Documente Academic
Documente Profesional
Documente Cultură
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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . . 4
JUMP STARTING, TOWING AND HOISTING . . . . 9
INDEX
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0 G?
AUTOMATIC POWER
Wh er e t im e a n d m ilea ge a r e list ed, follow t h e TRANSMISSION STEERING
in t er va l t h a t occu r s fir st . FLUID FLUID
,, . ,..... ,
Q ENGINE
COOLANT Q I
WINDSHIELD
WASHER FLUJD
9500-1
9400-9
INDEX
page
GENERAL INFORMATION
MAINTENANCE SCHEDULES . . . . . . . . . . . . . . . 4
52,500 Miles (84 000 km) or at 42 months 97,500 Miles (156 000 km) or at 78 months
• Ch a n ge en gin e oil. • Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er. • Repla ce en gin e oil filt er.
• F lu sh a n d r epla ce en gin e coola n t if n ot don e a t • Lu br ica t e st eer in g lin ka ge (4x4 on ly).
36 m on t h s.
• Lu br ica t e st eer in g lin ka ge (4x4 on ly). 105,000 Miles (168 000 km) or at 84 months
• Ch a n ge en gin e oil.
60,000 Miles (96 000 km) or at 48 months • Repla ce en gin e oil filt er.
• Ch a n ge en gin e oil. • Lu br ica t e st eer in g lin ka ge.
• Repla ce en gin e oil filt er. • F lu sh a n d r epla ce en gin e coola n t if it h a s been
• Re p la c e e n g in e a ir c le a n e r e le m e n t. 30,000 m iles (48 000 km ) or 24 m on t h s sin ce la st
• Re p la c e ig n itio n c a ble s . ch a n ge.
• Re p la c e s p a rk p lu g s . • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• In spect dr ive belt , a dju st t en sion a s n ecessa r y.
• Lu br ica t e st eer in g lin ka ge. 112,500 Miles (180 000 km) or at 90 months
• Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id. • Ch a n ge en gin e oil.
• Dr a in a n d r efill t r a n sfer ca se flu id. • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • In spect br a ke lin in gs.
• F lu sh a n d r epla ce en gin e coola n t if it h a s been
67,500 Miles (108 000 km) or at 54 months 30,000 m iles (48 000 km ) or 24 m on t h s sin ce la st
• Ch a n ge en gin e oil. ch a n ge.
• Repla ce en gin e oil filt er. • Lu br ica t e st eer in g lin ka ge (4x4 on ly).
• In spect br a ke lin in gs. • Dr a in a n d r efill m a n u a l t r a n sm ission flu id.
• Lu br ica t e st eer in g lin ka ge (4x4 on ly).
120,000 Miles (192 000 km) or at 96 months
75,000 Miles (120 000 km) or at 60 months • Ch a n ge en gin e oil.
• Ch a n ge en gin e oil. • Repla ce en gin e oil filt er.
• Repla ce en gin e oil filt er. • Re p la c e e n g in e a ir c le a n e r e le m e n t.
• Lu br ica t e st eer in g lin ka ge. • Re p la c e ig n itio n c a ble s .
• Re p la c e s p a rk p lu g s .
• In spect dr ive belt , a dju st t en sion a s n ecessa r y.
0-6 LUBRICATION AND MAINTENANCE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
• Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g lin ka ge.
• Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id. • Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id.
• Dr a in a n d r efill t r a n sfer ca se flu id. • Dr a in a n d r efill fr on t a n d r ea r a xles.‡
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • In spect br a ke lin in gs.
Im p o rta n t: In spect ion a n d ser vice sh ou ld a lso be • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
per for m ed a n y t im e a m a lfu n ct ion is obser ved or su s-
pect ed. 27,000 Miles (43 000 km)
• Ch a n ge en gin e oil.
SCHEDULE “B” • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge.
3,000 Miles (5 000 km)
• Ch a n ge en gin e oil. 30,000 Miles (48 000 km)
• Repla ce en gin e oil filt er. • Ch a n ge en gin e oil.
• Lu br ica t e st eer in g lin ka ge. • Repla ce en gin e oil filt er.
• Re p la c e e n g in e a ir c le a n e r e le m e n t.
6,000 Miles (10 000 km) • Re p la c e s p a rk p lu g s .
• Ch a n ge en gin e oil. • In spect dr ive belt , a dju st t en sion a s n ecessa r y.
• Repla ce en gin e oil filt er. • Lu br ica t e st eer in g lin ka ge.
• Lu br ica t e st eer in g lin ka ge. • Dr a in a n d r efill t r a n sfer ca se flu id.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
9,000 Miles (14 000 km) 33,000 Miles (53 000 km)
• Ch a n ge en gin e oil. • Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er. • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g lin ka ge.
12,000 Miles (19 000 km) 36,000 Miles (58 000 km)
• Ch a n ge en gin e oil. • Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er. • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g lin ka ge.
• Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id. • Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id.
• Dr a in a n d r efill fr on t a n d r ea r a xles.‡ • Dr a in a n d r efill fr on t a n d r ea r a xles.‡
• In spect br a ke lin in gs. • In spect br a ke lin in gs.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• Dr a in a n d r efill m a n u a l t r a n sm ission flu id.
15,000 Miles (24 000 km)
• Ch a n ge en gin e oil. 39,000 Miles (62 000 km)
• Repla ce en gin e oil filt er. • Ch a n ge en gin e oil.
• In s p e c t e n g in e a ir c le a n e r e le m e n t, re p la c e • Repla ce en gin e oil filt er.
a s n e c e s s a ry. • Lu br ica t e st eer in g lin ka ge.
• Lu br ica t e st eer in g lin ka ge.
42,000 Miles (67 000 km)
18,000 Miles (29 000 km) • Ch a n ge en gin e oil.
• Ch a n ge en gin e oil. • Repla ce en gin e oil filt er.
• Repla ce en gin e oil filt er. • Lu br ica t e st eer in g lin ka ge.
• Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• Dr a in a n d r efill m a n u a l t r a n sm ission flu id. 45,000 Miles (72 000 km)
• Ch a n ge en gin e oil.
21,000 Miles (34 000 km) • Repla ce en gin e oil filt er.
• Ch a n ge en gin e oil. • In s p e c t e n g in e a ir c le a n e r e le m e n t, re p la c e
• Repla ce en gin e oil filt er. a s n e c e s s a ry.
• Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g lin ka ge.
24,000 Miles (38 000 km) 48,000 Miles (77 000 km)
• Ch a n ge en gin e oil. • Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er. • Repla ce en gin e oil filt er.
XJ LUBRICATION AND MAINTENANCE 0-7
GEN ERAL I N FORM AT I ON (Cont inue d)
• Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g lin ka ge.
• Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id. • Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id.
• Dr a in a n d r efill fr on t a n d r ea r a xles.‡ • Dr a in a n d r efill fr on t a n d r ea r a xles.‡
• In spect br a ke lin in gs. • In spect br a ke lin in gs.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• Dr a in a n d r efill m a n u a l t r a n sm ission flu id.
51,000 Miles (82 000 km)
• Ch a n ge en gin e oil. 75,000 Miles (120 000 km)
• Repla ce en gin e oil filt er. • Ch a n ge en gin e oil.
• F lu sh a n d r epla ce en gin e coola n t . • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge. • In s p e c t e n g in e a ir c le a n e r e le m e n t, re p la c e
a s n e c e s s a ry.
54,000 Miles (86 000 km) • Lu br ica t e st eer in g lin ka ge.
• Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er. 78,000 Miles (125 000 km)
• Lu br ica t e st eer in g lin ka ge. • Ch a n ge en gin e oil.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • Repla ce en gin e oil filt er.
• Dr a in a n d r efill m a n u a l t r a n sm ission flu id. • Lu br ica t e st eer in g lin ka ge.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
57,000 Miles (91 000 km)
• Ch a n ge en gin e oil. 81,000 Miles (134 000 km)
• Repla ce en gin e oil filt er. • Ch a n ge en gin e oil.
• Lu br ica t e st eer in g lin ka ge. • Repla ce en gin e oil filt er.
• F lu sh a n d r epla ce en gin e coola n t if it h a s been
60,000 Miles (96 000 km) 30,000 m iles (48 000 km ) sin ce la st ch a n ge.
• Ch a n ge en gin e oil. • Lu br ica t e st eer in g lin ka ge.
• Repla ce en gin e oil filt er.
• Re p la c e e n g in e a ir c le a n e r e le m e n t. 84,000 Miles (134 000 km)
• Re p la c e ig n itio n c a ble s . • Ch a n ge en gin e oil.
• Re p la c e s p a rk p lu g s . • Repla ce en gin e oil filt er.
• In spect dr ive belt , a dju st t en sion a s n ecessa r y. • Lu br ica t e st eer in g lin ka ge.
• Lu br ica t e st eer in g lin ka ge. • Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id.
• Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id. • Dr a in a n d r efill fr on t a n d r ea r a xles.‡
• Dr a in a n d r efill t r a n sfer ca se flu id. • In spect br a ke lin in gs.
• Dr a in a n d r efill fr on t a n d r ea r a xles.‡ • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• In spect br a ke lin in gs.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. 87,000 Miles (139 000 km)
• Ch a n ge en gin e oil.
63,000 Miles (101 000 km) • Repla ce en gin e oil filt er.
• Ch a n ge en gin e oil. • Lu br ica t e st eer in g lin ka ge.
• Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge. 90,000 Miles (144 000 km)
• Ch a n ge en gin e oil.
66,000 Miles (106 000 km) • Repla ce en gin e oil filt er.
• Ch a n ge en gin e oil. • Re p la c e e n g in e a ir c le a n e r e le m e n t.
• Repla ce en gin e oil filt er. • Re p la c e s p a rk p lu g s .
• Lu br ica t e st eer in g lin ka ge. • In spect dr ive belt , a dju st t en sion a s n ecessa r y.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • Lu br ica t e st eer in g lin ka ge.
• Dr a in a n d r efill t r a n sfer ca se flu id.
69,000 Miles (110 000 km) • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• Ch a n ge en gin e oil. • Dr a in a n d r efill m a n u a l t r a n sm ission flu id.
• Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge. 93,000 Miles (149 000 km)
• Ch a n ge en gin e oil.
72,000 Miles (115 000 km) • Repla ce en gin e oil filt er.
• Ch a n ge en gin e oil. • Lu br ica t e st eer in g lin ka ge.
• Repla ce en gin e oil filt er.
0-8 LUBRICATION AND MAINTENANCE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
96,000 Miles (154 000 km) • F lu sh a n d r epla ce en gin e coola n t if it h a s been
• Ch a n ge en gin e oil. 30,000 m iles (48 000 km ) sin ce la st ch a n ge.
• Repla ce en gin e oil filt er. • Lu br ica t e st eer in g lin ka ge.
• Lu br ica t e st eer in g lin ka ge.
• Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id. 114,000 Miles (182 000 km)
• Dr a in a n d r efill fr on t a n d r ea r a xles.‡ • Ch a n ge en gin e oil.
• In spect br a ke lin in gs. • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • Lu br ica t e st eer in g lin ka ge.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
99,000 Miles (158 000 km)
• Ch a n ge en gin e oil. 117,000 Miles (187 000 km)
• Repla ce en gin e oil filt er. • Ch a n ge en gin e oil.
• Lu br ica t e st eer in g lin ka ge. • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g lin ka ge.
102,000 Miles (163 000 km)
• Ch a n ge en gin e oil. 120,000 Miles (192 000 km)
• Repla ce en gin e oil filt er. • Ch a n ge en gin e oil.
• Lu br ica t e st eer in g lin ka ge. • Repla ce en gin e oil filt er.
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. • Re p la c e e n g in e a ir c le a n e r e le m e n t.
• Re p la c e ig n itio n c a ble s .
105,000 Miles (168 000 km) • Re p la c e s p a rk p lu g s .
• Ch a n ge en gin e oil. • In spect dr ive belt , a dju st t en sion a s n ecessa r y.
• Repla ce en gin e oil filt er. • Lu br ica t e st eer in g lin ka ge.
• In s p e c t e n g in e a ir c le a n e r e le m e n t, re p la c e • Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id.
a s n e c e s s a ry. • Dr a in a n d r efill t r a n sfer ca se flu id.
• Lu br ica t e st eer in g lin ka ge. • Dr a in a n d r efill fr on t a n d r ea r a xles.‡
• In spect br a ke lin in gs.
108,000 Miles (173 000 km) • Lu br ica t e st eer in g a n d su spen sion ba ll join t s.
• Ch a n ge en gin e oil. ‡Off-h igh wa y oper a t ion , t r a iler t owin g, t a xi, lim ou -
• Repla ce en gin e oil filt er. sin e, bu s, sn ow plowin g, or ot h er t ypes of com m er cia l
• Lu br ica t e st eer in g lin ka ge. ser vice or pr olon ged oper a t ion wit h h ea vy loa din g,
• Dr a in a n d r efill a u t om a t ic t r a n sm ission flu id. especia lly in h ot wea t h er, r equ ir e fr on t a n d r ea r a xle
• Dr a in a n d r efill fr on t a n d r ea r a xles.‡ ser vice in dica t ed wit h a ‡ in Sch edu le “B”. P er for m
• In spect br a ke lin in gs. t h ese ser vices if t h e veh icle is u su a lly oper a t ed u n der
• Lu br ica t e st eer in g a n d su spen sion ba ll join t s. t h ese con dit ion s.
• Dr a in a n d r efill m a n u a l t r a n sm ission flu id. Im p o rta n t: In spect ion a n d ser vice sh ou ld a lso be
per for m ed a n y t im e a m a lfu n ct ion is obser ved or su s-
111,000 Miles (178 000 km) pect ed.
• Ch a n ge en gin e oil.
• Repla ce en gin e oil filt er.
XJ LUBRICATION AND MAINTENANCE 0-9
J U M P START I N G, T OWI N G AN D H OI ST I N G
INDEX
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page page
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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1 MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . 2
INDEX
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M AI N T EN AN CE SCH EDU LE
INDEX
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SCHEDULE—A
1 000 KM
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er.
XJ LUBRICATION AND MAINTENANCE 0-3
GEN ERAL I N FORM AT I ON (Cont inue d)
60 000 KM • Ch eck cor r ect t or qu e, exh a u st m a n ifold m ou n t -
• Ch a n ge en gin e oil. in g n u t s.
• Ch a n ge en gin e oil filt er. • Ch eck cor r ect t or qu e, t u r boch a r ger m ou n t in g
• Repla ce a ir filt er elem en t . n u t s.
• Ch eck glow plu g oper a t ion . • Ch eck cor r ect t or qu e, wa t er m a n ifold bolt s.
• Repla ce dr ive belt .
• Ch eck en gin e sm oke. 1 000 KM
• Repla ce en gin e coola n t . • Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er.
70 000 KM • Ch eck a ll flu id levels.
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er. 5 000 KM
• Ch a n ge en gin e oil.
80 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er. 10 000 KM
• Repla ce a ir filt er elem en t . • Ch a n ge en gin e oil.
• Ch eck dr ive belt t en sion . • Ch a n ge en gin e oil filt er.
• Ch eck glow plu g oper a t ion . • Repla ce a ir filt er elem en t .
• Repla ce fu el filt er /wa t er sepa r a t or elem en t .** • Ch eck dr ive belt t en sion .
• Ch eck glow plu g oper a t ion .
90 000 KM
• Ch a n ge en gin e oil. 15 000 KM
• Ch a n ge en gin e oil filt er. • Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er.
100 000 KM
• Ch a n ge en gin e oil. 20 000 KM
• Ch a n ge en gin e oil filt er. • Ch a n ge en gin e oil.
• Repla ce a ir filt er elem en t . • Ch a n ge en gin e oil filt er.
• Ch eck dr ive belt t en sion . • Repla ce a ir filt er elem en t .
• Ch eck glow plu g oper a t ion . • Ch eck dr ive belt t en sion .
• Ch eck glow plu g oper a t ion .
EVERY 40 000 KM AFTER 80 000 KM • Re to rqu e c y lin d e r h e a d bo lts .*
• Repla ce fu el filt er /wa t er sepa r a t or elem en t .** * E n gin es equ ipped wit h a st eel h ea d ga sket do n ot
**Th e fu el filt er /wa t er sepa r a t or elem en t sh ou ld be n eed t h is ser vice pr ocedu r e per for m ed. Refer t o
r epla ced on ce a yea r if t h e veh icle is dr iven less t h a n Gr ou p 9, E n gin es for h ea d ga sket iden t ifica t ion .
40 000 km a n n u a lly or if power loss fr om fu el st a r-
va t ion is det ect ed. 25 000 KM
• Ch a n ge en gin e oil.
EVERY 10 000 KM AFTER 100 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er. 30 000 KM
• Ch a n ge en gin e oil.
EVERY 20 000 KM AFTER 100 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil. • Repla ce a ir filt er elem en t .
• Ch a n ge en gin e oil filt er. • Ch eck glow plu g oper a t ion .
• Repla ce a ir filt er elem en t . • Repla ce dr ive belt .
• Ch eck dr ive belt t en sion . • Ch eck en gin e sm oke.
• Ch eck glow plu g oper a t ion . • Repla ce en gin e coola n t .
SCHEDULE—B 35 000 KM
• Ch a n ge en gin e oil.
500 KM • Ch a n ge en gin e oil filt er.
• Ch eck cor r ect t or qu e, in t a ke m a n ifold m ou n t in g
n u t s.
0-4 LUBRICATION AND MAINTENANCE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
40 000 KM • Repla ce a ir filt er elem en t .
• Ch a n ge en gin e oil. • Ch eck glow plu g oper a t ion .
• Ch a n ge en gin e oil filt er. • Repla ce dr ive belt .
• Repla ce a ir filt er elem en t . • Ch eck en gin e sm oke.
• Ch eck dr ive belt t en sion . • Repla ce en gin e coola n t .
• Ch eck glow plu g oper a t ion .
• Repla ce fu el filt er /wa t er sepa r a t or elem en t . 85 000 KM
• Ch a n ge en gin e oil.
45 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er. 90 000 KM
• Ch a n ge en gin e oil.
50 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil. • Repla ce a ir filt er elem en t .
• Ch a n ge en gin e oil filt er. • Ch eck dr ive belt t en sion .
• Repla ce a ir filt er elem en t . • Ch eck glow plu g oper a t ion .
• Ch eck dr ive belt t en sion .
• Ch eck glow plu g oper a t ion . 95 000 KM
• Ch a n ge en gin e oil.
55 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er. 100 000 KM
• Ch a n ge en gin e oil.
60 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil. • Repla ce a ir filt er elem en t .
• Ch a n ge en gin e oil filt er. • Ch eck dr ive belt t en sion .
• Repla ce a ir filt er elem en t . • Ch eck glow plu g oper a t ion .
• Ch eck dr ive belt t en sion . • Repla ce fu el filt er /wa t er sepa r a t or elem en t .
• Ch eck glow plu g oper a t ion .
• Repla ce fu el filt er /wa t er sepa r a t or elem en t . EVERY 5 000 KM AFTER 100 000 KM
• Ch a n ge en gin e oil.
65 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er. EVERY 10 000 KM AFTER 100 000 KM
• Ch a n ge en gin e oil.
70 000 KM • Ch a n ge en gin e oil filt er.
• Ch a n ge en gin e oil. • Repla ce a ir filt er elem en t .
• Ch a n ge en gin e oil filt er. • Ch eck dr ive belt t en sion .
• Repla ce a ir filt er elem en t . • Ch eck glow plu g oper a t ion .
• Ch eck dr ive belt t en sion .
• Ch eck glow plu g oper a t ion . EVERY 20 000 KM AFTER 100 000 KM
• Repla ce fu el filt er /wa t er sepa r a t or elem en t .
75 000 KM
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er.
80 000 KM
• Ch a n ge en gin e oil.
• Ch a n ge en gin e oil filt er.
XJ EXHAUST SYSTEM 11 - 1
EXHAUST SYSTEM
CON T EN T S
page page
EXHAUST
PIPE
TAILPIPE
CATALYTIC CONVERTER
Th e st a in less st eel ca t a lyt ic con ver t er body is
design ed t o la st t h e life of t h e veh icle. E xcessive h ea t
ca n r esu lt in bu lgin g or ot h er dist or t ion , bu t exces-
sive h ea t will n ot be t h e fa u lt of t h e con ver t er. If
-
u n bu r n ed fu el en t er s t h e con ver t er, over h ea t in g m a y
occu r. If a con ver t er is h ea t -da m a ged, cor r ect t h e
ca u se of t h e da m a ge a t t h e sa m e t im e t h e con ver t er
80abd2b9 is r epla ced. Also, in spect a ll ot h er com pon en t s of t h e
exh a u st syst em for h ea t da m a ge.
Fig. 1 Exhaust System—2.5L/4.0L Un lea ded ga solin e m u st be u sed t o a void con t a m i-
Th e exh a u st syst em u ses a sin gle m u ffler wit h a ca t - n a t in g t h e ca t a lyst cor e.
a lyt ic con ver t er con sist in g of du a l cer a m ic m on olit h s.
11 - 2 EXHAUST SYSTEM XJ
EXHAUST SYSTEM
EX H AU ST SY ST EM DI AGN OSI S CH ART
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.
REM OVAL AN D I N STALLAT I ON (6) Rem ove t h e cla m p n u t s a n d cla m p (F ig. 2). To
r em ove t h e exh a u st pipe fr om t h e ca t a lyt ic con ver t er,
EXHAUST PIPE a pply h ea t u n t il t h e m et a l becom es ch er r y r ed. Dis-
con n ect t h e exh a u st pipe fr om t h e ca t a lyt ic con ver t er
WARNING: IF TORCHES ARE USED WHEN WORK- (F ig. 2). Rem ove t h e exh a u st pipe.
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES. INSTALLATION
(1) Assem ble exh a u st pipe t o m a n ifold a n d ca t a -
lyt ic con ver t er loosely t o per m it pr oper a lign m en t of
CAUTION: When servicing exhaust system compo- a ll pa r t s.
nents, disconnect the oxygen sensor connector. (2) Use a n ew cla m p a n d t igh t en t h e n u t s t o 61
Allowing the exhaust system to hang by the oxygen N·m (45 ft . lbs.) t or qu e.
sensor harness will damage the wiring and/or sen- (3) Con n ect t h e exh a u st pipe t o t h e en gin e exh a u st
sor. m a n ifold. In st a ll a n ew sea l bet ween t h e exh a u st
m a n ifold a n d t h e exh a u st pipe (4.0L en gin e on ly).
Tigh t en t h e n u t s t o 31 N·m (23 ft . lbs.) t or qu e (F ig.
REMOVAL 2).
(1) Ra ise a n d su ppor t t h e veh icle. (4) In st a ll t h e r ea r cr ossm em ber. In st a ll a n d
(2) Sa t u r a t e t h e bolt s a n d n u t s wit h h ea t va lve t igh t en t h e fou r (4) cr ossm em ber t o r ea r m ou n t n u t s
lu br ica n t (F ig. 2). Allow 5 m in u t es for pen et r a t ion . t o 22 N·m (16 ft . lbs.) In st a ll a n d t igh t en t h e cr oss-
(3) Discon n ect t h e oxygen sen sor con n ect or (F ig. m em ber t o sill bolt s t o 42 N·m (31 ft . lbs.) t or qu e.
3). Rem ove t h e su ppor t fr om t h e t r a n sm ission .
(4) Discon n ect t h e exh a u st pipe fr om t h e en gin e (5) Coa t t h e oxygen sen sor wit h a n t i-seize com -
exh a u st m a n ifold. Disca r d t h e sea l (4.0L en gin e, pou n d. In st a ll t h e sen sor a n d t igh t en t h e n u t t o 27
on ly). N·m (20 ft . lbs.) t or qu e.
(5) Su ppor t t h e t r a n sm ission a n d r em ove t h e r ea r (6) Lower t h e veh icle.
cr ossm em ber.
XJ EXHAUST SYSTEM 11 - 3
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CATALYTIC
CONVERTER
EXHAUST PIPE
ASSEMBLY
MUFFLER
TAILPIPE ASSEMBLY
CLAMP 80b46c18
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e cla m ps fr om t h e ca t a lyt ic con ver t er
a n d m u ffler con n ect ion (F ig. 4).
(3) Discon n ect a n d r em ove t h e oxygen sen sor fr om
t h e ca t a lyt ic con ver t er.
(4) H ea t t h e ca t a lyt ic con ver t er a n d m u ffler con -
n ect ion wit h a n oxya cet ylen e t or ch u n t il t h e m et a l
becom es ch er r y r ed.
(5) Wh ile t h e m et a l is st ill ch er r y r ed, t wist t h e
m u ffler a ssem bly ba ck a n d for t h t o sepa r a t e it fr om
t h e ca t a lyt ic con ver t er.
(6) Discon n ect t h e exh a u st pipe fr om t h e ca t a lyt ic
con ver t er (F ig. 4). If n eeded, h ea t u p t h e pipes t o sep-
80b89896
a r a t e.
Fig. 3 Oxygen Sensor Location—2.5L/4.0L
INSTALLATION
(7) St a r t t h e en gin e a n d in spect for exh a u st lea ks (1) Con n ect t h e ca t a lyt ic con ver t er t o t h e exh a u st
a n d exh a u st syst em con t a ct wit h t h e body pa n els. pipe a n d t h e m u ffler /t a ilpipe a ssy. (F ig. 4). Use a n ew
Adju st t h e a lign m en t , if n eeded. cla m p a n d t igh t en t h e n u t s t o 61 N·m (45 ft . lbs.)
t or qu e.
CATALYTIC CONVERTER (2) In st a ll t h e m u ffler on t o t h e ca t a lyt ic con ver t er
u n t il t h e a lign m en t t a b is in ser t ed in t o t h e a lign -
WARNING: IF TORCHES ARE USED WHEN WORK-
m en t slot .
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINES.
11 - 4 EXHAUST SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove t h e fr on t exh a u st cla m p fr om t h e ca t -
a lyt ic con ver t er a n d m u ffler con n ect ion (F ig. 6).
MUFFLER
--------------
1 I
1
MUFFLER~
CATALYTIC
CONVERTER
I
80b8984e
Fig. 4 Catalytic Converter to Muffler and Exhaust
Pipe Connection TAILPIPE 80a9b369
(3) In st a ll a n ew cla m p a t t h e m u ffler a n d ca t a -
lyt ic con ver t er con n ect ion (F ig. 4). Tigh t en t h e cla m p Fig. 5 Front Exhaust Tailpipe Hanger
n u t t o 61 N·m (45 ft . lbs.) t or qu e.
CLAMP
(4) Coa t t h e oxygen sen sor wit h a n t i-seize com -
pou n d. In st a ll t h e sen sor a n d t igh t en t h e n u t t o 27
N·m (20 ft . lbs.) t or qu e.
(5) Lower t h e veh icle.
(6) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
Adju st t h e a lign m en t , if n eeded.
WARNING: IF TORCHES ARE USED WHEN WORK- Fig. 6 Catalytic Converter to Muffler Connection
ING ON THE EXHAUST SYSTEM, DO NOT ALLOW
THE FLAME NEAR THE FUEL LINE. (4) H ea t t h e ca t a lyt ic con ver t er-t o-m u ffler con n ec-
t ion wit h a n oxya cet ylen e t or ch u n t il t h e m et a l
becom es ch er r y r ed.
CAUTION: When servicing exhaust system compo- (5) Wh ile t h e m et a l is st ill ch er r y r ed, r em ove t h e
nents, disconnect the oxygen sensor connector. exh a u st m u ffler /t a ilpipe a ssem bly fr om t h e ca t a lyt ic
Allowing the exhaust system to hang by the oxygen con ver t er.
sensor harness will damage the wiring and/or sensor. (6) Slide t h e m u ffler /t a ilpipe a ssy. r ea r wa r d a n d
ou t of t h e r ea r exh a u st t a ilpipe m ou n t in g br a cket
REMOVAL (F ig. 7).
(1) Ra ise a n d su ppor t t h e veh icle. (7) Rem ove t h e m u ffler fr om t h e exh a u st t a ilpipe:
(2) Discon n ect fr on t t a ilpipe h a n ger fr om t h e in su - • To r em ove a n or igin a l equ ipm en t exh a u st m u f-
la t or (F ig. 5). fler /t a ilpipe com bin a t ion , cu t t h e exh a u st t a ilpipe
XJ EXHAUST SYSTEM 11 - 5
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) Align t h e t a ilpipe a n d in st a ll a n ew cla m p a t
t h e m u ffler t o t a ilpipe con n ect ion .
(7) Tigh t en t h e m u ffler t o t a ilpipe cla m p t o 61 N·m
(45 ft . lbs.)
(8) Lower t h e veh icle.
(9) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
Adju st t h e a lign m en t , if n eeded.
SPECI FI CAT I ON S
TORQUE SPECIFICATIONS
D e s c rip tio n To rqu e
Ca ta ly tic Co n v e rte r/Ex h a u s t P ip e
E xh a u st Cla m p Nu t . . . . . . . . . . 61 N·m (45 ft . lbs.)
Cro s s m e m be r to S ill
Bolt s . . . . . . . . . . . . . . . . . . . . . . 42 N·m (31 ft . lbs.)
MUFFLER/TAILPIPE Cro s s m e m be r to Tra n s m is s io n Mo u n t
ASSEMBLY
80abd2aa Nu t s . . . . . . . . . . . . . . . . . . . . . . 22 N·m (16 ft . lbs.)
Ex h a u s t P ip e to Ma n ifo ld
Fig. 7 Rear Exhaust Tailpipe Mounting Bracket Nu t s . . . . . . . . . . . . . . . . . . . . . . 31 N·m (23 ft . lbs.)
close t o t h e m u ffler. Colla pse t h e pa r t r em a in in g in Ex h a u s t Ma n ifo ld –2.5L En g in e
t h e m u ffler a n d r em ove. Bolt #1 . . . . . . . . . . . . . . . . . . . . 41 N·m (30 ft . lbs.)
• To r em ove a ser vice exh a u st t a ilpipe/m u ffler Ex h a u s t Ma n ifo ld –2.5L En g in e
com bin a t ion , a pply h ea t u n t il t h e m et a l becom es Nu t s #6&7 . . . . . . . . . . . . . . . . . 31 N·m (23 ft . lbs.)
ch er r y r ed. Rem ove t h e exh a u st t a ilpipe/m u ffler Ex h a u s t Ma n ifo ld –4.0L En g in e
cla m p a n d t wist t h e exh a u st t a ilpipe ou t of t h e m u f- Nu t s #6&7 . . . . . . . . . . . . . . . . . 31 N·m (23 ft . lbs.)
fler. Bolt #3 . . . . . . . . . . . . . . . . . . . . 33 N·m (24 ft . lbs.)
In ta k e Ma n ifo ld –2.5L En g in e
INSTALLATION Bolt #2–5 . . . . . . . . . . . . . . . . . . 31 N·m (23 ft . lbs.)
(1) In st a ll t h e m u ffler on t o t h e ca t a lyt ic con ver t er. In ta k e & Ex h a u s t Ma n ifo ld –2.5L En g in e
In st a ll t h e cla m p a n d t igh t en t h e n u t fin ger t igh t . Bolt s #2–5 . . . . . . . . . . . . . . . . . 31 N·m (23 ft . lbs.)
(2) In st a ll t h e exh a u st t a ilpipe in t o t h e r ea r of t h e In ta k e & Ex h a u s t Ma n ifo ld –4.0L En g in e
m u ffler. Nu t s/Bolt s #1,2,4,5,8–11 . . . . . . . 33 N·m (24 ft . lbs.)
(3) In st a ll t h e exh a u st t a ilpipe/m u ffler a ssem bly Mu ffle r to Ca ta ly tic Co n v e rte r
on t h e r ea r exh a u st t a ilpipe m ou n t in g br a cket . Ma ke E xh a u st Cla m p Nu t . . . . . . . . . . 61 N·m (45 ft . lbs.)
su r e t h a t t h e exh a u st t a ilpipe h a s su fficien t clea r- Ox y g e n S e n s o rs
a n ce fr om t h e floor pa n . Nu t . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (20 ft . lbs.)
(4) In st a ll fr on t t a ilpipe h a n ger in t o t h e in su la t or Re a r Ta il P ip e Ha n g e r
(F ig. 5).
Nu t s . . . . . . . . . . . . . . . . . . . . . . 54 N·m (40 ft . lbs.)
(5) Align t h e m u ffler a n d t igh t en t h e n u t s on t h e
m u ffler-t o-ca t a lyt ic con ver t er cla m p t o 61 N·m (45 ft .
lbs.) t or qu e (F ig. 6).
XJ EXHAUST SYSTEM AND TURBOCHARGER 11 - 1
page page
REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e fr on t m u ffler cla m p fr om t h e
exh a u st pipe a n d m u ffler con n ect ion .
(3) Rem ove t h e r ea r exh a u st t a ilpipe h a n ger cla m p
a n d r em ove t h e exh a u st t a ilpipe fr om t h e fr on t
J951 l-18 exh a u st t a ilpipe h a n ger.
(4) Rem ove t h e exh a u st t a ilpipe a ssem bly fr om t h e
Fig. 2 Exhaust Down Pipe to Front Exhaust Pipe m u ffler.
(4) Rem ove t h e cla m p n u t s a t m u ffler (F ig. 3). To INSTALLATION
r em ove t h e exh a u st pipe fr om t h e m u ffler, a pply h ea t (1) In st a ll t h e m u ffler on t o t h e exh a u st pipe.
u n t il t h e m et a l becom es ch er r y r ed. Discon n ect t h e In st a ll t h e cla m p a n d t igh t en t h e n u t s fin ger t igh t .
exh a u st pipe fr om t h e m u ffler. Rem ove t h e exh a u st (2) In st a ll t h e exh a u st t a ilpipe in t o t h e r ea r of t h e
pipe. m u ffler.
(3) In st a ll t h e exh a u st t a ilpipe/m u ffler a ssem bly
on t h e r ea r exh a u st t a ilpipe h a n ger. Ma ke su r e t h a t
t h e exh a u st t a ilpipe h a s su fficien t clea r a n ce fr om t h e
floor pa n .
(4) In st a ll t h e r em a in in g cla m ps a n d t h e fr on t
exh a u st t a ilpipe h a n ger.
(5) Tigh t en t h e n u t s on t h e m u ffler-t o-exh a u st pipe
cla m p t o 43 N·m t or qu e.
(6) Tigh t en t h e n u t s on t h e m u ffler-t o-exh a u st pipe
cla m p t o 43 N·m t or qu e.
(7) Lower t h e veh icle.
(8) St a r t t h e en gin e a n d in spect for exh a u st lea ks
a n d exh a u st syst em con t a ct wit h t h e body pa n els.
Adju st t h e a lign m en t , if n eeded.
80b9a496
TURBOCHARGER
ASSEMBLY
(REMOVED
FROM
VEHICLE)
~
EXHAUST MANIFOLD
DOWNPIPE 80b8992e
Fig. 7 Turbocharger Oil Return Hose Fig. 8 Turbocharger / Exhaust Manifold Assembly
CAUTION: Heatshield is very sharp. Wear gloves to WASTE GATE
OIL RETURN LINE
prevent injury. VACUUM
SUPPLY HOSE
(19) Rem ove t h e exh a u st down pipe h ea t sh ield by
pu llin g st r a igh t u p.
(20) Rem ove t h e (5) bolt s fr om exh a u st m a n ifold
down pipe a n d r em ove pipe.
(21) Rem ove t h e (8) exh a u st m a n ifold r et a in in g TURBOCHARGER
bolt s, it is n ecessa r y t o a ccess t h e bolt beh in d t h e ASSEMBLY
m a n ifold ou t let fr om t h e u n der n ea t h of t h e veh icle. (REMOVED
(22) Rem ove t h e exh a u st m a n ifold a n d t u r bo- FROM
ch a r ger a ssem bly fr om t h e veh icle. VEHICLE)
(23) P la ce a ssem bly in a vice t o r em ove t h e (3)
exh a u st m a n ifold t o t u r boch a r ger r et a in in g n u t s (F ig.
8).
Cleaning
All old ga sket s sh ou ld be in spect ed for a n y t ea r s or
sign s of pr ior lea ka ge. If a n y ga sket s sh ow su ch in di-
ca t ion s, t h ey sh ou ld be r epla ced wit h n ew ga sket s.
All ga sket m a t in g su r fa ces m u st be clea n ed of old
ga sket m a t er ia l t o pr odu ce a sm oot h a n d dir t fr ee
sea lin g su r fa ce for t h e n ew ga sket . Fig. 9 Turbocharger / Exhaust Manifold Assembly
EXHAUST SYSTEM
SUPPORT CLAMP
\
80b9a496
RIGHT:::::::::::::-
ENGINE MOUNT Fig. 11 Exhaust System Inlet Pipe Connection
THROUGH BOLT
NUT~ INNERCOOLER
OUTLET HOSE
EXHAUST MANIFOLD
DOWNPIPE 80b8992e
EXHAUST INLET
PIPE RETAINING
BOLTS
EXHAUST SYSTEM
SUPPORT CLAMP
80b9a496
,
VEHICLE) o
TURBOCHARGER Cleaning
OIL PRESSURE All old ga sket s sh ou ld be in spect ed for a n y t ea r s or
SUPPLY LINE AT sign s of pr ior lea ka ge. If a n y ga sket sh ows su ch in di-
ENGINE BLOCK sobse932 ca t ion s, it m u st be r epla ced wit h a n ew ga sket . All
ga sket m a t in g su r fa ces m u st be clea n ed of a ll old
Fig. 17 R.H.D. Turbo Position & Orientation ga sket m a t er ia l t o pr odu ce a sm oot h a n d dir t fr ee
(22) Rem ove t h e t u r boch a r ger oil pr essu r e su pply sea lin g su r fa ce for t h e n ew ga sket .
lin e fr om t h e en gin e block (F ig. 17).
(23) Wor kin g in side of t h e veh icle, r em ove t h e INSTALLATION
Kn ee Blocker. Refer t o Gr ou p 8E , In st r u m en t P a n el (1) In st a ll t h e t u r boch a r ger on t h e exh a u st m a n i-
Syst em s for t h e pr ocedu r e. fold (F ig. 19). Tor qu e n u t s t o 32 N·m (23 ft . lbs.).
11 - 8 EXHAUST SYSTEM AND TURBOCHARGER XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
WASTE GATE (5) P osit ion t h e t u r boch a r ger oil pr essu r e su pply
OIL RETURN LINE
VACUUM lin e in it s or igin a l posit ion (F ig. 20). Tor qu e t h e t u r bo
SUPPLY HOSE fit t in g t o 27 N·m (20 ft . lbs.).
(6) In st a ll t h e wa st ega t e a ct u a t or va cu u m su pply
h ose on t h e a ct u a t or (F ig. 20).
(7) In st a ll t h e exh a u st m a n ifold h ea t sh ield (F ig.
21). Tor qu e bolt s t o 11 N·m (97 in . lbs.).
TURBOCHARGER
ASSEMBLY CLUTCH
(REMOVED MASTER CYLINDER
FROM HEATSHIELD
VEHICLE) o
EXHAUST INLET
PIPE RETAINING
BOLTS
EXHAUST SYSTEM
SUPPORT CLAMP
80b9a496
Fig. 22 Exhaust Downpipe Heatshield Fig. 24 Exhaust System Inlet Pipe Connection
(20) In st a ll t h e clu t ch m a st er cylin der h ea t sh ield.
(21) In st a ll t h e in t a ke m a n ifold elbow a n d t h e
E GR va lve a s a n a ssem bly. Tor qu e t h e in t a ke elbow
bolt s t o 27 N·m (20 ft . lbs.).
(22) In st a ll t h e (2) bolt s h oldin g t h e E GR t u be t o
t h e E GR va lve. Tor qu e t o bolt s 27 N·m (20 ft . lbs.).
(23) Tor qu e t h e E GR t u be on t h e exh a u st m a n ifold
t o 28 N·m (21 ft . lbs.).
(24) In st a ll t h e in n er cooler in let a n d ou t let h oses
on t h e en gin e.
(25) In st a ll t h e E GR va cu u m su pply h ose on t h e
E GR va lve.
RIGHT:::::::::::::-
(26) In st a ll t h e a ir filt er cover a n d ou t let h ose on
ENGINE MOUNT
THROUGH BOLT t h e t u r boch a r ger.
(27) Con n ect t h e br ea t h er h ose on t h e a ir clea n er
NUT~
ou t let h ose.
(28) In st a ll t h e h ea t er cor e coola n t su pply a n d t h e
br a ke va cu u m su pply lin es in t h er e or igin a l posit ion .
(29) Con n ect t h e n ega t ive ba t t er y ca ble.
(30) F ill t h e coolin g syst em . Refer t o Gr ou p 7,
EXHAUST MANIFOLD
DOWNPIPE 80b8992e
Coolin g Syst em for t h e pr ocedu r e.
(31) St a r t t h e en gin e a n d ch eck for lea ks.
Fig. 23 Turbocharger Oil Return Hose
(19) In st a ll t h e Kn ee Blocker. Refer t o Gr ou p 8E ,
In st r u m en t P a n el Syst em s for pr ocedu r e.
11 - 10 EXHAUST SYSTEM AND TURBOCHARGER XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
page page
BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BU M PERS
INDEX
page page
-
t h e r et a in in g t a b. (3) In st a ll Tor x-h ea d bolt s t h a t a t t a ch bu m per t o
(2) In st a ll t h e scr ews a t t a ch in g t h e en d ca p t o t h e m ou n t in g br a cket s. Tigh t en bolt s t o 55 N·m (41 ft .
fr on t fen der. lbs.) t or qu e.
(3) In st a ll t h e bolt s a t t a ch in g t h e en d ca p t o t h e (4) Con n ect va cu u m lin e t o r eser voir.
bu m per. Tigh t en t h e n u t t o 9 N·m (7 ft . lbs.) t or qu e. (5) If equ ipped, en ga ge fog la m p wir e h a r n ess con -
(4) In st a ll t h e r ivet a t t a ch in g t h e en d ca p t o a ir n ect or s.
deflect or. (6) In st a ll bu m per en d ca ps.
13 - 2 FRAME AND BUMPERS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
END CAP
80b3b136
80aafb09
REAR BUMPER
REMOVAL
(1) F or veh icles equ ipped wit h a t r a iler h it ch ,
r em ove h it ch befor e r em ovin g bu m per. If n ecessa r y,
r efer t o r em ova l pr ocedu r e wit h in Gr ou p 13, F r a m e
a n d Bu m per s.
(2) Rem ove bu m per en d ca ps.
(3) Rem ove u pper n u t s t h a t a t t a ch bu m per t o
bu m per su ppor t br a cket s (F ig. 5).
(4) Rem ove lower bolt s t h a t a t t a ch bu m per t o
80b3b131 bu m per su ppor t br a cket s.
(5) Rem ove bu m per fr om veh icle.
Fig. 4 Front Tow Hook (6) If n ecessa r y, r em ove bu m per su ppor t br a cket s
(3) Lift t h e en d ca p sligh t ly u pwa r d a n d slide it fr om t h e r ea r sill.
r ea r wa r d t o r elea se it fr om t h e r et a in er.
(4) Sepa r a t e t h e en d ca p fr om t h e veh icle. INSTALLATION
(1) If r em oved, in st a ll bu m per su ppor t br a cket s on
INSTALLATION t h e r ea r sill. Tigh t en bolt s t o 55 N·m (41 ft . lbs.)
(1) P osit ion t h e en d ca p on t h e r ea r of t h e r et a in er t or qu e.
a n d t h e ou t er edge of t h e bu m per. (2) P osit ion bu m per on su ppor t br a cket s.
(2) Slide t h e en d ca p for wa r d on t o t h e r et a in er. (3) In st a ll bolt s t h a t a t t a ch bu m per t o bu m per
E n su r e t h e en d ca p over la ps t h e lip of t h e r ea r su ppor t br a cket s. Tigh t en n u t s t o 55 N·m (41 ft . lbs.)
wh eelh ou se lin er. t or qu e.
(3) In st a ll t h e scr ew a t t a ch in g t h e fr on t of t h e en d (4) In st a ll bu m per en d ca ps.
ca p t o t h e u n der side of t h e qu a r t er pa n el. (5) If r em oved, in st a ll t r a iler h it ch .
i
i
80b3b137
INSTALLATION
(1) P osit ion br a cket a n d t ow h ook on fr a m e r a il.
(2) In st a ll bolt s t h a t a t t a ch t ow h ook br a cket a n d
t ow h ook t o fr a m e r a il. Tigh t en bolt s t o 94 N·m (70
ft . lbs.) t or qu e.
FRAM E
INDEX
page page
J9223-165
RIVET H O L E S ~ INSTALLATION
~,P REl~CEMENT
RIVET
FUEL TANK
SKID PLATE
'
Fig. 3 Fuel Tank Skid Plate
80b5cc86
80aa0fe8
SPECI FI CAT I ON S
FRAME DIMENSIONS
F r a m e dim en sion s a r e list ed in m illim et er sca le.
All dim en sion s a r e fr om cen t er t o cen t er of P r in cipa l
Loca t in g P oin t (P LP ), or fr om cen t er t o cen t er of P LP
a n d fa st en er loca t ion (F ig. 6).
770.0 888.96
±1.5 . 43.0 720.0 772.0 ±1.5
912.0 ±0.25 ±1.5 ±1.5
±1.5 (L.H. ONLY) 41.0 870.0 927.96
I
m
0
5.0
±0.25
(L.H.-
I ±0.75 ±1.5 ±1.5
fm ONLY)
Fig. 6 Frame Dimensions
zc.n
5 •
zc.n 0
•
116.0 519.5
±0.50 ±1.5
151 .52
z ---
782.05-i
±0.7
1280.0
±0.50
±0.75
~
....;= 127.52
±0.75
f 539.5 -
~ -±0.75
m
~ 204.0
±3.0
150.16
±0.75
51 .5
25.0
±0.75
(L.H. ONLY)
178.0
±0.75
I I 1000.0 _ _ _ ____,
±l.5
51.5
±0.75
....
C0
~
13 - 7
w
u,
13 - 8 FRAME AND BUMPERS XJ
SPECI FI CAT I ON S (Cont inue d)
page page
INDEX
page
-
DISASSEMBLY AND ASSEMBLY
SWING AWAY SPARE TIRE CARRIER
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
80aef29c
FRAM E
INDEX
page
GENERAL INFORMATION
EMERGENCY TOW EYES . . . . . . . . . . . . . . . . . . 2
FUEL SYSTEM
CON T EN T S
page page
FU EL DELI V ERY SY ST EM
INDEX
page page
CAUTION: DO NOT use gasoline containing METH- • Th e u se of lea ded ga s is pr oh ibit ed by F eder a l
ANOL. Gasoline containing methanol may damage la w. Usin g lea ded ga solin e ca n im pa ir en gin e per for-
critical fuel system components. m a n ce, da m a ge t h e em ission con t r ol syst em , a n d
cou ld r esu lt in loss of wa r r a n t y cover a ge.
• An ou t -of-t u n e en gin e, or cer t a in fu el or ign it ion
MMT m a lfu n ct ion s, ca n ca u se t h e ca t a lyt ic con ver t er t o
MMT is a m a n ga n ese-con t a in in g m et a llic a ddit ive over h ea t . If you n ot ice a pu n gen t bu r n in g odor or
t h a t is blen ded in t o som e ga solin e t o in cr ea se oct a n e. som e ligh t sm oke, you r en gin e m a y be ou t of t u n e or
Ga solin e blen ded wit h MMT pr ovide n o per for m a n ce m a lfu n ct ion in g a n d m a y r equ ir e im m edia t e ser vice.
a dva n t a ge beyon d ga solin e of t h e sa m e oct a n e n u m - Con t a ct you r dea ler for ser vice a ssist a n ce.
ber wit h ou t MMT. Ga solin e blen ded wit h MMT • Wh en pu llin g a h ea vy loa d or dr ivin g a fu lly
r edu ce spa r k plu g life a n d r edu ce em ission syst em loa ded veh icle wh en t h e h u m idit y is low a n d t h e t em -
per for m a n ce in som e veh icles. Ch r ysler r ecom m en ds per a t u r e is h igh , u se a pr em iu m u n lea ded fu el t o
t h a t ga solin e wit h ou t MMT be u sed in you r veh icle. h elp pr even t spa r k kn ock. If spa r k kn ock per sist s,
Th e MMT con t en t of ga solin e m a y n ot be in dica t ed ligh t en t h e loa d, or en gin e pist on da m a ge m a y r esu lt .
on t h e ga solin e pu m p; t h er efor e, you sh ou ld a sk you r • Th e u se of fu el a ddit ives wh ich a r e n ow bein g
ga solin e r et a iler wh et h er or n ot h is/h er ga solin e con - sold a s oct a n e en h a n cer s is n ot r ecom m en ded. Most
t a in s MMT. of t h ese pr odu ct s con t a in h igh con cen t r a t ion s of
It is even m or e im por t a n t t o look for ga solin e wit h - m et h a n ol. F u el syst em da m a ge or veh icle per for-
ou t MMT in Ca n a da beca u se MMT ca n be u sed a t m a n ce pr oblem s r esu lt in g fr om t h e u se of su ch fu els
levels h igh er t h a n a llowed in t h e Un it ed St a t es. or a ddit ives is n ot t h e r espon sibilit y of Ch r ysler Cor-
MMT is pr oh ibit ed in F eder a l a n d Ca lifor n ia r efor- por a t ion a n d m a y n ot be cover ed u n der t h e n ew veh i-
m u la t ed ga solin e. cle wa r r a n t y.
XJ FUEL SYSTEM 14 - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
NOTE: Intentional tampering with emissions control • A sepa r a t e fu el pick-u p filt er (st r a in er )
systems can result in civil penalties being assessed • An elect r ic fu el pu m p
against you. • A t h r ea ded lockn u t t o r et a in m odu le t o t a n k
• A ga sket bet ween t a n k fla n ge a n d m odu le
• F u el ga u ge sen din g u n it (fu el level sen sor )
FUEL DELIVERY SYSTEM • F u el su pply t u be (lin e) con n ect ion
Th e fu el deliver y syst em con sist s of: Th e fu el ga u ge sen din g u n it , pick-u p filt er a n d fu el
• t h e fu el pu m p m odu le con t a in in g t h e elect r ic filt er /fu el pr essu r e r egu la t or m a y be ser viced sepa -
fu el pu m p, fu el filt er /fu el pr essu r e r egu la t or, fu el r a t ely. If t h e elect r ica l fu el pu m p r equ ir es ser vice,
ga u ge sen din g u n it (fu el level sen sor ) a n d a sepa r a t e t h e en t ir e fu el pu m p m odu le m u st be r epla ced.
fu el filt er loca t ed a t bot t om of pu m p m odu le
• fu el t u bes/lin es/h oses
• qu ick-con n ect fit t in gs
- ROLLOVER
________ VALVE ::j_l
• fu el in ject or r a il
• fu el in ject or s
RETAINER
• fu el t a n k CLAMP
• fu el t a n k filler /ven t t u be a ssem bly
• fu el t a n k filler t u be ca p
• a cceler a t or peda l
• t h r ot t le ca ble
F u el is r et u r n ed t h r ou gh t h e fu el pu m p m odu le
a n d ba ck in t o t h e fu el t a n k t h r ou gh t h e fu el filt er /
fu el pr essu r e r egu la t or. A sepa r a t e fu el r et u r n lin e
fr om t h e en gin e t o t h e t a n k is n ot u sed.
Th e fu el t a n k a ssem bly con sist s of: t h e fu el t a n k,
fu el pu m p m odu le a ssem bly, fu el pu m p m odu le lock-
n u t /ga sket , a n d r ollover va lve (r efer t o Gr ou p 25,
E m ission Con t r ol Syst em for r ollover va lve in for m a -
FUEL FIL TERI
FUEL PRESSURE
I\
REGULATOR 80aac284
t ion ).
A fu el filler /ven t t u be a ssem bly u sin g a pr essu r e/
Fig. 1 Fuel Tank/Fuel Pump Module (Top View)
va cu u m fu el filler ca p is u sed. Th e fu el filler t u be
con t a in s a spr in g-loa ded fla p (door ) loca t ed below t h e
fu el fill ca p. Th e fla p is u sed a s a secon da r y wa y of
sea lin g t h e fu el t a n k if t h e fu el fill ca p h a s n ot been
pr oper ly t igh t en ed. Th e fla p is u sed a s pa r t of t h e
E VAP m on it or syst em wh en t h e veh icle is equ ipped
wit h a Lea k Det ect ion P u m p (LDP ). Th e fla p will be
in st a lled t o a ll fu el filler t u bes (equ ipped/n ot
equ ipped wit h LDP a n d E VAP m on it or syst em ).
Also t o be con sider ed pa r t of t h e fu el syst em is t h e
eva por a t ion con t r ol syst em . Th is is design ed t o
r edu ce t h e em ission of fu el va por s in t o t h e a t m o-
sph er e. Th e descr ipt ion a n d fu n ct ion of t h e E va por a -
t ive Con t r ol Syst em is fou n d in Gr ou p 25, E m ission FUEL FILTER/FUEL
Con t r ol Syst em s. PRESSURE
Bot h fu el filt er s (a t bot t om of fu el pu m p m odu le REGULATOR
a n d wit h in fu el pr essu r e r egu la t or ) a r e design ed for
ext en ded ser vice. Th ey do n ot r equ ir e n or m a l sch ed- Fig. 2 Fuel Pump Module Components
u led m a in t en a n ce. F ilt er s sh ou ld on ly be r epla ced if
FUEL PUMP
a dia gn ost ic pr ocedu r e in dica t es t o do so.
DESCRIPTION
FUEL PUMP MODULE Th e elect r ic fu el pu m p is loca t ed in side of t h e fu el
Th e fu el pu m p m odu le is in st a lled in t h e t op of t h e pu m p m odu le.
fu el t a n k (F ig. 1) or (F ig. 2). Th e fu el pu m p m odu le
con t a in s t h e followin g com pon en t s:
• A com bin a t ion fu el filt er /fu el pr essu r e r egu la t or
14 - 4 FUEL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
OPERATION FUEL FILTER/FUEL PRESSURE REGULATOR
Th e fu el pu m p u sed in t h is syst em h a s a per m a n en t A com bin a t ion fu el filt er a n d fu el pr essu r e r egu la -
m a gn et elect r ic m ot or. F u el is dr a wn in t h r ou gh a filt er t or is u sed on a ll en gin es. It is loca t ed on t h e t op of
a t t h e bot t om of t h e m odu le a n d pu sh ed t h r ou gh t h e fu el pu m p m odu le (F ig. 1). A sepa r a t e fr a m e m ou n t ed
elect r ic m ot or gea r set t o t h e pu m p ou t let . fu el filt er is n ot u sed wit h a n y en gin e.
Ch e c k Va lv e Op e ra tio n : Th e pu m p ou t let con - F u e l P re s s u re Re g u la to r Op e ra tio n : Th e pr es-
t a in s a on e-wa y ch eck va lve t o pr even t fu el flow ba ck su r e r egu la t or is a m ech a n ica l device t h a t is n ot con -
in t o t h e t a n k a n d t o m a in t a in fu el su pply lin e pr es- t r olled by en gin e va cu u m or t h e P ower t r a in Con t r ol
su r e (en gin e wa r m ) wh en pu m p is n ot oper a t ion a l. It Modu le (P CM).
is a lso u sed t o keep t h e fu el su pply lin e fu ll of ga so- Th e r egu la t or is ca libr a t ed t o m a in t a in fu el syst em
lin e wh en pu m p is n ot oper a t ion a l. Aft er t h e veh icle oper a t in g pr essu r e of a ppr oxim a t ely 339 kP a ! 34
h a s cooled down , fu el pr essu r e m a y dr op t o 0 psi kP a (49.2 psi ! 5 psi) a t t h e fu el in ject or s. It con -
(cold flu id con t r a ct s), bu t liqu id ga solin e will r em a in t a in s a dia ph r a gm , ca libr a t ed spr in gs a n d a fu el
in fu el su pply lin e bet ween t h e ch eck va lve a n d fu el r et u r n va lve. Th e in t er n a l fu el filt er is a lso pa r t of
in ject or s. F u e l p re s s u re th a t h a s d ro p p e d to 0 t h e a ssem bly.
p s i o n a c o o le d d o w n v e h ic le (e n g in e o ff) is a
n o rm a l c o n d itio n . Refer t o t h e F u el P r essu r e Lea k
Down Test for m or e in for m a t ion .
Volt a ge t o oper a t e t h e elect r ic pu m p is su pplied
t h r ou gh t h e fu el pu m p r ela y.
OPERATION
Th e r esist or t r a ck is u sed t o sen d elect r ica l sign a ls t o
t h e P ower t r a in Con t r ol Modu le (P CM) for fu el ga u ge
oper a t ion a n d for OBD II em ission r equ ir em en t s.
80a4a5d3
F o r fu e l g a u g e o p e ra tio n : As fu el level
in cr ea ses, t h e floa t a n d a r m m ove u p. Th is decr ea ses Fig. 3 Fuel Filter/Fuel Pressure Regulator
t h e sen din g u n it r esist a n ce, ca u sin g t h e fu el ga u ge t o
r ea d fu ll. As fu el level decr ea ses, t h e floa t a n d a r m F u el is su pplied t o t h e filt er /r egu la t or by t h e elec-
m ove down . Th is in cr ea ses t h e sen din g u n it r esis- t r ic fu el pu m p t h r ou gh a n open in g t u be a t t h e bot -
t a n ce ca u sin g t h e fu el ga u ge t o r ea d em pt y. t om of filt er /r egu la t or (F ig. 3).
Aft er t h is fu el level sign a l is sen t t o t h e P CM, t h e Th e r egu la t or a ct s a s a ch eck va lve t o m a in t a in
P CM will t r a n sm it t h e da t a a cr oss t h e CCD bu s cir- som e fu el pr essu r e wh en t h e en gin e is n ot oper a t in g.
cu it s t o t h e in st r u m en t pa n el. H er e it is t r a n sla t ed Th is will h elp t o st a r t t h e en gin e. A secon d ch eck
in t o t h e a ppr opr ia t e fu el ga u ge level r ea din g. va lve is loca t ed a t t h e ou t let en d of t h e elect r ic fu el
F o r OB D II e m is s io n m o n ito r re qu ire m e n ts : A pu m p. Re fe r to F u e l P u m p —D e s c rip tio n a n d
volt a ge sign a l is sen t fr om t h e r esist or t r a ck on t h e Op e ra tio n fo r m o re in fo rm a tio n . Als o re fe r to
sen din g u n it t o t h e P CM t o in dica t e fu el level. Th e pu r- th e F u e l P re s s u re Le a k D o w n Te s t a n d th e F u e l
pose of t h is fea t u r e is t o pr even t t h e OBD II syst em P u m p P re s s u re Te s ts .
fr om r ecor din g/set t in g fa lse m isfir e a n d fu el syst em If fu el pr essu r e a t t h e pr essu r e r egu la t or exceeds
m on it or t r ou ble codes. Th e fea t u r e is a ct iva t ed if t h e a ppr oxim a t ely 49 psi, a n in t er n a l dia ph r a gm closes
fu el level in t h e t a n k is less t h a n a ppr oxim a t ely 15 per- a n d excess fu el is r ou t ed ba ck in t o t h e t a n k t h r ou gh
cen t of it s r a t ed ca pa cit y. If equ ipped wit h a Lea k t h e pr essu r e r egu la t or. A sepa r a t e fu el r et u r n lin e is
Det ect ion P u m p (E VAP syst em m on it or ), t h is fea t u r e n ot u sed.
will a lso be a ct iva t ed if t h e fu el level in t h e t a n k is
m or e t h a n a ppr oxim a t ely 85 per cen t of it s r a t ed ca pa c-
it y.
XJ FUEL SYSTEM 14 - 5
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
FUEL TANK
DESCRIPTION
Th e fu el t a n k is con st r u ct ed of a pla st ic m a t er ia l.
It s m a in fu n ct ion s a r e for fu el st or a ge a n d for pla ce-
m en t of t h e fu el pu m p m odu le.
OPERATION
All m odels pa ss a fu ll 360 degr ee r ollover t est NOZZLE
wit h ou t fu el lea ka ge. To a ccom plish t h is, fu el a n d
va por flow con t r ols a r e r equ ir ed for a ll fu el t a n k con -
n ect ion s.
A r ollover va lve(s) is m ou n t ed in t o t h e t op of t h e
fu el t a n k (or pu m p m odu le). Refer t o E m ission Con -
t r ol Syst em for r ollover va lve in for m a t ion . - ·- ,....., TOP (FUEL ENTRY) 8020cd8e
QUICK-CONNECT FITTINGS
Differ en t t ypes of qu ick-con n ect fit t in gs a r e u sed t o
a t t a ch va r iou s fu el syst em com pon en t s. Th ese a r e: a
sin gle-t a b t ype, a t wo-t a b t ype or a pla st ic r et a in er
r in g t ype. Som e a r e equ ipped wit h sa fet y la t ch clips.
Refer t o t h e Rem ova l/In st a lla t ion sect ion for m or e
in for m a t ion .
FUEL GAUGE SENDING UNIT (7) Un plu g con n ect or fr om a n y fu el in ject or.
Th e fu el ga u ge sen din g u n it con t a in s a va r ia ble (8) At t a ch on e en d of a ju m per wir e wit h a lliga t or
r esist or (t r a ck). As t h e floa t m oves u p or down , elec- clips (18 ga u ge or sm a ller ) t o eit h er in ject or t er m in a l.
t r ica l r esist a n ce will ch a n ge. Refer t o In st r u m en t (9) Con n ect ot h er en d of ju m per wir e t o posit ive
P a n el a n d Ga u ges for F u el Ga u ge t est in g. To t est t h e side of ba t t er y.
ga u ge sen din g u n it on ly, it m u st be r em oved fr om (10) Con n ect on e en d of a secon d ju m per wir e t o
veh icle. Th e u n it is pa r t of t h e fu el pu m p m odu le. r em a in in g in ject or t er m in a l.
Refer t o F u el P u m p Modu le Rem ova l/In st a lla t ion for
CAUTION: Powering an injector for more than a few
pr ocedu r es. Mea su r e t h e r esist a n ce a cr oss t h e sen d-
seconds will permanently damage the injector.
in g u n it t er m in a ls. Wit h floa t in u p posit ion , r esis-
t a n ce sh ou ld be 20 oh m s (+/- 5%). Wit h floa t in down (11) Mom en t a r ily t ou ch ot h er en d of ju m per wir e
posit ion , r esist a n ce sh ou ld be 270 oh m s (+/- 5%). t o n ega t ive t er m in a l of ba t t er y for n o m or e t h a n a
few secon ds.
FUEL INJECTOR TEST (12) P la ce a r a g or t owel below fu el lin e qu ick-con -
To per for m a com plet e t est of t h e fu el in ject or s a n d n ect fit t in g a t fu el r a il.
t h eir cir cu it r y, u se t h e DRB sca n t ool a n d r efer t o t h e (13) Discon n ect qu ick-con n ect fit t in g a t fu el r a il.
a ppr opr ia t e P ower t r a in Dia gn ost ics P r ocedu r es m a n - Refer t o Qu ick-Con n ect F it t in gs.
u a l. To t est t h e in ject or on ly, r efer t o t h e followin g: (14) Ret u r n fu el pu m p r ela y t o P DC.
Discon n ect t h e fu el in ject or wir e h a r n ess con n ect or (15) On e or m or e Dia gn ost ic Tr ou ble Codes (DTC’s)
fr om t h e in ject or. Th e in ject or is equ ipped wit h 2 m a y h a ve been st or ed in P CM m em or y du e t o fu el
elect r ica l t er m in a ls (pin s). P la ce a n oh m m et er a cr oss pu m p r ela y r em ova l. Th e DRB sca n t ool m u st be
t h e t er m in a ls. Resist a n ce r ea din g sh ou ld be a ppr oxi- u sed t o er a se a DTC.
m a t ely 12 oh m s !1.2 oh m s a t 20°C (68°F ).
FUEL TUBES/LINES/HOSES AND CLAMPS
SERV I CE PROCEDU RES
OPERATION
FUEL SYSTEM PRESSURE RELEASE Also r efer t o Qu ick-Con n ect F it t in gs.
PROCEDURE WARNING: THE FUEL SYSTEM IS UNDER A CON-
U s e fo llo w in g p ro c e d u re if fu e l ra il is o r is STANT PRESSURE (EVEN WITH THE ENGINE OFF).
n o t e qu ip p e d w ith fu e l p re s s u re te s t p o rt. BEFORE SERVICING ANY FUEL SYSTEM HOSES,
(1) Rem ove fu el fill ca p. FITTINGS OR LINES, THE FUEL SYSTEM PRES-
(2) Th e fu el filler t u be con t a in s a spr in g-loa ded SURE MUST BE RELEASED. REFER TO THE FUEL
fla p (door ) loca t ed below fu el fill ca p. Th e fla p is u sed SYSTEM PRESSURE RELEASE PROCEDURE IN
a s a secon da r y wa y of sea lin g fu el t a n k if fu el fill ca p THIS GROUP.
h a s n ot been pr oper ly t igh t en ed. It is pa r t of E VAP
m on it or syst em wh en veh icle is equ ipped wit h a In spect a ll h ose con n ect ion s su ch a s cla m ps, cou -
Lea k Det ect ion P u m p (LDP ). Th e v e h ic le m a y be plin gs a n d fit t in gs t o m a ke su r e t h ey a r e secu r e a n d
e qu ip p e d w ith fla p in s ta lle d in to fu e l fille r tu be lea ks a r e n ot pr esen t . Th e com pon en t sh ou ld be
e v e n th o u g h v e h ic le is n o t e qu ip p e d w ith LD P r epla ced im m edia t ely if t h er e is a n y eviden ce of deg-
a n d EVAP m o n ito r s y s te m . P la ce a n on m et a llic r a da t ion t h a t cou ld r esu lt in fa ilu r e.
object in t o fu el fill t u be a n d pr ess on fla p t o r elieve Never a t t em pt t o r epa ir a pla st ic fu el lin e/t u be.
a n y t a n k pr essu r e. Repla ce a s n ecessa r y.
(3) Rem ove F u el P u m p r ela y fr om P ower Dist r ibu - Avoid con t a ct of a n y fu el t u bes/h oses wit h ot h er
t ion Cen t er (P DC). F or loca t ion of r ela y, r efer t o la bel veh icle com pon en t s t h a t cou ld ca u se a br a sion s or
on u n der side of P DC cover. scu ffin g. Be su r e t h a t t h e pla st ic fu el lin es/t u bes a r e
(4) St a r t a n d r u n en gin e u n t il it st a lls. pr oper ly r ou t ed t o pr even t pin ch in g a n d t o a void h ea t
(5) At t em pt r est a r t in g en gin e u n t il it will n o sou r ces.
lon ger r u n . Th e lin es/t u bes/h oses u sed on fu el in ject ed veh icles
(6) Tu r n ign it ion key t o OF F posit ion . a r e of a specia l con st r u ct ion . Th is is du e t o t h e
XJ FUEL SYSTEM 14 - 11
SERV I CE PROCEDU RES (Cont inue d)
h igh er fu el pr essu r es a n d t h e possibilit y of con t a m i- (5) Tw o -Ta b Ty p e F ittin g : Th is t ype of fit t in g is
n a t ed fu el in t h is syst em . If it is n ecessa r y t o r epla ce equ ipped wit h t a bs loca t ed on bot h sides of fit t in g
t h ese lin es/t u bes/h oses, on ly t h ose m a r ked E F M/E F I (F ig. 16). Th e t a bs a r e su pplied for discon n ect in g
m a y be u sed. qu ick-con n ect fit t in g fr om com pon en t bein g ser viced.
If e qu ip p e d : Th e h ose cla m ps u sed t o secu r e r u b-
QUI CK-CONNECT
ber h oses on fu el in ject ed veh icles a r e of a specia l FITTING
r olled edge con st r u ct ion . Th is con st r u ct ion is u sed t o
pr even t t h e edge of t h e cla m p fr om cu t t in g in t o t h e
h ose. On ly t h ese r olled edge t ype cla m ps m a y be
u sed in t h is syst em . All ot h er t ypes of cla m ps m a y
cu t in t o t h e h oses a n d ca u se h igh -pr essu r e fu el lea ks.
Use n ew or igin a l equ ipm en t t ype h ose cla m ps.
Tigh t en h ose cla m ps t o 3 N·m (25 in . lbs.) t or qu e.
QUICK-CONNECT FITTINGS
Also r efer t o F u el Tu bes/Lin es/H oses a n d Cla m ps.
Differ en t t ypes of qu ick-con n ect fit t in gs a r e u sed t o
a t t a ch va r iou s fu el syst em com pon en t s, lin es a n d
INSERTED
t u bes. Th ese a r e: a sin gle-t a b t ype, a t wo-t a b t ype or TUBE END J9414-24
a pla st ic r et a in er r in g t ype. Sa fet y la t ch clips a r e
u sed on cer t a in com pon en t s/lin es. Cer t a in fit t in gs Fig. 13 Single-Tab Type Fitting
m a y r equ ir e u se of a specia l t ool for discon n ect ion .
DISCONNECTING
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSE,
FITTING OR LINE, FUEL SYSTEM PRESSURE MUST
BE RELEASED. REFER TO FUEL SYSTEM PRES-
SURE RELEASE PROCEDURE.
PUSH
INSTALLATION
FUEL
TUBE
STOP J9414-26
PLASTIC
RETAINER J9314-100
QUICK-CONNECT
TAB($} FITTING
80a35405
in to fittin g bo d y. If th is re ta in e r is c o c k e d
d u rin g re m o v a l, it m a y be d iffic u lt to d is c o n - Fig. 18 Latch Clip—Type 1
n e c t fittin g . U s e a n o p e n -e n d w re n c h o n (a ) Type 1: P r y u p on la t ch clip wit h a scr ew-
s h o u ld e r o f p la s tic re ta in e r rin g to a id in d is - dr iver (F ig. 18).
c o n n e c tio n . (b) Type 2: Sepa r a t e a n d u n la t ch 2 sm a ll a r m s
(b) Aft er discon n ect ion , pla st ic r et a in er r in g will on en d of clip (F ig. 19) a n d swin g a wa y fr om fu el
r em a in wit h qu ick-con n ect fit t in g con n ect or body. lin e.
(c) In spect fit t in g con n ect or body, pla st ic r et a in er (c) Slide la t ch clip t owa r d fu el r a il wh ile lift in g
r in g a n d fu el syst em com pon en t for da m a ge. wit h scr ewdr iver.
Repla ce a s n ecessa r y. (d) In ser t specia l fu el lin e r em ova l t ool (Sn a p-On
(7) La tc h Clip s : Depen din g on veh icle m odel a n d n u m ber F IH 9055-1 or equ iva len t ) in t o fu el lin e
en gin e, 2 differ en t t ypes of sa fet y la t ch clips a r e u sed (F ig. 20). Use t ool t o r elea se lockin g fin ger s in en d
(F ig. 18) or (F ig. 19). Type-1 is t et h er ed t o fu el lin e of lin e.
a n d t ype-2 is n ot . A specia l t ool will be n ecessa r y t o (e) Wit h specia l t ool st ill in ser t ed, pu ll fu el lin e
discon n ect fu el lin e a ft er la t ch clip is r em oved. Th e fr om fu el r a il.
la t ch clip m a y be u sed on cer t a in fu el lin e/fu el r a il
con n ect ion , or t o join fu el lin es t oget h er.
XJ FUEL SYSTEM 14 - 13
SERV I CE PROCEDU RES (Cont inue d)
...
(4) Con t in u e pu sh in g u n t il a click is felt .
SEPARATE (5) Sin gle-t a b t ype fit t in g: P u sh n ew t a b down
u n t il it locks in t o pla ce in qu ick-con n ect fit t in g.
(6) Ver ify a locked con dit ion by fir m ly pu llin g on
fu el t u be a n d fit t in g (15-30 lbs.).
(7) La t ch Clip E qu ipped: In st a ll la t ch clip (sn a ps
in t o posit ion ). If la tc h c lip w ill n o t fit, th is in d i-
c a te s fu e l lin e is n o t p ro p e rly in s ta lle d to fu e l
ra il (o r o th e r fu e l lin e ). Re c h e c k fu e l lin e c o n -
n e c tio n .
(8) Con n ect n ega t ive ca ble t o ba t t er y.
(9) St a r t en gin e a n d ch eck for lea ks.
REMOVAL
(1) Rem ove fu el t a n k. Refer t o F u el Ta n k Rem ova l/
In st a lla t ion .
(2) Clea n a r ea a r ou n d filt er /r egu la t or.
(3) Discon n ect fu el lin e a t filt er /r egu la t or. Refer t o
Qu ick-Con n ect F it t in gs in t h is gr ou p for pr ocedu r es.
(4) Rem ove r et a in er cla m p fr om t op of filt er /r egu -
la t or (F ig. 21). Cla m p sn a ps t o t a bs on pu m p m odu le.
Disca r d old cla m p.
(5) P r y filt er /r egu la t or fr om t op of pu m p m odu le
FUEL LINE wit h 2 scr ewdr iver s. Un it is sn a pped in t o m odu le.
(6) Disca r d ga sket below filt er /r egu la t or (F ig. 22).
(7) Befor e disca r din g filt er /r egu la t or a ssem bly,
in spect a ssem bly t o ver ify t h a t o-r in gs (F ig. 23) a r e
J9514-6
in t a ct . If t h e sm a llest of t h e t wo o-r in gs ca n n ot be
fou n d on bot t om of filt er /r egu la t or, it m a y be n eces-
Fig. 20 Fuel Line Disconnection Using Special Tool sa r y t o r em ove it fr om t h e fu el in let pa ssa ge in fu el
(f) Aft er discon n ect ion , lockin g fin ger s will pu m p m odu le.
r em a in wit h in qu ick-con n ect fit t in g a t en d of fu el
lin e. INSTALLATION
(8) Discon n ect qu ick-con n ect fit t in g fr om fu el sys- (1) Clea n r ecessed a r ea in pu m p m odu le wh er e fil-
t em com pon en t bein g ser viced. t er /r egu la t or is t o be in st a lled.
(2) Obt a in n ew filt er /r egu la t or (t wo n ew o-r in gs
CONNECTING sh ou ld a lr ea dy be in st a lled) .
(1) In spect qu ick-con n ect fit t in g body a n d fu el sys- (3) Apply a sm a ll a m ou n t of clea n en gin e oil t o
t em com pon en t for da m a ge. Repla ce a s n ecessa r y. o-r in gs. D o n o t in s ta ll o -rin g s s e p a ra te ly in to
(2) P r ior t o con n ect in g qu ick-con n ect fit t in g t o fu e l p u m p m o d u le . Th e y w ill be d a m a g e d w h e n
com pon en t bein g ser viced, ch eck con dit ion of fit t in g in s ta llin g filte r/re g u la to r.
a n d com pon en t . Clea n pa r t s wit h a lin t -fr ee clot h . (4) In st a ll n ew ga sket t o t op of fu el pu m p m odu le.
Lu br ica t e wit h clea n en gin e oil. (5) P r ess n ew filt er /r egu la t or in t o t op of pu m p
(3) In ser t qu ick-con n ect fit t in g in t o fu el t u be or m odu le u n t il it sn a ps in t o posit ion (a posit ive click
fu el syst em com pon en t u n t il bu ilt -on st op on fu el m u st be h ea r d or felt ).
t u be or com pon en t r est s a ga in st ba ck of fit t in g.
14 - 14 FUEL SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
_.TOFU~
INJECT RS
~,,.___.,,
-----.------\~lr---.Jo/,
FUEL SUPPLY
TUBE
O-RINGS
80a58b62
Fig. 21 Fuel Filter/Fuel Pressure Regulator Fig. 23 Fuel Filter/Fuel Pressure Regulator O-Rings
FUEL PUMP MODULE
F u el t a n k r em ova l will be n ecessa r y for fu el pu m p
m odu le r em ova l.
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE EVEN WITH ENGINE OFF.
BEFORE SERVICING THE FUEL PUMP MODULE,
FUEL SYSTEM PRESSURE MUST BE RELEASED.
I
FUEL FIL TERI
FUEL PRESSURE
REGULATOR 80aac284
INSTALLATION
(1) Sn a p n ew filt er t o bot t om of m odu le.
(2) In st a ll fu el pu m p m odu le. Refer t o F u el P u m p
Fig. 25 Locknut Removal/Installation—Typical Modu le Rem ova l/In st a lla t ion .
(3) In st a ll fu el t a n k. Refer t o F u el Ta n k Rem ova l/
(4) P osit ion lockn u t over t op of fu el pu m p m odu le. In st a lla t ion .
(5) Rot a t e m odu le u n t il m olded a r r ow (F ig. 24) is
poin t ed t owa r d fr on t of veh icle (12 o’clock posit ion ). FUEL GAUGE SENDING UNIT
Th is st ep m u st be don e t o pr even t floa t /floa t r od
Th e fu el ga u ge sen din g u n it (fu el level sen sor ) a n d
a ssem bly fr om con t a ct in g sides of fu el t a n k.
floa t a ssem bly is loca t ed on t h e side of fu el pu m p
(6) In st a ll Specia l Tool 6856 t o lockn u t .
m odu le (F ig. 27). Th e fu el pu m p m odu le is loca t ed
(7) Tigh t en lockn u t t o 74 N·m (55 ft . lbs.) t or qu e.
wit h in t h e fu el t a n k.
(8) Rot a t e fu el filt er /fu el pr essu r e r egu la t or u n t il
it s fit t in g is poin t ed t owa r d fr on t of veh icle (12 REMOVAL
o’clock posit ion ).
(1) Rem ove fu el t a n k. Refer t o F u el Ta n k Rem ova l/
(9) Con n ect fu el lin e a t filt er /r egu la t or. Refer t o
In st a lla t ion .
Qu ick-Con n ect F it t in gs in t h is gr ou p for pr ocedu r es.
(2) Rem ove fu el pu m p m odu le. Refer t o F u el P u m p
(10) In st a ll fu el t a n k. Refer t o F u el Ta n k In st a lla -
Modu le Rem ova l/In st a lla t ion .
t ion in t h is sect ion .
(3) Rem ove elect r ica l wir e con n ect or a t sen din g
u n it t er m in a ls.
(4) P r ess on r elea se t a b (F ig. 28) t o r em ove sen d-
in g u n it fr om pu m p m odu le.
14 - 16 FUEL SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(1) Rem ove fu el t a n k filler t u be ca p.
(2) P er for m F u el Syst em P r essu r e Relea se P r oce-
du r e a s descr ibed in t h is Gr ou p.
(3) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
(4) Rem ove a ir t u be a t t op of t h r ot t le body. Not e:
Som e en gin e/veh icles m a y r equ ir e r em ova l of a ir
clea n er du ct s a t t h r ot t le body.
(5) Rem ove in ject or h a r n ess elect r ica l con n ect or s
a t ea ch in ject or. E a ch in ject or con n ect or sh ou ld h a ve
a n u m er ica l t a g a t t a ch ed iden t ifyin g it s cor r espon d-
in g cylin der (F ig. 29). If n ot , iden t ify ea ch con n ect or
befor e r em ova l.
FUEL FILTER/FUEL NUMBERED
PRESSURE TAG
REGULATOR
80b6f034
-===------
(5) Rem ove 4 fu el h ose sh ield m ou n t in g bolt s a n d
r em ove fu el h ose sh ield (F ig. 33) fr om body. ----'\.
FUEL SUPPLY
LINE
CONNECTION
"' I .-J
\ /,~~~~~
STRAPS (2) _ \ (
~1
Fig. 36 Fuel Tank Mounting Straps/Nuts
WARNING: PLACE A SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
J8914-29
THROTTLE CABLE
REMOVAL
(1) F r om in side veh icle, h old u p a cceler a t or peda l.
Rem ove pla st ic ca ble r et a in er (clip) a n d t h r ot t le ca ble Fig. 40 Throttle (Accelerator) Cable at Throttle
cor e wir e fr om u pper en d of a cceler a t or peda l a r m Body—Typical
(F ig. 38). P la st ic ca ble r et a in er (clip) sn a ps in t o peda l
arm. INSTALLATION
(2) Rem ove ca ble cor e wir e a t peda l a r m . (1) Slide t h r ot t le ca ble t h r ou gh h ole in t h r ot t le
(3) F r om in side veh icle, pin ch bot h sides of ca ble body br a cket u n t il r et a in er t a bs lock in t o br a cket .
h ou sin g r et a in er t a bs (F ig. 38) a t da sh pa n el. (2) Con n ect ca ble ba ll en d t o t h r ot t le body lin ka ge
Rem ove ca ble h ou sin g fr om da sh pa n el a n d pu ll in t o ba ll (sn a ps on ).
en gin e com pa r t m en t . (3) Sn a p ca ble in t o ca ble gu ide on en gin e cylin der
(4) Rem ove ca ble fr om ca ble gu ide on en gin e cylin - h ea d (va lve) cover.
der h ea d (va lve) cover (F ig. 39). (4) P u sh ot h er en d of ca ble t h r ou gh open in g in
(5) Rem ove t h r ot t le ca ble ba ll en d socket a t t h r ot - da sh pa n el u n t il r et a in in g t a bs lock in t o pa n el.
t le body lin ka ge (sn a ps off) (F ig. 40). (5) F r om in side dr iver s com pa r t m en t , slide t h r ot t le
(6) Rem ove t h r ot t le ca ble fr om t h r ot t le body ca ble cor e wir e in t o open in g in t op of a cceler a t or
m ou n t in g br a cket by com pr essin g squ eeze t a bs (F ig. peda l a r m . P u sh ca ble r et a in er (clip) in t o peda l a r m
39) a n d pu sh in g ca ble t h r ou gh h ole in br a cket . open in g u n t il it sn a ps in pla ce.
(7) Rem ove t h r ot t le ca ble fr om veh icle. (6) Befor e st a r t in g en gin e, oper a t e a cceler a t or
peda l t o ch eck for a n y bin din g.
14 - 22 FUEL SYSTEM XJ
FU EL I N J ECT I ON SY ST EM
INDEX
page page
CAMSHAFT
~ - - POSITION
SENSOR
RUBBER
GROMMET
CRANKSHAFT \
POSITION \
SENSOR 80add429
© I
OIL PRESSURE SENSOR—PCM INPUT
D~/...L~,_...,.'....!.-.L....,..J.......,...c7°..J.---r..-1· ,t INTAKE MANIFOLD
AIR TEMPERATURE DESCRIPTION
MAP SENSOR SENSOR Th e en gin e oil pr essu r e sen sor (sen din g u n it ) is
80aac28d loca t ed in a n en gin e oil pr essu r e ga ller y.
~
OPERATION
Th e power gr ou n d is u sed t o con t r ol gr ou n d cir-
cu it s for t h e followin g P ower t r a in Con t r ol Modu le
(P CM) loa ds:
• Gen er a t or field win din g
• F u el in ject or s
• Ign it ion coil(s)
• Cer t a in r ela ys/solen oids
SENSOR
ELECTRICAL
CONNECTOR
J9414-60
Fig. 10 Vehicle Speed Sensor Location—2WD— Fig. 12 Power Distribution Center (PDC)
Typical Th e power t r a in con t r ol m odu le (P CM) a ct iva t es t h e
SENSOR A/C com pr essor t h r ou gh t h e A/C clu t ch r ela y. Th e
ELECTRICAL P CM r egu la t es A/C com pr essor oper a t ion by swit ch -
CONNECTOR in g t h e gr ou n d cir cu it for t h e A/C clu t ch r ela y on a n d
off.
Wh en t h e P CM r eceives a r equ est for A/C fr om A/C
eva por a t or swit ch , it will a dju st idle a ir con t r ol (IAC)
m ot or posit ion . Th is is don e t o in cr ea se idle speed.
Th e P CM will t h en a ct iva t e t h e A/C clu t ch t h r ou gh
t h e A/C clu t ch r ela y. Th e P CM a dju st s idle a ir con t r ol
(IAC) st epper m ot or posit ion t o com pen sa t e for
in cr ea sed en gin e loa d fr om t h e A/C com pr essor.
By swit ch in g t h e gr ou n d pa t h for t h e r ela y on a n d
off, t h e P CM is a ble t o cycle t h e A/C com pr essor
clu t ch . Th is is ba sed on ch a n ges in en gin e oper a t in g
con dit ion s. Th e P CM will a lso de-en er gize t h e r ela y if
coola n t t em per a t u r e exceeds 125°C (257°F ).
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS wit h a n a t t a ch ed n u m er ica l t a g (INJ 1, INJ 2 et c.).
Th e P ower t r a in Con t r ol Modu le (P CM) sen ds cer- Th is is u sed t o iden t ify ea ch fu el in ject or.
t a in ou t pu t sign a ls t h r ou gh t h e CCD bu s cir cu it s. Th e in ject or s a r e en er gized in dividu a lly in a
Th ese sign a ls a r e u sed t o con t r ol cer t a in in st r u m en t sequ en t ia l or der by t h e power t r a in con t r ol m odu le
pa n el loca t ed it em s a n d t o det er m in e cer t a in iden t i- (P CM). Th e P CM will a dju st in ject or pu lse widt h by
fica t ion n u m ber s. swit ch in g t h e gr ou n d pa t h t o ea ch in dividu a l in ject or
Refer t o Gr ou p 8E , In st r u m en t P a n el a n d Ga u ges on a n d off. In ject or pu lse widt h is t h e per iod of t im e
for a ddit ion a l in for m a t ion . t h a t t h e in ject or is en er gized. Th e P CM will a dju st
in ject or pu lse widt h ba sed on va r iou s in pu t s it
DATA LINK CONNECTOR—PCM INPUT AND r eceives.
Du r in g st a r t u p, ba t t er y volt a ge is su pplied t o t h e
OUTPUT in ject or s t h r ou gh t h e ASD r ela y. Wh en t h e en gin e is
Th e 16–wa y da t a lin k con n ect or (dia gn ost ic sca n oper a t in g, volt a ge is su pplied by t h e ch a r gin g sys-
t ool con n ect or ) lin ks t h e Dia gn ost ic Rea dou t Box t em . Th e P CM det er m in es in ject or pu lse widt h ba sed
(DRB) sca n t ool or t h e Mopa r Dia gn ost ic Syst em on va r iou s in pu t s.
(MDS) wit h t h e power t r a in con t r ol m odu le (P CM).
Th e da t a lin k con n ect or is loca t ed u n der t h e in st r u -
m en t pa n el t o t h e left of t h e st eer in g colu m n (F ig.
13). F or oper a t ion of t h e DRB sca n t ool, r efer t o t h e
a ppr opr ia t e P ower t r a in Dia gn ost ic P r ocedu r es ser-
vice m a n u a l.
16-WAY
DATA LINK
CONNECTOR
"- ELECTRIC!~ ~
CONNECT~~
~
INTAKE MANIFOLD
80ae8319 TEMPERATURE SENSOR
Fig. 20 Ignition Coil—4.0L Engine Fig. 21 Intake Manifold Air Temp. Sensor Location—
2.5L Engine
posit ion sen sor wir e con n ect or (a t dist r ibu t or ) is
fir m ly con n ect ed t o h a r n ess con n ect or. In spect spa r k (16) Ver ify MAP sen sor elect r ica l con n ect or is
plu g con dit ion . Con n ect veh icle t o a n oscilloscope a n d fir m ly con n ect ed t o MAP sen sor (F ig. 22). Also ver ify
in spect spa r k even t s for fou led or da m a ged spa r k r u bber L-sh a ped fit t in g fr om MAP sen sor t o t h r ot t le
plu gs or ca bles. Refer t o Gr ou p 8D, Ign it ion Syst em body is fir m ly con n ect ed (F ig. 23).
for a ddit ion a l in for m a t ion . (17) Ver ify fu el in ject or wir e h a r n ess con n ect or s
(6) Ver ify gen er a t or ou t pu t wir e, gen er a t or con n ec- a r e fir m ly con n ect ed t o in ject or s in cor r ect or der.
t or a n d gr ou n d wir e a r e fir m ly con n ect ed t o gen er a - E a ch h a r n ess con n ect or is n u m er ica lly t a gged wit h
t or. in ject or n u m ber (INJ 1, INJ 2 et c.) of it s cor r espon d-
(7) In spect syst em body gr ou n ds for loose or dir t y in g fu el in ject or a n d cylin der n u m ber.
con n ect ion s. Refer t o Gr ou p 8, Wir in g for gr ou n d (18) Ver ify h a r n ess con n ect or s a r e fir m ly con -
loca t ion s. n ect ed t o idle a ir con t r ol (IAC) m ot or a n d t h r ot t le
(8) Ver ify cr a n kca se ven t ila t ion (CCV) oper a t ion . posit ion sen sor (TP S) (F ig. 22).
Refer t o Gr ou p 25, E m ission Con t r ol Syst em for a ddi- (19) Ver ify wir e h a r n ess con n ect or is fir m ly con -
t ion a l in for m a t ion . n ect ed t o en gin e coola n t t em per a t u r e sen sor (F ig.
24).
14 - 38 FUEL SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
~ ENGINE COOLANT
IDLE AIR CONTROL IDLE AIR TEMPERATURE SENSOR
PASSAGE INLET CONTROL MODULE
I
© I
JJ;}-~ZI:C:Z:I:IJ::Z::.
1
' ,t INTAKE MANIFOLD
AIR TEMPERATURE
MAP SENSOR SENSOR
80aac28d 80a871b7
Fig. 22 Sensor Locations—4.0L Engine Fig. 24 Engine Coolant Temperature Sensor—
Typical
THROTTLE
BODY
DOWNSTREAM
RUBBER OXYGEN SENSOR
FITTING
80524e39
Fig. 25 Location of Oxygen Sensors
80a6l168
Fig. 23 Rubber L-Shaped Fitting—MAP Sensor-to- (26) 2.5L 4–Cylin der E n gin e On ly: Ver ify good
Throttle Body elect r ica l con n ect ion a t power st eer in g pr essu r e
swit ch (F ig. 28). Th is swit ch is n ot u sed wit h 4.0L
(20) Ra ise a n d su ppor t veh icle. en gin es.
(21) Ver ify bot h oxygen sen sor wir e con n ect or s a r e (27) Ver ify good elect r ica l con n ect ion s a t fu el pu m p
fir m ly con n ect ed t o sen sor s. In spect sen sor s a n d con - m odu le con n ect or a t fr on t of fu el t a n k (F ig. 29).
n ect or s for da m a ge (F ig. 25). (28) Ver ify good E VAP ca n ist er ven t lin e con n ec-
(22) In spect for pin ch ed or lea kin g fu el t u bes. t ion a t fr on t of fu el t a n k (F ig. 29).
In spect for pin ch ed, cr a cked or lea kin g fu el h oses. (29) Ver ify good fu el su pply lin e con n ect ion a t
(23) In spect for exh a u st syst em r est r ict ion s su ch fr on t of fu el t a n k (F ig. 29).
a s pin ch ed exh a u st pipes, colla psed m u ffler or (30) In spect a ll fu el lin es/h oses for cr a cks or lea ks.
plu gged ca t a lyt ic con ver t or. (31) In spect t r a n sm ission t or qu e con ver t or h ou sin g
(24) If equ ipped wit h a u t om a t ic t r a n sm ission , ver- (a u t om a t ic t r a n sm ission ) or clu t ch h ou sin g (m a n u a l
ify elect r ica l h a r n ess is fir m ly con n ect ed t o pa r k/n eu - t r a n sm ission ) for da m a ge t o t im in g r in g on dr ive
t r a l swit ch . Refer t o Au t om a t ic Tr a n sm ission sect ion pla t e/flywh eel.
of Gr ou p 21. (32) Ver ify ba t t er y ca ble a n d solen oid feed wir e
(25) Ver ify elect r ica l h a r n ess con n ect or is fir m ly con n ect ion s t o st a r t er solen oid a r e t igh t a n d clea n .
con n ect ed t o veh icle speed sen sor (F ig. 26) or (F ig. In spect for ch a ffed wir es or wir es r u bbin g u p a ga in st
27). ot h er com pon en t s.
XJ FUEL SYSTEM 14 - 39
DI AGN OSI S AN D T EST I N G (Cont inue d)
SENSOR
ELECTRICAL
CONNECTOR
4WD
TRANSFER
VEHICLE
CASE
SPEED
EXTENSION
SENSOR Fig. 28 Power Steering Pressure Switch—2.5L
80a35409 Engine
Fig. 26 Vehicle Speed Sensor—2WD
FUEL PUMP LEFT-REAR
MODULE CONNECTOR SHOCK ABSORBER
SENSOR
ELECTRICAL
CONNECTOR ~---'\;
-===------
FUEL SUPPLY
LINE
CONNECTION
-+~ i
ju m p e r w ire to th e re la y a t th is tim e .
TESTING
Th e followin g pr ocedu r e a pplies t o t h e ASD a n d
fu el pu m p r ela ys.
(1) Rem ove r ela y fr om con n ect or befor e t est in g.
(2) Wit h t h e r ela y r em oved fr om t h e veh icle, u se © I
80a6l168
10 50 17,990 21,810
Fig. 37 Intake Manifold Air Temperature Sensor—
20 68 11,370 13,610 4.0L Engine
25 77 9,120 10,880 (2) Test t h e r esist a n ce of sen sor wit h a h igh in pu t
30 86 7,370 8,750 im peda n ce (digit a l) volt -oh m m et er. Refer t o SE NSOR
40 104 4,900 5,750 RE SISTANCE (OH MS)—COOLANT TE MP E RA-
TURE SE NSOR/INTAKE AIR TE MP E RATURE
50 122 3,330 3,880
SE NSOR ch a r t . Th e r esist a n ce (a s m ea su r ed a cr oss
60 140 2,310 2,670 sen sor t er m in a ls) sh ou ld be wit h in r a n ge sh own in
70 158 1,630 1,870 ch a r t . If n ot , r epla ce sen sor.
80 176 1,170 1,340 (3) Test r esist a n ce of wir e h a r n ess. Do t h is
bet ween P CM wir e h a r n ess con n ect or A-15 a n d sen -
90 194 860 970 sor con n ect or t er m in a l. Also ch eck bet ween P CM con -
100 212 640 720 n ect or A-4 t o sen sor con n ect or t er m in a l. Repa ir wir e
110 230 480 540 h a r n ess a s n ecessa r y if r esist a n ce is gr ea t er t h a n 1
oh m .
120 248 370 410
POWER STEERING PRESSURE SWITCH
2.5L 4–Cylinder Engine Only
Th is swit ch (F ig. 39) pr ovides a n in pu t t o t h e P ow-
er t r a in Con t r ol Modu le (P CM). Th e in pu t is pr ovided
XJ FUEL SYSTEM 14 - 43
DI AGN OSI S AN D T EST I N G (Cont inue d)
"- ELECTRIC!~ ~
CONNECT~~
~
INTAKE MANIFOLD
TEMPERATURE SENSOR
Fig. 38 Intake Manifold Air Temperature Sensor— Fig. 39 Power Steering Pump Pressure Switch—2.5L
2.5L Engine Engine
du r in g per iods of h igh pu m p loa d a n d low en gin e EXTENDED IDLE SWITCH TEST
r pm ; su ch a s du r in g pa r kin g m a n eu ver s. Th e P CM
will t h en in cr ea se idle speed t h r ou gh t h e Idle Air OPTIONAL POLICE PACKAGE ONLY
Con t r ol (IAC) m ot or. Th is is don e t o pr even t t h e Th e ext en ded idle swit ch is u sed t o r a ise en gin e
en gin e fr om st a llin g u n der t h e in cr ea sed loa d. idle speed t o a ppr oxim a t ely 1000 r pm wh en t h e
Wh en st eer in g pu m p pr essu r e exceeds 3275 kP a ! sh ift er is in eit h er P a r k or Neu t r a l posit ion . A r ocker-
690 kP a (475 psi ! 100 psi), t h e n or m a lly closed t ype swit ch (ext en ded idle swit ch ) is m ou n t ed t o
swit ch cir cu it will open a n d t h e P CM will in cr ea se in st r u m en t pa n el. Th is s w itc h is a v a ila ble o n ly
t h e en gin e idle speed. w ith 4.0L e n g in e w h e n s u p p lie d w ith o p tio n a l
Wh en power st eer in g pu m p pr essu r e dr ops t o p o lic e p a c k a g e .
a ppr oxim a t ely 1379 kP a (200 psi), t h e swit ch cir cu it Th e ext en ded idle swit ch will con t r ol a gr ou n d cir-
will r e-close a n d idle speed will r et u r n t o n or m a l. cu it goin g t o t h e power t r a in con t r ol m odu le (P CM).
To te s t s w itc h : Wh en a gr ou n d sign a l (t h r ou gh t h e swit ch ) h a s been
(1) Discon n ect elect r ica l con n ect or a t swit ch . r eceived a t pin /ca vit y A-12 (cir cu it K78) of t h e P CM,
(2) Con n ect a pa ir of ju m per wir es t o swit ch t er m i- en gin e idle speed will in cr ea se.
n a ls. Rou t e a n d secu r e ju m per wir es a wa y fr om fa n (1) Br in g en gin e t o n or m a l oper a t in g t em per a t u r e
bla des a n d fa n belt . a n d t u r n ext en ded idle swit ch t o ON posit ion . E n gin e
(3) Con n ect a n oh m m et er t o ju m per wir es a n d idle speed sh ou ld n ow in cr ea se t o a ppr oxim a t ely
obser ve con t in u it y. Cir cu it sh ou ld be closed wit h 1000 r pm wh en sh ift er is in eit h er P a r k or Neu t r a l
en gin e n ot r u n n in g. If con t in u it y is obser ved, swit ch posit ion .
is OK. If swit ch cir cu it is open , r epla ce swit ch . (2) If idle speed does n ot in cr ea se, u n plu g 4–wa y
(4) St a r t en gin e a n d obser ve oh m m et er. Wit h elect r ica l con n ect or fr om swit ch .
en gin e a t idle speed, con t in u it y sh ou ld be obser ved (3) Ch eck cir cu it Z1L for gr ou n d. Gr ou n d sh ou ld
u n t il st eer in g wh eel h a s been t u r n ed t o left or r igh t be pr esen t a t a ll t im es. If n ot , r epa ir open cir cu it t o
posit ion . D o n o t h o ld s te e rin g w h e e l in fu ll le ft gr ou n d. Refer t o Gr ou p 8W, Wir in g Dia gr a m s for cir-
o r rig h t p o s itio n fo r m o re th a n a fe w s e c o n d s . cu it a n d wir in g in for m a t ion .
D a m a g e to p o w e r s te e rin g p u m p m a y o c c u r. (4) If gr ou n d is pr esen t a t Z1L, ch eck con t in u it y of
(5) If con t in u it y is st ill obser ved a ft er t u r n in g swit ch bet ween cir cu it s Z1L a n d K78. If con t in u it y is
wh eel (cir cu it did n ot open ) , r epla ce swit ch . n ot pr esen t , r epla ce swit ch . If swit ch is OK pr oceed
t o n ext st ep.
VEHICLE SPEED SENSOR (5) Wit h 4–wa y elect r ica l con n ect or st ill u n plu gged
To per for m a com plet e t est of t h e sen sor a n d it s fr om swit ch , a pply a good gr ou n d t o cir cu it K78.
cir cu it r y, r efer t o DRB sca n t ool a n d a ppr opr ia t e E n gin e idle speed sh ou ld in cr ea se. If n ot , pr oceed t o
P ower t r a in Dia gn ost ics P r ocedu r es m a n u a l. n ext st ep.
14 - 44 FUEL SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
(6) Gr ou n d pin /ca vit y A-12 dir ect ly a t P CM u sin g a (1) St a r t t h e en gin e a n d br in g t o oper a t in g t em -
sm a ll pa per clip. Be ca r efu l n ot t o da m a ge wir in g per a t u r e. Be su r e a ll a ccessor ies a r e off befor e per-
wit h pa per clip. If en gin e idle speed in cr ea ses, it ca n for m in g t h is t est .
be a ssu m ed t h a t P CM is fu n ct ion in g cor r ect ly. Repa ir (2) Sh u t off en gin e a n d r em ove a ir du ct a t t h r ot t le
open cir cu it in cir cu it K78. If en gin e idle speed will body.
n ot in cr ea se a ft er a pplyin g a gr ou n d t o pin /ca vit y (3) 2.5L 4–Cy lin d e r En g in e : Nea r fr on t /t op of
A-12 (cir cu it K78) dir ect ly a t P CM, r epla ce P CM. va lve cover, discon n ect CCV t u be a t fixed or ifice fit -
t in g (F ig. 41). In ser t Specia l Tool 6714 in t o en d of
THROTTLE POSITION SENSOR (TPS) discon n ect ed CCV t u be (in ser t eit h er en d of t ool in t o
To per for m a com plet e t est of t h e TP S (F ig. 37) a n d t u be). Let t ool a n d t u be h a n g discon n ect ed a t side of
it s cir cu it r y, r efer t o t h e DRB sca n t ool a n d a ppr opr i- en gin e.
a t e P ower t r a in Dia gn ost ics P r ocedu r es m a n u a l. To (4) 4.0L 6–Cy lin d e r En g in e : Discon n ect CCV
t est t h e TP S on ly, r efer t o t h e followin g: t u be (F ig. 42) a t in t a ke m a n ifold fit t in g. At t a ch a
Th e TP S ca n be t est ed wit h a digit a l volt m et er. sh or t piece of r u bber h ose t o specia l t ool 6714 (in ser t
Th e cen t er t er m in a l of t h e TP S is t h e ou t pu t t er m i- r u bber h ose t o eit h er en d of t ool). In st a ll r u bber h ose/
n a l. t ool t o in t a ke m a n ifold fit t in g. Let CCV t u be h a n g
Wit h t h e ign it ion key in t h e ON posit ion , ch eck t h e discon n ect ed a t side of en gin e.
TP S ou t pu t volt a ge a t t h e cen t er t er m in a l wir e of t h e
con n ect or. Ch eck t h is a t idle (t h r ot t le pla t e closed)
a n d a t Wide Open Th r ot t le (WOT). At idle, TP S ou t -
pu t volt a ge sh ou ld be gr ea t er t h a n .26 volt s bu t less
t h a n .95 volt s. At wide open t h r ot t le, TP S ou t pu t
volt a ge m u st be less t h a n 4.49 volt s. Th e ou t pu t volt -
a ge sh ou ld in cr ea se gr a du a lly a s t h e t h r ot t le pla t e is
slowly open ed fr om idle t o WOT.
Fig. 42 Install Orifice Tool 4.0L 6–Cylinder Engine Fig. 43 Power Distribution Center (PDC)
(10) Rem ove or ifice t ool a n d con n ect CCV t u be t o REMOVAL
en gin e. (1) Rem ove P DC cover.
(11) In st a ll a ir du ct t o t h r ot t le body. (2) Rem ove r ela y fr om P DC.
(3) Ch eck con dit ion of r ela y t er m in a ls a n d P DC
con n ect or t er m in a ls for da m a ge or cor r osion . Repa ir
REM OVAL AN D I N STALLAT I ON if n ecessa r y befor e in st a llin g r ela y.
(4) Ch eck for pin h eigh t (pin h eigh t sh ou ld be t h e
AUTOMATIC SHUTDOWN (ASD) RELAY sa m e for a ll t er m in a ls wit h in t h e P DC con n ect or ).
Th e ASD r ela y is loca t ed in t h e P ower Dist r ibu t ion Repa ir if n ecessa r y befor e in st a llin g r ela y.
Cen t er (P DC) (F ig. 43). Refer t o la bel on P DC cover
for r ela y loca t ion . INSTALLATION
(1) In st a ll r ela y t o P DC.
REMOVAL (2) In st a ll cover t o P DC.
(1) Rem ove P DC cover.
(2) Rem ove r ela y fr om P DC. THROTTLE BODY
(3) Ch eck con dit ion of r ela y t er m in a ls a n d P DC A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i-
con n ect or t er m in a ls for da m a ge or cor r osion . Repa ir ca lly lim it t h e posit ion of t h e t h r ot t le body t h r ot t le
if n ecessa r y befor e in st a llin g r ela y. pla t e. N e v e r a tte m p t to a d ju s t th e e n g in e id le
(4) Ch eck for pin h eigh t (pin h eigh t sh ou ld be t h e s p e e d u s in g th is s c re w. All idle speed fu n ct ion s a r e
sa m e for a ll t er m in a ls wit h in t h e P DC con n ect or ). con t r olled by t h e P ower t r a in Con t r ol Modu le (P CM).
Repa ir if n ecessa r y befor e in st a llin g r ela y.
REMOVAL
INSTALLATION (1) Rem ove a ir clea n er t u be a t t h r ot t le body.
(1) In st a ll r ela y t o P DC. (2) Discon n ect t h r ot t le body elect r ica l con n ect or s
(2) In st a ll cover t o P DC. a t MAP sen sor, IAC m ot or a n d TP S (F ig. 44) or (F ig.
45).
FUEL PUMP RELAY (3) Rem ove a ll con t r ol ca bles fr om t h r ot t le body
Th e fu el pu m p r ela y is loca t ed in t h e P ower Dist r i- (lever ) a r m . Refer t o t h e Acceler a t or P eda l a n d Th r ot -
bu t ion Cen t er (P DC) (F ig. 43). Refer t o la bel on P DC t le Ca ble sect ion of t h is gr ou p for a ddit ion a l in for m a -
cover for r ela y loca t ion . t ion .
(4) Rem ove fou r t h r ot t le body m ou n t in g bolt s.
(5) Rem ove t h r ot t le body fr om in t a ke m a n ifold.
14 - 46 FUEL SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
REMOVAL
(1) Discon n ect TP S elect r ica l con n ect or.
(2) Rem ove TP S m ou n t in g scr ews (F ig. 46).
(3) Rem ove TP S.
MAP SENSOR
80aac28d
' INSTALLATION
Th e t h r ot t le sh a ft en d of t h e t h r ot t le body slides
in t o a socket in t h e TP S (F ig. 47). Th e TP S m u st be
in st a lled so t h a t it ca n be r ot a t ed a few degr ees. (If
t h e sen sor will n ot r ot a t e, in st a ll t h e sen sor wit h t h e
t h r ot t le sh a ft on t h e ot h er side of t h e socket t a n gs).
Th e TP S will be u n der sligh t t en sion wh en r ot a t ed.
80a87223
INSTALLATION
(1) Clea n m a t in g su r fa ces of t h r ot t le body a n d
in t a ke m a n ifold.
(2) In st a ll n ew t h r ot t le body-t o-in t a ke m a n ifold
ga sket . Fig. 47 Throttle Position Sensor—Installation
(3) In st a ll t h r ot t le body t o in t a ke m a n ifold. (1) In st a ll TP S a n d r et a in in g scr ews.
(4) In st a ll fou r m ou n t in g bolt s. Tigh t en bolt s t o 11 (2) Tigh t en scr ews t o 7 N·m (60 in . lbs.) t or qu e.
N·m (100 in . lbs.) t or qu e. (3) Con n ect TP S elect r ica l con n ect or t o TP S.
(5) In st a ll con t r ol ca bles. (4) Ma n u a lly oper a t e t h r ot t le (by h a n d) t o ch eck
(6) In st a ll elect r ica l con n ect or s. for a n y TP S bin din g befor e st a r t in g en gin e.
(7) In st a ll a ir clea n er a t t h r ot t le body.
XJ FUEL SYSTEM 14 - 47
REM OVAL AN D I N STALLAT I ON (Cont inue d)
REMOVAL
(1) Rem ove a ir clea n er t u be a t t h r ot t le body.
(2) Discon n ect elect r ica l con n ect or fr om IAC m ot or.
(3) Rem ove t wo m ou n t in g bolt s (scr ews) (F ig. 48).
(4) Rem ove IAC m ot or fr om t h r ot t le body.
RUBBER
FITTING
80a6l168
REMOVAL
(1) Rem ove a ir clea n er in t a ke t u be a t t h r ot t le
body.
(2) Rem ove t wo MAP sen sor m ou n t in g bolt s
(scr ews) (F ig. 49).
(3) Wh ile r em ovin g MAP sen sor, slide t h e r u bber
L-sh a ped fit t in g (F ig. 49) fr om t h r ot t le body.
(4) Rem ove r u bber L-sh a ped fit t in g fr om MAP sen -
sor. Fig. 50 PCM Location
REMOVAL
INSTALLATION To a void possible volt a ge spike da m a ge t o t h e
(1) In st a ll r u bber L-sh a ped fit t in g t o MAP sen sor. P CM, ign it ion key m u st be off, a n d n ega t ive ba t t er y
(2) P osit ion sen sor t o t h r ot t le body wh ile gu idin g ca ble m u st be discon n ect ed befor e u n plu ggin g P CM
r u bber fit t in g over t h r ot t le body va cu u m n ipple. con n ect or s.
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
14 - 48 FUEL SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove O2S sen sor. Sn a p-On oxygen sen sor
wr en ch (n u m ber YA 8875) m a y be u sed for r em ova l
a n d in st a lla t ion .
80aac28f
INSTALLATION
(1) In st a ll a ir clea n er elem en t in t o h ou sin g.
(2) In st a ll a ir clea n er cover t o h ou sin g (t h r ee
clips). Be su r e cover is pr oper ly sea t ed t o a ir clea n er
h ou sin g.
(3) In st a ll a ir t u be a n d cla m p t o cover. Com pr ess
cla m p sn u gly wit h a dju st a ble plier s a s sh own in (F ig.
56).
l[J
© I
1, ,l INTAKE MANIFOLD
AIR TEMPERATURE
MAP SENSOR SENSOR
soaac28d
SENSOR SPEEDOMETER
ELECTRICAL PINION GEAR
CONNECTOR
ELECTRICAL
CONNECTOR
O-RING
SPEEDOMETER PINION
GEAR ADAPTER
VEHICLE
O-RING
SPEED
J9414-60 SENSOR J9314-188
Fig. 62 Sensor Removal/Installation
Fig. 60 Vehicle Speed Sensor Location—2WD— INSTALLATION
Typical (1) Clea n in side of speedom et er pin ion gea r
SENSOR a da pt er befor e in st a llin g speed sen sor.
ELECTRICAL (2) In st a ll sen sor in t o speedom et er gea r a da pt er
CONNECTOR a n d in st a ll m ou n t in g bolt . B e fo re tig h te n in g bo lt,
v e rify s p e e d s e n s o r is fu lly s e a te d (m o u n te d
flu s h ) to s p e e d o m e te r p in io n g e a r a d a p te r.
(3) Tigh t en sen sor m ou n t in g bolt t o 2.2 N·m (20 in .
lbs.) t or qu e.
(4) Con n ect elect r ica l con n ect or t o sen sor.
SPECI FI CAT I ON S
TORQUE CHART
D ES CRIP TION TORQU E
Air Clea n er H ou sin g Mou n t . Bolt s . . . . . . . . . 8 N·m
4WD (71 in . lbs.)
VEHICLE TRANSFER E n gin e Coola n t Tem per a t u r e Sen sor . . . . . . 11 N·m
SPEED CASE (96 in . lbs.)
SENSOR EXTENSION
IAC Mot or-To-Th r ot t le Body Bolt s . . . . . . . . . 7 N·m
80a35409
(60 in . lbs.)
In t a ke Ma n ifold Air Tem p. Sen sor . . . . . . . . 28 N·m
Fig. 61 Vehicle Speed Sensor Location—4WD— (20 ft . lbs.)
Typical MAP Sen sor Mou n t in g Scr ews . . 3 N·m (25 in . lbs.)
Oxygen Sen sor . . . . . . . . . . . . . . 30 N·m (22 ft . lbs.)
REMOVAL P CM Mou n t in g Scr ews . . . . . . . . 4 N·m (35 in . lbs.)
(1) Ra ise a n d su ppor t veh icle.
P ower St eer in g P r essu r e Swit ch . . . . . . . 14–22 N·m
(2) Discon n ect elect r ica l con n ect or fr om sen sor.
(124–195 in . lbs.)
(3) Rem ove sen sor m ou n t in g bolt (F ig. 62).
Th r ot t le Body Mou n t in g Bolt s . 11 N·m (100 in . lbs.)
(4) Rem ove sen sor (pu ll st r a igh t ou t ) fr om speed-
Th r ot t le P osit ion Sen sor Mou n t in g Scr ews . . 7 N·m
om et er pin ion gea r a da pt er (F ig. 62). Do n ot r em ove
(60 in . lbs.)
gea r a da pt er fr om t r a n sm ission .
14 - 52 FUEL SYSTEM XJ
SPECI FI CAT I ON S (Cont inue d)
D ES CRIP TION TORQU E
Veh icle Speed Sen sor Mou n t in g Bolt . . . . . . 2.2 N·m
(20 in . lbs.)
SPECI AL T OOLS
FUEL SYSTEM
page page
-
INDEX
page page
INDEX
page page
HIGH
PRESSURE
LINE
80ba77f9
Fig. 1 Typical Fuel Pressure Test at Injector Fig. 2 Fuel Filter/Water Separator Location
FUEL TANK MODULE Th e com bin a t ion fu el filt er /wa t er sepa r a t or pr o-
An elect r ic fu el pu m p is n ot a t t a ch ed t o t h e fu el t ect s t h e fu el in ject ion pu m p by h elpin g t o r em ove
t a n k m odu le for diesel power ed en gin es. F u el is wa t er a n d con t a m in a n t s fr om t h e fu el. Moist u r e col-
siph on ed by t h e fu el in ject ion pu m p. lect s a t t h e bot t om of t h e filt er /sepa r a t or in a pla st ic
Th e fu el t a n k m odu le is in st a lled in t h e t op of t h e bowl.
fu el t a n k. Th e fu el t a n k m odu le con t a in s t h e follow- Th e fu el filt er /wa t er sepa r a t or a ssem bly con t a in s
in g com pon en t s: t h e fu el filt er, fu el h ea t er elem en t , a n d fu el dr a in
• F u el r eser voir va lve.
• A sepa r a t e in -t a n k fu el filt er F or in for m a t ion on t h e fu el h ea t er, r efer t o F u el
• E lect r ic fu el ga u ge sen din g u n it H ea t er in t h is gr ou p.
• F u el su pply lin e con n ect ion Refer t o t h e m a in t en a n ce sch edu les in Gr ou p 0 in
• F u el r et u r n lin e con n ect ion t h is m a n u a l for t h e r ecom m en ded fu el filt er r epla ce-
m en t in t er va ls.
FUEL GAUGE SENDING UNIT F or per iodic dr a in in g of wa t er fr om t h e bowl, r efer
Th e fu el ga u ge sen din g u n it is a t t a ch ed t o t h e side t o F u el F ilt er /Wa t er Sepa r a t or Rem ova l/In st a lla t ion
of t h e fu el pu m p m odu le. Th e sen din g u n it con sist s of in t h is gr ou p.
a floa t , a n a r m , a n d a va r ia ble r esist or (t r a ck). Th e
t r a ck is u sed t o sen d a n elect r ica l sign a l u sed for fu el FUEL SHUTDOWN SOLENOID
ga u ge oper a t ion . Th e fu e l s h u td o w n s o le n o id is c o n tro lle d a n d
As t h e fu el level in cr ea ses, t h e floa t a n d a r m m ove o p e ra te d by th e MS A.
u p. Th is decr ea ses t h e sen din g u n it r esist a n ce, ca u s- Th e fu el sh u t down (sh u t -off) solen oid is u sed t o
in g t h e P CM t o sen d a sign a l t o t h e fu el ga u ge on t h e elect r ica lly sh u t off t h e diesel fu el su pply t o t h e h igh -
in st r u m en t pa n el t o r ea d fu ll. As t h e fu el level pr essu r e fu el in ject ion pu m p. Th e solen oid is
decr ea ses, t h e floa t a n d a r m m ove down . Th is m ou n t ed t o t h e r ea r of t h e in ject ion pu m p.
in cr ea ses t h e sen din g u n it r esist a n ce, ca u sin g t h e Th e solen oid con t r ols st a r t in g a n d st oppin g of t h e
P CM t o sen d a sign a l t o t h e fu el ga u ge on t h e in st r u - en gin e r ega r dless of t h e posit ion of t h e a cceler a t or
m en t pa n el t o r ea d em pt y. peda l. Wh en t h e ign it ion (key) swit ch is OF F, t h e
solen oid is sh u t off a n d fu el flow is n ot a llowed t o t h e
FUEL FILTER/WATER SEPARATOR fu el in ject ion pu m p. Wh en t h e key is pla ced in t h e
Th e fu el filt er /wa t er sepa r a t or a ssem bly is loca t ed ON or START posit ion s, fu el su pply is a llowed a t t h e
in t h e en gin e com pa r t m en t n ea r t h e st r u t t ower (F ig. in ject ion pu m p.
2).
14 - 4 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
INSTALLATION
FUEL DRAIN TUBES
FUEL INJECTORS
\•usH-~J
PLASTIC
RETAINER J9314-100
VISUAL INSPECTION
A visu a l in spect ion for loose, discon n ect ed, or in cor-
r ect ly r ou t ed wir es a n d h oses sh ou ld be m a de befor e
a t t em pt in g t o dia gn ose or ser vice t h e diesel fu el
in ject ion syst em . A visu a l ch eck will h elp fin d t h ese
con dit ion s. It a lso sa ves u n n ecessa r y t est a n d dia g-
n ost ic t im e. A t h or ou gh visu a l in spect ion of t h e fu el
in ject ion syst em in clu des t h e followin g ch ecks:
(1) Be su r e t h a t t h e ba t t er y con n ect ion s a r e t igh t
TERMINAL a n d n ot cor r oded.
1
(2) Be su r e t h a t t h e 60 wa y con n ect or is fu lly
en ga ged wit h t h e P CM (F ig. 9).
(3) Be su r e t h a t t h e 68 wa y con n ect or is fu lly
en ga ged wit h t h e MSA (F ig. 10).
POWERTRAIN MOUNTING
CONTROL BRACKET
80b6b14f
MODULE
{PCM)
Fig. 8 Fuel Heater Temperature Sensor and Element
Location
a ddit ion a l in for m a t ion . Th e fu e l h e a te r a n d fu e l
h e a te r re la y a re n o t c o n tro lle d by th e P o w e r-
tra in Co n tro l Mo d u le (ECM).
Cu r r en t dr a w for t h e h ea t er elem en t is 150 wa t t s
a t 14 volt s (DC).
\\~ACCELERATOR PEDAL
~ POSITION SENSOR LOWER
INSTRUMENT
PANEL
80accfe9 80ad08f8
SENSOR
CONNECTOR
4WD
TRANSFER
VEHICLE
80ba7975 CASE
SPEED
EXTENSION
Fig. 14 Fuel Injector Sensor SENSOR
80a35409
SENSOR
ELECTRICAL
CONNECTOR
Fig. 16 Vehicle Speed Sensor—4 Wheel Drive
PCM ECM r
ENGINE COOLANT ENGINE COOLANT'----
TEMPERATURE TEMPERATUR~E
(ECT) (ECT)
SENSOR SENSOR
PCMECT
\ SENSOR
) HARNESS
J9414-60 __,/ CONNECTOR
/ .,...,,,,. ..A:"\.~ "'
Fig. 15 Vehicle Speed Sensor—2 Wheel Drive Fig. 17 Engine Coolant Temperature Sensor
(18) Be su r e t h a t t h e gr ou n d con n ect ion s a r e t igh t Location
a n d fr ee of cor r osion . Refer t o Gr ou p 8, Wir in g for pu m p is loca t ed in t h e fr on t of en gin e (in t er n a l) a n d
loca t ion s of gr ou n d con n ect ion s. is dr iven fr om t h e cr a n ksh a ft gea r (F ig. 18). Discon -
(19) In spect t h e a ir clea n er elem en t (filt er ) for n ect t h e h ose a n d ch eck for m in im u m va cu u m fr om
r est r ict ion s. t h e pu m p. Refer t o Gr ou p 5, Br a ke Syst em for spec-
(20) Be su r e t h a t t h e t u r boch a r ger ou t pu t h ose is ifica t ion s a n d pr ocedu r es.
pr oper ly con n ect ed t o t h e ch a r ge a ir cooler (in t er- (22) Be su r e t h a t t h e a ccessor y dr ive belt is n ot
cooler ) in let t u be. Ver ify t h a t t h e ch a r ge a ir cooler da m a ged or slippin g.
ou t pu t h ose is pr oper ly con n ect ed t o t h e cooler a n d (23) Ver ify t h er e is a good con n ect ion a t t h e en gin e
t h e in t a ke m a n ifold. Refer t o Gr ou p 11, E xh a u st Sys- speed sen sor. Refer t o t h e F u el In ject ion Syst em in
t em a n d In t a ke Ma n ifold for in for m a t ion . t h is sect ion for loca t ion of t h e en gin e speed sen sor
(21) Be su r e t h a t t h e va cu u m h oses t o t h e va cu u m loca t ion .
pu m p a r e con n ect ed a n d n ot lea kin g. Th e va cu u m
14 - 10 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
AIR IN FUEL SYSTEM WARNING: DO NOT BLEED AIR FROM THE FUEL
Air will en t er t h e fu el syst em wh en ever t h e fu el SYSTEM OF A HOT ENGINE. DO NOT ALLOW FUEL
su pply lin es, fu el filt er /wa t er sepa r a t or, fu el filt er TO SPRAY ONTO THE EXHAUST MANIFOLD WHEN
bowl, in ject ion pu m p, h igh –pr essu r e lin es or in ject or s BLEEDING AIR FROM THE FUEL SYSTEM.
a r e r em oved or discon n ect ed. Air will a lso en t er t h e
fu el syst em wh en ever t h e fu el t a n k h a s been r u n To det er m in e wh ich fu el in ject or is m a lfu n ct ion in g,
em pt y. r u n t h e en gin e a n d loosen t h e h igh –pr essu r e fu el lin e
Air t r a pped in t h e fu el syst em ca n r esu lt in h a r d n u t a t t h e in ject or (F ig. 19). List en for a ch a n ge in
st a r t in g, a r ou gh r u n n in g en gin e, en gin e m isfir e, low en gin e speed. If en gin e speed dr ops, t h e in ject or wa s
power, excessive sm oke a n d fu el kn ock. Aft er ser vice oper a t in g n or m a lly. If en gin e speed r em a in s t h e
is per for m ed, a ir m u st be bled fr om t h e syst em sa m e, t h e in ject or m a y be m a lfu n ct ion in g. Aft er t est -
befor e st a r t in g t h e en gin e. in g, t igh t en t h e lin e n u t t o 30 N·m (22 ft . lbs.)
In spect t h e fu el syst em fr om t h e fu el t a n k t o t h e t or qu e. Test a ll in ject or s in t h e sa m e m a n n er on e a t
in ject or s for loose con n ect ion s. Lea kin g fu el is a n a t im e.
in dica t or of loose con n ect ion s or defect ive sea ls. Air On ce a n in ject or h a s been fou n d t o be m a lfu n ct ion -
ca n a lso en t er t h e fu el syst em bet ween t h e fu el t a n k in g, r em ove it fr om t h e en gin e a n d t est it . Refer t o
a n d t h e in ject ion pu m p. In spect t h e fu el t a n k a n d t h e Rem ova l/In st a lla t ion sect ion of t h is gr ou p for pr o-
fu el lin es for da m a ge t h a t m igh t a llow a ir in t o t h e cedu r es.
syst em . Aft er t h e in ject or h a s been r em oved, in st a ll it t o a
F or a ir bleedin g, r efer t o Air Bleed P r ocedu r e in ben ch –m ou n t in ject or t est er. Refer t o oper a t in g
t h e Ser vice P r ocedu r es sect ion of t h is gr ou p. in st r u ct ion s su pplied wit h t est er for pr ocedu r es.
Th e open in g pr essu r e or “pop” pr essu r e sh ou ld be
FUEL HEATER RELAY TEST 15,000–15,800 kP a (2175–2291 psi). If t h e fu el in jec-
Th e fu el h ea t er r ela y is loca t ed in t h e P ower Dis- t or n eedle va lve is open in g (“poppin g”) t o ea r ly or t o
t r ibu t ion Cen t er (P DC). Refer t o Rela ys—Oper a t ion / la t e, r epla ce t h e in ject or.
Test in g in F u el In ject ion Syst em sect ion of t h is gr ou p
for t est pr ocedu r es.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 11
DI AGN OSI S AN D T EST I N G (Cont inue d)
A defect ive fu el in ject ion pu m p, defect ive fu el t im -
in g solen oid or m isa dju st ed m ech a n ica l pu m p t im in g
ca n ca u se st a r t in g pr oblem s or pr even t t h e en gin e
fr om r evvin g u p. It ca n a lso ca u se:
• E n gin e su r ge a t idle
• Rou gh idle (wa r m en gin e)
• Low power
• E xcessive fu el con su m pt ion
• P oor per for m a n ce
• Low power
• Bla ck sm oke fr om t h e exh a u st
• Blu e or wh it e fog like exh a u st
• In cor r ect idle or m a xim u m speed
Th e elect r on ica lly con t r olled fu el pu m p h a s n o
m ech a n ica l gover n or like older m ech a n ica lly con -
t r olled fu el pu m ps. Do n ot r em ove t h e t op cover of
Fig. 19 Typical Inspection of Fuel Injector t h e fu el pu m p, or t h e scr ews fa st en in g t h e wir in g
pigt a il t o t h e side of t h e pu m p. Th e w a rra n ty o f
FUEL INJECTOR / NEEDLE MOVEMENT th e in je c tio n p u m p a n d th e e n g in e m a y be v o id
SENSOR TEST if th o s e s e a ls h a v e be e n re m o v e d o r ta m p e re d
Th e n eedle m ovem en t sen sor is u sed on ly on t h e w ith .
n u m ber –1 cylin der fu el in ject or (F ig. 20). It is n ot
u sed on t h e in ject or s for cylin der s n u m ber 2, 3, or 4. FUEL SUPPLY RESTRICTIONS
NEEDLE MOVEMENT FUEL INJECTOR
SENSOR LOW–PRESSURE LINES
(NUMBER 1
Rest r ict ed or P lu gged su pply lin es or fu el filt er ca n
CYLINDER ONLY}
ca u se a t im in g fa u lt t h a t will ca u se t h e E CM t o oper-
a t e t h e en gin e in a “Lim p H om e” m ode. See t h e
in t r odu ct ion of t h e F u el In ject ion Syst em in t h is
gr ou p for m or e in for m a t ion on t h e Lim p H om e m ode.
F u el su pply lin e r est r ict ion s ca n ca u se st a r t in g pr ob-
lem s a n d pr even t t h e en gin e fr om r evvin g u p. Th e
st a r t in g pr oblem s in clu de; low power a n d blu e or
wh it e fog like exh a u st . Test a ll fu el su pply lin es for
r est r ict ion s or blocka ge. F lu sh or r epla ce a s n eces-
sa r y. Bleed t h e fu el syst em of a ir on ce a fu el su pply
lin e h a s been r epla ced. Refer t o t h e Air Bleed P r oce-
SENSOR du r e sect ion of t h is gr ou p for pr ocedu r es.
CONNECTOR
HIGH–PRESSURE LINES
Rest r ict ed (kin ked or ben t ) h igh –pr essu r e lin es ca n
80ba7975
ca u se st a r t in g pr oblem s, poor en gin e per for m a n ce
Fig. 20 Needle Movement Sensor Location a n d bla ck sm oke fr om exh a u st .
E xa m in e a ll h igh –pr essu r e lin es for a n y da m a ge.
Test in g t h e n eedle m ovem en t sen sor r equ ir es t h e E a ch r a diu s on ea ch h igh –pr essu r e lin e m u st be
u se of a DRB Sca n t ool. Refer t o t h e P ower t r a in sm oot h a n d fr ee of a n y ben ds or kin ks.
Dia gn ost ic P r ocedu r es m a n u a l for a ddit ion a l in for- Repla ce da m a ged, r est r ict ed or lea kin g h igh –pr es-
m a t ion . su r e fu el lin es wit h t h e cor r ect r epla cem en t lin e.
FUEL INJECTION PUMP TEST CAUTION: The high–pressure fuel lines must be
Th e in je c tio n p u m p is n o t to be s e rv ic e d o r clamped securely in place in the holders. The lines
th e w a rra n ty m a y be v o id e d . If th e in je c tio n cannot contact each other or other components. Do
p u m p re qu ire s s e rv ic e , th e c o m p le te a s s e m bly not attempt to weld high–pressure fuel lines or to
m u s t be re p la c e d . repair lines that are damaged. Only use the recom-
In cor r ect in ject ion pu m p t im in g (m ech a n ica l or mended lines when replacement of high–pressure
elect r ica l) ca n ca u se poor per for m a n ce, excessive fuel line is necessary.
sm oke a n d em ission s a n d poor fu el econ om y.
14 - 12 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
Fig. 21 Typical Fuel Pressure Test at Injector CAUTION: Do not engage the starter motor for
CAUTION: The high–pressure fuel lines must be more than 30 seconds at a time. Allow 2 minutes
clamped securely in place in the holders. The lines between cranking intervals.
cannot contact each other or other components. Do
not attempt to weld high–pressure fuel lines or to
repair lines that are damaged. Only use the recom-
mended lines when replacement of high–pressure
fuel line is necessary.
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 13
SERV I CE PROCEDU RES (Cont inue d)
J9114-69
0
@ 0
FUEL HEATER
If t h e fu el h ea t er elem en t n eeds r epla cem en t , t h e
pla st ic filt er bowl a ssem bly m u st be r epla ced. Refer
t o F u el F ilt er /Wa t er Sepa r a t or for in for m a t ion .
REMOVAL REMOVAL
(1) Rem ove fu el t a n k. Refer t o F u el Ta n k Rem ova l/ (1) Discon n ect t h e n ega t ive ba t t er y ca ble.
In st a lla t ion . (2) Th or ou gh ly clea n t h e a r ea a r ou n d t h e in ject ion
(2) Rem ove fu el pu m p m odu le. Refer t o F u el P u m p pu m p a n d fu el lin es of a ll dir t , gr ea se a n d ot h er con -
Modu le Rem ova l/In st a lla t ion . t a m in a n t s. D u e to th e c lo s e in te rn a l to le ra n c e s
(3) Rem ove elect r ica l wir e con n ect or a t sen din g o f th e in je c tio n p u m p , th is s te p m u s t be p e r-
u n it t er m in a ls. fo rm e d be fo re re m o v in g p u m p .
(4) P r ess on r elea se t a b (F ig. 29) t o r em ove sen d-
in g u n it fr om pu m p m odu le.
14 - 16 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(9) Discon n ect t h e fou r h igh –pr essu r e fu el lin es
fr om t h e fu el in ject ion pu m p. Also discon n ect fu el
lin es a t t h e fu el in ject or s. F or pr ocedu r es, r efer t o
H igh –P r essu r e F u el Lin es in t h is gr ou p. P la ce a r a g
ben ea t h t h e fit t in gs t o ca t ch excess fu el.
(10) Rem ove t h e plu g fr om t im in g gea r cover.
(11) Th e “Top Dea d Cen t er ” (TDC) com pr ession fir-
in g st r oke for t h e #1 cylin der ca n be det er m in ed a s
follows:
(a ) Usin g a socket a t t a ch ed t o t h e fr on t of t h e
cr a n ksh a ft , r ot a t e t h e en gin e clockwise u n t il spe-
cia l a lign m en t t ool VM# 1035 ca n be in ser t ed
t h r ou gh t h e h ole in t h e bot t om of t h e clu t ch h ou s-
in g, st oppin g t h e flywh eel r ot a t ion . Th is posit ion is
TDC or 180° a wa y fr om TDC. En g in e m u s t be a t
TD C #1 c o m p re s s io n firin g s tro k e .
FUEL
T RELEASE
TAB
(b) To ver ify t h a t you a r e a t TDC. Rem ove t h e
oil fill ca p fr om t h e cylin der h ea d cover a n d t h e
a lign m en t t ool fr om t h e clu t ch h ou sin g.
RESERVOIR (c) Rot a t e t h e cr a n ksh a ft on e-qu a r t er t u r n clock-
MODULE wise a n d cou n t er-clockwise wh ile obser vin g t h e
80ad090e
r ocker a r m t h r ou gh t h e oil fill ca p h ole. If t h e
Fig. 29 Fuel Level Sensor Release Tab r ocker a r m m oves you a r e n ot a t TDC.
(d) If TDC wa s fou n d con t in u e, if n ot r ot a t e t h e
(3) Rem ove t h e en gin e a ccessor y dr ive belt . Refer
cr a n ksh a ft on e r evolu t ion u n t il t h e a lign m en t t ool
t o Gr ou p 7, Coolin g Syst em for pr ocedu r es.
ca n be r e-in st a lled in t h e flywh eel. You a r e n ow a t
(4) Rem ove t h e gen er a t or a ssem bly.
TDC for t h e #1 cylin der com pr ession fir in g st r oke.
(5) Rem ove t h e r u bber fu el r et u r n a n d su pply
Ma r k t h e da m per a n d t im in g cover for r efer en ce t o
h oses fr om t h e m et a l lin es a t t h e pu m p (F ig. 30).
TDC. Rem ove t h e a lign m en t t ool fr om t h e clu t ch
h ou sin g.
(12) Rem ove a ccess plu g a n d plu g wa sh er a t r ea r
of pu m p (F ig. 31). Th r ea d specia l dia l in dica t or a n d
a da pt er t ool VM.1011 (F ig. 32) in t o t h is open in g.
H a n d t igh t en on ly.
(13) Sligh t ly r ot a t e t h e en gin e in a cou n t er-clock-
wise dir ect ion u n t il t h e dia l ga u ge in dica t or st ops
m ovin g (20°-25° befor e TDC).
(14) Rem ove in ject ion pu m p dr ive gea r n u t (F ig.
33).
(15) A specia l 3–piece gea r r em ova l t ool set
VM.1003 (F ig. 34) m u st be u sed t o r em ove t h e in jec-
t ion pu m p dr ive gea r fr om t h e pu m p sh a ft .
(a ) Th r ea d t h e a da pt er (F ig. 35) in t o t h e t im in g
cover.
(b) Th r ea d t h e gea r pu ller in t o t h e in ject ion
pu m p dr ive gea r (F ig. 35). Th is t ool is a lso u sed t o
h old t h e gea r in syn ch r on iza t ion du r in g pu m p
r em ova l.
Fig. 30 Fuel Injection Pump (c) Rem ove t h e t h r ee in ject ion pu m p–t o–gea r
(6) Rem ove t h e elect r ica l con n ect or a t en gin e cool- cover m ou n t in g n u t s (F ig. 36). CAU TION : Th is
a n t t em per a t u r e sen sor. s te p m u s t be d o n e to p re v e n t in je c tio n p u m p
(7) Discon n ect t h e F u el In ject ion P u m p elect r ica l damage.
con n ect or a t fu el pu m p (F ig. 30). (d) In st a ll t h e dr ive bolt in t o t h e gea r pu ller
(8) Discon n ect t h e m a in en gin e wir in g h a r n ess (F ig. 35). Tigh t en t h e dr ive bolt t o pr ess (r em ove)
fr om t h e glow plu gs. t h e dr ive gea r fr om in ject ion pu m p sh a ft wh ile
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 17
REM OVAL AN D I N STALLAT I ON (Cont inue d)
TIMING
ACCESS GEAR
PLUG COVER
WASHER
80a0c5c8 80a0c5cc
Fig. 31 Access Plug at Rear of Pump Fig. 33 Removing Pump Drive Gear Nut
TIMING
COVER
ADAPTER
DRIVE
BOLT
~
GEAR
PULLER
80a0c5ca
ADAPTER
ACCESS
PLUG
DRIVE~<) e
BOLT~
WASHER
GEAR
PULLER 80a0c5cb 80a0c5c8
Fig. 35 Installing Pump Drive Gear Removal Tools Fig. 37 Access Plug at Rear of Pump
DIAL
INDICATOR
TOOL
PUMP
MOUNTING
NUTS (3) ' 80a0c5c6
~ FUEL
DRAIN TUBES 80a0c5d4
INSTALLATION
(1) P osit ion fu el t a n k on t r a n sm ission ja ck. Con -
n ect fu el filler t u be ven t h ose a n d r epla ce cla m p.
(2) Ra ise t a n k in t o posit ion a n d ca r efu lly wor k
filler t u be in t o t a n k. A ligh t coa t in g of clea n en gin e
oil on t h e t u be en d m a y be u sed t o a id a ssem bly.
(3) F eed filler ven t lin e t h or ou gh fr a m e r a il. Ca r e-
fu l n ot t o cr oss lin es.
(4) Tigh t en st r a p bolt s t o 9 N·m (80 in . lbs.).
Rem ove t r a n sm ission ja ck.
CAUTION: Ensure straps are not twisted or bent Fig. 45 Fuel Reservoir Module Lock Nut Removal
before or after tightening strap nuts.
(10) Ca r efu lly r em ove m odu le a n d o-r in g fr om
(5) Con n ect m odu le elect r ica l con n ect or. P la ce t a n k.
r et a in er in locked posit ion . (11) Disca r d old o-r in g.
(6) Lu br ica t e t h e fu el su pply a n d r et u r n lin es wit h
clea n 30 weigh t en gin e oil, in st a ll t h e qu ick con n ect INSTALLATION
fu el fit t in g. Refer t o Tu be/F it t in g Assem bly in t h e (1) Th or ou gh ly clea n lockn u t t h r ea ds a n d m a t in g
F u el Deliver y sect ion of t h is Gr ou p. fu le t a n k t h r ea ds. Use a soa p/wa t er solu t ion . D o n o t
(7) At t a ch filler lin e t o filler t u be. P u ll on con n ec- u s e c a rbu re to r c le a n e r to c le a n th re a d s .
t or t o m a ke su r e of con n ect ion . (2) Apply clea n wa t er t o t h e o-r in g sea l a n d pla ce
(8) F ill fu el t a n k, r epla ce ca p, a n d con n ect ba t t er y on t h e m a t in g fu el t a n k t h r ea ds.
n ega t ive ca ble. (3) Wipe sea l a r ea of t a n k clea n a n d pla ce a n ew
o-r in g sea l in posit ion on pu m p.
FUEL RESERVOIR MODULE (4) P osit ion fu el r eser voir m odu le in t a n k wit h
lockn u t .
REMOVAL (5) Tigh t en lockn u t t o 75 N·m (55 ft . lbs.).
(6) Con n ect fu el lin es.
WARNING: THE FUEL RESERVOIR OF THE FUEL (7) P lu g in elect r ica l con n ect or. Slide con n ect or
MODULE DOES NOT EMPTY OUT WHEN THE TANK lock in t o posit ion .
IS DRAINED. THE FUEL IN THE RESERVOIR WILL (8) Ra ise fu el t a n k, in st a ll bolt s in t o fu el t a n k
SPILL OUT WHEN THE MODULE IS REMOVED. st r a ps a n d t igh t en .
(9) Lower veh icle on h oist .
14 - 22 FUEL SYSTEM—2.5L DIESEL ENGINE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(10) Con n ect n ega t ive ca ble fr om ba t t er y. (5) Ver y ca r efu lly r em ove ea ch lin e fr om t h e
(11) F ill fu el t a n k. Ch eck for lea ks. en gin e. Not e t h e posit ion (fir in g or der ) of ea ch lin e
(12) In st a ll fu el filler ca p. wh ile r em ovin g. D o n o t be n d th e lin e w h ile
re m o v in g .
HIGH-PRESSURE LINES
All h igh –pr essu r e fu el lin es a r e of t h e sa m e len gt h CAUTION: Be sure that the high–pressure fuel lines
a n d in side dia m et er. Cor r ect h igh –pr essu r e fu el lin e are installed in the same order that they were
u sa ge a n d in st a lla t ion is cr it ica l t o sm oot h en gin e removed. Prevent the injection pump delivery valve
oper a t ion . holders from turning when removing or installing
high–pressure lines from injection pump.
CAUTION: The high–pressure fuel lines must be
clamped securely in place in the holders. The lines
cannot contact each other or other components. Do INSTALLATION
not attempt to weld high–pressure fuel lines or to (1) Ca r efu lly posit ion ea ch h igh –pr essu r e fu el lin e
repair lines that are damaged. Only use the recom- t o t h e fu el in ject or a n d fu el in ject ion pu m p deliver y
mended lines when replacement of high–pressure va lve h older in t h e cor r ect fir in g or der. Also posit ion
fuel line is necessary. ea ch lin e in t h e cor r ect lin e h older.
(2) Loosely in st a ll t h e lin e cla m p/h older bolt s.
(3) Tigh t en ea ch lin e a t t h e deliver y va lve t o 30
REMOVAL N·m (22 ft . lbs.) t or qu e.
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y. (4) Tigh t en ea ch lin e a t t h e fu el in ject or t o 30 N·m
(2) Rem ove t h e n ecessa r y cla m ps h oldin g t h e lin es (22 ft . lbs.) t or qu e.
t o t h e en gin e. B e s u re th e lin e s a re n o t c o n ta c tin g e a c h
(3) Clea n t h e a r ea a r ou n d ea ch fu el lin e con n ec- o th e r o r a n y o th e r c o m p o n e n t.
t ion . Discon n ect ea ch lin e a t t h e t op of ea ch fu el (5) Tigh t en t h e cla m p br a cket bolt s t o 24 N·m (18
in ject or (F ig. 46). ft . lbs.) t or qu e.
(6) Bleed a ir fr om t h e fu el syst em . Refer t o t h e Air
FUEL LINE HIGH-PRESSURE Bleed P r ocedu r e sect ion of t h is gr ou p.
INJECTOR FITTING FUEL LINE
-------- ~)
SPECI FI CAT I ON S
FUEL TANK CAPACITY
75 Lite rs (20.0 Ga ls .)
Nom in a l r efill ca pa cit ies a r e sh own . A va r ia t ion
m a y be obser ved fr om veh icle t o veh icle du e t o m a n -
u fa ct u r in g t oler a n ces, a m bien t t em per a t u r es a n d
r efill pr ocedu r es.
IDLE SPEED
900 rp m !25 rp m wit h en gin e a t n or m a l oper a t -
in g t em per a t u r e.
FU EL I N J ECT I ON SY ST EM —2 .5 L DI ESEL EN GI N E
INDEX
page page
DESCRI PT I ON AN D OPERAT I ON
POWERTRAIN CONTROL MODULE (PCM)
On LH D veh icles, t h e E CM is m ou n t ed beh in d t h e
lower In st r u m en t P a n el t o t h e r igh t of t h e a cceler a -
t or peda l (F ig. 1). On RH D veh icles, t h e E CM is
m ou n t ed beh in d t h e lower In st r u m en t P a n el t o t h e
left of t h e clu t ch peda l. Th e P ower t r a in Con t r ol Mod-
u le (P CM) is m ou n t ed in t h e en gin e com pa r t m en t .
(F ig. 2).
PCM
_,£-..---./--;_~_~_-_...:...,,-:,,"?I~_..,...,__ _ _ _
60-WAY
CONNECTOR
80a35314
in ject or for t h e n u m ber –1 cylin der (F ig. 4). It is n ot Fig. 5 Engine Coolant Temperature Sensor Location
u sed on t h e in ject or s for cylin der s n u m ber 2, 3, or 4.
ENGINE SPEED/CRANK POSITION SENSOR—
FUEL INJECTOR SENSOR—GROUND ECM INPUT
Th e en gin e speed sen sor is m ou n t ed t o t h e t r a n s-
FUEL INJECTOR
(NUMBER 1
m ission bellh ou sin g a t t h e left /r ea r side of t h e en gin e
CYLINDER ONLY) block (F ig. 6).
SENSOR
CONNECTOR
80a0c62e
80a0c62f
Fig. 10 Vehicle Speed Sensor—4 Wheel Drive Fig. 11 Glow Plug Lamp Symbol
In a ddit ion t o det er m in in g dist a n ce a n d veh icle SPEED CONTROL—PCM OUTPUTS
speed, t h e ou t pu t fr om t h e sen sor is u sed t o con t r ol Th ese t wo cir cu it s con t r ol t h e fu el qu a n t it y a ct u a -
speed con t r ol oper a t ion . t or t o r egu la t e veh icle speed. Refer t o Gr ou p 8H for
Speed Con t r ol in for m a t ion .
SPEED CONTROL—ECM INPUT
Th e speed con t r ol syst em pr ovides five sepa r a t e AIR CONDITIONING RELAY—ECM OUTPUT
in pu t s t o t h e E CM: On /Off, Set , Resu m e/Accel, Ca n - Th is cir cu it con t r ols a gr ou n d sign a l for oper a t ion
cel, a n d Decel. Th e On /Off in pu t in for m s t h e E CM of t h e A/C clu t ch r ela y. Also r efer t o Air Con dit ion in g
t h a t t h e speed con t r ol syst em h a s been a ct iva t ed.
Th e Set in pu t in for m s t h e E CM t h a t a fixed veh icle
XJ FUEL SYSTEM—2.5L DIESEL ENGINE 14 - 29
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
(A/C) Con t r ols—E CM In pu t for a ddit ion a l in for m a - MOUNTING
t ion . BOLT
Th e A/C r ela y is loca t ed in t h e P ower Dist r ibu t ion
Cen t er (P DC). Th e P DC is loca t ed n ext t o t h e ba t t er y
in t h e en gin e com pa r t m en t . F or t h e loca t ion of t h e
r ela y wit h in t h e P DC, r efer t o la bel on P DC cover.
80ad08f8
Th e P CM r ecieves en gin e r pm va lu es fr om t h e
E CM con t r oller, a n d t h en su pplies en gin e r pm va lu es
t o t h e Body Con t r oller t h a t t h en su pplies t h e in st r u - -30 C 15 SEC. 45SEC. 200 SEC.
m en t clu st er m ou n t ed t a ch om et er (if equ ipped). Refer
t o Gr ou p 8E for t a ch om et er in for m a t ion . -10 C 8SEC. 35SEC. 180 SEC.
C F MIN MAX
- BOOST PRESSURE
SENSOR HARNESS _-rrT,-u-"ill"T-.cllll.W
ELECTRICAL
CONNECTOR
CONNECTOR
80ad08f8
TESTING 80b77066
~.~~'7-_~~_J
80a18d42
ELECTRICAL
Fig. 22 Glow Plug
CONNECTOR
80ad08f8
REMOVAL
(1) Discon n ect t h e n ega t ive ba t t er y ca ble a t t h e
ba t t er y. MOUNTING
(2) Rem ove r ela y m ou n t in g bolt . BOLT 80a35314
INSTALLATION
(1) Aft er t h e P CM elect r ica l con n ect or h a s been
sepa r a t ed fr om t h e P CM, in spect t h e pin s for cor r o-
sion , bein g spr ea d a pa r t , ben t or m isa lign ed. Also
in spect t h e pin h eigh t s in t h e con n ect or. If t h e pin
h eigh t s a r e differ en t , t h is wou ld in dica t e a pin h a s
sepa r a t ed fr om t h e con n ect or. Repa ir a s n ecessa r y.
(2) E n ga ge 60–wa y con n ect or in t o P CM. Move
slide ba r t o lock con n ect or.
4WD
(3) Con n ect n ega t ive ca ble t o ba t t er y.
VEHICLE TRANSFER
CASE
VEHICLE SPEED SENSOR SPEED EXTENSION
Th e veh icle speed sen sor (F ig. 26) is loca t ed on t h e SENSOR
ext en sion h ou sin g of t h e t r a n sm ission for 2 wh eel 80a35409
dr ive veh icle, or on t h e t r a n sfer ca se h ou sin g for 4 Fig. 27 Vehicle Speed Sensor Location—4WD
wh eel dr ive veh icles (F ig. 27).
SPEEDOMETER
SENSOR PINION GEAR
ELECTRICAL
CONNECTOR ELECTRICAL
CONNECTOR
O-RING
TRANSMISSION
EXTENSION
HOUSING SPEEDOMETER PINION
GEAR ADAPTER
VEHICLE
O-RING
SPEED
SENSOR J9314-188
J9414-60
SPECI FI CAT I ON S
GLOW PLUG CURRENT DRAW
In itia l Cu rre n t D ra w : Appr oxim a t ely 22–25
a m ps per plu g.
Afte r 20 s e c o n d s o f o p e ra tio n : Appr oxim a t ely
9–12 a m ps per plu g.
_ _ _o_E_s_c_R_1P_T_1o_N_ ___.___T_o_R_Q_u_E
_ ____.I i. .1___o_E_s_c_R_1P_T_1_o_N_ _ _..___T_o_R_Q_u_E_ __,
Accelerator Pedal Bracket Fuel Injection Pump
Mounting Nuts ................................ 5 N•m (46 in. lbs.) Mounting Nuts .............................. 30 N•m (22 ft. lbs.)
Banjo-Type Fittings ........................ 19 N•m (14 ft. lbs.) Fuel Injection Pump
Drive Gear..................................... 88 N°m (65 ft. lbs.)
Engine Coolant
Temperature Sensor...................... 18 N•m (13 ft. lbs.) Fuel Line Clamp Bracket Bolts ..... 24 N-m (18 ft. lbs.)
Engine Speed Sensor Bolts ........... 19 N•m (14 ft. lbs.) Fuel Tank Nuts ............................... 11 N•m (100 in. lbs.)
Fuel Hose (Tube) Glow Plugs ..................................... 23 N•m (203 in.lbs.)
Clamps For Rubber Hose ............. 2 N•m (20 in. lbs.)
Powertrain Control Module
Fuel Injector.................................... 70 N•m (52 ft. lbs.) Mounting Bolts ............................... 1 N•m (9 in. lbs.)
Fuel Injector Line
Throttle Position Sensor
At Injector...................................... 30 N•m (22 ft. lbs.)
Mounting Bolts ............................... 7 N•m (60 in. lbs.)
Fuel Injector Line Vehicle Speed Sensor
At Injector Pump .......................... 30 N•m (22 ft. lbs.) Mounting Bolt... .............................. 3 N-m (26 in. lbs.)
80a13879
XJ STEERING 19 - 1
STEERING
CON T EN T S
page page
POWER ST EERI N G
INDEX
page page
-
(LHD) service procedures and torque specifications
• St eer in g lin ka ge
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.
19 - 2 STEERING XJ
ST EERI N G N OI SE
Th er e is som e n oise in a ll power st eer in g syst em s. On e of t h e m ost com m on is a h issin g sou n d eviden t a t a
st a n dst ill pa r kin g. Or wh en t h e st eer in g wh eel is a t t h e en d of it ’s t r a vel. H iss is a h igh fr equ en cy n oise sim ila r
t o t h a t of a wa t er t a p bein g closed slowly. Th e n oise is pr esen t in a ll va lves t h a t h a ve a h igh velocit y flu id pa ssin g
t h r ou gh a n or ifice. Th er e is n o r ela t ion sh ip bet ween t h is n oise a n d st eer in g per for m a n ce.
OBJECTIONAL HISS OR 1. Steering intermediate shaft to dash panel 1. Check and repair seal at dash
WHISTLE seal. panel.
POWER ST EERI N G PU M P
INDEX
page page
DESCRI PT I ON AN D OPERAT I ON
POWER STEERING PUMP
H ydr a u lic pr essu r e is pr ovided for oper a t ion of t h e
power st eer in g gea r by a belt dr iven power st eer in g
pu m p. Th e power st eer in g pu m p is a con st a n t flow
r a t e a n d displa cem en t , va n e-t ype pu m p. Th e in t er n a l
pa r t s in t h e h ou sin g oper a t e su bm er ged in flu id. Th e
flow con t r ol or ifice is pa r t of t h e h igh pr essu r e lin e
fit t in g. Th e pr essu r e r elief va lve in side t h e flow con -
t r ol va lve lim it s t h e pu m p pr essu r e. Th e r eser voir is
a t t a ch ed t o t h e pu m p body wit h spr in g clips on t h e
4.0L en gin e. On t h e 2.5L en gin e t h e r eser voir is sep-
a r a t e fr om t h e pu m p.
Th e power st eer in g pu m p is con n ect ed t o t h e st eer-
in g gea r by t h e pr essu r e a n d r et u r n h oses. Th e pu m p
sh a ft h a s a pr essed-on dr ive pu lley t h a t is belt dr iven
by t h e cr a n ksh a ft pu lley (F ig. 1).
ADAPTER RELIEF
ANALYZER ENGINE PRESSURE ! FLOW RATE (GPM)
FITTINGS
50
9653 kPa
2.5L
(1400 psi) 1500 RPM
9653 kPa 2.4 - 2.8 GPM
4.0L
(1400 psi)
80ae82e2
PUMP LEAKAGE DIAGNOSIS
Fig. 2 Power Steering Analyzer
(7) Open t h e t est va lve com plet ely.
(8) St a r t en gin e a n d let idle lon g en ou gh t o cir cu -
la t e power st eer in g flu id t h r ou gh flow/pr essu r e t est
ga u ge a n d t o get a ir ou t of t h e flu id. Th en sh u t off
en gin e.
(9) Ch eck flu id level, a dd flu id a s n ecessa r y. St a r t
en gin e a ga in a n d let idle.
(10) Ga u ge sh ou ld r ea d below 862 kP a (125 psi), if
a bove, in spect t h e h oses for r est r ict ion s a n d r epa ir a s
n ecessa r y. Th e in it ia l pr essu r e r ea din g sh ou ld be in
t h e r a n ge of 345-552 kP a (50-80 psi).
(11) In cr ea se t h e en gin e speed t o 1500 RP M a n d
r ea d t h e flow m et er. Th e r ea din g sh ou ld be 2.4 - 2.8
GP M, if t h e r ea din g is below t h is specifica t ion t h e
pu m p sh ou ld be r epla ced.
1. BUSHING (BEARING) WORN, SEAL WORN. REPLACE
PUMP.
CAUTION: The next step involves testing maximum
2. REPLACE RESERVOIR O-RING SEAL.
pump pressure output and flow control valve oper- 3. TORQUE HOSE FITTING NUT TO SPECIFICATIONS. IF
ation. Do not leave valve closed for more than three LEAKAGE PERSISTS, REPLACE O-RING SEAL.
4. TORQUE FITTING TO SPECIFICATIONS. IF LEAKAGE
seconds as the pump could be damaged.
PERSISTS, REPLACE O-RING SEAL.
5. REPLACE PUMP.
(12) Close va lve fu lly t h r ee t im es a n d r ecor d h igh - 6. CHECK OIL LEVEL: IF LEAKAGE PERSISTS WITH THE
est pr essu r e in dica t ed ea ch t im e. All th re e re a d - LEVEL CORRECT AND CAP TIGHT, REPLACE THE
CAP.
in g s m u s t be a bo v e s p e c ific a tio n s a n d w ith in 80a1c3c3
345 k P a (50 p s i) o f e a c h o th e r.
• P r essu r es a bove specifica t ion s bu t n ot wit h in SERV I CE PROCEDU RES
345 kP a (50 psi) of ea ch ot h er, r epla ce pu m p.
• P r essu r es wit h in 345 kP a (50 psi) of ea ch ot h er POWER STEERING PUMP – INITIAL
bu t below specifica t ion s, r epla ce pu m p. OPERATION
(13) Open t h e t est va lve, t u r n st eer in g wh eel
ext r em e left a n d r igh t posit ion s a ga in st t h e st ops. WARNING: THE FLUID LEVEL SHOULD BE
Recor d t h e h igh est in dica t ed pr essu r e a t ea ch posi- CHECKED WITH ENGINE OFF TO PREVENT INJURY
t ion . Com pa r e r ea din gs t o specifica t ion s. If h igh est FROM MOVING COMPONENTS.
ou t pu t pr essu r es a r e n ot t h e sa m e a ga in st eit h er
st op, t h e gea r is lea kin g in t er n a lly a n d m u st be
CAUTION: Use MOPAR Power Steering Fluid or
r epa ir ed.
equivalent. Do not use automatic transmission fluid
and do not overfill.
XJ STEERING 19 - 7
SERV I CE PROCEDU RES (Cont inue d)
Wipe filler ca p clea n , t h en ch eck t h e flu id level. REM OVAL AN D I N STALLAT I ON
Th e dipst ick sh ou ld in dica t e COLD wh en t h e flu id is
a t n or m a l t em per a t u r e. POWER STEERING PUMP
(1) F ill t h e pu m p flu id r eser voir t o t h e pr oper level
a n d let t h e flu id set t le for a t lea st t wo m in u t es. NOTE: The power steering pump is mounted in the
(2) St a r t t h e en gin e a n d let r u n for a few secon ds same position on LHD and RHD vehicles. On 4.0L
t h en t u r n en gin e off. RHD vehicles the front bracket is different. The ser-
(3) Add flu id if n ecessa r y. Repea t t h e a bove pr oce- vice procedures are the same.
du r e u n t il t h e flu id level r em a in s con st a n t a ft er r u n -
n in g t h e en gin e.
(4) Ra ise t h e fr on t wh eels off t h e gr ou n d. REMOVAL
(5) Slowly t u r n t h e st eer in g wh eel r igh t a n d left , (1) Rem ove ser pen t in e dr ive belt , r efer t o Gr ou p 7
ligh t ly con t a ct in g t h e wh eel st ops a t lea st 20 t im es. Coolin g.
(6) Ch eck t h e flu id level a dd if n ecessa r y. (2) Rem ove pr essu r e a n d r et u r n h oses fr om pu m p,
(7) Lower t h e veh icle, st a r t t h e en gin e a n d t u r n a n d dr a in pu m p.
t h e st eer in g wh eel slowly fr om lock t o lock. (3) Rem ove 3 pu m p m ou n t in g bolt s t h r ou gh pu lley
(8) St op t h e en gin e a n d ch eck t h e flu id level a n d a ccess h oles .
r efill a s r equ ir ed. (4) Loosen t h e 3 pu m p br a cket bolt s (F ig. 3) a n d
(9) If t h e flu id is ext r em ely foa m y or m ilky look- (F ig. 4).
in g, a llow t h e veh icle t o st a n d a few m in u t es a n d (5) Tilt pu m p down wa r d a n d r em ove fr om en gin e.
r epea t t h e pr ocedu r e. (6) Rem ove pu lley fr om pu m p.
PUMP PUMP
ASSEMBLY ASSEMBLY
2.SL 4.0L
PUMP BRACKET
80ae8361
PUMP ASSEMBLY
BRACKET 80500554
PUMP RESERVOIR-2.5L
REMOVAL
(1) Rem ove t h e h oses fr om t h e bot t om of t h e r es-
er voir a n d dr a in t h e r eser voir.
(2) Rem ove t h e pu sh -in fa st en er fr om t h e t op of
t h e fa n sh r ou d.
(3) Slide r eser voir u p off t h e fa n sh r ou d. J9319-45
~
(5) In st a ll power st eer in g pu m p.
(6) Add power st eer in g flu id, r efer t o P u m p In it ia l
Oper a t ion .
RESERVOIR
~
FITTING
TIGHTEN TO 75 N·m (55 FT. LBS) J9319-17
ASSEMBLY
(1) In st a ll spr in g a n d flow con t r ol va lve in t o pu m p
h ou sin g bor e. B e s u re th e h e x n u t e n d o f th e
v a lv e is fa c in g in to w a rd p u m p .
(2) In st a ll O-r in g sea l on t o fit t in g.
(3) In st a ll flow con t r ol va lve in pu m p h ou sin g a n d
t igh t en t o 75 N·m (55 ft . lbs.).
(4) In st a ll pr essu r e h ose t o va lve.
80315897
SPECI FI CAT I ON S
TORQUE CHART
SPECI AL T OOLS
POWER STEERING PUMP
8011c95S
Puller C-4333
XJ STEERING 19 - 11
INDEX
page page
~
ADAPTER
GEAR J9219-46
1. SIDE COVER LEAK - TORQUE 3. PRESSURE LINE FITTING -
SIDE COVER BOLTS TO TORQUE THE HOSE FITTING Fig. 2 Steering Gear Mounting (LHD)
SPECIFICATION. REPLACE NUT TO SPECIFICATIONS. IF
THE SIDE COVER SEAL
IFTHE LEAKAGE PERSISTS.
LEAKAGE PERSISTS, REPLACE
THE SEAL.
DI SASSEM BLY AN D ASSEM BLY
2. ADJUSTER PLUG SEAL -
REPLACE THE ADJUSTER
4. PITMAN SHAFT SEALS -
REPLACE THE SEALS.
HOUSING END PLUG
PLUG SEALS.
5. TOP COVER SEAL - REPLACE THE
SEAL.
DISASSEMBLY
80a1c3c2
(1) Un sea t a n d r em ove r et a in in g r in g fr om gr oove
wit h a pu n ch t h r ou gh t h e h ole in t h e en d of t h e
REM OVAL AN D I N STALLAT I ON
h ou sin g (F ig. 3).
STEERING GEAR
REMOVAL
(1) P la ce t h e fr on t wh eels in t h e st r a igh t a h ea d
posit ion wit h t h e st eer in g wh eel cen t er ed.
(2) Discon n ect a n d ca p t h e flu id h oses fr om st eer-
in g gea r.
(3) Rem ove t h e colu m n cou pler sh a ft fr om t h e
gea r.
(4) Rem ove pit m a n a r m fr om gea r.
(5) Rem ove t h e st eer in g gea r r et a in in g bolt s a n d
r em ove t h e gea r (F ig. 2) .
INSTALLATION
(1) Align t h e colu m n cou pler sh a ft t o st eer in g gea r.
(2) In st a ll st eer in g gea r (a n d br a cket ) on t h e fr a m e
r a il a n d t igh t en bolt s t o 95 N·m (70 ft . lbs.)
(3) Align a n d in st a ll t h e pit m a n a r m a n d t igh t en
n u t t o 251 N·m (185 ft . lbs.).
(4) Con n ect flu id h oses t o st eer in g gea r a n d
t igh t en t o 28 N·m (21 ft . lbs.). Fig. 3 End Plug Retaining Ring
(5) F ill power st eer in g syst em t o pr oper level. (2) Slowly r ot a t e st u b sh a ft wit h 12 poin t socket
COUNTE R-CLOCKWISE t o for ce t h e en d plu g ou t
fr om h ou sin g.
19 - 14 STEERING XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CAUTION: Do not turn stub shaft any further than PITMAN SHAFT/SEALS/BEARING
necessary. The rack piston balls will drop out of the
rack piston circuit if the stub shaft is turned too far. DISASSEMBLY
(3) Rem ove O-r in g fr om t h e h ou sin g (F ig. 4). (1) Clea n exposed en d of pit m a n sh a ft a n d h ou sin g
wit h a wir e br u sh .
(2) Rem ove pr eloa d a dju st er n u t (F ig. 6).
(3) Rot a t e t h e st u b sh a ft wit h a 12 poin t socket
fr om st op t o st op a n d cou n t t h e n u m ber of t u r n s.
(4) Cen t er t h e st u b sh a ft by r ot a t in g it fr om t h e
st op 1/2 of t h e t ot a l a m ou n t of t u r n s.
(5) Rem ove side cover bolt s a n d r em ove side cover,
ga sket a n d pit m a n sh a ft a s a n a ssem bly (F ig. 6).
HOUSING
ASSEMBLY
80a3543f
SPOOL VALVE
DISASSEMBLY
80aa4bf0 (1) Rem ove lock n u t (F ig. 9).
(2) Rem ove a dju st er n u t wit h Spa n n er Wr en ch
Fig. 7 Pitman Shaft Seals & Bearing C-4381.
(3) Rem ove t h r u st su ppor t a ssem bly ou t of t h e
SIDE COVER
AREA
h ou sin g (F ig. 10).
(4) P u ll st u b sh a ft a n d va lve a ssem bly fr om t h e
h ou sin g (F ig. 11).
~
(6) Coa t t h e du st sea l wit h s p e c ia l g re a s e su p-
plied wit h t h e n ew sea l.
(7) In st a ll du st sea l wit h a dr iver a n d h a n dle. (--~RUST HOUSING
(8) In st a ll pit m a n sh a ft t o side cover by scr ewin g
lsTjPPORT
) / /ASSEMBLY 80aa4bf2
sh a ft in u n t il it fu lly sea t s t o side cover.
Fig. 10 Thrust Support Assembly
19 - 16 STEERING XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
THRUST
SUPPORT
ADJUSTER
NUT
ROTATE
VALVE TO
REMOVE
80b6b2c6 J9319-37
~\~
6mm (1/4")
J9319-38
80accfc0
~CLAMP
, I
80aa4bf5
BALL GUIDE
Fig. 21 Worm Shaft
ASSEMBLY
RACK
PISTON NOTE: Clean and dry all components and lubricate
with power steering fluid.
J9219-12
J9319-39
Fig. 20 Rack Piston Teflon Ring and O-Ring
Fig. 22 Installing Balls in Rack Piston
(12) Rem ove t h e a dju st er lock n u t a n d a dju st er
n u t fr om t h e st u b sh a ft . CAUTION: The rack piston balls must be installed
(13) P u ll t h e st u b sh a ft wit h t h e spool va lve a n d alternately into the rack piston and ball guide. This
t h r u st su ppor t a ssem bly ou t of t h e h ou sin g. maintains worm shaft preload. There are 12 black
(14) Rem ove t h e wor m sh a ft fr om t h e h ou sin g balls and 12 silver (Chrome) balls. The black balls
(F ig. 21). are smaller than the silver balls.
XJ STEERING 19 - 19
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(4) Lu br ica t e a n d in st a ll r a ck pist on ba lls t h r ou gh ADJ U ST M EN T S
r et u r n gu ide h ole wh ile t u r n in g wor m sh a ft COUN-
TE RCLOCKWISE (F ig. 22). STEERING GEAR
(5) In st a ll r em a in in g ba lls in gu ide u sin g gr ea se t o
h old t h e ba lls in pla ce (F ig. 23). CAUTION: Steering gear must be adjusted in the
proper order. If adjustments are not performed in
GUIDE
order, gear damage and improper steering response
may result.
BALLS J9319-40
SPANNER
WRENCH
J8919-58
J9219-30
Fig. 25 Alignment Marking On Housing
Fig. 27 Aligning To The Second Mark
(2) St a r t in g a t eit h er st op, t u r n t h e st u b sh a ft
ba ck 1/2 t h e t ot a l n u m ber of t u r n s. Th is is t h e cen t er
of t h e gea r t r a vel (F ig. 28).
\ \1
ADJUSTMENT
SCREW
REFERENCE
~\
J8919-59
SPECI AL T OOLS
POWER STEERING GEAR
ST EERI N G LI N K AGE
INDEX
page page
ADJUSTMENT
SLEEVE
TIE ~--+-----DRAG
ROD LINK
J9502-6
ADJUSTMENT
SLEEVE
STEERING DAMPER
REMOVAL
(1) Rem ove t h e st eer in g da m per r et a in in g bolt
fr om t h e a xle br a cket .
(2) Rem ove t h e cot t er pin a n d n u t fr om t h e ba ll
st u d a t t h e dr a g lin k.
(3) Rem ove t h e st eer in g da m per ba ll st u d fr om t h e
dr a g lin k wit h P u ller C-3894-A.
INSTALLATION
(1) In st a ll st eer in g da m per on t o t h e a xle br a cket
SPECIAL TOOL a n d dr a g lin k.
C-4150-A (2) In st a ll st eer in g da m per bolt in a xle br a cket
a n d t igh t en n u t t o 75 N·m (55 ft . lbs.).
(3) In st a ll ba ll st u d n u t a t t h e dr a g lin k a n d
t igh t en n u t t o 75 N·m (55 ft . lbs.). In st a ll a n ew cot -
WRENCH t er pin .
SPECI AL T OOLS
STEERING LINKAGE
Puller C-3894–A
XJ STEERING 19 - 27
ST EERI N G COLU M N
INDEX
page page
STEERING
COLUMN
MOUNTING NUTS
80aac1 bb
STEERING
COLUMN
RELEASE
ACCESS
HOLE
80a35441 80aa980e
Fig. 2 Key Cylinder Release Access Hole Fig. 5 Steering Column Harness
Group 21 Transmission and Transfer Case for pro-
cedure.
INSTALLATION
LOWER SHROUD
(1) In st a ll u pper colu m n m ou n t in g br a cket on n on -
80aac1 ba t ilt colu m n . In st a ll t h e m ou n t in g bolt a n d t igh t en t h e
n u t t o 17 N·m (150 in . lbs.).
Fig. 3 Column Shrouds (2) In st a ll swit ch es, r efer t o Gr ou p 8 E lect r ica l for
(10) Discon n ect a n d r em ove t h e wir in g h a r n ess ser vice pr ocedu r es.
fr om t h e colu m n (F ig. 5). (3) Align a n d in st a ll colu m n in t o t h e st eer in g cou -
pler.
NOTE: If vehicle is equipped with automatic trans- (4) In st a ll colu m n h a r n ess a n d con n ect h a r n ess t o
mission, remove shifter interlock cable. Refer to swit ch es.
XJ STEERING 19 - 29
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(10) In st a ll lower colu m n sh r ou d a n d in st a ll
m ou n t in g scr ews.
(11) In st a ll ign it ion cylin der.
(12) In st a ll kn ee blocker a n d kn ee blocker cover,
Refer t o Gr ou p 8E In st r u m en t P a n el Syst em s.
(13) In st a ll st eer in g wh eel a n d t igh t en n u t t o 54
N·m (40 ft . lbs.).
SPECI FI CAT I ON S
TORQUE CHART
I iae5fb0
D ES CRIP TION TORQU E
Fig. 6 Non-Tilt Column Tilt S te e rin g Co lu m n
St eer in g Wh eel Nu t . . . . . . . . 54 N·m (40 ft . lbs.)
NOTE: If vehicle is equipped with automatic trans- Mou n t in g Nu t s . . . . . . . . . . . . 23 N·m (17 ft . lbs.)
mission install shifter interlock cable. Refer to
Cou pler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft . lbs.)
Group 21 Transmission and Transfer Case for pro-
N o n -Tilt S te e rin g Co lu m n
cedure.
St eer in g Wh eel Nu t . . . . . . . . 54 N·m (40 ft . lbs.)
(5) In st a ll u pper colu m n sh r ou ds. Mou n t in g Nu t s . . . . . . . . . . . . 23 N·m (17 ft . lbs.)
(6) In st a ll colu m n on t o t h e m ou n t in g st u ds. Cou pler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft . lbs.)
(7) In st a ll m ou n t in g n u t s a n d t igh t en t o 23 N·m Upper Br a cket Nu t . . . . . . . . 17 N·m (150 in . lbs.)
(17 ft . lbs.).
(8) In st a ll st eer in g colu m n cou pler bolt a n d t igh t en
t o 49 N·m (36 ft . lbs.).
(9) Cen t er t h e clock spr in g a n d in st a ll it on t h e
colu m n , r efer t o Gr ou p 8 E lect r ica l for ser vice pr oce-
du r es.
XJ STEERING 19 - 1
STEERING
CON T EN T S
page page
INDEX
page
GENERAL INFORMATION
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 1
INDEX
page page
POWER STEERING
PUMP PULLEY
HEX WRENCH
POWER
STEERING PUMP COUPLER COUPLER
RETAINING NUTS PINCH BOLT 80b9a49b
ENGINE MOUNT SILL
Fig. 4 Power Steering Pump PLATE BOLT
80b9a4be
(1) Tr a n sfer t h e pr essu r e lin e t o t h e n ew pu m p ,
m a kin g su r e lin e is in or igin a l posit ion . Fig. 6 Engine Mount Retaining Bolts
(2) Tr a n sfer t h e cou pler t o t h e n ew pu m p lea vin g (7) In st a ll t h e (4) en gin e m ou n t br a cket t o en gin e
pin ch bolt lose a t t h is t im e (F ig. 5). block r et a in in g bolt s. Tor qu e bolt s t o 47 N·m (35 ft .
(3) In st a ll t h e power st eer in g pu m p (F ig. 5). lbs.).
(8) Tor qu e t h e en gin e m ou n t sill pla t e bolt s t o 41
~ ENGINE BLOCK
N·m (30 ft . lbs.).
Io~ (9) Tor qu e t h e la r ger t r a ckba r su ppor t br a cket
bolt s t o 125 N·m (92ft . lbs.).
(10) Rem ove t h e ja ck st a n d.
(11) In st a ll t h e H -Block on t h e A/C com pr essor in
it s or igin a l posit ion a n d lea ve t h e bolt s loose a t t h is
t im e.
(12) P osit ion a n d in st a ll t h e A/C com pr essor.
(13) Slide t h e dr ive cou pler in it s or igin a l posit ion
a n d in st a ll t h e r em a in in g (2) H -Block bolt s.
(14) In st a ll t h e power st eer in g pu m p pu lley (F ig.
7). Tor qu e n u t t o 166 N·m (120 ft . lbs.).
(15) In st a ll t h e a ccessor y dr ive belt . See Gr ou p 7,
Coolin g Syst em for pr ocedu r e.
(16) Tor qu e a ll t h e H -Block bolt s.
(17) In st a ll t h e st eer in g sh a ft . Tor qu e t h e st eer in g
sh a ft pin ch bolt t o 49 N·m (36 ft . lbs.).
POWER (18) In st a ll t h e pr essu r e lin e on st eer in g gea r.
STEERING PUMP COUPLER COUPLER Tor qu e n u t t o 28 N·m (21 ft . lbs.).
RETAINING NUTS PINCH BOLT 80b9a49b
(19) In st a ll t h e power st eer in g flu id su pply h ose on
t h e pu m p.
Fig. 5 Power Steering Pump (20) Lower t h e veh icle fr om t h e h oist .
(21) In st a ll a n d t or qu e t h e en gin e m ou n t u pper sill
(4) In st a ll t h e en gin e m ou n t a n d t h e en gin e m ou n t
pla t e n u t s t o 41 N·m (30 ft . lbs.) (F ig. 8).
br a cket in t h e veh icle.
(22) Con n ect t h e A/C com pr essor elect r ica l con n ec-
(5) In st a ll t h e en gin e m ou n t t h r ou gh bolt a n d lea ve
t or.
loose a t t h is t im e.
XJ STEERING 19 - 5
REM OVAL AN D I N STALLAT I ON (Cont inue d)
POWER STEERING
PUMP PULLEY
HEX WRENCH
ENGINE MOUNT
80b9a4c1
80b9a4c2
Fig. 8 Engine Mount Sill Plate Nuts
(23) In st a ll t h e A/C lin e su ppor t br a cket bolt a t t h e Fig. 9 Removing Pump Pulley
r ea r of t h e va lve cover. NOTE: Mark position of the H-Block in relation to
(24) F ill t h e power st eer in g flu id. See Gr ou p 19, the A/C Compressor so it can be installed in the
St eer in g for P ower St eer in g P u m p-In it ia l oper a t ion same position.
pr ocedu r e.
(25) Con n ect t h e n ega t ive ba t t er y ca ble. (12) Rem ove t h e (2) bolt s r et a in in g t h e H -Block t o
t h e power st eer in g pu m p sh a ft cou pler.
(13) Loosen t h e cou pler pin ch bolt a n d slide cou -
pler t owa r ds pu m p.
19 - 6 STEERING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(14) Rem ove t h e left en gin e m ou n t t h r ou gh bolt n u t (1) In st a ll t h e pr essu r e lin e on pu m p in or igin a l
on ly. Do n ot r em ove t h e bolt a t t h is t im e. posit ion .
(15) Rem ove t h e r em a in in g 2 bolt s fr om t h e (2) Tr a n sfer t h e dr ive cou pler t o n ew pu m p lea vin g
H -Block a n d r em ove t h e H -Block fr om t h e com pr es- pin ch bolt lose a t t h is t im e (F ig. 11).
sor. (3) In st a ll t h e power st eer in g pu m p in t h e en gin e
(16) P osit ion a ja ck st a n d a n d r a ise weigh t off left block. Tor qu e r et a in in g n u t s t o 24 N·m (18 ft . lbs.)
en gin e m ou n t . (F ig. 11).
(17) Rem ove t h e (2) en gin e m ou n t sill pla t e bolt s.
(18) Rem ove t h e (4) en gin e m ou n t br a cket bolt s ~ ENGINE BLOCK
fr om t h e en gin e block.
(19) Rem ove t h e en gin e m ou n t t h r ou gh bolt . Io~
(20) Rem ove t h e en gin e m ou n t a n d en gin e m ou n t
br a cket fr om veh icle.
(21) Rem ove t h e (2) power st eer in g pu m p r et a in in g
n u t s (F ig. 10).
~ ENGINE BLOCK
Io~
POWER
STEERING PUMP COUPLER COUPLER
RETAINING NUTS PINCH BOLT 80b9a49b
ST EERI N G COLU M N
INDEX
page page
DASH COLUMN
PANEL COUPLER
T
PANEL
BRACKET
--®--e
I /2
CLOCK
SPRING
STEERING
WHEEL
LOWER
SHROUD PARK-LOCK STEERING
ASSEMBLY GEAR J9519-54
CAUTION: DO NOT
REMOVE IGNITION
LOCKING LINK
CAUTION: NEVER
,~-~M-REMOVE SHAFT
LOCK PLATE
8031589b
CAUTION: NEVER
Fig. 4 Steering Column Flash Removal And
~--~M-REMOVE SHAFT
LOCK PLATE Non-Serviceable Components
slot a t a n y poin t ligh t ly file t h e slider or slot u n t il
8031589a clea r a n ce is a ch ieved.
(3) If n o bin din g is fou n d, ligh t ly file t h e r a m p on
Fig. 2 Observe Cautions t h e ign it ion swit ch , (Th e r a m p fit s in t o t h e ca st in g)
u n t il bin din g n o lon ger occu r s.
CAUTION: NEVER REMOVE
SHAFT LOCK PLATE
RETAINER
REM OVAL AN D I N STALLAT I ON
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.
9019-6
REMOVAL
Fig. 3 Observe Cautions (1) P osit ion t h e fr on t wh eels s tra ig h t a h e a d .
(2) Rem ove t h e n ega t ive (gr ou n d) ca ble fr om t h e
DI AGN OSI S AN D T EST I N G ba t t er y.
(3) Disa r m a n d r em ove a ir ba g, st eer in g wh eel a n d
IGNITION SWITCH clockspr in g, r efer t o gr ou p 8M Rest r a in t Syst em s for
ser vice pr ocedu r es.
TEST AND REPAIR (4) Rem ove lower in st r u m en t pa n el/kn ee blocker.
If t h e ign it ion swit ch effor t is excessive, r em ove t h e (5) Rem ove colu m n cou pler u pper pin ch bolt (F ig.
ign it ion swit ch fr om t h e st eer in g colu m n . Refer t o 5).
Gr ou p 8D Ign it ion Syst em . Usin g a key cylin der, (6) Rem ove r ela y box.
ch eck t h e t u r n in g effor t of t h e swit ch . If t h e ign it ion (7) Rem ove t ilt lever (if equ ipped) fr om colu m n .
swit ch bin ds look for t h e followin g con dit ion s. (8) Rem ove u pper a n d lower st eer in g colu m n
(1) Look for r ou gh a r ea s or fla sh in t h e ca st in g sh r ou ds.
a n d if fou n d r em ove wit h a file (F ig. 4). (9) Rem ove lower fixed colu m n sh r ou d.
(2) Wit h t h e ign it ion swit ch r em oved, slide t h e (10) Rem ove colu m n br a ces (F ig. 6).
slider in it s slot in t h e sleeve a n d ver ify a loose fit (11) Rem ove colu m n br a cket m ou n t in g n u t s a n d
over t h e len gt h of t h e slot . If t h e slider bin ds in t h e lower colu m n .
19 - 10 STEERING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
DASH COLUMN
PANEL COUPLER
T
PANEL
BRACKET
--®--e
/0 CLOCK
SPRING
STEERING
WHEEL
LOWER
SHROUD PARK-LOCK STEERING
ASSEMBLY GEAR J9519-54
INSTALLATION
(1) Align a n d in st a ll t h e colu m n t o t h e cou pler. D o
n o t a p p ly fo rc e a t th e to p o f th e s te e rin g c o l-
u m n s h a ft.
(2) E n su r e t h e gr ou n d clip is posit ion (F ig. 8).
(3) In st a ll in t er lock ca ble fr om t h e st eer in g col-
u m n , r efer t o Gr ou p 21 Au t om a t ic Tr a n sm ission
Sh ift er /Ign it ion In t er lock.
(4) In st a ll wir in g h a r n ess con n ect ion s t o st eer in g
colu m n .En s u re th e w irin g is n o t p in c h e d a n d a ll
Fig. 6 Steering Column Braces c o n n e c tio n s a re c o rre c tly lo c k e d in p la c e .
(12) Rem ove u pper fixed colu m n sh r ou d. (5) In st a ll wir in g h a r n ess con n ect or on t o m u lt i
(13) Rem ove m u lt i-fu n ct ion swit ch t a m per pr oof fu n ct ion swit ch . Tigh t en fu n ct ion swit ch wir in g h a r-
m ou n t in g scr ews a n d con n ect or scr ew. Con n ect or n ess con n ect or r et a in in g bolt t o 2 N·m (17 in . lbs.).
scr ew will st a y in t h e con n ect or. (6) P lu g in wir in g h a r n ess con n ect or t o r em a in in g
(14) Un plu g wir in g h a r n ess fr om t h e colu m n swit ch es.
swit ch es (F ig. 7). (7) In st a ll ign it ion swit ch .
(15) Rem ove t h e wir in g h a r n ess fr om st eer in g col- (8) In st a ll u pper fixed colu m n sh r ou d cover.
umn. (9) In st a ll sh a ft cou pler pin ch bolt loose, loa d col-
u m n u p t o pa n el br a cket .
XJ STEERING 19 - 11
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CLIP SCREW
SPECI FI CAT I ON S
TORQUE CHART
COLUMN BRACKET
D ES CRIP TION TORQU E
RN832
Tilt S te e rin g Co lu m n
Fig. 8 Ground Clip & Spacer St eer in g Wh eel Nu t . . . . . . . . 54 N·m (40 ft . lbs.)
Mou n t in g Nu t s . . . . . . . . . . . . 23 N·m (17 ft . lbs.)
(10) Be su r e bot h spa cer s a r e fu lly sea t ed in t h e Cou pler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft . lbs.)
colu m n su ppor t br a cket . Tigh t en t h e colu m n pa n el N o n -Tilt S te e rin g Co lu m n
br a cket su ppor t n u t s t o 12 N·m (105 in . lbs.). St eer in g Wh eel Nu t . . . . . . . . 54 N·m (40 ft . lbs.)
(11) Tigh t en t h e cou pler pin ch bolt t o 47 N·m (35
Mou n t in g Nu t s . . . . . . . . . . . . 23 N·m (17 ft . lbs.)
ft . lbs.).
Cou pler Bolt . . . . . . . . . . . . . . 49 N·m (36 ft . lbs.)
(12) In st a ll lower fixed sh r ou d.
Upper Br a cket Nu t . . . . . . . . 17 N·m (150 in . lbs.)
(13) In st a ll u pper a n d lower sh r ou ds. In st a ll t h e
t ilt lever (if equ ipped).
(14) In st a ll r ela y box.
XJ SUSPENSION 2-1
SUSPENSION
CON T EN T S
page page
-
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 14
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 7
ALI GN M EN T
INDEX
page page
GEN ERAL I N FORM AT I ON edges of t h e fr on t t ir es. In cor r ect wh eel t oe posit ion
is t h e m ost com m on ca u se of u n st a ble st eer in g a n d
WHEEL ALIGNMENT u n even t ir e wea r. Th e wh eel t oe posit ion is t h e fin a l
Wh eel a lign m en t in volves t h e cor r ect posit ion in g of fr on t wh eel a lign m en t a dju st m en t .
t h e wh eels in r ela t ion t o t h e veh icle. Th e posit ion in g • S TEERIN G AXIS IN CLIN ATION AN GLE is
is a ccom plish ed t h r ou gh su spen sion a n d st eer in g m ea su r ed in degr ees a n d is t h e a n gle t h a t t h e st eer-
lin ka ge a dju st m en t s. An a lign m en t is con sider ed in g kn u ckles a r e t ilt ed. Th e in clin a t ion a n gle h a s a
essen t ia l for efficien t st eer in g, good dir ect ion a l st a bil- fixed r ela t ion sh ip wit h t h e ca m ber a n gle. It will n ot
it y a n d t o m in im ize t ir e wea r. Th e m ost im por t a n t ch a n ge except wh en a spin dle or ba ll st u d is da m -
m ea su r em en t s of a n a lign m en t a r e ca st er, ca m ber a ged or ben t . Th e a n gle is n ot a dju st a ble, da m a ged
a n d t oe posit ion (F ig. 1). com pon en t (s) m u st be r epla ced t o cor r ect t h e st eer in g
• CAS TER is t h e for wa r d or r ea r wa r d t ilt of t h e a xis in clin a t ion a n gle.
st eer in g kn u ckle fr om ver t ica l. Tilt in g t h e t op of t h e • THRU S T AN GLE is t h e a n gle of t h e r ea r a xle
kn u ckle r ea r wa r d pr ovides posit ive ca st er. Tilt in g t h e r ela t ive t o t h e cen t er lin e of t h e veh icle. In cor r ect
t op of t h e kn u ckle for wa r d pr ovides n ega t ive ca st er. t h r u st a n gle ca n ca u se off-cen t er st eer in g a n d exces-
Ca st er is a dir ect ion a l st a bilit y a n gle. Th is a n gle sive t ir e wea r. Th is a n gle is n ot a dju st a ble, da m a ged
en a bles t h e fr on t wh eels t o r et u r n t o a st r a igh t com pon en t (s) m u st be r epla ced t o cor r ect t h e t h r u st
a h ea d posit ion a ft er t u r n s. a n gle.
• CAMB ER is t h e in wa r d or ou t wa r d t ilt of t h e
CAUTION: Never attempt to modify suspension or
wh eel r ela t ive t o t h e cen t er of t h e veh icle. Tilt in g t h e
steering components by heating or bending.
t op of t h e wh eel in wa r d pr ovides n ega t ive ca m ber.
Tilt in g t h e t op of t h e wh eel ou t wa r d pr ovides posit ive
ca m ber. In cor r ect ca m ber will ca u se wea r on t h e NOTE: Periodic lubrication of the front suspension/
in side or ou t side edge of t h e t ir e. Th e a n gle is n ot steering system components may be required. Rub-
a dju st a ble, da m a ged com pon en t (s) m u st be r epla ced ber bushings must never be lubricated. Refer to
t o cor r ect t h e ca m ber a n gle. Group 0, Lubrication And Maintenance for the rec-
• WHEEL TOE P OS ITION is t h e differ en ce ommended maintenance schedule.
bet ween t h e lea din g in side edges a n d t r a ilin g in side
2-2 SUSPENSION XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
CAMBER TOE
WHEEL ~----------A-----~I
TRUE _ _.__ \~NTERLINE
VERTICAL NEGATIVE
CAMBER
ANGLE
SCRUB
0
~-RADIUS FRONT OF VEHICLE
POSITIVE CAMBER (NOT SHOWN) ~----B----------1.-
TOP OF WHEEL OUTBOARD NEGATIVE TOE (TOE oun B > A
POSITIVE TOE (TOE IN) B < A
CASTER
POSITIVE CASTER ~ I ~ THRUST ANGLE
_,.....,'~--' KING PIN I
I
I
ANGLE OF REAR AXLE
FRONT RELATIVE TO VEHICLE CENTERLINE
OF VEHICLE / ~VERTICAL (-) AXLE POINTS LEFT (+) AXLE POINTS RIGHT
80b34eaf
FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
EXCESSIVE PLAY IN 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
STEERING
2. Loose or worn steering or 2. Tighten or replace components as
suspension components. necessary.
3. Loose or worn steering gear. 3. Adjust or replace steering gear.
FRONT WHEELS SHIMMY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
VEHICLE INSTABILITY 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings.
EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear.
EFFORT
2. Power steering fluid low. 2. Add fluid and repair leak.
3. Column coupler binding. 3. Replace coupler.
4. Tire pressure. 4. Adjust tire pressure.
5. Alignment. 5. Align vehicle to specifications.
ADJUSTMENT
SLEEVE
-~-·-'=@ PITMAN
l ARM
ADJUSTMENT
SLEEVE
TIE
ROD
J9502-6
FRON T SU SPEN SI ON
INDEX
page page
LINKS STABILIZER
BAR
J9302-12
VIEW IN DIRECTION
OFARROWW
VIEW IN DIRECTION
OFARROWZ
J9502-4
·. ]T
);
a ga in st ot h er side of t h e bu sh in g.
(5) In st a ll bolt 7604 t h r ou gh r em over, bu sh in g a n d
r eceiver.
(6) In st a ll Lon g Nu t 7603 a n d t igh t en n u t t oo pu ll
bu sh in g ou t of t h e a xle br a cket .
AXLE BRACKET
RECEIVER
BOLT
FRAME
RAIL
(LT-2WD)
J9202-7
TRACK BAR
80b5cb79 REMOVAL
(1) Ra ise a n d su ppor t t h e veh icle.
Fig. 5 Bushing Installation (2) Rem ove t h e cot t er pin a n d n u t fr om t h e ba ll
st u d en d a t t h e body r a il br a cket .
STABILIZER BAR (3) Use a u n iver sa l pu ller t ool t o sepa r a t e t h e ba ll
st u d fr om t h e fr a m e r a il br a cket .
REMOVAL (4) Rem ove t h e bolt a n d fla g n u t fr om t h e a xle
(1) Ra ise a n d su ppor t t h e veh icle.
sh a ft t u be br a cket (F ig. 7).
(2) Rem ove n u t s, r et a in er s a n d gr om m et s fr om t h e
(5) Rem ove t h e t r a ck ba r.
lin ks a t t h e st a bilizer ba r (F ig. 6).
SUPPORT
BRACKET
BRAKE WASHER
SHIELD
RETAINER
COTTER PIN
TONE
WHEEL
(ABS) BOLT NUT J9302-43
INSTALLATION
(1) In st a ll t h e h u b bea r in g a n d br a ke du st sh ield
t o t h e kn u ckle.
(2) In st a ll t h e h u b bea r in g t o kn u ckle bolt s a n d
t igh t en t o 102 N·m (75 ft . lbs.).
(3) In st a ll t h e h u b wa sh er a n d n u t . Tigh t en t h e
h u b n u t t o 237 N·m (175 ft . lbs.). In st a ll t h e n u t
r et a in er a n d a n ew cot t er pin .
(4) In st a ll t h e br a ke r ot or, ca liper a n d ABS wh eel
speed sen sor, r efer t o Gr ou p 5 Br a kes.
(5) In st a ll t h e wh eel a n d t ir e a ssem bly.
Fig. 9 Wheel Stud Removal
(6) Rem ove su ppor t a n d lower t h e veh icle. INSTALLATION
(1) In st a ll n ew st u d in t o h u b fla n ge.
(2) In st a ll t h r ee wa sh er s on t o st u d, t h en in st a ll
lu g n u t wit h t h e fla t side of t h e n u t a ga in st t h e
wa sh er s.
XJ SUSPENSION 2 - 13
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Tigh t en lu g n u t u n t il t h e st u d is pu lled in t o SPECI AL T OOLS
t h e h u b fla n ge. Ver ify t h a t t h e st u d is pr oper ly
sea t ed in t o t h e fla n ge. FRONT SUSPENSION
(4) Rem ove lu g n u t a n d wa sh er s.
(5) In st a ll t h e br a ke r ot or a n d ca liper, r efer t o
Gr ou p 5 Br a kes for pr ocedu r e.
(6) In st a ll wh eel a n d t ir e a ssem bly, u se n ew lu g
n u t on st u d or st u ds t h a t wer e r epla ced.
(7) Rem ove su ppor t a n d lower veh icle.
SPECI FI CAT I ON S
TORQUE CHART
Remover/Installer Suspension Bushing 7932
D ES CRIP TION TORQU E
S h o c k Abs o rbe r
Upper Nu t . . . . . . . . . . . . . . . . . 11 N·m (8 ft . lbs.)
Lower Nu t . . . . . . . . . . . . . . . . 23 N·m (17 ft . lbs.)
S u s p e n s io n Arm U p p e r
F r on t Nu t . . . . . . . . . . . . . . . . 74 N·m (55 ft . lbs.)
Rea r Nu t . . . . . . . . . . . . . . . . . 89 N·m (66 ft . lbs.)
S u s p e n s io n Arm Lo w e r
F r on t Nu t . . . . . . . . . . . . . . . 115 N·m (85 ft . lbs.)
Rea r Nu t . . . . . . . . . . . . . . . . 115 N·m (85 ft . lbs.) Nut, Long 7603
S ta bilize r B a r
Cla m p Bolt . . . . . . . . . . . . . . . 54 N·m (40 ft . lbs.)
Lin k Upper Nu t . . . . . . . . . . . 36 N·m (27 ft . lbs.)
Lin k Lower Nu t . . . . . . . . . . . 95 N·m (70 ft . lbs.)
Tra c k B a r
Ba ll St u d Nu t . . . . . . . . . . . . . 81 N·m (60 ft . lbs.)
Axle Br a cket Bolt . . . . . . . . . 100 N·m (74 ft . lbs.)
Tra c k B a r B ra c k e t
Bolt s . . . . . . . . . . . . . . . . . . . 125 N·m (92 ft . lbs.)
Nu t . . . . . . . . . . . . . . . . . . . . 100 N·m (74 ft . lbs.) Bolt, Special 7604
Su ppor t Bolt s . . . . . . . . . . . . . 42 N·m (31 ft . lbs.)
Hu b/B e a rin g
Bolt s . . . . . . . . . . . . . . . . . . . 102 N·m (75 ft . lbs.)
Axle Nu t . . . . . . . . . . . . . . . 237 N·m (175 ft . lbs.)
Remover C-4150A
S011d8e6
REAR SU SPEN SI ON
INDEX
page page
J9503-6
LEAF SPRING
REMOVAL
(1) Ra ise veh icle a t body r a ils.
(2) Rem ove t h e wh eel a n d t ir e a ssem blies. SOCKET
(3) Su ppor t a xle wit h h ydr a u lic ja ck t o r elieve a xle WRENCH
weigh t . (DRIVER)
(4) Discon n ect t h e st a bilizer ba r lin k fr om t h e
spr in g br a cket st u d. FLAT THREADED
WASHER ROD J8917-20
(5) Rem ove n u t s, U-bolt s a n d spr in g br a cket fr om
a xle.
(6) Rem ove n u t a n d bolt a t t a ch in g spr in g fr on t eye Fig. 3 Spring Eye Bushing Removal
t o sh a ckle. (2) Assem ble a n d a lign t h e bu sh in g in st a lla t ion
(7) Rem ove n u t a n d bolt fr om spr in g r ea r eye. t ools.
(8) Rem ove spr in g fr om veh icle. (3) Align t h e bu sh in g wit h t h e spr in g eye or
sh a ckle eye a n d t igh t en t h e n u t a t t h e socket wr en ch
INSTALLATION en d of t h e t h r ea ded r od. Tigh t en u n t il t h e bu sh in g is
(1) P osit ion t h e spr in g fr on t eye in t h e br a cket . for ced in t o t h e spr in g eye.
Loosely in st a ll t h e a t t a ch in g bolt a n d n u t . Do n ot
t igh t en a t t h is t im e.
XJ SUSPENSION 2 - 17
REM OVAL AN D I N STALLAT I ON (Cont inue d)
NOTE: The bushing must be centered in the spring SPECI FI CAT I ON S
eye. The ends of the bushing must be flush or
slightly recessed within the end surfaces of the TORQUE CHART
spring eye.
page page
AX 5 M AN U AL T RAN SM I SSI ON
INDEX
page page
-
t h e t r a n sm ission a ssem bly a n d m ou n t ed in t h e sh ift • F ou r t h gea r : 1.00:1
t ower por t ion of t h e a da pt er /ext en sion h ou sin g (F ig. • F ift h gea r : 0.85:1
1). • Rever se gea r : 4.74:1
S0abfee7
I.D. CODE
NEAR DRAOINN PLUG
CASE
J8921-4
80abfee5
.~a~ SNAPRING
SLINGER
SNAP RING
COUNTER
GEAR
cou=•j,
GEAR
J9121-394
REFERENCE MARKS
GROMMET
CRANKSHAFT \
I~ j -:,'-@__
POSITION \ MOUNTING
SENSOR NUTS (2) soa4s1s1
J9316-2
SPECIAL
l•-----TOOL
C-4171
SPECIAL
TOOL
J9316-2
8211 (AX5} OR
8209 (AX15) 80b099ca
Fig. 10 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks Fig. 11 Install Front Bearing Retainer Seal
(26) In st a ll a n d t igh t en pr opeller sh a ft U–join t (2) Rem ove a n y r esidu a l ga sket m a t er ia l fr om t h e
cla m p bolt s t o 19 N·m (170 in . lbs.) t or qu e. sea lin g su r fa ces of t h e bea r in g r et a in er a n d t h e
(27) Align m a r ks on fr on t pr opeller sh a ft , a xle, t r a n sm ission ca se.
a n d t r a n sfer ca se yokes, if equ ipped. (3) In st a ll n ew fr on t bea r in g r et a in er ga sket t o t h e
fr on t bea r in g r et a in er.
XJ TRANSMISSION AND TRANSFER CASE 21 - 7
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) In st a ll t h e fr on t bea r in g r et a in er on t o t h e
SPECIAL TOOL SPECIAL TOOL
t r a n sm ission ca se.
C-4171 8212
(5) In st a ll t h e bolt s t o h old t h e bea r in g r et a in er
on t o t h e t r a n sm ission ca se.
(6) Tigh t en t h e bolt s t o 17 N·m (12 ft . lbs.). ~~
(7) In st a ll r elea se bea r in g a n d lever on t o t h e
t r a n sm ission .
2WD
EXTENSION HOUSING
J9121-385 J8921-1045
Fig. 12 Remove Extension Housing Seal Fig. 14 Remove Adapter Housing Seal
INSTALLATION INSTALLATION
(1) Clea n sea l bor e of ext en sion h ou sin g of a n y (1) Clea n sea l bor e of a da pt er h ou sin g of a n y
r esidu a l sea ler m a t er ia l fr om or igin a l sea l. r esidu a l sea ler m a t er ia l fr om or igin a l sea l.
(2) Usin g Tool H a n dle C-4171 a n d Sea l In st a ller (2) Usin g Tool H a n dle C-4171 a n d Sea l In st a ller
8212, in st a ll n ew ext en sion h ou sin g sea l so t h a t t h e 8208, in st a ll n ew sea l so t h a t t h e sea l is loca t ed 0 !
sea l is loca t ed 0 ! 0.5 m m (0 ! 0.02 in .) t o t h e fa ce 0.2 m m (0 ! 0.008 in .) t o t h e sea l bor e fa ce of
of t h e ext en sion h ou sin g (F ig. 13). a da pt er h ou sin g (F ig. 15).
(3) In st a ll pr opeller sh a ft . Refer t o Gr ou p 3, Differ- (3) In st a ll t r a n sfer ca se.
en t ia l a n d Dr ivelin e, for pr oper pr ocedu r es. (4) Ch eck a n d a dd flu id t o t r a n sm ission a s n eces-
(4) Ch eck a n d a dd flu id t o t r a n sm ission a s n eces- sa r y. Refer t o t h e Recom m en ded Lu br ica n t sect ion for
sa r y. Refer t o t h e Recom m en ded Lu br ica n t sect ion for pr oper flu id r equ ir em en t s.
pr oper flu id r equ ir em en t s. (5) Lower veh icle.
(5) Lower veh icle.
SPECIAL
TOOL SHIFT
8208 TOWER
J8921-1033
SHIFT
TOWER
ADAPTER/
HOUSING EXTENSION
Fig. 18 Clutch Housing
JS921-1032
Fig. 16 Remove Shift Tower
XJ TRANSMISSION AND TRANSFER CASE 21 - 9
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SHIFT DETENT
BALL
PENCIL
~NET
80abteet
Fig. 19 Remove Detent Ball Plug Fig. 21 Remove Detent Ball
J8921-1043
J8921-1044
LARGE
MAGNET Fig. 27 Remove Adapter/Extension Housing–Typical
SNAP LOCK---..-0 SNAP
~RING
RING~
J8921-1037
FRONT
BEARING
RETAINER
J8921-1046 J8921-1050
Fig. 29 Remove Front Bearing Retainer Fig. 31 Separate Intermediate Plate and
Transmission Case
INPUT
SHAFT
J8921-1051
Fig. 30 Remove Input Shaft Bearing Snap-ring
(23) Sepa r a t e in t er m edia t e pla t e a n d t r a n sm ission
Fig. 32 Remove Intermediate Plate from
ca se by t a ppin g t h em loose wit h pla st ic m a llet (F ig.
Transmission Case
31).
(24) Sepa r a t e t h e in t er m edia t e pla t e fr om t h e
t r a n sm ission ca se (F ig. 32).
ASSEMBLY
(1) Rem ove a n y r esidu a l sea ler fr om t r a n sm ission
ca se, in t er m edia t e pla t e, a n d a da pt er /ext en sion h ou s- GEAR
in g. CASE
(2) Apply a 1/8 t o 3/16 in ch wide bea d of Th r eeb-
on d! Liqu id Ga sket TB1281, P /N 83504038, a s
sh own , m a kin g su r e t o keep sea ler bea d t o in side of
bolt h oles (F ig. 33).
(3) Align gea r t r a in a n d sh ift r a ils wit h m a t in g
h oles in t r a n sm ission ca se a n d in st a ll t r a n sm ission
ca se t o t h e in t er m edia t e pla t e (F ig. 34). Ver ify t h a t J8921-l 118
t h e t r a n sm ission ca se is sea t ed on t h e in t er m edia t e
pla t e loca t in g pin s. Fig. 33 Apply Sealer to Transmission Gear Case
21 - 12 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
FRONT
BEARING
RETAINER
J8921-1051 J8921-1046
Fig. 36 Install Front Bearing Retainer
Fig. 34 Install Transmission Gear Case to the
Intermediate Plate (8) Apply a 1/8 t o 3/16 in ch wide bea d of Th r eeb-
on d! Liqu id Ga sket TB1281, P /N 83504038, t o sea l-
(4) In st a ll n ew fr on t bea r in g sn a p r in gs (F ig. 35). in g su r fa ce of a da pt er /ext en sion h ou sin g, m a kin g
su r e t o keep sea ler bea d t o in side of bolt h oles.
(9) In st a ll a da pt er or ext en sion h ou sin g on in t er-
m edia t e pla t e (F ig. 38). Tigh t en h ou sin g bolt s t o 34
N·m (25 ft . lbs.) t or qu e.
(10) P osit ion sh ift a r m in sh ift er t ower open in g of
a da pt er or ext en sion h ou sin g (F ig. 39). Be su r e t h a t
t h e sh ift er a r m is en ga ged in t o t h e sh ift r a ils.
SNAP LOCK _ _...,..,a SNAP
~RING
RING~
OUTPUT
SHAFT SPEEDOMETER
GROOVES GEAR
J8921-1119
Fig. 35 Install Front Bearing Snap-rings
Fig. 37 Speedometer Drive Gear Assembly
(5) In st a ll fr on t bea r in g r et a in er ga sket t o fr on t
(11) St a r t sh ift er a r m sh a ft in h ole in ba ck of
bea r in g r et a in er.
a da pt er or ext en sion h ou sin g. Align sh ift a r m a n d
(6) In st a ll t h e fr on t bea r in g r et a in er (F ig. 36) a n d
sh ift er a r m sh a ft a n d in ser t sh ift er a r m sh a ft
t igh t en bolt s t o 17 N·m (12 ft . lbs.).
t h r ou gh t h e sh ift er a r m a n d in t o t h e for wa r d por t ion
(7) On 4x2 t r a n sm ission s;
of t h e a da pt er or ext en sion h ou sin g (F ig. 40).
(a ) In st a ll speedom et er dr ive gea r loca t in g sn a p-
(12) Rot a t e t h e sh ift er a r m sh a ft u n t il t h e h ole in
r in g (F ig. 37).
t h e sh ift a r m is a lign ed wit h t h e h ole in t h e sh a ft .
(b) In st a ll speedom et er gea r lock ba ll in ou t pu t
(13) In st a ll t h e sh ift a r m r et a in er bolt a n d t igh t en
sh a ft a n d in st a ll speedom et er gea r on t o ou t pu t
t o 38 N·m (28 ft . lbs.) (F ig. 41).
sh a ft .
(14) In st a ll a n d t igh t en sh ift er a r m sh a ft plu g t o
(c) In st a ll speedom et er gea r r et a in in g sn a p-r in g
18 N·m (13 ft . lbs.) t or qu e (F ig. 42).
on t o ou t pu t sh a ft .
(15) In st a ll sh ift r est r ict or pin s in sh ift t ower a n d
t igh t en t o 27 N·m (20 ft . lbs.) (F ig. 43).
XJ TRANSMISSION AND TRANSFER CASE 21 - 13
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J8921-1044
Fig. 38 Install Adapter/Extension Housing–Typical Fig. 41 Install Shift Arm Retainer Bolt
SHIFT
ARM
PENCIL
~NET
SHIFT
TOWER
80abteet
Fig. 44 Install Detent Ball
ADAPTER/
HOUSING EXTENSION
JS921-1032
Fig. 47 Install Shift Tower
80abfeee
Fig. 45 Install Detent Spring
(19) In st a ll sh ift t ower ga sket on t o sh ift t ower.
(20) In st a ll t h e sh ift t ower oil deflect or a n d ga sket
on t o t h e a da pt er or ext en sion h ou sin g.
(21) In st a ll sh ift t ower on t o t r a n sm ission ca se
(F ig. 47).
(22) In st a ll bolt s t o h old sh ift t ower t o t r a n sm is-
sion ca se. Tigh t en t ower bolt s t o 18 N·m (13 ft . lbs.)
t or qu e. J892l- l 00
(23) In st a ll n ew m et a l o-r in g on t o t h e ba cku p la m p Fig. 48 Install Backup Lamp Switch
swit ch .
(24) In st a ll ba cku p la m p swit ch (F ig. 48). Tigh t en (25) In st a ll n ew sea l in a da pt er /ext en sion h ou sin g.
swit ch t o 44 N·m (32.5 ft . lbs.) t or qu e. (26) In st a ll veh icle speed sen sor, if n ecessa r y.
XJ TRANSMISSION AND TRANSFER CASE 21 - 15
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(27) In st a ll clu t ch h ou sin g, r elea se bea r in g, r elea se
for k a n d r et a in er clip.
80ac2c56
LOCK
BALL
NOTCH
FIFTH
GEAR
THRUST
RING
Fig. 55 Remove Fifth Gear Thrust Ring
-
J8921-1067
COUNTER
FIFTH
GEAR
.
=
COUNTERSHAFT
REAR BEARING
~ ~80ac2c6c
PENCIL
MAGNET
80ac2c98
"80ac2cc0
80b11958
3-4 SHIFT
RAIL
+
FIFTH GEAR
SHIFT RAIL
~
~ = INTERLOCK BALL
ORPIN
80b11956
1-2
SHIFT
RAIL
80ac6997
Fig. 76 Install 1–2 Check Ball Fig. 77 Install 1–2 Shift Rail Interlock Pin
(5) In st a ll sn a p-r in g on t o 3–4 sh ift r a il. (7) In st a ll t h e in t er lock pin in t o t h e r ever se sh ift
(6) In st a ll t h e r ever se ch eck ba ll in t o t h e in t er m e- r a il (F ig. 79).
dia t e pla t e (F ig. 78). (8) Assem ble t h e r ever se a r m br a cket t o t h e
r ever se for k (F ig. 80).
21 - 22 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
REVERSE
SHIFT
FORK
REVERSE
SHIFT RAIL AND
REVERSE FORK
ASSEMBLY
\~ft
Fig. 81 Install Reverse Shift Rail
80b11958
3-4
SHIFT
RAIL
\
r:
80ac2c6e
~~-PIN
REVERSE
IDLER GEAR
SHAFT
~MPRESSION
,--------- SPRING
------------_J{j __ __,,
80b099ed
Fig. 87 Install Shift Fork Bolts Fig. 89 Install Compression Spring And Pin
(30) Move t h e r ever se sh ift a r m in t o t h e r ever se
gea r posit ion . Th e r ever se gea r posit ion is wit h t h e
a r m m oved a wa y fr om t h e in t er m edia t e pla t e (F ig.
88).
(31) In st a ll t h e r ever se idler gea r a ssem bly in t o
posit ion on t h e m a in sh a ft a n d r ever se sh ift a r m .
(32) In st a ll t h e com pr ession spr in g a n d pin in t o
t h e r ever se idler gea r sh a ft (F ig. 89).
(33) In st a ll t h e r ever se idler sh a ft t h r ou gh t h e
in t er m edia t e pla t e a n d r ever se idler gea r a ssem bly
(F ig. 90) u n t il t h e idler sh a ft pin con t a ct s t h e gea r
a ssem bly. Ma ke su r e t h a t t h e n ot ch ed cu t -ou t in t h e
idler sh a ft is t o t h e r ea r of t h e t r a n sm ission .
LOCK
BALL
NOTCH
FIFTH
GEAR
THRUST
80b099cf RING
Fig. 92 Depress Pin In Reverse Idler Gear Shaft Fig. 94 Install Fifth Gear Thrust Ring
(36) In st a ll t h e r ever se idler gea r sh a ft t h e (46) Usin g a su it a ble m a llet a n d spa cer, t a p t h e
r em a in der of t h e wa y t h r ou gh t h e r ever se idler gea r fift h gea r blocker r in g on t o t h e cou n t er sh a ft .
a ssem bly. (47) In st a ll n ew bolt t o h old fift h gea r sh ift for k t o
(37) P osit ion t h e r ever se idler gea r sh a ft lock pla t e t h e fift h gea r sh ift r a il (F ig. 95).
on t o t h e in t er m edia t e pla t e.
(38) In st a ll a n ew bolt t o h old t h e idler gea r sh a ft SHIFT FORK _\~-.
RETAINER
lock pla t e t o t h e in t er m edia t e pla t e.
BOLT
(39) In st a ll t h e fift h gea r t h r u st r in g lock ba ll t o
t h e cou n t er sh a ft (F ig. 93).
(40) In st a ll t h e fift h gea r t h r u st r in g on t o t h e
cou n t er sh a ft a n d over t h e lock ba ll (F ig. 94).
FIFTH GEAR
SHIFT RAIL """"'L,..,.-
t0
80ac2c56
COUNTERSHAFT
DISASSEMBLY
(1) Rem ove select fit sn a p-r in g h oldin g t h e cou n -
t er sh a ft fr on t bea r in g on t o t h e cou n t er sh a ft (F ig. 96).
(2) Usin g Bea r in g Split t er P -334, a su it a ble spa cer
on cen t er of cou n t er sh a ft , a n d a sh op pr ess, r em ove
t h e cou n t er sh a ft fr on t bea r in g fr om t h e cou n t er sh a ft .
J8921-1089
BEARING
FRONT ROLLERS
BEARING
J8921-64
INPUT
SHAFT Fig. 100 Install Output Shaft Pilot Bearing Rollers
OUTPUT SHAFT
DISASSEMBLY
(1) Rem ove in pu t sh a ft a n d ou t pu t sh a ft pilot
bea r in g r oller s fr om ou t pu t sh a ft .
(2) Mea su r e a n d n ot e t h r u st clea r a n ce of ou t pu t
sh a ft gea r s (F ig. 101). Clea r a n ce sh ou ld be 0.10 –
1ST 2ND
THRUST CLEARANCE
IS 0.004 TO 0.01 2 INCH
I.D. Mark Snap Ring Thickness mm (in.) (0.1 0 TO 0.25 mm)
LOCK
BALL
J8921-37
Fig. 102 Remove Fifth Gear Snap-ring Fig. 104 Remove First Gear Bearing Inner Race
Lock Ball
3-4 SYNCHRONIZER
SNAP RING
..
FRONT
1-2 3-4
SYNCHRONIZER SYNCHRONIZER
ASSEMBLY ASSEMBLY
J8921-41 J8921-54
Fig. 106 Remove 3–4 Synchronizer Snap Ring Fig. 108 Synchronizer Identification
(4) In st a ll t h ir d gea r over bea r in g a n d on t o ou t pu t
sh a ft fla n ge.
(5) In st a ll t h ir d gea r syn ch r on izer r in g t o t h ir d
gea r.
(6) P osit ion t h e 3–4 syn ch r on izer on t o t h e ou t pu t
sh a ft .
(7) Usin g Ada pt er 6747-1A a n d a sh op pr ess, pr ess
t h e 3–4 syn ch r on izer on t o t h e ou t pu t sh a ft .
(8) Select t h e t h ickest sn a p-r in g t h a t will fit in t o
t h e sn a p-r in g gr oove of t h e ou t pu t sh a ft (F ig. 109).
J8921-59
J8921-58
Fig. 111 Install First Gear Bearing Inner Race Lock
Ball
XJ TRANSMISSION AND TRANSFER CASE 21 - 31
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(24) Ch eck fir st –secon d gea r t h r u st clea r a n ce (F ig.
113). St a n da r d clea r a n ce is 0.10 – 0.25 m m (0.004 –
0.010 in .). If clea r a n ce is ou t of specifica t ion , r efer t o
Clea n in g a n d In spect ion sect ion wit h in t h is gr ou p.
SELECT
FIFTH
GEAR
SNAP
RING
1ST 2ND
STANDARD CLEARANCE
0.004-0.01 0 INCH
(0.10-0.25 mm)
J8921-61
J892l-63
Fig. 114 Select/Install Fifth Gear Snap Ring
21 - 32 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
REVERSE
IDLER GEAR
D
REVERSE
IDLER GEAR 80b099f3
80b099f1
OUTPUT SHAFT
Ch eck t h ickn ess of t h e ou t pu t sh a ft a n d in n er
bea r in g r a ce fla n ges wit h a m icr om et er or ver n ier
ca liper s (F ig. 119).
J8921-45
COUNTERSHAFT
In spect t h e cou n t er sh a ft gea r t eet h . Repla ce t h e
cou n t er sh a ft if a n y t eet h a r e wor n or da m a ged.
In spect t h e bea r in g su r fa ces a n d r epla ce sh a ft if a n y
su r fa ce sh ows da m a ge or wea r.
Ch eck con dit ion of t h e cou n t er sh a ft fr on t bea r in g.
Repla ce t h e bea r in g if wor n , n oisy, or da m a ged.
SYNCHRONIZER
RING
J8921-46 J8921-48
Fig. 123 Check Synchronizer Ring Wear
Fig. 121 Check Gear–To–Race Clearance
FEELER
GAUGE
J8921-49
J8921-47
Fig. 124 Check Fork–To–Hub Clearance
Fig. 122 Check Gear–To–Shaft Oil Clearance
Ch eck sh ift for k–t o–syn ch r on izer h u b clea r a n ce
wit h a feeler ga u ge (F ig. 124). Repla ce t h e for k if
clea r a n ce exceeds 1.0 m m (0.039 in .).
(1) In spect a ll m a in sh a ft gea r t eet h . Repla ce a n y
gea r wh ich sh ows a n y wor n or da m a ged t eet h .
XJ TRANSMISSION AND TRANSFER CASE 21 - 35
SPECI FI CAT I ON S
TORQUE
D ES CRIP TION TORQU E
P lu gs, Access . . . . . . . . . . . . . . . . 19 N·m (14 ft .lbs.)
Bolt s, Ada pt er H ou sin g . . . . . . . . 34 N·m (25 ft .lbs.)
Swit ch , Ba ck-u p Ligh t . . . . . . . 44 N·m (32.5 ft .lbs.)
P lu gs, Dr a in a n d F ill . . . . . . . . 44 N·m (32.5 ft .lbs.)
Bolt s, F r on t Bea r in g Ret a in er . . . 17 N·m (12 ft .lbs.)
P lu gs, In t er lock a n d Det en t . . . . . 19 N·m (14 ft .lbs.) C-3995-A Installer, Extension Housing Seal
Scr ews, P r opeller Sh a ft Cla m p . . . . . . . . 16–23 N·m
(140–200 in .lbs.)
Bolt s, Rea r Mou n t t o Tr a n sm ission . . . . 33–60 N·m
(24–44 ft .lbs.)
Nu t , Rea r Mou n t Clevis . . 54–75 N·m (40–55 ft .lbs.)
Nu t s, Rea r Mou n t t o Cr ossm em ber . . . . 33–49 N·m
(24–36 ft .lbs.)
P in s, Rest r ict or . . . . . . . . . . . . . 27.4 N·m (20 ft .lbs.)
Bolt s, Rever se Sh ift Ar m Br a cket . . . . . . . . . 18 N·m
(13 ft .lbs.)
Scr ew, Sh ift Ar m Set . . . . . . . . . . 38 N·m (28 ft .lbs.)
Scr ews, Sh ift F or k Set . . . . . . . . . 20 N·m (15 ft .lbs.)
Nu t , Sh ift Kn ob . . . . . . . . 20–34 N·m (15–25 ft .lbs.)
Scr ews, Sh ift er F loor Cover . . . . . . . . . . . . 2–3 N·m
(17–30 in .lbs.)
Bolt s, Sh ift Tower . . . . . . . . . . . . 18 N·m (13 ft .lbs.)
Nu t s, Tr a n sfer Ca se Mou n t in g . . . . . . . . 30–41 N·m C-4171 Handle, Universal Tool
(22–30 ft .lbs.)
SPECI AL T OOLS
AX5
( Q)
8208 Installer, Seal
L-4507 Tube, Driver
AX 1 5 M AN U AL T RAN SM I SSI ON
INDEX
page page
J8921-1023
Js921-1024 ,
HARD SHIFTING
H a r d sh ift in g is u su a lly ca u sed by a low lu br ica n t
level, im pr oper, or con t a m in a t ed lu br ica n t s. Th e con -
sequ en ce of u sin g n on –r ecom m en ded lu br ica n t s is
n oise, excessive wea r, in t er n a l bin d, a n d h a r d sh ift -
in g. Su bst a n t ia l lu br ica n t lea ks ca n r esu lt in gea r,
sh ift r a il, syn ch r o, a n d bea r in g da m a ge. If a lea k
goes u n det ect ed for a n ext en ded per iod, t h e fir st in di-
ca t ion s of com pon en t da m a ge a r e u su a lly h a r d sh ift -
in g a n d n oise.
Com pon en t da m a ge, in cor r ect clu t ch a dju st m en t ,
or a da m a ged clu t ch pr essu r e pla t e or disc a r e a ddi-
Fig. 4 Drain Plug Location t ion a l pr oba ble ca u ses of in cr ea sed sh ift effor t . In cor-
r ect a dju st m en t or a wor n /da m a ged pr essu r e pla t e or
A lea k a t t h e fr on t of t h e t r a n sm ission will be fr om
disc ca n ca u se in cor r ect r elea se. If t h e clu t ch pr oblem
eit h er t h e fr on t bea r in g r et a in er or r et a in er sea l.
is a dva n ced, gea r cla sh du r in g sh ift s ca n r esu lt .
Lu br ica n t m a y be seen dr ippin g fr om t h e clu t ch
Wor n or da m a ged syn ch r o r in gs ca n ca u se gea r cla sh
h ou sin g a ft er ext en ded oper a t ion . If t h e lea k is
wh en sh ift in g in t o a n y for wa r d gea r. In som e n ew or
sever e, it m a y a lso con t a m in a t e t h e clu t ch disc ca u s-
r ebu ilt t r a n sm ission s, n ew syn ch r o r in gs m a y t en d t o
in g t h e disc t o slip, gr a b, a n d/or ch a t t er.
st ick sligh t ly ca u sin g h a r d or n oisy sh ift s. In m ost
A cor r ect lu br ica n t level ch eck ca n on ly be m a de
ca ses, t h is con dit ion will declin e a s t h e r in gs wea r –
wh en t h e veh icle is level. Also a llow t h e lu br ica n t t o
in .
set t le for a m in u t e or so befor e ch eckin g. Th ese r ec-
om m en da t ion s will en su r e a n a ccu r a t e ch eck a n d
NEEDLE
. __ _ BEARING
REAR
BEARING
INSERT
SPRING
1 SNAP
RING
(SELECTIVE)
INSERT
(3)
NEEDLE SYNCHRO
BEARING RING J8921-1093
REFERENCE MARKS
GROMMET
CRANKSHAFT \
I~ j -:,'-@__
POSITION \ MOUNTING
SENSOR NUTS (2) soa4s1s1
J9316-2
SPECIAL
TOOL
8211 (AX5} OR
8209 (AX.15) 80b099ca
J9316-2
Fig. 12 Install Front Bearing Retainer Seal
Fig. 11 Align Propeller Shaft And Rear Axle Yokes
Alignment Marks (2) Rem ove a n y r esidu a l ga sket m a t er ia l fr om the
sea lin g su r fa ces of t h e bea r in g r et a in er a n d the
(26) In st a ll a n d t igh t en pr opeller sh a ft U–join t t r a n sm ission ca se.
cla m p bolt s t o 19 N·m (170 in . lbs.) t or qu e. (3) In st a ll n ew fr on t bea r in g r et a in er ga sket t o the
(27) Align m a r ks on fr on t pr opeller sh a ft , a xle, fr on t bea r in g r et a in er.
a n d t r a n sfer ca se yokes, if equ ipped. (4) In st a ll t h e fr on t bea r in g r et a in er on t o the
(28) In st a ll a n d t igh t en pr opeller sh a ft U–join t t r a n sm ission ca se.
cla m p bolt s t o 19 N·m (170 in . lbs.) t or qu e.
XJ TRANSMISSION AND TRANSFER CASE 21 - 43
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) In st a ll t h e bolt s t o h old t h e bea r in g r et a in er (3) In st a ll pr opeller sh a ft . Refer t o Gr ou p 3, Differ-
on t o t h e t r a n sm ission ca se. en t ia l a n d Dr ivelin e, for pr oper pr ocedu r es.
(6) Tigh t en t h e bolt s t o 17 N·m (12 ft . lbs.). (4) Ch eck a n d a dd flu id t o t r a n sm ission a s n eces-
(7) In st a ll r elea se bea r in g a n d lever on t o t h e sa r y. Refer t o t h e Recom m en ded Lu br ica n t sect ion for
t r a n sm ission . pr oper flu id r equ ir em en t s.
(5) Lower veh icle.
EXTENSION HOUSING SEAL
ADAPTER HOUSING SEAL
REMOVAL
(1) Ra ise a n d su ppor t veh icle. REMOVAL
(2) Rem ove pr opeller sh a ft . Refer t o Gr ou p 3, Dif- (1) H oist a n d su ppor t veh icle.
fer en t ia l a n d Dr ivelin e, for pr oper pr ocedu r es. (2) Rem ove t r a n sfer ca se.
(3) Usin g a su it a ble sea l pu ller or scr ew wit h a (3) Usin g a su it a ble pr y t ool, or a slide h a m m er
slide h a m m er, r em ove t h e ext en sion h ou sin g sea l m ou n t ed scr ew, r em ove t h e a da pt er h ou sin g sea l
(F ig. 13). (F ig. 15).
SLIDE ADAPTER
HAMMER HOUSING
OIL SEAL
2WD
EXTENSION HOUSING
J9121-385 J8921-1045
Fig. 13 Remove Extension Housing Seal Fig. 15 Remove Adapter Housing Seal
INSTALLATION INSTALLATION
(1) Clea n sea l bor e of ext en sion h ou sin g of a n y (1) Clea n sea l bor e of a da pt er h ou sin g of a n y
r esidu a l sea ler m a t er ia l fr om or igin a l sea l. r esidu a l sea ler m a t er ia l fr om or igin a l sea l.
(2) Usin g Tool H a n dle C-4171 a n d Sea l In st a ller (2) Usin g Tool H a n dle C-4171 a n d Sea l In st a ller
8212, in st a ll n ew ext en sion h ou sin g sea l so t h a t t h e 8208, in st a ll n ew sea l so t h a t t h e sea l is loca t ed 0 !
sea l is loca t ed 0 ! 0.5 m m (0 ! 0.02 in .) t o t h e fa ce 0.2 m m (0 ! 0.008 in .) t o t h e sea l bor e fa ce of
of t h e ext en sion h ou sin g (F ig. 14). a da pt er h ou sin g (F ig. 16).
(3) In st a ll t r a n sfer ca se.
SPECIAL TOOL SPECIAL TOOL (4) Ch eck a n d a dd flu id t o t r a n sm ission a s n eces-
C-4171 8212
sa r y. Refer t o t h e Recom m en ded Lu br ica n t sect ion for
pr oper flu id r equ ir em en t s.
~,--,--- (5) Lower veh icle.
I
EXTENSION
HOUSING
80b099c4
SHIFT
TOWER
GASKET
J8921-1033
Fig. 18 Remove Shift Tower Gasket
(8) Rem ove r ever se sh ift h ea d det en t ba ll plu g
80b099c5
(F ig. 20).
Fig. 16 Install Adapter Housing Seal (9) Rem ove det en t ba ll spr in g a n d ba ll wit h pen cil
m a gn et (F ig. 21), (F ig. 22).
DI SASSEM BLY AN D ASSEM BLY
ADAPTER/EXTENSION HOUSING AND FRONT
BEARING RETAINER
DISASSEMBLY
(1) Dr a in t r a n sm ission lu br ica n t , if n ecessa r y.
(2) Rem ove r elea se bea r in g a n d lever.
(3) Rem ove clu t ch h ou sin g bolt s a n d r em ove h ou s-
in g (F ig. 19).
(4) Rem ove veh icle speed sen sor a n d speedom et er
a da pt er, if n ecessa r y.
(5) Rem ove bolt s h oldin g sh ift t ower t o t r a n sm is-
sion ca se.
(6) Rem ove sh ift t ower fr om t r a n sm ission ca se
(F ig. 17).
SHIFT
TOWER
ADAPTER/EXTENSION
HOUSING
J8921-1032
Fig. 17 Remove Shift Tower
XJ TRANSMISSION AND TRANSFER CASE 21 - 45
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
Fig. 20 Remove Detent Ball Plug Fig. 23 Shift Arm Retainer Bolt Removal
SHIFT LEVER
SHAFT
PLUG
LARGE
MAGNET
J8921-1037
J8921-1042
Fig. 27 Adapter/Extension Housing Bolts
XJ TRANSMISSION AND TRANSFER CASE 21 - 47
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
FRONT
BEARING
RETAINER
J8921-1043 J8921-1046
INPUT
SHAFT
J8921-1044
Fig. 29 Remove Adapter/Extension Housing Fig. 32 Remove Input Shaft Bearing Snap-ring
SNAP LOCK---..-Q SNAP
RING~ ~RING
SNAP
OUTPUT RING
SHAFT SPEEDOMETER PLIERS
GROOVES GEAR
CLUSTER
GEAR FRONT
BEARING
SNAP
RING
J8921-1119 J8921-1049
Fig. 30 Speedometer Drive Gear Assembly Fig. 33 Remove Cluster Gear Snap-ring
ASSEMBLY (2) Apply a 1/8 t o 3/16 in ch wide bea d of Th r eeb-
(1) Rem ove a n y r esidu a l sea ler fr om t r a n sm ission on d! Liqu id Ga sket TB1281, P /N 83504038, a s
ca se, in t er m edia t e pla t e, a da pt er /ext en sion h ou sin g, sh own , m a kin g su r e t o keep sea ler bea d t o in side of
a n d fr on t bea r in g r et a in er. bolt h oles (F ig. 36).
21 - 48 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
INTERMEDIATE
PLATE
J8921-1050 J8921-1051
Fig. 34 Separate Intermediate Plate and
Transmission Case Fig. 37 Install Transmission Gear Case to the
Intermediate Plate
(4) In st a ll n ew fr on t bea r in g sn a p r in gs (F ig. 38).
J8921-1051
Fig. 35 Remove Intermediate Plate from
Transmission Case
(3) Align gea r t r a in a n d sh ift r a ils wit h m a t in g
h oles in t r a n sm ission ca se a n d in st a ll t r a n sm ission
ca se t o t h e in t er m edia t e pla t e (F ig. 37). Ver ify t h a t
t h e t r a n sm ission ca se is sea t ed on t h e in t er m edia t e
pla t e.
FRONT
BEARING
RETAINER
J8921-1046 J8921-1044
Fig. 39 Install Front Bearing Retainer Fig. 41 Install Adapter/Extension Housing
(8) Apply a 1/8 t o 3/16 in ch wide bea d of Th r eeb- SHIFT
on d! Liqu id Ga sket TB1281, P /N 83504038, t o sea l- ARM
in g su r fa ce of a da pt er /ext en sion h ou sin g, m a kin g
su r e t o keep sea ler bea d t o in side of bolt h oles.
(9) In st a ll a da pt er or ext en sion h ou sin g on in t er-
m edia t e pla t e (F ig. 41). Tigh t en h ou sin g bolt s t o 37
N·m (27 ft . lbs.) t or qu e.
(10) P osit ion sh ift a r m in sh ift er t ower open in g of
a da pt er [e]xt en sion h ou sin g (F ig. 42). Be su r e t h a t
t h e sh ift er a r m is en ga ged in t o t h e sh ift r a ils.
SNAP LOCK---..-Q SNAP
RING~ ~RING
J8921-1119
Fig. 40 Speedometer Drive Gear Assembly
(11) St a r t sh ift er a r m sh a ft in h ole in ba ck of
a da pt er [e]xt en sion h ou sin g. Align sh ift a r m a n d
sh ift er a r m sh a ft a n d in ser t sh ift er a r m sh a ft
t h r ou gh t h e sh ift er a r m a n d in t o t h e for wa r d por t ion
of t h e a da pt er [e]xt en sion h ou sin g (F ig. 43).
(12) Rot a t e t h e sh ift er a r m sh a ft u n t il t h e h ole in
t h e sh ift a r m is a lign ed wit h t h e h ole in t h e sh a ft .
(13) In st a ll t h e sh ift a r m r et a in er bolt a n d t igh t en
t o 38 N·m (28 ft . lbs.) (F ig. 44).
(14) In st a ll a n d t igh t en sh ift er a r m sh a ft plu g t o
18 N·m (13 ft . lbs.) t or qu e (F ig. 45). Fig. 43 Install Shifter Arm Shaft
21 - 50 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
,1 J8921-1034
Fig. 44 Install Shift Arm Retainer Bolt Fig. 46 Install Shifter Restrictor Pins
J8921-97
Fig. 45 Shifter Arm Shaft Plug Installation
(15) In st a ll sh ift er r est r ict or pin s in sh ift t ower
a n d t igh t en t o 27 N·m (20 ft . lbs.) (F ig. 46).
(16) In st a ll sh ift det en t ba ll in det en t open in g (F ig.
47).
(17) In st a ll det en t spr in g (F ig. 48).
(18) In st a ll det en t plu g a n d t igh t en t o 19 N·m (14
ft . lbs.) (F ig. 49).
DETENT BACKUP
PLUG LAMP
SWITCH
INTERMEDIATE
----------PLATE
:----------BOLTS
AND
WASHERS
J8921-1054
Fig. 51 Positioning Intermediate Plate In Vise
21 - 52 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(2) Mea su r e t h r u st clea r a n ce bet ween cou n t er sh a ft
fift h gea r a n d t h r u st r in g wit h feeler ga u ge. Clea r-
a n ce sh ou ld be 0.10 t o 0.40 m m (0.003 t o 0.019 in .).
If clea r a n ce exceeds lim it s, gea r a n d/or r in g will h a ve
t o be r epla ced.
(3) Rem ove cou n t er sh a ft fift h gea r r et a in in g sn a p-
r in g (F ig. 52).
FIFTH GEAR
;)YNCHRO SLEEVE
COUNTER
FIFTH
GEAR
J8921-1065
LOCK
BALL
NOTCH
FIFTH
GEAR
THRUST
RING
REVERSE
Fig. 61 Remove Output Shaft Rear Bearing Retainer SHIFT
Bolts ARM
(14) Rem ove r ea r bea r in g r et a in er (F ig. 62).
OUTPUT SHAFT
REAR BEARING
RETAINER
J8921-1117
LOCK
BALL
PLUGS
Fig. 62 Remove Output Shaft Rear Bearing Retainer
(15) Rem ove r ever se idler gea r sh a ft a n d gea r (F ig.
63).
(16) Rem ove bolt s h oldin g r ever se sh ift a r m
br a cket t o in t er m edia t e pla t e (F ig. 64).
(17) Rem ove t h r ea ded lock ba ll plu gs fr om in t er-
m edia t e pla t e (F ig. 65).
(18) Th en r em ove lock ba ll a n d spr in g fr om plu g
h oles wit h pen cil m a gn et (F ig. 66).
J8921-1052
MAGNET
FIFTH
GEAR SHIFT
RAIL
REVERSE
SHIFT
FORK J8921-1075
J8921-l0?7
INTERMEDIATE
PLATE
INTERLOCK
PIN
J8921-1081
J8921-1082
/
INTERLOCK
PIN
INTERMEDIATE
PLATE
Fig. 85 Install 1–2 Shift Rail Interlock Plug Fig. 88 Install 3–4 Shift Rail Interlock Plug
3-4
SHIFT RAIL
;MAGNET J8921-l077
Fig. 86 Install 1–2 Shift Rail Interlock Pin Fig. 89 Install 3–4 Shift Rail
1-2
FORK J8921-1076
Fig. 87 Install 1–2 Shift Rail Fig. 90 Install Shift Fork To Shift Rail Bolts
(19) In st a ll n ew bolt s t o h old t h e sh ift for ks t o t h e (21) In st a ll t h e fift h gea r sh ift r a il lock ba ll in t h e
sh ift r a ils (F ig. 90). in t er m edia t e pla t e (F ig. 94).
(20) In st a ll c-r in gs t o 1–2 a n d 3–4 sh ift r a ils (F ig. (22) In st a ll t h e fift h gea r sh ift r a il in t o t h e in t er-
91). m edia t e pla t e.
XJ TRANSMISSION AND TRANSFER CASE 21 - 61
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
REVERSE
IDLER
SHAFT
NOTCH
J8921-l 109
Fig. 91 Install Shift Rail C-rings Fig. 93 Install Output Shaft Rear Bearing Retainer
(23) In st a ll r ever se idler gea r a n d idler gea r sh a ft
(F ig. 92). Ver ify t h a t t h e n ot ch in t h e idler sh a ft is t o
t h e r ea r of t h e t r a n sm ission .
(24) P osit ion ou t pu t sh a ft r ea r bea r in g r et a in er on
in t er m edia t e pla t e a n d in t o r ever se idler sh a ft n ot ch .
(25) In st a ll n ew bolt s t o h old r et a in er t o in t er m e- MAGNET
dia t e pla t e (F ig. 93).
INTERMEDIATE
PLATE
REVERSE
IDLER
SHAFT
SHAFT
NOTCH
LOCK
BALL
NOTCH
FIFTH
GEAR
THRUST
RING
Fig. 96 Install Fifth Gear Thrust Ring Fig. 99 Install Fifth Gear Synchronizer Ring
COUNTER
FIFTH
GEAR
AND SYNCHRO
ASSEMBLY
FIFTH
GEAR
SELECTM-----1-...,_rm.
SNAP
RING
J8921-1113
REVERSE
SHIFT
HEAD
AND
SHIFT
RAIL
SHIFT
ASSEMBLY
FORK (1) Rem ove a n y n icks or bu r r s on cou n t er sh a ft h u b
SET wit h fin e em er y or cr ocu s clot h .
SCREW (2) P osit ion cou n t er sh a ft fr on t bea r in g on en d of
cou n t er sh a ft . Be su r e t h e sn a p-r in g gr oove in bea r in g
is fa cin g for wa r d.
(3) Usin g Specia l Tool 8109 a n d a sh op pr ess,
pr ess bea r in g on t o cou n t er sh a ft .
(4) Select t h e t h ickest sn a p-r in g t h a t will fit in t o
t h e sn a p-r in g gr oove of t h e cou n t er sh a ft (F ig. 105).
J8921-1116 (5) In st a ll sn a p-r in g t o h old cou n t er sh a ft fr on t
bea r in g on t o cou n t er sh a ft .
Fig. 103 Install Fifth Gear Shift Fork Retainer Bolt
(40) In st a ll bolt s t o h old r ever se sh ift a r m t o t h e
in t er m edia t e pla t e. Tigh t en bolt s t o 18 N·m (13 ft .
lbs.).
21 - 64 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SELECT COUNTERSHAFT
FIT
RING
80ac6a0b
Fig. 109 Select Input Shaft Bearing Snap-ring Fig. 111 Remove Output Shaft Pilot Bearing
(3) Rem ove ou t pu t sh a ft fift h gea r sn a p r in g wit h
DISASSEMBLY
t wo scr ewdr iver s (F ig. 113).
(1) Rem ove in pu t sh a ft a n d ou t pu t sh a ft pilot
(4) Usin g Bea r in g Split t er P -334 or su it a ble pr ess
bea r in g fr om ou t pu t sh a ft (F ig. 111), if n ecessa r y.
pla t es posit ion ed u n der fir st gea r, pr ess fift h gea r,
NEEDLE
----BEARING
REAR
BEARING
INSERT
SPRING
1 SNAP
RING
(SELECTIVE)
INSERT
(3)
NEEDLE SYNCHRO
BEARING RING J8921-1093
OUTPUT
SHAFT
1ST 2ND FLANGE
CLEARANCE CLEARANCE
J8921-1092
J8921-37
-
FRONT
J8921-1099
Fig. 116 Remove 3–4 Synchronizer Snap Ring (3) In st a ll t h ir d gea r n eedle bea r in g on t o t h e ou t -
pu t sh a ft .
(13) Usin g Bea r in g Split t er P -334 or su it a ble pr ess (4) In st a ll t h ir d gea r over bea r in g a n d on t o ou t pu t
pla t es posit ion ed u n der t h ir d gea r, pr ess t h e 3–4 syn - sh a ft fla n ge.
ch r on izer a n d t h ir d gea r fr om ou t pu t sh a ft (F ig. 117). (5) In st a ll t h ir d gea r syn ch r on izer r in g t o t h ir d
gea r.
(6) P osit ion t h e 3–4 syn ch r on izer on t o t h e ou t pu t
sh a ft .
(7) Usin g Ada pt er 6761 a n d a sh op pr ess, pr ess
t h e 3–4 syn ch r on izer on t o t h e ou t pu t sh a ft .
(8) Select t h e t h ickest sn a p-r in g t h a t will fit in t o
t h e sn a p-r in g gr oove of t h e ou t pu t sh a ft (F ig. 119).
(9) In st a ll sn a p-r in g t o h old 3–4 syn ch r on izer on t o
ou t pu t sh a ft .
(10) Ver ify t h ir d gea r t h r u st clea r a n ce wit h feeler
ga u ge (F ig. 120). Clea r a n ce sh ou ld be 0.10 – 0.30 m m
(0.003 – 0.0118 in .). If clea r a n ce is ou t of specifica -
t ion , r efer t o Clea n in g a n d In spect ion sect ion wit h in
t h is gr ou p.
(11) In st a ll secon d gea r n eedle bea r in g on t o ou t pu t
sh a ft .
(12) In st a ll secon d gea r over bea r in g a n d on t o ou t -
pu t sh a ft fla n ge.
(13) In st a ll secon d gea r syn ch r on izer r in g on t o sec-
J8921-42
on d gea r.
(14) P osit ion 1–2 syn ch r on izer /r ever se gea r a ssem -
Fig. 117 Remove 3–4 Synchronizer And Third Gear bly on t o splin es of ou t pu t sh a ft .
(15) Usin g Dr iver MD-998805, Ada pt er 6761, a n d
(14) Rem ove t h ir d gea r n eedle r oller bea r in g fr om a sh op pr ess, pr ess t h e 1–2 syn ch r on izer /r ever se gea r
ou t pu t sh a ft or gea r. on t o t h e ou t pu t sh a ft .
(16) Select t h e t h ickest sn a p-r in g t h a t will fit in t o
t h e sn a p-r in g gr oove of t h e ou t pu t sh a ft (F ig. 121).
21 - 68 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SECOND SELECT
GEAR FIT
SNAP
RING
NEEDLE SYNCHRO
BEARING RING
I.D. SNAP RING
MM(IN.) I.D. SNAP RING
MARK THICKNESS MM(IN.)
MARK THICKNESS
A 1.80 - 1.85 (0.0709 - 0.0728)
B 1.85 - 1.90 (0.0728 - 0.0748)
B 2.35 - 2.40 (0.0925 - 0.0945)
C 1.90-1.95 (0.0748 - 0.0768)
C 2.40 - 2.45 (0.0945 - 0.0965)
D 1.95 - 2.00 (0.0768 - 0.0787)
D 2.45 - 2.50 (0.0965 - 0.0984)
E 2.00 - 2.05 (0.0787 - 0.0807)
E 2.50 - 2.55 (0.0984 - 0.1004)
F 2.05 - 2.10 (0.0807 - 0.0827)
F 2.55 - 2.60 (0. 1004 - 0.1024)
G 2. 10-2. 15 0.0827 - 0.0846)
G 2.60- 2.65 (0. 1024 - 0. 1043)
J8921 - 1101 J8921-1102
Fig. 119 Select 3–4 Synchronizer Snap-ring Fig. 121 Second Gear And Synchronizer Assembly
FEELER THIRD (23) In st a ll t h e fir st gea r t h r u st wa sh er on t o t h e
GAUGE GEAR
ou t pu t sh a ft . Rot a t e t h e t h r u st wa sh er u n t il t h e
wa sh er loca t in g pin a lign s wit h t h e n ot ch in t h e
wa sh er.
(24) P osit ion ou t pu t sh a ft r ea r bea r in g on t o ou t pu t
sh a ft . E n su r e t h a t t h e sn a p r in g gr oove in bea r in g
ou t er r a ce is t owa r d r ea r of ou t pu t sh a ft .
(25) Usin g Dr iver L-4507 a n d su it a ble m a llet ,
dr ive bea r in g on t o ou t pu t sh a ft .
(26) In st a ll sn a p-r in g on t o ou t pu t sh a ft r ea r bea r-
in g ou t er r a ce.
SYNCHRO SPACER BEARING FIFTH
RING GEAR
GEAR
JOURNAL
J8921-1095
COUNTERSHAFT
In spect t h e cou n t er sh a ft gea r t eet h . Repla ce t h e
cou n t er sh a ft if a n y t eet h a r e wor n or da m a ged. SYNCHRONIZER
RING
In spect t h e bea r in g su r fa ces a n d r epla ce sh a ft if a n y
su r fa ce sh ows da m a ge or wea r.
Ch eck con dit ion of t h e cou n t er sh a ft fr on t bea r in g. J8921-48
Repla ce t h e bea r in g if wor n , n oisy, or da m a ged.
Fig. 127 Check Synchronizer Ring Wear
GEAR AND SYNCHRONIZER Ch eck sh ift for k–t o–syn ch r on izer h u b clea r a n ce
In st a ll t h e n eedle bea r in gs in t h e fir st , secon d, wit h a feeler ga u ge (F ig. 128). Repla ce t h e for k if
t h ir d a n d cou n t er fift h gea r s. In st a ll t h e gea r s on t h e clea r a n ce exceeds 1.0 m m (0.039 in .).
ou t pu t sh a ft . Th en ch eck oil clea r a n ce bet ween t h e
gea r s a n d sh a ft wit h a dia l in dica t or (F ig. 126). Oil
clea r a n ce for a ll t h r ee gea r s is 0.16 m m (0.0063 in .)
m a xim u m .
J8921-49
8011 d42b
(_Q)
8109 Cup, Installer
AU T OM AT I C T RAN SM I SSI ON —3 0 RH
INDEX
page page
2 3 4 5 6 7 8 9 10 11
20
18 17 16 15 14 13
@) CONVERTER CLUTCH
80a13873
Fig. 1 30RH Automatic Transmission
21 - 76 TRANSMISSION AND TRANSFER CASE XJ
GEN ERAL I N FORM AT I ON (Cont inue d)
PARK/BRAKE
INTERLOCK CABLE
SHIFT-~~-.,,...
CABLE
80a13876
I
followin g:
(a ) If pr opeller sh a ft t u r n s bu t wh eels do n ot ,
pr oblem is wit h differ en t ia l or a xle sh a ft s.
(b) If pr opeller sh a ft does n ot t u r n a n d t r a n sm is-
INTERLOCK sion is n oisy, st op en gin e. Rem ove oil pa n , a n d
CABLE
ch eck for debr is. If pa n is clea r, r em ove t r a n sm is-
sion a n d ch eck for da m a ged dr ive pla t e, con ver t er,
oil pu m p, or in pu t sh a ft .
J9319-47
(c) If pr opeller sh a ft does n ot t u r n a n d t r a n sm is-
sion is n ot n oisy, per for m h ydr a u lic-pr essu r e t est t o
Fig. 4 Ignition Key Cylinder Actuation
det er m in e if pr oblem is h ydr a u lic or m ech a n ica l.
n eeded t o m a in t a in n or m a l speeds wit h a pr oper ly
t u n ed en gin e. PARK/NEUTRAL POSITION SWITCH
(6) P er for m h ydr a u lic pr essu r e t est if sh ift pr ob- Th e cen t er t er m in a l of t h e pa r k/n eu t r a l posit ion
lem s wer e n ot ed du r in g r oa d t est . swit ch is t h e st a r t er-cir cu it t er m in a l. It pr ovides t h e
(7) P er for m a ir-pr essu r e t est t o ch eck clu t ch -ba n d gr ou n d for t h e st a r t er solen oid cir cu it t h r ou gh t h e
oper a t ion . select or lever in PARK a n d NE UTRAL posit ion s on ly.
Th e ou t er t er m in a ls on t h e swit ch a r e for t h e ba cku p
VEHICLE IS DISABLED la m p cir cu it .
(1) Ch eck flu id level a n d con dit ion .
(2) Ch eck for br oken or discon n ect ed gea r sh ift or SWITCH TEST
t h r ot t le lin ka ge. To t est t h e swit ch , r em ove t h e wir in g con n ect or.
(3) Ch eck for cr a cked, lea kin g cooler lin es, or loose Test for con t in u it y bet ween t h e cen t er t er m in a l a n d
or m issin g pr essu r e-por t plu gs. t h e t r a n sm ission ca se. Con t in u it y sh ou ld exist on ly
wh en t h e t r a n sm ission is in PARK or NE UTRAL.
XJ TRANSMISSION AND TRANSFER CASE 21 - 79
DI AGN OSI S AN D T EST I N G (Cont inue d)
Sh ift t h e t r a n sm ission in t o RE VE RSE a n d t est con dit ion is a dva n ced, a n over h a u l will be n ecessa r y
con t in u it y a t t h e swit ch ou t er t er m in a ls. Con t in u it y t o r est or e n or m a l oper a t ion .
sh ou ld exist on ly wh en t h e t r a n sm ission is in A slippin g clu t ch or ba n d ca n oft en be det er m in ed
RE VE RSE . Con t in u it y sh ou ld n ot exist bet ween t h e by com pa r in g wh ich in t er n a l u n it s a r e a pplied in t h e
ou t er t er m in a ls a n d t h e ca se. va r iou s gea r r a n ges. Th e Clu t ch a n d Ba n d Applica -
Ch eck gea r sh ift lin ka ge a dju st m en t befor e r epla c- t ion ch a r t pr ovides a ba sis for a n a lyzin g r oa d t est
in g a swit ch t h a t t est s fa u lt y. r esu lt s.
Test Four - Transmission In Reverse Governor pressure too high Governor valve sticking open
at idle speed
Th is t est ch ecks pu m p ou t pu t , pr essu r e r egu la t ion
a n d t h e fr on t clu t ch a n d r ea r ser vo cir cu it s. Use 300 Governor pressure low at all Governor valve sticking closed
psi Test Ga u ge C-3293-SP for t h is t est . mph figures
(1) Con n ect 300 psi ga u ge t o r ea r ser vo por t (F ig.
Lubrication pressure low at Cloiged drainback valve, oil
6) a n d (F ig. 7). coo er or lines, seal rings
all throttle positions
(2) St a r t a n d r u n en gin e a t 1600 r pm for t est . leaking, output shaft plugged
(3) Move va lve body select or lever fou r det en t s with debris, worn bushings in
r ea r wa r d fr om t h e fu ll for wa r d posit ion . Th is is pump or clutch retainer
Rever se r a n ge. J952l -l 29
(4) Move t h r ot t le lever a ll wa y for wa r d t h en a ll
wa y r ea r wa r d a n d n ot e ga u ge r ea din gs. Fig. 9 Pressure Test Analysis
(5) P r essu r e sh ou ld be 145 - 175 psi (1000-1207 CONVERTER STALL TEST
kP a ) wit h lever for wa r d a n d in cr ea se t o 230 - 280 psi St a ll t est in g in volves det er m in in g m a xim u m
(1586-1931 kP a ) a s lever is m oved r ea r wa r d. en gin e speed obt a in a ble a t fu ll t h r ot t le wit h t h e r ea r
wh eels locked a n d t h e t r a n sm ission in D r a n ge. Th is
Test Five - Governor Pressure
t est ch ecks t h e h oldin g a bilit y of t h e con ver t er over-
Th is t est ch ecks gover n or oper a t ion by m ea su r in g r u n n in g a n d t r a n sm ission clu t ch es.
gover n or pr essu r e r espon se t o ch a n ges in en gin e
speed. It is u su a lly n ot n ecessa r y t o ch eck gover n or WARNING: NEVER ALLOW ANYONE TO STAND
oper a t ion u n less sh ift speeds a r e in cor r ect or if t h e DIRECTLY IN LINE WITH THE VEHICLE FRONT OR
t r a n sm ission will n ot down sh ift . REAR DURING A STALL TEST. ALWAYS BLOCK
(1) Con n ect 100 psi Test Ga u ge C-3292 t o gover n or THE WHEELS AND FULLY APPLY THE SERVICE
pr essu r e por t (F ig. 6) a n d (F ig. 7). AND PARKING BRAKES DURING THE TEST.
(2) Move sh ift lever t o D r a n ge.
21 - 82 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
STALL TEST PROCEDURE a n d list en for n oise com in g fr om t h e con ver t er h ou s-
(1) Con n ect t a ch om et er t o en gin e. P osit ion t a ch om - in g.
et er so it ca n be viewed fr om dr iver ’s sea t .
(2) Dr ive veh icle t o br in g t r a n sm ission flu id u p t o AIR TESTING TRANSMISSION CLUTCH AND
n or m a l oper a t in g t em per a t u r e. Veh icle ca n be dr iven BAND OPERATION
on r oa d or on ch a ssis dyn a m om et er, if a va ila ble. Air-pr essu r e t est in g ca n be u sed t o ch eck t r a n sm is-
(3) Ch eck t r a n sm ission flu id level. Add flu id if n ec- sion fr on t /r ea r clu t ch a n d ba n d oper a t ion . Th e t est
essa r y. ca n be con du ct ed wit h t h e t r a n sm ission eit h er in t h e
(4) Block fr on t wh eels. veh icle or on t h e wor k ben ch , a s a fin a l ch eck, a ft er
(5) F u lly a pply ser vice a n d pa r kin g br a kes. over h a u l.
(6) Open t h r ot t le com plet ely a n d r ecor d m a xim u m Air-pr essu r e t est in g r equ ir es t h a t t h e oil pa n a n d
en gin e speed r egist er ed on t a ch om et er. It t a kes 4-10 va lve body be r em oved fr om t h e t r a n sm ission . Th e
secon ds t o r ea ch m a x r pm . On c e m a x rp m h a s ser vo a n d clu t ch a pply pa ssa ges a r e sh own (F ig. 10).
be e n a c h ie v e d , d o n o t h o ld w id e o p e n th ro ttle
fo r m o re th a n 4-5 s e c o n d s .
Stall Speed Normal But Acceleration Poor Rear Clutch Air Test
If st a ll speeds a r e n or m a l (1800-2300 r pm ) bu t P la ce on e or t wo fin ger s on t h e clu t ch h ou sin g a n d
a bn or m a l t h r ot t le open in g is r equ ir ed for a cceler a - a pply a ir pr essu r e t h r ou gh r ea r clu t ch a pply pa ssa ge.
t ion , or t o m a in t a in cr u ise speed, t h e con ver t er over- P ist on m ovem en t ca n be felt a n d a soft t h u m p h ea r d
r u n n in g clu t ch is seized. Th e t or qu e con ver t er will a s t h e clu t ch a pplies.
h a ve t o be r epla ced.
Front Servo Apply Air Test
Converter Noise During Test Apply a ir pr essu r e t o t h e fr on t ser vo a pply pa s-
A wh in in g n oise ca u sed by flu id flow is n or m a l du r- sa ge. Th e ser vo r od sh ou ld ext en d a n d ca u se t h e
in g a st a ll t est . H owever, lou d m et a llic n oises in di- ba n d t o t igh t en a r ou n d t h e dr u m . Spr in g pr essu r e
ca t e a da m a ged con ver t er. To con fir m t h a t t h e n oise sh ou ld r elea se t h e ser vo wh en a ir pr essu r e is
is or igin a t in g fr om t h e con ver t er, oper a t e t h e veh icle r em oved.
a t ligh t t h r ot t le in DRIVE a n d NE UTRAL on a h oist
XJ TRANSMISSION AND TRANSFER CASE 21 - 83
DI AGN OSI S AN D T EST I N G (Cont inue d)
Rear Servo Air Test
Apply a ir pr essu r e t o t h e r ea r ser vo a pply pa ssa ge.
Th e ser vo r od sh ou ld ext en d a n d ca u se t h e ba n d t o
t igh t en a r ou n d t h e dr u m . Spr in g pr essu r e sh ou ld
r elea se t h e ser vo wh en a ir pr essu r e is r em oved.
excess fluid is picked up and churned by the gear Fig. 14 Transmission Pan
train. This will significantly reduce fluid life.
DIPSTICK
( MIN
U~if::½¥0
I
,~MAXIMUM
ACCEPTABLE CORRECT
FLUID FLUID
LEVEL LEVEL 804d8eae
REMOVAL MOUNTING
BOLT
(1) Discon n ect ba t t er y n ega t ive ca ble.
(2) Discon n ect a n d lower or r em ove n ecessa r y
exh a u st com pon en t s.
(3) Rem ove en gin e-t o-t r a n sm ission ben din g br a ces. J958D-2
(4) Discon n ect flu id cooler lin es a t t r a n sm ission .
(5) Rem ove st a r t er m ot or. Fig. 17 Crankshaft Position Sensor—4.0L Engine
(6) Discon n ect a n d r em ove cr a n ksh a ft posit ion sen - m odels, it will a lso be n ecessa r y t o r em ove bolt
sor. Ret a in sen sor a t t a ch in g bolt s. a t t a ch in g t r a n sfer ca se ven t t u be t o con ver t er h ou s-
in g.
CAUTION: The crankshaft position sensor can be (11) Ma r k t or qu e con ver t er a n d dr ive pla t e for
damaged during transmission removal (or installa- a ssem bly a lign m en t . Not e t h a t bolt h oles in cr a n k-
tion) if the sensor is still bolted to the engine block. sh a ft fla n ge, dr ive pla t e a n d t or qu e con ver t er a ll
To avoid damage, remove the sensor before remov- h a ve on e offset h ole.
ing the transmission. (12) Rot a t e cr a n ksh a ft in clockwise dir ect ion u n t il
con ver t er bolt s a r e a ccessible. Th en r em ove bolt s on e
a t a t im e. Rot a t e cr a n ksh a ft wit h socket wr en ch on
da m pen er bolt .
(13) Ma r k pr opeller sh a ft a n d a xle yokes for
a ssem bly a lign m en t . Th en discon n ect a n d r em ove
pr opeller sh a ft . On 4 x 4 m odels, r em ove bot h pr opel-
ler sh a ft s.
(14) Discon n ect wir es fr om pa r k/n eu t r a l posit ion
swit ch a n d veh icle speed sen sor.
(15) Discon n ect gea r sh ift ca ble fr om t r a n sm ission
m a n u a l va lve lever.
(16) Discon n ect t h r ot t le va lve ca ble fr om t r a n sm is-
sion br a cket a n d t h r ot t le va lve lever.
(17) On 4 x 4 m odels, discon n ect sh ift r od fr om
t r a n sfer ca se sh ift lever or r em ove sh ift lever fr om
t r a n sfer ca se.
(18) Su ppor t r ea r of en gin e wit h sa fet y st a n d or
Fig. 16 Crankshaft Position Sensor—2.5L Engine ja ck.
(7) Rem ove t or qu e con ver t er a ccess cover. (19) Ra ise t r a n sm ission sligh t ly wit h ser vice ja ck
(8) If t r a n sm ission is bein g r em oved for over h a u l, t o r elieve loa d on cr ossm em ber a n d su ppor t s.
r em ove t r a n sm ission oil pa n , dr a in flu id a n d r ein st a ll (20) Rem ove bolt s secu r in g r ea r su ppor t a n d cu sh -
pa n . ion t o t r a n sm ission a n d cr ossm em ber. Ra ise t r a n s-
(9) Rem ove skid pla t e for a ccess, if n ecessa r y. m ission sligh t ly, slide exh a u st h a n ger a r m fr om
(10) Rem ove fill t u be br a cket bolt s a n d pu ll t u be br a cket a n d r em ove r ea r su ppor t .
ou t of t r a n sm ission . Ret a in fill t u be sea l. On 4 x 4
XJ TRANSMISSION AND TRANSFER CASE 21 - 95
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(21) Rem ove bolt s a t t a ch in g cr ossm em ber t o fr a m e (8) P osit ion t r a n sm ission on ja ck a n d secu r e it
a n d r em ove cr ossm em ber. wit h sa fet y ch a in s.
(22) Discon n ect t r a n sfer ca se ven t h ose. Th en dis- (9) Ch eck con dit ion of con ver t er dr ivepla t e.
con n ect va cu u m swit ch h a r n ess. Repla ce t h e pla t e if cr a cked, dist or t ed or da m a ged.
(23) On 4 x 4 m odels, r em ove t r a n sfer ca se. Als o be s u re tra n s m is s io n d o w e l p in s a re s e a te d
(24) Rem ove a ll con ver t er h ou sin g bolt s. in e n g in e blo c k a n d p ro tru d e fa r e n o u g h to
(25) Ca r efu lly wor k t r a n sm ission a n d t or qu e con - h o ld tra n s m is s io n in a lig n m e n t.
ver t er a ssem bly r ea r wa r d off en gin e block dowels. (10) Ra ise t r a n sm ission a n d a lign con ver t er wit h
(26) H old t or qu e con ver t er in pla ce du r in g t r a n s- dr ive pla t e a n d con ver t er h ou sin g wit h en gin e block.
m ission r em ova l. (11) Move t r a n sm ission for wa r d. Th en r a ise, lower
(27) Lower t r a n sm ission a n d r em ove a ssem bly or t ilt t r a n sm ission t o a lign con ver t er h ou sin g wit h
fr om u n der t h e veh icle. en gin e block dowels.
(28) To r em ove t or qu e con ver t er, ca r efu lly slide (12) Rot a t e con ver t er so a lign m en t m a r ks scr ibed
t or qu e con ver t er ou t of t h e t r a n sm ission . on con ver t er a r e a lign ed wit h m a r k on dr ivepla t e.
(13) Ca r efu lly wor k t r a n sm ission for wa r d a n d over
INSTALLATION en gin e block dowels u n t il con ver t er h u b is sea t ed in
(1) Ch eck t or qu e con ver t er h u b a n d h u b dr ive cr a n ksh a ft .
n ot ch es for sh a r p edges bu r r s, scr a t ch es, or n icks. (14) In st a ll a n d t igh t en bolt s t h a t a t t a ch t r a n sm is-
P olish t h e h u b a n d n ot ch es wit h 320/400 gr it pa per sion con ver t er h ou sin g t o en gin e block (F ig. 19).
a n d cr ocu s clot h if n ecessa r y. Th e h u b m u st be
sm oot h t o a void da m a gin g pu m p sea l a t in st a lla t ion . CAUTION: Be sure the converter housing is fully
(2) Lu br ica t e con ver t er dr ive h u b a n d oil pu m p seated on the engine block dowels before tighten-
sea l lip wit h t r a n sm ission flu id. ing any bolts.
(3) Lu br ica t e con ver t er pilot h u b wit h t r a n sm is-
sion flu id. (15) In st a ll t or qu e con ver t er a t t a ch in g bolt s.
(4) Align con ver t er a n d oil pu m p. Tigh t en bolt s t o followin g t or qu e.
(5) Ca r efu lly in ser t con ver t er in oil pu m p. Th en • 54 N·m (40 ft . lbs.) wit h 9.5 in . 3-lu g con ver t er
r ot a t e con ver t er ba ck a n d for t h u n t il fu lly sea t ed in • 74 N·m (55 ft . lbs.) wit h 9.5 in . 4-lu g con ver t er
pu m p gea r s. • 74 N·m (55 ft . lbs.) wit h 10.0 in . 4-lu g con ver t er
(6) Ch eck con ver t er sea t in g wit h st eel sca le a n d • 31 N·m (270 in . lbs.) wit h 10.75 in . 4-lu g con -
st r a igh t edge (F ig. 18). Su r fa ce of con ver t er lu gs ver t er
sh ou ld be 1/2 in . t o r ea r of st r a igh t edge wh en con - (16) In st a ll cr a n ksh a ft posit ion sen sor.
ver t er is fu lly sea t ed. (17) In st a ll t r a n sm ission fill t u be a n d sea l. In st a ll
(7) Tem por a r ily secu r e con ver t er wit h C-cla m p. n ew fill t u be sea l in t r a n sm ission befor e in st a lla t ion .
(18) Con n ect t r a n sm ission cooler lin es t o t r a n sm is-
sion .
(19) In st a ll t r a n sfer ca se on t o t r a n sm ission .
(20) In st a ll r ea r cr ossm em ber a n d a t t a ch t r a n s-
m ission r ea r su ppor t t o cr ossm em ber.
(21) Rem ove en gin e su ppor t fixt u r e.
(22) Rem ove t r a n sm ission ja ck.
(23) Con n ect veh icle speed sen sor wir es.
(24) Con n ect wir es t o pa r k/n eu t r a l posit ion swit ch .
(25) In st a ll cr a n ksh a ft posit ion sen sor.
(26) In st a ll con ver t er h ou sin g a ccess cover.
(27) In st a ll exh a u st pipes a n d su ppor t br a cket s, if
r em oved.
(28) In st a ll st a r t er m ot or a n d cooler lin e br a cket .
(29) In st a ll n ew pla st ic r et a in er gr om m et on a n y
sh ift lin ka ge r od or lever t h a t wa s discon n ect ed.
Gr om m et s sh ou ld n ot be r eu sed. Use pr y t ool t o
r em ove r od fr om gr om m et a n d cu t a wa y old gr om -
m et . Use plier s t o sn a p n ew gr om m et in t o lever a n d
t o sn a p r od in t o gr om m et a t a ssem bly.
Fig. 18 Typical Method Of Checking Converter (30) Con n ect gea r sh ift a n d lin ka ge a n d t h r ot t le
Seating ca ble.
(31) Con n ect t r a n sfer ca se sh ift lin ka ge.
21 - 96 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
'
SET-TO SERVICE
BOLT TORQUE
A 35 N·m (26 ft-lbs)
D----
FILL
TUBE
0-RING
TORQUE
SHAFT
BRACKET
J9121-374
SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3995-A
80a983a7
INSTALLATION
(1) P la ce sea l in posit ion on ext en sion h ou sin g.
(2) Dr ive sea l in t o ext en sion h ou sin g wit h Sea l EXTENSION
In st a ller C-3995-A or C-3972 (F ig. 22). HOUSING
(3) Ca r efu lly gu ide pr opeller sh a ft slip yoke in t o BUSHING
80a11095
h ou sin g a n d on t o ou t pu t sh a ft splin es. Align m a r ks
m a de a t r em ova l a n d con n ect pr opeller sh a ft t o r ea r Fig. 23 Bushing Removal—Typical
a xle pin ion yoke.
INSTALLATION
EXTENSION HOUSING BUSHING (1) Align bu sh in g oil h ole wit h oil slot in ext en sion
h ou sin g.
REMOVAL (2) Ta p bu sh in g in t o pla ce wit h In st a ller 6951 a n d
(1) Rem ove h ou sin g yoke sea l. H a n dle C-4171.
(2) In ser t Rem over 6957 in t o ext en sion h ou sin g. (3) In st a ll n ew oil sea l in h ou sin g u sin g Sea l
Tigh t en t ool t o bu sh in g a n d r em ove bu sh in g (F ig. In st a ller C-3995–A (F ig. 24).
23).
21 - 98 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(1) In st a ll n ew r ea r sea l in ext en sion h ou sin g. Use
Tool H a n dle C-4171 a n d Sea l In st a ller C-3860-A t o
SPECIAL in st a ll sea l.
SPECIAL TOOL TOOL (2) P la ce ext en sion h ou sin g ga sket in posit ion on
C-4171 C-3995-A
r ea r of t r a n sm ission .
(3) Slide ext en sion h ou sin g for wa r d a n d over ou t -
pu t sh a ft (F ig. 25).
(4) Gu ide pa r k sh a ft in t o pa r k spr a g a n d pu sh
ext en sion h ou sin g for wa r d u n t il r od pa sses t h r ou gh
open in g beh in d spr a g. It m a y be n ecessa r y t o u se a
wir e t o h old spr a g t o t h e side for r od t o pa ss t h r ou gh .
(5) In st a ll bolt s t o h old ext en sion h ou sin g t o r ea r
of t r a n sm ission .
(6) In st a ll t r a n sfer ca se.
S0a983a7
(7) In st a ll pr opeller sh a ft s.
(8) In st a ll r ea r t r a n sm ission m ou n t a n d skid pla t e.
Fig. 24 Extension Housing Seal Installation (9) Lower veh icle a n d ver ify t r a n sm ission flu id
level. Add flu id a s n ecessa r y.
EXTENSION HOUSING
SPEEDOMETER ADAPTER
REMOVAL Rea r a xle gea r r a t io a n d t ir e size det er m in e speed-
(1) H oist a n d su ppor t veh icle on sa fet y st a n ds.
om et er pin ion r equ ir em en t s.
(2) Su ppor t t r a n sm ission wit h a su it a ble lift in g
device. REMOVAL
(3) Rem ove t r a n sm ission skid pla t e. Refer t o
(1) Ra ise veh icle.
Gr ou p 13, F r a m e a n d Bu m per s, for pr oper pr ocedu r e.
(2) Discon n ect wir es fr om veh icle speed sen sor.
(4) Rem ove pr opeller sh a ft s. Refer t o Gr ou p 3, Dif-
(3) Rem ove a da pt er cla m p a n d scr ew (F ig. 26).
fer en t ia l a n d Dr ivelin e, for pr oper pr ocedu r e.
(4) Rem ove speed sen sor a n d speedom et er a da pt er
(5) Rem ove t r a n sfer ca se.
a s a ssem bly.
(6) Rem ove bolt s h oldin g ext en sion h ou sin g t o
(5) Rem ove speed sen sor r et a in in g scr ew a n d
t r a n sm ission ca se (F ig. 25).
r em ove sen sor fr om a da pt er.
(7) Sepa r a t e ext en sion h ou sin g fr om t r a n sm ission .
(6) Rem ove speedom et er pin ion fr om a da pt er.
(8) Slide ext en sion h ou sin g r ea r wa r d a n d off ou t -
(7) In spect sen sor a n d a da pt er O-r in gs (F ig. 26).
pu t sh a ft (F ig. 25).
Rem ove a n d disca r d O-r in gs if wor n or da m a ged.
(8) In spect t er m in a l pin s in speed sen sor. Clea n
EXTENSIO:RANSMISSION
pin s wit h Mopa r ! elect r ica l spr a y clea n er if dir t y or
HOUSING oxidized. Repla ce sen sor if fa u lt y, or pin s a r e loose,
sever ely cor r oded, or da m a ged.
INSTALLATION
(1) Th or ou gh ly clea n a da pt er fla n ge a n d a da pt er
m ou n t in g su r fa ce in h ou sin g. Su r fa ces m u st be clea n
for pr oper a da pt er a lign m en t a n d speedom et er oper-
a t ion .
(2) In st a ll n ew O-r in gs on speed sen sor a n d speed-
om et er a da pt er if n ecessa r y (F ig. 26).
(3) Lu br ica t e sen sor a n d a da pt er O-r in gs wit h
t r a n sm ission flu id.
S0a47368 (4) In st a ll veh icle speed sen sor in speedom et er
a da pt er. Tigh t en sen sor a t t a ch in g scr ew t o 2-3 N·m
Fig. 25 Extension Housing (15-27 in . lbs.) t or qu e.
(5) In st a ll speedom et er pin ion in a da pt er.
INSTALLATION
(6) Cou n t n u m ber of t eet h on speedom et er pin ion .
Clea r ga sket m a t er ia l fr om sea lin g su r fa ces on
Do t h is befor e in st a llin g a ssem bly in h ou sin g. Th en
ext en sion h ou sin g a n d r ea r of t r a n sm ission . Repla ce
lu br ica t e pin ion t eet h wit h t r a n sm ission flu id.
ou t pu t sh a ft bea r in g, if n ecessa r y.
XJ TRANSMISSION AND TRANSFER CASE 21 - 99
REM OVAL AN D I N STALLAT I ON (Cont inue d)
ITEM TORQUE
A 2-3 N•m (15-27 in. lbs.)
B 10-12 N•m (90-110 in. lbs.)
SENSOR
O-RING
SPEEDOMETER
PINION
VEHICLE
SPEED
SENSOR J9321-385
SWITCH
J9321-386
Fig. 28 Park/Neutral Position Switch
Fig. 27 Index Numbers On Speedometer Pinion
(2) In st a ll n ew sea l on swit ch a n d in st a ll swit ch in
Adapter
ca se. Tigh t en swit ch t o 34 N·m (25 ft . lbs.) t or qu e.
21 - 100 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Test con t in u it y of n ew swit ch wit h 12V t est (8) Discon n ect t h e ca ble eyelet fr om t h e bellcr a n k
la m p. (F ig. 30).
(4) Con n ect swit ch wir es a n d lower veh icle.
(5) Top off t r a n sm ission flu id level.
GEARSHIFT CABLE
REMOVAL
(1) Sh ift t r a n sm ission in t o P a r k.
(2) Rem ove sh ift lever bezel a n d n ecessa r y con sole
pa r t s for a ccess t o sh ift lever a ssem bly.
(3) Discon n ect ca ble a t sh ift lever a n d feed ca ble
t h r ou gh da sh pa n el open in g t o u n der side of veh icle.
(4) Ra ise veh icle.
(5) Disen ga ge ca ble eyelet a t t r a n sm ission sh ift
lever a n d pu ll ca ble a dju st er ou t of m ou n t in g
br a cket . Th en r em ove old ca ble fr om veh icle.
PARK/BRAKE
INTERLOCK CABLE
SHIFT-~~-.,,...
CABLE
80a13876
ACCUMULATOR
PISTON OUTER
SPRING
~~~~""
CONVERTER ~ ~
INNER
SPRING {32RH)
PISTON
SEAL
RINGS
\\CLUTCH ~~ ~ 80a3b190
SOLENOID ~
CONNECTOR aoa3b1ad
Fig. 32 Accumulator Piston And Springs
INSTALLATION
Fig. 31 Solenoid Wire Connector
(1) Ver ify t h a t pa r k/n eu t r a l posit ion swit ch is N OT
(7) Rem ove va lve body a t t a ch in g scr ews. in st a lled. Va lve body ca n n ot be in st a lled wit h swit ch
(8) Lower va lve body en ou gh t o r em ove a ccu m u la - in pla ce. Rem ove swit ch if n ecessa r y.
t or pist on a n d pist on spr in g (F ig. 32). (2) In st a ll n ew sea ls on a ccu m u la t or pist on if n ec-
(9) P u ll va lve body for wa r d t o disen ga ge pa r k r od. essa r y, a n d in st a ll pist on in ca se. Use sm a ll a m ou n t
(10) P u sh m a n u a l lever sh a ft a n d solen oid ca se of pet r oleu m jelly t o h old pist on in pla ce.
con n ect or ou t of t r a n sm ission ca se. (3) P la ce va lve body m a n u a l lever in low (1 posi-
t ion ) t o ea se in ser t in g pa r k r od in t o spr a g.
21 - 102 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Rem ove sn a p r in g t h a t r et a in s r ea r bea r in g on
ou t pu t sh a ft (F ig. 34).
(3) Rem ove bea r in g fr om ou t pu t sh a ft .
INSTALLATION
(1) In st a ll bea r in g on ou t pu t sh a ft . Be su r e r et a in -
in g r in g gr oove in ou t er cir cu m fer en ce of bea r in g is
t owa r d t h e gover n or.
(2) In st a ll r ea r bea r in g r et a in in g sn a p r in g (F ig.
34).
(3) In st a ll ext en sion h ou sin g.
PARK LOCK
REMOVAL
(1) Ra ise veh icle a n d r em ove pr opeller sh a ft .
(2) Rem ove ext en sion h ou sin g.
(3) Slide spr a g sh a ft ou t of ext en sion h ou sin g a n d
r em ove spr a g a n d spr in g (F ig. 38).
(4) Rem ove sn a p r in g a n d slide r ea ct ion plu g a n d
pin a ssem bly ou t of h ou sin g.
(5) If pa r k r od r equ ir es ser vice, it will be n ecessa r y
t o r em ove va lve body.
Fig. 36 Snap Rings And Spacer
INSTALLATION
GOVERNOR/PARK GEAR ASSEMBLY (1) In spect spr a g sh a ft for scor es a n d fr ee m ove-
m en t in h ou sin g a n d spr a g. In spect spr a g a n d con t r ol
r od spr in gs for dist or t ion a n d loss of t en sion . r epla ce
wor n , da m a ged pa r t s a s n ecessa r y.
(2) In spect squ a r e lu g on spr a g for br oken edges.
Ch eck lu gs on pa r k gea r for da m a ge. In spect kn ob on
en d of con t r ol r od for wea r gr ooves, or bein g seized
on r od. Repla ce r od if ben t , if kn ob is wor n /gr ooved,
or it h a s seized on r od. Repla ce pa r k gea r if lu gs a r e
da m a ged. Repla ce t h e pa r k lock r od if it is su spect ed
t h a t t h e r od is n ot t h e cor r ect len gt h .
(3) In st a ll r ea ct ion plu g a n d pin a ssem bly in h ou s-
in g a n d secu r e wit h n ew sn a p r in g (F ig. 38).
(4) P osit ion spr a g a n d spr in g in h ou sin g a n d in ser t
spr a g sh a ft . Be su r e squ a r e lu g on spr a g is t owa r d
pa r k gea r. Also be su r e spr in g is posit ion ed so it
Fig. 37 Governor Body m oves spr a g a wa y fr om gea r.
(3) Slip gover n or body over ou t pu t sh a ft a n d a lign (5) In st a ll ext en sion h ou sin g.
por t t o filt er. (6) In st a ll pr opeller sh a ft a n d lower veh icle.
(4) In st a ll bolt s t o h old gover n or body t o pa r k gea r. (7) Ch eck t r a n sm ission flu id level. Add flu id if n ec-
Tigh t en bolt s t o 11 N·m (95 in . lbs.) t or qu e (F ig. 37). essa r y.
21 - 104 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
GOVERNOR
~
PLUG
AND
PIN CONTROL INTERMEDIATE
ROD 80a3b197
WEIGHT
Fig. 38 Park Lock Fig. 40 Snap Ring, Washer, and Outer Weight
DI SASSEM BLY AN D ASSEM BLY
GOVERNOR AND PARK GEAR
DISASSEMBLY
(1) Rem ove gover n or body fr om t r a n sm ission .
SPECIAL
TOOL
6823
---~,r---
(2) Clea n a n d in spect gover n or filt er (F ig. 39).
(3) Rem ove sn a p r in g a n d wa sh er t h a t secu r e gov-
er n or weigh t a ssem bly in body (F ig. 40).
(4) Rem ove gover n or weigh t a ssem bly fr om gover-
n or body bor e. NUT
(5) Slide in t er m edia t e a n d in n er weigh t fr om ou t er DRIVER
weigh t .
(6) P osit ion in t er m edia t e weigh t on su it a ble size
socket (F ig. 41).
(7) P u sh in n er weigh t down wa r d wit h n u t dr iver.
Th en r em ove in n er weigh t sn a p r in g wit h Miller INTERMEDIATE
P lier Tool 6823 (F ig. 41). WEIGHT
(8) Rem ove in n er weigh t a n d spr in g fr om in t er m e-
SUITABLE
dia t e weigh t .
SIZE
SOCKET J9521-33
(1) Rem ove scr ews a t t a ch in g a dju st in g scr ew Fig. 44 Adjusting Screw Bracket, Springs, Valve
br a cket t o va lve body a n d t r a n sfer pla t e. H old Removal
br a cket fir m ly a ga in st spr in g for ce wh ile r em ovin g (10) Rem ove pa r k r od E -clip a n d sepa r a t e r od fr om
la st scr ew. m a n u a l lever (F ig. 48).
21 - 106 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(14) Rem ove con ver t er clu t ch va lve, fa il sa fe va lve,
a n d spr in gs (F ig. 51).
(15) Tu r n va lve body over so t r a n sfer pla t e is fa c-
in g u pwa r d (F ig. 52). Wit h va lve body in t h is posi-
t ion , va lve body ch eck ba lls will r em a in in pla ce a n d
n ot fa ll ou t wh en t r a n sfer pla t e is r em oved.
(16) Rem ove scr ews a t t a ch in g t r a n sfer pla t e t o
va lve body (F ig. 52).
(17) Rem ove t r a n sfer pla t e a n d sepa r a t or pla t e
fr om va lve body (F ig. 52). Not e posit ion of filt er a n d
DETENT BALL AND SPRING HOUSING J9321-121
clu t ch solen oid for r efer en ce. Rem ove va lve body
Fig. 45 Securing Detent Ball And Spring With ch eck ba lls.
Retainer Tool (18) P osit ion t r a n sfer pla t e on ben ch so sepa r a t or
pla t e, a n d filt er a r e fa cin g u p. Th is will a void h a vin g
r ea r clu t ch a n d r ea r ser vo ch eck ba lls fa ll ou t wh en
pla t es a r e sepa r a t ed.
~E-CLIP
VALVE
BODY
Fig. 46 Manual And Throttle Levers PARK
ROD J9121-81
VALVE
BODY
TORQUE
80a48368
CONVERTER
CLUTCH
Fig. 47 Manual Valve SOLENOID
(11) Rem ove con ver t er clu t ch solen oid fr om sepa r a -
t or pla t e (F ig. 49). A T25 t or x bit is r equ ir ed t o Fig. 49 Converter Clutch Solenoid
r em ove solen oid a t t a ch in g scr ew.
(12) Rem ove scr ews a t t a ch in g con ver t er clu t ch (19) Rem ove scr ews a t t a ch in g sepa r a t or pla t e t o
m odu le t o va lve body a n d r em ove m odu le a n d con - t r a n sfer pla t e (F ig. 53).
n ect in g t u be (F ig. 50). (20) Not e posit ion of filt er, r ea r clu t ch ser vo a n d
(13) Rem ove scr ews a t t a ch in g en d cover pla t e t o r ea r ser vo ch eck ba lls for a ssem bly r efer en ce
t or qu e con ver t er m odu le (F ig. 51). (F ig. 53) a n d (F ig. 54).
XJ TRANSMISSION AND TRANSFER CASE 21 - 107
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(22) Rem ove sh u t t le va lve E -clip a n d r em ove sec-
on da r y spr in g a n d spr in g gu ides fr om en d of va lve
(F ig. 56).
J9121-178
T~~~~~~~ODULE
NVERTER
COVER
PLATE
REAR TRANSFER
SERVO PLATE
CHECK
BALL
MODULE CONNECTING
TUBE 80a410c0
REAR
CLUTCH
CHECK
BALL
B0a47396
SHUTTLE
VALVE
END PLATE
i
VALVE I
BODY
J
'
1
el,§
B0a47394
SHUTTLE
VALVE
THROTTLE
PLUG
2-3
GOVERNOR
PLUG
2-3 SHIFT
VALVE
END
PLATE
KICKDOWN LIMIT
VALVE BODY
80a13872
REAR
CLUTCH
CHECK
BALL
80a47396
TRANSFER
PLATE
COVER
PLATE
~E-CLIP
MODULE CONNECTING
PARK
TUBE ROD J9121-81
80a410c0
J9121-178
TORQUE
CONVERTER
CLUTCH
SOLENOID
VALVE
BODY
Fig. 66 Converter Clutch Solenoid
(43) In ser t t h r ot t le lever in t o gr oove in m a n u a l
va lve (F ig. 71).
(44) In st a ll sea l, wa sh er, a n d E -clip t o r et a in m a n -
u a l sh a ft t o va lve body (F ig. 70). 80a48368
(45) In st a ll swit ch va lve a n d spr in g, pr essu r e r eg-
u la t or va lve a n d spr in g, kickdown va lve a n d spr in g, Fig. 69 Manual Valve
a n d t h r ot t le va lve in t o va lve body (F ig. 72).
21 - 112 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
TRANSMISSION
DISASSEMBLY
(1) Rem ove t r a n sm ission fr om veh icle.
(2) In st a ll a su it a ble t a il sh a ft h ou sin g plu g t o
a void con t a m in a t in g in t er n a l com pon en t s wit h clea n -
in g solven t s.
(3) Clea n ext er ior of t r a n sm ission wit h su it a ble
solven t or pr essu r e wa sh er.
(4) Rem ove t or qu e con ver t er fr om t r a n sm ission .
(5) Rem ove t h r ot t le a n d sh ift lever s fr om va lve
body m a n u a l sh a ft a n d t h r ot t le lever sh a ft .
(6) Mou n t t r a n sm ission in r epa ir st a n d C-3750-B
VALVE or sim ila r t ype st a n d (F ig. 73).
BODY (7) Rem ove ext en sion h ou sin g.
(8) Rem ove flu id pa n .
Fig. 70 Manual And Throttle Levers (9) Rem ove pa r k/n eu t r a l posit ion swit ch a n d sea l
(F ig. 74).
(10) Rem ove va lve body.
(11) Rem ove a ccu m u la t or spr in g a n d pist on (F ig.
75).
TRANSMISSION
VALVE
ADJUSTER LINE Fig. 73 Repair Stand
BRACKET PRESSURE NEUTRAL
ADJUSTER SWITCH
THROTTLE
PRESSURE ADJUSTER 80a3f1ea
FRONT
CLUTCH
AND
DRUM
THRUST
PLATE
80a3b191
Fig. 79 Front/Rear Clutch Assemblies Fig. 81 Output Shaft Thrust Plate and Washer
TRANSMISSION
//HOUSING
//" 80a3b192
TRANSMISSION
HOUSING
J9421-186
J9121-136
~
OVERRUNNING
CLUTCH
I
TRANSMISSION
//HOUSING
//" 80a3b192
FRONT
CLUTCH
AND
DRUM
80a3b191
PILOT
Fig. 108 Front Band Linkage Installation STUD
TOOLS
C-3288-B
J9121-195
CLUTCH
1/L - ' J ~ - - - RACE
HUB OF
LOW-REVERSE
DRUM
SEAL
RING PISTON
ROD
GUIDE
SERVO
SERVO
OVERRUNNING SPRING
CLUTCH
J9121-135 RING 80a3b194
Fig. 117 Temporary Assembly Of Clutch And Drum Fig. 119 Front Servo
To Check Operation
REAR SERVO PISTON
(3) Rem ove a n d disca r d ser vo com pon en t O-r in g
a n d sea l r in gs. DISASSEMBLY
(1) Rem ove sm a ll sn a p r in g a n d r em ove plu g a n d
ASSEMBLY spr in g fr om ser vo pist on (F ig. 120).
(1) Lu br ica t e n ew O-r in g a n d sea l r in gs wit h (2) Rem ove a n d disca r d ser vo pist on sea l r in g.
pet r oleu m jelly a n d in st a ll t h em on pist on , gu ide a n d
r od. ASSEMBLY
(2) In st a ll r od in pist on . In st a ll spr in g a n d wa sh er (1) Lu br ica t e pist on a n d gu ide sea ls wit h pet r o-
on r od. Com pr ess spr in g a n d in st a ll sn a p r in g (F ig. leu m jelly. Lu br ica t e ot h er ser vo pa r t s wit h Mopa r !
119). ATF P lu s 3, Type 7176, t r a n sm ission flu id.
(3) Set ser vo com pon en t s a side for in st a lla t ion du r- (2) In st a ll n ew sea l r in g on ser vo pist on .
in g t r a n sm ission r ea ssem bly. (3) Assem ble pist on , plu g, spr in g a n d n ew sn a p
r in g.
(4) Lu br ica t e pist on sea l lip wit h pet r oleu m jelly.
XJ TRANSMISSION AND TRANSFER CASE 21 - 123
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J9121-64
J9321-214
REACTION
SHAFT
y
SUPPORT I
'
SPECIAL
TOOL
C-4171 SPECIAL
TOOL
SP-5117
J9221-242
J9221-243
Fig. 126 Removing Oil Pump Bushing Fig. 128 Replacing Reaction Shaft Support Bushing
ASSEMBLY
(1) Lu br ica t e gea r bor e in pu m p h ou sin g wit h
t r a n sm ission flu id.
(2) Lu br ica t e pu m p gea r s wit h t r a n sm ission flu id.
(3) Su ppor t pu m p h ou sin g on wood blocks (F ig.
129).
(4) In st a ll ou t er gea r in pu m p h ou sin g (F ig. 129).
Gea r ca n be in st a lled eit h er wa y (it is n ot a on e-wa y
fit ).
(5) In st a ll pu m p in n er gea r (F ig. 130).
REACTION
SHAFT
PUMP SUPPORT
HOUSING
J9321-219
SPECIAL_ _ _ _ _ _ _
TOOL
C-4193
PUMP
BODY
PUMP
SEAL
J9321-183
SUPPORT
HUB J9321-218
Fig. 133 Pump Oil Seal Installation
Fig. 131 Hub Seal Ring Position
21 - 126 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
RETAINER HUB
SEAL
SNAP RING
(WAVED)
SPRING
RETAINER
SNAP RING
PRESSURE
PLATE
SPRING
FRONT CLUTCH RETAINER RETAINER
CLUTCH PLATES
J9321-222
SMALL TABS
ON RETAINER
FACE
UPWARD
J9321-224
J9121-146
PISTON 80a483e9
,,....,.,...,.,__ REAR
REAR CLUTCH
CLUTCH THRUST
RETAINER SHAFT WASHER
FRONT (FIBER)
SEAL
RING
(TEFLON) CLUTCH
PACK
SNAP
RING
(SELECTIVE)
WAVE
SPRING
J9121-539
ASSEMBLY
(1) Soa k clu t ch discs in t r a n sm ission flu id wh ile
a ssem blin g ot h er clu t ch pa r t s.
(2) In st a ll n ew sea l r in gs on clu t ch r et a in er h u b
Fig. 141 Removing/Installing Input Shaft Snap-Ring
a n d in pu t sh a ft if n ecessa r y (F ig. 142).
(a ) Be su r e clu t ch h u b sea l r in g is fu lly sea t ed in (6) In st a ll n ew sea ls on clu t ch pist on . Be su r e lip
gr oove a n d is n ot t wist ed. of ea ch sea l fa ces in t er ior of clu t ch r et a in er.
(3) Lu br ica t e splin ed en d of in pu t sh a ft a n d clu t ch (7) Lu br ica t e lip of pist on sea ls wit h gen er ou s
r et a in er wit h t r a n sm ission flu id. Th en pr ess in pu t qu a n t it y of Mopa r ! Door E a se. Th en lu br ica t e
sh a ft in t o r et a in er. Use a su it a bly sized pr ess t ool t o r et a in er h u b a n d bor e wit h ligh t coa t of t r a n sm ission
su ppor t r et a in er a s close t o in pu t sh a ft a s possible. flu id.
(4) In st a ll in pu t sh a ft sn a p-r in g (F ig. 141). (8) In st a ll clu t ch pist on in r et a in er. Use t wist in g
(5) In ver t r et a in er a n d pr ess in pu t sh a ft in oppo- m ot ion t o sea t pist on in bot t om of r et a in er. A t h in
sit e dir ect ion u n t il sn a p-r in g is sea t ed.
XJ TRANSMISSION AND TRANSFER CASE 21 - 129
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
st r ip of pla st ic (a bou t 0.020" t h ick), ca n be u sed t o
BE SURE
gu ide sea ls in t o pla ce if n ecessa r y. RING ENDS
ARE HOOKED
CAUTION: Never push the clutch piston straight in. TOGETHER
This will fold the seals over causing leakage and AFTER INSTALLATION
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. METAL
REAR
(9) In st a ll pist on spr in g in r et a in er a n d on t op of SEAL
pist on (F ig. 145). Con ca ve side of spr in g fa ces down - RING
wa r d (t owa r d pist on ).
(10) In st a ll wa ve spr in g in r et a in er (F ig. 145). Be
su r e spr in g is com plet ely sea t ed in r et a in er gr oove.
( TEFLON
FRONT
SEAL
RING
(SQUEEZE RING
TOGETHER SLIGHTLY
BEFORE INSTALLATION
FOR BETTER FIT)
J9121-151
INPUT
SHAFT
SEAL
RINGS
J9121-538
REAR
CLUTCH
RETAINER
WAVE
SPRING
J9121-153
Fig. 145 Piston Spring/Wave Spring Position Fig. 147 Installing Rear Clutch Thrust Washer
• .098–.100 in . (5) Sepa r a t e fr on t a n n u lu s a n d pla n et a r y gea r s
• .095–.097 in . (F ig. 150).
• .083–.085 in . (6) Rem ove fr on t pla n et a r y gea r fr on t t h r u st
• .076–.078 in . wa sh er fr om a n n u lu s gea r h u b.
• .071–.073 in . (7) Sepa r a t e a n d r em ove dr ivin g sh ell, r ea r pla n e-
• .060–.062 in . t a r y a n d r ea r a n n u lu s fr om ou t pu t sh a ft (F ig. 151).
(16) Coa t r ea r clu t ch t h r u st wa sh er wit h pet r o- (8) Rem ove fr on t pla n et a r y r ea r t h r u st wa sh er
leu m jelly a n d in st a ll wa sh er over in pu t sh a ft a n d fr om dr ivin g sh ell.
in t o clu t ch r et a in er (F ig. 147). Use en ou gh pet r oleu m (9) Rem ove t a bbed t h r u st wa sh er s fr om r ea r pla n -
jelly t o h old wa sh er in pla ce. et a r y gea r.
(10) Rem ove lock r in g t h a t r et a in s su n gea r in
DIAL INDICATOR dr ivin g sh ell. Th en r em ove su n gea r, spa cer a n d
t h r u st pla t es.
GAUGE DRIVING
BAR SHELL PLANETARY
SNAP
RING
~
80a483ec
REAR
ANNULUS
GEAR
THRUST TABBED
WASHER THRUST
WASHER
FRONT
FRONT THRUST
PLANETARY WASHER
REAR
PLANETARY
J9421-177
J9421-178
J9121-158
REAR
THRUST
PLATE J9121-162
J9121-159
WOOD
BLOCK
J9121-163
SPACER
FRONT
PLANETARY
GEAR
J9121-165
J9121-167
FRONT
ANNULUS
J9421-179
Fig. 161 Installing Rear Thrust Washer On Front Fig. 163 Positioning Thrust Plate On Front Annulus
Planetary Gear Support
21 - 134 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
WASHER FRONT
FLAT ANNULUS
ALIGNS THRUST
WITH FLAT WASHER
ON PLANETARY
HUB
TAB REAR
FACES ANNULUS
FRONT GEAR
J9121-168
FRONT
ANNULUS
SNAP
RING J9121-171
\
Fig. 167 Checking Planetary Geartrain End Play
CLEAN I N G AN D I N SPECT I ON
GOVERNOR AND PARK GEAR
Th or ou gh ly clea n a ll t h e gover n or pa r t s in a su it -
a ble clea n in g solu t ion bu t do n ot u se a n y t ype of
ca u st ic clea n in g a gen t s.
Th e gover n or weigh t com pon en t s (F ig. 168) a n d t h e
gover n or va lve (F ig. 169), m u st slide fr eely in t h eir
bor es wh en clea n a n d dr y. Min or su r fa ce scr a t ch es
a n d bu r r s ca n be sm oot h ed wit h cr ocu s clot h .
Fig. 165 Installing Front Annulus Snap Ring Th e a lu m in u m gover n or va lve a n d ou t er weigh t
SELECTIVE
h a ve a h a r d coa t in g on t h em . Ch eck con dit ion of t h is
SNAP coa t in g ca r efu lly. Do n ot r eu se eit h er pa r t if t h e coa t -
RING in g is da m a ged.
In spect t h e gover n or weigh t spr in g for dist or t ion .
Repla ce t h e spr in g, if dist or t ed, colla psed, or br oken .
Clea n t h e filt er in solven t a n d dr y it wit h com pr essed
a ir. Repla ce t h e filt er, if da m a ged. In spect t h e pa r k
gea r for ch ipped or wor n gea r t eet h or da m a ged r in g
gr ooves. Repla ce t h e gea r, if da m a ged.
Ch eck t h e t eet h on t h e pa r k gea r for wea r or da m -
a ge. Repla ce t h e gea r if n ecessa r y. In spect t h e m et a l
sea l r in gs on t h e pa r k gea r h u b. Repla ce t h e r in gs
on ly if sever ely wor n , or br oken .
J9121-170
INTERMEDIATE
WEIGHT
SNAP
RING
INNER
WEIGHT
SPRING
INNER
WEIGHT J9521-23
SEAL
GOVERNOR
RING
BODY
(PLAIN
END)
~
FILTER'
~
{f~HIN) SNAP
RING
.
.
1
GOVERNOR
SNAP
RING
(THICK)
GOVERNOR
WEIGHT
ASSEMBLY
WASHER
ti
J9521-30
21 - 136 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
J9121-46
PARALLEL
JAW
SNAP
RING
PLIERS
J9121-45
SHUTTLE
VALVE
THROTTLE
PLUG
2-3
GOVERNOR
PLUG
2-3 SHIFT
VALVE
END
PLATE
KICKDOWN LIMIT
VALVE BODY
80a13872
T
Repla ce t h e clu t ch discs if wa r ped, wor n , scor ed,
bu r n ed or ch a r r ed, or if t h e fa cin g is fla kin g off.
Repla ce t h e st eel pla t es if h ea vily scor ed, wa r ped, or
br oken . Be su r e t h e dr ivin g lu gs on t h e pla t es a r e in
good con dit ion . Th e lu gs m u st n ot be ben t , cr a cked or
da m a ged in a n y wa y.
PISTON J9121-64 Repla ce t h e clu t ch spr in g a n d spr in g r et a in er if
eit h er is dist or t ed, wa r ped or br oken .
Fig. 175 Rear Servo Components Ch eck t h e lu g gr ooves in t h e clu t ch r et a in er. Th e
st eel pla t es sh ou ld slide fr eely in t h e slot s. Repla ce
OIL PUMP AND REACTION SHAFT SUPPORT t h e r et a in er if t h e gr ooves a r e wor n or da m a ged.
(1) Clea n pu m p a n d su ppor t com pon en t s wit h sol- Ch eck a ct ion of t h e ch eck ba ll in t h e r et a in er (F ig.
ven t a n d dr y t h em wit h com pr essed a ir. 176). Th e ba ll m u st m ove fr eely a n d n ot st ick.
(2) Ch eck con dit ion of t h e sea l r in gs a n d t h r u st
wa sh er on t h e r ea ct ion sh a ft su ppor t . Th e sea l r in gs NOTE: Inspect the clutch retainer bushings care-
do n ot n eed t o be r epla ced u n less cr a cked, br oken , or fully (Fig. 177). The retainer bushings are NOT ser-
sever ely wor n . viceable. It will be necessary to replace the retainer
(3) In spect t h e pu m p a n d su ppor t com pon en t s. if either bushing is scored, or worn.
Repla ce t h e pu m p or su ppor t if t h e sea l r in g gr ooves
or m a ch in ed su r fa ces a r e wor n , scor ed, pit t ed, or In spect t h e pist on a n d r et a in er sea l su r fa ces for
da m a ged. Repla ce t h e pu m p gea r s if pit t ed, wor n n icks or scr a t ch es. Min or scr a t ch es ca n be r em oved
ch ipped, or da m a ged. wit h cr ocu s clot h . H owever, r epla ce t h e pist on a n d/or
(4) In spect t h e pu m p bu sh in g. Th en ch eck t h e r et a in er if t h e sea l su r fa ces a r e ser iou sly scor ed.
r ea ct ion sh a ft su ppor t bu sh in g. Repla ce eit h er bu sh -
in g on ly if h ea vily wor n , scor ed or da m a ged. It is n ot REAR CLUTCH
n ecessa r y t o r epla ce t h e bu sh in gs u n less t h ey a r e Clea n t h e clu t ch com pon en t s wit h solven t a n d dr y
a ct u a lly da m a ged. t h em wit h com pr essed a ir.
(5) In st a ll t h e gea r s in t h e pu m p body a n d m ea - Ch eck con dit ion of t h e in pu t sh a ft sea l r in gs. It is
su r e pu m p com pon en t clea r a n ces a s follows: n ot n ecessa r y t o r em ove or r epla ce r in gs u n less t h ey
(a ) Clea r a n ce bet ween ou t er gea r a n d r ea ct ion a r e br oken , cr a cked, or n o lon ger secu r ely h ooked
sh a ft h ou sin g sh ou ld be 0.010 t o 0.063 m m (0.0004 t oget h er.
t o 0.0025 in .). Clea r a n ce bet ween in n er gea r a n d In spect t h e in pu t sh a ft splin es a n d m a ch in ed su r-
r ea ct ion sh a ft h ou sin g sh ou ld be 0.010 t o 0.063 fa ces. Ver y m in or n icks or scr a t ch es ca n be sm oot h ed
m m (0.0004 t o 0.0025 in .). Bot h clea r a n ces ca n be off wit h cr ocu s clot h . r epla ce t h e sh a ft if t h e splin es
m ea su r ed a t t h e sa m e t im e by: a r e da m a ged, or a n y of t h e m a ch in ed su r fa ces a r e
(I) In st a llin g t h e pu m p gea r s in t h e pu m p sever ely scor ed.
h ou sin g.
21 - 140 TRANSMISSION AND TRANSFER CASE XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
RETAINER Ch eck t h r u st wa sh er con dit ion . Wa sh er t h ickn ess
CHECK BALL sh ou ld be 1.55 t o 1.60 m m (0.061 t o 0.063 in .).
Repla ce t h e wa sh er if wor n or da m a ged.
Ch eck con dit ion of t h e t wo sea l r in gs on t h e in pu t
sh a ft a n d t h e sin gle sea l r in g on t h e pist on r et a in er
h u b. Repla ce t h e sea l r in gs on ly if sever ely wor n ,
cr a cked, or ca n n ot be h ooked t oget h er.
~
t on /lever sh ou ld n ot m ove.
~I
INCH-POUND
TORQUE
WRENCH '- ADAPTER
~
" - C-3705
(TIGHTEN ADJUSTING
SCREW TO ONLY
5 N·m/50 IN-LBS
IF ADAPTER IS USED)
J9121-233
Fig. 184 Rear Band Adjustment Screw Location
Fig. 183 Band Adjustment Adapter Tool
Lin e a n d t h r ot t le pr essu r es a r e in t er depen den t
REAR BAND ADJUSTMENT beca u se ea ch a ffect s sh ift qu a lit y a n d t im in g. As a
Th e t r a n sm ission oil pa n m u st be r em oved for r esu lt , bot h a dju st m en t s m u st be per for m ed pr oper ly
a ccess t o t h e r ea r ba n d a dju st in g scr ew. a n d in t h e cor r ect sequ en ce. Adju st lin e pr essu r e fir st
(1) Ra ise veh icle. a n d t h r ot t le pr essu r e la st .
(2) Rem ove t r a n sm ission oil pa n a n d dr a in flu id.
(3) Loosen ba n d a dju st in g scr ew lockn u t 5-6 t u r n s. LINE PRESSURE ADJUSTMENT
Be su r e a dju st in g scr ew t u r n s fr eely in lever. Mea su r e dist a n ce fr om t h e va lve body t o t h e in n er
(4) Tigh t en a dju st in g scr ew t o 5 N·m (41 in . lbs.) edge of t h e a dju st in g scr ew wit h a n a ccu r a t e st eel
(F ig. 184). sca le (F ig. 185).
(5) Ba ck off a dju st in g scr ew 7 t u r n s. Dist a n ce sh ou ld be 33.4 m m (1-5/16 in .).
(6) H old a dju st in g scr ew in pla ce a n d t igh t en lock- If a dju st m en t is r equ ir ed, t u r n t h e a dju st in g scr ew
n u t t o 34 N·m (25 ft . lbs.) t or qu e. in , or ou t , t o obt a in r equ ir ed dist a n ce set t in g.
(7) P osit ion n ew ga sket on oil pa n a n d in st a ll pa n
on t r a n sm ission . Tigh t en pa n bolt s t o 17 N·m (13 ft . NOTE: The 33.4 mm (1-5/16 in.) setting is an
lbs.) t or qu e. approximate setting. Manufacturing tolerances may
(8) Lower veh icle a n d r efill t r a n sm ission wit h make it necessary to vary from this dimension to
Mopa r ! ATF P lu s 3, Type 7176, flu id. obtain desired pressure.
- - - OIL PRESSURES - - -
'
'-> 1·--======-=-~~~-
••
21 - 145
OIL FILTER
J9021-160
HYDRAULIC FLOW IN PARK/NEUTRAL
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
21 - 146
GOVERNOR VAL VE REAR SERVO
FRONT CLUTCH
- - - OIL PRESSURES---
LINE 75 PSI - I CONVERTER 5-75 PSI ~
PUMP SUCTION ~
b.:.w:,.:.:J LUBRICATION 5-30 PSI k ::::J
THROTTLE 40 PSI ~ 1-2 SHIFT CONTROL
......... .... .. 25-35 P S I ~
,- - - - - - • • • • • • - • • • -1 OIL FILTER GOVERNOR 0-75 PSI IIIIDIII TORQUE CONVERTER
SELECTOR LEVER IN
DRIVE (BREAKAWAY)
HALF THROTTLE
XJ
HYDRAULIC FLOW IN D-FIRST GEAR
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
XJ
GOVERNOR VALVE REAR SERVO
FRONT CLUTCH ACCUMULATOR
CONVERTER
CLUTCH
VALVE
t:=-=-=---=--=--=--=-----.~=============::::::::=======:::::::======~--::::,.., ; 11 : /
ELECTRONIC TUBE
SOLENOID
(32RH ONLY)
FRONT
- - - O I L PRESSURES---
LINE 75 PSI - I CONVERTER 5-75 PSI ~
PUMP SUCTION ~
~
LUBRICATION 5-30 PSI H: ::j
THROTTLE 40 P S I ~ 1-2 SHIFT CONTROL
25-35 P S I ~
....... ... OIL FILTER GOVERNOR 6-75 PSI IIDDD
SELECTOR LEVER IN TORQUE CONVERTER-
21 - 147
DRIVE (SECOND)
HALF THROTTLE
HYDRAULIC FLOW IN D-SECOND GEAR
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
21 - 148
GOVERN O R VA LVE REAR SERVO
FRONT CLUTCH
TO
LUBRICATION
- - - O I L PRESSURES---
LINE 57-94 PSI - I CONVERT!:R 5-75 PSI ~
PUMP SUCTION ~
~ LUBRICATION 5-30 PSI H::: J
THROTTLE 0-94 P S I ~
. . . . .. .. ... OILFILTER
GOVERNOR 6-94 PSI ffllDD TORQUE CONVERTER
SELECTOR LEVER IN
DRIVE (DIRECT)
J9521 -81
XJ
HYDRAULIC FLOW IN D-THIRD GEAR
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
XJ
GOVERNOR VALVE REAR SERVO
FRONT CLUTCH ACCUMULATOR
CONVERTER
CLUTCH
VALVE
TUBE
ELECTRONIC
SOLENOID
(32RH ONLY)
THROTTLE
4
PSI
0-94 PSI ~
=
- - - O I L PRESSURES---
21 - 149
DRIVE-CONVERTER
CLUTCH ENGAGED J9521-82
HYDRAULIC FLOW IN D-THIRD GEAR (CONVERTER CLUTCH APPLIED)
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
21 - 150
GOVERNOR VALVE REAR SERVO
REAR CLUTCH FRONT CLUTCH ACCUMULATOR
WITH
SOLENOID
- - - - OIL PRESSURES----
LINE 57-94 PSI - I CONVERTER 5-94 PSI ~
PUMP SUCTION ~
~
LUBRICATION 5-30 PSI re::::::: I
55-70 PSI ~
THROTTLE 0-75 P S I ~ CONTROL r.7771
l-2 SHIFT
XJ
HYDRAULIC FLOW AT PART THROTTLE 3-2 KICKDOWN
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
XJ
GOVERNOR VALVE
FRONT CLUTCH ACCUMULATOR
r.::::::.========:--:::..=-=-=-=-=-=-=-=-=-=-=-=-==-~::.-=-=-=-=-=-=-='..==-=-=-=-=-=-=-=-=---~--- ; 11 : \--. 1
WITHOUT
SOLENOID
ELECTRONIC TUBE
SOLENOID
(32RH ONLY)
- - - O I L PRESSURES---
LINE 94 PSI - I CONVERTER 5-94 PSI ~
PUMP SUCTION ~
~ LUBRICATION 5-30 PSI k :< J
THROTTLE 94 P S I ~
1-2 SHIFT CONTROL
55-70 PSI l7777l
lL'.LL'.LJ
GOVERNOR 30-73 PSI IIIDII
SELECTOR LEVER IN DRIVE TORQUE CONVERTER
21 - 151
(FULL THROTTLE KICKDOWN )
J9521-84
HYDRAULIC FLOW AT FULL THROTTLE 3-2 KICKDOWN
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
21 - 152
GOVERNOR V AL VE REAR SERVO
REAR CLUTCH FRONT CLUTCH ACCUMULATOR
-::=...--=---=------=--~ -,--_-_-_-_-_-_-_-_-_-~--._,. . . ,
'-'--r,-- _- _- _- _-_ _,,,_-,,,'--r-- _- _- _-_ - _- _--------,.., : 11 : ' I'
WITH
SOLENOID
~~J'X?Z&iiVAid¼Z¾¼d&dV:o/)-A&?i?¼Zq/ .....
~AJ ~ O O L E R
~ :c-=J1
TO
UBRICATION
o- 8
....a..______(L
SWITCH
- - - OIL PRESSURES--- VALVE
LINE 57 PSI - I CONVERTER 5-57 PSI ~
PUMP SUCTION ~
~
LUBRICATION 5-30 PSI j':: : : j
GOVERNOR 6-57 PSI DJDII 1-2 SHIFT CONTROL
• l • l•[-J..,.....'.~ ' ._
•• ·- ::c-: ... ... ·- 25-35 PSlfim
c ?.:-·-·.·.-.·.·.·.·.·.·.·.·j OIL FILTER
TORQUE CONVERTER
SELECTOR LEVER IN
TWO (MANUAL SECOND)
CLOSED THROTTLE J9521-85
XJ
HYDRAULIC FLOW IN MANUAL SECOND
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
XJ
GOVERNOR VAL VE REAR SERVO
FRONT CLUTCH
CONVERTER
CLUTCH
VALVE
TUBE
g~g
-'l__Q__ FRONT
SWITCH
- - - O I L PRESSURES - -- VALVE
LINE 57 PSI - I CONVERTER 5-57 PSI ~
PUMP SUCTION ~
~ LUBRICATION 5-30 PSI I: :I
ONTROL l777J
1-2 SHIFT C 25-35 P S I ~
21 - 153
ONE (MANUAL LOW)
CLOSED THROTTLE
HYDRAULIC FLOW IN MANUAL LOW
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
21 - 154
GOVERNOR VALVE
FRONT CLUTCH
-~--------I~~ ~
I/TUBE
~~'aU-;rf!~.h
TO
LUBRICATION
TORQUE CONVERTER
- - - O I L PRESSURES---
LINE 160-270 PSI . . I CONVERTER 95-130PSI ~
PUMP SUCTION CTI LUBRICATION 60-85 PSI I::::: :::j
THROTTLE 0-100 P S I ~ 1-2 SHIFT CONTROL
• • •• • < • • • • • < < X • <
25-70 P S I ~
,, .. ,., OIL FILTER
SELECTOR LEVER LINE TO THROTTLE Bl
IN REVERSE VALVE 50-100 PSI
XJ
HYDRAULIC FLOW IN REVERSE
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
XJ
REAASftNO FRONTS8Ml ACCUMIJlATOR OVEROIIM
UUTCH
-
LINE PRESSURE
(55-62 psi)
- 1-2 SHIFT
CONTROL
(25-35 psi)
1111111111111111111111111111111111
GOVERNOR
PRESSURE
(0-30 psi)
l(tf.ltExl':i]!t~j(1l1vl
CONVERTER/
!::::::::::;::::::::~
PUMP
SUCTION
[}-T};:=i·':i3-H)'.'.j]
OVERDRIVE
PRE-FILL
PRESSURE
10 UAM:AllON
flONI
QI/IOI (0-5 psi)
u.lCAllON
21 - 155
J9421-163
HYDRAULIC FLOW IN MANUAL FIRST GEAR (1)
SCH EM AT I CS AN D DI AGRAM S (Cont inue d)
21 - 156
~
OVERDRIVE
CLUTCH
~
1-2 SHIFT
CONTROL
(25-35 psi)
lllllllllllllllllllllllllllll
GOVERNOR
PRESSURE
(6-57 psi)
CONVERTER/
LUBE PRESSURE
(5-57 psi)
1::::::::::::::::::::1
PUMP
SUCTION
1: ·:,; :) ;:-;::.:/;,-.:': I
··r--4 OVERDRIVE
•• h-TTnj PRE-FILL
PRESSURE
TO LUIIIICATION
FRONT (0-5 psi)
aUTCH
U-UICATION
J9421-164
XJ
HYDRAULIC FLOW IN MANUAL SECOND GEAR (2)
XJ TRANSMISSION AND TRANSFER CASE 21 - 157
SPECI FI CAT I ON S
30RH AUTOMATIC TRANSMISSION
GENERAL
PRESSURE TEST—ALL
TORQUE
D ES CRIP TION TORQU E
Bolt , t or qu e con ver t or . . . . . . . . . 31 N·m (23 ft . lbs.)
Bolt /n u t , cr ossm em ber . . . . . . . . 68 N·m (50 ft . lbs.)
Bolt , dr ivepla t e t o cr a n ksh a ft . . . 75 N·m (55 ft . lbs.)
P lu g, fr on t ba n d r ea ct ion . . . . . . 17 N·m (13 ft . lbs.)
Lockn u t , fr on t ba n d a dj. . . . . . . . 34 N·m (25 ft . lbs.)
Swit ch , pa r k/n eu t r a l . . . . . . . . . . 34 N·m (25 ft . lbs.)
Bolt , flu id pa n . . . . . . . . . . . . . . 17 N·m (13 ft . lbs.)
Bolt , oil pu m p . . . . . . . . . . . . . . . 20 N·m (15 ft . lbs.) Retainer, Detent Ball and Spring—6583
Bolt , over r u n n in g clu t ch ca m . . . 17 N·m (13 ft . lbs.)
P lu g, pr essu r e t est por t . . . . . . . 14 N·m (10 ft . lbs.)
Bolt , r ea ct ion sh a ft su ppor t . . . . 20 N·m (15 ft . lbs.)
Lockn u t , r ea r ba n d . . . . . . . . . . . 41 N·m (30 ft . lbs.)
Bolt . speedom et er a da pt er . . . . . . 11 N·m (8 ft . lbs.)
Scr ew, flu id filt er . . . . . . . . . . . . . 4 N·m (35 in . lbs.)
Bolt , va lve body t o ca se . . . . . . 12 N·m (100 in . lbs.)
SPECI AL T OOLS
30RH TRANSMISSIONS
Snap-ring Plier—6823
Remover—6957
Pilot Stud—C-3288-B
Installer—6951
Pressure Gauge—C-3292
XJ TRANSMISSION AND TRANSFER CASE 21 - 159
SPECI AL T OOLS (Cont inue d)
Remover, Bushing—SP-3550
Seal Remover—C-3985-B
Remover, Bushing—SP-3629
Bushing, Remover—6957
Installer, Bushing—SP-5511
Flusher, Oil Cooler—6906
Snap-ring Plier—C-3915
Installer—C-3995-A
21 - 162 TRANSMISSION AND TRANSFER CASE XJ
SPECI AL T OOLS (Cont inue d)
Remover/Installer—C-4470
Universal Handle—C-4171
INDEX
page page
ADJUSTMENTS SPECIFICATIONS
BRAKE TRANSMISSION SHIFT INTERLOCK AW-4 AUTOMATIC TRANSMISSION . . . . . . . . . 269
CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . 267 SPECIAL TOOLS
GEARSHIFT CABLE . . . . . . . . . . . . . . . . . . . . . 267 AW-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
TRANSMISSION THROTTLE VALVE CABLE
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 268
J8921-398
r epa ir
Th e u se of n on r ecom m en ded flu ids ca n r esu lt in
t r a n sm ission fa ilu r e. Th e u su a l r esu lt s a r e er r a t ic
3 THIRD GEAR (MANUAL)
SENSORS
Sen sor s in clu de:
• t h r ot t le posit ion sen sor (TP S)
• t r a n sm ission speed sen sor
• veh icle speed sen sor 80aef248
• pa r k/n eu t r a l posit ion swit ch
• br a ke swit ch Fig. 4 Torque Converter (With Clutch)
Th e t h r ot t le posit ion sen sor is m ou n t ed on t h e Th e clu t ch disc is a t t a ch ed t o t h e con ver t er fr on t
t h r ot t le body. It elect r on ica lly det er m in es t h r ot t le cover. Th e clu t ch pist on a n d clu t ch spr in gs a r e
posit ion a n d r ela ys t h is in for m a t ion t o t h e t r a n sm is- a t t a ch ed t o t h e t u r bin e h u b. Th e spr in gs da m pen
sion con t r ol m odu le t o det er m in e sh ift poin t s a n d en gin e fir in g im pu lses a n d loa ds du r in g t h e in it ia l
con ver t er clu t ch en ga gem en t . ph a se of con ver t er clu t ch en ga gem en t .
Th e t r a n sm ission speed sen sor con sist s of a r ot or Clu t ch en ga gem en t is con t r olled by t r a n sm ission
a n d m a gn et on t h e t r a n sm ission ou t pu t sh a ft a n d a va lve body solen oid n u m ber t h r ee a n d by t h e con -
swit ch in t h e ext en sion h ou sin g or a da pt er. Th e sen - ver t er clu t ch r ela y va lve. Th e solen oid ch a n n els lin e
sor swit ch is a ct iva t ed ea ch t im e t h e r ot or a n d m a g- pr essu r e t o t h e clu t ch t h r ou gh t h e r ela y va lve a t
n et com plet e on e r evolu t ion . Sen sor sign a ls a r e sen t clu t ch en ga gem en t speeds.
t o t h e t r a n sm ission con t r ol m odu le. Tor qu e con ver t er clu t ch en ga gem en t occu r s in sec-
Th e pa r k/n eu t r a l posit ion swit ch is m ou n t ed on t h e on d gea r in 1–2 posit ion ; t h ir d gea r in 3 posit ion a n d
va lve body m a n u a l sh a ft . Th e swit ch sign a ls sh ift t h ir d a n d fou r t h gea r in D posit ion .
lin ka ge a n d m a n u a l va lve posit ion t o t h e t r a n sm is-
sion con t r ol m odu le t h r ou gh a n in t er con n ect in g h a r- FOURTH GEAR OVERDRIVE COMPONENTS
n ess. Th e swit ch pr even t s en gin e st a r t in g in a ll gea r s Th e over dr ive syst em con sist s of t h e in pu t sh a ft ,
ot h er t h a n P a r k or Neu t r a l. on e–wa y clu t ch , pla n et a r y su n gea r, r in g gea r, pla n -
Th e br a ke swit ch is in cir cu it wit h t h e t or qu e con - et a r y ca r r ier, over dr ive clu t ch a n d over dr ive br a ke
ver t er clu t ch solen oid. Th e swit ch disen ga ges t h e (F ig. 5). Th e over dr ive elem en t s a r e con t r olled a n d
con ver t er clu t ch wh en ever t h e br a kes a r e a pplied.
XJ TRANSMISSION AND TRANSFER CASE 21 - 167
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
INPUT SUN
SHAFT ONE-WAY GEAR PLANETARY
CLUTCH CARRIER
J8921-402
FRONT PLANETARY
CARRIER
Shift Lever
Position
p
Gear
Park
Valve Body
Solenoid
No.1
ON
Valve Body
Solenoid
No.2
OFF
Ill
?::z:
....
!~
.:,
0>u
•
·~
2:z:
2u
ti5
I!;
i!5"'
u
Ill
?: ...
!1111
·= 80= s= ;!:=
0!:• =u• =·
...
a..,..,
z:;1111
u.;•
a..,
Z1111 ..... :,:
... 1111
Ill
?:~:z:
!I:~
•.la:>
•z ..
gou
>e:z:
--:I~
O•
zit:
~:z:
Nlil:U
i.:.!i
z ..
ou
R Reverse ON OFF • • • •
N Neutral ON OFF •
First ON OFF • • • •
D
Second ON ON • • • • •
Third OFF ON • • • • •
OD OFF OFF • • • •
First ON OFF • • • •
3 Second ON ON • • • • • •
Third OFF ON • • • • •
1-2
First ON OFF • • • • •
Second ON ON • • • • • •
• = Applied J8921 -405
Th e h ydr a u lic syst em con sist s of t h e pu m p, va lve
UPPER
body a n d solen oids, a n d fou r h ydr a u lic a ccu m u la t or s. BODY----.~
Th e oil pu m p pr ovides lu br ica t ion a n d oper a t in g
pr essu r e.
Th e va lve body con t r ols a pplica t ion of t h e clu t ch es,
br a kes, secon d coa st ba n d, a n d t h e con ver t er clu t ch .
Th e va lve body solen oids con t r ol sequ en cin g of t h e
1–2, 2–3 a n d 3–4 sh ift va lves. Th e solen oids a r e a ct i-
va t ed by sign a ls fr om t h e t r a n sm ission con t r ol m od-
u le.
Th e a ccu m u la t or s a r e u sed in t h e clu t ch a n d br a ke
feed cir cu it s t o con t r ol in it ia l a pply pr essu r e. Spr in g
loa ded a ccu m u la t or pist on s m odu la t e t h e in it ia l
su r ge of a pply pr essu r e for sm oot h en ga gem en t .
0
LOWER 0
BODY
ACCUMULATOR
CONTROL
VALVE
PRIMARY
REGULATOR
VALVE
MANUAL VALVE
80aef262
DOWNSHIFT PLUG
UPPER
BODY
CUT-BACK VALVE
80aef263
•
DRAIN
CUT-BACK
DOWNSHIFT
l:WI----PLUG
30R~-2,
RANGE
PRESSURE
(FROM CUT-BACK
VALVE)
¢--------'
DRAIN
80aef265
¢:i THROTTLE
PRESSURE THROTTLE PRESSURE
(TO PRIMARY
LINE PRESSURE
¢:i (FROM MANUAL REGULATOR VALVE)
80aef266
VALVE
"R" RANGE)
Fig. 12 Throttle Valve And Downshift Plug
¢:i LINE
PRESSURE Th e down sh ift plu g a n d t h r ot t le va lve a r e oper a t ed
(FROM PUMP)
by t h e t h r ot t le va lve ca m a n d t h r ot t le ca ble in
CONVERTER r espon se t o en gin e t h r ot t le posit ion . Th r ot t le va lve
PRESSURE pr essu r e is a lso m odu la t ed by t h e cu t –ba ck va lve in
..
DRAIN
TO CONVERTER
CLUTCH RELAY VALVE
t
secon d, t h ir d a n d fou r t h gea r r a n ges.
CUT–BACK VALVE
Th e cu t –ba ck va lve (F ig. 13) h elps pr even t exces-
sive pu m p pr essu r e bu ildu p in secon d, t h ir d a n d
fou r t h gea r. Th e va lve is a ct u a t ed by t h r ot t le pr es-
su r e a n d by lin e pr essu r e fr om t h e secon d br a ke. Th e
va lve a lso h elps r egu la t e lin e pr essu r e by con t r ollin g
LINE-;;;_., t h e a m ou n t of cu t –ba ck pr essu r e t o t h e t h r ot t le
PRESSURE
va lve.
¢:i THROTTLE
PRESSURE TO CONVERTER
CLITCH (ENGAGED)
L....,~-1---
•CUT-BACK
PRESSURE t ~-~----------=-----=----::::'._~~--______,--U-¢:i
TO LINE PRESSURE
THROTTLE (FROM 1-2 SHIFT VALVE)
VALVE ¢:i CONVERTER
c.r-----'--i---.- PRESSURE
SECOND BRAKE c.r-----...-,...- • DRAIN
LINE PRESSURE
-~ ~CUT-BACK
c:::> VALVE
.
PRESSURE (TO t h e m a n u a l va lve a n d pr im a r y r egu la t or va lve.
RELAY VALVE) Wh en t h e TCM a ct iva t es solen oid No. 1, lin e pr es-
su r e a t t h e t op of t h e 2–3 va lve is r elea sed t h r ou gh
t h e solen oid dr a in por t . Spr in g t en sion m oves t h e
FROM PRIMARY7/\i71
REGULATOR VALVE LJ
LUBRICATION
PRESSURE 80aef26a
l' va lve u p t o h old t h e va lve in secon d gea r posit ion . As
t h e solen oid is dea ct iva t ed, lin e pr essu r e t h en m oves
t h e va lve down exposin g t h e dir ect clu t ch feed por t
Fig. 14 Secondary Regulator Valve
for t h e sh ift t o t h ir d gea r.
CONVERTER CLUTCH RELAY VALVE
Th e con ver t er clu t ch r ela y va lve (F ig. 15) con t r ols
flu id flow t o t h e con ver t er clu t ch . Th e va lve is oper-
a t ed by lin e pr essu r e fr om t h e 1–2 sh ift va lve a n d is
con t r olled by solen oid va lve n u m ber t h r ee.
XJ TRANSMISSION AND TRANSFER CASE 21 - 173
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
LINE PRESSURE
(FROM SOLENOID LINE PRESSURE
LINE PRESSURE
VALVE NO. 2) (FROM 2-3 SHIFT
(FROM MANUAL
¢ VALVE)
VALVE IN "D" "2"
OR "L" RANGE) Lr---"-~~c=- + TO 2ND COAST
MODULATOR VALVE
LINE PRESSURE
(FROM MANUAL
VALVE IN "R" + TO ACCUMULATORS
RANGE) AND SOLENOID
VALVE NO. 3
TO FIRST/REVERSE
c:=_•BRAKE L.,-L-------'----~ + TO FIRST/REVERSE
9 FROM LOW COAST BRAKE
'-T---'-------'--,-
MODULATOR
VALVE
LINE PRESSURE
L=~-9 (FROM 2-3 SHIFT
VALVE, IN 3RD
OR OD GEAR)
80aef26c
LINE PRESSURE
(FROM MANUAL =c:::::>=------~
VALVE)
2NDGEARf------L-___,_____,
80aef26d
(FROM 2-3 I I
I I
SHIFT VALVE)
'o
I I
~.------L--L..... I
LINE PRESSURE
(FROM 1-2 SHIFT /.
VALVE) LOW COAST
LOW COAST
; MODULATOR
PRESSURE TO
MODULATOR FIRST/REVERSE
PRESSURE ._ BRAKE
SECOND --------j
0 0
COAST BRAKE 0 0
0 0
0
80aef270
SECOND
DIRECT BRAKE
ACCUMULATOR CLUTCH
LINE
PRESSURE c:::> CONTROL
(FROM PUMP) PRESSURE
L,'-----',..._ _ . . (TO
ACCUMULATORS)
80aef272
80aef271
Fig. 22 Accumulators
Fig. 21 Accumulator Control Valve
ACCUMULATORS
F ou r a ccu m u la t or s a r e u sed t o cu sh ion clu t ch a n d
br a ke a pplica t ion . Th e a ccu m u la t or s (F ig. 22), con sist
of spr in g loa ded pist on s. Th e pist on s da m pen t h e in i-
t ia l su r ge of a pply pr essu r e t o pr ovide sm oot h
en ga gem en t du r in g sh ift s.
Con t r ol pr essu r e fr om t h e a ccu m u la t or con t r ol
va lve is con t in u ou sly a pplied t o t h e ba ck pr essu r e
side of t h e a ccu m u la t or pist on s. Th is pr essu r e plu s
spr in g t en sion h olds t h e pist on s down . As lin e pr es-
su r e fr om t h e sh ift va lves en t er s t h e opposit e en d of
t h e pist on bor e, con t r ol pr essu r e a n d spr in g t en sion
m om en t a r ily dela y a pplica t ion of fu ll lin e pr essu r e t o
cu sh ion en ga gem en t . Th e a ccu m u la t or s a r e a ll
loca t ed in t h e t r a n sm ission ca se (F ig. 22).
COOLER
LINE
BRACKET
COOLER
RETURN
LINE
u
RADIATOR
RETURN
LINE
(TO
TRANSMISSION) J9221-53
PARK/BRAKE
INTERLOCK CABLE
SHIFT-~~-.,,...
CABLE
80a13876
.
PERFORM MANUAL SHIFTING NOT OK---,
TEST
,i,
I
NOT OK
~
REPAIR OR REPLACE PROBLEM REPAIR TRANSMISSION AS
COMPONENTS NECESSARY
J8921-423
HYDRAULIC PRESSURE TEST CAUTION: Do not hold wide open throttle for more
than 4 seconds.
Pressure Test Procedure
(1) Con n ect pr essu r e t est ga u ge t o t est por t on (10) If lin e pr essu r e is n ot wit h in specifica t ion s,
pa ssen ger side of t r a n sm ission (F ig. 27). Use Ada pt er a dju st t r a n sm ission t h r ot t le ca ble a n d r epea t pr es-
7554 t o con n ect ga u ge. Be su r e t est ga u ge h a s m in i- su r e t est .
m u m ca pa cit y of 300 psi (2100 kP a ).
(2) Be su r e t r a n sm ission flu id is a t n or m a l oper a t - PRESSURE TEST ANALYSIS
in g t em per a t u r e. If pr essu r es in D a n d Rever se a r e h igh er t h a n
specified in t est , ch eck for t h e followin g:
PRESSURE TEST • t h r ot t le ca ble loose, wor n , bin din g or ou t of
GAUGE PORT
a dju st m en t
• t h r ot t le va lve, down sh ift plu g, t h r ot t le ca m , or
pr im a r y r egu la t or va lve a r e st ickin g, wor n or da m -
a ged
If pr essu r es in D a n d Rever se a r e lower t h a n spec-
ified in t est , ch eck for followin g:
• t h r ot t le ca ble loose, wor n , bin din g or ou t of
a dju st m en t
• t h r ot t le va lve, down sh ift plu g, or t h r ot t le ca m
st ickin g, wor n or da m a ged
• pr im a r y r egu la t or va lve st ickin g, wor n , or da m -
a ged
• oil pu m p gea r s or h ou sin g wor n , or da m a ged
• over dr ive clu t ch wor n , or da m a ged
If pr essu r es a r e low in D r a n ge on ly, ch eck for fol-
lowin g:
• for wa r d clu t ch wor n or da m a ged
• flu id lea ka ge in D r a n ge cir cu it (com pon en t sea l
J8921-424 a n d O–r in gs)
If pr essu r es a r e low in Rever se on ly, ch eck for fol-
Fig. 27 Pressure Test Gauge Connection lowin g:
(3) Apply pa r kin g br a kes a n d block wh eels. • sh ift ca ble a n d m a n u a l va lve ou t of a dju st m en t
• flu id lea ka ge in r ever se cir cu it (com pon en t sea l
WARNING: DO NOT ALLOW ANYONE TO STAND AT a n d O–r in gs)
THE FRONT OR REAR OF THE VEHICLE WHILE • dir ect clu t ch wor n or da m a ged
PERFORMING THE FOLLOWING STEPS IN THE • fir st /r ever se br a ke wor n or da m a ged.
PRESSURE TEST.
TORQUE CONVERTER STALL TEST
(4) Ch eck a n d a dju st en gin e cu r b idle speed. St a ll t est in g ch ecks t h e h oldin g a bilit y of t h e t r a n s-
(5) Apply (a n d h old) ser vice br a kes. m ission clu t ch es a n d br a kes a n d of t h e t or qu e con -
(6) Sh ift t r a n sm ission in t o D r a n ge a n d n ot e lin e ver t er st a t or over r u n n in g clu t ch . S ta ll s p e e d s a re
pr essu r e wit h en gin e a t cu r b idle speed. P r essu r e c h e c k e d in bo th D riv e a n d Re v e rs e ra n g e s w ith
sh ou ld be 61–t o–70 psi (421–t o–481 kP a ). th e AW–4 tra n s m is s io n .
(7) P r ess a cceler a t or peda l t o wide open t h r ot t le (1) Befor e st a r t in g t est , be su r e flu id level is cor-
posit ion a n d n ot e lin e pr essu r e. P r essu r e sh ou ld be r ect a n d flu id is a t n or m a l oper a t in g t em per a t u r e.
173–t o–209 psi (1196–t o–1442 kP a ). (2) Con n ect t a ch om et er t o en gin e. P osit ion t a ch om -
et er so it ca n be viewed fr om dr iver s sea t .
CAUTION: Do not hold wide open throttle for more
(3) Apply pa r kin g br a kes a n d block wh eels.
than 3–4 seconds at a time.
(4) Apply a n d h old ser vice br a kes.
(8) Sh ift t r a n sm ission in t o Rever se a n d n ot e lin e (5) Sh ift t r a n sfer ca se in t o 2H posit ion .
pr essu r e wit h en gin e a t cu r b idle speed. P r essu r e (6) St a r t en gin e.
sh ou ld be 75–t o–90 psi (519–t o–618 kP a ).
WARNING: DO NOT ALLOW ANYONE TO STAND AT
(9) P r ess a cceler a t or t o wide open t h r ot t le posit ion
THE FRONT OR REAR OF THE VEHICLE DURING
a n d n ot e lin e pr essu r e in Rever se. P r essu r e sh ou ld
THE TEST.
be 213–t o–263 psi (1471–t o–1814 kP a ).
21 - 180 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
(7) Sh ift t r a n sm ission in t o D r a n ge. en gin e a t cu r b idle speed. E n ga gem en t t im e is m ea -
(8) Open t h r ot t le com plet ely a n d r ecor d m a xim u m su r ed for D a n d Rever se posit ion s. A st op wa t ch is
en gin e r pm r egist er ed on t a ch om et er. It t a kes a n y- r ecom m en ded for t est a ccu r a cy.
wh er e fr om 4 t o 10 secon ds t o r ea ch m a xim u m r pm .
H owever, on ce m a xim u m r pm h a s been a ch ieved, d o TEST PROCEDURE
n o t h o ld w id e o p e n th ro ttle fo r m o re th a n 3–4 (1) Ch eck a n d a dju st t r a n sm ission flu id level if
seconds. n ecessa r y.
(2) Br in g t r a n sm ission t o n or m a l oper a t in g t em -
CAUTION: Stalling the converter causes a rapid per a t u r e.
increase in fluid temperature. To avoid fluid over- (3) Apply pa r kin g br a kes a n d t u r n off a ir con di-
heating, hold wide open throttle for no more than 4 t ion in g u n it .
seconds after reaching peak rpm. In addition, if (4) Sh ift t r a n sfer ca se in t o 2H r a n ge.
more than one stall test is required, run the engine (5) St a r t en gin e a n d ch eck cu r b idle speed. Adju st
at 1000 rpm with the transmission in Neutral for at speed if n ecessa r y. Cu r b idle m u st be cor r ect t o
least 20 seconds to cool the fluid. en su r e a ccu r a t e t est r esu lt s.
(6) Sh ift t r a n sm ission in t o Neu t r a l a n d set st op
(9) St a ll speed sh ou ld be in 2100–2400 r pm r a n ge
wa t ch .
in Dr ive.
(7) Du r in g followin g t est st eps, st a r t st op wa t ch a s
(10) Relea se t h r ot t le, sh ift t r a n sm ission in t o Neu -
soon a s sh ift lever r ea ch es D a n d Rever se r a n ges.
t r a l, a n d r u n en gin e for 20–30 secon ds t o cool flu id.
(8) Sh ift t r a n sm ission in t o D r a n ge a n d r ecor d
(11) Sh ift t r a n sm ission in t o Rever se.
t im e it t a kes for en ga gem en t . Repea t t est t wo m or e
(12) Repea t st a ll t est .
t im es.
(13) St a ll speed in Rever se sh ou ld a lso be in 2100–
(9) Reset st op wa t ch a n d sh ift t r a n sm ission ba ck
2400 r pm r a n ge.
t o Neu t r a l.
(14) Relea se a cceler a t or peda l, sh ift t r a n sm ission
(10) Sh ift t r a n sm ission in t o Rever se a n d r ecor d
in t o Neu t r a l, a n d r u n en gin e for 20–30 secon ds t o
t im e it t a kes for en ga gem en t . Repea t t est t wo m or e
cool flu id.
t im es.
(11) E n ga gem en t t im e in D r a n ge sh ou ld be a
STALL SPEED TEST ANALYSIS m a xim u m of 1.2 secon ds. E n ga gem en t t im e for
If en gin e r pm is lower t h a n specified in D a n d Rever se sh ou ld be a m a xim u m of 1.5 secon ds.
Rever se, ch eck for t h e followin g:
• en gin e ou t pu t /per for m a n ce in su fficien t TIME LAG TEST ANALYSIS
• st a t or over r u n n in g clu t ch in t or qu e con ver t er If en ga gem en t t im e is lon ger t h a n specified for D
n ot h oldin g if en gin e speed wa s 1500 r pm or less. r a n ge, ch eck for t h e followin g:
If st a ll speed in D r a n ge is h igh er t h a n specified, • sh ift ca ble m isa dju st ed
ch eck for t h e followin g: • lin e pr essu r e low
• lin e pr essu r e low • for wa r d clu t ch wor n
• for wa r d clu t ch slippin g • over dr ive clu t ch wor n or da m a ged.
• No. 2 on e–wa y clu t ch n ot h oldin g If en ga gem en t t im e is lon ger t h a n specified for
• over dr ive on e–wa y clu t ch n ot h oldin g Rever se, ch eck for t h e followin g:
If st a ll speed in Rever se wa s h igh er t h a n specified, • sh ift ca ble m isa dju st ed
ch eck for t h e followin g: • lin e pr essu r e low
• lin e pr essu r e low • dir ect clu t ch wor n
• dir ect clu t ch slippin g • fir st /r ever se br a ke wor n
• fir st / r ever se br a ke slippin g • over dr ive clu t ch wor n or da m a ged.
• over dr ive on e–wa y clu t ch n ot h oldin g
If st a ll speeds wer e h igh er t h a n specified in bot h D
SERVICE DIAGNOSIS
a n d Rever se, ch eck for t h e followin g:
• low flu id level
• lin e pr essu r e low
TRANSMISSION SOLENOID TESTING
Test solen oid r esist a n ce wit h a n oh m m et er. Con -
• over dr ive on e–wa y clu t ch n ot h oldin g.
n ect t h e oh m m et er lea ds t o t h e solen oid m ou n t in g
br a cket a n d t o t h e solen oid wir e t er m in a l (F ig. 28).
TIME LAG TEST
Solen oid r esist a n ce sh ou ld be 11–15 oh m s. Repla ce
Th is t est ch ecks gen er a l con dit ion of t h e over dr ive
t h e solen oid if r esist a n ce is a bove or below t h e spec-
clu t ch , for wa r d clu t ch , r ea r clu t ch a n d fir st /r ever se
ified r a n ge.
br a ke. Con dit ion is in dica t ed by t h e a m ou n t of t im e
r equ ir ed for clu t ch /br a ke en ga gem en t wit h t h e
XJ TRANSMISSION AND TRANSFER CASE 21 - 181
DI AGN OSI S AN D T EST I N G (Cont inue d)
DI AGN OSI S TABLE
VEHICLE WILL NOT BACK UP OR Shift cable out of adjustment or damaged Adjust cable or replace cable
MOVE FORWARD Valve body or primary regulator faulty Inspect/repair valve body
Park lock pawl faulty Repair park pawl
Torque converter fault Replace torque converter
Converter drive plate roken Replace drive plate
Oil pump intake screen blocked Clean screen
Transmission faulty Disassemble and repair transmission
DELAYED 1-2, 2-3 OR 3-4 Electronic control problem Locate problem with DRB Tester
UP-SHIFT, OR DOWN-SHIFTS Valve body faulty Repair valve body
FROM 4-3 OR 3-2 AND SHIFTS Solenoid faulty Repair solenoid
BACKTO4OR3
SLIPS ON 1-2, 2-3 OR 3-4 Shift cable out of adjustment Adjust cable
UP-SHIFT, OR SLIPS OR Throttle cable out of adjustment Adjust cable
SHUDDERS DURING Valve body faulty Repair valve body
ACCELERATION Solenoid faul7c Replace solenoid
Transmission aulty Disassemble and repair transmission
DRAG OR BIND ON 1-2, 2-3 Shift cable out of adjustment Adjust cable
OR 3-4 UP-SHIFT Valve body faulty Repair valve body
Transmission faulty Disassemble and repair transmission
CONVERTER CLUTCH DOES NOT Electronic control problem Check with DRB Tester
ENGAGE IN 2ND, 3RD OR 4TH Valve body faulty Repair valve body
Solenoid foul% Replace solenoid
Transmission ulty Disassemble and repair transmission
J9321-93
21 - 182 TRANSMISSION AND TRANSFER CASE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
DI AGN OSI S TABLE CON T I N U ED
VEHICLE DOES NOT HOLD Shift cable out of adjustment Adjust cable
IN PARK Parking lock pawl cam and spring faulty Replace cam and spring
OVERHEAT DURING NORMAL Low fluid level Add fluid and check for leaks
OPERATION (FLUID
DISCOLORED, SMELLS BURNED) Fluid cooler, lines blocked, or cooler cracked Flush cooler and lines and re~lace
(oil in engine coolant) radiator if transmission fluid as
entered coolant
OVERHEAT DURING Vehicle not properly equipped for trailer Be sure vehicle is equipped with
COMMERCIAL OPERATION towing or commercial use recommended optional components
OR WHILE TRAILER TOWING (i.e., HD springs, transmission, axle,
(FLUID DARK AND BURNED larger CID engine, auxiliary cooler,
WITH SOME SLUDGE correct axle ratio, etc.). If vehicle is not
FORMATION) so equipped, it should not be used for
severe service operation
Vehicle not equipped with auxiliary Drain fluid, change filter, and install
fluid cooler auxiliary cooler
Extensive idling time or operation in heavy Cut down on idlin~ time; shift into
traffic in hot weather neutral every so o en and run en~ine
at l 000 rpm to help circulate flui
through cooler
OIL COMES OUT FILLER TUBE Transmission overfilled Drain fluid to correct level; remove neutral
switch and drain through switch hole
with suction gun
J9321-94
XJ TRANSMISSION AND TRANSFER CASE 21 - 183
DI AGN OSI S AN D T EST I N G (Cont inue d)
SWITCH
TERMINAL
IDENTIFICATION
D C B A
B C A E G H
J8921-435 1-2
-
Fig. 28 Testing Transmission Valve Body Solenoid J8921-429
CONNECTOR ROTATING
TOOL
STOPPER
TOOL
ROTOR
J8921-462
c:::(ADD I IFULL -
I
CHECK
(7) Let en gin e r u n a t n or m a l cu r b idle speed, a pply
ser vice br a kes. Th en sh ift t r a n sm ission t h r ou gh a ll
--1 I OK RANGE
gea r r a n ges a n d ba ck t o PARK (lea ve en gin e r u n -
n in g).
(8) Rem ove dipst ick a n d ch eck flu id level. Add on ly
en ou gh flu id t o br in g level t o F u ll m a r k on dipst ick.
J8921-427
Do n ot over fill. If to o m u c h flu id is a d d e d , e x c e s s
Fig. 32 Transmission Fluid Level a m o u n t c a n be re m o v e d w ith s u c tio n g u n a n d
p la s tic tu bin g . Tu bin g o n ly h a s to be lo n g
(8) If flu id level is low, t op off level wit h Mopa r e n o u g h to e x te n d in to o il p a n .
Dexr on IIE /Mer con . Mopa r Dexr on II ca n be u sed bu t (9) Wh en flu id level is cor r ect , sh u t en gin e off,
on ly if Mer con is n ot a va ila ble. D o n o t o v e rfill r elea se pa r k br a ke, r em ove fu n n el, a n d r esea t dip-
tra n s m is s io n . Ad d o n ly e n o u g h flu id to brin g st ick in fill t u be.
le v e l to F u ll m a rk .
(9) If t oo m u ch flu id wa s a dded, excess a m ou n t ca n TRANSMISSION CONTROL MODULE (TCM)
be r em oved wit h su ct ion gu n a n d a ppr opr ia t e dia m e-
t er pla st ic t u bin g. Tu bin g on ly h a s t o be lon g en ou gh
SERVICE
Use t h e DRB sca n t ool t o dia gn ose t r a n sm ission
t o ext en d in t o oil pa n .
con t r ol m odu le fu n ct ion wh en ever a fa u lt is su s-
pect ed. Repla ce t h e m odu le on ly wh en t h e sca n t ool
CHECKING FLUID CONDITION
in dica t es t h e m odu le is a ct u a lly fa u lt y.
In spect t h e a ppea r a n ce of t h e flu id du r in g t h e flu id
level ch eck. F lu id color sh ou ld r a n ge fr om da r k r ed t o
pin k a n d be fr ee of for eign m a t er ia l, or pa r t icles. If
OIL PUMP VOLUME CHECK
Aft er t h e n ew or r epa ir ed t r a n sm ission h a s been
t h e flu id is da r k br own or bla ck in color a n d sm ells
in st a lled, fill t o t h e pr oper level wit h Mopa r ! ATF
bu r n t , t h e flu id h a s been over h ea t ed a n d m u st be
P LUS 3 (Type 7176) a u t om a t ic t r a n sm ission flu id.
ch a n ged.
Th e volu m e sh ou ld be ch ecked u sin g t h e followin g
pr ocedu r e:
21 - 186 TRANSMISSION AND TRANSFER CASE XJ
SERV I CE PROCEDU RES (Cont inue d)
(1) Discon n ect t h e F ro m c o o le r lin e a t t h e t r a n s- n en t s. D O N OT u se solven t s con t a in in g a cids, wa t er,
m ission a n d pla ce a collect in g con t a in er u n der t h e ga solin e, or a n y ot h er cor r osive liqu ids.
discon n ect ed lin e. (2) Rein st a ll filler plu g on Tool 6906.
(3) Ver ify pu m p power swit ch is t u r n ed OF F. Con -
CAUTION: With the fluid set at the proper level, n ect r ed a lliga t or clip t o posit ive (+) ba t t er y post .
fluid collection should not exceed (1) quart or inter- Con n ect bla ck (-) a lliga t or clip t o a good gr ou n d.
nal damage to the transmission may occur. (4) Discon n ect t h e cooler lin es a t t h e t r a n sm ission .
TRANSMISSION
FILL
TUBE
BRACKET
BRACKET B J9121-397
1~
ver t er is fu lly sea t ed.
(7) If n ecessa r y, t em por a r ily secu r e con ver t er wit h
C-cla m p a t t a ch ed t o t h e con ver t er h ou sin g.
(8) In st a ll t h e t r a n sm ission in t h e veh icle.
(9) F ill t h e t r a n sm ission wit h t h e r ecom m en ded
flu id. SPEED
SPEED
SENSOR
SENSOR
J9121-379
SPEED SENSOR
REMOVAL
(1) Discon n ect sen sor wir e h a r n ess con n ect or.
(2) Rem ove sen sor r et a in er bolt a n d r em ove sen sor
(F ig. 38).
Fig. 36 Checking Torque Converter Seating (3) Rem ove a n d disca r d speed sen sor O–r in g.
ADAPTER HOUSING SEAL INSTALLATION
(1) In st a ll n ew O–r in g on speed sen sor a n d in st a ll
REMOVAL
sen sor in t r a n sm ission ca se.
(1) Ra ise veh icle.
(2) In st a ll sen sor br a cket a n d r et a in er bolt .
(2) Discon n ect or r em ove com pon en t s n ecessa r y t o
Tigh t en bolt t o 7.4 N·m (65 in . lbs.) t or qu e.
ga in a ccess t o sea l (e.g. pr opeller sh a ft , cr ossm em ber,
(3) Con n ect sen sor wir e h a r n ess con n ect or.
sh ift lin ka ge, t r a n sfer ca se, exh a u st com pon en t s,
h oses, wir es).
(3) On 4X2 veh icles, r em ove du st sh ield fr om t h e
SPEEDOMETER ADAPTER
a da pt er h ou sin g by t a ppin g gen t ly wit h a br a ss dr ift Rea r a xle gea r r a t io a n d t ir e size det er m in e speed-
a n d h a m m er (F ig. 37). om et er pin ion r equ ir em en t s.
(4) On 4X2 veh icles, r em ove t h e a da pt er h ou sin g
sea l wit h Sea l P u ller 7550.
REMOVAL
(5) On 4X4 veh icles, r em ove t h e a da pt er h ou sin g (1) Ra ise veh icle.
sea l u sin g a slide h a m m er m ou n t ed scr ew. (2) Discon n ect wir es fr om veh icle speed sen sor.
(3) Rem ove a da pt er cla m p a n d scr ew (F ig. 39).
21 - 190 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
RETAINER (9) Rot a t e a da pt er u n t il r equ ir ed r a n ge n u m ber s
BOLT a r e a t 6 o’clock posit ion . Be su r e r a n ge in dex n u m -
ber s cor r espon d t o n u m ber of t eet h on pin ion gea r.
(10) In st a ll speedom et er a da pt er cla m p a n d r et a in -
in g scr ew. Tigh t en cla m p scr ew t o 10-12 N·m (90-110
in . lbs.) t or qu e.
(11) Con n ect wir es t o veh icle speed sen sor.
(12) Lower veh icle a n d t op off t r a n sm ission flu id
level, if n ecessa r y.
ITEM TORQUE
A 2-3 N•m (15-27 in. lbs.)
B 10-12 N•m (90-110 in. lbs.)
SENSOR
\
SPEEDOMETER
PINION
VEHICLE
SPEED
SENSOR J9321-385
SPEEDOMETER DRIVE
GEAR
J9321-386 SNAP
RING
Fig. 40 Index Numbers On Speedometer Pinion
Adapter
PARK/NEUTRAL POSITION SWITCH J8921-464
ADJUSTING
BOLT
OUTPUT
J8921-431
SHAFT
GEARSHIFT CABLE
1 \1~~~~~
NE~TRAL ~ -
SWITCHd REMOVAL
(1) Sh ift t r a n sm ission in t o P a r k.
(2) Rem ove sh ift lever bezel a n d n ecessa r y con sole
pa r t s for a ccess t o sh ift lever a ssem bly.
(3) Discon n ect ca ble a t sh ift lever a n d feed ca ble
t h r ou gh da sh pa n el open in g t o u n der side of veh icle.
(4) Ra ise veh icle.
(5) Disen ga ge ca ble eyelet a t t r a n sm ission sh ift
lever a n d pu ll ca ble a dju st er ou t of m ou n t in g
br a cket . Th en r em ove old ca ble fr om veh icle.
INSTALLATION
ATTACHING (1) Rou t e ca ble t h r ou gh h ole in da sh pa n el. F u lly
NUT J8921-430
sea t ca ble gr om m et in t o da sh pa n el.
(2) P la ce t h e a u t o t r a n sm ission m a n u a l sh ift con -
Fig. 43 Park/Neutral Position Switch Removal/ t r ol lever in “P a r k” det en t (r ea r m ost ) posit ion a n d
Installation r ot a t e pr op sh a ft t o en su r e t r a n sm ission is in pa r k.
(5) Ver ify t h a t t r a n sm ission is in Neu t r a l. (3) Con n ect sh ift ca ble t o sh ift er m ech a n ism by
(6) Rot a t e swit ch t o a lign n eu t r a l st a n da r d lin e sn a ppin g ca ble r et a in in g ea r s in t o sh ift er br a cket
wit h ver t ica l gr oove on m a n u a l va lve sh a ft (F ig. 44). a n d pr ess ca ble en d fit t in g on t o lever ba ll st u d.
(7) Align swit ch st a n da r d lin e wit h gr oove or fla t (4) P la ce t h e floor sh ift er lever in pa r k posit ion .
on m a n u a l va lve sh a ft . E n su r e t h a t t h e pa wl is sea t ed wit h in t h e con fin es of
(8) Tigh t en swit ch a dju st in g bolt t o 13 N·m (9 ft . t h e a dju st m en t ga u ge clip.
lbs.) t or qu e. (5) Sn a p t h e ca ble in t o t h e t r a n sm ission br a cket so
(9) Ben d a t lea st t wo wa sh er lock t a bs over swit ch t h e r et a in in g ea r s a r e en ga ged a n d con n ect ca ble en d
a t t a ch in g n u t t o secu r e it . fit t in g on t o t h e m a n u a l con t r ol lever ba ll st u d.
XJ TRANSMISSION AND TRANSFER CASE 21 - 193
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(6) Lock sh ift ca ble in t o posit ion by pu sh in g (5) P u sh t h e spr in g-loa ded ca ble a dju st er for wa r d
u pwa r d on t h e a dju st in g lock bu t t on . a n d sn a p ca ble in t o br a cket .
(7) Rem ove a n d disca r d t h e sh ift ca ble a dju st m en t (6) Adju st t h e br a ke t r a n sm ission sh ift er in t er lock
ga u ge clip fr om t h e pa r k ga t e of t h e sh ift er. ca ble. Refer t o t h e Adju st m en t por t ion of t h is sect ion
for pr oper pr ocedu r es.
BRAKE TRANSMISSION SHIFT INTERLOCK (7) Ver ify t h a t t h e ca ble a dju st er lock cla m p is
pu sh ed down wa r d t o t h e locked posit ion .
REMOVAL (8) Test t h e pa r k-lock ca ble oper a t ion .
(1) Rem ove lower st eer in g colu m n cover. Refer t o (9) In st a ll t h e floor con sole a n d r ela t ed t r im .
Gr ou p 8E , In st r u m en t P a n el a n d Ga u ges, for pr oper (10) In st a ll t ie st r a p t o h old ca ble t o ba se of st eer-
pr ocedu r e. in g colu m n .
(2) Rem ove lower st eer in g colu m n sh r ou d. Refer t o (11) In st a ll lower st eer in g colu m n sh r ou d a n d ign i-
Gr ou p 19, St eer in g, for pr oper pr ocedu r e. t ion lock.
(3) Rem ove t ie st r a p n ea r t h e solen oid r et a in in g (12) In st a ll lower st eer in g colu m n cover.
t h e br a ke t r a n sm ission in t er lock ca ble t o t h e st eer in g
colu m n . TRANSMISSION VALVE BODY SOLENOIDS
(4) Disen ga ge wir e con n ect or fr om solen oid.
(5) Wit h t h e ign it ion r em oved or in t h e u n locked REMOVAL
posit ion , disen ga ge lock t a b h oldin g ca ble en d t o (1) Rem ove t r a n sm ission oil pa n dr a in plu g a n d
st eer in g colu m n (F ig. 45). dr a in flu id.
(6) P u ll ca ble en d fr om st eer in g colu m n . (2) Rem ove pa n bolt s a n d r em ove oil pa n .
(7) Rem ove t h e floor con sole a n d r ela t ed t r im . (3) Rem ove oil scr een bolt s a n d r em ove scr een
Refer t o Gr ou p 23, Body, for pr oper pr ocedu r e. (F ig. 47) a n d ga sket . Disca r d t h e ga sket .
(8) Discon n ect t h e ca ble eyelet fr om t h e bellcr a n k (4) Discon n ect solen oid wir e con n ect or (F ig. 48).
(F ig. 46). (5) If a ll solen oids a r e bein g r em oved, m a r k or t a g
wir es for a ssem bly r efer en ce befor e discon n ect in g
IGNITION
t h em .
LOCK
(6) Rem ove bolt a t t a ch in g solen oids t o va lve body
a n d r em ove solen oids (F ig. 49). Do n ot a llow a n y
va lve body com pon en t s t o fa ll ou t wh en solen oids a r e
r em oved.
(7) Clea n oil filt er a n d pa n wit h solven t a n d dr y
wit h com pr essed a ir.
(8) Rem ove old sea ler m a t er ia l fr om oil pa n a n d
t r a n sm ission ca se.
INSTALLATION
(1) P osit ion solen oids on va lve body a n d in st a ll
solen oid bolt s. Tigh t en bolt s t o 10 N·m (7 ft . lbs.)
t or qu e.
80a47369
(2) Con n ect feed wir es t o solen oids.
Fig. 45 Brake/Park Interlock Cable (3) In st a ll n ew ga sket s on oil scr een a n d in st a ll
scr een . Tigh t en scr een bolt s t o 10 N·m (7 ft . lbs.)
(9) Discon n ect a n d r em ove t h e ca ble fr om t h e sh ift t or qu e.
br a cket . (4) Apply bea d of Th r eebon d! Liqu id Ga sket
TB1281, P /N 83504038, sea ler t o oil pa n sea lin g su r-
INSTALLATION fa ce. Sea ler bea d sh ou ld be a t lea st 3.0 m m (1/8 in .)
(1) Rou t e r epla cem en t ca ble beh in d in st r u m en t wide.
pa n el a n d u n der floor con sole a r ea t o sh ift m ech a - (5) In st a ll oil pa n on t r a n sm ission . Tigh t en pa n
n ism (F ig. 46). bolt s t o 7 N·m (65 in . lbs.) t or qu e.
(2) In ser t ca ble en d in t o open in g in st eer in g col- (6) In st a ll a n d t igh t en oil pa n dr a in plu g t o 20
u m n h u b u n der ign it ion lock. P u sh ca ble in wa r d N·m (15 ft . lbs.) t or qu e.
u n t il lock t a b en ga ges. (7) F ill t r a n sm ission wit h Mopa r ! Dexr on IIE /Mer-
(3) Con n ect t h e ca ble en d eyelet on t o sh ift er con .
bellcr a n k pin .
(4) P la ce gea r select or in PARK.
21 - 194 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
PARK/BRAKE
INTERLOCK CABLE
SHIFT-~~-.,,...
CABLE
80a13876
_ _ _----'J9121-376
0 0
....____ _o _ _0_ _ _
VALVE BODY
SOLENOIDS
J892l-434
J892l-437
J8921-433
THROTTLE
Fig. 50 Solenoid Wire Connectors CABLE
(6) Rem ove va lve body bolt s. Bolt loca t ion s a r e
ou t lin ed in (F ig. 53). J8921-438
(7) Lower va lve body a n d r em ove over dr ive clu t ch
a ccu m u la t or spr in gs, dir ect clu t ch a ccu m u la t or Fig. 52 Removing/Installing Throttle Cable
spr in gs a n d secon d br a ke a ccu m u la t or spr in g (F ig. (6) In st a ll va lve body oil t u bes. Be su r e t u be en ds
54). (L) a n d (M) a r e in st a lled a s sh own in (F ig. 57).
(8) Rem ove va lve body a n d ch eck ba ll a n d spr in g (7) Rem ove old sea ler m a t er ia l fr om oil pa n a n d
(F ig. 55). t r a n sm ission ca se.
(8) Clea n oil scr een a n d oil pa n wit h solven t (if n ot
INSTALLATION don e pr eviou sly). Dr y bot h com pon en t s wit h com -
(1) Con n ect ca ble t o t h r ot t le ca m (F ig. 52). pr essed a ir on ly. Do n ot u se sh op t owels.
(2) In st a ll ch eck ba ll a n d spr in g (F ig. 55). (9) In st a ll n ew ga sket s on oil scr een a n d in st a ll
(3) P osit ion a ccu m u la t or spr in gs a n d spa cer s on scr een on ca se. Tigh t en scr een a t t a ch in g bolt s t o 10
va lve body. N·m (7 ft . lbs.) t or qu e.
(4) Align va lve body m a n u a l va lve wit h sh ift sect or (10) Apply bea d of Th r eebon d! Liqu id Ga sket
(F ig. 56) a n d ca r efu lly posit ion va lve body on ca se. TB1281, P /N 83504038 t o sea lin g su r fa ce of oil pa n .
(5) In st a ll va lve body bolt s (F ig. 53). Tigh t en bolt s Sea ler bea d sh ou ld be a t lea st 3 m m (1/8 in .) wide.
even ly t o 10 N·m (7 ft . lbs.) t or qu e.
21 - 196 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
• =BOLT LOCATIONS
J8921-439 J892l-44l
Fig. 53 Transmission Valve Body Bolt Locations Fig. 55 Removing/Installing Check Ball And Spring
MANUAL
VALVE
«(~-- I O
~i~~~~VE /
11 I
DIREc~cHT
ACCUMULATOR ACCUMULATOR
SPRINGS SPRINGS
OVERDRIVE SECOND BRAKE
BRAKE ACCUMULATOR
ACCUMULATOR SPRING
SPRING J9121-377
SHIFT
SECTOR J8921-442
Fig. 54 Accumulator Springs
Th en in st a ll oil pa n a n d t igh t en pa n bolt s t o 7.4 N·m Fig. 56 Shift Sector And Manual Valve Alignment
(65 in . lbs.) t or qu e. To r em ove t h e m odu le, discon n ect t h e wir e h a r-
(11) In st a ll n ew ga sket on oil pa n dr a in plu g a n d n ess, r em ove t h e m ou n t in g scr ews a n d r em ove t h e
in st a ll plu g in pa n . Tigh t en plu g t o 20 N·m (15 ft . m odu le fr om t h e fin ish pa n el. Tigh t en t h e m odu le
lbs.) t or qu e. m ou n t in g scr ews secu r ely a ft er in st a lla t ion . Also be
(12) F ill t r a n sm ission wit h Mopa r ! Dexr on IIE / su r e t h e wir e h a r n ess is n ot t wist ed, kin ked or t ou ch -
Mer con . in g a n y body pa n els.
SOLENOID WIRE
CONNECTORS
~
L
M
OIL
TUBES
(INSTALL
Li AS SHOWN)
M
J8921-443
J9421-150
J8921-436
I
PARK
SPACER
ROD
SLEEVE J8921-446
SHIFT
SECTOR Fig. 64 Removing/Installing Park Rod
(5) Cu t spa cer sleeve wit h ch isel a n d r em ove it
fr om m a n u a l va lve sh a ft (F ig. 65).
J8921-444
(6) Rem ove pin fr om sh a ft a n d sect or wit h pin
pu n ch .
Fig. 62 Manual Valve Shaft And Seals
(1) Rem ove pa r k/n eu t r a l posit ion swit ch a n d dis-
con n ect t r a n sm ission sh ift lever (F ig. 62).
(2) Rem ove oil pa n a n d va lve body.
(3) Rem ove bolt s a t t a ch in g pa r k r od br a cket t o
ca se (F ig. 63).
PARK
ROD
MANUAL
VALVE
SHAFT
J8921-447
INSTALLATION
J8921-445
(1) In spect t h e m a n u a l va lve sh a ft a n d sect or.
Repla ce eit h er com pon en t if wor n or da m a ged.
Fig. 63 Removing/Installing Park Rod Bracket (2) Coa t r epla cem en t sh a ft sea ls wit h pet r oleu m
jelly a n d sea t t h em in t h e ca se u sin g a n a ppr opr i-
(4) Rem ove pa r k r od fr om sh ift sect or (F ig. 64). a t ely sized dr iver /socket (F ig. 67).
XJ TRANSMISSION AND TRANSFER CASE 21 - 199
REM OVAL AN D I N STALLAT I ON (Cont inue d)
MANUAL
VALVE
SHAFT SPACER
SEAL SLEEVE
J8921-450
J8921-448
Fig. 68 Installing Spacer Sleeve On Sector
Fig. 66 Removing Manual Valve Shaft Seals (8) Con n ect pa r k r od t o sect or (F ig. 64).
(9) In st a ll pa r k r od br a cket (F ig. 69). Tigh t en
br a cket bolt s t o 10 N·m (7 ft . lbs.) t or qu e.
PARK
ROD
BRACKET
SHAFT
SEAL
INSTALLER
J8921-449
RETAINER
CLIP
J9121-414
INSTALLATION
(1) In spect pist on s, spr in gs a n d pist on bor es.
Repla ce wor n da m a ged pist on s. Repla ce br oken , col-
la psed or dist or t ed spr in gs. Repla ce ca se if pist on A. OVERDRIVE CLUTCH ACCUMULATOR PISTON AND SPRINGS
B. OVERDRIVE BRAKE ACCUMULATOR PISTON AND SPRINGS
bor es a r e da m a ged. C. DIRECT CLUTCH ACCUMULATOR PISTON AND SPRINGS
(2) If sm a ll cu sh ion spr in g in a n y pist on m u st be D. SECOND BRAKE ACCUMULATOR PISTON AND SPRINGS
r epla ced, r em ove spr in g r et a in er clip a n d r em ove
spr in g fr om pist on (F ig. 71). A sm a ll h ooked t ool or
sm a ll t h in bla de scr ewdr iver ca n be u sed t o r em ove
J9121-378
clip. A t h in wa ll, deep socket , or pin pu n ch ca n be
u sed t o sea t clip a ft er spr in g r epla cem en t . Fig. 72 Accumulator Pistons, Springs And Spacers
(3) In st a ll n ew O–r in g sea ls on pist on s. Lu br ica t e
sea ls a n d pist on s a n d pist on bor es wit h t r a n sm ission (2) Rem ove ser vo pist on cover sn a p r in g wit h sn a p
flu id. r in g plier s (F ig. 73).
(4) In st a ll pist on s a n d spr in gs (F ig. 72). (3) Rem ove ser vo pist on a n d cover wit h com -
(5) In st a ll va lve body, oil scr een a n d oil pa n . pr essed a ir. Apply com pr essed a ir t h r ou gh oil h ole in
ser vo boss t o ea se pist on ou t of bor e (F ig. 74).
SECOND COAST BRAKE SERVO (4) Rem ove a n d disca r d sea l a n d O–r in gs fr om
cover a n d pist on (F ig. 75). In spect E –r in g, pist on ,
REMOVAL spr in g a n d r et a in er, pist on r od a n d pist on spr in g.
Repla ce wor n or da m a ged pa r t s.
(1) Rem ove va lve body.
XJ TRANSMISSION AND TRANSFER CASE 21 - 201
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SERVO
PISTON
SERVO
PISTON COVER
SNAP RING
SNAP
---RING
PLIERS
E-RING
~
I
SERVO
SERVO COVER
SNAP RING COVER O-RINGS J8921-459
PARK
ROD
BRACKET
J8921-458
PARK
ROD
J8921-446
Fig. 77 Removing/Installing Park Rod
(3) Rem ove pa r k r od fr om m a n u a l va lve sh a ft sec-
t or (F ig. 77). Fig. 78 Removing/Installing Park Pawl, Pin And
(4) Rem ove pa r k r od. Spring
(5) Rem ove pa r k pa wl, pin a n d spr in g (F ig. 78).
TRANSMISSION THROTTLE CABLE
INSTALLATION
(1) E xa m in e pa r k r od, pa wl, pin a n d spr in g. REMOVAL
Repla ce a n y com pon en t t h a t is wor n or da m a ged. (1) In en gin e com pa r t m en t , discon n ect ca ble fr om
(2) In st a ll pa wl in ca se. In ser t pin a n d in st a ll t h r ot t le lin ka ge. Th en com pr ess ca ble m ou n t in g ea r s
spr in g. Be su r e spr in g is posit ion ed a s sh own in F ig- a n d r em ove ca ble fr om en gin e br a cket (F ig. 79).
u r e 35.
(3) In st a ll pa r k r od a n d br a cket (F ig. 76). Tigh t en
br a cket bolt s t o 10 N·m (7 ft . lbs.) t or qu e.
(4) In st a ll va lve body, oil scr een a n d oil pa n .
CONVERTER
HOUSING
CABLE
RETAINER
SCREW
J9321-84
INSTALLATION
Fig. 80 Removing/Installing Transmission Throttle
(1) Lu br ica t e lip of n ew sea l wit h t r a n sm ission
Cable
flu id a n d in st a ll sea l in pu m p wit h t ool 7549 (F ig.
(5) Rem ove ca ble br a cket bolt a n d r em ove ca ble 82).
a n d br a cket fr om ca se (F ig. 81).
THROTTLE
CABLE
CABLE
BRACKET
J8921-452 J8921-471
DI SASSEM BLY AN D ASSEM BLY (7) Rem ove a da pt er h ou sin g, speedom et er dr ive
gea r, a n d speed sen sor r ot or.
TRANSMISSION (8) Rem ove t r a n sm ission oil pa n , oil scr een a n d
scr een ga sket s (F ig. 85).
DISASSEMBLY OIL
(1) Rem ove t or qu e con ver t er. SCREEN
(2) Rem ove cla m ps a t t a ch in g wir e h a r n ess a n d
t h r ot t le ca ble (F ig. 83) t o t r a n sm ission .
J8921-474
Fig. 83 Typical Harness And Cable Clamp
Attachment
(3) Rem ove sh ift lever fr om m a n u a l va lve sh a ft a t
left side of t r a n sm ission .
(4) Rem ove pa r k/n eu t r a l posit ion swit ch .
(5) Rem ove speed sen sor.
(6) Rem ove con ver t er h ou sin g bolt s a n d r em ove
h ou sin g (F ig. 84) fr om ca se.
J8921-437
CONVERTER HOUSING
J8921-476
Fig. 84 Converter Housing Removal
XJ TRANSMISSION AND TRANSFER CASE 21 - 205
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J8921-439
J8921-433 Fig. 89 Valve Body Bolt Locations
Fig. 87 Solenoid Wire Location
THROTTLE
BRACKET CAM
J8921-478
Fig. 90 Disconnecting Throttle Cable
J8921-436
Fig. 88 Removing Bracket And Harness
(12) Rem ove va lve body bolt s (F ig. 89).
(13) Discon n ect t h r ot t le ca ble fr om t h r ot t le ca m
(F ig. 90).
21 - 206 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(14) Rem ove va lve body fr om ca se. Th en r em ove
a ccu m u la t or spr in gs, ch eck ba ll, a n d spr in g (F ig. 91).
OVERDRIVE
BRAKE
PISTON
J9121-381
Fig. 91 Removing Accumulator Springs, Spacers
And Check Ball
(15) Rem ove secon d br a ke a n d clu t ch a ccu m u la t or
pist on s wit h com pr essed a ir (F ig. 92). Apply a ir pr es-
su r e t h r ou gh feed por t a n d ea se t h e pist on s a n d
spr in gs ou t of t h e bor e. Not e a n d iden t ify t h e or igin a l
loca t ion of a ll spr in gs.
(16) Rem ove over dr ive br a ke a ccu m u la t or pist on
wit h com pr essed a ir (F ig. 92). Not e a n d iden t ify t h e
or igin a l loca t ion of a ll spr in gs.
(17) Rem ove over dr ive clu t ch a ccu m u la t or pist on
wit h com pr essed a ir (F ig. 92).
(18) Rem ove t h r ot t le ca ble.
(19) Rem ove oil pu m p bolt s a n d r em ove pu m p wit h
br idge–t ype P u ller 7536 (F ig. 93).
(20) Rem ove r a ce fr om oil pu m p (F ig. 94).
(21) Rem ove over dr ive pla n et a r y gea r a n d clu t ch
a ssem bly (F ig. 95).
(22) Rem ove r a ce fr om over dr ive pla n et a r y (F ig.
96).
J8921-480
OIL
PUMP J8921-481
PLANETARY
(OVERDRIVE)
RACE
J8921-482
J8921-484
J8921-485
(24) Mea su r e st r oke len gt h of over dr ive br a ke pis- Fig. 98 Removing Overdrive Brake Pack Snap Ring
t on a s follows:
(a ) Mou n t dia l in dica t or on ca se u sin g Miller (29) Rem ove over dr ive br a ke pa ck discs a n d
Tool C-3339 a n d a su it a ble bolt t h r ea ded in t o t h e pla t es. In spect a n d r epla ce a s n ecessa r y.
t r a n sm ission ca se. (30) Rem ove over dr ive su ppor t lower r a ce a n d
(b) Ver ify t h a t t h e dia l in dica t or is m ou n t ed sol- u pper bea r in g a n d r a ce a ssem bly (F ig. 99).
idly a n d squ a r e t o t h e dir ect ion of t h e pist on UPPER BEARING AND RACE
t r a vel.
(c) Apply 57–114 psi a ir pr essu r e t h r ou gh pist on
a pply por t a n d n ot e pist on st r oke on dia l in dica t or.
St r oke len gt h sh ou ld be: 1.40 – 1.70 m m (0.055 –
0.0699 in .).
(d) Recor d t h e r ea din g for u se du r in g r e-a ssem -
bly.
(e) Rem ove t h e dia l in dica t or set -u p fr om t h e
t r a n sm ission .
(25) Mea su r e st r oke len gt h of secon d coa st br a ke
pist on r od a s follows:
(a ) In st a ll a sm a ll wir e t ie st r a p a r ou n d t h e sec-
on d coa st br a ke pist on r od t igh t a ga in st t h e t r a n s-
m ission ca se.
(b) Apply 57–114 psi a ir pr essu r e t h r ou gh pist on
feed h ole a n d ch eck st r oke len gt h wit h Ga u ge Tool
7552.
(c) St r oke len gt h sh ou ld be 1.5 – 3.0 m m (0.059
J8921-489
– 0.118 in .).
(d) Recor d t h e r ea din g for u se du r in g r e-a ssem - Fig. 99 Overdrive Support Bearing/Race Removal
bly.
(26) Rem ove t h e bolt h oldin g t h e in pu t speed sen -
sor t o t h e t r a n sm ission ca se.
XJ TRANSMISSION AND TRANSFER CASE 21 - 209
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(31) Rem ove over dr ive su ppor t sn a p r in g wit h BRIDGE-TYPE
Sn a p Rin g P lier Tool 7540 (F ig. 100). PULLER TOOL
OVERDRIVE
SUPPORT
J8921-492
J8921-493
b.
SERVO DIRECT
PISTON SEAL SPRING PISTON CLUTCH
RING
l@'" . ,--&" ~
AND . · R.OD .
PISTON
SPRING
E-RING
~
I
SERVO
SERVO COVER
COVER O-RINGS
SNAP RING J8921-459
J8921-497
BRAKE BAND
E-RING
SECOND
COAST
BRAKE
BAND
J8921-496
SNAP RING
PLANETARY PLIERS
GEAR
J8921-499
Fig. 108 Front Planetary Ring Gear Removal
J8921-502
(41) Rem ove t h r u st bea r in g a n d r ea r r a ce fr om
r in g gea r (F ig. 109).
Fig. 110 Removing Planetary Snap Ring And Gear
(45) Rem ove su n gea r, in pu t dr u m , on e–wa y
BEARING clu t ch , a n d t h r u st wa sh er a s a ssem bly (F ig. 111).
AND REAR
RACE SUN GEAR
INPUT DRUM
ONE-WAY CLUTCH
ASSEMBLY
J8921-500
Fig. 109 Removing Ring Gear Bearing And Rear
Race J8921-503
Fig. 111 Removing Sun Gear, Input Drum And
(42) Rem ove pla n et a r y t h r u st r a ce. One–Way Clutch
(43) P u sh for wa r d on ou t pu t sh a ft t o r elieve t h e
loa d on t h e pla n et a r y sn a p r in g.
21 - 212 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(46) Mea su r e secon d br a ke clu t ch pa ck clea r a n ce (48) Rem ove secon d br a ke clu t ch pa ck (F ig. 114).
(F ig. 112). Clea r a n ce sh ou ld be 0.62 – 1.98 m m In spect a n d r epla ce a s n ecessa r y.
(0.0244 – 0.0780 in .). Recor d m ea su r em en t for u se
du r in g r e-a ssem bly.
FEELER
GAUGE SECOND
BRAKE
CLUTCH
PACK
SECOND
BRAKE
CLUTCH
PACK
J8921-504
Fig. 112 Checking Second Brake Clutch Pack
Clearance
(47) Rem ove secon d br a ke clu t ch pa ck sn a p r in g MIN. DISC THICKNESS
IS 1.84MM (.0?2 IN)
(F ig. 113).
J8921-506
Fig. 114 Removing/Measuring Second Brake Clutch
Disc Thickness
(49) Rem ove bolt s a t t a ch in g pa r k r od br a cket t o
ca se. Th en discon n ect pa r k r od fr om m a n u a l sh a ft
lever a n d r em ove r od a n d br a cket (F ig. 115).
(50) Rem ove pa r k pa wl spr in g, pin a n d pa wl (F ig.
116).
(51) Mea su r e clea r a n ce of fir st –r ever se br a ke
clu t ch pa ck (F ig. 117). Clea r a n ce sh ou ld be: 0.70 –
1.2 m m (0.028 – 0.047 in .). r ecor d m ea su r em en t for
u se du r in g r e-a ssem bly.
(52) Rem ove secon d br a ke pist on sleeve (F ig. 118).
(53) Rem ove secon d br a ke sn a p-r in g.
(54) Rem ove r ea r pla n et a r y gea r, secon d br a ke
dr u m a n d ou t pu t sh a ft a s a n a ssem bly (F ig. 119).
(55) Rem ove pla n et a r y a n d br a ke dr u m t h r u st
J8921-505 bea r in g a n d r a ce a ssem bly (F ig. 120).
Fig. 113 Removing Second Brake Clutch Pack Snap
Ring
XJ TRANSMISSION AND TRANSFER CASE 21 - 213
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
Fl RST-REVERSE
CLUTCH PACK
J8921-508
J8921-507
Fig. 115 Removing Park Rod And Bracket
PISTON
SLEEVE
JB921-509
PLANETARY,
BRAKE DRUM
AND OUTPUT
SHAFT ASSEMBLY
REAR
BUSHING
J8921-512
Fig. 119 Removing Rear Planetary, Second Brake Fig. 121 Checking Rear Bushing Inside Diameter
Drum And Output Shaft
FIRST-REVERSE
BRAKE
(IN CASE)
Fig. 120 Removing/Installing Bearing And Race Fig. 122 Checking First–Reverse Brake Piston
Assembly Operation
(58) Ch eck fir st /r ever se br a ke pist on oper a t ion
wit h com pr essed a ir (F ig. 122). P ist on sh ou ld m ove
sm oot h ly a n d n ot bin d or st ick. If pist on oper a t ion is
in cor r ect , ca se or pist on m a y r equ ir e r epla cem en t .
XJ TRANSMISSION AND TRANSFER CASE 21 - 215
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(59) Com pr ess pist on r et u r n spr in gs wit h Tool (63) Rem ove No. 1 fir st /r ever se br a ke pist on wit h
7539 a n d r em ove pist on sn a p r in g (F ig. 123). P ist on P u ller 7543 (F ig. 125). Slip t ool u n der pist on
a n d lift t ool a n d pist on ou t of ca se.
COMPRESSOR
TOOL TOOL
NO. 1
PISTON
J8921-6 l 8
(60) Rem ove Tool 7539 a n d r em ove pist on r et u r n Fig. 125 Removing/Installing First–Reverse Brake
spr in gs. No.1 Piston
(61) Rem ove No. 2 fir st –r ever se br a ke pist on wit h
com pr essed a ir. Apply a ir t h r ou gh sa m e t r a n sm ission ASSEMBLY
feed h ole u sed for ch eckin g pist on oper a t ion . (1) Du r in g a ssem bly, lu br ica t e com pon en t s wit h
(62) Rem ove r ea ct ion sleeve wit h Sleeve Rem over t r a n sm ission flu id or pet r oleu m jelly a s in dica t ed.
Tool 7542 (F ig. 124). In ser t t ool fla n ges u n der sleeve (2) Ver ify t h r u st bea r in g a n d r a ce in st a lla t ion du r-
a n d lift t ool a n d sleeve ou t of ca se. in g a ssem bly. Refer t o t h e Th r u st Bea r in g Ch a r t (F ig.
126) for bea r in g a n d r a ce loca t ion a n d cor r ect posi-
TOOL
t ion in g.
(3) In st a ll n ew sea ls on t o t h e No.1 fir st -r ever se
br a ke pist on . Lu br ica t e sea ls wit h t r a n sm ission flu id.
REACTION
SLEEVE (4) In st a ll t h e No.1 fir st -r ever se br a ke pist on in t o
t h e t r a n sm ission ca se.
(5) In st a ll n ew sea l on t o t h e fir st -r ever se br a ke
pist on r ea ct ion sleeve. Lu br ica t e sea ls wit h t r a n sm is-
sion flu id.
J8921-619
G) @ ® 0 ® ® @
II
J8921-669
Fig. 126 Thrust Bearing Chart
(6) In st a ll t h e fir st -r ever se br a ke pist on r ea ct ion (14) Ver ify No. 10 t h r u st bea r in g a n d r a ce (F ig.
sleeve in t o t h e t r a n sm ission ca se. 126). Bea r in g a n d r a ce ou t er dia m et er is 57.7 m m
(7) In st a ll n ew sea l on t o t h e No. 2 fir st -r ever se (2.272 in .) a n d in side dia m et er is 39.2 m m (1.543 in .).
br a ke pist on . Lu br ica t e sea ls wit h t r a n sm ission flu id. (15) Coa t t h r u st bea r in g a n d r a ce a ssem bly wit h
(8) In st a ll t h e No. 2 fir st -r ever se br a ke pist on in t o pet r oleu m jelly a n d in st a ll in ca se (F ig. 127). Ra ce
t h e t r a n sm ission ca se. fa ces down . Bea r in g r oller s fa ce u p.
(9) In st a ll t h e spr in g pla t e in t o t h e No. 2 fir st -r e- (16) Align t eet h of secon d br a ke dr u m a n d clu t ch
ver se br a ke pist on . pa ck (F ig. 128).
(10) In st a ll Spr in g Com pr essor 7539 on t o t h e fir st - (17) Align r ea r pla n et a r y-ou t pu t sh a ft a ssem bly
r ever se br a ke pist on . t eet h wit h ca se slot s a n d in st a ll a ssem bly in ca se
(11) Com pr ess t h e fir st -r ever se br a ke pist on spr in g (F ig. 129).
a n d in st a ll t h e fir st -r ever se br a ke pist on sn a p-r in g. (18) In st a ll r ea r pla n et a r y sn a p r in g wit h sn a p
(12) Rem ove Spr in g Com pr essor 7539. r in g plier s. Ch a m fer ed side of sn a p r in g fa ces u p a n d
(13) In st a ll r ea r pla n et a r y gea r, secon d br a ke t owa r d ca se fr on t (F ig. 130).
dr u m a n d ou t pu t sh a ft a s ou t lin ed in followin g st eps:
XJ TRANSMISSION AND TRANSFER CASE 21 - 217
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
..A. FRONT
~-r_-_-_----==--=--:Jiua
CASE
SLOTS
ALIGN
CLUTCH/DRUM
TEETH
WITH
CASE
SLOTS J8921-672
SECOND
BRAKE
•
DRUM
CLUTCH
PACK -
ALIGN
DRUM AND J8921-673
CLUTCH PACK
TEETH
J8921-671 Fig. 130 Planetary Snap Ring Installation
Fig. 128 Aligning Second Brake Drum And Clutch (20) In st a ll secon d br a ke pist on sleeve (F ig. 132).
Pack Teeth Sleeve lip fa ces u p a n d t owa r d ca se fr on t a s sh own .
(21) In st a ll secon d br a ke dr u m ga sket .
(19) Ch eck fir st –r ever se br a ke pa ck clea r a n ce wit h (22) In st a ll pa r k lock pa wl, spr in g a n d pin
feeler ga u ge (F ig. 131). Clea r a n ce sh ou ld be 0.70 – (F ig. 133).
1.20 m m (0.028 – 0.047 in .). If clea r a n ce is in cor r ect , (23) In st a ll t h e m a n u a l va lve sh ift a ssem bly.
pla n et a r y a ssem bly, t h r u st bea r in g or sn a p r in g is (24) Con n ect pa r k lock r od t o m a n u a l va lve sh ift
n ot pr oper ly sea t ed in ca se. Rem ove a n d r ein st a ll sect or (F ig. 134).
com pon en t s if n ecessa r y.
21 - 218 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J8921-674
PISTON
SLEEVE
PARK
LOCK
ROD
J8921-675
J8921-678
Fig. 132 Second Brake Piston Sleeve Installation Fig. 134 Park Lock Rod Installation
(25) P osit ion pa r k lock r od br a cket on ca se a n d (27) In st a ll No. 1 on e–wa y clu t ch (F ig. 137). Sh or t
t igh t en br a cket a t t a ch in g bolt s t o 10 N·m (7 ft . lbs.) fla n ged side of clu t ch fa ces u p a n d t owa r d ca se fr on t .
t or qu e (F ig. 135). (28) In st a ll secon d br a ke pa ck (F ig. 138). In st a ll
(26) Ver ify pa r k lock oper a t ion . Move sh ift sect or disc t h en pla t e. Con t in u e in st a lla t ion sequ en ce u n t il
t o P a r k posit ion . P a r k pa wl sh ou ld be fir m ly en ga ged five discs a n d five pla t es a r e in st a lled.
(locked) in pla n et a r y r in g gea r (F ig. 136).
XJ TRANSMISSION AND TRANSFER CASE 21 - 219
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J8921-679
Fig. 135 Park Rod Bracket Installation
REAR
PLANETARY J8921-682
RING GEAR
J8921-680
Fig. 136 Checking Park Pawl Engagement
~ FRONT
J8921-683
Fig. 139 Checking Second Brake Pack Clearance
(32) In st a ll pla n et a r y su n gea r a n d in pu t dr u m
(F ig. 140). Be su r e dr u m t h r u st wa sh er t a bs a r e
sea t ed in dr u m . Use pet r oleu m jelly t o h old t h r u st
wa sh er in posit ion if n ecessa r y.
(33) In st a ll fr on t pla n et a r y gea r on su n gea r
J8921-681 (F ig. 141).
Fig. 137 Installing No. 1 One–Way Clutch (34) Su ppor t ou t pu t sh a ft wit h wood blocks
(F ig. 142).
21 - 220 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J8921-686
Fig. 140 Installing Sun Gear And Input Drum Fig. 142 Supporting Output Shaft
J8921-687
Fig. 141 Installing Front Planetary Gear
Fig. 143 Installing Front Planetary Snap Ring
(35) In st a ll pla n et a r y sn a p r in g on su n gea r wit h
sn a p r in g plier t ool 7541 (F ig. 143).
(36) In st a ll t a bbed t h r u st r a ce on fr on t pla n et a r y
gea r. Wa sh er t a bs fa ce down a n d t owa r d gea r. Ra ce
ou t er dia m et er is 47.8 m m (1.882 in .). In side dia m e-
t er is 34.3 m m (1.350 in .).
XJ TRANSMISSION AND TRANSFER CASE 21 - 221
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(37) In st a ll secon d coa st br a ke ba n d (F ig. 144).
SECOND
COAST
BRAKE
BAND
THRUST
BEARING
RING
GEAR
RACE
• FRONT FORWARD-DIRECT
CLUTCH ASSEMBLY
d-~,~~"b"'"""'""·1;l'tg
J8921-691
RACE
THRUST
BEARING
~
u
J8921-692
-,t.FRONT
J8921-695
PISTON
ROD
J8921-699
J8921-701
I
(' (' MARK
J8921-702
SNAP
RING
J8921-708
J8921-706
• FRONT
LOWER J8921-713
RACE
Fig. 165 Installing Overdrive Planetary Ring Gear
J8921-712
OVERDRIVE THRUST
THRUST PLANETARY BEARING
RACE AND RACE
(TABBED) ASSEMBLY
• FRONT
L-~--CLUTCHINPUT
~~lb.::: SHAFT
J8921-715
J8921-717
PUMP
THRUST
RACE
TO PUMP
THROTTLE
CAM
J8921-478
J9121-421
J8921-721
SOLENOID WIRE
DETENT CONNECTORS
SPRING
MANUAL
VALVE
J8921-724
J8921-433
Fig. 175 Aligning Manual Valve, Shift Sector And Fig. 177 Connecting Valve Body Solenoid Wires
Detent Spring
THROTTLE
CAM
M
OIL
TUBES
(INSTALL
Li AS SHOWN)
M
J8921-443
J8921-725
Fig. 178 Installing Valve Body Oil Tubes
Fig. 176 Connecting Transmission Throttle Cable
(90) In st a ll m a gn et in oil pa n . Be su r e m a gn et
(85) In st a ll a n d t igh t en va lve body–t o–ca se bolt s t o
does n ot in t er fer e wit h va lve body oil t u bes.
10 N·m (7 ft . lbs.) t or qu e.
(91) Apply Th r eebon d! Liqu id Ga sket TB1281,
(86) Con n ect va lve body solen oid wir es t o solen oids
P /N 83504038, t o sea lin g su r fa ce of oil pa n . Sea ler
(F ig. 177).
bea d sh ou ld be a t lea st 3 m m (1/8 in .) wide. In st a ll
(87) In st a ll n ew O–r in g on solen oid h a r n ess
pa n on ca se a n d t igh t en pa n bolt s t o 7 N·m (65 in .
a da pt er a n d secu r e a da pt er t o ca se.
lbs.) t or qu e.
(88) In st a ll va lve body oil t u bes (F ig. 178). Ta p
(92) In st a ll t r a n sm ission speed sen sor r ot or a n d
t u bes in t o pla ce wit h a pla st ic m a llet . Be su r e t h e
key on ou t pu t sh a ft (F ig. 179).
fla n ged t u be en ds a n d st r a igh t t u be en ds a r e
(93) In st a ll spa cer a n d speedom et er dr ive gea r on
in st a lled a s sh own .
ou t pu t sh a ft . Th en in st a ll r et a in in g sn a p r in g (F ig.
(89) In st a ll n ew ga sket s on oil scr een a n d in st a ll
180).
scr een on va lve body. Tigh t en scr een bolt s t o 10 N·m
(94) Apply bea d of Th r eebon d! Liqu id Ga sket
(7 ft . lbs.) t or qu e.
TB1281, P /N 83504038, t o sea lin g su r fa ce a t r ea r of
ca se (F ig. 181).
21 - 230 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SPEED
SENSOR
ROTOR
J8921-726
J8921-72B
Fig. 179 Installing Transmission Speed Sensor
Fig. 181 Applying Sealer To Case Rear Flange
Rotor And Key
SPEEDOMETER
DRIVE
GEAR
SNAP RING
J8921-729
J8921-72? II
Fig. 180 Installing Spacer And Speedometer Drive Fig. 182 Installing Transmission Speed Sensor
Gear (100) Mou n t pa r k/n eu t r a l posit ion swit ch on m a n -
(95) In st a ll a da pt er h ou sin g on t r a n sm ission . u a l va lve sh a ft a n d t igh t en swit ch a dju st in g bolt ju st
Tigh t en a da pt er bolt s t o 34 N·m (25 ft . lbs.) t or qu e. en ou gh t o keep swit ch fr om m ovin g (F ig. 184).
(96) In st a ll t r a n sm ission speed sen sor (F ig. 182). (101) In st a ll pa r k/n eu t r a l posit ion swit ch t a bbed
Tigh t en sen sor bolt t o 7.4 N·m (65 in . lbs.) t or qu e wa sh er a n d r et a in in g n u t (F ig. 184). Tigh t en n u t t o
a n d con n ect sen sor wir e h a r n ess con n ect or. 6.9 N·m (61 in . lbs.) t or qu e, bu t do n ot ben d a n y of
(97) In st a ll con ver t er h ou sin g (F ig. 183). Tigh t en t h e wa sh er t a bs a ga in st t h e n u t a t t h is t im e.
12 m m dia m et er h ou sin g bolt s t o 57 N·m (42 ft . lbs.) (102) Align pa r k/n eu t r a l posit ion swit ch st a n da r d
t or qu e. Tigh t en 10 m m dia m et er h ou sin g bolt s t o 34 lin e wit h gr oove or fla t on m a n u a l sh a ft (F ig. 184).
N·m (25 ft . lbs.) t or qu e. (103) Tigh t en pa r k/n eu t r a l posit ion swit ch a dju st -
(98) In st a ll t r a n sm ission sh ift lever on m a n u a l in g bolt t o 13 N·m (9 ft . lbs.) t or qu e.
va lve sh a ft . Do n ot in st a ll lever a t t a ch in g n u t a t t h is (104) In st a ll t r a n sm ission sh ift lever on m a n u a l
t im e. va lve sh a ft . Tigh t en lever a t t a ch in g n u t t o 16 N·m
(99) Move t r a n sm ission sh ift lever fu lly r ea r wa r d. (12 ft . lbs.) t or qu e.
Th en m ove lever t wo det en t posit ion s for wa r d. (105) In st a ll r et a in in g cla m p for wir e h a r n ess a n d
t h r ot t le ca ble (F ig. 185).
XJ TRANSMISSION AND TRANSFER CASE 21 - 231
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
RETAINING
CLAMPS
J8921-731 J8921-732
Fig. 183 Installing Converter Housing Fig. 185 Installing Cable/Harness Clamps
CONVERTER
MOUNTING PAD
NEUTRAL
STANDARD LINE
ADJUSTING
BOLT
J8921-431
J8921-733
Fig. 184 Park/Neutral Position Switch Installation/
Adjustment Fig. 186 Checking Converter Installation
(106) In st a ll t or qu e con ver t er. (109) In st a ll lower h a lf of t r a n sm ission fill t u be
(107) Ver ify t h a t con ver t er is sea t ed by m ea su r in g (in st a ll u pper h a lf a ft er t r a n sm ission is in veh icle).
dist a n ce bet ween con ver t er h ou sin g fla n ge a n d on e of
t h e con ver t er m ou n t in g pa ds (F ig. 186). Use st r a igh t - CAUTION: The transmission cooler and lines must
edge a n d ver n ier ca liper s t o m ea su r e dist a n ce. On be reverse flushed if overhaul corrected a malfunc-
6–cyl. t r a n sm ission s, dist a n ce sh ou ld be 16.5 m m tion that generated sludge, metal particles, or
(0.650 in .). clutch friction material. The torque converter should
(108) Secu r e con ver t er in t r a n sm ission wit h also be replaced if contaminated by the same mal-
C–cla m p or m et a l st r a ppin g. Do t h is befor e m ou n t in g function. Debris and residue not flushed from the
t r a n sm ission on ja ck or m ovin g t r a n sm ission u n der cooler and lines will flow back into the transmission
veh icle. and converter. The result will be a repeat failure and
shop comeback.
21 - 232 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
STATOR
SHAFT
PUMP
I
r
0-RING
J8921-516
ASSEMBLY
(1) Mea su r e in side dia m et er of pu m p body bu sh in g
wit h bor e ga u ge or in side m icr om et er (F ig. 188).
Dia m et er sh ou ld be m a xim u m of 38.19 m m (1.5035
in .). Repla ce pu m p body if bu sh in g I.D. is gr ea t er
t h a n specified.
(2) Mea su r e in side dia m et er of st a t or sh a ft bu sh -
in g (F ig. 188). Ta ke m ea su r em en t s a t fr on t a n d r ea r
of bu sh in g. Dia m et er sh ou ld be m a xim u m of 21.58
m m (0.08496 in .) a t fr on t a n d 27.08 m m (1.0661 in .)
a t r ea r. Repla ce st a t or sh a ft if bu sh in g dia m et er is STATOR
SHAFT
gr ea t er t h a n specified. BUSHING
(3) Mea su r e oil pu m p clea r a n ces (F ig. 189).
• Clea r a n ce bet ween pu m p dr iven gea r a n d pu m p
body sh ou ld be m a xim u m of 0.3 m m (0.012 in ).
• Clea r a n ce bet ween t ips of pu m p gea r t eet h J8921-517
sh ou ld be m a xim u m of 0.3 m m (0.012 in ).
Fig. 188 Checking Pump/Stator Shaft Bushings
• Clea r a n ce bet ween r ea r su r fa ce of pu m p h ou sin g
a n d pu m p gea r s sh ou ld be m a xim u m of 0.1 m m (5) In st a ll n ew sea l wit h Sea l In st a ller 7549 (F ig.
(0.004 in .). 190).
(4) Repla ce pu m p body a n d gea r s if a n y clea r a n ce (6) Lu br ica t e a n d in st a ll gea r s in pu m p body.
is gr ea t er t h a n specified. (7) Assem ble st a t or sh a ft a n d pu m p body. Tigh t en
sh a ft –t o–body bolt s t o 10 N·m (7 ft . lbs.) t or qu e.
XJ TRANSMISSION AND TRANSFER CASE 21 - 233
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
PUMP SEAL
J8921-519
GEAR-TO-GEAR
TOOTH CLEARANCE
TORQUE
CONVERTER
J8921-520
0
\
CLUTCH DRUM
BEARING AND
RACE ASSEMBLY
CLUTCH
PLATES
BEARING
ONE-WAY CLUTCH
OUTER RACE
RETAINING PLATE
RACE
PLANETARY
RING GEAR
J8921-521
(1) Ch eck oper a t ion of on e–wa y clu t ch in clu t ch (b) In st a ll a su it a ble t h r ea ded bolt /r od in t o oil
dr u m (F ig. 192). H old dr u m a n d t u r n pla n et a r y sh a ft pu m p for u se in m ou n t in g Miller Tool C-3339 dia l
clockwise a n d cou n t er clockwise. Sh a ft sh ou ld t u r n in dica t or com pon en t s secu r ely.
clockwise fr eely bu t lock wh en t u r n ed cou n t er clock- (c) Mou n t dia l in dica t or on t h e bolt /r od a n d posi-
wise. Repla ce on e–wa y clu t ch if n ecessa r y. t ion t h e dia l in dica t or squ a r ely on t h e clu t ch pis-
(2) Rem ove over dr ive clu t ch fr om pla n et a r y gea r t on .
(F ig. 193). (d) Apply com pr essed a ir t h r ou gh clu t ch feed
(3) Mea su r e st r oke len gt h of over dr ive clu t ch pis- h ole in oil pu m p a n d n ot e pist on st r oke len gt h .
t on a s follows: St r oke len gt h sh ou ld be 1.85 – 2.15 m m (0.0728 –
(a ) Mou n t oil pu m p on t or qu e con ver t er. Th en 0.0846 in .).
m ou n t clu t ch on oil pu m p (F ig. 194).
XJ TRANSMISSION AND TRANSFER CASE 21 - 235
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CLUTCH DRUM OVERDRIVE
CLUTCH
/ PLANETARY
SHAFT
J8921-522 J8921-525
THRUST BEARING
AND RACE
~I'
PLANETARY
GEAR
', t! )f
J8921-523
J8921-527
(8) Com pr ess pist on r et u r n spr in g wit h Tool 7538 Fig. 198 Removing Overdrive Clutch Piston
(F ig. 197). Rem ove sn a p r in g a n d r em ove com pr essor
t ool. (12) Mea su r e fr ee len gt h of pist on r et u r n spr in gs
wit h spr in gs in r et a in er (F ig. 199). Len gt h sh ou ld be
16.8 m m (0.661 in .). Repla ce spr in g a n d r et a in er
a ssem bly if n ecessa r y.
COMPRESSOR
TOOL
J8921-536
Fig. 197 Removing Clutch Piston Snap Ring
(9) Rem ove t h e pist on r et u r n spr in gs. Fig. 199 Checking Piston Return Spring Length
(10) Mou n t oil pu m p on con ver t er. Th en m ou n t (13) Ch eck clu t ch pist on ch eck ba ll (F ig. 200).
clu t ch on oil pu m p (F ig. 198). Sh a ke pist on t o see if ba ll m oves fr eely. Th en ch eck
(11) H old clu t ch pist on by h a n d a n d a pply com - ba ll sea lin g by a pplyin g low pr essu r e com pr essed a ir
pr essed a ir t h r ou gh oil pu m p feed h ole t o ea se pist on t o ba ll in let a s sh own . Air sh ou ld n ot lea k pa st ch eck
ou t (F ig. 198). Apply on ly en ou gh a ir pr essu r e t o ba ll.
r em ove pist on .
XJ TRANSMISSION AND TRANSFER CASE 21 - 237
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CLUTCH PISTON
CHECK BALL
BEARING,--..,
USE LOW-PRESSURE
COMPRESSED AIR
TO TEST BALL SEATING
J8921-537
(14) Ch eck in side dia m et er of clu t ch dr u m bu sh - Fig. 202 Removing Ring Gear Bearing And Race
in gs wit h bor e ga u ge or in side m icr om et er (F ig. 201).
Ma xim u m in side dia m et er is 27.11 m m (1.0673 in .).
Repla ce dr u m if bu sh in g in side dia m et er is gr ea t er
t h a n specified.
CLUTCH
DRUM
RING
GEAR
J8921-538 HUB
ONE-WAY
CLUTCH
AND
OUTER
RACE
ASSEMBLY
JS921-532
Fig. 204 Remove Planetary Gear Race
(18) Rem ove sn a p r in g a n d r em ove r et a in in g pla t e
(F ig. 205).
J8921-534
RETAINING
PLATE
J8921-533
Fig. 205 Removing Snap Ring And Retaining Plate
(19) Rem ove on e–wa y clu t ch a n d ou t er r a ce a s
a ssem bly. Th en sepa r a t e r a ce fr om clu t ch (F ig. 206).
(20) Rem ove t h r u st wa sh er (F ig. 207).
(21) Ch eck in side dia m et er of pla n et a r y gea r bu sh -
in g (F ig. 208). Ma xim u m in side dia m et er is 11.27
m m (0.4437 in .). Repla ce pla n et a r y gea r if bu sh in g J8921-535
in side dia m et er is gr ea t er t h en specified. Fig. 207 Removing Planetary Thrust Washer
(3) In st a ll on e–wa y clu t ch in t o t h e ou t er r a ce (F ig.
ASSEMBLY 210). Be su r e fla n ged side of clu t ch is fa cin g u pwa r d.
(1) In st a ll t h r u st wa sh er in pla n et a r y gea r (F ig.
(4) In st a ll clu t ch r et a in in g pla t e a n d sn a p r in g in
209). Gro o v e d s id e o f w a s h e r fa c e s u p a n d
pla n et a r y gea r.
to w a rd fro n t.
(5) Coa t pla n et a r y r a ce wit h pet r oleu m jelly a n d
(2) In st a ll clu t ch r a ce in t o pla n et a r y gea r.
in st a ll it on pla n et a r y gea r. Ou t side dia m et er of r a ce
XJ TRANSMISSION AND TRANSFER CASE 21 - 239
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
PLANETARY FLANGED
BUSHING SIDE OF CLUTCH
FACES UP
J8921-539 J8921-540
Fig. 208 Checking Planetary Bushing Fig. 210 Assembling One–Way Clutch And Race
J8921-535 J8921-530
Fig. 209 Install Planetary Thrust Washer Fig. 211 Install Ring Gear Bearing And Race
sh ou ld be 41.8 m m (1.646 in .); in side dia m et er is 27.1 (9) Lu br ica t e n ew clu t ch pist on O–r in gs wit h
m m (1.067 in .). Mopa r ! Door E a se, or Ru –Glyde. Th en in st a ll r in gs
(6) In st a ll h u b in pla n et a r y r in g gea r a n d in st a ll on clu t ch pist on a n d in st a ll pist on in clu t ch dr u m .
sn a p r in g. (10) In st a ll pist on r et u r n spr in gs in clu t ch pist on
(7) Coa t r a ce a n d bea r in g wit h pet r oleu m jelly a n d (F ig. 212).
in st a ll in pla n et a r y r in g gea r (F ig. 211). (11) In st a ll pist on sn a p r in g. Com pr ess pist on
(8) Ver ify bea r in g/r a ce size. Ou t side dia m et er of r et u r n spr in gs wit h Tool 7538 a n d sh op pr ess (F ig.
r a ce is 47.8 m m (1.882 in .) a n d in side dia m et er is 213).
24.2 m m (0.953 in .). Ou t side dia m et er of bea r in g is (12) In st a ll over dr ive clu t ch pa ck in dr u m . In st a ll
46.8 m m (1.843 in .) a n d in side dia m et er is 26 m m st eel pla t e fir st , t h en a disc (F ig. 214). Con t in u e
(1.024 in .). in st a lla t ion sequ en ce u n t il r equ ir ed n u m ber of discs
a n d pla t es h a ve been in st a lled.
21 - 240 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CLUTCH
RETURN DISC
SPRINGS
STEEL
PLATE
J8921-543
J8921-541 Fig. 214 Installing Overdrive Clutch Discs And
Fig. 212 Installing Piston Return Springs Plates
SNAP
RING
CLUTCH PACK
RETAINER
J8921-542
Fig. 213 Installing Clutch Piston Snap Ring
(13) In st a ll clu t ch pa ck r et a in er wit h fla t side fa c-
in g down wa r d. Th en in st a ll r et a in er sn a p r in g (F ig.
215). Com pr ess spr in gs wit h su it a ble t ool.
(14) In st a ll clu t ch dr u m bea r in g a n d r a ce a ssem bly
(F ig. 216). Be su r e bea r in g r oller s fa ce u pwa r d a s J8921-544
sh own . Ou t side dia m et er of a ssem bled bea r in g a n d
r a ce is 50.2 m m (1.976 in .). In side dia m et er is 28.9 Fig. 215 Installing Retainer And Snap Ring
m m (1.138 in .). OVERDRIVE SUPPORT
(15) In st a ll clu t ch on pla n et a r y gea r.
(16) Ver ify on e–wa y clu t ch oper a t ion . H old dr u m DISASSEMBLY
a n d t u r n pla n et a r y sh a ft clockwise a n d cou n t er clock- (1) Ch eck br a ke pist on oper a t ion . Mou n t su ppor t
wise. Sh a ft sh ou ld t u r n clockwise fr eely bu t lock on clu t ch (F ig. 217).
wh en t u r n ed cou n t er clockwise.
XJ TRANSMISSION AND TRANSFER CASE 21 - 241
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
BEARING
AND
RACE
ASSEMBLY
/ROLLERS
CLUTCH
DRUM
00 0
J8921-545
Fig. 216 Installing Clutch Drum Bearing And Race Fig. 218 Removing Support Thrust Bearing And
Assembly Races
(2) Apply com pr essed a ir t h r ou gh su ppor t feed
h ole a n d obser ve br a ke pist on m ovem en t (F ig. 217).
P ist on sh ou ld m ove sm oot h ly a n d n ot bin d or st ick. If
oper a t ion is in cor r ect , r epla ce pist on a n d su ppor t .
OVERDRIVE
SUPPORT
THRUST
WASHER
J8921-547
Fig. 217 Checking Brake Piston Movement J8921-549
(3) Rem ove t h r u st bea r in g fr on t r a ce, t h r u st bea r-
Fig. 219 Removing Clutch Drum Thrust Washer And
in g a n d r ea r r a ce (F ig. 218).
Race
(4) Tu r n over dr ive su ppor t over a n d r em ove bea r-
in g r a ce a n d clu t ch dr u m t h r u st wa sh er (F ig. 219). (5) Com pr ess pist on r et u r n spr in g wit h Spr in g
Com pr essor 7537 a n d r em ove pist on sn a p r in g (F ig.
220).
21 - 242 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SEAL
RINGS (2)
J8921-550 SUPPORT
THRUST
BEARING
BRAKE PISTON
PISTON RETURN SPRING O-RINGS
J8921-546
FRONT
RACE
SPRING
RETAINER
J8921-536 00 J8921-553
Fig. 223 Checking Piston Return Spring Length Fig. 225 Installing Support Thrust Bearing And
Races
(8) Ver ify br a ke pist on oper a t ion . Use sa m e pr oce-
du r e descr ibed a t begin n in g of disa ssem bly. P ist on
sh ou ld oper a t e sm oot h ly a n d n ot bin d or st ick.
DIRECT CLUTCH
DISASSEMBLY
(1) Rem ove dir ect clu t ch fr om for wa r d clu t ch (F ig.
226).
DIRECT CLUTCH
/PORT OVERDRIVE
J8921-552
J8921-556
J8921-558
Fig. 227 Removing Clutch Drum Thrust Washer
Fig. 229 Checking Direct Clutch Piston Stroke
(3) Ch eck clu t ch pist on st r oke len gt h a s ou t lin ed Length
in followin g st eps.
eit h er t h e clu t ch pa ck r et a in er or clu t ch discs will
(4) Mou n t dir ect clu t ch on over dr ive su ppor t
h a ve t o be r epla ced.
a ssem bly (F ig. 228).
(8) Rem ove clu t ch pa ck sn a p r in g a n d r em ove
DIRECT CLUTCH r et a in er a n d clu t ch pa ck fr om dr u m (F ig. 230).
DIRECT
CLUTCH
DRUM
OVERDRIVE
SUPPORT
J8921-557
J8921-536
J8921-560
Fig. 233 Checking Piston Return Spring Length
Fig. 231 Removing Piston Return Spring (15) Ch eck clu t ch pist on ch eck ba ll (F ig. 234).
Sh a ke pist on t o see if ba ll m oves fr eely. Th en ch eck
t h r ou gh pist on feed h ole in su ppor t t o r em ove pist on . ba ll sea t in g by a pplyin g low pr essu r e com pr essed a ir
Use on ly en ou gh a ir t o ea se pist on ou t . t o ba ll in let a s sh own . Air sh ou ld n ot lea k pa st ch eck
ba ll.
CLUTCH PISTON PISTON
CHECK BALL
USE LOW-PRESSURE
AIR TO CHECK
SEATING
DIRECT CLUTCH
PISTON
SUPPORT
FEED HOLE
J8921-562
Fig. 232 Removing Direct Clutch Piston Fig. 234 Testing Piston Check Ball Seating
(12) Rem ove a n d disca r d clu t ch pist on O–r in gs. (16) Mea su r e in side dia m et er of clu t ch dr u m bu sh -
(13) Mea su r e clu t ch disc t h ickn ess. Min im u m in g. In side dia m et er sh ou ld be n o m or e t h a n 53.97
a llowa ble t h ickn ess is 1.84 m m (0.0724 in ). Repla ce m m (2.1248 in .). Repla ce dr u m if bu sh in g in side
clu t ch pa ck if a n y disc is below m in im u m t h ickn ess. dia m et er is gr ea t er t h a n specified.
(14) Mea su r e fr ee len gt h of pist on r et u r n spr in gs
wit h spr in gs in r et a in er (F ig. 233). Len gt h sh ou ld be ASSEMBLY
21.32 m m (0.839 in .). Repla ce r et u r n spr in gs if n ot (1) Lu br ica t e a n d in st a ll r epla cem en t O–r in gs on
wit h in specifica t ion . clu t ch pist on (F ig. 235).
21 - 246 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
CLUTCH PACK
SNAP RING
CLUTCH PACK RETAINER
CLUTCH
'6-CYLINDER CLUTCH DISC'
FOUR DISCS.USES FOUR PLATES - PLATE'
J8921-554
J8921-563
FORWARD
CLUTCH J8921-566
BEARING
=\
AND RACE
Q)O
\
BEARING
RACE
SEAL RINGS
CUSHION PLATE
I
CLUTCH PACK
SNAP RING
*6-CYLINDER M PLATE*
PLATES AND Dgg~~S USE SIX
JS921-567
BEARING RACE
FORWARD
CLUTCH
DRUM
J8921-571
SNAP
RING
FEED
HOLE
J8921-572
CLUTCH
DRUM
HUB
THRUST
BEARING
AND
RACE
ASSEMBLY
J8921-573 J8921-575
\.-__ CLUTCH
DISC
MICROMETER
J8921-574
BEARING
ROLLERS
FACE UP
FORWARD
CLUTCH
J8921-536
USE LOW
AIR PRESSURE
FOR TEST
J8921-577
APPROXIMATELY
71.2mm---'
DIRECT (2.80 in.)
CLUTCH
CLUTCH 1
DISCS - + - -
.,_----1_ CLUTCH
PLATES
J8921-582
J8921-580
Fig. 255 Checking Forward Clutch Assembled
Fig. 253 Installing Forward Clutch Discs And Plates Height
FRONT PLANETARY GEAR
DISASSEMBLY
(1) Rem ove r in g gea r fr om pla n et a r y gea r (F ig.
~----_-_-_~...JI 256).
(2) Rem ove fr on t bea r in g a n d t h e t wo r a ces fr om
r in g gea r (F ig. 256).
(3) Rem ove t a bbed t h r u st r a ce fr om pla n et a r y gea r
(F ig. 256).
(4) Rem ove sn a p r in g a t t a ch in g pla n et a r y gea r t o
sh a ft a n d r em ove gea r.
(5) Rem ove r ea r bea r in g a n d r a ce fr om pla n et a r y
gea r.
(6) Mea su r e in side dia m et er of r in g gea r bu sh in g.
Ma xim u m a llowa ble dia m et er is 24.08 m m (0.9480
in .). Repla ce r in g gea r if bu sh in g in side dia m et er is
gr ea t er t h a n specified.
(7) Ch eck con dit ion of pla n et a r y gea r. Repla ce gea r
J8921-581
if t eet h a r e wor n , pin s a r e loose, or ca r r ier is cr a cked,
Fig. 254 Installing Thrust Bearing And Race dist or t ed, or wor n .
XJ TRANSMISSION AND TRANSFER CASE 21 - 253
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
FRONT PLANETARY RING GEAR
FORWARD REAR
RACE RACE
THRUST REAR
RACE BEARING
J8921-583
TABBED
THRUST FRONT
RACE BEARING
AND
RACE
- ·
PLANETARY
I I
GEAR
~ . I
·~·
6~o
J9121-399
J8921-586
SUN GEAR
SNAP RING
ONE-WAY CLUTCH
AND SECOND BRAKE
HUB ASSEMBLY
SNAP RING
SEAL RINGS
J9121-400
J8921-590
0 0
J8921-591
.,__ _ SUN
GEAR
J8921-592
J8921-595
J8921-593
Fig. 267 Installing Clutch And Hub Assembly On
Fig. 265 Removing/Installing Second Snap Ring Sun Gear
ASSEMBLY wise a n d cou n t er clockwise. H u b sh ou ld t u r n clock-
(1) In st a ll fir st sn a p r in g on su n gea r. wise fr eely, bu t lock wh en t u r n ed cou n t er clockwise.
(2) In st a ll su n gea r in dr u m a n d in st a ll r em a in in g
sn a p r in g. SECOND BRAKE
(3) Coa t r epla cem en t sea l r in gs wit h pet r oleu m
jelly a n d in st a ll t h em on su n gea r. B e s u re s e a l DISASSEMBLY
rin g e n d s a re in te rlo c k e d . (1) Rem ove secon d br a ke dr u m fr om ou t pu t sh a ft
(4) In st a ll t h r u st wa sh er. Be su r e wa sh er t a bs a r e (F ig. 268).
sea t ed in dr u m slot s. (2) Rem ove t h r u st wa sh er fr om secon d br a ke dr u m
(5) In st a ll on e–wa y clu t ch /secon d br a ke h u b (F ig. 269).
a ssem bly on su n gea r. Deep side of h u b fla n ge fa ces (3) Com pr ess pist on r et u r n spr in gs wit h sh op
u pwa r d (F ig. 267). pr ess a n d t ool 7538. Th en r em ove pist on sn a p r in g
(6) Ch eck on e–wa y clu t ch oper a t ion a ga in (F ig. (F ig. 270).
260). H old su n gea r a n d t u r n secon d br a ke h u b clock- (4) Rem ove com pr essor t ool a n d r em ove spr in g
r et a in er a n d r et u r n spr in gs.
XJ TRANSMISSION AND TRANSFER CASE 21 - 257
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
~ SPRING RETAINER
SNAP RING
THRUST WASHER
J8921-597
J8921-536
J8921-599
Fig. 272 Measuring Second Brake Piston Return
Fig. 270 Removing/Installing Second Brake Piston Springs
Snap Ring (4) Ch eck br a ke pist on oper a t ion wit h low pr es-
PISTON su r e com pr essed a ir (F ig. 273). Apply a ir pr essu r e
AND t h r ou gh feed h ole in dr u m . P ist on sh ou ld m ove
SLEEVE
sm oot h ly wh en a pplyin g–r elea sin g a ir pr essu r e.
PISTON
J8921-600
SPRING
RETAINER
TABS
J8921-602
ONE-WAY CLUTCH
INNER RACE
RACES
SNAP RING
THRUST
BEARING
OUTPUT SHAFT
J8921-603
J8921-604
0-- SEAL
RING
J8921-605
J8921-607
REAR
PLANETARY
GEAR
J8921-606
CLUTCH
INNER
RACE
J8921-609
0 2 ONE-WAY
N . CLUTCH
Fig. 280 Removing/Installing Clutch Inner Race
(9) Rem ove No. 2 on e–wa y clu t ch bot t om en d ca p
fr om pla n et a r y.
(10) Rem ove fr on t a n d r ea r t h r u st wa sh er s fr om
pla n et a r y gea r (F ig. 282).
(11) Rem ove t h r u st bea r in g a n d wa sh er s fr om r in g
gea r (F ig. 283).
(12) Rem ove r in g gea r sn a p r in g a n d r em ove r in g
gea r h u b (F ig. 284).
(13) In spect a n d r epla ce a n y wor n or da m a ged
pla n et a r y gea r com pon en t s.
PLANETARY
GEAR
J8921-6 l 0
REAR
THRUST
WASHER
SNAP
RING
J8921-611
J8921-613
REAR
PLANETARY
J8921-614
PRESSURE
RELIEF VALVE
MULATOR
tc5~¥ROL VALVE
J9121-384
¾:~ ((({((/{~
'l
THROTTLE
VALVE
ADJUSTING
RINGS AND SPRING
"' SECONDARY
REGULATOR
VALVE AND SPRING
UPPER BODY
V,
~PLUNGER 'l SECOND COAST MODULATOR
VALVE AND SPRING
SLEM ~
LOCK-UP RELAY VALVE :
AND SPRING
I
I
STRAINER~ I
I I
.J
----
I
I
I
CHECK BALLS---.._o o o I
0 0 0 PLUG~
l.,_
'J:;E
0 0 0 (
RETAINER~
! CAM ~
L~' VMVESTOP
J8921-625
Transmission Fluid ........... . .. . ..... . . . .... . .... . .... . . . ... .. . Jeep automatic transmission fluid or DEXRON® II
Fluid Level .. . . . ... . . . . .. . . .... . ..... .. ... . .. . . . . .. ... To "Full" mark with fluid hot (normal operating temperature)
Fluid Capacity (all models) ... . . . . .... .. .. . .. . ... . .. . . ....... . ..... . . . . ..... . . . . .. ... .. 8.0 Liters (8 .45 qts.)
Test Specifications
Stall Speed:
In D Range and Reverse ........................ .. .... ... ... . . .. .. ... .... . .... .. ....... 2100-2400 rpm
Line Pressure:
In D at Curb Idle . ... ... ... . . .. . . . ... . .... . . . ... . ............ . .... . .. . . . ... .... 61-70 psi (421-481 kPa)
In D at WOT ........................ . ........ ... .... . .... . ........... . ... 173-209 psi (1196-1442 kPa)
In Reverse at Curb Idle .. .. ... .... .. ... .. ... ... .... . .......... . ......... . . . .... .. 75-90 psi (519-618 kPa)
In Reverse at WOT ...... . ..... ... . . ...... ... . . .. .. . ...... .. . . ... . . .... .. .. . 213-263 psi (1471-1814 kPa)
Engagement in D Range .. .. .... . .... . .. . ... .. .... . .... .. .... . ......... . .. . .. .. ... .... .... 1.2 seconds
Engagement in Reverse ... .. ................. . ......... ... ........ .. . . . . ..... . . . ... .. ... . . 1.5 seconds
Valve Body Solenoid Resistance ................ ... .... . ..... . .......... . ............... .. .... . 11-15 ohms
Transmission Fluid Normal Operating Temperature ........ . ................ . ..... .. .... . .. 50-80°C (122-176°F)
TPS Input Voltage (AU) . .... . .. . .. .. .. . ...... .. .... .. .......... . .......... . .... . ...... 5.0 Volts (approx.)
J9121-401
XJ TRANSMISSION AND TRANSFER CASE 21 - 271
SPECI FI CAT I ON S (Cont inue d)
AW-4 OIL PUMP WEAR LIMITS
Drive Gear
Tip Clearance:
Gear-ta-Pump Body
End Clearance:
Standard ..... .. ..... . .... .. .... ... ... .. ..... .... .. . . . ... .. ....... . ................ . .. ............. 0.02-0.05 mm (0.0008-0.0020 in.)
Driven Gear-ta-Pump
Body Clearance:
Maximum Allowance . . ... .... . .. . .. . . .. . . . . .... ... ..... ... . . . ... . .. . ... . .. . . . ... . ... . ... .. . ... . . . .. . . .. .... ..... . . . 0.3 mm (0.01 2 in.)
18921-740
Clutch Disc (all except first-reverse and forward clutch discs) 1.84 mm (0.0724 in.)
J9l21-402
21 - 272 TRANSMISSION AND TRANSFER CASE XJ
SPECI FI CAT I ON S (Cont inue d)
AW-4 BUSHING AND PISTON CLEARANCE
BUSHING INSIDE DIAMETER (MAXIMUM)
Component Specification
J9121-.403
XJ TRANSMISSION AND TRANSFER CASE 21 - 273
SPECI FI CAT I ON S (Cont inue d)
AW-4 RETAINER AND PISTON SPECIFICATIONS
OVERDRIVE BRAKE RETAINER SELECTION
J9121-A05
J9121-A06
XJ TRANSMISSION AND TRANSFER CASE 21 - 275
SPECI FI CAT I ON S (Cont inue d)
AW-4 VALVE AND SPRING IDENTIFICATION
(l)
~-UffimM--l 17 DODDto
I
(2) L - - - - - - - - - - - - - - - - - :
~ --aaa- -q][)[):[J- ~
~ - - Ql=D:D::0 - -OD
Spring Free Length
(4)
(1) Downshift Plug 27.3 mm (1.074 in.)
~ --c:J![J:::C}- --[HJ
(2) Throttle Valve 20.6 mm (.811 in.)
(8)
[]::D:t]::D:0::- -~ - -00
(9)
O=[:]II:::::J- - ~--Dll
J9121-408
21 - 276 TRANSMISSION AND TRANSFER CASE XJ
SPECI FI CAT I ON S (Cont inue d)
AW-4 ACCUMULATOR COMPONENT
IDENTIFICATION
Approxlrnata
Component Outside Diameter
,~ r-M
D
VL
B E
c---i ~F PK ~N
~G
J9121-407
XJ TRANSMISSION AND TRANSFER CASE 21 - 277
SPECI FI CAT I ON S (Cont inue d)
AW-4 TORQUE SPECIFICATIONS
.______ _ _ _ __.l
o_e_s_cr_i_pt_i_o_n_ _ _ __,__ _ _ _T_o_r_q_ue _,____o_e_sc_r_ip_t_io_n_ _ _ _~_ _ _ _T_o_rq_u_e_ _ _ _~
Converter Housing Bolts Rear Mount-To-Transmission
10mm 32-36 N•m (23-27 ft. lbs. ) Bolts ........ . 60-81 N•m (44-66 ft. lbs.)
12mm. 55-59 N•m (40-43 ft. lbs.) Rear Mount-To-Clevis Bracket
Cooler Line Retaining Bolt/Nut ......... . 54-75 N•m (40-55 ft. lbs.)
Clip Nuts . 2-4 N• m (18-35 in. lbs.) Rear Mount Clevis Bracket-To-
Cooler Line Bracket Crossmember Nuts ..... 33-49 N•m (24-36 ft. lbs.)
Nuts. 5-11 N•m (48-96 in . lbs. ) Shift Cable Bracket Screws
Cooler Line Fitting Nuts At Transmission ...... .. . . 25-39 N•m (221-345 in. lbs.)
(at auto. trans. fittings) ... 18-23 N•m (160-200 in. lbs.) Shift Lever Mounting
Detent Spring Bolt . 9-11 N•m (80-96 in . lbs.) Cover Screws .... ..... . 1-2 N•m (9-20 in. lbs.)
Dust Caver Nuts/ Bolts . ........... . 18-23 N•m (159-203 in. lbs. ) Shift Lever Housing Nuts ......... . . 16-26 N•m (141-230 in. lbs.)
Extension Housing Bolts ... . 32-36 N•m (23-27 ft. lbs.) Solenoid Harness Bolt . . . . .. . . . . 6-8 N•m (57-75 in . lbs.)
Fill Tube Bracket Bolt 50-64 N•m (37-47 ft. lbs.) Speedometer Adapter
Neutral Switch Clamp Screw ...... . 10-12 N•m (90-110 in. lbs.)
Bolt ...... . . . .. . .. . . . . . 12-14 N•m (8-10 ft. lbs.) Speed Sensor Coupling Nut ..... 14-20 N•m (125-175 in. lbs.)
Nut........ .. . ..... . . . . . 6-8 N•m (53-70 in. lbs. ) Throttle Cable Engine
OD Support Bolt (to case) 23-27 N•m (18-20 ft. lbs.) Bracket Screws ... ..... . . .. ... . 7-11 N•m (63-94 in. lbs.)
Oil Pan Bolts ... , ..... . .. . . .. . . . 6-8 N•m (53-70 in. lbs. ) Throttle Cable Retaining
Oil Pan Drain Plug . 19-21 N•m (14-16 ft. lbs.) Screw (at transmission) ... 8-10 N•m (70-98 in. lbs.)
Oil Pump Bolt Transfer Case Mounting Nuts ...... . 30-41 N•m (22-30 ft. lbs.)
(to case) 21-23 N•m (16-18 ft. lbs.) Transmission Shift Lever Nut ....... . 15-17 N•m (134-154 in. lbs.)
Oil Pump Bolt Transmission-To-Engine
(to stator shaft) 9-11 N•m (80-96 in. lbs. ) Block Bolts .. 50-64 N•m (37-47 ft. lbs. )
Oil Screen Bolt 9-11 N•m (80-96 in. lbs.) Valve Body Bolts (to case) ........ . 9-11 N•m (80-96 in. lbs.)
Park Pawl Bracket ............ . . . . 9-11 N•m (80-96 in. lbs. ) Valve Body Bolts (to valve body) . 6-7 N•m (54-58 in. lbs.)
Propeller Shaft Clamp
Screws. . .... . . .. . . . . 16-23 N•m (140-200 in. lbs.)
J9321-88
21 - 278 TRANSMISSION AND TRANSFER CASE XJ
SPECI AL T OOLS
AW-4
C-4960 Micrometer
C-3293-SP Gauge
'
7538 Compressor, Piston #2 Spring
8011d42b
INDEX
page page
GEN ERAL I N FORM AT I ON power in off r oa d sit u a t ion s. Low r a n ge r edu ct ion
r a t io is 2.72:1.
NV231 TRANSFER CASE
Th e NV231 is a pa r t -t im e t r a n sfer ca se wit h a low SHIFT MECHANISM
r a n ge r edu ct ion gea r syst em . Th e NV231 h a s t h r ee Oper a t in g r a n ges a r e select ed wit h a floor m ou n t ed
oper a t in g r a n ges plu s a Neu t r a l posit ion . A low r a n ge sh ift lever. Th e sh ift lever is con n ect ed t o t h e t r a n s-
syst em pr ovides a r edu ct ion r a t io for in cr ea sed low fer ca se r a n ge lever by a n a dju st a ble lin ka ge r od. A
speed t or qu e ca pa bilit y. st r a igh t lin e sh ift pa t t er n is u sed. Ra n ge posit ion s
Th e in pu t gea r is splin ed t o t h e t r a n sm ission ou t - a r e m a r ked on t h e sh ift er bezel cover pla t e.
pu t sh a ft . Th e in pu t gea r dr ives t h e m a in sh a ft
t h r ou gh t h e pla n et a r y a ssem bly a n d r a n ge h u b. Th e TRANSFER CASE IDENTIFICATION
fr on t ou t pu t sh a ft is oper a t ed by a dr ive ch a in t h a t A cir cu la r ID t a g is a t t a ch ed t o t h e r ea r ca se of
con n ect s t h e sh a ft t o a dr ive spr ocket on t h e m a in - ea ch t r a n sfer ca se (F ig. 1). Th e ID t a g pr ovides t h e
sh a ft . Th e dr ive spr ocket is en ga ged/disen ga ged by t r a n sfer ca se m odel n u m ber, a ssem bly n u m ber, ser ia l
t h e m ode for k, wh ich oper a t es t h e m ode sleeve a n d n u m ber, a n d low r a n ge r a t io.
h u b. Th e sleeve a n d h u b a r e n ot equ ipped wit h a Th e t r a n sfer ca se ser ia l n u m ber a lso r epr esen t s
syn ch r on izer m ech a n ism for sh ift in g. t h e da t e of bu ild.
Th e gea r t r a in is m ou n t ed in t wo a lu m in u m ca se
h a lves a t t a ch ed wit h bolt s. Th e m a in sh a ft fr on t a n d
r ea r bea r in gs a r e m ou n t ed in a lu m in u m r et a in er
h ou sin gs bolt ed t o t h e ca se h a lves.
OPERATING RANGES
Tr a n sfer ca se oper a t in g r a n ges a r e:
• 2WD (2-wh eel dr ive)
• 4x4 (4-wh eel dr ive)
• 4 Lo (4-wh eel dr ive low r a n ge
Th e 2WD r a n ge is for u se on a n y r oa d su r fa ce a t
a n y t im e.
Th e 4x4 a n d 4 Lo r a n ges a r e for off r oa d u se on ly.
Th ey a r e n ot for u se on h a r d su r fa ce r oa ds. Th e on ly
except ion bein g wh en t h e r oa d su r fa ce is wet or slip-
per y or cover ed by ice a n d sn ow.
Th e low r a n ge r edu ct ion gea r syst em is oper a t ive Fig. 1 Fill/Drain Plug And I.D. Tag Locations
in 4 Lo r a n ge on ly. Th is r a n ge is for ext r a pu llin g
XJ TRANSMISSION AND TRANSFER CASE 21 - 281
GEN ERAL I N FORM AT I ON (Cont inue d)
RECOMMENDED LUBRICANT AND FILL LEVEL fill plu g h ole. Be su r e t h e veh icle is level t o en su r e
Recom m en ded lu br ica n t for t h e NV231 t r a n sfer a n a ccu r a t e flu id level ch eck.
ca se is Mopa r ! Dexr on II, or ATF P lu s 3, t ype 7176.
Appr oxim a t e lu br ica n t fill ca pa cit y is 1.2 lit er s (2.5
pin t s).
Th e fill a n d dr a in plu gs a r e bot h in t h e r ea r ca se
(F ig. 1). Cor r ect fill level is t o t h e bot t om edge of t h e
REM OVAL AN D I N STALLAT I ON (7) Con n ect in dica t or swit ch h a r n ess t o t r a n sfer
ca se swit ch , if n ecessa r y. Secu r e wir e h a r n ess t o clips
TRANSFER CASE on t r a n sfer ca se.
(8) Align a n d con n ect pr opeller sh a ft s. Refer t o
REMOVAL Gr ou p 3, Differ en t ia l a n d Dr ivelin e, for pr oper pr oce-
(1) Sh ift t r a n sfer ca se in t o Neu t r a l. du r es a n d specifica t ion s.
(2) Ra ise veh icle. (9) F ill t r a n sfer ca se wit h cor r ect flu id. Ch eck
(3) Dr a in t r a n sfer ca se lu br ica n t . t r a n sm ission flu id level. Cor r ect a s n ecessa r y.
(4) Ma r k fr on t a n d r ea r pr opeller sh a ft yokes for (10) In st a ll r ea r cr ossm em ber, or skid pla t e.
a lign m en t r efer en ce. Tigh t en cr ossm em ber bolt s t o 41 N·m (30 ft . lbs.)
(5) Su ppor t t r a n sm ission wit h ja ck st a n d. t or qu e.
(6) Rem ove r ea r cr ossm em ber, or skid pla t e. (11) Rem ove t r a n sm ission ja ck a n d su ppor t st a n d.
(7) Discon n ect fr on t /r ea r pr opeller sh a ft s a t t r a n s- (12) Con n ect sh ift r od t o t r a n sfer ca se r a n ge lever.
fer ca se. (13) Adju st t r a n sfer ca se sh ift lin ka ge.
(8) Discon n ect veh icle speed sen sor wir es. (14) Lower veh icle a n d ver ify t r a n sfer ca se sh ift
(9) Discon n ect t r a n sfer ca se lin ka ge r od fr om oper a t ion .
r a n ge lever.
(10) Discon n ect t r a n sfer ca se ven t h ose (F ig. 2) SHIFT LEVER
a n d in dica t or swit ch h a r n ess, if n ecessa r y.
(11) Su ppor t t r a n sfer ca se wit h t r a n sm ission ja ck. REMOVAL
(12) Secu r e t r a n sfer ca se t o ja ck wit h ch a in s. (1) Sh ift t r a n sfer ca se in t o 4L.
(13) Rem ove n u t s a t t a ch in g t r a n sfer ca se t o t r a n s- (2) Ra ise veh icle.
m ission . (3) Loosen a dju st in g t r u n n ion lockn u t a n d slide
(14) P u ll t r a n sfer ca se a n d ja ck r ea r wa r d t o disen - sh ift r od ou t of t r u n n ion (F ig. 3). If r od la cks en ou gh
ga ge t r a n sfer ca se. t r a vel t o com e ou t of t r u n n ion , pu sh t r u n n ion ou t of
(15) Rem ove t r a n sfer ca se fr om u n der veh icle. t or qu e sh a ft .
(4) Lower veh icle.
(5) Rem ove con sole. Refer t o Gr ou p 23, Body, for
pr oper pr ocedu r es.
(6) Rem ove scr ews a t t a ch in g lever a ssem bly t o
floor pa n a n d r em ove a ssem bly a n d sh ift r od (if left
a t t a ch ed).
INSTALLATION
(1) If sh ift r od wa s n ot r em oved fr om lever a ssem -
bly, wor k r od down t h r ou gh floor pa n open in g. Th en
posit ion lever a ssem bly on floor pa n a n d in st a ll
a ssem bly a t t a ch in g scr ews.
(2) In st a ll con sole. Refer t o Gr ou p 23, Body, for
pr oper pr ocedu r es.
(3) Ra ise veh icle.
(4) Con n ect t r u n n ion t o t or qu e sh a ft a r m . Or, slide
sh ift r od in t o t r u n n ion on r a n ge lever. Be su r e sh ift
Fig. 2 Transfer Case Mounting r od slides fr eely in t r u n n ion .
INSTALLATION (5) Ver ify t h a t r a n ge lever is in 4L posit ion . Th en
(1) Mou n t t r a n sfer ca se on a t r a n sm ission ja ck. t igh t en t r u n n ion lock bolt .
(2) Secu r e t r a n sfer ca se t o ja ck wit h ch a in s. (6) Lower veh icle a n d ch eck t r a n sfer ca se sh ift
(3) P osit ion t r a n sfer ca se u n der veh icle. oper a t ion .
(4) Align t r a n sfer ca se a n d t r a n sm ission sh a ft s
a n d in st a ll t r a n sfer ca se on t r a n sm ission . SPEEDOMETER
(5) In st a ll a n d t igh t en t r a n sfer ca se a t t a ch in g n u t s
t o 35 N·m (26 ft . lbs.) t or qu e (F ig. 2). REMOVAL
(6) Con n ect veh icle speed sen sor wir es, a n d ven t (1) Ra ise veh icle.
h ose. (2) Discon n ect wir es fr om veh icle speed sen sor.
(3) Rem ove a da pt er cla m p a n d scr ew (F ig. 4).
XJ TRANSMISSION AND TRANSFER CASE 21 - 283
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SHIFT
LEVER
ASSEMBLY
TORQUE
FLOORPAN
SHAFT
TRANSFER
CASE
BRACKET
TRUNNION
LOCK BOLT
0 SELECTOR
ROD AND
TRUNNION
TRANSFER
CASE
SHIFT
LEVER TORQUE
SHAFT J9321-185
\~B~
B 10-12 N•m (90-110 in. lbs.)
SENSOR
\
SPEEDOMETER
PINION
VEHICLE
SPEED
SENSOR J9321-385
J9321-386
Fig. 5 Location Of Index Numbers On Speedometer Fig. 6 Remove Front Output Shaft Seal
Adapter
INSTALLATION
(1) In st a ll n ew fr on t ou t pu t sea l in fr on t ca se wit h
In st a ller Tool 8143 a s follows:
(a ) P la ce n ew sea l on t ool. Ga r t er spr in g on sea l
goes t owa r d in t er ior of ca se.
(b) St a r t sea l in bor e wit h ligh t t a ps fr om h a m -
m er (F ig. 7). On ce sea l is st a r t ed, con t in u e t a ppin g
sea l in t o bor e u n t il in st a ller t ool sea t s a ga in st ca se.
XJ TRANSMISSION AND TRANSFER CASE 21 - 285
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SNAP-RING
Fig. 7 Front Output Seal Installation Fig. 9 Slinger Stop Spacer and Snap-ring
DI SASSEM BLY AN D ASSEM BLY (6) Use a su it a ble pr y t ool, or a slide h a m m er
m ou n t ed scr ew, t o r em ove t h e sea l fr om t h e r ea r
NV231 TRANSFER CASE r et a in er (F ig. 10).
(7) Rem ove t h e r ea r ou t pu t bea r in g I.D. r et a in in g
DISASSEMBLY r in g (F ig. 11).
P osit ion t r a n sfer ca se on sh a llow dr a in pa n . (8) Rem ove t h e bolt s h oldin g t h e r ea r r et a in er t o
Rem ove dr a in plu g a n d dr a in lu br ica n t r em a in in g in t h e r ea r ca se h a lf.
ca se.
REAR BEARING
I.D. RETAINING
RING
80010964 0-RING RR21F27
Fig. 11 Output Shaft Rear Bearing Retaining Ring Fig. 14 Pick-up Tube O-ring Location
da r d t wo ja w pu ller (F ig. 16). Be su r e pu ller t ool is
posit ion ed on yoke a n d n ot on slin ger a s slin ger will
be da m a ged.
IMPACT
WRENCH
J PUMP
Fig. 15 Yoke Nut Removal
D
80010966
SPLINE HEAD
BOLT (1) PICKUP PICKUP
DOWEL BOLT TUBE SCREEN
80010979
AND
WASHER (2)
Fig. 20 Oil Pickup Tube Removal
MODE-----~~
SPRING
80010969
MODE
SLEEVE
FRONT
OUTPUT
SHAFT
SHAFT
FRONT
BEARING 80010971
RANGE
FORK
8001096b
80010973
POPPET BORE
(IN CASE)
8001096a
MAINSHAFT DISASSEMBLY
(1) Rem ove m ode h u b r et a in in g r in g wit h h ea vy
Fig. 26 Shift Sector Removal
du t y sn a p-r in g plier s (F ig. 28).
(2) Slide m ode h u b off m a in sh a ft (F ig. 29). INPUT GEAR AND LOW RANGE GEAR REMOVAL
(3) Slide dr ive spr ocket off m a in sh a ft (F ig. 30). (1) Rem ove fr on t bea r in g r et a in er a t t a ch in g bolt s
(F ig. 31).
XJ TRANSMISSION AND TRANSFER CASE 21 - 289
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SECTOR
/ SHAFT
\BORE
\ \
DRIVE
SPROCKET
8001096e
Fig. 27 Sector Bushing And O-Ring Removal Fig. 30 Drive Sprocket Removal
FRONT
CASE
SNAP RING
PLIERS
(HEAVY DUTY)
8001096d
Fig. 28 Mode Hub Retaining Ring Removal Fig. 31 Front Bearing Retainer Bolts
FRONT
BEARING
RETAINER
MODE
HUB
80010961 RETAINER
SLOT
Fig. 29 Mode Hub Removal
(2) Rem ove fr on t bea r in g r et a in er. P r y r et a in er
loose wit h pr y t ool posit ion ed in slot s a t ea ch en d of J8921-266
r et a in er (F ig. 32).
Fig. 32 Front Bearing Retainer Removal
21 - 290 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
(3) Rem ove fr on t bea r in g r et a in er sea l. Ta p sea l
ou t wit h dr ift a n d h a m m er.
(4) Rem ove in pu t gea r r et a in in g r in g wit h h ea vy
du t y sn a p-r in g plier s (F ig. 33)
\\ \INPUT
GEAR
BEARING
rJ/tiJJ 80010975
80010944
FRONT
Fig. 34 Input Gear And Planetary Carrier Removal TABBED
THRUST
INPUT AND LOW RANGE GEAR DISASSEMBLY WASHER
(1) Rem ove sn a p-r in g t h a t r et a in s in pu t gea r in
low r a n ge gea r (F ig. 35).
(2) Rem ove r et a in er (F ig. 36).
(3) Rem ove fr on t t a bbed t h r u st wa sh er (F ig. 37).
(4) Rem ove in pu t gea r (F ig. 38).
(5) Rem ove r ea r t a bbed t h r u st wa sh er fr om low
r a n ge gea r (F ig. 39). Fig. 37 Front Tabbed Thrust Washer Removal
ASSEMBLY
Lu br ica t e t r a n sfer ca se com pon en t s wit h Mopa r !
Dexr on II a u t om a t ic t r a n sm ission flu id or pet r oleu m
jelly (wh er e in dica t ed) du r in g a ssem bly.
XJ TRANSMISSION AND TRANSFER CASE 21 - 291
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
LOW
RANGE
GEAR
REAR TABBED
THRUST WASHER
J9321-36
Fig. 39 Rear Tabbed Thrust Washer Removal Fig. 41 Front Output Shaft Bearing Retaining Ring
BEARING AND SEAL INSTALLATION Removal
SPECIAL TOOL
L-4454-1
AND
L-4454-3
S0a98366
HANDLE
C-4171
--- 'TRANSFER
CASE
---- S0a11094
__,._ ~ )9321-55
Fig. 48 Output Shaft Rear Bearing Installation Depth
80a11090
SPECIAL
TOOL Fig. 51 Remove Input Gear Pilot Bearing
C-4210
PILOT BEARING
J9521-43
Fig. 49 Input Shaft Bearing Removal
loca t in g r in g m u st be fu lly sea t ed a ga in st ca se su r-
fa ce (F ig. 50).
SPECIAL
TOOL
5065
INPUT
GEAR
8001b777
800bdfa9
OIL PUMP
FEED
SPECIAL HOUSING
TOOL
7888 ....._
HOUSING
SEAL
LOW RANGE
GEAR
J9521-35
MODE
DRIVE HUB
SPROCKET
8001096c
MODE
SLEEVE
80010971
Fig. 62 Range Lever Installation Fig. 65 Assembling Mode Fork And Sleeve
(5) Align a n d in ser t r a n ge for k pin in sh ift sect or (9) In st a ll a ssem bled m ode for k a n d sleeve (F ig.
slot . 66). Be su r e for k r a il goes t h r ou gh r a n ge for k a n d
' \
in t o ca se bor e. Also be su r e sleeve is a lign ed a n d
RANGE sea t ed on m a in sh a ft h u b.
HUB
\\
RANGE
FORK
(
Q
B00cedfb
POPPET BORE
(IN CASE)
DRIVE
8001096a SPROCKET
J9321-72
Fig. 67 Shift Detent Components
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION Fig. 68 Installing Drive Chain And Front Output
(1) Lu br ica t e fr on t ou t pu t sh a ft -spr ocket a ssem bly, Shaft
dr ive ch a in , a n d dr ive spr ocket wit h t r a n sm ission
flu id.
(2) Assem ble dr ive ch a in a n d fr on t ou t pu t sh a ft
(F ig. 68).
MODE
(3) St a r t ch a in on m a in sh a ft dr ive spr ocket . SPRING
(4) Gu ide fr on t sh a ft in t o bea r in g a n d dr ive
spr ocket on t o m a in sh a ft dr ive gea r (F ig. 68).
(5) In st a ll m ode spr in g on u pper en d of m ode for k
sh ift r a il (F ig. 69).
MAGNET
J892l-288
O-RING
YOKE
NUT
J9321-1
MODE DRIVE
HUB SPROCKET
MAINSHAFT
MODE HUB
RETAINING RING 80010947
REAR
THRUST
WASHER
FRONT
THRUST CARRIER
WASHER LOCK CARRIER
RING LOCK
RETAINING
RING
PLANETARY
CARRIER
INPUT
GEAR
8001b751
BOOT
REAR
SLINGER
LOCATING
REAR WASHER
REAR SEAL
RETAINER
REAR SLINGER
SLINGER
LOCATING
RING
REAR
BEARING O.D.
REAR RETAINING
BEARING RING
80010949
8001094b
Fig. 85 Seal Contact Surface Of Yoke Slinger Fig. 86 Low Range Annulus Gear
XJ TRANSMISSION AND TRANSFER CASE 21 - 303
SPECI AL T OOLS
NV231
FLOORPAN
LINKAGE
BRACKET
Installer—C-4076-B
•RANGE~
TORQUE LEVER
SHAFT ROD
TORQUE SHAFT /
BRACKET J9521-163
Puller, Slinger—MD-998056–A
Installer—MD-998323
21 - 304 TRANSMISSION AND TRANSFER CASE XJ
SPECI AL T OOLS (Cont inue d)
Seal Protector—6992
Installer, Seal—C-4210
Installer, Seal—8143
Installer, Bearing—5065
Installer, Bushing—5066
Handle, Universal—C-4171
XJ TRANSMISSION AND TRANSFER CASE 21 - 305
SPECI AL T OOLS (Cont inue d)
INDEX
page page
SHIFT MECHANISM
Oper a t in g r a n ges a r e select ed wit h a floor m ou n t ed
sh ift lever. Th e sh ift lever is con n ect ed t o t h e t r a n s-
fer ca se r a n ge lever by a n a dju st a ble lin ka ge r od. A
st r a igh t lin e sh ift pa t t er n is u sed. Ra n ge posit ion s
a r e m a r ked on t h e sh ift er bezel cover pla t e, or on t h e
sh ift kn ob.
I'
Condition I
Possible Cause I
Correction 7
-
Transfer case difficult to shift or will 1) Transfer case shift linkage 1) Repair or replace linkage as
not shift into desired range. binding. necessary.
2) Insufficient or incorrect lubricant. 3) Drain and refill transfer case with
-
the correct type and quantity of
lubricant.
3) Internal transfer case 3) Repair or replace components as
-
components binding, worn, or necessary.
damaged.
Transfer case noisy in all drive 1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
modes. the correct type and quantity of
lubricant.
Lubricant leaking from transfer case 1) Transfer case overfilled. 1) Drain lubricant to the correct
seals or vent. level.
2) Transfer case vent closed or 2) Clean or replace vent as
restricted. necessary.
3) Transfer case seals damaged or 3) Replace suspect seal.
installed incorrectly.
-
Transfer case will not shift through 1) Incomplete shift due to drivetrain 1) Momentarily release the
4X4 part time range (light remains torque load. accelerator pedal to complete the
on) 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.
-
.__ _J
21 - 308 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (7) Con n ect in dica t or swit ch h a r n ess t o t r a n sfer
ca se swit ch , if n ecessa r y. Secu r e wir e h a r n ess t o clips
TRANSFER CASE on t r a n sfer ca se.
(8) Align a n d con n ect pr opeller sh a ft s. Refer t o
REMOVAL Gr ou p 3, Differ en t ia l a n d Dr ivelin e, for pr oper pr oce-
(1) Sh ift t r a n sfer ca se in t o Neu t r a l. du r es a n d specifica t ion s.
(2) Ra ise veh icle. (9) F ill t r a n sfer ca se wit h cor r ect flu id. Ch eck
(3) Dr a in t r a n sfer ca se lu br ica n t . t r a n sm ission flu id level. Cor r ect a s n ecessa r y.
(4) Ma r k fr on t a n d r ea r pr opeller sh a ft yokes for (10) In st a ll r ea r cr ossm em ber, or skid pla t e.
a lign m en t r efer en ce. Tigh t en cr ossm em ber bolt s t o 41 N·m (30 ft . lbs.)
(5) Su ppor t t r a n sm ission wit h ja ck st a n d. t or qu e.
(6) Rem ove r ea r cr ossm em ber, or skid pla t e. (11) Rem ove t r a n sm ission ja ck a n d su ppor t st a n d.
(7) Discon n ect fr on t /r ea r pr opeller sh a ft s a t t r a n s- (12) Con n ect sh ift r od t o t r a n sfer ca se r a n ge lever.
fer ca se. (13) Adju st t r a n sfer ca se sh ift lin ka ge.
(8) Discon n ect veh icle speed sen sor wir es. (14) Lower veh icle a n d ver ify t r a n sfer ca se sh ift
(9) Discon n ect t r a n sfer ca se lin ka ge r od fr om oper a t ion .
r a n ge lever.
(10) Discon n ect t r a n sfer ca se ven t h ose (F ig. 3) SHIFT LEVER
a n d in dica t or swit ch h a r n ess, if n ecessa r y.
(11) Su ppor t t r a n sfer ca se wit h t r a n sm ission ja ck. REMOVAL
(12) Secu r e t r a n sfer ca se t o ja ck wit h ch a in s. (1) Sh ift t r a n sfer ca se in t o 4L.
(13) Rem ove n u t s a t t a ch in g t r a n sfer ca se t o t r a n s- (2) Ra ise veh icle.
m ission . (3) Loosen a dju st in g t r u n n ion lockn u t a n d slide
(14) P u ll t r a n sfer ca se a n d ja ck r ea r wa r d t o disen - sh ift r od ou t of t r u n n ion (F ig. 4). If r od la cks en ou gh
ga ge t r a n sfer ca se. t r a vel t o com e ou t of t r u n n ion , pu sh t r u n n ion ou t of
(15) Rem ove t r a n sfer ca se fr om u n der veh icle. t or qu e sh a ft .
(4) Lower veh icle.
(5) Rem ove con sole. Refer t o Gr ou p 23, Body, for
pr oper pr ocedu r es.
(6) Rem ove scr ews a t t a ch in g lever a ssem bly t o
floor pa n a n d r em ove a ssem bly a n d sh ift r od (if left
a t t a ch ed).
INSTALLATION
(1) If sh ift r od wa s n ot r em oved fr om lever a ssem -
bly, wor k r od down t h r ou gh floor pa n open in g. Th en
posit ion lever a ssem bly on floor pa n a n d in st a ll
a ssem bly a t t a ch in g scr ews.
(2) In st a ll con sole. Refer t o Gr ou p 23, Body, for
pr oper pr ocedu r es.
(3) Ra ise veh icle.
(4) Con n ect t r u n n ion t o t or qu e sh a ft a r m . Or, slide
sh ift r od in t o t r u n n ion on r a n ge lever. Be su r e sh ift
Fig. 3 Transfer Case Mounting r od slides fr eely in t r u n n ion .
INSTALLATION (5) Ver ify t h a t r a n ge lever is in 4L posit ion . Th en
(1) Mou n t t r a n sfer ca se on a t r a n sm ission ja ck. t igh t en t r u n n ion lock bolt .
(2) Secu r e t r a n sfer ca se t o ja ck wit h ch a in s. (6) Lower veh icle a n d ch eck t r a n sfer ca se sh ift
(3) P osit ion t r a n sfer ca se u n der veh icle. oper a t ion .
(4) Align t r a n sfer ca se a n d t r a n sm ission sh a ft s
a n d in st a ll t r a n sfer ca se on t r a n sm ission . SPEEDOMETER
(5) In st a ll a n d t igh t en t r a n sfer ca se a t t a ch in g n u t s
t o 35 N·m (26 ft . lbs.) t or qu e (F ig. 3). REMOVAL
(6) Con n ect veh icle speed sen sor wir es, a n d ven t (1) Ra ise veh icle.
h ose. (2) Discon n ect wir es fr om veh icle speed sen sor.
(3) Rem ove a da pt er cla m p a n d scr ew (F ig. 5).
XJ TRANSMISSION AND TRANSFER CASE 21 - 309
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SHIFT
LEVER
ASSEMBLY
TORQUE
FLOORPAN
SHAFT
TRANSFER
CASE
BRACKET
TRUNNION
LOCK BOLT
0 SELECTOR
ROD AND
TRUNNION
TRANSFER
CASE
SHIFT
LEVER TORQUE
SHAFT J9321-185
\~B~
B 10-12 N•m (90-110 in. lbs.)
SENSOR
\
SPEEDOMETER
PINION
VEHICLE
SPEED
SENSOR J9321-385
J9321-386
Fig. 6 Location Of Index Numbers On Speedometer Fig. 7 Remove Front Output Shaft Seal
Adapter
INSTALLATION
(1) In st a ll n ew fr on t ou t pu t sea l in fr on t ca se wit h
In st a ller Tool 6952-A a s follows:
(a ) P la ce n ew sea l on t ool. Ga r t er spr in g on sea l
goes t owa r d in t er ior of ca se.
(b) St a r t sea l in bor e wit h ligh t t a ps fr om h a m -
m er (F ig. 8). On ce sea l is st a r t ed, con t in u e t a ppin g
sea l in t o bor e u n t il in st a ller t ool sea t s a ga in st ca se.
XJ TRANSMISSION AND TRANSFER CASE 21 - 311
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SPECIAL
-_ /TOOL
TRANSFER MD998056-A
CASE~
~
~
80a50352
80a50353
SNAP
RING
PLIERS
~' D. RETAINING
EAR BEARING
RING
80010964 0-RING RR21F27
Fig. 13 Rear Bearing I.D. Retaining Ring Removal Fig. 16 Pickup Tube O-Ring Location
(12) Rem ove bolt s a t t a ch in g r ea r ca se t o fr on t ca se
(F ig. 17). Not e posit ion of t h e t wo bla ck fin ish bolt s
a t ea ch en d of t h e ca se. Th ese bolt s go t h r ou gh t h e
ca se dowels a n d r equ ir e a wa sh er u n der t h e bolt
h ea d.
DOWEL BOLT
AND
WASHER (2)
J PUMP
(13) Rem ove r ea r ca se fr om fr on t ca se (F ig. 18).
In ser t scr ewdr iver s in t o slot s ca st in t o ea ch en d of
ca se. Th en pr y u pwa r d t o br ea k sea ler bea d a n d
D r em ove r ea r ca se.
FRONT
CASE
RP1099
PICKUP PICKUP
TUBE SCREEN
80010979
IMPACT
WRENCH YOKE
SOCKET Fig. 22 Range Lever Removal
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Rem ove dr ive spr ocket sn a p-r in g (F ig. 23).
(2) Rem ove dr ive spr ocket a n d ch a in (F ig. 24).
(3) Rem ove fr on t ou t pu t sh a ft (F ig. 25).
J8921-253
J8921-251
Fig. 25 Removing Front Output Shaft
Fig. 23 Drive Sprocket Snap-Ring Removal
PLUNGER
PLUG
0-RING
SHIFT
RAIL
MODE
FORK
J8921-255
J8921-257
INTERMEDIATE
CLUTCH
SHAFT
CLUTCH
SHAFT
THRUST
RING
J8921-259 J8921-261
Fig. 31 Clutch Shaft Thrust Ring Removal Fig. 33 Differential Snap-Ring Removal
INTERMEDIATE
CLUTCH DIFFERENTIAL
SHAFT
J8921-260 J8921-262
J8921-263 J8921-263
FORK HUB
J8921-207
Iii
Fig. 38 Sector Bushing And O-Ring Removal
Fig. 36 Low Range Fork And Hub Removal (5) Rem ove low r a n ge gea r sn a p-r in g (F ig. 42).
INPUT GEAR/LOW RANGE ASSEMBLY REMOVAL AND (6) Rem ove in pu t gea r r et a in er, t h r u st wa sh er s
DISASSEMBLY a n d in pu t gea r fr om low r a n ge gea r (F ig. 43).
(1) Rem ove fr on t bea r in g r et a in er bolt s. (7) In spect low r a n ge a n n u lu s gea r (F ig. 44). Ge a r
(2) Rem ove fr on t bea r in g r et a in er. Ca r efu lly pr y is n o t a s e rv ic e a ble c o m p o n e n t. If d a m a g e d ,
r et a in er loose wit h scr ewdr iver (F ig. 39). P osit ion re p la c e g e a r a n d fro n t c a s e a s a s s e m bly.
scr ewdr iver in slot s ca st in t o r et a in er. (8) Rem ove oil sea ls fr om followin g com pon en t s:
(3) Rem ove in pu t gea r sn a p-r in g (F ig. 40). • fr on t bea r in g r et a in er.
(4) Rem ove in pu t /low r a n ge gea r a ssem bly fr om • r ea r r et a in er.
bea r in g wit h Tool H a n dle C-4171 a n d Tool 7829A • oil pu m p.
(F ig. 41). • ca se h a lves.
21 - 318 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SPECIAL
TOOL
SPECIAL C-4171
TOOL
7829A
LOW RANGE
GEAR SNAP
RING
J8921-267 J8921-269
Fig. 40 Input Gear Snap-Ring Removal Fig. 42 Low Range Gear Snap-Ring Removal/
Installation
DIFFERENTIAL DISASSEMBLY
(1) Ma r k differ en t ia l ca se h a lves for r efer en ce. (5) Rem ove t h r u st wa sh er s a n d pla n et gea r s fr om
(2) Rem ove differ en t ia l ca se bolt s. ca se pin s (F ig. 46).
(3) In ver t differ en t ia l on wor kben ch . (6) Rem ove m a in sh a ft a n d spr ocket gea r s fr om
(4) Sepa r a t e t op ca se fr om bot t om ca se. Use slot s bot t om ca se (F ig. 47). Not e gea r posit ion for r efer en ce
in ca se h a lves t o pr y t h em a pa r t (F ig. 45). befor e sepa r a t in g t h em .
XJ TRANSMISSION AND TRANSFER CASE 21 - 319
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J8921-214
SPROCKET GEAR
J8921-273
J8921-274
SPECIAL
TOOL
C-4210
80a11090
HANDLE
C-4171
INSTALLER
J8921-219
8128
Fig. 53 Seating Input Gear Bearing
(11) In st a ll n ew sea l in fr on t bea r in g r et a in er wit h
In st a ller 7884 (F ig. 56).
(12) Rem ove ou t pu t sh a ft r ea r bea r in g wit h t h e
scr ew a n d ja ws fr om Rem over L-4454 a n d Cu p 8148
(F ig. 57). 80a98364
(13) In st a ll n ew bea r in g wit h Tool H a n dle C-4171
a n d In st a ller 5066 (F ig. 58). Lu br ica t e bea r in g a ft er Fig. 55 Install Input Gear Pilot Bearing
in st a lla t ion .
(14) In st a ll n ew sea l in oil pu m p feed h ou sin g wit h
Specia l Tool 7888 (F ig. 59).
(15) In st a ll n ew picku p t u be O-r in g in oil pu m p
(F ig. 60).
21 - 322 TRANSMISSION AND TRANSFER CASE XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
SPECIAL
TOOL
7884
J9521-41
Fig. 56 Front Bearing Retainer Seal Installation Fig. 58 Install Front Output Shaft Rear Bearing
SPECIAL TOOL
L-4454-1
AND SPECIAL
L-4454-3 TOOL
7888 ....._
HOUSING
SEAL
J9521-35
PICKUP TUBE
0-RING
J8921-286 J8921-280
Fig. 60 Pickup Tube O-Ring Installation Fig. 62 Installing Mainshaft And Planet Gears
CASE MARKS
ALIGNMENT
BOTTOM J8921-281
J8921-279 CASE
LOW RANGE
GEAR
J8921-267
\
RETAINER
Fig. 66 Input Gear Snap Ring Installation
J8921-214 (8) In st a ll fr on t bea r in g r et a in er (F ig. 67). Tigh t en
r et a in er bolt s t o 16 ft . lbs. (21 N·m ) t or qu e.
Fig. 64 Low Range And Input Gear Assembly
I
I
LOW RANGE
GEAR SNAP
RING
l J8921-276
J8921-263
MAINSHAFT
BEARING
ROLLERS
J8921-278
INTERMEDIATE
CLUTCH
SHAFT
J8921-260
MAINSHAFT
Fig. 74 Installing Intermediate Clutch Shaft
ch eck spr in gs a n d slider br a cket (F ig. 77). Repla ce
J8921-283 wor n , da m a ged com pon en t s.
CLUTCH
SHAFT
THRUST
RING
J8921-259
INTERMEDIATE
CLUTCH
SHAFT
J8921-258
J8921-257
J8921-284
PLUNGER
J8921-255
J8921-285
MAGNET
J8921-288
11~----- REAR
RETAINER
800bdfa9
REAR SNAP
BEARING O.D. ,,...._ _ _ RING
OIL RETAINING PLIERS
SCREEN RING
J8921-287
80a50355
NV242 TRANSFER CASE
Clea n t h e t r a n sfer ca se pa r t s wit h a st a n da r d
Fig. 89 Output Shaft Seal and Protector pa r t s clea n in g solven t . Rem ove a ll t r a ces of sea ler
fr om t h e ca ses a n d r et a in er s wit h a scr a per a n d a ll
SPECIAL TOOL pu r pose clea n er. Use com pr essed a ir t o r em ove sol-
MD998323 ven t r esidu e fr om oil feed pa ssa ges in t h e ca se
h a lves, r et a in er s, gea r s, a n d sh a ft s.
Th e oil picku p scr een ca n be clea n ed wit h solven t .
Sh a ke excess solven t fr om t h e scr een a ft er clea n in g
a n d a llow it t o a ir dr y. Do n ot u se com pr essed a ir.
MAINSHAFT/SPROCKET/HUB INSPECTION
In spect t h e splin es on t h e h u b a n d sh a ft a n d t h e
t eet h on t h e spr ocket . Min or n icks a n d scr a t ch es ca n
be sm oot h ed wit h a n oilst on e. H owever, r epla ce a n y
pa r t is da m a ged.
Ch eck t h e con t a ct su r fa ces in t h e spr ocket bor e
a n d on t h e m a in sh a ft . Min or n icks a n d scr a t ch es ca n
be sm oot h ed wit h 320–400 gr it em er y clot h bu t do
n ot t r y t o sa lva ge t h e sh a ft if n icks or wea r is sever e.
Fig. 90 Rear Seal Installation
(10) In st a ll r ea r slin ger wit h in st a ller C-4076-A INPUT GEAR AND PLANETARY CARRIER
a n d h a n dle MD-998323 (F ig. 90). Ch eck t h e t eet h on t h e gea r (F ig. 92). Min or n icks
(11) In st a ll boot on ou t pu t sh a ft slin ger a n d cr im p ca n be dr essed off wit h a n oilst on e bu t r epla ce t h e
r et a in in g cla m p wit h t ool C-4975-A (F ig. 91). gea r if a n y t eet h a r e br oken , cr a cked, or ch ipped. Th e
bea r in g su r fa ce on t h e gea r ca n be sm oot h ed wit h
300–400 gr it em er y clot h if n ecessa r y.
XJ TRANSMISSION AND TRANSFER CASE 21 - 331
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
REAR
THRUST
WASHER
FRONT
THRUST CARRIER
WASHER LOCK CARRIER
RING LOCK
RETAINING
RING
PLANETARY
CARRIER
INPUT
GEAR
8001b751
BOOT
REAR
SLINGER
LOCATING
REAR WASHER
REAR SEAL
RETAINER
REAR SLINGER
SLINGER
LOCATING
RING
REAR
BEARING O.D.
REAR RETAINING
BEARING RING
80010949
ADJ U ST M EN T S
SHIFT LINKAGE ADJUSTMENT TORQUE
(1) Sh ift t r a n sfer ca se in t o 4L posit ion . SHAFT ROD
(2) Ra ise veh icle. J9521-163
(3) Loosen lock bolt on a dju st in g t r u n n ion (F ig.
97). Fig. 97 Shift Linkage
(4) Be su r e lin ka ge r od slides fr eely in t r u n n ion .
Clea n r od a n d a pply spr a y lu be if n ecessa r y.
(5) Ver ify t h a t t r a n sfer ca se r a n ge lever is fu lly
en ga ged in 4L posit ion .
(6) Tigh t en a dju st in g t r u n n ion lock bolt .
(7) Lower veh icle.
21 - 334 TRANSMISSION AND TRANSFER CASE XJ
SPECI FI CAT I ON S
TORQUE
D ES CRIP TION TORQU E
P lu g, Det en t . . . . . . . . . . 16–24 N·m (12–18 ft . lbs.)
Bolt , Diff. Ca se . . . . . . . . 17–27 N·m (15–24 ft . lbs.)
P lu g, Dr a in /F ill . . . . . . . . 20–25 N·m (15–25 ft . lbs.)
Bolt , F r on t Br g. Ret a in er . . . . 16–27 N·m (12–20 ft .
lbs.)
Bolt , Ca se H a lf . . . . . . . . 35–46 N·m (26–34 ft . lbs.)
Nu t , F r on t Yoke . . . . . 122–176 N·m (90–130 ft . lbs.) Remover—C-4210
Scr ew, Oil P u m p . . . . . . 1.2–1.8 N·m (12–15 in . lbs.)
Nu t , Ra n ge Lever . . . . . . 27–34 N·m (20–25 ft . lbs.)
Bolt , Rea r Ret a in er . . . . . 35–46 N·m (26–34 ft . lbs.)
Nu t s, Mou n t in g . . . . . . . . . . . . . 35 N·m (26 ft . lbs.)
Bolt s, U-J oin t . . . . . . . . . . . . . . . 19 N·m (17 ft . lbs.)
SPECI AL T OOLS
NV242
Puller, Slinger—MD-998056–A
Installer—C-4076-B
Installer—MD-998323
Installer, Bearing—5064
Handle, Universal—C-4171
XJ TRANSMISSION AND TRANSFER CASE 21 - 335
SPECI AL T OOLS (Cont inue d)
Installer—8128 Cup—8148
Installer—6952-A
Installer, Input Gear Bearing—7829-A
Remover—L-4454
Installer, Seal—7884
21 - 336 TRANSMISSION AND TRANSFER CASE XJ
SPECI AL T OOLS (Cont inue d)
page page
AX 1 5 M AN U AL T RAN SM I SSI ON
INDEX
page page
-
TRANSMISSION GEAR RATIOS . . . . . . . . . . . . . . 3 TRANSMISSION NOISE . . . . . ............... 3
TRANSMISSION IDENTIFICATION . . . . . . . . . . . . 2 REMOVAL AND INSTALLATION
TRANSMISSION LUBRICANT . . . . . . . . . . . . . . . . 2 TRANSMISSION . . . . . . . . . . . ............... 3
TRANSMISSION SHIFT PATTERN . . . . . . . . . . . . 2 SPECIFICATIONS
TRANSMISSION SWITCH AND PLUG TORQUE . . . . . . . . . . . . . . . . ............... 6
LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . .... 2
J8921-1023
J8921-1024
J
~
Fig. 2 Identification Code Number Location
on d a n d t h ir d n u m ber s in dica t e m on t h of m a n u fa c-
t u r e. Th e n ext ser ies of n u m ber s is t h e t r a n sm ission
ser ia l n u m ber. '
3 5
2 4 R
J8921-1025
Fig. 5 Drain Plug/Backup Light Switch Location
Fig. 3 AX 15 Shift Pattern
Th e AX 15 is equ ipped wit h a r ever se lockou t
m ech a n ism . Th e sh ift lever m u st be m oved t h r ou gh
t h e Neu t r a l det en t befor e m a kin g a sh ift t o r ever se.
TRANSMISSION LUBRICANT
Recom m en ded lu br ica n t for AX 15 t r a n sm ission s is
Mopa r 75W–90, AP I Gr a de GL–3 gea r lu br ica n t , or
equ iva len t .
XJ TRANSMISSION AND TRANSFER CASE 21 - 3
GEN ERAL I N FORM AT I ON (Cont inue d)
4WD
Fig. 6 Drain Plug and Backup Light Switch Location TRANSFER
VEHICLE CASE
SPEED EXTENSION
SENSOR
80a35409
CLUTCH HOUSING
AND TRANSMISSION
CLUTCH COVER
80abfe70
CLUTCH
HOUSING BOLT 80ad087e
INDEX
page page
OPERATING RANGES
Tr a n sfer ca se oper a t in g r a n ges a r e:
• 2WD (2-wh eel dr ive)
• 4x4 (4-wh eel dr ive)
• 4 Lo (4-wh eel dr ive low r a n ge
Th e 2WD r a n ge is for u se on a n y r oa d su r fa ce a t
a n y t im e. DRAIN PLUG 80b09a60
Th e 4x4 a n d 4 Lo r a n ges a r e for off r oa d u se on ly. Fig. 1 Fill/Drain Plug And I.D. Tag Locations
Th ey a r e n ot for u se on h a r d su r fa ce r oa ds. Th e on ly
except ion bein g wh en t h e r oa d su r fa ce is wet or slip- RECOMMENDED LUBRICANT AND FILL LEVEL
per y or cover ed by ice a n d sn ow. Recom m en ded lu br ica n t for t h e NV231 t r a n sfer ca se
Th e low r a n ge r edu ct ion gea r syst em is oper a t ive is Mopa r ! Dexr on II, or ATF P lu s 3, t ype 7176. Appr ox-
in 4 Lo r a n ge on ly. Th is r a n ge is for ext r a pu llin g im a t e lu br ica n t fill ca pa cit y is 1.2 lit er s (2.5 pin t s).
power in off r oa d sit u a t ion s. Low r a n ge r edu ct ion Th e fill a n d dr a in plu gs a r e bot h in t h e r ea r ca se
r a t io is 2.72:1. (F ig. 1). Cor r ect fill level is t o t h e bot t om edge of t h e
fill plu g h ole. Be su r e t h e veh icle is level t o en su r e
a n a ccu r a t e flu id level ch eck.
21 - 8 TRANSMISSION AND TRANSFER CASE XJ
NV231 DIAGNOSIS
DI AGN OSI S CH ART
REM OVAL AN D I N STALLAT I ON (7) Con n ect in dica t or swit ch h a r n ess t o t r a n sfer
ca se swit ch , if n ecessa r y. Secu r e wir e h a r n ess t o clips
TRANSFER CASE on t r a n sfer ca se.
INSTALLATION
(1) P osit ion sh ift lever on t r a n sm ission . Use ca r e
wh en pa ssin g t h e sh ift lever t h r ou gh t h e sh ift er boot
t o pr even t da m a ge t o t h e sh ift er boot .
(2) In st a ll bolt s t o h old sh ift lever t o t r a n sm ission .
(3) In st a ll t r u n n ion t o sh ift lever, if n ecessa r y.
TRANSMISSION J9321-237 (4) In st a ll sh ift r od t o t r u n n ion , if n ecessa r y.
(5) Move sh ift lever a n d t r a n sfer ca se t o 4L posi-
Fig. 2 Transfer Case Mounting t ion .
(6) Tigh t en t r u n n ion lock bolt .
INSTALLATION
(7) Lower veh icle.
(1) Mou n t t r a n sfer ca se on a t r a n sm ission ja ck.
(8) In st a ll sh ift kn ob on sh ift lever.
(2) Secu r e t r a n sfer ca se t o ja ck wit h ch a in s.
(9) In st a ll n u t t o h old sh ift er kn ob t o sh ift lever.
(3) P osit ion t r a n sfer ca se u n der veh icle.
(10) In st a ll sh ift er kn ob ca p.
(4) Align t r a n sfer ca se a n d t r a n sm ission sh a ft s
(11) Ver ify t r a n sfer ca se oper a t ion .
a n d in st a ll t r a n sfer ca se on t r a n sm ission .
(5) In st a ll a n d t igh t en t r a n sfer ca se a t t a ch in g n u t s
t o 35 N·m (F ig. 2).
SPEEDOMETER
(6) Con n ect veh icle speed sen sor wir es, a n d ven t
h ose.
REMOVAL
(1) Ra ise veh icle.
(2) Discon n ect wir es fr om veh icle speed sen sor.
21 - 10 TRANSMISSION AND TRANSFER CASE XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) Rem ove speed sen sor r et a in in g scr ew a n d
r em ove sen sor fr om a da pt er.
(6) Rem ove speedom et er pin ion fr om a da pt er.
Repla ce pin ion if ch ipped, cr a cked, or wor n .
(7) In spect sen sor a n d a da pt er O-r in gs (F ig. 4).
Rem ove a n d disca r d O-r in gs if wor n or da m a ged.
(8) In spect t er m in a l pin s in speed sen sor. Clea n
pin s wit h Mopa r ! elect r ica l spr a y clea n er if dir t y or
oxidized. Repla ce sen sor if fa u lt y, or if pin s a r e loose,
sever ely cor r oded, or da m a ged.
ITEM TORQUE
A 2-3 N•m {15-27 in. lbs.)
B 10-12 N•m (90-110 in. lbs.)
\
SPEEDOMETER
PINION
VEHICLE
SPEED
J9321-385
SENSOR
-----------------
TRANSFER
CASE
80a9b39e
J9321-386
Fig. 7 Front Output Seal Installation
Fig. 5 Location Of Index Numbers On Speedometer
Adapter
REAR RETAINER BUSHING AND SEAL
FRONT OUTPUT SHAFT SEAL REMOVAL
(1) Ra ise veh icle.
REMOVAL (2) Rem ove r ea r pr opeller sh a ft . Refer t o Gr ou p 3,
(1) Ra ise veh icle. Differ en t ia l a n d Dr ivelin e, for pr oper pr ocedu r e.
(2) Rem ove fr on t pr opeller sh a ft . Refer t o Gr ou p 3, (3) Usin g a su it a ble pr y t ool or slide-h a m m er
Differ en t ia l a n d Dr ivelin e, for pr oper pr ocedu r e. m ou n t ed scr ew, r em ove t h e r ea r r et a in er sea l.
(3) Rem ove fr on t ou t pu t sh a ft yoke. (4) Usin g Rem over 6957, r em ove bu sh in g fr om
(4) Rem ove sea l fr om fr on t ca se wit h pr y t ool (F ig. r ea r r et a in er (F ig. 8).
6).
REAR
RETAINER
BUSHING
80a98373
REAR
RETAINER
BUSHING
Installer, Seal—8143
80a9b39f
Fig. 9 Rear Retainer Bushing Install Remover, Bushing—6957
SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3995-A
Installer, Bushing—8160
80a983a7
Fig. 10 Install Rear Retainer Seal
(5) In st a ll pr opeller sh a ft .
(6) Ver ify pr oper flu id level.
(7) Lower veh icle.
TORQUE
D ES CRIP TION TORQU E
P lu g, Dr a in /F ill . . . . . . . . . . . . . . . . . . . . . . 40 N·m
Nu t s, Mou n t in g . . . . . . . . . . . . . . . . . . . . . . 35 N·m
Swit ch , In dica t or . . . . . . . . . . . . . . . . . . . . . 26 N·m
XJ TIRES AND WHEELS 22 - 1
page page
TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
T I RES
INDEX
page page
sidewa ll.
TIRE CHAINS
300 km/h (186 mph)
Th e speed r a t in g is n ot a lwa ys pr in t ed on t h e t ir e
~
flexin g, a n d possible t ir e fa ilu r e (F ig. 2).
TIRE TYPE / / i P E C T [ O RIM DIAMETER
P- PASSENGER (SECTION HEIGHT) (INCHES)
T - TEMPORARY (SECTION WIDTH) 13 THIN TIRE
C- COMMERCIAL 70 14 TREAD
LT - LIGHT TRUCK 75 15 AREAS
16
SECTION WIDTH 80
(MILLIMETERS) CONSTRUCTION TYPE
185 R - RADIAL
195 B - BIAS• BELTED
205 D - DIAGONAL (BIAS)
ETC.
J9222-1
l
Fig. 1 Tire Identification
J9322-6
loss of t h e t ir e’s a bilit y t o cu sh ion sh ocks (F ig. 3).
THIN TIRE
TREAD
AREA
RADIAL-PLY TIRES
Ra dia l-ply t ir es im pr ove h a n dlin g, t r ea d life a n d
r ide qu a lit y, a n d decr ea se r ollin g r esist a n ce.
Ra dia l-ply t ir es m u st a lwa ys be u sed in set s of
fou r. Un der n o cir cu m st a n ces sh ou ld t h ey be u sed on
t h e fr on t on ly. Th ey m a y be m ixed wit h t em por a r y
spa r e t ir es wh en n ecessa r y. A m a xim u m speed of 50
MP H is r ecom m en ded wh ile a t em por a r y spa r e is in
u se. J9222-2
Ra dia l-ply t ir es h a ve t h e sa m e loa d-ca r r yin g ca pa c-
it y a s ot h er t ypes of t ir es of t h e sa m e size. Th ey a lso Fig. 3 Over Inflation Wear
u se t h e sa m e r ecom m en ded in fla t ion pr essu r es. Im pr oper in fla t ion ca n ca u se:
Th e u se of over sized t ir es, eit h er in t h e fr on t or • Un even wea r pa t t er n s
r ea r of t h e veh icle, ca n ca u se veh icle dr ive t r a in fa il- • Redu ced t r ea d life
u r e. Th is cou ld a lso ca u se in a ccu r a t e wh eel speed • Redu ced fu el econ om y
sign a ls wh en t h e veh icle is equ ipped wit h An t i-Lock • Un sa t isfa ct or y r ide
Br a kes. • Veh icle dr ift
Th e u se of t ir es fr om differ en t m a n u fa ct u r es on t h e F or pr oper t ir e pr essu r e specifica t ion r efer t o t h e
sa m e veh icle is NOT r ecom m en ded. Th e pr oper t ir e Tir e In fla t ion P r essu r e Ch a r t pr ovided wit h t h e veh i-
pr essu r e sh ou ld be m a in t a in ed on a ll fou r t ir es. cle.
Tir e pr essu r es h a ve been ch osen t o pr ovide sa fe
SPARE TIRE–TEMPORARY oper a t ion , veh icle st a bilit y, a n d a sm oot h r ide. Tir e
Th e t em por a r y spa r e t ir e is design ed for em er- pr essu r e sh ou ld be ch ecked cold on ce a m on t h . Th e
gen cy u se on ly. Th e or igin a l t ir e sh ou ld be r epa ir ed spa r e t ir e pr essu r e sh ou ld be ch eck a t lea st t wice
or r epla ced a t t h e fir st oppor t u n it y a n d r ein st a ll. Do a n n u a lly. Tir e pr essu r e decr ea ses a s t h e a m bien t
n ot exceed speeds of 50 MP H . Refer t o Own er ’s Ma n - t em per a t u r e dr ops. Ch eck t ir e pr essu r e fr equ en t ly
u a l for com plet e det a ils. wh en a m bien t t em per a t u r e va r ies widely.
XJ TIRES AND WHEELS 22 - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
In fla t ion pr essu r es specified on t h e pla ca r ds a r e WARNING: FAILURE TO EQUIP THE VEHICLE WITH
cold in fla t ion pr essu r e. Th e veh icle m u st sit for a t TIRES HAVING ADEQUATE SPEED CAPABILITY
lea st 3 h ou r s t o obt a in t h e cor r ect cold in fla t ion pr es- CAN RESULT IN SUDDEN TIRE FAILURE.
su r e r ea din g. Or dr iven less t h a n on e m ile a ft er sit -
t in g for 3 h ou r s. Tir e in fla t ion pr essu r es m a y
in cr ea se fr om 2 t o 6 pou n ds per squ a r e in ch (psi)
du r in g oper a t ion , du e t o in cr ea sed t ir e t em per a t u r e.
DI AGN OSI S AN D T EST I N G
(120 km /h ).
F or em er gen cy veh icles t h a t a r e dr iven a t speeds
over 90 m ph (144 km /h ), specia l h igh speed t ir es
m u st be u sed. Con su lt t ir e m a n u fa ct u r er for cor r ect
in fla t ion pr essu r e r ecom m en da t ion s.
REPLACEMENT TIRES I
Th e or igin a l equ ipm en t t ir es pr ovide a pr oper ba l-
a n ce of m a n y ch a r a ct er ist ics su ch a s:
• Ride
• Noise
-
• H a n dlin g -
~
-
• Du r a bilit y WEAR
INDICATOR
• Tr ea d life
• Tr a ct ion J8922-5
• Rollin g r esist a n ce
• Speed ca pa bilit y Fig. 4 Tread Wear Indicators
It is r ecom m en d t h a t t ir es equ iva len t t o t h e or igi- TIRE WEAR PATTERNS
n a l equ ipm en t t ir es be u sed wh en r epla cem en t is
Un der in fla t ion will ca u se wea r on t h e sh ou lder s of
n eeded.
t ir e. Over in fla t ion will ca u se wea r a t t h e cen t er of
F a ilu r e t o u se equ iva len t r epla cem en t t ir es m a y
t ir e.
a dver sely a ffect t h e sa fet y a n d h a n dlin g of t h e veh i-
E xcessive ca m ber ca u ses t h e t ir e t o r u n a t a n
cle.
a n gle t o t h e r oa d. On e side of t r ea d is t h en wor n
Th e u se of over size t ir es n ot list ed in t h e specifica -
m or e t h a n t h e ot h er (F ig. 5).
t ion ch a r t s m a y ca u se in t er fer en ce wit h veh icle com -
E xcessive t oe-in or t oe-ou t ca u ses wea r on t h e
pon en t s. Un der ext r em es of su spen sion a n d st eer in g
t r ea d edges a n d a fea t h er ed effect a cr oss t h e t r ea d
t r a vel, in t er fer en ce wit h veh icle com pon en t s m a y
(F ig. 5).
ca u se t ir e da m a ge.
22 - 4 TIRES AND WHEELS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
EFFECT
UNBALANCED
EXCESSIVE CAMBER INCORRECT TOE
WHEEL LACK OF
ROTATION
It
UNDER-INFLATION / OF TIRES
CAUSE OR OR
VALVE STEM
VALVE
STEM I REFERENCE
MARK J9322-4
J9322-3
CLEANING TIRES
Rem ove pr ot ect ive coa t in g on t ir es befor e deliver y
of veh icle. Th is coa t in g m a y ca u se det er ior a t ion of
t ir es.
To r em ove t h e pr ot ect ive coa t in g a pplyin g wa r m
wa t er a n d let it soa k for a few m in u t es. Th en scr u b
t h e coa t in g a wa y wit h a soft br ist le br u sh . St ea m
clea n in g m a y a lso be u sed t o r em ove t h e coa t in g.
SPECI FI CAT I ON S
J8922-6 TIRE SIZE
Fig. 11 Tire Repair Area
TIRE SIZE SUPPLIER
P215/75R15 Goodyear
P225/75R15 Goodyear
P225/70R15 Goodyear
XJ TIRES AND WHEELS 22 - 7
WH EELS
INDEX
page page
MOUNTING
CONE
SPINDLE
SHAFT
/
LATERAL
RUNOUT WING NUT
PLASTIC
CUP
DIAL INDICATOR 80a611da
ADD BALANCE
WEIGHTS HERE
't
OF SPINDLE
---..-----+
'---~
L. • • ., .....
<i
OF SPINDLE
CORRECTIVE WEIGHT
LOCATION
HEAVY SPOT
WHEEL SHIMMY
AND VIBRATION
J8922-9
BODY
CON T EN T S
page page
-
23 - 2 BODY XJ
PAI N T
INDEX
page page
SPECI FI CAT I ON S
AFTERMARKET PAINT REPAIR PRODUCTS
EXTERIOR COLOR
CHRY AKZO
EXTERIOR S-W**
CODE PPG DuPONT NOBEL ICI**
COLOR M-S**
* SIKKENS
Flame Red Clear 2NN6B
PR4 4679 B9326 46916 CHA93:PR4
Coat
Chili Pepper Red VEA 5361 B9823 54470 CHA98:VEA HMT3B
Medium Fern
RJP 4969 B9524 50270 CHA99:RJP 7CD6B
Pearl Coat
Forest Green
SG8 5065 B9609 51062 CHA95:SG8 7MR8B
Pearl Coat
Intense Blue Pearl
VB3 5357 B9822 54468 CHA98:VB3 HMR9B
Coat
Desert Sand WTD 5474 B9884 56153 CHA99:WTD KGC7B
Deep Amethyst FNE4B
TCN 5246 B9736 52026 CHA97:TCN
Pearl Coat
Black Clear Coat DX8 9700 99 34858 CHA85:DX8 TC60B
Gunmetal Pearl ERA9B
TQ7 5248 B9735 52952 CHA97:TQ7
Coat
Stone White Clear 8KY5B
SW1 83542 B9622 51539 CHA96:SW1
Coat
INTERIOR COLOR
AKZO
INTERIOR CHRY S-W**
PPG DuPONT NOBEL ICI**
COLOR CODE* M-S**
SIKKENS
9856 / CHALAZI 7WC8
Agate AZ C9208 45994
2-1461
Camel / Dark N/A K5/G8
KG N/A N/A N/A
Green
INDEX
page page
WARNING: DO NOT OPERATE THE VEHICLE It is difficu lt t o sa lva ge a win dsh ield du r in g t h e
WITHIN 24 HOURS OF WINDSHIELD INSTALLATION. r em ova l oper a t ion . Th e win dsh ield is pa r t of t h e
IT TAKES AT LEAST 24 HOURS FOR URETHANE st r u ct u r a l su ppor t for t h e r oof. Th e u r et h a n e bon din g
ADHESIVE TO CURE. IF IT IS NOT CURED, THE u sed t o secu r e t h e win dsh ield t o t h e fen ce is difficu lt
WINDSHIELD MAY NOT PERFORM PROPERLY IN t o cu t or clea n fr om a n y su r fa ce. If t h e m oldin gs a r e
AN ACCIDENT. set in u r et h a n e, it wou ld a lso be u n likely t h ey cou ld
URETHANE ADHESIVES ARE APPLIED AS A SYS- be sa lva ged. Befor e r em ovin g t h e win dsh ield, ch eck
TEM. USE GLASS CLEANER, GLASS PREP SOL- t h e a va ila bilit y of t h e win dsh ield a n d m oldin gs fr om
VENT, GLASS PRIMER, PVC (VINYL) PRIMER AND t h e pa r t s su pplier.
PINCH WELD (FENCE) PRIMER PROVIDED BY THE
ADHESIVE MANUFACTURER. IF NOT, STRUCTURAL REM OVAL AN D I N STALLAT I ON
INTEGRITY COULD BE COMPROMISED.
CHRYSLER DOES NOT RECOMMEND GLASS
WINDSHIELD
ADHESIVE BY BRAND. TECHNICIANS SHOULD
Th e win dsh ield is posit ion ed in t h e r evea l m oldin g
REVIEW PRODUCT LABELS AND TECHNICAL DATA
a n d is bon ded t o t h e win dsh ield fr a m e wit h u r et h a n e
SHEETS, AND USE ONLY ADHESIVES THAT THEIR
a dh esive.
MANUFACTURES WARRANT WILL RESTORE A
Depen din g on t h e cir cu m st a n ces, eit h er on e of t wo
VEHICLE TO THE REQUIREMENTS OF FMVSS 212.
win dsh ield gla ss in st a lla t ion m et h ods ca n be u sed:
TECHNICIANS SHOULD ALSO INSURE THAT PRIM-
• Th e sh or t m et h od.
ERS AND CLEANERS ARE COMPATIBLE WITH THE
• Th e ext en ded m et h od.
PARTICULAR ADHESIVE USED.
Th e sh or t m et h od is u sed wh en t h e win dsh ield
BE SURE TO REFER TO THE URETHANE MANU-
gla ss is r em oved in t a ct , a n d t h e body open in g a n d
FACTURER’S DIRECTIONS FOR CURING TIME
t h e pin ch weld fla n ges do n ot r equ ir e r epa ir.
SPECIFICATIONS, AND DO NOT USE ADHESIVE
Th e ext en ded m et h od m u st be u sed wh en t h e body
AFTER ITS EXPIRATION DATE.
open in g or a fla n ge is da m a ged. Th e ext en ded
VAPORS THAT ARE EMITTED FROM THE URE-
m et h od m u st a lso be u sed wh en u r et h a n e n o lon ger
THANE ADHESIVE OR PRIMER COULD CAUSE
a dh er es t o eit h er t h e win dsh ield gla ss or t h e pin ch -
PERSONAL INJURY. USE THEM IN A WELL-VENTI-
weld fla n ges.
LATED AREA.
SKIN CONTACT WITH URETHANE ADHESIVE
REMOVAL
SHOULD BE AVOIDED. PERSONAL INJURY MAY
(1) Cover t h e in t er ior a n d ext er ior body su r fa ce
RESULT.
a r ea s wit h a pr ot ect ive cover in g.
ALWAYS WEAR EYE AND HAND PROTECTION
(2) Rem ove t h e win dsh ield wiper a r m s a n d t h e
WHEN WORKING WITH GLASS.
r ea r view m ir r or.
(3) Usin g a r a zor kn ife, slide t h e bla de bet ween
CAUTION: Protect all painted and trimmed surfaces t h e win dsh ield gla ss a n d t h e in boa r d edge of t h e
from coming in contact with urethane or primers. r evea l m oldin g.
(4) Cu t a r ou n d t h e in t er ior per im et er of t h e r evea l
m oldin g a n d sever t h e ca p of t h e r evea l m oldin g.
XJ BODY 23 - 5
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(5) Usin g a cold kn ife, cu t t h e u r et h a n e a r ou n d t h e (6) Adju st win dsh ield gla ss posit ion u n t il it is
per im et er of t h e win dsh ield (F ig. 1). a lign ed wit h t h e fla n ges a n d a dh esive.
(6) Rem ove t h e win dsh ield gla ss fr om t h e fr a m e. (7) Usin g a gr ea se pen cil or equ iva len t , m a ke
a lign m en t m a r ks on t h e gla ss a n d body.
WINDSHIELD
(8) Rem ove r epla cem en t win dsh ield fr om win d-
sh ield open in g.
(9) P osit ion t h e win dsh ield in side u p on a su it a ble
wor k su r fa ce wit h t wo pa dded, wood 10 cm by 10 cm
by 50 cm (4 in . by 4 in . by 20 in .) blocks, pla ced pa r-
a llel 75 cm (2.5 ft .) a pa r t (F ig. 2).
WINDSHIELD
AND
MOLDINGS
"
80a28c10
SUPPORT
SPACERS
1-INCH WIDE
MASKING TAPE
J8923-76
(1) Rem ove t h e a ll of u r et h a n e fr om a ll pin ch weld Fig. 5 Windshield Bottom Support Spacers
fla n ges. molding to the windshield during the installation
(2) In spect a n d r epa ir t h e win dsh ield open in g a n d procedure.
pin ch weld fla n ges.
(3) P r im e t h e pin ch weld fla n ges wit h a u r et h a n e (4) Apply t h e r evea l m oldin g t o t h e win dsh ield:
ba se pr im er. H owever, if t h e fla n ge is color-coa t ed • Wit h t h e m oldin g a t r oom t em per a t u r e, pr ess
wit h pa in t , pr im e t h e fla n ges wit h a pa in t fin ish t h e m oldin g on t o t h e win dsh ield cor n er s.
pr im er. Th is is im p o rta n t be c a u s e u re th a n e • F r om cor n er t o cor n er, wor k t h e m oldin g t o t h e
a d h e s iv e w ill n o t a d h e re to a ll c o lo r-c o a t cen t er of ea ch side. (Som e st r et ch in g of t h e m oldin g
p a in ts . Allow pr im er su fficien t t im e t o dr y. m a y be r equ ir ed du r in g t h is pr ocedu r e).
(5) In st a ll a n d in spect t h e fit of t h e win dsh ield on
NOTE: The reveal molding has an adhesive applied t h e pin ch weld fla n ges a s follows:
to the windshield contact surface to help secure the • P osit ion win dsh ield u n t il it is a lign ed wit h in
win dsh ield open in g.
XJ BODY 23 - 7
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CUT NOZZLE THIS SHAPE CAUTION: Be prepared to install the glass immedi-
FOR EXTENDED PROCEDURE ately after applying the adhesive, as the adhesive
will begin to cure in less than 10 minutes.
WINDOW
GLASS
INSTALLATION
CORD
J9223-118
QUARTER
WINDOW
WNENT
J9123-54
SEAT S
INDEX
page page
HEAD
RESTRAINT
EXTRACTOR
TOOL
6773
SEAT
BACK
;----: ~ ~\
80aa980b
-------- COVER
LOCK RELEASE
~~\---~ )
THUMBWHEEL so31es41
INSTALLATION
(1) P osit ion sea t on floor pa n .
23 - 12 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) Wh ile posit ion in g t h e sea t t r a ck on t h e bu cket
sea t pla t for m , r ou t e t h e power sea t swit ch con n ect or
t h r ou gh t h e a ccess h ole in t h e sea t cu sh ion fr a m e, if
equ ipped.
(2) In st a ll t h e n u t s a t t a ch in g t h e sea t t r a ck t o t h e
bu cket sea t pla t for m .
(3) If equ ipped, en ga ge t h e power sea t con n ect or t o
t h e power sea t swit ch .
(4) In st a ll scr ews a t t a ch in g t h e side sh ield t r im
cover t o t h e sea t .
(5) In st a ll bu cket sea t .
BUCKET SEATBACK
REMOVAL
(1) Rem ove side sh ield t r im cover.
(2) Rem ove in boa r d sea t ba ck pivot bolt .
(3) Rem ove bolt s a t t a ch in g r eclin er t o sea t cu sh ion
fr a m e (F ig. 11).
(4) Sepa r a t e sea t ba ck fr om veh icle.
80aafb05
SEAT BACK
CUSHION
' INSTALLATION
Fig. 11 Bucket Seatback
INSTALLATION
80aafb03 (1) P osit ion t h e cover on t h e cu sh ion .
(2) In st a ll t h e h og r in gs a t t a ch in g t h e cover t o t h e
Fig. 10 Hook And Loop Fastener cu sh ion su ppor t wir es.
(3) Wit h t h e cu sh ion side down , en ga ge t h e for-
wa r d, r ea r wa r d a n d in boa r d J -st r a ps.
(4) E n ga ge t h e clips a t t a ch in g t h e ou t boa r d side of
t h e cover t o t h e cu sh ion fr a m e.
23 - 14 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SEAT CUSHION
/ 80aafb06
REAR SEATBACK
SEAT
COVER
REMOVAL
(1) Disen ga ge t h e sea t cu sh ion a t t h e r ea r by pu ll-
in g u pwa r d on t h e r elea se st r a p.
(2) Tilt t h e sea t cu sh ion for wa r d.
(3) Rem ove t h e sh ou lder /la p belt bu ckles fr om t h e
ela st ic st r a ps.
J8923-98
(4) Relea se t h e sea t ba ck la t ch fr om t h e st r iker.
(5) Rem ove t h e pivot bolt s a n d t h e wa sh er s fr om
Fig. 16 Seat Cushion Cover Retaining Clip Removal
t h e wh eelh ou se pa n el a n ch or s (F ig. 15).
(6) Tilt t h e sea t ba ck for wa r d, lift it u pwa r d a n d
r em ove it fr om t h e veh icle.
INSTALLATION
(1) P osit ion t h e sea t ba ck in t h e veh icle.
(2) In st a ll t h e pivot bolt s a n d t h e wa sh er. Tigh t en
t h e bolt s wit h 33 N·m (25 ft . lbs.) t or qu e.
(3) E n ga ge t h e sea t ba ck la t ch wit h t h e st r iker.
(4) In ser t t h e sh ou lder /la p belt bu ckles in t h e ela s-
t ic st r a ps.
(5) P ivot t h e sea t cu sh ion t o t h e h or izon t a l posi-
t ion a n d lock it in -pla ce by pr essin g fir m ly on t h e
cen t er of t h e cu sh ion u n t il t h e la t ch en ga ges.
/
REMOVAL
(1) Rem ove t h e sea t cu sh ion fr om t h e veh icle.
(2) Rem ove t h e cover side, fr on t a n d r ea r r et a in in g
clips fr om t h e wir e r et a in er s wit h a n a ppr opr ia t e
/8923-97
Fig. 17 Seat Cushion Cover Retaining Clip Removal
r em ova l t ool (F ig. 16).
(3) Rem ove t h e ser r a t ed r et a in er s fr om t h e fr on t REAR SEATBACK LATCH STRIKER AND
en ds of t h e cover wit h a t r im pa n el r em ova l t ool (F ig. BUMPER
17).
(4) Rem ove t h e sea t cover fr om t h e cu sh ion . REMOVAL
(1) Disen ga ge sea t cu sh ion a t t h e r ea r by pu llin g
INSTALLATION u pwa r d on t h e r elea se st r a p.
(1) P osit ion t h e r epla cem en t cover on t h e cu sh ion . (2) Tilt sea t cu sh ion for wa r d.
(2) Com pr ess t h e cover a n d a t t a ch t h e r et a in in g (3) Relea se sea t ba ck la t ch fr om st r iker.
clips t o t h e fr on t a n d r ea r wir e r et a in er s. (4) Tilt sea t ba ck for wa r d for a ccess t o st r iker
(3) In st a ll t h e ser r a t ed r et a in er s a t t h e en ds of t h e br a cket .
cover. (5) Rem ove scr ews (F ig. 18) a t t a ch in g la t ch st r iker
(4) In st a ll t h e sea t cu sh ion in t h e veh icle. If n eces- br a cket a n d sh im s t o t r im pa n el.
sa r y, r efer t o t h e in st a lla t ion pr ocedu r e.
INSTALLATION
(1) P osit ion sh im s a n d la t ch st r iker br a cket on
t r im pa n el.
23 - 16 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
COVER
ZIPPER
J8923-99
SEAT
CUSHION Fig. 19 Seatback Cover Removal
80b89834
(3) E n ga ge t h e cover zipper s.
Fig. 18 Seatback Latch Striker Bracket (4) In st a ll t h e sea t la t ch r elea se bezel a n d h a n dle.
(5) In st a ll t h e sea t ba ck in t h e veh icle.
(2) In st a ll scr ews a t t a ch in g la t ch st r iker br a cket
a n d sh im s t o t r im pa n el. Tigh t en scr ews t o 6 N·m (50
in . lbs.) t or qu e. SPECI AL T OOLS
(3) E n ga ge sea t ba ck la t ch wit h st r iker.
(4) P ivot sea t cu sh ion t o h or izon t a l posit ion a n d SEATS
lock it in -pla ce by pr essin g fir m ly on cen t er of t h e
cu sh ion u n t il la t ch en ga ges.
INSTALLATION
(1) In st a ll t h e cover on t h e sea t ba ck.
(2) At t a ch t h e cover J -st r a p t o t h e sea t ba ck fr a m e.
XJ BODY 23 - 17
INDEX
page page
NUT
BODY
80b8982b
STRIKER VIEW
FROM RIGHT
FRONT
1. LATCH
2. BUMPER
3. CATCH
4. CLIP
5. BELLCRANK
6. ROD
7. CLIP
8. CABLE
9. GROMMET
10. SHOULDER BOLT
11. STRIKER
12. SHIM
13. SPRING
VIEW IN DIRECTION
OFARROWZ
80a9f0f8
ROD
SPRING ROD 80ab5cd8
HINGE
BASE
Fig. 5 Hood Latch
(4) Rem ove t h e h ea dla m p wit h m ou n t in g bu cket
80abac3b a t t a ch ed fr om t h e a dju st in g scr ews.
(5) Rem ove t h e u pper bolt a t t a ch in g t h e st r iker t o
Fig. 4 Hood Hinge and Seal t h e t op of t h e (GOP ).
(6) Rem ove t h e lower bolt a t t a ch in g t h e st r iker t o
INSTALLATION
t h e (GOP ).
(1) P osit ion h in ge over st u ds a n d a lign wit h r efer-
(7) Rem ove t h e st r iker a n d sh im s.
en ce m a r ks.
(2) In st a ll n u t s.
INSTALLATION
NOTE: If a replacement hinge seal is being (1) P osit ion t h e sh im s a n d st r iker on t h e (GOP )
installed, position it around hinge arm, force it a n d in st a ll t h e bolt s.
against hinge base. (2) In st a ll t h e h ea dla m p a n d m ou n t in g bu cket .
(3) In st a ll pa r kla m p.
(3) P osit ion h in ge sea l a r ou n d h in ge a r m a n d on (4) In st a ll t h e h ea dla m p bezel.
h in ge ba se. (5) Test t h e st r iker /h ood a lign m en t by open in g a n d
(4) Adju st h ood a s n ecessa r y. closin g t h e h ood sever a l t im es. Adju st t h e st r iker, if
n ecessa r y.
HOOD LATCH
HOOD RELEASE CABLE
REMOVAL
(1) Rem ove t h e scr ew t h a t a t t a ch es t h e la t ch t o REMOVAL
t h e h ood in n er pa n el (F ig. 5). (1) Dr ill ou t bellcr a n k t o h ood r ivet h ea ds a n d
(2) Discon n ect t h e la t ch con n ect in g r od. r em ove r ivet s (F ig. 6).
(3) Rem ove t h e la t ch fr om t h e h ood. (2) Discon n ect bellcr a n k fr om la t ch r od a n d h ood
r elea se ca ble. Rem ove bellcr a n k fr om h ood.
INSTALLATION (3) Discon n ect h ood r elea se ca ble fr om clips on
(1) Con n ect t h e la t ch t o t h e la t ch con n ect in g r od h ood.
and (4) Rem ove left cowl side t r im pa n el.
(2) P osit ion t h e la t ch on t h e h ood in n er pa n el. (5) Rem ove ca ble br a cket scr ews fr om cowl side
(3) In st a ll t h e scr ew t h a t a t t a ch es t h e la t ch t o t h e pa n el.
h ood in n er pa n el. (6) Rou t e ca ble t h r ou gh da sh pa n el a n d r em ove it
fr om u n der in st r u m en t pa n el.
HOOD LATCH STRIKER
INSTALLATION
REMOVAL (1) In ser t r epla cem en t ca ble en d t h r ou gh h ole in
(1) Rem ove h ea dla m p bezel. da sh pa n el in t o en gin e com pa r t m en t .
(2) Rem ove pa r kla m p. (2) Rou t e ca ble for wa r d a n d sea t gr om m et in da sh
(3) Relea se t h e spr in g a t t a ch in g t h e h ea dla m p pa n el.
m ou n t in g bu cket t o t h e gr ille open in g pa n el (GOP ).
XJ BODY 23 - 23
REM OVAL AN D I N STALLAT I ON (Cont inue d)
RIVET SAFETY LATCH STRIKER
REMOVAL
(1) Rem ove st r iker scr ews fr om r a dia t or su ppor t
cr ossm em ber (F ig. 8).
(2) Rem ove st r iker fr om cr ossm em ber.
BELLCRANK
GOP BRACKET
LATCH
1;...-----RELEASE
CABLE
J9223-68
80ab5cde
COWL WEATHERSTRIP
REMOVAL
Th e cowl wea t h er st r ip is a t t a ch ed t o t h e cowl wit h
a dh esive t a pe. GRILLE J9223-93
(1) P eel wea t h er st r ip fr om cowl (F ig. 10).
WEATHERSTRIP
Fig. 11 Cowl Grille, Screen & Washer Nozzles
(1) P osit ion t h e cowl gr ille a n d scr een on t h e cowl.
(2) In st a ll t h e win dsh ield wa sh er t u bes on t h e n oz-
zles.
(3) In st a ll t h e cowl scr een a n d gr ille scr ews wit h
n ew sea ler. Tigh t en in sequ en ce (F ig. 12).
@ SCREW
COWL
80b89831
' 0/
Fig. 10 Cowl Weatherstrip '
INSTALLATION
(1) Clea n con t a ct su r fa ce wit h Mopa r Su per Kleen
or equ iva len t .
(2) P osit ion wea t h er st r ip on cowl.
(3) P r ess wea t h er st r ip in t o pla ce.
COWL GRILLE
REMOVAL
(1) Rem ove t h e win dsh ield wiper a r m s fr om the
pivot s.
(2) Rem ove t h e scr ews t h a t a t t a ch t h e gr ille t o the Fig. 12 Cowl Grille Screw Tightening Sequence
cowl. BODY DECALS
(3) Rem ove t h e win dsh ield wa sh er t u bes fr om the Sm a ll n icks, scr a t ch es a n d ot h er su r fa ce m a r ks in
n ozzles. a deca l ca n be t ou ch ed-u p wit h pa in t .
(4) Rem ove t h e cowl gr ille a n d scr een fr om the To elim in a t e blist er s a n d a ir bu bbles in a deca l,
cowl (F ig. 11). pier ce t h em wit h a n eedle or pin .
A h ea t gu n ca n a lso be u sed t o r em ove sm a ll wr in -
INSTALLATION kles in a deca l.
Deca l r epla cem en t r equ ir es t h a t t h e m et a l r epa ir
CAUTION: The washer fluid tubes must be routed a n d pa in t r efin ish be com plet ed fir st .
and installed so that they are not pinched.
XJ BODY 23 - 25
REM OVAL AN D I N STALLAT I ON (Cont inue d)
Th e wor k a r ea t em per a t u r e sh ou ld be bet ween NOTE: If applicable, the body panel character line
21°C (70°F ) a n d 32°C (90°F ). A d e c a l s h o u ld n o t be can be used as the decal alignment reference.
re p la c e d if th e w o rk a re a te m p e ra tu re is le s s
th a n 21°C (70°F ). (7) P osit ion t h e deca l a n d ca r r ier on t h e body
Th e followin g equ ipm en t a n d m a t er ia l a r e n eces- pa n el (F ig. 14) a n d t h e m a r k len gt h wit h a wa x pen -
sa r y for r em ova l a n d in st a lla t ion : cil.
• Liqu id dish det er gen t (for t h e wet t in g solu t ion ). (8) P osit ion t h e deca l a n d ca r r ier on t h e body
• Mixt u r e of wet t in g solu t ion . pa n el a n d h old it in -pla ce wit h m a skin g t a pe.
• Com m er cia l wa x a n d silicon e r em ova l solu t ion . (9) Lift t h e bot t om edge of deca l a n d ca r r ier. Use
• Isopr opyl (r u bbin g) a lcoh ol. t h e t a pe sect ion s a s h in ges, a n d r ever se t h e posit ion
• Sm a ll squ eegee (pla st ic or h a r d r u bber ). of deca l a n d ca r r ier.
• Wa t er bu cket a n d spon ge.
• Clea n wipin g r a gs or pa per t owels. CAUTION: Always remove the carrier from the
• H ea t gu n (or in fr a -r ed h ea t bu lb). decal, never remove the decal from carrier
• Wa x pen cil.
(10) Ben d a cor n er of ca r r ier ou t wa r d a n d t h en ,
• Sh a r p kn ife, sin gle edge r a zor bla de or X-a ct o
wit h a flick of t h e fin ger, sepa r a t e t h e cor n er of ca r-
kn ife.
r ier fr om t h e deca l.
• P a ir of scissor s.
(11) Ret u r n t h e deca l ba ck t o it s or igin a l posit ion .
• Needle or pin .
If a solu t ion is bein g u sed, posit ion a dh esive side of
WARNING: USE DECAL REMOVAL SOLUTION IN A t h e deca l on pa n el. Apply t h e solu t ion t o t h e ou t side
WELL-VENTILATED AREA ONLY. of t h e deca l.
(12) H old t h e deca l a ga in st t h e pa n el su r fa ce wh ile
A deca l r em ova l solu t ion ca n be u sed for r em ova l sepa r a t in g t h e ca r r ier fr om t h e deca l.
a t a r ea s wh er e a h ea t gu n is in effect ive. F ollow t h e (13) If a pplica ble, r em ove t h e cover fr om fa ce of
m a n u fa ct u r er s in st r u ct ion s wh en ever t h is t ype of deca l.
pr odu ct is u sed. (14) Usin g a squ eegee sm oot h ou t t h e deca l t o
r em ove wr in kles a n d/or a ir bu bbles.
REMOVAL (15) In spect t h e deca l wit h r eflect ed ligh t t o fin d
(1) Clea n t h e r epa ir ed su r fa ce a s n ecessa r y. a n y da m a ge. Rem ove a ll t h e a ir a n d/or m oist u r e bu b-
(2) St a r t a t on e en d of t h e deca l a n d a pply h ea t bles.
wit h a h ea t gu n . Slowly peel t h e deca l fr om t h e pa n el STRAIGHT GREASE
by pu llin g it ba ck. D o n o t p u ll th e d e c a l o u tw a rd EDGE PENCIL
fro m p a n e l.
INSTALLATION
(1) Th e a r ea t h a t will be cover ed by t h e deca l m u st
be clea n ed wit h clea n in g solu t ion .
(2) F r esh ly pa in t ed su r fa ces m u st be t h or ou gh ly
dr y.
(3) Clea n t h e pa in t ed su r fa ce wit h a com m er cia l
wa x a n d silicon e r em ova l solu t ion . Wipe t h e su r fa ce
wit h a clea n clot h a n d a llow it t o dr y.
(4) P r epa r e a wet t in g solu t ion by m ixin g t wo or
t h r ee t ea spoon s of dish det er gen t wit h 1 ga llon of
wa t er. Do n ot u se soa p. BODY
PANEL J9123-588
NOTE: Too much detergent will reduce the effec-
Fig. 13 Decal Alignment Reference Mark
tiveness of the mixture.
EXTERIOR NAMEPLATES
(5) Use a clea n spon ge a n d a pply t h e wet t in g solu -
t ion t o t h e a dh esive side of t h e deca l a n d t o t h e REMOVAL
pa in t ed pa n el su r fa ce. Th e wet t in g solu t ion will per-
m it ea se of deca l m ovem en t wh en posit ion in g it . NOTE: Exterior nameplates are attached to body
(6) Align a st r a igh t edge wit h t h e exist in g deca l panels with adhesive tape.
en ds (F ig. 13).
23 - 26 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
HOOD
BUMPER
SCREW
80ae8355
INSTALLATION INSTALLATION
(1) P osit ion t h e fen der on t h e in n er fen der pa n el. (1) Repla ce a n y br oken or da m a ged pu sh -in fa st en -
(2) In st a ll a ll fen der scr ews fin ger-t igh t . er s.
(3) Align t h e fen der wit h t h e body pa n els a n d (2) Con n ect t h e power door locks/win dows/m ir r or s
t igh t en t h e scr ews a t t a ch in g t h e fen der t o t h e body wir e h a r n ess con n ect or s, if equ ipped.
pa n els. (3) Move t h e door t r im pa n el ou t wa r d a n d con n ect
(4) In st a ll t h e a ir deflect or. t h e h a n dle-t o-la t ch r ods.
(5) In st a ll t h e wh eelh ou se lin er. (4) P osit ion t h e t r im pa n el on t h e in n er belt sea l
(6) In st a ll t h e fen der fla r e a n d r et a in er s. a n d pu sh down t o sea t .
(7) In st a ll t h e fr on t bu m per. (5) Align t h e loca t in g pin s a n d pu sh - (F ig. 25) in
fa st en er s. P r ess in wa r d t o secu r e.
XJ BODY 23 - 29
REM OVAL AN D I N STALLAT I ON (Cont inue d)
WINDOW CRANK
REMOVAL TOOL
80ad2128
J898S-8
Fig. 24 Detaching Trim Panel Push-In Fasteners
FRONT DOOR
REMOVAL
(1) Rem ove door r est r a in t (ch eck) r et a in in g pin .
(2) F or veh icles equ ipped wit h power win dows,
power m ir r or s a n d power door locks, r em ove t r im
pa n el a n d wa t er da m . Discon n ect a ll com pon en t s a n d Fig. 27 Front Door Hinge
r ou t e wir e h a r n ess ou t of door. INSTALLATION
(3) Rem ove bolt s t h a t a t t a ch h in ge t o door. (F ig. (1) P osit ion h in ge pla t es a n d sh im s on door fa ce.
26). (2) Align door h in ges a n d sh im s wit h bolt h oles
(4) Rem ove door fr om veh icle. a n d in st a ll h in ge bolt s. Tigh t en bolt s t o 3 N·m (2 ft .
lbs.) t or qu e.
(3) Adju st /a lign la t ch st r iker a n d la t ch a s n eces-
sa r y.
(4) In st a ll door r est r a in t (ch eck) r et a in in g pin .
~
bolt s. Tigh t en bolt s t o 3 N·m (2 ft . lbs.) t or qu e.
(3) In st a ll door r est r a in t (ch eck) pin .
(4) If a pplica ble, r ou t e a n d con n ect wir e h a r n ess
con n ect or s.
(5) In st a ll door wa t er da m a n d t r im pa n el.
INSTALLATION
(1) P osit ion t h e in side h a n dle in t h e t r im pa n el.
(2) H ea t st a ke t h e in side h a n dle t o t h e t r im pa n el.
(3) In st a ll t h e door t r im pa n el.
LOCK OUTSIDE
CYLINDER
TO U HANDLE FRONT DOOR INNER BELT WEATHERSTRIP
'--~1__;.;;=.::~ TO
LATCH LATCH ROD
ROD 80aa4ad2 REMOVAL
(1) Roll win dow down .
Fig. 31 Door Latch (2) Rem ove door t r im pa n el.
(5) In st a ll wa t er da m a n d door t r im pa n el. (3) P u ll u p on t h e r ea r cor n er of t h e wea t h er st r ip
a n d lift fr om t h e door (F ig. 33).
FRONT DOOR LATCH STRIKER
REMOVAL
(1) Usin g a gr ea se pen cil or equ iva len t , m a r k posi-
t ion of st r iker.
(2) Rem ove scr ews a t t a ch in g st r iker t o B-pilla r
(F ig. 32).
(3) Sepa r a t e st r iker fr om B-pilla r.
80aa0fe2
INSTALLATION
(1) In st a ll t h e wea t h er st r ip in t h e followin g
sequ en ce:
• P r ess wea t h er st r ip in t o u pper r ea r cor n er.
• P r ess wea t h er st r ip in t o lower fr on t cor n er.
• Wor k/pr ess t h e wea t h er st r ip u pwa r d a n d t o t h e
u pper fr on t cor n er, sea t t h e wea t h er st r ip in t o t h e
ch a n n el. ENDS
VIEWIN MEET
• Con t in u e wor kin g/pr essin g t h e wea t h er st r ip in t o DIRECTION OF AT
t h e ch a n n el a lon g t h e u pper win dow fr a m e. ARROWZ CENTERLINE
• P r ess wea t h er st r ip in t o lower r ea r cor n er.
• Wor k/pr ess t h e wea t h er st r ip u pwa r d a n d t o t h e 80aa0fd7
INSTALLATION
(1) P osit ion wea t h er st r ip a t cor n er s. J9223-271
(2) Move u pwa r d a n d a r ou n d edge of door open in g.
Sea t sea l on fla n ge. Fig. 35 Door Opening Weatherstrip
(3) Wh en in st a llin g a door open in g wea t h er st r ip FRONT DOOR OPENING SECONDARY
sea l, st a r t a t t h e door sill cen t er lin e.
(4) Move u pwa r d a n d a r ou n d t h e per im et er of t h e WEATHERSTRIP
door open in g a n d sea t t h e wea t h er st r ip on t h e fla n ge
(F ig. 35). REMOVAL
(5) In st a ll cowl side t r im pa n el. Th e fr on t door open in g secon da r y wea t h er st r ip is
(6) In st a ll in n er scu ff pla t e. a t t a ch ed t o t h e A-pilla r wit h a dh esive t a pe (F ig. 34).
(7) In st a ll B-pilla r lower t r im pa n el. (1) Usin g a h ea t gu n , h ea t t h e wea t h er st r ip a n d
(8) In st a ll B-pilla r u pper t r im pa n el. slowly peel t h e wea t h er st r ip fr om t h e A-pilla r
(9) In st a ll A-pilla r t r im pa n el.
23 - 34 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) Clea n t h e con t a ct su r fa ce on t h e A-pilla r.
(2) Rem ove t h e ca r r ier ba ckin g a n d posit ion t h e
wea t h er st r ip on t h e A-pilla r. P r ess in t o pla ce.
I
FRONT DOOR GLASS EXTERIOR MOLDING
REMOVAL
(1) Open t h e win dow com plet ely.
(2) Rem ove t h e ou t er belt wea t h er st r ip.
(3) P r y a n d pu ll t h e m oldin g sect ion s fr om t h e
door pa n el fla n ge (F ig. 36).
UPPER
) LOOSEN'-;::_ _ _.;____'-------------'
MOLDING
NUTS 80ab5cdc
REAR
MOLDING
80aa0fe3
80a9f0f6
/ SCREW
.~
WINDOW
INNER
FRAME J9223-263
Fig. 40 Front Door Upper Spacer Block—Two-Door Fig. 41 Front Door Lower Spacer Block—Two-Door
(2) Upper spa cer block: In st a ll t h e r epla cem en t (4) Roll gla ss u p t o expose t h e bolt s a t t a ch in g t h e
r ivet s in t h e spa cer block a n d r ein for cem en t pla t e. gla ss t o t h e r egu la t or.
(3) Lower spa cer block: in st a ll t h e scr ews in t h e (5) Rem ove t h e bolt s a t t a ch in g t h e gla ss t o t h e
door fa ce. Tigh t en t h e scr ews t o 1 N·m (11 in -lbs) r egu la t or (F ig. 42).
t or qu e. (6) Lift t h e gla ss u pwa r d a n d ou t of t h e door.
NUT
TRIM
PANEL
PUSH-IN
FASTENER
WINDOW
REGULATOR CRANK
80aa4b51
SPACER
80aafb5b
Fig. 42 Front Door Glass Fig. 44 Rear Door Trim Panel—Manual Window
(5) In st a ll t h e wa t er da m .
(6) In st a ll t h e door t r im pa n el.
80ad2l28
J898S-8
Fig. 43 Window Crank—Typical Fig. 46 Detaching Trim Panel Push-In Fasteners
XJ BODY 23 - 37
REM OVAL AN D I N STALLAT I ON (Cont inue d)
80ab5cdf
LATCH
REAR ROD
DOOR LATCH
ADJUSTMENT
Fig. 50 Rear Door Outside Handle
SCREW
INSTALLATION B0524e45
DOOR
REMOVAL OUTER
(1) Usin g a gr ea se pen cil or equ iva len t , m a r k posi- PANEL
t ion of st r iker.
(2) Rem ove scr ews a t t a ch in g st r iker t o C-pilla r
(F ig. 53).
(3) Sepa r a t e st r iker fr om C-pilla r.
GLASS
CHANNEL
WEATHERSTRIP
80aa0fe6
80aa4ad3
INSTALLATION
(1) P osit ion t h e wea t h er st r ip on t h e door.
Fig. 53 Rear Door Latch Striker (2) P u sh wea t h er st r ip down t o sea t on t o door.
INSTALLATION (3) In st a ll door t r im pa n el.
(1) P osit ion a n d a lign st r iker on C-pilla r.
(2) In st a ll scr ews a t t a ch in g st r iker t o C-pilla r. REAR DOOR OUTER BELT WEATHERSTRIP
Tigh t en scr ews t o 28 N·m (20 ft . lbs.) t or qu e.
REMOVAL
REAR DOOR INSIDE HANDLE ACTUATOR (1) Roll win dow down .
(2) Usin g a t r im st ick, pr y u p t h e r ea r ou t er cor n er
REMOVAL of t h e wea t h er st r ip.
Th e r ea r door in side h a n dle a ct u a t or is h ea t st a ked (3) Slowly a n d ca r efu lly, lift t h e wea t h er st r ip u p t o
t o t h e r ea r door t r im pa n el du r in g t h e m a n u fa ct u r in g sepa r a t e fr om t h e door (F ig. 54).
pr ocess.
(1) Rem ove t h e door t r im pa n el. INSTALLATION
(2) Usin g a n X–ACTO kn ife or equ iva len t , cu t t h e (1) P osit ion t h e wea t h er st r ip on t h e door.
m elt ed t a bs secu r in g t h e in side h a n dle t o t h e door (2) P u sh wea t h er st r ip down t o sea t on t o door.
t r im pa n el.
(3) Sepa r a t e t h e in side h a n dle fr om t h e t r im REAR DOOR GLASS RUN CHANNEL
pa n el. WEATHERSTRIP
INSTALLATION REMOVAL
(1) P osit ion t h e in side h a n dle in t h e t r im pa n el. (1) Rem ove door t r im pa n el.
(2) H ea t st a ke t h e in side h a n dle t o t h e t r im pa n el. (2) Rem ove wa t er da m .
(3) In st a ll t h e door t r im pa n el. (3) Rem ove win dow gla ss.
23 - 40 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) St a r t in g a t r ea r cor n er, peel wea t h er st r ip fr om (5) Gr a sp sea l a n d sepa r a t e fr om door open in g
a r ou n d door fr a m e (F ig. 54). (F ig. 56).
FRONT SECONDARY
INSTALLATION DOOR
(1) St a r t in g a t t h e t op cor n er, pr ess sea l in t o pla ce. DOOR
A PILLAR SEAL SEAL
A sm a ll a m ou n t of a dh esive ca n be u sed t o h old t h e
wea t h er st r ip in -pla ce, if n ecessa r y.
(2) As a pplica ble, m ove down wa r d even ly u n t il t h e
wea t h er st r ip sea l is fu lly sea t ed in t h e ch a n n el.
(3) In st a ll win dow gla ss.
(4) In st a ll wa t er da m .
(5) In st a ll door t r im pa n el.
@- PRESS INWARD
FIRMLY AT
INDICATED AREA
B-PILLAR
REGULATOR
'18
SCREW AND
BUSHING
(8) Rem ove t h e win dow gla ss fr om door.
WINDOW
GLASS J9223-501
80aef1cb INSTALLATION
(1) P osit ion t h e r epla cem en t a ppliqu e t h e on pa n el
Fig. 61 Body Side Molding—4-Door a n d in st a ll t h e n u t s.
INSTALLATION (2) In st a ll t h e lift ga t e pilla r t r im .
(1) If t h e or igin a l m oldin g will be in st a lled, a pply
3M 5344 dou ble-sided t a pe on t h e m oldin g. DRIP RAIL MOLDING
(2) F or ver t ica l a lign m en t , u se m a skin g t a pe or a
st r in g a s r efer en ce. REMOVAL
(3) Rem ove t h e ba ckin g fr om t h e t a pe, a lign t h e (1) P r y t h e clips fr om t h e r oof fla n ge.
m oldin g a n d posit ion it on t h e body pa n el. (2) Rem ove t h e clips a n d m oldin g fr om t h e r oof
(4) P r ess t h e m oldin g on t o t h e body pa n el wit h a fla n ge (F ig. 63).
r oller or h a n d pr essu r e. (3) Rem ove t h e r em a in in g sea la n t a n d clea n the
r oof fla n ge.
REAR FENDER FLARE (1) P r y t h e clips fr om t h e r oof fla n ge.
(2) Rem ove t h e clips a n d m oldin g fr om t h e r oof
REMOVAL fla n ge (F ig. 63).
(1) Rem ove t h e scr ew a t t a ch in g t h e lower pa r t of (3) Rem ove t h e r em a in in g sea la n t a n d clea n the
fla r e t o t h e bot t om of t h e fen der. r oof fla n ge.
(2) Rem ove t h e n u t s a t t a ch in g t h e fen der fla r e
r et a in er t o t h e wh eelh ou se lin er (F ig. 62). INSTALLATION
(3) Sepa r a t e t h e fen der fla r e a n d r et a in er fr om t h e (1) P osit ion t h e dr ip r a il m oldin g wit h clips a t t h e
fen der. r oof fla n ge a n d for ce t h e clips on t o t h e r oof fla n ge.
XJ BODY 23 - 43
REM OVAL AN D I N STALLAT I ON (Cont inue d)
J9223-97
INSTALLATION INTERNAL
J9123-138
VIEW
(1) In st a ll 3M 06379 dou ble-sided t a pe, or a n
equ iva len t on skid st r ips.
Fig. 65 Door Opening Air Exhaust Grille
(2) Rem ove ba ckin g fr om dou ble-sided t a pe, a lign
ea ch skid st r ip on r oof, a n d posit ion it on r oof pa n el. INSTALLATION
(3) Ver ify t h a t ea ch skid st r ip is pr oper ly a lign ed. (1) P osit ion t h e slot loca t ed in t h e u pper en d of
(4) P r ess ea ch skid st r ip on t o r oof pa n el wit h a r epla cem en t gr ille a t t h e exh a u st por t a n d in ser t
r oller (or u se h a n d pr essu r e). edge in t h e slot .
(2) P u sh in wa r d a n d sea t t h e gr ille in t h e exh a u st
NOTE: To prevent water leaks, apply 3M Drip-Chek por t .
Sealant, or equivalent. (3) In st a ll t h e scr ew t o a t t a ch t h e gr ille t o t h e door
open in g pa n el.
(5) P osit ion lu gga ge r a ck on r oof wit h scr ew h oles
a lign ed.
23 - 44 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) P osit ion t h e A-pilla r t r im on t h e A-pilla r.
(2) In st a ll t h e scr ews a t t a ch in g t h e A-pilla r t r im t o
t h e A-pilla r.
(3) In st a ll t h e t r im plu gs.
(4) In st a ll t h e lower A-pilla r cowl t r im .
(5) In st a ll t h e in n er scu ff pla t e.
(6) In st a ll t h e a ssist h a n dles.
REMOVAL INSTALLATION
(1) Rem ove t h e in n er scu ff pla t e. (1) P osit ion t h e lower A-pilla r cowl t r im on t h e
A-pilla r lower cowl.
UPPER
QUARTER PANEL
TRIM
80a89433
REMOVAL INSTALLATION
(1) If n ecessa r y, r em ove t h e bu cket sea t side sh ield (1) P osit ion t h e h a n dle on t h e t r im .
t r im cover. (2) In st a ll t h e scr ews.
(2) Rem ove t h e scr ews a t t a ch in g t h e in n er scu ff (3) In st a ll t h e cover s.
pla t e t o t h e fr on t door sill (F ig. 66).
(3) Sepa r a t e t h e in n er scu ff pla t e fr om t h e door B-PILLAR TRIM
sill.
REMOVAL
INSTALLATION (1) Rem ove t h e in n er scu ff pla t e.
(1) P osit ion t h e in n er scu ff pla t e on t h e fr on t door (2) Rem ove t h e u pper door open in g t r im (4-door
sill. veh icles) (F ig. 69).
(2) In st a ll t h e scr ews a t t a ch in g t h e in n er scu ff (3) Rem ove t h e u pper qu a r t er pa n el t r im (2-door
pla t e t o t h e fr on t door sill. veh icles) (F ig. 66).
(3) If r em oved, in st a ll t h e bu cket sea t side sh ield (4) Rem ove t h e r ea r A-pilla r t r im scr ew.
t r im cover. (5) Rem ove t h e sh ou lder belt t u r n in g loop.
(6) Rem ove t h e sea t /sh ou lder belt a n ch or bolt .
DOOR SILL SCUFF PLATE (7) Rem ove t h e scr ews a t t a ch in g t h e B-pilla r t r im
t o t h e B-pilla r (2-door veh icles).
REMOVAL (8) Rou t e t h e sh ou lder belt t h r ou gh t h e lower
(1) Rem ove t h e scr ews a t t a ch in g t h e door sill scu ff B-pilla r t r im (2-door veh icles).
pla t e t o t h e door sill (F ig. 68). (9) Sepa r a t e t h e B-pilla r t r im fr om t h e B-pilla r.
(2) Sepa r a t e t h e scu ff pla t e fr om t h e door sill.
INSTALLATION
(1) Rou t e t h e sh ou lder belt t h r ou gh t h e lower
B-pilla r t r im (2-door veh icles).
(2) P osit ion t h e B-pilla r t r im on t h e B-pilla r a n d
a lign pu sh -in fa st en er s.
(3) P r ess t h e B-pilla r t r im on t h e B-pilla r t o
secu r e.
(4) In st a ll t h e scr ews a t t a ch in g t h e B-pilla r t r im t o
t h e B-pilla r (2-door veh icles).
(5) In st a ll t h e sea t /sh ou lder belt a n ch or bolt .
(6) In st a ll t h e sh ou lder belt t u r n in g loop.
(7) In st a ll t h e A-pilla r t r im .
(8) In st a ll t h e u pper qu a r t er pa n el t r im (2-door
veh icles) (F ig. 66).
(9) In st a ll t h e u pper door open in g t r im (4-door
veh icles) (F ig. 69).
Fig. 68 Door Sill Scuff Plate (10) In st a ll t h e in n er scu ff pla t e.
UPPER DOOR
OPENING TRIM
B-PILLAR
TRIM
LIFTGATE PILLA
TRIM R LOWER
QUARTER
PANEL
TRIM
QUARTER
PANEL TRIM
EXTENSION
~ INNER
y;] ~ SCUFF
COWL ~ PLATE
PANEL
TRIM NUT ACCESS DOOR 80a89434
INSTALLATION REMOVAL
(1) Rem ove t h e in n er scu ff pla t e.
(1) P osit ion t h e C-pilla r t r im on t h e C-pilla r.
(2) Rem ove qu a r t er pa n el t r im ext en sion .
(2) In st a ll t h e scr ews a t t a ch in g t h e C-pilla r t r im t o
(3) Rem ove lift ga t e scu ff pla t e.
t h e C-pilla r.
(4) Rem ove t h e scr ews a t t a ch in g t h e qu a r t er pa n el
(3) In st a ll t h e qu a r t er pa n el t r im ext en sion .
t r im fr om t h e qu a r t er pa n el a n d wh eelh ou se t r im
(4) In st a ll t h e u pper qu a r t er pa n el t r im .
cover (F ig. 69) a n d (F ig. 66).
(5) In st a ll t h e u pper door open in g t r im .
(5) If n ecessa r y, r em ove t h e t ir e a n d m ou n t in g
(6) In st a ll t h e in n er scu ff pla t e.
br a cket s fr om t h e left qu a r t er pa n el t r im (F ig. 70).
(6) Rem ove t h e scr ews a t t a ch in g t h e wh eelh ou se
QUARTER PANEL TRIM EXTENSION cover t o t h e wh eelh ou se.
(7) Sepa r a t e t h e wh eelh ou se cover fr om t h e wh eel-
REMOVAL h ou se.
(1) Rem ove t h e in n er scu ff pla t e.
(2) Sepa r a t e qu a r t er pa n el t r im ext en sion fr om t h e INSTALLATION
wh eelh ou se a n d qu a r t er t r im pa n els (F ig. 69). (1) P osit ion t h e wh eelh ou se cover on t h e wh eel-
h ou se.
INSTALLATION (2) In st a ll t h e scr ews a t t a ch in g t h e wh eelh ou se
(1) P osit ion t h e qu a r t er pa n el t r im ext en sion on cover t o t h e wh eelh ou se.
t h e wh eelh ou se a n d qu a r t er t r im pa n els. (3) If r em oved, in st a ll t h e t ir e a n d m ou n t in g
(2) In st a ll t h e in n er scu ff pla t e. br a cket on t h e left qu a r t er pa n el t r im .
(4) P osit ion t h e qu a r t er pa n el t r im on t h e qu a r t er
pa n el a n d wh eelh ou se cover.
XJ BODY 23 - 47
REM OVAL AN D I N STALLAT I ON (Cont inue d)
COVER
MOUNTING
BRACKET
QUARTER
TRIM
CAP
80a9f0f2
REMOVAL
(1) Slide t h e fr on t sea t s a ll t h e wa y for wa r d for
a ccess t o t h e belt a n ch or bolt .
(2) Discon n ect t h e belt wir e h a r n ess con n ect or.
(3) Rem ove t h e a n ch or bolt cover.
(4) Rem ove t h e a n ch or bolt a t t a ch in g t h e bu ckle t o
t h e sea t .
(5) Rem ove t h e t u r n in g loop cover con cea lin g t h e
Fig. 72 Liftgate Opening Upper Trim sh ou lder belt u pper a n ch or bolt .
(6) Use a Tor x bit t o r em ove t h e u pper a n ch or bolt
(1) P osit ion t r im on r oof pa n el.
(F ig. 74). Rem ove t h e su ppor t /gu ide wa sh er.
(2) In st a ll t h e scr ews a t t a ch in g t h e lift ga t e open -
(7) Rem ove t h e in n er scu ff pla t e/t r im pa n el fr om
in g u pper t r im t o t h e r oof pa n el.
t h e door sill a n d r em ove t h e sh ou lder belt lower
a n ch or bolt (s) wit h a Tor x bit (F ig. 75) a n d (F ig. 76).
LIFTGATE SCUFF PLATE (8) Rem ove t h e sh ou lder belt a n d t h e r et r a ct or.
REMOVAL
(1) Rem ove t h e scr ews a t t a ch in g t h e lift ga t e scu ff
pla t e t o t h e floor pa n (F ig. 73). TRIM PANEL
(2) Sepa r a t e t h e scu ff pla t e fr om t h e veh icle.
TURNING
LOOP
J(
\ ADJUSTER
\\
BELT
80abd242
REMOVAL
(1) P u ll r ea r sea t r elea se st r a p a n d t ilt sea t cu sh -
ion for wa r d.
(2) Rem ove sh ou lder belt bu ckle a n d la p belt /
bu ckle a n ch or pla t e bolt s fr om floor pa n (F ig. 77).
(3) Rem ove sh ou lder belt lower ou t er a n ch or bolt .
(4) Rem ove qu a r t er t r im pa n el. If n ecessa r y, r efer
t o r em ova l pr ocedu r e.
(5) Rem ove sh ou lder belt u pper a n ch or bolt .
(6) Rem ove bolt a t t a ch in g r et r a ct or t o r ea r qu a r t er
r a il.
(7) Sepa r a t e r et r a ct or a n d sh ou lder belt fr om t r im
80b01c2d
pa n el.
RETRACTOR
ADJUSTER
80b01c3a
REAR CARPET/MAT
REMOVAL
(1) Rem ove t h e lift ga t e la t ch st r iker a n d scu ff
pla t e.
(2) Dr ill-ou t t h e r et a in in g r ivet h ea ds a n d r em ove
80aafb60 t h e ca r go t ie-down foot m a n loops fr om t h e ca r pet .
Fig. 78 Floor Console (3) As n ecessa r y, r em ove t h e t r im pa n els a n d
m oldin gs.
INSTALLATION
(4) Rem ove t h e a ll ot h er in t er fer in g com pon en t s.
(1) P osit ion t h e con sole on t h e floor.
(5) Rem ove t h e ca r pet a n d m a t fr om t h e floor
(2) At t a ch t h e a ir du ct t o t h e a ir ou t let du ct .
pa n el.
(3) Con n ect t h e wir e h a r n ess con n ect or s.
(6) If n ecessa r y, r em ove t h e in su la t ion fr om t h e
(4) In st a ll t h e scr ews a t t a ch in g t h e con sole t o t h e
wh eelh ou se (F ig. 80).
m ou n t in g br a cket .
(5) In st a ll t h e sh ift in dica t or bezels (or cover
INSTALLATION
pla t e).
(1) If r em oved, in st a ll t h e in su la t ion on t h e wh eel-
(6) In st a ll t h e sh ift lever h a n dle/kn ob.
h ou ses.
XJ BODY 23 - 51
REM OVAL AN D I N STALLAT I ON (Cont inue d)
INSTALLATION
(1) P osit ion t h e m ir r or ba se a t t h e br a cket a n d
slide it down wa r d on t o t h e su ppor t br a cket .
(2) Tigh t en set scr ew t o1 N·m (9 in . lbs.) t or qu e.
FACE SIDE
REARVIEW MIRROR SUPPORT BRACKET
AD:rl:"_/ INSTALLATION
~ WHEELHOUSE
(1) Ma r k t h e posit ion for t h e m ir r or br a cket on t h e
ou t side of t h e win dsh ield gla ss wit h a wa x pen cil.
(2) Clea n t h e br a cket con t a ct a r ea on t h e gla ss.
PANEL
Use a m ild powder ed clea n ser on a clot h sa t u r a t ed
wit h isopr opyl (r u bbin g) a lcoh ol. F in a lly, clea n t h e
gla ss wit h a pa per t owel da m pen ed wit h a lcoh ol.
(3) Sa n d t h e su r fa ce on t h e su ppor t br a cket wit h
fin e gr it -sa n dpa per. Wipe t h e br a cket su r fa ce clea n
wit h a pa per t owel.
(4) Apply a cceler a t or t o t h e su r fa ce on t h e br a cket
a ccor din g t o t h e followin g in st r u ct ion s:
LOWER • Cr u sh t h e via l t o sa t u r a t e t h e felt a pplica t or.
INSULATION J9223-190 • Rem ove t h e pa per sleeve.
• Apply a cceler a t or t o t h e con t a ct su r fa ce on t h e
Fig. 80 Wheelhouse Insulation br a cket .
(2) P osit ion t h e m a t on t h e floor pa n el. • Allow t h e a cceler a t or t o dr y for five m in u t es.
(3) P osit ion t h e ca r pet on t h e m a t . • Do n ot t ou ch t h e br a cket con t a ct su r fa ce a ft er
(4) In st a ll a ll t h e com pon en t s t h a t wer e r em oved t h e a cceler a t or h a s been a pplied.
t o fa cilit a t e ca r pet a n d m a t r em ova l. (5) Apply a dh esive a cceler a t or t o t h e br a cket con -
(5) In st a ll t h e t r im pa n els a n d m oldin gs. t a ct su r fa ce on t h e win dsh ield gla ss. Allow t h e a ccel-
(6) In st a ll t h e ca r go t ie-down foot m a n loops on t h e er a t or t o dr y for on e m in u t e. Do n ot t ou ch t h e gla ss
ca r pet wit h r epla cem en t r ivet s. con t a ct su r fa ce a ft er t h e a cceler a t or h a s been
(7) In st a ll t h e lift ga t e scu ff pla t e a n d la t ch st r iker. a pplied.
(6) In st a ll t h e br a cket a ccor din g t o t h e followin g
REARVIEW MIRROR in st r u ct ion s:
• Apply on e dr op of a dh esive a t t h e cen t er of t h e
REMOVAL br a cket con t a ct -su r fa ce on t h e win dsh ield gla ss.
(1) Loosen t h e m ir r or ba se set scr ew (F ig. 81). • Apply a n even coa t of a dh esive t o t h e con t a ct
(2) Slide t h e m ir r or ba se u pwa r d a n d off t h e su r fa ce on t h e br a cket .
br a cket . • Align t h e br a cket wit h t h e m a r ked posit ion on
t h e win dsh ield gla ss.
• P r ess a n d h old t h e br a cket in pla ce for a t lea st
on e m in u t e.
80ad2f1f
SUNVISORS HEADLINER
Th e u pper t r im m oldin gs a n d t h e h ea dlin er a r e
REMOVAL a t t a ch ed t o t h e r oof r a il wit h a com bin a t ion of
(1) Rem ove t h e scr ews t h a t a t t a ch t h e su n visor scr ews, clip r et a in er s a n d r a il r et a in er s (F ig. 84).
a r m su ppor t br a cket t o t h e h ea dlin er a n d t h e r oof
pa n el (F ig. 82) a n d (F ig. 83).
(2) Discon n ect va n it y la m p con n ect or, if equ ipped.
(3) Det a ch t h e su n visor fr om t h e su ppor t clip.
(4) Rem ove t h e su n visor fr om t h e veh icle.
(5) Rem ove t h e r et a in in g scr ew a n d su ppor t clip.
On veh icles equ ipped wit h a n over h ea d con sole, t h e
su ppor t clip is in t egr a l wit h t h e over h ea d con sole.
HEADLINER
HEADLINER
WINDSHIELD
SIDE MOULDING J9223-223
('
SCREW
SUN VISOR
J9123-32
h ea dlin er a lon g wit h (a s a pplica ble):
• Assist h a n dles.
• Su n visor s.
• Dom e/ca r go la m ps.
• Over h ea d con sole.
Fig. 82 Sunvisor • All ot h er a t t a ch ed/over la ppin g com pon en t s.
Refer t o t h e a ppr opr ia t e r em ova l a n d in st a lla t ion
HEADLINER pr ocedu r e loca t e in t h is sect ion or in Gr ou p 8, E lec-
t r ica l.
REMOVAL
/~
i~ ·~
CAUTION: The headliner is a one-piece, molded
component (Fig. 85). It has limited flexibility and
must not be bent during removal/installation.
CLIP
I
~---~
RETAINER
HEADLINER REAR
80ae0eb6 80ae0eb4
TRIM
PANEL
80b01c2e
80abd2e1
Fig. 86 Upper Trim Molding—4-Door
(4) In st a ll t h e u pper t r im m oldin gs a r ou n d t h e Fig. 88 Liftgate Trim Panel
per im et er of t h e h ea dlin er. Tigh t en t h e r et a in in g INSTALLATION
scr ews t o 1 N·m (11 in . lbs.) t or qu e.
(1) P osit ion t h e t r im pa n el on lift ga t e.
(5) As a pplica ble, in st a ll:
(2) Usin g n ew pu sh -in fa st en er s, a lign t h e pu sh -in
• Assist h a n dles.
fa st en er s wit h t h e h oles in t h e lift ga t e in n er pa n el
• Su n visor s.
a n d pr ess t h e t r im pa n el in t o pla ce.
• Dom e/ca r go la m ps.
(3) In st a ll t h e scr ews t o a t t a ch t h e lift ga t e t r im
• Over h ea d con sole.
pa n el t o t h e lift ga t e.
• All ot h er a t t a ch ed/over la ppin g com pon en t s.
(4) In st a ll t h e scr ews a t t a ch in g t h e a ssist h a n dle
t o t h e lift ga t e.
LIFTGATE TRIM PANEL (5) P r ess t h e t r im plu gs in t o t h e lift ga t e a ssist
h a n dle.
REMOVAL
(1) Usin g a sm a ll fla t bla de, pr y ou t t h e t r im plu gs
fr om t h e lift ga t e a ssist h a n dle.
(2) Rem ove t h e scr ews a t t a ch in g t h e a ssist h a n dle
t o t h e lift ga t e (F ig. 88).
(3) Rem ove t h e scr ews t h a t a t t a ch t h e lift ga t e t r im
pa n el t o t h e lift ga t e.
(4) Usin g a t r im pa n el r em ova l t ool, det a ch t h e
pu sh -in fa st en er s fr om t h e lift ga t e.
23 - 54 BODY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
~~·
ACTUATOR TO
LIFTGATE
LOCK ROD
SUPPORT ROD
CYLINDER OUTSIDE
HANDLE
TO LATCH
ROD
LIFTGATE
WASHER 80aa0feb LATCH 80aa0fed
OUTSIDE INSTALLATION
HANDLE (1) P osit ion wea t h er st r ip sea l in t h e open in g wit h
OUTSIDE t h e left en d of t h e sea l a t t h e open in g cen t er lin e.
HANDLE In st a ll t h e sea l in a clockwise dir ect ion .
TO LATCH (2) Move t o t h e left a n d m a t e t h e sea l wit h t h e
ROD bot t om -left fla n ge (F ig. 95).
(3) Move u pwa r d a n d m a t e t h e sea l wit h t h e left -
side fla n ge.
(4) Move t o t h e r igh t a n d m a t e t h e sea l wit h t h e
Fig. 93 Liftgate Latch t op-left r oof fla n ge.
(2) Con n ect power lock con n ect or t o h a n dle, if (5) Sea t t h e in st a lled pa r t of t h e sea l wit h a r oller.
equ ipped. Move t h e r oller fr om t h e left -bot t om en d of sea l t o
(3) Con n ect la t ch r od. t h e t op-left h a lf of t h e sea l.
(4) In st a ll scr ews a t t a ch in g la t ch t o lift ga t e. (6) Move t o t h e r igh t a n d m a t e t h e sea l wit h t h e
Tigh t en scr ews t o 13 N·m (9 ft . lbs.) t or qu e. t op-r igh t r oof fla n ge.
(5) In st a ll lift ga t e t r im pa n el. (7) Move down wa r d a n d m a t e t h e sea l wit h t h e
r igh t -side fla n ge.
LIFTGATE LATCH STRIKER (8) Move t o t h e left a n d m a t e t h e sea l wit h t h e
bot t om -r igh t fla n ge.
REMOVAL (9) Cen t er a n d bu t t sea l t h e en ds t oget h er a t t h e
(1) F r om u n der side of veh icle, r em ove n u t s a t t a ch - cen t er lin e.
in g st r iker t o floor pa n (F ig. 94). (10) Sea t t h e r em a in in g pa r t of t h e sea l wit h a
(2) Sepa r a t e st r iker fr om veh icle. r oller. Move t h e r oller t h e fr om t op-left h a lf of t h e
sea l t o t h e r igh t -bot t om en d of t h e sea l.
_ _ _ _ _ _ _ HOOD BUMPER
7
J9223-75 ~ ADJUSTMENT
SHIMS
RADIATOR- /
Fig. 96 Hood Bumper
SCREW
0
SUPPORT~
CROSSMEMBER '
80b8994e
REAR SEATBACK
(1) Un la t ch a n d posit ion sea t ba ck in ca r go posi-
\1 t ion .
LATCH
MOUNTING
(2) Loosen t h e scr ews a t t a ch in g t h e st r iker s t o t h e
BOLTS r ea r wh eelh ou se.
(3) P osit ion t h e sea t ba ck in t h e fu ll u pr igh t posi-
t ion a n d secu r e t h e la t ch in t o t h e st r iker s.
(4) F r om t h e ca r go a r ea of t h e veh icle, pu sh t h e
r ea r of t h e sea t ba ck for wa r d.
(5) Un la t ch a n d posit ion sea t ba ck in ca r go posit ion .
(6) Tigh t en t h e scr ews a t t a ch in g t h e st r iker s t o
J9523-100
t h e r ea r wh eelh ou se.
(7) P osit ion t h e sea t ba ck in t h e fu ll u pr igh t posi-
Fig. 99 Door Latch Adjustment t ion a n d secu r e t h e la t ch in t o t h e st r iker s.
(8) Ver ify la t ch oper a t ion .
SPECI FI CAT I ON S
BODY LUBRICANTS
WELD LOCATIONS
UPPER COWL
W3
W2 -WELDING OF 2 PARTS
WJ -WELDING OF 3 PARTS
w4 -WELDING OF 4 PARTS
W2
80b6fddf
23 - 60 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
UPPER COWL
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS
W2
~~
~
W2
0
;1~ 0
80b6fde0
XJ BODY 23 - 61
SPECI FI CAT I ON S (Cont inue d)
COWL
W2
I W2-WELDI
W3 - WELDI~~ gF 2 PARTS-1
._W4 - WELDING OF
F34 PARTS
PARTS 80b697b4
23 - 62 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
A—PILLAR
OF 2 PARTS
W2 - WELDIN~ OF 3 PARTS
W3 - WELDING OF 4 PARTS
w4 -WELDIN
80b697b6
XJ BODY 23 - 63
SPECI FI CAT I ON S (Cont inue d)
A—PILLAR
W3
W2
I
c:::::i
c:::::i I
~-.=_
,.~--"-
Cl
~ ~
W2
-~- -:~-~,/
~( I
d~-
-,o
W2 - WELDING OF 2
W3 - WELDING O PARTS
W4 - WELDING OF 3 PARTS
F4 PARTS 80b69809
23 - 64 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
A—PILLAR
/{\ W2 \4W3
<\'\ \ \
\\\
\\\ \ -~,
\~'0
\
\
"'
,l,i
' '._
\ ,+
'... /
C
:<---}:;."'_;,<>-1
,;:">>-
-,-c-----
--- -- ---:-·l
/ 1\
\\
--~/_;~--
_ - - - - ~-~-
:-(---;:_____ \\
-~>-- ,1
3 \\ [,'-'- -,-_-_- --"
--=:.~03:-=:_ _---_ _-----\
- - - \',
W ->><;;(- :;
\
'--- -l -<~":~;/
- C)
- --:.-~-_r -
tt~~/'<
~
S0b698e7
XJ BODY 23 - 65
SPECI FI CAT I ON S (Cont inue d)
A—PILLAR
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS 80b698ee
23 - 66 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
B—PILLAR
W2
W2
W2 -WELDIN~=-=----
W3 -WELDIN~ OF 2 PARTS
W4 -WELDING OF
OF 4
3 PARTS
PARTS
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS 80b698e9
23 - 68 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
FUEL FILLER OPENING
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
80b698ea
CARGO AREA FLOOR PAN
SPECI FI CAT I ON S (Cont inue d)
XJ
W2
BODY
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS 80b698eb
23 - 69
23 - 70 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
ROOF AND D—PILLAR
W2
4 DOOR ONLY
2 DOOR ONLY
W2
F 2 PARTS
W2 - WELDIN~ gF 3 PARTS
W3 - WELDING OF 4 PARTS
W4 - WELDIN=--=--- B0b69Bec
XJ BODY 23 - 71
SPECI FI CAT I ON S (Cont inue d)
LIFTGATE OPENING
W2
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
23 - 72 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
ROOF
4DOOR
2 DOOR S0b6fde1
XJ BODY 23 - 73
SPECI FI CAT I ON S (Cont inue d)
ROOF
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS
W3
80b6fde2
23 - 74 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
FRAME RAIL
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
W2
(LEFT SIDE ONLY)
W2 80b698fb
XJ BODY 23 - 75
SPECI FI CAT I ON S (Cont inue d)
FRAME RAIL
j 0
0
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS 80b698fc
23 - 76 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
FRAME RAIL
W2
W3
0
0
0
@ OF 2 PARTS
W2 - WELDIN~ OF 3 PARTS
W3 - WELDING OF 4 PARTS
W4 -WELDl~N~:...:...__ _
S0b698fe
XJ BODY 23 - 77
SPECI FI CAT I ON S (Cont inue d)
FRAME RAIL
W2
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS
80b698ff
23 - 78 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
REINFORCEMENT
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
C}cr
0
80b69900
XJ BODY 23 - 79
SPECI FI CAT I ON S (Cont inue d)
FRONT INNER FENDER
W2
(RIGHT SIDE ONLY)
W2
W3
a oa
OF 2 PARTS
W2 -WELDINg OF 3 PARTS
W3 -WELDING OF 4 PARTS
W4 - WE=L~D~IN::::_.=..__ _
80b69901
23 - 80 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
FRONT INNER FENDER AND RADIATOR CLOSURE PANEL
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS
W2
'\\
,C 0
\\
\\ +
""
""
W3 "\'
\
() ",---
=
a --
I+----
' 0 C
W2
(RIGHT SIDE
~
ONLY) W3
~
()
()
80b69902
XJ BODY 23 - 81
SPECI FI CAT I ON S (Cont inue d)
REINFORCEMENT
W2 - WELDING OF 2 PARTS
()
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
80b69903
FRONT FENDER
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
W2
W2 80b69904
23 - 82 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE
W2 -WELDING 0
W3 -WELDING gF 2 PARTS
W4 -WELDING OF
F43 PARTS
PARTS
( __
0
)
W2
W2
W2
W3
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
ga@//_ _ _~~
W4 -WELDING OF 4 PARTS 11 \
(2 DOOR ONLY)
W2 ~
!~-----~~--~---~@®
W2
0 f---------
W2 - WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS 0
W4 - WELDING OF 4 PARTS
4 DOOR ONLY
W2
W2
W2
W2
W2 -WELDIN~::----
W3 - WELDINg gF 2 PARTS
W2 W4 - WELDING OF
F43 PARTS
PARTS
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS
W3 W2
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
80b6990a
23 - 88 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
W2
80b6fd5b
XJ BODY 23 - 89
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS W3
W4 - WELDING OF 4 PARTS 80b6fd5c
23 - 90 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS
W2
80b6fdde
XJ BODY 23 - 91
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY ;;
<X)
0)
<g
0
<X)
I
(/) (/) (/)
~~~
~ ~ ~
..... 0.: 0.:
N M 'l:t
LL LL LL
000
(!) (!) (!)
zzz
i:i i:i i:i
...J ...J ...J
WWW
3: 3: 3:
I I I
N M 'l:t
3: 3: 3:
23 - 92 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
W2
W2
OF 2 PARTS
W2 -WELDINg OF 3 PARTS
W3 -WELDING OF 4 PARTS
W4-WELDIN
80b698f0
XJ BODY 23 - 93
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
W2 -WELDI
W3 - WELDl~g OF 2 PARTS
W4 - WELDING OF 3 PARTS
OF 4 PARTS
S0b698f1
UNDERBODY
SPECI FI CAT I ON S (Cont inue d)
23 - 94
W3*
BODY
W2
*BOTH SIDES
W3* W2
W2
W2 - WELDING OF 2 PARTS
FRONT
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
80b698f2
XJ
XJ BODY 23 - 95
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
W2*
W3*
W2
D
D
W2
·O
REAR
W2 - WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
80b698f3
23 - 96 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
:..:r-----------------
,J \~,
I
C)
0
0
0
:!)
,------------'--,------
W3
00
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
W2
80b698f4
XJ BODY 23 - 97
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
W2
80b698f5
23 - 98 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
W2
r-
~-----Jo
0
W3 00
~~__,,,--
W2
W3 ~--
~~
~~
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
~
W2
(4 DOOR ONLY)
W2
W2
W2
80b698f6
XJ BODY 23 - 99
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
W2 W2
LEFT SIDE
W2
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS 80b698f7
23 - 100 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
W2 -WELDING OF 2 PARTS
W3 -WELDING OF 3 PARTS
W4 -WELDING OF 4 PARTS
80b698f8
XJ BODY 23 - 101
SPECI FI CAT I ON S (Cont inue d)
UNDERBODY
ti.,A1~t-r,-,--~, W2
(BOTH
SIDES)
W2 - WELDING OF 2 PARTS
W3 - WELDING OF 3 PARTS
W4 - WELDING OF 4 PARTS
80b698f9
23 - 102 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
3 METAL THICKNESS
2 METAL THICKNESS
JI 3 METAL THICKNESS
JI
2 METAL THICKNESS
SYMBOLS
\l!) THUMBGRADEABLE SEALER
- EXTRUDABLE THERMOPLASTIC
80b62b1 b
XJ BODY 23 - 103
SPECI FI CAT I ON S (Cont inue d)
COWL AND DASH PANEL
p p
PTH p
T
T = THUMBGRADABLE
P = PUMPABLE
G = GENERAL PURPOSE
PTH = PATCH
p
UPPER FRONT
PILLAR
REINFORCEMENT
80b6fde6
23 - 104 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
DASH PANEL AND FLOOR PAN
FRONT
FLOOR PAN
T
T = THUMBGRADABLE
P = PUMPABLE
80b6fde7
XJ BODY 23 - 105
SPECI FI CAT I ON S (Cont inue d)
FLOOR PAN
p = PUMPARABiEPURPOSE
G = GENE
p
(2 BEADS)
80b6fde8
23 - 106 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
REAR INNER WHEELHOUSE
T = THUMBGRADABLE
P = PUMPABLE REAR FLOOR PAN
G = GENERAL PURPOSE EXTENSION
1/
~
~
INNER WHEELHOUSE
~ (REF.)
(REF.)
80b6fde9
XJ BODY 23 - 107
SPECI FI CAT I ON S (Cont inue d)
FRONT INNER WHEELHOUSE
T = THUMBGRADABLE
P = PUMPABLE
WHEELHOUSE
OUTER PANEL
80b6fdea
23 - 108 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE
FRONT PILLAR
UPPER REINFORCEMENT
H
G = GENERAL PURPOSE
H = HEAT EXPANDABLE
80b6fdeb
XJ BODY 23 - 109
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE
BODY LOCK
PILLAR
ROCKER PANEL
G
G
(4 DOOR ONLY)
BODY FRONT
HINGE PILLAR
T = THUMBGRADABLE
P = PUMPABLE
G = GENERAL PURPOSE
H = HEAT EXPANDABLE
G
(2 DOOR ONLY) 80b6fdec
23 - 110 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
BODY SIDE
p
ROOF
CENTER
PILLAR
H
(4 DOOR ONLY)
G
(2 DOOR ONLY)
P = PUMPABLE
G = GENERAL PURPOSE
H = HEAT EXPANDABLE 80b6fded
XJ BODY 23 - 111
SPECI FI CAT I ON S (Cont inue d)
ROOF PANEL
80b6fdee
23 - 112 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
FUEL FILLER HOUSING
T = THUMBGRADABLE
P = PUMPABLE
REAR QUARTER
OUTER PANEL
FUEL FILLER
SUPPORT HOUSING
80b6fdef
XJ BODY 23 - 113
SPECI FI CAT I ON S (Cont inue d)
LIFTGATE OPENING
T = THUMBGRADABLE
P = PUMPABLE
80b6fdf0
23 - 114 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
STRUCTUR
15.0 MM DIA:~ ADHESIVE
(BOTH s~iE:~ LONG
80b6fde3
XJ BODY 23 - 115
SPECI FI CAT I ON S (Cont inue d)
REAR WHEELHOUSE
LADHESIVE
STRUCTURA 0 MM LONG
3.0 MM DIA X 1147.
B0b6fde4
23 - 116 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
ROOF BOWS
FRONT
STRUCTURAL ADHESIVE
10.0 MM DIA X 800.0 MM LONG
REAR 80b6fde5
XJ BODY 23 - 117
SPECI FI CAT I ON S (Cont inue d)
80b6fdf6
23 - 118 BODY XJ
SPECI FI CAT I ON S (Cont inue d)
80ae834e
80ae834f
80ae8351
80ae8352
0
0
80aac308
80a9tof9
1485.5
80ae8354
XJ BODY 23 - 125
SPECI FI CAT I ON S (Cont inue d)
LIFTGATE OPENING
LIFTGATE OPENING
0
0
00° 0
00
t
A. 860.50
80b3c727
SPECI AL T OOLS
BODY
page page
REFRIGERANT OIL
Th e oil u sed in t h e SD7H 15 com pr essor is a poly-
I
Fig. 4 Manifold Gauge Set
J9324-83
Pressure Diagnosis
Condition Possible Causes Correction
Rapid compressor clutch cycling 1. Low refrigerant system charge. 1. See Refrigerant System Leaks in
(ten or more cycles per minute). this group. Test the refrigerant
system for leaks. Repair, evacuate
and charge the refrigerant system, if
required.
Equal pressures, but the 1. No refrigerant in the refrigerant 1. See Refrigerant System Leaks in
compressor clutch does not system. this group. Test the refrigerant
engage. 2. Faulty fuse. system for leaks. Repair, evacuate
3. Faulty compressor clutch coil. and charge the refrigerant system, if
4. Faulty compressor clutch relay. required.
5. Improperly installed or faulty low 2. Check the fuses in the Power
pressure cycling clutch switch. Distribution Center and the junction
6. Faulty high pressure cut-off block. Repair the shorted circuit or
switch. component and replace the fuses, if
7. Faulty Powertrain Control Module required.
(PCM). 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 1. Excessive refrigerant oil in 1. See Refrigerant Oil Level in this
Performance Test air temperatures system. group. Recover the refrigerant from
at center panel outlet are too high. 2. Temperature control cable the refrigerant system and inspect
improperly installed or faulty. the refrigerant oil content. Restore
3. Blend-air door inoperative or the refrigerant oil to the proper level,
sealing improperly. if required.
2. See Temperature Control Cable in
this group. Inspect the temperature
control cable for proper routing and
operation and correct, if required.
3. 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.
24 - 12 HEATING AND AIR CONDITIONING XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
Pressure Diagnosis
Condition Possible Causes Correction
The low side pressure is normal or 1. Low refrigerant system charge. 1. See Refrigerant System Leaks in
slightly low, and the high side 2. Refrigerant flow through the this group. Test the refrigerant
pressure is too low. accumulator is restricted. system for leaks. Repair, evacuate
3. Refrigerant flow through the and charge the refrigerant system, if
evaporator coil is restricted. required.
4. Faulty compressor. 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.
The low side pressure is normal or 1. Condenser air flow restricted. 1. Check the condenser for
slightly high, and the high side 2. Inoperative cooling fan. damaged fins, foreign objects
pressure is too high. 3. Refrigerant system overcharged. obstructing air flow through the
4. Air in the refrigerant system. condenser fins, and missing or
5. Engine overheating. 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.
4. See Refrigerant System Leaks in
this group. Test the refrigerant
system for leaks. Repair, evacuate
and charge the refrigerant system, if
required.
5. Refer to Group 7 - Cooling
System for more information. Test
the cooling system and repair, if
required.
The low side pressure is too high, 1. Accessory drive belt slipping. 1. Refer to Group 7 - Cooling
and the high side pressure is too 2. Fixed orifice tube not installed. System for more information. Inspect
low. 3. Faulty compressor. 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.
XJ HEATING AND AIR CONDITIONING 24 - 13
DI AGN OSI S AN D T EST I N G (Cont inue d)
Pressure Diagnosis
Condition Possible Causes Correction
The low side pressure is too low, 1. Restricted refrigerant flow through 1. See Liquid Line and Suction and
and the high side pressure is too the refrigerant lines. Discharge Line in this group. Inspect
high. 2. Restricted refrigerant flow through the refrigerant lines for kinks, tight
the fixed orifice tube. bends or improper routing. Correct
3. Restricted refrigerant flow through the routing or replace the refrigerant
the condenser. 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.
If t h e veh icle h a s been oper a t ed r ecen t ly, wa it fif- OBSTRUCTED COOLANT FLOW
t een m in u t es or lon ger befor e r em ovin g t h e r a dia t or P ossible loca t ion s or ca u ses of obst r u ct ed coola n t
pr essu r e ca p. P la ce a r a g over t h e ca p a n d t u r n it t o flow:
t h e fir st sa fet y st op. Allow a n y pr essu r e t o esca pe • P in ch ed or kin ked h ea t er h oses.
t h r ou gh t h e over flow t u be. Wh en t h e syst em st a bi- • Im pr oper h ea t er h ose r ou t in g.
lizes, r em ove t h e ca p com plet ely. • P lu gged h ea t er h oses or su pply a n d r et u r n por t s
a t t h e coolin g syst em con n ect ion s (r efer t o Gr ou p 7 -
M AX I M U M H EAT ER OU T PU T Coolin g Syst em ).
E n gin e coola n t is deliver ed t o t h e h ea t er cor e • A plu gged h ea t er cor e.
t h r ou gh t wo h ea t er h oses. Wit h t h e en gin e idlin g a t If pr oper coola n t flow t h r ou gh t h e h ea t er syst em is
n or m a l oper a t in g t em per a t u r e, set t h e t em per a t u r e ver ified, a n d ou t let a ir t em per a t u r e is st ill low, a
con t r ol kn ob in t h e fu ll h ot posit ion , t h e m ode con t r ol m ech a n ica l pr oblem m a y exist .
swit ch kn ob in t h e F loor posit ion , a n d t h e blower
m ot or swit ch kn ob in t h e h igh est speed posit ion . MECHANICAL PROBLEMS
Usin g a t est t h er m om et er, ch eck t h e a ir t em per a t u r e P ossible loca t ion s or ca u ses of in su fficien t h ea t :
com in g fr om t h e floor ou t let s, r efer t o t h e Tem per a - • An obst r u ct ed cowl a ir in t a ke.
t u r e Refer en ce ch a r t (F ig. 7). • Obst r u ct ed h ea t er syst em ou t let s.
If t h e floor ou t let a ir t em per a t u r e is low, r efer t o • A blen d-a ir door n ot fu n ct ion in g pr oper ly.
Gr ou p 7 - Coolin g Syst em for t h e coola n t t em per a -
t u r e specifica t ion s. Bot h of t h e h ea t er h oses sh ou ld T EM PERAT U RE CON T ROL
be h ot t o t h e t ou ch . Th e coola n t r et u r n h ose sh ou ld If t h e h ea t er disch a r ge a ir t em per a t u r e ca n n ot be
be sligh t ly cooler t h a n t h e su pply h ose. If t h e coola n t a dju st ed wit h t h e t em per a t u r e con t r ol kn ob on t h e
24 - 14 HEATING AND AIR CONDITIONING XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
h ea t er-A/C con t r ol pa n el, t h e followin g cou ld r equ ir e (2) Con n ect t h e t est set va cu u m su pply h ose t o t h e
ser vice: h ea t -A/C syst em side of t h e va lve. Wh en con n ect ed t o
• Th e h ea t er-A/C con t r ol. t h is side of t h e ch eck va lve, n o va cu u m sh ou ld pa ss
• Th e t em per a t u r e con t r ol ca ble. a n d t h e t est set ga u ge sh ou ld r et u r n t o t h e 27 kP a (8
• Th e blen d-a ir door. in . H g.) set t in g. If OK, go t o St ep 3. If n ot OK,
• Im pr oper en gin e coola n t t em per a t u r e. r epla ce t h e fa u lt y va lve.
(3) Con n ect t h e t est set va cu u m su pply h ose t o t h e
VACUUM SYSTEM en gin e va cu u m side of t h e va lve. Wh en con n ect ed t o
Va cu u m con t r ol is u sed t o oper a t e t h e m ode door s t h is side of t h e ch eck va lve, va cu u m sh ou ld flow
in t h e h ea t er-A/C h ou sin g. Test in g of t h e h ea t er-A/C t h r ou gh t h e va lve wit h ou t r est r ict ion . If n ot OK,
m ode con t r ol swit ch oper a t ion will det er m in e if t h e r epla ce t h e fa u lt y va lve.
va cu u m , a n d m ech a n ica l con t r ols a r e fu n ct ion in g.
H owever, it is possible t h a t a va cu u m con t r ol syst em H EAT ER-A/C CON T ROLS
t h a t oper a t es per fect ly a t en gin e idle (h igh en gin e (1) Con n ect t h e t est set va cu u m pr obe t o t h e h ea t -
va cu u m ) m a y n ot fu n ct ion pr oper ly a t h igh en gin e A/C syst em va cu u m su pply (bla ck) t u be a t t h e t ee in
speeds or loa ds (low en gin e va cu u m ). Th is ca n be t h e en gin e com pa r t m en t . P osit ion t h e t est set ga u ge
ca u sed by lea ks in t h e va cu u m syst em , or a fa u lt y so t h a t it ca n be viewed fr om t h e pa ssen ger com pa r t -
va cu u m ch eck va lve. m en t .
A va cu u m syst em t est will h elp t o iden t ify t h e (2) P la ce t h e h ea t er-A/C m ode con t r ol swit ch kn ob
sou r ce of poor va cu u m syst em per for m a n ce, or loca t e in ea ch m ode posit ion , on e a t a t im e, a n d pa u se a ft er
va cu u m syst em lea ks. Befor e st a r t in g t h is t est , st op ea ch select ion . Th e t est set ga u ge sh ou ld r et u r n t o
t h e en gin e a n d m a ke cer t a in t h a t t h e pr oblem isn ’t a t h e 27 kP a (8 in . H g.) set t in g sh or t ly a ft er ea ch selec-
discon n ect ed va cu u m su pply t u be a t t h e en gin e t ion is m a de. If n ot OK, a com pon en t or va cu u m lin e
in t a ke m a n ifold va cu u m t a p or t h e va cu u m r eser voir. in t h e va cu u m cir cu it of t h e select ed m ode h a s a
Use a n a dju st a ble va cu u m t est set (Specia l Tool lea k. See t h e pr ocedu r e in Loca t in g Va cu u m Lea ks.
C-3707) a n d a su it a ble va cu u m pu m p t o t est t h e
h ea t er-A/C va cu u m con t r ol syst em . Wit h a fin ger CAUTION: Do not use lubricant on the switch ports
pla ced over t h e en d of t h e va cu u m t est h ose pr obe or in the holes in the plug, as lubricant will ruin the
(F ig. 8), a dju st t h e bleed va lve on t h e t est set ga u ge vacuum valve in the switch. A drop of clean water
t oVACUUM
obt aTEST
in BLEED
aSETva
PROBE
C-3707
VALVE VACUUM PUMP C-4289
cu u m of exa ct lyTOOL
27 kP a (8 in . H g.). in the connector plug holes will help the connector
Relea se a n d block t h e en d of t h e pr obe sever a l t im es slide onto the switch ports.
t o ver ify t h a t t h e va cu u m r ea din g r et u r n s t o t h e
exa ct 27 kP a (8 in . H g.) set t in g. Ot h er wise, a fa lse LOCAT I N G VACU U M LEAK S
r ea din g will be obt a in ed du r in g t est in g.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
OFF
VACUUM E
A B C F
0 0 0 B
(o o o o\
D E F G
VENTED
r
0
w
n
Blue
Red
PANEL FLOOR
E E
F F
Red Red
MIX DEFROST
E E
F F
B B
r r
0 0
w w
n n
®@©
©®®@
Blue
80aac2d2
D
A
E
B
F
C
G
-
V ACUUM
VENTED
E
OFF
G F
A/C-BI LEVEL
Black Red
Black Red
MIX
E
F
A/C-RECIRCULATION
E
G F
Black Red
Green
Black Red
FLOOR DEFROST
E E
F
80aac2d3
I I
- (6) Sepa r a t e t h e t wo en ds of t h e cou pler.
Component ml oz
- -
A/C System 240 8.1 I N STALLAT I ON
~
Accumulator 120
-
4 (1) Ch eck t o en su r e t h a t t h e ga r t er spr in g is in t h e
~
Condenser 30 1
- ca ge of t h e m a le cou pler fit t in g. If t h e ga r t er spr in g
-
Evaporator 60 2
- is m issin g, in st a ll a n ew spr in g by pu sh in g it in t o t h e
- I
- ca ge open in g. If t h e ga r t er spr in g is da m a ged,
Compressor drain and measure the oil from the r em ove it fr om t h e ca ge wit h a sm a ll wir e h ook (DO
I
old compressor - see text. _J NOT u se a scr ewdr iver ) a n d in st a ll a n ew ga r t er
spr in g.
REM OVAL AN D I N STALLAT I ON (2) Clea n a n y dir t or for eign m a t er ia l fr om bot h
h a lves of t h e cou plin g.
REFRIGERANT LINE COUPLER (3) In st a ll n ew O-r in gs on t h e m a le fit t in g.
WARNING: REVIEW THE WARNINGS AND CAU- CAUTION: Use only the specified O-rings as they
TIONS IN THE FRONT OF THIS GROUP BEFORE are made of a special material for the R-134a sys-
PERFORMING THE FOLLOWING OPERATION. tem. The use of any other O-ring may allow the con-
nection to leak intermittently during vehicle
operation.
REM OVAL
(1) Recover t h e r efr iger a n t fr om t h e r efr iger a n t (4) Lu br ica t e t h e m a le fit t in g a n d O-r in g, a n d t h e
syst em a s descr ibed in t h is gr ou p. in side of t h e fem a le fit t in g wit h clea n R-134a r efr ig-
(2) Rem ove t h e secon da r y clip fr om t h e cou pler. F it er a n t oil. Use on ly r efr iger a n t oil of t h e t ype r ecom -
t h e a ppr opr ia t e spr in g lock r efr iger a n t lin e cou pler m en ded for t h e com pr essor in t h e veh icle.
t ool (Specia l Tool 7193) t o t h e cou pler (F ig. 12). (5) F it t h e fem a le fit t in g t o t h e m a le fit t in g a n d
(3) Close t h e t ool a n d pu sh it in t o t h e open side of pu sh t oget h er u n t il t h e ga r t er spr in g sn a ps over t h e
t h e ca ge t o expa n d t h e ga r t er spr in g a n d r elea se t h e fla r ed en d of t h e fem a le fit t in g.
fem a le fit t in g. (6) E n su r e t h e cou pler is fu lly en ga ged by pu llin g
ba ck on t h e lin es on eit h er side of t h e cou pler.
NOTE: The garter spring may not release if the tool
(7) In st a ll t h e secon da r y clip on t h e cou pler.
is cocked while pushing it into the cage opening.
SUCTION
ACCUMULATOR
HEX
ANDNUT
DISCHARGE
LINE SCREW COMPRESSOR
CONDENSER
SCREW
FWD
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Recover t h e r efr iger a n t fr om t h e r efr iger a n t
syst em a s descr ibed in t h is gr ou p.
(3) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
h igh pr essu r e cu t -off swit ch .
(4) Rem ove t h e r a dia t or gr ille pa n el. Refer t o
Gr ou p 23 - Body for t h e pr ocedu r es.
(5) Rea ch t h r ou gh t h e gr ille open in g t o r em ove t h e
scr ew t h a t secu r es t h e disch a r ge lin e block fit t in g a t
t h e con den ser in let (F ig. 14) or (F ig. 15). In st a ll plu gs
in , or t a pe over a ll of t h e open r efr iger a n t fit t in gs.
ACCUMULATOR
J9424-32
I N STALLAT I ON
(1) In st a ll a n d t igh t en t h e h igh pr essu r e cu t -off
swit ch on t h e disch a r ge lin e fit t in g.
(2) P lu g t h e wir e h a r n ess con n ect or in t o t h e h igh
pr essu r e cu t -off swit ch .
(3) Con n ect t h e ba t t er y n ega t ive ca ble.
ACCUMULATOR SUCTION
HEX NUT AND DISCHARGE
ACCUMULATOR ---- LINE
CONDENSER
80abfedb
~CLIP
',
i
- ~------'-. ACCUMULATOR
~
CONDENSER
I ,1/ \
'·~
""
SCREW
NUT
CLIP
DISCHARGE
LINE JUMPER
80aac2db
Fig. 17 Suction and Discharge Line Remove/Install - Right-Hand Drive 4.0L Engine
24 - 26 HEATING AND AIR CONDITIONING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(3) Loosen a n d r em ove t h e ser pen t in e dr ive belt .
Refer t o Gr ou p 7 - Coolin g Syst em for t h e pr ocedu r es.
(4) If t h e veh icle is equ ipped wit h Righ t -H a n d
Dr ive (RH D) a n d t h e 4.0L en gin e, r a ise a n d su ppor t
t h e veh icle.
(5) Un plu g t h e com pr essor clu t ch coil wir e h a r n ess
con n ect or.
(6) Rem ove t h e su ct ion a n d disch a r ge r efr iger a n t
lin es fr om t h e com pr essor a s descr ibed in t h is gr ou p.
In st a ll plu gs in , or t a pe over a ll of t h e open r efr iger-
a n t fit t in gs.
(7) Rem ove t h e fou r bolt s t h a t secu r e t h e com pr es-
COMPRESSOR
sor t o t h e m ou n t in g br a cket (F ig. 18) or (F ig. 19). 80abd2a9
COMPRESSOR CLUTCH
Th e r efr iger a n t syst em ca n r em a in fu lly-ch a r ged
du r in g com pr essor clu t ch , pu lley, or coil r epla cem en t .
Th e com pr essor clu t ch ca n be ser viced in t h e veh icle.
J9524-25 J9524-28
J9524-26
I N SPECT I ON
E xa m in e t h e fr ict ion su r fa ces of t h e clu t ch pu lley
a n d t h e fr on t pla t e for wea r. Th e pu lley a n d fr on t
pla t e sh ou ld be r epla ced if t h er e is excessive wea r or
scor in g.
If t h e fr ict ion su r fa ces a r e oily, in spect t h e sh a ft
a n d n ose a r ea of t h e com pr essor for oil. Rem ove t h e
Fig. 22 External Snap Ring Remove felt fr om t h e fr on t cover. If t h e felt is sa t u r a t ed wit h
(9) In st a ll t h e pu ller t h r ou gh -bolt s (Specia l Tool oil, t h e sh a ft sea l is lea kin g a n d t h e com pr essor m u st
C-6461) t h r ou gh t h e pu ller fla n ge a n d in t o t h e ja ws be r epla ced.
of t h e r ot or pu ller a n d t igh t en (F ig. 24). Tu r n t h e
PULLEY ASSEMBLY
BEARING INSTALLER
lij
------
J9524-34
,/
Fig. 25 Clutch Coil Lead Wire Harness Fig. 27 Clutch Pulley Install
ure and severe damage to the front housing of the
compressor.
I N STALLAT I ON
(1) In st a ll t h e clu t ch field coil a n d sn a p r in g. J9524-32
(2) In st a ll t h e clu t ch coil lea d wir e h a r n ess r et a in -
in g clip on t h e com pr essor fr on t h ou sin g a n d t igh t en Fig. 28 Clutch Plate Driver
t h e r et a in in g scr ew. (8) Ch eck t h e clu t ch a ir ga p wit h a feeler ga u ge
(3) Align t h e r ot or a ssem bly squ a r ely on t h e fr on t (F ig. 29). If t h e a ir ga p does n ot m eet t h e specifica -
com pr essor h ou sin g h u b. t ion , a dd or su bt r a ct sh im s a s r equ ir ed. Th e a ir ga p
(4) In st a ll t h e pu lley bea r in g a ssem bly wit h t h e specifica t ion is 0.41 t o 0.79 m m (0.016 t o 0.031 in ch ).
in st a ller (Specia l Tool C-6871) (F ig. 27). Th r ea d t h e If t h e a ir ga p is n ot con sist en t a r ou n d t h e cir cu m fer-
in st a ller on t h e sh a ft , t h en t u r n t h e n u t u n t il t h e en ce of t h e clu t ch , ligh t ly pr y u p a t t h e m in im u m
pu lley a ssem bly is sea t ed. va r ia t ion s. Ligh t ly t a p down a t t h e poin t s of m a xi-
(5) In st a ll t h e ext er n a l fr on t sn a p r in g wit h sn a p m u m va r ia t ion .
r in g plier s. Th e bevel side of t h e sn a p r in g m u st be
fa cin g ou t wa r d. P r ess t h e sn a p r in g t o m a ke su r e it
is pr oper ly sea t ed in t h e gr oove.
J8924-28
INSTALLATION
(1) Rem ove t h e t a pe or plu gs fr om t h e liqu id lin e
ju m per a n d con den ser ou t let block fit t in gs. In st a ll
CLIP
t h e liqu id lin e ju m per t o t h e con den ser ou t let .
Tigh t en t h e m ou n t in g scr ew t o 12 N·m (105 in . lbs.).
(2) In st a ll t h e r a dia t or gr ille pa n el. Refer t o Gr ou p
23 - Body for t h e pr ocedu r es.
(3) Rem ove t h e t a pe or plu gs fr om t h e r efr iger a n t
lin e cou pler s on t h e liqu id lin e, t h e liqu id lin e
ju m per, a n d t h e eva por a t or in let . In st a ll t h e liqu id
lin e t o t h e liqu id lin e ju m per a n d t h e eva por a t or
in let r efr iger a n t lin e cou pler s. See Refr iger a n t Lin e
STUD Cou pler in t h is gr ou p for t h e pr ocedu r es.
(4) On Left -H a n d Dr ive m odels on ly, in st a ll t h e
scr ew t h a t secu r es t h e liqu id lin e block fit t in g t o t h e
liqu id lin e ju m per. Tigh t en t h e m ou n t in g scr ew t o 9
N·m (80 in . lbs.).
(5) Con n ect t h e ba t t er y n ega t ive ca ble.
(6) E va cu a t e a n d ch a r ge t h e r efr iger a n t syst em a s
descr ibed in t h is gr ou p.
Fig. 31 Liquid Line Remove/Install - Left-Hand Drive
2.5L Engine 4 .0 L EN GI N E
REMOVAL
EVAPORATOR (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
INLET ca ble.
(2) Recover t h e r efr iger a n t fr om t h e r efr iger a n t
CLIP syst em a s descr ibed in t h is gr ou p.
CONDENSER
CLIP (3) Discon n ect t h e liqu id lin e r efr iger a n t lin e cou -
pler s a t t h e eva por a t or in let a n d t h e con den ser ou t let
CLIP
/
LOW
PRESSURE
CYCLING
CLUTCH
SWITCH
~ LIQUID LINE
JUMPER WITH
ORIFICE TUBE
80abfede
ACCUMULATOR
ACCUMULATOR
BAND
LOW
NUTS PRESSURE BRACKET
CYCLINGCLIPCLUTCH
SWITCH
EVAPORATOR STUDS
FWD
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
REM OVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
SCREW
(2) Recover t h e r efr iger a n t fr om t h e r efr iger a n t
syst em a s descr ibed in t h is gr ou p.
(3) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
low pr essu r e cyclin g clu t ch swit ch .
(4) Loosen t h e scr ew t h a t secu r es t h e a ccu m u la t or
r et a in in g ba n d t o t h e su ppor t br a cket (F ig. 36) or
(F ig. 37). BAND
80abd2a6
~ ~ TO
~ ~ HEATER-A/C
-~~ CONTROLS
~~ TO ENGINE
:o:cy GROMMET
INTAKE
MANIFOLD
CONDENSER \LOWER
80abd2a3
CROSSMEMBER
80abfee2 Fig. 40 Vacuum Supply
(2) Not e t h e or ien t a t ion of t h e ch eck va lve in t h e
Fig. 39 Condenser Remove/Install - 4.0L Engine
va cu u m su pply lin e for cor r ect r ein st a lla t ion .
(7) Rem ove t h e u pper br a cket s fr om t h e r a dia t or (3) Un plu g t h e va cu u m ch eck va lve fr om t h e va c-
a n d t h e con den ser. u u m su pply lin e fit t in gs.
(8) Slide t h e con den ser lower br a cket s off of t h e (4) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
dowel pin s on t h e bot t om of t h e r a dia t or.
(9) Rem ove t h e con den ser fr om t h e r a dia t or. VACUUM RESERVOIR
(1) Rem ove t h e pa ssen ger side bu m per en d ca p
INSTALLATION fr om t h e fr on t bu m per. Refer t o Gr ou p 23 - Body for
(1) In st a ll t h e h oles of t h e con den ser lower br a ck- t h e pr ocedu r es.
et s over t h e dowel pin s on t h e bot t om of t h e r a dia t or. (2) Un plu g t h e va cu u m su pply lin e con n ect or fr om
(2) In st a ll t h e u pper br a cket s over t h e st u ds on t h e r eser voir (F ig. 41).
t h e t op of t h e r a dia t or a n d t h e con den ser. Tigh t en
t h e m ou n t in g n u t s t o 5.3 N·m (47 in . lbs.).
(3) In st a ll t h e r a dia t or a n d con den ser t o t h e veh i-
cle a s a u n it . Refer t o Gr ou p 7 - Coolin g Syst em for
t h e pr ocedu r es.
(4) Rem ove t h e t a pe or plu gs fr om t h e r efr iger a n t
lin e cou pler s on t h e con den ser ou t let a n d t h e liqu id
lin e (Left -H a n d Dr ive) or t h e liqu id lin e ju m per
(Righ t -H a n d Dr ive). In st a ll t h e liqu id lin e or t h e liq-
u id lin e ju m per t o t h e con den ser ou t let . See Refr iger-
a n t Lin e Cou pler in t h is gr ou p for t h e pr ocedu r es.
(5) Rem ove t h e t a pe or plu gs fr om t h e r efr iger a n t
lin e cou pler s on t h e con den ser in let a n d t h e dis-
ch a r ge lin e (Left -H a n d Dr ive) or t h e disch a r ge lin e
ju m per (Righ t -H a n d Dr ive). In st a ll t h e disch a r ge lin e
or t h e disch a r ge lin e ju m per t o t h e con den ser in let . RESERVOIR_,...~
See Refr iger a n t Lin e Cou pler in t h is gr ou p for t h e SCREWS~
pr ocedu r es.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. { 80aac282
k1
! lul
80abd276
I N STALLAT I ON
(1) Align a n d in st a ll t h e blower m ot or a n d wh eel
a ssem bly in t o t h e h ea t er-A/C h ou sin g.
(2) In st a ll a n d t igh t en t h e t h r ee scr ews t h a t secu r e
t h e blower m ot or t o t h e h ea t er A/C h ou sin g. Tigh t en
t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
80ab87bc
(3) P lu g in t h e blower m ot or wir e h a r n ess con n ec-
t or.
Fig. 43 Center Bezel Remove/Install
(4) If t h e veh icle is equ ipped wit h a ir con dit ion in g,
con n ect t h e a ccu m u la t or in let t u be t o t h e eva por a t or (5) Rem ove t h e cen t er bezel fr om t h e veh icle.
24 - 36 HEATING AND AIR CONDITIONING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
FLAG
TEMPERATURE
(6) Relea se t h e va cu u m WIRE
RETAINERCABLE
INSTRUMENT
CONTROL
CABLE
END
PANEL h a r HARNESS
n ess HEATER-A/C
puHEATER-A/C
CONNEC-
shVACUUM
TOR
-inCONTROLS
rCONTROLS
HARNESS
SCREW
et a in er h ea t er-A/C con t r ol fr om t h e fr on t of t h e in st r u m en t
fr om t h e in st r u m en t pa n el dir ect ly ben ea t h t h e h ea t - pa n el.
er-A/C con t r ol.
(7) Rem ove t h e fou r scr ews t h a t secu r e t h e h ea t er- I N STALLAT I ON
A/C con t r ol t o t h e in st r u m en t pa n el (F ig. 44). (1) Con n ect t h e t em per a t u r e con t r ol ca ble cor e en d
t o t h e t em per a t u r e con t r ol lever on t h e ba ck of t h e
INSTRUMENT HEATER-A/C h ea t er-A/C con t r ols.
PANEL CONTROLS (2) Sn a p t h e t em per a t u r e con t r ol ca ble h ou sin g
fla g r et a in er in t o t h e r ecept a cle on t h e ba ck of t h e
h ea t er-A/C con t r ols.
(3) P lu g in t h e wir e h a r n ess con n ect or t o t h e ba ck
of t h e h ea t er-A/C con t r ol.
(4) Rou t e t h e va cu u m h a r n ess t h r ou gh t h e in st r u -
m en t pa n el open in g a n d r ein st a ll t h e va cu u m h a r-
n ess pu sh -in r et a in er.
(5) Rea ch t h r ou gh t h e glove box open in g a n d plu g
in t h e va cu u m h a r n ess con n ect or.
(6) Roll u p t h e glove box a n d r ein st a ll t h e glove
box st op bu m per s.
(7) In st a ll t h e h ea t er-A/C con t r ols t o t h e in st r u -
m en t pa n el a n d secu r e wit h fou r scr ews. Tigh t en t h e
scr ews t o 2.2 N·m (20 in . lbs.).
Fig. 44 Heater-A/C Controls Remove/Install (8) In st a ll t h e in st r u m en t pa n el cen t er bezel.
(8) P u ll t h e h ea t er-A/C con t r ol a ssem bly a wa y (9) Con n ect t h e ba t t er y n ega t ive ca ble.
fr om t h e in st r u m en t pa n el fa r en ou gh t o a ccess t h e
con n ect ion s. TEMPERATURE CONTROL CABLE
(9) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
ba ck of t h e h ea t er-A/C con t r ol a ssem bly (F ig. 45). WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
HEATER-A/C RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
CABLE CONTROLS STEERING WHEEL, STEERING COLUMN, OR
END INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
FLAG
RETAINER
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
/
CABL~I
END-AIR DOOR
I
n~· CRANK ARM
tJ SCREW 80abd27c
80abd27e
REM OVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e in st r u m en t pa n el a ssem bly a s
descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s. ]~
~/" J'v\ NUT
STUD
~
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- FLAT BLADE
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- PRY TOOL
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CRANK ARM
PANEUDEMIST FLOOR DOOR PIVOT SHAFT
UPPER HEATER-A/C HOUSING
LOWER HEATER-A/C HOUSING (5) Rem ove t h e floor door fr om t h e h ea t er-A/C
t:==DOOR h ou sin g.
(6) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
LOWER HEATER-A/C
HOUSING
80abd29b
DEM I ST ER H OSES
(1) Rem ove t h e in st r u m en t pa n el a ssem bly a s
descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s.
(2) Discon n ect t h e en ds of t h e dem ist er h ose fr om
t h e dem ist er du ct (F ig. 66) a n d t h e defr ost du ct /de-
m ist er a da pt er (F ig. 65).
(3) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
DEM I ST ER DU CT S
(1) Rem ove t h e in st r u m en t pa n el a ssem bly a s Fig. 67 Floor Duct and Console Rear Duct Remove/
descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s. Install
(2) Rem ove t h e in st r u m en t pa n el en d ca p a s
descr ibed in Gr ou p 8E - In st r u m en t P a n el Syst em s. (3) Lift t h e r ea r of t h e con sole r ea r du ct ou t of t h e
(3) Discon n ect t h e dem ist er h oses fr om t h e dem is- con sole r ea r m ou n t in g br a cket on t h e floor pa n t r a n s-
t er du ct (F ig. 66). m ission t u n n el a n d slide t h e du ct r ea r wa r d t o disen -
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e dem is- ga ge it fr om t h e floor du ct a n d a da pt er.
t er du ct t o t h e t op of t h e in st r u m en t pa n el. (4) Rem ove t h e con sole r ea r du ct fr om t h e veh icle.
(5) Rem ove t h e dem ist er du ct fr om t h e in st r u m en t (5) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
pa n el.
24 - 46 HEATING AND AIR CONDITIONING XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
FLOOR DU CT AN D ADAPT ER (4) Rem ove t h e floor du ct a n d a da pt er fr om t h e
(1) Rem ove t h e in st r u m en t pa n el a s descr ibed in h ea t er-A/C h ou sin g.
Gr ou p 8E - In st r u m en t P a n el Syst em s. (5) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
(2) Rem ove t h e h ea t er-A/C h ou sin g a s descr ibed in Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
t h is gr ou p.
(3) Rem ove t h e t h r ee scr ews t h a t secu r e t h e floor
du ct a n d a da pt er t o t h e h ea t er-A/C h ou sin g (F ig. 67).
XJ EMISSION CONTROL SYSTEMS 25 - 1
page page
INDEX
page page
GEN ERAL I N FORM AT I ON P CM). Beca u se t h e con dit ion h a ppen s a t a n en gin e
speed a bove t h e m a xim u m t h r esh old (2000 r pm ), t h e
SYSTEM DESCRIPTION P CM will n ot st or e a DTC.
Th e P ower t r a in Con t r ol Modu le (P CM) m on it or s Th er e a r e sever a l oper a t in g con dit ion s for wh ich
m a n y differ en t cir cu it s in t h e fu el in ject ion , ign it ion , t h e P CM m on it or s a n d set s DTC’s. Refer t o Mon i-
em ission a n d en gin e syst em s. If t h e P CM sen ses a t or ed Syst em s, Com pon en t s, a n d Non -Mon it or ed Cir-
pr oblem wit h a m on it or ed cir cu it oft en en ou gh t o cu it s in t h is sect ion .
in dica t e a n a ct u a l pr oblem , it st or es a Dia gn ost ic
Tr ou ble Code (DTC) in t h e P CM’s m em or y. If t h e NOTE: Various diagnostic procedures may actually
code a pplies t o a n on -em ission s r ela t ed com pon en t or cause a diagnostic monitor to set a DTC. For
syst em , a n d t h e pr oblem is r epa ir ed or cea ses t o instance, pulling a spark plug wire to perform a
exist , t h e P CM ca n cels t h e code a ft er 40 wa r m -u p spark test may set the misfire code. When a repair
cycles. Dia gn ost ic t r ou ble codes t h a t a ffect veh icle is completed and verified, connect the DRB scan
em ission s illu m in a t e t h e Ma lfu n ct ion In dica t or tool to the 16–way data link connector (Fig. 1) to
(ch eck en gin e) La m p. Refer t o Ma lfu n ct ion In dica t or erase all DTC’s and extinguish the MIL.
La m p in t h is sect ion .
Tech n icia n s ca n displa y st or ed DTC’s by t h r ee dif-
Cer t a in cr it er ia m u st be m et befor e t h e P CM
fer en t m et h ods. Refer t o Dia gn ost ic Tr ou ble Codes in
st or es a DTC in m em or y. Th e cr it er ia m a y be a spe-
t h is sect ion . F or DTC in for m a t ion , r efer t o ch a r t s in
cific r a n ge of en gin e RP M, en gin e t em per a t u r e,
t h is sect ion .
a n d/or in pu t volt a ge t o t h e P CM.
Th e P CM m igh t n ot st or e a DTC for a m on it or ed
cir cu it even t h ou gh a m a lfu n ct ion h a s occu r r ed. Th is DESCRI PT I ON AN D OPERAT I ON
m a y h a ppen beca u se on e of t h e DTC cr it er ia for t h e
cir cu it h a s n ot been m et . F o r e x a m p le , a ssu m e t h e MALFUNCTION INDICATOR LAMP (MIL)
dia gn ost ic t r ou ble code cr it er ia r equ ir es t h e P CM t o As a fu n ct ion a l t est , t h e MIL (ch eck en gin e) illu m i-
m on it or t h e cir cu it on ly wh en t h e en gin e oper a t es n a t es a t key-on befor e en gin e cr a n kin g. Wh en ever
bet ween 750 a n d 2000 RP M. Su ppose t h e sen sor ’s t h e P ower t r a in Con t r ol Modu le (P CM) set s a Dia g-
ou t pu t cir cu it sh or t s t o gr ou n d wh en en gin e oper a t es n ost ic Tr ou ble Code (DTC) t h a t a ffect s veh icle em is-
a bove 2400 RP M (r esu lt in g in 0 volt in pu t t o t h e sion s, it illu m in a t es t h e MIL. If a pr oblem is
16–WAY DATA LINK
NECTOR
CON-
GENERIC
MIL SCAN DRB SCAN TOOL DESCRIPTION OF DIAGNOSTIC TROUBLE
HEX CODE
CODE TOOL DISPLAY CODE
CODE
12* Battery Disconnect Direct battery input to PCM was disconnected
within the last 50 Key-on cycles.
55* Completion of fault code display on Check
Engine lamp.
01 54** P0340 No Cam Signal at No camshaft signal detected during engine
PCM cranking.
02 53** P0601 Internal Controller PCM Internal fault condition detected.
Failure
05 47*** Charging System Battery voltage sense input below target
Voltage Too Low charging during engine operation. Also, no
significant change detected in battery voltage
during active test of generator output circuit.
06 46*** Charging System Battery voltage sense input above target
Voltage Too High charging voltage during engine operation.
0A 42* Auto Shutdown Relay An open or shorted condition detected in the
Control Circuit auto shutdown relay circuit.
0B 41*** Generator Field Not An open or shorted condition detected in the
Switching Properly generator field control circuit.
0C 37** P0743 Torque Converter An open or shorted condition detected in the
Clutch Soleniod/Trans torque converter part throttle unlock solenoid
Relay Circuits control circuit (3 speed auto RH trans. only).
0E 35** P1491 Rad Fan Control An open or shorted condition detected in the
Relay Circuit low speed radiator fan relay control circuit.
25 - 4 EMISSION CONTROL SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
GENERIC
MIL SCAN DRB SCAN TOOL DESCRIPTION OF DIAGNOSTIC TROUBLE
HEX CODE
CODE TOOL DISPLAY CODE
CODE
0F 34* Speed Control An open or shorted condition detected in the
Solenoid Circuits Speed Control vacuum or vent solenoid circuits.
10 33* A/C Clutch Relay An open or shorted condition detected in the
Circuit A/C clutch relay circuit.
12 31** P0443 EVAP Purge Solenoid An open or shorted condition detected in the
Circuit duty cycle purge solenoid circuit.
13 27** P0203 Injector #3 Control Injector #3 output driver does not respond
Circuit properly to the control signal.
or
14 P0202 Injector #2 Control Injector #2 output driver does not respond
Circuit properly to the control signal.
or
15 P0201 Injector #1 Control Injector #1 output driver does not respond
Circuit properly to the control signal.
19 25** P0505 Idle Air Control Motor A shorted or open condition detected in one or
Circuits more of the idle air control motor circuits.
1A 24** P0122 Throttle Position Throttle position sensor input below the
Sensor Voltage Low minimum acceptable voltage
or
1B P0123 Throttle Position Throttle position sensor input above the
Sensor Voltage High maximum acceptable voltage.
1E 22** P0117 ECT Sensor Voltage Engine coolant temperature sensor input below
Too Low minimum acceptable voltage.
or
1F P0118 ECT Sensor Voltage Engine coolant temperature sensor input above
Too High maximum acceptable voltage.
21 17* Engine Is Cold Too Engine did not reach operating temperature
Long within acceptable limits.
23 15** P0500 No Vehicle Speed No vehicle speed sensor signal detected during
Sensor Signal road load conditions.
24 14** P0107 MAP Sensor Voltage MAP sensor input below minimum acceptable
Too Low voltage.
or
25 P0108 MAP Sensor Voltage MAP sensor input above maximum acceptable
Too High voltage.
27 13** P1297 No Change in MAP No difference recognized between the engine
From Start to Run MAP reading and the barometric (atmospheric)
pressure reading from start-up.
28 11* No Crank Reference No crank reference signal detected during
Signal at PCM engine cranking.
2B P0351 Ignition Coil #1 Peak primary circuit current not achieved with
Primary Circuit maximum dwell time.
2C 42* No ASD Relay Output An Open condition Detected In The ASD Relay
Voltage at PCM Output Circuit.
XJ EMISSION CONTROL SYSTEMS 25 - 5
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
GENERIC
MIL SCAN DRB SCAN TOOL DESCRIPTION OF DIAGNOSTIC TROUBLE
HEX CODE
CODE TOOL DISPLAY CODE
CODE
31 63** P1696 PCM Failure Unsuccessful attempt to write to an EEPROM
EEPROM Write location by the PCM.
Denied
39 23** P0112 Intake Air Temp Intake air temperature sensor input below the
Sensor Voltage Low maximum acceptable voltage.
or
3A P0113 Intake Air Temp Intake air temperature sensor input above the
Sensor Voltage High minimum acceptable voltage.
3D 27** P0204 Injector #4 Control Injector #4 output driver does not respond
Circuit properly to the control signal.
3E 21** P0132 Upstream O2S Oxygen sensor input voltage maintained above
Shorted to Voltage the normal operating range.
44 53** PO600 PCM Failure SPI PCM internal fault condition detected
Communications
45 27** P0205 Injector #5 Control Injector #5 output driver does not respond
Circuit properly to the control signal.
or
46 P0206 Injector #6 Control Injector #6 output driver does not respond
Circuit properly to the control signal.
52 77* SPD CTRL PWR RLY; Malfuntion detected with power feed to speed
or S/C 12V Driver control servo solenoids
CKT
56 34* Speed Control Switch Speed control switch input above the maximum
Always High acceptable voltage.
or
57 Speed Control Switch Speed control switch input below the minimum
Always Low acceptable voltage.
65 42* Fuel Pump Relay An open or shorted condition detected in the
Control Circuit fuel pump relay control circuit.
66 21** P0133 Upstream O2S Slow Oxygen sensor response slower than minimum
Response required switching frequency.
or
67 P0135 Upstream O2S Heater Upstream oxygen sensor heating element
Failure circuit malfunction
69 P0141 Downstream or Oxygen sensor heating element circuit
Pre-Catalyst Heater malfunction.
Failure
6A 43** P0300 Multiple Cylinder Misfire detected in multiple cylinders.
Mis-fire
or
6B P0301 Cylinder #1 Mis-fire Misfire detected in cylinder #1.
or
6C P0302 Cylinder #2 Mis-fire Misfire detected in cylinder #2.
or
25 - 6 EMISSION CONTROL SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
GENERIC
MIL SCAN DRB SCAN TOOL DESCRIPTION OF DIAGNOSTIC TROUBLE
HEX CODE
CODE TOOL DISPLAY CODE
CODE
6D P0303 Cylinder #3 Mis-fire Misfire detected in cylinder #3.
or
6E P0304 Cylinder #4 Mis-fire Misfire detected in cylinder #4.
70 72** P0420 Efficency Failure Catalyst efficiency below required level.
71 31* P0441 Evap Purge Flow Insufficient or excessive vapor flow detected
Monitor Failure during evaporative emission system operation.
72 37** P1899 P/N Switch Stuck in Incorrect input state detected for the Park/
Park or in Gear Neutral switch, auto. trans. only.
76 52** P0172 Fuel System Rich A rich air/fuel mixture has been indicated by an
abnormally lean correction factor.
77 51** P0171 Fuel System Lean A lean air/fuel mixture has been indicated by an
abnormally rich correction factor.
7E 21** P0138 Downstream and Oxygen sensor input voltage maintained above
Pre-Catalyst O2S the normal operating range.
Shorted to Voltage
80 17** P0125 Closed Loop Temp Engine does not reach 20°F within 5 minutes
Not Reached with a vehicle speed signal.
84 24** P0121 TPS Voltage Does TPS signal does not correlate to MAP sensor
Not Agree With MAP
87 14** P1296 No 5 Volts To MAP 5 Volt output to MAP sensor open.
Sensor
8A 25** P1294 Target Idle Not Actual idle speed does not equal target idle
Reached speed.
94 37* P0740 Torq Conv Clu, No Relationship between engine speed and vehicle
RPM Drop At Lockup speed indicates no torque converter clutch
engagement (auto. trans. only).
95 42* Fuel Level Sending Open circuit between PCM and fuel gauge
Unit Volts Too Low sending unit.
or
96 Fuel Level Sending Circuit shorted to voltage between PCM and
Unit Volts Too High fuel gauge sending unit.
or
97 Fuel Level Unit No No movement of fuel level sender detected.
Change Over Miles
99 44** P1493 Ambient/Batt Temp Battery temperature sensor input voltage below
Sen VoltsToo Low an acceptable range.
or
9A P1492 Ambient/Batt Temp Battery temperature sensor input voltage above
Sensor VoltsToo High an acceptable range.
9B 21** P0131 Upstream O2S O2 sensor voltage too low, tested after cold
Shorted to Ground start.
or
XJ EMISSION CONTROL SYSTEMS 25 - 7
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
GENERIC
MIL SCAN DRB SCAN TOOL DESCRIPTION OF DIAGNOSTIC TROUBLE
HEX CODE
CODE TOOL DISPLAY CODE
CODE
9C P0137 Downstream and O2 sensor voltage too low, tested after cold
Pre-Catalyst O2S start.
Shorted to Ground
9D 11** P1391 Intermittent Loss of Intermittent loss of either camshaft or
CMP or CKP crankshaft position sensor
AE 43** P0305 Cylinder #5 Mis-fire Misfire detected in cylinder #5.
or
AF P0306 Cylinder #6 Mis-fire Misfire detected in cylinder #6.
BA 11** P1398 Mis-fire Adaptive CKP sensor target windows have too much
Numerator at Limit variation
CO 21 P0133 CAT MON SLOW O2 A slow switching oxygen sensor has been
1/1 detected in bank 1/1 during catalyst monitor
test.
* Ch eck E n gin e La m p (MIL) will n ot illu m in a t e if t h is Dia gn ost ic Tr ou ble Code wa s r ecor ded. Cycle Ign it ion
key a s descr ibed in m a n u a l a n d obser ve code fla sh ed by Ch eck E n gin e la m p.
** Ch eck E n gin e La m p (MIL) will illu m in a t e du r in g en gin e oper a t ion if t h is Dia gn ost ic Tr ou ble Code wa s
r ecor ded.
*** Gen er a t or La m p illu m in a t ed
EX H AU ST SY ST EM PCM SY ST EM GROU N D
Th e P CM ca n n ot det ect a plu gged, r est r ict ed or Th e P CM ca n n ot det er m in e a poor syst em gr ou n d.
lea kin g exh a u st syst em , a lt h ou gh it m a y set a fu el H owever, on e or m or e dia gn ost ic t r ou ble codes m a y
syst em fa u lt . be gen er a t ed a s a r esu lt of t h is con dit ion . Th e m od-
u le sh ou ld be m ou n t ed t o t h e body a t a ll t im es, a lso
FU EL I N J ECT OR M ECH AN I CAL du r in g dia gn ost ic.
M ALFU N CT I ON S
Th e P CM ca n n ot det er m in e if a fu el in ject or is PCM CON N ECT OR EN GAGEM EN T
clogged, t h e n eedle is st ickin g or if t h e wr on g in ject or Th e P CM m a y n ot be a ble t o det er m in e spr ea d or
is in st a lled. H owever, t h ese cou ld r esu lt in a r ich or da m a ged con n ect or pin s. H owever, it m igh t st or e
lea n con dit ion ca u sin g t h e P CM t o st or e a dia gn ost ic dia gn ost ic t r ou ble codes a s a r esu lt of spr ea d con n ec-
t r ou ble code for eit h er m isfir e, a n oxygen sen sor, or t or pin s.
t h e fu el syst em .
HIGH AND LOW LIMITS
EX CESSI V E OI L CON SU M PT I ON Th e P CM com pa r es in pu t sign a l volt a ges fr om ea ch
Alt h ou gh t h e P CM m on it or s en gin e exh a u st oxygen in pu t device wit h est a blish ed h igh a n d low lim it s for
con t en t wh en t h e syst em is in closed loop, it ca n n ot t h e device. If t h e in pu t volt a ge is n ot wit h in lim it s
det er m in e excessive oil con su m pt ion . a n d ot h er cr it er ia a r e m et , t h e P CM st or es a dia gn os-
t ic t r ou ble code in m em or y. Ot h er dia gn ost ic t r ou ble
T H ROT T LE BODY AI R FLOW code cr it er ia m igh t in clu de en gin e RP M lim it s or
Th e P CM ca n n ot det ect a clogged or r est r ict ed a ir in pu t volt a ges fr om ot h er sen sor s or swit ch es t h a t
clea n er in let or filt er elem en t . m u st be pr esen t befor e ver ifyin g a dia gn ost ic t r ou ble
code con dit ion .
VACU U M ASSI ST
Th e P CM ca n n ot det ect lea ks or r est r ict ion s in t h e
va cu u m cir cu it s of va cu u m a ssist ed en gin e con t r ol
LOAD VALUE
ENGINE IDLE/NEUTRAL 2500 RPM/NEUTRAL
All Engines 2% to 8% of Maximum Load 9% to 17% of Maximum Load
FUEL FWD
SUPPLY
TUBE EVAP
ALIGNMENT
CANISTER
ARROW
VENTFUEL
LINE FILTER/FUEL
SUREROLLOVER
REGULATOR
FUEL
RETAINERCLAMP
PRES-
VMODULE
LOCKNUT
ALVE
PUMP
PIGTAIL HARNESS
INDEX
page page
MOUNTING
BOLT
PURGE
Fig. 2 EVAP Canister Location—LHD Models ::) SOLENOID
~
Fig. 4 Duty Cycle EVAP Purge Solenoid (LHD
Shown)
CRANKCASE VENTILATION SYSTEM
All 2.5L 4–cylin der a n d 4.0L 6–cylin der en gin es
a r e equ ipped wit h a Cr a n kca se Ven t ila t ion (CCV)
syst em (F ig. 5) or (F ig. 6). Th e CCV syst em per for m s
t h e sa m e fu n ct ion a s a con ven t ion a l P CV syst em , bu t
does n ot u se a va cu u m con t r olled va lve.
YECI
LABEL
J9325-27
MOUNTING
BOLT
Fig. 9 EVAP Canister Location—RHD Models Fig. 10 Duty Cycle EVAP Canister Purge Solenoid—
(LHD Shown)
(2) Rem ove ca n ist er r et a in in g st r a p bolt .
(3) Rem ove ca n ist er fr om veh icle. I N STALLAT I ON
(1) In st a ll E VAP ca n ist er pu r ge solen oid a n d it s
I N STALLAT I ON m ou n t in g br a cket t o cowl pa n el.
(1) P osit ion ca n ist er in t o br a cket . (2) Tigh t en bolt t o 5 N·m (45 in . lbs.) t or qu e.
(2) In st a ll a n d t igh t en st r a p bolt t o 5 N·m (45 in . (3) Con n ect va cu u m h a r n ess a n d wir in g con n ect or.
lbs.) t or qu e.
(3) Con n ect va cu u m lin es a t E VAP ca n ist er. ROLLOVER VALVE(S)
Th e pr essu r e r elief/r ollover va lves(s) a r e/is m olded
DUTY CYCLE EVAP CANISTER PURGE SOLENOID in t o t h e fu el t a n k a n d a r e n ot ser viced sepa r a t ely. If
r epla cem en t is n ecessa r y, t h e fu el t a n k m u st be
REM OVAL r epla ced. Refer t o F u el Ta n k Rem ova l/In st a lla t ion in
On veh icles equ ipped wit h Left H a n d Dr ive (LH D), Gr ou p 14, F u el Syst em for pr ocedu r es.
t h e solen oid a t t a ch es t o a br a cket loca t ed in t h e
r igh t -r ea r side of en gin e com pa r t m en t n ea r t h e E VAP
ca n ist er (F ig. 10). On veh icles equ ipped wit h Righ t SPECI FI CAT I ON S
H a n d Dr ive (RH D), t h e solen oid a t t a ch es t o a br a cket
loca t ed in t h e left -r ea r side of en gin e com pa r t m en t . TORQUE CHART
Th e t op of t h e solen oid h a s t h e wor d UP or TOP on
it . Th e solen oid will n ot oper a t e pr oper ly u n less it is D e s c rip tio n To rqu e
in st a lled cor r ect ly. E VAP Ca n ist er Mou n t in g Bolt . . . 5 N·m (45 in . lbs.)
(1) Discon n ect elect r ica l wir in g con n ect or a t sole- E VAP Ca n ist er P u r ge Solen oid
n oid. Br a cket -t o-Body Mou n t in g Bolt . 5 N·m (45 in . lbs.)
(2) Discon n ect va cu u m h a r n ess a t solen oid.
(3) Rem ove solen oid a n d it s su ppor t br a cket .
XJ DIFFERENTIAL AND DRIVELINE 3-1
page page
PROPELLER SH AFT S
INDEX
page page
REAR
AXLE
TRANSFER
CASE
FRONT
PROPELLER
SHAFT
FRONT
AXLE
STRAP
80a53ac2
UNBALANCE
~
YOKE
NOTE: Removing and re-indexing the propeller
shaft 180° relative to the yoke may eliminate some
RETAINING vibrations.
CLIP J9216-4
Horizontal Level
(A) Output Yoke = 3 .0°
or
4 .9° (B) Axle Input Yoke = 3 .2° or
4 .9°
(C) Prop. Shaft = 4. 9° -3 .0° (C) Prop. Shaft = 4.9° -3 .2°
Transmission Output Axle Input 1.70
Operating Angle Operating Angle
<1 .
YOKE ' ' ""
CLAMP
SLINGER
80a53482 J9316-2
SNAP RING
~-~------
CLAMP
PRESS
SLINGER
80a50357 J9316-21'
CROSS
J9316-22
80a9539c
J9316-5
(4) Set t h e join t in a n a r bor pr ess or vise wit h a Fig. 24 Remove Bearing From Yoke
socket wh ose in side dia m et er is la r ge en ou gh t o
(7) F lip a ssem bly a n d r epea t St ep 4, St ep 5, a n d
r eceive t h e bea r in g ca p posit ion ed ben ea t h t h e lin k
St ep 6 t o r em ove t h e opposit e bea r in g ca p. Th is will
yoke.
t h en a llow r em ova l of t h e cr oss cen t er in g kit a ssem -
(5) P la ce a socket wit h a n ou t side dia m et er
bly a n d spr in g (F ig. 25).
sm a ller t h a n t h e u pper bea r in g ca p on t h e u pper
bea r in g ca p a n d pa r t ia lly pr ess on e bea r in g ca p fr om
t h e ou t boa r d side of t h e lin k yoke en ou gh t o gr a sp
t h e bea r in g ca p wit h vise ja ws (F ig. 23). Be su r e t o
r em ove gr ea se fit t in gs t h a t in t er fer e wit h r em ova l.
J9316-8
J9316-12
J9316-13 J9316-15
J9316-16
J9316-17
SHIM
SUSPENSION
ARM
J8916-22
J9316-18
Inclinometer—7663
XJ DIFFERENTIAL AND DRIVELINE 3 - 15
T U BE AN D 1 8 1 FBI AX LE
INDEX
page page
STANDARD DIFFERENTIAL
Th e differ en t ia l gea r syst em divides t h e t or qu e
bet ween t h e a xle sh a ft s. It a llows t h e a xle sh a ft s t o
r ot a t e a t differ en t speeds wh en t u r n in g cor n er s.
E a ch differ en t ia l side gea r is splin ed t o a n a xle
sh a ft . Th e pin ion gea r s a r e m ou n t ed on a pin ion
m a t e sh a ft a n d a r e fr ee t o r ot a t e on t h e sh a ft . Th e
pin ion gea r is fit t ed in a bor e in t h e differ en t ia l ca se
a n d is posit ion ed a t a r igh t a n gle t o t h e a xle sh a ft s.
In oper a t ion , power flow occu r s a s follows: PINION GEARS ROTATE
ON PINION SHAFT
• Th e pin ion gea r r ot a t es t h e r in g gea r. J9303-14
• Th e r in g gea r (bolt ed t o t h e differ en t ia l ca se)
r ot a t es t h e ca se. Fig. 2 Differential Operation—On Turns
• Th e differ en t ia l pin ion gea r s (m ou n t ed on t h e DI AGN OSI S AN D T EST I N G
pin ion m a t e sh a ft in t h e ca se) r ot a t e t h e side gea r s.
• Th e side gea r s (splin ed t o t h e a xle sh a ft s) r ot a t e GENERAL INFORMATION
t h e sh a ft s. Axle bea r in g pr oblem con dit ion s a r e u su a lly ca u sed
Du r in g st r a igh t -a h ea d dr ivin g, t h e differ en t ia l pin - by:
ion gea r s do n ot r ot a t e on t h e pin ion m a t e sh a ft . Th is • In su fficien t or in cor r ect lu br ica n t .
occu r s beca u se in pu t t or qu e a pplied t o t h e gea r s is • F or eign m a t t er /wa t er con t a m in a t ion .
divided a n d dist r ibu t ed equ a lly bet ween t h e t wo side • In cor r ect bea r in g pr eloa d t or qu e a dju st m en t .
gea r s. As a r esu lt , t h e pin ion gea r s r evolve wit h t h e • In cor r ect ba ckla sh .
pin ion m a t e sh a ft bu t do n ot r ot a t e a r ou n d it (F ig. 1). Axle gea r pr oblem con dit ion s a r e u su a lly t h e r esu lt
IN STRAIGHT AHEAD DRIVING of:
EACH WHEEL ROTATES AT 100% • In su fficien t lu br ica t ion .
OF CASE SPEED • In cor r ect or con t a m in a t ed lu br ica n t .
• Over loa din g (excessive en gin e t or qu e) or exceed-
in g veh icle weigh t ca pa cit y.
• In cor r ect clea r a n ce or ba ckla sh a dju st m en t .
Axle com pon en t br ea ka ge is m ost oft en t h e r esu lt
of:
• Sever e over loa din g.
• In su fficien t lu br ica n t .
• In cor r ect lu br ica n t .
• Im pr oper ly t igh t en ed com pon en t s.
DI AGN OSI S
LUBRICANT CHANGE
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e lu br ica n t fill h ole plu g fr om t h e
differ en t ia l h ou sin g cover.
(3) Rem ove t h e differ en t ia l h ou sin g cover a n d
dr a in t h e lu br ica n t fr om t h e h ou sin g.
(4) Clea n t h e h ou sin g ca vit y wit h a flu sh in g oil,
ligh t en gin e oil or lin t fr ee clot h . D o n o t u s e w a te r,
s te a m , k e ro s e n e o r g a s o lin e fo r c le a n in g .
(5) Rem ove t h e sea la n t fr om t h e h ou sin g a n d cover
su r fa ces. Use solven t t o clea n t h e m a t in g su r fa ces.
(6) Apply a bea d of Mopa r t Silicon e Ru bber Sea l-
a n t , or equ iva len t , t o t h e h ou sin g cover (F ig. 3).
In s ta ll th e h o u s in g c o v e r w ith in 5 m in u te s
a fte r a p p ly in g th e s e a la n t.
(7) In st a ll t h e cover a n d a n y iden t ifica t ion t a g.
Tigh t en t h e cover bolt s in a cr iss–cr oss pa t t er n t o 41
N·m (30 ft . lbs.) t or qu e.
(8) Refill t h e differ en t ia l wit h Mopa r t H ypoid
Gea r Lu br ica n t , or equ iva len t , t o bot t om of t h e fill
plu g h ole. Refer t o t h e Lu br ica n t Specifica t ion s in Fig. 3 Typical Housing Cover With Sealant
t h is gr ou p for t h e qu a n t it y n ecessa r y. (2) P osit ion a su it a ble lift in g device u n der t h e
(9) In st a ll t h e fill h ole plu g a n d lower t h e veh icle. a xle.
(3) Secu r e a xle t o device.
(4) Rem ove t h e wh eels a n d t ir es.
REM OVAL AN D I N STALLAT I ON
(5) Rem ove t h e br a ke r ot or s a n d ca liper s fr om t h e
a xle. Refer t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
DRIVE AXLE ASSEMBLY
(6) Discon n ect t h e wh eel sen sor wir in g h a r n ess
REM OVAL fr om t h e veh icle wir in g h a r n ess, if n ecessa r y.
(1) Ra ise a n d su ppor t t h e veh icle.
XJ DIFFERENTIAL AND DRIVELINE 3 - 21
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(7) Discon n ect t h e ven t h ose fr om t h e a xle sh a ft (13) Align t h e pr eviou sly m a de m a r ks on t h e pr o-
t u be. peller sh a ft a n d t h e yoke.
(8) Ma r k t h e pr opeller sh a ft a n d yoke for in st a lla - (14) In st a ll t h e st r a ps a n d bolt s t o h old t h e pr opel-
t ion a lign m en t r efer en ce. ler sh a ft t o t h e yoke.
(9) Rem ove pr opeller sh a ft . (15) Ch eck a n d fill a xle lu br ica n t . Refer t o t h e
(10) Discon n ect st a bilizer ba r lin ks a t t h e a xle. Lu br ica n t Specifica t ion s in t h is gr ou p for t h e qu a n -
(11) Discon n ect sh ock a bsor ber s fr om a xle br a ck- t it y n ecessa r y.
et s. (16) In st a ll t h e wh eel a n d t ir e a ssem blies.
(12) Discon n ect t r a ck ba r. (17) Rem ove t h e lift in g device fr om t h e a xle a n d
(13) Discon n ect t h e t ie r od a n d dr a g lin k fr om t h e lower t h e veh icle.
st eer in g kn u ckle. Refer t o Gr ou p 2, Su spen sion , for (18) Tigh t en t h e u pper su spen sion a r m n u t s t o 75
pr oper pr ocedu r es. N·m (55 ft . lbs.) t or qu e. Tigh t en t h e lower su spen sion
(14) Discon n ect t h e st eer in g da m per fr om t h e a xle a r m n u t s t o 115 N·m (85 ft . lbs.) t or qu e.
br a cket . (19) Tigh t en t h e t r a ck ba r bolt a t t h e a xle br a cket
(15) Discon n ect t h e u pper a n d lower su spen sion t o 100 N·m (74 ft . lbs.) t or qu e.
a r m s fr om t h e a xle br a cket s. (20) Ch eck t h e fr on t wh eel a lign m en t .
(16) Lower t h e lift in g device en ou gh t o r em ove t h e
a xle. Th e coil spr in gs will dr op wit h t h e a xle. TUBE AXLE ASSEMBLY
(17) Rem ove t h e coil spr in gs fr om t h e a xle.
REM OVAL
I N STALLAT I ON (1) Ra ise a n d su ppor t t h e veh icle.
(2) P osit ion a su it a ble lift in g device u n der t h e
CAUTION: The weight of the vehicle must be sup- a xle.
ported by the springs before suspension arms and (3) Secu r e a xle t o device.
track bar fasteners can be tightened. If the springs (4) Rem ove t h e wh eels a n d t ir es.
are not at their normal ride position, ride height and (5) Rem ove t h e br a ke r ot or s a n d ca liper s fr om t h e
handling could be affected. a xle. Refer t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
(6) Discon n ect t h e wh eel sen sor wir in g h a r n ess
(1) In st a ll t h e spr in gs a n d r et a in er clips. Tigh t en fr om t h e veh icle wir in g h a r n ess, if n ecessa r y.
t h e r et a in er bolt s t o 21 N·m (16 ft . lbs.) t or qu e. (7) Discon n ect st a bilizer ba r lin ks a t t h e a xle.
(2) Su ppor t t h e a xle on a su it a ble lift in g device (8) Discon n ect sh ock a bsor ber s fr om a xle br a cket s.
a n d posit ion a xle u n der t h e veh icle. (9) Discon n ect t r a ck ba r.
(3) Ra ise t h e a xle a n d a lign it wit h t h e spr in g (10) Discon n ect t h e t ie r od a n d dr a g lin k fr om t h e
pa ds. st eer in g kn u ckle. Refer t o Gr ou p 2, Su spen sion , for
(4) P osit ion t h e u pper a n d lower su spen sion a r m s pr oper pr ocedu r es.
in t h e a xle br a cket s. Loosely in st a ll bolt s a n d n u t s t o (11) Discon n ect t h e st eer in g da m per fr om t h e a xle
h old su spen sion a r m s t o t h e a xle br a cket s. br a cket .
(5) Con n ect t h e ven t h ose t o t h e a xle sh a ft t u be. (12) Discon n ect t h e u pper a n d lower su spen sion
(6) Con n ect t h e t r a ck ba r t o t h e a xle br a cket . a r m s fr om t h e a xle br a cket s.
Loosely in st a ll t h e bolt t o h old t h e t r a ck ba r t o t h e (13) Lower t h e lift in g device en ou gh t o r em ove t h e
a xle br a cket . a xle. Th e coil spr in gs will dr op wit h t h e a xle.
(7) In st a ll t h e sh ock a bsor ber s a n d t igh t en t h e (14) Rem ove t h e coil spr in gs fr om t h e a xle.
bolt s t o 23 N·m (17 ft . lbs.) t or qu e.
(8) In st a ll t h e st a bilizer ba r lin ks t o t h e a xle I N STALLAT I ON
br a cket s. Tigh t en t h e n u t t o 95 N·m (70 ft . lbs.)
t or qu e. CAUTION: The weight of the vehicle must be sup-
(9) In st a ll t h e dr a g lin k a n d t ie r od t o t h e st eer in g ported by the springs before suspension arms and
kn u ckles. Refer t o Gr ou p 2, Su spen sion , for pr oper track bar fasteners can be tightened. If the springs
pr ocedu r es. are not at their normal ride position, ride height and
(10) In st a ll t h e st eer in g da m per t o t h e a xle handling could be affected.
br a cket a n d t igh t en t h e n u t t o 75 N·m (55 ft . lbs.)
t or qu e. (1) In st a ll t h e spr in gs a n d r et a in er clips. Tigh t en
(11) In st a ll t h e br a ke r ot or s a n d ca liper s. Refer t o t h e r et a in er bolt s t o 21 N·m (16 ft . lbs.) t or qu e.
Gr ou p 5, Br a kes, for t h e pr oper pr ocedu r es. (2) Su ppor t t h e a xle on a su it a ble lift in g device
(12) Con n ect t h e wh eel speed sen sor wir in g h a r- a n d posit ion a xle u n der t h e veh icle.
n ess t o t h e veh icle wir in g h a r n ess, if n ecessa r y. (3) Ra ise t h e a xle a n d a lign it wit h t h e spr in g
pa ds.
SMALL-DIAMETER
SHAFT YOKE
WRENCH
SOCKET
BBEARING
EARING CAP
CAP
LARGE-DIAMETER
SNAP RINGS
SNAP
WRENCH
SOCKET
RINGS BEARING
BEARING
SPINDLE
BEARING
CAP
CAP
YOKE
VISE
AXLE
HOUSING
80a7e2bf
REM OVAL
(1) Ra ise a n d su ppor t t h e veh icle.
(2) Rem ove t h e wh eel a n d t ir e a ssem bly.
(3) Rem ove t h e br a ke ca liper a n d r ot or. Refer t o
Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
(4) Rem ove ABS wh eel speed sen sor, if n ecessa r y.
Refer t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
(5) Rem ove t h e cot t er pin , n u t r et a in er, a n d a xle
h u b n u t (F ig. 10), if n ecessa r y.
(6) Rem ove t h e h u b t o kn u ckle bolt s (F ig. 11).
(7) Rem ove t h e h u b fr om t h e st eer in g kn u ckle a n d
a xle sh a ft , if n ecessa r y.
(8) Rem ove h u b bea r in g a n d a xle sh a ft a ssem bly
Fig. 9 Check Pinion Rotation Torque (F ig. 12), or a xle sh a ft fr om a xle. Av o id d a m a g in g
th e a x le s h a ft o il s e a ls in th e a x le h o u s in g .
n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s u n t il pr oper
(9) Rem ove t h e br a ke r ot or sh ield fr om t h e h u b
r ot a t in g t or qu e is a ch ieved.
bea r in g or kn u ckle (F ig. 10).
(7) Align t h e in st a lla t ion r efer en ce m a r ks on t h e
pr opeller sh a ft a n d yoke, a n d in st a ll t h e pr opeller I N STALLAT I ON
sh a ft . (1) Th or ou gh ly clea n t h e a xle sh a ft (F ig. 10) a n d
(8) Ch eck a n d fill t h e gea r lu br ica n t . Refer t o t h e a pply a t h in film of Mopa r t Wh eel Bea r in g Gr ea se,
Lu br ica n t Specifica t ion s for gea r lu br ica n t r equ ir e- or equ iva len t , t o t h e sh a ft splin es, sea l con t a ct su r-
m en t s. fa ce, a n d h u b bor e.
(9) In st a ll t h e br a ke r ot or s a n d ca liper s. Refer t o (2) In st a ll t h e br a ke r ot or sh ield t o t h e kn u ckle.
Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
BRAKE WASHER
SHIELD
RETAINER
COTTER PIN
TONE
WHEEL
(ABS) BOLT NUT J9302-43
K N U CK LE REM OVAL
(1) Rem ove h u b bea r in g a n d a xle sh a ft .
(2) Discon n ect t h e t ie-r od or dr a g lin k fr om t h e
st eer in g kn u ckle a r m . Refer t o Gr ou p 2, Su spen sion ,
for pr oper pr ocedu r es.
(3) Rem ove t h e cot t er pin s fr om t h e u pper a n d
lower ba ll st u ds.
(4) Rem ove t h e u pper a n d lower ba ll st u d n u t s.
(5) St r ike t h e st eer in g kn u ckle wit h a br a ss h a m -
m er t o loosen kn u ckle fr om t h e ba ll st u ds. Rem ove
kn u ckle fr om ba ll st u ds (F ig. 13).
HUB
BEARING 80a7ae5b UPPER
BALL STUD
Fig. 11 Hub Bearing Bolts
4212F
4212F
6289-12
REMOVAL INSTALLATION
80a7e2a7
SPECIAL
SPECIAL TOOL
14"---TOOL 6289-4
'---~b---' 6289-1
SPECIAL
TOOL
4212F
REMOVAL INSTALLATION
80a7e2a8
SAFETY
HOLD
DOWN
TURNBUCKLE
Fig. 16 Bearing Cap Identification
pin s sea t ed in t h e loca t in g h oles (F ig. 21). In st a ll t h e
h olddown cla m ps a n d t igh t en t h e t ool t u r n bu ckle fin -
0
ger –t igh t .
(2) In st a ll a Gu ide P in C-3288-B a t t h e left side of 80a534c5
t h e differ en t ia l h ou sin g. At t a ch Dia l In dica t or C-3339
t o gu ide pin . Loa d t h e lever a da pt er a ga in st t h e Fig. 17 Install Axle Housing Spreader
opposit e side of t h e h ou sin g (F ig. 18) a n d zer o t h e CAUTION: Do not spread over 0.50 mm (0.020 in). If
in dica t or. the housing is over-spread, it could be distorted or
damaged.
SPECIAL
SPECIAL
SPECIAL
C-3339
TOOL
C-3288–B
C-3339
TOOL
TOOL
SPECIAL
W-129–B
TOOL DIAL
LEVER
SPECIALTOOL
INDICATOR
ADAPTER
W-129–B AXLE HOUSING
BEARING CUPS TURNBUCKLE DIFFERENTIAL
SAFETY
SPECIALTOOL
HOLDCASE
W-129–B
DOWEL
DOWN
SAFETY
HOLD
DOWN
TURNBUCKLE
80a534c5
J9003-92
J9302-21
RING GEAR
Th e r in g a n d pin ion gea r s a r e ser vice in a m a t ch ed
set . Do n ot r epla ce t h e r in g gea r wit h ou t r epla cin g
80a7e2a9
t h e pin ion gea r.
Fig. 23 Differential Bearing Removal
REM OVAL
(1) In st a ll differ en t ia l side bea r in g sh im s on t o dif- (1) Rem ove differ en t ia l fr om a xle h ou sin g.
fer en t ia l ca se h u bs. (2) P la ce differ en t ia l ca se in a su it a ble vise wit h
(2) Usin g In st a ller C-3716-A a n d H a n dle C-4171, soft m et a l ja w pr ot ect or s. (F ig. 26)
in st a ll differ en t ia l side bea r in gs (F ig. 24). (3) Rem ove bolt s h oldin g r in g gea r t o differ en t ia l
(3) In st a ll differ en t ia l in a xle h ou sin g. ca se.
(4) Usin g a soft h a m m er, dr ive r in g gea r fr om dif-
fer en t ia l ca se (F ig. 26).
RAWHIDE HAM-
MER TURNBUCKLE
DISCS 8110
6797 CASE RING GEAR RING GEAR
CASE SPECIAL SPECIAL
TOOL C-452
TOOL C-3281
YOKE TORQUE
RING GEAR
WRENCH
BOLT
RING
GEAR
J9202-77
REM OVAL
(1) Rem ove differ en t ia l a ssem bly fr om a xle h ou s-
in g.
(2) Ma r k pin ion yoke a n d pr opeller sh a ft for
in st a lla t ion a lign m en t .
(3) Discon n ect pr opeller sh a ft fr om pin ion yoke.
Usin g su it a ble wir e, t ie pr opeller sh a ft t o u n der body.
(4) Usin g H older 6958 t o h old yoke, r em ove t h e
pin ion n u t a n d wa sh er.
(5) Usin g Rem over C-452 a n d H older C-3281,
r em ove t h e pin ion yoke fr om pin ion sh a ft (F ig. 28).
Fig. 26 Ring Gear Removal
I N STALLAT I ON
J9302-25
I N STALLAT I ON
SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3972-A
Fig. 32 Inner Bearing Removal
INSTALLER
80a7e2be
Fig. 33 Rear Pinion Bearing Cup Installation (11) Ch eck bea r in g pr eloa d t or qu e wit h a n in ch
(4) In st a ll fr on t pin ion bea r in g, a n d oil slin ger, if pou n d t or qu e wr en ch (F ig. 39). Th e t or qu e n ecessa r y
equ ipped. t o r ot a t e t h e pin ion gea r sh ou ld be:
(5) Apply a ligh t coa t in g of gea r lu br ica n t on t h e • Or igin a l Bea r in gs—1 t o 3 N·m (10 t o 20 in . lbs.).
lip of pin ion sea l. In st a ll sea l wit h In st a ller C-3972-A • New Bea r in gs—2 t o 5 N·m (15 t o 35 in . lbs.).
a n d H a n dle C–4171 (F ig. 35). (12) If r ot a t in g t or qu e is a bove t h e desir ed
(6) In st a ll t h e r ea r pin ion bea r in g a n d oil slin ger, a m ou n t , r em ove t h e pin ion yoke a n d in cr ea se t h e
if equ ipped, on t h e pin ion gea r wit h In st a ller W-262 pr eloa d sh im pa ck t h ickn ess. In cr ea sin g t h e sh im
a n d a sh op pr ess (F ig. 36). pa ck t h ickn ess 0.025 m m (0.001 in .) will decr ea se t h e
(7) In st a ll pin ion bea r in g pr eloa d sh im s on t o t h e r ot a t in g t or qu e a ppr oxim a t ely 0.9 N·m (8 in . lbs.).
pin ion gea r (F ig. 37).
DRIVE
INSTALLA-
TION TOOL
PINION
PINION
REAR
GEAR
PRELOAD
BEARING
SHAFT
PINION
SPACER
PRELOAD SHIMSSHOULDER
FRONT
PRELOAD
FOR
BEARING
DRIVE
OIL
SPACER
PINION
SLINGER
CUP
PINION
GEARSLINGER FRONTPINION
BEARING
YOKE
CONE PINION OIL SEAL
WASHER AXLE
PINION
PINION
HOUSING
YOKE
NUT
PINION
YOKE
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING AXLE
HOUSING
80a7e2bf
WASHER
PINION
OIL SEAL
PINION PRELOAD
SPACER - - - - - - - FRONT
BEARING
CONE
J9203-63
FINAL ASSEMBLY
(1) Scr a pe t h e r esidu a l sea la n t fr om t h e h ou sin g
a n d cover m a t in g su r fa ces. Clea n t h e m a t in g su r fa ces
wit h m in er a l spir it s. Apply a bea d of Mopa r t Silicon e
Ru bber Sea la n t , or equ iva len t , on t h e h ou sin g cover
(F ig. 43).
In s ta ll th e h o u s in g c o v e r w ith in 5 m in u te s
a fte r a p p ly in g th e s e a la n t.
(2) In st a ll t h e cover on t h e differ en t ia l wit h t h e
a t t a ch in g bolt s. In st a ll t h e iden t ifica t ion t a g. Tigh t en
t h e cover bolt s t o 41 N·m (30 ft . lbs.) t or qu e.
Fig. 40 Mate Shaft Roll Pin Removal
SEALING
BEAD
NESS
MATE
SURFACE
6.35MM
THICK-
(1/4”)
SHAFT LOCKPIN CONTOUR
PINION
PUNCH
OF SHAFT
BEAD
MATE
AXLE COMPONENTS
Wa sh differ en t ia l com pon en t s wit h clea n in g solven t
a n d dr y wit h com pr essed a ir. D o n o t s te a m c le a n
th e d iffe re n tia l c o m p o n e n ts .
Wa sh bea r in gs wit h solven t a n d t owel dr y, or dr y
wit h com pr essed a ir. DO NOT spin bea r in gs wit h
com pr essed a ir. Cu p a n d be a rin g m u s t be
re p la c e d a s m a tc h e d s e ts o n ly.
Clea n a xle sh a ft t u bes a n d oil ch a n n els in h ou sin g.
In spect for ;
• Sm oot h a ppea r a n ce wit h n o br oken /den t ed su r-
Fig. 42 Mate Shaft Roll Pin Installation fa ces on t h e bea r in g r oller s or t h e r oller con t a ct su r-
fa ces.
CONTOUR OF BEAD
• Bea r in g cu ps m u st n ot be dist or t ed or cr a cked.
• Ma ch in ed su r fa ces sh ou ld be sm oot h a n d wit h -
ou t a n y r a ised edges.
• Ra ised m et a l on sh ou lder s of cu p bor es sh ou ld
be r em oved wit h a h a n d st on e.
• Wea r a n d da m a ge t o pin ion gea r m a t e sh a ft ,
pin ion gea r s, side gea r s a n d t h r u st wa sh er s. Repla ce
a s a m a t ch ed set on ly.
• Rin g a n d pin ion gea r for wor n a n d ch ipped
t eet h .
• Rin g gea r for da m a ged bolt t h r ea ds. Repla ced a s
a m a t ch ed set on ly.
• P in ion yoke for cr a cks, wor n splin es, pit t ed
a r ea s, a n d a r ou gh /cor r oded sea l con t a ct su r fa ce.
Repa ir or r epla ce a s n ecessa r y.
• P r eloa d sh im s for da m a ge a n d dist or t ion . In st a ll
n ew sh im s, if n ecessa r y.
ADJ U ST M EN T S
PINION GEAR DEPTH
Fig. 43 Typical Housing Cover With Sealant
CAUTION: Overfilling the differential can result in GEN ERAL I N FORM AT I ON
lubricant foaming and overheating. Rin g a n d pin ion gea r s a r e su pplied a s m a t ch ed
set s on ly. Th e iden t ifyin g n u m ber s for t h e r in g a n d
(3) Refill t h e differ en t ia l h ou sin g wit h gea r lu br i- pin ion gea r a r e et ch ed in t o t h e fa ce of ea ch gea r (F ig.
ca n t . Refer t o t h e Lu br ica n t Specifica t ion s sect ion of 44). A plu s (+) n u m ber, m in u s (–) n u m ber or zer o (0)
t h is gr ou p for t h e gea r lu br ica n t r equ ir em en t s. is et ch ed in t o t h e fa ce of t h e pin ion gea r. Th is n u m -
(4) In st a ll t h e fill h ole plu g. ber is t h e a m ou n t (in t h ou sa n dt h s of a n in ch ) t h e
dept h va r ies fr om t h e st a n da r d dept h set t in g of a
pin ion et ch ed wit h a (0). Th e st a n da r d set t in g fr om
t h e cen t er lin e of t h e r in g gea r t o t h e ba ck fa ce of t h e
DIFFERENTIAL
PRODUCTION
GEAR AS
(SAME MATCHING
RINGBERS
NUM-
GEAR
BEARING
NUMBER
SHIM
NUM-
BER) DRIVE
DRIVE
GEAR
PINION
DEPTHVARIANCE
GEAR
SHIM
PINION
DEPTH
t
PINION HEIGHT
PINION BLOCK BLOCK
SCOOTER BLOCK
Fig. 47 Pinion Height Block—Typical
J9403-45
DRIVE
PINION GEAR
DEPTH
SHIM
DIFFERENTIAL
CASE
80a534d2
Fig. 52 Seat Pinion Gear Side Differential Dummy
Side Bearing
80a7e2cf
Fig. 54 Differential Side play Measurement
ZERO DIAL INDICATOR FORCE DIFFERENTIAL
FACE CASE TO PINION
/~ "GEAR SIDE
0
SPECIAL
-TOOL
C-3339
'GEAR SIDE
-------
80a534d8
Ir----- FOR MORE BACKLASH------, a xle h ou sin g. It will a lso sh ow if t h e r in g gea r ba ck-
la sh h a s been a dju st ed cor r ect ly. Th e ba ckla sh ca n be
a dju st ed wit h in specifica t ion s t o a ch ieve desir ed
DECRtsE SHIM INCREASE LM
t oot h con t a ct pa t t er n s.
THIS SIDE FOR THIS SIDE FOR
MORE BACKLASH MORE BACKLASH (1) Apply a t h in coa t of h ydr a t ed fer r ic oxide, or
0 equ iva len t , t o t h e dr ive a n d coa st side of t h e r in g
gea r t eet h .
(2) Wr a p, t wist , a n d h old a sh op t owel a r ou n d t h e
pin ion yoke t o in cr ea se t h e t u r n in g r esist a n ce of t h e
pin ion gea r. Th is will pr ovide a m or e dist in ct con t a ct
pa t t er n .
(3) Usin g a boxed en d wr en ch on a r in g gea r bolt ,
Rot a t e t h e differ en t ia l ca se on e com plet e r evolu t ion
in bot h dir ect ion s wh ile a loa d is bein g a pplied fr om
sh op t owel.
INCREASE SHIM DECREASE SHIM Th e a r ea s on t h e r in g gea r t eet h wit h t h e gr ea t est
THIS SIDE FOR / THIS SIDE FOR degr ee of con t a ct a ga in st t h e pin ion gea r t eet h will
./ LESS BACKLASH squ eegee t h e com pou n d t o t h e a r ea s wit h t h e lea st
LESS rCKLASH
a m ou n t of con t a ct . Not e a n d com pa r e pa t t er n s on t h e
FOR LESS BACKLASH------'t
r in g gea r t eet h t o Gea r Toot h Con t a ct P a t t er n s ch a r t
J9302-28 (F ig. 61) a n d a dju st pin ion dept h a n d gea r ba ckla sh
a s n ecessa r y.
Fig. 60 Backlash Shim Adjustment
GEAR CONTACT PATTERN ANALYSIS
Th e r in g a n d pin ion gea r t eet h con t a ct pa t t er n s
will sh ow if t h e pin ion gea r dept h is cor r ect in t h e
HEEL DRIVE
RING GEAR
SIDETEETH
OF TOE TOE
COAST SIDE OF RINGTEETH
GEAR HEEL PINION
CORRECT.
GEAR
GEAR
PINION
CORRECT.
RING
CORRECT.
GEAR
REQUIRED.
DESIRABLE
PATTERN
ON
BUT
BE
CONTACT
THE
RING
CORRECT.
GEAR
REQUIRED.
THE
SOME
TOOTH.
BACKLASH.
TOE.
BACKLASH.
MAY
GEAR
GEAR
GEAR
GEAR
COAST
INCREASE
DECREASE
DRIVE
DEPTH
THICKER
SHOULD
THERE
DEPTH
PATTERN
THINNER
BE
CLEARANCE
DEPTH
DEPTH
CONTACT
SLIGHTLY
BACKLASH
BACKLASH
SIDE
SIDE
SHOULD
PINION
BE
PINION
SHIM
RING
AND
SHIM
RING
SHIM
SHIM
OF
CENTERED
BETWEEN
PATTERN.
TOWARD
TOP
ALWAYS
TOOTH.
TOOTH,
OF
J9003-24
SPECI FI CAT I ON S
181 FBI AXLE
SPECI AL T OOLS
181 FBI AXLE
Puller—C-452
Puller—C-293-PA
Wrench—C-3281
3 - 44 DIFFERENTIAL AND DRIVELINE XJ
SPECI AL T OOLS (Cont inue d)
8011c42b
Installer—W-162-D
Driver—C-3716-A
0
Cup—8109
Handle—C-4171
Remover/Installer—6289
Installer—D-146
XJ DIFFERENTIAL AND DRIVELINE 3 - 45
SPECI AL T OOLS (Cont inue d)
Installer—6761
Gauge Block—6733
Installer—6752
Spanner—6958
Installer Discs—8110
Installer—C-3972-A
Turnbuckle—6797
9
~ , , 6741 Spreader—W-129-B
~.,.
~
~
D-115-2
@
6739
~~~
~~
6733 6734 E,735
i
6740
Pilot Stud—C-3288-B
Remover—D-147
Installer—D-144
XJ DIFFERENTIAL AND DRIVELINE 3 - 47
1 9 4 RBI AX LE
INDEX
page page
DIFFERENTIAL
BEARING
SHIM-RING
GEAR SIDE
OUTER WHEEL
I 100% DIFFERENTIAL INNER WHEEL
I
DESCRI PT I ON AN D OPERAT I ON 110% CASE SPEED CASE SPEED 90% CASE SPEED
STANDARD DIFFERENTIAL
Th e differ en t ia l gea r syst em divides t h e t or qu e
bet ween t h e a xle sh a ft s. It a llows t h e a xle sh a ft s t o
r ot a t e a t differ en t speeds wh en t u r n in g cor n er s.
E a ch differ en t ia l side gea r is splin ed t o a n a xle
sh a ft . Th e pin ion gea r s a r e m ou n t ed on a pin ion
m a t e sh a ft a n d a r e fr ee t o r ot a t e on t h e sh a ft . Th e
pin ion gea r is fit t ed in a bor e in t h e differ en t ia l ca se
a n d is posit ion ed a t a r igh t a n gle t o t h e a xle sh a ft s.
PINION GEARS ROTATE
In oper a t ion , power flow occu r s a s follows: ON PINION SHAFT J9303-14
• Th e pin ion gea r r ot a t es t h e r in g gea r.
• Th e r in g gea r (bolt ed t o t h e differ en t ia l ca se) Fig. 3 Differential Operation—On Turns
r ot a t es t h e ca se.
• Th e differ en t ia l pin ion gea r s (m ou n t ed on t h e TRAC-LOK OPERATION
pin ion m a t e sh a ft in t h e ca se) r ot a t e t h e side gea r s. In a con ven t ion a l differ en t ia l, if on e wh eel spin s,
• Th e side gea r s (splin ed t o t h e a xle sh a ft s) r ot a t e t h e opposit e wh eel will gen er a t e on ly a s m u ch t or qu e
t h e sh a ft s. a s t h e spin n in g wh eel.
Du r in g st r a igh t -a h ea d dr ivin g, t h e differ en t ia l pin - In t h e Tr a c-lok differ en t ia l, pa r t of t h e r in g gea r
ion gea r s do n ot r ot a t e on t h e pin ion m a t e sh a ft . Th is t or qu e is t r a n sm it t ed t h r ou gh clu t ch pa cks wh ich
occu r s beca u se in pu t t or qu e a pplied t o t h e gea r s is con t a in m u lt iple discs. Th e clu t ch es will h a ve r a dia l
divided a n d dist r ibu t ed equ a lly bet ween t h e t wo side gr ooves on t h e pla t es, a n d con cen t r ic gr ooves on t h e
gea r s. As a r esu lt , t h e pin ion gea r s r evolve wit h t h e discs or bon ded fiber m a t er ia l t h a t is sm oot h in
pin ion m a t e sh a ft bu t do n ot r ot a t e a r ou n d it (F ig. 1). a ppea r a n ce.
Wh en t u r n in g cor n er s, t h e ou t side wh eel m u st In oper a t ion , t h e Tr a c-lok clu t ch es a r e en ga ged by
t r a vel a gr ea t er dist a n ce t h a n t h e in side wh eel t o t wo con cu r r en t for ces. Th e fir st bein g t h e pr eloa d
com plet e a t u r n . Th e differ en ce m u st be com pen sa t ed for ce exer t ed t h r ou gh Belleville spr in g wa sh er s
for t o pr even t t h e t ir es fr om scu ffin g a n d skiddin g wit h in t h e clu t ch pa cks. Th e secon d is t h e sepa r a t in g
t h r ou gh t u r n s. To a ccom plish t h is, t h e differ en t ia l for ces gen er a t ed by t h e side gea r s a s t or qu e is
a llows t h e a xle sh a ft s t o t u r n a t u n equ a l speeds (F ig. a pplied t h r ou gh t h e r in g gea r (F ig. 4).
CLUTCH
CASE
PACK RING GEAR SIDE GEAR PINION
DRIVE
CLUTCH
MATEPINION
GEAR
SHAFT
PACK
GEAR NOISE
Axle gea r n oise ca n be ca u sed by in su fficien t lu br i-
ca n t , in cor r ect ba ckla sh , t oot h con t a ct , or wor n /da m -
a ged gea r s.
Gea r n oise u su a lly h a ppen s a t a specific speed
r a n ge. Th e r a n ge is 30 t o 40 m ph , or a bove 50 m ph .
Th e n oise ca n a lso occu r du r in g a specific t ype of
dr ivin g con dit ion . Th ese con dit ion s a r e a cceler a t ion ,
deceler a t ion , coa st , or con st a n t loa d.
Wh en r oa d t est in g, a cceler a t e t h e veh icle t o t h e
speed r a n ge wh er e t h e n oise is t h e gr ea t est . Sh ift
ou t -of-gea r a n d coa st t h r ou gh t h e pea k–n oise r a n ge.
If t h e n oise st ops or ch a n ges gr ea t ly:
• Ch eck for in su fficien t lu br ica n t .
• In cor r ect r in g gea r ba ckla sh .
• Gea r da m a ge.
J9303-15 Differ en t ia l side a n d pin ion gea r s ca n be ch ecked
by t u r n in g t h e veh icle. Th ey u su a lly do n ot ca u se
Fig. 4 Trac-lok Limited Slip Differential Operation n oise du r in g st r a igh t –a h ea d dr ivin g wh en t h e gea r s
a r e u n loa ded. Th e side gea r s a r e loa ded du r in g veh i-
Th e Tr a c-lok design pr ovides t h e differ en t ia l a ct ion
cle t u r n s. A wor n pin ion gea r m a t e sh a ft ca n a lso
n eeded for t u r n in g cor n er s a n d for dr ivin g st r a igh t
ca u se a sn a ppin g or a kn ockin g n oise.
a h ea d du r in g per iods of u n equ a l t r a ct ion . Wh en on e
wh eel looses t r a ct ion , t h e clu t ch pa cks t r a n sfer a ddi-
BEARING NOISE
t ion a l t or qu e t o t h e wh eel h a vin g t h e m ost t r a ct ion .
Th e a xle sh a ft , differ en t ia l a n d pin ion gea r bea r-
Tr a c-lok differ en t ia ls r esist wh eel spin on bu m py
in gs ca n a ll pr odu ce n oise wh en wor n or da m a ged.
r oa ds a n d pr ovide m or e pu llin g power wh en on e
Bea r in g n oise ca n be eit h er a wh in in g, or a gr owlin g
wh eel looses t r a ct ion . P u llin g power is pr ovided con -
sou n d.
t in u ou sly u n t il bot h wh eels loose t r a ct ion . If bot h
P in ion gea r bea r in gs h a ve a con st a n t –pit ch n oise.
wh eels slip du e t o u n equ a l t r a ct ion , Tr a c-lok oper a -
Th is n oise ch a n ges on ly wit h veh icle speed. P in ion
t ion is n or m a l. In ext r em e ca ses of differ en ces of
bea r in g n oise will be h igh er beca u se it r ot a t es a t a
t r a ct ion , t h e wh eel wit h t h e lea st t r a ct ion m a y spin .
fa st er r a t e. Dr ive t h e veh icle a n d loa d t h e differ en -
t ia l. If bea r in g n oise occu r s, t h e r ea r pin ion bea r in g
DI AGN OSI S AN D T EST I N G is t h e sou r ce of t h e n oise. If t h e bea r in g n oise is
h ea r d du r in g a coa st , t h e fr on t pin ion bea r in g is t h e
GENERAL INFORMATION sou r ce.
Axle bea r in g pr oblem con dit ion s a r e u su a lly ca u sed Wor n or da m a ged differ en t ia l bea r in gs u su a lly pr o-
by: du ce a low pit ch n oise. Differ en t ia l bea r in g n oise is
• In su fficien t or in cor r ect lu br ica n t . sim ila r t o pin ion bea r in g n oise. Th e pit ch of differ en -
• F or eign m a t t er /wa t er con t a m in a t ion . t ia l bea r in g n oise is a lso con st a n t a n d va r ies on ly
• In cor r ect bea r in g pr eloa d t or qu e a dju st m en t . wit h veh icle speed.
• In cor r ect ba ckla sh . Axle sh a ft bea r in gs pr odu ce n oise a n d vibr a t ion
Axle gea r pr oblem con dit ion s a r e u su a lly t h e r esu lt wh en wor n or da m a ged. Th e n oise gen er a lly ch a n ges
of: wh en t h e bea r in gs a r e loa ded. Roa d t est t h e veh icle.
• In su fficien t lu br ica t ion . Tu r n t h e veh icle sh a r ply t o t h e left a n d t o t h e r igh t .
• In cor r ect or con t a m in a t ed lu br ica n t . Th is will loa d t h e bea r in gs a n d ch a n ge t h e n oise
3 - 50 DIFFERENTIAL AND DRIVELINE XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
level. Wh er e a xle bea r in g da m a ge is sligh t , t h e n oise • H igh en gin e idle speed.
is u su a lly n ot n ot icea ble a t speeds a bove 30 m ph . • Loose en gin e/t r a n sm ission /t r a n sfer ca se m ou n t s.
• Wor n U–join t s.
LOW SPEED KNOCK • Loose spr in g m ou n t s.
Low speed kn ock is gen er a lly ca u sed by a wor n • Loose pin ion gea r n u t a n d yoke.
U–join t or by wor n side–gea r t h r u st wa sh er s. A wor n • E xcessive r in g gea r ba ckla sh .
pin ion gea r sh a ft bor e will a lso ca u se low speed • E xcessive side gea r /ca se clea r a n ce.
kn ock. Th e sou r ce of a sn a p or a clu n k n oise ca n be det er-
m in ed wit h t h e a ssist a n ce of a h elper. Ra ise t h e veh i-
VIBRATION cle on a h oist wit h t h e wh eels fr ee t o r ot a t e. In st r u ct
Vibr a t ion a t t h e r ea r of t h e veh icle is u su a lly t h e h elper t o sh ift t h e t r a n sm ission in t o gea r. List en
ca u sed by a : for t h e n oise, a m ech a n ics st et h oscope is h elpfu l in
• Da m a ged dr ive sh a ft . isola t in g t h e sou r ce of a n oise.
• Missin g dr ive sh a ft ba la n ce weigh t (s).
• Wor n or ou t –of–ba la n ce wh eels. TRAC–LOK DIFFERENTIAL NOISE
• Loose wh eel lu g n u t s. Th e m ost com m on pr oblem is a ch a t t er n oise wh en
• Wor n U–join t (s). t u r n in g cor n er s. Befor e r em ovin g a Tr a c-lok u n it for
• Loose/br oken spr in gs. r epa ir, dr a in , flu sh a n d r efill t h e a xle wit h t h e spec-
• Da m a ged a xle sh a ft bea r in g(s). ified lu br ica n t . Refer t o Lu br ica n t ch a n ge in t h is
• Loose pin ion gea r n u t . Gr ou p.
• E xcessive pin ion yoke r u n ou t . A con t a in er of Mopa r t Tr a c-lok Lu br ica n t (fr ict ion
• Ben t a xle sh a ft (s). m odifier ) sh ou ld be a dded a ft er r epa ir ser vice or du r-
Ch eck for loose or da m a ged fr on t –en d com pon en t s in g a lu br ica n t ch a n ge.
or en gin e/t r a n sm ission m ou n t s. Th ese com pon en t s Aft er ch a n gin g t h e lu br ica n t , dr ive t h e veh icle a n d
ca n con t r ibu t e t o wh a t a ppea r s t o be a r ea r –en d m a ke 10 t o 12 slow, figu r e-eigh t t u r n s. Th is m a n eu -
vibr a t ion . Do n ot over look en gin e a ccessor ies, br a ck- ver will pu m p lu br ica n t t h r ou gh t h e clu t ch es. Th is
et s a n d dr ive belt s. will cor r ect t h e con dit ion in m ost in st a n ces. If t h e
All dr ivelin e com pon en t s sh ou ld be exa m in ed ch a t t er per sist s, clu t ch da m a ge cou ld h a ve occu r r ed
befor e st a r t in g a n y r epa ir.
Refer t o Gr ou p 22, Wh eels a n d Tir es, for a ddit ion a l
vibr a t ion in for m a t ion .
DRIVELINE SNAP
A sn a p or clu n k n oise wh en t h e veh icle is sh ift ed
in t o gea r (or t h e clu t ch en ga ged), ca n be ca u sed by:
XJ DIFFERENTIAL AND DRIVELINE 3 - 51
DI AGN OSI S AN D T EST I N G (Cont inue d)
TRAC–LOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRAC–LOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE. SPECIAL TOOL
6790WITH
Th e differ en t ia l ca n be t est ed wit h ou t r em ovin g t h e BOLT IN
differ en t ia l ca se by m ea su r in g r ot a t in g t or qu e. Ma ke CENTER
su r e br a kes a r e n ot dr a ggin g du r in g t h is m ea su r e- HOLE
m en t .
80a4d327
(1) P la ce blocks in fr on t a n d r ea r of bot h fr on t
wh eels. Fig. 5 Trac-lok Test —Typical
(2) Ra ise on e r ea r wh eel u n t il it is com plet ely off
t h e gr ou n d. SERV I CE PROCEDU RES
(3) E n gin e off, t r a n sm ission in n eu t r a l, a n d pa r k-
in g br a ke off. LUBRICANT CHANGE
(4) Rem ove wh eel a n d bolt Specia l Tool 6790 t o (1) Ra ise a n d su ppor t t h e veh icle.
st u ds. (2) Rem ove t h e lu br ica n t fill h ole plu g fr om t h e
(5) Use t or qu e wr en ch on specia l t ool t o r ot a t e differ en t ia l h ou sin g cover.
wh eel a n d r ea d r ot a t in g t or qu e (F ig. 5). (3) Rem ove t h e differ en t ia l h ou sin g cover a n d
(6) If r ot a t in g t or qu e is less t h a n 22 N·m (30 ft . dr a in t h e lu br ica n t fr om t h e h ou sin g.
lbs.) or m or e t h a n 271 N·m (200 ft . lbs.) on eit h er (4) Clea n t h e h ou sin g ca vit y wit h a flu sh in g oil,
wh eel t h e u n it sh ou ld be ser viced. ligh t en gin e oil, or lin t fr ee clot h . D o n o t u s e w a te r,
s te a m , k e ro s e n e , o r g a s o lin e fo r c le a n in g .
(5) Rem ove t h e or igin a l sea la n t fr om t h e h ou sin g
a n d cover su r fa ces.
(6) Apply a bea d of Mopa r t Silicon e Ru bber Sea l-
a n t , or equ iva len t , t o t h e h ou sin g cover (F ig. 6).
SEALANT AXLE HOUSING COVER
AXLE
HOUSING
80a8710c
3/4 DRIVE
TORQUE SPECIAL TOOL
WRENCH 80a4d33b C-452 J9102-31
REAR
BEARING
OIL
r------ PINION
GEAR
SLINGER
J9302-66
SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3972-A
J9302-25
PINION
YOKE
AXLE
HOUSING
80a8710c
~p..___ NUT
GUIDE
PLATE
J9003-45
GUIDE
Fig. 20 Axle Shaft C–Clip Lock
I N STALLAT I ON
(1) Lu br ica t e bea r in g bor e a n d sea l lip wit h gea r
lu br ica n t . In ser t a xle sh a ft t h r ou gh sea l, bea r in g,
a n d en ga ge it in t o side gea r splin es.
FOOT J9003-51
NOTE: Use care to prevent shaft splines from dam-
aging axle shaft seal lip. Also, exercise care not to Fig. 21 Axle Shaft Bearing Removal
damage the wheel speed sensor on vehicles (4) In spect t h e a xle sh a ft t u be bor e for r ou gh n ess
equipped with ABS brakes a n d bu r r s. Rem ove a s n ecessa r y.
(2) In ser t C–clip lock in en d of a xle sh a ft . P u sh I N STALLAT I ON
a xle sh a ft ou t wa r d t o sea t C–clip lock in side gea r. D o n o t in s ta ll th e o rig in a l a x le s h a ft s e a l.
(3) In ser t pin ion m a t e sh a ft in t o differ en t ia l ca se Alw a y s in s ta ll a n e w s e a l.
a n d t h r ou gh t h r u st wa sh er s a n d pin ion gea r s. (1) Wipe t h e a xle sh a ft t u be bor e clea n .
(4) Align h ole in sh a ft wit h h ole in t h e differ en t ia l (2) In st a ll a xle sh a ft bea r in g wit h In st a ller 6436
ca se a n d in st a ll lock scr ew wit h Loct it et on t h e a n d H a n dle C–4171. E n su r e t h a t t h e pa r t n u m ber on
t h r ea ds. Tigh t en lock scr ew t o 19 N·m (14 ft . lbs.) t h e bea r in g is a ga in st t h e in st a ller.
t or qu e. (3) In st a ll t h e n ew a xle sh a ft sea l wit h In st a ller
(5) In st a ll cover a n d a dd flu id. Refer t o Lu br ica n t 6437 a n d H a n dle C–4171 (F ig. 22).
Ch a n ge pr ocedu r e in t h is sect ion for pr ocedu r e a n d (4) In st a ll t h e a xle sh a ft .
lu br ica n t r equ ir em en t s.
INSTALLATION
ENCE LETTERS
SPECIAL
REFER- TOOL C-4171
SPECIAL TOOL 6437AXLE
SEALINSTALLATION
SHAFT TUBE
ENCE LETTERS
REFER- AXLE HOUSING
SPECIAL
SPECIAL
C-3288–B
C-3339
TOOL
TOOL
SPECIAL
W-129–B
TOOLTURNBUCKLE DIAL
LEVER
SAFETY
SPECIALTOOL
HOLD
INDICATOR
ADAPTER
W-129–B
DOWEL
DOWN
SPECIAL
TOOL6437
SAFETY
HOLD
DOWN
SPECIAL
TOOL
C-4171 J9103-8
TURNBUCKLE SPECIAL
Fig. 22 Axle Shaft Seal Installation TOOL
W-129-B
DIFFERENTIAL
0
REM OVAL 0
(1) Ra ise a n d su ppor t veh icle. 80a534c5
DOWEL
SAFETY
HOLD
DOWN
SPECIAL
TOOL
J9003-92 SP-3289
I N STALLAT I ON
(1) Usin g t ool C-3716-A wit h h a n dle C-4171,
in st a ll differ en t ia l side bea r in gs (F ig. 31).
(2) In st a ll differ en t ia l in a xle h ou sin g.
RING GEAR
Th e r in g a n d pin ion gea r s a r e ser vice in a m a t ch ed
set . Do n ot r epla ce t h e r in g gea r wit h ou t r epla cin g
t h e pin ion gea r.
REM OVAL
(1) Rem ove differ en t ia l fr om a xle h ou sin g.
(2) P la ce differ en t ia l ca se in a su it a ble vise wit h
soft m et a l ja w pr ot ect or s. (F ig. 26)
(3) Rem ove bolt s h oldin g r in g gea r t o differ en t ia l
ca se.
(4) Usin g a soft h a m m er, dr ive r in g gea r fr om dif-
fer en t ia l ca se (F ig. 26).
I N STALLAT I ON
/~~~~
Ca t ch t h e pin ion wit h you r h a n d t o pr even t it fr om
fa llin g a n d bein g da m a ged.
:;==========ll==:::::::11
/ RING GEAR
BOLT
J9202-77
REAR
BEARING
1 - - - - - - - PINION
OIL GEAR
SLINGER
J9302-22
J9302-66
J9302-23
INSTALLER
SPECIAL
SPECIAL TOOL TOOL
C-4171 C-3972-A
80a7e2be
INSTALLER HANDLE
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING
REAR
BEARING
/SHOUIDER
OIL
l------- PINION
GEAR
SLINGER
J9302-66
3/4 DRIVE
TORQUE
Fig. 44 Collapsible Preload Spacer WRENCH 80a4d33b
AXLE
HOUSING
80a8710c
I
DIFFERENTIAL ~ THRUST WASHER
CASE
~PINION
I
[ffp
_(tb{Q)~«-
\ I
~
$ SHAFT
~ /LOCK
@ ~ SCREW
CLUTCH PACK
DISC
SIDE
GEAR
~ PINION
RETAINER MATE
I SHAFT
80a77404
DI SASSEM BLY
(1) Cla m p Side Gea r H oldin g Tool 6965 in a vise.
(2) P osit ion t h e differ en t ia l ca se on Side Gea r
H oldin g Tool 6965 (F ig. 52).
(3) Rem ove r in g gea r, if n ecessa r y. Rin g gea r
r em ova l is n ecessa r y on ly if t h e r in g gea r is t o be
r epla ced. Th e Tr a c-lok differ en t ia l ca n be ser viced
wit h t h e r in g gea r in st a lled.
SPECIAL
TOOL
6965
VISE 80a7e2ae
PINION
MATE GEAR THREADED
ADAPTER
DISC
C-6960-1
80a773e1
TORQUE
WRENCH
FEELER
GAUGE RETAINER
80a98382
80a77406
Fig. 60 Side Gear & Clutch Disc Removal
Fig. 58 Remove Pinion Gear Thrust Washer (17) Rem ove differ en t ia l ca se fr om Side Gea r H old-
(11) In ser t Tu r n in g Ba r C-6960-2 in ca se (F ig. 59). in g Tool 6965. Rem ove side gea r, clu t ch pa ck r et a in er,
(12) Loosen t h e F or cin g Scr ew C-6960-4 in sm a ll a n d clu t ch pa ck. Keep pla t es in cor r ect or der du r in g
in cr em en t s u n t il t h e clu t ch pa ck t en sion is r elieved r em ova l.
a n d t h e differ en t ia l ca se ca n be t u r n ed u sin g Tu r n in g
ASSEM BLY
Ba r C-6960-2.
(13) Rot a t e differ en t ia l ca se u n t il t h e pin ion gea r s NOTE: The clutch discs are replaceable as com-
ca n be r em oved. plete sets only. If one clutch disc pack is damaged,
(14) Rem ove pin ion gea r s fr om differ en t ia l ca se. both packs must be replaced.
DIFFERENTIAL CASE CLUTCH
RETAINER
PACK LOWER
AND CLUTCH
SIDE
RETAINER
SIDE
GEAR
GEAR
PACK
DISC UPPER CLUTCH
SIDE GEAR
DISC
DIFFERENTIAL
PACK
SPECIAL
TOOLC-6960–3
AND CASE
.
SPECIAL
/
RETAINER
J8903-50
TOOL
C-6960-3
80a83887
t
PINION HEIGHT
BLOCK
COLLAPSIBLE
SPACER
DIFFERENTIAL
BEARING
SHIM-RING
GEAR SIDE
80a5037a
J9003-24
SPECI FI CAT I ON S
194 RBI AXLE
Puller—C-452
Puller—C-293-PA
XJ DIFFERENTIAL AND DRIVELINE 3 - 79
SPECI AL T OOLS (Cont inue d)
Cup—8109
Wrench—C-3281
Installer—C-3972-A
Handle—C-4171
Spanner—6958
Driver—C-3716-A
Installer Screw—8112
Installer—D-130
3 - 80 DIFFERENTIAL AND DRIVELINE XJ
SPECI AL T OOLS (Cont inue d)
Installer—6436
Installer—D-146
Remover—C-4345
Installer—6437
Remover—D-149
Installer—W-262
Gauge Block—6735
XJ DIFFERENTIAL AND DRIVELINE 3 - 81
SPECI AL T OOLS (Cont inue d)
~ I '
~.,. ~
6741
@
9
~ D-115-2 6739
~~~
6733 6734 E,735
i
6 74 0
Holder—6965
Adapter Kit—6987
Hub Puller—6790
Dial Indicator—C-3339
XJ DIFFERENTIAL AND DRIVELINE 3 - 83
8 1 /4 REAR AX LE
INDEX
page page
DRIVE
PINION
OUTER WHEEL
I 100% DIFFERENTIAL INNER WHEEL
I
110% CASE SPEED CASE SPEED 90% CASE SPEED
J9303-15
TRAC–LOK TEST
WARNING: WHEN SERVICING VEHICLES WITH A
TRAC–LOK DIFFERENTIAL DO NOT USE THE
ENGINE TO TURN THE AXLE AND WHEELS. BOTH
REAR WHEELS MUST BE RAISED AND THE VEHI-
CLE SUPPORTED. A TRAC–LOK AXLE CAN EXERT
ENOUGH FORCE IF ONE WHEEL IS IN CONTACT
WITH A SURFACE TO CAUSE THE VEHICLE TO
MOVE. SPECIAL TOOL
6790WITH
Th e differ en t ia l ca n be t est ed wit h ou t r em ovin g t h e BOLT IN
differ en t ia l ca se by m ea su r in g r ot a t in g t or qu e. Ma ke CENTER
su r e br a kes a r e n ot dr a ggin g du r in g t h is m ea su r e- HOLE
m en t .
80a4d327
(1) P la ce blocks in fr on t a n d r ea r of bot h fr on t
wh eels. Fig. 6 Trac-lok Test —Typical
(2) Ra ise on e r ea r wh eel u n t il it is com plet ely off
t h e gr ou n d. SERV I CE PROCEDU RES
(3) E n gin e off, t r a n sm ission in n eu t r a l, a n d pa r k-
in g br a ke off. LUBRICANT CHANGE
(4) Rem ove wh eel a n d bolt Specia l Tool 6790 t o (1) Ra ise a n d su ppor t t h e veh icle.
st u ds. (2) Rem ove t h e lu br ica n t fill h ole plu g fr om t h e
(5) Use t or qu e wr en ch on specia l t ool t o r ot a t e differ en t ia l h ou sin g cover.
wh eel a n d r ea d r ot a t in g t or qu e (F ig. 5). (3) Rem ove t h e differ en t ia l h ou sin g cover a n d
(6) If r ot a t in g t or qu e is less t h a n 22 N·m (30 ft . dr a in t h e lu br ica n t fr om t h e h ou sin g.
lbs.) or m or e t h a n 271 N·m (200 ft . lbs.) on eit h er (4) Clea n t h e h ou sin g ca vit y wit h a flu sh in g oil,
wh eel t h e u n it sh ou ld be ser viced. ligh t en gin e oil, or lin t fr ee clot h . D o n o t u s e w a te r,
s te a m , k e ro s e n e , o r g a s o lin e fo r c le a n in g .
(5) Rem ove t h e or igin a l sea la n t fr om t h e h ou sin g
a n d cover su r fa ces.
(6) Apply a bea d of Mopa r t Silicon e Ru bber Sea l-
a n t , or equ iva len t , t o t h e h ou sin g cover (F ig. 6).
SEALANT AXLE HOUSING COVER
AXLE SHAFT
REM OVAL AN D I N STALLAT I ON
REM OVAL
REAR AXLE (1) Ra ise a n d su ppor t veh icle. E n su r e t h a t t h e
t r a n sm ission is in n eu t r a l.
REM OVAL (2) Rem ove wh eel a n d t ir e a ssem bly.
(1) Ra ise a n d su ppor t t h e veh icle. (3) Rem ove br a ke dr u m . Refer t o Gr ou p 5, Br a kes,
(2) P osit ion a su it a ble lift in g device u n der t h e for pr oper pr ocedu r e.
a xle. (4) Clea n a ll for eign m a t er ia l fr om h ou sin g cover
(3) Secu r e a xle t o device. a r ea .
(4) Rem ove t h e wh eels a n d t ir es. (5) Loosen h ou sin g cover bolt s. Dr a in lu br ica n t
(5) Secu r e br a ke dr u m s t o t h e a xle sh a ft . fr om t h e h ou sin g a n d a xle sh a ft t u bes. Rem ove h ou s-
(6) Discon n ect t h e br a ke h ose a t t h e a xle ju n ct ion in g cover.
block. Do n ot discon n ect t h e br a ke h ydr a u lic lin es a t (6) Rot a t e differ en t ia l ca se so t h a t pin ion m a t e
t h e wh eel cylin der s. Refer t o Gr ou p 5, Br a kes, for gea r sh a ft lock scr ew is a ccessible. Rem ove lock
pr oper pr ocedu r es.
SIDE GEAR AXLEPINION
SHAFT
LOCK
SCREW
C-CLIPLOCK
GEAR MATE SHAFT PRY BAR AXLE
AXLE
SEAL
TUBE
J9003-45
THREADED
ROD
J9003-5l
I N STALLAT I ON
(1) Clea n t h e sea l con t a ct su r fa ce in t h e h ou sin g
bor e.
(2) E xa m in e t h e splin es on t h e pin ion sh a ft for
bu r r s or wea r. Rem ove a n y bu r r s a n d clea n t h e sh a ft .
(3) In spect pin ion yoke for cr a cks, wor n splin es
a n d wor n sea l con t a ct su r fa ce. Repla ce yoke if n eces-
sa r y.
J9003-57
J9003-57
Fig. 17 Mark For Installation Reference
(3) Rem ove bea r in g t h r ea ded a dju st er lock fr om Fig. 19 Bearing Caps & Bolts
ea ch bea r in g ca p. Loosen t h e bolt s, bu t do n ot (3) In st a ll bea r in g ca p bolt s a n d t igh t en t h e u pper
r em ove t h e bea r in g ca ps. bolt s t o 14 N·m (10 ft . lbs.). Tigh t en t h e lower bolt s
(4) Loosen t h e t h r ea ded a dju st er s wit h Wr en ch fin ger-t igh t u n t il t h e bolt h ea d is sea t ed.
C-4164 (F ig. 18). (4) P er for m t h e differ en t ia l bea r in g pr eloa d a n d
AXLE a dju st m en t pr ocedu r e.
TUBE (5) In st a ll a xle sh a ft s a n d differ en t ia l h ou sin g
cover.
REM OVAL
(1) Rem ove differ en t ia l fr om a xle h ou sin g.
(2) P la ce differ en t ia l ca se in a su it a ble vise wit h
soft m et a l ja w pr ot ect or s. (F ig. 22).
(3) Rem ove bolt s h oldin g r in g gea r t o differ en t ia l
ca se.
(4) Usin g a soft h a m m er, dr ive r in g gea r fr om dif-
SPECIAL
fer en t ia l ca se (F ig. 22).
TOOL
C-293-48
80a982f2
PINION GEAR
BEARING Th e r in g a n d pin ion gea r s a r e ser viced in a
m a t ch ed set . Do n ot r epla ce t h e pin ion gea r wit h ou t
80a0c4fe r epla cin g t h e r in g gea r.
RING
GEAR
J9202-77
PINION
YOKE
TOOL
C452
J9403-18
J9302-23
Fig. 29 Rear Bearing Removal
Fig. 27 Rear Bearing Cup Removal (14) Rem ove t h e dept h sh im s fr om t h e pin ion gea r
(12) Rem ove t h e colla psible pr eloa d spa cer (F ig. sh a ft . Recor d t h e t h ickn ess of t h e dept h sh im s.
28).
I N STALLAT I ON
(1) Apply Mopa r t Door E a se, or equ iva len t , st ick
lu br ica n t t o ou t side su r fa ce of bea r in g cu p.
(2) In st a ll t h e pin ion r ea r bea r in g cu p (F ig. 30)
wit h In st a ller C-4308 a n d Dr iver H a n dle C–4171.
(3) E n su r e cu p is cor r ect ly sea t ed.
INSTALLER
REAR
BEARING
/SHOUIDER
1 - - - - - - - PINION
OIL GEAR
SLINGER
J9302-66
INSTALLER HANDLE
INSTALLATION
TOOL
DRIVE
PINION GEAR
SHAFT
REAR BEARING
REAR
Fig. 32 Pinion Seal Installation BEARING
PINION
Fig. 35 Check Pinion Gear Rotating Torque MATE GEAR SIDE GEAR J9203-61
(18) In st a ll pr opeller sh a ft .
(19) In st a ll differ en t ia l in h ou sin g. Fig. 37 Pinion Mate Gear Removal
(4) Rem ove t h e differ en t ia l side gea r s a n d t h r u st
wa sh er s.
DIFFERENTIAL CASE CLUTCH PACK RETAINER
DISC RETAINER VISE
SIDE GEAR
DIFFERENTIAL
THRUST
PINION
WASHER PINION
SHAFT
MATE
SIDE
LOCK
SHAFT
GEAR
SCREW
INGHOLD-
TOOL
I
DIFFERENTIAL ~ THRUST WASHER
CASE
~PINION
I
[ffp
_(tb{Q)~«-
\ I
~
$ SHAFT
~ /LOCK
@ ~ SCREW
CLUTCH PACK
DISC
SIDE
GEAR
~ PINION
RETAINER MATE
I SHAFT
80a77404
TRAC-LOK DIFFERENTIAL
Th e Tr a c–lok differ en t ia l com pon en t s a r e illu s-
t r a t ed in (F ig. 38). Refer t o t h is illu st r a t ion du r in g
r epa ir ser vice.
DI SASSEM BLY
(1) Cla m p Side Gea r H oldin g Tool 8138 in a vise.
(2) P osit ion t h e differ en t ia l ca se on Side Gea r
H oldin g Tool 8138 (F ig. 39).
(3) Rem ove r in g gea r, if n ecessa r y. Rin g gea r
r em ova l is n ecessa r y on ly if t h e r in g gea r is t o be Fig. 39 Differential Case Holding Tool
r epla ced. Th e Tr a c-lok differ en t ia l ca n be ser viced
wit h t h e r in g gea r in st a lled. (6) In st a ll a n d lu br ica t e St ep P la t e 8140–2 (F ig.
(4) Rem ove t h e pin ion gea r m a t e sh a ft lock scr ew 42).
(F ig. 40). (7) Assem ble Th r ea ded Ada pt er 8140-1 in t o t op
(5) Rem ove t h e pin ion gea r m a t e sh a ft . If n eces- side gea r. Th r ea d F or cin g Scr ew 6960-4 in t o a da pt er
sa r y, u se a dr ift a n d h a m m er (F ig. 41). u n t il it becom es cen t er ed in a da pt er pla t e.
DRIFT
PINION MATE GEAR PINION
LOCK
SCREW
PINION
GEARSIDE
MATE
SHAFT
GEAR
MATE
SHAFT THREADED
THREADED
SPECIAL
DIFFERENTIAL
TOOL
ADAPTER
ROD8140–2
C-6960–4
DISC
8140–1
CASE
DISC
8140–2 LOWER
SLOT
SOCKET
SCREWDRIVER
IN
SIDE
ADAPTER
GEAR
J9302-47
PINION DIFFERENTIAL
MATE GEAR CASE 80a982ec
THREADED
ADAPTER
DISC
8140-1
80a773e1
Fig. 44 Tighten Belleville Spring Compressor Tool Fig. 46 Pinion Gear Removal
DIFFERENTIAL
CASE
THRUST
WASHER
SIDE GEAR
AND CLUTCH
DISC PACK
FEELER
GAUGE
RETAINER
80a77406 80a98382
Fig. 45 Remove Pinion Gear Thrust Washer Fig. 47 Side Gear & Clutch Disc Removal
ASSEM BLY (4) P osit ion t h e differ en t ia l ca se on Side Gea r
H oldin g Tool 8138.
NOTE: The clutch discs are replaceable as com- (5) In st a ll lu br ica t ed St ep P la t e 8140–2 in lower
plete sets only. If one clutch disc pack is damaged, side gea r (F ig. 50).
both packs must be replaced. (6) In st a ll t h e u pper side gea r a n d clu t ch disc pa ck
(F ig. 50).
Lu br ica t e ea ch com pon en t wit h gea r lu br ica n t (7) H old a ssem bly in posit ion . In ser t Th r ea ded
befor e a ssem bly. Ada pt er 8140-1 in t o t op side gea r.
(1) Assem ble t h e clu t ch discs in t o pa cks a n d (8) In ser t F or cin g Scr ew 6960-4.
secu r e disc pa cks wit h r et a in in g clips (F ig. 48). (9) Tigh t en for cin g scr ew t ool t o sligh t ly com pr ess
(2) P osit ion a ssem bled clu t ch disc pa cks on t h e clu t ch discs.
side gea r h u bs. (10) P la ce pin ion gea r s in posit ion in side gea r s
(3) In st a ll clu t ch pa ck a n d side gea r in t h e r in g a n d ver ify t h a t t h e pin ion m a t e sh a ft h oles a r e
gea r side of t h e differ en t ia l ca se (F ig. 49). B e s u re a lign ed.
c lu tc h p a c k re ta in in g c lip s re m a in in p o s itio n (11) Rot a t e ca se wit h Tu r n in g Ba r 6960-2 u n t il t h e
a n d a re s e a te d in th e c a s e p o c k e ts . pin ion m a t e sh a ft h oles in pin ion gea r s a lign wit h
DIFFERENTIAL CASE CLUTCH
RETAINER
PACK LOWER
AND CLUTCH
SIDE
RETAINER
SIDE
GEAR
GEAR
PACK
DISC UPPER CLUTCH
SIDE DIFFERENTIAL
GEAR
DISC PACK
SPECIAL
TOOL
AND CASE
8140–2
CLUTCH PACK
UPPER SIDE
GEAR AND CLUTCH
DISC PACK
.
SPECIAL
/
RETAINER
J8903-50
TOOL
8140-2
80a982ee
CLEAN I N G AN D I N SPECT I ON
8 1/4 AXLES
Wa sh differ en t ia l com pon en t s wit h clea n in g solven t
a n d dr y wit h com pr essed a ir. D o n o t s te a m c le a n
th e d iffe re n tia l c o m p o n e n ts .
Wa sh bea r in gs wit h solven t a n d t owel dr y, or dr y
wit h com pr essed a ir. DO NOT spin bea r in gs wit h
com pr essed a ir. Cu p a n d be a rin g m u s t be
re p la c e d a s m a tc h e d s e ts o n ly.
Clea n a xle sh a ft t u bes a n d oil ch a n n els in h ou sin g.
80a7739c In spect for :
• Sm oot h a ppea r a n ce wit h n o br oken /den t ed su r-
Fig. 49 Clutch Discs & Lower Side Gear Installation fa ces on t h e bea r in g r oller s or t h e r oller con t a ct su r-
h oles in ca se. It m a y be n ecessa r y t o sligh t ly t igh t en fa ces.
t h e for cin g scr ew in or der t o in st a ll t h e pin ion gea r s. • Bea r in g cu ps m u st n ot be dist or t ed or cr a cked.
(12) Tigh t en for cin g scr ew t o 122 N·m (90 ft . lbs.) • Ma ch in ed su r fa ces sh ou ld be sm oot h a n d wit h -
m a xim u m t o com pr ess t h e Belleville spr in gs. ou t a n y r a ised edges.
(13) Lu br ica t e a n d in st a ll t h r u st wa sh er s beh in d • Ra ised m et a l on sh ou lder s of cu p bor es sh ou ld
pin ion gea r s a n d a lign wa sh er s wit h a sm a ll scr ew be r em oved wit h a h a n d st on e.
dr iver. In ser t m a t e sh a ft in t o ea ch pin ion gea r t o ver- • Wea r a n d da m a ge t o pin ion gea r m a t e sh a ft ,
ify a lign m en t . pin ion gea r s, side gea r s a n d t h r u st wa sh er s. Repla ce
(14) Rem ove F or cin g Scr ew 6960-4, St ep P la t e a s a m a t ch ed set on ly.
8140–2, a n d Th r ea ded Ada pt er 8140-1.
PRODUCTION
GEAR
(SAME
PINION
AXLE
HOUSING
BEARING
GEAR
AS
MATCHING
RING
BERS
NUM-
CUP
GEAR
NUMBER
NUM-
BER) PINION
COLLAPSIBLE
DRIVE PINION
GEAR BEARING
SPACER
VARIANCE
DEPTH
PINION
DEPTH
SHIM
PRESOAK PLAT ES AN D DI SC
P la t es a n d discs wit h fiber coa t in g (n o gr ooves or
lin es) m u st be pr esoa ked in F r ict ion Modifier befor e
80a0c4f8
a ssem bly. Soa k pla t es a n d discs for a m in im u m of 20
m in u t es. Fig. 52 Shim Locations
If a n ew gea r set is bein g in st a lled, n ot e t h e dept h
ADJ U ST M EN T S va r ia n ce m a r ked on bot h t h e or igin a l a n d r epla ce-
m en t pin ion gea r. Add or su bt r a ct t h e t h ickn ess of
8 1/4 AXLE PINION GEAR DEPTH t h e or igin a l dept h sh im s t o com pen sa t e for t h e differ-
en ce in t h e dept h va r ia n ces. Refer t o t h e Dept h Va r i-
GEN ERAL I N FORM AT I ON a n ce ch a r t s.
Rin g a n d pin ion gea r s a r e su pplied a s m a t ch ed Not e wh er e Old a n d New P in ion Ma r kin g colu m n s
set s on ly. Th e iden t ifyin g n u m ber s for t h e r in g a n d in t er sect . In t er sect in g figu r e r epr esen t s plu s or
pin ion gea r a r e m a r ked on t h e fa ce of ea ch gea r (F ig. m in u s a m ou n t n eeded.
51). A plu s (+) n u m ber, m in u s (–) n u m ber or zer o (0) Not e t h e m a r ked n u m ber on t h e fa ce of t h e dr ive
is m a r ked on t h e fa ce of t h e pin ion gea r. Th is n u m - pin ion gea r (–1, –2, 0, +1, +2, et c.). Th e n u m ber s r ep-
ber is t h e a m ou n t (in t h ou sa n dt h s of a n in ch ) t h e r esen t t h ou sa n ds of a n in ch devia t ion fr om t h e st a n -
dept h va r ies fr om t h e st a n da r d dept h set t in g of a da r d. If t h e n u m ber is n ega t ive, a dd t h a t va lu e t o t h e
pin ion m a r ked wit h a (0). Th e st a n da r d dept h pr o- r equ ir ed t h ickn ess of t h e dept h sh im (s). If t h e n u m -
vides t h e best t eet h con t a ct pa t t er n . Refer t o Ba ck- ber is posit ive, su bt r a ct t h a t va lu e fr om t h e t h ickn ess
la sh a n d Con t a ct P a t t er n An a lysis P a r a gr a ph in t h is of t h e dept h sh im (s). If t h e n u m ber is 0 n o ch a n ge is
sect ion for a ddit ion a l in for m a t ion . n ecessa r y. Refer t o t h e P in ion Gea r Dept h Va r ia n ce
Ch a r t .
SPECIAL TOOLC-3715–B
SET PINION
BEARING GAUGE BLOCK AXLE HOUSING ADJUSTER
SP-5382
~-, /
~, Fig. 54 Gauge Block
==,
SP-6022 SP-534 (17) In st a ll Ga u ge Block SP -5383 a t t h e en d of
SP -5385.
~ (18) In st a ll Ca p Scr ew SP -536 a n d t igh t en wit h
SP-3193 Wr en ch SP -531.
(19) P osit ion Cr ossbor e Ar bor SP -6029 in t h e dif-
fer en t ia l h ou sin g (F ig. 55).
SP-536-(S? J9203-51 (20) Cen t er t h e a r bor t ool.
(21) P osit ion t h e bea r in g ca ps on t h e a r bor t ool.
Fig. 53 8 1/4 Axle Pinion Adjustment Tools (22) In st a ll t h e a t t a ch in g bolt s.
(11) Tigh t en t h e n u t t o sea t t h e pin ion bea r in gs in (23) Tigh t en t h e ca p bolt s t o 14 N·m (10 ft . lbs.).
t h e h ou sin g. Allow t h e sleeve t o t u r n sever a l t im es (24) Tr ia l fit dept h sh im (s) bet ween t h e cr ossbor e
du r in g t igh t en in g t o pr even t br in ellin g bea r in g cu ps a r bor a n d ga u ge block (F ig. 56). Th e d e p th s h im (s )
or bea r in gs. fit m u s t be s n u g bu t n o t tig h t (d ra g fric tio n o f a
(12) Loosen t h e com pr ession n u t t ool. fe e le r g a u g e bla d e ).
SHIMS CROSSBORE
AXLE HOUSING
ARBOR CROSSBORE ARBORBEARING CAP BACKING PLATE TOOL C-4164 AXLE TUBE
@A~
CAP
t h e r in g a n d pin ion gea r. Sea t t h e bea r in g cu ps wit h
t h e pr ocedu r e descr ibed a bove.
CROSSBORE1/ G G AXLE
ARBOR , TUBE
6 e
/~
J9403-31
6 6
Fig. 56 Depth Shim(s) Selection
(25) Select a sh im equ a l t o t h e sh im select ed a bove
plu s t h e dr ive pin ion gea r dept h va r ia n ce n u m ber
m a r ked on t h e fa ce of t h e pin ion gea r (F ig. 51) u sin g
t h e opposit e sign on t h e va r ia n ce n u m ber. F or exa m - BACKING
ple, if t h e dept h va r ia n ce is –2, a dd +0.002 in . t o t h e PLATE
dia l in dica t or r ea din g.
J9003-24
SPECI AL T OOLS
8 1/4 AXLES
Puller, Hub—6790
Handle—C-4171
Remover, Bearing—6310
Installer—C-4076-B
Installer—C-4198
Handle—C-4735-1
Holder—6719
3 - 112 DIFFERENTIAL AND DRIVELINE XJ
SPECI AL T OOLS (Cont inue d)
Puller—C-452 Adapters—C-293-48
Installer—C-3718 Plug—SP-3289
Puller/Press—C-293–PA Installer—C-4340
XJ DIFFERENTIAL AND DRIVELINE 3 - 113
SPECI AL T OOLS (Cont inue d)
Holder—8138
Installer—6448
Installer—C-4345
Trac-lok Tools—8140
Remover—C-4307
Trac-lok Tools—6960
D ~ 0
@
®
Installer—C-4308
~
Gauge Set—C-3715-B
Installer—D-130
XJ BRAKES 5-1
BRAKES
CON T EN T S
page page
BASE BRAK E SY ST EM
INDEX
page page
GEN ERAL I N FORM AT I ON flush brake system components. These are the only
cleaning materials recommended. If system contam-
BRAKE SYSTEM ination is suspected, check the fluid for dirt, discol-
P ower a ssist fr on t disc a n d r ea r dr u m br a kes a r e oration, or separation into distinct layers. Drain and
st a n da r d equ ipm en t . Disc br a ke com pon en t s con sist flush the system with new brake fluid if contamina-
of sin gle pist on ca liper s a n d ven t ila t ed r ot or s. Rea r tion is suspected.
dr u m br a kes a r e du a l sh oe u n it s wit h ca st br a ke
dr u m s.
CAUTION: Use Mopar brake fluid, or an equivalent
Th e pa r kin g br a ke m ech a n ism is lever a n d ca ble
quality fluid meeting SAE/DOT standards J1703 and
oper a t ed. Th e ca bles a r e a t t a ch ed t o lever s on t h e
DOT 3. Brake fluid must be clean and free of con-
r ea r dr u m br a ke secon da r y sh oes. Th e pa r kin g
taminants. Use fresh fluid from sealed containers
br a kes a r e oper a t ed by a h a n d lever.
only to ensure proper antilock component opera-
A du a l dia ph r a gm va cu u m power br a ke boost er is
tion.
u sed for a ll a pplica t ion s. All m odels h a ve a t wo-piece
m a st er cylin der wit h pla st ic r eser voir.
All m odels a r e equ ipped wit h a com bin a t ion va lve. CAUTION: Use Mopar multi-mileage or high temper-
Th e va lve con t a in s a pr essu r e differ en t ia l va lve a n d ature grease to lubricate caliper slide surfaces,
swit ch a n d a fixed r a t e r ea r pr opor t ion in g va lve. drum brake pivot pins, and shoe contact points on
F a ct or y br a ke lin in g on a ll m odels con sist s of a n the backing plates. Use multi-mileage grease or GE
or ga n ic ba se m a t er ia l com bin ed wit h m et a llic pa r t i- 661 or Dow 111 silicone grease on caliper bushings
cles. Th e lin in g does n ot con t a in a sbest os. and slide pins to ensure proper operation.
5-4 BRAKES XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
AIR
FILTER
PRIMARY
PUSH ROD
(TO BRAKE
MASTER PEDAL)
CYLINDER
MOUNTING
STUD (2)
BOOSTER
SECONDARY MOUNTING
PUSH ROD STUDS (4)
(TO MASTER
CYLINDER) J9505-58
XJ BRAKES 5-5
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
lin es, m a st er cylin der, boost er, a n d pa r kin g br a ke
PISTON com pon en t s.
Br a ke dia gn osis in volves det er m in in g if t h e pr ob-
lem is r ela t ed t o a m ech a n ica l, h ydr a u lic, or va cu u m
oper a t ed com pon en t .
Th e fir st dia gn osis st ep is t h e pr elim in a r y ch eck.
5-6 BRAKES XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
RIGHT REAR
BRAKE ASSEMBLY ADJUSTER
LEVER
HOLDDOWN SPRING
SPRING AND HOLDDOWN PINS
ADJUS~!TtlNERS ~
CABLE
SUPPORT PLATE
PARK
BRAKE
L~----=--STRUT
AND
;----Hf--d--SCREW SPRING
ASSEMBLY
J9005-13
SPONGY PEDAL
A spon gy peda l is m ost oft en ca u sed by a ir in t h e
syst em . H owever, t h in br a ke dr u m s or su bst a n da r d
br a ke lin es a n d h oses ca n a lso ca u se a spon gy peda l.
Th e pr oper cou r se of a ct ion is t o bleed t h e syst em , or
r epla ce t h in dr u m s a n d su spect qu a lit y br a ke lin es
a n d h oses.
5-8 BRAKES XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
ca liper s t h a t bin d on t h e slide su r fa ces ca n gen er a t e TERMINAL
a t h u m p or clu n k n oise. In a ddit ion , wor n ou t , PINS
im pr oper ly a dju st ed, or im pr oper ly a ssem bled r ea r
br a ke sh oes ca n a lso pr odu ce a t h u m p n oise.
XJ BRAKES 5-9
DI AGN OSI S AN D T EST I N G (Cont inue d)
va cu u m su pply, or va cu u m ch eck va lve is fa u lt y. P r o- (5) Va cu u m sh ou ld h old st ea dy. If ga u ge on pu m p
ceed t o t h e P OWE R BOOSTE R VACUUM TE ST. in dica t es va cu u m loss, ch eck va lve is fa u lt y a n d
(6) If t h e P OWE R BOOSTE R VACUUM TE ST sh ou ld be r epla ced.
pa sses, r ebu ild boost er va cu u m r eser ve a s follows:
Relea se br a ke peda l. In cr ea se en gin e speed t o 1500
r pm , close t h e t h r ot t le a n d im m edia t ely st op t u r n off
ign it ion t o st op en gin e.
(7) Wa it a m in im u m of 90 secon ds a n d t r y br a ke
a ct ion a ga in . Boost er sh ou ld pr ovide t wo or m or e va c-
u u m a ssist ed peda l a pplica t ion s. If va cu u m a ssist is
n ot pr ovided, boost er is fa u lt y.
5 - 10 BRAKES XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
Repla ce t h e r ot or u n der t h e followin g con dit ion s: P osit ion t h e m icr om et er a ppr oxim a t ely 25.4 m m (1
• sever ely scor ed in .) fr om t h e r ot or ou t er cir cu m fer en ce for ea ch m ea -
• t a per ed su r em en t .
• h a r d spot s Th ickn ess sh ou ld n ot v a ry by m or e t h a n 0.013 m m
• cr a cked (0.0005 in .) fr om poin t -t o-poin t on t h e r ot or. Ma ch in e
• below m in im u m t h ickn ess or r epla ce t h e r ot or if n ecessa r y.
ROT OR M I N I M U M T H I CK N ESS
Mea su r e r ot or t h ickn ess a t t h e cen t er of t h e br a ke
sh oe con t a ct su r fa ce. Repla ce t h e r ot or if wor n below
m in im u m t h ickn ess, or if m a ch in in g wou ld r edu ce
t h ickn ess below t h e a llowa ble m in im u m .
Rot or m in im u m t h ickn ess is u su a lly specified on
t h e r ot or h u b. Th e specifica t ion is eit h er st a m ped or
ca st in t o t h e h u b su r fa ce.
TAKE MINIMUM
ROT OR RU N OU T OF 6 MEASUREMENTS
Ch eck r ot or la t er a l r u n ou t wit h dia l in dica t or AROUND ROTOR
C-3339 (F ig. 9). E xcessive la t er a l r u n ou t will ca u se
br a ke peda l pu lsa t ion a n d r a pid, u n even wea r of t h e
br a ke sh oes. P osit ion t h e dia l in dica t or plu n ger
a ppr oxim a t ely 25.4 m m (1 in .) in wa r d fr om t h e r ot or J9405-103
edge.
BRAK E DRU M RU N OU T
Mea su r e dr u m dia m et er a n d r u n ou t wit h a n a ccu -
r a t e ga u ge. Th e m ost a ccu r a t e m et h od of m ea su r e-
m en t in volves m ou n t in g t h e dr u m in a br a ke la t h e
a n d ch eckin g va r ia t ion a n d r u n ou t wit h a dia l in di-
ca t or.
Va r ia t ion s in dr u m dia m et er sh ou ld n ot exceed
0.076 m m (0.003 in .). Dr u m r u n ou t sh ou ld n ot exceed
0.20 m m (0.008 in .) ou t of r ou n d. Ma ch in e t h e dr u m
DIAL if r u n ou t or va r ia t ion exceed t h ese va lu es. Repla ce
INDICATOR
J89O5-68 t h e dr u m if m a ch in in g ca u ses t h e dr u m t o exceed t h e
m a xim u m a llowa ble dia m et er.
Fig. 9 Checking Rotor Runout And Thickness
Variation BRAKE LINE AND HOSES
ROT OR T H I CK N ESS VARI AT I ON F lexible r u bber h ose is u sed a t bot h fr on t br a kes
Va r ia t ion s in r ot or t h ickn ess will ca u se peda l pu l- a n d a t t h e r ea r a xle ju n ct ion block. In spect t h e h oses
sa t ion , n oise a n d sh u dder. wh en ever t h e br a ke syst em is ser viced, a t ever y
Mea su r e r ot or t h ickn ess a t 6 t o 12 poin t s a r ou n d en gin e oil ch a n ge, or wh en ever t h e veh icle is in for
t h e r ot or fa ce (F ig. 10). ser vice.
In spect t h e h oses for su r fa ce cr a ckin g, scu ffin g, or
wor n spot s. Repla ce a n y br a ke h ose im m edia t ely if
LEVEL
FLUID
MARKS
BLEEDING
TUBES RESERVOIR
RESERVOIR
XJ BRAKES 5 - 11
DI AGN OSI S AN D T EST I N G (Cont inue d)
t h e fa br ic ca sin g of t h e h ose is exposed du e t o cr a cks
or a br a sion s.
Also ch eck br a ke h ose in st a lla t ion . F a u lt y in st a lla -
t ion ca n r esu lt in kin ked, t wist ed h oses, or con t a ct
wit h t h e wh eels a n d t ir es or ot h er ch a ssis com po-
n en t s. All of t h ese con dit ion s ca n lea d t o scu ffin g,
cr a ckin g a n d even t u a l fa ilu r e.
Th e st eel br a ke lin es sh ou ld be in spect ed per iodi-
ca lly for eviden ce of cor r osion , t wist s, kin ks, lea ks, or
ot h er da m a ge. H ea vily cor r oded lin es will even t u a lly
r u st t h r ou gh ca u sin g lea ks. In a n y ca se, cor r oded or
da m a ged br a ke lin es sh ou ld be r epla ced.
F a ct or y r epla cem en t br a ke lin es a n d h oses a r e r ec-
om m en ded t o en su r e qu a lit y, cor r ect len gt h a n d su pe-
r ior fa t igu e life. Ca r e sh ou ld be t a ken t o m a ke su r e - - - - - - - - - - - - - - - - - J9505- l 7
t h a t br a ke lin e a n d h ose m a t in g su r fa ces a r e clea n
a n d fr ee fr om n icks a n d bu r r s. Also r em em ber t h a t Fig. 11 Master Cylinder Fluid Level
r igh t a n d left br a ke h oses a r e n ot in t er ch a n gea ble. (2) At t a ch bleed t u bes t o cylin der ou t let por t s.
Use n ew copper sea l wa sh er s a t a ll ca liper con n ec- Th en posit ion ea ch t u be en d in t h e r eser voir flu id
t ion s. Be su r e br a ke lin e con n ect ion s a r e pr oper ly com pa r t m en t (F ig. 12).
m a de (n ot cr oss t h r ea ded) a n d t igh t en ed t o r ecom - (3) F ill r eser voir wit h fr esh br a ke flu id.
m en ded t or qu e. (4) P r ess cylin der pist on s in wa r d wit h wood dowel.
Th en r elea se pist on s a n d a llow t h em t o r et u r n u n der
BRAKE FLUID CONTAMINATION spr in g pr essu r e. Con t in u e bleedin g oper a t ion s u n t il
In dica t ion s of flu id con t a m in a t ion a r e swollen or a ir bu bbles a r e n o lon ger visible in t h e flu id r eser-
det er ior a t ed r u bber pa r t s. voir .
Swollen r u bber pa r t s in dica t e t h e pr esen ce of
pet r oleu m in t h e br a ke flu id.
To t est for con t a m in a t ion , pu t a sm a ll a m ou n t of
dr a in ed br a ke flu id in clea r gla ss ja r. If flu id sepa -
r a t es in t o la yer s, t h er e is m in er a l oil or ot h er flu id
con t a m in a t ion of t h e br a ke flu id.
If br a ke flu id is con t a m in a t ed, dr a in a n d t h or-
ou gh ly flu sh syst em . Repla ce m a st er cylin der, pr opor-
t ion in g va lve, ca liper sea ls, wh eel cylin der sea ls,
An t ilock Br a kes h ydr a u lic u n it a n d a ll h ydr a u lic
flu id h oses.
5 - 12 BRAKES XJ
SERV I CE PROCEDU RES (Cont inue d)
a ddit ion a l a ir t o be dr a wn in t o t h e syst em . Ch eck t h e in t h e for wa r d en d of t h e com bin a t ion va lve. Th e
cylin der flu id level fr equ en t ly a n d a dd flu id a s st em m u st eit h er be pr essed in wa r d, or h eld ou t wa r d
n eeded. sligh t ly. a spr in g clip t ool or h elper is n eeded t o h old
Bleed on ly on e br a ke com pon en t a t a t im e. Recom - t h e va lve st em in posit ion .
m en ded bleed sequ en ce is: F ollow t h e m a n u fa ct u r er s in st r u ct ion s ca r efu lly
• m a st er cylin der wh en u sin g pr essu r e equ ipm en t . Do n ot exceed t h e
• com bin a t ion va lve t a n k m a n u fa ct u r er s pr essu r e r ecom m en da t ion s. Gen -
• r igh t r ea r wh eel er a lly, a t a n k pr essu r e of 15-20 psi is su fficien t for
• left r ea r wh eel bleedin g.
• r igh t fr on t wh eel F ill t h e bleeder t a n k wit h r ecom m en ded flu id a n d
• left fr on t wh eel pu r ge a ir fr om t h e t a n k lin es befor e bleedin g.
Do n ot pr essu r e bleed wit h ou t a pr oper m a st er cyl-
M AN U AL BLEEDI N G in der a da pt er. Th e wr on g a da pt er ca n lea d t o lea k-
(1) Rem ove r eser voir filler ca ps a n d fill r eser voir a ge, or dr a win g a ir ba ck in t o t h e syst em .
wit h Mopa r, or equ iva len t qu a lit y DOT 3 br a ke flu id.
(2) If ca liper s, or wh eel cylin der s wer e over h a u led, DISC ROTOR MACHINING
open a ll ca liper a n d wh eel cylin der bleed scr ews. Rot or br a kin g su r fa ces ca n be sa n ded or m a ch in ed
Th en close ea ch bleed scr ew a s flu id st a r t s t o dr ip in a disc br a ke la t h e.
fr om it . Top off m a st er cylin der r eser voir on ce m or e Th e la t h e m u st m a ch in e bot h sides of t h e r ot or
befor e pr oceedin g. sim u lt a n eou sly wit h du a l (t wo) cu t t er h ea ds (F ig.
(3) At t a ch on e en d of bleed h ose t o bleed scr ew 14). E qu ipm en t ca pa ble of m a ch in in g on ly on e side a t
a n d in ser t opposit e en d in gla ss con t a in er pa r t ia lly a t im e will pr odu ce a t a per ed r ot or.
filled wit h br a ke flu id (F ig. 13). Be su r e en d of bleed Th e la t h e sh ou ld a lso be equ ipped wit h a gr in der
h ose is im m er sed in flu id. a t t a ch m en t or du a l sa n din g discs for fin a l clea n u p or
ligh t r efin ish in g (F ig. 15).
If t h e r ot or su r fa ces on ly n eed m in or clea n u p of
r u st , sca le, or m in or scor in g, u se a br a sive discs t o
clea n u p t h e r ot or su r fa ces. H owever, wh en a r ot or is
scor ed or wor n , m a ch in in g wit h cu t t in g t ools will be
r equ ir ed.
BLEED _ __ CAUTION: Do not machine the rotor if it will cause
HOSE the rotor to fall below minimum allowable thick-
ness.
XJ BRAKES 5 - 13
SERV I CE PROCEDU RES (Cont inue d)
FLARI N G PROCEDU RE
(1) Cu t off da m a ged t u be wit h Tu bin g Cu t t er.
(2) Rea m cu t edges of t u bin g t o en su r e pr oper
fla r e.
(3) In st a ll r epla cem en t t u be n u t on sect ion of t u be
t o be r epa ir ed.
(4) In ser t t u be in fla r in g t ool. Cen t er t u be in a r ea
bet ween ver t ica l post s.
(5) P la ce ga u ge for m over t h e en d of t h e t u be.
(6) P u sh t u bin g t h r ou gh fla r in g t ool ja ws u n t il
t u be con t a ct s r ecessed n ot ch in ga u ge t h a t m a t ch es
t u be dia m et er.
(7) Squ eeze fla r in g t ool ja ws t o lock t u bin g in
pla ce.
(8) In ser t plu g on ga u ge in t h e t u be. Th en swin g
com pr ession disc over ga u ge a n d cen t er t a per ed fla r-
in g scr ew in r ecess of com pr ession disc (F ig. 16).
(9) Tigh t en t ool h a n dle u n t il plu g ga u ge is sea t ed
on ja ws of fla r in g t ool. Th is will st a r t t h e in ver t ed
fla r e.
(10) Rem ove t h e plu g ga u ge a n d com plet e t h e
in ver t ed fla r e.
(11) Rem ove t h e fla r in g t ools a n d ver ify t h a t t h e
in ver t ed fla r e is cor r ect .
[ RH222
PR795A
Fig. 16 Inverted Flare Tools
Fig. 15 Rotor Grinder REM OVAL AN D I N STALLAT I ON
st eel lin e ca n be u sed for em er gen cy r epa ir wh en fa c-
t or y r epla cem en t pa r t s a r e n ot r ea dily a va ila ble. STOP LAMP SWITCH
Specia l, h ea vy du t y t u be ben din g a n d fla r in g
equ ipm en t is r equ ir ed t o pr epa r e dou ble wa ll br a ke REM OVAL
lin e. Specia l ben din g t ools a r e n eeded t o a void kin k- (1) Rem ove st eer in g colu m n cover a n d lower t r im
in g or t wist in g m et a l br a ke lin e. In a ddit ion , specia l pa n el for swit ch a ccess (if n ecessa r y).
fla r in g t ools a r e n eeded t o pr ovide t h e in ver t ed-t ype, (2) P r ess br a ke peda l down wa r d t o fu lly a pplied
dou ble fla r e r equ ir ed on m et a l br a ke lin es. posit ion .
SWITCH PLUNGERRETAINER TERMINALS BRAKE
WIRE PEDAL
HARNESS
NECTOR
CON- SWITCH TERMI-
NAL BUSHINGCOMBINATION
BOOSTERVALVE
ROD
5 - 14 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rot a t e swit ch a ppr oxim a t ely 30° in cou n t er-
~
clockwise dir ect ion t o u n lock swit ch r et a in er. Th en
pu ll swit ch r ea r wa r d a n d ou t of br a cket .
(4) Discon n ect swit ch wir e h a r n ess a n d r em ove
swit ch fr om veh icle (F ig. 17).
i!J BOOSTER
ROD
80ab88a7
BRAKE PEDAL
REM OVAL
(1) Rem ove kn ee blocker u n der t h e st eer in g col-
umn.
(2) Rem ove r et a in er clip secu r in g boost er pu sh r od
t o peda l (F ig. 18).
(3) Rem ove st op la m p swit ch .
(4) Rem ove n u t s secu r in g t h e boost er t o t h e peda l
su ppor t br a cket a n d n u t s t o t h e colu m n br a cket .
(5) Rem ove peda l a n d su ppor t br a cket a s a n
a ssem bly fr om t h e veh icle.
I N STALLAT I ON
(1) In st a ll peda l a n d su ppor t br a cket a s a n a ssem -
bly in t o t h e veh icle. WIRE HARNESS
COMBINATION
VALVE
(2) In st a ll n u t s secu r in g t h e boost er t o t h e peda l CONNECTOR
8031e88c
su ppor t br a cket a n d n u t s t o t h e colu m n br a cket .
(3) Tigh t en n u t s t o 39 N·m (29 ft . lbs.).
Fig. 19 Differential Pressure Switch
COMBINATION VALVE MASTER CYLINDER BRAKEPEDAL BUSHING BOOSTER ROD
XJ BRAKES 5 - 15
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Discon n ect br a ke lin es a t com bin a t ion va lve (1) Rem ove pr ot ect ive sleeve fr om pr im a r y pist on
(F ig. 20). sh a n k on n ew m a st er cylin der.
(2) Clea n cylin der m ou n t in g su r fa ce of br a ke
boost er.
(3) In st a ll m a st er cylin der on t o br a ke boost er
st u ds.
(4) In st a ll m ou n t in g n u t s a n d t igh t en t o 17.5 N·m
(155 in . lbs.).
(5) In st a ll com bin a t ion va lve a n d in st a ll m ou n t in g
n u t s.
(6) Con n ect br a ke lin es t o m a st er cylin der a n d
com bin a t ion va lve a n d t igh t en t o 19 N·m (170 in .
lbs.).
(7) Con n ect differ en t ia l pr essu r e swit ch wir e t o t h e
com bin a t ion va lve.
MASTER
(8) On RH D veh icles in st a ll t h e coola n t r eser ve/
CYLINDER
over flow t a n k. Refer t o Gr ou p 7 Coolin g Syst em .
8031e88d
(9) F ill a n d bleed br a ke syst em .
Fig. 20 Combination Valve
POWER BRAKE BOOSTER
(4) Rem ove m ou n t in g n u t a n d r em ove va lve.
REM OVAL
I N STALLAT I ON (1) On RH D veh icles r em ove t h e coola n t r eser ve/
(1) In st a ll va lve a n d t igh t en m ou n t in g n u t t o 17 over flow t a n k. Refer t o Gr ou p 7 Coolin g Syst em .
N·m (155 in . lbs.). (2) Discon n ect br a ke lin es a t m a st er cylin der.
(2) Con n ect br a ke lin es t o r epla cem en t va lve. St a r t (3) Discon n ect wir e a t com bin a t ion va lve differ en -
lin e fit t in gs by h a n d t o a void cr oss t h r ea din g. t ia l pr essu r e swit ch .
(3) Tigh t en br a ke lin e fit t in gs t o 19 N·m (170 in . (4) Rem ove n u t m ou n t in g com bin a t ion va lve
lbs.). br a cket t o boost er st u ds a n d r em ove va lve.
(4) Con n ect wir e t o pr essu r e differ en t ia l swit ch . (5) Rem ove n u t s m ou n t in g m a st er cylin der t o
(5) Bleed br a kes. boost er st u ds a n d r em ove cylin der.
(6) Discon n ect va cu u m h ose fr om boost er ch eck
MASTER CYLINDER va lve.
(7) Rem ove kn ee blocker u n der t h e st eer in g col-
REM OVAL umn.
(1) On RH D veh icles r em ove t h e coola n t r eser ve/ (8) Rem ove r et a in in g clip t h a t secu r es boost er
over flow t a n k. Refer t o Gr ou p 7 Coolin g Syst em . pu sh r od t o br a ke peda l (F ig. 21).
(2) Rem ove br a ke lin es a t m a st er cylin der a n d (9) Rem ove n u t s a t t a ch in g boost er t o pa ssen ger
com bin a t ion va lve (F ig. 20). com pa r t m en t side of da sh pa n el (F ig. 22).
(3) Discon n ect differ en t ia l pr essu r e swit ch wir e
~
fr om t h e com bin a t ion va lve.
(4) Rem ove m ou n t in g n u t s fr om t h e com bin a t ion
va lve br a cket a n d r em ove t h e va lve (F ig. 20).
(5) Rem ove m ou n t in g n u t s fr om t h e m a st er cylin -
der.
(6) Rem ove m a st er cylin der.
i!J BOOSTER
ROD
(7) Rem ove cylin der cover a n d dr a in flu id.
(8) If m a st er cylin der r eser voir r equ ir es ser vice,
r efer t o r eser voir r epla cem en t pr ocedu r e in t h is sec-
t ion .
I N STALLAT I ON
5 - 16 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
BOOSTER (13) Con n ect wir e t o com bin a t ion va lve swit ch .
(14) On RH D veh icles in st a ll t h e coola n t r eser ve/
over flow t a n k. Refer t o Gr ou p 7 Coolin g Syst em .
(15) F ill a n d bleed br a ke syst em .
(16) Ver ify pr oper br a ke oper a t ion befor e m ovin g
veh icle.
I N STALLAT I ON
(1) In st a ll da sh sea l on boost er.
(2) Align a n d posit ion boost er on da sh pa n el.
(3) In pa ssen ger com pa r t m en t , in st a ll boost er
m ou n t in g n u t s. Tigh t en n u t s ju st en ou gh t o h old
boost er in pla ce.
(4) Slide boost er pu sh r od on t o t h e br a ke peda l.
Th en secu r e pu sh r od t o peda l pin wit h r et a in in g
clip.
XJ BRAKES 5 - 17
REM OVAL AN D I N STALLAT I ON (Cont inue d)
TILT
CALIPER
{/ FITTING OUTBOARD
TO REMOVE
_!i~
\ ~ WASHERS
J9005-30
CALIPERS
8031e88f
5 - 18 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SHOE
SPRING
BRAKES HOE
TABON
LEDGE OUTER
SURFACE
J9005-83
1/
BOTTOM
LEDGE
J9005-35
r:i7~;
CORRECT SHANK LENGTH:
I: gg,~;!;:;--
;o
CALIPER 22 mm ,
C
I,
--11
Fig. 31 Inboard Brake Shoe Removal
BOLT (0.866 in.) •
THREAD LENGTH (2) St a r t in g on e en d of ou t boa r d sh oe in ca liper
a n d r ot a t in g sh oe down wa r d in t o pla ce. Ver ify sh oe
J9405-154 loca t in g lu gs a n d sh oe spr in g a r e sea t ed.
(3) In st a ll ca liper.
Fig. 29 Mounting Bolt Dimensions (4) In st a ll wh eel a n d t ir e a ssem bly.
(5) Rem ove su ppor t a n d lower veh icle.
NOTE: If original brake shoes will be used, keep (6) P u m p br a ke peda l u n t il ca liper pist on s a n d
them in sets left and right. They are not inter- br a ke sh oes a r e sea t ed.
changeable. (7) Top off br a ke flu id level if n ecessa r y.
(6) Secu r e ca liper t o n ea r by su spen sion pa r t wit h
wir e. D o n o t a llo w bra k e h o s e to s u p p o rt c a lip e r
DISC BRAKE ROTOR
w e ig h t. REM OVAL
(7) Wipe ca liper off wit h sh op r a gs or t owels. (1) Rem ove wh eel a n d t ir e a ssem ble.
(2) Rem ove ca liper.
CAUTION: Do not use compressed air, this can
(3) Rem ove r et a in er s secu r in g r ot or t o h u b st u ds
unseat dust boot and force dirt into piston bore.
(F ig. 32).
(4) Rem ove r ot or fr om h u b.
I N STALLAT I ON (5) If r ot or sh ield r equ ir es ser vice, r em ove fr on t
(1) In st a ll in boa r d sh oe in ca liper a n d ver ify sh oe h u b a n d bea r in g a ssem bly.
r et a in in g is fu lly sea t ed in t o t h e pist on .
ADJUSTER
RIGHT REAR
ASSEMBLY
CABLE
LEVER
SHOE
ADJUSTER
GUIDE
BRAKE
HOLDDOWN
SPRINGS
CABLE
RETURN
AND RETAINERS
SPRING ROTOR
SHOE
ADJUSTER
LEVERSPRING
GUIDE
PLATE
WASHER
RETAINER
LEADING
PIN BEARING
TRAILING
COTTER
NUT
PARK
SHOE
LOCK
NUT
SHOE
PIN
BRAKE
LEVER
SHOE
SPRING SPRING
HOLDDOWN
RETAINERS
ADJUSTER
AND CABLE
ASSEMBLY
SCREW
HOLE
PARK
SUPPORT
PLUG
CYLINDER-TO-
SUPPORT
BRAKE
HOLDDOWN
AND
PLATE
SPRING
STRUT
SEAL
PINS
ACCESS
PLUGS
XJ BRAKES 5 - 19
REM OVAL AN D I N STALLAT I ON (Cont inue d)
a t t h e r ea r of ba ckin g pla t e a n d ba ck off a dju st er
scr ew wit h br a ke t ool a n d scr ewdr iver.
(4) Rem ove U-clip a n d wa sh er secu r in g a dju st er
ca ble t o pa r kin g br a ke lever (F ig. 33).
(5) Rem ove pr im a r y a n d secon da r y r et u r n spr in gs
fr om a n ch or pin wit h br a ke spr in g plier s.
(6) Rem ove h old-down spr in gs, r et a in er s a n d pin s
wit h st a n da r d r et a in in g spr in g t ool.
(7) In st a ll spr in g cla m ps on wh eel cylin der s t o
h old pist on s in pla ce.
(8) Rem ove a dju st er lever, a dju st er scr ew a n d
spr in g.
(9) Rem ove a dju st er ca ble a n d ca ble gu ide.
(10) Rem ove br a ke sh oes a n d pa r kin g br a ke st r u t .
J9005-52
(11) Discon n ect ca ble fr om pa r kin g br a ke lever a n d
Fig. 32 Rotor & Hub r em ove lever .
I N STALLAT I ON I N STALLAT I ON
(1) If n ew r ot or is bein g in st a lled, r em ove pr ot ec- (1) Clea n su ppor t pla t e wit h br a ke clea n er.
t ive coa t in g fr om r ot or su r fa ces wit h ca r bu r et or (2) If n ew dr u m s a r e bein g in st a lled, r em ove pr o-
clea n er. t ect ive coa t in g wit h ca r bu r et or clea n er followed by
(2) In st a ll r ot or on h u b. fin a l r in se wit h br a ke clea n er.
(3) In st a ll ca liper. (3) Clea n a n d lu br ica t e a n ch or pin wit h ligh t coa t
(4) In st a ll n ew spr in g n u t s on wh eel st u ds. of Mopa r m u lt i-m ilea ge gr ea se.
(5) In st a ll wh eel a n d t ir e a ssem bly. (4) Apply Mopa r m u lt i-m ilea ge gr ea se t o br a ke
sh oe con t a ct su r fa ces of su ppor t pla t e (F ig. 34).
DRUM BRAKE SHOES (5) Lu br ica t e a dju st er scr ew t h r ea ds a n d pivot
wit h spr a y lu be.
REM OVAL (6) At t a ch pa r kin g br a ke lever t o secon da r y br a ke
(1) Ra ise veh icle a n d r em ove r ea r wh eels. sh oe. Use n ew wa sh er a n d U-clip t o secu r e lever.
(2) Rem ove a n d disca r d spr in g n u t s secu r in g (7) Rem ove wh eel cylin der cla m ps.
dr u m s t o wh eel st u ds. (8) At t a ch pa r kin g br a ke ca ble t o lever.
(3) Rem ove br a ke dr u m s. If dr u m s pr ove difficu lt
t o r em ove, r et r a ct br a ke sh oes. Rem ove a ccess plu g
RIGHT REAR
BRAKE ASSEMBLY ADJUSTER
LEVER
HOLDDOWN SPRING
SPRING AND HOLDDOWN PINS
RETAINERS ~ .
ADJUSTER .
CABLE , .
SUPPORT PLATE
SHOE
RETURN
SPRINGS
J9005-13
5 - 20 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
BRAKE SUPPORT PLATE
REM OVAL
(1) Rem ove wh eel a n d t ir e a ssem bly a n d br a ke
dr u m .
(2) Rem ove br a ke sh oe a ssem bly.
(3) Rem ove pa r kin g br a ke ca ble fr om pa r kin g
br a ke lever.
(4) Com pr ess pa r kin g br a ke ca ble r et a in er t a bs
wit h a h ose cla m p (F ig. 35). Th en pu sh r et a in er a n d
ca ble t h r ou gh a n d ou t of su ppor t pla t e.
J9005-14
XJ BRAKES 5 - 21
REM OVAL AN D I N STALLAT I ON (Cont inue d)
REAR PARKING BRAKE CABLES I N STALLAT I ON
(1) In st a ll n ew ca bles in ba ckin g pla t es. Be su r e
REM OVAL ca ble r et a in er is sea t ed.
(1) Ra ise veh icle a n d loosen equ a lizer n u t s u n t il (2) At t a ch ca ble t o lever on br a ke sh oe a n d in st a ll
r ea r ca bles a r e sla ck. br a ke sh oe on ba ckin g pla t e.
(2) Disen ga ge ca bles fr om equ a lizer a n d com pr ess (3) Adju st br a ke sh oes t o dr u m wit h br a ke ga u ge.
ca ble r et a in er s wit h a wor m dr ive h ose cla m p. (4) In st a ll br a ke dr u m s a n d wh eels.
(3) Rem ove ca bles fr om t h e ca ble br a cket (F ig. 36). (5) In st a ll ca bles in t o t h e ca ble br a cket a n d in su r e
(4) Rem ove r ea r wh eel a n d br a ke dr u m s. r et a in er s a r e sea t ed in t h e br a cket .
(5) Rem ove secon da r y br a ke sh oe a n d discon n ect (6) E n ga ge t h e ca ble en ds in t o t h e equ a lizer a n d
ca ble fr om lever on br a ke sh oe. in st a ll equ a lizer n u t .
(6) Com pr ess ca bles r et a in er wit h wor m dr ive h ose (7) Adju st pa r kin g br a kes.
cla m p (F ig. 37) a n d r em ove ca bles fr om ba ckin g
pla t es. PARKING BRAKE LEVER
Th e cen t er con sole m u st be r em oved t o ser vice t h e
EQUALIZER pa r kin g br a ke lever. Refer t o Gr ou p 23 In t er ior Com -
~ - - - . ~ CABLE
pon en t s for ser vice pr ocedu r es.
D REM OVAL
(1) Relea se pa r kin g br a kes.
(2) Ra ise veh icle.
(3) Rem ove a dju st in g n u t fr om t en sion er r od a t t h e
equ a lizer (F ig. 38).
I N STALLAT I ON
(1) In st a ll pa r kin g br a ke la m p swit ch .
Fig. 37 Cable Retainer (2) P osit ion lever a ssem bly on floor pa n a n d in st a ll
lever m ou n t in g bolt s.
PARKING
MOUNTING
BRAKE
LEVER
PARKING
BOLTS BRAKE SWITCH FRONT CABLE LEVER PRY GROMMETS
TOOL PIN PUNCH
MASTER CYLINDER
ROLL
BODY
PINS RESERVOIR
RESERVOIR
RESERVOIR
GROMMET
BODY
5 - 22 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
FRONT CABLE
LEVER
XJ BRAKES 5 - 23
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
J9505-49
5 - 24 BRAKES XJ
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
BOOT
COLLAPSE BOOT
WITH PUNCH
OR SCREWDRIVER
DUST
BOOT
CALIPER
SLIDE BOOT J9005-75
BUSHING J9005-73
Fig. 49 Mounting Bolt Bushing And Boot Fig. 52 Dust Boot On Piston
(4) In st a ll n ew pist on sea l in t o sea l gr oove wit h (9) Repla ce ca liper bleed scr ew if r em oved.
fin ger (F ig. 51).
(5) In st a ll du st boot on ca liper pist on a n d sea t boot WHEEL CYLINDER
in pist on gr oove (F ig. 52).
DI SASSEM BLY
(6) P r ess pist on in t o ca liper bor e by h a n d, u se a
(1) Rem ove pu sh r ods a n d boot s (F ig. 55).
t u r n a n d pu sh m ot ion t o wor k pist on in t o sea l (F ig.
(2) P r ess pist on s, cu ps a n d spr in g a n d expa n der
53).
ou t of cylin der bor e.
(7) P r ess ca liper pist on t o bot t om of bor e.
(3) Rem ove bleed scr ew.
(8) Sea t du st boot in ca liper wit h In st a ller Tool
C-4842 a n d Tool H a n dle C-4171 (F ig. 54).
PISTON
CUP
BOOTEXPAND-
ERS BLEED
SPRING
SCREWCYLINDER
DUST BOOT
PISTON
PUSH
HANDLE
PISTON
C-4171
ROD INSTALLER
CLIP CBOOT
-4842
XJ BRAKES 5 - 25
DI SASSEM BLY AN D ASSEM BLY (Cont inue d)
ASSEM BLY
(1) Lu br ica t e wh eel cylin der bor e, pist on s, pist on
cu ps a n d spr in g a n d expa n der wit h clea n br a ke flu id.
(2) In st a ll fir st pist on in cylin der bor e. Th en
in st a ll fir st cu p in bor e a n d a ga in st pist on . B e s u re
lip o f p is to n c u p is fa c in g in w a rd (to w a rd
s p rin g a n d e x p a n d e r) a n d fla t s id e is a g a in s t
p is to n .
(3) In st a ll spr in g a n d expa n der followed by
r em a in in g pist on cu p a n d pist on .
(4) In st a ll boot s on ea ch en d of cylin der a n d in ser t
pu sh r ods in boot s.
(5) In st a ll cylin der bleed scr ew.
J9105-32
CLEAN I N G AN D I N SPECT I ON
Fig. 53 Caliper Piston Installation CALIPER
CLEAN I N G
Clea n t h e ca liper com pon en t s wit h clea n br a ke
flu id or br a ke clea n on ly. Wipe t h e ca liper a n d pist on
dr y wit h lin t fr ee t owels or u se low pr essu r e com -
pr essed a ir.
I N SPECT I ON
Th e pist on is m a de fr om a ph en olic r esin (pla st ic
m a t er ia l) a n d sh ou ld be sm oot h a n d clea n .
Th e pist on m u st be r epla ced if cr a cked or scor ed.
Do n ot a t t em pt t o r est or e a scor ed pist on su r fa ce by
sa n din g or polish in g.
5 - 26 BRAKES XJ
CLEAN I N G AN D I N SPECT I ON (Cont inue d)
CALIPER
J9005-14
Fig. 56 Polishing Piston Bore
sca le fr om t h e br a ke sh oe con t a ct pa ds on t h e su p- Fig. 57 Shoe Contact Surfaces
por t pla t e wit h fin e sa n dpa per. Th e cylin der bor e ca n be ligh t ly polish ed bu t on ly
wit h cr ocu s clot h . Repla ce t h e cylin der if t h e bor e is
I N SPECT I ON scor ed, pit t ed or h ea vily cor r oded. H on in g t h e bor e t o
As a gen er a l r u le, r ivet ed br a ke sh oes sh ou ld be r est or e t h e su r fa ce is n ot r ecom m en ded.
r epla ced wh en wor n t o wit h in 0.78 m m (1/32 in .) of In spect t h e cylin der pist on s. Th e pist on su r fa ces
t h e r ivet h ea ds. Bon ded lin in g sh ou ld be r epla ced sh ou ld be sm oot h a n d fr ee of scr a t ch es, scor in g a n d
wh en wor n t o a t h ickn ess of 1.6 m m (1/16 in .). cor r osion . Repla ce t h e pist on s if wor n , scor ed, or cor-
E xa m in e t h e lin in g con t a ct pa t t er n t o det er m in e if r oded. Do a t t em pt t o r est or e t h e su r fa ce by sa n din g
t h e sh oes a r e ben t or t h e dr u m is t a per ed. Th e lin in g or polish in g.
sh ou ld exh ibit con t a ct a cr oss it s en t ir e widt h . Sh oes Disca r d t h e old pist on cu ps a n d t h e spr in g a n d
exh ibit in g con t a ct on ly on on e side sh ou ld be expa n der. Th ese pa r t s a r e n ot r eu sa ble. Th e or igin a l
r epla ced a n d t h e dr u m ch ecked for r u n ou t or t a per. du st boot s m a y be r eu sed bu t on ly if t h ey a r e in good
In spect t h e a dju st er scr ew a ssem bly. Repla ce t h e con dit ion .
a ssem bly if t h e st a r wh eel or t h r ea ds a r e da m a ged,
or t h e com pon en t s a r e sever ely r u st ed or cor r oded.
Disca r d t h e br a ke spr in gs a n d r et a in er com pon en t s ADJ U ST M EN T S
if wor n , dist or t ed or colla psed. Also r epla ce t h e
spr in gs if a br a ke dr a g con dit ion h a d occu r r ed. Over- STOP LAMP SWITCH
h ea t in g will dist or t a n d wea ken t h e spr in gs. (1) P r ess a n d h old br a ke peda l in a pplied posit ion .
In spect t h e br a ke sh oe con t a ct pa ds on t h e su ppor t (2) P u ll swit ch plu n ger a ll t h e wa y ou t t o fu lly
pla t e, r epla ce t h e su ppor t pla t e if a n y of t h e pa ds a r e ext en ded posit ion .
wor n or r u st ed t h r ou gh . Also r epla ce t h e pla t e if it is (3) Relea se br a ke peda l. Th en pu ll peda l fu lly r ea r-
ben t or dist or t ed (F ig. 57). wa r d. P eda l will set plu n ger t o cor r ect posit ion a s
peda l pu sh es plu n ger in t o swit ch body. Swit ch will
WHEEL CYLINDER m a ke r a t ch et in g sou n d a s it self a dju st s.
XJ BRAKES 5 - 27
ADJ U ST M EN T S (Cont inue d)
(2) Ra ise r ea r of veh icle a n d r em ove wh eels a n d t im es t o oper a t e a u t om a t ic a dju st er s a n d equ a lize
br a ke dr u m s. a dju st m en t .
(3) Ver ify t h a t left a n d r igh t a u t om a t ic a dju st er
lever s a n d ca bles a r e pr oper ly con n ect ed. NOTE: Bring vehicle to complete standstill at each
(4) In ser t br a ke ga u ge in dr u m . E xpa n d ga u ge stop. Incomplete, rolling stops will not activate
u n t il ga u ge in n er legs con t a ct dr u m br a kin g su r fa ce. automatic adjusters.
Th en lock ga u ge in posit ion (F ig. 58).
ADJ U ST M EN T WI T H ADJ U ST I N G T OOL
(1) Be su r e pa r kin g br a ke lever is fu lly r elea sed.
(2) Ra ise veh icle so r ea r wh eels ca n be r ot a t ed
fr eely.
(3) Rem ove plu g fr om ea ch a ccess h ole in br a ke
su ppor t pla t es.
(4) Loosen pa r kin g br a ke ca ble a dju st m en t n u t
u n t il t h er e is sla ck in fr on t ca ble.
(5) In ser t a dju st in g t ool t h r ou gh su ppor t pla t e
a ccess h ole a n d en ga ge t ool in t eet h of a dju st in g
scr ew st a r wh eel (F ig. 60).
J9005-26
5 - 28 BRAKES XJ
ADJ U ST M EN T S (Cont inue d)
NOTE: Bring vehicle to complete standstill at each
stop. Incomplete, rolling stops will not activate TENSIONER TENSIONER
automatic adjusters. BRACKET ROD
6.5 mm
-j r(l/4 in.)
ADJ U ST M EN T
(1) Ra ise veh icle. J9405-158
(2) Ba ck off t en sion er a dju st in g n u t t o cr ea t e sla ck
in ca bles. Fig. 61 Tensioner Rod Measurement
(3) Rem ove r ea r wh eel/t ir e a ssem blies a n d r em ove SPECI FI CAT I ON S
br a ke dr u m s.
(4) Ch eck r ea r br a ke sh oe a dju st m en t wit h st a n - BRAKE FLUID
da r d br a ke ga u ge. Ex c e s s iv e s h o e -to -d ru m c le a r- Th e br a ke flu id u sed in t h is veh icle m u st con for m
a n c e , o r w o rn bra k e c o m p o n e n ts w ill re s u lt in t o DOT 3 specifica t ion s a n d SAE J 1703 st a n da r ds.
fa u lty p a rk in g bra k e a d ju s tm e n t a n d o p e ra tio n . No ot h er t ype of br a ke flu id is r ecom m en ded or
(5) Ver ify t h a t pa r kin g br a ke ca bles oper a t e fr eely a ppr oved for u sa ge in t h e veh icle br a ke syst em . Use
a n d a r e n ot bin din g, or seized. Repla ce fa u lt y ca bles, on ly Mopa r br a ke flu id or a n equ iva len t fr om a
befor e pr oceedin g. t igh t ly sea led con t a in er.
(6) Rein st a ll br a ke dr u m s a n d wh eel/t ir e a ssem -
blies a ft er br a ke sh oe a dju st m en t is com plet e. CAUTION: Never use reclaimed brake fluid or fluid
(7) Lower veh icle en ou gh for a ccess t o pa r kin g from an container which has been left open. An
br a ke lever. Th en fu lly a pply pa r kin g br a kes. Lea ve open container will absorb moisture from the air
br a kes a pplied u n t il a dju st m en t is com plet e. and contaminate the fluid.
(8) Ra ise veh icle a n d m a r k t en sion er r od 6.5 m m
(1/4 in .) fr om t en sion er br a cket (F ig. 61).
(9) Tigh t en a dju st in g n u t a t equ a lizer u n t il m a r k CAUTION: Never use any type of a petroleum-
on t en sion er r od m oves in t o a lign m en t wit h t en sion er based fluid in the brake hydraulic system. Use of
br a cket . such type fluids will result in seal damage of the
(10) Lower veh icle u n t il r ea r wh eels a r e 15-20 cm vehicle brake hydraulic system causing a failure of
(6-8 in .) off sh op floor. the vehicle brake system. Petroleum based fluids
(11) Relea se pa r kin g br a ke lever a n d ver ify t h a t would be items such as engine oil, transmission
r ea r wh eels r ot a t e fr eely wit h ou t dr a g. fluid, power steering fluid ect.
(12) Lower veh icle.
5 - 30 BRAKES XJ
AN T I LOCK BRAK ES
INDEX
page page
CYLINDER
BOOSTER HCU/
CAB
HARNESS
ACCELERATION
SWITCH
WIRES TO
WHEEL
V
ca lly oper a t ed, a ll wh eel br a ke con t r ol syst em . I SPEED
Th e syst em is design ed t o pr even t wh eel locku p : SENSORS
a n d m a in t a in st eer in g con t r ol du r in g per iods of h igh
COMBINATION :
wh eel slip wh en br a kin g. P r even t in g locku p is a ccom - VALVE _:I _ ~~
plish ed by m odu la t in g flu id pr essu r e t o t h e wh eel _c ___ - I
br a ke u n it s. HYDRAULIC ~I.:::::.:::._- I I
I
ca l cir cu it s in t h e veh icle. A specia lly pr ogr a m m ed I
I
con t r oller a n t ilock br a ke u n it oper a t es t h e syst em
com pon en t s.
I
ABS syst em m a jor com pon en t s in clu de: 80a5ce11 L-------------------~
• Con t r oller An t ilock Br a kes (CAB)
• H ydr a u lic Con t r ol Un it (H CU) Fig. 1 Antilock Brake System
• Wh eel Speed Sen sor s (WSS) wh eel r ot a t ion begin s a ppr oa ch in g 20 t o 30 per cen t of
• Acceler a t ion Swit ch a ct u a l veh icle speed du r in g br a kin g. P er iods of h igh
• ABS Wa r n in g Ligh t wh eel slip occu r wh en br a ke st ops in volve h igh peda l
pr essu r e a n d r a t e of veh icle deceler a t ion .
DESCRI PT I ON AN D OPERAT I ON Ba t t er y volt a ge is su pplied t o t h e CAB ign it ion t er-
m in a l wh en t h e ign it ion swit ch is t u r n ed t o Ru n posi-
ANTILOCK BRAKE SYSTEM t ion . Th e CAB per for m s a syst em in it ia liza t ion
pr ocedu r e a t t h is poin t . In it ia liza t ion con sist s of a
Th e pu r pose of t h e a n t ilock syst em is t o pr even t
st a t ic a n d dyn a m ic self ch eck of syst em elect r ica l
wh eel locku p du r in g per iods of h igh wh eel slip. P r e-
com pon en t s.
ven t in g locku p h elps m a in t a in veh icle br a kin g a ct ion
Th e st a t ic ch eck occu r s a ft er t h e ign it ion swit ch is
a n d st eer in g con t r ol.
t u r n ed t o Ru n posit ion . Th e dyn a m ic ch eck occu r s
Th e a n t ilock CAB a ct iva t es t h e syst em wh en ever
wh en veh icle r oa d speed r ea ch es a ppr oxim a t ely 30
sen sor sign a ls in dica t e per iods of h igh wh eel slip.
kph (18 m ph ). Du r in g t h e dyn a m ic ch eck, t h e CAB
H igh wh eel slip ca n be descr ibed a s t h e poin t wh er e
HCU MOTORCAB
XJ BRAKES 5 - 31
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
br iefly cycles t h e pu m p a n d solen oids t o ver ify oper- ABS fa u lt s r em a in in m em or y u n t il clea r ed, or
a t ion . u n t il a ft er t h e veh icle is st a r t ed a ppr oxim a t ely 50
If a n ABS com pon en t exh ibit s a fa u lt du r in g in i- t im es. St or ed fa u lt s a r e n o t er a sed if t h e ba t t er y is
t ia liza t ion , t h e CAB illu m in a t es t h e a m ber wa r n in g discon n ect ed.
ligh t a n d r egist er s a fa u lt code in t h e m icr opr ocessor
m em or y.
N ORM AL BRAK I N G
Du r in g n or m a l br a kin g, t h e m a st er cylin der, power
boost er a n d wh eel br a ke u n it s a ll fu n ct ion a s t h ey
wou ld in a veh icle wit h ou t ABS. Th e H CU com po-
n en t s a r e n ot a ct iva t ed.
AN T I LOCK BRAK I N G
Th e a n t ilock syst em pr even t s locku p du r in g h igh
slip con dit ion s by m odu la t in g flu id a pply pr essu r e t o CAB
t h e wh eel br a ke u n it s.
Br a ke flu id a pply pr essu r e is m odu la t ed a ccor din g
t o wh eel speed, degr ee of slip a n d r a t e of deceler a -
t ion . A sen sor a t ea ch wh eel con ver t s wh eel speed
in t o elect r ica l sign a ls. Th ese sign a ls a r e t r a n sm it t ed
t o t h e CAB for pr ocessin g a n d det er m in a t ion of Fig. 2 Controller Antilock Brakes
wh eel slip a n d deceler a t ion r a t e. HYDRAULIC CONTROL UNIT
Th e ABS syst em h a s t h r ee flu id pr essu r e con t r ol Th e H CU con sist s of a va lve body, pu m p body,
ch a n n els. Th e fr on t br a kes a r e con t r olled sepa r a t ely a ccu m u la t or s, pu m p m ot or, a n d wir e h a r n esses (F ig.
a n d t h e r ea r br a kes in t a n dem . A speed sen sor in pu t 2).
sign a l in dica t in g a h igh slip con dit ion a ct iva t es t h e Th e pu m p, m ot or, a n d a ccu m u la t or s a r e com bin ed
CAB a n t ilock pr ogr a m . in t o a n a ssem bly a t t a ch ed t o t h e va lve body. Th e
Two solen oid va lves a r e u sed in ea ch a n t ilock con - a ccu m u la t or s st or e t h e ext r a flu id r elea sed t o t h e
t r ol ch a n n el. Th e va lves a r e a ll loca t ed wit h in t h e syst em for ABS m ode oper a t ion . Th e pu m p pr ovides
H CU va lve body a n d wor k in pa ir s t o eit h er in cr ea se, t h e flu id volu m e n eeded a n d is oper a t ed by a DC
h old, or decr ea se a pply pr essu r e a s n eeded in t h e t ype m ot or. Th e m ot or is con t r olled by t h e CAB.
in dividu a l con t r ol ch a n n els. Th e va lve body con t a in s t h e solen oid va lves. Th e
Th e solen oid va lves a r e n ot st a t ic du r in g a n t ilock va lves m odu la t e br a ke pr essu r e du r in g a n t ilock br a k-
br a kin g. Th ey a r e cycled con t in u ou sly t o m odu la t e in g a n d a r e con t r olled by t h e CAB.
pr essu r e. Solen oid cycle t im e in a n t ilock m ode ca n be Th e H CU pr ovides t h r ee ch a n n el pr essu r e con t r ol
m ea su r ed in m illisecon ds. t o t h e fr on t a n d r ea r br a kes. On e ch a n n el con t r ols
t h e r ea r wh eel br a kes in t a n dem . Th e t wo r em a in in g
CONTROLLER ANTILOCK BRAKES ch a n n els con t r ol t h e fr on t wh eel br a kes in dividu a lly.
Th e CAB m on it or s wh eel speed sen sor in pu t s con - Du r in g a n t ilock br a kin g, t h e solen oid va lves a r e
t in u ou sly wh ile t h e veh icle is in m ot ion . H owever, open ed a n d closed a s n eeded. Th e va lves a r e n ot
t h e CAB will n ot a ct iva t e a n y ABS com pon en t s a s st a t ic. Th ey a r e cycled r a pidly a n d con t in u ou sly t o
lon g a s sen sor in pu t s a n d t h e a cceler a t ion swit ch m odu la t e pr essu r e a n d con t r ol wh eel slip a n d decel-
in dica t e n or m a l br a kin g. er a t ion .
Th e CAB is m ou n t ed t o t h e H CU a n d oper a t es t h e Du r in g n or m a l br a kin g, t h e H CU solen oid va lves
ABS syst em (F ig. 2) sepa r a t e fr om ot h er veh icle elec- a n d pu m p a r e n ot a ct iva t ed. Th e m a st er cylin der a n d
t r ica l cir cu it s. CAB volt a ge sou r ce is t h r ou gh t h e power boost er oper a t e t h e sa m e a s a veh icle wit h ou t
ign it ion swit ch in t h e RUN posit ion . a n ABS br a ke syst em .
Th e CAB con t a in s du a l m icr opr ocessor s. A logic Du r in g a n t ilock br a kin g, solen oid va lve pr essu r e
block in ea ch m icr opr ocessor r eceives iden t ica l sen sor m odu la t ion occu r s in t h r ee st a ges, pr essu r e in cr ea se,
sign a ls. Th ese sign a ls a r e pr ocessed a n d com pa r ed pr essu r e h old, a n d pr essu r e decr ea se. Th e va lves a r e
sim u lt a n eou sly. a ll con t a in ed in t h e va lve body por t ion of t h e H CU.
Th e CAB con t a in s a self ch eck pr ogr a m t h a t illu - P re s s u re D e c re a s e
m in a t es t h e ABS wa r n in g ligh t wh en a syst em fa u lt Th e ou t let va lve is open ed a n d t h e in let va lve is
is det ect ed. F a u lt s a r e st or ed in a dia gn ost ic pr ogr a m closed du r in g t h e pr essu r e decr ea se cycle.
m em or y a n d a r e a ccessible wit h t h e DRB sca n t ool.
FRONT
SENSOR PICKUP
REAR
SENSOR
FACE
5 - 32 BRAKES XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
A pr essu r e decr ea se cycle is in it ia t ed wh en speed
sen sor sign a ls in dica t e h igh wh eel slip a t on e or
m or e wh eels. At t h is poin t , t h e CAB closes t h e in let
t h en open s t h e ou t let va lve, wh ich a lso open s t h e
r et u r n cir cu it t o t h e a ccu m u la t or s. F lu id pr essu r e is
a llowed t o bleed off (decr ea se) a s n eeded t o pr even t
wh eel lock.
On ce t h e per iod of h igh wh eel slip h a s en ded, t h e
CAB closes t h e ou t let va lve a n d begin s a pr essu r e
in cr ea se or h old cycle a s n eeded.
P re s s u re Ho ld
Bot h solen oid va lves a r e closed in t h e pr essu r e
h old cycle. F lu id a pply pr essu r e in t h e con t r ol ch a n -
n el is m a in t a in ed a t a con st a n t r a t e. Th e CAB m a in - PICKUP
t a in s t h e h old cycle u n t il sen sor in pu t s in dica t e a FACE J9205-6
pr essu r e ch a n ge is n ecessa r y.
P re s s u re In c re a s e Fig. 3 Wheel Speed Sensors
Th e in let va lve is open a n d t h e ou t let va lve is sen sor s h a ve a n a ir ga p spa cer a t t a ch ed t o t h e sen sor
closed du r in g t h e pr essu r e in cr ea se cycle. Th e pr es- picku p fa ce. Th e spa cer est a blish es cor r ect a ir ga p
su r e in cr ea se cycle is u sed t o cou n t er a ct u n equ a l wh en pr essed a ga in st t h e t on e r in g du r in g in st a lla -
wh eel speeds. Th is cycle con t r ols r e-a pplica t ion of t ion . As t h e t on e r in g r ot a t es, it peels t h e spa cer off
flu id a pply pr essu r e du e t o ch a n gin g r oa d su r fa ces or t h e sen sor t o cr ea t e t h e r equ ir ed a ir ga p. Rea r sen sor
wh eel speed. a ir ga p is 0.92-1.275 m m (0.036-0.05 in .).
Sen sor a ir ga p m ea su r em en t , or a dju st m en t pr oce-
WHEEL SPEED SENSORS AND TONE WHEEL du r es a r e pr ovided in t h is sect ion . Refer t o t h e fr on t ,
A speed sen sor is u sed a t ea ch wh eel. Th e fr on t or r ea r sen sor r em ova l a n d in st a lla t ion pr ocedu r es a s
sen sor s a r e m ou n t ed t o t h e st eer in g kn u ckles. Th e r equ ir ed.
r ea r sen sor s a t t h e ou t boa r d en d of t h e a xle.
Th e sen sor s con ver t wh eel speed in t o a sm a ll AC COMBINATION VALVE
elect r ica l sign a l. Th is sign a l is t r a n sm it t ed t o t h e Th e com bin a t ion va lve con t a in s a pr essu r e differ-
CAB. Th e CAB con ver t s t h e AC sign a l in t o a digit a l en t ia l va lve a n d swit ch a n d a r ea r br a ke pr opor t ion -
sign a l for ea ch wh eel. Th is volt a ge is gen er a t ed by in g va lve. Th e va lve is n ot r epa ir a ble. It m u st be
m a gn et ic in du ct ion wh en a t on e wh eel pa sses by t h e r epla ced if dia gn osis in dica t es t h is is n ecessa r y.
st a t ion a r y m a gn et of t h e wh eel speed sen sor. Th e pr essu r e differ en t ia l swit ch is con n ect ed t o t h e
A gea r t ype t on e r in g ser ves a s t h e t r igger m ech a - br a ke wa r n in g ligh t . Th e swit ch is a ct u a t ed by m ove-
n ism for ea ch sen sor. Th e t on e r in gs a r e m ou n t ed a t m en t of t h e swit ch va lve. Th e swit ch m on it or s flu id
t h e ou t boa r d en ds of t h e fr on t a n d r ea r a xle sh a ft s. pr essu r e in t h e sepa r a t e fr on t /r ea r br a ke h ydr a u lic
Differ en t sen sor s a r e u sed a t t h e fr on t a n d r ea r cir cu it s.
wh eels (F ig. 3). Th e fr on t /r ea r sen sor s h a ve t h e sa m e A decr ea se or loss of flu id pr essu r e in eit h er
elect r ica l va lu es bu t a r e n ot in t er ch a n gea ble. Th e h ydr a u lic cir cu it will ca u se t h e swit ch va lve t o sh u t -
sen sor s h a ve a r esist a n ce bet ween 900 a n d 1300 t le t o t h e low pr essu r e side. Movem en t of t h e va lve
oh m s. pu sh es t h e swit ch plu n ger u pwa r d. Th is a ct ion closes
t h e swit ch in t er n a l con t a ct s com plet in g t h e elect r ica l
SPEED SEN SOR AI R GAP
cir cu it t o t h e r ed wa r n in g ligh t . Th e swit ch va lve will
Front Sensor r em a in in a n a ct u a t ed posit ion u n t il r epa ir s a r e
m a de.
F r on t sen sor a ir ga p is fixed a n d n ot a dju st a ble.
Th e r ea r pr opor t ion in g va lve is u sed t o ba la n ce
On ly r ea r sen sor a ir ga p is a dju st a ble.
fr on t -r ea r br a ke a ct ion . Th e va lve a llows n or m a l
Alt h ou gh fr on t a ir ga p is n ot a dju st a ble, it ca n be
flu id flow du r in g m oder a t e effor t br a ke st ops. Th e
ch ecked if dia gn osis in dica t es t h is is n ecessa r y. F r on t
va lve on ly con t r ols (m et er s) flu id flow du r in g h igh
a ir ga p sh ou ld be 0.36 t o 1.5 m m (0.014 t o 0.059 in .).
effor t br a ke st ops.
If ga p is in cor r ect , t h e sen sor is eit h er loose, or da m -
a ged.
ACCELERATION SWITCH
Rear Sensor Th e a cceler a t ion swit ch is loca t ed u n der t h e r ea r
A r ea r sen sor a ir ga p a dju st m en t is on ly n eeded sea t . Th e swit ch (F ig. 4), pr ovides a n a ddit ion a l veh i-
wh en r ein st a llin g a n or igin a l sen sor. Repla cem en t cle deceler a t ion r efer en ce du r in g 4WD oper a t ion . Th e
SWITCH
NUMBER
PART ARROW
FRONT
PROPER
OF SWITCH
MOUNTING
INDICATES
FOR CAB
NESS
RELEASE
HAR- CAB FWD
XJ BRAKES 5 - 33
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
swit ch is m on it or ed by t h e CAB a t a ll t im es. Th e SERV I CE PROCEDU RES
swit ch r efer en ce sign a l is u t ilized by t h e CAB wh en
a ll wh eels a r e deceler a t in g a t t h e sa m e speed. BLEEDING ABS BRAKE SYSTEM
ABS syst em bleedin g r equ ir es con ven t ion a l bleed-
in g m et h ods plu s u se of t h e DRB sca n t ool. Th e pr o-
cedu r e in volves per for m in g a ba se br a ke bleedin g,
followed by u se of t h e sca n t ool t o cycle a n d bleed t h e
H CU pu m p a n d solen oids. A secon d ba se br a ke bleed-
in g pr ocedu r e is t h en r equ ir ed t o r em ove a n y a ir
r em a in in g in t h e syst em .
(1) P er for m ba se br a ke bleedin g. Refer t o ba se
br a ke sect ion for pr ocedu r e.
(2) Con n ect sca n t ool t o t h e Da t a Lin k Con n ect or.
(3) Select ANTILOCK BRAKE S, followed by MIS-
CE LLANE OUS, t h en ABS BRAKE S. F ollow t h e
ARROW INDICATES in st r u ct ion s displa yed. Wh en sca n t ool displa ys TE ST
FRONT OF SWITCH
FOR PROPER MOUNTING COMP LE TE , discon n ect sca n t ool a n d pr oceed.
)9505-94 (4) P er for m ba se br a ke bleedin g a secon d t im e.
Refer t o ba se br a ke sect ion for pr ocedu r e.
(5) Top off m a st er cylin der flu id level a n d ver ify
Fig. 4 Acceleration Switch
pr oper br a ke oper a t ion befor e m ovin g veh icle.
ABS WARNING LAMP
Th e a m ber ABS wa r n in g la m p is loca t ed in t h e
in st r u m en t clu st er. Th e la m p illu m in a t es a t st a r t -u p REM OVAL AN D I N STALLAT I ON
t o per for m a self ch eck. Th e la m p goes ou t wh en t h e
self ch eck pr ogr a m det er m in es t h e syst em is oper a t - HYDRAULIC CONTROL UNIT/CONTROLLER
in g n or m a l. If a n ABS com pon en t exh ibit s a fa u lt t h e ANTILOCK BRAKES
CAB will illu m in a t e t h e la m p a n d r egist er a t r ou ble
code in t h e m icr opr ocessor. REM OVAL
Th e la m p is con t r olled by t h e CAB. Th e la m p is (1) Rem ove n ega t ive ba t t er y ca ble fr om t h e ba t -
illu m in a t ed wh en t h e CAB sen ds a gr ou n d sign a l t o t er y.
t h e ABS r ela y. Th e ABS r ela y t h en gr ou n ds t h e la m p (2) P u ll u p on t h e CAB h a r n ess con n ect or r elea se
cir cu it a n d illu m in a t es t h e la m p. (F ig. 5) a n d r em ove con n ect or.
(3) Rem ove br a ke lin es fr om t h e H CU.
(4) Rem ove H CU/CAB m ou n t in g n u t s a n d bolt
DI AGN OSI S AN D T EST I N G (F ig. 6) a n d r em ove H CU/CAB.
5 - 34 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
HCU/CAB
MOTOR BRACKET
80aafb1e
XJ BRAKES 5 - 35
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) P u sh sen sor gr om m et s and sen sor wir es I N STALLAT I ON
t h r ou gh floor pa n . (1) If o rig in a l s e n s o r is bein g in st a lled, r em ove
a n y r em a in in g pieces of ca r dboa r d spa cer fr om sen -
sor picku p fa ce. Use dr y sh op t owel on ly t o r em ove
old spa cer m a t er ia l.
(2) In ser t sen sor wir e t h r ou gh su ppor t pla t e h ole.
Th en sea t sen sor gr om m et in su ppor t pla t e.
(3) Apply Mopa r Lock N’ Sea l or Loct it e t 242 t o
or igin a l sen sor bolt . Use n ew bolt if or igin a l is wor n
SENSOR or da m a ged.
MOUNTING
BRACKET (4) In st a ll sen sor bolt fin ger t igh t on ly a t t h is
t im e.
(5) If o rig in a l r ea r sen sor wa s in st a lled, a dju st
sen sor a ir ga p t o 0.92-1.275 m m (0.036-0.05 in .). Use
feeler ga u ge t o m ea su r e a ir ga p (F ig. 10). Tigh t en
sen sor bolt t o 13 N·m (115 in . lbs.).
WHEEL
SPEED
SENSOR
SENSOR /
HARNESS
FLOORPAN TO
TO LR. WHEEL R.R. WHEEL
SENSOR SENSOR J9205-19
AIR GAP
REAR SPACER
SENSOR ATTACHED TO
SENSOR FACE
J9205-35
5 - 36 BRAKES XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(9) Ver ify t h a t r ea r sen sor wir es a r e secu r ed t o
r ea r br a ke h ose a n d a xle wit h clips. Ver ify t h a t wir e
is clea r of r ot a t in g com pon en t s.
(10) In st a ll br a ke dr u m a n d wh eel a n d t ir e a ssem -
bly.
(11) Lower veh icle.
(12) Con n ect sen sor wir e t o h a r n ess con n ect or.
Th en r eposit ion ca r pet a n d fold r ea r sea t down .
ACCELERATION SWITCH
REM OVAL
(1) Ra ise a n d fold r ea r sea t a ssem bly for wa r d for
a ccess t o sen sor.
(2) Discon n ect swit ch h a r n ess.
(3) Rem ove swit ch m ou n t in g scr ews (F ig. 12)
(4) Rem ove t h e a cceler a t ion swit ch .
Fig. 13 Acceleration Switch
DI SASSEM BLY AN D ASSEM BLY
HYDRAULIC CONTROL UNIT/CONTROLLER
ANTILOCK BRAKE
DI SASSEM BLY
(1) Rem ove pu m p m ot or con n ect or fr om t h e CAB.
(2) Rem ove CAB m ou n t in g scr ews fr om t h e H CU
(F ig. 14).
(3) Rem ove CAB fr om t h e H CU.
SPECI FI CAT I ON S
T0RQUE CHART
CLUTCH
CON T EN T S
page page
6 - 10 CLUTCH XJ
SERV I CE PROCEDU RES (Cont inue d)
CLUTCH FLUID LEVEL FLYWHEEL
Th e clu t ch flu id r eser voir, m a st er cylin der, sla ve In spect t h e flywh eel wh en ever t h e clu t ch disc,
cylin der a n d flu id lin es a r e pr e-filled wit h flu id a t cover a n d h ou sin g a r e r em oved for ser vice. Ch eck
t h e fa ct or y du r in g a ssem bly oper a t ion s. con dit ion of t h e flywh eel fa ce, h u b, r in g gea r t eet h ,
Th e h ydr a u lic syst em sh ou ld n ot r equ ir e a ddit ion a l a n d flywh eel bolt s.
flu id u n der n or m a l cir cu m st a n ces. In fa ct , th e re s e r- Min or scr a t ch es, bu r r s, or gla zin g on t h e flywh eel
v o ir flu id le v e l w ill a c tu a lly in c re a s e a s n o rm a l fa ce ca n be r edu ced wit h 180 gr it em er y clot h . H ow-
c lu tc h w e a r o c c u rs . F o r th is re a s o n , it is im p o r- ever, t h e flywh eel sh ou ld be r epla ced if t h e disc con -
ta n t to a v o id o v e rfillin g , o r re m o v in g flu id fro m t a ct su r fa ce is sever ely scor ed, h ea t ch ecked, cr a cked,
th e re s e rv o ir. or obviou sly wor n .
If in spect ion or dia gn osis in dica t es a ddit ion a l flu id F lywh eel m a ch in in g is n ot r ecom m en ded. Th e fly-
m a y be n eeded, u se Mopa r t br a ke flu id, or a n equ iv- wh eel su r fa ce is m a n u fa ct u r ed wit h a u n iqu e con t ou r
a len t m eet in g st a n da r ds SAE J 1703 a n d DOT 3. Do t h a t wou ld be n ega t ed by m a ch in in g. H owever,
n ot u se a n y ot h er t ype of flu id. clea n u p of m in or flywh eel scor in g ca n be per for m ed
Clu t ch flu id level is ch ecked a t t h e m a st er cylin der by h a n d wit h 180 gr it em er y, or wit h su r fa ce gr in d-
r eser voir (F ig. 1). An in dica t or r in g is pr ovided eit h er in g equ ipm en t . Repla ce t h e flywh eel if scor in g is
on t h e side, or in t er ior r im of t h e r eser voir (F ig. 2). deeper t h a n 0.0762 m m (0.003 in .).
Be su r e t o wipe t h e r eser voir a n d cover clea n H ea vy st ock r em ova l by gr in din g is n o t re c o m -
befor e r em ovin g t h e cover. Th is will a void h a vin g dir t m e n d e d . E xcessive st ock r em ova l ca n r esu lt in fly-
or for eign m a t er ia l fa ll in t o t h e r eser voir du r in g a wh eel cr a ckin g or wa r pa ge a ft er in st a lla t ion . It ca n
flu id level ch eck. a lso wea ken t h e flywh eel a n d in t er fer e wit h pr oper
clu t ch r elea se.
RESERVOIR
CAP Ch eck flywh eel r u n ou t if m isa lign m en t is su s-
pect ed. Ru n ou t sh ou ld n ot exceed 0.08 m m (0.003
in .). Mea su r e r u n ou t a t t h e ou t er edge of t h e fly-
wh eel fa ce wit h a dia l in dica t or. Mou n t t h e dia l in di-
ca t or on a st u d in st a lled in pla ce of on e of t h e clu t ch
h ou sin g a t t a ch in g bolt s.
Clea n t h e cr a n ksh a ft fla n ge befor e m ou n t in g t h e
flywh eel. Dir t a n d gr ea se on t h e fla n ge su r fa ce m a y
cock t h e flywh eel ca u sin g excessive r u n ou t .
Ch eck con dit ion of t h e flywh eel h u b a n d a t t a ch in g
bolt s. Repla ce t h e flywh eel if t h e h u b exh ibit s cr a cks
in t h e a r ea of t h e a t t a ch in g bolt h oles.
CLUTCH In st a ll n ew a t t a ch in g bolt s wh en ever t h e flywh eel
MASTER FLUID is r epla ced a n d u se Mopa r t Lock N’ Sea l, or Loct it e
CYLINDER RESERVOIR LINE J9106-6
242 on t h e r epla cem en t bolt t h r ea ds.
Fig. 1 Clutch Master Cylinder Reservoir And Cap Recom m en ded flywh eel bolt t or qu es a r e:
• 142 N·m (105 ft . lbs.) for 6-cylin der flywh eels
CLUTCH • 68 N·m (50 ft . lbs.) plu s a n a ddit ion a l t u r n of
MASTER 60° for 4-cylin der flywh eels
CYLINDER
RESERVOIR In spect t h e t eet h on t h e st a r t er r in g gea r. If th e
te e th a re w o rn o r d a m a g e d , th e fly w h e e l s h o u ld
be re p la c e d a s a n a s s e m bly. Th is is th e re c o m -
m e n d e d a n d p re fe rre d m e th o d o f re p a ir.
In ca ses wh er e a n ew flywh eel is n ot r ea dily a va il-
a ble, a r epla cem en t r in g gea r ca n be in st a lled. H ow-
ever, t h e followin g pr eca u t ion s m u st be obser ved t o
a void da m a gin g t h e flywh eel a n d r epla cem en t gea r.
(1) Ma r k posit ion of t h e old gea r for a lign m en t r ef-
FLUID er en ce on t h e flywh eel. Use a scr iber for t h is pu r-
LEVEL pose.
INDICATOR
RING (2) Wea r pr ot ect ive goggles or a ppr oved sa fet y
J9106-11 gla sses. Also wea r h ea t r esist en t gloves wh en h a n -
dlin g a h ea t ed r in g gea r.
Fig. 2 Reservoir Fluid Level Indicator Ring
PUNCH
CLUTCH
FLYWHEEL
MARKS
COVER
XJ CLUTCH 6 - 11
SERV I CE PROCEDU RES (Cont inue d)
~::::
(3) Rem ove t h e old gea r by cu t t in g m ost of t h e wa y
t h r ou gh it (a t on e poin t ) wit h a n a br a sive cu t -off
wh eel. Th en com plet e r em ova l wit h a cold ch isel or
pu n ch .
(4) Th e r in g gea r is a sh r in k fit on t h e flywh eel.
Th is m ea n s t h e gea r m u st be expa n ded by h ea t in g in PUNCH MARKS
or der t o in st a ll it . Th e m e th o d o f h e a tin g a n d
e x p a n d in g th e g e a r is e x tre m e ly im p o rta n t.
E ver y su r fa ce of t h e gea r m u st be h ea t ed a t t h e sa m e ~ FLYWHEEL
t im e t o pr odu ce u n ifor m expa n sion . An oven or sim i-
la r en closed h ea t in g device m u st be u sed. Tem per a -
t u r e r equ ir ed for u n ifor m expa n sion is a ppr oxim a t ely
375° F.
6 - 12 CLUTCH XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
"FLYWHEEL SIDE"
STAMPED ON
THIS SURFACE J9506-3 J9106-18
Fig. 4 Clutch Disc And Pressure Plate Inspection Fig. 5 Typical Method Of Aligning Clutch Disc
(11) Apply ligh t coa t of Mopa r t h igh t em per a t u r e (3) Rem ove r elea se bea r in g, r elea se for k, a n d for k
bea r in g gr ea se t o pilot bea r in g h u b a n d splin es of boot fr om in pu t sh a ft a n d clu t ch h ou sin g.
t r a n sm ission in pu t sh a ft . Do n ot over lu br ica t e sh a ft (4) Rem ove bolt s a t t a ch in g clu t ch h ou sin g t o t r a n s-
splin es. Th is will r esu lt in gr ea se con t a m in a t ion of m ission (F ig. 8).
disc.
(12) In st a ll t r a n sm ission (F ig. 6) a n d (F ig. 7). I N STALLAT I ON
Refer t o Gr ou p 21, Tr a n sm ission a n d Tr a n sfer Ca se, (1) Clea n m ou n t in g su r fa ces of t r a n sm ission a n d
for pr oper pr ocedu r es. clu t ch h ou sin g. Use a wir e br u sh if n ecessa r y fol-
lowed by a wa x a n d gr ea se r em over, or sim ila r sol-
CLUTCH HOUSING REPLACEMENT—AX15 ven t . Also clea n en gin e block su r fa ce a s well.
(2) P osit ion clu t ch h ou sin g on t r a n sm ission a n d
REM OVAL in st a ll h ou sin g a t t a ch in g bolt s. Tigh t en bolt s t o 38
(1) Ra ise veh icle a n d su ppor t veh icle. N·m (28 ft . lbs.) t or qu e.
(2) Rem ove t r a n sm ission a n d clu t ch h ou sin g a s (3) In st a ll r elea se for k pivot ba ll st u d t o h ou sin g, if
a ssem bly. Refer t o Gr ou p 21, Tr a n sm ission a n d n ecessa r y.
Tr a n sfer Ca se, for pr oper pr ocedu r es.
BRACKET
J9506-4
XJ CLUTCH 6 - 13
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CLUTCH
HOUSING
J9506-5
RELEASE BEARING
REM OVAL
(1) Rem ove t r a n sm ission . Refer t o Gr ou p 21,
Tr a n sm ission a n d Tr a n sfer Ca se, for pr oper pr oce-
du r es.
(2) Discon n ect r elea se bea r in g fr om for k a n d
r em ove bea r in g (F ig. 9).
CONED WASHER
6 - 14 CLUTCH XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
I N STALLAT I ON ,,
(1) In spect r elea se bea r in g slide su r fa ce of t r a n s- KEEP BEARING STRAIGHT
m ission fr on t bea r in g r et a in er. Repla ce r et a in er if DURING INSTALLATION
slide su r fa ce is scor ed, wor n or cr a cked. TO AVOID DAMAGE
(2) In spect r elea se for k a n d for k pivot (F ig. 9). Be
su r e pivot is secu r e a n d in good con dit ion . Be su r e
for k is n ot dist or t ed or wor n . Repla ce r elea se for k
r et a in er spr in g if ben t or da m a ged in a n y wa y.
(3) Ligh t ly lu br ica t e pilot bea r in g, in pu t sh a ft
splin es, bea r in g r et a in er slide su r fa ce, for k pivot a n d
r elea se for k pivot su r fa ce wit h Mopa r t h igh t em per-
a t u r e bea r in g gr ea se. ~-•ALIGNMENT
TOOL
(4) In st a ll r elea se for k a n d bea r in g. Be su r e for k
a n d bea r in g a r e pr oper ly secu r ed.
(5) In st a ll t r a n sm ission . Refer t o Gr ou p 21, Tr a n s-
m ission a n d Tr a n sfer Ca se, for pr oper pr ocedu r es.
PILOT BEARING
REM OVAL
(1) Rem ove t r a n sm ission . Refer t o Gr ou p 21,
J9206-8
Tr a n sm ission a n d Tr a n sfer Ca se, for pr oper pr oce-
du r es. Fig. 10 Typical Method Of Installing Pilot Bearing
(2) Rem ove clu t ch cover a n d disc.
REM OVAL
(3) Use a su it a ble blin d h ole pu ller t o r em ove pilot
(1) Ra ise veh icle.
bea r in g.
(2) Rem ove fa st en er s a t t a ch in g sla ve cylin der t o
I N STALLAT I ON clu t ch h ou sin g.
(1) Clea n bea r in g bor e wit h solven t a n d wipe dr y (3) Rem ove sla ve cylin der fr om clu t ch h ou sin g
wit h sh op t owel. (F ig. 11).
(2) Lu br ica t e n ew pilot bea r in g wit h Mopa r t h igh (4) Disen ga ge clu t ch flu id lin e fr om body clips.
t em per a t u r e gr ea se. (5) Lower veh icle.
(3) P osit ion a n d st a r t n ew bea r in g in bea r in g bor e (6) Ver ify t h a t ca p on clu t ch m a st er cylin der r eser-
by h a n d. Not e t h a t pilot bea r in g h a s sea l a t on e en d. voir is t igh t . Th is is n ecessa r y t o a void u n du e spill-
In st a ll bea r in g so sea l is fa cin g ou t wa r d t owa r d a ge du r in g r em ova l.
t r a n sm ission . (7) Rem ove clu t ch m a st er cylin der a t t a ch in g n u t s.
(4) Sea t pilot bea r in g wit h clu t ch a lign m en t t ool Not e t h a t bot h n u t s a r e a ccessible fr om u n der in st r u -
(F ig. 10). Keep bea r in g st r a igh t du r in g in st a lla t ion . m en t pa n el (F ig. 12) a n d (F ig. 13).
Do n ot a llow bea r in g t o becom e cocked. Ta p bea r in g (8) Rem ove clu t ch m a st er cylin der pu sh r od fr om
in t o pla ce u n t il flu sh wit h edge of bea r in g bor e. Do peda l.
n ot r ecess bea r in g. (9) Discon n ect clu t ch peda l posit ion swit ch wir es.
(5) In st a ll t r a n sm ission . Refer t o Gr ou p 21, Tr a n s- (10) If peda l pin is equ ipped wit h bu sh in g, in spect
m ission a n d Tr a n sfer Ca se, for pr oper pr ocedu r es. con dit ion of bu sh in g a n d r epla ce it if wor n or da m -
a ged.
CLUTCH HYDRAULIC LINKAGE (11) Rem ove clu t ch h ydr a u lic lin ka ge t h r ou gh
Th e clu t ch m a st er cylin der, sla ve cylin der a n d con - en gin e com pa r t m en t .
n ect in g lin e a r e ser viced a s a n a ssem bly on ly. Th e
I N STALLAT I ON
lin ka ge com pon en t s ca n n ot be over h a u led or ser viced
(1) Be su r e r eser voir cover on clu t ch m a st er cylin -
sepa r a t ely. Th e cylin der s a n d con n ect in g lin e a r e
der is t igh t t o a void spills.
sea led u n it s. Also n ot e t h a t r em ova l/in st a lla t ion pr o-
(2) P osit ion clu t ch lin ka ge com pon en t s in veh icle.
cedu r es for r igh t a n d left h a n d dr ive m odels a r e ba si-
Wor k con n ect in g lin e a n d sla ve cylin der down wa r d
ca lly t h e sa m e. On ly m a st er cylin der loca t ion is
pa st en gin e a n d a dja cen t t o clu t ch h ou sin g.
differ en t .
(3) P osit ion clu t ch m a st er cylin der on da sh pa n el.
(4) At t a ch clu t ch m a st er cylin der pu sh r od t o
clu t ch peda l pin .
CLUTCHFWD
MASTER
CYLINDER
CYLINDER
FLUID LINE
DASH PANEL
SLAVE CYLIN-
CLUTCH
DER HOUSING PUSH
STUDS
ROD
(2)
XJ CLUTCH 6 - 15
REM OVAL AN D I N STALLAT I ON (Cont inue d)
SPECI FI CAT I ON S
TORQUE
COOLING SYSTEM
CON T EN T S
page page
SYSTEM COOLANT ROUTING CAUTION: Plastic tanks, while stronger than brass,
F or coolin g syst em flow r ou t in gs, r efer t o (F ig. 1) are subject to damage by impact, such as
(F ig. 2). wrenches.
TO
COOLANT
RECOVERY
BOTTLE
80a53b1e
I
wir e ext en sion cor d.
DESCRI PT I ON AN D OPERAT I ON
AUTOMATIC TRANSMISSION OIL COOLER
WAT ER-T O-OI L COOLER
All m odels equ ipped wit h a n a u t om a t ic t r a n sm is-
sion a r e equ ipped wit h a t r a n sm ission oil cooler
m ou n t ed in t er n a lly wit h in t h e r a dia t or t a n k. Th is
in t er n a l cooler is su pplied a s st a n da r d equ ipm en t on
a ll m odels equ ipped wit h a n a u t om a t ic t r a n sm ission .
Tr a n sm ission oil is cooled wh en it pa sses t h r ou gh
t h is sepa r a t e cooler. In ca se of a lea k in t h e in t er n a l
r a dia t or m ou n t ed t r a n sm ission oil cooler, en gin e cool-
a n t m a y becom e m ixed wit h t r a n sm ission flu id or
t r a n sm ission flu id m a y en t er en gin e coolin g syst em .
Fig. 2 Coolant Flow—4.0L 6-Cylinder Engine— Bot h coolin g syst em a n d t r a n sm ission sh ou ld be
Typical dr a in ed a n d in spect ed if t h e in t er n a l r a dia t or
If t h e pla st ic t a n k h a s been da m a ged, t h e pla st ic m ou n t ed t r a n sm ission cooler is lea kin g.
t a n k a n d/or o-r in gs a r e a va ila ble for ser vice r epa ir.
Ta n k r epla cem en t sh ou ld be don e by a qu a lified per- AI R-T O-OI L COOLER
son wit h pr oper equ ipm en t . An a u xilia r y a ir-t o-oil t r a n sm ission oil cooler is
a va ila ble wit h m ost en gin e pa cka ges.
ACCESSORY DRIVE BELT TENSION Th e a u xilia r y a ir-t o-oil t r a n sm ission oil cooler is
Cor r ect a ccessor y dr ive belt t en sion is r equ ir ed t o loca t ed in fr on t of t h e r a dia t or or A/C con den ser (if
en su r e opt im u m per for m a n ce of belt dr iven en gin e equ ipped) a n d beh in d t h e gr ill. It is m ou n t ed t o t h e
a ccessor ies. If specified t en sion is n ot m a in t a in ed, fr on t fr a m e cr ossm em ber.
belt slippa ge m a y ca u se: en gin e over h ea t in g, la ck of Th e a u xilia r y oil cooler s on a ll m odels oper a t e in
power st eer in g a ssist , loss of a ir con dit ion in g ca pa c- con ju n ct ion wit h t h e in t er n a l r a dia t or m ou n t ed m a in
it y, r edu ced gen er a t or ou t pu t r a t e, gr ea t ly r edu ced oil cooler. Th e t r a n sm ission oil is r ou t ed t h r ou gh t h e
belt life a n d object ion a ble u n der h ood n oise. m a in cooler fir st , t h en t h e a u xilia r y cooler, befor e
r et u r n in g t o t h e t r a n sm ission .
DOM EST I C LEFT H AN D DRI V E V EH I CLES
Belt t en sion is a dju st ed a t t h e power st eer in g COOLANT RESERVE/OVERFLOW SYSTEM
pu m p br a cket a n d idler pu lley a ssem bly. Th e syst em wor ks a lon g wit h t h e r a dia t or pr essu r e
ca p. Th is is don e by u sin g t h er m a l expa n sion a n d
DOM EST I C RI GH T H AN D DRI V E V EH I CLES con t r a ct ion of t h e coola n t t o keep t h e coola n t fr ee of
If equ ipped wit h a 4.0L 6-cylin der en gin e; t h e ser- t r a pped a ir. It pr ovides:
pen t in e belt is a dju st ed a t t h e gen er a t or m ou n t in g • A volu m e for coola n t expa n sion a n d con t r a ct ion .
br a cket . Wh en equ ipped wit h a 2.5L 4-cylin der • A con ven ien t a n d sa fe m et h od for ch eckin g/a d-
en gin e, t h e ser pen t in e belt is a dju st ed a t t h e power ju st in g coola n t level a t a t m osph er ic pr essu r e. Th is is
st eer in g pu m p br a cket a n d idler pu lley a ssem bly. don e wit h ou t r em ovin g t h e r a dia t or pr essu r e ca p.
• Som e r eser ve coola n t t o t h e r a dia t or t o cover
m in or lea ks a n d eva por a t ion or boilin g losses.
MOUNTING
CLAMP
BOLTS TUBE TO RADIATOR COOLANT
OVERFLOW
RESERVE/
LOWER
BRACKET
TANK
TUBE TO
RADIATOR
VACUUM J9307-10
VENT
(SHOWN IN V~~EPOSITION)
SEALI Fig. 6 Reverse Rotating Water Pump—Typical
J9207-5
E n gin es fr om pr eviou s m odel yea r s, depen din g
Fig. 5 Radiator Pressure Cap and Filler Neck— u pon a pplica t ion , m a y h a ve been equ ipped wit h a for-
Typical wa r d (clockwise) r ot a t in g wa t er pu m p. In st a lla t ion of
t r a ct s a n d cr ea t es a va cu u m in t h e coolin g syst em . t h e wr on g wa t er pu m p will ca u se en gin e over h ea t in g.
Th is ca u ses t h e va cu u m va lve t o open a n d coola n t in A qu ick t est t o det er m in e if t h e pu m p is wor kin g is
t h e r eser ve/over flow t a n k t o be dr a wn t h r ou gh it s t o ch eck if t h e h ea t er wa r m s pr oper ly. A defect ive
con n ect in g h ose in t o r a dia t or. If t h e va cu u m va lve is wa t er pu m p will n ot be a ble t o cir cu la t e h ea t ed cool-
st u ck sh u t , t h e r a dia t or h oses will colla pse on cool- a n t t h r ou gh t h e lon g h ea t er h ose t o t h e h ea t er cor e.
down .
A r u bber ga sket sea ls r a dia t or filler n eck. Th is is COOLING SYSTEM HOSES
don e t o m a in t a in va cu u m du r in g coola n t cool-down Ru bber h oses r ou t e coola n t t o a n d fr om t h e r a dia -
a n d t o pr even t lea ka ge wh en syst em is u n der pr es- t or, in t a ke m a n ifold a n d h ea t er cor e. Ra dia t or lower
su r e. h oses a r e spr in g-r ein for ced t o pr even t colla pse fr om
wa t er pu m p su ct ion a t m oder a t e a n d h igh en gin e
WATER PUMPS speeds.
A cen t r ifu ga l wa t er pu m p cir cu la t es coola n t
WARNING: CONSTANT TENSION HOSE CLAMPS
t h r ou gh t h e wa t er ja cket s, pa ssa ges, in t a ke m a n ifold,
ARE USED ON MOST COOLING SYSTEM HOSES.
r a dia t or cor e, coolin g syst em h oses a n d h ea t er cor e.
WHEN REMOVING OR INSTALLING, USE ONLY
Th e pu m p is dr iven fr om t h e en gin e cr a n ksh a ft by a
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
dr ive belt on a ll en gin es.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
Th e wa t er pu m p im peller is pr essed on t o t h e r ea r
6094) (Fig. 7). SNAP-ON CLAMP TOOL (NUMBER
of a sh a ft t h a t r ot a t es in bea r in gs pr essed in t o t h e
HPC-20) MAY BE USED FOR LARGER CLAMPS.
h ou sin g. Th e h ou sin g h a s a sm a ll h ole t o a llow seep-
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
a ge t o esca pe. Th e wa t er pu m p sea ls a r e lu br ica t ed
ING CONSTANT TENSION CLAMPS.
by t h e a n t ifr eeze in t h e coola n t m ixt u r e. No a ddi-
t ion a l lu br ica t ion is n ecessa r y.
VISCOUS
FAN DRIVE
TYPICAL
HOSE
CLAMP
NUMBER/LETTER J9507-37
LOCATION J9407-39
Fig. 9 Typical Viscous Fan Drive
Fig. 8 Clamp Number/Letter Location
On ly wh en su fficien t h ea t is pr esen t , will t h e vis-
In spect t h e h oses a t r egu la r in t er va ls. Repla ce
cou s fa n dr ive en ga ge. Th is is wh en t h e a ir flowin g
h oses t h a t a r e cr a cked, feel br it t le wh en squ eezed, or
t h r ou gh t h e r a dia t or cor e ca u ses a r ea ct ion t o t h e
swell excessively wh en t h e syst em is pr essu r ized.
bim et a llic coil. It t h en in cr ea ses fa n speed t o pr ovide
F or a ll veh icles: In a r ea s wh er e specific r ou t in g
t h e n ecessa r y a ddit ion a l en gin e coolin g.
cla m ps a r e n ot pr ovided, be su r e t h a t h oses a r e posi-
On ce t h e en gin e h a s cooled, t h e r a dia t or disch a r ge
t ion ed wit h su fficien t clea r a n ce. Ch eck clea r a n ce
t em per a t u r e will dr op. Th e bim et a llic coil a ga in
fr om exh a u st m a n ifolds a n d pipe, fa n bla des, dr ive
r ea ct s a n d t h e fa n speed is r edu ced t o t h e pr eviou s
belt s a n d swa y ba r s. Im pr oper ly posit ion ed h oses ca n
disen ga ged speed.
be da m a ged, r esu lt in g in coola n t loss a n d en gin e
over h ea t in g.
POWER
RIGHT
FENDER
DISTRIBUTION
CENTER BATTERY
N OI SE
It is n o rm a l fo r fa n n o is e to be lo u d e r (ro a r-
in g ) w h e n :
• Th e u n der h ood t em per a t u r e is a bove t h e en ga ge-
m en t poin t for t h e viscou s dr ive cou plin g. Th is m a y Fig. 10 Power Distribution Center (PDC)
occu r wh en a m bien t (ou t side a ir t em per a t u r e) is ver y DI AGN OSI S AN D T EST I N G
h igh .
• E n gin e loa ds a n d t em per a t u r es a r e h igh su ch a s ON-BOARD DIAGNOSTICS (OBD)
wh en t owin g a t r a iler.
• Cool silicon e flu id wit h in t h e fa n dr ive u n it is COOLI N G SY ST EM RELAT ED DI AGN OST I CS
bein g r edist r ibu t ed ba ck t o it s n or m a l disen ga ged Th e P ower t r a in Con t r ol Modu le (P CM) h a s been
(wa r m ) posit ion . Th is ca n occu r du r in g t h e fir st 15 pr ogr a m m ed t o m on it or t h e cer t a in followin g coolin g
secon ds t o on e m in u t e a ft er en gin e st a r t -u p on a cold syst em com pon en t s:
en gin e. • If t h e en gin e h a s r em a in ed cool for t oo lon g a
per iod, su ch a s wit h a st u ck open t h er m ost a t , a Dia g-
AUXILIARY ELECTRIC COOLING FAN n ost ic Tr ou ble Code (DTC) ca n be set .
Models equ ipped wit h a 4.0L 6-cylin der en gin e m a y • If a n open or sh or t ed con dit ion h a s developed in
a lso h a ve a n a u xilia r y elect r ica l coolin g fa n . Th is is t h e r ela y cir cu it con t r ollin g t h e elect r ic r a dia t or fa n ,
wit h m odels t h a t h a ve a ir con dit ion in g a n d/or h ea vy a Dia gn ost ic Tr ou ble Code (DTC) ca n be set .
du t y coolin g. Th e fa n is con t r olled by t h e coolin g fa n If t h e pr oblem is sen sed in a m on it or ed cir cu it
r ela y, wh ich is loca t ed in t h e power dist r ibu t ion cen - oft en en ou gh t o in dica t e a n a ct u a l pr oblem , a DTC is
t er (P DC) (F ig. 10). F or t h e loca t ion of r ela y wit h in st or ed. Th e DTC will be st or ed in t h e P CM m em or y
t h e P DC, r efer t o t h e la bel on P DC cover . for even t u a l displa y t o t h e ser vice t ech n icia n . (Refer
Wh en coola n t t em per a t u r e r ea ch es a ppr oxim a t ely t o Gr ou p 25, E m ission Con t r ol Syst em s for pr oper
103°C (218°F ), or wh en a ir con dit ion in g is r equ est ed, pr ocedu r es)
t h e power t r a in con t r ol m odu le (P CM) pr ovides a
gr ou n d pa t h for t h e fa n r ela y. Th is gr ou n d is pr o- ACCESSI N G DI AGN OST I C T ROU BLE CODES
vided t o t h e coolin g fa n r ela y t h r ou gh pin C2 of P CM To r ea d DTC’s a n d t o obt a in coolin g syst em da t a ,
con n ect or C3. Ba t t er y volt a ge is t h en a pplied t o t h e r efer t o Gr ou p 25, E m ission Con t r ol Syst em s for
fa n t h r ou gh t h e r ela y. Wh en coola n t t em per a t u r e pr oper pr ocedu r es.
dr ops below a ppr oxim a t ely 98°C (209°F ), t h e P CM
open s t h e gr ou n d pa t h t o t h e r ela y. Th is will pr even t DRB SCAN TOOL
t h e coolin g fa n fr om bein g en er gized. F or oper a t ion of t h e DRB sca n t ool, r efer t o t h e
a ppr opr ia t e P ower t r a in Dia gn ost ic P r ocedu r es ser-
vice m a n u a l.
XJ COOLING SYSTEM 7-9
DI AGN OSI S AN D T EST I N G (Cont inue d)
ENGINE ACCESSORY DRIVE BELTS
BELT DI AGN OSI S
Wh en dia gn osin g ser pen t in e a ccessor y dr ive belt s,
sm a ll cr a cks t h a t r u n a cr oss t h e r ibbed su r fa ce of t h e
belt fr om r ib t o r ib (F ig. 11), a r e con sider ed n or m a l.
Th ese a r e n ot a r ea son t o r epla ce t h e belt . H owever,
cr a cks r u n n in g a lon g a r ib (n ot a cr oss) a r e n o t n or- NORMAL CRACKS
BELT OK
m a l. An y belt wit h cr a cks r u n n in g a lon g a r ib m u st
be r epla ced (F ig. 11). Also r epla ce t h e belt if it h a s
excessive wea r, fr a yed cor ds or sever e gla zin g.
Refer t o t h e Ser pen t in e Dr ive Belt Dia gn osis
ch a r t s for fu r t h er belt dia gn osis.
HOSE OR HOSES COLLAPSE WHEN 1. Vacuum created in cooling system on 1. (a) Radiator cap relief valve stuck.
ENGINE IS COOLING engine cool-down is not being relieved Refer to Radiator Cap in this group.
through coolant reserve/overflow Replace if necessary.
system. (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 1. Fan relay, powertrain control module 1. Refer to Auxiliary Electric Cooling
ALL THE TIME (XJ MODELS WITH (PCM) or engine coolant temperature Fan-XJ Models with 4.0L 6-Cylinder
4.0L ENGINE EQUIPPED WITH sensor defective. engine in the manual text. Repair as
HEAVY DUTY COOLING AND/OR AIR necessary. Also refer to appropriate
CONDITIONING ONLY) Powertrain Diagnostic Procedures
service manual for operation of the
DRB scan tool.
ELECTRIC RADIATOR FAN WILL NOT 1. Fan motor defective. 1. Refer to Auxiliary Electric Cooling
RUN (XJ MODELS WITH 4.0L Fan-XJ Models with 4.0L 6-Cylinder
ENGINE EQUIPPED WITH HEAVY engine in the manual text. Repair as
DUTY COOLING AND/OR AIR necessary.
CONDITIONING ONLY) GAUGE 2. Fan relay, powertrain control module 2. Refer to Auxiliary Electric Cooling
READING HIGH OR HOT (PCM) or engine coolant temperature Fan-XJ Models with 4.0L 6-Cylinder
sensor defective. engine in the manual text. Repair as
necessary. Also refer to the appropriate
Powertrain Diagnostic Procedures
service manual for operation of the
DRB scan tool
3. Blown fuse in power distribution 3. Determine reason for blown fuse
center (PDC). and repair as necessary.
XJ COOLING SYSTEM 7 - 19
DI AGN OSI S AN D T EST I N G (Cont inue d)
RADIATOR COOLANT FLOW CHECK WARNING: HOT, PRESSURIZED COOLANT CAN
Th e followin g pr ocedu r e will det er m in e if coola n t is CAUSE INJURY BY SCALDING.
flowin g t h r ou gh t h e coolin g syst em .
If en gin e is cold, idle en gin e u n t il n or m a l oper a t in g Ca r efu lly r em ove t h e r a dia t or pr essu r e ca p fr om
t em per a t u r e is r ea ch ed. Th en feel t h e u pper r a dia t or t h e filler n eck a n d ch eck t h e coola n t level. P u sh
h ose. If h ose is h ot , t h e t h er m ost a t is open a n d wa t er down on t h e ca p t o disen ga ge it fr om t h e st op t a bs.
is cir cu la t in g t h r ou gh coolin g syst em . Wipe t h e in n er pa r t of t h e filler n eck a n d exa m in e
t h e lower in side sea lin g sea t for n icks, cr a cks, pa in t ,
TESTING COOLING SYSTEM FOR LEAKS dir t a n d solder r esidu e. In spect t h e r eser ve/over flow
t a n k t u be for in t er n a l obst r u ct ion s. In ser t a wir e
U LT RAV I OLET LI GH T M ET H OD t h r ou gh t h e t u be t o be su r e it is n ot obst r u ct ed.
All J eep m odels h a ve a lea k det ect ion a ddit ive In spect t h e ca m s on t h e ou t side pa r t of t h e filler
a dded t o t h e coolin g syst em befor e t h ey lea ve t h e fa c- n eck. If t h e ca m s a r e ben t , sea t in g of pr essu r e ca p
t or y. Th e a ddit ive is h igh ly visible u n der u lt r a violet va lve a n d t est er sea l will be a ffect ed. Repla ce ca p if
ligh t (bla ck ligh t ). If t h e fa ct or y or igin a l coola n t h a s ca m s a r e ben t .
been dr a in ed, pou r on e ou n ce of a ddit ive in t o t h e At t a ch pr essu r e t est er 7700 (or a n equ iva len t ) t o
coolin g syst em . Th e a ddit ive is a va ila ble t h r ou gh t h e t h e r a dia t or filler n eck (F ig. 13).
pa r t ’s depa r t m en t . P la ce t h e h ea t er con t r ol u n it in
TYPICAL COOLING
H E AT posit ion . St a r t a n d oper a t e t h e en gin e u n t il ii...--- SYSTEM PRESSURE
t h e r a dia t or u pper h ose is wa r m t o t h e t ou ch . Aim TESTER
t h e com m er cia lly a va ila ble bla ck ligh t t ool a t t h e
com pon en t s t o be ch ecked. If lea ks a r e pr esen t , t h e
bla ck ligh t will ca u se t h e a ddit ive t o glow a br igh t
gr een color.
Th e bla ck ligh t ca n be u sed a lon g wit h a pr essu r e
t est er t o det er m in e if a n y ext er n a l lea ks exist (F ig.
12).
XJ COOLING SYSTEM 7 - 21
DI AGN OSI S AN D T EST I N G (Cont inue d)
WARNING: USE EXTREME CAUTION WHEN THE SHOULD NOT BE REMOVED WHILE THE SYSTEM
ENGINE IS OPERATING. DO NOT STAND IN A IS HOT AND/OR UNDER PRESSURE.
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR FAN. DO
NOT WEAR LOOSE CLOTHING.
DEAERATION
~A\-''"-----PRESSURE As t h e en gin e oper a t es, a n y a ir t r a pped in coolin g
CAP syst em ga t h er s u n der t h e r a dia t or ca p. Th e n ext t im e
t h e en gin e is oper a t ed, t h er m a l expa n sion of coola n t
will pu sh a n y t r a pped a ir pa st r a dia t or ca p in t o t h e
coola n t r eser ve/over flow t a n k. H er e it esca pes t o t h e
a t m osph er e in t o t h e t a n k. Wh en t h e en gin e cools
down t h e coola n t , it will be dr a wn fr om t h e r eser ve/
over flow t a n k in t o t h e r a dia t or t o r epla ce a n y
r em oved a ir.
XJ COOLING SYSTEM 7 - 23
SERV I CE PROCEDU RES (Cont inue d)
WARNING: DO NOT OPEN RADIATOR DRAINCOCK
\ \\\
WITH ENGINE RUNNING OR WHILE ENGINE IS HOT
AND COOLING SYSTEM IS UNDER PRESSURE.
7 - 24 COOLING SYSTEM XJ
SERV I CE PROCEDU RES (Cont inue d)
CH EM I CAL CLEAN I N G REM OVAL AN D I N STALLAT I ON
If visu a l in spect ion in dica t es t h e for m a t ion of slu dge or
sca ly deposit s, u se a r a dia t or clea n er (Mopa r Ra dia t or TRANSMISSION OIL COOLERS
Kleen or equ iva len t ) befor e flu sh in g. Th is will soft en
sca le a n d ot h er deposit s a n d a id t h e flu sh in g oper a t ion . WAT ER-T O-OI L COOLER
Th e in t er n a l t r a n sm ission oil cooler loca t ed wit h in
CAUTION: Be sure instructions on the container t h e r a dia t or is n ot ser vicea ble. If it r equ ir es ser vice,
are followed. t h e r a dia t or m u st be r epla ced.
On ce t h e r epa ir ed or r epla cem en t r a dia t or h a s been
in st a lled, fill t h e coolin g syst em a n d in spect for lea ks.
REV ERSE FLU SH I N G RADI AT OR
Refer t o t h e Refillin g Coolin g Syst em a n d Test in g Cool-
Discon n ect t h e r a dia t or h oses fr om t h e r a dia t or fit -
in g Syst em F or Lea ks sect ion s in t h is gr ou p. If t h e
t in gs. At t a ch a sect ion of r a dia t or h ose t o t h e r a dia -
t r a n sm ission oper a t es pr oper ly a ft er r epa ir in g t h e lea k,
t or bot t om ou t let fit t in g a n d in ser t t h e flu sh in g gu n .
dr a in t h e t r a n sm ission a n d r em ove t h e t r a n sm ission oil
Con n ect a wa t er su pply h ose a n d a ir su pply h ose t o
pa n . In spect for slu dge a n d/or r u st . In spect for a dir t y
t h e flu sh in g gu n .
or plu gged in let filt er. If n on e of t h ese con dit ion s a r e
CAUTION: The cooling system normally operates fou n d, t h e t r a n sm ission a n d t or qu e con ver t or m a y n ot
at 97-to-124 kPa (14- to-18 psi) pressure. Exceeding r equ ir e r econ dit ion in g. Refer t o Gr ou p 21 for a u t om a t ic
this pressure may damage the radiator or hoses. t r a n sm ission ser vicin g.
XJ COOLING SYSTEM 7 - 25
REM OVAL AN D I N STALLAT I ON (Cont inue d)
COOLANT
AUTO. TRANS. OIL COOLER RESERVE/OVERFLOW
TANK
FRONT
MOUNTING
BOLTS
HOSE
CLAMPS J9507-39
J9407-26
I N STALLAT I ON
(1) P osit ion t a n k a n d t igh t en t o 2 N·m (17 in . lbs.)
t or qu e.
(2) P osit ion t u be a n d secu r e cla m p.
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 compo- Fig. 20 Reserve/Overflow Tank—With Right Hand
nents could have been damaged due to excessive Drive
vibration.
years, depending upon application, may be
Th e wa t er pu m p ca n be r em oved wit h ou t disch a r g- equipped with a forward (clockwise) rotating water
in g t h e a ir con dit ion in g syst em (if equ ipped). pump. Installation of the wrong water pump will
cause engine over heating.
CAUTION: All engines have a reverse (counter-
clockwise) rotating water pump. The letter R is Th e wa t er pu m p im peller is pr essed on t h e r ea r of
stamped into the back of the water pump impeller t h e pu m p sh a ft a n d bea r in g a ssem bly. Th e wa t er
(Fig. 21) to identify. Engines from previous model pu m p is ser viced on ly a s a com plet e a ssem bly.
R STAMPED INTO IMPELLER THERMAL DRIVE
COUS FAN
VIS- (4) FAN(4)
PUMP
BLADE-TO-VISCOUS
FAN
PULLEY
DRIVE
INTAKE
PUMP
HUB-TO-
BOLTS
NUTS
BRACKET
MANIFOLD
(4) FAN
FAB
WATER
HUB-TO-PUMP
BLADEPUMP
PUMP ASSEMBLY
WATER
PUL-
LEY
PULLEY
STUDS
PUMP
2.5L
7 - 26 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
'
(4) FAN HUB-TO-PUMP PULLEY NUTS
XJ COOLING SYSTEM 7 - 27
REM OVAL AN D I N STALLAT I ON (Cont inue d)
HEATER HOSE
(10) In st a ll u pper r a dia t or h ose.
FITTING (11) F ill coolin g syst em wit h coola n t a n d ch eck for
lea ks. Refer t o Refillin g Coolin g Syst em in t h is
UPPER gr ou p.
VENT (12) Con n ect ba t t er y ca ble t o ba t t er y.
HOLE
(13) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks.
LONG
BOLT
7 - 28 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
PUMP ASSEMBLY
-----~
PUMP BRACKET 80500555
XJ COOLING SYSTEM 7 - 29
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CAUTION: When installing the serpentine engine (4) Rem ove t h er m ost a t h ou sin g m ou n t in g bolt s,
accessory drive belt, the belt MUST be routed cor- t h er m ost a t h ou sin g, ga sket a n d t h er m ost a t (F ig. 28).
rectly. If not, the engine may overheat due to the Disca r d old ga sket .
water pump rotating in the wrong direction. Refer to
the Belt Removal and Installation in this group for LONG THERMOSTAT
BOLT
appropriate belt routing. You may also refer to the
Belt Routing Label in the vehicle engine compart-
ment.
r-
lea ks. Refer t o Refillin g Coolin g Syst em in t h is
gr ou p.
(14) Con n ect ba t t er y ca ble t o ba t t er y.
(15) St a r t a n d wa r m t h e en gin e. Ch eck for lea ks. THERMOSTAT
HOUSING
THERMOSTAT
SHORT
REM OVAL BOLT J9307-13
7 - 30 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) P osit ion dr a in pa n u n der dr a in cock. Open r a di-
a t or dr a in cock. Dr a in r a dia t or.
(4) Rem ove r a dia t or u pper a n d lower h ose cla m ps
(F ig. 7) (F ig. 8). Rem ove h oses.
(5) Rem ove E -clip fr om a lign m en t dowel a t r a dia -
t or lower m ou n t in g br a cket (F ig. 30).
(6) Discon n ect coola n t r eser ve/over flow t a n k h ose
fr om r a dia t or.
(7) Rem ove fou r r a dia t or fa n sh r ou d m ou n t in g
bolt s (F ig. 30). P u sh sh r ou d ba ck a ga in st fr on t of
en gin e.
(8) If equ ipped, discon n ect a n d plu g a u t om a t ic
t r a n sm ission flu id cooler lin es. Refer t o Gr ou p 21,
Tr a n sm ission for pr ocedu r es.
(9) Rem ove t wo r a dia t or t op m ou n t in g bolt s (F ig.
30).
(10) Air con dit ion in g equ ipped
(a ) Rem ove t h e r a dia t or gr ille m ou n t in g scr ews
a n d r em ove gr ill. Refer t o Gr ou p 23, Body for pr o-
cedu r es.
GROOVE J9307-25 (b) Rem ove t h e a ir con dit ion in g con den ser-t o-
r a dia t or m ou n t in g bolt . Use a n open en d wr en ch t o
Fig. 29 Thermostat Recess r em ove bot t om bolt s (F ig. 31).
(11) Lift r a dia t or st r a igh t u p a n d ou t of veh icle.
RADIATOR
Ta ke ca r e n ot t o da m a ge r a dia t or fin s. Wh en r em ov-
WARNING: DO NOT REMOVE THE CYLINDER in g r a dia t or, n ot e posit ion of t h e r u bber sea ls loca t ed
BLOCK DRAIN PLUGS, RADIATOR CAP, OR on t h e t op, bot t om a n d sides of r a dia t or (F ig. 30). To
LOOSEN THE RADIATOR DRAINCOCK WITH THE pr even t possible over h ea t in g, t h ese sea ls m u st be
SYSTEM HOT AND PRESSURIZED. SERIOUS in st a lled t o t h eir or igin a l posit ion s.
BURNS FROM THE COOLANT CAN OCCUR.
INSTALLATION
DO NOT WASTE r eu sa ble coola n t . If solu t ion is (1) In st a ll r a dia t or beh in d a ir con dit ion in g con -
clea n , dr a in coola n t in t o a clea n con t a in er for r eu se. den ser wit h bot t om a lign m en t dowel in ser t ed in t o
r a dia t or lower m ou n t in g br a cket (F ig. 30).
WARNING: CONSTANT TENSION HOSE CLAMPS (2) In st a ll E -clip t o r a dia t or a lign m en t dowel (F ig.
ARE USED ON MOST COOLING SYSTEM HOSES. 30).
WHEN REMOVING OR INSTALLING, USE ONLY (3) Tigh t en t h e fou r con den ser-t o-r a dia t or m ou n t -
TOOLS DESIGNED FOR SERVICING THIS TYPE OF in g bolt s t o 6.2 N·m (55 in . lbs.) t or qu e.
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER (4) If r em oved, in st a ll r a dia t or gr ille.
6094) (Fig. 7). SNAP-ON CLAMP TOOL (NUMBER (5) Tigh t en r a dia t or t op m ou n t in g bolt s t o 6 N·m
HPC-20) MAY BE USED FOR LARGER CLAMPS. (55 in . lbs.) t or qu e.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- (6) If equ ipped, con n ect a u t om a t ic t r a n sm ission
ING CONSTANT TENSION CLAMPS. flu id cooler lin es t o r a dia t or. Refer t o Gr ou p 21,
Tr a n sm ission for pr ocedu r es.
(7) In st a ll t h e r a dia t or fa n sh r ou d.
CAUTION: A number or letter is stamped into the (8) Con n ect t h e coola n t r eser ve/over flow t a n k h ose.
tongue of constant tension clamps (Fig. 8). If (9) Con n ect r a dia t or h oses a n d in st a ll h ose cla m ps.
replacement is necessary, use only an original (10) Con n ect n ega t ive ba t t er y ca ble.
equipment clamp with matching number or letter. (11) Close t h e dr a in cock.
(12) F ill coolin g syst em wit h cor r ect coola n t .
2 .5 L 4 -CY LI N DER EN GI N E (13) In st a ll r a dia t or ca p.
(14) Ch eck a n d a dju st a u t om a t ic t r a n sm ission
REMOVAL flu id level (if equ ipped).
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y.
(2) Obser ve t h e pr eviou s WARN IN GS . Rem ove
r a dia t or ca p.
RIGHT
CONDENSER
SIDE
A/CRUBBER
CONDENSER
SEAL 6 N·m (55
LBS.)
IN. UPPER
RADIATORLOWER
CROSSMEMBER
RADIATOR
MOUNTINGBRACKET
RECEIVER/DRIER
BOLTS
RUBBER
SEAL
LOWER
(2) E-CLIP
TOP MOUNTING BOLTS
LEFT(2)UPPER
SIDE RUBBER
RADIATOR
RUBBER
SEAL
FAN
FAN
SEAL
SHROUD
SHROUD
PORT
SUP- WELL
MOUNTING
BOLTS
NUTS
(2)
(4)
ALIGN DOWEL
XJ COOLING SYSTEM 7 - 31
REM OVAL AN D I N STALLAT I ON (Cont inue d)
UPPER
CROSSMEMBER
BOLTS (2)
UPPER
,_...._--RUBBER
SEAL
\
FAN SHROUD
MOUNTING
BOLTS (4)
E-CUP
19507-49
7 - 32 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
REMOVAL (11) Ma r k t h e posit ion of t h e h ood la t ch st r iker on
(1) Discon n ect n ega t ive ba t t er y ca ble a t ba t t er y. t h e r a dia t or cr ossm em ber a n d r em ove h ood la t ch
(2) Obser ve t h e pr eviou s WARN IN GS . st r iker.
(3) Rem ove pr essu r e ca p. (12) Rem ove t wo r a dia t or u pper cr ossm em ber-t o-
(4) F or a ccess t o r a dia t or dr a in cock, r em ove r a dia - isola t or n u t s (F ig. 33).
t or gr ille m ou n t in g scr ews a n d r em ove gr ill. Refer t o (13) Rem ove fou r r a dia t or u pper cr ossm em ber
Gr ou p 23, Body for pr ocedu r es. bolt s (F ig. 33) a n d r em ove u pper cr ossm em ber.
(5) At t a ch on e en d of a 24 in ch lon g X 1/4 in ch ID (14) If equ ipped wit h a ir con dit ion in g, sepa r a t e
h ose t o t h e r a dia t or dr a in cock. P u t t h e ot h er en d in t o r a dia t or fr om con den ser by r em ovin g con den ser-t o-r a -
a clea n con t a in er. Open dr a in cock a n d dr a in r a dia t or. dia t or m ou n t in g br a cket s (F ig. 34).
(6) If equ ipped, discon n ect a u xilia r y elect r ic cool- (15) Lift r a dia t or st r a igh t u p a n d ou t of en gin e
in g fa n elect r ica l con n ect or (F ig. 32). com pa r t m en t t a kin g ca r e n ot t o da m a ge fin s.
INSTALLATION
Th e r a dia t or is su pplied wit h t wo a lign m en t dowels
(F ig. 33) xxxxxxx (F ig. 35). Th ey a r e loca t ed on t h e
bot t om t a n k a n d fit in t o r u bber gr om m et s in t h e
r a dia t or lower cr ossm em ber.
(1) Lower r a dia t or in t o en gin e com pa r t m en t . P osi-
t ion a lign m en t dowels in t o r u bber gr om m et s in r a di-
a t or lower cr ossm em ber (F ig. 33) xxxxxxxx (F ig. 35)
(2) If equ ipped wit h a ir con dit ion in g, a t t a ch con -
den ser t o r a dia t or wit h m ou n t in g br a cket s (F ig. 34).
(3) In st a ll r a dia t or u pper cr ossm em ber a n d fou r
m ou n t in g bolt s.
(4) In st a ll r a dia t or u pper cr ossm em ber-t o-isola t or
n u t s. Tigh t en n u t s t o 10 N·m (86 in . lbs.) t or qu e. If
isola t or-t o-r a dia t or n u t s h a d been r em oved, t igh t en
t h em t o 5 N·m (47 in . lbs.) t or qu e.
(5) In st a ll h ood la t ch st r iker. Not e pr eviou sly
m a r ked posit ion .
(6) Con n ect r a dia t or u pper a n d lower h oses.
(7) If equ ipped, con n ect a u t om a t ic t r a n sm ission
flu id cooler lin es. Refer t o Gr ou p 21, Tr a n sm ission s
for pr ocedu r es. If equ ipped wit h r em ot e cooler, a t t a ch
Fig. 32 Auxiliary Electric Cooling Fan Wiring
cooler lin e t o br a cket a t bot t om of r a dia t or.
Connector—Typical
(8) In st a ll elect r ic coolin g fa n (if equ ipped). In ser t
(7) If equ ipped, r em ove t wo elect r ic coolin g fa n a lign m en t t a bs a t bot t om of fa n sh r ou d in t o slot s in
m ou n t in g bolt s. Lift coolin g fa n st r a igh t u p u n t il br a cket a t bot t om of r a dia t or. Tigh t en m ou n t in g bolt s
a lign m en t t a bs a t t h e bot t om a r e clea r of slot s in t o 3 N·m (31 in . lbs.) t or qu e.
br a cket a t bot t om of r a dia t or (F ig. 33). (9) Con n ect elect r ic coolin g fa n elect r ica l con n ec-
(8) Rem ove t h e t wo m ech a n ica l (n on -elect r ica l) fa n t or.
sh r ou d m ou n t in g bolt s. Lift sh r ou d st r a igh t u p u n t il (10) In st a ll m ech a n ica l coolin g fa n sh r ou d. In ser t
a lign m en t t a bs a t t h e bot t om a r e clea r of slot s in a lign m en t t a bs a t bot t om of sh r ou d in t o slot s in
br a cket a t bot t om of r a dia t or (F ig. 33). P la ce sh r ou d br a cket a t bot t om of r a dia t or. Tigh t en m ou n t in g bolt s
over m ech a n ica l fa n . t o 3 N·m (31 in . lbs.) t or qu e.
(9) If equ ipped, discon n ect a n d plu g a u t om a t ic (11) Close r a dia t or dr a in cock.
t r a n sm ission flu id cooler lin es. Refer t o Gr ou p 21, (12) In st a ll gr ille.
Tr a n sm ission s for pr ocedu r es. If equ ipped wit h (13) Con n ect n ega t ive ba t t er y ca ble.
r em ot e t r a n sm ission cooler, r em ove lin e t o cooler (14) F ill coolin g syst em wit h cor r ect coola n t . Refer
fr om br a cket a t bot t om of r a dia t or. t o t h e Coola n t sect ion of t h is gr ou p.
(10) Discon n ect r a dia t or u pper a n d lower h oses (15) In st a ll pr essu r e ca p.
cla m ps (F ig. 7) (F ig. 8). Discon n ect r a dia t or u pper (16) Ch eck a n d a dju st a u t om a t ic t r a n sm ission
a n d lower h oses. flu id level (if equ ipped).
UPPER
RUBBER
ALIGNMENT
RADIATOR
LOWER
METS
GROM-
SLOTS
MEMBER
CROSS-
(2)
MEMBER
CROSS-
(4) UPPER
RADIATOR
ISOLATOR
CROSSMEMBER
ALIGNMENT
NUTS
BOLTS
DOWELS
ALIGNMENT
(4)
TABS (2) RADIATOR
FAN
ALIGNMENT
SHROUD
RUBBER
MECHANICAL
DOWEL
MOUNTING
GROMMET
TORS
ISOLA-
(2)
FAN
BOLTS
SHROUD
(2) AIR
TIONING
CONDENSER
ELECTRIC
COOLING
CONDI-
ALIGNMENT
COOLING
FAN
TABS
WIRING
MOUNTING
BOLTS
FAN (2) HARNESS
RADIATOR
CLIPS
XJ COOLING SYSTEM 7 - 33
REM OVAL AN D I N STALLAT I ON (Cont inue d)
FAN SHROUD
MOUNTING BOLTS (2)
UPPER ~ ELECTRIC
CROSSMEMBER
BOLTS (4) •i· · ·.• MECHANICAL
FAN SHROUD COOLING
FAN
~ .
l
~ -~ -
--------
ALIGNMENT
~ WIRING
HARNESS
CLIPS
N<>
I
TABS
\
UPPER
RADIATOR
CROSSMEMBER
COOLING FAN
ALIGNMENT MOUNTING BOLTS (2)
SLOTS (4)
LOWER RADIATOR
CROSSMEMBER J9507-35
CONDENSER
TO RADIATOR RIGHT SIDE
MOUNTING BRACKETS
\
AIR CONDITIONING
J-8907-26 CONDENSER
Fig. 34 Condenser-to-Radiator Mounting Brackets— Fig. 35 Radiator Installation 4.0L 6-Cylinder Engine
4.0L 6- Cylinder Engine
MOUNTING
ELECTRIC
BOLT COOLING
ELECTRIC
FAN COOLING
CONNECTOR
FAN MOUNTINGBOLT BLOCKHEATER POWER CORD LOCATION
7 - 34 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
AUXILIARY ELECTRIC COOLING FAN DO NOT WASTE r eu sa ble coola n t . If solu t ion is
clea n , dr a in coola n t in t o a clea n con t a in er for r eu se.
REM OVAL (1) Dr a in coola n t fr om r a dia t or a n d en gin e cylin -
Th e a u xilia r y coolin g fa n is a t t a ch ed t o t h e r a dia - der block.
t or u pper cr ossm em ber beh in d t h e r a dia t or. (2) Un plu g power cor d fr om block h ea t er.
(1) Rem ove t h e t wo fa n m ou n t in g bolt s fr om r a di- (3) Loosen scr ew in cen t er of block h ea t er (F ig. 37)
a t or u pper cr ossm em ber (F ig. 36). (F ig. 38).
(2) Discon n ect t h e elect r ic fa n con n ect or . (4) Rem ove block h ea t er fr om cylin der block.
I N STALLAT I ON
(1) Th or ou gh ly clea n t h e en gin e cor e h ole a n d t h e
block h ea t er sea t .
(2) In ser t block h ea t er a ssem bly in t o cor e h ole
wit h elem en t loop poin t in g U p .
(3) Sea t block h ea t er flu sh a ga in st block fa ce.
Tigh t en m ou n t in g scr ew t o 3.6 N·m (32 in . lbs.)
t or qu e.
(4) F ill coolin g syst em wit h coola n t . P r essu r ize
syst em a n d in spect for lea ks.
(5) P lu g power cor d in t o block h ea t er. Rou t e cor d
a wa y fr om m ovin g pa r t s, lin ka ges a n d exh a u st sys-
t em com pon en t s. Secu r e cor d in pla ce wit h t ie-st r a ps.
POWER
CORD
LOCATION
I N STALLAT I ON
(1) Align lower r et a in in g t a bs of fa n sh r ou d wit h BLOCK
HEATER J9107-48
slot s in br a cket a t bot t om of r a dia t or. P u sh fa n down
in t o posit ion .
(2) Tigh t en t h e m ou n t in g bolt s t o 4 N·m (31 in . Fig. 37 Heater and Cord— 2.5L 4-Cylinder Engine
lbs.) t or qu e. ENGINE ACCESSORY DRIVE BELTS
(3) Con n ect a u xilia r y coolin g fa n elect r ica l con n ec- Cor r ect dr ive belt t en sion is r equ ir ed t o en su r e
t or. opt im u m per for m a n ce of t h e belt dr iven en gin e a cces-
sor ies. Th er e a r e differ en t t ypes of a dju st m en t
ENGINE BLOCK HEATER ga u ges for ch eckin g eit h er a ser pen t in e or a V-t ype
belt . Refer t o t h e in st r u ct ion s su pplied wit h t h e
REM OVAL ga u ge. Use t h e cor r ect ga u ge wh en ch eckin g belt t en -
Refer t o cor r ect illu st r a t ion (F ig. 37) (F ig. 38)wh en sion . P la ce ga u ge in t h e m iddle of t h e sect ion of belt
ser vicin g block h ea t er. bein g t est ed (bet ween t wo pu lleys) t o ch eck t en sion .
Do n ot a llow t h e ga u ge (or ga u ge a da pt er ) t o con t a ct
WARNING: DO NOT REMOVE THE CYLINDER
a n yt h in g bu t t h e belt .
BLOCK DRAIN PLUGS OR LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES- BELT SCH EM AT I CS
SURIZED. SERIOUS BURNS FROM THE COOLANT Th e belt r ou t in g sch em a t ics a r e pu blish ed fr om t h e
CAN OCCUR. la t est in for m a t ion a va ila ble a t t h e t im e of pu blica -
t ion . If a n y th in g d iffe rs be tw e e n th e s e s c h e m a t-
ic s a n d th e B e lt Ro u tin g La be l, u s e th e
BLOCK
POWER
LOCA-
CORD
HEATER
TION AC
+ IDL
+ALT
+ WP &
PS+FAN
+ IDL
+ FAN
+ IDL
+ CRANK
WP
CRANK
& ++
FAN
+ IDL
+ PS
PS
++
CRANK IDL ALT
ALT WP & FAN IDL
+ + ++
+ +
XJ COOLING SYSTEM 7 - 35
REM OVAL AN D I N STALLAT I ON (Cont inue d)
BLOCK
HEATER
sos6d9fc I
I N STALLAT I ON
(1) Ch eck con dit ion of a ll pu lleys.
Fig. 39 Models with 2.5L Engine—With A/C
CAUTION: When installing the serpentine acces-
BELT REPLACEM EN T OR ADJ U ST M EN T — sory drive belt, the belt MUST be routed correctly. If
LEFT H AN D DRI V E not, the engine may overheat due to the water
Belt t en sion is a dju st ed a t t h e power st eer in g pump rotating in the wrong direction. Refer to (Fig.
pu m p br a cket a n d idler pu lley a ssem bly. 39) xxxxx (Fig. 40) xxxx (Fig. 41) xxxxx (Fig. 42)
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y. xxxx for correct belt routing.
(2) Loosen idler pu lley bolt a t t h e power st eer in g
br a cket (F ig. 45). (2) In st a ll n ew belt .
(3) Loosen a dju st in g bolt u n t il belt ca n be r em oved (3) Usin g ser pen t in e belt t en sion ga u ge, t igh t en
fr om pu lleys. a dju st in g bolt u n t il belt r ea ch es pr oper t en sion . Refer
FAN
ALT
IDL
+AC
ALT
++IDL
+ CRANK
WP
CRANK
+ PS
++ WP
FAN
+PS
& +FAN
IDL
+ + AC
+ ALT
PULLEY
IDLER
IDL
+ BOLT
IDL
+ ADJUSTING
CRANK
BOLT
WP
++ FAN
PS
++ IDL
+
++ +
7 - 36 COOLING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
80570e03
Fig. 42 Models With 4.0L Engine—With A/C—Except Fig. 44 Models With 4.0L Engine—Without A/C—
RHD With RHD
80570e04
Fig. 43 Models With 4.0L Engine—With A/C—With Fig. 45 Power Steering Pump Bracket and Idler
RHD Pulley
t o Belt Ten sion a t t h e r ea r of t h is sect ion for pr oper (4) Loosen a dju st in g bolt a t u pper a lt er n a t or
belt t en sion . br a cket (F ig. 46) u n t il belt ca n be r em oved fr om pu l-
(4) Aft er belt is t en sion ed cor r ect ly, t igh t en idler leys.
pu lley bolt t o 47 N·m (35 ft . lbs.) (5) Rem ove belt .
(5) Aft er idler pu lley h a s been t igh t en ed in t o posi-
t ion , r ech eck belt t en sion . Adju st if n ecessa r y. I N STALLAT I ON
(1) Ch eck con dit ion of a ll pu lleys.
BELT REPLACEM EN T OR ADJ U ST M EN T —
RI GH T H AN D DRI V E (4 .0 L) CAUTION: When installing the serpentine acces-
(1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y. sory drive belt, the belt MUST be routed correctly. If
(2) Loosen lower a lt er n a t or m ou n t in g bolt a n d n u t . not, the engine may overheat due to the water
(3) Loosen u pper a lt er n a t or m ou n t in g n u t . pump rotating in the wrong direction. Refer to (Fig.
43) xxxxx (Fig. 44) for correct belt routing.
TENSION
UPPER ALTERNATOR
ADJUSTMENT
BOLTNUT THERMAL
COUS
BRACKET
DRIVE
FAN
VIS- (4) FAN(4)
PUMP
BLADE-TO-VISCOUS
PULLEY
FAN
PULLEY
DRIVE
HUB-TO-
NUTS
BOLTS
NUTS (4)
HUB/BEARING
FAN
FAB
WATER
HUB-TO-PUMP
BLADEPUMPWATER
WATER
PUL-
LEY
PULLEY
STUDS
PULLEY
PUMP
PUMP
XJ COOLING SYSTEM 7 - 37
REM OVAL AN D I N STALLAT I ON (Cont inue d)
'
Fig. 46 Generator Belt Tension Adjust Bracket FAN
(4) FAN HUB-TO-PUMP PULLEY NUTS BLADE J9307-7
(2) In st a ll n ew belt .
(3) Usin g ser pen t in e belt t en sion ga u ge, t igh t en
a dju st in g bolt u n t il belt r ea ch es pr oper t en sion . Refer
Fig. 47 Water Pump Mounted Cooling Fan
t o Belt Ten sion a t t h e r ea r of t h is sect ion for pr oper
belt t en sion .
(4) Tigh t en a lt er n a t or u pper a n d lower m ou n t in g
bolt s. WATER
(5) Aft er gen er a t or a n d a dju st br a cket h a ve been PUMP
t igh t en ed in t o posit ion , r ech eck belt t en sion . Adju st if
n ecessa r y.
MECHANICAL
COOLING COOLING AUXILIARY*
MODEL ENGINE RADIATOR A/C FAN
CAPACITY PACKAGE ELECTRIC FAN
(VISCOUS DRIVE)
2.5L 4.0L QTS. LITERS STD. HD. ROWS FINS DIA NO. BLADE DIA. NO. BLADE
OF PER (INCH) OF PITCH (INCH) OF PITCH
TUBES INCH BLADE (INCH) BLADES (INCH)
• 10.0 9.5 • 1 15 16.0 5 2.5
• 10.0 9.5 • 1 20 • 16.05 5 2.5
XJ • 12.0 11.4 • 1 19 15.0 7 1.88
• 12.0 11.4 • 1 19 • 15.0 7 1.88 11.0 6 1.75
• 12.0 11.4 • 2 19 15.0 7 1.88 11.0 6 1.75
• 12.0 11.4 • 2 19 • 15.0 7 1.88 11.0 6 1.75
*4.0L E NGINE WITH H E AVY DUTY COOLING AND /OR AIR CONDITIONING
COOLING SYSTEM CAPACITIES
XJ BATTERY 8A - 1
BATTERY
CON T EN T S
page page
Battery Diagnosis
Condition Possible Causes Correction
The battery seems weak or 1. The battery has an 1. See Specifications in this group. Replace the
dead when attempting to start incorrect size or rating for incorrect battery with the correct battery, if
the engine. this vehicle. required.
2. The battery is physically 2. Inspect the battery for loose terminal posts or a
damaged. cracked and leaking case. Replace the battery, if
3. The battery terminal damaged.
connections are loose or 3. See the Voltage Drop Test in this group. Clean
corroded. and tighten the battery terminal connections, if
4. The battery is discharged. required.
5. The electrical system is 4. See the Test Indicator, the Hydrometer Test, or
faulty. the Open-Circuit Voltage Test in this group to
6. The battery is faulty. determine the battery state-of-charge. Charge the
7. The starting system is battery, if required.
faulty. 5. See the Ignition-Off Draw Test in this group.
8. The charging system is Repair the electrical system, if required.
faulty. 6. See the Load Test in this group to determine
the battery condition. Replace the battery, if
required.
7. Refer to Group 8B - Starting Systems for more
information. Repair the starting system, if
required.
8. Refer to Group 8C - Charging Systems for
more information. Repair the charging system, if
required.
The battery state-of-charge 1. The battery has an 1. See Specifications in this group. Replace the
cannot be maintained. incorrect size or rating for incorrect battery with the correct battery, if
this vehicle. required.
2. The battery terminal 2. See the Voltage Drop Test in this group. Clean
connections are loose or and tighten the battery terminal connections, if
corroded. required.
3. The generator drive belt is 3. Refer to Group 7 - Cooling Systems for more
loose or worn. information. Replace or adjust the generator drive
4. The electrical system is belt, if required.
faulty. 4. See the Ignition-Off Draw Test in this group.
5. The battery is faulty. Repair the electrical system, if required.
6. The starting system is 5. See the Load Test in this group to determine
faulty. the battery condition. Replace the battery, if
7. The charging system is required.
faulty. 6. Check whether the starting system is
8. Electrical loads exceed the performing to specifictions. Refer to Group 8B -
output of the charging Starting Systems for more information. Repair the
system. starting system, if required.
9. Slow driving or prolonged 7. Refer to Group 8C - Charging Systems for
idling with high-amperage more information. Repair the charging system, if
draw systems in use. required.
8. Inspect the vehicle for aftermarket electrical
equipment which might cause excessive electrical
loads.
9. Advise the vehicle operator, as required.
The battery will not accept a 1. The battery is faulty. 1. See Battery Charging in this group. Replace
charge. the faulty battery, if required.
SIGHT
PLASTIC
GLASS
RODGREEN
BALL
GREEN
TEST INDICATOR/STATE-OF-
BLACK
CHARGE LOW ELECTROLYTE
CLEAR
BATTERY
TOP
8A - 6 BATTERY XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
GREEN _ _--1 TACT WITH THE SKIN, EYES, OR CLOTHING. IN
J948A-ll
BALL THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
Fig. 2 Built-In Test Indicator OF THE REACH OF CHILDREN.
Refer t o Gr ou p 8C - Ch a r gin g Syst em t o dia gn ose a n • IF THE BATTERY IS EQUIPPED WITH REMOV-
over ch a r gin g con dit ion . ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
TEST INDICATOR/STATE-OF-CHARGE SONAL INJURY AND/OR VEHICLE DAMAGE MAY
100%: -.:: 175'¾O I -
I I -
io
I
LOW
ELECTROLYTE
RESULT FROM LOOSE OR MISSING CELL CAPS.
XJ BATTERY 8A - 7
DI AGN OSI S AN D T EST I N G (Cont inue d)
et er is n ot a va ila ble, or for m a in t en a n ce-fr ee ba t t er-
SURFACE ies wit h n on -r em ova ble cell ca ps.
COHESION
WARNING:
• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI-
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
HYDROMETER
MAY RESULT.
BARREL • THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON-
TACT WITH THE SKIN, EYES, OR CLOTHING. IN
THE EVENT OF CONTACT, FLUSH WITH WATER
TEMPERATURE
READING AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
80a483b9
OF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-
Fig. 4 Hydrometer - Typical ABLE CELL CAPS, BE CERTAIN THAT EACH OF
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
26.6° C - -12.2° C = 38.8° C (80° F -
THE BATTERY IS RETURNED TO SERVICE. PER-
10° F = 70° F)
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
(2) Divide t h e r esu lt fr om St ep 1 by 5.5 (10):
RESULT FROM LOOSE OR MISSING CELL CAPS.
38.8° C 4 5.5 = 7 (70° F 4 10 = 7)
(3) Mu lt iply t h e r esu lt fr om St ep 2 by t h e t em per- Befor e pr oceedin g wit h t h is t est , com plet ely ch a r ge
a t u r e cor r ect ion fa ct or (0.004): t h e ba t t er y a s descr ibed in t h e Ba t t er y Ch a r gin g pr o-
7 X 0.004 = 0.028 cedu r e in t h is gr ou p.
(4) Th e t em per a t u r e a t t est in g wa s below 26.7° C (1) Befor e m ea su r in g t h e open -cir cu it volt a ge, t h e
(80° F ); t h er efor e, t h e t em per a t u r e cor r ect ion fa ct or su r fa ce ch a r ge m u st be r em oved fr om t h e ba t t er y.
is su bt r a ct ed: Tu r n on t h e h ea d la m ps for fift een secon ds, t h en
1.240 - 0.028 = 1.212 a llow u p t o five m in u t es for t h e ba t t er y volt a ge t o
Th e cor r ect ed specific gr a vit y of t h e ba t t er y in t h is st a bilize.
exa m ple is 1.212. (2) Discon n ect a n d isola t e bot h ba t t er y ca bles, n eg-
If t h e specific gr a vit y of a ll cells is a bove 1.235, bu t a t ive ca ble fir st .
t h e va r ia t ion bet ween cells is m or e t h a n fift y poin t s (3) Usin g a volt m et er con n ect ed t o t h e ba t t er y
(0.050), t h e ba t t er y sh ou ld be r epla ced. If t h e specific post s (r efer t o t h e in st r u ct ion s pr ovided wit h t h e
gr a vit y of on e or m or e cells is less t h a n 1.235, ch a r ge volt m et er ), m ea su r e t h e open -cir cu it volt a ge (F ig. 5).
t h e ba t t er y a t a r a t e of a ppr oxim a t ely five a m per es.
Con t in u e ch a r gin g t h e ba t t er y u n t il t h r ee con secu -
t ive specific gr a vit y t est s, t a ken a t on e-h ou r in t er-
va ls, a r e con st a n t . If t h e cell specific gr a vit y
va r ia t ion is m or e t h a n fift y poin t s (0.050) a t t h e en d
of t h e ch a r ge per iod, r epla ce t h e ba t t er y.
Wh en t h e specific gr a vit y of a ll cells is a bove 1.235,
a n d t h e cell va r ia t ion is less t h a n fift y poin t s (0.050),
t h e ba t t er y m a y be loa d t est ed t o det er m in e it s
cr a n kin g ca pa cit y. See t h e Loa d Test pr ocedu r e in
t h is gr ou p for m or e in for m a t ion .
8A - 8 BATTERY XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
See t h e Open -Cir cu it Volt a ge ch a r t . Th is volt a ge (1) Discon n ect a n d isola t e bot h ba t t er y ca bles, n eg-
r ea din g will in dica t e t h e ba t t er y st a t e-of-ch a r ge, bu t a t ive ca ble fir st . Th e ba t t er y t op a n d post s sh ou ld be
will n ot r evea l it s cr a n kin g ca pa cit y. If a ba t t er y h a s clea n .
a n open -cir cu it volt a ge r ea din g of 12.4 volt s or (2) Con n ect a su it a ble volt -a m m et er-loa d t est er
gr ea t er, it m a y be loa d t est ed t o r evea l it s cr a n kin g (F ig. 6) t o t h e ba t t er y post s (F ig. 7). Refer t o t h e
ca pa cit y. See t h e Loa d Test pr ocedu r e in t h is gr ou p oper a t in g in st r u ct ion s pr ovided wit h t h e t est er bein g
for m or e in for m a t ion . u sed. Ch eck t h e open -cir cu it volt a ge (n o loa d) of t h e
ba t t er y. Open -cir cu it volt a ge m u st be 12.4 volt s or
Open Circuit Voltage gr ea t er .
Open Circuit Volts Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
LOAD TEST
A ba t t er y loa d t est will ver ify t h e ba t t er y cr a n kin g
ca pa cit y. Th e t est is ba sed on t h e Cold Cr a n kin g
Am per a ge (CCA) r a t in g of t h e ba t t er y. Refer t o t h e
ba t t er y la bel, or see t h e Ba t t er y Cla ssifica t ion s a n d
-~
FIEl.DSELECTOfl
898A-8
Ra t in gs ch a r t in Specifica t ion s a t t h e ba ck of t h is
gr ou p for t h e CCA r a t in g of t h e fa ct or y-in st a lled ba t - Fig. 6 Volt-Ammeter-Load Tester - Typical
t er y.
INDUCTION
WARNING: AMMETER
• IF THE BATTERY SHOWS SIGNS OF FREEZ- CLAMP
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
CHARGE. THE BATTERY MAY ARC INTERNALLY
AND EXPLODE. PERSONAL INJURY AND/OR VEHI- POSITIVE
CLE DAMAGE MAY RESULT. CLAMP-------
• EXPLOSIVE HYDROGEN GAS FORMS IN AND
AROUND THE BATTERY. DO NOT SMOKE, USE
FLAME, OR CREATE SPARKS NEAR THE BATTERY.
PERSONAL INJURY AND/OR VEHICLE DAMAGE
MAY RESULT.
J948A-13
• THE BATTERY CONTAINS SULFURIC ACID,
WHICH IS POISONOUS AND CAUSTIC. AVOID CON- Fig. 7 Volt-Ammeter-Load Tester Connections -
TACT WITH THE SKIN, EYES, OR CLOTHING. IN Typical
THE EVENT OF CONTACT, FLUSH WITH WATER
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT (3) Rot a t e t h e loa d con t r ol kn ob (ca r bon pile r h eo-
OF THE REACH OF CHILDREN. st a t ) t o a pply a 300 a m per e loa d t o t h e ba t t er y for
• IF THE BATTERY IS EQUIPPED WITH REMOV- fift een secon ds, t h en r et u r n t h e con t r ol kn ob t o t h e
ABLE CELL CAPS, BE CERTAIN THAT EACH OF Off posit ion (F ig. 8). Th is will r em ove t h e su r fa ce
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE ch a r ge fr om t h e ba t t er y.
THE BATTERY IS RETURNED TO SERVICE. PER- (4) Allow t h e ba t t er y t o st a bilize t o open -cir cu it
SONAL INJURY AND/OR VEHICLE DAMAGE MAY volt a ge. It m a y t a ke u p t o five m in u t es for t h e ba t -
RESULT FROM LOOSE OR MISSING CELL CAPS. t er y volt a ge t o st a bilize.
(5) Rot a t e t h e loa d con t r ol kn ob t o m a in t a in a loa d
Befor e pr oceedin g wit h t h is t est , com plet ely ch a r ge equ a l t o 50% of t h e CCA r a t in g of t h e ba t t er y (F ig.
t h e ba t t er y a s descr ibed in t h e Ba t t er y Ch a r gin g pr o- 9). Aft er fift een secon ds, r ecor d t h e loa ded volt a ge
cedu r e in t h is gr ou p. r ea din g, t h en r et u r n t h e loa d con t r ol kn ob t o t h e Off
posit ion .
XJ BATTERY 8A - 9
DI AGN OSI S AN D T EST I N G (Cont inue d)
(7) If t h e volt m et er r ea din g fa lls below 9.6 volt s, a t
a m in im u m ba t t er y t em per a t u r e of 21° C (70° F ), t h e
ba t t er y is fa u lt y a n d m u st be r epla ced.
XJ BATTERY 8A - 11
DI AGN OSI S AN D T EST I N G (Cont inue d) ENGINE
GROUND BATTERY VOLTMETER
VOLTMETER-----!
80660061
Fig. 11 Test Battery Positive Connection Resistance Fig. 13 Test Ground Circuit Resistance - Typical
- Typical
SERV I CE PROCEDU RES
(3) Con n ect t h e volt m et er t o m ea su r e bet ween t h e
ba t t er y posit ive t er m in a l post a n d t h e st a r t er sole- BATTERY CHARGING
n oid ba t t er y t er m in a l st u d (F ig. 12). Rot a t e a n d h old A ba t t er y is fu lly-ch a r ged wh en :
t h e ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e • All cells a r e ga ssin g fr eely du r in g ba t t er y ch a r g-
volt m et er. If t h e r ea din g is a bove 0.2 volt , clea n a n d in g.
t igh t en t h e ba t t er y ca ble con n ect ion a t t h e solen oid. • A gr een color is visible in t h e sigh t gla ss of t h e
Repea t t h e t est . If t h e r ea din g is st ill a bove 0.2 volt , bu ilt -in t est in dica t or.
r epla ce t h e fa u lt y ba t t er y posit ive ca ble. • Th r ee cor r ect ed specific gr a vit y t est s, t a ken a t
(4) Con n ect t h e volt m et er t o m ea su r e bet ween t h e on e-h ou r in t er va ls, in dica t e n o in cr ea se in t h e spe-
ba t t er y n ega t ive t er m in a l post a n d a good clea n cific gr a vit y.
gr ou n d on t h e en gin e block (F ig. 13). Rot a t e a n d h old • Open -cir cu it volt a ge is 12.4 volt s or a bove.
8A - 12 BATTERY XJ
SERV I CE PROCEDU RES (Cont inue d)
WARNING: t est , r et u r n t h e ba t t er y t o u se. If t h e ba t t er y will n ot
• IF THE BATTERY SHOWS SIGNS OF FREEZ- en du r e a loa d t est , it is fa u lt y a n d m u st be r epla ced.
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- Clea n a n d in spect t h e ba t t er y h olddown s, t r a y, t er-
LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR m in a ls, post s, a n d t op befor e com plet in g ser vice. See
CHARGE. THE BATTERY MAY ARC INTERNALLY t h e Ba t t er y Rem ova l a n d In st a lla t ion pr ocedu r es in
AND EXPLODE. PERSONAL INJURY AND/OR VEHI- t h is gr ou p for m or e in for m a t ion .
CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN AND CH ARGI N G A COM PLET ELY DI SCH ARGED
AROUND THE BATTERY. DO NOT SMOKE, USE BAT T ERY
FLAME, OR CREATE SPARKS NEAR THE BATTERY. Th e followin g pr ocedu r e sh ou ld be u sed t o r ech a r ge
PERSONAL INJURY AND/OR VEHICLE DAMAGE a com plet ely disch a r ged ba t t er y. Un less t h is pr oce-
MAY RESULT. du r e is pr oper ly followed, a good ba t t er y m a y be
• THE BATTERY CONTAINS SULFURIC ACID, n eedlessly r epla ced.
WHICH IS POISONOUS AND CAUSTIC. AVOID CON- (1) Mea su r e t h e volt a ge a t t h e ba t t er y post s wit h a
TACT WITH THE SKIN, EYES, OR CLOTHING. IN volt m et er, a ccu r a t e t o 1/10 (0.10) volt (F ig. 14). If t h e
THE EVENT OF CONTACT, FLUSH WITH WATER r ea din g is below t en volt s, t h e ch a r ge cu r r en t will be
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT low. It cou ld t a ke som e t im e befor e t h e ba t t er y
OF THE REACH OF CHILDREN. a ccept s a cu r r en t gr ea t er t h a n a few m illia m per es.
• IF THE BATTERY IS EQUIPPED WITH REMOV- Su ch low cu r r en t m a y n ot be det ect a ble on t h e
ABLE CELL CAPS, BE CERTAIN THAT EACH OF a m m et er s bu ilt in t o m a n y ch a r ger s.
THE CELL CAPS IS IN PLACE AND TIGHT BEFORE
THE BATTERY IS RETURNED TO SERVICE. PER-
SONAL INJURY AND/OR VEHICLE DAMAGE MAY
RESULT FROM LOOSE OR MISSING CELL CAPS.
CAUTION:
• Always disconnect and isolate the battery neg-
ative cable before charging a battery. Do not exceed
sixteen volts while charging a battery. Damage to
the vehicle electrical system components may
result.
• Battery electrolyte will bubble inside the bat-
tery case during normal battery charging. Electro-
898A-12
lyte boiling or being discharged from the battery
vents indicates a battery overcharging condition. Fig. 14 Voltmeter Accurate to 1/10 Volt Connected -
Immediately reduce the charging rate or turn off the Typical
charger to evaluate the battery condition. Damage
to the battery may result from overcharging. (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
• The battery should not be hot to the touch. If ca ble. Con n ect t h e ba t t er y ch a r ger lea ds. Som e ba t -
the battery feels hot to the touch, turn off the t er y ch a r ger s a r e equ ipped wit h pola r it y-sen sin g cir-
charger and let the battery cool before continuing cu it r y. Th is cir cu it r y pr ot ect s t h e ch a r ger a n d/or t h e
the charging operation. Damage to the battery may ba t t er y fr om bein g da m a ged if t h ey a r e im pr oper ly
result. con n ect ed. If t h e ba t t er y st a t e-of-ch a r ge is t oo low for
t h e pola r it y-sen sin g cir cu it r y t o det ect , t h e ch a r ger
Som e ba t t er y ch a r ger s a r e equ ipped wit h pola r it y- will n ot oper a t e. Th is m a kes it a ppea r t h a t t h e ba t -
sen sin g cir cu it r y. Th is cir cu it r y pr ot ect s t h e ch a r ger t er y will n ot a ccept ch a r gin g cu r r en t . Refer t o t h e
a n d/or t h e ba t t er y fr om bein g da m a ged if t h ey a r e in st r u ct ion s pr ovided wit h t h e ba t t er y ch a r ger t o
im pr oper ly con n ect ed. If t h e ba t t er y st a t e-of-ch a r ge bypa ss t h e pola r it y-sen sin g cir cu it r y.
is t oo low for t h e pola r it y-sen sin g cir cu it r y t o det ect , (3) Ba t t er y ch a r ger s va r y in t h e a m ou n t of volt a ge
t h e ch a r ger will n ot oper a t e. Th is m a kes it a ppea r a n d cu r r en t t h ey pr ovide. Th e a m ou n t of t im e
t h a t t h e ba t t er y will n ot a ccept ch a r gin g cu r r en t . r equ ir ed for a ba t t er y t o a ccept m ea su r a ble ch a r ger
Refer t o t h e in st r u ct ion s pr ovided wit h t h e ba t t er y cu r r en t a t va r iou s volt a ges is sh own in t h e Ch a r ge
ch a r ger t o bypa ss t h e pola r it y-sen sin g cir cu it r y. Ra t e ch a r t . If t h e ch a r ge cu r r en t is st ill n ot m ea su r-
Aft er t h e ba t t er y h a s been ch a r ged t o 12.4 volt s or a ble a t t h e en d of t h e ch a r gin g t im e, t h e ba t t er y is
gr ea t er, per for m a loa d t est t o det er m in e t h e ba t t er y fa u lt y a n d m u st be r epla ced. If t h e ch a r ge cu r r en t is
cr a n kin g ca pa cit y. If t h e ba t t er y will en du r e a loa d m ea su r a ble du r in g t h e ch a r gin g t im e, t h e ba t t er y
BATTERY BATTERY
TERMINAL
PULLER
XJ BATTERY 8A - 13
SERV I CE PROCEDU RES (Cont inue d)
m a y be good a n d t h e ch a r gin g sh ou ld be com plet ed in
Battery Charging Timetable
t h e n or m a l m a n n er .
Charging 5 10 20
Charge Rate Amperage Amperes Amperes Amperes
Voltage Hours Open Cir-
16.0 volts maximum up to 4 hours cuit Volt- Hours Charging at 21°C (70°F)
14.0 to 15.9 volts up to 8 hours age
13.9 volts or less up to 16 hours 12.25 to 6 hours 3 hours 1.5 hours
12.39
CH ARGI N G T I M E REQU I RED
12.00 to 8 hours 4 hours 2 hours
Th e t im e r equ ir ed t o ch a r ge a ba t t er y will va r y,
12.24
depen din g u pon t h e followin g fa ct or s:
• B a tte ry Ca p a c ity - A com plet ely disch a r ged 11.95 to 12 hours 6 hours 3 hours
h ea vy-du t y ba t t er y r equ ir es t wice t h e ch a r gin g t im e 11.99
of a sm a ll ca pa cit y ba t t er y. 10.00 to 14 hours 7 hours 3.5 hours
• Te m p e ra tu re - A lon ger t im e will be n eeded t o 11.94
ch a r ge a ba t t er y a t -18° C (0° F ) t h a n a t 27° C (80° less than See Charging Completely Discharged
F ). Wh en a fa st ch a r ger is con n ect ed t o a cold ba t - 10.00 Battery
t er y, t h e cu r r en t a ccept ed by t h e ba t t er y will be ver y
low a t fir st . As t h e ba t t er y wa r m s, it will a ccept a
h igh er ch a r gin g cu r r en t r a t e (a m per a ge).
• Ch a rg e r Ca p a c ity - A ch a r ger t h a t su pplies
on ly five a m per es will r equ ir e a lon ger ch a r gin g
t im e. A ch a r ger t h a t su pplies t wen t y a m per es or
m or e will r equ ir e a sh or t er ch a r gin g t im e.
• S ta te -Of-Ch a rg e - A com plet ely disch a r ged
ba t t er y r equ ir es m or e ch a r gin g t im e t h a n a pa r t ia lly
disch a r ged ba t t er y. E lect r olyt e is n ea r ly pu r e wa t er BATTERY
in a com plet ely disch a r ged ba t t er y. At fir st , t h e
ch a r gin g cu r r en t (a m per a ge) will be low. As t h e ba t - 898A-4
t er y ch a r ges, t h e specific gr a vit y of t h e elect r olyt e
will gr a du a lly r ise. Fig. 15 Remove Battery Cable Terminal Clamp -
Typical
WARNING: NEVER EXCEED TWENTY AMPERES
WARNING: WEAR A SUITABLE PAIR OF RUBBER
WHEN CHARGING A COLD (-1° C/30° F) BATTERY.
GLOVES (NOT THE HOUSEHOLD TYPE) WHEN
THE BATTERY MAY ARC INTERNALLY AND
REMOVING A BATTERY BY HAND. SAFETY
EXPLODE. PERSONAL INJURY AND/OR VEHICLE
GLASSES SHOULD ALSO BE WORN. IF THE BAT-
DAMAGE MAY RESULT.
TERY IS CRACKED OR LEAKING, THE ELECTRO-
LYTE CAN BURN THE SKIN AND EYES.
8A - 14 BATTERY XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
dr iver. Add dist illed wa t er t o ea ch cell u n t il t h e liq-
u id r ea ch es t h e bot t om of t h e ven t well. DO NOT
TERMINAL OVE RF ILL.
BRUSH
~ __;;
I
J938B-20
XJ BATTERY 8A - 15
REM OVAL AN D I N STALLAT I ON (Cont inue d)
CLEANING BRUSH
BATTERY--~
WARM WATER
AND BAKING
SODA SOLUTION
8056d9e2
J928B-30
SPECI FI CAT I ON S
BATTERY
Battery Classifications and Ratings
BCI Group Size Cold Cranking Reserve Capac- Load Test
Part Number Ampere-Hours
Classification Amperage ity Amperage
56041105 58 500 85 Minutes 42 250
XJ STARTING SYSTEMS 8B - 1
STARTING SYSTEMS
CON T EN T S
page page
XJ STARTING SYSTEMS 8B - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)
NEGATIVE
CLAMP
Refer t o t h e P DC la bel for ASD r ela y iden t ifica t ion Fig. 3 Test Battery Positive Connection Resistance -
a n d loca t ion . Typical
(1) Con n ect t h e posit ive lea d of t h e volt m et er t o Repea t t h e t est . If t h e r ea din g is st ill a bove 0.2 volt ,
t h e ba t t er y n ega t ive t er m in a l post . Con n ect t h e n eg- r epla ce t h e fa u lt y ba t t er y posit ive ca ble.
BATTERY VOLTMETER
a t ive lea d of t h e volt m et er t o t h e ba t t er y n ega t ive
ca ble cla m p (F ig. 2). Rot a t e a n d h old t h e ign it ion
swit ch in t h e St a r t posit ion . Obser ve t h e volt m et er. If
volt a ge is det ect ed, cor r ect t h e poor con t a ct bet ween
t h e ca ble cla m p a n d t h e t er m in a l post .
8B - 6 STARTING SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
t est er (F ig. 7). Th er e sh ou ld be con t in u it y. If OK, go
t o St ep 3. If n ot OK, r epla ce t h e fa u lt y st a r t er a ssem -
bly.
8B - 8 STARTING SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
l. VERY HIGH FREQUENCY l. Excessive distance between pinion gear and 1. Move starter motor toward flywheel/drive
WHINE BEFORE ENGINE flywheel/drive plate gear. plate by removing shim(s), if possible.
STARTS; ENGINE STARTS OK.
2. VERY HIGH FREQUENCY 2. Insufficient distance between starter motor 2. Shim starter motor away from flywheel/drive
WHINE AFTER ENGINE STARTS pinion gear and flywheel/drive plate runout plate. Inspect flywheel/drive plate for
WITH IGNITION KEY RELEASED. can cause noise to be intermittent. damage; bent, unusual wear, and excessive
ENGINE STARTS OK. runout. Replace flywheel/drive plate as
necessary.
3. A LOUD "WHOOP" AFTER 3. Most probably cause is defective overrunning 3. Replace starter motor.
ENGINE STARTS WHILE clutch.
STARTER MOTOR IS ENGAGED.
4. A "RUMBLE," "GROWL," OR 4. Most probable cause is bent or unbalanced 4. Replace starter motor.
"KNOCK" AS STARTER MOTOR starter motor armature.
COASTS TO STOP AFTER
ENGINE STARTS.
NOTE: A high frequency whine during cranking is normal for this starter motor.
J958A-5
J908C-1
CONNECTORS
~SCREW
80aafb43
XJ STARTING SYSTEMS 8B - 9
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Rem ove t h e t wo st a r t er m ou n t in g scr ews, t h e (6) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
st a r t er m ot or, a n d a n y st a r t er m ot or sh im s. Tigh t en t h e st a r t er h a r dwa r e a s follows:
• Upper m ou n t in g scr ew (r ea r scr ew) - 55 N·m (40
NOTE: Shim thickness available is 0.381 mm (0.015 ftPOWER
. lbs.)
RIGHT
FENDER
DISTRIBUTION
CENTER BATTERY
in.). See Starter Noise - 2.5L Engine in this group • Lower m ou n t in g scr ew (fr on t scr ew) - 41 N·m
for more information. (30 ft . lbs.)
• Solen oid ba t t er y ca ble n u t - 10 N·m (90 in . lbs.)
(5) Rever se t h e r em ova l pr ocedu r es t o in st a ll. • Solen oid t er m in a l n u t - 6 N·m (55 in . lbs.).
Tigh t en t h e st a r t er h a r dwa r e a s follows:
• Mou n t in g scr ews - 45 N·m (33 ft . lbs.) STARTER RELAY
• Solen oid ba t t er y ca ble n u t - 10 N·m (90 in . lbs.) (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
• Solen oid t er m in a l n u t - 6 N·m (55 in . lbs.). ca ble.
(2) Rem ove t h e cover fr om t h e P ower Dist r ibu t ion
4 .0 L EN GI N E
Cen t er (P DC) (F ig. 13).
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Ra ise a n d su ppor t t h e veh icle.
(3) Discon n ect t h e ba t t er y ca ble a n d solen oid feed
wir e fr om t h e st a r t er solen oid (F ig. 12).
SPECI FI CAT I ON S
STARTING SYSTEM
Starter and Solenoid
Manufacturer Mitsubishi
Engine Application 2.5L, 4.0L
Power Rating 1.2 Kilowatt - 2.5L
1.4 Kilowatt - 4.0L
Voltage 12 Volts
Number of Fields 4
Number of Poles 4
Number of Brushes 4
Drive Type Planetary Gear Reduction
Free Running Test 11.2 Volts
Voltage
Free Running Test 90 Amperes
Maximum Amperage
Draw
Free Running Test 2600 rpm - 2.5L
Minimum Speed 2500 rpm - 4.0L
Solenoid Closing 7.8 Volts
Maximum Voltage
*Cranking Amperage 130 Amperes - 2.5L
Draw Test 160 Amperes - 4.0L
*Test at operating temperature. Cold engine, tight
(new) engine, or heavy oil will increase starter
amperage draw.
XJ CHARGING SYSTEM 8C - 1
CHARGING SYSTEM
CON T EN T S
page page
XJ CHARGING SYSTEM 8C - 3
DI AGN OSI S AN D T EST I N G (Cont inue d)
(5) In spect gen er a t or dr ive belt con dit ion a n d t en - (2) Ch eck con dit ion of ba t t er y ca bles a t ba t t er y.
sion . Tigh t en or r epla ce belt a s r equ ir ed. Refer t o Clea n if n ecessa r y.
Belt Ten sion Specifica t ion s in Gr ou p 7, Coolin g Sys- (3) St a r t t h e en gin e a n d a llow it t o r ea ch n or m a l
t em . oper a t in g t em per a t u r e.
(6) In spect a u t om a t ic belt t en sion er (if equ ipped). (4) Sh u t en gin e off.
Refer t o Gr ou p 7, Coolin g Syst em for in for m a t ion . (5) Con n ect a n en gin e t a ch om et er.
(7) In spect con n ect ion s a t gen er a t or field, ba t t er y (6) F u lly en ga ge t h e pa r kin g br a ke.
ou t pu t , a n d gr ou n d t er m in a ls. Also ch eck gr ou n d con -
n ect ion a t en gin e. Th ey sh ou ld a ll be clea n a n d t igh t . T EST
Repa ir a s r equ ir ed. (1) St a r t en gin e.
(2) P la ce h ea t er blower in h igh posit ion .
CHARGING SYSTEM RESISTANCE TESTS (3) Tu r n on h ea dla m ps a n d pla ce in h igh -bea m
Th ese t est s will sh ow t h e a m ou n t of volt a ge dr op posit ion .
a cr oss t h e gen er a t or ou t pu t wir e, fr om t h e gen er a t or (4) Tu r n veh icle in t er ior la m ps on .
ou t pu t (B+) t er m in a l t o t h e ba t t er y posit ive post . (5) Br in g en gin e speed u p t o 2400 r pm a n d h old.
Th ey will a lso sh ow t h e a m ou n t of volt a ge dr op fr om (6) Test in g (+) cir cu it r y:
t h e gr ou n d (-) t er m in a l on t h e gen er a t or t o t h e ba t - (a ) Tou ch t h e n ega t ive lea d of volt m et er dir ect ly
t er y n ega t ive post . A t ypica l gen er a t or wir in g h a r- t o ba t t er y posit ive post .
n ess is sh own in (F ig. 1). Wir in g h a r n ess r ou t in g a s (b) Tou ch t h e posit ive lea d of volt m et er t o t h e
sh own in (F ig. 1) m a y be sligh t ly differ en t depen din g B+ ou t pu t t er m in a l st u d on t h e gen er a t or (n ot t h e
on veh icle m odel a n d/or en gin e. Refer t o Gr ou p 8W, t er m in a l m ou n t in g n u t ). Volt a ge sh ou ld be n o
Wir in g Dia gr a m s for a ddit ion a l in for m a t ion . h igh er t h a n 0.6 volt s. If volt a ge is h igh er t h a n 0.6
volt s, t ou ch t est lea d t o t er m in a l m ou n t in g st u d
n u t a n d t h en t o t h e wir in g con n ect or. If volt a ge is
GROUND n ow below 0.6 volt s, look for dir t y, loose or poor
TERMINAL B+ con n ect ion a t t h is poin t . Also ch eck con dit ion of t h e
(OUTPUT TERMINAL) gen er a t or ou t pu t wir e-t o-ba t t er y bu llet con n ect or
(if equ ipped). Refer t o Gr ou p 8, Wir in g for con n ec-
t or loca t ion . A volt a ge dr op t est m a y be per for m ed
a t ea ch (+) con n ect ion in t h is cir cu it t o loca t e t h e
excessive r esist a n ce.
(7) Test in g (-) cir cu it r y:
(a ) Tou ch t h e n ega t ive lea d of volt m et er dir ect ly
t o ba t t er y n ega t ive post .
(b) Tou ch t h e posit ive lea d of volt m et er t o t h e
gr ou n d t er m in a l st u d on t h e gen er a t or ca se (n ot
t h e t er m in a l m ou n t in g n u t ). Volt a ge sh ou ld be n o
h igh er t h a n 0.3 volt s. If volt a ge is h igh er t h a n 0.3
volt s, t ou ch t est lea d t o t er m in a l m ou n t in g st u d
n u t a n d t h en t o t h e wir in g con n ect or. If volt a ge is
n ow below 0.3 volt s, look for dir t y, loose or poor
con n ect ion a t t h is poin t . A volt a ge dr op t est m a y be
per for m ed a t ea ch (-) con n ect ion in t h is cir cu it t o
80a3cc69 loca t e t h e excessive r esist a n ce. Th is t est ca n a lso
be per for m ed bet ween t h e gen er a t or ca se a n d t h e
Fig. 1 Generator Terminals (Typical Wiring Harness en gin e. If t est volt a ge is h igh er t h a n 0.3 volt s,
Shown) ch eck for cor r osion a t gen er a t or m ou n t in g poin t s or
A volt m et er wit h a 0–18 volt DC sca le sh ou ld be loose gen er a t or m ou n t in g.
u sed for t h ese t est s. By r eposit ion in g t h e volt m et er
t est lea ds, t h e poin t of h igh r esist a n ce (volt a ge dr op) CURRENT OUTPUT TEST
ca n ea sily be fou n d. Th e cu r r en t ou t pu t t est will det er m in e if t h e
ch a r gin g syst em ca n deliver it s m in im u m t est cu r-
PREPARAT I ON r en t (a m per a ge) ou t pu t . Refer t o t h e Specifica t ion s
(1) Befor e st a r t in g t est , m a ke su r e ba t t er y is in sect ion a t t h e en d of t h is gr ou p for m in im u m t est
good con dit ion a n d is fu lly-ch a r ged. See Gr ou p 8A, cu r r en t (a m per a ge) r equ ir em en t s.
Ba t t er y for m or e in for m a t ion . Th e fir st pa r t of t h is t est (Test 1) will det er m in e
t h e com bin ed a m per a ge ou t pu t of bot h t h e gen er a t or
8C - 4 CHARGING SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
a n d t h e E lect r on ic Volt a ge Regu la t or (E VR) cir cu it r y. (5) Wit h en gin e speed h eld a t 2500 r pm , slowly
Th e secon d pa r t of t h is t est (Test 2) will det er m in e a dju st t h e r h eost a t con t r ol (loa d) on t h e t est er t o
on ly gen er a t or a m per a ge a n d w ill n o t in clu de a n a l- obt a in t h e h igh est a m per a ge r ea din g. Do n ot a llow
ysis of E VR cir cu it r y. E VR cir cu it r y is loca t ed wit h in volt a ge t o dr op below 12 volt s. Recor d t h e r ea din g.
t h e P ower t r a in Con t r ol Modu le (P CM). To t est volt - Th is lo a d te s t m u s t be p e rfo rm e d w ith in 15 s e c -
a ge r egu la t or cir cu it r y, r efer t o t h e a ppr opr ia t e P ow- o n d s to p re v e n t d a m a g e to te s t e qu ip m e n t. On
er t r a in Dia gn ost ic P r ocedu r es ser vice m a n u a l. cer t a in br a n ds of t est equ ipm en t , t h is loa d will be
a pplied a u t om a t ica lly. Refer t o t h e oper a t in g m a n u a l
PREPARAT I ON su pplied wit h t est equ ipm en t .
(1) Det er m in e if a n y Dia gn ost ic Tr ou ble Codes (6) Th e a m m et er r ea din g m u st m eet t h e Min im u m
(DTC’s) exist . To det er m in e a DTC, r efer t o On -Boa r d Test Am ps specifica t ion s a s displa yed in t h e Gen er a -
Dia gn ost ics in t h is gr ou p. F or r epa ir, r efer t o t h e t or Ra t in gs ch a r t . Th is ca n be fou n d in t h e Specifica -
a ppr opr ia t e P ower t r a in Dia gn ost ic P r ocedu r es m a n - t ion s sect ion a t t h e en d of t h is gr ou p. A la bel st a t in g
u a l. a pa r t r efer en ce n u m ber is a t t a ch ed t o t h e gen er a t or
(2) Befor e st a r t in g t est , m a ke su r e ba t t er y is in ca se. On som e en gin es t h is la bel m a y be loca t ed on
good con dit ion a n d is fu lly-ch a r ged. See Gr ou p 8A, t h e bot t om of t h e ca se. Com pa r e t h is r efer en ce n u m -
Ba t t er y for m or e in for m a t ion . ber t o t h e Gen er a t or Ra t in gs ch a r t .
(3) Ch eck con dit ion of ba t t er y ca bles a t ba t t er y. (7) Rot a t e t h e loa d con t r ol t o t h e OF F posit ion .
Clea n if n ecessa r y. (8) Con t in u e h oldin g en gin e speed a t 2500. If E VR
(4) P er for m t h e pr eviou s Ch a r gin g Syst em Resis- cir cu it r y is OK, a m per a ge sh ou ld dr op below 15–20
t a n ce Test s (volt a ge dr op t est s). Th is will en su r e a m ps. Wit h a ll elect r ica l a ccessor ies a n d veh icle
clea n a n d t igh t gen er a t or /ba t t er y elect r ica l con n ec- ligh t in g off, t h is cou ld t a ke sever a l m in u t es of en gin e
t ion s. oper a t ion . If a m per a ge did n ot dr op, r efer t o t h e
(5) Be su r e t h e gen er a t or dr ive belt is pr oper ly a ppr opr ia t e P ower t r a in Dia gn ost ic P r ocedu r es m a n -
t en sion ed. Refer t o Gr ou p 7, Coolin g Syst em for u a l for t est in g.
in for m a t ion . (9) Rem ove volt /a m p t est er.
(6) A volt /a m p t est er equ ipped wit h bot h a ba t t er y If m in im u m a m per a ge cou ld n ot be m et , pr oceed t o
loa d con t r ol (ca r bon pile r h eost a t ) a n d a n in du ct ive- Test 2. Th is t est will det er m in e if t h e gen er a t or is
t ype picku p cla m p (a m m et er pr obe) will be u sed for fa u lt y, or if E VR cir cu it r y is defect ive.
t h is t est . Refer t o oper a t in g in st r u ct ion s su pplied
wit h t est er. Wh en u sin g a t est er equ ipped wit h a n T EST 2
in du ct ive-t ype cla m p, r em ova l of wir in g a t t h e gen er- (1) P er for m t h e pr eviou s t est pr epa r a t ion .
a t or will n ot be n ecessa r y. (2) F u lly en ga ge t h e pa r kin g br a ke.
(7) St a r t t h e en gin e a n d a llow it t o r ea ch oper a t in g (3) Con n ect on e en d of a ju m per wir e t o a good
t em per a t u r e. gr ou n d. Con n ect t h e ot h er en d of ju m per wir e t o t h e
(8) Sh u t en gin e off. gen er a t or field dr iver (-) t er m in a l. Th e 2 field t er m i-
(9) Tu r n off a ll elect r ica l a ccessor ies a n d a ll veh icle n a ls (+ a n d -) a r e loca t ed on t h e ba ck of t h e gen er a -
ligh t in g. t or (F ig. 1). To loca t e a n d iden t ify t h e (-) t er m in a l
(10) Con n ect t h e volt /a m p t est er lea ds t o t h e ba t - a n d cir cu it , r efer t o Gr ou p 8W, Wir in g Dia gr a m s.
t er y. Be su r e t h e ca r bon pile r h eost a t con t r ol is in t h e An ot h er wa y t o iden t ify t h e (-) t er m in a l is t o st a r t
OP E N or OF F posit ion befor e con n ect in g lea ds. See t h e en gin e a n d m ea su r e volt a ge a t bot h field t er m i-
Loa d Test in Gr ou p 8A, Ba t t er y for m or e in for m a t ion . n a ls. Th e (+) t er m in a l will sh ow ba t t er y volt a ge
Also r efer t o t h e oper a t in g in st r u ct ion s su pplied wit h (12.5–14.5 volt s). Th e (-) t er m in a l will sh ow 3–5 volt s
t est equ ipm en t . less t h a n ba t t er y volt a ge.
(11) Con n ect t h e in du ct ive cla m p (a m m et er pr obe).
Refer t o t h e oper a t in g in st r u ct ion s su pplied wit h t est CAUTION: Do not connect the jumper ground wire
equ ipm en t . to the generator field source (+) field terminal. Dam-
(12) If volt /a m p t est er is n ot equ ipped wit h a n age to electrical system components may result.
en gin e t a ch om et er, con n ect a sepa r a t e t a ch om et er t o
t h e en gin e. Con n ect in g t h e ju m per wir e will r em ove t h e volt -
a ge r egu la t or cir cu it r y fr om t h e t est . It will a lso gen -
T EST 1 er a t e a Dia gn ost ic Tr ou ble Code (DTC).
(1) P er for m t h e pr eviou s t est P r epa r a t ion . (4) St a r t en gin e. Im m e d ia te ly a ft er st a r t in g,
(2) F u lly en ga ge t h e pa r kin g br a ke. r edu ce en gin e speed t o idle. Th is will pr even t a n y
(3) St a r t en gin e. elect r ica l a ccessor y da m a ge fr om h igh volt a ge.
(4) Br in g en gin e speed t o 2500 r pm . (5) Adju st ca r bon pile r h eost a t (loa d) a n d en gin e
speed in slow in cr em en t s u n t il a speed of 1250 r pm ,
BATTERY TRAY BATTERY TEMPERATURE SENSOR
XJ CHARGING SYSTEM 8C - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)
a n d a volt m et er r ea din g of 15 volt s is obt a in ed. ,,______'I
Im m edia t ely r ecor d a m m et er r ea din g. Do n ot a pply BATTERY
loa d t o syst em lon ger t h a n 15 secon ds a s da m a ge t o
TEMPERATURE
SENSOR
t est equ ipm en t m a y r esu lt .
8C - 6 CHARGING SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(F ig. 4). P osit ion gen er a t or for a ccess t o wir e con n ec-
UPPER
t or s.
NUT
(4) Righ t H a n d Dr ive (RH D) Veh icles On ly:
Rem ove u pper n u t (gen er a t or a dju st m en t n u t ) a n d
--®~
bot h belt a dju st m en t bolt s (F ig. 5). Rem ove gen er a t or
lower n u t /bolt . P osit ion gen er a t or for a ccess t o wir e
con n ect or s.
LOWER
BELT BOLT
ADJUSTMENT
BOLTS
GENERATOR
80a92a69
B+TERMINAL
LOWER
BOLT
80a592b2
80a92a67
LOWER I N STALLAT I ON
BOLT (1) P osit ion gen er a t or t o en gin e a n d in st a ll wir in g
t o r ea r of gen er a t or. Tigh t en a ll wir in g fa st en er s a s
80a592b1
follows:
Fig. 4 Remove/Install Generator—4.0L Engine—LHD • Ba t t er y t er m in a l n u t -8.5 N·m (75 in . lbs.)
• Gr ou n d t er m in a l n u t -8.5 N·m (75 in . lbs.)
(5) Rem ove n u t s fr om h a r n ess h old-down , ba t t er y • H a r n ess h old-down n u t -8.5 N·m (75 in . lbs.)
t er m in a l, gr ou n d t er m in a l a n d 2 field t er m in a ls. • F ield t er m in a l n u t s-2.8 N·m (25 in . lbs.)
BATTERY TRAY BATTERY TEMPERATURE SENSOR
XJ CHARGING SYSTEM 8C - 7
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) LH D Veh icles: In st a ll gen er a t or fa st en er s a n d ,,______'I
t igh t en a s follows: BATTERY
• Gen er a t or u pper m ou n t in g bolt -55 N·m (41 ft .
TEMPERATURE
SENSOR
lbs.)
• Gen er a t or lower pivot bolt /n u t -55 N·m (41 ft .
lbs.)
SPECI FI CAT I ON S
GENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
DENSO 56005685AB 119 2.5L/4.0L 90
IGNITION SYSTEM
CON T EN T S
page page
8D - 2 IGNITION SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
• Secon da r y Ign it ion Ca bles
• Dist r ibu t or (con t a in s r ot or a n d ca m sh a ft posit ion
sen sor )
• P ower t r a in Con t r ol Modu le (P CM)
• Cr a n ksh a ft P osit ion , Ca m sh a ft P osit ion , Th r ot - SYNC
SIGNAL
t le P osit ion a n d MAP Sen sor s GENERATOR
DISTRIBUTOR
ASSEMBLY
XJ IGNITION SYSTEM 8D - 3
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Th e ca bles pr ovide su ppr ession of r a dio fr equ en cy gen er a t es pu lses t h a t a r e t h e in pu t sen t t o t h e pow-
em ission s fr om t h e ign it ion syst em . er t r a in con t r ol m odu le (P CM). Th e P CM in t er pr et s
t h e sen sor in pu t t o det er m in e t h e cr a n ksh a ft posi-
IGNITION COIL t ion . Th e P CM t h en u ses t h is posit ion , a lon g wit h
Ba t t er y volt a ge is su pplied t o t h e ign it ion coil pos- ot h er in pu t s, t o det er m in e in ject or sequ en ce a n d ign i-
it ive t er m in a l fr om t h e ASD r ela y. t ion t im in g.
Th e P ower t r a in Con t r ol Modu le (P CM) open s a n d Th e sen sor is a h a ll effect device com bin ed wit h a n
closes t h e ign it ion coil gr ou n d cir cu it for ign it ion coil in t er n a l m a gn et . It is a lso sen sit ive t o st eel wit h in a
oper a t ion . cer t a in dist a n ce fr om it .
B a s e ig n itio n tim in g is n o t a d ju s ta ble o n a n y
e n g in e . By con t r ollin g t h e coil gr ou n d cir cu it , t h e SEN SOR OPERAT I ON
P CM is a ble t o set t h e ba se t im in g a n d a dju st t h e Th e flywh eel/dr ive pla t e h a s gr ou ps of fou r n ot ch es
ign it ion t im in g a dva n ce. Th is is don e t o m eet ch a n g- a t it s ou t er edge. On 4.0L 6-cylin der en gin es t h er e
in g en gin e oper a t in g con dit ion s. a r e t h r ee set s of n ot ch es (F ig. 5). On 2.5L 4-cylin der
Th e ign it ion coil is n ot oil filled. Th e win din gs a r e en gin es t h er e a r e t wo set s of n ot ch es (F ig. 4).
em bedded in a n epoxy com pou n d. Th is pr ovides h ea t Th e n ot ch es ca u se a pu lse t o be gen er a t ed wh en
a n d vibr a t ion r esist a n ce t h a t a llows t h e ign it ion coil t h ey pa ss u n der t h e sen sor. Th e pu lses a r e t h e in pu t
t o be m ou n t ed on t h e en gin e. t o t h e P CM. F or ea ch en gin e r evolu t ion t h er e a r e t wo
gr ou ps of fou r pu lses gen er a t ed on 2.5L 4-cylin der
AUTOMATIC SHUTDOWN (ASD) RELAY en gin es. Th er e a r e 3 gr ou ps of fou r pu lses gen er a t ed
As on e of it s fu n ct ion s, t h e ASD r ela y will su pply on 4.0L 6-cylin der en gin es.
ba t t er y volt a ge t o t h e ign it ion coil. Th e gr ou n d cir- Th e t r a ilin g edge of t h e fou r t h n ot ch , wh ich ca u ses
cu it for t h e ASD r ela y is con t r olled by t h e P ower t r a in t h e pu lse, is fou r degr ees befor e t op dea d cen t er
Con t r ol Modu le (P CM). Th e P CM r egu la t es ASD (TDC) of t h e cor r espon din g pist on .
r ela y oper a t ion by swit ch in g t h e gr ou n d cir cu it Th e en gin e will n ot oper a t e if t h e P CM does n ot
on -a n d-off. r eceive a cr a n ksh a ft posit ion sen sor in pu t .
RUBBER
GROMMET Fig. 4 Sensor Operation—2.5L 4-Cyl. Engine
CRANKSHAFT \ CAMSHAFT POSITION SENSOR
POSITION \ Th e ca m sh a ft posit ion sen sor is loca t ed in t h e dis-
SENSOR 80a43752 t r ibu t or on a ll en gin es.
Th e sen sor con t a in s a h a ll effect device ca lled a
Fig. 3 Crankshaft Position Sensor—Typical syn c sign a l gen er a t or t o gen er a t e a fu el syn c sign a l.
E n gin e speed a n d cr a n ksh a ft posit ion a r e pr ovided Th is syn c sign a l gen er a t or det ect s a r ot a t in g pu lse
t h r ou gh t h e cr a n ksh a ft posit ion sen sor. Th e sen sor r in g (sh u t t er ) on t h e dist r ibu t or sh a ft . Th e pu lse r in g
NOTCHES
CRANKSHAFT POSITION
SENSOR FLYWHEEL
8D - 4 IGNITION SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
CRANKSHAFT INTAKE MANIFOLD AIR TEMPERATURE SENSOR
POSITION
SENSOR
F or a n oper a t ion a l descr ipt ion , dia gn osis a n d
r em ova l/in st a lla t ion pr ocedu r es, r efer t o Gr ou p 14,
F u el Syst em .
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CAUTION: When disconnecting a high voltage
cable from a spark plug or from the distributor cap,
F or a n oper a t ion a l descr ipt ion , dia gn osis a n d
twist the rubber boot slightly (1/2 turn) to break it
r em ova l/in st a lla t ion pr ocedu r es, r efer t o Gr ou p 14,
loose (Fig. 6). Grasp the boot (not the cable) and
F u el Syst em .
pull it off with a steady, even force.
ENGINE COOLANT TEMPERATURE SENSOR (1) Discon n ect t h e ign it ion coil secon da r y ca ble
F or a n oper a t ion a l descr ipt ion , dia gn osis a n d fr om cen t er t ower of t h e dist r ibu t or ca p. H old t h e
r em ova l/in st a lla t ion pr ocedu r es, r efer t o Gr ou p 14, ca ble t er m in a l a ppr oxim a t ely 12 m m (1/2 in .) fr om a
F u el Syst em . good en gin e gr ou n d (F ig. 7).
THROTTLE POSITION SENSOR WARNING: BE VERY CAREFUL WHEN THE
F or a n oper a t ion a l descr ipt ion , dia gn osis a n d ENGINE IS CRANKING. DO NOT PUT YOUR HANDS
r em ova l/in st a lla t ion pr ocedu r es, r efer t o Gr ou p 14, NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT
F u el Syst em . WEAR LOOSE FITTING CLOTHING.
CHECK
SPARK
CABLE
FOR SPARK
HERE
BOOT
PLUG
AND SPARK PLUG
A
ENGINE
GROUND
SPARK
GOOD TWIST
PLUG
PULLER
AND
BOOT
IGNITION
PULL COIL SECONDARYMOUNTING
MOUNTING
CABLE BOLTS
BOLTS (2) SECONDARY
CABLEIGNITIONELECTRICAL
COIL
ELECTRICAL
IGNITION
NECTOR
NECTOR
CON-
CON-
COIL
XJ IGNITION SYSTEM 8D - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)
IGNITION COIL TEST
SPARK PLUG BOOT To per for m a com plet e t est of t h e ign it ion coil a n d
PULLER
it s cir cu it r y, r efer t o t h e DRB sca n t ool. Also r efer t o
t h e a ppr opr ia t e P ower t r a in Dia gn ost ics P r ocedu r es
SPARK PLUG
CABLE AND m a n u a l. To t est t h e coil on ly, r efer t o t h e followin g:
BOOT Th e ign it ion coil (F ig. 8) or (F ig. 9) is design ed t o
oper a t e wit h ou t a n ext er n a l ba lla st r esist or .
958D-9
A GOOD
ENGINE
GROUND
EVIDENCE OF
PHYSICAL
CONTACT
WITH CAP J908D-48
CARBON
PATH
Fig. 14 Rotor Inspection—Typical
IGNITION TIMING
CHARRED OR
ERODED NOTE: Do not attempt to modify the distributor
TERMINALS housing to get distributor rotation. Distributor posi-
tion will have no effect on ignition timing.
8D - 8 IGNITION SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
CAMSHAFT POSITION SENSOR t er m in a l. Lea ve t h e P CM con n ect or con n ect ed for
Th e ca m sh a ft posit ion sen sor is loca t ed in t h e dis- t h is t est .
t r ibu t or (F ig. 15) on a ll en gin es. (9) If volt a ge is st ill n ot pr esen t , per for m veh icle
t est u sin g t h e DRB sca n t ool.
(10) If volt a ge is pr esen t a t ca vit y A-17, bu t n ot a t
t h e su pply wir e:
(a ) Ch eck con t in u it y bet ween t h e su pply wir e.
SYNC Th is is ch ecked bet ween t h e dist r ibu t or con n ect or
SIGNAL a n d ca vit y A-17 a t t h e P CM. If con t in u it y is n ot
GENERATOR pr esen t , r epa ir t h e h a r n ess a s n ecessa r y.
(b) Ch eck for con t in u it y bet ween t h e ca m sh a ft
posit ion sen sor ou t pu t wir e a n d ca vit y A-18 a t t h e
P CM. If con t in u it y is n ot pr esen t , r epa ir t h e h a r-
n ess a s n ecessa r y.
(c) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it wir e a t t h e dist r ibu t or con n ect or a n d gr ou n d.
If con t in u it y is n ot pr esen t , r epa ir t h e h a r n ess a s
DISTRIBUTOR n ecessa r y.
ASSEMBLY
(11) Wh ile obser vin g t h e volt m et er, cr a n k t h e
en gin e wit h ign it ion swit ch . Th e volt m et er n eedle
Fig. 15 Camshaft Position Sensor—Typical sh ou ld flu ct u a t e bet ween 0 a n d 5 volt s wh ile t h e
en gin e is cr a n kin g. Th is ver ifies t h a t t h e ca m sh a ft
To per for m a com plet e t est of t h is sen sor a n d it s
posit ion sen sor in t h e dist r ibu t or is oper a t in g pr op-
cir cu it r y, r efer t o t h e a ppr opr ia t e P ower t r a in Dia g-
er ly a n d a syn c pu lse sign a l is bein g gen er a t ed.
n ost ics P r ocedu r es ser vice m a n u a l. To t est t h e sen sor
If syn c pu lse sign a l is n ot pr esen t , r epla cem en t of
on ly, r efer t o t h e followin g:
t h e ca m sh a ft posit ion sen sor is n ecessa r y
F o r th is te s t, a n a n a lo g (n o n -d ig ita l) v o ltm e -
te r is n e e d e d . Do n ot r em ove t h e dist r ibu t or con n ec-
t or fr om t h e dist r ibu t or. Usin g sm a ll pa per clips,
ENGINE COOLANT TEMPERATURE SENSOR
F or a n oper a t ion a l descr ipt ion , dia gn osis a n d
in ser t t h em in t o t h e ba ckside of t h e dist r ibu t or wir e
r em ova l/in st a lla t ion pr ocedu r es, r efer t o Gr ou p 14,
h a r n ess con n ect or t o m a ke con t a ct wit h t h e t er m i-
F u el Syst em .
n a ls. Be su r e t h a t t h e con n ect or is n ot da m a ged
wh en in ser t in g t h e pa per clips. At t a ch volt m et er
lea ds t o t h ese pa per clips.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
F or a n oper a t ion a l descr ipt ion , dia gn osis a n d
(1) Con n ect t h e posit ive (+) volt m et er lea d in t o t h e
r em ova l/in st a lla t ion pr ocedu r es, r efer t o Gr ou p 14,
sen sor ou t pu t wir e. Th is is a t don e t h e dist r ibu t or
F u el Syst em .
wir e h a r n ess con n ect or. F or wir e iden t ifica t ion , r efer
t o Gr ou p 8W, Wir in g Dia gr a m s.
(2) Con n ect t h e n ega t ive (-) volt m et er lea d in t o t h e
SPARK PLUG CABLES
Ch eck t h e spa r k plu g ca ble con n ect ion s for good
gr ou n d wir e. F or wir e iden t ifica t ion , r efer t o Gr ou p
con t a ct a t t h e coil(s), dist r ibu t or ca p t ower s, a n d
8W, Wir in g Dia gr a m s.
spa r k plu gs. Ter m in a ls sh ou ld be fu lly sea t ed. Th e
(3) Set t h e volt m et er t o t h e 15 Volt DC sca le.
in su la t or s sh ou ld be in good con dit ion a n d sh ou ld fit
(4) Rem ove dist r ibu t or ca p fr om dist r ibu t or (t wo
t igh t ly on t h e coil, dist r ibu t or a n d spa r k plu gs. Spa r k
scr ews). Rot a t e (cr a n k) t h e en gin e u n t il t h e dist r ibu -
plu g ca bles wit h in su la t or s t h a t a r e cr a cked or t or n
t or r ot or is a ppr oxim a t ely in t h e 11 o’clock posit ion .
m u st be r epla ced.
Th e m ova ble pu lse r in g sh ou ld n ow be wit h in t h e
Clea n h igh volt a ge ign it ion ca bles wit h a clot h
sen sor picku p.
m oist en ed wit h a n on -fla m m a ble solven t . Wipe t h e
(5) Tu r n ign it ion key t o ON posit ion . Volt m et er
ca bles dr y. Ch eck for br it t le or cr a cked in su la t ion .
sh ou ld r ea d a ppr oxim a t ely 5.0 volt s.
(6) If volt a ge is n ot pr esen t , ch eck t h e volt m et er T EST I N G
lea ds for a good con n ect ion . Wh en t est in g secon da r y ca bles for da m a ge wit h a n
(7) If volt a ge is st ill n ot pr esen t , ch eck for volt a ge oscilloscope, follow t h e in st r u ct ion s of t h e equ ipm en t
a t t h e su pply wir e. F or wir e iden t ifica t ion , r efer t o m a n u fa ct u r er.
Gr ou p 8W, Wir in g Dia gr a m s. If a n oscilloscope is n ot a va ila ble, spa r k plu g ca bles
(8) If 5 volt s is n ot pr esen t a t su pply wir e, ch eck m a y be t est ed a s follows:
for volt a ge a t P CM 32-wa y con n ect or (ca vit y A-17).
Refer t o Gr ou p 8W, Wir in g for loca t ion of con n ect or /
NORMAL DRY DEPOSITS
BLACK COLD (CARBON) FOULING
XJ IGNITION SYSTEM 8D - 9
DI AGN OSI S AN D T EST I N G (Cont inue d)
CAUTION: Do not leave any one spark plug cable SPARK PLUG CONDITIONS
disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the N ORM AL OPERAT I N G
catalytic converter. Total test time must not exceed Th e few deposit s pr esen t on t h e spa r k plu g will
ten minutes. pr oba bly be ligh t t a n or sligh t ly gr a y in color. Th is is
eviden t wit h m ost gr a des of com m er cia l ga solin e
Wit h t h e en gin e r u n n in g, r em ove spa r k plu g ca ble (F ig. 16). Th er e will n ot be eviden ce of elect r ode
fr om spa r k plu g (on e a t a t im e) a n d h old n ext t o a bu r n in g. Ga p gr owt h will n ot a ver a ge m or e t h a n
good en gin e gr ou n d. If t h e ca ble a n d spa r k plu g a r e a ppr oxim a t ely 0.025 m m (.001 in ) per 1600 km (1000
in good con dit ion , t h e en gin e r pm sh ou ld dr op a n d m iles) of oper a t ion . Spa r k plu gs t h a t h a ve n or m a l
t h e en gin e will r u n poor ly. If en gin e r pm does n ot wea r ca n u su a lly be clea n ed, h a ve t h e elect r odes
dr op, t h e ca ble a n d/or spa r k plu g m a y n ot be oper a t - filed, h a ve t h e ga p set a n d t h en be in st a lled.
in g pr oper ly a n d sh ou ld be r epla ced. Also ch eck
en gin e cylin der com pr ession . NORMAL DRY BLACK COLD (CARBON) FOULING
DEPOSITS
Wit h t h e en gin e n ot r u n n in g, con n ect on e en d of a
t est pr obe t o a good gr ou n d. St a r t t h e en gin e a n d r u n
t h e ot h er en d of t h e t est pr obe a lon g t h e en t ir e
len gt h of a ll spa r k plu g ca bles. If ca bles a r e cr a cked
or pu n ct u r ed, t h er e will be a n ot icea ble spa r k ju m p
fr om t h e da m a ged a r ea t o t h e t est pr obe. Th e ca ble
r u n n in g fr om t h e ign it ion coil t o t h e dist r ibu t or ca p
ca n be ch ecked in t h e sa m e m a n n er. Cr a cked, da m -
a ged or fa u lt y ca bles sh ou ld be r epla ced wit h r esis-
t a n ce t ype ca ble. Th is ca n be iden t ified by t h e wor ds
E LE CTRONIC SUP P RE SSION pr in t ed on t h e ca ble
ja cket .
Use a n oh m m et er t o t est for open cir cu it s, exces-
sive r esist a n ce or loose t er m in a ls. Rem ove t h e dis- J908D-15
t r ibu t or ca p fr om t h e dist r ibu t or. D o n o t re m o v e
c a ble s fro m c a p . Rem ove ca ble fr om spa r k plu g. Fig. 16 Normal Operation and Cold (Carbon) Fouling
Con n ect oh m m et er t o spa r k plu g t er m in a l en d of Som e fu el r efin er s in sever a l a r ea s of t h e Un it ed
ca ble a n d t o cor r espon din g elect r ode in dist r ibu t or St a t es h a ve in t r odu ced a m a n ga n ese a ddit ive (MMT)
ca p. Resist a n ce sh ou ld be 250 t o 1000 Oh m s per in ch for u n lea ded fu el. Du r in g com bu st ion , fu el wit h MMT
of ca ble. If n ot , r em ove ca ble fr om dist r ibu t or ca p ca u ses t h e en t ir e t ip of t h e spa r k plu g t o be coa t ed
t ower a n d con n ect oh m m et er t o t h e t er m in a l en ds of wit h a r u st color ed deposit . Th is r u st color ca n be
ca ble. If r esist a n ce is n ot wit h in specifica t ion s a s m isdia gn osed a s bein g ca u sed by coola n t in t h e com -
fou n d in t h e Spa r k P lu g Ca ble Resist a n ce ch a r t , bu st ion ch a m ber. Spa r k plu g per for m a n ce is n ot
r epla ce t h e ca ble. Test a ll spa r k plu g ca bles in t h is a ffect ed by MMT deposit s.
m a n n er .
COLD FOU LI N G/CARBON FOU LI N G
MINIMUM MAXIMUM Cold fou lin g is som et im es r efer r ed t o a s ca r bon
250 Ohms Per Inch 1000 Ohms Per Inch fou lin g. Th e deposit s t h a t ca u se cold fou lin g a r e ba si-
3000 Ohms Per Foot 12,000 Ohms Per Foot ca lly ca r bon (F ig. 16). A dr y, bla ck deposit on on e or
t wo plu gs in a set m a y be ca u sed by st ickin g va lves
or defect ive spa r k plu g ca bles. Cold (ca r bon ) fou lin g
SPARK PLUG CABLE RESISTANCE
of t h e en t ir e set of spa r k plu gs m a y be ca u sed by a
To t est ign it ion coil-t o-dist r ibu t or ca p ca ble, do n ot clogged a ir clea n er elem en t or r epea t ed sh or t oper a t -
r em ove t h e ca ble fr om t h e ca p. Con n ect oh m m et er t o in g t im es (sh or t t r ips).
r ot or bu t t on (cen t er con t a ct ) of dist r ibu t or ca p a n d
t er m in a l a t ign it ion coil en d of ca ble. If r esist a n ce is WET FOU LI N G OR GAS FOU LI N G
n ot wit h in specifica t ion s a s fou n d in t h e Spa r k P lu g A spa r k plu g coa t ed wit h excessive wet fu el or oil
Ca ble Resist a n ce ch a r t , r em ove t h e ca ble fr om t h e is wet fou led. In older en gin es, wor n pist on r in gs,
dist r ibu t or ca p. Con n ect t h e oh m m et er t o t h e t er m i- lea kin g va lve gu ide sea ls or excessive cylin der wea r
n a l en ds of t h e ca ble. If r esist a n ce is n ot wit h in spec- ca n ca u se wet fou lin g. In n ew or r ecen t ly over h a u led
ifica t ion s a s fou n d in t h e Spa r k P lu g Ca ble en gin es, wet fou lin g m a y occu r befor e br ea k-in (n or-
Resist a n ce ch a r t , r epla ce t h e ca ble. In spect t h e ign i- m a l oil con t r ol) is a ch ieved. Th is con dit ion ca n u su -
t ion coil t ower for cr a cks, bu r n s or cor r osion .
GROUND
ELEC-
CENTER
TRODE
ELECTRODEGROUND ELECTRODE COVERED WITH WHITE OR YELLOW
CENTER
ELECTRODE
DEPOSITS
DEPOSITS
8D - 10 IGNITION SYSTEM XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
a lly be r esolved by clea n in g a n d r ein st a llin g t h e GROUND
fou led plu gs. ELECTRODE
DEPOSITS
OI L OR ASH EN CRU ST ED
If on e or m or e spa r k plu gs a r e oil or oil a sh
en cr u st ed (F ig. 17), eva lu a t e en gin e con dit ion for t h e
ca u se of oil en t r y in t o t h a t pa r t icu la r com bu st ion
ch a m ber .
J908D-l 1
XJ IGNITION SYSTEM 8D - 11
DI AGN OSI S AN D T EST I N G (Cont inue d)
GROUND BLISTERED
ELECTRODE CENTER WHITE OR
ELECTRODE GRAY
COLORED
INSULATOR
J908D-13 J908D-16
CENTER
ELECTRODE
DISSOLVED
FIRING ORDER:
REM OVAL AN D I N STALLAT I ON 1 3 4 2
CLOCKWISE
ROTATION
SPARK PLUG CABLES
CAUTION: When disconnecting a high voltage J908D-6
cable from a spark plug or from the distributor cap,
twist the rubber boot slightly (1/2 turn) to break it
Fig. 24 Engine Firing Order—2.5L 4-Cylinder Engine
loose (Fig. 23). Grasp the boot (not the cable) and
pull it off with a steady, even force.
8D - 12 IGNITION SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
PLU G GAP ADJ U ST M EN T
Ch eck t h e spa r k plu g ga p wit h a ga p ga u ge t ool. If
t h e ga p is n ot cor r ect , a dju st it by ben din g t h e
gr ou n d elect r ode (F ig. 26). N e v e r a tte m p t to a d ju s t
th e g a p by be n d in g th e c e n te r e le c tro d e .
.040 .035
.030
FIRING ORDER:
'\ GAUGE
l 5 3 6 2 4
CLOCKWISE
ROTATION
J908D-7
XJ IGNITION SYSTEM 8D - 13
REM OVAL AN D I N STALLAT I ON (Cont inue d)
REM OVAL (2) Con n ect en gin e h a r n ess con n ect or t o coil.
On t h e 2.5L 4-cylin der en gin e, t h e ign it ion coil is (3) Con n ect ign it ion coil ca ble t o ign it ion coil.
m ou n t ed t o a br a cket on side of en gin e (t o r ea r of
dist r ibu t or ) (F ig. 27). AUTOMATIC SHUTDOWN (ASD) RELAY
On t h e 4.0L 6-cylin der en gin e, t h e ign it ion coil is Th e ASD r ela y is loca t ed in t h e power dist r ibu t ion
m ou n t ed t o a br a cket on side of en gin e (t o fr on t of cen t er (P DC). Th e P DC is loca t ed in en gin e com pa r t -
dist r ibu t or ) (F ig. 28). m en t (F ig. 29). Refer t o la bel on P DC cover for r ela y
loca t ion .
'-
SECONDARY
~Jt
MOUNTING BOLTS--...
I N STALLAT I ON
(1) Ch eck con dit ion of r ela y wir e t er m in a ls a t P DC
for cor r osion or da m a ge. Also ch eck h eigh t s of r ela y
t er m in a l pin s a t P DC. P in h eigh t sh ou ld be t h e sa m e
for a ll pin s. Repa ir a s n ecessa r y befor e in st a llin g
Fig. 28 Ignition Coil—4.0L Engine r ela y.
(2) P u sh r ela y in t o con n ect or.
(1) Discon n ect ign it ion coil secon da r y ca ble fr om (3) In st a ll r ela y cover.
ign it ion coil.
(2) Discon n ect en gin e h a r n ess con n ect or fr om ign i- CRANKSHAFT POSITION SENSOR
t ion coil. Th e cr a n ksh a ft posit ion sen sor is m ou n t ed t o t h e
(3) Rem ove ign it ion coil m ou n t in g bolt s (n u t s a r e t r a n sm ission bellh ou sin g a t t h e left /r ea r side of
u sed on ba ck side of br a cket on som e coils). en gin e block (F ig. 30) or (F ig. 31).
(4) Rem ove coil fr om veh icle. On 2.5L 4-cylin der equ ipped wit h a m a n u a l t r a n s-
m ission , t h e sen sor is a t t a ch ed wit h t wo bolt s. On
I N STALLAT I ON
2.5L en gin es equ ipped wit h a n a u t om a t ic t r a n sm is-
(1) In st a ll ign it ion coil t o br a cket on cylin der block
sion , t h e sen sor is a t t a ch ed wit h t wo n u t s. All 4.0L
wit h m ou n t in g bolt s (a n d n u t s if equ ipped). If
6-cylin der en gin es h a ve t h e sen sor a t t a ch ed wit h t wo
equ ipped wit h n u t s a n d bolt s, t igh t en t o 11 N·m (100
bolt s.
in . lbs.) t or qu e. If equ ipped wit h bolt s on ly, t igh t en t o
5 N·m (50 in . lbs.) t or qu e.
8D - 14 IGNITION SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(3) Rem ove n u t h oldin g sen sor h a r n ess wir e cla m p
t o fu el r a il m ou n t in g st u d.
(4) Depen din g u pon a pplica t ion , r em ove eit h er sen -
sor m ou n t in g bolt s or n u t s.
(5) Rem ove sen sor.
(6) Rem ove cla m p fr om sen sor wir e h a r n ess.
I N STALLAT I ON
(1) In st a ll sen sor flu sh a ga in st open in g in t r a n s-
m ission h ou sin g.
(2) 2.5L en gin es equ ipped wit h a u t om a t ic t r a n s-
m ission : In st a ll a n d t igh t en t wo sen sor m ou n t in g
n u t s t o 19 N·m (14 ft . lbs.) t or qu e.
(3) 2.5L en gin es equ ipped wit h m a n u a l t r a n sm is-
sion or a n y 4.0L en gin es: In st a ll a n d t igh t en t wo sen -
sor m ou n t in g bolt s t o 19 N·m (14 ft . lbs.) t or qu e. Th e
tw o s e n s o r m o u n tin g bo lts a re s p e c ia lly
RUBBER
GROMMET m a c h in e d to c o rre c tly s p a c e u n it to fly w h e e l.
D o n o t a tte m p t to in s ta ll a n y o th e r bo lts .
CRANKSHAFT \ (4) Con n ect sen sor pigt a il h a r n ess elect r ica l con -
POSITION \
NUTS (2) n ect or t o m a in wir in g h a r n ess.
SENSOR soa4s1s1
(5) In st a ll cla m p on sen sor wir e h a r n ess.
Fig. 30 Crankshaft Position Sensor—2.5L 4-Cyl. (6) In st a ll cla m p over fu el r a il m ou n t in g st u d.
Engine With Auto. Trans. (7) In st a ll cla m p m ou n t in g n u t .
(8) In st a ll a ir clea n er t u be t o t h r ot t le body (if n ec-
essa r y).
REM OVAL
Dist r ibu t or r em ova l is n ot n ecessa r y t o r em ove
ca m sh a ft posit ion sen sor.
SYNC
DISTRIBUTOR
GENERATOR
ASSEMBLY
SIGNAL
(1) Discon n ect n ega t ive ba t t er y PULSE
ca bleRING
aCAMSHAFT
POSITION SEN-
t ba t t erSOR
y.
(2) Rem ove dist r ibu t or ca p fr om dist r ibu t or (t wo
scr ews).
(3) Discon n ect ca m sh a ft posit ion sen sor wir in g
h a r n ess fr om m a in en gin e wir in g h a r n ess.
RUBBER
GROMMET
CRANKSHAFT \ SYNC
POSITION \ SIGNAL
GENERATOR
SENSOR 80a43752
XJ IGNITION SYSTEM 8D - 15
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(4) Rem ove dist r ibu t or r ot or fr om dist r ibu t or sh a ft .
(5) Lift ca m sh a ft posit ion sen sor a ssem bly fr om
dist r ibu t or h ou sin g (F ig. 32).
I N STALLAT I ON
(1) In st a ll ca m sh a ft posit ion sen sor t o dist r ibu t or.
Align sen sor in t o n ot ch on dist r ibu t or h ou sin g.
(2) Con n ect wir in g h a r n ess.
(3) In st a ll r ot or.
(4) In st a ll dist r ibu t or ca p. Tigh t en m ou n t in g
scr ews.
PLASTIC
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR ALIGNMENT
F or r em ova l a n d in st a lla t ion , r efer t o Ma n ifold PIN
Absolu t e P r essu r e Sen sor in gr ou p 14, F u el Syst em s.
DISTRIBUTOR
All dist r ibu t or s con t a in a n in t er n a l oil sea l t h a t
pr even t s oil fr om en t er in g t h e dist r ibu t or h ou sin g.
Th e sea l is n ot ser vicea ble.
~-.. I ROTOR I
~y~~(
F a ct or y r epla cem en t dist r ibu t or s a r e equ ipped wit h
a pla st ic a lign m en t pin a lr ea dy in st a lled. Th e pin is
loca t ed in a n a ccess h ole on t h e bot t om of t h e dist r ib-
u t or h ou sin g (F ig. 33). It is u sed t o t em por a r ily lock
t h e r ot or t o t h e cylin der n u m ber 1 posit ion du r in g HOLDDOWN
in st a lla t ion . Th e pin m u st be r em oved a ft er in st a ll- I BOLT ~
in g t h e dist r ibu t or .
Th e ca m sh a ft posit ion sen sor is loca t ed in t h e dis- HOLDDOWN~>
CLAMP ···· ,~•. . .•. .•.
.•. . -- FORK
/,-
·+ WITH
t r ibu t or on a ll en gin es (F ig. 34). F or r em ova l/in st a l-
la t ion pr ocedu r es, r efer t o Ca m sh a ft P osit ion Sen sor.
GASKET ----0 SLOT
Ll-'-\_\..o..'-\-,-------~
11 O'CLOCK POSITION
CRANKSHAFT
VIBRATION DAMPER
TIMING MARK OIL
PUMP
J898D-14 SLOT J958D-7
XJ IGNITION SYSTEM 8D - 17
REM OVAL AN D I N STALLAT I ON (Cont inue d)
I N STALLAT I ON
(1) If t h e en gin e cr a n ksh a ft h a s been r ot a t ed a ft er
dist r ibu t or r em ova l, cylin der n u m ber 1 m u st be
r et u r n ed t o it s pr oper fir in g st r oke. Refer t o pr eviou s
RE MOVAL St ep 5 a n d St ep 6. Th ese st eps m u st be
don e befor e in st a llin g dist r ibu t or.
(2) Ch eck t h e posit ion of t h e slot on t h e oil pu m p
gea r. On t h e 2.5L en gin e, it sh ou ld be ju st sligh t ly
befor e (cou n t er clockwise of) t h e 10 o’clock posit ion
(F ig. 36). On t h e 4.0L en gin e, it sh ou ld be ju st
sligh t ly befor e (cou n t er clockwise of) t h e 11 o’clock
posit ion (F ig. 37). If n ot , pla ce a fla t bla de scr ew-
dr iver in t o t h e oil pu m p gea r a n d r ot a t e it in t o t h e
pr oper posit ion .
(3) F a ct or y r epla cem en t dist r ibu t or s a r e equ ipped
wit h a pla st ic a lign m en t pin a lr ea dy in st a lled (F ig.
33). Th is pin is u sed t o t em por a r ily h old t h e r ot or t o 2.5L
4-CYLINDER
t h e cylin der n u m ber 1 fir in g posit ion du r in g dist r ib- ENGINE
u t or in st a lla t ion . If t h is pin is in pla ce, pr oceed t o ALIGN. HOLE
St ep 8. If n ot , pr oceed t o n ext st ep. MATING ACCESS HOLE
(4) If t h e or igin a l dist r ibu t or is t o be r ein st a lled, IN DISTRIBUTOR HOUSING J958D-5
su ch a s du r in g en gin e over h a u l, t h e pla st ic pin will
n ot be a va ila ble. A 3/16 in ch dr ift pin pu n ch t ool m a y Fig. 38 Pin Alignment Holes
be su bst it u t ed for t h e pla st ic pin . r ot or a n d dist r ibu t or will r ot a t e clockwise du r in g
(5) Rem ove t h e ca m sh a ft posit ion sen sor fr om t h e in st a lla t ion . Th is is du e t o t h e h elica l cu t gea r s on
dist r ibu t or h ou sin g. Lift st r a igh t u p. t h e dist r ibu t or a n d ca m sh a ft . Wh en t h e dist r ibu t or is
(6) F ou r differ en t a lign m en t h oles a r e pr ovided on fu lly sea t ed t o t h e en gin e block, t h e cen t er lin e of t h e
t h e pla st ic r in g (F ig. 38). N o te th a t 2.5L a n d 4.0L ba se slot sh ou ld be a lign ed t o t h e cla m p bolt m ou n t -
e n g in e s h a v e d iffe re n t a lig n m e n t h o le s (F ig . in g h ole on t h e en gin e (F ig. 41). Th e r ot or sh ou ld
38). a lso be poin t ed a t t h e 5 o’clock posit ion .
(7) Rot a t e t h e dist r ibu t or sh a ft a n d in st a ll t h e pin It m a y be n ecessa r y t o r ot a t e t h e r ot or a n d dist r ib-
pu n ch t ool t h r ou gh t h e pr oper a lign m en t h ole in t h e u t or sh a ft (ver y sligh t ly) t o en ga ge t h e dist r ibu t or
pla st ic r in g (F ig. 38) a n d in t o t h e m a t in g a ccess h ole sh a ft wit h t h e slot in t h e oil pu m p gea r. Th e sa m e
in t h e dist r ibu t or h ou sin g. Th is will pr even t t h e dis- m a y h a ve t o be don e t o en ga ge t h e dist r ibu t or gea r
t r ibu t or sh a ft a n d r ot or fr om r ot a t in g. wit h t h e ca m sh a ft gea r .
(8) Clea n t h e dist r ibu t or m ou n t in g h ole a r ea of t h e Th e d is tribu to r is c o rre c tly in s ta lle d w h e n :
en gin e block. • t h e r ot or is poin t ed a t t h e 3 o’clock posit ion
(9) In st a ll a n ew dist r ibu t or-t o-en gin e block ga sket (2.5L en gin e), or a t t h e 5 o’clock posit ion (4.0L
(F ig. 34). en gin e).
(10) In st a ll t h e r ot or t o t h e dist r ibu t or sh a ft . • t h e pla st ic a lign m en t pin (or pin pu n ch t ool) is
(11) 2.5L 4-Cy lin d e r En g in e : P r e-posit ion t h e st ill in st a lled t o dist r ibu t or.
dist r ibu t or in t o t h e en gin e wh ile h oldin g t h e cen t er- • t h e n u m ber 1 cylin der pist on is set a t t op dea d
lin e of t h e ba se slot in t h e 1 o’clock posit ion (F ig. 39). cen t er (TDC) (com pr ession st r oke).
Con t in u e t o en ga ge t h e dist r ibu t or in t o t h e en gin e. • t h e cen t er lin e of t h e slot a t t h e ba se of t h e dis-
Th e r ot or a n d dist r ibu t or will r ot a t e clockwise du r in g t r ibu t or is a lign ed t o t h e cen t er lin e of t h e dist r ibu t or
in st a lla t ion . Th is is du e t o t h e h elica l cu t gea r s on h olddown bolt h ole on t h e en gin e. In t h is posit ion ,
t h e dist r ibu t or a n d ca m sh a ft . Wh en t h e dist r ibu t or is t h e h olddown bolt sh ou ld ea sily pa ss t h r ou gh t h e slot
fu lly sea t ed t o t h e en gin e block, t h e cen t er lin e of t h e a n d in t o t h e en gin e.
ba se slot sh ou ld be a lign ed t o t h e cla m p bolt m ou n t - No a dju st m en t s a r e n ecessa r y. P r oceed t o n ext
in g h ole on t h e en gin e (F ig. 40). Th e r ot or sh ou ld st ep.
a lso be poin t ed sligh t ly pa st (clockwise of) t h e 3 (12) In st a ll t h e dist r ibu t or h olddown cla m p a n d
o’clock posit ion . bolt . Tigh t en t h e bolt t o 23 N·m (17 ft . lbs.) t or qu e.
4.0L 6-Cy lin d e r En g in e : P r e-posit ion t h e dist r ib- (13) Rem ove t h e pin pu n ch t ool fr om t h e dist r ibu -
u t or in t o t h e en gin e wh ile h oldin g t h e cen t er lin e of t or. Or, if t h e pla st ic a lign m en t pin wa s u sed, r em ove
t h e ba se slot in t h e 1 o’clock posit ion (F ig. 39). Con - it st r a igh t down fr om t h e bot t om of t h e dist r ibu t or.
t in u e t o en ga ge t h e dist r ibu t or in t o t h e en gin e. Th e Disca r d pla st ic pin .
DISTRIBUTOR
BASEDISTRIBUTOR
1 POSITION
BASE
O’CLOCK
DISTRIBUTOR BASE
SLOTCLAMP
MOUNTING
BASE(ON
SLOT
FRONT
FRONT
ENGINE)
HOLE
BOLT DISTRIBUTOR
BASE DISTRIBUTOR
CLAMPBASE
HOLE
BOLT
SLOT
(ON
MOUNTING
ENGINE)FRONT
8D - 18 IGNITION SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
1 O'CLOCK FRONT • FRONT •
POSITION
\1 y
DISTRIBUTOR
BASE
SLOT
BASE
SLOT
DISTRIBUTOR
BASE
CLAMP BOLT
MOUNTING
DISTRIBUTOR HOLE
BASE J958D-8 (ON ENGINE) J958D-10
XJ IGNITION SYSTEM 8D - 19
REM OVAL AN D I N STALLAT I ON (Cont inue d)
KEY CYLINDER
••••••
PIN
PUNCH
ROTATE TO
80a43757 ON POSITION 80a43850
8D - 20 IGNITION SYSTEM XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
t ion s on VE CI la bel. Th e VE CI la bel is loca t ed in t h e
en gin e com pa r t m en t .
IGNITION TIMING
Ign it ion t im in g is n ot a dju st a ble on a n y en gin e.
Refer t o Ign it ion Tim in g in t h e Dia gn ost ics/Ser vice
P r ocedu r es sect ion of t h is gr ou p for m or e in for m a -
t ion .
FIRING ORDER:
1 3 4 2
Fig. 46 Ignition Switch Removal/Installation CLOCKWISE FRONT FIRING
1
CLOCKWISE
5 3 6 ORDER:
2 4 ROTATION
SHIFTER/IGNITION INTERLOCK
On m odels equ ipped wit h a n a u t om a t ic t r a n sm is-
sion , a ca ble con n ect s t h e ign it ion swit ch wit h t h e
floor sh ift lever. Th e sh ift er will be locked in t h e FIRING ORDER:
PARK posit ion wh en t h e ign it ion key is in t h e LOCK 1 5 3 6 2 4
or ACCE SSORY posit ion s. Th e ca ble ca n be a dju st ed CLOCKWISE
ROTATION
or r epla ced. Refer t o Gr ou p 21, Tr a n sm ission s for
pr ocedu r es. Th e ign it ion in t er lock device wit h in t h e J908D-7
st eer in g colu m n is n ot ser vicea ble. If ser vice is n ec-
essa r y, t h e st eer in g colu m n m u st be r epla ced. Refer
t o Gr ou p 19, St eer in g for pr ocedu r es.
SPECI FI CAT I ON S
VECI LABEL
If a n yt h in g differ s bet ween t h e specifica t ion s fou n d
on t h e Veh icle E m ission Con t r ol In for m a t ion (VE CI)
la bel a n d t h e followin g specifica t ion s, u se specifica -
XJ IGNITION SYSTEM 8D - 21
SPECI FI CAT I ON S (Cont inue d)
SPARK PLUGS SPARK PLUG CABLE RESISTANCE
----11-----
ELECTRODE MINIMUM MAXIMUM
ENGINE PLUG TYPE
GAP 250 Ohms Per Inch 1000 Ohms Per Inch
2.5/4.0L RC12LYC 0.89 mm 3000 Ohms Per Foot 12,000 Ohms Per Foot
(0.035 in.)
TORQUE CHART
page page
NOTE:
AIRBAG
CHECK
UPSHIFT
CRUISE
LOW
BATTERY
COOLANT
(MILES
SPEEDOMETER
(KILOMETERS
ODOMETER
FUEL
SEAT OIL
WASHER
BELT
1.5
PER
ENGINE
ON
PRESSURE
WARNING
SECONDS
TEMPERATURE
HOUR)
PER
(MIL)
HOUR)
AFTER
WARNING
WARNING
COMPLETING TEST, ALL 2START
POINTERS
SEC. DIAGNOSTICS
2 SEC.
SHOULD 2RETURN
SEC. TO
2 SEC.
POINTER
2 SEC.
STOP AND
2 SEC.
ODOMETER
2 SEC.
SHOULD
2 SEC.
BE
COMPLETE
TURNED
2 SEC.
OFF.
DIAGNOSTICS
2 SEC. ON
OFF
ON
OFF
ON
I I I I I I I I I OFF
1 2SEC. I 2SEC. 1 2 SEC. , 2 SEC. 1 2SEC. 1 2SEC. I 2 SEC. 1 2 SEC. 1 2 SEC. 1 2SEC. I ON
OFF
ON
ON
OFF
AIRBAG ON
OFF
OFF
ON
ON
OFF
ON
SEAT BELT OFF
OFF
ON
OFF
ON
UPSHIFT OFF
ON
CHECK ENGINE (MIL) OFF
ON
CRUISE ON OFF
ON
LOW WASHER OFF
LOW OIL PRESSURE ON
WARNING OFF
ON
BATTERY WARNING OFF
COOLANT TEMPERATURE
WARNING ON
OFF
SPEEDOMETER 0 20 55 80 100 80 55 20 0 0
(MILES PER HOUR) MPH MPH MPH 1 MPH MPH MPH MPH MPH MPH MPH I
NOTE: 1.5 SECONDS AFTER COMPLETING TEST, ALL POINTERS SHOULD RETURN TO POINTER STOP
AND ODOMETER SHOULD BE TURNED OFF.
80aac2c2
AIRBAG
UPSHIFT
CHECK
CRUISE
LOW
SPEEDOMETER
(MILES
(KILOMETERS
ODOMETER
VOLT
OIL
TEMPERATURE
FUEL
TACHOMETER
SEAT
NOTE:WASHER
FUEL
BELT
1.5
PER
GAUGES
ENGINE
ONSECONDS
WARNING
HOUR
PER
(MIL)
POLICE
EXCEPT
HOUR)
AFTERONLY)
POLICE)
COMPLETING TEST, ALL2 POINTERS
SEC.
START DIAGNOSTICS
2SHOULD
SEC. 2RETURN
SEC. TO
2 SEC.
POINTER
2 SEC.
STOP AND
2 SEC.
ODOMETER
2 SEC.SHOULD
2 SEC.
BE
COMPLETE
TURNED
2 SEC. OFF.
DIAGNOSTICS
2 SEC. ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
2SEC. 2SEC. 2SEC. 2SEC. 2SEC. 2SEC. 2SEC. 2SEC. 2SEC. 2SEC. OFF
ON
I I I OFF
ON
ON
LOW FUEL WARNING OFF
ON
OFF
OFF
ON
AIRBAG OFF
ON
SEAT BELT OFF
ON
UPSHIFT OFF
ON
CHECK ENGINE (MIL) OFF
ON
CHECK GAUGES OFF
ON
CRUISE ON OFF
ON
LOW WASHER OFF
I
0 20 55 80 125 80 55 20 0 0
SPEEDOMETER MPH I MPH 1 MPH 1 MPH 1 MPH MPH 1 MPH 1 MPH 1 MPH I MPH I
(MILES PER HOUR POLICE ONLY}
0 20 55 80 100 I 80 55 20 0 0
(MILES PER HOUR EXCEPT POLICE) I MPH MPH MPH MPH MPH MPH I MPH MPH MPH MPH 1
I
0 40 80 120 I 210 I 120 80 40 I 0 0
(KILOMETERS PER HOUR) 1
I
KM/H 1 KM/H KM/H 1 KM/H 1 KM/H 1 KM/H KM/H 1 KM/H 1 KM/H
1 1
KM/H I
I
I 40°C I 40°C I 100°c I 100°c I FULL I FULL I 100°c I 100°c I 40°C I 40°C I
TEMPERATURE I (100°F) I (100°F) I (210°F) I (210°F) I SCALE I SCALE I (210°F) I (210°F) I (100°F) I (100°F) I
1 0kg/cm2 I 0kg/cm2 I 4kg/cm2 I 4kg/cm2 I 8.3kg/cm2 18.3kg/cm2 I 4kg/cm2 I 4kg/cm2 I 0kg/cm2 I 0kg/cm2 I
OIL 1 (0 PSI) I (0 PSI) I (40 PSI) I (40 PSI) I (80 PSI) I (80 PSI) I (40 PSI) I (40 PSI) I (0 PSI) I (0 PSI) I
I I
I I I I I I I I I I I
ODOMETER I 000000 1 111111 1 222222 1 333333 1 444444 I 555555 I 666666 1 777777 1 888888 I 999999 I
I
NOTE: 1.5 SECONDS AFTER COMPLETING TEST, ALL POINTERS SHOULD RETURN TO POINTER STOP
AND ODOMETER SHOULD BE TURNED OFF.
80aac2c3
(1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go If t h e m a lfu n ct ion in dica t or la m p fa ils t o ligh t du r-
t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or in g t h e bu lb t est (a bou t t h r ee secon ds a ft er t h e ign i-
com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y fu se. t ion swit ch is t u r n ed t o t h e On posit ion ), r epla ce t h e
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion . m a lfu n ct ion in dica t or la m p bu lb wit h a kn own good
Ch eck for ba t t er y volt a ge a t t h e fu se in t h e ju n ct ion u n it . If t h e in dica t or la m p st ill fa ils t o oper a t e, dia g-
block. If OK, go t o St ep 3. If n ot OK, r epa ir t h e open n osis of t h e P ower t r a in Con t r ol Modu le (P CM) a n d
cir cu it t o t h e ign it ion swit ch a s r equ ir ed. t h e Ch r ysler Collision Det ect ion (CCD) da t a bu s
(3) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . sh ou ld be per for m ed wit h a DRB sca n t ool a s
Un plu g t h e wir e h a r n ess con n ect or fr om t h e wa sh er descr ibed in t h e pr oper Dia gn ost ic P r ocedu r es m a n -
flu id level sen sor. In st a ll a ju m per wir e bet ween t h e u a l. F or dia gn osis of t h e m a lfu n ct ion in dica t or la m p
t wo ca vit ies of t h e sen sor wir e h a r n ess con n ect or. a n d t h e in st r u m en t clu st er cir cu it r y, see In st r u m en t
Tu r n t h e ign it ion swit ch t o t h e On posit ion . Th e low Clu st er in t h is gr ou p.
wa sh er flu id wa r n in g la m p sh ou ld ligh t . Rem ove t h e
ju m per wir e a n d t h e la m p sh ou ld go off. If OK, SEAT BELT REMINDER LAMP
r epla ce t h e fa u lt y wa sh er flu id level sen sor. If n ot Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
OK, go t o St ep 4. sea t belt r em in der la m p con dit ion . If t h e la m p com es
(4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . on a n d fla sh es followin g it s displa y fu n ct ion (for
Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v- a bou t seven secon ds a ft er t h e ign it ion swit ch is
it y of t h e wa sh er flu id level sen sor wir e h a r n ess con - t u r n ed t o t h e On posit ion ), r efer t o t h e dia gn osis for
n ect or a n d a good gr ou n d. Th er e sh ou ld be t h e a ir ba g in dica t or la m p in t h is gr ou p. F or cir cu it
con t in u it y. If OK, go t o St ep 5. If n ot OK, r epa ir t h e descr ipt ion s a n d dia gr a m s, r efer t o 8W-40 - In st r u -
open cir cu it a s r equ ir ed. m en t Clu st er in Gr ou p 8W - Wir in g Dia gr a m s.
(5) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e in st r u m en t clu st er a s descr ibed in WARNING: ON VEHICLES EQUIPPED WITH AIR-
t h is gr ou p. Th e wa sh er flu id level sen sor wir e h a r- BAGS, REFER TO GROUP 8M - PASSIVE
n ess con n ect or is st ill u n plu gged. Ch eck for con t in u - RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
it y bet ween t h e wa sh er flu id level sen se cir cu it ca vit y STEERING WHEEL, STEERING COLUMN, OR
of t h e r igh t in st r u m en t clu st er wir e h a r n ess con n ec- INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
t or (con n ect or B) a n d a good gr ou n d. Th er e sh ou ld be SERVICE. FAILURE TO TAKE THE PROPER PRE-
n o con t in u it y. If OK, go t o St ep 6. If n ot OK, r epa ir CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
t h e sh or t cir cu it a s r equ ir ed. BAG DEPLOYMENT AND POSSIBLE PERSONAL
(6) Ch eck for con t in u it y bet ween t h e wa sh er flu id INJURY.
level sen se cir cu it ca vit ies of t h e r igh t in st r u m en t
clu st er wir e h a r n ess con n ect or (con n ect or B) a n d t h e If t h e sea t belt r em in der la m p fa ils t o ligh t du r in g
wa sh er flu id level sen sor wir e h a r n ess con n ect or. it s displa y fu n ct ion , r epla ce t h e sea t belt r em in der
Th er e sh ou ld be con t in u it y. If OK, r epla ce t h e fa u lt y la m p bu lb wit h a kn own good u n it . If t h e r em in der
bu lb. If n ot OK, r epa ir t h e open cir cu it a s r equ ir ed. la m p st ill fa ils t o oper a t e, see In st r u m en t Clu st er in
t h is gr ou p for dia gn osis of t h e sea t belt r em in der
MALFUNCTION INDICATOR LAMP la m p a n d t h e in st r u m en t clu st er cir cu it r y. Refer t o
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive Gr ou p 8U - Ch im e/Bu zzer Wa r n in g Syst em s for dia g-
m a lfu n ct ion in dica t or la m p con dit ion . If t h e la m p n osis of t h e dr iver sea t belt swit ch a n d cir cu it .
com es on a n d st a ys on wit h t h e en gin e r u n n in g, r efer
t o Gr ou p 14 - F u el Syst em s for dia gn osis. F or cir cu it TURN SIGNAL INDICATOR LAMP
descr ipt ion s a n d dia gr a m s, r efer t o 8W-40 - In st r u - Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
m en t Clu st er in Gr ou p 8W - Wir in g Dia gr a m s. t u r n sign a l in dica t or la m p con dit ion . F or a n y ot h er
t u r n sign a l pr oblem , r efer t o Gr ou p 8J - Tu r n Sign a l
a n d H a za r d Wa r n in g Syst em s for dia gn osis. If n o
8E - 22 INSTRUMENT PANEL SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
t u r n sign a l or h a za r d wa r n in g syst em pr oblem is sh ou ld be per for m ed wit h a DRB sca n t ool a s
fou n d, t h e followin g pr ocedu r e will h elp loca t e a descr ibed in t h e pr oper Dia gn ost ic P r ocedu r es m a n -
sh or t or open in t h e in dica t or la m p cir cu it . F or cir- u a l. F or dia gn osis of t h e u psh ift in dica t or la m p a n d
cu it descr ipt ion s a n d dia gr a m s, r efer t o 8W-40 - t h e in st r u m en t clu st er cir cu it r y, see In st r u m en t
In st r u m en t Clu st er a n d 8W-50 - F r on t Ligh t in g in Clu st er in t h is gr ou p.
Gr ou p 8W - Wir in g Dia gr a m s.
VOLTAGE WARNING LAMP
WARNING: ON VEHICLES EQUIPPED WITH AIR- If t h e pr oblem bein g dia gn osed is r ela t ed t o volt a ge
BAGS, REFER TO GROUP 8M - PASSIVE wa r n in g la m p a ccu r a cy, be cer t a in t o con fir m pr oper
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY ch a r gin g syst em oper a t ion befor e con sider in g volt a ge
STEERING WHEEL, STEERING COLUMN, OR wa r n in g la m p dia gn osis. Refer t o Gr ou p 8C - Ch a r g-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR in g Syst em for m or e in for m a t ion . Refer t o Gr ou p 8W
SERVICE. FAILURE TO TAKE THE PROPER PRE- - Wir in g Dia gr a m s for cir cu it descr ipt ion s a n d dia -
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- gr a m s.
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ca ble. Rem ove t h e in st r u m en t clu st er bezel a n d t h e STEERING WHEEL, STEERING COLUMN, OR
clu st er a s descr ibed in t h is gr ou p. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
(2) Con n ect t h e ba t t er y n ega t ive ca ble. Act iva t e SERVICE. FAILURE TO TAKE THE PROPER PRE-
t h e h a za r d wa r n in g syst em by m ovin g t h e h a za r d CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
wa r n in g swit ch bu t t on t o t h e On posit ion . Ch eck for BAG DEPLOYMENT AND POSSIBLE PERSONAL
ba t t er y volt a ge a t t h e in oper a t ive (r igh t or left ) t u r n INJURY.
sign a l cir cu it ca vit y of t h e clu st er wir e h a r n ess con -
n ect or (con n ect or A - left , or con n ect or B - r igh t ). If t h e volt a ge wa r n in g la m p fa ils t o ligh t du r in g
Th er e sh ou ld be a swit ch in g (on a n d off) ba t t er y volt - t h e bu lb t est (a bou t t wo secon ds a ft er t h e ign it ion
a ge sign a l. If OK, r epla ce t h e fa u lt y (r igh t or left ) swit ch is t u r n ed t o t h e On posit ion ), r epla ce t h e volt -
in dica t or la m p bu lb. If n ot OK, r epa ir t h e open cir- a ge wa r n in g la m p bu lb wit h a kn own good u n it . If
cu it t o t h e t u r n sign a l/h a za r d wa r n in g (m u lt i-fu n c- t h e volt a ge wa r n in g la m p st ill fa ils t o oper a t e, dia g-
t ion ) swit ch a s r equ ir ed. n osis of t h e syst em volt a ge in pu t cir cu it , t h e Ch r ysler
Collision Det ect ion (CCD) da t a bu s, a n d/or t h e P ow-
UPSHIFT INDICATOR LAMP er t r a in Con t r ol Modu le (P CM) sh ou ld be per for m ed
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive wit h a DRB sca n t ool a s descr ibed in t h e pr oper
u psh ift in dica t or la m p con dit ion . If la m p a ccu r a cy is Dia gn ost ic P r ocedu r es m a n u a l. F or dia gn osis of t h e
su spect , dia gn osis sh ou ld be per for m ed wit h a DRB volt a ge wa r n in g la m p a n d t h e in st r u m en t clu st er cir-
sca n t ool a s descr ibed in t h e pr oper Dia gn ost ic P r o- cu it r y, see In st r u m en t Clu st er in t h is gr ou p.
cedu r es m a n u a l. F or cir cu it descr ipt ion s a n d dia -
gr a m s, r efer t o 8W-40 - In st r u m en t Clu st er in Gr ou p
8W - Wir in g Dia gr a m s. REM OVAL AN D I N STALLAT I ON
SCREW
·~
SLOT
SNAP
CLIPS 80abac40
INSTRUMENT
PANEL
RIGHT FRONT
DOOR SILL
COWL SIDE
TRIM PANEL
=----- STEERING COLUMN
SIGHT SHIELD
CONNECTOR
HEADLAMP SWITCH
KNOB AND SHAFT 80abac43
80abac44
0
VIEWED FROM UNDERSIDE OF DASH
J898L-13
SELF-DOCKING
Fig. 10 Headlamp Switch Knob and Shaft Remove/ WIRE HARNESS
Install - Typical CONNECTORS
(5) P u ll t h e swit ch kn ob a n d sh a ft ou t of t h e h ea d-
la m p swit ch .
(6) Rem ove t h e spa n n er n u t t h a t secu r es t h e h ea d-
la m p swit ch t o t h e in st r u m en t pa n el (F ig. 11).
(7) Move t h e h ea dla m p swit ch in t o t h e st eer in g
colu m n open in g fa r en ou gh t o a ccess t h e wir e h a r-
n ess con n ect or s.
(8) Un plu g t h e t wo wir e h a r n ess con n ect or s fr om
t h e h ea dla m p swit ch . 80abac45
CLUSTER
HOOD AND MASK
INSTRUMENT
CLUSTER
HOUSING
ODOMETER
RESET KNOB
BOOT
80a9f12c
80abac46
Fig. 18 Glove Box Lamp and Switch Remove/Install Fig. 19 Glove Box Components Remove/Install
pu sh t h e u n it ou t t h r ou gh t h e in st r u m en t pa n el STEERING WHEEL, STEERING COLUMN, OR
m ou n t in g h ole. INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
(5) Rever se t h e r em ova l pr ocedu r es t o in st a ll. SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
GLOVE BOX COMPONENTS BAG DEPLOYMENT AND POSSIBLE PERSONAL
Th e glove box h in ge, bin , in n er door a n d la t ch a r e INJURY.
ser viced on ly a s a com plet e u n it . Th e glove box ou t er
door a n d lock cylin der a r e ser viced sepa r a t ely. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
H I N GE, BI N , I N N ER DOOR AN D LAT CH (2) Rem ove t h e glove box fr om t h e in st r u m en t
pa n el a s descr ibed in t h is gr ou p.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Rem ove t h e seven scr ews t h a t secu r e t h e in n er
BAGS, REFER TO GROUP 8M - PASSIVE glove box door t o t h e ou t er glove box door (F ig. 19).
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (4) Sepa r a t e t h e ou t er glove box door fr om t h e
STEERING WHEEL, STEERING COLUMN, OR in n er glove box door a ssem bly.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (5) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
SERVICE. FAILURE TO TAKE THE PROPER PRE- Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.).
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL LOCK CY LI N DER
INJURY. (1) In ser t t h e key in t o t h e glove box lock cylin der
a n d t u r n t h e lock cylin der t o t h e u n locked posit ion .
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (2) Open t h e glove box.
ca ble. (3) Wit h t h e key st ill in t h e lock cylin der, in ser t a
(2) Rem ove t h e glove box fr om t h e in st r u m en t sm a ll pin pu n ch or a st iff wir e in t o t h e lock cylin der
pa n el a s descr ibed in t h is gr ou p. r elea se h ole (F ig. 20) a n d depr ess t h e lock cylin der
(3) Rem ove t h e seven scr ews t h a t secu r e t h e in n er r et a in in g t u m bler .
glove box door t o t h e ou t er glove box door (F ig. 19). (4) Wh ile h oldin g t h e r et a in in g t u m bler depr essed,
(4) Sepa r a t e t h e in n er glove box door a ssem bly r ot a t e t h e key in t h e lock cylin der clockwise a n d
fr om t h e ou t er glove box door. pr ess ou t wa r d on t h e ba ck of t h e lock cylin der fr om
(5) Rever se t h e r em ova l pr ocedu r es t o in st a ll. t h e in side of t h e glove box door u n t il t h e lock cylin -
Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in . lbs.). der com es ou t of t h e glove box la t ch lock cylin der
bor e.
OU T ER DOOR (5) To in st a ll t h e lock cylin der, in ser t t h e key in
t h e cylin der a n d a lign t h e lock cylin der t u m bler s
WARNING: ON VEHICLES EQUIPPED WITH AIR-
wit h t h e r a m p in t h e glove box la t ch lock cylin der
BAGS, REFER TO GROUP 8M - PASSIVE
bor e. Th e r a m p is loca t ed a t a bou t t h e 7 o’clock posi-
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
RELEASE
LATCH
HOLE
STRIKERSTOP
LOCK
GLOVE
UPPER
CYLINDER
SCREWS
BUMPER
REINFORCEMENT
BOX OPENING
SLOTS LATCH HANDLE SCREWINSTRUMENT PANEL END CAP
PASSEN GER SI DE
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Roll down t h e glove box a s descr ibed in t h is
STOP BUMPER SLOTS 80abd249
gr ou p.
Fig. 21 Glove Box Latch Striker Remove/Install (3) Rem ove t h e in st r u m en t pa n el t op cover a s
descr ibed in t h is gr ou p.
STUDS
INSTRUMENT PANEL FLOOR PAN TRANSMISSION
TUNNEL
BRACKETNUT FWD PUSH-NUT FUSE
RIGHT
ACCESS
FRONT
PANEL
DOOR SILL COWL SIDE
SCREW
TRIM SILL
PANELTRIM
80abac67 80ab249a
Fig. 23 Center Support Bracket Remove/Install Fig. 24 Right Cowl Side Trim Remove/Install
(6) Rem ove t h e t wo n u t s t h a t secu r e t h e cen t er (4) Rem ove t h e scr ew loca t ed a bove t h e fu se a ccess
su ppor t br a cket t o t h e st u ds on t h e floor pa n t r a n s- open in g t h a t secu r es t h e r igh t cowl side t r im t o t h e
m ission t u n n el. r igh t cowl side in n er pa n el.
JUNCTIONBLOCK NUT STUD RIGHT PANEL
SIDE INNER
COWL
INSTRUM
COWL SIDE ERNT PANEL
OLLDOWN
Sc REWS
80a9f12b
AUDIO SYSTEMS
CON T EN T S
page page
80abac28
AMPLIFIER
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Disen ga ge t h e r ea r sea t cu sh ion la t ch by pu ll- 9323-141
in g u pwa r d on t h e r elea se st r a p. Tilt t h e sea t cu sh - U-NUT
PUSH-IN TENER
FAS- SPACER
WINDOW
DOOR
CRANK
TRIM PANEL
ion for wa r d. Fig. 6 Window Regulator Crank Handle Remove -
(3)SCREW
Lift t hAMPLIFIER
e ca r pet in g on t hWIRE
e r eaHARNESS
r floorCONNEC-
paTORS
FLOOR
REAR
nFWD
u nPAN
der Typical
t h e left en d of t h e sea t cu sh ion a s r equ ir ed t o a ccess
(3) Rem ove t h e scr ews t h a t secu r e t h e door t r im
t h e a m plifier.
pa n el t o t h e in n er door pa n el (F ig. 7) or (F ig. 8).
(4) Un plu g t h e t wo wir e h a r n ess con n ect or s fr om
t h e a m plifier (F ig. 5).
AMPLIFIER
REAR
-FLOOR
80abac29 PAN
Fig. 7 Front Door Trim Panel Remove/Install -
Manual Window
Fig. 5 Amplifier Remove/Install
(4) Usin g a t r im st ick or a n ot h er su it a ble wide
(5) Rem ove t h e fou r scr ews t h a t secu r e t h e a m pli-
fla t -bla ded t ool, gen t ly pr y t h e t r im pa n el a wa y fr om
fier t o t h e r ea r floor pa n .
SPEAKER
WIRE HARNESSSCREW
CONNEC-
TORS NUT FWD
XJ AUDIO SYSTEMS 8F - 9
REM OVAL AN D I N STALLAT I ON (Cont inue d)
WIRE HARNESS
CONNECTORS
SPEAKER
80abac2a
Fig. 8 Front Door Trim Panel Remove/Install - Power Fig. 9 Front Door Lower Speaker Remove/Install
Window
DOOR
t h e door a r ou n d t h e per im et er t o r elea se t h e t r im WFRONTDOOR FLAG TRIM
pa n el r et a in er s. PANEL
NOTE: To aid in the removal of the trim panel, start
at the bottom of the panel.
~"
fr om t h e door t o disen ga ge t h e t op of t h e pa n el fr om
t h e in n er belt wea t h er st r ip.
(6) P u ll t h e door t r im pa n el a wa y fr om t h e in n er
door fa r en ou gh t o a ccess t h e in side door la t ch _.___-~~
r elea se a n d lock lin ka ge r ods n ea r t h e ba ck of t h e
in side door r em ot e con t r ol.
(7) Un sn a p t h e pla st ic r et a in er clips fr om t h e
in side door r em ot e con t r ol en ds of t h e la t ch r elea se
a n d lock lin ka ge r ods, a n d r em ove t h e r od en ds fr om
t h e in side door r em ot e con t r ol.
80abd273
(8) If t h e veh icle is so equ ipped, u n plu g t h e wir e
h a r n ess con n ect or s fr om t h e door power swit ch m od-
Fig. 10 Front Door Flag Trim Panel Remove/Install
u le or, on t h e dr iver side on ly, t h e power m ir r or
swit ch . (3) Usin g a t r im st ick or a n ot h er su it a ble wide
(9) Rem ove t h e fr on t door t r im pa n el fr om t h e fla t -bla ded t ool, gen t ly pr y t h e door fla g t r im a wa y
veh icle. fr om t h e in n er door t o r elea se t h e t r im pa n el
(10) Rem ove t h e t wo scr ews t h a t secu r e t h e r et a in er.
spea ker t o t h e lower fr on t cor n er of t h e in n er door (4) Un plu g t h e u pper spea ker wir e h a r n ess con n ec-
pa n el (F ig. 9). t or.
(11) P u ll t h e spea ker a wa y fr om t h e in n er door (5) Un sn a p t h e spea ker fr om t h e r et a in er s m olded
pa n el fa r en ou gh t o u n plu g t h e spea ker wir e h a r n ess in t o t h e ba ck side of t h e door fla g t r im pa n el.
con n ect or. (6) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
(12) Rem ove t h e spea ker fr om t h e door.
(13) Rever se t h e r em ova l pr ocedu r es t o in st a ll. SOU N D BAR
(1) Rem ove t h e sou n d ba r fr om t h e veh icle a s
UPPER descr ibed in t h is gr ou p.
(1) Rem ove t h e fr on t door t r im pa n el a s descr ibed (2) F r om t h e in side of t h e sou n d ba r, st r a igh t en
u n der Lower F r on t Door Spea ker, in t h is gr ou p. t h e t a bs t h a t secu r e t h e spea ker gr ille t o t h e sou n d
(2) Rem ove t h e on e scr ew t h a t secu r es t h e door ba r (F ig. 11).
fla g t r im t o t h e in n er door pa n el (F ig. 10). (3) F r om t h e ou t side of t h e sou n d ba r, r em ove t h e
spea ker gr ille.
FWD
WIRE HARNESS PUSH
STUDSLENS
NUTS
LIFTGATE REINFORCEMENT
OPENING
SOUND
UPPER
BAR
8F - 10 AUDIO SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
PUSH
NUTS
LENS
SPEAKER
80abac2c GRILLE TABS 80abac2e
Fig. 11 Sound Bar Speaker Remove/Install - Typical Fig. 12 Sound Bar Remove/Install
(4) Ca r efu lly dr ill ou t t h e r ivet s t h a t secu r e t h e (12) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Use
spea ker t o t h e sou n d ba r. t wo n ew pu sh n u t s on t h e st u ds in t h e ca r go la m p
(5) Rem ove t h e spea ker fr om t h e sou n d ba r. h ou sin g wh en r ein st a llin g t h e sou n d ba r.
(6) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Use
n ew r ivet s in st a lled fr om t h e in side of t h e sou n d ba r ANTENNA
t o secu r e t h e spea ker.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
SOUND BAR BAGS, REFER TO GROUP 8M - PASSIVE
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ca ble. STEERING WHEEL, STEERING COLUMN, OR
(2) If t h e veh icle is so equ ipped, r em ove t h e ca r go INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
com pa r t m en t -m ou n t ed spa r e t ir e. SERVICE. FAILURE TO TAKE THE PROPER PRE-
(3) Rem ove t h e lift ga t e open in g u pper ga r n ish CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
m ou ldin g a n d t h e lift ga t e pilla r t r im pa n els. Refer t o BAG DEPLOYMENT AND POSSIBLE PERSONAL
Gr ou p 23 - Body for t h e pr ocedu r es. INJURY.
(4) Rem ove t h e len s fr om t h e ca r go la m p h ou sin g
(F ig. 12). (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(5) If t h e veh icle is so equ ipped, r em ove t h e r ea r ca ble.
r oof side r a il-m ou n t ed a ssist h a n dles. (2) Rem ove t h e r igh t fr on t fen der in n er spla sh
(6) Rem ove t h e scr ews t h a t secu r e t h e r ea r r oof sh ield. Refer t o Gr ou p 23 - Body for t h e pr ocedu r es.
side r a il ga r n ish m oldin gs. (3) Rea ch u n der t h e r igh t en d of t h e in st r u m en t
(7) Rem ove t h e left a n d r igh t r ea r r oof side r a il pa n el t o u n plu g t h e coa xia l ca ble con n ect or (F ig. 13).
ga r n ish m oldin gs. Un plu g t h e con n ect or by pu llin g it a pa r t wh ile t wist -
(8) Rem ove a n d disca r d t h e t wo pu sh n u t r et a in er s in g t h e m et a l con n ect or h a lves. Do n ot pu ll on t h e
fr om t h e st u ds in side t h e fr on t a n d r ea r of t h e ca r go ca ble.
la m p h ou sin g. (4) Un scr ew t h e a n t en n a m a st fr om t h e a n t en n a
(9) Lower t h e sou n d ba r fa r en ou gh t o u n plu g t h e body (F ig. 14).
wir e h a r n ess con n ect or s fr om bot h spea ker s a n d t h e (5) Rem ove t h e a n t en n a ca p n u t a n d a da pt er u sin g
ca r go la m p. a n a n t en n a n u t wr en ch (Specia l Tool C-4816) (F ig.
(10) Rem ove t h e a dh esive t a pe t h a t secu r es t h e 15).
wir e h a r n ess t o t h e in side of t h e sou n d ba r. (6) Lower t h e a n t en n a body a n d ca ble a ssem bly
(11) Rem ove t h e sou n d ba r fr om t h e veh icle. t h r ou gh t h e fen der fa r en ou gh t o a ccess t h e a n t en n a
body by r ea ch in g u p in t o t h e r ea r of t h e r igh t fr on t
ANTENNA
INSTRUMENT
CAPMAST
NUT
INSTRUMENT
PANEL ANTENNA
PANEL
HEATER-A/C
COAXIAL
CABLE
HOUSING
ADAPTER
ANTENNA
COVER
RIGHT-HAND
KICK
COAXIAL
LEFT-HAND
CABLE
DRIVE
DRIVE
FWD FWD TOOL GROMMET
ADAPTER
ANTENNANUT
ADAPTER
ANTENNA
CAP NUT
BODY AND
RIGHT
FWD
CABLE
FRONT
MAST FENDER
XJ AUDIO SYSTEMS 8F - 11
REM OVAL AN D I N STALLAT I ON (Cont inue d)
RIGHT-HAND DRIVE
HEATER-A/C HOUSING
KICK COVER 80ac2c51
MAST
Fig. 13 Antenna Cable Routing
ANTENNA RIGHT FRONT
MAST FENDER
GROMMET
80ac2c50
ANTENNA BODY
Fig. 14 Antenna Mast Remove/Install - Typical AND CABLE
fen der wh eel open in g bet ween t h e r igh t cowl side 80abac3a
HORN SYSTEMS
CON T EN T S
page page
XJ HORN SYSTEMS 8G - 3
DI AGN OSI S AN D T EST I N G (Cont inue d)
ju n ct ion block. Ch eck for con t in u it y bet ween t h e (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
st eer in g colu m n h a lf of t h e h or n swit ch feed wir e ca ble.
h a r n ess con n ect or a n d a good gr ou n d. Th er e sh ou ld (2) Rem ove t h e fu se a ccess pa n el by u n sn a ppin g it
be n o con t in u it y. If OK, go t o St ep 3. If n ot OK, fr om t h e r igh t cowl side t r im pa n el.
r epa ir t h e sh or t cir cu it a s r equ ir ed. (3) Rem ove t h e st a m ped n u t t h a t secu r es t h e r igh t
(3) Ch eck for con t in u it y bet ween t h e st eer in g col- cowl side t r im t o t h e ju n ct ion block st u d (F ig. 1).
u m n h a lf of t h e h or n swit ch feed wir e h a r n ess con -
n ect or a n d t h e h or n r ela y con t r ol cir cu it ca vit y for
t h e h or n r ela y in t h e ju n ct ion block. Th er e sh ou ld be
con t in u it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e
open cir cu it a s r equ ir ed.
(4) Ch eck for con t in u it y bet ween t h e h or n swit ch
feed wir e a n d t h e h or n swit ch gr ou n d wir e on t h e
a ir ba g m odu le. Th er e sh ou ld be n o con t in u it y. If OK,
go t o St ep 5. If n ot OK, r epla ce t h e fa u lt y h or n RIGHT FRONT
swit ch . DOOR SILL
(5) Depr ess t h e cen t er of t h e a ir ba g m odu le cover
a n d ch eck for con t in u it y bet ween t h e h or n swit ch
COWL SIDE
feed wir e a n d t h e h or n swit ch gr ou n d wir e on t h e
TRIM PANEL
a ir ba g m odu le. Th er e sh ou ld n ow be con t in u it y. If n ot
OK, r epla ce t h e fa u lt y h or n swit ch .
HORN
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
8W-41 - H or n s/Ciga r Ligh t er in Gr ou p 8W - Wir in g
Dia gr a m s.
(1) Mea su r e t h e r esist a n ce bet ween t h e h or n
m ou n t in g br a cket a n d a good gr ou n d. Th er e sh ou ld
be zer o oh m s r esist a n ce. If OK, go t o St ep 2. If n ot
OK, r epa ir t h e h or n gr ou n d con n ect ion a s r equ ir ed.
(2) Un plu g t h e h or n wir e h a r n ess con n ect or.
Depr ess t h e h or n swit ch . Th er e sh ou ld be ba t t er y
volt a ge a t t h e h or n wir e h a r n ess con n ect or. If OK,
80ab249a
r epla ce t h e fa u lt y h or n . If n ot OK, r epa ir t h e open
cir cu it t o t h e h or n r ela y a s r equ ir ed. Fig. 1 Right Cowl Side Trim Remove/Install
(4) Rem ove t h e scr ew loca t ed a bove t h e fu se a ccess
REM OVAL AN D I N STALLAT I ON open in g t h a t secu r es t h e r igh t cowl side t r im t o t h e
r igh t cowl side in n er pa n el.
HORN RELAY (5) Rem ove t h e scr ew t h a t secu r es t h e r igh t door
sill t r im a n d t h e r igh t cowl side t r im t o t h e r igh t
WARNING: ON VEHICLES EQUIPPED WITH AIR- door open in g sill.
BAGS, REFER TO GROUP 8M - PASSIVE (6) Rem ove t h e r igh t cowl side t r im pa n el fr om t h e
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY veh icle.
STEERING WHEEL, STEERING COLUMN, OR (7) Un plu g t h e h or n r ela y fr om t h e ju n ct ion block.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (8) In st a ll t h e h or n r ela y by a lign in g t h e r ela y t er-
SERVICE. FAILURE TO TAKE THE PROPER PRE- m in a ls wit h t h e ca vit ies in t h e ju n ct ion block a n d
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- pu sh in g t h e r ela y fir m ly in t o pla ce.
BAG DEPLOYMENT AND POSSIBLE PERSONAL (9) Con n ect t h e ba t t er y n ega t ive ca ble.
INJURY. (10) Test t h e r ela y oper a t ion .
(11) In st a ll t h e r igh t cowl side t r im a n d t h e fu se
a ccess pa n el.
MOUNTING
HORNBOLT
8G - 4 HORN SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
HORN SWITCH
WARNING: ON VEHICLES EQUIPPED WITH A
DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTE-
GRAL TO THE AIRBAG MODULE TRIM COVER.
SERVICE OF THIS COMPONENT SHOULD BE PER-
FORMED ONLY BY CHRYSLER-TRAINED AND
AUTHORIZED DEALER SERVICE TECHNICIANS.
FAILURE TO TAKE THE PROPER PRECAUTIONS MOUNTING
OR TO FOLLOW THE PROPER PROCEDURES BOLT
COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY. REFER TO GROUP 8M - PAS-
SIVE RESTRAINT SYSTEMS FOR THE SERVICE
PROCEDURES.
HORN
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Ra ise a n d su ppor t t h e veh icle.
(3) Rem ove t h e fr on t u n der body spla sh sh ield.
page page
GEN ERAL I N FORM AT I ON swit ch m odu les, five m o m e n ta ry con t a ct swit ch es,
su ppor t in g seven differ en t speed con t r ol fu n ct ion s
INTRODUCTION a r e u sed. Th e ou t pu t s fr om t h ese swit ch es a r e fil-
Th e veh icle speed con t r ol syst em is elect r on ica lly t er ed in t o on e in pu t . Th e P ower t r a in Con t r ol Modu le
con t r olled a n d va cu u m oper a t ed. Th e syst em is (P CM) det er m in es wh ich ou t pu t h a s been a pplied
design ed t o oper a t e bet ween a ppr oxim a t ely 35 a n d t h r ou gh re s is tiv e m u ltip le x in g . Th e in pu t cir cu it
85 m ph (56 a n d 137 km /h ). F ollowin g a r e gen er a l volt a ge is m ea su r ed by t h e P CM t o det er m in e wh ich
descr ipt ion s of t h e m a jor com pon en t s in t h e speed swit ch fu n ct ion h a s been select ed.
con t r ol syst em . F or dia gn osis of t h e en t ir e speed con - A speed con t r ol in dica t or la m p, loca t ed on t h e
t r ol syst em , r efer t o t h e a ppr opr ia t e P ower t r a in in st r u m en t pa n el clu st er is en er gized by t h e P CM via
Dia gn ost ic P r ocedu r es ser vice m a n u a l a n d t h e DRB t h e CCD Bu s. Th is occu r s wh en speed con t r ol syst em
sca n t ool. Refer t o Gr ou p 8W, Wir in g Dia gr a m s for power h a s been t u r n ed ON, a n d t h e en gin e is r u n -
com plet e cir cu it descr ipt ion s a n d wir in g dia gr a m s. n in g.
Th e t wo swit ch m odu les a r e la beled: ON/OF F, SE T,
RE SUME /ACCE L, CANCE L a n d COAST. Refer t o
DESCRI PT I ON AN D OPERAT I ON t h e own er ’s m a n u a l for m or e in for m a t ion on speed
con t r ol swit ch fu n ct ion s a n d set t in g pr ocedu r es. Th e
SPEED CONTROL SERVO in dividu a l swit ch es ca n n ot be r epa ir ed. If on e in di-
Th e ser vo u n it con sist s of a solen oid va lve body, a vidu a l swit ch fa ils, t h e swit ch m odu le m u st be
va cu u m ser vo a n d t h e m ou n t in g br a cket . Th e P ower- r epla ced.
t r a in Con t r ol Modu le (P CM) con t r ols t h e solen oid
va lve body. Th e solen oid va lve body con t r ols t h e STOP LAMP SWITCH
a pplica t ion a n d r elea se of va cu u m t o t h e dia ph r a gm Veh icles equ ipped wit h t h e speed con t r ol opt ion u se
of t h e va cu u m ser vo. A ca ble con n ect s t h e ser vo wit h a du a l fu n ct ion st op la m p swit ch . Th e swit ch is
t h e t h r ot t le lin ka ge. Th e ser vo u n it ca n n ot be m ou n t ed in t h e sa m e loca t ion a s t h e con ven t ion a l
r epa ir ed a n d is ser viced on ly a s a com plet e a ssem bly. st op la m p swit ch , on t h e br a ke peda l m ou n t in g
br a cket u n der t h e in st r u m en t pa n el. Th e P CM m on -
SPEED CONTROL SWITCHES it or s t h e st a t e of t h e du a l fu n ct ion st op la m p swit ch .
Two sepa r a t e speed con t r ol swit ch m odu les a r e Refer t o Gr ou p 5, Br a kes for m or e in for m a t ion on
m ou n t ed on t h e st eer in g wh eel t o t h e left a n d r igh t st op la m p swit ch ser vice a n d a dju st m en t pr ocedu r es.
side of t h e dr iver ’s a ir ba g m odu le. Wit h in t h e t wo
8H - 2 VEHICLE SPEED CONTROL SYSTEM XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
SERVO CABLE In st r u m en t P a n el a n d Ga u ges for speedom et er dia g-
Th e speed con t r ol ser vo ca ble is con n ect ed bet ween n osis.
t h e speed con t r ol va cu u m ser vo dia ph r a gm a n d t h e If a r oa d t est ver ifies a syst em pr oblem a n d t h e
t h r ot t le body con t r ol lin ka ge. Th is ca ble ca u ses t h e speedom et er oper a t es pr oper ly, ch eck for :
t h r ot t le con t r ol lin ka ge t o open or close t h e t h r ot t le • A Dia gn ost ic Tr ou ble Code (DTC). If a fla sh
va lve in r espon se t o m ovem en t of t h e va cu u m ser vo la m p code 15, 34 or 77 exist s a t t h e Ch eck E n gin e
dia ph r a gm . La m p (MIL), con du ct t est s per t h e P ower t r a in Dia g-
n ost ic P r ocedu r es ser vice m a n u a l.
POWERTRAIN CONTROL MODULE • A m isa dju st ed br a ke (st op) la m p swit ch . Th is
Th e speed con t r ol elect r on ic con t r ol cir cu it r y is cou ld a lso ca u se a n in t er m it t en t pr oblem .
in t egr a t ed in t o t h e P ower t r a in Con t r ol Modu le • Loose or cor r oded elect r ica l con n ect ion s a t t h e
(P CM). Th e P CM is loca t ed in t h e en gin e com pa r t - ser vo. Cor r osion sh ou ld be r em oved fr om elect r ica l
m en t . Th e P CM speed con t r ol fu n ct ion s a r e m on i- t er m in a ls a n d a ligh t coa t in g of Mopa r Mu lt iP u r pose
t or ed by t h e On -Boa r d Dia gn ost ics (OBD). All OBD- Gr ea se, or equ iva len t , a pplied.
sen sed syst em s a r e m on it or ed by t h e P CM. E a ch • Loose or lea kin g va cu u m h oses or con n ect ion s.
m on it or ed cir cu it is a ssign ed a Dia gn ost ic Tr ou ble • Secu r e a t t a ch m en t of bot h en ds of t h e speed con -
Code (DTC). Th e P CM will st or e a DTC in elect r on ic t r ol ser vo ca ble.
m em or y for cer t a in fa ilu r es it det ect s. See On -Boa r d • Sm oot h oper a t ion of t h r ot t le lin ka ge a n d t h r ot t le
Dia gn ost ic Test F or Speed Con t r ol Syst em in t h is body a ir va lve.
gr ou p for m or e in for m a t ion . Th e P CM ca n n ot be • F a iled speed con t r ol ser vo. Do t h e ser vo va cu u m
r epa ir ed a n d m u st be r epla ced if fa u lt y. t est .
Wh en elect r ica l con n ect ion s a r e r em oved, cor r osion PIN 1 PIN 2
sh ou ld be r em oved fr om elect r ica l t er m in a ls a n d a
SWITCH RESISTANCE BETWEEN
ligh t coa t in g of Mopa r Mu lt i-P u r pose Gr ea se, or POSITION PINS 1 AND 2
equ iva len t , sh ou ld be a pplied. 909 ohms
ON
In spect con n ect or s for da m a ged t er m in a ls. A poor +/- 9 ohms
elect r ica l con n ect ion ca n ca u se a com plet e or in t er- SET
6650 ohms
+/- 66 ohms
m it t en t m a lfu n ct ion . F or t h is r ea son , a poor con n ec-
15,400 ohms
t ion m a y be m isdia gn osed a s a com pon en t RESUME/ACCEL
+/- 154 ohms
m a lfu n ct ion . O ohms
CANCEL
(Close Circuit)
VEHICLE SPEED SENSOR COAST
2940 ohms
+/- 29 ohms
F or dia gn osis a n d t est in g of t h e Veh icle Speed Sen -
80aa0f31
sor (VSS), r efer t o t h e a ppr opr ia t e P ower t r a in Dia g-
n ost ic P r ocedu r es ser vice m a n u a l. Also r efer t o t h e Fig. 1 Speed Control Switch Continuity Tests
DRB sca n t ool.
(2) St a r t en gin e a n d obser ve ga u ge a t idle. Va c-
SPEED CONTROL SWITCHES u u m ga u ge sh ou ld r ea d a t lea st t en in ch es of m er-
cu r y.
F or com plet e speed con t r ol syst em dia gn osis, r efer
(3) If va cu u m is less t h a n t en in ch es of m er cu r y,
t o t h e a ppr opr ia t e P ower t r a in Dia gn ost ic P r ocedu r es
det er m in e sou r ce of lea k. Ch eck va cu u m lin e t o
m a n u a l. To t est ea ch of t h e speed con t r ol swit ch es
en gin e for lea ks. Also ch eck a ct u a l en gin e in t a ke
on ly, r efer t o t h e followin g:
m a n ifold va cu u m . If m a n ifold va cu u m does n ot m eet
WARNING: BEFORE ATTEMPTING TO DIAGNOSE, t h is r equ ir em en t , ch eck for poor en gin e per for m a n ce
REMOVE OR INSTALL ANY AIRBAG SYSTEM OR a n d r epa ir a s n ecessa r y.
RELATED STEERING WHEEL AND STEERING COL- (4) If va cu u m lin e t o en gin e is n ot lea kin g, ch eck
UMN COMPONENTS, YOU MUST FIRST DISCON- for lea k a t va cu u m r eser voir. To loca t e a n d ga in
NECT AND ISOLATE THE BATTERY NEGATIVE a ccess t o r eser voir, r efer t o Va cu u m Reser voir Rem ov-
(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEM a l/In st a lla t ion in t h is gr ou p. Discon n ect va cu u m lin e
CAPACITOR TO DISCHARGE BEFORE FURTHER a t r eser voir a n d con n ect a h a n d-oper a t ed va cu u m
SYSTEM SERVICE. FAILURE TO DO SO COULD pu m p t o r eser voir fit t in g. Reser voir va cu u m sh ou ld
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT n ot bleed off. If va cu u m is bein g lost , r epla ce r eser-
AND POSSIBLE PERSONAL INJURY. voir.
SPEED
CONTROL
SWITCH
SCREW
r
MOUNTING
80aac283
BUMPER
END CAP
. \ \\
VACUUM \ \~,
RESERVOIR\ so:a~~s1
VACUUM RESERVOIR
REM OVAL
Th e va cu u m r eser voir is loca t ed beh in d r igh t fr on t
bu m per en d ca p on veh icles equ ipped wit h LH D (Left
H a n d Dr ive) (F ig. 7). It is loca t ed beh in d left fr on t RESERVOIR_.,...~
SCREWS~
bu m per en d ca p on veh icles equ ipped wit h RH D
(Righ t H a n d Dr ive). { 80aac282
(1) Rem ove fr on t bu m per en d ca p. Refer t o F r on t
Bu m per E n d Ca p in Gr ou p 23, Body for pr ocedu r es. Fig. 8 Vacuum Reservoir Removal/Installation
(2) Rem ove va cu u m lin e a t r eser voir (F ig. 8).
(3) Rem ove 2 r eser voir m ou n t in g scr ews. SPECI FI CAT I ON S
(4) Rem ove r eser voir fr om bu m per ba r .
TORQUE CHART
I N STALLAT I ON
(1) P osit ion r eser voir t o bu m per ba r a n d in st a ll D e s c rip tio n To rqu e
m ou n t in g scr ews. Tigh t en scr ews t o 8 N·m (72 in . Ser vo Mou n t in g Br a cket -t o-
lbs.) t or qu e. Ser vo Nu t s . . . . . . . . . . . . . . 8.5 N·m (75 in . lbs.)
(2) In st a ll va cu u m lin e t o r eser voir Ser vo Mou n t in g Br a cket -t o-
(3) In st a ll fr on t bu m per en d ca p. Refer t o Gr ou p Body Bolt s . . . . . . . . . . . . . . . . 2 N·m (20 in . lbs.)
23, Body for pr ocedu r es. Speed Con t r ol Swit ch Mou n t in g
Scr ews . . . . . . . . . . . . . . . . . . 1.5 N·m (14 in . lbs.)
VEHICLE SPEED SENSOR Va cu u m Reser voir Mou n t in g
F or r em ova l/in st a lla t ion , r efer t o Veh icle Speed Bolt s . . . . . . . . . . . . . . . . . . . . 8 N·m (72 in . lbs.)
Sen sor in Gr ou p 14, F u el Syst em .
XJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1
page page
LOWER MOUNTING
PIN PUNCH TAB 80a4d2f2
~
wir e h a r n ess con n ect or s. If t h e veh icle is equ ipped
wit h t h e opt ion a l t ilt st eer in g colu m n , lift in g gen t ly
u pwa r d on t h e t ilt r elea se lever will pr ovide a ddi-
t ion a l clea r a n ce t o ea se m u lt i-fu n ct ion swit ch
HAZARD r em ova l.
- - ~ , WARNING (14) Un plu g t h e wir e h a r n ess con n ect or s fr om t h e
SWITCH\ m u lt i-fu n ct ion swit ch .
KNOB (15) Rem ove t h e m u lt i-fu n ct ion swit ch a n d wa t er
~ sh ield fr om t h e st eer in g colu m n a s a u n it .
(16) Gen t ly pu ll t h e wa t er sh ield over t h e h a za r d
wa r n in g swit ch kn ob a n d t h e m u lt i-fu n ct ion swit ch
80a4d2f1
lever.
(17) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
Fig. 5 Water Shield Upper Screws Remove/Install
(11) Rem ove t h e on e scr ew loca t ed below t h e
m u lt i-fu n ct ion swit ch lever t h a t secu r es t h e swit ch
XJ WIPER AND WASHER SYSTEMS 8K - 1
page page
WASHER PUMP
Th e wa sh er pu m ps a n d m ot or s a r e m ou n t ed n ea r
t h e bot t om of t h e wa sh er r eser voir. A ba r bed n ipple
on t h e pu m p h ou sin g pa sses t h r ou gh a r u bber gr om -
m et sea l in st a lled in a h ole n ea r t h e bot t om of t h e
r eser voir. Th e wa sh er pu m p is r et a in ed by a n in t er-
fer en ce fit bet ween t h e ba r bed pu m p n ipple a n d t h e
gr om m et sea l, wh ich is a ligh t pr ess fit .
80a5339c
A per m a n en t ly lu br ica t ed a n d sea led m ot or is cou -
pled t o a r ot or-t ype pu m p. Wa sh er flu id is gr a vit y-fed
Fig. 1 Windshield Wiper and Washer Switch fr om t h e r eser voir t o t h e pu m p. Wh en t h e m ot or is
en er gized, t h e pu m p pr essu r izes t h e wa sh er flu id
a n d for ces it t h r ou gh t h e plu m bin g t o t h e n ozzles.
On veh icles wit h t h e opt ion a l r ea r wiper /wa sh er
syst em , t h e fr on t wa sh er pu m p a n d m ot or is a lwa ys
m ou n t ed in t h e lower h ole of t h e r eser voir. Th e
8K - 4 WIPER AND WASHER SYSTEMS XJ
DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
wa sh er pu m p a n d m ot or u n it ca n n ot be r epa ir ed. If DI AGN OSI S AN D T EST I N G
fa u lt y, t h e en t ir e wa sh er pu m p a n d m ot or u n it m u st
be r epla ced. WIPER SYSTEM
WASHER FLUID LEVEL SENSOR FRON T
Th e wa sh er flu id level sen sor is m ou n t ed n ea r t h e F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
fr on t of t h e wa sh er r eser voir, a bove t h e t wo wa sh er 8W-53 - Wiper s in Gr ou p 8W - Wir in g Dia gr a m s.
pu m ps. A ba r bed n ipple on t h e sen sor is pr ess-fit in t o
a r u bber gr om m et sea l in st a lled in a h ole in t h e fr on t WARNING: ON VEHICLES EQUIPPED WITH AIR-
of t h e r eser voir. BAGS, REFER TO GROUP 8M - PASSIVE
Wh en t h e flu id level in t h e r eser voir fa lls below RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
t h e pivot in g floa t on t h e sen sor, t h e floa t ch a n ges STEERING WHEEL, STEERING COLUMN, OR
posit ion a n d closes t h e in t er n a l swit ch con t a ct s of t h e INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
sen sor. Refer t o Gr ou p 8E - In st r u m en t P a n el Sys- SERVICE. FAILURE TO TAKE THE PROPER PRE-
t em s for dia gn osis of t h e low wa sh er flu id wa r n in g CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
la m p a n d cir cu it , in clu din g t h e sen sor. BAG DEPLOYMENT AND POSSIBLE PERSONAL
Th e wa sh er flu id level sen sor ca n n ot be r epa ir ed. If INJURY.
fa u lt y or da m a ged, t h e sen sor u n it m u st be r epla ced.
(1) Ch eck t h e cir cu it br ea ker in t h e ju n ct ion block.
WASHER NOZZLE AND PLUMBING If OK, go t o St ep 2. If n ot OK, r epla ce t h e fa u lt y cir-
cu it br ea ker.
FRON T (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
P r essu r ized wa sh er flu id is fed t h r ou gh a sin gle ca ble. Un plu g t h e win dsh ield wiper swit ch wir e h a r-
h ose, a t t a ch ed t o a ba r bed n ipple on t h e fr on t wa sh er n ess con n ect or. Con n ect t h e ba t t er y n ega t ive ca ble.
pu m p. Th e h ose is r ou t ed t o a t ee fit t in g loca t ed in Tu r n t h e ign it ion swit ch t o t h e On posit ion . Ch eck
t h e cowl plen u m a r ea , ben ea t h t h e cowl plen u m cov- for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch ou t -
er /gr ille pa n el. H oses fr om t h e t ee fit t in g a r e r ou t ed pu t cir cu it ca vit y of t h e wiper swit ch wir e h a r n ess
t o t h e t wo n ozzles, wh ich a r e r ivet ed in t o open in gs in con n ect or. If OK, go t o St ep 3. If n ot OK, r epa ir t h e
t h e cowl plen u m cover /gr ille pa n el below t h e win d- open cir cu it t o t h e ju n ct ion block a s r equ ir ed.
sh ield. (3) If t h e pr oblem bein g dia gn osed in volves on ly
Th e t wo flu idic wa sh er n ozzles a r e n ot a dju st a ble. t h e pu lse wipe, wipe-a ft er-wa sh , or in t er m it t en t wipe
Th e n ozzles a n d h ose fit t in gs ca n n ot be r epa ir ed a n d, m odes, go t o St ep 4. If n ot , go t o St ep 5.
if fa u lt y or da m a ged, t h ey m u st be r epla ced. (4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
REAR Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
P r essu r ized wa sh er flu id is fed t h r ou gh a sin gle it y of t h e wiper swit ch wir e h a r n ess con n ect or a n d a
h ose, a t t a ch ed t o a ba r bed n ipple on t h e r ea r wa sh er good gr ou n d. Th er e sh ou ld be con t in u it y. If OK,
pu m p. Th e h ose is r ou t ed fr om t h e fr on t of t h e veh i- r epla ce t h e fa u lt y swit ch . If n ot OK, r epa ir t h e open
cle t o t h e lift ga t e wit h t h e body wir e h a r n ess. cir cu it t o gr ou n d a s r equ ir ed.
Loca t ed a t t h e h igh est poin t of t h e su pply h ose (5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
r ou t in g, ben ea t h t h e lift ga t e open in g u pper h ea der Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
ga r n ish m ou ldin g, a ch eck va lve pr even t s wa sh er Rem ove a n d ch eck t h e win dsh ield wiper a n d wa sh er
flu id dr a in -ba ck or siph on in g fr om occu r r in g. F r om swit ch con t in u it y a s descr ibed in t h is gr ou p. If OK,
t h e ch eck va lve, a n ot h er sin gle h ose is r ou t ed go t o St ep 6. If n ot OK, r epla ce t h e fa u lt y swit ch .
t h r ou gh a gr om m et t o t h e lift ga t e, wh er e it is con - (6) Un plu g t h e win dsh ield wiper m ot or wir e h a r-
n ect ed t o a n ipple t h a t pr ot r u des fr om t h e in side of n ess con n ect or. Ch eck for con t in u it y bet ween t h e
t h e r ea r wiper m ot or ou t pu t sh a ft bezel. gr ou n d cir cu it ca vit y in t h e body h a lf of t h e wiper
Th e wa sh er flu id pa sses t h r ou gh t h e bezel n ipple m ot or wir e h a r n ess con n ect or a n d a good gr ou n d.
t o t h e ou t side of t h e lift ga t e. Th er e a sin gle h ose is Th er e sh ou ld be con t in u it y. If OK, go t o St ep 7. If n ot
r ou t ed t h r ou gh a pla st ic t r ou gh -like gu a r d sn a pped OK, r epa ir t h e open cir cu it t o gr ou n d a s r equ ir ed.
t o t h e u n der side of t h e r ea r wiper a r m . Th e h ose is (7) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
t h en a t t a ch ed t o t h e sin gle r ea r wa sh er n ozzle. Th e ign it ion swit ch t o t h e On posit ion . Ch eck for ba t t er y
n ozzle sn a ps in t o pla ce on t h e r ea r wiper a r m . volt a ge a t t h e fu sed ign it ion swit ch ou t pu t cir cu it
Th e r ea r wa sh er n ozzle ca n n ot be a dju st ed. Th e ca vit y in t h e body h a lf of t h e wiper m ot or wir e h a r-
n ozzle, bezel, ch eck va lve, a n d h ose fit t in gs ca n n ot be n ess con n ect or. If OK, go t o St ep 8. If n ot OK, r epa ir
r epa ir ed a n d, if fa u lt y or da m a ged, t h ey m u st be t h e open cir cu it t o t h e ju n ct ion block a s r equ ir ed.
r epla ced.
XJ WIPER AND WASHER SYSTEMS 8K - 5
DI AGN OSI S AN D T EST I N G (Cont inue d)
(8) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . (4) Test t h e r ea r wiper a n d wa sh er swit ch a s
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. descr ibed in t h is gr ou p. If OK, go t o St ep 5. If n ot
Wit h t h e win dsh ield wiper a n d wa sh er swit ch wir e OK, r epla ce t h e fa u lt y swit ch .
h a r n ess con n ect or st ill u n plu gged, ch eck t h e ca vit ies (5) Rem ove t h e lift ga t e t r im pa n el a n d u n plu g t h e
for ea ch of t h e followin g cir cu it s in t h e body h a lf of r ea r wiper m ot or wir e h a r n ess con n ect or. Con n ect
t h e wiper m ot or wir e h a r n ess con n ect or for con t in u - t h e ba t t er y n ega t ive ca ble. Tu r n t h e ign it ion swit ch
it y t o gr ou n d. In ea ch ca se, t h er e sh ou ld be n o con t i- t o t h e On posit ion . Ch eck for ba t t er y volt a ge a t t h e
n u it y. If OK, go t o St ep 9. If n ot OK, r epa ir t h e sh or t fu sed ign it ion swit ch ou t pu t cir cu it ca vit y of t h e r ea r
cir cu it a s r equ ir ed. wiper m ot or wir e h a r n ess con n ect or. If OK, go t o
• Wiper pa r k swit ch sen se St ep 6. If n ot OK, r epa ir t h e open cir cu it t o t h e ju n c-
• Wiper swit ch low speed ou t pu t t ion block a s r equ ir ed.
• Wiper swit ch h igh speed ou t pu t . (6) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
(9) Ch eck for con t in u it y bet ween t h e ca vit ies in Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
t h e body h a lf of t h e wiper m ot or wir e h a r n ess con - Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
n ect or a n d t h e ca vit ies in t h e win dsh ield wiper a n d it y of t h e r ea r wiper m ot or wir e h a r n ess con n ect or
wa sh er swit ch wir e h a r n ess con n ect or for ea ch of t h e a n d a good gr ou n d. Th er e sh ou ld be con t in u it y. If
followin g cir cu it s. In ea ch ca se, t h er e sh ou ld be con - OK, go t o St ep 7. If n ot OK, r epa ir t h e open cir cu it t o
t in u it y. If OK, r epla ce t h e fa u lt y wiper m ot or. If n ot gr ou n d a s r equ ir ed.
OK, r epa ir t h e open cir cu it a s r equ ir ed. (7) Ch eck for con t in u it y bet ween t h e r ea r wiper
• Wiper pa r k swit ch sen se m ot or con t r ol cir cu it ca vit y of t h e r ea r wiper m ot or
• Wiper swit ch low speed ou t pu t wir e h a r n ess con n ect or a n d a good gr ou n d. Th er e
• Wiper swit ch h igh speed ou t pu t . sh ou ld be n o con t in u it y. If OK, go t o St ep 8. If n ot
OK, r epa ir t h e sh or t cir cu it a s r equ ir ed.
REAR (8) Ch eck for con t in u it y bet ween t h e r ea r wiper
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o m ot or con t r ol cir cu it ca vit ies of t h e r ea r wiper m ot or
8W-53 - Wiper s in Gr ou p 8W - Wir in g Dia gr a m s. wir e h a r n ess con n ect or a n d t h e r ea r wiper a n d
wa sh er swit ch wir e h a r n ess con n ect or. Th er e sh ou ld
WARNING: ON VEHICLES EQUIPPED WITH AIR- be con t in u it y. If OK, r epla ce t h e fa u lt y r ea r wiper
BAGS, REFER TO GROUP 8M - PASSIVE m ot or. If n ot OK, r epa ir t h e open cir cu it a s r equ ir ed.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR WASHER SYSTEM
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE- FRON T
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive
BAG DEPLOYMENT AND POSSIBLE PERSONAL wa sh er pu m p. If t h e wa sh er pu m p oper a t es, bu t n o
INJURY. wa sh er flu id is em it t ed fr om t h e wa sh er n ozzles, be
cer t a in t o ch eck t h e flu id level in t h e r eser voir. Ch eck
(1) Ch eck t h e fu se in t h e ju n ct ion block. If OK, go for ice or ot h er for eign m a t er ia l in t h e r eser voir, a n d
t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir cu it or for pin ch ed, discon n ect ed, br oken , or in cor r ect ly
com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y fu se. r ou t ed wa sh er syst em plu m bin g. F or cir cu it descr ip-
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive t ion s a n d dia gr a m s, r efer t o 8W-53 - Wiper s in Gr ou p
ca ble. Rem ove t h e r ea r wiper a n d wa sh er swit ch a n d 8W - Wir in g Dia gr a m s.
u n plu g t h e wir e h a r n ess con n ect or a s descr ibed in
t h is gr ou p. Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n WARNING: ON VEHICLES EQUIPPED WITH AIR-
t h e ign it ion swit ch t o t h e On posit ion . Ch eck for ba t - BAGS, REFER TO GROUP 8M - PASSIVE
t er y volt a ge a t t h e fu sed ign it ion swit ch ou t pu t cir- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
cu it ca vit y of t h e r ea r wiper a n d wa sh er swit ch wir e STEERING WHEEL, STEERING COLUMN, OR
h a r n ess con n ect or. If OK, go t o St ep 3. If n ot OK, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
r epa ir t h e open cir cu it t o t h e ju n ct ion block a s SERVICE. FAILURE TO TAKE THE PROPER PRE-
r equ ir ed. CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
(3) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . BAG DEPLOYMENT AND POSSIBLE PERSONAL
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. INJURY.
Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
it y of t h e r ea r wiper a n d wa sh er swit ch wir e h a r n ess (1) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
con n ect or a n d a good gr ou n d. Th er e sh ou ld be con t i- Tu r n t h e wiper swit ch t o t h e Low or H igh speed posi-
n u it y. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open t ion . Ch eck wh et h er t h e wiper s oper a t e. If OK, go t o
cir cu it t o gr ou n d a s r equ ir ed.
8K - 6 WIPER AND WASHER SYSTEMS XJ
DI AGN OSI S AN D T EST I N G (Cont inue d)
St ep 2. If n ot OK, see t h e Wiper Syst em dia gn osis in (2) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
t h is gr ou p. Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
(2) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Un plu g t h e r ea r wa sh er pu m p wir e h a r n ess con n ec-
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. t or. Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it
Un plu g t h e fr on t wa sh er pu m p wir e h a r n ess con n ec- ca vit y of t h e r ea r wa sh er pu m p wir e h a r n ess con n ec-
t or. Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it t or a n d a good gr ou n d. Th er e sh ou ld be con t in u it y. If
ca vit y of t h e fr on t wa sh er pu m p wir e h a r n ess con n ec- OK, go t o St ep 3. If n ot OK, r epa ir t h e open cir cu it t o
t or a n d a good gr ou n d. Th er e sh ou ld be con t in u it y. If gr ou n d a s r equ ir ed.
OK, go t o St ep 3. If n ot OK, r epa ir t h e open cir cu it t o (3) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
gr ou n d a s r equ ir ed. ign it ion swit ch t o t h e On posit ion . Depr ess t h e r ea r
(3) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e wa sh er swit ch . Ch eck for ba t t er y volt a ge a t t h e r ea r
ign it ion swit ch t o t h e On posit ion . Ch eck for ba t t er y wa sh er m ot or con t r ol cir cu it ca vit y of t h e r ea r
volt a ge a t t h e fr on t wa sh er swit ch ou t pu t cir cu it ca v- wa sh er pu m p wir e h a r n ess con n ect or. If OK, r epla ce
it y of t h e fr on t wa sh er pu m p wir e h a r n ess con n ect or t h e fa u lt y pu m p. If n ot OK, go t o St ep 4.
wh ile a ct u a t in g t h e wa sh er swit ch . If OK, r epla ce t h e (4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
fa u lt y wa sh er pu m p. If n ot OK, go t o St ep 4. Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
(4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Un plu g t h e r ea r wiper /wa sh er swit ch wir e h a r n ess
Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble. con n ect or. Ch eck for con t in u it y bet ween t h e r ea r
Un plu g t h e win dsh ield wiper /wa sh er swit ch wir e wa sh er m ot or con t r ol cir cu it ca vit y of t h e r ea r
h a r n ess con n ect or. Ch eck for con t in u it y bet ween t h e wa sh er pu m p wir e h a r n ess con n ect or a n d a good
fr on t wa sh er swit ch ou t pu t cir cu it ca vit y of t h e fr on t gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o
wa sh er pu m p wir e h a r n ess con n ect or a n d a good St ep 5. If n ot OK, r epa ir t h e sh or t cir cu it a s
gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go t o r equ ir ed.
St ep 5 If n ot OK, r epa ir t h e sh or t cir cu it a s r equ ir ed. (5) Ch eck for con t in u it y bet ween t h e r ea r wa sh er
(5) Ch eck for con t in u it y bet ween t h e fr on t wa sh er m ot or con t r ol cir cu it ca vit ies of t h e r ea r wa sh er
swit ch ou t pu t cir cu it ca vit ies of t h e fr on t wa sh er pu m p wir e h a r n ess con n ect or a n d t h e r ea r wiper /
pu m p wir e h a r n ess con n ect or a n d t h e wiper /wa sh er wa sh er swit ch wir e h a r n ess con n ect or. Th er e sh ou ld
swit ch wir e h a r n ess con n ect or. Th er e sh ou ld be con - be con t in u it y. If OK, r epla ce t h e fa u lt y swit ch . If n ot
t in u it y. If OK, r epla ce t h e fa u lt y swit ch . If n ot OK, OK, r epa ir t h e open cir cu it a s r equ ir ed.
r epa ir t h e open cir cu it a s r equ ir ed.
WIPER SWITCH AND WASHER SWITCH
REAR
Th e dia gn osis fou n d h er e a ddr esses a n in oper a t ive FRON T
wa sh er pu m p. If t h e wa sh er pu m p oper a t es, bu t n o P er for m t h e dia gn osis for t h e win dsh ield wiper sys-
wa sh er flu id is em it t ed fr om t h e wa sh er n ozzles, be t em a n d/or wa sh er syst em a s descr ibed in t h is gr ou p
cer t a in t o ch eck t h e flu id level in t h e r eser voir. Ch eck befor e t est in g t h e win dsh ield wiper a n d wa sh er
for ice or ot h er for eign m a t er ia l in t h e r eser voir, a n d swit ch . F or cir cu it descr ipt ion s a n d dia gr a m s, see
for pin ch ed, discon n ect ed, br oken , or in cor r ect ly 8W-53 - Wiper s in Gr ou p 8W - Wir in g Dia gr a m s.
r ou t ed wa sh er syst em plu m bin g. F or cir cu it descr ip-
t ion s a n d dia gr a m s, r efer t o 8W-53 - Wiper s in Gr ou p WARNING: ON VEHICLES EQUIPPED WITH AIR-
8W - Wir in g Dia gr a m s. BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
WARNING: ON VEHICLES EQUIPPED WITH AIR- STEERING WHEEL, STEERING COLUMN, OR
BAGS, REFER TO GROUP 8M - PASSIVE INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY SERVICE. FAILURE TO TAKE THE PROPER PRE-
STEERING WHEEL, STEERING COLUMN, OR CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR BAG DEPLOYMENT AND POSSIBLE PERSONAL
SERVICE. FAILURE TO TAKE THE PROPER PRE- INJURY.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
INJURY. ca ble.
(2) Un plu g t h e win dsh ield wiper a n d wa sh er
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . swit ch wir e h a r n ess con n ect or a s descr ibed in t h is
P la ce t h e r ea r wiper /wa sh er swit ch in t h e Wipe posi- gr ou p.
t ion . Ch eck wh et h er t h e r ea r wiper is oper a t in g. If (3) Usin g a n oh m m et er, per for m t h e swit ch con t i-
OK, go t o St ep 2. If n ot OK, see t h e Wiper Syst em n u it y ch ecks a t t h e swit ch t er m in a ls a s sh own in t h e
dia gn osis in t h is gr ou p.
INTERMITTENT
TWO SPEED
SWITCH
WIPER
WIPER
PINS
SWITCH PINS
H Pl L W P2 H Pl L W P2 E
DD ODD
3
DODD==
948K-38
Fig. 3 Rear Wiper and Washer Switch Continuity
Fig. 2 Windshield Wiper and Washer Switch REM OVAL AN D I N STALLAT I ON
Continuity
(4) If t h e swit ch fa ils a n y of t h e con t in u it y ch ecks, WIPER BLADE AND ELEMENT
r epla ce t h e fa u lt y swit ch . If t h e swit ch is OK, r epa ir
t h e wiper syst em a n d/or wa sh er syst em wir e h a r n ess FRON T
cir cu it s a s r equ ir ed.
NOTE: The notched retainer end of the wiper ele-
REAR ment should always be oriented towards the end of
P er for m t h e dia gn osis for t h e r ea r wiper syst em the wiper blade that is nearest to the wiper pivot.
a n d/or wa sh er syst em a s descr ibed in t h is gr ou p
To r em ove t h e win dsh ield wiper bla de a n d/or ele-
befor e t est in g t h e r ea r wiper a n d wa sh er swit ch . F or
m en t , pr oceed a s follows:
cir cu it descr ipt ion s a n d dia gr a m s, see 8W-53 - Wip-
(1) Lift t h e wiper a r m t o r a ise t h e wiper bla de a n d
er s in Gr ou p 8W - Wir in g Dia gr a m s.
elem en t off of t h e win dsh ield gla ss.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (2) Rem ove t h e wiper bla de fr om t h e wiper a r m , or
BAGS, REFER TO GROUP 8M - PASSIVE t h e wiper elem en t fr om t h e wiper bla de a s follows:
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY (a ) To r em ove t h e wiper bla de fr om t h e wiper
STEERING WHEEL, STEERING COLUMN, OR a r m , pu sh t h e r elea se t a b u n der t h e a r m t ip a n d
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR slide t h e bla de a wa y fr om t h e t ip t owa r ds t h e pivot
SERVICE. FAILURE TO TAKE THE PROPER PRE- en d of t h e a r m (F ig. 4).
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (b) To r em ove t h e wiper elem en t fr om t h e wiper
BAG DEPLOYMENT AND POSSIBLE PERSONAL bla de, pin ch t h e n ot ch ed r et a in er (pivot ) en d of t h e
INJURY. wiper elem en t t igh t ly bet ween t h e t h u m b a n d for e-
fin ger. Th en , pu ll t h e elem en t fir m ly t owa r ds t h e
(1) Rem ove t h e r ea r wiper a n d wa sh er swit ch a s wiper pivot u n t il t h e n ot ch ed r et a in er of t h e wiper
descr ibed in t h is gr ou p. elem en t clea r s t h e wiper bla de cla ws. On ce t h e
(2) Usin g a n oh m m et er, ch eck t h e swit ch con t in u - n ot ch ed r et a in er is r elea sed fr om t h e cla ws, t h e
it y a t t h e swit ch t er m in a ls a s sh own in t h e Rea r elem en t will slide ea sily ou t of t h e r em a in in g
Wiper a n d Wa sh er Swit ch Con t in u it y ch a r t (F ig. 3). cla ws.
(3) If t h e swit ch fa ils a n y of t h e con t in u it y ch ecks, (3) In st a ll t h e wiper bla de on t h e wiper a r m , or
r epla ce t h e fa u lt y swit ch . If t h e swit ch is OK, r epa ir t h e wiper elem en t in t h e wiper bla de a s follows:
t h e r ea r wiper syst em a n d/or wa sh er syst em wir e (a ) To in st a ll t h e wiper bla de on t h e wiper a r m ,
h a r n ess cir cu it s a s r equ ir ed. slide t h e bla de r et a in er in t o t h e U-sh a ped for m a -
8K - 8 WIPER AND WASHER SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
t h e pin ch -r elea se clip for t h e wiper elem en t is or i-
en t ed t owa r ds t h e en d of t h e wiper bla de t h a t is
n ea r est t o t h e r ea r wiper m ot or ou t pu t sh a ft .
RELEASE (b) To in st a ll t h e wiper elem en t in t h e wiper
TAB bla de, st a r t a t t h e r ea r wiper m ot or ou t pu t sh a ft
en d of t h e bla de a n d slide t h e elem en t t h r ou gh
ea ch pa ir of wiper bla de cla ws. Th e elem en t is fu lly
in st a lled wh en t h e cla ws on t h e r ea r wiper m ot or
ou t pu t sh a ft en d of t h e bla de a r e en ga ged in t h e
wiper elem en t r et a in in g clip n ot ch es.
WIPER ARM
Fig. 4 Wiper Blade Remove/Install - Typical
t ion on t h e t ip of t h e wiper a r m u n t il t h e r elea se FRON T
t a b sn a ps in t o it s locked posit ion . Be cer t a in t h a t
t h e n ot ch ed r et a in er for t h e wiper elem en t is or i- CAUTION: The use of a screwdriver or other prying
en t ed t owa r ds t h e en d of t h e wiper bla de t h a t is tool to remove a wiper arm may distort it. This dis-
n ea r est t o t h e wiper pivot . tortion could allow the arm to come off of the pivot
(b) To in st a ll t h e wiper elem en t in t h e wiper shaft, regardless of how carefully it is installed.
LOCKING LATCH
ARM
bla de, st a r t a t t h e wiper pivot en d of t h e bla de a n d
(1) Lift t h e wiper a r m t o per m it t h e la t ch t o be
slide t h e elem en t t h r ou gh ea ch pa ir of wiper bla de
pu lled ou t t o it s h oldin g posit ion , t h en r elea se t h e
cla ws. Th e elem en t is fu lly in st a lled wh en t h e
a r m (F ig. 5). Th e a r m will r em a in off t h e win dsh ield
n ot ch ed r et a in er on t h e wiper elem en t is en ga ged
wit h t h e la t ch in t h is posit ion .
wit h t h e cla ws on t h e wiper pivot en d of t h e wiper
bla de.
REAR
33-62 MM 23-52MM
J898K-29
LIFTGATE
REAR
80abd2e1
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Fig. 12 Liftgate Trim Panel Remove/Install
(2) F r om t h e ou t side of t h e lift ga t e gla ss, r em ove
t h e r ea r wiper a r m a s descr ibed in t h is gr ou p.
XJ WIPER AND WASHER SYSTEMS 8K - 11
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(10) Rem ove t h e eigh t scr ews t h a t secu r e t h e lift -
ga t e t r im pa n el t o t h e lift ga t e in n er pa n el on bot h
sides a n d a bove t h e lift ga t e gla ss.
(11) Usin g a t r im st ick or a n ot h er su it a ble wide
fla t -bla ded t ool, gen t ly pr y t h e lower edges of t h e
t r im pa n el a wa y fr om t h e lift ga t e in n er pa n el a r ou n d
t h e per im et er t o r elea se t h e t r im pa n el r et a in er s.
INSTRUMENT PANEL
LOWER MOUNTING
TAB aoa4d212
m u lt i-fu n ct ion swit ch off of t h e left side of t h e st eer- Fig. 16 Center Bezel Remove/Install
in g colu m n a s a u n it a n d m ove it ou t of t h e wa y. If (3) Rem ove t h e cen t er bezel fr om t h e veh icle.
t h e veh icle is equ ipped wit h t h e opt ion a l t ilt st eer in g (4) Rem ove t h e t h r ee scr ews t h a t secu r e t h e a cces-
colu m n , lift in g gen t ly u pwa r d on t h e t ilt r elea se lever sor y swit ch bezel t o t h e in st r u m en t pa n el (F ig. 17).
will pr ovide a ddit ion a l clea r a n ce t o ea se m u lt i-fu n c-
t ion swit ch r em ova l. ACCESSORY
(14) Gen t ly pu ll t h e win dsh ield wiper a n d wa sh er SWITCH BEZEL
swit ch u p a n d a wa y fr om t h e r igh t side of t h e st eer-
in g colu m n fa r en ou gh t o a ccess t h e wir e h a r n ess
con n ect or.
(15) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
win dsh ield wiper a n d wa sh er swit ch .
(16) Rem ove t h e win dsh ield wiper a n d wa sh er
swit ch fr om t h e st eer in g colu m n .
(17) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
REAR
WASHER SYSTEM
WASH ER RESERV OI R
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. RESERVOIR FILLER NECK AND CAP LEFT FENDERFWD
WASH ER N OZ Z LE
FRONT
(1) Rem ove t h e wiper a r m s a s descr ibed in t h is
gr ou p.
(2) Rem ove t h e eigh t scr ews t h a t secu r e t h e cowl
plen u m cover /gr ille pa n el a n d scr een t o t h e cowl t op
pa n el (F ig. 20).
LIFTGATE ~
SUPPLY HOSE
80ab8848
LAMPS
CON T EN T S
page page
INDEX
page page
8L - 4 LAMPS XJ
H EADLAM P ALI GN M EN T
INDEX
page page
VEHICLE I
CENTERLINE
7
7.62 ME ERS
(25 FEET)
I
803f58ad
XJ LAMPS 8L - 5
SERV I CE PROCEDU RES (Cont inue d)
ALI GN M EN T SCREEN PREPARAT I ON (1) Rem ove scr ews a n d bot h h ea dla m p bezels.
(1) P osit ion veh icle on a level su r fa ce per pen dicu - (2) Clea n fr on t of t h e h ea dla m ps.
la r t o a fla t wa ll 7.62 m et er s (25 ft ) a wa y fr om fr on t (3) P la ce h ea dla m ps on LOW bea m .
of h ea dla m p len s (F ig. 1). (4) Cover fr on t of t h e h ea dla m p t h a t is n ot bein g
(2) If n ecessa r y, t a pe a lin e on t h e floor 7.62 a dju st ed.
m et er s (25 ft ) a wa y fr om a n d pa r a llel t o t h e wa ll. (5) Tu r n ver t ica l a dju st m en t scr ew (F ig. 2) u n t il
(3) Mea su r e fr om t h e floor u p 1.27 m et er s (5 ft ) t h e h ea dla m p bea m pa t t er n on scr een /wa ll is sim ila r
a n d t a pe a lin e on t h e wa ll a t t h e cen t er lin e of t h e t o t h e pa t t er n depict ed in t h e a lign m en t scr een fig-
veh icle. Sigh t a lon g t h e cen t er lin e of t h e veh icle u r e.
(fr om r ea r of veh icle for wa r d) t o ver ify a ccu r a cy of
t h e lin e pla cem en t .
(4) Rock veh icle side-t o-side t h r ee t im es t o a llow
su spen sion t o st a bilize.
(5) J ou n ce fr on t su spen sion t h r ee t im es by pu sh in g
down wa r d on fr on t bu m per a n d r elea sin g.
(6) Mea su r e t h e dist a n ce fr om t h e cen t er of h ea d-
la m p len s t o t h e floor. Tr a n sfer m ea su r em en t t o t h e
a lign m en t scr een (wit h t a pe). Use t h is lin e for
u p/down a dju st m en t r efer en ce.
(7) Mea su r e dist a n ce fr om t h e cen t er lin e of t h e
veh icle t o t h e cen t er of ea ch h ea dla m p bein g a lign ed.
Tr a n sfer m ea su r em en t s t o scr een (wit h t a pe) t o ea ch
side of veh icle cen t er lin e. Use t h ese lin es for left /
r igh t a dju st m en t r efer en ce.
HEADLAMP ADJUSTMENT
A pr oper ly a im ed low bea m will pr oject t h e t op Fig. 2 Headlamp Beam Adjustment Screws
edge of h igh in t en sit y pa t t er n on t h e scr een fr om 50 NOTE: When using a headlamp aiming screen:
m m (2 in .) a bove t o 50 m m (2 in .) below h ea dla m p
cen t er lin e. Th e side-t o-side left edge of h igh in t en sit y • Adju st t h e h ea dla m ps so t h a t t h e bea m h or izon -
pa t t er n sh ou ld be fr om 50 m m (2 in .) left t o 50 m m t a l posit ion is a t 0.
(2 in .) r igh t of h ea dla m p cen t er lin e). Th e p re fe rre d • Adju st t h e bea m ver t ica l posit ion is 25 m m (1
h e a d la m p a lig n m e n t is 0 fo r th e le ft/rig h t in ) down wa r d fr om t h e la m p h or izon t a l cen t er lin e.
a d ju s tm e n t a n d 1” d o w n fo r th e u p /d o w n (6) Rot a t e t h e h or izon t a l a dju st m en t scr ew u n t il
a d ju s tm e n t. Th e h igh bea m s on a veh icle wit h du a l t h e h ea dla m p bea m pa t t er n on t h e a im in g scr een /
h ea dla m ps ca n n ot be a lign ed. Th e h igh bea m pa t t er n wa ll sim ila r t o t h e pa t t er n in t h e a lign m en t scr een
sh ou ld be cor r ect wh en t h e low bea m s a r e a lign ed figu r e.
pr oper ly. (7) Cover fr on t of t h e h ea dla m p t h a t h a s been
a dju st ed a n d a dju st t h e ot h er h ea dla m p bea m a s
in st r u ct ed a bove.
(8) In st a ll h ea dla m p bezels. Tigh t en t h e scr ews
secu r ely.
VEHICLE
CENTERLINE
ADJUSTMENT
FOG
SCREW
LAMP CENTER OF VEHICLE
OF FOG TO
LAMP
MOUNTING
CENTER
LENS
BRACKET FRONT OF FOG LAMP 7.62
HIGH-INTENSITY
METERS (25 FEET)
AREA FLOOR
OF FOG
100
TO
LAMP
mm
CENTER
(4
LENS
in.)
8L - 6 LAMPS XJ
SERV I CE PROCEDU RES (Cont inue d)
LENS ~~~~~g.L/
-
100 mm
(4 in.)
7.62 METERS
(25 FEET)
/
938L-26
XJ LAMPS 8L - 7
LAM P BU LB SERV I CE
INDEX
page page
FOG
LAMP
HEADLAMP BULB
SOCKET
'~
80ab884a
Fig. 1 Headlamp Bezel
(2) Rem ove t h e scr ews a t t a ch in g t h e r et a in in g r in g Fig. 2 Fog Lamp Components
t o t h e h ea dla m p bu cket . I N STALLAT I ON
(3) Discon n ect t h e h ea dla m p bu lb wir e h a r n ess
con n ect or. CAUTION: Do not touch the bulb glass with fin-
(4) Sepa r a t e t h e bu lb fr om t h e veh icle. gers or other oily surfaces. Reduced bulb life will
result.
I N STALLAT I ON
(1) Con n ect wir e h a r n ess con n ect or. (1) P osit ion bu lb elem en t in fog la m p.
(2) P osit ion bu lb in bu cket . (2) Con n ect wir e con n ect or s a t bu lb.
(3) P osit ion r et a in in g r in g on h ea dla m p bu lb a n d (3) In st a ll spr in g clip secu r in g bu lb t o fog la m p.
in st a ll scr ews. (4) In st a ll scr ews a t t a ch in g t h e a ccess cover t o t h e
(4) In st a ll h ea dla m p bezel. bot t om of t h e fog la m p.
8L - 8 LAMPS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Rem ove scr ews a t t a ch in g pa r k/t u r n sign a l (2) In st a ll bu lb a n d socket in ba ck of side m a r ker
la m p t o gr ille open in g pa n el. la m p.
(3) Rot a t e bu lb socket on e-t h ir d t u r n a n d r em ove (3) In st a ll side m a r ker la m p.
it fr om la m p (F ig. 3).
(4) Rem ove bu lb fr om socket . BACK-UP/REAR TURN SIGNAL/TAIL LAMP BULB
REM OVAL
PARK (1) Rem ove t a il la m p.
LAMP (2) Rot a t e bu lb socket on e-t h ir d t u r n a n d r em ove
bu lb socket fr om la m p (F ig. 5).
(3) Rem ove bu lb fr om socket .
80ab5cd0
TAIL
Fig. 3 Park/Turn Signal Lamp Bulb LAMP
I N STALLAT I ON
(1) In st a ll bu lb in socket .
(2) In st a ll socket in la m p.
(3) In st a ll pa r k/t u r n sign a l la m p. 80ab5cd1
I N STALLAT I ON
(1) In st a ll a r epla cem en t bu lb in la m p socket .
(2) In st a ll scr ews a t t a ch in g licen se pla t e la m p t o
lift ga t e.
XJ LAMPS 8L - 9
REM OVAL AN D I N STALLAT I ON (Cont inue d) CONSOLE
LENS FLAT BLADE
80ab5cce
8L - 10 LAMPS XJ
LAM P SERV I CE
INDEX
page page
REM OVAL AN D I N STALLAT I ON (3) Con n ect t h e wir e h a r n ess con n ect or.
(4) P osit ion t h e bu lb in t h e bu cket .
HEADLAMP (5) P osit ion r et a in in g r in g on t h e h ea dla m p bu lb
a n d in st a ll scr ews.
REM OVAL (6) In st a ll t h e h ea dla m p bezel.
(1) Rem ove t h e scr ews a t t a ch in g t h e bezel t o t h e
gr ille open in g pa n el FOG LAMP
(2) Rem ove t h e scr ews a t t a ch in g t h e r et a in in g r in g
t o t h e h ea dla m p bu cket . REM OVAL
(3) Discon n ect t h e h ea dla m p bu lb wir e h a r n ess (1) Discon n ect t h e fog la m p wir e h a r n ess con n ec-
con n ect or. t or.
(4) Sepa r a t e t h e bu lb fr om t h e veh icle. (2) Rem ove t h e scr ews a t t a ch in g t h e fog la m p t o
(5) Rem ove t h e spr in g a t t a ch in g t h e h ea dla m p t h e su ppor t (F ig. 2).
bu cket t o t h e gr ille open in g pa n el (F ig. 1). (3) Sepa r a t e t h e fog la m p fr om t h e veh icle.
(6) Slide t h e h ea dla m p bu cket down wa r d t o disen -
ga ge it fr om t h e h ea dla m p a dju st in g scr ews. FOG LAMP
HEADLAMP
BEZEL
PARK/TURN
LAMP
Fig. 1 Headlamp
'E£, I N STALLAT I ON
Fig. 2 Fog Lamp
80aa4b97
XJ LAMPS 8L - 11
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(2) Rem ove t h e scr ews a t t a ch in g t h e pa r k/t u r n sig- (2) In st a ll side m a r ker la m p in gr ille open in g
n a l la m p h ou sin g t o t h e gr ille open in g pa n el (F ig. 3). pa n el.
(3) Rem ove t h e bu lb socket s a n d sepa r a t e fr om t h e
veh icle. BACK-UP/REAR TURN SIGNAL/TAIL LAMP
REM OVAL
(1) Open t h e lift ga t e.
(2) Rem ove t h e bolt s a t t a ch in g t h e t a il la m p h ou s-
in g t o t h e qu a r t er pa n el (F ig. 5).
(3) Gr a sp t h e la m p a n d pu ll t o disen ga ge it fr om
t h e gr om m et a t t h e ba se of t h e la m p.
(4) Rot a t e t h e bu lb socket s on e-t h ir d t u r n a n d
r em ove t h e bu lb socket s fr om t h e la m p h ou sin g.
TAIL LAMP
I
t h e lift ga t e (F ig. 6).
(2) Discon n ect t h e wir e h a r n ess con n ect or.
(3) Sepa r a t e t h e CH MSL fr om t h e veh icle.
80ab5cd3 I N STALLAT I ON
(1) Con n ect t h e wir e h a r n ess con n ect or.
Fig. 4 Side Marker Lamp (2) P osit ion t h e CH MSL on t h e lift ga t e.
I N STALLAT I ON (3) In st a ll t h e scr ews a t t a ch in g t h e CH MSL t o t h e
(1) In st a ll bu lb a n d socket in ba ck of side m a r ker lift ga t e.
la m p.
U-NUT
CHMSL
LIFTGATE WIRE
WIRE
GROMMET
CONNEC-
HOLE
NUT
TOR FWD CONVOLUTED
SCREW
UNDERHOOD
DOME
HOOD
LAMP
AND
LENS
HEADLINER
NESS
INNER
WIRE
SWITCH
BULB
LAMP
COVER
PANEL
HAR-
8L - 12 LAMPS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
UNDERHOOD
AND SWITCH
CONVOLUTED
CHMSL WIRE HARNESS COVER
8L - 14 LAMPS XJ
INDEX
page page
I N STALLAT I ON
(1) P osit ion t h e m odu le on t h e r igh t fen der in n er
pa n el.
(2) In st a ll t h e a t t a ch in g scr ews. Tigh t en t h e
scr ews secu r ely.
(3) Con n ect t h e wir e h a r n ess con n ect or t o t h e m od-
u le.
XJ LAMPS 8L - 15
BU LB APPLI CAT I ON
INDEX
page page
LAMP B U LB
SPECI FI CAT I ON S A/C Con t r ol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Air ba g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
EXTERIOR LAMPS An t i-lock Br a ke . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Br a ke Wa r n in g . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
LAMP B U LB Ch eck E n gin e . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ba ck-u p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3157 Ch eck Ga u ges . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Cen t er H igh Mou n t ed St opla m p . . . . . . . . . . . . . 921 Ciga r Ligh t er . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
F og la m p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H 3 Coola n t Tem p H igh . . . . . . . . . . . . . . . . . . . . . . 194
F r on t Side Ma r ker . . . . . . . . . . . . . . . . . . . . . . . 168 Cr u ise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
H ea dla m p/Sea led Bea m . . . . . . . . . . . . . . . . . H 6054 F a st en Sea t Belt s . . . . . . . . . . . . . . . . . . . . . . . . . 74
Licen se P la t e . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 F ou r Wh eel Dr ive . . . . . . . . . . . . . . . . . . . . . . . . . 74
P a r k/Tu r n Sign a l . . . . . . . . . . . . . . . . . . . . . . . 3157 Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Ta il/St op . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3157 H ea t er Con t r ol . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Rea r Tu r n Sign a l . . . . . . . . . . . . . . . . . . . . . . . 3157 H igh Bea m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
INTERIOR LAMPS Illu m in a t ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Ser vice pr ocedu r es for m ost of t h e la m ps in t h e Low F u el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
in st r u m en t pa n el, In st r u m en t clu st er a n d swit ch es Low Oil P r essu r e . . . . . . . . . . . . . . . . . . . . . . . . 194
a r e loca t ed in Gr ou p 8E , In st r u m en t P a n el a n d Low Wa sh er F lu id . . . . . . . . . . . . . . . . . . . . . . . . 74
Ga u ges. Som e com pon en t s h a ve la m ps t h a t ca n on ly Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASC
be ser viced by a n Au t h or ized Ser vice Cen t er (ASC) Secu r it y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
a ft er t h e com pon en t is r em oved fr om t h e veh icle. Tr a n sfer Ca se . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
Con t a ct loca l dea ler for loca t ion of n ea r est ASC. Tr a n sm ission F loor Sh ift . . . . . . . . . . . . . . . . . . 658
Tu r n Sign a l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
LAMP B U LB Upsh ift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Ca r go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
Dom e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 561
XJ PASSIVE RESTRAINT SYSTEMS 8M - 1
page page
DRIVER
~
AIRBAG
HORN
MODULE
SWITCH
CLOCKSPRING WIRE NUT
STEERING
AIRBAG SPEED WHEEL
WIRE CONTROL WIRE 80ab88a2
Fig. 3 Vacuum Heater and A/C Outlets Fig. 4 Driver Side Airbag Module Remove/Install
'
RETAINER
@~@
HORN
SWITCH
(10) At t a ch t h e ACM t o t h e floor pa n ACM m ou n t - (10) In ser t a sm a ll scr ewdr iver or pin pu n ch
in g br a cket wit h t h e t h r ee m ou n t in g n u t s. Tigh t en t h r ou gh t h e a ccess h ole in t h e lower st eer in g colu m n
t h e m ou n t in g n u t s t o 7.3 N·m (65 in . lbs.). sh r ou d a n d depr ess t h e ign it ion lock cylin der r et a in -
(11) P lu g in t h e wir e h a r n ess con n ect or t o t h e in g t u m bler (F ig. 13).
ACM. Be cer t a in t h a t t h e con n ect or la t ch es a r e fu lly
en ga ged.
(12) P osit ion t h e ACM pr ot ect ive cover over t h e
ACM. Be cer t a in t h a t t h e wir e h a r n ess r et a in er is
cor r ect ly r ein st a lled in t h e slot t ed h ole of t h e ACM
pr ot ect ive cover. Tigh t en t h e m ou n t in g scr ews t o 4
N·m (35 in . lbs.).
(13) Rever se t h e r em a in in g r em ova l pr ocedu r es t o
com plet e t h e in st a lla t ion .
(14) Do n ot con n ect t h e ba t t er y n ega t ive ca ble a t
t h is t im e. See Air ba g Syst em in Dia gn osis a n d Test -
in g for t h e pr oper pr ocedu r es.
CLOCKSPRING
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,
COMPLEX ELECTROMECHANICAL UNIT. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- PIN PUNCH
BAG SYSTEM OR RELATED STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENTS YOU MUST FIRST DISCONNECT / 80a483e5
AND ISOLATE THE BATTERY NEGATIVE (GROUND)
CABLE. THEN WAIT TWO MINUTES FOR THE SYS- Fig. 13 Steering Column Shrouds Remove/Install
TEM CAPACITOR TO DISCHARGE BEFORE FUR-
THER SYSTEM SERVICE. THIS IS THE ONLY SURE (11) Wh ile h oldin g the r et a in in g t u m bler
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE depr essed, pu ll t h e ign it ion lock cylin der a n d key ou t
TO DO THIS COULD RESULT IN ACCIDENTAL AIR- of t h e ign it ion lock h ou sin g.
BAG DEPLOYMENT AND POSSIBLE PERSONAL (12) Rem ove t h e t h r ee scr ews t h a t secu r e t h e
INJURY. lower st eer in g colu m n sh r ou d t o t h e u pper sh r ou d.
(13) If t h e veh icle is equ ipped wit h a st a n da r d
(1) Tu r n t h e st eer in g wh eel u n t il t h e fr on t wh eels n on -t ilt st eer in g colu m n , loosen t h e t wo u pper st eer-
a r e in t h e st r a igh t -a h ea d posit ion befor e st a r t in g t h e in g colu m n m ou n t in g n u t s. If t h e veh icle is equ ipped
pr ocedu r e. wit h t h e opt ion a l t ilt st eer in g colu m n , m ove t h e t ilt
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive st eer in g colu m n t o t h e fu lly lower ed posit ion .
ca ble. If t h e a ir ba g h a s n ot been deployed, wa it t wo (14) Rem ove bot h t h e u pper a n d lower sh r ou ds
m in u t es for t h e syst em ca pa cit or t o disch a r ge befor e fr om t h e st eer in g colu m n .
fu r t h er ser vice. (15) Un plu g t h e t wo wir e h a r n ess con n ect or s fr om
(3) Rem ove t h e dr iver side a ir ba g m odu le a s t h e st eer in g colu m n side of t h e clockspr in g.
descr ibed in t h is gr ou p. (16) To r em ove t h e clockspr in g, ca r efu lly lift t h e
(4) If t h e veh icle is equ ipped wit h t h e opt ion a l loca t in g fin ger s of t h e clockspr in g a ssem bly fr om t h e
veh icle speed con t r ol, u n plu g t h e speed con t r ol st eer in g colu m n a s n ecessa r y. If t h e clockspr in g loca t -
swit ch wir e h a r n ess con n ect or in t h e st eer in g wh eel. in g fin ger s a r e br oken , be cer t a in t o r em ove t h e br o-
(5) Rem ove t h e n u t t h a t secu r es t h e st eer in g wh eel ken pieces fr om t h e u pper st eer in g colu m n h ou sin g.
t o t h e st eer in g colu m n u pper sh a ft . Th e clockspr in g ca n n ot be r epa ir ed. It m u st be
(6) Rem ove t h e st eer in g wh eel wit h a st eer in g r epla ced if fa u lt y or da m a ged, or if t h e a ir ba g h a s
wh eel pu ller (Specia l Tool C-3428B). been deployed.
8M - 10 PASSIVE RESTRAINT SYSTEMS XJ
REM OVAL AN D I N STALLAT I ON (Cont inue d)
(17) Wh en in st a llin g t h e clockspr in g, sn a p t h e (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
clockspr in g on t o t h e st eer in g colu m n . If t h e clock- ca ble. If t h e a ir ba g h a s n ot been deployed, wa it t wo
spr in g is n ot pr oper ly posit ion ed, see Clockspr in g m in u t es for t h e syst em ca pa cit or t o disch a r ge befor e
Cen t er in g in t h is gr ou p befor e in st a llin g t h e st eer in g fu r t h er ser vice.
wh eel. (3) Rem ove t h e a ir ba g m odu le a s descr ibed in t h is
(18) P lu g t h e t wo clockspr in g wir e h a r n ess con n ec- gr ou p.
t or s in t o t h e st eer in g colu m n side of t h e clockspr in g. (4) If t h e veh icle is equ ipped wit h t h e opt ion a l
Be cer t a in t h a t t h e wir e h a r n ess con n ect or la t ch es veh icle speed con t r ol, u n plu g t h e speed con t r ol
a r e fu lly en ga ged. swit ch wir e h a r n ess con n ect or in t h e st eer in g wh eel.
(19) Rein st a ll t h e st eer in g colu m n sh r ou ds a n d (5) Rem ove t h e n u t t h a t secu r es t h e st eer in g wh eel
ign it ion lock cylin der. t o t h e st eer in g colu m n u pper sh a ft .
(20) Rein st a ll t h e st eer in g colu m n open in g cover (6) Rem ove t h e st eer in g wh eel wit h a st eer in g
a s descr ibed in Gr ou p 8E - In st r u m en t P a n el Sys- wh eel pu ller (Specia l Tool C-3428B).
t em s. (7) Rot a t e t h e clockspr in g r ot or clockwise t o t h e
(21) Th e fr on t wh eels sh ou ld st ill be in t h e en d of it s t r a vel (F ig. 14). D o n o t a p p ly e x c e s s iv e
st r a igh t -a h ea d posit ion . In st a ll t h e st eer in g wh eel to rqu e .
bein g cer t a in t o fit t h e fla t s on t h e h u b of t h e st eer-
in g wh eel on t o t h e for m a t ion s on t h e in side of t h e
clockspr in g. P u ll t h e wir e h a r n ess t h r ou gh t h e lower
h ole in t h e st eer in g wh eel h u b. Tigh t en t h e st eer in g
wh eel n u t t o 61 N·m (45 ft . lbs.). Be cer t a in n ot t o
pin ch t h e wir in g bet ween t h e st eer in g wh eel a n d t h e
nut.
(22) In st a ll t h e a ir ba g m odu le a s descr ibed in t h is
gr ou p.
ADJ U ST M EN T S
CLOCKSPRING CENTERING
If t h e r ot a t in g t a pe wit h in t h e clockspr in g is n ot
posit ion ed pr oper ly in r ela t ion t o t h e st eer in g wh eel
a n d t h e fr on t wh eels, t h e clockspr in g m a y fa il du r in g
u se. Th e clockspr in g m u st be cen t er ed if it is n ot
kn own t o be pr oper ly posit ion ed, or if t h e fr on t
wh eels wer e m oved fr om t h e st r a igh t -a h ea d posit ion
wit h t h e clockspr in g r em oved du r in g a n y ser vice pr o-
cedu r e. 80a53484
page page
GROUND
WIRE
I J918N-2
(3) Wit h t h e n ega t ive lea d of t h e volt m et er, con t a ct
a good body gr ou n d poin t . Th e volt a ge r ea din g sh ou ld
n ot ch a n ge. If OK, go t o St ep 4. If n ot OK, r epa ir t h e
cir cu it t o gr ou n d a s r equ ir ed.
(4) Con n ect t h e n ega t ive lea d of t h e volt m et er t o
Fig. 1 Rear Window Glass Grid Test t h e r igh t side bu s ba r a n d t ou ch ea ch gr id lin e a t
m idpoin t C wit h t h e posit ive lea d. A r ea din g of
Th e a bove ch ecks will con fir m syst em oper a t ion .
a ppr oxim a t ely six volt s in dica t es a lin e is good. A
Illu m in a t ion of t h e defogger swit ch in dica t or la m p
r ea din g of zer o volt s in dica t es a br ea k in t h e gr id
m ea n s t h a t t h er e is elect r ica l cu r r en t a va ila ble a t t h e
lin e bet ween m idpoin t C a n d t h e left side bu s ba r. A
ou t pu t of t h e defogger r ela y, bu t does n ot con fir m
r ea din g of t en t o fou r t een volt s in dica t es a br ea k
t h a t t h e elect r ica l cu r r en t is r ea ch in g t h e r ea r gla ss
bet ween m idpoin t C a n d t h e r igh t side bu s ba r. Move
h ea t in g gr id lin es.
t h e posit ive lea d on t h e gr id lin e t owa r ds t h e br ea k
If t h e defogger syst em does n ot oper a t e, t h e pr ob-
a n d t h e volt a ge r ea din g will ch a n ge a s soon a s t h e
lem sh ou ld be isola t ed in t h e followin g m a n n er :
br ea k is cr ossed.
(1) Con fir m t h a t t h e ign it ion swit ch is in t h e On
posit ion .
DEFOGGER SWITCH
(2) E n su r e t h a t t h e r ea r gla ss h ea t in g gr id feed
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o
a n d gr ou n d wir es a r e con n ect ed t o t h e gla ss. Con fir m
8W-48 - Rea r Win dow Defogger in Gr ou p 8W - Wir-
t h a t t h e gr ou n d wir e h a s con t in u it y t o gr ou n d.
in g Dia gr a m s.
(3) Ch eck t h e fu ses in t h e P ower Dist r ibu t ion Cen -
t er (P DC) a n d in t h e ju n ct ion block. Th e fu ses m u st WARNING: ON VEHICLES EQUIPPED WITH AIR-
be t igh t in t h eir r ecept a cles a n d a ll elect r ica l con n ec- BAGS, REFER TO GROUP 8M - PASSIVE
t ion s m u st be secu r e. RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
Wh en t h e a bove st eps h a ve been com plet ed a n d t h e STEERING WHEEL, STEERING COLUMN, OR
r ea r gla ss or ou t side r ea r view m ir r or h ea t in g gr id is INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
st ill in oper a t ive, on e or m or e of t h e followin g is SERVICE. FAILURE TO TAKE THE PROPER PRE-
fa u lt y: CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
• Defogger swit ch BAG DEPLOYMENT AND POSSIBLE PERSONAL
• Defogger r ela y INJURY.
• In st r u m en t clu st er cir cu it r y
• Rea r win dow gr id lin es (a ll gr id lin es wou ld (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
h a ve t o be br oken or on e of t h e feed wir es discon - ca ble. Rem ove t h e defogger swit ch a n d u n plu g t h e
n ect ed for t h e en t ir e syst em t o be in oper a t ive) swit ch wir e h a r n ess con n ect or.
• Ou t side r ea r view m ir r or h ea t in g gr id. (2) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
If set t in g t h e defogger swit ch t o t h e On posit ion cu it ca vit y of t h e swit ch wir e h a r n ess con n ect or a n d
pr odu ces a sever e volt m et er deflect ion , ch eck for a a good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go
sh or t cir cu it bet ween t h e defogger r ela y ou t pu t a n d t o St ep 3. If n ot OK, r epa ir t h e open cir cu it a s
t h e r ea r gla ss or ou t side r ea r view m ir r or h ea t in g r equ ir ed.
gr ids. (3) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
cu it a n d r ea r win dow defogger swit ch sen se cir cu it
REAR GLASS HEATING GRID t er m in a ls on t h e ba ck of t h e swit ch h ou sin g (F ig. 2).
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o Th er e sh ou ld be m om en t a r y con t in u it y a s t h e defog-
8W-48 - Rea r Win dow Defogger in Gr ou p 8W - Wir- ger swit ch bu t t on is depr essed, a n d t h en n o con t in u -
RELAY CAVITIES
RELAY TERMINALS
85 87 J958A-2
TERMINAL LEGEND
NUMBER IDENTIFICATION
30 COMMON FEED
85 COIL GROUND
86 COIL BATTERY
87 NORMALLY OPEN
1--~87=--A--+-~N~ORMALLY CLOSED
1 2 3 4
Defogger Relay
SWITCH CONTINUITY
RELAY CI RCU I T T EST
POSITION BETWEEN
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is
OFF LAMPS
con n ect ed t o ba t t er y volt a ge a n d sh ou ld be h ot a t a ll
ON MOMENTARY 1 AND 2 t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open
ILLUMINATION LAMP 1 AND 4 cir cu it t o t h e P DC fu se a s r equ ir ed.
INDICATOR LAMP 1 AND 3 (2) Th e r ela y n or m a lly closed t er m in a l (87A) is
80a5035f con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion ,
Fig. 2 Defogger Switch Continuity bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3.
(3) Th e r ela y n or m a lly open t er m in a l (87) is con -
DEFOGGER RELAY n ect ed t o t h e com m on feed t er m in a l (30) in t h e en er-
gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
WARNING: ON VEHICLES EQUIPPED WITH AIR- t o t h e r ea r gla ss a n d ou t side r ea r view m ir r or h ea t -
BAGS, REFER TO GROUP 8M - PASSIVE in g gr ids a n d t h e defogger swit ch in dica t or la m p.
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY Th er e sh ou ld be con t in u it y bet ween t h e ca vit y for
STEERING WHEEL, STEERING COLUMN, OR r ela y t er m in a l 87 a n d t h e r ea r win dow defogger r ela y
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR ou t pu t cir cu it ca vit ies of t h e r ea r gla ss a n d ou t side
SERVICE. FAILURE TO TAKE THE PROPER PRE- r ea r view m ir r or h ea t in g gr ids a n d t h e defogger
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- swit ch in dica t or la m p a t a ll t im es. If OK, go t o St ep
BAG DEPLOYMENT AND POSSIBLE PERSONAL 4. If n ot OK, r epa ir t h e open cir cu it (s) a s r equ ir ed.
INJURY. (4) Th e coil gr ou n d t er m in a l (85) is con n ect ed t o
t h e elect r om a gn et in t h e r ela y. Th is t er m in a l is pr o-
RELAY T EST vided wit h gr ou n d by t h e in st r u m en t clu st er r ea r
Th e defogger r ela y is loca t ed in t h e ju n ct ion block, win dow defogger t im er a n d logic cir cu it r y t o en er gize
on t h e r igh t cowl side pa n el below t h e in st r u m en t t h e defogger r ela y. Th er e sh ou ld be con t in u it y t o
pa n el in t h e pa ssen ger com pa r t m en t . Rem ove t h e gr ou n d a t t h e ca vit y for r ela y t er m in a l 85 wh en t h e
defogger r ela y fr om t h e ju n ct ion block a s descr ibed in defogger swit ch is t u r n ed On . H owever, wit h t h e
t h is gr ou p t o per for m t h e followin g t est s: defogger r ela y r em oved, t h e defogger swit ch in dica t or
(1) A r ela y in t h e de-en er gized posit ion sh ou ld la m p will n ot ligh t t o sh ow t h a t t h e defogger syst em
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d is t u r n ed On . Be cer t a in t h a t you depr ess t h e defog-
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go ger swit ch a t lea st t wice t o con fir m t h a t t h e syst em
t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y. is t u r n ed on du r in g t h is t est . If OK, go t o St ep 5. If
(2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec- n ot OK, r epa ir t h e open cir cu it t o t h e in st r u m en t
t r om a gn et ) sh ou ld be 75 6 10 oh m s. If OK, go t o clu st er a s r equ ir ed.
St ep 3. If n ot OK, r epla ce t h e fa u lt y r ela y. (5) Th e coil ba t t er y t er m in a l (86) is con n ect ed t o
(3) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86. t h e elect r om a gn et in t h e r ela y. It is con n ect ed t o
Th er e sh ou ld n ow be con t in u it y bet ween t er m in a ls fu sed ign it ion swit ch ou t pu t volt a ge a n d sh ou ld be
30 a n d 87, a n d n o con t in u it y bet ween t er m in a ls 87A h ot wh en t h e ign it ion swit ch is in t h e On posit ion .
a n d 30. If OK, see t h e Rela y Cir cu it Test in t h is Ch eck for ba t t er y volt a ge a t t h e ca vit y for r ela y t er-
gr ou p. If n ot OK, r epla ce t h e fa u lt y r ela y. m in a l 86 wit h t h e ign it ion swit ch in t h e On posit ion .
MASKING
BREAK
TAPE GRID LINE
page page
/[J]
t h is gr ou p.
~J
DOOR MODULE 3 4
If t h e power lock syst em is in oper a t ive wit h eit h er = = =
6 7
= 8 9 10 11
fr on t door power lock swit ch , t est t h e P a ssen ger Door
Modu le (P DM). If t h e power lock syst em is in oper a - = = = = = =
t ive wit h on ly t h e dr iver side fr on t door power lock CONNECTOR 2 (C2)
swit ch , t est t h e Dr iver Door Modu le (DDM). F or cir-
cu it descr ipt ion s a n d dia gr a m s, r efer t o 8W-61 -
CONNECTOR 2 (C2)
P ower Door Locks in Gr ou p 8W - Wir in g Dia gr a m s.
SWITCH POSITION CONTINUITY BETWEEN
DRI V ER DOOR M ODU LE LOCK 7&8
Th e on ly fu n ct ion of t h e Dr iver Door Modu le UNLOCK 11 & 8
(DDM) in t h e power lock syst em is t o pr ovide a Lock
or Un lock sign a l t o t h e power lock syst em con t r ol cir- 80abd2c7
cu it r y con t a in ed wit h in t h e P a ssen ger Door Modu le Fig. 1 DDM Power Lock Switch Continuity $$1$
(P DM). Th e DDM sign a ls t h e P DM by pr ovidin g a PASSEN GER DOOR M ODU LE
h a r d-wir ed gr ou n d pa t h t h r ou gh t h e DDM gr ou n d Th e P a ssen ger Door Modu le (P DM) con t a in s t h e
cir cu it a n d t h e dr iver side power lock swit ch con t a ct s pa ssen ger side fr on t door power lock swit ch a n d t h e
t o t h e lock r equ est or u n lock r equ est t er m in a ls of t h e power lock syst em con t r ol cir cu it r y. In it s r ole a s a
P DM. Th e DDM power lock swit ch fu n ct ion ca n be power lock swit ch , it pr ovides t h e power lock syst em
t est ed a s follows: con t r ol cir cu it r y wit h a gr ou n d pa t h t h r ou gh t h e
P DM gr ou n d cir cu it a n d t h e dr iver side power lock
CONNECTOR
CONNECTOR
1 (C-1)
2 (C-2)
$$2$
80abd2e1
/HEADLINER 80abd253
80abd2e7
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VERTICAL UP
XJ POWER SEAT SYSTEMS 8R - 3
VERTICAL DOWN
REM OVAL AN D I N STALLAT I ON (Cont inue d)
HORIZONTAL FORWARD
SWITCH POSITION
HORIZONTAL AFT
OFF TILT UP
FRONT
CONTINUITY BETWEEN
80abd26d
Fig. 2 Power Seat Switch Remove/Install Fig. 3 Driver Seat Belt Switch Connector
POWER SEAT ADJUSTER AND MOTORS (6) Rem ove t h e n u t t h a t secu r es t h e in boa r d r ea r
(1) Move t h e sea t t o it s fu lly r a ised a n d fu lly for- of t h e sea t a dju st er fr a m e t o t h e st u d on t h e floor
wa r d posit ion , if possible. pa n .
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (7) Un plu g t h e power sea t wir e h a r n ess con n ect or
ca ble. fr om t h e body wir e h a r n ess con n ect or.
(3) Un plu g t h e sea t belt swit ch wir e h a r n ess con - (8) Rem ove t h e dr iver side power sea t a n d a dju st er
n ect or fr om t h e dr iver side sea t belt bu ckle h a lf on a ssem bly fr om t h e veh icle.
t h e in boa r d side of t h e sea t (F ig. 3). (9) Un plu g t h e power sea t wir e h a r n ess con n ect or s
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e fr on t of a t ea ch of t h e t h r ee power sea t m ot or s.
t h e sea t a dju st er fr a m e t o t h e floor pa n sea t m ou n t - (10) Rem ove t h e fou r n u t s t h a t secu r e t h e sea t
in g r ein for cem en t (F ig. 4). a dju st er a n d m ot or s a ssem bly t o t h e sea t cu sh ion
(5) Rem ove t h e scr ew t h a t secu r es t h e ou t boa r d fr a m e a n d r em ove t h e a dju st er a n d m ot or s a ssem bly
r ea r of t h e sea t a dju st er fr a m e t o t h e floor pa n . fr om t h e sea t (F ig. 5).
(11) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
Tigh t en t h e sea t m ou n t in g h a r dwa r e a s follows:
SCREW POWER NUT
SEATANDADJUSTER
MOTORS
SEAT CUSHION
FRAME DRIVER
SEAT
STUD
FRONT
CUSHION
SCREW
FRAME
SEAT
SIDE
~
lbs.).
80abd26f
80abd270
page page
dow syst em . Th e DDM a lso con t a in s a n in t egr a t ed LOCKOUT ON NO CONTINUITY BETWEEN C1 PIN 8
cir cu it t o su ppor t t h e on e-t ou ch down fea t u r e of t h e (DOWN) & C2 PIN 9
dr iver side fr on t door power win dow. Rem em ber t h a t 80abd2eb
t h e pa ssen ger side fr on t door power win dow swit ch Fig. 1 DDM Power Window Switch Continuity
a n d, on fou r-door m odels, t h e r ea r door power win -
dow swit ch es get t h eir ba t t er y cu r r en t t h r ou gh t h e
power win dow lockou t swit ch in t h e Dr iver Door
Modu le (DDM). In a ddit ion , ea ch in dividu a l power
win dow swit ch get s it s gr ou n d t h r ou gh t h e m a st er
swit ch in t h e DDM. CONNECTOR 2 (C-2)
Th e on e-t ou ch down fea t u r e cir cu it r y wit h in t h e
DDM will n ot oper a t e t h e power win dow m ot or if t h e POWER WINDOWS
door gla ss, win dow r egu la t or, or gea r box m ech a n ism OFF (NORMAL) C2 PIN 2 & C2 PIN 3
a r e st u ck, obst r u ct ed, or bin din g. If t h e dr iver side C2 PIN 4 & C2 PIN 9
fr on t door power win dow oper a t es a s design ed, bu t UP C2 PIN 2 & C2 PIN 3
t h e on e-t ou ch down fea t u r e is in oper a t ive, r epla ce C2 PIN 9 & C2 PIN 10
t h e fa u lt y DDM.
DOWN C2 PIN 2 & C2 PIN 10
If t h e pr oblem bein g dia gn osed is a n in oper a t ive
power win dow swit ch illu m in a t ion la m p, bu t t h e C2 PIN 4 & C2 PIN 9
power win dow swit ch oper a t es a s design ed, r epla ce 80abd2ec
t h e fa u lt y door m odu le. F or cir cu it descr ipt ion s a n d Fig. 2 PDM Power Window Switch Continuity
dia gr a m s, r efer t o 8W-60 - P ower Win dows in Gr ou p fr on t door swit ch es, see Door Modu le in t h is gr ou p. If
8W - Wir in g Dia gr a m s. t h e pr oblem bein g dia gn osed is a n in oper a t ive power
(1) Rem ove t h e door m odu le fr om t h e door t r im win dow swit ch illu m in a t ion la m p, bu t t h e power win -
pa n el a s descr ibed in t h is gr ou p. dow swit ch oper a t es a s design ed, r epla ce t h e fa u lt y
(2) Ch eck t h e door m odu le power win dow swit ch swit ch . F or cir cu it descr ipt ion s a n d dia gr a m s, r efer
a n d/or power win dow lockou t swit ch con t in u it y in t o 8W-60 - P ower Win dows in Gr ou p 8W - Wir in g
ea ch posit ion , a s sh own in t h e pr oper ch a r t (F ig. 1) Dia gr a m s.
or (F ig. 2). If OK, see t h e P ower Win dow Mot or dia g- (1) Rem ove t h e power win dow swit ch fr om t h e
n osis in t h is gr ou p. If n ot OK, r epla ce t h e fa u lt y door r ea r door t r im pa n el a s descr ibed in t h is gr ou p.
m odu le. (2) Ch eck t h e power win dow swit ch con t in u it y in
ea ch posit ion a s sh own in t h e Rea r Door P ower Win -
POWER WINDOW SWITCH dow Swit ch Con t in u it y ch a r t (F ig. 3). If OK, see t h e
Th e dia gn osis fou n d h er e a pplies on ly t o t h e r ea r P ower Win dow Mot or dia gn osis in t h is gr ou p. If n ot
door power win dow swit ch es. F or dia gn osis of t h e OK, r epla ce t h e fa u lt y swit ch .
INSIDE
LOCKDOOR
REMOTE
DOOR
U-NUT
TRIM
LATCH
PUSH-IN
CONTROLS
PANEL
AND
TENER
FAS-SCREWS CONNECTOR
CONNECTOR
DOOR
T2DOOR
1RIM
RECEP-
TACLE
MODULE
RECEPTA-
PANEL
CLE
3
==
5 6
==
~
DOOR MODULE
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e scr ews t h a t secu r e t h e door t r im
pa n el t o t h e in n er door pa n el (F ig. 4).
Fig. 5 Door Module Remove/Install
PUSH-IN TENER
FAS- U-NUT REAR DOOR
TRIM PANEL
j
SWITCH
PUSH-IN
FASTENER
80aafb5a
80abd2IO
Fig. 6 Rear Door Trim Panel Remove/Install
(3) Usin g a t r im st ick or a n ot h er su it a ble wide Fig. 7 Rear Door Power Window Switch Remove/
fla t -bla ded t ool, gen t ly pr y t h e t r im pa n el a wa y fr om Install
t h e door a r ou n d t h e per im et er t o r elea se t h e t r im (10) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
pa n el r et a in er s.
POWER WINDOW MOTOR
NOTE: To aid in the removal of the trim panel, start
at the bottom of the panel. FRON T DOOR
Th e fr on t door power win dow m ot or a n d m ech a -
(4) Lift t h e door t r im pa n el u pwa r ds a n d a wa y n ism is in t egr a l t o t h e fr on t door power win dow r eg-
fr om t h e door t o disen ga ge t h e t op of t h e pa n el fr om u la t or u n it . If t h e fr on t door power win dow m ot or or
t h e in n er belt wea t h er st r ip. m ech a n ism is fa u lt y or da m a ged, t h e en t ir e power
(5) P u ll t h e door t r im pa n el a wa y fr om t h e in n er win dow r egu la t or u n it m u st be r epla ced. Refer t o
door fa r en ou gh t o a ccess t h e in side door la t ch Gr ou p 23 - Body for t h e fr on t door win dow r egu la t or
r elea se a n d lock lin ka ge r ods n ea r t h e ba ck of t h e ser vice pr ocedu r es.
in side door r em ot e con t r ols.
(6) Un sn a p t h e pla st ic r et a in er clips fr om t h e REAR DOOR
in side door r em ot e con t r ol en ds of t h e la t ch r elea se Th e r ea r door power win dow m ot or a n d m ech a n ism
a n d lock lin ka ge r ods, a n d r em ove t h e r od en ds fr om is in t egr a l t o t h e r ea r door power win dow r egu la t or
t h e in side door r em ot e con t r ols. u n it . If t h e r ea r door power win dow m ot or or m ech -
a n ism is fa u lt y or da m a ged, t h e en t ir e power win dow
r egu la t or u n it m u st be r epla ced. Refer t o Gr ou p 23 -
Body for t h e r ea r door win dow r egu la t or ser vice
pr ocedu r es.
XJ POWER MIRROR SYSTEMS 8T - 1
page page
4 5 6
000
000
3 2 1
Fig. 1 Stand-Alone Power Mirror Switch Continuity Fig. 3 Power Mirror Test
STAND-ALONE
POWER MIRROR
SWITCH
5
c:::::::::i
6
c:::::::J
7
c:::::J
8
c:::::::J
CONNECTOR 1 (C-1)
DOOR MODULE
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. ~---'-_DOOR
MODULE
(2) Rem ove t h e scr ews t h a t secu r e t h e door t r im
pa n el t o t h e in n er door pa n el (F ig. 5).
80abd2da
80aafb5e
DOOR
WFRONTDOOR FLAG TRIM
PANEL
__.__---~ ~" ~
UPPER SPEAKER
WIRE HARNESS - ~ " " "
Fig. 8 Front Door Trim Panel Remove/Install -
Manual Window 80abd273
SIDE VIEW
MIRROR
WIRE
HARNESS
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