner from end of ki ckdown l i mi t
(32) Remove ki ckdown l i mi t val ve and spri ng from
ki ckdown l i mi t val ve body (Fi g. 107).
(33) Remove regul ator val ve end pl ate from val ve
body (Fi g. 107).
(34) Remove regul ator val ve l i ne pressure pl ug,
pressure pl ug sl eeve, regul ator val ve throttl e pres-
sure pl ug and spri ng (Fi g. 107).
ASSEMBLY
Cl ean and i nspect al l val ve body components for
damage or wear. Refer to the Cl eani ng and I nspec-
ti on secti on of thi s group for proper procedure.
Fig. 103 Transfer And Separator Plates
1 SEPARATOR PLATE
2 FILTER
3 TRANSFER PLATE
Fig. 104 Rear Servo and Rear Clutch Check Balls
1 REAR SERVO CHECK BALL
2 TRANSFER PLATE
3 REAR CLUTCH CHECK BALL
Fig. 105 Shuttle Valve End Plate
1 VALVE BODY
2 SHUTTLE VALVE END PLATE
Fig. 106 Shuttle Valve E-Clip And Secondary Spring
1 E-CLIP
2 SECONDARY SPRING AND GUIDES
3 SHUTTLE VALVE
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves,
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the valve body resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
(1) Lubri cate val ve body bores, val ves and pl ugs
wi th Mopar ATF Pl us 3, Type 7176, transmi ssi on
fl ui d.
(2) I nstal l regul ator val ve l i ne pressure pl ug, pres-
sure pl ug sl eeve, regul ator val ve throttl e pressure
pl ug, and spri ng i nto val ve body (Fi g. 107). Veri fy
val ve components sl i de freel y.
(3) I nstal l regul ator val ve end pl ate on val ve body
(Fi g. 107).
(4) I nstal l ki ckdown l i mi t val ve and spri ng i n ki ck-
down l i mi t val ve body (Fi g. 107). Veri fy val ve compo-
nents sl i de freel y.
(5) Compress spri ng i nto ki ckdown l i mi t val ve
body.
(6) I nstal l retai ner i n grooves at end of ki ckdown
l i mi t val ve body (Fi g. 107).
(7) I nstal l throttl e pressure pl ug i n ki ckdown l i mi t
(8) I nstal l 1-2 shi ft val ve and spri ng i nto val ve
body (Fi g. 107).
(9) I nstal l 2-3 shi ft val ve and spri ng i nto val ve
body (Fi g. 107).
(10) I nstal l 1-2 shi ft control val ve and spri ng i nto
(11) Veri fy val ve components sl i de freel y.
Fig. 107 Control Valves, Shift Valves, And Governor Plugs
2 SHUTTLE VALVE
3 12 GOVERNOR PLUG
4 VALVE BODY
6 SLEEVE
8 RETAINER
9 12 SHIFT VALVE
12 END PLATE
15 E-RING
16 23 SHIFT VALVE
17 GUIDES
18 23 GOVERNOR PLUG
19 PRIMARY SPRING
(12) Pl ace ki ckdown l i mi t val ve body and end pl ate
i n posi ti on on val ve body and compress spri ngs (Fi g.
107).
(13) I nstal l screws to attach ki ckdown l i mi t val ve
body to val ve body (Fi g. 107).
(14) I nstal l shuttl e val ve throttl e pl ug, pri mary
spri ng and shuttl e val ve i nto val ve body (Fi g. 107).
Veri fy val ve components sl i de freel y.
(15) I nstal l 1-2 and 2-3 shi ft val ve governor pl ugs
i nto val ve body (Fi g. 107). Veri fy val ve components
sl i de freel y.
(16) Pl ace governor pl ug end pl ate i n posi ti on on
val ve body and compress spri ng.
(17) I nstal l screws to attach governor pl ug end
pl ate to val ve body (Fi g. 107).
(18) Assembl e shuttl e val ve spri ng and gui des
(Fi g. 107). Pl ace spri ng and gui des i n posi ti on on
shuttl e val ve stem.
(19) Compress spri ng and i nstal l E-cl i p i n groove
on shuttl e val ve stem (Fi g. 108).
(20) Pl ace shuttl e val ve end pl ate i n posi ti on on
(21) I nstal l screws to attach shuttl e val ve end
pl ate to val ve body (Fi g. 109).
(22) I nstal l rear cl utch servo and rear servo check
bal l s i n proper cavi ti es i n transfer pl ate (Fi g. 110).
(23) I nsert fi l ter i nto openi ng i n separator pl ate
(Fi g. 111).
(24) Pl ace separator pl ate i n posi ti on on transfer
pl ate and i nstal l screws to attach separator pl ate to
transfer pl ate (Fi g. 111).
(25) Pl ace one 11/32 i n. check bal l and si x 1/4 i n.
check bal l s i n the proper cavi ti es i n the val ve body
(Fi g. 112).
(26) Pl ace transfer pl ate i n posi ti on on val ve body
(Fi g. 113).
(27) I nstal l screws to attach transfer pl ate to val ve
body (Fi g. 113).
(28) Turn val ve body over to expose the separator
pl ate.
(29) I nsert converter cl utch val ve and spri ng i nto
converter cl utch val ve modul e (Fi g. 114). Veri fy val ve
components sl i de freel y.
(30) I nsert spri ng and fai l -safe val ve i nto converter
cl utch val ve modul e (Fi g. 114). Veri fy val ve compo-
nents sl i de freel y.
(31) Pl ace cover pl ate i n posi ti on on converter
cl utch val ve modul e (Fi g. 114).
(32) I nstal l screws to attach cover to converter
cl utch val ve modul e (Fi g. 114).
Fig. 108 Shuttle Valve E-Clip And Secondary Spring
1 E-CLIP
2 SECONDARY SPRING AND GUIDES
3 SHUTTLE VALVE
Fig. 109 Shuttle Valve End Plate
1 VALVE BODY
2 SHUTTLE VALVE END PLATE
Fig. 110 Rear Servo and Rear Clutch Check Balls
1 REAR SERVO CHECK BALL
2 TRANSFER PLATE
3 REAR CLUTCH CHECK BALL
(33) I nsert connecti ng tube i nto converter cl utch
val ve modul e (Fi g. 114).
(34) I nsert connecti ng tube i nto val ve body open-
i ng (Fi g. 115).
(35) Pl ace converter cl utch val ve modul e i n posi -
ti on on separator pl ate. I nstal l screws to attach con-
verter cl utch modul e to val ve body (Fi g. 115).
(36) I f necessary, i nstal l a new O-ri ng on converter
cl utch sol enoi d (Fi g. 116).
(37) I nsert converter cl utch sol enoi d i nto transfer
pl ate (Fi g. 116).
(38) I nstal l screw to attach sol enoi d to transfer
pl ate (Fi g. 116).
(39) I f necessary, i nsert park rod end i nto manual
l ever and i nstal l E-cl i p (Fi g. 117).
(40) I nsert detent spri ng and bal l i nto openi ng i n
val ve body and i nstal l Retai ner Tool 6583 (Fi g. 118).
(41) I nstal l manual val ve i nto val ve body (Fi g.
119).
(42) I nsert throttl e l ever through transfer pl ate
si de of val ve body and upward (Fi g. 120).
(43) I nsert throttl e l ever i nto groove i n manual
val ve (Fi g. 121).
(44) I nstal l seal , washer, and E-cl i p to retai n man-
ual shaft to val ve body (Fi g. 120).
(45) I nstal l swi tch val ve and spri ng, pressure reg-
ul ator val ve and spri ng, ki ckdown val ve and spri ng,
and throttl e val ve i nto val ve body (Fi g. 122).
Fig. 111 Transfer And Separator Plates
1 SEPARATOR PLATE
2 FILTER
3 TRANSFER PLATE
Fig. 112 Correct Position Of Valve Body Check Balls
1 1/4 CHECK BALLS (6)
2 11/32 CHECK BALL (1)
Fig. 114 Converter Clutch Valve Module
1 COVER PLATE
2 CONVERTER CLUTCH VALVE
3 TORQUE CONVERTER CLUTCH MODULE
4 MODULE CONNECTING TUBE
5 FAIL-SAFE VALVE
Fig. 115 Clutch Module And Connecting Tube
1 MODULE AND CONNECTING TUBE
(46) Pl ace adjusti ng screw bracket and l i ne pres-
sure adjusti ng screw i n posi ti on on val ve body and
compress spri ngs (Fi g. 94).
(47) I nstal l screws to attach adjuster bracket to
val ve body.
TRANSMISSION
DISASSEMBLY
(1) Remove transmi ssi on from vehi cl e.
(2) I nstal l a sui tabl e tai l shaft housi ng pl ug to
avoi d contami nati ng i nternal components wi th cl ean-
i ng sol vents.
(3) Cl ean exteri or of transmi ssi on wi th sui tabl e
sol vent or pressure washer.
(4) Remove torque converter from transmi ssi on.
(5) Remove throttl e and shi ft l evers from val ve
body manual shaft and throttl e l ever shaft.
(6) Mount transmi ssi on i n repai r stand C-3750-B
or si mi l ar type stand (Fi g. 123).
(8) Remove fl ui d pan.
(9) Remove park/neutral posi ti on swi tch and seal
(Fi g. 124).
(10) Remove val ve body.
(11) Remove accumul ator spri ng and pi ston (Fi g.
125).
(12) Loosen front band adjusti ng screw l ock nut
(Fi g. 126) 4-5 turns. Then ti ghten band adjusti ng
Fig. 113 Valve Body Transfer Plate Screws
1 TRANSFER PLATE
2 VALVE BODY
3 SEPARATOR PLATE
Fig. 116 Converter Clutch Solenoid
1 VALVE BODY
2 TORQUE CONVERTER CLUTCH SOLENOID
Fig. 117 Park Rod
1 MANUAL LEVER
2 E-CLIP
3 PARK ROD
Fig. 118 Securing Detent Ball And Spring With
Retainer Tool
1 SPECIAL TOOL 6583
2 DETENT BALL AND SPRING HOUSING
screw unti l band i s ti ght around front cl utch. Thi s
prevents front/rear cl utches from comi ng out wi th
pump and possi bl y damagi ng cl utch or pump compo-
nents.
(13) Remove oi l pump bol ts.
(14) Thread bol ts of Sl i de Hammer Tool s C-3752
i nto threaded hol es i n pump body fl ange (Fi g. 127).
(15) Bump sl i de hammer wei ghts outward to
remove pump and reacti on shaft support assembl y
from case (Fi g. 127).
(16) Loosen front band adjusti ng screw unti l band
i s compl etel y l oose (Fi g. 126).
(17) Squeeze front band together and remove band
strut (Fi g. 128).
1 MANUAL VALVE
2 VALVE BODY
Fig. 120 Manual And Throttle Levers
1 PARK ROD
2 E-RING
3 WASHER
4 MANUAL LEVER
5 MANUAL VALVE
6 SPRING
7 DETENT BALL
8 VALVE BODY
Fig. 121 Manual Valve And Throttle Lever Alignment
1 THROTTLE LEVER
2 MANUAL LEVER VALVE ARM
3 MANUAL VALVE
4 KICKDOWN VALVE
Fig. 122 Adjusting Screw Bracket, Springs, and
Valves
1 ADJUSTER BRACKET
4 SWITCH VALVE
5 VALVE BODY
6 TRANSFER PLATE
7 THROTTLE VALVE
8 SLEEVE
9 KICKDOWN VALVE
Fig. 123 Repair Stand
1 TRANSMISSION
2 STAND
Fig. 124 Park/Neutral Position Switch
1 NEUTRAL SWITCH
2 SOLENOID CONNECTOR
Fig. 125 Accumulator Piston And Spring
2 PISTON SPRING
Fig. 126 Front Band Adjusting Screw Lock Nut
1 LOCK-NUT
2 FRONT BAND ADJUSTER
Fig. 127 Oil Pump/Reaction Shaft Support
1 OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY
2 SLIDE HAMMER TOOLS C-3752
(18) Remove front and rear cl utch uni ts as an
assembl y. Grasp i nput shaft, hol d cl utch uni ts
together and remove them from case (Fi g. 129).
(19) Li ft front cl utch off rear cl utch (Fi g. 130). Set
cl utch uni ts asi de for overhaul .
(20) Remove output shaft thrust washer from out-
put shaft (or from rear cl utch hub) (Fi g. 131).
(21) Remove output shaft thrust pl ate and washer
from output shaft hub (Fi g. 131).
(22) Remove front band from case (Fi g. 132).
(23) Remove extensi on housi ng from transmi ssi on
case.
(24) Remove governor body and park gear from
output shaft.
(25) Remove output shaft and pl anetary geartrai n
as assembl y (Fi g. 133). Support geartrai n wi th both
hands duri ng removal . Do not al l ow machi ned sur-
faces on output shaft to become ni cked or scratched.
Fig. 129 Front/Rear Clutch Assemblies
1 FRONT BAND
2 FRONT CLUTCH AND DRUM
4 REAR CLUTCH
Fig. 128 Front Band Strut
1 BAND LEVER
2 BAND STRUT
3 FRONT BAND
Fig. 130 Separating Front Clutch From Rear Clutch
1 FRONT CLUTCH
2 REAR CLUTCH
Fig. 131 Output Shaft Thrust Plate and Washer
1 OUTPUT SHAFT
2 THRUST PLATE
3 THRUST WASHER
(26) Loosen rear band adjusti ng screw 4-5 turns
(Fi g. 134).
(27) Remove snap ri ng that secures l ow-reverse
drum to rear support hub, however do not remove
drum (Fi g. 135).
(28) Remove bol ts attachi ng rear support to trans-
mi ssi on case and pul l support from l ow-reverse drum
(Fi g. 136).
(29) Remove bol ts attachi ng overrunni ng cl utch
cam and l ow-reverse drum to transmi ssi on case (Fi g.
137).
Fig. 132 Front Band
1 FRONT BAND
Fig. 133 Planetary Geartrain
1 SLOTS
2 LOW-REVERSE DRUM
5 LUGS
Fig. 134 Rear Band Adjuster Location
2 REAR BAND
3 LEVER
4 SERVO
5 ADJUSTER
Fig. 135 Low-Reverse Drum Snap Ring
1 REAR BAND
2 REAR SUPPORT HUB
3 LOW-REVERSE DRUM SNAP RING
4 LOW-REVERSE DRUM
(30) Usi ng snap-ri ng pl i er, pul l rear band anchor
pi n (l ocated on the servo si de of the rear support)
from transmi ssi on case.
(31) Remove rear band and l i nk from transmi ssi on
(Fi g. 138).
(32) Separate l i nk from rear band (Fi g. 139).
(33) I f necessary remove front and rear band servo
l evers. Al l transmi ssi on components can be servi ced
wi thout removi ng the l evers.
(a) Usi ng a 1/4 i nch dri ve extensi on remove
front band reacti on pi n access pl ug (Fi g. 140).
(b) Remove front band reacti on pi n wi th penci l
magnet. Pi n i s accessi bl e from converter housi ng
si de of case (Fi g. 141).
(c) Remove front band l ever (Fi g. 142).
(d) Usi ng snap-ri ng pl i er, pul l rear band l ever
pi vot from transmi ssi on case (Fi g. 143).
(e) Separate rear band servo l ever from trans-
mi ssi on.
Fig. 136 Rear Support
1 OIL PAN FACE
3 REAR SUPPORT
Fig. 137 Overrunning Clutch Cam Bolt Locations
1 OVERRUNNING CLUTCH CAM BOLTS
Fig. 138 Rear Band and Link
1 LINK
2 REAR BAND
Fig. 139 Rear Band and Link
1 NOTCHED SIDE OF LINK GOES TOWARD BAND
Fig. 140 Front Band Reaction Pin Access Plug
1 1/4 DRIVE EXTENSION
2 FRONT BAND REACTION PIN ACCESS PLUG
(34) Compress front servo rod gui de about 1/8 i n.
wi th l arge C-cl amp and Tool C-4470, or Spri ng Com-
pressor Tool C-3422-B (Fi g. 144).
(35) Remove front servo rod gui de snap ri ng (Fi g.
144). Exercise caution when removing snap
ring. Servo bore can be scratched or nicked if
care is not exercised.
(36) Remove compressor tool s and remove front
servo rod gui de, spri ng and servo pi ston.
(37) Compress rear servo spri ng retai ner about
1/16 i n. wi th C-cl amp and Tool C-4470 or SP-5560
(Fi g. 145). Val ve Spri ng Compressor C-3422-B can
al so be used to compress spri ng retai ner.
(38) Remove rear servo spri ng retai ner snap ri ng.
Then remove compressor tool s and remove rear servo
spri ng and pi ston.
ASSEMBLY
(1) I nstal l rear servo pi ston, spri ng and spri ng
retai ner. Compress rear servo spri ng and retai ner
wi th Compressor Tool C-3422-B (Fi g. 145) or a l arge
C-cl amp.
(2) I nstal l front servo pi ston, spri ng, and rod
gui de. Compress front servo rod gui de wi th Val ve
Spri ng Compressor C-3422-B and i nstal l servo snap
ri ng (Fi g. 144).
(3) Assembl e l i nk bar to band. Notched si de of l i nk
toward band (Fi g. 143).
(4) I nsert rear band through pan openi ng i n trans-
mi ssi on case.
(5) I nsert hook on band onto adjuster l ever.
(6) Al i gn hol es i n l i nk bar wi th hol e i n transmi s-
si on case outboard of rear support openi ng (Fi g. 142).
(7) I nsert anchor pi n i nto case through l i nk bar.
Fig. 141 Front Band Reaction Pin
1 PENCIL MAGNET
2 FRONT BAND REACTION PIN
Fig. 142 Front Band Lever
1 FRONT BAND LEVER
Fig. 143 Rear Band Servo Lever Pin
1 PARALLEL JAW SNAP RING PLIERS
2 REAR BAND LEVER PIVOT PIN
Fig. 144 Compressing Front Servo
1 SPRING COMPRESSOR TOOL C-3422B
2 ROD GUIDE SNAP RING
(8) Exami ne bol t hol es i n overrunni ng cl utch cam.
Note that one hol e i s not threaded (Fi g. 146). Thi s
hol e must al i gn wi th bl ank area i n cl utch cam bol t
ci rcl e.
NOTE: The bolt holes in cam are slightly counter-
sunk on one side. This side of cam faces rearward
(toward rear support).
(9) Lubri cate overrunni ng cl utch rol l ers, spri ngs
and cam wi th Mopar ATF Pl us 3, type 7176, trans-
mi ssi on fl ui d.
(10) Posi ti on overrunni ng cl utch on a cl ean, fl at
work surface wi th countersunk hol es downward.
(11) Pl ace rear of l ow-reverse drum over overrun-
ni ng cl utch and al i gn cl utch rol l ers to hub of drum.
(12) Whi l e sl i ghtl y pi voti ng l ow-reverse drum,
push hub of drum i nto overrunni ng cl utch. Veri fy
that countersunk hol es are faci ng outward. Cam
should be able to rotate in the drum clockwise
only.
(13) I nsert a sui tabl e awl through the rear support
mounti ng hol e cl osest to the pan seal i ng face. The
awl shoul d be next to the wi de space area at the
back of transmi ssi on case.
(14) I nsert l ow-reverse drum and overrunni ng
cl utch i nto front of transmi ssi on case and i nto rear
band.
(15) I nsert awl ti p i nto the threaded hol e next to
the non-threaded hol e i n the overrunni ng cl utch cam.
Veri fy that non-threaded hol e i s al i gned wi th wi de
space area on transmi ssi on case.
(16) Push l ow-reverse drum rearward to cl ose gap
between cam and case.
(17) I nstal l overrunni ng cl utch cam bol ts. Clutch
cam bolts are shorter than rear support bolts.
Ti ghten cam bol ts to 17 Nm (150 i n. l bs. or 13 ft.
l bs.) torque.
(18) Hol d l ow-reverse drum i n posi ti on so rear sup-
port wi l l not push i t out of overrunni ng cl utch.
(19) I nsert rear support i nto openi ng at rear of
(20) Al i gn support wi th the embossed arrow i n the
di recti on of the pan face.
Fig. 147 Rear Support
1 OIL PAN FACE
3 REAR SUPPORT
Fig. 145 Compressing Rear Servo Spring
1 LARGE C-CLAMP
2 TOOL C-4470 OR SP5560
3 SERVO SPRING RETAINER
Fig. 146 Clutch Cam Alignment
1 TRANSMISSION CASE
2 OVERRUNNING CLUTCH
3 NON-THREADER HOLE
4 WIDE SPACE AREA
(21) I nstal l and ti ghten rear support bol ts to 17
(22) I nstal l snap ri ng to retai n l ow-reverse drum
to hub of rear support (Fi g. 148).
(23) Lubri cate output shaft, rear support bore and
l ow-reverse drum hub wi th transmi ssi on fl ui d.
(24) I nstal l assembl ed output shaft and pl anetary
geartrai n i n case (Fi g. 149).
(25) Al i gn dri ve l ugs on rear pl anetary gear wi th
sl ots i n l ow-reverse drum (Fi g. 149). Then seat pl an-
etary assembl y i n drum.
(26) I nstal l governor on output shaft.
(27) Turn and secure transmi ssi on so that front
openi ng i s upward.
(28) Assembl e front and rear cl utches together.
(a) Check i nput shaft seal ri ngs (Fi g. 150). Veri fy
that di agonal -cut ends of Tefl on seal ri ng are
properl y joi ned and ends of metal ri ng are correctl y
hooked together. Al so be sure ri ngs are i nstal l ed i n
sequence shown.
(b) Al i gn teeth on cl utch di scs i n l i ne.
(c) I nsert i nput shaft on rear cl utch i nto center
of front cl utch (Fi g. 151).
(d) Engage teeth on rear cl utch hub i nto teeth on
cl utch (Fi g. 153). Rotate front cl utch retai ner back
and forth unti l compl etel y seated on rear cl utch.
Fig. 149 Output Shaft And Planetary Geartrain
1 SLOTS
2 LOW-REVERSE DRUM
5 LUGS
Fig. 148 Low-Reverse Drum Snap Ring
1 REAR BAND
2 REAR SUPPORT HUB
3 LOW-REVERSE DRUM SNAP RING
4 LOW-REVERSE DRUM
Fig. 150 Input Shaft Seal Ring Location
1 INPUT SHAFT
2 TEFLON SEAL RING
3 METAL SEAL RING
Fig. 151 Front and Rear Clutches
1 REAR CLUTCH
2 INPUT SHAFT
3 FRONT CLUTCH
(29) I nstal l output shaft thrust pl ate on shaft hub
i n pl anetary geartrai n dri vi ng shel l (Fi g. 152). Use
petrol eum jel l y to hol d thrust pl ate i n pl ace.
(30) Check rear cl utch thrust washer. Use addi -
ti onal petrol eum jel l y to hol d washer i n pl ace i f nec-
essary.
(31) Coat output shaft thrust washer wi th petro-
l eum jel l y. I nstal l washer i n rear cl utch hub (Fi g.
154). Use enough petrol eum jel l y to hol d washer i n
pl ace. Be sure grooved side of washer faces
rearward (toward output shaft) as shown. Also
note that washer only fits one way in clutch
hub.
(32) Al i gn dri ve teeth on rear cl utch di scs wi th
smal l screwdri ver (Fi g. 155). Thi s wi l l make i nstal l a-
ti on i nto front of pl anetary geartrai n easi er.
(33) I nsert front band i nto openi ng at front of
(34) I nstal l front and rear cl utch uni ts as assembl y
(Fi g. 157). Al i gn rear cl utch wi th front annul us gear
and i nstal l assembl y i n dri vi ng shel l . Be sure out-
put shaft thrust washer and thrust plate are
not displaced during installation.
(35) Careful l y work assembl ed cl utches back and
forth to engage and seat rear cl utch di scs on front
annul us gear. Veri fy that front cl utch dri ve l ugs are
Fig. 152 Output Shaft Thrust Plate
1 OUTPUT SHAFT HUB
2 OUTPUT SHAFT THRUST PLATE
Fig. 153 Assembling Front And Rear Clutch Units
1 TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 REAR CLUTCH ASSEMBLY
Fig. 154 Output Shaft Thrust Washer
1 REAR CLUTCH HUB
2 OUTPUT SHAFT THRUST WASHER
3 OUTPUT SHAFT
Fig. 155 Aligning Rear Clutch Disc Lugs
1 REAR CLUTCH DISCS
2 USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC
TEETH
ful l y engaged i n sl ots of dri vi ng shel l after i nstal l a-
ti on.
(36) Engage front band on adjusti ng screw and
hol d band i n pl ace.
(37) I nstal l strut between band l ever and front
band (Fi g. 158).
(38) Ti ghten front band adjusti ng screw unti l band
just gri ps cl utch retai ner. Veri fy that front/rear
cl utches are sti l l seated before conti nui ng.
(39) Veri fy that reacti on shaft support hub seal
ri ngs are hooked together (Fi g. 159).
(40) Coat front cl utch thrust washer wi th petro-
l eum jel l y to hol d i t i n pl ace. Then i nstal l washer
over reacti on shaft hub and seat i t on pump (Fi g.
160).
CAUTION: The thrust washer bore (I. D.), is cham-
fered on one side. Make sure the chamfered side is
installed so it faces the pump.
Fig. 156 Front Band
1 FRONT BAND
Fig. 157 Installing Front/Rear Clutch
1 FRONT BAND
2 FRONT CLUTCH AND DRUM
4 REAR CLUTCH
Fig. 158 Front Band Linkage Installation
1 BAND LEVER
2 BAND STRUT
3 FRONT BAND
Fig. 159 Reaction Shaft Support Seal Rings
1 REACTION SHAFT SUPPORT HUB
2 FRONT CLUTCH THRUST WASHER
3 SEAL RINGS
(41) Thread two Pi l ot Stud Tool s C-3288-B i nto
bol t hol es i n oi l pump fl ange (Fi g. 161).
(42) Al i gn and i nstal l oi l pump gasket (Fi g. 161).
(43) Lubri cate oi l pump seal s wi th Mopar Door-
Ease, or Ru-Gl yde, Door Eze, or ATF Pl us 3.
(44) I nstal l oi l pump (Fi g. 162). Al i gn and posi ti on
pump on pi l ot studs. Sl i de pump down studs and
work i t i nto front cl utch hub and case by hand. Then
i nstal l two or three pump bol ts to hol d pump i n
pl ace.
(45) Remove pi l ot stud tool s and i nstal l remai ni ng
oi l pump bol ts. Ti ghten bol ts al ternatel y i n di agonal
pattern to 20 Nm (15 ft. l bs.).
(46) Measure i nput shaft end pl ay (Fi g. 163).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or output shaft thrust
washer and/or thrust plate are worn and need to be
changed.
(a) Attach Adapter 82667 to Handl e 82668.
(b) Attach di al i ndi cator C-3339 to Handl e
82668.
(c) I nstal l the assembl ed tool onto the i nput
shaft of the transmi ssi on and ti ghten the retai ni ng
screw on Adapter 82667 to secure i t to the i nput
shaft.
(d) Posi ti on the di al i ndi cator pl unger agai nst a
fl at spot on the oi l pump and zero the di al i ndi ca-
tor.
(e) Move i nput shaft i n and out and record read-
i ng. End pl ay shoul d be 0.56 - 2.31 mm (0.022 -
0.091 i n.).
(47) Posi ti on transmi ssi on on work surface wi th
pan face upward.
(48) I nstal l val ve body.
(49) Adjust front and rear bands.
(50) I nstal l fl ui d fi l ter and pan.
(51) I nstal l rear extensi on housi ng.
(52) I nstal l torque converter.
Fig. 160 Front Clutch Thrust Washer Installation
1 THRUST WASHER
2 CHAMFERED SIDE OF WASHER BORE GOES TOWARD
PUMP
Fig. 161 Installing Pilot Studs And Oil Pump Gasket
1 OIL PUMP GASKET
2 PILOT STUD TOOLS C-3288B
Fig. 162 Installing Oil Pump And Reaction Shaft
Support
1 OIL PUMP
2 PILOT STUD TOOL
3 PILOT STUD TOOL
OVERRUNNING CLUTCH/LOW-REVERSE DRUM
DISASSEMBLY
(1) I f the cl utch assembl y came out wi th the l ow-
reverse drum, thread two cl utch cam bol ts i nto the
cam. Then l i ft the cam out of the drum wi th the bol ts
(Fi g. 164). Rotate the cam back and forth to ease
removal i f necessary.
(2) Remove the cl utch rol l er and spri ng assembl y
from the overrunni ng cl utch race.
ASSEMBLY
(1) Assembl e cl utch rol l ers and spri ngs i n retai ner
i f necessary (Fi g. 165).
(2) I nstal l overrunni ng cl utch rol l er, spri ng and
retai ner assembl y i n cl utch cam (Fi g. 166).
(3) Temporari l y assembl e and check overrunni ng
cl utch operati on as fol l ows:
(a) Assembl e cam and cl utch.
Fig. 164 Removing Overrunning Clutch From
Low-Reverse Drum
1 CAM BOLTS
2 LOW-REVERSE DRUM
3 OVERRUNNING CLUTCH AND CAM
Fig. 165 Overrunning Clutch Rollers, Springs,
Retainer
1 RETAINER
2 SPRING
3 ROLLER
Fig. 166 Assembling Overrunning Clutch And Cam
1 CLUTCH CAM
2 CLUTCH ROLL ASSEMBLY
Fig. 163 Checking Input Shaft End Play
1 TOOL 8266-8
2 TOOL 8266-7
3 TOOL C-3339
(b) I nstal l cl utch assembl y on l ow-reverse drum
wi th twi sti ng moti on (Fi g. 167).
(c) I nstal l drum-cl utch assembl y i n case and
i nstal l cl utch cam bol ts.
(d) I nstal l rear support and support attachi ng
bol ts.
(e) Check l ow-reverse drum rotati on. Drum
should rotate freely in clockwise direction
and lock when turned in counterclockwise
direction (as viewed from front of case).
FRONT SERVO PISTON
DISASSEMBLY
(1) Remove seal ri ng from rod gui de (Fi g. 169).
(2) Remove smal l snap ri ng from servo pi ston rod.
Then remove pi ston rod, spri ng and washer from pi s-
ton.
(3) Remove and di scard servo component O-ri ng
and seal ri ngs.
ASSEMBLY
(1) Lubri cate new O-ri ng and seal ri ngs wi th
petrol eum jel l y and i nstal l them on pi ston, gui de and
rod.
(2) I nstal l rod i n pi ston. I nstal l spri ng and washer
on rod. Compress spri ng and i nstal l snap ri ng (Fi g.
169).
(3) Set servo components asi de for i nstal l ati on dur-
i ng transmi ssi on reassembl y.
Fig. 167 Temporary Assembly Of Clutch And Drum
To Check Operation
1 LOW-REVERSE DRUM
2 CLUTCH RACE (ON HUB OF DRUM)
3 OVERRUNNING CLUTCH
Fig. 168 Assembled Overrunning Clutch
1 LOW-REVERSE DRUM
2 OVERRUNNING CLUTCH CAM
3 ROLLER AND SPRING ASSEMBLY
4 CLUTCH RACE
5 HUB OF LOW-REVERSE DRUM
Fig. 169 Front Servo
1 PISTON RINGS
2 O-RING
3 SNAP-RING
4 SEAL RING
5 PISTON ROD GUIDE
6 SNAP-RING
7 SERVO SPRING
8 PISTON ROD
9 SERVO PISTON
REAR SERVO PISTON
DISASSEMBLY
(1) Remove smal l snap ri ng and remove pl ug and
spri ng from servo pi ston (Fi g. 170).
(2) Remove and di scard servo pi ston seal ri ng.
ASSEMBLY
(1) Lubri cate pi ston and gui de seal s wi th petro-
l eum jel l y. Lubri cate other servo parts wi th Mopar
ATF Pl us 3, Type 7176, transmi ssi on fl ui d.
(2) I nstal l new seal ri ng on servo pi ston.
(3) Assembl e pi ston, pl ug, spri ng and new snap
ri ng.
(4) Lubri cate pi ston seal l i p wi th petrol eum jel l y.
OIL PUMP AND REACTION SHAFT SUPPORT
DISASSEMBLY
(1) Remove seal ri ng from housi ng and reacti on
shaft support (Fi g. 171).
(2) Mark pump housi ng and support assembl y for
al i gnment reference.
(3) Remove bol ts attachi ng pump body to support
(Fi g. 172).
(4) Separate support from pump housi ng (Fi g.
173).
(5) Remove i nner and outer gears from reacti on
shaft support (Fi g. 174).
(6) I f pump seal was not removed duri ng transmi s-
si on di sassembl y, remove seal wi th punch and ham-
mer.
(7) Remove front cl utch thrust washer from sup-
port hub (Fi g. 175).
Fig. 171 Removing Pump Seal Ring
1 PUMP HOUSING SEAL RING
Fig. 170 Rear Servo Components
1 SNAP RING
2 PISTON SEAL
3 PISTON PLUG
4 SPRING RETAINER
5 SNAP RING
6 PISTON SPRING
7 CUSHION SPRING
8 PISTON
Fig. 172 Pump Support Bolts
2 PUMP
Fig. 173 Separating Pump Housing From Reaction
Shaft Support
2 PUMP HOUSING
OIL PUMP BUSHING REPLACEMENT
(1) Remove pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng Remover SP-3551 from Tool Set
C-3887-J (Fi g. 176).
(2) I nstal l new pump bushi ng wi th Tool Handl e
C-4171 and Bushi ng I nstal l er SP-5117 (Fi g. 176).
Bushi ng shoul d be fl ush wi th pump housi ng bore.
(3) Stake new pump bushi ng i n two pl aces wi th
bl unt punch (Fi g. 177). Remove burrs from stake
poi nts wi th kni fe bl ade afterward.
REACTION SHAFT SUPPORT BUSHING REMOVAL
(1) Assembl e Bushi ng Remover Tool s SP-1191,
3633 and 5324 (Fi g. 178). Do not clamp any part
of reaction shaft or support in vise.
(2) Hol d Cup Tool SP-3633 fi rml y agai nst reacti on
shaft and thread remover SP-5324 i nto bushi ng as
far as possi bl e by hand. Then thread remover tool 3-4
addi ti onal turns i nto bushi ng wi th a wrench.
(3) Turn remover tool hex nut down agai nst
remover cup to pul l bushi ng from shaft. Cl ean al l
chi ps from shaft after bushi ng removal .
Fig. 174 Pump Gear Removal
2 INNER GEAR
3 OUTER GEAR
Fig. 175 Support Hub Thrust Washer
1 BUSHING
3 THRUST WASHER
4 HUB
Fig. 176 Removing Oil Pump Bushing
3 BUSHING
5 BUSHING
7 PUMP HOUSING
Fig. 177 Staking Oil Pump Bushing
1 NARROW BLADE
2 BLUNT PUNCH
3 TWO STAKES
(4) Li ghtl y gri p ol d bushi ng i n vi se or wi th pl i ers
and back remover tool out of bushi ng.
(5) Assembl e Bushi ng I nstal l er Tool s C-4171 and
SP-5325 (Fi g. 178).
(6) Sl i de new bushi ng onto I nstal l er Tool SP-5325.
(7) Posi ti on reacti on shaft support upri ght on a
cl ean smooth surface.
(8) Al i gn bushi ng i n bore. Then tap bushi ng i nto
pl ace unti l Bushi ng I nstal l er SP-5325 bottoms.
(9) Cl ean reacti on shaft support thoroughl y after
i nstal l i ng bushi ng.
ASSEMBLY
(1) Lubri cate gear bore i n pump housi ng wi th
(2) Lubri cate pump gears wi th transmi ssi on fl ui d.
(3) Support pump housi ng on wood bl ocks (Fi g.
179).
(4) I nstal l outer gear i n pump housi ng (Fi g. 179).
Gear can be i nstal l ed ei ther way (i t i s not a one-way
fi t).
(5) I nstal l pump i nner gear (Fi g. 180).
CAUTION: The pump inner gear is a one way fit.
The bore on one side of the gear inside diameter (I.
D.) is chamfered. Be sure the chamfered side faces
forward (to front of pump).
(6) I nstal l new thrust washer on hub of reacti on
shaft support. Lubri cate washer wi th transmi ssi on
fl ui d or petrol eum jel l y.
(7) I f reacti on shaft seal ri ngs are bei ng repl aced,
i nstal l new seal ri ngs on support hub (Fi g. 181).
Lubri cate seal ri ngs wi th transmi ssi on fl ui d or petro-
l eum jel l y after i nstal l ati on. Squeeze each ri ng unti l
ri ng ends are securel y hooked together.
CAUTION: The reaction shaft support seal rings
will break if overspread, or twisted. If new rings are
being installed, spread them only enough for instal-
lation. Also be very sure the ring ends are securely
hooked together after installation. Otherwise, the
rings will either prevent pump installation, or break
(8) I nstal l reacti on shaft support on pump housi ng
(Fi g. 182).
(9) Al i gn reacti on support on pump housi ng. Use
al i gnment marks made at di sassembl y. Or, rotate
support unti l bol t hol es i n support and pump housi ng
are al l al i gned (hol es are offset for one-way fi t).
Fig. 178 Replacing Reaction Shaft Support Bushing
5 REACTION SHAFT
7 BUSHING
Fig. 179 Supporting Pump And Installing Outer Gear
1 OUTER GEAR
2 PUMP HOUSING
3 WOOD BLOCKS
Fig. 180 Pump Inner Gear Installation
1 OUTER GEAR
2 INNER GEAR
(10) I nstal l al l bol ts that attach support to pump
housi ng. Then ti ghten bol ts fi nger ti ght.
(11) Ti ghten support-to-pump bol ts to requi red
torque as fol l ows:
(a) Reverse pump assembl y and i nstal l i t i n
transmi ssi on case. Posi ti on pump so bol ts are fac-
i ng out and are accessi bl e.
(b) Secure pump assembl y i n case wi th 2 or 3
bol ts, or wi th pi l ot studs.
(c) Ti ghten support-to-pump bol ts to 20 Nm (15
ft. l bs.).
(d) Remove pump assembl y from transmi ssi on
case.
(12) I nstal l new oi l seal i n pump wi th Speci al Tool
C-4193 and Tool Handl e C-4171 (Fi g. 183). Be sure
seal l i p faces i nward.
(13) I nstal l new seal ri ng around pump housi ng.
Be sure seal i s properl y seated i n groove.
(14) Lubri cate l i p of pump oi l seal and O-ri ng seal
FRONT CLUTCH
DISASSEMBLY
(1) Remove waved snap ri ng and remove pressure
pl ate, cl utch pl ates and cl utch di scs (Fi g. 184).
(2) Compress cl utch pi ston spri ng wi th Compressor
Tool C-3575-A (Fi g. 185). Be sure l egs of tool are
seated squarel y on spri ng retai ner before compress-
i ng spri ng.
(3) Remove retai ner snap ri ng and remove com-
pressor tool .
(4) Remove spri ng retai ner and cl utch spri ng. Note
posi ti on of retai ner on spri ng for assembl y reference.
(5) Remove cl utch pi ston from cl utch retai ner.
Remove pi ston by rotati ng i t up and out of retai ner.
(6) Remove seal s from cl utch pi ston and cl utch
retai ner hub. Di scard both seal s as they are not reus-
abl e.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal s on pi ston and i n hub of
retai ner. Be sure l i p of each seal faces i nteri or of
cl utch retai ner.
(3) Lubri cate l i ps of pi ston and retai ner seal s wi th
l i beral quanti ty of Mopar Door Ease, or Ru-Gl yde.
Then l ubri cate retai ner hub, bore and pi ston wi th
l i ght coat of transmi ssi on fl ui d.
(4) I nstal l cl utch pi ston i n retai ner (Fi g. 186). Use
twi sti ng moti on to seat pi ston i n bottom of retai ner. A
thi n stri p of pl asti c (about 0.020 thi ck), can be used
to gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
Fig. 181 Hub Seal Ring Position
1 SEAL RINGS
2 SUPPORT HUB
Fig. 182 Assembling Reaction Shaft Support And
Pump Housing
1 PUMP HOUSING
Fig. 183 Pump Oil Seal Installation
1 PUMP BODY
2 PUMP SEAL
(5) Posi ti on spri ng i n cl utch pi ston (Fi g. 187).
(6) Posi ti on spri ng retai ner on top of pi ston spri ng
(Fi g. 188). Make sure retainer is properly
installed. Small raised tabs should be facing
upward. Semicircular lugs on underside of
retainer are for positioning retainer in spring.
(7) Compress pi ston spri ng and retai ner wi th Com-
pressor Tool C-3575-A (Fi g. 185). Then i nstal l new
snap ri ng to secure spri ng retai ner and spri ng.
(8) I nstal l cl utch pl ates and di scs (Fi g. 184).
I nstal l steel pl ate then di sc unti l al l pl ates and di scs
are i nstal l ed. The front cl utch uses 4 cl utch di scs.
(9) I nstal l pressure pl ate and waved snap ri ng
(Fi g. 184).
(10) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pl ate cl earance (Fi g. 189).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 189).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and compress the waved snap-ri ng. Thi s
wi l l assure that the snap-ri ng i s at the top of the
groove.
(c) Rel ease the pressure pl ate and zero the di al
i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
waved snap-ri ng and record the di al i ndi cator read-
i ng.
Cl earance shoul d be 1.70 to 3.40 mm (0.067 to
0.134 i n.). I f cl earance i s i ncorrect, cl utch di scs,
pl ates pressure pl ates and snap ri ng may have to be
changed.
REAR CLUTCH
DISASSEMBLY
(1) Remove thrust washer from forward si de of
cl utch retai ner.
(2) Remove i nput shaft front/rear seal ri ngs.
(3) Remove sel ecti ve cl utch pack snap ri ng (Fi g.
190).
Fig. 184 Front Clutch Components
1 RETAINER HUB SEAL
2 CLUTCH PISTON
3 PISTON SPRING
4 SPRING RETAINER SNAP RING
5 CLUTCH DISCS
6 PRESSURE PLATE
7 SNAP RING (WAVED)
8 CLUTCH PLATES
9 SPRING RETAINER
10 PISTON SEAL
(4) Remove top pressure pl ate, cl utch di scs, steel
pl ates, bottom pressure pl ate and wave snap ri ng
and wave spri ng (Fi g. 190).
(5) Remove cl utch pi ston wi th rotati ng moti on.
(6) Remove and di scard pi ston seal s.
(7) Remove i nput shaft snap-ri ng (Fi g. 191). I t
may be necessary to press the i nput shaft i n sl i ghtl y
to rel i eve tensi on on the snap-ri ng
(8) Press i nput shaft out of retai ner wi th shop
press and sui tabl e si ze press tool . Use a sui tabl y
Fig. 185 Compressing Front Clutch Piston Spring
1 FRONT CLUTCH SPRING
2 COMPRESSOR TOOL C-3575A
3 RETAINER SNAP RING
4 SPRING RETAINER
Fig. 186 Front Clutch Piston Installation
1 CLUTCH PISTON
Fig. 187 Clutch Piston Spring Installation
1 RETAINER
2 CLUTCH SPRING
3 PISTON
Fig. 188 Correct Spring Retainer Installed Position
1 SMALL TABS ON RETAINER FACE UPWARD
Fig. 189 Measuring Front Clutch Pack Clearance
1 DIAL INDICATOR
2 WAVED SNAP-RING
3 FRONT CLUTCH
4 POINTER
5 GAUGE BAR
6 PRESSURE PLATE
si zed press tool to support the retai ner as cl ose to the
i nput shaft as possi bl e.
ASSEMBLY
(1) Soak cl utch di scs i n transmi ssi on fl ui d whi l e
assembl i ng other cl utch parts.
(2) I nstal l new seal ri ngs on cl utch retai ner hub
and i nput shaft i f necessary (Fi g. 192).
(a) Be sure cl utch hub seal ri ng i s ful l y seated i n
groove and i s not twi sted.
(3) Lubri cate spl i ned end of i nput shaft and cl utch
retai ner wi th transmi ssi on fl ui d. Then press i nput
shaft i nto retai ner. Use a sui tabl y si zed press tool to
support retai ner as cl ose to i nput shaft as possi bl e.
(4) I nstal l i nput shaft snap-ri ng (Fi g. 191).
(5) I nvert retai ner and press i nput shaft i n oppo-
si te di recti on unti l snap-ri ng i s seated.
(6) I nstal l new seal s on cl utch pi ston. Be sure l i p
of each seal faces i nteri or of cl utch retai ner.
(7) Lubri cate l i p of pi ston seal s wi th generous
quanti ty of Mopar Door Ease. Then l ubri cate
retai ner hub and bore wi th l i ght coat of transmi ssi on
fl ui d.
(8) I nstal l cl utch pi ston i n retai ner. Use twi sti ng
moti on to seat pi ston i n bottom of retai ner. A thi n
stri p of pl asti c (about 0.020 thi ck), can be used to
gui de seal s i nto pl ace i f necessary.
CAUTION: Never push the clutch piston straight in.
This will fold the seals over causing leakage and
clutch slip. In addition, never use any type of metal
tool to help ease the piston seals into place. Metal
tools will cut, shave, or score the seals.
Fig. 190 Rear Clutch Components
1 PISTON SPRING
2 REAR CLUTCH PISTON
3 CLUTCH PISTON SEALS
4 OUTPUT SHAFT THRUST WASHER (METAL)
7 INPUT SHAFT
8 REAR CLUTCH THRUST WASHER (FIBER)
9 CLUTCH PACK SNAP RING (SELECTIVE)
10 TOP PRESSURE PLATE
11 CLUTCH DISCS (4)
12 BOTTOM PRESSURE PLATE
13 WAVE SPRING
14 CLUTCH PLATES (3)
15 RETAINER SEAL RING
16 SHAFT REAR SEAL RING (PLASTIC)
17 SHAFT FRONT SEAL RING (TEFLON)
(9) I nstal l pi ston spri ng i n retai ner and on top of
pi ston (Fi g. 195). Concave si de of spri ng faces down-
ward (toward pi ston).
(10) I nstal l wave spri ng i n retai ner (Fi g. 195). Be
sure spri ng i s compl etel y seated i n retai ner groove.
(11) I nstal l bottom pressure pl ate (Fi g. 190).
Ri dged si de of pl ate faces downward (toward pi ston)
and fl at si de toward cl utch pack.
Fig. 191 Removing/Installing Input Shaft Snap-Ring
3 SNAP RING PLIERS
Fig. 192 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
1 REAR CLUTCH RETAINER HUB SEAL RING
2 INPUT SHAFT SEAL RINGS
Fig. 193 Input Shaft Seal Ring Identification
1 PLASTIC REAR SEAL RING
2 TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER
SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)
Fig. 194 Pressing Input Shaft Into Rear Clutch
Retainer
1 INPUT SHAFT
3 PRESS RAM
(12) I nstal l fi rst cl utch di sc i n retai ner on top of
bottom pressure pl ate. Then i nstal l a cl utch pl ate fol -
l owed by a cl utch di sc unti l enti re cl utch pack i s
i nstal l ed (4 di scs and 3 pl ates are requi red) (Fi g.
190).
(13) I nstal l top pressure pl ate.
(14) I nstal l sel ecti ve snap ri ng. Be sure snap ri ng
i s ful l y seated i n retai ner groove.
(15) Usi ng a sui tabl e gauge bar and di al i ndi cator,
measure cl utch pack cl earance (Fi g. 196).
(a) Posi ti on gauge bar across the cl utch drum
wi th the di al i ndi cator poi nter on the pressure
pl ate (Fi g. 196).
(b) Usi ng two smal l screw dri vers, l i ft the pres-
sure pl ate and rel ease i t.
(c) Zero the di al i ndi cator.
(d) Li ft the pressure pl ate unti l i t contacts the
snap-ri ng and record the di al i ndi cator readi ng.
Cl earance shoul d be 0.64 - 1.14 mm (0.025 - 0.045
i n.). I f cl earance i s i ncorrect, steel pl ates, di scs, sel ec-
ti ve snap ri ng and pressure pl ates may have to be
changed.
The sel ecti ve snap ri ng thi cknesses are:
.107.109 i n.
.098.100 i n.
.095.097 i n.
.083.085 i n.
.076.078 i n.
.071.073 i n.
.060.062 i n.
(16) Coat rear cl utch thrust washer wi th petro-
l eum jel l y and i nstal l washer over i nput shaft and
i nto cl utch retai ner (Fi g. 197). Use enough petrol eum
jel l y to hol d washer i n pl ace.
PLANETARY GEARTRAIN/OUTPUT SHAFT
DISASSEMBLY
(1) Remove pl anetary snap ri ng (Fi g. 198).
(2) Remove front annul us and pl anetary assembl y
from dri vi ng shel l (Fi g. 198).
(3) Remove snap ri ng that retai ns front pl anetary
gear i n annul us gear (Fi g. 199).
(4) Remove tabbed thrust washer and tabbed
thrust pl ate from hub of front annul us (Fi g. 200).
(5) Separate front annul us and pl anetary gears
(Fi g. 200).
Fig. 195 Piston Spring/Wave Spring Position
2 PISTON SPRING
3 WAVE SPRING
4 CLUTCH PISTON
Fig. 196 Checking Rear Clutch Pack Clearance
1 DIAL INDICATOR
2 PRESSURE PLATE
3 SNAP RING
4 STAND
5 REAR CLUTCH
6 GAUGE BAR
Fig. 197 Installing Rear Clutch Thrust Washer
2 REAR CLUTCH THRUST WASHER
(6) Remove front pl anetary gear front thrust
washer from annul us gear hub.
(7) Separate and remove dri vi ng shel l , rear pl ane-
tary and rear annul us from output shaft (Fi g. 201).
(8) Remove front pl anetary rear thrust washer
from dri vi ng shel l .
(9) Remove tabbed thrust washers from rear pl an-
etary gear.
(10) Remove l ock ri ng that retai ns sun gear i n
dri vi ng shel l . Then remove sun gear, spacer and
thrust pl ates.
ASSEMBLY
(1) Lubri cate output shaft and pl anetary compo-
nents wi th transmi ssi on fl ui d. Use petrol eum jel l y to
l ubri cate and hol d thrust washers and pl ates i n posi -
ti on.
(2) Assembl e rear annul us gear and support i f di s-
assembl ed. Be sure support snap ri ng i s seated and
that shoul der-si de of support faces rearward (Fi g.
202).
(3) I nstal l rear thrust washer on rear pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace. Al so be sure al l four washer tabs are properl y
engaged i n gear sl ots.
(4) I nstal l rear annul us over and onto rear pl ane-
tary gear (Fi g. 202).
(5) I nstal l assembl ed rear pl anetary and annul us
gear on output shaft (Fi g. 203). Veri fy that assembl y
i s ful l y seated on shaft.
(6) I nstal l front thrust washer on rear pl anetary
gear (Fi g. 204). Use enough petrol eum jel l y to hol d
Fig. 198 Front Annulus And Planetary Assembly
Removal
1 DRIVING SHELL
2 FRONT ANNULUS AND PLANETARY ASSEMBLY
3 PLANETARY SNAP RING
Fig. 199 Front Planetary Snap Ring Removal
1 FRONT ANNULUS GEAR
Fig. 200 Front Planetary And Annulus Gear
Disassembly
1 FRONT ANNULUS
2 THRUST WASHER
3 THRUST PLATE
4 FRONT THRUST WASHER
5 FRONT PLANETARY
Fig. 201 Removing Driving Shell, Rear Planetary
And Rear Annulus
1 REAR ANNULUS
2 REAR PLANETARY
3 DRIVING SHELL
4 OUTPUT SHAFT
washer on gear. Be sure al l four washer tabs are
seated i n sl ots.
(7) I nstal l spacer on sun gear (Fi g. 205).
(8) I nstal l thrust pl ate on sun gear (Fi g. 206). Note
that dri vi ng shel l thrust pl ates are i nterchangeabl e.
Use ei ther pl ate on sun gear and at front/rear of
shel l .
Fig. 202 Assembling Rear Annulus And Planetary
Gear
1 REAR ANNULUS GEAR
2 TABBED THRUST WASHER
3 REAR PLANETARY
Fig. 203 Installing Rear Annulus And Planetary On
Output Shaft
1 REAR ANNULUS AND PLANETARY GEAR ASSEMBLY
2 OUTPUT SHAFT
Fig. 204 Installing Rear Planetary Front Thrust
Washer
1 FRONT TABBED THRUST WASHER
2 REAR PLANETARY GEAR
Fig. 205 Installing Spacer On Sun Gear
1 SUN GEAR
2 SUN GEAR SPACER
(9) Hol d sun gear i n pl ace and i nstal l thrust pl ate
over sun gear at rear of dri vi ng shel l (Fi g. 207).
(10) Posi ti on wood bl ock on bench and support sun
gear on bl ock (Fi g. 208). Thi s makes i t easi er to al i gn
and i nstal l sun gear l ock ri ng. Keep wood bl ock
handy as i t wi l l al so be used for geartrai n end pl ay
check.
(11) Al i gn rear thrust pl ate on dri vi ng shel l and
i nstal l sun gear l ock ri ng. Be sure ri ng i s ful l y seated
i n sun gear ri ng groove (Fi g. 209).
(12) I nstal l assembl ed dri vi ng shel l and sun gear
on output shaft (Fi g. 210).
(13) I nstal l rear thrust washer on front pl anetary
gear (Fi g. 211). Use enough petrol eum jel l y to hol d
washer i n pl ace and be sure al l four washer tabs are
seated.
Fig. 207 Installing Driving Shell Rear Thrust Plate
1 DRIVING SHELL
2 SUN GEAR
3 REAR THRUST PLATE
Fig. 206 Installing Driving Shell Front Thrust Plate
On Sun Gear
1 SPACER
2 SUN GEAR
3 THRUST PLATE
Fig. 208 Supporting Sun Gear On Wood Block
1 SUN GEAR
2 DRIVING SHELL
3 WOOD BLOCK
Fig. 209 Installing Sun Gear Lock Ring
1 LOCK RING GROOVE
2 SUN GEAR LOCK RING
3 DRIVING SHELL
4 REAR THRUST PLATE
(14) I nstal l front pl anetary gear on output shaft
and i n dri vi ng shel l (Fi g. 212).
(15) I nstal l front thrust washer on front pl anetary
gear. Use enough petrol eum jel l y to hol d washer i n
pl ace and be sure al l four washer tabs are seated.
(16) Assembl e front annul us gear and support, i f
necessary. Be sure support snap ri ng i s seated.
(17) I nstal l front annul us on front pl anetary (Fi g.
212).
(18) Posi ti on thrust pl ate on front annul us gear
support (Fi g. 213). Note that plate has two tabs
on it. These tabs fit in notches of annulus hub.
(19) I nstal l thrust washer i n front annul us (Fi g.
214). Align flat on washer with flat on planetary
hub. Also be sure washer tab is facing up.
(20) I nstal l front annul us snap ri ng (Fi g. 215). Use
snap ri ng pl i ers to avoi d di storti ng ri ng duri ng
i nstal l ati on. Al so be sure ri ng i s ful l y seated.
(21) I nstal l pl anetary sel ecti ve snap ri ng wi th
snap ri ng pl i ers (Fi g. 216). Be sure ri ng i s ful l y
seated.
(22) Turn pl anetary geartrai n assembl y over so
dri vi ng shel l i s faci ng workbench. Then support
geartrai n on wood bl ock posi ti oned under forward
end of output shaft. Thi s al l ows geartrai n compo-
nents to move forward for accurate end pl ay check.
(23) Check pl anetary geartrai n end pl ay wi th
feel er gauge (Fi g. 217). Gauge goes between shoul der
on output shaft and end of rear annul us support.
Fig. 210 Installing Assembled Sun Gear And Driving
Shell On Output Shaft
1 SUN GEAR/DRIVING SHELL ASSEMBLY
2 OUTPUT SHAFT
Fig. 212 Installing Front Planetary And Annulus
Gears
1 FRONT PLANETARY GEAR
3 FRONT ANNULUS GEAR
Fig. 213 Positioning Thrust Plate On Front Annulus
Support
1 FRONT ANNULUS
2 THRUST PLATE
Fig. 211 Installing Rear Thrust Washer On Front
Planetary Gear
2 REAR TABBED THRUST WASHER
(24) Geartrai n end pl ay shoul d be 0.12 to 1.22 mm
(0.005 to 0.048 i n.). I f end pl ay i s i ncorrect, snap ri ng
(or thrust washers) may have to be repl aced. Snap
ri ng i s avai l abl e i n three di fferent thi cknesses for
adjustment purposes.
Fig. 214 Installing Front Annulus Thrust Washer
1 WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB
2 FRONT ANNULUS THRUST WASHER
3 TAB FACES FRONT
Fig. 215 Installing Front Annulus Snap Ring
1 SNAP RING PLIERS
2 FRONT ANNULUS SNAP RING
Fig. 216 Installing Planetary Selective Snap Ring
1 SELECTIVE SNAP RING
2 SNAP RING PLIERS
Fig. 217 Checking Planetary Geartrain End Play
1 OUTPUT SHAFT
2 REAR ANNULUS GEAR
3 FEELER GAUGE
Thoroughl y cl ean al l the governor parts i n a sui t-
abl e cl eani ng sol uti on but do not use any type of
causti c cl eani ng agents.
The governor wei ght components (Fi g. 218) and the
governor val ve (Fi g. 219), must sl i de freel y i n thei r
bores when cl ean and dry. Mi nor surface scratches
and burrs can be smoothed wi th crocus cl oth.
The al umi num governor val ve and outer wei ght
have a hard coati ng on them. Check condi ti on of thi s
coati ng careful l y. Do not reuse ei ther part i f the coat-
i ng i s damaged.
I nspect the governor wei ght spri ng for di storti on.
Repl ace the spri ng, i f di storted, col l apsed, or broken.
Cl ean the fi l ter i n sol vent and dry i t wi th compressed
ai r. Repl ace the fi l ter, i f damaged. I nspect the park
gear for chi pped or worn gear teeth or damaged ri ng
grooves. Repl ace the gear, i f damaged.
Check the teeth on the park gear for wear or dam-
age. Repl ace the gear i f necessary. I nspect the metal
seal ri ngs on the park gear hub. Repl ace the ri ngs
onl y i f severel y worn, or broken.
EXTENSION HOUSING AND PARK LOCK
Cl ean the housi ng and park l ock components i n
sol vent and dry them wi th compressed ai r.
Exami ne the park l ock components i n the housi ng.
I f repl acement i s necessary, remove the shaft wi th
paral l el jaw snap ri ng pl i ers (Fi g. 220) and remove
the sprag and spri ng. Then remove the spri ng cl i p
and reacti on pl ug (Fi g. 221). Compress the reac-
tion plug spring clip only enough to remove
and install it. Do not distort the clip during
removal or installation.
Be sure a repl acement sprag i s i nstal l ed so the
sprag l ocki ng l ug wi l l face the park gear (Fi g. 222).
Al so be sure the spri ng i s correctl y posi ti oned as
shown (Fi g. 222). The sprag may not retract i f the
spri ng i s i mproperl y i nstal l ed.
VALVE BODY
Servi ceabl e val ve body components are:
park l ock rod and E-cl i p
swi tch val ve and spri ng
pressure adjusti ng screw bracket
throttl e val ve l ever
manual l ever
manual l ever shaft seal , washer, E-cl i p and
detent bal l
fl ui d fi l ter
converter cl utch sol enoi d
The remai ni ng val ve body components are servi ced
onl y as part of a compl ete val ve body assembl y.
Fig. 218 Governor Weights
2 SNAP RING
3 INNER WEIGHT
4 INNER WEIGHT SPRING
5 OUTER WEIGHT
Cl ean the val ve body components i n a parts cl ean-
i ng sol uti on onl y. Do not use gasol i ne, kerosene, or
any type of causti c sol uti on. Dry the parts wi th com-
pressed ai r. Make sure al l passages are cl ean and
free from obstructi ons.
NOTE: Do not use rags or shop towels to wipe off
valve body components. Lint from these materials
will adhere to the valve body components. Lint will
interfere with valve operation and may clog filters
and fluid passages.
I nspect the throttl e and manual val ve l evers and
shafts. Do not attempt to strai ghten a bent shaft or
correct a l oose l ever. Repl ace these components i f
worn, bent, l oose or damaged i n any way.
I nspect al l of the val ve body mati ng surfaces for
scratches, ni cks, burrs, or di storti on. Use a strai ght-
edge to check surface fl atness. Mi nor scratches may
be removed wi th crocus cl oth usi ng onl y very l i ght
pressure.
Mi nor di storti on of a val ve body mati ng surface
may be corrected by smoothi ng the surface wi th cro-
cus cl oth. The cl oth shoul d be i n sheet form and be
posi ti oned on a surface pl ate, sheet of pl ate gl ass, or
equal l y fl at surface. However, i f di storti on i s severe
or any surfaces are heavi l y scored, the val ve body
wi l l have to be repl aced.
CAUTION: Many of the valve body valves and plugs
are made of coated aluminum. Aluminum compo-
nents can be identified by the dark color of the spe-
cial coating applied to the surface (or by testing
with a magnet). DO NOT polish or sand aluminum
valves or plugs with any type of material, or under
any circumstances. This practice might damage the
special coating and cause the valves and plugs to
stick and bind.
Fig. 219 Governor Components
1 SEAL RING (PLAIN END)
2 SEAL RING (HOOK END)
3 PARK GEAR
4 GOVERNOR BODY
5 GOVERNOR VALVE
6 VALVE SHAFT
7 E-CLIPS (2)
8 FILTER
9 SNAP RING (THIN)
10 SNAP RING (THICK)
11 SNAP RING
12 RETAINER WASHER
13 GOVERNOR WEIGHT ASSEMBLY
14 GOVERNOR BODY BOLTS (4)
15 WASHER
I nspect the val ves and pl ugs for scratches, burrs,
ni cks, or scores. Al so i nspect the coati ng on the al u-
mi num val ves and pl ugs (Fi g. 223). I f the coati ng i s
damaged or worn through, the val ve (or val ve body)
shoul d be repl aced.
Al umi num val ves and pl ugs shoul d not be sanded
or pol i shed under any ci rcumstances. However, mi nor
burrs or scratches on steel val ves and pl ugs can be
removed wi th crocus cl oth but do not round off the
val ve or pl ug edges. Squareness of these edges i s
vi tal l y i mportant. These edges prevent forei gn matter
from l odgi ng between the val ves, pl ugs and bore.
I nspect al l the val ve and pl ug bores i n the val ve
body. Use a penl i ght to vi ew the bore i nteri ors.
Repl ace the val ve body i f any bores are di storted or
scored. I nspect al l of the val ve body spri ngs. The
spri ngs must be free of di storti on, warpage or broken
coi l s.
Tri al fi t each val ve and pl ug i n i ts bore to check
freedom of operati on. When cl ean and dry, the val ves
and pl ugs shoul d drop freel y i nto the bores. Val ve
body bores do not change di mensi onal l y wi th use. I f
the val ve body functi oned correctl y when new, i t wi l l
conti nue to operate properl y after cl eani ng and
i nspecti on. I t shoul d not be necessary to repl ace a
val ve body assembl y unl ess i t i s damaged i n han-
dl i ng.
Fig. 220 Park Sprag, Shaft And Spring
1 SPRAG SHAFT
2 PARALLEL JAW SNAP RING PLIERS
3 SPRAG
4 SPRING
Fig. 221 Park Sprag Reaction Plug And Spring
Location
1 SPRING CLIP
2 REACTION PLUG
Fig. 222 Correct Position Of Sprag And Spring
1 SPRAG SHAFT
2 SPRAG LOCKING LUG
3 SPRING
TRANSMISSION
Cl ean the case i n a sol vent tank. Fl ush the case
bores and fl ui d passages thoroughl y wi th sol vent.
Dry the case and al l fl ui d passages wi th compressed
ai r. Be sure al l sol vent i s removed from the case and
that al l fl ui d passages are cl ear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will
readily adhere to case surfaces and transmission
components and will circulate throughout the trans-
mission after assembly. A sufficient quantity of lint
can block fluid passages and interfere with valve
body operation.
I nspect the case for cracks, porous spots, worn
servo bores, or damaged threads. However, the case
wi l l have to be repl aced i f i t exhi bi ts damage or wear.
Lubri cate the front band adjusti ng screw and l ock-
nut wi th petrol eum jel l y and thread i t part way i nto
the case. Be sure the screw turns freel y and does not
bi nd. I nstal l the l ocknut on the screw after checki ng
screw thread operati on.
I nspect al l the transmi ssi on bushi ngs duri ng over-
haul . Bushi ng condi ti on i s i mportant as worn, scored
bushi ngs contri bute to l ow pressures, cl utch sl i p and
accel erated wear of other components. Repl ace worn,
or scored bushi ngs, or i f doubt exi sts about bushi ng
condi ti on.
Use recommended tool s to repl ace bushi ngs. The
tool s are si zed and desi gned to remove, i nstal l and
seat bushi ngs correctl y. The bushi ng repl acement
Fig. 223 Valve Body Components
2 SHUTTLE VALVE
3 12 GOVERNOR PLUG
4 VALVE BODY
6 SLEEVE
8 RETAINER
9 12 SHIFT VALVE
12 END PLATE
15 E-RING
16 23 SHIFT VALVE
17 GUIDES
18 23 GOVERNOR PLUG
19 PRIMARY SPRING
tool s are i ncl uded i n Bushi ng Tool Sets C-3887-B, or
C-3887-J.
Pre-si zed servi ce bushi ngs are avai l abl e for
repl acement purposes. Onl y the sun gear bushi ngs
are not servi ced. Repl ace the gear as an assembl y i f
the bushi ngs are severel y scored, or worn.
Hel i -Coi l i nserts are recommended for repai ri ng
damaged, stri pped or worn threads i n al umi num
parts. Stai nl ess steel i nserts are preferred.
The use of crocus cl oth i s permi ssi bl e where neces-
sary, provi di ng i t i s used careful l y. When used on
val ves, use extreme care to avoi d roundi ng off sharp
edges. Sharp edges are vi tal as they prevent forei gn
matter from getti ng between the val ve and val ve
bore.
Do not reuse oi l seal s, gaskets, seal ri ngs, or
O-ri ngs duri ng overhaul . Repl ace these parts as a
matter of course. Al so do not reuse snap ri ngs or
E-cl i ps that are bent or di storted. Repl ace these parts
as wel l .
Lubri cate transmi ssi on parts wi th Mopar ATF
Pl us 3, Type 7176 transmi ssi on fl ui d duri ng assem-
bl y. Use Mopar Door Ease, or Ru-Gl yde to l ubri cate
pi ston seal s and O-ri ngs. Use petrol eum jel l y on
thrust washers and to hol d parts i n pl ace duri ng
reassembl y.
DRUM/OVERDRIVE PISTON RETAINER
Cl ean the overrunni ng cl utch assembl y, cl utch cam,
l ow-reverse drum, and overdri ve pi ston retai ner i n
sol vent. Dry them wi th compressed ai r after cl ean-
i ng.
I nspect condi ti on of each cl utch part after cl eani ng.
Repl ace the overrunni ng cl utch rol l er and spri ng
assembl y i f any rol l ers or spri ngs are worn or dam-
aged, or i f the rol l er cage i s di storted, or damaged.
Repl ace the cam i f worn, cracked or damaged.
Repl ace the l ow-reverse drum i f the cl utch race,
rol l er surface or i nsi de di ameter i s scored, worn or
damaged. Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Exami ne the overdri ve pi ston retai ner careful l y for
wear, cracks, scori ng or other damage. Be sure the
retai ner hub i s a snug fi t i n the case and drum.
Repl ace the retai ner i f worn or damaged.
FRONT SERVO
Cl ean the servo pi ston components wi th sol vent
and dry them wi th compressed ai r. Wi pe the band
cl ean wi th l i nt free shop towel s.
Repl ace the front band i f di storted, l i ni ng i s
burned, fl aki ng off, or worn to the poi nt where the
grooves i n the l i ni ng materi al are no l onger vi si bl e.
I nspect the servo components (Fi g. 224). Repl ace
the spri ngs i f col l apsed, di storted or broken. Repl ace
the gui de, rod and pi ston i f cracked, bent, or worn.
Di scard the servo snap ri ng i f di storted or warped.
Check the servo pi ston bore for wear. I f the bore i s
severel y scored, or damaged, i t wi l l be necessary to
repl ace the case.
Repl ace any servo component i f doubt exi sts about
condi ti on. Do not reuse suspect parts.
REAR SERVO
Remove and di scard the servo pi ston seal ri ng (Fi g.
225). Then cl ean the servo components wi th sol vent
and dry wi th compressed ai r. Repl ace ei ther spri ng i f
col l apsed, di storted or broken. Repl ace the pl ug and
pi ston i f cracked, bent, or worn. Di scard the servo
snap ri ngs and use a new ones at assembl y.
OIL PUMP AND REACTION SHAFT SUPPORT
(1) Cl ean pump and support components wi th sol -
vent and dry them wi th compressed ai r.
(2) Check condi ti on of the seal ri ngs and thrust
washer on the reacti on shaft support. The seal ri ngs
do not need to be repl aced unl ess cracked, broken, or
severel y worn.
(3) I nspect the pump and support components.
Repl ace the pump or support i f the seal ri ng grooves
or machi ned surfaces are worn, scored, pi tted, or
damaged. Repl ace the pump gears i f pi tted, worn
chi pped, or damaged.
Fig. 224
1 PISTON RINGS
2 O-RING
3 SNAP-RING
4 SEAL RING
5 PISTON ROD GUIDE
6 SNAP-RING
7 SERVO SPRING
8 PISTON ROD
9 SERVO PISTON
(4) I nspect the pump bushi ng. Then check the
reacti on shaft support bushi ng. Repl ace ei ther bush-
i ng onl y i f heavi l y worn, scored or damaged. I t i s not
necessary to repl ace the bushi ngs unl ess they are
actual l y damaged.
(5) I nstal l the gears i n the pump body and mea-
sure pump component cl earances as fol l ows:
(a) Cl earance between outer gear and reacti on
shaft housi ng shoul d be 0.010 to 0.063 mm (0.0004
to 0.0025 i n.). Cl earance between i nner gear and
reacti on shaft housi ng shoul d be 0.010 to 0.063
mm (0.0004 to 0.0025 i n.). Both cl earances can be
measured at the same ti me by:
(I ) I nstal l i ng the pump gears i n the pump
housi ng.
(I I ) Posi ti on an appropri ate pi ece of Pl asti -
gage across both gears.
(I I I ) Al i gn the pl asti gage to a fl at area on the
reacti on shaft housi ng.
(I V) I nstal l the reacti on shaft to the pump
housi ng.
(V) Separate the reacti on shaft housi ng from
the pump housi ng and measure the Pl asti gage
fol l owi ng the i nstructi ons suppl i ed wi th i t.
(b) Cl earance between i nner gear tooth and
outer gear shoul d be 0.08 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
(c) Cl earance between outer gear and pump
housi ng shoul d al so be 0.010 to 0.19 mm (0.0035 to
0.0075 i n.). Measure cl earance wi th an appropri ate
feel er gauge.
FRONT CLUTCH
Cl ean and i nspect the front cl utch components.
Repl ace the cl utch di scs i f warped, worn, scored,
burned or charred, or i f the faci ng i s fl aki ng off.
Repl ace the steel pl ates i f heavi l y scored, warped, or
broken. Be sure the dri vi ng l ugs on the pl ates are i n
good condi ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the cl utch spri ng and spri ng retai ner i f
ei ther i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged.
Check acti on of the check bal l i n the retai ner (Fi g.
226). The bal l must move freel y and not sti ck.
NOTE: Inspect the clutch retainer bushings care-
fully (Fig. 227). The retainer bushings are NOT ser-
viceable. It will be necessary to replace the retainer
if either bushing is scored, or worn.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y scored.
REAR CLUTCH
Cl ean the cl utch components wi th sol vent and dry
them wi th compressed ai r.
Check condi ti on of the i nput shaft seal ri ngs. I t i s
not necessary to remove or repl ace ri ngs unl ess they
are broken, cracked, or no l onger securel y hooked
together.
I nspect the i nput shaft spl i nes and machi ned sur-
faces. Very mi nor ni cks or scratches can be smoothed
off wi th crocus cl oth. repl ace the shaft i f the spl i nes
are damaged, or any of the machi ned surfaces are
severel y scored.
Fig. 225 Rear Servo Components
1 SNAP RING
2 PISTON SEAL
3 PISTON PLUG
4 SPRING RETAINER
5 SNAP RING
6 PISTON SPRING
7 CUSHION SPRING
8 PISTON
Fig. 226 Front Clutch Piston Retainer Check Ball
Location
1 RETAINER CHECK BALL
Repl ace the cl utch di scs i f warped, worn, scored,
burned/charred, the l ugs are damaged, or i f the fac-
i ng i s fl aki ng off.
Repl ace the steel pl ates and the pressure pl ate i f
heavi l y scored, warped, or broken. Be sure the dri v-
i ng l ugs on the di scs and pl ates are al so i n good con-
di ti on. The l ugs must not be bent, cracked or
damaged i n any way.
Repl ace the pi ston spri ng and wave spri ng i f ei ther
part i s di storted, warped or broken.
Check the l ug grooves i n the cl utch retai ner. The
steel pl ates shoul d sl i de freel y i n the sl ots. Repl ace
the retai ner i f the grooves are worn or damaged. Al so
check acti on of the retai ner check bal l . The bal l must
move freel y and not sti ck.
I nspect the pi ston and retai ner seal surfaces for
ni cks or scratches. Mi nor scratches can be removed
wi th crocus cl oth. However, repl ace the pi ston and/or
retai ner i f the seal surfaces are seri ousl y damaged.
Check thrust washer condi ti on. Washer thi ckness
shoul d be 1.55 to 1.60 mm (0.061 to 0.063 i n.).
Repl ace the washer i f worn or damaged.
Check condi ti on of the two seal ri ngs on the i nput
shaft and the si ngl e seal ri ng on the pi ston retai ner
hub. Repl ace the seal ri ngs onl y i f severel y worn,
cracked, or cannot be hooked together.
PLANETARY GEARTRAIN/OUTPUT SHAFT
Cl ean the i ntermedi ate shaft and pl anetary compo-
nents i n sol vent and dry them wi th compressed ai r.
Do not spi n the pl anetary pi ni on gears wi th com-
pressed ai r.
I nspect the pl anetary gear sets and annul us gears.
The pl anetary pi ni ons, shafts, washers, and retai ni ng
pi ns are servi ceabl e. However, i f a pi ni on carri er i s
damaged, the enti re pl anetary gear set must be
Repl ace the annul us gears i f the teeth are chi pped,
broken, or worn, or the gear i s cracked. Repl ace the
pl anetary thrust pl ates and the tabbed thrust wash-
ers i f cracked, scored or worn.
I nspect the machi ned surfaces of the output shaft.
Be sure the oi l passages are open and cl ear. Repl ace
the shaft i f scored, pi tted, or damaged.
I nspect the sun gear and dri vi ng shel l . I f ei ther
component i s worn or damaged, remove the sun gear
rear retai ni ng ri ng and separate the sun gear and
thrust pl ate from the dri vi ng shel l . Then repl ace the
necessary component.
Repl ace the sun gear as an assembl y i f the gear
teeth are chi pped or worn. Al so repl ace the gear as
an assembl y i f the bushi ngs are scored or worn. The
sun gear bushi ngs are not servi ceabl e. Repl ace the
thrust pl ate i f worn, or severel y scored. Repl ace the
dri vi ng shel l i f di storted, cracked, or damaged i n any
way.
Repl ace al l snap ri ngs duri ng geartrai n assembl y.
Reusi ng snap ri ngs i s not recommended.
ADJ USTMENTS
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n Park
and Neutral . Adjustment i s OK i f the engi ne starts
onl y i n these posi ti ons. Adjustment i s i ncorrect i f the
engi ne starts i n one but not both posi ti ons. I f the
engi ne starts i n any posi ti on other than Park or Neu-
tral , or i f the engi ne wi l l not start at al l , the park/
neutral posi ti on swi tch may be faul ty.
Gearshift Adjustment Procedure
(3) Rel ease cabl e adjuster cl amp (at transmi ssi on
end of cabl e) to unl ock cabl e.
(4) Unsnap cabl e from cabl e mounti ng bracket on
(5) Sl i de cabl e eyel et off transmi ssi on shi ft l ever.
(6) Veri fy transmi ssi on shi ft l ever i s i n Park
detent by movi ng l ever ful l y rearward. Last rearward
detent i s Park posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Sl i de cabl e eyel t onto transmi ssi on shi ft l ever.
(9) Snap shi ft cabl e adjuster i nto mounti ng
bracket on transmi ssi on.
(10) Lock shi ft cabl e by pressi ng cabl e adjuster
cl amp down unti l i t snaps i nto pl ace.
(11) Lower vehi cl e and check engi ne starti ng.
Engi ne shoul d start onl y i n Park and Neutral .
Fig. 227 Retainer Bushing Location/Inspection
1 FRONT CLUTCH RETAINER BUSHINGS (NON-
SERVICEABLE)
CABLE ADJUSTMENT
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove shi ft l ever bezel and consol e screws.
Rai se bezel and consol e for access to cabl e.
(3) Pul l cabl e l ock button up to rel ease cabl e (Fi g.
229).
(4) Turn i gni ti on swi tch to LOCK posi ti on.
(5) Use a spacer to create a one mi l l i meter gap
between the shi fter pawl and top of the shi ft gate.
(6) Pul l cabl e forward. Then rel ease cabl e and
press cabl e l ock button down unti l i t snaps i n pl ace.
(7) Check adjustment as fol l ows:
(a) Check movement of rel ease shi ft handl e but-
ton (fl oor shi ft) or rel ease l ever (col umn shi ft). You
shoul d not be abl e to press button i nward or move
col umn l ever.
(b) Turn i gni ti on swi tch to RUN posi ti on.
(c) Shi fti ng out of park shoul d not be possi bl e.
(d) Appl y the brake and attempt to shi ft out of
PARK. Shi fti ng shoul d be possi bl e.
(e) Whi l e the transmi ssi on i s shi fted out of
PARK, rel ease the brake and attempt to shi ft
through al l gears. Rel ease the shi ft button at l east
once duri ng thi s procedure. The i gni ti on key shoul d
not go to the LOCK posi ti on.
(f) Return transmi ssi on to the PARK posi ti on
wi thout appl yi ng the brake.
(8) Move shi ft l ever back to PARK and check i gni -
ti on swi tch operati on. You shoul d be abl e to turn
swi tch to LOCK posi ti on and shi ft l ever rel ease but-
ton/l ever shoul d not move.
ADJUSTMENT
The transmi ssi on throttl e val ve i s operated by a
cam on the throttl e l ever. The throttl e l ever i s oper-
ated by an adjustabl e cabl e (Fi g. 230). The cabl e i s
attached to an arm mounted on the throttl e l ever
shaft. A retai ni ng cl i p at the engi ne-end of the cabl e
i s removed to provi de for cabl e adjustment. The
retai ni ng cl i p i s then i nstal l ed back onto the throttl e
val ve cabl e to l ock i n the adjustment.
A correctl y adjusted throttl e val ve cabl e wi l l cause
the throttl e l ever on the transmi ssi on to move si mul -
taneousl y wi th the throttl e body l ever from the i dl e
posi ti on. Proper adjustment wi l l al l ow si mul taneous
movement wi thout causi ng the transmi ssi on throttl e
l ever to ei ther move ahead of, or l ag behi nd the l ever
on the throttl e body.
Checking Throttle Valve Cable Adjustment
(1) Turn i gni ti on key to OFF posi ti on.
(2) Remove ai r cl eaner.
(3) Veri fy that l ever on throttl e body i s at curb i dl e
posi ti on. Then veri fy that transmi ssi on throttl e l ever
(Fi g. 231) i s al so at i dl e (ful l y forward) posi ti on.
(4) Sl i de cabl e off attachment stud on throttl e body
l ever.
(5) Compare posi ti on of cabl e end to attachment
stud on throttl e body l ever:
Fig. 228 Shift Cable Attachment At
TransmissionTypical
1 THROTTLE VALVE CABLE
2 TRANSMISSION SHIFT LEVER
3 SHIFT CABLE
4 SHIFT CABLE BRACKET
Fig. 229 Park Lock Cable Attachment
1 PARK LOCK CABLE
2 CABLE LOCK BUTTON
3 SHIFT LEVER ASSEMBLY
4 SHIFT CABLE
Cabl e end and attachment stud shoul d be
al i gned (or centered on one another) to wi thi n 1 mm
(0.039 i n.) i n ei ther di recti on.
I f cabl e end and attachment stud are mi sal i gned
(off center), cabl e wi l l have to be adjusted as
descri bed i n Throttl e Val ve Cabl e Adjustment proce-
dure.
(6) Reconnect cabl e end to attachment stud. Then
wi th ai d of a hel per, observe movement of transmi s-
si on throttl e l ever and l ever on throttl e body.
I f both l evers move si mul taneousl y from i dl e to
hal f-throttl e and back to i dl e posi ti on, adjustment i s
correct.
I f transmi ssi on throttl e l ever moves ahead of, or
l ags behi nd throttl e body l ever, cabl e adjustment wi l l
be necessary. Or, i f throttl e body l ever prevents
transmi ssi on l ever from returni ng to cl osed posi ti on,
cabl e adjustment wi l l be necessary.
Throttle Valve Cable Adjustment Procedure
(1) Turn i gni ti on swi tch to OFF posi ti on.
(2) Remove ai r cl eaner i f necessary.
(3) Di sconnect cabl e end from attachment stud.
Carefully slide cable off stud. Do not pry or pull
cable off.
(4) Veri fy that transmi ssi on throttl e l ever i s i n
ful l y cl osed posi ti on. Then be sure l ever on throttl e
body i s at curb i dl e posi ti on.
(5) I nsert a smal l screwdri ver under edge of
retai ni ng cl i p and remove retai ni ng cl i p.
(6) Center cabl e end on attachment stud to wi thi n
1 mm (0.039 i n.).
NOTE: Be sure that as the cable is pulled forward
and centered on the throttle lever stud, the cable
housing moves smoothly with the cable. Due to the
angle at which the cable housing enters the spring
housing, the cable housing may bind slightly and
create an incorrect adjustment.
(7) I nstal l retai ni ng cl i p onto cabl e housi ng.
(8) Check cabl e adjustment. Veri fy transmi ssi on
throttl e l ever and l ever on throttl e body move si mul -
taneousl y.
FRONT BAND ADJUSTMENT
The front (ki ckdown) band adjusti ng screw i s
l ocated on the l eft si de of the transmi ssi on case
above the manual val ve and throttl e val ve l evers.
(2) Loosen band adjusti ng screw l ocknut (Fi g. 232).
Then back l ocknut off 3-5 turns. Be sure adjusti ng
screw turns freel y i n case. Appl y l ubri cant to screw
threads i f necessary.
(3) Ti ghten band adjusti ng screw to 8 Nm (72 i n.
l bs.) torque wi th I nch Pound Torque Wrench C-3380-A,
a 3-i n. extensi on and appropri ate Torx socket.
CAUTION: If Adapter C-3705 is needed to reach the
adjusting screw, tighten the screw to only 5 Nm
(47-50 in. lbs.) torque.
(4) Back off front band adjusti ng screw 2-1/2
turns.
(5) Hol d adjuster screw i n posi ti on and ti ghten
l ocknut to 41 Nm (30 ft. l bs.) torque.
Fig. 230 Throttle Cable Attachment At Engine
1 TRANSMISSION THROTTLE VALVE CABLE
2 ACCELERATOR CABLE
3 CABLE ENGINE BRACKET
4 THROTTLE BODY
5 CABLE GUIDE
Fig. 231 Throttle Cable Attachment At Transmission
1 RETURN SPRING
3 THROTTLE VALVE CABLE BRACKET
4 THROTTLE VALVE LEVER
5 GEAR SELECTOR LEVER
REAR BAND ADJUSTMENT
The transmi ssi on oi l pan must be removed for
access to the rear band adjusti ng screw.
(2) Remove transmi ssi on oi l pan and drai n fl ui d.
(3) Loosen band adjusti ng screw l ocknut 5-6 turns.
Be sure adjusti ng screw turns freel y i n l ever.
(4) Ti ghten adjusti ng screw to 5 Nm (41 i n. l bs.)
(Fi g. 233).
(5) Back off adjusti ng screw 7 turns.
(6) Hol d adjusti ng screw i n pl ace and ti ghten l ock-
nut to 34 Nm (25 ft. l bs.) torque.
(7) Posi ti on new gasket on oi l pan and i nstal l pan
on transmi ssi on. Ti ghten pan bol ts to 17 Nm (13 ft.
l bs.) torque.
(8) Lower vehi cl e and refi l l transmi ssi on wi th
Mopar ATF Pl us 3, Type 7176, fl ui d.
VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
val ve body;
Li ne Pressure
Throttl e Pressure
Li ne and throttl e pressures are i nterdependent
because each affects shi ft qual i ty and ti mi ng. As a
resul t, both adjustments must be performed properl y
and i n the correct sequence. Adjust l i ne pressure fi rst
and throttl e pressure l ast.
LINE PRESSURE ADJUSTMENT
Measure di stance from the val ve body to the i nner
edge of the adjusti ng screw wi th an accurate steel
scal e (Fi g. 234).
Di stance shoul d be 33.4 mm (1-5/16 i n.).
I f adjustment i s requi red, turn the adjusti ng screw
i n, or out, to obtai n requi red di stance setti ng.
NOTE: The 33.4 mm (1-5/16 in.) setting is an
approximate setting. Manufacturing tolerances may
make it necessary to vary from this dimension to
obtain desired pressure.
One compl ete turn of the adjusti ng screw changes
l i ne pressure approxi matel y 1-2/3 psi (9 kPa).
Turni ng the adjusti ng screw countercl ockwi se
i ncreases pressure whi l e turni ng the screw cl ockwi se
decreases pressure.
THROTTLE PRESSURE ADJUSTMENT
I nsert Gauge Tool C-3763 between the throttl e
l ever cam and the ki ckdown val ve stem (Fi g. 235).
Push the gauge tool i nward to compress the ki ck-
down val ve agai nst the spri ng and bottom the throt-
tl e val ve.
Mai ntai n pressure agai nst ki ckdown val ve spri ng.
Turn throttl e l ever stop screw unti l the screw head
touches throttl e l ever tang and the throttl e l ever cam
touches gauge tool .
Fig. 232 Front Band Adjustment Screw Location
1 LOCK-NUT
2 FRONT BAND ADJUSTER
Fig. 233 Rear Band Adjustment Screw Location
1 30RH REAR BAND LEVER AND ADJUSTING SCREW
2 32RH REAR BAND LEVER AND ADJUSTING SCREW
NOTE: The kickdown valve spring must be fully
compressed and the kickdown valve completely
bottomed to obtain correct adjustment.
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
Fig. 234 Line Pressure Adjustment
1 WRENCH
2 15/16 INCH
Fig. 235 Throttle Pressure Adjustment
1 HEX WRENCH (IN THROTTLE LEVER ADJUSTING SCREW)
2 SPECIAL TOOL C-3763 (POSITIONED BETWEEN THROTTLE
LEVER AND KICKDOWN VALVE)
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SPECIFICATIONS
30RH AUTOMATIC TRANSMISSION
GENERAL
COMPONENT METRIC INCH
Oil pump gear tip clearance 0.089-0.190 mm 0.0035-0.0075 in.
Planetary end play 0.125-1.19 mm 0.001-0.047 in.
Input shaft end play 0.56-2.31 mm 0.022-0.091 in.
Clutch pack clearance/Front 4-disc. 1.70-3.40 mm 0.067-0.134 in.
Clutch pack clearance/Rear 4-disc. 0.559-0.940 mm 0.022-0.037 in.
Front clutch spring usage 1 spring
30RH-Front Band adjustment from 72 in. lbs. Back off 2.5 turns
30RH-Rear Band adjustment from 41 in. lbs. Back off 7 turns
Recommended fluid Mopar, ATF Plus 3, Type 7176
THRUST WASHER/SPACER/SNAP RING DIMENSIONS
COMPONENT METRIC INCH
Front clutch thrust washer (reaction shaft support hub) 1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Output shaft thrust plate (output shaft pilot hub) 1.5-1.6mm 0.060-0.063 in.
Output shaft thrust washer (rear clutch hub) 1.3-1.4 mm 0.052-0.054 in.
1.7-1.8 mm 0.068-0.070 in.
2.1-2.2 mm 0.083-0.086 in.
Rear clutch pack snap ring 1.5-1.6 mm 0.06-0.062 in.
1.7-1.8 mm 0.068-0.070 in.
1.9-2.0 mm 0.076-0.078 in.
Planetary geartrain snap ring
(at front of output shaft)
1.0-1.1 mm 0.040-0.044 in.
1.6-1.7 mm 0.062-0.066 in.
2.1-2.2 mm 0.082-0.086 in.
PRESSURE TEST ALL
ITEM RANGE PRESSURE
Line pressure (at
accumulator)
Closed throttle 372-414 kPa (54-60 psi).
Front servo Third gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
ITEM RANGE PRESSURE
Governor D range closed throttle Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
TORQUE
DESCRIPTION TORQUE
Bol t/nut, crossmember . . . . . . . . 68 Nm (50 ft. l bs.)
Bol t, dri vepl ate to crankshaft . . 75 Nm (55 ft. l bs.)
Pl ug, front band reacti on . . . . . 17 Nm (13 ft. l bs.)
Locknut, front band adj. . . . . . . 34 Nm (25 ft. l bs.)
Swi tch, park/neutral . . . . . . . . . 34 Nm (25 ft. l bs.)
Bol t, fl ui d pan . . . . . . . . . . . . . . 17 Nm (13 ft. l bs.)
Bol t, oi l pump . . . . . . . . . . . . . . 20 Nm (15 ft. l bs.)
Bol t, overrunni ng cl utch cam . . 17 Nm (13 ft. l bs.)
Pl ug, pressure test port . . . . . . . 14 Nm (10 ft. l bs.)
Bol t, reacti on shaft support . . . . 20 Nm (15 ft. l bs.)
Locknut, rear band . . . . . . . . . . 41 Nm (30 ft. l bs.)
Bol t. speedometer adapter . . . . . . 11 Nm (8 ft. l bs.)
Screw, fl ui d fi l ter . . . . . . . . . . . . 4 Nm (35 i n. l bs.)
Bol t, val ve body to case . . . . . 12 Nm (100 i n. l bs.)
SPECIAL TOOLS
30RH TRANSMISSIONS
Remover6957
Installer6951
Retainer, Detent Ball and Spring6583
Snap-ring Plier6823
Pilot StudC-3288-B
Pressure GaugeC-3292
Pressure GaugeC-3293SP
Spring CompressorC-3422-B
Fixture, Engine SupportC-3487-A
Spring CompressorC-3575-A
Spring CompressorC-3863-A
Adapter, Band AdjusterC-3705
Transmission Repair StandC-3750-B
Puller, Slide HammerC-3752
Gauge, Throttle SettingC-3763
Seal InstallerC-3860-A
Bushing Remover/InstallerC-3887-J
Cup, RemoverSP-3633
Remover, BushingSP-5301
Installer, BushingSP-5118
Snap-ring PlierC-3915
Seal RemoverC-3985-B
Bushing, Remover6957
Flusher, Oil Cooler6906
InstallerC-3995-A
Universal HandleC-4171
Remover/InstallerC-4470
Nut, Bushing RemoverSP-1191
AW4 AUTOMATIC TRANSMISSION
TABLE OF CONTENTS
page page
AW4 AUTOMATIC TRANSMISSION . . . . . . . . . 218
FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
TRANSMISSION VALVE BODY COMPONENTS . 228
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
TRANSMISSION RANGES AND SHIFT LEVER
POSITIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 236
TRANSMISSION CONTROL MODULE (TCM) . . . 237
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . 237
TRANSMISSION COOLER . . . . . . . . . . . . . . . . . 237
MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . 238
GENERAL DIAGNOSIS INFORMATION . . . . . . . 239
EFFECTS OF INCORRECT FLUID LEVEL . . . . . 239
CAUSES OF BURNT FLUID . . . . . . . . . . . . . . . . 240
FLUID CONTAMINATION . . . . . . . . . . . . . . . . . . 240
PRELIMINARY INSPECTION AND
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 241
MANUAL SHIFTING TEST . . . . . . . . . . . . . . . . . 241
HYDRAULIC PRESSURE TEST . . . . . . . . . . . . . 241
PRESSURE TEST ANALYSIS . . . . . . . . . . . . . . . 242
TIME LAG TEST. . . . . . . . . . . . . . . . . . . . . . . . . 242
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 242
TIME LAG TEST ANALYSIS . . . . . . . . . . . . . . . . 243
SERVICE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 243
TRANSMISSION SOLENOID TESTING. . . . . . . . 245
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 246
THROTTLE VALVE CABLE. . . . . . . . . . . . . . . . . 246
SPEED SENSOR TESTING . . . . . . . . . . . . . . . . 246
FLOW TESTING TRANSMISSION MAIN
COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
TORQUE CONVERTER STATOR CLUTCH
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 247
SERVICE PROCEDURES
CHECKING FLUID LEVEL . . . . . . . . . . . . . . . . . 247
CHECKING FLUID CONDITION . . . . . . . . . . . . . 248
REFILLING AFTER OVERHAUL OR FLUID/
FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . 248
TRANSMISSION CONTROL MODULE (TCM)
SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 248
FLUSHING COOLERS AND TUBES . . . . . . . . . . 248
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 249
TRANSMISSION AND TORQUE CONVERTER . . 250
ADAPTER HOUSING SEAL . . . . . . . . . . . . . . . . 252
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 252
SPEEDOMETER ADAPTER . . . . . . . . . . . . . . . . 253
SPEED SENSOR ROTOR-SPEEDOMETER
DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . 254
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 256
BRAKE TRANSMISSION SHIFT INTERLOCK . . . 256
TRANSMISSION VALVE BODY SOLENOIDS . . . 258
TRANSMISSION VALVE BODY. . . . . . . . . . . . . . 259
TRANSMISSION CONTROL MODULE . . . . . . . . 260
SOLENOID HARNESS ADAPTER SEAL . . . . . . . 261
MANUAL VALVE SHAFT SEAL . . . . . . . . . . . . . . 262
ACCUMULATOR PISTONS AND SPRINGS. . . . . 264
SECOND COAST BRAKE SERVO . . . . . . . . . . . 265
PARK ROD AND PAWL. . . . . . . . . . . . . . . . . . . . 266
TRANSMISSION THROTTLE CABLE . . . . . . . . . 267
OIL PUMP SEAL. . . . . . . . . . . . . . . . . . . . . . . . . 268
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . 269
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
OVERDRIVE PLANETARY GEAR AND
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
OVERDRIVE SUPPORT . . . . . . . . . . . . . . . . . . . 309
DIRECT CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . 312
FORWARD CLUTCH . . . . . . . . . . . . . . . . . . . . . 317
FRONT PLANETARY GEAR . . . . . . . . . . . . . . . . 322
SUN GEAR AND NO. 1 ONEWAY CLUTCH. . . . 324
SECOND BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 327
PLANETARY/BRAKE PACK/OUTPUT SHAFT . . . 329
TRANSMISSION VALVE BODY. . . . . . . . . . . . . . 333
TRANSMISSION PARTS CLEANING AND
INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . 336
ADJUSTMENTS
GEARSHIFT CABLE. . . . . . . . . . . . . . . . . . . . . . 336
CABLE ADJUSTMENT. . . . . . . . . . . . . . . . . . . 336
ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . 337
SPECIFICATIONS
AW-4 AUTOMATIC TRANSMISSION . . . . . . . . . . 338
SPECIAL TOOLS
AW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
XJ AW4 AUTOMATIC TRANSMISSION 21 - 217
AW4 AUTOMATIC TRANSMISSION
DESCRIPTION
The AW4 i s a 4speed, el ectroni cal l y control l ed
automati c transmi ssi on (Fi g. 1).
The runni ng gear consi sts of an oi l pump, pl ane-
tary gear sets, cl utch and brake uni ts, hydraul i c
accumul ators, a val ve body wi th el ectri cal sol enoi ds,
and a transmi ssi on control modul e (TCM). Cabl es are
used to provi de shi ft and throttl e pressure control
i nformati on. A park/neutral posi ti on swi tch permi ts
engi ne starti ng i n the Park and Neutral ranges onl y.
The transmi ssi on I . D. pl ate i s attached to the case
(Fi g. 2). The pl ate contai ns the transmi ssi on seri al
and model numbers. Refer to the i nformati on on thi s
pl ate when orderi ng servi ce parts.
ELECTRONIC CONTROLS
The AW4 i s el ectroni cal l y control l ed i n 1, 2, 3 and
D ranges. Control s consi st of the transmi ssi on control
modul e (TCM), val ve body sol enoi ds and vari ous sen-
sors. The sensors moni tor vehi cl e speed, throttl e
openi ng, shi ft l ever posi ti on and brake pedal appl i ca-
ti on.
TRANSMISSION GEAR RATIOS
Fourth gear i s an 0.75:1 rati o overdri ve range.
Fi rst, second, thi rd and reverse gear are conventi onal
ranges. Thi rd gear rati o i s 1:1. A separate pl anetary
gear set provi des overdri ve operati on i n fourth gear.
OPERATION
GEARTRAIN OPERATION AND APPLICATION CHARTS
Operati on and appl i cati on of the fi rst through
fourth and reverse gear el ements are outl i ned i n the
functi on and appl i cati on charts.
The Component Functi on Chart descri bes basi c
functi on of vari ous geartrai n el ements. The Compo-
nent Appl i cati on Chart i ndi cates whi ch el ements
(i ncl udi ng val ve body sol enoi ds), are appl i ed i n the
vari ous gear ranges.
Fig. 1 AW4 Automatic Transmission
Fig. 2 Transmission Identification
1 TRANSMISSION I. D. PLATE
21 - 218 AW4 AUTOMATIC TRANSMISSION XJ
COMPONENT FUNCTION CHART
COMPONENT NAME COMPONENT FUNCTION
Overdrive Direct Clutch Connects overdrive sun gear and overdrive carrier.
Overdrive Brake Prevents overdrive sun gear from turning either clockwise or
counter-clockwise.
Overdrive One-Way Clutch When transmission is driven by engine, connects overdrive sun gear
and overdrive carrier.
Forward Clutch Connects input shaft and front ring gear.
Direct Clutch Connects input shaft to the front and rear ring gears.
Second Coast Brake Prevents front and rear sun gear from turning either clockwise or
counter-clockwise.
Second Brake Prevents outer race of number 1 one-way clutch from turning either
clockwise or counter-clockwise, thus preventing the front and rear sun
gears from turning counter-clockwise.
First/Reverse Brake Prevents the rear planetary carrier from turning either clockwise or
counter-clockwise.
Number 1 One-way Clutch When second brake is operating, prevents the front and rear sun
gears from turning counter-clockwise.
Number 2 One-Way Clutch Prevents the rear planetary carrier from turning counter-clockwise.
COMPONENT APPLICATION CHART
FIRST/SECOND/THIRD/REVERSE GEAR COMPONENTS
Fi rst through thi rd and reverse gear components
are outl i ned i n (Fi g. 3).
The i nput shaft i s meshed wi th the di rect cl utch
hub and the forward cl utch drum. These el ements
rotate as a uni t. The forward cl utch hub rotates as a
uni t wi th the front pl anetary ri ng gear. The di rect
cl utch drum i s meshed wi th the forward end of the
pl anetary sun gear.
The second brake hub serves as the outer race of
oneway cl utch No. 1. The cl utch i nner race i s l ocked
wi th the front/rear sun gear. The i nner race of one
way cl utch No. 2 i s spl i ned to the transmi ssi on case
and i s l ocked. The outer race rotates as a uni t wi th
the rear pl anetary carri er.
The rear pl anetary ri ng gear i s spl i ned to the out-
put shaft. The front pl anetary carri er and rear car-
ri er ri ng gear are meshed and rotate as a uni t wi th
the output shaft.
FOURTH GEAR OVERDRIVE COMPONENTS
The overdri ve system consi sts of the i nput shaft,
oneway cl utch, pl anetary sun gear, ri ng gear, pl an-
etary carri er, overdri ve cl utch and overdri ve brake
(Fi g. 4). The overdri ve el ements are control l ed and
appl i ed through transmi ssi on val ve body sol enoi d
number two.
I n fourth gear, the overdri ve brake prevents the
overdri ve sun gear from turni ng. The overdri ve i nput
shaft and pl anetary carri er rotate as a uni t. The sun
gear and overdri ve di rect cl utch drum are i n mesh
and operate as a si ngl e uni t. The di rect cl utch
spl i nes functi on as the hub for the overdri ve brake.
The oneway cl utch outer race i s i n mesh wi th the
pl anetary carri er. The i nner race i s fi xed to the sun
gear shaft.
FLUID
NOTE: Refer to the maintenance schedules in
Group 0, Lubrication and Maintenance for the rec-
ommended maintenance (fluid/filter change) inter-
vals for this transmission.
NOTE: Refer to Service Procedures in this group
for fluid level checking procedures.
DESCRIPTION
Mopar Dexron I I E/Mercon i s the recommended
fl ui d for the AW-4 automati c transmi ssi ons.
Fig. 3 First/Second/Third/Reverse Gear Components
1 2ND COAST BRAKE
2 DIRECT CLUTCH
3 FORWARD CLUTCH
4 FRONT PLANETARY RING GEAR
5 SECOND BRAKE
6 FIRST/REVERSE BRAKE
7 REAR PLANETARY CARRIER
8 REAR PLANETARY RING GEAR
9 OUTPUT SHAFT
10 FRONT & REAR PLANETARY SUN GEAR
11 ONE-WAY CLUTCH NO. 2
12 ONE-WAY CLUTCH NO. 1
13 FRONT PLANETARY CARRIER
14 INPUT SHAFT
Dexron II fluid IS NOT recommended. Clutch
chatter can result from the use of improper
fluid.
Mopar Dexron I I E/Mercon automati c transmi ssi on
fl ui d when new i s red i n col or. The ATF i s dyed red
so i t can be i denti fi ed from other fl ui ds used i n the
vehi cl e such as engi ne oi l or anti freeze. The red col or
i s not permanent and i s not an i ndi cator of fl ui d con-
di ti on. As the vehi cl e i s dri ven, the ATF wi l l begi n to
l ook darker i n col or and may eventual l y become
brown. This is normal. A dark brown/bl ack fl ui d
accompani ed wi th a burnt odor and/or deteri orati on
i n shi ft qual i ty may i ndi cate fl ui d deteri orati on or
transmi ssi on component fai l ure.
FLUID ADDITIVES
Dai ml erChrysl er strongl y recommends agai nst the
addi ti on of any fl ui ds to the transmi ssi on, other than
those automati c transmi ssi on fl ui ds l i sted above.
Excepti ons to thi s pol i cy are the use of speci al dyes
to ai d i n detecti ng fl ui d l eaks.
Vari ous speci al addi ti ves and suppl ements exi st
that cl ai m to i mprove shi ft feel and/or qual i ty. These
addi ti ves and others al so cl ai m to i mprove converter
cl utch operati on and i nhi bi t overheati ng, oxi dati on,
varni sh, and sl udge. These cl ai ms have not been sup-
ported to the sati sfacti on of Dai ml erChrysl er and
these addi ti ves must not be used. The use of trans-
mi ssi on seal ers shoul d al so be avoi ded, si nce they
may adversel y affect the i ntegri ty of transmi ssi on
seal s.
OPERATION
The automati c transmi ssi on fl ui d i s sel ected based
upon several qual i ti es. The fl ui d must provi de a hi gh
l evel of protecti on for the i nternal components by
provi di ng a l ubri cati ng fi l m between adjacent metal
components. The fl ui d must al so be thermal l y stabl e
so that i t can mai ntai n a consi stent vi scosi ty through
a l arge temperature range. I f the vi scosi ty stays con-
stant through the temperature range of operati on,
transmi ssi on operati on and shi ft feel wi l l remai n con-
si stent. Transmi ssi on fl ui d must al so be a good con-
ductor of heat. The fl ui d must absorb heat from the
i nternal transmi ssi on components and transfer that
heat to the transmi ssi on case.
Fig. 4 Fourth Gear Overdrive Components
1 CLUTCH
2 BRAKE
3 RING GEAR
4 PLANETARY CARRIER
5 SUN GEAR
6 ONE-WAY CLUTCH
7 INPUT SHAFT
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fi g. 5) i s a hydraul i c devi ce
that coupl es the engi ne crankshaft to the transmi s-
si on. The torque converter consi sts of an outer shel l
wi th an i nternal turbi ne, a stator, an overrunni ng
cl utch, an i mpel l er and an el ectroni cal l y appl i ed con-
verter cl utch. The converter cl utch provi des reduced
engi ne speed and greater fuel economy when
engaged. Cl utch engagement al so provi des reduced
transmi ssi on fl ui d temperatures. Torque converter
cl utch engagement occurs i n second gear i n 12 posi -
ti on; thi rd gear i n 3 posi ti on and thi rd and fourth
gear i n D posi ti on. The torque converter hub dri ves
the transmi ssi on oi l (fl ui d) pump.
The torque converter i s a seal ed, wel ded uni t that
i s not repai rabl e and i s servi ced as an assembl y.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
Fig. 5 Torque Converter Assembly
1 TURBINE
2 IMPELLER
3 HUB
4 STATOR
5 CONVERTER CLUTCH DISC
6 DRIVE PLATE
IMPELLER
The i mpel l er (Fi g. 6) i s an i ntegral part of the con-
verter housi ng. The i mpel l er consi sts of curved vanes
pl aced radi al l y al ong the i nsi de of the housi ng on the
transmi ssi on si de of the converter. As the converter
housi ng i s rotated by the engi ne, so i s the i mpel l er,
because they are one i n the same and are the dri vi ng
member of the system.
Fig. 6 Impeller
1 ENGINE FLEXPLATE
2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE
SECTION
3 IMPELLER VANES AND COVER ARE INTEGRAL
4 ENGINE ROTATION
5 ENGINE ROTATION
TURBINE
The turbi ne (Fi g. 7) i s the output, or dri ven, mem-
ber of the converter. The turbi ne i s mounted wi thi n
the housi ng opposi te the i mpel l er, but i s not mounted
to the housi ng. The i nput shaft i s i nserted through
the center of the i mpel l er and spl i ned i nto the tur-
bi ne. The desi gn of the turbi ne i s si mi l ar to the
i mpel l er, except the bl ades of the turbi ne are curved
i n the opposi te di recti on.
Fig. 7 Turbine
1 TURBINE VANE
2 ENGINE ROTATION
3 INPUT SHAFT
4 PORTION OF TORQUE CONVERTER COVER
5 ENGINE ROTATION
6 OIL FLOW WITHIN TURBINE SECTION
STATOR
The stator assembl y (Fi g. 8) i s mounted on a sta-
ti onary shaft whi ch i s an i ntegral part of the oi l
pump. The stator al so contai ns an overrunni ng
cl utch. The stator i s l ocated between the i mpel l er
and turbi ne wi thi n the torque converter case (Fi g. 9).
The overrunni ng cl utch of the stator al l ows the sta-
tor to rotate onl y i n a cl ockwi se di recti on.
The TCC (Fi g. 10) was i nstal l ed to i mprove the
effi ci ency of the torque converter that i s l ost to the
sl i ppage of the fl ui d coupl i ng. Al though the fl ui d cou-
pl i ng provi des smooth, shockfree power transfer, i t
i s natural for al l fl ui d coupl i ngs to sl i p. I f the i mpel -
l er and turbi ne were mechani cal l y l ocked together, a
zero sl i ppage condi ti on coul d be obtai ned. A hydraul i c
pi ston was added to the turbi ne, and a fri cti on mate-
ri al was added to the i nsi de of the i mpel l er housi ng
to provi de thi s mechani cal l ock-up.
OPERATION
The converter i mpel l er (Fi g. 11) (dri vi ng member),
whi ch i s i ntegral to the converter housi ng and bol ted
to the engi ne dri ve pl ate, rotates at engi ne speed.
The converter turbi ne (dri ven member), whi ch reacts
from fl ui d pressure generated by the i mpel l er, rotates
and turns the transmi ssi on i nput shaft.
TURBINE
As the fl ui d that was put i nto moti on by the i mpel -
l er bl ades stri kes the bl ades of the turbi ne, some of
the energy and rotati onal force i s transferred i nto the
turbi ne and the i nput shaft. Thi s causes both of them
Fig. 8 Stator Components
1 CAM (OUTER RACE)
2 ROLLER
3 SPRING
4 INNER RACE
Fig. 9 Stator Location
1 STATOR
2 IMPELLER
3 FLUID FLOW
4 TURBINE
Fig. 10 Torque Converter Clutch (TCC)
1 IMPELLER FRONT COVER
2 THRUST WASHER ASSEMBLY
3 IMPELLER
4 STATOR
5 TURBINE
6 FRICTION DISC
(turbi ne and i nput shaft) to rotate i n a cl ockwi se
di recti on fol l owi ng the i mpel l er. As the fl ui d i s l eav-
i ng the trai l i ng edges of the turbi nes vanes i t conti n-
ues i n a hi nderi ng di recti on back toward the
i mpel l er. I f the fl ui d i s not redi rected before i t stri kes
the i mpel l er, i t wi l l stri ke the i mpel l er i n such a
di recti on that i t woul d tend to sl ow i t down.
STATOR
Torque mul ti pl i cati on i s achi eved by l ocki ng the
cl utch to i ts shaft (Fi g. 12). Under stal l condi ti ons
(the turbi ne i s stati onary), the oi l l eavi ng the turbi ne
vanes stri kes the face of the stator vanes and tri es to
rotate them i n a countercl ockwi se di recti on. When
thi s happens the overrunni ng cl utch of the stator
l ocks and hol ds the stator from rotati ng. Wi th the
stator l ocked, the oi l stri kes the stator vanes and i s
redi rected i nto a hel pi ng di recti on before i t enters
the i mpel l er. Thi s ci rcul ati on of oi l from i mpel l er to
turbi ne, turbi ne to stator, and stator to i mpel l er, can
produce a maxi mum torque mul ti pl i cati on of about
2.2:1. As the turbi ne begi ns to match the speed of the
i mpel l er, the fl ui d that was hi tti ng the stator i n such
as way as to cause i t to l ockup i s no l onger doi ng so.
I n thi s condi ti on of operati on, the stator begi ns to
free wheel and the converter acts as a fl ui d coupl i ng.
Fig. 11 Torque Converter Fluid Operation
1 APPLY PRESSURE
2 THE PISTON MOVES SLIGHTLY FORWARD
3 RELEASE PRESSURE
4 THE PISTON MOVES SLIGHTLY REARWARD
Fig. 12 Stator Operation
1 DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 FRONT OF ENGINE
3 INCREASED ANGLE AS OIL STRIKES VANES
4 DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
I n a standard torque converter, the i mpel l er and
turbi ne are rotati ng at about the same speed and the
stator i s freewheel i ng, provi di ng no torque mul ti pl i -
cati on. By appl yi ng the turbi nes pi ston to the i mpel -
l ers fri cti on materi al , a total converter engagement
can be obtai ned. The resul t of thi s engagement i s a
di rect 1:1 mechani cal l i nk between the engi ne and
the transmi ssi on.
The engagement and di sengagement of the TCC
are automati c and control l ed by the Transmi ssi on
Control Modul e (TCM). I nputs that determi ne cl utch
engagement are: cool ant temperature, vehi cl e speed
and throttl e posi ti on. Cl utch engagement i s con-
trol l ed by transmi ssi on val ve body sol enoi d number
three and by the converter cl utch rel ay val ve. The
sol enoi d channel s l i ne pressure to the cl utch through
the rel ay val ve at cl utch engagement speeds.
OIL PUMP
DESCRIPTION
The oi l pump (Fi g. 13) i s l ocated i n the pump hous-
i ng i nsi de the bel l housi ng of the transmi ssi on case.
The oi l pump consi sts of an i nner and outer gear, a
housi ng, and a cover that al so serves as the reacti on
shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the i nner and outer gears. As the gears
rotate, the cl earance between the gear teeth
i ncreases i n the crescent area, and creates a sucti on
at the i nl et si de of the pump. Thi s sucti on draws
fl ui d through the pump i nl et from the oi l pan. As the
cl earance between the gear teeth i n the crescent area
decreases, i t forces pressuri zed fl ui d i nto the pump
outl et and to the val ve body.
1 PUMP SEAL
2 PUMP BODY
3 STATOR SHAFT
4 SEAL RINGS
5 GEAR
6 O-RING
TRANSMISSION VALVE BODY COMPONENTS
DESCRIPTION
Transmi ssi on operati ng pressure i s suppl i ed to the
cl utch and brake appl y ci rcui ts through the transmi s-
si on val ve body. The val ve body consi sts of an upper
body, l ower body, separator pl ate and upper and
l ower gaskets (Fi g. 14). The vari ous spool val ves,
sl eeves, pl ugs and spri ngs are l ocated wi thi n the two
body secti ons.
The manual val ve, 12 shi ft val ve, pri mary regul a-
tor val ve, accumul ator control val ve, check bal l s, and
oi l strai ners are l ocated i n the l ower body secti on
(Fi g. 15). The remai ni ng control and shi ft val ves pl us
check bal l s and one addi ti onal oi l strai ner are l ocated
i n the upper body secti on (Fi g. 16).
TRANSMISSION VALVE BODY SOLENOIDS
The sol enoi ds are mounted on the val ve body and
operated by the TCM. The sol enoi ds control operati on
of the converter cl utch and shi ft val ves i n response to
i nput si gnal s from the modul e.
Fig. 14 TwoSection Transmission Valve Body
1 UPPPER BODY
2 UPPER GASKET
3 SEPARATOR PLATE
4 LOWER GASKET
5 LOWER BODY
Fig. 15 Upper Body Components
1 ACCUMULATOR CONTROL VALVE
2 12 SHIFT VALVE
3 MANUAL VALVE
4 PRIMARY REGULATOR VALVE
5 LOWER BODY
OPERATION
MANUAL VALVE
The manual val ve i s operated by the gearshi ft l i nk-
age. The val ve di verts fl ui d to the appl y ci rcui ts
accordi ng to shi ft l ever posi ti on (Fi g. 17).
Fig. 16 Lower Body Components
1 DOWNSHIFT PLUG
2 LOCK-UP RELAY VALVE
3 SECONDARY REGULATOR VALVE
4 UPPER BODY
5 CUT-BACK VALVE
6 THROTTLE VALVE
7 LOW COAST MODULATOR VALVE
8 SECONDARY COAST MODULATOR VALVE
9 23 SHIFT VALVE
10 34 SHIFT VALVE
11 THROTTLE CAM
PRIMARY REGULATOR VALVE
The pri mary regul ator val ve (Fi g. 18) modul ates
l i ne pressure to the cl utches and brakes accordi ng to
engi ne l oad. The val ve i s actuated by throttl e val ve
pressure.
Duri ng hi gh l oad operati on, the val ve i ncreases
l i ne pressure to mai ntai n posi ti ve cl utch and brake
engagement. At l i ght l oad, the val ve decreases l i ne
pressure just enough to mai ntai n smooth engage-
ment.
THROTTLE VALVE AND DOWNSHIFT PLUG
The throttl e val ve and downshi ft pl ug (Fi g. 19)
control throttl e pressure to the pri mary regul ator
val ve.
The downshi ft pl ug and throttl e val ve are operated
by the throttl e val ve cam and throttl e cabl e i n
response to engi ne throttl e posi ti on. Throttl e val ve
pressure i s al so modul ated by the cutback val ve i n
second, thi rd and fourth gear ranges.
CUTBACK VALVE
The cutback val ve (Fi g. 20) hel ps prevent exces-
si ve pump pressure bui l dup i n second, thi rd and
fourth gear. The val ve i s actuated by throttl e pres-
sure and by l i ne pressure from the second brake. The
val ve al so hel ps regul ate l i ne pressure by control l i ng
the amount of cutback pressure to the throttl e
val ve.
SECONDARY REGULATOR VALVE
The secondary regul ator val ve (Fi g. 21) regul ates
converter cl utch and transmi ssi on l ubri cati on pres-
sure. When pri mary regul ator val ve pressure exceeds
requi rements for cl utch engagement or transmi ssi on
l ubri cati on, the secondary regul ator val ve i s moved
upward exposi ng the drai n port. Excess pressure
then bl eeds off as needed. As pressure drops, spri ng
Fig. 18 Primary Regulator Valve
1 THROTTLE PRESSURE
2 LINE PRESSURE (FROM MANUAL VALVE R RANGE)
3 LINE PRESSURE (FROM PUMP)
4 CONVERTER PRESSURE TO CONVERTER CLUTCH RELAY
VALVE
5 LINE PRESSURE
6 CONVERTER PRESSURE (TO SECONDARY REGULATOR
VALVE)
7 DRAIN
8 DRAIN
Fig. 19 Throttle Valve And Downshift Plug
1 LINE PRESSURE CABLE
2 THROTTLE VALVE CAM
3 DOWNSHIFT PLUG
4 THROTTLE VALVE
5 THROTTLE PRESSURE (TO PRIMARY REGULATOR VALVE)
6 LINE PRESSURE
7 CUT-BACK PRESSURE (FROM CUT-BACK VALVE)
tensi on moves the val ve downward cl osi ng the drai n
port.
CONVERTER CLUTCH RELAY VALVE
The converter cl utch rel ay val ve (Fi g. 22) control s
fl ui d fl ow to the converter cl utch. The val ve i s oper-
ated by l i ne pressure from the 12 shi ft val ve and i s
control l ed by sol enoi d val ve number three.
12 SHIFT VALVE
The 12 shi ft val ve (Fi g. 23) control s the 12
upshi fts and downshi fts. The val ve i s operated by the
No. 2 val ve body sol enoi d and l i ne pressure from the
manual val ve, second coast modul ator val ve and the
23 shi ft val ve.
When the transmi ssi on control modul e deacti vates
the sol enoi d, l i ne pressure at the top of the val ve
moves the val ve down cl osi ng the second brake accu-
mul ator feed port. As the sol enoi d i s acti vated and
the drai n port opens, spri ng force moves the val ve up
exposi ng the second brake feed port for the shi ft to
second gear.
23 SHIFT VALVE
The 23 shi ft val ve (Fi g. 24) control s the 23
upshi fts and downshi fts. The val ve i s actuated by the
No. 1 val ve body sol enoi d and by l i ne pressure from
the manual val ve and pri mary regul ator val ve.
Fig. 20 CutBack Valve
1 THROTTLE PRESSURE
2 CUT-BACK PRESSURE TO THROTTLE VALVE
3 CUT-BACK VALVE
4 SECOND BRAKE LINE PRESSURE
Fig. 21 Secondary Regulator Valve
Fig. 22 Converter Clutch Relay Valve
1 SOLENOID VALVE NO. 3
2 LINE PRESSURE (FROM 12 SHIFT VALVE)
3 CONVERTER PRESSURE
4 DRAIN
6 CONVERTER CLUTCH RELAY VALVE
7 TO CONVERTER CLUTCH (DISENGAGED)
8 TO OIL COOLER
9 TO CONVERTER CLUTCH (ENGAGED)
When the TCM acti vates sol enoi d No. 1, l i ne pres-
sure at the top of the 23 val ve i s rel eased through
the sol enoi d drai n port. Spri ng tensi on moves the
val ve up to hol d the val ve i n second gear posi ti on. As
the sol enoi d i s deacti vated, l i ne pressure then moves
the val ve down exposi ng the di rect cl utch feed port
for the shi ft to thi rd gear.
Fig. 23 12 Shift Valve
34 SHIFT VALVE
The 34 shi ft val ve (Fi g. 25) i s operated by the No.
2 sol enoi d and by l i ne pressure from the manual
val ve, 23 val ve and pri mary regul ator val ve.
Energi zi ng the No. 2 sol enoi d causes l i ne pressure
at the top of the 34 val ve to be rel eased through the
sol enoi d val ve drai n port. Spri ng tensi on moves the
val ve up exposi ng the overdri ve cl utch accumul ator
feed port to appl y the cl utch.
Deenergi zi ng the sol enoi d causes the drai n port to
cl ose. Li ne pressure then moves the val ve down
exposi ng the overdri ve brake accumul ator feed port
for the shi ft to fourth gear.
I n the 12 or 3 gearshi ft l ever posi ti ons, l i ne pres-
sure from the 23 shi ft val ve i s appl i ed to the l ower
end of the 34 val ve. Thi s hol ds the val ve upward,
cl osi ng off the overdri ve brake feed port preventi ng a
shi ft i nto fourth gear.
SECOND COAST MODULATOR VALVE
The second coast modul ator val ve (Fi g. 26) momen-
tari l y reduces l i ne pressure from the 12 shi ft val ve.
Thi s cushi ons appl i cati on of the second coast brake.
The val ve i s operati ve when the shi ft l ever and man-
ual val ve are i n the 3 posi ti on.
LOW COAST MODULATOR VALVE
The l ow coast modul ator val ve (Fi g. 27) momen-
tari l y reduces l i ne pressure from the 23 shi ft val ve;
thi s acti on cushi ons appl i cati on of the fi rst/reverse
1 TO OVER DRIVE BRAKE ACCUMULATOR
2 LINE PRESSURE (FROM PRIMARY REGULATOR VALVE)
3 LINE PRESSURE (FROM PRIMARY REGULATOR VALVE)
4 TO OVERDRIVE CLUTCH ACCUMULATOR
Fig. 26 Second Coast Modulator Valve
2 LOW COAST MODULATOR PRESSURE SECOND COAST
BRAKE
brake. The modul ator val ve operates when the shi ft
l ever and manual val ve are i n the 12 posi ti on.
ACCUMULATOR CONTROL VALVE
The accumul ator control val ve (Fi g. 28) cushi ons
the transmi ssi on cl utch and brake appl i cati ons. Thi s
i s achi eved by reduci ng back pressure to the accumu-
l ators when throttl e openi ng i s smal l . The val ve i s
operated by l i ne and throttl e pressure.
ACCUMULATORS
Four accumul ators are used to cushi on cl utch and
brake appl i cati on. The accumul ators (Fi g. 29), consi st
of spri ng l oaded pi stons. The pi stons dampen the i ni -
ti al surge of appl y pressure to provi de smooth
engagement duri ng shi fts.
Control pressure from the accumul ator control
val ve i s conti nuousl y appl i ed to the back pressure
si de of the accumul ator pi stons. Thi s pressure pl us
spri ng tensi on hol ds the pi stons down. As l i ne pres-
sure from the shi ft val ves enters the opposi te end of
the pi ston bore, control pressure and spri ng tensi on
momentari l y del ay appl i cati on of ful l l i ne pressure to
cushi on engagement. The accumul ators are al l
l ocated i n the transmi ssi on case (Fi g. 29).
Three sol enoi ds are used (Fi g. 30). The No. 1 and 2
sol enoi ds control shi ft val ve operati on by appl yi ng or
rel easi ng l i ne pressure. The si gnal to appl y or rel ease
pressure i s provi ded by the transmi ssi on control
modul e.
The No. 3 sol enoi d control s operati on of the torque
converter cl utch. The sol enoi d operates i n response to
si gnal s from the transmi ssi on control modul e.
When the No. 1 and 2 sol enoi ds are acti vated, the
sol enoi d pl unger i s moved off i ts seat openi ng the
drai n port to rel ease l i ne pressure. When ei ther sol e-
noi d i s deacti vated, the pl unger cl oses the drai n port.
The No. 3 sol enoi d operates i n reverse. When the
sol enoi d i s deacti vated, the sol enoi d pl unger i s moved
off i ts seat openi ng the drai n port to rel ease l i ne
pressure. When the sol enoi d i s acti vated, the pl unger
cl oses the drai n port.
PISTONS
DESCRIPTION
There are several si zes and types of pi stons used i n
an automati c transmi ssi on. Some pi stons are used to
appl y cl utches, whi l e others are used to appl y bands.
They al l have i n common the fact that they are
round or ci rcul ar i n shape, l ocated wi thi n a smooth
wal l ed cyl i nder, whi ch i s cl osed at one end and con-
verts fl ui d pressure i nto mechani cal movement. The
fl ui d pressure exerted on the pi ston i s contai ned
wi thi n the system through the use of pi ston ri ngs or
seal s.
Fig. 27 Low Coast Modulator Valve
2 LOW COAST MODULATOR PRESSURE TO FIRST/REVERSE
BRAKE
Fig. 28 Accumulator Control Valve
1 ACCUMULATOR CONTROL PRESSURE (TO
ACCUMULATORS)
2 THROTTLE PRESSURE
OPERATION
The pri nci pal whi ch makes thi s operati on possi bl e
i s known as Pascal s Law. Pascal s Law can be stated
as: Pressure on a confi ned fl ui d i s transmi tted
equal l y i n al l di recti ons and acts wi th equal force on
equal areas.
PRESSURE
Pressure (Fi g. 31) i s nothi ng more than force (l bs.)
di vi ded by area (i n or ft.), or force per uni t area.
Gi ven a 100 l b. bl ock and an area of 100 sq. i n. on
the fl oor, the pressure exerted by the bl ock i s: 100
l bs. 100 i n or 1 pound per square i nch, or PSI as i t i s
commonl y referred to.
PRESSURE ON A CONFINED FLUID
Pressure i s exerted on a confi ned fl ui d (Fi g. 32) by
appl yi ng a force to some gi ven area i n contact wi th
the fl ui d. A good exampl e of thi s i s a cyl i nder fi l l ed
wi th fl ui d and equi pped wi th a pi ston that i s cl osel y
fi tted to the cyl i nder wal l . I f a force i s appl i ed to the
pi ston, pressure wi l l be devel oped i n the fl ui d. Of
course, no pressure wi l l be created i f the fl ui d i s not
confi ned. I t wi l l si mpl y l eak past the pi ston. There
must be a resi stance to fl ow i n order to create pres-
sure. Pi ston seal i ng i s extremel y i mportant i n
hydraul i c operati on. Several ki nds of seal s are used
to accompl i sh thi s wi thi n a transmi ssi on. These
i ncl ude but are not l i mi ted to Ori ngs, Dri ngs, l i p
seal s, seal i ng ri ngs, or extremel y cl ose tol erances
between the pi ston and the cyl i nder wal l . The force
exerted i s downward (gravi ty), however, the pri nci pl e
remai ns the same no matter whi ch di recti on i s taken.
Fig. 29 Accumulators
1 OVERDRIVE CLUTCH
2 SECOND BRAKE
3 DIRECT CLUTCH
4 OVERDRIVE BRAKE
Fig. 30 Transmission Valve Body Solenoids
Fig. 31 Force and Pressure Relationship
The pressure created i n the fl ui d i s equal to the force
appl i ed, di vi ded by the pi ston area. I f the force i s 100
l bs., and the pi ston area i s 10 sq. i n., then the pres-
sure created equal s 10 PSI . Another i nterpretati on of
Pascal s Law i s that regardl ess of contai ner shape or
si ze, the pressure wi l l be mai ntai ned throughout, as
l ong as the fl ui d i s confi ned. I n other words, the
pressure i n the fl ui d i s the same everywhere wi thi n
the contai ner.
FORCE MULTIPLICATION
Usi ng the 10 PSI exampl e used i n the i l l ustrati on
(Fi g. 33), a force of 1000 l bs. can be moved wi th a
force of onl y 100 l bs. The secret of force mul ti pl i ca-
ti on i n hydraul i c systems i s the total fl ui d contact
area empl oyed. The i l l ustrati on, (Fi g. 33), shows an
area that i s ten ti mes l arger than the ori gi nal area.
The pressure created wi th the smal l er 100 l b. i nput
i s 10 PSI . The concept pressure i s the same every-
where means that the pressure underneath the
l arger pi ston i s al so 10 PSI . Pressure i s equal to the
force appl i ed di vi ded by the contact area. Therefore,
by means of si mpl e al gebra, the output force may be
found. Thi s concept i s extremel y i mportant, as i t i s
al so used i n the desi gn and operati on of al l shi ft
val ves and l i mi ti ng val ves i n the val ve body, as wel l
as the pi stons, of the transmi ssi on, whi ch acti vate
the cl utches and bands. I t i s nothi ng more than
usi ng a di fference of area to create a di fference i n
pressure to move an object.
PISTON TRAVEL
The rel ati onshi p between hydraul i c l ever and a
mechani cal l ever i s the same. Wi th a mechani cal
l ever i ts a wei ghttodi stance output rather than a
pressuretoarea output. Usi ng the same forces and
areas as i n the previ ous exampl e, the smal l er pi ston
(Fi g. 34) has to move ten ti mes the di stance requi red
to move the l arger pi ston one i nch. Therefore, for
every i nch the l arger pi ston moves, the smal l er pi s-
ton moves ten i nches. Thi s pri nci pl e i s true i n other
i nstances al so. A common garage fl oor jack i s a good
exampl e. To rai se a car wei ghi ng 2000 l bs., an effort
of onl y 100 l bs. may be requi red. For every i nch the
car moves upward, the i nput pi ston at the jack han-
dl e must move 20 i nches downward.
TRANSMISSION RANGES AND SHIFT LEVER
POSITIONS
The AW4 transmi ssi on has si x ranges and shi ft
l ever posi ti ons. Park, Reverse and Neutral are con-
venti onal and mechani cal l y operated. The 12, 3 and
D ranges provi de el ectroni cal l y control l ed shi fti ng.
The 12 posi ti on provi des fi rst and second gear
onl y. The 3 posi ti on provi des fi rst, second and thi rd
gear.
Fig. 32 Pressure on a Confined Fluid
Fig. 33 Force Multiplication
Fig. 34 Piston Travel
The D range provi des fi rst through fourth gear.
Overdri ve fourth gear range i s avai l abl e onl y when
the shi ft l ever i s i n D posi ti on (Fi g. 35).
DESCRIPTION
The modul e determi nes shi ft and converter cl utch
engagement ti mi ng based on si gnal s from sensors.
The val ve body sol enoi ds are acti vated, or deacti -
vated accordi ngl y.
The TCM has a sel f di agnosti c program. Compo-
nent and ci rcui try mal functi ons can be di agnosed
wi th the DRB scan tool . Once a mal functi on i s noted
and stored i n control modul e memory, i t i s retai ned
even after the probl em has been corrected. To cancel
a stored mal functi on, di sconnect and reconnect the
Trans. fuse i n the modul e harness.
SENSORS
Sensors i ncl ude:
throttl e posi ti on sensor (TPS)
transmi ssi on speed sensor
vehi cl e speed sensor
park/neutral posi ti on swi tch
brake swi tch
OPERATION
The throttl e posi ti on sensor i s mounted on the
throttl e body. I t el ectroni cal l y determi nes throttl e
posi ti on and rel ays thi s i nformati on to the transmi s-
si on control modul e to determi ne shi ft poi nts and
converter cl utch engagement.
The transmi ssi on speed sensor consi sts of a rotor
and magnet on the transmi ssi on output shaft and a
swi tch i n the extensi on housi ng or adapter. The sen-
sor swi tch i s acti vated each ti me the rotor and mag-
net compl ete one revol uti on. Sensor si gnal s are sent
to the transmi ssi on control modul e.
The park/neutral posi ti on swi tch i s mounted on the
val ve body manual shaft. The swi tch si gnal s shi ft
l i nkage and manual val ve posi ti on to the transmi s-
si on control modul e through an i nterconnecti ng har-
ness. The swi tch prevents engi ne starti ng i n al l gears
other than Park or Neutral .
The brake swi tch i s i n ci rcui t wi th the torque con-
verter cl utch sol enoi d. The swi tch di sengages the
converter cl utch whenever the brakes are appl i ed.
The swi tch i s mounted on the brake pedal bracket
and si gnal s the transmi ssi on control modul e when
the pedal i s pressed or rel eased.
HYDRAULIC SYSTEM
DESCRIPTION
The hydraul i c system consi sts of the pump, val ve
body and sol enoi ds, and four hydraul i c accumul ators.
The oi l pump provi des l ubri cati on and operati ng
pressure.
The val ve body control s appl i cati on of the cl utches,
brakes, second coast band, and the converter cl utch.
The val ve body sol enoi ds control sequenci ng of the
12, 23 and 34 shi ft val ves. The sol enoi ds are acti -
vated by si gnal s from the transmi ssi on control mod-
ul e.
The accumul ators are used i n the cl utch and brake
feed ci rcui ts to control i ni ti al appl y pressure. Spri ng
l oaded accumul ator pi stons modul ate the i ni ti al
surge of appl y pressure for smooth engagement.
TRANSMISSION COOLER
DESCRIPTION
MAIN COOLER
The transmi ssi on mai n cool er i s l ocated i n the
radi ator. The mai n cool er can be fl ushed when neces-
sary, however, the cool er i s not a repai rabl e compo-
nent. I f the cool er i s damaged, pl ugged, or l eaki ng,
the radi ator wi l l have to be repl aced.
AUXILIARY COOLER
The auxi l i ary cool er i s mounted i n front of the
radi ator at the dri ver si de of the vehi cl e (Fi g. 36).
The cool er can be fl ushed when necessary, whi l e
mounted i n the vehi cl e. The cool er can al so be
removed for access, repai r, or repl acement as needed.
The mai n and auxi l i ary cool ers shoul d both be
fl ushed whenever a transmi ssi on or converter cl utch
Fig. 35 AW4 Shift Lever Positions And
Transmission Ranges
mal functi on generates sl udge, debri s, or parti cl es of
cl utch fri cti on materi al .
COOLER SERVICE
The mai n cool er (and radi ator) and the auxi l i ary
cool er can be removed for servi ce or access to other
components. Auxi l i ary cool er removal requi res that
the front bumper and radi ator support be removed
for access to the cool er l i nes and attachi ng bracket.
MECHANISM
DESCRIPTION
The Brake Transmi ssi on Shi fter/I gni ti on I nterl ock
(BTSI ), i s a cabl e and sol enoi d operated system. I t
i nterconnects the automati c transmi ssi on fl oor
mounted shi fter to the steeri ng col umn i gni ti on
swi tch (Fi g. 37).
OPERATION
The system l ocks the shi fter i nto the PARK posi -
ti on. The I nterl ock system i s engaged whenever the
i gni ti on swi tch i s i n the LOCK or ACCESSORY posi -
ti on. An addi ti onal el ectri cal l y acti vated feature wi l l
prevent shi fti ng out of the PARK posi ti on unl ess the
brake pedal i s depressed at l east one-hal f an i nch. A
magneti c hol di ng devi ce i n l i ne wi th the park/brake
i nterl ock cabl e i s energi zed when the i gni ti on i s i n
the RUN posi ti on. When the key i s i n the RUN posi -
ti on and the brake pedal i s depressed, the shi fter i s
unl ocked and wi l l move i nto any posi ti on. The i nter-
l ock system al so prevents the i gni ti on swi tch from
bei ng turned to the LOCK or ACCESSORY posi ti on
(Fi g. 38) unl ess the shi fter i s ful l y l ocked i nto the
PARK posi ti on.
Fig. 36 Auxiliary Cooler Mounting (Left Hand Drive)
1 COOLER INLET LINE
2 COOLER RETURN LINE
3 COOLER LINE BRACKET
4 CLIP
5 RADIATOR
6 AUXILIARY COOLER
8 OUTLET LINE (FROM TRANSMISSION)
9 RETURN LINE (TO TRANSMISSION)
11 RADIATOR
GENERAL DIAGNOSIS INFORMATION
Shi ft poi nts are control l ed by the transmi ssi on con-
trol modul e (TCM). Before attempti ng repai r, deter-
mi ne i f a mal functi on i s el ectri cal or mechani cal .
The TCM used wi th the AW4 transmi ssi on has a
sel fdi agnosti c program compati bl e wi th the DRBI I I
scan tool . The tester wi l l i denti fy faul ts i n the el ec-
tri cal control system.
Di agnosi s shoul d begi n wi th the Prel i mi nary
I nspecti on And Adjustment procedure. I t i s wi l l hel p
determi ne i f a probl em i s mechani cal or el ectri cal .
The fi rst procedure step i s I ni ti al I nspecti on and
Adjustment.
EFFECTS OF INCORRECT FLUID LEVEL
A l ow fl ui d l evel al l ows the pump to take i n ai r
al ong wi th the fl ui d. Ai r i n the fl ui d wi l l cause fl ui d
pressures to be l ow and devel op sl ower than normal .
Fig. 37 Ignition Interlock Cable Routing
1 SHIFT MECHANISM
2 LOCK-TAB
4 STEERING COLUMN
5 SOLENOID
6 WIRE CONNECTOR
7 LEVER
8 MOUNT BRACKET
9 SHIFT CABLE
11 TIE STRAP
Fig. 38 Ignition Key Cylinder Actuation
1 SLIDER LOCKED
2 CAM RETURN SPRING
3 INTERLOCK CABLE
4 CAM
5 SLIDER
I f the transmi ssi on i s overfi l l ed, the gears churn the
fl ui d i nto foam. Thi s aerates the fl ui d and causi ng
the same condi ti ons occurri ng wi th a l ow l evel . I n
ei ther case, ai r bubbl es cause fl ui d overheati ng, oxi -
dati on and varni sh bui l dup whi ch i nterferes wi th
val ve, cl utch and servo operati on. Foami ng al so
causes fl ui d expansi on whi ch can resul t i n fl ui d over-
fl ow from the transmi ssi on vent or fi l l tube. Fl ui d
overfl ow can easi l y be mi staken for a l eak i f i nspec-
ti on i s not careful .
CAUSES OF BURNT FLUID
Burnt, di scol ored fl ui d i s a resul t of overheati ng
whi ch has two pri mary causes.
(1) A resul t of restri cted fl ui d fl ow through the
mai n and/or auxi l i ary cool er. Thi s condi ti on i s usu-
al l y the resul t of a faul ty or i mproperl y i nstal l ed
drai nback val ve, a damaged mai n cool er, or severe
restri cti ons i n the cool ers and l i nes caused by debri s
or ki nked l i nes.
(2) Heavy duty operati on wi th a vehi cl e not prop-
erl y equi pped for thi s type of operati on. Trai l er tow-
i ng or si mi l ar hi gh l oad operati on wi l l overheat the
transmi ssi on fl ui d i f the vehi cl e i s i mproperl y
equi pped. Such vehi cl es shoul d have an auxi l i ary
transmi ssi on fl ui d cool er, a heavy duty cool i ng sys-
tem, and the engi ne/axl e rati o combi nati on needed to
handl e heavy l oads.
FLUID CONTAMINATION
Transmi ssi on fl ui d contami nati on i s general l y a
resul t of:
addi ng i ncorrect fl ui d
Preliminary Diagnosis Check Procedure
fai l ure to cl ean di psti ck and fi l l tube when
checki ng l evel
engi ne cool ant enteri ng the fl ui d
i nternal fai l ure that generates debri s
overheat that generates sl udge (fl ui d break-
down)
fai l ure to reverse fl ush cool er and l i nes after
repai r
fai l ure to repl ace contami nated converter after
repai r
The use of non recommended fl ui ds can resul t i n
transmi ssi on fai l ure. The usual resul ts are errati c
shi fts, sl i ppage, abnormal wear and eventual fai l ure
due to fl ui d breakdown and sl udge formati on. Avoi d
thi s condi ti on by usi ng recommended fl ui ds onl y.
The di psti ck cap and fi l l tube shoul d be wi ped
cl ean before checki ng fl ui d l evel . Di rt, grease and
other forei gn materi al on the cap and tube coul d fal l
i nto the tube i f not removed beforehand. Take the
ti me to wi pe the cap and tube cl ean before wi thdraw-
i ng the di psti ck.
Engi ne cool ant i n the transmi ssi on fl ui d i s gener-
al l y caused by a cool er mal functi on. The onl y remedy
i s to repl ace the radi ator as the cool er i n the radi ator
i s not a servi ceabl e part. I f cool ant has ci rcul ated
through the transmi ssi on for some ti me, an overhaul
may al so be necessary; especi al l y i f shi ft probl ems
had devel oped.
The transmi ssi on cool er and l i nes shoul d be
reverse fl ushed whenever a mal functi on generates
sl udge and/or debri s. The torque converter shoul d
al so be repl aced at the same ti me.
Fai l ure to fl ush the cool er and l i nes wi l l resul t i n
recontami nati on. Fl ushi ng appl i es to auxi l i ary cool -
ers as wel l . The torque converter shoul d al so be
repl aced whenever a fai l ure generates sl udge and
debri s. Thi s i s necessary because normal converter
fl ushi ng procedures wi l l not remove al l contami -
nants.
PRELIMINARY INSPECTION AND ADJUSTMENT
(1) Check and adjust transmi ssi on shi ft cabl e i f
necessary.
(2) Veri fy transmi ssi on throttl e cabl e operati on.
Repai r or repl ace cabl e i f necessary.
(3) Check engi ne throttl e operati on. Operate accel -
erator pedal and observe i njector throttl e pl ate move-
ment. Adjust l i nkage i f throttl e pl ate does not reach
wi de open posi ti on.
(4) Check transmi ssi on fl ui d l evel when fl ui d i s at
normal operati ng temperature. Start engi ne. Shi ft
transmi ssi on through al l gear ranges then back to
Neutral . Correct l evel i s to Ful l or Add mark on di p-
sti ck wi th engi ne at curb i dl e speed.
(5) Check and adjust park/neutral posi ti on swi tch
i f necessary.
(6) Check throttl e posi ti on sensor adjustment and
operati on. Adjust the sensor i f necessary.
MANUAL SHIFTING TEST
(1) Thi s test determi nes i f probl em i s rel ated to
mechani cal or el ectri cal component.
(2) Stop engi ne and di sconnect transmi ssi on con-
trol modul e or modul e fuse.
(3) Road test vehi cl e. Shi ft transmi ssi on i nto each
gear range. Transmi ssi on shoul d operate as fol l ows:
l ock i n Park
back up i n Reverse
not move i n Neutral
provi de fi rst gear onl y wi th shi ft l ever i n 12
posi ti on
operate i n thi rd gear onl y wi th shi ft l ever i n 3
posi ti on
operate i n overdri ve fourth gear i n D posi ti on
(4) I f transmi ssi on operates as descri bed, proceed
to next step. However, i f forward gear ranges were
di ffi cul t to di sti ngui sh (al l feel the same), or vehi cl e
woul d not back up, refer to di agnosi s charts. Do not
perform stal l or ti me l ag tests.
CAUTION: Do not over speed the engine during the
next test step. Ease off the throttle and allow the
vehicle to slow before downshifting.
(5) Conti nue road test. Manual l y downshi ft trans-
mi ssi on from D to 3, and from 3 to 12 posi ti on.
Then manual l y upshi ft transmi ssi on through forward
ranges agai n.
(6) I f transmi ssi on operati on i s OK, perform stal l ,
ti me l ag and pressure tests. I f transmi ssi on shi fti ng
probl em i s encountered, refer to di agnosi s charts.
(7) I f a probl em sti l l exi sts, conti nue testi ng wi th
DRB scan tool .
HYDRAULIC PRESSURE TEST
Pressure Test Procedure
(1) Connect pressure test gauge to test port on
passenger si de of transmi ssi on (Fi g. 39). Use Adapter
7554 to connect gauge. Be sure test gauge has mi ni -
mum capaci ty of 300 psi (2100 kPa).
(2) Be sure transmi ssi on fl ui d i s at normal operat-
i ng temperature.
(3) Appl y parki ng brakes and bl ock wheel s.
WARNING: DO NOT ALLOW ANYONE TO STAND AT
THE FRONT OR REAR OF THE VEHICLE WHILE
PERFORMING THE FOLLOWING STEPS IN THE
PRESSURE TEST.
(4) Check and adjust engi ne curb i dl e speed.
(5) Appl y (and hol d) servi ce brakes.
(6) Shi ft transmi ssi on i nto D range and note l i ne
pressure wi th engi ne at curb i dl e speed. Pressure
shoul d be 61to70 psi (421to481 kPa).
(7) Press accel erator pedal to wi de open throttl e
posi ti on and note l i ne pressure. Pressure shoul d be
173to209 psi (1196to1442 kPa).
CAUTION: Do not hold wide open throttle for more
than 34 seconds at a time.
(8) Shi ft transmi ssi on i nto Reverse and note l i ne
pressure wi th engi ne at curb i dl e speed. Pressure
shoul d be 75to90 psi (519to618 kPa).
(9) Press accel erator to wi de open throttl e posi ti on
and note l i ne pressure i n Reverse. Pressure shoul d
be 213to263 psi (1471to1814 kPa).
CAUTION: Do not hold wide open throttle for more
than 4 seconds.
(10) I f l i ne pressure i s not wi thi n speci fi cati ons,
adjust transmi ssi on throttl e cabl e and repeat pres-
sure test.
PRESSURE TEST ANALYSIS
I f pressures i n D and Reverse are hi gher than
speci fi ed i n test, check for the fol l owi ng:
throttl e cabl e l oose, worn, bi ndi ng or out of
adjustment
throttl e val ve, downshi ft pl ug, throttl e cam, or
pri mary regul ator val ve are sti cki ng, worn or dam-
aged
I f pressures i n D and Reverse are l ower than spec-
i fi ed i n test, check for fol l owi ng:
throttl e cabl e l oose, worn, bi ndi ng or out of
adjustment
throttl e val ve, downshi ft pl ug, or throttl e cam
sti cki ng, worn or damaged
pri mary regul ator val ve sti cki ng, worn, or dam-
aged
oi l pump gears or housi ng worn, or damaged
overdri ve cl utch worn, or damaged
I f pressures are l ow i n D range onl y, check for fol -
l owi ng:
forward cl utch worn or damaged
fl ui d l eakage i n D range ci rcui t (component seal
and Ori ngs)
I f pressures are l ow i n Reverse onl y, check for fol -
l owi ng:
shi ft cabl e and manual val ve out of adjustment
fl ui d l eakage i n reverse ci rcui t (component seal
and Ori ngs)
di rect cl utch worn or damaged
fi rst/reverse brake worn or damaged
TIME LAG TEST
Thi s test checks general condi ti on of the overdri ve
cl utch, forward cl utch, rear cl utch and fi rst/reverse
brake. Condi ti on i s i ndi cated by the amount of ti me
requi red for cl utch/brake engagement wi th the
engi ne at curb i dl e speed. Engagement ti me i s mea-
sured for D and Reverse posi ti ons. A stop watch i s
recommended for test accuracy.
TEST PROCEDURE
(1) Check and adjust transmi ssi on fl ui d l evel i f
necessary.
(2) Bri ng transmi ssi on to normal operati ng tem-
perature.
(3) Appl y parki ng brakes and turn off ai r condi -
ti oni ng uni t.
(4) Shi ft transfer case i nto 2H range.
(5) Start engi ne and check curb i dl e speed. Adjust
speed i f necessary. Curb i dl e must be correct to
ensure accurate test resul ts.
(6) Shi ft transmi ssi on i nto Neutral and set stop
watch.
(7) Duri ng fol l owi ng test steps, start stop watch as
soon as shi ft l ever reaches D and Reverse ranges.
(8) Shi ft transmi ssi on i nto D range and record
ti me i t takes for engagement. Repeat test two more
ti mes.
(9) Reset stop watch and shi ft transmi ssi on back
to Neutral .
(10) Shi ft transmi ssi on i nto Reverse and record
ti me i t takes for engagement. Repeat test two more
ti mes.
Fig. 39 Pressure Test Gauge Connection
1 PRESSURE GAUGE
2 TEST PORT
(11) Engagement ti me i n D range shoul d be a
maxi mum of 1.2 seconds. Engagement ti me for
Reverse shoul d be a maxi mum of 1.5 seconds.
TIME LAG TEST ANALYSIS
I f engagement ti me i s l onger than speci fi ed for D
range, check for the fol l owi ng:
shi ft cabl e mi sadjusted
l i ne pressure l ow
forward cl utch worn
overdri ve cl utch worn or damaged
I f engagement ti me i s l onger than speci fi ed for
Reverse, check for the fol l owi ng:
shi ft cabl e mi sadjusted
l i ne pressure l ow
di rect cl utch worn
fi rst/reverse brake worn
overdri ve cl utch worn or damaged
SERVICE DIAGNOSIS
DIAGNOSIS TABLE
VEHICLE WILL NOT BACK UP OR
MOVE FORWARD
Shift cable out of adjustment or
damaged
Adjust cable or replace cable
Valve body or primary regulator
faulty
Inspect/repair valve body
Park lock pawl faulty Repair park pawl
Torque converter faulty Replace torque converter
Converter drive plate broken Replace drive plate
Oil pump intake screen blocked Clean screen
Transmission faulty Disassemble and repair
transmission
SHIFT LEVER POSITION
INCORRECT
Shift cable out of adjustment Adjust cable
Manual valve and lever faulty Repair valve body
HARSH ENGAGEMENT Throttle cable out of adjustment Adjust throttle cable
Valve body or primary regulator
faulty
Repair valve body
Accumulator pistons faulty Repair pistons
transmission
DELAYED 1-2, 2-3 OR 3-4
UP-SHIFT, OR DOWN-SHIFTS
FROM 4-3 OR 3-2 AND SHIFTS
BACK TO 4 OR 3
Electronic control problem Locate problem with DRB Tester
Valve body faulty Repair valve body
Solenoid faulty Repair solenoid
SLIPS ON 1-2, 2-3 OR 3-4
UP-SHIFT, OR SLIPS OR
SHUDDERS DURING
ACCELERATION
Throttle cable out of adjustment Adjust cable
Solenoid faulty Replace solenoid
transmission
DRAG OR BIND ON 1-2, 2-3 OR
3-4 UP-SHIFT
Transimssion faulty Disassemble and repair
transmission
CONVERTER CLUTCH DOES NOT
ENGAGE IN 2ND, 3RD OR 4TH
Electronic control problem Check with DRB Tester
transmission
HARSH DOWN-SHIFT Throttle cable out of adjustment Adjust cable
Throttle cable and cam faulty Replace cable and cam
Accumulator pistons faulty Repair pistons
transmission
NO DOWN-SHIFT WHEN
COASTING
DOWN-SHIFT LATE OR EARLY
DURING COAST
Throttle cable faulty Replace cable
Transmission faulty Disassembly and repair
transmission
NO 4-3, 3-2 OR 2-1 KICKDOWN Solenoid faulty Replace solenoid
NO ENGINE BRAKING IN 1-2
POSITION
transmission
VEHICLE DOES NOT HOLD IN
PARK
Parking lock pawl cam and spring
faulty
Replace cam and spring
OVERHEAT DURING NORMAL
OPERATION (FLUID
DISCOLORED, SMELLS BURNED)
Low fluid level Add fluid and check for leaks
Fluid cooler, lines blocked, or cooler
cracked (oil in engine coolant)
Flush cooler and lines and replace
radiator if transmission fluid has
entered coolant
OVERHEAT DURING
COMMERCIAL OPERATION OR
WHILE TRAILE TOWING (FLUID
DARK AND BURNED WITH SOME
SLUDGE FORMATION)
Vehicle not properly equipped for
trailer towing or commercial use
Be sure vehicle is equipped with
recommended optional components
(i.e. HD springs, transmission, axle,
larger CID engine, auxiliary cooler,
correct axle ratio, etc.). If vehicle is
not so equipped, it should not be
used for severe service operation
Vehicle not equipped with auxiliary
fluid cooler
Drain fluid, change filter, and install
auxiliary cooler
Extensive idling time or operation in
heavy traffic in hot weather
Cut down on idling time; shift into
neutral every so often and run
engine at 1000 rpm to help circulate
fluid through cooler
Tow vehicle overloaded (exceeding
vehicle tow capacity
Be sure vehicle is properly equipped
to handle load; do not tow Class
III-type loads with a vehicle that is
only rated for Class I or II operation
Air flow to auxiliary cooler blocked
by snow plow, front mounted spare
tire, bug screen, or similar item
Remove or reposition item causing
air flow blockage
OIL COMES OUT FILLER TUBE Transmission overfilled Drain fluid to correct level; remove
neutral switch and drain through
switch hole with suction gun
Breather vent in oil pump blocked Inspect and clear blockage
Fluid cooler or cooler lines plugged Flush cooler and lines
TRANSMISSION SOLENOID TESTING
Test sol enoi d resi stance wi th an ohmmeter. Con-
nect the ohmmeter l eads to the sol enoi d mounti ng
bracket and to the sol enoi d wi re termi nal (Fi g. 40).
Sol enoi d resi stance shoul d be 1115 ohms. Repl ace
the sol enoi d i f resi stance i s above or bel ow the spec-
i fi ed range.
SWITCH TESTING
Test swi tch conti nui ty wi th an ohmmeter. Di scon-
nect the swi tch and check conti nui ty at the connector
termi nal posi ti ons and i n the gear ranges i ndi cated
i n Fi gure 3. Swi tch conti nui ty shoul d be as fol l ows:
Conti nui ty shoul d exi st between termi nal s B
and C wi th the transmi ssi on i n Park and Neutral
onl y (Fi g. 41).
Conti nui ty shoul d exi st between termi nal s A and
E wi th the transmi ssi on i n Reverse (Fi g. 41).
G wi th the transmi ssi on i n thi rd gear (Fi g. 41).
H wi th the transmi ssi on i n fi rst and/or second gear
(Fi g. 41).
Conti nui ty shoul d not exi st i n D posi ti on.
Fig. 40 Testing Transmission Valve Body Solenoid
1 OHMMETER
2 WIRE TERMINAL
3 SOLENOID
GEARSHIFT CABLE
(1) The fl oor shi fter l ever and gate posi ti ons
shoul d be i n al i gnment wi th al l transmi ssi on PARK,
NEUTRAL, and gear detent posi ti ons.
(2) Engi ne starts must be possi bl e wi th fl oor shi ft
l ever i n PARK or NEUTRAL gate posi ti ons onl y.
Engi ne starts must not be possi bl e i n any other gear
posi ti on.
(3) Wi th fl oor shi ft l ever handl e push-button not
depressed and l ever i n:
(a) PARK posi ti onAppl y forward force on cen-
must be possi bl e.
(b) PARK posi ti onAppl y rearward force on cen-
must be possi bl e.
(c) NEUTRAL posi ti onNormal posi ti on. Engi ne
starts must be possi bl e.
(d) NEUTRAL posi ti onEngi ne runni ng and
brakes appl i ed, appl y forward force on center of
shi ft handl e. Transmi ssi on shal l not be abl e to shi ft
from neutral to reverse.
THROTTLE VALVE CABLE
Transmi ssi on throttl e val ve cabl e adjustment i s
extremel y i mportant to proper operati on. Thi s adjust-
ment posi ti ons the throttl e val ve, whi ch control s shi ft
speed, qual i ty, and part-throttl e downshi ft sensi ti vi ty.
I f cabl e setti ng i s too l oose, earl y shi fts and sl i p-
page between shi fts may occur. I f the setti ng i s too
ti ght, shi fts may be del ayed and part throttl e down-
shi fts may be very sensi ti ve. Refer to the Adjust-
ments secti on for the proper adjustment procedure.
SPEED SENSOR TESTING
Test the speed sensor wi th an ohmmeter. Pl ace the
ohmmeter l eads on the termi nal s i n the sensor con-
nector (Fi g. 42).
Rotate the transmi ssi on output shaft and observe
the ohmmeter needl e. The needl e shoul d defl ect i ndi -
cati ng the swi tch i s openi ng/cl osi ng as the rotor
moves past the sensor (Fi g. 42). Repl ace the sensor i f
the ohmmeter does not di spl ay any ki nd of readi ng.
I f a di gi tal ohmmeter i s bei ng used, the sensor
shoul d generate an ohmmeter readout each ti me the
swi tch opens and cl oses.
COOLER
Cool er fl ow i s checked by measuri ng the amount of
fl ui d fl ow through the cool er i n a 20 second ti me
peri od. The test i s performed wi th the engi ne run-
ni ng and transmi ssi on i n neutral . Fl ui d i s then
pumped through the cool er by the transmi ssi on oi l
pump.
(1) Di sconnect cool er i nl et l i ne at transmi ssi on fi t-
ti ng.
Fig. 41 Park/Neutral Position Switch Terminals And
Testing
Fig. 42 Speed Sensor Testing
1 CONNECTOR
2 OHMMETER
3 SENSOR
4 SENSOR SWITCH
5 ROTOR
(2) Securel y attach hose to end of i nl et l i ne and
posi ti on l i ne i n a one quart test contai ner.
(3) Add extra quart of fl ui d to transmi ssi on.
(4) Use stopwatch to check fl ow test ti me.
(5) Shi ft transmi ssi on i nto neutral and set parki ng
brake.
(6) Start and run engi ne at curb i dl e speed and
i mmedi atel y note cool er fl ow. Approxi matel y one
quart of fl ui d shoul d fl ow i nto test contai ner i n 20
second peri od.
(7) I f cool er fl ow i s i ntermi ttent, fl ows l ess than
one quart i n 20 seconds, or does not fl ow at al l ,
cool er i s faul ty and must be repl aced.
INSPECTION
(1) I nsert Rotati ng Tool 7547 i nto converter hub
and seat tool i n oneway cl utch (Fi g. 43).
(2) I nsert Stopper Tool 7548 i n one converter hub
notch and i nto outer race of rotati ng tool .
(3) Turn rotati ng tool cl ockwi se. Converter cl utch
shoul d rotate freel y and smoothl y. Less than 2.5 Nm
(22 i n. l bs.) of torque shoul d be requi red to rotate
cl utch i n cl ockwi se di recti on.
(4) Turn rotati ng tool i n countercl ockwi se di rec-
ti on. Converter cl utch shoul d l ock.
(5) Repl ace converter i f cl utch bi nds or wi l l not
l ock.
SERVICE PROCEDURES
CHECKING FLUID LEVEL
(1) Be sure transmi ssi on fl ui d i s at normal operat-
i ng temperature. Normal operati ng temperature i s
reached after approxi matel y 15 mi l es (25 km) of
operati on.
(2) Posi ti on vehi cl e on l evel surface. Thi s i s i mpor-
tant for an accurate fl ui d l evel check.
(3) Shi ft transmi ssi on through al l gear ranges and
back to Park.
(5) Veri fy that transmi ssi on i s i n Park.
(6) Wi pe off di psti ck handl e to prevent di rt from
enteri ng fi l l tube. Then remove di psti ck and check
fl ui d l evel and condi ti on.
(7) Correct fl ui d l evel i s to FULL mark on dip-
stick when fluid is at normal operating temper-
ature (Fi g. 44).
(8) I f fl ui d l evel i s l ow, top off l evel wi th Mopar
Dexron I I E/Mercon. Mopar Dexron I I can be used but
onl y i f Mercon i s not avai l abl e. Do not overfill
transmission. Add only enough fluid to bring
level to Full mark.
(9) I f too much fl ui d was added, excess amount can
be removed wi th sucti on gun and appropri ate di ame-
Fig. 43 Checking Operation Of Torque Converter
Stator OneWay Clutch
ter pl asti c tubi ng. Tubi ng onl y has to be l ong enough
to extend i nto oi l pan.
CHECKING FLUID CONDITION
I nspect the appearance of the fl ui d duri ng the fl ui d
l evel check. Fl ui d col or shoul d range from dark red to
pi nk and be free of forei gn materi al , or parti cl es. I f
the fl ui d i s dark brown or bl ack i n col or and smel l s
burnt, the fl ui d has been overheated and must be
changed.
Transmi ssi on operati on shoul d al so be checked i f
the fl ui d i s severel y di scol ored and contai ns quanti -
ti es of forei gn materi al , metal parti cl es, or cl utch di sc
fri cti on materi al .
A small quantity of friction material or metal
particles in the oil pan is normal. The particles
are usually generated during the breakin
period and indicate normal seating of the vari-
ous transmission components.
REFILLING AFTER OVERHAUL OR FLUID/
FILTER CHANGE
The best way to refi l l the transmi ssi on after a fl ui d
change or overhaul i s as fol l ows:
(1) I f transmi ssi on has been overhaul ed, i nstal l
transmi ssi on i n vehi cl e.
(2) Remove di psti ck and i nsert cl ean funnel i n
transmi ssi on fi l l tube.
(3) Add fol l owi ng i ni ti al quanti ty of Mopar Dexron
I I E/Mercon to transmi ssi on:
(4) I f fl ui d/fi l ter change was performed, add 4
pints (2 quarts) of fl ui d to transmi ssi on.
(a) I f transmi ssi on was compl etel y overhaul ed
and torque converter was repl aced or drai ned, add
10 pints (5 quarts) of fl ui d to transmi ssi on.
(b) Remove funnel and i nstal l di psti ck.
(5) Operate vehi cl e unti l fl ui d reaches normal
operati ng temperature.
(7) Let engi ne run at normal curb i dl e speed, appl y
servi ce brakes. Then shi ft transmi ssi on through al l
gear ranges and back to PARK (l eave engi ne run-
ni ng).
(8) Remove di psti ck and check fl ui d l evel . Add onl y
enough fl ui d to bri ng l evel to Ful l mark on di psti ck.
Do not overfi l l . If too much fluid is added, excess
amount can be removed with suction gun and
plastic tubing. Tubing only has to be long
enough to extend into oil pan.
(9) When fl ui d l evel i s correct, shut engi ne off,
rel ease park brake, remove funnel , and reseat di p-
sti ck i n fi l l tube.
SERVICE
Use the DRB scan tool to di agnose transmi ssi on
control modul e functi on whenever a faul t i s sus-
pected. Repl ace the modul e onl y when the scan tool
i ndi cates the modul e i s actual l y faul ty.
OIL PUMP VOLUME CHECK
Measuri ng the oi l pump output vol ume wi l l deter-
mi ne i f suffi ci ent oi l fl ow to the transmi ssi on oi l
cool er exi sts, and whether or not an i nternal trans-
mi ssi on fai l ure i s present.
Veri fy that the transmi ssi on fl ui d i s at the proper
l evel . Refer to the Fl ui d Level Check procedure i n
thi s secti on. I f necessary, fi l l the transmi ssi on to the
proper l evel wi th Mopar ATF+3, type 7176, Auto-
mati c Transmi ssi on Fl ui d.
(1) Di sconnect the To cooler l i ne at the cool er
i nl et and pl ace a col l ecti ng contai ner under the di s-
connected l i ne.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engi ne at curb idle speed , wi th the
shi ft sel ector i n neutral .
(3) I f one quart of transmi ssi on fl ui d i s col l ected i n
the contai ner i n 20 seconds or l ess, oi l pump fl ow vol -
ume i s wi thi n acceptabl e l i mi ts. I f fl ui d fl ow i s i nter-
mi ttent, or i t takes more than 20 seconds to col l ect
one quart of fl ui d, refer to the Hydraul i c Pressure
tests i n thi s secti on for further di agnosi s.
(4) Re-connect the To cooler l i ne to the transmi s-
si on cool er i nl et.
(5) Refi l l the transmi ssi on to proper l evel .
FLUSHING COOLERS AND TUBES
When a transmi ssi on fai l ure has contami nated the
fl ui d, the oi l cool er(s) must be fl ushed. The torque
converter must al so be repl aced. Thi s wi l l i nsure that
metal parti cl es or sl udged oi l are not l ater trans-
ferred back i nto the recondi ti oned (or repl aced) trans-
mi ssi on.
The onl y recommended procedure for fl ushi ng cool -
ers and l i nes i s to use Tool 6906A Cool er Fl usher.
Fig. 44 Transmission Fluid Level
CAUTION: The transmission oil cooler requires a
two stage flushing procedure due to an internally
mounted thermostat. Failure to follow the procedure
can result in severe transmission damage.
WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.11968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.
KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER IN THE AREA WHERE THE
FLUSHER WILL BE USED.
KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-
TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.
COOLER FLUSH USING TOOL 6906A
(1) Remove cover pl ate fi l l er pl ug on Tool 6906A.
Fi l l reservoi r 1/2 to 3/4 ful l of fresh fl ushi ng sol uti on.
Fl ushi ng sol vents are petrol eum based sol uti ons gen-
eral l y used to cl ean automati c transmi ssi on compo-
nents. DO NOT use sol vents contai ni ng aci ds, water,
gasol i ne, or any other corrosi ve l i qui ds.
(2) Rei nstal l fi l l er pl ug on Tool 6906A.
(3) Veri fy pump power swi tch i s turned OFF. Con-
nect red al l i gator cl i p to posi ti ve (+) battery post.
Connect bl ack (-) al l i gator cl i p to a good ground.
(4) Di sconnect the cool er l i nes at the transmi ssi on.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.
(5) Connect the BLUE pressure l i ne to the OUT-
LET (From) cool er l i ne.
(6) Connect the CLEAR return l i ne to the I NLET
(To) cool er l i ne
(7) Remove the transmi ssi on oi l cool er from the
vehi cl e. Refer to the Group 7, Cool i ng System, for the
proper procedures.
(8) Remove the transmi ssi on oi l cool er thermostat.
Refer to the Group 7, Cool i ng System, for the proper
procedures.
(9) Re-i nstal l the thermostat cover onto the oi l
cool er and i nstal l the snap ri ng.
(10) Re-connect the oi l cool er to the transmi ssi on
cool er l i nes.
NOTE: This flushes the bypass circuit of the cooler
only.
(12) Turn pump OFF.
cool er.
(14) I nstal l Speci al Tool Cool er Pl ug 8414 i nto the
transmi ssi on oi l cool er.
NOTE: This flushes the main oil cooler core pas-
sages only.
(16) Turn pump OFF.
cool er.
(18) Remove Speci al Tool Cool er Pl ug 8414 from
the transmi ssi on oi l cool er.
(19) I nstal l a new thermostat spri ng, thermostat,
cover, and snap-ri ng i nto the transmi ssi on oi l cool er.
(20) I nstal l the transmi ssi on oi l cool er onto the
vehi cl e.
(21) Di sconnect CLEAR sucti on l i ne from reservoi r
at cover pl ate. Di sconnect CLEAR return l i ne at
cover pl ate, and pl ace i t i n a drai n pan.
(22) Turn pump ON for 30 seconds to purge fl ush-
i ng sol uti on from cool er and l i nes. Turn pump OFF.
(23) Pl ace CLEAR sucti on l i ne i nto a one quart
contai ner of Mopar ATF Pl us 3, type 7176 automati c
(24) Turn pump ON unti l al l transmi ssi on fl ui d i s
removed from the one quart contai ner and l i nes. Thi s
purges any resi dual cl eani ng sol vent from the trans-
mi ssi on cool er and l i nes. Turn pump OFF.
(25) Di sconnect al l i gator cl i ps from battery. Recon-
nect fl usher l i nes to cover pl ate, and remove fl ushi ng
adapters from cool er l i nes.
ALUMINUM THREAD REPAIR
Damaged or worn threads i n the al umi num trans-
mi ssi on case and val ve body can be repai red by the
use of Hel i -Coi l s, or equi val ent. Thi s repai r consi sts
of dri l l i ng out the worn-out damaged threads. Then
tap the hol e wi th a speci al Hel i -Coi l tap, or equi va-
l ent, and i nstal l i ng a Hel i -Coi l i nsert, or equi val ent,
i nto the hol e. Thi s bri ngs the hol e back to i ts ori gi nal
thread si ze.
Hel i -Coi l , or equi val ent, tool s and i nserts are
readi l y avai l abl e from most automoti ve parts suppl i -
ers.
TRANSMISSION AND TORQUE CONVERTER
REMOVAL
(2) Drai n transmi ssi on fl ui d and rei nstal l oi l pan
drai n pl ug.
(3) On model s wi th 2pi ece fi l l tube, remove upper
hal f of tube (Fi g. 45).
(4) Di sconnect cool er l i nes at transmi ssi on.
(5) Support engi ne wi th safety stand and support
transmi ssi on wi th jack.
(6) Di sconnect transmi ssi on and transfer case shi ft
l i nkage.
(7) Remove necessary exhaust components.
(8) Di sconnect vehi cl e speed sensor wi res
(9) Mark posi ti on of front and rear propel l er shafts
for al i gnment reference. Then remove shafts from
vehi cl e.
(11) Di sconnect transmi ssi on shi ft cabl e at trans-
mi ssi on. Then di sconnect transmi ssi on throttl e val ve
cabl e at engi ne.
(12) Di sconnect necessary vacuum and fl ui d hoses.
(13) Remove transfer case from transmi ssi on.
(14) Di sconnect and remove crankshaft posi ti on
sensor (Fi g. 46).
CAUTION: The crankshaft position sensor can be
damaged during transmission removal (or installa-
tion) if the sensor is still bolted to the engine block.
To avoid damage, remove the sensor before remov-
ing the transmission.
(15) Remove starter motor.
(16) Remove bol ts attachi ng converter to dri ve
pl ate.
(17) Remove bol ts attachi ng converter housi ng to
engi ne.
Fig. 45 Transmission Fill Tube (TwoPiece)
1 UPPER HALF
2 TRANSMISSION FILL TUBE
3 LOWER HALF
Fig. 46 Crankshaft Position Sensor
1 CRANKSHAFT POSITION SENSOR
chai ns.
(19) Pul l transmi ssi on rearward for access to con-
verter. Then secure converter i n pump wi th Ccl amp
or strap bol ted to converter housi ng.
(20) Remove transmi ssi on from under vehi cl e.
(21) Remove torque converter i f converter or oi l
pump seal are to be servi ced.
INSTALLATION
(1) Mount transmi ssi on on transmi ssi on jack. Then
secure transmi ssi on to jack wi th safety chai ns.
(2) Lubri cate converter dri ve hub and oi l pump
seal l i p wi th transmi ssi on fl ui d. Then i nstal l con-
verter. Be sure converter i s ful l y seated i n oi l pump
gears before proceedi ng. Hol d converter i n pl ace wi th
Ccl amp or strap attached to converter housi ng.
(3) Lubri cate the pocket i n the rear of the crank-
shaft, i n whi ch the converter pi l ot hub ri des, wi th a
l i ght coati ng of Mopar Hi gh-Temp Grease.
(4) Al i gn and posi ti on transmi ssi on and converter
on engi ne.
(5) Remove cl amp or strap used to hol d torque con-
verter i n pl ace.
(6) Move transmi ssi on forward seat and i t on
engi ne. Be sure torque converter hub i s ful l y seated.
(7) I nstal l converter housi ngtoengi ne bol ts (Fi g.
47).
(8) I nstal l converter-to-dri ve pl ate bol ts.
(9) I nstal l and connect starter motor.
(11) I nstal l transfer case on transmi ssi on.
(12) Connect transfer case shi ft l i nkage and vac-
uum hoses.
(13) Connect exhaust components.
(14) I nstal l rear crossmember and remove jack
used to support transmi ssi on assembl y.
(15) Connect speed sensor wi re harness to sensor.
(16) Connect wi re harness to park/neutral posi ti on
swi tch.
(17) Al i gn and connect front and rear propel l er
shafts.
(18) Connect transmi ssi on wi re harnesses and
transfer case vacuum and wi re harnesses.
Fig. 47 Transmission Mounting
1 TRANSMISSION FILL TUBE
2 COVER
3 BRACKET
4 BRACKET
5 FILL TUBE O-RING
(19) Connect transmi ssi on cool er l i nes.
(20) Connect transmi ssi on throttl e cabl e at engi ne.
(21) I nstal l new Ori ng seal on upper hal f of
transmi ssi on fi l l tube. Then connect upper and l ower
tube hal ves.
(23) Fi l l transmi ssi on wi th Mopar Dexron I I E/
Mercon automati c transmi ssi on fl ui d.
TORQUE CONVERTER
REMOVAL
(1) Remove transmi ssi on and torque converter
from vehi cl e.
(2) Pl ace a sui tabl e drai n pan under the converter
housi ng end of the transmi ssi on.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pul l the torque converter forward unti l the cen-
ter hub cl ears the oi l pump seal .
(4) Separate the torque converter from the trans-
mi ssi on.
INSTALLATION
Check converter hub and dri ve notches for sharp
edges, burrs, scratches, or ni cks. Pol i sh the hub and
notches wi th 320/400 gri t paper or crocus cl oth i f nec-
essary. The hub must be smooth to avoi d damagi ng
the pump seal at i nstal l ati on.
(1) Lubri cate converter hub and oi l pump seal l i p
(2) Pl ace torque converter i n posi ti on on transmi s-
si on.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Al i gn torque converter to oi l pump seal open-
i ng.
(4) I nsert torque converter hub i nto oi l pump.
(5) Whi l e pushi ng torque converter i nward, rotate
converter unti l converter i s ful l y seated i n the oi l
pump gears.
(6) Check converter seati ng wi th a scal e and
(7) I f necessary, temporari l y secure converter wi th
C-cl amp attached to the converter housi ng.
(8) I nstal l the transmi ssi on i n the vehi cl e.
(9) Fi l l the transmi ssi on wi th the recommended
fl ui d.
ADAPTER HOUSING SEAL
REMOVAL
(2) Di sconnect or remove components necessary to
gai n access to seal (e.g. propel l er shaft, crossmember,
shi ft l i nkage, transfer case, exhaust components,
hoses, wi res).
(3) On 4X2 vehi cl es, remove dust shi el d from the
adapter housi ng by tappi ng gentl y wi th a brass dri ft
and hammer (Fi g. 49).
(4) On 4X2 vehi cl es, remove the adapter housi ng
seal wi th Seal Pul l er 7550.
(5) On 4X4 vehi cl es, remove the adapter housi ng
seal usi ng a sl i de hammer mounted screw.
INSTALLATION
(1) I nstal l new adapter housi ng seal wi th Seal
I nstal l er 7888.
(2) On 4X2 vehi cl es, i nstal l dust shi el d usi ng Spe-
ci al Tool D-187-B.
(3) Rei nstal l components removed to gai n access to
seal .
(4) Top off transmi ssi on fl ui d i f necessary.
SPEED SENSOR
REMOVAL
(1) Di sconnect sensor wi re harness connector.
Fig. 48 Checking Torque Converter Seating
1 SCALE
2 STRAIGHTEDGE
(2) Remove sensor retai ner bol t and remove sensor
(Fi g. 50).
(3) Remove and di scard speed sensor Ori ng.
INSTALLATION
(1) I nstal l new Ori ng on speed sensor and i nstal l
sensor i n transmi ssi on case.
(2) I nstal l sensor bracket and retai ner bol t.
Ti ghten bol t to 7.4 Nm (65 i n. l bs.) torque.
(3) Connect sensor wi re harness connector.
SPEEDOMETER ADAPTER
Rear axl e gear rati o and ti re si ze determi ne speed-
ometer pi ni on requi rements.
REMOVAL
as assembl y.
oxi di zed. Repl ace sensor i f faul ty, or pi ns are l oose,
INSTALLATION
ati on.
ometer adapter i f necessary (Fi g. 51).
pi ni on.
are at 6 ocl ock posi ti on. Be sure range i ndex num-
Fig. 49 Adapter Housing Seals
1 4WD ADAPTER HOUSING
2 SEAL
3 BUSHING
4 OIL TUBE
5 2WD EXTENSION HOUSING
6 SEAL
7 SPEED SENSOR
8 SPEED SENSOR
Fig. 50 Transmission Speed Sensor Removal/
Installation
1 RETAINER BOLT
2 SPEED SENSOR
i n. l bs.) torque.
l evel , i f necessary.
SPEED SENSOR ROTOR-SPEEDOMETER DRIVE
GEAR
REMOVAL
(2) Remove components necessary to gai n access to
rotor and dri ve gear such as propel l er shaft, transfer
case, crossmember, and shi ft l i nkage.
(3) Di sengage wi re connector from the output
speed sensor.
(4) Remove the bol t hol di ng the output speed sen-
sor to the adapter housi ng.
(5) Remove the output speed sensor from the
adapter housi ng.
(6) Remove the bol ts hol di ng the adapter housi ng
to the transmi ssi on case.
(7) Tap the adapter housi ng at the joi nt l i ne gentl y
wi th a rubber mal l et to separate the adapter housi ng
from the transmi ssi on case.
(8) Remove the adapter housi ng from the trans-
mi ssi on case.
(9) Remove speedometer dri ve gear snap ri ng (Fi g.
53).
(10) Remove the speedometer dri ve gear and
spacer, i f equi pped.
(11) Remove rotor from the output shaft. I t may be
necessary to use a wood dowel or hammer handl e
(Fi g. 54) to gentl y pry the rotor from the output
Fig. 51 Speedometer Pinion Adapter Components
1 SENSOR O-RING
3 ADAPTER O-RING
5 ADAPTER CLAMP
ITEM TORQUE
A 2-3 Nm (15-27 in. lbs.)
B 10-12 Nm (90-110 in. lbs.)
Fig. 52 Index Numbers On Speedometer Pinion
Adapter
shaft. Be sure to retri eve the rotor l ocati ng key from
the output shaft or rotor.
INSTALLATION
(1) Cl ean seal i ng surfaces of transmi ssi on case and
extensi on/adaptor housi ng.
(2) I nstal l rotor, spacer (i f equi pped) and dri ve
gear on output shaft. Then i nstal l dri ve gear snap
ri ng (Fi g. 53).
(3) Appl y 1/8 3/16 i nch wi de bead of Threebond
Li qui d Gasket TB1281, P/N 83504038, to transmi s-
si on case seal i ng surface and i nstal l extensi on/
adapter housi ng on case.
(4) Ti ghten adaptor housi ng bol ts to 34 Nm (25 ft.
l bs.) torque.
(5) I nstal l components removed to gai n access to
rotor and dri ve gear.
REMOVAL
(2) Di sconnect swi tch wi re harness connector.
(3) Pry washer l ock tabs upward and remove
swi tch attachi ng nut and tabbed washer (Fi g. 55).
(4) Remove swi tch adjusti ng bol t (Fi g. 55).
(5) Sl i de swi tch off manual val ve shaft.
Fig. 55 Park/Neutral Position Switch Removal/
Installation
1 ADJUSTING BOLT
2 ATTACHING NUT
3 NEUTRAL SWITCH
4 TABBED WASHER
Fig. 53 Removing/Installation Speedometer Drive
Gear
1 ROTOR
2 SPEEDOMETER DRIVE GEAR
3 SNAP RING
Fig. 54 Removing Speed Sensor Rotor
1 WOOD DOWEL OR HAMMER HANDLE
2 ROTOR
3 OUTPUT SHAFT
INSTALLATION
(1) Di sconnect shi ft l i nkage rod from shi ft l ever on
l eft si de of transmi ssi on.
(2) Rotate manual shi ft l ever al l the way rear-
ward. Then rotate l ever forward two detent posi ti ons
to Neutral .
(3) I nstal l swi tch on manual val ve shaft and
i nstal l swi tch adjusti ng bol t fi nger ti ght. Do not
ti ghten bol t at thi s ti me.
(4) I nstal l tabbed washer on manual val ve shaft
and i nstal l swi tch attachi ng nut. Ti ghten nut to 6.9
Nm (61 i n. l bs.) torque but do not bend washer l ock
tabs over nut at thi s ti me.
(5) Veri fy that transmi ssi on i s i n Neutral .
(6) Rotate swi tch to al i gn neutral standard l i ne
wi th verti cal groove on manual val ve shaft (Fi g. 56).
(7) Al i gn swi tch standard l i ne wi th groove or fl at
on manual val ve shaft.
(8) Ti ghten swi tch adjusti ng bol t to 13 Nm (9 ft.
l bs.) torque.
(9) Bend at l east two washer l ock tabs over swi tch
attachi ng nut to secure i t.
(10) Connect shi ft l i nkage rod to shi ft l ever on l eft
si de of case.
(11) Connect swi tch wi res to harness and l ower
vehi cl e.
(12) Check swi tch operati on. Engi ne shoul d start
i n Park and Neutral onl y.
GEARSHIFT CABLE
REMOVAL
(2) Remove shi ft l ever bezel and necessary consol e
parts for access to shi ft l ever assembl y.
(3) Di sconnect cabl e at shi ft l ever and feed cabl e
through dash panel openi ng to undersi de of vehi cl e.
(5) Di sengage cabl e eyel et at transmi ssi on shi ft
l ever and pul l cabl e adjuster out of mounti ng
bracket. Then remove ol d cabl e from vehi cl e.
INSTALLATION
(1) Route cabl e through hol e i n dash panel . Ful l y
seat cabl e grommet i nto dash panel .
(2) Pl ace the auto transmi ssi on manual shi ft con-
trol l ever i n Park detent (rearmost) posi ti on and
rotate prop shaft to ensure transmi ssi on i s i n park.
(3) Connect shi ft cabl e to shi fter mechani sm by
snappi ng cabl e retai ni ng ears i nto shi fter bracket
and press cabl e end fi tti ng onto l ever bal l stud.
(4) Pl ace the fl oor shi fter l ever i n park posi ti on.
Ensure that the pawl i s seated wi thi n the confi nes of
the adjustment gauge cl i p.
(5) Snap the cabl e i nto the transmi ssi on bracket so
the retai ni ng ears are engaged and connect cabl e end
fi tti ng onto the manual control l ever bal l stud.
(6) Lock shi ft cabl e i nto posi ti on by pushi ng
upward on the adjusti ng l ock button.
(7) Remove and di scard the shi ft cabl e adjustment
gauge cl i p from the park gate of the shi fter.
REMOVAL
(1) Remove l ower steeri ng col umn cover. Refer to
Group 8E, I nstrument Panel and Gauges, for proper
procedure.
(2) Remove l ower steeri ng col umn shroud. Refer to
Group 19, Steeri ng, for proper procedure.
(3) Remove ti e strap near the sol enoi d retai ni ng
the brake transmi ssi on i nterl ock cabl e to the steeri ng
col umn.
(4) Di sengage wi re connector from sol enoi d.
(5) Wi th the i gni ti on removed or i n the unl ocked
posi ti on, di sengage l ock tab hol di ng cabl e end to
steeri ng col umn (Fi g. 57).
(6) Pul l cabl e end from steeri ng col umn.
(7) Remove the fl oor consol e and rel ated tri m.
Refer to Group 23, Body, for proper procedure.
(8) Di sconnect the cabl e eyel et from the bel l crank
(Fi g. 58).
(9) Di sconnect and remove the cabl e from the shi ft
bracket.
Fig. 56 Park/Neutral Position Switch Adjustment
1 NEUTRAL STANDARD LINE
2 ADJUSTING BOLT
3 VERTICAL GROOVE ON MANUAL VALVE SHAFT
INSTALLATION
(1) Route repl acement cabl e behi nd i nstrument
panel and under fl oor consol e area to shi ft mechani sm
(Fi g. 58).
(2) I nsert cabl e end i nto openi ng i n steeri ng col umn
hub under i gni ti on l ock. Push cabl e i nward unti l l ock
tab engages.
(3) Connect the cabl e end eyel et onto shi fter
bel l crank pi n.
(4) Pl ace gear sel ector i n PARK.
(5) Push the spri ng-l oaded cabl e adjuster forward
and snap cabl e i nto bracket.
(6) Adjust the brake transmi ssi on shi fter i nterl ock
cabl e. Refer to the Adjustment porti on of thi s secti on
(7) Veri fy that the cabl e adjuster l ock cl amp i s
pushed downward to the l ocked posi ti on.
(8) Test the park-l ock cabl e operati on.
(9) I nstal l the fl oor consol e and rel ated tri m.
Fig. 58 Cable and Shifter
1 SHIFT MECHANISM
2 LOCK-TAB
4 STEERING COLUMN
5 SOLENOID
6 WIRE CONNECTOR
7 LEVER
8 MOUNT BRACKET
9 SHIFT CABLE
11 TIE STRAP
Fig. 57 Brake/Park Interlock Cable
1 IGNITION LOCK
2 LOCK TAB
3 CABLE END
(10) I nstal l ti e strap to hol d cabl e to base of steer-
i ng col umn.
(11) I nstal l l ower steeri ng col umn shroud and i gni -
ti on l ock.
(12) I nstal l l ower steeri ng col umn cover.
REMOVAL
(1) Remove transmi ssi on oi l pan drai n pl ug and
drai n fl ui d.
(2) Remove pan bol ts and remove oi l pan.
(3) Remove oi l screen bol ts and remove screen
(Fi g. 59) and gasket. Di scard the gasket.
(4) Di sconnect sol enoi d wi re connector (Fi g. 60).
(5) I f al l sol enoi ds are bei ng removed, mark or tag
wi res for assembl y reference before di sconnecti ng
them.
(6) Remove bol t attachi ng sol enoi ds to val ve body
and remove sol enoi ds (Fi g. 61). Do not al l ow any
val ve body components to fal l out when sol enoi ds are
removed.
(7) Cl ean oi l fi l ter and pan wi th sol vent and dry
wi th compressed ai r.
(8) Remove ol d seal er materi al from oi l pan and
INSTALLATION
(1) Posi ti on sol enoi ds on val ve body and i nstal l
sol enoi d bol ts. Ti ghten bol ts to 10 Nm (7 ft. l bs.)
torque.
(2) Connect feed wi res to sol enoi ds.
(3) I nstal l new gaskets on oi l screen and i nstal l
screen. Ti ghten screen bol ts to 10 Nm (7 ft. l bs.)
torque.
(4) Appl y bead of Threeebond Li qui d Gasket
TB1281, P/N 83504038, seal er to oi l pan seal i ng sur-
face. Seal er bead shoul d be at l east 3.0 mm (1/8 i n.)
wi de.
(5) I nstal l oi l pan on transmi ssi on. Ti ghten pan
(6) I nstal l and ti ghten oi l pan drai n pl ug to 20
(7) Fi l l transmi ssi on wi th Mopar Dexron I I E/Mer-
con.
Fig. 59 Oil Screen Removal/Installation
1 OIL SCREEN BOLTS
2 OIL SCREEN
Fig. 60 Solenoid Wire Connectors
1 SOLENOID WIRE CONNECTORS
Fig. 61 Transmission Valve Body Solenoids
1 VALVE BODY SOLENOIDS
TRANSMISSION VALVE BODY
REMOVAL
(1) Remove oi l pan pl ug and drai n transmi ssi on
fl ui d.
(2) Remove oi l pan and oi l screen. Cl ean pan and
screen i n sol vent and dry them wi th compressed ai r.
(3) Di sconnect sol enoi d wi re connectors (Fi g. 62).
Mark wi res for assembl y reference.
(4) Remove val ve body oi l tubes (Fi g. 63). Careful l y
pry tubes out of val ve body wi th screwdri ver.
(5) Di sconnect throttl e cabl e from throttl e cam
(Fi g. 64).
(6) Remove val ve body bol ts. Bol t l ocati ons are
outl i ned i n (Fi g. 65).
(7) Lower val ve body and remove overdri ve cl utch
accumul ator spri ngs, di rect cl utch accumul ator
spri ngs and second brake accumul ator spri ng (Fi g.
66).
(8) Remove val ve body and check bal l and spri ng
(Fi g. 67).
INSTALLATION
(1) Connect cabl e to throttl e cam (Fi g. 64).
(2) I nstal l check bal l and spri ng (Fi g. 67).
(3) Posi ti on accumul ator spri ngs and spacers on
val ve body.
(4) Al i gn val ve body manual val ve wi th shi ft sector
(Fi g. 68) and careful l y posi ti on val ve body on case.
(5) I nstal l val ve body bol ts (Fi g. 65). Ti ghten bol ts
evenl y to 10 Nm (7 ft. l bs.) torque.
(6) I nstal l val ve body oi l tubes. Be sure tube ends
(L) and (M) are i nstal l ed as shown i n (Fi g. 69).
(7) Remove ol d seal er materi al from oi l pan and
(8) Cl ean oi l screen and oi l pan wi th sol vent (i f not
done previ ousl y). Dry both components wi th com-
pressed ai r onl y. Do not use shop towel s.
screen on case. Ti ghten screen attachi ng bol ts to 10
Fig. 63 Removing Transmission Valve Body Oil
Tubes
1 OIL TUBES
Fig. 64 Removing/Installing Throttle Cable
1 THROTTLE CABLE
2 CABLE BRACKET
(10) Appl y bead of Threebond Li qui d Gasket
TB1281, P/N 83504038 to seal i ng surface of oi l pan.
Seal er bead shoul d be at l east 3 mm (1/8 i n.) wi de.
Then i nstal l oi l pan and ti ghten pan bol ts to 7.4 Nm
(65 i n. l bs.) torque.
(11) I nstal l new gasket on oi l pan drai n pl ug and
i nstal l pl ug i n pan. Ti ghten pl ug to 20 Nm (15 ft.
l bs.) torque.
(12) Fi l l transmi ssi on wi th Mopar Dexron I I E/
Mercon.
TRANSMISSION CONTROL MODULE
The transmi ssi on control modul e i s mounted under
the i nstrument panel . On l eft hand dri ve model s, i t i s
at the dri ver si de of the l ower fi ni sh panel (Fi g. 70).
On ri ght hand dri ve model s, i t i s at the passenger
si de of the l ower fi ni sh panel (Fi g. 71).
To remove the modul e, di sconnect the wi re har-
ness, remove the mounti ng screws and remove the
Fig. 65 Transmission Valve Body Bolt Locations
Fig. 66 Accumulator Springs
1 OVERDRIVE BRAKE ACCUMULATOR SPRING
2 SECOND BRAKE ACCUMULATOR SPRING
Fig. 67 Removing/Installing Check Ball And Spring
1 CHECK BALL AND SPRING
Fig. 68 Shift Sector And Manual Valve Alignment
1 MANUAL VALVE
2 SHIFT SECTOR
modul e from the fi ni sh panel . Ti ghten the modul e
mounti ng screws securel y after i nstal l ati on. Al so be
sure the wi re harness i s not twi sted, ki nked or touch-
i ng any body panel s.
SOLENOID HARNESS ADAPTER SEAL
REMOVAL
(1) Remove oi l pan and oi l screen.
(2) Di sconnect sol enoi d wi re connectors (Fi g. 72).
(3) Remove bracket securi ng sol enoi d harness
adaptor (Fi g. 73) to case.
(4) Pul l harness adapter and wi res out of case.
Fig. 69 Installing Transmission Valve Body Oil
Tubes
Fig. 70 TCM Location (Left Hand Drive)
1 TCM
2 LOWER FINISH PANEL
Fig. 71 TCM Location (Right Hand Drive)
1 REAR SIDE OF INSTRUMENT PANEL
2 TCM AND HARNESS
Fig. 73 Harness Adapter Removal/Installation
1 HARNESS ADAPTER
2 BRACKET
(5) Remove and di scard adapter Ori ng.
INSTALLATION
(1) Lubri cate new Ori ng and i nstal l i t on adapter.
(2) I nstal l sol enoi d wi re harness and adapter i n
case.
(3) I nstal l adapter bracket and bracket bol t.
(4) Connect wi res to sol enoi ds.
(5) I nstal l oi l screen.
(6) Appl y bead of Threeebond Li qui d Gasket
TB1281, P/N 83504038, to oi l pan seal surface.
Seal er bead shoul d be at l east 3 mm (1/8 i n.) wi de.
(7) I nstal l oi l pan on transmi ssi on. Ti ghten pan
(8) I nstal l and ti ghten oi l pan drai n pl ug to 20
(9) Fi l l transmi ssi on wi th Mopar Dexron I I E/Mer-
con.
MANUAL VALVE SHAFT SEAL
REMOVAL
(1) Remove park/neutral posi ti on swi tch and di s-
connect transmi ssi on shi ft l ever (Fi g. 74).
(2) Remove oi l pan and val ve body.
(3) Remove bol ts attachi ng park rod bracket to
case (Fi g. 75).
(4) Remove park rod from shi ft sector (Fi g. 76).
(5) Cut spacer sl eeve wi th chi sel and remove i t
from manual val ve shaft (Fi g. 77).
(6) Remove pi n from shaft and sector wi th pi n
punch.
(7) Remove shaft and sector from case.
Fig. 74 Manual Valve Shaft And Seals
1 SHAFT SEAL
2 PIN
3 MANUAL VALVE SHAFT
4 SHAFT SEAL
5 SPACER SLEEVE
6 SHIFT SECTOR
Fig. 75 Removing/Installing Park Rod Bracket
1 PARK ROD
2 PARK ROD BRACKET
Fig. 76 Removing/Installing Park Rod
1 SHIFT SECTOR
3 PARK ROD
(8) Pry shaft seal s out of case (Fi g. 78).
INSTALLATION
(1) I nspect the manual val ve shaft and sector.
Repl ace ei ther component i f worn or damaged.
(2) Coat repl acement shaft seal s wi th petrol eum
jel l y and seat them i n the case usi ng an appropri -
atel y si zed dri ver/socket (Fi g. 79).
(3) I nstal l new spacer sl eeve on sector (Fi g. 80).
(4) Lubri cate manual val ve shaft wi th petrol eum
jel l y and i nstal l i t through the l eft si de of the trans-
mi ssi on case.
Fig. 77 Cutting Spacer Sleeve
1 SPACER
Fig. 78 Removing Manual Valve Shaft Seals
1 MANUAL VALVE SHAFT SEAL
Fig. 79 Installing Manual Valve Shaft Seals
1 SHAFT SEAL INSTALLER
Fig. 80 Installing Spacer Sleeve On Sector
1 SHIFT SECTOR
2 SPACER SLEEVE
(5) Lubri cate sector and sl eeve wi th petrol eum
jel l y and i nstal l them on shaft.
(6) I nstal l the manual val ve shaft through the
remai nder of the transmi ssi on case.
(7) Al i gn hol e i n spacer sl eeve wi th notch i n sector.
Then i nstal l shi ft sector rol l pi n. Tap pi n i nto sector and
shaft and securel y stake sl eeve to sector and shaft.
(8) Connect park rod to sector (Fi g. 76).
(9) I nstal l park rod bracket (Fi g. 81). Ti ghten
(10) I nstal l val ve body, oi l screen and oi l pan.
(11) I nstal l park/neutral posi ti on swi tch.
ACCUMULATOR PISTONS AND SPRINGS
REMOVAL
(2) Remove accumul ator pi stons wi th compressed
ai r (Fi g. 82). Appl y ai r through smal l feed hol e next
to each pi ston bore. Catch each pi ston i n a shop
towel as i t exi ts bore.
CAUTION: Use only enough air pressure to ease each
piston out of the bore. In addition, remove the pistons
one at a time and tag the pistons and springs for
assembly reference. Do not intermix them.
(3) Remove and di scard pi ston Ori ng seal s. Then
cl ean pi stons and spri ngs wi th sol vent.
INSTALLATION
(1) I nspect pi stons, spri ngs and pi ston bores.
Repl ace worn damaged pi stons. Repl ace broken, col -
l apsed or di storted spri ngs. Repl ace case i f pi ston
bores are damaged.
(2) I f smal l cushi on spri ng i n any pi ston must be
repl aced, remove spri ng retai ner cl i p and remove
spri ng from pi ston (Fi g. 83). A smal l hooked tool or
smal l thi n bl ade screwdri ver can be used to remove
cl i p. A thi n wal l , deep socket, or pi n punch can be
used to seat cl i p after spri ng repl acement.
Fig. 81 Installing Park Rod Bracket
1 PARK ROD BRACKET
Fig. 82 Accumulator Piston Removal
1 AIR GUN NOZZEL IN FEED HOLE
2 PISTONS
Fig. 83 Small Cushion Spring Retention
1 ACCUMULATOR PISTON (TYPICAL)
2 SMALL CUSHION SPRING
3 RETAINER CLIP
(3) I nstal l new Ori ng seal s on pi stons. Lubri cate
seal s and pi stons and pi ston bores wi th transmi ssi on
fl ui d.
(4) I nstal l pi stons and spri ngs (Fi g. 84).
SECOND COAST BRAKE SERVO
REMOVAL
(2) Remove servo pi ston cover snap ri ng wi th snap
ri ng pl i ers (Fi g. 85).
(3) Remove servo pi ston and cover wi th com-
pressed ai r. Appl y compressed ai r through oi l hol e i n
servo boss to ease pi ston out of bore (Fi g. 86).
Fig. 84 Accumulator Pistons, Springs And Spacers
Fig. 85 Removing/Installing Servo Piston Cover
Snap Ring
1 SERVO PISTON COVER SNAP RING
2 SNAP RING PLIERS
Fig. 86 Removing Servo Cover And Piston
1 PISTON AND COVER
2 OIL HOLE
(4) Remove and di scard seal and Ori ngs from
cover and pi ston (Fi g. 87). I nspect Eri ng, pi ston,
spri ng and retai ner, pi ston rod and pi ston spri ng.
Repl ace worn or damaged parts.
INSTALLATION
(1) I nstal l new seal s on cover and pi ston.
(2) Lubri cate servo components wi th transmi ssi on
fl ui d.
(3) Assembl e and i nstal l servo components i n case.
Be sure servo pi ston rod i s properl y engaged i n the
second coast brake band.
(4) Compress cover and pi ston and i nstal l cover
snap ri ng.
PARK ROD AND PAWL
REMOVAL
(1) Remove val ve body as outl i ned i n thi s secti on.
case (Fi g. 88).
(3) Remove park rod from manual val ve shaft sec-
tor (Fi g. 89).
(4) Remove park rod.
Fig. 87 Second Coast Brake Servo Components
1 SERVO PISTON
2 SEAL RING
3 SPRING AND RETAINER
4 PISTON ROD
5 PISTON SPRING
6 SERVO COVER O-RINGS
7 SERVO COVER
8 SNAP RING
9 E-RING
Fig. 88 Removing/Installing Park Rod Bracket
1 PARK ROD BRACKET
Fig. 89 Removing/Installing Park Rod
1 SHIFT SECTOR
3 PARK ROD
(5) Remove park pawl , pi n and spri ng (Fi g. 90).
INSTALLATION
(1) Exami ne park rod, pawl , pi n and spri ng.
Repl ace any component that i s worn or damaged.
(2) I nstal l pawl i n case. I nsert pi n and i nstal l spri ng.
Be sure spri ng i s posi ti oned as shown i n Fi gure 35.
(3) I nstal l park rod and bracket (Fi g. 88). Ti ghten
TRANSMISSION THROTTLE CABLE
REMOVAL
(1) I n engi ne compartment, di sconnect cabl e from
throttl e l i nkage. Then compress cabl e mounti ng ears
and remove cabl e from engi ne bracket (Fi g. 91).
(3) Remove transmi ssi on oi l pan.
(4) Di sengage cabl e from throttl e val ve cam (Fi g.
92).
(5) Remove cabl e bracket bol t and remove cabl e
and bracket from case (Fi g. 93).
(6) Remove and di scard cabl e seal .
Fig. 91 Transmission Throttle Cable Attachment
1 THROTTLE CABLE
2 CABLE GUIDE
3 ACCELERATOR CABLE
4 CABLE ENGINE BRACKET
5 CONVERTER HOUSING
6 THROTTLE CABLE
7 CABLE RETAINER SCREW
8 CABLE BRACKET
9 DASH PANEL
10 THROTTLE BODY
Fig. 90 Removing/Installing Park Pawl, Pin And Spring
1 SPRING
2 PIN
3 PARK PAWL
INSTALLATION
(1) Lubri cate and i nstal l new seal on cabl e.
(2) I nsert cabl e i n transmi ssi on case.
(3) Attach cabl e to throttl e cam (Fi g. 92).
(4) I nstal l cabl e bracket on case and ti ghten
attachi ng bol t to 10 Nm (7 ft. l bs.) torque (Fi g. 93).
(5) I nstal l pan and ti ghten pan bol ts to 7 Nm (65
i n. l bs.) torque.
(6) I nstal l new gasket on oi l pan drai n pl ug.
I nstal l and ti ghten pl ug to 20 Nm (15 ft. l bs.) torque.
(7) Connect cabl e to engi ne bracket and throttl e
l i nkage.
(8) Fi l l transmi ssi on wi th Mopar Dexron/Mercon
I I E.
(9) Adjust the cabl e as descri bed i n cabl e adjust-
ment procedure.
OIL PUMP SEAL
REMOVAL
(1) Remove converter.
(2) Remove ol d seal . Use bl unt punch to col l apse
seal and pry seal out of pump housi ng. Do not
scratch or damage seal bore.
INSTALLATION
(1) Lubri cate l i p of new seal wi th transmi ssi on
fl ui d and i nstal l seal i n pump wi th tool 7549 (Fi g.
94).
(2) Lubri cate converter dri ve hub wi th transmi s-
si on fl ui d.
(3) Al i gn and i nstal l converter i n oi l pump.
Fig. 92 Removing/Installing Transmission Throttle
Cable
1 THROTTLE CABLE
2 CABLE BRACKET
Fig. 93 Removing/Installing Transmission Throttle
Cable And Bracket
1 THROTTLE CABLE
2 CABLE BRACKET
Fig. 94 Installing Oil Pump Seal
1 PUMP SEALER INSTALLER
TRANSMISSION
DISASSEMBLY
(1) Remove torque converter.
(2) Remove cl amps attachi ng wi re harness and
throttl e cabl e (Fi g. 95) to transmi ssi on.
(3) Remove shi ft l ever from manual val ve shaft at
l eft si de of transmi ssi on.
(4) Remove park/neutral posi ti on swi tch.
(5) Remove speed sensor.
(6) Remove converter housi ng bol ts and remove
housi ng (Fi g. 96) from case.
(7) Remove adapter housi ng, speedometer dri ve
gear, and speed sensor rotor.
(8) Remove transmi ssi on oi l pan, oi l screen and
screen gaskets (Fi g. 97).
Fig. 95 Typical Harness And Cable Clamp
Attachment
1 CLAMP
2 THROTTLE CABLE
3 TRANSMISSION HARNESS
Fig. 96 Converter Housing Removal
1 CONVERTER HOUSING
Fig. 97 Removing Oil Screen
1 OIL SCREEN BOLTS
2 OIL SCREEN
(9) Remove val ve body oi l feed tubes (Fi g. 98).
(10) Di sconnect val ve body sol enoi d wi res (Fi g. 99).
(11) Remove harness bracket bol t and remove har-
ness and bracket (Fi g. 100).
(12) Remove val ve body bol ts (Fi g. 101).
(13) Di sconnect throttl e cabl e from throttl e cam
(Fi g. 102).
(14) Remove val ve body from case. Then remove
accumul ator spri ngs, check bal l , and spri ng (Fi g. 103).
Fig. 98 Valve Body Oil Tube Removal
1 OIL TUBES
Fig. 99 Solenoid Wire Location
Fig. 100 Removing Bracket And Harness
1 HARNESS ADAPTER
2 BRACKET
Fig. 101 Valve Body Bolt Locations
(15) Remove second brake and cl utch accumul ator
pi stons wi th compressed ai r (Fi g. 104). Appl y ai r
pressure through feed port and ease the pi stons and
spri ngs out of the bore. Note and i denti fy the ori gi nal
l ocati on of al l spri ngs.
(16) Remove overdri ve brake accumul ator pi ston
wi th compressed ai r (Fi g. 104). Note and i denti fy the
ori gi nal l ocati on of al l spri ngs.
(17) Remove overdri ve cl utch accumul ator pi ston
wi th compressed ai r (Fi g. 104).
(18) Remove throttl e cabl e.
Fig. 102 Disconnecting Throttle Cable
1 THROTTLE CABLE
2 THROTTLE CAM
Fig. 103 Removing Accumulator Springs, Spacers
And Check Ball
1 CHECK BALL AND SPRING
2 ACCUMULATOR SPRINGS
Fig. 104 Accumulator Piston Removal
(19) Remove oi l pump bol ts and remove pump wi th
bri dgetype Pul l er 7536 (Fi g. 105).
(20) Remove race from oi l pump (Fi g. 106).
(21) Remove overdri ve pl anetary gear and cl utch
assembl y (Fi g. 107).
(22) Remove race from overdri ve pl anetary (Fi g.
108).
(23) Remove thrust beari ng, race and overdri ve
pl anetary ri ng gear (Fi g. 109).
(24) Measure stroke l ength of overdri ve brake pi s-
ton as fol l ows:
Fig. 105 Oil Pump Removal
1 PULLER TOOL
2 OIL PUMP
Fig. 106 Oil Pump Race Removal
1 OIL PUMP RACE
2 OIL PUMP
Fig. 107 Removing Overdrive Planetary And Clutch
Assembly
1 PLANETARY AND CLUTCH ASSEMBLY
Fig. 108 Fourth Gear Planetary Race Removal
1 PLANETARY (OVERDRIVE)
2 RACE
(a) Mount di al i ndi cator on case usi ng Mi l l er
Tool C-3339 and a sui tabl e bol t threaded i nto the
(b) Veri fy that the di al i ndi cator i s mounted sol -
i dl y and square to the di recti on of the pi ston
travel .
(c) Appl y 57114 psi ai r pressure through pi ston
appl y port and note pi ston stroke on di al i ndi cator.
Stroke l ength shoul d be: 1.40 1.70 mm (0.055
0.0699 i n.).
(d) Record the readi ng for use duri ng re-assem-
bl y.
(e) Remove the di al i ndi cator set-up from the
transmi ssi on.
(25) Measure stroke l ength of second coast brake
pi ston rod as fol l ows:
(a) I nstal l a smal l wi re ti e strap around the sec-
ond coast brake pi ston rod ti ght agai nst the trans-
mi ssi on case.
(b) Appl y 57114 psi ai r pressure through pi ston
feed hol e and check stroke l ength wi th Gauge Tool
7552.
(c) Stroke l ength shoul d be 1.5 3.0 mm (0.059
0.118 i n.).
(d) Record the readi ng for use duri ng re-assem-
bl y.
(26) Remove the bol t hol di ng the i nput speed sen-
sor to the transmi ssi on case.
(27) Remove the i nput speed sensor from the
(28) Remove overdri ve brake pack snap ri ng (Fi g.
110).
(29) Remove overdri ve brake pack di scs and
pl ates. I nspect and repl ace as necessary.
(30) Remove overdri ve support l ower race and
upper beari ng and race assembl y (Fi g. 111).
Fig. 109 Removing Bearing, Race And Planetary
Ring Gear
1 THRUST BEARING
2 RACE
3 OVERDRIVE PLANETARY RING GEAR
Fig. 110 Removing Overdrive Brake Pack Snap Ring
1 OVERDRIVE BRAKE SNAP RING
Fig. 111 Overdrive Support Bearing/Race Removal
1 UPPER BEARING AND RACE
2 LOWER RACE
(31) Remove overdri ve support snap ri ng wi th
Snap Ri ng Pl i er Tool 7540 (Fi g. 112).
(32) Remove overdri ve support bol ts (Fi g. 113).
(33) Remove overdri ve support (Fi g. 114) wi th
bri dgetype Pul l er 7536.
(34) Remove race from hub of overdri ve support
(Fi g. 115).
(35) Remove second coast brake pi ston snap ri ng
wi th Snap Ri ng Pl i er Tool 7540. Then remove pi ston
cover and pi ston assembl y.
(36) Di sassembl e second coast brake pi ston (Fi g.
116), i f necessary.
(37) Remove di rect and forward cl utch assembl y
(Fi g. 117).
Fig. 112 Overdrive Support Snap Ring Removal/
Installation
1 SNAP RING PLIERS
2 SUPPORT SNAP RING
Fig. 113 Overdrive Support Bolt Removal
1 SUPPORT BOLTS
Fig. 114 Removing Overdrive Support
1 BRIDGE-TYPE PULLER TOOL
2 OVERDRIVE SUPPORT
Fig. 115 Remove Overdrive Support Race
1 RACE
2 OVERDRIVE SUPPORT
(38) Remove thrust beari ng and race from cl utch
hub (Fi g. 118).
(39) Remove second coast brake band Eri ng from
band pi n and remove pi n and brake band (Fi g. 119).
Fig. 116 Second Coast Brake Piston Components
1 SERVO PISTON
2 SEAL RING
4 PISTON ROD
5 PISTON SPRING
6 SERVO COVER O-RINGS
7 SERVO COVER
8 SNAP RING
9 E-RING
Fig. 117 Removing Direct And
Forward Clutch Assembly
1 DIRECT AND FORWARD CLUTCH ASSEMBLY
Fig. 118 Bearing And Race Removal From Clutch Hub
1 BEARING
2 RACE
3 DIRECT CLUTCH
Fig. 119 Second Coast Brake Band Removal
1 BRAKE BAND E-RING
2 SECOND COAST BRAKE BAND
(40) Remove front pl anetary beari ng race and
remove front pl anetary ri ng gear (Fi g. 120).
(41) Remove thrust beari ng and rear race from
ri ng gear (Fi g. 121).
(42) Remove pl anetary thrust race.
(43) Push forward on output shaft to rel i eve the
l oad on the pl anetary snap ri ng.
(44) Remove pl anetary snap ri ng and remove pl an-
etary gear (Fi g. 122).
Fig. 120 Front Planetary Ring Gear Removal
1 RING GEAR BEARING RACE (FRONT)
Fig. 121 Removing Ring Gear Bearing And Rear Race
1 BEARING AND REAR RACE
Fig. 122 Removing Planetary Snap Ring And Gear
2 PLANETARY GEAR
3 SNAP RING PLIERS
(45) Remove sun gear, i nput drum, oneway
cl utch, and thrust washer as assembl y (Fi g. 123).
(46) Measure second brake cl utch pack cl earance
(Fi g. 124). Cl earance shoul d be 0.62 1.98 mm
(0.0244 0.0780 i n.). Record measurement for use
duri ng re-assembl y.
(47) Remove second brake cl utch pack snap ri ng
(Fi g. 125).
(48) Remove second brake cl utch pack (Fi g. 126).
I nspect and repl ace as necessary.
Fig. 123 Removing Sun Gear, Input Drum And
OneWay Clutch
1 SUN GEAR INPUT DRUM, ONE-WAY CLUTCH ASSEMBLY
Fig. 124 Checking Second Brake Clutch Pack
Clearance
1 FEELER GAUGE
2 SECOND BRAKE CLUTCH PACK
Fig. 125 Removing Second Brake Clutch Pack Snap
Ring
1 CLUTCH PACK SNAP RING
Fig. 126 Removing/Measuring Second Brake Clutch
Disc Thickness
case. Then di sconnect park rod from manual shaft
l ever and remove rod and bracket (Fi g. 127).
(50) Remove park pawl spri ng, pi n and pawl (Fi g.
128).
(51) Measure cl earance of fi rstreverse brake
cl utch pack (Fi g. 129). Cl earance shoul d be: 0.70
1.2 mm (0.028 0.047 i n.). record measurement for
use duri ng re-assembl y.
(52) Remove second brake pi ston sl eeve (Fi g. 130).
(53) Remove second brake snap-ri ng.
(54) Remove rear pl anetary gear, second brake
drum and output shaft as an assembl y (Fi g. 131).
(55) Remove pl anetary and brake drum thrust
beari ng and race assembl y (Fi g. 132).
(56) Remove second brake drum gasket from case
wi th screwdri ver.
(57) Measure i nsi de di ameter of transmi ssi on case
rear bushi ng wi th bore gauge or i nsi de mi crometer
(Fi g. 133). Maxi mum al l owabl e di ameter i s 38.18 mm
(1.5031 i n.). Replace transmission case if bush-
ing I. D. is greater than specified. Bushing is
not serviceable.
Fig. 127 Removing Park Rod And Bracket
1 PARK ROD BRACKET
2 SHIFT SETOR
Fig. 128 Removing Park Pawl, Pin And Spring
1 SPRING
2 PIN
3 PARK PAWL
Fig. 129 Checking FirstReverse Brake Clutch Pack
Clearance
1 FIRST-REVERSE CLUTCH PACK
2 FEELER GAUGE
(58) Check fi rst/reverse brake pi ston operati on
wi th compressed ai r (Fi g. 134). Pi ston shoul d move
smoothl y and not bi nd or sti ck. I f pi ston operati on i s
i ncorrect, case or pi ston may requi re repl acement.
(59) Compress pi ston return spri ngs wi th Tool
7539 and remove pi ston snap ri ng (Fi g. 135).
(60) Remove Tool 7539 and remove pi ston return
spri ngs.
Fig. 130 Removing Second Brake Piston Sleeve
1 REMOVER TOOL
2 PISTON SLEEVE
Fig. 131 Removing Rear Planetary, Second Brake
Drum And Output Shaft
1 PLANETARY, BRAKE DRUM AND OUTPUT SHAFT
ASSEMBLY
Fig. 132 Removing/Installing Bearing And Race
Assembly
1 BEARING AND RACE ASSEMBLY
Fig. 133 Checking Rear Bushing Inside Diameter
1 BORE GAUGE
2 REAR BUSHING
3 TRANSMISSION CASE
(61) Remove No. 2 fi rstreverse brake pi ston wi th
compressed ai r. Appl y ai r through same transmi ssi on
feed hol e used for checki ng pi ston operati on.
(62) Remove reacti on sl eeve wi th Sl eeve Remover
Tool 7542 (Fi g. 136). I nsert tool fl anges under sl eeve
and l i ft tool and sl eeve out of case.
(63) Remove No. 1 fi rst/reverse brake pi ston wi th
Pi ston Pul l er 7543 (Fi g. 137). Sl i p tool under pi ston
and l i ft tool and pi ston out of case.
ASSEMBLY
(1) Duri ng assembl y, l ubri cate components wi th
transmi ssi on fl ui d or petrol eum jel l y as i ndi cated.
(2) Veri fy thrust beari ng and race i nstal l ati on dur-
i ng assembl y. Refer to the Thrust Beari ng Chart (Fi g.
Fig. 135 Removing/Installing Piston Snap Ring
1 RETURN SPRINGS
2 COMPRESSOR TOOL
3 PISTON SNAP RING
Fig. 134 Checking FirstReverse Brake Piston
Operation
1 LOW-PRESSURE AIR
2 FIRST-REVERSE BRAKE (IN CASE)
Fig. 136 Removing/Installing Reaction Sleeve
1 REACTION SLEEVE
2 TOOL
Fig. 137 Removing/Installing FirstReverse Brake
No.1 Piston
1 NO. 1 PISTON
2 TOOL
138) for beari ng and race l ocati on and correct posi -
ti oni ng.
(3) I nstal l new seal s onto the No.1 fi rst-reverse
brake pi ston. Lubri cate seal s wi th transmi ssi on fl ui d.
(4) I nstal l the No.1 fi rst-reverse brake pi ston i nto
(5) I nstal l new seal onto the fi rst-reverse brake
pi ston reacti on sl eeve. Lubri cate seal s wi th transmi s-
si on fl ui d.
(6) I nstal l the fi rst-reverse brake pi ston reacti on
sl eeve i nto the transmi ssi on case.
(7) I nstal l new seal onto the No.2 fi rst-reverse
brake pi ston. Lubri cate seal s wi th transmi ssi on fl ui d.
(8) I nstal l the No.2 fi rst-reverse brake pi ston i nto
(9) I nstal l the spri ng pl ate i nto the No.2 fi rst-re-
verse brake pi ston.
(10) I nstal l Spri ng Compressor 7539 onto the fi rst-
reverse brake pi ston.
(11) Compress the fi rst-reverse brake pi ston spri ng
and i nstal l the fi rst-reverse brake pi ston snap-ri ng.
(12) Remove Spri ng Compressor 7539.
(13) I nstal l rear pl anetary gear, second brake
drum and output shaft as outl i ned i n fol l owi ng steps:
(14) Veri fy No. 10 thrust beari ng and race (Fi g.
138). Beari ng and race outer di ameter i s 57.7 mm
(2.272 i n.) and i nsi de di ameter i s 39.2 mm (1.543 i n.).
(15) Coat thrust beari ng and race assembl y wi th
petrol eum jel l y and i nstal l i n case (Fi g. 139). Race
faces down. Beari ng rol l ers face up.
(16) Al i gn teeth of second brake drum and cl utch
pack (Fi g. 140).
Fig. 138 Thrust Bearing Chart
(17) Al i gn rear pl anetary-output shaft assembl y
teeth wi th case sl ots and i nstal l assembl y i n case
(Fi g. 141).
(18) I nstal l rear pl anetary snap ri ng wi th snap
ri ng pl i ers. Chamfered si de of snap ri ng faces up and
toward case front (Fi g. 142).
(19) Check fi rstreverse brake pack cl earance wi th
feel er gauge (Fi g. 143). Cl earance shoul d be 0.70
1.20 mm (0.028 0.047 i n.). I f cl earance i s i ncorrect,
pl anetary assembl y, thrust beari ng or snap ri ng i s
not properl y seated i n case. Remove and rei nstal l
components i f necessary.
(20) I nstal l second brake pi ston sl eeve (Fi g. 144).
Sl eeve l i p faces up and toward case front as shown.
(21) I nstal l second brake drum gasket.
Fig. 139 Installing Thrust Bearing And No. 10 Race
1 THRUST BEARING AND RACE
Fig. 140 Aligning Second Brake Drum And Clutch
Pack Teeth
1 SECOND BRAKE DRUM
2 CLUTCH PACK
3 ALIGN DRUM AND CLUTCH PACK TEETH
Fig. 141 Output Shaft/Rear Planetary Assembly
Installation
1 ALIGN CLUTCH/DRUM TEETH WITH CASE SLOTS
2 CASE SLOTS
Fig. 142 Planetary Snap Ring Installation
1 REAR PLANETARY SNAP RING
(22) I nstal l park l ock pawl , spri ng and pi n (Fi g.
145).
(23) I nstal l the manual val ve shi ft assembl y.
(24) Connect park l ock rod to manual val ve shi ft
sector (Fi g. 146).
Fig. 143 Checking FirstReverse Brake Pack
Clearance
1 FEELER GAUGE
Fig. 144 Second Brake Piston Sleeve Installation
1 PISTON SLEEVE
Fig. 145 Park Lock Pin, Spring And Pawl Installation
1 SPRING
2 PIN
3 PAWL
Fig. 146 Park Lock Rod Installation
1 SHIFT SECTOR
2 PARK LOCK ROD
(25) Posi ti on park l ock rod bracket on case and
ti ghten bracket attachi ng bol ts to 10 Nm (7 ft. l bs.)
torque (Fi g. 147).
(26) Veri fy park l ock operati on. Move shi ft sector
to Park posi ti on. Park pawl shoul d be fi rml y engaged
(l ocked) i n pl anetary ri ng gear (Fi g. 148).
(27) I nstal l No. 1 oneway cl utch (Fi g. 149). Short
fl anged si de of cl utch faces up and toward case front.
(28) I nstal l second brake pack (Fi g. 150). I nstal l
di sc then pl ate. Conti nue i nstal l ati on sequence unti l
fi ve di scs and fi ve pl ates are i nstal l ed.
(29) I nstal l second brake pack retai ner wi th
rounded edge of retai ner faci ng di sc.
(30) I nstal l second brake pack snap ri ng.
Fig. 147 Park Rod Bracket Installation
1 PARK ROD BRACKET
Fig. 148 Checking Park Pawl Engagement
2 PARK PAWL
Fig. 149 Installing No. 1 OneWay Clutch
1 NO. 1 ONE-WAY CLUTCH
Fig. 150 Second Brake Pack Installation
1 SECOND BRAKE PACK
(31) Check brake pack cl earance wi th feel er gauge
(Fi g. 151). Cl earance shoul d be 0.062 1.98 mm
(0.024 0.078 i n.). I f brake pack cl earance i s not cor-
rect, brake pack components are not seated. Reas-
sembl e brake pack i f necessary.
(32) I nstal l pl anetary sun gear and i nput drum
(Fi g. 152). Be sure drum thrust washer tabs are
seated i n drum. Use petrol eum jel l y to hol d thrust
washer i n posi ti on i f necessary.
(33) I nstal l front pl anetary gear on sun gear (Fi g.
153).
(34) Support output shaft wi th wood bl ocks (Fi g.
154).
Fig. 151 Checking Second Brake Pack Clearance
1 BRAKE PACK
2 FEELER GAUGE
Fig. 152 Installing Sun Gear And Input Drum
1 SUN GEAR AND INPUT DRUM
Fig. 153 Installing Front Planetary Gear
Fig. 154 Supporting Output Shaft
1 OUTPUT SHAFT
2 WOOD BLOCKS
(35) I nstal l pl anetary snap ri ng on sun gear wi th
snap ri ng pl i er tool 7541 (Fi g. 155).
(36) I nstal l tabbed thrust race on front pl anetary
gear. Washer tabs face down and toward gear. Race
outer di ameter i s 47.8 mm (1.882 i n.). I nsi de di ame-
ter i s 34.3 mm (1.350 i n.).
(37) I nstal l second coast brake band (Fi g. 156).
(38) I nstal l pi n i n second coast brake band. Then
i nstal l retai ni ng ri ng on pi n (Fi g. 157).
(39) I nstal l thrust beari ng and race i n forwarddi -
rect cl utch (Fi g. 158). Coat beari ng/race wi th petro-
l eum jel l y to hol d them i n pl ace.
(40) Veri fy forwarddi rect cl utch thrust beari ng
si ze.
Race outer di ameter i s 48.9 mm (1.925 i n.) and
i nsi de di ameter i s 26.0 mm (1.024 i n.).
Beari ng outer di ameter i s 46.7 mm (1.839 i n.)
and i nsi de di ameter i s 26.0 mm (1.024 i n.).
(41) Coat front pl anetary ri ng gear race wi th
petrol eum jel l y and i nstal l i t i n ri ng gear (Fi g. 159).
Fig. 155 Installing Front Planetary Snap Ring
1 SNAP RING PLIER TOOL
2 FRONT PLANETARY
3 SNAP RING
Fig. 156 Installing Second Coast Brake Band
Fig. 157 Installing Second Coast Brake Band
Retaining Pin
2 BAND RETAINING PIN
3 RETAINING RING (INSTALL ON PIN)
(42) Veri fy ri ng gear race si ze. Outer di ameter i s
47.0 mm (1.850 i n.) and i nsi de di ameter i s 26.5 mm
(1.045 i n.).
(43) Al i gn forwarddi rect cl utch di sc spl i nes wi th
screwdri ver (Fi g. 160).
(44) Al i gn and i nstal l front pl anetary ri ng gear i n
forwarddi rect cl utch (Fi g. 161).
(45) Coat beari ng and race wi th petrol eum jel l y
and i nstal l them i n ri ng gear (Fi g. 162). Veri fy bear-
i ng/race si ze.
Race outer di ameter i s 53.6 mm (2.110 i n.) and
i nsi de di ameter i s 30.6 mm (1.205 i n.).
(46) I nstal l assembl ed pl anetary gear/forwarddi -
rect cl utch (Fi g. 163).
(47) Check cl earance between sun gear i nput drum
and di rect cl utch drum (Fi g. 164). Cl earance shoul d
be 9.8 11.8 mm (0.386 0.465 i n.). I f cl earance i s
i ncorrect, pl anetary gear/forwarddi rect cl utch
assembl y i s not seated or i s i mproperl y assembl ed.
Remove, and correct i f necessary.
Fig. 158 Installing ForwardDirect Clutch Thrust
Bearing And Race
1 THRUST BEARING
2 RACE
3 FORWARD-DIRECT CLUTCH ASSEMBLY
Fig. 159 Installing Planetary Ring Gear Race
1 PLANETARY RING GEAR
2 THRUST RACE
Fig. 160 Aligning ForwardDirect Clutch Splines
1 CLUTCH SPLINE ALIGNING TOOL
2 FORWARD-DIRECT CLUTCH
Fig. 161 Installing Front Planetary Ring Gear
1 RING GEAR
2 FORWARD-DIRECT CLUTCH
petrol eum jel l y and i nstal l i t on cl utch shaft. Beari ng
faces up and toward case front as shown. Veri fy bear-
i ng/race si ze. Beari ng and race outer di ameter i s 47.8
mm (1.882 i n.) and i nsi de di ameter i s 33.6 mm (1.301
i n.).
(49) Assembl e second coast brake pi ston compo-
nents (Fi g. 165).
(50) I nstal l assembl ed second coast brake pi ston i n
case. Veri fy that the pi ston rod contacts the second
coast brake band.
(51) I nstal l repl acement seal s on second coast
brake pi ston cover and i nstal l cover i n case.
(52) I nstal l second coast brake pi ston snap ri ng
wi th snap ri ng pl i er tool (Fi g. 166).
(53) Check second coast brake pi ston stroke as fol -
l ows:
Fig. 162 Installing Ring Gear Bearing And Race
1 THRUST BEARING
2 RACE
Fig. 163 Installing Front Planetary And
ForwardDirect Clutch Assembly
1 FRONT PLANETARY AND FOWARD-DIRECT CLUTCH
ASSEMBLY
Fig. 164 Checking Input DrumToDirect Clutch
Drum Clearance
Fig. 165 Assembling Second Coast Brake Piston
1 E-CLIP
2 PISTON
3 O-RING
4 PISTON SPRING
6 PISTON ROD
(a) I nstal l a smal l wi re ti e strap around the sec-
ond coast brake pi ston rod ti ght agai nst the trans-
mi ssi on case.
(b) Appl y 57114 psi ai r pressure through pi ston
feed hol e and check stroke l ength wi th Gauge Tool
7552.
(c) Stroke l ength shoul d be 1.5 3.0 mm (0.059
0.118 i n.).
(d) I f stroke l ength i s i ncorrect, pi ston, cover or
snap ri ng i s not seated. Reassembl e and check
stroke agai n i f necessary.
(54) Coat thrust race and tabbed washer wi th
petrol eum jel l y and i nstal l them on overdri ve support
(Fi g. 169). Veri fy race si ze. Race outer di ameter i s
50.9 mm (2.004 i n.) and i nsi de di ameter i s 36.2 mm
(1.426 i n.).
(55) I nstal l overdri ve support i n case. Use two l ong
bol ts to hel p al i gn and gui de support i nto posi ti on
(Fi g. 170).
(56) I nstal l overdri ve support snap ri ng wi th Snap
Ri ng Pl i er Tool 7540 (Fi g. 171). Chamfered si de of
snap ri ng faces up and toward case front. Snap ring
ends must be aligned with case opening with
ring ends approximately 24 mm (0.94 in.) from
center line of case opening.
(57) I nstal l and ti ghten overdri ve support bol ts to
25 Nm (19 ft. l bs.) torque (Fi g. 172).
Fig. 167 Marking Brake Piston Rod
1 BRAKE PISTON ROD
2 REFERENCE MARK
3 PISTON FEED HOLE
Fig. 166 Installing Second Coast Brake Piston Snap
Ring
1 PISTON SNAP RING
2 SNAP RING TOOL
Fig. 168 Checking Second Coast Brake Piston
Stroke
1 PISTON ROD REFERENCE MARK
2 GAUGE TOOL
3 AIR GUN
4 GAUGE TOOL
Fig. 169 Installing Overdrive Support Thrust Race
And Washer
1 THRUST RACE
2 TABBED THRUST WASHER
3 OVERDRIVE SUPPORT
Fig. 170 Installing Overdrive Support
1 USE LONG BOLTS TO INSTALL SUPPORT
2 OVERDRIVE SUPPORT
Fig. 171 Installing Overdrive Support Snap Ring
1 SNAP RING TOOL
2 SNAP RING ENDS CENTERED IN CASE OPENING
3 SNAP RING
Fig. 172 Installing Overdrive Support Bolts
1 OVERDRIVE SUPPORT BOLTS
(58) Check output shaft end pl ay wi th di al i ndi ca-
tor (Fi g. 173). End pl ay shoul d be 0.27 0.86 mm
(0.0106 0.0339 i n.).
(59) I f output shaft end pl ay i s i ncorrect, one or
more of i nstal l ed components i s not seated. Reassem-
bl e as necessary and check end pl ay agai n.
(60) I nstal l overdri ve brake cl utch pack (Fi g. 174).
I nstal l thi ckest cl utch pl ate fi rst. Rounded edge of
pl ate faces up. I nstal l fi rst di sc fol l owed by another
pl ate unti l four di scs and three pl ates are i nstal l ed.
(61) I nstal l stepped ri ng retai ner pl ate wi th fl at
si de faci ng di sc. Then i nstal l brake pack snap ri ng
(Fi g. 175).
(62) Check overdri ve brake pi ston stroke as fol -
l ows:
(a) Mount di al i ndi cator on case usi ng Mi l l er
Tool C-3339 and a sui tabl e bol t threaded i nto the
(b) Veri fy that the di al i ndi cator i s mounted sol -
i dl y and square to the di recti on of the pi ston
travel .
(c) Appl y 57114 psi ai r pressure through pi ston
appl y port and note pi ston stroke on di al i ndi cator.
Stroke l ength shoul d be: 1.40 1.70 mm (0.055
0.0699 i n.).
(d) I f stroke i s i ncorrect, brake pack or pi ston i s
i nstal l ed i ncorrectl y. Check and correct as neces-
sary and measure pi ston stroke agai n.
(e) Remove the di al i ndi cator set-up from the
transmi ssi on.
(63) Coat overdri ve l ower race, thrust beari ng and
upper race wi th petrol eum jel l y and i nstal l them i n
overdri ve support (Fi g. 176). Be sure races and bear-
i ng are assembl ed and i nstal l ed as shown.
(64) Veri fy beari ng/race si zes before proceedi ng.
Beari ng race si zes are:
Outer di ameter of l ower race i s 47.8 mm (1.882
i n.) and i nsi de di ameter i s 34.3 mm (1.350 i n.).
Outer di ameter of beari ng i s 47.7 mm (1.878 i n.)
Outer di ameter of upper race i s 47.8 mm (1.882
i n.) and i nsi de di ameter i s 30.7 mm (1.209 i n.).
(65) I nstal l overdri ve pl anetary ri ng gear i n sup-
port (Fi g. 177).
(66) Coat ri ng gear thrust race and thrust beari ng
assembl y wi th petrol eum jel l y and i nstal l them i n
gear (Fi g. 178).
(67) Veri fy beari ng/race si ze before proceedi ng.
Outer di ameter of ri ng gear racebeari ng i s 47.8
i n.).
Fig. 173 Checking Output Shaft End Play
1 DIAL INDICATOR
2 OUTPUT SHAFT
Fig. 174 Installing Overdrive Brake Clutch Pack
Fig. 175 Installing Overdrive Brake Snap Ring
(68) Coat tabbed thrust race wi th petrol eum jel l y
and i nstal l i t on pl anetary gear (Fi g. 179). Race outer
di ameter i s 41.8 mm (1.646 i n.) and i nsi de di ameter
i s 27.1 mm (1.067 i n.).
(69) I nstal l assembl ed overdri ve pl anetary gear
and cl utch (Fi g. 180).
petrol eum jel l y and i nstal l i t on cl utch i nput shaft
(Fi g. 181). Beari ng and race outer di ameter i s 50.2
i n.).
(71) Coat thrust beari ng race wi th petrol eum jel l y
and i nstal l i t i n oi l pump (Fi g. 182). Beari ng race
outer di ameter i s 47.2 mm (1.858 i n.) and i nsi de
di ameter i s 28.1 mm (1.106 i n.).
Fig. 176 Installing Overdrive Support Thrust Bearing
And Races
1 THRUST BEARING
2 UPPER RACE
3 LOWER RACE
Fig. 177 Installing Overdrive Planetary Ring Gear
Fig. 178 Installing Ring Gear Thrust Bearing And
Race
1 THRUST BEARING-RACE ASSEMBLY
2 THRUST RACE (TABBED)
Fig. 179 Installing Planetary Thrust Race
1 THRUST RACE (TABBED)
2 OVERDRIVE PLANETARY
(72) Lubri cate and i nstal l repl acement Ori ng on
oi l pump body.
(73) I nstal l oi l pump i n case. Al i gn pump and case
bol t hol es and careful l y ease pump i nto pl ace.
CAUTION: Do not use force to seat the pump. The
seal rings on the stator shaft could be damaged if
they bind or stick to the direct clutch drum.
(74) Ti ghten oi l pump bol ts to 22 Nm (16 ft. l bs.)
torque.
(75) Veri fy i nput shaft rotati on. Shaft shoul d
rotate smoothl y and not bi nd.
(76) Lubri cate and i nstal l new Ori ng on trans-
mi ssi on throttl e cabl e adapter and i nstal l cabl e i n
case (Fi g. 183).
Fig. 180 Installing Overdrive Planetary And Clutch
Assembly
1 OVERDRIVE PLANETARY AND CLUTCH ASSEMBLY
2 RING GEAR
Fig. 181 Installing Input Shaft Thrust Bearing And
Race Assembly
1 THRUST BEARING AND RACE ASSEMBLY
2 CLUTCH INPUT SHAFT
Fig. 182 Installing Oil Pump Thrust Race
1 OIL PUMP
2 PUMP THRUST RACE
Fig. 183 Installing Transmission Throttle Cable
1 THROTTLE CABLE
2 THROTTLE CAM
(77) Check cl utch and brake operati on. Operate
cl utches and brakes wi th compressed ai r appl i ed
through feed hol es i n case (Fi g. 184). Li sten for
cl utch and brake appl i cati on. I f you do not hear a
cl utch or brake appl y, di sassembl e transmi ssi on and
repai r faul t before proceedi ng. It is necessary to
block the overdrive clutch accumulator feed
hole No. 8 (Fig. 184) in order to check direct
clutch operation.
(78) Lubri cate and i nstal l new Ori ngs on accumu-
l ator pi stons (Fi g. 185).
(79) Assembl e and i nstal l accumul ator pi stons and
spri ngs (Fi g. 185).
(80) I nstal l new check bal l body and spri ng (Fi g.
186).
(81) Posi ti on val ve body on case (Fi g. 187).
(82) I nstal l detent spri ng (Fi g. 187).
(83) Al i gn manual val ve, detent spri ng and shi ft
sector (Fi g. 187).
(84) Connect transmi ssi on throttl e cabl e to throttl e
val ve cam (Fi g. 188).
(85) I nstal l and ti ghten val ve bodytocase bol ts to
(86) Connect val ve body sol enoi d wi res to sol enoi ds
(Fi g. 189).
(87) I nstal l new Ori ng on sol enoi d harness
adapter and secure adapter to case.
(88) I nstal l val ve body oi l tubes (Fi g. 190). Tap
tubes i nto pl ace wi th a pl asti c mal l et. Be sure the
Fig. 184 Clutch And Brake Feed Hole Locations
Fig. 185 Accumulator Piston And Spring Installation
Fig. 186 Installing Check Ball Body And Spring
1 CHECK BALL BODY AND SPRING
fl anged tube ends and strai ght tube ends are
i nstal l ed as shown.
screen on val ve body. Ti ghten screen bol ts to 10 Nm
(90) I nstal l magnet i n oi l pan. Be sure magnet
does not i nterfere wi th val ve body oi l tubes.
(91) Appl y Threebond Li qui d Gasket TB1281,
P/N 83504038, to seal i ng surface of oi l pan. Seal er
bead shoul d be at l east 3 mm (1/8 i n.) wi de. I nstal l
pan on case and ti ghten pan bol ts to 7 Nm (65 i n.
l bs.) torque.
(92) I nstal l transmi ssi on speed sensor rotor and
key on output shaft (Fi g. 191).
(93) I nstal l spacer and speedometer dri ve gear on
output shaft. Then i nstal l retai ni ng snap ri ng (Fi g.
192).
(94) Appl y bead of Threebond Li qui d Gasket
TB1281, P/N 83504038, to seal i ng surface at rear of
case (Fi g. 193).
Fig. 187 Aligning Manual Valve, Shift Sector And
Detent Spring
1 DETENT SPRING
2 SHIFT SECTOR
3 VALVE BODY
4 MANUAL VALVE
Fig. 188 Connecting Transmission Throttle Cable
1 THROTTLE CABLE
2 THROTTLE CAM
Fig. 189 Connecting Valve Body Solenoid Wires
Fig. 190 Installing Valve Body Oil Tubes
(95) I nstal l adapter housi ng on transmi ssi on.
Ti ghten adapter bol ts to 34 Nm (25 ft. l bs.) torque.
(96) I nstal l transmi ssi on speed sensor (Fi g. 194).
Ti ghten sensor bol t to 7.4 Nm (65 i n. l bs.) torque
and connect sensor wi re harness connector.
(97) I nstal l converter housi ng (Fi g. 195). Ti ghten
12 mm di ameter housi ng bol ts to 57 Nm (42 ft. l bs.)
torque. Ti ghten 10 mm di ameter housi ng bol ts to 34
(98) I nstal l transmi ssi on shi ft l ever on manual
val ve shaft. Do not i nstal l l ever attachi ng nut at thi s
ti me.
(99) Move transmi ssi on shi ft l ever ful l y rearward.
Then move l ever two detent posi ti ons forward.
(100) Mount park/neutral posi ti on swi tch on man-
ual val ve shaft and ti ghten swi tch adjusti ng bol t just
enough to keep swi tch from movi ng (Fi g. 196).
(101) I nstal l park/neutral posi ti on swi tch tabbed
washer and retai ni ng nut (Fi g. 196). Ti ghten nut to
Fig. 191 Installing Transmission Speed Sensor
Rotor And Key
1 SPEED SENSOR ROTOR
2 ROTOR KEY
Fig. 192 Installing Spacer And Speedometer Drive
Gear
1 SPEEDOMETER DRIVE GEAR
2 SNAP RING
3 SPACER
Fig. 193 Applying Sealer To Case Rear Flange
1 SEALER BEAD
2 CASE REAR FLANGE
Fig. 194 Installing Transmission Speed Sensor
1 SENSOR BOLT
2 SPEED SENSOR
6.9 Nm (61 i n. l bs.) torque, but do not bend any of
the washer tabs agai nst the nut at thi s ti me.
(102) Al i gn park/neutral posi ti on swi tch standard
l i ne wi th groove or fl at on manual shaft (Fi g. 196).
(103) Ti ghten park/neutral posi ti on swi tch adjust-
i ng bol t to 13 Nm (9 ft. l bs.) torque.
(104) I nstal l transmi ssi on shi ft l ever on manual
val ve shaft. Ti ghten l ever attachi ng nut to 16 Nm
(105) I nstal l retai ni ng cl amp for wi re harness and
throttl e cabl e (Fi g. 197).
(106) I nstal l torque converter.
(107) Veri fy that converter i s seated by measuri ng
di stance between converter housi ng fl ange and one of
the converter mounti ng pads (Fi g. 198). Use strai ght-
edge and verni er cal i pers to measure di stance. On
6cyl . transmi ssi ons, di stance shoul d be 16.5 mm
(0.650 i n.).
(108) Secure converter i n transmi ssi on wi th
Ccl amp or metal strappi ng. Do thi s before mounti ng
transmi ssi on on jack or movi ng transmi ssi on under
vehi cl e.
(109) I nstal l l ower hal f of transmi ssi on fi l l tube
(i nstal l upper hal f after transmi ssi on i s i n vehi cl e).
CAUTION: The transmission cooler and lines must
be reverse flushed if overhaul corrected a malfunc-
tion that generated sludge, metal particles, or
clutch friction material. The torque converter should
also be replaced if contaminated by the same mal-
function. Debris and residue not flushed from the
cooler and lines will flow back into the transmission
and converter. The result will be a repeat failure and
shop comeback.
Fig. 195 Installing Converter Housing
1 CONVERTER HOUSING
2 HOUSING BOLTS
Fig. 196 Park/Neutral Position Switch Installation/
Adjustment
1 NEUTRAL STANDARD LINE
2 ADJUSTING BOLT
3 VERTICAL GROOVE ON MANUAL VALVE SHAFT
Fig. 197 Installing Cable/Harness Clamps
1 TRANSMISSION HARNESS
2 THROTTLE CABLE
3 RETAINING CLAMPS
OIL PUMP
DISASSEMBLY
(1) Remove pump body Ori ng (Fi g. 199).
(2) Remove pump seal .
(3) Remove pump seal ri ngs (Fi g. 199).
(4) Remove bol ts attachi ng stator shaft to pump
body and separate components.
(5) Remove dri ve gear and dri ven gear from pump
body (Fi g. 199).
Fig. 199 Oil Pump Components
1 PUMP SEAL
2 PUMP BODY
3 STATOR SHAFT
4 SEAL RINGS
5 GEAR
6 O-RING
Fig. 198 Checking Converter Installation
1 HOUSING FLANGE
2 CONVERTER MOUNTING PAD
3 STRAIGHTEDGE
4 VERNIER CALIPERS
ASSEMBLY
(1) Measure i nsi de di ameter of pump body bushi ng
wi th bore gauge or i nsi de mi crometer (Fi g. 200).
Di ameter shoul d be maxi mum of 38.19 mm (1.5035
i n.). Repl ace pump body i f bushi ng I . D. i s greater
than speci fi ed.
(2) Measure i nsi de di ameter of stator shaft bush-
i ng (Fi g. 200). Take measurements at front and rear
of bushi ng. Di ameter shoul d be maxi mum of 21.58
mm (0.08496 i n.) at front and 27.08 mm (1.0661 i n.)
at rear. Repl ace stator shaft i f bushi ng di ameter i s
greater than speci fi ed.
(3) Measure oi l pump cl earances (Fi g. 201).
Cl earance between pump dri ven gear and pump
body shoul d be maxi mum of 0.3 mm (0.012 i n).
Cl earance between ti ps of pump gear teeth
shoul d be maxi mum of 0.3 mm (0.012 i n).
Cl earance between rear surface of pump housi ng
and pump gears shoul d be maxi mum of 0.1 mm
(0.004 i n.).
(4) Repl ace pump body and gears i f any cl earance
i s greater than speci fi ed.
Fig. 200 Checking Pump/Stator Shaft Bushings
1 BORE GAUGE
2 PUMP BODY BUSHING
3 BORE GAUGE
4 STATOR SHAFT BUSHING
Fig. 201 Checking Pump Gear Clearances
(5) I nstal l new seal wi th Seal I nstal l er 7549 (Fi g.
202).
(6) Lubri cate and i nstal l gears i n pump body.
(7) Assembl e stator shaft and pump body. Ti ghten
shafttobody bol ts to 10 Nm (7 ft. l bs.) torque.
(8) I nstal l new Ori ng on pump body and new seal
ri ngs on stator shaft.
(9) I nstal l pump i n torque converter and check
pump gear rotati on (Fi g. 203). Gears must rotate
smoothl y when turned cl ockwi se and countercl ock-
wi se.
(10) Lubri cate pump Ori ng and seal ri ngs wi th
petrol eum jel l y.
Fig. 202 Installing Pump Seal
1 SEAL INSTALLER TOOL
2 PUMP SEAL
Fig. 203 Checking Pump Gear Rotation
1 OIL PUMP
2 TORQUE CONVERTER
OVERDRIVE PLANETARY GEAR AND CLUTCH
DISASSEMBLY
(1) Check operati on of oneway cl utch i n cl utch
drum (Fi g. 204). Hol d drum and turn pl anetary shaft
cl ockwi se and countercl ockwi se. Shaft shoul d turn
Overdrive Planetary Gear And Clutch Components
1 CLUTCH DRUM
2 CLUTCH PISTON
3 PISTON RETURN SPRING
4 CLUTCH DISCS
5 RETAINER PLATE
7 CLUTCH PLATES
8 PISTON SNAP RING
9 O-RINGS
10 ONE-WAY CLUTCH
11 CLUTCH DRUM BEARING AND RACE ASSEMBLY
12 PLANETARY GEAR
13 SNAP RING
14 RING GEAR HUB
15 THRUST WASHER
16 BEARING
17 ONE-WAY CLUTCH OUTER RACE
18 RETAINING PLATE
19 SNAP RING
21 RACE
cl ockwi se freel y but l ock when turned countercl ock-
wi se. Repl ace oneway cl utch i f necessary.
(2) Remove overdri ve cl utch from pl anetary gear
(Fi g. 205).
(3) Measure stroke l ength of overdri ve cl utch pi s-
ton as fol l ows:
(a) Mount oi l pump on torque converter. Then
mount cl utch on oi l pump (Fi g. 206).
(b) I nstal l a sui tabl e threaded bol t/rod i nto oi l
pump for use i n mounti ng Mi l l er Tool C-3339 di al
i ndi cator components securel y.
(c) Mount di al i ndi cator on the bol t/rod and posi -
ti on the di al i ndi cator squarel y on the cl utch pi s-
ton.
(d) Appl y compressed ai r through cl utch feed
hol e i n oi l pump and note pi ston stroke l ength.
Stroke l ength shoul d be 1.85 2.15 mm (0.0728
0.0846 i n.).
(4) Remove thrust beari ng and race assembl y from
cl utch drum (Fi g. 207).
(5) Remove cl utch pack snap ri ng and remove the
cl utch pack (Fi g. 208).
(6) Measure overdri ve cl utch di sc thi ckness. Mi ni -
mum al l owabl e thi ckness i s 1.84 mm (0.0724 i n.).
(7) I f the cl utch pack stroke l ength i s out of speci -
fi cati on or any cl utch di sc fai l s to meet the mi ni mum
thi ckness, new di scs wi l l need to be i nstal l ed duri ng
assembl y.
(8) Compress pi ston return spri ng wi th Tool 7538
(Fi g. 209). Remove snap ri ng and remove compressor
tool .
(9) Remove the pi ston return spri ngs.
(10) Mount oi l pump on converter. Then mount
cl utch on oi l pump (Fi g. 210).
(11) Hol d cl utch pi ston by hand and appl y com-
pressed ai r through oi l pump feed hol e to ease pi ston
Fig. 204 Checking OneWay Clutch
1 CLUTCH DRUM
2 PLANETARY SHAFT
Fig. 205 Removing Overdrive Clutch From Gear
1 OVERDRIVE CLUTCH
2 PLANETARY GEAR
Fig. 206 Assembling Converter, Pump And Clutch
For Test
1 OVERDRIVE CLUTCH
2 OIL PUMP
3 TORQUE CONVERTER
out (Fi g. 210). Appl y onl y enough ai r pressure to
remove pi ston.
(12) Measure free l ength of pi ston return spri ngs
wi th spri ngs i n retai ner (Fi g. 211). Length shoul d be
16.8 mm (0.661 i n.). Repl ace spri ng and retai ner
assembl y i f necessary.
(13) Check cl utch pi ston check bal l (Fi g. 212).
Shake pi ston to see i f bal l moves freel y. Then check
bal l seal i ng by appl yi ng l ow pressure compressed ai r
to bal l i nl et as shown. Ai r shoul d not l eak past check
bal l .
Fig. 207 Removing Clutch Drum Bearing And Race
1 CLUTCH DRUM
Fig. 208 Removing Clutch Pack Snap Ring
1 SNAP RING
2 CLUTCH RETAINER
Fig. 209 Removing Clutch Piston Snap Ring
1 COMPRESSOR TOOL
2 CLUTCH PISTON SNAP RING
Fig. 210 Removing Overdrive Clutch Piston
1 CLUTCH RETAINER
2 CLUTCH PISTON
3 OIL PUMP
4 CONVERTER
(14) Check i nsi de di ameter of cl utch drum bush-
i ngs wi th bore gauge or i nsi de mi crometer (Fi g. 213).
Maxi mum i nsi de di ameter i s 27.11 mm (1.0673 i n.).
Repl ace drum i f bushi ng i nsi de di ameter i s greater
than speci fi ed.
(15) Remove beari ng and race from ri ng gear (Fi g.
214).
Fig. 211 Checking Piston Return Spring Length
1 PISTON RETURN SPRINGS
2 SPRING RETAINER
Fig. 212 Testing Clutch Piston Check Ball
1 CLUTCH PISTON CHECK BALL
2 USE LOW-PRESSURE COMPRESSED AIR TO TEST BALL
SEATING
Fig. 213 Checking Clutch Drum Bushings
1 CLUTCH DRUM
Fig. 214 Removing Ring Gear Bearing And Race
1 BEARING
2 RACE
3 RING GEAR
(16) Remove snap ri ng from ri ng gear and remove
ri ng gear hub (Fi g. 215).
(17) Remove race from pl anetary gear (Fi g. 216).
(18) Remove snap ri ng and remove retai ni ng pl ate
(Fi g. 217).
Fig. 215 Removing Ring Gear Hub
1 SNAP RING
2 RING GEAR
3 RING GEAR HUB
Fig. 216 Remove Planetary Gear Race
1 PLANETARY GEAR
2 RACE
Fig. 217 Removing Snap Ring And Retaining Plate
1 SNAP RING
2 PLANETARY GEAR
3 RETAINING PLATE
(19) Remove oneway cl utch and outer race as
assembl y. Then separate race from cl utch (Fi g. 218).
(20) Remove thrust washer (Fi g. 219).
(21) Check i nsi de di ameter of pl anetary gear bush-
i ng (Fi g. 220). Maxi mum i nsi de di ameter i s 11.27
mm (0.4437 i n.). Repl ace pl anetary gear i f bushi ng
i nsi de di ameter i s greater then speci fi ed.
Fig. 218 Removing OneWay Clutch
1 ONE-WAY CLUTCH AND OUTER RACE ASSEMBLY
2 PLANETARY GEAR
3 RACE
4 CLUTCH
Fig. 219 Removing Planetary Thrust Washer
1 THRUST WASHER
2 PLANETARY GEAR
Fig. 220 Checking Planetary Bushing
1 PLANETARY BUSHING
2 PLANETARY GEAR
ASSEMBLY
(1) I nstal l thrust washer i n pl anetary gear (Fi g.
221). Grooved side of washer faces up and
toward front.
(2) I nstal l cl utch race i nto pl anetary gear.
(3) I nstal l oneway cl utch i nto the outer race (Fi g.
222). Be sure fl anged si de of cl utch i s faci ng upward.
(4) I nstal l cl utch retai ni ng pl ate and snap ri ng i n
pl anetary gear.
(5) Coat pl anetary race wi th petrol eum jel l y and
i nstal l i t on pl anetary gear. Outsi de di ameter of race
shoul d be 41.8 mm (1.646 i n.); i nsi de di ameter i s 27.1
mm (1.067 i n.).
(6) I nstal l hub i n pl anetary ri ng gear and i nstal l
snap ri ng.
(7) Coat race and beari ng wi th petrol eum jel l y and
i nstal l i n pl anetary ri ng gear (Fi g. 223).
(8) Veri fy beari ng/race si ze. Outsi de di ameter of
race i s 47.8 mm (1.882 i n.) and i nsi de di ameter i s
24.2 mm (0.953 i n.). Outsi de di ameter of beari ng i s
46.8 mm (1.843 i n.) and i nsi de di ameter i s 26 mm
(1.024 i n.).
(9) Lubri cate new cl utch pi ston Ori ngs wi th
Mopar Door Ease, or RuGl yde. Then i nstal l ri ngs
on cl utch pi ston and i nstal l pi ston i n cl utch drum.
(10) I nstal l pi ston return spri ngs i n cl utch pi ston
(Fi g. 224).
(11) I nstal l pi ston snap ri ng. Compress pi ston return
spri ngs wi th Tool 7538 and shop press (Fi g. 225).
(12) I nstal l overdri ve cl utch pack i n drum. I nstal l
steel pl ate fi rst, then a di sc (Fi g. 226). Conti nue
Fig. 222 Assembling OneWay Clutch And Race
1 FLANGED SIDE OF CLUTCH FACES UP
2 ONE-WAY CLUTCH
3 CLUTCH RACE
Fig. 223 Install Ring Gear Bearing And Race
1 BEARING
2 RACE
3 RING GEAR
Fig. 221 Install Planetary Thrust Washer
1 THRUST WASHER
2 PLANETARY GEAR
i nstal l ati on sequence unti l requi red number of di scs
and pl ates have been i nstal l ed.
(13) I nstal l cl utch pack retai ner wi th fl at si de fac-
i ng downward. Then i nstal l retai ner snap ri ng (Fi g.
227). Compress spri ngs wi th sui tabl e tool .
Fig. 225 Installing Clutch Piston Snap Ring
1 PRESS RAM
2 COMPRESSOR TOOL
3 SNAP RING
Fig. 224 Installing Piston Return Springs
1 RETURN SPRINGS
2 CLUTCH PISTON
Fig. 226 Installing Overdrive Clutch Discs And Plates
1 CLUTCH DISC
2 STEEL PLATE
3 CLUTCH DRUM
Fig. 227 Installing Retainer And Snap Ring
1 CLUTCH PACK RETAINER
2 RETAINER SNAP RING
(14) I nstal l cl utch drum beari ng and race assembl y
(Fi g. 228). Be sure beari ng rol l ers face upward as
shown. Outsi de di ameter of assembl ed beari ng and
race i s 50.2 mm (1.976 i n.). I nsi de di ameter i s 28.9
mm (1.138 i n.).
(15) I nstal l cl utch on pl anetary gear.
(16) Veri fy oneway cl utch operati on. Hol d drum
and turn pl anetary shaft cl ockwi se and countercl ock-
wi se. Shaft shoul d turn cl ockwi se freel y but l ock
when turned countercl ockwi se.
OVERDRIVE SUPPORT
DISASSEMBLY
(1) Check brake pi ston operati on. Mount support
on cl utch (Fi g. 229).
(2) Appl y compressed ai r through support feed
hol e and observe brake pi ston movement (Fi g. 229).
Pi ston shoul d move smoothl y and not bi nd or sti ck. I f
operati on i s i ncorrect, repl ace pi ston and support.
(3) Remove thrust beari ng front race, thrust bear-
i ng and rear race (Fi g. 230).
(4) Turn overdri ve support over and remove bear-
i ng race and cl utch drum thrust washer (Fi g. 231).
(5) Compress pi ston return spri ng wi th Spri ng
Compressor 7537 and remove pi ston snap ri ng (Fi g.
232).
Fig. 228 Installing Clutch Drum Bearing And Race
Assembly
1 BEARING AND RACE ASSEMBLY
2 CLUTCH DRUM
3 RACE
4 ROLLERS
Fig. 229 Checking Brake Piston Movement
1 BRAKE PISTON
2 OVERDRIVE SUPPORT
3 SUPPORT FEED HOLE
4 CLUTCH
Fig. 230 Removing Support Thrust Bearing And
Races
1 THRUST BEARING
2 FRONT RACE
3 REAR RACE
(6) Mount support i n di rect cl utch and remove
brake pi ston wi th compressed ai r. Appl y ai r to same
feed hol e used when checki ng pi ston operati on.
(7) Remove and di scard support Ori ngs (Fi g. 233).
(8) Remove support seal ri ngs (Fi g. 234).
wi th spri ngs mounted i n retai ner (Fi g. 235). Length
shoul d be 17.23 mm (0.678 i n.).
(10) Cl ean support components and dry them wi th
compressed ai r.
(11) I nspect overdri ve support and brake pi ston.
Repl ace support and pi ston i f ei ther part i s worn or
damaged.
ASSEMBLY
(1) Lubri cate new support seal ri ngs. Then com-
press ri ngs and i nstal l them on support (Fi g. 236).
(2) Lubri cate and i nstal l new Ori ngs on brake
pi ston. Then careful l y seat pi ston i n support.
(3) I nstal l return spri ngs on brake pi ston.
(4) Compress return spri ngs wi th Spri ng Compres-
sor 7537 (Fi g. 232) and i nstal l pi ston snap ri ng.
(5) I nstal l support beari ng race and cl utch drum
thrust washer (Fi g. 231).
(6) I nstal l thrust beari ng and front and rear bear-
i ng races. Thrust beari ng rol l ers shoul d face upward
as shown (Fi g. 236).
(7) Veri fy thrust beari ng/race si zes (Fi g. 237).
Front race outer di ameter i s 47.8 mm (1.882 i n.)
Rear race outer di ameter i s 47.8 mm (1.882 i n.)
(8) Veri fy brake pi ston operati on. Use same proce-
dure descri bed at begi nni ng of di sassembl y. Pi ston
shoul d operate smoothl y and not bi nd or sti ck.
Fig. 231 Removing Clutch Drum Thrust Washer And
Race
1 BEARING RACE
2 OVERDRIVE SUPPORT
3 THRUST WASHER
Fig. 232 Removing/Installing Piston Snap Ring
1 COMPRESSOR TOOL
2 SNAP RING
Fig. 233 Overdrive Support Components
1 PISTON SNAP RING
2 BRAKE PISTON
3 FRONT RACE
4 REAR RACE
5 OVERDRIVE SUPPORT
6 THRUST BEARING
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
2 SPRING RETAINER
DIRECT CLUTCH
DISASSEMBLY
(1) Remove di rect cl utch from forward cl utch (Fi g.
238).
(2) Remove cl utch drum thrust washer (Fi g. 239).
Fig. 236 Installing Support Seal Rings
1 COMPRESS SEAL RINGS BEFORE INSTALLATION
2 OVERDRIVE SUPPORT
Fig. 237 Installing Support Thrust Bearing And
Races
1 REAR RACE
2 THRUST BEARING
3 FRONT RACE
Fig. 238 Separate Direct Clutch From Forward
Clutch
1 DIRECT CLUTCH
2 FORWARD CLUTCH
Fig. 239 Removing Clutch Drum Thrust Washer
1 THRUST WASHER
2 CLUTCH DRUM
(3) Check cl utch pi ston stroke l ength as outl i ned
i n fol l owi ng steps.
(4) Mount di rect cl utch on overdri ve support
assembl y (Fi g. 240).
(5) Mount di al i ndi cator on cl utch and posi ti on
i ndi cator pl unger on cl utch pi ston (Fi g. 241).
(6) Appl y 57114 psi ai r pressure through feed
hol e i n overdri ve support and note pi ston stroke
l ength (Fi g. 241). Check stroke at l east twi ce.
(7) Pi ston stroke l ength shoul d be 1.37 mm 1.67
mm (0.054 0.065 i n.). I f stroke l ength i s i ncorrect,
ei ther the cl utch pack retai ner or cl utch di scs wi l l
have to be repl aced.
(8) Remove cl utch pack snap ri ng and remove
retai ner and cl utch pack from drum (Fi g. 242).
(9) Compress cl utch pi ston return spri ngs wi th tool
7538 and remove cl utch pi ston snap ri ng (Fi g. 243).
(10) Remove compressor tool and return spri ng.
(11) Remove cl utch pi ston. Remount cl utch on
overdri ve support (Fi g. 244). Appl y compressed ai r
through pi ston feed hol e i n support to remove pi ston.
Use onl y enough ai r to ease pi ston out.
(12) Remove and di scard cl utch pi ston Ori ngs.
(13) Measure cl utch di sc thi ckness. Mi ni mum
al l owabl e thi ckness i s 1.84 mm (0.0724 i n). Repl ace
cl utch pack i f any di sc i s bel ow mi ni mum thi ckness.
wi th spri ngs i n retai ner (Fi g. 245). Length shoul d be
21.32 mm (0.839 i n.). Repl ace return spri ngs i f not
wi thi n speci fi cati on.
(15) Check cl utch pi ston check bal l (Fi g. 246).
Shake pi ston to see i f bal l moves freel y. Then check
bal l seati ng by appl yi ng l ow pressure compressed ai r
Fig. 240 Mount Direct Clutch On Overdrive Support
1 DIRECT CLUTCH
2 OVERDRIVE SUPPORT
Fig. 241 Checking Direct Clutch Piston Stroke
Length
1 INDICATOR PLUNGER
2 DIAL INDICATOR
3 CLUTCH PISTON
4 OVERDRIVE SUPPORT
5 CLUTCH PISTON
Fig. 242 Removing Clutch Pack Snap Ring
2 DIRECT CLUTCH DRUM
to bal l i nl et as shown. Ai r shoul d not l eak past check
bal l .
(16) Measure i nsi de di ameter of cl utch drum bush-
i ng. I nsi de di ameter shoul d be no more than 53.97
mm (2.1248 i n.). Repl ace drum i f bushi ng i nsi de
di ameter i s greater than speci fi ed.
Fig. 243 Removing Piston Return Spring
1 PRESS RAM
2 COMPRESSOR TOOL
3 SNAP RING PLIERS
4 RETURN SPRING
Fig. 244 Removing Direct Clutch Piston
2 CLUTCH PISTON
3 OVERDRIVE SUPPORT
4 SUPPORT FEED HOLE
2 SPRING RETAINER
Fig. 246 Testing Piston Check Ball Seating
1 PISTON CHECK BALL
2 USE LOW-PRESSURE AIR TO CHECK SEATING
3 DIRECT CLUTCH PISTON
ASSEMBLY
(1) Lubri cate and i nstal l repl acement Ori ngs on
cl utch pi ston (Fi g. 247).
(2) I nstal l cl utch pi ston i n drum and i nstal l return
spri ngs on pi ston.
(3) Compress pi ston return spri ngs wi th Tool 7538
and i nstal l snap ri ng (Fi g. 243). Be sure snap ri ng
end gap i s not al i gned wi th spri ng retai ner tab.
(4) I nstal l cl utch di scs and pl ates (Fi g. 248).
I nstal l pl ate then di sc unti l al l pl ates and di scs are
i nstal l ed. Four pl ates and di scs are requi red.
(5) I nstal l cl utch pack retai ner i n drum (Fi g. 249).
(6) I nstal l cl utch pack snap ri ng (Fi g. 249).
(7) Check snap ri ng posi ti on. I f necessary, shi ft
snap ri ng unti l end gap i s not al i gned wi th any
notches i n cl utch drum (Fi g. 250).
(8) Lubri cate cl utch drum thrust washer wi th
petrol eum jel l y and i nstal l i t i n drum (Fi g. 240).
(9) Mount di rect cl utch assembl y on forward cl utch
assembl y and check assembl ed hei ght (Fi g. 251).
Hei ght shoul d be 70.3 to 71.5 mm (2.767 to 2.815
i n.).
(10) I f assembl ed hei ght i s i ncorrect, cl utches are
not seated.
Fig. 247 Direct Clutch Components
2 DIRECT CLUTCH PISTON
3 O-RINGS
5 CLUTCH DRUM THRUST WASHER
6 CLUTCH PISTON SNAP RING
8 RETAINER
9 CLUTCH PACK
10 CLUTCH DISC*
11 CLUTCH PLATE*
Fig. 248 Installing Direct Clutch Discs And Plates
1 CLUTCH PLATES
2 CLUTCH DISCS
Fig. 249 Install Clutch Pack Retainer
1 CLUTCH PACK RETAINER
2 RETAINER
3 SNAP RING
Fig. 250 Adjusting Clutch Pack Snap Ring Position
2 DRUM NOTCH
3 SHIFT SNAP RING END GAP AWAY FROM DRUM NOTCHES
Fig. 251 Checking Direct Clutch Assembled Height
1 DIRECT CLUTCH
2 HEIGHT SHOULD BE 70.3-71.5 mm (2.767-2.815 in.)
3 FORWARD CLUTCH
FORWARD CLUTCH
DISASSEMBLY
(1) Check cl utch pi ston stroke as outl i ned i n fol -
l owi ng steps.
(2) Posi ti on overdri ve support on wood bl ocks and
mount forward cl utch drum on support (Fi g. 253).
(3) Remove beari ng and race from forward cl utch
drum (Fi g. 253).
(4) I nstal l a sui tabl e threaded bol t/rod i nto the
si de of the overdri ve support.
(5) Mount Mi l l er Tool C-3339 di al i ndi cator compo-
nents onto the threaded rod as necessary.
(6) Posi ti on di al i ndi cator pl unger squarel y agai nst
cl utch pi ston.
Fig. 252 Forward Clutch Components
(7) Appl y compressed ai r through ri ght si de feed
hol e i n support and note pi ston stroke l ength on di al
i ndi cator.
(8) Stroke l ength shoul d be 3.55 3.73 mm (0.1348
0.1469 i n.).
(9) Repl ace cl utch di scs i f stroke l ength i s i ncor-
rect.
(10) Remove cl utch pack snap ri ng and remove
retai ner and cl utch pack (Fi g. 254).
(11) Remove cl utch pack cushi on pl ate (Fi g. 255).
(12) Compress cl utch spri ngs wi th Tool 7538 and
remove pi ston snap ri ng.
(13) Remove spri ng compressor tool and pi ston
return spri ngs.
(14) Remount forward cl utch drum on overdri ve
support (Fi g. 256).
(15) Appl y compressed ai r through feed hol e i n
support to remove pi ston (Fi g. 256). Use onl y enough
ai r pressure to ease pi ston out of drum.
(16) Remove and di scard cl utch pi ston Ori ngs
(Fi g. 257).
(17) Remove cl utch drum Ori ng from rear hub of
drum.
(18) Remove three seal ri ngs from cl utch drum
shaft (Fi g. 258).
(19) Remove thrust beari ng and race assembl y
from cl utch drum (Fi g. 259).
Fig. 253 Positioning Drum And Support On Wood
Blocks
1 THRUST BEARING
2 BEARING RACE
3 FORWARD CLUTCH DRUM
4 OVERDRIVE SUPPORT
5 WOOD BLOCKS
Fig. 254 Removing Retainer And Clutch Pack
1 RETAINER AND CLUTCH PACK
2 SNAP RING
Fig. 255 Removing Cushion Plate
1 CUSHION PLATE
2 RETURN SPRINGS
3 CUSHION PLATE
Fig. 256 Removing Forward Clutch Piston
1 CLUTCH PISTON
2 OVERDRIVE SUPPORT
3 FEED HOLE
4 CLUTCH DRUM
Fig. 257 Removing/Installing Clutch Drum ORing
1 CLUTCH DRUM HUB
2 O-RING
Fig. 258 Removing Clutch Drum Seal Rings
1 SEAL RINGS
2 CLUTCH DRUM SHAFT
Fig. 259 Removing Clutch Drum Thrust Bearing
Assembly
1 THRUST BEARING AND RACE ASSEMBLY
(20) Measure cl utch di sc thi ckness (Fi g. 260). Mi n-
i mum al l owabl e thi ckness i s 1.51 mm (0.0595 i n.).
Repl ace cl utch pack i f any di sc fal l s bel ow speci fi ed
mi ni mum thi ckness.
shoul d be 19.47 mm (0.767 i n.). Repl ace spri ngs and
retai ner i f l ength i s i ncorrect.
(22) I nspect cl utch pi ston check bal l (Fi g. 262).
Bal l shoul d move freel y wi thi n pi ston. Check bal l
seati ng by appl yi ng l ow pressure compressed ai r to
bal l feed hol e. Bal l shoul d seat fi rml y and not l eak
ai r.
(23) Measure i nsi de di ameter of bushi ng i n cl utch
drum hub. Maxi mum al l owabl e di ameter i s 24.08
mm (0.9480 i n.). Repl ace cl utch drum i f bushi ng
i nsi de di ameter i s greater than speci fi ed.
ASSEMBLY
(1) Lubri cate beari ng and race assembl y wi th
petrol eum jel l y and i nstal l i t i n cl utch drum (Fi g.
263). Race si de of assembl y faces downward and
toward drum. Beari ng rol l ers face up (Fi g. 263)
(2) Coat new cl utch drum shaft seal ri ngs wi th
petrol eum jel l y. Before i nstal l i ng drum shaft seal
ri ngs, squeeze each ri ng so ri ng ends overl ap (Fi g.
264). Thi s ti ghtens ri ng maki ng cl utch i nstal l ati on
easi er.
(3) I nstal l seal ri ngs on shaft. Keep ri ngs cl osed as
ti ghtl y as possi bl e duri ng i nstal l ati on. Avoi d over-
spreadi ng them.
(4) Mount cl utch drum on overdri ve support.
(5) Lubri cate and i nstal l new Ori ng on cl utch
drum hub (Fi g. 257).
Fig. 260 Measuring Clutch Disc Thickness
1 CLUTCH DISC
2 MICROMETER
Fig. 261 Checking Return Spring Length
2 SPRING RETAINER
Fig. 262 Testing Piston Check Ball
1 PISTON CHECK BALL
2 USE LOW AIR PRESSURE FOR TEST
(6) Lubri cate new cl utch pi ston Ori ngs wi th
Mopar Door Ease, or RuGl yde. I nstal l ri ngs on
cl utch pi ston and i nstal l pi ston i n drum.
(7) I nstal l pi ston return spri ngs.
(8) Compress pi ston return spri ngs wi th Tool 7538
and shop press and i nstal l pi ston snap ri ng. Be sure
snap ri ng end gap i s not al i gned wi th any notches i n
drum.
(9) I nstal l cushi on pl ate i n drum. Concave si de of
pl ate faces downward (Fi g. 255).
(10) I nstal l cl utch di scs, pl ates and retai ner (Fi g.
265). I nstal l tabbed pl ate fol l owed by di sc unti l
requi red number of pl ates and di scs are i nstal l ed.
Use si x pl ates and di scs.
(11) I nstal l cl utch pack snap ri ng.
(12) Recheck cl utch pi ston stroke l ength usi ng
same method outl i ned at begi nni ng of di sassembl y
procedure. I f stroke l ength i s not wi thi n speci fi ed
l i mi ts, repl ace cl utch di scs.
(13) Lubri cate race and beari ng wi th petrol eum
jel l y and i nstal l them i n cl utch drum (Fi g. 266). Be
sure beari ng rol l ers face up and race l i p seats i n
drum as shown.
(14) Veri fy beari ng and race si ze.
Outer di ameter of beari ng i s 46.7 mm (1.839 i n).
Outer di ameter of race i s 48.9 mm (1.925 i n.).
I nner di ameter of beari ng and race i s 26.0 mm
(1.024 i n.).
(15) Mount forward cl utch on di rect cl utch and
check assembl ed hei ght (Fi g. 267). Hei ght shoul d be
70.3 71.5 mm (2.767 2.815 i n.).
Fig. 263 Installing Thrust Bearing And Race
1 BEARING ROLLERS FACE UP
3 FORWARD CLUTCH
Fig. 264 Installing Clutch Drum Shaft Seal Rings
1 SEAL RINGS (COMPRESS BEFORE INSTALLATION)
2 CLUTCH DRUM SHAFT
Fig. 265 Installing Forward Clutch Discs And Plates
1 RETAINER
2 CLUTCH PLATES
3 CLUTCH DISCS
FRONT PLANETARY GEAR
DISASSEMBLY
(1) Remove ri ng gear from pl anetary gear (Fi g. 268).
(2) Remove front beari ng and the two races from
(3) Remove tabbed thrust race from pl anetary gear
(Fi g. 268).
(4) Remove snap ri ng attachi ng pl anetary gear to
shaft and remove 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
3 FRONT BEARING
4 SNAP RING
5 REAR RACE
6 REAR BEARING
8 THRUST RACE
9 FRONT RACE
Fig. 266 Installing Thrust Bearing And Race
2 CLUTCH DRUM
(5) Remove rear beari ng and race from pl anetary gear.
(6) Measure i nsi de di ameter of ri ng gear bushi ng.
Maxi mum al l owabl e di ameter i s 24.08 mm (0.9480
i n.). Repl ace ri ng gear i f bushi ng i nsi de di ameter i s
(7) Check condi ti on of pl anetary gear. Repl ace gear
i f teeth are worn, pi ns are l oose, or carri er i s cracked,
di storted, or worn.
ASSEMBLY
(1) Lubri cate pl anetary and ri ng gear beari ngs and
races wi th petrol eum jel l y.
(2) I denti fy pl anetary beari ngs and races before
i nstal l ati on. (Fi g. 268). Beari ngs and races can be
i denti fi ed by fol l owi ng di mensi ons:
Outer di ameter of rear beari ng i s 47.7 mm
(1.878 i n.). I nner di ameter i s 35.5 mm (1.398 i n.).
Outer di ameter of rear race 47.6 mm (1.874 i n.).
I nner di ameter i s 33.7 mm (1.327 i n.).
Outer di ameter of front race i s 53.6 mm (2.110
i n.). I nner di ameter i s 30.5 mm (1.201 i n.).
Outer di ameter of front beari ng i s 47.7 mm
(1.878 i n.). I nner di ameter i s 32.6 (1.283 i n.).
Outer di ameter of forward race i s 47.0 mm
(1.850 i n.). I nner di ameter i s 26.5 mm 1.043 i n.).
(3) I nstal l rear race and beari ng i n gear (Fi g. 269).
(4) Turn pl anetary over and i nstal l thrust race
(Fi g. 270).
(5) I nstal l front race and beari ng and forward race
i n ri ng gear (Fi g. 271).
Fig. 269 Front Planetary Rear Bearing and Race
Installation
1 REAR BEARING AND RACE
2 PLANETARY GEAR
Fig. 270 Front Planetary Thrust Race Installation
1 TABBED THRUST RACE
2 PLANETARY GEAR
Fig. 271 Front Planetary Front Bearing And Races
Installation
1 FRONT BEARING AND RACE
2 FORWARD RACE
SUN GEAR AND NO. 1 ONEWAY CLUTCH
DISASSEMBLY
(1) Hol d sun gear and turn second brake hub
cl ockwi se and countercl ockwi se (Fi g. 272). Hub
shoul d rotate freel y cl ockwi se but l ock when turned
countercl ockwi se. Repl ace oneway cl utch and hub i f
they do not operate properl y.
(2) Remove oneway cl utch/second brake hub
assembl y from drum (Fi g. 273).
Fig. 272 Checking OneWay Clutch Operation
1 SECOND BRAKE HUB
2 SUN GEAR
Sun Gear And OneWay Clutch Components
1 SNAP RING
2 SUN GEAR
3 SUN GEAR INPUT DRUM
4 THRUST WASHER
5 ONE-WAY CLUTCH AND SECOND BRAKE HUB ASSEMBLY
6 SNAP RING
7 SEAL RINGS
Fig. 273 Removing/Installing Brake Hub And Clutch
Assembly
1 HUB AND CLUTCH ASSEMBLY
2 DRUM
(3) Remove thrust washer from drum (Fi g. 274).
(4) Remove two seal ri ngs from sun gear (Fi g.
275).
(5) Support sun gear on wood bl ock (Fi g. 276).
Then remove fi rst sun gear snap ri ng and separate
drum from gear.
(6) Remove remai ni ng snap ri ng from sun gear
(Fi g. 277).
(7) Measure i nsi de di ameter of sun gear bushi ngs
wi th bore gauge or i nsi de mi crometer (Fi g. 278).
Maxi mum al l owabl e di ameter i s 27.08 mm (1.0661
i n.). Repl ace sun gear i f bushi ng i nsi de di ameter i s
Fig. 274 Removing/Installing Thrust Washer
1 THRUST WASHER
Fig. 275 Removing/Installing Sun Gear Seal Rings
1 SEALS RINGS (2)
Fig. 276 Removing/Installing Sun Gear
1 SUN GEAR
2 SNAP RING
3 WOOD BLOCK
4 INPUT DRUM
Fig. 277 Removing/Installing Second Snap Ring
1 SUN GEAR
2 SECOND SNAP RING
ASSEMBLY
(1) I nstal l fi rst snap ri ng on sun gear.
(2) I nstal l sun gear i n drum and i nstal l remai ni ng
snap ri ng.
(3) Coat repl acement seal ri ngs wi th petrol eum
jel l y and i nstal l them on sun gear. Be sure seal
ring ends are interlocked.
(4) I nstal l thrust washer. Be sure washer tabs are
seated i n drum sl ots.
(5) I nstal l oneway cl utch/second brake hub
assembl y on sun gear. Deep si de of hub fl ange faces
upward (Fi g. 279).
Fig. 279 Installing Clutch And Hub Assembly On
Sun Gear
1 CLUTCH AND HUB ASSEMBLY
Second Brake Components
1 THRUST WASHER
2 SNAP RING
3 SPRING RETAINER
5 REAR PLANETARY/OUTPUT SHAFT/FIRST-REVERSE
BRAKE
6 SECOND BRAKE DRUM
7 O-RINGS
8 SECOND BRAKE PISTON
9 PISTON SLEEVE
Fig. 278 Checking Sun Gear Bushings
1 BORE GAUGE
(6) Check oneway cl utch operati on agai n (Fi g.
272). Hol d sun gear and turn second brake hub cl ock-
wi se and countercl ockwi se. Hub shoul d turn cl ock-
wi se freel y, but l ock when turned countercl ockwi se.
SECOND BRAKE
DISASSEMBLY
(1) Remove second brake drum from output shaft
(Fi g. 280).
(2) Remove thrust washer from second brake drum
(Fi g. 281).
(3) Compress pi ston return spri ngs wi th shop
press and tool 7538. Then remove pi ston snap ri ng
(Fi g. 282).
(4) Remove compressor tool and remove spri ng
retai ner and return spri ngs.
(5) Remove second brake pi ston and sl eeve from
drum wi th compressed ai r (Fi g. 283). Use onl y
enough ai r pressure to ease pi ston out of drum.
(6) Remove and di scard brake pi ston Ori ngs.
shoul d be approxi matel y 16.05 mm (0.632 i n.).
Repl ace return spri ngs i f l ength i s l ess than speci -
fi ed.
Fig. 280 Removing/Installing Second Brake
Assembly
1 SECOND BRAKE ASSEMBLY
2 OUTPUT SHAFT
Fig. 281 Removing/Installing Second Brake Drum
Thrust Washer
1 THRUST WASHER
2 SECOND BRAKE DRUM
Fig. 282 Removing/Installing Second Brake Piston
Snap Ring
1 COMPRESSOR TOOL
2 PISTON SNAP RING
ASSEMBLY
(1) Lubri cate and i nstal l new Ori ngs on brake
pi ston. Then i nstal l brake pi ston i n drum.
(2) I nstal l return spri ngs and retai ner on brake
pi ston.
(3) Compress return spri ngs wi th shop press and
Compressor Tool 7538. I nstal l pi ston snap ri ng and
remove brake assembl y from press.
(4) Check brake pi ston operati on wi th l ow pres-
sure compressed ai r (Fi g. 285). Appl y ai r pressure
through feed hol e i n drum. Pi ston shoul d move
smoothl y when appl yi ngrel easi ng ai r pressure.
(5) Coat thrust washer wi th petrol eum jel l y and
i nstal l i t i n drum. Be sure washer notches are
al i gned wi th tabs on spri ng retai ner (Fi g. 286).
Fig. 283 Removing/Installing Piston And Sleeve
1 PISTON AND SLEEVE
2 DRUM
Fig. 284 Measuring Second Brake Piston Return
Springs
2 SPRING RETAINER
Fig. 285 Checking Second Brake Piston Operation
1 PISTON
2 DRUM
Fig. 286 Installing Second Brake Thrust Washer
1 THRUST WASHER NOTCHES
2 SPRING RETAINER TABS
PLANETARY/BRAKE PACK/OUTPUT SHAFT
Rear Planetary, Brake Pack, Output Shaft Components
1 FIRST-REVERSE BRAKE PACK
2 SNAP RING
5 REAR THRUST WASHER
7 ONE-WAY CLUTCH INNER RACE
8 SNAP RING
9 RING GEAR HUB
11 THRUST BEARING
12 RACES
13 OUTPUT SHAFT
14 SEAL RING
DISASSEMBLY
(1) Remove output shaft from gear assembl y (Fi g.
287).
(2) Remove and di scard shaft seal ri ng (Fi g. 288).
(3) Remove brake pack from pl anetary gear (Fi g.
289).
(4) Remove pl anetary gear from ri ng gear (Fi g.
290).
(5) Check No. 2 oneway cl utch (Fi g. 291). Hol d
pl anetary gear and turn cl utch i nner race i n both
di recti ons. Race shoul d turn freel y countercl ockwi se,
but l ock when turned cl ockwi se. Repl ace oneway
cl utch i f necessary.
Fig. 287 Removing/Installing Output Shaft
1 GEAR ASSEMBLY
2 OUTPUT SHAFT
Fig. 288 Removing/Installing Shaft Seal Ring
1 SEAL RING
2 OUTPUT SHAFT
Fig. 289 Removing/Installing FirstReverse Brake
Pack
1 FIRST-REVERSE BRAKE PACK
Fig. 290 Removing/Installing Rear Planetary
2 RING GEAR
(6) Remove cl utch i nner race from pl anetary gear
(Fi g. 292).
(7) Remove cl utch snap ri ng and remove No. 2
oneway cl utch top end cap from pl anetary.
(8) Remove No. 2 oneway cl utch from pl anetary
(Fi g. 293).
(9) Remove No. 2 oneway cl utch bottom end cap
from pl anetary.
Fig. 291 Checking No. 2 OneWay Clutch Operation
1 CLUTCH INNER RACE
2 PLANETARY GEAR
Fig. 292 Removing/Installing Clutch Inner Race
1 CLUTCH INNER RACE
2 REAR PLANETARY
Fig. 293 Removing/Installing OneWay Clutch
1 CLUTCH SNAP RING
3 PLANETARY GEAR
(10) Remove front and rear thrust washers from
pl anetary gear (Fi g. 294).
(11) Remove thrust beari ng and washers from ri ng
gear (Fi g. 295).
(12) Remove ri ng gear snap ri ng and remove ri ng
gear hub (Fi g. 296).
(13) I nspect and repl ace any worn or damaged
pl anetary gear components.
ASSEMBLY
(1) Measure thi ckness of each brake pack di sc.
Mi ni mum thi ckness i s 1.51 mm (0.0594 i n.). Repl ace
al l di scs i f any di sc i s thi nner than speci fi ed.
(2) I nstal l hub and snap ri ng i n ri ng gear (Fi g.
296)
(3) I denti fy ri ng gear thrust beari ng and races by
fol l owi ng di mensi ons (Fi g. 295) :
Outer di ameter of bottom race i s 44.8 mm (1.764
i n.) and i nner di ameter i s 27.6 mm (1.087 i n.).
and i nner di ameter i s 30.1 mm (1.185 i n.).
Outer di ameter of upper race i s 44.8 mm (1.764
i n.) and i nner di ameter i s 28.8 mm (1.134 i n.).
(4) Lubri cate ri ng gear thrust beari ng and races
wi th petrol eum jel l y and i nstal l them i n ri ng gear
(Fi g. 295).
Fig. 294 Removing/Installing Rear Planetary Thrust
Washers
Fig. 295 Removing/Installing Ring Gear Thrust
Bearing And Races
1 THRUST BEARING AND RACES
2 RING GEAR
Fig. 296 Removing/Installing Ring Gear Hub
1 SNAP RING
2 RING GEAR
3 HUB
(5) Coat pl anetary thrust washers wi th petrol eum
jel l y and i nstal l them i n gear (Fi g. 294).
(6) I nstal l No. 2 oneway cl utch bottom end cap
i nto the pl anetary gear.
(7) I nstal l No. 2 oneway cl utch i n pl anetary gear.
Be sure fl anged si de of cl utch faces upward (Fi g.
297).
(8) I nstal l No. 2 oneway cl utch top end cap i nto
the pl anetary gear.
(9) I nstal l cl utch retai ni ng snap ri ng and i nstal l
cl utch i nner race (Fi g. 292). Turn race countercl ock-
wi se to ease i nstal l ati on.
(10) Veri fy oneway cl utch operati on. Hol d gear
and turn i nner race i n both di recti ons. Race shoul d
turn freel y countercl ockwi se, but l ock when turned
cl ockwi se.
(11) I nstal l pl anetary gear i n ri ng gear.
(12) I nstal l thrust beari ng and washers onto the
(13) Assembl e cl utch di scs and cl utch pl ates (Fi g.
289). Sequence i s di sc fi rst, then a pl ate. Use seven
di scs and pl ates.
(14) I nstal l brake pack on pl anetary gear (Fi g.
289).
(15) I nstal l new seal ri ng on output shaft (Fi g.
288). Be sure ri ng ends are i nterl ocked as shown.
The val ve body assembl y consi sts of two secti ons
whi ch are the upper body and l ower body (Fi g. 298)
and (Fi g. 299). Di sassembl y, i nspecti on and overhaul
procedures for each secti on are outl i ned separatel y.
Refer to the appropri ate procedure as needed.
Fig. 297 Installing No. 2 OneWay Clutch
1 FLANGED SIDE OF CLUTCH
3 REAR PLANETARY
Fig. 298 Lower Body Components
1 RETAINER
2 STRAINERS
3 PRESSURE RELIEF VALVE
4 NO. 2 SOLENOID AND O-RING
5 ACCUMULATOR CONTROL VALVE
6 RETAINER
7 SLEEVE
8 CLIP
9 PRESSURE REDUCING PLUG
12 RETAINER
13 SLEEVE
14 PLUNGER
15 VALVE SPRING
16 WASHER
17 PRIMARY REGULATOR VALVE
18 CHECK VALVE AND BALL
19 LOWER BODY
20 CHECK VALVE
21 1-2 SHIFT VALVE
22 PLUG
Fig. 299 Upper Body Components
INSPECTION
Cl ean the transmi ssi on components wi th sol vent
and dry them wi th compressed ai r onl y. Do not use
shop towel s or rags.
Bl ow compressed ai r through al l oi l feed passages
and channel s to be sure they are cl ear. I nspect the
transmi ssi on components for wear and damage.
Repl ace components that are damaged or worn
beyond the l i mi ts speci fi ed i n the i ndi vi dual overhaul
procedures.
Repl ace al l Ori ngs, gaskets and seal s. These com-
ponents are not reusabl e. Al so repl ace any snap ri ng
that i s di storted or damaged.
Duri ng overhaul assembl y operati ons, l ubri cate the
transmi ssi on components wi th Mopar Mercon auto-
mati c transmi ssi on fl ui d or petrol eum jel l y as i ndi -
cated. Petrol eum jel l y shoul d be used to prel ubri cate
thrust beari ngs, washers and races. I t can al so be
used to hol d parts i n posi ti on duri ng assembl y.
Soak replacement clutch and brake pack
components in transmission fluid for at least 30
minutes before installation.
ADJ USTMENTS
GEARSHIFT CABLE
Check adjustment by starti ng the engi ne i n Park
and Neutral . Adjustment i s OK i f the engi ne starts
onl y i n these posi ti ons. Adjustment i s i ncorrect i f the
engi ne starts i n one but not both posi ti ons. I f the
engi ne starts i n any posi ti on other than Park or Neu-
tral , or i f the engi ne wi l l not start at al l , the park/
neutral posi ti on swi tch may be faul ty.
Gearshift Adjustment Procedure
(3) Rel ease cabl e adjuster cl amp (at transmi ssi on
end of cabl e) to unl ock cabl e.
(4) Unsnap cabl e from cabl e mounti ng bracket on
(5) Sl i de cabl e eyel et off transmi ssi on shi ft l ever.
(6) Veri fy transmi ssi on shi ft l ever i s i n Park
detent by movi ng l ever ful l y rearward. Last rearward
detent i s Park posi ti on.
(7) Veri fy posi ti ve engagement of transmi ssi on
park l ock by attempti ng to rotate propel l er shaft.
Shaft wi l l not rotate when park l ock i s engaged.
(8) Sl i de cabl e eyel t onto transmi ssi on shi ft l ever.
(9) Snap shi ft cabl e adjuster i nto mounti ng
bracket on transmi ssi on.
(10) Lock shi ft cabl e by pressi ng cabl e adjuster
cl amp down unti l i t snaps i nto pl ace.
(11) Lower vehi cl e and check engi ne starti ng.
Engi ne shoul d start onl y i n Park and Neutral .
CABLE ADJUSTMENT
(1) Shi ft transmi ssi on i nto PARK.
(2) Remove shi ft l ever bezel and consol e screws.
Rai se bezel and consol e for access to cabl e.
(3) Pul l cabl e l ock button up to rel ease cabl e (Fi g.
301).
(4) Turn i gni ti on swi tch to LOCK posi ti on.
(5) Use a spacer to create a one mi l l i meter gap
between the shi fter pawl and top of the shi ft gate.
(6) Pul l cabl e forward. Then rel ease cabl e and
press cabl e l ock button down unti l i t snaps i n pl ace.
(7) Check adjustment as fol l ows:
(a) Check movement of rel ease shi ft handl e but-
ton (fl oor shi ft) or rel ease l ever (col umn shi ft). You
shoul d not be abl e to press button i nward or move
col umn l ever.
(b) Turn i gni ti on swi tch to RUN posi ti on.
(c) Shi fti ng out of park shoul d not be possi bl e.
(d) Appl y the brake and attempt to shi ft out of
PARK. Shi fti ng shoul d be possi bl e.
(e) Whi l e the transmi ssi on i s shi fted out of
PARK, rel ease the brake and attempt to shi ft
Fig. 300 Shift Cable Attachment At
TransmissionTypical
2 TRANSMISSION SHIFT LEVER
3 SHIFT CABLE
through al l gears. Rel ease the shi ft button at l east
once duri ng thi s procedure. The i gni ti on key shoul d
not go to the LOCK posi ti on.
(f) Return transmi ssi on to the PARK posi ti on
wi thout appl yi ng the brake.
(8) Move shi ft l ever back to PARK and check i gni -
ti on swi tch operati on. You shoul d be abl e to turn
swi tch to LOCK posi ti on and shi ft l ever rel ease but-
ton/l ever shoul d not move.
ADJUSTMENT
(1) Shi ft transmi ssi on i nto Park, shut engi ne off
and rai se hood.
(2) Press cabl e rel ease button (Fi g. 302).
(3) Push cabl e condui t back i nto cabl e sheath as
far as possi bl e (Fi g. 303).
(4) Rotate l ever on throttl e body to wi de open
throttl e posi ti on. Cabl e wi l l ratchet to correct adjust-
ment poi nt as l ever i s rotated (Fi g. 303).
Fig. 301 Park Lock Cable Attachment
1 PARK LOCK CABLE
2 CABLE LOCK BUTTON
4 SHIFT CABLE
Fig. 302 Throttle Cable Components
1 CONDUIT
2 RELEASE BUTTON
3 CABLE CONNECTOR
4 CABLE
Fig. 303 Throttle Cable Adjustment
1 RELEASE BUTTON
2 ROTATE THROTTLE BODY LEVER TO W. O. T. POSITION
3 CABLE
4 CABLE BRACKET
SPECIFICATIONS
AW-4 AUTOMATIC TRANSMISSION
AW-4 GENERAL SPECIFICATIONS
Gear Rati os:
Fi rst . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.804:1
Second . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.531:1
Thi rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.000:1
Fourth (Overdri ve) . . . . . . . . . . . . . . . . . . 0.753:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . 2.393:1
Transmi ssi on Fl ui d . . Jeep automati c transmi ssi on
fl ui d or DEXRON I I
Fl ui d Level . To Ful l mark wi th fl ui d hot (normal
operati ng temperature)
Fl ui d Capaci ty (al l model s) . . . 8.0 Li ters (8.45 qts.)
Test Specifications
Stal l Speed:
I n D Range and Reverse . . . . . . . 2100-2400 rpm
Li ne Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I n D at Curb I dl e . . . . . 6170 psi (421481 kPa)
I n D at WOT . . . . . . 173-209 psi (1196-1442 kPa)
I n Reverse at Curb I dl e . 75-90 psi (519-618 kPa)
I n Reverse at WOT . 213-263 psi (1471-1814 kPa)
Ti me Lag Test:
Engagement i n D Range . . . . . . . . . . 1.2 seconds
Engagement i n Reverse . . . . . . . . . . . 1.5 seconds
Val ve Body Sol enoi d Resi stance . . . . . . 11-15 ohms
Transmi ssi on Fl ui d Normal Operati ng
Temperature . . . . . . . . . . . . 50-80C (122-176F)
TPS I nput Vol tage (AU) . . . . . . . 5.0 Vol ts (approx.)
TPS Output Vol tage . . . . . . . . . . . . . . . . . . . . . . . . .
4Cyl i nder . . . . . . . . . . . . . . . 0.2 Vol ts (approx.)
6Cyl i nder . . . . . . . . . . . . . . . 4.2 Vol ts (approx.)
AW-4 OIL PUMP WEAR LIMITS
Dri ve Gear
Ti p Cl earance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard . . . 0.110.14 mm (0.0043 0.0055 i n.)
Maxi mum Al l owance . . . . . . . . 0.3 mm (0.012 i n.)
Gear-to-Pump Body
End Cl earance:
Standard . . . . . 0.020.05 mm (0.00080.0020 i n.)
Dri ven Gear-to-Pump
Body Cl earance:
Standard . . . . . 0.070.15 mm (0.00280.0059 i n.)
AW-4 CLUTCH DISC AND PLATE THICKNESS
Component Minimum Allowable Thickness
Clutch Disc (all except first-reverse and forward clutch
discs)
1.84 mm (0.0724 in.)
6-Cylinder Forward Clutch Disc 1.51 mm (0.0594 in.)
6-Cylinder Direct Clutch Plates:
Thin Plate (1) 2.3 mm (0.905 in.)
Thick Plates (3) 3.0 mm (0.118 in.)
6-Cylinder Forward Clutch Plate 1.8 mm (0.070 in.)
First-Reverse Brake Disc (All) 1.51 mm (0.0594 in.)
AW-4 BUSHING AND PISTON CLEARANCE
AW-4 RETAINER AND PISTON SPECIFICATIONS
AW-4 VALVE BODY BALL DIMENSIONS
AW-4 CLUTCH AND BRAKE PACK REQUIREMENTS
AW-4 VALVE AND SPRING IDENTIFICATION
AW-4 ACCUMULATOR COMPONENT IDENTIFICATION
AW-4 TORQUE SPECIFICATIONS
Description Torque
Converter Housi ng Bol ts . . . . . . . . . . . . . . . . . . . . .
10 mm . . . . . . . . . . . . 3236 Nm (2327 ft. l bs.)
12 mm . . . . . . . . . . . . 5559 Nm (4043 ft. l bs.)
Cool er Li ne Retai ni ng Cl i p Nuts . . . . . . . . 24 Nm
(1835 i n. l bs.)
Cool er Li ne Bracket Nuts . . . . . . . . . . . . 511 Nm
(4896 i n. l bs.)
Cool er Li ne Fi tti ng Nuts (at auto. trans.
fi tti ngs) . . . . . . . . . 1823 Nm (160200 i n. l bs.)
Detent Spri ng Bol t . . . . . 911 Nm (8096 i n. l bs.)
Dust Cover Nuts/Bol ts . . . . . . . . . . . . . . 1823 Nm
(159203 i n. l bs.)
Extensi on Housi ng Bol ts . . . . . . . . . . . . 3236 Nm
(2327 ft. l bs.)
Fi l l Tube Bracket Bol t . . 5064 Nm (3747 ft. l bs.)
Neutral Swi tch Bol t . . . . . 1214 Nm (810 ft. l bs.)
Nut . . . . . . . . . . . . . . . . . 68 Nm (5370 ft. l bs.)
OD Support Bol t (to case) . . . . . . . . . . . 2327 Nm
(1820 ft. l bs.)
Description Torque
Oi l Pan Bol ts . . . . . . . . . . . 68 Nm (5370 i n. l bs.)
Oi l Pan Drai n Pl ug . . . . 1921 Nm (1416 ft. l bs.)
Oi l Pump Bol t (to case) . 2123 Nm (1618 ft. l bs.)
Oi l Pump Bol t (to stator shaft) . . . . . . . . . 911Nm
(8096 i n. l bs.)
Oi l Screen Bol t . . . . . . . . 911 Nm (8096 i n. l bs.)
Park Pawl Bracket . . . . . 911 Nm (8096 i n. l bs.)
Propel l er Shaft Cl amp Screws . . . . . . . . 1623Nm
(140200 i n. l bs.)
Rear Mount-To-Transmi ssi on Bol ts . . . . . 6081Nm
(44 ft. l bs.)
Rear Mount-To-Cl evi s Bracket
Bol t/Nut . . . . . . . . . . . 5475 Nm (4055 ft. l bs.)
Rear Mount Cl evi s Bracket-To-Crossmember
Nuts . . . . . . . . . . . . . . 3349 Nm (2436 ft. l bs.)
Shi ft Cabl e Bracket Screws At
Transmi ssi on . . . . . 2539 Nm (221345 i n. l bs.)
Shi ft Lever Mounti ng Cover Screws . . . . . 12 Nm
(920 i n. l bs.)
Shi ft Lever Housi ng Nuts . . . . . . . . . . . 1626 Nm
(141230 i n. l bs.)
Component Approximate Outside Diameter
SECOND BRAKE ACCUMULATOR
SPRING A
PISTONB
SPRING C
14.17 mm (.558 in.)
36.9 mm (1.453 in.)
19.91 mm (.784 in.)
DIRECT CLUTCH ACCUMULATOR
SPRING D
PISTON E
SPRING F
SPRING G
12.07 mm (.475 in.)
36.9 mm (1.453 in.)
20.19 mm (.795 in.)
14.81 mm (.583 in.)
OVERDRIVE BRAKE
ACCUMULATOR
SPRING H
PISTON J
SPRING K
14.10 mm (.555 in.)
31.9 mm (1.256 in.)
19.99 mm (.785 in.)
OVERDRIVE CLUTCH
ACCUMULATOR
SPRING L
SPRING M
PISTON N
14.0 mm (0.551 in.)
20.3 mm (0.799 in.)
29.9 mm (1.177 in.)
Description Torque
Sol enoi d Harness Bol t . . . . 68 Nm (5775 i n. l bs.)
Speedometer Adapter Cl amp Screw . . . . 1012 Nm
(90110 i n. l bs.)
Speed Sensor Coupl i ng Nut . . . . . . . . . . 1420 Nm
(125175 i n. l bs.)
Throttl e Cabl e Engi ne Bracket Screws . . 711 Nm
(6394 i n. l bs.)
Throttl e Cabl e Retai ni ng Screw
(at transmi ssi on) . . . . . 810 Nm (7098 i n. l bs.)
Transfer Case Mounti ng Nuts . . . . . . . . 3041 Nm
(2230 ft. l bs.)
Transmi ssi on Shi ft Lever Nut . . . . . . . . 1517 Nm
(134154 i n. l bs.)
Transmi ssi on-To-Engi ne Bl ock Bol ts . . . 5064 Nm
(3747 ft. l bs.)
Val ve Body Bol ts (to case) . . . . . . . . . . . . 911 Nm
(8096 i n. l bs.)
Val ve Body Bol ts (to val ve body) . . . . . . . . 67 Nm
(5458 i n. l bs.)
SPECIAL TOOLS
AW-4
C-484 Snap Ring Plier
C-3293-SP Gauge
C-3339 Dial Indicator Set
C-4959 Caliper, Metric Vernier
C-4960 Micrometer
7536 Puller, Oil Pump
7538 Compressor, Piston #2 Spring
7539 Compressor, Piston #3 Spring
7540 Pliers, Large Snap Ring
7542 Puller, Reaction Sleeve
7543 Puller, Piston #1
7544 Installer, Brake Drum Seal
7552 Gauge, 3.0 mm Wire
7554 Adapter, Pressure Port
NV231 TRANSFER CASE
TABLE OF CONTENTS
page page
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 346
LUBRICANT AND FILL LEVEL . . . . . . . . . . . . . . 347
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 347
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . 348
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 349
SPEEDOMETER. . . . . . . . . . . . . . . . . . . . . . . . . 350
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . 350
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 351
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 369
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . 372
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
SPECIAL TOOLS
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
NV231 TRANSFER CASE
DESCRIPTION
The NV231 i s a part-ti me transfer case wi th a l ow
range reducti on gear system. The NV231 has three
operati ng ranges pl us a Neutral posi ti on. A l ow range
system provi des a reducti on rati o for i ncreased l ow
speed torque capabi l i ty.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
Transfer case operati ng ranges are:
2WD (2-wheel dri ve)
4x4 (4-wheel dri ve)
4 Lo (4-wheel dri ve l ow range
The 2WD range i s for use on any road surface at
any ti me.
The 4x4 and 4 Lo ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4 Lo range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate.
IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
OPERATION
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range hub. The
front output shaft i s operated by a dri ve chai n that
connects the shaft to a dri ve sprocket on the mai n-
shaft. The dri ve sprocket i s engaged/di sengaged by
the mode fork, whi ch operates the mode sl eeve and
Fig. 1 Fill/Drain Plug And I. D. Tag Locations
1 I. D. TAG
2 FILL PLUG
3 DRAIN PLUG
21 - 346 NV231 TRANSFER CASE XJ
hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
LUBRICANT AND FILL LEVEL
DESCRIPTION
Recommended l ubri cant for the NV231 transfer
case i s Mopar Dexron I I , or ATF Pl us 3, type 7176.
Approxi mate l ubri cant fi l l capaci ty i s 1.2 l i ters (2.5
pi nts).
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 2). Correct fi l l l evel i s to the bottom edge of the
fi l l pl ug hol e. Be sure the vehi cl e i s l evel to ensure
an accurate fl ui d l evel check.
NV231 DIAGNOSIS
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.
1) Vehicle speed to great to permit
shifting.
1) Slow vehicle and shift into
desired range.
2) If vehicle was operated for an
extended period in 4H mode on dry
surface, driveline torque load may
cause difficulty.
2) Stop vehicle and shift transfer
case to Neutral position. Transfer
case can then be shifted to the
desired mode.
3) Transfer case shift linkage
binding.
3) Repair or replace linkage as
necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case
components binding, worn, or
damaged.
5) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
lubricant.
Fig. 2 Fill/Drain Plug Locations
1 I. D. TAG
2 FILL PLUG
3 DRAIN PLUG
XJ NV231 TRANSFER CASE 21 - 347
Condition Possible Cause Correction
Transfer case noisy while in, or
jumps out of, 4L mode.
1) Transfer case not completely
engaged in 4L position.
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of
adjustment.
2) Adjust linkage as necessary.
3) Transfer case shift linkage loose
or binding.
3) Repair, replace, or tighten linkage
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
necessary.
5) Low range gear worn or
damaged.
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4H mode
on dry surfaces,
1) Operate vehicle in 2H mode on
dry surfaces.
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember, or ski d pl ate.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 3)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (26 ft. l bs.) torque (Fi g. 3).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
Fig. 3 Transfer Case Mounting
1 VENT TUBE
2 TRANSFER CASE
3 TRANSMISSION
(8) Al i gn and connect propel l er shafts. Refer to
Group 3, Di fferenti al and Dri vel i ne, for proper proce-
dures and speci fi cati ons.
(9) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 Nm (30 ft. l bs.)
torque.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 4). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
torque shaft.
(5) Remove consol e. Refer to Group 23, Body, for
proper procedures.
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. Refer to Group 23, Body, for
proper procedures.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
Fig. 4 Shift Linkage
1 RIVNUT (4)
3 FLOORPAN
4 TRUNNION LOCK BOLT
5 SELECTOR ROD AND TRUNNION
6 SHIFT LEVER ROD
7 TORQUE SHAFT FRAME BRACKET
8 TORQUE SHAFT
9 TRANSFER CASE SHIFT LEVER
10 TORQUE SHAFT TRANSFER CASE BRACKET
TORQUE
A 3-4 Nm (27-35 in. lbs.)
B 11-14 Nm (97-123 in. lbs.)
C 8-14 Nm (72-120 in. lbs.)
(6) Lower vehi cl e and check transfer case shi ft
operati on.
SPEEDOMETER
REMOVAL
as an assembl y.
Repl ace pi ni on i f chi pped, cracked, or worn.
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
INSTALLATION AND INDEXING
ati on.
ometer adapter (Fi g. 5), i f necessary.
pi ni on.
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
i n. l bs.) torque.
l evel i f necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
Fig. 5 Speedometer Components
1 SENSOR O-RING
3 ADAPTER O-RING
5 ADAPTER CLAMP
ITEM TORQUE
A 2-3 Nm (15-27 in. lbs.)
B 10-12 Nm (90-110 in. lbs.)
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
7).
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143 as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 8). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
NV231 TRANSFER CASE
DISASSEMBLY
Posi ti on transfer case on shal l ow drai n pan.
Remove drai n pl ug and drai n l ubri cant remai ni ng i n
case.
REAR RETAINER AND OIL PUMP REMOVAL
(1) Remove the speedometer adapter.
(2) Spread band cl amp whi ch hol ds output shaft
boot to sl i nger wi th a sui tabl e awl , or equi val ent.
(3) Remove output shaft boot from sl i nger and out-
put shaft.
(4) Usi ng Pul l er MD-998056-A, remove rear
sl i nger (Fi g. 9).
(5) Use a sui tabl e pry tool , or a sl i de hammer
mounted screw, to remove the seal from the rear
(6) Remove the rear output beari ng I . D. retai ni ng
ri ng (Fi g. 11).
(7) Remove the bol ts hol di ng the rear retai ner to
the rear case hal f.
(8) Tap rear retai ner wi th rawhi de or rubber mal -
l et to l oosen seal er bead.
Fig. 6 Location Of Index Numbers On Speedometer
Adapter
Fig. 7 Remove Front Output Shaft Seal
1 OUTPUT SHAFT SEAL
2 PRYBAR
Fig. 8 Front Output Seal Installation
1 INSTALLER 8143
2 TRANSFER CASE
(9) Remove rear retai ner from rear case hal f (Fi g.
12).
(10) Remove snap-ri ng hol di ng oi l pump i n posi -
ti on on output shaft.
(11) Di sengage oi l pi ckup tube from oi l pump and
remove oi l pump assembl y. Remove oi l pump by ti l t-
i ng the edge of the oi l pump from under the edge of
the rear case hal f and sl i di ng the pump (Fi g. 13).
(12) Remove pi ck-up tube o-ri ng from oi l pump
(Fi g. 14), i f necessary. Do not di sassembl e the oi l
pump, i t i s not servi ceabl e.
Fig. 9 Rear Slinger Removal
1 TRANSFER CASE
2 SPECIAL TOOL MD998056A
3 SLINGER
Fig. 10 Rear Retainer Seal
1 REAR RETAINER
2 OUTPUT SHAFT SEAL
Fig. 11 Output Shaft Rear Bearing Retaining Ring
1 REAR RETAINER
2 OUTPUT SHAFT SEAL
Fig. 12 Rear Retainer Removal
1 MAINSHAFT
2 REAR RETAINER
1 OIL PUMP
YOKE AND RANGE LEVER REMOVAL
(1) Remove transfer case i ndi cator swi tch.
(2) Remove front yoke nut as fol l ows:
(a) Move range l ever to 4L posi ti on.
(b) Then remove nut wi th socket and i mpact
wrench (Fi g. 15).
(3) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 16). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
(4) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(5) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 17).
Fig. 14 Pick-up Tube O-ring Location
1 OIL PUMP
2 O-RING
Fig. 15 Yoke Nut Removal
1 IMPACT WRENCH
2 SOCKET
3 YOKE
1 PULLER TOOL
2 YOKE
Fig. 17 Range Lever Removal
1 RANGE LEVER
2 SECTOR SHAFT
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Support transfer case so rear case i s faci ng
upward.
(2) Remove bol ts hol di ng front case to rear case.
The case al i gnment bol ts requi re fl at washers (Fi g.
18).
(3) Loosen rear case wi th fl at bl ade screwdri ver to
break seal er bead. I nsert pry tool bl ade onl y i nto
notches provi ded at each end of case (Fi g. 19).
(4) Remove rear case from front case.
(5) Remove oi l pi ckup tube from rear case (Fi g.
20).
(6) Remove mode fork spri ng (Fi g. 21).
(7) Pul l front output shaft upward and out of front
output shaft beari ng (Fi g. 22).
(8) Remove front output shaft and chai n.
Fig. 18 Rear Case Alignment Bolt Locations
1 DOWEL BOLT AND WASHER (2)
2 CASE BOLT (5)
3 SPLINE HEAD BOLT (1)
Fig. 19 Loosening Rear Case
1 REAR CASE
2 PRY TOOL (IN CASE SLOT)
3 FRONT CASE
Fig. 20 Oil Pickup Tube Removal
1 CONNECTING HOSE
2 PICKUP SCREEN
3 PICKUP TUBE
Fig. 21 Mode Fork Spring Removal
1 MODE SPRING
SHIFT FORKS AND MAINSHAFT REMOVAL
(1) Remove detent pl ug, O-ri ng, detent spri ng and
detent pl unger (Fi g. 23).
(2) Remove mai nshaft from mode sl eeve and i nput
gear pi l ot beari ng.
(3) Remove mode fork and sl eeve as an assembl y
(Fi g. 24). Note posi ti on of sl eeve for assembl y refer-
ence. The short si de of the sl eeve faces upward.
(4) Remove range fork and hub as an assembl y
(Fi g. 25). Note fork posi ti on for i nstal l ati on reference.
(5) Remove shi ft sector from front case (Fi g. 26).
(6) Remove shi ft sector bushi ng and O-ri ng (Fi g.
27).
Fig. 22 Remove Front Output Shaft And Chain
1 DRIVE CHAIN
2 FRONT OUTPUT SHAFT
3 SHAFT FRONT BEARING
Fig. 23 Detent Plug, Spring And Plunger Removal
1 POPPET
2 SPRING
3 SCREW
4 POPPET BORE (IN CASE)
Fig. 24 Mode Fork And Sleeve Removal
1 MODE SLEEVE
2 MODE FORK AND RAIL
Fig. 25 Range Fork And Hub Removal
1 RANGE HUB
2 RANGE FORK
MAINSHAFT DISASSEMBLY
(1) Remove mode hub retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 28).
(2) Sl i de mode hub off mai nshaft (Fi g. 29).
(3) Sl i de dri ve sprocket off mai nshaft (Fi g. 30).
Fig. 26 Shift Sector Removal
1 SHIFT SECTOR
Fig. 27 Sector Bushing And O-Ring Removal
1 SEAL RETAINER
2 SECTOR SHAFT BORE
3 O-RING SEAL
Fig. 28 Mode Hub Retaining Ring Removal
1 MODE HUB
2 SNAP RING PLIERS (HEAVY DUTY)
3 MODE HUB RETAINING RING
Fig. 29 Mode Hub Removal
1 MAINSHAFT
2 MODE HUB
INPUT GEAR AND LOW RANGE GEAR REMOVAL
(1) Remove front beari ng retai ner attachi ng bol ts
(Fi g. 31).
(2) Remove front beari ng retai ner. Pry retai ner
l oose wi th pry tool posi ti oned i n sl ots at each end of
(3) Remove front beari ng retai ner seal . Tap seal
out wi th dri ft and hammer.
(4) Remove i nput gear retai ni ng ri ng wi th heavy
duty snap-ri ng pl i ers (Fi g. 33)
Fig. 30 Drive Sprocket Removal
1 DRIVE SPROCKET
2 MAINSHAFT
Fig. 31 Front Bearing Retainer Bolts
1 FRONT CASE
3 RETAINER BOLTS
Fig. 32 Front Bearing Retainer Removal
2 RETAINER SLOT
Fig. 33 Removing Input Gear Retaining Ring
1 INPUT GEAR BEARING RETAINING RING
2 INPUT GEAR BEARING
3 SNAP RING PLIERS
(5) Pl ace front case i n hori zontal posi ti on. Then
remove i nput gear and l ow range gear as an assem-
bl y (Fi g. 34). Tap gear out of beari ng wi th pl asti c
mal l et i f necessary.
INPUT AND LOW RANGE GEAR DISASSEMBLY
(1) Remove snap-ri ng that retai ns i nput gear i n
l ow range gear (Fi g. 35).
(2) Remove retai ner (Fi g. 36).
(3) Remove front tabbed thrust washer (Fi g. 37).
(4) Remove i nput gear (Fi g. 38).
(5) Remove rear tabbed thrust washer from l ow
range gear (Fi g. 39).
Fig. 34 Input Gear And Planetary Carrier Removal
1 PLANETARY ASSEMBLY
2 INPUT GEAR
Fig. 35 Input Gear Snap-Ring Removal
1 CARRIER LOCK RETAINING RING
2 INPUT GEAR
3 PLANETARY CARRIER
4 SCREWDRIVER
Fig. 36 Input Gear Retainer Removal
1 INPUT GEAR
2 LOW RANGE GEAR
3 RETAINER
Fig. 37 Front Tabbed Thrust Washer Removal
1 FRONT TABBED THRUST WASHER
ASSEMBLY
Lubri cate transfer case components wi th Mopar
Dexron I I automati c transmi ssi on fl ui d or petrol eum
jel l y (where i ndi cated) duri ng assembl y.
BEARING AND SEAL INSTALLATION
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
(1) Remove the front output shaft seal from case
wi th pry tool (Fi g. 40).
(2) Remove the front output shaft beari ng retai n-
i ng ri ng wi th screwdri ver (Fi g. 41).
(3) Remove beari ng wi th Tool Handl e C-4171 and
Tool 5065 (Fi g. 42).
Fig. 38 Input Gear Removal
1 INPUT GEAR
2 LOW RANGE GEAR
Fig. 39 Rear Tabbed Thrust Washer Removal
1 LOW RANGE GEAR
2 REAR TABBED THRUST WASHER
Fig. 40 Front Output Seal Removal
1 OUTPUT SHAFT SEAL
2 PRYBAR
Fig. 41 Front Output Shaft Bearing Retaining Ring
Removal
1 SCREWDRIVERS
2 SNAP RING
3 FRONT OUTPUT SHAFT BEARING
4 FRONT CASE
(4) I nstal l front output shaft front beari ng i n case
wi th Tool Handl e C-4171 and I nstal l er 5064 (Fi g. 43).
(5) I nstal l output shaft front beari ng retai ni ng
ri ng (Fi g. 44). Start ri ng i nto pl ace by hand. Then
use smal l screwdri ver to work ri ng i nto case groove.
Be sure ri ng i s ful l y seated before proceedi ng.
I nstal l er Tool 8143 as fol l ows:
(a) Pl ace new seal on tool . Garter spring on
seal goes toward interior of case.
mer (Fi g. 45). Once seal i s started, conti nue tap-
pi ng seal i nto bore unti l i nstal l er tool bottoms
agai nst case.
(7) Remove the output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 46).
(8) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 47). The beari ng bore i s
chamfered at the top. I nstal l the beari ng so i t i s
fl ush wi th the l ower edge of thi s chamfer (Fi g. 48).
Fig. 42 Front Output Shaft Bearing Removal
1 FRONT CASE
3 SPECIAL TOOL 5065
Fig. 43 Front Output Shaft Bearing Installation
2 SPECIAL TOOL 5064
Fig. 44 Installing Output Shaft Front Bearing
Retaining Ring
1 WORK RETAINING RING INTO BORE GROOVE WITH SMALL
SCREWDRIVER
1 INSTALLER 8143
2 TRANSFER CASE
(9) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng from i nsi de the annul us
gear openi ng i n the case. (Fi g. 49).
(10) I nstal l l ocati ng ri ng on new beari ng.
(11) Posi ti on case so forward end i s faci ng upward.
(12) Usi ng Remover C-4210 and Handl e C-4171,
dri ve i nput shaft beari ng i nto case. The beari ng
l ocati ng ri ng must be ful l y seated agai nst case sur-
face (Fi g. 50).
(13) Remove i nput gear pi l ot beari ng by i nserti ng
a sui tabl y si zed dri ft i nto the spl i ned end of the i nput
gear and dri vi ng the beari ng out wi th the dri ft and a
hammer (Fi g. 51).
(14) I nstal l new pi l ot beari ng wi th I nstal l er 5065
Fig. 46 Output Shaft Rear Bearing Removal
1 REAR CASE
2 SPECIAL TOOL L-44541 AND L-44543
3 SPECIAL TOOL 8148
Fig. 47 Output Shaft Rear Bearing Installation
1 HANDLE C-4171
2 OUTPUT SHAFT INNER BEARING
3 INSTALLER 5066
Fig. 48 Output Shaft Rear Bearing Installation Depth
1 BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 CHAMFER
Fig. 49 Input Shaft Bearing Removal
(15) Remove front beari ng retai ner seal wi th sui t-
abl e pry tool .
(16) I nstal l new front beari ng retai ner seal wi th
I nstal l er 7884 (Fi g. 53).
(17) Remove seal from oi l pump housi ng wi th a
sui tabl e pry tool
Fig. 50 Seating Input Shaft Bearing
1 SNAP RING
Fig. 51 Remove Input Gear Pilot Bearing
1 DRIFT
2 INPUT GEAR
Fig. 52 Install Input Gear Pilot Bearing
2 SPECIAL TOOL 5065
3 INPUT GEAR
Fig. 53 Install Front Bearing Retainer Seal
2 SPECIAL TOOL 7884
(18) I nstal l new seal i n oi l pump housi ng wi th
(19) Remove rear retai ner beari ng wi th I nstal l er
8128 and Handl e C-4171.
(20) I nstal l rear beari ng i n retai ner wi th Handl e
C-4171 and I nstal l er 5064 (Fi g. 55).
INPUT AND LOW RANGE GEAR ASSEMBLY
(1) Lubri cate gears and thrust washers (Fi g. 56)
wi th recommended transmi ssi on fl ui d.
(2) I nstal l fi rst thrust washer i n l ow range gear
(Fi g. 56). Be sure washer tabs are properl y al i gned i n
gear notches.
(3) I nstal l i nput gear i n l ow range gear. Be sure
i nput gear i s ful l y seated.
(4) I nstal l remai ni ng thrust washer i n l ow range
gear and on top of i nput gear. Be sure washer tabs
are properl y al i gned i n gear notches.
(5) I nstal l retai ner on i nput gear and i nstal l snap-
ri ng.
INPUT GEAR AND LOW RANGE GEAR INSTALLATION
(1) Al i gn and i nstal l l ow range/i nput gear assem-
bl y i n front case (Fi g. 57). Be sure l ow range gear
pi ni ons are engaged i n annul us gear and that i nput
gear shaft i s ful l y seated i n front beari ng.
(2) I nstal l snap-ri ng to hol d i nput/l ow range gear
i nto front beari ng (Fi g. 58).
(3) Cl ean gasket seal er resi due from retai ner and
i nspect retai ner for cracks or other damage.
(4) Appl y a 3 mm (1/8 i n.) bead of Mopar gasket
maker or si l i cone adhesi ve to seal i ng surface of
retai ner.
(5) Al i gn cavi ty i n seal retai ner wi th fl ui d return
hol e i n front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Mopar gas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(6) I nstal l bol ts to hol d retai ner to transfer case
(Fi g. 59). Ti ghten to 21 Nm (16 ft. l bs.) of torque.
Fig. 54 Oil Pump Seal Installation
1 HOUSING SEAL
2 SPECIAL TOOL 7888
3 OIL PUMP FEED HOUSING
Fig. 55 Installing Rear Bearing In Retainer
2 SPECIAL TOOL 5064
3 REAR RETAINER
Fig. 56 Input/Low Range Gear Components
1 SNAP RING
2 RETAINER PLATE
3 INPUT GEAR
4 LOW RANGE GEAR
5 THRUST WASHERS
MAINSHAFT ASSEMBLY
(1) Lubri cate mai nshaft spl i nes wi th recommended
(2) Sl i de dri ve sprocket onto mai nshaft.
(3) Sl i de mode hub onto mai nshaft.
(4) I nstal l mode hub retai ni ng ri ng. Veri fy that the
retai ni ng ri ng i s ful l y seated i n mai nshaft groove.
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 60).
(2) I nstal l shi ft sector i n case (Fi g. 61). Lubri cate
sector shaft wi th transmi ssi on fl ui d before i nstal l a-
ti on.
(3) I nstal l range l ever, washer, and nut on sector
shaft (Fi g. 62). Ti ghten range l ever nut to 2734 N.m
(4) Assembl e and i nstal l range fork and hub (Fi g.
63). Be sure hub i s properl y seated i n l ow range gear
and engaged to the i nput gear.
(5) Al i gn and i nsert range fork pi n i n shi ft sector
sl ot.
(6) I nstal l assembl ed mai nshaft (Fi g. 64). Be sure
shaft i s seated i n pi l ot beari ng and i nput gear.
(7) I nstal l new pads on mode fork i f necessary.
Fig. 57 Input/Low Range Gear Installation
1 ANNULUS GEAR
2 INPUT/LOW RANGE GEAR
Fig. 58 Install Snap-Ring
1 INPUT GEAR
2 SNAP RING
Fig. 59 Install Front Bearing Retainer
Fig. 60 Sector O-Ring And Bushing Installation
1 SECTOR BUSHING
2 O-RING
(8) I nsert mode sl eeve i n mode fork mode fork. Be
sure l ong si de of sl eeve i s toward l ong end of shi ft
rai l (Fi g. 65).
(9) I nstal l assembl ed mode fork and sl eeve (Fi g.
66). Be sure fork rai l goes through range fork and
i nto case bore. Al so be sure sl eeve i s al i gned and
seated on mai nshaft hub.
(10) Rotate sector to Neutral posi ti on.
(11) I nstal l new O-ri ng on detent pl ug (Fi g. 67).
(12) Lubri cate detent pl unger wi th transmi ssi on
fl ui d or l i ght coat of petrol eum jel l y.
(13) I nstal l detent pl unger, spri ng and pl ug (Fi g.
67).
(14) Veri fy that pl unger i s properl y engaged i n sec-
tor.
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) Lubri cate front output shaft-sprocket assembl y,
dri ve chai n, and dri ve sprocket wi th transmi ssi on
fl ui d.
Fig. 61 Shift Sector Installation
1 SHIFT SECTOR
Fig. 62 Range Lever Installation
1 RANGE LEVER
2 LEVER NUT
Fig. 63 Install Range Fork And Hub Assembly
1 RANGE HUB
2 RANGE FORK
Fig. 64 Mainshaft Assembly Installation
1 DRIVE SPROCKET
2 MODE HUB
3 MAINSHAFT
Fig. 65 Assembling Mode Fork And Sleeve
1 MODE SLEEVE
(2) Assembl e dri ve chai n and front output shaft
(Fi g. 68).
(3) Start chai n on mai nshaft dri ve sprocket.
(4) Gui de front shaft i nto beari ng and dri ve
sprocket onto mai nshaft dri ve gear (Fi g. 68).
(5) I nstal l mode spri ng on upper end of mode fork
shi ft rai l (Fi g. 69).
OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION
(1) I nstal l magnet i n front case pocket (Fi g. 70).
(2) Assembl e oi l pi ckup screen, connecti ng hose,
and tube.
(3) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 71).
(4) I nsert oi l pi ckup tube i n oi l pump i nl et.
(5) Posi ti on assembl ed oi l pump and pi ckup tube
i n rear case. Be sure pi ckup screen i s securel y seated
i n case sl ot. Al so be sure oi l pump l ocati ng tabs are
outsi de rear case (Fi g. 72).
(6) Appl y 3 mm (1/8 i n.) wi de bead of Mopar gas-
ket maker or si l i cone adhesi ve seal er to mounti ng
Fig. 66 Mode Fork And Sleeve Installation
1 MODE SLEEVE
Fig. 67 Shift Detent Components
1 POPPET
2 SPRING
3 SCREW
4 POPPET BORE (IN CASE)
Fig. 68 Installing Drive Chain And Front Output
Shaft
2 DRIVE CHAIN
3 MAINSHAFT
4 DRIVE SPROCKET
Fig. 69 Install Mode Fork Spring
1 MODE SPRING
fl ange of front case. Work seal er bead around bol t
hol es.
(7) Li ft rear case and oi l pump and careful l y posi -
ti on assembl y on front case. Be sure case dowel s are
al i gned and that mode fork rai l extends through rear
case before seati ng rear case on front case.
(8) I nstal l case attachi ng bol ts. Al i gnment bol ts at
each end of case are onl y ones requi ri ng washers
(Fi g. 73).
(9) Ti ghten case bol ts to 27-34 Nm (20-25 ft. l bs.)
torque.
YOKE AND RANGE LEVER INSTALLATION
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
swi tch to 2034 Nm (1525 ft. l bs.) torque.
(2) I nstal l range l ever, washer and l ocknut on sec-
tor shaft (Fi g. 74). Ti ghten l ocknut to 27-34 Nm
(20-25 ft. l bs.) torque.
(3) I nstal l new seal washer on front output shaft
(Fi g. 76).
(4) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(5) I nstal l new seal washer on front shaft.
(6) I nstal l yoke and new yoke nut on front output
shaft (Fi g. 75).
(7) Ti ghten yoke nut to 122-176 Nm (90-130 ft.
l bs.) torque. Use Tool C-3281, or si mi l ar tool to hol d
yoke whi l e ti ghteni ng yoke nut.
REAR RETAINER INSTALLATION
(1) Appl y bead of Mopar Seal er P/N 82300234, or
Locti te Ul tra Gray, to mati ng surface of rear
retai ner. Seal er bead shoul d be a maxi mum of 3/16
i nch.
(2) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 2027 Nm (1520 ft. l bs.) torque.
(3) I nstal l rear beari ng I . D. retai ni ng ri ng and
spacer on output shaft.
Fig. 70 Installing Case Magnet
1 MAGNET
Fig. 71 Pickup Tube O-Ring Position
1 OIL PUMP
2 O-RING
Fig. 72 Oil Pump And Pickup Tube Installation
1 OIL PUMP
2 PICKUP TUBE
3 PICKUP SCREEN AND CONNECTOR
Fig. 73 Alignment Bolt Location
1 ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
(4) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(5) Sl i de seal onto Seal Protector 6992 (Fi g. 77).
Sl i de seal protector and seal onto output shaft.
(6) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th I nstal l er
C-4076-B and Handl e MD-998323 (Fi g. 78).
(7) I nstal l rear sl i nger wi th I nstal l er 8408.
(8) I nstal l boot on output shaft sl i nger and cri mp
retai ni ng cl amp wi th tool C-4975-A (Fi g. 79).
Fig. 74 Range Lever Installation
1 RANGE LEVER
2 WASHER
3 LOCKNUT
Fig. 75 Output Shaft Yoke Installation
1 OUTPUT SHAFT YOKE
2 YOKE NUT
Fig. 76 Yoke Seal Washer Installation
1 YOKE SEAL WASHER
Fig. 77 Output Shaft Seal and Protector
1 OUTPUT SHAFT SEAL
2 SPECIAL TOOL 6992
3 TRANSFER CASE
Fig. 78 Rear Seal Installation
2 SPECIAL TOOL MD998323
3 TRANSFER CASE
NV231 TRANSFER CASE
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and 3M
al l purpose cl eaner. Use compressed ai r to remove
sol vent resi due from oi l feed passages i n the case
hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket (Fi g. 80). Mi nor ni cks and
scratches can be smoothed wi th an oi l stone. However,
repl ace any part that i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320400 gri t emery cl oth but do
not try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 81). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
Fig. 80 Mainshaft, Mode Hub, And Drive Sprocket
1 MODE HUB
2 DRIVE SPROCKET
3 MAINSHAFT
4 MODE HUB RETAINING RING
Fig. 79 Slinger Boot Installation
2 SLINGER
3 BOOT
4 CLAMP
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 82). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320400 gri t emery cl oth.
I nspect the shi ft fork wear pads (Fi g. 83). The
mode fork pads are servi ceabl e and can be repl aced i f
necessary. The range fork pads are not servi ceabl e.
The fork must be repl aced as an assembl y i f the pads
are worn or damaged.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
I nspect the retai ner components (Fi g. 84). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
Fig. 83 Shift Fork And Wear Pad Locations
1 RANGE FORK
2 MODE FORK
3 WEAR PADS (SERVICEABLE)
4 WEAR PADS (NON-SERVICEABLE)
Fig. 81 Input Gear And Carrier Components
1 PLANETARY CARRIER
4 CARRIER LOCK RING
6 INPUT GEAR
Fig. 82 Shift forks
1 RANGE FORK
3 MODE SPRING
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and 3M al l
purpose cl eaner. Thi s wi l l ensure proper adhesi on of
the seal er duri ng reassembl y.
Repl ace the sl i nger and seal outri ght; do not reuse
ei ther part.
Repl ace any part i f di storted, bent, or broken. Al so
repl ace the boot i f cut or torn. Repl ace the boot band
cl amps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 85). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke nut
and seal washer as nei ther part shoul d be reused.
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320400 gri t emery
to smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 86)
FRONT-REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and
3M al l purpose cl eaner. Thi s wi l l ensure proper
seal er adhesi on at assembl y. Repl ace the i nput
retai ner seal ; do not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Fig. 84 Rear Retainer Components
1 REAR RETAINER
2 REAR BEARING I. D. RETAINING RING
3 REAR SEAL
4 BOOT
5 BAND CLAMPS
6 REAR SLINGER
7 REAR BEARING O. D. RETAINING RING
8 REAR BEARING
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai nl ess
steel i nserts i f requi red.
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ADJ USTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shi ft transfer case i nto 4L posi ti on.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
87).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
Fig. 85 Seal Contact Surface Of Yoke Slinger
1 FRONT SLINGER (PART OF YOKE)
2 SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 86 Low Range Annulus Gear
1 FRONT CASE
2 LOW RANGE ANNULUS GEAR
1 TRANSFER CASE SHIFT LEVER SHAFT
2 SEAL
3 TRANSFER CASE SHIFT LEVER ASSEMBLY
4 FLOORPAN
6 SHIFT ROD
7 ADJUSTING TRUNNION
8 TORQUE SHAFT BRACKET
9 RANGE LEVER
10 TORQUE SHAFT ROD
11 TORQUE SHAFT
12 LINKAGE BRACKET
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Detent . . . . . . . . . . 1624 Nm (1218 ft. l bs.)
Pl ug, Drai n/Fi l l . . . . . . . 2034 Nm (1525 ft. l bs.)
Bol t, Front Brg. Retai ner . . . . . 21 Nm (16 ft. l bs.)
Bol t, Front Brg. Retai ner . . . . . 21 Nm (16 ft. l bs.)
Bol t, Case Hal f . . . . . . . . 2734 Nm (2025 ft. l bs.)
Nut, Front Yoke . . . . 122176 Nm (90130 ft. l bs.)
Nut, Range Lever . . . . . . 2734 Nm (2025 ft. l bs.)
Bol t, Rear Retai ner . . . . 3546 Nm (2634 ft. l bs.)
Nuts, Mounti ng . . . . . . . 3547 Nm (2635 ft. l bs.)
Swi tch, I ndi cator . . . . . . 2034 Nm (1525 ft. l bs.)
SPECIAL TOOLS
NV231
InstallerC-4076-B
Puller, SlingerMD-998056A
InstallerMD-998323
Seal Protector6992
Installer, Boot ClampC-4975-A
Installer, Seal8143
Handle, UniversalC-4171
Installer, SealC-4210
Installer, Bearing5064
Installer, Bushing5066
RemoverL-4454
Cup8148
Installer, Seal7884
Installer, Pump Housing Seal7888
NV242 TRANSFER CASE
TABLE OF CONTENTS
page page
NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 375
LUBRICANT AND FILL LEVEL . . . . . . . . . . . . . . 376
NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 376
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . 377
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 377
SPEEDOMETER. . . . . . . . . . . . . . . . . . . . . . . . . 378
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . 379
NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 380
NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 402
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . 405
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
SPECIAL TOOLS
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
NV242 TRANSFER CASE
DESCRIPTION
The NV242 i s a ful l -ti me transfer case (Fi g. 1). I t
provi des ful l ti me 2-wheel , or 4-wheel dri ve opera-
ti on.
A di fferenti al i n the transfer case i s used to control
torque transfer to the front and rear axl es. A l ow
range gear provi des i ncreased l ow speed torque capa-
bi l i ty for off road operati on. The l ow range provi des a
2.72:1 reducti on rati o.
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. I t dri ves the mai nshaft through the pl an-
etary gear and range hub. The front output shaft i s
operated by a dri ve chai n that connects the shaft to a
dri ve sprocket on the mai nshaft. The dri ve sprocket
i s engaged/di sengaged by the mode fork, whi ch oper-
ates the mode sl eeve and hub. The sl eeve and hub
are not equi pped wi th a synchro mechani sm for shi ft-
i ng.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
TRANSFER CASE IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 2). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
Fig. 1 NV242 Transfer Case
Fig. 2 Fill/Drain Plug And I. D. Tag Locations
1 I. D. TAG
2 FILL PLUG
3 DRAIN PLUG
OPERATING RANGES
NV242 operati ng ranges are 2WD (2-wheel dri ve),
4x4 part-ti me, 4x4 ful l ti me, and 4 Lo.
The 2WD and 4x4 ful l ti me ranges can be used at
any ti me and on any road surface.
The 4x4 part-ti me and 4 Lo ranges are for off road
use onl y. The onl y ti me these ranges can be used on
hard surface roads, i s when the surface i s covered
wi th snow and i ce.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate, or on the
shi ft knob.
LUBRICANT AND FILL LEVEL
DESCRIPTION
Recommended l ubri cant for the NV242 transfer
case i s Mopar Dexron I I , or ATF Pl us, type 7176.
Approxi mate l ubri cant fi l l capaci ty i s 1.35 l i ters (2.85
pi nts).
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 3). Correct fi l l l evel i s to the bottom edge of the
fi l l pl ug hol e. Be sure the vehi cl e i s l evel to ensure
an accurate fl ui d l evel check.
NV242 DIAGNOSIS
DIAGNOSIS CHART
Transfer case difficult to shift or will
not shift into desired range.
1) Transfer case shift linkage
binding.
1) Repair or replace linkage as
necessary.
lubricant.
3) Internal transfer case
components binding, worn, or
damaged.
necessary.
Transfer case noisy in all drive
modes.
lubricant.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Fig. 3 Fill/Drain Plug Locations
1 I. D. TAG
2 FILL PLUG
3 DRAIN PLUG
Transfer case will not shift through
4X4 part time range (light remains
on)
1) Incomplete shift due to drivetrain
torque load.
1) Momentarily release the
accelerator pedal to complete the
shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive Tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember, or ski d pl ate.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 4)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (26 ft. l bs.) torque (Fi g. 4).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
(8) Al i gn and connect propel l er shafts. Refer to
Group 3, Di fferenti al and Dri vel i ne, for proper proce-
dures and speci fi cati ons.
(9) Fi l l transfer case wi th correct fl ui d. Check
transmi ssi on fl ui d l evel . Correct as necessary.
(10) I nstal l rear crossmember, or ski d pl ate.
Ti ghten crossmember bol ts to 41 Nm (30 ft. l bs.)
torque.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(3) Loosen adjusti ng trunni on l ocknut and sl i de
shi ft rod out of trunni on (Fi g. 5). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
torque shaft.
(5) Remove consol e. Refer to Group 23, Body, for
proper procedures.
Fig. 4 Transfer Case Mounting
1 VENT TUBE
2 TRANSFER CASE
3 TRANSMISSION
(6) Remove screws attachi ng l ever assembl y to
fl oorpan and remove assembl y and shi ft rod (i f l eft
attached).
INSTALLATION
(1) I f shi ft rod was not removed from l ever assem-
bl y, work rod down through fl oorpan openi ng. Then
posi ti on l ever assembl y on fl oorpan and i nstal l
assembl y attachi ng screws.
(2) I nstal l consol e. Refer to Group 23, Body, for
proper procedures.
(4) Connect trunni on to torque shaft arm. Or, sl i de
shi ft rod i nto trunni on on range l ever. Be sure shi ft
rod sl i des freel y i n trunni on.
(5) Veri fy that range l ever i s i n 4L posi ti on. Then
ti ghten trunni on l ock bol t.
(6) Lower vehi cl e and check transfer case shi ft
operati on.
SPEEDOMETER
REMOVAL
as an assembl y.
Repl ace pi ni on i f chi pped, cracked, or worn.
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
1 RIVNUT (4)
3 FLOORPAN
5 SELECTOR ROD AND TRUNNION
6 SHIFT LEVER ROD
7 TORQUE SHAFT FRAME BRACKET
8 TORQUE SHAFT
9 TRANSFER CASE SHIFT LEVER
10 TORQUE SHAFT TRANSFER CASE BRACKET
TORQUE
A 3-4 Nm (27-35 in. lbs.)
B 11-14 Nm (97-123 in. lbs.)
C 8-14 Nm (72-120 in. lbs.)
INSTALLATION AND INDEXING
ati on.
ometer adapter (Fi g. 6), i f necessary.
pi ni on.
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
i n. l bs.) torque.
l evel i f necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
Fig. 6 Speedometer Components
1 SENSOR O-RING
3 ADAPTER O-RING
5 ADAPTER CLAMP
ITEM TORQUE
A 2-3 Nm (15-27 in. lbs.)
B 10-12 Nm (90-110 in. lbs.)
Fig. 7 Location Of Index Numbers On Speedometer
Adapter
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
8).
INSTALLATION
I nstal l er Tool 6952-A as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
mer (Fi g. 9). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
NV242 TRANSFER CASE
DISASSEMBLY
REAR RETAINER REMOVAL
(1) Remove output shaft boot. Spread band cl amp
that secures boot on sl i nger wi th a sui tabl e awl .
Then sl i de boot off shaft (Fi g. 10).
(2) Usi ng pul l er MD-998056-A, remove rear sl i nger
(Fi g. 11).
1 OUTPUT SHAFT SEAL
2 PRYBAR
1 INSTALLER 6952A
2 TRANSFER CASE
Fig. 10 Output BootTypical
1 SLINGER
2 BOOT
3 AWL
4 TRANSFER CASE
Fig. 11 Rear Slinger Removal
1 TRANSFER CASE
2 SPECIAL TOOL MD998056A
3 SLINGER
(3) Remove rear seal from retai ner (Fi g. 12). Use
pry tool , or col l apse seal wi th punch to remove i t.
(4) Remove rear output beari ng I . D. retai ni ng
ri ng (Fi g. 13).
(5) Remove speedometer adapter.
(6) Remove rear retai ner bol ts.
(7) Remove rear retai ner. Tap retai ner wi th mal l et
and pry upward to break seal er bead. Then sl i de
retai ner off case and output shaft (Fi g. 14).
(8) Remove rear beari ng O. D. retai ni ng ri ng wi th
snap ri ng pl i ers. Then ti l t pump and sl i de i t off out-
put shaft (Fi g. 15)
(9) Remove pi ckup tube O-ri ng from pump (Fi g.
16) but do not di sassembl e pump; i t i s not a repai r-
abl e part.
(10) Remove seal from oi l pump wi th pry tool .
(11) Remove bol ts attachi ng rear case to front case
(Fi g. 17). Note posi ti on of the two bl ack fi ni sh bol ts
Fig. 12 Rear Seal Removal
1 REAR RETAINER
2 OUTPUT SHAFT SEAL
Fig. 13 Rear Bearing I. D. Retaining Ring Removal
1 SNAP RING PLIERS
Fig. 14 Rear Retainer Removal
1 MAINSHAFT
2 REAR RETAINER
1 OIL PUMP
Fig. 16 Pickup Tube O-Ring Location
1 OIL PUMP
2 O-RING
at each end of the case. These bol ts go through the
case dowel s and requi re a washer under the bol t
head.
(12) Remove rear case from front case (Fi g. 18).
I nsert screwdri vers i nto sl ots cast i nto each end of
case. Then pry upward to break seal er bead and
remove rear case.
CAUTION: Do not pry on the sealing surface of
either case half as the surfaces will become dam-
aged.
(13) Remove oi l pi ckup tube and screen from rear
case (Fi g. 19).
YOKE AND RANGE LEVER REMOVAL
(1) Remove front yoke nut:
(a) Move range l ever to 4L posi ti on.
(b) Remove nut wi th socket and i mpact wrench
(Fi g. 20).
(2) Remove yoke. I f yoke i s di ffi cul t to remove by
hand, remove i t wi th beari ng spl i tter, or wi th stan-
dard two jaw pul l er (Fi g. 21). Be sure pul l er tool i s
posi ti oned on yoke and not on sl i nger as sl i nger wi l l
be damaged.
Fig. 17 Spline And Dowel Bolt Locations
1 DOWEL BOLT AND WASHER (2)
2 CASE BOLT (5)
3 SPLINE HEAD BOLT (1)
Fig. 18 Loosening/Removing Rear case
1 MAINSHAFT
2 SCREWDRIVER
3 FRONT CASE
4 SCREWDRIVER
5 REAR CASE
Fig. 19 Oil Pickup Screen, Hose And Tube Removal
1 CONNECTING HOSE
2 PICKUP SCREEN
3 PICKUP TUBE
Fig. 20 Yoke Nut Removal
1 IMPACT WRENCH
2 SOCKET
3 YOKE
(3) Remove seal washer from front output shaft.
Di scard washer as i t shoul d not be reused.
(4) Remove nut and washer that attach range
l ever to sector shaft. Then move sector to neutral
posi ti on and remove range l ever from shaft (Fi g. 22).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Remove dri ve sprocket snap-ri ng (Fi g. 23).
(2) Remove dri ve sprocket and chai n (Fi g. 24).
(3) Remove front output shaft (Fi g. 25).
SHIFT FORKS AND MAINSHAFT REMOVAL AND
DISASSEMBLY
(1) Remove shi ft detent pl ug, spri ng and pi n (Fi g.
26).
(2) Remove seal pl ug from l ow range fork l ockpi n
access hol e. Then move shi ft sector to al i gn l ow range
fork l ockpi n wi th access hol e.
(3) Remove range fork l ockpi n wi th si ze number
one easy-out tool as fol l ows:
(a) I nsert easy-out tool through access hol e i n
si de of transfer case and i nto l ock-pi n.
(b) Tap easy-out tool i nto l ock-pi n wi th hammer
unti l tool i s securel y engaged i nto the l ock-pi n.
1 PULLER TOOL
2 YOKE
Fig. 22 Range Lever Removal
1 RANGE LEVER
2 SECTOR SHAFT
Fig. 23 Drive Sprocket Snap-Ring Removal
1 DRIVE SPROCKET
2 DRIVE SPROCKET SNAP RING
Fig. 24 Drive Sprocket And Chain Removal
1 DRIVE SPROCKET
2 DRIVE CHAIN
(c) I nstal l a t-handl e, such as from a tap and di e
set, onto the easy-out tool .
(d) Securel y ti ghten the t-handl e onto the tool .
(e) I n one moti on, pul l upward and turn the
t-handl e counter-cl ockwi se to remove the l ock-pi n.
(4) Remove shi ft rai l by pul l i ng i t strai ght up and
out of fork (Fi g. 27).
(5) Remove mode fork and mai nshaft as assembl y
(Fi g. 28).
(6) Remove mode shi ft sl eeve and mode fork
assembl y from mai nshaft (Fi g. 29). Note posi ti on of
mode sl eeve i n fork and remove sl eeve.
Fig. 25 Removing Front Output Shaft
Fig. 26 Detent Component Removal
1 PLUNGER
2 O-RING
3 PLUG
4 SPRING
Fig. 27 Shift Rail Removal
1 SHIFT RAIL
2 MODE FORK
Fig. 28 Mode Fork And Mainshaft Removal
1 MAINSHAFT ASSEMBLY
2 MODE FORK
(7) Remove i ntermedi ate cl utch shaft snap-ri ng
(Fi g. 30).
(8) Remove cl utch shaft thrust ri ng (Fi g. 31).
(9) Remove i ntermedi ate cl utch shaft (Fi g. 32).
Fig. 29 Mode Fork And Sleeve Removal
1 MAINSHAFT
2 SLEEVE
3 MODE FORK ASSEMBLY
Fig. 30 Intermediate Clutch Shaft Snap-Ring
Removal
1 SNAP RING
2 INTERMEDIATE CLUTCH SHAFT
Fig. 31 Clutch Shaft Thrust Ring Removal
1 CLUTCH SHAFT THRUST RING
(10) Remove di fferenti al snap-ri ng (Fi g. 33).
(11) Remove di fferenti al (Fi g. 34).
(12) Remove di fferenti al needl e beari ngs and both
needl e beari ng thrust washers from mai nshaft.
(13) Sl i de l ow range fork pi n out of shi ft sector sl ot
(Fi g. 35).
(14) Remove l ow range fork and hub (Fi g. 36).
(15) Remove shi ft sector (Fi g. 37).
Fig. 32 Intermediate Clutch Shaft Removal
Fig. 33 Differential Snap-Ring Removal
1 DIFFERENTIAL SNAP RING
Fig. 34 Differential Removal
1 DIFFERENTIAL
2 MAINSHAFT
Fig. 35 Disengaging Low Range Fork
1 SHIFT SECTOR
2 LOW RANGE FORK
3 PIN
4 SLOT
(16) Remove shi ft sector bushi ng and O-ri ng (Fi g.
38).
INPUT GEAR/LOW RANGE ASSEMBLY REMOVAL AND
DISASSEMBLY
(1) Remove front beari ng retai ner bol ts.
(2) Remove front beari ng retai ner. Careful l y pry
retai ner l oose wi th screwdri ver (Fi g. 39). Posi ti on
screwdri ver i n sl ots cast i nto retai ner.
(3) Remove i nput gear snap-ri ng (Fi g. 40).
Fig. 36 Low Range Fork And Hub Removal
1 LOW RANGE FORK
2 FORK HUB
Fig. 37 Shift Sector Position
1 SHIFT SECTOR
2 LOW RANGE FORK
3 PIN
4 SLOT
Fig. 38 Sector Bushing And O-Ring Removal
1 SHIFT SECTOR BUSHING
2 O-RING
Fig. 39 Front Bearing Retainer Removal
2 RETAINER SLOT
(4) Remove i nput/l ow range gear assembl y from
beari ng wi th Tool Handl e C-4171 and Tool 7829A
(Fi g. 41).
(5) Remove l ow range gear snap-ri ng (Fi g. 42).
(6) Remove i nput gear retai ner, thrust washers
and i nput gear from l ow range gear (Fi g. 43).
(7) I nspect l ow range annul us gear (Fi g. 44). Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oi l seal s from fol l owi ng components:
front beari ng retai ner.
rear retai ner.
oi l pump.
case hal ves.
Fig. 40 Input Gear Snap-Ring Removal
1 INPUT GEAR
2 SNAP RING
Fig. 41 Input And Low Range Gear Assembly
Removal
1 INPUT-LOW RANGE GEARS
Fig. 42 Low Range Gear Snap-Ring Removal/
Installation
1 LOW RANGE GEAR SNAP RING
Fig. 43 Low Range Gear Disassembly
1 THRUST WASHERS
2 LOW RANGE GEAR
3 INPUT GEAR
4 RETAINER
DIFFERENTIAL DISASSEMBLY
(1) Mark di fferenti al case hal ves for reference.
(2) Remove di fferenti al case bol ts.
(3) I nvert di fferenti al on workbench.
(4) Separate top case from bottom case. Use sl ots
i n case hal ves to pry them apart (Fi g. 45).
(5) Remove thrust washers and pl anet gears from
case pi ns (Fi g. 46).
(6) Remove mai nshaft and sprocket gears from
bottom case (Fi g. 47). Note gear posi ti on for reference
before separati ng them.
ASSEMBLY
Lubri cate transfer case components wi th automati c
transmi ssi on fl ui d or petrol eum jel l y (where i ndi -
cated) duri ng assembl y.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
Fig. 45 Separating Differential Case Halves
1 TOP CASE
2 CASE BOLTS
3 CASE BOLTS
4 CASE SLOTS
5 CASE BOLTS
Fig. 44 Inspecting Low Range Annulus Gear
Fig. 46 Planet Gears And Thrust Washer Removal
1 BOTTOM CASE
2 THRUST WASHERS (12)
3 PLANET GEARS (6)
BEARING AND SEAL INSTALLATION
(1) Remove snap-ri ng that retai ns front output
shaft front beari ng i n case (Fi g. 48). Then remove
beari ng. Use hammer handl e, or hammer and brass
punch to tap beari ng out of case.
(2) I nstal l new front output shaft front beari ng
wi th Tool Handl e C-4171 and I nstal l er 8033A wi th
the tapered cone upward (Fi g. 49).
(3) I nstal l front beari ng snap-ri ng (Fi g. 48).
(4) Remove front output shaft seal usi ng an appro-
pri ate pry tool (Fi g. 50) or sl i de-hammer mounted
screw.
(5) I nstal l new front output shaft oi l seal wi th
I nstal l er 6952-A (Fi g. 51).
Fig. 48 Front Output Shaft Front Bearing Snap-Ring
Removal
1 FRONT BEARING SNAP RING
Fig. 47 Mainshaft And Sprocket Gear Removal
1 MAINSHAFT GEAR
2 SPROCKET GEAR
3 BOTTOM CASE
Fig. 49 Front Output Shaft Front Bearing Installation
1 OUTPUT SHAFT SEAL
2 PRYBAR
(6) Remove i nput gear beari ng wi th Tool Handl e
C-4171 and Remover C-4210 (Fi g. 52).
(7) I nstal l snap-ri ng on new i nput gear beari ng.
(8) I nstal l new i nput gear beari ng wi th Tool Han-
dl e C-4171 and Remover C-4210. I nstal l beari ng far
enough to seat snap-ri ng agai nst case (Fi g. 53).
(9) Remove the i nput gear pi l ot beari ng by i nsert-
i ng a sui tabl y si zed dri ft i nto the spl i ned end of the
i nput gear and dri vi ng the beari ng out wi th the dri ft
and a hammer (Fi g. 54).
(10) I nstal l new pi l ot beari ng wi th I nstal l er 8128
(11) I nstal l new seal i n front beari ng retai ner wi th
(12) Remove output shaft rear beari ng wi th the
screw and jaws from Remover L-4454 and Cup 8148
(Fi g. 57).
Fig. 51 Install Front Output Shaft Seal
1 INSTALLER 6952A
2 TRANSFER CASE
Fig. 52 Input Gear Bearing Removal
Fig. 53 Seating Input Gear Bearing
1 SNAP RING
Fig. 54 Remove Input Gear Pilot Bearing
1 DRIFT
2 INPUT GEAR
(13) I nstal l new beari ng wi th Tool Handl e C-4171
and I nstal l er 5066 (Fi g. 58). Lubri cate beari ng after
i nstal l ati on.
(14) I nstal l new seal i n oi l pump feed housi ng wi th
Speci al Tool 7888 (Fi g. 59).
Fig. 55 Install Input Gear Pilot Bearing
1 HANDLE C-4171
2 INSTALLER 8128
3 INPUT GEAR
Fig. 56 Front Bearing Retainer Seal Installation
2 SPECIAL TOOL 7884
Fig. 57 Remove Front Output Shaft Rear Bearing
1 REAR CASE
2 SPECIAL TOOL L-44541 AND L-44543
3 SPECIAL TOOL 8148
Fig. 58 Install Front Output Shaft Rear Bearing
1 HANDLE C-4171
2 OUTPUT SHAFT INNER BEARING
3 INSTALLER 5066
(15) I nstal l new pi ckup tube O-ri ng i n oi l pump
(Fi g. 60).
DIFFERENTIAL ASSEMBLY
(1) Lubri cate di fferenti al components wi th auto-
mati c transmi ssi on fl ui d.
(2) I nstal l sprocket gear i n di fferenti al bottom case
(Fi g. 61).
(3) I nstal l di fferenti al pl anet gears and new thrust
washers (Fi g. 62). Be sure thrust washers are
installed at top and bottom of each planet gear.
(4) I nstal l di fferenti al mai nshaft gear (Fi g. 62).
(5) Al i gn and posi ti on di fferenti al top case on bot-
tom case (Fi g. 63). Al i gn usi ng scri be marks made at
di sassembl y.
(6) Whi l e hol di ng di fferenti al case hal ves together,
i nvert the di fferenti al and start the di fferenti al case
bol ts.
(7) Ti ghten di fferenti al case bol ts to speci fi ed
torque.
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assembl e l ow range gear, i nput gear thrust
washers, i nput gear and i nput gear retai ner (Fi g. 64).
(2) I nstal l l ow range gear snap ri ng (Fi g. 65).
Fig. 59 Oil Pump Seal Installation
1 HOUSING SEAL
2 SPECIAL TOOL 7888
3 OIL PUMP FEED HOUSING
Fig. 60 Pickup Tube O-Ring Installation
1 PICKUP TUBE O-RING
Fig. 61 Installing Differential Sprocket Gear
1 SPROCKET GEAR
2 BOTTOM CASE
Fig. 62 Installing Mainshaft And Planet Gears
1 MAINSHAFT GEAR
2 THRUST WASHERS (12)
3 PLANET GEARS (6)
Fig. 63 Differential Case Assembly
1 TOP CASE
2 BOTTOM CASE
3 CASE ALIGNMENT MARKS
Fig. 64 Low Range And Input Gear Assembly
1 THRUST WASHERS
2 LOW RANGE GEAR
3 INPUT GEAR
4 RETAINER
Fig. 65 Install Low Range Gear Snap Ring
1 LOW RANGE GEAR SNAP RING
(3) Lubri cate i nput gear and l ow range gears wi th
automati c transmi ssi on fl ui d.
(4) Start i nput gear shaft i nto front case beari ng.
(5) Press i nput gear shaft i nto front beari ng.
(6) I nstal l new i nput gear snap ri ng (Fi g. 66).
ket maker or si l i cone adhesi ve seal er to seal surface
of front beari ng retai ner.
(8) I nstal l front beari ng retai ner (Fi g. 67). Ti ghten
retai ner bol ts to 16 ft. l bs. (21 Nm) torque.
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) I nstal l new sector shaft O-ri ng and bushi ng
(Fi g. 68).
(2) I nstal l shi ft sector.
(3) I nstal l new pads on l ow range fork, i f neces-
sary, (Fi g. 69).
(4) Assembl e l ow range fork and hub (Fi g. 69).
Fig. 67 Installing Front Bearing Retainer
Fig. 69 Assembling Low Range Fork And Hub
1 LOW RANGE FORK
2 PADS
3 HUB
Fig. 66 Input Gear Snap Ring Installation
1 INPUT GEAR
2 SNAP RING
Fig. 68 Sector O-Ring And Bushing Installation
1 SECTOR BUSHING
2 O-RING
(5) Posi ti on l ow range fork and hub i n case. Be
sure l ow range fork pi n i s engaged i n shi ft sector sl ot
(Fi g. 70).
(6) I nstal l fi rst mai nshaft beari ng spacer on mai n-
shaft (Fi g. 71).
(7) I nstal l beari ng rol l ers on mai nshaft (Fi g. 71).
Coat bearing rollers with generous quantity of
petroleum jelly to hold them in place.
(8) I nstal l remai ni ng beari ng spacer on mai nshaft
(Fi g. 71). Do not di spl ace any beari ngs whi l e i nstal l -
i ng spacer.
(9) I nstal l di fferenti al (Fi g. 72). Do not displace
mainshaft bearings when installing differential.
(10) I nstal l di fferenti al snap-ri ng (Fi g. 73).
(11) I nstal l i ntermedi ate cl utch shaft (Fi g. 74).
(12) I nstal l cl utch shaft thrust washer (Fi g. 75).
(13) I nstal l cl utch shaft snap-ri ng (Fi g. 76).
(14) I nspect mode fork assembl y (Fi g. 77). Repl ace
pads and bushi ng i f necessary. Repl ace fork tube i f
bushi ngs i nsi de tube are worn or damaged. Al so
check spri ngs and sl i der bracket (Fi g. 77). Repl ace
worn, damaged components.
Fig. 70 Positioning Low Range Fork
1 SHIFT SECTOR
2 LOW RANGE FORK
3 PIN
4 SLOT
Fig. 71 Installing Mainshaft Bearing Rollers and
Spacers
1 MAINSHAFT BEARING ROLLERS
2 BEARING SPACERS
Fig. 72 Differential Installation
1 DIFFERENTIAL
2 MAINSHAFT
Fig. 73 Installing Differential Snap-Ring
1 DIFFERENTIAL SNAP RING
Fig. 74 Installing 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
(15) I nstal l mode sl eeve i n mode fork (Fi g. 78).
Then i nstal l assembl ed sl eeve and fork on mai nshaft.
Be sure mode sl eeve spl i nes are engaged i n di fferen-
ti al spl i nes.
(16) I nstal l mode fork and mai nshaft assembl y i n
case (Fi g. 79). Rotate mai nshaft sl i ghtl y to engage
shaft wi th l ow range gears.
(17) Rotate mode fork pi n i nto shi ft sector sl ot.
(18) I nstal l shi ft rai l (Fi g. 80). Be sure rail is
seated in both shift forks.
(19) Rotate shi ft sector to al i gn l ockpi n hol e i n l ow
range fork wi th access hol e i n case.
(20) I nsert an easy-out i n range fork l ockpi n to
hol d i t securel y for i nstal l ati on (Fi g. 81). Lockpin is
slightly tapered on one end. Insert tapered end
into fork and rail.
(21) I nsert l ockpi n through access hol e and i nto
shi ft fork (Fi g. 81). Then remove easy-out and seat
the pi n wi th pi n punch.
(22) I nstal l pl ug i n l ockpi n access hol e.
(23) I nstal l detent pl unger, detent spri ng and
detent pl ug i n case (Fi g. 82).
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) I nstal l front output shaft (Fi g. 83).
(2) I nstal l dri ve chai n (Fi g. 83). Engage chai n wi th
front output shaft sprocket teeth.
(3) I nstal l dri ve sprocket (Fi g. 83). Engage dri ve
sprocket teeth wi th chai n. Then engage sprocket
spl i nes wi th mai nshaft spl i nes.
Fig. 77 Mode Fork Assembly Inspection
1 SLIDER
2 MODE FORK
3 BUSHING/SPRING
4 TUBE
5 PADS
Fig. 78 Installing Mode Fork And Sleeve
1 MAINSHAFT
2 SLEEVE
3 MODE FORK ASSEMBLY
Fig. 79 Assembled Mainshaft And Mode Fork
Installation
1 MAINSHAFT ASSEMBLY
2 MODE FORK
Fig. 80 Shift Rail Installation
1 SHIFT RAIL
2 MODE FORK
Fig. 81 Installing Low Range Fork Lockpin
1 LOW RANGE FORK LOCK PIN
2 ACCESS HOLE
3 EASY-OUT
Fig. 82 Detent Pin, Spring And Plug Installation
1 PLUNGER
2 O-RING
3 PLUG
4 SPRING
(4) I nstal l dri ve sprocket snap-ri ng (Fi g. 84).
OIL PUMP AND REAR CASE INSTALLATION
(1) I nsert oi l pi ckup tube i n oi l pump and attach
oi l screen and connector hose to pi ckup tube. Then
i nstal l assembl ed pump, tube and screen i n rear case
(Fi g. 85). Be sure screen i s seated i n case sl ot as
shown.
(2) I nstal l magnet i n front case pocket (Fi g. 86).
Fig. 83 Drive Chain And Sprocket Installation
2 DRIVE CHAIN
3 DRIVE SPROCKET
Fig. 84 Drive Sprocket Snap-Ring Installation
1 DRIVE SPROCKET
2 DRIVE SPROCKET SNAP RING
Fig. 85 Oil Screen And Pickup Tube Installation
1 OIL PUMP
2 OIL SCREEN
3 CONNECTOR
4 PICKUP TUBE
Fig. 86 Installing Case Magnet
1 MAGNET
ket maker or si l i cone adhesi ve seal er to seal surface
of front case.
(4) Al i gn and i nstal l rear case on front case. Be
sure case l ocati ng dowel s are i n pl ace and that mai n-
shaft spl i nes are engaged i n oi l pump i nner gear.
(5) I nstal l and ti ghten front case-to-rear case bol ts
to 41 Nm (30 ft. l bs.) torque. Be sure to install a
washer under each bolt used at case dowel
locations.
REAR RETAINER INSTALLATION
(1) Remove rear beari ng i n retai ner usi ng I nstal l er
8128 and Handl e C-4171.
(2) I nstal l rear beari ng i n retai ner wi th Tool s
C-4171 and 5064 (Fi g. 87).
(3) I nstal l rear beari ng O. D. retai ni ng ri ng wi th
snap-ri ng pl i ers (Fi g. 88). Be sure retai ni ng ri ng i s
ful l y seated i n retai ner groove.
(4) Appl y bead of Mopar Seal er P/N 82300234, or
Locti te Ul tra Gray, to mati ng surface of rear
retai ner. Seal er bead shoul d be a maxi mum of 3/16
i n.
(5) I nstal l rear retai ner on rear case. Ti ghten
retai ner bol ts to 2027 Nm (1520 ft. l bs.) torque.
(6) I nstal l rear beari ng I . D. retai ni ng ri ng and
spacer on output shaft.
(7) Appl y l i beral quanti ty of petrol eum jel l y to new
rear seal and to output shaft. Petrol eum jel l y i s
needed to protect seal l i ps duri ng i nstal l ati on.
(8) Sl i de seal onto Seal Protector 6992 (Fi g. 89).
Sl i de seal protector and seal onto output shaft.
(9) Sl i de I nstal l er C-4076-B onto seal protector
wi th the recessed si de of the tool toward the seal .
Dri ve seal i nto rear beari ng retai ner wi th I nstal l er
C-4076-B and Handl e MD-998323 (Fi g. 90).
(10) I nstal l rear sl i nger wi th I nstal l er 8408.
(11) I nstal l boot on output shaft sl i nger and cri mp
retai ni ng cl amp wi th tool C-4975-A (Fi g. 91).
FRONT YOKE AND SWITCH INSTALLATION
(1) I nstal l i ndi cator swi tch i n front case. Ti ghten
swi tch to 2034 Nm (1525 ft. l bs.) torque.
(2) Lubri cate yoke hub wi th transmi ssi on fl ui d and
i nstal l yoke on front shaft.
(3) I nstal l new seal washer on front shaft.
(4) I nstal l yoke on front shaft. Secure yoke wi th
new nut.
Fig. 87 Installing Rear Bearing In Retainer
2 SPECIAL TOOL 5064
3 REAR RETAINER
Fig. 88 Rear Bearing Retaining Ring Installation
2 SNAP RING PLIERS
Fig. 89 Output Shaft Seal and Protector
1 OUTPUT SHAFT SEAL
2 SPECIAL TOOL 6992
3 TRANSFER CASE
NV242 TRANSFER CASE
Cl ean the transfer case parts wi th a standard
parts cl eani ng sol vent. Remove al l traces of seal er
from the cases and retai ners wi th a scraper and al l
purpose cl eaner. Use compressed ai r to remove sol -
vent resi due from oi l feed passages i n the case
hal ves, retai ners, gears, and shafts.
The oi l pi ckup screen can be cl eaned wi th sol vent.
Shake excess sol vent from the screen after cl eani ng
and al l ow i t to ai r dry. Do not use compressed ai r.
MAINSHAFT/SPROCKET/HUB INSPECTION
I nspect the spl i nes on the hub and shaft and the
teeth on the sprocket. Mi nor ni cks and scratches can
be smoothed wi th an oi l stone. However, repl ace any
part i s damaged.
Check the contact surfaces i n the sprocket bore
and on the mai nshaft. Mi nor ni cks and scratches can
be smoothed wi th 320400 gri t emery cl oth but do
not try to sal vage the shaft i f ni cks or wear i s severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fi g. 92). Mi nor ni cks
can be dressed off wi th an oi l stone but repl ace the
gear i f any teeth are broken, cracked, or chi pped. The
beari ng surface on the gear can be smoothed wi th
300400 gri t emery cl oth i f necessary.
Exami ne the carri er body and pi ni on gears for
wear or damage. The carri er wi l l have to be repl aced
as an assembl y i f the body, pi ni on pi ns, or pi ni on
gears are damaged.
Check the l ock ri ng and both thrust washers for
wear or cracks. Repl ace them i f necessary. Al so
repl ace the l ock retai ni ng ri ng i f bent, di storted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condi ti on of the shi ft forks and mode fork
shi ft rai l (Fi g. 93). Mi nor ni cks on the shi ft rai l can
be smoothed wi th 320400 gri t emery cl oth.
I nspect the shi ft fork wear pads. The mode fork
pads are servi ceabl e and can be repl aced i f necessary.
The range fork pads are al so servi ceabl e.
Check both of the sl eeves for wear or damage,
especi al l y on the i nteri or teeth. Repl ace the sl eeves i f
wear or damage i s evi dent.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
I nspect the retai ner components (Fi g. 94). Repl ace
the beari ng i f rough or noi sy. Check the retai ner for
cracks or wear i n the beari ng bore. Cl ean the
retai ner seal i ng surfaces wi th a scraper and al l pur-
pose cl eaner. Thi s wi l l ensure proper adhesi on of the
seal er duri ng reassembl y.
Repl ace the sl i nger and seal outri ght; do not reuse
ei ther part.
I nspect the retai ni ng ri ngs and washers. Repl ace
any part i f di storted, bent, or broken. Reuse i s not
recommended. Al so repl ace the boot i f cut or torn.
Repl ace the boot band cl amps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condi ti on of the seal contact surfaces of the
yoke sl i nger (Fi g. 95). Thi s surface must be cl ean and
smooth to ensure proper seal l i fe. Repl ace the yoke
nut and seal washer as nei ther part shoul d be
reused.
Fig. 91 Slinger Boot Installation
2 SLINGER
3 BOOT
4 CLAMP
Fig. 90 Rear Seal Installation
2 SPECIAL TOOL MD998323
3 TRANSFER CASE
I nspect the shaft threads, sprocket teeth, and bear-
i ng surfaces. Mi nor ni cks on the teeth can be
smoothed wi th an oi l stone. Use 320400 gri t emery
to smooth mi nor scratches on the shaft beari ng sur-
faces. Rough threads on the shaft can be chased i f
necessary. Repl ace the shaft i f the threads are dam-
aged, beari ng surfaces are scored, or i f any sprocket
teeth are cracked or broken.
Exami ne the dri ve chai n and shaft beari ngs.
Repl ace the chai n and both sprockets i f the chai n i s
stretched, di storted, or i f any of the l i nks bi nd.
Repl ace the beari ngs i f rough, or noi sy.
LOW RANGE ANNULUS GEAR
I nspect annul us gear condi ti on careful l y. The gear
i s onl y servi ced as part of the front case. I f the gear
i s damaged, i t wi l l be necessary to repl ace the gear
and front case as an assembl y. Do not attempt to
remove the gear (Fi g. 96).
FRONT-REAR CASES AND FRONT RETAINER
I nspect the cases and retai ner for wear and dam-
age. Cl ean the seal i ng surfaces wi th a scraper and al l
purpose cl eaner. Thi s wi l l ensure proper seal er adhe-
si on at assembl y. Repl ace the i nput retai ner seal ; do
not reuse i t.
Check case condi ti on. I f l eaks were a probl em, l ook
for gouges and severe scori ng of case seal i ng sur-
faces. Al so make sure the front case mounti ng studs
are i n good condi ti on.
Check the front case mounti ng studs and vent
tube. The tube can be secured wi th Locti te 271 or
680 i f l oose. The stud threads can be cl eaned up wi th
a di e i f necessary. Al so check condi ti on of the fi l l /
drai n pl ug threads i n the rear case. The threads can
be repai red wi th a thread chaser or tap i f necessary.
Or the threads can be repai red wi th Hel i coi l stai nl ess
steel i nserts i f requi red.
Fig. 92 Input Gear And Carrier Components
1 PLANETARY CARRIER
4 CARRIER LOCK RING
6 INPUT GEAR
Fig. 93 Shift forks
1 RANGE FORK
3 MODE SPRING
Fig. 94 Rear Retainer Components
1 REAR RETAINER
3 REAR SEAL
4 BOOT
5 BAND CLAMPS
6 REAR SLINGER
8 REAR BEARING
Fig. 95 Seal Contact Surface Of Yoke Slinger
1 FRONT SLINGER (PART OF YOKE)
2 SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 96 Low Range Annulus Gear
1 FRONT CASE
OIL PUMP/OIL PICKUP
Exami ne the oi l pump pi ckup parts. Repl ace the
pump i f any part appears to be worn or damaged. Do
not di sassembl e the pump as i ndi vi dual parts are not
avai l abl e. The pump i s onl y avai l abl e as a compl ete
assembl y. The pi ckup screen, hose, and tube are the
onl y servi ceabl e parts and are avai l abl e separatel y.
ADJ USTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shi ft transfer case i nto 4L posi ti on.
(3) Loosen l ock bol t on adjusti ng trunni on (Fi g.
97).
(4) Be sure l i nkage rod sl i des freel y i n trunni on.
Cl ean rod and appl y spray l ube i f necessary.
(5) Veri fy that transfer case range l ever i s ful l y
engaged i n 4L posi ti on.
(6) Ti ghten adjusti ng trunni on l ock bol t.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Detent . . . . . . . . . . 1624 Nm (1218 ft. l bs.)
Bol t, Di ff. Case . . . . . . . . 1727 Nm (1524 ft. l bs.)
Pl ug, Drai n/Fi l l . . . . . . . 2025 Nm (1525 ft. l bs.)
Bol t, Front Brg. Retai ner . . . . . . . . . . . . 1627 Nm
(1220 ft. l bs.)
Bol t, Case Hal f . . . . . . . . 3546 Nm (2634 ft. l bs.)
Nut, Front Yoke . . . . 122176 Nm (90130 ft. l bs.)
Screw, Oi l Pump . . . . . 1.21.8 Nm (1215 i n. l bs.)
Nut, Range Lever . . . . . . 2734 Nm (2025 ft. l bs.)
Bol t, Rear Retai ner . . . . 3546 Nm (2634 ft. l bs.)
Nuts, Mounti ng . . . . . . . . . . . . . 35 Nm (26 ft. l bs.)
Bol ts, U-Joi nt . . . . . . . . . . . . . . 19 Nm (17 ft. l bs.)
1 TRANSFER CASE SHIFT LEVER SHAFT
2 SEAL
3 TRANSFER CASE SHIFT LEVER ASSEMBLY
4 FLOORPAN
6 SHIFT ROD
7 ADJUSTING TRUNNION
8 TORQUE SHAFT BRACKET
9 RANGE LEVER
10 TORQUE SHAFT ROD
11 TORQUE SHAFT
12 LINKAGE BRACKET
SPECIAL TOOLS
NV242
InstallerC-4076-B
Handle, UniversalC-4171
RemoverC-4210
Puller, SlingerMD-998056A
InstallerMD-998323
Installer8128
Installer5066
Installer6952-A
RemoverL-4454
Cup8148
Seal Protector6992
Installer, Input Gear Bearing7829-A
Installer, Seal7884
Installer, Pump Housing Seal7888
Installer, Bearing8033-A
Installer, Boot ClampC-4975-A
TIRES AND WHEELS
TABLE OF CONTENTS
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TIRES
TABLE OF CONTENTS
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . . . . . 2
SPARE TIRETEMPORARY . . . . . . . . . . . . . . . . . . 2
TIRE INFLATION PRESSURES . . . . . . . . . . . . . . . 2
TIRE PRESSURE FOR HIGH SPEED. . . . . . . . . . . 3
REPLACEMENT TIRES . . . . . . . . . . . . . . . . . . . . . 3
PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . . . 3
TREAD WEAR INDICATORS . . . . . . . . . . . . . . . . . 3
TIRE WEAR PATTERNS. . . . . . . . . . . . . . . . . . . . . 3
TIRE NOISE OR VIBRATION . . . . . . . . . . . . . . . . . 3
SERVICE PROCEDURES
ROTATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MATCH MOUNTING. . . . . . . . . . . . . . . . . . . . . . . . 4
REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 5
CLEANING TIRES . . . . . . . . . . . . . . . . . . . . . . . . . 6
SPECIFICATIONS
TIRE SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TIRES
DESCRIPTION
Ti res are desi gned and engi neered for each speci fi c
vehi cl e. They provi de the best overal l performance
for normal operati on. The ri de and handl i ng charac-
teri sti cs match the vehi cl es requi rements. Wi th
proper care they wi l l gi ve excel l ent rel i abi l i ty, trac-
ti on, ski d resi stance, and tread l i fe.
Dri vi ng habi ts have more effect on ti re l i fe than
any other factor. Careful dri vers wi l l obtai n i n most
cases, much greater mi l eage than severe use or care-
l ess dri vers. A few of the dri vi ng habi ts whi ch wi l l
shorten the l i fe of any ti re are:
Rapi d accel erati on
Severe brake appl i cati ons
Hi gh speed dri vi ng
Excessi ve speeds on turns
Stri ki ng curbs and other obstacl es
Radi al -pl y ti res are more prone to i rregul ar tread
wear. I t i s i mportant to fol l ow the ti re rotati on i nter-
val shown i n the secti on on Ti re Rotati on. Thi s wi l l
hel p to achi eve a greater tread l i fe.
TIRE IDENTIFICATION
Ti re type, si ze, aspect rati o and speed rati ng are
encoded i n the l etters and numbers i mpri nted on the
si de wal l of the ti re. Refer to the chart to deci pher
the ti re i denti fi cati on code (Fi g. 1).
Performance ti res have a speed rati ng l etter after
the aspect rati o number.
The speed rati ng i s not al ways pri nted on the ti re
si dewal l .
LETTER SPEED RATING
S 180 km/h (112 mph)
T 190 km/h (118 mph)
U 200 km/h (124 mph)
H 210 km/h (130 mph)
V 240 km/h (149 mph)
W 270 km/h (168 mph)
Y 300 km/h (186 mph)
XJ TIRES AND WHEELS 22 - 1
TIRE CHAINS
Ti re snow chai ns may be used on certain model s.
Refer to the Owners Manual for more i nformati on.
RADIAL-PLY TIRES
DESCRIPTION
Radi al -pl y ti res i mprove handl i ng, tread l i fe and
ri de qual i ty, and decrease rol l i ng resi stance.
Radi al -pl y ti res must al ways be used i n sets of
four. Under no ci rcumstances shoul d they be used on
the front onl y. They may be mi xed wi th temporary
spare ti res when necessary. A maxi mum speed of 50
MPH i s recommended whi l e a temporary spare i s i n
use.
Radi al -pl y ti res have the same l oad-carryi ng capac-
i ty as other types of ti res of the same si ze. They al so
use the same recommended i nfl ati on pressures.
The use of oversi zed ti res, ei ther i n the front or
rear of the vehi cl e, can cause vehi cl e dri ve trai n fai l -
ure. Thi s coul d al so cause i naccurate wheel speed
si gnal s when the vehi cl e i s equi pped wi th Anti -Lock
Brakes.
The use of ti res from di fferent manufactures on the
same vehi cl e i s NOT recommended. The proper ti re
pressure shoul d be mai ntai ned on al l four ti res.
SPARE TIRETEMPORARY
DESCRIPTION
The temporary spare ti re i s desi gned for emer-
gency use onl y. The ori gi nal ti re shoul d be repai red
or repl aced at the fi rst opportuni ty, then rei nstal l ed.
Do not exceed speeds of 50 M. P. H. when usi ng the
temporary spare ti re. Refer to Owners Manual for
compl ete detai l s.
TIRE INFLATION PRESSURES
Under i nfl ati on wi l l cause rapi d shoul der wear, ti re
fl exi ng, and possi bl e ti re fai l ure (Fi g. 2).
Over i nfl ati on wi l l cause rapi d center wear and
l oss of the ti res abi l i ty to cushi on shocks (Fi g. 3).
I mproper i nfl ati on can cause:
Uneven wear patterns
Fig. 1 Tire Identification
Fig. 2 Under Inflation Wear
1 THIN TIRE THREAD AREAS
Fig. 3 Over Inflation Wear
1 THIN TIRE THREAD AREA
22 - 2 TIRES AND WHEELS XJ
Reduced tread l i fe
Reduced fuel economy
Unsati sfactory ri de
Vehi cl e dri ft
For proper ti re pressure speci fi cati on refer to the
Ti re I nfl ati on Pressure Chart provi ded wi th the vehi -
cl e.
Ti re pressures have been chosen to provi de safe
operati on, vehi cl e stabi l i ty, and a smooth ri de. Ti re
pressure shoul d be checked col d once a month. The
spare ti re pressure shoul d be check at l east twi ce
annual l y. Ti re pressure decreases as the ambi ent
temperature drops. Check ti re pressure frequentl y
when ambi ent temperature vari es wi del y.
I nfl ati on pressures speci fi ed on the pl acards are
col d i nfl ati on pressure. The vehi cl e must si t for at
l east 3 hours to obtai n the correct col d i nfl ati on pres-
sure readi ng. Or dri ven l ess than one mi l e after si t-
ti ng for 3 hours. Ti re i nfl ati on pressures may
i ncrease from 2 to 6 pounds per square i nch (psi )
duri ng operati on, due to i ncreased ti re temperature.
WARNING: OVER OR UNDER INFLATED TIRES
CAN AFFECT VEHICLE HANDLING AND TREAD
WEAR. THIS MAY CAUSE THE TIRE TO FAIL SUD-
DENLY, RESULTING IN LOSS OF VEHICLE CON-
TROL.
TIRE PRESSURE FOR HIGH SPEED
DESCRIPTION
Where speed l i mi ts al l ow the vehi cl e to be dri ven
at hi gh speeds, correct ti re i nfl ati on pressure i s very
i mportant. For speeds up to and i ncl udi ng 120 km/h
(75 mph), ti res must be i nfl ated to the pressures
shown on the ti re pl acard. For conti nuous speeds i n
excess of 120 km/h (75 mph), ti res must be i nfl ated
to the maxi mum pressure speci fi ed on the ti re si de-
wal l .
Vehi cl es l oaded to the maxi mum capaci ty shoul d
not be dri ven at conti nuous speeds above 75 mph
(120 km/h).
For emergency vehi cl es that are dri ven at speeds
over 90 mph (144 km/h), speci al hi gh speed ti res
must be used. Consul t ti re manufacturer for correct
i nfl ati on pressure recommendati ons.
REPLACEMENT TIRES
DESCRIPTION
The ori gi nal equi pment ti res provi de a proper bal -
ance of many characteri sti cs such as:
Ri de
Noi se
Handl i ng
Durabi l i ty
Tread l i fe
Tracti on
Rol l i ng resi stance
Speed capabi l i ty
I t i s recommended that ti res equi val ent to the ori g-
i nal equi pment ti res be used when repl acement i s
needed.
Fai l ure to use equi val ent repl acement ti res may
adversel y affect the safety and handl i ng of the vehi -
cl e.
The use of oversi ze ti res may cause i nterference
wi th vehi cl e components. Under extremes of suspen-
si on and steeri ng travel , i nterference wi th vehi cl e
components may cause ti re damage.
WARNING: FAILURE TO EQUIP THE VEHICLE WITH
TIRES HAVING ADEQUATE SPEED CAPABILITY
CAN RESULT IN SUDDEN TIRE FAILURE.
PRESSURE GAUGES
A qual i ty ai r pressure gauge i s recommended to
check ti re pressure. After checki ng the ai r pressure,
repl ace val ve cap fi nger ti ght.
TREAD WEAR INDICATORS
Tread wear i ndi cators are mol ded i nto the bottom
of the tread grooves. When tread depth i s 1.6 mm
(1/16 i n.), the tread wear i ndi cators wi l l appear as a
13 mm (1/2 i n.) band (Fi g. 4).
Ti re repl acement i s necessary when i ndi cators
appear i n two or more grooves or i f l ocal i zed bal di ng
occurs.
TIRE WEAR PATTERNS
Under i nfl ati on wi l l cause wear on the shoul ders of
ti re. Over i nfl ati on wi l l cause wear at the center of
ti re.
Excessi ve camber causes the ti re to run at an
angl e to the road. One si de of tread i s then worn
more than the other (Fi g. 5).
Excessi ve toe-i n or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fi g. 5).
TIRE NOISE OR VIBRATION
Radi al -pl y ti res are sensi ti ve to force i mpul ses
caused by i mproper mounti ng, vi brati on, wheel
defects, or possi bl y ti re i mbal ance.
To fi nd out i f ti res are causi ng the noi se or vi bra-
ti on, dri ve the vehi cl e over a smooth road at varyi ng
speeds. Note the noi se l evel duri ng accel erati on,
decel erati on and sl i ght l eft and ri ght steeri ng i nputs.
SERVICE PROCEDURES
ROTATION
Ti res on the front and rear operate at di fferent
l oads and perform di fferent steeri ng, dri vi ng, and
braki ng functi ons. For these reasons they wear at
unequal rates and tend to devel op i rregul ar wear
patterns. These effects can be reduced by rotati ng
the ti res at regul ar i nterval s. The benefi ts of ti re
rotati on are:
I ncrease tread l i fe
Mai ntai n tracti on l evel s
A smooth, qui et ri de
The suggested method of ti re rotati on i s (Fi g. 6).
Other rotati on methods can be used, but they wi l l
not provi de al l the ti re l ongevi ty benefi ts.
MATCH MOUNTING
Ti res and wheel s are currentl y match mounted at
the factory. Match mounti ng i s a techni que used to
reduce runout i n the wheel /ti re assembl y. Thi s means
that the hi gh spot of the ti re i s al i gned wi th the l ow
spot on the wheel ri m. The hi gh spot on the ti re i s
marked wi th a pai nt mark or a bri ght col ored adhe-
si ve l abel on the outboard si dewal l . The l ow spot on
the ri m i s i denti fi ed wi th a l abel on the outsi de of the
ri m and a dot on the i nsi de of the ri m. I f the outsi de
l abel has been removed the ti re wi l l have to be
removed to l ocate the dot on the i nsi de of the ri m.
Fig. 5 Tire Wear Patterns
Fig. 4 Tread Wear Indicators
1 THREAD ACCEPTABLE
2 THREAD UNACCEPTABLE
3 WEAR INDICATOR
Fig. 6 Tire Rotation Pattern
Before di smounti ng a ti re from i ts wheel , a refer-
ence mark shoul d be pl aced on the ti re at the val ve
stem l ocati on. Thi s reference wi l l ensure that i t i s
remounted i n the ori gi nal posi ti on on the wheel .
(1) Use a di al i ndi cator to l ocate the hi gh spot of
the ti re on the center tread ri b (Fi g. 7). Record the
i ndi cator readi ng and mark the hi gh spot on the ti re.
Pl ace a mark on the ti re at the val ve stem l ocati on
(Fi g. 8).
(2) Break down the ti re and remount i t 180
degrees on the ri m (Fi g. 9).
(3) Measure the total runout agai n and mark the
ti re to i ndi cate the hi gh spot.
(4) I f runout i s sti l l excessi ve use the fol l owi ng
procedures.
(a) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot and i s sti l l excessi ve, repl ace the
ti re.
(b) I f the hi gh spot i s wi thi n 101.6 mm (4.0 i n.)
of the fi rst spot on the wheel , the wheel may be out
of speci fi cati ons. Refer to Wheel and Ti re Runout.
(c) I f the hi gh spot i s NOT wi thi n 101.6 mm (4.0
i n.) of ei ther hi gh spot, draw an arrow on the tread
from second hi gh spot to fi rst. Break down the ti re
and remount i t 90 degrees on ri m i n that di recti on
(Fi g. 10). Thi s procedure wi l l normal l y reduce the
runout to an acceptabl e amount.
REPAIRING LEAKS
For proper repai ri ng, a radi al ti re must be removed
from the wheel . Repai rs shoul d onl y be made i f the
defect, or puncture, i s i n the tread area (Fi g. 11). The
ti re shoul d be repl aced i f the puncture i s l ocated i n
the si dewal l .
Fig. 7 Dial Indicator
Fig. 8 First Measurement On Tire
1 REFERENCE MARK
2 1ST MEASUREMENT
HIGH SPOT MARK TIRE AND RIM
3 WHEEL
4 VALVE STEM
Fig. 9 Remount Tire 180 Degrees
1 VALVE STEM
2 REFERENCE MARK
Defl ate ti re compl etel y before removi ng the ti re
from the wheel . Use l ubri cati on such as a mi l d soap
sol uti on when di smounti ng or mounti ng ti re. Use
tool s free of burrs or sharp edges whi ch coul d dam-
age the ti re or wheel ri m.
Before mounti ng ti re on wheel , make sure al l rust
i s removed from the ri m bead and repai nt i f neces-
sary.
I nstal l wheel on vehi cl e, and ti ghten to proper
torque speci fi cati on.
CLEANING TIRES
Remove the protecti ve coati ng on the ti res before
del i very of a vehi cl e. Thi s coati ng may cause deteri -
orati on of the ti res.
To remove the protecti ve coati ng, appl y warm
water and l et i t soak for a few mi nutes. Afterwards,
scrub the coati ng away wi th a soft bri stl e brush.
Steam cl eani ng may al so be used to remove the coat-
i ng.
NOTE: DO NOT use gasoline, mineral oil, oil-based
solvent or a wire brush for cleaning.
SPECIFICATIONS
TIRE SIZE
Fig. 10 Remount Tire 90 Degrees In Direction of
Arrow
1 2ND HIGH SPOT ON TIRE
2 1ST HIGH SPOT ON TIRE
Fig. 11 Tire Repair Area
1 REPAIRABLE AREA
TIRE SIZE SUPPLIER
P215/75R15 Goodyear
P225/75R15 Goodyear
P225/70R15 Goodyear
P225/70R16 Goodyear
WHEELS
TABLE OF CONTENTS
page page
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WHEEL INSPECTION. . . . . . . . . . . . . . . . . . . . . . . 7
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . . . . . 7
SERVICE PROCEDURES
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . 8
TIRE AND WHEEL BALANCE. . . . . . . . . . . . . . . . . 9
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . . 11
WHEEL
DESCRIPTION
The ri m si ze i s on the vehi cl e safety certi fi cati on
l abel l ocated on the dri vers door shut face. The si ze
of the ri m i s determi ned by the dri vetrai n package.
Ori gi nal equi pment wheel s/ri ms are desi gned for
operati on up to the speci fi ed maxi mum vehi cl e capac-
i ty.
Al l model s use stamped steel , cast al umi num or
forged al umi num wheel s. Every wheel has rai sed sec-
ti ons between the ri m fl anges and ri m drop wel l
cal l ed safety humps (Fi g. 1).
I ni ti al i nfl ati on of the ti re forces the bead over
these rai sed secti ons. I n case of rapi d l oss of ai r pres-
sure, the rai sed secti ons hel p hol d the ti re on the
wheel .
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. Al l al umi num and some steel wheel s
have wheel stud nuts wi th an enl arged nose. Thi s
enl arged nose i s necessary to ensure proper retenti on
of the wheel s. Do not use repl acement studs or nuts
wi th a di fferent desi gn or l esser qual i ty.
WHEEL INSPECTION
I nspect wheel s for:
Excessi ve run out
Dents or cracks
Damaged wheel l ug nut hol es
Ai r Leaks from any area or surface of the ri m
NOTE: Do not attempt to repair a wheel by ham-
mering, heating or welding.
I f a wheel i s damaged an ori gi nal equi pment
repl acement wheel shoul d be used. When obtai ni ng
repl acement wheel s, they shoul d be equi val ent i n
l oad carryi ng capaci ty. The di ameter, wi dth, offset,
pi l ot hol e and bol t ci rcl e of the wheel shoul d be the
same as the ori gi nal wheel .
WARNING: FAILURE TO USE EQUIVALENT
REPLACEMENT WHEELS MAY ADVERSELY AFFECT
THE SAFETY AND HANDLING OF THE VEHICLE.
USED WHEELS ARE NOT RECOMMENDED. THE
SERVICE HISTORY OF THE WHEEL MAY HAVE
INCLUDED SEVERE TREATMENT OR VERY HIGH
MILEAGE. THE RIM COULD FAIL WITHOUT WARN-
ING.
TIRE AND WHEEL RUNOUT
Radi al runout i s the di fference between the hi gh
and l ow poi nts on the ti re or wheel (Fi g. 2).
Lateral runout i s the wobble of the ti re or wheel .
Fig. 1 Safety Rim
1 FLANGE
2 RIDGE
3 WELL
Radi al runout of more than 1.5 mm (.060 i nch)
measured at the center l i ne of the tread may cause
the vehi cl e to shake.
Lateral runout of more than 2.0 mm (.080 i nch)
measured near the shoul der of the ti re may cause the
vehi cl e to shake.
Someti mes radi al runout can be reduced. Rel ocate
the wheel and ti re assembl y on the mounti ng studs
(See Method 1). I f thi s does not reduce runout to an
acceptabl e l evel , the ti re can be rotated on the wheel .
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Dri ve vehi cl e a short di stance to el i mi nate ti re
fl at spotti ng from a parked posi ti on.
(2) Check wheel beari ngs and adjust i f adjustabl e
or repl ace i f necessary.
(3) Check the wheel mounti ng surface.
(4) Rel ocate wheel on the mounti ng, two studs
over from the ori gi nal posi ti on.
(5) Ti ghten wheel nuts unti l al l are properl y
torqued, to el i mi nate brake di storti on.
(6) Check radi al runout. I f sti l l excessi ve, mark
ti re si dewal l , wheel , and stud at poi nt of maxi mum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
(1) Remove ti re from wheel and mount wheel on
servi ce dynami c bal ance machi ne.
(2) Check wheel radi al runout (Fi g. 3) and l ateral
runout (Fi g. 4).
STEEL WHEELS: Radi al runout 0.040 i n., Lat-
eral runout 0.045 i n. (maxi mum)
ALUMI NUM WHEELS: Radi al runout 0.030 i n.,
Lateral runout 0.035 i n. (maxi mum)
(3) I f poi nt of greatest wheel l ateral runout i s near
ori gi nal chal k mark, remount ti re 180 degrees.
Recheck runout, Refer to match mounti ng procedure.
SERVICE PROCEDURES
WHEEL INSTALLATION
The wheel studs and nuts are desi gned for speci fi c
appl i cati ons. They must be repl aced wi th equi val ent
parts. Do not use repl acement parts of l esser qual i ty
or a substi tute desi gn. Al l al umi num and some steel
wheel s have wheel stud nuts whi ch feature an
enl arged nose. Thi s enl arged nose i s necessary to
ensure proper retenti on of the al umi num wheel s.
NOTE: Do not use chrome plated lug nuts with
chrome plated wheels.
Before i nstal l i ng the wheel , be sure to remove any
bui l d up of corrosi on on the wheel mounti ng surfaces.
Ensure wheel s are i nstal l ed wi th good metal -to-metal
contact. I mproper i nstal l ati on coul d cause l ooseni ng
of wheel nuts. Thi s coul d affect the safety and han-
dl i ng of your vehi cl e.
To i nstal l the wheel , fi rst posi ti on i t properl y on
the mounti ng surface. Al l wheel nuts shoul d then be
ti ghtened just snug. Gradual l y ti ghten them i n
Fig. 2 Checking Tire/Wheel/Hub Runout
1 RADIAL RUNOUT
2 LATERAL RUNOUT
Fig. 3 Radial Runout
1 MOUNTING CONE
2 SPINDLE SHAFT
3 WING NUT
4 PLASTIC CUP
5 DIAL INDICATOR
6 WHEEL
7 DIAL INDICATOR
sequence to the proper torque speci fi cati on (Fi g. 5).
Never use oil or grease on studs or nuts.
WHEEL REPLACEMENT
Wheel s must be repl aced i f they have:
Excessi ve runout
Bent or dented
Leak ai r through wel ds
Have damaged bol t hol es
Wheel repai rs empl oyi ng hammeri ng, heati ng, or
wel di ng are not al l owed.
Ori gi nal equi pment wheel s are avai l abl e through
your deal er. Repl acement wheel s from any other
source shoul d be equi val ent i n:
Load carryi ng capaci ty
Di ameter
Wi dth
Offset
Mounti ng confi gurati on
Fai l ure to use equi val ent repl acement wheel s may
affect the safety and handl i ng of your vehi cl e.
Repl acement wi th used wheel s i s not recommended.
Thei r servi ce hi story may have i ncl uded severe treat-
ment.
TIRE AND WHEEL BALANCE
I t i s recommended that a two pl ane servi ce
dynami c bal ancer be used when a ti re and wheel
assembl y requi re bal anci ng. Refer to bal ancer opera-
ti on i nstructi ons for proper cone mounti ng proce-
dures. Typi cal l y use front cone mounti ng method for
steel wheel s. For al umi num wheel use back cone
mounti ng method wi thout cone spri ng.
NOTE: Static should be used only when a two
plane balancer is not available.
NOTE: Cast aluminum and forged aluminum wheels
require coated balance weights and special align-
ment equipment.
Wheel bal anci ng can be accompl i shed wi th ei ther
on or off vehi cl e equi pment. When usi ng on-vehi cl e
bal anci ng equi pment, remove the opposi te wheel /ti re.
Off-vehi cl e bal anci ng i s recommended.
For stati c bal anci ng, fi nd l ocati on of heavy spot
causi ng the i mbal ance. Counter bal ance wheel
di rectl y opposi te the heavy spot. Determi ne wei ght
requi red to counter bal ance the area of i mbal ance.
Pl ace hal f of thi s wei ght on the inner ri m fl ange and
the other hal f on the outer ri m fl ange (Fi g. 6).
For dynami c bal anci ng, the bal anci ng equi pment i s
desi gned to l ocate the amount of wei ght to be appl i ed
to both the i nner and outer ri m fl ange (Fi g. 7).
Fig. 4 Lateral Runout
1 MOUNTING CONE
2 SPINDLE SHAFT
3 WING NUT
4 PLASTIC CUP
5 DIAL INDICATOR
6 WHEEL
7 DIAL INDICATOR
Fig. 5 Lug Nut Tightening Pattern
Fig. 6 Static Unbalance & Balance
1 HEAVY SPOT
2 CENTER LINE OF SPINDLE
3 ADD BALANCE WEIGHTS HERE
4 CORRECTIVE WEIGHT LOCATION
5 TIRE OR WHEEL TRAMP, OR WHEEL HOP
Fig. 7 Dynamic Unbalance & Balance
1 CENTER LINE OF SPINDLE
2 ADD BALANCE WEIGHTS HERE
3 CORRECTIVE WEIGHT LOCATION
4 HEAVY SPOT WHEEL SHIMMY AND VIBRATION
SPECIFICATIONS
TORQUE CHART
DESCRIPTION TORQUE
Lug Nut
1/2 X 20 wi th 60 Cone . . . . . . . . . . 115-150 Nm
(85-115 ft. l bs.)
BODY
TABLE OF CONTENTS
page page
DESCRIPTION AND OPERATION . . . . . . . . . . . . . . 1
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . 3
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STATIONARY GLASS. . . . . . . . . . . . . . . . . . . . . . . . 6
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BODY COMPONENT SERVICE . . . . . . . . . . . . . . . 21
TABLE OF CONTENTS
page
BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 1
BODY COMPONENTS
PAINT
DESCRIPTION
The ori gi nal equi pment fi ni sh i s a mul ti -step pro-
cess that i nvol ves cl eani ng, el ectrodeposi ti on (e-coat),
base coat, and cl ear coat steps. Addi ti onal l y, sel ected
areas of the vehi cl e may be coated wi th an anti -chi p
fi ni sh.
OPERATION
On most vehi cl es a two-stage pai nt appl i cati on
(base coat/cl ear coat) i s used. Col or that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
STATIONARY GLASS
DESCRIPTION
Wi ndshi el ds and sel ected stati onary gl ass are
structural members of the vehi cl e. The wi ndshi el d
gl ass i s bonded to the wi ndshi el d frame wi th ure-
thane adhesi ve.
OPERATION
Wi ndshi el ds are made of two pi eces of gl ass wi th a
pl asti c i nner l ayer. Wi ndshi el ds and other stati onary
gl ass protect the occupants from the effects of the
el ements. Wi ndshi el ds are al so used to retai n some
ai rbags i n posi ti on duri ng depl oyment. Urethane
bonded gl ass i s di ffi cul t to sal vage duri ng removal .
The urethane bondi ng i s di ffi cul t to cut or cl ean from
any surface. Before removi ng the gl ass, check the
avai l abi l i ty of repl acement components.
SEATS
DESCRIPTION
Seat modul es are made up of a seat frame, seat
cushi on, seat back cushi on, a coveri ng materi al , and
the el ectri cal components used for power operati on, i f
equi pped. Some seat systems al so contai n seat bel t
components and suppl emental restrai nt systems.
OPERATION
Seat assembl i es transport the occupants i n comfort
and safety. Seat assembl i es al so hel p posi ti on occu-
pants correctl y i n the event of ai rbag depl oyment.
Seat cushi ons, coveri ngs, and el ectri cal components
are servi ceabl e. Refer to the appropri ate group i n
thi s manual .
EXTERIOR COMPONENTS
DESCRIPTION
Exteri or sheet metal components make up the
exteri or of the vehi cl e. Some exteri or metal systems
are wel ded assembl i es, such as doors and hoods.
Some exteri or tri m i tems are made of composi te.
XJ BODY 23 - 1
OPERATION
The exteri or i s fi ni shed i n vari ous metal stampi ngs
and composi te mol di ngs. These assembl i es gi ve the
vehi cl e a fi ni shed appearance and protect the occu-
pants from the el ements. Some components are part
of the energy absorbi ng system used to protect the
occupants i n col l i si ons. The exteri or sheet metal i s
repai rabl e and adjustabl e for fi t and fi ni sh. Wel ded
component systems are adjustabl e as a system. Tri m
components made of composi te are stamped wi th the
type of materi al used. Dai ml erChrysl er uses vari ous
fasteners to retai n tri m i tems. At ti mes, i t i s not pos-
si bl e to remove tri m i tems wi thout damagi ng the fas-
tener. I f i t i s not possi bl e to remove an i tem wi thout
damagi ng a component, cut or break the fasteners
and use new ones when i nstal l i ng the component.
23 - 2 BODY XJ
SAFETY PRECAUTIONS
TABLE OF CONTENTS
page
SERVICE PROCEDURES
SAFETY PRECAUTIONS AND WARNINGS . . . . . . 3
SERVICE PROCEDURES
SAFETY PRECAUTIONS AND WARNINGS
DESCRIPTION
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
DO NOT STAND UNDER A HOISTED VEHICLE
THAT IS NOT PROPERLY SUPPORTED ON SAFETY
STANDS. PERSONAL INJURY CAN RESULT.
CAUTION: When holes must be drilled or punched
in an inner body panel, verify depth of space to the
outer body panel, electrical wiring, or other compo-
nents. Damage to vehicle can result.
Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
the repair area. Fire or hazardous conditions, can
result.
Always have a fire extinguisher ready for use
when welding.
Disconnect the negative (-) cable clamp from the
battery when servicing electrical components that
are live when the ignition is OFF. Damage to electri-
cal system can result.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
Do not use harsh alkaline based cleaning sol-
vents on painted or upholstered surfaces. Damage
to finish or color can result.
Do not hammer or pound on plastic trim panel
when servicing interior trim. Plastic panels can
break.
Dai ml erChrysl er Corporati on uses many di fferent
types of push-i n fasteners to secure the i nteri or and
exteri or tri m to the body. Most of these fasteners can
be reused to assembl e the tri m duri ng vari ous repai r
procedures. At ti mes, a push-i n fastener cannot be
removed wi thout damagi ng the fastener or the com-
ponent i t i s hol di ng. I f i t i s not possi bl e to remove a
fastener wi thout damagi ng a component or body, cut
or break the fastener and use a new one when
i nstal l i ng the component. Never pry or pound on a
pl asti c or pressed-board tri m component. Usi ng a
sui tabl e fork-type pryi ng devi ce, pry the fastener
from the retai ni ng hol e behi nd the component bei ng
removed. When i nstal l i ng, veri fy fastener al i gnment
wi th the retai ni ng hol e by hand. Push di rectl y on or
over the fastener unti l i t seats. Appl y a l ow-force pul l
to the panel to veri fy that i t i s secure.
When i t i s necessary to remove components to ser-
vi ce another, i t shoul d not be necessary to appl y
excessi ve force or bend a component to remove i t.
Before damagi ng a tri m component, veri fy hi dden
fasteners or captured edges hol di ng the component i n
pl ace.
XJ BODY 23 - 3
PAINT
TABLE OF CONTENTS
page page
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BASE COAT/CLEAR COAT FINISH. . . . . . . . . . . . . 4
FINESSE SANDING, BUFFING, AND
POLISHING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . . . . 4
SPECIFICATIONS
AFTERMARKET PAINT REPAIR PRODUCTS . . . . . 5
PAINT CODE
The pai nt code i s i denti fi ed on the Vehi cl e Safety
Certi fi cati on Label whi ch i s l ocated on the dri vers
door shut face. The col or names provi ded i n the Pai nt
and Tri m Code Descri pti on chart are the col or names
used on most repai r product contai ners.
BASE COAT/CLEAR COAT FINISH
DESCRIPTION
On most vehi cl es a two-part pai nt appl i cati on (base
coat/cl ear coat) i s used. Col or pai nt that i s appl i ed to
pri mer i s cal l ed base coat. The cl ear coat protects the
base coat from ul travi ol et l i ght and provi des a dura-
bl e hi gh-gl oss fi ni sh.
CAUTION: Do not use abrasive chemicals or com-
pounds on painted surfaces. Damage to finish can
result.
Do not use harsh alkaline based cleaning sol-
vents on painted surfaces. Damage to finish or
color can result.
POLISHING
DESCRIPTION
Mi nor aci d etchi ng, orange peel , or smudgi ng i n
cl ear coat or si ngl e-stage fi ni shes can be reduced
wi th l i ght fi nesse sandi ng, hand buffi ng, and pol i sh-
i ng. If the finish has been finesse sanded in the
past, it cannot be repeated. Finesse sanding
operation should be performed by a trained
automotive paint technician.
CAUTION: Do not remove clear coat finish, if
equipped. Base coat paint must retain clear coat for
durability.
PAINTED SURFACE TOUCH-UP
DESCRIPTION
When a pai nted metal surface has been scratched
or chi pped, i t shoul d be touched-up as soon as possi -
bl e to avoi d corrosi on. For best resul ts, use Mopar
Scratch Fi l l er/Pri mer, Touch-Up Pai nts and Cl ear Top
Coat. Refer to I ntroducti on group of thi s manual for
Body Code Pl ate i nformati on.
WARNING: USE A OSHA APPROVED BREATHING
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
OPERATION
(1) Scrape l oose pai nt and corrosi on from i nsi de
scratch or chi p.
(2) Cl ean affected area wi th Mopar Tar/Road Oi l
Remover, and al l ow to dry.
(3) Fi l l the i nsi de of the scratch or chi p wi th a coat
of fi l l er/pri mer. Do not overl ap pri mer onto good sur-
face fi ni sh. The appl i cator brush shoul d be wet
enough to puddl e-fi l l the defect wi thout runni ng. Do
not stroke brush appl i cator on body surface. Al l ow
the fi l l er/pri mer to dry hard.
(4) Cover the fi l l er/pri mer wi th col or touch-up
pai nt. Do not overl ap touch-up col or onto the ori gi nal
col or coat around the scratch or chi p. Butt the new
col or to the ori gi nal col or, i f possi bl e. Do not stroke
appl i cator brush on body surface. Al l ow touch-up
pai nt to dry hard.
(5) On vehi cl es wi thout cl ear coat, the touch-up
col or can be l i ghtl y fi nesse sanded (1500 gri t) and
pol i shed wi th rubbi ng compound.
(6) On vehi cl es wi th cl ear coat, appl y cl ear top coat
to touch-up pai nt wi th the same techni que as
descri bed i n Step 4. Al l ow cl ear top coat to dry hard.
I f desi red, Step 5 can be performed on cl ear top coat.
23 - 4 BODY XJ
WARNING: AVOID PROLONGED SKIN CONTACT
WITH PETROLEUM OR ALCOHOL BASED CLEAN-
ING SOLVENTS. PERSONAL INJURY CAN RESULT.
AVOID PROLONGED SKIN CONTACT WITH
PETROLEUM OR ALCOHOL BASED CLEANING
SOLVENTS. PERSONAL INJURY CAN RESULT.
SPECIFICATIONS
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLOR
EXTERIOR
COLOR
DAIMLER
CHRYSLER
CODE
PPG DuPONT
S-W**
M-S**
AKZO
NOBEL
SIKKENS
SPIES
HECKER
ICI**
Flame Red
Clear Coat
PR4 4679 B9326 46916 CHA93:PR4
30116 2NN6B
Chili Pepper
Red
VEA 5361 B9823 54470 CHA98:VEA
33688 HMT3B
Medium Fern
Pearl Coat
RJP 4969 B9524 50270 CHA99:RJP
61088
7CD6B
Forest Green
Pearl Coat
SG8 5065 B9609 51062 CHA95:SG8
61633
7MR8B
Intense Blue
Pearl Coat
VB3 5357 B9822 54468 CHA98:VB3
55321
HMR9B
Desert Sand WTD 5474 B9884 56153 CHA99:WTD 81764 KGC7B
Deep
Amethyst
Pearl Coat
TCN 5246 B9736 52026 CHA97:TCN
54755 FNE4B
Black Clear
Coat
DX8 9700 99 34858 CHA85:DX8
73328 TC60B
Gunmetal
Pearl Coat
TQ7 5248 B9735 52952 CHA97:TQ7
73320 ERA9B
Stone White
Clear Coat
SW1 83542 B9622 51539 CHA96:SW1
15069 8KY5B
INTERIOR COLOR
INTERIOR
COLOR
DIAMLER
CHRYSLER
CODE*
PPG DuPONT
S-W**
M-S**
AKZO
NOBEL
SIKKENS
SPIES
HECKER
ICI**
Agate AZ
9856 /
2-1461
C9208 45994
CHALAZI 75016 7WC8
Camel / Dark
Green
KG N/A N/A N/A
N/A NA K5/G8
NOTE: *Herberts Standox and BASF use the
Chrysler paint code as listed on the Body Code
Plate and the Vehicle Safety Certification label. **
S-W = Sherwin-Williams, M-S = Martin Senour, ICI =
ICI Autocolor.
XJ BODY 23 - 5
STATIONARY GLASS
TABLE OF CONTENTS
page page
WINDSHIELD SAFETY PRECAUTIONS . . . . . . . . . 6
WINDSHIELD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REAR DOOR STATIONARY WINDOW GLASS . . . . 9
REAR QUARTER WINDOW GLASS . . . . . . . . . . . 10
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . . . . 11
WINDSHIELD SAFETY PRECAUTIONS
DESCRIPTION
WARNING: DO NOT OPERATE THE VEHICLE
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION.
IT TAKES AT LEAST 24 HOURS FOR URETHANE
ADHESIVE TO CURE. IF IT IS NOT CURED, THE
WINDSHIELD MAY NOT PERFORM PROPERLY IN
AN ACCIDENT.
URETHANE ADHESIVES ARE APPLIED AS A SYS-
TEM. USE GLASS CLEANER, GLASS PREP SOL-
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL
INTEGRITY COULD BE COMPROMISED.
DAIMLERCHRYSLER DOES NOT RECOMMEND
GLASS ADHESIVE BY BRAND. TECHNICIANS
SHOULD REVIEW PRODUCT LABELS AND TECHNI-
CAL DATA SHEETS, AND USE ONLY ADHESIVES
THAT THEIR MANUFACTURES WARRANT WILL
RESTORE A VEHICLE TO THE REQUIREMENTS OF
FMVSS 212. TECHNICIANS SHOULD ALSO INSURE
THAT PRIMERS AND CLEANERS ARE COMPATIBLE
WITH THE PARTICULAR ADHESIVE USED.
BE SURE TO REFER TO THE URETHANE MANU-
FACTURERS DIRECTIONS FOR CURING TIME
SPECIFICATIONS, AND DO NOT USE ADHESIVE
AFTER ITS EXPIRATION DATE.
VAPORS THAT ARE EMITTED FROM THE URE-
THANE ADHESIVE OR PRIMER COULD CAUSE
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
SHOULD BE AVOIDED. PERSONAL INJURY MAY
RESULT.
ALWAYS WEAR EYE AND HAND PROTECTION
WHEN WORKING WITH GLASS.
CAUTION: Protect all painted and trimmed surfaces
from coming in contact with urethane or primers.
Be careful not to damage painted surfaces when
removing moldings or cutting urethane around
windshield.
OPERATION
The wi ndshi el d i s attached to the wi ndow frame
wi th urethane adhesi ve. The urethane adhesi ve i s
appl i ed col d and seal s the surface area between the
wi ndow openi ng and the gl ass. The pri mer adheres
the urethane adhesi ve to the wi ndshi el d.
I t i s di ffi cul t to sal vage a wi ndshi el d duri ng the
removal operati on. The wi ndshi el d i s part of the
structural support for the roof. The urethane bondi ng
used to secure the wi ndshi el d to the fence i s di ffi cul t
to cut or cl ean from any surface. I f the mol di ngs are
set i n urethane, i t woul d al so be unl i kel y they coul d
be sal vaged. Before removi ng the wi ndshi el d, check
the avai l abi l i ty of the wi ndshi el d and mol di ngs from
the parts suppl i er.
WINDSHIELD
The wi ndshi el d i s posi ti oned i n the reveal mol di ng
and i s bonded to the wi ndshi el d frame wi th urethane
adhesi ve.
Dependi ng on the ci rcumstances, ei ther one of two
wi ndshi el d gl ass i nstal l ati on methods can be used:
The short method.
The extended method.
The short method i s used when the wi ndshi el d
gl ass i s removed i ntact, and the body openi ng and
the pi nchwel d fl anges do not requi re repai r.
The extended method must be used when the body
openi ng or a fl ange i s damaged. The extended
method must al so be used when urethane no l onger
adheres to ei ther the wi ndshi el d gl ass or the pi nch-
wel d fl anges.
REMOVAL
(1) Cover the i nteri or and exteri or body surface
areas wi th a protecti ve coveri ng.
23 - 6 BODY XJ
(2) Remove the wi ndshi el d wi per arms and the
rearvi ew mi rror.
(3) Usi ng a razor kni fe, sl i de the bl ade between
the wi ndshi el d gl ass and the i nboard edge of the
reveal mol di ng.
(4) Cut around the i nteri or peri meter of the reveal
mol di ng and sever the cap of the reveal mol di ng.
(5) Usi ng a col d kni fe, cut the urethane around the
peri meter of the wi ndshi el d (Fi g. 1).
(6) Remove the wi ndshi el d gl ass from the frame.
INSTALLATION SHORT METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
(1) Tri m the urethane from the pi nchwel d fl anges.
Leave a 3 mm (0.1 i n.) l evel base of urethane on the
pi nchwel d fl anges.
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(2) Cl ean i nsi de of wi ndshi el d wi th ammoni a based
gl ass cl eaner and l i nt-free cl oth.
(3) Pri me outer peri meter of i nteri or si de of gl ass
16 mm (5/8 i nch) from edge. Use a wi pe-off type ure-
thane pri mer and wi pe gl ass dry after pri mer appl i -
cati on.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Appl y the mol di ng to the wi ndshi el d:
Wi th the mol di ng at room temperature, press
the mol di ng onto the wi ndshi el d corners.
From corner to corner, work the mol di ng to the
center of each si de. (Some stretchi ng of the mol di ng
may be requi red duri ng thi s procedure.)
(5) Pl ace the gl ass on the pi nchwel d fl anges and
i nspect for gaps i n the urethane. Gaps i n excess of 3
mm (1/8 i nch) must be fi l l ed wi th urethane.
(6) Adjust wi ndshi el d gl ass posi ti on unti l i t i s
al i gned wi th the fl anges and adhesi ve.
(7) Usi ng a grease penci l or equi val ent, make
al i gnment marks on the gl ass and body.
(8) Remove repl acement wi ndshi el d from wi nd-
shi el d openi ng.
(9) Posi ti on the wi ndshi el d i nsi de up on a sui tabl e
work surface wi th two padded, wood 10 cm by 10 cm
by 50 cm (4 i n. by 4 i n. by 20 i n.) bl ocks, pl aced par-
al l el 75 cm (2.5 ft.) apart (Fi g. 2).
CAUTION: Avoid spilling or dripping primer on
painted surfaces. Clean spills or drips immediately.
The primer will damage the paint if it remains on
the surface for any length of time.
(10) I f the repl acement wi ndshi el d gl ass does not
have bl ackout pri mer:
Attach a 25 mm (1 i n) wi de maski ng tape band
around the i nteri or si de of the gl ass 16 mm (5/8 i n)
from the edge of the gl ass (Fi g. 3).
Do not attach tape al ong the bottom of the gl ass
and attach it only to the inside of the glass.
Cl ean the 16-mm (5/8-i n) wi de surface area
around the gl ass wi th i sopropyl al cohol .
Thoroughl y mi x and appl y gl ass bl ackout pri mer
to the 16 mm (5/8 i n) surface area around the i nte-
ri or si de of the gl ass (Fi g. 4).
Al l ow the pri mer to dry for at l east 10-12 mi n-
utes.
(11) Appl y a smal l amount of adhesi ve to the bot-
tom support spacers and attach the support spacers
to the bottom of the wi ndshi el d, 170 mm i nboard
from the outer wi ndshi el d edge (Fi g. 5).
(12) Cut the urethane adhesi ve appl i cator nozzl e
(Fi g. 6).
CAUTION: Be prepared to install the glass immedi-
ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
(13) Appl y a conti nuous, 6-mm (1/4-i n) di ameter
bead of urethane adhesi ve to the surface area.
(14) Al i gn the gl ass wi th the reference marks and
posi ti on the gl ass on the pi nchwel d fl anges. Ensure
that the wi ndshi el d gl ass i s correctl y seated on the
support spacers.
Fig. 1 Cutting Urethane Around WindshieldTypical
1 WINDSHIELD
2 COLD KNIFE
XJ BODY 23 - 7
(15) Force the wi ndshi el d gl ass i nward just enough
to wet-out and set the urethane. Use care to avoi d
excessi ve squeeze-out of adhesi ve.
(16) Water test the wi ndshi el d wi th a water spray
after i nstal l ati on. Do not di rect hi gh pressure
streams of water di rectl y at urethane. I f any l eaks
are detected, appl y urethane as necessary.
(17) I f used, remove the maski ng tape from the
i nner surface of the gl ass.
(18) I nstal l al l components and cl ean the vehi cl e.
(19) Open the vehi cl e wi ndows to prevent i nteri or
pressure whi l e the urethane i s curi ng. If not
vented, pressure in the interior of the vehicle
may interfere with proper glass bonding.
(20) I nstal l the rearvi ew mi rror.
INSTALLATION EXTENDED METHOD
WARNING: REVIEW ALL WARNINGS AND CAU-
TIONS IN THIS GROUP BEFORE PRECEDING WITH
INSTALLATION.
(1) Remove the al l of urethane from al l pi nchwel d
fl anges.
Fig. 2 Work Surface Set up
1 WINDSHIELD AND MOLDINGS
2 BLOCKS
Fig. 3 Masking Tape Location For Blackout Primer
1 POSITION TAPE 5/8 INCH FROM EDGE OF GLASS
2 1-INCH WIDE MASKING TAPE
Fig. 4 Blackout Primer Application
1 APPLY PRIMER TO THIS AREA OF GLASS
2 BLACKOUT PRIMER APPLICATOR
3 TAPE
Fig. 5 Windshield Bottom Support Spacers
1 SUPPORT SPACERS
2 WINDSHIELD
3 SUPPORT SPACER
4 COWL
5 MOLDING
23 - 8 BODY XJ
(2) I nspect and repai r the wi ndshi el d openi ng and
pi nchwel d fl anges.
(3) Pri me the pi nchwel d fl anges wi th a urethane
base pri mer. However, i f the fl ange i s col or-coated
wi th pai nt, pri me the fl anges wi th a pai nt fi ni sh
pri mer. This is important because urethane
adhesive will not adhere to all color-coat
paints. Al l ow pri mer suffi ci ent ti me to dry.
NOTE: The reveal molding has an adhesive applied
to the windshield contact surface to help secure the
molding to the windshield during the installation
procedure.
(4) Appl y the reveal mol di ng to the wi ndshi el d:
Wi th the mol di ng at room temperature, press
the mol di ng onto the wi ndshi el d corners.
From corner to corner, work the mol di ng to the
center of each si de. (Some stretchi ng of the mol di ng
may be requi red duri ng thi s procedure).
(5) I nstal l and i nspect the fi t of the wi ndshi el d on
the pi nchwel d fl anges as fol l ows:
Posi ti on wi ndshi el d unti l i t i s al i gned wi thi n
wi ndshi el d openi ng.
Measure the gap between the pi nchwel d fl anges
and gl ass around peri meter of the gl ass and fl ange.
The reveal mol di ng shoul d equal l y cover the
A-Pi l l ars on both si des.
The fl anges shoul d al so extend above the gl ass
edge equal l y around the peri meter of the openi ng.
(6) I f the pi nchwel d fl anges requi re repai r, remove
the wi ndshi el d gl ass and strai ghten, al i gn, or repai r
the fl ange(s) as necessary.
(7) Posi ti on the wi ndshi el d i n the openi ng and
i nspect the wi ndshi el d fi t agai n. Mark the wi ndshi el d
fi nal posi ti on on the gl ass and body wi th a wax pen-
ci l (or use maski ng tape). The marks (or maski ng
tape) wi l l be used for i nstal l ati on al i gnment refer-
ence.
(8) I f the repl acement wi ndshi el d does not have
bl ackout pri mer:
Attach a 25-mm (1-i n) wi de maski ng tape band
around the i nteri or si de of gl ass 16 mm (5/8 i n) from
edge of gl ass (Fi g. 3).
Do not attach tape al ong the bottom of the gl ass
and attach only to the inside of glass.
Thoroughl y mi x and appl y bl ackout pri mer to
the 16 mm (5/8 i n) surface area around the i nteri or
si de of the gl ass (Fi g. 4).
Al l ow the pri mer to dry for at l east 10-12 mi n-
utes.
(9) Appl y a smal l amount of adhesi ve to the bot-
tom support spacers and attach the support spacers
to the bottom of the wi ndshi el d, 170 mm i nboard
from the outer wi ndshi el d edge (Fi g. 5).
(10) Cut the urethane appl i cator nozzl e (Fi g. 6).
(11) Appl y a conti nuous bead of urethane to the
surface area wi th bl ackout pri mer on the i nteri or
si de of gl ass. The bead shoul d be 9-mm (3/8-i n) wi de
by 12.7-mm (1/2-i n) deep for best resul ts.
CAUTION: Be prepared to install the glass immedi-
ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
(12) Al i gn the wi ndshi el d wi th the wax penci l
i nstal l ati on al i gnment reference marks (or the tape
stri ps). Posi ti on the wi ndshi el d on pi nchwel d fl anges
and spacers.
(13) Force the wi ndshi el d i nward just enough to
wet-out and set the urethane. Use care to avoi d
excessi ve squeeze-out of adhesi ve.
(14) Water test the wi ndshi el d wi th a water spray
after i nstal l ati on. Do not di rect hi gh pressure
streams of water di rectl y at the urethane. I f any
l eaks are detected, appl y urethane as necessary.
(15) I f used, remove the maski ng tape from the
i nner surface of gl ass.
(16) I nstal l al l components and cl ean the vehi cl e.
I f necessary, refer to the i nstal l ati on procedures.
(17) Open the vehi cl e wi ndows to prevent i nteri or
pressure whi l e the urethane adhesi ve i s curi ng. If
not vented, pressure in the interior of vehicle
will interfere with glass bonding.
(18) I nstal l the rearvi ew mi rror on the bracket.
REAR DOOR STATIONARY WINDOW GLASS
REMOVAL
The rear door stati onary wi ndow gl ass i s bonded to
the di vi si on bar and i s servi ced as an assembl y.
(1) Lower the wi ndow gl ass.
(2) Remove the i nner and outer bel tl i ne weather-
stri p.
Fig. 6 Applicator Nozzle Preparation
1 CUT NOZZLE THIS SHAPE FOR EXTENDED PROCEDURE
2 CUT NOZZLE THIS SHAPE FOR SHORT PROCEDURE
XJ BODY 23 - 9
(3) Remove the tri m panel and waterdam from
door i nner panel .
(4) Remove the screws attachi ng the di vi si on bar/
gl ass to the door (Fi g. 7).
(5) Ti l t the di vi si on bar/gl ass forward and remove
i t from the door.
INSTALLATION
(1) Posi ti on the di vi si on bar/gl ass i n the door.
(2) I nstal l the screws attachi ng the di vi si on bar/
gl ass to the door. Fi nger ti ghten the screws.
(3) Ti ghten the upper screw to 6 Nm (5 ft-l bs)
torque.
(4) Ti ghten the l ower screw to 6 Nm (5 ft-l bs)
torque.
(5) I nstal l the bel tl i ne weatherstri p.
(6) I nstal l the door waterdam and tri m panel .
REAR QUARTER WINDOW GLASS
REMOVAL
(1) I f equi pped, remove the quarter wi ndow reveal
mol di ng (Fi g. 8).
(2) Remove the quarter wi ndow i nteri or tri m cov-
ers.
(3) Separate the weatherstri p seal l i p from the
wi ndow openi ng fl anges. Use a pry tool and careful l y
push the wi ndow gl ass and seal outward.
(4) Remove the weatherstri p seal and wi ndow
gl ass from wi ndow openi ng.
(5) Remove the weatherstri p seal from the wi ndow
gl ass.
INSTALLATION
(1) Cl ean the ori gi nal seal ant from the weather-
stri p channel s and wi ndow openi ng fl anges.
(2) Appl y a 4-mm (1/6-i n) di ameter bead of seal ant
to the wi ndow channel i n the weatherstri p seal .
(3) I nstal l the weatherstri p on the wi ndow gl ass.
I nstal l the seal i nstal l ati on cord i n the wi ndow open-
i ng fl ange channel (Fi g. 9) as fol l ows:
Moi sten a l ength of 6-mm (1/4-i n) di ameter cord
wi th a soap and water sol uti on.
Ensure that the cord i s l ong enough to go al l the
way around the peri meter of the weatherstri p.
I nsert the cord i nto the wi ndow openi ng fl ange
channel i n the weatherstri p seal .
(4) Appl y a 6-mm (1/4-i n) di ameter bead of seal ant
to the wi ndow openi ng fl anges.
(5) For two-door vehi cl es, appl y a 3-mm (1/8-i n)
di ameter bead of seal ant at the quarter panel appl i -
que and l i ftgate pi l l ar seam.
(6) Posi ti on the quarter wi ndow gl ass and the
weatherstri p seal i n the wi ndow openi ng (Fi g. 10)
wi th the free ends of the cord i nsi de the vehi cl e (Fi g.
11).
(7) Pul l on each end of the cord to pul l the weath-
erstri p seal channel l i p over the wi ndow openi ng
fl anges.
(8) Test the vent wi ndow for water l eaks.
(9) I nstal l the i nteri or tri m cover.
(10) I f equi pped, i nstal l the quarter wi ndow reveal
mol di ng.
Fig. 7 Division Bar/Stationary Glass
1 UPPER SCREW
2 GLASS
3 LOWER SCREW
4 DIVISION BAR
Fig. 8 Quarter Window Reveal Molding, Glass and
Seal
1 GLASS
2 REVEAL MOULDING
3 WEATHERSTRIP SEAL
23 - 10 BODY XJ
LIFTGATE GLASS
REMOVAL
(1) Open l i ftgate.
(2) Remove l i ftgate tri m panel .
(3) Di sconnect heated backl i te (HBL) connector.
(4) Remove wi per arm.
(5) Remove CHMSL l ens.
(6) Usi ng a razor kni fe, sl i de the bl ade between
the l i ftgate gl ass and the i nboard edge of the reveal
mol di ng.
(7) Cut around the i nteri or peri meter of the reveal
mol di ng and severe the cap of the reveal mol di ng.
(8) Usi ng a col d kni fe, cut urethane bondi ng from
around l i ftgate gl ass. A pneumati c cutti ng devi ce can
be used i f avai l abl e.
(9) Separate gl ass from Li ftgate.
INSTALLATION
CAUTION: Open a window before installing glass.
This will avoid pressurizing the passenger compart-
ment. If a door or liftgate is slammed before ure-
thane is cured, water leaks can result.
(1) Tri m the urethane from the l i ftgate gl ass open-
i ng fl anges. Leave a 3 mm (0.1 i n.) l evel base of ure-
thane on the fl anges.
(2) Starti ng i n the corners, press reveal mol di ng
onto gl ass.
(3) Pl ace repl acement gl ass i nto l i ftgate openi ng
and posi ti on gl ass i n the center of the openi ng
agai nst fl ange.
(4) Veri fy the gl ass l ays evenl y agai nst the fence at
the si des, top and bottom. I f not, the fl ange must be
formed to the shape of the new gl ass.
(5) Usi ng a grease penci l or equi val ent, make ref-
erences marks on the gl ass and body.
(6) Remove repl acement gl ass from l i ftgate open-
i ng.
(7) Posi ti on the gl ass i nsi de up on a sui tabl e work
surface.
Fig. 9 Weatherstrip Seal and Cord Installation
1 WINDOW GLASS
2 INSTALLATION CORD END
3 WEATHERSTRIP SEAL
4 WINDOW GLASS
5 WEATHERSTRIP SEAL
6 INSTALLATION CORD
Fig. 10 Quarter Window With Vent
1 QUARTER WINDOW W/VENT
2 WEATHERSTRIP SEAL
3 INSTALLATION CORD
Fig. 11 Quarter Window Glass and Seal Installation
1 WEATHERSTRIP
2 1/4-INCH DIAMETER CORD (POSITION IN WEATHERSTRIP
GLASS CHANNEL)
XJ BODY 23 - 11
WARNING: DO NOT USE SOLVENT BASED GLASS
CLEANER TO CLEAN WINDSHIELD BEFORE
APPLYING GLASS PREP AND PRIMER. POOR
ADHESION CAN RESULT.
(8) Cl ean i nsi de of gl ass wi th Mopar Gl ass Cl eaner
and l i nt-free cl oth.
(9) Appl y PVC (vi nyl ) pri mer 25 mm (1 i n.) wi de
around edge of gl ass. Wi pe wi th cl ean/dry l i nt-free
cl oth.
(10) I f necessary, appl y fence pri mer around edge
of fence. Al l ow at l east ei ghteen mi nutes dryi ng ti me.
(11) Appl y a 10 mm (0.4 i n.) bead of urethane
around gl ass border.
(12) Posi ti on gl ass i nto l i ftgate openi ng and refer-
ence marks.
(13) Push the gl ass i nward unti l the reveal mol d-
i ng i s seated onto the l i ftgate frame. Use care to
avoi d excessi ve squeeze-out of adhesi ve.
(14) Open wi ndows to prevent pressure bui l d-up
whi l e the urethane i s curi ng.
(15) Appl y 150 mm (6 i n.) l engths of 50 mm (2 i n.)
maski ng tape spaced 250 mm (10 i n.) apart to hol d
gl ass i n pl ace unti l urethane cures.
(16) I nstal l the wi per arm.
(17) I nstal l CHMSL l ens.
(18) Connect heated backl i te (HBL) connector.
(19) After urethane has cured, remove tape stri ps
and water test to veri fy repai r.
(20) I nstal l l i ftgate tri m panel .
23 - 12 BODY XJ
SEATS
TABLE OF CONTENTS
page page
HEAD RESTRAINT SLEEVE. . . . . . . . . . . . . . . . . 13
HEAD RESTRAINT COVER . . . . . . . . . . . . . . . . . 14
BUCKET SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
BUCKET SEAT TRACK. . . . . . . . . . . . . . . . . . . . . 15
BUCKET SEAT PLATFORM . . . . . . . . . . . . . . . . . 15
BUCKET SEATBACK COVER. . . . . . . . . . . . . . . . 16
BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . . . . 16
BUCKET SEAT CUSHION COVER . . . . . . . . . . . . 17
BUCKET SEAT RECLINER. . . . . . . . . . . . . . . . . . 17
REAR SEAT CUSHION. . . . . . . . . . . . . . . . . . . . . 17
REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . . 18
REAR SEAT CUSHION COVER . . . . . . . . . . . . . . 19
REAR SEATBACK LATCH STRIKER AND
BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
REAR SEATBACK COVER. . . . . . . . . . . . . . . . . . 20
SPECIAL TOOLS
SPECIAL TOOLSSEATS . . . . . . . . . . . . . . . . . . 20
HEAD RESTRAINT SLEEVE
REMOVAL
NOTE: When replacing a head restraint sleeve, the
retaining tabs on the sleeve will be damaged during
the removal process. Check the availability of
replacement parts before servicing.
(1) Rai se head restrai nt to the ful l up posi ti on.
(2) Turn head restrai nt l ock thumbwheel to rel ease
head restrai nt and pul l head restrai nt upward to
remove from seat back.
(3) I nsert head restrai nt sl eeve extractor (speci al
tool 6773) (Fi g. 1) and (Fi g. 2) i nto the seat back.
(4) The retai ni ng tabs are posi ti oned on each si de
of the sl eeve, when i nserti ng the extractor, ensure
that the fl at of the col l ar i s faci ng the si de of the
seatback (Fi g. 3).
(5) Usi ng a smal l hammer, tap extractor down-
ward to rel ease sl eeve retai ni ng tab.
(6) Remove extractor tool from sl eeve, rotate tool
180 degrees (Fi g. 4) and repeat steps 3 and 4.
(7) Remove extractor tool from sl eeve and remove
sl eeve from seat back.
Fig. 1 Head Restraint Sleeve Extractor
1 SEAT BACK
2 HEAD RESTRAINT SLEEVE
3 EXTRACTOR TOOL 6773
XJ BODY 23 - 13
INSTALLATION
(1) Posi ti on the sl eeve i n the seat back.
(2) Fi rml y, push sl eeve down to snap i nto pl ace.
(3) I nstal l head restrai nt.
HEAD RESTRAINT COVER
REMOVAL
(1) Remove head restrai nt from the bucket seat.
(2) Remove the screws attachi ng the bezel and
adjuster bar to the head restrai nt (Fi g. 5).
(3) Pul l the adjuster bar from the head restrai nt.
(4) Rol l the cover upward and separate from the
head restrai nt cushi on (Fi g. 6).
INSTALLATION
(1) Posi ti on the cover on the head restrai nt cush-
i on and rol l the cover downward.
(2) Posi ti on the adjuster bar i n the head restrai nt.
(3) I nstal l the screws attachi ng the bezel and
adjuster bar to the head restrai nt.
(4) I nstal l head restrai nt i n the bucket seat.
Fig. 2 Head Restraint Sleeve Extractor Installation
1 SEAT BACK
2 HEAD RESTRAINT SLEEVE
Fig. 3 Head Restraint Sleeve Extractor Positioning
2 SEAT BACK
3 LOCK RELEASE THUMBWHEEL
Fig. 4 Head Restraint Sleeve Extractor Positioning
2 SEAT BACK
3 LOCK RELEASE THUMBWHEEL
Fig. 5 Head Restraint
1 HEAD RESTRAINT
2 BEZEL
3 ADJUSTER BAR
23 - 14 BODY XJ
BUCKET SEAT
REMOVAL
(1) Remove bol ts attachi ng seat to fl oor pan (Fi g.
7).
(2) Remove nut attachi ng seat to fl oor pan.
(3) For power seat, di sconnect wi re harness con-
nector. I f equi pped, di sconnect wi re harness for
heated seat.
(4) Di sconnect seat bel t buckl e warni ng wi re har-
ness connector.
(5) Separate seat from fl oor panel .
INSTALLATION
(1) Posi ti on seat on fl oor pan.
(2) Connect seat bel t buckl e warni ng wi re harness
connector.
(3) For power seats, connect wi re harness connec-
tor. I f equi pped, connect harness for heated seat.
(4) I nstal l front fasteners attachi ng seat to fl oor
pan. Ti ghten to 27 Nm (20 ft. l bs.) torque.
(5) I nstal l rear fasteners attachi ng seat to fl oor
pan. Ti ghten to 27 Nm (20 ft. l bs.) torque.
(6) I nstal l nut attachi ng seat to fl oor pan. Ti ghten
BUCKET SEAT TRACK
REMOVAL
NOTE: If the vehicle is equipped with manually
adjusted bucket seats, the inboard or outboard seat
track may be serviced separately.
(1) Remove bucket seat from vehi cl e.
(2) Remove screws attachi ng the si de shi el d tri m
cover from the seat.
(3) I f equi pped, di sengage the power seat connec-
tor from the power seat swi tch.
(4) Remove the nuts attachi ng the seat track to
the bucket seat pl atform.
(5) When separati ng the seat track from the pl at-
form, route the power seat swi tch connector through
the access hol e i n the seat cushi on frame, i f
equi pped.
INSTALLATION
(1) Whi l e posi ti oni ng the seat track on the bucket
seat pl atform, route the power seat swi tch connector
through the access hol e i n the seat cushi on frame, i f
equi pped.
(2) I nstal l the nuts attachi ng the seat track to the
bucket seat pl atform.
(3) I f equi pped, engage the power seat connector to
the power seat swi tch.
(4) I nstal l screws attachi ng the si de shi el d tri m
cover to the seat.
(5) I nstal l bucket seat.
BUCKET SEAT PLATFORM
Bucket seat pl atforms are not repai rabl e. I f the
seat pl atform i s damaged, repl ace pl atform as a uni t.
Fig. 6 Head Restraint Cover
1 HEAD RESTRAINT COVER
2 HEAD RESTRAINT CUSHION
Fig. 7 Bucket SeatPower Seat
1 NUT
2 DRIVER SIDE FRONT SEAT
3 SCREW
4 STUD
5 SCREW
XJ BODY 23 - 15
BUCKET SEATBACK COVER
REMOVAL
(1) Remove seat.
(2) Remove head restrai nt, i f equi pped.
(3) Remove screws attachi ng si de shi el d tri m cover
to bucket seat.
(4) I f equi pped, di sengage power seat wi re connec-
tor from power seat swi tch.
(5) Remove the i nboard seatback pi vot bol t and
l arge pl asti c washer.
(6) Posi ti on the seatback i n the ful l forward or ful l
recl i ne posi ti on.
(7) Remove the seatback cover J straps from the
base of the seatback.
(8) Rol l the seatback cover upward, di sengage el ec-
tri cal connectors for heated seat gri d, i f equi pped.
(Fi g. 8).
(9) Di sengage the hogri ngs attachi ng the seatback
cover to the seatback cushi on support wi res (Fi g. 9).
(10) Rol l the seatback cover upward and di sengage
the hook and l oop fastener (Fi g. 10).
(11) Rol l seatback cover up and over the head
restrai nt sl eeves, i f equi pped and separate from the
seatback.
INSTALLATION
(1) Posi ti on the seatback cover on the seatback
cushi on and rol l seatback cover down over the head
restrai nt sl eeves. Route the sl eeves through the
access hol es i n the cover, i f equi pped.
(2) Rol l the seatback cover downward and engage
the hook and l oop fastener. Engage el ectri cal connec-
tors for heated seat gri d, i f equi pped.
(3) Conti nue rol l i ng the cover downward and
engage the hogri ngs attachi ng the seatback cover to
the seatback cushi on support wi res.
(4) Engage the seatback cover J straps to the base
of the seatback.
(5) I nstal l the i nboard seatback pi vot bol t and
l arge pl asti c washer.
(6) I nstal l the si de shi el d tri m cover.
(7) I nstal l head restrai nt, i f equi pped.
(8) I nstal l seat.
BUCKET SEATBACK
REMOVAL
(1) Remove seat.
(2) Remove si de shi el d tri m cover.
(3) Remove i nboard seatback pi vot bol t and
washer.
Fig. 8 Seatback Cover
1 SEAT BACK COVER
2 SEAT BACK CUSHION
Fig. 9 Hog Ring
1 SEAT BACK CUSHION
2 HOG RING
3 SUPPORT
Fig. 10 Hook And Loop Fastener
1 SEAT BACK COVER
2 HOOK AND LOOP FASTENER
3 SEAT BACK CUSHION
23 - 16 BODY XJ
(4) Remove bol ts attachi ng recl i ner to seat cushi on
frame (Fi g. 11).
(5) Separate seatback from vehi cl e.
INSTALLATION
(1) Posi ti on seatback on seat cushi on frame.
(2) I nstal l i nboard seatback pi vot bol t and washer.
(3) I nstal l bol ts attachi ng recl i ner to seat cushi on
frame.
(4) I nstal l si de shi el d tri m cover.
(5) I nstal l seat.
BUCKET SEAT CUSHION COVER
REMOVAL
(1) Remove seat from vehi cl e.
(3) Remove seatback.
(4) Wi th the cushi on si de down, di sengage the for-
ward, rearward and i nboard J-straps.
(5) Di sengage the cl i ps attachi ng the outboard si de
of the cover to the cushi on frame.
(6) Turn the cushi on over and rol l the cover off the
cushi on.
(7) Di sengage the el ectri cal connectors for the
heated seat, i f equi pped.
(8) Remove the hog ri ngs attachi ng the cover to
the cushi on support wi res (Fi g. 12).
(9) Separate the cover from the cushi on.
INSTALLATION
(1) Posi ti on the cover on the cushi on.
(2) Engage the el ectri cal connectors for the heated
seat, i f equi pped.
(3) I nstal l the hog ri ngs attachi ng the cover to the
cushi on support wi res.
(4) Wi th the cushi on si de down, engage the for-
ward, rearward and i nboard J-straps.
(5) Engage the cl i ps attachi ng the outboard si de of
the cover to the cushi on frame.
(6) I nstal l seatback.
(8) I nstal l seat.
BUCKET SEAT RECLINER
REMOVAL
(2) Di sengage seatback cover zi pper.
(3) Rol l outer seatback cover upward.
(4) Remove bol ts attachi ng recl i ner to seatback
and seat cushi on frames (Fi g. 13).
(5) Separate recl i ner from seat.
INSTALLATION
(1) Posi ti on recl i ner on seat.
(2) I nstal l bol ts attachi ng recl i ner to seatback and
seat cushi on frames (Fi g. 13).
(3) Rol l seatback cover downward.
(4) Engage seatback cover zi pper.
REAR SEAT CUSHION
REMOVAL
(1) Di sengage seat cushi on at rear by pul l i ng
upward on rel ease strap (Fi g. 14).
(2) Ti l t seat cushi on forward.
(3) Di sengage seat cushi on l atch wi th ri ght si de
rel ease l ever. Separate ri ght si de l atch and l eft si de
seat bracket from fl oor anchor bol ts, and remove
cushi on from vehi cl e (Fi g. 15).
Fig. 11 Bucket Seatback
1 SEAT BACK
2 RECLINER
3 SEAT CUSHION
Fig. 12 Seat Cushion Cover Hog Rings
1 SEAT CUSHION COVER
2 SEAT CUSHION
3 HOG RING
XJ BODY 23 - 17
INSTALLATION
(1) Posi ti on seat cushi on i n vehi cl e.
(2) I nsert l eft pi vot i n anchor grommet.
(3) Force ri ght si de l atch onto anchor bol t and
pi vot seat cushi on to hori zontal posi ti on.
(4) Lock seat cushi on i n-pl ace by pressi ng fi rml y
on center of cushi on unti l l atch engages.
REAR SEATBACK
REMOVAL
(1) Di sengage the seat cushi on at the rear by pul l -
i ng upward on the rel ease strap.
(2) Ti l t the seat cushi on forward.
(3) Remove the shoul der/l ap bel t buckl es from the
el asti c straps.
(4) Rel ease the seatback l atch from the stri ker.
(5) Remove the pi vot bol ts and the washers from
the wheel house panel anchors (Fi g. 15).
(6) Ti l t the seatback forward, l i ft i t upward and
remove i t from the vehi cl e.
INSTALLATION
(1) Posi ti on the seatback i n the vehi cl e.
(2) I nstal l the pi vot bol ts and the washer. Ti ghten
the bol ts wi th 33 Nm (25 ft. l bs.) torque.
(3) Engage the seatback l atch wi th the stri ker.
(4) I nsert the shoul der/l ap bel t buckl es i n the el as-
ti c straps.
(5) Pi vot the seat cushi on to the hori zontal posi -
ti on and l ock i t i n-pl ace by pressi ng fi rml y on the
center of the cushi on unti l the l atch engages.
Fig. 13 Bucket Seat Recliner
1 SEAT BACK CUSHION
2 SEAT CUSHION
3 REMOVE
4 RECLINER HANDLE
5 RECLINER
Fig. 14 Seat Cushion Release Strap
1 REAR SEAT CUSHION
2 RELEASE STRAP
Fig. 15 Rear Seat Cushion/Seat Back
1 SEAT BACK LATCH STRIKER BRACKET
2 SEAT BACK LATCH STRIKER
3 SEAT BACK
4 PIVOT SPACER
5 GROMMET
6 SEAT CUSHION
7 BUSHING
23 - 18 BODY XJ
REAR SEAT CUSHION COVER
REMOVAL
(1) Remove the seat cushi on from the vehi cl e.
(2) Remove the cover si de, front and rear retai ni ng
cl i ps from the wi re retai ners wi th an appropri ate
removal tool (Fi g. 16).
(3) Remove the serrated retai ners from the front
ends of the cover wi th a tri m panel removal tool (Fi g.
17).
(4) Remove the seat cover from the cushi on.
INSTALLATION
(1) Posi ti on the repl acement cover on the cushi on.
(2) Compress the cover and attach the retai ni ng
cl i ps to the front and rear wi re retai ners.
(3) I nstal l the serrated retai ners at the ends of the
cover.
(4) I nstal l the seat cushi on i n the vehi cl e. I f neces-
sary, refer to the i nstal l ati on procedure.
BUMPER
REMOVAL
(1) Di sengage seat cushi on at the rear by pul l i ng
upward on the rel ease strap.
(2) Ti l t seat cushi on forward.
(3) Rel ease seatback l atch from stri ker.
(4) Ti l t seatback forward for access to stri ker
bracket.
(5) Remove screws (Fi g. 18) attachi ng l atch stri ker
bracket and shi ms to tri m panel .
INSTALLATION
(1) Posi ti on shi ms and l atch stri ker bracket on
tri m panel .
(2) I nstal l screws attachi ng l atch stri ker bracket
and shi ms to tri m panel . Ti ghten screws to 6 Nm (50
i n. l bs.) torque.
(3) Engage seatback l atch wi th stri ker.
Fig. 16 Seat Cushion Cover Retaining Clip Removal
1 REMOVER TOOL
2 SEAT COVER
Fig. 17 Seat Cushion Cover Retaining Clip Removal
1 CLIP REMOVER TOOL
2 SEAT COVER CLIPS
Fig. 18 Seatback Latch Striker Bracket
1 SEAT BACK LATCH STRIKER BRACKET
2 SEAT BACK LATCH STRIKER
3 SEAT BACK
4 SEAT CUSHION
XJ BODY 23 - 19
(4) Pi vot seat cushi on to hori zontal posi ti on and
l ock i t i n-pl ace by pressi ng fi rml y on center of the
cushi on unti l l atch engages.
REAR SEATBACK COVER
REMOVAL
(1) Remove the seatback from the vehi cl e.
(2) Remove the seatback l atch rel ease handl e and
bezel from the seatback.
(3) Di sengage the cover zi ppers.
(4) Di sengage the J-strap attachi ng the cover to
the seat back frame (Fi g. 19).
(5) Remove the cover from the seatback pad.
INSTALLATION
(1) I nstal l the cover on the seatback.
(2) Attach the cover J-strap to the seatback frame.
(3) Engage the cover zi ppers.
(4) I nstal l the seat l atch rel ease bezel and handl e.
(5) I nstal l the seatback i n the vehi cl e.
SPECIAL TOOLS
SPECIAL TOOLS SEATS
Fig. 19 Seatback Cover Removal
1 SEAT BACK
2 COVER ZIPPER
Extractor Head Restraint Sleeve 6773
23 - 20 BODY XJ
BODY COMPONENT SERVICE
TABLE OF CONTENTS
page page
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SERVICE PROCEDURES
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . . . . 23
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GRILLE OPENING PANEL (GOP) . . . . . . . . . . . . . 24
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HOOD LATCH STRIKER. . . . . . . . . . . . . . . . . . . . 26
HOOD RELEASE CABLE . . . . . . . . . . . . . . . . . . . 27
HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . . . . 27
SAFETY LATCH STRIKER . . . . . . . . . . . . . . . . . . 27
HOOD SILENCER PAD . . . . . . . . . . . . . . . . . . . . 27
COWL WEATHERSTRIP. . . . . . . . . . . . . . . . . . . . 28
COWL GRILLE. . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . 29
EXTERIOR NAMEPLATES . . . . . . . . . . . . . . . . . . 30
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . 31
FRONT FENDER FLARE . . . . . . . . . . . . . . . . . . . 31
FRONT WHEELHOUSE LINER. . . . . . . . . . . . . . . 32
RIGHT FRONT FENDER . . . . . . . . . . . . . . . . . . . 32
LEFT FRONT FENDER. . . . . . . . . . . . . . . . . . . . . 32
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . . . . 33
FRONT DOOR WATERDAM. . . . . . . . . . . . . . . . . 34
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . . . . 35
FRONT DOOR RESTRAINT . . . . . . . . . . . . . . . . . 35
FRONT DOOR OUTSIDE HANDLE. . . . . . . . . . . . 35
FRONT DOOR LOCK CYLINDER . . . . . . . . . . . . . 36
LOCK CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . 37
FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . . . . 37
FRONT DOOR LATCH STRIKER . . . . . . . . . . . . . 37
FRONT DOOR INSIDE HANDLE ACTUATOR . . . . 37
FRONT DOOR INNER BELT WEATHERSTRIP . . . 37
FRONT DOOR OUTER BELT WEATHERSTRIP . . 38
FRONT DOOR GLASS RUN CHANNEL
WEATHERSTRIP. . . . . . . . . . . . . . . . . . . . . . . . 38
FRONT DOOR OPENING WEATHERSTRIP . . . . . 38
FRONT DOOR OPENING SECONDARY
WEATHERSTRIP. . . . . . . . . . . . . . . . . . . . . . . . 39
FRONT DOOR GLASS EXTERIOR MOLDING . . . 39
FRONT DOOR WINDOW REGULATOR . . . . . . . . 39
FRONT DOOR SPACER BLOCKSTWO-
DOOR VEHICLES . . . . . . . . . . . . . . . . . . . . . . . 41
FRONT DOOR GLASS . . . . . . . . . . . . . . . . . . . . . 41
REAR DOOR TRIM PANEL. . . . . . . . . . . . . . . . . . 42
REAR DOOR WATERDAM . . . . . . . . . . . . . . . . . . 42
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
REAR DOOR RESTRAINT . . . . . . . . . . . . . . . . . . 43
REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . . . . 43
REAR DOOR OUTSIDE HANDLE. . . . . . . . . . . . . 44
REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . . . . 44
REAR DOOR LATCH STRIKER . . . . . . . . . . . . . . 45
REAR DOOR INSIDE HANDLE ACTUATOR . . . . . 45
REAR DOOR INNER BELT WEATHERSTRIP . . . . 45
REAR DOOR OUTER BELT WEATHERSTRIP . . . 45
REAR DOOR GLASS RUN CHANNEL
WEATHERSTRIP. . . . . . . . . . . . . . . . . . . . . . . . 46
REAR DOOR GLASS EXTERIOR MOLDING. . . . . 46
REAR DOOR WEATHERSTRIP . . . . . . . . . . . . . . 46
REAR DOOR WINDOW REGULATOR . . . . . . . . . 47
REAR DOOR WINDOW GLASS . . . . . . . . . . . . . . 47
BODY SIDE MOLDING. . . . . . . . . . . . . . . . . . . . . 48
REAR FENDER FLARE . . . . . . . . . . . . . . . . . . . . 49
QUARTER WINDOW APPLIQUE . . . . . . . . . . . . . 49
DRIP RAIL MOLDING. . . . . . . . . . . . . . . . . . . . . . 49
LUGGAGE RACK. . . . . . . . . . . . . . . . . . . . . . . . . 50
AIR EXHAUST GRILLE. . . . . . . . . . . . . . . . . . . . . 50
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LOWER A-PILLAR COWL TRIM . . . . . . . . . . . . . . 51
FRONT INNER SCUFF PLATE . . . . . . . . . . . . . . . 52
DOOR SILL SCUFF PLATE . . . . . . . . . . . . . . . . . 52
ASSIST HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . 52
B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . 52
C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . 53
QUARTER PANEL TRIM EXTENSION . . . . . . . . . 54
QUARTER PANEL TRIM AND WHEELHOUSE
COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
LIFTGATE PILLAR TRIM . . . . . . . . . . . . . . . . . . . 55
LIFTGATE OPENING UPPER TRIM . . . . . . . . . . . 55
LIFTGATE SCUFF PLATE. . . . . . . . . . . . . . . . . . . 55
FRONT SHOULDER BELT/BUCKLE . . . . . . . . . . . 55
REAR SHOULDER/LAP BELT/BUCKLE . . . . . . . . 57
FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . 57
FRONT CARPET/MAT . . . . . . . . . . . . . . . . . . . . . 58
REAR CARPET/MAT . . . . . . . . . . . . . . . . . . . . . . 58
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . 59
REARVIEW MIRROR SUPPORT BRACKET . . . . . 59
SUNVISORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
HEADLINER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . . . . . 61
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
LIFTGATE HINGE. . . . . . . . . . . . . . . . . . . . . . . . . 62
LIFTGATE SUPPORT ROD CYLINDER. . . . . . . . . 63
LIFTGATE SUPPORT ROD BALL STUD . . . . . . . . 63
XJ BODY 23 - 21
LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . . . . 63
LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . . . . 64
LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . . . . 64
LIFTGATE LATCH STRIKER. . . . . . . . . . . . . . . . . 64
LIFTGATE WEATHERSTRIP. . . . . . . . . . . . . . . . . 65
ADJUSTMENTS
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
DOOR LATCH ADJUSTMENT. . . . . . . . . . . . . . . . 66
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
REAR SEATBACK . . . . . . . . . . . . . . . . . . . . . . . . 67
SPECIFICATIONS
BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . 67
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 68
BODY SEALING LOCATIONS . . . . . . . . . . . . . . . 112
STRUCTURAL ADHESIVE LOCATIONS . . . . . . . 124
BODY GAP AND FLUSH MEASUREMENTS . . . . 127
BODY OPENING DIMENSIONS . . . . . . . . . . . . . 128
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . 135
SPECIAL TOOLS
BODY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
WATER LEAKS
Water l eaks can be caused by poor seal i ng,
i mproper body component al i gnment, body seam
porosi ty, mi ssi ng pl ugs, or bl ocked drai n hol es. Cen-
tri fugal and gravi tati onal force can cause water to
dri p from a l ocati on away from the actual l eak poi nt,
maki ng l eak detecti on di ffi cul t. Al l body seal i ng
poi nts shoul d be water ti ght i n normal wet-dri vi ng
condi ti ons. Water fl owi ng downward from the front of
the vehi cl e shoul d not enter the passenger or l uggage
compartment. Movi ng seal i ng surfaces wi l l not
al ways seal water ti ght under al l condi ti ons. At
ti mes, si de gl ass or door seal s wi l l al l ow water to
enter the passenger compartment duri ng hi gh pres-
sure washi ng or hard dri vi ng rai n (severe) condi -
ti ons. Overcompensati ng on door or gl ass
adjustments to stop a water l eak that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After compl eti ng
a repai r, water test vehi cl e to veri fy l eak has stopped
before returni ng vehi cl e to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Veri fy that fl oor and body pl ugs are i n pl ace, body
drai ns are cl ear, and body components are properl y
al i gned and seal ed. I f component al i gnment or seal -
i ng i s necessary, refer to the appropri ate secti on of
thi s group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the condi ti ons causi ng a water l eak have
been determi ned, si mul ate the condi ti ons as cl osel y
as possi bl e.
I f a l eak occurs wi th the vehi cl e parked i n a
steady l i ght rai n, fl ood the l eak area wi th an open-
ended garden hose.
I f a l eak occurs whi l e dri vi ng at hi ghway speeds
i n a steady rai n, test the l eak area wi th a reasonabl e
vel oci ty stream or fan spray of water. Di rect the
spray i n a di recti on comparabl e to actual condi ti ons.
I f a l eak occurs when the vehi cl e i s parked on an
i ncl i ne, hoi st the end or si de of the vehi cl e to si mu-
l ate thi s condi ti on. Thi s method can be used when
the l eak occurs when the vehi cl e accel erates, stops or
turns. I f the l eak occurs on accel erati on, hoi st the
front of the vehi cl e. I f the l eak occurs when braki ng,
hoi st the back of the vehi cl e. I f the l eak occurs on l eft
turns, hoi st the l eft si de of the vehi cl e. I f the l eak
occurs on ri ght turns, hoi st the ri ght si de of the vehi -
cl e. For hoi sti ng recommendati ons refer to Group 0,
Lubri cati on and Mai ntenance, General I nformati on
secti on.
WATER LEAK DETECTION
To detect a water l eak poi nt-of-entry, do a water
test and watch for water tracks or dropl ets formi ng
on the i nsi de of the vehi cl e. I f necessary, remove i nte-
ri or tri m covers or panel s to gai n vi sual access to the
l eak area. I f the hose cannot be posi ti oned wi thout
bei ng hel d, have someone hel p do the water test.
Some water l eaks must be tested for a consi derabl e
l ength of ti me to become apparent. When a l eak
appears, fi nd the hi ghest poi nt of the water track or
drop. The hi ghest poi nt usual l y wi l l show the poi nt of
entry. After l eak poi nt has been found, repai r the
l eak and water test to veri fy that the l eak has
stopped.
Locati ng the entry poi nt of water that i s l eaki ng
i nto a cavi ty between panel s can be di ffi cul t. The
trapped water may spl ash or run from the cavi ty,
often at a di stance from the entry poi nt. Most water
l eaks of thi s type become apparent after accel erati ng,
stoppi ng, turni ng, or when on an i ncl i ne.
MIRROR INSPECTION METHOD
When a l eak poi nt area i s vi sual l y obstructed, use
a sui tabl e mi rror to gai n vi sual access. A mi rror can
al so be used to defl ect l i ght to a l i mi ted-access area
to assi st i n l ocati ng a l eak poi nt.
23 - 22 BODY XJ
BRIGHT LIGHT LEAK TEST METHOD
Some water l eaks i n the l uggage compartment can
be detected wi thout water testi ng. Posi ti on the vehi -
cl e i n a bri ghtl y l i t area. From i nsi de the darkened
l uggage compartment i nspect around seal s and body
seams. I f necessary, have a hel per di rect a drop l i ght
over the suspected l eak areas around the l uggage
compartment. I f l i ght i s vi si bl e through a normal l y
seal ed l ocati on, water coul d enter through the open-
i ng.
PRESSURIZED LEAK TEST METHOD
When a water l eak i nto the passenger compart-
ment cannot be detected by water testi ng, pressuri ze
the passenger compartment and soap test exteri or of
the vehi cl e. To pressuri ze the passenger compart-
ment, cl ose al l doors and wi ndows, start engi ne, and
set heater control to hi gh bl ower i n HEAT posi ti on. I f
engi ne can not be started, connect a charger to the
battery to ensure adequate vol tage to the bl ower.
Wi th i nteri or pressuri zed, appl y di sh detergent sol u-
ti on to suspected l eak area on the exteri or of the
vehi cl e. Appl y detergent sol uti on wi th spray devi ce or
soft bri stl e brush. I f soap bubbl es occur at a body
seam, joi nt, seal or gasket, the l eak entry poi nt coul d
be at that l ocati on.
WIND NOISE
Wi nd noi se i s the resul t of most ai r l eaks. Ai r l eaks
can be caused by poor seal i ng, i mproper body compo-
nent al i gnment, body seam porosi ty, or mi ssi ng pl ugs
i n the engi ne compartment or door hi nge pi l l ar areas.
Al l body seal i ng poi nts shoul d be ai rti ght i n normal
dri vi ng condi ti ons. Movi ng seal i ng surfaces wi l l not
al ways seal ai rti ght under al l condi ti ons. At ti mes,
si de gl ass or door seal s wi l l al l ow wi nd noi se to be
noti ced i n the passenger compartment duri ng hi gh
cross wi nds. Over compensati ng on door or gl ass
adjustments to stop wi nd noi se that occurs under
severe condi ti ons can cause premature seal wear and
excessi ve cl osi ng or l atchi ng effort. After a repai r pro-
cedure has been performed, test vehi cl e to veri fy
noi se has stopped before returni ng vehi cl e to use.
Wi nd noi se can al so be caused by i mproperl y fi tted
exteri or mol di ngs or body ornamentati on. Loose
mol di ngs can fl utter, creati ng a buzzi ng or chatteri ng
noi se. An open cavi ty or protrudi ng edge can create a
whi stl i ng or howl i ng noi se. I nspect the exteri or of the
vehi cl e to veri fy that these condi ti ons do not exi st.
VISUAL INSPECTION BEFORE TESTS
Veri fy that fl oor and body pl ugs are i n pl ace and
body components are al i gned and seal ed. I f compo-
nent al i gnment or seal i ng i s necessary, refer to the
appropri ate secti on of thi s group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Dri ve the vehi cl e to veri fy the general l ocati on
of the wi nd noi se.
(2) Appl y 50 mm (2 i n.) maski ng tape i n 150 mm
(6 i n.) l engths al ong weatherstri ps, wel d seams or
mol di ngs. After each l ength i s appl i ed, dri ve the vehi -
cl e. I f noi se goes away after a pi ece of tape i s appl i ed,
remove tape, l ocate, and repai r defect.
POSSIBLE CAUSE OF WIND NOISE
Mol di ngs standi ng away from body surface can
catch wi nd and whi stl e.
Gaps i n seal ed areas behi nd overhangi ng body
fl anges can cause wi nd-rushi ng sounds.
Mi sal i gned movabl e components.
Mi ssi ng or i mproperl y i nstal l ed pl ugs i n pi l l ars.
Wel d burn through hol es.
SERVICE PROCEDURES
BODY LUBRICATION
Al l mechani sms and l i nkages shoul d be l ubri cated
when necessary. Thi s wi l l mai ntai n ease of operati on
and provi de protecti on agai nst rust and excessi ve
wear. The weatherstri p seal s shoul d be l ubri cated to
prol ong thei r l i fe as wel l as to i mprove door seal i ng.
Al l appl i cabl e exteri or and i nteri or vehi cl e operat-
i ng mechani sms shoul d be i nspected and cl eaned.
Pi vot/sl i di ng contact areas on the mechani sms shoul d
then be l ubri cated.
(1) When necessary, l ubri cate the operati ng mech-
ani sms wi th the speci fi ed l ubri cants.
(2) Appl y si l i cone l ubri cant to a cl oth and wi pe i t
on door seal s to avoi d over-spray that can soi l pas-
sengers cl othi ng.
(3) Before appl yi ng l ubri cant, the component
shoul d be wi ped cl ean. After l ubri cati on, any excess
l ubri cant shoul d be removed.
(4) The hood l atch, l atch rel ease mechani sm, l atch
stri ker, and safety l atch shoul d be l ubri cated peri od-
i cal l y.
(5) The door l ock cyl i nders shoul d be l ubri cated
twi ce each year (preferabl y autumn and spri ng).
Spray a smal l amount of l ock cyl i nder l ubri cant
di rectl y i nto the l ock cyl i nder.
Appl y a smal l amount to the key and i nsert i t
i nto the l ock cyl i nder.
Rotate i t to the l ocked posi ti on and then back to
the unl ocked posi ti on several ti mes.
Remove the key. Wi pe the l ubri cant from i t wi th
a cl ean cl oth to avoi d soi l i ng of cl othi ng.
XJ BODY 23 - 23
GRILLE
REMOVAL
(1) Remove the headl amp/park l amp bezel s.
(2) Remove the screws attachi ng the gri l l e to the
gri l l e openi ng panel (GOP) (Fi g. 1).
(3) Separate the gri l l e from the GOP.
INSTALLATION
(1) Posi ti on the gri l l e i n the GOP.
(2) I nstal l the screws.
(3) I nstal l the headl amp/park l amp bezel s.
GRILLE OPENING PANEL (GOP)
REMOVAL
(1) Remove headl amp bezel s.
(2) Remove gri l l e.
(3) Remove si de marker l amps.
(4) Remove headl amps and park/turn si gnal
l amps.
(5) Open hood.
(6) Remove nuts that attach GOP to front fenders
(Fi g. 2).
(7) Remove nuts attachi ng GOP to support
bracket.
(8) Pul l GOP forward and di sconnect harness cl i ps
and front l amp harness connectors.
(9) Remove GOP from vehi cl e.
INSTALLATION
(1) Pl ace GOP on bumper and secure al l harness
cl i ps.
(2) Connect al l l amp wi re harness connectors.
(3) Posi ti on GOP on vehi cl e.
(4) I nstal l nuts attachi ng GOP to front fenders.
Ti ghten nuts to 4 Nm (38 i n-l bs) torque.
(5) I nstal l nuts attachi ng GOP to support bracket.
Ti ghten nuts to 4 Nm (38 i n-l bs) torque.
(6) I nstal l headl amps and park/turn si gnal l amps.
(7) I nstal l gri l l e.
(8) I nstal l si de marker l amps.
(9) I nstal l headl amp bezel s.
(10) Adjust headl amp ai m, i f necessary.
HOOD
REMOVAL
(1) Rai se hood.
(2) Di sconnect underhood l amp wi re harness con-
(3) Di sconnect rel ease cabl e from l atch rel ease
bel l crank.
(4) Remove l atch rel ease cabl e cl i ps and remove
cabl e from hood (Fi g. 3).
(5) Mark l ocati on of hood, hi nges and hi nge shi ms
for i nstal l ati on.
(6) Remove bol ts that attach hi nges to hood.
(7) Remove hood from vehi cl e wi th ai d of a hel per.
INSTALLATION
(1) Posi ti on hood on shi ms and hi nges; fi nger-
ti ghten hi nge bol ts.
(2) Al i gn hi nges and shi ms wi th reference marks
and ti ghten hi nge bol ts.
(3) Connect l atch rel ease cabl e and l atch connect-
i ng rod to bel l crank.
(4) Attach l atch rel ease cabl e to cl i ps.
(5) Connect underhood l amp wi re harness connec-
tor.
Fig. 1 Grille
1 NUT
2 GRILLE
3 GRILLE OPENING PANEL
Fig. 2 Grille Opening Panel
1 SUPPORT BRACKET
2 GRILLE OPENING PANEL
3 BODY
23 - 24 BODY XJ
Fig. 3 Hood Components
XJ BODY 23 - 25
HOOD HINGE
REMOVAL
(1) Rai se and support hood.
(2) Usi ng a grease penci l or equi val ent, mark posi -
ti on of hood.
(3) Remove seal from hi nge base (Fi g. 4).
(4) Remove hi nge retai ni ng nuts from studs.
INSTALLATION
(1) Posi ti on hi nge over studs and al i gn wi th refer-
ence marks.
(2) I nstal l nuts.
NOTE: If a replacement hinge seal is being
installed, position it around hinge arm, force it
against hinge base.
(3) Posi ti on hi nge seal around hi nge arm and on
hi nge base.
(4) Adjust hood as necessary.
HOOD LATCH
REMOVAL
(1) Remove the screw that attaches the l atch to
the hood i nner panel (Fi g. 5).
(2) Di sconnect the l atch connecti ng rod.
(3) Remove the l atch from the hood.
INSTALLATION
(1) Connect the l atch to the l atch connecti ng rod
and
(2) Posi ti on the l atch on the hood i nner panel .
(3) I nstal l the screw that attaches the l atch to the
hood i nner panel .
HOOD LATCH STRIKER
REMOVAL
(1) Remove headl amp bezel .
(2) Remove parkl amp.
(3) Rel ease the spri ng attachi ng the headl amp
mounti ng bucket to the gri l l e openi ng panel (GOP).
(4) Remove the headl amp wi th mounti ng bucket
attached from the adjusti ng screws.
(5) Remove the upper bol t attachi ng the stri ker to
the top of the (GOP).
(6) Remove the l ower bol t attachi ng the stri ker to
the (GOP).
(7) Remove the stri ker and shi ms.
INSTALLATION
(1) Posi ti on the shi ms and stri ker on the (GOP)
and i nstal l the bol ts.
(2) I nstal l the headl amp and mounti ng bucket.
(3) I nstal l parkl amp.
(4) I nstal l the headl amp bezel .
(5) Test the stri ker/hood al i gnment by openi ng and
cl osi ng the hood several ti mes. Adjust the stri ker, i f
necessary.
Fig. 4 Hood Hinge and Seal
1 HINGE
2 SEAL
3 HINGE BASE
4 DASH PANEL
5 NUT
6 HOOD
Fig. 5 Hood Latch
1 RETAINER CLIP
2 LATCH CONNECTING ROD
3 ROD SPRING
4 HOOD LATCH
5 HOOD
23 - 26 BODY XJ
HOOD RELEASE CABLE
REMOVAL
(1) Dri l l out bel l crank to hood ri vet heads and
remove ri vets (Fi g. 6).
(2) Di sconnect bel l crank from l atch rod and hood
rel ease cabl e. Remove bel l crank from hood.
(3) Di sconnect hood rel ease cabl e from cl i ps on
hood.
(4) Remove l eft cowl si de tri m panel .
(5) Remove cabl e bracket screws from cowl si de
panel .
(6) Route cabl e through dash panel and remove i t
from under i nstrument panel .
INSTALLATION
(1) I nsert repl acement cabl e end through hol e i n
dash panel i nto engi ne compartment.
(2) Route cabl e forward and seat grommet i n dash
panel .
(3) Posi ti on cabl e bracket on cowl si de panel and
i nstal l screws.
(4) I nstal l l eft cowl si de tri m panel .
(5) Connect cabl e and l atch rod to bel l crank.
(6) Posi ti on bel l crank on hood and i nstal l ri vets.
(7) Attach cabl e to cl i ps.
(8) Test rel ease cabl e for proper operati on.
HOOD SAFETY LATCH
REMOVAL
(1) Open and support hood.
(2) Remove the nuts attachi ng the safety l atch to
the i nner hood panel (Fi g. 7).
(3) Separate the safety l atch from the hood.
INSTALLATION
(1) Posi ti on the safety l atch on the hood.
(2) I nstal l the nuts attachi ng the safety l atch to
the i nner hood panel .
(3) Cl ose hood.
SAFETY LATCH STRIKER
REMOVAL
(1) Remove stri ker screws from radi ator support
crossmember (Fi g. 8).
(2) Remove stri ker from crossmember.
INSTALLATION
(1) Posi ti on stri ker on radi ator support crossmem-
ber and i nstal l screws.
(2) Test safety l atch operati on.
HOOD SILENCER PAD
REMOVAL
(1) Open and support hood.
(2) Remove the hood l atch rel ease bel l crank.
(3) Remove the cl i ps attachi ng the l atch connect-
i ng rod to the hood i nner panel .
(4) Remove the retai ners attachi ng the hood
si l encer pad to the i nner hood panel (Fi g. 9).
(5) Separate the hood si l encer pad from the hood.
Fig. 6 Hood Release Cable Bellcrank
1 HOOD INNER PANEL
2 RIVET
3 BELLCRANK
4 LATCH RELEASE CABLE
5 LATCH CONNECTING ROD
Fig. 7 Hood Safety Latch
1 NUT
2 HOOD SAFETY LATCH
3 HOOD
4 STUD
5 HOOD BUMPER
XJ BODY 23 - 27
INSTALLATION
(1) Posi ti on the hood si l encer pad on the hood
i nner panel .
(2) I nstal l the retai ners attachi ng the hood
si l encer pad to the i nner hood panel .
(3) I nstal l the cl i ps attachi ng the l atch connecti ng
rod to the hood i nner panel .
(4) I nstal l the hood l atch rel ease bel l crank.
(5) Cl ose hood.
COWL WEATHERSTRIP
REMOVAL
The cowl weatherstri p i s attached to the cowl wi th
adhesi ve tape.
(1) Peel weatherstri p from cowl (Fi g. 10).
INSTALLATION
(1) Cl ean contact surface wi th Mopar Super Kl een
or equi val ent.
(2) Posi ti on weatherstri p on cowl .
(3) Press weatherstri p i nto pl ace.
COWL GRILLE
REMOVAL
(1) Remove the wi ndshi el d wi per arms from the
pi vots.
(2) Remove the screws that attach the gri l l e to the
cowl .
(3) Remove the wi ndshi el d washer tubes from the
nozzl es.
(4) Remove the cowl gri l l e and screen from the
cowl (Fi g. 11).
INSTALLATION
CAUTION: The washer fluid tubes must be routed
and installed so that they are not pinched.
(1) Posi ti on the cowl gri l l e and screen on the cowl .
(2) I nstal l the wi ndshi el d washer tubes on the noz-
zl es.
(3) I nstal l the cowl screen and gri l l e screws wi th
new seal er. Ti ghten i n sequence (Fi g. 12).
Fig. 8 Hood Safety Latch Striker
1 RADIATOR SUPPORT CROSSMEMBER
2 HOOD SAFETY LATCH STRIKER
3 SCREW
4 GOP BRACKET
5 RADIATOR
Fig. 9 Hood Silencer Pad
1 HOOD
2 SILENCER PAD
3 RETAINER
Fig. 10 Cowl Weatherstrip
1 WEATHERSTRIP
2 DASH PANEL
3 COWL
23 - 28 BODY XJ
NOTE: Force the cowl grille rearward while tighten-
ing the screws.
(4) I nstal l the wi ndshi el d wi per arms on the pi v-
ots.
BODY DECALS
Smal l ni cks, scratches and other surface marks i n
a decal can be touched-up wi th pai nt.
To el i mi nate bl i sters and ai r bubbl es i n a decal ,
pi erce them wi th a needl e or pi n.
A heat gun can al so be used to remove smal l wri n-
kl es i n a decal .
Decal repl acement requi res that the metal repai r
and pai nt refi ni sh be compl eted fi rst.
The work area temperature shoul d be between
21C (70F) and 32C (90F). A decal should not be
replaced if the work area temperature is less
than 21C (70F).
The fol l owi ng equi pment and materi al are neces-
sary for removal and i nstal l ati on:
Li qui d di sh detergent (for the wetti ng sol uti on).
Mi xture of wetti ng sol uti on.
Commerci al wax and si l i cone removal sol uti on.
I sopropyl (rubbi ng) al cohol .
Smal l squeegee (pl asti c or hard rubber).
Water bucket and sponge.
Cl ean wi pi ng rags or paper towel s.
Heat gun (or i nfra-red heat bul b).
Wax penci l .
Sharp kni fe, si ngl e edge razor bl ade or X-acto
kni fe.
Pai r of sci ssors.
Needl e or pi n.
WARNING: USE DECAL REMOVAL SOLUTION IN A
WELL-VENTILATED AREA ONLY.
A decal removal sol uti on can be used for removal
at areas where a heat gun i s i neffecti ve. Fol l ow the
manufacturers i nstructi ons whenever thi s type of
product i s used.
REMOVAL
(1) Cl ean the repai red surface as necessary.
(2) Start at one end of the decal and appl y heat
wi th a heat gun. Sl owl y peel the decal from the panel
by pul l i ng i t back. Do not pull the decal outward
from panel.
INSTALLATION
(1) The area that wi l l be covered by the decal must
be cl eaned wi th cl eani ng sol uti on.
(2) Freshl y pai nted surfaces must be thoroughl y
dry.
(3) Cl ean the pai nted surface wi th a commerci al
wax and si l i cone removal sol uti on. Wi pe the surface
wi th a cl ean cl oth and al l ow i t to dry.
(4) Prepare a wetti ng sol uti on by mi xi ng two or
three teaspoons of di sh detergent wi th 1 gal l on of
water. Do not use soap.
NOTE: Too much detergent will reduce the effec-
tiveness of the mixture.
(5) Use a cl ean sponge and appl y the wetti ng sol u-
ti on to the adhesi ve si de of the decal and to the
pai nted panel surface. The wetti ng sol uti on wi l l per-
mi t ease of decal movement when posi ti oni ng i t.
Fig. 11 Cowl Grille, Screen & Washer Nozzles
1 PLASTIC PUSH-RIVET
2 SCREEN
3 SCREEN
4 RIVET
5 NOZZLE
6 GRILLE
7 PLASTIC PUSH-RIVET
8 GRILLE
9 NOZZLE
Fig. 12 Cowl Grille Screw Tightening Sequence
XJ BODY 23 - 29
(6) Al i gn a strai ght edge wi th the exi sti ng decal
ends (Fi g. 13).
NOTE: If applicable, the body panel character line
can be used as the decal alignment reference.
(7) Posi ti on the decal and carri er on the body
panel (Fi g. 14) and the mark l ength wi th a wax pen-
ci l .
(8) Posi ti on the decal and carri er on the body
panel and hol d i t i n-pl ace wi th maski ng tape.
(9) Li ft the bottom edge of decal and carri er. Use
the tape secti ons as hi nges, and reverse the posi ti on
of decal and carri er.
CAUTION: Always remove the carrier from the
decal, never remove the decal from carrier
(10) Bend a corner of carri er outward and then,
wi th a fl i ck of the fi nger, separate the corner of car-
ri er from the decal .
(11) Return the decal back to i ts ori gi nal posi ti on.
I f a sol uti on i s bei ng used, posi ti on adhesi ve si de of
the decal on panel . Appl y the sol uti on to the outsi de
of the decal .
(12) Hol d the decal agai nst the panel surface whi l e
separati ng the carri er from the decal .
(13) I f appl i cabl e, remove the cover from face of
decal .
(14) Usi ng a squeegee smooth out the decal to
remove wri nkl es and/or ai r bubbl es.
(15) I nspect the decal wi th refl ected l i ght to fi nd
any damage. Remove al l the ai r and/or moi sture bub-
bl es.
EXTERIOR NAMEPLATES
REMOVAL
NOTE: Exterior nameplates are attached to body
panels with adhesive tape.
(1) Appl y a l ength of maski ng tape on the body,
paral l el to the top edge of the namepl ate to use as a
gui de, i f necessary.
(2) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun. Do not exceed 52C
(120F) when heati ng embl em.
(3) I nsert a pl asti c tri m sti ck or a hard wood
wedge behi nd the embl em to separate the adhesi ve
backi ng from the body.
(4) Cl ean adhesi ve resi due from body wi th MOPAR
Super Cl ean sol vent or equi val ent.
INSTALLATION
(1) Remove protecti ve cover from adhesi ve tape on
back of embl em.
(2) Posi ti on embl em properl y on body (Fi g. 15).
(3) Press embl em fi rml y to body wi th pal m of
hand.
(4) I f temperature i s bel ow 21C (70F) warm
embl em wi th a heat l amp or gun to assure adhesi on.
Do not exceed 52C (120F) when heati ng embl em.
Fig. 13 Decal Alignment Reference Mark
1 STRAIGHT EDGE
2 GREASE PENCIL
3 BODY PANEL
Fig. 14 Body Decals
23 - 30 BODY XJ
SIDE VIEW MIRROR
REMOVAL
(1) Remove the door tri m panel .
(2) Remove the screw attachi ng the mi rror tri m
cover/speaker gri l l e to the door i nner panel .
(3) remove push-i n fastener attachi ng tri m cover
to door i nner panel (use speci al tool C-4829).
(4) Di sconnect the power mi rror wi re connector, i f
equi pped.
(5) Remove the screws attachi ng the mi rror to the
door (Fi g. 16).
(6) Separate the mi rror from the door.
INSTALLATION
(1) Posi ti on the mi rror on the door.
(2) I nstal l the screws attachi ng the mi rror to the
door.
(3) Connect the power mi rror wi re connector, i f
equi pped.
(4) I nstal l new push-i n fastener.
(5) I nstal l the mi rror tri m cover/speaker gri l l e.
(6) I nstal l the door tri m panel .
FRONT FENDER FLARE
REMOVAL
(1) Remove the screw attachi ng the l ower part of
fl are to the bottom of the fender.
(2) Remove the nuts attachi ng the fender fl are
retai ner to the wheel house spl ash shi el d (Fi g. 17).
(3) Remove the l i ner from the fender.
(4) Remove the fasteners attachi ng the fender fl are
and retai ner to the fender.
(5) Separate the fender fl are and retai ner from the
fender.
INSTALLATION
(1) Posi ti on the fender fl are and retai ner on the
fender.
(2) I nstal l the nuts attachi ng the fender fl are and
retai ner to the wheel house fender.
(3) I nstal l the screw attachi ng the l ower part of
Fig. 15 Exterior Nameplates
1 CHEROKEE
2 LIMITED-SPORT-CLASSIC
Fig. 16 Side View Mirror
1 SIDE VIEW MIRROR
2 WIRE HARNESS
3 SEAL
4 GROMMET
5 DOOR
Fig. 17 Fender Flare
1 FENDER FLARE
2 RETAINER
3 FENDER
4 LINER
5 PUSH NUT
6 RETAINER
XJ BODY 23 - 31
FRONT WHEELHOUSE LINER
REMOVAL
(1) Hoi st vehi cl e.
(2) Remove ti re.
(3) Remove the push-i n fasteners attachi ng the
wheel house l i ner to the i nner fender.
(4) Separate the wheel house l i ner from the fender
(Fi g. 18).
INSTALLATION
(1) Posi ti on the wheel house l i ner i n the fender.
(2) I nstal l new push-i n fasteners attachi ng the
wheel house l i ner to the i nner fender.
(3) I nstal l ti re.
RIGHT FRONT FENDER
REMOVAL
(1) Rai se and support the hood.
(2) Remove the gri l l e openi ng panel (GOP).
(3) I f equi pped, remove the radi o antenna mast,
and components from the fender.
(4) Remove the cool ant recovery bottl e.
(6) Remove the ri ght front wheel .
(7) Remove the front bumper end cap.
(8) Remove the wheel house l i ner.
(9) Remove the fender fl are and retai ners.
(10) Di sconnect al l wi re harness connectors.
(11) Remove the ai r defl ector.
(12) Remove the fender l ower screws (Fi g. 19).
(13) Remove the fender top, front and the rear
screws.
(14) Remove the screws attachi ng the fender to the
i nner support bracket (Fi g. 20).
(15) Separate the fender from the i nner fender
panel .
INSTALLATION
(1) Posi ti on the fender on the i nner fender panel .
(2) I nstal l al l fender screws fi nger-ti ght.
(3) Al i gn the fender wi th the body panel s and
ti ghten the screws attachi ng the fender to the body
panel s.
(4) I nstal l the ai r defl ector.
(5) I nstal l the fender fl are and retai ners.
(6) I nstal l the wheel house l i ner.
(7) I nstal l the front bumper end cap.
(8) I nstal l the wheel , remove the support and
(9) I nstal l the gri l l e openi ng panel (GOP).
(10) I nstal l the radi o antenna.
LEFT FRONT FENDER
REMOVAL
(1) Rai se and support the hood.
(2) Remove the gri l l e openi ng panel (GOP).
(4) Remove the l eft front wheel .
(5) Remove the front bumper end cap.
(6) Remove the fender fl are and retai ners.
(7) Remove the wheel house l i ner.
(8) Remove the ai r defl ector.
(9) Remove the fender l ower screws.
(10) Remove the fender top, front and the rear
screws.
(11) Remove the screws attachi ng the fender to the
i nner support bracket.
(12) Separate the fender from the i nner fender
panel .
INSTALLATION
(1) Posi ti on the fender on the i nner fender panel .
(2) I nstal l al l fender screws fi nger-ti ght.
(3) Al i gn the fender wi th the body panel s and
ti ghten the screws attachi ng the fender to the body
panel s.
(4) I nstal l the ai r defl ector.
(5) I nstal l the wheel house l i ner.
(6) I nstal l the fender fl are and retai ners.
(7) I nstal l the front bumper.
(8) I nstal l the wheel , remove the support and
(9) I nstal l the gri l l e openi ng panel (GOP).
Fig. 18 Front Wheelhouse Liner
1 FENDER
2 WHEELHOUSE LINER
3 INNER FENDER PANEL
4 BRACE
5 PUSH-IN FASTENER
6 RETAINER
23 - 32 BODY XJ
FRONT DOOR TRIM PANEL
REMOVAL
(1) Rol l wi ndow down.
(2) Remove wi ndow crank, i f equi pped (Fi g. 21).
(3) Remove the screws attachi ng the tri m panel to
the door i nner panel (Fi g. 22) and (Fi g. 23).
(4) Separate the tri m panel fasteners from door
i nner panel wi th a pry tool (use speci al tool C-4829)
(Fi g. 24).
(5) Li ft the tri m panel up and outward to separate
from the i nner bel t seal .
(6) Move the door tri m panel outward and di scon-
nect the handl e-to-l atch rods.
(7) Di sconnect the power door l ocks/wi ndows/mi r-
rors wi re harness connectors, i f equi pped.
(8) Remove the tri m panel from door.
INSTALLATION
(1) Repl ace any broken or damaged push-i n fasten-
ers.
(2) Connect the power door l ocks/wi ndows/mi rrors
wi re harness connectors, i f equi pped.
(3) Move the door tri m panel outward and connect
the handl e-to-l atch rods.
(4) Posi ti on the tri m panel on the i nner bel t seal
and push down to seat.
(5) Al i gn the l ocati ng pi ns and push- (Fi g. 25) i n
fasteners. Press i nward to secure.
(6) I nstal l the screws attachi ng the tri m panel to
the door i nner panel .
(7) I nstal l the wi ndow crank, i f equi pped.
Fig. 19 Right Front Fender
1 SCREW
2 HOOD BUMPER
3 U-NUT
4 INNER FENDER PANEL
5 FENDER BRACE
6 FRAME SILL-TO-BAFFLE BRACE
7 U-NUT
8 OUTER FENDER PANEL
9 U-NUT
Fig. 20 Inner Support Bracket
1 U-NUT
2 FRONT FENDER
3 SUPPORT BRACKET
XJ BODY 23 - 33
FRONT DOOR WATERDAM
REMOVAL
The waterdam i s attached to the door i nner panel
wi th a butl y adhesi ve. I f cohesi ve separati on of the
butl y between the waterdam and door i nner panel
occurs duri ng the removal process, cut the strands of
butl y wi th a razor kni fe or equi val ent.
(1) Remove door tri m panel .
(2) Di sengage cl i ps attachi ng wi re harnesses to the
door i nner panel .
(3) Push the harnesses/connectors through the
waterdam and i nto the door.
(4) Grasp the upper and l ower rearward corners of
the waterdam and rapi dl y peel back the waterdam
from the door i nner panel .
(5) Separate the waterdam from the door i nner
panel .
INSTALLATION
(1) Route the l atch rods through the waterdam.
(2) Posi ti on the waterdam on the door, appl y adhe-
si ve as necessary and press i nto pl ace.
(3) Route the harnesses/connectors through the
waterdam.
Fig. 21 Window CrankTypical
1 WINDOW CRANK REMOVAL TOOL
2 WINDOW CRANK
Fig. 22 Front Door Trim Panel-Manual Window
1 U-NUT
2 DOOR
3 TRIM PANEL
4 WINDOW CRANK
5 SPACER
6 PUSH-IN FASTENER
Fig. 23 Front Door Trim Panel-Power Window
1 U-NUT
2 DOOR
3 TRIM PANEL
4 PUSH-IN FASTENER
Fig. 24 Detaching Trim Panel Push-In Fasteners
23 - 34 BODY XJ
(4) Engage cl i ps attachi ng wi re harnesses to the
door i nner panel .
(5) I nstal l door tri m panel .
FRONT DOOR
REMOVAL
(1) Remove door restrai nt (check) retai ni ng pi n.
(2) For vehi cl es equi pped wi th power wi ndows,
power mi rrors and power door l ocks, remove tri m
panel and waterdam. Di sconnect al l components and
route wi re harness out of door.
(3) Remove bol ts that attach hi nge to door (Fi g.
26).
(4) Remove door from vehi cl e.
INSTALLATION
(1) Posi ti on door i n body openi ng.
(2) Al i gn door hi nges, pl ates and shi ms and i nstal l
bol ts. Ti ghten bol ts to 3 Nm (2 ft. l bs.) torque.
(3) I nstal l door restrai nt (check) pi n.
(4) I f appl i cabl e, route and connect wi re harness
connectors.
(5) I nstal l door waterdam and tri m panel .
FRONT DOOR HINGE
REMOVAL
(2) Remove door hi nge bol ts and shi ms (Fi g. 26).
(3) Retai n door hi nge shi ms for correct i nstal l a-
ti on.
INSTALLATION
(1) Posi ti on hi nge pl ates and shi ms on door face.
(2) Al i gn door hi nges and shi ms wi th bol t hol es
and i nstal l hi nge bol ts. Ti ghten bol ts to 3 Nm (2 ft.
l bs.) torque.
(3) Adjust/al i gn l atch stri ker and l atch as neces-
sary.
(4) I nstal l door restrai nt (check) retai ni ng pi n.
FRONT DOOR RESTRAINT
REMOVAL
(2) Remove door radi o speaker from door i nner
panel .
(3) Remove door restrai nt (check) retai ni ng pi n
from bracket wi th a punch.
(4) Remove nuts and remove restrai nt vi a speaker
openi ng. (Fi g. 27).
INSTALLATION
(1) Posi ti on door restrai nt i n door by way of open-
i ng and i nstal l nuts.
NOTE: Ensure the spring on the door restraint is
facing outward.
(2) Posi ti on door restrai nt i n bracket wi th hol es
al i gned and i nsert retai ni ng pi n.
(3) I nstal l radi o speaker and door tri m panel .
FRONT DOOR OUTSIDE HANDLE
REMOVAL
(1) Remove the door tri m panel and waterdam.
Fig. 25 Push-In Fasteners
1 LOCATING PINS
2 TRIM PANEL
3 PUSH-IN FASTENERS
Fig. 26 Front Door Hinge
1 UPPER HINGE
2 SHIM
3 LOWER HINGE
4 FRONT DOOR
XJ BODY 23 - 35
(2) Remove the access hol e cover and remove the
rearward nut attachi ng the door handl e to the door.
(Fi g. 28).
(3) Di sconnect the handl e-to-l atch rod from the
handl e l atch rel ease l ever arm.
(4) Remove the forward nut attachi ng the handl e
to the door.
(5) Separate the handl e from the door.
INSTALLATION
(1) Posi ti on the handl e i n the door.
(2) I nstal l the forward nut attachi ng the handl e to
the door.
(3) Connect the l atch to handl e rod, to the handl e
l atch rel ease l ever arm.
(4) I nstal l the rearward nut attachi ng the door
handl e to the door.
(5) I nstal l the access hol e cover.
(6) I nstal l the door waterdam and tri m panel .
FRONT DOOR LOCK CYLINDER
REMOVAL
(2) Peel back waterdam to access l ock cyl i nder.
(3) Di sconnect the door l atch-to-l ock cyl i nder rod
at the door l atch (Fi g. 29).
(4) Remove the l ock cyl i nder retai ner cl i p.
(5) Remove the l ock cyl i nder.
(6) I f appl i cabl e, remove the door l atch-to-l ock cyl -
i nder rod from the ori gi nal l ock cyl i nder. Connect i t
to the repl acement l ock cyl i nder.
INSTALLATION
(1) Posi ti on the l ock cyl i nder and i n the door open-
i ng.
(2) I nstal l the retai ner cl i p.
(3) Connect the door l atch-to-l ock cyl i nder rod to
the door l atch.
(4) Press the waterdam i nto posi ti on.
Fig. 27 Door Restraint (Check)
1 A-PILLAR
2 RETAINING PIN
3 NUT
4 DOOR RESTRAINT
5 RESTRAINT BRACKET
6 DOOR INNER PANEL
7 SPEAKER OPENING
Fig. 28 Front Door Outside Handle
1 OUTSIDE DOOR HANDLE
2 OUTSIDE HANDLE TO LATCH ROD
3 DOOR LATCH
Fig. 29 Door Lock Cylinder
1 ACCESS PLUG
2 RETAINER
3 LOCK CYLINDER TO LATCH ROD
4 LATCH
6 LOCK CYLINDER
7 GASKET
23 - 36 BODY XJ
LOCK CYLINDERS
I gni ti on, door, deck l i d, and rear hatch l ock cyl i n-
ders are al l codabl e to the key. Lock barrel s, tum-
bl ers, and tumbl er spri ngs are avai l abl e to al l ow the
techni ci an to change repl acement l ocks cyl i nders to
match the customers ori gi nal key set. See the appro-
pri ate secti on i n thi s manual for l ock cyl i nder
removal . See the Mopar catal ogue for part numbers
and l ock codi ng procedures.
FRONT DOOR LATCH
REMOVAL
(1) Remove door tri m panel and waterdam.
(2) Remove screws attachi ng l atch to door.
(3) Di sconnect al l rods from l atch (Fi g. 30).
(4) Di sconnect power l ock motor wi re connector, i f
equi pped.
(5) Remove l atch from door face.
INSTALLATION
(1) Posi ti on l atch on door face.
(2) Connect power l ock motor wi re connector, i f
equi pped.
(3) Connect al l rods to l atch.
(4) I nstal l screws attachi ng l atch to door. Ti ghten
screws to 11 Nm (8 ft. l bs.) torque.
(5) I nstal l waterdam and door tri m panel .
FRONT DOOR LATCH STRIKER
REMOVAL
ti on of stri ker.
(2) Remove screws attachi ng stri ker to B-pi l l ar
(Fi g. 31).
(3) Separate stri ker from B-pi l l ar.
INSTALLATION
(1) Posi ti on and al i gn stri ker on B-pi l l ar.
(2) I nstal l screws attachi ng stri ker to B-pi l l ar.
Ti ghten screws to 28 Nm (20 ft. l bs.) torque.
FRONT DOOR INSIDE HANDLE ACTUATOR
REMOVAL
The front door i nsi de handl e actuator i s heat
staked to the front door tri m panel duri ng the man-
ufacturi ng process.
(2) Usi ng an X-ACTO kni fe or equi val ent, cut the
mel ted tabs securi ng the i nsi de handl e to the door
tri m panel .
(3) Separate the i nsi de handl e from the tri m
panel .
INSTALLATION
(1) Posi ti on the i nsi de handl e i n the tri m panel .
(2) Heat stake the i nsi de handl e to the tri m panel .
FRONT DOOR INNER BELT WEATHERSTRIP
REMOVAL
(3) Pul l up on the rear corner of the weatherstri p
and l i ft from the door (Fi g. 32).
Fig. 30 Door Latch
1 FRONT DOOR LATCH
2 LOCK BUTTON TO LATCH ROD
3 INSIDE HANDLE TO LATCH ROD
Fig. 31 Front Door Latch Striker
1 SPACER
2 TAPPING PLATE
3 STRIKER
XJ BODY 23 - 37
INSTALLATION
(1) Posi ti on the weatherstri p on the door.
(2) Push weatherstri p down to seat onto door.
FRONT DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(2) Usi ng a tri m sti ck, pry up the rear outer corner
of the weatherstri p.
(3) Li ft the weatherstri p up to separate from the
door (Fi g. 32).
INSTALLATION
WEATHERSTRIP
REMOVAL
(2) Remove waterdam.
(3) Starti ng at rear corner, peel weatherstri p from
around door frame.
INSTALLATION
(1) I nstal l the weatherstri p i n the fol l owi ng
sequence:
Press weatherstri p i nto upper rear corner.
Press weatherstri p i nto l ower front corner.
Work/press the weatherstri p upward and to the
upper front corner, seat the weatherstri p i nto the
channel .
Conti nue worki ng/pressi ng the weatherstri p i nto
the channel al ong the upper wi ndow frame.
Press weatherstri p i nto l ower rear corner.
Work/press the weatherstri p upward and to the
upper rear corner, seat the weatherstri p i nto the
channel .
Press the weatherstri p to seat i nto the front
l ower gl ass run channel .
(2) As appl i cabl e, move upward and forward
evenl y unti l the weatherstri p seal i s ful l y seated i n
the channel .
(3) I nstal l waterdam.
FRONT DOOR OPENING WEATHERSTRIP
REMOVAL
(1) Remove A-pi l l ar tri m panel .
(2) Remove B-pi l l ar upper tri m panel .
(3) Remove cowl si de tri m panel .
(4) Remove i nner scuff pl ate.
(5) Remove B-pi l l ar l ower tri m panel .
(6) Grasp seal and separate from door openi ng.
Fig. 32 Front Door Inner/Outer Belt Weatherstrip
1 OUTER BELT WEATHERSTRIP
2 INNER BELT WEATHERSTRIP
3 DOOR INNER PANEL
Fig. 33 Door Opening Weatherstrip
1 FRONT DOOR SEAL
2 A PILLAR
3 SECONDARY DOOR SEAL
4 FRONT DOOR SEAL
5 REAR DOOR SEAL
6 ENDS MEET AT CENTERLINE
7 A PILLAR
23 - 38 BODY XJ
INSTALLATION
(1) Posi ti on weatherstri p at corners.
(2) Move upward and around edge of door openi ng.
Seat seal on fl ange.
(3) When i nstal l i ng a door openi ng weatherstri p
seal , start at the door si l l center l i ne.
(4) Move upward and around the peri meter of the
door openi ng and seat the weatherstri p on the fl ange
(Fi g. 34).
(5) I nstal l cowl si de tri m panel .
(6) I nstal l i nner scuff pl ate.
(7) I nstal l B-pi l l ar l ower tri m panel .
(8) I nstal l B-pi l l ar upper tri m panel .
(9) I nstal l A-pi l l ar tri m panel .
WEATHERSTRIP
REMOVAL
The front door openi ng secondary weatherstri p i s
attached to the A-pi l l ar wi th adhesi ve tape (Fi g. 33).
(1) Usi ng a heat gun, heat the weatherstri p and
sl owl y peel the weatherstri p from the A-pi l l ar
INSTALLATION
(1) Cl ean the contact surface on the A-pi l l ar.
(2) Remove the carri er backi ng and posi ti on the
weatherstri p on the A-pi l l ar. Press i nto pl ace.
FRONT DOOR GLASS EXTERIOR MOLDING
REMOVAL
(1) Open the wi ndow compl etel y.
(2) Remove the outer bel t weatherstri p.
(3) Pry and pul l the mol di ng secti ons from the
door panel fl ange (Fi g. 35).
INSTALLATION
(1) Start at the forward end of the upper mol di ng,
force the mol di ng onto the door panel and conti nue
rearward unti l i t i s compl etel y seated on the fl ange.
(2) Mate the rear mol di ng wi th the upper mol di ng
and force the mol di ng edge i nward.
(3) Conti nue pressi ng and movi ng downward to
compl ete the i nstal l ati on.
(4) I nstal l the outer bel t weatherstri p.
FRONT DOOR WINDOW REGULATOR
REMOVAL
(2) Remove the waterdam.
(3) Remove the wi ndow gl ass
1 VENT HOLES
2 VENT HOLES
3 FINISH
4 START
5 FINISH
6 START
7 B-PILLAR
8 SEAL
9 REAR DOOR WEATHERSTRIP SEAL
10 FRONT DOOR WEATHERSTRIP SEAL
11 FLANGE
12 SEAL
13 FLANGE
Fig. 35 Front Door Glass Exterior Molding
1 UPPER MOLDING
2 SHIM
3 REAR MOLDING
XJ BODY 23 - 39
(4) Loosen the bol ts attachi ng the regul ator to the
i nner door panel (Fi g. 36) and (Fi g. 37) as appl i cabl e.
(5) Li ft the regul ator upward to rel ease i t from the
key hol e sl ots and remove i t through the access hol e
i n the door i nner panel .
INSTALLATION
(1) Posi ti on the regul ator i n the door and al i gn
wi th key hol e sl ots.
(2) Attach the regul ator to door i nner panel wi th
bol ts (Fi g. 38).
(3) I nstal l the wi ndow gl ass
(4) I nstal l the waterdam.
(5) I nstal l the tri m panel .
Fig. 38 Front Door Regulator
1 GLASS
Fig. 36 Power Window Regulator
1 FRONT DOOR
2 LOOSEN BOLTS
3 LOOSEN NUTS
Fig. 37 Manual Window Regulator
1 FRONT DOOR
2 LOOSEN BOLTS
23 - 40 BODY XJ
FRONT DOOR SPACER BLOCKS TWO-DOOR
VEHICLES
REMOVAL
(1) Upper spacer bl ock: dri l l -out the ri vet heads
and remove them from the rei nforcement pl ate (Fi g.
39).
(2) Lower spacer bl ock: remove the screws from
the door face (Fi g. 40).
(3) As appl i cabl e, remove the spacer bl ock from the
door wi ndow frame or door face.
INSTALLATION
(1) As appl i cabl e, posi ti on the spacer bl ock on the
door wi ndow frame or door face.
(2) Upper spacer bl ock: I nstal l the repl acement
ri vets i n the spacer bl ock and rei nforcement pl ate.
(3) Lower spacer bl ock: i nstal l the screws i n the
door face. Ti ghten the screws to 1 Nm (11 i n-l bs)
torque.
FRONT DOOR GLASS
REMOVAL
(3) Remove i nner and outer bel t weatherstri p.
(4) Rol l gl ass up to expose the bol ts attachi ng the
gl ass to the regul ator.
(5) Remove the bol ts attachi ng the gl ass to the
regul ator (Fi g. 41).
(6) Li ft the gl ass upward and out of the door.
INSTALLATION
(1) Posi ti on the gl ass i n the door.
(2) I nstal l the bol ts attachi ng the gl ass to the reg-
ul ator Ti ghten the bol ts to 4 Nm (36 i n-l bs) torque.
(3) I nstal l i nner and outer bel t weatherstri p.
Fig. 39 Front Door Upper Spacer BlockTwo-Door
1 FRONT DOOR WINDOW FRAME
2 RIVET
3 WINDOW OUTER FRAME
4 WINDOW INNER FRAME
5 WINDOW GLASS
6 REINFORCEMENT PLATE
7 RIVET
8 DOOR UPPER SPACER BLOCK
9 WINDOW OUTER FRAME
10 REINFORCEMENT PLATE
11 DOOR UPPER SPACER BLOCK
12 WINDOW INNER FRAME
13 RIVET
14 ADHESIVE
Fig. 40 Front Door Lower Spacer BlockTwo-Door
1 DOOR SPACER
2 DOOR FACE
3 DOOR FACE
4 DOOR SPACER
5 SCREW
6 SCREW
Fig. 41 Front Door Glass
1 NUT
2 RETAINER
3 WINDOW GLASS
4 REGULATOR
XJ BODY 23 - 41
(4) Attach the door waterdam to the door i nner
panel wi th adhesi ve/seal ant.
REAR DOOR TRIM PANEL
REMOVAL
(2) Remove wi ndow crank, i f equi pped (Fi g. 42).
(3) Remove the screws attachi ng the tri m panel to
the door i nner panel (Fi g. 43) and (Fi g. 44).
(4) Separate the tri m panel fasteners from door
i nner panel wi th a pry tool (use speci al tool C-4829)
(Fi g. 45).
(5) Li ft the tri m panel up and outward to separate
from the i nner bel t seal .
(6) Move the door tri m panel outward and di scon-
nect the handl e-to-l atch rods (Fi g. 46).
(7) Di sconnect the power wi ndows wi re harness
connectors, i f equi pped.
(8) Remove the tri m panel from door.
INSTALLATION
(1) Repl ace any broken or damaged push-i n fasten-
ers.
(2) Connect the power wi ndow wi re harness con-
nectors, i f equi pped.
(3) Move the door tri m panel outward and connect
the handl e-to-l atch rods.
(4) Posi ti on the tri m panel on the i nner bel t seal
and push down to seat.
(5) Al i gn the l ocati ng pi ns and push-i n fasteners
(Fi g. 47). Press i nward to secure.
(6) I nstal l the screws attachi ng the tri m panel to
(7) I nstal l the wi ndow crank, i f equi pped.
REAR DOOR WATERDAM
REMOVAL
(2) Peel the waterdam from the door.
(3) Route the l atch rods and wi re harnesses
through the waterdam.
(4) Separate the waterdam from the door i nner
panel .
INSTALLATION
(1) Route the l atch rods and wi re harnesses
through the waterdam.
Fig. 42 Window CrankTypical
1 WINDOW CRANK REMOVAL TOOL
2 WINDOW CRANK
Fig. 43 Rear Door Trim PanelManual Window
1 TRIM PANEL
2 WINDOW CRANK
3 SPACER
4 PUSH-IN FASTENER
Fig. 44 Rear Door Trim PanelPower Window
1 U-NUT
2 REAR DOOR
3 TRIM PANEL
4 PUSH-IN FASTENER
23 - 42 BODY XJ
(2) Posi ti on the waterdam on the door, appl y adhe-
si ve as necessary and press i nto pl ace.
REAR DOOR
REMOVAL
(2) For vehi cl es equi pped wi th power wi ndows and
power door l ocks, remove tri m panel and waterdam.
Di sconnect al l components and route wi re harness
out of door.
(3) Remove bol ts attachi ng hi nge to door face.
(4) Separate door from vehi cl e.
INSTALLATION
(1) Posi ti on door i n body openi ng.
(2) Al i gn door hi nges, pl ates and shi ms and i nstal l
bol ts. Ti ghten bol ts to 3 Nm (2 ft. l bs.) torque.
(3) I nstal l door restrai nt (check).
(4) I f appl i cabl e, route and connect wi re harness
connectors.
(5) I f necessary, i nstal l door waterdam and tri m
panel .
REAR DOOR RESTRAINT
REMOVAL
(2) Remove the door restrai nt (check) retai ni ng pi n
from the bracket wi th a punch.
(3) Remove the nuts and remove the restrai nt vi a
the access openi ng i n the door i nner panel (Fi g. 48).
INSTALLATION
(1) Posi ti on the door restrai nt i n the door by way
of the openi ng and i nstal l the nuts. Ti ghten the nuts
to 10 Nm (7 ft-l bs) torque.
(2) Posi ti on the door restrai nt i n bracket wi th the
hol es al i gned and i nsert the retai ni ng pi n.
REAR DOOR HINGE
REMOVAL
(1) Remove door restrai n (check) pi n.
(2) Remove door hi nge bol ts and shi ms.
(3) Retai n bol ts and shi ms for correct i nstal l ati on.
Fig. 45 Detaching Trim Panel Push-In Fasteners
Fig. 46 Latch Rods
2 INSIDE HANDLE ACTUATOR
3 CLIP
4 LOCK TO LATCH ROD
Fig. 47 Push-In Fasteners
1 LOCATING PINS
2 PUSH-IN FASTENERS
XJ BODY 23 - 43
INSTALLATION
(1) Posi ti on hi nge pl ates and shi ms on door face.
(2) Al i gn door hi nges and shi ms wi th bol t hol es
and i nstal l hi nges. Ti ghten bol ts to 3 Nm (2 ft. l bs.).
(3) Adjust/al i gn l atch stri ker and l atch as neces-
sary.
(4) I nstal l door restrai n (check) retai ni ng pi n.
REAR DOOR OUTSIDE HANDLE
REMOVAL
(2) Rol l the wi ndow to the ful l up posi ti on.
(3) Peel back the waterdam to access the fasteners
for the outsi de handl e.
(4) Remove the l atch.
(5) Remove the access hol e cover.
(6) Remove the nuts attachi ng the door handl e to
the door (Fi g. 49).
(7) Di sconnect the handl e-to-l atch rod from the
handl e l atch rel ease l ever arm (Fi g. 50).
INSTALLATION
(1) Posi ti on the handl e at the door panel .
(2) Connect the l atch-to-handl e rod to the handl e
l atch rel ease l ever arm.
(3) I nstal l nuts attachi ng the door handl e to the
door.
(4) I nstal l the l atch.
REAR DOOR LATCH
REMOVAL
(1) Remove access pl ug.
(4) Remove screws attachi ng door l atch to door
(Fi g. 51).
(5) Di sconnect al l rods from door l atch.
(6) Remove door l atch from door.
INSTALLATION
(1) Posi ti on door l atch i n door.
(2) Connect al l rods to door l atch.
Fig. 48 Door Restraint (Check)
1 RETAINING PIN
2 DOOR RESTRAINT
3 ACCESS OPENING
4 DOOR INNER PANEL
5 NUT
6 RESTRAINT BRACKET
7 B-PILLAR
Fig. 49 Rear Door Outside Handle
2 LOCK TO LATCH ROD
3 OUTSIDE HANDLE
Fig. 50 Latch Rod
1 OUTSIDE HANDLE
3 CLIP
23 - 44 BODY XJ
(3) I nstal l screws attachi ng door l atch to door.
(6) I nstal l access pl ug.
REAR DOOR LATCH STRIKER
REMOVAL
ti on of stri ker.
(2) Remove screws attachi ng stri ker to C-pi l l ar
(Fi g. 52).
(3) Separate stri ker from C-pi l l ar.
INSTALLATION
(1) Posi ti on and al i gn stri ker on C-pi l l ar.
(2) I nstal l screws attachi ng stri ker to C-pi l l ar.
REAR DOOR INSIDE HANDLE ACTUATOR
REMOVAL
The rear door i nsi de handl e actuator i s heat staked
to the rear door tri m panel duri ng the manufacturi ng
process.
(2) Usi ng an XACTO kni fe or equi val ent, cut the
mel ted tabs securi ng the i nsi de handl e to the door
tri m panel .
(3) Separate the i nsi de handl e from the tri m
panel .
INSTALLATION
(1) Posi ti on the i nsi de handl e i n the tri m panel .
(2) Heat stake the i nsi de handl e to the tri m panel .
REAR DOOR INNER BELT WEATHERSTRIP
REMOVAL
(3) Pul l up on the rear corner of the weatherstri p
and l i ft from the door (Fi g. 53).
INSTALLATION
REAR DOOR OUTER BELT WEATHERSTRIP
REMOVAL
(2) Usi ng a tri m sti ck, pry up the rear outer corner
of the weatherstri p.
(3) Sl owl y and careful l y, l i ft the weatherstri p up to
separate from the door (Fi g. 53).
Fig. 51 Rear Door Latch
1 ACCESS HOLE
2 INSIDE RELEASE TO LATCH ROD
3 INSIDE LOCK TO LATCH ROD
4 HANDLE
5 LATCH ROD
6 LATCH ADJUSTMENT SCREW
7 REAR DOOR
Fig. 52 Rear Door Latch Striker
1 SPACER
2 TAPPING PLATE
3 STRIKER
XJ BODY 23 - 45
INSTALLATION
WEATHERSTRIP
REMOVAL
(3) Remove wi ndow gl ass.
(4) Starti ng at rear corner, peel weatherstri p from
around door frame (Fi g. 53).
INSTALLATION
(1) Starti ng at the top corner, press seal i nto pl ace.
A smal l amount of adhesi ve can be used to hol d the
weatherstri p i n-pl ace, i f necessary.
(2) As appl i cabl e, move downward evenl y unti l the
weatherstri p seal i s ful l y seated i n the channel .
(3) I nstal l wi ndow gl ass.
REAR DOOR GLASS EXTERIOR MOLDING
REMOVAL
(1) Open the wi ndow.
(2) Remove the outer bel t mol di ng.
(3) Pry and pul l the mol di ng secti ons from the
door panel fl ange (Fi g. 54).
INSTALLATION
(1) Starti ng at the forward end of the upper mol d-
i ng, force the mol di ng onto the door panel fl ange and
conti nue rearward unti l i t i s compl etel y seated on
the fl ange.
(2) Mate the rear mol di ng wi th the upper mol di ng
and force the mol di ng edge i nward.
(3) Conti nue pressi ng and movi ng downward to
(4) I nstal l the outer bel t mol di ng.
REAR DOOR WEATHERSTRIP
REMOVAL
(1) Remove B-pi l l ar upper tri m.
(2) Remove i nner scuff pl ate.
(3) Remove B-pi l l ar l ower tri m.
(4) Remove upper door openi ng tri m.
(5) Grasp seal and separate from door openi ng
(Fi g. 55).
Fig. 53 Rear Door Inner/Outer Belt Weatherstrip
1 OUTER BELT WEATHERSTRIP
2 INNER BELT WEATHERSTRIP
3 GLASS CHANNEL WEATHERSTRIP
4 DOOR INNER PANEL
5 GLASS CHANNEL
6 DOOR OUTER PANEL
Fig. 54 Rear Glass Exterior Molding
1 UPPER MOLDING
2 MOLDING
3 SHIM
4 OUTER BELT MOLDING
5 SHIM
6 OUTER DOOR PANEL
23 - 46 BODY XJ
INSTALLATION
(1) When i nstal l i ng a door openi ng weatherstri p
seal , start at the door si l l center l i ne.
(2) Move upward and around edge of door openi ng.
Seat seal on fl ange.
(3) Move upward and around the peri meter of the
door openi ng and seat the weatherstri p on the fl ange
(Fi g. 56).
(4) I nstal l upper door openi ng tri m.
(5) I nstal l i nner scuff pl ate.
(6) I nstal l B-pi l l ar l ower tri m panel .
(7) I nstal l B-pi l l ar upper tri m panel .
REAR DOOR WINDOW REGULATOR
REMOVAL
(3) Remove the bol t attachi ng the wi ndow gl ass to
the regul ator and support the gl ass (Fi g. 57).
(4) Remove the l ower bol ts attachi ng the regul ator
to the i nner door panel (Fi g. 58).
(5) Remove the nuts attachi ng the regul ator motor
to the i nner door panel , i f equi pped.
(6) Loosen the upper bol t that attaches the regul a-
tor to the i nner door panel .
(7) Di sconnect the wi re harness connector from the
regul ator dri ve motor, i f equi pped.
(8) Remove the regul ator and dri ve motor, i f
equi pped.
INSTALLATION
(1) Posi ti on wi ndow regul ator and, i f equi pped,
dri ve motor wi thi n the door panel s.
(2) I nstal l the fasteners attachi ng the regul ator to
(3) Connect the regul ator wi re harness connector.
(4) Posi ti on the wi ndow gl ass at the regul ator and
i nstal l the retai ner, bushi ng and bol t.
REAR DOOR WINDOW GLASS
REMOVAL
(1) Lower the wi ndow gl ass.
(2) Remove the tri m panel .
1 FRONT DOOR SEAL
2 A PILLAR
3 SECONDARY DOOR SEAL
4 FRONT DOOR SEAL
5 REAR DOOR SEAL
6 ENDS MEET AT CENTERLINE
7 A PILLAR
1 VENT HOLES
2 VENT HOLES
3 FINISH
4 START
5 FINISH
6 START
7 B-PILLAR
8 SEAL
9 REAR DOOR WEATHERSTRIP SEAL
10 FRONT DOOR WEATHERSTRIP SEAL
11 FLANGE
12 SEAL
13 FLANGE
XJ BODY 23 - 47
(4) Remove i nner and outer bel tl i ne weatherstri p.
(5) Remove the wi ndow weatherstri p from the
door.
(6) Remove the di vi si on bar/stati onary gl ass (Fi g.
59).
(7) Remove the wi ndow gl ass screw, bushi ng and
retai ner from the regul ator.
(8) Remove the wi ndow gl ass from door.
INSTALLATION
(1) I nstal l the gl ass i n the door, and i nstal l the
retai ner, bushi ng and screw.
(2) Ti ghten the gl ass attachi ng screw 6 Nm (53 i n-
l bs) torque.
(3) I nstal l the di vi si on bar/stati onary gl ass i n the
door.
(4) I nstal l the gl ass run channel weatherstri p.
(5) I nstal l the i nner and outer bel tl i ne weather-
stri p.
BODY SIDE MOLDING
REMOVAL
(1) Loosen the body si de mol di ng (Fi g. 60) wi th a
heat gun.
(2) Li ft edge of mol di ng wi th a putty kni fe and
peel mol di ng from body panel . Appl y heat to any
l ocati on where the mol di ng remai ns adhered to a
panel .
(3) Remove the adhesi ve from the body panel wi th
Mopar Super Cl ean sol vent or equi val ent.
(4) I f the ori gi nal mol di ng wi l l be i nstal l ed, al so
remove al l adhesi ve from i t.
INSTALLATION
(1) I f the ori gi nal mol di ng wi l l be i nstal l ed, appl y
3M 5344 doubl e-si ded tape on the mol di ng.
(2) For verti cal al i gnment, use maski ng tape or a
stri ng as reference.
Fig. 57 Regulator To Glass Screw Removal/
Installation
1 ANCHOR
2 RETAINER (WITH TABS)
3 BRACKET
4 REGULATOR
5 SCREW AND BUSHING
6 WINDOW GLASS
Fig. 58 Rear Door Window
1 REAR DOOR
2 LOOSEN BOLT
3 REMOVE NUTS
4 REMOVE BOLTS
5 REGULATOR MOTOR
Fig. 59 Division Bar/Stationary Glass
1 UPPER SCREW
2 GLASS
3 LOWER SCREW
4 DIVISION BAR
23 - 48 BODY XJ
(3) Remove the backi ng from the tape, al i gn the
mol di ng and posi ti on i t on the body panel .
(4) Press the mol di ng onto the body panel wi th a
rol l er or hand pressure.
REAR FENDER FLARE
REMOVAL
(1) Remove the screw attachi ng the l ower part of
(2) Remove the nuts attachi ng the fender fl are
retai ner to the wheel house l i ner (Fi g. 61).
(3) Separate the fender fl are and retai ner from the
fender.
INSTALLATION
(1) Posi ti on the fender fl are and retai ner on the
fender.
(2) I nstal l the nuts attachi ng the fender fl are and
retai ner to the wheel house l i ner.
(3) I nstal l the screw attachi ng the l ower part of
QUARTER WINDOW APPLIQUE
REMOVAL
(1) Remove the l i ftgate pi l l ar tri m.
(2) Remove nuts from i nsi de vehi cl e (Fi g. 62).
(3) Usi ng a tri m si ck or equi val ent, careful l y pry
the appl i que the from panel .
INSTALLATION
(1) Posi ti on the repl acement appl i que the on panel
and i nstal l the nuts.
(2) I nstal l the l i ftgate pi l l ar tri m.
DRIP RAIL MOLDING
REMOVAL
(1) Pry the cl i ps from the roof fl ange.
(2) Remove the cl i ps and mol di ng from the roof
fl ange (Fi g. 62).
Fig. 60 Body Side Molding4-Door
Fig. 61 Fender Flare
1 CENTER RETAINER
2 WHEELHOUSE LINER
3 BODY
4 REAR RETAINER
5 FENDER FLARE
Fig. 62 Quarter Window Applique and Drip Molding
1 VEHICLE ROOF
2 DRIP MOLDING
3 DRIP MOLDING CLIP
4 DRIP MOLDING
5 CLIP
6 QUARTER WINDOW APPLIQUE
7 VEHICLE BODY
8 NUT
9 SEALANT
XJ BODY 23 - 49
(3) Remove the remai ni ng seal ant and cl ean the
roof fl ange.
INSTALLATION
(1) Posi ti on the dri p rai l mol di ng wi th cl i ps at the
roof fl ange and force the cl i ps onto the roof fl ange.
(2) Appl y seal ant to the i nner si de of the mol di ng
to seal the roof fl ange.
LUGGAGE RACK
REMOVAL
(1) Remove sl i de rai l screws (Fi g. 63).
(2) Remove l uggage rack from roof.
NOTE: Skid strips are attached to roof panel with
adhesive.
(3) Loosen each ski d stri p wi th a heat gun.
(4) Li ft one edge of each ski d stri p wi th a putty
kni fe and peel i t from roof panel .
(5) Remove ori gi nal adhesi ve from roof wi th an
adhesi ve removal sol uti on.
(6) I f ori gi nal ski d stri ps are i nstal l ed, remove al l
ori gi nal adhesi ve from m.
INSTALLATION
(1) I nstal l 3M 06379 doubl e-si ded tape, or an
equi val ent on ski d stri ps.
(2) Remove backi ng from doubl e-si ded tape, al i gn
each ski d stri p on roof, and posi ti on i t on roof panel .
(3) Veri fy that each ski d stri p i s properl y al i gned.
(4) Press each ski d stri p onto roof panel wi th a
rol l er (or use hand pressure).
NOTE: To prevent water leaks, apply 3M Drip-Chek
Sealant, or equivalent.
(5) Posi ti on l uggage rack on roof wi th screw hol es
al i gned.
(6) I nstal l and ti ghten sl i de rai l screws.
AIR EXHAUST GRILLE
REMOVAL
(1) Remove the screw that attaches the gri l l e to
door the openi ng panel (Fi g. 64).
(2) Pry the bottom edge of the gri l l e from the door
openi ng panel .
(3) Pul l downward and remove the gri l l e from
exhaust port i n the door openi ng panel .
INSTALLATION
(1) Posi ti on the sl ot l ocated i n the upper end of
repl acement gri l l e at the exhaust port and i nsert
edge i n the sl ot.
(2) Push i nward and seat the gri l l e i n the exhaust
port.
(3) I nstal l the screw to attach the gri l l e to the door
openi ng panel .
Fig. 63 Luggage Rack
1 SIDE RAIL
2 CROSS RAIL
3 CROSS RAIL ADJUSTMENT RELEASE BUTTON
4 RIVET-NUT
5 SCREW
6 SKID STRIP
7 ROOF
Fig. 64 Door Opening Air Exhaust Grille
1 SCREW
2 AIR EXHAUST GRILLE
3 C-PILLER
4 AIR EXHAUST GRILLE
5 DOOR OPENING PANEL
23 - 50 BODY XJ
A-PILLAR TRIM
REMOVAL
(1) Remove front and rear assi st handl es, i f
equi pped.
(2) Remove the i nner scuff pl ate.
(3) Remove the l ower A-pi l l ar cowl tri m.
(4) Usi ng a smal l fl at bl ade, pry the tri m pl ugs
from the A-pi l l ar tri m.
(5) Remove the screws attachi ng the A-pi l l ar tri m
to the A-pi l l ar (Fi g. 65).
(6) Separate the A-pi l l ar tri m from the A-pi l l ar.
INSTALLATION
(1) Posi ti on the A-pi l l ar tri m on the A-pi l l ar.
(2) I nstal l the screws attachi ng the A-pi l l ar tri m to
the A-pi l l ar.
(3) I nstal l the tri m pl ugs.
(4) I nstal l the l ower A-pi l l ar cowl tri m.
(5) I nstal l the i nner scuff pl ate.
(6) I nstal l the assi st handl es.
LOWER A-PILLAR COWL TRIM
REMOVAL
(2) Remove the nut behi nd the fuse panel access
door (Ri ght si de onl y) (Fi g. 66).
(3) Remove the fasteners attachi ng the l ower A-pi l -
l ar cowl tri m to the A-pi l l ar l ower cowl .
(4) Separate the l ower A-pi l l ar cowl tri m from the
A-pi l l ar l ower cowl .
Fig. 65 Trim Panels2-Door Vehicles
1 SPACER
2 LIFTGATE PILLAR TRIM
3 UPPER QUARTER PANEL TRIM
4 COAT HOOK
5 WHEELHOUSE COVER
6 LOWER QUARTER PANEL TRIM
7 COVER
8 LOWER B-PILLAR TRIM
9 PUSH-IN FASTENER
10 NUT
11 INNER SCUFF PLATE
12 ACCESS DOOR
13 COWL PANEL TRIM
14 TRIM PLUG
15 OVERHEAD ASSIST HANDLE
16 A-PILLAR TRIM
17 UPPER B-PILLAR TRIM
XJ BODY 23 - 51
INSTALLATION
(1) Posi ti on the l ower A-pi l l ar cowl tri m on the
A-pi l l ar l ower cowl .
(2) I nstal l the screws attachi ng the l ower A-pi l l ar
cowl tri m to the A-pi l l ar l ower cowl .
(3) I nstal l the nut behi nd the fuse panel access
door (Ri ght si de onl y).
FRONT INNER SCUFF PLATE
REMOVAL
(1) I f necessary, remove the bucket seat si de shi el d
tri m cover.
(2) Remove the screws attachi ng the i nner scuff
pl ate to the front door si l l (Fi g. 65).
(3) Separate the i nner scuff pl ate from the door
si l l .
INSTALLATION
(1) Posi ti on the i nner scuff pl ate on the front door
si l l .
(2) I nstal l the screws attachi ng the i nner scuff
pl ate to the front door si l l .
(3) I f removed, i nstal l the bucket seat si de shi el d
tri m cover.
DOOR SILL SCUFF PLATE
REMOVAL
(1) Remove the screws attachi ng the door si l l scuff
pl ate to the door si l l (Fi g. 67).
(2) Separate the scuff pl ate from the door si l l .
INSTALLATION
(1) Posi ti on the scuff pl ate on the door si l l .
(2) I nstal l the screws attachi ng the door si l l scuff
pl ate to the door si l l .
ASSIST HANDLE
REMOVAL
(1) Usi ng a tri m sti ck or equi val ent, open the end
covers to access the screws.
(2) Remove the screws (Fi g. 65).
(3) Separate the assi st handl e from the tri m.
INSTALLATION
(1) Posi ti on the handl e on the tri m.
(2) I nstal l the screws.
(3) I nstal l the covers.
B-PILLAR TRIM
REMOVAL
(2) Remove the upper door openi ng tri m (4-door
vehi cl es) (Fi g. 68).
(3) Remove the upper quarter panel tri m (2-door
(4) Remove the rear A-pi l l ar tri m screw.
(5) Remove the shoul der bel t turni ng l oop.
(6) Remove the seat/shoul der bel t anchor bol t.
(7) Remove the screws attachi ng the B-pi l l ar tri m
to the B-pi l l ar (2-door vehi cl es).
(8) Route the shoul der bel t through the l ower
B-pi l l ar tri m (2-door vehi cl es).
(9) Separate the B-pi l l ar tri m from the B-pi l l ar.
Fig. 66 Lower A-Pillar Cowl Trim
1 COWL PANEL
2 COWL PANEL TRIM
3 ACCESS DOOR
4 NUT
Fig. 67 Door Sill Scuff Plate
1 REAR DOOR SILL SCUFF PLATE
2 FRONT DOOR SILL SCUFF PLATE
23 - 52 BODY XJ
INSTALLATION
(1) Route the shoul der bel t through the l ower
B-pi l l ar tri m (2-door vehi cl es).
(2) Posi ti on the B-pi l l ar tri m on the B-pi l l ar and
al i gn push-i n fasteners.
(3) Press the B-pi l l ar tri m on the B-pi l l ar to
secure.
(4) I nstal l the screws attachi ng the B-pi l l ar tri m to
the B-pi l l ar (2-door vehi cl es).
(5) I nstal l the seat/shoul der bel t anchor bol t.
(6) I nstal l the shoul der bel t turni ng l oop.
(7) I nstal l the A-pi l l ar tri m.
(8) I nstal l the upper quarter panel tri m (2-door
(9) I nstal l the upper door openi ng tri m (4-door
C-PILLAR TRIM
REMOVAL
(2) Remove the upper door openi ng tri m.
(3) Remove the upper quarter panel tri m.
(4) Remove the quarter panel tri m extensi on.
(5) Remove the screws attachi ng the C-pi l l ar tri m
to the C-pi l l ar (Fi g. 68).
(6) Separate the C-pi l l ar tri m from the C-pi l l ar.
INSTALLATION
(1) Posi ti on the C-pi l l ar tri m on the C-pi l l ar.
Fig. 68 B-Pillar Trim4-Door Vehicles
1 UPPER DOOR OPENING TRIM
2 C-PILLAR TRIM
3 UPPER QUARTER PANEL TRIM
4 LIFTGATE PILLAR TRIM
5 WHEEL HOUSE COVER
6 LOWER QUARTER PANEL TRIM
7 QUARTER PANEL TRIM EXTENSION
8 COAT HOOK
9 OVERHEAD ASSIST HANDLE
10 INNER SCUFF PLATE
11 PUSH-IN FASTENER
12 ACCESS DOOR
13 NUT
14 COWL PANEL TRIM
15 A-PILLAR TRIM
16 HEADLINER
17 B-PILLAR TRIM
18 TRIM PLUG
XJ BODY 23 - 53
(2) I nstal l the screws attachi ng the C-pi l l ar tri m to
the C-pi l l ar.
(3) I nstal l the quarter panel tri m extensi on.
(4) I nstal l the upper quarter panel tri m.
(5) I nstal l the upper door openi ng tri m.
QUARTER PANEL TRIM EXTENSION
REMOVAL
(2) Separate quarter panel tri m extensi on from the
wheel house and quarter tri m panel s (Fi g. 68).
INSTALLATION
(1) Posi ti on the quarter panel tri m extensi on on
the wheel house and quarter tri m panel s.
QUARTER PANEL TRIM AND WHEELHOUSE
COVER
REMOVAL
(2) Remove quarter panel tri m extensi on.
(3) Remove l i ftgate scuff pl ate.
(4) Remove the screws attachi ng the quarter panel
tri m from the quarter panel and wheel house tri m
cover (Fi g. 68) and (Fi g. 65).
(5) I f necessary, remove the ti re and mounti ng
brackets from the l eft quarter panel tri m (Fi g. 69).
(6) Remove the screws attachi ng the wheel house
cover to the wheel house.
(7) Separate the wheel house cover from the wheel -
house
INSTALLATION
(1) Posi ti on the wheel house cover on the wheel -
house.
(2) I nstal l the screws attachi ng the wheel house
cover to the wheel house.
(3) I f removed, i nstal l the ti re and mounti ng
bracket on the l eft quarter panel tri m.
Fig. 69 Spare Tire
1 MOUNTING BRACKET
2 QUARTER TRIM
3 TIRE REST
4 COVER
5 TIRE/WHEEL
6 CUP
7 WING NUT
8 CAP
9 MOUNTING BRACKET
10 HOLD DOWN BOLT
23 - 54 BODY XJ
(4) Posi ti on the quarter panel tri m on the quarter
panel and wheel house cover.
(5) I nstal l the screws attachi ng quarter panel tri m
on the quarter panel and wheel house cover
(6) I nstal l l i ftgate scuff pl ate.
(7) I nstal l quarter panel tri m extensi on.
LIFTGATE PILLAR TRIM
REMOVAL
(1) Remove the l i ftgate openi ng upper tri m.
(2) Remove the l i ftgate pi l l ar tri m screws (Fi g. 70).
(3) Remove the screws attachi ng the l ower quarter
panel tri m to the l i ftgate pi l l ar.
(4) Pul l the tri m panel outward to detach the
spri ng steel cl i ps attachi ng the tri m panel to the pi l -
l ar (2-dr vehi cl es).
(5) Remove l i ftgate pi l l ar tri m.
INSTALLATION
(1) Posi ti on the l i ftgate pi l l ar tri m on the l i ftgate
pi l l ar.
(2) Press the tri m panel i nto pl ace to engage the
spri ng steel cl i ps attachi ng the tri m panel to the pi l -
l ar (2-dr vehi cl es).
(3) I nstal l the screws attachi ng the l ower quarter
panel tri m to the l i ftgate pi l l ar.
(4) I nstal l the l i ftgate pi l l ar tri m screws.
(5) I nstal l the l i ftgate openi ng upper tri m.
LIFTGATE OPENING UPPER TRIM
REMOVAL
(1) Remove the screws attachi ng the l i ftgate open-
i ng upper tri m to the roof panel (Fi g. 71).
(2) Pul l downward to di sengage steel cl i ps attach-
i ng the l i ftgate openi ng upper tri m to the roof panel .
(3) Separate tri m from vehi cl e.
INSTALLATION
Steel cl i ps are used for manufacturi ng purposes
and are not requi red for servi ce.
(1) Posi ti on tri m on roof panel .
(2) I nstal l the screws attachi ng the l i ftgate open-
i ng upper tri m to the roof panel .
LIFTGATE SCUFF PLATE
REMOVAL
(1) Remove the screws attachi ng the l i ftgate scuff
pl ate to the fl oor pan (Fi g. 72).
(2) Separate the scuff pl ate from the vehi cl e.
INSTALLATION
(1) Posi ti on the scuff pl ate on the vehi cl e.
(2) Center stri ker i n openi ng.
(3) I nstal l the screws attachi ng the l i ftgate scuff
pl ate to the fl oor pan.
FRONT SHOULDER BELT/BUCKLE
CAUTION: Inspect the front shoulder belts and
buckles. Replace any belt that is either cut, frayed,
torn or damaged in any way. Replace the shoulder
belt if the retractor is damaged or inoperative.
Fig. 70 Liftgate Pillar Trim
1 UPPER LIFTGATE OPENING TRIM
2 UPPER LIFTGATE PILLAR TRIM
3 LOWER QUARTER TRIM
Fig. 71 Liftgate Opening Upper Trim
1 UPPER LIFTGATE OPENING TRIM
XJ BODY 23 - 55
REMOVAL
(1) Sl i de the front seats al l the way forward for
access to the bel t anchor bol t.
(2) Di sconnect the bel t wi re harness connector.
(3) Remove the anchor bol t cover.
(4) Remove the anchor bol t attachi ng the buckl e to
the seat.
(5) Remove the turni ng l oop cover conceal i ng the
shoul der bel t upper anchor bol t.
(6) Use a Torx bi t to remove the upper anchor bol t
(Fi g. 73). Remove the support/gui de washer.
(7) Remove the i nner scuff pl ate/tri m panel from
the door si l l and remove the shoul der bel t l ower
anchor bol t(s) wi th a Torx bi t (Fi g. 74) and (Fi g. 75).
(8) Remove the shoul der bel t and the retractor.
INSTALLATION
(1) Posi ti on the shoul der bel t retractor i n the
shi el d and i nstal l the l ower anchor bol t wi th a Torx
bi t. Ti ghten bol t to 43 Nm (32 ft. l bs.) torque.
(2) Posi ti on the support/gui de washer and shoul der
bel t upper anchor pl ate on the tri m panel . I nstal l the
upper anchor bol t wi th a Torx bi t.
(3) Route bel t through tri m panel .
(4) Ti ghten the upper and l ower anchor bol ts to 43
(5) I nstal l the door si l l i nner scuff pl ate/tri m panel
and i nstal l the cap over the upper anchor bol t.
(6) I nstal l the shoul der bel t buckl e and anchor
bol t. Connect the wi re harness connectors. Ti ghten
the buckl e anchor bol t to 43 Nm (32 ft. l bs.) torque.
Fig. 72 Liftgate Scuff Plate
1 LIFTGATE SCUFF PLATE
Fig. 73 Anchor Bolt
1 TRIM PANEL
2 TURNING LOOP
3 BELT
4 ADJUSTER
Fig. 74 Front Shoulder Belt2-Door Vehicles
1 ADJUSTER
2 TRIM PANEL
3 TURNING LOOP
4 RETRACTOR
5 TRIM PANEL
23 - 56 BODY XJ
REAR SHOULDER/LAP BELT/BUCKLE
WARNING: Inspect rear shoulder/lap belts and
buckles. Replace any belt that is either cut, frayed,
torn or damaged in any way. Replace shoulder belt
if retractor is damaged or inoperative.
REMOVAL
(1) Pul l rear seat rel ease strap and ti l t seat cush-
i on forward.
(2) Remove shoul der bel t buckl e and l ap bel t/
buckl e anchor pl ate bol ts from fl oor pan (Fi g. 76).
(3) Remove shoul der bel t l ower outer anchor bol t.
(4) Remove quarter tri m panel . I f necessary, refer
to removal procedure.
(5) Remove shoul der bel t upper anchor bol t.
(6) Remove bol t attachi ng retractor to rear quarter
rai l .
(7) Separate retractor and shoul der bel t from tri m
panel .
INSTALLATION
(1) Posi ti on shoul der bel t buckl e and l ap bel t/
buckl e anchor pl ates on fl oor panel .
(2) I nstal l anchor bol ts. Ti ghten bol ts to 43 Nm
(3) I nstal l retractor support on rear quarter rai l .
Ti ghten screw.
(4) Route shoul der bel t through quarter tri m panel
sl ot.
(5) Posi ti on shoul der bel t at roof rai l and i nstal l
upper anchor bol t. Ti ghten bol t to 43 Nm (32 ft. l bs.)
torque.
(6) I nstal l quarter tri m panel .
(7) I nstal l shoul der bel t l ower anchor bol t. Ti ghten
bol t to 43 Nm (32 ft. l bs.) torque.
(8) Return rear seat cushi on to normal posi ti on
and engage l atch.
FULL FLOOR CONSOLE
REMOVAL
(1) Remove the transmi ssi on shi ft l ever handl e/
knob:
Automati c transmi ssi ons, pul l the handl e
strai ght upward to remove i t.
I nsert a thi n-bl ade tool under the edge of the
transmi ssi on shi ft i ndi cator bezel and pry up to
remove.
Manual transmi ssi ons, l oosen the l ocknut and
un-thread the shi ft knob from the shaft.
Pul l the shi ft boot up to remove.
(2) I nsert a thi n-bl ade tool under the edge of the
transfer case shi ft i ndi cator bezel or cover pl ate and
pry up to remove.
Fig. 75 Front Shoulder Belt4-Door Vehicles
1 TRIM PANEL
2 TURNING LOOP
3 RETRACTOR
4 TRIM PANEL
5 ADJUSTER
Fig. 76 Rear Seat Shoulder/Lap Belts and Buckles
1 TURNING LOOP
2 RETRACTOR
3 LAP BELT AND BUCKLE
XJ BODY 23 - 57
(3) Open the consol e l i d.
(4) Remove the screws attachi ng the consol e to the
fl oor and mounti ng bracket (Fi g. 77).
(5) Di sconnect the wi re harness connector.
(6) Separate the consol e from the fl oor.
INSTALLATION
(1) Posi ti on the consol e on the fl oor.
(2) Attach the ai r duct to the ai r outl et duct.
(3) Connect the wi re harness connectors.
(4) I nstal l the screws attachi ng the consol e to the
mounti ng bracket.
(5) I nstal l the shi ft i ndi cator bezel s (or cover
pl ate).
(6) I nstal l the shi ft l ever handl e/knob.
FRONT CARPET/MAT
REMOVAL
(1) Remove the door si l l i nner scuff pl ates.
(2) Remove the front and rear seats (as appl i ca-
bl e).
(3) Remove fl oor consol e.
(4) As necessary, remove the tri m panel s and
mol di ngs.
(5) Remove al l other i nterferi ng components.
(6) Remove the carpet and mat from the fl oor
panel (Fi g. 78).
INSTALLATION
(1) Posi ti on the carpet and mat on the fl oor panel .
(2) I nstal l al l the components that were removed
to faci l i tate carpet/mat removal .
(3) I nstal l the tri m panel s and mol di ngs.
(4) I nstal l the door si l l i nner scuff pl ates.
(5) I nstal l fl oor consol e.
(6) I nstal l the front and rear seats (as appl i cabl e).
REAR CARPET/MAT
REMOVAL
(1) Remove the l i ftgate l atch stri ker and scuff
pl ate.
(2) Dri l l -out the retai ni ng ri vet heads and remove
the cargo ti e-down footman l oops from the carpet.
(3) As necessary, remove the tri m panel s and
mol di ngs.
(4) Remove the al l other i nterferi ng components.
(5) Remove the carpet and mat from the fl oor
panel .
(6) I f necessary, remove the i nsul ati on from the
wheel house (Fi g. 79).
INSTALLATION
(1) I f removed, i nstal l the i nsul ati on on the wheel -
houses.
(2) Posi ti on the mat on the fl oor panel .
(3) Posi ti on the carpet on the mat.
(4) I nstal l al l the components that were removed
to faci l i tate carpet and mat removal .
(5) I nstal l the tri m panel s and mol di ngs.
(6) I nstal l the cargo ti e-down footman l oops on the
carpet wi th repl acement ri vets.
(7) I nstal l the l i ftgate scuff pl ate and l atch stri ker.
Fig. 77 Floor Console
1 TRANSFER CASE SHIFT BEZEL
2 COVER
3 TRANS SHIFT BEZEL
4 FLOOR CONSOLE
5 WASHER (2WD)
6 BRACKET
7 DUCT
Fig. 78 Front Carpet and Mat
1 CARPET AND MAT
2 POWER SEAT WIRE HARNESS SLOT
3 FLOOR PANEL
4 SEAT FRAME STUD
23 - 58 BODY XJ
REARVIEW MIRROR
REMOVAL
(1) Loosen the mi rror base setscrew (Fi g. 80).
(2) Sl i de the mi rror base upward and off the
bracket.
INSTALLATION
(1) Posi ti on the mi rror base at the bracket and
sl i de i t downward onto the support bracket.
(2) Ti ghten setscrew to1 Nm (9 i n. l bs.) torque.
REARVIEW MIRROR SUPPORT BRACKET
INSTALLATION
(1) Mark the posi ti on for the mi rror bracket on the
outsi de of the wi ndshi el d gl ass wi th a wax penci l .
(2) Cl ean the bracket contact area on the gl ass.
Use a mi l d powdered cl eanser on a cl oth saturated
wi th i sopropyl (rubbi ng) al cohol . Fi nal l y, cl ean the
gl ass wi th a paper towel dampened wi th al cohol .
(3) Sand the surface on the support bracket wi th
fi ne gri t-sandpaper. Wi pe the bracket surface cl ean
wi th a paper towel .
(4) Appl y accel erator to the surface on the bracket
accordi ng to the fol l owi ng i nstructi ons:
Crush the vi al to saturate the fel t appl i cator.
Remove the paper sl eeve.
Appl y accel erator to the contact surface on the
bracket.
Al l ow the accel erator to dry for fi ve mi nutes.
Do not touch the bracket contact surface after
the accel erator has been appl i ed.
(5) Appl y adhesi ve accel erator to the bracket con-
tact surface on the wi ndshi el d gl ass. Al l ow the accel -
erator to dry for one mi nute. Do not touch the gl ass
contact surface after the accel erator has been
appl i ed.
(6) I nstal l the bracket accordi ng to the fol l owi ng
i nstructi ons:
Appl y one drop of adhesi ve at the center of the
bracket contact-surface on the wi ndshi el d gl ass.
Appl y an even coat of adhesi ve to the contact
surface on the bracket.
Al i gn the bracket wi th the marked posi ti on on
the wi ndshi el d gl ass.
Press and hol d the bracket i n pl ace for at l east
one mi nute.
NOTE: Verify that the mirror support bracket is cor-
rectly aligned, because the adhesive will cure rap-
idly.
(7) Al l ow the adhesi ve to cure for 8-10 mi nutes.
Remove any excess adhesi ve wi th an al cohol -damp-
ened cl oth.
(8) Al l ow the adhesi ve to cure for an addi ti onal
8-10 mi nutes before i nstal l i ng the mi rror.
Fig. 79 Wheelhouse Insulation
1 REAR WHEELHOUSE
2 FACE SIDE
3 ADHESIVE
4 WHEELHOUSE PANEL
5 FACE SIDE
6 ADHESIVE
7 WHEELHOUSE PANEL
8 LOWER INSULATION
9 UPPER INSULATION
Fig. 80 Rearview Mirror
1 MIRROR
2 SUPPORT BUTTON
XJ BODY 23 - 59
SUNVISORS
REMOVAL
(1) Remove the screws that attach the sunvi sor
arm support bracket to the headl i ner and the roof
panel (Fi g. 81) and (Fi g. 82).
(2) Di sconnect vani ty l amp connector, i f equi pped.
(3) Detach the sunvi sor from the support cl i p.
(4) Remove the sunvi sor from the vehi cl e.
(5) Remove the retai ni ng screw and support cl i p.
On vehi cl es equi pped wi th an overhead consol e, the
support cl i p i s i ntegral wi th the overhead consol e.
INSTALLATION
(1) I nstal l the support bracket and the retai ni ng
screw.
(2) Connect vani ty l amp connector, i f equi pped.
(3) Posi ti on the sunvi sor i n the support cl i p and
al i gn the arm support bracket hol es wi th the head-
l i ner hol es.
(4) I nstal l the screws that attach the sunvi sor arm
support bracket to the headl i ner and the roof panel .
HEADLINER
The upper tri m mol di ngs and the headl i ner are
attached to the roof rai l wi th a combi nati on of
screws, cl i p retai ners and rai l retai ners (Fi g. 83).
To remove a headl i ner, al l of the upper tri m mol d-
i ngs must be removed from the peri meter of the
headl i ner al ong wi th (as appl i cabl e):
Assi st handl es.
Sunvi sors.
Dome/cargo l amps.
Overhead consol e.
Al l other attached/overl appi ng components.
Fig. 81 Sunvisor
1 HEADLINER
2 VEHICLE ROOF
3 HEADLINER
4 SUPPORT CLIP
5 SCREW
6 SUN VISOR
7 SCREW
8 SUN VISOR ARM SUPPORT BRACKET
Fig. 82 Sunvisor w/Vanity Lamp
1 HEADLINER
2 SUPPORT CLIP
3 SUNVISOR
Fig. 83 Headliner Trim Moldings
1 ROOF RAIL
2 HEADLINER MOULDING
3 SCREW
4 SPACER
5 LIFTGATE PILLAR TRIM COVER
6 ASSIST HANDLE
7 SCREW
8 ASSIST HANDLE
9 WINDSHIELD SIDE MOULDING
10 COVER PLUG
11 SCREW
23 - 60 BODY XJ
Refer to the appropri ate removal and i nstal l ati on
procedure l ocate i n thi s secti on or i n Group 8, El ec-
tri cal .
REMOVAL
CAUTION: The headliner is a one-piece, molded
component (Fig. 84). It has limited flexibility and
must not be bent during removal/installation.
(1) Remove the upper tri m mol di ngs from the
peri meter of the headl i ner (Fi g. 85).
(2) Ensure that al l the retai ner cl i ps and screws
are di sengaged before removi ng the headl i ner.
(3) Di sengage tabs attachi ng headl i ner/speaker
structure to roof rai l , i f equi pped (Fi g. 84).
(4) Di sengage rear speaker harness connector, i f
equi pped.
INSTALLATION
(1) Engage tabs attachi ng headl i ner/speaker struc-
ture to roof rai l , i f equi pped. (Fi g. 84)
(2) On vehi cl es wi thout headl i ner speakers, ensure
that the retai ner cl i ps on upper l i ftgate openi ng tri m
and rai l s are i nstal l ed. (Fi g. 86)
(3) Engage rear speaker harness connector.
(4) I nstal l the upper tri m mol di ngs around the
peri meter of the headl i ner. Ti ghten the retai ni ng
screws to 1 Nm (11 i n. l bs.) torque.
(5) As appl i cabl e, i nstal l :
Assi st handl es.
Sunvi sors.
Dome/cargo l amps.
Overhead consol e.
Al l other attached/overl appi ng components.
LIFTGATE TRIM PANEL
REMOVAL
(1) Usi ng a smal l fl at bl ade, pry out the tri m pl ugs
from the l i ftgate assi st handl e.
(2) Remove the screws attachi ng the assi st handl e
to the l i ftgate (Fi g. 87).
Fig. 84 Headliner
1 TAB
2 SPEAKER
3 GRILLE
4 CARGO LAMP
5 HEADLINER
Fig. 85 Upper Trim Molding4-Door
1 ROOF RAIL
2 SCREW
3 SPACER
4 ROOF RAIL
5 HEADLINER SLOT
6 SPACER
7 REAR HEADLINER TRIM MOLDING
8 FRONT HEADLINER TRIM MOLDING
9 TRIM MOLDING
Fig. 86 Headliner Retainer Clip and Retainer Rail
1 CLIP
2 RETAINER REAR
XJ BODY 23 - 61
(3) Remove the screws that attach the l i ftgate tri m
panel to the l i ftgate.
(4) Usi ng a tri m panel removal tool , detach the
push-i n fasteners from the l i ftgate.
(5) Remove the tri m panel from the l i ftgate.
INSTALLATION
(1) Posi ti on the tri m panel on l i ftgate.
(2) Usi ng new push-i n fasteners, al i gn the push-i n
fasteners wi th the hol es i n the l i ftgate i nner panel
and press the tri m panel i nto pl ace.
(3) I nstal l the screws to attach the l i ftgate tri m
panel to the l i ftgate.
(4) I nstal l the screws attachi ng the assi st handl e
to the l i ftgate.
(5) Press the tri m pl ugs i nto the l i ftgate assi st
handl e.
LIFTGATE
REMOVAL
WARNING: DO NOT DISCONNECT SUPPORT ROD
CYLINDERS WITH LIFTGATE CLOSED. SUPPORT
ROD PISTONS ARE OPERATED BY HIGH PRES-
SURE GAS. THIS COULD CAUSE DAMAGE AND/OR
PERSONAL INJURY IF THEY ARE REMOVED WHILE
PISTONS ARE COMPRESSED.
(1) Remove center hi gh mounted stop l amp
(CHMSL).
(2) Open and support l i ftgate.
(4) Di sconnect and pl ug backl i te washer fl ui d sup-
pl y l i ne.
(5) Remove screws that attach rear wi per and l i ft-
gate power l ock wi re harness connectors to l i ftgate
and di sconnect connectors.
(6) Usi ng access hol e created by removal of
CHMSL, route backl i te washer fl ui d suppl y l i ne and
rear wi per and l i ftgate power l ock wi re harness/
grommets through access hol e and separate from l i ft-
gate.
(7) Remove retai ner cl i ps that secure support rods
to bal l studs.
(8) Remove support rods from bal l studs.
(9) Remove bol ts attachi ng hi nges to l i ftgate.
(10) Remove l i ftgate from vehi cl e.
INSTALLATION
(1) Posi ti on and support l i ftgate at openi ng i n body
and i nstal l bol ts attachi ng hi nges to l i ftgate. Ti ghten
(2) Connect l i ftgate support rods to bal l studs and
i nstal l retai ner cl i ps.
(3) Route backl i te washer fl ui d suppl y l i ne and
rear wi per and l i ftgate power l ock wi re harnesses/
grommets through access hol e.
(4) Connect connectors and i nstal l screws that
attach rear wi per and l i ftgate power l ock wi re har-
ness connectors to l i ftgate
(5) Unpl ug and connect backl i te washer fl ui d sup-
pl y l i ne.
(7) Remove supports and cl ose l i ftgate.
(8) I nstal l (CHMSL).
LIFTGATE HINGE
REMOVAL
I t i s not necessary to remove the l i ftgate to repl ace
one or both hi nges.
(1) Open and support the l i ftgate.
(2) Remove the l i ftgate openi ng upper tri m.
(3) Remove the bol ts attachi ng the hi nge to the
header panel (Fi g. 88).
(4) Remove the bol ts attachi ng the hi nge to the
l i ftgate.
Fig. 87 Liftgate Trim Panel
1 TRIM PANEL
2 PUSH NUT
3 LIFTGATE
4 ASSIST HANDLE
5 PLUG
23 - 62 BODY XJ
INSTALLATION
(1) Posi ti on the hi nge on the l i ftgate.
(2) I nstal l the bol ts attachi ng the hi nge to the l i ft-
gate. Ti ghten to 26 Nm (19 ft. l bs.) torque.
(3) I nstal l the bol ts attachi ng the hi nge to the
header panel . Ti ghten to 26 Nm (19 ft. l bs.) torque.
(4) I nstal l the l i ftgate openi ng upper tri m.
(5) Remove the support and cl ose the l i ftgate.
LIFTGATE SUPPORT ROD CYLINDER
REMOVAL
WARNING: DO NOT REMOVE A SUPPORT ROD
CYLINDER WITH THE LIFTGATE CLOSED. EACH
SUPPORT ROD PISTON IS OPERATED BY HIGH
PRESSURE GAS. IT CAN CAUSE DAMAGE AND/OR
PERSONAL INJURY IF IT IS REMOVED WITH THE
PISTON COMPRESSED. DO NOT ATTEMPT TO DIS-
ASSEMBLE OR REPAIR A SUPPORT ROD CYLIN-
DER.
(1) Open the l i ftgate.
(2) Support the l i ftgate i n the open posi ti on.
(3) Remove the cl i p attachi ng the support rod to
the bal l stud.
(4) Di sconnect the support rod from the bal l stud.
(5) Remove the bol ts attachi ng the support rod to
the l i ftgate (Fi g. 89).
(6) Separate the support rod from the l i ftgate.
INSTALLATION
(1) Posi ti on the support rod on the l i ftgate.
(2) I nstal l the bol ts attachi ng the support rod to
the l i ftgate.
(3) Connect the support rod to the bal l stud.
(4) Secure the support rod to the bal l stud wi th
the retai ner cl i p.
(5) Remove the support from the l i ftgate.
LIFTGATE SUPPORT ROD BALL STUD
REMOVAL
(1) Open the l i ftgate.
(2) Support the l i ftgate i n the open posi ti on.
(3) Remove the retai ner cl i p attachi ng the support
rod to the bal l stud.
(4) Di sconnect the support rod from the bal l stud.
(5) Remove the bal l stud.
INSTALLATION
(1) I nstal l the repl acement bal l stud.
(2) Connect the support rod to the bal l stud.
(3) Secure the support rod to the bal l stud wi th
the cl i p.
(4) Remove the support from the l i ftgate.
LIFTGATE OUTSIDE HANDLE
REMOVAL
(2) Di sconnect l i ftgate actuator l i nkages.
(3) Di sconnect l i ftgate outsi de handl e to l atch rod.
(4) Remove nut attachi ng outsi de handl e to l i ftgate
(Fi g. 90).
(5) Separate outsi de handl e from l i ftgate.
(6) I f necessary, remove l ock cyl i nder (Fi g. 91).
Fig. 88 Liftgate Hinge
1 LIFTGATE HINGE
2 LIFTGATE
3 HEADER PANEL
4 HEADER PANEL
Fig. 89 Liftgate Support Rod
1 LIFTGATE
2 SUPPORT ROD CYLINDER
3 WASHER
4 BALL STUD
XJ BODY 23 - 63
INSTALLATION
(1) I f necessary, i nstal l l ock cyl i nder.
(2) Posi ti on outsi de handl e on l i ftgate.
(3) I nstal l nut attachi ng outsi de handl e to l i ftgate.
(4) Connect l i ftgate outsi de handl e to l atch rod.
(5) Connect l i ftgate actuator l i nkages.
LIFTGATE LOCK CYLINDER
For servi ce procedures, refer to the Li ftgate Out-
si de Handl e Removal /I nstal l ati on procedures.
LIFTGATE LATCH
REMOVAL
(1) Rai se l i ftgate.
(3) Remove screws attachi ng l atch to l i ftgate (Fi g.
92).
(4) Di sconnect rod from l atch.
(5) Di sconnect power l ock connector from handl e, i f
equi pped.
(6) Remove l atch from l i ftgate.
INSTALLATION
(1) Posi ti on l atch i n l i ftgate.
(2) Connect power l ock connector to handl e, i f
equi pped.
(3) Connect l atch rod.
(4) I nstal l screws attachi ng l atch to l i ftgate.
LIFTGATE LATCH STRIKER
REMOVAL
(1) From undersi de of vehi cl e, remove nuts attach-
i ng stri ker to fl oor pan (Fi g. 93).
(2) Separate stri ker from vehi cl e.
INSTALLATION
(1) Posi ti on stri ker on vehi cl e.
(2) I nstal l nuts. Ti ghten nuts to 54 Nm (40 ft.
l bs.) torque.
Fig. 90 Liftgate Outside Handle
1 POWER ACTUATOR
2 LIFTGATE LOCK
3 OUTSIDE HANDLE
5 LIFTGATE LATCH
6 ACTUATOR TO LIFTGATE LOCK ROD
Fig. 91 Liftgate Lock Cylinder
1 CLIP
2 OUTSIDE HANDLE
3 LOCK CYLINDER
Fig. 92 Liftgate Latch
1 POWER ACTUATOR
2 LIFTGATE LOCK
3 OUTSIDE HANDLE
5 LIFTGATE LATCH
6 ACTUATOR TO LIFTGATE LOCK ROD
23 - 64 BODY XJ
LIFTGATE WEATHERSTRIP
REMOVAL
(1) Pul l the seal away from the fl ange around the
peri meter of l i ftgate openi ng and remove i t.
(2) Cl ean the fl ange as necessary.
INSTALLATION
(1) Posi ti on weatherstri p seal i n the openi ng wi th
the l eft end of the seal at the openi ng centerl i ne.
I nstal l the seal i n a cl ockwi se di recti on.
(2) Move to the l eft and mate the seal wi th the
bottom-l eft fl ange (Fi g. 94).
(3) Move upward and mate the seal wi th the l eft-
si de fl ange.
(4) Move to the ri ght and mate the seal wi th the
top-l eft roof fl ange.
(5) Seat the i nstal l ed part of the seal wi th a rol l er.
Move the rol l er from the l eft-bottom end of seal to
the top-l eft hal f of the seal .
(6) Move to the ri ght and mate the seal wi th the
top-ri ght roof fl ange.
(7) Move downward and mate the seal wi th the
ri ght-si de fl ange.
(8) Move to the l eft and mate the seal wi th the
bottom-ri ght fl ange.
(9) Center and butt seal the ends together at the
centerl i ne.
(10) Seat the remai ni ng part of the seal wi th a
rol l er. Move the rol l er the from top-l eft hal f of the
seal to the ri ght-bottom end of the seal .
ADJ USTMENTS
HOOD
The hood bol t hol es are el ongated for fore and aft
and si de-to-si de adjustment.
(1) I f hood i s l ow to the cowl panel , i nsert shi ms
between the hi nge and hood at the rear hi nge bol ts.
(2) Adjust the hood bumper (Fi g. 95) i n or out to
provi de proper hood-to-fender hei ght al i gnment.
(3) Adjust the hood stri kers (Fi g. 96) wi th shi ms
as necessary. Ti ghten the screws to 22 Nm (16 ft-l bs)
torque after adjustment.
(4) Al i gn each l atch and stri ker so that the stri ker
enters l atch squarel y.
DOOR
IN AND OUT MINOR ADJUSTMENT
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker i nward i f the door charac-
ter l i ne i s outboard of the body character l i ne or tap
the l atch stri ker outward i f the door character l i ne i s
i nboard of the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker
wi th 28 Nm (20 ft. l bs.) torque.
Fig. 93 Liftgagte Striker
1 OVERSLAM BUMPER
2 STRIKER PLATE
3 STRIKER
4 SHIM
Fig. 94 Liftgate Weatherstrip Installation
1 LIFTGATE OPENING
2 WEATHERSTRIP SEAL
XJ BODY 23 - 65
UP AND DOWN MINOR ADJUSTMENT
(1) Loosen the l atch stri ker.
(2) Tap the l atch stri ker downward i f the door
character l i ne i s hi gher than the body character l i ne
or tap the l atch stri ker upward i f the door character
l i ne i s l ower than the body character l i ne.
(3) I nspect al i gnment. I f correct, ti ghten stri ker
wi th 28 Nm (20 ft. l bs.) torque.
ALIGNMENT MAJOR ADJUSTMENT
Adjustment for al i gnment of the door i s made by
i nstal l i ng shi ms between hi nge and door face (Fi g.
97).
(1) I f not l oosened, l oosen the door hi nge bol ts.
(2) Add or remove shi ms as necessary to obtai n
the best door fi t.
(3) Ti ghten door hi nge bol ts to 3 Nm (2 ft-l bs)
torque after adjustment i s compl eted.
(4) Appl y general purpose seal ant around the door
hi nges/door face mati ng area.
DOOR LATCH ADJUSTMENT
(1) Locate access hol e (Fi g. 98).
(2) I nsert a 5/32-i nch hex-wrench through hol e and
i nto adjustment screw. Loosen screw.
(3) Operate outsi de handl e button several ti mes to
rel ease any restri cti on because of mi s-al i gnment.
(4) Ti ghten adjustment screw to 3 Nm (30 i n-l bs)
torque.
(5) Test handl e button and l ock cyl i nder for proper
operati on.
Fig. 95 Hood Bumper
1 HOOD LATCH STRIKER REINFORCEMENT PANEL
2 HOOD BUMPER
Fig. 96 Hood Latch Striker
1 RADIATOR SUPPORT CROSSMEMBER
2 SCREW
3 RADIATOR BAFFLE
4 SHIM
5 HOOD LATCH STRIKER
6 SCREW
Fig. 97 Door Adjustment Shims
1 ADJUSTMENT SHIMS
23 - 66 BODY XJ
LIFTGATE
The posi ti on of l i ftgate can be adjusted upward or
downward by use of sl ots i n the hi nge. An i nward or
outward adjustment i s achi eved by use of sl ots i n the
body. I f an i nward or outward adjustment i s needed,
use 3M Fast and Fi rm or equi val ent on the hi nge
to body mati ng surface as a seal ant.
REAR SEATBACK
(1) Unl atch and posi ti on seatback i n cargo posi -
ti on.
(2) Loosen the screws attachi ng the stri kers to the
rear wheel house.
(3) Posi ti on the seat back i n the ful l upri ght posi -
ti on and secure the l atch i nto the stri kers.
(4) From the cargo area of the vehi cl e, push the
rear of the seatback forward.
(5) Unl atch and posi ti on seatback i n cargo posi -
ti on.
(6) Ti ghten the screws attachi ng the stri kers to
the rear wheel house.
(7) Posi ti on the seat back i n the ful l upri ght posi -
ti on and secure the l atch i nto the stri kers.
(8) Veri fy l atch operati on.
SPECIFICATIONS
BODY LUBRICANTS
COMPONENT SERVICE INTERVAL LUBRICANT
Door Latches As Required Multi-Purpose Grease NLGI GC-LB
(Water Resistant) (1)
Hood Latch, Release Mechanism & Safety
Latch
As Required
(When Performing Other
Underhood Service)
Multi-Purpose Grease NLGI GC-LB 2 EP
(2)
Hood Hinges As Required Engine Oil
Seat Track & Release Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2 EP
(2)
Liftgate Hinge As Required Multi-Purpose Grease NLGI GC-LB 2 EP
(2)
Liftgate Support Arms As Required Engine Oil
Liftgate Latches As Required White Spray Lubricant (3)
Liftgate Release Handle (Pivot & Slide
Contact Surfaces)
As Required Multi-Purpose Grease NLGI GC-LB 2 EP
(2)
Window System Components As Required White Spray Lubricant (3)
Lock Cylinders Twice A Year Lock Cylinder Lubricant (4)
Parking Brake Mechanism As Required Multi-Purpose Grease NLGI GC-LB 2 EP
(1)
1 = Mopar Wheel Bering Grease (High Temp)
2 = Mopar Multi-Mileage Lubricant
3 = Mopar Spray White Lube
4 = Mopar Lock Cylinder Lubricant
Fig. 98 Door Latch Adjustment
1 ACCESS HOLE
2 DOOR
3 LATCH MOUNTING BOLTS
4 LATCH
XJ BODY 23 - 67
WELD LOCATIONS
UPPER COWL
23 - 68 BODY XJ
UPPER COWL
XJ BODY 23 - 69
COWL
23 - 70 BODY XJ
A PILLAR
XJ BODY 23 - 71
A PILLAR
23 - 72 BODY XJ
A PILLAR
XJ BODY 23 - 73
A PILLAR
23 - 74 BODY XJ
B PILLAR
XJ BODY 23 - 75
D PILLAR
23 - 76 BODY XJ
FUEL FILLER OPENING
XJ BODY 23 - 77
CARGO AREA FLOOR PAN
23 - 78 BODY XJ
ROOF AND D PILLAR
XJ BODY 23 - 79
LIFTGATE OPENING
23 - 80 BODY XJ
ROOF
XJ BODY 23 - 81
ROOF
23 - 82 BODY XJ
FRAME RAIL
XJ BODY 23 - 83
FRAME RAIL
23 - 84 BODY XJ
FRAME RAIL
XJ BODY 23 - 85
FRAME RAIL
23 - 86 BODY XJ
REINFORCEMENT
XJ BODY 23 - 87
FRONT INNER FENDER
23 - 88 BODY XJ
FRONT INNER FENDER AND RADIATOR CLOSURE
PANEL
XJ BODY 23 - 89
REINFORCEMENT
23 - 90 BODY XJ
FRONT FENDER
XJ BODY 23 - 91
BODY SIDE
23 - 92 BODY XJ
REAR WHEELHOUSE
XJ BODY 23 - 93
REAR INNER WHEELHOUSE
23 - 94 BODY XJ
BODY SIDE
XJ BODY 23 - 95
BODY SIDE
23 - 96 BODY XJ
BODY SIDE
XJ BODY 23 - 97
BODY SIDE
23 - 98 BODY XJ
BODY SIDE
XJ BODY 23 - 99
BODY SIDE
23 - 100 BODY XJ
UNDERBODY
XJ BODY 23 - 101
UNDERBODY
23 - 102 BODY XJ
UNDERBODY
XJ BODY 23 - 103
UNDERBODY
23 - 104 BODY XJ
UNDERBODY
XJ BODY 23 - 105
UNDERBODY
23 - 106 BODY XJ
UNDERBODY
XJ BODY 23 - 107
UNDERBODY
23 - 108 BODY XJ
UNDERBODY
XJ BODY 23 - 109
UNDERBODY
23 - 110 BODY XJ
UNDERBODY
XJ BODY 23 - 111
BODY SEALING LOCATIONS
APPLICATION METHODS
23 - 112 BODY XJ
COWL AND DASH PANEL
XJ BODY 23 - 113
DASH PANEL AND FLOOR PAN
23 - 114 BODY XJ
FLOOR PAN
XJ BODY 23 - 115
REAR INNER WHEELHOUSE
23 - 116 BODY XJ
FRONT INNER WHEELHOUSE
XJ BODY 23 - 117
BODY SIDE
23 - 118 BODY XJ
BODY SIDE
XJ BODY 23 - 119
BODY SIDE
23 - 120 BODY XJ
ROOF PANEL
XJ BODY 23 - 121
FUEL FILLER HOUSING
23 - 122 BODY XJ
LIFTGATE OPENING
XJ BODY 23 - 123
STRUCTURAL ADHESIVE LOCATIONS
LEFT QUARTER PANEL
23 - 124 BODY XJ
REAR WHEELHOUSE
XJ BODY 23 - 125
ROOF BOWS
23 - 126 BODY XJ
BODY GAP AND FLUSH MEASUREMENTS
LOCATION GAP FLUSH
A Front Door to Windshield Pillar 6.4 +/- 2.0 1.6 +/- 2.0
B Front Door to REar Door 6.4 +/1 1.5 0.0 +/- 1.5
C Front Door to Aperture at Sill 8.1 +/- 1.5 0.0 +/- 1.5
D Front Door to Fender 6.4 +/- 1.5 00 +/- 1.5
E Hood to Fender 5.6 +/- 1.5 0.5 +/- 1.5
F Headlamp to Fender 5.6 +/- 1.5 0.5 +/- 1.5
G Headlamp to Roof N/A 0.74 +/- 1.0
H Grille to Hood 6.0 +/- 1.5 0.24 +/- 1.5
I Liftgate to Roof 7.5 +/- 1.5 0.5 +/- 1.5
J Liftgate to Aperture 6.5 +/- 1.5 0.0 +/- 1.5
K Liftgate to Fascia X. X +/- 2.0 N/A
L Rear Door to Quarter Panel 6.4 +/- 1.5 0.0 +/- 1.5
XJ BODY 23 - 127
BODY OPENING DIMENSIONS
WINDSHIELD OPENING
A. & B. Center of radi us at bottom to center of
radi us at top
23 - 128 BODY XJ
FRONT DOOR OPENING 2DOOR
A. Center of front door l ower rear radi us to cen-
ter of A-pi l l ar radi us
B. Center of radi us at bottom rear to center of
radi us at l ower A-pi l l ar
C. Center of radi us at bottom front to center of
radi us at top rear
XJ BODY 23 - 129
FRONT DOOR OPENING 4DOOR
C. Center of front door l ower rear radi us to cen-
ter of A-pi l l ar radi us
E. Center of radi us at bottom rear to center of
radi us at l ower A-pi l l ar
F. Center of radi us at bottom front to center of
radi us at top rear
23 - 130 BODY XJ
REAR DOOR OPENING
A. Quarter panel to front outer body si de upper
and l ower seam
B. Center of front upper door radi us to center of
rear l ower door radi us
C. Center of front l ower door radi us to center of
rear upper door radi us
D. Fl ange to rear door stri ker mount
XJ BODY 23 - 131
QUARTER WINDOW OPENING 2DOOR
A. Center of upper and l ower rear quarter wi n-
dow openi ng
B. Center of radi us front l ower corner to center
of radi us rear upper corner
C. Center of radi us front upper corner to center
of radi us rear l ower corner
23 - 132 BODY XJ
QUARTER WINDOW OPENING 4DOOR
A. Center of upper and l ower rear quarter wi n-
dow openi ng
B. Center of radi us front l ower corner to center
of radi us rear upper corner
C. Center of radi us front upper corner to center
of radi us rear l ower corner
XJ BODY 23 - 133
ENGINE COMPARTMENT
LIFTGATE OPENING
A. Center of upper l i ftgate openi ng to l i ftgate
stri ker mount
B. & C. Center of radi us upper corner to center
of radi us l ower corner
D. Di stance between outer quarter panel to tai l
l amp mounti ng panel to i nner quarter panel seams
23 - 134 BODY XJ
DESCRIPTION TORQUE
Bucket Seat to Fl oor Pan Bol t . . 27 Nm (20 ft. l bs.)
Bucket Seat to Fl oor Pan Nut . . 40 Nm (30 ft. l bs.)
Front Door Hi nge Bol ts . . . . . . . . . 3 Nm (2 ft. l bs.)
Front Door Latch Screw . . . . . . . 11 Nm (8 ft. l bs.)
Front Door Latch Stri ker Screw . . . . . . . . . 28 Nm
(20 ft. l bs.)
Front Seat Bel t Anchor Bol t . . . 43 Nm (32 ft. l bs.)
Front Retractor Anchor Bol t . . . 43 Nm (32 ft. l bs.)
Front Seat Bel t Buckl e Anchor Bol t . . . . . . 43 Nm
(32 ft. l bs.)
GOP to Support Bracket Nut . . . 4 Nm (38 i n. l bs.)
GOP to Fender Nut . . . . . . . . . . 4 Nm (38 i n. l bs.)
Li ftgate Hi nge to Body and/or
Li ftgate Bol t . . . . . . . . . . . . . . . . . . . . . . 26 Nm
(19 ft. l bs.)
Li ftgate Latch Screw . . . . . . . . . . 13 Nm (9 ft. l bs.)
Li ftgate Latch Stri ker Nut . . . . 54 Nm (40 ft. l bs.)
Rear Door Hi nge Bol t . . . . . . . . . . 3 Nm (2 ft. l bs.)
Rear Door Latch Screw . . . . . . . . 11 Nm (8 ft. l bs.)
Rear Door Latch Stri ker Screw . 28 Nm (20 ft. l bs.)
Rear Shoul der Bel t Lower Anchor Bol t . . . . 43 Nm
(32 ft. l bs.)
DESCRIPTION TORQUE
Rear Seatback Pi vot Bol t . . . . . 33 Nm (25 ft. l bs.)
Rear Seat Bel t/Buckl e Anchor Bol t . . . . . . . 43 Nm
(32 ft. l bs.)
Rear Shoul der Bel t Upper Anchor Bol t . . . . 43 Nm
(32 ft. l bs.)
SPECIAL TOOLS
BODY
Remover, Moldings C-4829
XJ BODY 23 - 135
HEATING AND AIR CONDITIONING
TABLE OF CONTENTS
page page
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 2
BLOWER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . 2
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . . 2
BLOWER MOTOR RESISTOR. . . . . . . . . . . . . . . . 3
BLOWER MOTOR SWITCH. . . . . . . . . . . . . . . . . . 3
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPRESSOR CLUTCH. . . . . . . . . . . . . . . . . . . . 3
COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . . 4
CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DUAL FUNCTION HIGH PRESSURE SWITCH
(4.0 L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . 4
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . . . . 5
HEATER AND AIR CONDITIONER. . . . . . . . . . . . . 5
HEATER AND AIR CONDITIONER CONTROL . . . . 6
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . . . . 6
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . . . . 7
LOW PRESSURE CYCLING CLUTCH SWITCH. . . 7
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERANT LINES. . . . . . . . . . . . . . . . . . . . . . 7
REFRIGERANT LINE COUPLERS . . . . . . . . . . . . . 8
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . . . . . 8
REFRIGERANT SYSTEM SERVICE PORT. . . . . . . 9
VACUUM CHECK VALVE. . . . . . . . . . . . . . . . . . . . 9
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . . 9
A/C PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . 9
BLOWER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . 12
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . 13
BLOWER MOTOR RESISTOR. . . . . . . . . . . . . . . 14
BLOWER MOTOR SWITCH. . . . . . . . . . . . . . . . . 14
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMPRESSOR CLUTCH COIL . . . . . . . . . . . . . . 15
COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . 15
DUAL FUNCTION HIGH PRESSURE
SWITCH/HIGH PRESSURE CUT-OFF
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HEATER PERFORMANCE . . . . . . . . . . . . . . . . . . 16
LOW PRESSURE CYCLING CLUTCH SWITCH. . 17
REFRIGERANT SYSTEM LEAKS. . . . . . . . . . . . . 17
VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES
REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . . . . 19
REFRIGERANT RECOVERY. . . . . . . . . . . . . . . . . 22
REFRIGERANT SYSTEM EVACUATE. . . . . . . . . . 22
REFRIGERANT SYSTEM CHARGE . . . . . . . . . . . 22
REFRIGERANT SYSTEM SERVICE
EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE WARNINGS AND PRECAUTIONS . . . . 23
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 25
BLEND-AIR DOOR MOTOR . . . . . . . . . . . . . . . . 26
BLOWER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . 26
BLOWER MOTOR RELAY . . . . . . . . . . . . . . . . . . 27
BLOWER MOTOR RESISTOR. . . . . . . . . . . . . . . 27
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 28
COMPRESSOR CLUTCH. . . . . . . . . . . . . . . . . . . 29
COMPRESSOR CLUTCH RELAY. . . . . . . . . . . . . 31
CONDENSER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DUCTS AND OUTLETS . . . . . . . . . . . . . . . . . . . . 33
EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . 35
FIXED ORIFICE TUBE . . . . . . . . . . . . . . . . . . . . . 35
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . . . . 35
HEATER-A/C HOUSING. . . . . . . . . . . . . . . . . . . . 36
HEATER-A/C HOUSING DOOR . . . . . . . . . . . . . . 39
HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . . . . 41
LIQUID LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
LOW PRESSURE CYCLING CLUTCH SWITCH. . 42
KICK COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
MODE DOOR VACUUM ACTUATOR . . . . . . . . . . 43
REFRIGERANT LINE COUPLER . . . . . . . . . . . . . 45
SUCTION AND DISCHARGE LINE . . . . . . . . . . . 45
VACUUM CHECK VALVE. . . . . . . . . . . . . . . . . . . 46
VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . . . 47
SPECIFICATIONS
A/C APPLICATION TABLE. . . . . . . . . . . . . . . . . . 47
XJ HEATING AND AIR CONDITIONING 24 - 1
ACCUMULATOR
DESCRIPTION
The accumul ator i s mounted i n the engi ne com-
partment between the evaporator coi l outl et tube and
the compressor i nl et.
OPERATION
Refri gerant enters the accumul ator cani ster as a
l ow pressure vapor through the i nl et tube. Any l i q-
ui d, oi l -l aden refri gerant fal l s to the bottom of the
cani ster, whi ch acts as a separator. A desi ccant bag i s
mounted i nsi de the accumul ator cani ster to absorb
any moi sture whi ch may have entered and become
trapped wi thi n the refri gerant system (Fi g. 1).
BLOWER MOTOR
DESCRIPTION
The bl ower motor and bl ower wheel are l ocated i n
the passenger si de end of the heater-A/C housi ng,
bel ow the gl ove box. The bl ower motor control s the
vel oci ty of ai r fl owi ng through the heater-A/C hous-
i ng by spi nni ng a squi rrel cage-type bl ower wheel
wi thi n the housi ng at the sel ected speed. The bl ower
motor and wheel can be removed through an openi ng
i n the engi ne compartment si de of the dash panel
wi thout heater-A/C housi ng removal .
OPERATION
The bl ower motor wi l l onl y operate when the i gni -
ti on swi tch i s i n the On posi ti on, and the heater-A/C
mode control swi tch knob i s i n any posi ti on, except
Off. The bl ower motor recei ves a fused battery feed
through the bl ower motor rel ay whenever the i gni -
ti on swi tch i s i n the On posi ti on. The bl ower motor
battery feed ci rcui t i s protected by a fuse i n the
Power Di stri buti on Center (PDC). Bl ower motor
speed i s control l ed by regul ati ng the ground path
through the heater-A/C control bl ower motor swi tch
and the bl ower motor resi stor.
The bl ower motor and bl ower motor wheel cannot
be repai red and, i f faul ty or damaged, they must be
repl aced. The bl ower motor and bl ower wheel are ser-
vi ced onl y as a uni t.
BLOWER MOTOR RELAY
DESCRIPTION
The bl ower motor rel ay i s a I nternati onal Stan-
dards Organi zati on (I SO)-type rel ay. The rel ay i s a
el ectromechani cal devi ce that swi tches battery cur-
rent from a fuse i n the Power Di stri buti on Center
(PDC) di rectl y to the bl ower motor. The rel ay i s ener-
gi zed when the rel ay coi l i s provi ded a vol tage si gnal
by the i gni ti on swi tch. See Bl ower Motor Rel ay i n the
Di agnosi s and Testi ng secti on of thi s group for more
i nformati on.
OPERATION
The bl ower motor rel ay i s i nstal l ed i n a wi re har-
ness connector that i s secured to the passenger si de
outboard end of the heater-A/C housi ng i n the pas-
senger compartment, next to the heater-A/C wi re
harness connector.
The bl ower motor rel ay cannot be repai red and, i f
faul ty or damaged, i t must be repl aced.
Fig. 1 Accumulator - Typical
1 LOW PRESSURE CYCLING CLUTCH SWITCH
2 PRESSURE SWITCH FITTING
3 OUTLET TO COMPRESSOR
4 ANTI-SIPHON HOLE
5 DESICCANT BAG
6 OIL RETURN ORIFICE FILTER
7 VAPOR RETURN TUBE
8 ACCUMULATOR DOME
9 O-RING SEAL
10 INLET FROM EVAPORATOR
24 - 2 HEATING AND AIR CONDITIONING XJ
BLOWER MOTOR RESISTOR
DESCRIPTION
The bl ower motor resi stor i s mounted to the bot-
tom of the heater-A/C housi ng on the passenger si de
of the vehi cl e under the i nstrument panel . I t can be
accessed for servi ce by removi ng the heater-A/C
housi ng ki ck cover.
OPERATION
The resi stor has mul ti pl e resi stor wi res, each of
whi ch reduce the current fl ow to the bl ower motor, to
change the bl ower motor speed. The bl ower motor
swi tch di rects the ground path through the correct
resi stor wi re to obtai n the sel ected speed. When the
hi ghest bl ower speed i s sel ected, the bl ower motor
swi tch connects the bl ower motor di rectl y to ground,
bypassi ng the bl ower motor resi stor.
The bl ower motor resi stor cannot be repai red and,
i f faul ty or damaged, i t must be repl aced.
BLOWER MOTOR SWITCH
DESCRIPTION
The heater-onl y or heater-A/C bl ower motor i s con-
trol l ed by a four posi ti on rotary-type bl ower motor
swi tch, mounted i n the heater-A/C control panel . The
swi tch al l ows the sel ecti on of one of four bl ower
motor speeds, but can onl y be turned off by sel ecti ng
the Off posi ti on wi th the heater-A/C mode control
swi tch knob.
OPERATION
The bl ower motor swi tch di rects the bl ower motor
ground path through the mode control swi tch to the
bl ower motor resi stor, or di rectl y to ground, as
requi red to achi eve the sel ected bl ower motor speed.
The bl ower motor swi tch cannot be repai red and, i f
faul ty or damaged, the enti re heater-onl y or heater-
A/C control uni t must be repl aced.
COMPRESSOR
DESCRIPTION
The ai r condi ti oni ng system uses a Sanden
SD7H15 seven cyl i nder, reci procati ng wobbl e pl ate-
type compressor on al l model s. Thi s compressor has a
fi xed di spl acement of 150 cubi c centi meters (9.375
cubi c i nches), and has both the sucti on and di scharge
ports l ocated on the cyl i nder head. A l abel i denti fyi ng
the use of R-134a refri gerant i s l ocated on the com-
pressor.
OPERATION
The compressor i s dri ven by the engi ne through an
el ectri c cl utch, dri ve pul l ey and bel t arrangement.
The compressor i s l ubri cated by refri gerant oi l that i s
ci rcul ated throughout the refri gerant system wi th the
refri gerant.
The compressor draws i n l ow-pressure refri gerant
vapor from the evaporator through i ts sucti on port. I t
then compresses the refri gerant i nto a hi gh-pressure,
hi gh-temperature refri gerant vapor, whi ch i s then
pumped to the condenser through the compressor di s-
charge port.
The compressor cannot be repai red. I f faul ty or
damaged, the enti re compressor assembl y must be
repl aced. The compressor cl utch, pul l ey and cl utch
coi l are avai l abl e for servi ce.
COMPRESSOR CLUTCH
DESCRIPTION
The compressor cl utch assembl y consi sts of a sta-
ti onary el ectromagneti c coi l , a hub beari ng and pul -
l ey assembl y, and a cl utch pl ate (Fi g. 2). The
el ectromagneti c coi l uni t and the hub beari ng and
pul l ey assembl y are each retai ned on the nose of the
compressor front housi ng wi th snap ri ngs. The cl utch
pl ate i s keyed to the compressor shaft and secured
wi th a nut. These components provi de the means to
engage and di sengage the compressor from the
engi ne serpenti ne accessory dri ve bel t.
OPERATION
When the cl utch coi l i s energi zed, i t magneti cal l y
draws the cl utch i nto contact wi th the pul l ey and
dri ves the compressor shaft. When the coi l i s not
energi zed, the pul l ey freewheel s on the cl utch hub
Fig. 2 Compressor Clutch - Typical
1 CLUTCH PLATE
2 SHAFT KEY
3 PULLEY
4 COIL
5 CLUTCH SHIMS
6 SNAP RING
7 SNAP RING
beari ng, whi ch i s part of the pul l ey. The compressor
cl utch and coi l are the onl y servi ced parts on the
compressor.
The compressor cl utch engagement i s control l ed by
several components: the heater-A/C mode control
swi tch, the l ow pressure cycl i ng cl utch swi tch, the
hi gh pressure cut-off swi tch, the compressor cl utch
rel ay, and the Powertrai n Control Modul e (PCM).
The PCM may del ay compressor cl utch engagement
for up to thi rty seconds. Refer to Group 14 - Fuel
System for more i nformati on on the PCM control s.
COMPRESSOR CLUTCH RELAY
DESCRIPTION
The compressor cl utch rel ay i s a I nternati onal
Standards Organi zati on (I SO) mi cro-rel ay. The termi -
nal desi gnati ons and functi ons are the same as a con-
venti onal I SO rel ay. However, the mi cro-rel ay
termi nal ori entati on (footpri nt) i s di fferent, the cur-
rent capaci ty i s l ower, and the rel ay case di mensi ons
are smal l er than those of the conventi onal I SO rel ay.
The compressor cl utch rel ay i s l ocated i n the Power
Di stri buti on Center (PDC) i n the engi ne compart-
ment. Refer to the PDC l abel for rel ay i denti fi cati on
and l ocati on.
OPERATION
The compressor cl utch rel ay i s a el ectromechani cal
devi ce that swi tches battery current to the compres-
sor cl utch coi l when the Powertrai n Control Modul e
(PCM) grounds the coi l si de of the rel ay. The PCM
responds to i nputs from the heater-A/C mode control
swi tch, the l ow pressure cycl i ng cl utch swi tch, and
the hi gh pressure cut-off swi tch. See Compressor
Cl utch Rel ay i n the Di agnosi s and Testi ng secti on of
thi s group for more i nformati on.
The compressor cl utch rel ay cannot be repai red
and, i f faul ty or damaged, i t must be repl aced.
CONDENSER
DESCRIPTION
The condenser i s l ocated i n the ai r fl ow i n front of
the engi ne cool i ng radi ator. The condenser i s a heat
exchanger that al l ows the hi gh-pressure refri gerant
gas bei ng di scharged by the compressor to gi ve up i ts
heat to the ai r passi ng over the condenser fi ns.
OPERATION
When the refri gerant gas gi ves up i ts heat, i t con-
denses. When the refri gerant l eaves the condenser, i t
has become a hi gh-pressure l i qui d refri gerant. The
vol ume of ai r fl owi ng over the condenser fi ns i s cri t-
i cal to the proper cool i ng performance of the ai r con-
di ti oni ng system. Therefore, i t i s i mportant that
there are no objects pl aced i n front of the radi ator
gri l l e openi ngs i n the front of the vehi cl e or forei gn
materi al on the condenser fi ns that mi ght obstruct
proper ai r fl ow. Al so, any factory-i nstal l ed ai r seal s or
shrouds must be properl y rei nstal l ed fol l owi ng radi a-
tor or condenser servi ce.
The condenser cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
DUAL FUNCTION HIGH PRESSURE SWITCH
(4. 0 L)
DESCRIPTION
The Dual Functi on Hi gh Pressure Swi tch control s
both A/C cl utch engagement/di sengagement, and el ec-
tri c cool i ng fan operati ons. The swi tch i s l ocated on
the di scharge l i ne near the compressor. The swi tch i s
screwed onto a fi tti ng that contai ns a Schrader-type
val ve, whi ch al l ows the swi tch to be servi ced wi thout
di schargi ng the refri gerant system. The di scharge
l i ne fi tti ng i s equi pped wi th an O-ri ng to seal the
swi tch connecti on.
OPERATION
The dual functi on swi tch i s connected i n seri es
el ectri cal l y wi th the l ow pressure cycl i ng cl utch
swi tch between ground and the Powertrai n Control
Modul e (PCM). The swi tch contacts open and cl ose
causi ng the PCM to turn the compressor cl utch on
and off. Thi s prevents compressor operati on when the
di scharge l i ne pressure approaches hi gh l evel s, and
al so reduces el ectri cal surgi ng from compressor
cl utch engagement.
The dual functi on swi tch control s the el ectri c cool -
i ng fan operati on by moni tori ng refri gerant l i ne pres-
sures. When the di scharge l i ne pressure ri ses above
1900 to 2200 kPa (280 to 320 psi ) the fan wi l l turn
on. The cool i ng fan wi l l turn off when the di scharge
l i ne pressure drops to 1600 kPa (235 psi ).
The dual functi on swi tch control s the A/C cl utch
operati on by di sengagi ng the cl utch when the di s-
charge l i ne pressure ri ses above 3100 to 3375 kPa
(450 to 490 psi ). The swi tch contacts wi l l cl ose and
al l ow A/C cl utch engagement when the di scharge l i ne
pressure drops to 1860 to 2275 kPa (270 to 330 psi ).
The Dual Functi on Hi gh Pressure Swi tch i s a fac-
tory-cal i brated uni t. The swi tch cannot be adjusted
or repai red and, i f faul ty or damaged, i t must be
repl aced.
EVAPORATOR COIL
DESCRIPTION
The evaporator coi l i s l ocated i n the heater-A/C
housi ng, under the i nstrument panel . The evaporator
coi l i s posi ti oned i n the heater-A/C housi ng so that
al l ai r that enters the housi ng must pass over the
fi ns of the evaporator before i t i s di stri buted through
the system ducts and outl ets. However, ai r passi ng
over the evaporator coi l fi ns wi l l onl y be condi ti oned
when the compressor i s engaged and ci rcul ati ng
refri gerant through the evaporator coi l tubes.
OPERATION
Refri gerant enters the evaporator from the fi xed
ori fi ce tube as a l ow-temperature, l ow-pressure l i q-
ui d. As ai r fl ows over the fi ns of the evaporator, the
humi di ty i n the ai r condenses on the fi ns, and the
heat from the ai r i s absorbed by the refri gerant. Heat
absorpti on causes the refri gerant to boi l and vapor-
i ze. The refri gerant becomes a l ow-pressure gas when
i t l eaves the evaporator.
The evaporator coi l cannot be repai red and, i f
FIXED ORIFICE TUBE
DESCRIPTION
The fi xed ori fi ce tube i s i nstal l ed i n the l i qui d l i ne
(l eft-hand dri ve) or l i qui d l i ne jumper (ri ght-hand
dri ve) between the outl et of the condenser and the
i nl et of the evaporator. The fi xed ori fi ce tube i s
l ocated i n the end of the l i qui d l i ne or l i qui d l i ne
jumper that i s cl osest to the condenser outl et tube.
The i nl et end of the fi xed ori fi ce tube has a nyl on
mesh fi l ter screen, whi ch fi l ters the refri gerant and
hel ps to reduce the potenti al for bl ockage of the
meteri ng ori fi ce by refri gerant system contami nants
(Fi g. 3). The outl et end of the tube has a nyl on mesh
di ffuser screen. The O-ri ngs on the pl asti c body of
the fi xed ori fi ce tube seal the tube to the i nsi de of
the l i qui d l i ne and prevent the refri gerant from
bypassi ng the fi xed meteri ng ori fi ce.
OPERATION
The fi xed ori fi ce tube i s used to meter the fl ow of
l i qui d refri gerant i nto the evaporator coi l . The hi gh-
pressure l i qui d refri gerant from the condenser
expands i nto a l ow-pressure l i qui d as i t passes
through the meteri ng ori fi ce and di ffuser screen of
the fi xed ori fi ce tube.
The fi xed ori fi ce tube cannot be repai red and, i f
faul ty or pl ugged, the l i qui d l i ne and fi xed ori fi ce
tube uni t or l i qui d l i ne jumper and fi xed ori fi ce tube
uni t must be repl aced.
HEATER AND AIR CONDITIONER
DESCRIPTION
Al l vehi cl es are equi pped wi th a common heater-
A/C housi ng assembl y (Fi g. 4). The system combi nes
ai r condi ti oni ng, heati ng, and venti l ati ng capabi l i ti es
i n a si ngl e uni t housi ng mounted under the i nstru-
ment panel . On heater-onl y systems, the evaporator
coi l and reci rcul ati ng ai r door are omi tted from the
housi ng.
Outsi de fresh ai r enters the vehi cl e through the
cowl top openi ng at the base of the wi ndshi el d, and
passes through a pl enum chamber to the heater-A/C
system bl ower housi ng. Ai r fl ow vel oci ty can then be
adjusted wi th the bl ower motor speed sel ector swi tch
on the heater-A/C control panel . The ai r i ntake open-
i ngs must be kept free of snow, i ce, l eaves, and other
obstructi ons for the heater-A/C system to recei ve a
suffi ci ent vol ume of outsi de ai r.
I t i s al so i mportant to keep the ai r i ntake openi ngs
cl ear of debri s because l eaf parti cl es and other debri s
that i s smal l enough to pass through the cowl pl e-
num screen can accumul ate wi thi n the heater-A/C
housi ng. The cl osed, warm, damp and dark envi ron-
ment created wi thi n the heater-A/C housi ng i s i deal
for the growth of certai n mol ds, mi l dews and other
fungi . Any accumul ati on of decayi ng pl ant matter
Fig. 3 Fixed Orifice Tube - Typical
1 DIFFUSER SCREEN
2 O RINGS
3 INLET FILTER SCREEN
4 ORIFICE
Fig. 4 Common Blend-Air Heater-Air Conditioner
System - Typical
1 HEATER CORE
2 BLEND-AIR DOOR
3 EVAPORATOR A/C ONLY
4 RECIRCULATING AIR DOOR A/C ONLY
5 FLOOR/PANEL DOOR
6 FLOOR/DEFROST DOOR
provi des an addi ti onal food source for fungal spores,
whi ch enter the housi ng wi th the fresh ai r. Excess
debri s, as wel l as objecti onabl e odors created by
decayi ng pl ant matter and growi ng fungi can be di s-
charged i nto the passenger compartment duri ng
heater-A/C system operati on.
OPERATION
The heater and opti onal ai r condi ti oner are bl end-
ai r type systems. I n a bl end-ai r system, a bl end-ai r
door control s the amount of uncondi ti oned ai r (or
cool ed ai r from the evaporator on model s wi th ai r
condi ti oni ng) that i s al l owed to fl ow through, or
around, the heater core. A temperature control knob
on the heater-A/C control panel determi nes the di s-
charge ai r temperature by control l i ng an el ectri c
motor, whi ch moves the bl end-ai r door. Thi s al l ows
an al most i mmedi ate control of the output ai r tem-
perature of the system.
The mode control knob on the heater-onl y or heat-
er-A/C control panel i s used to di rect the condi ti oned
ai r to the sel ected system outl ets. Both mode control
swi tches use engi ne vacuum to control the mode
doors, whi ch are operated by vacuum actuator
motors.
On ai r condi ti oned vehi cl es, the outsi de ai r i ntake
can be shut off by sel ecti ng the Reci rcul ati on Mode
wi th the mode control knob. Thi s wi l l operate a vac-
uum actuated reci rcul ati ng ai r door that cl oses off
the outsi de fresh ai r i ntake and reci rcul ates the ai r
that i s al ready i nsi de the vehi cl e.
The opti onal ai r condi ti oner for al l model s i s
desi gned for the use of non-CFC, R-134a refri gerant.
The ai r condi ti oni ng system has an evaporator to cool
and dehumi di fy the i ncomi ng ai r pri or to bl endi ng i t
wi th the heated ai r. Thi s ai r condi ti oni ng system
uses a fi xed ori fi ce tube i n the l i qui d l i ne near the
condenser outl et tube to meter refri gerant fl ow to the
evaporator coi l . To mai ntai n mi ni mum evaporator
temperature and prevent evaporator freezi ng, a fi xed
pressure setti ng swi tch on the accumul ator cycl es the
compressor cl utch.
HEATER AND AIR CONDITIONER CONTROL
DESCRIPTION
Both the heater-onl y and heater-A/C systems use a
combi nati on of mechani cal , el ectri cal , and vacuum
control s. These control s provi de the vehi cl e operator
wi th a number of setti ng opti ons to hel p control the
cl i mate and comfort wi thi n the vehi cl e. Refer to the
owners manual i n the vehi cl e gl ove box for more
i nformati on on the features, use, and suggested oper-
ati on of these control s.
OPERATION
The heater-onl y or heater-A/C control panel i s
l ocated to the ri ght of the i nstrument cl uster on the
i nstrument panel . The control panel contai ns a rota-
ry-type temperature control knob, a rotary-type mode
control swi tch knob, and a rotary-type bl ower motor
speed swi tch knob.
The heater-onl y or heater-A/C control panel cannot
be repai red. I f faul ty or damaged, the enti re uni t
must be repl aced. The i l l umi nati on l amps are avai l -
abl e for servi ce repl acement.
HEATER CORE
DESCRIPTION
The heater core i s l ocated i n the heater-A/C hous-
i ng, under the i nstrument panel . I t i s a heat
exchanger made of rows of tubes and fi ns.
OPERATION
Engi ne cool ant i s ci rcul ated through heater hoses
to the heater core at al l ti mes. As the cool ant fl ows
through the heater core, heat removed from the
engi ne i s transferred to the heater core fi ns and
tubes. Ai r di rected through the heater core pi cks up
the heat from the heater core fi ns. The bl end ai r door
al l ows control of the heater output ai r temperature
by control l i ng how much of the ai r fl owi ng through
the heater-A/C housi ng i s di rected through the
heater core. The bl ower motor speed control s the vol -
ume of ai r fl owi ng through the heater-A/C housi ng.
The heater core cannot be repai red and, i f faul ty or
damaged, i t must be repl aced. Refer to Group 7 -
Cool i ng System for more i nformati on on the engi ne
cool i ng system, the engi ne cool ant and the heater
hoses.
HIGH PRESSURE CUT-OFF SWITCH
DESCRIPTION
The hi gh pressure cut-off swi tch i s l ocated on the
di scharge l i ne between the compressor and the con-
denser i nl et. The swi tch i s screwed onto a fi tti ng that
contai ns a Schrader-type val ve, whi ch al l ows the
swi tch to be servi ced wi thout di schargi ng the refri g-
erant system. The di scharge l i ne fi tti ng i s equi pped
wi th an O-ri ng to seal the swi tch connecti on.
OPERATION
The hi gh pressure cut-off swi tch i s connected i n
seri es el ectri cal l y wi th the l ow pressure cycl i ng
cl utch swi tch between ground and the Powertrai n
Control Modul e (PCM). The swi tch contacts open and
cl ose causi ng the PCM to turn the compressor cl utch
on and off. Thi s prevents compressor operati on when
the di scharge l i ne pressure approaches hi gh l evel s.
The hi gh pressure cut-off swi tch contacts are open
when the di scharge l i ne pressure ri ses above 3100 to
3375 kPa (450 to 490 psi ). The swi tch contacts wi l l
cl ose when the di scharge l i ne pressure drops to 1860
to 2275 kPa (270 to 330 psi ).
The hi gh pressure cut-off swi tch i s a factory-cal i -
brated uni t. The swi tch cannot be adjusted or
repai red and, i f faul ty or damaged, i t must be
repl aced.
HIGH PRESSURE RELIEF VALVE
DESCRIPTION
A hi gh pressure rel i ef val ve i s l ocated on the com-
pressor mani fol d, whi ch i s on the si de of the com-
pressor. Thi s mechani cal val ve i s desi gned to vent
refri gerant from the system to protect agai nst dam-
age to the compressor and other system components,
caused by condenser ai r fl ow restri cti on or an over-
charge of refri gerant.
OPERATION
The hi gh pressure rel i ef val ve vents the system
when a di scharge pressure of 3445 to 4135 kPa (500
to 600 psi ) or above i s reached. The val ve cl oses
when a mi ni mum di scharge pressure of 2756 kPa
(400 psi ) i s reached.
The hi gh pressure rel i ef val ve vents onl y enough
refri gerant to reduce the system pressure, and then
re-seats i tsel f. The majori ty of the refri gerant i s con-
served i n the system. I f the val ve vents refri gerant, i t
does not mean that the val ve i s faul ty.
The hi gh pressure rel i ef val ve i s a factory-cal i -
brated uni t. The val ve cannot be adjusted or
repai red, and must not be removed or otherwi se di s-
turbed. The val ve i s onl y servi ced as a part of the
compressor assembl y.
LOW PRESSURE CYCLING CLUTCH SWITCH
DESCRIPTION
The l ow pressure cycl i ng cl utch swi tch i s l ocated
on the top of the accumul ator. The swi tch i s screwed
onto an accumul ator fi tti ng that contai ns a Schrader-
type val ve, whi ch al l ows the swi tch to be servi ced
wi thout di schargi ng the refri gerant system. The
accumul ator fi tti ng i s equi pped wi th an O-ri ng to
seal the swi tch connecti on.
OPERATION
The l ow pressure cycl i ng cl utch swi tch i s connected
i n seri es el ectri cal l y wi th the hi gh pressure cut-off
swi tch, between ground and the Powertrai n Control
Modul e (PCM). The swi tch contacts open and cl ose
causi ng the PCM to turn the compressor cl utch on
and off. Thi s regul ates the refri gerant system pres-
sure and control s evaporator temperature. Control -
l i ng the evaporator temperature prevents condensate
water on the evaporator fi ns from freezi ng and
obstructi ng ai r condi ti oni ng system ai r fl ow.
The l ow pressure cycl i ng cl utch swi tch contacts are
open when the sucti on pressure i s approxi matel y 141
kPa (20.5 psi ) or l ower. The swi tch contacts wi l l cl ose
when the sucti on pressure ri ses to approxi matel y 234
to 262 kPa (34 to 38 psi ) or above. Lower ambi ent
temperatures, bel ow approxi matel y -1 C (30 F), wi l l
al so cause the swi tch contacts to open. Thi s i s due to
the pressure/temperature rel ati onshi p of the refri ger-
ant i n the system.
The l ow pressure cycl i ng cl utch swi tch i s a factory-
cal i brated uni t. I t cannot be adjusted or repai red
and, i f faul ty or damaged, i t must be repl aced.
REFRIGERANT
DESCRIPTION
The refri gerant used i n thi s ai r condi ti oni ng sys-
tem i s a HydroFl uoroCarbon (HFC), type R-134a.
Unl i ke R-12, whi ch i s a Chl oroFl uoroCarbon (CFC),
R-134a refri gerant does not contai n ozone-depl eti ng
chl ori ne. R-134a refri gerant i s a non-toxi c, non-fl am-
mabl e, cl ear, and col orl ess l i quefi ed gas.
Even though R-134a does not contai n chl ori ne, i t
must be recl ai med and recycl ed just l i ke CFC-type
refri gerants. Thi s i s because R-134a i s a greenhouse
gas and can contri bute to gl obal warmi ng.
OPERATION
R-134a refri gerant i s not compati bl e wi th R-12
refri gerant i n an ai r condi ti oni ng system. Even a
smal l amount of R-12 added to an R-134a refri gerant
system wi l l cause compressor fai l ure, refri gerant oi l
sl udge or poor ai r condi ti oni ng system performance.
I n addi ti on, the Pol yAl kyl ene Gl ycol (PAG) syntheti c
refri gerant oi l s used i n an R-134a refri gerant system
are not compati bl e wi th the mi neral -based refri ger-
ant oi l s used i n an R-12 refri gerant system.
R-134a refri gerant system servi ce ports, servi ce
tool coupl ers and refri gerant di spensi ng bottl es have
al l been desi gned wi th uni que fi tti ngs to ensure that
an R-134a system i s not acci dental l y contami nated
wi th the wrong refri gerant (R-12). There are al so
l abel s posted i n the engi ne compartment of the vehi -
cl e and on the compressor i denti fyi ng to servi ce tech-
ni ci ans that the ai r condi ti oni ng system i s equi pped
wi th R-134a.
REFRIGERANT LINES
DESCRIPTION
The refri gerant l i nes and hoses are used to carry
the refri gerant between the vari ous ai r condi ti oni ng
system components. A barri er hose desi gn wi th a
nyl on tube, whi ch i s sandwi ched between rubber l ay-
ers, i s used for the R-134a ai r condi ti oni ng system on
thi s vehi cl e. Thi s nyl on tube hel ps to further contai n
the R-134a refri gerant, whi ch has a smal l er mol ecu-
l ar structure than R-12 refri gerant. The ends of the
refri gerant hoses are made from l i ghtwei ght al umi -
num or steel , and commonl y use braze-l ess fi tti ngs.
Any ki nks or sharp bends i n the refri gerant pl umb-
i ng wi l l reduce the capaci ty of the enti re ai r condi -
ti oni ng system. Ki nks and sharp bends reduce the
fl ow of refri gerant i n the system. A good rul e for the
fl exi bl e hose refri gerant l i nes i s to keep the radi us of
al l bends at l east ten ti mes the di ameter of the hose.
I n addi ti on, the fl exi bl e hose refri gerant l i nes shoul d
be routed so they are at l east 80 mi l l i meters (3
i nches) from the exhaust mani fol d.
OPERATION
Hi gh pressures are produced i n the refri gerant sys-
tem when the ai r condi ti oni ng compressor i s operat-
i ng. Extreme care must be exerci sed to make sure
that each of the refri gerant system connecti ons i s
pressure-ti ght and l eak free. I t i s a good practi ce to
i nspect al l fl exi bl e hose refri gerant l i nes at l east once
a year to make sure they are i n good condi ti on and
properl y routed.
The refri gerant l i nes and hoses are coupl ed wi th
other components of the HVAC system wi th peanut-
bl ock styl e fi tti ngs. A stat-O seal type fl at steel gas-
ket wi th a captured compressi bl e O-ri ng, i s used to
mate pl umbi ng l i nes wi th A/C components to ensure
the i ntegri ty of the refri gerant system.
The refri gerant l i nes and hoses cannot be repai red
and, i f faul ty or damaged, they must be repl aced.
REFRIGERANT LINE COUPLERS
DESCRIPTION
Spri ng-l ock type refri gerant l i ne coupl ers are used
to connect many of the refri gerant l i nes and other
components to the refri gerant system. These coupl ers
requi re a speci al tool for di sengagi ng the two coupl er
hal ves.
OPERATION
The spri ng-l ock coupl er i s hel d together by a garter
spri ng i nsi de a ci rcul ar cage on the mal e hal f of the
fi tti ng (Fi g. 5). When the two coupl er hal ves are con-
nected, the fl ared end of the femal e fi tti ng sl i ps
behi nd the garter spri ng i nsi de the cage on the mal e
fi tti ng. The garter spri ng and cage prevent the fl ared
end of the femal e fi tti ng from pul l i ng out of the cage.
Two O-ri ngs on the mal e hal f of the fi tti ng are
used to seal the connecti on. These O-ri ngs are com-
pati bl e wi th R-134a refri gerant and must be repl aced
wi th O-ri ngs made of the same materi al .
Secondary cl i ps are i nstal l ed over the two con-
nected coupl er hal ves at the factory for added bl owoff
protecti on. I n addi ti on, some model s have a pl asti c
ri ng that i s used at the factory as a vi sual i ndi cator
to confi rm that these coupl ers are connected. After
the coupl er i s connected, the pl asti c i ndi cator ri ng i s
no l onger needed; however, i t wi l l remai n on the
refri gerant l i ne near the coupl er cage.
REFRIGERANT OIL
DESCRIPTION
The refri gerant oi l used i n R-134a refri gerant sys-
tems i s a syntheti c-based, Pol yAl kyl ene Gl ycol (PAG),
wax-free l ubri cant. Mi neral -based R-12 refri gerant
oi l s are not compati bl e wi th PAG oi l s, and shoul d
never be i ntroduced to an R-134a refri gerant system.
There are di fferent PAG oi l s avai l abl e, and each
contai ns a di fferent addi ti ve package. The 10PA17
compressor used i n thi s vehi cl e i s desi gned to use an
ND-8 PAG refri gerant oi l . Use onl y refri gerant oi l of
thi s same type to servi ce the refri gerant system.
OPERATION
After performi ng any refri gerant recovery or recy-
cl i ng operati on, al ways repl eni sh the refri gerant sys-
tem wi th the same amount of the recommended
refri gerant oi l as was removed. Too l i ttl e refri gerant
Fig. 5 Spring-Lock Coupler - Typical
1 MALE HALF SPRING-LOCK COUPLER
2 FEMALE HALF SPRING-LOCK COUPLER
3 SECONDARY CLIP
4 CONNECTION INDICATOR RING
5 COUPLER CAGE
6 GARTER SPRING
7 COUPLER CAGE
8 O RINGS
oi l can cause compressor damage, and too much can
reduce ai r condi ti oni ng system performance.
PAG refri gerant oi l i s much more hygroscopi c than
mi neral oi l , and wi l l absorb any moi sture i t comes
i nto contact wi th, even moi sture i n the ai r. The PAG
oi l contai ner shoul d al ways be kept ti ghtl y capped
unti l i t i s ready to be used. After use, recap the oi l
contai ner i mmedi atel y to prevent moi sture contami -
nati on.
REFRIGERANT SYSTEM SERVICE PORT
DESCRIPTION
The two refri gerant system servi ce ports are used
to charge, recover/recycl e, evacuate, and test the ai r
condi ti oni ng refri gerant system. Uni que servi ce port
coupl er si zes are used on the R-134a system, to
ensure that the refri gerant system i s not acci dental l y
contami nated by the use of the wrong refri gerant
(R-12), or refri gerant system servi ce equi pment.
OPERATION
The hi gh pressure servi ce port i s l ocated on the
refri gerant l i ne, near the di scharge port of the com-
pressor. The l ow pressure servi ce port i s l ocated on
the l i qui d l i ne at the rear of the engi ne compartment,
near the evaporator i nl et tube.
Each of the servi ce ports has a threaded pl asti c
protecti ve cap i nstal l ed over i t from the factory. After
servi ci ng the refri gerant system, al ways rei nstal l
both of the servi ce port caps.
VACUUM CHECK VALVE
DESCRIPTION
A vacuum check val ve i s i nstal l ed i n the accessory
vacuum suppl y l i ne i n the engi ne compartment, near
the vacuum tap on the engi ne i ntake mani fol d, and
at the HVAC uni t takeout. The vacuum check val ve
i s desi gned to al l ow vacuum to fl ow i n onl y one di rec-
ti on through the accessory vacuum suppl y ci rcui ts.
OPERATION
The use of a vacuum check val ve hel ps to mai ntai n
the system vacuum needed to retai n the sel ected
heater-A/C mode setti ngs. The check val ve wi l l pre-
vent the engi ne from bl eedi ng down system vacuum
through the i ntake mani fol d duri ng extended heavy
engi ne l oad (l ow engi ne vacuum) operati on.
The vacuum check val ve cannot be repai red and, i f
VACUUM RESERVOIR
DESCRIPTION
The vacuum reservoi r i s mounted to the front
bumper bar behi nd the passenger si de bumper end
cap. The bumper end cap must be removed from the
vehi cl e to access the vacuum reservoi r for servi ce.
OPERATION
Engi ne vacuum i s stored i n the vacuum reservoi r.
The stored vacuum i s used to operate the vacuum-
control l ed vehi cl e accessori es duri ng peri ods of l ow
engi ne vacuum such as when the vehi cl e i s cl i mbi ng
a steep grade, or under other hi gh engi ne l oad oper-
ati ng condi ti ons.
The vacuum reservoi r cannot be repai red and, i f
A/C PERFORMANCE
The ai r condi ti oni ng system i s desi gned to provi de
the passenger compartment wi th l ow temperature
and l ow humi di ty ai r. The evaporator, l ocated i n the
heater-A/C housi ng on the dash panel bel ow the
i nstrument panel , i s cool ed to temperatures near the
freezi ng poi nt. As warm damp ai r passes through the
cool ed evaporator, the ai r transfers i ts heat to the
refri gerant i n the evaporator and the moi sture i n the
ai r condenses on the evaporator fi ns. Duri ng peri ods
of hi gh heat and humi di ty, an ai r condi ti oni ng sys-
tem wi l l be more effecti ve i n the Reci rcul ati on Mode.
Wi th the system i n the Reci rcul ati on Mode, onl y ai r
from the passenger compartment passes through the
evaporator. As the passenger compartment ai r dehu-
mi di fi es, the ai r condi ti oni ng system performance
l evel s i mprove.
Humi di ty has an i mportant beari ng on the temper-
ature of the ai r del i vered to the i nteri or of the vehi -
cl e. I t i s i mportant to understand the effect that
humi di ty has on the performance of the ai r condi ti on-
i ng system. When humi di ty i s hi gh, the evaporator
has to perform a doubl e duty. I t must l ower the ai r
temperature, and i t must l ower the temperature of
the moi sture i n the ai r that condenses on the evapo-
rator fi ns. Condensi ng the moi sture i n the ai r trans-
fers heat energy i nto the evaporator fi ns and tubi ng.
Thi s reduces the amount of heat the evaporator can
absorb from the ai r. Hi gh humi di ty greatl y reduces
the abi l i ty of the evaporator to l ower the temperature
of the ai r.
However, evaporator capaci ty used to reduce the
amount of moi sture i n the ai r i s not wasted. Wri ng-
i ng some of the moi sture out of the ai r enteri ng the
vehi cl e adds to the comfort of the passengers.
Al though, an owner may expect too much from thei r
ai r condi ti oni ng system on humi d days. A perfor-
mance test i s the best way to determi ne whether the
system i s performi ng up to standard. Thi s test al so
provi des val uabl e cl ues as to the possi bl e cause of
troubl e wi th the ai r condi ti oni ng system.
Revi ew the Servi ce Warni ngs and Precauti ons i n
the front of thi s group before performi ng thi s proce-
dure. The ai r temperature i n the test room and i n
the vehi cl e must be a mi ni mum of 21 C (70 F) for
thi s test.
(1) Connect a tachometer and a mani fol d gauge
set.
(2) Set the heater-A/C mode control swi tch knob i n
the Reci rcul ati on Mode posi ti on, the temperature
control knob i n the ful l cool posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
(3) Start the engi ne and hol d the i dl e at 1,000 rpm
wi th the compressor cl utch engaged.
(4) The engi ne shoul d be at operati ng temperature.
The doors and wi ndows must be open.
(5) I nsert a thermometer i n the dri ver si de center
A/C (panel ) outl et. Operate the engi ne for fi ve mi n-
utes.
(6) The compressor cl utch may cycl e, dependi ng
upon the ambi ent temperature and humi di ty. I f the
cl utch cycl es, unpl ug the l ow pressure cycl i ng cl utch
swi tch wi re harness connector from the swi tch
l ocated on the accumul ator (Fi g. 6). Pl ace a jumper
wi re across the termi nal s of the l ow pressure cycl i ng
cl utch swi tch wi re harness connector.
(7) Wi th the compressor cl utch engaged, record the
di scharge ai r temperature and the compressor di s-
charge pressure.
(8) Compare the di scharge ai r temperature to the
Performance Temperature and Pressure chart. I f the
di scharge ai r temperature i s hi gh, see Refri gerant
System Leaks and Refri gerant System Charge i n thi s
group.
Performance Temperature and Pressure
Ambient Air
Temperature
21C
(70F)
27C
(80F)
32C
(90F)
38C
(100F)
43C
(110F)
Air Temperature at
Center Panel Outlet
-3 to 3C
(27 to 38F)
1 to 7C
(33 to 44F)
3 to 9C
(37 to 48F)
6 to 13C
(43 to 55F)
10 to 18C
(50 to 64F)
Evaporator Inlet
Pressure at Charge
Port
179 to 241 kPa
(26 to 35 psi)
221 to 283
kPa
(32 to 41 psi)
262 to 324
kPa
(38 to 47 psi)
303 to 365
kPa
(44 to 53 psi)
345 to 414 kPa
(50 to 60 psi)
Compressor Discharge
Pressure
1240 to 1655
kPa
(180 to 240
psi)
1380 to 1790
kPa
(200 to 260
psi)
1720 to 2070
kPa
(250 to 300
psi)
1860 to 2345
kPa
(270 to 340
psi)
2070 to 2690
kPa
(300 to 390 psi)
(9) Compare the compressor di scharge pressure to
the Performance Temperature and Pressure chart. I f
the compressor di scharge pressure i s hi gh, see the
Pressure Di agnosi s chart.
Fig. 6 Low Pressure Cycling Clutch Switch - Typical
2 ACCUMULATOR
Pressure Diagnosis
Rapid compressor clutch
cycling (ten or more cycles
per minute).
1. Low refrigerant system
charge.
1. See Refrigerant System Leaks in this group.
Test the refrigerant system for leaks. Repair,
evacuate and charge the refrigerant system, if
required.
Equal pressures, but the
compressor clutch does not
engage.
1. No refrigerant in the
refrigerant system.
2. Faulty fuse.
3. Faulty compressor clutch
coil.
4. Faulty compressor clutch
relay.
5. Improperly installed or
faulty low pressure cycling
clutch switch.
6. Faulty high pressure
cut-off switch.
7. Faulty Powertrain Control
Module (PCM).
required.
2. Check the fuses in the Power Distribution
Center and the junction block. Repair the shorted
circuit or component and replace the fuses, if
required.
3. See Compressor Clutch Coil in this group. Test
the compressor clutch coil and replace, if
required.
4. See Compressor Clutch Relay in this group.
Test the compressor clutch relay and relay
circuits. Repair the circuits or replace the relay, if
required.
5. See Low Pressure Cycling Clutch Switch in
this group. Test the low pressure cycling clutch
switch and tighten or replace, if required.
6. See High Pressure Cut-Off Switch in this
group. Test the high pressure cut-off switch and
replace, if required.
7. Refer to the proper Diagnostic Procedures
manual for testing of the PCM. Test the PCM and
replace, if required.
Normal pressures, but A/C
Performance Test air
temperatures at center panel
outlet are too high.
1. Excessive refrigerant oil in
system.
2. Blend-Air door inoperative
or sealing improperly.
3. Blend-Air door motor faulty
or inoperative.
1. See Refrigerant Oil Level in this group.
Recover the refrigerant from the refrigerant
system and inspect the refrigerant oil content.
Restore the refrigerant oil to the proper level, if
required.
2. See Blend-Air Door under Heater-A/C Housing
Door in this group. Inspect the blend-air door for
proper operation and sealing and correct, if
required.
3. Perform Blend-Air door motor diagnosis,
replace if faulty.
The low side pressure is
normal or slightly low, and
the high side pressure is too
low.
1. Low refrigerant system
charge.
2. Refrigerant flow through
the accumulator is restricted.
3. Refrigerant flow through
the evaporator coil is
restricted.
4. Faulty compressor.
required.
2. See Accumulator in this group. Replace the
restricted accumulator, if required.
3. See Evaporator Coil in this group. Replace the
restricted evaporator coil, if required.
4. See Compressor in this group. Replace the
compressor, if required.
Pressure Diagnosis
The low side pressure is
normal or slightly high, and
the high side pressure is too
high.
1. Condenser air flow
restricted.
2. Inoperative cooling fan.
3. Refrigerant system
overcharged.
4. Air in the refrigerant
system.
5. Engine overheating.
1. Check the condenser for damaged fins, foreign
objects obstructing air flow through the condenser
fins, and missing or improperly installed air seals.
Refer to Group 7 - Cooling System for more
information on air seals. Clean, repair, or replace
components as required.
2. Refer to Group 7 - Cooling System for more
information. Test the cooling fan and replace, if
required.
3. See Refrigerant System Charge in this group.
Recover the refrigerant from the refrigerant
system. Charge the refrigerant system to the
proper level, if required.
required.
information. Test the cooling system and repair, if
required.
The low side pressure is too
high, and the high side
pressure is too low.
1. Accessory drive belt
slipping.
2. Fixed orifice tube not
installed.
3. Faulty compressor.
information. Inspect the accessory drive belt
condition and tension. Tighten or replace the
accessory drive belt, if required.
2. See Fixed Orifice Tube in this group. Install the
missing fixed orifice tube, if required.
3. See Compressor in this group. Replace the
compressor, if required.
The low side pressure is too
low, and the high side
pressure is too high.
1. Restricted refrigerant flow
through the refrigerant lines.
through the fixed orifice tube.
through the condenser.
1. See Liquid Line and Suction and Discharge
Line in this group. Inspect the refrigerant lines for
kinks, tight bends or improper routing. Correct the
routing or replace the refrigerant line, if required.
2. See Fixed Orifice Tube in this group. Replace
the restricted fixed orifice tube, if required.
3. See Condenser in this group. Replace the
restricted condenser, if required.
BLOWER MOTOR
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT
SYSTEMS BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, OR INSTRUMENT
PANEL COMPONENT DIAGNOSIS OR SERVICE. FAIL-
URE TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
For ci rcui t descri pti ons and di agrams, refer to
8W-42 - Ai r Condi ti oni ng/Heater i n Group 8W - Wi r-
i ng Di agrams. Possi bl e causes of an i noperati ve
bl ower motor i ncl ude:
Faul ty fuse
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors
Faul ty bl ower motor resi stor
Faul ty bl ower motor rel ay
Faul ty bl ower motor swi tch
Faul ty heater-A/C mode control swi tch
Faul ty bl ower motor.
Possi bl e causes of the bl ower motor not operati ng
i n al l speeds i ncl ude:
Faul ty fuse
Faul ty bl ower motor swi tch
Faul ty bl ower motor resi stor
Faul ty bl ower motor ci rcui t wi ri ng or wi re har-
ness connectors.
VIBRATION
Possi bl e causes of bl ower motor vi brati on i ncl ude:
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower wheel out of bal ance or bent
Bl ower motor faul ty.
NOISE
To veri fy that the bl ower i s the source of the noi se,
unpl ug the bl ower motor wi re harness connector and
operate the heater-A/C system. I f the noi se goes
away, possi bl e causes i ncl ude:
Forei gn materi al i n the heater-A/C housi ng
I mproper bl ower motor mounti ng
I mproper bl ower wheel mounti ng
Bl ower motor faul ty.
BLOWER MOTOR RELAY
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RELAY TEST
The bl ower motor rel ay (Fi g. 7) i s l ocated i n a wi re
harness connector that i s secured to the heater-A/C
housi ng behi nd the gl ove box on the passenger si de
of the vehi cl e, next to the heater-A/C wi re harness
connector i n the passenger compartment. Remove the
rel ay from i ts connector to perform the fol l owi ng
tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test procedure
i n thi s group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
i ng Di agrams.
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to fused battery feed di rectl y from a fuse
i n the Power Di stri buti on Center (PDC), and shoul d
be hot at al l ti mes. Check for battery vol tage at the
connector cavi ty for rel ay termi nal 30. I f OK, go to
Step 2. I f not OK, repai r the open ci rcui t to the PDC
fuse as requi red.
(2) The rel ay normal l y cl osed termi nal cavi ty (87A)
i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the bl ower motor. When the rel ay i s
energi zed, termi nal 87 i s connected to termi nal 30
and provi des ful l battery current to the bl ower motor
feed ci rcui t. There shoul d be conti nui ty between the
connector cavi ty for termi nal 87 and the bl ower
motor rel ay output ci rcui t cavi ty of the bl ower motor
wi re harness connector at al l ti mes. I f OK, go to Step
4. I f not OK, repai r the open ci rcui t to the bl ower
motor as requi red.
(4) The coi l battery termi nal cavi ty (86) i s con-
nected to the i gni ti on swi tch. When the i gni ti on
swi tch i s pl aced i n the On posi ti on, fused i gni ti on
swi tch output i s di rected from a fuse i n the juncti on
bl ock to the rel ay el ectromagneti c coi l to energi ze the
rel ay. There shoul d be battery vol tage at the connec-
tor cavi ty for rel ay termi nal 86 wi th the i gni ti on
swi tch i n the On posi ti on. I f OK, go to Step 5. I f not
OK, repai r the open ci rcui t to the juncti on bl ock fuse
as requi red.
(5) The coi l ground termi nal cavi ty (85) i s con-
nected to ground. Thi s termi nal suppl i es the ground
for the rel ay el ectromagnet coi l . There shoul d be con-
ti nui ty between the connector cavi ty for rel ay termi -
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 7 Blower Motor Relay
nal 85 and a good ground at al l ti mes. I f not OK,
repai r the open ci rcui t as requi red.
i ng Di agrams.
INJURY.
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the ki ck cover from the heater-A/C
housi ng and unpl ug the wi re harness connector from
the bl ower motor resi stor.
(3) Check for conti nui ty between each of the
bl ower motor swi tch i nput termi nal s of the resi stor
and the resi stor output termi nal . I n each case there
shoul d be conti nui ty. I f OK, repai r the wi re harness
ci rcui ts between the bl ower motor swi tch and the
bl ower motor resi stor or bl ower motor rel ay as
requi red. I f not OK, repl ace the faul ty bl ower motor
resi stor.
BLOWER MOTOR SWITCH
i ng Di agrams.
INJURY.
(1) Check for battery vol tage at the fuse i n the
Power Di stri buti on Center (PDC). I f OK, go to Step
2. I f not OK, repai r the shorted ci rcui t or component
as requi red and repl ace the faul ty fuse.
(2) Turn the i gni ti on swi tch to the Off posi ti on.
Di sconnect and i sol ate the battery negati ve cabl e.
Remove the heater-A/C control from the i nstrument
panel . Check for conti nui ty between the ground ci r-
cui t cavi ty of the heater-A/C control wi re harness
connector and a good ground. There shoul d be conti -
nui ty. I f OK, go to Step 3. I f not OK, repai r the open
ci rcui t to ground as requi red.
(3) Wi th the heater-A/C control wi re harness con-
nector unpl ugged, pl ace the heater-A/C mode control
swi tch knob i n any posi ti on except the Off posi ti on.
Check for conti nui ty between the ground ci rcui t ter-
mi nal and each of the bl ower motor dri ver ci rcui t ter-
mi nal s of the heater-A/C control as you move the
bl ower motor swi tch knob to each of the four speed
posi ti ons. There shoul d be conti nui ty at each dri ver
ci rcui t termi nal i n onl y one bl ower motor swi tch
speed posi ti on. I f OK, test and repai r the bl ower
dri ver ci rcui ts between the heater-A/C control con-
nector and the bl ower motor resi stor as requi red. I f
not OK, repl ace the faul ty heater-A/C control uni t.
COMPRESSOR
When i nvesti gati ng an ai r condi ti oni ng rel ated
noi se, you must fi rst know the condi ti ons under
whi ch the noi se occurs. These condi ti ons i ncl ude:
weather, vehi cl e speed, transmi ssi on i n gear or neu-
tral , engi ne speed, engi ne temperature, and any
other speci al condi ti ons. Noi ses that devel op duri ng
ai r condi ti oni ng operati on can often be mi sl eadi ng.
For exampl e: What sounds l i ke a fai l ed front beari ng
or connecti ng rod, may be caused by l oose bol ts, nuts,
mounti ng brackets, or a l oose compressor cl utch
assembl y.
Dri ve bel ts are speed sensi ti ve. At di fferent engi ne
speeds and dependi ng upon bel t tensi on, bel ts can
devel op noi ses that are mi staken for a compressor
noi se. I mproper bel t tensi on can cause a mi sl eadi ng
noi se when the compressor cl utch i s engaged, whi ch
may not occur when the compressor cl utch i s di sen-
gaged. Check the serpenti ne dri ve bel t condi ti on and
tensi on as descri bed i n Group 7 - Cool i ng System
before begi nni ng thi s procedure.
(1) Sel ect a qui et area for testi ng. Dupl i cate the
compl ai nt condi ti ons as much as possi bl e. Swi tch the
compressor on and off several ti mes to cl earl y i den-
ti fy the compressor noi se. Li sten to the compressor
whi l e the cl utch i s engaged and di sengaged. Probe
the compressor wi th an engi ne stethoscope or a l ong
screwdri ver wi th the handl e hel d to your ear to bet-
ter l ocal i ze the source of the noi se.
(2) Loosen al l of the compressor mounti ng hard-
ware and reti ghten. Ti ghten the compressor cl utch
mounti ng nut. Be certai n that the cl utch coi l i s
mounted securel y to the compressor, and that the
cl utch pl ate and pul l ey are properl y al i gned and have
the correct ai r gap. See Compressor and Compressor
Cl utch i n the Removal and I nstal l ati on secti on of thi s
group for the procedures.
(3) To dupl i cate a hi gh-ambi ent temperature condi -
ti on (hi gh head pressure), restri ct the ai r fl ow
through the condenser. I nstal l a mani fol d gauge set
to be certai n that the di scharge pressure does not
exceed 2760 kPa (400 psi ).
(4) Check the refri gerant system pl umbi ng for
i ncorrect routi ng, rubbi ng or i nterference, whi ch can
cause unusual noi ses. Al so check the refri gerant l i nes
for ki nks or sharp bends that wi l l restri ct refri gerant
fl ow, whi ch can cause noi ses. See Sucti on and Di s-
charge Li ne i n the Removal and I nstal l ati on secti on
of thi s group for more i nformati on.
(5) I f the noi se i s from openi ng and cl osi ng of the
hi gh pressure rel i ef val ve, evacuate and recharge the
refri gerant system. See Refri gerant System Evacuate
and Refri gerant System Charge i n the Servi ce Proce-
dures secti on of thi s group. I f the hi gh pressure rel i ef
val ve sti l l does not seat properl y, repl ace the com-
pressor.
(6) I f the noi se i s from l i qui d sl uggi ng on the suc-
ti on l i ne, repl ace the accumul ator. See Accumul ator
i n the Removal and I nstal l ati on secti on of thi s group
for the procedures. Check the refri gerant oi l l evel
and the refri gerant system charge. See Refri gerant
Oi l Level and Refri gerant System Charge i n the Ser-
vi ce Procedures secti on of thi s group. I f the l i qui d
sl uggi ng condi ti on conti nues fol l owi ng accumul ator
repl acement, repl ace the compressor.
(7) I f the noi se conti nues, repl ace the compressor
and repeat Step 1.
COMPRESSOR CLUTCH COIL
i ng Di agrams. The battery must be ful l y-charged
before performi ng the fol l owi ng tests. Refer to Group
8A - Battery for more i nformati on.
(1) Connect an ammeter (0 to 10 ampere scal e) i n
seri es wi th the cl utch coi l termi nal . Use a vol tmeter
(0 to 20 vol t scal e) wi th cl i p-type l eads for measuri ng
the vol tage across the battery and the compressor
cl utch coi l .
(2) Wi th the heater-A/C mode control swi tch i n any
A/C mode, and the bl ower motor swi tch i n the l owest
speed posi ti on, start the engi ne and run i t at normal
i dl e.
(3) The compressor cl utch coi l vol tage shoul d read
wi thi n two vol ts of the battery vol tage. I f there i s
vol tage at the cl utch coi l , but the readi ng i s not
wi thi n two vol ts of the battery vol tage, test the
cl utch coi l feed ci rcui t for excessi ve vol tage drop and
repai r as requi red. I f there i s no vol tage readi ng at
the cl utch coi l , use a DRB scan tool and the proper
Di agnosti c Procedures manual for testi ng of the com-
pressor cl utch ci rcui t. The fol l owi ng components
must be checked and repai red as requi red before you
can compl ete testi ng of the cl utch coi l :
Fuses i n the juncti on bl ock and the Power Di s-
tri buti on Center (PDC)
Heater-A/C mode control swi tch
Compressor cl utch rel ay
Hi gh pressure cut-off swi tch
Low pressure cycl i ng cl utch swi tch
Powertrai n Control Modul e (PCM).
(4) The compressor cl utch coi l i s acceptabl e i f the
current draw measured at the cl utch coi l i s 2.0 to 3.9
amperes wi th the el ectri cal system vol tage at 11.5 to
12.5 vol ts. Thi s shoul d onl y be checked wi th the work
area temperature at 21 C (70 F). I f system vol tage
i s more than 12.5 vol ts, add el ectri cal l oads by turn-
i ng on el ectri cal accessori es unti l the system vol tage
drops bel ow 12.5 vol ts.
(a) I f the cl utch coi l current readi ng i s four
amperes or more, the coi l i s shorted and shoul d be
repl aced.
(b) I f the cl utch coi l current readi ng i s zero, the
coi l i s open and shoul d be repl aced.
RELAY TEST
The compressor cl utch rel ay (Fi g. 8) i s l ocated i n
the Power Di stri buti on Center (PDC). Refer to the
PDC l abel for rel ay i denti fi cati on and l ocati on.
Remove the rel ay from the PDC to perform the fol -
l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see Rel ay Ci rcui t Test i n the Di agno-
si s and Testi ng secti on of thi s group. I f not OK,
repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
i ng Di agrams.
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to fused battery feed. There shoul d be bat-
tery vol tage at the cavi ty for rel ay termi nal 30 at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the fuse i n the PDC as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s not
used i n thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal cavi ty (87) i s
connected to the compressor cl utch coi l . There shoul d
be conti nui ty between thi s cavi ty and the A/C com-
pressor cl utch rel ay output ci rcui t cavi ty of the com-
pressor cl utch coi l wi re harness connector. I f OK, go
to Step 4. I f not OK, repai r the open ci rcui t as
requi red.
(4) The rel ay coi l battery termi nal (86) i s con-
nected to the fused i gni ti on swi tch output (run/start)
ci rcui t. There shoul d be battery vol tage at the cavi ty
for rel ay termi nal 86 wi th the i gni ti on swi tch i n the
On posi ti on. I f OK, go to Step 5. I f not OK, repai r the
open ci rcui t to the fuse i n the juncti on bl ock as
requi red.
(5) The coi l ground termi nal cavi ty (85) i s swi tched
to ground through the Powertrai n Control Modul e
(PCM). There shoul d be conti nui ty between thi s cav-
i ty and the A/C compressor cl utch rel ay control ci r-
cui t cavi ty of the PCM wi re harness connector C
(gray) at al l ti mes. I f not OK, repai r the open ci rcui t
as requi red.
DUAL FUNCTION HIGH PRESSURE SWITCH/
Before performi ng di agnosi s of the dual functi on
hi gh pressure swi tch, or the hi gh pressure cut-off
swi tch, veri fy that the refri gerant system has the cor-
rect refri gerant charge. See Refri gerant System
Charge i n the Servi ce Procedures secti on of thi s
group for more i nformati on.
i ng Di agrams.
cabl e.
(2) Unpl ug the hi gh pressure swi tch wi re harness
connector from the swi tch on the refri gerant system
fi tti ng.
(3) On the dual functi on hi gh pressure swi tch,
check for conti nui ty between termi nal s C and D. On
the two termi nal swi tch, check for conti nui ty
between both termi nal s of the hi gh pressure cut-off
swi tch. There shoul d be conti nui ty. I f OK, test and
repai r the A/C swi tch sense ci rcui t as requi red. I f not
OK, repl ace the faul ty swi tch.
HEATER PERFORMANCE
Before performi ng the fol l owi ng tests, refer to
Group 7 - Cool i ng System for the procedures to check
the radi ator cool ant l evel , serpenti ne dri ve bel t ten-
si on, radi ator ai r fl ow and the radi ator fan operati on.
Al so be certai n that the accessory vacuum suppl y
l i ne i s connected at the engi ne i ntake mani fol d.
MAXIMUM HEATER OUTPUT
Engi ne cool ant i s del i vered to the heater core
through two heater hoses. Wi th the engi ne i dl i ng at
normal operati ng temperature, set the temperature
control knob i n the ful l hot posi ti on, the mode control
swi tch knob i n the fl oor heat posi ti on, and the bl ower
motor swi tch knob i n the hi ghest speed posi ti on.
Usi ng a test thermometer, check the temperature of
the ai r bei ng di scharged at the heater-A/C housi ng
fl oor outl ets. Compare the test thermometer readi ng
to the Temperature Reference chart.
Temperature Reference
Ambient Air Temperature
15.5C
(60F)
21.1C
(70F)
26.6C
(80F)
32.2C
(90F)
Minimum Air Temperature at
Floor Outlet
62.2C
(144F)
63.8C
(147F)
65.5C
(150F)
67.2C
(153F)
TERMINAL LEGEND
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
87A NORMALLY CLOSED
Fig. 8 Compressor Clutch Relay
I f the fl oor outl et ai r temperature i s too l ow, refer
to Group 7 - Cool i ng System to check the engi ne cool -
ant temperature speci fi cati ons. Both of the heater
hoses shoul d be hot to the touch. The cool ant return
heater hose shoul d be sl i ghtl y cool er than the cool ant
suppl y heater hose. I f the return hose i s much cool er
than the suppl y hose, l ocate and repai r the engi ne
cool ant fl ow obstructi on i n the cool i ng system. Refer
to Group 7 - Cool i ng System for the procedures.
OBSTRUCTED COOLANT FLOW Possi bl e l oca-
ti ons or causes of obstructed cool ant fl ow:
Pi nched or ki nked heater hoses.
I mproper heater hose routi ng.
Pl ugged heater hoses or suppl y and return ports
at the cool i ng system connecti ons.
A pl ugged heater core.
I f proper cool ant fl ow through the cool i ng system i s
veri fi ed, and heater outl et ai r temperature i s sti l l
l ow, a mechani cal probl em may exi st.
MECHANI CAL PROBLEMS Possi bl e l ocati ons or
causes of i nsuffi ci ent heat:
An obstructed cowl ai r i ntake.
Obstructed heater system outl ets.
A bl end-ai r door not functi oni ng properl y.
TEMPERATURE CONTROL
I f the heater outl et ai r temperature cannot be
adjusted wi th the temperature control knob on the
heater-A/C control panel , the fol l owi ng coul d requi re
servi ce:
The heater-A/C control .
The temperature control motor.
The bl end-ai r door.
I mproper engi ne cool ant temperature.
Before performi ng di agnosi s of the l ow pressure
cycl i ng cl utch swi tch, be certai n that the swi tch i s
properl y i nstal l ed on the accumul ator fi tti ng. I f the
swi tch i s too l oose i t may not open the Schrader-type
val ve i n the accumul ator fi tti ng, whi ch wi l l prevent
the swi tch from correctl y moni tori ng the refri gerant
system pressure. Remember that l ower ambi ent tem-
peratures, bel ow about -1 C (30 F), duri ng col d
weather wi l l open the swi tch contacts and prevent
compressor operati on due to the pressure/tempera-
ture rel ati onshi p of the refri gerant.
Al so veri fy that the refri gerant system has the cor-
rect refri gerant charge. See Refri gerant System
Charge i n the Servi ce Procedures secti on of thi s
group for more i nformati on.
i ng Di agrams.
cabl e.
(2) Unpl ug the l ow pressure cycl i ng cl utch swi tch
wi re harness connector from the swi tch on the accu-
mul ator fi tti ng.
(3) I nstal l a jumper wi re between the two cavi ti es
of the l ow pressure cycl i ng cl utch swi tch wi re har-
ness connector.
(4) Connect a mani fol d gauge set to the refri gerant
system servi ce ports. See Refri gerant System Servi ce
Equi pment and Refri gerant System Servi ce Ports i n
the Descri pti on and Operati on secti on of thi s group
for more i nformati on.
(6) Pl ace the heater-A/C mode control swi tch knob
i n any A/C posi ti on and start the engi ne.
(7) Check for conti nui ty between the two termi nal s
of the l ow pressure cycl i ng cl utch swi tch. There
shoul d be conti nui ty wi th a sucti on pressure readi ng
of 262 kPa (38 psi ) or above, and no conti nui ty wi th a
sucti on pressure readi ng of 141 kPa (20.5 psi ) or
bel ow. I f OK, test and repai r the A/C swi tch sense
ci rcui t as requi red. I f not OK, repl ace the faul ty
swi tch.
REFRIGERANT SYSTEM LEAKS
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
LEAK TESTING THE SYSTEM.
I f the ai r condi ti oni ng system i s not cool i ng prop-
erl y, determi ne i f the refri gerant system i s ful l y-
charged. See A/C Performance i n thi s group for the
procedures. I f the refri gerant system i s l ow or empty;
a l eak at a refri gerant l i ne, connector fi tti ng, compo-
nent, or component seal i s l i kel y.
An el ectroni c l eak detector desi gned for R-134a
refri gerant, or a fl uorescent R-134a l eak detecti on
dye and a bl ack l i ght are recommended for l ocati ng
and confi rmi ng refri gerant system l eaks. Refer to the
operati ng i nstructi ons suppl i ed by the equi pment
manufacturer for proper care and use of thi s equi p-
ment.
An oi l y resi due on or near refri gerant system l i nes,
connector fi tti ngs, components, or component seal s
can i ndi cate the general l ocati on of a possi bl e refri g-
erant l eak. However, the exact l eak l ocati on shoul d
be confi rmed wi th an el ectroni c l eak detector pri or to
component repai r or repl acement.
To detect a l eak i n the refri gerant system wi th an
el ectroni c l eak detector, perform one of the fol l owi ng
procedures:
SYSTEM EMPTY
(1) Evacuate the refri gerant system. See Refri ger-
ant System Evacuate i n thi s group for the proce-
dures.
(2) Connect and di spense 0.283 ki l ograms (0.625
pounds or 10 ounces) of R-134a refri gerant i nto the
evacuated refri gerant system. See Refri gerant Sys-
tem Charge i n thi s group for the procedures.
(3) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(4) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Because
R-134a refri gerant i s heavi er than ai r, the l eak detec-
tor probe shoul d be moved sl owl y al ong the bottom
si de of al l refri gerant l i nes, connector fi tti ngs and
components.
(5) To i nspect the evaporator coi l for l eaks, i nsert
the el ectroni c l eak detector probe i nto the center
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, and the mode control
swi tch i n the reci rcul ati on mode.
SYSTEM LOW
(1) Posi ti on the vehi cl e i n a wi nd-free work area.
Thi s wi l l ai d i n detecti ng smal l l eaks.
(2) Bri ng the refri gerant system up to operati ng
temperature and pressure. Thi s i s done by al l owi ng
the engi ne to run wi th the ai r condi ti oni ng system
turned on for fi ve mi nutes.
(3) Wi th the engi ne not runni ng, use a el ectroni c
R-134a l eak detector and search for l eaks. Because
R-134a refri gerant i s heavi er than ai r, the l eak detec-
tor probe shoul d be moved sl owl y al ong the bottom
si de of al l refri gerant l i nes, connector fi tti ngs and
components.
(4) To i nspect the evaporator coi l for l eaks, i nsert
the el ectroni c l eak detector probe i nto the center
i nstrument panel outl et. Set the bl ower motor swi tch
to the l owest speed posi ti on, and the mode control
swi tch i n the reci rcul ati on mode.
VACUUM SYSTEM
Vacuum control i s used to operate the mode doors
i n the heater-onl y and heater-A/C housi ngs. Testi ng
of the heater-onl y and heater-A/C mode control
swi tch operati on wi l l determi ne i f the vacuum, el ec-
tri cal , and mechani cal control s are functi oni ng. How-
ever, i t i s possi bl e that a vacuum control system that
operates perfectl y at engi ne i dl e (hi gh engi ne vac-
uum) may not functi on properl y at hi gh engi ne
speeds or l oads (l ow engi ne vacuum). Thi s can be
caused by l eaks i n the vacuum system, or a faul ty
vacuum check val ve.
A vacuum system test wi l l hel p to i denti fy the
source of poor vacuum system performance or vac-
uum system l eaks. Before starti ng thi s test, stop the
engi ne and make certai n that the probl em i s not a
di sconnected vacuum suppl y tube at the engi ne
i ntake mani fol d vacuum tap or at the vacuum reser-
voi r.
Use an adjustabl e vacuum test set (Speci al Tool
C-3707-B) and a sui tabl e vacuum pump to test the
heater-A/C vacuum control system. Wi th a fi nger
pl aced over the end of the vacuum test hose probe
(Fi g. 9), adjust the bl eed val ve on the test set gauge
to obtai n a vacuum of exactl y 27 kPa (8 i n. Hg.).
Rel ease and bl ock the end of the probe several ti mes
to veri fy that the vacuum readi ng returns to the
exact 27 kPa (8 i n. Hg.) setti ng. Otherwi se, a fal se
readi ng wi l l be obtai ned duri ng testi ng.
VACUUM CHECK VALVE
(1) Remove the vacuum check val ve. The val ve i s
l ocated i n the vacuum suppl y tube (bl ack) at the
heater-A/C system vacuum tee.
(2) Connect the test set vacuum suppl y hose to the
heater-A/C control si de of the val ve. When connected
to thi s si de of the check val ve, no vacuum shoul d
pass and the test set gauge shoul d return to the 27
kPa (8 i n. Hg.) setti ng. I f OK, go to Step 3. I f not OK,
repl ace the faul ty val ve.
(3) Connect the test set vacuum suppl y hose to the
engi ne vacuum si de of the val ve. When connected to
thi s si de of the check val ve, vacuum shoul d fl ow
through the val ve wi thout restri cti on. I f not OK,
repl ace the faul ty val ve.
HEATER-A/C CONTROLS
(1) Connect the test set vacuum probe to the heat-
er-A/C vacuum suppl y (bl ack) tube at the tee i n the
engi ne compartment. Posi ti on the test set gauge so
that i t can be vi ewed from the passenger compart-
ment.
Fig. 9 Adjust Vacuum Test Bleed Valve
1 VACUUM PUMP TOOL C-4289
2 VACUUM TEST SET C-3707
3 BLEED VALVE
4 PROBE
(2) Pl ace the heater-A/C mode control swi tch knob
i n each mode posi ti on, one posi ti on at a ti me, and
pause after each sel ecti on. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each sel ecti on i s made. I f not OK, a component or
vacuum l i ne i n the vacuum ci rcui t of the sel ected
mode has a l eak. See the procedure i n Locati ng Vac-
uum Leaks.
CAUTION: Do not use lubricant on the switch ports
or in the holes in the plug, as lubricant will ruin the
vacuum valve in the switch. A drop of clean water
in the connector plug holes will help the connector
slide onto the switch ports.
LOCATING VACUUM LEAKS
INJURY.
(1) Di sconnect the vacuum harness connector
behi nd the gl ove box and i nboard of the gl ove box
openi ng on the heater-A/C housi ng.
(2) Connect the test set vacuum hose probe to each
port i n the heater-A/C housi ng hal f of the vacuum
harness connector, one port at a ti me, and pause
after each connecti on (Fi g. 10). The test set gauge
shoul d return to the 27 kPa (8 i n. Hg.) setti ng
shortl y after each connecti on i s made. I f OK, repl ace
the faul ty heater-A/C control . I f not OK, go to Step 3.
(3) Determi ne the vacuum l i ne col or of the vacuum
ci rcui t that i s l eaki ng. To determi ne the vacuum l i ne
col ors, refer to the Vacuum Ci rcui ts chart (Fi g. 11) or
(Fi g. 12).
(4) Di sconnect and pl ug the vacuum l i ne from the
component (fi tti ng, actuator, val ve, swi tch, or reser-
voi r) on the other end of the l eaki ng ci rcui t. I nstru-
ment panel di sassembl y or removal may be necessary
to gai n access to some components. See the servi ce
procedures i n thi s group.
(5) Connect the test set hose or probe to the open
end of the l eaki ng ci rcui t. The test set gauge shoul d
return to the 27 kPa (8 i n. Hg.) setti ng shortl y after
each connecti on i s made. I f OK, repl ace the faul ty
di sconnected component. I f not OK, go to Step 6.
(6) To l ocate a l eak i n a vacuum l i ne, l eave one
end of the l i ne pl ugged and connect the test set hose
or probe to the other end of the l i ne. Run your fi n-
gers sl owl y al ong the l i ne whi l e watchi ng the test set
gauge. The vacuum readi ng wi l l fl uctuate when your
fi ngers contact the source of the l eak. To repai r the
vacuum l i ne, cut out the l eaki ng secti on of the l i ne.
Then, i nsert the l oose ends of the l i ne i nto a sui tabl e
l ength of 3 mi l l i meter (0.125 i nch) i nsi de di ameter
rubber hose.
SERVICE PROCEDURES
REFRIGERANT OIL LEVEL
When an ai r condi ti oni ng system i s assembl ed at
the factory, al l components except the compressor are
refri gerant oi l free. After the refri gerant system has
been charged and operated, the refri gerant oi l i n the
compressor i s di spersed throughout the refri gerant
system. The accumul ator, evaporator, condenser, and
compressor wi l l each retai n a si gni fi cant amount of
the needed refri gerant oi l .
I t i s i mportant to have the correct amount of oi l i n
the refri gerant system. Thi s ensures proper l ubri ca-
ti on of the compressor. Too l i ttl e oi l wi l l resul t i n
damage to the compressor. Too much oi l wi l l reduce
the cool i ng capaci ty of the ai r condi ti oni ng system.
I t wi l l not be necessary to check the oi l l evel i n the
compressor or to add oi l , unl ess there has been an oi l
l oss. An oi l l oss may occur due to a rupture or l eak
from a refri gerant l i ne, a connector fi tti ng, a compo-
nent, or a component seal . I f a l eak occurs, add 30
mi l l i l i ters (1 fl ui d ounce) of refri gerant oi l to the
refri gerant system after the repai r has been made.
Refri gerant oi l l oss wi l l be evi dent at the l eak poi nt
by the presence of a wet, shi ny surface around the
l eak.
Refri gerant oi l must be added when a accumul ator,
evaporator coi l , or condenser are repl aced. See the
Refri gerant Oi l Capaci ti es chart. When a compressor
Fig. 10 Vacuum Circuit Test
VACUUM CIRCUIT LEGEND
I. D. Function Color
A Not Used N/A
B Defrost
Actuator (Full
Position)
Yellow
C Floor Actuator Brown
D Defrost
Actuator
(Mid-Position)
Blue
E Vacuum Supply
(Reservoir)
Black
F Panel Actuator Red
G Not Used N/A
Fig. 11 Vacuum Circuits - Heater Only
VACUUM CIRCUIT LEGEND
I. D. Function Color
A Not Used N/A
B Defrost Actuator (Full Position) Yellow
C Floor Actuator Brown
D Defrost Actuator (Mid-Position) Blue
E Vacuum Supply (Reservoir) Black
F Panel Actuator Red
G Recirculation Actuator Green
Fig. 12 Vacuum Circuits - Heater-A/C
i s repl aced, the refri gerant oi l must be drai ned from
the ol d compressor and measured. Drai n al l of the
refri gerant oi l from the new compressor, then fi l l the
new compressor wi th the same amount of refri gerant
oi l that was drai ned out of the ol d compressor.
REFRIGERANT RECOVERY
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE
RECOVERING REFRIGERANT.
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to recover the refri gerant from an R-134a refri g-
erant system. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for the proper
care and use of thi s equi pment.
REFRIGERANT SYSTEM EVACUATE
NEAR THE FRONT OF THIS GROUP BEFORE EVAC-
UATING THE SYSTEM.
I f the refri gerant system has been open to the
atmosphere, i t must be evacuated before the system
can be charged. I f moi sture and ai r enters the system
and becomes mi xed wi th the refri gerant, the com-
pressor head pressure wi l l ri se above acceptabl e
operati ng l evel s. Thi s wi l l reduce the performance of
the ai r condi ti oner and damage the compressor.
Evacuati ng the refri gerant system wi l l remove the
ai r and boi l the moi sture out of the system at near
room temperature. To evacuate the refri gerant sys-
tem, use the fol l owi ng procedure:
(1) Connect a R-134a refri gerant recovery/recy-
cl i ng/chargi ng stati on that meets SAE Standard
J2210 and a mani fol d gauge set to the refri gerant
system of the vehi cl e.
(2) Open the l ow and hi gh si de val ves and start
the chargi ng stati on vacuum pump. When the suc-
ti on gauge reads 88 kPa (26 i n. Hg.) vacuum or
greater, cl ose al l of the val ves and turn off the vac-
uum pump.
(a) I f the refri gerant system fai l s to reach the
speci fi ed vacuum, the system has a l eak that must
be corrected. See Refri gerant System Leaks i n the
Di agnosi s and Testi ng secti on of thi s group for the
procedures.
(b) I f the refri gerant system mai ntai ns the spec-
i fi ed vacuum for fi ve mi nutes, restart the vacuum
pump, open the sucti on and di scharge val ves and
evacuate the system for an addi ti onal ten mi nutes.
(3) Cl ose al l of the val ves, and turn off the charg-
i ng stati on vacuum pump.
(4) The refri gerant system i s now ready to be
charged wi th R-134a refri gerant. See Refri gerant
System Charge i n the Servi ce Procedures secti on of
thi s group.
REFRIGERANT SYSTEM CHARGE
CHARGING THE REFRIGERANT SYSTEM.
After the refri gerant system has been tested for
l eaks and evacuated, a refri gerant charge can be
i njected i nto the system. See Refri gerant Charge
Capaci ty for the proper amount of the refri gerant
charge.
A R-134a refri gerant recovery/recycl i ng/chargi ng
stati on that meets SAE Standard J2210 must be
used to charge the refri gerant system wi th R-134a
refri gerant. Refer to the operati ng i nstructi ons sup-
pl i ed by the equi pment manufacturer for proper care
and use of thi s equi pment.
REFRIGERANT CHARGE CAPACITY
The R-134a refri gerant system charge capaci ty for
thi s vehi cl e i s 0.567 ki l ograms (1.25 pounds).
REFRIGERANT SYSTEM SERVICE EQUIPMENT
WARNING: EYE PROTECTION MUST BE WORN
WHEN SERVICING AN AIR CONDITIONING REFRIG-
ERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE)
ALL VALVES ON THE EQUIPMENT BEING USED,
BEFORE CONNECTING TO OR DISCONNECTING
FROM THE REFRIGERANT SYSTEM. FAILURE TO
OBSERVE THESE WARNINGS MAY RESULT IN PER-
SONAL INJURY.
When servi ci ng the ai r condi ti oni ng system, a
R-134a refri gerant recovery/recycl i ng/chargi ng sta-
ti on that meets SAE Standard J2210 must be used.
Contact an automoti ve servi ce equi pment suppl i er for
refri gerant recovery/recycl i ng/chargi ng equi pment.
Refer to the operati ng i nstructi ons suppl i ed by the
Refrigerant Oil Capacities
Component ml fl oz
A/C System 180 6.1
Accumulator 90 3
Condenser 22 .75
Evaporator 45 1.5
Compressor
drain and measure
the oil from the old
compressor as noted
equi pment manufacturer for proper care and use of
thi s equi pment.
A mani fol d gauge set may be needed wi th some
recovery/recycl i ng/chargi ng equi pment (Fi g. 13). The
servi ce hoses on the gauge set bei ng used shoul d
have manual (turn wheel ), or automati c back-fl ow
val ves at the servi ce port connector ends. Thi s wi l l
prevent refri gerant from bei ng rel eased i nto the
atmosphere.
MANIFOLD GAUGE SET CONNECTIONS
CAUTION: Do not use an R-12 manifold gauge set
on an R-134a system. The refrigerants are not com-
patible and system damage will result.
LOW PRESSURE GAUGE HOSE The l ow pressure
hose (Bl ue wi th Bl ack stri pe) attaches to the sucti on
servi ce port. Thi s port i s l ocated on the sucti on l i ne
between the accumul ator outl et and the compressor.
HI GH PRESSURE GAUGE HOSE The hi gh pres-
sure hose (Red wi th Bl ack stri pe) attaches to the di s-
charge servi ce port. Thi s port i s l ocated on the
di scharge l i ne between the compressor and the con-
denser i nl et.
RECOVERY/RECYCLI NG/EVACUATI ON/CHARG-
I NG HOSE The center mani fol d hose (Yel l ow, or
Whi te, wi th Bl ack stri pe) i s used to recover, evacu-
ate, and charge the refri gerant system. When the l ow
or hi gh pressure val ves on the mani fol d gauge set
are opened, the refri gerant i n the system wi l l escape
through thi s hose.
SERVICE WARNINGS AND PRECAUTIONS
WARNING:
THE AIR CONDITIONING SYSTEM CONTAINS
REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER
SERVICE PROCEDURES. REPAIRS SHOULD ONLY
BE PERFORMED BY QUALIFIED SERVICE PERSON-
NEL.
AVOID BREATHING THE REFRIGERANT AND
REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.
DO NOT EXPOSE THE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELEC-
TRONIC LEAK DETECTOR IS RECOMMENDED.
IF ACCIDENTAL SYSTEM DISCHARGE
OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING SERVICE. LARGE AMOUNTS OF
REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.
THE EVAPORATION RATE OF R-134a REFRIG-
ERANT AT AVERAGE TEMPERATURE AND ALTI-
TUDE IS EXTREMELY HIGH. AS A RESULT,
ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.
THE R-134a SERVICE EQUIPMENT OR THE
VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.
Fig. 13 Manifold Gauge Set - Typical
1 HIGH PRESSURE GAUGE
2 VALVE
3 VACUUM/REFRIGERANT HOSE (YELLOW W/BLACK
STRIPE)
4 HIGH PRESSURE HOSE (RED W/BLACK STRIPE)
5 LOW PRESSURE HOSE (BLUE W/BLACK STRIPE)
6 VALVE
7 LOW PRESSURE GAUGE
CAUTION:
Liquid refrigerant is corrosive to metal sur-
faces. Follow the operating instructions supplied
with the service equipment being used.
Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
R-12 refrigerant oil must not be mixed with
R-134a refrigerant oil. They are not compatible.
Do not use R-12 equipment or parts on the
R-134a system. Damage to the system will result.
Do not overcharge the refrigerant system. This
will cause excessive compressor head pressure
and can cause noise and system failure.
Recover the refrigerant before opening any fit-
ting or connection. Open the fittings with caution,
even after the system has been discharged. Never
open or loosen a connection before recovering the
refrigerant.
Do not remove the secondary retention clip
from any spring-lock coupler connection while the
refrigerant system is under pressure. Recover the
refrigerant before removing the secondary retention
clip. Open the fittings with caution, even after the
system has been discharged. Never open or loosen
a connection before recovering the refrigerant.
The refrigerant system must always be evacu-
ated before charging.
Do not open the refrigerant system or uncap a
replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.
Before disconnecting a component, clean the
outside of the fittings thoroughly to prevent con-
tamination from entering the refrigerant system.
Immediately after disconnecting a component
from the refrigerant system, seal the open fittings
with a cap or plug.
Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.
Do not remove the sealing caps from a replace-
ment component until it is to be installed.
When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.
Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.
When disconnecting a refrigerant fitting, use a
wrench on both halves of the fitting. This will pre-
vent twisting of the refrigerant lines or tubes.
Refrigerant oil will absorb moisture from the
atmosphere if left uncapped. Do not open a con-
tainer of refrigerant oil until you are ready to use it.
Replace the cap on the oil container immediately
after using. Store refrigerant oil only in a clean, air-
tight, and moisture-free container.
Keep service tools and the work area clean.
Contamination of the refrigerant system through
careless work habits must be avoided.
COOLING SYSTEM REQUIREMENTS
To mai ntai n the performance l evel of the heati ng-
ai r condi ti oni ng system, the engi ne cool i ng system
must be properl y mai ntai ned. The use of a bug
screen i s not recommended. Any obstructi ons i n front
of the radi ator or condenser wi l l reduce the perfor-
mance of the ai r condi ti oni ng and engi ne cool i ng sys-
tems.
The engi ne cool i ng system i ncl udes the heater core
and the heater hoses. Refer to Group 7 - Cool i ng Sys-
tem for more i nformati on before the openi ng of, or
attempti ng any servi ce to the engi ne cool i ng system.
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS
Ki nks or sharp bends i n the refri gerant pl umbi ng
wi l l reduce the capaci ty of the enti re system. Hi gh
pressures are produced i n the system when i t i s oper-
ati ng. Extreme care must be exerci sed to make sure
that al l refri gerant system connecti ons are pressure
ti ght.
A good rul e for the fl exi bl e hose refri gerant l i nes i s
to keep the radi us of al l bends at l east ten ti mes the
di ameter of the hose. Sharp bends wi l l reduce the
fl ow of refri gerant. The fl exi bl e hose l i nes shoul d be
routed so they are at l east 80 mi l l i meters (3 i nches)
from the exhaust mani fol d. I t i s a good practi ce to
i nspect al l fl exi bl e refri gerant system hose l i nes at
l east once a year to make sure they are i n good con-
di ti on and properl y routed.
There are two types of refri gerant fi tti ngs:
Al l fi tti ngs wi th O-ri ngs need to be coated wi th
refri gerant oi l before i nstal l ati on. Use onl y O-ri ngs
that are the correct si ze and approved for use wi th
R-134a refri gerant. Fai l ure to do so may resul t i n a
l eak.
Uni fi ed pl umbi ng connecti ons wi th gaskets can-
not be servi ced wi th O-ri ngs. The gaskets are not
reusabl e and new gaskets do not requi re l ubri cati on
before i nstal l i ng.
Usi ng the proper tool s when maki ng a refri gerant
pl umbi ng connecti on i s very i mportant. I mproper
tool s or i mproper use of the tool s can damage the
refri gerant fi tti ngs. Al ways use two wrenches when
l ooseni ng or ti ghteni ng tube fi tti ngs. Use one wrench
to hol d one si de of the connecti on stati onary, whi l e
l ooseni ng or ti ghteni ng the other si de of the connec-
ti on wi th a second wrench.
The refri gerant must be recovered compl etel y from
the system before openi ng any fi tti ng or connecti on.
Open the fi tti ngs wi th cauti on, even after the refri g-
erant has been recovered. I f any pressure i s noti ced
as a fi tti ng i s l oosened, ti ghten the fi tti ng and
recover the refri gerant from the system agai n.
Do not di scharge refri gerant i nto the atmosphere.
Use an R-134a refri gerant recovery/recycl i ng devi ce
that meets SAE Standard J2210.
The refri gerant system wi l l remai n chemi cal l y sta-
bl e as l ong as pure, moi sture-free R-134a refri gerant
and refri gerant oi l i s used. Di rt, moi sture, or ai r can
upset thi s chemi cal stabi l i ty. Operati onal troubl es or
seri ous damage can occur i f forei gn materi al i s
present i n the refri gerant system.
When i t i s necessary to open the refri gerant sys-
tem, have everythi ng needed to servi ce the system
ready. The refri gerant system shoul d not be l eft open
to the atmosphere any l onger than necessary. Cap or
pl ug al l l i nes and fi tti ngs as soon as they are opened
to prevent the entrance of di rt and moi sture. Al l l i nes
and components i n parts stock shoul d be capped or
seal ed unti l they are to be i nstal l ed.
Al l tool s, i ncl udi ng the refri gerant recycl i ng equi p-
ment, the mani fol d gauge set, and test hoses shoul d
be kept cl ean and dry. Al l tool s and equi pment must
be desi gned for R-134a refri gerant.
ACCUMULATOR
PERFORMING THE FOLLOWING OPERATION.
REMOVAL
cabl e.
(2) Recover the refri gerant from the refri gerant
system. See Refri gerant Recovery i n thi s group for
the procedures.
(3) Unpl ug the wi re harness connector from the
l ow pressure cycl i ng cl utch swi tch.
(4) Loosen the screw that secures the accumul ator
retai ni ng band to the support bracket on the dash
panel (Fi g. 14).
(5) Di sconnect the sucti on l i ne from the accumul a-
tor outl et tube refri gerant l i ne fi tti ng. See Refri ger-
ant Li ne Coupl er i n thi s group for the procedures.
I nstal l pl ugs i n, or tape over al l of the opened refri g-
erant l i ne fi tti ngs.
(6) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne fi tti ng from the evaporator outl et tube. See
Refri gerant Li ne Coupl er i n thi s group for the proce-
dures. I nstal l pl ugs i n, or tape over al l of the opened
refri gerant l i ne fi tti ngs.
(7) Pul l the accumul ator and retai ni ng band uni t
forward unti l the screw i n the band i s cl ear of the
sl otted hol e i n the support bracket on the dash panel .
(8) Remove the accumul ator from the vehi cl e.
INSTALLATION
(1) I nstal l the accumul ator and retai ni ng band as
a uni t by sl i di ng the screw i n the band i nto the sl ot-
ted hol e i n the support bracket on the dash panel .
(2) Remove the tape or pl ugs from the refri gerant
l i ne fi tti ngs on the accumul ator i nl et tube and the
evaporator outl et tube. Connect the accumul ator i nl et
tube refri gerant l i ne coupl er to the evaporator outl et
tube. See Refri gerant Li ne Coupl er i n thi s group for
the procedures.
(3) Ti ghten the accumul ator retai ni ng band screw
to 5 Nm (45 i n. l bs.).
l i ne fi tti ngs on the sucti on l i ne and the accumul ator
outl et tube. Connect the sucti on l i ne to the accumu-
Fig. 14 Accumulator Remove/Install
2 CLIP
3 EVAPORATOR
4 STUDS
5 BRACKET
6 NUTS
7 BAND
8 ACCUMULATOR
9 SCREW
l ator outl et tube refri gerant l i ne coupl er. See Refri g-
erant Li ne Coupl er i n thi s group for the procedures.
(5) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
dures.
(8) Charge the refri gerant system. See Refri gerant
System Charge i n thi s group for the procedures.
NOTE: If the accumulator is replaced, add 120 mil-
liliters (4 fluid ounces) of refrigerant oil to the
refrigerant system. Use only refrigerant oil of the
type recommended for the compressor in the vehi-
cle.
BLEND-AIR DOOR MOTOR
INJURY.
REMOVAL
cabl e.
(2) Di sconnect the wi re connector from the bl end-
ai r door motor.
(3) Remove the screws that secure the bl end-ai r
door motor to the housi ng (Fi g. 15).
(4) Remove the bl end-ai r door motor.
INSTALLATION
(1) Reverse the removal procedures for i nstal l a-
ti on.
(2) I nstal l and ti ghten the screws that secures the
bl end-ai r door motor to the housi ng. Ti ghten the
mounti ng screws to 1 Nm (10 i n. l bs.).
BLOWER MOTOR
REMOVAL
(1) I f the vehi cl e i s equi pped wi th ai r condi ti oni ng,
recover the refri gerant from the refri gerant system.
See Refri gerant Recovery i n thi s group for the proce-
dures.
cabl e.
the accumul ator must be rel ocated i n order to servi ce
the bl ower motor. Thi s i s done by l ooseni ng the accu-
mul ator retai ni ng band screw and di sconnecti ng the
accumul ator i nl et tube from the evaporator outl et
tube. The accumul ator can then be moved far enough
to access and remove the bl ower motor. See Accumu-
l ator i n thi s group for the procedures.
(4) Unpl ug the bl ower motor wi re harness connec-
tor (Fi g. 16).
(5) Remove the three screws that secure the
bl ower motor and wheel assembl y to the heater-A/C
housi ng.
(6) Rotate and ti l t the bl ower motor uni t as needed
for cl earance to remove the bl ower motor and wheel
from the heater-A/C housi ng.
INSTALLATION
(1) Al i gn and i nstal l the bl ower motor and wheel
assembl y i nto the heater-A/C housi ng.
(2) I nstal l and ti ghten the three screws that secure
the bl ower motor and wheel assembl y to the heater-
A/C housi ng. Ti ghten the mounti ng screws to 2.2
Nm (20 i n. l bs.).
(3) Pl ug i n the bl ower motor wi re harness connec-
tor.
connect the accumul ator i nl et tube to the evaporator
outl et tube and ti ghten the accumul ator retai ni ng
band screw. See Accumul ator i n thi s group for the
procedures.
Fig. 15 Blend-Air Door Motor
2 BLEND-AIR DOOR MOTOR
3 SCREW MOUNTING POINTS
evacuate the refri gerant system. See Refri gerant Sys-
tem Evacuate i n thi s group for the procedures.
charge the refri gerant system. See Refri gerant Sys-
tem Charge i n thi s group for the procedures.
BLOWER MOTOR RELAY
INJURY.
cabl e.
(2) Rol l the gl ove box down from the i nstrument
panel . Refer to Gl ove Box i n Group 8E - I nstrument
Panel Systems for the procedures.
(3) Reach through the i nstrument panel gl ove box
openi ng to l ocate the bl ower motor rel ay (Fi g. 17).
(4) Unpl ug the bl ower motor rel ay from i ts wi re
harness connector.
(5) I nstal l the bl ower motor rel ay by al i gni ng the
rel ay termi nal s wi th the cavi ti es i n the wi re harness
connector and pushi ng the rel ay fi rml y i nto pl ace.
(6) Rol l the gl ove box back up i nto the i nstrument
(8) Test the rel ay operati on.
INJURY.
cabl e.
housi ng. See Ki ck Cover i n thi s group for the proce-
dures.
(3) Pul l out the l ock on the bl ower motor resi stor
wi re harness connector to unl ock the connector l atch
(Fi g. 18).
(4) Depress the l atch on the bl ower motor resi stor
wi re harness connector and unpl ug the connector
from the resi stor.
(5) Remove the two screws that secure the resi stor
to the heater-A/C housi ng.
(6) Remove the resi stor from the heater-A/C hous-
i ng.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the mounti ng screws to 2.2 Nm (20 i n l bs.).
Fig. 16 Blower Motor Remove/Install
1 BLOWER MOTOR
3 MOUNTING SCREWS
Fig. 17 Blower Motor Relay Remove/Install
1 BLOWER MOTOR RELAY
2 VACUUM HARNESS
3 HEATER-A/C WIRE HARNESS CONNECTOR
4 HEATER-A/C HOUSING
COMPRESSOR
The compressor may be removed and reposi ti oned
wi thout di sconnecti ng the refri gerant l i nes or di s-
chargi ng the refri gerant system. Di schargi ng i s not
necessary i f servi ci ng the compressor cl utch or cl utch
coi l , the engi ne, the cyl i nder head, or the generator.
REMOVAL
the procedures.
cabl e.
(3) Remove the serpenti ne dri ve bel t. Refer to
Group 7 - Cool i ng System for the procedures.
(4) Unpl ug the compressor cl utch coi l wi re harness
connector.
(5) Remove the sucti on and di scharge refri gerant
l i ne mani fol d from the compressor. See Sucti on and
Di scharge Li ne i n thi s group for the procedures.
I nstal l pl ugs i n, or tape over al l of the opened refri g-
erant fi tti ngs.
(6) Remove the four bol ts that secure the compres-
sor to the mounti ng bracket (Fi g. 19).
(7) Remove the compressor from the mounti ng
bracket.
INSTALLATION
NOTE: If a replacement compressor is being
installed, be certain to check the refrigerant oil
level. See Refrigerant Oil Level in this group for the
procedures. Use only refrigerant oil of the type rec-
ommended for the compressor in the vehicle.
(1) I nstal l the compressor to the mounti ng bracket.
Ti ghten the four mounti ng bol ts as fol l ows:
Al l 2.5L and 4.0L engi nes - 27 Nm (20 ft. l bs.)
(2) Remove the tape or pl ugs from al l of the
opened refri gerant l i ne fi tti ngs. I nstal l the sucti on
and di scharge l i ne mani fol d to the compressor. See
Sucti on and Di scharge Li ne i n thi s group for the pro-
cedures.
(3) I nstal l the serpenti ne dri ve bel t. Refer to
(4) Pl ug i n the compressor cl utch coi l wi re harness
connector.
dures.
Fig. 18 Blower Motor Resistor Remove/Install
1 SCREWS
3 CONNECTOR LOCK
5 BLOWER MOTOR RESISTOR
Fig. 19 Compressor Remove/Install - All 2.5L/4.0L
Engines
1 BOLT
2 MOUNTING BRACKET
3 ENGINE
4 COMPRESSOR
COMPRESSOR CLUTCH
The refri gerant system can remai n ful l y-charged
duri ng compressor cl utch, pul l ey, or coi l repl acement.
The compressor cl utch can be servi ced i n the vehi cl e.
REMOVAL
cabl e.
(2) Remove the serpenti ne dri ve bel t. Refer to
(3) Unpl ug the compressor cl utch coi l wi re harness
connector.
(4) Remove the four bol ts that secure the compres-
sor to the mounti ng bracket.
(5) Remove the compressor from the mounti ng
bracket. Support the compressor i n the engi ne com-
partment whi l e servi ci ng the cl utch.
(6) I nsert the two pi ns of the spanner wrench
(Speci al Tool C-4489) i nto the hol es of the cl utch
pl ate. Hol d the cl utch pl ate stati onary and remove
the hex nut (Fi g. 20).
(7) Remove the cl utch pl ate wi th a pul l er (Speci al
Tool C-6461) (Fi g. 21).
(8) Remove the compressor shaft key and the
cl utch shi ms.
(9) Remove the external front housi ng snap ri ng
wi th snap ri ng pl i ers (Fi g. 22).
(10) I nstal l the l i p of the rotor pul l er (Speci al Tool
C-6141-1) i nto the snap ri ng groove exposed i n the
previ ous step, and i nstal l the shaft protector (Speci al
Tool C-6141-2) (Fi g. 23).
(11) I nstal l the pul l er through-bol ts (Speci al Tool
C-6461) through the pul l er fl ange and i nto the jaws
of the rotor pul l er and ti ghten (Fi g. 24). Turn the
pul l er center bol t cl ockwi se unti l the rotor pul l ey i s
free.
(12) Remove the screw and retai ner from the
cl utch coi l l ead wi re harness on the compressor front
(13) Remove the snap ri ng from the compressor
hub and remove the cl utch fi el d coi l (Fi g. 26). Sl i de
the cl utch fi el d coi l off of the compressor hub.
INSPECTION
Exami ne the fri cti on surfaces of the cl utch pul l ey
and the front pl ate for wear. The pul l ey and front
pl ate shoul d be repl aced i f there i s excessi ve wear or
scori ng.
I f the fri cti on surfaces are oi l y, i nspect the shaft
and nose area of the compressor for oi l . Remove the
Fig. 20 Clutch Nut Remove
1 CLUTCH PLATE
2 SPANNER
Fig. 21 Clutch Plate Remove
1 CLUTCH PLATE PULLER
2 CLUTCH PLATE
Fig. 22 External Snap Ring Remove
1 PULLEY
2 SNAP RING PLIERS
fel t from the front cover. I f the fel t i s saturated wi th
oi l , the shaft seal i s l eaki ng and the compressor must
be repl aced.
Check the cl utch pul l ey beari ng for roughness or
excessi ve l eakage of grease. Repl ace the beari ng, i f
requi red.
INSTALLATION
(1) I nstal l the cl utch fi el d coi l and snap ri ng.
(2) I nstal l the cl utch coi l l ead wi re harness retai n-
i ng cl i p on the compressor front housi ng and ti ghten
the retai ni ng screw.
(3) Al i gn the rotor assembl y squarel y on the front
compressor housi ng hub.
(4) I nstal l the pul l ey beari ng assembl y wi th the
i nstal l er (Speci al Tool C-6871) (Fi g. 27). Thread the
i nstal l er on the shaft, then turn the nut unti l the
pul l ey assembl y i s seated.
(5) I nstal l the external front snap ri ng wi th snap
ri ng pl i ers. The bevel si de of the snap ri ng must be
faci ng outward. Press the snap ri ng to make sure i t
i s properl y seated i n the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) I nstal l the compressor shaft key and the ori gi -
nal cl utch shi ms on the compressor shaft.
Fig. 23 Shaft Protector and Puller
1 PULLER JAW
2 SHAFT PROTECTOR
Fig. 24 Install Puller Plate
1 PULLER JAW
2 PULLER
Fig. 25 Clutch Coil Lead Wire Harness
1 COIL
2 COIL WIRE
3 RETAINER SCREW
Fig. 26 Clutch Field Coil Snap Ring Remove
1 COIL
2 SNAP RING PLIERS
(7) I nstal l the cl utch pl ate wi th the dri ver (Speci al
Tool C-6463) (Fi g. 28). I nstal l the shaft hex nut and
ti ghten to 14.4 Nm (10.5 ft. l bs.).
(8) Check the cl utch ai r gap wi th a feel er gauge
(Fi g. 29). I f the ai r gap does not meet the speci fi ca-
ti on, add or subtract shi ms as requi red. The ai r gap
speci fi cati on i s 0.41 to 0.79 mi l l i meter (0.016 to 0.031
i nch). I f the ai r gap i s not consi stent around the ci r-
cumference of the cl utch, l i ghtl y pry up at the mi ni -
mum vari ati ons. Li ghtl y tap down at the poi nts of
maxi mum vari ati on.
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use 1.0, 0.50, and 0.13 milli-
meter (0.040, 0.020, and 0.005 inch) shims from the
clutch hardware package that is provided with the
new clutch.
(9) Reverse the remai ni ng removal procedures to
CLUTCH BREAK-IN
After a new compressor cl utch has been i nstal l ed,
cycl e the compressor cl utch approxi matel y twenty
ti mes (fi ve seconds on, then fi ve seconds off). Duri ng
thi s procedure, set the heater-A/C control to the
Reci rcul ati on Mode, the bl ower motor swi tch i n the
hi ghest speed posi ti on, and the engi ne speed at 1500
to 2000 rpm. Thi s procedure (burni shi ng) wi l l seat
the opposi ng fri cti on surfaces and provi de a hi gher
compressor cl utch torque capabi l i ty.
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 30).
(3) Refer to the l abel on the PDC for compressor
cl utch rel ay i denti fi cati on and l ocati on.
(4) Unpl ug the compressor cl utch rel ay from the
PDC.
(5) I nstal l the compressor cl utch rel ay by al i gni ng
the rel ay termi nal s wi th the cavi ti es i n the PDC and
pushi ng the rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
(8) Test the rel ay operati on.
Fig. 27 Clutch Pulley Install
1 PULLEY BEARING ASSEMBLY
2 INSTALLER
Fig. 28 Clutch Plate Driver
1 CLUTCH PLATE
2 DRIVER
Fig. 29 Check Clutch Air Gap
1 FEELER GAUGE
CONDENSER
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
REMOVAL
cabl e.
the procedures.
(3) Di sconnect the di scharge l i ne refri gerant l i ne
fi tti ng at the condenser i nl et. See Refri gerant Li ne
Coupl er i n thi s group for the procedures. I nstal l
pl ugs i n, or tape over al l of the opened refri gerant
l i ne fi tti ngs.
(4) Di sconnect the l i qui d l i ne (Left-Hand Dri ve) or
l i qui d l i ne jumper (Ri ght-Hand Dri ve) refri gerant
l i ne fi tti ng at the condenser outl et. See Refri gerant
Li ne Coupl er i n thi s group for the procedures. I nstal l
l i ne fi tti ngs.
(5) Remove the radi ator and the condenser from
the vehi cl e as a uni t. Refer to Group 7 - Cool i ng Sys-
tem for the procedures.
(6) Remove the two nuts that secure the condenser
studs to the upper brackets of the radi ator (Fi g. 31).
(7) Sl i de the condenser down from the radi ator far
enough for the condenser studs to cl ear the upper
radi ator bracket hol es, and for the l ower condenser
bracket hol es to cl ear the dowel pi ns on the bottom of
the radi ator.
(8) Remove the condenser from the radi ator.
INSTALLATION
(1) I nstal l the hol es of the condenser l ower brack-
ets over the dowel pi ns on the bottom of the radi ator.
(2) Sl i de the condenser upwards unti l both of the
condenser studs are i nstal l ed through the hol es i n
the radi ator upper brackets. Ti ghten the mounti ng
nuts to 5.3 Nm (47 i n. l bs.).
(3) Renstal l the radi ator and condenser uni t i n the
vehi cl e. Refer to Group 7 - Cool i ng System for the
procedures.
l i ne fi tti ngs on the condenser outl et and the l i qui d
l i ne (Left-Hand Dri ve) or the l i qui d l i ne jumper
(Ri ght-Hand Dri ve). I nstal l the l i qui d l i ne or the l i q-
Fig. 30 Power Distribution Center
1 RIGHT FENDER
2 BATTERY
3 POWER DISTRIBUTION CENTER
Fig. 31 Condenser Remove/Install
1 NUT
2 RADIATOR
3 GROMMET
4 LOWER CROSSMEMBER
5 CONDENSER
6 STUDS
ui d l i ne jumper to the condenser outl et. See Refri ger-
ant Li ne Coupl er i n thi s group for the procedures.
l i ne fi tti ngs on the condenser i nl et and the di scharge
l i ne. Connect the di scharge l i ne to the condenser
i nl et. See Refri gerant Li ne Coupl er i n thi s group for
the procedures.
dures.
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
DUAL FUNCTION HIGH PRESSURE SWITCH/
REMOVAL
cabl e.
dual functi on hi gh pressure swi tch or the hi gh pres-
sure cut-off swi tch, whi ch i s mounted to a fi tti ng on
the non-fl exi bl e secti on of the di scharge l i ne nearest
the compressor.
(3) Unscrew the hi gh pressure swi tch from the di s-
charge l i ne fi tti ng.
(4) Remove the hi gh pressure swi tch from the
vehi cl e.
(5) Remove the O-ri ng seal from the di scharge l i ne
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the di scharge l i ne fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(2) I nstal l and ti ghten the hi gh pressure swi tch on
the di scharge l i ne fi tti ng.
(3) Pl ug the wi re harness connector i nto the hi gh
pressure cut-off swi tch.
DUCTS AND OUTLETS
INJURY.
PANEL OUTLET DUCTS
The panel outl et ducts are i ntegral to the i nstru-
ment panel assembl y. Refer to I nstrument Panel
Assembl y i n Group 8E - I nstrument Panel Systems
for the procedures.
PANEL OUTLET BARRELS
(1) Use a tri m sti ck or another sui tabl e wi de fl at-
bl aded tool to gentl y pry the panel outl et barrel out
of the panel outl et housi ng (Fi g. 32). The barrel i s
retai ned by a l i ght snap fi t.
(2) To i nstal l , posi ti on the barrel i n the panel out-
l et housi ng and press fi rml y unti l the barrel snaps
i nto pl ace.
DEMISTER OUTLETS
The si de wi ndow demi ster outl ets are i ntegral to
the i nstrument panel end caps. Refer to I nstrument
Panel End Cap i n Group 8E - I nstrument Panel Sys-
tems for the procedures.
DEFROST DUCT/DEMISTER ADAPTER
(1) Remove the i nstrument panel assembl y from
the vehi cl e. Refer to I nstrument Panel Assembl y i n
Group 8E - I nstrument Panel Systems for the proce-
dures.
(2) Di sconnect the demi ster hoses from the defrost
duct/demi ster adapter (Fi g. 33).
Fig. 32 Panel Outlet Barrels
1 DEMISTER OUTLETS
2 PANEL OUTLET BARRELS
(3) Remove the three screws that secure the
defrost duct/demi ster adapter to the i nstrument
panel .
(4) Remove the defrost duct/demi ster adapter from
the i nstrument panel .
Ti ghten the mounti ng screws to 2.2 Nm (20 i n. l bs.).
DEMISTER HOSES
dures.
(2) Di sconnect the ends of the demi ster hose from
the demi ster duct (Fi g. 34) and the defrost duct/de-
mi ster adapter (Fi g. 33).
DEMISTER DUCTS
dures.
(2) Remove the end cap from the i nstrument
panel . Refer to I nstrument Panel End Cap i n Group
8E - I nstrument Panel Systems for the procedures.
(3) Di sconnect the demi ster hoses from the demi s-
ter duct (Fi g. 34).
(4) Remove the two screws that secure the demi s-
ter duct to the top of the i nstrument panel .
(5) Remove the demi ster duct from the i nstrument
panel .
CONSOLE REAR DUCT
cabl e.
(2) Remove the fl oor consol e from the fl oor panel
transmi ssi on tunnel (Fi g. 35). Refer to Group 23 -
Body for the procedures.
(3) Li ft the rear of the consol e rear duct out of the
consol e rear mounti ng bracket on the fl oor panel
transmi ssi on tunnel and sl i de the duct rearward to
di sengage i t from the fl oor duct and adapter.
(4) Remove the consol e rear duct from the vehi cl e.
FLOOR DUCT AND ADAPTER
(1) Remove the i nstrument panel from the vehi cl e.
Refer to I nstrument Panel Assembl y i n Group 8E -
I nstrument Panel Systems for the procedures.
(2) Remove the heater-A/C housi ng from the vehi -
cl e. See Heater-A/C Housi ng i n thi s group for the
procedures.
(3) Remove the three screws that secure the fl oor
duct and adapter to the heater-A/C housi ng (Fi g. 35).
(4) Remove the fl oor duct and adapter from the
heater-A/C housi ng.
Fig. 33 Defrost Duct/Demister Adapter
1 HOSE
2 INSTRUMENT PANEL
3 DEFROST DUCT/DEMISTER ADAPTER
4 SCREW
5 HOSE
Fig. 34 Demister Duct Remove/Install
1 DEMISTER DUCT
2 SCREWS
3 DEMISTER HOSE
EVAPORATOR COIL
INJURY.
(1) Remove and di sassembl e the heater-A/C hous-
i ng. See Heater-A/C Housi ng i n thi s group for the
procedures.
(2) Li ft the evaporator coi l uni t out of the l ower
hal f of the heater-A/C housi ng (Fi g. 36).
(3) Reverse the removal procedures to i nstal l . Be
certai n that the evaporator foam i nsul ator wrap and
rubber tube seal are rei nstal l ed.
NOTE: If the evaporator is replaced, add 60 millili-
ters (2 fluid ounces) of refrigerant oil to the refrig-
erant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
FIXED ORIFICE TUBE
The fi xed ori fi ce tube i s l ocated i n the l i qui d l i ne
(Left-Hand Dri ve) or the l i qui d l i ne jumper (Ri ght-
Hand Dri ve) near the condenser. The ori fi ce has fi l ter
screens on the i nl et and outl et ends of the tube body.
I f the fi xed ori fi ce tube i s faul ty or pl ugged, the l i q-
ui d l i ne uni t or l i qui d l i ne jumper uni t must be
repl aced. See Li qui d Li ne i n thi s group for the ser-
vi ce procedures.
HEATER-A/C CONTROL
INJURY.
REMOVAL
cabl e.
(2) Rol l down the gl ove box from the i nstrument
openi ng to access and unpl ug the two hal ves of the
heater-A/C vacuum harness connector.
Fig. 35 Floor Duct and Console Rear Duct Remove/
Install
1 FLOOR CONSOLE
2 SCREW
3 FLOOR DUCT AND ADAPTER
4 CONSOLE REAR DUCT
Fig. 36 Evaporator Coil Remove/Install
1 EVAPORATOR COIL
2 TUBE SEAL
3 CONDENSATE DRAIN TUBE
4 FOAM INSULATOR WRAP
(4) Remove the center bezel from the i nstrument
panel . Refer to I nstrument Panel Center Bezel i n
dures.
(5) Rel ease the vacuum harness push-i n retai ner
from the i nstrument panel di rectl y beneath the heat-
er-A/C control .
(6) Remove the four screws that secure the heater-
A/C control to the i nstrument panel (Fi g. 37).
(7) Pul l the heater-A/C control assembl y away
from the i nstrument panel far enough to access the
connecti ons on the back of the control .
(8) Unpl ug the wi re harness connectors from the
back of the heater-A/C control (Fi g. 38).
openi ng to gui de the heater-A/C control hal f of the
vacuum harness around any obstacl es whi l e pul l i ng
the heater-A/C control out from the front of the
i nstrument panel .
INSTALLATION
(1) Pl ug the wi re harness connectors i nto the back
of the heater-A/C control .
(2) Route the vacuum harness through the i nstru-
ment panel openi ng and rei nstal l the vacuum har-
ness push-i n retai ner.
openi ng to reconnect the two hal ves of the heater-A/C
vacuum harness connector.
(4) Rol l the gl ove box back up i nto the i nstrument
(5) Posi ti on the heater-A/C control i n the i nstru-
ment panel and secure i t wi th four screws. Ti ghten
the screws to 2.2 Nm (20 i n. l bs.).
(6) Rei nstal l the center bezel onto the i nstrument
panel . Refer to I nstrument Panel Center Bezel i n
dures.
HEATER-A/C HOUSING
The heater-A/C housi ng assembl y must be removed
from the vehi cl e and the two hal ves of the housi ng
separated for servi ce access of the heater core, evap-
orator coi l , bl end-ai r door, and each of the vari ous
mode control doors.
INJURY.
REMOVAL
cabl e.
(2) Remove the i nstrument panel from the vehi cl e.
Fig. 37 Heater-A/C Control Remove/Install
1 MOUNTING HOLES
2 CONTROL HEAD
3 HEATER-A/C CONTROL HEAD
4 MOUNTING HOLES
5 VACUUM HARNESS
6 TEMPERATURE SELECT CONTROL
7 MODE SELECT CONTROL
8 BLOWER SPEED CONTROL
Fig. 38 Heater-A/C Control Connections
1 HEATER-A/C CONTROL HEAD
2 MODE SELECT CONTROL
3 BLOWER SPEED CONTROL
4 ELECTRICAL CONNECTORS
5 VACUUM HARNESS
6 TEMPERATURE SELECT CONTROL
(3) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 6. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, recover the refri gerant from the
refri gerant system. See Refri gerant Recovery i n thi s
(4) Di sconnect the l i qui d l i ne refri gerant l i ne fi t-
ti ng from the evaporator i nl et tube. See Refri gerant
Li ne Coupl er i n thi s group for the procedures. I nstal l
l i ne fi tti ngs.
(5) Di sconnect the accumul ator i nl et tube refri ger-
ant l i ne fi tti ng from the evaporator outl et tube. See
(6) Drai n the engi ne cool i ng system. Refer to
(7) Di sconnect the heater hoses from the heater
core tubes. Refer to Group 7 - Cool i ng System for the
procedures. I nstal l pl ugs i n, or tape over the opened
heater core tubes.
(8) Unpl ug the heater-A/C system vacuum suppl y
l i ne connector from the tee fi tti ng near the heater
core tubes.
(9) Unpl ug the heater-A/C uni t wi re harness con-
nector, whi ch i s fastened to the heater-A/C housi ng
next to the bl ower motor rel ay (Fi g. 39).
(10) Remove the fi ve nuts from the heater-A/C
housi ng mounti ng studs on the engi ne compartment
si de of the dash panel (Fi g. 40). Remove or reposi ti on
the evaporati on cani ster for addi ti onal access, i f
requi red.
(11) Pul l the heater-A/C housi ng rearward far
enough for the mounti ng studs and the evaporator
condensate drai n tube to cl ear the dash panel hol es.
cl e.
DISASSEMBLY
cl e and pl ace i t on a work bench.
(2) Unpl ug the vacuum harness connectors from
the fl oor door actuator and, i f the uni t i s so equi pped,
the reci rcul ati on ai r door actuator.
(3) Di sengage the vacuum harness from any rout-
i ng cl i ps l ocated on the l ower hal f of the heater-A/C
housi ng.
(4) Di sengage the heater-A/C wi re harness connec-
tor and the bl ower motor rel ay wi re harness connec-
tor push-i n retai ners from thei r mounti ng hol es on
the heater-A/C housi ng.
(5) Remove the bl ower motor and bl ower wheel
uni t from the heater-A/C housi ng. See Bl ower Motor
i n thi s group for the procedures.
(6) Careful l y remove the foam seal from the fl ange
around the bl ower motor openi ng i n the heater-A/C
housi ng. I f the seal i s deformed or damaged, i t must
be repl aced.
(7) Pul l the vacuum suppl y l i ne and connector
through the foam seal on the heater core and evapo-
rator coi l tube mounti ng fl ange of the heater-A/C
(8) I f the uni t i s equi pped wi th ai r condi ti oni ng,
remove the screw that secures the cl amp to the evap-
orator coi l tubes and remove the cl amp.
Fig. 39 Heater-A/C Unit Connector
1 BLOWER MOTOR RELAY
2 VACUUM HARNESS
3 HEATER-A/C WIRE HARNESS CONNECTOR
Fig. 40 Heater-A/C Housing Remove/Install
2 STUD
3 NUT
4 STUD
5 RIGHT FRONT FENDER
(9) Careful l y remove the foam seal from the heater
core and evaporator coi l tube mounti ng fl ange of the
heater-A/C housi ng. I f the seal i s deformed or dam-
aged, i t must be repl aced.
(10) Use a screwdri ver to pry off the two snap cl i ps
that hel p secure the upper and l ower heater-A/C
housi ng hal ves to each other.
(11) Remove the 14 screws that secure the upper
and l ower heater-A/C housi ng hal ves to each other.
(12) Careful l y separate the upper heater-A/C hous-
i ng hal f from the l ower hal f.
ASSEMBLY
(1) Assembl e the upper heater-A/C housi ng hal f to
the l ower hal f. Duri ng assembl y, be certai n of the fol -
l owi ng:
(a) That each of the mode door pi vot shaft ends
i s properl y engaged i n i ts pi vot hol e (Fi g. 42).
(b) That the bl ower motor venturi ri ng i s prop-
erl y i ndexed and i nstal l ed.
(c) I f the uni t i s equi pped wi th ai r condi ti oni ng,
that the evaporator coi l tube rubber seal i s prop-
erl y posi ti oned i n the grooves i n both the upper
and l ower heater-A/C housi ng hal ves.
(2) I nstal l the 14 screws and two snap cl i ps that
secure the upper and l ower heater-A/C housi ng
hal ves to each other. Ti ghten the screws to 2.2 Nm
(20 i n. l bs.).
(3) I nstal l the bl ower motor and wheel uni t i n the
heater-A/C housi ng. See Bl ower Motor i n thi s group
for the procedures.
(4) I nstal l the foam seal s on the fl anges around
the bl ower motor openi ng and the heater core and
evaporator coi l tube mounti ng fl ange of the heater-
A/C housi ng.
(5) I nsert the vacuum suppl y l i ne and connector
through the foam seal on the heater core and evapo-
rator coi l tube mounti ng fl ange of the heater-A/C
housi ng.
(6) I f the uni t i s equi pped wi th ai r condi ti oni ng,
rei nstal l the evaporator coi l tube cl amp. Ti ghten the
mounti ng screw to 2.2 Nm (20 i n. l bs.).
(7) Engage the heater-A/C wi re harness connector
and bl ower motor rel ay wi re harness connector
push-i n retai ners wi th thei r mounti ng hol es i n the
(8) Engage the vacuum harness to the routi ng
cl i ps and pl ug i n the vacuum harness connector at
the fl oor door actuator and, i f the uni t i s so equi pped,
at the reci rcul ati on ai r door actuator.
(9) I nstal l the heater-A/C housi ng i n the vehi cl e.
INSTALLATION
(1) Posi ti on the heater-A/C housi ng to the dash
panel . Be certai n that the evaporator condensate
drai n tube and the housi ng mounti ng studs are
i nserted i nto thei r correct mounti ng hol es.
(2) I nstal l and ti ghten the fi ve nuts onto the heat-
er-A/C housi ng mounti ng studs on the engi ne com-
partment si de of the dash panel . Ti ghten the nuts to
6.2 Nm (55 i n. l bs.).
(3) I f the evaporati on cani ster was reposi ti oned
duri ng the removal procedure, rei nstal l i t to i ts
proper posi ti on.
(4) Connect the heater-A/C system vacuum suppl y
l i ne connector to the tee fi tti ng near the heater core
tubes.
(5) Unpl ug or remove the tape from the heater
core tubes. Connect the heater hoses to the heater
Fig. 41 Heater-A/C Housing Disassembly
1 SEALS
2 EVAPORATOR TUBE CLAMP
3 CLIPS
4 HEATER CORE TUBES
5 VACUUM SUPPLY LINE
6 BLOWER MOTOR
Fig. 42 Heater-A/C Housing Assembly
1 BLOWER MOTOR VENTURI RING
2 BLEND-AIR DOOR PIVOT
3 EVAPORATOR COIL TUBE RUBBER SEAL
4 RECIRCULATION AIR DOOR PIVOTS
core tubes and fi l l the engi ne cool i ng system. Refer to
(6) I f the vehi cl e i s not equi pped wi th ai r condi -
ti oni ng, go to Step 10. I f the vehi cl e i s equi pped wi th
ai r condi ti oni ng, unpl ug or remove the tape from the
accumul ator i nl et tube and the evaporator outl et
tube fi tti ngs. Connect the accumul ator i nl et tube cou-
pl er to the evaporator outl et tube. See Refri gerant
Li ne Coupl er i n thi s group for the procedures.
(7) Unpl ug or remove the tape from the l i qui d l i ne
and the evaporator i nl et tube fi tti ngs. Connect the
l i qui d l i ne coupl er to the evaporator i nl et tube. See
dures.
dures.
(10) I nstal l the i nstrument panel i n the vehi cl e.
(12) Start the engi ne and check for proper opera-
ti on of the heati ng and ai r condi ti oni ng systems.
HEATER-A/C HOUSING DOOR
INJURY.
BLEND-AIR DOOR
procedures.
(2) Li ft the bl end-ai r door pi vot shaft out of the
pi vot hol e i n the bottom of the l ower hal f of the heat-
er-A/C housi ng (Fi g. 43).
PANEL/DEMIST DOOR AND LEVER
procedures.
(2) Remove the defrost and panel /demi st door vac-
uum actuators from the heater-A/C housi ng. See
Mode Door Vacuum Actuator i n thi s group for the
procedures.
(3) I nsert a screwdri ver i nto the l atch hol e (Fi g.
44) of the panel /demi st door pi vot shaft to rel ease the
l atch of the panel /demi st door l ever, and pul l the
l ever out of the pi vot shaft from the outsi de of the
upper hal f of the heater-A/C housi ng.
(4) Reach i nsi de the upper hal f of the heater-A/C
housi ng and careful l y fl ex the panel /defrost door (Fi g.
45) enough so that the door pi vot cl ears the pi vot
hol e i n the housi ng.
(5) Remove the panel /demi st door from the heater-
A/C housi ng.
Fig. 43 Blend-Air Door
1 BLEND-AIR DOOR
2 EVAPORATOR COIL
3 PIVOT HOLE
4 HEATER CORE
Fig. 44 Mode Door Lever Remove/Install - Typical
1 DOOR PIVOT SHAFT
2 LATCH HOLE
3 CRANK ARM LATCH
4 FLAT BLADE PRY TOOL
DEFROST DOOR AND LEVER
procedures.
(2) Remove the panel /demi st door and l ever from
the upper heater-A/C housi ng. See Panel /Demi st
Door and Lever i n thi s group for the procedures.
44) of the defrost door pi vot shaft to rel ease the l atch
of the defrost door l ever, and pul l the l ever out of the
pi vot shaft from the outsi de of the upper hal f of the
(4) Reach i nsi de the upper hal f of the heater-A/C
housi ng and careful l y fl ex the defrost door (Fi g. 45)
enough so that the door pi vot cl ears the pi vot hol e i n
the housi ng.
(5) Remove the defrost door from the heater-A/C
housi ng.
FLOOR DOOR AND LEVER
procedures.
(2) Remove the fl oor door vacuum actuator from
the l ower heater-A/C housi ng. See Mode Door Vac-
uum Actuator i n thi s group for the procedures.
44) of the fl oor door pi vot shaft to rel ease the l atch of
the fl oor door l ever, and pul l the l ever out of the
pi vot shaft from the outsi de of the l ower hal f of the
(4) Reach i nsi de the l ower hal f of the heater-A/C
housi ng and careful l y fl ex the fl oor door (Fi g. 46)
enough so that the door pi vot cl ears the pi vot hol e i n
the housi ng.
(5) Remove the fl oor door from the heater-A/C
housi ng.
RECIRCULATION AIR DOOR
A reci rcul ati on ai r door and vacuum actuator are
used onl y on model s wi th the opti onal ai r condi ti on-
i ng system.
procedures.
(2) Remove the reci rcul ati on ai r door vacuum
actuator from the l ower heater-A/C housi ng. See
Mode Door Vacuum Actuator i n thi s group for the
procedures.
(3) Reach i nsi de the l ower hal f of the heater-A/C
housi ng and l i ft the bottom edge of the reci rcul ati on
ai r door upwards (Fi g. 47).
(4) Gui de the reci rcul ati on ai r door l ever through
the ai r i ntake gri l l e of the heater-A/C housi ng whi l e
removi ng the door from the housi ng.
Fig. 45 Panel/Demist and Defrost Doors
1 PANEL/DEMIST DOOR
2 UPPER HEATER-A/C HOUSING
3 DEFROST DOOR
Fig. 46 Floor Door
1 LOWER HEATER-A/C HOUSING
2 PIVOT SHAFT
3 CRANK ARM
4 FLOOR DOOR
HEATER CORE
INJURY.
procedures.
(2) Li ft the heater core out of the l ower hal f of the
heater-A/C housi ng (Fi g. 48).
(3) Reverse the removal procedures to i nstal l . Be
certai n that the heater core foam i nsul ator i s rei n-
stal l ed.
LIQUID LINE
properl y routed.
REMOVAL
cabl e.
the procedures.
(3) Di sconnect the l i qui d l i ne refri gerant l i ne cou-
pl ers at the evaporator i nl et and the condenser outl et
(Fi g. 49). See Refri gerant Li ne Coupl er i n thi s group
for the procedures. I nstal l pl ugs i n, or tape over al l of
the opened refri gerant l i ne fi tti ngs.
(4) Remove the l i qui d l i ne from the vehi cl e.
INSTALLATION
l i ne fi tti ngs on the l i qui d l i ne, the evaporator i nl et
and the condenser outl et. Connect the l i qui d l i ne to
the evaporator i nl et and condenser outl et refri gerant
l i ne coupl ers. See Refri gerant Li ne Coupl er i n thi s
Fig. 47 Recirculation Air Door
1 RECIRCULATION AIR DOOR
3 LEVER
4 PIVOT SHAFT
Fig. 48 Heater Core Remove/Install
1 HEATER CORE
dures.
REMOVAL
cabl e.
l ow pressure cycl i ng cl utch swi tch on the top of the
accumul ator (Fi g. 50).
(3) Unscrew the l ow pressure cycl i ng cl utch swi tch
from the fi tti ng on the top of the accumul ator.
(4) Remove the O-ri ng seal from the accumul ator
fi tti ng and di scard.
INSTALLATION
(1) Lubri cate a new O-ri ng seal wi th cl ean refri g-
erant oi l and i nstal l i t on the accumul ator fi tti ng.
Use onl y the speci fi ed O-ri ngs as they are made of a
speci al materi al for the R-134a system. Use onl y
refri gerant oi l of the type recommended for the com-
pressor i n the vehi cl e.
(2) I nstal l and ti ghten the l ow pressure cycl i ng
cl utch swi tch on the accumul ator fi tti ng. The swi tch
shoul d be hand-ti ghtened onto the accumul ator fi t-
ti ng.
(3) Pl ug the wi re harness connector i nto the l ow
pressure cycl i ng cl utch swi tch.
KICK COVER
INJURY.
REMOVAL
cabl e.
(2) Loosen the two screws that secure the upper
hal f of the ki ck cover to the heater-A/C housi ng
Fig. 49 Liquid Line Remove/Install
1 LIQUID LINE WITH ORIFICE TUBE
2 CLIP
3 CONDENSER
4 OUTLET TUBE
5 STUD
6 CLIP
7 CLIP
8 EVAPORATOR INLET
Fig. 50 Low Pressure Cycling Clutch Switch
Remove/Install - Typical
2 ACCUMULATOR
under the passenger si de end of the i nstrument panel
(Fi g. 51).
(3) Remove the two screws that secure the l ower
hal f of the ki ck cover to the heater-A/C housi ng.
(4) Pul l the ki ck cover down towards the fl oor
panel to di sengage the sl otted upper mounti ng tabs
from under the two l oosened heater-A/C housi ng
screws.
housi ng.
INSTALLATION
(1) Posi ti on the sl otted upper ki ck cover mounti ng
tabs under the heads of the two l oosened heater-A/C
housi ng screws. Ti ghten the screws to 2.2 Nm (20 i n.
l bs.).
(2) I nstal l the two screws that secure the l ower
ki ck cover to the heater-A/C housi ng. Ti ghten the
screws to 2.2 Nm (20 i n. l bs.).
MODE DOOR VACUUM ACTUATOR
INJURY.
DEFROST DOOR ACTUATOR
cabl e.
dures.
(3) Unpl ug the two vacuum harness connectors
from the defrost door actuator (Fi g. 52).
(4) I nsert a tri m sti ck or another sui tabl e wi de
fl at-bl aded tool i nto the l atch hol e on the heater-A/C
housi ng actuator mount (Fi g. 53). Gentl y pry the
actuator l atch whi l e pul l i ng fi rml y outwards on the
actuator to remove the actuator from the mount.
(5) Rotate and ti l t the vacuum actuator as
requi red to di sengage the hol e on the end of the
actuator l i nk from the hooked pi n on the end of the
defrost door l ever.
(6) Remove the defrost door vacuum actuator from
the vehi cl e.
FLOOR DOOR ACTUATOR
cabl e.
Fig. 51 Kick Cover Remove/Install
2 MOUNTING SCREWS
3 KICK COVER
Fig. 52 Defrost, Floor, and Panel/Demist Door
Vacuum Actuators
1 PANEL/DEMIST DOOR ACTUATOR
2 DEFROST DOOR ACTUATOR
3 FLOOR DOOR ACTUATOR
dures.
(3) Unpl ug the vacuum harness connector from the
fl oor door actuator (Fi g. 52).
fl oor door l ever.
(6) Remove the fl oor door vacuum actuator from
the vehi cl e.
PANEL/DEMIST DOOR ACTUATOR
(1) Remove the defrost door actuator from the
heater-A/C housi ng. See Defrost Door Actuator i n
thi s group for the procedures.
panel /demi st door actuator (Fi g. 52).
panel /demi st door l ever.
(5) Remove the panel /demi st door vacuum actuator
from the vehi cl e.
RECIRCULATION AIR DOOR ACTUATOR
A reci rcul ati on ai r door and vacuum actuator are
used onl y on model s wi th the opti onal ai r condi ti on-
i ng system.
cabl e.
housi ng. See Ki ck Cover i n thi s group for the proce-
dures.
reci rcul ati on ai r door actuator (Fi g. 54).
Fig. 53 Vacuum Actuator Remove/Install - Typical
1 ACTUATOR MOUNT LATCH HOLE
2 TRIM STICK
3 ACTUATOR LATCH
Fig. 54 Recirculation Air Door Vacuum Actuator
Remove/Install
1 HOOK
2 LEVER
3 RECIRCULATION AIR DOOR ACTUATOR
4 BLOWER MOTOR RESISTOR
reci rcul ati on ai r door l ever.
(6) Remove the reci rcul ati on ai r door vacuum
actuator from the vehi cl e.
REFRIGERANT LINE COUPLER
NEAR THE FRONT OF THIS GROUP BEFORE PER-
FORMING THE FOLLOWING OPERATION.
REMOVAL
system. See Refri gerant Recovery i n the Servi ce Pro-
cedures secti on of thi s group.
(2) Remove the secondary cl i p from the spri ng-l ock
coupl er.
(3) Fi t the proper si ze A/C l i ne di sconnect tool
(Speci al Tool Ki t 7193) over the spri ng-l ock coupl er
cage (Fi g. 55).
(4) Cl ose the two hal ves of the A/C l i ne di sconnect
tool around the spri ng-l ock coupl er.
(5) Push the A/C l i ne di sconnect tool i nto the open
si de of the coupl er cage to expand the garter spri ng.
Once the garter spri ng i s expanded and whi l e sti l l
pushi ng the di sconnect tool i nto the open si de of the
coupl er cage, pul l on the refri gerant l i ne attached to
the femal e hal f of the coupl er fi tti ng unti l the fl ange
on the femal e fi tti ng i s separated from the garter
spri ng and cage on the mal e fi tti ng wi thi n the di s-
connect tool .
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
(6) Open and remove the A/C l i ne di sconnect tool
from the di sconnected spri ng-l ock coupl er.
(7) Compl ete the separati on of the two hal ves of
the coupl er fi tti ng.
INSTALLATION
(1) Check to ensure that the garter spri ng i s
l ocated wi thi n the cage of the mal e coupl er fi tti ng,
and that the garter spri ng i s not damaged.
(a) I f the garter spri ng i s mi ssi ng, i nstal l a new
spri ng by pushi ng i t i nto the coupl er cage openi ng.
(b) I f the garter spri ng i s damaged, remove i t
from the coupl er cage wi th a smal l wi re hook (DO
NOT use a screwdri ver) and i nstal l a new garter
spri ng.
(2) Cl ean any di rt or forei gn materi al from both
hal ves of the coupl er fi tti ng.
(3) I nstal l new O-ri ngs on the mal e hal f of the cou-
pl er fi tti ng.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(4) Lubri cate the mal e fi tti ng and O-ri ngs, and the
i nsi de of the femal e fi tti ng wi th cl ean R-134a refri g-
erant oi l . Use onl y refri gerant oi l of the type recom-
mended for the compressor i n the vehi cl e.
(5) Fi t the femal e hal f of the coupl er fi tti ng over
the mal e hal f of the fi tti ng.
(6) Push together fi rml y on the two hal ves of the
coupl er fi tti ng unti l the garter spri ng i n the cage on
the mal e hal f of the fi tti ng snaps over the fl anged
end on the femal e hal f of the fi tti ng.
(7) Ensure that the spri ng-l ock coupl er i s ful l y
engaged by tryi ng to separate the two coupl er hal ves.
Thi s i s done by pul l i ng the refri gerant l i nes on ei ther
si de of the coupl er away from each other.
(8) Rei nstal l the secondary cl i p over the spri ng-
l ock coupl er cage.
SUCTION AND DISCHARGE LINE
Fig. 55 Refrigerant Line Spring-Lock Coupler
Disconnect
properl y routed.
REMOVAL
cabl e.
the procedures.
hi gh pressure cut-off swi tch.
(4) Di sconnect the di scharge l i ne refri gerant l i ne
fi tti ng from the condenser i nl et tube (Fi g. 56). See
(5) Remove the nut that secures the sucti on l i ne
bl ock fi tti ng to the accumul ator outl et. I nstal l pl ugs
i n, or tape over al l of the opened refri gerant l i ne fi t-
ti ngs.
(6) Remove the screw that secures the sucti on and
di scharge l i ne mani fol d to the compressor. I nstal l
l i ne fi tti ngs.
(7) Remove the sucti on and di scharge l i ne assem-
bl y from the vehi cl e.
INSTALLATION
(1) Remove the tape or pl ugs from the sucti on and
di scharge l i ne mani fol d and the compressor. I nstal l
the sucti on and di scharge l i ne mani fol d to the com-
pressor. Ti ghten the mounti ng screw to 28 Nm (250
i n. l bs.).
(2) Remove the tape or pl ugs from the sucti on l i ne
and the accumul ator outl et bl ock fi tti ngs. I nstal l the
sucti on l i ne to the accumul ator outl et and ti ghten the
mounti ng nut to 9 Nm (80 i n. l bs.).
l i ne fi tti ngs on the di scharge l i ne and the condenser
i nl et tube. Connect the di scharge l i ne refri gerant l i ne
coupl er to the condenser i nl et tube. See Refri gerant
Li ne Coupl er i n thi s group for the procedures.
(4) Pl ug i n the wi re harness connector to the hi gh
pressure cut-off swi tch.
dures.
VACUUM CHECK VALVE
(1) Unpl ug the heater-A/C vacuum suppl y l i ne con-
nector at the vacuum check val ve (Fi g. 57).
(2) Note the ori entati on of the check val ve i n the
vacuum suppl y l i ne for correct rei nstal l ati on.
(3) Unpl ug the vacuum check val ve from the vac-
uum suppl y l i ne fi tti ngs.
Fig. 56 Suction and Discharge Line
1 SUCTION AND DISCHARGE LINE
2 SCREW
3 COMPRESSOR
4 CONDENSER
5 INLET
6 CLIP
7 HEX NUT
8 ACCUMULATOR
VACUUM RESERVOIR
(1) Remove the passenger si de bumper end cap
from the front bumper. Refer to Group 23 - Body for
the procedures.
(2) Unpl ug the vacuum suppl y l i ne connector from
the vacuum reservoi r (Fi g. 58).
(3) Remove the two screws that secure the vacuum
reservoi r to the front bumper.
(4) Remove the vacuum reservoi r from behi nd the
front bumper.
SPECIFICATIONS
A/C APPLICATION TABLE
Fig. 57 Vacuum Supply
1 VACUUM CHECK VALVE
2 TO ENGINE INTAKE MANIFOLD
3 TO HEATER-A/C CONTROLS
4 TO VACUUM RESERVOIR
5 TO SPEED CONTROL SERVO
6 VACUUM SUPPLY LINE
Fig. 58 Vacuum Reservoir Remove/Install
1 VACUUM LINE
2 RESERVOIR SCREWS
3 VACUUM RESERVOIR
Item Description Notes
Vehicle XJ Cherokee/
Laredo
System R134a w/orifice
tube
Compressor Sanden
SD7H15
SP-20 PAG oil
Freezeup
Control
Low Pressure
cycling cutout
switch
accumulator
mounted
Low psi Control opens < 25 psi
- resets > 43
psi
High psi Control switch - opens
> 450-490 psi -
resets <
270-330 psi
discharge line
Control Head manual type
Mode Door vacuum
Blend-Air Door electric
Fresh/Recirc
door
vacuum
Blower Motor hardwired to
control head
resistor block
Cooling Fan viscous for
cooling, single
speed electric
for A/C
Clutch
Control relay PCM
Draw 2 - 3.7 amps @
12V
0.5V @ 70F
Gap 0.016 - 0.031
DRB III
Reads TPS, RPM, A/C
switch test
Actuators clutch and fan
relay
ABS BRAKE SYSTEM, BLEEDING . . . . . . . . . 5-36
ABS WARNING LAMP . . . . . . . . . . . . . . . . . . 5-35
ABSOLUTE PRESSURE (MAP) SENSOR,
MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
ABSOLUTE PRESSURE (MAP)
SENSORPCM INPUT, MANIFOLD. . . . . . . 14-32
ABSORBER, SHOCK . . . . . . . . . . . . . . . . 2-17,2-9
ABSORBERS, SHOCK . . . . . . . . . . . . . . . 2-16,2-7
A/C APPLICATION TABLE . . . . . . . . . . . . . . . 24-47
A/C PERFORMANCE . . . . . . . . . . . . . . . . . . . 24-9
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . 14-21
ACCESSORY DRIVE BELT DIAGNOSIS . . . . . . 7-9
ACCESSORY DRIVE BELTS, ENGINE . . . . . . . 7-35
ACCESSORY SWITCH BEZEL,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . 8E-15
ACCUMULATOR; HEATING AND AIR
CONDITIONING . . . . . . . . . . . . . . . . . . 24-2,24-25
ACCUMULATOR; TRANSMISSION AND
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-117
ACCUMULATOR PISTONS AND SPRINGS . 21-264
ACTUATION TEST MODE, CIRCUIT . . . . . . . . 25-2
ACTUATOR, FRONT DOOR INSIDE
HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
ACTUATOR, MODE DOOR VACUUM . . . . . . 24-43
ACTUATOR, REAR DOOR INSIDE
HANDLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
ADAPTER HOUSING . . . . . . . . . . . . . . . . . 21-147
ADAPTER HOUSING SEAL . . . . . . . . . 21-252,21-7
ADAPTER SEAL, SOLENOID HARNESS . . . . 21-261
ADAPTER, SPEEDOMETER . . . . . . 21-148,21-253
ADAPTER/EXTENSION HOUSING AND
FRONT BEARING RETAINER . . . . . . . . . . . . . 21-8
ADDITIONAL, COOLANTADDING . . . . . . . . 7-21
ADHESIVE LOCATIONS, STRUCTURAL . . . 23-124
ADJ USTER AND MOTORS, POWER
SEAT . . . . . . . . . . . . . . . . . . . . . . 8R-1,8R-2,8R-3
ADJ USTMENT, BRAKE TRANSMISSION
SHIFT INTERLOCK CABLE . . . . . . . 21-198,21-336
ADJ USTMENT, COMPASS VARIATION . . . . . . 8V-4
ADJ USTMENT, DOOR LATCH . . . . . . . . . . . . 23-66
ADJ USTMENT, FOG LAMP . . . . . . . . . . . . . . . 8L-8
ADJ USTMENT, FRONT BAND . . . . . . . . . . . 21-199
ADJ USTMENT, HEADLAMP . . . . . . . . . . . . . . 8L-6
ADJ USTMENT, PRELIMINARY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-241
ADJ USTMENT, REAR BAND . . . . . . . . . . . . 21-200
ADJ USTMENT, SHIFT LINKAGE . . . 21-372,21-405
ADJ USTMENT, TRANSMISSION
THROTTLE VALVE CABLE . . . . . . . 21-198,21-337
AERATION, COOLANTLOW LEVEL . . . . . . . 7-21
AFTER OVERHAUL OR FLUID/FILTER
CHANGE, REFILLING . . . . . . . . . . . . . . . . . 21-248
AFTERMARKET PAINT REPAIR
PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5
AIR CLEANER ELEMENT (FILTER) . . . . . . . . 14-49
AIR CONDITIONER CONTROL, HEATER . . . . . 24-6
AIR CONDITIONER, HEATER . . . . . . . . . . . . . 24-5
AIR CONDITIONING-HEATER, 8W-42 . . . . . . 8W-1
AIR CONTROL (IAC) MOTOR, IDLE . . . . . . . 14-45
AIR CONTROL (IAC) MOTORPCM
OUTPUT, IDLE . . . . . . . . . . . . . . . . . . . . . . . 14-35
AIR EXHAUST GRILLE . . . . . . . . . . . . . . . . . 23-50
AIR FLOW CHECK PROCEDURE,
THROTTLE BODY MINIMUM . . . . . . . . . . . . 14-42
AIR TEMPERATURE SENSOR, INTAKE
MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . . . . 14-50
AIR TEMPERATURE SENSORPCM
INPUT, INTAKE MANIFOLD . . . . . . . . . . . . . 14-32
AIR TESTING TRANSMISSION CLUTCH
AND BAND OPERATION. . . . . . . . . . . . . . . 21-131
AIRBAG CONTROL MODULE . . . . . . . 8M-12,8M-3
AIRBAG DOOR, PASSENGER SIDE . . . . . . . 8M-11
AIRBAG MODULE, DRIVER SIDE . . . . 8M-2,8M-6
AIRBAG MODULE, PASSENGER SIDE . 8M-3,8M-9
AIRBAG MODULE TRIM COVER, DRIVER
SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
AIRBAG SYSTEM . . . . . . . . . . . . 8M-1,8M-4,8M-5
AIRBAG SYSTEM, 8W-43 . . . . . . . . . . . . . . . 8W-1
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 2-1,2-6
ALIGNMENT, HEADLAMP . . . . . . . . . . . 8L-6,8L-9
ALIGNMENT SCREEN PREPARATION,
LAMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-6
ALIGNMENT, VEHICLE PREPARATION
FOR HEADLAMP . . . . . . . . . . . . . . . . . . . . . . 8L-6
ALIGNMENT, WHEEL . . . . . . . . . . . . . . . . . 2-1,2-4
ALUMINUM THREAD REPAIR . . . . 21-144,21-249
AMBIENT TEMPERATURE SENSOR . . . . . . . . 8V-8
AMPERAGE TEST, FUEL PUMP . . . . . . . . . . . 14-8
AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-7
ANALYSIS, GEAR CONTACT PATTERN . . . . 3-129,
3-59,3-97
ANALYSIS, PRESSURE TEST . . . . . . . . . . . 21-242
ANALYSIS, TIME LAG TEST . . . . . . . . . . . . 21-243
ANALYZING ROAD TEST . . . . . . . . . . . . . . 21-129
ANGLE, FRONT AXLE PINION INPUT . . . . . . 3-15
ANGLE MEASUREMENT PREPARATION,
DRIVELINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ANGLE MEASUREMENT, PROPELLER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ANGLE, PROPELLER SHAFT J OINT . . . . . . . . . 3-3
ANGLE, REAR AXLE PINION INPUT . . . . . . . 3-15
ANTENNA . . . . . . . . . . . . . . . . . . . 8F-10,8F-2,8F-5
ANTILOCK BRAKE, HYDRAULIC
CONTROL UNIT/CONTROLLER . . . . . . . . . . . 5-39
ANTILOCK BRAKE SYSTEM . . . . . . . . . . . . . . 5-33
ANTILOCK BRAKES . . . . . . . . . . . . . . . . 5-33,5-36
ANTI-LOCK BRAKES, 8W-35 . . . . . . . . . . . . 8W-1
ANTILOCK BRAKES, CONTROLLER . . . . . . . . 5-33
ANTILOCK BRAKES, HYDRAULIC
CONTROL UNIT/CONTROLLER . . . . . . . . . . . 5-36
A-PILLAR COWL TRIM, LOWER . . . . . . . . . 23-51
A-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-51
APPLICATION, BULB . . . . . . . . . . . . . . . . . . 8L-20
APPLICATION TABLE, A/C . . . . . . . . . . . . . . 24-47
APPLIQUE, QUARTER WINDOW . . . . . . . . . 23-49
ARM AND BLADE, WIPER . . . . . . . . . . . . . . . . 8K-2
ARM, LOWER SUSPENSION . . . . . . . . . . . . . 2-10
ARM, PITMAN . . . . . . . . . . . . . . . . . . . . . . . 19-24
ARM, ROCKER . . . . . . . . . . . . . . . . . . . . 9-6,9-66
ARM, UPPER SUSPENSION . . . . . . . . . . . . . 2-11
ARM, WIPER . . . . . . . . . . . . . . . . . . . . . . . . . 8K-8
ARMS AND BUSHINGS, LOWER
SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ARMS AND BUSHINGS, UPPER
SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ARMS AND PUSH RODS, ROCKER . . 9-113,9-36,
9-53,9-96
ASD AND FUEL PUMP RELAYS . . . . . . . . . . 14-41
ASSEMBLY, DRIVE AXLE . . . . . . . . . . . . . . . . 3-22
ASSEMBLY, ENGINE . . . . . . . . . . . . . . . . . . . . 9-92
ASSEMBLY, 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 SYSTEMS . . . . . . . . . . . . . . . . . . . . . 8F-12
AUGAT CONNECTORS, TERMINAL/
CONNECTOR REPAIR- . . . . . . . . . . . . . . . . 8W-11
AUTO SHUTDOWN (ASD) RELAYPCM
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
AUTOMATIC SHUTDOWN (ASD) RELAY . . . 14-43
SENSEPCM INPUT. . . . . . . . . . . . . . . . . . 14-29
AUTOMATIC TRANSMISSION, 30RH . . . . 21-212,
21-89
AUTOMATIC TRANSMISSION, AW-4 . . . . . 21-338
AUTOMATIC TRANSMISSION, AW4 . . . . . 21-218
AUTOMATIC TRANSMISSION, AW4
AUTOMATIC TRANSMISSIONAW4 . . . . . . 21-217
AUTOMATIC TRANSMISSION DIAGNOSIS . 21-126
AUTOMATIC TRANSMISSION OIL
COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
AUTOMATIC TRANSMISSIONAW4
AUTOMATIC TRANSMISSION, AW4. . . . . 21-217
30RHAUTOMATIC TRANSMISSION
30RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-88
AW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-344
AW-4 AUTOMATIC TRANSMISSION . . . . . . 21-338
AW4 AUTOMATIC TRANSMISSION . . . . . 21-218
AW4 AUTOMATIC TRANSMISSIONAW4
AUTOMATIC TRANSMISSION . . . . . . . . . . 21-217
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-40
AX5 MANUAL TRANSMISSION . . . . . . . . . . . 21-1
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 21-37
AXLE, 181 AND 186 FBI . . . . . . . . . . . . . . . . 3-61
AXLE, 181 FBI . . . . . . . . . . . . . . . . . . . . 3-16,3-61
AXLE, 186 FBI . . . . . . . . . . . . . . . . . . . . 3-17,3-61
AXLE, 194 RBI . . . . . . . . . . . . . . . . . . . 3-65,3-99
AXLE, 8 1/4 . . . . . . . . . . . . . . . . . . . . 3-103,3-125
AXLE, 8 1/4 INCH . . . . . . . . . . . . . . . . . . . . 3-131
AXLE, 8 1/4 REAR . . . . . . . . . . . . . . . . . . . . 3-103
AXLE ASSEMBLY, DRIVE . . . . . . . . . . . . . . . . 3-22
AXLE ASSEMBLY, TUBE . . . . . . . . . . . . . . . . . 3-23
AXLE BUSHING, FRONT . . . . . . . . . . . . . . . . 2-11
AXLE BUSHING REPLACEMENT . . . . . . . . . . 3-33
AXLE COMPONENTS . . . . . . . . . . . . . . . 3-47,3-91
AXLE PINION GEAR DEPTH, 8 1/4 . . . . . . . 3-126
AXLE PINION INPUT ANGLE, FRONT . . . . . . 3-15
AXLE PINION INPUT ANGLE, REAR . . . . . . . 3-15
AXLE, REAR . . . . . . . . . . . . . . . . . . . . 3-111,3-72
AXLE SEAL AND BEARING . . . . . . . . . . . . . 3-112
AXLE SHAFT . . . . . . . . . . . . . . . . . . . . 3-111,3-76
AXLE SHAFT, HUB BEARING . . . . . . . . . . . . . 3-30
AXLE SHAFT OIL SEAL . . . . . . . . . . . . . . . . . 3-36
AXLE SHAFT SEAL AND BEARING . . . . . . . . 3-77
AXLE SHAFTCARDAN U-J OINT . . . . . . . . . 3-23
AXLE, TUBE, 181, AND 186 FBI . . . . . . . . . . 3-16
AXLES, 8 1/4 . . . . . . . . . . . . . . . . . . . . . . . . 3-131
BACKLASH, 181 FBI DIFFERENTIAL
BEARING PRELOAD AND GEAR . . . . . . . . . . 3-52
BACKLASH, 186 FBI DIFFERENTIAL
BEARING PRELOAD AND GEAR . . . . . . . . . . 3-56
BACKLASH, DIFFERENTIAL BEARING
PRELOAD AND GEAR . . . . . . . . . . . . . 3-127,3-94
BACK-UP/BRAKE/REAR TURN SIGNAL/
TAIL LAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
BACK-UP/BRAKE/REAR TURN SIGNAL/
TAIL LAMP BULB . . . . . . . . . . . . . . . . . . . . 8L-11
BALANCE, TIRE AND WHEEL . . . . . . . . . . . . . . 22-9
BALL STUD, LIFTGATE SUPPORT ROD . . . . 23-63
BALL STUDS, STEERING KNUCKLE . . . . . . . 3-31
BAND ADJ USTMENT, FRONT . . . . . . . . . . . 21-199
BAND ADJ USTMENT, REAR . . . . . . . . . . . . 21-200
BAND OPERATION, AIR TESTING
TRANSMISSION CLUTCH . . . . . . . . . . . . . 21-131
BANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-123
BAR, STABILIZER . . . . . . . . . . 2-12,2-16,2-17,2-9
BAR, TRACK . . . . . . . . . . . . . . . . . . . . . . 2-12,2-9
BASE BRAKE BLEEDING . . . . . . . . . . . . . . . . 5-13
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . 5-1,5-7
BASE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . 5-32
BASE COAT/CLEAR COAT FINISH . . . . . . . . . 23-4
BATTERY . . . . . . . . 8A-1,8A-21,8A-23,8A-24,8A-5
BATTERY CABLES . . . . . . . . . . . 8A-14,8A-18,8A-3
BATTERY CHARGING . . . . . . . . . . . . . . . . . . 8A-16
BATTERY HOLD DOWNS . . . . . . . . . . . 8A-20,8A-4
BATTERY REPLACEMENT, REMOTE
KEYLESS ENTRY TRANSMITTER . . . . . . . . . 8P-6
BATTERY TEMPERATURE SENSOR . . . . 8C-2,8C-5
BATTERY THERMOGUARD . . . . . . . . . 8A-22,8A-5
BATTERY TRAY . . . . . . . . . . . . . . . . . . 8A-22,8A-5
BATTERY VOLTAGEPCM INPUT . . . . . . . . 14-29
BEARING AND AXLE SHAFT, HUB . . . . . . . . . 3-30
BEARING, AXLE SEAL . . . . . . . . . . . . . . . . . 3-112
BEARING, AXLE SHAFT SEAL . . . . . . . . . . . . 3-77
BEARING, CLUTCH RELEASE . . . . . . . . . . . . . 6-3
BEARING, HUB . . . . . . . . . . . . . . . . . . . . . . . 2-12
BEARING NOISE . . . . . . . . . . . . . 3-109,3-21,3-70
BEARING, OUTPUT SHAFT REAR . . . . . . . 21-153
BEARING, PILOT . . . . . . . . . . . . . . . . . . . . . . 6-12
BEARING PRELOAD AND GEAR
BACKLASH, 181 FBI DIFFERENTIAL . . . . . . . 3-52
BACKLASH, 186 FBI DIFFERENTIAL . . . . . . . 3-56
BACKLASH, DIFFERENTIAL . . . . . . . . . 3-127,3-94
BEARING, RELEASE . . . . . . . . . . . . . . . . . . . . 6-12
BEARING RETAINER, ADAPTER/
EXTENSION HOUSING AND FRONT. . . . . . . . 21-8
BEARING RETAINER SEAL, FRONT . . . . . . . . 21-6
BEARINGS, CAMSHAFT . . . . . . . . . . . . 9-104,9-47
BEARINGS, CRANKSHAFT MAIN . . . . . 9-105,9-47
BEARINGS, DIFFERENTIAL SIDE . 3-115,3-36,3-80
BEARINGS, FITTING CONNECTING ROD . . . . 9-80
BEARINGS, FITTING CRANKSHAFT MAIN . . 9-23,
9-83
BEARINGSFITTING, CONNECTING ROD . . . 9-21
BELT DIAGNOSIS, ACCESSORY DRIVE . . . . . . 7-9
BELT SWITCH, DRIVER SEAT . . . . . . . . . . . . 8U-2
BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . 7-40
BELT WEATHERSTRIP, FRONT DOOR
INNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
BELT WEATHERSTRIP, FRONT DOOR
OUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
BELT WEATHERSTRIP, REAR DOOR
INNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
BELT WEATHERSTRIP, REAR DOOR
OUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
BELT/BUCKLE, FRONT SHOULDER . . . . . . . 23-55
XJ INDEX 1
Description Group-Page Description Group-Page Description Group-Page
BELT/BUCKLE, REAR SHOULDER/LAP . . . . . 23-57
BELTS, ENGINE ACCESSORY DRIVE . . . . . . . 7-35
BETTS CONNECTORS, TERMINAL/
CONNECTOR REPAIRTHOMAS . . . . . . . . 8W-10
BEZEL, CLUSTER . . . . . . . . . . . . . . . . . . . . . 8E-16
BEZEL, INSTRUMENT PANEL
ACCESSORY SWITCH . . . . . . . . . . . . . . . . . 8E-15
BEZEL, INSTRUMENT PANEL CENTER . . . . 8E-14
BIN DOOR, GARAGE DOOR OPENER
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8
BIN, GARAGE DOOR OPENER STORAGE . . . 8V-3
BIN, SUNGLASSES STORAGE . . . . . . . . 8V-3,8V-8
BLADE, FAN . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
BLADE, WIPER . . . . . . . . . . . . . . . . . . . . . . . 8K-8
BLADE, WIPER ARM . . . . . . . . . . . . . . . . . . . 8K-2
BLEEDING ABS BRAKE SYSTEM . . . . . . . . . . 5-36
BLEEDING, BASE BRAKE . . . . . . . . . . . . . . . . 5-13
BLEEDING, MASTER CYLINDER . . . . . . . . . . 5-12
BLEND-AIR DOOR MOTOR . . . . . . . . . . . . . 24-26
BLOCK, 8W-12 J UNCTION . . . . . . . . . . . . . . 8W-1
BLOCK, CYLINDER . . . 9-112,9-114,9-5,9-53,9-54,
9-65
BLOCK HEATER . . . . . . . . . . . . . . . . . . . . 7-35,7-4
BLOCK, J UNCTION . . . . . . . . . . . . . . . . 8O-3,8O-6
BLOCKER, KNEE . . . . . . . . . . . . . . . . . . . . . 8E-14
BLOCKSTWO-DOOR VEHICLES, FRONT
DOOR SPACER . . . . . . . . . . . . . . . . . . . . . . 23-41
BLOWER MOTOR . . . . . . . . . . . . . 24-12,24-2,24-26
BLOWER MOTOR RELAY . . . . . . 24-13,24-2,24-27
BLOWER MOTOR RESISTOR . . 24-14,24-27,24-3
BLOWER MOTOR SWITCH . . . . . . . . . 24-14,24-3
BODY COMPONENT SERVICE . . . . . . . . . . . 23-21
BODY COMPONENTS . . . . . . . . . . . . . . . . . . . 23-1
BODY COMPONENTS, TRANSMISSION
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-228
BODY DECALS . . . . . . . . . . . . . . . . . . . . . . . 23-29
BODY GAP AND FLUSH
MEASUREMENTS . . . . . . . . . . . . . . . . . . . 23-127
BODY LUBRICANTS . . . . . . . . . . . . . . . . . . . 23-67
BODY LUBRICATION . . . . . . . . . . . . . . . . . . 23-23
BODY MINIMUM AIR FLOW CHECK
PROCEDURE, THROTTLE. . . . . . . . . . . . . . . 14-42
BODY OPENING DIMENSIONS . . . . . . . . . . 23-128
BODY SEALING LOCATIONS . . . . . . . . . . . 23-112
BODY SIDE MOLDING . . . . . . . . . . . . . . . . . 23-48
BODY SOLENOIDS, TRANSMISSION
VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-258
BODY, THROTTLE . . . . . . . . . . . . . . . 14-36,14-44
BODY, TRANSMISSION VALVE . . . 21-259,21-333
BODY, VALVE . . . . 21-102,21-151,21-156,21-191,
21-200
BOOSTER, MASTER CYLINDER/POWER . . . . 5-10
BOOSTER, POWER BRAKE . . . . . . . . . . . 5-17,5-3
BORES, HONING CYLINDER . . . . . . . . . 9-26,9-87
BOX COMPONENTS, GLOVE . . . . . . . . . . . . 8E-23
BOX, GLOVE . . . . . . . . . . . . . . . . . . . . . . . . 8E-22
BOX LATCH STRIKER, GLOVE . . . . . . . . . . . 8E-24
B-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . 23-52
BRACKET, INSTRUMENT PANEL CENTER
SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-26
BRACKET, REARVIEW MIRROR SUPPORT . 23-59
BRAKE BLEEDING, BASE . . . . . . . . . . . . . . . . 5-13
BRAKE BOOSTER, POWER . . . . . . . . . . . 5-17,5-3
BRAKE CABLE TENSIONER, PARKING . . . . . . 5-31
BRAKE CABLES, REAR PARKING . . . . . . . . . 5-23
BRAKE CALIPER, DISC . . . . . . . . . . . . . . . . . 5-25
BRAKE CALIPER, FRONT DISC . . . . . . . . . . . 5-18
BRAKE COMPONENTS . . . . . . . . . . . . . . . . . . 5-32
BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . 5-11
BRAKE DRUM MACHINING . . . . . . . . . . . . . . 5-14
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 5-31
BRAKE FLUID CONTAMINATION . . . . . . . . . . 5-12
BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . 5-12
BRAKE HOSES AND LINES . . . . . . . . . . . . . . . 5-7
BRAKE, HYDRAULIC CONTROL
UNIT/CONTROLLER ANTILOCK . . . . . . . . . . . 5-39
BRAKE LAMP SWITCH; BRAKES . . 5-15,5-2,5-30,
5-9
BRAKE LAMP SWITCH; SPEED CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3
BRAKE LEVER, PARKING . . . . . . . . . . . . . . . 5-23
BRAKE LINE AND HOSES . . . . . . . . . . . . . . . 5-12
BRAKE, PARKING . . . . . . . . . . . . . . . . . . . . . . 5-5
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . 5-15,5-2
BRAKE, REAR DRUM . . . . . . . . . . . 5-29,5-30,5-5
BRAKE ROTOR, DISC . . . . . . . . . . . . . . 5-11,5-21
BRAKE, SECOND . . . . . . . . . . . . . . . . . . . . 21-327
BRAKE SERVO, SECOND COAST . . . . . . . . 21-265
BRAKE SHOES, DRUM . . . . . . . . . . . . . . . . . 5-21
BRAKE SHOES, FRONT DISC . . . . . . . . . . . . . 5-20
BRAKE SUPPORT PLATE . . . . . . . . . . . . . . . . 5-22
BRAKE SWITCHPCM INPUT . . . . . . . . . . 14-29
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 5-2
BRAKE SYSTEM, ANTILOCK . . . . . . . . . . . . . 5-33
BRAKE SYSTEM, BASE . . . . . . . . . . . . . . . 5-1,5-7
BRAKE SYSTEM, BLEEDING ABS . . . . . . . . . 5-36
BRAKE TRANSMISSION SHIFT
INTERLOCK . . . . . . . . . . . . . . . . . . 21-150,21-256
INTERLOCK CABLE ADJ USTMENT . . . . . . 21-198,
21-336
INTERLOCK MECHANISM . . . . . . . 21-125,21-238
BRAKE TUBE FLARING . . . . . . . . . . . . . . . . . 5-14
BRAKE WARNING LAMP, RED . . . . . . . . . 5-3,5-9
BRAKES, 8W-35 ANTI-LOCK . . . . . . . . . . . . 8W-1
BRAKES, ANTILOCK . . . . . . . . . . . . . . . 5-33,5-36
BRAKES, BASE . . . . . . . . . . . . . . . . . . . . . . . 5-32
BRAKES, CONTROLLER ANTILOCK . . . . . . . . 5-33
BRAKES, FRONT DISC . . . . . . . . . . . . . . . . . . . 5-4
BRAKES, HYDRAULIC CONTROL
UNIT/CONTROLLER ANTILOCK . . . . . . . . . . . 5-36
BREAKER, CIRCUIT; POWER SEAT
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-2
BREAKER, CIRCUIT; POWER WINDOW
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 8S-2,8S-3
BUCKET SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 23-15
BUCKET SEAT CUSHION COVER . . . . . . . . . 23-17
BUCKET SEAT PLATFORM . . . . . . . . . . . . . . 23-15
BUCKET SEAT RECLINER . . . . . . . . . . . . . . 23-17
BUCKET SEAT TRACK . . . . . . . . . . . . . . . . . 23-15
BUCKET SEATBACK . . . . . . . . . . . . . . . . . . . 23-16
BUCKET SEATBACK COVER . . . . . . . . . . . . . 23-16
BUFFING, AND POLISHING, FINESSE
SANDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
BULB APPLICATION . . . . . . . . . . . . . . . . . . . 8L-20
BULB, BACK-UP/BRAKE/REAR TURN
SIGNAL/TAIL LAMP . . . . . . . . . . . . . . . . . . . 8L-11
BULB, CARGO LAMP . . . . . . . . . . . . . . . . . . 8L-13
BULB, CENTER HIGH MOUNTED STOP
LAMP (CHMSL) . . . . . . . . . . . . . . . . . . . . . . 8L-12
BULB, FOG LAMP . . . . . . . . . . . . . . . . . . . . 8L-10
BULB, FRONT PARK/TURN SIGNAL
LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11
BULB, 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 VANITY LAMP . . . . . . . . . . . . 8L-13
BUMPER, COIL SPRING/J OUNCE . . . . . . . . . . 2-9
BUMPER END CAP, FRONT . . . . . . . . . . . . . . 13-2
BUMPER END CAP, REAR . . . . . . . . . . . . . . . 13-4
BUMPER, FRONT . . . . . . . . . . . . . . . . . . . . . . 13-3
BUMPER, J OUNCE . . . . . . . . . . . . . . . . . . . . . 2-7
BUMPER, REAR . . . . . . . . . . . . . . . . . . . . . . . 13-4
BUMPER, REAR SEATBACK LATCH
STRIKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-19
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2
BUMPERS, FRAME . . . . . . . . . . . . . . . . . . . . 13-1
BUMPERS, J OUNCE . . . . . . . . . . . . . . . . . . . 2-16
BURNT FLUID, CAUSES OF . . . . . . 21-126,21-240
BUS (+/-) CIRCUITS-PCM OUTPUTS, CCD . 14-35
BUSHING, EXTENSION HOUSING . . . . . . . 21-147
BUSHING, FRONT AXLE . . . . . . . . . . . . . . . . 2-11
BUSHING, LEAF SPRING AND SHACKLE . . . . 2-18
BUSHING, REAR HOUSING YOKE . . . . . . . . 21-48
BUSHING REPLACEMENT, AXLE . . . . . . . . . . 3-33
BUSHINGS, LOWER SUSPENSION ARMS . . . . 2-8
BUSHINGS, UPPER SUSPENSION ARMS . . . . 2-8
BUTTON MODULE, PUSH . . . . . . . . . . . . . . . 8V-7
CABLE ADJ USTMENT, BRAKE
TRANSMISSION SHIFT INTERLOCK . . . . . 21-198,
21-336
CABLE ADJ USTMENT, TRANSMISSION
THROTTLE VALVE . . . . . . . . . . . . . 21-198,21-337
CABLE, GEARSHIFT . . . . . 21-128,21-150,21-197,
21-246,21-256,21-336
CABLE, HOOD RELEASE . . . . . . . . . . . . . . . 23-27
CABLE RESISTANCE, SPARK PLUG . . . . . . 8D-23
CABLE, SERVO . . . . . . . . . . . . . . . . . . . 8H-3,8H-6
CABLE TENSIONER, PARKING BRAKE . . . . . . 5-31
CABLE, THROTTLE . . . . . . . . . . . . . . . . . . . 14-22
CABLE, THROTTLE VALVE . . . . . . . 21-129,21-246
CABLE, TRANSMISSION THROTTLE . . . . . 21-267
CABLES, BATTERY . . . . . . . . . . 8A-14,8A-18,8A-3
CABLES, REAR PARKING BRAKE . . . . . . . . . 5-23
CABLES, SPARK PLUG . . . . . . . . . . . . 8D-10,8D-7
CABLES-2.5L ENGINE, SPARK PLUG . . . . . . 8D-2
CALIBRATION, COMPASS . . . . . . . . . . . . . . . 8V-5
CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
CALIPER, DISC BRAKE . . . . . . . . . . . . . . . . . 5-25
CALIPER, FRONT DISC BRAKE . . . . . . . . . . . 5-18
CAM, TURN SIGNAL CANCELLING . . . . . . . . 8J -3
CAMSHAFT . . . . . . . . . . . . . . 9-103,9-44,9-6,9-66
CAMSHAFT BEARINGS . . . . . . . . . . . . 9-104,9-47
CAMSHAFT PIN REPLACEMENT . . . . . . . . . . 9-45
CAMSHAFT POSITION SENSOR-2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-4
CAMSHAFT POSITION SENSOR2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-14
CAMSHAFT POSITION SENSOR4.0L
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . 8D-15,8D-5
CANCELLING CAM, TURN SIGNAL . . . . . . . . 8J -3
CANISTER, EVAP . . . . . . . . . . . . . . . . 25-24,25-27
CANISTER PURGE SOLENOID, DUTY
CYCLE EVAP . . . . . . . . . . . . . . . . . . . 25-24,25-27
CAP, FRONT BUMPER END . . . . . . . . . . . . . . 13-2
CAP, FUEL TANK FILLER TUBE . . . . . . 14-21,14-6
CAP, INSTRUMENT PANEL END . . . . . . . . . 8E-25
CAP, RADIATOR PRESSURE . . . . . . . . . . 7-39,7-5
CAP, REAR BUMPER END . . . . . . . . . . . . . . . 13-4
CAP-2.5L ENGINE, DISTRIBUTOR . . . . . . . . . 8D-6
CAPACITIES, FLUID . . . . . . . . . . . . . . . . . . . . . 0-3
CAPACITY, FUEL TANK . . . . . . . . . . . . . . . . 14-23
CAPACITY TEST, FUEL PUMP . . . . . . . . . . . . 14-7
CAPPRESSURE TESTING, RADIATOR . . . . 7-20
CAP-TO-FILLER NECK SEALPRESSURE
RELIEF CHECK, RADIATOR . . . . . . . . . . . . . . 7-20
CARDAN J OINT, DOUBLE . . . . . . . . . . . . . . . 3-11
CARDAN U-J OINT . . . . . . . . . . . . . . . . . . . . . 3-47
CARDAN UNIVERSAL J OINT, SINGLE . . . . . . . 3-9
CARGO LAMP . . . . . . . . . . . . . . . . . . . . . . . 8L-17
CARGO LAMP BULB . . . . . . . . . . . . . . . . . . 8L-13
CARPET/MAT, FRONT . . . . . . . . . . . . . . . . . 23-58
CARPET/MAT, REAR . . . . . . . . . . . . . . . . . . 23-58
CASE COVER OIL SEAL, TIMING . . . . . 9-112,9-41
CASE COVER, TIMING . . . . . . . . . . . . . 9-101,9-42
CASE, NV231 TRANSFER . 21-346,21-351,21-369
CASE, NV231 TRANSFER CASENV231
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-346
CASE, NV242 TRANSFER . 21-375,21-380,21-402
CASE, NV242 TRANSFER CASENV242
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-375
CASE SKID PLATE, TRANSFER . . . . . . . . . . . 13-6
CASE, TRANSFER . . . . . . . . . . . . . 21-348,21-377
CASENV231 TRANSFER CASE, NV231
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-346
CASENV242 TRANSFER CASE, NV242
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-375
CATALYTIC CONVERTER . . . . . . . . . . . . . . . . 11-6
CATALYTIC CONVERTERS . . . . . . . . . . . . . . . 11-2
CAUSES OF BURNT FLUID . . . . . . 21-126,21-240
CAUTIONS, AND WARNINGS, NOTES . . . . . 8W-7
CAUTIONS, SERVICE WARNINGS & . . . . . . . . 5-2
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . 14-35
CENTER BEZEL, INSTRUMENT PANEL . . . . 8E-14
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB . . . . . . . . . . . . . . . . . . . . . . 8L-12
CENTER, POWER DISTRIBUTION . . . . 8O-2,8O-4,
8O-7
CENTER SUPPORT BRACKET,
INSTRUMENT PANEL. . . . . . . . . . . . . . . . . . 8E-26
CENTERING, CLOCKSPRING . . . . . . . . . . . . 8M-15
CERTIFICATION LABEL, VEHICLE SAFETY . Intro.-2
CHAIN AND SPROCKETS, TIMING . . . 9-102,9-43
CHANGE, LUBRICANT . . . . . . . . . 3-110,3-21,3-71
CHANGE, REFILLING AFTER OVERHAUL
OR FLUID/FILTER. . . . . . . . . . . . . . . . . . . . 21-248
CHANNEL WEATHERSTRIP, FRONT DOOR
GLASS RUN. . . . . . . . . . . . . . . . . . . . . . . . . 23-38
CHANNEL WEATHERSTRIP, REAR DOOR
GLASS RUN. . . . . . . . . . . . . . . . . . . . . . . . . 23-46
CHARGE, REFRIGERANT SYSTEM . . . . . . . . 24-22
CHARGING, BATTERY . . . . . . . . . . . . . . . . . 8A-16
CHARGING SYSTEM . . . . . . . . . . . . . . . 8C-1,8C-2
CHARGING SYSTEM, 8W-20 . . . . . . . . . . . . 8W-1
CHARGING SYSTEM, ON-BOARD
DIAGNOSTIC TEST . . . . . . . . . . . . . . . . . . . . 8C-3
CHART, T0RQUE . . . . . . . . . . . . . . . . . . . . . . 5-40
2 INDEX XJ
CHART, TORQUE; BRAKES . . . . . . . . . . . . . . 5-32
CHART, TORQUE; CHARGING SYSTEM . . . . . 8C-5
CHART, TORQUE; EMISSION CONTROL
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-28
CHART, TORQUE; FUEL SYSTEM . . . . 14-24,14-51
CHART, TORQUE; IGNITION SYSTEM . . . . . 8D-24
CHART, TORQUE; SPEED CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-7
CHART, TORQUE; STEERING . 19-10,19-21,19-25,
19-28
CHART, TORQUE; SUSPENSION . . . . . . 2-14,2-19
CHART, TORQUE; TIRES AND WHEELS . . . . 22-11
CHARTS, CLUTCH DIAGNOSIS . . . . . . . . . . . . 6-7
CHARTS, DIAGNOSIS . . . . . . . . . . . . . . . . 21-133
CHARTS, POWER STEERING SYSTEM
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
CHECK, COOLANTLEVEL . . . . . . . . . . . . . . 7-21
CHECK, COOLANTROUTINE LEVEL . . . . . . 7-21
CHECK, FLUID LEVEL . . . . . . . . . . . . . . . . 21-141
CHECK, OIL PUMP VOLUME . . . . . 21-142,21-248
CHECK PROCEDURE, THROTTLE BODY
MINIMUM AIR FLOW . . . . . . . . . . . . . . . . . 14-42
CHECK, RADIATOR CAP-TO-FILLER NECK
SEALPRESSURE RELIEF . . . . . . . . . . . . . . 7-20
CHECK, RADIATOR COOLANT FLOW . . . . . . . 7-17
CHECK VALVE SERVICE, CONVERTER
DRAINBACK . . . . . . . . . . . . . . . . . . . . . . . . 21-142
CHECK VALVE, VACUUM . . . . . . . . . . . 24-46,24-9
CHECKING FLUID CONDITION . . . . . . . . . . . 21-248
CHECKING FLUID LEVEL . . . . . . . . . . . . . . 21-247
CHECKS, PRELIMINARY . . . . . . . . . . . . . . . . 7-11
CHIME WARNING SYSTEM . . . . . . . . . . . . . . 8U-1
CHIME WARNING SYSTEM SWITCHES . . . . 8U-4
CIGAR LIGHTER, INSTRUMENT PANEL . . . 8E-11,
8E-3
CIGAR LIGHTER RELAY . . . . . . 8E-12,8E-16,8E-4
CIRCUIT ACTUATION TEST MODE . . . . . . . . . 25-2
CIRCUIT BREAKER; POWER SEAT
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8R-2
CIRCUIT BREAKER; POWER WINDOW
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 8S-2,8S-3
CIRCUIT FUNCTIONS . . . . . . . . . . . . . . . . . . 8W-4
CIRCUIT INFORMATION . . . . . . . . . . . . . . . . 8W-4
CIRCUIT SENSEPCM INPUT, IGNITION . . 14-31
CIRCUITS, NON-MONITORED . . . . . . . . . . . 25-22
CIRCUITS, SPEED CONTROL SOLENOID . . . 8H-2
CIRCUITS-PCM OUTPUTS, CCD BUS (+/-) . 14-35
CLAMPS, FUEL TUBES/LINES/HOSES . . . . . . 14-6
CLAMPS, HOSE . . . . . . . . . . . . . . . . . . . . . . . . 7-6
CLASSIFICATION OF LUBRICANTS . . . . . . . . . 0-1
CLEANER ELEMENT (FILTER), AIR . . . . . . . 14-49
CLEANING AND INSPECTION,
TRANSMISSION PARTS. . . . . . . . . . . . . . . 21-336
CLEANING TIRES . . . . . . . . . . . . . . . . . . . . . . 22-6
CLEARANCE, SIDE GEAR . . . . . . . . . . . . . . . 3-129
CLOCKSPRING . . . . . . . . . . . . . . . . . 8M-13,8M-4
CLOCKSPRING CENTERING . . . . . . . . . . . . 8M-15
CLUSTER, 8W-40 INSTRUMENT . . . . . . . . . 8W-1
CLUSTER BEZEL . . . . . . . . . . . . . . . . . . . . . 8E-16
CLUSTER COMPONENTS, INSTRUMENT . . . 8E-19
CLUSTER, INSTRUMENT; CHIME/BUZZER
WARNING SYSTEMS . . . . . . . . . . . . . . 8U-1,8U-3
CLUSTER, INSTRUMENT; ELECTRICALLY
HEATED SYSTEMS . . . . . . . . . . . . . . . . 8N-2,8N-5
CLUSTER, INSTRUMENT; INSTRUMENT
PANEL SYSTEMS . . . . . . . . . . . . 8E-18,8E-2,8E-5
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CLUTCH AND BAND OPERATION, AIR
TESTING TRANSMISSION . . . . . . . . . . . . . 21-131
CLUTCH COIL, COMPRESSOR . . . . . . . . . . . 24-15
CLUTCH COMPONENT LUBRICATION . . . . . . . 6-9
CLUTCH, COMPRESSOR . . . . . . . . . . . 24-29,24-3
CLUTCH CONTAMINATION . . . . . . . . . . . . . . . 6-6
CLUTCH COVER AND DISC . . . . . . . . . . . . . . 6-11
CLUTCH COVER AND DISC RUNOUT . . . . . . . 6-7
CLUTCH DIAGNOSIS CHARTS . . . . . . . . . . . . . 6-7
CLUTCH DIAGNOSTIC INFORMATION . . . . . . . 6-4
CLUTCH, DIRECT . . . . . . . . . . . . . . . . . . . . 21-312
CLUTCH DISC . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
CLUTCH FLUID LEVEL . . . . . . . . . . . . . . . . . . 6-10
CLUTCH FLYWHEEL RUNOUT . . . . . . . . . . . . . 6-6
CLUTCH, FORWARD . . . . . . . . . . . . . . . . . 21-317
CLUTCH, FRONT . . . . . . . . 21-120,21-180,21-196
CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . 6-13
CLUTCH HOUSING MISALIGNMENT . . . . . . . . 6-6
CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . 6-13
CLUTCH INSPECTION, TORQUE
CONVERTER STATOR . . . . . . . . . . . . . . . . 21-247
CLUTCH LINKAGE FLUID . . . . . . . . . . . . . . . . . 6-9
CLUTCH LINKAGE, HYDRAULIC . . . . . . . . . . . 6-4
CLUTCH MISALIGNMENT . . . . . . . . . . . . . . . . 6-6
CLUTCH, OVERDRIVE PLANETARY GEAR . 21-301
CLUTCH, OVERRUNNING . . . . . . . . . . . . . 21-122
CLUTCH PRESSURE PLATE . . . . . . . . . . . . . . . 6-2
CLUTCH, REAR . . . . . . . . . 21-121,21-181,21-196
CLUTCH RELAY, COMPRESSOR . . . . 24-15,24-31,
24-4
CLUTCH RELEASE BEARING . . . . . . . . . . . . . . 6-3
CLUTCH RELEASE OR ENGAGEMENT,
IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
CLUTCH, SUN GEAR AND NO. 1
ONEWAY . . . . . . . . . . . . . . . . . . . . . . . . . 21-324
CLUTCH SWITCH, LOW PRESSURE
CYCLING . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7
CLUTCH/LOW-REVERSE DRUM,
OVERRUNNING . . . . . . . . . . . . . . . . . . . . . 21-175
CLUTCH/LOW-REVERSE DRUM/
OVERDRIVE PISTON RETAINER,
OVERRUNNING . . . . . . . . . . . . . . . . . . . . . 21-195
COAST BRAKE SERVO, SECOND . . . . . . . . 21-265
COAT FINISH, BASE COAT/CLEAR . . . . . . . . . 23-4
COAT/CLEAR COAT FINISH, BASE . . . . . . . . . 23-4
CODE DESCRIPTIONS, DIAGNOSTIC
TROUBLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3
CODE, PAINT . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
CODES, DIAGNOSTIC TROUBLE . . . . . . . . . . 25-2
COIL, COMPRESSOR CLUTCH . . . . . . . . . . . 24-15
COIL, EVAPORATOR . . . . . . . . . . . . . . 24-35,24-4
COIL RESISTANCE2.5L ENGINE,
IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
COIL RESISTANCE4.0L ENGINE,
IGNITION. . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
COIL SPRING/J OUNCE BUMPER . . . . . . . . . . . 2-9
COIL SPRINGS AND ISOLATORS . . . . . . 2-16,2-8
COIL-2.5L ENGINE, IGNITION . . . . . . . . . . . . 8D-3
COIL2.5L ENGINE, IGNITION . . . . . . . . . . 8D-12
COIL4.0L ENGINE, IGNITION . . . . . 8D-12,8D-3
COLLAPSIBLE SPACER . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . 8V-2,8V-9
COMPASS, AND THERMOMETER
DISPLAY MODULE, TRIP COMPUTER. . 8V-3,8V-7
COMPASS CALIBRATION . . . . . . . . . . . . . . . . 8V-5
COMPASS DEMAGNETIZING . . . . . . . . . . . . . 8V-6
COMPASS VARIATION ADJ USTMENT . . . . . . 8V-4
COMPRESSION PRESSURE TEST,
CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73
COMPRESSOR . . . . . . . . . . . . . . 24-14,24-28,24-3
COMPRESSOR CLUTCH . . . . . . . . . . . 24-29,24-3
COMPRESSOR CLUTCH COIL . . . . . . . . . . . 24-15
COMPRESSOR CLUTCH RELAY . 24-15,24-31,24-4
COMPUTER, COMPASS, AND
THERMOMETER DISPLAY MODULE,
TRIP . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-3,8V-7
COMPUTER, TRIP . . . . . . . . . . . . . . . . . . . . . 8V-1
CONDENSER . . . . . . . . . . . . . . . . . . . . 24-32,24-4
CONDITION, CHECKING FLUID . . . . . . . . . 21-248
CONDITIONER CONTROL, HEATER AND
AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-6
CONDITIONER, HEATER AND AIR . . . . . . . . . 24-5
CONDITIONING-HEATER, 8W-42 AIR . . . . . . 8W-1
CONDITIONS, SPARK PLUG . . . . . . . . . . . . . 8D-8
CONNECTING ROD BEARINGS, FITTING . . . . 9-80
CONNECTING ROD BEARINGSFITTING . . . 9-21
CONNECTING ROD, PISTON . . . . . . 9-51,9-6,9-66
CONNECTING RODS, PISTONS . . . . . . . . . . 9-108
CONNECTIONS, INTERMITTENT AND
POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-8
CONNECTOR AND TERMINAL
REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . 8W-12
CONNECTOR INFORMATION . . . . . . . . . . . . 8W-7
CONNECTOR LOCATIONS, 8W-90 . . . . . . . . 8W-1
CONNECTOR PIN-OUTS, 8W-80 . . . . . . . . . . 8W-1
CONNECTOR REPLACEMENT . . . . . . . . . . . 8W-12
CONNECTOR/GROUND LOCATIONS . . . . . . . 8W-1
CONNECTORPCM INPUT AND
OUTPUT, DATA LINK . . . . . . . . . . . . . . . . . . 14-35
CONNECTORS, TERMINAL/CONNECTOR
REPAIR- AUGAT . . . . . . . . . . . . . . . . . . . . . 8W-11
REPAIR-MOLEX . . . . . . . . . . . . . . . . . . . . . 8W-10
REPAIRTHOMAS AND BETTS . . . . . . . . . 8W-10
CONSOLE, 8W-49 OVERHEAD . . . . . . . . . . . 8W-1
CONSOLE, FULL FLOOR . . . . . . . . . . . . . . . 23-57
CONSOLE, OVERHEAD . . . . . . . . . . . . . 8V-1,8V-6
CONTACT PATTERN ANALYSIS, GEAR . . . . 3-129,
3-59,3-97
CONTAMINATION, BRAKE FLUID . . . . . . . . . . 5-12
CONTAMINATION, CLUTCH . . . . . . . . . . . . . . . 6-6
CONTAMINATION, FLUID . . . . . . . . 21-127,21-240
CONTROL, 8W-33 VEHICLE SPEED . . . . . . . 8W-1
CONTROL, HEATER AND AIR
CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . 24-6
CONTROL, HEATER-A/C . . . . . . . . . . . . . . . . 24-35
CONTROL (IAC) MOTOR, IDLE AIR . . . . . . . 14-45
CONTROL (IAC) MOTORPCM OUTPUT,
IDLE AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
CONTROL INFORMATION (VECI) LABEL,
VEHICLE EMISSION. . . . . . . . . . . . . . . . . . . 25-26
CONTROL MODULE, AIRBAG . . . . . . 8M-12,8M-3
CONTROL MODULE (PCM),
POWERTRAIN . . . . . . . . . . . . . . . . . . 14-25,14-46
CONTROL MODULE (TCM) SERVICE,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-248
CONTROL MODULE (TCM),
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-237
CONTROL MODULE, TRANSMISSION . . . . 21-260
CONTROL SERVO, SPEED . . . . . . . . . . 8H-2,8H-5
CONTROL SOLENOID CIRCUITS, SPEED . . . 8H-2
CONTROL SWITCH, SPEED . . . . . . . . . . . . . . 8H-5
CONTROL SWITCHES, SPEED . . . . . . . . . . . . 8H-2
CONTROL SYSTEM, 8W-31
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 8W-1
CONTROL SYSTEM, EVAPORATION . . . . . . . 25-23
CONTROL SYSTEM, SPEED . . . . . . . . . . . . . 8H-1
CONTROL UNIT, HYDRAULIC . . . . . . . . . . . . 5-34
CONTROL UNIT/CONTROLLER ANTILOCK
BRAKE, HYDRAULIC . . . . . . . . . . . . . . . . . . . 5-39
CONTROL UNIT/CONTROLLER ANTILOCK
BRAKES, HYDRAULIC . . . . . . . . . . . . . . . . . . 5-36
CONTROLLER ANTILOCK BRAKES . . . . . . . . 5-33
CONTROLS, EVAPORATIVE EMISSION . . . . 25-23
CONVERTER, CATALYTIC . . . . . . . . . . . . . . . . 11-6
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-142
CONVERTER DRAINBACK VALVE . . . . . . . . 21-125
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 21-132
CONVERTER STATOR CLUTCH
INSPECTION, TORQUE. . . . . . . . . . . . . . . . 21-247
CONVERTER, TORQUE . . . 21-146,21-222,21-252,
21-97
CONVERTER, TRANSMISSION AND
TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-250
CONVERTERS, CATALYTIC . . . . . . . . . . . . . . . 11-2
COOLANT FLOW CHECK, RADIATOR . . . . . . . 7-17
COOLANT RESERVE TANK . . . . . . . . . . . . . . . 7-23
COOLANT RESERVE/OVERFLOW SYSTEM . . . 7-2
COOLANT TEMPERATURE SENSOR,
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
COOLANT TEMPERATURE SENSOR
PCM INPUT, ENGINE . . . . . . . . . . . . . . . . . . 14-30
COOLANTADDING ADDITIONAL . . . . . . . . . 7-21
COOLANTLEVEL CHECK . . . . . . . . . . . . . . . 7-21
COOLANTLOW LEVEL AERATION . . . . . . . 7-21
COOLANTROUTINE LEVEL CHECK . . . . . . . 7-21
COOLER, AUTOMATIC TRANSMISSION
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
COOLER, FLOW TESTING
TRANSMISSION MAIN. . . . . . . . . . . . . . . . 21-246
COOLER, TRANSMISSION . . . . . . . . . . . . . 21-237
COOLERS AND TUBES, FLUSHING . . . . . . 21-143,
21-248
COOLERS, TRANSMISSION OIL . . . . . . . . . . 7-23
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
COOLING FAN, ELECTRIC . . . . . . . . . . . . 7-19,7-8
COOLING FAN2.5L, ELECTRIC . . . . . . . . . . 7-33
COOLING FAN4.0L, ELECTRIC . . . . . . . . . . 7-34
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-1
COOLING SYSTEM FANS . . . . . . . . . . . . . 7-3,7-38
COOLING SYSTEM HOSES . . . . . . . . . . . . . . 7-40
COOLING SYSTEMDRAINING AND
FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
COOLING SYSTEMREVERSE
FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
COOLING SYSTEMTESTING FOR
LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
CORE, HEATER . . . . . . . . . . . . . . . . . . 24-41,24-6
XJ INDEX 3
COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . 21-30
COUPLER, REFRIGERANT LINE . . . . . . . . . . 24-45
COUPLERS, REFRIGERANT LINE . . . . . . . . . . 24-8
COURTESY LAMP BULB, READING . . . . . . . . 8V-8
COURTESY LAMP, READING . . . . . . . . . . . . . 8V-2
COVER AND DISC, CLUTCH . . . . . . . . . . . . . 6-11
COVER AND DISC RUNOUT, CLUTCH . . . . . . . 6-7
COVER, BUCKET SEAT CUSHION . . . . . . . . 23-17
COVER, BUCKET SEATBACK . . . . . . . . . . . . 23-16
COVER, CYLINDER HEAD . . . 9-113,9-35,9-67,9-7,
9-96
COVER, DRIVER SIDE AIRBAG MODULE
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
COVER, HEAD RESTRAINT . . . . . . . . . . . . . 23-14
COVER, INSTRUMENT PANEL TOP . . . . . . . 8E-21
COVER, KICK . . . . . . . . . . . . . . . . . . . . . . . . 24-42
COVER OIL SEAL, TIMING CASE . . . . . 9-112,9-41
COVER, QUARTER PANEL TRIM AND
WHEELHOUSE . . . . . . . . . . . . . . . . . . . . . . . 23-54
COVER, REAR SEAT CUSHION . . . . . . . . . . 23-19
COVER, REAR SEATBACK . . . . . . . . . . . . . . 23-20
COVER, STEERING COLUMN OPENING . . . . 8E-13
COVER, TIMING CASE . . . . . . . . . . . . . 9-101,9-42
COWL GRILLE . . . . . . . . . . . . . . . . . . . . . . . 23-28
COWL TRIM, LOWER A-PILLAR . . . . . . . . . 23-51
COWL WEATHERSTRIP . . . . . . . . . . . . . . . . 23-28
C-PILLAR TRIM . . . . . . . . . . . . . . . . . . . . . . . 23-53
CRANKCASE VENTILATION SYSTEM . 25-25,25-27
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . 9-5,9-65
CRANKSHAFT MAIN BEARINGS . . . . . 9-105,9-47
CRANKSHAFT MAIN BEARINGS, FITTING . . 9-23,
9-83
CRANKSHAFT OIL SEALSREAR . . . . . . . . 9-110
CRANKSHAFT POSITION (CKP) SENSOR . . 8D-13
CRANKSHAFT POSITION SENSOR . . . . . . . . 8D-4
CUSHION COVER, BUCKET SEAT . . . . . . . . 23-17
CUSHION COVER, REAR SEAT . . . . . . . . . . 23-19
CUSHION, REAR SEAT . . . . . . . . . . . . . . . . . 23-17
CUT-OFF SWITCH, DUAL FUNCTION
HIGH PRESSURE SWITCH/HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . 24-16,24-33
CUT-OFF SWITCH, HIGH PRESSURE . . . . . . . 24-6
CYCLE EVAP CANISTER PURGE
SOLENOID, DUTY . . . . . . . . . . . . . . . 25-24,25-27
CYCLING CLUTCH SWITCH, LOW
PRESSURE . . . . . . . . . . . . . . . . 24-17,24-42,24-7
CYLINDER BLEEDING, MASTER . . . . . . . . . . 5-12
CYLINDER BLOCK . . . 9-112,9-114,9-5,9-53,9-54,
9-65
CYLINDER BORES, HONING . . . . . . . . . 9-26,9-87
LEAKAGE TEST . . . . . . . . . . . . . . . . . . . 9-13,9-73
CYLINDER COMPRESSION PRESSURE
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73
CYLINDER, FRONT DOOR LOCK . . . . . . . . . 23-36
CYLINDER HEAD . . 9-113,9-38,9-40,9-5,9-65,9-98
CYLINDER HEAD COVER . . . 9-113,9-35,9-67,9-7,
9-96
CYLINDER HEAD, ENGINE . . . . . . . . . . . . . . . 9-54
CYLINDER HEAD GASKET FAILURE
DIAGNOSIS, ENGINE . . . . . . . . . . . . . . . 9-13,9-73
CYLINDER, IGNITION SWITCH AND KEY . . 8D-20
CYLINDER, IGNITION SWITCH AND KEY
LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9
CYLINDER, LIFTGATE LOCK . . . . . . . . . . . . 23-64
CYLINDER, LIFTGATE SUPPORT ROD . . . . . 23-63
CYLINDER, MASTER . . . . . . . . . . . . . . . . 5-16,5-3
CYLINDER RESERVOIR, MASTER . . . . . . . . . 5-24
CYLINDER, WHEEL . . . . . . . . . . . . 5-21,5-28,5-29
CYLINDER/POWER BOOSTER, MASTER . . . . 5-10
CYLINDERS, LOCK . . . . . . . . . . . . . . . . . . . 23-37
DAMAGED OR WORN THREADS, REPAIR . . 9-27,
9-88
DAMPER, STEERING . . . . . . . . . . . . . . . . . . 19-25
DAMPER, VIBRATION . . . . . . . . . . . . . 9-101,9-41
DAMPER2.5L ENGINE, FUEL INJ ECTOR
RAIL/FUEL . . . . . . . . . . . . . . . . . . . . . . 14-16,14-5
DAMPER4.0L ENGINE, FUEL INJ ECTOR
RAIL/FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
DAMPER4.0L ENGINE, FUEL
RAIL/FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
DATA LINK CONNECTORPCM INPUT
AND OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . 14-35
DAYTIME RUNNING LAMP MODULE . . . . . . 8L-19
DEAERATION . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
DECALS, BODY . . . . . . . . . . . . . . . . . . . . . . 23-29
DEFINITION, TRIP . . . . . . . . . . . . . . . . . . . . 25-21
DEFOGGER, 8W-48 REAR WINDOW . . . . . . 8W-1
DEFOGGER RELAY . . . . . . . . . . . . 8N-3,8N-4,8N-7
DEFOGGER SWITCH . . . . . . . . . . . 8N-2,8N-4,8N-6
DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . 8N-3
DEFOGGER SYSTEM, REAR WINDOW . . . . . 8N-1
DELAY MODULE, SENTINEL HEADLAMP . . . 8L-19
DELIVERY SYSTEM, FUEL . . . . . . . . . . . . . . . 14-1
DEMAGNETIZING, COMPASS . . . . . . . . . . . . 8V-6
DEPTH, 181 FBI PINION GEAR . . . . . . . . . . . 3-48
DEPTH, 186 FBI PINION GEAR . . . . . . . . . . . 3-50
DEPTH, 8 1/4 AXLE PINION GEAR . . . . . . . 3-126
DEPTH, PINION GEAR . . . . . . . . . . . . . . . . . . 3-91
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
DESCRIPTION AND OPERATION; BODY . . . . 23-1
DESCRIPTION AND OPERATION; FRAME
AND BUMPERS . . . . . . . . . . . . . . . . . . . . . . . 13-1
DESCRIPTIONS, DIAGNOSTIC TROUBLE
CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3
DETECTION PUMP (LDP), LEAK . . . . 25-24,25-27,
25-28
DEVICES, ELECTROSTATIC DISCHARGE
(ESD) SENSITIVE . . . . . . . . . . . . . . . . . . . . . 8W-8
DIAGNOSIS, ACCESSORY DRIVE BELT . . . . . . 7-9
DIAGNOSIS, AUTOMATIC
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-126
DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . 21-133
DIAGNOSIS CHARTS, CLUTCH . . . . . . . . . . . . 6-7
DIAGNOSIS CHARTS, POWER STEERING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
DIAGNOSIS, CONVERTER HOUSING
FLUID LEAK . . . . . . . . . . . . . . . . . . . . . . . . 21-132
DIAGNOSIS, ENGINE CYLINDER HEAD
GASKET FAILURE . . . . . . . . . . . . . . . . . 9-13,9-73
DIAGNOSIS INFORMATION, GENERAL . . . 21-239
DIAGNOSIS, INTAKE MANIFOLD
LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-72
DIAGNOSIS, LAMP . . . . . . . . . . . . . . . . . . . . 8L-3
DIAGNOSIS, NV231 . . . . . . . . . . . . . . . . . . 21-347
DIAGNOSIS, NV242 . . . . . . . . . . . . . . . . . . 21-376
DIAGNOSIS, PRELIMINARY . . . . . . . . . . . . 21-128
DIAGNOSIS, PUMP LEAKAGE . . . . . . . . . . . . 19-7
DIAGNOSIS, SERVICE . . . . . . . . . . . . . . . . 21-243
DIAGNOSIS, SHOCK . . . . . . . . . . . . . . . . . . . . 2-9
DIAGNOSIS, SYSTEM . . . . . . . . . . . . . . . . . . 8L-3
DIAGNOSISINTRODUCTION, ENGINE . 9-68,9-8
DIAGNOSISMECHANICAL, SERVICE . 9-10,9-70
DIAGNOSISPERFORMANCE, SERVICE . 9-69,9-9
DIAGNOSTIC INFORMATION, CLUTCH . . . . . . 6-4
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . 8L-3
DIAGNOSTIC TEST FOR CHARGING
SYSTEM, ON-BOARD . . . . . . . . . . . . . . . . . . 8C-3
DIAGNOSTIC TROUBLE CODE
DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . 25-3
DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . 25-2
DIAGNOSTICS (OBD), ON-BOARD . . . . . . . . . . 7-9
DIAGNOSTICS, ON-BOARD . . . . . . . . . . . . . . 25-1
DIFFERENTIAL . . . . . . . . . . . . . . . 3-114,3-33,3-78
GEAR BACKLASH . . . . . . . . . . . . . . . . 3-127,3-94
GEAR BACKLASH, 181 FBI . . . . . . . . . . . . . . 3-52
GEAR BACKLASH, 186 FBI . . . . . . . . . . . . . . 3-56
DIFFERENTIAL NOISE, TRACLOK . . 3-109,3-70
DIFFERENTIAL SIDE BEARINGS . 3-115,3-36,3-80
DIFFERENTIAL, STANDARD . . . 3-105,3-120,3-18,
3-46,3-66,3-86
DIFFERENTIAL, TRAC-LOK . . 3-105,3-121,3-66,
3-87
DIMENSIONS, BODY OPENING . . . . . . . . . 23-128
DIMENSIONS, FRAME . . . . . . . . . . . . . . . . . . 13-7
DIODE REPLACEMENT . . . . . . . . . . . . . . . . 8W-14
DIRECT CLUTCH . . . . . . . . . . . . . . . . . . . . 21-312
DISC BRAKE CALIPER . . . . . . . . . . . . . . . . . . 5-25
DISC BRAKE CALIPER, FRONT . . . . . . . . . . . 5-18
DISC BRAKE ROTOR . . . . . . . . . . . . . . . 5-11,5-21
DISC BRAKE SHOES, FRONT . . . . . . . . . . . . . 5-20
DISC BRAKES, FRONT . . . . . . . . . . . . . . . . . . . 5-4
DISC, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
DISC, CLUTCH COVER . . . . . . . . . . . . . . . . . 6-11
DISC ROTOR MACHINING . . . . . . . . . . . . . . . 5-13
DISC RUNOUT, CLUTCH COVER . . . . . . . . . . . 6-7
DISCHARGE (ESD) SENSITIVE DEVICES,
ELECTROSTATIC. . . . . . . . . . . . . . . . . . . . . . 8W-8
DISCHARGE LINE, SUCTION . . . . . . . . . . . . 24-45
DISPLAY MODULE, TRIP COMPUTER,
COMPASS, AND THERMOMETER . . . . . 8V-3,8V-7
DISPLAY TEST MODE, STATE . . . . . . . . . . . . 25-2
DISTANCE SENSORPCM INPUT,
VEHICLE SPEED . . . . . . . . . . . . . . . . . . . . . 14-34
DISTRIBUTION, 8W-10 POWER . . . . . . . . . . 8W-1
DISTRIBUTION, 8W-15 GROUND . . . . . . . . . 8W-1
DISTRIBUTION CENTER, POWER . . . . 8O-2,8O-4,
8O-7
DISTRIBUTION SYSTEM, POWER . . . . . . . . . 8O-1
DISTRIBUTION SYSTEMS, POWER . . . . . . . 8O-10
DISTRIBUTOR CAP-2.5L ENGINE . . . . . . . . . 8D-6
DISTRIBUTOR ROTOR-2.5L ENGINE . . . . . . . 8D-6
DISTRIBUTOR-2.5L ENGINE . . . . . . . . . . . . . 8D-2
DISTRIBUTOR2.5L ENGINE . . . . . . . . . . . 8D-17
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-65
DOOR, FRONT . . . . . . . . . . . . . . . . . . . . . . . 23-35
DOOR, GARAGE DOOR OPENER
STORAGE BIN . . . . . . . . . . . . . . . . . . . . . . . . 8V-8
DOOR GLASS EXTERIOR MOLDING,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
DOOR GLASS EXTERIOR MOLDING,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
DOOR GLASS, FRONT . . . . . . . . . . . . . . . . . 23-41
DOOR GLASS RUN CHANNEL
WEATHERSTRIP, FRONT . . . . . . . . . . . . . . . 23-38
DOOR GLASS RUN CHANNEL
WEATHERSTRIP, REAR . . . . . . . . . . . . . . . . 23-46
DOOR, HEATER-A/C HOUSING . . . . . . . . . . 24-39
DOOR HINGE, FRONT . . . . . . . . . . . . . . . . . 23-35
DOOR HINGE, REAR . . . . . . . . . . . . . . . . . . 23-43
DOOR INNER BELT WEATHERSTRIP,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
DOOR INNER BELT WEATHERSTRIP,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
DOOR INSIDE HANDLE ACTUATOR,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
DOOR INSIDE HANDLE ACTUATOR,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
DOOR J AMB SWITCH, DRIVER . . . . . . . . . . . 8U-2
DOOR LATCH ADJ USTMENT . . . . . . . . . . . . 23-66
DOOR LATCH, FRONT . . . . . . . . . . . . . . . . . 23-37
DOOR LATCH, REAR . . . . . . . . . . . . . . . . . . 23-44
DOOR LATCH STRIKER, FRONT . . . . . . . . . 23-37
DOOR LATCH STRIKER, REAR . . . . . . . . . . 23-45
DOOR LOCK CYLINDER, FRONT . . . . . . . . . 23-36
DOOR LOCKS, 8W-61 POWER . . . . . . . . . . . 8W-1
DOOR MODULE; POWER LOCK
SYSTEMS . . . . . . . . . . . . . . . . . . . 8P-2,8P-3,8P-7
DOOR MODULE; POWER MIRROR
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . 8T-2,8T-3
DOOR MODULE; POWER WINDOW
SYSTEMS . . . . . . . . . . . . . . . . . . . 8S-2,8S-3,8S-4
DOOR MOTOR, BLEND-AIR . . . . . . . . . . . . . 24-26
DOOR OPENER STORAGE BIN DOOR,
GARAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8
DOOR OPENER STORAGE BIN, GARAGE . . . 8V-3
DOOR OPENING SECONDARY
WEATHERSTRIP, FRONT . . . . . . . . . . . . . . . 23-39
DOOR OPENING WEATHERSTRIP, FRONT . . 23-38
DOOR OUTER BELT WEATHERSTRIP,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
DOOR OUTER BELT WEATHERSTRIP,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
DOOR OUTSIDE HANDLE, FRONT . . . . . . . . 23-35
DOOR OUTSIDE HANDLE, REAR . . . . . . . . . 23-44
DOOR, PASSENGER SIDE AIRBAG . . . . . . . 8M-11
DOOR, REAR . . . . . . . . . . . . . . . . . . . . . . . . 23-43
DOOR RESTRAINT, FRONT . . . . . . . . . . . . . 23-35
DOOR RESTRAINT, REAR . . . . . . . . . . . . . . 23-43
DOOR SILL SCUFF PLATE . . . . . . . . . . . . . . 23-52
DOOR SPACER BLOCKSTWO-DOOR
VEHICLES, FRONT . . . . . . . . . . . . . . . . . . . . 23-41
DOOR STATIONARY WINDOW GLASS,
REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9
DOOR TRIM PANEL, FRONT . . . . . . . . . . . . 23-33
DOOR TRIM PANEL, REAR . . . . . . . . . . . . . 23-42
DOOR VACUUM ACTUATOR, MODE . . . . . . 24-43
DOOR WATERDAM, FRONT . . . . . . . . . . . . . 23-34
DOOR WATERDAM, REAR . . . . . . . . . . . . . . 23-42
DOOR WEATHERSTRIP, REAR . . . . . . . . . . . 23-46
DOOR WINDOW GLASS, REAR . . . . . . . . . . 23-47
DOOR WINDOW REGULATOR, FRONT . . . . 23-39
DOOR WINDOW REGULATOR, REAR . . . . . 23-47
DOUBLE CARDAN J OINT . . . . . . . . . . . . . . . . 3-11
DOWNS, BATTERY HOLD . . . . . . . . . . 8A-20,8A-4
DRAG LINK . . . . . . . . . . . . . . . . . . . . . . . . . 19-24
DRAINBACK CHECK VALVE SERVICE,
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-142
DRAINBACK VALVE, CONVERTER . . . . . . . 21-125
4 INDEX XJ
DRAW FUSE, IGNITION-OFF; AUDIO
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1
DRAW FUSE, IGNITION-OFF; POWER
DISTRIBUTION SYSTEMS. . . . . . . . . . . 8O-2,8O-5
DRB SCAN TOOL . . . . . . . . . . . . . . . . . . . . . . . 7-9
DRIP RAIL MOLDING . . . . . . . . . . . . . . . . . 23-49
DRIVE AXLE ASSEMBLY . . . . . . . . . . . . . . . . 3-22
DRIVE BELT DIAGNOSIS, ACCESSORY . . . . . . 7-9
DRIVE BELTS, ENGINE ACCESSORY . . . . . . . 7-35
DRIVE GEAR, SPEED SENSOR
ROTOR-SPEEDOMETER . . . . . . . . . . . . . . . 21-254
DRIVE REMOVAL/INSTALLATION,
VISCOUS FAN . . . . . . . . . . . . . . . . . . . . . . . . 7-39
DRIVE, VISCOUS FAN . . . . . . . . . . . . . . . 7-19,7-7
PREPARATION. . . . . . . . . . . . . . . . . . . . . . . . . 3-6
DRIVELINE SNAP . . . . . . . . . . . . 3-109,3-21,3-70
DRIVER DOOR J AMB SWITCH . . . . . . . . . . . 8U-2
DRIVER SEAT BELT SWITCH . . . . . . . . . . . . 8U-2
DRIVER SIDE AIRBAG MODULE . . . . . 8M-2,8M-6
DRIVER SIDE AIRBAG MODULE TRIM
COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
DRUM, BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 5-11
DRUM BRAKE, REAR . . . . . . . . . . . 5-29,5-30,5-5
DRUM BRAKE SHOES . . . . . . . . . . . . . . . . . . 5-21
DRUM MACHINING, BRAKE . . . . . . . . . . . . . 5-14
DRUM, OVERRUNNING CLUTCH/LOW-
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-175
DRUM/OVERDRIVE PISTON RETAINER,
OVERRUNNING CLUTCH/LOW-
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-195
SWITCH (4.0 L) . . . . . . . . . . . . . . . . . . . . . . . 24-4
SWITCH. . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33
DUCTS AND OUTLETS . . . . . . . . . . . . . . . . . 24-33
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . 25-24,25-27
EFFECTS OF INCORRECT FLUID LEVEL . . 21-126,
21-239
ELECTRIC COOLING FAN . . . . . . . . . . . . . 7-19,7-8
ELECTRIC COOLING FAN2.5L . . . . . . . . . . 7-33
ELECTRIC COOLING FAN4.0L . . . . . . . . . . 7-34
ELECTRONIC VOLTAGE REGULATOR . . . . . . . 8C-2
ELECTROSTATIC DISCHARGE (ESD)
SENSITIVE DEVICES. . . . . . . . . . . . . . . . . . . 8W-8
ELEMENT AND SENSOR, HEATED SEAT . . 8N-11,
8N-9
ELEMENT (FILTER), AIR CLEANER . . . . . . . 14-49
EMERGENCY TOW HOOKS . . . . . . . . . . . . . . 0-11
EMISSION CONTROL INFORMATION
(VECI) LABEL, VEHICLE. . . . . . . . . . . . . . . . 25-26
EMISSION CONTROLS, EVAPORATIVE . . . . 25-23
EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . 25-1
END CAP, FRONT BUMPER . . . . . . . . . . . . . . 13-2
END CAP, INSTRUMENT PANEL . . . . . . . . . 8E-25
END CAP, REAR BUMPER . . . . . . . . . . . . . . . 13-4
END PLUG, HOUSING . . . . . . . . . . . . . . . . . 19-12
ENGAGEMENT, IMPROPER CLUTCH
RELEASE OR . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
ENGINE . . . . . . . . . . . . . . . . . . . . . . 9-2,9-31,9-62
ENGINE, 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
ENGINE, 4.0L . . . . . . . . . . . . . . . . . . . . 9-119,9-61
ENGINE ACCESSORY DRIVE BELTS . . . . . . . 7-35
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . 9-92
ENGINE ASSEMBLY (SHORT BLOCK),
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 9-27,9-88
ENGINE, CAMSHAFT POSITION
SENSOR-2.5L . . . . . . . . . . . . . . . . . . . . . . . . 8D-4
SENSOR2.5L . . . . . . . . . . . . . . . . . . . . . . 8D-14
SENSOR4.0L . . . . . . . . . . . . . . . . . . 8D-15,8D-5
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
SENSORPCM INPUT . . . . . . . . . . . . . . . . 14-30
ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . 9-54
ENGINE CYLINDER HEAD GASKET
FAILURE DIAGNOSIS . . . . . . . . . . . . . . . 9-13,9-73
ENGINE DIAGNOSISINTRODUCTION . . 9-68,9-8
ENGINE, DISTRIBUTOR CAP-2.5L . . . . . . . . . 8D-6
ENGINE, DISTRIBUTOR ROTOR-2.5L . . . . . . 8D-6
ENGINE, DISTRIBUTOR-2.5L . . . . . . . . . . . . . 8D-2
ENGINE, DISTRIBUTOR2.5L . . . . . . . . . . 8D-17
ENGINE, ENGINE FIRING ORDER2.5L
4-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
ENGINE, ENGINE FIRING ORDER4.0L
6-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
ENGINE, EXHAUST MANIFOLD4.0L . . . . . . 9-96
ENGINE FIRING ORDER2.5L
4-CYLINDER ENGINE . . . . . . . . . . . . . . . . . 8D-23
ENGINE FIRING ORDER4.0L
6-CYLINDER ENGINE . . . . . . . . . . . . . . . . . 8D-23
ENGINE, FUEL INJ ECTOR RAIL/FUEL
DAMPER2.5L . . . . . . . . . . . . . . . . . . 14-16,14-5
ENGINE, FUEL INJ ECTOR RAIL/FUEL
DAMPER4.0L . . . . . . . . . . . . . . . . . . . . . . 14-17
ENGINE, FUEL RAIL/FUEL DAMPER
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
ENGINE, IGNITION COIL RESISTANCE
2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
ENGINE, IGNITION COIL RESISTANCE
4.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
ENGINE, IGNITION COIL-2.5L . . . . . . . . . . . . 8D-3
ENGINE, IGNITION COIL2.5L . . . . . . . . . . 8D-12
ENGINE, IGNITION COIL4.0L . . . . . 8D-12,8D-3
ENGINE MOUNTREAR . . . . . . . . . . . . 9-30,9-91
ENGINE MOUNTSFRONT . . . . . . . . . . 9-29,9-90
ENGINE OIL LEAK INSPECTION . . . . . . 9-14,9-74
ENGINE OIL PRESSURE . . . . . . . . . . . . 9-15,9-75
ENGINE OIL SERVICE . . . . . . . . . . . . . . 9-27,9-88
ENGINE PERFORMANCE . . . . . . . . . . . . 9-26,9-87
ENGINE, POWER STEERING PRESSURE
SWITCH2.5L . . . . . . . . . . . . . . . . . . . . . . 14-47
ENGINE, SPARK PLUG CABLES-2.5L . . . . . . 8D-2
ENGINE SPECIAL TOOLS, 2.5L. . . . . . . . . . . . . 9-60
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . 9-55
ENGINE, STARTER MOTOR NOISE - 2.5L . . . 8B-8
ENTRY RECEIVER PROGRAMMING,
REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8P-6
ENTRY RECEIVER, REMOTE KEYLESS . 8P-2,8P-5,
8P-8
ENTRY SYSTEM, POWER LOCK SYSTEM
AND REMOTE KEYLESS . . . . . . . . . . . . . . . . 8P-3
ENTRY SYSTEM, REMOTE KEYLESS . . . . . . 8P-1
ENTRY TRANSMITTER BATTERY
REPLACEMENT, REMOTE KEYLESS . . . . . . . 8P-6
ENTRY TRANSMITTER PROGRAMMING,
REMOTE KEYLESS . . . . . . . . . . . . . . . . . . . . 8P-6
ENTRY TRANSMITTER, REMOTE
KEYLESS . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . 25-23
EVAPORATIVE EMISSION CONTROLS . . . . . 25-23
EVAPORATOR COIL . . . . . . . . . . . . . . . 24-35,24-4
EXHAUST GRILLE, AIR . . . . . . . . . . . . . . . . 23-50
EXHAUST MANIFOLD . . . . . . . . . . . 9-35,9-68,9-8
EXHAUST MANIFOLD, INTAKE . . . . . . . . . . . . 9-95
EXHAUST MANIFOLD4.0L ENGINE . . . . . . 9-96
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . 11-5
EXHAUST SYSTEM . . . . . . . . . . . . . . . . 11-1,11-4
EXTENDED IDLE SWITCHPCM INPUT . . . 14-30
EXTENSION HOUSING AND PARK LOCK . . 21-191
EXTENSION HOUSING BUSHING . . . . . . . . 21-147
EXTENSION HOUSING SEAL . . . . . . . . . . . . . 21-7
EXTENSION, QUARTER PANEL TRIM . . . . . 23-54
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . 8L-20
EXTERIOR MOLDING, FRONT DOOR
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
EXTERIOR MOLDING, REAR DOOR
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
EXTERIOR NAMEPLATES . . . . . . . . . . . . . . . 23-30
FAILURE DIAGNOSIS, ENGINE CYLINDER
HEAD GASKET. . . . . . . . . . . . . . . . . . . . 9-13,9-73
FAN BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
FAN DRIVE REMOVAL/INSTALLATION,
VISCOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
FAN DRIVE, VISCOUS . . . . . . . . . . . . . . . 7-19,7-7
FAN, ELECTRIC COOLING . . . . . . . . . . . . 7-19,7-8
FAN RELAYPCM OUTPUT, RADIATOR . . . 14-36
FAN2.5L, ELECTRIC COOLING . . . . . . . . . . 7-33
FAN4.0L, ELECTRIC COOLING . . . . . . . . . . 7-34
FANS, COOLING SYSTEM . . . . . . . . . . . . 7-3,7-38
FASTENER IDENTIFICATION . . . . . . . . . . . Intro.-3
FASTENER USAGE . . . . . . . . . . . . . . . . . . . Intro.-3
FBI AXLE, 181 . . . . . . . . . . . . . . . . . . . . 3-16,3-61
FBI AXLE, 181 AND 186 . . . . . . . . . . . . . . . . 3-61
FBI AXLE, 186 . . . . . . . . . . . . . . . . . . . . 3-17,3-61
FBI AXLE, TUBE, 181, AND 186 . . . . . . . . . . 3-16
FBI DIFFERENTIAL BEARING PRELOAD
AND GEAR BACKLASH, 181 . . . . . . . . . . . . . 3-52
FBI DIFFERENTIAL BEARING PRELOAD
AND GEAR BACKLASH, 186 . . . . . . . . . . . . . 3-56
FBI PINION, 181 . . . . . . . . . . . . . . . . . . . . . . 3-36
FBI PINION, 186 . . . . . . . . . . . . . . . . . . . . . . 3-41
FBI PINION GEAR DEPTH, 181 . . . . . . . . . . . 3-48
FBI PINION GEAR DEPTH, 186 . . . . . . . . . . . 3-50
FBI PINION SHAFT SEAL, 181 . . . . . . . . . . . . 3-24
FBI PINION SHAFT SEAL, 186 . . . . . . . . . . . . 3-26
FENDER FLARE, FRONT . . . . . . . . . . . . . . . . 23-31
FENDER FLARE, REAR . . . . . . . . . . . . . . . . . 23-49
FENDER, LEFT FRONT . . . . . . . . . . . . . . . . . 23-32
FENDER, RIGHT FRONT . . . . . . . . . . . . . . . . 23-32
FILL LEVEL, LUBRICANT . . . . . . . . 21-347,21-376
FILL PROCEDURE, TRANSMISSION . . . . . 21-142
FILLER TUBE CAP, FUEL TANK . . . . . . 14-21,14-6
FILLING, COOLING SYSTEMDRAINING . . . 7-21
FILTER, FUEL PUMP INLET . . . . . . . . . . . . . 14-15
FILTER REPLACEMENT, FLUID . . . . . . . . . 21-141
FILTER/FUEL PRESSURE REGULATOR,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-13,14-3
FINAL ASSEMBLY . . . . . . . . . . . . . . . . . 3-47,3-85
POLISHING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
FINISH, BASE COAT/CLEAR COAT . . . . . . . . . 23-4
FIRING ORDER2.5L 4-CYLINDER
ENGINE, ENGINE. . . . . . . . . . . . . . . . . . . . . . 8D-23
FIRING ORDER4.0L 6-CYLINDER
ENGINE, ENGINE . . . . . . . . . . . . . . . . . . . . . 8D-23
FITTING CONNECTING ROD BEARINGS . . . . 9-80
FITTING CRANKSHAFT MAIN BEARINGS . . . 9-23,
9-83
FITTING, PISTON . . . . . . . . . . . . . . . . . . . . . . 9-77
FITTINGS, QUICK-CONNECT . . . . . . . . 14-10,14-6
FIVE VOLT SENSOR SUPPLIES
PRIMARY AND SECONDARY . . . . . . . . . . . . 14-29
FIXED ORIFICE TUBE . . . . . . . . . . . . . . 24-35,24-5
FLARE, FRONT FENDER . . . . . . . . . . . . . . . . 23-31
FLARE, REAR FENDER . . . . . . . . . . . . . . . . . 23-49
FLARING, BRAKE TUBE . . . . . . . . . . . . . . . . . 5-14
FLASHER, COMBINATION . . . . . . . . . . . 8J -3,8J -5
FLOOR CONSOLE, FULL . . . . . . . . . . . . . . . 23-57
FLOW AND PRESSURE, POWER . . . . . . . . . . 19-6
FLOW CHECK PROCEDURE, THROTTLE
BODY MINIMUM AIR. . . . . . . . . . . . . . . . . . 14-42
FLOW CHECK, RADIATOR COOLANT . . . . . . . 7-17
COOLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-246
FLUID . . . . . . . . . . . . . . . . . . . . . . . 21-220,21-96
FLUID AND FILTER REPLACEMENT . . . . . . 21-141
FLUID, BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 5-31
FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . 0-3
FLUID, CAUSES OF BURNT . . . . . . 21-126,21-240
FLUID, CLUTCH LINKAGE . . . . . . . . . . . . . . . . 6-9
FLUID CONDITION, CHECKING . . . . . . . . . 21-248
FLUID CONTAMINATION . . . . . . . . 21-127,21-240
FLUID CONTAMINATION, BRAKE . . . . . . . . . . 5-12
FLUID LEAK DIAGNOSIS, CONVERTER
HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . 21-132
FLUID LEVEL, BRAKE . . . . . . . . . . . . . . . . . . 5-12
FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . 21-141
FLUID LEVEL, CHECKING . . . . . . . . . . . . . 21-247
FLUID LEVEL, CLUTCH . . . . . . . . . . . . . . . . . 6-10
FLUID LEVEL, EFFECTS OF INCORRECT . . 21-126,
21-239
FLUID LEVEL SENSOR, WASHER . . . . . . . . . 8K-4
FLUID/FILTER CHANGE, REFILLING
AFTER OVERHAUL OR. . . . . . . . . . . . . . . . 21-248
FLUSH MEASUREMENTS, BODY GAP . . . . 23-127
FLUSHING COOLERS AND TUBES . 21-143,21-248
FLUSHING, COOLING SYSTEM
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . 6-10,6-2
FLYWHEEL RUNOUT, CLUTCH . . . . . . . . . . . . . 6-6
FOG LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15
FOG LAMP ADJ USTMENT . . . . . . . . . . . . . . . 8L-8
FOG LAMP BULB . . . . . . . . . . . . . . . . . . . . . 8L-10
FORM-IN-PLACE GASKETS . . . . . . . . . . 9-25,9-86
FORWARD CLUTCH . . . . . . . . . . . . . . . . . . 21-317
FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . 0-10
FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6
FRAME AND BUMPERS . . . . . . . . . . . . . . . . . 13-1
FRAME DIMENSIONS . . . . . . . . . . . . . . . . . . 13-7
FRAME TORQUE SPECIFICATIONS . . . . . . . . 13-9
FREQUENCY INTERFERENCE, RADIO . . . . . . 8F-6
FRONT AXLE BUSHING . . . . . . . . . . . . . . . . . 2-11
FRONT AXLE PINION INPUT ANGLE . . . . . . . 3-15
XJ INDEX 5
FRONT BAND ADJ USTMENT . . . . . . . . . . . 21-199
FRONT BEARING RETAINER, ADAPTER/
EXTENSION HOUSING. . . . . . . . . . . . . . . . . . 21-8
FRONT BEARING RETAINER SEAL . . . . . . . . 21-6
FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . 13-3
FRONT BUMPER END CAP . . . . . . . . . . . . . . 13-2
FRONT CARPET/MAT . . . . . . . . . . . . . . . . . . 23-58
FRONT CLUTCH . . . . . . . . . 21-120,21-180,21-196
FRONT DISC BRAKE CALIPER . . . . . . . . . . . . 5-18
FRONT DISC BRAKE SHOES . . . . . . . . . . . . . 5-20
FRONT DISC BRAKES . . . . . . . . . . . . . . . . . . . 5-4
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-35
FRONT DOOR GLASS . . . . . . . . . . . . . . . . . 23-41
FRONT DOOR GLASS EXTERIOR
MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-38
FRONT DOOR HINGE . . . . . . . . . . . . . . . . . . 23-35
FRONT DOOR INNER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-37
FRONT DOOR INSIDE HANDLE
ACTUATOR. . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
FRONT DOOR LATCH . . . . . . . . . . . . . . . . . . 23-37
FRONT DOOR LATCH STRIKER . . . . . . . . . . 23-37
FRONT DOOR LOCK CYLINDER . . . . . . . . . . 23-36
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-39
FRONT DOOR OPENING WEATHERSTRIP . . 23-38
FRONT DOOR OUTER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-38
FRONT DOOR OUTSIDE HANDLE . . . . . . . . 23-35
FRONT DOOR RESTRAINT . . . . . . . . . . . . . . 23-35
FRONT DOOR SPACER BLOCKSTWO-
DOOR VEHICLES . . . . . . . . . . . . . . . . . . . . . 23-41
FRONT DOOR TRIM PANEL . . . . . . . . . . . . . 23-33
FRONT DOOR WATERDAM . . . . . . . . . . . . . 23-34
FRONT DOOR WINDOW REGULATOR . . . . . 23-39
FRONT FENDER FLARE . . . . . . . . . . . . . . . . 23-31
FRONT FENDER, LEFT . . . . . . . . . . . . . . . . . 23-32
FRONT FENDER, RIGHT . . . . . . . . . . . . . . . . 23-32
FRONT INNER SCUFF PLATE . . . . . . . . . . . . 23-52
FRONT LIGHTING, 8W-50 . . . . . . . . . . . . . . 8W-1
FRONT OUTPUT SHAFT SEAL . . . . 21-350,21-379
FRONT PARK/TURN SIGNAL LAMP . . . . . . . 8L-15
FRONT PARK/TURN SIGNAL LAMP BULB . . 8L-11
FRONT PLANETARY GEAR . . . . . . . . . . . . . 21-322
FRONT PROPELLER SHAFT . . . . . . . . . . . . . . . 3-8
FRONT SERVO . . . . . . . . . . . . . . . . . . . . . . 21-195
FRONT SERVO PISTON . . . . . . . . . . . . . . . 21-176
FRONT SHOULDER BELT/BUCKLE . . . . . . . . 23-55
FRONT SKID PLATE . . . . . . . . . . . . . . . . . . . . 13-6
FRONT SUSPENSION . . . . . . . . . . . . . . . 2-15,2-7
FRONT TOW HOOK . . . . . . . . . . . . . . . . . . . . 13-3
FRONT WHEEL SPEED SENSOR . . . . . . . . . . 5-37
FRONT WHEELHOUSE LINER . . . . . . . . . . . 23-32
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . 14-1
FUEL FILTER/FUEL PRESSURE
REGULATOR . . . . . . . . . . . . . . . . . . . . 14-13,14-3
FUEL GAUGE SENDING UNIT . . 14-10,14-16,14-3
FUEL INJ ECTION SYSTEM . . . . . . . . . . . . . . 14-25
FUEL INJ ECTOR RAIL/FUEL DAMPER
2.5L ENGINE . . . . . . . . . . . . . . . . . . . . 14-16,14-5
FUEL INJ ECTOR RAIL/FUEL DAMPER
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 14-17
FUEL INJ ECTOR TEST . . . . . . . . . . . . . . . . . 14-10
FUEL INJ ECTORS . . . . . . . . . . . . . . . . 14-19,14-4
FUEL INJ ECTORSPCM OUTPUT . . . . . . . . 14-35
FUEL LEVEL SENSORPCM INPUT . . . . . . 14-30
FUEL PRESSURE LEAK DOWN TEST . . . . . . 14-7
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . 14-8
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . 14-7
FUEL PUMP INLET FILTER . . . . . . . . . . . . . 14-15
FUEL PUMP MODULE . . . . . . . . . . . . . 14-14,14-2
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . 14-6
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . 14-44
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . 14-35
FUEL PUMP RELAYS, ASD . . . . . . . . . . . . . 14-41
FUEL RAIL/FUEL DAMPER4.0L ENGINE . . 14-5
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . 14-23
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-52
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . 14-23
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 14-10
FUEL TANK . . . . . . . . . . . . . . . . . . . . . 14-19,14-4
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . 14-23
FUEL TANK FILLER TUBE CAP . . . . . . 14-21,14-6
FUEL TANK SKID PLATE . . . . . . . . . . . . . . . . 13-7
FUEL TUBES/LINES/HOSES AND CLAMPS . . 14-6
FUEL/IGNITION SYSTEM, 8W-30 . . . . . . . . . 8W-1
FULL FLOOR CONSOLE . . . . . . . . . . . . . . . . 23-57
FUNCTION HIGH PRESSURE SWITCH
(4.0 L), DUAL . . . . . . . . . . . . . . . . . . . . . . . . 24-4
FUNCTION HIGH PRESSURE SWITCH/
HIGH PRESSURE CUT-OFF SWITCH,
DUAL . . . . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33
FUNCTIONS, CIRCUIT . . . . . . . . . . . . . . . . . . 8W-4
FUSE, IGNITION-OFF DRAW; AUDIO
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1
FUSE, IGNITION-OFF DRAW; POWER
GAP AND FLUSH MEASUREMENTS,
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-127
GARAGE DOOR OPENER STORAGE BIN . . . . 8V-3
GARAGE DOOR OPENER STORAGE BIN
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8
GASKET FAILURE DIAGNOSIS, ENGINE
CYLINDER HEAD. . . . . . . . . . . . . . . . . . 9-13,9-73
GASKETS, FORM-IN-PLACE . . . . . . . . . . 9-25,9-86
GAUGE SENDING UNIT, FUEL . . 14-10,14-16,14-3
GAUGES, PRESSURE . . . . . . . . . . . . . . . . . . . 22-3
GEAR AND CLUTCH, OVERDRIVE
PLANETARY . . . . . . . . . . . . . . . . . . . . . . . . 21-301
GEAR AND NO. 1 ONEWAY CLUTCH,
SUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-324
GEAR BACKLASH, 181 FBI DIFFERENTIAL
BEARING PRELOAD. . . . . . . . . . . . . . . . . . . . 3-52
GEAR BACKLASH, 186 FBI DIFFERENTIAL
BEARING PRELOAD. . . . . . . . . . . . . . . . . . . . 3-56
GEAR BACKLASH, DIFFERENTIAL
BEARING PRELOAD. . . . . . . . . . . . . . . 3-127,3-94
GEAR CLEARANCE, SIDE . . . . . . . . . . . . . . . 3-129
GEAR CONTACT PATTERN ANALYSIS . 3-129,3-59,
3-97
GEAR DEPTH, 181 FBI PINION . . . . . . . . . . . 3-48
GEAR DEPTH, 186 FBI PINION . . . . . . . . . . . 3-50
GEAR DEPTH, 8 1/4 AXLE PINION . . . . . . . 3-126
GEAR DEPTH, PINION . . . . . . . . . . . . . . . . . . 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, RING . . . . . . . . . . . . . . . . 3-116,3-45,3-80
GEAR, SEMI-SYNCHRONIZED REVERSE
IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-36
GEAR, SPEED SENSOR ROTOR-
SPEEDOMETER DRIVE . . . . . . . . . . . . . . . 21-254
GEAR, STEERING . . . . . . . . . . . . . . . 19-12,19-19
GEARSET, PLANETARY . . . . . . . . . . . . . . . 21-122
GEARSHIFT CABLE . . . . . . 21-128,21-150,21-197,
21-246,21-256,21-336
GEARSHIFT MECHANISM . . . . . . . . . . . . . 21-124
GEARTRAIN, SHIFT MECHANISM . . . . . . . . 21-17
GEARTRAIN/OUTPUT SHAFT,
PLANETARY . . . . . . . . . . . . . . . . . . 21-185,21-197
GENERAL DIAGNOSIS INFORMATION . . . . 21-239
GENERAL INFORMATION . . . . . . 3-106,3-19,3-67
GENERAL INFORMATION, 8W-01 . . . . . . . . . 8W-1
GENERATOR . . . . . . . . . . . . . . . . . . . . . 8C-1,8C-3
GENERATOR RATINGS . . . . . . . . . . . . . . . . . 8C-5
GLASS EXTERIOR MOLDING, FRONT
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
GLASS EXTERIOR MOLDING, REAR
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
GLASS, FRONT DOOR . . . . . . . . . . . . . . . . . 23-41
GLASS HEATING GRID, REAR . . . . . . . 8N-2,8N-4
GLASS HEATING GRID REPAIR, REAR . . . . . 8N-6
GLASS, LIFTGATE . . . . . . . . . . . . . . . . . . . . 23-11
GLASS, REAR DOOR STATIONARY
WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9
GLASS, REAR DOOR WINDOW . . . . . . . . . . 23-47
GLASS, REAR QUARTER WINDOW . . . . . . . 23-10
GLASS RUN CHANNEL WEATHERSTRIP,
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-38
GLASS RUN CHANNEL WEATHERSTRIP,
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . 23-46
GLASS, STATIONARY . . . . . . . . . . . . . . . . . . 23-6
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . 8E-22
GLOVE BOX COMPONENTS . . . . . . . . . . . . . 8E-23
GLOVE BOX LATCH STRIKER . . . . . . . . . . . 8E-24
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . 21-124
GOVERNOR AND PARK GEAR . . . 21-153,21-154,
21-191
GRID, OUTSIDE MIRROR HEATING . . . . . . . 8N-2
GRID, REAR GLASS HEATING . . . . . . . 8N-2,8N-4
GRID REPAIR, REAR GLASS HEATING . . . . . 8N-6
GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-24
GRILLE, AIR EXHAUST . . . . . . . . . . . . . . . . 23-50
GRILLE, COWL . . . . . . . . . . . . . . . . . . . . . . 23-28
GRILLE OPENING PANEL (GOP) . . . . . . . . . 23-24
GROUND DISTRIBUTION, 8W-15 . . . . . . . . . 8W-1
GROUNDS, POWER . . . . . . . . . . . . . . . . . . . 14-33
G-SWITCH . . . . . . . . . . . . . . . . . . . . . . . 5-35,5-38
GUIDE AND SEAL, VALVE . . . . . . . . . . . . . . . 9-15
GUIDE, VALVE . . . . . . . . . . . . . . . . . . . . . 9-67,9-7
HANDLE ACTUATOR, FRONT DOOR
INSIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
HANDLE ACTUATOR, REAR DOOR
INSIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
HANDLE, ASSIST . . . . . . . . . . . . . . . . . . . . . 23-52
HANDLE, FRONT DOOR OUTSIDE . . . . . . . . 23-35
HANDLE, LIFTGATE OUTSIDE . . . . . . . . . . . 23-63
HANDLE, REAR DOOR OUTSIDE . . . . . . . . . 23-44
HARD SHIFTING . . . . . . . . . . . . . . . . . 21-3,21-44
HARNESS ADAPTER SEAL, SOLENOID . . . 21-261
HAZARD WARNING SWITCH, TURN
SIGNAL SWITCH . . . . . . . . . . . . . . 8J -2,8J -5,8J -6
HAZARD WARNING SYSTEM . . . . . . . . . . . . . 8J -1
HAZARD WARNING SYSTEMS, TURN
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -4
HEAD COVER, CYLINDER . . . 9-113,9-35,9-67,9-7,
9-96
HEAD, CYLINDER . 9-113,9-38,9-40,9-5,9-65,9-98
HEAD, ENGINE CYLINDER . . . . . . . . . . . . . . . 9-54
HEAD GASKET FAILURE DIAGNOSIS,
ENGINE CYLINDER . . . . . . . . . . . . . . . . 9-13,9-73
HEAD RESTRAINT COVER . . . . . . . . . . . . . . 23-14
HEAD RESTRAINT SLEEVE . . . . . . . . . . . . . 23-13
HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8L-14
HEADLAMP ADJ USTMENT . . . . . . . . . . . . . . 8L-6
HEADLAMP ALIGNMENT . . . . . . . . . . . . 8L-6,8L-9
HEADLAMP ALIGNMENT, VEHICLE
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 8L-6
HEADLAMP BULB . . . . . . . . . . . . . . . . . . . . 8L-10
HEADLAMP DELAY MODULE, SENTINEL . . . 8L-19
HEADLAMP SWITCH; CHIME/BUZZER
HEADLAMP SWITCH; INSTRUMENT
PANEL SYSTEMS. . . . . . . . . . . . . . . . . . . . . 8E-17
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . 23-60
HEAT INTERFACE MODULE, SEAT . . . 8N-12,8N-9
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . 11-8
HEATED SEAT ELEMENT AND SENSOR . . . 8N-11,
8N-9
HEATED SEAT RELAY . . . . . . . . 8N-11,8N-12,8N-9
HEATED SEAT SWITCH . . . . . . 8N-10,8N-12,8N-8
HEATED SEAT SYSTEM . . . . . . . . . . . . 8N-8,8N-9
HEATER AND AIR CONDITIONER . . . . . . . . . 24-5
HEATER AND AIR CONDITIONER
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-6
HEATER, BLOCK . . . . . . . . . . . . . . . . . . . 7-35,7-4
HEATER CORE . . . . . . . . . . . . . . . . . . . 24-41,24-6
HEATER PERFORMANCE . . . . . . . . . . . . . . . 24-16
HEATER-A/C CONTROL . . . . . . . . . . . . . . . . 24-35
HEATER-A/C HOUSING . . . . . . . . . . . . . . . . 24-36
HEATER-A/C HOUSING DOOR . . . . . . . . . . . 24-39
HEATING GRID, OUTSIDE MIRROR . . . . . . . 8N-2
HEATING GRID, REAR GLASS . . . . . . . 8N-2,8N-4
HEATING GRID REPAIR, REAR GLASS . . . . . 8N-6
HIGH AND LOW LIMITS . . . . . . . . . . . . . . . 25-22
HIGH MOUNTED STOP LAMP (CHMSL)
BULB, CENTER . . . . . . . . . . . . . . . . . . . . . . 8L-12
HIGH MOUNTED STOP LAMP (CHMSL),
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
HIGH PRESSURE CUT-OFF SWITCH . . . . . . . 24-6
HIGH PRESSURE RELIEF VALVE . . . . . . . . . . 24-7
HIGH PRESSURE SWITCH (4.0 L), DUAL
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-4
HIGH PRESSURE SWITCH/HIGH
PRESSURE CUT-OFF SWITCH, DUAL
FUNCTION . . . . . . . . . . . . . . . . . . . . . 24-16,24-33
HIGH SPEED, TIRE PRESSURE . . . . . . . . . . . 22-3
HINGE, FRONT DOOR . . . . . . . . . . . . . . . . . 23-35
HINGE, HOOD . . . . . . . . . . . . . . . . . . . . . . . 23-26
HINGE, LIFTGATE . . . . . . . . . . . . . . . . . . . . . 23-62
HINGE, REAR DOOR . . . . . . . . . . . . . . . . . . 23-43
HITCH, TRAILER . . . . . . . . . . . . . . . . . . . . . . 13-7
HOISTING, J UMP STARTING, TOWING . . . . . . 0-9
HOISTING RECOMMENDATIONS . . . . . . . . . . 0-11
HOLD DOWNS, BATTERY . . . . . . . . . . 8A-20,8A-4
HOLE REPAIR, THREADED . . . . . . . . . . . . Intro.-3
6 INDEX XJ
HONING CYLINDER BORES . . . . . . . . . . 9-26,9-87
HOOD . . . . . . . . . . . . . . . . . . . . . . . . 23-24,23-65
HOOD HINGE . . . . . . . . . . . . . . . . . . . . . . . . 23-26
HOOD LATCH . . . . . . . . . . . . . . . . . . . . . . . . 23-26
HOOD LATCH STRIKER . . . . . . . . . . . . . . . . 23-26
HOOD RELEASE CABLE . . . . . . . . . . . . . . . . 23-27
HOOD SAFETY LATCH . . . . . . . . . . . . . . . . . 23-27
HOOD SILENCER PAD . . . . . . . . . . . . . . . . . 23-27
HOOK, FRONT TOW . . . . . . . . . . . . . . . . . . . . 13-3
HOOK, REAR TOW . . . . . . . . . . . . . . . . . . . . . 13-5
HOOKS, EMERGENCY TOW . . . . . . . . . . . . . . 0-11
HORN . . . . . . . . . . . . . . . . . . . . . . 8G-1,8G-4,8G-5
HORN RELAY . . . . . . . . . . . . . . . . 8G-2,8G-3,8G-4
HORN SWITCH . . . . . . . . . . . . . . . . . . . 8G-2,8G-4
HORN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 8G-1
HORN/CIGAR LIGHTER/POWER OUTLET,
8W-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . 7-6
HOSES AND LINES, BRAKE . . . . . . . . . . . . . . . 5-7
HOSES, BRAKE LINE . . . . . . . . . . . . . . . . . . . 5-12
HOSES, COOLING SYSTEM . . . . . . . . . . . . . . 7-40
HOUSING, ADAPTER . . . . . . . . . . . . . . . . . 21-147
HOUSING AND FRONT BEARING
RETAINER, ADAPTER/EXTENSION. . . . . . . . . 21-8
HOUSING AND PARK LOCK, EXTENSION . 21-191
HOUSING BUSHING, EXTENSION . . . . . . . 21-147
HOUSING, CLUTCH . . . . . . . . . . . . . . . . . . . . 6-13
HOUSING DOOR, HEATER-A/C . . . . . . . . . . 24-39
HOUSING END PLUG . . . . . . . . . . . . . . . . . . 19-12
HOUSING FLUID LEAK DIAGNOSIS,
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-132
HOUSING, HEATER-A/C . . . . . . . . . . . . . . . . 24-36
HOUSING MISALIGNMENT, CLUTCH . . . . . . . . 6-6
HOUSING SEAL, ADAPTER . . . . . . . . 21-252,21-7
HOUSING SEAL, EXTENSION . . . . . . . . . . . . . 21-7
HOUSING YOKE BUSHING, REAR . . . . . . . . 21-48
HUB BEARING . . . . . . . . . . . . . . . . . . . . . . . . 2-12
HUB BEARING AND AXLE SHAFT . . . . . . . . . 3-30
HUB/BEARING . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
HYDRAULIC CLUTCH LINKAGE . . . . . . . . . . . . 6-4
HYDRAULIC CONTROL UNIT . . . . . . . . . . . . . 5-34
HYDRAULIC CONTROL UNIT/
CONTROLLER ANTILOCK BRAKE . . . . . . . . . 5-39
HYDRAULIC CONTROL UNIT/
CONTROLLER ANTILOCK BRAKES . . . . . . . . 5-36
HYDRAULIC LINKAGE, CLUTCH . . . . . . . . . . 6-13
HYDRAULIC PRESSURE TEST . . . . 21-129,21-241
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . 21-201
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . 21-237
HYDRAULIC TAPPET . . . . . . . . . . . . . . . . 9-67,9-7
HYDRAULIC TAPPETS . . . . . . . . 9-100,9-113,9-40
HYDROSTATIC LOCK . . . . . . . . . . . . . . . 9-27,9-88
IDENTIFICATION, FASTENER . . . . . . . . . . . Intro.-3
IDENTIFICATION NUMBER, VEHICLE . . . . Intro.-1
IDENTIFICATION, SECTION . . . . . . . . . . . . . . 8W-5
IDLE AIR CONTROL (IAC) MOTOR . . . . . . . 14-45
IDLE AIR CONTROL (IAC) MOTORPCM
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
IDLE SWITCHPCM INPUT, EXTENDED . . . 14-30
IDLER GEAR, SEMI-SYNCHRONIZED
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-36
IGNITION CIRCUIT SENSEPCM INPUT . . 14-31
IGNITION COIL RESISTANCE2.5L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
IGNITION COIL RESISTANCE4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
IGNITION COIL-2.5L ENGINE . . . . . . . . . . . . 8D-3
IGNITION COIL2.5L ENGINE . . . . . . . . . . 8D-12
IGNITION COIL4.0L ENGINE . . . . . . 8D-12,8D-3
IGNITION SWITCH AND KEY CYLINDER . . . 8D-20
IGNITION SWITCH AND KEY LOCK
CYLINDER . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9
IGNITION SWITCH, KEY-IN . . . . . . . . . . 8U-2,8U-3
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . 8D-1
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . 8D-23
IGNITION-OFF DRAW FUSE; AUDIO
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1
IGNITION-OFF DRAW FUSE; POWER
IMMOBILIZER MODULE, SENTRY KEY . 8Q-1,8Q-4
IMMOBILIZER SYSTEM INDICATOR
LAMP, SENTRY KEY . . . . . . . . . . . . . . . . . . . 8Q-3
IMMOBILIZER SYSTEM, SENTRY KEY . 8Q-1,8Q-3
IMMOBILIZER SYSTEM TRANSPONDER
PROGRAMMING, SENTRY KEY . . . . . . . . . . . 8Q-4
IMMOBILIZER TRANSPONDER, SENTRY
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-2
ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
INCH AXLE, 8 1/4 . . . . . . . . . . . . . . . . . . . . 3-131
INCORRECT FLUID LEVEL, EFFECTS OF . . 21-126,
21-239
INDEX, 8W-02 COMPONENT . . . . . . . . . . . . 8W-1
INDICATOR LAMP (MIL), MALFUNCTION . . . 25-2
INDICATOR LAMP, SENTRY KEY
IMMOBILIZER SYSTEM. . . . . . . . . . . . . . . . . 8Q-3
INDICATORS, TREAD WEAR . . . . . . . . . . . . . 22-3
INFLATION PRESSURES, TIRE . . . . . . . . . . . 22-2
INITIAL OPERATION, POWER STEERING
PUMP - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7
INJ ECTION SYSTEM, FUEL . . . . . . . . . . . . . 14-25
INJ ECTOR RAIL/FUEL DAMPER2.5L
ENGINE, FUEL . . . . . . . . . . . . . . . . . . . 14-16,14-5
INJ ECTOR RAIL/FUEL DAMPER4.0L
ENGINE, FUEL . . . . . . . . . . . . . . . . . . . . . . . 14-17
INJ ECTOR TEST, FUEL . . . . . . . . . . . . . . . . . 14-10
INJ ECTORS, FUEL . . . . . . . . . . . . . . . . 14-19,14-4
INJ ECTORSPCM OUTPUT, FUEL . . . . . . . 14-35
INLET FILTER, FUEL PUMP . . . . . . . . . . . . . 14-15
INNER BELT WEATHERSTRIP, FRONT
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
INNER BELT WEATHERSTRIP, REAR
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
INNER SCUFF PLATE, FRONT . . . . . . . . . . . 23-52
INPUT AND OUTPUT, DATA LINK
CONNECTORPCM. . . . . . . . . . . . . . . . . . . 14-35
INPUT ANGLE, FRONT AXLE PINION . . . . . . . . 3-15
INPUT ANGLE, REAR AXLE PINION . . . . . . . 3-15
INPUT, AUTOMATIC SHUTDOWN (ASD)
RELAY SENSEPCM . . . . . . . . . . . . . . . . . 14-29
INPUT, BATTERY VOLTAGEPCM . . . . . . . . 14-29
INPUT, BRAKE SWITCHPCM . . . . . . . . . . 14-29
INPUT, ENGINE COOLANT
TEMPERATURE SENSORPCM . . . . . . . . . 14-30
INPUT, EXTENDED IDLE SWITCHPCM . . . 14-30
INPUT, FUEL LEVEL SENSORPCM . . . . . . 14-30
INPUT, IGNITION CIRCUIT SENSEPCM . . 14-31
INPUT, INTAKE MANIFOLD AIR
TEMPERATURE SENSORPCM . . . . . . . . . 14-32
INPUT, MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSORPCM . . . . . . . 14-32
INPUT, OIL PRESSURE SENSORPCM . . . 14-33
INPUT, OXYGEN SENSORPCM . . . . . . . . . 14-30
INPUT, POWER STEERING PRESSURE
SWITCHPCM . . . . . . . . . . . . . . . . . . . . . . 14-33
INPUT, SENSOR RETURNPCM . . . . . . . . . 14-34
INPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . . 21-30
INPUT, THROTTLE POSITION SENSOR
(TPS)PCM . . . . . . . . . . . . . . . . . . . . . . . . 14-34
INPUT, VEHICLE SPEED AND DISTANCE
SENSORPCM . . . . . . . . . . . . . . . . . . . . . . 14-34
INSIDE HANDLE ACTUATOR, FRONT
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
INSIDE HANDLE ACTUATOR, REAR
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
INSPECTION AND ADJ USTMENT,
PRELIMINARY . . . . . . . . . . . . . . . . . . . . . . 21-241
INSPECTION, ENGINE OIL LEAK . . . . . . 9-14,9-74
INSPECTION, TORQUE CONVERTER
STATOR CLUTCH . . . . . . . . . . . . . . . . . . . . 21-247
INSPECTION, TRANSMISSION PARTS
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 21-336
INSPECTION, UNSCHEDULED . . . . . . . . . . . . . 0-4
INSPECTION, VISUAL . . . . . . . . . . . . . . . . . 14-37
INSPECTION, WHEEL . . . . . . . . . . . . . . . . . . 22-7
USAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
INSTALLATION, WHEEL . . . . . . . . . . . . . . . . . 22-8
INSTRUMENT CLUSTER; CHIME/BUZZER
INSTRUMENT CLUSTER; ELECTRICALLY
HEATED SYSTEMS . . . . . . . . . . . . . . . . 8N-2,8N-5
INSTRUMENT CLUSTER; INSTRUMENT
PANEL SYSTEMS . . . . . . . . . . . . 8E-18,8E-2,8E-5
INSTRUMENT CLUSTER, 8W-40 . . . . . . . . . 8W-1
INSTRUMENT CLUSTER COMPONENTS . . . 8E-19
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-1
INSTRUMENT PANEL ACCESSORY
SWITCH BEZEL . . . . . . . . . . . . . . . . . . . . . . 8E-15
INSTRUMENT PANEL ASSEMBLY . . . . . . . . 8E-26
INSTRUMENT PANEL CENTER BEZEL . . . . . 8E-14
INSTRUMENT PANEL CENTER SUPPORT
BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-26
INSTRUMENT PANEL CIGAR LIGHTER . . . . 8E-11,
8E-3
INSTRUMENT PANEL END CAP . . . . . . . . . . 8E-25
INSTRUMENT PANEL POWER OUTLET . . . 8E-12,
8E-4
INSTRUMENT PANEL SYSTEM . . . . . . . . . . . 8E-1
INSTRUMENT PANEL TOP COVER . . . . . . . 8E-21
INTAKE AND EXHAUST MANIFOLD . . . . . . . . 9-95
INTAKE MANIFOLD . . . . . . . . . . . . . 9-33,9-67,9-8
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50
SENSORPCM INPUT . . . . . . . . . . . . . . . . 14-32
INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . 9-13,
9-72
INTERFACE MODULE, SEAT HEAT . . . 8N-12,8N-9
INTERFERENCE, RADIO FREQUENCY . . . . . . 8F-6
INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . 8L-20
INTERIOR LIGHTING, 8W-44 . . . . . . . . . . . . 8W-1
INTERLOCK, BRAKE TRANSMISSION
SHIFT. . . . . . . . . . . . . . . . . . . . . . . 21-150,21-256
INTERLOCK CABLE ADJ USTMENT,
BRAKE TRANSMISSION SHIFT . . . 21-198,21-336
INTERLOCK MECHANISM, BRAKE
TRANSMISSION SHIFT . . . . . . . . . 21-125,21-238
INTERLOCK, SHIFTER/IGNITION . . . . . . . . . 8D-22
INTERMITTENT AND POOR
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 8W-8
INTERNATIONAL SYMBOLS;
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . Intro.-2
INTERNATIONAL SYMBOLS;
LUBRICATION AND MAINTENANCE. . . . . . . . . 0-1
INTRODUCTION; AUDIO SYSTEMS . . . . . . . . 8F-1
INTRODUCTION; CHIME/BUZZER
WARNING SYSTEMS. . . . . . . . . . . . . . . . . . . 8U-1
INTRODUCTION; ELECTRICALLY HEATED
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . 8N-1,8N-8
INTRODUCTION; OVERHEAD CONSOLE
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-1
INTRODUCTION; POWER LOCK
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-1
INTRODUCTION; POWER MIRROR
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-1
INTRODUCTION; POWER SEAT SYSTEMS . . 8R-1
INTRODUCTION; POWER WINDOW
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-1
INTRODUCTION; VEHICLE THEFT/
SECURITY SYSTEMS . . . . . . . . . . . . . . . . . . 8Q-1
INTRODUCTION; WIPER AND WASHER
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-1
INTRODUCTION; WIRING DIAGRAMS . . . . . 8W-1
ISOLATORS, COIL SPRINGS . . . . . . . . . . 2-16,2-8
J AMB SWITCH, DRIVER DOOR . . . . . . . . . . . 8U-2
J OINT ANGLE, PROPELLER SHAFT . . . . . . . . . 3-3
J OINT, DOUBLE CARDAN . . . . . . . . . . . . . . . 3-11
J OINT, SINGLE CARDAN UNIVERSAL . . . . . . . 3-9
J OINTS, PROPELLER SHAFT . . . . . . . . . . . . . . 3-2
J OUNCE BUMPER . . . . . . . . . . . . . . . . . . . . . . 2-7
J OUNCE BUMPERS . . . . . . . . . . . . . . . . . . . . 2-16
J UMP STARTING PROCEDURE . . . . . . . . . . . . 0-9
J UMP STARTING, TOWING AND
HOISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
J UNCTION BLOCK . . . . . . . . . . . . . . . . 8O-3,8O-6
J UNCTION BLOCK, 8W-12 . . . . . . . . . . . . . . 8W-1
KEY CYLINDER, IGNITION SWITCH . . . . . . 8D-20
KEY IMMOBILIZER MODULE, SENTRY . 8Q-1,8Q-4
KEY IMMOBILIZER SYSTEM INDICATOR
LAMP, SENTRY . . . . . . . . . . . . . . . . . . . . . . . 8Q-3
KEY IMMOBILIZER SYSTEM, SENTRY . 8Q-1,8Q-3
KEY IMMOBILIZER SYSTEM
TRANSPONDER PROGRAMMING,
SENTRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-4
KEY IMMOBILIZER TRANSPONDER,
SENTRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Q-2
KEY LOCK CYLINDER, IGNITION SWITCH . . 8D-5,
8D-9
KEY-IN IGNITION SWITCH . . . . . . . . . . 8U-2,8U-3
KEYLESS ENTRY RECEIVER
PROGRAMMING, REMOTE . . . . . . . . . . . . . . 8P-6
KEYLESS ENTRY RECEIVER, REMOTE . 8P-2,8P-5,
8P-8
KEYLESS ENTRY SYSTEM, POWER LOCK
SYSTEM AND REMOTE . . . . . . . . . . . . . . . . . 8P-3
KEYLESS ENTRY SYSTEM, REMOTE . . . . . . 8P-1
KEYLESS ENTRY TRANSMITTER
BATTERY REPLACEMENT, REMOTE . . . . . . . 8P-6
KEYLESS ENTRY TRANSMITTER
PROGRAMMING, REMOTE . . . . . . . . . . . . . . 8P-6
KEYLESS ENTRY TRANSMITTER,
REMOTE . . . . . . . . . . . . . . . . . . . . . . . . 8P-2,8P-5
XJ INDEX 7
KICK COVER . . . . . . . . . . . . . . . . . . . . . . . . 24-42
KNEE BLOCKER . . . . . . . . . . . . . . . . . . . . . . 8E-14
KNOCK, LOW SPEED . . . . . . . . . . 3-109,3-21,3-70
KNUCKLE AND BALL STUDS, STEERING . . . 3-31
KNUCKLE, STEERING . . . . . . . . . . . . . . . . . . 2-10
LABEL, VEHICLE EMISSION CONTROL
INFORMATION (VECI) . . . . . . . . . . . . . . . . . 25-26
LABEL, VEHICLE SAFETY CERTIFICATION . Intro.-2
LAG TEST ANALYSIS, TIME . . . . . . . . . . . . 21-243
LAG TEST, TIME . . . . . . . . . . . . . . . . . . . . 21-242
LAMP, ABS WARNING . . . . . . . . . . . . . . . . . . 5-35
LAMP ADJ USTMENT, FOG . . . . . . . . . . . . . . . 8L-8
LAMP ALIGNMENT SCREEN
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 8L-6
LAMP, BACK-UP/BRAKE/REAR TURN
SIGNAL/TAIL . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
LAMP BULB, BACK-UP/BRAKE/REAR
TURN SIGNAL/TAIL . . . . . . . . . . . . . . . . . . . 8L-11
LAMP BULB, CARGO . . . . . . . . . . . . . . . . . . 8L-13
LAMP BULB, FOG . . . . . . . . . . . . . . . . . . . . 8L-10
LAMP BULB, FRONT PARK/TURN
SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11
LAMP BULB, LICENSE PLATE . . . . . . . . . . . 8L-12
LAMP BULB, MAP READING . . . . . . . . . . . . 8L-13
LAMP BULB, READING AND COURTESY . . . 8V-8
LAMP BULB SERVICE . . . . . . . . . . . . . . . . . 8L-10
LAMP BULB, SIDE MARKER . . . . . . . . . . . . 8L-11
LAMP BULB, UNDERHOOD . . . . . . . . . . . . . . 8L-12
LAMP BULB, VISOR VANITY . . . . . . . . . . . . 8L-13
LAMP, CARGO . . . . . . . . . . . . . . . . . . . . . . . 8L-17
LAMP (CHMSL) BULB, CENTER HIGH
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-12
LAMP (CHMSL), CENTER HIGH
MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-16
LAMP DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 8L-3
LAMP, FOG . . . . . . . . . . . . . . . . . . . . . . . . . 8L-15
LAMP, FRONT PARK/TURN SIGNAL . . . . . . 8L-15
LAMP, LICENSE PLATE . . . . . . . . . . . . . . . . 8L-16
LAMP, MAP/READING . . . . . . . . . . . . . . . . . 8L-17
LAMP (MIL), MALFUNCTION INDICATOR . . . 25-2
LAMP MODULE, DAYTIME RUNNING . . . . . 8L-19
LAMP, READING AND COURTESY . . . . . . . . . 8V-2
LAMP, RED BRAKE WARNING . . . . . . . . . 5-3,5-9
LAMP, SENTRY KEY IMMOBILIZER
SYSTEM INDICATOR . . . . . . . . . . . . . . . . . . . 8Q-3
LAMP SERVICE . . . . . . . . . . . . . . . . . . . . . . 8L-14
LAMP, SIDE MARKER . . . . . . . . . . . . . . . . . 8L-15
LAMP SWITCH, BRAKE; BRAKES . . 5-15,5-2,5-30,
5-9
LAMP SWITCH, BRAKE; SPEED
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-3
LAMP SYSTEMS . . . . . . . . . . . . . . . . . 8L-1,8L-19
LAMP, UNDERHOOD . . . . . . . . . . . . . . . . . . 8L-16
LAMP, VISOR VANITY . . . . . . . . . . . . . . . . . 8L-18
LAMPS, EXTERIOR . . . . . . . . . . . . . . . . . . . 8L-20
LAMPS, INTERIOR . . . . . . . . . . . . . . . . . . . . 8L-20
LATCH ADJ USTMENT, DOOR . . . . . . . . . . . . 23-66
LATCH, FRONT DOOR . . . . . . . . . . . . . . . . . 23-37
LATCH, HOOD . . . . . . . . . . . . . . . . . . . . . . . 23-26
LATCH, HOOD SAFETY . . . . . . . . . . . . . . . . 23-27
LATCH, LIFTGATE . . . . . . . . . . . . . . . . . . . . 23-64
LATCH, REAR DOOR . . . . . . . . . . . . . . . . . . 23-44
LATCH STRIKER AND BUMPER, REAR
SEATBACK . . . . . . . . . . . . . . . . . . . . . . . . . . 23-19
LATCH STRIKER, FRONT DOOR . . . . . . . . . 23-37
LATCH STRIKER, GLOVE BOX . . . . . . . . . . . 8E-24
LATCH STRIKER, HOOD . . . . . . . . . . . . . . . 23-26
LATCH STRIKER, LIFTGATE . . . . . . . . . . . . . 23-64
LATCH STRIKER, REAR DOOR . . . . . . . . . . 23-45
LATCH STRIKER, SAFETY . . . . . . . . . . . . . . 23-27
LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . 2-18
LEAF SPRING AND SHACKLE BUSHING . . . . 2-18
LEAK DETECTION PUMP (LDP) . . . . 25-24,25-27,
25-28
LEAK DIAGNOSIS, CONVERTER
HOUSING FLUID . . . . . . . . . . . . . . . . . . . . 21-132
LEAK DOWN TEST, FUEL PRESSURE . . . . . . 14-7
LEAK INSPECTION, ENGINE OIL . . . . . . 9-14,9-74
LEAKAGE DIAGNOSIS, INTAKE
MANIFOLD. . . . . . . . . . . . . . . . . . . . . . . 9-13,9-72
LEAKAGE DIAGNOSIS, PUMP . . . . . . . . . . . . 19-7
LEAKAGE, POWER STEERING GEAR . . . . . . 19-11
LEAKAGE TEST, CYLINDER COMBUSTION
PRESSURE . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73
LEAKS, COOLING SYSTEMTESTING . . . . . 7-17
LEAKS, REFRIGERANT SYSTEM . . . . . . . . . 24-17
LEAKS, REPAIRING . . . . . . . . . . . . . . . . . . . . 22-5
LEAKS, WATER . . . . . . . . . . . . . . . . . . . . . . 23-22
LEFT FRONT FENDER . . . . . . . . . . . . . . . . . 23-32
LEVEL AERATION, COOLANTLOW . . . . . . . 7-21
LEVEL, BRAKE FLUID . . . . . . . . . . . . . . . . . . 5-12
LEVEL CHECK, COOLANTROUTINE . . . . . . 7-21
LEVEL CHECK, FLUID . . . . . . . . . . . . . . . . 21-141
LEVEL, CHECKING FLUID . . . . . . . . . . . . . 21-247
LEVEL, CLUTCH FLUID . . . . . . . . . . . . . . . . . 6-10
LEVEL, EFFECTS OF INCORRECT FLUID . . 21-126,
21-239
LEVEL, LOW LUBRICANT . . . . . . . . . . 21-3,21-44
LEVEL, LUBRICANT AND FILL . . . . 21-347,21-376
LEVEL, REFRIGERANT OIL . . . . . . . . . . . . . 24-19
LEVEL SENSOR, WASHER FLUID . . . . . . . . . 8K-4
LEVEL SENSORPCM INPUT, FUEL . . . . . . 14-30
LEVER, PARKING BRAKE . . . . . . . . . . . . . . . 5-23
LEVER POSITIONS, TRANSMISSION
RANGES AND SHIFT . . . . . . . . . . . . . . . . . 21-236
LEVER, SHIFT . . . . . . . . . . . . . . . . 21-349,21-377
LICENSE PLATE LAMP . . . . . . . . . . . . . . . . 8L-16
LICENSE PLATE LAMP BULB . . . . . . . . . . . 8L-12
LIFTGATE . . . . . . . . . . . . . . . . . . . . . . 23-62,23-67
LIFTGATE GLASS . . . . . . . . . . . . . . . . . . . . . 23-11
LIFTGATE HINGE . . . . . . . . . . . . . . . . . . . . . 23-62
LIFTGATE LATCH . . . . . . . . . . . . . . . . . . . . . 23-64
LIFTGATE LATCH STRIKER . . . . . . . . . . . . . 23-64
LIFTGATE LOCK CYLINDER . . . . . . . . . . . . . 23-64
LIFTGATE OPENING UPPER TRIM . . . . . . . . 23-55
LIFTGATE OUTSIDE HANDLE . . . . . . . . . . . . 23-63
LIFTGATE PILLAR TRIM . . . . . . . . . . . . . . . 23-55
LIFTGATE SCUFF PLATE . . . . . . . . . . . . . . . 23-55
LIFTGATE SUPPORT ROD BALL STUD . . . . 23-63
LIFTGATE SUPPORT ROD CYLINDER . . . . . 23-63
LIFTGATE TRIM PANEL . . . . . . . . . . . . . . . . 23-61
LIFTGATE WEATHERSTRIP . . . . . . . . . . . . . 23-65
LIGHTER, INSTRUMENT PANEL CIGAR . . . 8E-11,
8E-3
LIGHTER RELAY, CIGAR . . . . . . 8E-12,8E-16,8E-4
LIGHTER/POWER OUTLET, 8W-41
HORN/CIGAR . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
LIGHTING, 8W-44 INTERIOR . . . . . . . . . . . . 8W-1
LIGHTING, 8W-50 FRONT . . . . . . . . . . . . . . 8W-1
LIGHTING, 8W-51 REAR . . . . . . . . . . . . . . . 8W-1
LIMITS, HIGH AND LOW . . . . . . . . . . . . . . . 25-22
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 . . . . . . . . 24-45
LINER, FRONT WHEELHOUSE . . . . . . . . . . . 23-32
LINES, BRAKE HOSES . . . . . . . . . . . . . . . . . . . 5-7
LINES, REFRIGERANT . . . . . . . . . . . . . . . . . . 24-7
LINK CONNECTORPCM INPUT AND
OUTPUT, DATA. . . . . . . . . . . . . . . . . . . . . . . 14-35
LINK, DRAG . . . . . . . . . . . . . . . . . . . . . . . . . 19-24
LINKAGE ADJ USTMENT, SHIFT . . . 21-372,21-405
LINKAGE AND PIVOT, WIPER . . . . . . . . 8K-2,8K-9
LINKAGE, CLUTCH HYDRAULIC . . . . . . . . . . 6-13
LINKAGE FLUID, CLUTCH . . . . . . . . . . . . . . . . 6-9
LINKAGE, HYDRAULIC CLUTCH . . . . . . . . . . . 6-4
LINKAGE, STEERING . . . . . . . . 19-22,19-23,19-25
LIQUID LINE . . . . . . . . . . . . . . . . . . . . . . . . 24-41
LOAD VALUE . . . . . . . . . . . . . . . . . . . . . . . . 25-22
LOCATIONS, 8W-90 CONNECTOR . . . . . . . . 8W-1
LOCATIONS, 8W-95 SPLICE . . . . . . . . . . . . . 8W-1
LOCATIONS, BODY SEALING . . . . . . . . . . . 23-112
LOCATIONS, CONNECTOR/GROUND . . . . . . 8W-1
LOCATIONS, SPLICE . . . . . . . . . . . . . . 8W-1,8W-7
LOCATIONS, STRUCTURAL ADHESIVE . . . 23-124
LOCATIONS, WELD . . . . . . . . . . . . . . . . . . . 23-68
LOCK CYLINDER, FRONT DOOR . . . . . . . . . 23-36
LOCK CYLINDER, IGNITION SWITCH AND
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9
LOCK CYLINDER, LIFTGATE . . . . . . . . . . . . 23-64
LOCK CYLINDERS . . . . . . . . . . . . . . . . . . . . 23-37
LOCK, EXTENSION HOUSING AND PARK . 21-191
LOCK, HYDROSTATIC . . . . . . . . . . . . . . 9-27,9-88
LOCK MOTOR, POWER . . . . . . . . 8P-2,8P-4,8P-7
LOCK, PARK . . . . . . . . . . . . . . . . . . . . . . . 21-154
LOCK SWITCH, POWER . . . . . . . . . . . . . . . . 8P-2
LOCK SYSTEM AND REMOTE KEYLESS
ENTRY SYSTEM, POWER . . . . . . . . . . . . . . . 8P-3
LOCK SYSTEM, POWER . . . . . . . . . . . . . . . . 8P-1
LOCKS, 8W-61 POWER DOOR . . . . . . . . . . . 8W-1
LOW LIMITS, HIGH . . . . . . . . . . . . . . . . . . . 25-22
LOW LUBRICANT LEVEL . . . . . . . . . . . 21-3,21-44
LOW PRESSURE CYCLING CLUTCH
SWITCH. . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7
LOW SPEED KNOCK . . . . . . . . . . 3-109,3-21,3-70
LOWER A-PILLAR COWL TRIM . . . . . . . . . . 23-51
LOWER SUSPENSION ARM . . . . . . . . . . . . . . 2-10
LOWER SUSPENSION ARMS AND
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
LUBRICANT; DIFFERENTIAL AND
DRIVELINE . . . . . . . . . . . . . . . . . 3-104,3-17,3-66
LUBRICANT; TRANSMISSION AND
TRANSFER CASE . . . . . . . . . . . . . . . . . 21-2,21-43
LUBRICANT AND FILL LEVEL . . . . 21-347,21-376
LUBRICANT CHANGE . . . . . . . . . 3-110,3-21,3-71
LUBRICANT LEVEL, LOW . . . . . . . . . . 21-3,21-44
LUBRICANT RECOMMENDATIONS,
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
LUBRICANTS, BODY . . . . . . . . . . . . . . . . . . 23-67
LUBRICANTS, CLASSIFICATION OF . . . . . . . . . 0-1
LUBRICATION, BODY . . . . . . . . . . . . . . . . . . 23-23
LUBRICATION, CLUTCH COMPONENT . . . . . . . 6-9
LUBRICATION SYSTEM . . . . . . . . . . . . . . 9-2,9-62
LUGGAGE RACK . . . . . . . . . . . . . . . . . . . . . 23-50
MACHINING, BRAKE DRUM . . . . . . . . . . . . . 5-14
MACHINING, DISC ROTOR . . . . . . . . . . . . . . 5-13
MAIN BEARINGS, CRANKSHAFT . . . . . 9-105,9-47
MAIN BEARINGS, FITTING CRANKSHAFT . . 9-23,
9-83
MAIN COOLER, FLOW TESTING
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-246
MAIN OIL SEAL, REAR . . . . . . . . . . . . . . . . . 9-52
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . 0-4
MALFUNCTION INDICATOR LAMP (MIL) . . . . 25-2
MANAGER, TASK . . . . . . . . . . . . . . . . . . . . . 25-16
SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
SENSORPCM INPUT . . . . . . . . . . . . . . . . 14-32
MANIFOLD AIR TEMPERATURE SENSOR,
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50
MANIFOLD AIR TEMPERATURE
SENSORPCM INPUT, INTAKE. . . . . . . . . . 14-32
MANIFOLD, EXHAUST . . . . . . . . . . . 9-35,9-68,9-8
MANIFOLD, INTAKE . . . . . . . . . . . . . 9-33,9-67,9-8
MANIFOLD, INTAKE AND EXHAUST . . . . . . . 9-95
MANIFOLD LEAKAGE DIAGNOSIS,
INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . 9-13,9-72
MANIFOLD4.0L ENGINE, EXHAUST . . . . . . 9-96
MANUAL SHIFTING TEST . . . . . . . . . . . . . 21-241
MANUAL TRANSMISSION, AX5 . . . . . . . . . . . 21-1
MANUAL TRANSMISSION COMPONENTS,
AX5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37
MANUAL TRANSMISSION, NV3550 . . 21-42,21-85
MANUAL TRANSMISSION, NV3550
MANUAL TRANSMISSIONNV3550. . . . . . . . 21-42
MANUAL TRANSMISSIONNV3550
MANUAL TRANSMISSION, NV3550. . . . . . . 21-42
MANUAL VALVE SHAFT SEAL . . . . . . . . . . 21-262
MAP READING LAMP BULB . . . . . . . . . . . . 8L-13
MAP/READING LAMP . . . . . . . . . . . . . . . . . 8L-17
MARKER LAMP BULB, SIDE . . . . . . . . . . . . 8L-11
MARKER LAMP, SIDE . . . . . . . . . . . . . . . . . 8L-15
MASTER CYLINDER . . . . . . . . . . . . . . . . 5-16,5-3
MASTER CYLINDER BLEEDING . . . . . . . . . . . 5-12
MASTER CYLINDER RESERVOIR . . . . . . . . . 5-24
MASTER CYLINDER/POWER BOOSTER . . . . . 5-10
MATCH MOUNTING . . . . . . . . . . . . . . . . . . . . 22-4
MEASUREMENT PREPARATION,
DRIVELINE ANGLE . . . . . . . . . . . . . . . . . . . . . 3-6
MEASUREMENT, PROPELLER SHAFT
ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
MEASUREMENTS, BODY GAP AND
FLUSH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-127
MECHANISM AND GEARTRAIN, SHIFT . . . . 21-17
MECHANISM, BRAKE TRANSMISSION
SHIFT INTERLOCK . . . . . . . . . . . . . 21-125,21-238
MECHANISM, GEARSHIFT . . . . . . . . . . . . . 21-124
METHODS AND PARTS USAGE,
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . 6-4
METRIC SYSTEM . . . . . . . . . . . . . . . . . . . Intro.-6
MINIMUM AIR FLOW CHECK
PROCEDURE, THROTTLE BODY . . . . . . . . . 14-42
MIRROR HEATING GRID, OUTSIDE . . . . . . . 8N-2
MIRROR, POWER . . . . . . . . . . . . . . . . . 8T-1,8T-4
MIRROR, REARVIEW . . . . . . . . . . . . . . . . . . 23-59
MIRROR, SIDE VIEW . . . . . . . . . . . . . . . . . . 23-31
MIRROR SUPPORT BRACKET, REARVIEW . 23-59
MIRROR SWITCH, POWER . . . . . . . . . . 8T-1,8T-3
8 INDEX XJ
MIRROR SYSTEM, POWER . . . . . . . . . . 8T-1,8T-2
MIRRORS, 8W-62 POWER . . . . . . . . . . . . . . 8W-1
MISALIGNMENT, CLUTCH . . . . . . . . . . . . . . . . 6-6
MISALIGNMENT, CLUTCH HOUSING . . . . . . . . 6-6
MODE, CIRCUIT ACTUATION TEST . . . . . . . . 25-2
MODE DOOR VACUUM ACTUATOR . . . . . . . 24-43
MODE, STATE DISPLAY TEST . . . . . . . . . . . . 25-2
MODES OF OPERATION . . . . . . . . . . . . . . . . 14-26
MODULE, AIRBAG CONTROL . . . . . . 8M-12,8M-3
MODULE, DAYTIME RUNNING LAMP . . . . . 8L-19
MODULE, DOOR; POWER LOCK
SYSTEMS . . . . . . . . . . . . . . . . . . . 8P-2,8P-3,8P-7
MODULE, DOOR; POWER MIRROR
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . 8T-2,8T-3
MODULE, DOOR; POWER WINDOW
SYSTEMS . . . . . . . . . . . . . . . . . . . 8S-2,8S-3,8S-4
MODULE, DRIVER SIDE AIRBAG . . . . 8M-2,8M-6
MODULE, FUEL PUMP . . . . . . . . . . . . 14-14,14-2
MODULE, PASSENGER SIDE AIRBAG . 8M-3,8M-9
MODULE (PCM), POWERTRAIN
CONTROL . . . . . . . . . . . . . . . . . . . . . 14-25,14-46
MODULE, PUSH BUTTON . . . . . . . . . . . . . . . 8V-7
MODULE, SEAT HEAT INTERFACE . . . 8N-12,8N-9
MODULE, SENTINEL HEADLAMP DELAY . . . 8L-19
MODULE, SENTRY KEY IMMOBILIZER . 8Q-1,8Q-4
MODULE (TCM) SERVICE,
TRANSMISSION CONTROL . . . . . . . . . . . . 21-248
MODULE (TCM), TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 21-237
MODULE, TRANSMISSION CONTROL . . . . 21-260
MODULE TRIM COVER, DRIVER SIDE
AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
MODULE, TRIP COMPUTER, COMPASS,
AND THERMOMETER DISPLAY . . . . . . . 8V-3,8V-7
MOLDING, BODY SIDE . . . . . . . . . . . . . . . . 23-48
MOLDING, DRIP RAIL . . . . . . . . . . . . . . . . . 23-49
MOLDING, FRONT DOOR GLASS
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-39
MOLDING, REAR DOOR GLASS
EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
MONITORED SYSTEMS . . . . . . . . . . . . . . . . 25-19
MONITORS, COMPONENT . . . . . . . . . . . . . . 25-21
MOTOR, BLEND-AIR DOOR . . . . . . . . . . . . . 24-26
MOTOR, BLOWER . . . . . . . . . . . 24-12,24-2,24-26
MOTOR, IDLE AIR CONTROL (IAC) . . . . . . . 14-45
MOTOR NOISE - 2.5L ENGINE, STARTER . . . 8B-8
MOTOR, POWER LOCK . . . . . . . . 8P-2,8P-4,8P-7
MOTOR, POWER WINDOW . . . . . 8S-2,8S-4,8S-6
MOTOR RELAY, BLOWER . . . . . 24-13,24-2,24-27
MOTOR RESISTOR, BLOWER . . 24-14,24-27,24-3
MOTOR, STARTER . . . . . . . . . . . 8B-11,8B-2,8B-9
MOTOR SWITCH, BLOWER . . . . . . . . . 24-14,24-3
MOTOR, WIPER . . . . . . . . . . . . . . . . . . 8K-2,8K-9
MOTORPCM OUTPUT, IDLE AIR
CONTROL (IAC) . . . . . . . . . . . . . . . . . . . . . . 14-35
MOTORS, POWER SEAT ADJ USTER . . 8R-1,8R-2,
8R-3
MOUNTED STOP LAMP (CHMSL) BULB,
CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-12
MOUNTED STOP LAMP (CHMSL),
CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-16
MOUNTING, MATCH . . . . . . . . . . . . . . . . . . . 22-4
MOUNTING STUDS, WHEEL . . . . . . . . . . . . . 2-13
MOUNTREAR, ENGINE . . . . . . . . . . . 9-30,9-91
MOUNTSFRONT, ENGINE . . . . . . . . . . 9-29,9-90
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
MUFFLER AND TAILPIPE . . . . . . . . . . . . . . . . 11-6
NAMEPLATES, EXTERIOR . . . . . . . . . . . . . . 23-30
NECK SEALPRESSURE RELIEF CHECK,
RADIATOR CAP-TO-FILLER . . . . . . . . . . . . . . 7-20
NOISE - 2.5L ENGINE, STARTER MOTOR . . . 8B-8
NOISE, BEARING . . . . . . . . . . . . . 3-109,3-21,3-70
NOISE, GEAR . . . . . . . . . . . . . . . . 3-109,3-21,3-70
NOISE OR VIBRATION, TIRE . . . . . . . . . . . . . 22-3
NOISE SUPPRESSION COMPONENTS,
RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-11
NOISE SUPPRESSION, RADIO . . . . . . . . . . . . 8F-2
NOISE, TRACLOK DIFFERENTIAL . . 3-109,3-70
NOISE, TRANSMISSION . . . . . . . . . . . 21-3,21-44
NOISE, WIND . . . . . . . . . . . . . . . . . . . . . . . . 23-23
NON-MONITORED CIRCUITS . . . . . . . . . . . . 25-22
NOTES, CAUTIONS, AND WARNINGS . . . . . 8W-7
NOZZLE AND PLUMBING, WASHER . . . . . . . 8K-4
NUMBER, VEHICLE IDENTIFICATION . . . . Intro.-1
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-373
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . 21-347
NV231 TRANSFER CASE . . 21-346,21-351,21-369
NV231 TRANSFER CASENV231
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-346
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-406
NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . 21-376
NV242 TRANSFER CASE . . 21-375,21-380,21-402
NV242 TRANSFER CASENV242
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-375
NV3550 MANUAL TRANSMISSION . . 21-42,21-85
NV3550 MANUAL
TRANSMISSIONNV3550 MANUAL
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . 21-42
OIL COOLER, AUTOMATIC
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 7-2
OIL COOLERS, TRANSMISSION . . . . . . . . . . 7-23
OIL LEAK INSPECTION, ENGINE . . . . . . 9-14,9-74
OIL LEVEL, REFRIGERANT . . . . . . . . . . . . . 24-19
OIL PAN . . . . . . . . . . . . . . . . 9-107,9-49,9-67,9-7
OIL PRESSURE, ENGINE . . . . . . . . . . . . 9-15,9-75
OIL PRESSURE SENSORPCM INPUT . . . 14-33
OIL PUMP; ENGINE . . . . . . . . . . . . . . . 9-111,9-50
OIL PUMP; TRANSMISSION AND
TRANSFER CASE . . . . . . . . 21-101,21-227,21-298
OIL PUMP AND REACTION SHAFT
SUPPORT . . . . . . . . . . . . . . . . . . . 21-177,21-195
OIL PUMP SEAL . . . . . . . . . . . . . . . . . . . . 21-268
OIL PUMP VOLUME CHECK . . . . . 21-142,21-248
OIL, REFRIGERANT . . . . . . . . . . . . . . . . . . . . 24-8
OIL SEAL, AXLE SHAFT . . . . . . . . . . . . . . . . . 3-36
OIL SEAL, REAR MAIN. . . . . . . . . . . . . . . . . . . 9-52
OIL SEAL, TIMING CASE COVER . . . . . 9-112,9-41
OIL SEALS, VALVE SPRINGS . . . . . . . . . . . . . 9-97
OIL SEALSREAR, CRANKSHAFT . . . . . . . 9-110
OIL SERVICE, ENGINE . . . . . . . . . . . . . . 9-27,9-88
ON-BOARD DIAGNOSTIC TEST FOR
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . 8C-3
ON-BOARD DIAGNOSTICS . . . . . . . . . . . . . . . 25-1
ON-BOARD DIAGNOSTICS (OBD) . . . . . . . . . . 7-9
ONEWAY CLUTCH, SUN GEAR AND
NO. 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-324
OPENER STORAGE BIN 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 . . . . . . . . . . . . . . . . . . . . . . . 23-39
OPENING UPPER TRIM, LIFTGATE . . . . . . . 23-55
OPENING WEATHERSTRIP, FRONT DOOR . . 23-38
OPERATION, AIR TESTING
TRANSMISSION CLUTCH AND BAND . . . . 21-131
OPERATION, DESCRIPTION; BODY . . . . . . . . 23-1
OPERATION, DESCRIPTION; FRAME AND
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1
OPERATION, MODES OF . . . . . . . . . . . . . . . 14-26
OPERATION, POWER STEERING PUMP -
INITIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7
ORIFICE TUBE, FIXED . . . . . . . . . . . . . 24-35,24-5
OUTER BELT WEATHERSTRIP, FRONT
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
OUTER BELT WEATHERSTRIP, REAR
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
OUTLET, 8W-41 HORN/CIGAR
LIGHTER/POWER . . . . . . . . . . . . . . . . . . . . . 8W-1
OUTLET, INSTRUMENT PANEL POWER . . . 8E-12,
8E-4
OUTLETS, DUCTS . . . . . . . . . . . . . . . . . . . . 24-33
OUTPUT, AUTO SHUTDOWN (ASD)
RELAYPCM . . . . . . . . . . . . . . . . . . . . . . . 14-34
OUTPUT, DATA LINK CONNECTORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-35
OUTPUT, FUEL INJ ECTORSPCM . . . . . . . 14-35
OUTPUT, FUEL PUMP RELAY-PCM . . . . . . . 14-35
OUTPUT, IDLE AIR CONTROL (IAC)
MOTORPCM. . . . . . . . . . . . . . . . . . . . . . . 14-35
OUTPUT, RADIATOR FAN RELAYPCM . . . 14-36
OUTPUT SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-31
OUTPUT SHAFT REAR BEARING . . . . . . . . 21-153
OUTPUT SHAFT SEAL, FRONT . . . 21-350,21-379
OUTPUTS, CCD BUS (+/-) CIRCUITS-PCM . 14-35
OUTSIDE HANDLE, FRONT DOOR . . . . . . . . 23-35
OUTSIDE HANDLE, LIFTGATE . . . . . . . . . . . 23-63
OUTSIDE HANDLE, REAR DOOR . . . . . . . . . 23-44
OUTSIDE MIRROR HEATING GRID . . . . . . . . 8N-2
OVERDRIVE PLANETARY GEAR AND
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-301
OVERDRIVE SUPPORT . . . . . . . . . . . . . . . 21-309
OVERHAUL OR FLUID/FILTER CHANGE,
REFILLING AFTER . . . . . . . . . . . . . . . . . . . 21-248
OVERHEAD CONSOLE . . . . . . . . . . . . . . 8V-1,8V-6
OVERHEAD CONSOLE, 8W-49 . . . . . . . . . . . 8W-1
OVERRUNNING CLUTCH . . . . . . . . . . . . . . 21-122
DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-175
DRUM/OVERDRIVE PISTON RETAINER . . . 21-195
OXYGEN SENSOR . . . . . . . . . . . . . . . . . . . . 14-47
OXYGEN SENSORPCM INPUT . . . . . . . . . 14-30
PACK/OUTPUT SHAFT, PLANETARY/
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-329
PAD, HOOD SILENCER . . . . . . . . . . . . . . . . 23-27
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
PAINT CODE . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
PAINT REPAIR PRODUCTS,
AFTERMARKET . . . . . . . . . . . . . . . . . . . . . . . 23-5
PAINTED SURFACE TOUCH-UP . . . . . . . . . . . 23-4
PAN, OIL . . . . . . . . . . . . . . . . 9-107,9-49,9-67,9-7
PANEL ACCESSORY SWITCH BEZEL,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 8E-15
PANEL ASSEMBLY, INSTRUMENT . . . . . . . . 8E-26
PANEL CENTER BEZEL, INSTRUMENT . . . . 8E-14
PANEL CENTER SUPPORT BRACKET,
INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 8E-26
PANEL CIGAR LIGHTER, INSTRUMENT . . . 8E-11,
8E-3
PANEL END CAP, INSTRUMENT . . . . . . . . . 8E-25
PANEL, FRONT DOOR TRIM . . . . . . . . . . . . 23-33
PANEL (GOP), GRILLE OPENING . . . . . . . . . 23-24
PANEL, INSTRUMENT . . . . . . . . . . . . . . . . . . 8E-1
PANEL, LIFTGATE TRIM . . . . . . . . . . . . . . . . 23-61
PANEL POWER OUTLET, INSTRUMENT . . . 8E-12,
8E-4
PANEL, REAR DOOR TRIM . . . . . . . . . . . . . 23-42
PANEL SYSTEM, INSTRUMENT . . . . . . . . . . . 8E-1
PANEL TOP COVER, INSTRUMENT . . . . . . . 8E-21
PANEL TRIM AND WHEELHOUSE COVER,
QUARTER . . . . . . . . . . . . . . . . . . . . . . . . . . 23-54
PANEL TRIM EXTENSION, QUARTER . . . . . 23-54
PARK GEAR, GOVERNOR . 21-153,21-154,21-191
PARK LOCK . . . . . . . . . . . . . . . . . . . . . . . . 21-154
PARK LOCK, EXTENSION HOUSING . . . . . 21-191
PARK ROD AND PAWL . . . . . . . . . . . . . . . 21-266
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . 5-5
PARKING BRAKE CABLE TENSIONER . . . . . . 5-31
PARKING BRAKE CABLES, REAR . . . . . . . . . 5-23
PARKING BRAKE LEVER . . . . . . . . . . . . . . . . 5-23
PARK/NEUTRAL POSITION SWITCH . . . . . 21-128,
21-149,21-245,21-255
PARK/TURN SIGNAL LAMP BULB,
FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11
PARK/TURN SIGNAL LAMP, FRONT . . . . . . 8L-15
PARTS AND LUBRICANT
RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . 0-1
PARTS CLEANING AND INSPECTION,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-336
PARTS USAGE, INSTALLATION METHODS . . . 6-4
PASSENGER SIDE AIRBAG DOOR . . . . . . . 8M-11
PASSENGER SIDE AIRBAG MODULE . 8M-3,8M-9
PASSIVE RESTRAINT SYSTEMS . . . . . . . . . 8M-16
PATTERN ANALYSIS, GEAR CONTACT . . . . 3-129,
3-59,3-97
PATTERNS, TIRE WEAR . . . . . . . . . . . . . . . . 22-3
PAWL, PARK ROD . . . . . . . . . . . . . . . . . . . 21-266
PCM VIN REPROGRAMMING . . . . . . . . . . . . 14-1
PEDAL, ACCELERATOR . . . . . . . . . . . . . . . . 14-21
PEDAL, BRAKE . . . . . . . . . . . . . . . . . . . . 5-15,5-2
PERFORMANCE, A/C . . . . . . . . . . . . . . . . . . . 24-9
PERFORMANCE, ENGINE . . . . . . . . . . . . 9-26,9-87
PERFORMANCE, HEATER . . . . . . . . . . . . . . 24-16
PILLAR TRIM, LIFTGATE . . . . . . . . . . . . . . . 23-55
PILOT BEARING . . . . . . . . . . . . . . . . . . . . . . . 6-12
PIN REPLACEMENT, CAMSHAFT . . . . . . . . . . 9-45
PINION, 181 FBI . . . . . . . . . . . . . . . . . . . . . . 3-36
PINION, 186 FBI . . . . . . . . . . . . . . . . . . . . . . 3-41
PINION GEAR . . . . . . . . . . . . . . . . . . . 3-117,3-81
PINION GEAR DEPTH . . . . . . . . . . . . . . . . . . 3-91
PINION GEAR DEPTH, 181 FBI . . . . . . . . . . . 3-48
PINION GEAR DEPTH, 186 FBI . . . . . . . . . . . 3-50
PINION GEAR DEPTH, 8 1/4 AXLE . . . . . . . 3-126
PINION INPUT ANGLE, FRONT AXLE . . . . . . 3-15
PINION INPUT ANGLE, REAR AXLE . . . . . . . 3-15
PINION SEAL . . . . . . . . . . . . . . . . . . . . . . . . 3-113
PINION SHAFT SEAL . . . . . . . . . . . . . . . . . . . 3-72
PINION SHAFT SEAL, 181 FBI . . . . . . . . . . . . 3-24
PINION SHAFT SEAL, 186 FBI . . . . . . . . . . . . 3-26
XJ INDEX 9
PIN-OUTS, 8W-80 CONNECTOR . . . . . . . . . . 8W-1
PIPE, EXHAUST . . . . . . . . . . . . . . . . . . . . . . . 11-5
PISTON AND CONNECTING ROD . . 9-51,9-6,9-66
PISTON AND WORM SHAFT, RACK . . . . . . . 19-16
PISTON FITTING . . . . . . . . . . . . . . . . . . . . . . 9-77
PISTON, FRONT SERVO . . . . . . . . . . . . . . 21-176
PISTON, REAR SERVO . . . . . . . . . . . . . . . 21-177
PISTON RETAINER, OVERRUNNING
CLUTCH/LOW-REVERSE DRUM/
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-195
PISTON RINGFITTING . . . . . . . . . . . . 9-18,9-77
PISTONFITTING . . . . . . . . . . . . . . . . . . . . . 9-17
PISTONS . . . . . . . . . . . . . . . . . . . . 21-118,21-234
PISTONS AND CONNECTING RODS . . . . . . 9-108
PISTONS AND SPRINGS, ACCUMULATOR . 21-264
PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . 19-24
PITMAN SHAFT/SEALS/BEARING . . . . . . . . 19-12
PIVOT, WIPER LINKAGE . . . . . . . . . . . . 8K-2,8K-9
PLANETARY GEAR AND CLUTCH,
OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-301
PLANETARY GEAR, FRONT . . . . . . . . . . . . 21-322
PLANETARY GEARSET . . . . . . . . . . . . . . . . 21-122
PLANETARY GEARTRAIN/OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-185,21-197
PLANETARY/BRAKE PACK/OUTPUT
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-329
PLATE, BRAKE SUPPORT . . . . . . . . . . . . . . . 5-22
PLATE, CLUTCH PRESSURE. . . . . . . . . . . . . . . . 6-2
PLATE, DOOR SILL SCUFF . . . . . . . . . . . . . 23-52
PLATE, FRONT INNER SCUFF . . . . . . . . . . . 23-52
PLATE, FRONT SKID . . . . . . . . . . . . . . . . . . . 13-6
PLATE, FUEL TANK SKID . . . . . . . . . . . . . . . . 13-7
PLATE LAMP BULB, LICENSE . . . . . . . . . . . 8L-12
PLATE LAMP, LICENSE . . . . . . . . . . . . . . . . 8L-16
PLATE, LIFTGATE SCUFF . . . . . . . . . . . . . . . 23-55
PLATE, TRANSFER CASE SKID . . . . . . . . . . . 13-6
PLATFORM, BUCKET SEAT . . . . . . . . . . . . . 23-15
PLUG CABLE RESISTANCE, SPARK . . . . . . 8D-23
PLUG CABLES, SPARK . . . . . . . . . . . . 8D-10,8D-7
PLUG CABLES-2.5L ENGINE, SPARK . . . . . . 8D-2
PLUG CONDITIONS, SPARK . . . . . . . . . . . . . 8D-8
PLUG, HOUSING END . . . . . . . . . . . . . . . . . 19-12
PLUGS, SPARK . . . . . . . . . . . . 8D-10,8D-2,8D-23
PLUMBING, WASHER NOZZLE . . . . . . . . . . . 8K-4
POLISHING, FINESSE SANDING,
BUFFING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
POOR CONNECTIONS, INTERMITTENT . . . . 8W-8
PORT, REFRIGERANT SYSTEM SERVICE . . . . 24-9
POSITION (CKP) SENSOR, CRANKSHAFT . . 8D-13
POSITION SENSOR, CRANKSHAFT . . . . . . . . 8D-4
POSITION SENSOR (TPS), THROTTLE . . . . 14-45
POSITION SENSOR (TPS)PCM INPUT,
THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
POSITION SENSOR-2.5L ENGINE,
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-4
POSITION SENSOR2.5L ENGINE,
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 8D-14
POSITION SENSOR4.0L ENGINE,
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . 8D-15,8D-5
POSITION SWITCH, PARK/NEUTRAL . . . . 21-128,
21-149,21-245,21-255
POSITIONS, TRANSMISSION RANGES
AND SHIFT LEVER. . . . . . . . . . . . . . . . . . . 21-236
POWER BRAKE BOOSTER . . . . . . . . . . . . 5-17,5-3
POWER DISTRIBUTION, 8W-10 . . . . . . . . . . 8W-1
POWER DISTRIBUTION CENTER . 8O-2,8O-4,8O-7
POWER DISTRIBUTION SYSTEM . . . . . . . . . 8O-1
POWER DISTRIBUTION SYSTEMS . . . . . . . 8O-10
POWER DOOR LOCKS, 8W-61 . . . . . . . . . . . 8W-1
POWER FLOW AND PRESSURE . . . . . . . . . . 19-6
POWER GROUNDS . . . . . . . . . . . . . . . . . . . 14-33
POWER LOCK MOTOR . . . . . . . . . 8P-2,8P-4,8P-7
POWER LOCK SWITCH . . . . . . . . . . . . . . . . . 8P-2
POWER LOCK SYSTEM . . . . . . . . . . . . . . . . . 8P-1
POWER LOCK SYSTEM AND REMOTE
KEYLESS ENTRY SYSTEM . . . . . . . . . . . . . . 8P-3
POWER MIRROR . . . . . . . . . . . . . . . . . . 8T-1,8T-4
POWER MIRROR SWITCH . . . . . . . . . . . 8T-1,8T-3
POWER MIRROR SYSTEM . . . . . . . . . . 8T-1,8T-2
POWER MIRRORS, 8W-62 . . . . . . . . . . . . . . 8W-1
POWER OUTLET, INSTRUMENT PANEL . . . 8E-12,
8E-4
POWER SEAT, 8W-63 . . . . . . . . . . . . . . . . . . 8W-1
POWER SEAT ADJ USTER AND MOTORS . . . 8R-1,
8R-2,8R-3
POWER SEAT SWITCH . . . . . . . . . 8R-1,8R-2,8R-3
POWER SEAT SYSTEM . . . . . . . . . . . . . 8R-1,8R-2
POWER STEERING . . . . . . . . . . . . . . . . . . . . 19-1
POWER STEERING GEAR . . . . . . . . . 19-11,19-21
POWER STEERING GEAR LEAKAGE . . . . . . 19-11
POWER STEERING PRESSURE LINE . . . . . . . 19-5
POWER STEERING PRESSURE
SWITCH2.5L ENGINE. . . . . . . . . . . . . . . . 14-47
POWER STEERING PRESSURE
SWITCHPCM INPUT . . . . . . . . . . . . . . . . 14-33
POWER STEERING PUMP . . . . . . 19-10,19-5,19-7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7
POWER STEERING RETURN LINE . . . . . . . . . 19-6
POWER STEERING SYSTEM DIAGNOSIS
CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
POWER WINDOW MOTOR . . . . . . 8S-2,8S-4,8S-6
POWER WINDOW SWITCH . . . . . . 8S-1,8S-4,8S-5
POWER WINDOW SYSTEM . . . . . . . . . 8S-1,8S-2
POWER WINDOWS, 8W-60 . . . . . . . . . . . . . 8W-1
POWERTRAIN CONTROL MODULE (PCM) . 14-25,
14-46
PRE-ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . 2-4
PRECAUTIONS AND WARNINGS, SAFETY . . . 23-3
PRECAUTIONS, SAFETY; BODY . . . . . . . . . . . 23-3
PRECAUTIONS, SAFETY; CLUTCH . . . . . . . . . . 6-4
PRECAUTIONS, SAFETY; LAMPS . . . . . . . . . . 8L-2
PRECAUTIONS, SERVICE WARNINGS . . . . . 24-23
PRECAUTIONS, WINDSHIELD SAFETY . . . . . 23-6
PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . 7-11
PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . . 21-128
PRELIMINARY INSPECTION AND
ADJ USTMENT . . . . . . . . . . . . . . . . . . . . . . 21-241
PRELOAD AND GEAR BACKLASH, 181
FBI DIFFERENTIAL BEARING. . . . . . . . . . . . . 3-52
PRELOAD AND GEAR BACKLASH, 186
FBI DIFFERENTIAL BEARING. . . . . . . . . . . . . 3-56
PRELOAD AND GEAR BACKLASH,
DIFFERENTIAL BEARING . . . . . . . . . . . 3-127,3-94
PREPARATION, DRIVELINE ANGLE
MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 3-6
PREPARATION FOR HEADLAMP
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 . . . . . . . 24-6
PRESSURE CYCLING CLUTCH SWITCH,
LOW . . . . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7
PRESSURE, ENGINE OIL . . . . . . . . . . . . 9-15,9-75
PRESSURE FOR HIGH SPEED, TIRE . . . . . . . 22-3
PRESSURE, FUEL SYSTEM . . . . . . . . . . . . . 14-23
PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . 22-3
PRESSURE LEAK DOWN TEST, FUEL . . . . . . 14-7
PRESSURE LEAKAGE TEST, CYLINDER
COMBUSTION . . . . . . . . . . . . . . . . . . . . 9-13,9-73
PRESSURE LINE, POWER STEERING . . . . . . 19-5
PRESSURE (MAP) SENSOR, MANIFOLD
ABSOLUTE. . . . . . . . . . . . . . . . . . . . . . . . . . 14-46
PRESSURE (MAP) SENSORPCM
INPUT, MANIFOLD ABSOLUTE. . . . . . . . . . . 14-32
PRESSURE PLATE, CLUTCH . . . . . . . . . . . . . . 6-2
PRESSURE, POWER FLOW . . . . . . . . . . . . . . 19-6
PRESSURE REGULATOR, FUEL
FILTER/FUEL . . . . . . . . . . . . . . . . . . . . 14-13,14-3
PRESSURE RELEASE PROCEDURE, FUEL
SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
PRESSURE RELIEF VALVE, HIGH . . . . . . . . . 24-7
PRESSURE SENSORPCM INPUT, OIL . . . 14-33
PRESSURE SWITCH (4.0 L), DUAL
FUNCTION HIGH . . . . . . . . . . . . . . . . . . . . . . 24-4
PRESSURE SWITCH/HIGH PRESSURE
CUT-OFF SWITCH, DUAL FUNCTION
HIGH . . . . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33
PRESSURE SWITCH2.5L ENGINE,
POWER STEERING . . . . . . . . . . . . . . . . . . . 14-47
PRESSURE SWITCHPCM INPUT,
POWER STEERING . . . . . . . . . . . . . . . . . . . 14-33
PRESSURE TEST ANALYSIS . . . . . . . . . . . 21-242
PRESSURE TEST, CYLINDER
COMPRESSION . . . . . . . . . . . . . . . . . . . 9-13,9-73
PRESSURE TEST, FUEL PUMP . . . . . . . . . . . 14-6
PRESSURE TEST, HYDRAULIC . . . 21-129,21-241
PRESSURES, TIRE INFLATION . . . . . . . . . . . 22-2
PROBLEMS, TROUBLESHOOTING
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-9
PRODUCTS, AFTERMARKET PAINT
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5
PROGRAMMING, REMOTE KEYLESS
ENTRY RECEIVER . . . . . . . . . . . . . . . . . . . . . 8P-6
PROGRAMMING, REMOTE KEYLESS
ENTRY TRANSMITTER . . . . . . . . . . . . . . . . . 8P-6
PROGRAMMING, SENTRY KEY
IMMOBILIZER SYSTEM TRANSPONDER. . . . 8Q-4
PROPELLER SHAFT . . . . . . . . . . . . . 3-1,3-14,3-15
PROPELLER SHAFT ANGLE
MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 3-6
PROPELLER SHAFT, FRONT . . . . . . . . . . . . . . 3-8
PROPELLER SHAFT J OINT ANGLE . . . . . . . . . 3-3
PROPELLER SHAFT J OINTS . . . . . . . . . . . . . . 3-2
PROPELLER SHAFT, REAR . . . . . . . . . . . . . . . 3-8
PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . 3-1
PROPELLER SHAFTS AND UJ OINTS . . . . . . 3-15
PULLEY, PUMP . . . . . . . . . . . . . . . . . . . . . . . 19-8
PUMP - INITIAL OPERATION, POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7
PUMP AMPERAGE TEST, FUEL . . . . . . . . . . . 14-8
PUMP AND REACTION SHAFT SUPPORT,
OIL. . . . . . . . . . . . . . . . . . . . . . . . . 21-177,21-195
PUMP CAPACITY TEST, FUEL . . . . . . . . . . . . 14-7
PUMP, FUEL . . . . . . . . . . . . . . . . . . . . . . . . . 14-3
PUMP INLET FILTER, FUEL . . . . . . . . . . . . . 14-15
PUMP (LDP), LEAK DETECTION . . . . 25-24,25-27,
25-28
PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . 19-7
PUMP MODULE, FUEL . . . . . . . . . . . . 14-14,14-2
PUMP, OIL; ENGINE . . . . . . . . . . . . . . . . 9-111,9-50
PUMP, OIL; TRANSMISSION AND
TRANSFER CASE . . . . . . . . 21-101,21-227,21-298
PUMP, POWER STEERING . . . . . 19-10,19-5,19-7
PUMP PRESSURE TEST, FUEL . . . . . . . . . . . 14-6
PUMP PULLEY . . . . . . . . . . . . . . . . . . . . . . . 19-8
PUMP RELAY, FUEL . . . . . . . . . . . . . . . . . . . 14-44
PUMP RELAY-PCM OUTPUT, FUEL . . . . . . . 14-35
PUMP RELAYS, ASD AND FUEL . . . . . . . . . 14-41
PUMP RESERVOIR . . . . . . . . . . . . . . . . . . . . 19-8
PUMP RESERVOIR-2.5L . . . . . . . . . . . . . . . . 19-7
PUMP SEAL, OIL . . . . . . . . . . . . . . . . . . . . 21-268
PUMP VOLUME CHECK, OIL . . . . . 21-142,21-248
PUMP, WASHER . . . . . . . . . . . . . . . . . . . . . . 8K-4
PUMP, WATER . . . . . . . . . . . . . . . . . 7-24,7-39,7-6
PURGE SOLENOID, DUTY CYCLE EVAP
CANISTER . . . . . . . . . . . . . . . . . . . . . 25-24,25-27
PUSH BUTTON MODULE . . . . . . . . . . . . . . . . 8V-7
PUSH RODS, ROCKER ARMS . . 9-113,9-36,9-53,
9-96
QUARTER PANEL TRIM AND
WHEELHOUSE COVER . . . . . . . . . . . . . . . . . 23-54
QUARTER PANEL TRIM EXTENSION . . . . . . 23-54
QUARTER WINDOW APPLIQUE . . . . . . . . . . 23-49
QUARTER WINDOW GLASS, REAR . . . . . . . 23-10
QUICK-CONNECT FITTINGS . . . . . . . . . 14-10,14-6
RACK, LUGGAGE . . . . . . . . . . . . . . . . . . . . . 23-50
RACK PISTON AND WORM SHAFT . . . . . . . 19-16
RADIAL-PLY TIRES . . . . . . . . . . . . . . . . . . . . 22-2
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . 7-39,7-5
RADIATOR CAPPRESSURE TESTING . . . . . 7-20
RADIATOR CAP-TO-FILLER NECK
SEALPRESSURE RELIEF CHECK . . . . . . . . 7-20
RADIATOR COOLANT FLOW CHECK . . . . . . . 7-17
RADIATOR FAN RELAYPCM OUTPUT . . . 14-36
RADIATOR PRESSURE CAP . . . . . . . . . . 7-39,7-5
RADIATOR2.5L . . . . . . . . . . . . . . . . . . . . . 7-29
RADIATOR4.0L . . . . . . . . . . . . . . . . . . . . . 7-31
RADIO . . . . . . . . . . . . . . . . . . . . . . 8F-1,8F-4,8F-7
RADIO FREQUENCY INTERFERENCE . . . . . . . 8F-6
RADIO NOISE SUPPRESSION . . . . . . . . . . . . 8F-2
RADIO NOISE SUPPRESSION
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 8F-11
RAIL MOLDING, DRIP . . . . . . . . . . . . . . . . . 23-49
RAIL/FUEL DAMPER2.5L ENGINE,
FUEL INJ ECTOR . . . . . . . . . . . . . . . . . 14-16,14-5
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5
FUEL INJ ECTOR. . . . . . . . . . . . . . . . . . . . . . 14-17
RANGES AND SHIFT LEVER POSITIONS,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-236
RATINGS, GENERATOR . . . . . . . . . . . . . . . . . 8C-5
RBI AXLE, 194 . . . . . . . . . . . . . . . . . . . 3-65,3-99
REACTION SHAFT SUPPORT, OIL PUMP . 21-177,
21-195
READING AND COURTESY LAMP . . . . . . . . . 8V-2
READING AND COURTESY LAMP BULB . . . . 8V-8
READING LAMP BULB, MAP . . . . . . . . . . . . 8L-13
REAR AXLE . . . . . . . . . . . . . . . . . . . . . 3-111,3-72
10 INDEX XJ
REAR AXLE, 8 1/4 . . . . . . . . . . . . . . . . . . . . 3-103
REAR AXLE PINION INPUT ANGLE . . . . . . . . 3-15
REAR BAND ADJ USTMENT . . . . . . . . . . . . 21-200
REAR BEARING, OUTPUT SHAFT . . . . . . . 21-153
REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . 13-4
REAR BUMPER END CAP . . . . . . . . . . . . . . . 13-4
REAR CARPET/MAT . . . . . . . . . . . . . . . . . . . 23-58
REAR CLUTCH . . . . . . . . . . 21-121,21-181,21-196
REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . 23-43
REAR DOOR GLASS EXTERIOR
MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-46
REAR DOOR HINGE . . . . . . . . . . . . . . . . . . . 23-43
REAR DOOR INNER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-45
REAR DOOR INSIDE HANDLE ACTUATOR . . 23-45
REAR DOOR LATCH . . . . . . . . . . . . . . . . . . . 23-44
REAR DOOR LATCH STRIKER . . . . . . . . . . . 23-45
REAR DOOR OUTER BELT
WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-45
REAR DOOR OUTSIDE HANDLE . . . . . . . . . 23-44
REAR DOOR RESTRAINT . . . . . . . . . . . . . . . 23-43
REAR DOOR STATIONARY WINDOW
GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9
REAR DOOR TRIM PANEL . . . . . . . . . . . . . . 23-42
REAR DOOR WATERDAM . . . . . . . . . . . . . . 23-42
REAR DOOR WEATHERSTRIP . . . . . . . . . . . . 23-46
REAR DOOR WINDOW GLASS . . . . . . . . . . 23-47
REAR DOOR WINDOW REGULATOR . . . . . . 23-47
REAR DRUM BRAKE . . . . . . . . . . . . 5-29,5-30,5-5
REAR FENDER FLARE . . . . . . . . . . . . . . . . . 23-49
REAR GLASS HEATING GRID . . . . . . . . 8N-2,8N-4
REAR GLASS HEATING GRID REPAIR . . . . . 8N-6
REAR HOUSING YOKE BUSHING . . . . . . . . 21-48
REAR LIGHTING, 8W-51 . . . . . . . . . . . . . . . 8W-1
REAR MAIN OIL SEAL . . . . . . . . . . . . . . . . . . 9-52
REAR PARKING BRAKE CABLES . . . . . . . . . . 5-23
REAR PROPELLER SHAFT . . . . . . . . . . . . . . . . 3-8
REAR QUARTER WINDOW GLASS . . . . . . . 23-10
REAR SEAT CUSHION . . . . . . . . . . . . . . . . . 23-17
REAR SEAT CUSHION COVER . . . . . . . . . . . 23-19
REAR SEATBACK . . . . . . . . . . . . . . . . 23-18,23-67
REAR SEATBACK COVER . . . . . . . . . . . . . . . 23-20
BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-19
REAR SERVO . . . . . . . . . . . . . . . . . . . . . . . 21-195
REAR SERVO PISTON . . . . . . . . . . . . . . . . 21-177
REAR SHOULDER/LAP BELT/BUCKLE . . . . . 23-57
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . 2-16
REAR TOW HOOK . . . . . . . . . . . . . . . . . . . . . 13-5
REAR WHEEL SPEED SENSOR . . . . . . . . . . . 5-37
REAR WINDOW DEFOGGER, 8W-48 . . . . . . 8W-1
REAR WINDOW DEFOGGER SYSTEM . . . . . . 8N-1
REAR WIPER AND WASHER SYSTEM . . . . . 8K-2
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . 23-59
REARVIEW MIRROR SUPPORT BRACKET . . 23-59
RECEIVER PROGRAMMING, REMOTE
KEYLESS ENTRY . . . . . . . . . . . . . . . . . . . . . . 8P-6
RECEIVER, REMOTE KEYLESS ENTRY . 8P-2,8P-5,
8P-8
RECLINER, BUCKET SEAT . . . . . . . . . . . . . . 23-17
RECOMMENDATIONS, HOISTING . . . . . . . . . 0-11
RECOMMENDATIONS, PARTS AND
LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1
RECOVERY, REFRIGERANT . . . . . . . . . . . . . 24-22
RED BRAKE WARNING LAMP . . . . . . . . . . 5-3,5-9
REFERENCES, TORQUE . . . . . . . . . . . . . . . Intro.-6
REFILLING AFTER OVERHAUL OR
FLUID/FILTER CHANGE . . . . . . . . . . . . . . . 21-248
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . 24-7
REFRIGERANT LINE COUPLER . . . . . . . . . . 24-45
REFRIGERANT LINE COUPLERS . . . . . . . . . . 24-8
REFRIGERANT LINES . . . . . . . . . . . . . . . . . . 24-7
REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . 24-8
REFRIGERANT OIL LEVEL . . . . . . . . . . . . . . 24-19
REFRIGERANT RECOVERY . . . . . . . . . . . . . 24-22
REFRIGERANT SYSTEM CHARGE . . . . . . . . 24-22
REFRIGERANT SYSTEM EVACUATE . . . . . . . 24-22
REFRIGERANT SYSTEM LEAKS . . . . . . . . . . 24-17
REFRIGERANT SYSTEM SERVICE
EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . 24-22
REFRIGERANT SYSTEM SERVICE PORT . . . . 24-9
REGULATOR, ELECTRONIC VOLTAGE . . . . . . 8C-2
REGULATOR, FRONT DOOR WINDOW . . . . 23-39
REGULATOR, FUEL FILTER/FUEL
PRESSURE . . . . . . . . . . . . . . . . . . . . . 14-13,14-3
REGULATOR, REAR DOOR WINDOW . . . . . 23-47
RELAY, AUTOMATIC SHUTDOWN (ASD) . . . 14-43
RELAY, BLOWER MOTOR . . . . . 24-13,24-2,24-27
RELAY, CIGAR LIGHTER . . . . . . 8E-12,8E-16,8E-4
RELAY, COMPRESSOR CLUTCH . . . . 24-15,24-31,
24-4
RELAY, DEFOGGER . . . . . . . . . . . . 8N-3,8N-4,8N-7
RELAY, FUEL PUMP . . . . . . . . . . . . . . . . . . . 14-44
RELAY, HEATED SEAT . . . . . . . 8N-11,8N-12,8N-9
RELAY, HORN . . . . . . . . . . . . . . . . 8G-2,8G-3,8G-4
RELAY SENSEPCM INPUT, AUTOMATIC
SHUTDOWN (ASD) . . . . . . . . . . . . . . . . . . . 14-29
RELAY, STARTER . . . . . . . . . . . 8B-10,8B-13,8B-3
RELAYPCM OUTPUT, AUTO
SHUTDOWN (ASD) . . . . . . . . . . . . . . . . . . . 14-34
RELAYPCM OUTPUT, RADIATOR FAN . . . 14-36
RELAY-PCM OUTPUT, FUEL PUMP . . . . . . . 14-35
RELAYS, ASD AND FUEL PUMP . . . . . . . . . 14-41
RELEASE BEARING . . . . . . . . . . . . . . . . . . . . 6-12
RELEASE BEARING, CLUTCH . . . . . . . . . . . . . 6-3
RELEASE CABLE, HOOD . . . . . . . . . . . . . . . 23-27
RELEASE OR ENGAGEMENT, IMPROPER
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
RELEASE PROCEDURE, FUEL SYSTEM
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 14-10
RELIEF CHECK, RADIATOR CAP-TO-
FILLER NECK SEALPRESSURE . . . . . . . . . 7-20
RELIEF VALVE, HIGH PRESSURE . . . . . . . . . 24-7
REMOTE KEYLESS ENTRY RECEIVER . 8P-2,8P-5,
8P-8
REMOTE KEYLESS ENTRY RECEIVER
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 8P-6
REMOTE KEYLESS ENTRY SYSTEM . . . . . . . 8P-1
REMOTE KEYLESS ENTRY SYSTEM,
POWER LOCK SYSTEM. . . . . . . . . . . . . . . . . 8P-3
REMOTE KEYLESS ENTRY
TRANSMITTER . . . . . . . . . . . . . . . . . . . 8P-2,8P-5
TRANSMITTER BATTERY
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 8P-6
TRANSMITTER PROGRAMMING . . . . . . . . . . 8P-6
REMOVAL/INSTALLATION, VISCOUS FAN
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 HEATING GRID . . . . . 8N-6
REPAIR, THREADED HOLE . . . . . . . . . . . . Intro.-3
REPAIR, WIRING . . . . . . . . . . . . . . . . . . . . 8W-10
REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . 22-5
REPAIR-MOLEX CONNECTORS,
TERMINAL/CONNECTOR. . . . . . . . . . . . . . . 8W-10
REPAIRTHOMAS AND BETTS
CONNECTORS, TERMINAL/CONNECTOR . . 8W-10
REPROGRAMMING, PCM VIN . . . . . . . . . . . . 14-1
REQUIREMENTS, FUEL . . . . . . . . . . . . . . . . 14-23
RESERVE TANK, COOLANT . . . . . . . . . . . . . . 7-23
RESERVE/OVERFLOW SYSTEM,
COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
RESERVOIR, MASTER CYLINDER . . . . . . . . . 5-24
RESERVOIR, PUMP . . . . . . . . . . . . . . . . . . . . 19-8
RESERVOIR, VACUUM; HEATING AND
AIR CONDITIONING. . . . . . . . . . . . . . . 24-47,24-9
RESERVOIR, VACUUM; SPEED CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 8H-3,8H-6
RESERVOIR, WASHER . . . . . . . . . . . . . . . . . 8K-3
RESERVOIR-2.5L, PUMP . . . . . . . . . . . . . . . . 19-7
RESISTANCE, SPARK PLUG CABLE . . . . . . 8D-23
RESISTANCE2.5L ENGINE, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
RESISTANCE4.0L ENGINE, IGNITION
COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-23
RESISTOR, BLOWER MOTOR . . 24-14,24-27,24-3
RESTRAINT COVER, HEAD . . . . . . . . . . . . . 23-14
RESTRAINT, FRONT DOOR . . . . . . . . . . . . . 23-35
RESTRAINT, REAR DOOR . . . . . . . . . . . . . . 23-43
RESTRAINT SLEEVE, HEAD . . . . . . . . . . . . . 23-13
RESTRAINT SYSTEMS, PASSIVE . . . . . . . . 8M-16
RETAINER, ADAPTER/EXTENSION
HOUSING AND FRONT BEARING. . . . . . . . . . 21-8
RETAINER, OVERRUNNING CLUTCH/
LOW-REVERSE DRUM/OVERDRIVE
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-195
RETAINER SEAL, FRONT BEARING . . . . . . . . 21-6
RETURN LINE, POWER STEERING . . . . . . . . 19-6
RETURNPCM INPUT, SENSOR . . . . . . . . . 14-34
REVERSE IDLER GEAR, SEMI-
SYNCHRONIZED . . . . . . . . . . . . . . . . . . . . . 21-36
RIGHT FRONT FENDER . . . . . . . . . . . . . . . . 23-32
RING GEAR . . . . . . . . . . . . . . . . . 3-116,3-45,3-80
RINGFITTING, PISTON . . . . . . . . . . . . 9-18,9-77
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-4
ROAD TEST, ANALYZING . . . . . . . . . . . . . . 21-129
ROAD TESTING . . . . . . . . . . . . . . . . . . . . . 21-129
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . 9-6,9-66
ROCKER ARMS AND PUSH RODS . . . 9-113,9-36,
9-53,9-96
ROD AND PAWL, PARK . . . . . . . . . . . . . . . 21-266
ROD BALL STUD, LIFTGATE SUPPORT . . . . 23-63
ROD BEARINGS, FITTING CONNECTING . . . . 9-80
ROD BEARINGSFITTING, CONNECTING . . . 9-21
ROD CYLINDER, LIFTGATE SUPPORT . . . . . 23-63
ROD, PISTON AND CONNECTING . . 9-51,9-6,9-66
ROD, TIE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-23
RODS, PISTONS AND CONNECTING . . . . . . 9-108
RODS, ROCKER ARMS AND PUSH . . 9-113,9-36,
9-53,9-96
ROLLOVER VALVE . . . . . . . . . . . . . . . . . . . . 25-23
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . 25-27
ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-4
ROTOR, DISC BRAKE . . . . . . . . . . . . . . . . 5-11,5-21
ROTOR MACHINING, DISC . . . . . . . . . . . . . . 5-13
ROTOR-2.5L ENGINE, DISTRIBUTOR . . . . . . 8D-6
ROTOR-SPEEDOMETER DRIVE GEAR,
SPEED SENSOR. . . . . . . . . . . . . . . . . . . . . 21-254
RUN CHANNEL WEATHERSTRIP, FRONT
DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . 23-38
RUN CHANNEL WEATHERSTRIP, REAR
DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . 23-46
RUNNING LAMP MODULE, DAYTIME . . . . . 8L-19
RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
RUNOUT, CLUTCH COVER AND DISC . . . . . . . 6-7
RUNOUT, CLUTCH FLYWHEEL . . . . . . . . . . . . . 6-6
RUNOUT, TIRE AND WHEEL . . . . . . . . . . . . . 22-7
SAFETY CERTIFICATION LABEL, VEHICLE . Intro.-2
SAFETY LATCH, HOOD . . . . . . . . . . . . . . . . 23-27
SAFETY LATCH STRIKER . . . . . . . . . . . . . . . 23-27
SAFETY PRECAUTIONS; BODY . . . . . . . . . . . 23-3
SAFETY PRECAUTIONS; CLUTCH . . . . . . . . . . 6-4
SAFETY PRECAUTIONS; LAMPS . . . . . . . . . . 8L-2
SAFETY PRECAUTIONS AND WARNINGS . . . 23-3
SAFETY PRECAUTIONS, WINDSHIELD . . . . . 23-6
SANDING, BUFFING, AND POLISHING,
FINESSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4
SCAN TOOL, DRB . . . . . . . . . . . . . . . . . . . . . . 7-9
SCHEDULES, MAINTENANCE . . . . . . . . . . . . . 0-4
SCHEMATICS, HYDRAULIC . . . . . . . . . . . . 21-201
SCHEMATICS, VACUUM . . . . . . . . . . . . . . . 25-26
SCREEN PREPARATION, LAMP
ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 8L-6
SCUFF PLATE, DOOR SILL . . . . . . . . . . . . . 23-52
SCUFF PLATE, FRONT INNER . . . . . . . . . . . 23-52
SCUFF PLATE, LIFTGATE . . . . . . . . . . . . . . . 23-55
SEAL, 181 FBI PINION SHAFT . . . . . . . . . . . . 3-24
SEAL, 186 FBI PINION SHAFT . . . . . . . . . . . . 3-26
SEAL, ADAPTER HOUSING . . . . . . . . 21-252,21-7
SEAL AND BEARING, AXLE . . . . . . . . . . . . . 3-112
SEAL AND BEARING, AXLE SHAFT . . . . . . . . 3-77
SEAL, AXLE SHAFT OIL . . . . . . . . . . . . . . . . . 3-36
SEAL, EXTENSION HOUSING . . . . . . . . . . . . . 21-7
SEAL, FRONT BEARING RETAINER . . . . . . . . 21-6
SEAL, FRONT OUTPUT SHAFT . . . 21-350,21-379
SEAL, MANUAL VALVE SHAFT . . . . . . . . . 21-262
SEAL, OIL PUMP . . . . . . . . . . . . . . . . . . . . 21-268
SEAL, PINION . . . . . . . . . . . . . . . . . . . . . . . 3-113
SEAL, PINION SHAFT . . . . . . . . . . . . . . . . . . 3-72
SEAL, REAR MAIN OIL . . . . . . . . . . . . . . . . . 9-52
SEAL REPLACEMENT, YOKE . . . . . . . . . . . 21-147
SEAL, SOLENOID HARNESS ADAPTER . . . 21-261
SEAL, TIMING CASE COVER OIL . . . . . 9-112,9-41
SEAL, VALVE, GUIDE . . . . . . . . . . . . . . . . . . . 9-15
SEAL, VALVE SPRING . . . . . . . . . . . . . . . . . . 9-37
SEAL, VALVE STEM . . . . . . . . . . . . . . . . . 9-67,9-8
SEALING LOCATIONS, BODY . . . . . . . . . . . 23-112
SEAL2WD, YOKE . . . . . . . . . . . . . . . . . . . 21-47
SEALPRESSURE RELIEF CHECK,
RADIATOR CAP-TO-FILLER NECK . . . . . . . . . 7-20
SEALS, VALVE SPRINGS AND OIL . . . . . . . . 9-97
SEALSREAR, CRANKSHAFT OIL . . . . . . . 9-110
SEAT, 8W-63 POWER . . . . . . . . . . . . . . . . . . 8W-1
SEAT ADJ USTER AND MOTORS, POWER . . 8R-1,
8R-2,8R-3
XJ INDEX 11
SEAT BELT SWITCH, DRIVER . . . . . . . . . . . . 8U-2
SEAT, BUCKET . . . . . . . . . . . . . . . . . . . . . . . 23-15
SEAT CUSHION COVER, BUCKET . . . . . . . . 23-17
SEAT CUSHION COVER, REAR . . . . . . . . . . 23-19
SEAT CUSHION, REAR . . . . . . . . . . . . . . . . . 23-17
SEAT ELEMENT AND SENSOR, HEATED . . 8N-11,
8N-9
SEAT HEAT INTERFACE MODULE . . . . 8N-12,8N-9
SEAT PLATFORM, BUCKET . . . . . . . . . . . . . 23-15
SEAT RECLINER, BUCKET . . . . . . . . . . . . . . 23-17
SEAT RELAY, HEATED . . . . . . . 8N-11,8N-12,8N-9
SEAT SWITCH, HEATED . . . . . . 8N-10,8N-12,8N-8
SEAT SWITCH, POWER . . . . . . . . 8R-1,8R-2,8R-3
SEAT SYSTEM, HEATED . . . . . . . . . . . . 8N-8,8N-9
SEAT SYSTEM, POWER . . . . . . . . . . . . 8R-1,8R-2
SEAT TRACK, BUCKET . . . . . . . . . . . . . . . . . 23-15
SEATBACK, BUCKET . . . . . . . . . . . . . . . . . . 23-16
SEATBACK COVER, BUCKET . . . . . . . . . . . . 23-16
SEATBACK COVER, REAR . . . . . . . . . . . . . . 23-20
SEATBACK LATCH STRIKER AND
BUMPER, REAR. . . . . . . . . . . . . . . . . . . . . . 23-19
SEATBACK, REAR . . . . . . . . . . . . . . . 23-18,23-67
SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-13
SECOND BRAKE . . . . . . . . . . . . . . . . . . . . 21-327
SECOND COAST BRAKE SERVO . . . . . . . . 21-265
SECONDARY, FIVE VOLT SENSOR
SUPPLIESPRIMARY. . . . . . . . . . . . . . . . . . 14-29
SECONDARY WEATHERSTRIP, FRONT
DOOR OPENING . . . . . . . . . . . . . . . . . . . . . 23-39
SECTION IDENTIFICATION . . . . . . . . . . . . . . 8W-5
SECURITY SYSTEM, 8W-39 VEHICLE
THEFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
SEMI-SYNCHRONIZED REVERSE IDLER
GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-36
SENDING UNIT, FUEL GAUGE . . 14-10,14-16,14-3
SENSEPCM INPUT, AUTOMATIC
SHUTDOWN (ASD) RELAY . . . . . . . . . . . . . 14-29
SENSEPCM INPUT, IGNITION CIRCUIT . . 14-31
SENSITIVE DEVICES, ELECTROSTATIC
DISCHARGE (ESD) . . . . . . . . . . . . . . . . . . . . 8W-8
SENSOR, AMBIENT TEMPERATURE . . . . . . . 8V-8
SENSOR, BATTERY TEMPERATURE . . . 8C-2,8C-5
SENSOR, CRANKSHAFT POSITION . . . . . . . . 8D-4
SENSOR, CRANKSHAFT POSITION (CKP) . . 8D-13
SENSOR, ENGINE COOLANT
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-49
SENSOR, FRONT WHEEL SPEED . . . . . . . . . . 5-37
SENSOR, HEATED SEAT ELEMENT . . . 8N-11,8N-9
SENSOR, INTAKE MANIFOLD AIR
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-50
SENSOR, MANIFOLD ABSOLUTE
PRESSURE (MAP) . . . . . . . . . . . . . . . . . . . . 14-46
SENSOR, OXYGEN . . . . . . . . . . . . . . . . . . . . 14-47
SENSOR, REAR WHEEL SPEED . . . . . . . . . . . 5-37
SENSOR RETURNPCM INPUT . . . . . . . . . 14-34
SENSOR ROTOR-SPEEDOMETER DRIVE
GEAR, SPEED . . . . . . . . . . . . . . . . . . . . . . 21-254
SENSOR, SPEED . . . . . . . . . . . . . . . . . . . . 21-252
SENSOR (SPEED CONTROL OPERATION),
VEHICLE SPEED . . . . . . . . . . . . . . . . . . . . . . 8H-4
SENSOR SUPPLIESPRIMARY AND
SECONDARY, FIVE VOLT . . . . . . . . . . . . . . . 14-29
SENSOR TESTING, SPEED . . . . . . . . . . . . . 21-246
SENSOR (TPS), THROTTLE POSITION . . . . 14-45
SENSOR (TPS)PCM INPUT, THROTTLE
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-34
SENSOR, VEHICLE SPEED . . . . . . . . . . . . . . 14-51
SENSOR, WASHER FLUID LEVEL . . . . . . . . . 8K-4
SENSOR-2.5L ENGINE, CAMSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-4
SENSOR2.5L ENGINE, CAMSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-14
SENSOR4.0L ENGINE, CAMSHAFT
POSITION . . . . . . . . . . . . . . . . . . . . . . 8D-15,8D-5
SENSORPCM INPUT, ENGINE
COOLANT TEMPERATURE . . . . . . . . . . . . . . 14-30
SENSORPCM INPUT, FUEL LEVEL . . . . . . 14-30
SENSORPCM INPUT, INTAKE
MANIFOLD AIR TEMPERATURE. . . . . . . . . . 14-32
SENSORPCM INPUT, MANIFOLD
ABSOLUTE PRESSURE (MAP) . . . . . . . . . . . 14-32
SENSORPCM INPUT, OIL PRESSURE . . . 14-33
SENSORPCM INPUT, OXYGEN . . . . . . . . . 14-30
SENSORPCM INPUT, VEHICLE SPEED
AND DISTANCE . . . . . . . . . . . . . . . . . . . . . . 14-34
SENSORS AND TONE WHEEL, WHEEL
SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SENTINEL HEADLAMP DELAY MODULE . . . 8L-19
SENTRY KEY IMMOBILIZER MODULE . 8Q-1,8Q-4
SENTRY KEY IMMOBILIZER SYSTEM . 8Q-1,8Q-3
SENTRY KEY IMMOBILIZER SYSTEM
INDICATOR LAMP . . . . . . . . . . . . . . . . . . . . . 8Q-3
SENTRY KEY IMMOBILIZER SYSTEM
TRANSPONDER PROGRAMMING . . . . . . . . . 8Q-4
SENTRY KEY IMMOBILIZER
TRANSPONDER. . . . . . . . . . . . . . . . . . . . . . . 8Q-2
SERVO CABLE . . . . . . . . . . . . . . . . . . . 8H-3,8H-6
SERVO, FRONT . . . . . . . . . . . . . . . . . . . . . 21-195
SERVO PISTON, FRONT . . . . . . . . . . . . . . 21-176
SERVO PISTON, REAR . . . . . . . . . . . . . . . 21-177
SERVO, REAR . . . . . . . . . . . . . . . . . . . . . . 21-195
SERVO, SECOND COAST BRAKE . . . . . . . . 21-265
SERVO, SPEED CONTROL . . . . . . . . . . 8H-2,8H-5
SERVOS . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-123
SHACKLE BUSHING, LEAF SPRING . . . . . . . . 2-18
SHAFT ANGLE MEASUREMENT,
PROPELLER. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
SHAFT, AXLE . . . . . . . . . . . . . . . . . . . . 3-111,3-76
SHAFT, FRONT PROPELLER . . . . . . . . . . . . . . 3-8
SHAFT, HUB BEARING AND AXLE . . . . . . . . . 3-30
SHAFT, INPUT . . . . . . . . . . . . . . . . . . . . . . . 21-30
SHAFT J OINT ANGLE, PROPELLER . . . . . . . . . 3-3
SHAFT J OINTS, PROPELLER . . . . . . . . . . . . . . 3-2
SHAFT OIL SEAL, AXLE . . . . . . . . . . . . . . . . . 3-36
SHAFT, OUTPUT . . . . . . . . . . . . . . . . . . . . . 21-31
SHAFT, PLANETARY GEARTRAIN/
OUTPUT. . . . . . . . . . . . . . . . . . . . . 21-185,21-197
SHAFT, PLANETARY/BRAKE PACK/
OUTPUT. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-329
SHAFT, PROPELLER . . . . . . . . . . . . 3-1,3-14,3-15
SHAFT, RACK PISTON AND WORM . . . . . . . 19-16
SHAFT REAR BEARING, OUTPUT . . . . . . . 21-153
SHAFT, REAR PROPELLER . . . . . . . . . . . . . . . 3-8
SHAFT SEAL, 181 FBI PINION . . . . . . . . . . . . 3-24
SHAFT SEAL, 186 FBI PINION . . . . . . . . . . . . 3-26
SHAFT SEAL AND BEARING, AXLE . . . . . . . . 3-77
SHAFT SEAL, FRONT OUTPUT . . . 21-350,21-379
SHAFT SEAL, MANUAL VALVE . . . . . . . . . 21-262
SHAFT SEAL, PINION . . . . . . . . . . . . . . . . . . 3-72
SHAFT SUPPORT, OIL PUMP AND
REACTION . . . . . . . . . . . . . . . . . . . 21-177,21-195
SHAFTCARDAN U-J OINT, AXLE . . . . . . . . . 3-23
SHAFTS AND UJ OINTS, 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 ADJ USTMENT,
BRAKE TRANSMISSION . . . . . . . . 21-198,21-336
SHIFT INTERLOCK MECHANISM, BRAKE
TRANSMISSION. . . . . . . . . . . . . . . 21-125,21-238
SHIFT LEVER . . . . . . . . . . . . . . . . . 21-349,21-377
SHIFT LEVER POSITIONS,
TRANSMISSION RANGES . . . . . . . . . . . . . 21-236
SHIFT LINKAGE ADJ USTMENT . . . 21-372,21-405
SHIFT MECHANISM AND GEARTRAIN . . . . . 21-17
SHIFT TOWER . . . . . . . . . . . . . . . . . . . . . . . 21-47
SHIFTER/IGNITION INTERLOCK . . . . . . . . . 8D-22
SHIFTING, HARD . . . . . . . . . . . . . . . . . 21-3,21-44
SHIFTING TEST, MANUAL . . . . . . . . . . . . . 21-241
SHOCK ABSORBER . . . . . . . . . . . . . . . . . 2-17,2-9
SHOCK ABSORBERS . . . . . . . . . . . . . . . . 2-16,2-7
SHOCK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 2-9
SHOCK, SPRING . . . . . . . . . . . . . . . . . . . . . . 2-17
SHOES, DRUM BRAKE . . . . . . . . . . . . . . . . . 5-21
SHOES, FRONT DISC BRAKE . . . . . . . . . . . . . 5-20
SHOULDER BELT/BUCKLE, FRONT . . . . . . . 23-55
SHOULDER/LAP BELT/BUCKLE, REAR . . . . . 23-57
SHUTDOWN (ASD) RELAY, AUTOMATIC . . . 14-43
SHUTDOWN (ASD) RELAY SENSEPCM
INPUT, AUTOMATIC. . . . . . . . . . . . . . . . . . . 14-29
SHUTDOWN (ASD) RELAYPCM
OUTPUT, AUTO . . . . . . . . . . . . . . . . . . . . . . 14-34
SIDE AIRBAG DOOR, PASSENGER . . . . . . . 8M-11
SIDE AIRBAG MODULE, DRIVER . . . . 8M-2,8M-6
SIDE AIRBAG MODULE, PASSENGER . 8M-3,8M-9
SIDE AIRBAG MODULE TRIM COVER,
DRIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
SIDE BEARINGS, DIFFERENTIAL . 3-115,3-36,3-80
SIDE GEAR CLEARANCE . . . . . . . . . . . . . . . 3-129
SIDE MARKER LAMP . . . . . . . . . . . . . . . . . 8L-15
SIDE MARKER LAMP BULB . . . . . . . . . . . . 8L-11
SIDE MOLDING, BODY . . . . . . . . . . . . . . . . 23-48
SIDE VIEW MIRROR . . . . . . . . . . . . . . . . . . 23-31
SIGNAL AND HAZARD WARNING
SYSTEMS, TURN . . . . . . . . . . . . . . . . . . . . . . 8J -4
SIGNAL CANCELLING CAM, TURN . . . . . . . . 8J -3
SIGNAL LAMP BULB, FRONT PARK/
TURN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11
SIGNAL LAMP, FRONT PARK/TURN . . . . . . 8L-15
SIGNAL SWITCH AND HAZARD
WARNING SWITCH, TURN. . . . . . . 8J -2,8J -5,8J -6
SIGNAL SYSTEM, TURN . . . . . . . . . . . . . . . . 8J -1
SIGNALS, 8W-52 TURN . . . . . . . . . . . . . . . . 8W-1
SIGNAL/TAIL LAMP, BACK-UP/BRAKE/
REAR TURN. . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
SIGNAL/TAIL LAMP BULB, BACK-UP/
BRAKE/REAR TURN. . . . . . . . . . . . . . . . . . . 8L-11
SILENCER PAD, HOOD . . . . . . . . . . . . . . . . 23-27
SILL SCUFF PLATE, DOOR . . . . . . . . . . . . . 23-52
SINGLE CARDAN UNIVERSAL J OINT . . . . . . . 3-9
SIZE, TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
SKID PLATE, FRONT . . . . . . . . . . . . . . . . . . . 13-6
SKID PLATE, FUEL TANK . . . . . . . . . . . . . . . . 13-7
SKID PLATE, TRANSFER CASE . . . . . . . . . . . 13-6
SLEEVE, HEAD RESTRAINT . . . . . . . . . . . . . 23-13
SNAP, DRIVELINE . . . . . . . . . . . . 3-109,3-21,3-70
SOLENOID CIRCUITS, SPEED CONTROL . . . 8H-2
SOLENOID, DUTY CYCLE EVAP
CANISTER PURGE . . . . . . . . . . . . . . . 25-24,25-27
SOLENOID HARNESS ADAPTER SEAL . . . 21-261
SOLENOID TESTING, TRANSMISSION . . . . 21-245
SOLENOIDS, TRANSMISSION VALVE
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-258
SPACER BLOCKSTWO-DOOR
VEHICLES, FRONT DOOR . . . . . . . . . . . . . . 23-41
SPACER, COLLAPSIBLE . . . . . . . . . . . . . 3-27,3-74
SPARE TIRETEMPORARY . . . . . . . . . . . . . . 22-2
SPARK PLUG CABLE RESISTANCE . . . . . . . 8D-23
SPARK PLUG CABLES . . . . . . . . . . . . 8D-10,8D-7
SPARK PLUG CABLES-2.5L ENGINE . . . . . . . 8D-2
SPARK PLUG CONDITIONS . . . . . . . . . . . . . . 8D-8
SPARK PLUGS . . . . . . . . . . . . . 8D-10,8D-2,8D-23
SPEAKER . . . . . . . . . . . . . . . . . . . . 8F-2,8F-4,8F-8
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 9-115
SPECIFICATIONS, ENGINE . . . . . . . . . . . . . . . 9-55
SPECIFICATIONS, FRAME TORQUE . . . . . . . . 13-9
SPECIFICATIONS, TORQUE; BODY . . . . . . 23-135
SPECIFICATIONS, TORQUE; COOLING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
SPECIFICATIONS, TORQUE; ENGINE . . . . . . 9-118
SPECIFICATIONS, TORQUE; EXHAUST
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
SPECIFICATIONSTORQUE . . . . . . . . . . . . . 9-59
SPEED AND DISTANCE SENSORPCM
INPUT, VEHICLE . . . . . . . . . . . . . . . . . . . . . 14-34
SPEED CONTROL, 8W-33 VEHICLE . . . . . . . 8W-1
SPEED CONTROL SERVO . . . . . . . . . . . 8H-2,8H-5
SPEED CONTROL SOLENOID CIRCUITS . . . . 8H-2
SPEED CONTROL SWITCH . . . . . . . . . . . . . . 8H-5
SPEED CONTROL SWITCHES . . . . . . . . . . . . 8H-2
SPEED CONTROL SYSTEM . . . . . . . . . . . . . . 8H-1
SPEED KNOCK, LOW . . . . . . . . . . 3-109,3-21,3-70
SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . 21-252
SPEED SENSOR, FRONT WHEEL . . . . . . . . . . 5-37
SPEED SENSOR, REAR WHEEL . . . . . . . . . . . 5-37
SPEED SENSOR ROTOR-SPEEDOMETER
DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . 21-254
SPEED SENSOR (SPEED CONTROL
OPERATION), VEHICLE . . . . . . . . . . . . . . . . . 8H-4
SPEED SENSOR TESTING . . . . . . . . . . . . . 21-246
SPEED SENSOR, VEHICLE . . . . . . . . . . . . . . 14-51
SPEED SENSORS AND TONE WHEEL,
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
SPEED, TIRE PRESSURE FOR HIGH . . . . . . . 22-3
SPEEDOMETER . . . . . . . . . . . . . . . 21-350,21-378
SPEEDOMETER ADAPTER . . . . . . . 21-148,21-253
SPLICE INFORMATION, 8W-70 . . . . . . . . . . . 8W-1
SPLICE LOCATIONS . . . . . . . . . . . . . . 8W-1,8W-7
SPLICE LOCATIONS, 8W-95 . . . . . . . . . . . . . 8W-1
SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . 19-14
SPRING AND SEAL, VALVE . . . . . . . . . . . . . . 9-37
SPRING AND SHACKLE BUSHING, LEAF . . . . 2-18
SPRING AND SHOCK . . . . . . . . . . . . . . . . . . . 2-17
SPRING, LEAF . . . . . . . . . . . . . . . . . . . . . . . . 2-18
SPRING, VALVE . . . . . . . . . . . . . . . . . . . . 9-67,9-7
SPRING/J OUNCE BUMPER, COIL . . . . . . . . . . 2-9
SPRINGS, ACCUMULATOR PISTONS . . . . 21-264
SPRINGS AND ISOLATORS, COIL . . . . . . 2-16,2-8
SPRINGS AND OIL SEALS, VALVE . . . . . . . . 9-97
SPRINGS, VALVES AND VALVE . . . . . . . . . . 9-100
SPROCKETS, TIMING CHAIN . . . . . . . . 9-102,9-43
STABILIZER BAR . . . . . . . . . . . 2-12,2-16,2-17,2-9
12 INDEX XJ
STANDARD DIFFERENTIAL . . . . 3-105,3-120,3-18,
3-46,3-66,3-86
STARTER MOTOR . . . . . . . . . . . . 8B-11,8B-2,8B-9
STARTER MOTOR NOISE - 2.5L ENGINE . . . 8B-8
STARTER RELAY . . . . . . . . . . . . 8B-10,8B-13,8B-3
STARTING PROCEDURE, J UMP . . . . . . . . . . . . 0-9
STARTING SYSTEM . . . . . 8B-1,8B-14,8B-15,8B-4
STARTING SYSTEM, 8W-21 . . . . . . . . . . . . . 8W-1
STARTING, TOWING AND HOISTING,
J UMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
STATE DISPLAY TEST MODE . . . . . . . . . . . . . 25-2
STATIONARY GLASS . . . . . . . . . . . . . . . . . . . 23-6
STATIONARY WINDOW GLASS, REAR
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-9
STATOR CLUTCH INSPECTION, TORQUE
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-247
STEERING COLUMN . . . . . . . . . . . . . . . . . . 19-26
STEERING COLUMN OPENING COVER . . . . 8E-13
STEERING DAMPER . . . . . . . . . . . . . . . . . . 19-25
STEERING GEAR . . . . . . . . . . . . . . . . 19-12,19-19
STEERING GEAR LEAKAGE, POWER . . . . . . 19-11
STEERING GEAR, POWER . . . . . . . . . 19-11,19-21
STEERING KNUCKLE . . . . . . . . . . . . . . . . . . . 2-10
STEERING KNUCKLE AND BALL STUDS . . . . 3-31
STEERING LINKAGE . . . . . . . . 19-22,19-23,19-25
STEERING, POWER . . . . . . . . . . . . . . . . . . . . 19-1
STEERING PRESSURE LINE, POWER . . . . . . 19-5
STEERING PRESSURE SWITCH2.5L
ENGINE, POWER . . . . . . . . . . . . . . . . . . . . . 14-47
STEERING PRESSURE SWITCHPCM
INPUT, POWER . . . . . . . . . . . . . . . . . . . . . . 14-33
STEERING PUMP - INITIAL OPERATION,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-7
STEERING PUMP, POWER . . . . . 19-10,19-5,19-7
STEERING RETURN LINE, POWER . . . . . . . . 19-6
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . 19-1
STEERING SYSTEM DIAGNOSIS CHARTS,
POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
STEERING SYSTEM, SUSPENSION . . . . . . . . . 2-3
STEM SEAL, VALVE . . . . . . . . . . . . . . . . . 9-67,9-8
STOP LAMP (CHMSL) BULB, CENTER
HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . 8L-12
STOP LAMP (CHMSL), CENTER HIGH
MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
STORAGE BIN DOOR, GARAGE DOOR
OPENER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8V-8
STORAGE BIN, GARAGE DOOR OPENER . . . 8V-3
STORAGE BIN, SUNGLASSES . . . . . . . . 8V-3,8V-8
STRIKER AND BUMPER, REAR
SEATBACK LATCH . . . . . . . . . . . . . . . . . . . . 23-19
STRIKER, FRONT DOOR LATCH . . . . . . . . . 23-37
STRIKER, GLOVE BOX LATCH . . . . . . . . . . . 8E-24
STRIKER, HOOD LATCH . . . . . . . . . . . . . . . 23-26
STRIKER, LIFTGATE LATCH . . . . . . . . . . . . . 23-64
STRIKER, REAR DOOR LATCH . . . . . . . . . . 23-45
STRIKER, SAFETY LATCH . . . . . . . . . . . . . . 23-27
STRUCTURAL ADHESIVE LOCATIONS . . . . 23-124
STUD, LIFTGATE SUPPORT ROD BALL . . . . 23-63
STUDS, STEERING KNUCKLE AND BALL . . . 3-31
STUDS, WHEEL MOUNTING . . . . . . . . . . . . . 2-13
SUCTION AND DISCHARGE LINE . . . . . . . . 24-45
SUN GEAR AND NO. 1 ONEWAY
CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . 21-324
SUNGLASSES STORAGE BIN . . . . . . . . 8V-3,8V-8
SUNVISORS . . . . . . . . . . . . . . . . . . . . . . . . . 23-60
SUPPLIESPRIMARY AND SECONDARY,
FIVE VOLT SENSOR . . . . . . . . . . . . . . . . . . . 14-29
SUPPLY TEST, VACUUM . . . . . . . . . . . . . . . . 8H-4
SUPPORT BRACKET, INSTRUMENT
PANEL CENTER . . . . . . . . . . . . . . . . . . . . . . 8E-26
SUPPORT BRACKET, REARVIEW MIRROR . 23-59
SUPPORT, OIL PUMP AND REACTION
SHAFT . . . . . . . . . . . . . . . . . . . . . . 21-177,21-195
SUPPORT, OVERDRIVE . . . . . . . . . . . . . . . 21-309
SUPPORT PLATE, BRAKE . . . . . . . . . . . . . . . 5-22
SUPPORT ROD BALL STUD, LIFTGATE . . . . 23-63
SUPPORT ROD CYLINDER, LIFTGATE . . . . . 23-63
SUPPRESSION COMPONENTS, RADIO
NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-11
SUPPRESSION, RADIO NOISE . . . . . . . . . . . . 8F-2
SURFACE TOUCH-UP, PAINTED . . . . . . . . . . . 23-4
SUSPENSION AND STEERING SYSTEM . . . . . 2-3
SUSPENSION ARM, LOWER . . . . . . . . . . . . . 2-10
SUSPENSION ARM, UPPER . . . . . . . . . . . . . 2-11
SUSPENSION ARMS AND BUSHINGS,
LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SUSPENSION ARMS AND BUSHINGS,
UPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SUSPENSION COMPONENT . . . . . . . . . . . . . . 2-16
SUSPENSION COMPONENTS . . . . . . . . . . . . . 2-7
SUSPENSION, FRONT . . . . . . . . . . . . . . . 2-15,2-7
SUSPENSION, REAR . . . . . . . . . . . . . . . . . . . 2-16
SWITCH (4.0 L), DUAL FUNCTION HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 24-4
SWITCH AND HAZARD WARNING
SWITCH, TURN SIGNAL. . . . . . . . . 8J -2,8J -5,8J -6
SWITCH AND KEY CYLINDER, IGNITION . . 8D-20
SWITCH AND KEY LOCK CYLINDER,
IGNITION . . . . . . . . . . . . . . . . . . . . . . . 8D-5,8D-9
SWITCH AND WASHER SWITCH, WIPER . . 8K-11,
8K-3,8K-7
SWITCH BEZEL, INSTRUMENT PANEL
ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . 8E-15
SWITCH, BLOWER MOTOR . . . . . . . . . 24-14,24-3
SWITCH, BRAKE LAMP; BRAKES . . 5-15,5-2,5-30,
5-9
SWITCH, BRAKE LAMP; SPEED
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-3
SWITCH, DEFOGGER . . . . . . . . . . 8N-2,8N-4,8N-6
SWITCH, DRIVER DOOR J AMB . . . . . . . . . . . 8U-2
SWITCH, DRIVER SEAT BELT . . . . . . . . . . . . 8U-2
SWITCH, DUAL FUNCTION HIGH
PRESSURE SWITCH/HIGH PRESSURE
CUT-OFF . . . . . . . . . . . . . . . . . . . . . . 24-16,24-33
SWITCH, HEADLAMP; CHIME/BUZZER
SWITCH, HEADLAMP; INSTRUMENT
PANEL SYSTEMS. . . . . . . . . . . . . . . . . . . . . 8E-17
SWITCH, HEATED SEAT . . . . . . . 8N-10,8N-12,8N-8
SWITCH, HIGH PRESSURE CUT-OFF . . . . . . . 24-6
SWITCH, HORN . . . . . . . . . . . . . . . . . . 8G-2,8G-4
SWITCH, KEY-IN IGNITION . . . . . . . . . . 8U-2,8U-3
SWITCH, LOW PRESSURE CYCLING
CLUTCH. . . . . . . . . . . . . . . . . . . 24-17,24-42,24-7
SWITCH, PARK/NEUTRAL POSITION . . . . 21-128,
21-149,21-245,21-255
SWITCH, POWER 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
SWITCH, WIPER SWITCH AND WASHER . . 8K-11,
8K-3,8K-7
SWITCHES, CHIME WARNING SYSTEM . . . . 8U-4
SWITCHES, SPEED CONTROL . . . . . . . . . . . . 8H-2
SWITCH, DUAL FUNCTION HIGH
PRESSURE . . . . . . . . . . . . . . . . . . . . 24-16,24-33
SWITCH2.5L ENGINE, POWER
STEERING PRESSURE. . . . . . . . . . . . . . . . . 14-47
SWITCHPCM INPUT, BRAKE . . . . . . . . . . 14-29
SWITCHPCM INPUT, EXTENDED IDLE . . . 14-30
SWITCHPCM INPUT, POWER
STEERING PRESSURE. . . . . . . . . . . . . . . . . 14-33
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-5
SYMBOLS, INTERNATIONAL;
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . Intro.-2
SYMBOLS, INTERNATIONAL;
LUBRICATION AND MAINTENANCE. . . . . . . . . 0-1
SYSTEM, 8W-20 CHARGING . . . . . . . . . . . . 8W-1
SYSTEM, 8W-21 STARTING . . . . . . . . . . . . . 8W-1
SYSTEM, 8W-30 FUEL/IGNITION . . . . . . . . . 8W-1
SYSTEM, 8W-31 TRANSMISSION
CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
SYSTEM, 8W-39 VEHICLE THEFT
SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
SYSTEM, 8W-43 AIRBAG . . . . . . . . . . . . . . . 8W-1
SYSTEM, 8W-47 AUDIO . . . . . . . . . . . . . . . . 8W-1
SYSTEM, AIRBAG . . . . . . . . . . . 8M-1,8M-4,8M-5
SYSTEM AND REMOTE KEYLESS ENTRY
SYSTEM, POWER LOCK . . . . . . . . . . . . . . . . 8P-3
SYSTEM, ANTILOCK BRAKE . . . . . . . . . . . . . 5-33
SYSTEM, AUDIO . . . . . . . . . . . . . . . . . . 8F-1,8F-2
SYSTEM, BASE BRAKE . . . . . . . . . . . . . . . 5-1,5-7
SYSTEM, BLEEDING ABS BRAKE . . . . . . . . . 5-36
SYSTEM, BRAKE . . . . . . . . . . . . . . . . . . . . . . . 5-2
SYSTEM CHARGE, REFRIGERANT . . . . . . . . 24-22
SYSTEM, CHARGING . . . . . . . . . . . . . . 8C-1,8C-2
SYSTEM, CHIME WARNING . . . . . . . . . . . . . 8U-1
SYSTEM, COOLANT RESERVE/
OVERFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
SYSTEM, COOLING . . . . . . . . . . . . . . . . . . . . . 7-1
SYSTEM, CRANKCASE VENTILATION . . . . . 25-25,
25-27
SYSTEM, DEFOGGER . . . . . . . . . . . . . . . . . . 8N-3
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . 8L-3
SYSTEM DIAGNOSIS CHARTS, POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2
SYSTEM, EMISSION . . . . . . . . . . . . . . . . . . . 25-1
SYSTEM EVACUATE, REFRIGERANT . . . . . . 24-22
SYSTEM, EVAPORATION CONTROL . . . . . . . 25-23
SYSTEM, EXHAUST . . . . . . . . . . . . . . . . 11-1,11-4
SYSTEM FANS, COOLING . . . . . . . . . . . . 7-3,7-38
SYSTEM, FUEL . . . . . . . . . . . . . . . . . . . . . . 14-52
SYSTEM, FUEL DELIVERY . . . . . . . . . . . . . . . 14-1
SYSTEM, FUEL INJ ECTION . . . . . . . . . . . . . 14-25
SYSTEM, HAZARD WARNING . . . . . . . . . . . . 8J -1
SYSTEM, HEATED SEAT . . . . . . . . . . . . 8N-8,8N-9
SYSTEM, HORN . . . . . . . . . . . . . . . . . . . . . . 8G-1
SYSTEM HOSES, COOLING . . . . . . . . . . . . . . 7-40
SYSTEM, HYDRAULIC . . . . . . . . . . . . . . . . 21-237
SYSTEM, IGNITION . . . . . . . . . . . . . . . . . . . . 8D-1
SYSTEM INDICATOR LAMP, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . 8Q-3
SYSTEM, INSTRUMENT PANEL . . . . . . . . . . . 8E-1
SYSTEM LEAKS, REFRIGERANT . . . . . . . . . 24-17
SYSTEM, LUBRICATION . . . . . . . . . . . . . 9-2,9-62
SYSTEM, METRIC . . . . . . . . . . . . . . . . . . . Intro.-6
SYSTEM, ON-BOARD DIAGNOSTIC TEST
FOR CHARGING. . . . . . . . . . . . . . . . . . . . . . . 8C-3
SYSTEM, POWER DISTRIBUTION . . . . . . . . . . 8O-1
SYSTEM, POWER LOCK . . . . . . . . . . . . . . . . 8P-1
SYSTEM, POWER LOCK SYSTEM AND
REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . 8P-3
SYSTEM, POWER MIRROR . . . . . . . . . . 8T-1,8T-2
SYSTEM, POWER SEAT . . . . . . . . . . . . 8R-1,8R-2
SYSTEM, POWER WINDOW . . . . . . . . . 8S-1,8S-2
SYSTEM PRESSURE, FUEL . . . . . . . . . . . . . 14-23
SYSTEM PRESSURE RELEASE
PROCEDURE, FUEL . . . . . . . . . . . . . . . . . . . 14-10
SYSTEM, REAR WINDOW DEFOGGER . . . . . 8N-1
SYSTEM, REAR WIPER AND WASHER . . . . . 8K-2
SYSTEM, REMOTE KEYLESS ENTRY . . . . . . 8P-1
SYSTEM, SENTRY KEY IMMOBILIZER . 8Q-1,8Q-3
SYSTEM SERVICE EQUIPMENT,
REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 24-22
SYSTEM SERVICE PORT, REFRIGERANT . . . . 24-9
SYSTEM, SPEED CONTROL . . . . . . . . . . . . . 8H-1
SYSTEM, STARTING . . . . . 8B-1,8B-14,8B-15,8B-4
SYSTEM, STEERING . . . . . . . . . . . . . . . . . . . 19-1
SYSTEM, SUSPENSION AND STEERING . . . . . 2-3
SYSTEM SWITCHES, CHIME WARNING . . . . 8U-4
SYSTEM TRANSPONDER
PROGRAMMING, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . 8Q-4
SYSTEM, TURN SIGNAL . . . . . . . . . . . . . . . . 8J -1
SYSTEM, VACUUM . . . . . . . . . . . . . . . . . . . 24-18
SYSTEM, WASHER . . . . . . . . . . . . . . . 8K-13,8K-6
SYSTEM, WINDSHIELD WASHER . . . . . . . . . 8K-1
SYSTEM, WINDSHIELD WIPER . . . . . . . . . . . 8K-1
SYSTEM, WIPER . . . . . . . . . . . . . . . . . . . . . . 8K-4
SYSTEMDRAINING AND FILLING,
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
SYSTEMREVERSE FLUSHING,
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
SYSTEMTESTING FOR LEAKS,
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
SYSTEMS, AUDIO . . . . . . . . . . . . . . . . . . . . 8F-12
SYSTEMS, LAMP . . . . . . . . . . . . . . . . . 8L-1,8L-19
SYSTEMS, MONITORED . . . . . . . . . . . . . . . 25-19
SYSTEMS, PASSIVE RESTRAINT . . . . . . . . 8M-16
SYSTEMS, POWER DISTRIBUTION . . . . . . . 8O-10
SYSTEMS, TURN SIGNAL AND HAZARD
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -4
T0RQUE CHART . . . . . . . . . . . . . . . . . . . . . . . 5-40
TABLE, A/C APPLICATION . . . . . . . . . . . . . . 24-47
TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
TAILPIPE, MUFFLER . . . . . . . . . . . . . . . . . . . 11-6
TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . . . 8W-7
TANK CAPACITY, FUEL . . . . . . . . . . . . . . . . 14-23
TANK, COOLANT RESERVE . . . . . . . . . . . . . . 7-23
TANK FILLER TUBE CAP, FUEL . . . . . . 14-21,14-6
TANK, FUEL . . . . . . . . . . . . . . . . . . . . . 14-19,14-4
TANK SKID PLATE, FUEL . . . . . . . . . . . . . . . . 13-7
TAPPET, HYDRAULIC . . . . . . . . . . . . . . . . 9-67,9-7
TAPPETS, HYDRAULIC . . . . . . . 9-100,9-113,9-40
TASK MANAGER . . . . . . . . . . . . . . . . . . . . . 25-16
TEMPERATURE SENSOR, AMBIENT . . . . . . . 8V-8
TEMPERATURE SENSOR, BATTERY . . . 8C-2,8C-5
TEMPERATURE SENSOR, ENGINE
COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . 14-49
XJ INDEX 13
TEMPERATURE SENSOR, INTAKE
MANIFOLD AIR . . . . . . . . . . . . . . . . . . . . . . 14-50
TEMPERATURE SENSORPCM INPUT,
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . 14-30
TEMPERATURE SENSORPCM INPUT,
INTAKE MANIFOLD AIR . . . . . . . . . . . . . . . . 14-32
TENSION, BELT . . . . . . . . . . . . . . . . . . . . . . . 7-40
TENSIONER, PARKING BRAKE CABLE . . . . . . 5-31
TERMINAL REPLACEMENT . . . . . . . . . . . . 8W-13
TERMINAL REPLACEMENT, CONNECTOR . 8W-12
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . 8W-11
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . 8W-10
TERMINAL/CONNECTOR REPAIR
THOMAS AND BETTS CONNECTORS . . . . . 8W-10
TEST ANALYSIS, PRESSURE . . . . . . . . . . . 21-242
TEST ANALYSIS, TIME LAG . . . . . . . . . . . . 21-243
TEST, ANALYZING ROAD . . . . . . . . . . . . . . 21-129
TEST, CYLINDER COMBUSTION
PRESSURE LEAKAGE . . . . . . . . . . . . . . 9-13,9-73
TEST, CYLINDER COMPRESSION
PRESSURE . . . . . . . . . . . . . . . . . . . . . . 9-13,9-73
TEST FOR CHARGING SYSTEM,
ON-BOARD DIAGNOSTIC. . . . . . . . . . . . . . . . 8C-3
TEST, FUEL INJ ECTOR . . . . . . . . . . . . . . . . . 14-10
TEST, FUEL PRESSURE LEAK DOWN . . . . . . 14-7
TEST, FUEL PUMP AMPERAGE . . . . . . . . . . . 14-8
TEST, FUEL PUMP CAPACITY . . . . . . . . . . . . 14-7
TEST, FUEL PUMP PRESSURE . . . . . . . . . . . . . 14-6
TEST, HYDRAULIC PRESSURE . . . 21-129,21-241
TEST, MANUAL SHIFTING . . . . . . . . . . . . . 21-241
TEST MODE, CIRCUIT ACTUATION . . . . . . . . 25-2
TEST MODE, STATE DISPLAY . . . . . . . . . . . . 25-2
TEST PROCEDURE . . . . . . . . . . . . . . . . . . . 21-242
TEST, ROAD . . . . . . . . . . . . . . . . . . . . . . . . . 8H-4
TEST, TIME LAG . . . . . . . . . . . . . . . . . . . . 21-242
TEST, TRACLOK . . . . . . . . . . . . . . . 3-110,3-71
TEST, VACUUM SUPPLY . . . . . . . . . . . . . . . . 8H-4
TESTING, RADIATOR CAPPRESSURE . . . . 7-20
TESTING, ROAD . . . . . . . . . . . . . . . . . . . . . 21-129
TESTING, SPEED SENSOR . . . . . . . . . . . . . 21-246
TESTING TRANSMISSION CLUTCH AND
BAND OPERATION, AIR . . . . . . . . . . . . . . . 21-131
TESTING TRANSMISSION MAIN COOLER,
FLOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-246
TESTING, TRANSMISSION SOLENOID . . . . 21-245
TESTS, TROUBLESHOOTING . . . . . . . . . . . . 8W-9
THEFT SECURITY SYSTEM, 8W-39
VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
THERMOGUARD, BATTERY . . . . . . . . . 8A-22,8A-5
THERMOMETER . . . . . . . . . . . . . . . . . . 8V-2,8V-4
THERMOMETER DISPLAY MODULE, TRIP
COMPUTER, COMPASS. . . . . . . . . . . . . 8V-3,8V-7
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . 7-28,7-4
THREAD REPAIR, ALUMINUM . . . . 21-144,21-249
THREADED HOLE REPAIR . . . . . . . . . . . . . Intro.-3
THREADS, REPAIR DAMAGED OR WORN . . 9-27,
9-88
THROTTLE BODY . . . . . . . . . . . . . . . . 14-36,14-44
THROTTLE BODY MINIMUM AIR FLOW
CHECK PROCEDURE . . . . . . . . . . . . . . . . . . 14-42
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . 14-22
THROTTLE CABLE, TRANSMISSION . . . . . 21-267
THROTTLE POSITION SENSOR (TPS) . . . . . 14-45
THROTTLE POSITION SENSOR
(TPS)PCM INPUT. . . . . . . . . . . . . . . . . . . 14-34
THROTTLE VALVE CABLE . . . . . . . 21-129,21-246
THROTTLE VALVE CABLE ADJ USTMENT,
TRANSMISSION. . . . . . . . . . . . . . . 21-198,21-337
TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-23
TIME LAG TEST . . . . . . . . . . . . . . . . . . . . . 21-242
TIME LAG TEST ANALYSIS . . . . . . . . . . . . 21-243
TIMING CASE COVER . . . . . . . . . . . . . 9-101,9-42
TIMING CASE COVER OIL SEAL . . . . . 9-112,9-41
TIMING CHAIN AND SPROCKETS . . . . 9-102,9-43
TIMING, IGNITION . . . . . . . . . . . . . . . . . . . . 8D-23
TIMING, VALVE . . . . . . . . . . . . . . . . . . . 9-15,9-75
TIRE AND WHEEL BALANCE . . . . . . . . . . . . . 22-9
TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . 22-7
TIRE INFLATION PRESSURES . . . . . . . . . . . . 22-2
TIRE NOISE OR VIBRATION . . . . . . . . . . . . . 22-3
TIRE PRESSURE FOR HIGH SPEED . . . . . . . 22-3
TIRE SIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6
TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . 22-3
TIRETEMPORARY, SPARE . . . . . . . . . . . . . . 22-2
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1
TIRES, CLEANING . . . . . . . . . . . . . . . . . . . . . 22-6
TIRES, RADIAL-PLY . . . . . . . . . . . . . . . . . . . . 22-2
TIRES, REPLACEMENT . . . . . . . . . . . . . . . . . 22-3
TONE WHEEL, WHEEL SPEED SENSORS . . . 5-34
TOOL, DRB SCAN . . . . . . . . . . . . . . . . . . . . . . 7-9
TOOLS, 2.5L ENGINE SPECIAL . . . . . . . . . . . 9-60
TOOLS, TROUBLESHOOTING . . . . . . . . . . . . 8W-8
TOOLSBODY, SPECIAL . . . . . . . . . . . . . . 23-135
TOOLSSEATS, SPECIAL . . . . . . . . . . . . . . 23-20
TOP COVER, INSTRUMENT PANEL . . . . . . . 8E-21
TORQUE; CLUTCH . . . . . . . . . . . . . . . . . . . . . 6-15
TORQUE; DIFFERENTIAL AND DRIVELINE . . . 3-61
TORQUE; TRANSMISSION AND
TRANSFER CASE . . 21-213,21-373,21-39,21-405,
21-85
TORQUE CHART; BRAKES . . . . . . . . . . . . . . . 5-32
TORQUE CHART; CHARGING SYSTEM . . . . . 8C-5
TORQUE CHART; EMISSION CONTROL
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-28
TORQUE CHART; FUEL SYSTEM . . . . 14-24,14-51
TORQUE CHART; IGNITION SYSTEM . . . . . 8D-24
TORQUE CHART; SPEED CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-7
TORQUE CHART; STEERING . . 19-10,19-21,19-25,
19-28
TORQUE CHART; SUSPENSION . . . . . . . 2-14,2-19
TORQUE CHART; TIRES AND WHEELS . . . . 22-11
TORQUE CONVERTER . . . . 21-146,21-222,21-252,
21-97
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-247
TORQUE CONVERTER, TRANSMISSION . . 21-250
TORQUE REFERENCES . . . . . . . . . . . . . . . Intro.-6
TORQUE SPECIFICATIONS; BODY . . . . . . . 23-135
TORQUE SPECIFICATIONS; COOLING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40
TORQUE SPECIFICATIONS; ENGINE . . . . . . 9-118
TORQUE SPECIFICATIONS; EXHAUST
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-8
TORQUE SPECIFICATIONS, FRAME . . . . . . . . 13-9
TOUCH-UP, PAINTED SURFACE . . . . . . . . . . . 23-4
TOW, 8W-54 TRAILER . . . . . . . . . . . . . . . . . 8W-1
TOW HOOK, FRONT . . . . . . . . . . . . . . . . . . . . 13-3
TOW HOOK, REAR . . . . . . . . . . . . . . . . . . . . . 13-5
TOW HOOKS, EMERGENCY . . . . . . . . . . . . . . 0-11
TOWER, SHIFT . . . . . . . . . . . . . . . . . . . . . . 21-47
TOWING AND HOISTING, J UMP
STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9
TOWING, FOUR-WHEEL-DRIVE VEHICLE . . . 0-10
TOWING, TWO-WHEEL-DRIVE VEHICLE . . . . 0-10
(TPS)PCM INPUT, THROTTLE
POSITION SENSOR . . . . . . . . . . . . . . . . . . . 14-34
TRACK BAR . . . . . . . . . . . . . . . . . . . . . . . 2-12,2-9
TRACK, BUCKET SEAT . . . . . . . . . . . . . . . . . 23-15
TRAC-LOK . . . . . . . . . . . . . . . . . . . . 3-125,3-91
TRAC-LOK DIFFERENTIAL . . . 3-105,3-121,3-66,
3-87
TRACLOK DIFFERENTIAL NOISE . . 3-109,3-70
TRACLOK TEST . . . . . . . . . . . . . . . 3-110,3-71
TRAILER HITCH . . . . . . . . . . . . . . . . . . . . . . . 13-7
TRAILER TOW, 8W-54 . . . . . . . . . . . . . . . . . 8W-1
TRANSFER CASE . . . . . . . . . . . . . . 21-348,21-377
TRANSFER CASE, NV231 . 21-346,21-351,21-369
TRANSFER CASE, NV231 TRANSFER
CASENV231 . . . . . . . . . . . . . . . . . . . . . . . . 21-346
TRANSFER CASE, NV242 . 21-375,21-380,21-402
TRANSFER CASE, NV242 TRANSFER
CASENV242 . . . . . . . . . . . . . . . . . . . . . . . . 21-375
TRANSFER CASE SKID PLATE . . . . . . . . . . . . 13-6
TRANSFER CASENV231 TRANSFER
CASE, NV231. . . . . . . . . . . . . . . . . . . . . . . 21-346
TRANSFER CASENV242 TRANSFER
CASE, NV242. . . . . . . . . . . . . . . . . . . . . . . 21-375
TRANSMISSION . . 21-144,21-163,21-194,21-269,
21-3,21-44,21-48
TRANSMISSION, 30RH AUTOMATIC . . . . 21-212,
21-89
TRANSMISSION AND TORQUE
CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-250
TRANSMISSION, AW-4 AUTOMATIC . . . . . 21-338
TRANSMISSION, AW4 AUTOMATIC . . . . . 21-218
TRANSMISSION, AW4 AUTOMATIC
TRANSMISSIONAW4 AUTOMATIC . . . . . . 21-217
TRANSMISSION, AX5 MANUAL . . . . . . . . . . . 21-1
TRANSMISSION CLUTCH AND BAND
OPERATION, AIR TESTING . . . . . . . . . . . . 21-131
TRANSMISSION COMPONENTS . . . . . . . . . 21-83
TRANSMISSION COMPONENTS, AX5
MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-37
TRANSMISSION CONTROL MODULE . . . . 21-260
(TCM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-237
(TCM) SERVICE . . . . . . . . . . . . . . . . . . . . . 21-248
TRANSMISSION CONTROL SYSTEM,
8W-31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
TRANSMISSION COOLER . . . . . . . . . . . . . 21-237
TRANSMISSION DIAGNOSIS,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . 21-126
TRANSMISSION FILL PROCEDURE . . . . . . 21-142
TRANSMISSION MAIN COOLER, FLOW
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-246
TRANSMISSION NOISE . . . . . . . . . . . . 21-3,21-44
TRANSMISSION, NV3550 MANUAL . . 21-42,21-85
TRANSMISSION, NV3550 MANUAL
TRANSMISSIONNV3550 MANUAL . . . . . . . . 21-42
TRANSMISSION OIL COOLER,
AUTOMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
TRANSMISSION OIL COOLERS . . . . . . . . . . . 7-23
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . 21-336
TRANSMISSION RANGES AND SHIFT
LEVER POSITIONS. . . . . . . . . . . . . . . . . . . 21-236
TRANSMISSION SHIFT INTERLOCK,
BRAKE . . . . . . . . . . . . . . . . . . . . . . 21-150,21-256
TRANSMISSION SHIFT INTERLOCK
CABLE ADJ USTMENT, BRAKE . . . . 21-198,21-336
TRANSMISSION SHIFT INTERLOCK
MECHANISM, BRAKE . . . . . . . . . . 21-125,21-238
TRANSMISSION SOLENOID TESTING . . . . 21-245
TRANSMISSION THROTTLE CABLE . . . . . . 21-267
TRANSMISSION THROTTLE VALVE
CABLE ADJ USTMENT . . . . . . . . . . 21-198,21-337
TRANSMISSION VALVE BODY . . . . 21-259,21-333
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . 21-228
SOLENOIDS . . . . . . . . . . . . . . . . . . . . . . . . 21-258
TRANSMISSIONAW4 AUTOMATIC
TRANSMISSION, AW4 AUTOMATIC. . . . . 21-217
TRANSMISSION30RH, AUTOMATIC
TRANSMISSION30RHAUTOMATIC. . . . . . 21-88
TRANSMISSION30RHAUTOMATIC
TRANSMISSION30RH, AUTOMATIC. . . . . 21-88
TRANSMISSIONNV3550 MANUAL
TRANSMISSION, NV3550 MANUAL. . . . . . . 21-42
TRANSMISSIONS, 30RH . . . . . . . . . . . . . . 21-213
TRANSMITTER BATTERY REPLACEMENT,
TRANSMITTER PROGRAMMING,
TRANSMITTER, REMOTE KEYLESS
ENTRY. . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2,8P-5
TRANSPONDER PROGRAMMING,
SENTRY KEY IMMOBILIZER SYSTEM. . . . . . 8Q-4
TRANSPONDER, SENTRY KEY
IMMOBILIZER . . . . . . . . . . . . . . . . . . . . . . . . 8Q-2
TRAY, BATTERY . . . . . . . . . . . . . . . . . . 8A-22,8A-5
TREAD WEAR INDICATORS . . . . . . . . . . . . . . 22-3
TRIM AND WHEELHOUSE COVER,
QUARTER PANEL . . . . . . . . . . . . . . . . . . . . . 23-54
TRIM, A-PILLAR . . . . . . . . . . . . . . . . . . . . . 23-51
TRIM, B-PILLAR . . . . . . . . . . . . . . . . . . . . . 23-52
TRIM COVER, DRIVER SIDE AIRBAG
MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-7
TRIM, C-PILLAR . . . . . . . . . . . . . . . . . . . . . 23-53
TRIM EXTENSION, QUARTER PANEL . . . . . 23-54
TRIM, LIFTGATE OPENING UPPER . . . . . . . 23-55
TRIM, LIFTGATE PILLAR . . . . . . . . . . . . . . . 23-55
TRIM, LOWER A-PILLAR COWL . . . . . . . . . 23-51
TRIM PANEL, FRONT DOOR . . . . . . . . . . . . 23-33
TRIM PANEL, LIFTGATE . . . . . . . . . . . . . . . . 23-61
TRIM PANEL, REAR DOOR . . . . . . . . . . . . . 23-42
TRIP COMPUTER . . . . . . . . . . . . . . . . . . . . . 8V-1
TRIP COMPUTER, COMPASS, AND
THERMOMETER DISPLAY MODULE . . . 8V-3,8V-7
TRIP DEFINITION . . . . . . . . . . . . . . . . . . . . . 25-21
TROUBLE CODE DESCRIPTIONS,
DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 25-3
TROUBLE CODES, DIAGNOSTIC . . . . . . . . . . 25-2
TROUBLESHOOTING TESTS . . . . . . . . . . . . . 8W-9
TROUBLESHOOTING TOOLS . . . . . . . . . . . . 8W-8
TROUBLESHOOTING WIRING PROBLEMS . . 8W-9
TUBE, 181, AND 186 FBI AXLE . . . . . . . . . . . 3-16
TUBE AXLE ASSEMBLY . . . . . . . . . . . . . . . . . 3-23
TUBE CAP, FUEL TANK FILLER . . . . . . 14-21,14-6
TUBE, FIXED ORIFICE . . . . . . . . . . . . . 24-35,24-5
14 INDEX XJ
TUBE FLARING, BRAKE . . . . . . . . . . . . . . . . . 5-14
TUBES, FLUSHING COOLERS . . . . 21-143,21-248
TUBES/LINES/HOSES AND CLAMPS,
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-6
TURN SIGNAL AND HAZARD WARNING
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -4
TURN SIGNAL CANCELLING CAM . . . . . . . . . 8J -3
TURN SIGNAL SWITCH AND HAZARD
WARNING SWITCH . . . . . . . . . . . . 8J -2,8J -5,8J -6
TURN SIGNAL SYSTEM . . . . . . . . . . . . . . . . . 8J -1
TURN SIGNALS, 8W-52 . . . . . . . . . . . . . . . . 8W-1
TURN SIGNAL/TAIL LAMP, BACK-UP/
BRAKE/REAR . . . . . . . . . . . . . . . . . . . . . . . . 8L-16
TURN SIGNAL/TAIL LAMP BULB,
BACK-UP/BRAKE/REAR . . . . . . . . . . . . . . . . 8L-11
TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . 0-10
U-J OINT, AXLE SHAFTCARDAN . . . . . . . . . 3-23
U-J OINT, CARDAN . . . . . . . . . . . . . . . . . . . . . 3-47
UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . 8L-16
UNDERHOOD LAMP BULB . . . . . . . . . . . . . 8L-12
UNIT, FUEL GAUGE SENDING . . 14-10,14-16,14-3
UNIT, HYDRAULIC CONTROL . . . . . . . . . . . . 5-34
UNIT/CONTROLLER ANTILOCK BRAKE,
HYDRAULIC CONTROL . . . . . . . . . . . . . . . . . 5-39
UNIT/CONTROLLER ANTILOCK BRAKES,
HYDRAULIC CONTROL . . . . . . . . . . . . . . . . . 5-36
UNIVERSAL J OINT, SINGLE CARDAN . . . . . . . 3-9
UJ OINTS, PROPELLER SHAFTS . . . . . . . . . . . 3-15
UNSCHEDULED INSPECTION . . . . . . . . . . . . . 0-4
UPPER SUSPENSION ARM . . . . . . . . . . . . . . 2-11
UPPER SUSPENSION ARMS AND
BUSHINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
UPPER TRIM, LIFTGATE OPENING . . . . . . . 23-55
USAGE, FASTENER . . . . . . . . . . . . . . . . . . Intro.-3
USAGE, INSTALLATION METHODS AND
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
VACUUM ACTUATOR, MODE DOOR . . . . . . 24-43
VACUUM CHECK VALVE . . . . . . . . . . . 24-46,24-9
VACUUM RESERVOIR; HEATING AND AIR
CONDITIONING . . . . . . . . . . . . . . . . . . 24-47,24-9
VACUUM RESERVOIR; SPEED CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 8H-3,8H-6
VACUUM SCHEMATICS . . . . . . . . . . . . . . . . 25-26
VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . 8H-4
VACUUM SYSTEM . . . . . . . . . . . . . . . . . . . . 24-18
VALUE, LOAD . . . . . . . . . . . . . . . . . . . . . . . 25-22
VALVE BODY . . . . . 21-102,21-151,21-156,21-191,
21-200
VALVE BODY COMPONENTS,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-228
VALVE BODY SOLENOIDS,
TRANSMISSION. . . . . . . . . . . . . . . . . . . . . 21-258
VALVE BODY, TRANSMISSION . . . 21-259,21-333
VALVE CABLE ADJ USTMENT,
TRANSMISSION THROTTLE . . . . . 21-198,21-337
VALVE CABLE, THROTTLE . . . . . . . 21-129,21-246
VALVE, COMBINATION . . . . . . 5-11,5-16,5-3,5-35
VALVE, CONVERTER DRAINBACK . . . . . . . 21-125
VALVE GUIDE . . . . . . . . . . . . . . . . . . . . . 9-67,9-7
VALVE, GUIDE AND SEAL . . . . . . . . . . . . . . . 9-15
VALVE, HIGH PRESSURE RELIEF . . . . . . . . . 24-7
VALVE, ROLLOVER . . . . . . . . . . . . . . . . . . . 25-23
VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . 9-75
VALVE SERVICE, CONVERTER
DRAINBACK CHECK. . . . . . . . . . . . . . . . . . 21-142
VALVE SHAFT SEAL, MANUAL . . . . . . . . . 21-262
VALVE, SPOOL . . . . . . . . . . . . . . . . . . . . . . . 19-14
VALVE SPRING . . . . . . . . . . . . . . . . . . . . 9-67,9-7
VALVE SPRING AND SEAL . . . . . . . . . . . . . . 9-37
VALVE SPRINGS AND OIL SEALS . . . . . . . . . 9-97
VALVE SPRINGS, VALVES . . . . . . . . . . . . . . 9-100
VALVE STEM SEAL . . . . . . . . . . . . . . . . . 9-67,9-8
VALVE TIMING . . . . . . . . . . . . . . . . . . . . 9-15,9-75
VALVE, VACUUM CHECK . . . . . . . . . . . 24-46,24-9
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6,9-67
VALVES AND VALVE SPRINGS . . . . . . . . . . 9-100
VALVE(S), ROLLOVER . . . . . . . . . . . . . . . . . 25-27
VANITY LAMP BULB, VISOR . . . . . . . . . . . . 8L-13
VANITY LAMP, VISOR . . . . . . . . . . . . . . . . . 8L-18
VARIATION ADJ USTMENT, COMPASS . . . . . . 8V-4
VEHICLE EMISSION CONTROL
INFORMATION (VECI) LABEL . . . . . . . . . . . 25-26
VEHICLE IDENTIFICATION NUMBER . . . . . Intro.-1
VEHICLE PREPARATION FOR HEADLAMP
ALIGNMENT. . . . . . . . . . . . . . . . . . . . . . . . . . 8L-6
VEHICLE SAFETY CERTIFICATION LABEL . Intro.-2
VEHICLE SPEED AND DISTANCE
SENSORPCM INPUT . . . . . . . . . . . . . . . . 14-34
VEHICLE SPEED CONTROL, 8W-33 . . . . . . . 8W-1
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . 14-51
VEHICLE SPEED SENSOR (SPEED
CONTROL OPERATION) . . . . . . . . . . . . . . . . . 8H-4
VEHICLE THEFT SECURITY SYSTEM,
8W-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1
VEHICLE TOWING, FOUR-WHEEL-DRIVE . . . 0-10
VEHICLE TOWING, TWO-WHEEL-DRIVE . . . . 0-10
VENTILATION SYSTEM, CRANKCASE . . . . . 25-25,
25-27
VIBRATION . . . . . . . . . . . . . . 3-109,3-21,3-4,3-70
VIBRATION DAMPER . . . . . . . . . . . . . . 9-101,9-41
VIBRATION, TIRE NOISE OR . . . . . . . . . . . . . 22-3
VIEW MIRROR, SIDE . . . . . . . . . . . . . . . . . . 23-31
VIN REPROGRAMMING, PCM . . . . . . . . . . . . 14-1
VISCOUS FAN DRIVE . . . . . . . . . . . . . . . . 7-19,7-7
VISCOUS FAN DRIVE REMOVAL/
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . 7-39
VISOR VANITY LAMP . . . . . . . . . . . . . . . . . 8L-18
VISOR VANITY LAMP BULB . . . . . . . . . . . . 8L-13
VISUAL INSPECTION . . . . . . . . . . . . . . . . . . 14-37
VOLT SENSOR SUPPLIESPRIMARY
AND SECONDARY, FIVE. . . . . . . . . . . . . . . . 14-29
VOLTAGE REGULATOR, ELECTRONIC . . . . . . 8C-2
VOLTAGEPCM INPUT, BATTERY . . . . . . . . 14-29
VOLUME CHECK, OIL PUMP . . . . . 21-142,21-248
WARNING LAMP, ABS . . . . . . . . . . . . . . . . . . 5-35
WARNING LAMP, RED BRAKE . . . . . . . . . 5-3,5-9
WARNING SWITCH, TURN SIGNAL
SWITCH AND HAZARD . . . . . . . . . 8J -2,8J -5,8J -6
WARNING SYSTEM, CHIME . . . . . . . . . . . . . 8U-1
WARNING SYSTEM, HAZARD . . . . . . . . . . . . 8J -1
WARNING SYSTEM SWITCHES, CHIME . . . . 8U-4
WARNING SYSTEMS, TURN SIGNAL AND
HAZARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J -4
WARNINGS & CAUTIONS, SERVICE . . . . . . . . 5-2
WARNINGS AND PRECAUTIONS,
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23
WARNINGS, NOTES, CAUTIONS . . . . . . . . . 8W-7
WARNINGS, SAFETY PRECAUTIONS . . . . . . . 23-3
WASHER FLUID LEVEL SENSOR . . . . . . . . . . 8K-4
WASHER NOZZLE AND PLUMBING . . . . . . . . 8K-4
WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . 8K-4
WASHER RESERVOIR . . . . . . . . . . . . . . . . . . 8K-3
WASHER SWITCH, WIPER SWITCH . 8K-11,8K-3,
8K-7
WASHER SYSTEM . . . . . . . . . . . . . . . 8K-13,8K-6
WASHER SYSTEM, REAR WIPER . . . . . . . . . 8K-2
WASHER SYSTEM, WINDSHIELD . . . . . . . . . 8K-1
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . 23-22
WATER PUMP . . . . . . . . . . . . . . . . . 7-24,7-39,7-6
WATERDAM, FRONT DOOR . . . . . . . . . . . . . 23-34
WATERDAM, REAR DOOR . . . . . . . . . . . . . . 23-42
WEAR INDICATORS, TREAD . . . . . . . . . . . . . 22-3
WEAR PATTERNS, TIRE . . . . . . . . . . . . . . . . 22-3
WEATHERSTRIP, COWL . . . . . . . . . . . . . . . . 23-28
WEATHERSTRIP, FRONT DOOR GLASS
RUN CHANNEL . . . . . . . . . . . . . . . . . . . . . . 23-38
WEATHERSTRIP, FRONT DOOR INNER
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37
WEATHERSTRIP, FRONT DOOR OPENING . . 23-38
WEATHERSTRIP, FRONT DOOR OPENING
SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . 23-39
WEATHERSTRIP, FRONT DOOR OUTER
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38
WEATHERSTRIP, LIFTGATE . . . . . . . . . . . . . 23-65
WEATHERSTRIP, REAR DOOR . . . . . . . . . . . 23-46
WEATHERSTRIP, REAR DOOR GLASS
RUN CHANNEL . . . . . . . . . . . . . . . . . . . . . . 23-46
WEATHERSTRIP, REAR DOOR INNER
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
WEATHERSTRIP, REAR DOOR OUTER
BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45
WELD LOCATIONS . . . . . . . . . . . . . . . . . . . . 23-68
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . 2-1,2-4
WHEEL BALANCE, TIRE . . . . . . . . . . . . . . . . . 22-9
WHEEL CYLINDER . . . . . . . . . . . . 5-21,5-28,5-29
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . 22-7
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . 22-8
WHEEL MOUNTING STUDS . . . . . . . . . . . . . . 2-13
WHEEL RUNOUT, TIRE . . . . . . . . . . . . . . . . . 22-7
WHEEL SPEED SENSOR, FRONT . . . . . . . . . . 5-37
WHEEL SPEED SENSOR, REAR . . . . . . . . . . . 5-37
WHEEL SPEED SENSORS AND TONE
WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
WHEEL, WHEEL SPEED SENSORS AND
TONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
WHEELHOUSE COVER, QUARTER PANEL
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-54
WHEELHOUSE LINER, FRONT . . . . . . . . . . . 23-32
WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . 23-23
WINDOW APPLIQUE, QUARTER . . . . . . . . . 23-49
WINDOW DEFOGGER, 8W-48 REAR . . . . . . 8W-1
WINDOW DEFOGGER SYSTEM, REAR . . . . . 8N-1
WINDOW GLASS, REAR DOOR . . . . . . . . . . 23-47
WINDOW GLASS, REAR DOOR
STATIONARY . . . . . . . . . . . . . . . . . . . . . . . . . 23-9
WINDOW GLASS, REAR QUARTER . . . . . . . 23-10
WINDOW MOTOR, POWER . . . . . 8S-2,8S-4,8S-6
WINDOW REGULATOR, FRONT DOOR . . . . 23-39
WINDOW REGULATOR, REAR DOOR . . . . . 23-47
WINDOW SWITCH, POWER . . . . . 8S-1,8S-4,8S-5
WINDOW SYSTEM, POWER . . . . . . . . . 8S-1,8S-2
WINDOWS, 8W-60 POWER . . . . . . . . . . . . . 8W-1
WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . 23-6
WINDSHIELD SAFETY PRECAUTIONS . . . . . . 23-6
WINDSHIELD WASHER SYSTEM . . . . . . . . . 8K-1
WINDSHIELD WIPER SYSTEM . . . . . . . . . . . 8K-1
WIPER AND WASHER SYSTEM, REAR . . . . . 8K-2
WIPER ARM . . . . . . . . . . . . . . . . . . . . . . . . . 8K-8
WIPER ARM AND BLADE . . . . . . . . . . . . . . . 8K-2
WIPER BLADE . . . . . . . . . . . . . . . . . . . . . . . . 8K-8
WIPER LINKAGE AND PIVOT . . . . . . . . 8K-2,8K-9
WIPER MOTOR . . . . . . . . . . . . . . . . . . . 8K-2,8K-9
WIPER SWITCH AND WASHER SWITCH . . 8K-11,
8K-3,8K-7
WIPER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 8K-4
WIPER SYSTEM, WINDSHIELD . . . . . . . . . . . 8K-1
WIPERS, 8W-53 . . . . . . . . . . . . . . . . . . . . . . 8W-1
WIRING PROBLEMS,
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . 8W-9
WIRING REPAIR . . . . . . . . . . . . . . . . . . . . . 8W-10
WIRING/TERMINAL . . . . . . . . . . . . . . . . . . 8W-15
WORM SHAFT, RACK PISTON . . . . . . . . . . . 19-16
WORN THREADS, REPAIR DAMAGED OR . . 9-27,
9-88
YOKE BUSHING, REAR HOUSING . . . . . . . . 21-48
YOKE SEAL REPLACEMENT . . . . . . . . . . . 21-147
YOKE SEAL2WD . . . . . . . . . . . . . . . . . . . 21-47
XJ INDEX 15

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